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WO1991006371A1 - Multiple rapper control for electrostatic precipitator - Google Patents

Multiple rapper control for electrostatic precipitator Download PDF

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Publication number
WO1991006371A1
WO1991006371A1 PCT/US1989/004850 US8904850W WO9106371A1 WO 1991006371 A1 WO1991006371 A1 WO 1991006371A1 US 8904850 W US8904850 W US 8904850W WO 9106371 A1 WO9106371 A1 WO 9106371A1
Authority
WO
WIPO (PCT)
Prior art keywords
rapper
memory
computer
appropriate information
sending
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1989/004850
Other languages
French (fr)
Inventor
David F. Johnston
Michael M. Mahler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BHA Group Inc
Original Assignee
BHA Group Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by BHA Group Inc filed Critical BHA Group Inc
Priority to PCT/US1989/004850 priority Critical patent/WO1991006371A1/en
Priority to PCT/US1990/003748 priority patent/WO1991006372A1/en
Priority to CA002072129A priority patent/CA2072129C/en
Publication of WO1991006371A1 publication Critical patent/WO1991006371A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B03SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03CMAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03C3/00Separating dispersed particles from gases or vapour, e.g. air, by electrostatic effect
    • B03C3/34Constructional details or accessories or operation thereof
    • B03C3/74Cleaning the electrodes
    • B03C3/76Cleaning the electrodes by using a mechanical vibrator, e.g. rapping gear ; by using impact
    • B03C3/763Electricity supply or control systems therefor

Definitions

  • This invention relates generally to electrostatic precipitators for air pollution control and, more specifically, concerns the control of the rapping process used to clean the internal collection plates and discharge electrodes of electrostatic precipitators.
  • An electrostatic precipitator is an air pollution control device designed to electrically charge and col ⁇ lect particulates generated from industrial processes such as those occurring in cement plants, pulp and paper mills and utilities. Particulate laden gas flows through the precipitator where the particulate is negatively charged. These negatively charged particles are attracted to, and collected by, positively charged metal plates. The cleaned process gas may then be further processed or safely discharged to the atmos ⁇ phere.
  • the cleaning mechanism typically consists of a mechanical rapper that acts as a hammer to dislodge by mechanical vibration any par ⁇ ticulate from the collector plate surfaces and discharge electrodes.
  • An electronic rap ⁇ per controller determines the sequence, intensity, and duration of rapping. Once the particulate is dislodged from the plates, it falls into collection hoppers at the bottom of the precipitator.
  • rapper control has been limited to manually controlling and adjusting the current level to an entire group of rappers, rather than individual rapper control.
  • rappers in different locations within the group may operate more efficiently with different current levels. Since the number of rapper groups, as well as the number of rappers within each group, may vary and prior art rapper control only allows for intensity adjustment of an entire group, a compromise in control standards therefore prevails. The result is often rapper inefficiencies that reduce precipitator and production capacity as well as increase emission levels.
  • the prior art uses fuse or relay technology to detect and isolate fault conditions. This technology is slow in that the devices re- quire up to several full cycles before electrical protection can be assured. Within several full cycles of a fault condition significant damage can occur to rapper circuitry.
  • Some commercial rapper control systems purport to incorporate solid state fault detection, but the trip level is set high because all rappers are required to have the same trip level. The trip level cannot be individually adjusted to a specific single rap ⁇ per within these systems and a compromise in control standards results.
  • Another drawback of the prior art is that rapper control technology is an open looped system. The current level is set at a particular point in time, considering the present rapper conditions in the electrostatic precipitator. But, rapper conditions are not static.
  • the prior art does not provide an easy or economical way to check the present operating conditions of rappers in large precipitators.
  • technicians must per ⁇ sonally walk near each precipitator while watching and listening to determine whether a specific rapper is operating.
  • large precipitators for instance, 250 rappers or more
  • the present invention provides an improved way to control power to a rapper within an electrostatic precipitator. Since manually adjusting current to rappers as a unit is inherently inefficient, an important object of this invention is to provide a means for individually pre-setting electrical operating conditions for each rapper within a multiple rapper precipitator. Another object of this invention is to provide a means for individually setting short and open trip conditions for each rapper within a multiple rapper precipitator. This will eliminate the compromise required in the prior art and increase rapper ef ⁇ ficiency.
  • Still another object of this invention is to provide fault protection which assures detecting and isolating a fault condition within 1/2 cycle from the moment a fault oc ⁇ curs. Reducing fault trip response times from several full cycles to 1/2 cycle will great ⁇ ly increase circuit protection and increase the useful life expectancy of the rappers and precipitator as a whole.
  • Another object of this invention is to provide a closed-loop control means for a rapper. Enabling the rapper current control to sense, measure and adjust the input current in the event the actual current is not substantially similar to the pre-set electri ⁇ cal input current will greatly aid rapper efficiency.
  • Another important object of this invention is to provide present operating con ⁇ ditions for each rapper within a precipitator and to store the rapper operating condi ⁇ tions. This will provide an economical way to check the actual operating conditions of each rapper as well as provide information for troubleshooting and trending.
  • Fig. 1 is a block diagram illustrating a multiple rapper control constructed in accordance with a preferred embodiment of the invention
  • Fig.2 is a block diagram showing the power source and power control means of the multiple rapper control in more detail
  • Fig.3 is a block diagram showing the current detecting means of the multiple rapper control in greater detail.
  • Fig.4 is a block diagram showing the power source and power control means, along with an optional voltage selection relay and the AC DC relay of the multiple rapper control.
  • This invention specifically contemplates the control of a plurality of rappers for an electrostatic precipitator.
  • This description uses two rappers for illustrative pur ⁇ poses and not as as a limitation on the number of rappers to be used in practicing the invention.
  • Control block 10 is connected to a central computer 12, a power source 18 and a plurality of rappers as schematically indicated by Rapper 1 and Rapper 2 blocks. More specifically, central computer 12 is bi-directionally connected to a microcomputer 14 which in turn is connected to both a power control means 16 and a TRIAC switch device 20. Power control means 16 is connected between a power source 18 and TRIAC switch device 20. A current detecting means 22 senses and measures the current between power control means 16 and TRIAC switch device 20. Current detecting means 22 is connected to the output of power control means 16 and is bi-directionally connected to microcomputer 14.
  • Rapper 1 and Rapper 2 are each individually connected to a TRIAC within the TRIAC switch device 20.
  • each rapper is connected to only one TRIAC and, conversely, each TRIAC is connected to only one rapper.
  • the TRIAC may be typically characterized as a silicon bi-directional triode thyristor, such as T6420M of Motorola designated for a 600 volt rating for 40 amps.
  • the power control means 16 and power source 18 are illustrated in Fig. 2.
  • Power control means 16 comprises an SCR firing circuit 28, a full-wave rectifier 30, an SCR 1 and an SCR 2.
  • Power source 18 comprises a transformer 26 and two input terminals 24 to which power is applied. The input terminals 24 are connected to the primary of transformer 26.
  • One side of the secondary of transformer 26 is connected to an inverse parallel SCR 1 and SCR 2 which connects, along with the other side of the secondary of transformer 26, to full-wave rectifier 30.
  • SCR firing circuit 28 is con ⁇ nected serially between microcomputer 14 and the inverse parallel SCR 1 and SCR 2.
  • the current detecting means 22 is best illustrated in Fig.3.
  • One sense resistor 32 is connected serially between power control means 16 and TRIAC switch device 20.
  • the sense resistor 32 is also connected across a conventional input protection cir ⁇ cuit 33 and then to an isolation amplifier 34 connected serially with a precision rec- tifier 36.
  • Precision rectifier 36 is connected with a peak detector 38 which bi-directionally connects to microcomputer 14.
  • Isolation amplifier 34 may typically comprise an AD202JN chip such as manufactured by Analog Devices of Norwood, Massachusetts.
  • Precision rectifier 36 comprises two operational amplifiers and two high speed switching diodes (such as 1N4148 diodes) appropriately biased to rectify the input characteristic to a DC level that is independent of the voltage drop across the diodes.
  • the two operational amplifiers may comprise TL032CP operational amplifiers characterized as an enhanced JFET (junction field effect transistor), low power, low offset, analog operational amplifier such as manufactured by Texas Instru ⁇ ments of Dallas, Texas.
  • the peak detector 38 may typically comprise a PKD01FP chip such as manufactured by Precision Monolithics Inc. of Santa Clara, California and characterized as a monolithic peak detector with reset and hold mode.
  • Microcomputer 14 is connected to both a voltage selection relay 40 and an AC/DC relay 42.
  • Voltage selection relay 40 is connected to a normally open contact 44 and a normally closed contact 46.
  • Normal- ly closed contact 46 is connected to the 240 volt lead of power source 18, and normal ⁇ ly open contact 44 is connected to the 120 volt lead of power source 18.
  • Both contacts 44 and 46 are connected to the inverse parallel SCRl and SCR2.
  • the AC/DC relay 42 is connected to two normally open contacts 48 and 50 and two normally closed con ⁇ tacts 52 and 54.
  • Normally open contact 48 is connected to the inverse parallel SCRl and SCR2 while normally open contact 50 is connected directly to the power source 18. Both normally open contacts 48 and 50 are connected to TRIAC switch device 20. Normally closed contacts 52 and 54 are connected to the positive and negative output of bridge rectifier 30, respectfully. Both normally closed contacts 52 and 54 connect with TRIAC switch device 20. In operation, a look-up table including characteristics for each individual rap ⁇ per is determined, entered and stored in central computer 12.
  • the look-up table parameters comprise the location of each rapper, the rapper type (i.e., AC or DC volt ⁇ age), the voltage level, the pre-set current characteristic of each rapper, open and short trip conditions for each rapper, the maximum duration of energization and the mini ⁇ mum time delay between energization cycles for each rapper.
  • Microcomputer 14 is a slave to central computer 12 in that the microcomputer 14 waits for instruction from the central computer 12 before beginning operation. Upon receiving instruction from central computer 12 to energize Rapper 1, the microcomputer receives the location of Rapper 1, the voltage type and level of Rapper 1, the pre-set current characteristic for Rapper 1, the time duration of energization and the open and short trip conditions for Rapper 1.
  • the pre-set current characteristic is stored in local memory at microcomputer 14 and then transmitted to power control means 16.
  • the duration of energization is converted into a time equivalent number of frequency 1/2 cycles. This number of half cycles is transmitted to power control means 16.
  • the open and short trip conditions are also stored in local memory at the microcomputer 14.
  • the loca ⁇ tion of Rapper 1 is translated at microcomputer 14 into a specific TRIAC switch and information to energize the appropriate TRIAC is transmitted to TRIAC switch device 20.
  • SCR firing circuit 28 of the power control means 16 receives the pre-set Rap ⁇ per 1 current characteristic, and duration of energization in terms of half cycles, from microcomputer 14.
  • the SCR firing circuit 28 translates the pre-set current charac ⁇ teristic for Rapper 1 into a firing angle, Theta, which is sent to SCR 1 and SCR 2.
  • Power is applied to the rapper in terms of SCR firing angle degrees.
  • the sinusoidal electrical cycle contains 360 degrees, and consists of a positive half cycle and a nega ⁇ tive half cycle with respect to polarity. Each SCR can be fired anywhere from 0 degrees to 180 degrees in the electrical cycle, 0 degrees being full power and 180 degrees being 0 power.
  • an SCR When an SCR is fired at 45 degrees, for example, it will conduct from 45 degrees to 180 degrees. Therefore, a difference in firing angles can be represented as a distance along the abscissa of the sine wave. Due to polarity reversal, the SCR stops conducting at 180 degrees.
  • SCR 1 and SCR 2 The normal operating state of SCR 1 and SCR 2 is 180 degrees which allows 0 power from transformer 26 to pass through to the rappers.
  • SCR firing circuit 28 After SCR firing circuit 28 translates the pre-set current characteristic into the appropriate firing angle, it sends this angle to SCR 1 and SCR 2 which begins allowing the appropriate current to pass through to full-wave rectifier 30.
  • SCR firing circuit 28 also counts the number of half cycles that pass through the SCR combination. SCR 1 and SCR 2 remain ener- gized until the number of half cycles counted equals the number of half cycles trans- mitted from microcomputer 14. At this point SCR firing circuit 28 sends SCR 1 and SCR 2 a firing angle of 180 degrees, in effect ceasing power flow.
  • Full-wave rectifier 30 converts the AC signal which passes through SCR 1 and SCR 2 into a pulsating DC signal. As the pulsating DC signal exits full-wave rectifier
  • TRIAC switch device 20 a multi-layered solid-state device, acts as an AC switch. There is one TRIAC per rapper. When a rapper is ener ⁇ gized, its associated TRIAC is energized. Microcomputer 14, having translated the location of Rapper 1 into Rapper l's corresponding switch and transmitted this infor-
  • TRIAC switch device 20 may consists of a number of circuit boards with up to 16 TRIACs per board.
  • Microcomputer 14 can typically accommodate a total of 16 cir ⁇ cuit boards with 16 TRIACs per board. Thus, one microcomputer could characteris-
  • control block 10 including a second microcomputer, current detecting means, power control means and TRIAC switch means
  • the central computer 12 and power source 18 would be connected to any additional control block 10 added
  • the pulsating DC signal exiting power control means 16 is sensed and measured by current detecting means 22.
  • This actual rapper input current is sensed and converted to a voltage by external sense resistors 32.
  • This voltage passes through isolation amplifier 34, the output of which is an AC voltage proportional to the cur ⁇ rent flowing to Rapper 1.
  • the output of isolation amplifier 34 is routed to precision
  • rectifier 36 which rectifies an analog input to a DC level that is proportional to the sensed rapper input current.
  • the DC level is independent of the voltage drop across the diodes within precision rectifier 36.
  • the output of precision rectifier 36 is routed to a peak detector 38.
  • the peak detector 38 upon a command from microcomputer 14 will detect the peak value of the
  • microcomputer 14 While Rapper 1 is being energized, microcomputer 14 instructs peak detector 38 to detect peak current. The microcomputer 14 takes the output of peak detector
  • current detecting means 22 must sense and measure the actual peak current entering Rapper 1; microcomputer 14 must take that information, convert it to a digital word, compare it to the stored short and open trip conditions, determine that a trip condition is met, and transmit information to SCR firing circuit 28 to designate a firing angle of 180 degrees before the SCRs are fired a second time. Preventing the SCRs from firing a second time in the event of a short or open condi ⁇ tion is a significant improvement over the prior art and can be best accomplished by utilizing the speed inherent in microcomputers.
  • the same digital word is compared within microcomputer 14 to the previously stored pre-set input current characteristic for Rapper 1. Based on that comparison, information is transmitted to power control means 16 to perform any adjustments required to have the actual current entering Rapper 1 be substantially similar to the stored input current characteristic for Rapper 1.
  • microcomputer 14 converts the output of peak detector 38 into a digital word, this same information is transmitted to central computer 12 and stored. This information is stored according to its corresponding rapper and is available for present operating conditions and trending purposes.
  • Fig.4 The embodiment of Fig.4 is used to allow the rappers within a precipitator to operate at different voltage levels and with different signal types (AC or DC).
  • the rapper type AC or DC
  • voltage level is included.
  • Microcomputer 14 transmits to voltage selection relay 40 the required voltage level. If 240 volts is needed, the normally closed contact 46 remains closed, and normally open contact 44 remains open, allowing all 240 volts available from power source 18 to pass. If 120 volts is needed, voltage selection relay 40 causes normally closed con ⁇ tact 46 to open and normally open contact 44 to close, which allows only 120 volts to pass from power source 18. Further, microcomputer 14 transmits to AC/DC relay 42 which voltage type the energized rapper requires.

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  • Engineering & Computer Science (AREA)
  • Automation & Control Theory (AREA)
  • Mechanical Engineering (AREA)
  • Ac-Ac Conversion (AREA)
  • Rectifiers (AREA)
  • Electrostatic Separation (AREA)
  • Emergency Protection Circuit Devices (AREA)

Abstract

A multiple rapper control (10) for an electrostatic precipitator for monitoring and individually controlling each of a plurality of rappers based on computer (12) stored rapper characteristics including the voltage type, the voltage level, the pre-set electrical input current, the minimum increment between energization cycles, and the maximum duration of energization. Each rapper is connected to a TRIAC switch device (20) linked to a computer (14) and a power control means (16) to vary the input power to each rapper supplied from a power source (18). Current detecting means (22) is bi-directionally connected to the computer (14) and is connected to the power control means (16) to sense and measure the peak electrical input current to each rapper. A preselected logic sequence stored in the computer (12) controls power to each rapper.

Description

MULTIPLE RAPPER CONTROL FOR ELECTROSTATIC PRECIPITATOR
Background and Summary of the Invention This invention relates generally to electrostatic precipitators for air pollution control and, more specifically, concerns the control of the rapping process used to clean the internal collection plates and discharge electrodes of electrostatic precipitators.
Continuous emphasis on environmental quality has resulted in increasingly strenuous regulatory controls on industrial emissions. One technique which has proven highly effective in controlling air pollution has been the removal of undesirable particulate matter from a gas stream by electrostatic precipitation. An electrostatic precipitator is an air pollution control device designed to electrically charge and col¬ lect particulates generated from industrial processes such as those occurring in cement plants, pulp and paper mills and utilities. Particulate laden gas flows through the precipitator where the particulate is negatively charged. These negatively charged particles are attracted to, and collected by, positively charged metal plates. The cleaned process gas may then be further processed or safely discharged to the atmos¬ phere.
During continuous operation of an electrostatic precipitator, the collector plates and electrodes must be periodically cleaned to remove the dust build-up which accumulates on these surfaces. The cleaning mechanism typically consists of a mechanical rapper that acts as a hammer to dislodge by mechanical vibration any par¬ ticulate from the collector plate surfaces and discharge electrodes. An electronic rap¬ per controller determines the sequence, intensity, and duration of rapping. Once the particulate is dislodged from the plates, it falls into collection hoppers at the bottom of the precipitator.
In practice, numerous operational problems associated with the cleaning process may be experienced. Excessive rapping results in the particulate billowing from the plate into the gas stream where it is re-entrained in gas flow and must be recaptured. Otherwise, the re-entrained dust will be discharged from the exhaust stack, resulting in unacceptable emissions into the atmosphere. Insufficient rapping prevents the particulate from falling from the surfaces to be cleaned. In either case, collection efficiency of the precipitator is reduced which reduces the gas volumes that can be treated by the precipitator. In most industrial applications there is a direct cor¬ relation between precipitator capacity and production capacity. Therefore, there are significant monetary benefits to be derived from maximizing rapper efficiency. Also, grossly inefficient precipitators which allow an excessive amount of particulate emis- sions into the atmosphere can prompt the Environmental Protection Agency to shut a particular process down indefinitely.
In the prior art, rapper control has been limited to manually controlling and adjusting the current level to an entire group of rappers, rather than individual rapper control. However, rappers in different locations within the group may operate more efficiently with different current levels. Since the number of rapper groups, as well as the number of rappers within each group, may vary and prior art rapper control only allows for intensity adjustment of an entire group, a compromise in control standards therefore prevails. The result is often rapper inefficiencies that reduce precipitator and production capacity as well as increase emission levels.
Similarly, open and short trip values must be set for the rappers as a unit. Since rappers at different locations may have different current protection requirements, the prior art represents yet another compromise. To protect the rappers as a unit the least sensitive rapper must de-energize when a circuit condition occurs that is threatening to the most sensitive rapper. This is inefficient since some rappers will at times be de- energized unnecessarily even though their particular operating parameters are not ex¬ ceeded.
With respect to circuit protection, the prior art uses fuse or relay technology to detect and isolate fault conditions. This technology is slow in that the devices re- quire up to several full cycles before electrical protection can be assured. Within several full cycles of a fault condition significant damage can occur to rapper circuitry. Some commercial rapper control systems purport to incorporate solid state fault detection, but the trip level is set high because all rappers are required to have the same trip level. The trip level cannot be individually adjusted to a specific single rap¬ per within these systems and a compromise in control standards results. Another drawback of the prior art is that rapper control technology is an open looped system. The current level is set at a particular point in time, considering the present rapper conditions in the electrostatic precipitator. But, rapper conditions are not static. Numerous things can change rapping conditions which often affect current flow to the rappers. For instance, the precipitators get hot which changes the ambient temperature of the rapper. Rapper slugs as they energize travel through a sleeve which often gets dirty and sticky. Numerous influences change the rappers characteristics but the prior art requires control just as if the conditions are constant. This again results in inefficiencies.
The prior art does not provide an easy or economical way to check the present operating conditions of rappers in large precipitators. Presently, technicians must per¬ sonally walk near each precipitator while watching and listening to determine whether a specific rapper is operating. To determine the present current flow to a rapper, or to determine what current a particular style of rapper draws, a technician must per¬ sonally measure each rapper input with a meter. In large precipitators (for instance, 250 rappers or more) it becomes cost prohibitive to personally check the efficiency of each rapper.
Similarly, the prior art is unable to provide trending information for specific rappers, which can be very important in troubleshooting, calculating overall operat¬ ing efficiencies, as well as calculating the useful life expectancies of specific rappers. Along felt need in the air pollution control industry remains for improvements in rapper control for electrostatic precipitators to alleviate the many operational and maintenance difficulties which have been encountered in the past. The primary goal of this invention is to fulfill this need.
The present invention provides an improved way to control power to a rapper within an electrostatic precipitator. Since manually adjusting current to rappers as a unit is inherently inefficient, an important object of this invention is to provide a means for individually pre-setting electrical operating conditions for each rapper within a multiple rapper precipitator. Another object of this invention is to provide a means for individually setting short and open trip conditions for each rapper within a multiple rapper precipitator. This will eliminate the compromise required in the prior art and increase rapper ef¬ ficiency.
Still another object of this invention is to provide fault protection which assures detecting and isolating a fault condition within 1/2 cycle from the moment a fault oc¬ curs. Reducing fault trip response times from several full cycles to 1/2 cycle will great¬ ly increase circuit protection and increase the useful life expectancy of the rappers and precipitator as a whole.
Another object of this invention is to provide a closed-loop control means for a rapper. Enabling the rapper current control to sense, measure and adjust the input current in the event the actual current is not substantially similar to the pre-set electri¬ cal input current will greatly aid rapper efficiency. Another important object of this invention is to provide present operating con¬ ditions for each rapper within a precipitator and to store the rapper operating condi¬ tions. This will provide an economical way to check the actual operating conditions of each rapper as well as provide information for troubleshooting and trending.
Other and further objects of the invention, together with the features of novel- ty appurtenant thereto, will appear in the course of the following description. Description of the Drawings In the accompanying drawings which form a part of the specification and are to be read in conjunction therewith, and in which like reference numerals are used to indicate like parts in the various views: Fig. 1 is a block diagram illustrating a multiple rapper control constructed in accordance with a preferred embodiment of the invention;
Fig.2 is a block diagram showing the power source and power control means of the multiple rapper control in more detail;
Fig.3 is a block diagram showing the current detecting means of the multiple rapper control in greater detail; and
Fig.4 is a block diagram showing the power source and power control means, along with an optional voltage selection relay and the AC DC relay of the multiple rapper control.
This invention specifically contemplates the control of a plurality of rappers for an electrostatic precipitator. This description uses two rappers for illustrative pur¬ poses and not as as a limitation on the number of rappers to be used in practicing the invention.
A multiple rapper control embodying the principles of this invention is shown in Fig. 1 of the drawings with the control block designated generally by the reference numeral 10. Control block 10 is connected to a central computer 12, a power source 18 and a plurality of rappers as schematically indicated by Rapper 1 and Rapper 2 blocks. More specifically, central computer 12 is bi-directionally connected to a microcomputer 14 which in turn is connected to both a power control means 16 and a TRIAC switch device 20. Power control means 16 is connected between a power source 18 and TRIAC switch device 20. A current detecting means 22 senses and measures the current between power control means 16 and TRIAC switch device 20. Current detecting means 22 is connected to the output of power control means 16 and is bi-directionally connected to microcomputer 14. Rapper 1 and Rapper 2 are each individually connected to a TRIAC within the TRIAC switch device 20. In other words, each rapper is connected to only one TRIAC and, conversely, each TRIAC is connected to only one rapper. The TRIAC may be typically characterized as a silicon bi-directional triode thyristor, such as T6420M of Motorola designated for a 600 volt rating for 40 amps.
The power control means 16 and power source 18 are illustrated in Fig. 2.
Power control means 16 comprises an SCR firing circuit 28, a full-wave rectifier 30, an SCR 1 and an SCR 2. Power source 18 comprises a transformer 26 and two input terminals 24 to which power is applied. The input terminals 24 are connected to the primary of transformer 26. One side of the secondary of transformer 26 is connected to an inverse parallel SCR 1 and SCR 2 which connects, along with the other side of the secondary of transformer 26, to full-wave rectifier 30. SCR firing circuit 28 is con¬ nected serially between microcomputer 14 and the inverse parallel SCR 1 and SCR 2.
The current detecting means 22 is best illustrated in Fig.3. One sense resistor 32 is connected serially between power control means 16 and TRIAC switch device 20. The sense resistor 32 is also connected across a conventional input protection cir¬ cuit 33 and then to an isolation amplifier 34 connected serially with a precision rec- tifier 36. Precision rectifier 36 is connected with a peak detector 38 which bi-directionally connects to microcomputer 14. Isolation amplifier 34 may typically comprise an AD202JN chip such as manufactured by Analog Devices of Norwood, Massachusetts. Precision rectifier 36 comprises two operational amplifiers and two high speed switching diodes (such as 1N4148 diodes) appropriately biased to rectify the input characteristic to a DC level that is independent of the voltage drop across the diodes. The two operational amplifiers may comprise TL032CP operational amplifiers characterized as an enhanced JFET (junction field effect transistor), low power, low offset, analog operational amplifier such as manufactured by Texas Instru¬ ments of Dallas, Texas. The peak detector 38 may typically comprise a PKD01FP chip such as manufactured by Precision Monolithics Inc. of Santa Clara, California and characterized as a monolithic peak detector with reset and hold mode.
The components which allow a rapper to receive either an AC or DC signal at 120 volts or 240 volts are best illustrated in Fig.4. Microcomputer 14 is connected to both a voltage selection relay 40 and an AC/DC relay 42. Voltage selection relay 40 is connected to a normally open contact 44 and a normally closed contact 46. Normal- ly closed contact 46 is connected to the 240 volt lead of power source 18, and normal¬ ly open contact 44 is connected to the 120 volt lead of power source 18. Both contacts 44 and 46 are connected to the inverse parallel SCRl and SCR2. The AC/DC relay 42 is connected to two normally open contacts 48 and 50 and two normally closed con¬ tacts 52 and 54. Normally open contact 48 is connected to the inverse parallel SCRl and SCR2 while normally open contact 50 is connected directly to the power source 18. Both normally open contacts 48 and 50 are connected to TRIAC switch device 20. Normally closed contacts 52 and 54 are connected to the positive and negative output of bridge rectifier 30, respectfully. Both normally closed contacts 52 and 54 connect with TRIAC switch device 20. In operation, a look-up table including characteristics for each individual rap¬ per is determined, entered and stored in central computer 12. The look-up table parameters comprise the location of each rapper, the rapper type (i.e., AC or DC volt¬ age), the voltage level, the pre-set current characteristic of each rapper, open and short trip conditions for each rapper, the maximum duration of energization and the mini¬ mum time delay between energization cycles for each rapper. Microcomputer 14 is a slave to central computer 12 in that the microcomputer 14 waits for instruction from the central computer 12 before beginning operation. Upon receiving instruction from central computer 12 to energize Rapper 1, the microcomputer receives the location of Rapper 1, the voltage type and level of Rapper 1, the pre-set current characteristic for Rapper 1, the time duration of energization and the open and short trip conditions for Rapper 1. The pre-set current characteristic is stored in local memory at microcomputer 14 and then transmitted to power control means 16. The duration of energization is converted into a time equivalent number of frequency 1/2 cycles. This number of half cycles is transmitted to power control means 16. The open and short trip conditions are also stored in local memory at the microcomputer 14. The loca¬ tion of Rapper 1 is translated at microcomputer 14 into a specific TRIAC switch and information to energize the appropriate TRIAC is transmitted to TRIAC switch device 20.
SCR firing circuit 28 of the power control means 16 receives the pre-set Rap¬ per 1 current characteristic, and duration of energization in terms of half cycles, from microcomputer 14. The SCR firing circuit 28 translates the pre-set current charac¬ teristic for Rapper 1 into a firing angle, Theta, which is sent to SCR 1 and SCR 2. Power is applied to the rapper in terms of SCR firing angle degrees. The sinusoidal electrical cycle contains 360 degrees, and consists of a positive half cycle and a nega¬ tive half cycle with respect to polarity. Each SCR can be fired anywhere from 0 degrees to 180 degrees in the electrical cycle, 0 degrees being full power and 180 degrees being 0 power. When an SCR is fired at 45 degrees, for example, it will conduct from 45 degrees to 180 degrees. Therefore, a difference in firing angles can be represented as a distance along the abscissa of the sine wave. Due to polarity reversal, the SCR stops conducting at 180 degrees.
The normal operating state of SCR 1 and SCR 2 is 180 degrees which allows 0 power from transformer 26 to pass through to the rappers. After SCR firing circuit 28 translates the pre-set current characteristic into the appropriate firing angle, it sends this angle to SCR 1 and SCR 2 which begins allowing the appropriate current to pass through to full-wave rectifier 30. SCR firing circuit 28 also counts the number of half cycles that pass through the SCR combination. SCR 1 and SCR 2 remain ener- gized until the number of half cycles counted equals the number of half cycles trans- mitted from microcomputer 14. At this point SCR firing circuit 28 sends SCR 1 and SCR 2 a firing angle of 180 degrees, in effect ceasing power flow.
Full-wave rectifier 30 converts the AC signal which passes through SCR 1 and SCR 2 into a pulsating DC signal. As the pulsating DC signal exits full-wave rectifier
5 30, it also exits power control means 16. From power control means 16 the pulsating DC signal enters TRIAC switch device 20. The TRIAC, a multi-layered solid-state device, acts as an AC switch. There is one TRIAC per rapper. When a rapper is ener¬ gized, its associated TRIAC is energized. Microcomputer 14, having translated the location of Rapper 1 into Rapper l's corresponding switch and transmitted this infor-
10 mation to TRIAC switch device 20, the appropriate switch is energized to allow the DC pulsating signal to pass to Rapper 1.
TRIAC switch device 20 may consists of a number of circuit boards with up to 16 TRIACs per board. Microcomputer 14 can typically accommodate a total of 16 cir¬ cuit boards with 16 TRIACs per board. Thus, one microcomputer could characteris-
15 tically accommodate a total of 256 TRIACs and 256 rappers. For a precipitator with more than 256 rappers, another control block 10 (including a second microcomputer, current detecting means, power control means and TRIAC switch means) could be added as required to replicate the system illustrated in Fig. 1. The central computer 12 and power source 18 would be connected to any additional control block 10 added
20 to the basic arrangement.
The pulsating DC signal exiting power control means 16 is sensed and measured by current detecting means 22. This actual rapper input current is sensed and converted to a voltage by external sense resistors 32. This voltage passes through isolation amplifier 34, the output of which is an AC voltage proportional to the cur¬ rent flowing to Rapper 1. The output of isolation amplifier 34 is routed to precision
25 rectifier 36 which rectifies an analog input to a DC level that is proportional to the sensed rapper input current. The DC level is independent of the voltage drop across the diodes within precision rectifier 36.
The output of precision rectifier 36 is routed to a peak detector 38. The peak detector 38 upon a command from microcomputer 14 will detect the peak value of the
30 wave form at its input. This is a sample and hold device which, on command, will store the peak value. Current detecting means 22 provides an elect; cally isolated rectified peak detection of the input current for selected Rapper 1.
While Rapper 1 is being energized, microcomputer 14 instructs peak detector 38 to detect peak current. The microcomputer 14 takes the output of peak detector
35 38 and converts it to a digital word. This digital word is then compared by microcom¬ puter 14 to previously stored short and open trip conditions and the pre-set input cur- rent characteristics for Rapper 1. At this point the speed of computation is very im¬ portant. Once SCR 1 and SCR 2 of power control means 16 are energized, they can¬ not be turned off until the voltage passing through them drops to 0. The voltage through these SCRs drops to 0 approximately every 8.33 milliseconds. During that 8.33 millisecond time period current detecting means 22 must sense and measure the actual peak current entering Rapper 1; microcomputer 14 must take that information, convert it to a digital word, compare it to the stored short and open trip conditions, determine that a trip condition is met, and transmit information to SCR firing circuit 28 to designate a firing angle of 180 degrees before the SCRs are fired a second time. Preventing the SCRs from firing a second time in the event of a short or open condi¬ tion is a significant improvement over the prior art and can be best accomplished by utilizing the speed inherent in microcomputers.
In the event a trip condition is not present, the same digital word is compared within microcomputer 14 to the previously stored pre-set input current characteristic for Rapper 1. Based on that comparison, information is transmitted to power control means 16 to perform any adjustments required to have the actual current entering Rapper 1 be substantially similar to the stored input current characteristic for Rapper 1.
Each time microcomputer 14 converts the output of peak detector 38 into a digital word, this same information is transmitted to central computer 12 and stored. This information is stored according to its corresponding rapper and is available for present operating conditions and trending purposes.
At the end of the rapping cycle, if there are no short or open conditions, all TRIACs are shut off and the microcomputer 14 waits for the next instruction. Central computer 12 at this time determines when the next rapper should.be energized. When that time is reached the above process is repeated for the appropriate rapper. If a short or open condition does occur, the fault condition is sent to the central computer and that rapper's energization cycle is passed over in the future.
The embodiment of Fig.4 is used to allow the rappers within a precipitator to operate at different voltage levels and with different signal types (AC or DC). When central computer 12 downloads the operating characteristics for a rapper to microcomputer 14, the rapper type (AC or DC) and voltage level is included. Microcomputer 14 transmits to voltage selection relay 40 the required voltage level. If 240 volts is needed, the normally closed contact 46 remains closed, and normally open contact 44 remains open, allowing all 240 volts available from power source 18 to pass. If 120 volts is needed, voltage selection relay 40 causes normally closed con¬ tact 46 to open and normally open contact 44 to close, which allows only 120 volts to pass from power source 18. Further, microcomputer 14 transmits to AC/DC relay 42 which voltage type the energized rapper requires. If DC voltage is needed, normally closed contacts 52 and 54 remain closed and normally open contacts 48 and 50 remain open. This connects TRIAC switch device 20 to the output of full wave bridge rec- tifier 30, which will in effect supply a DC signal to the rapper. If AC voltage is re¬ quired, AC/DC relay 42 causes normally open contacts 48 and 50 to close and normally closed contacts 52 and 54 to open. This allows the AC signal leaving the inverse paral¬ lel SCRl and SCR2 to bypass bridge rectifier 30, which in effect supplies the rapper with an AC signal. It should be noted that the relay contacts in Fig.4 were illustrative as one embodiment and that solid state devices or comparable variations are under¬ stood to be included within this disclosure.
From the foregoing it will be seen that this invention is one well adapted to at¬ tain all end and objects hereinabove set forth together with the other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.

Claims

Having thus described our invention, we claim:
1. A multiple rapper control for an electrostatic precipitator, said rapper con¬ trol comprising: a plurality of electrostatic precipitator rappers; a TRIAC switch device having a plurality of TRIACs wherein each said rapper is connected to at least one of said TRIACs; power control means with an output connected to said TRIAC switch device to vary the input power to each said rapper; a power source connected to said power control means to supply input power to said power control means; current detecting means connected to said output of said power control means to sense and measure the peak electrical input current to each said rapper; a computer with memory means connected to said current detecting means, to said power control means and to said TRIAC switch device for storing a look-up table including the operating characteristics of each said rapper; and logic means stored in said computer to control power to each said rapper in a preselected logic sequence.
2. The multiple rapper control as in Claim 1, wherein said look-up table of operating characteristics of each said rapper comprises the pre-set electrical input cur- rent, the minimum increment between energization cycles, and the maximum dura¬ tion of energization.
3. The multiple rapper control as in Claim 2, said logic sequence comprising: retrieving from said memory said increment between said energization cycles and determining the appropriate time to begin energizing each said rapper; retrieving from memory said duration of energization and said pre-set electri- cal input current characteristic; sending to said power control means appropriate information to pass rapper current from said power source substantially similar to said pre-set electrical input characteristic; sending to said power control means appropriate information to determine the completion of said energization cycle and to cease energization of each said rapper at that time; sending to said TRIAC switch device appropriate information to allow current to flow to each said rapper; sending to said current detecting means appropriate information to sense, measure, and hold the actual peak electrical input current to each said rapper; retrieving from said current detecting device said measurement of the actual peak electrical input current to each said rapper, and converting said measurement to a digital word; comparing said digital word with said pre-set stored electrical input current characteristic; sending to said power control means appropriate information, accounting for required adjustments based on said comparison, to pass rapper current from said power source substantially similar to said pre-set electrical input current characteris¬ tic, the sequence of retrieving from said current detecting means said measure¬ ment of actual rapper input current, converting said measurement to said digital word, comparing said digital word to said pre-set electrical input current characteristic, and sending appropriate information to said power control means is repeated until said energization cycle is complete; and determining the completion of said energization cycle and sending appropriate information to said TRIAC switch device to de-energize said rapper.
4. The multiple rapper control as in Claim 3, wherein each of said digital words representing said measured rapper input current is stored at a different address within said memory allowing present and past operating conditions of each said rapper to be available to an operator.
5. The multiple rapper control as in Claim 4 wherein open and short circuit fault conditions are determined and each said rapper is automatically de-energized in such cases, said rapper control including: pre-set open and short trip conditions stored in said look-up table; and said logic sequence adapted to retr *ve said open and short trip conditions from said look-up table and compare said digital word, representing actual peak rapper input current, with said pre-set open and short trip conditions to determine a fault condition, and to send appropriate information to said power control means to de- energize each said rapper upon fault detection; and said computer having logic means to avoid re-energizing each said rapper with fault in the future.
6. The multiple rapper control as in Claim 5, wherein a fault condition is recog¬ nized and each said rapper is de-energized within one-half cycle to assure maximum circuit protection.
7. The multiple rapper control as in Claim 3, wherein said look-up table of operating characteristics includes the location of each said rapper, and is stored in said look-up table; and said logic sequence includes receiving said location of each said rapper and sending said TRIAC switch device appropriate information to ener¬ gize said rapper, and sending said digital word, representing peak rapper input cur¬ rent, to an appropriate address within said memory to allow an operator to determine which digital words correspond with each said rapper. 5
8. The multiple rapper control as in Claim 1, wherein said power control means comprises: an SCR firing circuit connected to said computer; an inverse parallel SCR combination connected to said SCR firing circuit; and a full-wave bridge rectifier connected to said inverse parallel SCR combina- 0 tion and said power source.
9. The multiple rapper control as in Claim 1, wherein said current detecting means comprises: one sense resistor connected serially between said power means and said
TRIAC switch device; 5 an isolation amplifier connected across said sense resistor; a precision rectifier serially connected to said isolation amplifier; and a sample and hold peak detector serially connected to said precision rectifier and bi-directionally connected to said computer.
10. The multiple rapper control as in Claim 3, wherein said computer com- 0 prises a master computer with memory and a slave computer with memory, said memory of said master computer comprising said look-up table and said stored digi¬ tal words containing trending information, and said master computer having logic means to determine when a particular rapper is to be energized and communicating appropriate information to said slave computer with memory, and said memory of said slave computer receives appropriate information from said master computer, cor¬ responding to the specific rapper to be energized, to allow said logic sequence to be performed on each said rapper with said information is stored in memory of said slave computer until the energization cycle of said specific rapper is complete, and said slave computer having logic means to retrieve appropriate information from memory of said slave computer and to perform said logic sequence and to communicate appropriate 0 information to said master computer with memory.
11. The multiple rapper control as in Claim 1 including: a voltage selection relay having voltage selection relay contacts connected be¬ tween said power source and said power control means to select the voltage level ex¬ iting said power source; and 5 an AC/DC relay having AC/DC relay contacts connected between said power control means and said TRIAC switch device to select the voltage type which enters said TRIAC switch device.
12. The multiple rapper control as in Claim 11, wherein said look-up table of operating characteristics of each said rapper comprises the voltage type, the voltage level, the pre-set electrical input current, the minimum increment between energiza¬ tion cycles, and the maximum duration of energization.
13. The multiple rapper control as in Claim 12, said logic sequence compris¬ ing: retrieving from said memory said increment between said energization cycles and determining the appropriate time to begin energizing each said rapper; retrieving from said memory said voltage type and said voltage level; sending to said voltage selection relay information to arrange said voltage selection relay contacts to allow the proper voltage level to exit said power source; sending to said AC/DC relay information to allow the proper voltage type to enter said TRIAC switch device; retrieving from memory said duration of energization and said pre-set electri¬ cal input current characteristic; sending to said power control means appropriate information to pass rapper current from said power source substantially similar to said pre-set electrical input characteristic; sending to said power control means appropriate information to determine the completion of said energization cycle and to cease energization of each said rapper at that time; sending to said TRIAC switch device appropriate information to allow current to flow to each said rapper; sending to said current detecting means appropriate information to sense, measure, and hold the actual peak electrical input current to each said rapper; retrieving from said current detecting device said measurement of the actual peak electri 'nput current to each said rapper, and converting said measurement to a digital worα, comparing said digital word with said pre-set stored electrical input current characteristic; sending to said power control means appropriate information, accounting for required adjustments based on said comparison, to pass rapper current from said power source substantially similar to said pre-set electrical input current characteris¬ tic, the sequence of retrieving from said current detecting means said measure¬ ment of actual rapper input current, converting said measurement to said digital word, comparing said digital word to said pre-set electrical input current characteristic, and sending appropriate information to said power control means is repeated until said energization cycle is complete; and determining the completion of said energization cycle and sending appropriate information to said TRIAC switch device to de-energize said rapper.
14. The multiple rapper control as in Claim 13, wherein each of said digital words representing said measured rapper input current is stored at a different address within said memory allowing present and past operating conditions of each said rap¬ per to be available to an operator.
15. The multiple rapper control as in Claim 14 wherein open and short circuit fault conditions are determined and each said rapper is automatically de-energized in such cases, said rapper control including: pre-set open and short trip conditions stored in said look-up table; and said logic sequence adapted to retrieve said open and short trip conditions from said look-up table and compare said digital word, representing actual peak rapper input current, with said pre-set open and short trip conditions to determine a fault condition, and to send appropriate information to said power control means to de- energize each said rapper upon fault detection; and said computer having logic means to avoid re-energizing each said rapper with fault in the future.
16. The multiple rapper control as in Claim 15, wherein a fault condition is recognized and each said rapper is de-energized within one-half cycle to assure max¬ imum circuit protection.
17. The multiple rapper control as in Claim 13, wherein said look-up table of operating characteristics includes the location of each said rapper, and is stored in said look-up table; and said logic sequence includes receivmg said location of each said rapper and sending said TRIAC switch device appropriate information to ener¬ gize said rapper, and sending said digital word, representing peak rapper input cur- rent, to an appropriate address within said memory to allow an operator to determine which digital words correspond with each said rapper.
18. The multiple rapper control as in Claim 11, wherein said power control means comprises: an SCR firing circuit connected to said computer; an inverse parallel SCR combination connected to said SCR firing circuit; and a full-wave bridge rectifier connected to said inverse parallel SCR combina¬ tion and said power source.
19. The multiple rapper control as in Claim 11, wherein said current detecting means comprises: one sense resistor connected serially between said power means and said
TRIAC switch device; an isolation amplifier connected across said sense resistor; a precision rectifier serially connected to said isolation amplifier; and a sample and hold peak detector serially connected to said precision rectifier and bi-directionally connected to said computer.
20. The multiple rapper control as in Claim 13, wherein said computer com¬ prises a master computer with memory and a slave computer with memory, said memory of said master computer comprising said look-up table and said stored digi¬ tal words containing trending information, and said master computer having logic means to determine when a particular rapper is to be energized and communicating appropriate information to said slave computer with memory, and said memory of said slave computer receives appropriate information from said master computer, cor¬ responding to the specific rapper to be energized, to allow said logic sequence to be performed on each said rapper with said information is stored in memory of said slave computer until the energization cycle of said specific rapper is complete, and said slave computer having logic means to retrieve appropriate information from memory of said slave computer and to perform said logic sequence and to communicate appropriate information to said master computer with memory.
PCT/US1989/004850 1989-10-30 1989-10-30 Multiple rapper control for electrostatic precipitator Ceased WO1991006371A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
PCT/US1989/004850 WO1991006371A1 (en) 1989-10-30 1989-10-30 Multiple rapper control for electrostatic precipitator
PCT/US1990/003748 WO1991006372A1 (en) 1989-10-30 1990-06-29 Multiple rapper control for electrostatic precipitator
CA002072129A CA2072129C (en) 1989-10-30 1990-06-29 Multiple rapper control for electrostatic precipitator

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US1989/004850 WO1991006371A1 (en) 1989-10-30 1989-10-30 Multiple rapper control for electrostatic precipitator

Publications (1)

Publication Number Publication Date
WO1991006371A1 true WO1991006371A1 (en) 1991-05-16

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PCT/US1990/003748 Ceased WO1991006372A1 (en) 1989-10-30 1990-06-29 Multiple rapper control for electrostatic precipitator

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US4086646A (en) * 1976-12-30 1978-04-25 Belco Pollution Control Corporation System for the control of rappers in an electrostatic precipitator
US4290003A (en) * 1979-04-26 1981-09-15 Belco Pollution Control Corporation High voltage control of an electrostatic precipitator system
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Also Published As

Publication number Publication date
CA2072129C (en) 1995-06-13
CA2072129A1 (en) 1991-05-01
WO1991006372A1 (en) 1991-05-16

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