11) Precipitator Maintenance and Operations
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Transcript of 11) Precipitator Maintenance and Operations
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8/8/2019 11) Precipitator Maintenance and Operations
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Worldwide Pollution
Control Association
FirstEnergy ESP Seminar
November 27th 28th, 2007
Visit our website at www.wpca.info
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Precipitator Maintenance and
Operations
By Scott Williams
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External Dust Collection
Concerns
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Preheater Basket
Material Can
Ground Out
Precipitators
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Carbon Loss on Ignition Decreases Collection Capability
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Carbon Loss on Ignition Increases Emissions and Opacity
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Proper Gas Flow is Critical
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Ash Build-up on Turning Vanes in the Duct Causes Poor Gas
Flow
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Ash Build-up at Precipitator Inlet
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Ash Buildup at Access Door
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High Voltage Arcing and
Tracking Causes ComponentFailures
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Knife Blade Switch Arcing and High Voltage Cable Failure
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Power Path High Voltage Failure
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Broken High Voltage Insulator
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Tracked Post Insulator Inside a T/R Set
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Support Insulator inside T/R - Tracking
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High Voltage Insulator Tracking
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Water/Air Leakage is a Major
Concern
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A Hole in the Precipitator Hot Roof due to ThermalStress/Corrosion
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Holes in the Side of the Precipitator Due to Corrosion
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Water Leaks From Ductwork
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High Voltage Guard Air Leakage
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Corrosion of High Voltage Guard Due to Air Leakage
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Water Leakage Around Rapper Boot Seal
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Ash Buildup in Hopper
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Water Leakage Through the Precipitator Roof
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Roof Corrosion Due to Water Standing for a Long Period of
Time
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Corrosion Around Access Door
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Thermal Stress Concerns
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Structural Component Bowing due to Thermal Stress
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Plate Bowing Due to Thermal Fatigue
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Thermal Stress Crack in Casing
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Center Wall Cracking
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Thermal Fatigue Cracking At Turning Vane Support
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Mechanical Component Failures
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Hopper Baffle Door- This causes increased opacity
B t St t l C B i
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Bent Structural Cross Brasing
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Baffle Component Failure- Gas will bypass the baffle
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Cracked Plate- Mechanical Stress
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Crack Plate
C k Pl S d
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Crack Plate Swords
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Cracked Plate on top
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Plate Repairs
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Weld Failure At Top of Plate
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Channel Cracking at Top of Plate
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Insulation Problems
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Poor Insulation Can Promote Corrosion
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Plate to Wire Clearances are
Important
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The Wire/Electrode Carries the Charge
The Plate Collects the Ash
Plate to Wire Clearance is Critical
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Rapper Failures
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Rapper Shaft Cracked at Anvil Beam- Shaft has fell down
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Broken Rapper Shaft- In the Penthouse
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Broken Tumbling Hammer
Chain of Tumbling Hammer Sprocket
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g p
Vibrator Shaft Broken
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Vibrator Shaft Broken
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Operational Problems
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Ammonia System Ash Buildup
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Ash Hopper Overfilled
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Ash Buildup on Electrodes- Opacity Can Increase
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Structural Erosion
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Erosion Due to Ash if Flue Gas on Structural Support
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T/R Set Oil Leakage
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Start Up Procedure
Back section should be energized first atstart of first mill operation.
Sections added as needed.
Start SO3 injection at 125oC.
Start NH4 injection when SO3 effects are
evident (usually the next day).