ESP Rectifier transformer: ESP Rectifier transformer M.G.

Morshad / ACM Transformer Mtce / TPS II Principle of operation: Principle of operation Electrodes at high voltage create a corona effect (ionized atmosphere) surrounding them. This charges the passing particles. Once charged, particles are subject to a transverse electrostatic force that pulls them toward the collecting plates. Plates are periodically rapped (vibrated) to make the collected particles fall down into a receiver hopper. Back corona: Back corona - + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + Positively charged collecting plates - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - High resistive dust particles Negatively charged dust particles Negatively charged emitting electrodes Spark between layers of dust particles In case of high resistive dust ( dry dust) , dust layer creates an insulation between the positively charged collecting plate and negatively charged dust particles. In such condition, spark / arc within the layer of dust particle is formed with the increase of KV (DC). This phenomena is known as BACK CORONA. As a result of spark / arc formation , field current (mA ) gets increased with substantial decrease in field voltage KV (DC). To avoid back corona, field voltage KV(DC) has to be reduced sufficiently, but such measures finally reduces the collection efficiency of the field Field short : Field short In case of low resistive dust ( wet dust), dust layer gets positively charged. In such condition whenever the gap between positively charged dust particles & negatively charged electrodes gets reduced due to accumulation of dust layer , spark ( that extinguishes with the reduction of applied voltage ) or arc ( that does not extinguish with the reduction of applied voltage ) gets emitted from emitting electrode to the collecting plates causing shorting of fields. As a result of field shorting , field voltage KV (DC) gets collapsed with drawing of high field current (mA ) between emitting electrode and the collecting plates. This may cause the failure of HV winding if transformer is not switched off immediately after field short. - + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + Negatively charged emitting electrodes Spark between layers of dust particles + + + + + + + + + + + + ++++++++++++++++++++++++++++++++++++++++++ +++++++++++++++++++++++++++++++++++++++++ Voltage - current characteristics : Voltage - current characteristics KV ( DC) mA ( DC) Back Corona Zone Operating Zone Field Short 0 Operating Zone : With the increase of field voltage [KV (DC)], field current (mA) increases linearly and no spark is emitted. Back Corona zone : Spark starts emitting causing decrease in field voltage KV(DC)

with high increase in field current (mA) Field short : Spark persist continuously causing field voltage KV(DC) to become zero with maximum flow of field current (mA) Parameters affect the performance of ESP: Parameters affect the performance of ESP 1. Gas Temperature : Normally ESP is designed to operate in the temperature range 180- 200 Deg C. At higher temperature, the quality of insulation deteriorate and flash over voltage limit decreases. In such condition operating voltage has to be brought down to avoid back corona that results in lower dust collecting efficiency . At temperature below the acid dew point, deposition of acid in the structure leads to faster corrosion . 2. Moisture content : Moisture content has a large influence on the performance of ESP. Moisture increases the ionization tendency and decreases the resistivity of the dust particles. As an effect of these factors dust collection efficiency increases with reduced back corona tendency . 3.Dust particle size: The collecting efficiency increases with increase in particle size since the larger particles receive charge more quickly and attains migration velocity. (Migration velocity is proportional to diameter when d>1pm and is independent when d<1m). Hence , collection efficiency decreases with the increase of fineness of the dust particles. 4. Dust resistively: Dust resistivity increases with the increase of dryness of dust and quality of fuel. At higher dust resistivity , internal spark over between two layers of dust takes place as a result of potential difference created by the high resistance of dust. This phenomena is called Back Corona. Once the back corona starts , field intensity ( KV DC) start reducing with increase of field current . This reduces the collecting efficiency of the ESP. 5. Rapping frequency : Whenever the electrode surface is subjected to rapping shock, reentertainment of particles takes place in the main flow path and carried away by the gas causing increase in emission level . To reduce the re-entertainment to a minimum level, it must be allowed to form a layer of significant thickness of dust so that when it is dislodged by rapping, the layer breaks into agglomerate masses, sufficiently large to fall into the hopper before, being carried out by the moving gas stream into the outlet duct. Secondly rapping frequency is to be set to optimum level for each field in accordance with the concentration and type of dust entering the field to minimize penetration. Components of rectifier transformers : Components of rectifier transformers Microprocessor based Voltage controller Control panel Analog Meters for quick visual indication of operating level. Electronic Controller for Controlling power (KV and mA) delivered to the TR. SCR Module with Heat Sinks under control of the Electronic Controller for Phase Control of the AC Feed to the TR. Circuit Breaker, Contactor and Misc. control and interlock relays Phase control Thyristor, Transformer unit Series reactor, Transformer coil, Rectifier bridge, Resistor assembly HF choke. Insulating oil LV & HV Bushing Control feed back terminals SCR controller :

SCR controller The single phase input voltage of 480 V is applied across the SCR assembly which is made up of two SCRs connected in a reverse polarity parallel configuration . The primary voltage of transformer is controlled by changing the conduction angle of the SCR with the help of feed back signal ( mA & KV) taken from DC side of the secondary The SCRs are protected from dv/dt damage by a resistor capacitor snubber network consist of metal oxide varistor and fuse to protect against over current conditions. Transformer Unit : Transformer Unit Rectifier Bridge + - DC Volt / Current AC Input = 415 V,200A AC Out put = 53570 V, 1.40 A Voltage Ratio 1:143.42 Output DC Voltage = 53570 x (1.414/1.08) = 70KV Output DC current = 1.40 / 1.414= 0.990 A Output KWr = V x I = 70 x0.990 = 69.3KW Input KVA = 373.5 x 200 = 75KVA Input KW = 75KVA x1 = 75KW Single phase transformer with higher voltage ratio is used to create high voltage at secondary terminal Transformer is operated with 2 phase supply for achieving natural commutation of rectifier bridge. Transformer KVA is controlled by controlling the voltage & current with the help of SCR controller Heat generation during operation is equal to (Input 75 KW Output 69.3 KW ) 5.7 KW is carried away by the silicon oil to maintain the temperature. Gas generation due to high temperature is detected by BUCHOLTZ relay PRIMARY ( LV) SECONDARY ( HV) KVA Volt Amps Volt Amps DC mA 30 373.5 80 53570 0.56 400 45 373.5 120 53570 0.84 600 60 373.5 160 53570 1.12 800 75 373.5 200 53570 1.40 1000 90 373.5 240 53570 1.68 1200 105 373.5 280 53570 1.96 1400 Various capacity of transformer CLR Current Limiting Reactor : Current Limiting Reactor Rectifier unit L V H V Series Reactor 373.5 V Supply Impedance (Z) = V/I (AC Resistance) Z = V/I = L x 2 f Ohms % Z = [(L x 2 f x I) / V ] x 100 Ohms L = (V x %Z) x (I x 2 f ) Henry CLR reactance (L) = 1.5 mH CLR resistance ( R ) =9 m Impedance of CLR =24.64% TR impedance = 10% System impedance = 34 .64% A system impedance of 50% limits the maximum AC current to twice the rated current. At 33% the limit is three times the rated current The primary purpose of the CLR is to limit the surge current that is produced due to generation of spark & arc in the ESP field . The typical CLR value is selected in such a way that it can limit the current surge, within a 8.3 msec (Line Cycle) to approximately 2 4 limitation is required because the SCR controller cannot respond (turn off) until the end of the line cycle. The secondary purposed of the CLR is provide a means for decreasing mA and KV ripple on the DC Power delivered to the ESP. The reduced Ripple results in increased average KV levels, and increased ESP performance (efficiency) 415 V Supply Rectifier Diode assembly : Rectifier Diode assembly The diode assembly is used to convert the high voltage AC output of the transformer to a DC signal. The diode assembly is made up of a series string of many diode junctions. This series string of diodes should be

capable of blocking at least twice the peak output voltage of the T/R. i.e. (2 x 70 KVp = 150 KV) For obtaining high blocking voltage special measures are employed to assure proper voltage sharing. Improper voltage sharing is caused by variation of the reverse leakage of individual diode junctions. This variation results in an uneven distribution of the PIV among the diodes. In such case the diodes will fail in a domino fashion HF Choke : HF Choke High Frequency Choke / Air Core Reactor (ACR) is an electric coil that is connected between the rectifier bridge and HV bushing for protecting the TR Rectifier Bridge from high frequency, high voltage spikes and disturbances that occur within the sparking ESP. ACRs used in modern T/Rs are rated from 20 to 50 (mH) and must be capable of withstanding up to 2 times peak rated voltage. As the ESP sparks and arcs, the full ESP voltage will be impressed across the ACR. ACR design must provide sufficient layer insulation and clearance to accommodate such voltage. Typical failure mode for ACRs is a spark over of the layer insulation. Since the ACR is physically much smaller than the transformer secondary coil, it is subject to extreme voltage stress. In the event of any contamination of the dielectric fluid, the ACR is often the first component to fail. Resistance board assembly - feed back signal for control & monitoring: Resistance board assembly - feed back signal for control & monitoring 1. mA feed back This signal is used for Control and monitoring. The mA Feed back is implemented by a power resistance of approximately 10 Ohms. It is used to provide a 10 Volt DC signal that will correspond to a 1000 ma TR output. Other resistor values may be used for other ratios. The ma feed back is electrically connected between the Positive (+) leg of the HV Bridge and Earth Ground. The Resistor must be of High Reliability Rating and also backed up by a protective HV Device. If this component fails the rated High Voltage is imposed upon this feed back wire. 2. KV Feed back signal The KV signal is implemented through use of a high voltage divider with a typical ratio 8,000 to 1. The ratio uses an 80 Meg Ohm resistor on the high end and a 10K Ohm resistor on the low end, thus producing a feedback of 8 KV per volt. 120 Meg dividers are sometimes used for higher voltage TRs. Typical KV Feed Back systems are not frequency compensated, yet provide a reasonable representation of the ESP signal. One of the most important feedback signals is secondary voltage or kV. Although this is one of the most commonly inaccurate signals found in many installations, inaccuracies in KV feed back can be calculated by the following formula : KV ( DC ) = (Primary current x Primary Voltage X 700) / Secondary mA Like the ma Feed Back.. This signal must be protected since the full output voltage of the TR can be imposed on this wire Insulating oil : Insulating oil The Dielectric Fluid is used to provide cooling for the TR internal components as well as to provide high voltage insulation. Mineral Oil, Silicone Oil

and R-Temp Oil are fluids used. PCB fluid - Askeral (Prior to 1970) ,Silicon Fluid , R-Temp type fluids are having higher fire point and therefore they are used where fire is of greater concern. Silicon fluid is more viscous than mineral oil at temperatures above 10 Deg c and therefore requires additional radiator or bigger tank for proper cooling. Silicone fluid has a greater affinity for water absorption compared to Mineral oil (Water saturation point for Mineral oil is approx 70 ppm while silicone can be as high as 200 ppm) . Silicone fluid can maintain a higher dielectric properties at high water concentrations. The solid insulation of silicon oil filled transformer gets contaminated with water easily since the Silicone fluid has a greater affinity for water absorption and about 90% of the water present in oil is absorbed by the insulation due to natural migration of moisture. Hence HOC is required frequently in silicon fluid for keeping the solid insulation dry. Decomposition of Silicon fluid due to internal arcing generates gases and carbon particles. When Bucholtz relay is actuated by gases, carbon particles contaminated the oil as well as gets attracted to the transformer windings which finally causes the failure of the transformer due to insulation failure. Hence to remove the contamination from the oil , proper oil filtration or total oil replacement is required before installing the transformer after repair and rectification. Characteristics of silicon oil : Characteristics of silicon oil Principle of operation: Principle of operation Depending upon gas temperature, dust resistivity and gas velocity following parameters are set- uni pulse mode/ Semi pulse mode , peak mode , charge ratio, spark control rate ( S & T) secondary DC current limit mA Time Current limit Max Current at which spark occur 20ms Blocking time S T With switching on primary , SCR controller increase the conduction angle depending upon the DC feed back signal (mA & KV) till it reaches the set current. During the current rise whenever the secondary encounters with sparks which is detected by low voltage and high current DC feed back signal , SCR controller immediately stops conduction. SCR controller restarts conduction after 20 ms with slop less than 5% This process goes on continuously to keep the field in energized condition with negative polarity without any spark. Uni pulse / Semi pulse mode: Uni pulse / Semi pulse mode In uni pulse mode of operation fields are in continuous charging state with all half cycle of sinusoidal input ( Charge ratio = 1). This results in imposing of high peak voltage and high average current on the field which causes higher power consumption, lower dust collecting efficiency due to frequent occurrence of Back Corona Effect in the field. In semi pulse mode of operation fields are in intermittent charging state with only preset half cycle of sinusoidal input ( Charge ratio >1). This results in imposing of high peak voltage and lower average current on the field which causes Lower power consumption, Higher dust collecting efficiency due to complete avoiding of Back

Corona Effect in the field. V I V I SCR controller Rectifier Uni pulse Semi pulse Sinusoidal input Charge Ratio : Charge Ratio To avoid back corona , optimization of field voltage KV (DC) is needed and It is achieved by increasing the time gap between the consecutive voltage pulse which is denoted as charge ratio. For higher dust resistivity, higher charge ratio is required so that field voltage is imposed after a sufficient interval to avoid back corona To maintain the sufficient average field current for increasing collection efficiency , field current is to be set at 200% for charge ratio more than 1 Power consumption reduces with the increase of charge ratio For setting field current at 200% , HV coil is frequently exposed to high current that may lead to failure of coil. Since lignite ash is low resistive dust ( Wet dust), system can be set for charge ratio between 1 & 3 . Uni pulse mode Semi pulse mode Charge Ratio 1 Charge Ratio 3 Charge Ratio 5 Semi pulse mode 1 2 3 4 5 6781234567812345678 spark control rate ( S & T control): spark control rate ( S & T control) The spark rate is determined by the settings of S-control and T-control. Suppose T-Control is set at 20% , the time required by the rectifier to reach the rated current after a spark, from zero current will be 2 minutes. Suppose S-Control is set 5% of the rated current, the time from SControl break point to next spark will then be 5% of the T-Control time (5% of 2 minutes), that is 6 seconds. If we do not account for the thyristor block time (20mS) then 6 seconds is the statistical interval between sparks in the ESP. SControl & T-Control are affected neither by the absolute value of current nor of the voltage at which a spark occurs, the spark rate is constant. 5% 95% S T= 6 sec Field current setting : Field current setting Formula Field I Field II Field III Field IV Field V Field VI Secondary DC Current mA 100.00 200.00 500.00 500.00 700.00 700.00 Secondary AC Current I 2 = (mA x 1.4141)/1000 0.14 0.28 0.71 0.71 0.99 0.99 Secondary DC Voltage KVp = (70 x mA)/1000 7.00 14.00 35.00 35.00 49.00 49.00 Secondary AC Voltage KV 2 = (KVp x 1.08)/1.414 5.35 10.69 26.73 26.73 37.42 37.42 Out Put KW Kwo = (mAxKVp)/1000 0.70 2.80 17.50 17.50 34.30 34.30 Trfo voltage ratio R 143.42 143.42 143.42 143.42 143.42 143.42 Primary AC Voltage V 1 = (KV 2 /R)*1000 37.28 74.55 186.38 186.38 260.93 260.93 Primary AC Current I 1 = I 2 x K 20.28 40.56 101.41 101.41 141.97 141.97 In Put KW Kwi = (V1 x I1)/100 0.76 3.02 18.90 18.90 37.04 37.04 Trfo Loss KW loss = ( Kwi - KWo ) 0.06 0.22 1.40 1.40 2.74 2.74 LV HV CLR HFC mA KVp + Positive Negative KV 2 I 2 I 1 V 1 415 V supply Specification - Stage II transformers: Specification - Stage II transformers Name Rectifier Transformer Supply Voltage 415 V AC two phase Make BHEL Location Stage II ESP roof top Capacity 75

KVA Rated primary Voltage ( LV) 373.5 V Rated primary current () 200.8 A Rated secondary voltage (HV) 53570 V Rated secondary current (HV) 1.4 A Voltage ratio 143.42 Oil Capacity 400 Liters ( 2 Barrels) Type of oil Silicon oil Total weight including oil 1300 Kg Location - stage II transformers : Location - stage II transformers 5A 1A 2A 3A 4A 6A 11A 7A 8 A 9 A 10A 12 A 5B 1B 2B 3B 4B 6B 11B 7B 8 B 9 B 10B 12 B Clean gases to chimney Dusty gases from RAPH Transformer connection / Stage II : Transformer connection / Stage II HF Choke H.V Resistance a1 av a3 LV ACR HV AR AS2 AS1 A2 A1 Protection diode Diode Stack Terminal / Parts Purpose a3 - av AC series Reactor to restrict primary current incase of shorted secondary ( Resistance 9.32 m Ohms) av- a1 winding terminal ( Resistance 14.6 m Ohms) Internal Terminal HV winging terminal (Resistance 454 Ohms) a3 a1 Two phase AC input terminal (Resistance 24.84 m Ohms) A1 Negative terminal to create negative potential in the fields A2 Positive terminal earthling point to create positive potential in the structure AS2 AR DC feed back voltage measuring terminal HF Choke To reduce sparking rate at HV terminal ( Inductance 50mH, 6.74 Ohms) Diode Stack Full wave bridge rectifier for converting AC to DC H.V resistance Voltage divider Protection diode To protect the bridge from reverse biasing Open circuit test BHEL Transformer : Open circuit test BHEL Transformer Voltage Applied on LV terminals Using Variac (Volt) Magnetizing current measured on LV terminals (Amps) DC feed Back voltage measured between AS2&AR (V) 50 0.116 20.20 100 0.176 41.00 150 0.190 58.20 200 0.280 77.20 250 0.490 96.50 300 2.460 116.00 350 3.110 133.00 374 4.240 140.50 Short circuit test BHEL Transformer : Short circuit test BHEL Transformer Voltage Applied on LV terminals Using Variac (Volt) Current measured on LV terminals (Amps) DC feed Back Current measured between AS2 & AS1 ( mA ) DC Current measured on HV terminals (A ) 20 36.00 0.220 0.101 40 67.00 0.400 0.183 60 98.00 0.580 0.230 80 131.00 0.770 0.320 100 171.00 1000.000 0.420 120 199.00 1140.000 0.500 130 206.00 1160.000 0.510 Acceptance test / Stage II : Acceptance test / Stage II Parameters Value IR Value Minimum 200 M Ohm HV E , ( 2.5 KV Megger), HV ( 2.5 KV Megger), LV E ( 0.5 KV Megger) LV Winding resistance 14- 15 m Ohms AC Reactor resistance 9 9.5 m Ohms Combined resistance 24 25 m Ohms Magnetizing current test Voltage current As2 AR 50 Volt 108 mA 19 V DC 100 volt 170 mA 39 V DC 150 volt 200 mA 59

V DC 200 Volt 0.26 A 79 V DC 250 Volt 0.46 A 99 V DC 300 Volt 1.25 A 118 V DC 350 Volt 2.81 A 136 V DC 400 Volt 4.0 A 145 V DC Fault detection / Stage II : Fault detection / Stage II Parameters Value Two phase Input AC voltage 110 to 120 Volt Primary current 0.2 to 0.3 Amps Secondary Voltage 33 KV Secondary current Zero OCC test at local Keeping A1 open Parameters Value Two phase Input AC voltage 110 to 120 Volt Primary current 14 15 Amps Secondary Voltage 33 KV Secondary current 100 mA Load test at local Keeping A1 close Fault detection Actuations of Buchholtz relay BOTTOM FLOAT Actuations of Buchholtz relay TOP FLOAT Causes Internal short circuit between turns Short Circuit between phase & earth Phase to phase short circuit Insulation break down Causes Low oil level Air accumulation Fault in core lamination Break down in core blot Insulation Local over heating in the winding Wrong connection Specifications Stage I transformers: Specifications Stage I transformers Make MERLIN GERIN ( France) Location ESP I,II,II Population / Unit 24 Nos Total Population 3 x 24 = 72 Nos Capacity 75 KVA % impedance 8% Primary rated current 181 amps (AC) Voltage Ratio 415 V / 54000V Output voltage 75Kv(DC) Output current 0.13 Amps (DC) DC out put 59 KW Primary fuse rating 250 amps / 500 Volt Protection DGPT 2000 ( Gas emission, internal pressure & Temperature) Total weight of one transformer 900 Kg Oil weight per transformer 290 Kg Type of oil used HUILE OIL ( Askarel ) Location stage I transformers: Location stage I transformers A5 A1 A2 A3 A4 A6 B5 B1 B2 B3 B4 B6 C5 C1 C2 C3 C4 C6 D5 D1 D2 D3 D4 D6 Dusty gases from RAPH Clean gases to chimney Transformer connection / Stage I : Transformer connection / Stage I HF Choke b c a LV ACR HV m + HV Bushing Diode Stack 17 nos resistors, each 4M 182 K, W resistors Spark detector Terminal / Parts Purpose a - c AC series Reactor to restrict primary current incase of shorted secondary ( Resistance 11.2 m Ohms) c- b LV winding terminal ( Resistance 18.8 m Ohms) a-b Two phase AC input terminal (Resistance 29.5 m Ohms) + Grounding point of HV DC terminal earthling point to create positive potential in the structure m Spark detector terminals Open circuit test Stage I transformer : Open circuit test Stage I transformer Voltage applied between (a-b) Current through primary winding 50 Volt 89.2 m A 100 Volt 148.2 m A 150 Volt 0.19A 200 Volt 0.27 A 225 Volt 0.34 A 250 Volt 0.42 A 275 Volt 0.57 A 300 Volt 0.77 A 325 Volt 1.04 A Fault detection through meter readings (1):

Fault detection through meter readings (1) Primary side Secondary side 1. Check if controller is responding to sparking. If it is, use a scope to verify that sparks/arcs are occurring. Run T/R with precipitator disconnected to verify that T/R is not sparking internally. 2. Check for open SCR fuses. 3. Verify that SCRs are firing. 4. Check for open CLR. 5. Check for proper operation of controller power components - circuit breaker, contactor No power to T/R set Primary side Secondary side Short CircuitDC Side 1. Run T/R set with HV bushing disconnected from the precipitator. a. If no current flows the short is in the precipitator. b. If current still flows the short is in the T/R set. 2. If precipitator is shorted, check electrodes and insulators for shorts. 3. If T/R is shorted, check HV bushing and external switch (if applicable) for shorts Fault detection through meter readings (2): Fault detection through meter readings (2) 1. Megger diodes for shorts. 2. Run T/R without diodes. If AAC still high, transformer is bad. Primary side Secondary side Short Circuit T/R set Primary side Secondary side 1. Run T/R set with HV bushing grounded externally. a. If current flows, precipitator field is open. b. If no current flows, T/R is open. 2. If precipitator is open, check all HV connections to electrodes. 3. If T/R is open, megger unit. Check for open diodes or connections in T/R tank Open circuit Failure sequence : Failure sequence In cases of severe arcs or shorted field, the current may instantly rise to twice rating but quickly reduced by the controller to safe level and this instant over current is permitted to continue with every automatic switching on , excessive heat is generated in the HV winding & diodes stack . As a result of heat the solder that fastens the diodes to the PC board to melt away and causes arcing between the diode lead and the PC board . Actuation of B Relay Instant arching causes generation of gas Arcing results in the breakdown of the dielectric fluid . Continuous arching causes generation of carbon particles Carbon particle gets accumulated in HV windings HV winding gets shorted As a result of heat the HV winging joints gets melted. inter winding arcing HV winding gets opened Measures to be taken for avoiding frequent failure of transformer : Measures to be taken for avoiding frequent failure of transformer 1. Transformer must be switched off whenever it encounter with field short. 2. Whenever transformer gets failed due to internal arc , Transformer shall be filled with new oil after rectification. 3. Since silicon oil is highly hygroscopic, periodical oil circulation is required to avoid moisture absorption in solid insulation which may lead to failure of transformer due to weakness in solid insulation. 4. Availability of feed back signal ( mA & KV) must be ensured before putting the transformer in service since wrong feed back may lead to spurious power input ( Voltage & current ) to the Transformer due to malfunction of thyristor controller. 5. Ensure cleanliness of field and ash level in hopper before switching on the transformer for avoiding switching on of transformer with field short. 6. Set charge ratio 1 for

repaired transformer and 3 for non repaired transformer for achieving current setting according to the physical condition of the transformer.