Title of Invention	A KIT FOR PORTABLE APPLICATION IN OFF-LOAD TESTING OF ELECTRONIC CONTROLLER
Abstract	The present invention relates to a kit for portable application in off-load testing of Electronic Controllers. A kit (1) for portable application in off-load testing of Electronic Controllers comprising a single phase transformer (2), a power supply card (3), a firing circuit card (4), an AC amperemeter (5), an AC voltmeter (6), a DC Milliamperemeter (7), a DC Kilovoltmeter (8), a light load resistor (9), a single phase bridge rectifier (10), a single phase step down transformer (11), a plurality of LEDs (12) and a plurality of microswitches (13). The portable kit (1) generates, receives feedback and simulates the commands necessary for said testing and calibration of meters under off-load condition, at the location and with low power.

Title of Invention

A KIT FOR PORTABLE APPLICATION IN OFF-LOAD TESTING OF ELECTRONIC CONTROLLER

Abstract

The present invention relates to a kit for portable application in off-load testing of Electronic Controllers. A kit (1) for portable application in off-load testing of Electronic Controllers comprising a single phase transformer (2), a power supply card (3), a firing circuit card (4), an AC amperemeter (5), an AC voltmeter (6), a DC Milliamperemeter (7), a DC Kilovoltmeter (8), a light load resistor (9), a single phase bridge rectifier (10), a single phase step down transformer (11), a plurality of LEDs (12) and a plurality of microswitches (13). The portable kit (1) generates, receives feedback and simulates the commands necessary for said testing and calibration of meters under off-load condition, at the location and with low power.

Full Text	FIELD OF INVENTION This invention relates to Electronic Controller (EC) for Electrostatic Precipitator (ESP) in general and to a test kit for portable application in off-load testing of Electronic Controllers, in particular. BACKGROUND OF THE INVENTION The Electronic Controller (EC) is an integral part of Electrostatic Precipitator (ESP) used in Thermal Power stations for reducing pollution mainly caused by fly ash produced after combustion of Coal in the Boiler. The Electrostatic Precipitator unit comprises of a Electronic Controller, HVR (High Voltage Rectiformer) and the Precipitator refer fig 1(a). The Electronic Controller is a microprocessor based controller, which is used to achieve a High Voltage Constant Current. The constant current ensures optimum collection of ash particles on the collecting electrode. The testing of Electronic Controller involves wiring check, functional testing, no load testing, full load testing, calibration of meters, annunciation test etc. This takes minimum 4-5 hrs to prove the healthiness of the panel. Conventionally, refer fig 1(a), the testing of Electronic Controller is done by connecting each Electronic Control Panel, microprocessor based controller commonly known as BAPCON & HVR (High Voltage Rectiformer) received form other sources. These equipments are project specific. So every time, due to change of rating, set-up has to be changed. BAPCON is very complex and sensitive equipment and it gets damaged due to any error in wiring. The output of HVR (High Voltage Rectiformer) is fed to resistance load bank for full load testing. The amount of energy dissipated in load bank, while testing one panel at 95 kV DC peak and 1400 mA for 2-3 hrs, was about 200 kWhr considering about 800 to 1000 panels are manufactured per year, the total energy consumption per annum due to this testing is estimated about 200 MWhr. To bridge the power gap, more number of thermal power plants are being set up and this quantity of panels will be in multiple of 2-3 times. Further there will be more dependency on HVR and BAPCON received from other sources for testing of Electronic Control Panel. There is only one test bed to test the panel. The panel has to be moved to the testing area by crane for complete testing of the panel as the other associated equipments, which are bulky and fixed at test bed area. In existing method of testing there was much dependency on other associated equipments for testing viz. HVR, input voltage regulator, the load bank and the microprocessor based controller, say BAPCON. OBJECTS OF THE INVENTION This method had the following disadvantages:- 1) During the full load testing of Electronic Controller certain energy is consumed, which is a national loss. 2) Load Bank resistor is continuously cooled by fan. After excessive heating we have to stop the testing for some time. 3) There is regular maintenance of load bank due failure of resistance. 4) In case of defect in the wiring, it damages the BAPCON and other components. 5) The testing personnel have to operate at full voltage of 70/95 kV DC and full power which was hazardous. 6) Only one test bed is available, so only one panel can be tested at a time. 7) Every panel is to be shifted to the test bed area before and after testing by crane. To overcome above disadvantages, a portable Off-Load Test Kit was explored and invented for testing of Electronic Controller. DESCRIPTION OF THE INVENTION The invented method has many advantages such as 1) No BAPCON, no HVR, no high voltage load bank required for testing. 2) No need of checking wiring manually. 3) Being portable test kit, the panel can be tested & calibrated at the place of wiring at the location of the panel. 4) All circuits can be tested independently so there is no cross linking of faults. It saves other components. 5) All faults in the EC panel can be isolated. 6) Saving of power (EC panel tested at low power testing). 7) Saving of time (time for connection and disconnection to power, load bank and BAPCON saved). 8) Saving of man power (only one person required to test the job). 9) Enhanced safety. 10)So far 1000 panels have been tested with the kit. ll)Every year approximately 200 MWh energy will be saved which will be a national gain, further if this electricity was being generated in thermal power station, it would have resulted in emission of about 250 tons of carbon dioxide. The invention will now be described with the help of accompanying drawings which depict as exemplary embodiment of invention. However, there can be other embodiments all of which are deemed covered by the description. BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS Fig-1(a)- shows layout diagram of a typical Thermal power station. Fig-1(b)- shows the testing of ECs with prior art. Fig-2(a)- shows testing of panel through invented test kit. Fig-2(b)- shows details of invented test kit. DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION With the invented design of portable Off-Load test kit refer fig 2(a); the use of BAPCON, HVR and the load bank has been eliminated fully; coupled with the elimination of panel movement to the test bed. A kit (1) as shown in fig 2(b) has been developed which houses a single phase transformer (2) for input supply 0- 415 V AC, Power Supply card (3), Firing Circuit card (4) for firing of thyristors in the Electronic Control Panel, single phase step down transformer (11) for light load, a single phase bridge rectifier (10), a light load resistor (9), AC Current meter (5), AC Voltmeter (6), DC Milliampere meter (7), DC Kilovoltmeter (8), set of LEDs (light emitting diodes)(12), for fault annunciation and set of micro-switches (13) for control command to Electronic Controller. The calibration of meters is provided by voltage and current feedback generated with in kit through a light load resistor (9). Other commands, faults and annunciation are simulated with the help of micro-switches and LEDs. WE CLAIM 1. A kit (1) for portable application in off-load testing of Electronic Controllers comprising: - a single phase transformer (2), - a power supply card (3), - a firing circuit card (4), - an AC amperemeter (5), - an AC voltmeter (6), - a DC Milliamperemeter (7), - a DC Kilovoltmeter (8), - a light load resistor (9), - a single phase bridge rectifier (10), - a single phase step down transformer (11), - a plurality of LEDs (12), and - a plurality of microswitches (13) characterised in that the portable kit (1) generates, receives feedback and simulates the commands necessary for said testing and calibration of meters under off-load condition, at the location and with low power. 2. The kit (1) as claimed in claim 1, wherein said single phase transformer (2) supplies input voltage in the range 0-415 V AC. 3. The kit (1) as claimed in claim 1, wherein said power supply card (3) supplies power to firing circuit card (4) for thyristor in the EC panel. 4. The kit (1) as claimed in claim 1, wherein said single phase step down transformer (11) provides light load. 5. The kit (1) as claimed in claim 1, wherein said meters AC voltmeter (6), DC Milliamperemeter (7) & DC Kilovoltmeter (8) are calibrated by providing voltage and current feedback generated within the kit through a variable light load resistor (9). 6. The kit (1) as claimed in claim l, wherein said microswitches (13) are provided for control command and the LEDs (12) are for fault annunciation. 7. The kit (1) as claimed in claim 1, wherein said simulation of the commands necessary for testing is done by the microswitches and the LEDs (12). 8. The kit (1) as claimed in claim 1, which saves essential energy of about 200 MWhr per year. 9. The kit (1) as claimed in claim 1, which eliminates hazardous high testing voltage upto 95 KV DC and full power during testing. 10.The kit (1) as claimed in claim 1, which enables the testing to be done by only one person. The present invention relates to a kit for portable application in off-load testing of Electronic Controllers. A kit (1) for portable application in off-load testing of Electronic Controllers comprising a single phase transformer (2), a power supply card (3), a firing circuit card (4), an AC amperemeter (5), an AC voltmeter (6), a DC Milliamperemeter (7), a DC Kilovoltmeter (8), a light load resistor (9), a single phase bridge rectifier (10), a single phase step down transformer (11), a plurality of LEDs (12) and a plurality of microswitches (13). The portable kit (1) generates, receives feedback and simulates the commands necessary for said testing and calibration of meters under off-load condition, at the location and with low power.

Full Text

FIELD OF INVENTION
This invention relates to Electronic Controller (EC) for Electrostatic Precipitator
(ESP) in general and to a test kit for portable application in off-load testing of
Electronic Controllers, in particular.
BACKGROUND OF THE INVENTION
The Electronic Controller (EC) is an integral part of Electrostatic Precipitator (ESP)
used in Thermal Power stations for reducing pollution mainly caused by fly ash
produced after combustion of Coal in the Boiler. The Electrostatic Precipitator unit
comprises of a Electronic Controller, HVR (High Voltage Rectiformer) and the
Precipitator refer fig 1(a). The Electronic Controller is a microprocessor based
controller, which is used to achieve a High Voltage Constant Current. The constant
current ensures optimum collection of ash particles on the collecting electrode.
The testing of Electronic Controller involves wiring check, functional testing, no
load testing, full load testing, calibration of meters, annunciation test etc. This
takes minimum 4-5 hrs to prove the healthiness of the panel.
Conventionally, refer fig 1(a), the testing of Electronic Controller is done by
connecting each Electronic Control Panel, microprocessor based controller
commonly known as BAPCON & HVR (High Voltage Rectiformer) received form
other sources. These equipments are project specific. So every time, due to
change of rating, set-up has to be changed. BAPCON is very complex and sensitive
equipment and it gets damaged due to any error in wiring. The output of HVR
(High Voltage Rectiformer) is fed to resistance load bank for full load testing. The

amount of energy dissipated in load bank, while testing one panel at 95 kV DC
peak and 1400 mA for 2-3 hrs, was about 200 kWhr considering about 800 to
1000 panels are manufactured per year, the total energy consumption per annum
due to this testing is estimated about 200 MWhr. To bridge the power gap, more
number of thermal power plants are being set up and this quantity of panels will
be in multiple of 2-3 times. Further there will be more dependency on HVR and
BAPCON received from other sources for testing of Electronic Control Panel. There
is only one test bed to test the panel. The panel has to be moved to the testing
area by crane for complete testing of the panel as the other associated
equipments, which are bulky and fixed at test bed area.
In existing method of testing there was much dependency on other associated
equipments for testing viz. HVR, input voltage regulator, the load bank and the
microprocessor based controller, say BAPCON.
OBJECTS OF THE INVENTION
This method had the following disadvantages:-
1) During the full load testing of Electronic Controller certain energy is
consumed, which is a national loss.
2) Load Bank resistor is continuously cooled by fan. After excessive heating
we have to stop the testing for some time.
3) There is regular maintenance of load bank due failure of resistance.
4) In case of defect in the wiring, it damages the BAPCON and other
components.
5) The testing personnel have to operate at full voltage of 70/95 kV DC and
full power which was hazardous.
6) Only one test bed is available, so only one panel can be tested at a time.

7) Every panel is to be shifted to the test bed area before and after testing by
crane.
To overcome above disadvantages, a portable Off-Load Test Kit was explored and
invented for testing of Electronic Controller.
DESCRIPTION OF THE INVENTION
The invented method has many advantages such as
1) No BAPCON, no HVR, no high voltage load bank required for testing.
2) No need of checking wiring manually.
3) Being portable test kit, the panel can be tested & calibrated at the place of
wiring at the location of the panel.
4) All circuits can be tested independently so there is no cross linking of faults.
It saves other components.
5) All faults in the EC panel can be isolated.
6) Saving of power (EC panel tested at low power testing).
7) Saving of time (time for connection and disconnection to power, load bank
and BAPCON saved).
8) Saving of man power (only one person required to test the job).
9) Enhanced safety.
10)So far 1000 panels have been tested with the kit.
ll)Every year approximately 200 MWh energy will be saved which will be a
national gain, further if this electricity was being generated in thermal
power station, it would have resulted in emission of about 250 tons of
carbon dioxide.

The invention will now be described with the help of accompanying drawings
which depict as exemplary embodiment of invention. However, there can be other
embodiments all of which are deemed covered by the description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig-1(a)- shows layout diagram of a typical Thermal power station.
Fig-1(b)- shows the testing of ECs with prior art.
Fig-2(a)- shows testing of panel through invented test kit.
Fig-2(b)- shows details of invented test kit.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE
INVENTION
With the invented design of portable Off-Load test kit refer fig 2(a); the use of
BAPCON, HVR and the load bank has been eliminated fully; coupled with the
elimination of panel movement to the test bed. A kit (1) as shown in fig 2(b) has
been developed which houses a single phase transformer (2) for input supply 0-
415 V AC, Power Supply card (3), Firing Circuit card (4) for firing of thyristors in
the Electronic Control Panel, single phase step down transformer (11) for light
load, a single phase bridge rectifier (10), a light load resistor (9), AC Current meter
(5), AC Voltmeter (6), DC Milliampere meter (7), DC Kilovoltmeter (8), set of LEDs
(light emitting diodes)(12), for fault annunciation and set of micro-switches (13)
for control command to Electronic Controller. The calibration of meters is provided
by voltage and current feedback generated with in kit through a light load resistor
(9). Other commands, faults and annunciation are simulated with the help of
micro-switches and LEDs.

WE CLAIM
1. A kit (1) for portable application in off-load testing of Electronic Controllers
comprising:
- a single phase transformer (2),
- a power supply card (3),
- a firing circuit card (4),
- an AC amperemeter (5),
- an AC voltmeter (6),
- a DC Milliamperemeter (7),
- a DC Kilovoltmeter (8),
- a light load resistor (9),
- a single phase bridge rectifier (10),
- a single phase step down transformer (11),
- a plurality of LEDs (12), and
- a plurality of microswitches (13)
characterised in that the portable kit (1) generates, receives feedback and
simulates the commands necessary for said testing and calibration of meters
under off-load condition, at the location and with low power.
2. The kit (1) as claimed in claim 1, wherein said single phase transformer (2)
supplies input voltage in the range 0-415 V AC.
3. The kit (1) as claimed in claim 1, wherein said power supply card (3)
supplies power to firing circuit card (4) for thyristor in the EC panel.
4. The kit (1) as claimed in claim 1, wherein said single phase step down
transformer (11) provides light load.

5. The kit (1) as claimed in claim 1, wherein said meters AC voltmeter (6), DC
Milliamperemeter (7) & DC Kilovoltmeter (8) are calibrated by providing
voltage and current feedback generated within the kit through a variable
light load resistor (9).
6. The kit (1) as claimed in claim l, wherein said microswitches (13) are
provided for control command and the LEDs (12) are for fault annunciation.
7. The kit (1) as claimed in claim 1, wherein said simulation of the commands
necessary for testing is done by the microswitches and the LEDs (12).
8. The kit (1) as claimed in claim 1, which saves essential energy of about 200
MWhr per year.
9. The kit (1) as claimed in claim 1, which eliminates hazardous high testing
voltage upto 95 KV DC and full power during testing.
10.The kit (1) as claimed in claim 1, which enables the testing to be done by
only one person.

The present invention relates to a kit for portable application in off-load testing of
Electronic Controllers. A kit (1) for portable application in off-load testing of
Electronic Controllers comprising a single phase transformer (2), a power supply
card (3), a firing circuit card (4), an AC amperemeter (5), an AC voltmeter (6), a
DC Milliamperemeter (7), a DC Kilovoltmeter (8), a light load resistor (9), a single
phase bridge rectifier (10), a single phase step down transformer (11), a plurality
of LEDs (12) and a plurality of microswitches (13). The portable kit (1) generates,
receives feedback and simulates the commands necessary for said testing and
calibration of meters under off-load condition, at the location and with low power.

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=NwE66tFzhhC9EL3wPxA8EA==&loc=wDBSZCsAt7zoiVrqcFJsRw==

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Patent Number

279402

Indian Patent Application Number

43/KOL/2009

PG Journal Number

04/2017

Publication Date

27-Jan-2017

Grant Date

19-Jan-2017

Date of Filing

07-Jan-2009

Name of Patentee

BHARAT HEAVY ELECTRICALS LIMITED

Applicant Address

REGIONAL OFFICES AT REGIONAL OPERATIONS DIVISION (ROD), PLOT NO: 9/1, DJBLOCK 3RD FLOOR, KARUNAMOYEE, SALT LAKE CITY, KOLKATA-700091, HAVING ITS REGISTERED OFFICE AT BHEL HOUSE, SIRI FORT, NEW DELHI-110049, INDIA

Inventors:

#	Inventor's Name	Inventor's Address
1	A.K. BHARGAVA	BAY-8, BLOCK-4, SCR, BHEL, BHOPAL
2	V.K. KAUSHAL	BLOCK-3, ANNEXE, CEE, BHEL, BHOPAL
3	ASHISH SHRIVASTAVA	BAY-8, BLOCK-4, SCR, BHEL, BHOPAL

PCT International Classification Number

H04Q7/22

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA