WELCOME TO POWER ENGINEERS

"Don't Do Different Things - Do Things Differently"



May 20, 2010

PROS AND CONS OF NUCLEAR ENERGY

Pros:-
1. Little Pollution :As demand for electricity soars, the pollution produced from fossil fuel-burning plants is heading towards dangerous levels. Coal, gas and oil burning power plants are already responsible for half of America's air pollution. Burning coal produces carbon dioxide, which depletes the protection of the ozone. The soft coal, which many power plants burn, contains sulfur When the gaseous byproducts are absorbed in clouds, precipitation becomes sulfuric acid.. Coal also contains radioactive material. A coal-fired power plant emits more radiation into the air than a nuclear power plant.
      The world's reserves of fossil fuels are running out. The sulfurous coal which many plants use is more polluting than the coal that was previously used. Most of the anthracite, which plants also burn, has been used up. As more soft coal is used, the amount of pollution will increase. According to estimates, fossil fuels will be burned up within fifty years. There are large reserves of uranium, and new breeder reactors can produce more fuel than they use. Unfortunately this doesn't mean we can have an endless supply of fuel Breeder reactors need a feedstock of uranium and thorium, so when we run out of these two fuels (in about 1000 years), breeder reactors will cease to be useful. This is still a more lengthy solution to the current burning of coal, gas, and oil.
2. Reliability :Nuclear power plants need little fuel, so they are less vulnerable to shortages because of strikes or natural disasters. International relations will have little effect on the supply of fuel to the reactors because uranium is evenly deposited around the globe. One disadvantage of uranium mining is that it leaves the residues from chemical processing of the ore, which leads to radon exposure to the public. These effects do not outweigh the benefits by the fact that mining uranium out of the ground reduces future radon exposures. Coal burning leaves ashes that will increase future radon exposures. The estimates of radon show that it is safer to use nuclear fuel than burn coal. Mining of the fuel required to operate a nuclear plant for one year will avert a few hundred deaths, while the ashes from a coal-burning plant will cause 30 deaths.
3. Safety :Safety is both a pro and con, depending on which way you see it. The results of a compromised reactor core can be disastrous, but the precautions that prevent this from happening prevent it well. Nuclear power is one the safest methods of producing energy. Each year, 10,000 to 50,000 Americans die from respiratory diseases due to the burning of coal, and 300 are killed in mining and transportation accidents. In contrast, no Americans have died or been seriously injured because of a reactor accident or radiation exposure from American nuclear power plants. There are a number of safety mechanisms that make the chances of reactor accidents very low. A series of barriers separates the radiation and heat of the reactor core from the outside. The reactor core is contained within a 9-inch thick steel pressure vessel. The pressure vessel is surrounded by a thick concrete wall. This is inside a sealed steel containment structure, which itself is inside a steel-reinforced concrete dome four feet thick. The dome is designed to withstand extremes such as earthquakes or a direct hit by a crashing airliner. There is also a large number of sensors that pick up increases in radiation or humidity. An increase in radiation or humidity could mean there is a leak. There are systems that control and stop the chain reaction if necessary. An Emergency Core Cooling System ensures that in the event of an accident there is enough cooling water to cool the reactor.
Cons -

1. Meltdowns :
If there is a loss of coolant water in a fission reactor, the rods would overheat. The rods that contain the uranium fuel pellets would dissolve, leaving the fuel exposed. The temperature would increase with the lack of a cooling source. When the fuel rods heat to 2800°C, the fuel would melt, and a white-hot molten mass would melt its way through the containment vessels to the ground below it. This is a worst case scenario, as there are many precautions taken to avoid this. Emergency water reservoirs are designed to immediately flood the core in the case of sudden loss of coolant. There are normally multiple sources of water to draw from, as the low pressure injection pumps, containment spray system, and refueling pumps are all potentially available, and all draw water from different sources. The disaster at Three Mile Island was classified as a partial meltdown, caused by the failure to supply coolant to the core. Although the core was completely destroyed, the radioactive mass never penetrated the steel outlining the containment structure. Several feet of special concrete, a standard precaution, was capable of preventing leakage for several hours, giving operators enough time to fix the flooding system of the reactor core. The worst case of a nuclear disaster was in 1986 at the Chernobyl facility in the Ukraine. A fire ripped apart the casing of the core, releasing radioactive isotopes into the atmosphere. Thirty-one people died as an immediate result. And estimated 15,000 more died in the surrounding area after exposure to the radiation. Three Mile Island and Chernobyl are just examples of the serious problems that meltdowns can create.

2. Radiation :Radiation doses of about 200 rems cause radiation sickness, but only if this large amount of radiation is received all at once. The average person receives about 200 millirems a year from everyday objects and outer space. This is referred to as background radiation. If all our power came from nuclear plants we would receive an extra 2/10 of a millirem a year. The three major effects of radiation (cancer, radiation sickness and genetic mutation) are nearly untraceable at levels below about 50 rems. In a study of 100,000 survivors of the atomic bombs dropped on Hiroshima and Nagasaki, there have been 400 more cancer deaths than normal, and there is not an above average rate of genetic disease in their children. During the accident at Three Mile Island in America, people living within a 50 mile radius only received an extra 3/10 of one percent of their average annual radiation. This was because of the containment structures, the majority of which were not breached. The containment building and primary pressure vessel remained undamaged, fulfilling their function.

3. Waste Disposal :The byproducts of the fissioning of uranium-235 remains radioactive for thousands of years, requiring safe disposal away from society until they lose their significant radiation values. Many underground sites have been constructed, only to be filled within months. Storage facilities are not sufficient to store the world’s nuclear waste, which limits the amount of nuclear fuel that can be used per year. Transportation of the waste is risky, as many unknown variables may affect the containment vessels. If one of these vessels were compromised, the results may be deadly.


SIMPLY KNOW ABOUT NUCLEAR POWER

      A nuclear power plant works pretty much like a conventional power plant, but it produces heat energy from atoms rather than by burning coal, oil, gas, or another fuel. The heat it produces is used to boil water to make steam, which drives one or more giant steam turbines connected to generators—and those produce the electricity we're after. Here's how:

1. First, uranium fuel is loaded up into the reactor—a giant concrete dome that's reinforced in case it explodes. In the heart of the reactor (the core), atoms split apart and release heat energy, producing neutrons and splitting other atoms in a chain reaction.
2. Control rods made of materials such as cadmium and boron can be raised or lowered into the reactor to soak up neutrons and slow down or speed up the chain reaction.
3. Water is pumped through the reactor to collect the heat energy that the chain reaction produces. It constantly flows around a closed loop linking the reactor with a heat exchanger.
4. Inside the heat exchanger, the water from the reactor gives up its energy to cooler water flowing in another closed loop, turning it into steam. Using two unconnected loops of water and the heat exchanger helps to keep water contaminated with radioactivity safely contained in one place and well away from most of the equipment in the plant.
5. The steam from the heat exchanger is piped to a turbine. As the steam blows past the turbine's vanes, they spin around at high speed.
6. The spinning turbine is connected to an electricity generator and makes that spin too.
7. The generator produces electricity that flows out to the power grid—and to our homes, shops, offices, and factories.


May 17, 2010

QMM FOR COAL HANDLING PLANTS .


Maintenance of coal handling plants (CHP) of thermal power stations has traditionally as the processes related to the performance of routine, unscheduled and emergency maintenance. It doesn’t include operational factors such as scheduling, procedures, and  work/systems control. The failures of equipments have led to high maintenance and  operation costs. Developing Quality Assured Maintenance Management (QAMM) for CHP is very important for improving quality and reducing operating costs. This type of  maintenance policy and strategy will improve performance of CHP through availability  of equipment, reduction in railway costs through demurrage and further supplying  constant flow of fuel to boiler to avoid failure of energy supply to consumers.
Introduction: -
Almost all CHP these days implies Reactive Maintenance with some support of preventive maintenance. Generally repairs are made after the equipment is out of order and it cannot perform its normal function any longer. Under such condition, operation persons call on the maintenance persons to rectify the defect. The maintenance department checks the defects and makes the necessary repairs.
Maintenance is the coordinated integration of the operations, maintenance, engineering support, training, and administrative areas of any process in order to increase the efficiency, reliability, and safety of the process. Coal handling plant should be divided into five sections for QAMM.  
° Unloading Units
° Feeding Units
° Crushing and Screening Units
° Stacking and Reclaiming Units
° Bunkers
Objectives of QAMM: -
Quality Assured Maintenance Management should have ability to provide assurances for reliability. The objectives of QAMM for CHP are given below.
*Prediction of impending failures of critical plant components like Crusher Rotors, Conveyor Pulley Shafts, in real time resulting in enhanced safety, operational reliability, availability, and maintainability.
*Establishing an alarm level based on the variations of a physical parameter like
vibration, power consumption, temperature etc.
*Reduction of the life cycle cost by optimization of the plant operation and
maintenance schedule.
*Facilitation of design revisions as new technologies of active control and
structural materials evolve.   
QAMM Implementations: -
Quality Assurance maintenance management, which meets the same requirements for Equipment Reliability, is demonstrated in the ISO 9001:2000 Standard [1]. The process is managed through QMS, which is clear on PDCA as a process method. PDCA is Plan, Do, and Check Act. Most modern maintenance management activities are not linked to QMS, which have particular management characteristics. Using these characteristics transforms modern maintenance practice into what may be the next generation of maintenance management. See Figure No 1. The steps in implementing QAMM for CHP are
* Identify the maintenance work.
*Planned the maintenance work
* Scheduled the maintenance work
*Execute the work as per schedule and record it
* Analysis of maintenance record for implementation for further improvement.
 Maintenance Planning: -
Maintenance Planning is the process of acquiring a system commencing with the identification of a need and involving the research, modification and evaluation activities.
a).A detailed maintenance plan, which describes proposed echelons or levels of maintenance and recommended function to be performed at each echelon. The material presented under maintenance plan must cover a) Definition of task: detailed tasks are identified to cover all acquisition function like research, modification and evaluation activities.
b) Scheduling of tasks: using Gantt chart, PERT chart, and CPM chart etc.
This planning include
a) A plan for the basic maintenance, which is built by the best combination of
preventive, predictive and proactive maintenance.
1: Corrective Action
2: Maintenance Work Data Recording
3: Maintenance Work Execution
4: Maintenance (History) Data Analysis
5: Maintenance Work Scheduling
6: Maintenance Work Planning
7 Maintenance Work Identification
 b) A plan for the acquisition of test and support equipment and handling equipment.
c) A supply support plans to cover the acquisition of spares and repair parts.
d) A technical data plan to include system maintenance procedures i.e. servicing,
inspection, calibration and overhaul instructions.
e) A personnel and training plan to cover system operator training and maintenance training.
f) A plan for Scheduled shutdowns should provide unique opportunities to a
maintenance department not normally available during standard operation or
even during short shutdown periods. Lost capacity can be restored to an
overtaxed facility during an extended shutdown. Major equipment overhauls can
be performed to help prevent future unscheduled shutdowns. Government
mandated inspections and repairs could be accomplished during a shutdown,
bringing a plant into better compliance.
Objective Of Maintenance Planing: -
A plant is a place, where men, materials, money, equipment, machinery, etc., are brought together for manufacturing products. Today in modern industry, equipment and machinery are a very important part of total productive effort that was the case years ago.
Moreover, with the development of special purpose and sophisticated machines, equipment and machinery cost a lot more money and therefore their idle or downtime becomes more expensive. For this reasons, it is vitally important that the plant machinery should be properly maintained. The aggregate of direct and supporting actions that detect, preclude or mitigate the degradation of system or component functionality, or restore that function to an acceptable level of performance following failure. Coal handling plants Maintenance plan should be developed in order to maximize equipment availability and utilization by following points.
• Adjusting planned maintenance start times due to changes in Railway schedules.
• Taking advantage of shift change over down time.
• Ensuring preventive maintenance on critical equipment is carried out.
• Ensuring equipment is available for maintenance when planned
Coal handling Plant Maintenance planners need enhanced skills in job planning (as distinct from job scheduling), and Maintenance Supervisors need enhanced skills in Leadership and Management, and that all Maintenance personnel need enhanced skills [3] in Failure Investigation and Analysis. In general terms, Maintenance management process can be considered as having seven phases, as shown in Figure No This can be recognized as being similar to the familiar control loops, where plans are put in place, actions take place, and then the outputs are compared with the original plan and appropriate action taken.
Maintenance Scheduling: -
Scheduling is the function of coordinating all of the logistical issues around the issues regarding the execution phase of the work. This can also uncover some areas of planning deficiency, which needs to be captured.
Scheduling is best performed in a capacity-scheduling manner, whereby the following takes place. Most modern systems have the capacity to output data to spreadsheets or similar. This is where the majority of scheduling work needs to occur. 

* Overhead labor hours such as safety and toolbox meetings, break times and training times are to be gathered, along with holidays and scheduled as standing works orders for future analysis of these.
* Hours for PM completion to be deduced form data. This focuses on ensuring the
equipment is maintained to its best levels.
* Addition of corrective and approved improvement actions as dictated by the
prioritization system and operations plan. These are to be Planned works orders only.
A guide could be: Age of works orders against priority (As a measure of the priority
systems effectiveness) 
The combination of corrective, preventative and improvement work needs to total the levels set for planned / scheduled work. Although this does constitute the most effective use of labor and resources, there are advantages to planned/unscheduled works.
 Development Of Maintenance System For QAMM: - 
The combination of all these methods will develop a system for coal handling plant
maintenance. It is the activity that most determines the success. It can forecast with some degree of certainty that we will be able to achieve the schedules that we have established. This, in turn, has a direct impact on equipment availability, utilization, and operating and maintenance costs.    
Basic Maintenance Program: - 
In addition to preventive maintenance the predictive maintenance technology will be practical approaches to enhance solutions to maintenance problems. As this program is based upon the combination of two methods, it is desired to follow first preventive maintenance and then carry for predictive maintenance technology. But it is not sufficient for this type of plant, so it is required to follow up for proactive maintenance.   
 Preventive Maintenance:
A better method than reactive maintenance is to create a maintenance schedule based on plant data and breakdown history. The schedules are created for routine check and replacement ofcomponents whose lifetime is estimated over time based upon the life span of previous components of the similar type. The approach to preventive maintenance may become inefficient because some parts are no where near breaking but are replaced with new parts, although, they can still serve without problems. The “mean” is to be defined for preventive maintenance this mean is decided after the data, which is received from maintenance history. Otherwise less mean time is costly and more mean time will be harmful. Much of the success of preventive maintenance is dependent upon inter-departmental relationships other wise mechanical department planned for same machine and other department like electrical testing, instrumentation &control, electrical maintenance will plan for other day. This will fail preventive maintenance schedule. Continuous feedback is required for improvement of preventive maintenance.    

 Predictive Maintenance: - 
This system measures and detects the onset of a degradation mechanism thereby allowing casual stresses to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicate current and future functional capability.  .
Proactive Maintenance: - 
Proactive Maintenance is based upon reliability criteria with priority given to the most critical components. It determine types of failures are likely to occur with focus on preventing failures whose consequences are likely to be serious. 
It requires careful analysis of failure modes and effects. And identify effective
maintenance tasks or mitigation strategies. This helps integration into the existing
maintenance system.   

1: Corrective Action
2: Maintenance Work Data Recording
3: Maintenance Work Execution
4: Maintenance (History) Data Analysis
5: Maintenance Work Scheduling
6: Maintenance Work Planning
7 Maintenance Work Identification

 Conclusions: - 
By applying QAMM it will allows to plan shutdown before severe damage occurs and reduce reactive maintenance practice. 
The transition to QAMM for CHP will require a substantial investment. The return on this investment will be dependent on the effectiveness of its implementation and the commitment of all personnel. 
Effective use of QAMM offers will benefits in plant availability, optimized use of
resources, reduced downtime, which reduce railway demurrage and further insure smooth and interrupt coal flow for boilers.












   

































































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