Comparative Study of the Conventional
Electrostatic Precipitator and the Proposed
Smart Electrostatic Precipitator Based on the
Various Electrical Erection Challenges

S; eep R Krishnan; Sethuraman K V; Anna Philo Antony

Comparative Study of the Conventional Electrostatic Precipitator and the Proposed Smart Electrostatic Precipitator Based on the Various Electrical Erection Challenges

Sandeep R Krishnan¹, Sethuraman K V², Anna Philo Antony³

PG Student, M.Tech Power System, Department of EEE, SASTRA University, Thanjavur, India¹
PG Student, M.Tech Power System, Department of EEE, SASTRA University, Thanjavur, India²
PG Student, M.Tech Power Electronics and Drives, Department of EEE, SASTRA University, Thanjavur, India³

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Abstract

Aninsight view of the various electrical equipments and working of Electrostatic precipitator is explained in this paper along with the challenges that are being faced while carrying out the erection of the various electricalequipments, testing and commissioning of the Electrostatic precipitator. As a case study an Electrostatic precipitator that is commonly usedin an integrated steel plant is analyzed.A new proposal of the smart Electrostatic precipitator is being done in this paper. This minimizes the total cost that includes the erection costs, the time required for erection,testing and commissioning.

Keywords

Electrostatic Precipitator, ZigbeeTransceiver, Rapping Motor, Transformer Rectifier Unit

INTRODUCTION

An electrostatic precipitator (ESP) is a device that will collect the particles and removes it from a flue gas by using the force of an induced electrostatic charge from the transformer rectifier unit which is located at the top of the ESP. Electrostatic precipitators are highly efficient filtration devices that minimally impede the flow of gases through the device, and can easily remove fine particulate matter such as dust and smoke from the air stream. Nowadays these ESPs are gaining importance as to obtain the environmental clearance for setting up of new industrial plants and green environment.

REVIEW OF LITERATURE

Many Research work is being carried out Worldwide in designing the better ESP in terms of their operation, mechanical and electrical design. But there are less research work in order for reducing the tedious electrical erection and commissioning of the ESPs. XU Guosheng et.al, has discussed about the principle and application ofElectrostatic Precipitator [1].Durga Prasad et al., has proposed an automatic control technique and management for electrostatic precipitator [7]. H E Jianet l., has briefly described about the V-I Characteristic Principle of Electrostatic Precipitator [4].

THE ELECTRICAL EQUIPMENTS AND INSTRUMENTATION SYSTEMS FOR ESP

The major electrical and instrumentation system of ESP are described below:

1. Transformer Rectifier Sets: This is used to step up the input AC supply and rectify it into DC supply and feed the positive into the emitting electrode and the negative will be grounded.

2. Controllers: Microcontroller based controllers are used to control the input to the rectifier transformer with SCR .The input for the controller is based on the mA and KV feedback from the field andcontrolsthe firing of SCR further controlling the input voltage to the transformer.

3. Rapping Geared Motors: These motors are used for rapping the dust that is collected in the collecting plates, emitting electrode and inlet gas distribution screens.

There are three types of Rapping motors:

i. Rapping motors for Emitting Electrodes

ii. Rapping motors for Collecting Electrodes

iii. Rapping motors for Inlet Gas Distribution screen

4. Support and shaft Insulator Heaters

5. Hopper Heaters.

6. Thermostat for Hopper & Support Insulator Heaters

7. Dust Level Switches for Hoppers

8. Double Cone Valve Motors

9. Chain Conveyor Motors

10. Zero Speed Switches for Chain Conveyor Motors

11. Position Limit Switches for DCV Motors

12. Position Limit Switches for Live and Earth position status

13. Mechanical Safety Interlocks

14. RTD & Temperature Transmitter at ESP Inlet & Outlet

15. Pressure Transmitter at ESP Inlet

16. CO Analyzer at ESP Inlet duct

17. PLC and SCADA system with HMI (Human Man Interface) Screens

The Power and control cable Erection scheme is illustrated in the figure1 of the Existing ESP.

OVERCOMING THE ERECTION CHALLENGES OF PRESENT ESPAND BENEFITS OF PROPOSED SMART ESP

The erection challenges that are faced in the present ESP isthat the location of the Transformer Rectifier set is on the top of the ESP which is approximately 36 meters above the ground level. So cable tray work and cable laying is to be carried out form the substation where the respective panels are kept to the transformers and motors. Hence the total power and control cables length required will be up to 20 kilometers. Thus a new concept of smart ESP equipped by wireless means with Zigbee Technology arises. As all the erection work is to be carried out in several heights above the ground level there are many safety concerns related to it.

Some of the Benefits of the smart ESP from the present ESP areexplained below:

1. Reduction in the Quantity of Control Cableand Perforated Cable Trays:The total length of control cables used for erection will be around eight to nine kilometers as the location of the Transformer Rectifier is on the top of the ESP which is approximately 36 meters above the ground level.Thus a concept of new Smart ESP where the length of the cable can be reduced to 300to 400meters as loop cable is only required inside ESP. Thus a huge cost reduction occurs in the total project.

2. Reduction in the Erection cost for cable Trays and Cable Laying: The Electrical contractor will cost huge amount for the erection of the cable trays and cable laying as because of the height in which the work is to be carried out. If the Smart ESP is introduces the cost for cable laying and the perforated cable tray work can be reduced.

3. The Erection and time saving: Inturnkey projects the time for completion of the project will be too short. As the smart ESP is introduced the time can be saved in the electrical erection of cable tray and cable laying. It can also save the commissioning time of the total work.

4. Control Cable Ferules and termination work and making Commissioning easy:As the control cables used is reduced drastically in the smart ESP, the ferules and the cable termination work is reduced. During the time of commissioning the number of Inputs and Outputs and loop checking for PLC can be reduced as the Zigbee transceiver is used.

5. Safety Concern:The major erection challenge that faced is the height in which labour has to work in order to carry out the erection of the cable tray work and then the cable laying. The safety factor is to be considered as more caution as there is a more prone to accidents .So by the concept of smart ESP the erection work and control cable is reduced.

THE POWER AND CONTROL CABLES SCHEMES FOR THE PRESENT ESP AND PROPOSED SMART ESP

The major electrical equipments in the ESP are the Transformer Rectifier Sets and The rapping motors. The Power and the Control cable for the present and the proposed smart ESP scheme is illustrated below in the figure 1 and 2. In the Present ESP control cables is to be laid to the LCS(Local Control Station) in order to control the rapping motor.There will be around two emitting rapping motors and one collecting rapping motors and two gas distribution rapping motors in the field 1 of the ESP .The field wise configuration of ESP is shown in the table 1.

The Equipment wise control cable requirement is given in table 2 and the number of control cables and the approximate length can be saved.

A. ILLUSTRATION OF THE POWER AND CONTROL CABLES SCHEMES FOR THE TRANSFORMER RECTIFIER UNITS AT THE ROOF TOP OF ESP

The power and control cable schemes for the Rectifier Transformers in the present and proposed ESP is illustrated in the figure 1 and 2respectively. In the proposed Smart ESP, instead of the Control cables the signals can be transmitted using Zigbee Transceiver. The Loop control cable will be used in order to connect to the Zigbee transceiver. Another Transceiver is located in the substation and it will be connected with the respective control panel.

B. ILLUSTRATION OF THE POWER AND CONTROL CABLES SCHEMES FOR RAPPING MOTOR

The Power and control cable schemes for the Rapping Motors in the present and proposed ESP is illustrated in the figure 3 and 4respectively. In the proposed Smart ESP, instead of the Control cables the signals can be transmitted using Zigbee Transceiver. The Loop control cable will be used in order to connect the LCS to the Zigbee transceiver. Another Transceiver is located in the substation and it will be connected with the respective motor control panel.

CONCLUSION

The Proposed Smart Electrostatic Precipitator Model can save a huge cost in the ways of saving the Control cables used, the erection cost for the cables, cable trays. It also saves a lot of commissioning time and the time for completion of the project time.The erection challenges that are faced in the present ESP are overwhelm in the proposed smart ESP. The tedious task of Control cable feruling and termination is reduced in the proposed Smart ESP.

Tables at a glance


Table 1	Table 2

Figures at a glance


Figure 1	Figure 2	Figure 3

Figure 4	Figure 5	Figure 6

References

XU Guosheng, XU Libo “Five Stages Electrostatic Precipitator Principles and Application” 11th International Conference on Electrostatic Precipitation,Hangzhou, pp 70-72, 2008.
United States Environmental Protection Agency (EPA) “Operation and Maintenance Manual for Electrostatic Precipitators” EPA/625/1- 85/017 September 1985
S. Jr. Oglesby. Tang Tianyou Translating, Electrical Precipitator.China Water-Power Power Press. 1983.
H E Jian, XU Guosheng, YU Guoqiang “V-I Characteristic Principle of Electrostatic Precipitator” 11th International Conference on Electrostatic Precipitation,Hangzhou, pp 370-373,2008.
YU Fusheng, HAN Xu, LI Xionghao, HAI Jiang, DU Rongli, LI Zaishi,“Study on Improving the Performance of Electrostatic Precipitator in the Large-scale Semi-dry Flue Gas Desulfurization System”,11th International Conference on Electrostatic Precipitation,Hangzhou, pp 527-530, 2008.
Benmabrouk. Zaineb, Ben Hamed. Mouna,Lassaad. Sbita“Wireless Control for an Induction Motor”,International Journal of Electrical and Electronics Engineering, vol.5,no. 1, 2011.
Durga Prasad,Lakshminarayana, T. ; Narasimham, J.R.K. ; Verman, T.M. “Automatic control and management of electrostatic precipitator” Industry Applications, IEEE Transactions, vol.35 ,no. 3