Tuning of ESP operation

5.1. Spark settings

See heading 7.2. Spark detection and control on page 45.

5.2. Process parameters

EPIC III has six sets of parameters in the Process Settings/Mode Settings window. Each set for use in different operating conditions. The default data of these modes at delivery provides an approximate value only. For proper operation of the actual process must these parameters be tuned at site. All modes have an identical set of parameters. It is the selected value of the parameters that determine if the mode is useful for a certain process operation. It is however not necessary to set parameters for more modes than needed.

5.3. Process settings

Each of the six modes has one set of the following parameters.
Figure 27. The Process Settings/Mode Settings window

5.3.1. Voltage peak limit This parameter should be set to the maximum peak voltage that the precipitator is allowed to operate at during this mode. This is useful for example, to limit peak voltage below sparking level during start up of ESP. 5.3.2. Current pulse limit This parameter limits the pulse current. For charge ratio = 1:1 the same as the average value on the mA meter. For more information, see heading 7.1.1. Current measurements on page 43.
Page 40 5. Tuning of ESP operation

5.3.3. Charging ratio This parameter controls the Semipulse energization. For example, if the set value is 1:3 it means that one half period will be fired, but the following two will not be fired. 1:1 means that each half period will be fired. 5.3.4. EPOQ This is an algorithm for optimisation of the ESP. See section 7. Function descriptions on page 43. 5.3.5. Rapping Factor This parameter makes it possible to prolong the repetition time for the rappers. 5.3.6. Rapp all This parameter starts all the rappers in EPIC III. 5.3.7. Spark rate limit This parameter limits the number of sparks per minute. 5.3.8. Current step This parameter reduces the secondary current after a spark-over. The reduction is in percent of the secondary current at the time of the spark. 5.3.9. Short quenching This parameter determines the blocking time in half periods (also see Quench mode below). 5.3.10. Quench mode

This parameter has three modes: Self= No quenching after a spark Short= Short quenching time after a spark. Self + Short= Short quenching only if a spark occurs on two consecutive half periods. 5.3.11. Opacity controlled The Opacity control for this unit can be activated or deactivated. This assumes that the Opacity optimisation in the EPS Master window is set to On and that this unit is within the ESP address limits for master control. Remember to save all settings by clicking on the Save Settings

Operation of single T/R

If more information about a single T/R is needed or if there is a need to control a T/R separately, this can be done by double-clicking on the actual unit from the Name column in the PC-MTU software and then selecting the appropriate window for the task. The most common windows for daily operation are: 6.2.1. Operation In this window alarms can be reset (but can more conveniently be made in the PC-MTU software). The T/R can be individually turned On and Off. The active mode can be individually selected. The reason for any limitation of current is displayed. The most important measurements are displayed and it is possible to change parameters for the mode that is in operation. 6.2.2. Readings In this window more detailed readings are available. 6.2.3. Alarms/Alarm list This window contains an alarm list. Alarms can be reset in the PC-MTU software. By double-clicking in the alarm field in the EPIC III that gives the alarm, the corresponding alarm window will be displayed. See the Operators Guide.
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7. Function descriptions
7.1. General measurements and control
The measurements are synchronised to the line frequency and all presented values are averaged over approximately one second. This means that for instance 100 peak values are averaged in the kVp value at 50 Hz and Charging ratio (CR) = 1:1, but only 2 values at CR 1:51. For CR values lower than 1:101 the update and average frequency will be equal to the firing frequency for those values that depend on CR. 7.1.1. Current measurements Measurement of secondary current includes Peak, Pulse and Average. These values are measured as follows:
Figure 29. The secondary current
Peak Pulse

Average Average Pulse Peak Theoretical pulse value is equal to the CR rate multiplied with the measured average value CR = 1:1 CR = 1:3 Page 44 7. Function descriptions

7.1.2. Voltage measurement Measurement of secondary voltage includes Average, Peak, and Valley values. These values are measured as follows:
Figure 30. The secondary voltage

7.1.3. On-Off control The T/R can easily be switched on and off over the Ethernet using the Operation window or by using PC-MTU software or a ProMo. If power is lost for longer than 200 ms the EPIC IIIs restart routine will switch High voltage = Off. This routine prevents unwanted restarts when power is restored after dropouts > 200 ms. By using the Operation window, the High voltage can be switched On again. 7.1.4. Current limitation One of the set up parameters in the Set Up / T/R window is called Primary current limit trip (ARMS). It is set to the T/R rated primary current, using this window, during first start up of the T/R. If the primary current tends to rise above this value the EPIC III will first try to keep it below the limit by reducing the SCR firing angle. If the primary current still stays above the limit for more than 5 seconds the EPIC III will trip the T/R and indicate an alarm. The delay-time is fixed because all short over-current situations will be handled by the control of ignition angle. When this limit control fails (when the EPIC III loses control of the SCRs) the EPIC III will trip the contactor.
Peak Average Valley No load Normal load Page 45 7. Function descriptions

7.2. Spark detection and control

Sparks are handled by the EPIC III by three different software functions: Spark detecting Spark quenching Spark level following function: 7.2.1. Spark and arch detecting function A. Sparks are normally detected from the kV measurement samples (Voltage Method), they are continuously analysed for slopes that indicates sparkover. If found, a signal is given to the quenching function to actuate proper action. The Spark sensitivity detector determines how steep the current has to rise in order to detected as a spark situation. The variable is adjustable and is defined in kV/ms. It is located in the Process settings/Spark settings

window. B. Arcs are detected by analysing the kVv values. Arching is defined as kVv < Arc detection level continuously for 10 fired periods. (During Semipulse, one period means one total semipulse cycle.) If arc is detected, a signal is given to the quenching function to actuate proper action. T/R units which only have secondary current measurement feedback can be controlled by using the Current method instead of the Voltage method. By doing so only sparks can be detected (instead of detecting both sparks and arcs). 7.2.2. Spark quenching function Four methods of quenching are used. 7.2.2.1. Quench mode = Self ( Not use ) This method is useful when the spark does not need any explicit quenching period except the normal time to next firing. Nothing is done by the quenching function. The T/R decreases the current according to settings in Current step. Be careful while using this mode since it may cause severe arcing conditions. The arcs can be studied by the arc counter. 7.2.2.2. Quench mode = Short This method is useful when the spark always needs a short blocking time. This quenching time is selectable in half periods from 2 to 9. During semipulse operation, the next fired pulse will start immediately after the quenching period. The spark level follower decreases the current according to settings in Current step.
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7.2.2.3. Quench mode = Self + Short (recommended for general use) This method is useful when the spark does not normally need any explicit quenching period, except for the normal time to next firing, but if two sparks occur on consecutive half periods then short quenching is needed and actuated. The T/R decreases the current according to settings in Current step. While used, this function should not cause more than 1/10 of double sparks compared to sparks, else use quench mode = Short. 7.2.2.4. Arc quenching = 1-99 This function takes place when arcs are detected. The quench time is adjustable in half periods from 1 to 99. The Arc quenching function is always active. 7.2.3. Spark level following The spark level follower, see figure 31, is a function that has factory set parameters. Its purpose is to maintain maximum voltage in the ESP. These factory settings can very often be used without any change at all, but they can be adjusted to suit the process. The figure below shows that the spark level follower in the EPIC III raises the current to the ESP. Consequently the voltage in the ESP will rise and at a certain level there will be a spark in the ESP. Spark quenching (Short quenching) then brings the current down to 0 for a short time. The spark level following function will then re-apply the current again. The current

will, however, not be restored to the same level immediately, but to one step lower (called current step).
Figure 31. The Spark level follower

From this level the current is set to rise and follow three slopes (slope A, B and C), see figure 32. The slope parameters Slope Rise A, Slope Time A and Slope Rise C can be changed. Slope Time A determines the time for slope A as a percentage of the average time between sparks. Slope Rise A determines the increase in current during slope A as a percentage of the current step. t (s)
Current Spark detection mA Spark quenching (Short quenching) Current step
12

Spark level

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The parameters for slope B cannot directly be changed by the user. The time and rise parameters are calculated as follows: after a spark the EPIC III seeks to establish the same current level as before the spark and in a time equal to the average time between sparks (Slope Time A + Slope Time B). Most likely a new spark will occur here (marked with a second spark symbol). If no spark occurs, slope B continues for a period equal to the period before the assumed spark. If still no spark occurs, slope B will be succeed by Slope C. Slope C (Slope Rise C can be set) will raise the current until a spark occurs or the voltage or current limit for the EPIC III is reached.
Figure 32. Slope times etc.

Sparks are normally detected from the kV measurement which is continuously analysed for negative slopes, indicating sparks. If found, the output is quenched for a set time (Short Quenching - 2-9 half-periods). Spark sensitivity determines how steep the slope must be in order to be detected as a spark. The spark sensitivity detector is adjustable and is defined in kV/ms. Arcs are detected by analysing the kV measurement. Arcing is defined when the ESP voltage is continuously lower than the Arc Detection Level for more than 10 half-periods. If an arc is detected, the output is quenched for a set time (Arc Quenching 1-99 half-periods in steps of one half-period). 7.2.4. Spark detection sensitivity tuning Spark sensitivity can only be adjusted if the precipitator produces sparks. If the operation conditions are so that maximum T/R output voltage does not reach the break over voltage, and no sparks are produced, it is possible to temporarily decrease the distance between emitting and collecting electrode by insertion of some metal object.
Note! Be sure then to follow ESP safety regulations.
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The EPIC III can use the secondary voltage or the secondary current for

detecting of sparks. The voltage sensing is selected as default. This is the safest sensing method and shall be used if the T/R provides a kV measuring signal. Normally the ESP will function using the delivery default setting of spark sensitivity. If any adjustment is needed, find correct setting as follows: 1. Select Quench mode= Short 2. Set Ignition angle limit = 100% Voltage pulse peak limit = MAX Current limit = MAX Charging ratio = 1:11 3. Start T/R and observe that the Limiter = Spark. 4. Make the spark detector more and more sensitive by setting lower and lower values on Spark sensitivity* (kV/ms) until normal voltage shapes are falsely detected as sparks. This is the situation when the spark level in kV or mA is decreasing and dependent on the setting of Spark sensitivity. 5. Write down the value of Spark sensitivity* (false det.) where false detection starts. 6. Set Charging ratio = 1:1 7. Make the spark detector less and less sensitive by setting higher and higher values on Spark sensitivity* (kV/ms) until the sparks in the ESP are not detected. This is the situation when the primary and secondary current makes abrupt increasing jumps for short periods. Easiest to see on analogue panel meters. 8. Write down the value on Spark sensitivity* (kV/ms) (no det.) where no detection starts. 9. Set Spark sensitivity to the average between Spark sensitivity* (false det.) and Spark sensitivity (no det.) achieved above. 10. Restore the previous settings except Spark sensitivity* and then remember to save the changes by clicking on the Save Settings button. * or Level (0-32) if current sensing method is used. 7.2.5. Tuning of spark quenching The most suitable spark quench mode for a certain application has to be found out by carrying out process tests. Here are, however, some general information: Quench mode = Short is the safest mode to use because it always actuates a blocking period. On the other hand it also gives a loss of current input to the ESP during the blocking. Quench mode = Self+Short is useful if the majority of the sparks are of the self quenching type. This mode then produces a smoother operation and higher current input. Try this mode first and observe the spark counters.
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If a majority of double sparks is detected or if arcs are detected, Quench mode = Short should be selected. Quench mode = Self is the mode that may force the highest average current into the ESP, but it is not generally recommended. Because there is no quenching action like blocking inserted it can easily cause arcing in most processes. However, it is easy to test by observing the arc counter during a

test period. 7.2.6. Tuning of other spark parameters The tuning of other spark parameters as Spark rate limit, Current step and Slope is totally process related. Please ask ALSTOM Power for the latest data available for these settings on the actual process.