WPCA AMEREN ESP SEMINAR Undrstanding ESP Controls By John Knapik 2004, Gnral Elctric Company
Efficincy vs. Spcific Corona Powr KNOW WHERE YOUR ESP RUNS ON THE CURVE 99.9 99.0 Collction Efficincy (Prcnt) 80.0 0 100 200 300 400 500 600 Corona Powr Watts/1000 ACFM Propritary 2
AVC Cabint, CLR & T/R St Propritary 3
Typical SCR-CLR Elctrical Systm + SCR Stack - + L-1 Currnt Limiting Ractor (CLR) Primary Voltag Mtr Transformr/Rctifir (T/R) St V CT L-2 Primary Currnt Mtr A Scondary ma Currnt Mastr Firing Circuit Scondary Voltag KV Mtr Microprocssor(s) Control Modul Automatic Voltag Control Propritary Prcipitator Fild ma Signal Rsistor 4
Just Rmmbr, th Primary of a T-R St is Ratd in Units of RMS, th Scondary is in Avrag 400 V AC RMS 120 A AC RMS 45 KV DC Avrag 750 ma DC Avrag Thrfor us an RMS Rading Mtr to Calibrat th Primary Mtrs Propritary 5
Not! How Do You Tll Th Diffrnc? Iron Van Movmnt D Arsonval Avrag RMS Th Mtr Scal Distanc is not th Sam on th RMS Mtr. Propritary 6
Primary Currnt Mtr + SCR Stack - + L-1 Currnt Limiting Ractor (CLR) Primary Voltag Mtr Transformr/Rctifir (T/R) St V CT L-2 Primary Currnt Mtr A Scondary ma Currnt Mastr Firing Circuit Scondary Voltag KV Mtr Microprocssor(s) Control Modul Automatic Voltag Control Propritary Prcipitator Fild ma Signal Rsistor 7
Finding th Primary Currnt Wavform Propritary 8
Primary Currnt A Choppd Sin Wav Propritary 9
Primary Currnt Wavform - Positiv and Ngativ Half-Cycls = SCR 1 and SCR 2
Scondary Currnt Mtr + SCR Stack - + L-1 Currnt Limiting Ractor (CLR) Primary Voltag Mtr Transformr/Rctifir (T/R) St V CT L-2 Primary Currnt Mtr A Scondary ma Currnt Mastr Firing Circuit Scondary Voltag KV Mtr Microprocssor(s) Control Modul Automatic Voltag Control Propritary Prcipitator Fild ma Signal Rsistor 11
Finding th ma Signal Propritary 12
Scondary Currnt Pulsating DC Propritary 13
Typical Primary and Scondary Currnt Propritary 14
Scondary Voltag Mtr + SCR Stack - + L-1 Currnt Limiting Ractor (CLR) Primary Voltag Mtr Transformr/Rctifir (T/R) St V CT L-2 Primary Currnt Mtr A Scondary ma Currnt Mastr Firing Circuit Scondary Voltag KV Mtr Microprocssor(s) Control Modul Automatic Voltag Control Propritary Prcipitator Fild ma Signal Rsistor 15
Currnt Limit - ma & KV Propritary 16
Scondary Voltag Wavforms Tru Ngativ ma KVmi n Propritary KVpak 17
Nxt Th Automatic Voltag Control + SCR Stack - + L-1 Currnt Limiting Ractor (CLR) Primary Voltag Mtr Transformr/Rctifir (T/R) St V CT L-2 Primary Currnt Mtr A Scondary ma Currnt Mastr Firing Circuit Scondary Voltag KV Mtr Microprocssor(s) Control Modul Automatic Voltag Control Propritary Prcipitator Fild ma Signal Rsistor 18
Th AVC is th BRAINS of th ESP
Oldr Analog AVC Propritary 20
Microprocsso r Basd AVC Propritary 21
Th AVC has 2 Jobs to Excut Propritary Control th amount of sparking in th ESP. If a T/R st is not sparking, thn its AVC should b pushing that T/R st to on of its pr-st, halthy limits (volts, amps, KV, ma, or firing angl). I ll xplain what is mant by halthy in a minut 22
Th AVC has 2 Jobs to Excut But how dos th AVC know what s happning in th ESP?
Transformr Rctifir St Th ma signal is its ys! ma Mtr Currnt) Ground Rturn Lg Plat (+) (Prcipitator Voltag) KV Mtr KV (Prcipitator ma Elctrod + + + + + Fr Elctrons = Positiv & Ngativ Ions = + Chargd Particls = Propritary 24
AVC Cabint, CLR & T/R St Propritary 25
AVC Spark Rspons SPARK SETBACK QUENCH Propritary FAST RAMP SPARK RATE 26
Good Initial Sttings for an AVC 1. Qunch = 1 Full Cycl 2. Fast Ramp = 5 or 6 Half Cycls 3. Stback = 15 to 20% 4. Spark Rat = 30SPM Propritary 27
Propr AVC Rspons to Sparking Propritary 28
Spark Rspons - Scondary Currnt Wavform Propritary 29
Spark Rspons - Scondary Currnt and Voltag Wavforms Propritary 30
Typical Spark Rspons - ma & KV Propritary 31
Furthr Control A Sarch Ramp Rat Nw Spark Thrshold or T/R Limit Sarch Ramp Spark Thrshold P O W E R AUTO PRCS FLWR Stback PHASE BACK Fast Ramp Qunch (Rspons to Spark) INTERRUPT Propritary Slow Ramp (dtrmind by spark rat) RAMP PEDESTAL T IM E 32
Spit Spark Rspons (ma) Propritary 33
Spit Spark Rspons - Scondary Currnt and Voltag Wavforms Propritary 34
Exampls of AVC s at a Limit
AVC SPARK LIMITED DOING IT S JOB Propritary 36
T/R Currnt Limitd with Sparking Propritary 37
T-R CURRENT LIMITED WITHOUT SPARKING Propritary 38
T-R VOLTA LIMITED WITH SPARKING Propritary 39
What is mant by Halthy Limits? Primary or Scondary Limit is not halthy whn accompanid by a Primary Voltag lvl < 90 VAC or a Scondary lvl < 12KV. It usually indicats a short circuit. Scondary Voltag Limit is not halthy whn thr is vry littl Scondary Currnt. It usually indicats an opn circuit. Nithr condition is aiding in particl captur Propritary 40
Th T-R St + SCR Stack - + L-1 Currnt Limiting Ractor (CLR) Primary Voltag Mtr Transformr/Rctifir (T/R) St V CT L-2 Primary Currnt Mtr A Scondary ma Currnt Mastr Firing Circuit Scondary Voltag KV Mtr Microprocssor(s) Control Modul Automatic Voltag Control Propritary Prcipitator Fild ma Signal Rsistor 41
Transformr Rctifir (T/R) St Propritary 42
Insid T/R Tank Propritary 43
High Voltag Transformr Propritary 44
Diod Stack Propritary 45
T/R St Low Voltag Junction Box Propritary 46
Low Voltag Junction Box Propritary 47
T/R Namplat Propritary 48
Th KV Mtr + SCR Stack - + L-1 Currnt Limiting Ractor (CLR) Primary Voltag Mtr Transformr/Rctifir (T/R) St V CT L-2 Primary Currnt Mtr A Scondary ma Currnt Mastr Firing Circuit Scondary Voltag KV Mtr Microprocssor(s) Control Modul Automatic Voltag Control Propritary Prcipitator Fild ma Signal Rsistor 49
Voltag Dividr Propritary 50
SCR S + SCR Stack - + L-1 Currnt Limiting Ractor (CLR) Primary Voltag Mtr Transformr/Rctifir (T/R) St V CT L-2 Primary Currnt Mtr A Scondary ma Currnt Mastr Firing Circuit Scondary Voltag KV Mtr Microprocssor(s) Control Modul Automatic Voltag Control Propritary Prcipitator Fild ma Signal Rsistor 51
SCR Propritary 52
Typical Sin Wav SCR Firing Angl (90 ) + - Powr On Zro Crossings Tim Conduction Angl (90 ) 0 90 180 270 360 8.33 millisconds Propritary 53
SCR: Low Voltag to T-R St Firing Angl 140 Conduction angl 40 Propritary 54
SCR: High Powr to T-R St 400 Firing Angl 40 Conduction angl 140 Propritary 55
Th CLR + SCR Stack - + L-1 Currnt Limiting Ractor (CLR) Primary Voltag Mtr Transformr/Rctifir (T/R) St V CT L-2 Primary Currnt Mtr A Scondary ma Currnt Mastr Firing Circuit Scondary Voltag KV Mtr Microprocssor(s) Control Modul Automatic Voltag Control Propritary Prcipitator Fild ma Signal Rsistor 56
Currnt Limiting Ractor (CLR) Propritary 57
Currnt Limiting Ractor Propritary 58
Currnt Limiting Ractor at T-R St Propritary 59
SCR s ar why CLR s ar Ndd Th diagram would rprsnt th wavform with th SCRs turning on at 90. If this wavform wr applid to th T/R st, vry infficint opration would occur. Output powr from th T/R st would b gratly rducd. Propritary 90 90 60
Elctrical Basics: CLR To incras th fficincy of th T/R st, a dvic calld a CLR (currnt limiting ractor) is usd. A CLR is an inductor. Rcall that th proprty of an inductor is to oppos a chang in currnt. Bcaus of this proprty, th shap of th currnt wavform is changd and it starts looking mor lik a sin wav. Propritary 61
CLR Function Limit short circuit currnt Shap T/R scondary wav to b mor sinusoidal Provid propr form factor Protct SCRs and T/R diods from stp currnt ris Incras prcipitator voltag and currnt Not to b confusd with air cor ractor Propritary 62
CLR Wavform Changs with Impdanc Propritary 63
Propr CLR Sizs for Common T/R Sts All T/R primaris ar ratd at 400V Propritary PRI Currnt (Amps) Sc. Currnt (ma) 40 80 120 160 200 240 250 500 750 1000 1250 1500 Minimum (mh) 13.0 6.6 4.4 3.3 2.6 2.2 64
Basic Troublshooting Enrgy
TR Namplat Valus (For this xrcis) Primary Currnt 160 Amps Primary Voltag 480 Volts Scondary Currnt 1200 ma Scondary Voltag 45 kv Propritary 66
160 480 First Indication 1200 45 Scond Indication Short Propritary 67
Clos Claranc 160 Propritary 480 1200 45 68
Conductiv Dust, Outlt Fild 160 Propritary 480 1200 45 69
Bad KV Rturn 160 Propritary 480 1200 45 70
Opn 160 Propritary 480 1200 45 71
Normal Running Condition 160 Propritary 480 1200 45 72
SCRs Not Firing 160 Propritary 480 1200 45 73
Qustions? Thank You.