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Welcome to ESP Presentation
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Contact:
www.imecolimited.com
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Index
Index
Controlling Air Pollution
Introduction
Design Features
Principle of Operation
Components
Operations & Performance
Corona Power
Maintenance & Troubleshooting
About Us
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Air
pollution
Controlling Air Pollution
Cont…
Clean Air is an essential resource to the people surrounding the Industrial establishments. The Air pollution is one of the main problems of the Environmental Pollution. The Industrial waste gases directly harm people’s health and also affect further development of the Industries.
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Air
pollution
Now a days Electrostatic Precipitators have come a long way and are widely used in all major Power Plants, Chemical Industries, Cement Industries & Steel Industries. They absorb more than 99% of dust particles and other substances while passing through the ESP and the exhaust gases coming out of chimney are with in the Emission Standard prescribed by Central Pollution Control Board.
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In all industries the burnt gases are passing through an Equipment called Electrostatic Precipitator to eliminate the dust particles.
In the simplest terms, a Precipitator is a large box. The dust-laden gases are drawn into one side of the box. Inside, high voltage electrodes impart a negative charge to the particles entrained in the gas. These negatively charged particles are then attracted to a grounded collecting surface, which is positively charged.
The gas then leaves the box up to 99.9% cleaner than when it entered.
Introduction to ESP
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Electrostatic Precipitator removes dust particles from the exhaust gas stream of a process industry. Often, the process involves combustion, but it can be any industrial process that would otherwise emit dust particles to the atmosphere. There are six activities that take place:
• Ionization - Charging of particles
• Migration - Transporting the charged particles to the collecting surfaces
• Collection - Precipitation of the charged particles onto the collecting surfaces
• Charge dissipation - Neutralizing the charged particles on the collecting surfaces • Particle dislodging - Removing the particles from the collecting surface to the hopper
• Particle removal - Conveying the particles from the hopper to a disposal point
Introduction to ESP
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Electrostatic Precipitators are not only used in Power Plant applications but also other industries (for other exhaust gas particles) such as Cement (dust), Pulp & Paper (salt cake & lime dust), Petrochemicals (sulfuric acid mist), and Steel (dust & fumes).
Introduction to ESP
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History of Electrostatic
Precipitator Technology
Introduction to ESP
In 1907, the first commercial Electrostatic Precipitator (ESP) was designed. By 1912, this fledgling art had progressed to a cement application and the ESP was established as an economically viable device for the prevention of large-scale particulate air pollution.
Till date, although periodically challenged, the Precipitator remains the dominant device for this purpose on a worldwide basis. Along with its rapid commercial acceptance, the technology quickly developed its form and design characteristics that remain unchanged to this day.
Although variations exist, these design precepts are still almost universally followed till date.
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Electrostatic Precipitator (ESP) is the most widely used device in India for particulate emission control. Over the years, ESP design has improved with the experiences from its application and operation in various industries. The stringent emission regulations that have been stipulated in the recent years have set new targets for the ESP manufacturers. Efforts to improve ESPs through upgraded technologies and managing operational problems through careful improvement of the ESP operational practices have proved its success till date.
Status of Electrostatic Precipitator
Technology usage in India
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Over a year, these work out to half a million tonne of ash and 80000 tonnes of SO2. The total amount of pollutants from all the thermal power plants, if allowed to pervade our atmosphere without any control, would seriously pose a threat to ecological balance, climate, and atmosphere.
Thermal Power Plants
In Thermal Power Stations, suspended particulate matter (SPM), sulphur dioxide (SO2), and oxides of nitrogen (NOx) are the major emissions, resulting from fuel combustion during power generation. To generate 200 MW electrical energy, the power station consumes about 2700 tonnes/day of coal producing daily about 1200 tonnes of ash and 216 tonnes of SO2.Cont….
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ESPs are used in all thermal power plants to control particulate
emissions. Ash generated in a power plant has nearly 30 per cent
by weight in 10 m
THERMAL POWER PLANTS
Introduction to ESP
range and 10 per cent in 2
m
range.
Also
the
concentration of dust is
extremely high of the order
of 30 grain/ft3 of flue gas. A
high efficiency collector is
capable
of
collecting
particles of less than even
one micron size.
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Dust emission problems in the sintering plant of the Steel Factory mainly arise from the exhaust gases from the combustion zones and from the ventilation air out of crushers, sieves, coolers, and loading stations. The average dust emission level is about 15–20 kg/tonne of sinter which is returned to the process when collected. Blast furnaces may have outputs upto 2000– 3000 tonnes/24 hr. Waste gas is produced at a rate of approximately 4000 m3 at STP per tonne of pig iron with a dust content after coarse separation of approximately 10 gm/m3. The dust contained in the exhaust gas extracted from the top of the blast furnace mainly consists of iron oxide, silica, and lime.
STEEL INDUSTRY
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The use of ESPs in cement plants has been since its invention. This is due to its recovery value and the finest and best cement can be collected through ESP. Use of ESP in cement plants has dominated every market in the world. In India, there was raised growth during 70s and 80s. ESPs are generally used in cement kilns and cement grinding mills. In kiln waste gas, the range of gas quantity is 150 000 m3/hr at a temperature of 250 °C. However, gas cooling tower brings down their temperature. In cement grinding mill, the gas range is 45 000 m3/hr approximately at a temperature of 80 °C. The application of ESPs has undergone considerable change with the advent of new processes for cement
CEMENT PLANTS
Since the dry process is widely being adopted by all the plants including the old plants (with wet process converting to dry process), the dust loading is increased and thus improved ESPs with Pulse Energization techniques are used.
Introduction to ESP
manufacture (especially the introduction of dry cement manufacturing process) and also wider awareness of environmental factors. The cement industries with the stringent air borne emission standards have begun to use conventional ESPs for control of emissions in kilns (in kilns ESPs were used together with conditioning tower) and coal mills.
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APPLICATIONS FOR
ELECTROSTATIC PRECIPITATORS
Production plants for cement,
limestone
and gypsum (Kilns, Mills, Driers
and
coolers)
Coal fired boilers
Refuse and sludge incinerators
Gas production plants
Iron and steel production plants(ore
dressing, blast furnaces,
convertors and Sinter Plants)
Production plants in the electro –
metallurgical, chemical and
pulp and paper industry
Sponge Iron Plants
Burning wood waste
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Generally ESP…
- can collect dust in both wet and dry conditions;
- can collect all sizes of particles, from microns
to coarsers;
- probably the most versatile collecting equipment;
- offers the highest efficiency, can be designed
in principle for any
- efficiency without excessive pressure drop;
- operates with low operation cost (though initial cost is more);
- can operate over a wide range of inlet conditions, i.e., temperature,
pressure, dust burden, humidity, etc.;
- offers negligible pressure drop (rarely crosses 10–15 mm); can be built in
multiple units, for almost any gas volume;
- has a long life, comparatively free from abrasioneffect due to low operating
velocity;
FEATURES / ADVANTAGES
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ESPs
ESPs
Traditional North American Design
Traditional European Design
ESP DESIGNS
ESP DESIGNS
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TRADITIONAL ESP DESIGNS
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TRADITIONAL NORTH AMERICAN DESIGN
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TRADITIONAL EUROPEAN DESIGN
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Electrostatic precipitation is a physical process by which particles suspended in gas stream are charged electrically, and under the influence of electric field are separated from the gas stream. The precipitation system consists of a positively charged collecting surface and a high voltage discharge electrode wire suspended from an insulator at the top and held in position by a weight at the bottom. At a very high DC voltage of the order of 50 kV, a corona discharge occurs close to the negative electrode, setting up an electric field between the emitter and the charged surface.
ESP – Principle of Operation
PRINCIPLE OF OPERATION
PRINCIPLE OF OPERATION
The particle-laden gas enters inlet side of ESP and flows through . The gas close to the negative electrode is, thus, ionized upon passing through the corona. As the negative ions and electrons migrate towards the charged surface, they in turn charge the passing particles. The electrostatic field then draws the particles to the collector surface where they are deposited. Periodically, the collected particles are removed from the collecting surface by rapping or vibrating the collector to dislodge the particles. The dislodged particles drop below the electrical treatment zone and are collected through hoppers for ultimate disposal.
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Charging
Particles are given strong negative
charge by ionizing corona produced
by high-voltage electrodes
Collection
The electric field causes charged
particles to migrate and precipitate on
the grounded plates, where they
agglomerate and are held by the
electric field
Removal
The
particulate
matter
is
mechanically rapped off the plates
in large ‘clumps’, falling into
hoppers for removal
HOW A ESP FUNCTIONS
HOW A ESP FUNCTIONS
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TWO STAGE ELECTROSTATIC PRECIPITATOR
ESP – Principle of Operation
STAGE I
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TWO STAGE ELECTROSTATIC PRECIPITATOR
ESP – Principle of Operation
STAGE II
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SCHEMATIC OF A PARALLEL-PLATE PRECIPITATOR
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TYPICAL HORIZONTAL FLOW PRECIPITATOR
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COMPONENTS FOR
ELECTROSTATIC PRECIPITATORS
The devices used for gas – solid separation, Electrostatic Precipitators has the widest of application in view of its various advantages. It can handle Large volume of gases from which solid particles are removed. The critical components of Electrostatic Precipitator are indicated below. COLLECTING ELECTRODE PLAIN BEARING SUPPORT INSULATOR SHAFT INSULATOR EMITTING ELECTRODE SHOCK BAR RAPPING HAMMERS GAS SCREEN SHEET
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COLLECTING ELECTRODES
Collecting plates are designed to receive and retain the precipitated particles and then removed into the hopper. In addition, the collecting plates are part of the electrical power circuit of the precipitator. Baffle plates shield the precipitated particles from the gas flow. And smooth surfaces provide for high operating voltages. Collecting plates are suspended from the precipitator casing and form the gas passages of the precipitator.
ESP - Components
Collecting plates are connected at or near the center by rapper beams, which then serve as impact points for the rapping system. Top, center, or bottom spacer bars may be used to keep the collecting plates aligned. This maintains electrical clearances to the discharge system. ESP Collecting Electrodes are manufactured from steel strip which is cold roll formed to the desired profiles.
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Discharge electrodes emit charging current and provide voltage. This generates an electrical field between the discharge electrodes and the collecting plates. The electrical field forces dust particles in the gas stream to migrate towards the collecting plates. Finally the particles precipitate onto the plates. Common types of discharge electrodes include
DISCHARGE / EMIITING ELECTRODES
ESP - Components
• straight round wires • twisted pairs of wires • barbed discharge wires • rigid masts
• rigid frames
• rigid spiked pipes
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ESP - Components
Discharge electrodes are typically
supported
from
the
upper
discharge frame and are held in
alignment between the upper and
lower discharge frames. The upper
discharge
frame
is
in
turn
supported from the roof of the
precipitator casing. High-voltage
insulators are incorporated into the
support system. In weighted wire
systems, the discharge electrodes
are held taut by weights at the
lower end of the wires.
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DISCHARGE ELECTRODE TYPES
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ELECTRODE ARRANGEMENT
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ELECTRODE DESIGN (CONT’D)
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Emitting (Discharge) Electrodes
Reliability criteria: sturdy designs
Application specific configurations
Current voltage characteristics
Overcome corona supression: fine
particulates
Collecting Electrodes
Height up to 15 meters with efficient
cleaning
Ease of installation
ESP - Components
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ESP - Components
These Screens are of modular design manufactured out of Steel sheets and hang within a frame work in the ESP inlet casing to maintain uniform distribution pattern of gas flow throughout the cross section of ESP.
GAS DISTRIBUTION SCREENS
SUPPORT AND SHAFT INSULATORS
The whole emitting frame system is suspended from the roof through Supporting Insulator to avoid any short circuiting.
The Rapping Mechanism Shaft for electrodes is connected to the driving mechanism through Shaft Insulator.
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The collecting electrodes are fixed loosely to
suspension beams on pins. They are joined
together in the bottom rapping beam. Both,
the firm bottom and the top loose
attachment provide a perfect transfer of
energy from the rapping hammers to the
entire row of collecting electrodes. The
rapping
is
carried
out
in
regular,
programmed intervals and guarantees
removal of deposited dust from the
electrodes
to
the
hoppers.
Tumbling Hammers Strike the collecting
plates and rigid electrodes directly, so that
all areas receive proper rapping acceleration
and no energy is lost to support structure.
SUSPENSION AND RAPPING MECHANISM
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Precipitator hoppers are designed
to completely discharge their dust
load on demand. Usually the
hoppers are rectangular in
cross-section with sides of at least 60°
slope. They are insulated from the
neck above the discharge flange
with the insulation covering the
entire hopper area. In addition,
the lower 1/4-1/3 of the hopper
wall may be heated. Discharge
diameters are generally 8" - 12".
HOPPERS
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ESP
Carbon Steel
Mild Steel
Corten
A516-70
Duplex & Stainless Steel
AR Plate
MATERIALS OF CONSTRUCTION
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FACTORS INFLUENCING PERFORMANCE OF ESPS
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ESP – Corona Power
Precipitator corona power is the useful electrical power applied to the flue gas
stream to precipitate particles. Either precipitator collecting efficiency or outlet
residual can be expressed as a function of corona power in Watts/1000 acfm of
flue gas, or in Watts/1000 ft of collection area.
The separation of particles from the gas flow in an electrostatic precipitator
depends on the applied corona power. Corona power is the product of corona
current and voltage. Current is needed to charge the particles. Voltage is
needed to support an electrical field, which in turn transports the particles to
the collecting plates.
CORONA POWER
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ESP – Corona Power
In the lower range of collecting
efficiencies, relatively small increases in
corona power result in substantial
increases in collecting efficiency. On the
other hand, in the upper ranges, even
large increases in corona power will
result in only small efficiency increases.
Equally, in the lower range of the corona
power levels, a small increase in the
corona power results in a substantial
reduction in the gas stream particle
content. In the upper range of the corona
power level, a large increase is required
to reduce the particle content.
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ESP – Corona Power
Gas velocity: Uniformity Fly ash: Particle size
Resistivity
Voltage controls: Spark rate setting
Current & voltage limits Design: Plate spacing
Collecting plate and discharge electrode design
Rapping system: Frequency and intensity Support insulator: Purge air system operation
OPTIMIZING CORONA POWER
Optimum conditions depend upon the location of the field (inlet, center, outlet), fly ash characteristics (resistivity), and physical conditions (collecting plates and discharge wires). Corona power levels can be optimized by adjusting or optimizing the following:
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Back–Corona
in the
Dust Layer
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One of the easiest
ways to determine if
you have a back
corona problem is to
plot a V-I curve for
the ESP section
RECOGNIZING BACK CORONA
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PREVENTIVE MAINTENANCE CHECKLIST FOR A TYPICAL ESP
• Take and record electrical readings and transmitter data.• Check operation of hoppers and ash removal system
• Examine control room ventilation system
• Investigate cause of abnormal arcing in T-R enclosures and bus dust.
Maintenance & Troubleshooting
• Check rapper operation
• Check and clean air filter
• Inspect control set interiors
WEEKLY
• Check operation of standby top-housing pressurizing fan and thermostat.
• Check operation of hopper heaters.
• Check hopper level alarm operation
MONTHLY
DAILY
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• Check and clean rapper and vibrator switch contacts. • Check transmissometer calibration
QUARTERLY
• Clean and lubricate access-door dog bolt and hinges. • Clean and lubricate interlock covers.
• Clean and lubricate test connections.
• Check exterior for visual signs of deterioration, and abnormal vibration, noise, leaks
HALF YEARLY
• Conduct internal inspection
• Clean top housing or insulator compartment and all electrical insulation surfaces.
• Check and correct defective alignment.
• Examine and clean all contactors and inspect tightness of all electrical connections.
ANNUAL
Cont…
Maintenance & Troubleshooting
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• Check and tighten rapper insulator connections • Observe and record areas of corrosion
• Record air-load readings during and after each outage.
• Clean and check interior of control sets during each outage of more than 72 hours
• Clean all internal bushings during outages of more than 5 days. • Inspect condition of all grounding devices during each outage
over 72 hours
• Clean all shorts and hopper buildups during each outage
• Inspect and record amount and location of residual dust deposits on electrodes during each outage over 72 hours
• Check all alarms, interlocks, and all other safety devices during each outage.
SITUATIONAL
Maintenance & Troubleshooting
PREVENTIVE MAINTENANCE CHECKLIST FOR A TYPICAL ESP
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COMMON PROBLEMS WITH ESP
1. Discharge electrode failure; Rapper malfunctioning;
2. Dust building; Transformer / Rectifier Failure; Hopper choking
3. Overfilling of dust hoppers 4. Electrode breakage
5. Misalignment and jamming in rapping mechanism 6. High gas flow
7. Hopper heater failure
8. Insulator failure due to dust build – up.
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MAJOR CAUSES OF PROBLEMS IN ESP
Problem Causes
Excessive Gas Volume
The ESP is not designed property Hot excess air
Air leakage
High gas temperature
Rapping Acceleration is not high enough Electrode arrangement is not right Failure of rapper motors
Gas Distribution Model study not carried out or carried out incorrectly Discharge
Electrode Breakage
Electrode is not strong enough to overcome flash voltage and high intensity rapping
Corrosion resistant material for electrode is not chosen
Discharge Overflow
in Hoppers Improper designing capacity of hopperCoal quality changes beyond the range Dust evacuation is not proper
Level Switch not acting properly Choking of dust hoppers
Electrical Dust build – up on electrodes Insulator breakdown
Misalignment of electrode Failure to maintain dust hopper
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i. Replace the defective rapper with a new one.
ii. Rebuild the defective rapper.
TROUBLESHOOTING
DUST ACCUMULATION
The most common cause of excessive dust accumulation on electrodes is a failure of the rapper control system. Unless there is reason to suspect otherwise (known high resistivity potential of the ash or other indications of hopper plugging), this should be one of the first areas checked if power input to the ESP decreases markedly. Checks of the control system will include:
i. Make sure that the power is on and that the fuse or circuit breaker has not been opened. ii. Check for proper operation of the switch and drive on rotary switches.
iii. Check manufacturer recommended procedures for testing rapper control systems.
Rapper failure is also a potential cause of dust accumulation. The ESP's use magnetic impulse/gravit impact type rappers.
A common cause of failure of this type of rapper is a short in the coil that
lifts the rapper. Methods for correcting this problem include:
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Corrective action for misalignment can only be done during a complete ESP shutdown. Corrective actions include:
i) Plate straightening by: hydraulic press, localized heating with an oxy/acetylene torch followed by water quench, remove the warped section of a plate with a cutting torch and replace it. Major rebuilding will require removal of the top of the ESP and replacement of entire plates. ii) Wire correction: Bent wire frames or lower guide frames often cause the wires to slacken and bow towards the plates. Distorted lower guide frames are often difficult to straighten and may have to be replaced. If the distortion is not too serious and only a few wires are slack, then they can be removed. The wires can be tightened by crimping them in the direction of gas flow.
iii) General misalignment caused by a shift in guide frame
components can usually be corrected by realigning the frame.
Air Infiltration
Routine inspections of the ESP will reveal any locations of air infiltration into the unit. Correction of this problem involves simple sealing of the leaking joint, surface or door/hatch gasket.
TROUBLESHOOTING
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i. When preparing for start-up, assure that all tools and safety devices (including lock out/tag out) have been removed from or taken off of the controls of the ESP. The plant superintendent or his designated representative shall be responsible for final inspection of the ESP to determine that the unit is ready for start-up.
ii. During the final pre-start-up inspection, the inspector shall assure that the ESP has been properly closed up and the keys for the interlock system have been returned to their appropriate locations.
iii. Conduct an air load test for each T-R set and if possible, for each bus section. This activity is used to determine that maintenance has been completed, all foreign matter has been removed and that the ESP is ready for operation.
iv. If the insulator heaters have been inspected during the shut-down, make sure that they have been turned back on at least 2 - 12 hours prior to ESP start-up. Purge air systems will also be activated at this time. Be aware of the potential for particulates to pass through the system and be emitted to the atmosphere when the purge air is activated.
v. The rapping system will be in operation during start-up to remove any settled dust.
Energize the ESP according to procedures established during
previous plant turnarounds.
START – UP PRACTICES
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Except in the instance of an emergency shutdown, this process should be essentially the reverse of the start-up procedure.
A) Deenergization usually begins at the inlet fields and progresses toward the outlet. At the point that the boiler is off-line, the fields (T-R sets) should be deenergized. This should be done sequentially toward the ESP outlet and as quickly as possible to prevent unnecessary sparking, condensation or insulator build-up. B) The rappers should be allowed to operate for several hours to remove residual dust.
SHUTDOWN PRACTICES
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• The erection team arrives 5 days in advance prior to the stoppage of the plant for making pre arrangements.
• After stopping the plant the fan, screw conveyor, rapping system is run for a day till the temperature reaches low so that the persons shall enter the ESP
• Hopper is cut to a suitable size after removing the insulation in that local area.
• The field is arrested before starting any cutting operations
• Cleaning is carried out so that persons are able to work inside the ESP
• The damaged collecting and emitting electrodes are removed and new electrodes are erected.
• Support insulators are dismantled and new insulators are installed; if required
• All the damaged CE and DE hammers are replaced
SCHEDULE / PROCEDURE FOR RETROFITTING OF ESP
Maintenance & Troubleshooting
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•
Plain bearing is replaced
•
Gas distribution is also replaced with
new screen; if damaged.
•
After
releasing
the
temporary
arresting the entire field is aligned
•
The hopper opening is closed again
and welded & reinsulated.
•
Gas distribution test is carried out to
assess the distribution.
•
After aligning, the field is charged for
no load test.
•
ESP is full load charged in the
process.
•
Performance is monitored 2 days.
Maintenance & Troubleshooting
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About Us
IMECO Limited, established in 1975, is
one of the leading Engineering
Organisation
manufacturing
and
supplying various equipments and
spares to Core Sector Industries
including
Power,
Steel,
Cement,
Petrochemical
&
Oil,
Fertilizer,
Chemicals etc. competing throughtout
the Globe, Imeco has been able to
create a name for itself for its dedicated
services.
Dependable
quality
at
economic prices, quick availability and
prompt after sales service find easy
acceptability of our products from
almost all conceivable industries.
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About Us
Our vision is to become a world class, innovative, competitive
engineering enterprise providing effective business solutions. Our
greatest strength lies in our highly skilled and committed work force,
who by continuous training and a positive and participative style of
management have engendered a work culture leading to enhanced
productivity and higher levels of quality.
We are constantly investing in resources for
product development with an objective to
provide market-leading products that reduce our
customer's downtime. A combination of our
knowledge and the extensive experience gained
by our engineers on sites throughout the world
enables us to support our customers when such
occassion arises.
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About Us
• Mechanical Inspections to identify
Improvement Opportunities.
• Electrical Inspections to Optimize
Performance or avoid breakdowns.
• Structural Inspections to assure Trouble
free Operation.
• Replacement of Damaged Fields.
• Optimizing Corona Power.
• Conducting GD test for uniform gas flow
in the ESP.
We offer services in the field of technical support as well as for supply of
internals / spares, both mechanical and electrical.
OUR SERVICES INCLUDE
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About Us
• COLLECTING ELECTRODES • DISCHARGE ELECTRODES • GAS SCREEN SHEETS
• COLLECTING /DISCHARGE ELECTRODE FRAMES • RAPPING MECHANISM WITH SHAFTS AND HAMMERS.
• INNER AND OUTER ARMS FOR RAPPING MECHANISM
• HEATING ELEMENTS FOR HOPPER AND SUPPORT INSULATOR
• DISCONNECTING SWITCH ASSEMBLY • GEARED MOTORS
• ALL MECHANICAL PARTS
WE HAVE COMPLETE MANUFACTURING FACILITIES FOR SUPPLY OF FOLLOWING SPARES FOR ESP
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OUR ESTEEMED CUSTOMERS
• Assam State Electricity Board • Neyveli Lignite Corporation Ltd • National Aluminium Company Ltd • Visakhapatnam Steel Plant
• Bihar State Electricity Board
• The Tata Iron & Steel Company Ltd • Steel Authority of India Ltd
• Maharashtra State Electricity Board • Hindustan Paper Corporation Ltd • Madhya Pradesh Electricity Board
• Andhra Pradesh Power Generation Corp Ltd • Chettinad Cement Corporation Ltd
• Ballarpur Industries Limited • Karnataka Power Corp Ltd • UP State Electricity Board • Gujarat Electricity Board • J.K.Paper mills
• Sterlite Group
• National Thermal Power Corp. Ltd • Chhatisgarh State Electricity Board • Renusagar Power Co Ltd