Bhel Journa Sep 06

BHEL JOURNAL
Volume 27 No. 2 September 2006

Editorial Advior! "ommittee
Ram#i Rai
$. Ravi%umar
&. '(dra(
S.$. )o!al
Editor * R.$. B+atta,+ar!a
Ao,iate Editor * &. Ro!
BHEL JOURNAL i publi+ed -uarterl!.
All ,orrepo(de(,e a(d e(-uirie are to be
addreed to * .r. R.$. B+atta,+ar!a Editor/ BHEL Jour(al B+arat Heav! Ele,tri,al Limited BHEL Houe/ Siri 0ort/ Ne1 &el+i2330 045 6+e tateme(t a(d vie1 e7preed i( t+i
Jour(al are e(tirel! t+oe o8 t+e aut+or/
a(d (ot (e,earil! t+at o8 t+e Or9a(iatio(. "o(te(t ma! be re8erred to or reprodu,ed partiall! 1it+ due a,%(o1led9eme(t. "op!ri9+t reerved.
"ON6EN6S:a9e
A&VAN"ES 'N .A6ER'ALS 0OR
A&VAN"E& S6EA. ";"LE :O<ER :LAN6S3
SEL02E="'6A6'ON 'N >2:HASE S?U'RREL
"A)E 'N&U"6'ON )ENERA6OR 0OR
<'N&.'LL A::L'"A6'ON20
6URBO2)ENERA6OR 'N&U"E& VOL6A)E
<AVE0OR. "O.:U6A6'ON AN&
6ELE:HONE HAR.ON'" "A:AB'L'6;
:RE&'"6'ON26
E00E"6 O0 :RELOA& 0A"6OR AN&
<ORN &E:6H ON 6HE &;NA.'"
"OE00'"'EN6S AN& S6AB'L'6; O0 A
LOA&'N) AR" @<ORNA 6<O2LOBE
BEAR'N) USE& 'N 6URBO2)ENERA6OR>B
"OLLE"6'ON/ HAN&L'N) AN&
6REA6.EN6 O0 L'?U'& E00LUEN6S
'N 6HER.AL :O<ER :LAN64B
'NNOVA6'ONS C 0RO. BHELBD
RE"EN6 .AJOR A"H'EVE.EN6S O0 BHEL
@duri(9 .ar,+E062Au9utE06A62
3 2 4 >"over :+oto9rap+ 3.600.< <eter( .ou(tai( )a 6urbi(e :o1er :la(t/ Lib!a. 2.Sriailam H!dro2ele,tri, :la(t @77330 .<A. >.NAL"O "aptive :o1er :la(t @560 .<A.
4.Adva(,ed "o(trol Room at 27B00 .< @Sta9e2''A
Ri+a(d S6:S.
3 BHEL JOURNAL/ September 2006
A&VAN"ES 'N .A6ER'ALS 0OR A&VAN"E& S6EA.
";"LE :O<ER :LAN6S
$ulvir Si(9+
S;NO:S'S
6+e e88i,ie(,! o8 ,o(ve(tio(al boiler or team
turbi(e
8oil 8uel 8ired po1er pla(t i tro(9l! baed
o( team
temperature a(d preure. Si(,e t+e e(er9! ,rii
o8 t+e
3570/ t+ere +ave bee( e88ort 1orld1ide to
i(,reae
bot+ * e7te(ive reear,+ +a bee( purued
1orld1ide.
6+e (eed to redu,e ,arbo( dio7ide emiio( +a
provided
8urt+er impetu to improve e88i,ie(,!. &evelopme(t
o8
tro(9er +i9+2temperature material i t+e prime
re-uireme(t. E:R' a(d ma(! ot+er or9a(iFatio(
+ave
e7te(ivel! revie1ed t+e material te,+(olo9! 8or
ultra
uper,riti,al po1er pla(t. 6+i arti,le revie1
t+e pote(tial
be(e8it/ operatio(al e7perie(,e/ t+e pree(t
tre(d a(d
t+e adva(,e i( material t+at re-uire pe,ial
atte(tio(/
i( repe,t o8 po1er pla(t 1it+ uper,riti,al
team
,o(ditio(. 6+i 1ill erve a a bai 8or
de8i(i(9 material
iue 8or bot+ t+e boiler a(d t+e turbi(e i(
(e7t2
9e(eratio( ultra uper,riti,al po1er
pla(t.
$e! <ord*
:o1er :la(tG "reep2Reita(t SteelG RotorG
"ai(9G
BoilerG Super+eater.
3.'N6RO&U"6'ON
A( e(+a(,ed e,olo9i,al a1are(e i( t+e
i(dutrialied
,ou(trie prompted i(,reaed i(itiative 1orld
over
to redu,e "O2 emiio( level i( t+e po1er
pla(t.
6+i i ee(tiall! a,+ieved b! improvi(9 t+e
e88i,ie(,!
o8 t+e pla(t. 0i9ure23 +o1 ome
poibilitie o8
i(,reai(9 po1er pla(t e88i,ie(,! H3I. '(
,o(ve(tio(al
0'). 3 * E00'"'EN"; '.:ROV'N) .EASURES 0OR S6EA. :O<ER :LAN6S H3I
0'). 2 * &EVELO:.EN6 O0 UN'6 S'JES AN& S6EA. :ARA.E6ERS 'N JA:AN H3I
0'). > * :O<ER :LAN6 E00'"'EN"'ES 'N JA:AN H3I
po1er pla(t/ a mar%ed improveme(t o8 e88i,ie(,!
,a( be a,+ieved b! adva(,i(9 team parameter. 6+e
reulti(9 developme(t o8 u(it iFe a(d team
parameter are illutrated i( 0i9.2 H3I. 6+e po1er
pla(t e88i,ie(,ie a,+ieved a(d pla((ed 8or (e1
pla(t i( Japa( are +o1( i( 0i9.>. Steam
,o(ditio(
1ere raied ver! rapidl! duri(9 t+e 35B0 a(d a
(umber o8 et 1it+ uper,riti,al team
,o(ditio(
1ere i(talled i( 35B0 a(d 60. Sube-ue(tl!/
t+e
tre(d 1a revered i( repe,t o8 t+e team
,o(ditio(
> BHEL JOURNAL/ September 2006
but t+e ,apa,it! o8 i(dividual et/ +o1ever/
,o(ti(ued
to i(,reae till a limit 1it+ t+e e7iti(9
8abri,atio(
a(d +a(dli(9 te,+(olo9ie +a bee( rea,+ed. 6+e
reveral i( team ,o(ditio( i primaril! t+e
reult o8
e7perie(,e i( 3560 a(d 70 1+e( everal (e1l!
,ommiio(ed pla(t 1it+ adva(,ed team ,o(ditio(
did (ot live up to e7pe,tatio( i( repe,t o8
availabilit!
o8 et ,aued b! operatio(al problem.
'(itiall!/ t+e per8orma(,e o8 t+e uper,riti,al
pla(t
1a o poor t+at ma(! utilitie e7perie(,ed
,o(iderable do1(time a(d i9(i8i,a(t 8i(a(,ial
lo
H2I. "o(e-ue(tl!/ it ,reated mi,o(,eptio( t+at
improved e88i,ie(,! a,ri8i,e reliabilit! a(d
t+ere
1a rapid retre(,+me(t to ub,riti,al u(it o( t+e
aumptio( t+at t+e! 1ould be more reliable.
6+ere8ore/ pla(t 1it+ operati(9 temperature o8
B>DK" re,eived a 1ide 8avour i( late 3560 a(d
70.
Ho1ever/ t+e ,o(,erted e88ort o8 dei9(er i(
liaio(
1it+ metallur9it a(d material ,ie(tit i(
u(derta(di(9 o8 i(itial problem a(d ta%i(9
,orre,tive tep led to a 9reat deal o8
improveme(t
i( pla(t per8orma(,e. A(al!i o8 t+e +itori,al
re,ord a(d t+e to,% o8 a,,ompli+me(t o8
uper,riti,al pla(t +o1 t+at t+eir
reliabilit! i
,omparable to t+e ,o(ve(tio(al u(it H>2BI. 6+e
t1o
oil ,rie i( 357> a(d 357D 1+i,+ ,aued a
drati,
i(,reae i( 8uel ,ot a(d t+e e(,oura9i(9
operatio(al
reult (o1 available 8rom earlier
uper,riti,al u(it
prompted a re(e1ed i(teret i( uper,riti,al
,o(ditio( to ma%e t+e bet ue o8 t+e +eat
rate
adva(ta9e provided b! t+ee adva(,eme(t H625I.
3.3:ote(tial Be(e8it
.aterial developme(t 1or% over t+e pat t1o
de,ade +a paved t+e 1a! 8or lar9e t+ermal
po1er
pla(t to be built toda! 1it+ live team
temperature
o8 630K"/ re+eat temperature o8 62BK" a(d
uper,riti,al team preure. 6+e li%el!
pote(tial 8or
redu,i(9 t+e +eat rate b! i(,reai(9 t+e
preure a(d
temperature o8 t+e team admitted to t+e
turbi(e o(
t+e bai o8 i(9le a(d double re+eati(9 i
+o1( i(
0i9.4 H30I. At live team ,o(ditio( o8 600K"
a(d
>00 bar 1it+ double re+eati(9/ 8or e7ample/ t+e
+eat
0'). 4 * NE6 HEA6 RA6E '.:ROVE.EN6 0OR S'N)LE AN& &OUBLE REHEA6 ";"LES H30I
rate ,a( be redu,ed b! DL ,ompared 1it+ t+e +eat
rate o8 toda!E ta(dard po1er tatio( 8eaturi(9
team parameter o8 B40K"M3D0 bar a(d i(9le
re+eat.
6+i improveme(t i( t+ermal e88i,ie(,! +elp
,o(iderabl! to ,o(erve 8uel reour,e a(d redu,e
"O2 emiio( b! 20L. 6+i i a ubta(tial
,o(tributio( o( t+e part o8 po1er 9e(erati(9
i(dutrie to1ard a,+ievi(9 t+e )erma(!E tar9et
o8
lo1eri(9 "O2 emiio( b! 2B2>0L b! 200B H30I.
6+i ob#e,tive re-uire a( ambitiou developme(t
pro9ramme 8or adva(,ed material/ 1+i,+ ,a(
1it+ta(d u,+ team ,o(ditio(. 6+e reear,+
pro9ramme +a bee( u(derta%e( imulta(eoul! b!
USA/ Japa( a(d Europea( (atio(. 't +a 8o,ued o(
developi(9 8urt+er t+e e7iti(9 +i9+2temperature2
reita(t 8erriti, marte(iti, 32L "r.oV Steel
8or
t+e produ,tio( o8 rotor/ ,ai(9 a(d ,+et/
pipe
a(d +eader ,apable o8 operati(9 at B5>K"/ a 1ell
a 8urt+er developme(t o8 t+e e7iti(9 +i9+2
temperature aute(iti, teel uitable 8or i(let
team
temperature up to 645K". 0or maller +i9+l!
treed ,ompo(e(t u,+ a 8irt ta9e movi(9
blade a(d bolt/ t+e ob#e,tive 1a to emplo!
a(d
8urt+er develop e7iti(9 +i9+2temperature2
reita(t
uperallo! e9. Nim D0A a(d 50 et,.
0urt+er developme(t o8 8erriti, teel 9eared
to i(let
team temperature up to appro7imatel! 62BK" i(
t+e
,o(te7t o8 "OS6 B03 Europea( reear,+ pro9ramme
1a purred b! reear,+ a,tivitie i( USA a(d
Japa(.
0i9ure2B 9ive a( overvie1 o8 t+e i(ter(atio(al
reear,+
pro9ramme aimed at developi(9 po1er pla(t
materialH30I. 6oda!/ 6B part(er 8rom 3>
,ou(trie
are i(volved i( t+e Europea( pro9ramme ba,%ed
b!
a reear,+ bud9et o8 ome &.>3 millio(.
'( t+e ,ae o8 pulveriFed2,oal28ired boiler/
eve( a
mar9i(al improveme(t i( pla(t e88i,ie(,!/ a!
8rom
>4 to >7L/ i reported to bri(9 a avi(9 o8 at
leat
NB millio( a !ear 8or ea,+ 3000 .< o8 ,apa,it!
H2I.
Ho1ever/ i( etimati(9 t+e a,tual 9ai(/ t+e
pla(t (et
+eat rate 9ai( +ould be 1ei9+ed a9ai(t t+e
i(,reae
i( total pla(t ,ot. '(,reae i( team
parameter
re-uire more e7pe(ive material o8
,o(tru,tio( a
t+ee adva(,eme(t i(,reae t+e everit! o8 t+e
ervi,e
,o(ditio( t+e ,ompo(e(t mut u(der9o.
0'). B * 'N6ERNA6'ONAL RESEAR"H :RO)RA..ES 0OR &EVELO:'N) A&VAN"E& S6EA. ";"LE :LAN6S H30I
B BHEL JOURNAL/ September 2006
A tud! 8u(ded b! Ele,tri, :o1er Reear,+
'(titute
@E:R'A/ USA/ u99eted 7B0 .< u(it a optimal
iFe 8or t+e adva(,ed team ,o(ditio( o88eri(9 a
30L improveme(t i( t+ermal e88i,ie(,!/ ,ompared
1it+ pree(t ,ommer,ial dei9( H2I. 6+e
te,+(olo9!
promie a drop i( +eat rate o8 a mu,+ a D6B
BtuM
%<+. Aumi(9 a 8irt !ear 8uel ,ot o8 N3.>DMD6B
B6UM%<+/ t+e tud! ,o(,luded t+at ,ot avi(9 i(
operatio( ,ould 9o a +i9+ a N360 millio( @357D
valueA over t+e pla(tE li8e time. "apital ,ot/
o( t+e
ot+er +a(d/ are etimated to be > to BL more t+a(
t+oe 8or ,o(ve(tio(al ,apa,it! @ND00M%< veru
N77BM%<A. $eepi(9 i( vie1 t+e ,urre(t +i9+ a(d
e,alati(9 level o8 8uel a(d ,apital ,ot/ t+e
pote(tial
8uel avi(9/ i(,reai(9 e(viro(me(tal
,o(,iou(e/
t+e uper,riti,al team ,o(ditio( 1it+ adva(,ed
material o88er i9(i8i,a(t be(e8it t+at re-uire
eriou
atte(tio( i( ele,ti(9 8uture ,apa,it! additio(.
Ho1ever/ it i (e,ear! to ,o(ider lo,al
,o(ditio(
u,+ a 9rid iFe/ e7pe,ted a((ual utiliatio(
period/
,!,li(9 dut! re-uireme(t/ 8uel ,ot et,. to 1or%
out
optimal u(it ,apa,it! a(d operatio(al ,o(ditio(
i(,ludi(9 t+e (umber o8 re+eat.
3.2Servi,e E7perie(,e
Baed o( t+e operati(9 data 8rom uper,riti,al
double re+eat u(it i( t+e ra(9e 8rom 6002D2B .<
pla(t iFe/ <eti(9+oue a(d )E" reported H2I
t+at
t+e! a,+ieved avera9e availabilit! o8 D0L. 6+i i
+i9+er t+a( t+e avera9e availabilit! o8 6002D2B
.<
u(it a a 1+ole a(d i ,omparable to t+at o8
mall u(it. A V)B evaluatio( alo +o1 t+at t+e
operatio(al availabilit! o8 t+eir uper,riti,al
pla(t i
appro7imatel! t+e ame a 1it+ ub2,riti,al u(it
HBI. Avera9e 8or,ed outa9e rate 8or t+e period 35702D> 8or ABB turbi(e operati(9 1it+ uper,riti,al mai( team preure i( everal ,ou(trie i( Europe 1a o(l! about 3L HDI. A 300 .< team turbi(e +a bee( operati(9 8or everal te( t+oua(d +our i(
USSR/ a a tet u(it u(der team ,o(ditio( o8
25.4 .:a a(d 6>026B0K" a(d re+eat team ,o(ditio( o8 > .:a a(d B6BK". 6+i u(it 1a dei9(ed 1it+ ,ooli(9 o8 ma(! eleme(t o8 H: +oui(9 a(d t+e
operati(9 e7perie(,e +o1 t+at it i +i9+l!
reliable H5I.
E(viro(me(tal ,o(ditio( i( everal ,ae +ave
proved to be importa(t i( t+e availabilit! o8
t+e
pla(t. Operatio(al error i( t+e 1ater
treatme(t led
to tre ,orroio( ,ra,%i(9 o8 aute(iti,
tai(le
teel tube i( ome po1er tatio( HBI. &ue to
1ide
pread deterioratio( o8 t+e -ualit! o8 ,oal i(
everal
,ou(trie/ a (umber o8 po1er tatio(
e7perie(,ed
8ire ide ,orroio( o8 tube. '( u,+ pla,e/
(e1
ub,riti,al po1er u(it i(talled i( t+e ame
period
alo +o1ed imilar redu,ed availabilit! H2I.
Super,riti,al u(it u(der t+oe ,o(ditio(
re-uired
a -uite u(e,o(omi, puri8i,atio( o8 bai, 8uel
H3>I.
'( ,ae o8 oil28ired or dual28ired boiler/
aute(iti,
tai(le teel uper+eater tube u88ered 8rom
e7,eive
,orroio( problem.
3.>:ree(t 6re(d
E(,oura9i(9 operatio(al +itor! o8 t+e earlier
uper,riti,al u(it/ availabilit! o8 more
veratile
material at a reao(able ,ot/ pro9re i(
dei9(
tool u,+ a ,omputer pro9ramme/ e7perie(,e
9ai(ed i( t+e dei9(i(9 a(d ma(u8a,ture o8
lar9e
team turbi(e a(d t+e ,o(ti(uoul! i(,reai(9
tre(d
o8 8uel ,ot/ all to9et+er prompted everal
leadi(9
po1er pla(t upplier/ i( t+e re,e(t pat/ to
revive
t+eir i(teret i( u(it 1it+ adva(,ed team
,o(ditio(.
6o avoid a(! te,+(i,al ri%/ t+e developme(t
pro9ramme +ave bee( pla((ed i( a p+aed
ma((er.
61o u,+ pro9ramme 1ere lau(,+ed i(depe(de(tl!
o( imilar li(e b! t+e E:R' H5I a(d 6o+iba
"orporatio(/ Japa( H7I.
Si(,e mot o8 t+e ,o(ve(tio(al material
readil!
available are e7pe,ted to meet at leat 8or t+e
8irt t1o p+ae/ t+e developme(tal pro9ramme mai(l!
,o(,e(trated i( ratio(aliFi(9 t+e dei9(
t+rou9+ ,omputer2aided pro9rammed a(d i( per8e,ti(9 t+e
ma(u8a,turi(9 te,+(olo9ie epe,iall! i( t+e
,ae o8 lar9e2iFed ,ompo(e(t. Havi(9 ,ompleted u,+ e7er,ie 8or t+e u(it o8 700 .< ,apa,it! 1it+ team ,o(ditio( o8 B66MB66MB66K" a(d >2.2 .:a/
bot+ E:R' a(d 6o+iba are e7pe,ted to ta%e up
t+eir
produ,tio(/ 1+ile t+e developme(tal a,tivitie
to meet t+e remai(i(9 t1o p+ae 1ill ,o(ti(ue to
pro9re. .itubi+i Heav! '(dutrie Ltd./
Japa(/
o( t+e ot+er +a(d/ i(,e t+e! +ave alread!
upplied
8ive out o8 t+e te( 4B0 .< team turbi(e (o1 i(
operatio( i( Japa( 1it+ team temperature o8
B66K"/ i alread! ma%i(9 proo8 tet o8 material
a(d
turbi(e eleme(t/ ui(9 a( a,tual po1er pla(t/ 8or
team temperature o8 B5026B0K". A B0 .<
protot!pe u(it ma(u8a,tured b! .itubi+i 1it+
team temperature o8 B5026B0K" 1a put i(to
operatio( i( t+e !ear 35D7 H6I. At pree(t/ ma(!
o8
t+e u(it up to t+e iFe o8 3000.< are operati(9
i( Europe/ USA a(d Japa( 1it+ t+e team parameter
o8 600M630M630K" temperature a(d >00 bar preure.
2.RE?U'RE.EN6S O0 .A6ER'ALS
0OR H')H26E.:ERA6URE A::L'2
"A6'ONS
<+e( a u(it +a to be dei9(ed a(d built to a +i9+
i(te9rit!/ o(e o8 tarti(9 poi(t i ,o(,er(ed
1it+ t+e
,+oi,e o8 material. A +o1( b! t+e e7perie(,e
9ai(ed/ t+i aume additio(al emp+ai 1it+ t+e
uper,riti,al et a t+e e-uipme(t reliabilit!
a(d
availabilit! ot+er1ie ma! (ulli8! t+e per8orma(,e
be(e8it e7pe,ted to a,,rue 8rom t+e adva(,eme(t
i( te,+(olo9!. )e(erall! pea%i(9/ t+e proper
material
8or ue at elevated temperature i t+e o(e t+at
bet
meet t+e 8ollo1i(9 re-uireme(t at t+e lo1et
,ot*
3.Ade-uate tre(9t+ to reit de8ormatio( a(d
rupture 1+e( e7poed at t+e dei9(
,o(ditio(
8or t+e dei9(ed li8e/ to t+e operati(9
e(viro(me(t. 2.Ade-uate 8ati9ue tre(9t+ at t+e dei9( ,o(ditio( a(d dampi(9 ,apa,it! 1+e( vibrator! tree are i(volved. >.Su88i,ie(t du,tilit! to a,,ommodate ,umulative plati, trai( a(d (ot,+ tre(9t+ to reit tre ,o(,e(tratio( duri(9 t+e ervi,e li8e. 4.)ood reita(,e to ervi,e e(viro(me(t to 1it+ta(d o7idatio(/ ,orroio( a(d eroio(. B.Stru,tural tabilit! to reit dama9i(9
metallur9i,al ,+a(9e at operati(9
,o(ditio(.
6.Abilit! to be 8abri,ated 1it+ eae/ a b!
ma,+i(i(9/ 8or9i(9/ ,ati(9 a(d 1eldi(9.
7.Lo1 ,oe88i,ie(t o8 t+ermal e7pa(io( to
reit t+e t+ermal tree impoed b!
di88ere(tial temperature a(d t+ermal
,!,li(9
or +o,% duri(9 +eat treatme(t/ 1eldi(9
a(d operatio(.
D.)ood t+ermal ,o(du,tivit! 8or e88i,ie(t
+eat
tra(8er a(d to mi(imie t+ermal 9radie(t
alo(9 t+e 1all t+i,%(e o8 t+e t+i,%
1alled
,ompo(e(t o a to redu,e t+ermal
tree
duri(9 tart2up or -ue(,+i(9 due to ,arr!
over.
5.Lo1 de(it! to provide a +i9+ tre(9t+2to2
1ei9+t ratio 8or appli,atio( u,+ a t+e
lat
ta9e bladi(9 o8 t+e lar9e ,apa,it! team
turbi(e.
30.Availabilit! i( t+e deired iFe a(d +ape.
33.E(ou9+ lo(92term tet data to allo1
u88i,ie(t
+i9+2temperature a(al!i to validate t+e
dei9( to t+e ati8a,tio( o8 t+e a8et!
re9ulatio( a(d li,e(i(9 aut+oritie.
6+e po1er pla(t +ave depe(ded mai(l! o( t+e
lo12
allo! teel 8or metal temperature up to about
BD0K". At temperature above t+i level/ t+eir
reita(,e to ,reep i u,+ t+at t+e reulti(9
1all
t+i,%(e be,ome u(e,o(omi,al. Alo/ t+eir
o7idatio( reita(,e at +i9+er temperature i
(ot
u88i,ie(t. <it+ i(,reaed metal temperature
above
BD0K"/ aute(iti, tai(le teel 1ere
emplo!ed 8or mot o8 t+e po1er pla(t ,ompo(e(t dei9(ed i(
earl! 35B0. Ho1ever/ aute(iti, tai(le
teel/
t+ou9+ t+e! are uperior i( +i9+2temperature
tre(9t+/
+ave problem u,+ a team o7idatio(/ a(d
+i9+2
temperature ,orroio( i( oil28ired boiler.
0urt+er/
t+e! are ver! e7pe(ive/ u,eptible to tre
,orroio(
,ra,%i(9 a(d 9ive rie to 1eld problem.
0erriti,
teel/ o( t+e ot+er +a(d/ o88er everal
te,+(olo9i,al
adva(ta9e u,+ a better 1or%abilit!/ +i9+
t+ermal ,o(du,tivit! a(d lo1er ,oe88i,ie(t o8 t+ermal
e7pa(io( a ,ompared to aute(iti, tai(le
teel.
A a reult/ to brid9e t+e 9ap bet1ee( t+e lo12
allo!
8erriti, teel a(d aute(iti, tai(le teel/
everal
+i9+2allo! 8erriti, teel 1ere developed duri(9
t+e
lat t+ree to 8our de,ade. 6+ee i(,lude B"r.o/
6"r.oV<6i/ 7"r.o6i/ D"r.o6i/ 5"r.o/
5"r.oVNb/ 5"r.o<VNb/ 32"r.oV a(d
32"r.o<VNb teel. Amo(9 t+ee/ 5"r a(d 32"r
,la o8 teel 1ere e7te(ivel! tudied a(d
u,,e8ull!
emplo!ed i( everal po1er tatio(. '( 8a,t/ t+ere
are
over t1o +u(dred 9rade o8 32"r teel 1it+
di88ere(t trade (ame ,ited i( t+e literature/ o8
1+i,+
a (umber o8 teel are 9e(erall! ued 8or
di88ere(t
appli,atio( i( 9a turbi(e/ a(d a 8e1 i( t+ermal
a
1ell a (u,lear po1er pla(t H34/3BI. A brie8 lit
o8
material i 9ive( i( 6able23 a(d 2.
<it+ t+e operati(9 temperature arou(d a(d above
600K"/ aute(iti, tai(le teel are re-uired
to be
ued 8or +i9+2temperature tre(9t+ ,ombi(ed
1it+
reita(,e to e(viro(me(tal atta,%. Simple
aute(iti,
teel o8 t!pe A'S' >04/ >36 a(d >47 +ave bee(
e7te(ivel! ued 8or po1er pla(t ,ompo(e(t.
But
everal ,omple7 aute(iti, o8 t+e t!pe
Ee+ete 32B0/
Allo! D00 H/ 37234"u.o/ A2D6 a(d N0705 +ave
bee( developed to 9ive improved ervi,e
per8orma(,e
arou(d 6B0K". Baed o( t+e a,tual ervi,e
,o(ditio(
o8 a ,ompo(e(t/ everal +i9+er allo! i(,ludi(9
(i,%el
bae allo! are alo bei(9 ,o(idered a
,a(didate
material 8or meeti(9 e7a,ti(9 re-uireme(t to
improve
reliabilit!. '( vie1 o8 t+e above/ t+e
,a(didate material
8or adva(,ed team ,!,le are u99eted/ a(d
t+e
approa,+e to meet t+e +i9+er team ,!,le are
di,ued/ i( t+e 8ollo1i(9 e,tio(.
6ABLE23 * "AN&'&A6E .A6ER'ALS 0OR BO'LER 6UBES/ :':ES AN& HEA&ERS
Sl. No..A6ER'ALS 0OR BO'LER 6UBES AN& :':ES
Sub "riti,alSuper "riti,al
3."2.( SteelH".2S @62>A
2.O.o @63A7 "r.oV 6iB 30 30 @624A
>.3P"rO.oQSi @633A=20 "r.oV 32 3
4.2P"r3.o @622A=30"r.oVNb 53 @6 53A
B.=20 "r.oV 32 3=30"r.o<VNb 533 @E533A
6.=30"r.oVNb 53 @6 53A=30"r.o<VNb 52 @6 522N0636A
7.A'S' >04=30"r.oVNb 32 3 @6 322A D.A'S' >30=30"rNi.o6iB 3B 3B 5.A'S' >36=D"rNi.oVNb 36 3> 30.A'S' >23=>"rNi.oNb 36 36 33.A'S' >47N0 705 32.E32B0Allo! D00 3>.37234"u.oHR >" 34.=30"rNi.o6iB 3B 3BHR6< 3B.=D"rNi.oV(b 36 3>A"66
D BHEL JOURNAL/ September 2006
>.BO'LER .A6ER'ALS
>.3Super+eater a(d Re+eater 6ubi(9
Super+eater a(d re+eater tube operate i( t+e
,reep
ra(9e i(,e t+eir mai( 8u(,tio( i to provide +eat
tra(8er bet1ee( t+e +ot 8lue 9a a(d t+e
:reuried team ,arried 1it+i( t+em. 6+e! are/ t+ere8ore/ dei9(ed primaril! baed o( t+e ma7imum allo1able
tre to rupture i( 300/000 +our/ a pe,i8ied
b!
t+e ma(dator! ,ode or ta(dard. 6+e ot+er
propert! bae 8or t+eir ele,tio( are a ,ombi(atio( o8
ade-uate ,orroio( reita(,e to bot+ team a(d
t+e
8lue 9a a(d eae o8 8abri,atio(/ parti,ularl! i(
re9ard
to be(di(9 a(d 1eldi(9. Re+eater re,eive
partiall! e7pa(ded team 8rom t+e turbi(e a(d erve to raie
it operati(9 temperature to t+e re-uired i(let
level
o8 t+e '(termediate preure turbi(e.
"o(e-ue(tl!/
t+e! operate at lo1er preure a(d are made o8
lar9er diameter but t+i((er 1alled tube/ a ,ompared to
uper+eater. 6able23 lit ,a(didate material
8or
uper+eater a(d re+eater tubi(9 8or po1er pla(t
appli,atio(. 0i9ure26 a(d 7 +o1 t+eir
ma7imum
6ABLE22 * .A6ER'ALS USE& 0OR 6HE A&VAN"E& S6EA. 6URB'NES A6 H')H 6E.:ERA6URES H47I
"ompo(e(tB66K"620K"700K"760K"
"ai(9M+ell"r .oV @,atA5230L"r @<A"0D"R""A637
@ValveG team30"r .oVNb32"r< @"oA""A637'(,o(el 740
,+etG (oFFle'(,o(el 62B
bo7G ,!li(derA'N 73D
Nimo(i, 26>
Bolti(94225232L"r.o VNimo(i,30BU700
5232L "r.o VA2D6Nimo(i,33BU730
Nimo(i,D0A'N 73D<apalo!U720
'N 73DNimo(i, 30B
Nimo(i, 33B
RotorM&i,3 "r .oV5232L "r<"o""A637""A637
32 "r.oVNbN32"r.o<VNbN""A637'(,o(el 740
26Ni"r.oV33 BHa!(e 2>0
'(,o(el 740
Va(eMBlade4225232L "r<"o<rou9+t Ni Bae<rou9+t Ni Bae
30 "r.oVNbN
:ipi(9:22/ :53:53/ :52""A637'(,o(el 740
0'). 6 *.A='.U. ALLO<ABLE S6RESSES 0OR VAR'OUS BO'LER )RA&E S6EELS H20I
allo1able tree a(d 300/000+ tre rupture
tre(9t+/ repe,tivel! H34220I.
"arbo( teel are uitable a(d e,o(omi,al up to
about 400 to 4B0K" metal temperature. Lo12allo!
teel .o @SA205 63A/ 3..."r .oCSi @SA23>
633A a(d 2..."r3.o @SA23> 622A are ued 1idel!
8or metal temperature up to 4D0/ BB0 a(d BD0K"
repe,tivel! H23I. 622 teel 1+i,+ +a bee(
e7te(ivel!
ued 8or t+e 8i(al uper+eater 8or ,o(ve(tio(al
u(it operati(9 at a mai( team temperature o8 B40K" +a too lo1 a ,reep tre(9t+ to be a,,epted a a 8i(al ta9e uper+eater material 8or ue 1it+ a team
temperature o8 B6BK". 6+ou9+ t+ee teel ,a(
till be ued 8or t+e tube ba(% operati(9 up to t+eir e7iti(9 allo1able temperature i( t+e boiler o8
uper,riti,al u(it/ 1it+ t+e i(,reae i( team
preure
t+eir re-uired 1all t+i,%(e i(,reae. 6+ere i
a
tro(9 i(,e(tive i( ui(9 improved ,arbo( teel
(o1 available 1it+ +i9+er allo1able !ield tre(9t+ at lo1er temperature up to 4B0K" a(d i( bri(9i(9 do1( t+e temperature ra(9e o8 appli,atio( o8 t+e
lo12allo! teel u,+ t+at tro(9 +i9+2allo!
8erriti,
teel ,a( be ued to ome e7te(t eve( at team
temperature li9+tl! belo1 B40K". 6+i
olutio(
permit t+i,%(e o8 tube le t+a( t+oe
(eeded 8or
t+e ,ommo( lo12allo! teel 8or t+e ame
operati(9
,o(ditio( a +o1( i( 0i9. D. 6+i reult i(
avi(9
o8 bae material a(d 1eldi(9 8iller material/
redu,e
t+ermal tree a(d 1eldi(9 problem a(d alo
improve t+e +eat tra(8er e88i,ie(,!.
0'). 7 * 3/00/000H S6RESS RU:6URE S6REN)6H 0OR BO'LER .A6ER'ALS H30I
0'). D *"O.:AR'SON O0 6HE S'JE O0 6HE <ALL 6H'"$NESS O0 :22/ =20/ :53 AN& N0636 S6EEL :':ES 30"r.o5.30 N0636 =20653M:53 30 BHEL JOURNAL/ September 2006
A t+e boiler team adva(,e/ t+e metal
temperature
o8 t+e lat ba(% o8 t+e uper+eater tube o8 t+e
B6BK" u(it e7,eed t+e ma7imum allo1able limit o8
t+e lo12allo! teel. '( t+ee re9io(/ +i9+2allo!
8erriti, teel are re-uired to be ued.
5"r3.oVNb
@SA23>653A teel +a improved o7idatio(
reita(,e.
6+e allo1able tree 8or 5"r3.oVNb @SA23>653A
are about 300L +i9+er t+a( 622 teel at
temperature
above B40K" a(d are eve( +i9+er t+a( =20 "r.oV
32 3 @&'N3737B 2 3.4522A teel i( t+e ra(9e o8 B00
to 6B0K". 6+e ot+er t1o +i9+2allo! 8erriti, teel
5"r3.o<VNb @SA23> 652A a(d
=32"r.o<VNbN 30 33 @E533A developed i( USA
a(d Japa( are mu,+ uperior i( t+eir tre
rupture
tre(9t+ a ,ompared to all ot+er 8erriti, teel
i(,ludi(9 t+e 32"r teel @=20 "r.oV 32 3A upto
about 6B0K". 6+eir allo1able tree are alo
+i9+er
t+a( 6:>04H a(d 6:>23H at temperature belo1
600K". 5"r3.oVNb teel/ due to it lo1 ,arbo(
,o(te(t e7+ibit 9ood 1eldabilit! a(d 1or%abilit!
a(d +a bee( 9ivi(9 ati8a,tor! ervi,e a
uper+eater
a(d re+eater/ 8or over t1o de,ade i( Japa( H22I.
=20 "r.oV 32 3 i alo upplied 1it+ 0.4 to 0.6L
tu(9te(/ 1+i,+ i t+e( dei9(ated a =20 "r.o<V
32 3 @&'N 37 37B23.45>BA H3BI. Additio( o8
tu(9te( i reported to 9ive 9reater ,reep
tre(9t+
t+a( t+e teel 1it+out tu(9te( but/ baed o(
ome
lo(92time i(veti9atio( (o e88e,t o8 tu(9te( +a
bee( 8ou(d 8or additio( up to 3L H34I. 't i/
+o1ever/ reported to be be(e8i,ial 8or t+i,%
e,tio(.
Bot+ =20 "r.oV 32 3 a(d =20 "r.o<V 32 3
1ere developed a(d e7te(ivel! ued i( Europe 8or
uper+eater a(d re+eater tube. 6+ee teel bei(9 marte(iti, 9rade +ave a tro(9 el82+arde(i(9 propert!. &ue to t+e 8ormatio( o8 marte(ite/ t+e 1eld metal a(d t+e +eat a88e,ted Fo(e @HAJA
be,ome ver! brittle o( ,ooli(9. 0or better
reult/ bot+ pre+eat a(d pot 1eld +eat treatme(t are ma(dator!. 5"r3.oVNb teel +a bee( e7te(ivel! tudied 8or over t1o de,ade i( USA a(d it tube ample are ,urre(tl! i( ervi,e i( t+e USA S U$ H3DI. O8 t+e t1o V a(d Nb beari(9 5"r teel/ t+i o88er better rupture tre(9t+. Amo(9 t+e variou +i9+2allo! 8erriti, teel/ =20 "r.oV 32 3/ 5"r3.oVNb @6M:53A a(d 5"r3.o<VNb @6M:52A
are t+e t+ree mot promii(9 ,a(didate 8or
tubi(9.
:52 +a a( ed9e over t+e ot+er t1o due to it
+i9+
rupture tre(9t+.
Aute(iti, teel 1ould be re-uired 8or 8i(al
uper+eater o8 B5>K" u(it a(d 8or mot o8 t+e
uper+eater a(d re+eater o8 t+e 6B0K" u(it.
6+e
dei9( tre value derived b! variou boiler
,ode
di88er baed o( t+e approa,+e adopted b! t+em.
Similarl!/ ra(%i(9 o8 aute(iti, teel >04/
>36/ >47/
baed o( t+eir allo1able tree varie
depe(di(9 o(
t+e ,ode. Ho1ever/ >04/ >36 a(d >47 t!pe o8
tube
are 1idel! ued 8or operatio( at +i9+er team
temperature. 6:>47H t!pe o8 tube are
e7te(ivel!
ued i( USA/ Japa( a(d )erma(! HB/ 22I due to
it
uperior propertie u,+ a reita(,e to 8ire2
ide
,orroio(/ team2ide o7idatio( a(d +i9+er
t+ermal
8ati9ue tre(9t+/ a ,ompared to >36 t!pe o8
teel.
Alo/ AS.E Boiler ,ode allo1 +i9+er dei9(
tre
8or 6: >47H a ,ompared to 6:>36H t!pe H3BI/
1+erea i( t+e ,ae o8 BS'/ t+e revere i true
H26I.
6!pe >47 a(d >23 teel are pro(e to trai(2
i(du,ed
embrittleme(t due to t+e 8ormatio( o8 tro(9
,arbide li%e Nb" a(d 6i" H26I. A a reult/
A'S'
>36 teel i pre8erred i( U.$. 0or uper+eater
operati(9 at t+e +i9+et temperature o8 t+e
+i9+2
preure u(it/ tro(9er aute(iti, teel li%e
'(,olo!
D00H/ 37234 "u.o/ E+ete 32B0/ N0636 a(d 3B2
3BN/ =D"rNi.oNb 36 3> a(d =>"rNi.oN 37 3>
1ould be re-uired 8or reliable operatio(. 0or
mot
e7a,ti(9 ,o(ditio(/ material u,+ a '(,o(el
637
1+i,+ ,o(tai( 32.BL "o/ t+ou9+ ver! ,otl!/
ma!
alo +ave to be ,o(idered.
>.2Steam :ipi(9 a(d Header
0erriti, teel are pre8erred be,aue o8 t+eir
+i9+er
t+ermal ,o(du,tivitie a(d lo1er ,oe88i,ie(t o8
t+ermal
e7pa(io( ,oupled 1it+ t+eir 9ood
8abri,abilit!.
Hi9+2tre(9t+ +i9+2allo! 8erriti, teel u,+
a =20"r.oV 32 3/ =20"r.o<V 32 3/ 5"r3.oVNb a(d 5"r3.o<VNb are/ t+ere8ore/ emplo!ed 8or
temperature up to 62BK". 6+ee teel are/
+o1ever/
ub#e,t to temper embrittleme(t i( t+e
temperature
ra(9e o8 B40 to B5BK"/ 1+ere adva(,ed
uper,riti,al team po1er pla(t operate. 6+ou9+ t+e temper
embrittleme(t be+aviour i (ot li%el! to +ave
a(!
e88e,t o( t+eir ue 8or pipi(9/ it ,a( be
,o(trolled
b! mai(tai(i(9 lo1 level o8 ma(9a(ee a(d ili,o(
,o(te(t H5I. Alo lo1 level o8 ulp+ur +ould be
mai(tai(ed/ a t+e tou9+(e o8 t+ee teel i
ver!
e(itive to ulp+ur ,o(te(t.
At 6B0K" team ,o(ditio(/ it i (e,ear! to ue
+i9+er2tre(9t+ aute(iti, teel. Niobium
tabiliFed
aute(iti, teel o8 t+e t!pe >47 are pre8erred i(
)erma(! be,aue o8 t+eir +i9+ 8ati9ue tre(9t+ a(d
uperior team2ide o7idatio( a ,ompared to
(iobium2
8ree teel H27I. &ue to temperature2,o(trai(ed
e7pa(io( duri(9 a(d a8ter 1eldi(9/ (iobium teel
+ould be ued i( t+e ,ae o8 1all t+i,%(e up to
>0mm/ 1+erea (iobium28ree aute(iti, teel
=D"rNi.oNb 36 3> a(d => "rNi.oN 37 3> are
deirable 8or t+i,% 1alled pipe. '( ,ae o8 >36
tai(le teel/ mai( team pipe 8ailure due to
i9ma
p+ae 8ormatio( 1a reported H5I. E7te(ive
databae
up to about 300/000 +our available o( E+ete
32B0/
N0705/ HR6< teel ,o(8irm t+eir reliabilit! 8or
team pipe a(d +eader appli,atio( H35/ 46I.
>.2.30'RE2S'&E "ORROS'ON
'( ,oal28ired boiler/ t+e a+ ,orroio( reult
8rom
t+e 8ormatio( o8 ,omple7 al%ali iro( ulp+ate i(
a+
depoit/ 1+i,+ be,ome a99reive i( molte( tate.
6+e everit! o8 li-uid a+ ,orroio( varie 1it+
temperature a(d 8ollo1 a bell2+aped ,urve H25I.
"orroio( i(,reae +arpl! 8rom about B5BK" to
700K". Belo1 B5BK"/ t+e ,orrode(t i( t+e a+ depoit 1ill be i( a 8airl! dr! tate a(d
t+ere8ore do
(ot a99reivel! atta,% t+e tube. A t+e
temperature i i(,reaed up to about 700K"/ t+e ,orrode(t be,ome molte( a(d t+e ,orroio( rate i(,reae. <it+ 8urt+er i(,reae i( temperature/ t+e molted ulp+ate be9i( to vaporiFe a(d be,ome u(table/ de,reai(9 t+e ,orroio( rate.
Super+eater a(d re+eater o8 t+e uper,riti,al
pla(t
at B66K" operate ,loe to t+e be9i((i(9 o8 t+e
bell2 +aped ,urve. 5"r a(d 32"r tube +ould be 9ood
e(ou9+ to erve 1it+out e7perie(,i(9 a(!
i9(i8i,a(t 8ireide ,orroio(. But t+e 8i(al uper+eater a(d re+eater o8 t+e pla(t at B5>K" a(d 645K" 1ould
operate at t+e ape7 o8 t+e ,urve/ 1+ere ,orroio(
i
mot evere. Al%ali ulp+ate ,orroio( rate
de,reae
1it+ t+e i(,reae i( ,+romium ,o(te(t a(d a
uperior reita(,e ,a( be obtai(ed 1it+
,+romium
,o(te(t o8 over 2BL @0i9.5A H>0I. Simulated
li-uid
a+ ,orroio( tet ,arried out o( di88ere(t
uper+eater
tubi(9 allo! +o1 t+at t+eir reita(,e var!
1idel!
a +o1( i( 0i9.30 H>3I. Amo(9t t+e allo!
teted/
0'). 5 *"O.:AR'SON O0 0'RE2S'&E "ORROS'ON
RES'S6AN"E O0 VAR'OUS ALLO;S H>3I
0'). 30 *HO62"ORROS'ON <E')H62LOSS 1rt "r "ON6EN6 0OR VAR'OUS ALLO;S H>0I
t+e 37234"u.o aute(iti, teel ued 8or
uper+eater
tubi(9 i( Edd!to(e u(it H5I e7perie(,ed t+e
+i9+et
,orroio( rate/ 1+ile t+e '(,o(el 673 @B0"r2B0NiA
allo! 1a pra,ti,all! immu(e to li-uid a+
,orroio(.
't ,a( alo be ee( t+at t+e 37234 "u .o allo!/ o(
,+romiFi(9/ e7+ibit li-uid a+ ,orroio(
reita(,e
almot imilar to '(,o(el 673. 6+ere are variou
pote(tial mea( o8 over,omi(9 t+e ,oal a+
,orroio(
problem o8 uper+eater tubi(9 u,+ a ba(da9e
+ield o8 more ,orroio(2reita(t material/
ur8a,e
,oati(9/ 9rai( re8i(eme(t a(d ,ompoite tube.
Ba(da9e +ieldi(9 de,reae +eat tra(8er
e88i,ie(,!
be,aue o8 t+e i(ulati(9 air 9ap/ a(d it ma! alo
reult i( i9(i8i,a(t i(,reae i( ,orroio( rate
o8 (o(2
ba(da9ed tubi(9 H>2I. Sur8a,e ,oati(9 u,+ a
,+romiFi(9 H>>I/ ,+romati(9 H22I/ ,+romium plati(9
H>>I a(d ,aloriFi(9 H>2I +ave bee( attempted.
6+ee
met+od re-uire 8urt+er detailed tud! 8or t+eir
e88e,t o( 8abri,atio(/ du,tilit! a(d +i9+2
temperature
,reep tre(9t+. Ho1ever/ tudie ,arried out o( a
,+romiFed aute(iti, teel +o1ed e(,oura9i(9
reult
H>>I. Si(,e bot+ outide ur8a,e ,a( be ,+romiFed
at t+e ame time/ it appear to be a promii(9
approa,+ to preve(t ,orroio( o8 bot+ t+e
ur8a,e.
)rai( re8i(eme(t promote t+e 9rai( bou(dar!
di88uio( o8 ,+romium to t+e ur8a,e H22I. 6+i
reult i( improved ,orroio( reita(,e H20I but
it
+a a( advere e88e,t o( t+e rupture tre(9t+ o8
t+e
material. 0or mot adva(,ed uper,riti,al team
,o(ditio( a(d u(der +i9+l! a99reive ervi,e
,o(ditio( 9e(erated 8or ,ombutio( o8 ,oal 1it+
+i9+ ,+lori(e ,o(te(t 1+ere a i(9le material
,a((ot provide a( e,o(omi,all! viable olutio(/ te,+(i,al adva(ta9e provided b! t1o di88ere(t material ,a( be utilied b! emplo!i(9 ,ompoite
tube. "ompoite tube are produ,ed b! ,o2
e7truio(
o8 t1o di88ere(t material ,omprii(9 a +i9+2
tre(9t+ i((er material u,+ a Ee+ete 32B0/ allo! D00H/ 37234 "u .o to provide t+e tre2beari(9 ,apa,it! a(d a( outer ,ai(9 o8 material o8 +i9+ ,+romium ,o(te(t li%e 6:>30 or '(,o(el 673 8or prote,tio(
a9ai(t ,orroio(. 6+e problem e7pe,ted 8rom
u,+
tubi(9 are t+ermal 8ati9ue/ 1eldi(9 a(d i9ma
p+ae 8ormatio( i( outer ,ai(9 H2DI. 6+e ervi,e per8orma(,e 8or everal !ear i( a (umber o8 po1er tatio(/ +o1ever/ ,o(8irm t+e i(te9rit! a(d
e,o(omi, o8 ui(9 ,ompoite tube H35I. 0or
dema(di(9 e(viro(me(tal appli,atio(/ it ma!
ometime be (e,ear! to ele,t eve( (i,%el or
,obalt bae allo!/ provided e,o(omi, permit.
>.2.2S6EA.2S'&E O='&A6'ON
)e(eral e7perie(,e i(di,ate t+at t+e o7idatio(
reita(,e o8 +i9+2temperature teel i( dr!
uper+eated team i almot t+e ame a t+eir
o7idatio( reita(,e to air at t+e
,orrepo(di(9
temperature H26I. 6+e o7ide ,ale 8ormed o(
t+e
i(ter(al ur8a,e o8 uper+eater tube/ re+eater
tube/
+eader a(d pipi(9 pall o88/ or e78oliate/
1+e( t+e
t+ermal tree due to di88ere(tial t+ermal
e7pa(io(
bet1ee( t+e o7ide ,ale a(d t+e bae metal
e7,eed
t+e bo(d tre(9t+ o8 o7ide ,ale. 5"r a(d 32"r
teel/ due to t+eir lo1 ,oe88i,ie(t o8 t+ermal
e7pa(io(/ o88er better reita(,e to o7ide
e78oliatio(
a ,ompared to aute(iti, teel/ i( t+e
temperature
ra(9e o8 t+eir appli,atio(. 6+e palled o7ide
,a( be
evere e(ou9+ to ,lo9 t+e be(d i( uper+eater
a(d
re+eater tubi(9/ eve(tuall! leadi(9 to over+eat
8ailure.
At +i9+ team preure/ t+ee o7ide 8rom
+eader
a(d team pipe ,a( be ,arried to t+e turbi(e
at +i9+
velo,itie a(d ,aue turbi(e eroio(. 6urbi(e
eroio(
dama9e (ot o(l! ,aue a lo i( e88i,ie(,! but
alo
i e7pe(ive to repair a(d i(,reae t+e time
o8
turbi(e over+aul outa9e H>4I. 't 1a reported
t+at
t+e eroio( dama9e +ad led to t+e detru,tio(
o8 a
turbi(e. Si(,e t+e rate o8 team o7idatio(
varie
e7po(e(tiall! 1it+ temperature H>BI/
e78oliatio( ,a(
be mu,+ more o8 a t+reat to adva(,ed
uper,riti,al
team pla(t. Amo(9t t+e ,o(ve(tio(al
aute(iti,
tai(le teel/ 6:>47H provide better
reita(,e to bot+ 8ire2ide ,orroio( a(d team o7idatio(/ preumabl! due to it +i9+ ,+romium ,o(te(t.
Steam o7idatio(/ a i( t+e ,ae o8 8ire2ide
,orroio(/ i a 8u(,tio( o8 ,+romium ,o(te(t i( t+e i((er
ur8a,e o8 t+e tube. 6o over,ome team
o7idatio( problem/ everal met+od u,+ a ,+romiFi(9/
,+romati(9/ 9rai( iFe re8i(eme(t a(d ,old
1or%i(9
o8 t+e i((er ur8a,e t+rou9+ +ot
pee(i(9Mblati(9/
all o8 1+i,+ i(,reae t+e ,+romium ,o(te(t at
t+e
ur8a,e/ are appli,able. "+romiFi(9 bei(9 a
ver!
+i9+2temperature pro,e/ i appli,able to o(l!
(e1
3> BHEL JOURNAL/ September 2006
a(d repla,eme(t ,ompo(e(t. "+romati(9/ o( t+e
ot+er +a(d/ ,a( be per8ormed at lo1er temperature
a(d eve( o( aembled part. Bot+ 9rai( re8i(eme(t
a(d ur8a,e +ot pee(i(9 met+od aim at e(+a(,i(9
t+e ,+romium di88uio( rate to t+e ur8a,e/ but
t+eir
e88e,t i lot duri(9 t+e pro,e o8 1eldi(9 or
1+e(
tre relie8 a((eali(9 +a to be ,arried out
a8ter
be(di(9. "ombi(atio( o8 ,+romiFi(9 a(d ,+romati(9
te,+(i-ue eem to be t+e bet ,+oi,e to
over,ome
t+e e(viro(me(tal problem.
4.6URB'NE .A6ER'ALS
'( t+e ,ae o8 turbi(e/ t+e adva(,eme(t i( team
,o(ditio( mai(l! a88e,t it +i9+ preure @H:A
a(d
i(termediate preure @':A e,tio(. A a reult/
t+e
ao,iated rotatio( a 1ell a tatio(ar! part
o8
t+ee e,tio( e7perie(,e more evere ervi,e
,o(ditio( t+a( t+at o8 ,o(ve(tio(al et. Si(,e
t+e!
operate 1ell 1it+i( t+e ,reep ra(9e/ t+eir dei9(
i
baed primaril! o( t+e lo(92term ,reep tre(9t+ o8
t+e material/ but t+e tre level duri(9 tead!
a(d
(o(2tead! operati(9 ,o(ditio(/ parti,ularl!
duri(9
tart2up a(d +ut2do1( period/ mut alo be
ta%e(
i(to a,,ou(t. 0i9ure233 +o1 t+e temperature
ra(9e
8or appli,atio( o8 di88ere(t 9rade o8 teel
H4I. 't i
,lear t+at t+e lo12allo! 8erriti, teel are
limited to
ue at temperature up to about BB0K"/ a(d
t+eir
ra(9e o8 appli,atio( 8urt+er de,reae 8or
rotati(9
,ompo(e(t. 6able22 9ive a lit o8 ,a(didate
material
o8 i(teret/ a(d 0i9. 33 depi,t t+eir 300/000+
rupture tre(9t+ a a 8u(,tio( o8 temperature
H4/ B/
>6/ >7/ >DI. 0or t+e a%e o8 ,ompario( a(d
,omplete(e/ ome o8 t+e lo12allo! 8erriti,
teel are
alo i(,luded.
4.3H:M': Rotor
A ,a( be ee( 8rom 0i9.33/ 32"r teel ,a( be
emplo!ed 8or H:M': turbi(e rotor at B66K"
team
temperature. =22 "r.oV 323 +a bee(
u,,e8ull!
ued 8or rotor o8 t+e uper,riti,al u(it 8or
ma(!
!ear. <it+ rotor ,ooli(9/ it ,a( alo be ued
up to
B5BK". Bot+ E:R' H5I a(d 6o+iba H5I +ave
,+oe(
32"r teel 8or H: a(d ': rotor o8 turbi(e 8or
operatio( at B66K". 6+eir adva(,ed dei9( at
0'). 33 * 3/00/000H "REE: S6REN)6H 0OR S6EA. 6URB'NE A::L'"A6'ONS H30I 34 BHEL JOURNAL/ September 2006
B5>K" ,o(template t+e ue o8 32"r teel rotor 1it+
team ,ooli(9 to bri(9 t+e rotor temperature do1(
to B66K"/ 1+ere it ,reep tre(9t+ i ade-uate to
meet t+e dei9( preure. Ho1ever/ pree(tl!
everal
uper 32"r teel 1it+ mu,+ uperior ,reep
reita(,e
are available a(d t+e! +ould alo be ,o(idered
be8ore a 8i(al de,iio( i ta%e(. Above B5>K"
team
temperature/ =32"r.o<VNbN 30 33 a(d aute(iti,
tai(le teel mut be ,o(idered. Amo(9t t+e
aute(iti, teel/ A2D6 a(d =D"rNi.oBNb 36 36
o88er better ,reep tre(9t+ 8or a( H: rotor o8
adva(,ed et operati(9 at 645K".
O(e o8 t+e rotor2related problem i t+e ma7imum
iFe t+at ,a( be produ,ed 8rom t+e 32"r a(d
aute(iti, teel. &ue to evere e9re9atio( i(
,o(ve(tio(al i(9ot/ t+e iFe o8 t+e aute(iti,
teel
rotor ued i( earlier uper,riti,al u(it 1a
limited
to mall iFe/ a a reult o8 1+i,+/ it be,ame
(e,ear! to divide t+e H: turbi(e i(to t1o ta9e
H5I. 't i etimated t+at a lar9e adva(,ed pla(t
1ould
re-uire a o(e2pie,e uper2allo! H: rotor 8or9i(9
1ei9+i(9 33/>00 %9 1it+ a barrel diameter o8
D50mm. Similarl!/ a double28lo1 re+eat rotor made
o8 32"r teel i e7pe,ted to be about 33B0mm i(
diameter a(d >3/7B0 %9 i( 1ei9+t/ 1+i,+ 1ould
re-uire to tart 1it+ a( i(9ot iFe o8 6>/B00 %9
H5I.
Si9(i8i,a(t pro9re +a bee( made/ i( re,e(t
!ear/
i( i(,reai(9 t+e iFe a 1ell a t+e -ualit! o8
t+e
8or9i(9 b! emplo!i(9 moder( teel ma%i(9
te,+(i-ue
u,+ a lo1 ul8ur ili,o( deo7idatio( @lo1 SA/
va,uum o7!9e( de,arburiFatio( @VO&A/ va,uum
,arbo( deo7idatio( @V"&A/ ,e(tral Fo(e re8i(i(9 @"JRA/ ele,tro la9 +ot toppi(9 @ESH6A a(d ele,tro
la9 remelti(9 @ESRA. B! emplo!i(9 t+ee
te,+(i-ue/ eit+er i(dividuall! or i( ,ombi(atio(/ produ,tio(
e7perie(,e 1it+ lo12allo! 8erriti, H>5I/ 32"r a
1ell a aute(iti, teel H4/ 40I demo(trate t+at t+e
rotor o8 t+e ,a(didate material ,a( be made to
t+e
re-uired iFe a(d -ualit! 1it+out e7perie(,i(9
mu,+ problem. 4.2Bladi(9 "o(ve(tio(al 32"r.oV teel blade are ade-uate to meet t+e team temperature at B66K". But a 1ide
variet! o8 +i9+2temperature blade material
1it+
prove( ervi,e per8orma(,e i( lar9e 9a
turbi(e are
available/ a(d t+e! +ould be ,o(idered 8or
more
adva(,ed team ,o(ditio(. 6+ee i(,lude uper
32"r teel/ aute(iti, teel/ Nimo(i, D0A/
50/ 30B/
33B/ '(73D a(d pre,iio( ,ati(9 allo! u,+ a
Udimet B00 a(d 'N 7>DL".
4.>L: Rotor
6+e pri(,ipal re-uireme(t o8 material 8or lo12
preure @L:A rotor are +i9+ !ield tre(9t+ to
1it+ta(d t+e +i9+ tre impoed o( it b! lo(9
blade a(d +i9+ 8ra,ture tou9+(e to mi(imiFe
ub2
,riti,al 8la1 9ro1t+ o a to avoid t+e
poibilit! o8
8at 8ra,ture. >.BNi"r.oV teel i 1idel! ued
8or
L: rotor t+rou9+out t+e po1er i(dutr!. 6o
avoid
temper embrittleme(t/ t+e ma7imum operati(9
temperature o8 t+e L: rotor made o8 t+i teel
i
9e(erall! limited to about >B0K" H5I. 6+e i(let
team temperature to L: turbi(e o8 t+e
uper,riti,al
u(it/ o( t+e ot+er +a(d/ i di,tated b! t+e
e7+aut
team 8rom t+e e,o(d ': e,tio(. 6+e ':2L:
,roover temperature 8rom adva(,ed
uper,riti,al
u(it at team temperature o8 B5>K" a(d above
1ould be 40024BBK" H5I. 6o mai(tai( t+e i(let
team temperature o8 L: turbi(e at it pree(t
ma7imum allo1able limit/ it 1ould be (e,ear!
to
,ool t+e team eit+er t+rou9+ ,ooli(9 o8 t+e
rotor
or b! addi(9 a( additio(al ta9e o8 e7pa(io(
to t+e
': turbi(e. 6+e latter approa,+ 1ould be a
di88i,ult
dei9( ta%/ a it re-uire ua9e o8 lo(9
blade at +i9+ temperature/ 1+erea t+e 8ormer approa,+ +a to
a,ri8i,e a part o8 t+e t+ermal
e88i,ie(,!. A(ot+er approa,+ to t+e problem 1ould be to
re(der L: rotor material more reita(t to
temper
embrittleme(t H43I. E88ort are/ t+ere8ore/
bei(9
made to improve t+e 8ra,ture tou9+(e o8 t+e
':
rotor teel b! improved teel ma%i(9 te,+(olo9!
a(d ,loer ,o(trol o8 ,+emi,al ,ompoitio(. 6+e
i(tera,tio( bet1ee( .(/ Si/ : a(d S( 1a +o1(
to
+ave promoted t+e de9ree o8 temper
embrittleme(t H43I. Reita(,e to temper embrittleme(t o8 >.BNi"r.oV rotor teel 1it+ lo1 .( a(d lo1 Si ,o(te(t 1a 8ou(d to +ave 9reatl! improved a
3B BHEL JOURNAL/ September 2006
,ompared to ,o(ve(tio(al teel H5I. B! utilii(9
t+e
moder( teel ma%i(9 te,+(olo9ie/ it i (o1
poible
to de,reae bot+ .( a(d Si ,o(te(t to level o8
0.003 2 0.002L.
4.4Heav! Se,tio( Statio(ar! :art
Hi9+2preure turbi(e re-uire a (umber o8 +eav!
e,tio( tati, ,ompo(e(t u,+ a t+e i((er a(d
outer
,ai(9/ tati, ,ompo(e(t u,+ a t+e i((er a(d
outer
,ai(9/ t+e team valve/ t+e (oFFle bo7/ a(d t+e
i(let
pipe. Beide +i9+ temperature a(d preure/ t+ee
part are ub#e,t to t+ermal ,!,li(9. '8 t+e
e,tio(
iFe are ver! +i9+/ t+ere i a da(9er o8
e7perie(,i(9
t+ermal ,ra,%i(9 a a reult o8 t+e +eav! t+ermal
tree t+at mi9+t develop duri(9 tart2up or
,arr!2
over. 't i/ t+ere8ore/ deirable to mi(imiFe t+e
e,tio(
iFe b! ui(9 +i9+2tre(9t+ teel o a to redu,e
t+ermal tree. &epe(di(9 o( t+e tree a(d
t+e
re-uired 1all t+i,%(ee/ it mi9+t be adviable
to
emplo! 32"r teel at temperature lo1er t+a( B66K"
a(d aute(iti, teel at temperature a lo1 a
B66K".
6+i ,ould be adva(ta9eou epe,iall! i( t+e ,ae
o8
+i9+2preure u(it dei9(ed 8or >3 .:a a(d above.
)ive( t+e ,+oi,e/ 8or9i(9 are pre8erred a t+e!
allo1
t+i((er e,tio( but it 1ould be e,o(omi,al to ue
,ati(9. 6o+iba H7I 1ill be ui(9 a 32"r ,at
teel
@30"r.oVNbNA 8or t+ee part o8 t+e u(it at
B66K"/ 1+erea E:R' H5I i(te(d to 9ive pre8ere(,e
to 8or9i(9 8or t+e i(itial adva(,ed
u(it.
'( order to mi(imiFe di88ere(tial t+ermal
e7pa(io(/
it i deirable to ma%e t+e rotor a(d t+e
tatio(ar!
part o8 t+e turbi(e o8 t+e ame material.
Ho1ever/
8or B5>K" u(it/ it i li%el! t+at t+e rotor 1ould
be
made o8 32"r teel/ 1+ile t+e i((er ,ai(9 1ould
be
made o8 aute(iti, teel. U(der u,+
,ir,umta(,e/
+a8t eal mut be ued to a,,ommodate t+e
9reater t+ermal e7pa(io( o8 t+e ,ai(9. Lar9er ,leara(,e
are re-uired to be 9ive(/ 1+e( aute(iti, teel
are
emplo!ed 8or rotati(9 a(d tatio(ar! part/ 8or
mot adva(,ed team ,o(ditio(. Bot+ t+e dei9( re-uireme(t/ 32"r rotor ,ooli(9 at B5>K" a(d
lar9er ,leara(,e to be provided 1it+ aute(iti,
teel at +i9+er temperature/ adverel! a88e,t t+e ,!,le
e88i,ie(,!. 6+i/ i( tur(/ partl! redu,e t+e (et
+eat
rate 9ai( a,+ieved b! elevati(9 t+e team
parameter.
'( additio(/ rotor ,ooli(9 ,ompli,ate t+e
dei9( o8
t+e turbi(e a(d it e7ter(al pipi(9/ a(d ,all
8or a(
overall e,o(omi, #uti8i,atio( i( 8i(al
ele,tio( o8 t+e
,a(didate material.
Si(,e t+e outer ,ai(9 i ub#e,ted to ,ooler
a(d lo12
preure team a ,ompared to t+e ot+er ,ai(9/
t+i
,ould be till made o8 t+e ,o(ve(tio(al lo12
allo!
8erriti, teel.
4.B6ra(itio( <eld Joi(t
'( ,ae 1+ere mai( team pipi(9 a(d t+e outer
,ai(9 are made o8 aute(iti, a(d lo12allo!
8erriti,
teel/ repe,tivel!/ t+e i(let pipi(9 to t+e
turbi(e
1ill +ave to utiliFe tra(itio( #oi(t. A(
approa,+
u99eted to t+i problem i to ma%e t+e #oi(t
i(
t+ree e,tio(/ utilii(9 a material o8
i(termediate
t+ermal e7pa(io( ,oe88i,ie(t u,+ a Allo!
D00H i(
bet1ee( t+e pipe a(d t+e ,ai(9 1it+ (i,%el2
baed
8iller metal 8or 1eldi(9. Ni,%el2baed 8iller
metal
improve t+e rupture li8e a mu,+ a 8ive time
more
t+a( t+e aute(iti, 8iller metal. &ue ,are
mut alo
be ta%e( i( dei9( to mi(imiFe be(di(9
tree/ a
li8e o8 tra(itio( #oi(t i 9reatl! redu,ed i8
be(di(9
tree are uperimpoed upo( tree 8rom
t+ermal
e7pa(io(.
4.6Bolti(9
Bolt a(d tud are ued i( ma(! #oi(t o8 t+e
turbi(e/ 1+i,+ (eed to be eparated 8or
mai(te(a(,e
or repair/ a 8or e7ample/ ,ati(9 a(d
valve. 6+e bolt a(d tud di88er 8rom all ot+er turbi(e
,ompo(e(t i( t+at t+e! are (ot,+ed/ ub#e,ted
to
,old a 1ell a +ot trei(9 a(d a var!i(9
patter( to trei(9 due to pra,ti,e o8 ti9+te(i(9 a(d
reti9+te(i(9. 6+e trai( to 1+i,+ bolt are
ti9+te(ed
i baed o( bot+ t+e propertie o8 t+e
material a(d
t+e dei9( pra,ti,e. 6+e uual trai( applied i(
U$
i 0.3BL H44I/ 1+ilt it i 0.2L i( )erma(!
H>6I.
6+e elati, trai( produ,ed b! t+e i(itial
ti9+te(i(9
o8 t+e bolt i pro9reivel! ,o(verted to
,reep trai(/
t+ereb! redu,i(9 t+e e88e,tive load o( t+e
#oi(t. Bolt 8or turbi(e part are re-uired to poe
u88i,ie(t reita(,e to tre rela7atio( to
mai(tai(
8la(9e tou9+(e a9ai(t i(ter(al team preure
at
leat 8or t+e period bet1ee( over+aul a(d +ould
be
re2uable t+rou9+out t+e li8e o8 t+e pla(t. '(
additio(/ bolti(9 material mut +ave ,oe88i,ie(t
o8
t+ermal e7pa(io( ,loe to t+at o8 8la(9e
material/
+i9+ proo8 tre(9t+/ 9ood (ot,+ rupture du,tilit!
a(d reita(,e to embrittleme(t.
6+e tre rela7atio( be+aviour o8 bolti(9
material
t+at +ave alread! demo(trated t+eir u,,e8ul
ervi,e per8orma(,e i( po1er tatio( i +o1( i(
0i9.32 H>6/ 4BI. 3"r3.oCV6iB teel/ 1+i,+ i
e7te(ivel! ued i( t+e ,o(ve(tio(al u(it
ma(u8a,tured i( t+e ,ou(tr!/ ,a( till be ued 8or
outer ,ai(9 #oi(t o8 t+e uper,riti,al u(it/
but it
i deirable to ue 32"r teel 8or i((er ,ai(9
8la(9e
bolt. At team temperature o8 B66K"/ t+e
di88ere(,e
i( t+e tre rela7atio( be+aviour o8 t+ee t1o
teel/
a +o1( i( 0i9.32/ i a a reult o8 t+e
di88ere(,e
i( t+eir i(itial trai(. But/ at t+e ame i(itial
trai(
level o8 0.3BL/ 32"r bolti(9 teel poe better
reita(,e to tre rela7atio(. '( ome o8 t+e
earlier
u(it/ 32"r bolt 1ere alo ued at +i9+er
temperature t+rou9+ team ,ooli(9 H3>I. Si(,e t+e
32"r bolt u(der9o e7te(ive tre rela7atio( at
B5>K"/ ,o(ideratio( i bei(9 9ive( b! E:R' to a
(umber o8 +i9+2tre(9t+ (i,%el2baed bolti(9
material. 0or u(it at 645K" team
temperature/
(i,%el2baed bolti(9 material are re-uired to
be
ued/ a t+e aute(iti, teel bolt are (ot
tro(9
e(ou9+ to meet t+e re-uireme(t. Baed o( a
,riti,al
urve! o8 1orld1ide e7perie(,e a(d tre
rela7atio(
tet/ '(,olo! =7B0/ Nimo(i, D0A/ Nimo(i, 50/
Re8ra,talo! 26 a(d :ER 2B +ave bee( ide(ti8ied
a
t+e bet ,a(didate 8or ue up to 6B0K".
B.SU..AR; AN& "ON"LUS'ONS
iA6+e -uet 8or lo1er2,ot po1er 9e(eratio(
led to a rapid pro9re i( t+e team
,o(ditio(/
re+eat ,!,le a(d output ,apa,it! o8 t+e
po1er pla(t duri(9 35B0 a(d 60.
Super,riti,al po1er pla(t o88er
,o(iderable
9ai( i( +eat rate.
iiA&uri(9 t+e lat t1o de,ade/ 8erriti,2
marte(iti, 5 to 32L "r teel +ave bee(
developed u(der i(ter(atio(al reear,+
pro9ramme/ 1+i,+ permit @liveA i(let
team
temperature 8or t+ermal po1er tatio(
up
to appro7imatel! 630K"/ preure o8 up
to
about >00 bar a(d re+eat temperature up
to
about 62BK". 6+e reult +ave bee(
improveme(t i( e88i,ie(,! o8 arou(d DL
veru ,o(ve(tio(al team parameter.
iiiA6+e (e1l! developed 5232L "r teel are
alread! bei(9 ued i( 32 Europea( a(d >4
Japa(ee po1er tatio( 1it+ i(let team
temperature o8 up to about 630K". 6+e e7perie(,e 1it+ t+e ,ompo(e(t made o8 t+ee teel +a bee( de,idedl! poitive. ivAAdva(,eme(t i( team parameter i(,reae
t+e everit! o8 t+e ervi,e ,o(ditio(
t+at material mut u(der9o. 6+e pree(tl!
available lo1 a(d +i9+ allo! 8erriti,
teel
1it+ prove( ervi,e e7perie(,e ,a( meet
t+e
re-uireme(t o8 bot+ boiler a(d team
turbi(e ,ompo(e(t o8 u(it dei9(ed 8or team temperature at 600K". vA0or adva(,ed team pla(t o8 temperature 0'). 32 *"O.:AR'SON O0 >0/000H RELA=E& S6RESS 0OR BOL6'N) .A6ER'ALS H20I
above 600K"/ aute(iti, teel are re-uired
to
be emplo!ed 8or 8i(al ta9e o8 uper
+eater
a(d tati, ,ompo(e(t o8 t+e team turbi(e/
u,+ a i((er ,ai(9/ team valve a(d (oFFle
blo,%. 32"r teel ,a( be ued 8or H:M':
rotor ub#e,t to reliable dei9( 8or
,ooli(9
t+em o a to bri(9 t+e material temperature
do1( to B66K".
viAAt team temperature o8 645K"M623K"/
+i9+2tre(9t+ marte(iti, teel are
re-uired
8or H:M': team turbi(e rotor a(d
tatio(ar!
,ompo(e(t. :reve(tive meaure u,+ a
appli,atio( o8 ,ompoite or ,+romiFed tube
to 1it+ta(d 8ireide ,orroio( o8
uper+eater
a(d re+eater a 1ell a tep to mi(imiFe
team2ide o7idatio( +ould be ta%e(.
viiA0or team turbi(e bladi(9 a(d bolti(9 at
temperature above B5>K"/ material u,+ a
Nimo(i, a(d Re8ra,talo! 26 et,. +ould be
,o(idered.
viiiA6o meet t+e ':2L: ,roover temperature 8or
u(it at team temperature o8 B5>K" a(d
above/ it i (e,ear! to improve t+e temper
embrittleme(t o8 t+e e7iti(9 >.BNi"r.oV
L: rotor teel/ b! emplo!i(9 moder( teel
ma%i(9 te,+(i-ue to elimi(ate eleme(t
u,+ a .(/ Si/ : a(d S(. Alter(ativel!/
t+e
team +ould be ,ooled i( t+e ': turbi(e to
limit t+e L: i(let team temperature to t+e
e7iti(9 ma7imum allo1able level o8 about >B0K". Re8ere(,e 3.Huema((/ R.U./ et.al./ E:ro,ei(9 a(d :ra,ti,al Appli,atio( o8 Ne1 .aterial i( :o1er :la(t "o(tru,tio(E/ V)B $ra8t1er%te,+(i%/ 7B@>A/ 355B/ 24322BB 2.E:R' Jour(al/ September 35D3/ 22 >.Spe(,er/ R."./ :ro,. Amer. :o1er "o(8. 42/ 35D0/ 22B
4.Haa/ H./ et al./ :ro,. Amer. :o1er "o(8./
44/
35D2/ >>0
B.S,+(eider/ A./ V)B $ra8t1er%te,+(il%/ BD/
357D/ 36D
6.$a1ai/ 6./ 6urboma,+i(er! '(ter(atio(al/
2B/
.ar,+ 35D4/ >4
7.A%iba/ .. a(d AiFa1a/ $./ 6urboma,+i(er!
'(ter(atio(al/ 2B/ .ar,+ 35D4/ >7
D..u+l+auer/ H./ Bro1( Boveri Revie1/ 73/
35D4/ 320
5.)old/ .. a(d Ja88ee/ R.'./ J. .aterial 8or
E(er9! S!tem/ 6/ 35D4/ 3>D
30..a!er/ $.H./ et.al./ ENe1 .aterial 8or
'mprovi(9 t+e E88i,ie(,! o8 0oil 0ired
6+ermal
:o1er Statio(E/ V)B :o1er 6e,+/ Ja(
355D/
22227
33.6ro#a(o1%i#/ B.../ V)B $ra8t1er%te,+(i%/
60 @35D0A B2B
32.:lato1/ B./ et al./ '(t. "o(8. o( "reep
a(d
0ati9ue i( Elevated 6emperature
Appli,atio(/
'(t(. .e,+. E(9r. S+e88ield/ 3574/
:aper
"45M 74
3>.)emmill/ ..)./ AS6. Jl. 6eti(9 a(d
Evaluatio(/ 2/ 3574/ >
34.Bri99/ J.J. a(d :ar%er/ 6.&./ ESuper 32L
"r
SteelE "lima7 .ol!bde(um ,ompa(!/ Ne1
;or%/ N;/ 356B
3B.Se,tio( '/ :o1er Boiler/ AS.E Boiler a(d
:reure Veel "ode/ AS.E/ Ne1 ;or%/
35D> S' Editio(/ 3762227 36."+ara,teriti, o8 H".5. Steel 6ubi(9 8or
Boiler appli,atio(/ .itubi+i Heav!
'(dutrie Ltd. @.H'A a(d Sumitomo .etal '(dutrie Ltd. @S.'A. Jul! 3575. 37.Sumitomo/ Hi9+ Stre(9t+ Boiler 6ube/ S.'/ D0202No.30D3
3D."a(o(i,o/ &.A./ 6+e 8a,tor t+at '(8lue(,e
t+e Sele,tio( o8 Hi9+ 6emperature .aterial/
pree(ted at t+e Natio(al S!mpoium o(
"reep
3D BHEL JOURNAL/ September 2006
Reita(t Steel 8or :o1er :la(t/ BHEL
RS&/
H!derabad @'(diaA/ Ja(uar! 35D>
35.Orr/ J. a(d Nile1ar/ V.B./ Stai(le
Steel2D4/
6+e '(titute o8 .etal/ Lo(do( 35DB/ B>>
20.Vi1a(at+a(/ R./ E&ama9e .e,+a(im a(d
Li8e Aeme(t o8 Hi9+ 6emperature
"ompo(e(t/E AS. '(tl./ 35D5
23.Ra(9a(at+a(/ S./ et al./ Natio(al S!mpoium
o( "reep Reita(t Steel 8or :o1er :la(t/
BHEL RS&/ H!derabad @'(diaA/ Ja(uar!
35D>/ :aper No. 3.0>
22.'(oue/ ../ et al./ 6+e Sumitomo Sear,+ (o.
25
Nov 35D4/ 64
2>.0ri,%er/ H. a(d <aler/ B./ 0erriti, Steel
8or
0at Rea,tor Steam )e(erator/ BNES/
Lo(do(/
357D/>B
24.:ropertie o8 5"r teel tube a(d pipe/
S'./
D04282No. 3354/ 0ebruar! 35D4
2B."aubo/ ../ 'mproved 8erriti, teel 8or uper
+eater tubi(9/ AS.E paper No. 6>2<A2246/
356>
26.)emmill/ ..)./ 6+e te,+(olo9! a(d propertie
a(d 8errou allo! 8or +i9+ temperature ue/
)eor9e Ne1(e Ltd./ Lo(do(/ 3566
27.<!att/ L.../ .aterial o8 ,o(tru,tio( 8or
team po1er pla(t/ applied ,ie(,e
publi+er
Ltd./ Lo(do(/ 3576
2D.<!att/ L.../ .at. S,i. a(d E(99./ 3/ 3573/
27> 25.$oopma(/ J.)./ et al./ :ro,. Ameri,a( :o1er "o(8./ 23/ 35B5/ 2>6 >0.Sumitomo/ Hi9+ allo! ,ompoite tube 8or
pulveriFed ,oal 8ired boiler appli,atio(/
S.'/ D0>202No. 3006
>3.O+tomo/ A./ et al./ EHi9+ temperature
,orroio(
,+ara,teriti,o8 uper+eater tubeE/ 'H'
E(99. Rev./ 36@4A/ O,tober 35D>
>2.0latl!/ 6./ a(d Lat+om/ E./ .aterial i(
po1erpla(t/ pri(9 reide(tial ,oure '(t(. o8
.etallur9it/ "+amelo( pre/ Lo(do(/
357B/ 6>
>>.Sumitomo/ "+romiFed tai(le teel tube/
S.' D0>202No. 3075/ Ju( 35D>
>4.Haberma(/ J.A./ a(d $e!to(/ H./ :ro,.
Amer.
:o1er ,o(8./ 44/ 35D2/ 3570
>B.Re+(/ '.../ et al./ NA"E ,orroio( D0/
"+i,a9o/
'L/ .ar,+ 35D0/ :aper No. 352
>6.<arm8ete Ho,+1arm8ete <er%to88e 0ur
S,+raube( a(d .atter(/ )utevor,+ri8te(/
&'N
37240/ Jul! 3576
>7.<e9t/ ).<./ Sta+l,+luel/ Verla9
Sta+l,+luel
<e9t )mbH/ 35D>
>D.<arm8eter 0erriti,+er Sta+l9uT/
6e,,+(i,+e
Lie8erbedi(9u(9e(/ &'N3724B/ O,tober/
3577
>5.S1ami(at+a(/ V.:. a(d Ja88ee/ R.'./ .etal
:ro9re/ 32D/ &e,ember 35DB/ B2
40..a(u8a,turi(9 o8 6rial A 2D6 Rotor
0or9i(9/
$obe Steel/ 6$E D>2B7/ Ja(uar! 35D4
43.6odeu/ H./ et al./ .itubi+i :o1er
S!tem
Bulleti( .BB2D233>E/ November 35D2
42.<ata(abe/ J. a(d .ura%ami/ ;./ :ro,. Amer.
:etroleum '(t./ 35D3/ 236
4>.Vi1a(at+a(/ R./ et al./ E&iimilar .etal
<eld i( :o1er :la(tE/ :ree(ted at A<S2
E:R' "o(8. o( Joi(i(9 &iimilar .etal/
:ittbur9+/ :A/ Au9ut 35D2
44.Bra(,+/ ).&./ et al./ '(t. "o(8. o( "reep
a(d
8ra,ture i( Elevated 6emperature
Appli,atio(/ S+e88ield/ 3574/ :aper "352M7> 4B.Briti+ Steel "orporatio(E &ata S+eet o( &ure+ete 500 a(d &ure+ete 30BB Steel 46.Oa%e!/ J.E./ :i(der/ L.<./ Va(to(e/ R./ He(dero(/ .. a(d O9erb! S/ ERevie1 o8 tatu o8 adva(,ed material 8or po1er 9e(eratio(E/ Report (o. "OAL R224/ &6'M URN 02M3B05/ 200>
47.<ri9+t/ '.)./ .aFiaF/ :.J./ Elli/ 0.V./
)ibbo(/
6.B. a(d <ood8ord/ &.A./ E.aterial
iue 8or
turbi(e 8or operatio( i( ultra
uper,riti,al teamE/ ORNL report/ USA.
.r. $ulvir Si(9+ 9raduated i( .etallur9i,al
E(9i(eeri(9 8rom U(iverit! o8 Roor%ee/ @(o1
''6/ Roor%eeA i( t+e !ear 35D3. He ,ompleted
..6e,+. @.etallur9!A 8rom ''6/ $a(pur/ i(
35D>.
6+erea8ter/ .r. Si(9+ #oi(ed .etallur9!
&epartme(t o8 "orporate RS&/ BHEL/
H!derabad. Si(,e t+e be9i((i(9/ +e 1a i(volved
i( i(di9e(iFatio( o8 ,reep2reita(t teel 8or
team
turbi(e a(d boiler appli,atio(. Sube-ue(tl!/
+e
alo tudied tru,ture propert! ,orrelatio( a(d
,reep ,ra,% 9ro1t+ be+aviour o8 po1er pla(t
teel. He +a alo ,arried out e7te(ive
tudie o(
t+e ,reep2rupture be+aviour o8 :53 a(d =20
teel/ t+eir 1eldme(t a(d imulated +eat2
a88e,ted
Fo(e. He i a,tivel! i(volved i( reidual li8e
aeme(t o8 team a(d 9a turbi(e ,ompo(e(t.
He i alo 1or%i(9 i( t+e area o8 i(di9e(ou
developme(t o8 9a turbi(e bu,%et a(d +eat
treatme(t o8 teel b! mi,ro1ave. Hi ot+er
a,tivitie i(,lude ma(! importa(t 8ailure
i(veti9atio( o8 boiler/ team a(d 9a turbi(e
,ompo(e(t a(d pro,e i(dutr! e-uipme(t. He
i ,urre(tl! 1or%i(9 a &!. )e(eral .a(a9er a(d
+eadi(9 "reep Lab o8 t+e .etallur9! &epartme(t.
.r. Si(9+ +a publi+edMpree(ted over B0
te,+(i,al paper i( variou (atio(al a(d
i(ter(atio(al #our(al a(d ,o(8ere(,e. He +a
alo re,eived BHEL E7,el A1ard i( t+e bet
6e,+(i,al :aper ,ate9or! 8or t+e !ear 200>.
SEL02E="'6A6'ON 'N >2:HASE S?U'RREL "A)E
'N&U"6'ON )ENERA6OR 0OR <'N&.'LL A::L'"A6'ON
:.$. $+a((a
S;NO:S'S
'( '(dia/ t+ere are ,ertai( area 1+ere ple(t! o8
e(er9!
i available but it remai( u(tapped. <i(d e(er9!
i
o(e u,+ area. Alo/ it i 1ell %(o1( t+at
'(du,tio(
)e(erator are bet uited 8or po1er 9e(eratio(
t+rou9+
1i(dmill due to t+eir imple ,o(tru,tio(. '( t+i
paper/
a( attempt +a bee( made to de,ribe +o1 a(
'(du,tio(
)e(erator ,a( be made to 9et el82e7,itatio( a(d
t+u
be ued i( a(! ta(d2alo(e ituatio(/ epe,iall!
8or
1i(dmill appli,atio(.
$e! <ord*
'(du,tio( )e(eratorG Sel82E7,itatio(G Sta(d2Alo(e.
3.'N6RO&U"6'ON
<it+ t+e adva(,eme(t o8 te,+(olo9!/ a (eed i
al1a! 8elt to +ave a mu,+ impli8i,atio( a i
poible but 1it+ +i9+ reliabilit! o8 operatio(.
'(du,tio( )e(erator i o(e u,+ ,ate9or! o8
ma,+i(e/
1+i,+ i mot imple i( it ,o(tru,tio(/ a 1ell
a
i( operatio(. A t+e (ame implie/ t+e '(du,tio(
)e(erator +a a -uirrel ,a9e rotor. 6+i obviate
bru+ 9ear aembl!/ bru+le e7,itatio( !tem
or
perma(e(t ma9(et et,. a i (e,ear! 8or ot+er
%i(d o8 9e(erator. 0or e7,itatio( o8 t+e i(du,tio(
9e(erator/ a ,apa,itor ba(% i ued a,ro t+e
tator
termi(al. 6+e mai( adva(ta9e o8 u,+ 9e(erator
i
imple ,o(tru,tio(/ lo1 ,ot a(d +i9+
reliabilit!. 2.6;:ES O0 S?U'RREL "A)E 'N&U"6'ON )ENERA6OR 6+ee are o8 t1o t!pe* @iA'( t+e 8irt t!pe/ 1+e( a -uirrel ,a9e motor
i ru( above it !(,+ro(ou peed/ it
tart
8u(,tio(i(9 a a 9e(erator. '( t+i t!pe/
it i
al1a! (e,ear! t+at t+e ma,+i(e ru(
above
it !(,+ro(ou peed a(d it +ould
remai(
,o((e,ted to po1er uppl! 8or e7,itatio(.
@iiA'( t+e e,o(d t!pe/ 1+e( a -uirrel ,a9e
motor ru((i(9 (ear to it !(,+ro(ou
peed
i 1it,+ed o88 a(d imulta(eoul! a
,apa,itor
ba(% i ,o((e,ted a,ro t+e motor
termi(al/
it tart 8u(,tio(i(9 a a 9e(erator.
6+i t!pe
i ,+ara,teried b! el82
e7,itatio(.
'( t+i arti,le/ t+e e,o(d t!pe o8 9e(erator
o(l!
@el82e7,itatio( t!peA +a bee( di,ued i(
detail.
>.:R'N"':LE O0 <OR$'N) O0 6HE
SEL02E="'6A6'ON 6;:E
<+e( a( '(du,tio( motor i ru((i(9 u(der tead!
tate ,o(ditio(/ a( e.m.8. @EA e7it a,ro
it tator
1i(di(9. No1/ i8 t+e peed o8 motor i
mai(tai(ed
t+rou9+ a prime mover a(d uppl! to i(du,tio(
motor i 1it,+ed o88/ imulta(eoul!
,o((e,ti(9 it
a,ro a ,apa,itor ba(%/ t+ere i a 8lo1 o8
e7,itatio(
,urre(t i( t+e tator 1i(di(9 a per t+e load
li(e o8
,apa,itor @0i9. 3A. 6+i ,urre(t produ,e
rotati(9
8lu7/ 1+i,+/ i( tur(/ i(du,e e.m.8. i( t+e
tator
1i(di(9. U(der tead! tate ,o(ditio(/ t+e
e.m.8. i(du,ed i( t+e 1i(di(9 +a a ma9(itude a(d
dire,tio( t+e ame a t+at o8 t+e ori9i(al
e.m.8.@EA. 6+u/ t+e volta9e E ,o(ti(ue to be utai(ed. 4.:HENO.ENON O0 SEL02 E="'6A6'ON
6+e mot importa(t ,o(ditio( 8or el82
e7,itatio( to
ta%e pla,e i t+at t+ere +ould be pree(,e o8
reidual
8lu7 i( t+e rotor. <+e( a ,apa,itor ba(% i
,o((e,ted
a,ro t+e tator 1i(di(9 a8ter 1it,+i(9 o88 it
uppl!/ ,apa,itive ,urre(t 8lo1 i( t+e tator
1i(di(9.
6+e( t+e 8lu7 produ,ed b! t+i ,urre(t aid t+e
reidual 8lu7. 6+e i(,reae i( 8lu7 i(,reae t+e
i(du,ed e.m.8. i( t+e 1i(di(9 a(d t+i ,!,le
,o(ti(ue
till t+ere i aturatio(. U(der t+i ,o(ditio(/
t+e
tead! tate e.m.8. i 9ive( b! t+e i(tere,tio(
o8 t+e
ma9(etiFi(9 ,urve o8 motor 1it+ t+e ,apa,itive
load
li(e. '8 t+e reidual 8lu7 i( t+e rotor i (ot
u88i,ie(t/
t+e el82e7,itatio( 8ail to o,,ur a(d t+ere8ore/
t+e
volta9e at t+e termi(al doe (ot build up.
6+e lope o8 t+e motor ma9(etiFi(9 ,urve i ,alled
t+e ,riti,al lope. 6+e iFe o8 t+e ,apa,itor i(
t+e
,apa,itor ba(% i ,+oe( i( u,+ a 1a! t+at it
,apa,itive rea,ta(,e i le t+a( t+e ,riti,al
lope o8
t+e ma9(etiFi(9 ,urve/ ot+er1ie el82e7,itatio(
1ill
(ot ta%e pla,e. 0i9ure22 +o1 t+e ,ae i( 1+i,+
t+e
load li(e o8 ,apa,ita(,e i ta(9e(t to t+e
,riti,al
lope a(d/ t+u/ el82e7,itatio( doe (ot ta%e
pla,e.
6+i p+e(ome(o( ,a( be oberved i( a laborator!
alo b! ,o((e,ti(9 t+ree2p+ae uppl! to a(
'(du,tio(
ma,+i(e drive( b! a prime mover/ At t+e rated
peed/ 1+e( t+e uppl! to t+e motor i 1it,+ed
o88
a(d imulta(eoul! a ,apa,itor ba(% i
,o((e,ted
a,ro it/ a tead! tate volta9e i 9e(erated
at t+e
motor termi(al.
6+e value o8 ,apa,ita(,e i( t+e ,apa,itor ba(%
+ould (eit+er be too lo1 (or too +i9+. '8 t+e
value
o8 ,apa,ita(,e i too lo1/ el82e7,itatio( 1ill
(ot ta%e
pla,e. '8 t+e value o8 ,apa,ita(,e i too +i9+/
t+ere
1ill be i(ade-uate build2up o8 tead! tate
volta9e
due to aturatio( o8 8lu7 pat+. He(,e/ t+ere
i a
(eed to ue optimum iFe o8 ,apa,itor 8or
proper
build2up o8 volta9e a(d alo 8or %eepi(9 t+e
,ot o8
,apa,itor ba(% lo1.
B."ON0')URA6'ONS O0 S6A6OR
<'N&'N) AN& "A:A"'6OR BAN$
6+ere are variou ,o(8i9uratio( o8 tator
1i(di(9
a(d ,apa,itor ba(%/ 1+i,+ are poible 8or t+e
purpoe o8 el82e7,itatio(/ e.9.*
@iAStar2,o((e,ted tator 1i(di(9 a(d Star2
,o((e,ted ,apa,itor ba(% @0i9. >A
@iiAStar2,o((e,ted tator 1i(di(9 a(d &elta2
,o((e,ted ,apa,itor ba(%.@0i9. 4A
0'). 3 *LOA& L'NE O0 "A:A"'6AN"E "U66'N)
6HE .A)NE6'S'N) "URVE
0'). 2 * LOA& L'NE O0 "A:A"'6AN"E 6AN)EN6 6O 6HE .A)NE6'S'N) "URVE S6AR2"ONNE"6E&S6AR2"ONNE"6E& S6A6OR <'N&'N)"A:A"'6OR BAN$ 0'). >
@iiiA&elta2,o((e,ted tator 1i(di(9 a(d Star2
,o((e,ted ,apa,itor ba(% @0i9. BA
@ivA&elta2,o((e,ted tator 1i(di(9 a(d &elta2
,o((e,ted ,apa,itor ba(% @0i9. 6A
'( all t+e above 8our ,ae/ 1+e(ever t+e
,apa,itor
are ,o((e,ted i( &elta/ t+e value o8
,apa,ita(,e
re-uired i( ea,+ p+ae redu,e to o(e t+ird o8
it
,orrepo(di(9 value i( Star/ but t+e :ea%
'(vere
Volta9e @:'VA o8 t+e ,apa,itor re-uired
be,ome U>
time it ,orrepo(di(9 value i( Star ,o((e,ted
,apa,itor ba(%. A 8ar a per8orma(,e o8 t+e
'(du,tio(
)e(erator i ,o(,er(ed/ bot+ Star a(d &elta
,o((e,ted ,apa,itor ba(% are e-uivale(t 8or a
9ive(
,o((e,tio( o8 tator 1i(di(9/ a(d 9ive t+e ame
per8orma(,e.
6.'N&U"6'ON )ENERA6OR ON
LOA& @0i9. 7A
U(der (o2load ,o(ditio(/ i(,e o(l! t+e
ma9(etiFi(9
,urre(t i 8lo1i(9 t+rou9+ tator 1i(di(9/
volta9e
drop i( tator 1i(di(9 i ver! mall/ a(d
t+ere8ore
t+e volta9e at t+e 9e(erator termi(al i
almot e-ual
to t+e i(du,ed e.m.8. i( tator 1i(di(9.
<+e( t+e '(du,tio( )e(erator i ,o((e,ted to a
pure reitive load a(d ,urre(t 8lo1 t+rou9+
tator
1i(di(9/ t+ere i a volta9e drop i( t+e tator
1i(di(9/ 1+i,+ i uuall! le t+a( BL o8 t+e
i(du,ed e.m.8. No1/ i8 t+e load ,urre(t i
i(,reaed
8urt+er/ t+e( at a ,ertai( poi(t/ 1+ere t+e
,riti,al
lope o8 ma9(etiFi(9 ,urve ,oi(,ide 1it+ t+e
load
li(e o8 ,apa,itor/ t+e '(du,tio( )e(erator
top
S6AR2"ONNE"6E&&EL6A2"ONNE"6E&
S6A6OR <'N&'N)"A:A"'6OR BAN$
0'). 4
&EL6A2"ONNE"6E&S6AR2"ONNE"6E&
S6A6OR <'N&'N)"A:A"'6OR BAN$
0'). B &EL6A2"ONNE"6E&&EL6A2"ONNE"6E& S6A6OR <'N&'N)"A:A"'6OR BAN$ 0'). 60'). 7 * )ENERA6OR <'6H LOA&
9e(erati(9 a(! volta9e. 6+u/ i( a( '(du,tio(
)e(erator 1it+ a reitive load/ t+ere i (o
poibilit!
o8 over+eati(9 o8 t+e '(du,tio( )e(erator due to
over2load M over2,urre(t.
<+e( t+ere i a( i(du,tive load put a,ro t+e
9e(erator/ a part o8 t+e ,apa,itive ,urre(t due to
,apa,itor ba(% 1ill 9et (eutraliFed b! t+e
i(du,tive
load ,urre(t. 6+u/ t+e ma9(etiFi(9 ,urre(t
available
to t+e 9e(erator 1ill 9et redu,ed. 6+ere8ore/ more
,apa,ita(,e 1ill be re-uired to be added i( t+e
,apa,itor ba(% 8or mai(tai(i(9 t+e termi(al
volta9e
o8 t+e '(du,tio( )e(erator.
7.&E6ER.'NA6'ON O0 "A:A"'2
6AN"E VALUE
6+e 8ollo1i(9 pro,edure ,a( be adopted 8or
determi(i(9 t+e value o8 ,apa,ita(,e re-uired i(
t+e
,apa,itor ba(% u(der (o2load ,o(ditio( 2
&ra1 t+e (o2load ,+ara,teriti, o8 '(du,tio(
.otor.
"al,ulate t+e ,riti,al lope o8 t+e ma9(etiFi(9
,urre(t @0i9. DA. &ra1 a load li(e o8 ,apa,itor
+avi(9 a lope le t+a( t+e ,riti,al lope o8
ma9(etiFi(9 ,urre(t. 0rom t+i/ ba,% ,al,ulate t+e
value o8 ,apa,ita(,e re-uired u(der (o2load
,o(ditio(.
6o ,al,ulate t+e ,apa,ita(,e u(der 8ull2load
,o(ditio(/
t+e 8ollo1i(9 pro,edure ma! be adopted*
6+ere 1ill be a volta9e drop o8 appro7. BL i(
termi(al volta9e due to reitive load.
'(du,tive load
,urre(t 1ill +ave to be provided b!
,apa,ita(,e.
He(,e/ load li(e o8 ,apa,ita(,e 1it+ i(du,tive
load
i dra1( a,,ordi(9l!/ a +o1( i( 0i9. D. 0rom
t+i/
ba,% ,al,ulate t+e value o8 ,apa,ita(,e
re-uired
u(der 8ull2load ,o(ditio(.
)e(erator o8 t+i t!pe are bet uited 8or
reitive
load.
D."'R"U'6 6O ENSURE SEL02
E="'6A6'ON
&ue to a(! reao(/ i8 t+ere i (o reidual 8lu7
i( t+e
motor/ t+e pro,e o8 el82e7,itatio( ,a( be
i(itiated
b! ,o((e,ti(9 a batter! mome(taril! a,ro o(e
o8
t+e ,apa,itor o8 t+e ,apa,itor ba(% @0i9. 5A.
<it+
t+i/ t+e ,apa,itor ba(% 9et ,+ar9ed a(d 1+e(
it
di,+ar9e t+rou9+ t+e tator 1i(di(9/ a 8lu7
i
produ,ed i( t+e rotor o8 '(du,tio( .a,+i(e.
0'). D * &E6ER.'NA6'ON O0 "A:A"'6AN"E VALUE 0'). 5 * SEL02E="'6A6'ON <'6H 6HE A'& O0 BA66ER; 5.VOL6A)E RE)ULA6'ON 6+ou9+ i( t+e above para9rap+/ it +a bee(
preumed t+at at rated volta9e t+e rotor ,ore
9et
8ull! aturated/ but pra,ti,all! t+e ,ore i
(ever
aturated 8ull! a(d t+u/ it 1ould al1a!
reult i(
lar9e variatio( o8 t+e termi(al volta9e 1it+
repe,t
to load ,urre(t. 6+i problem o8 drop i(
volta9e
1it+ load ,a( be over,ome i( t+e 8ollo1i(9 t1o
1a!*
@iA.a(ual Volta9e Re9ulator
'( t+i ,ae/ t+e variable ,apa,itor are
ued
i( t+e ,apa,itor ba(% i( pla,e o8 8i7ed
,apa,itor. B! ma(uall! var!i(9 t+e
,apa,ita(,e 1it+ repe,t to load/ t+e
termi(al
volta9e ,a( be mai(tai(ed. <+ile ele,ti(9
t+e ra(9e 8or t+e variable ,apa,itor/ it
+ould
be e(ured t+at t+e lo1er value o8
,apa,ita(,e
,orrepo(d to load li(e o8 9e(erator u(der
(o2load ,o(ditio(/ a(d t+at t+e +i9+er
value
o8 ,apa,ita(,e i( t+e ra(9e ,orrepo(d to
load li(e o8 9e(erator u(der 8ull!2loaded
,o(ditio(. '( t+i ,ae/ 1+ile tarti(9/
t+e
9e(erator operatio( mut be tarted 1it+
lo1er value o8 ,apa,ita(,e a,ro t+e
termi(al.
@iiAAutomati, Volta9e Re9ulator
'( t+i ,ae/ t+ere i a mai( ,apa,itor
ba(%/
1+i,+ i ued 8or (o2load operatio( o8
t+e
9e(erator. 6+e(/ a proviio( i %ept 8or
addi(9 a(ot+er ,apa,itor ba(% i( parallel
to
t+e 8irt o(e 1+e( t+ere i a dip i(
volta9e
at t+e termi(al. "o((e,tio( o8 a(ot+er
,apa,itor ba(% i( parallel i a,+ieved
t+rou9+
a( ele,tro(i, ,ir,uit @0i9.30A.
0'). 30 * AU6O.A6'" VOL6A)E RE)ULA6'ON O0 'N&U"6'ON )ENERA6OR
30."ON"LUS'ON
6+e '(du,tio( .a,+i(e 1+e( operated a a )e(erator
al1a! re-uire it e7,itatio( 8rom outide.
Eit+er it
remai( ,o((e,ted to t+e uppl! i8 it i to 8eed
po1er
to 9rid or it e7,itatio( ,a( be provided t+rou9+
a
,apa,itor ba(% i8 it i 8eedi(9 po1er to a ta(d2
alo(e
!tem. '( ta(d2alo(e !tem li%e 1i(d mill
i(talled
i( a remote area +avi(9 (o 9rid po1er uppl!/
t+ere
are variou optio( available 8or providi(9 t+e
(e,ear! e7,itatio( to '(du,tio( )e(erator a(d
alo
8or mai(tai(i(9 a ,o(ta(t termi(al volta9e at
di88ere(t load.
A,%(o1led9eme(t
6+e aut+or 1i+e to e7pre +i i(,ere 9ratitude
to
S+ S.$. )o!al/ ))./ "orp. R S &/ BHEL/
H!derabad/ 8or +i ,o(ti(uou e(,oura9eme(t a(d
9uida(,e i( 1riti(9 t+i paper. 6+a(% are alo
due
to S+ ..S. &+ami/ A). @E.EA S S+ S.". )oel/
S&). @..A 8or t+eir upport a(d +elp i(
,ompleti(9 t+i paper.
Biblio9rap+!
3.S.S. .urt+!/ ".S. J+a a(d :.S. Na9e(drarao/
VA(al!i o8 9rid ,o((e,ted i(du,tio(
9e(erator
drive( b! +!droM1i(d turbi(e u(der
realiti,
!tem ,o(trai(t/V i( 'EEE 6ra(.
E(er9!
"o(verio(/ vol. B/ pp. 327/ .ar. 3550.
2.L. S+rid+ar/ B. Si(9+/ ".S. J+a a(d B.:.
Si(9+/ VA(al!i o8 el82e7,ited
i(du,tio(
9e(erator 8eedi(9 i(du,tio( motor/V i(
'EEE
:o1er E(9. So,./ Summer .eeti(9/ 3554/
pp.
327.
>.L. S+rid+ar/ B.Si(9+/ ".S. J+a/ B.:. Si(9+
a(d
S.S. .urt+!/ VSele,tio( o8 ,apa,itor 8or
t+e el8
re9ulated +ort +u(t el82e7,ited
i(du,tio(
9e(erator/V i( 'EEE 6ra(. E(er9!
"o(verio(/
vol. 30/ pp. 30237/ .ar. 355B.
4.S.:. Si(9+/ Sa(#a! $. Jai( a(d J. S+arma/
VVolta9e re9ulatio( optimiFatio( o8
,ompe(ated
el82e7,ited i(du,tio( 9e(erator 1it+
d!(ami,
load/V i( 'EEE 6ra(. E(er9! "o(verio(/
vol.
35/ pp. 72427>2/ &e,. 2004.
.r. :.$. $+a((a 9raduated i( Ele,tri,al E(9i(eeri(9 8rom '(dia( '(titute o8 6e,+(olo9!/ Ne1 &el+i/ i( t+e !ear 3575. .r. $+a((a #oi(ed BHEL/ Harid1ar/ a a( E(9i(eer 6rai(ee i( 3575 a(d 1a poted i( A" .a,+i(e E(9i(eeri(9 &epartme(t. 0or more t+a( 24 !ear/
+e +a bee( i(volved i( t+e ele,tri,al S
me,+a(i,al
dei9( o8 variou ,apa,itie o8 tailor2made A"
motor 8or 6+ermal :o1er Statio(/ 'rri9atio(/ "eme(t/ :etro,+emi,al a(d ot+er '(dutrie. He
+a alo u(derta%e( retro8it #ob to develop
,omplete dei9( o8 A" motor to repla,e (o(2BHEL2ma%e
A" motor 8or variou ,utomer. At pree(t/ +e
i 1or%i(9 a &eput! )e(eral .a(a9er i( Ele,tri,al .a,+i(e E(9i(eeri(9 at Harid1ar a(d i i(volved i( dei9( a(d developme(t o8 >00 .VA 6AR' Air "ooled )e(erator. :rior to t+i paper/ .r. $+a((a +a ,o(tributed
o(e te,+(i,al paper i( a( '(ter(atio(al
"o(8ere(,e +eld at ''6/ Roor%ee/ re,e(tl!.
6URBO)ENERA6OR 'N&U"E& VOL6A)E <AVE0OR.
"O.:U6A6'ON AN& 6ELE:HONE HAR.ON'"
"A:AB'L'6; :RE&'"6'ON
". :rem $umar
S;NO:S'S
6+e 0i(ite Eleme(t met+od +a e(abled a,,urate
etimatio( o8 t+e ma9(eti, 8ield i( ele,tri,al
ma,+i(e
a(d devi,e. 6+e approa,+ +a t+ere8ore made
poible
t+e a,,urate etimatio( o8 t+e variou 8lu72
related
parameter C t+e i(du,ed volta9e ma9(itude bei(9
o(e
amo(9 t+em. 6+ou9+ t+e ma,+i(e ,+ara,teriti,
,urve
or t+e ope(2,ir,uit ,+ara,teriti, i readil!
dedu,ible/
t+e i(du,ed volta9e 1ave8orm/ +o1ever/ i (ot.
6+i
paper pree(t detail o8 a met+od 8or t+e
,omputatio(
o8 turbo9e(erator i(du,ed volta9e 1ave8orm/ it
+armo(i,
,o(te(t a(d ma,+i(e 6elep+o(e Harmo(i, 0a,tor or
t+e
6elep+o(e '(ter8ere(,e 0a,tor C all at dei9(
ta9e.
$e! <ord*
Volta9e <ave8ormG Harmo(i,G S!(,+ro(ou
.a,+i(eG 6elep+o(e Harmo(i, "apabilit!.
3.'N6RO&U"6'ON
A,,urate evaluatio( o8 t+e ma9(eti, 8ield
ditributio(
i( ele,tri,al ma,+i(e +a bee( made poible b!
t+e 0i(ite Eleme(t met+od. .a9(eti, 8ield2related ma,+i(e parameter u,+ a i(du,ta(,e/ i(du,ed volta9e ma9(itude S 1ave8orm/ ue8ul S tra!
8lu7e/ lea%a9e ,o2e88i,ie(t/ i(du,tio(2related
loe/ aturatio( e88e,t et,/ i( tur(/ ta(d a,,uratel!
evaluated. 6+ou9+ t+e ope(2,ir,uit ,+ara,teriti,
i readil! dedu,ible 8rom t+e ma9(eti, 8ield mappi(9/ t+e i(du,ed volta9e 1ave8orm/ +o1ever/ i (ot. 6+e time variatio( o8 t+e i(du,ed e.m.8 i( a ,o(du,tor
o8 t+e tator i( a !(,+ro(ou ma,+i(e +a t+e
ame
8orm a t+e pa,e ditributio( o8 t+e 8lu7 de(it!
i(
t+e air 9ap. 6+ere8ore/ o(l! a i(uoidal 1ave
o8 t+e
air9ap 8lu7 de(it! ,a( reult i( a i(e21ave
i(du,ed
volta9e. Several 8a,tor u,+ a rotor
aturatio(/
+ape o8 t+e rotor ,ore a(d t+e t!le o8 8ield
,oil
dipoitio( re(der realiatio( o8 a i(uoidal
air9ap
8lu7 1ave impoible.
6+i arti,le detail a( approa,+ to t+e
evaluatio( o8
i(du,ed volta9e 1ave8orm i( a turbo9e(erator/
-ua(ti8i,atio( o8 +armo(i, volta9e ma9(itude
a(d
,omputatio( o8 6elep+o(e Harmo(i, ,apabilit! o8
t+e ma,+i(e C all at dei9( ta9e.
2.0E ANAL;S'S
O8 t+e everal approa,+e propa9ated/ t+e 0E
met+od
+a 8ou(d i(,reai(9 a,,epta(,e 8rom i(dutr!.
6+e
8ormulatio( o8 t+e 0E. a(d it appli,atio( to
ma9(eti, 8ield a(al!i +a bee( ade-uatel!
detailed
ele1+ereH3 to DI. 6+e 0E approa,+ i t+e
,+eapet/
8atet a(d ,ertai(l! t+e uret 1a! to t+e
predi,tio(
o8 ma,+i(e parameter at dei9( ta9e. 6+e
8ield
olutio( i o(l! t+e 8irt tep i( t+e a(al!i
pro,e. .ore importa(t a(d releva(t i( i(dutr! are t+e
ma,+i(e parameter derivable 8rom t+e 8ield
olutio(.
6+e availabilit! o8 a88ordable de%2top
,omputi(9 po1er a(d t+e arrival o8 po1er8ul me(u2drive(
o8t1are +ave lar9el! ,o(tributed to t+e
a,,epta(,e o8 u,+ met+od i( dei9( o88i,eH3/2I.
2.36urbo9e(erator .a9(eti, 0ield at
No2 load :redi,tio( o8 t+e i(du,ed volta9e 1ave8orm i( a
turbo9e(erator (e,eitate etimatio( o8 t+e
(o2load
ma9(eti, 8ield ditributio( i( t+e ma,+i(e. At
(o2
load/ t+e i(9l! e7,ited ma9(eti, ,ir,uit o8 t+e
turbo9e(erator pree(t a pi,ture o8 !mmetr! bot+
alo(9 t+e dire,t a(d -uadrature a7i. A !mmetri,
-uarter re9io( o8 t+e ma,+i(e ,ro2e,tio(
e7te(di(9
8rom t+e dire,t a7i to t+e ad#a,e(t -uadrature
a7i i
u88i,ie(t to evaluate t+e (o2load parameter o8 a
t1o2
pole turbo9e(erator. Ho1ever/ i( t+e ,ae o8
+!dro9e(erator/ t+e re9io( 8or a(al!i mut alo
e(ure !mmetr! o8 t+e tator lot. 0i9ure23
+o1 t+e
8lu7 ditributio( i( a !mmetri, -uarter e,tio(
o8 a
t1o2pole turbo9e(erator. 6+e ,orrepo(di(9 8lu7
de(it! ditributio( i +o1( i( 0i9.
2.
>.A'R2)A: 'N&U"6'ON :RO0'LE
6+e air9ap 8lu7 de(it! pro8ile ,a( be
e7tra,ted 8rom
t+e 8lu7 de(it! plot b! mappi(9 t+e 8lu7
de(it! o(
to a( ar, at t+e mea( radiu o8 t+e ma,+i(e
air9ap.
0i9ure2> +o1 t+e radial ,ompo(e(t a(d t+e
8lu7
de(it! ma9(itude mapped alo(9 a mea( air9ap
li(e
o8 t+e ma,+i(e. A ,a( be ee( 8rom t+e 9rap+/
t+e
(ormal ,ompo(e(t o8 t+e 8lu7 de(it! i e-ual
to t+e
ma9(itude o8 t+e 8lu7 de(it! 8or a lar9e
portio( o8
t+e ,urve e7,ept at t+e -uadrature a7i 1+ere
t+e
ta(9e(tial ,ompo(e(t ,o(tribute i9(i8i,a(tl!
to
t+e 8lu7 de(it! ma9(itude. O8 t+e t1o
,ompo(e(t
o8 t+e air9ap 8lu7 de(it!/ o(l! t+e radial
,ompo(e(t
,o(tribute to t+e i(du,ed tator volta9e 1+ile
t+e
perip+eral ,ompo(e(t doe (ot. '( realit!/ t+e
radial
,ompo(e(t o8 t+e air9ap i(du,tio( i ver!
(earl!
e-ual to t+e total i(du,tio( at ever! poi(t i(
t+e
air9ap o8 t+e ma,+i(e.
0'). 3 * 0LU= &'S6R'BU6'ON A6 NO2LOA&
0'). 2 * 0LU= &ENS'6; &'S6R'BU6'ON A6 NO2LOA& 0'). > * A'R)A: 0LU= &ENS'6; :RO0'LE A6 NO2LOA&
>.3Evaluati(9 t+e Volta9e '(du,i(9 0lu7
6+e ue8ul 8lu7 i de8i(ed a t+e 8lu7 li(%i(9
t+e
tator 1i(di(9 a(d ,aui(9 t+e i(du,ed volta9e.
6+i
8lu7 i leer t+a( t+e total 8lu7 b! t+e
amou(t o8
lea%a9e 8lu7. 6+e ue8ul 8lu7 i( a
turbo9e(erator ,a(
be arrived at b! i(te9rati(9 t+e radial
,ompo(e(t o8 t+e air9ap i(du,tio( alo(9 t+e a8ore2me(tio(ed air9ap li(e. 2D BHEL JOURNAL/ September 2006
6+e e7preio( 8or t+e ue8ul 8lu7 per pole i
9ive(
b! 2
u W XYZ.dl[\L'\S8\.8@1bA@3A
1+ere
ui t+e ue8ul 8lu7 per pole i( 1eber
Bi t+e radial ,ompo(e(t o8 t+e air9ap
i(du,tio( i( 6ela
L'i t+e (ett le(9t+ o8 iro( i( meter
S8i t+e ta,%i(9 8a,tor@t!pi,all! arou(d 0.54A
.8i t+e model 8a,tor
4.'N&U"E& E...0 "O.:U6A6'ON
6+e i(du,ed p+ae volta9e i( a >2p+ae !(,+ro(ou
ma,+i(e ,a( readil! be arrived at 8rom t+e ue8ul
8lu7 per pole ,omputed earlier/ to9et+er 1it+
,ertai(
tator 1i(di(9 detail.
6+e i(du,ed e.m.8 per p+ae i 9ive( b! H5/3>/34I2
Ep+ W 4.44\%d\%p\8\6p+\H uI @VoltA@2A
1+ere
%di t+e tator 1i(di(9 ditributio( 8a,tor
%pi t+e tator 1i(di(9 pit,+ 8a,tor
8i t+e 8re-ue(,! i( HertF
6p+i t+e (umber o8 erie tur( per p+ae o8 t+e
tator 1i(di(9 ui t+e ue8ul 8lu7 per pole i( 1eber. B.HAR.ON'" ANAL;S'S 6+e time variatio( o8 t+e i(du,ed e.m.8 i( a
,o(du,tor o8 t+e tator 1i(di(9 i( a
turbo9e(erator +a t+e ame 8orm a t+e pa,e ditributio( o8 t+e
8lu7 de(it! i( t+e air9ap. 6+ere8ore/ o(l! a
i(uoidal
1ave o8 t+e air9ap 8lu7 de(it! ,a( reult i( a
i(e2
1ave i(du,ed volta9e. Several 8a,tor u,+ a
rotor
aturatio(/ +ape o8 t+e rotor ,ore a(d t+e t!le
o8
8ield ,oil dipoitio( re(der realiatio( o8 a
i(uoidal air9ap 8lu7 1ave impoible.
No(2i(uoidal air9ap i(du,tio( u,+ a t+e
o(e
+o1( i( 0i9.> ,a( be reolved i(to a
8u(dame(tal
a(d +i9+er2order ,ompo(e(t ui(9 0ourier
A(al!i.
6+e !mmetri, air9ap 8lu7 de(it! 1ave reult
i(
t+e ,a(,ellatio( o8 eve( +armo(i,/ leavi(9 a
pa,e
ditributio( ,omprii(9 a 8u(dame(tal a(d
+armo(i,
1+i,+ are odd multiple o8 t+e 8u(dame(tal
H5/30/33I2
B WB3i(@]A R B>i(@>]A R BBi(@B]A R ^.
^. R
B(i(@(]A@>A
1+ere B3 i t+e 8u(dame(tal ,ompo(e(t o8 t+e
air9ap 8lu7 de(it! a(d B>/ BB et,. are t+e
t+ird
+armo(i, a(d 8i8t+ +armo(i, ,ompo(e(t
repe,tivel!.
6!pi,al +armo(i, pe,trum o8 t+e air9ap
i(du,tio(
8or a turbo9e(erator i +o1( i( 0i9. 4.
6+e de,ompoed repree(tatio( o8 t+e air9ap
8lu7
de(it! ditributio( e(able ,o(ideratio( o8
t+e
ma,+i(e a +avi(9 2p pair o8 8u(dame(tal
pole@8i,titiouA/ 6p pair o8 pole
,o(tributi(9 to
t+ird +armo(i,/ 30p pair o8 pole ,o(tributi(9
to
8i8t+ +armo(i, ,ompo(e(t a(d/ i( 9e(eral/ 2(p
pole
,o(tributi(9 to t+e (t+ +armo(i, ,ompo(e(t o8
t+e
8ield 8orm. 6+e 8u(dame(tal a 1ell a t+e
+armo(i,
pole 8lu7e 9e(erate e.m.8 o8 ,orrepo(di(9
8re-ue(,!
i( t+e ,o(du,tor/ but t+e proportio( o8
+armo(i,
i( t+e p+ae a(d li(e e.m.8 1ave8orm i redu,ed
due
to 9roupi(9 a(d 8a,tor related to t+e tator
1i(di(9
dipoitio(.
0'). 4 * A'R)A: 'N&U"6'ON HAR.ON'" S:E"6RU. 25 BHEL JOURNAL/ September 2006
6.'N&U"E& VOL6A)E <AVE0OR.
6+e r.m. i(du,ed volta9e per p+ae due to t+e
(t+
+armo(i, ,ompo(e(t o8 t+e 8lu7 de(it! i 9ive( b!
H5/33/3>/34/3BI 2
Ep+ ( W 4.44 %d( %p( 8( _( 6p+ @VoltA@4A
1+ere
Ep+ (Wr.m. i(du,ed p+ae volta9e due to t+e (t+
+armo(i,
%d(Wi(@(`M2A M @(`M2A i t+e ditributio(
8a,tor 8or (t+ +armo(i,
%p(Wi(@(`M2A i t+e pit,+ 8a,tor 8or (t+
+armo(i,
8(W(t+ +armo(i, 8re-ue(,!
_(W@B( r.m.\Li\ aM(A i t+e (t+ +armo(i, 8lu7
( W+armo(i, (umber
6p+W(umber o8 erie tur( per p+ae
a(d
`Wp+ae2belt a(9ular 1idt+ i( ele,. radia(
bW,oil2pit,+ i( ele,. radia(
B( r.m.Wr.m. value o8 t+e (t+ +armo(i, 8lu7
de(it!
LiWa,tive le(9t+ o8 iro(
aWpole2pit,+ i( air29ap
6+e ma9(itude o8 t+e i(du,ed r.m. volta9e due
to
ea,+ o8 t+e +armo(i, ,a( be evaluated ui(9
t+e
above e7preio(.
6+e variatio( i( time o8 t+e 8u(dame(tal/
+armo(i,
a(d ,umulative volta9e ,omputed ui(9 t+e
pro,edure
de,ribed above i +o1( i( 0i9. B 8or a
!(,+ro(ou
9e(erator 1+oe li(e2to2li(e volta9e i 33%V.
A(d 8i(all!/ t+e r.m. value o8 t+e reulta(t
p+ae
volta9e i 9ive( b! H33/32/3>I 2
0'). B * 6;:'"AL "O.:U6E& HAR.ON'" VOL6A)E :RO0'LES 0OR A 33%V )ENERA6OR >0 BHEL JOURNAL/ September 2006
Ep+ WUH@Ep+ 3A2 R @Ep+ >A2 R @Ep+ BA2 R ^ R@Ep+
(A2I
@VoltA^@BA
Ep+ WEp+ 3\UH3 R @Ep+ > M Ep+ 3A2 R ^ R@Ep+
(MEp+ 3A2I
@VoltA^@B.aA
6+e value i( t+e radi,al i ver! (earl! u(it!/
leadi(9
to t+e p+ae volta9e bei(9 e-ual to 8u(dame(tal
alo(e i(,e t+e +armo(i, ma9(itude are mall i(
,ompario( to t+e 8u(dame(tal.
7.6ELE:HONE HAR.ON'" 0A"6OR
6elep+o(eM"ommu(i,atio( li(e ru((i(9 parallel to
po1er 9rid li(e ,a( e7perie(,e evere
i(ter8ere(,e
b! i(du,tio(/ reulti(9 i( +um a(d +i9+ pit,+
(oie
be,aue o8 t+e pree(,e o8 +arm8ul 8re-ue(,ie i(
t+e
9rid. 't i/ t+ere8ore/ (e,ear! to limit t+e
+armo(i,
,o(te(t i( t+e output volta9e 1ave8orm o8 ever!
9e(erator li%el! to be ,o((e,ted to t+e 9rid.
6+e 'E" tet pro,edure a(d re,omme(datio( o(
t+e tolerable limit o8 telep+o(e +armo(i, 8a,tor
@6H0A 8or !(,+ro(ou ma,+i(e i reprodu,ed
belo1 2
D.5.2 Limit * <+e( teted o( ope( ,ir,uit a(d at
rated
peed a(d volta9e/ t+e telep+o(e +armo(i,
8a,tor@6H0A
o8 t+e li(e2to2li(e termi(al volta9e a meaured
a,,ordi(9
to t+e met+od laid do1( i( D.5.> +all (ot e7,eed
t+e
8ollo1i(9 value*
Rated output o8 t+e ma,+i(eL 6H0 >00%<@or$VAAc :N c 3000%<@or%VAAB.0L 3000%<@or$VAAc :N c B000%<@or%VAA>.0L B000%<@or$VAAc :N3.BL 6+e e,tio( D.5.> o8 'E" detail t+e tet a(d t+e approa,+ to be adopted 8or t+e meaureme(t o8 !(,+ro(ou ma,+i(e 6H0. 6+e 6H0 ,apabilit! o8 a ma,+i(e i 9ive( b! 2
6H0@LA W 300.U@E32.d2RE22.d2RE>2.d2R^^
E(2.d2A U
1+ere
E(i t+e r.m. value o8 t+e (t+ +armo(i, o8 t+e
li(e2to2li(e termi(al volta9e
Ui t+e r.m. value o8 t+e li(e2to2li(e
termi(al
volta9e o8 t+e ma,+i(e
d i t+e 1ei9+ti(9 8a,tor 8or 8re-ue(,!
,orrepo(di(9 to (t+ +armo(i,
D.V<AVEVC6HE S:REA&2SHEE6
"O&E
6+e pro,edure detailed i( t+e arti,le +ave
bee(
,oded i(to a dei9( o88i,e utilit! pa,%a9e b!
(ame
V<AVEV. E7,luivel! developed 8or !(,+ro(ou
ma,+i(e/ t+e .i,roo8t E7,el pread2+eet
utilit!
,ode ,ompute a(d dipla! 9rap+i,all! t+e
i(8ormatio( o( +armo(i, volta9e ma9(itudeM
1ave8orm/ ,umulative volta9e 1ave8orm a(d
ma,+i(e
6elep+o(e Harmo(i, 0a,tor @6H0A 8or ea,+
+armo(i,
a(d ,umulative value up to t+e 300t+ +armo(i,.
6+e pro9ram +a built2i( lo9i, to a,,ou(t 8or
triple(
+armo(i, a(d eve( +armo(i, 8rom t+e ,omputed
value 8or li(e a(d p+ae -ua(titie.
6+e ,ode i tru,tured i( t1o level a(d pread
over
32 +eet a(d ,a( be tailored to uit
i(dividual
dei9( o88i,e re-uireme(t. A( overvie1 o8 t+e
,ode
8ollo1 *
6+e .a,+i(e '& Se,tio( o8 t+e utilit! i a(
ide(ti8ier e,tio( 8or dei9( o88i,e
do,ume(tatio(M
re,ord a(d ,o(tai( i(8ormatio( o( ,utomer
(ame/
order (umber a(d ma,+i(e (omi(al rati(9
parti,ular. 6+e pro9ram ue ,olour ,odi(9 to diti(9ui+ u(lo,%ed i(put ,ell 8rom lo,%ed ,oded ,ell. 6+e '(put Se,tio( ee% ma,+i(e dime(io(al
i(8ormatio( u,+ a 9ro le(9t+/ (umber o8
radial
ve(tilati(9 du,t S t+eir 1idt+/ rotor
diameter/
tator i((er diameter/ ,oil2t+ro1/ bar per
lot et,. 6+ee i(put detail are made ue o8 i( t+e ,omputatio( t+rou9+ 8ormulae embedded i( t+e ,ell @0i9. 6A. 6+e "omputatio( Se,tio( ue t+e i(put data to
,ompute +armo(i, 1i(di(9 8a,tor/ pole2pit,+
value 8or ea,+ +armo(i,/ +armo(i, 8lu7 ma9(itude/
>3 BHEL JOURNAL/ September 2006 0'). 6 * 6HE 'N:U6S SHEE6 'N V<AVEVCS:REA&2SHEE6 U6'L'6;
>2 BHEL JOURNAL/ September 2006
i(du,ed p+ae e.m.8 due to ea,+ +armo(i, et, 8or
t+e 8u(dame(tal a(d +armo(i, up to t+e 300t+. 6+e
pro9ram ,a( dete,t a(d dipla! t+e t!pe o8 1i(di(9
emplo!ed. 6+e pro9ram ,a( ta,%le bot+ i(te9ral2
lot
a(d 8ra,tio(al2lot ,+orded 1i(di(9 1+i,+ are ver!
,ommo( 1it+ pra,ti,al !(,+ro(ou ma,+i(e 1it+
t1o2pole ,!li(dri,al rotor ,o(tru,tio( a(d
multiple
alie(t2pole lo12peed +!dro9e(erator.
6+e 6H0 Se,tio( ue t+e embedded +armo(i,
1ei9+ti(9 8a,tor to ,ompute t+e i(dividual a(d
,umulative 6H0 due to ea,+ +armo(i, up to
prede8i(ed i9(i8i,a(t +armo(i,. 6+i e,tio( alo
9e(erate a plot o8 t+e L6H0 veru +armo(i,
(umber/ a +o1( i( 0i9. 7.
Ot+er 0eature *)rap+i,al ,ompario( o8 t+e
relative ma9(itude o8 8u(dame(tal a(d i9(i8i,a(t
+armo(i, @up to3>t+A a(d it variatio( i( time
are
provided to9et+er 1it+ a Foom o8 i9(i8i,a(t
+armo(i,. 6+e 'E"*3556 re,omme(datio( o( t+e
1ei9+ti(9 8a,tor 8or variou 8re-ue(,ie to be
ued
8or t+e ,omputatio( o8 6elep+o(e Harmo(i,
0a,tor
@6H0A +ave bee( built i(to t+e pro9ram. 6+e
air9ap
8lu7 de(it! +armo(i, ma9(itude are ued to
re,o(tru,t a(d ,ompare 1it+ t+e ori9i(al
air9ap
i(du,tio( ,urve.
5."ON"LUS'ON
6+e 0i(ite Eleme(t approa,+ +a bee( ued 8or
t+e
a,,urate etimatio( o8 t+e ma9(eti, 8ield i( a
turbo9e(erator at (o2load. Harmo(i, ,ompo(e(t
o8
t+e air9ap i(du,tio( ,omputed 8rom t+e air9ap
i(du,tio( pro8ile +ave bee( ued to arrive at
t+e
+armo(i, volta9e ma9(itude a(d t+e ,umulative
i(du,ed volta9e 1ave8orm ui(9 a ,ode
pe,i8i,all!
0'). 7 * 6H0 "ON6R'BU6'ON 0RO. 'N&'V'&UAL HAR.ON'"S AN& "U.ULA6'VE VAR'A6'ON <'6H 'N"REAS'N) HAR.ON'" NU.BER
>> BHEL JOURNAL/ September 2006
developed. 6+e a(al!i i(di,ate t+at 8or a V(V
lot
ma,+i(e/ t+e @(23At+ +armo(i, a(d t+e @(R3At+
+armo(i, are predomi(a(tH33I. 6+e 6elep+o(e
Harmo(i, 0a,tor or t+e 6elep+o(e '(ter8ere(,e
0a,tor +ave bee( ,omputed 8or t+e ma,+i(e
a(al!ed.
6+e +armo(i, level o8 t+e air9ap i(du,tio( are
di,tated b! t+e air9ap i(du,tio( pro8ile 1+i,+/ i(
tur(/ re8le,t t+e radial air9ap permea(,e
pree(ted
b! t+e ma9(eti, bou(darie ,o(tituted b! t+e
tator
a(d rotor iro(. A eparate tud! i(veti9ati(9 t+e
depe(da(,e o8 6H0 o( aturatio( i( t+e ma,+i(e
i u(der 1a!.
Re8ere(,e
@3A..V.$. "+ari/ :.Silveter/ VA(al!i o8
6urboalter(ator .a9(eti, 0ield b! 0i(ite
Eleme(tV/ 'EEE 6ra(. o( :AS/ Vol2:AS250/
No*2/ .ar,+2April 3573/ pp.4B4 to 464.
@2A..V.$. "+ari V0i(ite Eleme(t A(al!i o8
Ele,tri,al .a,+i(er! a(d &evi,eV/ 'EEE
6ra(.
o( .a9(eti,/ Vol..A)236/ No.B/ Sept.35D0/
pp. 3034 to 3035.
@>A..V.$. "+ari/ VNo(li(ear 0i(ite Eleme(t
Solutio( o8 Ele,tri,al .a,+i(e U(der No2
load
a(d 0ull2Load "o(ditio(V/ pp.6D6 to 6D5.
@4A:.Silveter a(d ..V.$. "+ari/ V0i(ite Eleme(t
olutio( o8 Saturable .a9(eti, 0ield
:roblemV/
'EEE. 6ra(. o( :AS/ Vol.:AS2D5/ No.7/ Sept2
O,t 3570/ pp.3642 to 36B3. @BA:. Silveter/ H.S. "aba!a( a(d B.6. Bro1(e/
VE88i,ie(t 6e,+(i-ue 8or 0i(ite Eleme(t
a(al!i o8 Ele,tri, .a,+i(eV/ 'EEE 6ra(. o( :AS/ Vol.:AS252 3573/pp.3274 to 32D3. @6A:arviF Ra8i(e#ad et al/V0i(ite Eleme(t "omputer :ro9ram i( &ei9( o8
Ele,troma9(eti, &evi,eV/ 'EEE 6ra(. o(
.a9(eti,/ Vol. .A)232/ No.B/ Sept3576/
pp.B7B to B7D.
@7A.ulu%utla S.Sarma/ V.a9(etotati, 0ield
"omputatio( b! 0i(ite Eleme(t
0ormulatio(V/
'EEE. 6ra(. o( .a9(eti,/ Vol..A)232/
No.6/
Nov3576/ pp30B0 to 30B2.
@DAJ.R. Brauer/ E.A. Aro(o( et al/V6+ree
&ime(io(al 0i(ite Eleme(t "al,ulatio( o8
Saturable .a9(eti, 0lu7e a(d 6or-ue o8
a(
A,tuatorV/ 'EEE. 6ra(. o( .a9(eti,/
Vol..A)224/ No.3/ Ja(uar! 35DD/ pp4BB to
4BD.
@5A..). Sa!/ V6+e :er8orma(,e a(d &ei9( o8
Alter(ati(9 "urre(t .a,+i(eV/ Sir 'aa,
:itma( S So(/ Lo(do(.
@30ARalp+ R.La1re(,e S He(r! E. Ri,+ard/
V:ri(,iple o8 Alter(ati(9 "urre(t
.a,+i(er!V/
.,)ra12Hill Boo% "ompa(!/ USA.
@33AAle7a(der S. La(9dor8/ V6+eor! o8
Alter(ati(92
"urre(t .a,+i(er!V/ .,)ra12Hill Boo%
"ompa(!/ USA.
@32ARobert L.Ame/ VA.". )e(erator* &ei9(
a(d
Appli,atio(V/Jo+( <ile! S So(/ USA.
@3>A.ulu%utla S. Sarma/ VS!(,+ro(ou .a,+i(e
2 6+eir 6+eor!/ Stabilit! a(d E7,itatio(
S!temV/ )ordo( S Brea,+ S,ie(,e
:ubli+er/ Ne1 ;or%.
@34AEam S. Hamdi/ V&ei9( o8 Small
Ele,tri,al .a,+i(eV/ Jo+( <ile! S So(/ USA. @3BABria( "+almer S Ala( <illiamo(/ VA.".
.a,+i(e 2 Ele,troma9(eti, a(d &ei9(V/
Jo+( <ile! S So( '(,/ USA.
.r. ". :rem $umar obtai(ed +i E(9i(eeri(9
de9ree 8rom Ba(9alore U(iverit! i( t+e !ear
357B.
.r. :rem $umar #oi(ed BHEL at t+e "orporate
RS& &iviio(/ H!derabad/ a8ter a brie8 ti(t
1it+
.M Oblum Ele,tri,al '(dutrie/ H!derabad.
"urre(tl!/ +e i 1or%i(9 at t+e Ele,tri,al
.a,+i(e
Lab i( t+e RS& "omple7/ a Se(ior &eput!
)e(eral .a(a9er. He pe,ialiFe i( t+e modelli(9
a(d a(al!i o8 lar9e rotati(9 ele,tri,al
ma,+i(e
ui(9 t+e 0i(ite Eleme(t approa,+.
.r. :rem $umar +a everal paper to +i ,redit/
publi+ed S pree(ted i( (atio(al S
i(ter(atio(al
8orum.
>B BHEL JOURNAL/ September 2006
E00E"6 O0 :RELOA& 0A"6OR AN& <ORN &E:6H ON
6HE &;NA.'" "OE00'"'EN6S AN& S6AB'L'6; O0 A
LOA&'N) AR" @<ORNA 6<O2LOBE BEAR'N) USE&
'N 6URBO2)ENERA6OR
$. &ar9aia+ a(d :. $amalam
S;NO:S'S
6+i paper i t+e e7te(io( o8 a( earlier paper
publi+ed
i( BHEL Jour(al/ @Vol. 26 No.3 0ebruar! 200BA/
1+erei( it 1a ,o(,luded t+at t+e load ,apa,it! o8
a
loadi(9 ar, @1or(A t1o2lobe beari(9 ued i( turbo2
9e(erator i 8ou(d +i9+er a(d t+at t+e tabilit!
Fo(e i
limited 1+e( ,ompared to a (ormal t1o2lobe beari(9
1it+out loadi(9 ar, @ eo W0.0A ued i( team turbi(e. '(
t+e pree(t paper/ t+e tabilit! @1+irl
o(etMt+re+old
peedA o8 a 1or( t1o2lobe beari(9 LM&W0.D2 o8
Sieme( dei9( ued i( turbo29e(erator 1a tudied
at
di88ere(t preload 8a,tor a(d 1or( dept+. Beari(9
per8orma(,e data 1a obtai(ed at preload 8a,tor
@deltaA W 0.B/ 0.6 a(d 0.7B a(d (o(2dime(io(al
1or(
dept+ @ Aeo A W 0.0/ 0.3 a(d 0.2/ 1+i,+ are o8
pra,ti,al
importa(,e i( t+e dei9( o8 turbo29e(erator
beari(9.
6+e reult pree(ted i( t+i paper +elp t+e
dei9(er i(
ele,ti(9 a uitable ,ombi(atio( o8 preload
8a,tor a(d
1or( dept+ i( order to obtai( t+e deired
beari(9
per8orma(,e i( term o8 Sommer8eld (umber
@3Mload
,apa,it!A/ d!(ami, ,oe88i,ie(t a(d tabilit!.
6+e beari(9
d!(ami, ,oe88i,ie(t are ue8ul 8or rotor
d!(ami,
a(al!i.
$e! <ord*
61o2lobe Beari(9G Loadi(9 Ar, @1or( re9io(AG
<ear
&ept+ @1ear de(tAG <+irl O(et @6+re+oldA
Speed.
NO.EN"LA6URE
"+Wide ,leara(,e @mA or "p W pad radial ,leara(,e
"vWtop ,leara(,eM2 @mA or "b W beari(9 radial ,leara(,e &Wbeari(9 diameter @mA &eltaW:re load 8a,tor W @"+2"vAM"+ eWe,,e(tri,it! @mA 9W9ravitatio(al ,o(ta(t @mMe,2A +W8ilm t+i,%(e @mA LWbeari(9 le(9t+ @mA NWrotati(9 peed @rpA RW&M2 @mA <Wload o( t+e beari(9 @NA pu(itW<ML&/ u(it preure o( t+e beari(9 @.paA fWA(9ular peed o8 #our(al @radMe,A
gWe,,e(tri,it! ratio @eM"+A
eW1ear dept+ @mmA
eoWma7imum 1ear dept+ @mmA
hWlubri,a(t vi,oit! @N e,Mm2A
$i#/ 1+ere iW7/! S #W7/!Wti88(e ,oe88i,ie(t @NMmA
"i#/ 1+ere iW7/! S #W7/!Wdampi(9 ,oe88i,ie(t @N e,MmA
No(2dime(io(al -ua(titie*
SWSommer8eld (umberW@hNL&M<A@RM"+A2
AeoW(o(2dime(io(al ma7imum 1ear dept+WeoM"+
iW(o(2dime(io(al 1+irl o(et @t+re+oldA peedWf@"+M9A3M2
A$i#^/W(o(2dime(io(al ti88(e ,oe88i,ie(tW$i# @"+M<A
A"i#^/W(o(2dime(io(al dampi(9 ,oe88i,ie(tW"i# @"+fM<A
3.'N6RO&U"6'ON
Loadi(9 ar, @1or(A t1o2lobe #our(al beari(9 are
ued i( upporti(9 t+e +eav! rotor o8 turbo2
9e(erator. 6+ee beari(9 are ori9i(all! dei9(ed
b! Sieme(. Load per u(it area o( t+i t!pe o8
beari(9 i +i9+ @arou(d 2.B .:aA 1+e( ,ompared
to a (ormal t1o2lobe beari(9 1it+out loadi(9 ar,
ued i( team turbi(e. 6+e loadi(9 ar, o8 a
t1o2
lobe beari(9 i imilar to lemo( t!pe beari(9
1it+ a ,!li(dri,al ur8a,e 60 de9. ar, ma,+i(ed
at t+e bottom +al8 o8 t+e beari(9 @0i9.3A. 6+e
ma7imum dept+ @1ear dept+A o8 a loadi(9 ar, i
alo a ,riti,al parameter i( additio( to
preload
8a,tor/ 1+i,+ a88e,t t+e beari(9 per8orma(,e
,o(iderabl!.
0'). 3 * NO.EN"LA6URE O0 A LOA&'N) AR" @<ORNA 6<O2LOBE BEAR'N)
&u8ra(e et al H3I +ave etabli+ed 1ear pro8ile
model 8rom a,tual meaured data a(d modi8ied
t+e 8ilm t+i,%(e e-uatio( a a 8u(,tio( o8 1ear
dept+ @0i9.3A. Ha+imoto et al H2/>I tudied t+e
tead! tate a(d d!(ami, ,+ara,teriti, o8 1or(
,!li(dri,al #our(al beari(9 @LM&W3A i( bot+
lami(ar
a(d turbule(t re9ime. 6+e! ,o(,luded t+at t+e
t+re+old peed @1+irl o(etA 8or 1or( #our(al
beari(9 o8Aeo c 0.> i lo1er/ a(d t+at 8orAeo j
0.>
i +i9+er/ t+a( t+at o8 (o(21or( beari(9. 6a(a%a
a(d Hori H4I a(d 6a(a%a a(d SuFu%i HBI made
t+eoreti,al a(d e7perime(tal tudie repe,tivel!
o(
a li9+tl! loaded +i9+2peed t1o2lobe #our(al
beari(9
1it+ 1ear de(t/ a(d ,o(,luded t+at t+e li(ear
tabilit! i 8ou(d to 1ore( drati,all! due to
1ear
de(t. 6+e aut+or o8 t+i paper earlier pree(ted
H6I
t+e a(al!i a(d per8orma(,e data o8 a +eavil!
loaded 1or( t1o2lobe beari(9 @LM&W0.D2/ preload
8a,tor W 0.67>A at di88ere(t (o(2dime(io(al 1ear
dept+ 8rom 0.0 to 0.2. '( t+e pree(t paper/ t+e
beari(9 (o(2dime(io(al data/ 1+i,+ i(,lude tead!
tate/ d!(ami, ,oe88i,ie(t a(d 1+irl o(et
@t+re+oldA peed o8 a ri9id rotor/ i pree(ted
i(
9rap+i,al 8orm at di88ere(t 1ear dept+ 8rom 0 to
0.2. E88e,t o8 preload 8a,tor a(d 1ear dept+ o(
t+e
beari(9 per8orma(,e i di,ued. 6+i paper i
t+e
e7te(io( o8 a( earlier 1or% H6I a(d it +elp t+e
dei9(er i( ele,ti(9 a uitable ,ombi(atio( o8
preload 8a,tor a(d 1or( dept+ i( order to obtai(
t+e deired beari(9 per8orma(,e i( term o8
Sommer8eld (umber @3Mload ,apa,it!A/ d!(ami,
,oe88i,ie(t a(d tabilit!.
2.H;&RO&;NA.'" ANAL;S'S 6+e (o(2dime(io(al +!drod!(ami, e-uatio( 8or beari(9 lubri,atio( H7I i 9ive( b!* M ] @A+k ApM ]A R rV M F @A+k ApM FA W 2>g i( ] R 6 @Au i( b3 RAv ,o b3A@3A 0ilm t+i,%(e e-uatio( i 9ive( b!* A+@]A W 3Rg ,o]/ 8or (o(21or( re9io(@2A A+@]A W3Rg,o] RAe@]A/ 8or 1or( re9io(@>A
1+ere t+e 1or( pro8ile H3I i 9over(ed b!*
Ae@]AW Aeo 2 @3 R ,o ]AAe j
0
W 0/ ot+er1ie@4A
E-uatio( @3A i olved 8or p @preureA b!
8i(ite
eleme(t met+od @0E.A 1it+ Re!(old bou(dar!
,o(ditio( 8or (o(21or( a(d 1or( re9io( H7I.
61o
,ompo(e(t o8 oil 8ilm 8or,e/ 07 a(d 0!/ are
obtai(ed b! i(te9rati(9 t+e ,al,ulated preure
ditributio(. 6+e e-uilibrium poitio( o8 t+e
#our(al
,e(tre i obtai(ed b! ma%i(9 07 W 0 b! ,+a(9i(9
t+e
attitude a(9le. 6+e load ,apa,it! o8 t+e
beari(9 i 0!
at t+e e-uilibrium poitio(. S/ Sommer8eld
(umber/
i 3M0!. 6+e tead! tate per8orma(,e
,+ara,teriti,/
li%e oil 8lo1 rate/ po1er lo/ temperature2
rie a(d
mi(imum oil 8ilm t+i,%(e/ i obtai(ed at
e-uilibrium poitio( 8or di88ere(t e,,e(tri,it!
ratio.
Sti88(e a(d dampi(9 ,oe88i,ie(t are obtai(ed
ui(9
t+e met+od 9ive( b! S+a(9 a(d &ie( H6I. 6+i
met+od +elp to obtai( ei9+t d!(ami,
,oe88i,ie(t
b! olvi(9 Re!(old e-uatio( o(l! o(,e. '( t+e
pree(t paper/ t+e 8i(ite eleme(t met+od ued
i t+e
ame a i( H7I. 0our ti88(e a(d 8our dampi(9
,oe88i,ie(t are ued 8or ,omputi(9 t+e 1+irl
o(et
@t+re+oldA peed. Rout+2Hur1itF ,riterio( 1a
ued
8or tabilit! a(al!i aumi(9 a ri9id rotor
upported
o( t1o ide(ti,al !mmetri,all! ali9(ed beari(9
H>I.
'( t+e pree(t paper/ t+e (o(2dime(io(al
reult o8
8our ti88(e a(d 8our dampi(9 ,oe88i,ie(t
a(d
t+re+old peed are pree(ted a a 8u(,tio( o8
Sommer8eld (umber at di88ere(t preload 8a,tor
a(d 1or( dept+. >.RESUL6S AN& &'S"USS'ON
0i9ure 224 +o1 t+e variatio( o8 oil 8ilm
ti88(e
,oe88i,ie(t @A$iiA at 1or( dept+ @AeoW0.02
0.2A a(d preload 8a,tor @deltaA 0.B/ 0.6 a(d 0/7B 1it+ Sommer8eld (umber @SA. 't ,a( be ee( 8rom t+e
9rap+ t+atA$!! i.e. verti,al ti88(e i
i(,reai(9 1it+ i(,reae i( delta at all S. Ho1ever/ t+ee
,oe88i,ie(t are (o(2li(ear 1.r.t S. A$77/ i.e.
+oriFo(tal
ti88(e/ i de,reai(9 1it+ i(,reae i( delta
at all
S 8or (o(21or( beari(9 @AeoW0.0A/ 1+erea 8or
ot+er 1or( beari(9 @eoW0.3 a(d 0.2A/ it i li9+tl!
>D BHEL JOURNAL/ September 2006
0'). 2 *VAR'A6'ON O0 S6'00NESS "OE00'"'EN6 @$iiA <'6H SO..ER0EL& NU.BER@SA A6 &'00EREN6 :RELOA&
0A"6ORS @&EL6AA 0OR LM& W 0.D2/A eeee
e
oW0.0
0'). > *VAR'A6'ON O0 S6'00NESS "OE00'"'EN6 @$iiA <'6H SO..ER0EL& NU.BER@SA A6 &'00EREN6 :RELOA&
e
oW0.3
0'). 4 *VAR'A6'ON O0 S6'00NESS "OE00'"'EN6 @$iiA <'6H SO..ER0EL& NU.BER@SA A6 &'00EREN6 :RELOA& 0A"6ORS @&EL6AA 0OR LM& W 0.D2/A
eeee
eoW0.2
i(,reai(9. 0i9ure B27 +o1 t+e variatio( o8 t+e
,ro ti88(e ,oe88i,ie(t @A$i#A at 1or( dept+
@AeoW0.020.2A a(d preload 8a,tor @deltaA 0.B/
0.6
a(d 0.7B 1it+ Sommer8eld (umber @SA. 't i
oberved t+at t+ee ,oe88i,ie(t are (o(2li(ear.
A$7!
i (e9ative 8or all value o8 S 8or 1or( beari(9
a(d
ome value o8 S 8or (o(21or( beari(9. 0i9ure D2
30 +o1 t+e variatio( o8 dampi(9 ,oe88i,ie(t
@A"i#A
1it+ Sommer8eld (umber @SA/ at 1or( dept+
@AeoW0.020.2A a(d preload 8a,tor @deltaA 0.B/
0/6
a(d 0.7B. 't ,a( be ee( 8rom t+e 9rap+ t+at A"77
a(d A"!! are i(,reai(9 1it+ i(,reae i( delta/
a(d
,ro dampi(9 ,oe88i,ie(t @A"7!WA"!7A are 8ou(d
to be (e9ative a8ter ,ertai( value o8 S/ a(d
dampi(9
,oe88i,ie(t are alo +i9l! (o(2li(ear. 0i9ure
332
3> +o1 t+e 1+irl o(et @t+re+oldA peed @iA
1it+
S at preload 8a,tor @0.B/ 0.6 a(d 0.7BA a(d 1or(
dept+ @0.020.2A. 0or (o(21or( beari(9 @0i9. 33A/
t+e beari(9 i al1a! table at deltaW0.B 8rom
SW0.0237 to 0.>BD6/ at deltaW0.6 8rom SW0.0B>05
to 0.2BB6/ a(d at deltaW0.7B 8rom SW0.0>4B to
0.3>65. 't ,a( be oberved 8rom reult t+at
tabilit!
parameter i de,reai(9 1it+ i(,reae i( preload
8a,tor 8or (o(21or( beari(9 @AeoW0.0A. Similar
tre(d ,a( be ee( 8or 1or( beari(9 @0i9. 3223>A
1it+ di88ere(t table re9io( o8 operatio(.
4."ON"LUS'ONS
A t+eoreti,al tud! +a bee( ,arried out at
di88ere(t
preload 8a,tor @0.B/0.6 a(d 0.7BA a(d 1or( dept+
@0.0/ 0.3/ a(d 0.2A o( t+e loadi(9 ar, @1or(A t1o2 lobe beari(9 @LM& W0.D2Aued i( turbo 9e(erator o8
Sieme( dei9(/ a(d t+e 8ollo1i(9 ,o(,luio(
are
dra1(.
'.:reload 0a,tor*
Sti88(e
,oe88i,ie(t*
Verti,al oil 8ilm ti88(e
@A$!!A
i i(,reai(9 a(d +oriFo(tal oil 8ilm ti88(e
@A$77A
i de,reai(9 1it+ i(,reae i( preload 8a,tor
8or (o(2
1or( beari(9 @AeoW0.0A/ 1+erea verti,al
ti88(e i
i(,reai(9 at +i9+er rate t+a( +oriFo(tal
ti88(e 8or
1or( beari(9 @AeoW0.3a(d 0.2A at all
Sommer8eld
(umber. "ro ti88(e ,oe88i,ie(t @A$!7A i
i(,reai(9 a(d @A$7!A i de,reai(9 1it+
i(,reae i(
delta at all value o8 S. 6+ee ,oe88i,ie(t
are (o(2
li(ear.
&ampi(9 ,oe88i,ie(t* Verti,al @A"!!A a(d
+oriFo(tal
@A"77A dampi(9 ,oe88i,ie(t are i(,reai(9 a(d
,ro
dampi(9 ,oe88i,ie(t @A"7!WA"!7A are de,reai(9
1it+ i(,reae i( delta at all value o8 S a(d
t+e! are
(o(2li(ear.
<+irl o(et @t+re+oldA peed
@
iiii
i
A* Stabilit! parameter
i de,reai(9 1it+ i(,reae i( preload 8a,tor
8or (o(2
1or( a(d 1or( beari(9 @AeoW0.0 to 0.2A/
Similar
tre(d ,a( be ee( 8or 1or( beari(9 @0i9. 322
3>A
1it+ di88ere(t table re9io( o8
operatio(.
''.<or( &ept+* Stabilit! ra(9e o8
Sommer8eld
(umber 8or di88ere(t preload 8a,tor a(d
1or( dept+ i 9ive( i( 6able23.
6+e above 6able i ver! ue8ul 8or ,+e,%i(9 t+e
tabilit! o8 e7iti(9 beari(9 a(d 8or dei9(i(9
a (e1
beari(9 o8 LM& W 0.D2/ +eavil! loaded 6)
beari(9. 6ABLE2' * S6AB'L'6; RAN)E O0 SO..ER0EL& NU.BERS :reload 0a,tor @deltaA <or( &ept+ @A
eeee
e oA0.B0.60.7B 0.000.0237 2 0.>BD60.0B>3 2 0.2BB60.0>4B 2 0.3>65 0.300.023B 2 0.3B260.03D3 2 0.32530.037> 2 0.0>7> 0.200.066> 2 0.34540.04B2 2 0.32040.0355 2 0.075D
0'). B *VAR'A6'ON O0 "ROSS S6'00NESS "OE00'"'EN6 @$i#A <'6H SO..ER0EL& NU.BER@SA A6 &'00EREN6
:RELOA& 0A"6ORS @&EL6AA 0OR LM& W 0.D2/A eeee
e
oW0.0
0'). 6 *VAR'A6'ON O0 "ROSS S6'00NESS "OE00'"'EN6 @$i#A <'6H SO..ER0EL& NU.BER@SA A6 &'00EREN6
e
oW0.3
0'). 7 *VAR'A6'ON O0 "ROSS S6'00NESS "OE00'"'EN6 @$i#A <'6H SO..ER0EL& NU.BER@SA A6 &'00EREN6 :RELOA& 0A"6ORS @&EL6AA 0OR LM& W 0.D2/A
eeee
eoW0.2
0'). D *VAR'A6'ON O0 &A.:'N) "OE00'"'EN6 @"i#A <'6H SO..ER0EL& NU.BER@SA A6 &'00EREN6 :RELOA&
e
oW0.0
0'). 5 *VAR'A6'ON O0 &A.:'N) "OE00'"'EN6 @"i#A <'6H SO..ER0EL& NU.BER@SA A6 &'00EREN6 :RELOA&
e
oW0.3
0'). 30 *VAR'A6'ON O0 &A.:'N) "OE00'"'EN6 @"i#A <'6H SO..ER0EL& NU.BER@SA A6 &'00EREN6 :RELOA& 0A"6ORS @&EL6AA 0OR LM& W 0.D2/A
eeee
eoW0.2
0'). 33 *VAR'A6'ON O0 6HRESHOL& S:EE& @<H'RL ONSE6A <'6H SO..ER0EL& NU.BER@SA A6 &'00EREN6
e
oW0.00
0'). 32 *VAR'A6'ON O0 6HRESHOL& S:EE& @<H'RL ONSE6A <'6H SO..ER0EL& NU.BER@SA A6 &'00EREN6
e
oW0.3
0'). 3> *VAR'A6'ON O0 6HRESHOL& S:EE& @<H'RL ONSE6A <'6H SO..ER0EL& NU.BER@SA A6 &'00EREN6 :RELOA& 0A"6ORS @&EL6AA 0OR LM& W 0.D2/A
eeee
eoW0.2
6+e dei9(er +ould ele,t a( optimum 1ear dept+
a(d preload 8a,tor 1+i,+ +ould ati8! bot+ load2
,arr!i(9 ,apa,it! @3MSA a(d tabilit! limit peed
1+ile dei9(i(9 a loadi(9 ar, t1o2lobe #our(al
beari(9. 6+e reult i.e./ tead! tate/ d!(ami,
,oe88i,ie(t a(d t+re+old peed data/ pree(ted
i(
t+i paper/ ,a( be ued 8or per8orma(,e evaluatio(
o8 loadi(9 ar, t1o2lobe beari(9 8or di88ere(t
load/
peed a(d lubri,a(t ,o(ditio(. Alo/ t+e beari(9
d!(ami, ,oe88i,ie(t data ,a( be ued 8or rotor
d!(ami, a(al!i.
Re8ere(,e
3.&u8ra(e/ $.0./ $a((el/ J.<./ a(d .,"lo%e!/
6.H./ V<ear o8 Steam 6urbi(e Jour(al
Beari(9
at Lo1 Operati(9 SpeedV/ AS.E 6ra(./
Jour(al o8 Lubri,atio( 6e,+(olo9!/ Vol.
30B/
Jul! 35D>/ pp. >3>2>37.
2.Ha+imoto / H./ <ada / S./a(d No#ima/ $./
V:er8orma(,e "+ara,teriti, o8 <or(
Jour(al
Beari(9 i( Bot+ Lami(ar a(d 6urbule(t
Re9imeV. :art '* Stead! State
,+ara,teriti,V/
ASLE 6ra(. Vol. 25/35D6/ 4/ B6B2B73.
>.Ha+imoto / H/ <ada / S./ a(d No#ima/ $./
V:er8orma(,e ,+ara,teriti, o8 <or(
Jour(al
Beari(9 i( Bot+ Lami(ar a(d 6urbule(t
Re9ime. :art ''* &!(ami,
"+ara,teriti,V/
ASLE Vol. 25/35D6/ 4/ B722B77.
4.6a(a%a/ ../ a(d Hori/ ;./ VStabilit!
"+ara,teriti, o8 <or( Jour(al
Beari(9V/
:ro,. >rd '06O.. Rotor d!(ami,
,o(8ere(,e/
L!o(/3556/5>257.
B.6a(a%a/ ../ a(d SuFu%i/ $./ VE7perime(tal
Veri8i,atio( o8 Stabilit! "+ara,teriti,
o8 61o2
Lobe Jour(al Beari(9 1it+ Sur8a,e <ear
&e(tV/ 'me,+E/ 3556/ pp. 34>23B0.
6.&ar9aia+/$./ a(d $amalam/:./ VA(al!i a(d
:er8orma(,e &ata o8 a Loadi(9 Ar,@1or(A
t1o2lobe beari(9 ued i( 6urbo2
)e(eratorV/
BHEL #our(al/ vol. 2B No.2/ 0ebruar!
200B.
7.S+a(9/ L./ a(d &ie(/ '.$./ V A matri7
.et+od 8or "omputi(9 t+e Sti88(e a(d
&ampi(9 "oe88i,ie(t o8 .ulti2Ar, Jour(al
Beari(9V/ S6LE 6ribolo9! 6ra(./ Vol.>2/
35D5/pp.>572404
D.&ar9aia+/ $./ $amalam/ :./ a(d :rab+u/
B.S./
VA 0i(ite Eleme(t .et+od 8or "omputi(9
&!(ami, "oe88i,ie(t o8 .ulti2Lobe
Jour(al
Beari(9V/ S6LE/ 6ribolo9! 6ra(a,tio(/
Vol.
>6/355>/ No.3./ pp. 7>2D>.
.r. $. &ar9aia+ 9raduated i( .e,+a(i,al
E(9i(eeri(9 8rom t+e Oma(ia E(9i(eeri(9
"olle9e/ H!derabad/ i( 3576/ a(d ,ompleted
..S. 8rom t+e Ja1a+arlal Ne+ru 6e,+(olo9i,al
U(iverit!/ H!derabad/ i( 35D4. He obtai(ed +i
:+.&. de9ree 8rom ''62.adra i( 3554.
&r. &ar9aia+ #oi(ed t+e "orporate RS& &iviio(
o8 BHEL/ H!derabad/ i( 3577. He 1a a,tivel!
i(volved i( etti(9 up t+e 6ribolo9! Laborator!
i(
t+i RS& "omple7. He +a developed a #our(al
beari(9 tet ri9 a(d ,arried out a (umber o8
e7perime(tal a(d a(al!ti,al i(veti9atio( o(
,!li(dri,al/ ri(92lubri,ated/ multi2lobe a(d
tilti(9
pad +!drod!(ami, #our(al beari(9. At pree(t/
+e i 1or%i(9 a &eput! )e(eral .a(a9er i( t+e
.a,+i(e &!(ami, Laborator! o8 t+e RS&
"omple7.
&r. &ar9aia+ +a pree(ted S publi+ed a (umber
o8 paper i( t+e area o8 +!drod!(ami, #our(al
beari(9/ i( (atio(al a 1ell a i(ter(atio(al
,o(8ere(,e a(d #our(al o( 6ribolo9!.
.. :. $amalam did +er :ot29raduatio( i(
.at+emati, 8rom t+e .adra U(iverit! a(d
,ompleted +er do,torate 8rom '(dia( '(titute o8
S,ie(,e/ Ba(9alore/ i( 357B.
&r. $amalam #oi(ed "orporate RS& &iviio( o8
BHEL/ H!derabad/ i( 3577. Here/ +e +a bee(
a,tivel! i(volved i( reear,+ i( t+e 8ield o8
Heat
6ra(8er/ Ele,tro .a9(etim a(d 6ribolo9!. S+e
developed 0E. pro9ram i( t+e area o8
,!li(dri,al/
multi2lobe a(d tilti(9 pad beari(9. S+e alo
developed 0E. pro9ram i( t+e 8ield o8
ele,troma9(eti, 8or tra(8ormer. At pree(t/
+e
i 1or%i(9 a Se(ior &eput! )e(eral .a(a9er i(
Ele,tri,al .a,+i(e Laborator! o8 t+e RS&
"omple7.
&r. $amalam +a pree(ted S publi+ed a (umber
o8 paper i( t+e area o8 beari(9/ i(
i(ter(atio(al ,o(8ere(,e a(d #our(al o( 6ribolo9!.
"OLLE"6'ON/ HAN&L'N) AN& 6REA6.EN6 O0
L'?U'& E00LUEN6S 'N 6HER.AL :O<ER :LAN6
:. S+a(dil!a/ S.S. :+o9at/ ).S. .a+al/ S. Bala#i a(d Sud+ir
B+arti!a
S;NO:S'S
:o1er pla(t ue 8uel/ air a(d 1ater i(put a(d
9e(erate ele,tri, po1er. Li-uid/ olid a(d 9aeou
e88lue(t are alo 9e(erated i( t+e pro,e o8
po1er
9e(eratio(.
A+ i t+e ma#or olid 1ate. 't i 9e(erall!
pumped to
a+ po(d/ a a+ lurr!. A per t+e ,urre(t
pollutio(
(orm/ a+ i to be 300L utiliFed a(d +e(,e
dipoed
o8 a dr! a+.
)aeou emiio( are SO=/ NO=/ "O2/ a(d
parti,ulate
matter i( t+e 8lue 9ae. 6+ee are ,urre(tl!
,o(trolled
b! ES: a(d proviio( o8 tall ,+im(e! to meet
pollutio(
(orm.
6+e li-uid e88lue(t ma! ,o(tai( o(e or more o8
t+e
,o(tami(a(t li%e +i9+ upe(ded olid/ oil/ +i9+
diolved olid/ +i9+ reidual ,+lori(e/ pH value
outide
t+e permitted ra(9e et,. 6+e a,,eptable limit o8
t+ee
polluta(t are pe,i8ied b! t+e pollutio( ,o(trol
aut+oritie.
)e(eratio( o8 e88lue(t depe(d o( t+e i(put
-ua(titie/
pro,e ued a(d (ature o8 pla(t operatio(/ 1+i,+
ma!
be ,o(ti(uou/ i(termitte(t or ver!
i(8re-ue(t.
6+e proviio( 8or ,olle,tio(/ treatme(t a(d
dipoal o8
li-uid e88lue(t (eed to be vie1ed i( t+e ,o(te7t
o8
pra,ti,al ape,t o8 li-uid +a(dli(9/ i(,ludi(9
e-uipme(t
ele,tio( 8or rated 8lo1 a(d 8re-ue(,! M duratio(
o8 e-uipme(t M !tem operatio(. 6+i paper deal 1it+ t+e (ature a(d 8re-ue(,! o8
li-uid e88lue(t 9e(erated i( ,oal28ired M
,ombi(ed2,!,le
pro#e,t/ a(d t+eir +a(dli(9 S treatme(t/ 9ivi(9
due
,o(ideratio( to t+e operati(9 pra,ti,e/
i(tallatio( ,ot a(d ,ode re-uireme(t.
$e! <ord*
E88lue(tG :ollutio(G Emiio(G pH ValueG
Blo12
do1(G "ombi(ed2,!,leG 6urbidit!G &iolved
SolidG
Al%ali(eG "O"G Slud9eG .a%e2upG 6+i,%e(erG
"e(tri8u9eG HVA"G Ba,%21a+G Jero2di,+ar9eG
""::G ppm.
3.'N6RO&U"6'ON
6+ermal po1er pla(t ,a( be broadl! ,lai8ied
i(
t1o 9roup viF. "oal28ired po1er pla(t a(d
"ombi(ed2,!,le po1er pla(t. Bot+ t+ee t!pe
o8
:o1er pla(t ue 8uel @,oal/ oil a(d 9aA/ air
a(d
1ater i(put/ a(d 9e(erate ele,tri, po1er.
Lubri,ati(9
oil a(d ,+emi,al are alo ued i( t+e po1er
pla(t.
Solid/ 9aeou a(d li-uid e88lue(t are
9e(erated
alo(9 1it+ po1er 9e(eratio(. A+/ produ,ed 8rom
,oal ,ombutio(/ i t+e ma#or olid 1ate. 't
i
+a(dled a(d dipoed o8 i( t+e A+ +a(dli(9
!tem.
6+e ot+er olid e88lue(t ,a( be lud9e 8rom
,e(tri8u9e.
ES:/ A:H a(d ,+im(e! dei9( are ma#or
proviio(
8or +a(dli(9 8lue 9a @9aeou e88lue(tA.
6+i paper deal 1it+ t+e li-uid e88lue(t
o(l!.
Li-uid e88lue(t/ 8rom po1er pla(t/ ,a( be
,lai8ied i( t+e 8ollo1i(9 t+ree ,ate9orie* lHi9+2turbidit! e88lue(t. lHi9+2diolved2olid e88lue(t/ i(,ludi(9 a,idi, M al%ali(e e88lue(t. lOil! e88lue(t.
6+e ditributio( o8 1ater uppl!/ i( t+e pla(t/
i +o1( i( S,+emati,23 V:la(t 1ater !temV. 6+i ,+eme alo +o1 t+e e88lue(t 9e(erated 8rom variou pro,ee.
S,+emati,22V<ate 1ater ma(a9eme(t !tem baed
o( Fero2di,+ar9e p+iloop+!V +o1 o(l! t+e
e88lue(t 9e(erated 8rom di88ere(t pro,ee/ a(d
t+eir +a(dli(9 M dipoal !tem.
2.)ENERA6'ON O0 L'?U'&
E00LUEN6S &UE 6O NA6URE O0
:LAN6 O:ERA6'ON
6+e ma#or li-uid e88lue(t 9e(erated due to (ature
o8 pla(t operatio(/ are 9ive( belo1*
l Seao(al,+a(9e i( ra1 1ater -ualit! a88e,t
t+e 8ollo1i(9*
:re2treatme(t pla(t lud9e 8lo1 rate/
"ooli(9 1ater !tem blo12do1( 8lo1
rate/
"ooli(9 1ater !tem blo12o1( -ualit!.
lStorm 1ater drai( i alo o8 eao(al(ature.
't 8lo1 rate i ver! lar9e 1it+ +ort
duratio(.
l '(termitte(t operatio( produ,e i(termitte(t
e88lue(t. 0ollo1i(9 are t+e ,ommo( e7ample
o8 u,+ e88lue(t*
&. pla(t re9e(eratio( lead to
i(termitte(t 8lo1 rate 8rom t+e
(eutraliFi(9 pit.
Servi,e 1ater 8rom 8loor 1a+i(9
operatio( i 9e(erated i( a +ort pa(
o8 2 to > +our. l:la(t mal2operatio( or 8ailure ma! reult i(
e88lue(t 1it+ 8lo1 rate o8 variable
(ature.
6ime pa( 8or u,+ 8lo1 i 8ailure2
pe,i8i,.
Alarm !tem/ 1it+ or 1it+out auto
operatio(/ i 9e(erall! provided 8or u,+ e88lue(t. l.ai(te(a(,e e88lue(t ,a( be +a(dled i( a pla((ed 1a! i(,e t+eir -ua(titie a(d -ualitie are 8airl! 1ell %(o1( i( adva(,e. lSe1a9e e88lue(t i motl! di,+ar9ed duri(9 da!time. 't i treated a(d dipoed o8 i(depe(de(t o8 t+e ot+er pro,e e88lue(t.
>.H')H26URB'&'6; L'?U'&
E00LUEN6S
6+ere i (o 1ell2a,,epted borderli(e o8 +i9+
turbidit!.
<e ,a( ,o(ider +i9+ turbidit! re8erri(9 to
t+oe
e88lue(t tream 1+i,+ +ave upe(ded olid o8
appro7imatel! 300 ppm or 9reater/ i(,e t+e
e88lue(t
turbidit! above 300 ppm i (ot permitted. 6+i
,ate9or! 1ill t!pi,all! i(,lude t+e 8ollo1i(9
e88lue(t*
lSlud9e 8rom ra1 1ater :re26reatme(t :la(t
@:6:A a(d 8rom E88lue(t 6reatme(t :la(t
@E6:A e-uipme(t u,+ a lamella
,lari8ier
a(d t+i,%e(er.
l"< blo12do1( 9e(erall! 8all i( t+i ,ate9or!/
depe(di(9 o( t+e ma%e2up 1ater upe(ded
olid ,o(te(t a(d t+e operati(9 "!,le
o8
"o(,e(tratio( @"O"A.
l0ilter ba,%1a+e @8rom 9ravit! M preure M
ide tream 8ilterA.
l<ate1ater 8rom routi(e 8loor 1a+i(9.
lA+ lurr! 1ater.
l"oal pile ru(2o88.
>.3:re26reatme(t :la(t @:6:A a(d E6:
Slud9e
Slud9e i produ,ed 8rom ,lari8ier/ 8rom t+e
turbidit!
o8 ra1 1ater uppl! to t+e pla(t. 6+e ra1 1ater
uppl!
to t+e pla(t i primaril! 8or meeti(9 t+e
re-uireme(t
o8 ,lari8ied 1ater a(d dire,t ra121ater ma%e2up
to
,o(umer li%e 8ire 1ater !tem/ a+ +a(dli(9
pla(t/ ervi,e 1ater !tem et,. Ra1 1ater re-uireme(t
9e(erall! doe (ot var! mu,+ duri(9 pla(t
operatio(.
'( t+e eve(t o8 a+ 1ater re,over! 8rom t+e a+
po(d/ 1+i,+ ma! ta%e 22> !ear a8ter i(itial pla(t
,ommiio(i(9/ t+ere ma! be a (eed to ,ut do1(
o(
ra1 1ater re-uireme(t. Redu,ed ra1 1ater
re-uireme(t
lead to redu,tio( i( lud9e 9e(eratio(
alo.
Ra1 1ater turbidit! i a ma#or variable @i(
additio(
to ra1 1ater 8lo1 rateA/ 1+i,+ de,ide t+e
-ua(tum
o8 lud9e 9e(eratio(. 6urbidit! i( t+e our,e
o8 ra1
1ater uppl! i li%el! to +ave t+e variatio(
a 9ive( i( 6able2'.
4D BHEL JOURNAL/ September 2006
6+e variatio( i( turbidit! 8rom reervoir a(d
riverM
,a(al our,e/ i ite2pe,i8i, a(d depe(d o( t+e
iFe
o8 reervoir/ our,e o8 river/ time M period
related to
rai(! eao( et,.
:6: lud9e up to appro7imatel! 60 m>M+ ,a( be
e88e,tivel! di,+ar9ed 8rom t+e pla(t t+rou9+ a+
dipoal !tem/ a(d t+i pra,ti,e i prevale(t i(
t+e
e7iti(9 pla(t.
't i re,omme(ded to adopt t+i pra,ti,e/ a a
8irt
pre8ere(,e/ 8or :6: lud9e dipoal. 't ma! be
appre,iated t+at t+e (ormal a+ ,o(ite(,!/ a
di,+ar9ed 8rom a+ lurr! ump/ i about 202>0L.
6+e :6: lud9e/ 1it+ 22> L ,o(ite(,!/
pra,ti,all!
be+ave li%e ma%e2up 1ater to a+ lurr! ump/
1+ere a+ lurr! dipoal !tem i e(via9ed. '(
,ertai( pla(t/ 1+ere lurr! dipoal !tem i
(ot
e(via9ed a(d o(l! dr! dipoal !tem i
pe,i8ied/ eparate lud9e dipoal M treatme(t 1ould +ave to be ,o(idered.
6+e turbidit! level are (ot u(i8orm t+rou9+out
t+e !ear. '( t+e eve(t o8 t+e lud9e 9e(eratio( rate e7,eedi(9 t+e ma7imum limit a,,eptable to a+ +a(dli(9 !tem/ t+e 8ollo1i(9 met+od ,a( be ued 8or it dipoal. iA&ipoal o8 lud9e @duri(9 +i9+2turbidit! periodA t+rou9+ pla(t drai(a9e !tem. 6+i ma! be a,,eptable to pollutio( ,o(trol
aut+oritie a t+e 1ater tream 1+i,+
re,eive
t+i e88lue(t alo +ave ver! +i9+
upe(ded
olid i( mo(oo(/ a(d i(,e t+e
upe(ded
olid 9e(erall! ,o(it o8 ,la!/ t+e!
are (ot
a +ealt+ +aFard.
iiA:ro,ei(9 o8 t+e total lud9e i(
t+i,%e(er
a(d ,e(tri8u9e. 6+i alter(ative +a t+e
adva(ta9e o8 1ater re,over! @a(d reueA
8rom t+e lud9e. Ho1ever/ it i a(
e7pe(ive
proviio(/ i8 i(te(ded to be ued i(
mo(oo(
eao( o(l!.
>.2"ooli(9 <ater @"<A S!tem Blo12&o1(
"< !tem temperature rie b! D230K". 't i
,ooled
b! t+e ame e7te(t i( ,ooli(9 to1er. 6+e
,ooli(9
e88e,t i a,+ieved b! lo o8 "</ b!
evaporatio(.
About 3.DL o8 "< 8lo1 rate i lot b!
evaporatio(/ 8or ever! 300 " ,ooli(9 e88e,t. "ooli(9 1ater !tem blo12do1( i pra,tied to mai(tai( ,o(,e(tratio( o8 upe(ded M diolved
olid i( t+e ,ir,ulati(9 1ater/ o t+at t+e
,ali(9 M
,orroio( o8 t+e 1etted ur8a,e i mi(imiFed.
6+e
blo12do1( -ua(tit! i a 8u(,tio( o8 ,ir,ulati(9
8lo1
rate a(d t+e ,!,le o8 ,o(,e(tratio( @"O"A
adopted. A,id doi(9 a(d ide tream 8iltratio( ,a( be
#udi,ioul! ued 8or t+e ele,ted "O" a(d ma%e2
up
6ABLE2' * 6URB'&'6; VAR'A6'ONS 'N 6HE R'VER <A6ER SU::L; 6O :LAN6S
Sour,e o8 Ra1 <ater Suppl!6!pi,al 6urbidit! Level
Ra1 1ater uppl! 8rom ea.6urbidit! i lo1 @t!pi,all! 302B0 ppmA.
Ra1 1ater uppl! 8rom bore21ell.6urbidit! i lo1 @t!pi,all! B230 ppmA.
Ra1 1ater uppl! 8rom reervoir.6urbidit! i 9e(erall! lo1 @t!pi,all! 302300
ppmA. &epe(di(9
o( ite lo,atio( a(d reervoir iFe/ it ,a( +o1ever rie to
about
200 ppm i( mo(oo( mo(t+.
Ra1 1ater uppl! 8rom riverM,a(al.)e(erall! lo1er t+a( uppl! 8rom reervoir/
but
variatio( duri(9 mo(oo( mo(t+ ,a( be 2002B00 ppm.
B0 BHEL JOURNAL/ September 2006
1ater -ualit!/ to mai(tai( t+e permitted limit o8
,ale a(d ,orroio(.
6+e -ualit! o8 ,ooli(9 to1er blo12do1( 1ater
depe(d o( t+e 1ater ,+emitr! i( t+e "< !tem/
"< treatme(t provided/ "O" a(d rate o8 blo12
do1(. 6!pi,al detail are 9ive( i( 6able2''.
6ABLE2''*6;:'"AL "OOL'N) 6O<ER BLO<m
&O<N ?UAL'6;
"o(titue(t?ua(tit!
6otal diolved olid>B02D00 m9Ml
pH7.D2D.D
Supe(ded olid300 m9Ml
Oil a(d 9reaeB m9Ml
0ree available "+lori(e0.> m9Ml
:ermiible limit o8 "ooli(9 to1er blo12do1(
e88lue(t/ i8 dipoed o8 eparatel!/ are 9ive( i(
6able2'''.
6ABLE2'''*:ER.'SS'BLE L'.'6S O0
"OOL'N) 6O<ER BLO<2&O<N
AS :ER ":"B NOR.S
"o(titue(t?ua(tit!
6otal "+romium0.2 m9Ml
Ji(,3 m9Ml
:+op+ateB.0 m9Ml
0ree available "+lori(e0.B m9Ml Ot+er ,orroio(Limit to be i(+ibiti(9 materialetabli+ed o( ,ae2to2,ae bai >.2.3:ER.'SS'BLE L'.'6S 0OR 6E.:ERA6URE2 R'SE @O0 "OOL'N) <A6ER 'N 6HE "ON&ENSERA AS :ER ":"B NOR.S l Ne1 t+ermal po1er pla(t ,ommiio(ed a8ter Ju(e 3/ 3555* Ne1 t+ermal po1er pla(t/ 1+i,+ 1ill be
ui(9 1ater 8rom river M la%e M
reervoir/
+all i(tall ,ooli(9 to1er irrepe,tive
o8
lo,atio( a(d ,apa,it!. 0or t+ermal po1er
pla(t 1+i,+ 1ill ue ea1ater 8or
,ooli(9
purpoe/ t+e ,o(ditio( belo1 1ill appl!.
lNe1 pro#e,t i( ,oatal area ui(9 ea
1ater *
6+e t+ermal po1er pla(t ui(9 ea 1ater
+ould adopt uitable !tem to redu,e
1ater
temperature at t+e 8i(al di,+ar9e poi(t
o
t+at t+e reulta(t rie i( t+e
temperature o8
re,eivi(9 1ater doe (ot e7,eed 7K" over
a(d
above t+e ambie(t temperature o8 t+e
re,eivi(9 1ater bodie.
l E7iti(9 t+ermal po1er pla(t*
Rie i( temperature o8 ,o(de(er ,ooli(9
1ater 8rom i(let to t+e outlet o8
,o(de(er
+all (ot be more t+a( 30K".
l &i,+ar9e poi(t 9uideli(e*
6+e di,+ar9e poi(t +all pre8erabl! be
lo,ated
at t+e bottom o8 t+e 1ater bod! at mid2
tream 8or proper diperio( o8 t+ermal
di,+ar9e. '( ,ae o8 di,+ar9e o8
,ooli(9
1ater i(to ea/ proper mari(e out8all
+all be
dei9(ed to a,+ieve t+e pre,ribed
ta(dard.
6+e poi(t o8 di,+ar9e ma! be ele,ted i(
,o(ultatio( 1it+ t+e ,o(,er(ed State
Aut+oritie. No ,ooli(9 1ater di,+ar9e
+all
be permitted i( etuarie or (ear
e,olo9i,all!
e(itive area u,+ a ma(9rove/ ,oral
ree8M pa((i(9 a(d breedi(9 9rou(d o8 a-uati, 8lora a(d 8au(a. >.2.2&'S:OSAL O0 "OOL'N) <A6ER l"< blo12do1( +ould pre8erabl! be ued
8or a+ dipoal i( ,oal28ired pla(t.
't ue
8or a+ dipoal 1ill lead to redu,ed
ma%e2 up 1ater re-uireme(t 8or AH: a(d ,o(e-ue(tl! lo1er dema(d o8 ra1 1ater. l"ooli(9 to1er blo12do1( i (ormall! ,o(tami(ated 1it+ treatme(t ,+emi,al. 't
9e(erall! +a +i9+ +ard(e M diolved
olid.
6+e 8lo1 -ua(titie bei(9 ver! +i9+/ it ,a(
be e88e,tivel! ued to dilute ot+er
,o(tami(a(t li%e oil a(d pH/ i( "e(tral
.o(itori(9 Bai( @".BA.
l'( ,ae 1et a+ dipoal i (ot pra,tied @a(d
alo i( ,ae o8 ,ombi(ed2,!,le pla(t/ 1+ere
a+ dipoal i (ot appli,ableA/ t+e "<
blo12
do1(/ bei(9 o8 +u9e -ua(tit!/ ,a((ot be
8ull! utiliFed 1it+out treatme(t. '( u,+ a
ituatio(/ "< blo12do1( (eed to be
dipoed o8 dire,tl! 8rom t+e pla(t.
lAlter(ativel! @i8 Fero2di,+ar9e i e(via9ed
i( t+e tri,t e(eA/ "< blo12do1( 1ater
@a8ter mi7i(9 1it+ ot+er e88lue(t i( t+e
".BA (eed to be treated 8or re,!,le. 6+e
8ollo1i(9 treatme(t i re-uired*
"lari8i,atio( a(d ube-ue(t ue o8
,lari8ied
1ater 8or t+e 8ollo1i(9 appli,atio(*
0or dut uppreio( i( ,oal +a(dli(9
pla(t.
Servi,e 1ater appli,atio(.
Boiler blo12do1( ,ooli(9.
Suppl! to ot+er ,o(umer o8 t+e
,lari8ied 1ater @e7,ept &. :la(t/
:otable
1aterA.
0ire prote,tio( !tem ma%e2up.
6reatme(t o8 ,lari8ied 1ater i( RO !tem
a(d 8urt+er ue o8 t+e permeate i( t+e
8ollo1i(9 !tem*
Suppl! to &. :la(t "< ma%e2up HVA" !tem ma%e2up
Si(,e t+e "< blo12do1( 8lo1 rate i ver! +i9+/ it treatme(t b! RO i a ver! ,otl! propoal/ a(d +ould be avoided a 8ar a poible/ u(le t+e additio(al ,ot ,a( be #uti8ied. 6+e RO ,o(,e(trate/ i( t+i optio( o8 Fero2 di,+ar9e/ re-uire to be evaporated i(
evaporatio( po(d/ to be pe,i8i,all!
provided 8or t+i purpoe.
>.><a+ <ater E88lue(t
Some o8 t+e utilitie +ave a pra,ti,e o8 ui(9
ervi,e
1ater 8or 1a+i(9 dut 8rom boiler area a(d 6)
+all
to improve +oue %eepi(9. 6+e 8ollo1i(9 area
o8
t+e pla(t are 9e(erall! provided 1it+ 1a+i(9
8a,ilitie*
iABoiler area
6+e 1a+ 1ater di,+ar9e i li%el! to be
appli,able 8or a period o8 22> +our i(
t+e
9e(eral +i8t. 6+i 1a+ 1ater i
,o(tami(ated
1it+ a+. <a+ 1ater i ,olle,ted i(
lo,al
ump a(d ube-ue(tl! pumped to E6:
ump 8or 8urt+er treatme(t i( Lamella M
6ube
t!pe ,lari8ier. 6+e ,lari8ier
uper(ata(t i
di,+ar9ed to t+e ".B.
iiA6urbi(e +all 9rou(d 8loor
6+e 1a+ 1ater di,+ar9e i li%el! to be
appli,able 8or a period o8 22> +our i(
t+e
9e(eral +i8t. 6+i 1a+ 1ater i
,o(tami(ated
1it+ upe(ded matter. Oil ,o(te(t i( t+e
1a+ 1ater i mi(or depe(di(9 o( t+e area
to be 1a+ed. 't i redu,ed to (e9li9ible
value
a8ter dilutio( e88e,t o8 ot+er
e88lue(t.
<a+ 1ater i ,olle,ted i( lo,al ump
a(d
ube-ue(tl! pumped to Lamella M 6ube
t!pe
,lari8ier. 6+e ,lari8ier uper(ata(t i
di,+ar9ed to t+e ".B.
6+e lud9e 9e(erated i( t+e lamella/
provided to remove upe(ded matter 8rom 1a+
1ater e88lue(t/ i ver! little. La!out
permitti(9/ it i re,omme(ded to drai( it to t+e pre2
treatme(t pla(t lud9e ump/ to impli8!
it
dipoal. Alter(ativel!/ t+e lud9e
-ua(tit!
bei(9 little/ it ,a( be dipoed o8
ma(uall! i( a( a,,eptable 1a!. iiiA<a+ 1ater 8rom buildi(9
't i o8 mi(or (ature. 't drai( to
repe,tive
buildi(9 drai( !tem a(d doe (ot #oi(
t+e E88lue(t 6reatme(t :la(t @E6:A 8or t+e pro,ee de,ribed i( t+i paper.
>.40ilter Ba,%2<a+
Ba,%21a+ 1ater 8rom t+e 9ravit! or preure
8ilter
+a up to 3B00 ppm upe(ded olid. 6+e ba,%2
1a+ 1ater ma! be re,ir,ulated ba,% to t+e
,lari8ier
to mi(imiFe 1ata9e o8 1ater.
>.BA+ Slurr! <ater
A+ lurr! 1ater i 9e(erall! dipoed o8 8rom t+e
a+
po(d. About D0L o8 1ater uppl! to a+ lurr!
ump ma! alo be re,overed 8rom a+ po(d/ 8or
reue
i( t+e pla(t A+ dipoal !tem. A+ 1ater
re,over!
i 9e(erall! dela!ed/ a8ter pla(t ,ommiio(i(9.
6+e
dela! period ,a( be 8rom 6 mo(t+ to 2 !ear. 6+e
re,overed 1ater +a i9(i8i,a(t -ua(tit! o8
upe(ded
a(d diolved olid. 't ,a( be/ +o1ever/ ued 8or
ma%e2up to t+e a+ 1ater ump 8or a+ dipoal
'8 ,ooli(9 1ater blo12do1( +a bee( ued 8or ma%e2
up to t+e a+ +a(dli(9 !tem/ t+e ituatio(
,+a(9e
a8ter AH: re,over! tart. "< treatme(t !tem
,apabilit! permitti(9/ t+e "O" ,a( be 8urt+er
i(,reaed/ leadi(9 to redu,ed ra1 1ater dema(d 8or
t+e pla(t. 6+e di,+ar9e ta(dard o8 a+ po(d
e88lue(t are 9ive( i( 6able2'V.
6ABLE2'V*&'S"HAR)E S6AN&AR&S O0 ASH :ON&
E00LUEN6 AS :ER ":"B NOR.S
:arameterLimit
pH Valve6.B2D.B/ pre8erabl! j 7
Supe(ded Solid300 m9Ml Oil S )reae20 m9Ml >.6"oal :ile Ru(2o88
"oal pile ru(2o88 -ua(tit! i ite2pe,i8i,/
primaril! depe(di(9 o( t+e rai(8all a(d t+e ,oal !ard
topo9rap+!. '8 ite ,o(ditio( u99et i9(i8i,a(t
,oal
pile ru(2o88/ it (eed to be ,olle,ted i( a belo12
9rade
po(d. "oal pile ru(2o88 ma! +ave i9(i8i,a(t
-ua(tit! o8 upe(ded matter. A8ter a reao(able period 8or ettleme(t o8 t+e upe(ded matter/ t+e e88lue(t @,o(e-ue(t to t+e rai(A 1ill be di,+ar9ed to t+e pla(t drai( !tem.
4.L'?U'&2E00LUEN6S HAV'N)
H')H2&'SSOLVE&2SOL'&S
Hi9+2diolved2olid2,o(te(t li-uid e88lue(t
re8er
to e88lue(t tream +avi(9 +i9+ io(i, load. '(
po1er
pla(t/ t+i ,ate9or! o8 e88lue(t 1ill
t!pi,all! i(,lude
t+e 8ollo1i(9*
l<ate 8rom &. M ":U (eutraliFatio( pit.
lBoiler M HRS) blo12do1(
l"< blo12do1(.
4.3Re,omme(datio( 8or &. :la(t M ":U
(eutraliFatio( 1ate M ,+emi,al
1ate
&. :la(t re9e(eratio( 1ate @a 1ell a ":U
re9e(eratio( 1ate i8 ":U +a bee( providedA
i
,olle,ted i( t+e (eutraliFatio( pit @N:A. 't i
(ormall!
el82(eutraliFed. &oi(9 !tem i alo
provided 8or
N:/ to (eutraliFe t+e re9e(eratio( 1ate/ i(
,ae it
i (ot el82(eutraliFed. 6+e N: e88lue(t i
pumped
to ".B. 6!pi,al a(al!i o8 &.2re9e(eratio(
1ate
i 9ive( i( 6able2V.
6ABLE2V*6;:'"AL ANAL;S'S O0 &.2
RE)ENERA6'ON <AS6E
"o(titue(t?ua(tit!
6otal &iolved Solid440026000 ppm
pH6.B27.B
Supe(ded olid300 ppm
B.O'L; E00LUEN6S
'( (ormal operatio(/ oil! e88lue(t are (ot
e7pe,ted
8rom area o8 t+e po1er pla(t ot+er t+a( t+e
8uel oil
+a(dli(9 area. Oil! 1ater e88lue(t 1it+ oil
,o(te(t 9reater t+a( 20 ppm ma! arie 8rom tra(8ormer
area duri(9 ab(ormal ,o(ditio( u,+ a
8ire M a,,ide(t et,. 6+e ma#or our,e o8 oil! e88lue(t are* iAOil! E88lue(t 8rom 8uel oil tora9e area.
6+i e88lue(t +ould be ,olle,ted i(
lo,al
B> BHEL JOURNAL/ September 2006
ump. Oil i eparated @up to 30 ppm A i(
t+e oilM1ater eparator. 6+e treated 1ater
,a(
be pumped to ".B 8or 8urt+er dipoal.
iiA0loor 1a+ 1ater e88lue(t 8rom 8uel oil
u(loadi(9/ tora9e a(d pumpi(9 area.
iiiAOil lea%a9e M pilla9e 8rom t+e turbi(e M
B0:
lube oil !tem a(d 1or%+op.
6+i e88lue(t/ i8 a(!/ i i(i9(i8i,a(t a(d
re-uire to be ,olle,ted i( lo,al tra! M
1iped
1it+ ,otto( 1ate.
ivA)e(erator 6ra(8ormer area e88lue(t.
6+e e88lue(t 8rom t+e 9e(erator tra(8ormer
area ori9i(ate eit+er 8rom rai( or
,o(e-ue(t
to t+e operatio( o8 8ire prote,tio( !tem.
A
ump i provided to ,olle,t t+i 1ater 8rom
tra(8ormer area. E7perie(,e +o1 t+at
(ormall! t+ere i (o oil lea%a9e 8rom t+e
tra(8ormer.
'( ,ae o8 8ire/ 1ater i pra!ed i( t+e
tra(8ormer
area. 6+i 1ater drai( to t+e ump. '( t+e eve(t
o8
oil lea%a9e duri(9 8ire/ bot+ oil a(d 1ater drai(
to
t+e ump. 6+e 8ollo1i(9 i re,omme(ded 8or
dipoal
o8 t+e e88lue(t 8rom t+e 9e(erator tra(8ormer
ump*
aA'8 t+ere i (o oil lea%a9e/ pump t+e ump
1ater to pla(t drai( !tem.
bA'( ,ae o8 oil di,+ar9e ,o(e-ue(t to t+e
8ailure o8 t+e oil !tem o8 t+e
tra(8ormer/ t+e 1ater i 8irt di,+ar9ed to t+e pla(t
drai( !tem. <+e( t+e oil tart ,omi(9/
oil bei(9 above 1ater/ it +ould be ,olle,ted i( t+e drum. 6.BO'LER BLO<2&O<N Boiler blo12do1( rate i a 8u(,tio( o8 boiler 8eed 1ater !tem 1ater ,+emitr! pro9ram. Blo12do1( rate o8 32>L @o8 mai( team 8lo1 rateA +ave bee( ued. A value o8 O L 8or moder( +i9+2preure boiler i (ot u(uual t+ee da!. 6+e -ualit! o8 boiler blo12do1( 1ater depe(d o( t+e 1ater ,+emitr! o8 po1er ,!,le !tem a(d t+e
rate o8 boiler blo12do1(. 6!pi,al detail are
9ive( i(
6able2V'.
6ABLE2V'*6;:'"AL &E6A'LS O0 BO'LER BLO<2
&O<N 0OR 2B0 .< UN'6
"o(titue(t?ua(tit!
Supe(ded olid366 ppm
6&S300 ppm
pHD.5
Oil a(d 9reae0.2 ppm
Sili,a0.2 ppm a SiO2
:ermiible limit o8 boiler blo12do1(
e88lue(t/ i8
dipoed o8 eparatel!/ are 9ive( i( 6able2
V''.
6ABLE2V''*:ER.'SS'BLE L'.'6S O0 BO'LER
BLO<2&O<N E00LUEN6S '0
&'S:OSE& O0 SE:ARA6EL;
"o(titue(t?ua(tit!
Supe(ded olid300 m9Ml
Oil a(d 9reae20 m9Ml
"opper total3.0 m9Ml
'ro( total3.0 m9Ml
0ree available ,+lori(e0.B m9Ml
Boiler blo12do1( doe (ot re-uire a(!
treatme(t/
a(d it ,a( be dire,tl! pumped to ".B.
7.SE<A)E M "AN6EEN <AS6E
6+e e1a9e 8rom t+e pla(t buildi(9 a(d ,a(tee(
i
9e(erall! led to e1a9e treatme(t pla(t. 6+e
treated
1ater ,a( be ued 8or +orti,ulture. 't i
re,omme(ded
t+at t+i e88lue(t (ot be mi7ed 1it+ pro,e
e88lue(t. D.E00LUEN6S )ENERA6E& &UR'N) "O..'SS'ON'N) AN& .A'N62 ENAN"E A"6'V'6'ES
"lea(i(9 e88lue(t 8rom boiler au7iliarie are
li%el!
duri(9 ,ommiio(i(9 a(d mai(te(a(,e ta9e.
6+i
i a pla((ed ,ommiio(i(9Mmai(te(a(,e a,tivit!/
a(d it i do(e o(l! 1+e( t+e pla(t i u(der +ut2
do1(.
6+e ma7imum 8re-ue(,! o8 1a+i(9 8or Air2pre2
+eater a(d Ele,trotati, pre,ipitator ,ould be
o(,e a
!ear. 6+e a,id ,lea(i(9 a,tivit! a(d al%ali2boil2
out
operatio( are ,ommiio(i(9 a,tivitie.
't i (ot adviable to provide perma(e(t
i(tallatio(
8or ,olle,tio( o8 t+ee e88lue(t. 6+e e88lue(t
,+ara,teriti, 8or t+e above operatio( bei(9
u(,ertai(/
prede8i(ed treatme(t/ i8 provided/ ma! (ot 1or%
e88i,ie(tl!. 6emporar! arra(9eme(t 8or e88lue(t
,olle,tio( a(d dipoal i ,o(idered appropriate
a(d
#uti8iable. 't i re,omme(ded t+at temporar!
arra(9eme(t be provided 8or dipoal o8 t+ee
e88lue(t.
5."OLLE"6'ON AN& 0'NAL
&'S:OSAL O0 L'?U'& E00LUEN6S
Ea,+ ,ate9or! o8 e88lue(t i 9e(erall! treated
i(dividuall! 8or removi(9 oil/ upe(ded olid
a(d
pH ,orre,tio(/ i8 t+ee parameter ,a((ot be
ma(a9ed
to meet t+e 8i(al dipoal limit. All e88lue(t
are
,olle,ted i( t+e "e(tral .o(itori(9 Bai( @".BA
be8ore dipoal 8rom t+e pla(t.
6+e ".B i 9e(erall! i( t1o ,ompartme(t. <+ile
e88lue(t o8 o(e ,ompartme(t are u(der dipoal/
a8ter 8i(al pH ,orre,tio(/ t+e ot+er ,ompartme(t
i
u(der 8illi(9. Ea,+ ,ompartme(t i 9e(erall! iFed
8or 2 +our i(8lo1 ,apa,it!. &i,+ar9e pump are
provided i( t+e ,ommo( ,ompartme(t.
A,,eptable limiti(9 parameter o8 pe,i8i,
e88lue(t +ave bee( pe,i8ied above 8or "< blo12do1(/ boiler blo12do1( a(d a+2po(d e88lue(t. Ho1ever 8or t+e
e88lue(t ,olle,ted i( t+e ".B/ (o pe,i8i,
e88lue(t limit +ave bee( 9ive( 8or po1er pla(t. 6+e 8ollo1i(9 limit are 9e(erall! pe,i8ied b! pla(t o1(er 8or ,oal28ired po1er pla(t* :arameterLimit Supe(ded olid*300 ppm Oil a(d 9reae*30 ppm Reidual ,+lori(e*0.B ppm pH*6.B to D.B
6+e upe(ded olid/ oil M 9reae a(d reidual
,+lori(e parameter o8 t+e ".B e88lue(t/ are
9e(erall! table/ 1+erea pH ma! +ave mar9i(al
8lu,tuatio(/ t+ereb! re-uiri(9 it ,orre,tio(.
6o ta%e
,are o8 t+i ape,t/ o(2li(e pH i(di,ator i
provided
i( t+e ".B di,+ar9e pipi(9. Ot+er parameter
viF.
upe(ded olid/ ,o(du,tivit!/ oil M 9reae
a(d
reidual ,+lori(e/ are teted i( t+e
laborator!.
30.E00LUEN6S 0RO. "O.B'NE&2
";"LE :O<ER :LAN6S @""::A
6+e pollutio( ,o(trol re-uireme(t 8or "":: i
imilar to t+at 8or ,oal28ired pla(t e7,ept 8or
t+e
8ollo1i(9*
iASi(,e ,oal +a(dli(9 a(d a+ +a(dli(9
pa,%a9e
are (ot appli,able/ t+e 8ollo1i(9
e88lue(t are
(ot 9e(erated i( ""::*
l"oal pile ru(2o88.
lA+2po(d e88lue(t.
lBoiler2area 8loor 1a+i(9 e88lue(t @i(,e
t+e 1a+i(9 re-uireme(t i
i(i9(i8i,a(tA.
iiA'( t+e abe(,e o8 A+ Ha(dli(9 pla(t/ t+e
lud9e 8rom ,lari8ier ,a((ot be dipoed
o8
1it+ t+e a+ lurr!. 6+i,%e(er a(d
,e(tri8u9e
1ill be re-uired i8 t+e lud9e -ua(tit!
i
i9(i8i,a(t.
iiiA6+e permiible limit 8or e88lue(t*
6+e 8ollo1i(9 limit +ave bee( pe,i8ied
b!
"e(tral :ollutio( "o(trol Board @":"BA
8or )a M Nap+t+a baed po1er pla(t* :arameterLimit pHW6.B2D.B 6emperatureWA appli,able to ,oal28ired pla(t "opper totalW3 ppm 'ro( totalW3 ppm Ji(,W3 ppm "+romium totalW0.2 ppm :+op+ateWB ppm 6otal upe(ded olidW300 ppm ma7 0ree ,+lori(eW0.B ppm ma7
BB BHEL JOURNAL/ September 2006
Oil a(d 9reaeW0or di,+ar9e to
i(la(d ur8a,e
1ater* (ot
e7,eedi(9 30 ppm.
0or di,+ar9e to
mari(e ,oatal
area* (ot
e7,eedi(9 20 ppm
33.JERO2&'S"HAR)E E6:
33.3"lai8i,atio( o8 E88lue(t
6+e e88lue(t 8rom t+e pla(t ,a( be ,lai8ied i(
t+e
8ollo1i(9 t1o broad ,ate9orie*
iA :ro,e e88lue(t / a 8rom "< !tem/ boiler
blo12do1(/ 1ater treatme(t !tem/ 8loor
1a+i(9/ buildi(9 e88lue(t et,. 6+ee
e88lue(t
+ave beari(9 o( t+e iFe a(d operati(9
,o(ditio( o8 t+e !tem ,o(,er(ed.
iiA E88lue(t u,+ a torm 1ater drai( . 6+i
t!pe o8 e88lue(t i ite2pe,i8i,. 't i
9e(erated
i( lar9e 8lo1 volume i( a +ort time.
33.2"o(ideratio( 8or Appl!i(9 Jero2
&i,+ar9e "o(,ept
6+e 8ollo1i(9 ape,t o8 pra,ti,al (ature (eed to
be
,o(idered 1+e( appl!i(9 t+i ,o(,ept to t+e po1er
pla(t*
'( ,ae o8 "":: a(d ,oal28ired pla(t 1it+ dr!
a+
dipoal @a(d alo i( ,ae o8 ,oal28ired pla(t
1it+ a lo1 value o8 ,o(de(er ,ooli(9 1ater "O"A/ t+e
li-uid e88lue(t 8rom t+e pla(t be,ome urplu
eve(
a8ter all #uti8iable reue i( t+e pla(t. '( u,+
a
ituatio(/ t+e Fero di,+ar9e ,a( be attempted
o(l! at a ver! +i9+ ,ot.
'( vie1 o8 t+e above/ it i t+e ,o(idered vie1 o8
t+e aut+or t+at t+e (eed 8or Fero di,+ar9e +ould be
pe,i8ied 1it+ t+e ,o(ideratio( i( repe,t o8
retur( o( i(vetme(t.
32."ON"LUS'ON
6+e proviio( o8 E6: 8or po1er pla(t i a
relativel! (e1 re-uireme(t. 0or earlier pla(t/
t+e
9e(eral re-uireme(t 1a pla(t dei9( to meet
limiti(9 parameter o8 t+e li-uid e88lue(t
8rom
t+e pla(t. Re,e(t tatutor! ,+a(9e i(,lude
revied
limitatio( o( t+e ,o(de(er ,ooli(9 1ater
retur(
temperature.
:erma(e(t proviio( 8or +a(dli(9 a(d treatme(t
o8 e88lue(t/ 1+i,+ are mai(te(a(,e M
,ommiio(i(9 related/ i (ot e,o(omi,all!
#uti8ied.
't i our vie1 t+at u,+ 8a,ilitie +ould be
o8
temporar! (ature a(d a,tivit!2pe,i8i,. Alo i8
t+e
-ua(tit! o8 ome e88lue(t i i(i9(i8i,a(t/
perma(e(t
i(tallatio( 8or treatme(t a(d dipoal o8
u,+
e88lue(t 1ill o(l! i(,reae t+e i(itial ,ot
o8 t+e
pla(t/ a(d ma! (ot be available 8or ue @due to
i(ade-uate mai(te(a(,eA 1+e( reall! (eeded. 0or
u,+ ,ae/ mobile ta(%er ,ould be provided to
,olle,t t+e 1ate1ater a(d treat i( t+e E6:
lo,ated ele1+ere.
6+e uppl! o8 ra1 1ater to po1er pla(t/ i
be,omi(9 more a(d more retri,ted. '( vie1 o8
t+i/
ome o8 t+e pro#e,t are bei(9 ,leared baed o(
proviio( o8 Fero li-uid di,+ar9e 8rom t+e
pla(t.
6+i re-uireme(t (eed a re2loo% i( vie1 o8 t+e
(eed
8or ,o(e-ue(tial proviio(/ i8 it i to be
8ollo1ed
literall!.
Biblio9rap+! 3.+tpp*MM111.,p,b.(i,.i(Mta(dard6>.+tm
2.+ttp*MMe(v8or.(i,.i(Mle9iMle9i.+
tml >..i(imal Natio(al Sta(dard @.'NASA. 4.:. S+a(dil!a a(d S S :+o9at/ VE(viro(me(t
ma(a9eme(t i( po1er pla(tV/ >rd
'(ter(atio(al
"o(8ere(,e/ <orld "ou(,il o8 :o1er
Utilitie/ Ne1 &el+i/ 23224 Nov. 2003.
.r. :rab+a%ar S+a(dil!a obtai(ed +i B.6e,+
@"+emi,al E(99.A de9ree i( 3566 8rom '.'.6
$a(pur.
.r. S+a(dil!a 1or%ed 1it+ B'R& S "o. Ltd i(
t+eir ale/ dei9(/ i(tallatio( departme(t
8or
1ater treatme(t e-uipme(t 8or D !ear be8ore
#oi(i(9 J$ S!(t+eti, $ota i( t+eir A,r!li,
0ibre
:la(t a a pro,e e(9i(eer 8or 3 !ear. He
#oi(ed
BHEL i( 3576 a(d +a bee( repo(ible 8or
dei9( S e7e,utio( o8 BO: @Bala(,e o8 :la(tA
8or variou t+ermal po1er tatio(. Hi ,ore
,ompete(,e i i( t+e area o8 1ater S 1ate1ater
treatme(t 8or po1er tatio(. He 1a trai(ed
abroad 1it+ $<U )erma(! 8or o(e !ear. He
retired a )e(eral .a(a9er S Head @.A=A 8rom
:E./ Ne1 &el+i/ i( .a! 200B.
.r. S+a(dil!a i ,urre(tl! 1or%i(9 a Vi,e
:reide(t @E(99A 1it+ L.JE'L/ &el+i/ a(d i
repo(ible 8or t+e e7e,utio( o8 BO: 8or N6:"
Sipat M Bar+ > = 660 .< :o1er Statio(/ a(d
,o(tra,t ,loi(9 o8 H'L &a+e# 60 .< "aptive
:o1er Statio(.
.r. S.S. :+o9at obtai(ed +i B.S,. @E(99A de9ree
1it+ Ho(our i( .e,+a(i,al E(99./ 8rom t+e
:u(#ab U(iverit!.
.r. :+o9at #oi(ed BHEL2B+opal/ i( :o1er Statio( E(99 &ept./ i( t+e !ear 3570 a(d 1a tra(8erred to ert1+ile "o(ulta(,! Servi,e &iviio( @(o1
:E.A i( 3574. He u(der1e(t o(2t+e2#ob trai(i(9
1it+ .M Sieme(/ )erma(!/ 8or o(e !ear.
:ree(tl!/ +e i 1or%i(9 a Addl. )e(eral
.a(a9er
a(d &epartme(t Head o8 .e,+a(i,al Au7iliar!
&epartme(t i( :E./ a(d i repo(ible 8or
:ro#e,t E(9i(eeri(9 o8 Bala(,e o8 :la(t.
.r. :+o9at +a bee( a,tivel! i(volved i( t+e
:ro#e,t E(9i(eeri(9 o8 :o1er "!,le S!tem/
:la(t La!out a(d BO:. He +a aut+ored everal
te,+(i,al paper o( Air2"ooled "o(deer/
6+ermal '(ulatio(/ 6ube2"lea(i(9 a(d &ebri
S!tem/ "at+ode :rote,tio(/ :ipi(9 a(d :umpi(9 S!tem/ E88lue(t 6reatme(t :la(t/ <ater 6reatme(t et,.
.r. ).S. .a+alobtai(ed +i B.S,. @E(99.A de9ree
1it+ 't "la Ho(our i( .e,+a(i,al E(99 8rom
t+e :u(#ab E(9i(eeri(9 "olle9e/ "+a(di9ar+ i(
3572. 6+erea8ter +e obtai(ed +i ..E de9ree
8rom
t+e Birla '(titute o8 6e,+(olo9! S S,ie(,e/
:ila(i
i( t+e !ear 3574.
.r. .a+al #oi(ed BHEL i( 357B a E.6 i( t+e
ert1+ile "o(ulta(,! Servi,e &iviio( @(o1
:E.A. He +a bee( repo(ible 8or &ei9( S
E(9i(eeri(9 o8 .aterial Ha(dli(9 S!tem o8
6+ermal :o1er Statio( a(d +a more t+a( t+ree
de,ade o8 e7perie(,e i( t+e related 8ield o8
.aterial Ha(dli(9 S!tem. He i pree(tl!
1or%i(9 a Addl. )e(eral .a(a9er i( :E..
.r. .a+al i a member o8 t+e (atio(al level B'S
ub,ommittee .E 7 o( .aterial Ha(dli(9
S!tem.
.r. S. Bala#i obtai(ed +i E(9i(eeri(9 de9ree i(
.etallur9! 8rom t+e '(dia( '(titute o8 S,ie(,e/
Ba(9alore/ i( 35D>/ 1i((i(9 t+e :ro8. Bra+m
:ra%a+ .edal. Earlier +e +ad 9raduated i( B.S,.
@"+emitr!A 8rom t+e U(iv. o8 .adra i( 35D0.
He 1a trai(ed abroad u(der t+e "olombo pla(
to a,-uire a :. ). &iploma i( .a(a9eme(t o8
E(vrio(me(t 8rom t+e .aatri,+t S,+ool o8
.a(a9eme(t/ 6+e Net+erla(d i( t+e !ear 2000.
.r. Bala#i #oi(ed BHEL a E.6 i( 35D> at 6ri,+!.
Si(,e t+e( +e +a bee( 1or%i(9 i( variou
8u(,tio( u,+ a Lab/ ?"/ ?ualit! .a(a9eme(t/
Healt+/ Sa8et! S E(viro(me(t. At pree(t/ +e i
1or%i(9 a &!. )e(eral .a(a9er i( t+e E(99
8u(,tio( i( <ater "+emitr! e,tio( o8 :E..
.r. Sud+ir B+arti!a9raduated i( .e,+a(i,al E(9i(eeri(9 8rom .. E(99 "olle9e/ )ora%+pur/ i( t+e !ear 355B/ a(d 1e(t o( to obtai( a :.). &iploma i( 6+ermal :o1er :la(t E(99 8rom N6:' &el+i. Be8ore #oi(i(9 BHEL i( 355D a E.6/ .r. B+arti!a 1or%ed i( t+e 8ield o8 po1er pla(t
operatio( i( Bi+ar State Ele,tri,it! Board.
Si(,e 355D/ +e +a bee( 1or%i(9 i( t+e 8ield o8 1ater ,+emitr! a(d +a bee( mai(l! deali(9 1it+ pretreatme(t pla(t/ e88lue(t treatme(t pla(t/ ,o(de(ate poli+i(9 u(it a(d &emi(eraliFatio(
pla(t 8or di88ere(t po1er pla(t. He i
,urre(tl! 1or%i(9 a Sr. E(9i(eer i( E(99 8u(,tio( i( t+e <ater "+emitr! e,tio( o8 :E..
BD BHEL JOURNAL/ September 2006
'NNOVA6'ONS C 0RO. BHEL
&ES')N AU6O.A6'ON O0 B00 .<
"ON&ENSER US'N) $NO<LE&)E BASE&
EN)'NEER'N) C AN .OU :ROJE"6
$(o1led9e .a(a9eme(t +a bee( ide(ti8ied a o(e
o8 t+e %e! ,orporate trate9ie to automate total
pro,e o8 produ,t dei9( i(,ludi(9 releae o8
ma(u8a,turi(9 dra1i(9 a(d all e(9i(eeri(9
do,ume(t/1it+ a vie1 to meeti(9 t+e dema(d 8or
+orter deliverie a(d ti9+t ,ommiio(i(9
,+edule
o8 po1er pro#e,t. '( order to meet t+i
ob#e,tive/
a( .OU pro#e,t V&ei9( Automatio( o8 B00 .<
"o(de(er Ui(9 $(o1led9e2Baed E(9i(eeri(9V
1a ta%e( up b! BHEL2 HEE:/ Harid1ar/ to be9i(
1it+. 6+e pro#e,t +a (o1 bee( u,,e8ull!
,ompleted.
Steam ur8a,e ,o(de(er i o(e o8 t+e ma#or %e!
e-uipme(t i( a t+ermal po1er pla(t. 6+e dei9(
olel! depe(d o( t+e ite ,o(ditio( vi2n2vi
t+e
pla(t la!out/ ,ooli(9 1ater ,+emitr! a(d t+e t!pe
o8 ,ooli(9 1ater !tem.
'( t+i pro#e,t/t+e total automatio( o8 ,o(de(er
dei9( +a bee( do(e ,apturi(9 dei9( i(put ri9+t
8rom t+e te(deri(9 ta9e up to t+e ,o(tra,t
e7e,utio(
ta9e. A o8t1are tool %it +a bee( developed
baed
o( ,utom2made pro9ram lo9i, a(d $(o1led9e
0uio( tool to +elp dei9( ,o(de(er i( a(
automated 8a+io(. A 1iFard +a bee( developed i(,orporati(9
developed )rap+i, Uer '(ter8a,e @)U'A/
i(te9rated le9a,! o8t1are to per8orm t+ermo2+!drauli, dei9( a(d 8or 9e(eratio( o8 per8orma(,e ,urve/ detailed dei9( ,al,ulatio(/ >2& parametri, model o8 ,o(de(er 1it+ >0 ma(u8a,turi(9 9roup ,omprii(9 (earl! 3000 part/ preparatio( o8 e(9i(eeri(9 do,ume(t ,omprii(9 22& ma(u8a,turi(9 dra1i(9 8or t+e >0 ma(u8a,turi(9 9roup/ 34 ere,tio( dra1i(9/ > ,utomer dra1i(9 a(d 3 te(der dra1i(9 @e-uivale(t to (earl! >000 A4 dra1i(9A. All 22& dra1i(9 are i( Auto"A& 8ormat. <ei9+t ,al,ulatio(/ 9e(eratio( o8 BO./ 9e(eratio( o8
&ata+eet a(d "ot Etimatio( +ave alo
bee(
,overed.
<it+ t+e ,ompletio( o8 t+i pro#e,t/ t+e
%(o1led9e
o8 dei9( ,ode/ +a(dboo%/ %(o1led9e
aimilated
t+rou9+ ,ollaborator/ i(2+oue RS&
developme(t/
dei9( improveme(t/ ,ompetitorE pra,ti,e
i(,ludi(9
ri,+ e7perie(,e o8 1or%28or,e i( ,o(de(er area
Call
t+ee +ave bee( i(te9rated ui(9 proper
lo9iti, o
a to avoid @or to %eep at bare mi(imumA +uma(
i(terve(tio( duri(9 total pro,e o8 dei9(/ i(
order
to evolve variou dei9( alter(ative a(d
ele,t optimum dei9(.
6+e e88e,tive ue o8 t+i pro#e,t 1ill !ield
optimiFed
,o(de(er dei9( 1it+ redu,tio( i( dei9(
,!,le
time S ,ot a(d improveme(t i( -ualit! S
deliver! b! 1a! o8 ue o8 moder( '6 tool. &EVELO:.EN6 O0 H;&RO 6URB'NE BLA&EMRUNNER .O&EL 6HROU)H RA:'& :RO6O6;:'N) 6E"HN'?UE
BHEL i t+e lar9et ma(u8a,turer o8 +!dro
turbi(e
i( t+e ,ou(tr!. At pree(t/ ,aled model o8
ea,+ a(d ever! (e1 ma,+i(e i made to demo(trate t+e
>2& .odel o8 B00.< "o(de(er Aembl!
+!drauli, e88i,ie(,! a(d related parameter/ prior
to
t+e ma(u8a,turi(9 pro,e. 6+ee model are bei(9
made t+rou9+ a le(9t+! a(d time2,o(umi(9 pro,e.
Rapid :rotot!pi(9 te,+(i-ue i 1idel! bei(9
adopted
i(ter(atio(all! b! ma#or ma(u8a,turer 8or ,!,le
time redu,tio( i( e(9i(eeri(9 epe,iall! 1+e( (e1
produ,t are i(trodu,ed. '( li(e 1it+ t+i tre(d/
t+e
8eaibilit! o8 adopti(9 t+e Rapid :rotot!pi(9 @R:A
te,+(i-ue 8or ma%i(9 metalli, model o8 H!dro
6urbi(e BladeMRu((er 1a ta%e(up i( BHEL.
6+e Ru((er blade bei(9 t+e mot ,riti,al
,ompo(e(t/
1a modeled t+rou9+ t+e R: te,+(i-ue. "ro1( S
lo1er ri(9 1ere made b! ,o(ve(tio(al ma,+i(i(9.
Se,tio( pro8ile a(d olid model o8 t+e +!dro
turbi(e
blade 1ere 9e(erated 8rom t+e dra1i(9 ui(9
'&EAS o8t1are. Solid model o8 t+e mat,+i(9
,ro1( a(d t+e lo1er ri(9 1ere alo 9e(erated 8or
aembl! ,+e,%.
Ui(9 t+e olid model o8 t+e H!dro 6urbi(e blade/
R: mater o8 t+e blade 1a made b! t+e
Stereolit+o9rap+! te,+(i-ue. 6+i 1a i(pe,ted b!
pro8ile ,+e,%i(9 template a(d alo b! >& ,o2
ordi(ate meaureme(t e-uipme(t. A ili,o(e rubber
mould 1a made/ ui(9 t+e R: mater a t+e
patter(/ a(d 1a7 patter( 1ere made ui(9 t+i
mould. Stai(le teel blade 1ere made ui(9
t+ee
1a7 patter( b! i(vetme(t ,ati(9.
B! adopti(9 Rapid :rotot!pi(9 te,+(i-ue 8or ma%i(9
t+e blade a(d ui(9 ,o(ve(tio(al met+od 8or
ma%i(9 ,ro1( a(d lo1er ri(9/ avi(9 i( time
a(d
,ot 1ere a,+ieved. A ,ommo( >& olid model
,a(
be ued 8or ma(u8a,turi(9 a(d "0& a(al!i/
t+ereb! mi(imiFi(9 di,repa(,! i( t+e
t+eoreti,al
a(d e7perime(tal reult.
33%V M 7B0 .VA @0.2B SE"ON&SA
<'6HS6AN&'N) E:O=; 6ER.'NAL
BUSH'N)S 0OR H')H2VOL6A)E A"
.O6ORS &EVELO:E&
Epo7! termi(al bu+i(9 are o(e o8 t+e ,riti,al
item
o8 a +i9+2volta9e a, motor/ a t+e! ,arr! +i9+
volta9e
a(d +i9+ ,urre(t. "urre(t level 1it+ta(di(9
re-uireme(t o8 t+ee +i9+2volta9e bu+i(9 are
i(,reai(9 da! b! da! 8rom ,utomer. BHEL/ a
leadi(9 upplier o8 +i9+2volta9e a, motor i(
t+e
,ou(tr!/ +a bee(/ +it+erto/ importi(9 t+ee
bu+i(9.
'( order to i(di9e(ie t+ee bu+i(9G BHEL +a
(o1 developed 7B0 .VA @0.2B e,o(dA 8ault
level
1it+ta(di(9 epo7! termi(al bu+i(9 8or 33%V
+i9+2volta9e a, motor o a to meet t+e mar%et
dema(d.
A (umber o8 dei9( 1ere made 1it+ di88ere(t
varia(t/ a(d 8i(all! t1o dei9(/ viF. @aA
,ir,ular
,ollar t!pe a(d @bA ellipti,al ,ollar t!pe/
1ere
8i(aliFed to meet t+e re-uireme(t o8 e7iti(9
termi(al
bo7 ma(u8a,tured at BHEL. A( optimum pro,e
,!,le 1a etabli+ed to pro,e a(d
ma(u8a,ture
ample bu+i(9.
Routi(e a(d t!pe tet 1ere ,o(du,ted o(
t+ee bu+i(9 at ER&A/ Vadodara /a(d "orporate RS& &iviio( o8 BHEL. 6+e bu+i(9 u,,e8ull! "ir,ular "ollar 6!pe Bu+i(9
1it+tood t+e 8ollo1i(9 pe,i8ied tet to meet
t+e
re-uireme(t o8 33 %V i(ulatio( !temCimpule/
partial di,+ar9e/ po1er 8re-ue(,!/ brea%do1(
volta9e/
ta( delta/ ,apa,ita(,e a(d +ort2time ,urre(t
rati(9
@at 44 %A 8or 0.2B e,o(dA.
<it+ t+i i(di9e(ou developme(t o8 e7po7!2baed
termi(al bu+i(9/ BHEL 1ould be able to ue t+ee
bu+i(9 i( all t+e (o(28lameproo8 +i9+2volta9e a,
motor o8 33 %VM3200 A rati(9/ a(d t+ereb! ave i(
8orei9( e7,+a(9e.
&'S"HAR)E "URREN6 6ES6 ON HV SER'ES
"A:A"'6OR C 0A"'L'6; ES6ABL'SHE& 'N
BHEL
BHEL +a developed HV erie ,apa,itor 8or 400
%V erie ,ompe(atio( pro#e,t/ 8or t+e 8irt time
i(
t+e ,ou(tr!. 'E" 6034> ta(dard ,all 8or ome
pe,ial tet li%e &i,+ar9e "urre(t 6et 8or HV
erie ,apa,itor ued i( lo(9 tra(miio( li(e.
6+i tet 8a,ilit! i (ot available i(di9e(oul!/
a(d eve( 9etti(9 t+i tet ,o(du,ted at reputed
'(ter(atio(al 6eti(9 a9e(,ie i beet 1it+
problem. '( vie1 o8 t+i/ BHEL u(dertoo% a(d impleme(ted
etabli+i(9 o8 t+i tet 8a,ilit! i(2+oue 8or
t+e 8irt
time i( t+e ,ou(tr!/ to meet &i,+ar9e "urre(t
6et re-uireme(t o8 our eteemed ,utomer/ .M :o1er
)rid "orporatio(. 6+i tet 8a,ilit! 1a
etabli+ed 1it+ i(ter(al reour,e mobiliFed 1it+i( BHEL2 B+opal.
6+e teti(9 1a ,ompleted u,,e8ull! i( t+e
pree(,e o8 t+e repree(tative o8 t+e "utomer. 6+u/ BHEL +a added o(e more (e1 tet 8a,ilit! to t+e erie o8 (e1 tet 8a,ilitie it +a bee(
developi(9 8or ,o(du,ti(9 pe,ial tet i(2
+oue/ i(
a,,orda(,e 1it+ '(ter(atio(al Sta(dard.
EVALUA6'ON O0 'NH'B'6ORS 0OR SS >04
AN& A&.'RAL6; BRASS "ON&ENSER 6UBE
.A6ER'ALS 'N "ON6A"6 <'6H R'VER
<A6ER
&ue to i(,reae i( i(dutrialiFatio(/ t+ere i
deterioratio( i( t+e -ualit! o8 ur8a,e 1ater/
but t+ere
i (o alter(ative e7,ept to ue t+e (aturall!
available
1ater 8or ,ooli(9 purpoe. Natural 1ater
,o(tai(
diolved olid/ 9ae a(d ometime ,olloidal
or
upe(ded matter. All t+ee impuritie a88e,t
t+e
,ali(9 M ,orroio( propertie o8 t+e 1ater i(
relatio(
to t+e metal 1it+ 1+i,+ it i i( ,o(ta,t.
6+i lead
to ma(! operatio(al problem li%e ,orroio(/
eroio(/
,ali(9/ 8ouli(9 et,. <+ere t+e available
our,e o8
,ooli(9 1ater i 8rom a river/ eit+er SS >04 or
,opper allo! i ued a tube material i( po1er pla(t
"o(de(er. Ho1ever/ due to bad -ualit! o8
1ater/
t+ee material/ t+ou9+ reita(t to ,orroio(/
are alo
pro(e to ,orroio( atta,%. '( order to mi(imiFe
t+e
,orroio(/ ,ommer,iall! available i(+ibitor
are doed
i(to t+e ,ooli(9 1ater. Additio( o8 t+ee
i(+ibitor
ubta(tiall! redu,e t+e ,orroio( rate o8 t+e
tube
material/ t+u i(,reai(9 t+e li8e o8 t+e
,o(de(er.
:er8orma(,e evaluatio( o8 variou i(+ibitor
8or SS
>04 a(d admiralt! bra 1a re,e(tl! ta%e( up
at "orporate RS& &iviio( o8 BHEL.
Ellipti,al "ollar 6!pe Bu+i(9
"apa,itor u(der9oi(9 &i,+ar9e "urre(t
6et
6+ree ,ommer,ial i(+ibitor 1ere evaluated 8or
admiralt! bra a(d ,upro2(i,%el @50M30A i( river
medium/ i( tati, a 1ell a d!(ami, ,o(ditio(.
Ele,tro,+emi,al e7perime(t 1ere ,o(du,ted to
ae
t+e ,orroio( rate o8 t+ee tube material 1it+
a(d
1it+out t+e additio( o8 i(+ibitor. 6+e optimum
,o(,e(tratio( o8 t+e i(+ibitor 1a 8ou(d to be
0.3L. '( order to ,arr! out t+e ,orroio(
e7perime(t
u(der d!(ami, ,o(ditio(/ pe,ial probe 1ere ued
i( t+e d!(ami, ,orroio( tet ri9 to evaluate t+e
per8orma(,e o8 t+e i(+ibitor t+rou9+ li(ear
polariFatio( te,+(i-ue. 6+e ,orroio( ,urre(t 1a
,o(ti(uoul! meaured a(d re,orded i( t+e data
a,-uiitio( !tem.
Reult *
All t+e i(+ibitor per8ormed 1ell u(der d!(ami,
,o(ditio( a(d redu,ed t+e ,orroio( ,urre(t
lar9el!/
e7+ibiti(9 a( e88i,ie(,! o8 (earl! 55L o( "opper
allo!. '( river 1ater medium/ SS >04 +a +i9+
,orroio( reita(,e ,ompared to ,opper allo!/
a(d
+e(,e additio( o8 i(+ibitor i (ot re-uired. 0or
,opper allo!/ a(! o(e o8 t+e t+ree i(+ibitor
teted
,a( be ued/ baed o( t+e e,o(omi, ,o(ideratio(.
6+e tudie ,o(du,ted a(d t+e data ,olle,ted/
+all
be ue8ul to dia9(oe/ a(al!e a(d i(terpret
variou
,ooli(9 1ater ,+emitr! related problem i(
,o(de(er. Appropriate i(+ibitor ,a( alo be
re,omme(ded to mi(imiFe t+e ,orroio( o8 ,o(de(er
tube material.
2B0 L:& SOLAR <A6ER HEA6'N) S;S6E.
<'6H HEA6 :':E "OLLE"6ORS &EVELO:E&
Baed o( t+e u,,e8ul developme(t o8 300 L:&
Solar )e!er @a alread! reported i( t+e
&e,ember
2004 iueA/ a(d alo 8rom t+e mar%et tud!/
t+ere
1a a (eed to develop +i9+er2,apa,it! &ometi,
Solar <ater Heati(9 S!tem to ,ater to t+e
di88ere(t
e9me(t o8 ,utomer. He(,e/ developme(t o8
2B0
L:& Solar <ater Heati(9 S!tem 1it+ +eat pipe
,olle,tor 1a ta%e( up. A a reult/ t1o
protot!pe
+ave bee( developed a(d i(talled 8or lo(92term
teti(9 at t+e "orporate RS& &iviio(. 6+e
!tem
deliver 2B0 litre o8 +ot 1ater per da! at a
temperature o8 60 to 700"/ depe(di(9 o( t+e
olar
i(te(it!.
6+e 2B0 L:& !tem baed o( +eat pipe ,olle,tor
i mu,+ more e88i,ie(t a ,ompared to a
ta(dard
t+ermo2!p+o( !tem/ a t+ere i (o +eat lo
due
to revere ,ir,ulatio( duri(9 t+e (i9+t/ i(,e
t+e +eat
pipe a,t a a t+ermal diode/. 0urt+er/ t+e
!tem
developed doe (ot re-uire i(ter,o((e,ti(9
i(ulated
pipeli(e bet1ee( tora9e ta(% a(d t+e ,olle,tor
arra!.
6+e 2B0 L:& S!tem developed 1ill meet t+e
dema(d o8 t+e +i9+er2e(d dometi, ,utomer a
1ell a Lar9e Solar <ater Heati(9 S!tem.
6+ee
!tem ,a( be ,o((e,ted i( erie a(d parallel
,ombi(atio( to meet t+e re-uired ,apa,it! o8
Lar9e
Solar <ater Heati(9 S!tem/ i.e. 8our !tem
o8
2B0 L:& ,a( be upplied 8or a 3000 L:& !tem.
6+e !tem ,a( be i(talled ,loe to t+e
utilit! poi(t/ t+ereb! redu,i(9 +ot 1ater lo i( t+e pipeli(e. &!(ami, "orroio( 6et Ri9 2B0 L:& Solar <ater Heati(9 S!tem
RE"EN6 .AJOR A"H'EVE.EN6S O0 BHEL
@duri(9 .ar,+E062Au9utE06A
OR&ERS BA))E&
Overea
lA,+ieved !et a(ot+er brea%t+rou9+ i( t+e
i(ter(atio(al mar%et b! 1i((i(9 it e,o(d
,o(e,utive order 8rom Et+iopia 8or 2>0 %V
ubtatio( o( E:" bai 8rom Et+iopia(
Ele,tri, :o1er "orporatio( @EE:"OA. Lat
!ear/ BHEL 1o( a imilar ,o(tra,t/ 8u(ded
b! t+e <orld Ba(%/ 8or ubtatio(/ ma%i(9
i(road i( Et+iopia. BHEL +a 1o( t+e
,o(tra,t outbiddi(9 "+i(ee a(d ot+er
multi(atio(al ,ompa(ie. 6+e pro#e,t i
8u(ded b! t+e $u1ait 0u(d. 6+e ,o(tra,t
a9reeme(t 8or t+i pro#e,t/ i9(ed bet1ee(
BHEL a(d EE:"O/ i part o8 a(
ele,tri8i,atio( pro9ramme i(itiated b! t+e
Et+iopia( )over(me(t i( t+e A8ar State o8
Et+iopia. BHELE ,ope o8 1or% i( t+e
pro#e,t i(,lude dei9(/ uppl!/ ere,tio(/
,ivil
,o(tru,tio( a(d ,ommiio(i(9 o8 2>0 %V
Semera a(d &i,+oto ubtatio(. 6+e
ubtatio( are to be ,ompleted i( a
,+edule
o8 3D mo(t+.
l<o( a preti9iou ,o(tra,t 8or etti(9 up 2>0 %V ubtatio( o( E:" bai i( Ba(9lade+. Outbiddi(9 "+i(ee/ .ala!ia( a(d '(dia( "ompa(ie/ BHEL +a 1o( t+e ,o(tra,t 8or
uppl! a(d i(tallatio( o8 a 2>0 %V
ubtatio( at Ba9+abari :o1er :la(t a(d e7te(io( o8 a 2>0 %V ubtatio( at '+urdi. 6+e Aia( &evelopme(t Ba(% @A&BA 8u(ded ,o(tra,t +a bee( pla,ed o( BHEL b! :o1er )rid "ompa(! o8 Ba(9lade+. 6+i i t+e 8irt
order 8or BHEL 8or ubtatio( i(
Ba(9lade+. BHELE ,ope o8 1or% i( t+e pro#e,t i(,lude
dei9(/ uppl!/ ere,tio(/ ,ivil
,o(tru,tio( a(d ,ommiio(i(9 o8 a 2>0 %V ubtatio( at
Ba9+abari a(d e7pa(io( o8 '+urdi
ubtatio(.
lSe,ured t1o preti9iou ,o(tra,t i(
A89+a(ita( a part o8 t+e ,ompa(!E
a99reive pla( 8or i(,reai(9 bui(e
i(
Sout+ Aia. 6+i alo mar% BHELE 8ora!
i(
A89+a(ita(/ 1+i,+ i a pote(tial mar%et.
6+e t1o tur(%e! ,o(tra,t +ave bee(
e,ured
b! BHEL 8rom :o1er )rid "orporatio( o8
'(dia 8or etti(9 up a 220 %V ubtatio(
at
$abul/ a(d 8rom <ater S :o1er "o(ulta(,!
Servi,e @<A:"OSA/ '(dia/ 8or uppl! a(d
i(tallatio( o8 Ele,trome,+a(i,al
:a,%a9e
8or 42 .< Salma H!droele,tri, :o1er :la(t
i( A89+a(ita(.
lA,+ieved a brea%t+rou9+ i( t+e i(ter(atio(al
mar%et 8or tra(8ormer b! e,uri(9 a
preti9iou e7port order 8rom E9!pt. <o(
i(
t+e 8a,e o8 ti88 i(ter(atio(al
,ompetitio(/
t+e order +a bee( pla,ed o( BHEL b! t+e
E9!ptia( Ele,tri,it! 6ra(miio( "o.
@EE6"A. 6+i i t+e i(9le2lar9et order
8or
tra(8ormer ever re,eived b! BHEL a(d
t+e
maide( order 8or tra(8ormer 8rom E9!pt.
6+i order i e7pe,ted to 9ive a 8illip
to
BHELE e88ort at pla!i(9 a more
promi(e(t
role i( t+e lar9e :o1er :ro#e,t pla((ed
i( E9!pt C o(e o8 t+e lar9et ,ou(trie i( A8ri,a( ,o(ti(e(t. A 1+oll! o1(ed
)over(me(t or9a(iFatio( u(der t+e
.i(itr! o8 Ele,tri,it! a(d E(er9!/ E9!pt/ EE6" i repo(ible 8or .a(a9eme(t/ Operatio( a(d
.ai(te(a(,e o8 Hi9+ a(d Ultra +i9+
Volta9e
Ele,tri, :o1er 6ra(miio( 9rid/ all
over t+e ,ou(tr!. &ometi, lSe,ured ,o(tra,t 8or etti(9 up a B00 .< t+ermal po1er pla(t @272B0 .<A i( Uttar :rade+. Repoi(9 ,o(8ide(,e i( BHELE
,apabilit! a(d te,+(olo9i,al e7,elle(,e/
Uttar
:rade+ Ra#!a Vid!ut Utpada( Ni9am
Limited @U:RVUNLA +a pla,ed order 8or
etti(9 up 2 u(it o8 2B0 .< ea,+ @U(it
BS6A at :ari,++a 6:S E7t(. 6+e pro#e,t i
lated 8or ,ommiio(i(9 i( 8i,al 2005230.
<it+ t+i/ BHEL +a mai(9tai(ed it tra,%
re,ord o8 ba99i(9 mot o8 t+e order pla,ed
b! U:RUVNL 8or po1er 9e(erati(9
e-uipme(t i( Uttar :rade+. So 8ar/ BHEL
+a ,ommiio(ed over 5/000 .< o8 po1er
9e(erati(9 et i( t+e tate. 6+ee i(,lude
t+ermal/ 9a2baed/ (u,lear a(d +!dro u(it
o8 variou rati(9.
lSe,ured ,o(tra,t 8rom '(diaE lar9et :o1er
Utilit!/ N6:"/ 8or etti(9 up t+e 8irt u(it
o8 450.< ,apa,it!/ at it Natio(al "apital
6+ermal :o1er :ro#e,t @N"6::A Sta9e2''/ at
&adri i( Uttar :rade+. <it+ t+i/ N6:"
+a o(,e a9ai( repoed ,o(8ide(,e i( BHELE
prove( te,+(olo9i,al e7,elle(,e a(d
,apabilit!
i( e7e,uti(9 pro#e,t o8 t+i ma9(itude.
6+e
pro#e,t i lated 8or ,ommiio(i(9 i(
8i,al
2005230.
lA,+ieved a ma#or u,,e i( t+e 8orm o8 a
preti9iou ,o(tra,t 8or a 2B0 .< 6+ermal
:o1er Statio( @6:SA/ ba99ed i( t+e 8a,e o8
ti88 ,ompetitio( 8rom "+i(ee a(d $orea(
e-uipme(t upplier. 6+e ,o(tra,t +a bee(
1o( 8rom 6ata :o1er "ompa(! @6:"A
u(der ,ompetitive biddi(9. Notabl!/ t+i i
t+e 8irt order e,ured b! BHEL 1+ere t+e boiler 1ill be dei9(ed to uit 8iri(9 o8
imported ,oal. 6:" +a repoed it
,o(8ide(,e i( BHEL b! pla,i(9 t+e order 8or dei9(/ e(9i(eeri(9/ ma(u8a,ture/ uppl!/ ere,tio(/ teti(9 a(d ,ommiio(i(9 o8 mai( pla(t pa,%a9e 8or U(it2D o8 6romba! 6:S i( .a+ara+tra. lSe,ured ,o(tra,t 8or etti(9 up t1o t+ermal po1er pro#e,t i( Ra#at+a(. Repoi(9
,o(8ide(,e i( BHELE te,+(olo9i,al
e7,elle(,e
a(d pro#e,t e7e,utio( ,apabilitie/
Ra#at+a( Ra#!a Vid!ut Utpada( Limited @RVUNLA +a pla,ed order/ ,umulativel! valued at
R.D42 "rore/ 8or etti(9 up a 2B0 .<
u(it
at Surat9ar+ 6:S a(d a 35B .< u(it at
$ota 6:S. 6+e u(it are lated 8or
,ommiio(i(9 i( 8i,al 200D205/
8ollo1i(9
1+i,+ po1er ituatio( i( t+e tate 1ill
eae
,o(iderabl!. <it+ t+ee ,o(tra,t/ BHEL
+a mai(tai(ed it tra,% re,ord o8
ba99i(9 all
t+e order pla,ed b! RVUNL 8or po1er
9e(erati(9 e-uipme(t i( Ra#at+a(. BHEL
+a o 8ar ,ommiio(ed over 2400 .< o8
po1er 9e(erati(9 et i( Ra#at+a(.
lSe,ured ,o(tra,t 8or t+e uppl! a(d ere,tio(
o8 Ele,trome,+a(i,al e-uipme(t 8or t1o
eparate H!dro Ele,tri, :ro#e,t @HE:A i(
A(d+ra :rade+/ 1o( i( t+e 8a,e o8
i(te(e
,ompetitio( 8rom Europea( a(d "+i(ee
multi(atio(al ,ompa(ie. 6+e order 1a
ba99ed b! BHEL u(der '(ter(atio(al
"ompetitive Biddi(9 @'"BA/ a it o88er
1a
8ou(d te,+(o2e,o(omi,all! t+e bet.
"umulativel! valued at (earl! R.D2
"rore/
t+e order 8or Na9ar#u(aa9ar 6ail :o(d
&am @272B .<A a(d Srirama9ar HE:
E7t(. @375 .<A/ +ave bee( pla,ed o(
BHEL b! A(d+ra :rade+ :o1er )e(eratio(
"orporatio( @A:)e(,oA a(d are a meaure
o8 t+e ,utomerE ,o(8ide(,e i( BHELE
prove( ,apabilitie i( e7e,utio( o8 +!del
po1er pro#e,t.
lSe,ured order 8or etti(9 up a Li8t 'rri9atio(
S,+eme i( A(d+ra :rade+. 6+e ,+eme 1ill
be(e8it t+oua(d o8 8armer o8 t+e tate
b!
irri9ati(9 2.7B La%+ +e,tare o8 par,+ed
la(d a(d ma%i(9 it arable. <o( a9ai(t ti88 ,ompetitio(/ t+e order 8or t+e B7>0 .< $al1a%urt+! Li8t 'rri9atio( S,+eme/ +a bee( pla,ed o( BHEL b! )ammo( '(dia/
1+o e,ured t+e E:" ,o(tra,t 8or t+e
pro#e,t
8rom t+e A: )ovt. BHEL i alread!
e7e,uti(9
Sta9e2' o8 t+e S,+eme/ t+e order 8or
1+i,+ 1a pla,ed o( t+e ,ompa(! b! :atel E(9i(eeri(9. lBHEL i to et up o( tur(%e! bai/ a(ot+er
li9(ite2baed po1er pro#e,t i( )u#arat
8or
)':"L. 6+e po1er pla(t 1ill be e-uipped
1it+ a( e,o28rie(dl!/ tate2o82t+e2art
"ir,ulati(9 0luidied Bed "ombutio(
@"0B"A Boiler/ pe,i8i,all! dei9(ed to
utiliFe
lo129rade 8uel li%e li9(ite/ +i9+ a+ ,oal/
1a+er! re#e,t et,. 6o t+i e88e,t/ )':"L
+a
o(,e a9ai( repoed ,o(8ide(,e i( BHELE
prove( te,+(olo9i,al e7,elle(,e a(d
,apabilit!
b! pla,i(9 a( order valued at R.3200 "rore
8or etti(9 up 2 u(it o8 32B .< ea,+
@U(it >S4A 8or Surat Li9(ite 6+ermal :o1er
Statio( E7pa(io( pro#e,t. 6+e t1o u(it
1ill be ,ommiio(ed i( a ti9+t ,+edule o8
>> a(d >7 mo(t+ repe,tivel!.
lSe,ured order 8or a ,aptive po1er pla(t to be
i(talled i( a teel pla(t i( )u#arat.
Repoi(9
,o(8ide(,e i( BHELE ,apabilitie/ t+e Ear
)roup +a pla,ed a( order 8or a 330.6 .<
)a 6urbi(e )e(erator Set 8or a( ope(2,!,le
,aptive po1er pla(t 8or t+e e7pa(io( o8
t+e
e7iti(9 ,aptive po1er pla(t at Ear
)roupE
HaFira pro#e,t. 6+e upplie 8or t+e pro#e,t
are lated 8or ,ompletio( i( a ver! ti9+t
,+edule o8 #ut 34 mo(t+. 0or Ear/ BHEL
i alread! e7e,uti(9 a( order 8or a ,aptive
po1er pla(t o8 imilar rati(9 at HaFira.
6+e
pro#e,t i i( a( adva(,ed ta9e a(d i
e7pe,ted to be ,ommiio(ed +ortl!. 6+e
!(,+ro(iFatio( o8 t+ee u(it 1ill e(ure
,o(ti(uou uppl! o8 236 .< o8 -ualit!
po1er to t+e teel pla(t/ 1+i,+ 1ill be
+i9+l! ,ot2e88e,tive 8or t+e ,utomer/ ma%i(9 t+e e(d produ,t e,o(omi,al. "O..'SS'ON'N) H')HL')H6S l6+e 8irt B00 .< u(it at N6:"E Vi(d+!a,+al Super 6+ermal :o1er Statio(
@S6:SA Sta9e2'''/ i( .ad+!a :rade+/ +a
bee( ,ommiio(ed. <it+ t+e
!(,+ro(iFatio(
o8 t+e u(it/ 32 millio( u(it o8
ele,tri,it!
1ill be added to t+e 9rid o8 t+e po1er2
de8i,it
tate/ ever! da!. Valued at R.232B
"rore/
N6:" +ad pla,ed t+e .ai( :la(t :a,%a9e
,o(tra,t 8or t+e 27B00.< Vi(d+!a,+al
S6:S 2 Sta9e ''' o( BHEL/ o(,e a9ai(
repoi(9 ,o(8ide(,e i( BHELE
te,+(olo9i,al
e7,elle(,e S ,apabilit! i( e7e,uti(9
pro#e,t
o8 t+i ma9(itude. <it+ t+e ,ommiio(i(9
o8 t+i u(it/ t+e ,umulative 9e(erati(9
,apa,it! o8 t+e po1er tatio( +a 9o(e up
to
2760 .<. 6+e e,o(d u(it i alo tar9eted
8or ,ommiio(i(9 b! BHEL i( 8i,al 20062
07. O( ,ompletio( o8 Sta9e2'''/ t+e
9e(erati(9 ,apa,it! o8 Vi(d+!a,+al S6:S
1ill be e(+a(,ed to >260 .</ ma%i(9 it
'(diaE lar9et po1er 9e(erati(9
tatio(.
A<AR&S
l0or outta(di(9 e7port per8orma(,e/ BHEL
+a 1o( t+e E(9i(eeri(9 E7port :romotio(
"ou(,il @EE:"AE a1ard/ 8or t+e 36t+ !ear
i( u,,eio(. "o(8erred o( BHEL i( t+e
,ate9or! EStar :er8ormer i( 200420B*
:o1er
)e(eratio( E-uipme(t a(d :art C Lar9e
E(terprieE/ t+e a1ard 1a pree(ted b!
t+e
Ho(Eble U(io( .i(iter 8or "ommer,e S
'(dutr!/ .r. $amal Nat+/ o( Au9ut 30/
2006. Overea bui(e +a bee(
ide(ti8ied a a ma#or t+rut area b! t+e ,ompa(!. '( t+i dire,tio(/ +ort2term a(d lo(92term pla( +ave bee( ,+al%ed out 1+i,+ are !ieldi(9 ri,+ divide(d. &uri(9 t+e lat
8i,al/ BHEL boo%ed t+e +i9+et2ever
p+!i,al
e7port order o8 R.>/>4D "rore C a i72
8old i(,reae over t+e previou !ear.
Ri+a(d S6:SCBHEL +a upplied 27B00 .< et.
$a!am%ulam "":: @>B0 .<A.
Re9itratio( No. RN227700M76
B+arat Heav! Ele,tri,al
Limited
BHEL Houe/ Siri 0ort/ Ne1 &el+i2330 045 Viit our <ebite at * +ttp*MM111.b+el.,om :ubli+ed b! B+arat Heav! Ele,tri,al Ltd./ a(d pri(ted at V'BA :RESS :V6. L6&./
"266M>/ O%+la '(dl. Area/ :+ae2''/ Ne1 &el+i2330020. 6el. * 43633>00/ 6ele8a7 *
26>D6B00

Bhel Journa Sep 06

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Bhel Journa Sep 06

Uploaded by

Copyright:

Available Formats

BHEL JOURNAL

Volume 27 No. 2 September 2006

You might also like