TRIAD White Paper April 2011 REV4

8/6/2019 TRIAD White Paper April 2011 REV4

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CE Power Solutions White Paper April 2011

Reliability Assessment Program Series Paper/Presentation

Electrostatic Precipitator Transformer Rectifier Sets and Power ModulesTransformer Rectifier Insulation Analysis and Diagnostics - TRIAD

Mark S. McCloy Director Marketing CE Power Solutions Cincinnati, OH

PRELUDE

CE Power is developing a series of technical publications, papers and presentations to

further communicate, support and develop condition-based maintenance practices forelectrical power equipment and systems; Reliability Assessment Program (RAP).

ABSTRACT

This paper will provide an informational foundation for the Development,implementation and benefits of applying Condition-based Maintenance protocols and

practices to coal-fired, power generation facilities Electrostatic Precipitators key

components the Transformer Rectifier and Power Modules.

Transformer Rectifiers and Power Modules are utilized in todays electric Utilities coal-

fired Power Plants, as components of the Electrostatic Precipitator System (ESP); the

ESP is the first line of particulate control (extraction) in Emissions Control. ThePrecipitator removes particulate from the flue gas or the smoke from the stacks.

Transformer Rectifiers Power Module


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Electrostatic Precipitators (ESPs) are critical to the clean delivery of electric power as

well as controlling particulate emissions from various industrial processes. TheEnvironmental Protection Agency has increased the required compliance with its Clean

Air Act. Thus, the importance of ESP performance continues to rise. The

transformer/rectifier (TR) is a key component of the power supply system to the ESPs.

The failure of a TR can limit the performance of the ESP system and therefore limitproduction and output. Many of the existing TRs have been in service for several decades

and therefore are in need of evaluation, repair and/or refurbishment.

TR Maintenance and Inspections are seldom performed and was time based or reactive.

In order to meet the needs of an aging TR fleet, CE Power Solutions has developed aReliability Assessment Program (RAP) specific to TRs. This new program will

incorporate our TRIAD (Transformer Rectifier Insulation Analysis and Diagnostics)

methodology; consisting of specific dielectric fluid sampling and analysis services along

with physical inspections and electrical testing. This comprehensive series of tests,combined with our diagnostic evaluation software, enables us to evaluate the current

condition of your Precipitators transformer/rectifier and power modules to allowprioritization of Maintenance and Replacement Budgets and Tasks based upon thecurrent Operating Condition and Performance of the TR Set and associated Power

Module.

We begin by providing a basic understanding of the Electrostatic Precipitator system.

Electrostatic Precipitator

Electrostatic precipitation has been a reliable technology since the early 1900's.Originally developed to abate serious smoke nuisances, the manufacturers of zinc,

copper, and lead quickly found electric gas cleaning a cost efficient way to recovervaluable product carried out of the stacks from furnace operations. Today electrostaticprecipitators are found mainly on large power plants, cement plants, incinerators, and

various boiler applications.Electrostatic precipitators have taken on considerably greater

importance in recent years, particularly in view of the increased emphasis upon

maintaining a clean environment.

The theory behind the operation of an electrostatic precipitator involves the generation ofa strong electrical field through which stack gases pass, so that the particles carried by the

stack gases can be electrically charged. By charging the particles electrically they can be

separated from the gas stream and collected, and thereby not enter and pollute the

atmosphere. The generation of such electrical fields requires electrical power suppliesthat can provide a high DC voltage to charge the particulate matter and thereby permit its

collection. The existing systems are based upon AC corona theory, using a single phase

transformer-rectifier set to rectify AC power to DC power and provide a high DCpotential between a charging electrode, to charge the particles, and a collection surface,

usually a plate, so that the stack gases are subjected to the maximum current obtainable

through the gas without complete breakdown.


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That approach is believed to produce the maximum ionization of the particles and thereby

the maximum efficiency in effecting removal of such particles.

A precipitator is a relatively simple device. The main components are as follows:

An insulated and lagged shell

Collection plates or tubes

Discharge electrodes

Collection Plate Rappers/Electrode Vibrators

Hoppers

Power: A typical precipitator will take 480 volt AC and with the assistance of

transformer/rectifier converts the power to operated the discharge electrode's at 55-70 kV

DC. This leads most inquirers to conclude they are huge electricity consumers. In reality,the electrostatic precipitator is the lower power consumer available to accomplish the job.

Electrostatic forces are applied directly to the particles and not the entire gas stream.

Combining this feature with the low-pressure drop (0.5" wc) across the system results in

power requirements approximately 50% of comparable wet systems and 25% ofequivalent bag filter systems.

Power Supplies and Controls

The power supply system is designed to provide voltage to the electrical field (or bus

section) at the highest possible level. The voltage must be controlled to avoid causingsustained arcing or sparking between the electrodes and the collecting plates.


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Electrically, a precipitator is divided into a grid, with electrical fields in series (in the

direction of the gas flow) and one or more bus sections in parallel (cross-wise to the gasflow). When electrical fields are in series, the power supply for each field can be adjusted

to optimize operation of that field. Likewise, having more than one electrical bus section

in parallel allows adjustments to compensate for their differences, so that power input can

be optimized. The power supply system has four basic components:

Automatic voltage control

Step-up transformerHigh-voltage rectifier

Sensing device

Voltage Control

Automatic voltage control varies the power to the transformer-rectifier in response tosignals received from sensors in the precipitator and the transformer-rectifier itself. It

monitors the electrical conditions inside the precipitator, protects the internal components


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from arc-over damages, and protects the transformer-rectifier and other components in

the primary circuit.

The ideal automatic voltage control would produce the maximum collecting efficiency by

holding the operating voltage of the precipitator at a level just below the spark-over

voltage. However, this level cannot be achieved given that conditions change frommoment to moment. Instead, the automatic voltage control increases output from the

transformer-rectifier until a spark occurs. Then the control resets to a lower power level,and the power increases again until the next spark occurs.

Transformer-Rectifiers

The transformer-rectifier rating should be matched to the load imposed by the electrical

field or bus section. The power supply will perform best when the transformer-rectifiersoperate at 70 - 90% of the rated capacity, without excessive sparking. This reduces the

maximum continuous-load voltage and corona power inputs. Practical operating voltagesfor transformer-rectifiers depend on:

Collecting plate spacing

Gas and dust conditionsCollecting plate and discharge electrode geometry


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At secondary current levels over 1500 mA, internal impedance of a transformer-rectifieris low, which makes stable automatic voltage control more difficult to achieve. The

design of the transformer-rectifier should call for the highest possible impedance that is

corresponding with the application and performance requirements. Often, this limits the

size of the electrical field or bus section.

It is general practice to add additional impedance in the form of a current-limiting reactorin the primary circuit. This reactor will limit the primary current during arcing and also

improve the wave shape of the voltage/current fed into the transformer-rectifier.

Inductance

The unit of measure for reactors is the henry. The ability of a reactor to impede the flowof AC current is termed inductance. The inductance of CLRs is usually from 5 to 20

millihenries (.005H to .020H).The CLR value that is required is based upon the totalsystem impedance that is desired for the power supply. This system impedance limits themaximum amount of current that can flow in the primary circuit and is usually specified

as percent impedance. A value of from 30% to 50% is usually employed. The impedance

of the reactor can be calculated by:

Zclr = L x (2 x x f) = L x 377 where Zclr = impedance in ohms L = inductance in

henries = 3.1415 f= frequency in hertz

The percent impedance that the CLR provides is calculated by:

%Z = L x 377 x I x 100/V where %Z = percent impedance L = inductance in henries

I = rated primary current V = system voltage (typically 480 or 575 VAC)

The same formula can be used for calculating the inductance required for a desired %impedance by:

L = V x %Z / I x 377 x 100

The system impedance also includes the reactance of the transformer, which is typically

5% to 10%. 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. When specifying the CLR,the inductance in henries, the primary rated current, and the anticipated spark rate must

be given. Since the ESP will periodically spark, the actual average current that the CLR

will need to withstand is greater than the T/R rated current.


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In an electrostatic precipitator, the polluted gas is conducted between electrodes

connected to a high-voltage rectifier. Usually, this is a high-voltage transformer withthyristor control on the primary side and a rectifier bridge on the secondary side. This

arrangement is connected to the ordinary AC mains and thus is supplied at a frequency,

which is 50 or 60 Hz.The power control is effected by varying the firing angles of the thyristors. The smaller

the firing angle, i.e. the longer conducting period, the more current supplied to the

precipitator and the higher the voltage between the electrodes of the precipitator.

When separating dust of low or moderate resistivity, the degree of separation increases as

the voltage between the electrodes increases. However, the possible voltage is not only

restricted by the construction of the high-voltage rectifier, but also by the fact that at

sufficiently high voltage, there will be flashover between the electrodes in theprecipitator.

This is effected by slowly increasing the current until flashover occurs. Subsequently, thecurrent is reduced in a predetermined manner and then again slowly increased until the

next flashover. The process is repeated periodically. If the circumstances result in a

highly varying flashover limit, more than 100 flashovers a minute may be acceptable. In

more stable processes, 10 flashovers a minute may be involved. In certain processes, thebest separation is however obtained at very high flashover frequencies although the

operation is very stable.


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In case of flashover, the current is interrupted during a first time interval, and then the

current is rapidly increased from zero, during a second time interval after which it isincreased slowly when a given value, depending on the value before the flashover, has

been achieved.

To ensure that the flashover does not lead to a permanent arc and, thus, sets the

precipitator out of operation for a long time, the first time interval, during which the

current is interrupted, must be at least a half-cycle of the mains voltage. The current is

usually interrupted during an entire cycle of the mains voltage, partly because otherwisethe excitation of the transformer, when reconnected, yields a very high overload on the

mains and increases the losses in the transformer windings.

This technique therefore implies that the precipitator is dead for 20 milliseconds up to100 times a minute or even more frequently. Moreover, it will be appreciated that the

separation is not fully effective also during the second time interval, when the precipitator

is being recharged and the voltage between the electrodes is essentially below the value atwhich the flashover occurred. If the second time interval is estimated at about 100

milliseconds, the precipitator may, in extreme cases, be out of operation during almost as

much as 10% of the total time. This is a strongly restricting factor at a high flashoverfrequency.In conventional thyristor-controlled rectifiers, the current cannot be interrupted until the

next zero point of the mains voltage. This means that the precipitator can function as a

short-circuit load for a considerable time, between the flashover and the next zero pointof the mains voltage. If the flashover occurs early during the half-cycle, this state can

prevail for almost 10 milliseconds.

Transformer

The step-up transformer is the major component of the T/R system. Transformers

designed for ESP applications employ design techniques specifically developed for thisuse. ESP transformer coils must be capable of withstanding repeated sparking and arcing

of the load. Disruptions such as these, along with occasional shorted fields, cause current

surges well above the system ratings. These surges cause the windings of the transformerto exert considerable physical force on the system insulation and support mechanism. If

not properly accounted for, these forces will eventually cause premature destruction ofthe insulation and system failure.


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The transformer is typically the most reliable component in the system. Failures of

transformers, however, do occur and can often be placed in two general categories. Thefirst is degenerative failure that is caused by the long term breakdown of a component

part. If the transformer is used within its rated parameters, then degenerative failure is

most likely due to a defect of material or workmanship. The second failure category is

overstress failure. Overstress failure is caused by subjecting the transformer to eitherexcessive voltage or excessive current. Overstress failure is usually the case for

transformers that fail between five and twenty years of operation.Of the components and materials used on T/Rs, the layer insulation on the transformer

winding determines the life expectancy of the system. Modern designs use Kraft

insulation. The life expectancy of the insulation is a function of stress level (voltageacross the insulation) and temperature of the insulation material. The operating

temperature of the insulation is usually assumed to be 10 (C) higher than the overall

temperature rise of the winding. The 10 margin is based upon the assumption that heat

transfer between the coils and the oil can never be absolutely uniform. The expected lifeof the insulation for modern designs is 34 years if the unit is continuously subjected to

rated current and rated voltage (REF ANSI C57.91.1981). Degenerative insulation failureafter less than 15 years, although possible is statistically very unlikely, unless there areother contributing factors. Degenerative insulation failure can be caused by abrasion

caused by excessive vibration and physical movement of the transformer windings.

Vibration is induced by the 60 cycle AC current while coil movement is induced bycurrent surges. ESPs by nature present a harsh load for transformers due to the sparks and

arcs that are expected. T/Rs designed for such applications must therefore employ

extraordinary measures to tolerate such conditions. If such measures are not employed or

improperly employed, then the abrasion of the coils will occur.

The main problem that results from operating a precipitator at a level at which sparking

occurs is that the automatic controller for the transformer-rectifier set must sense an arcand immediately reduce the voltage on the precipitator collector plate, because any spark

can quickly create an arc between the plate and the electrode, with a resultant high

current flow. The high current flow can cause severe damage to the precipitator grid orplate, or it can cause the transformer-rectifier set to fail. Any of those incidents will cause

a section of the precipitator to be temporarily off-line, until the failures have been

repaired. Repair can be a matter of minutes, or it can be weeks if the transformer-rectifier

set has to be replaced.

Reliability Assessment Program (RAP) Development

As stated above, degenerative insulation failure is the primary root cause to TR failures in

todays ESP systems. A method of measuring and trending the integrity of the insulation

system in a TR can be developed and implemented, based upon the extremely effectiveand time-proven methods developed in the utilities Transmission and Distribution


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departments and the management of traditional substation-class, oil-filled power

transformers.

Transformer Rectifier Insulation Analysis or TRIAD; was developed to assist in

identifying several TR fault/failure modes. These include various modes of degenerative

failure, such as:

Overheating of TR ComponentsPartial Discharge within the TR

Arcing within the TR

The first and very key component of the TRIAD program is the TR fluid analysis.

Under normal operating conditions very little decomposition of the insulating oil or

insulating cellulose occurs. However, when degenerative faults occur, the oil and

cellulose insulation will undergo chemical degradation. The fault-induced breakdownproducts, indicated below, are low molecular weight gaseous compounds that are soluble

in the oil.

Hydrogen - H2 Methane - CH4 Ethane - C2H6 Ethylene - C2H4

Acetylene - C2H2 Carbon Monoxide CO Carbon Dioxide - CO2

Quantitative analysis of the gases present in the oil DGA (Dissolved Gas Analysis)

allows one to identify fault processes such as Partial Discharge, Sparking, Overheatingand Arcing.

In addition to the DGA, it is also important to understand the physical condition of thedielectric fluid. TRIAD incorporates several fluid analyses that measure the dielectric

fluids insulation quality, fluid characteristics, fluid degradation and impurity content.

Table 1 illustrates how these various tests can be used to identify failure modes in yourTR.

Failure Diagnostic Tools

Overloading DGA

Moisture moisture dielectric color/visual

Partial Discharge DGA

Carbon dielectric breakdown color/visual

AVC (overvoltage) DGA

Failing / Failed Diodes (Arcing) DGASludging IFT acid color/visual

High Contact Resistance DGA

Deteriorated paper insulation DGA

Table 1


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TRIAD Overall Compilation Report

Bank OE

M

SampleDate Fluid kV

A

Volts H2 CH

4

C2H6 C2H4 C2H2 CO CO2 N2 O2 TDG TDC

G

HS EqTCG%

TRA6 N

W

L

5/25/07 Silicone

Fluid

1

0

9

46

0

1

5

9

10

5

11 0 11 16

08

13

20

2

154

242

23

94

6

193

284

18

94

0.8663

TRA4 N

W

L

5/25/07 Silicone

Fluid

1

0

9

46

0

1

1

9

47 11 3 1 22

15

11

17

2

145

118

21

11

8

179

804

23

96

1.1486

TRA5 N

W

L

5/25/07 Silicone

Fluid

1

0

9

46

0

1

3

7

18 9 25 2 78

6

88

89

120

157

38

65

0

168

673

97

7

0.5719

TRA3 N

W

L

5/25/07 Silicone

Fluid

1

0

9

46

0

0 2 1 1 0 59 55

14

122

638

51

92

4

180

139

63 0.0288


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Individual Insulating Fluid Sampling Results

TESTRESULTS

AlternativeTechnologies, Inc. Serial Number:

92-1204

12350 River RidgeBlvd.

Client Number:10001171

Burnsville,MN 55337

Date Received:6-7-2007

Telephone (800) 255-8656 or(952) 894-3455

Report Date:6-14-2007

Type /Tank:

TRN PO: 14621

KVA:109 JOB: 400025

KevinCarter

Voltage:

460

Location: UNIT 5

CE PowerSolutions

Gallons:

135

Bank &Phase: TRA6

P.O. Box147

ManufDate:

Manufacturer: NWL

Lake Hamilton, FL33851

FluidType:

SiliconeFluid

Container No.: AB244

DISSOLVED GAS IN OIL

ANALYSIS

Date:

25-May-07

Tem

p:60C

Hydrogen (H2) 159 ppm

Methane (CH4) 105 ppm

Ethane (C2H6) 11 ppmEthylene

(C2H4) 0 ppmAcetylene(C2H2) 11 ppmCarbon

Monoxide (CO) 1608 ppmCarbon Dioxide

(CO2) 13202 ppm

Nitrogen (N2) 154242 ppm

Oxygen (O2) 23946 ppm

TotalGas 193284 ppmTotalCombustible

Gas 1894 ppm

Equivalent TCG Reading 0.8663 %


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Comm

ents:

Presence of Acetylene may indicate arcing in

Silicone FluidRecommen

ded Retest:

Investigate

Immediately

PHYSICAL AND CHEMICALTESTS

Date

:

25-May-

07

Moisture in Oil 19 ppmInterfacial

Tension 36.9 dynes/cm

Acid Number


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TEST RESULTS

Alternative Technologies, Inc.Serial Number: NA

12350 River Ridge Blvd.Client Number:

10001

167

Burnsville, MN55337

Date Received:6-7-2007

Telephone (800) 255-8656 or (952) 894-3455 Report Date: 6-14-2007

Type /Tank:

TRN PO: 14621

KVA: 109 JOB: 400025

Kevin Carter Voltage: 460 Location: UNIT 5CE Power

Solutions Gallons: 135

Bank &

Phase: TRA4

P.O. Box 147

Manuf

Date:

Manufactu

rer: NWL

Lake Hamilton, FL

33851

Fluid

Type:

Silicone

Fluid

Container

No.: AM186


ANALYSIS

Date:

25-May-07

Tem

p:60C




(C2H4) 3 ppmAcetylene(C2H2) 1 ppmCarbon

Monoxide (CO) 2215 ppm

Carbon Dioxide(CO2) 11172 ppm



Total

Gas 179804 ppmTotal

CombustibleGas 2396 ppm


Comm

ents:


Silicone Fluid

Recommen

ded Retest:

Investigate

Immediately


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PHYSICAL AND CHEMICAL

TESTS

Date:

25-May-07



Acid Number


16/23

TEST RESULTS

Alternative Technologies, Inc.Serial Number:

92-

1200


10001169

Burnsville, MN

55337Date Received:

6-7-

2007

Telephone (800) 255-8656 or (952) 894-3455


Type /

Tank:

TR

N PO: 14621

KVA: 109 JOB: 400025

Kevin Carter Voltage: 460 Location: UNIT 5

CE PowerSolutions Gallons: 135

Bank &Phase: TRA5

P.O. Box 147Manuf

Date:Manufactu

rer: NWL

Lake Hamilton, FL

33851

Fluid

Type:

Silicone

Fluid

Container

No.: AL170

DISSOLVED GAS IN OILANALYSIS

Date

:

25-May-

07Tem

p:60C




(C2H4) 25 ppmAcetylene

(C2H2) 2 ppmCarbon

Monoxide (CO) 786 ppm

Carbon Dioxide(CO2) 8889 ppm



Total

Gas 168673 ppmTotal

Combustible

Gas 977 ppm


Comm

ents:


Silicone Fluid

Recommen

ded Retest:

Investigate

Immediately


17/23


TESTS

Date:

25-May-07



Acid Number


18/23

TEST RESULTS

Alternative Technologies, Inc.Serial Number:

92-

1201


10001166

Burnsville, MN

55337Date Received:

6-7-

2007

Telephone (800) 255-8656 or (952) 894-3455


Type /

Tank:

TR

N PO: 14621

KVA: 109 JOB: 400025

Kevin Carter Voltage: 460 Location: UNIT 5

CE PowerSolutions Gallons: 135

Bank &Phase: TRA3

P.O. Box 147Manuf

Date:Manufactu

rer: NWL

Lake Hamilton, FL

33851

Fluid

Type:

Silicone

Fluid

Container

No.: 0353


ANALYSIS

Date

:

25-May-

07

Temp:

25C

Hydrogen (H2) 0 ppm

Methane (CH4) 2 ppm


(C2H4) 1 ppm

Acetylene(C2H2) 0 ppmCarbonMonoxide (CO) 59 ppmCarbon Dioxide

(CO2) 5514 ppm



Total

Gas 180139 ppmTotalCombustible

Gas 63 ppm


Comments:

All gases at acceptableconcentrations for Silicone Fluid

Recommended Retest: 1 Year


19/23


TESTS

Date:

25-May-07



Acid Number


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In addition to the fluid analysis, a detailed physical inspection of the TR is performed

along with electrical performance tests that include TTR, Megger & Continuity andWinding Resistance. This comprehensive group of tests and analysis provide the current

condition of your TR asset.

Physical Inspections

WORKSCOPE

TRANSFORMER/RECTIFIER ON SITE

DESCRIPTION OF SERVICES

NAME/DATE OF

INSPECTOR

OVERALL T/R SET INSPECTION _______/_________

INITIAL TESTING, MEGGAR, OIL SAMPLEING _______/_________

DOCUMENT SCHEMATIC FOR TEST REPORT _______/_________

NOTE ALL PHYSICAL, MECHANICAL, OR ELECTRICAL PROBLEMS _______/_________

REMOVE OIL FROM VESSEL VIA PRESS OR DEGAS SYSTEM _______/_________

REMOVE ALL NECESSARY GASKETING FOR REPLACEMENT _______/_________

INTERNAL TANK INSPECTION AND TORQUE ALL CONNECTIONS _______/_________

DISCUSS ANY PROBLEMS FOUND WITH CUSTOMER

REMOVE ALLBUSHINGS (IF APPLICABLE) _______/_________

INSPECT DIODE PAK _______/_________

INDIVIDUALCOMPONENT TEST (IF APPLICABLE) _______/_________

REMOVE RADIATORS (IF APPLICABLE) _______/_________

PREP TANK FOR

PAINTING (IF APPLICABLE) _______/_________

RE-WIND

XFMR (IF APPLICABLE) _______/_________

ATTACH LID _______/_________

PRIME AND PAINT

UNIT (IF APPLICABLE) _______/_________

VACUUM FILL APPLICABLE OIL _______/_________

FINAL TEST

T/R SET _______/_________

INSPECT ALL ASSOCIATED INSTRUMENTATION _______/_________

TEST OIL WITH PORTABLE DIELECTRIC SET

PRESSURE TEST FOR

LEAKS _______/_________

ASSIST CUSTOMER WITH START UP _______/_________FINAL OIL SAMPLE AFTER UNIT IS ON LINE _______/_________

LEAD TECH SIGN OFF: _______________________/_________

NOTES:


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Electrical Tests and Inspections

TRANSFORMER

RECTIFIER TEST REPORT

Customer: Job # Date:

Make: Ser #

INCOMING FWRD REV OUTGOING FWRD REV

H1 to 5 H1 to 5

H1 to 7 H1 to 7

Hi to 10 & 11 Hi to 10 & 11

H1 to G H1 to G

10 to 11

10 to

11

10 & 11 to G 10 & 11 to G

TEST VALUE IS 1,000 VDC ALL READINGS IN MEGOHMS

INCOMING POWER

FACTOR: TTR: Calculated:

FINAL POWER FACTOR: Actual:

HUMIDITY: TEMP:

NOTES:

Test Equipment Serial Number:

Technician ID:


22/23

Power Module and Diode Stack Performance Improvements through Design

Diode Stacks Power Module

Newly designed Modules typically have half the mass of equivalent older-style Modules,

using hockey puck devices. Hockey puck designs require heat sink and clamp

assemblies that add to the already heavy copper pole face and ceramic body. The fact that

the New, Improved Power Modules do not require a clamp assembly allows for easierrepair and maintenance without special tools. New Power Module heat-sinks are

electrically isolated, which allows for easier mounting without proximity issues

promoting a safer installation.

Heat-sink mounting is common across multiple modules. This allows for minimized

mechanical configurations. Modules feature push-on lead terminals, New Power Modulesare designed for quick installation for all applications. The modules require torque to the

heat sink only. No special bus bars are required and connections can be made directly to

the module.

New Power Modules also feature increased tracking distance between anode and cathodeterminations.

Newly Designed Diode stacks offer high surge current rating. They are compensated to

insure voltage sharing across all internal components enhancing product reliability. New

Diode stacks incorporate a 2X safety factor in current ratings to further insure reliableperformance. New Diode Stacks are manufactured by hand using high quality soldering

techniques that ball the solder joints to minimize potential corona effects.

ConclusionThe loss of ESP fields will eventually affect generation revenue and effective particulate

emissions control. The heart of the ESP system - TR Sets have traditionally beenforgotten or ignored, regarding diligent maintenance and testing for Operating integrity.

Without the implementation of a pro-active Field Service Testing and Maintenance

Program on the ESPs Transformer Rectifiers; it is a certainty that failure will occur; theonly question is when?


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Applying the protocols of the CE Power Reliability Assessment Program utilizingTRIAD; will proactively avert future failures and potential catastrophes; furthermore it

allow the process of planning future Capital expenditures and assure compliance to

applicable emission controls standards requirements while insuring maximum reliability

and revenue potential.

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