Professional Documents
Culture Documents
Electrostatic Precipitator
Operation Manual
Tel: +86-575-87211558
Fax: +86-575-87383308
E-mail: ftd@feidaep.com
1. Range of Application
2. Normative Reference
3. General Introduction
4. Principle of Operation
5. Briefing of Equipment
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1 Range of Application
adjustment, trial run, operation, maintenance and troubleshooting, and safety points for
This manual is suitable for the commission, operation and maintenance of dry
metallurgy, paper-making, building materials, chemicals, etc. This manual can be used as
reference code for GP-model and ZH-model ESPs. For wet type and vertical ESPs, this
2 Normative Reference
3 General Introduction
The ESP is a highly-efficient, energy-saving equipment for flue gas cleaning, having
merits of high collection efficiency, large gas volume to be treated, long life span and low
becoming more and more stringent, ESPs are used more widely. During the operation of
an ESP, its operation manual must be strictly followed. Any points that are not mentioned
in this manual should be handled as per the requirements in ESP drawings and
documents.
Our ESPs have their model numbers with the designation as follows, for example:
2
Note: The above model number can be simplified as:
Resistivity: 1×105Ω.cm~1×1014Ω.cm
ESPs can treat flue gas that contains corrosives (called anticorrosive ESPs).
This manual does not apply to the treatment of flammable or explosive gases.
When the design operation conditions are beyond the application range of this
manual, the quality index should be specified in the product’s technical documents (e.g.
technical agreement).
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4 Principle of Operation
When passing through the high voltage electrostatic fields, dust particles in the gas
will be charged by colliding with positive ions, negative ions and electrons or in the ion
dispersion movement. The particles with electrons and ions will then move, under the
influence of the electric force, toward and later accumulate on the electrodes of opposite
polarity. By means of rapping, the layer of dust particles on the electrodes will be
Practice shows that the higher the strength of electrostatic field, the more effective an
ESP will be, and that it is preferable to have an ESP operating with negative corona.
Therefore, our ESPs are designed in the structure of high voltage negative corona
5 Briefing of Equipment
Structurally an ESP is divided into two portions, electrical portion and mechanical
The electrical portion consists of high voltage DC power source (including its control
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system) and low voltage control system.
5.1.1 Conventionally we use Model GGAJ02 high voltage power source. Designation of
This power source can automatically adjust the voltage applied to the electric field
according to the changes of gas conditions therein and can adjust the spark ratio in the
field to the optimum level that the highest results of dust collection can be achieved.
This device can be furnished with computer management system and host computer
This portion can be divided structurally into internals, casing and auxiliaries.
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5.2.1 Internals
The collecting system consists of suspension devices, collecting plates, shock bars,
etc. Collecting plates are shaped by steel coils 1.2 to 1.5 mm in thickness on special
rolling machines. At present, our company provides two kinds of collecting plates: 480C
The surface of several collecting plates linked together must have good rigidity, and
its flatness should be kept within the specified range so as to assure the limited deviation
The emitting system consists of suspension devices, top horizontal beam, vertical
beam, upper, middle and lower frames, discharge wires, etc. The discharge wires are
manufactured by special equipment. Two types of discharge wires can be offered by our
plant, i. e. tubular barbed wire and spiral wire, both are ESP’s key parts.
Emitting suspension devices are used to support the whole emitting system from the
The function of the planar structure combined by vertical beam, top horizontal beam,
angle iron, etc. is to fix the upper, middle and lower frames and the emitting rapping
shafts.
The upper, middle and lower frames are the holders of discharge wires.
Collecting rapping system consists of drive, series of shafts, plain bearing, etc.
Emitting rapping system consists of drive, vertical shaft, major and minor pin wheels,
rapping shaft, plain bearing, etc. (for top-driven design) or of drive, series of shafts, plain
Rapping devices are important parts of ESPs. By rapping at regular intervals, dust
accumulated on both collecting plates and discharge wires is dislodged and falls into
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hoppers.
Both collecting and emitting rapping systems use tumbling hammers to carry out
side rapping.
Since the plain bearings are attached to the elements of emitting system at negative
high voltage, to isolate the high voltage, a porcelain shaft insulator is inserted serially
5.2.2 Casing
The inlet nozzle is the transition between the inlet flue duct and the ESP casing.
Inside the inlet nozzle there are 2 or 3 layers of gas distribution screens to make the
The gas flow will speed down when passing through the nozzle and some dust with
bigger size will accumulate by natural settlement on the distribution screens and the
nozzle. So some ESPs treating flue gas containing clogging dust are equipped with
The outlet nozzle lets the cleaned flue gas go into the exhaust flue duct. The
structure and shape of outlet nozzle also has something to do with gas distribution. Under
normal conditions, a row of outlet gas distribution screens (channeled plates with no
holes) is installed at the interface between the outlet nozzle and the casing.
5.2.2.3 Roofs
Roofs consist of inner roof and outer roof, of which the top girder is a key element as
it carries heavy loads from both the collecting and emitting systems. High voltage
electricity from the power source (no matter it lies on ESP top or on ground level) is fed in
through the top girder to the emitting system. To guarantee good insulating status of the
support insulators, heating devices are equipped within the insulator compartments to
maintain their dryness. Two types of heating can be adopted, electric heating or electric
5.2.2.4 Casing
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The ESP casing is made up of pillars, side panels, end panels, pipe bracings, etc.
Casing, together with nozzles, roofs and hoppers, forms a sealed container.
The hopper ridge beam is used to connect the hoppers to the casing
The hopper is a container for collecting dislodged dust. To prevent flue gas from
bypassing the hoppers, as will reduce the collection efficiency; anti-sneaking baffles are
installed in the hoppers. To guarantee that ash can flow down by itself in the hopper, the
hopper must have a right valley angle. To avoid condensation occurrence as the result of
dust temperature falling to below the dew point, heating is applied to the lower part of the
hopper (in some cases, all over the hopper).Two types of hopper heating are at choice:
From the flange at the hopper bottom, pneumatic ash conveying system or gate
5.2.3 Auxiliaries
These are provided for easy access to different locations at various levels so as to
Support bearings are placed between the ESP casing and its support elements
(concrete pillars or steel columns). Besides supporting the ESP loading, the bearings
compensate displacement caused by thermal expansion, since the ESP is a hot body
Support bearings usually take the form of plate type compound material (friction pad)
slide bearings. But plane ball bearings are sometimes sued in ESPs of medium size or
smaller.
To ensure the normal operation of an ESP and to prevent gas temperature from
dropping to below the dew point, thermal insulation should be laid over the ESP casing.
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The principal function of the thermal insulation is to reduce heat exchange. By
applying thermal insulation, the minimum gas temperature must be guaranteed at a level
The structural design of ESP thermal insulation should specify the kind of insulating
5.2.3.4 Earthing
The ESP is operating under high voltage and normally with negative corona, which
means its casing and collecting system have the same potential. To protect high voltage
equipment and ensure personal safety, the ESP must be earthed reliably with
requirements as follows:
a. Resistance of the earthed grid should be less than 2 ohms all the year round;
b. The arrangement of the earthed grid should be such that the surroundings have
6.1 The installation of the equipment should meet the requirements in “ESP’s Installation
Manual”.
Respective check and adjustment should be made to the electric and mechanical
portions after the equipment is erected but prior to its being put into operation.
6.2.1.1 Make second corrections of any deformed or bent collecting plates and discharge
wires within the electric fields to ensure that all the distances between opposite
electrodes are kept within the following deviations; for ESPs with plate height H≤7 m, this
6.2.1.2 Make adjustments in the electric fields wherever the distance between emitting
system and other insulated parts is less than the distance between opposite electrodes.
6.2.1.3 Check all the bolts and nuts to see that they are properly tightened and welded
dead.
6.2.1.4 Check to see that the contact positions between the rapping hammers and anvils
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are exactly as required by the approved drawings, and that the shafts and hammers can
rotate freely.
6.2.1.5 Remove all foreign materials left within the electric fields.
6.2.1.6 Check to see that the motors for dampers, rapping, ash discharge, etc. have the
correct direction of revolution, that they can turn freely, that the chains are mounted with
proper tension and that all locations calling for lubrication have been oiled or greased. For
6.2.1.7 Check to see that all the insulators are mounted steady, under evenly distributed
6.2.1.8 Check to see that different parts of the ESP casing and all inspection doors are
properly sealed. Make gas-tightness tests as per Annex B of “EPS’s Installation Manual”
6.2.1.9 The rapping system is designed on the principles of improving the dust dislodging
effects, reducing dust re-entrainment, enhancing collection efficiency, lengthening the life
span of rapping elements etc. For details, refer to the ESP electric technical agreement of
the project. After a period of trial run, the rapping system is to be adjusted to its optimum
mode.
6.2.1.10 For the details of the ON-OFF system of ash discharge valve at hopper lower
end, refer to the ESP electric technical agreement. If pneumatic ash conveying system is
used, there is no need for ash discharge valve. In such a case, the hopper outlet is
connected direct to the ash transmitter, and the discharge of ash is carried out by means
of the inlet valve, which is controlled by the level indicator, on the transmitter.
6.2.1.11 Because the real actual gas distribution devices are designed and manufactured
on the acceptable results of gas distribution model tests, it is decided that no adjustment
6.2.2.1 Measure the ground resistance of the ESP proper and see that it is less than 2
ohms.
6.2.2.2 Use a 2500V mega meter to measure the insulation resistance of the high voltage
6.2.2.4 Use a 500V mega meter to measure the insulation resistance of all motors and
their cables and make sure it is not less than 0.5 megohms.
6.2.2.5 Check to see that the operating mechanism in the high voltage isolating
switchgear has high mobility and can be set to the exact positions.
6.2.2.6 Check to see that all wiring between different electric parts is correctly laid as per
6.2.2.7 Adjust the spark frequency in accordance with the electric conductivity of the flue
as automatic tracing of sparks; therefore it will make the ESP operate under optimum
status, hence obtaining the realistic collection efficiency and having the lowest operating
cost.
6.2.2.8 The set value of the thermostat for insulator heating is normally 15-25℃ above
the gas dew point. The electric controllers are so required that the electric heaters are
energized when the temperature falls below the lower limit and de-energized when the
temperature exceeds the upper limit. Since the cover plate of the support insulator is so
designed that it allows a small amount of air to be sucked into the insulator to reduce its
contamination, and the cover plate is of high voltage, the temperature-measuring point is
far from the heat source but near to the cold air inlet. Therefore the indicated temperature
6.2.2.9 Electric control circuits are to be adjusted according to the specified rapping and
6.2.2.10 For various items in electric commissioning, such as LV control loop, HV control
loop, no-load voltage step-up test, cold trial run, hot load run, etc. refer to Annex B in the
control systems.
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7 Safety Regulations of Equipment
ESP operators and those working temporarily in the ESP must have the general
7.1.1 The ESP is a high voltage installation, so special attention must be paid to personal
safety. Whenever the inlet part of high voltage T/R and the insulator compartment are in
7.1.2 The inside of any electric field is a dangerous area of high voltage and no one is
allowed to enter during the operation of the ESP. All inspection doors must be interlocked
for safety.
7.1.3 Boards or signs bearing “Danger! High Voltage!” must be hung on each of the
control cubicles in the control room, on cable trays and trenches, on inspection doors and
on all high voltage equipment. They are not to be moved at random or approached by
non-operators.
7.1.4 The ESP is a high-altitude installation, so the stairs, platforms and handrails must
be reliably strong, and no accumulation of water or snow is allowed thereon. Also all the
matter it is outside the ESP casing or at high-located parts inside the ESP fields,
personnel must wear safety helmets and tie safety belts that have ropes connected or
7.1.6 The ESP is an installation operating at high temperature, high negative pressure
and under dusty condition, so no part of the human body is allowed to touch any hot part
of the ESP in operation. When the ESP is shut down for inspection/maintenance, the
doors should be spend to cool down the inside temperature to below 40℃ before people
can enter.
7.1.7 Should any door is left open during the operation of ESP, anyone near the door is
likely to be sucked in due to high negative pressure, resulting in bodily injures and even
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electric shock. Therefore, the doors must be interlocked.
7.1.8 Personnel to enter the ESP after its shut-down must follow the user’s safety
regulation.
7.1.9 To avoid human bodies from being infected by smoke and dust, wash the body and
7.1.10 Wear a gas mask when you want to enter the ESP where there is too much dust
and smoke.
7.2.1 Make regular checks of the earthing cabling and other connections to see if they
have good electric conductivity and if other protective devices are in good order.
7.2.2 Make sure that all the locks on boxes for relays and switches are reliable, so that
7.2.3 The portable lamps for use in the ESP must be of safe voltage.
7.3.1 Make sure that the transformer-rectifier (T/R) has been de-energized with its safety
7.3.2 Check to see that all the switches on the control panel are in OFF positions.
7.3.5 Earth the T/R high voltage parts with the earthing devices provided.
7.3.6 Make sure the above steps have all been executed before T/R maintenance.
7.4.2 For maintenance inside the ESP, at least 2 persons are needed and one of them is
in charge of monitoring. Maintainers of ESP must be familiar with the design of the ESP
as well as the functions of its various parts and components. They should also know the
properties of the gas and the dust, their potential harms and the effective protective
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measures to be taken.
7.4.3 The shutdown of an ESP and personnel to enter it should follow the regulations
listed below:
c. Turn off the safety switches of all rapping motors and the motors for ash
d. Turn off and earth the HV isolating switches close to the HV T/R sets, earth the
e. Turn the switches of ESP blower and I.D. fan to OFF position and secure them
with locks.
f. Shut off the dampers in ESP inlet and outlet flue ducts, turn off the damper
g. Open all the inspection (access) doors to ventilate the ESP inside and wait for
inside the temperature to drop to below 40℃ before people can enter. To
speed the process of cooling, the dampers in outlet flue ducts can be opened
and the I.D. fan turned on. But in such a case, the access doors must be
h. Maintainers entering the ESP should be aware of the risk of being scalded by
local not spots because of different degrees in cooling different parts and
components.
i. After entering the ESP, maintainers should first inspect to see if there is dust
accumulated somewhere. If there is, clean it to avoid mishaps. At the same time,
j. When the maintenance is finished, maintainers should check their tools lest
8.1 To ensure the reliability of operation of the ESP, before a new installation is put into
formal service after erection and commissioning or before an old installation is to resume
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operation after a long period of stoppage, a pre-operation trial run must be made.
trial run. And the items to be checked should be planned and strict site records be kept.
To avoid damages caused during the operation by condensation of moisture in flue gas
or by not inspecting all the parts and components, the following checks should be made:
a. Check to confirm all the items listed in 6.2 above have been carried out with
acceptable results.
c. Check to confirm that no one is inside the ESP or within other dangerous areas
of high voltage.
e. Check the open situation of flue duct dampers to ensure reliable operation both
f. Check the alarm functions on the test control panels to see if the tripping
8.2.2 After inspection of all the pre-operation items of has been made with acceptable
b. Switch on the motors in turn for rapping, watch each link in operation and ash
c. Detach the earthing devices from the high voltage parts to have an open circuit
d. Turn on the HV isolating switches of the power units and lock them in the
operation positions.
8.2.3 Turn on the automatic voltage-adjusting system and observe the conditions of
8.2.4 Keep records of the changes in primary voltage and current and secondary voltage
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and current. Since the no-load current has something to do with the temperature and
humidity of the air at the time of the trial run, pay attention to the capacity of the
8.2.5 After the trial run is over, analyze and eliminate all the troubles occurred during the
trial run.
8.2.6 Plot the voltage-current characteristic curves for each electric field. On a sheet of
increase in current until the current reaches its rated value. Connecting the points
together will result in a curve, which is called voltage-current characteristic curve, and
which can be used as reference for the check of erection quality and for comparison with
later no-load curves of the same electric field each time after the ESP is overhauled.
8.2.7 Keep records of the loaded ESP’s primary voltage and current and secondary
8.2.8 Using the same method as described above to plot the loaded ESP’s V-A curves
8.2.9 Re-check the air leakage status of the ESP casing, inspection door, etc.
8.2.10 Shut the ESP down. (Refer to 9.5 below for details.)
8.2.11 Check the inside of the support insulator and the shaft insulator to see if they are
cracked or damaged.
8.2.12 Eliminate all the troubles occurred during the loaded trial run.
9.1 The ESP should be operated and managed by professional people, who must have a
and maintenance, and who are familiar with THIS MANUAL. The owner of the ESP must
first have these people qualified by means of examination and check before they are to
9.2 Before the start of ESP operation, make a final strict check of the equipment, keep
inspection records for each item and the records should be signed and approved by the
9.3.1 Make sure that pre-operation inspection is over, all the safety measures are taken
9.3.2 All the heaters have been turned on for at least 8 hours before the start-up of ESP,
so as to ensure the inside of all hoppers and various insulators (support insulators, shaft
insulators, etc) are dry, and to avoid any damage caused by electric creepage due to
9.3.3 Open all the dampers in inlet and outlet flue ducts (but with the exception of those in
9.3.5 Lead flue gas into the ESP to eliminate the moisture on various internals. This
period of warm-up depends on the temperature and humidity within each field and is
usually ended when the temperature at the outlet of the last field reaches a level higher
than the gas dew point. When oil is burning in the boiler never put the high voltage T/R
into operation.
9.3.8 Turn on all the functions of the rapping system. Set alarms, inter locking,
temperature detector and controller, ash level indicator, ash discharger, etc. all in a mode
of controllable operation.
9.3.9 When the fuel has changed from oil to coal and when the temperature in the ESP is
higher than the gas dew point, the ESP can be put into operation, but must be running
9.3.10 Start of the hot-air purging system: First turn on the electric heaters, after 5
minutes have passed, start the fan. For shutdown, turn off the fan first, then the heaters.
9.4.1 There should be sufficient people on duty in the ESP control room. They should
make regular checks of the operation of the equipment. They should search for abnormal
phenomena, analyze the causes of troubles and solve them. For each work shift, beside
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being on duty in the control room at least two patrols should be made to check the
transformers and all rotary devices to see if they function properly and if the
a. Check to see that the operating current of each heating system is correct.
b. Check all the indicator lamps and alarms to see if they function properly.
correct.
d. Check to see if the ash discharge system has any problem in discharging the
collected ash.
e. Regularly check to see if the rapping shafts turn normally and the hammers hit
9.4.3 Observe and optimize the spark ratio, rapping sequence and ash discharge
program of each electric field until the satisfactory collection efficiency is obtained.
9.4.4 Persons on duty must keep intact records of the operation status of the equipment,
especially of the primary current and voltage and the secondary current and voltage
b. Switch off, in the order of electric fields, the high voltage power source to each
c. Shut off all the dampers in both inlet and outlet flue ducts;
b. Turn off the isolating switch to each high voltage bus section , turn it to the
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earthing position and have it locked;
c. Turn off all systems of heating temperature measuring/controlling and ash level
controlling;
d. Keep in operation the rapping and ash discharge systems until all the smoke
e. Turn off the main power switch (with the exception of lighting);
9.6 For operation of the HV, LV control system and the host computer, refer to “Electric
Instructions”.
To obtain the goal of the long-term reliable operation of ESP with required collection
and maintenance. These people must know the ESP’s design, principles, functions and
performance and are able to operate, to maintain and to troubleshoot the ESP.
During each shut-down of ESP, a general check should be made to clean its inside,
to correct the deformed plates and wires, to clear the insulators of dirt, to measure the
earth resistance and to eliminate all defects occurred during its previous operation
Normally the ESP is to undergo a minor overhaul once a year, items of which includes the
replacement of worn parts. Every third year (or based on the power plant’s overhaul
made inside the ESP and adjustment and replacement of defective or worn parts and
10.1.1 After entering the ESP, first check to see if there is dust accumulated. If there is,
10.1.2 Check the side panels, access doors and insulator compartments on top of ESP to
see if there are phenomena of air leakage, condensation, corrosion or dust accumulation,
10.1.3 Check the motor temperatures, oil level in speed-reducers, shaft bearings and
rapping hammers to see if they are in good order and if the hammers hit on the correct
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locations. Lubricate the speed-reducers as per manufacturer’s manual.
10.1.4 Sometimes the gas distribution screens may have dust accumulations or
blockages somewhere due to low gas velocity thereon. Check and clean manually.
10.1.5 Check the emitting frames and discharge wires to ensure that they are not
10.1.6 Check the collecting plates and shock bars to ensure that they are not bent and
10.1.7 The support insulators support and isolate the emitting system. During the ESP’s
operation, these insulators will be usually covered with dust and dirt, which lead to
possible cracks resulting from high voltage breakdown. Clean both inside and outside of
the insulator and search for flaws by using a flashlight. To suck in hot air to reduce
insulator’s inside pollution, there should be two oblong holes of 5~10 mm in the
10.1.8 Check and clean the shaft insulators in emitting rapping shafts, if there are flaws,
10.1.9 With reference to the manufacturer’s manual, check the T/R sets to see if the
measuring and controlling, alarms, earthing devices, etc. are normal. Eliminate the
10.2 Warnings
10.2.1 Take strict precautions against sever dust build-ups in electric fields:
Excessive dust build-ups inside the electric field are usually caused by failure in the
dust conveying system, insufficient conveying capacity, the failure of hopper heater or
poor hopper insulation. In such cases, dust collected by the hopper will adhere or “bridge”
and it can’t be discharged in time, resulting in huge amount of dust piling in the hopper.
When the accumulated dust reaches the electrodes, there will be short-circuits formed in
the electric field, causing the failure of collecting rapping system, making collecting
electrodes drop off their hooks, and even deforming the emitting frames. As a result, the
electric field is out of function, and severe consequences occur. What calls for high
attention is the condition that, when the electric field is out of service, the boiler is still in
operation and there is still abundant dust falling down by natural settlement. Therefore, if
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the problem of hopper’s over storage of dust is not solved in time, there will be
irreversible damages to the ESP. Emergent dust discharge measures must be taken to
stop further damages to the ESP.
a. Take strict precautions against over-storage of dust in the hoppers. When there
is alarm for hopper high level, the actual operation condition of the dust
conveying system must be checked, and necessary measures taken to ensure
smooth conveying so that the dust level in the hopper can be lowered, and the
high level alarm, deactivated.
b. When the dust accumulation exceeds the upper level of the hopper and trips
and electric field, emergent dust discharging measures should be taken within
the shortest time. Within 3 hours, the dust should be removed and within 8
hours, the dust level should be lowered to below the hopper’s upper opening,
so that the operation of the affected electric field can resume.
d. If, within 48 hours, all the measures fail to bring the dust level lower than the
hopper’s upper opening and the electric field is still in a tripped state, the ESP,
the boiler must be shut down so that their reliability and safety are secured.
Otherwise, there will be severe consequences.
10.2.3 Non-professional personnel are allowed to enter the top of the ESP
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Analyses and treatment of comprehensive defaults
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3. 3 Severe flashovers,
(9) Too much dust is stored in the hopper and it rises See Item 6, c and d in Clause 10.2.1
resulting in tripped field. above the hopper upper opening, even reaches both above.
electrodes, resulting in reduced isolating property
between them.
4. Se4 Secondary current changes Dust is deposited on some electrode, where the Remove the dust deposit.
irreirregularly voltage dis distance is smaller, causing sparkovers
5. 5 Secondary current
Ds The remaining part of a broken emitting wire sway Replace the broken wire.
changes periodically
6. 6 There is secondary D 1) Excessive dust loading causing corona blockage 1) Improve the technological process
voltage but no or very little 2) Severe dust deposits on collecting and emitting to reduce dust loading in gas.
secondary current. systems. 2) Intensify rapping and remove dust
3) High ground resistance and poor high voltage deposits.
loop. 3) Reduce the ground resistance to
4) Broken circuit in the measuring loop of ampere the specified value.
meter in HV loop. 4) Rectify the broken circuit.
5) Poor contacts between HV outlet and electric field 5) Check the connections and make
6) Point of millimeter gets Stuck. them in full contact.
6) Repair the meter.
7. 7 Abnormally plentiful sparks 1) Leaks in access doors let wet air in. 1) Take corresponding measures
2) Poor contact in T/R secondary side or open circuit 2) Find the real cause and repair or
in diode of rectifing bridge. replace.
3) Uneven gas flow distribution 3) Replace the gas distributors.
4) Voltage distance turns smaller. 4) Adjust the voltage distance.
5) Hopper is full of dust. Or there are areas of dust 5) Remove the dust deposits.
deposits and dust can’t drop smoothly. 6) Replace the damping resistor.
6) Damping resistor is broken an causes electric
discharge
8. 8 Normal primary and 1) Too big voltage distance. 1) Adjust it,
secondary current and 2) Uneven gas distribution, gas screens blocked by 2) Remove the dust, OR replace the
voltage, but the collection dust. gas screens.
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efficiency is low. 3) Excessive air in leakage resulting in changes in 3) Make repair welds where there is
operation conditions. Increase of gas velocity, air in leakage.
decrease of temperature, weak charging 4) Condition the gas quality and
possibility of dust particles, etc. adjust the work point.
4) High resistivity of dust, backcorona may exist, 5) Adjust the parameters.
slow charge neutralization in dust layers on 6) Collection efficiency is be
electrodes and rapping unable to dislodge them calculated by using correction
due to significant adhesiveness. curves to the actual operation
5) Unreasonable setting of control parameters. conditions
6) Conditions of gas entering the ESP do not agree 7) Repair as needed, if rapping is not
with the original ones resulting in changes of sufficient, replace with heavier
operation conditions. hammers.
7) Mechanical problems such as abnormal rapper. 8) Check to solve the problem.
8) Gas flow by-passes due to fallen gas baffles in
hoppers.
9. 9 Stuck ash discharge 1) Hammer dropped Shut down the equipment to repair.
device, OR tripped safety 2) Foreing matter in discharge mechanism.
device 3) Broken chain in case a drag chain conveyer is
used
10 Failure in control, alarming 1) Thyristor is broken down. Find the causes before repair or
tripped 2) Thyristor’s initial wire is at a wrong position or the replacement.
plugging leg is short-circuited.
3) Primary side of T/R is earthed or short-circuited.
Or before the secondary side sampling loop there
is a short circuit. Or the negative HV is earthed. Or
there is a short circuit in current and voltage
sampling loop.
11 Thyristor’s outlet can’t be 1) Thyristor is broken down. 1) Replace it.
controlled 2) Feedback quantities disappear 2) Check relevant elements and loops
Sampling resistor row is damages. 3) Adjust the parameters.
3) Wrong setting of parameters.
12 Abnormal operation of 1) Safety interlocking is not in place 1) Check to see if the access doors
control loop and main loop 2) Interlocking for HV isolating switch is not in place and cabinet doors are closed
3) Broken wire in switching-in coil and loop. properly.
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4) Poor contact in auxiliary switch 2) Check the switch to see if it is
properly interlocked.
3) Replace the coil and check the
wiring.
4) Check and repair it.
13 No lamp indication on 1) Poor contact in loops and between elements. 1) Check every element and loop for
control panel when it is 2) Burnt bulbs wiring
energized. 3) Burnt fuse 2) Replace them
3) Replace it.
14 When the voltage is being 1) There are faults in the meters. 1) Repair and calibrate the meters
adjusted, no indication is 2) There is no trigger output pulse. 2) Use an oscilloscope to determine
on the control meters 3) Broken quick-break fuse. the number and width of the
4) Open circuit in thyristor element. pulses
5) AC & DC sampling loops broken 3) Replace
6) Poor contact of change-over switch in AC 4) Change
voltmeter 5) Check the secondary wiring
6) Check the switch contacts.
15 There is signal on 1) There is foreign interference 1) Check the earthing of the shield
flashover indicator but 2) Signal transfer is blocked by flashover and some 2) Add a by-path and replace
other meters on the elements are damaged. damaged elements.
control panel do not act
16 After a flashover, the 1) The first blocking pulse is too wide upon the 1) Change the parameter to adjust
secondary voltage does flashover the pulse width.
not rise by its own but 2) The given value of the rising ratio of voltage 2) Increase the given voltage
initiates an alarm. +△v/△t is too small
17 During loaded voltage 1) Open circuit in current sampling loop. 1) Check the secondary wiring
step-up, there is normal 2) Broken wire in ammeter 2) Measure the voltage.
voltage indication but
current is zero.
18 During voltage step-up, 1) Open circuit and false soldering points in T/R 1) Lift the T/R core to check and
primary voltage can be secondary coil and silicon stack. eliminate the defaults.
adjusted properly, but 2) Insufficient safety distance from HV down-lead to 2) Check and reconnect the HV
secondary voltage ESP casing. down-lead.
appears and disappears 3) Open circuit in DC component voltage sampling 3) Lift the T/R core to check and
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alternatively and is loop. repair.
accompanied by sound of
electric discharge.
19 Tripping of oil pressure Breakdown or short-circuit in T/R secondary coil or Lift the T/R core to check and replace
alarm and ozone smell silicon stack. the damaged part.
from T/R
20 Tripping and alarm T/R oil level is lower than the lower limit. Troubleshoot and add oil to T/R up to
activated by oil level signal the suitable level.
21 Tripping of oil pressure There is gas in the gas relay. Open the discharge valve to get rid of
alarm the gas.
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10.4 Replacement of spiral wires and support insulators
Discharge wires are the heart part of an ESP. They set off electric energy to the gas, and
function in an adverse environment. Under high voltage conditions there would be flashovers
and arcs, each of which is a kind of corrosion by electric spark to the discharge wires. For spiral
wires, when they are rapped, they will vibrate in the way strings on a musical instrument will do.
Therefore, after long service the spiral wires may break due to fatigue (but the rate of breakage
is very low). If a spiral wire breaks, it will lean against one of the adjacent collecting plates and
short-circuit will happen, resulting in the shut-down of the related bus section.
During the replacement of spiral wires, in addition to the five points of attention as
a. Put the upper end hook of the spiral wire into the hanger ring.
b. Connect the other end hook of the wire to the special stretching tool and pull down
gently by holding the rope on the tool. By doing so, be sure to let the spiral wire turn
freely. When the wire is stretched to a point of 200 mm to 300 mm away from the lower
hanger ring, manage to put the hook into the ring by hand. Special care should be taken
to the following:
1) Should a spiral wire be stretched beyond its length as it is hung, it should be discarded.
re-use.
2) Do not pull the wire directly by hand as this will cause accumulation of inner stress in the
3) The spiral wire must be hung between the two corresponding hanger rings of a support
frame.
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Use a straight ruler to measure the distances from the tie rod to the compartment top cover and
the walls a, b and c, and have them recorded (or written on walls).
10.4.2.1 Dismounting
b. Insert the lifting tool through the bushing and hook on to the upper support beam of
c. Turn the nut on the lifting tool to raise the emitting frame to let loose the support
insulator. Unscrew the nut on the tie rod, remove the top washer and dismount the
broken insulator.
10.4.2.2 Mounting
a. Check and clean the top and bottom washers of the insulator;
d. Check the location of the tie-rod, be sure that it is in the exact position as it was
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