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During the operation of a wet electrostatic precipitator, damage and cracking of insulating porcelain insulators often occur, which will lead to failure to apply high external voltage or transmit power. What are the causes of this situation?

1. Condensation Leakage: During the operation of the dust collection chamber, the temperature drops and SO? condenses on the surface, which often causes leakage. Therefore, the equipment must be operated at an appropriate temperature (300℃ at the outlet).
2. Damage During Installation: The installation work shall be carried out with caution, and care must be taken to avoid collision or improper installation.

Replacement of Insulating Porcelain Insulators for Wet Electrostatic Precipitator

Phenomenon: Excessively frequent flashover, accompanied by decreased dust collection efficiency

Causes:
(1) Discharge occurs outside the electric field of the electrostatic demister, such as discharge at the isolating switch, high-voltage cable, damping resistor, etc.
(2) The spark rate of the electric control cabinet is not properly adjusted.
(3) Fluctuations in operating conditions lead to drastic changes in flue gas parameters.
(4) Improper adjustment of the distance between cathode wires and anode plates.

Troubleshooting:

(1) Eliminate the discharge at the faulty parts.
(2) Adjust the spark rate potentiometer and switch the device to automatic mode.
(3) Notify the chief operator to optimize process conditions and improve flue gas parameters.
(4) Adjust the distance between cathode wires and anode plates to the standard range.

Phenomenon:
 
Low primary and secondary voltage; low secondary current. The primary current is much higher than normal, rises rapidly, and is disproportionate to the secondary current rise.Cause: Turn-to-turn short circuit occurs in the rectifier transformer, or the silicon stack is open-circuited or broken down.

Troubleshooting: 

Conduct an open-circuit test. If current is detected on the primary side, it indicates internal component damage, magnetic bias or short circuit in the transformer. Lift the transformer core for maintenance and replace the damaged components.

Phenomenon: 

Low primary and secondary voltage; low secondary current. The primary current is extremely high, rises disproportionately to the secondary current, surges and changes abruptly. This may blow the quick fuse, and the transformer emits obvious abnormal noise.

Causes:

(1) Short circuit fault in the low-voltage winding of the rectifier transformer;
(2) Insulation damage to the rectifier transformer core (including through-core bolts), resulting in severe eddy current.

Troubleshooting:

(1) Replace the low-voltage winding;
(2) Re-insulate the transformer core.

Phenomenon: 

When primary and secondary currents reach rated values, the primary voltage stays between 280–330V, the secondary voltage ranges from 40–50kV, and no flashover occurs.Cause: Severe leakage at the high-voltage cable and its terminal.

Troubleshooting: Reconstruct the high-voltage cable and its terminal.

Phenomenon: 

Frequent frequency conversion of the alkali supply pump, large fluctuation in rotation speed, and drastic changes in the pH value of the circulating water tank.Cause: Clogging of the neutralization pipe in the circulating water system by foreign matters.

Troubleshooting: 

Clean the foreign matters inside the anode tubes of the electrostatic demister.

Phenomenon: 

Gradual decrease in circulating water flow, accompanied by a progressive drop in dust collection efficiency.

Cause:

Scaling on the pipelines of the electrostatic demister and the circulating water pump.Troubleshooting: Appropriately reduce the pH value of the circulating water tank to 5.2 during operation.

Wet Electrostatic Precipitator (WESP)

To ensure the long-term stable operation of an electrostatic precipitator and achieve the expected dust removal efficiency, a designated person shall be assigned to be responsible for its operation and maintenance. The person in charge must meet the four understandings and three competencies requirements for the electrostatic precipitator.The four understandings refer to: understanding the structure, understanding the working principle, understanding the performance, and understanding the functions.The three competencies refer to: being competent in operation, being competent in maintenance, and being competent in troubleshooting.

An inspection shall be conducted on the electrostatic precipitator every time it is shut down, including cleaning the electric field, straightening severely deformed anode plates and cathode wires, wiping the insulating porcelain components, measuring the insulation resistance, and troubleshooting faults occurring during operation. In addition, a medium maintenance shall be carried out once a year, which includes replacing damaged parts. For each overhaul, the electric field shall be comprehensively cleaned and adjusted, all parts that affect performance or are damaged shall be replaced, and the lubricating oil shall be changed regularly.

Routine Inspection and Maintenance of Electrostatic Precipitators

1.1 First check the dust accumulation status inside the electric field before cleaning it.

1.2 Check the side walls of the electric field, access doors, insulator chambers on the top cover, and other parts for air leakage, condensation, dust caking, corrosion, or dust accumulation, and remove these defects accordingly.

1.3 Check the temperature of each drive motor, the oil level inside the reducer, whether the rapping shaft bearings are jammed, whether the hammer heads rotate flexibly and are not loose or missing, and whether the impact contact positions are accurate. Apply lubricating oil to the motors in accordance with the product specifications.

1.4 Sometimes the gas distribution plates in areas with low flue gas velocity may be prone to dust accumulation and clogging; inspect and perform manual cleaning on them.

1.5 Check the cathode frame and cathode wires for deformation and dust accumulation.

1.6 Check the anode plates and rapping rods for deformation and dust accumulation.

1.7 Insulating porcelain sleeves are used to support and insulate the discharge system. During operation, a layer of dust and dirt often accumulates on the surface of the porcelain sleeves, which may easily lead to surface high-voltage breakdown and thus crack the insulators. Therefore, the porcelain sleeves shall be kept clean. Wipe the inner and outer walls of the porcelain sleeves every time the equipment is shut down, and carefully check for tiny cracks with a flashlight.

1.8 Check the porcelain rotating shafts for the discharge electrode rapping device for dust adhesion and wipe them clean; replace them immediately if cracks are found.

1.9 Check whether the high-voltage silicon rectifier transformer (in accordance with the manufacturer’s instructions), high-voltage isolating switch, relays, heating element functions, temperature measurement and control instruments, alarm devices, and grounding devices are in normal condition, and eliminate any faults detected.

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