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Copyright reserved. STPS.
ADVANCES IN MATERIALS FOR ADVANCED STEAM
CYCLE POWER PLANTS
Kulvir Singh
SYNOPSIS issues for both the boilers and the turbines in next-
generation ultra supercritical power plants.
The efficiency of conventional boiler or steam turbine
fossil fuel fired power plants is strongly based on steam
temperature and pressure. Since the energy crisis of the Key Words:
1970s, there have been efforts worldwide to increase
Power Plants; Creep-Resistant Steels; Rotors; Casings;
both : extensive research has been pursued worldwide.
Boiler; Superheater.
The need to reduce carbon dioxide emissions has provided
further impetus to improve efficiency. Development of
stronger high-temperature materials is the prime 1. INTRODUCTION
requirement. EPRI and many other organizations have
extensively reviewed the materials technology for ultra An enhanced ecological awareness in the industrialised
supercritical power plants. This article reviews the potential countries prompted increased initiatives world over
benefits, operational experiences, the present trend and to reduce CO2 emission levels in the power plants.
the advances in materials that require special attention, This is essentially achieved by improving the efficiency
in respect of power plants with supercritical steam of the plants. Figure-1 shows some possibilities of
conditions. This will serve as a basis for defining material increasing power plant efficiency [1]. In conventional
FIG. 4 : NET HEAT RATE IMPROVEMENT FOR SINGLE AND DOUBLE REHEAT CYCLES [10]
FIG. 5 : INTERNATIONAL RESEARCH PROGRAMMES FOR DEVELOPING ADVANCED STEAM CYCLE PLANTS [10]
allowable stresses and 100,000h stress rupture steels can be used to some extent even at steam
strength, respectively [14-20]. temperatures slightly below 540°C. This solution
permits thickness of tubes less than those needed for
Carbon steels are suitable and economical up to the common low-alloy steels for the same operating
about 400 to 450°C metal temperature. Low-alloy conditions as shown in Fig. 8. This results in saving
steels ⏐ Mo (SA209 T1), 1...Cr ⏐ Mo—Si (SA213 of base material and welding filler material, reduces
T11) and 2...Cr1Mo (SA213 T22) are used widely thermal stresses and welding problems and also
for metal temperatures up to 480, 550 and 580°C improves the heat transfer efficiency.
respectively [21]. T22 steel which has been extensively
used for the final superheater for conventional units
operating at a main steam temperature of 540°C has
too low a creep strength to be accepted as a final 10CrMo9.10
stage superheater material for use with a steam
temperature of 565°C. Though these steels can still NF616
be used for the tube banks operating up to their
existing allowable temperatures in the boilers of
supercritical units, with the increase in steam pressure
their required wall thickness increases. There is a
strong incentive in using improved carbon steels now X20 T91/P91
available with higher allowable yield strength at
lower temperatures up to 450°C and in bringing
down the temperature range of application of the
FIG. 8 : COMPARISON OF THE SIZE OF THE WALL THICKNESS
low-alloy steels such that strong high-alloy ferritic OF P22, X20, P91 AND NF616 STEEL PIPES
4.4 Heavy Section Stationary Parts Since the outer casing is subjected to cooler and low-
pressure steam as compared to the other casing, this
High-pressure turbine requires a number of heavy could be still made of the conventional low-alloy
section static components such as the inner and outer ferritic steel.
casings, static components such as the inner and outer
casings, the steam valve, the nozzle box, and the inlet
pipe. Besides high temperature and pressure, these 4.5 Transition Weld Joints
parts are subject to thermal cycling. If the section
In cases where main steam piping and the outer
sizes are very high, there is a danger of experiencing
casing are made of austenitic and low-alloy ferritic
thermal cracking as a result of the heavy thermal
steels, respectively, the inlet piping to the turbine
stresses that might develop during start-up or carry-
will have to utilize transition joints. An approach
over. It is, therefore, desirable to minimize the section
suggested to this problem is to make the joint in
size by using high-strength steel so as to reduce
three sections, utilising a material of intermediate
thermal stresses. Depending on the stresses and the
thermal expansion coefficient such as Alloy 800H in
required wall thicknesses, it might be advisable to
between the pipe and the casing with nickel-based
employ 12Cr steel at temperatures lower than 566°C
filler metal for welding. Nickel-based filler metal
and austenitic steels at temperatures as low as 566°C.
improves the rupture life as much as five times more
This could be advantageous especially in the case of
than the austenitic filler metals. Due care must also
high-pressure units designed for 31 MPa and above.
be taken in design to minimize bending stresses, as
Given the choice, forgings are preferred as they allow
life of transition joints is greatly reduced if bending
thinner sections but it would be economical to use
stresses are superimposed upon stresses from thermal
castings. Toshiba [7] will be using a 12Cr cast steel
expansion.
(10CrMoVNbN) for these parts of the units at
566°C, whereas EPRI [9] intends to give preference
to forgings for the initial advanced units. 4.6 Bolting
In order to minimize differential thermal expansion, Bolts and studs are used in many joints of the
it is desirable to make the rotor and the stationary turbine, which need to be separated for maintenance
parts of the turbine of the same material. However, or repairs, as for example, castings and valves. The
for 593°C units, it is likely that the rotor would be bolts and studs differ from all other turbine
made of 12Cr steel, while the inner casing would be components in that they are notched, subjected to
made of austenitic steel. Under such circumstances, cold as well as hot stressing and a varying pattern
shaft seals must be used to accommodate the greater to stressing due to practice of tightening and
thermal expansion of the casing. Larger clearances retightening. The strain to which bolts are tightened
are required to be given, when austenitic steels are is based on both the properties of the materials and
employed for rotating and stationary parts, for most the design practice. The usual strain applied in UK
advanced steam conditions. Both the design is 0.15% [44], whilst it is 0.2% in Germany [36].
requirements, 12Cr rotor cooling at 593°C and The elastic strain produced by the initial tightening
larger clearance to be provided with austenitic steels of the bolts is progressively converted to creep strain,
at higher temperatures, adversely affect the cycle thereby reducing the effective load on the joint.
efficiency. This, in turn, partly reduces the net heat Bolts for turbine parts are required to possess
P.K. Khanna
STAR-CONNECTED STAR-CONNECTED
FIG. 2 : LOAD LINE OF CAPACITANCE TANGENT STATOR WINDING CAPACITOR BANK
TO THE MAGNETISING CURVE FIG. 3
6. INDUCTION GENERATOR ON
(iii) Delta-connected stator winding and Star- LOAD (Fig. 7)
connected capacitor bank (Fig. 5)
Under no-load condition, since only the magnetizing
(iv) Delta-connected stator winding and Delta- current is flowing through stator winding, voltage
connected capacitor bank (Fig. 6) drop in stator winding is very small, and therefore
the voltage at the generator terminals is almost equal
to the induced e.m.f. in stator winding.
DELTA-CONNECTED STAR-CONNECTED
STATOR WINDING CAPACITOR BANK
FIG. 5
DELTA-CONNECTED DELTA-CONNECTED
STATOR WINDING CAPACITOR BANK
FIG. 6 FIG. 7 : GENERATOR WITH LOAD
9. VOLTAGE REGULATION
Though in the above paragraphs, it has been
presumed that at rated voltage the rotor core gets
fully saturated, but practically the core is never
saturated fully and thus, it would always result in
large variation of the terminal voltage with respect
FIG. 8 : DETERMINATION OF CAPACITANCE VALUE to load current. This problem of drop in voltage
The Induction Machine when operated as a Generator 1. S.S. Murthy, C.S. Jha and P.S. Nagendrarao,
always requires its excitation from outside. Either it "Analysis of grid connected induction generators
remains connected to the supply if it is to feed power driven by hydro/wind turbine under realistic
to grid or its excitation can be provided through a system constraints," in IEEE Trans. Energy
capacitor bank if it is feeding power to a stand-alone Conversion, vol. 5, pp. 1-7, Mar. 1990.
system. In stand-alone system like wind mill installed 2. L. Shridhar, B. Singh, C.S. Jha and B.P.
in a remote area having no grid power supply, there Singh, "Analysis of self-excited induction
are various options available for providing the generator feeding induction motor," in IEEE
necessary excitation to Induction Generator and also Power Eng. Soc., Summer Meetings, 1994, pp.
for maintaining a constant terminal voltage at 1-7.
different loads.
3. L. Shridhar, B.Singh, C.S. Jha, B.P. Singh and
S.S. Murthy, "Selection of capacitors for the self
Acknowledgement regulated short shunt self-excited induction
generator," in IEEE Trans. Energy Conversion,
The author wishes to express his sincere gratitude to vol. 10, pp. 10-17, Mar. 1995.
Sh S.K. Goyal, GGM, Corp. R & D, BHEL,
Hyderabad, for his continuous encouragement and 4. S.P. Singh, Sanjay K. Jain and J. Sharma,
guidance in writing this paper. Thanks are also due "Voltage regulation optimization of compensated
to Sh M.S. Dhami, AGM (EME) & Sh S.C. Goel, self-excited induction generator with dynamic
SDGM (MM) for their support and help in load," in IEEE Trans. Energy Conversion, vol.
completing this paper. 19, pp. 724-732, Dec. 2004.
Mr. Khanna joined BHEL, Haridwar, as an Engineer Prior to this paper, Mr. Khanna has contributed
Trainee in 1979 and was posted in AC Machines one technical paper in an International Conference
Engineering Department. For more than 24 years, held at IIT, Roorkee, recently.
C. Prem Kumar
5. HARMONIC ANALYSIS
FIG. 7 : THF CONTRIBUTION FROM INDIVIDUAL HARMONICS AND CUMULATIVE VARIATION WITH INCREASING HARMONIC NUMBER
(1) M.V.K. Chari, P.Silvester, "Analysis of (9) M.G. Say, "The Performance and Design of
Turboalternator Magnetic Fields by Finite Alternating Current Machines", Sir Isaac
Elements", IEEE Trans. on PAS, Vol-PAS-90, Pitman & Sons, London.
No:2, March-April 1971, pp.454 to 464.
(10) Ralph R.Lawrence & Henry E. Richards,
(2) M.V.K. Chari "Finite Element Analysis of "Principles of Alternating Current Machinery",
Electrical Machinery and Devices", IEEE Trans. McGraw-Hill Book Company, USA.
on Magnetics, Vol.MAG-16, No.5, Sept.1980,
pp. 1014 to 1019. (11) Alexander S. Langsdorf, "Theory of Alternating-
Current Machinery", McGraw-Hill Book
(3) M.V.K. Chari, "Nonlinear Finite Element Company, USA.
Solution of Electrical Machines Under No-load
and Full-Load Conditions", pp.686 to 689. (12) Robert L.Ames, "A.C. Generators: Design and
Application",John Wiley & Sons, USA.
(4) P.Silvester and M.V.K. Chari, "Finite Element
solution of Saturable Magnetic Field Problems", (13) Mulukutla S. Sarma, "Synchronous Machines
IEEE. Trans. on PAS, Vol.PAS-89, No.7, Sept- - Their Theory, Stability and Excitation
Oct 1970, pp.1642 to 1651. Systems", Gordon & Breach Science Publishers,
New York.
(5) P. Silvester, H.S. Cabayan and B.T. Browne,
"Efficient Techniques for Finite Element analysis (14) Essam S. Hamdi, "Design of Small Electrical
of Electric Machines", IEEE Trans. on PAS, Machines", John Wiley & Sons, USA.
Vol.PAS-92 1971,pp.1274 to 1281.
(15) Brian Chalmers & Alan Williamson, "A.C.
(6) Parviz Rafinejad et al,"Finite Element Machines - Electromagnetics and Design", John
Computer Programs in Design of Wiley & Sons Inc, USA.
Mr. C. Prem Kumar obtained his Engineering Mr. Prem Kumar has several papers to his credit,
degree from Bangalore University in the year published & presented in national & international
1975. forums.
SYNOPSIS depths (Aδo) = 0.0, 0.1 and 0.2, which are of practical
importance in the design of turbo-generator bearing.
This paper is the extension of an earlier paper published The results presented in this paper helps the designer in
in BHEL Journal, (Vol. 26 No.1 February 2005), selecting a suitable combination of preload factor and
wherein it was concluded that the load capacity of a worn depth in order to obtain the desired bearing
loading arc (worn) two-lobe bearing used in turbo- performance in terms of Sommerfeld number (1/load
generator is found higher and that the stability zone is capacity), dynamic coefficients and stability. The bearing
limited when compared to a normal two-lobe bearing dynamic coefficients are useful for rotor dynamic
without loading arc (δo=0.0) used in steam turbine. In analysis.
the present paper, the stability (whirl onset/threshold
speed) of a worn two-lobe bearing L/D=0.82 of
Siemens design used in turbo-generator was studied at Key Words:
different preload factors and worn depths. Bearing
performance data was obtained at preload factors Two-lobe Bearing; Loading Arc (worn region); Wear
(delta) = 0.5, 0.6 and 0.75 and non-dimensional worn Depth (wear dent); Whirl Onset (Threshold) Speed.
NOMENCLATURE
Ch = side clearance (m) or Cp = pad radial clearance
Cv = top clearance/2 (m) or Cb = bearing radial clearance
D = bearing diameter (m)
Delta = Pre load factor = (Ch-Cv)/Ch
e = eccentricity (m)
g = gravitational constant (m/sec2)
h = film thickness (m)
L = bearing length (m)
N = rotating speed (rps)
R = D/2 (m)
W = load on the bearing (N)
punit = W/LD, unit pressure on the bearing (Mpa)
ω = Angular speed of journal (rad/sec)
Non-dimensional quantities:
S = Sommerfeld number = (μNLD/W)(R/Ch)2
Aδo = non-dimensional maximum wear depth = δo/Ch
γ = non-dimensional whirl onset (threshold) speed = ω(Ch/g)1/2
AKij…, = non-dimensional stiffness coefficients = Kij (Ch/W)
ACij…, = non-dimensional damping coefficients = Cij (Chω/W)
2. HYDRODYNAMIC ANALYSIS
3. RESULTS AND DISCUSSION
The non-dimensional hydrodynamic equation for
Figures 2-4 show the variation of oil film stiffness
bearing lubrication [7] is given by:
coefficients (AKii) at worn depths (Aδo=0.0-0.2) and
∂/∂θ (Ah≥∂Ap/∂θ) + r"∂/∂z (Ah≥∂Ap/∂z) preload factors (delta) 0.5, 0.6 and 0,75 with
= -3ε sin θ + 6 (Au sin α1 +Av cos α1) (1) Sommerfeld number (S). It can be seen from the
graph thatAKyy i.e. vertical stiffness is increasing
Film thickness equation is given by: with increase in delta at all S. However, these
coefficients are non-linear w.r.t S. AKxx, i.e. horizontal
Ah(θ) = 1+ε cosθ, for non-worn region (2) stiffness, is decreasing with increase in delta at all
S for non-worn bearing (Aδo=0.0), whereas for other
Ah(θ) =1+εcosθ +Aδ(θ), for worn region (3) worn bearings (δo=0.1 and 0.2), it is slightly
FIG. 3 : VARIATION OF STIFFNESS COEFFICIENT (Kii) WITH SOMMERFELD NUMBER(S) AT DIFFERENT PRELOAD
δo=0.1
FACTORS (DELTA) FOR L/D = 0.82,Aδ
FIG. 4 : VARIATION OF STIFFNESS COEFFICIENT (Kii) WITH SOMMERFELD NUMBER(S) AT DIFFERENT PRELOAD
δo=0.2
FACTORS (DELTA) FOR L/D = 0.82,Aδ
δo)
Worn Depth (Aδ 0.5 0.6 0.75
FIG. 6 : VARIATION OF CROSS STIFFNESS COEFFICIENT (Kij) WITH SOMMERFELD NUMBER(S) AT DIFFERENT
δo=0.1
PRELOAD FACTORS (DELTA) FOR L/D = 0.82,Aδ
FIG. 7 : VARIATION OF CROSS STIFFNESS COEFFICIENT (Kij) WITH SOMMERFELD NUMBER(S) AT DIFFERENT
δo=0.2
PRELOAD FACTORS (DELTA) FOR L/D = 0.82,Aδ
FIG. 9 : VARIATION OF DAMPING COEFFICIENT (Cij) WITH SOMMERFELD NUMBER(S) AT DIFFERENT PRELOAD
δo=0.1
FACTORS (DELTA) FOR L/D = 0.82,Aδ
FIG. 10 : VARIATION OF DAMPING COEFFICIENT (Cij) WITH SOMMERFELD NUMBER(S) AT DIFFERENT PRELOAD
δo=0.2
FACTORS (DELTA) FOR L/D = 0.82,Aδ
FIG. 12 : VARIATION OF THRESHOLD SPEED (WHIRL ONSET) WITH SOMMERFELD NUMBER(S) AT DIFFERENT
δo=0.1
PRELOAD FACTORS (DELTA) FOR L/D = 0.82,Aδ
FIG. 13 : VARIATION OF THRESHOLD SPEED (WHIRL ONSET) WITH SOMMERFELD NUMBER(S) AT DIFFERENT
δo=0.2
PRELOAD FACTORS (DELTA) FOR L/D = 0.82,Aδ
The major liquid effluents generated due to nature ● Sludge from raw water Pre-Treatment Plant
of plant operation, are given below: (PTP) and from Effluent Treatment Plant
(ETP) equipment such as lamella clarifiers
● Seasonal changes in raw water quality affect and thickeners.
the following:
● CW blow-down generally falls in this category,
Pre-treatment plant sludge flow rate, depending on the make-up water suspended
solids content and the operating Cycles of
Cooling water system blow-down flow
Concentration (COC).
rate,
● Filter backwashes (from gravity / pressure /
Cooling water system blow-own quality.
side stream filters).
● Storm water drain is also of seasonal nature. ● Wastewater from routine floor washing.
Its flow rate is very large with short duration. ● Ash slurry water.
● Intermittent operations produce intermittent ● Coal pile run-off.
effluents. Following are the common examples
of such effluents:
3.1 Pre-Treatment Plant (PTP) and ETP
DM plant regeneration leads to
Sludge
intermittent flow rate from the
neutralizing pit. Sludge is produced from clarifiers, from the turbidity
Service water from floor washing of raw water supply to the plant. The raw water supply
operation is generated in a short span to the plant is primarily for meeting the requirements
of 2 to 3 hours. of clarified water and direct raw-water make-up to
consumers like fire water system, ash handling plant,
● Plant mal-operation or failure may result in service water system etc. Raw water requirement
effluents with flow rates of variable nature. generally does not vary much during plant operation.
Time span for such flows is failure-specific. In the event of ash water recovery from the ash pond,
Alarm system, with or without auto operation, which may take 2-3 years after initial plant
is generally provided for such effluents. commissioning, there may be a need to cut down on
raw water requirement. Reduced raw water requirement
● Maintenance effluents can be handled in a leads to reduction in sludge generation also.
planned way since their quantities and
qualities are fairly well known in advance. Raw water turbidity is a major variable (in addition
to raw water flow rate), which decides the quantum
● Sewage effluent is mostly discharged during of sludge generation. Turbidity in the source of raw
daytime. It is treated and disposed of water supply is likely to have the variations as given
independent of the other process effluents. in Table-I.
Raw water supply from sea. Turbidity is low (typically 10-50 ppm).
Raw water supply from bore-well. Turbidity is low (typically 5-10 ppm).
Raw water supply from reservoir. Turbidity is generally low (typically 10-100 ppm). Depending
on site location and reservoir size, it can however rise to about
200 ppm in monsoon months.
Raw water supply from rivers/canals. Generally lower than supply from reservoirs, but
variations during monsoon months can be 200-500 ppm.
The variations in turbidity from reservoir and river/ authorities as the water streams which receive
canal source, is site-specific and depends on the size this effluent also have very high suspended
of reservoir, source of river, time / period related to solids in monsoon, and since the suspended
rainy season etc. solids generally consist of clay, they are not
a health hazard.
PTP sludge up to approximately 60 m3/h can be
effectively discharged from the plant through ash ii) Processing of the total sludge in thickener
disposal system, and this practice is prevalent in the and centrifuge. This alternative has the
existing plants. advantages of water recovery (and reuse)
from the sludge. However, it is an expensive
It is recommended to adopt this practice, as a first provision, if intended to be used in monsoon
preference, for PTP sludge disposal. It may be season only.
appreciated that the normal ash consistency, as
discharged from ash slurry sump, is about 20-30%.
The PTP sludge, with 2-3 % consistency, practically 3.2 Cooling Water (CW) System Blow-Down
behaves like make-up water to ash slurry sump,
where ash slurry disposal system is envisaged. In CW system temperature rises by 8-10°C. It is cooled
certain plants, where slurry disposal system is not by the same extent in cooling tower. The cooling
envisaged and only dry disposal system is specified, effect is achieved by loss of CW, by evaporation.
separate sludge disposal / treatment would have to About 1.8% of CW flow rate is lost by evaporation,
be considered. for every 100 C cooling effect.
The turbidity levels are not uniform throughout the Cooling water system blow-down is practised to
year. In the event of the sludge generation rate maintain concentration of suspended / dissolved
exceeding the maximum limit acceptable to ash solids in the circulating water, so that the scaling /
handling system, the following methods can be used corrosion of the wetted surfaces is minimized. The
for its disposal. blow-down quantity is a function of circulating flow
rate and the cycles of concentration (COC) adopted.
i) Disposal of sludge (during high-turbidity
period) through plant drainage system. This Acid dosing and side stream filtration can be
may be acceptable to pollution control judiciously used for the selected COC and make-up
Clarification and subsequent use of clarified ii) Turbine hall ground floor
water for the following applications:
The wash water discharge is likely to be
For dust suppression in coal handling applicable for a period of 2-3 hours in the
plant. general shift. This wash water is contaminated
Service water applications. with suspended matter. Oil content in the
Boiler blow-down cooling. wash water is minor depending on the area
Supply to other consumers of the to be washed. It is reduced to negligible value
clarified water (except DM Plant, Potable after dilution effect of other effluents.
water).
Wash water is collected in local sumps and
Fire protection system make-up. subsequently pumped to Lamella / Tube type
Treatment of clarified water in RO system clarifiers. The clarifier supernatant is
and further use of the permeate in the discharged to the CMB.
following systems:
The sludge generated in the lamella, provided
Supply to DM Plant to remove suspended matter from wash
CW make-up water effluent, is very little. Layout permitting,
HVAC system make-up it is recommended to drain it to the pre-
treatment plant sludge sump, to simplify its
Since the CW blow-down flow rate is very disposal. Alternatively, the sludge quantity
high, its treatment by RO is a very costly being little, it can be disposed of manually
proposal, and should be avoided as far as in an acceptable way.
possible, unless the additional cost can be
justified. iii) Wash water from buildings
The RO concentrate, in this option of zero- It is of minor nature. It drains to respective
discharge, requires to be evaporated in building drain system and does not join the
evaporation pond, to be specifically provided Effluent Treatment Plant (ETP) for the
for this purpose. processes described in this paper.
Ash slurry water is generally disposed of from the ash ● Boiler / HRSG blow-down
pond. About 80% of water supply to ash slurry ● CW blow-down.
sump may also be recovered from ash pond, for reuse
in the plant Ash disposal system. Ash water recovery
is generally delayed, after plant commissioning. The 4.1 Recommendations for DM Plant / CPU
delay period can be from 6 months to 2 years. The neutralization waste / chemical waste
recovered water has significant quantity of suspended
and dissolved solids. It can be, however, used for DM Plant regeneration waste (as well as CPU
make-up to the ash water sump for ash disposal regeneration wastes if CPU has been provided) is
collected in the neutralization pit (NP). It is normally
If cooling water blow-down has been used for make- self-neutralized. Dosing system is also provided for
up to the ash handling system, the situation changes NP, to neutralize the regeneration waste, in case it
after AHP recovery starts. CW treatment system is not self-neutralized. The NP effluent is pumped
capability permitting, the COC can be further to CMB. Typical analysis of DM-regeneration waste
increased, leading to reduced raw water demand for is given in Table-V.
the plant. The discharge standards of ash pond
effluents are given in Table-IV. TABLE-V: TYPICAL ANALYSIS OF DM-
REGENERATION WASTE
TABLE-IV: DISCHARGE STANDARDS OF ASH POND
EFFLUENT AS PER CPCB NORMS Constituent Quantity
Total Dissolved Solids 4400-6000 ppm
Parameter Limit
pH 6.5-7.5
pH Valve 6.5-8.5, preferably > 7 Suspended solids 100 ppm
Suspended Solids 100 mg/l
Oil & Greases 20 mg/l
5. OILY EFFLUENTS
3.6 Coal Pile Run-off In normal operations, oily effluents are not expected
from areas of the power plant other than the fuel oil
Coal pile run-off quantity is site-specific, primarily
handling area. Oily water effluents with oil content
depending on the rainfall and the coal yard
greater than 20 ppm may arise from transformer
topography. If site conditions suggest significant coal
areas during abnormal conditions such as fires /
pile run-off, it needs to be collected in a below-grade
accidents etc.
pond. Coal pile run-off may have significant quantity
of suspended matter. After a reasonable period for The major sources of oily effluents are:
settlement of the suspended matter, the effluent
(consequent to the rain) will be discharged to the i) Oily Effluent from fuel oil storage area.
plant drain system. This effluent should be collected in local
In view of the above, it is the considered view of the 4. P. Shandilya and S S Phogat, "Environment
authors that the need for zero discharge should be management in power plants", 3rd International
specified with the considerations in respect of return Conference, World Council of Power Utilities,
on investment. New Delhi, 21-24 Nov. 2001.
All the inhibitors performed well under dynamic The 250 LPD system based on heat pipe collector
condition and reduced the corrosion current largely, is much more efficient as compared to a standard
exhibiting an efficiency of nearly 99% on Copper thermo-syphon system, as there is no heat loss due
alloys. In river water medium, SS 304 has high to reverse circulation during the night, since the heat
corrosion resistance compared to copper alloys, and pipe acts as a thermal diode,. Further, the system
hence addition of inhibitors is not required. For developed does not require interconnecting insulated
copper alloys, any one of the three inhibitors tested pipeline between storage tank and the collector array.
can be used, based on the economic considerations.
The 250 LPD System developed will meet the
The studies conducted and the data collected, shall demand of the higher-end domestic customers as
be useful to diagnose, analyse and interpret various well as Large Solar Water Heating Systems. These
cooling water chemistry related problems in systems can be connected in series and parallel
condensers. Appropriate inhibitor can also be combination to meet the required capacity of Large
recommended to minimize the corrosion of condenser Solar Water Heating System, i.e. four systems of
tube materials. 250 LPD can be supplied for a 1000 LPD system.
The system can be installed close to the utility point,
thereby reducing hot water loss in the pipelines.
Dynamic Corrosion Test Rig 250 LPD Solar Water Heating System
Published by Bharat Heavy Electricals Ltd., and printed at VIBA PRESS PVT. LTD.,
C-66/3, Okhla Indl. Area, Phase-II, New Delhi-110020. Tel. : 41611300, Telefax : 26386500