OPERATION & MAINTENANCE MANUAL

FOR

ELECTROSTATIC PRECIPITATOR

INSTALLED F0R

70 TPH AFBC BOILER

(SOLID FUEL –BASED CPP)

AT

M/S AMBUJA CEMENTS LTD.

BHATAPARA

(ACC Job. No. 1904 A)

SUBMITTED BY

ACC LIMITED
ENVIRONMENT & ENERGY CONSERVATION CELL
ACC THANE COMPLEX, LBS MARG,
THANE - 400 604, INDIA.

1
 INDEX

• PART I – OPERATION & MAINTENANCE MANAUL FOR

ELECTROSTATIC PRECIPITATOR

• PART II- OPERATION & MAINTENANCE MANUAL FOR

T.R.SET & CONTROL PANEL

• PART III- OPERATION & MAINTENANCE MANUAL FOR

RAPPER CONTROL PANEL

• PART IV - OPERATION & MAINTENANCE MANUAL FOR EXP

AUXILLARIES

• PART V – REFEREENCE DRAWINGS FOR ELECTROSTATIC

PRECIPITATOR

2
 PART I

OPERATION & MAINTENANCE MANAUAL

FOR

ELECTROSTATIC PRECIPITATOR

3
 TABLE OF CONTENTS

SR NO SECTION TITLE PAGE

1 Section-1 Introduction 5
2 Section-2 Important Instruction 6
3 Section-3 ESP-Operating Principle 8
4 Section-4 Electrostatic Precipitator
11
Design Specifications
5 Section-5 Safety 14
Section-6 Preventive Maintenance
6 20
Section-7 Operation & Maintenance
7 33
Overview
Section-8 Standard Spares List For
8 49
ESP
Section-9 Performance Guarantee
9 50
Test Criteria

4
 SECTION - 1
INTRODUCTION
PURPOSE AND CONTENTS OF THIS MANUAL
This manual contains both general and specific information for the safe
operation and maintenance of the precipitation equipment installed at M/S
AMBUJA CEMENTS LTD. BHATAPARA. The warranty is valid
provided the equipment is operated and maintained as per the instructions
given in this manual.

Because the equipment has been custom design, certain specific adjustments
and setting can only be made during operation. Information regarding these
adjustments will be supplied during start-up by ACC-EEG field personnel
who will also:

1. Perform a quality assurance inspection.

2. Startup the equipment on air and gas load.

3. Adjust and set electrical equipment.

4. Record data.

5. Train plant personnel in operation and maintenance.

DESCRIPTION OF INSTALLATION

PURPOSE

01 No. of Electrostatic Precipitation equipment is designed for 70 TPH

AFBC BOILER SOLID FUEL – BASED CPP AT M/S AMBUJA
CEMENTS LTD, BHATAPARA.

SCOPE

The equipment furnished by ACC-EECC under this contract consists 01 No.

Electrostatic Precipitator with G-Opzel type collecting plates; "Pipe-Spike
™“ rigid discharge electrodes, MIGI rapper, Support insulators & Seal air
system.

5
 SECTION -2

IMPORTANT INSTRUCTIONS

1.1 DONT’S

) Do not by-pass safety interlocks.

) Avoid excessive spark within the ESP.

) Do not enter / touch any internals without grounding the field with
portable grounding sticks after throwing the grounding switch to
‘ground’ position.

) Do not use ESP hoppers as silo to store dust.

) Do not reduce the under-voltage setting below 10 KV.

) Do not by-pass any operational inter-lock (elect / instrumentation)

1.2 DO’S

) Ensure all safety precautions are adhered to while operating the

ESP especially with respect to high voltage system.

) Ensure that proper cleanliness and ventilation / air conditioning of

the control room are maintained to prevent entry of dust inside the
control equipment/panels.
6
) Ensure periodically logging of the readings of the TR set control
Panel and Rapper Panel / settings.

) Ensure operation of the ESP above the acid dew point temperature
to avoid corrosion of internals.

) Ensure that during oil firing no unburned carbon is present (If

applicable).

) Ensure that the ESP gas inlet temp, do not exceed the designed
Temperature limit.

) Ensure that the rapping mechanism is in operation as per sequence.

) Ensure proper evacuation of hoppers and dust build-up do not

exceed the specified level in the hopper.

) Ensure that CO and O2 monitors are in circuit (if applicable).

) Ensure all access doors are properly closed / sealed.

) Stop / trip the unit if the Hopper level (High) signal stays beyond 1
hour to avoid internal damage/collapse of hopper or structure.

) Ensure seal air system is ON at all time and to be put OFF only
during long shutdown / stoppage.

7
 SECTION -3
ESP –OPERATING PRINCIPLE

Electrostatic precipitation uses the forces of an electric field on electrically

charged particles to separate solids from a gas stream. The dust-laden gas
passes through an electrically charged field causing the particles to migrate
toward an oppositely charged electrode, which acts as a collection surface.
Gravity or rapping the electrode removes the particles from the precipitator.

Commercial ESP’s accomplish charging using a charged direct-current

corona surrounding a highly charged electrode, such as a wire. The large
potential gradient near the electrode causes a corona discharge comprising
electrons. The gas molecule in the vicinity of this electrode become ionized
with charges of the same sign as the wire electrode. These ions then collide
with and attach to the dust particles, there by charging the particles.

The behavior of these charged particles depends on the polarity of the

electrodes; a negative corona is formed if the discharge electrode is negative,
and a positive corona is formed if the discharge electrode is positive. When a
corona is negative the free electrons leaving the active zone are transformed
into negative ions with a substantially lower mobility on their way to the
plates. The negative charge carriers thus cover the first part of their path as
fast, free electrons and the second part as slower ions; their average mobility
is lower than that of free electrons but higher than that of the large ions. On
the other hand, when a corona is positive, the positive charge carriers are
large, slow ions by origin and retain this form throughout their motion.
Consequently, a negative corona always has a higher corona current than a
positive corona for an applied voltage.

8
Basically An Electrostatic Precipitator consists of a steel airtight chamber
housing the Collecting & discharge electrodes. The Discharge electrodes are
usually suspended from the top through support insulators. The Collecting
electrodes (plates) are connected to ground & the emitting electrodes are
supplied with a high negative voltage, which is in Kilovolts. Rapping system
periodically cleans the dust collected on the collecting electrodes. The dust
is collected in pyramid or trough type hoppers before they are discharged
pneumatically or through a combination of Rotary Air Lock Valve & dust
conveying system. The inlet & outlet cones ensure gradual drop in velocity
till it retains the design velocity on reaching the collecting are. Gas
Distribution plates at the inlet & outlet ensure uniform gas distribution
across the length & width of the ESP.

The collecting & emitting electrodes are alternately placed across the width
of the ESP, each pair of Collecting Electrodes forming a gas passage, which
is usually spaced at 300 mm or 400 mm. The emitting electrodes are of
various types, each having some type of sharp points, which are the corona
generating sources. These are divided into sections or fields to reduce the
effect of electrical disturbance called sparking. The ESP are usually with 2 –
3 fields in series for treating smaller quantity of gas volumes & can be upto
5 –7 series field for larger capacity Power Plants.

The High Voltage source is a transformer – rectifier. The power is controlled

in the L.T side by using an anti-parallel combination of SCR’s. The firing of
these SCR’s is controlled by Microprocessor based controllers which
regulate the power depending up to the set values & sparking conditions.
The regulated power is then converted to Kilovolts by High Voltage
transformer & then rectified using Diode Bridge Rectifiers. The Power is fed
to the emitting electrodes through High Voltage bus, which acts as a

9
protective guard. Usually a grounding switch is provided between the TR set
& the emitting electrodes (field) to isolate the TR set & connect the field to
ground potential during ESP maintenance.

The rapping, which is usually, either top rapping using MIGI rappers or side
rapping using rotating hammers driven by geared motors. The inlet field,
which sees more dust, naturally collects more dust as compared to the outlet
field. Generally for a three field ESP, the inlet field collects around 80%
dust, the second field collects 16% dust & the third field collects 4% dust.
However the collecting depends on the power available for these fields as
well as the process conditions. Accordingly the inlet rappers are cleaned
faster as compared to the outlet rappers.

The higher dust load at the inlet results in lower operating current & requires
a higher operating voltage. Typically the current increases as we go from the
inlet field to the last field. At the same time the voltage reduces as we go
from the inlet field to the outlet field. Unusually high currents at the inlet are
an indication of problems in the ESP.

The ESP is very sensitive to deviations in process parameters from the

design parameters.

10
 SECTION -4
ELECTROSTATIC PRECIPITATOR DESIGN
SPECIFICATIONS

ELECTROSTATIC PRECIPITATOR DESIGN SPECIFICATIONS

SPECIFICATIONS OF ESP:

No. Of ESP 1 No.

ESP Size 1P, 1C, 19GP (15.75”x 32’x
65.2’) 4F (4 x 16.3’)
No. of Fields / ESP 4 Nos.
No. of Bus Section 5 Nos.
Material of Construction IS 2062
Design Pressure - ESP casing MMWC -250
Pressure drop across the ESP MMWC 25-30
Temperature for structural design in 0 C 250
No. of Chambers/Precipitator 1 No.
No. of Gas Passages/chamber 19 Nos.
Migration Velocity cm/sec 3.92
Aspect Ratio 2.04
T/R Set Quantity 5 Nos. 500 mA, 110 KV (P)

COLLECTING ELECTRODES
Material IS 513
Collecting Surface Height (Mtrs.) 9.754
Width of collecting electrode (Mtrs.) 2.225 + 2.74
Collecting plate spacing 400 mm
No of Electrodes / ESP (20*4F + 20*4F) 80 + 80

DISCHARGE ELECTRODES
Type Rigid Pipe & Spike
Material IS 513
Height (Mtrs.) 9.75
Total No of Electrodes / ESP (171 * 4 F) 684Nos.

11
RAPPING ARRANGEMENT

Type MIGI (Magnetic Impulse Gravity

Impact)
No of C E Rappers / ESP (10 * 4 F) 40 Nos.
No of D E Rappers / ESP (4 * 4 F) 16 Nos.
No. of PDPL Rappers 08 Nos.
Rapper Controller Type PLC based

SEAL AIR SYSTEM

Quantity / ESP 01 No.

Motor Rating 2.2 KW

No. of Heater Banks / SAS 03 Nos.

No. of Heating Elements / Bank 12 Nos.
Heater rating 2 KW each

HOPPER

Type Pyramidal

Material of Construction IS 2062

Thickness of Plate 5
Valley Angle (approx) Deg 60

12
HOPPER HEATERS

Quantity / ESP 16 Nos.

No. of Heaters / Hopper 04 Nos.

Heater Rating 1.5 KW each

HOPPER VIBRATORS

Quantity / ESP 16 Nos.

No. of Vibrators / Hopper 04 Nos.

ESP Operating Parameters:

Gas Volume in Am3 / hr 1,29,600

Type of dust Fly Ash
Operating Temperature in 0 C 140
Operating Pressure mmWC - 225
ESP Inlet Dust Concentration in (gm / Nm3) 91

ESP Outlet Dust Concentration (mg /Nm3) 30

13
 SECTION -5

SAFETY

1.0 INTERLOCK SYSTEM

A safety key interlock system is provided with this equipment to prohibit

entry into a precipitator or high voltage transformer enclosure unless all
electrical energization systems have been de-energized and grounded. The
interlock systems consists of a series of locks and keys located and sequenced
to control the step of de-energizing grounding, and opening of equipment to
prevent personnel from coming in contact with energized high-voltage
components. The detailed procedure for using the key system is described in
the OPERATION Section of this manual.

The key system controls access any to hinged access openings used during
normal operation and routine maintenance. Bolted access covers and junction
boxes of 415 volts or less are not incorporated in the interlock system.

The key interlock system is designed to prevent inadvertent contact with

charged high voltage equipment, but is not designed to prevent a determined
person from deliberately endangering his life. Defeating the key interlock
system creates a mortal danger to all personnel working on the precipitator,
therefore Never Attempt To Bypass Any Interlock Under Any Circumstances,
If the lock system fails to work properly, repair it; don't defeat it or ignore it!
Electrocution Could Result.

14
2.0 GROUNDING

The portable ground sticks provide additional personal protection

against accidental contact with charged equipment. Never approach
(with the intention of touching) high voltage components without first
attaching a grounding device. Remember, The Only Ground You Can
Trust Is One You Can See.

3.0 WORKING AROUND LIVE ELECTRICAL EQUIPMENT

The key interlock system will not protect against contact with the
following:
1. High Voltage Bus Duct.
Use extreme caution when removing access covers from the bus duct.
Lock out the T-R associated with the bus, and attach a portable ground
to the bus to bleed off any static charge before touching it. The static
charge in the precipitator can be transferred from energized bus sections
to a de-energized section, so keep a ground on the de-energized section,
so keep a ground on the de-energized bus at all times while working on
it.

2. 415 Volts in the T-R Control

CAUTION: When troubleshooting in an energized T-R Control
Cabinet, beware of -
1) 415 Volts A.C. on SCR heat sinks -
2) A.C. Voltmeter Terminals -
3) Other terminal points as identified on the electrical prints -

15
 4) DO not operate the controls with the doors open unless live

troubleshooting is absolutely necessary, and then use extreme

caution.

4.0 HOT DUST HAZARD

The dust in precipitator hoppers and plenums can remain dangerously
hot for several days after shutdown. Use extreme caution when
opening hopper doors, as hot dust is very fluid and can cause severe
burns. Do not step into dust piles inside the precipitator, and use
caution while working around dust pickles.

5.0 PRECIPITATOR ENTRY PRECAUTIONS

1. Securely close and lock out dampers, which could admit flue gas into
the precipitator. Depending on the situation, use blanks.

2. Unlock the precipitator using the key interlock system.

3. Open hopper doors with caution. Beware of flowing hot dust.

4. Ventilate the precipitator thoroughly, and test for safe atmosphere.

5. Keep a safety person outside the precipitator whenever anyone is

inside.

6. Use portable ground sticks before contacting high voltage

components.

7. Never close a door unless absolutely certain no one is inside, the best
practice is to close the door you have used as soon as you come out,
before someone has the chance to go in behind you. The use of "vessel
entry permits" or a similar type of system, to account for whoever is
inside the precipitator, is recommended.

16
6.0 POTENTIAL FOR FIRES/EXPLOSIONS IN THE
PRECIPITATOR
When combustible mixture of fuel and oxygen is allowed to enter the
precipitator, a fire or explosion may occur, causing severe damage to
ESP. In the event that a quantity of unburned fuel has been supplied
to the precipitator, minimizing. If a fire hazard is suspected, the
precipitator T-R's should be turned off to eliminate sparking as a
source of ignition. The precipitator should then be rapped clean while
flue gas O2 is kept to a minimum.

A fire or explosion will occur when three conditions are met

simultaneously:

1. A combustible material is present.

2. Oxygen sufficient to support combustion is present.

3. A source of ignition is present.

One or more of these conditions must be eliminated to prevent a fire

or explosion from occurring in the precipitator.

6.1 COMBUSTIBLE MATERIALS

Build-up of combustible materials in the precipitator can be

minimized by:

1. Emptying hoppers continuously or as often as practical.

2. Checking the collecting and discharge electrode cleaning mechanisms

for proper operation.

17
6.2 OXYGEN SOURCES
The amount of oxygen sufficient to support combustion varies with
the concentration of combustible material present in the dust/ash. In
general, damaging fires cannot occur regardless of combustible
concentration when the oxygen level of the flue gas is below 4%
Oxygen levels exceeding approximately 7% are potentially dangerous.
The following procedures should be followed to minimize flue gas
Oxygen:

1. Do not open flue access doors during operation, and make sure
that all access doors and other openings (such as hopper poke
holes) are fully sealed.

2. Minimize tramp air in leakage around slide gates, expansion

joints, air heaters, and out-of-service boilers or precipitators.

3. Hopper air-lancing and fluidizing air system should not be

used. If air -lancing systems are installed on a precipitator, they
should be used only in a pulsing mode and as seldom as
possible. A continuous flow of air into a hopper should never
be permitted.

4. Ensure that penthouse or insulator compartment seal air

systems are adjusted to provide the proper flow rates.

18
6.3 IGNITION SOURCES

Precipitator sparking is a potential source of ignition when

combustibles and Oxygen are present in quantities sufficient to
support combustion. For this reason, the precipitator T-R s must be
de-energized immediately during emergency situations. Power must
be left off until Oxygen, combustibles, or both are reduced below the
point of supporting combustion.

To facilitate removal of precipitator power during emergencies, flame

safety interlocks/O2 sensor interlocks and/or emergency trip switches
are often appropriate.

7.0 OZONE HAZARD

Precipitators generate substantial quantities of toxic ozone gas when
energized. Never energize a precipitator while people are working in
ductwork associated with the precipitator, as ozone gas can flow
hundreds of feet in closed ductwork and accumulate in deadly
concentrations. Ventilate the precipitator and ductwork thoroughly
before entering.

19
 SECTION -6

PREVENTIVE MAINTENANCE

1.0 MAINTENANCE OVERVIEW

2.0 OPERATIONAL CHECKLIST

2.1 Continuous checks
2.2 Daily Checks
2.3 Weekly Checks
2.4 Semi-annual Checks

3.0 OUTAGE INSPECTIONS

3.1 Inspections and Record Keeping
3.2 Outage Checklist

4.0 KEY INTERLOCK MAINTENANCE

4.1 Warning
4.2 Key Replacement
4.3 Lock Maintenance

20
1.0 MAINTENANCE OVERVIEW

Efficiency and reliability of precipitator operation is dependent upon

the establishment of accurate record keeping and preventive
maintenance routines. Systematic recording and analysis of pre-
cipitator electrical data and process data will enable the operator to
detect gradual degradation of the will enable the operator to detect
gradual degradation of the equipment which may not be obvious to
the casual observer. Inspection and preventive maintenance of key
elements of the precipitator during outage opportunities will minimize
unplanned downtime and expensive component failure. The checklist
provided in this section should be amended as necessary to suit the
particulars of this installation, and should then become the basis of a
permanent record keeping and maintenance program.

2.0 OPERATIONAL CHECKLIST

2.1 CONTINUOUS CHECKS

1. Maintain flue gas conditions as per the design ratings of precip-

itator. In particular, monitor gas temperature, O2, and combus-
tible carry-over. Failure to maintain design operating
conditions at all times can result in damage to the precipitator
internal components (e.g. corrosion).
Maintain pent-house temperature above acid dew point to avoid
corrosion.

2. Respond promptly to alarms from essential systems such as

rappers, hopper levels detectors, hopper heaters, dust
conveyors, and seal air system. Problems in these systems can
quickly cause major problems with the precipitator as a whole.

21
 3. As situations warrant, make visual checks of critical compo-
nents such as rappers, particulate removal equipment, etc.,
rather than relying on alarms alone to detect problems. Check
any equipment that does not generate alarms in the turned-off
state, to ensure that it is switched on.

4. Maintain pent-house temperature above acid dew-point

temperature to avoid corrosion.

5. Maintain pressurization of the pent-house compartment to

prevent entry of direct gas inside (specially during start-up).

2.2 DAILY CHECKS

1. Record transformer-rectifier electrical data, using the

Transformer-Rectifier Electrical Readings from provided. At
the time the data is recorded, the operator should compare the
data with past readings under similar operating conditions,
looking for changes that signal developing problems in the
precipitator. Section G.O. of the Operation chapter of this
manual gives guidelines for evaluating electrical data.

If the optional central control system is used for automatic

printout of operating data, the operator should not overlook the
task of daily analysis of the printout.

22
 2. Check operation of hopper equipment to ensure that collected
particulate is being removed from the hoppers. Frequent and
thorough emptying of the collected particulate is essential to
avoid hopper pluggage. Particulate removal checks may
include: high-level indicators, hopper heater operation,
particulate conveying system function, and hopper throat
temperatures.

3. Examine precipitator control room ventilation system. Over-

heating can cause failure of transformer-rectifier and rappers
controls, and entrance of corrosive gases can cause
deterioration of electronic circuits.

2.3 WEEKLY CHECKS

1. Check operation of rapper system. Although the rapper control

generates alarm on most malfunctions, this system is essential
to precipitator operation. Good practice calls for periodic visual
checks of actual rapper operation.
2. Check seal air system operation and air filter condition.

2.4 SEMI-ANNUAL CHECKS

1. Check calibration of level detectors, pressure switches, flow

switches, and motion detector switches where provided.

2. Simulate and check alarms from rappers, transformer rectifier

controls, and other equipment with alarm outputs.

3. Test any electrical safety interlocks used in the system, such as

emergency transformer-rectifier shutdown.

23
3.0 OUTAGE INSPECTIONS

3.1 INSPECTIONS AND RECORD KEEPING

The following checklist should be followed when plant personnel

make an outage inspection of the precipitator internals. Such internal
inspections should take place whenever an outage occurs after 6
months of continuous operation, although longer periods of trouble-
free operation need not be interrupted solely for the purpose of
inspecting the equipment. Consideration should be given to more
frequent inspections during the first year of a precipitator's life and
after periods of questionable operation.

ACC-EEG field service representatives will make more extensive

checks than shown on the following list during a scheduled inspection
of older equipment. The particulars of factory authorized inspections
depend on the life history of the unit, problems reported by the
purchaser, and performance experience with similar equipment at
other installations.

To schedule an inspection visit, contact:

DURING COMMISSIONING PERIOD:

Sr. Manager (Projects)
ACC Ltd.
E .E .C.C
Technical Support Service
ACC Thane Complex
L.B.S. Marg,
Thane - 400 604
Fax:(022) 2580 1302 / 2582-0962

24
 DURING AND AFTER COMMISSIONING PERIOD:

Manager (Field Services)

ACC Ltd.
E .E. C.C
Technical Support Service
ACC Thane Complex
L.B.S. Marg,
Thane - 400 604

Ph:(022) 2583-3035
Fax:(022) 2580 1302/2582-0962

3.2 OUTAGE CHECKLIST

1. Measure average particulate deposits on discharge and collecting
electrodes, for comparison with past and future inspections. "Normal"
dusts levels vary widely between installations, but 1/4 inch on the
surface of collecting plates and a light deposit on sharp edges of
discharge electrodes are not unusual. Excessively clean collecting
plates may indicate rapping re-entrainment. (At time of shutdown,
turn off transformer-rectifiers and rappers simultaneously to retain
dust levels. Running the rappers after shutdown of the transformer-
rectifiers reduces the residual dust level and makes these
measurements less meaningful).
2. Check for broken rapper rod insulators, cracked support bushing
insulators, and broken or loose stabilizer bar insulators. Clean,
tighten, or replace insulators as required.
3. Check for any corrosion of internal component. In case of any major
problems report it to ACC for corrective action.

25
3.2.2 SUPPORT INSULATOR REPLACEMENT
In the event it becomes necessary to replace a support insulator, the
high-tension frame must be shored-up at its operational elevation prior
to removal of the old piece. Penetrations of the precipitator hot roof
are provided for installation of frame erection support members. The
new insulator should be installed in accordance with the pertinent
ACC-EEG drawing. After replacement is complete, confirm proper
inter-electrode alignment.

3.3 Check for signs of plugging of gas distribution plates and excessive
floor buildup on inlet and outlet plenum surfaces.

3.4 Check for signs of hopper plugging.

3.5 Check for dust clinkers or abnormal build-ups between high voltage
components and ground in any section where operating records may
indicate abnormally low voltage or high sparking. Remove any such
deposits thoroughly so they cannot serve as the nucleus of future
built-ups.

3.6 Check for signs of air in leakage around access doors and shell seams,
which might cause corrosion or abnormal buildups.

3.7 Check for signs of misalignment between collecting plates and

discharge electrodes. Under ordinary conditions, electrode alignment
will not change over the life of the precipitator, and ACC-EEG
construction procedures provide for electrode alignment within

26
 precise tolerances as recorded in the construction documents. Any
misalignment found after startup should be investigated closely, as it
is indicative of abnormal conditions. Likely causes of misalignment
are:
1. (Bottom electrode alignment) Loose or broken stabilizer bar
insulators, if provided. High voltage frames should move only
slightly when pushed. Bars should be attached firmly to bottoms of
collecting plates, loosely to high voltage frame.
2. (Bottom electrode alignment) Collecting plat spacer bar connections
to side frames or partition walls may have come loose. This
connection is welded and bolted with a slotted hole to provide vertical
movement during heat expansion, but no horizontal movement.
Check for weld failure at this connection.
3. (Top electrode alignment) If a support bushing insulator needs to be
replaced, care must be taken to reposition the upper frame in the
original position when installing the new insulator. Simple
misalignment of the upper frame indicates improper positioning after
repair.

4. (Distortion of electrodes) Collecting plates and discharge electrodes

are never perfectly straight, due to inevitable distortion during
transportation and handling.

Careful positioning and field straightening techniques, however, are

used to compensate for minor distortion while maintaining construction
tolerances. If component bends are noted, no action should be taken unless
actual measurement indicates alignment outside tolerances.

27
 Severe distortion of internal components is a sign of thermal stress
caused by fire in the precipitator. If this condition is suspected, a thorough
inspection by ACC-EEG is recommended. Fires do not occur in
precipitators under normal operating conditions. Any evidence of fire
warrants complete and prompt review of operating procedures to prevent the
occurrence of catastrophic fire causing total equipment loss.

3.8 Make notes of nature and location of all abnormalities found in the
precipitator, whether corrected during the outage or not. Use diagrams to
record locations of failed components. These records are useful for
identifying possible patterns of repetitive component failures and will be the
basis of future outage inspections.

3.9 Welding onto high voltage frames In the event it becomes necessary
to do work involving arc welding onto a precipitator high voltage frame, the
high voltage conductor must be removed from the frame's support insulator
spider (and grounded) to isolate the Transformer-Rectifier. The frame itself
should then be grounded using a dedicated grounding jumper prior to
welding. Remove jumper and re-connect high voltage conductor after
welding is complete.

4.0 KEY INTERLOCK MAINTENANCE

4.1 WARNING
ACC-EMD has provided an appropriate key interlock system that is
installed on all hinged access doors of the precipitator to protect
persons involved in precipitator operation and maintenance from
accidental contact with energized high voltage components. This
system must be maintained in AS NEW condition, and there should

28
 exist no extra or additional keys for the system. Should the interlock
system be modified, removed, or otherwise not maintained in its
proper operating condition, or should the Purchaser, or anyone acting
on behalf of the Purchase obtain additional keys for the interlock
system, a significantly dangerous condition would exist for persons
involved in maintaining the equipment for which ACC-EEG disclaims
responsibility. ACC-EEG disclaims responsibility for damage or
injury resulting from the failure of proper maintenance to the interlock
system.

4.2 KEY REPLACEMENT

Because duplicate keys defeat the purpose of the interlock system, no
duplicate keys are provided. The key blanks are of a special pattern
not stocked by locksmiths. In the event a key is lost, the Purchaser or
his Agents must sign indemnity forms before duplicate or replacement
keys will be issued by ACC-EEG. Keys will not be supplied directly
by the Manufacturer, and should be ordered as shown below:

ACC Ltd.
Environment Energy Conservation Celll
Technical Support Service
ACC Thane Complex
L.B.S. Marg,
Thane – 400604,
Ph. (022) 2583-3035,
Fax (022) 2580-1302/2582-0962

29
 DUPLICATE AND/OR REPLACEMENT INTERLOCK KEY
RELEASE
REFERENCE: CUSTOMER -
LOCATION -
JOB NUMBER -

In accepting duplicate and/or replacement interlock keys the purchaser

agrees to the following:
Purchaser and his employees agree to indemnify and hold harmless ACC-
EEG it's officer, employees, agents and those in interest with it against all
claims, valid or invalid, and liability for injuries to, or death of persons or
damage to property connected in any way with possession or use of interlock
keys.
Please return signed form to the undersigned.
Sincerely yours,
ACC Ltd.
Environment Equipment Group
Technical Support Service
ACC Thane Complex
L.B.S. Marg,
Thane - 400 604

Signature Of Plant Official

Name:
Title:
Date:
Place:

30
 ATTACHMENT B
INTERLOCK INDEMNITY
If ACC-EEG previously provided a key interlock system with the original
electrostatic precipitator(s) or is furnishing additions or alterations to the
original system or is providing the initial key interlock system under this
contract, the following shall apply:

For said interlock system to be an effective means of protecting persons

involved in precipitator operation and maintenance, said system must be
maintained in new condition and there should exist no extra or additional
keys for the system. Should the Purchaser, its employees, agents, engineers
or anyone else acting on behalf of the Purchaser tamper with, compromise or
otherwise not maintain the interlock system in its proper operating
conditions of should extra or additional keys for said interlock system be
made or obtained by any means whatever, the Purchaser agrees to indemnify
and hold harmless ACC-EEG, its officers, employees, and agents from any
and all liability arising out of said failure to maintain the key interlock
system in proper operating order, or arising out of the existence of extra or
additional keys for the system.

If said interlock system, in the opinion of a ACC-EEG Field Service

Representative, has been tampered with, compromised or otherwise not
maintained in its proper operating condition, the Field Service
Representative may at his discretion refuse to perform services in, on and
around equipment that contains said interlock system. The Purchaser shall
still be obligated to pay the minimum daily rate for work refused under the
above conditions.

31
LOCK MAINTENANCE

Keep protective lock covers in place at all times to prevent dust or other
contaminates from fouling the lock mechanisms.

Periodically insert flaked or liquid-suspended graphite solution into each

lock cylinder, working it into the slots with the keys. Never lubricate the
locks with oil or build up in the lock. When oil is left for long periods of
time, a film sets up on the lock components, which introduces a frictional
load, making the lock mechanism harder to actuate.

If locks become difficult to operate, clean the lock mechanisms by injecting

light mineral spirits into the locks. Then using compressed air to purge the
lock interiors. Re-lubricate with flaked graphite.

Never apply excessive force to interlock keys, such as by turning keys with
pliers. They are made of brass, and are easily broken.

32
 SECTION -7
OPERATION AND MAINTENANCE OVERVIEW

1.0 KEY INTERLOCK SYSTEM

1.1 Warning
1.2 Key Interlock Operation

2.0 AIR LOAD TESTING

2.1 Air Load Overview
2.2 Air Load Procedure

3.0 STARTUP PROCEDURES

3.1 Overview
3.2 Startup Checklist

4.0 SHUTDOWN PROCEDURES

5.0 EVALUATING OPERATION

5.1 Normal Operation
5.2 Typical Problems

6.0 DATA SHEETS

6.1 Precipitator Air Load Electrical Readings
6.2 Voltage-Current Characteristics (Graph)
6.3 T/R Electrical Readings

33
1.0 KEY INTERLOCK SYSTEM
1.1 WARNING
Refer to the SAFETY section of this manual for precautions regarding
use and maintenance of the Key Interlock System. Failure to properly
use and maintain the key interlock system could result in a serious
electrocution hazard. Refer to the MAINTENANCE section of this
manual for lock maintenance procedures and information on
replacement of lost or broken keys.

1.2 KEY INTERLOCK OPERATION

The principal purpose of the key interlock system is to prohibit entry
into the precipitator via normal interlocked man way access doors
until the high voltage transformers are locked off and grounded.

Note: The interlock system is not designed to protect personnel from

hazards such as the removal of bolted access plates on high voltage
pipe and guard, etc., which are external to the precipitator vessel and
outside the scope of the interlock system. To enter the precipitator,
proceed as follows:

1. Push all transformer-rectifier circuit breakers OFF. Turn the

interlock key next to each breaker to lock it OFF, and remove keys.
(Keys cannot be removed when breakers are in the ON position.)
Note that the I.D. number stamped on each key matches the number
on each lock to facilitate key handling.

2. Take the breaker keys to the transformer-rectifier ground switch

enclosures, and unlock each ground switch according to the matching

34
I.D. numbers on the keys and locks. Turn the ground switches to the
Ground position.

3. Turn the other interlock keys next to the ground switches to

lock the switches in GROUND position. Remove the ground switch
keys. (Keys cannot be removed until switches are locked in the
GROUND position.)

4. Take the ground switch keys to the transfer box and insert them
into the locks according to matching I.D. numbers. After all ground
switch keys are inserted, the locks can be rotated simultaneously,
releasing the door keys.

5. Enter penthouse area first and put all safety ground sticks on all
high voltage bus sections as a redundant safety measure. (Note:
Remember to remove ground sticks prior to putting precipitator back
in service!)

6. Use the door keys to unlock the precipitator access doors.

7. (For applications using nuclear hopper level detectors) To gain

access to the hoppers insert access door keys into the level detector
control locks. The level detectors can then be locked in the OFF
position, freeing keys for the hopper access doors. This step is
required to protect personnel from radiation emitted by the nuclear
level detectors.

8. Read And Observe Safety Procedures Outlined In The Safety

Section Before Entering Precipitator:
35
 9. Locking the precipitator for returning it to service is the reverse
of the above procedure.

10. Always Replace Lock Covers After Using The Key System To
Prevent Dust Or Other Contaminants From Fouling The Lock
Mechanisms.

PRECIPITATOR ELECTRICAL CHECKINGS

OPEN CIRCUIT TEST & SHORT CIRCUIT TEST: These checks are
performed to check the healthiness of the TR sets.

OPEN CIRCUIT TEST:

Disconnect the HT link between the TR set and the ESP Field. Charge the
TR set gradually increasing the setting. The TR set should be energized to
the rated secondary KV without any sparks or primary / secondary current.
Record the primary voltage & secondary KV

SHORT CIRCUIT TEST:

Connect the TR set secondary to Earth. Gradually increase the milliamps to
the rated current. The TR set should develop the rated milliamps without
sparking. The TR set should not be subjected to this condition for more than
5 minutes. Record the Primary Amps & secondary milliamps

36
2.0 AIR LOAD TESTING

2.1 AIR LOAD OVERVIEW

The purpose of an air load is to check the operation of the precipitator

Transformer-Rectifiers and fields prior to startup. The term "air load"
refers to energizing the high voltage transformers and controls with
only air in the precipitator, as opposed to process gas, which is done
during "gas load". Air load testing does not require air movement,
and is preferably done with dampers closed to minimize draft through
the precipitator.

As stated in the safety section of this manual, precipitators generate

substantial quantities of toxic ozone gas when energized. Never
energize a precipitator while people are working in ductwork
associated with the precipitator, as ozone gas can flow hundreds of
feet in closed ductwork and accumulate in deadly concentrations.

The first air load is done by ACC-EECC personnel as a part of

commissioning activities of the new precipitator. The initial data is
submitted to the customer in the startup report, and should be kept
permanently on file for comparison with subsequent air loads
conducted by plant operating personnel. The data should conform
reasonably well. Large deviations from the voltage-current
relationships generally indicate close electrode spacing, excessive dust
accumulations on electrodes, or malfunction of a transformer-rectifier
set.

37
 The equipment is designed such that the secondary current rating of
the transformer-rectifier sets may be achieved without sparking on air
load. If sparking does occur, it is normally caused by close inter-
electrode spacing, foreign matter, or moisture. Certain ambient
conditions, such as excessive moisture, can cause sparking and failure
to attain rated transformer-rectifier current, and may not indicate a
problem.

The following data is usually recorded during air load testing:

1. Ambient air temperature
2. Weather conditions (dry or humid, sunny or rainy etc.)
3. Date and time of day
4. Transformer-rectifier control set meter readings in increments
of 50 Milliamps from zero to set rating.

AIR LOAD TEST:

This test should be conducted during the initial field charging &
subsequently after every outage. The readings should be recorded for each
field in the format as mentioned below.

CAUTION: Before starting Air Load Test, the Seal Air System should
be energized at least 4 hours in advance.

2.2 AIR LOAD PROCEDURE

1. Energize the seal air system fan and heater, at least two hours
prior to air-load testing. This will eliminate or reduce any
moisture condensation on insulator surfaces that might cause

38
 sparking during air-load. This step may be skipped if the
precipitator internals are known to be dry.
2. Reduce stack draft or airflow to the precipitator, if possible,
little or no stack draft is desired.
3. Remove all personnel from ductwork associated with the pre-
cipitator.

WARNING: Toxic Ozone Gas Generated During Air Load

Testing Will Flow Through Ductwork And May Accumulate In
Deadly Concentrations. Ventilate Precipitator And Ductwork
Thoroughly Before Re-Entering.

4. Check settings of transformer-rectifier control operating

parameters and trip points, as outlined in Power Supply System
To The ESP. Proceeding with each transformer-rectifier control
one at a time:
5. Set control secondary current limit to 50 milliamps, and turn on
transformer-rectifier. Record primary and secondary volts and
amps as indicated on the transformer-rectifier control. Use
record form attached to this section.
6. Reset control secondary current limit to 100 milliamps and
again record data.

7. Continue raising secondary current limit at increments indicated

on the record form until a nameplate current or voltage rating is
achieved. If sparking in the precipitator (indicated on the
control display) prevents obtaining a nameplate rating,
determine cause. (Sparking caused by ambient moisture
usually disappears after a short period of energization.)

39
 8. Compare air load data between each transformer-rectifier set
and with any prior air load. Account for any serious discrepan-
cies before concluding air-load.

9. Reset secondary current limit to nameplate rating of trans-

former-rectifier or to other value recommended by ACC-EECC.

3.0 STARTUP

3.1 OVERVIEW
During the initial air load of the precipitator, the transformer-rectifier
control parameters are preset to allow the transformer-rectifier sets to
operate at optimum power levels for maximum collection efficiency.
Startup consists of simply turning on the precipitator controls in the
correct sequence when process conditions are suitable.

3.2 CO ANALYSER (IF APPLICABLE)

Before energizing the ESP it should be ensured that CO Analyzer is
functioning properly. In no case, the setting for tripping on high CO,
exceed 1 % volume. Also it is recommended that chemical analysis
of the flue gas be carried out periodically (once in three months) and
its results compared with CO Analyzer readings. Any error should be
taken care of by adjusting the trip settings accordingly.

3.3 STARTUP CHECKLIST

A formal startup procedure is useful to ensure that the precipitator
components are put on-line in the correct sequence and at the right
times to avoid causing operating problems and damaging equipment.

40
 The following standard checklist may be modified if necessary to suit
the particular requirements of your plant: Any questions related to
proper startup procedure, sequence, etc., should be referred to ACC-
EEG.

) Check that all required outage maintenance has been completed, all
grounding devices removed, and all doors closed securely. (A
brief air-load test at this time is useful to ensure that all sections
are free of grounds.)

) Turn on seal air system at least three hours prior to introducing flue
gas into the precipitator. Check thermostat setting of seal air heater.

) Turn on rappers anytime prior to introducing flue gas. Turn on

hoppers particulate removal equipment at this time to carry away
any remaining dust that falls off the plates due to rapping. (Failure
to do so may results in plugged hoppers!)

) Ensure that the pent-house temperature is above acid dew point.

Introduce flue gas into the precipitator. Before the transformer-
rectifier controls are turned on, the following conditions should be
met:

) Precipitator outlet temperature should be above acid dew point.

(This ensures that precipitator internals are above dew point
eliminating arcing across damp insulator surfaces.)

) Process operation should be stabilized, with minimal potential of

combustible carry-over into the precipitator.

) If these conditions cannot be met the situation should be discussed

with to determine what special startup procedure may be
appropriate.

41
 ) Turn on transformer-rectifier controls, and check control displays
for indications of normal operation.

4.0 SHUTDOWN PROCEDURES

During shutdown, equipment is generally taken off-line in reverse
sequence from startup:

) Turn off transformer-rectifier controls before gas temperature

drops below dew point to ensure that condensation doesn't cause
arcing across insulator surfaces.

) Continue to operate rappers and particulate removal equipment for

several hours after process shutdown to remove residual dust,
leaving the precipitator in cleaner condition for the next startup.
(Exception: If an internal inspection is planned to check dust levels
on electrodes, turn rappers off when transformer-rectifier's are
turned off to preserve dust levels.)

) Seal air system may be left on or off, according to preference. If

an internal inspection is planned, the heaters should be turned off
to allow the precipitator to cool for entry. During a brief outage
with no inspection planned, no harm is done, by leaving this
equipment turned on.

42
5.0 EVALUATING OPERATION

5.1 NORMAL OPERATION

Precipitator operation varies constantly in accordance with changing
gas conditions. As a result, control set electrical readings will
fluctuate frequently and will differ between controls, so that no one
set of readings can represent "Normal" operation. Comparison with
prior operating records for similar gas loads and condition can provide
the best clause to norms of operating. The following general
indications should, however, be obtained under any operating
conditions:

1. Precipitator voltage should be above about 25 kilovolts D.C.

and 100 volts A.C. in all fields.

2. Precipitator current (milliamps D.C. and amps A.C) should

increase from inlet to outlet fields, usually approaching nameplate
ratings in the outlet fields. Absolute values cannot be predicted, as
they vary widely with operating conditions. Also when electrical
sections are of different sizes, the larger sections will draw more
current than the smaller ones, all other things being equal.

3. Precipitator sparking should diminish from inlet to outlet field

seldom exceeding about 20 sparks per minute on any one control.
The spark- rates will vary widely even under constant conditions, due
to the effect of rapping, and due to power changes initiated by the
automatic controls

43
5.2 TYPICAL PROBLEMS
Following is a summary of the most frequently occurring problems,
which might show up in transformer-rectifier electrical readings.
1. PROBLEMS - Grounded high voltage bus section.
SYMPTOMS - Abnormally low primary and secondary Voltage.
- Control trips off on "Under-voltage."
CAUSES - Hopper overfilled to level of bottom frame.
- Grounding device left on high voltage frame.
- Foreign material left in precipitator.
- Broken high voltage insulator.
2. PROBLEM - High resistance ground or close clearance between
high voltage and ground.
SYMPTONS - Abnormally low primary and secondary voltage.
- Abnormally low primary and secondary current.
- Abnormally high spark rate.
CAUSE - Hopper overfilled to level of bottom frame.
- Dirty wet, or cracked H.V. insulators.
- Rappers not working, allowing dust bridging between
electrodes.
3. PROBLEM - Automatic control failing to increase power to highest
level for efficiency.
SYMPTOMS - Abnormally low primary and secondary voltage.
- Abnormally low primary and secondary current.
- No sparking or very little sparking.
CAUSES - Control turned down manually.
- External signal turning control down (Remote
manual control. Energy Management System, etc.)
- Automatic control misadjusted or Control
malfunction.

44
 4. PROBLEM - Automatic control failing to limit current below
Name plate rating.
SYMPTOMS - Abnormally high primary and secondary current
- Control trips off on "Over-current."
CAUSES - Automatic control misadjusted.
- Control malfunctioning.
5. PROBLEM - Excessive emissions while precipitator is operating at
high power.
SYMPTOMS – Normally, primary and secondary voltage.
- Normally low primary and secondary current.
- Abnormally high stack opacity.
CAUSES - Rappers misadjusted to excessively high intensity or
Short cycles.
- Volume of flue gas above design.
- Change in stack gas chemistry, due to ammonia
injection, or other cause of non-particulate emissions.
6.0 DATA SHEETS
Proper record keeping is essential to the maintenance of efficient and
reliable precipitator operation. The following standardized data sheets
should be used to document baseline operation for comparison over
the lifetime of the equipment.
6.1 PRECIPITATOR AIR LOAD READINGS
This data sheet is appropriate for recording voltage/current
relationships under air load conditions. Data recorded on these forms
should be compared with air load readings provided by ACC-EEG in
the startup report from the original commissioning of the equipment.
This data should be taken after any major outage where work has been
done in the precipitator that might affect electrode.

45
 ESP Field #1 A
Date Time Weather Conditions
Set No. Set Size ___

E.PRI
ISEC 50 100 150 200 250 300 350 400 450 500
IPRI
E SEC.KV1

SPK RATE

ESP Field # 1B
Set No. Set Size ___

E.PRI
ISEC 50 100 150 200 250 300 350 400 450 500
IPRI
E SEC.KV1

SPK RATE

ESP Field #2
Set No. Set Size ___

E.PRI
ISEC 50 100 150 200 250 300 350 400 450 500
IPRI
E SEC.KV1

SPK RATE

46
 ESP Field #3
Set No. Set Size ___

E.PRI
ISEC 50 100 150 200 250 300 350 400 450 500
IPRI
E SEC.KV1

SPK RATE

ESP Field #4
Set No. Set Size ___

E.PRI
ISEC 50 100 150 200 250 300 350 400 450 500
IPRI
E SEC.KV1

SPK RATE

6.3 T/R ELECTRICAL READINGS

This data should be used on at least a daily basis unless automatic

printout of operating data by a central system has been provided. It
provides for recording a single set of readings from each transformer-
rectifier set. Data on this form should be compared daily with data
from previous operating periods under similar operating conditions.
A format similar to the attached sample of GAS LOAD DATA should
be used.
47
6.4 GAS LOAD DATA

Since precipitator transformer-rectifier readings vary with process

conditions, electrical readings without corresponding process data are
practically useless for analysis or troubleshooting.

For generating such data, the purchaser should devise a suitable form
which encompasses all parameters likely to affect gas stream volume,
temperature and chemistry of dust. A typical sheet is enclosed.
Variations of this format can be generated based on the type of
application
Daily log sheet:
Date:
Time Field Pri. Pri. Sec. Sec. Spark % ESP ESP Plant
Volts Amps Kv MA /min O2 I/L I/L Load
Temp press Data

• Plant Load data: :

a. MW Load
b. Steam generation
c. Coal/fuel Feed T/H
d. Type of Coal/fuel (Grade)
• Operation of Ash Conveying System
a. Ash evacuation – probe mode / Timer Mode
b. Cycle of operation in case of Timer Mode
c. Compressed Air Pressure – Seal Pressure & conveying pressure
48
 SECTION -8
STANDARD SPARES LIST FOR ESP
SR. DESCRIPTION OF ITEMS
NO.
A GENERAL
1 Support Insulator
2 Wall through Bushing
3 Double Tapered Shaft Insulator (FRP)
4 Hopper Level Controller with Probe
5 Boot Seal for Rapper Assembly
6 MIGI Coils for Rapper
B SEAL AIR SYSTEM
1 Primary & Secondary Filter
2 Flow Switch
3 Seal air Heating element
4 Heater Thermostat
5 Pent House Thermostat
C HOPPER HEATING SYSTEM
1 Hopper Elements
2 Thermostat
D HOPPER VIBRATORS
1 Hopper Vibrators
2 Solenoid Valves

Note: 1. For spares list of TR set and panel, Rapper panel refer individual
Manuals enclosed.
2. For spare list of MCC refer details of BOM furnished by
Manufacturer

49
 SECTION -9

PERFORMANCE GUARANTEE TEST CRITERIA:

1. Outlet Emission at ESP Stack

30 mg/Nm3 with all fields of ESP in Operation at design condition.

The performance test shall be conducted as per the procedure elaborated in

part III of the norms of Central Pollution Control Board which in accordance
with IS: 11255 (part 1) 1985. /EPA 17

50