New Mechanical Project Topics / Ideas / Brainstorming
1. Flexible Mirror - Roll a 6 feet mirror and pack it along with your luggage. As and when required unroll the mirror and use it.
2. Imagination Travelling - A neuroscience project to travel in your imagination and get the required things. For Example you have read a book and now you are unable to remember the required information then you travel through your imagination and get the required information. This is based on the fact that the brain is capable of storing all the information that has come across during one's life time.
3.Use the exhaust energy of an automobile for refrigeration inside the automobile.
4. A horizontal lift similar to a rope way that can travel horizontally with less energy in places where there is difficult to construct a road and also in places such as forests where the cutting of trees can be avoided. This can also be an option for tourist places.
5. Anti-Rainfall books - Books doesn't get wet or the content will not be lost. Books that can be used in heavily rain prone areas.
6. Innovative science city.
7. Villas in an apartment.
2. Imagination Travelling - A neuroscience project to travel in your imagination and get the required things. For Example you have read a book and now you are unable to remember the required information then you travel through your imagination and get the required information. This is based on the fact that the brain is capable of storing all the information that has come across during one's life time.
3.Use the exhaust energy of an automobile for refrigeration inside the automobile.
4. A horizontal lift similar to a rope way that can travel horizontally with less energy in places where there is difficult to construct a road and also in places such as forests where the cutting of trees can be avoided. This can also be an option for tourist places.
5. Anti-Rainfall books - Books doesn't get wet or the content will not be lost. Books that can be used in heavily rain prone areas.
6. Innovative science city.
7. Villas in an apartment.
Basic Thread Concepts - Pitch Dia, Helix Angle, Root, Crest, Pitch, Thread Angle Minor Diameter and Major Diameter
Bottoming Cycle
For example in the above figure, the thermal energy is produced in the process and this is used for steam generation. Later this steam is used for power generation.
Inspections that can be performed during Maintenance Outages
Maintenance
outages provide an opportunity to gain access to the tubes and other
internals to assess their present condition, and to allow for data to
be obtained to predict their the future reliability of the
components. Inspections that can be performed during outages
include:
a. Visual examination.
b. Wall thickness measurements.
c. Tube diameter or tube circumference
measurements.
d. Tube sagging or bowing measurements.
e. Pit depth gauging.
f. Intelligent Pigs.
g. Radiography.
h. Hardness measurements.
i. Borescope/video probe.
j. In-situ metallography/replication.
k. Dye penetrant testing.
l. Magnetic particle testing.
m. Tube section removal for creep testing.
n. Tube section removal for metallography.
o. Tube removal for detailed visual
examination.
p. Testing of tubeskin thermocouples.
Go Green - Reduce Pollution and Recycle Good
Separate Plastics from other waste
Do not burn any plastics in your yard or house
Do not buy goods packed in PVC packing
Buy products that can be reused or refilled (glass, metal)
Compost organic waste
Demand your municipality to organize recycling of paper, glass and metals
Return plastics to the shop to send to the producer for recycling
Do not burn any plastics in your yard or house
Do not buy goods packed in PVC packing
Buy products that can be reused or refilled (glass, metal)
Compost organic waste
Demand your municipality to organize recycling of paper, glass and metals
Return plastics to the shop to send to the producer for recycling
Project Ideas / Topics for Mechanical Engineers
1. A battery charging shoe/ sandal - Use the energy during walk to charge your re-chargeable batteries
2. A cooking equipment - Select the item you would like to cook and provide the necessary inputs such as salt, sugar, ghee, oil etc in the trays / buckets of the machine. After the required time you get your item ready whether it is a fry or a curry or boiled items etc.
3. Auto Train Ticket allotment for RAC seats based on a ticket punching machine installed in the coaches. The ticket will have a barcode or a unique number that needs to be entered after entering into the train. Based on the auto check availability the seats will be allotted.
4. Garbage collection from Railway Tracks - Firstly Install garbage collection points inside the train and secondly the last compartment of the train may have a special system to attract / collect all the garbage being thrown out of the train by some vacuum sucking arrangement.
5. Go Green - Tree plantation across the road and rail tracks with sufficient distance to avoid any tree falling during cyclone.
6. Auto rail coach cleaning once the train enter the garage through robotic arms similar to a car water washing.
7. Advance Rain water harvesting system - Drill the earth with small bore pipes that has puncture holes all across its surface and these pipes are to be installed all across the river water streams horizontally / vertically / with some inclination. Because of this arrangement the water flowing in the river stream will enter easily deep into the earth and replenish the ground water reserves.
8. Modern Railway Coach - Design a modern railway coach with all basic amenities, sufficient lighting and ventilation, self-cleaning surfaces and necessary electrical points, water bottle points, hangers etc.
2. A cooking equipment - Select the item you would like to cook and provide the necessary inputs such as salt, sugar, ghee, oil etc in the trays / buckets of the machine. After the required time you get your item ready whether it is a fry or a curry or boiled items etc.
3. Auto Train Ticket allotment for RAC seats based on a ticket punching machine installed in the coaches. The ticket will have a barcode or a unique number that needs to be entered after entering into the train. Based on the auto check availability the seats will be allotted.
4. Garbage collection from Railway Tracks - Firstly Install garbage collection points inside the train and secondly the last compartment of the train may have a special system to attract / collect all the garbage being thrown out of the train by some vacuum sucking arrangement.
5. Go Green - Tree plantation across the road and rail tracks with sufficient distance to avoid any tree falling during cyclone.
6. Auto rail coach cleaning once the train enter the garage through robotic arms similar to a car water washing.
7. Advance Rain water harvesting system - Drill the earth with small bore pipes that has puncture holes all across its surface and these pipes are to be installed all across the river water streams horizontally / vertically / with some inclination. Because of this arrangement the water flowing in the river stream will enter easily deep into the earth and replenish the ground water reserves.
8. Modern Railway Coach - Design a modern railway coach with all basic amenities, sufficient lighting and ventilation, self-cleaning surfaces and necessary electrical points, water bottle points, hangers etc.
General Preparatory Work required to carry out the inspection
Before the inspection, the tools needed for
inspection should be checked for availability, proper working
condition, and accuracy. This includes tools and equipment that are
needed for personnel safety. Safety signs should be provided where
needed before work is started. The following tools are needed to
inspect fired heaters and stacks:
a. Portable lights, including a flashlight.
b. Thin-bladed knife or scraper.
c. Broad chisel or scraper.
d. Pointed scraper.
e. Inspector’s hammer.
f. Inside calipers.
g. Outside calipers.
h. Direct-reading calipers or special shapes.
i. Mechanical tube caliper or micrometer for
measuring the inside diameter of tubes.
j. Pocketknife.
k. Steel rule.
l. Special D calipers.
m. Pit depth cage.
n. Paint or crayon.
o. Notebook.
p. Magnifying glass.
q. Wire brush.
r. Plumb bob and line.
s. At least one type of special thickness
measurement equipment (see next list).
t. Small mirror.
u. Magnet.
v. 25-foot tape measure
The following tools should be readily available
in case they are needed:
a. Surveyor’s level.
b. Carpenter's or plumber’s level.
c. Magnetic-particle inspection equipment.
d. Liquid-penetrant inspection materials.
e. Radiographic inspection equipment.
f. Ultrasonic inspection equipment.
g. Megger ground tester.
h. Grit blasting equipment.
i. Micrometer (0 in. – 1 in.).
j. Electronic strain gauge caliper.
k. Borescope.
l. Fiberscope.
Note: When selecting products which will be
used to mark or applied to stainless steel tubes, these products
should not contain chlorides to prevent stress corrosion cracking.
Additionally, any equipment or paint which can/will contact the
stainless steel tube surfaces should not be made or coated with
aluminum, zinc, lead, and cadmium to prevent liquid metal
embrittlement concerns.
Other related equipment that may be provided
for inspection includes planking, scaffold material, a bosun’s
chair, and portable ladders. If external scaffolding is required, it
may be possible to erect it before the unit is shut down.
Before the inspection is started, all persons
working around a fired heater or boiler, flue duct, or stack should
be informed that people will be working on the inside. A safety guard
(“hole watch”) should be stationed at the inspection door of the
equipment being inspected. This person can serve as a guard and can
also record data from the inspection findings.
Personnel working inside this equipment should
be informed when any work is going to be done on the outside so that
any unexpected noise will not cause needless alarm. Vibration of the
tubes and the setting should be minimized while internal inspection
work is being performed to prevent injuries due to the dislodging of
loose refractory.
Mechanical Deterioration of tubes and fittings
Mechanical deterioration may materially reduce
the service life of heater tubes and fittings. The two most common causes of
this are leakage in the tube rolls—the rolled joints between tubes and
fittings—and damage during mechanical cleaning. Leakage in the tube rolls may
result from faulty roll procedures or workmanship when the tubes were
originally installed, or may be caused from thermal upsets during operation.
Similarly, damage to a tube during mechanical cleaning may be caused by faulty
procedures or workmanship. One of the most common causes is allowing the
cleaner to operate in one position for so long that it cuts the tube metal.
Machined surfaces of plug-type header fittings can be damaged by contact with
cleaning tools. Cleaning by steam-air decoking can cause serious oxidation and
other deterioration of tubes unless temperatures are carefully controlled.
Undue force used to close fittings may result
in the development of cracks in the fitting body or at the base of fitting ears
and may cause excessive wear or distortion of the plugs of U-bend seats,
fitting ears, or holding sections and members-dogs or caps and screws. The use
of excess force commonly occurs because of improper cleaning of ground surfaces
or mismating of plugs to return bends. Training and close supervision of
personnel with regard to the proper care, use, and amount of tightening
permissible are essential to prevent this damage. Casting or forging defects
may also result in cracks in the fitting body or at the base of fitting ears. One
common practice to aid in removing plugs and to reduce the chance of damaging
the casting is to heat the fittings. Overheating with a torch may cause the
fitting to crack. The depth and seriousness of cracks formed by overheating
with a torch should be investigated.
Thermal expansion that has not been
accommodated can cause deterioration. Tube materials expand when heated. If the
expansion can not be accommodated, it can create stresses that are high enough
to cause serious weakening and deformation of the tube or fitting. For
instance, tube failures have resulted from refractory repair work, which did
not allow the tubes to expand, and created high enough local stresses to result
in creep rupture.
Inspector Qualifications for Heater and Boiler Mechanical Reliability
Inspection of heaters and boilers should be
performed by someone trained and experienced with heater operation, heater
deterioration mechanisms and the appropriate inspection techniques to identify
or monitor them. The inspector should have experience with or have access to an
individual(s) with understanding of burners, tubes, tube hangers and supports,
refractories, and overall heater operation. Examiners performing specific NDE
procedures should be trained and qualified in the applicable procedures in
which the examiner is involved. In some cases, the examiner may be required to
hold other certifications necessary to satisfy owner or user requirements.
Examples of other certifications include American Society for Non-Destructive
Testing SNT-TC-1A or American Welding Society Welding Inspection certification.
Certification of boiler inspectors may be
governed by jurisdictions. Some jurisdictions may require the inspector to have
a National Board of Boiler and Pressure Vessel Inspectors certification.
Heater and Boiler Mechanical Reliability - RELIABILITY PROGRAMS
Reliability programs have evolved from
inspection during unit maintenance outages to integrity management programs
encompassing on-stream tube life monitoring, continual heater and boiler
efficiency analyses and detailed and varied inspections during maintenance
opportunities. In the simplest programs, heater and boiler reliability focus on
preventing failures of the pressure boundary. The strategy is to prevent leaks
and ruptures of the tubes and in the case of boilers, the drums too. Further
refinements to these programs consider the operations of the heater and boiler
and associated hardware to ensure they are operating optimally and at design
levels. Oftentimes, poor performance or
failure of associated hardware can lead to deterioration of the tubes.
Tube failures result from progressive
deterioration from a variety of deterioration mechanisms. Therefore, one needs
to understand the active and potential mechanisms in a particular heater and
boiler in order to prevent them from causing a failure. For example, in elevated
temperature services like boiler and heater tubes, creep and stress rupture are
potential deterioration mechanisms. The tube operating variables which affect
tube creep life/stress rupture life include: the base metal creep/stress
rupture properties, tube metal temperatures, applied stress from internal
operating pressure and from mechanical loading (i.e., from supports or lack of
supports), and time operating at each unique combination of stress and metal
temperature.
Tube reliability not only requires an
understanding of the mechanisms by which the tubes can fail, but also requires
data on how the previous operating history has impacted tube life, predictions
of deterioration rate, how the future operation will impact tube life, and
finally, monitoring of operations and deterioration to ensure the analyses and
predictions are accurate and appropriate. Historically, inspection data
gathered during outages assessed the immediate condition of the tubes with
varying degrees of accuracy or success. Typical inspections included a visual
examination for bulges in tubes and thickness measurements of accessible tubes.
Now, inspections can also include detailed strapping/gauging for bulges,
internal ultrasonic (UT) inspection pigs to gather detailed tube wall
thickness and diameter maps (including the difficult to inspect heater
convective tubes), on-stream infrared tube temperature measurements,
destructive testing to identify specific types of deterioration or to determine
actual remaining creep life, to name a few.
Components of a typical tube reliability
program for individual heaters and boilers include:
a. List of active and potential deterioration
mechanisms.
b. Inspection techniques to identify whether the
potential deterioration mechanisms are active.
c. Review of historical heater and boiler
operations and maintenance repairs records to identify active or previously
active deterioration mechanisms.
d. Assessment of previous operations and repairs
impact on tube remaining life.
e. Defined tasks or procedures, if practical, to
minimize the likelihood of potential damaging mechanisms.
f. Rate of deterioration of tubes for active
deterioration mechanisms.
g. Method or technique to assess the impact of
process changes or heater and boiler operations on rate of deterioration.
h. Assessment of remaining tube life for each
mechanism considering previous operations and repairs, current condition and
the rate of deterioration.
i. Defined integrity operating windows in which
the tube life and rate of deterioration projections remain valid.
j. On-stream monitoring tasks to ensure
operating conditions remain within the boundaries and procedure to address or
assess the impact on tube life of out-of-bounds operations.
k. Inspection plan and monitoring/assessment of
other hardware and equipment that impact the deterioration of the tubes like
burners, hangers and supports, and thermocouples.
Schematic Representation of a Back Pressure Turbine
Different Gear Arrangements
Straight Bevel Gears
Spiral Bevel Gears
Worm Gear Set
Hypoid Gears
Planetary Gear Set
Helical Gears
Herringbone Gears
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