OPERATION

PREPARATION AFTER MAINTENANCE

• Check the precipitator internals and remove the
tools and other foreign materials.
• Check all the insulators visually.
• Inspect the rapping motors and top-up with oil.
• Run the rapping motors and ascertain that they
function normally.
• Check that the heating elements.
• Check the dielectric strength of transformer
oil
• Megger and test all the fields on air load.
• Ensure that the ash handling system is
working properly.
START UP PROCEDURE
• Switch on the heating elements at least 24
hours before the start up of the boiler.
• Switch on the rapping mechanisms as soon as
the boiler is lighted up.
• The HVR shall not be energised until the gas
temperature is above 100°C.
OPERATIONAL CHECKS

• Check the normal function of Precipitator

• Logging of readings hourly.
• Record the failures and outages.
 SHUTDOWN PROCEDURE

• Switch off the fields when the gas temperature is

below acid dew point.
• Continue the operation of the rapping motors in
intermittent mode for 4hrs.
• Evacuate the ash from all hoppers.
• The access doors may be opened after following
the interlock sequence.
SHUTDOWN INSPECTION

Inspect the internals for :

• Snapped or loose wires.
• Excessive ash accumulation.
• Dislocation of shock bars, shock bar guides and CE
• Rapping system, hammers, plain bearing shaft etc
• Insulators
• Disconnecting switch and contacts.
• All heating elements
• Any other abnormality.
 OPERATION
PREPARATION AFTER MAINTENANCE
i. Check the precipitator internals and remove the
tools and other foreign materials. Remove
temporary earthing connections if any, on the
emitting system.
ii. Check all the insulators visually.
iii. Inspect the rapping motors and top-up with oil,
if necessary.
iv. Run the rapping motors and ascertain that they
function normally.
v. Check that the heating elements function
normally.
vi. Check the dielectric strength of the
transformer oil and centrifuge the oil if
required. Conduct open circuit test to ensure
the healthiness of the transformer –
rectifiers.
vii. Close all the inspection doors and covers
and ensure that the interlocking system is in
order.
viii. Megger and test all the fields on air load.
ix. Ensure that the ash handling system is
working properly.
 START UP PROCEDURE
i Switch on the heating elements at least 24
hours before the start up of the boiler.
ii Switch on the rapping mechanisms as soon
as the boiler is lighted up.
iii The precipitator design allows for start up
from a cold condition. However if the
precipitator is energised in cold condition,
considerable moisture from the gases will
condense on the EP internals leading to
formation of ashcake, which is difficult to
dislodge by normal rapping. Hence the
transformers shall not be energised until the
iv The optimum amperage setting depends
upon various factors such as flue gas
conditions, dust concentration etc. Excess
amperage setting may cause frequent
snapping of emitting electrodes due to
spark erosion and bring down the useful
corona power.The optimum amperage for
each field is just below the spark over level.
OPERATIONAL CHECKS
i. Check the normal function of Transformer
Rectifiers, Electronic controllers, Auxiliary control
panels, Rapping mechanisms, Heating elements
and Ash handling system.
ii. The following shall be recorded hourly in a
logbook.
• All the meter reading in the electronic controller
and Auxiliary control panel
• Boiler load.
• Flue gas temperature at the inlet of the
precipitator.
• The failure of components the outage and the
probable cause will be recorded. Corrective action
wherever necessary shall be taken.
 SHUTDOWN
i. Switch off the transformer rectifiers when
the gas temperature has dropped below acid
dew point of the gas.
ii. Continue the operation of the rapping
motors in continuous mode for
approximately 30 minutes before switching
off .
iii. Continue the operation of the fly ash
evacuation system until all hoppers are
completely emptied.
iv. When the precipitator internals have
cooled down to a safe level, the access
doors may be opened after following the
interlock sequence.
v. During shut down, inspect the internals for :
• Snapped or loose wires.
• Excessive ash accumulation.
• Dislocation of shock bars, shock bar guides and
collecting electrodes.
• Any other abnormality.
Normally the precipitator does not require any
periodical manual cleaning since the rapping
system ensure adequate cleaning of EP internals
during the operation.
• However operation of EP under following
conditions may cause excessive dust deposit on
the internals.
• Prolonged operation of EP without rapping.
• Energisation of EP with wet internals.
• Operation of EP below acid dew point.
• Flue gas entering the EP is misty due to
incomplete oil combustion particularly at the
time of initial boiler operation.
Accumulation of such dust deposits not only
causes the reduction of precipitator
efficiency but also results in unstable
operation, rapid corrosion of electrodes,
failure of insulators and fire hazard.
Therefore during any shutdown, if excessive
ash deposit is noticed, clean the internals
and identify the cause of such excessive
deposit for rectification. Removal of such
sticky dust may be done with brushes,
scrapers, compressed air or water.
 MAXIMISING PRECIPITATOR
PERFORMANCE
The performance of the precipitator is
influenced by number of factors, many
of which are controllable. It should be
the aim of every operator to maximise
the performance by judiciously
adjusting the controllable variables.
CLEANING OF ELECTRODES

GAS TEMPEATURE
• Failure of em itting electrodes due to stress
corrosion cracking
• Corrosion of the internals
• Collection of wet dust on the electrodes
leading to formation of “ Hard-to rap” layers
and consequent reduction in the performance
of ESP
• D ifficulty in the rem ovalof w etdustfrom
the hoppers
SPARK RATE

RAPPING FREQUENCY/
EFFICIENCY

ASH EVACUATION

GAS DISTRIBUTION

GAS FLOW
MAINTENANCE
GENERAL
• Do not disturb the guide vanes, splitters,
deflector plates on the gas distribution
screen or the internal alignments during the
inspection to maintenance.
• Every available shut down may be utilised
to remove the excessive ash build up, if any.
• A llthe
, , internals,casing,hoppers and roofshall
be inspect// ed for corrosion/erosion/w ear and
tear/leakage periodically.
• The asbestos ropes and gaskets shall be
replaced whenever required.
MECHANICAL SYSTEM
(i) Collecting Electrode system
• Check the alignment of collecting
electrodes, shock bars and guides.
• Replace the shock bars if the shock pad is
worn out excessively.
• Check the rapping mechanism if dust build
up is excessive.
(ii) Emitting Electrode system
• Check the emitting electrodes for
excessive electrical erosion and snapping.
Remove the eroded/snapped electrodes, if
any.
• Care shall be taken not to disturb the
healthy electrodes while replacing with
new electrodes.
• Wherever the access is difficult, the
intervening electrodes may be unhooked
• W hile ,stretching,alw ays use the stretching
tool.
• If an electrode is over stretched the sam e
should be discarded.
Insulators
• The insulator shall be inspected during
shut down for cleanliness, cracks and
rigidity of metal parts
• Dusty insulators should be cleaned with
Carbon tetrachloride.
• Cracked insulators should be replaced.
• Support insulators shall be replaced, if
required, with the help of lifting tool and
alignment jig as per procedure.
MAINTENANCE
GENERAL

• Ensure the guide vanes, splitters, deflector plates

on the gas distribution screen as per original.
• Remove the excessive ash build up, if any.
• Inspect for corrosion, wear and tear of internals, casing,
hoppers and roof periodically.
• The asbestos ropes and gaskets shall be replaced whenever
required to arrest leakage.
MECHANICAL SYSTEM
(i) Collecting Electrode system
• Check the alignment of CE, shock bars and
guides.
• Replace the shock bars/shock pads if worn out
excessively.
• Check the rapping mechanism if dust build up is
excessive.
Tack weld all the fasteners after tightening. Care
should be taken not to tack weld the HSFC bolts if
used for CE and shock bars
(ii) Emitting Electrode system
• Check the emitting electrodes for
excessive electrical erosion and snapping.
Remove the eroded/snapped electrodes, if
any.
• Care shall be taken not to disturb the
healthy electrodes while replacing with
new electrodes.
• Wherever the access is difficult, the
intervening electrodes may be unhooked
• While stretching, always use the stretching
tool.
• If an electrode is over stretched the same
should be discarded.
Insulators
• The insulator shall be inspected during shut
down for cleanliness, cracks and rigidity of metal
parts
• Dusty insulators should be cleaned with Carbon
tetrachloride / Petrol in both inner and outer
portions.
• Cracked insulators should be replaced.
• Support insulators shall be replaced, if required,
with the help of lifting tool and alignment jig as
per procedure.
AIR LOAD TEST AFTER MAINT.,
Please ensure:
•All foreign materials are removed.
•All heaters are energized
•Meggering of fields ( around 500 Meg Ohms)
•Charge the fields with still air load and ensure:
•Fields building up up to rated current and kV without
sparking. Incase of sparking attend the discrepancy and
repeat the test.
•Air load test is a must after every maintenance of fields.