PR# 2032665 ESP RECTIFIER TRANSFORMER 500mA 72kV (STOCK HOUSE)

Objective
To purchase 1-unit Rectifier Transformer to replace faulty unit for ESP Stock House Panel # 4.

Transfer detail as below:

Model: ZZDJ-500MA/KV-HW S-2
Primary voltage: AX1-72kV, AX2-64kV, AX3-57kV
Rated Capacity: 53KVA
OEM: Dalian Lanqing Electric Co. Ltd

Background
Stock House ESP running as to control dust emission toward environment. This ESP system to
collect/suction dust from Stock House plant to prevent from pollution or environment issue. This
ESP consist 4-unit panel to control 4-unit transformer to collect dust inside ESP chamber.
Function of this transformer is to supply High DC voltage to Discharge Electrode in order to
create negative charge. The negative charged dust will be accumulated at Collecting Plate then
knocked down by rapping system.

Current Condition
Out of 4 transformers, 1 unit was down which is for panel no #1. This transformer was installed
since plant commissioning. Testing result was not meeting the requirement and has been shared
with OEM. Reply form OEM, this faulty could be due to internal bridge rectifier (silicon stack)
malfunction. OEM also mentioned that this part already discontinued as they already upgrade
their product. (See attached feedback from OEM).
Risk to Operation
1. Failure in transformer resulted collecting of dust efficiency drop where dust entering ESP
chamber unable to trap down resulted release into chimney as emission.

2. Dust emission at chimney is visible and may attract DOE as the emission must be control
within the limit under Environment Quality act (clean air).

Counter Action
We have swap faulty transformer no 1 with transformer no 4 because panel no 1 is the most
important for dust trapping. 80% dust are collected from panel 1.

For panel no 4 we have installed recondition transformer 400mA (lower capacity).

Conclusion and Recommendation

Since OEM cannot supply the internal spare part anymore, we recommend to purchase new unit
transformer. Even though plant still able to run, we are in risk operation as DOE may stop plant
operation due to environment issue.
. This transformer to generate DC supply to ionize dust to +ve ion, the cathode plate was
negatively(-ve) charge and cause the +ve of particle attract to cathode plate.

1. Transformer #1 ESP stock house malfunction to prevent dust emission.

2. Urgently needed due to need to control dust emission.
3. Currently ESP Stock House running with 3-unit transformer. Therefore, less efficiency to
trap the dust emission.
4. Without this transformer will cause environmental issues during discharge due lack of
dust trap in ESP.
5. Based on theory, TX#1 trap more high dust concentration around 80% compare others
TX.
Conclusion & Action Plan

1. Therefore, this transformer needs to purchase to prevent from environmental issue and
process control to become more efficiency.
2. To prevent dust issue from DOE that can stop plant.
3. The malfunction unit will send to repair and keep as used spare

Each transformer has role itself, in theory the percentage of dust collection for each transformer
as below:

Transformer no1 collect dust ≈ 80%,

Transformer no2 collect dust ≈ 16%,
Transformer no3 collect dust ≈ 3%,
Transformer no4 collect dust ≈ 0.75%,
Therefore, when the transformer no1 not functioning and transformer no2 not stable, the
efficiency of ESP become lesser as designed.