ESP TECHNOLOGIES (P) LTD

Flat – H9, Jain Swarnakamal Apts, 69, Arcot Road, Saligramam

Chennai – 600093. Tamilnadu. India

E-mails: balagurunathansundaram@gmail.com

: sundarambalagurunathan@yahoo.com

Telephone : ++(91) 98 409 92528

Technical Workshop on the

Best Practices in the

Operation & Maintenance of

Electrostatic Precipitators for Plant Engineers

In the present context of increased awareness of the need to protect the environment in and around

the power / process plants coupled with deteriorating coal qualities and process vagaries and the

growing demand on collection efficiencies to meet the stringent particulate emission standards, the

role of particulate control devices like ELECTROSTATIC PRECIPITATORS installed in many coal-

fired power and process plants has become quite significant and important in the recent times. There

is therefore a dire necessity to develop competent engineers in this field to operate, maintain and

trouble shoot the electrostatic precipitators in such large coal fired power stations and process plants,

the sizes of which have grown phenomenally in the recent years.

• The success of an air pollution abatement program ultimately depends upon

effective operation and maintenance (O&M) of the installed air pollution control

equipment.

• Regardless of how well an air pollution control system is designed, poor O&M will

lead to the deterioration of its various components and a resulting decrease in its

particulate removal efficiency.

• Effective O&M also affects equipment reliability, on-line availability, continuing

regulatory compliance and regulatory agency/source relations.

• Lack of timely and proper O&M leads to a gradual deterioration in the equipment

which in turn increases the probability of equipment failure and decreases both its

reliability and on-line availability.

• These latter two items can decrease plant productivity if process operations are

forced to be curtailed or shut down to minimize emissions during air pollution

control equipment outages. Frequent violations of emission limits can result in

more inspections, potential fines for noncompliance and in some cases, mandatory

shutdown until emission problems are solved.

This series of presentations will focus discuss on the operation, maintenance and

trouble-shooting of typical electrostatic precipitators and emphasize the

importance of monitoring key operating parameters at the inlet of

ELECTROSTATIC PRECIPITATORS,including the electrical readings ( kV and mA of

the fields), the flue gas flow rate, temperature, composition, moisture levels etc.

The workshop will also cover the theory, mechanical and electrical components

design parameters, selection and sizing of ELECTROSTATIC PRECIPITATORS etc.

Introduction ...

Need for the program ...

• Although O&M-related air pollution problems cannot be completely eliminated,

they can be minimized by the conscientious application of a well planned O&M

program. The causes of such problems often vary widely and their effects on

deteriorating performance may be direct, indirect or synergistic.

• Process, particle, mechanical, environmental and gas flow dynamics factors

dictate that O&M programs and trouble-shooting actions are approached from a

total system or process point of view. The variable nature of these factors also

requires that O&M programs are individualized and specifically tailored to the

needs of the process and installation served.

The objectives of the program are:

to give a basic understanding of the fundamental theory and principles of electrostatic

precipitation

to provide guidelines on routine maintenance to maintain and improve the reliability and

performance of the precipitator system and

to give a basic understanding of how system changes can affect precipitator operation

The technical workshop and the series of lectures will be delivered by S.BALAGURUNATHAN,

MANAGING DIRECTOR, ESP TECHNOLOGIES (P) LTD, CHENNAI.This program is designed for

engineers responsible for the operation and maintenance of electrostatic precipitators in power and

industrial plants.Project engineers involved in the selection, sizing, installation and commissioning of

electrostatic precipitators will also benefit from this workshop.At the end of this workshop, the

participants will acquire an enhanced understanding of the following aspects of ELECTROSTATIC

PRECIPITATOR:

Theory and operating principle

Design parameters

Fly ash resistivity and its impact on the ESP performance

Selection and sizing

Mechanical and Electrical systems

Operation and Performance Monitoring

Maintenance and Trouble- shooting

Performance Up-grading and Retrofitting

Program Objectives ...

The program will be scheduled for three days to make it very detailed, effective and

interactive. The technical lectures will be on various topics related to electrostatic precipitator from

concept to commissioning and trouble shooting. Attached below is a broad outline of topics which will be

covered during the program and the tentative schedule.

WORKSHOP CONTENT & SCHEDULE

DAY 1: 9.00 AM – 5.00 PM (Registration at 8.30 AM)

Topic

Number

Title of the topic Contents

1 Introduction Need for dust collection in coal-fired power

plants

International standards for Particulate

Emission

Types of dust collectors-operating principles –

merits and demerits etc

Advantages of electrostatic precipitators

2 Operation of Electrostatic

Precipitators

Theory and Principle of operation of

electrostatic precipitator

Types of electrostatic precipitators

Application of electrostatic precipitator in

industries

Cold-side / Hot-side electrostatic precipitators

Wet type electrostatic precipitators

Program Content ...

3 Design Parameters of

Electrostatic Precipitators

Equation for collection efficiency of

electrostatic precipitators

Design parameters for selection and sizing of

electrostatic precipitators

Influence of design parameters on the

collection efficiency of electrostatic

precipitators

Fly ash generation

Coal / ash analysis and their chemistry

Flue gas and fly ash characteristics

4 Resistivity of fly ash and

its effect on the

performance of

electrostatic precipitators

Electrical Resistivity of fly ash

Factors influencing the electrical resistivity of

fly ash

Back corona and its mechanism

Techniques to handle high electrical resistivity

fly ash

5 Selection and sizing of

electrostatic precipitator

Discussion on critical design criteria like

migration velocity, Specific Collection Area

(SCA), Aspect Ratio, Treatment Time, Corona

Power, degree of high tension sectionalization,

gas velocity etc

Layout of electrostatic precipitator system

Arrangement of electrical bus sections

Flue gas ducting arrangement and layout

considerations

Model testing / Computational Fluid Dynamics

(CFD)

DAY 2: 9.00 AM – 5.00 PM

Topic Number Title of the topic Contents

6 Mechanical Systems of

electrostatic precipitator

Detailed discussions on Electrode

Systems – collecting electrodes &

discharge electrodes – types / profiles /

materials of construction / design criteria

etc

Detailed discussions on Rapping

mechanisms – types / requirement of

accelerations

Gas Distribution systems

Gas Screening systems

Casing / hoppers / bearings etc

Ash evacuation systems

Mechanical interlocking systems

7 Electrical systems of

electrostatic precipitator

High voltage electrical system

Rapper / heater controls

Power distribution

Shaft / Support insulators – heaters / hot

air flushing / scavenging systems

Electrostatic Precipitator Management

Systems (EPMS)

8 Pre-commissioning /

Commissioning of

electrostatic precipitator

Pre-commissioning check lists

Air inleakage tests

Gas distribution tests

Air load / Gas load

Voltage – Current (VI) characteristics

Commissioning check lists

9 Operation and

Data Logging

Start-up and shut down procedures

Performance monitoring

Tuning of the mechanical / electrical

systems of electrostatic precipitator

Data logging Formats

DAY 3: 9.00 AM – 5.00 PM

Topic Number Title of the topic Contents

10 Trouble Shooting - 1 Classification of problems

Detailed discussions on fundamental /

mechanical / operational problems

Problems & Causes

Failure Analysis

Trouble shooting

11 Trouble Shooting - 2 Detailed discussions on process upsets

and their effects on the performance of

electrostatic precipitator

Problems with auxiliary systems like ash

evacuation, hot air flushing, fluidizing etc

12 Maintenance Recommended procedures

On-load / off-load inspection

Preventive maintenance

13 Performance Testing Selection of test locations

Velocity traverses

Iso-kinetic particulate sampling

Flue gas analysis

14 Performance upgrading /

retrofitting

Need for upgrading the performance

Feasibility studies

Magnitude of enhancement

Technical evaluation of available

alternatives

Case studies

Sharing of experience

15 Recent technological

developments in ESP

Mechanical systems

Electrical systems

The technical sessions will be delivered in accordance with the general terms and

conditions described here under:

1. Medium of instruction: English

2. Each session will be tentatively of two hours duration

3. Each session will be followed with an interactive / question-answer session

4. The sessions will be of class-room type lectures assisted by MS PowerPoint

presentations including equipment related photographs. The audio / video

systems, projectors etc are to be arranged by the client

5. Maximum number of participants : 20

6. To make the programme very effective the level of participants shall not be below

the rank of executives / shift in-charge / qualified engineers

1. Inspection of internals of electrostatic precipitator

2. Tuning of mechanical / electrical systems and controls of the electrostatic

precipitator

General Terms & Conditions ...

Exclusions ...

The technical sessions will be handled by S.BALAGURUNATHAN, MANAGING DIRECTOR,

ESP TECHNOLOGIES (P) LIMITED, CHENNAI- 600093.

During a greater part of his tenure in BHEL, he had been involved in all aspects of

ELECTROSTATIC PRECIPITATOR technology including the technical marketing,

engineering (for new and retrofit applications), research and development, erection,

commissioning and trouble shooting of ESP. He was head of the engineering and external

services departments of electrostatic precipitator in BHEL, Ranipet, India.

During his tenure in BHEL, he had been directly involved in the engineering and

execution of major contracts for electrostatic precipitators to many reputed power

generating corporations like National Thermal Power Corporation (NTPC), Neyveli

Lignite Corporation (NLC), Reliance Power Limited (RPL), various State Electricity Boards

(SEBs) and Independent Power Generating Corporations (IPPs) and large cement

manufacturing companies like Associated Cement Companies (ACC), Tamilnadu Cements

Corporation (TANCEM) etc. for applications in coal-fired boilers, cement plants etc. With

an experience spanning over 45 years, he brings with him a very deep and extensive

knowledge of the electrostatic precipitator with particular reference to handling highly

resistive fly ashes resulting from the combustion of Indian coals. He had served in a

Program Director ...

Mr. S. BALAGURUNATHAN is a Post Graduate in

engineering with specialization in the Design

and Production of Thermal Power Equipment.

He is a retired Executive Director from Bharat

Heavy Electricals Limited (BHEL), a premier

organization in India engaged in the design,

manufacture, erection, operation and

maintenance of power plants in India and

abroad. He had served this organization for almost

38 years in various capacities since 1968.

number of technical committees constituted by reputed organizations including the

Central Pollution Control Board, Ministry of Environment and Forest, Government of

India, Central Electricity Authority, Ministry of Power, Government of India on matters

related to controlling of particulate emissions from stationary sources. He had visited a

number of countries including United States / United Kingdom / Sweden / Denmark /

Poland / Japan / Australia / Canada / Greece / France / Malaysia in connection with

discussions with clients on business matters related to electrostatic precipitator and

other particulate control devices, coal gasification, research & development, joint

ventures, technical collaborations etc.

He is currently the Managing Director of ESP Technologies (P) Ltd.

CLIENT ADDRESS VENUE OF THE

PROGRAM

MONTH /

YEAR

ORGANISATIONS PARTICIPATED

ENGINEERING

STAFF COLLEGE

OF INDIA

HYDERABAD

ANDHRA

PRADESH INDIA

ESCI CAMPUS,

GACHI BOWLI,

HYDERABAD

OCTOBER,

2012

1. HARYANA

POWER GENERATION

CORPORATION LIMITED (HPGCL)

2. MAHARASHTRA STATE POWER

GENERATION

COMPANY LIMITED

(MAHAGENCO) 3. DAMODAR

VALLEY

CORPORATION (DVC)

4. VASAVADATTA CEMENTS

THE COMPETENCY

CENTRE FOR

ENERGY

INDUSTRY SDN

BHD

KUALA LUMPUR

MALAYSIA

HOTEL GRAND

DORSETT,

SUBANG JAYA,

KUALA LUMPUR

JANUARY,

2013

1.TENAGA NASIONAL

BERHAD (TNB),

KUALA LUMPUR 2. TNB

JANAMANJUNG SDN BHD

(MANJUNG

THERMAL POWER STATION)

3.KAPAR ENERGY VENTURES SDN

BHD

(SULTAN SALAHUDDIN

ABDUL AZIZ THERMAL POWER

PLANT) 4. JIMAH O & M

SDN BHD

List of clients ...

MINDSCAPE ASIA

INC

MUMBAI

MAHARASHTRA

INDIA

MUMBAI APRIL,

2013

1.TATA POWER COMPANY

2.SRF LIMITED

3. TOYO ENGG LIMITED

4. GUJARAT STATE ELECTRICITY

CORPORATION LIMITED (GSECL)

5. ASSOCIATED

CEMENT COMPANIES (ACC)

6. JK CEMENTS

MINDSCAPE ASIA

INC

MUMBAI

MAHARASHTRA

INDIA

DELHI APRIL,

2013

1. ASSOCIATED

CEMENT COMPANIES (ACC)

2. HINDUSTAN ZINC LIMITED

3. ISGEC HEAVY ENGINEERING

4. IFFCO,

PHULPUR 5. NATIONAL

THERMAL POWER CORPORATION

(NTPC)

6. SRF LIMITED

MINDSCAPE ASIA

INC

MUMBAI

MAHARASHTRA

INDIA

CHENNAI MAY,

2013

1.TATA METALLIKS

2. NATIONAL THERMAL POWER

CORPORATION

(NTPC) 3. IFFCO, PARADEP

4. TATA STEELS LIMITED

5. MAITHON POWER LIMITED

6. TATA POWER

LIMITED 7. INDIAN METALS

& FERRO ALLOYS

MINDSCAPE ASIA

INC

MUMBAI

MAHARASHTRA

INDIA

KOLKATTA MAY,

2013

1.F.L.SMIDTH

2. ANDHRA

PRADESH PAPER MILS (APPM)

3. TATA PROJECTS LIMITED

4. DELTA PAPER MILLS

5. SAINT GOBAIN

INDIA LIMITED 6. TATA STEELS

LIMITED

INDIA GLYCOLS

LIMITED KASHIPUR

UTTARAKHAND INDIA

KASHIPUR JUNE, 2013

PLANT ENGINEERS

OF INDIA GLYCOLS LIMITED,

KASHIPUR UTTARAKHAND

JINDAL POWER

LIMITED

TAMNAR RAIGARH Distt

CHATTISGARH INDIA

O.P.JINDAL SUPER THERMAL

POWER

STATION, TAMNAR,

RAIGARH

JULY, 2013

PLANT ENGINEERS OF O.P.JINDAL

SUPER THERMAL

POWER STATION, TAMNAR,

RAIGARH, CHATTISGARH

( 4 X 250 MW

POWER STATION)

ENGINEERING

STAFF COLLEGE

OF INDIA

HYDERABAD

ANDHRA

PRADESH INDIA

ESCI CAMPUS,

GACHI BOWLI,

HYDERABAD

JULY,

2013

1. HARYANA

POWER

GENERATION CORPORATION

LIMITED (HPGCL) 2. DAMODAR

VALLEY

CORPORATION (DVC)

3. TATA POWER LIMITED

4. PUNJAB STATE POWER

CORPORATION

LIMITED (PSPCL)

GUJARAT STATE

ELECTRICITY CORPORATION

LIMITED (GSECL),

VADODARA, GUJARAT

INDIA

WANAKBORI

THERMAL

POWER STATION

AUGUST, 2013

PLANT ENGINEERS

OF WANAKBORI AND SIKKA

THERMAL POWER STATIONS OF

GUJARAT STATE

ELECTRICITY CORPORATION

LIMITED (GSECL)

GUJARAT STATE

ELECTRICITY

CORPORATION LIMITED (GSECL),

VADODARA, GUJARAT

INDIA

UKAI THERMAL

POWER STATION

AUGUST, 2013

PLANT ENGINEERS

OF UKAI AND GANDHINAGAR

THERMAL POWER STATIONS OF

GUJARAT STATE

ELECTRICITY CORPORATION

LIMITED (GSECL)

JSW ENERGY

LIMITED, TORANAGALLU,

KARNATAKA

INDIA

THERMAL POWER

STATION, TORANAGALLU

DECEMBER,

2013

PLANT ENGINEERS OF 2 X 130 MW

AND 4 X 300 MW THERMAL POWER

STATIONS OF JSW

ENERGY LIMITED, TORANAGALLU

INDIAN FARMERS

FERTILIZERS CO-OPERATIVE

(IFFCO). Unit: PHULPUR

UTTAR PRADESH,

INDIA

PHULPUR PLANT,

PHULPUR.

OCTOBER,

2014

PLANT ENGINEERS OF IFFCO,

PHULPUR UNIT.

HELIOS

INFRAPRO LIMITED,

KOLKATA

INDIA

KOLKATA NOVEMBER,

2014

1. HINDALCO INDUSTRIE

S

2. AMBUJA CEMENTS

3. NTPC LIMITED

4. SARDA ENERGY &

MINERALS

LTD 5. JK

CEMENTS LTD

6. TATA

SPONGE IRON LTD

MASTERS IN

TRAINING, MUMBAI

INDIA

MUMBAI NOVEMBER, 2014

1. TATA PROJECTS

LIMITED

2. SHREE CEMENTS

LTD 3. UPRVUNL

(OBRA TPS) 4. TATA

POWER

COMPANY 5. HEUBACH

COLOUR PVT LTD

6. TATA STEEL

LTD

SASAN POWER LIMITED, SASAN

INDIA

SASAN ULTRA MEGA POWER

PROJECT (UMPP)

FEBRUARY,

2015

PLANT

ENGINEERS OF SASAN UMPP

(6 x 660 MW),

SINGRAULI

TAMILNADU NEWSPRINT AND

PAPERS LIMITED, KAGITHAPURAM,

INDIA

KAGITHAPURAM SEPTEMBER,2015

PLANT

ENGINEERS OF

TAMILNADU NEWSPRINT

AND PAPERS LIMITED

Appreciation from Mr.Kenneth R. Parker, UK ...

Accolades from clients ...

Jan 18, 2014

Dear Sundaram,

I have now been through your complete set of excellent presentation slides

and if the students etc., retain a high proportion of the data it should help

in their understanding of the theory and operation of ESPs, hopefully,

such that they can efficiently maintain them to achieve optimum

performance.

From the Course Material you have provided, I believe and must

congratulate you in producing an excellent resume of the theory and

practice of electrostatic precipitation, and as indicated above, if the

attendees retain a high percentage of the data, then this can only prove

useful in reducing particulate pollution from industrial sources fitted

with ESPs in India.

Regards and best wishes,

Ken

(Mr. KENNETH R. PARKER joined Lodge Cottrell, UK in 1958 as a Research

Engineer and remained with the company for more than 35 years, ultimately as

Technical Director of both the Lodge Cottrell and Lodge Sturtevant Companies.

Editor and major contributor to the book "APPLIED ELECTROSTATIC PRECIPITATION". Published by Chapman and Hall, London. December 1996. Ref: ISBN 0 7514 02664. Editor of “ELECTRICAL OPERATION OF ELECTROSTATIC PRECIPITATORS”. Published by the IEE, UK. February 2003. Ref: ISBN 0 85296 1375.