Tuesday, 31 July 2018

AIR ENTRAINED CONCRETE


The process which involves the introduction of tiny air bubbles into concrete is called air entrainment. And the concrete formed through this process is called air entrained concrete. Using air entraining Portland cement or air entraining agents such as admixture, air entrainment is done in concrete. The amount of air in such concrete is usually between four to seven percent of the volume of concrete. It is measured by galvanometric method, volumetric method and pressure method. The air bubbles relieve internal pressure on the concrete by providing chambers for water to expand when it freezes.


Process

Here are the ways of incorporating air in concrete:
  • Using gas forming materials as aluminium powder, zinc powder and hydrogen peroxide.
  • Using surface active agents that reduces surface tension. They may be natural wood resins and their soaps, animal or vegetable fats or oils, alkali salts of sulfonated or sulphated organic compounds.
  • Using cement dispersing agents.

Advantages

Some of the advantages of air entrained concrete are given below:

  • Workability of concrete increases.
  • Use of air entraining agent reduces the effect of freezing and thawing.
  • Bleeding, segregation and laitance in concrete reduces.
  • Entrained air improves the sulphate resisting capacity of concrete.
  • Reduces the possibility of shrinkage and crack formation in the concrete surface.

Disadvantages

Some of the disadvantages of air entrained concrete are given below:
  • The strength of concrete decreases.
  • The use of air entraining agent increases the porosity of concrete thereby reducing the unit weight.
  • Air-entrainment in concrete must not be done if the site control is not good. This is due to the fact that the air entrained in a concrete varies with the change in sand grading, errors in proportioning and workability of the mix and temperatures.

Monday, 30 July 2018

FLUIDS


Ideal fluid:

A fluid, which is incompressible and having no viscosity, is known as an ideal fluid. Ideal fluid is only an imaginary fluid as all the fluids, which exist, have some viscosity.

Real fluid:
A fluid, which possesses viscosity, is known as real fluid. All the fluids, in actual practice, are real fluids.
Example : Water, Air etc.

Newtonian fluid:
A real fluid, in which shear stress in directly proportional to the rate of shear strain or velocity gradient, is known as a Newtonian fluid.
Example : Water, Benzine etc
.
Non Newtonian fluid:
A real fluid, in which shear stress in not directly proportional to the rate of shear strain or velocity gradient, is known as a Non Newtonian fluid.
Example : Plaster, Slurries, Pastes etc. 

Ideal plastic fluid:
A fluid, in which shear stress is more than the yield value and shear stress is proportional to the rate of shear strain or velocity gradient, is known as ideal plastic fluid.

Incompressible fluid:
A fluid, in which the density of fluid does not change which change in external force or pressure, is known as incompressible fluid. All liquid are considered in this category.


Compressible fluid:
A fluid, in which the density of fluid changes while change in external force or pressure, is known as compressible fluid. All gases are considered in this category.
Graphical representation of different fluids





















CLASSIFICATION OF FLOWS ON THE BASIS OF MACH NUMBER.
  1. Incompressible flow-M less than 0.3
  2. Compressible subsonic flow-M between 0.3 and 1
  3. Transonic flow-M ranging between values less than 1 and more than 1
  4. Supersonic flow-M greater than 1 but less than 5
  5. Hypersonic flow - M greater than 5

Types of fluid
Density
Viscosity
Ideal fluid
Constant
Zero
Real fluid
Variable
Non zero
Newtonian fluid
Constant/ Variable
T = u(du/dy)
Non Newtonian fluid
Constant/ Variable
T ≠ u(du/dy)
Incompressible fluid
Constant
Non zero/zero
Compressible fluid
Variable
Non zero/zero

Saturday, 28 July 2018

HOT WORKING VS COLD WORKING

HOT WORKING VS COLD WORKING

They both are the metal forming processes. When plastic deformation of metal is carried out at temperature above the recrystallization temperature the process, the process is known as hot working. If this deformation is done below the recrystallization temperature the process is known as cold working. There are many other differences between these processes which are described as below.

Difference between Hot Working and Cold Working:

S.No.
 
Cold working
 
 
Hot working
 
1
 
It is done at a temperature below the recrystallization temperature.
 
Hot working is done at a temperature above recrystallization temperature.
 
2.
 
It is done below recrystallization temperature so it is accomplished by strain hardening.
 
Hardening due to plastic deformation is completely eliminated.
 
3.
 
Cold working decreases mechanical properties of metal like elongation, reduction of area and impact values.
 
It increases mechanical properties.
 
4.
 
Crystallization does not take place.
 
Crystallization takes place.
 
5.
 
Material is not uniform after this working.
 
Material is uniform thought.
 
6.
 
There is more risk of cracks.
 
There is less risk of cracks.
 
7.
 
Cold working increases ultimate tensile strength, yield point hardness and fatigue strength but decreases resistance to corrosion.
 
In hot working, ultimate tensile strength, yield point, corrosion resistance are unaffected.
 
8.
 
Internal and residual stresses are produced.
 
Internal and residual stresses are not produced.
 
 
9.

Cold working required more energy for plastic deformation.

It requires less energy for plastic deformation because at higher temperature metal become more ductile and soft.
 
10.

More stress is required.

Less stress required.
 
11.

It does not require pickling because no oxidation of metal takes place.

Heavy oxidation occurs during hot working so pickling is required to remove oxide.
 
12.

Embrittlement does not occur in cold working due to no reaction with oxygen at lower temperature.

There is chance of embrittlement by oxygen in hot working hence metal working is done at inert atmosphere for reactive metals.

Friday, 27 July 2018

Electrolesk A Guide to Practical Electrical Installation Work.

Basics you should know .

The mode of generating Electricity for various requirements of the mankind today are numerous . Electrical Power Generation methods can be from Thermal, Hydropower, Nuclear ,Solar ,Wind Power or some other form.
The generated power is distributed through an Electrical Distribution system.
The Power Utility Companies or Government Power Utility Institutes take the responsibility of bringing the Electrical Power to the Consumer. A Consumer can be a large manufacturing industry or just a Home of a person.
The Consumer’s requirements vary greatly according to his electrical power requirements or the useage of Electricity.
Electrical Installations are needed for the Consumer to use Electricity for his requirements as Lighting, Heating and Air Conditioning , running all types of Electrical Equipment , to name a few.
It is for the above , that we intend to address here and to gather practical methods and ways for implementation to improve the knowhow on the subject.


First we need to be familier with words such as

Current, Voltage and Resistance and their relationship to each other.
Then about Electrical Power and the relationship to above.
Also about Direct Current,Single Phase ,Three Phase and the Neutral.
Real Power, Apparent Power and Reactive Power
About Earthing and the relationship to the Neutral
The Incoming Supply from the Utility and the Consumer Unit.
About Electric Cables , Main Switches and MCCB units.
Distribution Boards and MCB modules.
RCCB or RCD devices.
Socket outlets and Switches for power distribution and Illumination or Lighting.
Electrical Wiring Diagrams and Electrical Load Calculation to commence an Electrical Installation
Single Phase and Three Phase Supply for Alternative or AC Current usage.
Power Factor and Improving of Power Factor for large Electrical Installations


Work Scope of a general Electrical Installation

* Preparing Electrical Layout Drawings and Schematic Drawings based on Architechtural Drawings
* Determine Electrical Specifications
* List out Material and Component requirements
* Decide Main Distribution Board locations
* Lay conduits or Trunkings in the building as necessary
* Install boxes for Switches and Sockets
* Install Distribution Boards and Main Switches
* Install Cables from Distribution Boards to Switches, Light/Fan points, and Socket outlets [receptacles]
* Install Earth Electrode for the Electrical System.
* Install Lights, Switches, Sockets and other accessories
* Test the Installation and obtain Test Certificate
* Obtain Service Connection from Power Utility Company
* Ready for Commissioning of the Electrical Installation.

Thursday, 26 July 2018

CULVERT

culvert (from Tamil கல்வெட்டு (Kalvettu), meaning 'drilled/cut/carved stone'; from Kal, meaning 'stone', and Vettu, meaning 'cut/drill' is a structure that allows water to flow under a road, railroad, trail, or similar obstruction from one side to the other side. Typically embedded so as to be surrounded by soil, a culvert may be made from a pipe, reinforced concrete or other material. In the United Kingdom the word can also be used for a longer artificially buried watercourse. A structure that carries water above land is known as an aqueduct.
Culverts are commonly used both as cross-drains for ditch relief and to pass water under a road at natural drainage and stream crossings. A culvert may be a bridge-like structure designed to allow vehicle or pedestrian traffic to cross over the waterway while allowing adequate passage for the water. Culverts come in many sizes and shapes including round, elliptical, flat-bottomed, pear-shaped, and box-like constructions. The culvert type and shape selection is based on a number of factors including requirements for hydraulic performance, limitation on upstream water surface elevation, and roadway embankment height.
If the span of crossing is greater than 12 feet (3.7 m), the structure is termed as bridge and otherwise is culvert.
The process of removing culverts, which is becoming increasingly prevalent, is known as daylighting. In the UK, the practice is also known as deculverting.

MATERIALS
Culverts can be constructed of a variety of materials including cast-in-place or precast concrete (reinforced or non-reinforced), galvanized steel, aluminum, or plastic, typically high-density polyethylene.
Two or more materials may be combined to form composite structures. For example, open-bottom corrugated steel structures are often built on concrete footings.

DESIGN AND ENGINEERING
Construction or installation at a culvert site generally results in disturbance of the site soil, stream banks, or streambed, and can result in the occurrence of unwanted problems such as scour holes or slumping of banks adjacent to the culvert structure.
Culverts must be properly sized and installed, and protected from erosion and scour. Many US agencies such as the Department of Transportation Federal Highway Administration (FHWA), Bureau of Land Management (BLM),and Environmental Protection Agency (EPA)as well as state or local authoritiesrequire that culverts be designed and engineered to meet specific federal, state, or local regulations and guidelines to ensure proper function and to protect against culvert failures.
Culverts are classified by standards for their load capacities, water flow capacities, life spans, and installation requirements for bedding and backfill. Most agencies adhere to these standards when designing, engineering, and specifying culverts.

Environmental impacts

This culvert has a natural surface bottom connecting wildlife habitat.
Safe and stable stream crossings can accommodate wildlife and protect stream health while reducing expensive erosion and structural damage.
Undersized and poorly placed culverts can cause problems for water quality and aquatic organisms. Poorly designed culverts can degrade water quality via scour and erosion and also restrict aquatic organisms from being able to move freely between upstream and downstream habitat. Fish are a common victim in the loss of habitat due to poorly designed crossing structures. Culverts that offer adequate aquatic organism passage reduce impediments to movement of fish, wildlife and other aquatic life that require instream passage. These structures are less likely to fail in medium to large scale rain and snow melt events.

Poorly designed culverts are also more apt to become jammed with sediment and debris during medium to large scale rain events. If the culvert cannot pass the water volume in the stream, the water may overflow over the road embankment. This may cause significant erosion, washing out the culvert. The embankment material that is washed away can clog other structures downstream, causing them to fail as well. It can also damage crops and property. A properly sized structure and hard bank armoring can help to alleviate this pressure.
Culvert style replacement is a widespread practice in stream restoration. Long-term benefits of this practice include reduced risk of catastrophic failure and improved fish passage. If best management practices are followed, short-term impacts on the aquatic biology are minimal.

Wednesday, 25 July 2018

HEAT EXCHANGERS

 Types Of Heat Exchangers

A heat exchanger is a device designed to efficiently transfer or “exchange” heat from one matter to another (between a solid object and a fluid, or between two or more fluids). When a fluid is used to transfer heat, the fluid could be a liquid, such as water or oil, or could be moving air. The fluids may be separated by a solid wall to prevent mixing or they may be in direct contact.

Their applications includes:
  1. Space heating
  2. Refrigeration
  3. Air conditioning
  4. Power stations
  5. Chemical plants
  6. Petroleum refineries
  7. Natural-gas processing
  8. Sewage treatment
The classic example of a heat exchanger is found in an IC (Internal Combustion) Engine in which a circulating fluid known as engine coolant flows through radiator coils and air flows past the coils, which cools the coolant and heats the incoming air. Another example is the heat sink , which is a passive heat exchanger that transfers the heat generated by an electronic or a mechanical device to a fluid medium, often air or a liquid coolant.


Heat is transferred by conduction through the exchanger materials which separate the mediums being used. A shell and tube heat exchanger passes fluids through and over tubes, whereas an air-cooled heat exchanger passes cool air through a core of fins to cool a liquid.

There are various types of heat exchangers-

  1. Shell and tube heat exchanger
  2. Plate heat exchangers
  3. Plate and shell heat exchanger
  4. Adiabatic wheel heat exchanger
  5. Plate fin heat exchanger
  6. Pillow plate heat exchanger
  7. Fluid heat exchangers
  8. Waste heat recovery unitsDynamic scraped surface heat exchanger
  9. Phase-change heat exchangers
  10. Direct contact heat exchangers
  11. Micro-channel heat exchangers
Heat exchangers are commonly used for cooling of hot gasses and liquids, especially in industrial and manufacturing processes. They can also be used to generate heat; for example, an Exhaust Gas Heat Exchanger can use the heat from exhaust gasses to heat up a water circuit, which can then be used around a building.

Tuesday, 24 July 2018

Wiring system design: Cable tray vs. conduit


To be useful, electrical wiring must get from one place to another. Distribution is a necessary phase of system wiring design in order to get power or impulse signals to their final destinations. Historically, wires and cables have been pulled through conduit.

 


To be useful, electrical wiring must get from one place to another. Distribution is a necessary phase of system wiring design in order to get power or impulse signals to their final destinations.
Historically, wires and cables have been pulled through conduit. Plant environments are characterized by patterns of plentiful parallel conduit runs (Fig. 1). Conduit continues to be the mainstay of electrical power distribution.
However, cable trays are making inroads into industrial plants. In Canada, about 85% of industrial plants use cable trays instead of conduit. That figure is somewhat smaller in the U.S., accounting for less than 50% of industrial plants using cable trays. But the trend in the U.S. is moving toward cable tray use. To date, the U.S. data and communication cable market has readily accepted wire cable tray, while power system engineers and contractors are yet to fully embrace this trend. Wire cable tray is still a relative newcomer to the electrical power segment of the market.

Cable tray

According to the National Electrical Code, a cable tray system is "a unit or assembly of units or sections and associated fittings forming a rigid structural system used to securely fasten or support cables and raceways."
Cable tray advantages include wiring system design flexibility, simplicity, and lower installation cost. In plants where equipment is added, taken away, or is moved, cable trays provide a flexible advantage (Fig. 2). Cable trays can typically adapt to complex configurations with a simple set of tools. The cost of material procurement for cable tray systems is not necessarily lower than that of conduit systems in all cases. However, compared to labor cost of conduit installation, cable trays present significant savings.


There are six basic cable tray types:
  • Ladder — provides solid side rail protection, system strength, smooth radius fittings, and a wide selection of materials and finishes. Ladder cable tray is generally used in applications with intermediate to long support spans
  • Solid bottom — provides nonventilated continuous support for delicate cables with added cable protection available in metallic and fiberglass. Also available are solid bottom metallic trays with solid metal covers for nonplenum-rated cable in environmental air areas. Solid Bottom cable tray is generally used for minimal heat-generating electrical or telecommunication applications with short to intermediate support spans.
  • Trough — provides moderate ventilation and added cable support frequency, with the bottom configuration providing cable support every 4 in. Available in metal and nonmetallic materials, trough cable tray is generally used for moderate heat generating applications with short to intermediate support spans.
  • Channel — provides an economical support for cable drops and branch cable runs from the backbone cable tray system. Channel cable tray is used for installations with limited numbers of tray cable when conduit is undesirable.
  • Wire mesh — provides job site or field-adaptable support systems primarily for low-voltage wiring. Wire mesh tray generally is used for telecommunication and fiber optic applications. Wire mesh tray systems are typically zinc plated steel wire mesh.
  • Single rail — provides the quickest system installation and the most freedom for cables to enter and exit the tray system. Typically, single-rail cable tray is used for low-voltage and power cable installations where maximum cable freedom, side fill, and installation speed are factors. These aluminum systems may be single-hung or wall-mounted systems in single or multiple tiers.
    • Cable tray configurations
      Straight sections are available to route cables in a horizontal or vertical plane. Fittings route cables in various directions in either the horizontal or vertical planes. Typical fittings include elbows, tees, crosses, and risers. These fittings are available in various radii and bend angles.
      Support methods include trapeze (single or multitier), hanger rod clamps, "J" hangers, center hung support, wall support, underfloor support, and pipe stanchions. Trapeze supports are recommended in applications where cables will be pulled through the cable tray. Center-hung supports typically are used when cables will be installed from the side of the cable tray. Also, center-hung supports are especially useful when future cable additions are necessary.
      Wall and underfloor supports are useful when ceiling structure is not available or undesired. Outdoor installations are controlled by the structures available to support the cable tray.

      Conduit

      The primary benefit of conduit systems is the ability to ground and bond. Grounding and bonding play a significant role in minimizing electromagnetic interference (EMI). Steel conduit reduces electromagnetic fields by up to 95%, effectively shielding computers and sensitive electronic equipment from the electromagnetic interference (EMI) caused by power distribution systems.
      Benefits of conduit include:
      • Competitive life-cycle costs
      • EMI shielding
      • Physical protection of conductors
      • Proven equipment grounding conductor
      • Chemically compatible with concrete
      • Coefficient of expansion compatible with common building materials
      • Noncombustible
      • Recyclable
      • High tensile strength.
        There are two primary reasons to use steel conduit. According to the Steel Tube Institute of North America, steel conduit is the best possible protection of your electrical conductor and wiring systems, and it facilitates the insertion and extraction of conductors and wiring. Steel conduit is used in more than 50% of U.S. manufacturing and other industrial facilities in a variety of indoor, outdoor, and underground applications, including those where corrosive and hazardous conditions exist.
        Rigid metal conduit (RMC) has the thickest wall, making it the heaviest steel conduit. Inside and outside are zinc-coated to provide corrosion resistance. RMC can be used indoors, outdoors, underground, and in concealed or exposed applications


        Intermediate metal conduit (IMC) has a thinner wall and weighs less than RMC. A zinc-based coating is used on the outside; an organic corrosion-resistant coating is used on the inside. IMC can be used for the same applications as galvanized rigid metal conduit


        Electrical metallic tubing (EMT) is the lightest weight steel conduit manufactured. EMT is made of galvanized steel and is unthreaded. It is joined by setscrew, indentation, or compression-type connectors and couplings. This joining method makes EMT easy to alter, reuse, or redirect. Even though EMT is made of lighter-walled steel, it provides substantial physical protection and can be used in most exposed locations except where severe physical damage is possible.

          RMC, IMC, and EMT are permitted as an equipment grounding conductor in accordance with NEC 250.118. A supplementary equipment grounding conductor sized in accordance with NEC 250.122 may be added as well. If a supplementary equipment grounding conductor is used, it is still important to comply with NEC 300.10 and 300.12, since approximately 90-95% of the ground current flows on the conduit and not in a supplementary conductor.
          Environmental considerations for conduit
          The coefficient of expansion for steel conduit/EMT is 6.5x10-6in./in./deg F. This is significant as it relates to whether or not expansion fittings would be required in a particular application. Expansion fittings are installed where significant temperature differentials are anticipated. These temperature shifts cause materials to expand and contract and could result in the conduit being pulled apart at the joints. Expansion fittings are not normally required with steel conduit/tubing because their coefficient of expansion is similar to that of other common building materials. However, when steel conduit is installed on bridges, rooftops, or as an outdoor raceway span between buildings, expansion fittings may be required. In these types of installations, there is a probability that expansion and contraction would occur, resulting from the direct heat of the sun coupled with significant temperature drops at night.
          Couplings that accommodate thermal expansion while maintaining grounding and bonding integrity are now available. Such a coupling uses an internal bonding jumper to maintain electrical continuity (Fig. 3). An internal, keyed, sliding bushing allows conduit movement. Installation is simple, requiring no disassembly. These couplings are installed by sliding the fitting onto the moving conduit until it stops at the internal slide bushing, then tightening. The next step is to tighten the gland nut with a wrench to compress the packing, creating a weather-resistant seal around the moving conduit. The final step is to thread the next length of conduit (stationary) into the other end of the fitting.
          PLANT ENGINEERING magazine extends its appreciation to Cablofil, Inc., Cable Tray Institute, Square D/Schneider Electric, Steel Tube Institute of North America, and Thomas & Betts Corp. for the use of their materials in the preparation of this article.



          Cable tray selection checklist

          When selecting cable trays, cable tray configurations, and support methods, seek the answers to the following questions:

          Where will the cable trays be used?

          Job site and installation considerations include:
          Indoor
          Support locations available affect the length and strength of the system.
          Industrial installations may require a 200 lb concentrated load.
          Office installation may make system appearance, system weight, and space available important factors.
          Environmental air handling areas may affect cable types, cable tray material, or cable tray type, as well as the potential need for covers.
          Classified hazardous locations affect the acceptable cable types.
          Outdoor
          Available supports affect length and strength requirements.
          Environmental requirements include loads, ice, wind, snow, and possibly seismic situations.
          Corrosion requirements affect materials and finishes.
          Classified hazardous locations affect acceptable cable types.

          What types of cables will be supported, and how many?

          NEC cable fill requirements dictate size, width, and depth of cable tray.
          Cable support requirement may necessitate bottom type.
          Largest bending radius of cable controls fitting radius.
          Total cable weight determines load to support.

          What are the future requirements of your system?

          Cable entry/exit freedom may change.
          Designing a partially full or an expandable system may produce big savings later.
          Support type should allow for expansion needs.

          Conduit installation tip

          • Conduit having factory-cut threads are supplied with corrosion protection applied.
          • Field cut threads are required to be coated "with an approved electrically conductive, corrosion-resistant compound where corrosion protection is necessary," according to NEC 2002 300.6 (A). Field-cut threads should be protected from corrosion if they will be installed in wet or outdoor locations. Protect the thread surface with conductive rust resistant coating such as zinc-rich paint. Other conductive coatings are appropriate as well.
          • Field threads should be cut one thread short. This ensures a good connection and allows the entire thread surface to be inside the coupling.
         

Monday, 23 July 2018

Power Plant

     Basics of Combined Cycle Power Plant

Introduction:
  • In a combined cycle power plant (Fig. 1), electricity is produced by two turbines, a gas and a steam turbine.
  • The gas turbine is operated by the combustion products of the fuel (Brayton cycle), while the steam turbine (Rankine cycle) is operated by the steam generated by HRSG from the heat content of the exhaust gases leaving the gas turbine.
  • The name combined cycles is because the gas turbine operates according to the Brayton cycle and the steam system operates according to the Rankine cycle.
Heat Recovery Steam Generator 
  • The HRSG receives the exhaust gases from the GT discharge. The exhaust gas, flowing in counter flow with respect to the steam/water coils, cools down by transferring heat to steam/water.
  • The flue gas temperature at the stack is about 110°C. Lower temperatures 93°C can be used if the fuel gas is very clean and sulphur free.
  • The HRSG is similar to a heat exchanger in which the shell side carries the flue gas and the tube side carry steam or water.
  • It has also the characteristics of a boiler because there are steam drums, where the generated steam is separated from boiling water before entering the superheaters. The HRSG can be horizontal or vertical, according to the direction of flue gas path.
  • The horizontal HRSGs are most common. The vertical ones mainly are limited to installations where space is very tight.
HRSG Pressure and Temperature Levels:
The HRSG can have one, two, or three pressure levels according to the size of the plant.
  • For plant sizes of 200–400 MW, the pressure levels used are HP, IP, and LP.
  • Plants down to 30–60 MW usually have two pressure levels (HP and LP),
  • Smaller units only have one pressure level. Sometimes, with three pressure levels, the LP section produces the steam needed for deaeration only.
  • The following tube banks are used for each pressure level (starting from the GT exhaust): 1) steam superheaters, 2) evaporator, and 3) economizer.
HRSG Design Features:
  • Sometimes empty module is inserted in the flue gas ducts of large HRSGs where flue gas temperature is 350–380°C, which can be used in future for installation of a selective catalytic reduction unit for further NOx abatement.
  • Sometimes, a spool piece for future addition of an oxidation catalyst for CO abatement is included for the same purpose as the SCR and located in the same position.
  • The pressure drop across the HRSG on the flue gas path is in the range of 200–375 mm water column. This pressure drop is the back-pressure of the GT and influences its generated power and efficiency by 1 and 2%, respectively.
  • The HRSGs are provided with a set of motor-operated valves that are installed in the steam and water lines.
  • The feedwater inlet lines to the economizers are also provided with on/off shut-off valves. Having these shut-off valves allows the “bottling in” of the HRSG by closing all inlet and outlet lines, thereby to keep the boiler pressurized when the shut-down period is expected to be short. Additional motor-operated valves are used to remotely and automatically operate the drains in the superheaters.
  • The HRSG also includes a pressurized blow-down tank and an atmospheric blow-off tank, and is also equipped with chemical injection pumps to maintain the water and steam chemistry specifications.
  • The HRSG is also equipped with nitrogen connections for purging (dry lay-up) to prevent corrosion in case of long shut-down periods.
Steam Turbine 
  • Steam turbines extract energy from the steam and convert it to work, which rotates the shaft of the turbine.
  • The amount of energy that the steam turbine extracts from the steam depends on the enthalpy drop across the machine.
  • The enthalpy of the steam is a function of its temperature and pressure. As inlet and outlet temperature and pressure are known, one can use a Mollier diagram to determine the amount of energy available.
  • Steam turbine sizes range from a few kilowatts to over 1000 megawatts.
It operates in three control modes:
  • Fixed pressure mode – Below 50% load, which corresponds to about 50% of the live steam pressure, the steam turbine will be operated in a fixed pressure mode. In this mode of operation a pressure from the steam generator remains constant and is controlled by main control  In case the steam turbine is not taking all produced steam,  pressure of a steam generator is controlled by the bypass valves.
  • Sliding pressure mode – When the 50% load is reached the main control valve is fully open. With increasing gas turbine loads the steam turbine will be operated in sliding pressure mode. In this case the live steam pressure varies proportionally with the steam flow.
  • Load control – when the generator is synchronized to grid, its frequency is governed by the grid. Turbine controller maintains the base load by adjusting the steam flow.
Air Cooled Condenser 


  • The air-cooled steam condenser (ACC) condenses the turbine exhaust steam or the de-superheated steam from the turbine bypass.
  • The condensate collected in the steam/condensate headers drains under gravity to the condensate tank, from where it is pumped by the condensate extraction pumps to the boiler system on level control.
  • The turbine backpressure is controlled by fans using pressure transmitters on ST exhaust. Pressure transmitters protect the ACC in case of overpressure.
  • The control system modulates number of fans into operation and fan speed and steam isolating valve position to meet backpressure set point.
  • Temperature transmitters in the main steam duct protect the condenser against overheating.
Types of Condensing System:
Selection of condensing system varies based on environmental conditions. They are classified into following categories:
  • Water cooled surface condensers and wet condensing system
  • Air cooled condensers
  • Alternative condensing systems
Air Extraction System:
  • The non–condensable have to be evacuated from the condenser before steam can be introduced at start-up (hogging process) and should be continuously removed during normal operation (holding process)
  • HOGGING PROCESS – For the hogging process, the requirements are to lower the pressure as quickly as possible from the atmospheric pressure (946 mbar(a)) to 250 mbar(a) ) within 30 minutes.
  • HOLDING PROCESS – Once the vacuum is established and during normal operation, hogging extraction skid is shut down and only one holding vacuum set continuously removes the non-condensable.
Bypass Stack and Diverter:
  • In some instances, when the electric power generation is a must, it should be possible to run the gas turbine in open cycle and exhaust the flue gas to the atmosphere instead of sending it to the HRSG, regardless of the overall efficiency.
  • This requires a bypass stack and a diverter that closes the path to the HRSG and opens it to the atmosphere through the bypass stack.
  • The diverter is connected to the GT exhaust duct before the diverting cone of the HRSG, and this implies that the GT has to meet the plant emissions limits, as any SCR in the HRSG is also bypassed.
  • Throttling by the diverter could also be used to control steam generation in the HRSG. This configuration is rare.
  • The most important characteristic of a well-designed diverter is its ability to completely switch the flue gas from the bypass stack to HRSG, under all operating conditions.
Auxiliary Systems:
Boiler Feed Water Pump:
  • The LP drum can be used to feed the boiler feedwater (BFW) pumps on level control as explained in three elements control system.
  • If there are HP and IP sections, the BFW pumps can be multiple-stage centrifugal pumps with an intermediate discharge for the IP section.
  • Automatic minimum flow bypass, Three-way Yarway valve, on the HP discharge nozzle of the pump is used for minimum flow protection.
Bypass System:
  • The superheated steam to the steam turbine is bypassed to condenser during the start-up, ST shutdown and load rejection.
  • The bypass arrangement includes
  • HP bypass from HP header to IP header (cold reheat side if reheating is implemented)
  • IP bypass from IP header (hot reheat side if reheating is implemented) to the condenser.
  • LP by-pass from LP header to the condenser.
  • Each bypass requires a pressure reduction and desuperheating with boiler feedwater or condensate to meet downstream condenser conditions.
Blow Down Tank:
  • To keep the required steam purity, a small percentage (1–3%) of the water in the steam drums is discharged to continuous blow-down.
  • For large boilers there is a pressure blow-down tank into which the HP and IP steam drums drain. In addition an atmospheric blow-off tank is also provided to receive the water from the blow-down tank plus the drains from the LP drum and the blow-off from the HP and IP drums.
Demineralization Plant:
  • The water needed for filling the HRSG and as make-up water during normal operation is generated in a demineralization plant. The demineralization plant is usually controlled by its own PLC, which is interfaced with the DCS, but sometimes is controlled directly by the plant DCS system.
  • The demineralized water is stored in a tank that should be sized sufficiently large to provide water in case of disruption in the production. It should also store enough water to supply the quantity needed for pipe blowing in the pre-commissioning stage, without the need for waiting for the production of new water. This consideration can be the basis for sizing the demineralized water storage tank
Closed Circuit Cooling Water:
If an air condenser is used, the closed-circuit cooling water system becomes much smaller, because the amount of water needed in the rest of the plant is a relatively small percentage of that needed for the water condenser. The users of the CCCW are turbine generator, condensate and feed water pumps, sampling system etc.
CCPP – Start-up:
  • The main concern in starting a CCPP is to avoid thermal stresses to the machines that would shorten its life and produce unsafe conditions.
  • This consideration extends the time for start-up, while economics require that start-up to take place in the minimum possible time and with minimum fuel consumption.
  • Each manufacturer of the main plant equipment sets the requirements for its machine,
  • The process design engineers shall combine these requirements with their own to arrive at start-up procedures that will minimize the overall start-up time.
  • Gas turbine is the fastest starting component in CCPP. It takes about less than 10 min to get to the synchronized speed.
  • HRSG has thermal inertia and rapid heating may result in high thermal stresses which would affect the life of the HRSG.
  • In HRSG, HP steam drum is most vulnerable to build up of thermal stresses if heating is done rapidly. To avoid this possibility the drum is heated in a controlled manner.
  • Magnitude of the thermal stress depends on the temperature difference which in turn depends on the material, operating pressure, thickness of the material.
  • The temperature difference can be effectively controlled by controlling the pressure inside the drum. If a certain temperature difference is close to the design limit it can be controlled at that level by holding the pressure constant. This is indicated by constant pressure/temperature line.
  • The heat input is controlled by operating the GT at a reduced load. A gas side bypass system, which diverts part of the hot GT gasses to atmosphere is also used to control the heat input to the boiler.
HRSG start up without gas bypass damper:
  • The CT and the HRSG are connected directly without a bypass damper if the power production is to be maximized and there is no requirement of simple cycle operation.
  • It is possible under certain circumstances to run the HRSG ‘dry’ or produce no steam while the CT is operating. Usually this requires additional constraints in the design and limitations on CT exhaust temperature.
HRSG start up with gas bypass damper:
  • The damper can control the gas flow to the HRSG, part of the gas at operating temperature passes through the HRSG. Thus the amount of steam production and the drum pressure can be maintained at the required level by allowing the required amount of gas through the HRSG
  • Most of the damper systems have limited turndown capability. Therefore venting or bypassing of the steam is still needed, though the capacity and time required may be less.
  • The bypass damper must be utilized when there is a need to run the plant in simple cycle.
  • The heating of IP and LP drums and the steam production in these drums is not of much concern because they are operated at low pressures and have low capacities.
Steam turbine warm up:
  • The steam turbine has the most mass and has components with much thicker cross-sections. Therefore, it needs the longest warming up time.
  • Warm up generally takes three to five hours
  • Since the ST start-up takes longer, the HRSG needs to be maintained at the low load operation for a much longer time if the steam is supplied for warm-up.
  • Various combinations of start-up scenarios are feasible for a power plant. These are mainly determined by the temperature of each of the component at the start-up time. For instance
  • a ‘cold’ state means that the component is at room temperature, having been down for a considerable time, usually days.
  • A ‘warm’ start results when the unit was down for few hours and most of the heat is not lost.
  • A ‘hot’ start occurs when the unit is shut-off for a very short period of time after operating for a considerable time at full load.