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5. ELECTROSTATIC PRECIPITAROR-STAGE II-ELECTRICAL

SYSTEMS
DESCRIPTION AND OPERATION
5.1 ELECTRICAL SYSTEM
Electric system in ESP- II stage comprises of

LT Main switch board

Auxiliary Control Panel

High Voltage D.C. Supply Equipment.

5.2 LT MAIN SWITCH BOARD

It consists of two, 3 phase, four wire 415 V, 3000Amps, buses
viz., Bus-A and Bus-B (short circuit rating of the bus being 50 KA, rms for one
second) (Refer fig-1).These two buses are fed by two 2000 KVA, 6.6 KV / 415
V transformers A and B respectively. The transformers are connected to the
respective buses through draw out type incomer breaker, which is also of
draw out type. Necessary interlocks are provided between incomer and buscoupler breakers such that any two breakers can only be in closed position at
any instant. All the three breakers are Air circuit breakers of 3200A Capacity.
Under normal circumstances each incomer will be feeding the loads of its
own stream of ESP. Auto closing of Bus-Coupler (When one of the incomer
trips) is not provided. Bus Coupler has to be closed manually under such
conditions. The incomers and Bus Coupler are provided with Earth-Fault
Protection, Over Current Protection and under voltage Protection. All these
protections are wired in parallel so as to actuate a master tripping, direct
tripping is also provided. Restricted earth fault protection is also provided to
trip the incoming HT Breaker. After any tripping, closing could be possible
only after resetting the relays.
In total, 36 outgoing feeders are available which are equally
distributed between the two buses, each bus feeding to one stream of ESP.
The outgoing feeders are fed through switch fuse units of non-draw out type.
The loads are as under.

5.3 BUS A ( 18 FEEDERS)

1. Electronic Controller 1A to 12A (2 phase feeders)

- 12 Feeders.

2. Electronic Controller Spare Feeder (2 phase feeder)

- 1 Feeder.

3. Auxiliary Control Panel Feeder (3 phase feeder)

- 1 Feeder.

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4. Air Conditioning Feeder (3 phase feeder)

- 1 Feeder.

5. Air conditioning Feeder-Spare Feeder (3 phase feeder) -1 Feeder.

6. Illumination Feeder (3 phase feeder)

-1 Feeder.

7. Ventilation Feeder (3 phase feeder)

-1 Feeder.

5.4 BUS B (18 FEEDERS)

1. Electronic Controller 1B to 12B (2 phase feeders)

-12 Feeders.

2. Electronic Controller Spare Feeder (2 phase feeder)

-1 Feeder.

3. Auxiliary Control Panel Feeder (3 phase feeder)

-1 Feeder.

4. Air Conditioning Feeder (3 phase feeder)

-1 Feeder.

5. Illumination Feeder (3 phase feeder)

-1 Feeder.

6. Spare for Illumination and Ventilation Feeder

(3 phase feeder)
7. Spare for Auxiliary control panel (3 phase feeder)

-1 Feeder.
-1 Feeder.

5.5 Load distribution for Electronics controller Feeders are

as follows:
Phase

Electronic controllers
Connected to Bus-A

Electronic controllers
Connected to Bus-B

R & Y phases 1A
12B

6A

7A

12A

1B

6B

7B

Y & B phases 2A
11B

5A

8A

11A

2B

5B

8B

R & B phases 3A
10B

4A

9A

10A

3B

4B

9B

5.6 AUXILIARY CONTROL PANEL

Control and Power circuits of the auxiliary equipments for each
stream of gas flow are housed in their corresponding Auxiliary Control Panels.
The incoming supply 415 volts, 3 phase, 3 wire A.C. is coming from the LT
Main Switchboard Buses A & B and each ACP incomer is provided with 3
phase switch fuse unit, indicating lamps, Voltmeter and Ammeter. The
Following feeders are connected to each ACP.
1) 12 feeders for emitting electrode-rapping motor.

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2) 6 feeders for collecting electrodes-rapping motor.
3) 12 feeders for hopper heaters - (2 hopper heater per feeder).
4) 2 feeders for support insulators - (6 bus section insulator housing
per feeder).
5) 2 feeders for heaters of shaft insulators - (6 bus section shaft
insulator per feeder).
6) 1 feeder for Gas Distribution for rapping motor.

5.7 CONTROL AND INTERLOCKS

Control supply for the auxiliary equipments is provided from Y &
B phases of 415V supply through a 415/240/110V control supply transformer.
Three numbers control supply (P1, P2, P3) are taken for the control circuit.
(Refer Fig-2) 240V supply (P3) is taken from the transformer and is used for
master control operations. Another 110V supply P2 is taken directly from the
control supply transformer tapping for hopper heater and insulator heater
controls. Another 110V supply P1 is taken through start/stop push button and
relay d for control supplies switching ON & OFF of rapping motor controls
and ash level indicator control. One of the NO contacts of d relay is used
for master controller supply switching, so that 240V master controller supply
(P3) will be available only if the rapping motor control supply is switched
ON. For control supply transformer ON h1 indication lamp is provided. For
rapping motor control supply (P1) ON and OFF h2 and h3 indication lamps
are provided respectively.

5.8 RAPPING MOTOR CONTROLS

For switching ON and OFF of the individual motors, separate
control circuits are used. (Ref. Fig. 3) Rapping motors may be switched ON
in two modes. One mode is through master controller (Intermittent mode)
that switches ON the motor in a sequence combining all the rapping
motors. Another mode is a continuous mode controlled by start/stop push
buttons. For the motor TRIP, ON and OFF indications are available. 3-phase
supply from the ACP is wired through switch unit a in the panel. Rapping
motor control supply P1 (110 volts A.C.), is wired through auxiliary terminals
a1 of the switch a. Mode selection is carried out through a selection switch
(SS). In the continuous mode as well as master controller mode, contractor
k will close through its relay and supply to the rapping motor is available

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and h2 indicator will also glow, showing motor is in ON condition. In the
master controller mode, as long as the switching contact from the master
controller is available, k contact will be in closed condition.

Once if the

master controller contact opens, k relay will drop put and thereby K contact
will open and so supply is switched off. In the continuous mode operation, by
pressing start push button either in the local or remote, K relay will energies
and in turn close the K contact. It will be in close condition and stop push
button in the local or remote is pressed. Even in the master controller mode,
if stop push button is latched, the K relay will drop out and K contact is
open and motor is switched off. Through K contactors NC contact motor
OFF indication (h3) is available. h3 will glow if K relay drops out and the
indication shows the motor OFF condition.
As the rapping motor loads are connected to gear and tumbling
hammer arrangement, overload of the motor is possible at any time.
Overload relay contacts (98) are provided in the control circuit for switching
off K relays supply, thereby K contact will open. h1 indication will also be
available to show the motor trip condition.

5.9 HEATER CONTROLS

Three phase supply from the ACP is wired through switch unit a and
its auxiliary terminals are used for switching P2 control supply. A rotary
switch in series with thermostat is used to energies the K relay which in
turn closes the K contact. h1 and h2 indications are available in the
panel to indicate the heaters ON and OFF conditions respectively.
30/5A C.T. operated ammeter with selector switch is also provided in the
panel to indicate the current flow through heaters.

5.10 ASH LEVEL INDICATOR CONTROLS

Ash level indicating sensing probe is mounted in the top of the
hopper. 110V control supply (P1) is wired through All Control Supply Switch
(Ref. Fig.5). An indicator is provided to show the all control supply switch
OFF condition. In the level indicating sensing probe, 110V-switching contact
closes once the ash level crosses the maximum level. This contact is used to
energies the d, relay. Once the relay is energized, through one of the NO
contact d relay is retain for energisation and through another NO contact,
indication will be available showing the hopper over filled indication. For the

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ash level-sensing probe, 24V supply is used. 24V is made available through
110V/24V transformer. One of the NO contacts of 6 ash level indicator relays
are wired in parallel for the annunciations circuit so that if any one of the
sensing probe senses hopper over filled condition, annunciation will be
available. One reset push button is also provided for each ash level indicator,
to reset d relay. If the switching contact from the sensing probe is not in
closed condition, (i.e.,) if ash over filled condition is not available, by
pressing reset push button, d, relay can be reset.

5.11 ANNUNICATIONS
Following annunciations are provided in the ACP:
1. For rapping motor tripped annunciation one NO contact from
each rapping motor control circuit is used.
2. For hopper over filled annunciation, if any one of NO contact
of the ash level indicator closes, this annunciation will be
available.
3. One NO contact from the electronic controller is used for ESP
rectifier faculty annunciation.
4. One NO contact from the LT main switchboard is used for ESP
supply faculty annunciation.

5.12 HIGH VOLTAGE DC SUPPLY EQUIPMENT

High voltage D.C. supply Equipment for each bus section of a field
consist of two parts:
1. High Voltage Transformer Rectifier.
2. Electronic Controller Panel.
High voltage transformer rectifier unit is mounted in the rooftop
of the ESP and consist of a A.C. reactor in the primary side high voltage
single phase transformer, High voltage rectifier, High frequency choke
and D.C. voltage and current measuring circuits.
Electronic controller panel is mounted in the ESP control room
and it consists of intelligent controller (ICE-C), Thyristors and triggering
circuits, protection circuits, metering circuits and feedback signal
circuits. A simplified scheme of the high voltage D.C. supply is given in
Fig.6.

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415 volts phase-to-phase supply from LT Main Switchboard
comes to the Electronics Controller panel through cable. In the
electronic controller panel the antiparallel connected thyristor pair in
single phase is arranged to control the primary side A.C. supply of the
high voltage transformer rectifier unit. From the intelligent controller
gate pulses are given to the triggering circuit of the thyristors.
Intelligent controller is programmed to control current, voltage,
sparking and fault situations etc. Feedback from the high voltage D.C.
insupply is also fed to the intelligent controller and settings are done in
the controller. In the high voltage transformer rectifier unit, the
controlled primary side A.C. supply is stepped up to 70KV peak
(continuously peak) and then rectified. It is fed through a high
frequency chokes and fed to ESP emitting electrodes.

5.13 HIGH VOLTAGE TRANSFORMER RECTIFIER UNIT

All components of high voltage transformer-rectifier unit are
housed in a steel tank filled with transformer oil. (To 19935/silicone oil
to Dow coring 561). Tank is provided with bidirectional plain rollers,
lifting lugs, jacking lugs, earth terminals and valves for training and
filtering of oil.
The technical details are follows:
Input voltage

: 0 to 373.5 voltages A.C.

Output voltage

: 0 to 70 KV peak (continuously adjustable)

Input current

: 200 Amps A.C.

Output current

: 1000 mA D.C. Average.

Phase

: single

Frequency

: 50Hz

Cooling

: ONAN

5.14 OIL TEMPERATURE INDICATOR

It is located in the thermometer box to provide local indication. It
indicates oil temperature. The indicator is fitted with a maximum
pointer and two mercury switches to provide alarm and trip signals.

5.15 BUCHOLZ RELAY

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A double float relay is fitted in the pipe connection between the
conservator and the HVR tank. Each float is fitted with the mercury
switch. The contacts are brought to the thermometer box for alarm and
tripping. Conservator is provided with oil level indicator, Dehydrating
breather, and Relief vent. Bushings are provided on the tank side for LV
input terminals (a1, a3) Low voltage measurement terminals (av), High
voltage output terminals A1& A2 (HV + VC, HV - VC), shunt terminals
(AS1 & AS2), high voltage resistor terminals (AR).

5.16 AC REACTOR (ACR)

This is provided for limiting the primary current in the event of
flash over or short circuit on D.C. side. It also helps in improving the
form factor of current. Inductance of AC reactor is 1.5 mH at 1000
milliamps.

5.17 HIGH FREQUENCY CHOKE (HFC)

This provides high impedance to high frequency currents that
may be generated due to sparking/ arcing at the electrodes due to
their capacitive effect. It also provides limiting effects on di/dt for the
rectifier diodes. Its inductance is 30mH.

5.18 HIGH VOLTAGE RECTIFIERS

High voltage rectifiers are made of specially designed diodes. High
voltage rectifier modules consist of an integrated series connection of
avalanche diodes. Seven modules are connected in series by screw to form
an arm of single-phase bridge rectifier. Such four arms are assembled along
with bus termination for A.C. and D.C. connection of full wave single-phase
bridge rectifier. The complete fixed inside the oil filled transformer tank.

5.19 DC CURRENT AND VOLTAGE MEASURING CIRCUIT

The D.C. current on HV side is measured by sensing the voltage drop
across the shunt resistor SHR (2 ohms) on the positive end of the rectifier
output. The other end of the shunt resistor is at an earth potential. The
voltage across the shunt is limited to a safe value by the Diodes S1, S2. The
current feedback is made proportional to the actual D.C. current through the
shunt resistor. D.C. voltage is measured by sensing the current through
potential divider resistor (HVRC). The chain of potential divider resistor

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(HVRC) and shunt protection diodes (S 1, S2) are mounted on a glass fiber
plate, called high voltage resistor board from which the measuring signal is
tapped.

5.20 ELECTRONIC CONTROLLER PANEL

Indications available in the panel are:
LP 1 - Mains ON indicating Lamp.
LP 2 - HT ON indicating Lamp.
LP 3 - Lamp for alarm indication.
LP 4 - Lamp for trip indication.
LP 5 - Lamp for ash level high.
LP 6 - Lamp for oil level low.
Apart from the above indication lamps, A.C. ammeter and AC voltmeter
for the primary side and D.C. ammeter and D.C. voltmeter at secondary sides
are also provided in the panel. One isolating switch fuse unit is also provided.
Once the isolating switch fuse is switched ON, control supply circuit is
switched ON, control supply for the Intelligent Controller 24V A.C. is fed
from transformerT3. A 415/230V transformer T2 is used for energising power
contactor coil (52), (ML12) & the power contactor is interlocked with HT
interlock switch 43HT and with K1 relay NO contact. K1 relay will be
energisied only after the intelligent controller gives the command. So, for
switching ON and OFF of the main power contactor, signal is coming from the
ICE-C. Once the main power contactor is picked up through K1 relays NO
contact, Lamp LP-2 will glow. K3 relay is used for giving alarm during Bucholz
top floats and transformer high temperature conditions. K3 relays NO
contact is used for alarm and Lamp indication LP-3. K2 relay is used as a trip
indication relay. It is energisied during bucholz bottom float and transformer
very high temperature reached conditions. K2 relays NO contact is used for
trip lamp indication LP-4. For K2 and K3 relay energisation signal are coming
from

ICE-C

intelligent

controller.

Bucholz

relay

signal,

transformer

temperature signals from thermometer box of HVR fed to the ICE-C through
upto isolator. Lamps LP-5 and LP-6 are used for alarm indications of ash level
overfilled indication and for oil level low indication respectively and that is
also wired through K5 and K6 relays. For both alarm and trip indications
hooter indication will come. Through K4 relays NO contact, hooter ON

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circuit is wired. Once alarm accepts push button is pressed K4 relay will pick
up, so hooter will be OFF. Below the lamp indications HT interlock switch
outer accept push button at Time totalizer counter for hours of ESP in service
are mounted. In the bottom of the front panel isolating switch is provided.

5.21 THYRISTOR CONTROL AND TRIGGERING CIRCUIT

Two thyristors in a back-to-back arrangement in a single phase is
arranged to control the primary side of the high voltage transformer.
Thyristors of 350 Amps and 1500 volts rating with clamp plate and fitting
screws are fitted in a Bakelite panel with aluminum heat sink in the thyristor
assembly. For triggering of the thyristor positive thyristor trigger signal and
negative thyristor trigger signals are coming from ICE-C to the trigger card
and then to the gate circuits. Trigger card and gate circuit cards are
separately mounted in the thyristor panel assembly.

5.22 INTELIGENT CONTROLLER (ICE-C)

Intelligent controller is a based on Intel 8085 microprocessor. ESP
functioning can be monitored on the ICE-C panel. It is to regulate and control
power input to the ESP by controlling the firing angle of the thyristors. If a
high voltage is applied between the electrodes, high spark rate will occur. For
a lower voltage, dust precipitation will be lower. So ICE-C should be selected
to an optimum spark rate level. Spark is identified from the DC current and
Voltage levels of the ESP. If Voltage decreases and current shoots up
suddenly, it means dielectric strength of the medium breaks, so a spark
occurs. If a spark is sensed by ICE C through its control inputs (DC current,
DC voltage and primary voltage phase angle) then immediately, for a small
period for one cycle (i.e. 20ms) firing of the thyristors will be blocked and
there is no field voltage appears across the electrodes. To establish the
above all functions in the ICE-C panel following controls and measurements
are available. (Fig.8)
1.

A 3-digit display of measured values or set values of the

parameter being monitored or controlled in percentage is shown.

2.

Nearby the display is a system health LED, flickering during

healthy conditions.

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3.

A single digit display select number to select the particular

parameter for display 14 displays of indications E, H, 0, 1, 2, 3, 4,
5, 6, 7, 8, 9 corresponds to 14 parameters.

Display number, parameter, and their functions are as follows:

Displa
y
E
H
0
1
2
3
4
5
6
7
8
9
4.

Parameter
Precipitator current
Precipitator Voltage
Spark rate (sparks per min.)
Current limit Im (Max. Current)
Current limit Is (set current)
S control
T control
First ignition angle after spark
Under voltage limit
Charge ratio
Pulse current limit
Loop gain
Address

Function
Measured value
Measured value
Measured value
Setting value
Setting value
Setting value
Setting value
Setting value
Setting value
Setting value
Setting value
Setting value
Selection.

Increment and decrement push buttons for display select is

provided to select a particular parameter.

5.

Separately 7 numbers of LED alarm indications are provided out

which first 5 indications belong to transformer temperature high,
bucholz top float, and bucholz bottom float, under voltage and
Thermal overload and transformer temperature very high. Other
two LEDs are provided for voltage peak is reached and for remote
command. Remote is not used here. Voltage peak reached
condition will come during back corona reached condition.

6.

Time override (T/O) function control touch push button is provided

to increase the ESP current fast. This function for 5 seconds, then
the build up follows the T setting in order to reach the set current
limit (Is).

7. One reset push button is provided for alarm reset of the

ICE-C.
8.

HT ON/OFF touch push button is provided for switching ON/OFF

of ESP.

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9.

FOR Peak mode selection function, touch push button is provided.

The high resistivity dust gives abnormal high electric field strength
in the dust layer on the collecting electrodes. The high field
strength may lead to spurious discharges within the dust layer.
These discharges or back corona can decrease the voltage
between the Electrodes in spite of an increasing current. The peak
more decreases the current to a value the peak ESP voltage
occurs.

10. One current limit setting potentiometer is provided. Before start up

display select No.1 is to be selected for I s limit setting. Using the
current limit potentiometer Is limit will be set.
11. One six-digit counter, which is of non-resettable type is provided
to count the number of sparks. The accumulated sparks will be
shown in the counter.
12. Remote and local selection switch is provided for master controller
selection with serial communication link in the remote mode and
during local mode selection, Individual Intelligent controller will be
controlled of its own.

5.23 PARAMETERS SETTINGS

01. Current Limit Im : (Display No.Q)
Maximum current limit setting is done in this, 100 mA is the Maximum
current limit available. It is set at 100% setting.
02. Current Limit Is: (Display No.1)
Operating current limit is set in this. As explained earlier, current limit
potentiometer in the ICE-C panel is used for setting it. It will vary from field
to field. Operator will set this depending upon the boiler condition.
03. S Control: (Display No.2)
Whenever a spark is detected (by measuring the output voltage and
current) for 20 ms (i.e.) for one cycle, current is blocked. Then the current is
restarted. During restarting, current suddenly raises up to a level called S
level as shown in the figure. It is slightly lower than the current at which
spark occurred. This current difference is called STEP (i.e.) S. Normally S
control is set at 5% of the rated current.
04. T Control: (Display No.3)

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After reaching the S level to reach I s, current slope has to be seen
which will be done by T control, which is a time set function. In order to reach
the set current limit Is, time required to reach will be set in this. During start
up for fast current rise TO function (i.e. time override function) will be used,
then the built up follows the T setting in order to reach I s. Normally it is set
at 20%.

Spark rate will be controlled by the set values of the S and T

Parameters. (Refer. Fig. 9).

05. First Ignition Angle After Spark: (Display No.4)
Normally after spark i.e. after 20mS thyristor ignition angle will be
selected through this setting. It is set at 30%.
06. Under voltage limit: (Display No.5)
It is normally set at 10%. If the voltage maintains below the set value,
under voltage alarm will appear. After resetting, even if the alarms persist,
field has to be switched off and a thorough check up has to be carried out.
07. Charged Ratio: (Display No.6)
(Semi pulse mode) The number of half cycles, thyristor conducting can
be set in this. Normally odd numbers are selected. The selected number
indicates the number of half cycle the thyristor should conduct. Generally,
the charge ratio is selected in increasing order with respect to field number.
08. Pulse Current Limit: (Display No.7)
This current limit setting indicate semi pulse mode. Maximum setting is
200%.
09. Loop gain: (Display N0. 8)
Set a 30%. For the feed back loop, the gain is set here. From the
feedback, signals are taken according to the loop gain; accordingly the
current regulation is carried out.
10. Address: (Display No.9)
It is selected in the case of remote operations. It is not in our system
since our system is local operated.
In the rear side of the ICE-C, 17 LEDs are mounted to indicate the
status of I/O signals. These are used for functional verification and
troubleshooting.
LED

SIGNAL

DESCRIPTION

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N1

Input

N2

Input

N3
N4
N5
N6
N7 to
N10
N11
N12
N13
N14
N15

Input
Input
Input
Input
Input/output
Output
Output
Output
Output
Output

N16

Output

N17

Output

Signal from alarm contact. Thermal

overload or Transformer Temperature
very high
Signal from alarm contact. Transformer
Temperature high.
Bucholz top float alarm contact.
Buchloz bottom float alarm contact.
Contractor ON feedback to ICE-C
Safety line healthy.
Serial communication link for master
controller in remote operation.
Trigger pulses to negative thyristor.
Trigger pulses to positive thyristor.
Tripped due to alarm.
Alarm present.
Flickers momentarily at HT ON
command.
Flickers momentarily at HT OFF
command.
Flickers momentarily at detection of
spark.

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