Esp Index

OPERATION & MAINTENANCE MANUAL
For
Electrostatic Precipitator for 90 TPH AFBC Boiler
Client
M/s. Lloyds Metals & Engineers Ltd.
ELEX (India) Pvt.Ltd.

Thane-India
DOs & DON’Ts
DO s
1. Read the manual and gather complete knowledge about the Plant & the
Equipments before starting the plant.
2. Maintain the process parameters within the specified limits.
3. Keep the ESP temp. below the max. permissible limit of 200 Deg.C.
4. Evacuate the ESP hoppers at a regular interval.
5. Adjust the TR setting to operate ESP fields with minimum sparks.
6. Keep the required readings in a logbook for reference.
7. In the event of any doubt / question, please contact ELEX INDIA.
8. Put the correct GRADE of oil in Rapping Motor Gear-Box.
9. Allow proper combustion in the boiler to avoid fire / damage to ESP.
10. Avoid accumulation of un-burnt in the hoppers as it may lead to hopper fire and
damage to ESP.
11. SAFETY MEASURES
It is to be strictly ensured that no flue gas is allowed to pass through the ESP before
the ESP has been completely erected, interlocks installed & established and air load
test conducted successfully.
ESP Hoppers are not meant to be used for storage of dust. It is to be strictly ensured
that Hopper evacuation system is in continuous operation and no dust is stored in the
Hopper at any point of time. In case dust is allowed to be kept in any of the Hoppers,
un-burnt particles in the dust may start smouldering which can eventually lead to fire /
explosion inside the ESP causing extensive damage. It is therefore, absolutely
necessary to maintain all the Hoppers cleared of any accumulated dust. In case, dust
is found to be accumulating for any reason whatsoever, immediate action to be taken
to switch off the T.R. Sets, switch off the I.D. Fan and stop further ingress of flue gas
through the ESP. Hoppers to be fully cleared before restarting the system.
Job No : 240 Rev : 0 Page : 1

DOs & DON’Ts
It is also extremely important to continuously monitor the formation / presence of any

gas like Carbon Monoxide, Methane, etc. Presence of such components in the flue
gas may lead to serious damage due to explosion / fire in the equipment through
which it is likely to pass through. Hence, adequate precautionary measures against
formation of such gases in the process, is of utmost importance.
In the event of formation of such gases in the process, continuous monitoring of such
gases & Oxygen is essential to identify and appropriate interlocks should be provided
to shut down the entire system to prevent any untoward incident.

DOs & DON’Ts
DON’Ts
1. Do not exceed the specified temp. limit. This can damage the equipment / plant.
2. Do not by-pass the inter-lock.
3. Do not enter the ESP without cooling & gas analysis against presence of any
poisonous gases.
4. Do not stop the conveying equipments below the ESP when the equipments are in
operation.
5. Do not by-pass any safety requirement.
6. Do not keep ESP fields on if the hopper level is high.
7. Do not ignore any fault signal from any equipment.
8. Do not run the Rapping Motors without Gear-Box oil.
9. Do not use the hopper as silo.
10. Do not over-rap the ESP.
11. Do not run the ESP with faulty controller.
12. Do not close the Purge Air Fan damper.

Operation & Maintenance Manual
for
Electrostatic Precipitator ( ESP )

List Of Contents
Electrostatic Precipitator
Title Section Pages
Your Documentation 1 1
General Safety Rules 2 4
Description of Installation 3 13
Plant Commissioning 4 5
& Start-up
Operation 5 6
Maintenance 6 21
Faults & Repairs 7 10
Technical Data 8 2
Supplier’s Documentation 9
Geared motor drive for Rapping

TR set & controls
General Arrangement Drawing of ESP

Your Documentation
1. Your documentation
Your documentation for the electrostatic precipitator installation is

made of the following parts:
• Operating manual (OM)
• Technical documentation (TD)
Operating This operating manual is written for the user and the operating
Manual personnel of the electrostatic precipitator installation.
All necessary instructions and information for the operation of the
electrostatic precipitator is included in this operating manual.
Technical The technical documentation is written for qualified, technical

documentation personnel only.
All necessary instructions and information for maintenance, service and
repair as well as the documentation of sub-suppliers is included in this
technical documentation.
About this operating manual

This operating manual is written for the user and the operating personnel of
the electrostatic precipitator installation.
You have to read this operating manual carefully before you start work or
activities at or with the electrostatic precipitator.
You will find some important safety instructions for the operation of the
electrostatic precipitator installation in this operating manual. You have to
read and follow the safety instructions.
If you have some questions about this operating manual or about the
electrostatic precipitator installation in general, you can directly ask ELEX
INDIA for assistance. The address is listed in chapter 8, technical data.
Reading assistance in this documentation

Relevant “Relevant information” highlights text passages, which are
information especially important:
• for the comprehension of the installation;
• for the optimal operation of the installation.
Marginal note Important terms are printed bold in the left column. This is helping you to find
relevant information very quickly.
→ This arrow indicates activities to be carried out.
TD This indicates a reference to the technical documentation (TD).
Job No: 240 Rev : 0 Page : 1- 1

General Safety Rules
2 General safety rules
2.1 Symbols
This danger symbol is indicating text passages which are dealing with
danger and risk.
Disregarding these warnings can have even fatal consequences.
The caution symbol is indicating text passages which are dealing with
danger and risks to the installation itself.
Disregarding these warnings will lead to substantial material damage.
2.2 Use as directed
The electrostatic precipitator is especially designed and built for the

application which is specified in the contract. Every other use must be
checked and approved by ELEX INDIA prior to actual use.
The design is based on the parameters that were known to ELEX INDIA
at the date of signing the contract. Every change of the parameters must
be checked and approved by ELEX INDIA prior to actual use.
The state The installation is built according to the state of the art and
of the art complies with approved safety measures and rules generally known at
the date of signing the contract. Nevertheless, there is always a certain
risk remaining which is combined to the normal operation of the
installation. Reading this operating manual carefully and full compliance
with all the safety measures and rules will avoid and reduce possible
danger and risk both for persons and installation. The electrostatic
precipitator may only run in faultless physical condition and all data and
parameters listed in this operating manual must be fully complied with.
Misuse Any misuse of the electrostatic precipitator is generally not permitted.

For example:
Job No : 240 Rev : 0 Page 2- 1

Exceeding the maximum permissible positive or negative pressure at the

inlet will lead to irreparable damages to the mechanical structure of the
electrostatic precipitator.
It’s therefore not allowed to operate the electrostatic precipitator beyond

the pressure limits specified by ELEX INDIA.
Exceeding the maximum permissible gas temperature at the inlet will
also lead to irreparable damages to the mechanical structure of the
It’s therefore not allowed to operate the electrostatic precipitator beyond
the temperature limits specified by ELEX INDIA.
2.3 Working in accordance with the safety measures and rules
Make a contribution to safety!

• Do only a job at or with the electrostatic precipitator when you are
authorised to do so and when you have fully read and understood
the content of this operating manual.
• Observe all the safety measures and rules contained in this manual.
• Observe all additional safety instructions and rules of the
safety/risk manager/organisation of your company.
• Observe all other internal safety measures and rules.
• Wear the protective personal equipment wherever requested.
• Before starting the electrostatic precipitator:
- Make sure that the electrostatic precipitator installation is in
faultless condition.
- Report damages or malfunction immediately to the head of your
department.
- Make sure that nobody is inside the electrostatic precipitator.
• Don’t carry out alterations or repairs. Only especially qualified
personnel is allowed to do this work.
• Never enter into the electrostatic precipitator during operation.
2.4 Responsibility of the client of ELEX INDIA
As owner and operator of the ELEX INDIA electrostatic precipitator

installation you are responsible for the proper use as specified in this
operating manual. Don’t make any compromises at the expense of
safety.
Your staff must be in a position to work in accordance with the safety
measures and rules:
• Establish alarm instructions and procedures to be followed in case of
an emergency.
• Establish internal safety and working instructions.
• Clearly define who is responsible for what and what are the
competencies.

• Train your staff.

• The operating instructions must be available for all people dealing
with the electrostatic precipitator installation.
• Everyone has to read and understand the relevant part of this
operating instructions before they start to work at the installation.
• Only personnel that understands the language of this operating
instructions is allowed to work at the electrostatic precipitator
installation.
• Instruct your personnel to keep the electrostatic precipitator
installation in a well maintained condition.
• Make the following instructions generally available:
- First aid in case of accidents with electricity.
- Prevention of fire on electrical installation.
- First aid in case of accidents.
2.5 Safety devices
The safety devices are designed and built for your safety. Therefore
never shut down, remove or alter safety devices!
The electrostatic precipitator installation must only be put in operation
when all safety devices are available and in faultless condition.
Every damage or fault must be repaired by qualified personnel only.
The electrostatic precipitator installation is equipped with the following
safety devices:
• Earthing switch in the high tension circuit.
• Earthing devices for the electrostatic precipitator high tension part
and discharge system.
• Mechanical interlocking system.
2.6 Components and spare parts
Use only ELEX INDIA original spare parts.

All components including accessories are specially designed, selected
and approved for this application. The use of products that are not
approved by ELEX INDIA can influence the characteristic and reduce
the safety.
2.7 Disposal
The collected dust of the electrostatic precipitator installation has to be

disposed properly. If applicable, rules and laws concerning the
protection of the environment must be followed.
In case of dismantling the electrostatic precipitator installation or parts
thereof, polluted or contaminated parts have to be disposed
corresponding to rules and laws concerning the protection of the
environment.

2.8 Additional rules
Rules, laws, norms and guidelines valid in your Country/State must also
be complied with, such as:
• rules for accident protection,

• rules for disposal of hazardous material.
2.9 Exclusion from liability
ELEX INDIA is under no circumstances liable or responsible for injury or

damage which is related to:
• Use of spare parts or accessories which are not especially approved
and supplied by ELEX INDIA.
• Improper handling of the electrostatic precipitator installation or parts
thereof during transport, storage, erection, operation, maintenance
etc.
• Not used as directed.
• Non-compliance with the safety measures and rules.

Description of the Installation
3. Description of the Installation
Further documents The following sub-supplier components are described in Technical

documentation.
Component
TD/4 High tension set
3.1 Description
3.1.1 Casing
Job No: 240 Rev : 0 Page : 3- 1

The main parts of the casing consists of the side walls, roof, walk-able
roof covering the thermal insulation, inlet and outlet transitions, dust
collecting hoppers and the insulator house (Pent House). The casing is
welded gastight.
The dust collecting hoppers are below the electrical fields. Vertical baffle
plates prevent bypass flow through the hoppers.
3.1.2 Inspection doors
Inspection doors are at four different locations of the electrostatic

precipitator. They are to be used for checks and inspections during
standstill periods only.
• Access to the Support Insulator and Heating element is provided

through the inspection door on the cold roof.
• Access to the discharge electrodes rapping devices, the suspension
of the discharge and collecting electrodes is provided through the
inspection doors on the hot roof (Inside Pent House).
• Access to the collecting electrodes rapping devices and to the gas
distribution is provided through the inspection doors at the side
walls.
• Access to the hoppers is provided through the inspection doors at
the hoppers. The inspection doors of the hoppers are equipped with
a poke hole near the access doors.
Job No: 240 Rev : 0 Page : 3- 2

3.1.3 Collecting Electrode System
The collecting electrodes are made of cold rolled profiled plates.

The collecting electrodes are movably hung in rows on suspension
bars. They are guided at the bottom end by the rapping bars without
hampering their thermal expansion.
Two collecting electrodes of each row are connected to the rapping
bar by supporting pins.
Job No: 240 Rev : 0 Page : 3- 3

3.1.4 Discharge Electrode System
As discharge electrodes ELEX INDIA is exclusively using the so called “RS”

electrodes, which are virtually unbreakable. They are fixed at the upper
discharge frame so that they are exactly in the centre of two collecting
electrodes.
Job No: 240 Rev : 0 Page : 3- 4

The connection between the connection pieces forms the lower

discharge frame.
The discharge system consisting of frames and discharge electrodes is
supported on insulators in order to achieve the electrical insulation from
the precipitator casing.
3.1.5 Gas distribution
The gas distribution consists of perforated sheets in the inlet transition

and the baffle plates in the outlet transition. Every row of perforated
sheets in the inlet is connected with the next row by connection bars.
3.1.6 Collecting electrodes rapping device
The collecting plates rapping device consists of the rapping hammers,

which are fixed in spirals on the rapping shaft, the shaft itself and the
geared motor.
Every electrical field has its own collecting electrodes rapping device.
3.1.7 Discharge electrodes rapping device
The discharge rapping device consists of the rapping hammers, which

are fixed in spirals on the rapping shaft, the shaft itself, the pinwheel, the
ratchets, the lifting rod, the rapping insulator and the geared motor.
Every electrical field has its own discharge electrodes rapping device.
3.1.8 High tension set
The high tension set consists of the high tension unit and the high
tension control panel.
The high tension unit contains in a hermetic closed oil tank a single
phase high voltage transformer, a current limiting reactor, a high voltage
rectifier in single phase bridge connection, a high voltage dividing
resistor and a HF-choke.
The high tension control panel consists of the high voltage controller and
the thyristor set.
Job No: 240 Rev : 0 Page : 3- 5

3.2 Description of the function
The gases to be cleaned are channeled through ducts to the precipitator

and evenly distributed over the whole cross section by means of distribution
baffles and perforated plates, which are placed inside the inlet transition.
Inside the precipitator the gases are flowing through parallel gas passages,
which are formed by the collecting electrodes located one after the other.
The discharge electrodes are fixed in the centre line of each gas passage.
Corrona effect The negative high tension produced by the HV-sets is applied to the
discharge electrodes. At the tips of these electrodes a corona effect is
produced due to the high voltage. This corona effect is separating the gas
molecules into negative and positive ions. Mainly the negative ions collide
on their way to the earthed collecting electrodes with the dust particles in
the gas stream.
The now negatively charged particles are attracted by the positive collecting
electrodes.
The positive ions travel only a short distance to the negatively charged
discharge electrodes. They encounter few dust particles on the way and
consequently the number of particles adhering onto these electrodes is
relatively small.
Job No: 240 Rev : 0 Page : 3- 6

The discharge system and the collecting electrodes are to be

periodically cleaned by means of rapping devices.
The dust falls down into the hoppers and will be extracted by the dust
conveying system.
For electrostatic precipitators with more than one field, every field is
electrically and mechanically separated from the other fields.
Economical ELEX INDIA electrostatic precipitators are more economical than other
dedusting installations. The energy consumption is low, the maintenance
and repair requirements are very little and the availability is generally
very high.
3.2.1 Casing
The cross section in the electrical field is much larger than at the inlet.
The gas to be treated has to expand in the inlet transition quite
considerably and the gas velocity slows down to normally less than 1.5
m/s. For a satisfactorily efficiency of the electrostatic precipitator, the
gases must be evenly distributed over the whole cross section of the
electrical fields. This is achieved with distribution baffles and various
rows of perforated plates in the inlet transition.
3.2.2 Hopper
The hoppers are placed below the electrical fields. The geometry is
designed that precipitated, dry dust can be discharged easily.
The baffle plates inside the hoppers prevent that gas to be cleaned can
bypass the electrical fields through the hoppers.
The tip of the hoppers are kept warm by hopper heatings wherever
necessary, even during standstill periods. The hopper heatings prevent
the condensation of humidity at the hopper tips (which cool down
normally the fastest).
Collected dust would normally cling to these humid areas and the
hopper outlet might be quickly blocked.
The hopper heatings are turned on and off by a thermostat. These
thermostats are located at a hopper side wall.
The hopper heatings are switched off only during longer standstill
periods, for example maintenance stops. The hopper heatings have to
be switched on for 30 minutes longer than gas actually flows through the
The hopper heatings wherever provided have to be started at least 4

hours before starting, respectively gas flows through the electrostatic
precipitator.
Job No: 240 Rev : 0 Page : 3- 7

3.2.3 Insulator heating
The insulator heatings around the supporting insulators hold the

temperature inside the insulator compartments above the dew point
temperature of the gas to be cleaned. This prevents that the surface of
the insulator itself becomes humid. This would lead to flash-overs on
the surface under high tension and consequently destroy the insulator.
The heating elements are constantly turned on. They are switched off
only during longer standstill periods, for example maintenance stops.
The insulator heatings have to be started at least 4 hours before
starting, respectively gas flows through the electrostatic precipitator.
Job No: 240 Rev : 0 Page : 3- 8

The gas distribution devices are distributing the gas stream evenly over
the whole cross section of the electrical fields, thus completely utilizing
the active collecting surface area of the precipitator. Some dust particles
may always stick to the gas distribution devices, thus influencing the
uniform gas flow. To avoid such an influence and to keep the devices
clean, they are periodically rapped.
The necessary flail hammers are integrated in the collecting electrodes
rapping system of the first field.
The baffle plates in the outlet transition are not rapped.
3.2.5 Collecting electrodes rapping device
The collecting electrodes are held in rows by rapping bars, which are
equipped with anvils. Flail hammers, which are mounted in spirals on the
rapping shaft, hit the anvils of the rapping bars. The impact of the blow is
transferred to the collecting electrodes, shaking off the dust layer. The
hammers are hitting the anvils individually in a certain sequence in order
to prevent a temporary overload of the dust conveying system.
Job No: 240 Rev : 0 Page : 3- 9

The rapping shaft is driven by a geared motor, which is connected by a

flexible coupling.
The fixed bearing is placed on the motor bracket, the floating bearings
are placed inside of the precipitator. A stuffing box is sealing the shaft
bushing through the precipitator side wall.
The rapping device is controlled by a microprocessor, which switches on
and off the drive in predetermined intervals, thus reducing the
mechanical wear and tear to a minimum. The rapping time sequences
will be determined by considering the kind of dust as well as the
precipitated quantity of dust.
The default rapping cycle setting is as furnished below :-
1st Field 2nd Field 3rd Field 4th Field
ON Time 6 sec. 6 sec. 6 sec. 6 sec.
OFF Time 3 min. 41 min. 103 min. 121 min.
This rapping cycle time is to ensure adequate rapping to the CE

system for dislodging the dust. Minor adjustments to this setting, if
required, are carried out during commissioning. It should be noted
that the rapping cycle time settings are not to be altered without
the prior consent from ELEX INDIA. Over rapping of the CE system
may lead to pre-mature failure of components of CE, its
suspension and its rapping system.
3.2.6 Discharge electrodes rapping device
The suspension bars for the discharge electrodes are equipped with
anvils. Flail hammers are hitting the anvils in a certain sequence, the
impact of the blow is transferred to the discharge electrodes, thus
shaking off the dust adhering to them.
The rapping shaft is driven by a geared motor, which is electrically

insulated from the parts under high tension by means of the rapping
insulator.
The rotation of the geared motor driving shaft is converted by an
eccentric into a linear motion of the lifting rod. The rapping insulator
electrically separates the lifting rod, which is under high tension and the
geared motor. The up and down motion of the lifting rod is again
converted into step by step rotation of the rapping shaft by means of the
pin-wheel with attached lifting and locking ratchet.
The rapping device is controlled by a microprocessor, which switches on
and off the drive in predetermined intervals, thus reducing the
mechanical wear and tear to a minimum. The rapping time sequences
will be determined by considering the kind of dust as well as the
precipitated quantity of dust.
Job No: 240 Rev : 0 Page : 3- 10

3.2.7 Dust conveying system
The precipitated dust is collected in the hoppers and is extracted by

means of the dust conveying system.
The efficiency of the electrostatic precipitator can be seriously hampered
if false air can enter through the dust conveying system. It must be kept
in a gas-tight condition.
Job No: 240 Rev : 0 Page : 3- 11

3.2.8 High tension set
The collecting efficiency of an electrostatic precipitator depends mainly

on the voltage between the negatively charged discharge electrodes and
the earthed collecting electrodes. Normally the efficiency reaches its
optimum when the highest precipitator voltage possible is applied i.e.
when the voltage is kept just below the disruptive discharge limit.
The value of the particular disruptive discharge voltage depends on the
physical and chemical conditions of the gases and on the dust content.
As the value of the momentary disruptive discharge voltage is
immeasurable, it can only be determined by achieving the disruptive
discharge (flashover).
The high voltage controller is raising the precipitator voltage upto the
disruptive discharge. After the flashover took place, the voltage is
quenched for a short period and raised again from a voltage value which
is lower by the voltage cutback. The voltage increasing velocity depends
on the flashover sequence and on the selected flashover density. This
velocity is controlled by the high voltage controller.
If the disruptive discharge voltage lies above the achievable voltage, no
flashover can occur.
TD High tension set se TD.
3.2.9 Earthing switch
Every high tension set is equipped with a single pole earthing switch.
All parts of the electrostatic precipitator, which are on high tension, can
immediately be earthed by the earthing switches.
With a closed switch resp. with an earthed discharge system, no corona

effect, arcs or flash overs are possible, thus preventing the ignition of an
explosive gas mixture inside the electrostatic precipitator.
The operation of the earthing switch is through Key-interlock stystem.
Job No: 240 Rev : 0 Page : 3- 12

3.2.11 Mechanical Interlocking system
The inspection doors of the electrostatic are locked by a mechanical

interlocking system against unauthorised opening. They can only be
opened after the high voltage is turned off and the high tension sets are
earthed. In the reverse case the high voltage can’t be turned on as long
as some inspection doors are opened and the high tension sets are
earthed.
With this system the correct interlocking sequence is ascertained.
OM The procedure to switch on the high voltage is described in the

operating manual.
OM The procedure to open the inspection doors is described in the

operating manual.
3.2.12 Earthing device / Grounding Stick
Prior to entering into an electrostatic precipitator, all parts which are on

high tension must be manually earthed at the inspection door itself.
This is a very important personal safety protection against switching on
the high voltage by any possible mistake.
OM The procedure to earth the discharge systems is described in

the operating manual.
Job No: 240 Rev : 0 Page : 3- 13

Commissioning
4. Plant Commissioning
4.1 Pre-Commissioning checks:
ESP
• Check the Field alignment
• Check all possible welding as per the drg.
• Check for correct installation of GD Plates and rapping system.
• Check the rapping system & drives for proper alignment and freeness.
• Conduct dry run of the rapping drives by running the motors.
• The bolts for hammers should be tighten as specified. No tack welding to be done at
this stage. ( After commissioning, in the first available shut-down, the bolts should be
again tighten fully and tack welded as specified).
• Check the interlock system for proper operation with the entire ckt.
• Ensure all internal work is over and no one is inside the ESP.
• Check the TR panel and TR sets for proper installation, correctness of cable
connection, termination ( no loose connection is permitted ).
• Check the complete earthing system for proper installation and connection.
• Check all the signal cables and connection of TR and the annunciation of TR set for
proper operation.
• Test the TR sets with Panel on No-load ( if permitted by the manufacturer ) & Short
ckt., check & calibrate the feed-back if required.
• Switch on the insulator heaters and allow the Support insulators to get heated to the
required temp.
• Box-up the ESP and conduct Air-load test. This can be done with the ambient
condition and very low air flow through the ESP, with natural chimney draft. Switch
on the TR set one by one and increase the power level from 0 to rated current
gradually. The field should reach the rated current level without sparking. In case of
any sparking, check the field alignment and correct it. Record the readings Voltage
(KV) & Current (ma) for future reference.
• Conduct a GD test by running the ID Fan to ensure correct distribution.
• Once this test is over, now the ESP is ready for commissioning.
Note:
As per the practice and for the warranty validity, the plant must be started
after completion of all the jobs and after receipt of a completion certificate
from the authorized ELEX INDIA Engineer.
Job No : 240 Rev : 0 Page : 4 - 1

Commissioning
4.2 Commissioning of The Gas Cleaning System
It is essential to follow all the SAFETY norms as mentioned in the O&M manual for safe
operation of the plant. Hence it is advisable that the plant operating people should read
the manual well in advance and familiarize themselves with the equipments, it’s controls
and emergency requirements. Start-up should be done only by authorized and trained
and qualified technicians / engineers.
The steps for commissioning shall be as follows:
• Start the ESP insulator heating, hopper heating system and Purge Air Fan at least 4-6
Hrs. before start-up.
• Start the dust conveying system at the bottom of the ESP hoppers.
• Start the Air lock valves below ESP hoppers ( ensure slide-gates are open ).
• Start the ESP Rapping systems CE & DE both in all the fields.
• Allow the Gas through ESP Gradually.
• Energize the ESP and keep the power-level low.
• Monitor the ESP Inlet temp. as it should be around 115-120 Deg.C.
• In case of any abnormal increase in the temp. beyond 200 Deg.C., the Fan should be
tripped and flow should be stopped to prevent any damage to the equipment.
• Adjust the controls to stabilize the ESP Inlet temp. as specified.
• When the system stabilizes, optimize the ESP power level and adjust the rapping
frequency.
• Record the process parameters:
• Record the TR Panel readings.
• Maintain the above information in the Plant Log on an hourly basis.
4.3 Start-up
• Please follow the steps mentioned in the Commissioning.

• Tune-up the controls as mentioned when the plant stabilizes.
• Log the readings hourly for future reference and fault-study.
Job No : 240 Rev : 0 Page : 4 - 2

Commissioning
High Voltage
The electrostatic precipitator installation is operating with

extremely dangerous voltages.
• Make absolutely sure that nobody stays inside the electrostatic
precipitator.
Commissioning only by ELEX INDIA personnel

The first commissioning should only be carried out by ELEX INDIA personnel.
Further
documents The commissioning of the sub-supplier components is described in the technical
documentation.
Components
TD High tension set
4.4 Preliminary works
→ Check all electrical connections, including earth conductor on filter casing.

→ Check that there are no foreign bodies on the discharge electrodes (use
inspection lamp and check each gas passage).
→ Check that no tools or foreign bodies have been forgotten inside the
precipitator and Pent House
→ Check the sense of rotation of all rapping devices with a test run.
→ Check that all hoppers are empty and free from dust deposits.
→ Check that all earthing cables have been removed from the high-tension
system.
→ Close the inspection doors gas tight and lock it with the mechanical
interlocking system against unauthorised opening.
→ Close the insulation doors covering the inspection doors.
→ Connect the main switches of the high tension sets.
→ Prior to start up the whole installation, the electrostatic precipitator has to be
checked under high tension but without gas flow
Job No : 240 Rev : 0 Page : 4 - 3

Safety Key Interlock Operation Procedure
Electro Mechanical Interlock (ESP)
The Interlock has been provided to operate during ESP Shut-down. The respective keys should
be preserved properly in place for smooth operation.
For Opening the Inspection Doors:
1. Switch off TR panel, lock the switch and remove the P1, P2 & P3 keys.
2. Put the P1, P2 & P3 keys in the Grounding Switch Lock.
3. Un-lock the HT by press and turning the key (key shall remain in lock).
4. Rotate the Grounding Switch to grounding position by operating handle provided in the
Grounding switch.
5. Lock the Grounding switch in Grounding Position by rotating the key E1, E2 & E3. And
release E1, E2 & E3 keys from the lock.
6. Insert the E1, E2 & E3 keys in key exchange box 1 in the respective area.
7. Release the X1 keys from the key box 1 Insert X1 key in Key box 2.
8. Release X2 & X3 keys from Key box 2. Insert X2 Key in Key Box 3.
9. Release the following keys from the key box 3.
a. H1 – Hopper door key
b. C1 – Casing Door Key
10. Insert the X3 key in Key box 4.
11. Release the following keys from the key box 4.
a. B1 – Bus Duct door Key
b. D1 – DE Door key
c. J1 – IHJB Switch key
12. Insert the J1 key in the IHJB lock. Through J1 key switch Off the supply by manually.
And release ‘X4’ key from the lock (This lock is having interlock with J1 key unless
other wise put back the X4 key no one can switch On the heater supply).
13. Insert the X4 key in key box 5. And release ‘I1’ key from the lock.
a. I1 – Pent House Door Key
14. Use the above keys to un-lock the inspection door lock in respective area
For Switching On the ESP
1. Lock the entire Inspection door and release all the keys from respective area.
2. Insert ‘I1’ key in the Key Box 5 and release the ‘X4’ key.
3. Insert X4 key in IHJB combined lock and unlock the supply by releasing the ‘J1’ key.
4. Insert the J1 key in key box 4 along with other door keys in key box 3 & 4 and release the
‘X2 & X3’ keys from key box 3 & 4 respectively.
5. Insert the X2 & X3 keys in Key box 2 and release the ‘E1, E2 & E3’ keys.
6. Insert the E1, E2 & E3 keys in respective HT Isolator Grounding Switch and unlock the
system.
7. Put the Switch in HT position and lock the system.
8. Release ‘P1, P2 & P3’ keys and Insert in respective TR panel.
9. Unlock the Panel. The ESP is ready for charging.
Note:
1. Once the P keys are removed the TR panel automatically goes to off position.
2. Without the P keys no one can enter into the ESP.
Reference Drg
a) Safety Key Interlock Scheme Drg No: 240-1-0E-20

Commissioning
4.5 Air Load Test :
This test should be carried-out first by ELEX INDIA engineer after successful
testing of the TR set and Panel. Follow the procedure :
Note : - Test to be done with normal air-flow through the ESP ( no need to run
the fan , but open the dampers )
1. Switch on Insulator Heaters 2 hours before Air Load Test.
2. Switch on the TR one by one.
3. Increase the current gradually to full / rated current and record the KV
readings w.r.t. the HT current mA.
4. The power level should reach the max. HT current level without sparking.
This shows the healthy-ness of the field.
5. If spark is observed, switch off HT, ground the field and rectify the faults /
alignment of the field. Again verify before commissioning / re-
commissioning.
6. Do this test after every shut down and keep the record of AKV-mA plot for
future reference / problem diagnosis.
4.6 Start up
When the process is ready, start the process of Start-up as follows.
→ Start the Hopper Heaters at least 4 hours before starting the plant.
→ Start the Insulator heating at least 4 hour before starting the system.
→ Start the dust conveying system heating (if existing) at least 4 hours before
starting plant.
Damage to the installation
1. Non-compliance with the 2 hours heating up time before Air Load Test can
have consequences of damage to the supporting insulators.
2. Frequent Start / Stop may lead to insulator failure.
Job No : 240 Rev : 0 Page : 4 - 5

Operation
5 Operation
High Voltage
The electrostatic precipitator installation is operating with extremely

dangerous voltages.
• Make sure that no persons are inside of the electrostatic precipitator.
Damaging the installation
Non-compliance with the permissible dust emission limits.

The behaviour of the electrostatic precipitator installation may change,
if you alter adjustments or set values.
• Only change the adjustment or set value of the electrostatic
precipitator installation when you know exactly the function and
impact of that specific parameter on the overall operation.
• Check the efficiency resp. the emission values after every change.
• Correct the new adjustments or set values if necessary.
Job No : 240 Rev : 0 Page : 5 - 1

Operation
Further
documents The operation of the sub-supplier’s components are described in the
technical documentation (HIND RECTIFIER’s manual).
Component
High tension set
5.1 Operating elements
The high tension sets can be operated from the central control room
(CCR) as well as from the high tension control panels (local control
room/substation) depending on the arrangement.
However the operation from the CCR is limited to Start and stop and
the reset of the undervoltage alarm/fault. All other disturbances, faults
or alarm messages must be resetted in the local control
room/substation.
The high tension control panels allows a far more detailed operation of
the equipment. However, the central control room must first give the
permission to operate from local control room/substation. A
lightened lamp at the high tension control panel indicates when this
permission is activated.
Job No : 240 Rev : 0 Page : 5 - 2

Operation
Operating elements of the high tension control panel
• Please refer to the manual of HIND RECTIFIER.
High tension set START
Manual mode:
→ Select the Remote/Local Switch in Local Mode.

→ Press the key marked start in Micro Processor Controller.
→ During pressing the key marked ↑ increase, the voltage increases.
→ During pressing the key marked ↓ decrease, the voltage
decreases.
Automatic mode:
→ Select the Local /Remote Switch in Remote Mode.
→ Press the key marked start from PLC or Remote.
OM The controller increases automatically the voltage of the electrostatic

precipitator and adapts itself to the changing conditions. The principle
of operation is described at the operating manual.
Changing from manual mode to automatic mode and back is possible

at all times (even during operation). But it is advisable to run the ESP only on
AUTO mode. Manual mode should be used for testing only.
The actual mode is shown with LED above the respective key.
High tension set STOP
Manual and automatic mode:
→ Press the key marked stop.
By pressing the key marked stop the high tension set is switched off
under all circumstances.
Job No : 240 Rev : 0 Page : 5 - 3

Operation
Reset of disturbances, faults or alarm messages of the high

tension sets.
The high tension set will immediately be switched off in such cases.
The messages are shown in detail on the display.
• Under-voltage
• TR Fault
5.2 Ready for start of the high tension sets
Before the high tension sets can be switched on, they must be ready
for starting.

→ The keys P of the mechanical interlocking system must be
inserted in the high tension control panels. The procedure is
described in the operating manual.
→ Check that there are no un-resetted disturbances at the high tension
control panel. Only in case of under-voltage disturbances the high
tension set can be started. all other disturbances require a prior
resetting as described before in detail.
The high tension sets will only be ready for starting if there are no
more disturbances present.
5.3 Start up
→ Start the insulator heatings at least 4 hours before starting the plant.
→ Start the hopper heatings at least 4 hours before starting the plant.
Damaging of the installation

Non-compliance with the 4 hours waiting time can destroy the main
insulators or block the hoppers or the dust conveying system.
→ Start the high tension sets.

→ Start the dust conveying system.
→ Start the rapping system.
Job No : 240 Rev : 0 Page : 5 - 4

Operation
5.4 Shut down of the electrostatic precipitator
→ Keep the electrostatic precipitator for 2 more hours in operation

after the shut-down of the installation it is serving
→ Switch off the rapping systems.
→ Switch off the high tension sets.
→ Switch off the dust conveying system.
Non-compliance with set emission limits.

Switching off some or all high tension sets or several or all chambers
of the electrostatic precipitator while the plant is running can lead to
non-compliance with given emission limits.
5.5 Shut down for inspection
If the installation has to be shut down for inspection, the following

steps will have to be followed.
→ Stop the dust conveying system heatings. (if provided)

→ Stop the hopper heatings.
→ Stop the insulator heatings.
5.6 Procedures in case of disturbances
As soon as a part of the electrostatic precipitator installation is disturbed, that

part will automatically be stopped. The disturbance is indicated at the CCR
and in the local control room/substation.
OM A check list with possible faults and hints for repair is included in the
operating manual.
Running the electrostatic precipitator installation in defective
condition will create a danger of personal injury as well as a
danger for the installation itself.
• Run the installation only if all the equipment is in proper condition

and well maintained.
• Damages must be repaired immediately by qualified personnel.
Job No : 240 Rev : 0 Page : 5 - 5

Operation
5.7 Procedures in case of emergency.
Stop immediately all high tension sets and motor drives in case
of an emergency.
The high tension sets can be stopped any time in the CCR or by pressing the
key marked ,,stop” at the high tension control panel.
5.8 Hoppers of ESP
Hoppers should not be used as silo to store material / dust. It is essential to

maintain the hopper seal and to evacuate the hoppers on a continuous basis.
Major hopper build-up can lead to damage to ESP field and uncontrolled and
un-noticed build-up can lead to over-loading of the support / ESP structure and
collapse of the structure.
Hopper level indicator should be kept in operation and the signal should be
respected.
Job No : 240 Rev : 0 Page : 5 - 6

Maintenance
6 Maintenance
Carry out maintenance and inspections always in set intervals.

Carry out maintenance inside the precipitator always in the following
sequences:
• Preliminary work
• Maintenance
• Final works
High Voltage
The electrostatic precipitator installation operates with extremely
dangerous voltages.
• Only qualified electrical personnel is allowed to carry out activities at the
electrical installation.
• Switch all electrical installations free from any possible electrical
source.
• Protect equipment from possible restart (disconnect and remove the main
fuses of the high tension sets for example).
• Connect the entire discharge system with the earth from the
respective inspection doors.
Danger of bruises and cuts

by sharp-edged sheets and heavy parts.
Wear gloves and security shoes.
• Use the right tools for transport and lifting of heavy parts.
• Protect heavy parts from failing down.
Job No : 240 Rev : 0 Page : 6- 1

Maintenance
Burns
During normal operation, some parts of the electrostatic precipitator
installation can become very hot. Touching these parts can cause
burning.
• Shut down the installation before you start with maintenance or
repairs.
• Let the installation cool down for at least 24 hours.
• Dust deposits in the hoppers can remain hot for even a longer
period.
• The inspection doors at the hoppers may only be opened after
checking the inside of the hoppers from above. The hoppers must be
completely empty so that no dust deposits can fall down when
entering from below. Otherwise you have to empty the hoppers and remove
the dust deposits before opening the inspection doors at the hoppers.
• The insulator heatings have to be switched off for works inside the Pent
House. Time for cooling down must be respected.
Poisoning
Precipitated dust or gas to cleaned can be toxic or caustic.
• Ensure that the inside of the precipitator is flushed sufficiently with fresh air.
• Check the inside of the precipitator against toxic or caustic gases before
you enter.
• Wear the requested protective clothing.
• Observe internal safety rules.
Danger of downfall
There is a permanent risk of falling down inside the electrostatic
precipitator.
• Use the right security equipment.
• Look out for a safe step.
Job No : 240 Rev : 0 Page : 6- 2

Maintenance
Electricity
Inside the precipitator only lamps as per VDE 0100 – § 32/2 must be
used.
Inside electrostatic precipitators or ducts the following equipment only
the following equipment is admitted for lighting:
• Using alternating current: max. 42 V or use of an isolating
transformer.
• Using direct current: a safely measure against indirect touching must be
provided, for example a protective insulation.
Additional rules
• Precipitator inspections must always be carried out by at least 2 persons.
• Observe internal safety rules.
• Use only original spare parts from ELEX INDIA.
Further
documents The maintenance of the sub-supplier parts is described in the technical
documentation.
Component
TD Geared motor
Job No : 240 Rev : 0 Page : 6- 3

Maintenance
6.1 Preliminary works
OM → Shut down the electrostatic precipitator according to operating

manual 5.
→ Use the mechanical interlocking system in the sequence described in the
manual to open the inspection doors.
→ Take all safety measures which are described before.

Especially:
→ Obtain permit to enter in to ESP from the plant operator.
→ Disconnect the main switches of all high tension sets.
→ Connect the entire high tension system to earth from the
inspection doors in the following sequence.
Sequence to earth the discharge system

→ Disconnect and remove all main fuses of the TR sets.
→ Put the earthing cables and the earthing rod near the inspection
doors
→ Open the insulation and inspection doors.
→ Put the earth connecting clamp of the earthing cable over the
earthing bolt by the inspection door and fix it.
→ Every individual electrical field has to be earthed
separately in the same way with Grounding Sticks!
→ Check the inside of the precipitator against toxic or caustic gases before
you enter.
Job No : 240 Rev : 0 Page : 6- 4

Maintenance
→ Pay attention to the temperature inside the precipitator.

→ The inspection doors of the hoppers may only be opened after
checking from the inside of the hoppers from above. They must be
empty and free from dust deposits which can fall down when the hopper
inspection doors are opened. Otherwise you have to empty the hoppers
and remove the dust deposits before you open the inspection doors at
the hoppers.
→ Inside the precipitator only lamps as per VDE 0100-§32/2 may be used.
Inside electrostatic precipitators or ducts the following equipment only
the following equipment is admitted for lighting:
• Using alternating current: max. 42 V or use of an isolating transformer.
• Using direct current: a safety measure against indirect touching must be
provided, for example a protective insulation.
Precipitator inspections must always be carried out by at least 2

persons. See also:
• VDE 0100
• VDE 0105, part 8
• VDE 2264
→ Clean the internal parts (for example with compressed air).

The dust conveying system has to be stopped while cleaning.
Job No : 240 Rev : 0 Page : 6- 5

Maintenance
The dust conveying system has to be covered or the slide gates at the
hopper outlet if present have to be closed during the operation.
→ In order to avoid internal corrosion, the opening of the inspection doors has
to be kept to a minimum.
→ For welding work at the discharge system the following rules have
to be observed:
The discharge system is electrically isolated by the supporting insulators and

can be earthed during standstill periods by the earthing switch on the high
tension transformer.
• The earth connection of the welding machine must be fixed
directly at the discharge frame.
• It is not allowed to use the earthing switches or the security
earthing cables as ground wires for the welding machine.
Non-observance of this instruction can result in destruction of the
earthing switch.
6.2 Schedule for checks and maintenance
The schedules for checks and maintenance are split into several time
intervals. The schedules contain information what has to be done at
which parts with what frequency. In the column “What” reference can
be made to the respective chapters.
The electrostatic precipitator installation has to be inspected at least
once a year. We recommend the delegation of one of our specialists
for the supervision of these checks.
In addition we recommend the following daily checks:
Job No : 240 Rev : 0 Page : 6- 6

Maintenance
6.2.1 Daily checks
Part What
Casing Visual check
• Locate and eliminate damages of the
thermal insulation and/or the cover thereof.
• Locate and eliminate leaks.
• Check the tightness of any connecting
elements and correct if necessary.
Hopper Check
• Dust levels in the hoppers
a) With Hopper level switch
b) through the poke holes.
c) by the dust quantity in the dust
conveying system
Danger of burning by outflow of hot dust
though the poke holes.
• In the unlike event of dust build up remove
them through poke holes and establish free
dust flowing condition inside the hopper.
Dust conveying system Visual check
• Locate and eliminate damages of the
thermal insulation and/or the cover thereof.
• Locate and eliminate leaks
• Check the tightness of connecting elements
and correct if necessary.
High tension sets Electrical values
• read and record Primary & Secondary
Voltage & Current values.
Job No : 240 Rev : 0 Page : 6- 7

Maintenance
6.2.2 Yearly checks and maintenance
Part What
Insulator heatings Check

• Function of the insulator heatings.
Support Insulators Check

• Open top covers and inspect inside surface
of the insulators.
• Inspect outside surface of insulators
• Clean with dry cloth.
Gas distribution Check

• Physical condition.
• Dust deposits on perforated plates.
• Function of the rapping device.
No lubrication is necessary.
Collecting system Check:

• Physical condition of the collecting
electrodes.
• Dust deposits on the collecting electrodes.
Lubrication of the rapping device required.
Discharge system Check:

• Physical condition of the discharge
electrodes.
• Dust deposits on the discharge electrodes.
• Physical condition of the supporting
insulators.
• Cleanness the supporting insulators.
Lubrication of the rapping device required.
Job No : 240 Rev : 0 Page : 6- 8

Maintenance
Part What
High tension sets Check:
• Cleanness.
Mechanical interlocking system Check:

• Function.
• Lubricate as required
Earthing device Check:

• Condition.
Hopper heatings Checks:

• Condition.
• Function.
• Thermostats
Purge Air Fan Check:

• Operation & effectiveness (air flor to
Pent-house)
Various inspections Check:

• Hopper dust level.
• Tightness of casing against intake of
false air.
• Corrosion inside of the casing.
• Thermal insulation in general.
• Earth connection and Earthing system.
Final check A final check must be made after each

yearly maintenance by a responsible
person.
Job No : 240 Rev : 0 Page : 6- 9

Maintenance
6.3 Maintenance
6.3.1 Insulator heatings
Insulator heatings
→ Control of the function.
• Defective heating elements have to be replaced.
→ Check cleanliness, clean if necessary.
→ Check condition of elements regarding corrosion, deformation,

suspension.
• Defective parts have to be replaced or repaired.
→ Check the perforated plates in the inlet transition regarding dust

deposits, the holes must be free over the entire cross section.
• Inspection of rapping device function is required, if excessive dust
deposits are found and clean manually.
Rapping device for gas distribution

→ Check the function with the collecting electrodes rapping device of
the first electrostatic precipitator field in continuous operation.
→ Check the physical condition of the hammers and the anvils

(usage, deformation, bolt connections).
• Worn out anvils and hammers have to be replaced or repaired
by building-up welding.
→ Check the connection rods between the rows of performed plates.

• Broken connection rods have to be replaced.
Job No : 240 Rev : 0 Page : 6- 10

Maintenance
6.3.3 Collecting system
Collecting electrodes
Check whether all collecting electrodes are straight and hanging
vertically. Allowed asymmetries:
• Collecting electrodes top end: tolerance = +/- 10 mm
• Collecting electrodes middle: tolerance = +/- 15 mm
• Collecting electrodes bottom end: tolerance = +/- 10 mm
• Deformed collecting electrodes have to be exchanged or aligned
properly.
Check whether there are no excessive dust deposits on the

collecting electrodes (dust layers on electrodes of up to 3 cm can
be normal).
• Inspection of rapping device function with the collecting.
electrodes rapping device in continuous operation.
• Adjust the rapping sequence if necessary.
Check whether all collecting electrodes are properly suspended.

• Check whether the supporting pins are properly inserted in the
supporting bar.
→ Check whether all rapping bars are properly fixed.

• Check the locking pins of the supporting pins.
→ Check by pushing in the direction of the rapping force whether all

rapping bars are moving freely. Rectify if necessary.
→ Check the rapping bar guide plates for wear. Repair or replace if
free distance is in excess of 5 mm.
→ Check that collecting electrode guide plates in the middle of elec-trode

height are in correct position and collecting electrodes are interlocked. Rectify if
necessary.
Job No : 240 Rev : 0 Page : 6- 11

Maintenance
Collecting electrodes rapping device inside of precipitator

→ Control the physical condition of the hammers and the anvils.
• At cold precipitator allhammers have to hit the anvils approx. 10 mm
below of the centre.
• At view from above all hammers have to hit the anvils exactly in the
centre.
→ Check all bolts and their locking.

• Worn out anvils and hammers have to be replaced or repaired by
building up welding.
→ Check all bolts and their locking.

• Worn out parts have to be replaced.
Collecting electrodes rapping device outside of precipitator
→ Check the geared motor
TD • Smooth run
• Fastening to the support
See technical documental
→ Inspect the physical condition of the coupling.
→ Check the fixed bearing regardng for a tight fit.
→ Check the stuffingbox of the shaft bushing.

• Worn out stuffing material has to be replaced.
After repair works on the geared motor or on its electrical

connection the sense of turning of the rapping device has to be
checked.
A wrong sense of turning may cause damages inside the precipitator.

Check by a short activation of the drive of ax. 2 seconds.
Job No : 240 Rev : 0 Page : 6- 12

Maintenance
6.3.4 Discharge system

Discharge electrodes
→ Check whether all discharge electrodes are straight and are
hanging vertically.
• Deformed discharge electrodes have to be exchanged or adjusted.
→ Check the distance between the discharge and the collecting

electrodes.
The discharge electrodes have to be placed exactly in the centre
of the gas passages. Allowed asymmetries:
• Discharge electrodes top end: tolerance = +/- 10 mm
• Discharge electrodes middle: tolerance = +/- 15 mm
• Discharge electrodes bottom end: tolerance = +/- 10 mm
→ Check whether all electrodes are correctly fastened to the

supporting bars.
→ Check the connecting pieces of the lower discharge frame.

• Defective or missing connecting pieces have to be replaced.
→ Check whether there are no excessive dust deposits on the

discharge electrodes (dust layers on electrodes of up to 1 cm
can be normal).
• Inspection of rapping device function with the discharge electrodes
rapping device in continuous operation.
• Adjust the rapping sequence if necessary.
→ Check that the supporting insulators are clean from dust and
other deposits and that there no cracks or traces visible on the
insulator surface.
• Clean dirty supporting insulators with a dry cloth.
• Defective supporting insulators have to be replaced. See operating
manual, index 7.
• Clean the suspension tube.
→ Check the stabilising fingers (only if existing).

• Defective stabilising fingers have to be replaced.
Job No : 240 Rev : 0 Page : 6- 13

Maintenance
→ Control of the function with the drive in continuous operation.

• All hammers have to hit the anvils exactly in the centre. Adjust if necessary.
→ Check the condition of the hammers and the anvils.

• Worn out anvils and hammers have to be replaced or repaired by
• building-up welding.
→ Check the pin wheel and the ratchets for wear and tear.
• Worn out ratchets have to be replaced.
→ Check all the bolt connections and their locking.

• Defective bolt connections have to be replaced and locked again.
→ Check the condition of the bearings.

• Worn out parts have to be replaced.
Discharge electrodes rapping device inside of insulator box

→ Check the bearing of the eccentric for wear and tear.
• Replace if necessary.
→ Check that the rapping insulators are clean from dust and other
deposits and that there no cracks or traces visible on the
insulator surface.
• Clean dirty insulators with a dry cloth.
• Defective insulators have to be replaced.
→ Check the lifting rod.
→ Check the stuffing box and the sliding bush in the insulator
cover.
• Worn out stuffing material and bushes have to be replaced.
Job No : 240 Rev : 0 Page : 6- 14

Maintenance
Discharge electrodes rapping device inside of precipitator

→ Check the geared motor.
• Smooth run
• Fastening to the support.
TD → Lubrication see TD
6.3.5 High tension sets
High tension sets

→ Check that the bushing insulator is clean from dust and other
deposits and that there no cracks or traces visible on the
insulator surface.
• Clean with compressed air and dry cloth.
→ Check the bolt connections.

→ Check the connections to earth.
→ Do not remove the cover of the high tension part for oil analysis!
Analyse the transformer oil only if the transformer has been
opened e.g. for repair works.
TD See technical documentation.
Job No : 240 Rev : 0 Page : 6- 15

Maintenance
6.3.6 Earthing switch
Earthing Switch
→ Check the contactor of the switch.
→ Check of the function by operating the switch.
→ Check the connections to earth.
6.3.7 Mechanical interlocking system
Mechanical interlocking system

→ Control of the function
→ Grease the locks with graphite
6.3.8 Earthing device
Earthing device
→ Check of the physical condition.
• Defective parts have to be replaced immediately.
Job No : 240 Rev : 0 Page : 6- 16

Maintenance
6.3.9 Hopper heatings
Hopper heatings
→ Control of the function
→ Check the set point of the thermostats.

The set point value can be found in the technical documentation.
TD
6.3.10 Support Insulators
Support Insulators
→ Inspect for any cracks / damange
→ Clean inside & outside surfaces with dry cloth.
TD → Replace, if required.
6.3.11 Various inspections
Dust level in the hoppers
Check the dust levels in the hoppers., In the unlikely event of dust build
up remove them and clean the hopper side walls and establish a free
dust flowing condition inside the hopper.
If the hoppers get filled with dust up to the electric field during
operation., it will cause a short-circuit and that electrical field will be out
of operation.
Non-compliance with the emission limits

The breakdown of one or more electrical fields, leads to non-compliance
with set emissions limits.
Damaging the electrostatic precipitator

Full hoppers can cause furthermore the deformation of the hopper
baffles and the distortion and misalignment of the entire discharge
system.
If the dust doesn’t flow out of the hopper properly, the following
measures should be taken.
Job No : 240 Rev : 0 Page : 6- 17

Maintenance
Emptying of the hoppers

→ Check whether the conveying system is working correctly and is
not overloaded.
→ Try to empty the hopper by rapping the hopper walls or by

loosening the dust through the poke holes.
Danger of burning by outflow of hot dust through the poke
holes if not sufficient cooling down time was allowed for.
→ If the first two procedures are failing the hoppers have to be

emptied from the top by means of poking rods.
The inspection doors at the hoppers may only be opened
after checking from above that the hoppers are empty.
Otherwise there is a danger of sudden outflow of dust through the
inspection door. The dust might be even hot if not sufficient
cooling down time was allowed for.
→ Investigate the reason why the outflow of dust was hampered.

Possible causes:
• Intake of false air through the dust conveying system.
• Excessive quantity of dust, even only momentarily.
• Insufficient thermal insulation of the dust conveying system or of the hopper
flanges.
• Defective consecutive dust conveying system.
→ Defects have to be repaired.
Job No : 240 Rev : 0 Page : 6- 18

Maintenance
Tightness
Tightness
• The precipitator casing, the hoppers and the dust conveying system have to
be checked for tightness.
Intake of false air can cause serious troubles.
• Whirl up of already precipitated dust and transportation back into the
electrical field or even worse directly to the outlet.
• Increased gas volume.
• Lower gas temperature and lower dew point, both normally
impairs the efficiency of the electrostatic precipitator due to
worsened physical conditions.
• Check of the inspection doors, in order to secure a air tight closure.

• The threads of the clamps have to be kept running well.
• If necessary replace gaskets.
• Check gate valves, dampers and all other items too for tightness.
Corrosion
Corrosion
• The whole internal equipment has to be checked against corrosion
and take preventive measures as soon as possible.
Thermal insulation
Thermal insulation
• Check the cladding of the thermal insulation of the precipitator and the
ductwork for tightness against rain water.
• Repair immediately where necessary.
Job No : 240 Rev : 0 Page : 6- 19

Maintenance
Earthing
Earthing
• All metal parts have to be connected to earth, if they can get connected
with parts under tension by direct contact or by arc in all possible cases of
faulty conditions. (DIN/VDE 0141)
• The following parts must have a separate earthing connection to the

precipitator casing and earth by wire or rod:
• High tension set.
• All flange joints at the insulator compartments.
• Cover of the insulator compartments.
• Inspection doors.
• Precipitator supporting structure.
• Connections at the earthing points have to be firmly fixed, form- fitting and
in a good electrical conductive condition. The earthing wire or rods
themselves have to be connected properly from the electrical conduction
point of view either by welding, screwing or clamping (screw dimension at
least M10).
• Minimum cross sections required for earthing connections:

• for copper 16 mm2
• for steel 50 mm2 (galvanised or copper-plated)
• for aluminium 35 mm2
• For the returning line of the electrostatic precipitator current from the
collecting electrodes to the high tension sets, a separate conductor is
necessary with an induction as low as possible. Therefore the cover of the
oil tank of the high tension transformer/rectifier, the oil tank itself and the
precipitator casing have to be connected with each other in the required
manner.
• Minimum section for this returning line:

• for copper 16 mm2
• for steel 50 mm2 (galvanised or copper-plated)
• for aluminium 35 mm2
• Defective or missing earth connection or returning line parts have to be
replaced.
Job No : 240 Rev : 0 Page : 6- 20

Maintenance
6.3.11 Final Inspection
After carrying out all checks and repairs the following items have to be
checked by the responsible person:
Final Inspection
→ Check whether there are foreign bodies on the discharge elec-
trodes (use inspection lamp and check each gas passage).
→ Check whether tools or foreign bodies have been forgotten

inside the precipitator.
→ Check whether all rapping hammers are back in their initial

position.
→ Check whether the hoppers are empty. Dust deposits have to

be eliminated.
→ Check whether the security devices inside the precipitator have

been removed.
→ Close the inspection doors gas tight and lock it with the
mechanical interlocking system against unauthorised opening.
→ Close doors provided with insulation.
→ Prior to start up the plant, the electrostatic precipitator has to be

checked with high tension but without gas flow (Air Load ).
6.4 Lubrication
List of lube points Follow vendor’s manual.
Job No : 240 Rev : 0 Page : 6- 21

Faults & Repairs
7 Faults and Repairs
Carry out repairs inside the ESP always in the following sequence:
• Preliminary work
• Repairs
• Final works
Further Documents :
The repairing of the items supplied by vendor is described in Technical Documentation

TD.
7.1 Faults
In the following table possible causes and tips of how to remove

the Faults are listed. Before starting with repairs inside of the
precipitator the security instructions as listed at chapter 6 have to
be observed and the preliminary works as listed at chapter 6.1
have to be carried out.
Job No : 240 Rev : 0 Page : 7- 1

Faults & Repairs
Observation Possible cause Repair

Abnormal high • Supporting insulator • Clean the support-
Frequency of flash dirty ing insulator.
Over/arcs, in general • Replace the sup-
Low electrical values • Supporting insulator porting insulator.
defective
• See TD,
• High tension set
defective
• See TD
• Condition of trans-
former oil
• Check the earthing
• Earthing switch switch.
defective • Check DE system
• Discharge
Electrodes system
Out of centre line • Check the discharge
system.
• Discharge electrode bent
or loose • Check the discharge
electrodes rapping
• Excessive dust deposits device.
on discharge
electrodes • Check the collecting
electrodes rapping
• Excessive dust device.
deposits on collecting
electrodes • Check each gas
passage with a
• Loose parts inside of inspection lamp
the precipitator
Job No : 240 Rev : 0 Page : 7- 2

Faults & Repairs

Abnormal high • Excessive dust deposits • Clean the gas
Frequency of flash on gas distribution distribution devices,
Over/arcs, in general devices
Low electrical values
• Dust bridge between • Remove the dust
earthed parts and bridge
discharge system
• Hopper filled up with dust • Empty the hoppers.
• Rapping impact • Check the rapping

insufficient devices and the
electrode rapping
program.
• Dew point temperature • Check the operating

too low data
• Intake of false air • Repair the leak
• Gas volume too high • Check the operating

data
• Gas temperature • Check the operating
changed data
• Raw gas dust content • Check the operating

changed data
• Unstable operation of • Stabilise the process

plant
V low, I up to max., • Supporting insulator dirty Clean the support - ing
HV – set tripping insulator.
Job No : 240 Rev : 0 Page : 7- 3

Faults & Repairs

V low, I up to max., HV – • Supporting insulator • Replace the
set tripping defective supporting insulator.
See chapter 7.2.1
• High tension • Check the high
connection loose tension connection
• High tension set • See TD, index 4

defective
•
• Inadequate • See TD, index 4
condition of trans- •
former oil
• Check the earthing
• Earthing switch switch. See chapter
defective
• Check the
• Discharge electrode bent discharge system.
or loose
• Remove the dust
• Dust bridge between bridge
earthed parts and
discharge system
• Empty the hoppers,
• Hopper filled up with dust
HV-set can’t be • Fuse defective or circuit • Replace the fuse or
switched on after breaker tripped reset circuit breaker
switching off
• Contractor fault • Clean or replace the
contacts of the
contractors. See TD
HV-set can’t be • Wrong operating • Change the

switched on after tripping mode operating mode
(Substation/CCR)
Job No : 240 Rev : 0 Page : 7- 4

Faults & Repairs

HV-set can’t be switched • Key of the mechanical • Put in the key and turn
on after tripping interlocking system not it on.
inserted or not turned.
• Fuse defective or circuit • Replace the fuse or

breaker tripped reset circuit breaker
• High tension set • See TD.

defective
• High voltage controller • See TD

defective
• Thyristor defective • See TD
• Motor circuit breaker • Reset the motor circuit

tripped breaker
• Earthing switch defective • Check the earthing

switch,
HV-set tripping, restart • High tension set • See TD

only possible after a few defective
minutes • See TD
• Lack of oil
• See TD
• Oil temperature too high
Cracking or other • High tension set • See TD, index
unusual noise from the defective / loose
HV-transformer connection
Job No : 240 Rev : 0 Page : 7- 5

Faults & Repairs

Insulator heating • Short circuit of a heating • Replace the defec-
Tripping element Tive heating
Element.The in-
Sulator heating can be
restarted after
Disconnecting the
defective element.
Insulator heating fault • One or more • Replace the

but not tripping Heating elements defective heating
Out of order Element.
Hopper heatings tripping • Short circuit of a Replace the defective
heating element heating element. The
hopper heating can be
restarted after
disconnecting the defective
element.
Hopper heating • One or more heating Replace the defective
disturbance but not elements out of order heating element.
tripping
Rapping device is not • Fuse defective • Replace the fuse
Operating
• Motor circuit breaker • Reset the motor circuit
tripped. breaker
• Fault of the drive • Check the drive see
• Lubrication inadequate • See TD

Rapping device not • Local switch turned Turn on the safety switch
ready but no disturbance off
Job No : 240 Rev : 0 Page : 7- 6

Faults & Repairs

Drive doesn’t operate • Fault of the drive • Check the drive
smoothly (rapping
device, dust conveying
system) • Lubrication inadequate • Lubricate-TD
High dust emission at • Supporting insulators • Clean the suporting
the stack, low electrical dirty insulator. See chapter
values 6.3.4
• Supporting insulator • Replace the supporting

defective insulator. See chapter
7.2.1
• High tension • Check the high tension

Connection loose connection
• Inadequate condition of • See TD, index 4

transformer oil
• Discharge electrode • Check the discharge

frame out of centre system. See chapter
6.3.4
• Discharge electrode bent • Check the discharge

or loose system. See chapter
6.3.4.
• Excessive dust deposits • Check the discharge

on discharge electrodes electrodes rapping
device. See chapter
6.3.4
• Excessive dust deposits • Check the collecting
on collecting electrodes electrodes rapping
device.
Job No : 240 Rev : 0 Page : 7- 7

Faults & Repairs

High dust emission at the • Gas volume too high • Check the operating
stack, normal electrical data
values • Gas temperature
changed • Check the operating
Data.
• Raw gas dust content
change • Check the operating
data
Job No : 240 Rev : 0 Page : 7- 8

Faults & Repairs

High dust emission at • Loose parts inside of • Check each gas
the stack, low electrical precipitator passage with a
values inspection lamp.
• Excessive dust deposits • Clean the gas

on gas distribution distribution devices.
devices. See chapter 6.3.2
• Dust bridge between • Remove the dust bridge

earthed parts and
discharge system
• Hopper filled up with dust • Empty the hoppers,

See chapter 6.3.10.
• Rapping impact • Check the rapping
insufficient devices and the
electrode rapping
program,.
• Dew point temperature • Check the operating

too low. data
• Ingress of false air • Repair the leak

• Gas volume too high • Check the operating
data
• Raw gas dust content • Check the operating
changed data
• Unstable operation of • Stabilise the process
plant
High dust emission at • Dust conveying system • Check tightness of the
the stack, normal not gastight dust conveying system
electrical values
Job No : 240 Rev : 0 Page : 7- 9

Faults & Repairs
7.2 Repairs
7.2.1 Replacement of a defective supporting insulator
¾ Carry out the preliminary works as described in earlier chapter.

¾ Take off the cover from the insulator compartment where the defective
insulator is thought to be.
¾ Remove the geared motor and the rapping insulator on insulator
compartments with a rapping drive.
¾ Disconnect and remove the insulator heating element if necessary.
¾ Measure and note the following dimension inside the electrostatic
precipitator. It will be a great help later for the realignment of the
discharge electrodes system after the insulator has been exchanged.
• Distance between roof – upper discharge frame at 4 points

• Distance between side walls – upper discharge frame at the 4
corners of the frame.
• Distance from the upper intermediate walls – upper discharge
frame at 2 points at the 4 corners of the frame.
¾ Lift the discharge frame simultaneously on both sides of the defective
insulator by means of a hoist until the insulator is relieved form any
load.
¾ Unlock the safety nut and remove the nut from the suspension tube
¾ Remove the insulator cover and take out the defective insulator.
¾ Clean the insulator supporting surface
¾ Place the new insulator with new gaskets exactly in the centre.
¾ Bring the insulator cover back to position
¾ Screw on the nut to the suspension tube
¾ Lower the discharge frame to its initial position
¾ Check the reference dimensions and adjust as long until you read the
same values than before the insulator change
¾ Check the position of the discharge frame. Accepted asymmetries.
• Discharge electrode top end: tolerance = +/- 10 mm
• Discharge electrode middle: tolerance = +/- 15 mm
• Discharge electrode bottom end: tolerance = +/- 10 mm
¾ Tighten and secure the nut of the suspension tube
¾ Place back and connect the insulator heating element
¾ Reassemble the geared motor and the rapping insulator
¾ Close the (insulator) Pent House with its door and check that it is
correctly sealed
¾ Final inspection
¾ Test run with high tension without load (no gas flow)
Job No : 240 Rev : 0 Page : 7- 10

Technical Data
8. Technical data
8.1 Manufacturer :
ELEX (India) Pvt. Ltd.

Plot No. A-97, Road No.-18,
Wagle Industrial Estate,
Thane 400 604
Tel: 022 2581 2266

Fax: 022 2581 2733
Email: info@elexindia.co.in
8.2 Mechanical data
Number of EP’s 1
Type 3422 / 4F
Number of electrically separated fields: 4 / chamber
Number of mechanically separated fields 4 / chamber
Number of gas passages 12 / chamber
Spacing of gas passages 400 mm
Length of collecting electrodes 10 m
Length of one field 5.4 m
ESP Configuration
Job No: 240 Rev : 0 Page : 8 - 1

Technical Data
8.3 Electrical data
Supply voltage 415 VAC

Frequency 50 Hz
Number of HV-sets 3 Nos.
Secondary current of 1 HV-set 400 mA - 2 Nos.
900 mA - 1 No.
8.4 Operating condition
Combination of Ukhni
100% Ukhni Coal Coal + Char & Washery
Rejects
Gas Volume (Am3/sec) 47.17 57.48

Gas temperature (Operating) (Deg. C) 115 120
Gas pressure (design) (mm WG) (-) 250 (-) 250
Raw gas dust content (g/Nm3) 34 70
Mech. Design Temp (Deg. C) 200 200
Clean gas dust content (mg/Nm3) 75 75

(with all fields in service) (wet)
Job No: 240 Rev : 0 Page : 8 - 2

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OPERATION & MAINTENANCE MANUAL

Electrostatic Precipitator for 90 TPH AFBC Boiler

M/s. Lloyds Metals & Engineers Ltd.

ELEX (India) Pvt.Ltd.

2. Maintain the process parameters within the specified limits.

4. Evacuate the ESP hoppers at a regular interval.

5. Adjust the TR setting to operate ESP fields with minimum sparks.

6. Keep the required readings in a logbook for reference.

7. In the event of any doubt / question, please contact ELEX INDIA.

8. Put the correct GRADE of oil in Rapping Motor Gear-Box.

9. Allow proper combustion in the boiler to avoid fire / damage to ESP.

11. SAFETY MEASURES

Job No : 240 Rev : 0 Page : 1

It is also extremely important to continuously monitor the formation / presence of any

Job No : 240 Rev : 0 Page : 2

2. Do not by-pass the inter-lock.

5. Do not by-pass any safety requirement.

6. Do not keep ESP fields on if the hopper level is high.

7. Do not ignore any fault signal from any equipment.

8. Do not run the Rapping Motors without Gear-Box oil.

9. Do not use the hopper as silo.

10. Do not over-rap the ESP.

11. Do not run the ESP with faulty controller.

12. Do not close the Purge Air Fan damper.

Job No : 240 Rev : 0 Page : 3

Electrostatic Precipitator ( ESP )

Title Section Pages

General Safety Rules 2 4

Faults & Repairs 7 10

Geared motor drive for Rapping

General Arrangement Drawing of ESP

Your documentation for the electrostatic precipitator installation is

Technical The technical documentation is written for qualified, technical

About this operating manual

Reading assistance in this documentation

TD This indicates a reference to the technical documentation (TD).

Job No: 240 Rev : 0 Page : 1- 1

2 General safety rules

2.2 Use as directed

The electrostatic precipitator is especially designed and built for the

Misuse Any misuse of the electrostatic precipitator is generally not permitted.

Job No : 240 Rev : 0 Page 2- 1

Exceeding the maximum permissible positive or negative pressure at the

It’s therefore not allowed to operate the electrostatic precipitator beyond

2.3 Working in accordance with the safety measures and rules

Make a contribution to safety!

2.4 Responsibility of the client of ELEX INDIA

As owner and operator of the ELEX INDIA electrostatic precipitator

Job No : 240 Rev : 0 Page 2- 2

• Train your staff.

2.5 Safety devices

2.6 Components and spare parts

Use only ELEX INDIA original spare parts.

The collected dust of the electrostatic precipitator installation has to be

Job No : 240 Rev : 0 Page 2- 3

2.8 Additional rules

• rules for accident protection,

2.9 Exclusion from liability

ELEX INDIA is under no circumstances liable or responsible for injury or

Job No : 240 Rev : 0 Page 2- 4

3. Description of the Installation

Further documents The following sub-supplier components are described in Technical

TD/4 High tension set