Electro Static Precipitator Controler

7/29/2019 Electro Static Precipitator Controler

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PRESENTATION

ON

ESP CONTROLLERS


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R&D Center


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ESP T/R SET CONTROL

ANALOG CONTROLLER AICE - C

RAPPING CONTROL

SYNCHRONOUS

PROGRAMMER

AUTORAPPER

UP BASED RAPPER

CONTROLLER

MANUAL CONTROLCOMPUTER CONTROLLED

PRECIPITATOR OPERATION

ESP CONTROL

BAPCON

RAPCON

(IOS)

ADVANCEMENTS IN ESP CONTROLS


4/93

Basic factors affecting ESP

performance

Properties of Flyash

- Particle size distribution

-small particles are difficult to

collect

- surface area affects visibility,space charge


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+

+

+

+

+

+

BACK CORONA

x i

qs

++

++

--

-

----

EP

Qs E p

F = Qs . Eav Ep . Eav

Vp . Vav


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7/93

Modified Intermittent Charging

Increases the base voltage

More suited for high charge ratio operation

suitable for high resistivity dust

Outlet emission Power consumption

(mg/Nm^3) (kW)Conventional charging 351 300

Intermittent charging 127 57


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Energy Saving

Reduction in energy costs due to modified

intermittent charging

210 MW ESP

Reduction in power : 243 kW

At 2 Rs./kWH and 65% duty,

yearly saving : 27.7 Lakhs Rs.


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BAPCON


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BAPCON

Intermittent charging, requirement of wide

charge ratio (CR) range of 1:159.

Optimiser logic for C.R, avoids tedious manualtunning.

Base charging, increases base voltage.

Peak & valley KV measurement : Diagnostic &

tunning facilitated.


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VARIOUS DISPLAYS IN BAPCON

- Precipitator currentE - Precipitator voltage

H - Sparks per minuteO - Im limit

1 - Is limit

2 - S control

3 - Time control

4 - Stabilization time

5 - U.V. Limit

6 - C.R.

7 - Pulse current limit

8 - Repeat time

9 - Address

- Peak & valley voltage

P - Base charge

L - Base charge current


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ALARMS IN BAPCON

TRIP ALARMS: E1 - Safety chain broken.

E2 - EPROM faulty.

E3 - Power supply failure.

E4 - Over voltage E5 - Ash level very high (for 10 min.)

E6 - T/R temp very high / TH. Ovld.

E7 - Bucholtz bottom float.

WARNING ALARMS: T/R temp high.

Bucholtz top float.

Ash level high.

Under voltage.


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RAPCON


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MICROPROCESSOR CONTROLLER

Processor

Memory

Interrupts

Timers

Communication

I / O ports

Display

Auto restart

Intel 8085 CPU at 3.072MHZ

Rom / Eprom: 2x16k. Ram: 1x16k

Hardware interrupts:

8259 - 8 interrupts

8085 - 3 interrupts

Timer IC 8254 (3 timers)

Serial communication

IC 8251 - 2NOS.

1.balance current loop(+/-10mA)

2. RS232-C communication or balanced current loop.

Digital I / O: IC-8255 (2NOS) with provision for 42 digital

I/O analog I/O: Inputs-4NOS,(4-20mA)outputs - 2NOS, (4-

20mA)

Provision for display controller 8279 for 80 leds.

Watch dog pulses.


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DATA COMMUNICATION CARD

FUNCTIONS:

Provides communication path between COMCON RAPCON & BAPCON

Provides Rs-232-C serial communication between P.C. & COMCON.

Provides hardware communication by-pass in case of power failure/unit

faulty.

Extends sum - alarm signal for external annunciation.

Provides 24V A.C. power supply to COMCON / RAPCON.

Provides isolated 24V DC power supply to relay card & digital buffer card.

LED indication in case of 24V DC power supply fuse failure.


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ADVANCED FEATURES OF RAPCON

Error checking for the motors.

Setting of rapper timings. Setting of real time.

Auto on/off selection.

Manual on/off selection.

Password protection.

Setting of program set no.

Reading of rapper times.

Reading of real time.

Reading of program set no.

Reading of rapcon address. Reset alarm.

Stan by mode selection.

Communication with IOS-PC

Rapping factor selection - [IOS]


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RAPCON FUNCTION SELECTION

1999.05.19 10:23:45

SET

FUNCTION

9. PROGRAMSET NO?

8. DISPLAY REAL TIME?

7. DISPLAY TIMES?

1. PASSWORD?

2. SET RAPPER TIMES?

3. SET REAL TIME?

4. SET AUTO ON/OFF?

5. SET MANUAL ON/OFF?

6. SET PROGRAM SETNO?

10. RAPCON ADDRESS?

11. RESET ALARM?

NEXT FUNCTION NO =

To reach a function with

function 1 to 6 the RAPCON

must be in LOCAL mode

Access to functions 2 to 6

possible only if pass word is

answered correctly.

Acess to functions 7 to 11 does

not require answering the pass

word.


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To reach next function number either press the required

number meant for the function and press enter yes (OR)

press set function repeatedly till the required function is

displayed.

NEXT FUNCTION NO =

NEXT FUNCTION NO = 7 7 DISPLAY TIMES ?

7

ENTER

YES


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PARAMETERS IN RAPCON

CONTROLLED BY IOS - P.C.

Rapping factor.

Program set no.

Auto on/off.

Manual on/off.

Set real time.

Set rapping time.

Get rapping time.

Reset alarm.


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COMMAND TO RAPCON

Force stand alone / standby

Auto ON / OFF for all motors

Manual ON / OFF for all motors Program set selection 1 - 64

Time factor 0 - 25.5

Alarm reset

REPLY FROM RAPCON

Remote local Auto ON / OFF status

Manual ON / OFF status

Program set

Time factor

Alarm status

Motor status

Motor status 30 sec. In advance

Next on status


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IOS


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NEED FOR COMPUTER CONTROL OF ESPs

Tedious manual tuning of parameters in each control.

Status monitoring of large number of fields.

Optimisation of ESP parameters.

The need of supervision & control of ESP from UCB.

Data logging, alarm logging & Graphical

representation of precipitator parameters.

Communication with plant computer.


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IOS CONSISTS OF ..

BAPCON

RAPCON

IOS - PC

BHELs advanced precipitatorcontroller.

Rapper controller.

Multitasking real time PC.


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FUNCTIONS OF IOS - PC

Controls & monitors BAPCONs & RAPCONs.

Closed loop control of ESP through.

Opacity algorithm.

Rapping set no. Algorithm. Rapping power off algorithm.

Rapping time factor algorithm.

Optimiser algorithm.

Centralised monitoring & control from UCB.

Alarm monitoring & print out of status.


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ADVANTAGES OF IOS

Wide C.R suitable for Indian conditions.

Automatic optimisation of C.R.

base charging.

Peak & valley KV measurement.

Pre-programmed rapping sequences.Reduces emission & energy consumption.

Pays back investment in couple of years.

Software on ROM cards.

Indigenous Hardware & Software.

Upgradable.

Maintenance support.

Customising to needs.


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NT-IOS

Integrated Operating System on

Windows NT platform

Bharat Heavy Electricals Limited, Ranipet


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NT-IOS

Windows based IOS

Integrated Datalogging

Track Ball & Mouse

operation Industrial Computing

platform

Industrial grade desktopmounting


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Main features

Graphical User Interface

Trend curves display

Compatibility with latest printers User friendly help features

Information access through Intranet

can be upgradable easily


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NT-IOS

PC

BAPCON1 BAPCON2

NT-IOS HARDWARE ARCHITECTURE

RAPCON-n RAPCON2

BAPCON-n

RAPCON-1

Boiler loadOpacity


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GUI

User friendly windows screens for giving

command to different controllers anddisplaying the ESP field status.


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Trend curves display

VI curve for each field

Line Graphs for

Current , Voltage,

Spark rate,

Opacity and

boiler load

Bar chart for Analog input of Opacity and boilerload


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Compatibility for Printers

All printers supported by Windows NT canbe used for Text log , Graph log and VI

curves


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User friendly help features

Help feature covers the Technical andoperating details of this package withImages.

Context sensitive help for each screen isavailable.


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Information access through Intranet

ESP field operating parameters like TRON/OFF , current , voltage, Rapper On/OFF

etc. are made available to all intranet usersthrough a JSP software.


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Future upgrade

New customer requirements can be addedeasily

Can be upgraded easily for latest / futureversions of Microsoft Windows OperatingSystems. ( Eg. Windows 2000 and latest)


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Salient Features

Pass word protection at two levels

Communication channel health monitoring &indication at relevant forms

Operators input validation Warning messages

Web server to publish WEB page developed in

JSP Successfully tested at Mettur TPS &

Ramagundam STPS

H d C fi ti f NT IOS


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Hardware Configuration of NT-IOS

Opacity monitor & calib.input

Boiler

load

DATA-

LOGGER PC

PRINTER

SUPPORT

INS

HEATER

SHAFT

INS

HEATER

ESP

BUSSECTION 1

ESP

BUSSECTION 2

FIELD-1

FIELD-2

FIELD-3

FIELD-4

FIELD-5

FIELD-6

FIELD-7

FIELD-8

HOPPER

HEATER

ESP

1 2

ALI

LOW

ESP

1 2

BHELSTATCON-E1

REBOOT

ALIVE

SUPPORT

INS

HEATER

SHAFT

INS

HEATER

ESP

BUSSECTION 1

ESP

BUSSECTION 2

FIELD-1

FIELD-2

FIELD-3

FIELD-4

FIELD-5

FIELD-6

FIELD-7

FIELD-8

HOPPER

HEATER

ESP

1 2

ALI

LOW

ESP

1 2

BHEL

STATCON-E2

REBOOT

ALIVE

RAPCO

N 4

RAPCO

N 1

BAPCO

N 1

BAPCO

N 2

BAPCON 3

BAPCON

24


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Opening Screen


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BAPCON Display


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RAPCON Display


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ANALOG Display - BAPCON


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Command Screen


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BAPCON Command


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RAPCON Command


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SETUP - Selection


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SETUP-BAPCON Base Data


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ALGORITHM SELECTION

h l i


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Graph Log - Selection

G h L


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Graph Log


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SELECT BAPCON for VI Curve


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VI Curve - BAPCON1

HELP


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HELP


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CURRENT LOOP vs MULTIDROP


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CURRENT LOOP vs MULTIDROP

DATAHIGHWAY

By pass relay is required incase controller is removed /fails

Network has to be physicallyre configured if there is a

breakage in maincommunication line.

Low protocol overhead, moreefficient at low speeds itself.

communication frames of

varying sizes allowed.

Termination resistance & bypass relay is required in casecontroller is removed / fails.

Network has to be physically reconfigured if there is a

breakage in maincommunication line.

Protocol overhead is high,therefore higher speed is must.

Communication frame size

standardized. Large messagewill have to be split.


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ALGORITHMS IN IOS

Opacity algorithm

Rapping power off algorithm

Rapping set no. Algorithm

Optimiser algorithm

Rapping power factor algorithm

Auto selection of opacity monitor basedon ID fan status.

REFERENCE LIST FOR IOS


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REFERENCE LIST FOR IOS

PROJECTS

Panki TPS unit - 3

Mettur TPS unit - 1

Panki TPS unit -4

Mettur TPS units - 2,3 & 4

Ennore TPS unit -

Kothagudem units - 9 & 10

Renusagar units - 7 & 9

Singrauli TPS 5 X 200MW

Korba TPS 3 X 200MW

Farakka TPS 3 X 200MW

Unchahar TPS 2 X 210MW

Vindhyachal TPS 6 X 2.0MW

Ramagundam TPS 3 X 500MW

Singrauli TPS 2 X 500MW

Korba TPS 3 X 500MW

Rihand TPS 2 X 500MW

Unchahar TPS 2 X 210MW


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RESULTS FROM A 120MW THERMAL PLANT

Increase in peak KV : 37%

Reduction in emission : 29%

Reduction in power consumption :150KW

(0.79 Million units/year at PLF :0.6 )


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CORONA POWER CONSUMPTION

PROJECT GAURANTEE CONVENTIONAL INTERMITTENT PERIOD

CHARGING CHARGING

RAMAGUNDAM #4 360KW 232.8KW 52.6KW Mar-90

PASS DRAMAGUNDAM #5 313.6KW 67.6KW Jan-92

PASS B

RAMAGUNDAM #6 242.4KW 74.5KW Dec-91

PASS CBADARPUR #1 400KW 184.0KW 26.0KW Feb-91

NALCO #1 450KW 164.0KW 24.0KW Dec-92


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PRELIMINARY RESULTS

SSTPS #6

COMPARISON OF KV-PEAK ( % )

CC I.E

EP1 AB 63 71

CD 48 60

EP2 AB 57 63

CD 57 66

EP3 AB 55 63

CD 63 68

EP4 AB 56 62

56 57

AVERAGE 57 64 12%


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ADVANCED OPERATING LOGIC:ETPS

C.R.RANGE O.D. W/O B.CH O.DW B.CH

UPTO 1:99 18.0% 16.2%

UPTO 1:31 18.6% 16.8%

UPTO 1:15 26.2% 23.9%

OPTIMUM CRs: 11, 37, 51, 57, 75

B.CH: 3, 3, 5, 7, 12

REDUCTION IN CMISSION: 38%

FROM:26.2

TO :16.2

INTEGRATED OPERATING SYSTEM


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ENNORE TPS #1

TEST RESULTS (SERIES - 1)

REDUCTION IN EMISSION : 38%

OPTICAL DENSITY

CR SETTING WITH BASE WITHOUT BASE

RANGE CHARGING CHARGING

1 - 15 25.2 26.1

1 - 31 17 21.1

1 - 99 16.2 19.7

ETPS #1COMPARISON OF PERFORMANCE OF BAPCON


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COMPARISON OF PERFORMANCE OF BAPCON

Vs

OTHER INTERMITTENT CHARGING

CONTROLLERS:

OPTICAL DENSITYBAPCON (CR UPTO 1:99) OTHER CONTROLLERS

WITH BASE CHARGE (CR UPTO 1:15, NO

BASE CHARGE FEATURE )SERIES 1 16.2 26.2

SERIES 2 16.2 26.1

CRs 11,37, 51, 57, 75 5, 7, 9, 11, 13

B.CH. 3, 3, 5, 7, 12

MEASURED REDUCTION IN OPTICAL DENSITY(EMISSION ) DUE TO BAPCON AS COMPARED TO OTHER

INTERMITTENT CHARGING

CONTROLLERS : 38%


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Latest Controllers


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BAPCONplus

Engineering Unit display

Designed for 660MWapplication

VFD display

Local & Remoteoperation

CR mode

Base Charge mode

Warning & TRIP Alarms


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BAPCON-II

Single board design

Fewer components, Higherreliability

RS-485 bus based high-speed network

Remote operation

Concealed in HVR panel

In-built rapping


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BAPCONsigma

Primary parametersmeasurement

Power Measurement

Open Standard MultiMasterNetwork

Peer to Peer communication

Spark & Arc detection andsuppression

Single card design Concealed in HVR panel


78/93

RTU

Light weight Hand held unit

Graphical Display

64x128 pixel LCD

Membrane keypad RS-485 network

User interface unit forBAPCON-II, RAPCON-II


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RTUsigma

Graphical User Interface

240x128 pixel LCD

Tactile membrane keypad

Open standard Multi masterprotocol communication

Parameter trending

Alarm logging

Flash based programming


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RAPCON-24

Supports up to 12 fields

Hot-Standby feature

Real Time Clock (RTC)

User set parameters Storedin NVRAM

Labeling of outputs

Isolated Inputs and Outputs


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RAPCON-II

RS-485 based network

Only Remote operation

Concealed inside the panel RTC and NVRAM

Lesser components


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REDUNDANT RAPCON FEATURES

Master will be active, when it is Healthy.

The Slave will become active, when Master

becomes Faulty. The taking over time is 1 Sec.

Communication between Master & Slave will

happen in every 100 ms.

The Slave will become passive, when Master

becomes Healthy.

A


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FIELD-1

FIELD-2

FIELD-3

FIELD-4

FIELD-5

FIELD-6

ESP-1 ESP-2 ESP-1 ESP-2

ALI-HIGH HOPPER HEATER

ESP-1

ESP-2

SUPPORT INS.

HEATER

SHAFT INS.

HEATER

ALIVE

STATCON-E

REBOOT

Ash Level Indicator


86/93

Micro controller PIC 16F877 (Flash, EEPROM)

Single monitor handles 64 sensors

A single twisted - pair wire carries both signal & power betweensensor and monitor

Digital tuning for setting full and empty level of each hopper frommonitor end

Intellicom Protocol Converter


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Micro controller PIC 17C756 (16K,900B)

Dual com port handles dual protocol Supports RS232 or RS485 or RS232 current loop

Compact size DIN rail mountable


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COMMON TERMINAL FOR MULTIPLE IOS

CENTRALISED CONTROL SYSTEM

CONTROL & DISPLAY FOR INDIVIDUAL SUB-CONTROLLERSTHROUGH IOS

INTERFACE : RS-232C TO RS-485

PROTOCOL : MODBUS ( ASCII )

WINDOWS BASED APPLICATION SOFTWARE

CENTRALISED CONTROL & DISPLAY FOR MULTIPLE IOSs


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IOS

#6

IOS

#7

IOS

#8

IOS

#9

IOS

#10

IOS

#11

CIOS

PC

RS-232C TO RS-485

CONVERTOR

BAPCON COMMAND SCREEN


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RAPCON COMMAND SCREEN


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RAPCON STATUS DISPLAY


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THANKING YOU

Documents

Electro Static Precipitator Controler