Operating Manual For ESP Operation and Maintenance

Operating Manual
for
ESP Operation and Maintenance
Shanghai Metallurgical & Mining Machine

Manufactory
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Preface
Management and maintenance are essential to the stable and efficient
operation of electrostatic precipitators(ESP). In this regard, we must
establish a perfect scientific management mechanism so that ESP can
give play to its best de-dusting performance in a relatively long period of
time. Displaying its best de-dusting performance means that ESP can
maintain its best quality and minimum problems will appear.
1. Operation of ESP
As for ESP, special personnel on duty should be arranged, personnel on
duty should have the basic knowledge of elementary electrician and ESP
worker. After passing safety regulations and operation procedure test,
they are qualified for work.
The main responsibility of ESP personnel on duty is to regularly know the

equipment load, inspect the flue gas temperature, as well as whether the
heating system of the insulting room is normal. They should also inspect
the rising temperature of the motor, the lubrication of the gearbox, the
hopper situation, as well as whether different kinds of rapping devices
can work normally. Furthermore, they should inspect or adjust secondary
voltage and current value in the operation cabin so as to make them work
in the best way. Field voltage, current and other related parameters should
be recorded according to the time requirement. Different bugs happening
on the equipment should be analyzed and eliminated.
In terms of high temperature, high dew point ESP containing flue gas
clearing, in order to prevent dewing and corrosion, we should pay
particular attention to whether there’s something wrong with the heat
insulating layer of the equipment, whether the manhole door is tight. In
the meantime, the electrode and insulator should be kept clean.
1.1 Test and inspection before commissioning

Before putting into use, according to related standards and regulations,
test and inspection should be conducted on newly-installed or overhauled
ESP. The inspection mainly includes:
(1) Go through all the procedures of the work bill and remove the safety
facilities concerning the inspection. Guard bars and index plates
should remain.
(2) The equipment and components are complete and the symbols are
clear and correct. Tight faying surfaces, complete insulation and ample

lighting should be available.
(3) The motors are wired, the earthing wire is fixedly connected. The
safety hood should be installed and has no collision, as well as contact
with the rotation part.
(4) Discharging and collecting rapping devices, dust discharging valve,
screw dust discharging machine and other rotation equipment work
normally. The oil quality of the gear box is qualified and the oil
position is normal. Oil should be added to the driving chain so that
chains can move flexibly.
(5) All the meters, switches, protection devices, regulation devices,
temperature test devices, alarm signals and indicating lamps are intact,
complete and normal.
(6) The heating device of high voltage insulation bushing room and
hopper heating device are intact.
(7) The high voltage rectifier device is clean, it is the same with insulation
parts. There’s no oil leakage in the rectifier transformer and resistor.
The oil quality is qualified and the oil position is normal. The lead
wire of the rectifier device has a good contact ability and the buffer
resistance is intact. The rectifying control cabinet and the automatic
regulation device are intact. The adjustment button or knob is
complete and the instruction is correct.
High voltage isolating disconnecting link should have a good contact
ability. The operation mechanism is flexible and can be earthed
reliably. The disconnecting link is in the earthing position.
(8) ESP’s high voltage cable lead-in cabin is clean. Lead-in wires have
good contact ability and the buffer resistance is complete.
(9) All the switches and disconnecting links of the low voltage distributor
work normally. All the power insurance and operation insurance are
intact.
(10) When confirming that silicon controlled plates, heating and rapping
devices switch off, we will power the above equipment.
As for the breakdown or failure, generally, we will inspect the rotation
part or the failure part. After confirming that it is normal, it can be put
into use.
1.2 Switch on ESP

Before switching on the ESP, we should confirm that there’s no person in
the ESP. The manhole door is closed and there’s no person in the high
voltage area. High voltage isolating disconnecting link is put in the
operation position.

Switch on the heating device 4-8 hours in advance. Heat the porcelain
through insulator, column insulator and electromagnetic shaft so as to
prevent dewing and creepage.
Switch on the hopper heating equipment and remove the moisture on the
inner wall of the hopper.
Switch on the rapping device of the ESP collection electrode and
discharging electrode. Remove the dust particle attached on the electrode.
Switch on the main blower fan to preheat and dry the electrode system of
the field.
Switch off the earthing device and put high-voltage power in.
Refer to drawing one for the operation procedure of ESP
Operation starts
Switch on the distributor
Switch on the heating power of the insulator
Close the door of the inlet and maintenance
Switch on the dust particle discharging and

treatment device
Switch on the rapping device of the discharging electrode
Switch on the rapping device of the discharging electrode
Switch on the collecting electrode rapping

device
Switch off the earthing device
Actuate the air blower

Judge whether the treatment of flue gas is normal
Switch on ESP
Automatic manual( commission)
automatic or manual
Transmit DC HV to ESP. And then it transmit DC voltage to ESP set

can work automatically. voltage manually
End
Table 1 Operation procedure of ESP
1.3 Operation and inspection of ESP

ESP works under high temperature and poor process condition full of
corrosive gas. Sometimes the flow, pressure and concentration of flue gas
fluctuate, flue gas contains sticky tar substance. Under such kind of
conditions, in order to prevent the decline of de-dusting efficiency, we
must often inspect the equipment operation condition and solve problems
in time.
After the newly-installed or overhauled ESPs are put into use, a
characteristic test under the load condition will be given. Record the
primary and secondary voltage, current, conduction angle and flash
situation. Draw C-V characteristic and determine the optimum parameter,
make some adjustments until it can work under the best condition.
During the operation process of ESP, we should monitor whether the HV
rectifier control cabinet, the meter of the console, as well as the indicating
lamp are normal. In the operation, every 2 hours, we record primary and
secondary voltage, current and conduction angle. On each shift, we
conduct 2 regular checks and make records.
(1) Inspect the equipment in the low-voltage switchhouse. It’s supposed to
5

have no overheating, discoloration, burning odor or oil leakage.
(2) Oil colour and oil position of the rectifier transformer are normal and
so is the oil temperature of the transformer. The highest temperature
shouldn’t overpass 85°C, silicon gel doesn’t change its colour.
(3) Buffer resistance is intact and there’s no discharging phenomenon
There’s no evident discharging on the top of HV rectifier transformer,
high voltage isolation disconnecting link, DC HV lead-in wire, linking
wire and ESP.
(4) The temperature in HV cabinet can’t overpass regulated temperature.
If it does so, switch on silicon-controlled ventilator.
(5) During operation, people are not allowed to enter the HV room with
electricity or open the high-voltage insulating room cover for
inspection
(6) ESP, pipe and manhole doors are tight
(7) The hopper and hopper heating device work normally and no dust
blocking or dust leakage happens. The rapping device and other
rotation equipment work normally
(8) The heating device of the HV insulating sleeve and the thermometer
are normal
(9) All the protection covers and service platform lighting of the motion
parts should be kept in a good state
(10) Oil should be added to the rotation equipment based on the time
requirement and the oil position is normal
Refer to drawing 1 for the times of checking and checking position of
ESP
Drawing 1 Checking position and time of ESP
Item Checking Times of Normal state Special

position checking treatment
Chimney Flue gas 2 times/day No Inspect each
discharging concentration position
increase
Rapping Driving and 3 times a day Normal Inspect each
device rapping rapping position
system
Casing Each part on 1 time a day Manhole is Sealed with
the case tight and no asbestos
wind leakage rope
no dislodging repair
6

of heat
insulating
layer
No wind repair
leakage of the
flange inlet
No corrosion repair
of the roof
plate
Power Secondary 3 times a day Work voltage Inspect
part current of corona and power
current supply
voltmeter 1 time a day Conform to
regulated
value
Insulator 1 time a day No broken Change parts
line in the Inspect the
electric heater wind
The air machine
heating pipeline
system is
normal
During operation, if we find any deficiency, we should fill in records and

inform the maintenance staff in time, as for serious deficiency, we should
immediately report it to the person in charge, in the meantime, we should
make records.
1.4 Switching off of ESP

When the main frame is switched off, ESP temporarily stops and the field
HV isolating disconnecting link is placed on the earthing position.
After the power cut of the field, the heating device and rapping
mechanism will continue to work until the dust in the field is cleaned
The dust in the hopper should be cleared instead of being emptied
completely.
When ESP stops working because of long-term or middle-term overhaul,
we can treat it as temporary machine halting. The rapping device at least
works for 4 hours and then the heating system stops working. Empty the
dust in the hopper. In the field, the earthing rod is added and the site is
kept clean. Make records of the machine halting.
7

Refer to drawing 2 for the machine halting procedure
Stop operation
The air blower stops working
Close the flue valve
The rectifier stops working
The earthing device is earthed
Stop the discharging electrode rapping
Halt the collecting electrode rapping
Dust discharging device stops
Switch off the insulator heating power

(after the machine halting is over 24 hours)
Close the hopper heating equipment
End
Table 2: Operation procedure of halting the machine
2. Maintenance of ESP
With regard to the maintenance work of ESP, besides the regular
inspection on key parts, we must conduct careful maintenance based on
the ESP equipment and the instruction of other mechanical and electrical
products. Furthermore, taking the opportunity of machine halting, we’ll
launch a thoroughgoing inspection on the field and HV control room.
Refer to table 2 for the inspection content. If abnormal situation happens,
treat it timely.
Normal maintenance of ESP includes:
Clear the accumulated dust on the insulation parts;

Lubricate all the driving parts once every week;
Every 3 months, add sewing machine oil to silicon-controlled cooling fan
for 1 time;
Timely clean HV control cabinet and the automatic voltage adjuster,
inspect whether the switch of the contact, coil of the relay, as well as the
contactor are reliable;
Every 3 months we check the resistance and heating components, every 6
months, we check thermometric components for one time;
Once every year, the drier of the respirator in the rectifier transformer
should be changed;
Once every year, an oil pressure test of the rectifier transformer should be
conducted . The average breakdown value is higher than 35KV/2.5mm;
The earthing resistance of ESP should be tested each year(not higher than
4Ώ).The rectifier transformer earthing and electric control earthing
resistance are not larger than 1 Ώ;
If ESP stops working for a long time, we need to take measures to prevent
rust in the field. The rapping device should be switched on often so as to
prevent the hammerhead and connecting rod from rusting;
We should choose to inspect the case of ESP, case of rectifier transformer
so as to guarantee that no loosing place or serious corrosion happens.
Table 2: Inspection and requirement after halting the machine

Item Inspection position Normal state Special
treatment
Inlet and Dust accumulation No dust Clear inlet and
outlet in the inlet and accumulation, no outlet
outlet pipe, dust adhesion, distribution
straighting vane, even current plate
porous plate
Discharging Polar curve, frame, No local Adjust the
electrode anvic, hammerhead thickness, no rapping device
broken wire or and change
burning. There’s broken wires,
no frame adjust and
transformation, no change
dislodging of rapping
hammerhead. components
Collection Polar plate, girder, No local dust Adjust the
electrode shocking bar, anvil, accumulation, no rapping device
hammerhead bending of and clear the
9

shocking bar and dust.
polar plate. The Straighten,
difference adjust, and
between change
electrodes are components
precise, no
dislodging of the
anvil
hammerhead, no
corrosion or rust
Rapping Driving device, Accurate rapping, Adjust and
device rapping shaft, normal change worn
hammerhead, mechanical components
bearing suspension structure
Hopper nozzle No dust, no dust Clear sticky
particle dust, repair
accumulation, no the hopper
dislodging of heat
insulating layer
Insulating Porcelain through No sticky dust, Clean and
room insulator, porcelain creepage, change broken
insulator, heating breakdown parts, clear the
parts phenomenon dust and seal
Case Pillar, supporting No Shaping,
side wall plate transformation, adjustment
the support repairation
doesn’t shift
greatly. No wind
leakage, no
dislodging of the
heat insulating
layer
Earthing Earthing electrode, Earthing Take remedial
system earthing bus bar, resistance doesn’t measures or
earthing main overpass the repair
original value and
no broken wire is
found
Power device HV rectifier The operation is Inspect and
transformer, buffer normal and there add oil.
10

resistance, are no abnormal Change
discharging sound and oil grinding
electricity capacity. leakage. The case armature
High and low is earthed. No contactor or
voltage control broken wire and change, fasten
cabinet, feedback burning can be the earthing
resistance, high found. No noise wire Repair,
voltage sampling exists in the change
resistance, switch. Beating components,
automatic and earthing are repair
pressure-adjustmen good. Feedback switches.
t device, HV resistance, HV
insulation switch sampling
resistance don’t
discharge to the
ground( earthing
wire is
complete).Printin
g plate
components have
normal contacting
points. And they
rotate flexibly.
Motor Rapping The lubrication oil Add or change
of the bearing is oil. Check the
ample and not iron core and
dirty. The coil.
temperature rise
doesn’t overpass
the limit.
Based on the requirement of the usage instruction of high and low voltage
electric equipment, we inspect and maintain the electric equipment.
Maintenance and operation personnel should have their respective work,
in the meantime, they should cooperate with each other.
Refer to table 3 for the respective work of the operation and maintenance
personnel.
Responsibility of operation Responsibility of maintenance

personnel personnel
Operate and inspect Inspection and maintenance of key
11

parts
Daily check Daily check and special inspection
Monitor the check record Handle usual problems
Provide lubrication grease Halt the machine and inspect
Clean and maintain the equipment First-aid
Tackle accidents and make Single task
suggestions related to improvement
Fill in all kinds of records and Preparation of back-up products
deficiencies
Attend equipment grading and Attend equipment grading and
inspect deficiency formulate the inspection deficiency
Halt the machine and discharge the Technical improvement and work
dust innovation
3. Inspection of ESP
Just like all the other production equipment, ESP should regularly be
given short-term, middle-term and long-term overhaul in a planned and
systematic manner. Although the motion components are few and the
equipment life is long, its inner components work with dust particle under
high temperature and high voltage. Therefore, abrasion and electric
chemical corrosion loom large. Some components should be changed
regularly.
ESP’s inspection plan should comply with the inspection period of
production equipment. In the meantime, according to the component life,
bugs and bug-happening frequency, we formulate regular or annual
inspection plans, devise equipment improvement schemes, change broken
parts and know the back-up product quantity and expense budget.
Regular inspection should combine with daily check. If the daily
inspection proceeds well, we can decrease the daily inspection work and
the time interval is prolonged.
A prevention-oriented planned inspection should be conducted on the ESP,
it is vital to prolonging the equipment life, guaranteeing the stability and
highly efficient operation. When it comes to the planned inspection, we
should adhere to “Quality First” policy and implement the spirit of
seeking truth from facts. We should make sure the overhaul work is well
done and the equipment are always in perfect condition.
Refer to table 4 for long-term overhaul. Refer table 5 for short-term and
mid-term overhaul.
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Table 4 Main content of the ESP overhaul
Item Main content
HV power supply equipment 1. Dissembling and inspection of
rectifier transformer
2. Dissembling and inspection of
reactor
3.Insulating oil pressure endurance
test; Test insulating resistance
4.HV isolation disconnecting link
and operation mechanism
5.Cleaning and inspection of HV
lead wire, buffer resistance,
insulation sleeve, heating
components and all the insulation
components
6.Cleaning and inspection of
rectifier transformer, outer part of
reactor, buffer resistance, lead-in
wire, linkage wire and support
insulator in the HV room
7. Preventive test of HV DC cable
8.Cleaning and inspection of HV
control cabinet and components in
the meter control plate, calibration
of meter.
9.Protection and calibration of
rectifier device, inspection of
safety locking device.
the ventilator in the control room.
Inspection of ventilation system.
Low voltage electrical equipment 1. Inspection of low voltage
distributor, verification of
related component constant
value
2. Change and inspection of
rapping and heating distributor
all the motors
4. Cleaning and inspection of
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rapping, dust discharging
system, signal circuit and
components. Inspection and
calibration of the rapping
procedure and self-control
heating components.
5. Inspection of operation and
dynamic cable. Measurement
of insulating resistance
Mechanical part 1. A thoroughgoing cleaning and
inspection of the inner part of
the field
2. Change transformed corroded
collecting plate
3. Change unrepaired and broken
discharging wire
4. Adjust discharging electrode
frame and distance
5. Change or repair the rapping
hammerhead and anvil
the motor and reducer.
7. Abrasion situation of baffler, air
current plate and the inspection
of the erection position
8. Check whether the case and
pipe system have dust, abrasion
and corrosion so as to bring
convenience to change,
repairation and reinforcement
9. Change or repair the dust
discharging system
10. Change or repair the hopper
heating device and the
insulating room wind heating
system
14

Table 5 Main content of ESP short-term and mid-term overhaul
Part Item Inspection content
outside 1.manhole door 1. whether it’s sealed
2. whether it is
corroded
2. rapping and driving 1. lubrication oil
device position of the
reducer
2. whether the reducer
has oil leakage
3. whether the safety
piece is complete
3 hopper dust 1. whether the dust
discharging device discharging is
abrased
2. whether the hopper
has wind leakage
3. whether the dust
transmitting device
is normal
Inner part of the field 1.air current 1.whether it’s blocked
distribution plate 2.whether it’s
transformed
2.distance between 1.whether there’s local
electrodes reduction
2.whether the relative
position of the rapping
hammer and baffle
plate changes
15

3.insulator and 1. whether there’s dust
protection cover adhersion or broken
parts
2. whether the
protection cover is
corroded
Collecting system 1.collecting plate 1. whether there’s dust

accumulation
2. whether it’s
corroded and
transformed
3. whether it touches
the lower baffle
plate
4. whether the rapping
anvil bolt is loose
16

2.rapping device 1. whether the
hammer and anvil
coordinate
2. whether the
contacting point has
evident
transformation
3. whether the driving
of rapping shaft is
smooth
4. whether there’s
excessive abrasion
of the rapping
bearing
5. whether there’s air
leakage
6. whether the rapping
hammer bolt is
fastened
Discharging system 1.discharging electrode 1. whether there’s
increased thickness
broken wire
abnormal
transformation
4. whether there’s any
corrosion
17

2.rapping device Besides the rapping
device of the collection
electrode,
1. whether the
insulation porcelain
shaft has pollution
crack on the
insulation porcelain
shaft
transformation on
the dust resisting
insulation plate
4. whether it’s clean
and heat-insulating
in the insulation
room
Electric part 1.control plate 1. whether the
measurement meter
has deficiency
2. whether the joint is
loose
3. whether the setting
is correct
2.rectifier divice 1. whether the
insulating oil
position complies
with regulations
any broken area in
the HV bushing and
LV(low
voltage)joint
3. whether the joints
are loose
18

3 others 1. whether there’s any
broke area in the
HV switch
insulator, bus bar
supporting insulator
and wall bushing
2. whether the joints
and bolts are loose
3. whether the
earthing resistance
is normal
4. whether the
insulating
resistance is normal
4. Safety and technical regulations

In order to enable ESP to synchronize with the main engine, reduce the
air emission and guarantee the safety of the personnel and equipment,
staff responsible for the operation and maintenance must comply with the
safety and technical regulations of the operation and maintenance of ESP
4.1 Safety and technical regulations of ESP operation

After the erection and overhaul of ESP, trial test work should be
conducted. Personnel responsible for the trial test should peruse the
instruction and related technical information, get familiar with the
equipment property, structure. This should be done in a step-by-step
manner.
(1) Before switching on the ESP, we must inspect different parts of
ESP, after confirming that the equipment works well and there’s
no person in the field and each manhole door is closed, we can
switch on the machine
(2) Four hours before ESP operates, all the insulation heating system
and hopper insulation system should be put into operation first.
(3) When the dust enters ESP, all the rapping device and dust
discharging system should be put into use at the same time. When
the flue gas temperature is higher than the dew point temperature,
it means the field is in normal state and we can offer the field
electricity.
(4) Before switching on the machine, we should enhance our
19

inspection, if any problem occurs, we should handle them
correctly.
(5) During the ESP operation, the automatic voltage adjustor is not
allowed to have arc, as well as adjustment inefficiency, if the
following deficiency happens, we should stop supplying
electricity to the correspondent field. After the deficiency is
tackled, we can reswitch on the ESP.
1) In the operation, primary current overpasses rated value;
2) Flashing phenomenon in the HV insulating component is serious;
3) Buffer resistance flash is frequent and sometimes it causes fire;
4) The rectifier transformer has temperature excursion alarm, oil
gushing, oil leakage and abnormal sound;
5) The power supply device deviates greatly;
6) The current limit is out of control;
7) After 2 times’ trial use, the power supply equipment trips;
8)Controllable silicon radiation fin is over 60ºC;
9) There’s sth wrong with dust discharging valve, dust blocks up the
hopper
10) Changes happen on the main engine and other situations that may
bring harm to the equipment or endanger people
(6) We should record the following content in the operation
Every 1 –2 hours, we record primary and secondary voltage, current
value and operation temperature value of ESP; 1) We record rectifier
transformer temperature twice on each shift; 2) Switch-on and
switch-off record of all the ESP; 3) Abnormal situation and equipment
deficiency record; 4) Assembling and dissembling record of the
earthing wire; 5)record of warning plates
(7) During the operation of ESP, the following should be monitored
daily, if any problems occur, we should handle them timely 1) At
some particular time each shift, the alarming device is tested. 2)
Primary and secondary voltage current value; 3) Rapping,
electricity heating and dust position control system; 4) Oil
temperature, oil colour, discharging and leakage of the transformer;
5) Operation situation of the rapping system; 6) Operation
situation of electric screen, cabinet, box and plate; 7) Controllable
component cooling fan operation, no flash of baffle resistance;
8) There’s good sealing condition of the manhole door, no
dislodging of the insulation layer.
(8) If ESP stops working, we should adjust the field voltage to the
zero position, pull down the general disconnecting link and other
20

disconnecting links. Then close the insulation room, conduct
continuous rapping on all the manual rapping system, stop rapping
after clearing the dust in the polar plate and frame. When we make
sure that the hopper is emptied, we should close the
dust-discharging system, in the meantime, we stop the work of the
hopper heating system and dust transmitting system.
(9) One person is responsible for the operation and another for
supervision. The protection work should be conducted well.
(10) When the ESP is operating, the manhole door is not allowed to
be opened. If entering the field is inevitable, we should cut off the
power first and turn down the air door or stop the induced draft.
(11) To prevent overvoltage, in the operation, HV isolation switch
is not allowed to be opened, under the open-circuit circumstance,
power transmission is not allowed.
(12) When there’s a fire on the electrical equipment, firstly, we
should cut off high and low power supply, water is not allowed to
be used in extinguishing the fire. When a power accident happens,
firstly, cut off the power, then first aid is given, saving other
people single-handedly is prohibited
(13) If the flue gas temperature overpasses the set value of ESP due
to abnormal process flow, we should stop the machine and take
emergent measures. Switch on the machine until the work
condition is normal.
4.2 Inspection and safety regulations of ESP

Stopping of ESP should be conducted based on the stopping procedure,
after entering the field and conducting the inspection, we should abide by
the following regulations:
(1) The control plate and operation plate switch of the HV power
supply device should be cut off;
(2) An inspection plate should be hung on the operation plate so as to
avoid switching on wrongly;
(3) HV cut-off switch is connected on the earthing part, discharging
electrode should also be earthed (in the inspection process, it
should always be earthed)
(4) Use a portable earthing rod to release residual electricity in the HV
system
(5) When there’s no power in the field, the rapping device continues
to operate and the dust adhering to the electrode is cleaned, the
hopper dust discharging device also continuously operates until
21

the dust in the hopper is completely discharged
(6) When the field cools off step by step,( the cooling time is not less
than 8 hours), the manhole door is allowed to be opened, or the
sudden entry of cold air easily leads to the plate transformation
under high temperature.
(7) When there are some people working in the ESP, supplementary
equipment(such as the major exhaust blower, rapping system, dust
discharging device) should be locked or an inspection board
should be hung;
(8) Based on the field condition, inspection and maintenance
personnel should wear dust-proof cover, dust-proof clothes,
dust-proof shoes and corrosion-proof gloves, as well as other
protection devices to enter the field;
(9) When the hopper is blocked by the dust, the hopper manhole door
is not allowed to be opened and discharge dust
(10) Personnel who enter the inspection and maintenance site
should wear safety helmets. If the falling height is above 2-meter
datum, construction personnel should wear safety belts.
(11) Before entering the field, CO and other toxic gases, treatment
of accumulated dust and gas in the device should be inspected
Drawing 3 is the operation procedure and confirmation items from the
safety perspective, its intention is to guarantee the safety by using
forcible means.
Switch off the operation Judge from the indicating lamp
The switch of the operation plate is

installed at the side of the grounding device
Use the earthing device Judge from the earthing

indicating lamp
Switch on all the earthing Check whether the switch is

device complete
Open the manhole, put the Judge from whether HV

earthing return circuit to the indicator powers off
electric components
22

5. Common factors of abnormal operation of ESP
When abnormal conditions happen in the operation of ESP and if certain
rules can be used, it’s easy to make some judgement. Sometimes, it’s
complicated, in this respect, we need not only experience, but information
and data as well.
As the information of the equipment, on the one hand, ESP operation
record reflects the operation situation of ESP, on the other hand, it is the
basis for analysing the problem, because some general problems in the
operation of ESP are formed on a step-by-step basis. During the operation
process of ESP, if there’s sth wrong with the electrical parameter and
dedusting efficiency, staff on duty should analyse and make judgement
based on these circumstances, they should find possible causes and solve
the problem as soon as possible.
In the ESP operation, refer to table 6, 7, 8 for abnormal phenomenon and
possible cause.
Table 6 Common factors concerning abnormal operation of ESP

factor Abnormal electric parameter Abnormal dust removing efficiency
Because of disruptive Becaus High Low Dedusting Concen Dedusting
discharge, low e of voltage Voltage efficiency tration efficiency
voltage and current inverse Low current High is low is is unstable
corona, current increasing
low
voltage,
great
current
Dust Dust thick thick big change
Condi concentrati
tion on
Flue gas High Relativ High change

temp. temp. ely Temp.
high
Flue gas little little little change
water
content
Grain size thin thin thin
Dust high Very high Very high change
specific high
resistance
23

Equip Electrode little little little
Ment distance
Condi Rapping little little little big
tion strength
Rapping little little little
frequency
Spark Not
frequency Approp
riate
Electric Not appro Not
control priate appropriate
Flue gas Too big change change
flow rate
Table 7. Abnormal phenomenon and its cause in the dynamic part

phenomenon cause
The fuse of controllable silicon Abnormal transformer causes
rectifier is broken overcurrent
Thermo relay action Setting button of overload and limit
current is excessively operated
Open the HV switch plate Wrong operation
Close HV switch Wrong operation
The fuse of controllable silicon Fan problem
rectifier fan is broken
The fuse of the dynamic part Fan problem
control plate fan is broken
Return circuit fuse of the Wrong operation of controllable
controllable silicon rectifier silicon rectifier
secondary short circuit is broken
Table 8 The reason why there’s no power or the voltage is lowered

phenomenon cause
Discharging wire is broken 1. Wrong erection( it appears
within 1 to 2 months after the
erection, it may not appear later)
2. It breaks due to
fatigue( vibration, corrosion)
24

3. Accumulation of dust( too much
dust accumulation, disruptive
discharge is violent)
4. Foreign particles’s entry( tools,
foreign particles or too much
dust on the top falls down)
The insulator is polluted and wet 1. The insulating room is rusty and
has dust, the surface is dirty and
has electricity leakage.
2. The heater of the insulating
room is broken
3. Condensation water appears in
the insulating room or the
insulating room is wet because
of the water from outside
Change of the electrode distance 1. Deviation of the collection
plate( heat transformation,
wrong rapping and corrosion)
2. Due to wrong erection, the
discharging wire bends
Sticky dust on the electrode surface 1. Rapping motor deficiency
2. Rapping relay deficiency
3. Rapping transmission system
deficiency
4. When switching on the boiler,
ESP is used for too long or the
oil and coal is cooked for too
long
Hopper dust accumulation 1. The heating system on the outer

wall of the hopper is abnormal
2. The dust transmitting system
has deficiency
6. Problem happening on the ESP

There are few components on the ESP so it can operate reliably for a long
time. If we maintain the machine in an appropriate way, no problem will
appear in a relatively long period of time
The failure type of ESP has sth to do with the ESP structure and its way
25

of use. According to the research from related department, the most
common operation failure of ESP is the broken discharging wire, which
accounts for 68% of the researched objects, the causes of the failure
mostly are mechanical fatigue. It is caused by frequent local disruptive
discharge or corrosion. Another opt-happened failure is on the rapping
part, standing at 40% of the researched objects. Furthermore, insulation
failure and short circuit failure account for 28% respectively, the hopper
failure 24%, transformer rectifier 20%. Refer to table 9 for failure percent
of different parts.
Table 9 Failure percent of different parts.

Part description Failure percent
Rapping failure in the field 32
Dust discharging valve 18
Control cabinet 14
hopper 6
others 30
The rapping system failure is mainly caused by the error from the
transformation of structure pieces due to the heat in the erection and
operation
The failure of ESP relates to its design, manufacture, erection and
operation conditions. Most importantly, when problems happen, we
should find the cause and solution
6.1 Typical failure and its analysis

The life of ESP relates to its design and work conditions, the depreciation
period generally is over 20 years. The failure type and failure frequency
vary because of different work conditions, but the main component
failure and its cause are as follows
6.1.1 Failure of the discharging electrode

(1) Broken discharging wire. Broken discharging wires have multiple
causes. For instance, aging causes discharging electrode to have
no enough strength, electric corrosion, deficiency in the erection
and construction work and too much rapping force are also the
culprit. Because there are sth wrong with the flue gas and dust, the
supporting component of the discharging electrode is corroded
and then its usage life is shortened. High specific resistance leads
to inverse corona. When the rapping is conducted repeatedly and
26

the discharging electrode vibrates, the hammer and discharging
electrode are running and its contacting position will give rise to
electricity corrosion.
Broken electric wire means the collection electrode has burrs. The
discharging electrode vibrates and shortens the electrode distance,
which leads to the local field strength increase. The discharging wire
is broken because of the disruptive discharge. Electric corrosion will
happen after ESP is operated for years.
(2) Thickness of the discharging electrode. Outside dust particle
thickness of the discharging wire concerns the property,
concentration, vibration force and rapping mechanism of the dust
particle. In the field, positive electricity adheres to the discharging
wire and a membrane is formed. Because of inefficient rapping
dust clearing and accumulated dust, the discharging wire is thick.
When collecting high specific resistance dust particle, the corona
current will decrease, corona discharge diminishes and disruptive
discharge increases
Based on the above circumstance, we should adjust the rapping force,
readjust the rapping time and rapping period.
If the electrode’s thickness is caused by the flue gas below the dew
temperature or frequent switching on or off the machine, please improve
the insulating measures and power supply. Before the flue temperature
falls down to the dew point, clear the dust of the continuous electrode
rapping. Continuous rapping is conducted within several hours of
stopping the machine.
6.1.2 Failure of the collection electrode

Failure of the collection electrode mainly includes:
(1) Dust accumulation of the collection electrode. Just like the
thickness of the discharging electrode, local dust accumulation of
the collection electrode will reduce the discharging property and
the collection efficiency will be lowered. Local dust accumulation
relates to the nature of smoke, dust concentration, as well as
rapping conditions. The major cause is no enough rapping force or
uneven rapping force distribution. Sometimes, it’s because of the
loosing of the connection bolt on the collection plate or inefficient
rapping force transmission. And then we need to enter the field to
ascertain the reason.
(2) Transformation of the electrode plate. Transformation of electrode
27

plate makes the electrode distance have some changes. The reason
is that the flue gas temperature is high, the electrode plate is
transformed due to some limitation. Or accumulated high
temperature dust cause thermal storage and then transformation
occurs; or the flue gas temperature overpasses regulated
temperature value; or the breakdown arc inside the electrode plate
transforms the electrode plate. If it is due to the redundant polar
plate room or erection problem, when the electrode plate is
transformed because of the flue gas, its phenomenon is that the
voltage can reach the rated value, when smoke appears, voltage
will drop with the rise of temperature. When we stop providing
flue gas, the voltage will rise little by little. This kind of failure
will appear on the ESP which is newly put into use. If the local
transformation is caused by thermal storage and arc, we need to
ascertain the reason and change transformed electrode plates and
solve the problem from adjusting the electrode distance or
improve the rapping system.
6.1.3 Failure of the rapping device

Use hammer rapping for ESP, the transmission part is on the outside of
ESP, the rapping hammer is in the field, the failure of the rapping part can
be judged according to the change of the secondary voltage or rthe
decrease of the dust removing efficiency. As for the discharging electrode
rapping, if there’s sth wrong with the insulation part, the whole field can’t
work, this situation will immediately be detected, but if an individual
hammer fails or breaks down, we can’t find it until it is inspected.
Major failures of the rapping and transmission devices include the
following:
(1) Shaft locking. Main causes for shaft locking are:(1) the supporting
shaft of the rapping shaft has a serious abrasion.(2) rapping shaft
bearing is not on the same line and it overpasses the compensation
ability of coupling and affects the concentricity of the rapping
shaft.
(2) During the operation, the hammer and rapping anvil is not aligned.
Besides the erection problem, most are caused by the heat
inflation of the rapping shaft and ensuing rapping hammer
dislocation
(3) The rapping and transmission porcelain shaft of the discharging
electrode is broken. Firstly, it’s the porcelain shaft quality problem,
before erection, we should strictly inspect it. If the porcelain shaft
28

has no certificate, or has cracks on the surface, it shouldn’t be
used. During the trial run, we should timely re-inspect. Secondly,
the rapping shaft torsion is too big, furthermore, there are other
factors concerning excessive leakage current or breaking of the
uneven heating of porcelain shaft caused by the dust accumulation
and dewing.
6.1.4 HV insulator
Mechanical failure easily happens on the HV insulator. Furthermore,
when HV insulator adheres to the conductive dust, it loses its insulation
property and evokes the reduction of ESP efficiency. If dust adheres to the
insulator in an all-round way, the leakage current increases, the corona
current needed for dust removing will decrease. If the adhered dust is not
distributed evenly, it will get hot because of local current increase and
then, the insulator greatly lowers its insulation ability and the inner part
of the insulation bushing will have the state of flashing. This is the main
cause for the accident. Another accident is dewing and creepage, it is
caused by great humidity, low temperature of the dust, inappropriate
heating , no heating facility, as well as the accumulation of condensation
water on the insulator. Thirdly, the erection of insulator is not level, then
the whole discharging electrode has uneven load and it may cause the
breaking of the insulator.
6.1.5 Power supply part

Based on the equipment, major problems of the supply part include the
following
(1) Rectifier transformer:1) the conservator of the equipment is small,
and it will gush oil when the temperature is 60ºC .2) Outdoors, as
for the rectifier transformer, in summer, the oil temperature rise is
frequent due to insolation or bad ventilation.3) oil leakage of the
transformer.4)the rectifier transformer inner coil, silicon series
string, voltage sharing resistive-capacitive components fail
because of open circuit, short circuit and arc
(2) HV power supply:1)controllable silicon is burned, generally in
summer, this problem looms large;2) the fan of the HV control
cabinet shaft frequently fails, most of them are bearing problems.3)
buffer resistance is burned, some companies use porcelain buffer
resistance.4)AC contactor in the HV control cabinet abrades
because of spark dust, the iron core surface is not flat, and the
vibration noise is loud
29

(3) Low voltage power supply: Programmable controller is used for
rapping control, some failures will happen due to high work
environment
6.2 Electrical failure

There are several kinds of electrical failure
6.2.1 Controllable silicon of booster rectifier is not conducted or the

controllable silicon fuse is broken
Phenomenon:
(1) The alarm sounds, the trip indicator lights, rectifier trips
(2) When it restarts, no voltage for 2 times, “ manual” or “automatic”
voltage boosting has no effect
Cause
(1) The adjustment circuit has problems and the control electrode has
no voltage
(2) Controllable silicon fuse has bad contacting
(3) Controllable silicon fuse is little or voltage booster rectifier
transformer has problems on the side circuit.
Treatment
(1) Reset the alarm check or change the fuse
(2) If it is not the fuse problem, please inform the inspection team for
treatment
6.2.2 Voltage boosting rectifier controllable protection component or

controllable silicon breakdown
Phenomenon
(1) Voltage boosting transformer has abnormal sound, it has loud sound in
the starting and operating process, and the transformer vibration can
be detected.
(2) The alarm sounds, the trip indicator lights and contactor trips
(3) When it is restarted, the primary and secondary voltage rise quickly
and overpasses the normal value, in the meantime, it flashes and trips
Cause
(1) Resistive-capacitive absorption components have problems or
controllable silicon doesn’t have a good quality.
(2) Primary return circuit has overvoltage
Treatment
After the reset alarm, inform the inspection team
30

6.2.3 As for the controllable silicon of voltage boosting, one can be
conducted and the other can’t be conducted.
Phenomenon:
(1) After switching on the rectifier transformer, the primary and secondary
voltage and current show abnormal sign and the hand sways
(2) There’s abnormal sound on the voltage boosting rectifier transformer.
With the current swaying increases, “ keng” sound is heard
Cause:
(1) There’s sth wrong with the adjustment circuit
(2) A controllable silicon control link circuit
Treatment
(1) Immediately stop the operation of rectifier transformer
(2) Inform the inspection team
6.2.4 High voltage DC return circuit open circuit

Phenomenon
(1) After the starting of rectifier transformer, the primary and secondary
voltage rapidly rise, but the primary and secondary current have no
indication
(2) During the operation of the rectifier transformer, the primary and
secondary voltage are normal, but the primary and secondary current
have no indication, the rectifier transformer trips
Cause:
(1) High voltage isolation switch is not on the proper position
(2) High voltage return circuit’s resistor is burned
Treatment
(1) Stop the operation of rectifier transformer, switch off the isolation
switch and then start it according to the regulation
(2) Repair it timely
6.2.5 Breakdown of silicon series components in the voltage boosting

rectifier transformer
Phenomenon
(1) After starting the rectifier, the primary voltage is low, primary current
is high and amounts to rated value. Secondary voltage can be adjusted
to 30kv and secondary current is low too.
(2) In the operation of rectifier, the above phenomenon happens, the
temperature of the rectifier transformer thermometer is higher than the
original and the oil position rises or overflows from the oil-adding
hole.
31

Cause:
Break down of one or two silicon series string components, which makes
one coil of high voltage have short circuit.
Treatment
Because low-voltage protection can’t be used, if oil temperature
abnormity and temperature protection failure can’t be found or they are
not put into use for long, the rectifier transformer may be burned or even
fired, we must stop starting or operation, inspect the transformer and
inform the inspection team.
6.2.6 Tripping of the voltage boosting rectifier transformer

Phenomenon:
(1) The alarm sounds and the tripping indicator lights
(2) When it restarts, the voltage can’t rise or the voltage rise to a certain
degree and it trips
Cause
(1) High voltage direct current (including field inner plate line) has
permanent breakdown point or short circuit point
(2) Rectifier component failure
(3) Full hopper dust makes the discharging and collecting electrode have
short circuit
Treatment
(1) Reset alarm and inspect the equipment
(2) When it belongs to the above (1) (2) reason, inform the inspection
team, when it belongs to the (3) reason, treat the dust system and
remove accumulated dust.
6.3 Equipment failure

From the view point of decrease of dust removing efficiency caused by
the equipment failure, the biggest influence comes from the earthing short
circuit. If a short circuit happens, the field can’t offer electricity and then
the dust removing function stops.
Earthing short circuit has complete and incomplete short circuit. As for
incomplete short circuit, the voltage and current greatly decrease, a little
increased voltage will result in flash
Short circuit of the field is: Flash, overcurrent and arc occur at the same
time, low voltage trips and an alarm is heard. If the power supply has
problems, generally, overcurrent protection works, high voltage trips and
32

the alarm is heard. Controllable silicon, resistor, electric capacity,
transistor, transformer, destruction of silicon series string, rapid fuse
burning all belong to the electric device failure, inspect silicon series
string transformer and open circuit is prohibited.
Refer to table 10 General for the cause and treatment of ground short
Circuit
Short circuit cause treatment

Complete short circuit 1. The discharging 1. Remove bad
electrode failure, discharging
it contacts the electrode
collection 2. Inspect
electrode and insulation
other earthing protection
components heating
2. The insulator has equipment,
no good Clean air
insulation, blowing
especially failures equipment
are caused by 3. Discharge
the insulator the dust in
protection heating the hopper
equipment, clean 4. Remove the
air blowing materials
equipment ,which causing
makes the short circuit
insulator surface 5. Discharge
dew and causes the cable and
spark flash cable head.
3. Too much hopper Inspect the
dust insulation
accumulation, it resistor. It
links the must be over
discharging 1000MΩ
electrode
4. The dislodging
rusty iron
contacts the
33

discharging
electrode
5. HV cable or HV
cable head
doesn’t have
good insulation
Incomplete short 1. Broken line of 1. Remove the
circuit or flash discharging broken
electrode, it discharging
sways in the flue electrode
gas and has no 2. Clean the
complete contact electrode and
with the earthing readjust the
components, the rapping force
output voltage 3. Ditto
meter and imput 4. Identify with
current meter of item 5 which
the operation is completely
plate vibrate short circuited
periodically 5. Inspect
2. Dust adheres to insulation
the discharging resistor
and collection 6. Remove short
electrode and circuit piece
forms thick
accumulation,
the electrode
distance
becomes
narrower and
flash happens
3. Partial dust
accumulation is
formed and
excessive flash
happens
4. High voltage
cable and high
voltage cable
leakage
34

5. The insulator has
no good
insulation
6. Dislodging of
iron pieces and
iron rust, it
contacts the
earthing side
6.4 Analyse the failure based on the meter

The failure of the ESP is caused not only by itself, but also by the
treatment of flue gas. The complexity of flue gas gives rise to the
diversity of the ESP failure. On the surface, some failures looks exactly
the same, but actually, they are quite different, some failures of the same
type vary due to the failure degree or work condition. Recently, through
long time’s observation and practice, China’s ESP technical and
management staff have summarized some methods in analyzing the ESP
failure.
6.4.1 Primary and secondary voltage meter and current meter have
no indication
(1) The major return circuit contactor can’t work. The major reason is:
safety interlocking plate, contacting position of HV isolation switch
block device isn’t closed, the starting return circuit is switched off, the
control core of the return circuit is broken or has poor contacting. The
automatic voltage adjuster trips inside, the relay contacting point can’t
be released
(2) Although the main return circuit can’t operate, when “manual” or
“automatic” is conducted, there’s no voltage but increase of current
Main reasons:
(1) The automatic voltage adjuster has no current. At this time, primary
and secondary current are both zero, but there’s 50V primary current, 8kv
secondary voltage( they are called starting leakage voltage). Controllable
silicon conduction angle has zero setting.
The most common reason why A type power supply device has no power
is because the supplementary power supply device has not a good
contacting ability, this contactor is designed according to the general low
voltage control return circuit. The actual connection and disconnection
automatic voltage adjuster has a work voltage of 23V, because of the low
voltage, it’s easy to get bad contacting.
35

D type power supply contactor is linked in the 220V control return circuit,
which makes the automatic voltage adjuster greatly decrease its power
failure
One simply way to adjust whether automatic voltage adjuster has no
power is to press the flash button, it the adjuster has power, the flash
indicator should light
⑵ The fuse or rapid fuse of the major return circuit is broken. Under this
kind of circumstance, the primary and secondary current is zero, drain
voltage can’t be seen, controllable silicon conduction angle is 100%.
Controllable silicon conduction angle’s indication comes from the
number of trigger pulse input of the voltage adjuster, because the major
return circuit switches off and no secondary current is feedbacked on the
automatic voltage adjuster, according to the principle of automatic spark
tracking, the output pulse increases to the utmost. Understanding 100%
conduction angle will contribute to our quick judgment on the failure.
6.4.2 Secondary voltage is zero, secondary current has

indication
1. In most cases, there’s a short circuit in the field. Main characteristic of
this is:
(1) When it is used in the field, secondary current will rise following
secondary voltage, there’s no turning point of discharge inception
voltage.
(2) When it is started, the starting primary and secondary drain voltage
don’t exist.
(3) The field doesn’t have flash, each voltage and current meter doesn’t
sway up and down
(4) In secondary current, after short circuit, primary current decreases. As
for the field working in the state of flash, after the short circuit,
secondary current rises and is limited to the current limit value, and
then primary current rises.
(5) For the field with relatively little secondary voltage and current,
because of secondary current increase and rectifier transformer high
impedance feature, primary voltage rises, in the field where secondary
voltage and current are great or current limit value in the automatic
voltage adjuster is relative little, primary voltage decreases.
(6) Use 2500VMΩ meter to measure the insulation situation of the field,
if it is below 10MΩ or zero.
Common causes of the complete short circuit of the field
The full hopper causes short circuit, metal short circuit in the field or the
36

insulation components are broken down.
2.Incomplete short circuit of the field. When the field increases its voltage,
secondary voltage rises step by step, when it attains certain value, it is
broken down to zero, the current rapidly rises and is limited to the limit
value of current. At this time, the field parameter is like the complete
short circuit of the field. Stop using “ manual decrease”, when primary
voltage lowers to a certain value, secondary voltage resumes to a certain
value. This field has started drain voltage, use 2500 VMΩ to measure the
insulation situation of the field, the data depends on the reason of
breakdown, but it is not zero.
The common cause for incomplete short circuit of the field: There are
foreign particles existing between the discharging and collecting
electrodes; Hot bloating of the plate makes the distance of discharging
and collecting electrode nearer. The insulator is polluted seriously.
3. Secondary voltage measures return circuit failure or the meter failure.

The parameter is different from that of the field short circuit, we can
compare the parameter situation of the short circuit with the field in
the same situation, analyse whether there’s a real short circuit or false
short circuit on the meter. If it belongs to the failure of secondary
return circuit, D-type power supply device will trip because of the low
voltage delay
6.4.3 Low secondary voltage

Because of the decreased load, the field characteristic curve changes, in
the relative low voltage value, secondary current has attained the current
limit value. When it is used in the first and second field, dust
concentration in the third field decreases and secondary voltage is limited
by the current limit. Under such kind of circumstance, low voltage is
normal. The cause for low voltage failure is:
1. Poor rapping. Bad rapping of discharging and collecting electrodes
cause the decrease of secondary voltage, decrease of secondary current,
increase of the field flash. Common causes are:
(1) The rapping mechanism is locked, generally, it is caused by the
hammer, besides the hammer’s being locked by inappropriate
installation, the hammer’s not being reset after the inspection of
the field is one of the reasons.
(2) Broken fuse
(3) In rapping, the control return circuit fails or rapping period can’t
37

be chosen correctly
(4) Rapping device can’t be installed appropriately, the welding is not
fastened and the rapping acceleration of the electrode decreases.
2. Reversed polarity change in the field. The causes are:
⑴ There are metal pieces in the field
⑵ Structure pieces are transformed in the field
⑶ The polar plate is transformed by heat inflation, heat inflation
enables secondary voltage to have following characteristics when it
decreases
Under the same voltage, if secondary current is high, the more
crooked plates are, the more the current is
In cold position, the voltage rise is normal, in hot position, the voltage
decreases
With the increase of load, the voltage lowers step by step
Open the manhole door of the correspondent field, the voltage can
completely or partially rise.
During the shutdown period, the sign of the hopper air deflector’s
being bent can be seen.
(4) The insulation components are humid and polluted
(5) The power supply device has serious magnetic field deviation
Magnetic field deviation of the power supply device is that AC is
inputted into the rectifier transformer through controllable silicon and
the voltage curve is not symmetrical, as for light field deviation, other
parameters don’t have evident changes except the slight increase of
primary current, the most serious situation of magnetic field deviation
is that there are only positive and negative curve, this voltage is like
DC pulse voltage, at this time, secondary voltage and current are low
and primary current is high and it overpasses rated value. Primary
voltage is 200V in the return circuit induction function, controllable
silicon conduction angle indication is 100%. Because of the field
abnormity, there are abnormal vibration and sound inside the rectifier
transformer, the increase of iron loss and copper loss enables the
rectifier transformer to have a temperature rise. Light magnetic
deviation is because two groups of trigger pulse have asymmetrical
parameters, serious deviation is caused by one group of pulse output
failure or one controllable silicon failure.
6.4.4 Secondary voltage is higher than the normal value

Secondary voltage relates to the erection quality in the field, size of
ESP, flue gas, dust concentration and equipment operation situation.
38

Under the same condition, the front and back field voltage are
different, if we exclude these normal difference, secondary voltage
increase will be caused by the following
1. High voltage return circuit has no good contacting, sometimes it’s
linked and sometimes it’s disconnected. At this time, the field
parameter has such characteristics: Frequent field flash, flash
terminal voltage sometimes is high, sometimes is normal, when
the voltage is high, the current is low or even no current at all. If
this problem can’t be solved, it probably cause complete open
circuit.
Bad contacting is: After several operations, HV isolation switch’s
spring leaf is concave, which makes the link loose or the switch can’t
be used because of the operation mechanism corrosion; The work
earthing line is loose or broken, buffer resistance is burnt but the
broken area is short and is broken down by high voltage electricity,
buffer resistance and discharging wall bushing’s linking position
maybe are loose or burnt.
2. High voltage return circuit is complete open. The characteristic is
(1) When the major contactor is closed, there are high primary and
secondary starting drain voltage
(2) When raising the voltage, primary and secondary voltage rapidly
rise, secondary voltage is 85-100kw, primary voltage is 380V,
secondary current is zero, primary current is less than 10A
6.4.5 Secondary voltage and current are normal, primary

current is high
The main reason is that there are problems existing in the primary
current measurement return circuit or there are problems existing
inside the rectifier transformer.
Inside the rectifier transformer, the place where problems easily
happen is the breakdown of AC HV part or silicon series string. The
most common way to judge whether the transformer has problems is
to use power supply device when the transformer is in open circuit
situation, then, secondary current is zero, primary current will explode
following the rise of primary voltage.
6.5 Common problems and treatment

Refer to table 11 for common problems and treatment of ESP
39

Table 11 common problems and treatment of ESP
Position Phenomenon Cause Treatment
Discharging Broken Remove broken The erection is
electrode discharging line line not good
Improve the Focus on local
process flow stress
Improve the Fatigued
rapping and destruction
shape of the Flue gas
discharging corrosion
electrode
Decrease the
swaying of
frame and
discharging
electrode
Improve the
material of
discharging
electrode
Thick The dust is Improve the flue
discharging humid and gas temperature
electrode sticky Adjust rapping
Not enough frequency
rapping force Increase the
weight of the
rapping hammer
Swaying of Uneven air Correct air

discharging or current current
frame distribution Fix the insulator
Loose
supporting part
Collection Grave local dust Rapping Adjust rapping
electrode accumulation hammer is not device
aligned Ditto
Not enough
rapping force or
failure
40

Leakage of wind Improve sealing
Leakage of rain Block
Deformation of High Adjust rapping
polar plate temperature dust force
collects heat Repair and
Wrong erection adjust
Full hopper Clean the dust
Rapping device Broken fuse Stop using for a Clean and
long time, the reerect
rotation part is
rusty
Erection of the Readjustment
fuse is not
correct
Broken hammer Change hamper
handle handle
The hammer is Limit axis
locked due to dislocation
shaft reason
Excessive Change or adjust
bearing abrasion the bearing
The hammer is Not enough Increase the pin
dislodged strength of the and hamper
hammer handle handle size,
or pin improve its
process flow
Decreasing Excessive Change the

rapping force abrasion of the hammerhead
hammerhead and rapping
and rapping anvil
anvil
Too much dust Dust pile is
and the cleaned
operation is
influenced
The Readjusted
hammerhead
and rapping
anvil are not
41

aligned
Burnt motor Overload Remove the
factor of locking
the shaft or
hammer
HV insulator Mechanical Uneven stress Try to make the
failure Contort machine stable
Adjust the frame
and rapping
device
Deficiency change
Electric Dust Regularly clean

breakdown accumulation and improve the
Surface dewing structure
Erect or repair
the heating
device
Lock the wind
leakage place
Enhance the
insulation room
temperature
Draught fan Vibration of the Dust Regularly clean
bearing seat accumulation in
the impeller is
uneven
Wind machine Adjust
shaft and motor
shaft are not
concentric
Blower fan The gap of the Adjust the gap
bearing bearing is too
increases its big or too small
temperature The lubrication Change
greatly oil is bad or stale
Dust discharging Blocking of the Dust in the Erect the
device hopper and dust hopper is vibrator
discharging accumulated
device Foreign particles Remove
42

enter the hopper
device
Not enough dust Use big volumn
discharging
amount
Lumpy dust Remove
Too little valve Improve the
angle inner structure
Wind leakage of of the valve
the valve Repair the air
Abrasion of the leakage part
valve Change
Inlet part Dust Air current Add baffle and

accumulation in deviates rectifier plate
the inlet pipe Inappropriate Readjustment
erection area of
rectifier plate
Thick dust Clean when it
particles and stops
concentration
Low flue gas Make the tube
speed smaller
Uneven air Sticky dust in Clean or rap

current speed the multi-pole when it stops
plate
Inappropriate Readjust the
design of air spot
current device
Operation plate Secondary Short circuit Remove the
current is high, between the foreign particle
voltage is low or electrodes of the short
even zero circuit between
the electrodes
Inner wall Clean and
dewing in the increase the
insulator temperature of
the insulating
room
43

Porcelain shaft Ditto
pollution or
dewing of the
discharging
electrode
rapping device
Cable or cable Change
head breakdown
to the ground
Dust Remove the
accumulation of accumulated
the hopper and dust
short circuit.
Broken Change broken
discharging wire wire
Secondary The distance Inspect the

current is normal
between the distance
or high, voltageelectrodes is between the
is low smaller electrodes
There are Remove the
foreign particles sundries
between the two
electrodes
The insulator is Increase the
sticky and temperature of
there’s the insulating
electricity room
leakage
Positive voltage Take
appears on the improvement
insulation room measures
Cable Change
breakdown or
electricity
leakage
Secondary Dust Remove
voltage is accumulation is accumulated
normal, current serious in the dust
44

decreases plate and wire
The rapping is Inspect and
not opened or repair the
partial failure rapping device
happens
The corona Analyse the
electrode is thick reason and treat
based on the
symptom
Corona is Decrease the
blocked wind speed and
increase the
voltage
Secondary Broken Cut the

current is not discharging wire remaining
stable discharging wire
The work Obliterate the
condition instable factor of
changes quickly flue gas
condition
The insulation Inspect the
tube or the cable earthing
insulation is not discharging
good place and handle
it on the spot
Rectifier voltage Milliampere Ascertain the

and primary meter and reason and solve
current are electric capacity the problem
normal, failure
secondary Transformer and
current has no milliampere
indication wiring
The hand of the
milliampere
meter is locked
High voltage When the given Open circuit or Inspect the
rectifier potentiometer is short circuit of failure and treat
45

reset, the output the dislocation
voltage is higher winding
than the normal The current Adjust the
value adjustment potentiometer to
potentiometer the appropriate
has position
inappropriate
adjustment or
the voltage
fluctuates
greatly
Adjust the No voltage Inspect the

potentiometer output in the rectifier
and the voltage given power components and
has no change supply potentiometer
Magnet manifier Inspect the
coiling open winding or
circuit or components
component
failure
Saturated core
reactor control
coiling open
circuit
Potentiometer is The voltage is Chang the

adjusted to the too low transformer tap
utmost, the Phase current Adjust phase
voltage can’t can’t be adjusted shift current
meet the appropriately
required level Components Inspect the
failure in the component
control circuit
The magnetizing The voltage of Inspect the

current increases the main return voltage
and saturated circuit is low
core reactor has Negative Inspect the
high temperature feedback circuit circuit
46

failure
Phase shift
control circuit
failure
HV rectifier Short circuit Find the short

trips inside the field circuit or open
Short circuit circuit position
inside the field
Inner failure of Detect the
the rectifier reason
device
Cable Breakdown of Insulation Change

the insulation breakdown of
Oil leakage of the turning place
the cable Inappropriate Repair
treatment of the
cable head
Oil leakage Change into dry
cable
Construction Reconstruct
problem Repair
Sealing problem
Cable problem Change
47

Operating Manual For ESP Operation and Maintenance

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Operating Manual For ESP Operation and Maintenance

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Operating Manual

Shanghai Metallurgical & Mining Machine

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The main responsibility of ESP personnel on duty is to regularly know the

1.1 Test and inspection before commissioning

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1.2 Switch on ESP

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Switch on the distributor

Switch on the heating power of the insulator

Close the door of the inlet and maintenance

Switch on the dust particle discharging and

Switch on the rapping device of the discharging electrode

Switch on the rapping device of the discharging electrode

Switch on the collecting electrode rapping

Switch off the earthing device

Actuate the air blower

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Automatic manual( commission)

Transmit DC HV to ESP. And then it transmit DC voltage to ESP set

Table 1 Operation procedure of ESP

1.3 Operation and inspection of ESP

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Drawing 1 Checking position and time of ESP

Item Checking Times of Normal state Special

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During operation, if we find any deficiency, we should fill in records and

1.4 Switching off of ESP

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The air blower stops working

Close the flue valve

The rectifier stops working

The earthing device is earthed

Stop the discharging electrode rapping

Halt the collecting electrode rapping

Dust discharging device stops

Switch off the insulator heating power

Close the hopper heating equipment

Table 2: Operation procedure of halting the machine

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Table 2: Inspection and requirement after halting the machine

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Responsibility of operation Responsibility of maintenance

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Collecting system 1.collecting plate 1. whether there’s dust

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4. Safety and technical regulations

4.1 Safety and technical regulations of ESP operation

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4.2 Inspection and safety regulations of ESP

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