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ENGINEERING, SUPPLY, REPAIR, UPGRADE & PREVENTATIVE MAINTENANCE OF ELECTROSTATIC PRECIPITATOR

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GE TEK Electronics Private Limited has the expertise to provide highly trained professionals for Electrostatic precipitator design,trouble shooting, maintenance, and repair and start up. We offer services to maintain ESP and rebuild the same at an optimum cost. Our “precipitator replacement parts division” maintains a full inventory of ESP parts including insulators, rappers, discharge electrodes etc to improve the turnaround time.With today’s stringent regulations on air pollution control, it is important that all the electrostatic precipitators (ESP) are regularly serviced and their efficiency is optimized.GE TEK Electronics specializes in repairing both wet and dry ESP repair, precipitator upgrade & preventative precipitator maintenance that can effectively reduce particulate emissions.

We undertake vertical integration of Engineering, Design, Manufacturing, Construction and Service of ESP. Besides GE TEK has specialized in retrofitting of older equipment to meet the emission standards in today’s contract.GE TEK make advanced digital controller GE-02V2 for controlling High Voltage DC power supply for Electro static precipitator application is giving improved ESP performance. We offer single point service support for both Mechanical and Electrical products and spares support for various types of Electro Static Precipitators.

Our service team compresses of experts in air pollution control field the mission of continuous operation and maintenance of air pollution control systems. We also look for trouble shooting, replacement of worn out or repaired components, rebuild as well as upgrade existing equipment’s.

Types of Precipitator Repairs:

From aging electrostatic air cleaners to modern industrial electrostatic precipitators, GE TEK can repair virtually every class of ESP precipitator in the market. We are experienced with repairs all the popular makes of electrostatic precipitator. Our precipitator repair field service crews are on call 24 hours a day for everything from routine precipitator maintenance to ESP field rebuilds

• Back Corona
• Problem of cracked Insulator
• Air in leakage through hoppers
• Corrosion
• Gas Bypass around ESP
• Heavy Deposits on plates of ESP
• Stack puffing
• Controller tripping
• Poor Electrode Alignment
• Broken Electrodes
• Distorted or skewed electrode plates

Electrostatic Precipitator Systems:

• Inlet and outlet Gas distribution screens
• Collecting electrodes and discharge electrodes.
• Rapping mechanism with shaft and hammers
• Geared motors
• Support and shaft insulators
• Hopper, Nozzles and manhole doors.
• High current rectifier transformers and controllers
• Heaters, vibrators, level probes and thermostat
• Purge air systems
• Inner and outer roofs

Collecting Electrodes:

Collecting plates are designed to receive and retain the precipitated particles and then removed into the hopper. In addition, the collecting plates are part of the electrical power circuit of the precipitator. Baffle plates shield the precipitated particles from the gas flow and smooth surfaces provide for high operating voltages. Collecting plates are suspended from the precipitator casing and form the gas passages of the precipitator.

Discharge Electrodes:

Discharge electrodes are typically supported from the upper discharge frame and are held in alignment between the upper and lower discharge frames. The upper discharge frame is in turn supported from the roof of the precipitator casing

Gas distribution Screens:

These Screens are of modular design manufactured out of Steel sheets and hang within a frame work in the Electrostatic Precipitator inlet casing to maintain uniform distribution pattern of gas flow throughout the cross the section of ESP.

Rapping Mechanism:

Rappers are used to transmit strong shearing forces to collecting plates in order to release deposited dust particles. Rapping is the process by which electrodes and particles are broken apart by vibrations from the rappers. Often used in electrostatic precipitators, rappers relapse the caked on dust layer which then descends into a hopper. Number, size, and frequency of the rappers vary from system to system based upon the specific characteristics of the dust being collected. The whole emitting frame system is suspended from the roof through Supporting Insulator to avoid any short-circuiting. The Rapping Mechanism Shaft for electrodes is connected to the driving mechanism through Shaft Insulator. The collecting electrodes are fixed loosely to suspension beams on pins. They are joined together in the bottom rapping beam. Both, the firm bottom and the top loose attachment provide a perfect transfer of energy from the rapping hammers to the entire row of collecting electrodes. The rapping is carried out in regular, programmed intervals and guarantees removal of deposited dust from the electrodes to the hoppers. Hammers strike the collecting plates and rigid electrodes directly, so that all areas receive proper rapping acceleration and no energy is lost to support structure.

Insulators:

Would improve ladders, stairs and platforms make your ESP maintenance easier, We custom design, fabricate and install ladders and platforms to suit your specific needs.

Purge Air System:

Purge Air Systems protect high-voltage support insulators from moisture and dust that could accumulate on their surfaces and cause them to fail. Support insulators provide many years of use when properly maintained, such as preheating prior to start-up. The constant flow of dry heated air prevents condensation and prevents flue gas from entering.

Heaters:

Rapid temperature changes or the introduction of moisture can cause tracking and cracking of insulators. Heaters should be utilized to prevent condensation and ash build up by arming the insulators prior to start up.

     

Transformers and Controllers :

The transformer/rectifier set is specifically designed to provide the high voltage DC necessary for electrostatic precipitation. T/R Controls - The control units contain all components necessary for controlling and protecting a TR set. Serial data ports are included for transmitting and Receiving data from a central control system. Microprocessor-based controls are used to manage and control the rapping of the precipitator for proper cleaning of the collecting plates and discharge electrodes.

Ash Level Probes :

Ash level sensor using to measure the ash level of hoppers. By using this probe the operating efficiency of ESP hoppers improves drastically as proper level management for effective removing of ash

Hopper Vibrators :

Vibrator use is to promote material flow or to clean out or clean of vessel walls, corners and sticking points. Vibrators unload the ash from hopper and it will eliminate bridging, stuck materials and uneven flow of ash in hoppers.

Mechanical Safety interlock system:

A mechanical safety  key interlock system ensures the safety of operators when performing maintenance on a ESP. Before access is granted to any  doors, hazardous energy is disconnected and grounded. The mechanical safety key interlock system ensures a predetermined sequence of events is followed

ESP Spares available with us:

A motor control centre (MCC) is an assembly of one or more enclosed sections having a common power bus and principally containing motor control units. Motor control centres are in modern practice a factory assembly of several motor starters. A motor control centre can include variable frequency drives, programmable controllers, and metering and may also be the electrical service entrance for the building.

GE TEK Make Modular IGBT switch mode rectifiers are designed to give best electrical performance fro electroplating/Anodizing process and get excellent platting quality. These rectifiers are modular design, reducing user's power consumption and integrated with timer control and RS485 communication interface.

Technical Data:

1. Rectifier Type      -   IGBT High Frequency Modular Structure
2. I/P Voltage           -   380-440VAC 3 Phase 50Hz
3. O/P Voltage         -   6V-200VDC
4. O/P Current          -  10A-10KA
5. Control Accuracy -   ≤± 0.5%
6. Power Factor       -   ≥ 0.98
7. Efficiancy            -    Better than 90% at rated Output
8. Control Mode      -   Constant Voltage/Current
9. Cooling               -   Forced Air/ Water Cooling
10. Protections

• Output Over current protection
• Short Circuit protection
• Over Heat Protection
• Input Over/Under voltage protection

Optional Facility:

We can provide touch screen type HMI for programming the plating cycle. Programming facility is available up to 15 different models and each model can have 30 steps.

MID Frequency ESP control panels:

Our Products , control cards are 100% indigenous & are designed , programmed by our team. Our make MID Frequency control panels are widely used at power plant's Electrostatic precipitator to maintain the average high voltage to reduce dust emission from the plants. it operates in modest frequency of 400 -500 HZ. Best ESP Efficiency is obtained due to reduced ripple with Transformer rectifier which can maintain field's required average voltage.

The Transformer-rectifier set, also called a TR or a TR set, converts the low voltage of the plant power system to the high voltage required for precipitator operation. It is referred to as a “set” because the tank contains both the high voltage transformer used to convert relatively low voltage high current AC to high voltage and low current AC, and the full wave diode (rectifier) bridge used to convert the AC to DC for use in the precipitator

Special features of our control panel:

• Fast control during sparking / arcing results in power discharge in to precipitator gives long life of ESP
• Balanced load on auxiliary power
• Working as near unity power factor results in considerable reduction in auxiliary input KVA
• Buyback period on investment by saving on KVA consumption would be about 12 to 17 months
• Need of extending additional field control emission level can be avoided in most of the cases.

Advantages of MID frequency control panels:

• Medium frequency power switching (MFPS), operate in the more modest frequency of 400Hz, the medium frequency system are capable of using existing 50/60 Hz TR's and existing control cabinet locations for significant cost savings.
• The increased efficiency is realized because of the decrease in ripple on the KV voltage that allows higher average KV before spark over occurs
• The technology uses an increased exciting frequency of up to 400 Hz and controls power level delivered to the TR primary by variations of the duty cycle of the AC power feed. This technique is commonly referred as "PWM".

Retrofitting/ Up-Gradation of ESP control panels: We have done massive quantity of retrofit jobs for ESP control panels of clients from northern and southern India.We have our precious satisfied customers are listed here where our product installed / up-gradation of ESP control panels. Our controller is performing well and improving performance of dust collection in Electrostatic precipitators. List of Major Retrofit / Up gradation:

• Chinese HVR controllers to GE TEK make advanced controllers
• Hind Rectifier controllers to GE TEK make advanced controllers
• Ador ESP Controllers to GE TEK make advanced controllers
• Kraft Powercon controllers to GE TEK make advanced controllers
• BHEL Controllers to GE TEK make advanced controllers