Shyamrai Electronics

Kasba, Kolkata, West Bengal

 ESPC Ver III is user’s friendly third generation Dual Micro-controller based digital programmable Electrostatic-Precipitator’s T/R set controller. This is easy to install and can be interfaced with any make of T/R set for retrofitting. It controls the ESP’s filter current and voltage as per the preset value. It can also program the inbuilt Rapping Controller in Power Controlled Rapping Mode in stand-alone mode and automatically in management mode when connected to PMS (Precipitator Management System). ESPC Ver III maintains the spark rate at a suitable level for large variations in gas flow, gas temperature, dust composition etc. It regulates the rectifier in such a way that the current through the ESP is corrected as the conditions for sparking change. ESPC Ver III controller gives alarm messages to the operator when values are lower or higher than set, including if one or several alarm contacts are activated etc.  ESPC III can operate both in Stand-alone and Management System.  All the special features available in others make controller are already their in ESPC III. So the feature you name it, we have it.

It is a custom-built multi channel resistance to current converter for PLC or damper interfacing.

Shyamrai make Micro-Controller based BAG-FILTER CONTROLLER has unique features with lower cost, thus making it most efficient and reliable and unparalleled in Industry. • Single Chip Micro Controller is used to reduce the component count of the controller. Hence the chance of failure of components is reduced and all the timings like On time and Off time variation is  + 1 mili second. • Micro switch push buttons are used to set all the timings and no. of channel selection instead of Thumb wheel switch, which has reduced the chance of failure the contact of Thumb wheel switches. • EEPROM is provided to store all the Time and Channel Setting, which will never loss the setting parameters. • The controller controls the Bag-Filter for 1 to 32 nos. of channel in multiplexing mode or 1 to 12 no. of channel for direct connection. More channel is available on customer request. • Substantial reduction in cost of Cabling and erection cost in multiplexing mode. • All the Outputs are Short Circuit protected and also has the skipping facility.

We are offering high frequency transformer set. Ferrite core based high frequency transformer rectifier (hftr) unit is a high voltage switch mode power supply (smps) unit for electro static precipitator (esp). It supplies a smooth and ripple free high voltage dc into the esp field using the small internal capacitance of the fields.

   The Thyristor controlled panel supply the fully controlled Voltage and current to the Primary of the Transformer-Rectifier Set of ESP. It is a 2mm thick sheet steel powder coated encloser consisting of Switch fuse Unit, Contactor, Relays Control Transformers, Thyristors, Protection Circuits and a Micro-processor based controller. It supplies required voltage to the TR Sets from single phase 415 volts input by controlling the firing angle of two Thyristors connected back to back. Four nos of analouge meters mounted on the panel door indicate Primary voltage, Current and Secondary Voltage (kV) & Current (mA). Four nos of 22.5 mm LED lamps indicate Supply on, TR on, system Warning & System Trips respectively. It also gives the audiable sound during warning and trip. All types of safety & security interlocking facilities are provided. The thyristor control panel can also be designed and manufacture as per the customer requirement.

   Transformer-Rectifier (T/R) sets supply specified DC Voltage and current to the field of electrostatic precipitators. Shyamrai makes both standard and custom T/R sets, and both the set very standard for quality and adaptability in retrofit and new applications for ESPs. Shyamrai make T/R sets and associated control panel and Micro-processor based controller meet all electrical requirements for all types of ESPs. The T/R Set – Product Description The T/R set consists of a transformer, an in built current-limiting reactor (CLR), High voltage rectifiers, High voltage resistance for signal feed back to controller, R.F. Choke and switches - all contained in an oil- filled tank that is completely sealed and suitably painted for outdoor use. Standard semi-outdoor bushing are supplied on these units and are suitable for outdoor use when enclosed in a bus duct to protect them from the elements. Available any ratings are from 40 kV DC 100mA to 120kV DC 2000mA. Main transformer: This is a high-voltage, step-up transformer designed to convert low-voltage input into the high voltage required for ESP operation. The transformer is located on the bottom of the tank. Primary winding is designed to match the type of controller being used; secondary voltages and currents are set to meet load requirements. The transformers unique design helps prolong its life by distributing the electrical and mechanical stresses incurred in operating the ESP. Rectifier: To ensure the optimum reliability, our minimum rating for high-voltage rectifiers are 1.5 times the PIV of the T/R maximum peak KV. A full wave rectifier bridge is connected across the transformer secondary. The negative polarity i.e. DC output from the rectifiers is connected to a H.F Choke in such a way that the bridge is easily removable and replaceable from the top of the T/R set. Transformer-Rectifier Tank: T/R tanks are rectangular in shape. Lugs and supports are available to aid in lifting by crane or forklift. Powder coating or suitable outdoor paint is standard, but can meet other individual specifications on request. Current limiting reactor (CLR): Because of sparking and consequent short circuiting during ESP operation, current must be limited to protect the T/R set. When a Silicon Controlled Rectifier (SCR) controller is used as the voltage regulating device, it must be protected for adverse short-circuit conditions. Besides improving waveform and waveform factor, the CLR protects both the T/R set and SCR controller as follows: 1. By limiting current to SCR 2. By limiting peak current to the T/R set during precipitator sparking. The CLR is designed so that short-circuit current is limited to a value specified by the user or ESP manufacturer (usually a maximum of three times rated current). The CLR is connected in series to the T/R set primary. By using a CLR, less inductive reactance is required in the high-voltage transformer, thus allowing for greater reliability in transformer construction. Use of a CLR also allows more efficient utilization of SCR devices, without which higher current carrying SCR devices would have to be used, because of derating for lower conduction angles. CLRs are individually designed to match the load specified by each customer for particular ESP requirements. Location of CLR is inside the tank.

 This is a newly developed control panel for the conventional TR Set. This panel can be used to increase the ESP’s efficiency over the conventional control system. The design, controlling, safety, warning and Trip philosophy of this panel is almost the same as the Thyristor Control Panel excepting some points mentioned below : 1. Used IGBT bridge instead of back to back thyristors 2. Used three phase and neutral supply instead of Single phase 415 volt supply. 3. Power factor is 0.98 to 1.0 4. Supply 0 to 350 volts 100 Hz square wave to the Primary of the T/R Set. As a result a ripple free DC kV is available into the ESP field, which improves the efficiency of the ESP. 5. The Sme panel is used as a control panel for HFTR, where the operating frequency is 20KHz instead of 100Hz.  

   Thyristor / IGBT control panel with Micro-processor based controller is self sufficient to control, indications, fault indication / response in a stand alone mode. The panel can operate and communicate to the host through RS-485 port while in management mode. Moreover the controller has inbuilt digital IOs and 4 to 20mA output for major 3 parameters (i.e. Primary currrent, Secondary Current and Secondary Voltage) by which customer can cantrol and get the indication of major parameters by using our Remote indicating control panel. This panel will indicate kv, mA & primary current of the fields in the digital panel meters. Customer will get the TR status indication by some led panel indicators. Customer also operate the TR set for on/off and alarm reset function.  This panel is mostly used where DCS / PMS is absent.

 PMS is an operation, analysis and presentation package for controlling process parameters such as Voltage (kV), Current (mA), Spark Rate etc. to improve the efficiency of Electrostatic Precipitator. Data are collected from ESPC (Electrostatic Precipitator Controller) and continuous communication between the host computer and ESPC guarantees that the data are graphically presented in real time. The program package “PMS” is used in the serial transfer of data from ESPC to personal computer situated at the CCR or via a modem at greater distances. PMS is a WINDOWS based program and is run on Pentium PCs with colored SVGA monitor. PMS includes routines for the rapid retrieval of data and for monitoring and setting the ESPC unit, the central unit in T/R Set monitoring system. The data, which can be automatically transferred at given intervals, are stored in a database and can be presented numerically or graphically on the computer screen. A built-in alarm function is displayed when there is any alarm conditions in the T/R sets.  The data can be presented with a time resolution, which is suitable for each application. This is especially useful in cases where temporal information is required instantaneously. PMS can also pass on data from the computer via a telephone communication network, to the other user. With the program package, it is possible to generate number of statistical reports at any time of the night or day.  The version of the software includes many new features that turn your control room into a powerful tool for OPERATION AND MAINTENANCE of multiple Electrostatic Precipitator (EP) units. Some of the advantages of PMS over other system are highlighted below: • Can control, display, optimize, log data and store data, print data of 99 nos. Controllers from a single Computer.  • Savings in atleast 20 - 40% of Power Consumption of your existing system. • Less manpower required for attending individual ESP Panel as the same can be done by the operator from the computer itself. 

Shyamrai make Micro-Controller based BAG-FILTER CONTROLLER has unique features with lower cost, thus making it most efficient and reliable and unparalleled in Industry.

   Ferrite core based High frequency Transformer Rectifier (HFTR) unit is a High voltage Switch Mode Power Supply (SMPS) unit for Electro Static Precipitator (ESP). It supplies a smooth and ripple free High voltage DC into the ESP field using the small internal capacitance of the fields. It improves the efficiency of ESP than the conventional Thyristor controlled TR Set. The HFTR is powered by a Micro-Controller based IGBT controlled Panel. The supply voltage of the panel is 3 Phase 415 V 50 / 60 Hz. Schematic Diagram of the operation as below: Fine particles emissions are much more dangerous to health than the larger ones. Collecting of fine particles below 10 micro meter (PM10 ) in Electro-static precipitators has not been very efficient with conventional system. A new High frequency TR set was developed with a pulse duration below 50 Micro-Second to used it with existing precipitators the current capability had to be in the kA range. It is possible to generate a high charge density in the electrode area, which leads increase charging of the fine particles. Flash over / Sparks are mainly avoided due to the short pulse duration. Data can be recorded on a real time precipitation in any ESP. 1. Input Supply : 3 Phase 415 V AC 50 / 60Hz. 2. Input Current : 60 Amps (Max.) 3. Power Factor : 0.98 to 1.0 4. Output Voltage: 50, 000 Volts DC (Max.) 5. Output Current: 0.5 Amps (Max.) 6. Operating freq. : 20KHz. (Max.) 7. Efficiency : >95% 8. Output Power : 25KVA