Status of R&D Projects

45th Technical Committee Meeting

Condenser & Heat Exchanger
HEEP, Haridwar

5/28/2011

Heat Exchanger Engineering

COMPLETED PIRs

5/28/2011

Heat Exchanger Engineering

Completed R&D Project

Project Title: DESIGN DEVELOPMENT OF TURBINE OIL COOLER
WITHOUT INNER CASING FOR 500 MW SETS
Start - Dec2009 Finish Oct2010 Outlay - Rs. 15 LAKHS
Benefits :- New Product Development.
- Cost / Cycle time reduction.
- More competitive design.
Status : Completed.
- New Design developed shall be manufactured through
development Indent.

5/28/2011

Heat Exchanger Engineering

Completed R&D Project

OUTER CASING
OUTER CASING

INNER CASING

TUBE BUNDLE

Existing
5/28/2011

Modified
Heat Exchanger Engineering

Completed R&D Project

SNo

FEATURES / PROCESS

Savings
(Rs. Lacs)

Thermal sizing Of Turbine Oil cooler using HTRI

software

Nil

Use of Plain tubes in place of Low Fin Tubes.

8.5

Removal of Inner casing and Insert.

0.5

Use of segmental baffles in place of Disc & Doughnut.

Nil

Change in Floating Head design and corresponding

change in Shell & Upper water box design.

Nil

Use of latest ASME code for Mechanical design

optimisation.

0.3

Change in gasket design from 'O' ring to simple full face

Gasket.

0.2

Reduction in manufacturing cost due to design

simplification.

1.0

5/28/2011

Heat Exchanger Engineering

Completed R&D Project

Project Title: DESIGN DEVELOPMENT OF H2 COOLER FOR 800 MW
SUPER CRITICAL TG SET
Start May 2010 Finish Jan 2011 Outlay - Rs11.76 LAKHS
Benefits :- New Product Development.
- Business potential enhancement.
- Capability building for 800MW Super-critical set.

Status : Completed
- New Design developed shall be offered and manufactured for
800MW Yermarus project.
5/28/2011

Heat Exchanger Engineering

Completed R&D Project

Hydrogen Cooler
5/28/2011

Heat Exchanger Engineering

Completed R&D Project

COMPARISON WITH 500MW HYDROGEN COOLER
Hydrogen Cooler

For 800 MW

For 500MW

Heat Load(KW)

6610

5032

Duct Size(sq.mm)(LXBXNo.)

910X760X2

1100X360X4

LBTP(mm)

4315

3565

Tube Size(mm)

DIA16X1

DIA19X1

No. of turns of Cu wire fin

52

55

CW Flow

530

540

Allow. Pressure drop(mmwc)

100

70

Total Surface Area Provided(sq.m)

2038

1546

Total Area provided per KW

0.308

0.308

DESIGN

COMPACT

STANDARD

5/28/2011

Heat Exchanger Engineering

Completed R&D Project

Project Title: VIBRATION ANALYSIS OF TUBE BUNDLE OF
GENERATOR AIR / GAS COOLER
Start - July2010 Finish Sept2010 Outlay - Rs.4.2 LAKHS
Benefits :- Design Capability building.
- Optimization of tube holder design.
- Ease in assembly.
Status : Completed.
The results shall be used in design modification of existing and
new Air/ Gas Cooler design.

5/28/2011

Heat Exchanger Engineering

Completed R&D Project

RESULT AND CONCLUSIONS:
- Tube sagging calculations carried out for different tube support span.
- Calculated Tube support span optimized for no resonance condition.
- The optimized value for support tube span shall be used for the design of
Air / Gas Cooler.

5/28/2011

Heat Exchanger Engineering

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Completed R&D Project

Project Title: DESIGN DEVELOPMENT OF STEAM THROW DEVICE FOR
TG SETS WITH HIGH HRH TEMPERATURE
Start April 2010

Finish Dec 2010 Outlay - Rs7.2 LAKHS

Benefits :- New Product Development.

- Business potential enhancement.
- Capability building.
Status : Completed.
- New Design developed has been used for 600MW Derang and
Kakatiya projects.

5/28/2011

Heat Exchanger Engineering

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Completed R&D Project

STEAM THROW DEVICE

5/28/2011

Heat Exchanger Engineering

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Completed R&D Project

FEATURES
- Diaphragm forging developed to meet the HRH temperature of 565 Deg C.
- Thermo-hydraulic design for LP By-pass exit pipe and spray water piping.
- Steam Throw Device developed shall be used for 600MW TG sets.

5/28/2011

Heat Exchanger Engineering

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ONGOING PIRs

5/28/2011

Heat Exchanger Engineering

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Ongoing MOU Project

Project Title: DESIGN DEVELOPMENT OF CONDENSER FOR 600MW
USING THIN WALLED SS TUBES OF 0.5MM
Start - April2010 Finish Mar2011 Outlay - Rs. 21.97 LAKHS
Benefits :- Development of new technology of employing thin-walled tubes.

- Benchmarking with state of art technology.

- Reduction in weight and cost.
Status : On schedule

- Thermal Design, Tube layout finalized.

- Mechanical Design using FEM technique established using ANSYS.
- Tube sample for mockup plate has been arranged.

- Mockup plate and testing in MRL is planned in Ist week of Feb.

5/28/2011

Heat Exchanger Engineering

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Ongoing R&D Project

Project Title: USE OF 12.7MM THICK SUPPORT PLATE IN PLACE OF
16MM SUPPORT PLATE AND STUDY OF IMPACT ON
MECHANICAL DESIGN OF CONDENSER.
Start Sep.2010 Finish Dec2010 Outlay - Rs.4.0 LAKHS
Benefits :-

- Design optimization.
- Business potential enhancement.
- Capability building.
Status : On schedule.
- Sizing calculation for tube span as per HEI completed.
- Mechanical calculations for effect of reduction in support plate
thickness with respect to condenser design is in progress.
5/28/2011

Heat Exchanger Engineering

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Ongoing R&D Project

Project Title: DESIGN DEVELOPMENT OF CONDENSER FOR
700 MW TG SET
Start Jan 2011 Finish Dec 2011 Outlay - Rs.19.36 LAKHS
Benefits :- New Product Development.
- Business potential enhancement.
- Capability building for 700MW Super-critical set.
Status : On schedule
- Thermal Design completed and tube layout generation is in progress.

5/28/2011

Heat Exchanger Engineering

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Ongoing R&D Project

Project Title: DESIGN OPTIMISATION OF CONDENSER UPPER PART
FOR 600 MW TG SET USING FEM.
Start - Jan2011 Finish March2011 Outlay 11.52 lakhs
Benefits :- Design optimisation.
- Business potential enhancement.
- Capability building.
Status : On schedule
- 3-D model generation for analysis is in progress.

5/28/2011

Heat Exchanger Engineering

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NEW PIRs

5/28/2011

Heat Exchanger Engineering

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NEW MOU Project

Project Title: DEVELOPMENT and DETAILED DESIGN OF FIRST DUAL
PRESSURE, DUAL SHELL, SERIES CONDENSER FOR
800MW SUPERCRITCAL TG SET.
Start - April2011 Finish Mar2012 Outlay - Rs. 24.97 LAKHS
Benefits :-

- New Product Development and Establishment of new technology.

- Benchmarking with state of art technology.
- Advantage in Turbine Cycle Heat Rate

- Competitive Edge in Business

Status : New PIR

5/28/2011

Heat Exchanger Engineering

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New R&D Project

Justification of Project:
- Dual Pressure Condenser is being adopted for the first time.
- New Design of Water Box due to large CW Flow and Interconnection Pipe
- Condensate Level Control (in Hotwell ) due to Differential Pressure in
Condensers.

- New Design of Dome Internal Stiffening due to Duplex L P Heater in

Condenser Neck.
- Design of Solid Support in view of Dual Operating Condition.

- To Resolve Interface Issues with various departments like PEM-Layout

/ PEM-System Engg. / PED / STE etc.

5/28/2011

Heat Exchanger Engineering

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NEW R&D Project

Project Title: SEISMIC ANALYSIS FOR CONDENSER DESIGN.

Start - April2011 Finish Feb2012 Outlay - Rs. 15.97 LAKHS

Benefits :-

- Benchmarking with Design suitability for seismic conditions.

Status : New PIR
Justification of Project:

- Technological Gap bridging for suitability of Condenser design for Seismic

zones.

5/28/2011

Heat Exchanger Engineering

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NEW R&D Project

Project Title: 3-D Model for 660MW Condenser and generation of 2-D
drawings for manufacturing using 3-D model.
Start - April2011 Finish Dec2011 Outlay - Rs. 20.0 LAKHS
Benefits :-

- Establishing design process using 3-D modeling.

- Benchmarking with Design practices.
Status : New PIR

Justification of Project:
- To meet the Design Automation Roadmap.
- Shift from 2-D Design practice to 3-D Design practices.

- Preparedness for PLM / ERP.

5/28/2011

Heat Exchanger Engineering

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NEW R&D Project

Project Title: FEASIBILITY STUDY FOR USE OF PTFE (TEFLON) BEARINGS
IN PLACE OF MULTI-BALL BEARINGS FOR SOLID SUPPORTED
CONDENSER.

Start - April2011 Finish Oct.2011 Outlay - Rs. 15.00 LAKHS

Benefits :- Capability building in use of PTFE bearings for condenser application
- Cost savings due to indigenisation of Bearings.
- Easy availability due to sufficient number of PTFE bearing suppliers.

Status : New PIR

5/28/2011

Heat Exchanger Engineering

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New R&D Project

Justification of Project:
Solid supported Condensers envisage Multi Ball Bearings as solid supports
for 660/800MW condensers as per Siemens philosophy. There is only one
available vendor developed by Siemens for these special bearings. Hence the
need for undertaking the feasibility study of using alternate bearings for
condenser supports. PTFE Bearings are chosen for the study as these are
widely used for bridge structure support applications, are cost effective and
have sufficient number of established vendors.
Technical assistance from IIT, Roorkee is envisaged for feasibility study.

5/28/2011

Heat Exchanger Engineering

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thanks

5/28/2011

Heat Exchanger Engineering

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