Mechanical Talks

The shortage of coal in the power generation sector being reported from different parts of the country has been grabbing the headlines in the past few days. Out of 135 thermal power stations in the country, 104 had coal stocks only for five days, as of October 17, according to the government data. The reasons for this situation could be several short and long term factors connected with production, supply chain, stocking, demand fluctuation etc. Whatever may be the contributory factors, the situation seems to be precarious and has caused concern in many sectors that depend on uninterrupted power supply like large outsourcing firms and continuous production facilities. Long power cuts have been reported from some states. The crisis has coincided with the global focus on climate change and preparations for the next round of climate change talks beginning in Glasgow on October 31. The Conference of Parties (COP) of the UN Framework Convention on Climate Change (UNFCCC) will grapple once again with the vexed question of reduction in carbon emissions from coal, oil and other fossil fuels. The coal crisis has led to a predictable slugfest among political parties, the Central government and Opposition ruled states. The discourse is on the looming shortfall in electricity and skirts the larger issue of the future of coal as a source of energy in India. Coal is still a dominant contributor to India’s energy mix. Of the 3.88 lakh MW installed power capacity, over 60% is in thermal power plants (mostly coal fired). The hydro-based power plants account for more than 11% of the installed capacity. Renewable sources of energy — solar and wind — are the next big contributors accounting for 11 and 10%, respectively. The rest 8% installed capacity is in nuclear, small hydro and bio power plants, with much hyped nuclear adding just 1.7% to the power kitty. These are all installed capacity shares. The actual power generated is much lower, particularly in renewable power plants where power generation depends on sunshine and wind speeds. While coal and hydro continue to be dominant sources, renewables like solar and wind have grown dramatically in the past two decades. Coal directly adds to carbon emissions. Mining the coal locked in the reserves often located in forest areas results in emissions due to clearing of forests and other environmental impacts. Hydropower plants don’t add to direct emissions but are considered harmful to the environment in several other ways. The ecological fall out of large hydropower stations in hilly states like Uttarakhand has caused concern in recent years. As a result, many projects have been stalled and those completed are working at very low capacities. To keep the global temperature rise below the threshold of 1.5 degrees as per consensus under the Paris Agreement, carbon emissions will have to be reduced in all sectors — automobiles, buildings, agriculture, industry, power production and so on. Some of the deepest cuts will have to come from the power sector. The share of coal and hydro in the energy mix must go down, and new capacities should come from solar and wind which have a minimum carbon footprint. In other carbon emit ting sectors like transportation, the transition is just about beginning with electric vehicles but it won’t be meaningful unless the source of electricity (to power vehicles) is also green. In the same way, if domestic cooking has to shift to induction stoves from biomass and LPG, the source of electricity should be renewable. That’s why the transition from fossil fuels to renewables in the power sector is critical for meaningful and sustainable low-car bon transition in other sectors as well. In the industrialised world, Germany is fast progressing with about 43% of its power generation coming from solar photovoltaic and wind energy in 2021. The figure was 48% last year. Germany’s renewable roadmap envisages it to become carbon neutral by 2045. In recent elections, the Green Party has emerged as a key player and if it joins the new coalition government, it will seek a faster exit of coal than earlier planned year of 2038. Japan has announced that it will stop investing in coal-based power plants in other countries. At the recent UN General Assembly meeting, China said it would stop overseas coal financing in developing countries. However, it has remained non-committal on any reduction in domestic consumption of coal, given that it is facing power outages current ly. Australia, a major fossil fuel exporter, has also not made any commitments. India has unveiled large plans for renewables such as the International Solar Alliance but has not presented any firm plan of replacing coal with solar in the energy mix as yet. The climate change imperatives strongly favour the phase-out of coal based power but the future of coal depends on several political, economic and technological factors. Falling prices of renewables are making them competitive increasingly. Over the years, subsidies and fiscal policies boosted coal-based power. Now onward, investors are unlikely to put their money in coal as it becomes financially unviable. Multilateral financial institutions are planning to introduce ‘energy transition mechanisms’ basically to help countries retire coal plants before their life cycle ends. More investment is needed in research and development to address critical technological challenges like energy storage and integrated smart grids. The energy question is intrinsically linked with the economic growth, infrastructure development and competitiveness of nations. Even if the climate talks make little progress on emission cuts and timelines, the only way forward is decarbonisation. It is in the common interest of all to end the dominance of fossil fuels for the sake of the environment, human health and to prevent catastrophic impacts of climate change. The current coal crisis has provided India an opportunity to rethink coal.

Source: The Tribune

✨PISTON TYPES AND DESIGNS ------------------->>>>

Piston design impacts how the ignition flame travels, the quality of airflow, fuel distribution, and more. The style you choose is usually based on valve clearance and compression requirements.

1. Flat Top Piston-----------------------------------------------------
This piston has a flat top. It is typically used in mass-produced engines. It is easy to manufacture, which keeps the cost low.

2. Domed Type Pistons------------------------------------------------
This piston has a dome-shaped top. It reduces the chamber volume and increases Compression Ratio. However, it can create slow-burning, inefficient combustion chambers.

3.Dished Pistons---------------------------------------------------
This piston has a bowl- or dish-shaped top. It is used to reduce Compression Ratio because it adds volume to the chamber. It can be used in turbocharged or supercharged engines to help avoid Detonation. It makes for a fast-burning, compact combustion chamber.

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💥BOLT & NUT Assembly

🌟Run-out:-
The thread run out portion of a bolt is where the threaded section transitions into the bolt shank. This area exists beyond where the usable thread stops. In other words, if you were to assemble a nut all the way onto a bolt, the nut will stop, but there will still be a small portion of thread which is unusable as it transitions into the smooth body shank of the bolt.

🔅Shank:-
The shank is the threadless part of the bolt between the head and thread. There are two main ways of using the shank of the bolt. One is to make the shank increase the shearing capacity. The other way is to reduce the shank to increase the elastic resilience of the joint.

✨Thread Length:-
Depending on the type of bolt you are using the thread length can vary greatly. There is not an inclusive thread length standard that covers all fasteners. Depending on the applications, manufacturer, and a number of other factors the amount thread may change.

💦Nominal Length:-
The nominal length of a screw is the length or size which is used to define the length of the fastener; it is the name of the screw size, and not necessarily the overall length of the component.

💢Grip Length:-
Grip length refers to the unthreaded shank of the screw and it is measured from underneath the fl**ge head to the beginning of threads

👉Note:- The table is given for various Thread lengths according to diameter and nominal length of bolt.

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🔥Explanation of Charted Fl**ges:

💥Pipe Fl**ges:
Fl**ges are piping components bolted together using gasket in between two fl**ges as a sealing material. Fl**ges are used to connect pipes with each other, connect pipes to fl**ged valves, connect pipes to fl**ged fittings, and connect pipes to fl**ged piping

✨Blind Fl**ge:
The purpose of these is to block off a section of pipe or a nozzle on a vessel that is not used. (A nozzle is typically a pipe coming out of a vessel and is usually fl**ged so it can be connected to valves or piping).

🌟Welding Neck/ Welded Fl**ges:
A welding neck fl**ge features a long tapered hub that can be welded with a pipe. This fl**ge type is used, normally, in high-pressure and high/low temperatures applications that require an unrestricted flow of the fluid conveyed by the piping system

⚡Slip on/ SO Fl**ges:
They are mainly used for fluids at low pressure or with little risk of leakage. It is very common to find these fl**ges today in cooling water lines, fire fighting water lines, low-pressure compressed air lines, and process lines for substances such as steam, oil, gas, condensates, etc.

💨Socket Weld Fl**ge:
Socket-weld pipe fl**ges are typically used on smaller sizes of high pressure pipes. These pipe fl**ges are attached by inserting the pipe into the socket end and applying fillet weld around the top. This allows for a smooth bore and better flow of the fluid or gas inside of the pipe.

💢Threaded/ Screwed Fl**ge:
Threaded fl**ges are used with pipes that have external threads. The benefit of these fl**ges is that it can be attached without welding. Threaded fl**ges can be fitted to pipes of various sizes without welding and this is one chief benefit for which these fl**ges are highly demanded.

🔅Lap Joint/ Steel Lap Joint Fl**ges:
Lap joint pipe fl**ges slide directly over the pipe and are most commonly used with stub end fittings. Lap joint fl**ges are usually used in low pressure applications and are not suitable when there are high loads on the fl**ge pair. Some types of piping require the use of lap joint fl**ges. For example, metallic pipe that has been plastic lining may have lap joint fl**ges

🟡Plate Fl**ges:
Plate Fl**ges are used to seal the end of pipelines, valves or other connection. With high tensile strength, these steel plate fl**ges are available with a raised face and back ups for easy installation.

💥Reducing Fl**ges:
A reducing fl**ge consists of a fl**ge with one specified diameter having a bore of a different and smaller, diameter. Except for the bore and hub dimensions, the fl**ge will have dimensions of the larger pipe size. Reducing fl**ges are used in pipe-to-pipe connections. Reducing fl**ges are a little easier to bolt up than non-reducing fl**ges. They provide the most perfect solution when you need to connect different size fl**ges. These fl**ges are available in all types and pressures. Reducing fl**ges are fixed by welding, gluing or clamping fl**ges of equal dimensions provided with different connecting pieces. They offer the simplest and least expensive method of mating two different sized fl**ges.

💦DIN and ANSI Fl**ges:
The American National Standards Institute (ANSI) is a nongovernment, nonprofit organization that coordinates U.S. industry standards with international standards so that U.S. products can reach the global market. In essence, ANSI serves as an accreditation body for standards developed by other organizations, companies, consumer groups, and government agencies.
The Deutsches Institut für Normung (DIN), or the German Institute for Standardization, serves a similar function. However, DIN is a government organization that embodies German concerns within the framework of European and International standards. DIN has a wide reach, and over 30,000 DIN standards provide comprehensive coverage for various products and technologies.

🔥Forged Steel Fl**ge:
Forged fl**ges are used as a connection component for pipes, valves, pumps and other equipment to form a pipework system. They provide easy access for cleaning, inspection, modification or repairs.

🌟Metal Fl**ge:
A fl**ge is a forged or cast ring of steel designed to connect mechanically sections of pipe or join pipe to a pressure vessel, pump, valve or any other piece of equipment.

🔅Long Weld Neck Fl**ge:
Long Weld Neck Fl**ges are like weld neck fl**ges, except for the neck, which is extended and acts like a boring extension. Long weld neck fl**ges can be used in high pressure industrial applications, as well as high temperature situations. They are often utilized in the oil and gas or petrochemical industries.

✔Ring Joint Fl**ge:
A Ring type joint fl**ge (RTJ) is a machined metallic ring with a deep groove cut into its face. This groove rests a metal ring which gets compressed when the connecting bolts of the fl**ge are tightened. This compression results in a leak-proof, close-fitting seal on the pipe or connection. Ring-Type Joint (RTJ) The Ring Type Joint fl**ges are typically used in high pressure (Class 600 and higher rating) and/or high temperature services above 800°F (427°C). They have grooves cut into their faces which steel ring gaskets.

⚡ASME Fl**ges:
ASME is abbreviations of the American Society of Mechanical Engineers, a non-profit and private organization created for bringing uniformity in voluntary standards used in engineering and industrial disciplines. The ASME is mainly focused on setting codes and standards for mechanical devices. They founded in 1880, after the numerous steam boiler and pressure vessel explosion in various parts of the world.

💨ASTM Fl**ges:
This was established in 1902, ASTM International is one of the world's largest international standards developing organizations. At ASTM International, producers, users, consumers, and others from all over the world join together to develop voluntary consensus standards. ASTM standards are developed under a process that embraces the World Trade Organization Technical Barriers to Trade Agreement principles. The ASTM standards development process is open and transparent, allowing individuals and governments to participate directly, and as equals, in a global consensus decision.

💥Pin Type Fl**ge:
Bush pin type fl**ge is used for slightly imperfect alignment of the two shafts.
This is modified form of the protected type fl**ge coupling. This type of coupling has pins and it works with coupling bolts. The rubber or leather bushes are used over the pins. The coupling has two halves dissimilar in construction. The pins are rigidly fastened by nuts to one of the fl**ge and kept loose on the other fl**ge. This coupling is used to connect shafts which have a small parallel misalignment, angular misalignment or axial misalignment. In this coupling the rubber bushing absorbs shocks and vibration during its operations. This type of coupling is mostly used to couple electric motors and machines.

✨Puddle Fl**ges:
Puddle Fl**ges ensure a watertight and pressure-tight seal where pipes pass through concrete walls of any structure or building. When a pipe is required to pass through a wall or concrete structure it is usually cast at the point of construction. The concrete will not bond to the pipe and will usually shrink during curing, leaving an ingress path along the outside of the pipe allowing materials such as water, gases and hydrocarbons to pass through the structure or building.

🪂Split Fl**ges:
A split fl**ge is a type of fl**ge that can be easily installed on pre-existing piping. Because it is made of two parts, split fl**ges are used to reinforce weakened areas of piping, or to add an attachment in places conventional fl**ges cannot. Split-fl**ge fittings use rubber O-rings to seal joints and contain pressurized fluid. The O-ring sits in a groove on the fl**ge, and then mates with a port’s flat surface. The fl**ge is then attached to the port with four mounting bolts. The bolts tighten downward onto the clamps of the fl**ge, thereby eliminating the need for large wrenches to connect the components of large-diameter tubing.

🌟Cast Fl**ges:
The advantages of fl**ges manufactured by the casting, has lower costs of production, the ability to make more intricate parts at lower costs, as well as having no true upper limit on size when it comes to your part. There are, however, some drawbacks to cast iron fl**ges. The most important of these being how susceptible they are to internal defects, Due to this, cast fl**ges are not suitable for high pressure applications or applications in which the probability of corrosion is high. Despite advancement of casting technology and computer optimization of the casting process and designs, it is still difficult to meet the standards required for petrochemical industry applications.

🟡Or***ce Fl**ge:
The function of the or***ce fl**ge is to measure the rate of the flow of the commodity through the piping system. Or***ce fl**ges are easy to recognize because they have a hole drilled through the face of the fl**ge perpendicular to the pipe. They also have an additional set of bolts called jack screws.

💢PTFE lined reducing Fl**ge:
It is the most cost effective way to transact between the pipes. This is also a good alternative to connect the various diameters pipes together. It can be used in Oil & Gas Industries, Chemical Industries etc.

💨Fl**ge Connector:
A fl**ge connector is a device that allows the connection of many types of hoses and fittings on to a fl**ged pipeline. Typically manufactured from stainless or high-carbon steel, a fl**ge connector is connected to a fl**ged pipe with bolts, and a gasket is sandwiched between the pipe fl**ge and the connector. Common in manufacturing facilities, a fl**ge connector is often used to allow a smaller and more manageable hose to be split off from a large feeder pipeline. A fl**ge-type connector can also be used to block off a pipeline.

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🔥Flywheel:

✔Purpose/Function:
The function of the flywheel is to store the energy during the power stroke of an engine and releases the same energy required for the non-power stroke actions (Suction, Compression, Exhaust strokes). The energy is stored in a flywheel due to its mass (mass moment of inertia).

💥Springs in Flywheel:
They are small coil springs located between the clutch disc splined hub and the friction disc assembly. When the clutch is engaged, the pressure plate jams the stationary disc against the spinning flywheel. The torsion springs compress and soften the shock as the disc first begins to turn with the flywheel.

🌟Planetary Gear/Wheel:
The purpose of the planetary gear/wheel is to connect the driving side of the flywheel with the driven side of the flywheel. This is also arranged to provide the damping arrangement to the working of flywheel.

✨Materials Used:
Cast Iron, High Strength Steel, Carbon Steel, Carbon-Fiber composites.

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✓Suspension system of a vehicle.

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