Journal of the Air Pollution Control Association

ISSN: 0002-2470 (Print) (Online) Journal homepage: https://www.tandfonline.com/loi/uawm16

Maintenance and Operation Problems of

Electrostatic Precipitators

Jacob Katz

To cite this article: Jacob Katz (1978) Maintenance and Operation Problems of Electrostatic
Precipitators, Journal of the Air Pollution Control Association, 28:9, 868-870, DOI:
10.1080/00022470.1978.10470670

To link to this article: https://doi.org/10.1080/00022470.1978.10470670

Published online: 14 Mar 2012.

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 Maintenance and Operation Problems of
Electrostatic Precipitators
Jacob Katz
Precipitator Technology, Inc.
Munhall, Pennsylvania
A general background is offered to the potential sources and solu-
tions of maintenance difficulties involved with the electrostatic pre-
cipitator. The purpose of the discussion is not only to show the Inherent
complexity of the situation, but to stress areas of problem identifi-
cation and activity for the user of this equipment. The information
contained in this paper should provide an overall base for the details
covered in the subsequent papers of this conference.
After the advent of the Clean Air Act in 1970, the number of
electrostatic precipitator installations has grown at an accel-
erated pace. While much has been discussed and written on
attaining collection performance with the precipitator, a major
void has occurred in the identification and transfer of infor-
mation needed to help reduce maintenance costs and to pre-
vent deterioration of the collector performance through the
failure of equipment.
The purpose of this conference was to explore and open up
to discussions many of the repetitive problems that have
plagued the users of precipitators. The existence of these
problems could be related to the complexity of the process or
to a lack of well defined operating techniques among other
reasons. We intend to emphasize where and how these areas
provide a major impact on the maintenance problems of
precipitators.
The manufacturer and user presenters in this conference
were charged with basically representing their respective
groups. They were handling a difficult subject in that the
maintenance problems discussed as well as solutions are open
to a wide degree of interpretation. Whether long term solu-
tions are applied often rests with proper identification and
implementation techniques that have not been stressed in our
rush to meet regulation deadlines with the installation of more
and more collectors. This conference was an attempt to step
back for a respite and face up to the possibility that we may
not have total control over the technology of precipitation.
Copyright 1978-Air Pollution Control Association
868
Many success stories of the high collection performance of
precipitators are well documented. But to many users a con-
stant battle is waged to maintain these performance levels.
I shall explore many of the background reasons for this sit-
uation—the fault often lying jointly with government and
manufacturer, as well as the user. I will then briefly discuss
each phase of the precipitator application where careful input
will often improve the chance for operation and maintenance
success.
Background Basis of the Problem
It is not the intent of the following comments merely to
assign the responsibility for some of our operating and
maintenance problems to specific groups but rather to help
provide insight for future solutions.
Governmental Input
The input to the problems of the precipitator as well as
other abatement equipment by governmental sources has been
subtle. While the intent was well meaning, the edict to clean
up all industrial sources within a 5 to 6 year period was totally
impractical. That produced an accelerated growth in the then
existing capability of the precipitator manufacturers for a
device whose success depended as much on past experience
as on scientific input. Most of the previous experience of the
50's and 60's involved installations designed for the 97.5 to
98.5% collection range.
Thus we entered into designs of 99.5% collection containing
more and more component parts without the reasonable time
span normally required for the training, knowledge, field
problems, and solutions of the older jobs to catch up with
newer installations. While there has been a concentrated effort
in recent years to understand precipitators, the result is lik-
ened to placing the cart before the horse. The key point I
would like to make is that a major part of the problem rests
with the concentrated efforts that were required in a short
period of time to meet regulatory demands. I strongly suggest
that regulatory agencies take that premise into consideration
when discussions are held on trouble jobs.
Journal of the Air Pollution Control Association
 Pertinent to the problem of finances, the rush to collect the
last bit of material from the gas stream often detracts from
additional money that could be considered for reliability op-
tions. There is only so much money available; I contend that
it is better to design for the range of 99.2% collection ef-
ficiencies with more money going into the reliability aspects
of design—than to push continually toward the 99.8% plus
design with its potentially major trouble spots.
Manufacturer Input
The manufacturers of precipitators have not held an envi-
able position in recent years. They have had to meet strong
demands for retrofit and new installations at a time when
confusion reigned in many areas of the field. Efforts to con-
serve energy complicated the picture. Fast turnover of field
personnel lessened the effective feedback of problems to en-
gineering and design departments.
When one considers that 2 to 3 years will often pass between
the initial discussions for the procurement of the precipitator
and the actual start-up date, the close supervision of field
problems is of utmost importance. It is quite easy to have a 4
to 5 year generation of inherent problems wrapped up in the
design and installation phase. In respect to this problem, the
transfer of information has to be improved if recurring
maintenance troubles are to be reduced. Methods and tech-
niques to train field service people must be improved and the
ability to hold these people for many years in the field must
be developed.
User Input
The user of the precipitator often holds the key to successful
operation and maintenance performance. Often the user has
not recognized effects of minor changes in the process on such
areas as dew point conditions on metal corrosion and the re-
moval of material from hoppers.
We have all heard the statement that since the air pollution
equipment does not produce money for the user, he does not
pay attention to it. While this may be true in isolated cases,
I often observe the opposite where repetitive problems cause
a disproportionate share of maintenance money and time to
be spent on the collector. The user is usually putting out fires
and not directing his efforts toward eliminating the sources
of his problems.
Where the user (and his consultant if used) needs to place
more emphasis on eventual maintenance problems is in the
initial discussions with the manufacturer. Options should be
discussed in the early design stage that can minimize potential
sources of trouble.
By the comprehensive discussion in the papers to follow,
we hope the user will avail himself of pertinent information
that points toward useful solutions. The maintenance inter-
actions and phases can be best identified by discussing the
main ingredients of an effective program.
Aspects of an Effective Program
Obviously it is exceedingly difficult to predict where some
of the maintenance troubles may occur, but there are eight (8)
key areas that should be emphasized.
1. Raw material and operation forecasts—original design.
2. Design concepts.
3. Construction phase.
4. Initial check and training.
5. Personnel assignment.
6. Control of process.
7. Record keeping.
8. The actual maintenance program.
September 1978 Volume 28, No. 9
Raw Material and Operation Forecasts
This may be the toughest, but yet the most important phase
to help minimize future problems. The user has to forecast
possible raw material or operation changes that can affect the
precipitator. The manufacturer's representative must know
what to ask for in terms of the parameters. For example, with
a wet process kiln that is currently operating with a 500° F
back-end gas temperature, additional chains may be con-
templated that will reduce the gas temperature to 400° F. This
future course may alter the design of rapper and hopper
evacuation equipment.
Design Concepts
Just how much is placed into a design to overcome operating
and maintenance problems must be discussed as much in
detail as the emphasis on performance levels. Simple concepts
such as the number of bolts on access doors or the number and
location of walkways can be quite important for inspection
activity.
While each option or change may add additional cost to the
initial installation, it may prove far less costly for the long
term. You will read about many of these options in this con-
ference report, and each must be weighed on its own mer-
its.
Construction Phase
The best precipitator design can be adversely affected in
its fabricating and erection phases. Just how the quality of
welding is controlled or the shaping of the component is finally
accomplished in the shop could have a significant effect on the
final operating characteristics of the precipitator.
How the material is handled on the job site can be impor-
tant to prevent a tendency to distort long electrode elements.
Weather protection is of primary concern if long storage time
is required.
There are advantages for the user to assign an inspector
during the actual erection phase. Cross checks of the actual
erection procedures can help all concerned. Of special im-
portance are critical clearances and welded connections that
could prevent expansion of the collector electrodes after op-
erating temperatures are attained.
Check-out and Training
The manufacturer will usually send a service man during
the last days of the precipitator construction for the final
check-out of electrode alignment and electrical circuits. The
user representative should use this opportunity to observe
techniques and various measurements used in the analyses
of the circuits. On-site experience has advantages compared
to later training. It is up to the manufacturer service man to
provide pertinent methods and answer all questions metho-
dically. If this does not occur, the user representative should
ask for another service man.
Several of the key areas checked before start-up include:
1. All safety aspects including placement of signs, condition
of grounding sticks, and complete interlock system.
2. Cross-check the identification of equipment so that all
control panels are hooked to the correct power supply.
3. Determine that all the devices for overload or under-voltage
protection function properly.
4. Obtain the electrical characteristics of each of the fields in
its smallest subdivision. This check is called "Air load" and
will serve as background data for a clean electrode condi-
tion. All system information should be recorded and usu-
ally spark-over does not exist during this test.
869
ESP OPERATION AND MAINTENANCE
Whoever is assigned by the user to accompany the manu-
facturer's service man should carefully record all information
in a start-up manual that would be available for plant use. In
addition, the manufacturer will usually offer a training course
over and above the normal operating and maintenance man-
ual.
Personnel Assignment
Just who to assign to the precipitator system should be
given much thought. The value of the initial check-out and
contacts with the manufacturer can be lost if the user repre-
sentative is moved to another assignment.
A person that can be assigned long term to overseeing the
precipitator system and monitor the process as to how it af-
fects the collector is probably the best investments company
can make. Recent years have shown the advantage of close
supervision for large precipitator installations. It takes a
special person not only willing to spend hours in dusty un-
comfortable working conditions when necessary, but willing
to take the responsibility to assure successful conditions to
the precipitator.
Control of Process
The weakness in recent years in coping with precipitator
problems, both from maintenance and performance stand-
point, is the lack of knowledge and understanding of the ef-
fects of the process on the conditions that can occur in the
collector.
Of special importance is the effect of start-up and shut-
down procedures of the process on present and future troubles
of the precipitator. Gas temperature and moisture levels can
affect hopper evacuation conditions. Seasonal and daily am-
bient temperature variations must be considered. Raw ma-
terial variations should be closely monitored. Batch operations
will impose potential for hopper difficulties.
Record Keeping
Minimal efforts for recording difficulties and failure of
Solving Problems in the Electrical
Energization of Electrostatic Precipitators
Herbert J. Hall
H. J. Associates, Inc.
Princeton, New Jersey
Achieving and maintaining continuous, reliable performance in
electrostatic precipitators depends critically upon the proper design,
application, operation, and maintenance of the high voltage electrical
energization system. Common problems among these factors are
Copyright 1978-Air Pollution Control Association
870
equipment will often produce benefits. While we can all agree
that it is too much to expect for an installation to be 100% free
of breakdowns, repetitive failures should not be considered
normal. For example, the pattern of where wire electrodes fail
can point out potential causes. Periodic recording of the
electrical characteristics of the precipitator fields can point
out both internal difficulties or changes in the process. I rec-
ommend that several key process factors be logged with the
precipitator readings such as production, gas temperature
entering collector, gas moisture, and air flow levels.
Actual Maintenance Program
Sincere efforts in each of the above categories will go far to
help minimize the situation where problems continually exist
with the precipitator. The first year is critical in this overall
program. Internal inspections by trained personnel should
form the basis of ascertaining future trouble spots. Emphasis
must be placed on periodic check-outs and cleaning of certain
apparatus. The key point—do not continue to live with re-
petitive problems.
Summary
There is no substitute for the building of maximum reli-
ability into modern precipitator designs. Attempts to build
sheer size into the collector in order to overcome a failure rate
factor may be a dangerous path. More electrodes, rappers,
hoppers or more of any equipment that has continually to face
flue gas conditions is fraught with danger—if there are weak
spots in this equipment.
The economic advantages to be gained by improvements
in reliability design vary, dependent on the specific process
characteristics, and even the attitudes of personnel at certain
plants. Therefore, the information required to overcome po-
tential trouble spots should be freely discussed in the early
negotiation and specification stage of purchasing a precipi-
tator.
Elimination of stack puffs and upset conditions is the goal
of all, but this goal will not be achieved within reasonable
precipitator sizes unless concerted efforts are made by regu-
latory, manufacturer, and user groups to work toward un-
derstanding the basic problems.
discussed, and effects on performance are illustrated from field ex-
perience. Practical recommendations for solving problems and for
preventing their occurrence in the electrical aspects of precipitation
are presented for effective use by designers, operators, and main-
tenance personnel.
Journal of the Air Pollution Control Association