ESP DESIGN,

OPERATION &
MAINTENANCE

TAPASH NAG
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The Electrostatic Precipitator

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 Data required for ESP
Application
Process Data
Gas Composition
Gas pressure
Gas Moisture
Dust Composition
Particle size distribution

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 Basic Design Data
Gas Flow Rate
Gas temperature
Inlet dust concentration
Sulphur Content
Ash resistivity
Environmental requirements
Outlet emissions

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 Design data governs
No. of ESP per boiler
No. of required fields
Specific collecting area
Maximum gas velocity
Minimum aspect ratio
Maximum area connected to one TR set
Collecting electrode spacing
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 ESP - Advantages
Very high collection efficiency
Low pressure drop
Capacity to collect sub micron particles
Robust construction Longer life
Less maintenance
Adaptability

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ESP Working Principle
The precipitation process involves
4 main functions :
Corona generation
Particle charging
Particle collection
Removal of particles

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ESP Working Principle
Corona generation:
Due to ionization of gas molecules +ve
ions, -ve ions and free electrons are
generated

Particle charging:
The ve charges of ions and free electrons
move towards +ve electrodes and the +ve
charges of ions move towards ve
electrodes.
When ve ions travel towards +ve
electrodes, the ve charges get attached to
the dust particles and thus the dust
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ESP Effect of ash resistivity
Ash Resistivity:
The ease with ash particle acquires an
electrical charge
Ranges from 1 x 108 ohm-cm to 1 x 1014
ohm-cm
Ideal Resistivity is 5 x 109 ohm-cm to 5 x
1010 ohm-cm
Low resistivity- Collected particles loose
charge and get re-entrained
High resistivity- Requires bigger ESP size
High resistivity- Effective migration velocity
is lower
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V0 High resistivity- Gives rise to Back Corona
ESP Effect of ash resistivity

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ESP Temp v/s ash resistivity
Ash resistivity is lower at lower temperatures
At lower temperature, moisture and sulphur
oxides reduce the ash resistivity
Ash resistivity is higher at 140-160oC
Ash resistivity reduces at higher
temperatures but it is due to the semi
conductor effect
High resistivity- Requires bigger ESP size
High resistivity- Effective migration velocity
is lower
High resistivity- Gives rise to Back Corona
effect. Discharge current increase abnormally
&
TN applied
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ESP Temp v/s ash resistivity

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ESP Temp v/s Migration
Velocity

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ESP Sizing Theory
Deutsch Anderson Equation:
ESP Collection efficiency = 1-exp(-
w.SCA)
SCA = Specific Collection area =
A/Q
Where w = Drift or Migration
velocity
A = Total surface area of
electrodes
TN 09 JAN 2015 Q= gas volumetric flow rate
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ESP Related Terms
Flue gas velocity (m/s)=
Flue gas flow in m3/s
Effective cross section area in m2
Aspect Ratio =
Effective length of ESP in m
Height of Collecting electrode in
m
Treatment time (s) =
Effective Length of ESP in m
Flue gas velocity in m/s
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ESP Gas velocity
Velocity is decided by the gas flow and
collection efficiency required
Higher the velocity, higher the carryover
of particles without collection. Re-
entrainment
Very poor velocity alters the flow
distribution pattern and affects the settling
of dust particles
Optimum velocity improves the
performance of the ESP
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ESP Aspect Ratio
During rapping, the dust particles fall in a
trajectory path
Lower the aspect ratio, the trajectory dust
travel along with gas flow
Does not fall into hoppers- Leads to Re-
entrainment
Higher the ratio, better the performance
Optimum aspect ratio depends on allowable
velocity, required collection efficiency and
available space
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ESP Treatment time
Time available for capturing the dust
particles
More treatment time at reasonable
velocity improves the collection
efficiency
Probability of capturing the re-
entrained particles improves with time

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ESP Cold Startup
Energize insulator and hopper heaters at least 6
hours before startup or leave energized if shutdown
is taken for a short duration

Energize rappers and ash evacuation systems 2

hours before Startup

Increase rapper force and frequency until normal

operating temperature is reached to limit adhesion of
damp ash on Electrodes

Energize TRs one at a time as needed to maintain

opacity limit and maintain power levels below
maximum to minimize sparking once the flue gas
temp is above 120oC after coal firing

Atnormal
TN operating temperature, switch TR
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ESP Cold Startup
Point of Contention: Should the
inlet or outlet electrical fields be
energized first?
Energize TRs Inlet to Outlet
Minimizes Power Consumption
Limits Damp Ash Collection to Outlet Fields

Energize TRs Outlet to Inlet

Limits Collection of Damp Ash on Electrodes
by allowing dropout in Non-Energized Front
Electrical Fields

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ESP Shutdown procedure
The ESP Shutdown Procedure is just as
important as the Startup Procedure to
the operating integrity of the ESP
De-energize the electrical fields one at a
time as required to maintain opacity limit.
Again, Two Approaches:
De-energize outlet TRs first, outlet to inlet: Power
savings since outlet fields tend to operate near rated
power levels

De-energize Inlet TRs first, inlet to outlet: Avoids

opacity spikes due to rapper re-entrainment since
downstream
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ESP Shutdown
procedure(Contd)
After ESP Shutdown, maintain operation
of rappers, hopper evacuation system,
and hopper heaters for at least 2 hours
following purge procedure.
This will ensure the ESP remains in an
operational clean state to the best
extent possible for subsequent startup

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ESP Performance Monitoring
As with the operation of any piece of
equipment, performance monitoring and
recordkeeping are essential to establishing a
good operation and maintenance program.
The key to any monitoring program is
establishing an adequate baseline of
acceptable ranges that is used as a reference
point.
Then, by monitoring and recording key
operating parameters, the operator can
identify performance problems, need for
maintenance,
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ESP Performance Monitoring
As with the operation of any piece of
equipment, performance monitoring and
recordkeeping are essential to establishing a
good operation and maintenance program.
The key to any monitoring program is
establishing an adequate baseline of
acceptable ranges that is used as a reference
point.
Then, by monitoring and recording key
operating parameters, the operator can
identify performance problems, need for
maintenance,
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ESP Performance
Monitoring(2)
Typical parameters that can be
monitored include:
Voltage/current
Opacity
Gas temperature
Gas flow rate and distribution
Gas composition and moisture

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ESP Typical Checklist
Daily:
1.Take and record electrical readings & Opacity meter
data
2.Check operation of hoppers and ash removal system
3.Examine control room HVAC system
4.Investigate cause of abnormal arcing in T-R
enclosures & bus ducts
Weekly:
5.Check rapper operation
6.Check & clean air filter
7.Inspect control panel internals
Monthly:
8.Check Operation of standby top housing pressurizing
fan and thermostat
9.Check operation of hopper heaters
10.Check hopper level alarm operation
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ESP Typical Checklist(Contd)
Quarterly:
1.Check & clean vibrator & rapper switch contacts
2.Check opacity meter calibration
Half Yearly:
3.Clean & lubricate access doors dog bolts and hinges
4.Clean & lubricate interlock covers
5.Clean & lubricate test connections
6.Check exteriors for visual signs of deterioration,
abnormal vibration, noise and leaks
7.Check oil level in T-R set and surge-arrestor spark gap
Annually:
8.Conduct internal inspection
9.Clean top housing or insulator compartment and all
electrical insulating surfaces
10.Check & correct defective alignment
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ESP Typical Checklist(Contd)
Annually (Contd):
1.Examine & clean all contactors and inspect tightness of all
electrical connections
2.Clean & inspect all gasketed connections
3.Check & adjust operation of switch gear
4.Check & tighten rapper insulator connections
5.Observe & record areas of corrosion
Opportunity based:
6.Record air load and gas load readings during & after each outage
7.Clean & check interior of control sets during each outage of
more than 72 hours
8.Clean all internal bushings in outage more than 5 days
9.Inspect condition of all grounding devices during each outage
over 72 hours
10.Clean hopper build ups during each outage
11.Inspect & record amount and location of residual dust deposits
on electrodes during each outage of 72 hours or longer
12.Check all alarms, interlocks and safety devices during each
outage
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Source: Bibbo 1982
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ESP Problems
Dust Accumulation
Wire Breakage
Insulator cracking
Hopper Pluggage
Air Ingression

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ESP Dust Accumulation
Inadequate rapping system
Sticky dust
Operation at temperatures below dew
point level

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 ESP Wire breakage
Wire breakage is on of the major problems for deteriorating
the performance of ESP. Much time and effort is required to
determine the reasons of wire breakage. Although most new
ESPs have either rigid frames or rigid electrodes, and some
weighted-wire systems have been retrofitted to rigid
electrodes, the most common ESP in service today is still the
weighted wire.

Wires usually fail in one of three areas: at the top of the

wire, at the bottom of the wire, and wherever misalignment
or slack wires reduce the clearance between the wire and
plate. Wire failure may be due to electrical erosion,
mechanical erosion, corrosion or combination of
these.

When wire failures occur, they usually short-out the field

where they are located. In some cases, they may short-out
anTNadjacent
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field as well. Thus, the failure of one wire 31
can
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 ESP Wire breakage
Electrical erosion is caused by excessive sparking.
Sparking usually occurs at points where there is close
clearance within a field due to a warped plate, misaligned
guidance frames, or bowed wires. The maximum operating
voltage is usually limited by these close tolerance areas
because the spark-over voltage depends on the distance
between the wire and the plate.

Design faults and the failure to maintain alignment

generally contribute to mechanical erosion (or wear) of
the wire. In some designs, the lower guide frame guides the
wires or their weight hooks (not the weights themselves)
into alignment with the plates.

Corrosion of the wires can also lead to wire failures.

Corrosion, an electrochemical reaction, can occur for several
reasons, the most common being acid dew point. When the
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rate 09 corrosion
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the
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 ESP Wire breakage
Wire crimping is another cause of wire failure. Crimps
usually occur at the top and bottom of the wires where
they attach to the upper wire frame or bottle weight;
however, a crimp may occur at any point along the
wire. Because a crimp creates a residual stress point,
all three mechanisms (electrical erosion, mechanical
erosion, and corrosion) may be at work in this situation.
A crimp can:

Distort the electric field along the wire and promote

sparking

Mechanically weaken the wire and make it thinner

Subject the wire to a stress corrosion failure

(materials under stress tend to corrode more rapidly
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than those not under stress)
 ESP Insulator Cracking
Misalignment

Thermal break down

It is the external electric field that destroys energy

balance & causes intrinsic & avalanche breakdown
Due to the tunnel effect the electrons pass through
the valance bond to conduction band causing Zener
breakdown
Breakdown occurs due to combined electrical &
thermal action

Insulation aging
Local discharge by gas induces local corona
Ionization energy of 10-11 ev is enough to break the
ceramic material molecule.
Oxidation
TN at surface may cause corrosion &
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 ESP Hopper Pluggage
Perhaps no other problem (except fire or explosion) has
the potential for degrading ESP performance as much
as hopper pluggage. Hopper pluggage can
permanently damage an ESP and severely affect both
short-term and long-term performance. Hopper
pluggage is difficult to diagnose because its effect is
not immediately apparent on the T-R set panel meters.
Depending on its location, a hopper can usually be
filled in 4 to 24 hours. In many cases, the effect of
pluggage does not show up on the electrical readings
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ESP Hopper Pluggage
Hopper pluggage can be caused by the
following:
Obstructions due to fallen wires and/or bottle
weights
Inadequately sized solids-removal equipment
Use of hoppers for dust storage
Inadequate insulation and hopper heating
Air ingress through access doors
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 ESP Air Ingression
Air ingress is often overlooked as an operating problem. In
some instances, it can be beneficial to ESP performance, but
in most cases its effect is detrimental. Air ingress may occur
within the process itself or in the ESP and is caused by
leaking access doors, leaking ductwork, and even open
sample ports. Air ingress usually cools the gas stream, and
can also introduce additional moisture. Air ingress often
causes localized corrosion of the ESP shell, plates, and wires.
The temperature differential also can cause electrical
disturbances (sparking) in the field. Finally, the introduction
of ambient air can affect the gas distribution near the point
of entry.

The primary entrance paths are through the ESP access

and hopper doors. Air ingress through hopper doors may re-
entrain and excessively cool the dust in the hopper, which
can cause both re-entrainment in the gas stream and hopper
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pluggage.
V0 Air ingress through the access doors is normally
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ESP Corona generation

Positive
Ion
+ Free
Electron
-
Free
Electron
- + -
Gas
Molecule -

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ESP Inter electrode Zone
Electron Gas Negative gas
Molecule Ion

- + - - + -
To
Collectin
- + - - + - g Plate

- + - - + -

- + - - + -

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ESP Particle Charging
Negatively
charged
particle
- +- - +-
- +-
- +- - +-

- +- - +-
- +-
- +-
Negative
Gas Ion

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ESP Zener & Avalanche
Breakdown
Zener breakdown
In Zener breakdown the electrostatic attraction
between the negative electrons and a large positive
voltage is so great that it pulls electrons out of their
covalent bonds and away from their parent atoms.
i.e., Electrons are transferred from the valence to the
conduction band. In this situation the current can still
be limited by the limited number of free electrons
produced by the applied voltage so it is possible to
cause Zener breakdown without damaging the
semiconductor.

Avalanche breakdown
Avalanche breakdown occurs when the applied
voltage is so large that electrons that are pulled from
their covalent bonds are accelerated to great
velocities. These electrons collide with the silicon
atoms
TN 09 and knock off more electrons. These electrons
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