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Precipitator Inspections

Inspections & Maintenance
An effective electrostatic precipitator inspection is part of
routine equipment maintenance. For example, at the
municipal utilities power station in Sikeston, Missouri,
precipitator blast-cleaning is done every year along with a
walk-through and routine rapper tune-ups. Complete detail
inspections and larger repairs are scheduled every other year
during longer outages.

“By keeping up with this maintenance, and also doing a more

thorough inspection every other year, we get a lot more
longevity out of the run,” explains Ed Boyd, Sikeston’s
electrical supervisor and project engineer, who has been in
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the industry for 34 years.

Any inspection, whether a quick walk-through or a more

lengthy check-up, requires some legwork up front, and a plan
for prioritization during and afterward. This article outlines
best practices for a smooth inspection. If you’re doing the
inspection yourself, treat this as a checklist. If you’re hiring a
contractor, make sure these steps are part of their routine
procedure.

First, clarify desired outcomes of the inspection with whoever

will get a report afterward and is authorized to act on
recommendations. Having a clear objective up front will save
time, money and headaches later. The scope of work for a
preventative maintenance (PM) inspection will be different
from one focused on troubleshooting speci눛�c problems.

Next, get background information from people responsible for

operating each area of the equipment (electrical, mechanical,
ash handling). Ask these people if there are speci눛�c issues
they’re troubleshooting. Piecing this information together will
provide a picture of current operating conditions and possible
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problem areas. For example, electrical issues might be
traceable back to hopper pluggage.

“It’s easy to get sidetracked or impatient looking for people

who have this information,” notes Jim Parsons, Senior
Environmental Consultant at Neundorfer, who has been doing
inspections for 30 years. “But it’s worth spending the time
gathering background information and clarifying expectations
before jumping in the ESP box.”

Background information gathered ahead of the inspection

should include original design speci눛�cations. These specs
enable you to create an accurate precipitator layout form (a
grid showing the location of plates, wires and other
components) to mark with notes during the inspection. A
layout form is especially vital if you’re inspecting a large
precipitator; without a map showing where things are located,
the job can be daunting.

“After a while, it’s like walking around in a cave with

sunglasses on,” Parsons says. “You can easily get overwhelmed
if you don’t have a clear idea of what to look for.”
With design specs, information about troubleshooting efforts,
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and understanding about expectations, you can effectively
prioritize where to begin and what to look for during the
inspection.

Before actually heading into the precipitator, of course, make

sure all safety protocols–including tag-out and lock-out–are
being followed. This is high-voltage equipment and not
something to mess around with.

Usually, the inspection scope of work includes a standard list

of maintenance items and at least a few requests to look for
speci눛�c problems. At Sikeston, inspection work is prioritized
눛�rst based on job tickets, such as a report of rappers not
operating properly. It’s also standard practice to check for
broken insulators.

“We start with anything that’s obvious from the outside,” Boyd
explains. “Then, we go inside and look for anything unusual.”

Things can get pretty interesting during an inspection if you

are troubleshooting speci눛�c issues, but even a routine
maintenance walk-through will turn up items in one area that
impact performance elsewhere and require further
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investigation.

“If an ash line is clogged and we 눛�nd foreign material when

clearing it, during the inspection we go look for where that
material came from,” Boyd notes, citing one troubleshooting
example. “Or, if we do a quick inspection of the high voltage
area and 눛�nd arcing, we know there is moisture and we need
to look for leaks.”

Finally, an exit review meeting should be part of any

inspection. During this meeting, give the person you’re
reporting to a punch list of items that need to be addressed
right away.

A punch list is different from the more detailed report you’ll

submit later, which will focus on longer-term follow-up. For
example, if you 눛�nd bowed plates in a section of the
precipitator, the punch list might recommend pulling wires in
those areas to prevent electrical shorts. The longer report
would specify that the plates need to be straightened or
replaced.
It’s important that any inspection be performed by
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experienced professionals who understand how all
components of the system work, know what to look for, and
are informed about how to prioritize what needs maintenance
immediately and what can wait.

Purpose

Internal inspections of Electrostatic Precipitator’s (ESP) are a

necessary part of maintaining the “mechanical portion of the
electrical” to obtain maximum performance. In some
instances, when performance is deemed acceptable prior to a
scheduled outage, inspections often overlook speci눛�c internal
areas that can detract from collection ef눛�ciency during the
next on-line period of the ESP. Detailed internal inspections
are required to properly schedule current and future
maintenance and as a prelude to failures. The following are
recommendations, generic in nature, for the conduction of an
inspection that will “time freeze” the condition of the internal
ESP components.

Legal Notice
CAUTION – Inspections should only be accomplished under
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the direction of personnel familiar with all Electrostatic
Precipitator Safety procedures. It is important that proper
grounding procedures and removal of all sources of power be
accomplished prior to entering the Precipitator. LETHAL
VOLTAGES CAN BE PRESENT AND CAN LEAD TO DEATH BY
ELECTROCUTION IF THE PROPER PROCEDURES ARE NOT
FOLLOWED.   Hot dust may be present on the interior surface
of the ESP. These dust deposits may be cool on the surface,
but the interior of the deposit may retain suf눛�cient heat to
cause SEVERE BURNS ESPECIALLY WHEN OPENING HOPPER
DOORS. CONSULT YOUR PLANT’S SAFETY MANUAL FOR PROPER
PROCEDURES. Neundorfer, Inc. is not responsible for any
damages or injury as the result of this document and the use
of the document is at the sole risk of the USER and NOT
Neundorfer, Inc.

Pre-Inspection Preparation

1. Take electrical readings from all High Voltage Controls (MC)

at normal operating conditions.
 2. If possible, take a set of V-I Curves for each MVC identifying
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the “corona” onset voltage. (First ῎�ow of secondary
current).

3. Record all Rapper Control Parameters including cycle

times, time between raps and intensities.

4. Develop “Cell Diagrams” of each ESP Field showing every

Collecting Electrode (CE) and Discharge Electrode (DE) with
numbers on CE’s and Gas Passages (GP).

5. Develop “Roof Plan Diagrams” of the ESP showing the

Transformer-Recti눛�ers (T-R), CE and DE Rappers and
locations of High Voltage Support and Rapper Shaft
Insulators.

6. As soon as the Fuel supply is turned off (I.E. coal mills

stopped, wood/wood waste feeders stopped, Black Liquor
Guns pulled, etc.) Turn off the Rapper Controls.

7. Leave the T-R sets on until the Fans are shutdown.

8. After Fan shutdown, turn off the MVC’s.

9. Remove all ash from the Hoppers.

10. Follow speci눛�c owner and ESP Manufacturer instructions

for Key Interlock Lock-Out and Tag-Out of the Transformer-
 Recti눛�ers.
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11. Follow speci눛�c owner and ESP Manufacturer instructions
for entry into the Precipitator following all grounding,
entry and Personal Protection Equipment (PPE)
procedures.

Dirty Inspection

The purpose of the Dirty Inspection is to examine dust

deposits on the ESP internals.   It becomes a guide for
determining the effectiveness of the Rapping System, Flue Gas
Conditioning System (if equipped), Gas Flow Distribution and
unusual build-up’s, etc. Dust deposits not compacted by the
ESP electrical forces are often quite fragile so minimum
disturbance is recommended.
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1. Observe dust deposits in inlet and outlet ductwork and
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diffusers (I.E. Nozzles and/or Plenums, etc.), gas
distribution devices (such as Turning Vanes, Perforated
Distribution Plates) and any other internal struts, braces,
etc.

2. Conduct a GP by GP inspection noting the depth of dust

deposits on the CE’s and the characteristics of the
particulate. (I.E. Color, Density, Muddy, Cement like, etc.)
Note if deposits are more in a given area. (Measuring
depths is recommended.) Inspect all lower and mid-point
CE horizontal spacers and CE Alignment devices attached
to the Casing.

3. Inspect all DE’s noting dust deposits on the DE’s and Lower
Discharge Electrode Frame (LDE). (DE deposits could be
light, donuts, smooth, pointy, etc.) Examine the condition
of the lower Anti-Sway insulators is so equipped,
especially for carbon and tracking.

4. Measure and record all CE to DE spacing.

5. Look down into the hoppers and note any buildups in the
corners, valley angles and baf῎�es.
6. From the inside of the Penthouse or Insulator
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Compartments inspect all High Voltage Support and
Rapper Shaft Insulators noting dust deposits, cracked
and/or tracking.

7. Inspect all other High Voltage Insulators such as Standoff,

Feed-Through, etc, for dust deposits and tracking.

8. Inspect all Buss Ducts and High Voltage Conductors and

connections.

9. Observe dusting on the interior surfaces of the Penthouse

or Insulator Compartments. Observe any air-in and water-
in leakages.

10. Open “Hot Roof” access doors noting gasket, hold-downs

and corrosion.

11. Inspect the Upper Discharge Electrode Frame (UDE) and

tops of CE’s noting dust build-up and dust characteristics.

12. Check the UDE Frame for vertical position from the tops of
the CE’s in four locations.

13. Check the High Voltage Support Insulators from the top of
the UDE frame and the corona shield (if so furnished)
noting any corrosion or miss-alignment of the UDE Support
 Rod or Pipe. Check all welds of the Support Rod/Pipe to
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the UDE Frame.

14. Check all DE connections to the UDE Frame noting any

corrosion or electrical erosion. Look for bent or twisted
DE’s and bent emitter pins (Rigid Discharge Electrodes).

15. At approximately the four outermost corners of the UDE

Frame Measure the DE to CE Spacing in the direction and
perpendicular to Gas Flow. This will determine the relative
position of the UDE Frame with regard to the CE System.
Place a level on the UDE frame between Support
Rods/Pipes and record.

16. Check all CE suspension bolts and Rapper Shaft

connections to the CE’s and/or CE Suspension. Inspect all
welds.

17. Look for any water-in leakage and/or corrosion on the

sidewalls and girders of the casing and underside of the
hot roof. Pay close attention to any penetrations in the hot
roof including High Voltage Support Lifting Rod Nipples
and Rapper Shafts.

18. From the Hopper Access Doors Inspect all internal hopper
surfaces and Door Condition.
19. Exhausted and dirty, clean up and take a well-deserved
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break while transposing notes to the Cell and Roof Plan
Diagrams.

Interpretation of Dirty Inspection Results

1. From the dust deposits and DE to CE Spacing recorded on

the Cell Diagrams, compare these to the electrical readings
taken ahead of the shutdown. Using a “rule of thumb” of 10
KV/Inch of clearance between the DE’s, CE’s and other
grounded surfaces a general agreement should be noted.

2. DE deposits usually result in higher KV and lower MA.

3. CE deposits usually result in lower KV and MA.

4. Dust deposits that are found to be heaver in one part of a

Field as compared to other parts dramatically detract from
performance.

5. Schedule maintenance/repairs from recorded non-

operating Rappers.

6. Re-align DE’s to CE’s to achieve the ESP Manufacturer’s

Tolerances.