Integrated Precipitator Management Solutions

Forry® ESP ProductsClear Skies Ahead

Forry Integrated Precipitator Management Solutions

ERCRapper Control

ERCRapper Control

Workstations

DataserverDCS/OPC

AVCVoltage Control

AVCVoltage Control

MIUModbus Interface

DCUDistributed Control

Biomass

As the trusted leader in the power industry, Stock is giv-ing you better control of your ESP and your bottom line, with innovative precipitator management solutions. Our Forry Integrated Precipitator Management Solutions suite ties together voltage controls, rapper controls, a Windows user interface, DCS communications and additional I/O in a single inte-grated package.

A high level of product integration makes possible advanced features like power-reduced rapping, load-based rapping, detailed graphs and reports of ESP operation, and “Rapper-Tracker” to trouble-shoot opacity spikes. All of which are designed to make your ESPs run more effec-tively.

LimestoneCoal

To Stoker Boiler Economizer

Boiler

Electrostatic Precipitator

Wet FGD System

Non-Pressurized Feeders

Conical Distributor

AVC Voltage controls, ERC Rapper controls

& T/R Sets

Clear Plume

The Forry line of T/Rs offers uncompromising quality, ruggedness and reliability. Based on the original, time tested, ABB/ Westinghouse design, these T/R sets provide dependable, low main-tenance service for decades. We don’t take any shortcuts in the design of our T/Rs — each T/R is equipped with 100% copper-wound transformers and heavy duty R/C compensated diode stacks. Our heavy duty steel tanks provide superior mechanical strength and full-vacuum processing capability.

Our T/R design center will custom design a T/R to your specifications. We design high quality retrofits for Research-Cottrell, ABB, NWL, GE and many other in a variety of ratings and forms factors.

Our exact replacements will save you time and the high cost of modifications needed to make an off -the-shelf supply fit your installation. Finally, each T/R undergoes a battery of tests in our specially designed test cage to insure quality.

Not only will we customize the T/R design to your specifications, but we also offer a long list of options. We can provide metering, taps, nalarm contacts and paint options as required. Finally, each T/R undergoes a battery of tests in our special test chamber. Tests include voltage ratios, impedance, grounding, spark over and a six hour pressure test. All this insures that your order is built to your specifications and built to last.

T/R Sets

Advantages

Proven ABB/Westinghouse Design

100% Copper-Wound Transformers

Custom Design Center for High Quality Retrofits

Extensive Testing of Each Unit

Heavy Duty Diode Stacks

RATINGS• Secondary Voltage: Outputs of 36 to 75k V DC, 126 kV Peak• Primary Voltage: Inputs up to 600 VAC• Current: 100-2500 mA DC

FLUIDS• Mineral Oil• DOW 56111 Silicone

ELECTRICAL & LEAK TESTSThe following electrical tests are conducted on FORRY T/R Sets:• Resistance

– LV Winding– HV Winding– Choke Coil

• Transformer Voltage Ratio• No-Load and Impedance• Diode Stack Forward and Reverse Meggar Reading: Repeated to Assure Rectifier was Not Damaged During the insulation Test• Resistor Test• Induced Potential and Spark Test• Applied Potential Test• Grounding Switch Resistance Test• Completed unit is pressure tested at 8 psig for 6 hours. In addition, the tank is subjected to a full vacuum during the core/coil processing and filling operation.

FORM FACTORS• Customer specified

OPTIONAL ACCESSORIES & EQUIPMENT• Internal Voltage Divider Resistor(s), Typically 80 Megohms, for Feedback to Automatic Voltage Control• External Voltage Metering Resistor• External Current Metering Resistor• Low Voltage Taps for Varying the Primary Input Voltage• Vacuum-Pressure Gauge• Alarm Contacts for; – Thermometer – Liquid Level Gauge – Vacuum Pressure• Non-Standard Ambient (Standard=45˚C avg/55˚C max)• Altitude Above 3,300 Feet• Premium Epoxy Paint System for Corrosive Environments• Special Paint Colors (ANSI 70, Light Gray, Std)• Current Limiting Reactor Available with: – No Enclosures (Open Core & Coil assembly) – NEMA 3R Enclosure – T/R LV Bushing Enclosure• Custom Retrofit Designs for Replacement of Existing T/R Sets• External / Internal Ground Switches

The AVC X-M is the first state-of-the-art voltage controller to combine optimum ESP control with advanced diagnostic features. Its high speed Digital Signal Processor (DSP) allows the most accurate and stable ESP control possible, while advanced control algorithms provide superior spark detection and management. Thanks to its sophisticated Max Power mode, the AVC X-M ignores self-quenching sparking, so it can send maximum power to your ESP more often. And of course, our Forry AVC X-M also includes all the standard features you might expect - like spark/arc control, back corona detection, intermittent energization and pulse blocking.

Our Forry AVC X-M’s high resolution color graphics display shows detailed primary and secondary voltage and current waveforms, so you’ll never need to pull out a scope to diagnose your ESP again. It also lets you easily monitor all waveforms, Vi curves, spark response graphs and more, right at the control. Or, with the AVCWin Windows* interface, you can view the very same data remotely, from the control room. With this level of status and troubleshooting data within easy reach, you’ll be able to find and fix ESP problems faster than ever. And that’s going to positively affect your bottom line.

The highly customizable AVCWin Windows* graphical user interface displays all voltage control states and critical process variables at a glance. The AVC X-M can be started, stopped, programmed and configured remotely, for incredible convenience. AVCWin even provides detailed logong to back ESP performance over-time, as well as customizable reporting features that make regulatory reporting remarkably simple.

To help ensure a long, reliable life span, the AVC X-M’s inputs are protected by a combination of special filter-ing, ESD protection, voltage limiting amplifiers and optical isolation. And unlike many competitive controls out there, the AVC X-M’s inputs are produced on modern, automated equipment to guarantee quality.

AVC X-M Voltage Control

ADVANTAGES

High-speed, high-resolution sampling for superior stability and control.

Detailed waveforms allow ESP troubleshooting without a scope.

Simple configuration and built-in Help & Troubleshooting tips.

Advanced control modes allow more power to the ESP more often.

Sophisticated diagnostics help find and

fix ESP and process problems faster.

State-of-the-art components and manufacturing for superior quality.

Triple level circuit protection for longer life.

AVCWin Windows* interface for remote monitoring, control, logging and configuration.

Windows is a registered trademark of Microsoft Corporation.

Specifications for theForry AVC X-M Voltage Control

PROGRAM SETTINGSSparks/Minute Set PointArcs/Minute Set PointMax Power ModeSpark ModeArc ModeQuenchRecovery RampSetbackSpark SensitivityPulse Blocking On/Off CyclesEnergy ManagementAdjustable Background PowerBack Corona Detection/Handling

STATUS INDICATIONSPrimary/Secondary Volts/Current Sparks/Arcs per Minute Kilowatts Firing Angle Actual Conditions vs. Program Parameters vs. T/R Ratings

LIMIT CONDITIONSPrimary/Secondary Volts/Current Peak Primary/Secondary Volts/Current KW Firing Angle Undervoltage

ALARMSUnbalance AlarmShort AlarmBack Corona AlarmUser-Defined Alarm InputsMaster Fuel Trip Input AlarmT/R Temp Input AlarmSCR Temp Input Alarm

DIAGNOSTICSImmediate, peak and spark waveforms of primary/secondary volts/ampsVI curvesSpark Simulation5 minute to 24 hour KW trendsIntegrated Help and Troubleshooting

ELECTRONICSHigh-resolution color graphics displayState-of-the-art surface mount componentsConformal coating protection for harsh environmentsThree levels of circuit protectionModern, high-speed 32-bit processorHigh-speed DSP

OTHER FEATURESDCS and OPC integrationPower Off/Power Reduced RappingUpgrade kits for all competitors’ products

OPTIONSIn-cabinet tumbling hammer rapper controllerCabinet digital panel displayCabinet mounted terminal

AVCWin FEATURESGraphical Display of ESP and all AVC statesAlarm indicationsProgram selection and configurationData logging of all voltages, currents, KW and alarmsWaveform generation and displayComplete, online control configurationBuilt-in customizable reportsBackup and Restore of all controlsClient/Server configuration no charge for multiple workstationsRemote access options

For years, Stock’s Forry ERC 1001 rapper control has proven itself with trouble-free performance in hundreds of plants, with hundreds of configurations and conditions, worldwide. No matter what type of system you have — tumbling hammers, impactors, vibrators, sonic horns or others — the ERC 1001 supports them. Its modular design can accommodate any combination of digital and analog 1/0, so any system, large or small, can be customized and expanded to meet your specific needs.

As conditions change, so too can your cleaning strategy. That’s because Stock’s Forry ERC 1001’s many, highly-configurable rapper programs can be automatically selected based on boiler load, time of day, DCS parameters or external signal inputs. For maximum cleaning, the ERC 1001 easily integrates with voltage controls from Forry and other vendors to perform Power Off/Power Reduced rapping. And thanks to its auto-matic anti-coincidence control, opacity excursions caused by reentrainment are effectively minimized.

Stock’s Forry ERC 1001 also helps you keep your rappers performing at their best. It gives you current feed-back for each rapper, and provides a dedicated maintenance program for fast rapper walkdowns. It even lets you test rappers individually, without affecting the current rapping program. And if a rapper does go bad, it will be bypassed automatically — without disturbing the other rappers’ operation.

The ERCWin for Windows* interface works with the ERC 1001 to give you remote monitoring, logging, con-figuration and programming of all rappers. Its innovative “Rapper Tracker” feature graphs rapper firings vs. opacity spikes, to help you find re-entrainment problems. Extensive alarm, status and rapping logs accu-rately track your rapping system’s performance over time. Reporting options help you keep tabs on which rappers will need to be serviced. And simple programming screens, along with a rapping duty cycle display, make it easier than ever to reconfigure rapping programs whenever you need to.

Advantages

Highly-flexible, modular design can be customized and expanded as needed.

Power Off/Power Reduced rapping support provides maximum cleaning.

Automatic program control and detailed program parameters select cleaning strategies based on process changes.

Innovative “Rapper Tracker” feature quickly diagnoses re-entrainment problems.

Thorough, time-saving diagnostics allow quick and easy troubleshooting.

The ERCWin interface enables control and monitoring anywhere in the plant — or even remotely.

Anti-coincidence groups eliminate concurrent rapping in a passage, preventing re-entrainment problems.

*Windows is a registered trademark of Microsoft Corporation.

ERC 1001 Rapper Control

Specifications for the Forry ERC 1001 Rapper Control

STANDARD HARDWARE

CPU Card Communications Card (RS232, 485 and Fiber Optics) Power Supply Card Eurocard Rack

For Impactors

Firing Circuit Card

Monitor Cards (Current Feedback)

Output Cards

For All Others

Isolated Digital 1/0 Cards and/or Output Cards

OPTIONAL HARDWARE

DCUs (Distributed Control Units)

Analog 1/0 Cards

Digital 1/0 Cards

Mimic Panel Display and Card

MIU1001 Modbus Interface Card

Portable Programming Terminal

RAPPER TYPES SUPPORTED

AC/DC Vibrators

Single/Multiple Impactors

Pneumatic Vibrators/ Rappers

Tumbling Hammers

Sonic Horns

SYSTEM CAPACITY

512 rappers per control 8 linked controls per DCU

Total of 4096 rappers per DCU

Many additional 1/0 points for status and alarming

PROGRAM PARAMETERS

On Time/Repeat Time

Lift Pulses/Intensity/Frequency

Starting Rapper/Rap Direction

POR/PRR Power Down Delay

Rest Time/Rest Method

Anti-Coincidence Group

CONFIGURATION PARAMETERS

Interweave

Lift Correction

Short/Open Current Threshold

PROGRAM CONTROL

Local/Remote

Time of Day

Boiler Load

DCS Input

External Analog/Digital Input

OPERATIONS, FUNCTIONS

Start/Stop Rappers

Bypass Rappers

Clear Rapper Errors

Select Local/Global Rapping Programs

Rap Inhibit Input

Rapper Program input

DIAGNOSTICS

Rapper Test Fire

Rapper Maintenance Program

Rapper Current Display and Logging

Rapper Shorted/O pen/ Feedback Failure

ERCWifi FEATURES

Graphical ESP Display of all rappers

Easy configuration and programming

Change running rapper programs

Rapper Status and Alarm Logs

Client/Server – No charge for additional workstations

Backup/Restore configurations

Custom Reports

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Stock Equipment Company, Inc.16490 Chillicothe RoadChagrin Falls, Ohio 44023T+1 440.543.6000F+1 440.543.5944stock.sales@stockequipment.comwww.stockequipment.com

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Stock Equipment Company is the global market leader of solutions for the power industry, supplying complete bulk material handling and environmental system solutions.

Stock Equipment Company develops, manufactures and markets a full range of solutions, products and systems on the basis of combining process engineering expertise, reliable components and field-proven technology.