PRESENTATION

ON
ESP CONTROLLERS
R&D Center
ESP T/R SET CONTROL
ANALOG CONTROLLER AICE - C
RAPPING CONTROL
SYNCHRONOUS
PROGRAMMER
AUTORAPPER
UP BASED RAPPER
CONTROLLER
MANUAL CONTROL
COMPUTER CONTROLLED
PRECIPITATOR OPERATION
ESP CONTROL
BAPCON
RAPCON
(IOS)
ADVANCEMENTS IN ESP CONTROLS
Basic factors affecting ESP
performance
Properties of Flyash
- Particle size distribution
-small particles are difficult to
collect
- surface area affects visibility,
space charge
+
+
+
+
+
+

BACK CORONA
x i
qs
+
+
+
+
-
-
-
-
-
-
-
EP
Qs E p
F = Qs . Eav Ep . Eav
Vp . Vav
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
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.
BAPCON
BAPCON
_Intermittent charging, requirement of wide
charge ratio (CR) range of 1:159.
_Optimiser logic for C.R, avoids tedious manual
tunning.
_Base charging, increases base voltage.
_Peak & valley KV measurement : Diagnostic &
tunning facilitated.
VARIOUS DISPLAYS IN BAPCON
- Precipitator current
E - Precipitator voltage
H - Sparks per minute
O - 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
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.
RAPCON
MICROPROCESSOR CONTROLLER
Processor
Memory
Interrupts


Timers
Communication


I / O ports

Display
Auto restart
p Intel 8085 CPU at 3.072MHZ
p Rom / Eprom: 2x16k. Ram: 1x16k
p Hardware interrupts:
8259 - 8 interrupts
8085 - 3 interrupts
p Timer IC 8254 (3 timers)
p Serial communication
IC 8251 - 2NOS.
1.balance current loop(+/-10mA)
2. RS232-C communication or balanced current loop.
p Digital I / O: IC-8255 (2NOS) with provision for 42 digital
I/O analog I/O: Inputs-4NOS,(4-20mA)outputs - 2NOS, (4-
20mA)
p Provision for display controller 8279 for 80 leds.
p Watch dog pulses.
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.
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]
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.
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
PARAMETERS IN RAPCON
CONTROLLED BY IOS - P.C.
O Rapping factor.
O Program set no.
O Auto on/off.
O Manual on/off.
O Set real time.
O Set rapping time.
O Get rapping time.
O Reset alarm.

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
IOS
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.
IOS CONSISTS OF ..
BAPCON

RAPCON

IOS - PC
BHELs advanced precipitator
controller.
Rapper controller.

Multitasking real time PC.
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.
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.
NT-IOS

Integrated Operating System on
Windows NT platform
Bharat Heavy Electricals Limited, Ranipet
NT-IOS
Windows based IOS
Integrated Datalogging
Track Ball & Mouse
operation
Industrial Computing
platform
Industrial grade desktop
mounting


Main features
Graphical User Interface
Trend curves display
Compatibility with latest printers
User friendly help features
Information access through Intranet
can be upgradable easily
NT-IOS
PC
BAPCON1 BAPCON2
NT-IOS HARDWARE ARCHITECTURE
RAPCON-n RAPCON2
BAPCON-n
RAPCON-1
Boiler load
Opacity
GUI
User friendly windows screens for giving
command to different controllers and
displaying the ESP field status.
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 boiler
load
Compatibility for Printers
All printers supported by Windows NT can
be used for Text log , Graph log and VI
curves
User friendly help features
Help feature covers the Technical and
operating details of this package with
Images.
Context sensitive help for each screen is
available.

Information access through Intranet
ESP field operating parameters like TR
ON/OFF , current , voltage, Rapper On/OFF
etc. are made available to all intranet users
through a JSP software.
Future upgrade
New customer requirements can be added
easily
Can be upgraded easily for latest / future
versions of Microsoft Windows Operating
Systems. ( Eg. Windows 2000 and latest)

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

Hardware Configuration of NT-IOS
Opacity monitor & calib.input
Boiler
load
DATA-
LOGGER PC
PRINTER
SUPPORT
INS
HEATER
SHAFT
INS
HEATER
ESP
BUS SECTI ON 1
ESP
BUS SECTI ON 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-E1
REBOOT
ALIVE
SUPPORT
INS
HEATER
SHAFT
INS
HEATER
ESP
BUS SECTI ON 1
ESP
BUS SECTI ON 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
BAPCO
N 3
BAPCON
24
NT-
IOS
PC
Opening Screen
BAPCON Display
RAPCON Display
ANALOG Display - BAPCON
Command Screen
BAPCON Command
RAPCON Command
SETUP - Selection
SETUP-BAPCON Base Data
ALGORITHM SELECTION
Graph Log - Selection
Graph Log
SELECT BAPCON for VI Curve
VI Curve - BAPCON1
HELP
CURRENT LOOP vs MULTIDROP
DATAHIGHWAY
By pass relay is required in
case controller is removed /
fails
Network has to be physically
re configured if there is a
breakage in main
communication line.
Low protocol overhead, more
efficient at low speeds itself.
communication frames of
varying sizes allowed.
Termination resistance & by
pass relay is required in case
controller is removed / fails.
Network has to be physically re
configured if there is a
breakage in main
communication line.
Protocol overhead is high,
therefore higher speed is must.
Communication frame size
standardized. Large message
will have to be split.
ALGORITHMS IN IOS
LOpacity algorithm
LRapping power off algorithm
LRapping set no. Algorithm
LOptimiser algorithm
LRapping power factor algorithm
LAuto selection of opacity monitor based
on ID fan status.

REFERENCE LIST FOR IOS
g PROJECTS
gPanki TPS unit - 3
gMettur TPS unit - 1
gPanki TPS unit -4
gMettur TPS units - 2,3 & 4
gEnnore TPS unit -
gKothagudem units - 9 & 10
gRenusagar units - 7 & 9
gSingrauli TPS 5 X 200MW
gKorba TPS 3 X 200MW
g Farakka TPS 3 X 200MW
gUnchahar TPS 2 X 210MW
gVindhyachal TPS 6 X 2.0MW
gRamagundam TPS 3 X 500MW
gSingrauli TPS 2 X 500MW
gKorba TPS 3 X 500MW
gRihand TPS 2 X 500MW
gUnchahar TPS 2 X 210MW
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 )
CORONA POWER CONSUMPTION
PROJECT GAURANTEE CONVENTIONAL INTERMITTENT PERIOD
CHARGING CHARGING
RAMAGUNDAM #4 360KW 232.8KW 52.6KW Mar-90
PASS D
RAMAGUNDAM #5 313.6KW 67.6KW Jan-92
PASS B
RAMAGUNDAM #6 242.4KW 74.5KW Dec-91
PASS C
BADARPUR #1 400KW 184.0KW 26.0KW Feb-91
NALCO #1 450KW 164.0KW 24.0KW Dec-92
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%
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
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 #1
COMPARISON OF PERFORMANCE OF BAPCON
Vs
OTHER INTERMITTENT CHARGING
CONTROLLERS:
OPTICAL DENSITY
BAPCON (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%
Latest Controllers
BAPCONplus
Engineering Unit display
Designed for 660MW
application
VFD display
Local & Remote
operation
CR mode
Base Charge mode
Warning & TRIP Alarms



BAPCON-II
Single board design
Fewer components, Higher
reliability
RS-485 bus based high-
speed network
Remote operation
Concealed in HVR panel
In-built rapping

BAPCONsigma
Primary parameters
measurement
Power Measurement
Open Standard MultiMaster
Network
Peer to Peer communication
Spark & Arc detection and
suppression
Single card design
Concealed in HVR panel
RTU
Light weight Hand held unit
Graphical Display
64x128 pixel LCD
Membrane keypad
RS-485 network
User interface unit for
BAPCON-II, RAPCON-II
RTUsigma
Graphical User Interface
240x128 pixel LCD
Tactile membrane keypad
Open standard Multi master
protocol communication
Parameter trending
Alarm logging
Flash based programming


RAPCON-24
Supports up to 12 fields
Hot-Standby feature
Real Time Clock (RTC)
User set parameters Stored
in NVRAM
Labeling of outputs
Isolated Inputs and Outputs


RAPCON-II
RS-485 based network
Only Remote operation
Concealed inside the panel
RTC and NVRAM
Lesser components




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.

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
Micro controller PIC 16F877 (Flash, EEPROM)
Single monitor handles 64 sensors
A single twisted - pair wire carries both signal & power between
sensor and monitor
Digital tuning for setting full and empty level of each hopper from
monitor end
Intellicom Protocol Converter
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
COMMON TERMINAL FOR MULTIPLE IOS
CENTRALISED CONTROL SYSTEM
CONTROL & DISPLAY FOR INDIVIDUAL SUB-CONTROLLERS
THROUGH IOS
INTERFACE : RS-232C TO RS-485
PROTOCOL : MODBUS ( ASCII )
WINDOWS BASED APPLICATION SOFTWARE


CENTRALISED CONTROL & DISPLAY FOR MULTIPLE IOSs
IOS
#6
IOS
#7
IOS
#8
IOS
#9
IOS
#10
IOS
#11
CIOS
PC
RS-232C TO RS-485
CONVERTOR
BAPCON COMMAND SCREEN
RAPCON COMMAND SCREEN
RAPCON STATUS DISPLAY
THANKING YOU