IMECO LIMITED Welcome to ESP Presentation IMECO LIMITED

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IMECO LIMITED Welcome to ESP Presentation IMECO LIMITED Contact: www. imecolimited. com ESP Presentation

IMECO LIMITED Welcome to ESP Presentation IMECO LIMITED Contact: www. imecolimited. com ESP Presentation

IMECO LIMITED Index Controlling Air Pollution Introduction Design Features Principle of Operation Components Operations

IMECO LIMITED Index Controlling Air Pollution Introduction Design Features Principle of Operation Components Operations & Performance Corona Power Maintenance & Troubleshooting About Us Index

IMECO LIMITED Controlling Air Pollution Clean Air is an essential resource to the people

IMECO LIMITED Controlling Air Pollution 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. Cont… Air pollution

IMECO LIMITED Controlling Air Pollution Now a days Electrostatic Precipitators have come a long

IMECO LIMITED Controlling 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 are with gases coming out of chimney in the Emission Standard prescribed by Central Pollution Control Board. Air pollution

IMECO LIMITED Electrostatic Precipitators In all industries the burnt gases are passing through an

IMECO LIMITED Electrostatic Precipitators 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

IMECO LIMITED Electrostatic Precipitators Electrostatic Precipitator removes dust particles from the exhaust gas stream

IMECO LIMITED Electrostatic Precipitators 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

IMECO LIMITED Electrostatic Precipitators are not only used in Power Plant applications but also

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

IMECO LIMITED History of Electrostatic Precipitator Technology In 1907, the first commercial Electrostatic Precipitator

IMECO LIMITED History of Electrostatic Precipitator Technology 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, universally followed till date. Introduction to ESP these design precepts are still almost

IMECO LIMITED Status of Electrostatic Precipitator Technology usage in India Electrostatic Precipitator (ESP) is

IMECO LIMITED Status of Electrostatic Precipitator Technology usage in India 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. Introduction to ESP

IMECO LIMITED Thermal Power Plants In Thermal Power Stations, suspended particulate matter (SPM), sulphur

IMECO LIMITED Thermal Power Plants In Thermal Power Stations, suspended particulate matter (SPM), sulphur dioxide (SO 2), 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 SO 2. Over a year, these work out to half a million tonne of ash and 80000 tonnes of SO 2. The total amount of pollutants from all thermal power plants, if allowed to pervade our atmosphere without any control, would seriously pose a threat to ecological balance, climate, and atmosphere. Cont…. Introduction to ESP

IMECO LIMITED THERMAL POWER PLANTS ESPs are used in all thermal power plants to

IMECO LIMITED THERMAL POWER PLANTS 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 range and 10 per cent in 2 m range. concentration Also of dust the is extremely high of the order of 30 grain/ft 3 of flue gas. A high efficiency collector is capable of collecting particles of less than even one micron size. Introduction to ESP

IMECO LIMITED STEEL INDUSTRY Dust emission problems in the sintering plant of the Steel

IMECO LIMITED STEEL INDUSTRY 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 m 3 at STP per tonne of pig iron with a dust content after coarse separation of approximately 10 gm/m 3. The dust contained in the exhaust gas extracted from the top of the blast furnace mainly consists of iron oxide, silica, and lime. Introduction to ESP

IMECO LIMITED CEMENT PLANTS The use of ESPs in cement plants has been since

IMECO LIMITED CEMENT PLANTS 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 70 s and 80 s. ESPs are generally used in cement kilns and cement grinding mills. In kiln waste gas, the range of gas quantity is 150 000 m 3/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 m 3/hr approximately at a temperature of 80 °C. The application of ESPs has undergone considerable change with the advent of new processes for cement manufacture (especially the introduction of dry cement manufacturing process) and also wider awareness of environmental factors. The cement industries with the stringent air borne emission standards have begun to use conventional ESPs for control of emissions in kilns (in kilns ESPs were used together with conditioning tower) and coal mills. 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

IMECO LIMITED APPLICATIONS FOR ELECTROSTATIC PRECIPITATORS Introduction to ESP § Production plants for cement,

IMECO LIMITED APPLICATIONS FOR ELECTROSTATIC PRECIPITATORS Introduction to ESP § 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 waste

IMECO LIMITED FEATURES / ADVANTAGES Generally ESP… - can collect dust in both wet

IMECO LIMITED FEATURES / ADVANTAGES 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; Introduction to ESP

IMECO LIMITED ESP DESIGNS ESPs Traditional North American Design Traditional European Design ESP -

IMECO LIMITED ESP DESIGNS ESPs Traditional North American Design Traditional European Design ESP - Designs

IMECO LIMITED TRADITIONAL ESP DESIGNS ESP - Designs

IMECO LIMITED TRADITIONAL ESP DESIGNS ESP - Designs

IMECO LIMITED TRADITIONAL NORTH AMERICAN DESIGN ESP - Designs

IMECO LIMITED TRADITIONAL NORTH AMERICAN DESIGN ESP - Designs

IMECO LIMITED TRADITIONAL EUROPEAN DESIGN ESP - Designs

IMECO LIMITED TRADITIONAL EUROPEAN DESIGN ESP - Designs

IMECO LIMITED PRINCIPLE OF OPERATION Electrostatic precipitation is a physical process by which particles

IMECO LIMITED PRINCIPLE OF OPERATION 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 k. V, a corona discharge occurs close to the negative electrode, setting up an electric field between the emitter and the charged surface. 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. ESP – Principle of Operation

IMECO LIMITED HOW A ESP FUNCTIONS Charging Particles are given strong negative charge by

IMECO LIMITED HOW A ESP FUNCTIONS 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 ESP – Principle of Operation

IMECO LIMITED TWO STAGE ELECTROSTATIC PRECIPITATOR STAGE I ESP – Principle of Operation

IMECO LIMITED TWO STAGE ELECTROSTATIC PRECIPITATOR STAGE I ESP – Principle of Operation

IMECO LIMITED TWO STAGE ELECTROSTATIC PRECIPITATOR STAGE II ESP – Principle of Operation

IMECO LIMITED TWO STAGE ELECTROSTATIC PRECIPITATOR STAGE II ESP – Principle of Operation

IMECO LIMITED SCHEMATIC OF A PARALLEL-PLATE PRECIPITATOR ESP – Principle of Operation

IMECO LIMITED SCHEMATIC OF A PARALLEL-PLATE PRECIPITATOR ESP – Principle of Operation

IMECO LIMITED TYPICAL HORIZONTAL FLOW PRECIPITATOR ESP – Principle of Operation

IMECO LIMITED TYPICAL HORIZONTAL FLOW PRECIPITATOR ESP – Principle of Operation

IMECO LIMITED COMPONENTS FOR ELECTROSTATIC PRECIPITATORS The devices used for gas – solid separation,

IMECO LIMITED COMPONENTS FOR ELECTROSTATIC 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

IMECO LIMITED COLLECTING ELECTRODES Collecting plates are designed to receive and retain the precipitated

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 precipitator. Baffle plates power circuit of the 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. 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. ESP - Components

IMECO LIMITED DISCHARGE / EMIITING ELECTRODES Discharge electrodes emit charging current and provide voltage.

IMECO LIMITED DISCHARGE / EMIITING ELECTRODES 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 • • straight round wires twisted pairs of wires barbed discharge wires rigid masts rigid frames rigid spiked pipes spiral wires ESP - Components Cont…

IMECO LIMITED DISCHARGE / EMIITING ELECTRODES Discharge electrodes are typically supported from the upper

IMECO LIMITED DISCHARGE / EMIITING ELECTRODES 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. ESP - Components

IMECO LIMITED DISCHARGE ELECTRODE TYPES ESP - Components

IMECO LIMITED DISCHARGE ELECTRODE TYPES ESP - Components

IMECO LIMITED ELECTRODE ARRANGEMENT ESP - Components

IMECO LIMITED ELECTRODE ARRANGEMENT ESP - Components

IMECO LIMITED ELECTRODE DESIGN (CONT’D) ESP - Components

IMECO LIMITED ELECTRODE DESIGN (CONT’D) ESP - Components

IMECO LIMITED Advances in Electrode Design Emitting (Discharge) Electrodes v Reliability criteria: sturdy designs

IMECO LIMITED Advances in Electrode Design Emitting (Discharge) Electrodes v Reliability criteria: sturdy designs v Application specific configurations v Current voltage characteristics v Overcome corona supression: fine particulates Collecting Electrodes ESP - Components v Height up to 15 meters with efficient cleaning v Ease of installation

IMECO LIMITED GAS DISTRIBUTION SCREENS These Screens are of modular design manufactured out of

IMECO LIMITED GAS DISTRIBUTION SCREENS 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. 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 connected to the driving mechanism Insulator. ESP - Components electrodes is through Shaft

IMECO LIMITED SUSPENSION AND RAPPING MECHANISM The collecting electrodes are fixed loosely to suspension

IMECO LIMITED SUSPENSION AND RAPPING MECHANISM 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 programmed intervals and removal deposited dust electrodes of to the in regular, guarantees from 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. ESP - Components

IMECO LIMITED HOPPERS Precipitator hoppers are designed to completely discharge their dust load on

IMECO LIMITED HOPPERS Precipitator hoppers are designed to completely discharge their dust load on demand. Usually the hoppers are rectangular in crosssection 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". ESP - Components

IMECO LIMITED MATERIALS OF CONSTRUCTION ü ESP üCarbon Steel ü Mild Steel üCorten üA

IMECO LIMITED MATERIALS OF CONSTRUCTION ü ESP üCarbon Steel ü Mild Steel üCorten üA 516 -70 üDuplex & Stainless Steel üAR Plate ESP - Components

IMECO LIMITED FACTORS INFLUENCING PERFORMANCE OF ESPS Operation & Performance

IMECO LIMITED FACTORS INFLUENCING PERFORMANCE OF ESPS Operation & Performance

IMECO LIMITED Influence Of Gas Flow On Performance Operation & Performance

IMECO LIMITED Influence Of Gas Flow On Performance Operation & Performance

IMECO LIMITED Influence of Inlet Burden on Performance Operation & Performance

IMECO LIMITED Influence of Inlet Burden on Performance Operation & Performance

IMECO LIMITED “Normal” Precipitator Electrical Characteristics Operation & Performance

IMECO LIMITED “Normal” Precipitator Electrical Characteristics Operation & Performance

IMECO LIMITED VOLUME RESISTIVITY Operation & Performance

IMECO LIMITED VOLUME RESISTIVITY Operation & Performance

IMECO LIMITED SURFACE RESISTIVITY Operation & Performance

IMECO LIMITED SURFACE RESISTIVITY Operation & Performance

IMECO LIMITED INFLUENCE OF FLY ASH COMPONENTS ON VOLUME RESISTIVITY Operation & Performance

IMECO LIMITED INFLUENCE OF FLY ASH COMPONENTS ON VOLUME RESISTIVITY Operation & Performance

IMECO LIMITED CORONA POWER Precipitator corona power is the useful electrical power applied to

IMECO LIMITED 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. Cont… ESP – Corona Power

IMECO LIMITED CORONA POWER In the lower range of collecting efficiencies, relatively small increases

IMECO LIMITED 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. ESP – Corona Power

IMECO LIMITED OPTIMIZING CORONA POWER Optimum conditions depend upon the location of the field

IMECO LIMITED 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: 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 ESP – Corona Power

IMECO LIMITED Back–Corona in the Dust Layer ESP – Corona Power

IMECO LIMITED Back–Corona in the Dust Layer ESP – Corona Power

IMECO LIMITED RECOGNIZING BACK CORONA One of the easiest ways to determine if you

IMECO LIMITED RECOGNIZING BACK CORONA 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 ESP – Corona Power

IMECO LIMITED PREVENTIVE MAINTENANCE CHECKLIST FOR A TYPICAL ESP DAILY • Take and record

IMECO LIMITED PREVENTIVE MAINTENANCE CHECKLIST FOR A TYPICAL ESP DAILY • 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. WEEKLY • Check rapper operation • Check and clean air filter • Inspect control set interiors MONTHLY • Check operation of standby top-housing pressurizing fan and thermostat. • Check operation of hopper heaters. • Check hopper level alarm operation Maintenance & Troubleshooting

IMECO LIMITED PREVENTIVE MAINTENANCE CHECKLIST FOR A TYPICAL ESP QUARTERLY • • Check and

IMECO LIMITED PREVENTIVE MAINTENANCE CHECKLIST FOR A TYPICAL ESP QUARTERLY • • Check and clean rapper and vibrator switch contacts. Check transmissometer calibration HALF YEARLY • • 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 ANNUAL • • 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. Cont… Maintenance & Troubleshooting

IMECO LIMITED PREVENTIVE MAINTENANCE CHECKLIST FOR A TYPICAL ESP • Check and tighten rapper

IMECO LIMITED PREVENTIVE MAINTENANCE CHECKLIST FOR A TYPICAL ESP • 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 SITUATIONAL • 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. Cont… Maintenance & Troubleshooting

IMECO LIMITED COMMON PROBLEMS WITH ESP 1. Discharge electrode failure; Rapper malfunctioning; 2. Dust

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

IMECO LIMITED MAJOR CAUSES OF PROBLEMS IN ESP Problem Causes Excessive Gas Volume The

IMECO LIMITED MAJOR CAUSES OF PROBLEMS IN ESP Problem Causes Excessive Gas Volume The ESP is not designed property Hot excess air Air leakage High gas temperature Rapping Acceleration is not high enough Electrode arrangement is not right Failure of rapper motors Gas Distribution Model study not carried out or carried out incorrectly Discharge Electrode Breakage Electrode is not strong enough to overcome flash voltage and high intensity rapping Corrosion resistant material for electrode is not chosen Discharge Overflow in Hoppers Improper designing capacity of hopper Coal quality changes beyond the range Dust evacuation is not proper Level Switch not acting properly Choking of dust hoppers Electrical Dust build – up on electrodes Insulator breakdown Misalignment of electrode Failure to maintain dust hopper Maintenance & Troubleshooting

IMECO LIMITED TROUBLESHOOTING DUST ACCUMULATION The most common cause of excessive dust accumulation on

IMECO LIMITED 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 power input 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 properation 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 type of rapper is a short in the coil that lifts the rapper. Methods for correcting this problem include: i. Replace the defective rapper with a new one. ii. Rebuild the defective rapper. Maintenance & Troubleshooting

IMECO LIMITED TROUBLESHOOTING Corrective action for misalignment can only be done during a complete

IMECO LIMITED TROUBLESHOOTING 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. Maintenance & Troubleshooting

IMECO LIMITED START – UP PRACTICES i. ii. iv. v. viii. When preparing for

IMECO LIMITED START – UP PRACTICES i. ii. iv. v. viii. 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. 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. 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. 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. 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. Maintenance & Troubleshooting

IMECO LIMITED SHUTDOWN PRACTICES Except in the instance of an emergency shutdown, this process

IMECO LIMITED SHUTDOWN PRACTICES 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. Maintenance & Troubleshooting

IMECO LIMITED SCHEDULE / PROCEDURE FOR RETROFITTING OF ESP • The erection team arrives

IMECO LIMITED SCHEDULE / PROCEDURE FOR RETROFITTING OF ESP • 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 Maintenance & Troubleshooting Cont. .

IMECO LIMITED SCHEDULE / PROCEDURE FOR RETROFITTING OF ESP • Plain bearing is replaced

IMECO LIMITED SCHEDULE / PROCEDURE FOR RETROFITTING OF ESP • 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

IMECO LIMITED IMECO Limited, established in 1975, is one of the leading Engineering Organisation

IMECO LIMITED 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. About Us

IMECO LIMITED Our vision is to become a world class, innovative, competitive engineering enterprise

IMECO LIMITED 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. About Us

IMECO LIMITED OUR SERVICES We offer services in the field of technical support as

IMECO LIMITED OUR SERVICES We offer services in the field of technical support as well as for supply of internals / spares, both mechanical and electrical. OUR SERVICES INCLUDE • 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. About Us

IMECO LIMITED OUR PRODUCTS WE HAVE COMPLETE MANUFACTURING FACILITIES FOR SUPPLY OF FOLLOWING SPARES

IMECO LIMITED OUR PRODUCTS WE HAVE COMPLETE MANUFACTURING FACILITIES FOR SUPPLY OF FOLLOWING SPARES FOR ESP • 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 About Us

IMECO LIMITED OUR ESTEEMED CUSTOMERS • • • • • • Assam State Electricity

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 About Us

IMECO LIMITED ESP SERVICES RELATED PROJECTS • National Aluminium Company Ltd • Dishergargh Power

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 About Us

IMECO LIMITED CONTACT US REGISTERED OFFICE : 26, R. N. MUKHERJEE ROAD, KOLKATA -

IMECO LIMITED CONTACT US REGISTERED OFFICE : 26, R. N. MUKHERJEE ROAD, KOLKATA - 700001 Tel : 91 33 2248 1888 Fax: 91 33 2248 0242 E-mail: info@imecolimited. com 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: infoch@imecolimited. com, Web: www. imecolimited. com About Us

IMECO LIMITED THANK YOU

IMECO LIMITED THANK YOU