This presentation is made for understanding the working of ESP in power plant. and also what are equipment are used with technical data.

1. “Electrostatic Precipitator ESP”
Stage II, 2*660MW
MPPGCL, Khandwa
PRESENTED BY:
VINAY VISHWAKARMA
G.E.T.

2. Electrostatic Precipitator

3. Introduction
 A device that removes suspended dust particles from a gas or exhaust by applying a high-voltage
electrostatic charge and collecting the particles on charged plates.
 Electrostatic precipitation is a method of dust collection that uses electrostatic forces, and consists of
discharge wires (negative plates) and collecting plates. (positive plates)
 A high voltage is applied to the discharge wires to form an electrical field between the wires and the
collecting plates, and also ionizes the air around the discharge wires to supply ions.
 When air that contains an aerosol (dust, mist) flows between the collecting plates and the discharge wires,
the aerosol particles in the air are charged by the ions.
 The Coulomb force caused by the electric field causes the charged particles to be collected on the
collecting plates, and the gas is purified.

4. Basic Diagram of ESP

5. Location of ESP
Step Up
Transformer TG Area Boiler ESP Chimney

6. Purpose of Installing
The flue gases produced due to combustion of solid pulverized fuel in the furnace contain plenty of dust
particles.
 When a chimney releases these flue gases in the atmosphere without filtering these dust particles, the
atmosphere may get polluted.
 Hence, these dust particles need to be removed from the flue gases as much as possible before these flue
gases get discharged to the atmosphere.
By removing the dust particles from flue gases, we can control the air pollution.
Electrostatic precipitator does this work for a furnace system.
We install this device in the way of flue gases from the furnace to the chimney so that the device can filter
the flue gases before they enter the chimney.

7. Working
The working principle of the electrostatic precipitator is quite simple. It has two sets of electrodes one is
positive, and another is negative. The negative electrodes are in the form of rod or wire mesh. Positive
electrodes are in the form of plates.
The positive plates and negative electrodes are placed vertically in the electrostatic precipitator alternatively
one after another.
The negative electrodes are connected to a negative terminal of high voltage DC source, and positive plates
are connected to the positive terminal of the DC source. The positive terminal of the DC source may be
grounded to get stronger negativity in the negative electrodes.
The distance between each negative electrode and positive plate and the DC voltage applied across them are
so adjusted that the voltage gradient between each negative electrode and adjacent positive plate becomes
quite high to ionize the medium between these.

8. To be continued…

9. To be continued…

10. To be continued…

11. Parts of ESP
1. Collecting Electrodes
2. Discharge Electrodes
3. Transformer Rectifier Set (TR Set)
4. Support Insulator Heater (SIH)
5. Rapper Coil (CR, DR, GD)
6. Temperature Transmitter
7. Pressure Transmitter
8. Opacity Monitor/ Blower
9. Resistance Temperature Detector
10. Hopper Area
11. Hopper Heater (26 Module)
12. Low Level - Dust Level Indicator
13. High Level - Dust Level Indicator
14. Electronic Unit
15. Thermostat

12. Trestle

13. Control Room - PMCC
1. Source/ Power Transformer
2. Power cum Motor Control Centre (PMCC)
3. TR Panel Room

14. SOURCE/ POWER TRANSFORMER

15. Source/ Power Transformer
This Power transformer is a step down type transformer which fed power to TR Set, PMCC
Panel and then to all load which is used in ESPs.
Voltage level: 11KV to 440V.
Such load are Hopper Heater, Support Insulator Heater, Dust Level Indicator, Rapper Coil,
Hoist, Opacity Blower, Lighting Induced Draught Fan and all machine which is working for ID
fan.
Power is directly fed to PMCC panel through busbar duct.

17. Name Plate Detail of Power
Transformer

18. POWER CUM MOTOR CONTROL CENTRE

19. Power cum Motor Control Centre
 It is an assembly from where the power of an equipment or machine is being controlled which is in center
location.
 It consists of Breaker, Busbar, Fuse, Indication Light, Relay, Contactor, Protection Transformer metering
equipment.
 Here Panel used 440V to feed load.
 It contains TR Panel feeder, SIH feeder, Hopper Heater feeder, Opacity Blower Power Supply, Rapper
Panel Power Supply, DLI feeder, ID fan feeder etc.
 It also having an arrangement of Bus-coupler to transfer power from one side to another to feed load
during maintenance of Power Transformer.

20. PMCC Testing
Before charging a PMCC Panel some test have been followed by vendor/ client. They are as follows:
1. Megger Test on Busbar: By this test we are confirming that our Busbar is short/ open. If short then the
megger reads 0Ωs and if it is open then megger reads above GΩ.
2. HiPot Test on Busbar (High Potential): By this test we are injecting 2KV (4-5 times of rated voltage) to
Busbar by the help of Step-up Transformer and takes the value of current reading. If clamp meter reads
below 50mA then the busbar is in healthy condition. It is also known as Dielectric Withstand test.
3. Relay Testing: In this test we check that relay is working properly or not. (Under Voltage Trip, Over
Current Trip, Over Voltage Trip, Differential Protection).
4. Contact Resistance Meter (CRM): This test is especially important for contacts that carry large amounts
of current (switchgear busbars) because higher contact resistance lead to lower current carrying capacity and
higher losses. Ductor testing is usually performed using a micro/ milli- ohmmeter or low ohmmeter.
#To ensure the busbars joints are giving minimum reading.
#Gradually increase the injected DC current to a specified current (e.g. 100A, 200A), then take the
micro-ohms reading.

21. To be continued…
Contact
CRM Test
Breaker AssemblyDistance between two Busbar
Megger & Hi-Pot Test CRM Test

22. Feeder given on PMCC Panel
S. No FEEDER CAPACITY FUNCTION
1. To TR panel (Pass A) 400A To give supply to Transformer Rectifier Set for charging field/ electrode.
2. To SIH JB 25.5KW To give supply to support insulator heater for maintain the temperature of insulator.
3. To Electrical Hoist Motor Feeder 63A To give supply to hoist for loading & unloading of machine.
4. Power Supply to Rapper Panel 63A To give supply to rapper panel to run rapping system.
5. To hopper heater JB 23KW To give supply to hopper heater JB to increase the temperature of ash/ dust.
6. To ID fan MCC 250A To run ID fan for taking out minute particles in the air through chimney.
7. Raw power supply to EPMS 63A To run PLC for automation of an equipment located on remote area from control room.
8. Blower for opacity monitor 0.55KW To run opacity blower/ motor
9. 9:10A MCB O/G (7w+2S) 9:10A To give supply to DLI to operate.
10. LINE-A PT & Auxiliary
Equipment
50VA
11. Incomer – I 4000A
12. To Welding Receptacles for SWR.
Room
63A To give supply for doing welding in location site.
13. BUS-A PT & Auxiliary Equipment 50VA
14. Spare 23KW For future use
15. Spare 63A For future use

23. TR Panel Feeder
1. TR Panel feeder is only used to transfer power to
TR Panel from PMCC Panel.
2. It is used when user want maintenance in TR
Panel.

24. Hopper Heater Feeder
1. The hopper heater is designed to preheat the hopper to prevent moisture condensate from
collecting ash in it during startup conditions.
2. In addition, they maintain the hopper and fly ash at temperatures (50⁰C to 150⁰C) above the flue
gas acid dew point during normal operating conditions.

25. To be continued…

26. Circuit Diagram
26 Heater Module per hopper

27. Dust/ Ash Level Indicator (DLI/ ALI)
1. DLI is a electronic device which is used to detect the ash level in hopper to protect the hopper from
overloading.
2. A change of Level of material in the hopper causes a change in dielectric which in turn causes a change
in admittance of this imperfect capacitor. An accurate measurement of this change affords an indirect
measure of the level of material in the tank.

28. Support Insulator Heater Feeder
# Cylindrical or conical support insulators are used for the
suspension of the collecting electrodes and to provide
insulation to the ESP housing.

29. To be continued…

30. Rapper Panel & Rapper JB
1. Rappers are used to transmit strong shearing forces to collecting plates in order to release deposited dust
particles.
2. Rapping is the process by which electrodes and particles are broken apart by vibrations from the rappers.
Often used in electrostatic precipitators, rappers relapse the caked on dust layer which then descends into a
hopper.
3. Number, size, and frequency of the rappers vary from system to system based upon the specific
characteristics of the dust being collected.

31. To be continued…

32. Cross- Sectional View of ESP
Ground Discharge Rapper
Funnel
Hopper
Gas Distribution System
Collecting Electrode
Support Insulator
Discharge Electrode
Rapping System
HV Transformer DC

33. Temperature Transmitter & Pressure
Transmitter
1. A pressure transducer, often called a pressure transmitter, is a transducer that converts pressure into an
analog electrical signal. Although there are various types of pressure transducers, one of the most common is
the strain-gauge base transducer.
2. A temperature transmitter is an electrical instrument that interfaces a temperature sensor (e.g.
thermocouple, RTD, or thermistor) to a measurement or control device (e.g. PLC, DCS, PC, loop controller,
data logger, display, recorder, etc.).
3. An RTD or Resistance Temperature Detector is a passive circuit element whose resistance increases with
increasing temperature in a predictable manner.2

34. Pressure Transmitter & RTD

35. Opacity Monitor (OPM)

36. Electrical Hoist

37. TRANSFORMER RECTIFIER PANEL

38. TR PANEL ROOM

39. Name Plate on TR panel
ELECTRONIC CONTROLLER
FOR H.V. RECTIFIER FOR ELECTROSTATIC PRECIPITATOR
MODEL ADOR CORONA
SERIAL NO. 15701-01-07-2018
CUSTOMER M/S L&T
PROJECT NO. 6678
ORDER REFERENCE NO. 01/1100/ 01334
RATED INPUT VOLTAGE 415 V AC 50 Hz
RATED INPUT CURRENT 302 AMPS
RATED OUTPUT VOLTAGE 95 KV (P) DC
RATED OUTPUT CURRENT 1300 mA DC
DATE OF MANUFACTURE JULY-2016
MADE IN INDIA
ADOR POWERTRON LIMITED. PUNE-411019 0551-2000-16-35/3

40. Need of TR Panel
The main purpose of installing TR Panel before TR Set is as follows:
1. Built in current limiting reactor to protect the electrical system from frequent short circuits in the field.
2. Extra heavy duty design suitable for 95 to 120 KV peak voltage, based on application requirement.

41. Inside TR Panel
Meter KV, V, mA, A
Meter Calibration card
Display
Emergency Stop Button
Local/ Remote Button
SCR
Mechanical Interlock CTs
TB 4
HRC Fuse 415V
Main Contactor
Fuse
DOC IV- Controller
Relay
Control Transformer
Auxiliary Contactor
Earthing Busbar
MCBs for Controller
Lamp Holder
Manual handle for ON/ OFF

42. Testing of a TR Panel/ Transformer
Before charging the Transformer firstly, we do some test on TR Panel and H.V. Transformer. The test
are as follows:
1. Cable Continuity and Megger Value should not be less than 1GΩ. (Megger Voltage 5KV)
2. Transformer Primary and Secondary winding megger test. It should also not less than 1GΩ.
3. TR Panel test i.e. checking that panel giving rated output voltage. If not then controller may be
faulty. This test is called “Lamp Load Test”. (Controller should be in Manual Mode)
4. If controller healthy then we do “Open Circuit Test” on a Transformer and observe the input and
output voltage. (Rated input voltage is applied)
5. Then we do “Short Circuit Test” on a Transformer and observe the input and output current.
(Rated input current is applied)
6. Then finally we charge the transformer and put under observation.

43. Problem & Troubleshooting on TR Panel
S. No PROBLEM TROUBLESHOOTING REMARKS
1. INPUT VOLTAGE NOT INCREASING
2. INPUT CURRENT NOT INCREASING
3. OUTPUT VOLTAGE NOT INCREASING
4. OUTPUT CURRENT NOT INCREASING
5. INSTANTANEOUSLY CURRENT
INCREASING
SCR UNBALANCED
6. EXTERNAL ALARM 1 DLI HIGH LEVEL H1
7. EXTERNAL ALARM 2 DLI HIGH LEVEL H2
8. EXTERNAL ALARM 3
9. EXTERNAL ALARM 4
10. MAIN CONTACTOR NOT PICK-UP

44. Transformer Rectifier Set (TR Set)
1. The TR is a static transformer which step up the voltage from 440V to 95KV and then converted
the A.C. voltage into D.C. voltage with the help of Bridge Thyristor.
2. The negative terminal of transformer is carried by Busbar (copper tube) to the field into
discharge electrode with the help of support insulator.
3. The positive terminal of output voltage is given to collecting electrode.
4. Both the electrodes are always in open condition. So there will be induce electric field between
the electrode.
5. That electric field energize the ash particles and attracted by the collecting electrode (positive
terminal).
6. Then after sometime rapping system works, which removes the dust particles from electrode and
get collected to the hopper.

45. Transformer Rectifier Set

46. P.L.C. AND S.C.A.D.A.
Programmable Logical
Controller
Supervisory Control And Data
Acquisition

47. Programmable Logical Controller (PLC)
Programmable logic controller
Its a hardware, which is directly in
contact with field instruments. It
works according to the logic
stored in PLC Memory.
It uses a language called “Relay Ladder Logic”.
Positive Logic (most PLCs follow this convention)
True = logic 1 = input energized.
False = logic 0 = input NOT energized

49. Supervisory Control And Data Acquisition
(SCADA)
1. Its a software, which shows the output and feedback in Visual manner,
that PLC can't do.
2. A programmer design the animation as per PLC programming and
field equipment position, then make communication between SCADA
and PLC.
3. After successful communication between SCADA and PLC we can
Visualize the operation which is happen in field from Control Room.

50. Some Pictures of SCADA screen

58. EARTHING

59. Importance of Earthing
Overload Protection – In scenarios where excessive power surge occurs, a grounded system
helps immensely. This simple form of surge protection can instantly save your electrical machine
and devices from getting fried by excessive electrical power, saving your data as well as
equipment.
Voltage Stabilization – When it comes to calculating the right amount of power to be
distributed between voltage sources, the earth provides that universal standard point of reference.
Earthing takes the guesswork out of voltage stabilization, helping to ensure that no circuits
overload or blow up.
Damage, Injury & Death Prevention – Blown fuses or a tripped circuit breakers are far more
welcome than electrical fires or shocks, which can pose serious safety hazards to people and
property. Essentially, grounding protects against equipment, property and data loss, as well as
injuries and fatalities.

60. CABLE DATASHEET

61. S.No. EQUIPMENT SIZE CABLE TYPE
1. TRANSFORMER RECTIFIER 2C-300 SQ.MM ARMOURED
2. RAPPER PANEL 3C-25 SQ.MM ARMOURED
3. RAPPER COIL 2C-2.5 SQ.MM ARMOURED
4. OPACITY BLOWER 3C-6 SQ.MM ARMOURED
5. SUPPORT INSULATOR HEATER 3C-50 SQ.MM ARMOURED
6. HOPPER HEATER 3C-35 SQ.MM ARMOURED
7. DUST LEVEL INDICATOR 2C-6 SQ.MM ARMOURED
8. HOPPER HEATER LOOPING 3C-10 SQ.MM ARMOURED
9. WELDING RECEPTICLES 3.5C-35 SQ.MM ARMOURED
10. EPMS/ PLC 3C-6 SQ.MM ARMOURED
11. ELECTRICAL HOIST 3C-16 SQ.MM ARMOURED
12. CONTROL CABLE 27C, 7C,5C, 3C, 2C-2.5 SQ.MM ARMOURED
13.
14.
PAIR CABLE
COMMUNICATION CABLE
16P, 8P, 4P, 2P-0.5 SQ.MM
2P-0.35 SQ.MM
SCREENED
SCREENED
* Above cable are used for this plant only, where load will be different then cable size are also changed.

62. THANK YOU
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