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Electrostatic Precipitators

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IMECO LIMITED Welcome to ESP Presentation IMECO LIMITED Contact: www.imecolimited.com ESP Presentation
Transcript
Page 1: Electrostatic Precipitators

IMECO LIMITED

Welcome to ESP PresentationIMECO LIMITED

Contact:www.imecolimited.com

ESP Presentation

Page 2: Electrostatic Precipitators

IMECO LIMITEDIMECO LIMITED

Index

Index

Controlling Air Pollution

Introduction

Design Features

Principle of Operation

Components

Operations & Performance

Corona Power

Maintenance & Troubleshooting

About Us

Page 3: Electrostatic Precipitators

IMECO LIMITED

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.

Page 4: Electrostatic Precipitators

IMECO LIMITED

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.

Controlling Air Pollution

Page 5: Electrostatic Precipitators

IMECO LIMITED

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

Electrostatic Precipitators

Page 6: Electrostatic Precipitators

IMECO LIMITED

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

Electrostatic Precipitators

Page 7: Electrostatic Precipitators

IMECO LIMITED

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

Electrostatic Precipitators

Page 8: Electrostatic Precipitators

IMECO LIMITED

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.

Page 9: Electrostatic Precipitators

IMECO LIMITED

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

Introduction to ESP

Page 10: Electrostatic Precipitators

IMECO LIMITED

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….

Introduction to ESP

Page 11: Electrostatic Precipitators

IMECO LIMITED

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.

Page 12: Electrostatic Precipitators

IMECO LIMITED

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

Introduction to ESP

Page 13: Electrostatic Precipitators

IMECO LIMITED

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 emissionstandards have begun to use conventional ESPs for control of emissions in kilns (in kilns ESPs were used together with conditioning tower) and coal mills.

Page 14: Electrostatic Precipitators

IMECO LIMITEDAPPLICATIONS 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 wasteIntroduction to ESP

Page 15: Electrostatic Precipitators

IMECO LIMITED

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

Introduction to ESP

Page 16: Electrostatic Precipitators

IMECO LIMITED

ESPsESPs

Traditional North American Design

Traditional European Design

ESP DESIGNSESP DESIGNS

ESP - Designs

Page 17: Electrostatic Precipitators

IMECO LIMITED

TRADITIONAL ESP DESIGNS

ESP - Designs

Page 18: Electrostatic Precipitators

IMECO LIMITED

TRADITIONAL NORTH AMERICAN DESIGN

ESP - Designs

Page 19: Electrostatic Precipitators

IMECO LIMITED

TRADITIONAL EUROPEAN DESIGN

ESP - Designs

Page 20: Electrostatic Precipitators

IMECO LIMITED

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 OPERATIONPRINCIPLE 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.

Page 21: Electrostatic Precipitators

IMECO LIMITED

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 FUNCTIONSHOW A ESP FUNCTIONS

ESP – Principle of Operation

Page 22: Electrostatic Precipitators

IMECO LIMITED

TWO STAGE ELECTROSTATIC PRECIPITATOR

ESP – Principle of Operation

STAGE I

Page 23: Electrostatic Precipitators

IMECO LIMITED

TWO STAGE ELECTROSTATIC PRECIPITATOR

ESP – Principle of Operation

STAGE II

Page 24: Electrostatic Precipitators

IMECO LIMITED

SCHEMATIC OF A PARALLEL-PLATE PRECIPITATOR

ESP – Principle of Operation

Page 25: Electrostatic Precipitators

IMECO LIMITED

TYPICAL HORIZONTAL FLOW PRECIPITATOR

ESP – Principle of Operation

Page 26: Electrostatic Precipitators

IMECO LIMITED

COMPONENTS FORELECTROSTATIC 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

ESP - Components

Page 27: Electrostatic Precipitators

IMECO LIMITED

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.

Page 28: Electrostatic Precipitators

IMECO LIMITED

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 • spiral wires Cont…

Page 29: Electrostatic Precipitators

IMECO LIMITED

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.

DISCHARGE / EMIITING ELECTRODES

Page 30: Electrostatic Precipitators

IMECO LIMITED

DISCHARGE ELECTRODE TYPES

ESP - Components

Page 31: Electrostatic Precipitators

IMECO LIMITED

ELECTRODE ARRANGEMENT

ESP - Components

Page 32: Electrostatic Precipitators

IMECO LIMITED

ELECTRODE DESIGN (CONT’D)

ESP - Components

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IMECO LIMITED

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

Advances in Electrode Design

Page 34: Electrostatic Precipitators

IMECO LIMITED

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.

Page 35: Electrostatic Precipitators

IMECO LIMITED

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

ESP - Components

Page 36: Electrostatic Precipitators

IMECO LIMITED

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

ESP - Components

Page 37: Electrostatic Precipitators

IMECO LIMITED

ESP

Carbon Steel

Mild Steel

Corten

A516-70

Duplex & Stainless Steel

AR Plate

MATERIALS OF CONSTRUCTION

ESP - Components

Page 38: Electrostatic Precipitators

IMECO LIMITED

FACTORS INFLUENCING PERFORMANCE OF ESPS

Operation & Performance

Page 39: Electrostatic Precipitators

IMECO LIMITED

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

Cont…

Page 40: Electrostatic Precipitators

IMECO LIMITED

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.

CORONA POWER

Page 41: Electrostatic Precipitators

IMECO LIMITED

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:

Page 42: Electrostatic Precipitators

IMECO LIMITED

Back–Corona

in the

Dust Layer

ESP – Corona Power

Page 43: Electrostatic Precipitators

IMECO LIMITED

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

ESP – Corona Power

Page 44: Electrostatic Precipitators

IMECO LIMITEDPREVENTIVE 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

Page 45: Electrostatic Precipitators

IMECO LIMITED

• 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

PREVENTIVE MAINTENANCE CHECKLIST FOR A TYPICAL ESP

Page 46: Electrostatic Precipitators

IMECO LIMITED

• 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

Cont…

Page 47: Electrostatic Precipitators

IMECO LIMITED

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.

Maintenance & Troubleshooting

Page 48: Electrostatic Precipitators

IMECO LIMITEDMAJOR CAUSES OF PROBLEMS IN ESP

Problem Causes

Excessive GasVolume

The ESP is not designed property Hot excess airAir leakageHigh gas temperature

Rapping Acceleration is not high enoughElectrode arrangement is not rightFailure of rapper motors

Gas Distribution Model study not carried out or carried out incorrectly

DischargeElectrode Breakage

Electrode is not strong enough to overcome flash voltage and high intensity rappingCorrosion resistant material for electrode is not chosen

Discharge Overflow in Hoppers

Improper designing capacity of hopperCoal quality changes beyond the rangeDust evacuation is not properLevel Switch not acting properlyChoking of dust hoppers

Electrical Dust build – up on electrodesInsulator breakdownMisalignment of electrode Failure to maintain dust hopper

Maintenance & Troubleshooting

Page 49: Electrostatic Precipitators

IMECO LIMITED

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 powerinput 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 typeof rapper is a short in the coil thatlifts the rapper. Methods for correcting thisproblem include:

Maintenance & Troubleshooting

Page 50: Electrostatic Precipitators

IMECO LIMITED

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

Maintenance & 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

Maintenance & Troubleshooting

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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

Maintenance & Troubleshooting

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IMECO LIMITED

• 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

Cont..

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IMECO LIMITED

• 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

SCHEDULE / PROCEDURE FOR RETROFITTING OF ESP

Page 55: Electrostatic Precipitators

IMECO LIMITED

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.

Page 56: Electrostatic Precipitators

IMECO LIMITED

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.

Page 57: Electrostatic Precipitators

IMECO LIMITED

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

OUR SERVICES

Page 58: Electrostatic Precipitators

IMECO LIMITED

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

OUR PRODUCTS

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IMECO LIMITED

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

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IMECO LIMITED

ESP SERVICES RELATED PROJECTS• National Aluminium Company Ltd• Dishergargh Power Supply Company Ltd• Indian Aluminium Company Ltd• Bokaro Power Supply Company Ltd• The Tata Iron & Steel Company Ltd• Steel Authority of India Ltd• Prakash Industries Limited• My Home Power Limited

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IMECO LIMITED

CONTACT US

REGISTERED OFFICE : 26, R.N. MUKHERJEE ROAD,KOLKATA - 700001Tel : 91 33 2248 1888 Fax: 91 33 2248 0242E-mail: [email protected]

WORKS: 1) : KOLKATA – MUMBAI NATIONAL HIGHWAY, OPP. TATA BEARINGS, KHARAGPUR , WEST BENGAL.

2): 4/5, KALI PRASANNA SINGHEE ROAD, KOLKATA – 700002, WEST BENGAL CHENNAI OFFICE:

32, T.T.K ROAD, ALWARPET, CHENNAI - 600018 Tel: 91 44 2498 2888/ Fax 91 44 24985988

E-mail: [email protected], Web: www.imecolimited.com

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IMECO LIMITED

THANK YOU

IMECO LIMITED


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