ESP Operation

&
Maintenance
Electrostatic Precipitator
Training Seminar
Content
• ESP Safety
• ESP Maintenance Planning
ESP Safety

ZERO ACCIDENT WORKING SAFELY

IS OUR GOAL IS THE WAY

1. Hazardous environment in ESP

2. The right tools/equipment
3. Safe Practices
- Startup & Shutdown Procedure
ESP Safety

Hazard Condition
Access difficulties, Inadequate illumination, Inadequate
Confined space
ventilation
Toxic gas Presence of harmful chemicals in dust

Electrical shock Residual charge, Welding job, Broken electrical cables

Elevated Work at height

Engulfment Hopper dust build-up, Dust build-up on internal parts

Fire/Explosion Hot works

Thermal High temperature

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Welding works Chemical in dust Confined space

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Cutting works Hopper full of dust Elevated

ESP Safety

• Gas analyzer
• Safety equipment and ventilation
• Personal Protective Equipment (PPE)
• Safety Key Interlock
ESP Safety

Gas testing before entering ESP

• Ensure that
19.5% < [O2] < 23.5%, LEL < 30%,
H2S < 10ppm, CO < 35ppm,
Temperature < 50°C
• To determine if the working
atmosphere is safe for the proposed
work
• Gradually move inside the ESP
ESP Safety

Inside ESP

Life line Access inside the ESP

(scaffolding)

SCBA – self-contained breathing

apparatus
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Outside ESP

Fan Fire Grounding

First aid kit
Extinguisher rod
Others:
• Communications
• Emergency Rescue Plan and
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Safety helmet Head light

Ear plugs Goggles
Earmuffs Mask

Gloves
Protective
working suit

(Hot works)
Safety shoes
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Main T/R set grounding

switch
Control key box
Access doors

• Ensure your own safety during maintenance shutdowns

• Enforce safety procedures / startup and shutdown
procedure
• Energize system by authorized person / avoid human error
ESP Safety

Ground switch
on
Main switch off

Manhole Key box Ground on / TR Set

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Isolation
• Shutdown the main breaker
• Gauge reading are zero
• Disconnect the connecting rod from T/R
sets
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Grounding/Earthing
• Turn T/R Set Earth Switch to
“Ground” position.

Post signs
• Attach the lock & tag, put working
notice.
• Make sure that all energy sources
have been shutdown then tryout.
ESP Safety

Attendant
• Stays at the area all the time.
• Monitor activities and working
condition.
• Understands the hazardous
environment.
• Able to recognize signs and
symptoms of exposure.
• Must know his role in rescue
procedures.

Attendant
ESP Safety

ESP Control Panel Rapping System

 T/R Set Power off
 Control Panel MCC Off
 Interlock Keys
 Working Notice on Control Panel
HV Side Earthing Switch
 Disconnect T/R HV to ESP
 Earthing Switch to ‘GND’
 Stop Rapping System
 Working Notice on Control Panel
Personal Protection Equipment
 Goggles / Helmet / Mask / Flash
Light / Gloves
 Test on Oxygen: 19.5% < [O2] <
23.5%

Portable Earthing Probe Inspection Completion, Leaving ESP

 Earth the HV side（DE system）  Confirm that all inspectors and
to Ground personnel are out of the ESP
ESP Safety

A. Confirm that the system has been shut

down.

B. Press the Stop button on the control panel

to stop power supply to the ESP.

C. Rapping system & ash handling system

should keep running for 2~4 hrs.

D. After 2~4 hrs., turn off rapping system.

ESP Safety

E. After rapping system is turned off for

30min., turn off ash handling system.

F. Turn off MCC control panel main

breaker.

G. Use safety interlock keys from control ZERO

room to activate grounding switches
and open the manholes.
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• No tools/parts are left inside the ESP.

• All personnel need to leave the ESP

area.

• Access doors are closed and locked.

• Grounding switch set to HV position.

ESP Safety

A. Turn on heaters for around 8 hours.

B. Turn on ash handling system.
C. Turn on rapping system.
D. Bring in gas flow into ESP.
E. Check the temperature.
F. Energize TR set.
G. Check if the controllers for normal TR operation.
H. Adjust the controller operating parameters.
1. Maintenance Planning
(A) TR set operational data
(B) Control panel operational conditions
Daily
(C) Purge air and insulator heaters operational
(D) Status of ash handling system

(A) The condition of TR and panel by seeing

(B) The condition of access doors and gasket
Weekly leakage

(C) Make sure the rapping system is working fine

1. Maintenance Planning

(A) The condition of purge air system (replace the

filter)
Every
months (B) The condition of hopper heater
(C) The hopper level

(A) Bolt and nut inspection and lubrication of access

Every door
six (B) Interlock box inspection and lubrication
months
(C) T/R set oil level and oil temperature
1. Maintenance Planning
(A) Ground boxes grounding impedance
measurement
• Grounding resistivity: lower than 5Ω
• Insulation resistance of：
- Low voltage wire：Higher than1MΩ
- High voltage wire：Higher than100MΩ
(B) The condition of Rapping system
Every • Hammer 、Bearing 、Shaft wear condition
shutdown (C) Control panel clean and contact check
(D) Access door gasket renew
(E) Control panel linkage and alarm
(F)EP casing leakage and corrosion
(G) The condition of ESP internal parts
CE, DE, GD screens, etc.
2. Mechanical Inspection
(Tai & Chyun Mechanical Inspection
Scope)
Casing Structure / duct works
Surface corrosion , Welding line Failure, Cladding &
Insulation

Hoppers & Side Wall

Dust Build up, Corrosion

Access Doors (manholes)

Surface corrosion, Sealing
2. Mechanical Inspection
(Tai & Chyun Mechanical Inspection
Scope)
Collecting Electrodes
Dust Build up & Deformation, Cracking, Broken
Discharge Electrodes
Dust Build up, Broken, Slack

Rapping system
Wearing On Bearing, Shaft, Lifting Mechanism,
Hammer, Anvil

Gas distribution screen

Dust Build-up, Abrasion On Screens
2. Mechanical Inspection
(Tai & Chyun Mechanical Inspection
Scope)
Insulators
Dust Build-up, Burn Mark, Water Mark,
Cracking

Heaters (purge air and ring heaters)

Heater Failure, Blower Failure,
Thermostat Failure

Anti-sneak baffle plates

Welding Line Failure, Surface Abrasion, Dust
Build-up
2. Mechanical Inspection
(Tai & Chyun Mechanical Inspection
Scope)
ESP Inspection chart
3. Electrical Inspection
(Tai & Chyun Electrical Inspection
Scope)
Transformers
Physical Appearance, HV bushing, Primary
and Secondary Terminal, Wiring Connections,
Oil Leakage, Insulation and Grounding Testing

Controller
Controller Keypads, Controller Board for TR
set and Rappers, Wiring Connections,
SCR/Thyristor, Rapper controller, Power
Breakers and Contactors
3. Electrical Inspection
(Tai & Chyun Electrical Inspection
Scope)
Transformer Rectifier Set
Insulation Oil Refill / Change /
Filtering/oil sampling
LV / HV Bushing Replacement

Grounding Switch Repair

Signal / Protection Circuit Repair /

Replacement
T/R Set Replacement
3. Electrical Inspection
(Tai & Chyun Electrical Inspection
Scope)
Control Panel
Grounding Resistance Check
Thyristor (SCR) Replacement
AVC Controller and Keypad Replacement
Control Relays / Fuses / Power Supply TR
Replacement
Network Check & Correction
Interface / IO Module / CAN Opener Check
Alarm / Lamp / Push Button Repair
Cable / Wire Connection & Termination Re-tighten
Interior Cleaning
3. Electrical Inspection
(Tai & Chyun Electrical Inspection
Scope)

Ring, Hopper and Purge Air Heaters

Resistance measurement, Terminal
Connections, Physical appearance

Rapping and Purge Air Heater Motors

Winding testing, Wiring connections,
Fan and blowers of purge air heaters,
Appearance
3. Electrical Inspection
(Tai & Chyun Electrical Inspection
Scope)
Open circuit test VI curve

Short circuit test Before start up After start up

Collecting to discharge
No load testing Air load testing
electrodes testing

V-I curve
3. Electrical Inspection
ESP Performance-VI Curve
3. Electrical Inspection
ESP Performance-VI Curve

Description kV mA
Misalignment
Low Low
(spark & arc)
Insulation
Low High
Problem
DE Dust build-
High Low
up
Normal High High
YOUR PARTNER FOR A CLEAR STACK

END OF THE SESSION