Reducing Maintenance Turnaround Time Using MIGI Rapper Control Panel for ESP Cleaning
08 June | Castlet
Electrostatic precipitators (ESPs) remove particulate from industrial flue gas by charging dust particles via a high-voltage corona discharge and collecting them on collecting plates. To maintain peak performance ≥99.9% collection efficiency, these plates and discharge electrodes must be regularly “rapped” (mechanically shaken) to dislodge accumulated dust.
We are delighted to have reduced maintenance turnaround time through rapid fault identification and modular card swaps.
Castlet Engineering Team
Our Solution
Solution
Our MIGI rapper control panel has a mild-steel cabinet with lockable door, weather-proof gasket seals, and powder-coat finish. The internal layout is built on three key elements; modular plug-in cards for ease of service, CAN-bus transceiver modules for reliable, noise-immune field communication, and separate power and logic compartments to minimise electrical interference.
We enhanced the programme timing and sequencing for optimal use, meaning the plunger lift height could be set per device, per group, or globally to match dust loading.
What we did
We enhanced the programme timing and sequencing for optimal use, meaning the plunger lift height could be set per device, per group, or globally to match dust loading. With up to six distinct rapping programmes now stored in non-volatile memory for rapid switching (e.g., fuel changes, load variations), we ensured the processing worked smoothly.
For real-time monitoring of each rapper device’s current draw and circuit continuity, our solution identifies the device number and fault cause (open circuit, over-current) on the panel’s display.
The results
We provide this through testing verified for timing accuracy, intensity adjustments, and fault-reporting functionality.
With reduced energy consumption, enhanced uptime and future-proof flexibility, the programme is now compliant. The rapper timing and intensity programmes every 5–10 years to incorporate advances in control strategies. With our installations we offer to you on going support to future-proof your business and can supply microprocessor cards and HMI modules to retrofit existing/obsolete controllers.