1.

GENERAL: This is flue gas cleaning system for cleaning the gases from Alumina calcination plant. The system consist of ESP model TBG
2

The hot gases having maximum Temperature of 225 Deg. C (325 Deg. C for 1 Hour) are allowed to pass through the inlet nozzle. Gas distribution plates inside the nozzle ensure equal distribution of the gases through different parallel paths formed by the arrangement of collecting plates and discharge electrodes. The collecting area is divided into three sections. All the three sections are fed by TR set of 1500 mA (3 Nos.) mounted on the ESP rooftop. High voltage of 111 kV DC (peak value) is applied to the discharge electrodes. The dust gets collected on the collecting plates. The collecting plates are intermediately rapped from the bottom and discharge electrodes are continuously rapped from the top by tumbling hammers whose operation is controlled by Microprocessor based controller located in the TR Set control panel. Due to rapping, the dust collected on collecting plates is dislodged and collected in the hopper. The dust is discharged to the dust discharge equipment through hopper.

2.

MODE OF OPERATION There are two modes of operation namely Manual and Automatic Mode. This can be selected with key selector switch provided on respective panel door OR the same can be selected from customer PLC/DCS.

2.1

Manual Mode of operation: Under Manual Mode of operation each equipments can be started and stopped from the respective panel with push button or touch buttons (in case of T/R set) provided the selector switch is in LOCAL position OR Local permissive signal is available from customer PLC/DCS.

2.2

Automatic Mode of operation: Under Automatic Mode of operation each TR set and other equipment feeders of auxiliary control panel can be started and stopped from PLC/DCS, provided the corresponding selector switch is in REMOTE position.

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3. 3.1

CONTROLS AND INTERLOCKS PROVIDED FOR THE SYSTEM Auxiliary control panel: (Customer scope) Auxiliary control panel is used for distributing the power supply and control of various consumers of ESP. Separate TR set control panel (TRCC) is provided for controlling high voltage fed to ESP. Consumers: - TR set control panel Heater Group 1. Insulator heater 2. Purge Air System (Purge Air Blower + Purge Air Heater) Hammer Group 1. CE hammer motor (CE Rapper) 2. DE hammer motor (DE Rapper) 3. GD hammer motor (GD Rapper) Motorized Grounding Switch

Hammer Group : Collecting Electrode hammer motor (CE Rapper) Discharge Electrode hammer motor (DE Rapper) Gas Distribution screen hammer motor (GD Rapper) Each hammer motor is having typical DOL starter with control circuit. All the hammer motors run at adjustable operating & pause periods whose operation is controlled by micro-processor based controller which is located in TR control panel. The operating & pause periods of each hammer motor can be individually modified: Operating period: 0 sec to 3,600 sec Pause period: 0 sec to 86,400 sec If the pause period is set to 0 sec, the hammer motor will run continuously. The DE & GD hammer motors are running continuously and the CE hammer motors are running at intermitted mode with operating & pause periods.

Interlocks:
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The CE hammer motors of each section are interlocked to prevent same time operations. 3.2 TR set & TR control panel: Each TR set is having an independent free standing control panel. Operation, control & indication are carried out via the control / display unit installed in the doors of the TR set control panel. The TR set should only be started when the insulator heaters have reached the working temperature. The detail TR set functions are described in the TR set & controller operation & maintenance manual. TR set control panel front door is provided with: - 1 x Key pad display unit - 1 x Selector switch for local / remote operation - 3 x Indicating lamp (Mains ON, HT ON, Alarm/Trip) - 4 x Indicating Meters (V, I, kV & mA) The key pad display unit is used for: - Indication for kV, mA, Ip & etc. - Indication of fault - Parameter changes for voltage controller - Manual mode operation of Start, Stop & Fault reset, etc.
2

Interlock 1) In automatic mode, the TR set can only be started, if the insulator heaters have reached the minimum temperature limit. (125 Deg. C) 2) In automatic mode, the TR set can only be started, if the Purge Air system is ON & has reached the minimum temperature limit. (125 Deg. C) Insulator Heater & Fuse Distribution Box (Field Terminal Box): 1000 W Ring heater is provided around each support insulator in order to avoid moisture on the insulator before the TR set is started. A thermostat is provided in the end insulator compartment house to maintain the temperature at 125 Deg. C There is a field terminal box (Fuse Distribution Box) containing 12 MCBs with auxiliary contact and 12 ON/OFF switches located at ESP rooftop. Each ring heater is protected by one MCB and the auxiliary contacts in MCB are wired in series and this signal is sent to auxiliary panel. There is one common 415 Volt 3 Phase power supply from Auxiliary control panel to this field terminal box which is distributed by MCBs for each ring heater. MCB output is cabled to each ring heater.

3.3

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Start or Stop commands from ACP will switch ON or OFF all 12 insulator heaters simultaneously. If there is short circuit in any one of the heater an alarm will be energized on the auxiliary panel. By opening Fuse Distribution Box and checking the MCB one can immediately find out which heater is under short circuit and can be replaced at the next plant outage. In order to avoid condensation on support insulators the insulator heater is started 10 hours before the calcinating plant is started. Within 10 hours the insulator heaters are heated up & temperature will attain the set point value adjusted on the corresponding thermostats. 3.4 Purge Air System (Purge Air Blower + Purge Air Heater): There is an interlock between purge air blower & purge air heater in this group heater. When this group is started, first the blower is ON. When the blower has attained its rated RPM, then only the purge air heater is ON. If this group is stopped, first the purge air heater is OFF & then purge air blower is OFF. If the blower is switched off or tripped during operation whatever reason it is, the heater will also off immediately. The heater could only be started, if the fan is running. The purge air heater is protected from over heating by an over temperature switch. This over temperature switch is provided with reset knob. In case there is an over temperature alarm, the purge air heater is switched off. Before starting the purge air heater again, one has to find out the cause of the problem. Most probably the purge air fan air input is blocked. This fault shall be cleared & the reset knob shall be pressed before the purge air heater is started again. Start Sequence: Purge air blower ON If blower is ON & air flow > min Then purge air heater will be started Stop Sequence: Purge air heater OFF If the heater is OFF, then the blower will be switched off after a time delay of 5 sec approximately. If purge air system (Purge air fan & Heater) fails during normal operating condition following precautions to be take care. ESP can be run up to the minimum operating temperature limit of Purge air system with required air flow rate. Below this temperature TR set should be switched OFF.
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TR set can be start again when the Purge air system reaches its minimum temperature limit of Purge air system. To start the Purge air system again with required air flow rate, first find out the cause of problem & rectify the problem. Most probably the purge air fan air input is blocked & over temperature switch operated. This fault can be cleared & the reset knob of over temperature switch to be pressed before the purge air heater is started again. 3.5
3

Mechanical door interlock system: The system ensures that no person can enter inside the ESP unless all the Transformer Rectifier units are de-energized; isolated and grounding switches of TR sets are in ESP grounded position via motorized grounding switch. Local push button station (LPBS) has been provided at the ESP roof top near the TR set. Operational Philosophy of Mechanical door interlocks system Following sequence to be maintained for accessibility of ESP internals through the access doors. (Please refer below Door Interlock diagram) 1) Switch OFF all TR Control panels (TRCC-1 to 3) & take out the door keys D1, D2 & D3 from interlocks keys mounted on TR Control panels. These door keys are electrically interlocked with the main power contactor circuit to cut of the main power supply to TR set. 2) Put all these keys D1, D2 & D3 on respective grounding switch & operate the locks. Now grounding switch position can be change from HT to Earth. 3) Change the grounding switch position from HT to ESP Earth position with the help of Motorized operation using LPBS. 4) Once the Grounding switch is in Earth position, the bolts of the keys G1, G2 & G3 will be extended & then only keys G1, G2 & G3 will be released. 5) Put all these keys G1, G2 & G3 in transfer block `A G1, G2 & G3 and operate these locks. Now `X key will be released from the transformer block `A. 6) Put the `X key on lock `X in the transfer block `B & operate this lock. Now the keys X1 & X2 will be released for transfer blockC1 & C2 7) Put the `X1 & X2 keys on locks `X1 & X2 in the transfer block `C1 & C2 respectively & operate this lock. Now the keys for all (21 nos.) access doors shall be released. 8) Put these access door keys on access door locks & operate the locks. This will allow operator to open the access door & have access to ESP internals. 9) For switching ON the TR set again the operations are to be carried out in the reverse direction & exactly in same steps.

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Door Interlock diagram

3.6
2

Dust conveying system: (Customer scope) Dust conveying system shall be ON (running) all the time. If dust conveying system is tripped / stopped, ESP input feeding system shall trips.
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4.

THEORY OF OPERATION: ESP construction & operation is based on the fact that dust particles are passed between a highly charged & grounded electrode. The particles get collected on the grounded electrode. Accordingly, the Thermax ESP is designed to: 1) Apply a highly negative charge to gas borne ash particles. 2) Collect the particles on grounded metal plates, which are rapped periodically to dislodge the dust into hoppers. The particles are charged by rows of vertical high-voltage electrodes mounted in parallel frames. The frames are connected at the top to the negative terminal of a high-voltage DC power supply. The collecting plates (grounded electrodes) are parallel to the rows of discharge electrodes & alternate with them -- i.e., collecting plate, discharge electrode frame, plate, collecting plate, discharge electrode frame. In operation, the high potential between the negative & grounded electrodes ionizes the surrounding gas & produces a large number of negative ions. (This is known as corona effect.) These negative ions collide with the ash particles & impact their negative charges to them. The negatively charged particles then are drawn to the grounded collecting plates, from which they are periodically dislodged by means of a rapping mechanism.

5.

VOLTAGE CONTROL: As the dust laden flue gas passes through the collecting electrodes and discharge electrode, the ESP can be considered as a capacitance having variable di-electric strength. The di-electric strength varies due to changing parameters of the flue gases. The high DC voltage applied to the ESP has to be continuously adjusted to minimize sparking across the discharge electrodes and collecting plates. The voltage controller provided in the Transformer Rectifier control cabinet senses the current feedback from the ESP and does the following functions. I. It maintains the voltage across the ESP at the spark threshold level in all the conditions to achieve maximum efficiency. II. During no sparking conditions, maximum power is made available across the ESP.

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III. In case of spark, it brings down the voltage by preset value. The voltage is gradually raised to spark threshold level if no further spark is detected. IV. In case of arc it brings down the voltage to zero and blocks it for preset time. The voltage is restored to the preset value by fast ramp and then to the spark threshold level by slows ramp. 6. ESP START UP PROCEDURE I. Start insulator heaters & purge air system ten hours prior to flue gas passing through the precipitator from Auxiliary Control Panel. II. Start the dust discharge equipments. III. About one hour before the system is started. Start the discharge electrode and collecting plate hammer motor. IV. Ensure that the system is running and flue gas temperature is above the acid dew point temperature & the insulator heater system reached a minimum temperature. If the flue gas temperature is less than the acid dew point temperature then damp acid sludge will form on the precipitator internals, and scaling will take place. This will reduce the life of discharge electrode and collecting electrodes. If dust conveying system or dust discharge equipment trips / fail, then trip the ESP input feeding system. V. After the flue gas temperature reaches above the acid dew point temperature & the insulator heater system reached a minimum temperature, TR units should be energized. Ensure that TRCC panels are in Auto mode before switching on. After all the TR sets are energized the electrical meter readings should be observed. 7.
2

PRECIPITATOR SHUTDOWN (NORMAL) i. During normal system shutdown, first the TR sets should be de energized. ii. After all the TR sets are de-energized the discharge electrode and collecting electrode hammer motor should be maintained in service for approximate two hours. iii. Dust discharge equipment / dust conveying system should be in service for sufficient hours after discharge electrode and collecting electrode hammer motors are stopped. iv. The insulator heater can be switch off after 24 hours. During short shut down (< 3 days), the heater remains in operation.

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v. The purge air system remains in function for at least 72 hours. During short shut down (< 3 days), the purge air system remains in operation.
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PRECIPITATOR SHUTDOWN (MAINTENANCE) i. During precipitator shutdown for maintenance, first the TR sets should be de energized; isolated and grounding switches of TR sets are in ESP grounded position via motorized grounding switch. ii. After all the TR sets are de-energized the discharge electrode and collecting electrode hammer motor should be maintained in service for approximate two hours. iii. Dust discharge equipment / dust conveying system should be in service for sufficient hours after discharge electrode and collecting electrode hammer motors are stopped. iv. For the calcinating plant shout down the purge air system & insulator heaters should run at least further 4 hours.

8.

CAUTION: a) It is mandatory that dust discharge equipment / dust conveying system below ESP hopper must be running whenever the ESP input feeding system is working. It is always to be ensured that there is no dust accumulation whatsoever in the hoppers. The dust accumulation in the hopper may damage the ESP internals. b) ESP hopper doors to be opened, only after total system is shutdown. This is necessary to avoid sudden ingress of fresh air in the hopper which contains ash with high carbon content. c) Dust discharge equipment / dust conveying system shall be running all the time. d) Hammer motors shall be ON (running) all the time irrespective of ESP is charged or not during normal operation of ESP. e) If the ESP is switched off due to loss of power not less than 5 hours, the insulator heater & purge air system should run 2 hours before staring the ESP. f) If the ESP is switched off due to loss of power not more than 5 to 10 hours, the insulator heater & purge air system should run 5 hours before staring the ESP.

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9.

ALARMS: Following alarms will be provided on

A)

Auxiliary control panel. (Customer Scope) a) b) c) d) e) f) g) h) i) Insulator Heater fault. Purge air heater over temperature. Purge air flow low Purge air blower overload tripped. DE hammer motor overload tripped. CE hammer motor overload tripped. GD hammer motor overload tripped. Motorized Grounding switch overload Trip Spare

B)

Transformer-Rectifier control panel :

(Note: The following alarms will be indicated on the TRCC controller LCD display)

a) b) c) d) e) f) g) h)

Transformer oil temperature high alarm. Transformer oil temperature high trip. Transformer Buchlotz relay alarm. Transformer Buchlotz relay trip. SCR temperature high trip. Over voltage trip. Under voltage trip. Thermal overload trip.

10. INDICATIONS: Following indications will be provided: A) i. ii. iii. iv. Auxiliary control panel: (Customer Scope) Incomer feeder: T/R sets feeder: Insulator Heater feeder: Purge Air Heater feeder:
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R, Y& B phase indicating lamp. Breaker ON, OFF & TRIP Supply ON, OFF Lamp. ON, OFF & Temp Trip lamp. ON, OFF & Temp Trip & Over Temp. lamp.
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v. vi. vii. viii. ix.

3

Purge air Blower feeder: DE hammer Motor1-3 feeder: CE hammer Motor1-3 feeder: GD hammer Motor feeder:

ON, OFF & Over-load trip lamp. ON, OFF & Over-load trip lamp. ON, OFF & Over-load trip lamp. ON, OFF & Over-load trip lamp.

Motorized Grounding Switch1-3 Feeder: HT to Earth ON, Earth to HT ON, OFF, Over-load trip, ESP Earthed & ESP connected to HT. Control transformer feeder: Control supply ON lamp.

x. B)

Transformer Rectifier Control Panel: i) ii) iii) Mains on lamp HT on lamp Alarm / Trip lamp.

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