ESP Rectifier transformer

M.G.Morshad / ACM
Transformer Mtce / TPS II

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
+++++++++++++++++++++
- - - - - - - - - - - - - - - - - - Spark between
layers of dust
particles

Negatively
charged
emitting
electrodes

- - - - - - - - - - - - - - - - - - -

Negativel
y charged
dust
particles

High
resistive
dust
particles

Positively
charged
collecting
plates

++++++++++++++++ +++++
+
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 decrease 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

Spark between
layers of dust
particles

+++++++++++++++++++++
+ + + + + + + + + + + + + + + + + + + +
+ + + + + + + + + + + + + + + + + + +
+ + + + + + + + + + + + + + + + + +
+ + + + + + + + + + + + + + + + + + +
+ + + + + + + + + + + + + + + + + + +
+ + + + + + + + + + + + + + + + + + + +
++++++++++++++++ +++++
+

Negatively
charged
emitting
electrodes

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.

Voltage - current characteristics

mA ( DC)
Field Short

Back Corona Zone

Operating Zone
KV ( DC)

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

flow of field current (mA)

causing field voltage KV(DC) to become zero with maximum

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, re-entertainment of particles takes place in
the main flow path and carried away by the gas causing increase in emission level . To reduce the reentertainment 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

Components of rectifier transformers

Microprocessor based
Voltage controller
Control panel
1.
2.
3.
4.

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
1.Series reactor,
2.Transformer coil,
3.Rectifier bridge,
4.Resistor assembly
5.HF choke.
6.Insulating oil
7.LV & HV Bushing
8.Control feed back terminals

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
AC Input = 415 V,200A

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

CLR
Input KVA = 373.5 x 200 = 75KVA
Input KW = 75KVA x1 = 75KW

Voltage
Ratio
1:143.42

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

AC Out put = 53570 V, 1.40 A

Rectifier
Bridge

DC Volt / Current

Various capacity of transformer

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

Current Limiting Reactor

Impedance (Z) = V/I (AC Resistance)
Z = V/I = L x 2f Ohms
% Z = [(L x 2f x I) / V ] x 100 Ohms
L = (V x %Z) x (I x 2f ) Henry
CLR reactance (L) = 1.5 mH
CLR resistance ( R ) =9 m
Impedance of CLR =24.64%
TR impedance = 10%
System impedance = 34 .64%

415 V
Supply

Series
Reactor

373.5 V
Supply

L
V

H
V

Rectifier
unit

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

1. 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.
2. 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)

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

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
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
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

Principle of operation
Depending upon gas temperature, dust
resistivity and gas velocity following
parameters are set1.uni pulse mode/ Semi pulse mode ,
2.peak mode ,
3.charge ratio,
4.spark control rate ( S & T)
5.secondary DC current limit
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.

Current limit

mA

Max Current at which spark occur

SCR controller restarts conduction after

20 ms with slop less than 5%

S
T

20ms Blocking time

Time

This process goes on continuously to

keep the field in energized condition with
negative polarity without any spark.

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.
SCR controller

Rectifier

Uni pulse
V

Sinusoidal input

Semi pulse
V
I

Charge Ratio
Uni pulse mode
Charge Ratio 1
1

Semi pulse mode

Charge Ratio 3

Semi pulse mode

Charge Ratio 5

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.

spark control rate

5%

95%

( S & T control)

T= 6 sec

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 S-Control 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.
S-Control & 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.

Field current setting

I1

CLR
415 V
supply

V1

+ Positive

I2

mA

L
V

H
V

KV2

KVp

- Negative

Formula
Secondary
Current
Secondary
Current
Secondary
Voltage
Secondary
Voltage

HFC

Field
Field I Field II Field III
IV

Field V

Field
VI

DC
AC
DC
AC

Out Put KW
Trfo voltage
ratio
Primary AC

mA
I2 = (mA x
1.4141)/1000
KVp = (70 x
mA)/1000
KV2 = (KVp x
1.08)/1.414
Kwo =
(mAxKVp)/1000

100.00 200.00 500.00 500.00 700.00 700.00

143.42 143.42 143.42 143.42 143.42 143.42

V = (KV /R)*1000

0.14

0.28

0.71

0.71

0.99

0.99

7.00

14.00

35.00

35.00

49.00

49.00

5.35

10.69

26.73

26.73

37.42

37.42

0.70

2.80

17.50

17.50

34.30

34.30

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

Clean gases to chimney

6A

12 A

6B

12 B

5A

11A

5B

11B

4A

10A

4B

10B

3A

9A

3B

9B

2A

8A

2B

8B

1A

7A

1B

7B

Dusty gases from RAPH

Transformer connection / Stage II

AR
AS
2

Protection
diode

A2

AS
1a3
ACR
av
LV

HV

Diode
Stack

H.V
Resistance

a1
A1
Terminal / Parts
a3 - av
av- a1
Internal Terminal
a3 a1
A1
A2
AS2 AR
HF Choke
Diode Stack
H.V resistance
Protection diode

HF Choke

Purpose
AC series Reactor to restrict primary current incase of shorted secondary ( Resistance 9.32 m Ohms)
winding terminal ( Resistance 14.6 m Ohms)
HV winging terminal (Resistance 454 Ohms)
Two phase AC input terminal (Resistance 24.84 m Ohms)
Negative terminal to create negative potential in the fields
Positive terminal earthling point to create positive potential in the structure
DC feed back voltage measuring terminal
To reduce sparking rate at HV terminal ( Inductance 50mH, 6.74 Ohms)
Full wave bridge rectifier for converting AC to DC
Voltage divider
To protect the bridge from reverse biasing

Open circuit test BHEL Transformer

Voltage Applied on LV
Magnetizing current measured DC feed Back voltage measured
terminals Using Variac (Volt)
on LV terminals (Amps)
between AS2&AR (V)
0.116
20.20
50
0.176
41.00
100
0.190
58.20
150
0.280
77.20
200
0.490
96.50
250
2.460
116.00
300
3.110
133.00
350
4.240
140.50
374

Short circuit test BHEL Transformer

Voltage Applied on LV Current measured on DC feed Back Current
terminals Using Variac LV terminals
measured between DC Current measured
(Volt)
(Amps)
AS2 & AS1 (mA)
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

Parameters

Value

Minimum 200 M Ohm

HV E , ( 2.5 KV Megger),

IR Value

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

Magnetizing
current test

24 25 m Ohms

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

OCC test at local Keeping A1 open
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

Actuations of
Buchholtz relay
BOTTOM FLOAT

Fault
detection

Load test at local Keeping A1 close

Parameters
Two phase Input AC voltage
Primary current
Secondary Voltage
Secondary current

Value
110 to 120 Volt
14 15 Amps
33 KV
100 mA

Causes
Internal short circuit between turns
Short Circuit between phase &
earth
Phase to phase short circuit
Insulation break down

Causes

Actuations of
Buchholtz relay
TOP FLOAT

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

Make
Location

MERLIN GERIN ( France)

ESP I,II,II

Population / Unit

24 Nos

Total Population

3 x 24 = 72 Nos

Capacity
% impedance
Primary rated current
Voltage Ratio

75 KVA
8%
181 amps (AC)
415 V / 54000V

Output voltage

75Kv(DC)

Output current

0.13 Amps (DC)

DC out put
Primary fuse rating
Protection

59 KW
250 amps / 500 Volt
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

Clean gases to chimney

A6

B6

C6

D6

A5

B5

C5

D5

A4

B4

C4

D4

A3

B3

C3

D3

A2

B2

C2

D2

A1

B1

C1

D1

Dusty gases from RAPH

Transformer connection / Stage I

Spark detector

+
a

182
K,
W
resistor
s

ACR
c
LV

HV

HV Bushing
Terminal / Parts
a-c
c- b
a-b
+
m

Diode
Stack

17 nos
resistor
s, each
4M

HF
Choke

Purpose
AC series Reactor to restrict primary current incase of shorted secondary ( Resistance 11.2 m Ohms)
LV winding terminal ( Resistance 18.8 m Ohms)
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
Spark detector terminals

Open circuit test Stage I transformer

Voltage applied
between (a-b)
50 Volt
100 Volt
150 Volt
200 Volt
225 Volt
250 Volt
275 Volt
300 Volt
325 Volt

Current through
primary winding
89.2 m A
148.2 m A
0.19A
0.27 A
0.34 A
0.42 A
0.57 A
0.77 A
1.04 A

Fault detection through meter readings (1)

Primary side

Secondary side

No power to T/R set

Primary side

Secondary side

Short CircuitDC 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

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)

Primary side

Secondary side
1. Megger diodes for shorts.
2. Run T/R without diodes. If AAC still high,
transformer is bad.

Short Circuit T/R set

Primary side

Secondary side

Open circuit

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

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.

As a result of heat the HV winging joints gets melted.

inter winding arcing

HV winding gets opened

Arcing results in the breakdown of the dielectric fluid .

Instant arching causes generation of gas

Continuous arching causes generation of carbon

particles

Actuation of B Relay

Carbon particle gets accumulated in HV windings

HV winding gets shorted

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.