Engineering Talk

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gor Independenee on Aug xrb?

z. Wby was James Bond AssoeIared wIrb
rbe Number ooy?

. WbIeb Is rbe onIy sporr wbIeb Is nor
aIIowed ro pIay Ietr banded?

. WbIeb Is rbe mosr soId as weII as mosr
sbop IItred book ot rbe worId?

. WbIeb Is rbe onIy pIaner rbar rorares
eIoekwIse?

Turn ro Iasr page tor answers!!
^.... ... - ^.... ... - ^.... ... - ^.... ... -
A very warm welcome to the Fourth
Edition of Engineering 1alk. Editorial
team feel proud that we have come along
for almost one year and we can't really
help saying that time really does fly. We
strongly feel that without everyone's
support and contribution we would not
have come this far.

Aow glancing into our fourth edition, it
seeks to reflect many interesting articles
covering wide variety of subjects related
to extreme engineering. Engineering
1alk team would like to express
thankfulness to the authors of the
articles for contributing their experience
and sharing their valuable knowledge
through their articles.

With this in mind lets start exploring the
new horizons of this knowledge resource.

Happy Reading
Editorial 1eam
. . -. .,.... . . -. .,.... . . -. .,.... . . -. .,....
"OenIus azen't anythIng noze than eIegant connon sense." -]osh BIIIIngs
Artiole on Uuotile iron material Artiole on Uuotile iron material Artiole on Uuotile iron material Artiole on Uuotile iron material
with wide range of variety in with wide range of variety in with wide range of variety in with wide range of variety in
piping joints for u0 sewer piping joints for u0 sewer piping joints for u0 sewer piping joints for u0 sewer
applioation applioation applioation applioation
3 33 3
Uistillation : ow 1o 3peoify & Uistillation : ow 1o 3peoify & Uistillation : ow 1o 3peoify & Uistillation : ow 1o 3peoify &
lnstall Cartridge 1rays lnstall Cartridge 1rays lnstall Cartridge 1rays lnstall Cartridge 1rays
5 55 5
air Pin eat Lxohangers air Pin eat Lxohangers air Pin eat Lxohangers air Pin eat Lxohangers 7 77 7
Column Column Column Column- -- -Reboiler Analysis Reboiler Analysis Reboiler Analysis Reboiler Analysis 9 99 9
Bio Bio Bio Bio- -- -Uiesel: An Alternate Uiesel: An Alternate Uiesel: An Alternate Uiesel: An Alternate
Renewable luel Renewable luel Renewable luel Renewable luel
11 11 11 11
Lnergy Lffioient Uistribution Lnergy Lffioient Uistribution Lnergy Lffioient Uistribution Lnergy Lffioient Uistribution
1ransformer 1ransformer 1ransformer 1ransformer
16 16 16 16
An Applioation to Lstimate Con- An Applioation to Lstimate Con- An Applioation to Lstimate Con- An Applioation to Lstimate Con-
orete uantities in Balanoe of orete uantities in Balanoe of orete uantities in Balanoe of orete uantities in Balanoe of
Plant 3truotures for lossil Plant 3truotures for lossil Plant 3truotures for lossil Plant 3truotures for lossil
Power Plants Power Plants Power Plants Power Plants
17 17 17 17
Uetailed leasibility Report Uetailed leasibility Report Uetailed leasibility Report Uetailed leasibility Report - -- - lor lor lor lor
PCL, Bhatinda PCL, Bhatinda PCL, Bhatinda PCL, Bhatinda
14 14 14 14
Ioic 0overed Ioic 0overed
31ANUARU3 l0R UuC1lLL lR0N 31ANUARU3 l0R UuC1lLL lR0N 31ANUARU3 l0R UuC1lLL lR0N 31ANUARU3 l0R UuC1lLL lR0N
MA1LRlAL3 MA1LRlAL3 MA1LRlAL3 MA1LRlAL3

A31M (Amerioan 3ooiety for 1esting and A31M (Amerioan 3ooiety for 1esting and A31M (Amerioan 3ooiety for 1esting and A31M (Amerioan 3ooiety for 1esting and
Materials) 3td # Materials) 3td # Materials) 3td # Materials) 3td #

A31M A 746 3tandard 3peoifioation
for Uuotile lron 0ravity 3ewer Pipe

AwwA (Amerioan water works Assooiation) AwwA (Amerioan water works Assooiation) AwwA (Amerioan water works Assooiation) AwwA (Amerioan water works Assooiation)
3td # 3td # 3td # 3td #

AwwA C110/A21.10 Uuot i l e- l r on
and 0ray-lron littings, 3 in. 1hrough 48 in.
(76 mm 1hrough 1219 mm), for water
AwwA C111/A21.11 Rubber gasket
joints for duotile iron pressure pipes &
fittings.
AwwA C151/A21.51 Uuot i l e- l r on
Pipe, Centrifugally Cast, for water
AwwA C600 lnstallation prooedure
for duotile iron joints.

lN1R0UuC1l0N lN1R0UuC1l0N lN1R0UuC1l0N lN1R0UuC1l0N
0enerally this duotile iron pipes are utilized
in general utility servioes in u0
applioations like sewer systems / waste
water systems.
lollowing's are the few advantages for
duotile iron material applioation.
1here is a muoh wider variety for joints
available for duotile iron pipe than any
other piping material, providing greater
flexibility & versatility in piping design &
installation to aooommodate the partioular
oondition at the job site.
1hese joints are time proven to be strong,
dependable & bottle tight.
Uurability, ease of installation & availability
of std fittings with wider range of joints
duotile iron material proven to be oost
oompetitive & material of ohoioe for waste
water & sewer applioations.
Requires less support and provides greater
flow area oompared with pipe made from
other materials.
Long servioe life without any failure &
infiltration.
1he physioal properties of Uuotile lron pipe
do not ohange with time, therefore,
oorrosion (both external and internal) is the
main faotor that oan affeot the struotural
integrity of the pipe. owever it should be
overoome with Cement-mortar linings &
ooating.
igher strength of Uuotile lron pipe permits
a wide variety of design applioations in u0
sewer systems.

UL3l0N l310R BLlN UL3l0N l310R BLlN UL3l0N l310R BLlN UL3l0N l310R BLlNU UuC1lLL lR0N U UuC1lLL lR0N U UuC1lLL lR0N U UuC1lLL lR0N
PlPL3 & ll11lN03 10lN13 PlPL3 & ll11lN03 10lN13 PlPL3 & ll11lN03 10lN13 PlPL3 & ll11lN03 10lN13
About 550 years ago the first oast iron pipe
were made with flanged joint using lead or
leather gaskets.
ln 1785 1he bell & spigot joint was
developed whioh was assembled by
oaulking yarn or braided hemp into the
base of annular bell oavity & then pouring
molten lead into the remaining spaoe of
the bell.
ln 1937 a Roll-on joint was developed,
the assembly of this joint involved a
oompressed rubber gasket rolled under a
restriotion ring, followed by a oaulked
square-braided jute. 1he remainder of the
joint was paoked with the bituminous
oompound.

10UA'3 UL3l0N 3CLNA 10UA'3 UL3l0N 3CLNA 10UA'3 UL3l0N 3CLNA 10UA'3 UL3l0N 3CLNARl0 l0R UuC1lLL Rl0 l0R UuC1lLL Rl0 l0R UuC1lLL Rl0 l0R UuC1lLL
lR0N PlPL3 & ll11lN03 10lN13 lR0N PlPL3 & ll11lN03 10lN13 lR0N PlPL3 & ll11lN03 10lN13 lR0N PlPL3 & ll11lN03 10lN13
ln today's design the Push-on joints (i.e.
p u s h - o n s o o k e t n s p i g o t
joint) ,Meohanioal joints & llanged joints
are most prominent in use.

(A) Push (A) Push (A) Push (A) Push- -- -on joint (i.e. push on joint (i.e. push on joint (i.e. push on joint (i.e. push- -- -on sooket n on sooket n on sooket n on sooket n
spigot joint) : spigot joint) : spigot joint) : spigot joint) :
lt is the most popular, quiokest & easiest
to assemble joint for duotile iron pipe &
fittings in under ground applioation. 1his
joint oonsists a single rubber gasket
plaoed (integrally oast) in a groove inside
a sooket at the bell end of the pipe (pipe
having bell end that is sooket end &
spigot end that is plain end, & this spigot/
plain end inserted into sooket end).
Now after lubrioating (normally soapy
water or any other piping lubrioant used)
the bell end of pipe aooording to standard
the beveled / plain end of the pipe is
pushed past the gasket, oompressing it
and forming a pressure tight &
dependable seal joint.
Applioation of this joint is very simple &
fast and also it oan be assembled under
wet trenoh or even under water.
ere in figure typioal push on joints are
shown with rubber gasket integrally oast
into the bell end of the pipe & beveled
end is pushed past the gasket.
1he two type of push-on joint are 1yton
type & lastite type. they differ in
somewhat oonfiguration of groove only.

(B) Meohanioal joint : (B) Meohanioal joint : (B) Meohanioal joint : (B) Meohanioal joint :
1he meohanioal joint uses the basio
prinoipal of stuffing box & gland.
1his joint has four parts as shown in
figure :
A flange oast with a bell end.
A rubber gasket that fits in the bell
sooket.
A gland or a follower ring to oompress
the gasket.
A tee head bolts and nuts for tighten the
joint.
1his joint assembly is labor intensive but
very simple & required only one tool (i.e.
ordinary ratohet wrenoh) for tighten the
bolts. 1his joint mainly use with fittings
rather than pipes.
Not e : Push- on j oi nt i s more
eoonomioal , faster to install, more
trouble free joint than meohanioal joint.

(C) llanged joint : (C) llanged joint : (C) llanged joint : (C) llanged joint :
lt is normal a flange to flange oonneotion
joint. here flange is oast at both end of
the pipe & fittings.
3ee the figure for flanged joint.

As above mention, these are the most
prominent & wide usage of joints in
duotile iron pipes. other than this there
are some speoial designed joints are
also there for speoifio applioation as &
when required.

3PLClAL UL3l0NLU 10l 3PLClAL UL3l0NLU 10l 3PLClAL UL3l0NLU 10l 3PLClAL UL3l0NLU 10lN13 l0R N13 l0R N13 l0R N13 l0R
3PLClllC APPLlCA1l0N3 ARL A3 3PLClllC APPLlCA1l0N3 ARL A3 3PLClllC APPLlCA1l0N3 ARL A3 3PLClllC APPLlCA1l0N3 ARL A3
l0LL0wlN0 l0LL0wlN0 l0LL0wlN0 l0LL0wlN0

(A) Restrained push (A) Restrained push (A) Restrained push (A) Restrained push- -- -on gasket joint: on gasket joint: on gasket joint: on gasket joint:
1his joint oonsists a speoial patented
gasket that oontain high strength
stainless steel elements spaoe around
the gasket that develops a dependable
gripping aotion with wedge.
Beoause of this wedging design the
foroe between the spigot/plain end &
the bell/sooket end of the pipe is
essentially oonstant at any given
pressure thrust regardless of the
tightness or looseness of the joint.
"No nattez how gzeat youz wozds nay be, you wIII be judged by youz actIons." -Anonynous
Artiole on Uuotile lron Material with wide Range of variety in Piping 1oints for u0 Artiole on Uuotile lron Material with wide Range of variety in Piping 1oints for u0 Artiole on Uuotile lron Material with wide Range of variety in Piping 1oints for u0 Artiole on Uuotile lron Material with wide Range of variety in Piping 1oints for u0
3ewer Applioation 3ewer Applioation 3ewer Applioation 3ewer Applioation
Contributed by: Nirav v 3hah, L1C, Baroda Contributed by: Nirav v 3hah, L1C, Baroda Contributed by: Nirav v 3hah, L1C, Baroda Contributed by: Nirav v 3hah, L1C, Baroda
cK6|KttR|K6 TALK cK6|KttR|K6 TALK cK6|KttR|K6 TALK cK6|KttR|K6 TALK cK6|KttR|K6 TALK cK6|KttR|K6 TALK cK6|KttR|K6 TALK cK6|KttR|K6 TALK
APkIl 2000 PA0 3
Vo|ame 1, Issae 4
1his oonfiguration as shown in the figure.
1his speoial type of gaskets are available
for both 1yton & fastite push-on joints. they
have been in same basio shape as the
regular gasket. so they oan be uses in any
standard push-on joints also where in field
adaptable restrained is desired.

(B) 3peoially designed Push (B) 3peoially designed Push (B) 3peoially designed Push (B) 3peoially designed Push- -- -on restrained on restrained on restrained on restrained
joints: joints: joints: joints:
1his joint oonsists a push-on gasket &
speoially bell end design in oonjunotion
with their restraint meohanisms.
1his type of joint is assembled by making a
standard push-on joint assembly and then
inserting the flex ring, split ring or a ring
segments (depending on design),
extending the joint to remove any slaok in
the looking meohanism. (different
arrangements are as shown in figure).
1he speoial push 1he speoial push 1he speoial push 1he speoial push- -- -on gasket use in this design on gasket use in this design on gasket use in this design on gasket use in this design
might not be interohangeable with standard might not be interohangeable with standard might not be interohangeable with standard might not be interohangeable with standard
push push push push- -- -on gaskets. on gaskets. on gaskets. on gaskets.

(C) Meohanioal restrained joints: (C) Meohanioal restrained joints: (C) Meohanioal restrained joints: (C) Meohanioal restrained joints:
1his joints offer a method of providing joint
restraint with a standard meohanioal joint
sooket of a pipes & fittings.
(different arrangements are as shown in
figure).
1he tee bolts for this joints are not
standard length. speoial long length tee
bolts are required for this joints.

(U) Ball & sooket joints: (U) Ball & sooket joints: (U) Ball & sooket joints: (U) Ball & sooket joints:
Uuotile iron pipe with ball & sooket joints
are the extremely tough with heavy wall
thiokness.
1his duotile iron pipe is boltless joint. they
oonsist of a preoision maohined ball that
fits into a maohined sooket , a rubber
gasket is provide a pressure tight seal
and a retainer ring provides a longitudinal
restraint.
(different arrangements are as shown in
figure).

(L) 0rooved & shouldered joints: (L) 0rooved & shouldered joints: (L) 0rooved & shouldered joints: (L) 0rooved & shouldered joints:
0rooved joints: 0rooved joints: 0rooved joints: 0rooved joints:
1he grooved joint uses a bolted,
segmental, olamp type meohanioal
ooupling having a housing that enoloses a
u-shaped rubber gasket.
1he housing looks the pipe ends together
and oompressed the gasket against the
outside of the pipe ends. 1he ends of the
pipe are maohine groove to aooept the
housing.

3houldered joints: 3houldered joints: 3houldered joints: 3houldered joints:
1he shouldered joints is similar to
grooved joints exoept that the pipe ends
are shouldered instead of grooved.

3o, these are the variety of piping joints in
duotile iron material.

LlMl1A1l0N 0l UuC1lL LlMl1A1l0N 0l UuC1lL LlMl1A1l0N 0l UuC1lL LlMl1A1l0N 0l UuC1lLL lR0N PlPlN0 L lR0N PlPlN0 L lR0N PlPlN0 L lR0N PlPlN0
At last one question/doubt oomes in mind
that is even though duotile iron material
having wide variety of joints and also
having no of advantages in usage of u0
sewer applioations, it is not most
oommonly used material in refineries
applioation.
1here are oertain limitations of duotile
iron piping as follows whioh olear the
above mentioned doubt.
Uuotile iron pipes are usually made by
Centrifugal oasting prooess and Cast
pipes in refineries are not very popular.
Many of the refineries do not prefer
Uuotile iron pipes for u/0 servioe mainly
beoause it has lower allowable tensile
and bending stresses as oompared to
Carbon 3teel pipes.
when piping subjeoted to oombined
loading oondition (i.e. internal pressure
& external loading oondition/soil
pressure), duotile iron pipes behaves as
a flexible oonduit and it needs to
designed separately with higher
thiokness to withstand oombined
loading oondition.

C0NCLu3l0N C0NCLu3l0N C0NCLu3l0N C0NCLu3l0N
3o, there is a muoh wider variety for
joints available for duotile iron pipes &
fittings than any other piping material for
u0 applioations.
Also duotile iron proves to be very oost
effeotive as oompared to oarbon steel
piping.
"It Is easIez to pzepaze and pzevent than to zepaIz and zepent." - Anonynous
Artiole on Uuotile lron Material with wide Range of variety in Piping 1oints for u0 Artiole on Uuotile lron Material with wide Range of variety in Piping 1oints for u0 Artiole on Uuotile lron Material with wide Range of variety in Piping 1oints for u0 Artiole on Uuotile lron Material with wide Range of variety in Piping 1oints for u0
3ewer Applioation 3ewer Applioation 3ewer Applioation 3ewer Applioation
Contributed by: Nirav v 3hah, L1C, Baroda Contributed by: Nirav v 3hah, L1C, Baroda Contributed by: Nirav v 3hah, L1C, Baroda Contributed by: Nirav v 3hah, L1C, Baroda
APkIl 2000 PA0 4
Vo|ame 1, Issae 4
., -. ., -. ., -. ., -.
A young executive with
poor self-esteem was pro-
moted but he couldn't rec-
oncile himself to his new
office and position. There
was a knock at his door.
To show how important
and busy he was, he
picked up the phone and
then asked the visitor to
come in. As the man
waited for the executive,
the executive kept talking
on the phone, nodding and
saying, "No problem, I can
handle that." After a few
minutes he hung up and
asked the visitor what he
could do for him.
The man replied, "Sir, I'm
here to connect your
phone."
ln any prooess industry the mass transfer
is one of the main prooess aotivity-taking
plaoes in the Column (Mass transfer
equipment). Lffioienoy of the mass transfer
prooess is dependents on the interfaoe
oontaot between two immisoible phases
(0as-Liquid or Liquid-Liquid). 1rays are the
means for providing the neoessary oontaot
area for the interfaoing. 1rays are used for
Uistillation, Abortion, Lxtraotion, 3tripping,
for reaotion distillation eto
lor the small diameter oolumns, it is
diffioult to enter in the oolumn to inspeot,
lnstalled & maintain the 1rays / lnternals
due to the less spaoe available.
Cartridge trays oan be the perfeot
hardware solution for distillation oolumns
that are less than 3 feet (900mm) in
diameter and have a unique need for trays.
Paoking is usually the preferred ohoioe for
small-diameter oolumns, but there are
several oiroumstanoes in whioh trays are
advantageous. Lxamples inolude fouling
systems, oertain foaming systems, high-
pressure applioations and systems that
require high effioienoy and a large
turndown. All of these oan be
aooommodated with various tray designs
installed muoh faster than traditional ring-
supported trays. 0n the other hand,
oartridge trays are less simple than
traditional trays. And the key to suooess
with them lies in understanding how
oartridge trays are oonfigured, speoified
and installed.
A33LMBL 0l C0MP0NLN13 A33LMBL 0l C0MP0NLN13 A33LMBL 0l C0MP0NLN13 A33LMBL 0l C0MP0NLN13
Cartridge trays oonsist of eight to ten trays
preassembled in a bundle. 1he trays
themselves oan be of any type: sieve,
valve, bubble oap or other. 1he tray deoks
are oonneoted together by at least five tie-
rods that run the length of the bundle.
3paoer rods are inserted over the tie -rods
to ensure the oorreot tray spaoing. 1he
bundle is bolted at the ends to make
oomplete unit, whioh is inserted into the
oolumn through a body flange. 1he bundles
are bolted together as they are installed,
so that all the trays in a seotion of oolumn
are oonneoted together. ln order to prevent
the uplift of the bundle, hold down
arrangement is provided by fixing the top
tray at the flange.
1he bundles rest on support olips welded
to the shell at the bottom of a given
oolumn seotion. 1he downoomers are
envelope-style, and are integral to the tray
deok. 1he trays are sealed to the oolumn
wall by oiroumferential gaskets. ligure 1
shows a bundle of proprietary oartridge
trays.
ligure 2 shows the oonneotion between
the bundles in more detail. 1he tie-rods
have threaded oonneotions on both ends.
A braoket plus double nuts are used to
join the tie-rods together. 1he overall
height of the braoket and nuts is set to
give the proper tray spaoing for the trays
at the interfaoe between the bundles.

lN31ALLA1l0N 0l CAR1RlU0L lN31ALLA1l0N 0l CAR1RlU0L lN31ALLA1l0N 0l CAR1RlU0L lN31ALLA1l0N 0l CAR1RlU0L
Although oartridge trays oan be installed
rapidly, the installation prooedure
requires speoial oare-in faot, it diotates a
need for partioular attention to details
during the earlier design and fabrioation
phases of the projeot. Uuring installation,
eaoh bundle is inserted into the oolumn
through the top body flange, so the area
above the oolumn must be free. lirst, the
bundle that oontains the bottom trays is
lifted with a orane above the body flange.
1he proper orientation is established, and
then the bundle is lowered into the
oolumn.
1ust before the last (uppermost) trays of
the first bundle (whioh will beoome the
lowest bundle within the oolumn) go into
the oolumn, wooden blooks are inserted
under that tray. 1he bundle is
disoonneoted from the orane, and the
partially inserted bundle rests on the
wooden blooks. 1hen the next bundle is
lifted, its orientation is established, and
that bundle is bolted to the partially
inserted one. 1he wooden blooks are
removed, and the joined bundles are
then lowered into the oolumn. 1ust
before the last tray goes in, the wooden
blooks are again inserted. 1his prooess
is repeated for as many bundles as
neoessary. As the trays are lowered into
the oolumn, oreating the seal with the
inside of the oolumn wall. 1he trays
eventually rest on support olips at the
bottom of the oolumn. 1he bundles
will be inserted into the oolumn under
the power of their own weight, the
gaskets will seal properly, the trays will
rest properly on the support olips, and
all equipment will mate up at the
designated plaoes.
"8uccess Is the abIIIty to go Izon one IaIIuze to anothez wIthout Ioss oI EnthusIasn" - Anonynous
Uistillation : ow 1o 3peoify & lnstall Cartridge 1rays Uistillation : ow 1o 3peoify & lnstall Cartridge 1rays Uistillation : ow 1o 3peoify & lnstall Cartridge 1rays Uistillation : ow 1o 3peoify & lnstall Cartridge 1rays
Contributed by: Krishna Uesai, L1C, Baroda Contributed by: Krishna Uesai, L1C, Baroda Contributed by: Krishna Uesai, L1C, Baroda Contributed by: Krishna Uesai, L1C, Baroda
APkIl 2000 PA0 5
Vo|ame 1, Issae 4
ligure 1. Cartridge unit of trays ligure 1. Cartridge unit of trays ligure 1. Cartridge unit of trays ligure 1. Cartridge unit of trays
ligure 2. Conneotion between bundles ligure 2. Conneotion between bundles ligure 2. Conneotion between bundles ligure 2. Conneotion between bundles
1he following are some of the tips will help
to ensure oorreot installation of oartridge
unit.

0PLRA1l0N & MAlN1AlNANCL 0PLRA1l0N & MAlN1AlNANCL 0PLRA1l0N & MAlN1AlNANCL 0PLRA1l0N & MAlN1AlNANCL
1hink of oartridge trays as being akin to a
pre-fabrioated house. 1hey must endure
shipping and installation without losing
their struotural integrity. 1he tray spaoing
and overall bundle length should not
ohange even when they are shipped over
bumpy roads and lifted by oranes in their
shipping orates. 3peoifying heavy-duty
hardware and tray deoks helps to make
the bundles more rigid and less prone to
ooming loose during shipment and
installation. lt is preferred to have tie-rods
of -in. (13-mm) diameter, and in.,
sohedule 80 spaoer pipes, whioh results in
very tight fit between the two, and gives
the bundle more rigidity. 1en-gage tray
deoks are speoified for the same reason.
1he gasket design is very important, and
extra thought should be given to it during
the design phase of a trays. 1ray
performanoe will suffer greatly if the gasket
seal loosens over time. Uuring the design
stage, it is preferred that, the gaskets are
attaohed to the tray deok by a olamp ring
and bolts. lt is a good idea to request a
heavy-duty olamp ring, and to oheok the
design to ensure plenty of bolting. lor oost-
effeotiveness, the gaskets and olamp ring
are usually out into six or eight pieoes. 1o
avoid the possibility of leaks, it is very
important that the resulting six to eight
gasket junotures do not align with the
olamp ring junotures.

1RA / 10wLR lN1LRlACL 1RA / 10wLR lN1LRlACL 1RA / 10wLR lN1LRlACL 1RA / 10wLR lN1LRlACL
Uuring the design phase of trays, oonsider
how the other tower hardware will mate up
with the trays. lt is important to make
allowanoes for slight imperfeotions in the
elevation & orientation of the bundle. lor
instanoe, you would not want a reflux pipe,
a feed pipe, or thermo wells to have to
mate up to a very olose toleranoe. 1he
bundles may rotate slightly during
installation, or the height of the bundle
may be off by some amount.

Making these allowanoes is espeoially
important if you need to divide the oolumn
in to more than one seotion and to have
more than one set of tray support olips. lor
example, if, flashing feed devioe is to be
welded to the tower shell, the bundles
oould not be inserted over this devioe so
the tower has to be divided in to two
seotions. An extra set of body flange was
required below the devioe. 1he lower
trays were inserted through the lower
body flange and supported by the set of
support olips in the bottom of the tower.
1he upper trays inserted through the
upper body flange and supported by the
supported olips above the flashing feed
devioe. 1he downoomer from the tray in
the upper seotion was required to mate of
with trays in lower seotions of the oolumn.
Lnsure that, there is adequate
downoomer olearanoe at this interfaoe is
important.

1he other thing to oonsider in design is
the importanoe of manways aooess to all
sets of tray support olips to ensure proper
resting of bundle on olips and the ability
to repair if neoessary, as it is oritioal to
the levelness of the trays. 1he
arrangement is shown in the figure 3.

R0uNUNL33 0l 1L C0LuMN 3LLL R0uNUNL33 0l 1L C0LuMN 3LLL R0uNUNL33 0l 1L C0LuMN 3LLL R0uNUNL33 0l 1L C0LuMN 3LLL
1he roundness of the oolumn shell is
really the most important aspeot of the
oartridge tray installation. 1he tray must
seal to the tower shell with the gasket, or
they won't work. 0n the other hand, if the
tower shell is too tight, and the trays get
stuok, it is not advisable to apply great
amount of foroe to avoid the damaging of
trays. 1he most oommon problem during
the fabrioation is related to welding,
wherever signifioant welding takes plaoe
on the tower, there is a tendenoy for the
metal to pull in, resulting in a tight spot.
welds to attaoh large nozzle, lifting lugs,
support olips are the main oulprits.
"8uccess Is when skIII neets oppoztunIty. FaIIuze Is when Iantasy neets zeaIIty." -BzokIns
Uistillation : ow 1o 3peoify & lnstall Cartridge 1rays Uistillation : ow 1o 3peoify & lnstall Cartridge 1rays Uistillation : ow 1o 3peoify & lnstall Cartridge 1rays Uistillation : ow 1o 3peoify & lnstall Cartridge 1rays
Contributed by: Krishna Uesai, L1C, Baroda Contributed by: Krishna Uesai, L1C, Baroda Contributed by: Krishna Uesai, L1C, Baroda Contributed by: Krishna Uesai, L1C, Baroda
APkIl 2000 PA0 0
Vo|ame 1, Issae 4
ligure 3 ligure 3 ligure 3 ligure 3
9 1 2 6
8 5 4 3 1
7 1 6
2 4
5 8 6 2 3
4 7 3 9 1
8 2 9 7 4
5
9 5 6 3 7 8
.,. .,. .,. .,.
TMG EOiTOMiML
TGM

1. 1itesh Sheth from L1C,
Baroda
2. Shaunak Bhatt from L&1-
S&L, Baroda
3. Anirban Pandit from L&1
Engineering, Baroda
4. C. Manoj from L1C,
Mumbai
5. Darshan Shah from L1C,
Baroda
. Devendra Parab, L&1 En-
gineering, Mumbai
7. Sanjay S. Shenoy from
Mid and Downstream In-
ternational
8. Pradeep 1hakur from L&1
Engineering, Faridabad
9. Pradumna from L&1-Culf
1. Ravi Prakash from L&1-
Jaldel

ln Refinery & Petroohemioal Complex eat
Lxohangers plays very important role by
exohanging heat energy. 3hell & 1ube eat
exohanger is very oommonly used in
Refinery & Petroohemioal applioation. air
Pin eat Lxohanger is a type of 3 & 1 eat
Lxohanger. 3imple oonfiguration of air Pin
eat Lxohanger is shown in lig. 1.

APPLlCA1l0N: APPLlCA1l0N: APPLlCA1l0N: APPLlCA1l0N:
air pin eat Lxohangers oan be used as
an alternative to shell & tube exohangers
under following oonditions,
Uuty < 500 kw
Low llow rates
Large 1emperature oross
Uiameter of shell & tube heat exohanger is
8" (200 mm) or less.
lor the oonditions listed above a
oonventional shell & tube heat exohanger
beoomes uneoonomioal as large number of
small diameter shells in series is required
to provide adequate velooities and near
oounter-ourrent flow to aohieve desired
performanoe.

C0N31RuC1l0N: C0N31RuC1l0N: C0N31RuC1l0N: C0N31RuC1l0N:
A hairpin heat exohanger oan be desoribed
as a single-pass shell-and-tube unit that
has been folded in half to give it a hairpin
appearanoe. lt is olassified based on
oonstruotion as follows,
Uouble Pipe eat Lxohanger
Multitube eat Lxohanger
Uouble Pipe eat Lxohanger:
1he basio double-pipe oonstruotion
oonsists of a single pipe or tube, plaoed
oonoentrioally inside a larger pipe or tube
(0uter shell) as shown in lig. 2. At front
end, olosure is provided with tube side
inlet oonneotions. 1hese olosures use
independent tube-side and shell-side
gasketing that prevent inter stream
leakage. 1he olosure arrangement is also
provided with external split ring that looks
the tube element to the shell. At rear end
two inner tubes are joined together by a
welded on u-bend, while the two outer
shells are joined together by a dished
head and a flanged joint as shown in lig.
2. 1he depth of dished head is sized to
allow free axial thermal movement of
inner tubes & bend within the shell.

MuL1l1uBL LA1 LXCA MuL1l1uBL LA1 LXCA MuL1l1uBL LA1 LXCA MuL1l1uBL LA1 LXCAN0LR: N0LR: N0LR: N0LR:
ln Multitube heat exohanger there is a
bundle of u-tubes as shown in lig. 3,
instead of a single inner tube as double
pipe. Laoh leg of the u-bundle has its own
tubesheet and design permits free
thermal movement of the bundle and its
withdrawal from the shell. 1he front end
and rear end oonstruotion of Multitube
heat exohanger is similar to that of
double pipe. Plain tubes are supported by
segmental baffles inside shell. air Pin
heat exohanger is supported by moveable
support braokets. 1hese braokets are
provided with slotted holes for anohor
bolts whioh allow for shell expansion and
oontraotion.

PR0CL33 BLNLll13: PR0CL33 BLNLll13: PR0CL33 BLNLll13: PR0CL33 BLNLll13:
air pin heat exohanger has tube-side &
shell-side fluids running oounterourrent
to eaoh other. 1rue oounterourrent flow
is an effioient flow arrangement beoause
the temperature differenoe between the
two streams is maximized. Another
benefit offered by oounterourrent flow is
the ability to attain oloser temperature
approaohes and aooommodate a
temperature oross using a single hairpin
seotion. Long radius u-bends takes oare
of thermal expansion in the tubes henoe
el i mi nat i ng the requi rement of
expansion bellows.

MAlN1LNANCL 0l AlR PlN LA1 MAlN1LNANCL 0l AlR PlN LA1 MAlN1LNANCL 0l AlR PlN LA1 MAlN1LNANCL 0l AlR PlN LA1
LXCAN0LR3: LXCAN0LR3: LXCAN0LR3: LXCAN0LR3:
air pin heat exohangers are very easy
to dismantle and maintenanoe oan be
performed easily during plant shutdown.
3peoially designed olosure arrangement
permits the tubeside oonneotions to be
removed. 1hese enable the inner tube or
tube bundle & bend to be removed as a
unit from the shells, from the rear end,
after first removing the rear end
assembly.

UL1AlL3 0l 31ANUARU uNl13: UL1AlL3 0l 31ANUARU uNl13: UL1AlL3 0l 31ANUARU uNl13: UL1AlL3 0l 31ANUARU uNl13:
As the dimensions of the oomponents
tend to be small, air pin heat
exohangers are readily designed for
high-pressure servioes, and units are
available for pressures well in aooess of
those enoountered in shell & tube heat
exohanger design. air pin heat
exohanger also provides the advantages
of standardization and modular
oonstruotion.

Although there is no international
standard for air Pin eat Lxohangers, a
system developed by Brown lintube"
has aohieved some reoognition aoross
the globe. Aooording to them these units
are available in nominal shell size of 3"
to 30".
"PeopIe begIn to becone successIuI the nInute they decIde to be." PhIIIp Czosby
air Pin eat Lxohangers air Pin eat Lxohangers air Pin eat Lxohangers air Pin eat Lxohangers
Contributed by: Mr. Uhiren 1rivedi & Mr. Purav Uesai, L1C, Baroda Contributed by: Mr. Uhiren 1rivedi & Mr. Purav Uesai, L1C, Baroda Contributed by: Mr. Uhiren 1rivedi & Mr. Purav Uesai, L1C, Baroda Contributed by: Mr. Uhiren 1rivedi & Mr. Purav Uesai, L1C, Baroda
APkIl 2000 PA0 7
Vo|ame 1, Issae 4
ligure. 1 ligure. 1 ligure. 1 ligure. 1
ligure. 2 ligure. 2 ligure. 2 ligure. 2
air Pin eat Lxohangers are used for
temperature range of -200 C to 700 C
and up to pressure of 350 bars. lt oan
withstand pressure upto 680 bars with
speoial designs.
Based on the servioe, the unit is available
with Bare tubes, linned tubes & 1wisted
tubes oonstruotion.

llNNLU 1uBL C0N31RuC llNNLU 1uBL C0N31RuC llNNLU 1uBL C0N31RuC llNNLU 1uBL C0N31RuC1l0N 1l0N 1l0N 1l0N
lt is used when one of the heat transfer
ooeffioient is about one-half, or less, of
the other. 1ypioal examples being high-
visoosity liquid, or a gas, with water or
oondensing steam as other fluid.

1wl31LU 1uBL C0N31Ru 1wl31LU 1uBL C0N31Ru 1wl31LU 1uBL C0N31Ru 1wl31LU 1uBL C0N31RuC1l0N C1l0N C1l0N C1l0N
lt is used when tubeside fluid is visoous
(> 1 op). lt eliminates dead spaoes on
shellside and inoreases turbulenoe on
both sides.
"Don't pIay In soneone eIse's unIvezse. DeIIne youz own." -Donny Deutsch
air Pin eat Lxohangers air Pin eat Lxohangers air Pin eat Lxohangers air Pin eat Lxohangers
Contributed by: Mr. Uhiren 1rivedi & Mr. Purav Uesai, L1C, Baroda Contributed by: Mr. Uhiren 1rivedi & Mr. Purav Uesai, L1C, Baroda Contributed by: Mr. Uhiren 1rivedi & Mr. Purav Uesai, L1C, Baroda Contributed by: Mr. Uhiren 1rivedi & Mr. Purav Uesai, L1C, Baroda
APkIl 2000 PA0 8
Vo|ame 1, Issae 4
.. .. .. .. ^.... ^.... ^.... ^....
Teacher to Pappu :
"Where were U born?"

Pappu : In
Tiruvananthapuram.

Teacher: SpeII it?

Pappu: (after thinking)
WeII.. I think I was
born in GOA.
vertioal reboilers (shell & 1ube eat
exohanger) are widely used in
Petroohemioal industry. 1he thermosyphon
Reboiler is most oommonly used. lor that
piping engineer need to oonduot stress
analysis, but in oolumn reboiler analysis
find diffioulty to pass the system in nozzle
loads beoause of piping engineer not able
to provide flexibility to piping oonneoted to
the reboiler and oolumn by adding elbows
due to prooess oonstraints.
ln this oase the only way out is to play with
support to pass the system.

ln the Column reboiler 3ystem depending
upon supporting there are two types

1) Reboiler supported from oolumn itself.
2) Reboiler supported from independent
struoture

1) Reboiler supported from oolumn itself. 1) Reboiler supported from oolumn itself. 1) Reboiler supported from oolumn itself. 1) Reboiler supported from oolumn itself.
when the reboiler not muoh heavy and
oolumn oan take the weight of the reboiler
then this system is adopted. 1he main
advantage of this system is not
requirement of independent struoture for
supporting reboiler.

2) Reboiler supported from independent 2) Reboiler supported from independent 2) Reboiler supported from independent 2) Reboiler supported from independent
struoture. struoture. struoture. struoture.
when it is not possible to mount a reboiler
on oolumn due to its heavy weight, and
oolumn is not oapable for taking these
loads, then there required independent
struoture for supporting reboiler. lig 1.1
shows typioal arrangement for this type.
owever in oolumn- reboiler system heavy
nozzle loads ooming on to nozzle are due
to UlllLRLN1lAL LXPAN3l0N between
oolumn and reboiler.
1he differential expansion results due the
following differenoes between the oolumn
and reboiler.
Lquipment 3upport to nozzle height.
1emperature of equipments at normal
operation, design, start-up / 3hutdown /
emergenoy oonditions.
Material of oonstruotion of equipment.
3o, there are two methods for reduoing
nozzle loads.
By reduoing differential expansion by
proper supporting.
By adopting spring supports instead of
rigid support for Reboiler.
ln first oase we oan support the oolumn
suoh that differential expansion will be
minimized this oan be aohieved by
supporting the Reboiler near skirt
elevation.

UlllLRLN1lAL LXPAN3l0N UlllLRLN1lAL LXPAN3l0N UlllLRLN1lAL LXPAN3l0N UlllLRLN1lAL LXPAN3l0N
A typioal 1hermosyphon type reboiler with
independent struoture for supporting is
shown in lig 1.1.

As
N4- Prooess fluid inlet / Column
N3- Prooess fluid outlet. / Column
11- Prooess fluid inlet / Reboiler
12- Prooess fluid outlet. / Reboiler
1hen for Nozzle N4 vertioal Nozzle
movement given by
o = N x e1 (Considering
oolumn Lxpansion)
r = M x e2 (Considering
Reboiler Lxpansion)

where,
e1-unit thermal expansion at respeotive
metal temp. for oolumn.
e2-unit thermal expansion at respeotive
metal temp. for reboiler.
M- Uistanoe between nozzle N4 and
reboiler lug.
N- Uistanoe between nozzle N4 and
oolumn skirt elevation.

1hen, Uifferential Lxpansion given by-
UlllLRLN1lAL LXPAN3l0N = the

algebraio differenoe between o and r,
0nly one parameter i.e. the elevation of
Reboiler support oan be varied by a
piping engineer. varying this dimension
one oan make sure that the differential
expansion between the direot ooupled
nozzles is kept to the minimum for all
the possible oonditions.
1he 1humb rule proposed here is as
follows 1he oolumn and reboiler nozzles
are flexible and oan generally absorb the
differential expansion suoh that
exoessive stresses are
not introduoed in the nozzle and
supports.
1he limits for the differential are:
2 mm differential expansion during
normal operating oonditions.
3 mm differential expansion during
desi gn and st ar t - up/shut - down
oonditions.
1he nozzle should not be reinforoed
beyond that required for pressure
oontainment, sinoe nozzle flexibility is
required to aooommodate differential
vertioal expansions. lf permitted
di fferent i al s exoeed t he above
mentioned limits, reboiler should to be
mounted on spring. 1he support and
nozzles to be designed for 10 exoess
out of balanoe weight loads in empty
and full oases in oase the reboiler is
mounted on springs. lor oaloulation of
the system in CAL3AR, the stiffness of
nozzles shall be feed in to stress model.
1he loading oaloulated by stress analysis
shall be submitted to vendor for load
oonfirmation. 1he loading will be
normally higher than that aohieved by
the springs. Majority of the times finite
element analysis will be required to
approve the loads.
1he loading information should be made
available to vendor only after the
oaloulations are made. 1ill suoh time the
nozzle loading for the nozzle in question
to be kept under hold. 3inoe this will be
a hold up point piping group to give
priority to this arrangement.
1he solid support design has the
following advantages:
1his is a more stable arrangement - 1he
ohanoe of the imbalanoe due to spring
arrangement is avoided, vibrations if any
in the system will be dampened.
Better oontrol over the system oan be
aohieved as guiding of reboiler is simpler
and easier with slots in the supporting
lug.
Cost savings as the springs and the
related maintenanoe is avoided.
"AIn Ioz the top. Theze Is pIenty oI zoon theze. It Is aInost IoneIy theze!" -8anueI InsuII
Column Column Column Column- -- -Reboiler Analysis Reboiler Analysis Reboiler Analysis Reboiler Analysis
Contributed by: arshvardhan Khatkole, L1C, Baroda Contributed by: arshvardhan Khatkole, L1C, Baroda Contributed by: arshvardhan Khatkole, L1C, Baroda Contributed by: arshvardhan Khatkole, L1C, Baroda
APkIl 2000 PA0 0
Vo|ame 1, Issae 4
Lase of ereotion and testing.
when it is not possible to reduoe nozzle
loads by applying Rigid support for the
reboiler or the differential expansion is
more than 2 mm in operating and 3 mm in
Uesign oonditions there is only way for
reduoing nozzle loads is by providing
springs support for reboiler. lig 1.2 shows
spring mounted Reboiler.
ln this depending upon the no of
supporting lug we oan use same no of
spring as well, generally this oan be 3 or
4.
1hen theoretioally oold load for the spring
is Cold load for eaoh spring = Avg. load of
Reboiler in water filled and empty load /
No. of springs (1 .1)
3pring setting has been done at the
average load of water filled and empty
loads. lurther the loading has been
adjusted to a small extent (up to 5
towards the operating weight) to get
favorable results, as this does not
inolude weight of pipe, pipe fittings.
And depending upon differential
expansion ohoose spring rate.
But, this arrangement having it's own
problems the main problem faoed by
piping engineer to pass s/m, is passing
nozzle loads in both operating and
design oondition when there is huge
differenoe between reboiler empty and
operating weight.
1able 1.1 shows reboiler L-5116 s/m
with it's Uesign parameters.
ear we see that differenoe between
Reboiler Lmpty and 0perating weight is
41 KN, that means if we seleot spring on
the Lmpty weight ( 91 KN) or operating
weight ( 132 KN ) in both oases we are
exerting 41 KN extra load on Nozzle N4
( Refer fig 1.1 ) but that is not
aooeptable. lor this we have to seleot
spring on average of 91 KN and 132 KN
i.e. 111.5 KN

3o from formula 1.1 theoretioal oold load
for the 4 no. of spring is of 111.5 / 4 =
27.875 KN

enoe, designing the spring on Avg. load
of Reboiler in water filled and empty
load.
lf the nozzle loads are still higher then
adopt teohnique that spring to be looked
before emptying Reboiler. 1hat means
spring will be aoted only at operating
oondition and not at empty oondition of
Reboiler.

"BusIness In a nutsheII Is aII about nanagIng peopIe, pzoducts and pzoIIt" -Lee Iacocca
Column Column Column Column- -- -Reboiler Analysis Reboiler Analysis Reboiler Analysis Reboiler Analysis
Contributed by: arshvardhan Khatkole, L1C, Baroda Contributed by: arshvardhan Khatkole, L1C, Baroda Contributed by: arshvardhan Khatkole, L1C, Baroda Contributed by: arshvardhan Khatkole, L1C, Baroda
APkIl 2000 PA0 10
Vo|ame 1, Issae 4
RLB0LlLR M0ULL
Reboiler L-5116
No. of lines 4
LlNL 3lLL 24' 10' 14' 4'
3LRvlCL MA MA LP3 LPC
Phase v/L L v L
0perating temp ( C ) 75 73 130 105
Uesign 1emp ( C ) 165 165 180 180
0perating Pressure ( Kpa) 780 780 100 20
0perating Pressure ( Kpa) 1150/lv 1150/lv 650/lv 700/lv
lnsulation 1K (mm) 75 65 75 -
Reboiler weight (KN)
Lmpty
91
0perating
132
1able 1.1 1able 1.1 1able 1.1 1able 1.1
.. .. .. .. ^.... ^.... ^.... ^....
Patient Pappu: In my
dreams monkeys pIay
footbaII every night.

Doctor: Take this
medicine from tonight.

Patient Pappu: Can I
start from tomorrow
because tonight is
FinaI
lt is well known faot that 0il Reserves on
earth are not going to be replenished. 1he
energy orisis is going higher and higher.
Many soientists and Researoh institutes
are trying to find out a solution for this
problem. 0ne of the solution is found in
erbs i.e. Bio- diesel

wA1 l3 Bl0 wA1 l3 Bl0 wA1 l3 Bl0 wA1 l3 Bl0- -- -UlL3LL? UlL3LL? UlL3LL? UlL3LL?
Bio-Uiesel is the name for a variety of ester
based oxygenated fuels made from oertain
edible and non-edible oils like 3oya,
3unflower, Palm, 1atropha, Pongamia
(Karanj), Mahua eto. Pure Bio-Uiesel is
Biodegradable, Non-1oxio and essentially
free from sulfur and aromatios. lt is a
renewable resouroe based on oil orop that
are grown eaoh year. lt oan be produoed
domestioally, reduoing our oountry's
dependenoe on imported oil, thus huge
savings on imports. lt requires no engine
modifioations or ohanges in fuel handling
and delivery systems. Bio-Uiesel also
provides signifioant lubrioity improvement
over petroleum diesel fuel.
Most of the vegetable oils and animals fats
oontain triglyoerides, whioh on simple
prooessing give fatty aoid esters, oalled
'Bio-Uiesel'. 1he ohemioal reaotion
involving a lower aloohol (Lthanol or
Methanol), produoing 0lyoerin as a oo-
produot, is oalled trans-esterifioation.
1atropha Curoas (vana Lrand or 1angli
Lrandi or Ratan 1yot) has been found to be
most suitable for this purpose beoause of
its advantages over any other speoies.
1atropha Curoas, is a drought-resistant
perennial plant whioh grows almost
anywhere- in marginal/ poor soil even on
gravelly, sandy and saline soils. lt oan
thrive on the poorest stony soil. lt oan grow
even in the orevioes of rooks.
MANulAC1uRlN0 0l Bl0 MANulAC1uRlN0 0l Bl0 MANulAC1uRlN0 0l Bl0 MANulAC1uRlN0 0l Bl0- -- -UlL3LL lR0M UlL3LL lR0M UlL3LL lR0M UlL3LL lR0M
1 ar r opha ouroas 1 ar r opha ouroas 1 ar r opha ouroas 1 ar r opha ouroas ( RA1AN1 01) : ( RA1AN1 01) : ( RA1AN1 01) : ( RA1AN1 01) :
LX1RAC1l0N, 1RAN3L31LRlllCA1l0N, LX1RAC1l0N, 1RAN3L31LRlllCA1l0N, LX1RAC1l0N, 1RAN3L31LRlllCA1l0N, LX1RAC1l0N, 1RAN3L31LRlllCA1l0N,
PR0CL33 C0N1R0L, uALl1 C0N1R0L PR0CL33 C0N1R0L, uALl1 C0N1R0L PR0CL33 C0N1R0L, uALl1 C0N1R0L PR0CL33 C0N1R0L, uALl1 C0N1R0L
ANU uALl1 A33uRANCL ANU uALl1 A33uRANCL ANU uALl1 A33uRANCL ANU uALl1 A33uRANCL

lntroduotion: lntroduotion: lntroduotion: lntroduotion:
Raw material for bio-diesel from 1arropha
ouroas (Ratanjyot) is the seed of the
plant, whioh has upto 38 fatty aoids as
glyoerol esters. 1he main fatty aoids are
Palmitio aoid, steario aoid, oleio aoid,
linoleio aoid and lenolenio aoid.

3peoifioation for Raw Material: 3peoifioation for Raw Material: 3peoifioation for Raw Material: 3peoifioation for Raw Material:
loreign matter: Not more than 2.0
1otal ash : Not more than 6.0
Aoid insoluble ash: Not more than 0.3
Lthanol soluble extraotive: Not less than
25.0
water soluble extraotive: Not less than
7.0
Loss on drying: Not more than 11.0
But limits may be matter of in house
speoifioation

Adulterants/ substitutes Adulterants/ substitutes Adulterants/ substitutes Adulterants/ substitutes: 3eeds of 1.
g|anou||fera and l|o|nus oommun|s are
oommonly used to adulterate the seeds
of 1. ouroas. owever, the seeds of 1.
ouroas are bigger .

MANulAC1uRlN0 0l Bl0 UlL3LL MANulAC1uRlN0 0l Bl0 UlL3LL MANulAC1uRlN0 0l Bl0 UlL3LL MANulAC1uRlN0 0l Bl0 UlL3LL
Lxtraotion: Lxtraotion: Lxtraotion: Lxtraotion: 1he seeds (passing the
speoifioation) are passed through 0il -
Press, where the orude oil is oolleoted for
transesterifioation prooess.

1ransesterifioation: 1ransesterifioation: 1ransesterifioation: 1ransesterifioation: 1ransesterifioation is
a prooess of exohanging the alkoxy
group of an ester oompound by an
another aloohol where reaotion is
oatalyzed by aoid or base.
InteIIectuaIs soIve pzobIens, genIuses pzevent then. -AIbezt EInsteIn
Bio Bio Bio Bio- -- -Uiesel: An Alternate Renewable luel Uiesel: An Alternate Renewable luel Uiesel: An Alternate Renewable luel Uiesel: An Alternate Renewable luel
Contributed by: vishnukumar Pamnani, L1C, Baroda Contributed by: vishnukumar Pamnani, L1C, Baroda Contributed by: vishnukumar Pamnani, L1C, Baroda Contributed by: vishnukumar Pamnani, L1C, Baroda
APkIl 2000 PA0 11
Vo|ame 1, Issae 4
Catalytio Reaotor Catalytio Reaotor Catalytio Reaotor Catalytio Reaotor
Ratanjyot or 1atropha fruits Ratanjyot or 1atropha fruits Ratanjyot or 1atropha fruits Ratanjyot or 1atropha fruits
NLLU3 0l 1RAN3L31LRl NLLU3 0l 1RAN3L31LRl NLLU3 0l 1RAN3L31LRl NLLU3 0l 1RAN3L31LRlllCA1l0N llCA1l0N llCA1l0N llCA1l0N
1atropha Cuoas oil has following
oharaoteristios:-
igh visoosity
Poor volatility
Polymerization in oombustion ohamber
leading to deposit
luel line and filter ologging
Polymerization of triglyoerides in lube oil
3o, the easiest way to make it fuel grade is
1ransesterifioation prooess. 1ransesterifioation prooess. 1ransesterifioation prooess. 1ransesterifioation prooess.

AUvAN1A0L3 lR0M AUvAN1A0L3 lR0M AUvAN1A0L3 lR0M AUvAN1A0L3 lR0M
1RAN3L31LRlllCA1l0N 1RAN3L31LRlllCA1l0N 1RAN3L31LRlllCA1l0N 1RAN3L31LRlllCA1l0N
Bio-diesel is non-toxio and biodegradable.
lt reduoes the emission of harmful
pollutants from diesel engine (80 less
C02 and 100 less 3ulphur dioxide).
lt has a high oetane number than diesel.
Cetane number is a measure of fuel's
ignition quality. 1he high oetane number of
bio-diesel oontributes to easy oold starting
and low idle noise.
lt inoreases the life of diesel engine as it is
more lubrioating.
Bio-diesel replaoes the exhaust order of
engine with a more pleasant smell.

uALl1 C0N1R0L uALl1 C0N1R0L uALl1 C0N1R0L uALl1 C0N1R0L
1he key quality oontrol issues involves
oomplete (or nearly oomplete) removal of
aloohol, oatalyst, water, soap, glyoerin and
un-reaoted or partially reaoted
triglyoerides. lailing to remove these
oauses bio-diesel to fail in one or more
fuel standards. . . .
1he presenoe free fatty aoids (llA)
i nt erfere i n t ransest eri fi oat i on,
deaotivating the basio oatalysts.

uALl1 A33uRANCL uALl1 A33uRANCL uALl1 A33uRANCL uALl1 A33uRANCL
Bio-diesel is reoognized world wide as an
alternative fuel and qualities for
mandatory programmes in both the
Luropean union and u3A. 0f the many
required tests produoers use the test
method LN 14105 and or A31M U6584
as the most oritioal Pass/fail" tests of
bio-diesel. 1hese oritioal tests are often
the first run. lf the fuel does not pass, re-
work or blending is done before further
testing.

A31M U6585 method,
Presenoe of glyoerin in fuel oan oause
ologged fuel system, injeotor deposits,
filter plugging and built up in the
vehioles fuel tanks. 1herefore low level
of free and total glyoerin are oritioal to
speoifioation of bio-diesel.
igh levels of free and total glyoerin are
oaused by improper or low oonversion
of oil or fat into the desired mono-
methyl-esters. 1he bio diesel assay for
free and total glyoerin is outlined in
A31M U6584 (Amerioan 3ooiety for
1esting and Material ), whioh provides
method for quantitative determination of
free and total glyoerin in 100 bio diesel
fuel(B100 methyl ester) by high
temperature gas ohromatography after
silylating the sample with N-methyl-N-
(tri methyl si l yl ) tri fl uoroaoetami de
(M31lA). An example of the 0C analysis
of bio-diesel following A31M U6584
methodology is as indioated in the
figure: Chromatographio oonditions as Chromatographio oonditions as Chromatographio oonditions as Chromatographio oonditions as
per A31M U6584 method, per A31M U6584 method, per A31M U6584 method, per A31M U6584 method,

0C Column : 1-5, 12 m x 0.32 mm l.U.
x 0.1 mm df, (3upeloo, Cat. No. 25002)
Pre-oolumn : 1-5 pre-oolumn, 6 m x
0.53 mm l.U. x 0.1 mm df
(3upeloo, Cat. No. 25004)
0ven : 50C, 15C/min. to 180
C, 7C/min. to 230C, 30C/min. to
380C, hold 10 min.
Ueteotor : llU, 380o
Carrier gas : ydrogen, 3 ml/minimum
50C
lnjeotion : 1 mL, oool-on-oolumn
3ample : 12 mg

C0MMLRClAL Bl0 C0MMLRClAL Bl0 C0MMLRClAL Bl0 C0MMLRClAL Bl0- -- -UlL3L UlL3L UlL3L UlL3LL PLAN13 lN L PLAN13 lN L PLAN13 lN L PLAN13 lN
lNUlA lNUlA lNUlA lNUlA
1inna 0ils & Chemioals Ltd. (10CL),
whioh has M/s. Aroher Uaniels Midland
Co. (AUM) of u3A as a majority equity
partner, are setting up a 50 tonnes per
day Biodiesel plant in Latur in
Maharashtra. 1his plant will run on the
patented CU-Prooess developed
In the zace oI IIIe, theze aze onIy thzee optIons; Lead, FoIIow oz Oet out oI the way. -Anonynous
APkIl 2000 PA0 12
Vo|ame 1, Issae 4
Mixer Reaotor Mixer Reaotor Mixer Reaotor Mixer Reaotor ( (( (1ransesterifioation proo- 1ransesterifioation proo- 1ransesterifioation proo- 1ransesterifioation proo-
ess takes plaoe ess takes plaoe ess takes plaoe ess takes plaoe) )) )
washing 1ank washing 1ank washing 1ank washing 1ank
3etting 1ank 3etting 1ank 3etting 1ank 3etting 1ank
by AUM and produoe high quality Bio-
Uiesel of Luropean Norms (LN 14214).
lnstallation of 1inna's Bio-diesel plant will
give oonfidenoe to all the farmers and of
1atropha as they will have a ready buyer of
1atropha seeds. 1inna is working with
farmer groups to promote oultivation of
1atropha. 1inna is also in the prooess to
put large plantations of 1atropha in
Maharashtra and other states of the
oountry. Nursery raising of 1atropha is
being undertaken to develop high oil
yielding varieties of 1atropha, these
saplings are being distributed to the
farmers for plantation. 1inna is the best
positioned player whioh has oomplete
expertise for making Bio-Uiesel business
a suooess.
A wIse nan wIII nake noze oppoztunItIes than he IInds. -FzancIs Bacon
APkIl 2000 PA0 13
Vo|ame 1, Issae 4
50 tones per day bio 50 tones per day bio 50 tones per day bio 50 tones per day bio- -- -diesel plant of 10CL installed in Latoor (Maharashtra) diesel plant of 10CL installed in Latoor (Maharashtra) diesel plant of 10CL installed in Latoor (Maharashtra) diesel plant of 10CL installed in Latoor (Maharashtra)

1. A printer consists of 3
main parts: the case, the
jammed paper tray and the
blinking red light.

2. To Err is human, to for-
give is not a Company pol-
icy.

3. Don't be surprised if you
find mistakes in this issue
of magazine. We print
something for everyone.
And some people are al-
ways looking for mistakes.

4. Saving is the best thing.
Especially when your par-
ents have done it for you.

5. I believe we should all
pay our tax with a smile. I
tried - but they wanted
cash.

6. The road to success....
is always under construc-
tion.

7. Someday is not a day of
the week.

8. It's not hard to meet ex-
penses, they are every-
where.

9. The trouble with being
punctual is that no one is
there to appreciate it.

10. If you can't convince
them, confuse them.

... . ..... ... . ..... ... . ..... ... . .....

PCL is a lortune 500 oompany, with an
annual turnover of over Rs 1,03,837
Crores ($ 25,142 Millions) during l 2007-
08, 16 Refining & Marketing share in
lndia and a strong market infrastruoture.
Corresponding annual turnover figures for
l 2006-07 were: Rs 91,448 orores
($20,892 Million).

1he Corporation operates 2 major
refineries produoing a wide variety of
petroleum fuels & speoialties, one in
Mumbai (west Coast) of 5.5 Million Metrio
1onnes Per Annum (MM1PA) oapaoity and
the other in vishakapatnam, (Last Coast)
with a oapaoity of 7.5 MM1PA. PCL holds
an equity stake of 16.95 in Mangalore
Refinery & Petroohemioals Limited, a state-
of-the-art refinery at Mangalore with a
oapaoity of 9 MM1PA. ln addition, PCL is
progressing towards setting up of a refinery
in the state of Punjab in the joint seotor
with M/s Mittal Lnergy Limited. 1his joint
venture oompany is known as PCL Mittal
Lnergy Limited (MLL) and the refinery
shall be known as 0uru 0obind 3ingh
Refinery Limited (003R).

PCL's Produots Lvaouation Projeot
(003RPLP) group was entrusted the job of
evaouation and distribution of the finished
marketable produots from 0uru 0obind
3ingh Refinery (003R), Raman Mandi to
northern and western regions of the
oountry. 3inoe pipeline transportation is
most suitable for bulk movement of liquid
oonsignment over long distanoe, Pipeline
mode of transportation was oonsidered
most favorable.

PCL had the job of preparation of the
Uetailed leasibility reports for two
proposed pipeline projeots and feasibility
study on an existing pipeline:
UlR for Raman Mandi-Bathinda
pipeline.
UlR for Reverse Pumping in existing
Mundra Uelhi pipeline.

L&1-0uLl bagged this preparation of UlR
projeot. L&1-0uLl rose to the oooasion and
oompleted the job in reoord time, way
ahead of the stipulated sohedule. 1he draft
report of the first UlR was submitted 2
weeks ahead of sohedule and the seoond
UlR was submitted 1 week ahead of the
sohedule against the two months
stipulated time. 1he oompany won
aooolades from the Client for the high

quality deliverables. 1he final oopies of
the UlRs were also submitted to the
olient 2

weeks prior to the due date.

1he soope of the above UlRs / projeot is
elaborated in the following paragraphs.

UlR l0R RAMAN MANUl UlR l0R RAMAN MANUl UlR l0R RAMAN MANUl UlR l0R RAMAN MANUl - -- - BA1lNUA BA1lNUA BA1lNUA BA1lNUA
PlPLLlNL (UlR PlPLLlNL (UlR PlPLLlNL (UlR PlPLLlNL (UlR- -- -l) l) l) l)
A Multi produot pipeline shall be laid from
003R, Raman Mandi to PCL's existing
depot in Bathinda (approximately 30
kms) with a future provision to extend the
pipeline from Bathinda to 3angrur
(approximately 86 kms). 1he projeot
requirement is to transport 0.929 MM1PA
of white P0L produots namely LuR0 - lll
M3, LuR0 - lll 3U and 3uperior
Kerosene 0il (3K0) in the ear 2011-12
(Phase-l) and 1.375 MM1PA in the ear
2021-22 (Phase-ll) from 003R to PCL's
existing depot at Bathinda.

Pipeline from Raman Mandi to Bathinda
and the 3tations are designed for the
projeoted throughput of 1.375 MM1PA
(Phase - ll). owever, the pump/driver is
designed suoh that presently it shall oater
to the requirement of Phase-l throughput
of Bathinda alone. 3paoe provision shall
be made for additional pumps to be
installed at a later date to oater the
requirement of Phase - ll throughput for
the volumes upto 3angrur.

Batohing being a very oritioal aspeot for
transportation of multiple produots in a
pipeline has a major role to play in the
leasibility analysis. 1he objeotive of batoh
analysis is to determine the most
praotioal batoh sizing and sequenoing,
lnterfaoe optimization and determination
of gross storage requirements for the
produots.
1he following doouments were provided
by PCL for oompletion of the study.
Approved 0ptimization 3tudy
Approved Uesign basis
Preliminary Layouts
Preliminary P&lUs

UlR l0R RAMAN MANUl UlR l0R RAMAN MANUl UlR l0R RAMAN MANUl UlR l0R RAMAN MANUl - -- -
BAAUuR0AR PlPLLlNL (UlR BAAUuR0AR PlPLLlNL (UlR BAAUuR0AR PlPLLlNL (UlR BAAUuR0AR PlPLLlNL (UlR- -- -ll) ll) ll) ll)
1he projeot requirement is to transport
3.965 MM1PA of white P0L produots
namely LuR0 - lll M3, LuR0 - lv M3,
LuR0 - lll 3U, LuR0 - lv 3U, 3uperior

Kerosene 0il (3K0), Aviation 1urbine
luel (A1l) and NAP1A in the ear
2011-12
(Phase-l) and 4.71 MM1PA of the
produots in the ear 2021-22 (Phase-ll)
from 003R to PCL's existing terminal
at Bahadurgarh.
Batohing being a very oritioal aspeot for
transportation of multiple produots in a
pipeline has a major role to play in the
leasibility analysis. 1he objeotive of
batoh analysis is to determine the most
praotioal batoh sizing and sequenoing,
l n t e r f a o e o p t i mi z a t i o n a n d
determi nat i on of gross storage
requirements for the produots.

L&1-0uLl's soope of work for UlR-l and
UlR-ll broadly oovered following:

l. linalization of design basis.
ll. 0ptimization of pipeline system for
eoonomioal operation.
lll. Cal oul at i on of bat oh si zes,
requirement of gross volume
storage at 3tations.
lv. Basi o Pr ooess desi gn and
preparation of hydraulio gradient for
the seleoted option.
l t i nvol ves pr epar at i on of
Preliminary P&lUs, datasheets,
equipment list, broad equipment
speoifioations, Prooess desoription
and 0perat i ng and Cont rol
Philosophy
v. Basio Lngineering involves the
aotivities presented as under:
li nal i z at i on of l i ne pi pe
speoifioations and seleotion of
suitable oorrosion ooating system
and M10 estimation for oosting
purposes.
Basi o pumpi ng requirement
oonfiguration.
Preliminary Plot Plans/Lquipment
Layouts.
Preparation of basio eleotrioal
soheme, 3LUs & Load list, CP
system.
Basio soheme for optioal fiber
based 1eleoom system, CC1v &
video oonferenoing system.
3CAUA & APP3 phi l osophy
oovering leak deteotion eto.
lnstrumentation & Control system
philosophy.
3ize of various Civil 3truotures, fire
fighting soheme.
"Ozowth begIns when we stazt to accept ouz own weaknesses" -]ean VanIez
Uetailed leasibility Report Uetailed leasibility Report Uetailed leasibility Report Uetailed leasibility Report - -- - lor PCL, Bhatinda lor PCL, Bhatinda lor PCL, Bhatinda lor PCL, Bhatinda
Contributed by: 1uhi 0arg, L&1 Contributed by: 1uhi 0arg, L&1 Contributed by: 1uhi 0arg, L&1 Contributed by: 1uhi 0arg, L&1- -- -0ulf Limited 0ulf Limited 0ulf Limited 0ulf Limited
APkIl 2000 PA0 14
Vo|ame 1, Issae 4
v. Projeot implementation philosophy &
sohedule.
vl. Uetailed oost estimates for both
oapital/operating oosts.
003R proposes expansion of the refinery
from 9 MM1PA to 18 MM1PA in future
years and therefore keeping that in mind,
the pipeline with assooiated faoilities was
designed. 1he profile attaohed below
shows the looation of the future
lntermediate pumping station whioh shall
oater to 18 MM1PA throughput
requirements.
UlR l0R RLvLR3L PuMP UlR l0R RLvLR3L PuMP UlR l0R RLvLR3L PuMP UlR l0R RLvLR3L PuMPlN0 lN LXl31lN0 lN0 lN LXl31lN0 lN0 lN LXl31lN0 lN0 lN LXl31lN0
MuNURA ULLl PlPLLlN MuNURA ULLl PlPLLlN MuNURA ULLl PlPLLlN MuNURA ULLl PlPLLlNL (UlR L (UlR L (UlR L (UlR- -- -lll) lll) lll) lll)

1here is an existing 1054 kms pipeline
from Mundra to Uelhi with pump stations
at Mundra, Palanpur, 3antalpur, Awa,
Ajmer and 1aipur. 1he tap-offs are at
Rewari, 1aipur, Ajmer and Palanpur. 1he
projeot requirement is to meet the
demands at Rewari, 1aipur, Ajmer and
Palanpur totally to 2.83 MM1PA of white
P0L produots namely LuR0 - lll M3, LuR0
- lv M3, LuR0 - lll 3U, LuR0 - lv 3U
and 3uperior Kerosene 0il (3K0) by
reverse pumping from Bahadurgarh to
Mundra. 1he possibility of bidireotional
pumping either partly or fully, from Mundra
& Bahadurgarh was also studied.
lor this UlR, the feasibility of reverse
pumping was even more restrioted by the
batohing studies and permissible
oontamination level sinoe the produot
demands were low and they had to be
transported over long distanoes. After
having analyzed all the possible options,
the most viable answer whioh was a
oombination of both forward and reverse
pumping was ohosen.
L10's soope of work for UlR-lll broadly
oovered following:
3tudy of various alternative soenarios of
r e v e r s e / f o r wa r d p u mp i n g &
oorresponding Batoh sizes/sequenoe and
thereby establishing suitability, maximum
attainable throughput.
Caloulation of batoh sizes, requirement of
gross volume storage at terminals and
additional area requirements.
Basio prooess design.
Basio Lngineering whioh is inolusive of
the following

Bas i o pumpi ng r equi r ement /
oonfiguration.
Preliminary Plot Plans / Lquipment
layouts for Bahadurgarh 3tation.
Preparation of basio eleotrioal soheme,
3LUs & Load list.
lnstrumentation and Control system
philosophy.
3ize of various Civil 3truotures.
M10 for oosting purpose.

Projeot implementation philosophy &
sohedule.
Uetailed oost estimates for both oapital/
operating oosts as well as oost estimation
to asoertain the oost for proposed
modifioations/operations.
"I'n IookIng Ioz a Iot oI nen wIth an InIInIte capacIty Ioz not knowIng what cannot be done" -Henzy Fozd
Uetailed leasibility Report Uetailed leasibility Report Uetailed leasibility Report Uetailed leasibility Report - -- - lor PCL, Bhatinda lor PCL, Bhatinda lor PCL, Bhatinda lor PCL, Bhatinda
Contributed by: 1uhi 0arg, L&1 Contributed by: 1uhi 0arg, L&1 Contributed by: 1uhi 0arg, L&1 Contributed by: 1uhi 0arg, L&1- -- -0ulf Limited 0ulf Limited 0ulf Limited 0ulf Limited
APkIl 2000 PA0 15
Vo|ame 1, Issae 4
.. . -. .. . -. .. . -. .. . -.
1. The first city in the world
to have a population of
more than one million was
Rome

2. About 190 billion emails
are sent daily - more than 2
million per second - by 1.2
billion email senders. About
70% (133 billion emails) are
spam and viruses. There are
about 1.4 billion registered
email addresses.

3. Neil Armstrong stepped
on the moon with his left
foot first.

4. Henry Ford forgot to put
reverse gear in the first car
he made.

5. The average age of
Forbes's 400 wealthiest indi-
viduals is 63

6. The oldest inhabited city
is Damascus, Syria

7. 80% of millionaires drive
second-hand cars.

8. If California was a coun-
try, it would be the 5th larg-
est economy in the world.

9. Tourism is the world's
biggest industry, affecting
240 million jobs.

10. There are 92 known
cases of nuclear bombs lost
at sea.
1ransformers are the key oomponents in
every Lleotrioal distribution network. 1he
effioienoy of modern power transformers is
in exoess of 97 to 98. owever this figure
means that upto 3 peroent of the total
Lleotrioal power generated is wasted in
1ransformer. ln this environmentally
oonsoious era, anything that oan be done
to reduoe them even 1 has potential to
deliver huge savings.
1he latest development is to use
amorphous oore for 1ransformer whioh oan
have signifioant impaot on the losses. 1he
oore losses or iron losses reduoe by 70
oompared to oonventional transformers
(CR00).

1he oore of the oonventional transformer is
made up of staoks of silioon steel
laminations with an almost uniform
orystalline struoture. ln transformer with
amorphous oores, a ribbon of steel is
wound, usually into a reotangular toroid
shape to form oore. Although the material
used for the oore is still a form of silioon
steel, it is made in suoh a way that it has
no regular orystalline struoture and henoe
name amorphous, whioh means no
struoture. 1his metal resembles with
glass and also referred as 0lass Metal".

1he non-orystalline struoture and random
arrangement of atoms give low field
magnetization whioh in turns reduoes
ysteresis losses and high eleotrioal
resistivity whioh suppresses the eddy
ourrent. As suoh oore losses of
amorphous metal alloys are reduoed to
by 42 per oent and magnetizing ourrent
by 53 per oent. use of amorphous steel
lowers ysteresis whioh means that less
energy is wasted in magnetizing and
demagnetizing it during eaoh oyole and
also lowers the eddy ourrent losses.
Amorphous strips are four times harder
than CR00 steel.

Amorphous oore transformers are
available upto 1500 kvA in lndia. 1he
usual objeotion to prefer amorphous oore
transformer is that it is approximately 20-
30 oostlier than oonventional
transformers. ln reoent years, silioon steel
used in oonventional transformer has
inoreased in prioe muoh more rapidly
than the amorphous materials, so the
prioe differenoe between two types is now
beoome small.
1he oomparative ohart between
oonventional transformer oore (CR00)
and amorphous oore transformers for
some of the rating are given in the
following table.
3ignifioant energy saving oan be
aohieved over the transformer life oyole
of 20 to 25 years. Amorphous oore
1ransformer opens a oost-effeotive route
for aohieving savings whioh may seems
in peroentage terms, but whioh in terms
of kwh of energy and tonnes of C02
saved per year are truly enormous.

C031 BLNLll1 ANAL3l C031 BLNLll1 ANAL3l C031 BLNLll1 ANAL3l C031 BLNLll1 ANAL3l3 33 3

By replaoing a oonventional 500kvA
transformer with new energy effioient
amorphous oore transformer, the no
load power oonsumption was reduoed by
70 due to reduotion in oore loss.

Annual energy saving aohieved by
implementing this projeot was around
Rs 0.5 millions. 1he total investment for
new amorphous metal oore transformer
was around Rs 0.4 millions, whioh will
be paid baok in 96 month.
"Youz Iutuze depends on nany thIngs but nostIy on you" -Fzank Tygez
Lnergy Lffioient Uistribution 1ransformer Lnergy Lffioient Uistribution 1ransformer Lnergy Lffioient Uistribution 1ransformer Lnergy Lffioient Uistribution 1ransformer
Contributed by: Anand Balasubramanian, L&1 Contributed by: Anand Balasubramanian, L&1 Contributed by: Anand Balasubramanian, L&1 Contributed by: Anand Balasubramanian, L&1- -- -3&L, Baroda 3&L, Baroda 3&L, Baroda 3&L, Baroda
cK6|KttR|K6 cK6|KttR|K6 cK6|KttR|K6 cK6|KttR|K6 cK6|KttR|K6 cK6|KttR|K6 cK6|KttR|K6 cK6|KttR|K6 TALK TALK TALK TALK TALK TALK TALK TALK
APkIl 2000 PA0 10
Vo|ame 1, Issae 4
Rating Rating Rating Rating
(kvA) (kvA) (kvA) (kvA)
No Load Loss (w) No Load Loss (w) No Load Loss (w) No Load Loss (w) Load loss (w) Load loss (w) Load loss (w) Load loss (w) Lffioienoy () Lffioienoy () Lffioienoy () Lffioienoy ()
Amor- Amor- Amor- Amor-
phous phous phous phous
CR00 CR00 CR00 CR00
CR00 CR00 CR00 CR00
CR00 CR00 CR00 CR00
250 180 570 3200 4000 98.7 98.2
500 250 900 4800 6550 99 98.53
630 200 1000 5200 8000 99.1 98.54
730 365 1250 6050 9000 99.2 98.65
1000 450 1500 7650 11800 99.2 98.68

Power plant design and system planning
requires oonsideration of both engineering
design and eoonomios. Cost effeotive
power plant design is imperative for an
engineering design firm. 0rganizations
having the ability and reputation for
designing reliable, low-oost power plants
and systems are sought in the inoreasingly
oompetitive environment.
ln the present study, the Balanoe of
Plant-B0P buildings are oovered beoause
they are required in eaoh and every power
plant and possess many similarities. 1he
variations of these buildings are limited to
known faotors whioh oan be generalized.
1he design parameters for suoh known
similarities and variations oan be analyzed
and a database of different quantities oan
be oreated. ln order to aooelerate the work
and perform quiok analysis and design, a
visual basio applioation for M3-Lxoel has
been developed. using this applioation, the
building oould be modeled with minimum
effort, thus saving time, whioh oould
otherwise be required for modeling of
building. 1he saved effort oan be utilized to
optimize the building. ln the present work,
the results of design are developed
graphioally.

BulLUlN0 C0Nll0uRA1l BulLUlN0 C0Nll0uRA1l BulLUlN0 C0Nll0uRA1l BulLUlN0 C0Nll0uRA1l0N 0N 0N 0N
Buildings in B0P area of power plants
are generally single storey and are
designed as reinforoed oonorete moment
resisting framed struotures. 1he lig. 1
shows the 3-U view and the framing plan
of the building oovered under the present
study.
1he slab is provided at roof level while the
beams are provided at the plinth, lintel and
roof level. 1he external walls are usually
230 mm thiok briok masonry with
plastering and painting. 1he parapets are
also standard in most of the plants.
1he loading on suoh buildings will be
1. Uead load of the building = 3elf
weight of building oomponents.
2. Roof Live
3. water proofing
4. Larthquake load is lumped at plinth
level due to briok wall weight and at
roof level due to dead load.
1he variables for B0P buildings are
mentioned in 1able 1.
usi ng t hese var i abl es, many
oombinations of buildings are derived
whioh represents most variety of B0P
buildings. 1hese buildings are designed
and the output is oaptured in form of
database for different oomponents.

M0ULLlN0, ANAL3l3 A M0ULLlN0, ANAL3l3 A M0ULLlN0, ANAL3l3 A M0ULLlN0, ANAL3l3 ANU UL3l0N NU UL3l0N NU UL3l0N NU UL3l0N
u3lN0 3AP2000 u3lN0 3AP2000 u3lN0 3AP2000 u3lN0 3AP2000
1he time required for modeling a single
bui l di ng al ong wi th neoessary
assignments like loading, member
properties, eto is muoh more and to
aooelerate the prooess, some automation
was evident. 1herefore, a need aroused
to develop a tool whioh oould model the
building easily with minimum input and
effort, thus saving time, whioh would
otherwise be required for modeling of
building. ln order to aooelerate the work
and perform quiok analysis and design,
a Miorosoft Lxoel Maoro is made. ln this
applioation, two different modules are
developed. 1he first module generates
modeling data for geometry and loading
within Lxoel, based on input defined.
1he seoond module oonverts the data
produoed in Lxoel into 3AP2000
oompatible text input fil e. 1his
applioation will produoe neoessary input
data, viz., geometry, loading, load
oombination, releases, eto., oompatible
to 3AP2000, by providing minimum
input in Lxoel.

0LNLRA1l0N 0l lRAML UA1A 0LNLRA1l0N 0l lRAML UA1A 0LNLRA1l0N 0l lRAML UA1A 0LNLRA1l0N 0l lRAML UA1A
Basio data like number of bays in X
and di reot i on, bay spaoi ng,
requirement of seoondary beams,
foundation level, plinth level, lintel level,
roof level and preliminary sizes of
oolumns & beams at various looations,
wall thiokness, unit weight of materials,
eto. is given in Lxoel input page. lig. 2
shows a soreenshot for the input page.
"AIways aIn Ioz achIevenent, and Iozget about success" -HeIen Hayes
An Applioation to Lstimate Conorete uantities in Balanoe of An Applioation to Lstimate Conorete uantities in Balanoe of An Applioation to Lstimate Conorete uantities in Balanoe of An Applioation to Lstimate Conorete uantities in Balanoe of
Plant 3truotures for lossil Power Plants Plant 3truotures for lossil Power Plants Plant 3truotures for lossil Power Plants Plant 3truotures for lossil Power Plants
Contributed by: Raja l. Bagga & 1ignesh v. Chokshi, L&1 Contributed by: Raja l. Bagga & 1ignesh v. Chokshi, L&1 Contributed by: Raja l. Bagga & 1ignesh v. Chokshi, L&1 Contributed by: Raja l. Bagga & 1ignesh v. Chokshi, L&1- -- -3&L, Baroda 3&L, Baroda 3&L, Baroda 3&L, Baroda
APkIl 2000 PA0 17
Vo|ame 1, Issae 4
lig. 1 3 lig. 1 3 lig. 1 3 lig. 1 3- -- -U view of the B0P building and lraming plan showing Column Looations U view of the B0P building and lraming plan showing Column Looations U view of the B0P building and lraming plan showing Column Looations U view of the B0P building and lraming plan showing Column Looations
Bay width
L m
width of
building
B m
loundation
Level Bf m
eight
1 m
Ah

5 6 3 5 10
6 8 4 6 15
8 10 5 8 20
1able 1 Combination of Building variables and Parameters 1able 1 Combination of Building variables and Parameters 1able 1 Combination of Building variables and Parameters 1able 1 Combination of Building variables and Parameters
lig.2. lnput Page to 0enerate lnput Uata lig.2. lnput Page to 0enerate lnput Uata lig.2. lnput Page to 0enerate lnput Uata lig.2. lnput Page to 0enerate lnput Uata
By pressing the lRAML ioon, Lxoel
generates neoessary geometry and loading
data using this input page within Lxoel.

0LNLRA1l0N 0l 3AP2000 lNPu1 llLL 0LNLRA1l0N 0l 3AP2000 lNPu1 llLL 0LNLRA1l0N 0l 3AP2000 lNPu1 llLL 0LNLRA1l0N 0l 3AP2000 lNPu1 llLL
ln the next step, seoond module oalled
3AP llLL' is exeouted whioh oonverts the
data produoed in Lxoel from basio input to
approximately 900 lines of 3AP2000
oompatible text input data within split of
seoond. 1hus, with bare minimum input in
input page, this applioation oould generate
the oomplete input file oompatible to
3AP2000 $2k file, inoluding node
definitions, member definitions and
member properties, loading, analysis
options eto. lig. 3 shows a soreenshot of
the .$2k file generated.
ANAL3l3 ANU UL3l0N ANAL3l3 ANU UL3l0N ANAL3l3 ANU UL3l0N ANAL3l3 ANU UL3l0N
1he entire data is oopied into a text file
with suitable name. 1he .$2k file is
imported in 3AP2000 and analysis is
performed. Based on the analysis results,
the RC design, based on l3 456-2000, for
beams at different levels, oolumns at
oorners, oolumns at gable ends,
intermediate oolumns and foundations are
designed using tools developed in-house.
1he suitability of assumed member sizes is
verified and if the members are not
suitable or praotioal, then the revised sizes
are given in input page and the prooedure
is oontinued until the members are safe.
Results for eaoh element is oaptured in
separate Lxoel file for their physioal sizes
and reinforoement for further analysis
purpose.

ANAL3l3 0l RL3uL13 UA1A ANU ANAL3l3 0l RL3uL13 UA1A ANU ANAL3l3 0l RL3uL13 UA1A ANU ANAL3l3 0l RL3uL13 UA1A ANU
UA1ABA3L UA1ABA3L UA1ABA3L UA1ABA3L
lor eaoh building designed, various
design data has been oolleoted and
stored in a tabular format. 3inoe, different
oomponent vary with respeot to various
ohanges in the building variables, the
faotors are derived to analyze the data.
ln the present study, 67 faotors are
identified, but here 1 faotor is exemplified
for understanding purpose. Laoh faotor
represents some struotural quantity with
respeot to the parameters representing
the building. 1he quantities are mainly
the oonorete volume of oomponent and
the reinforoement quantity.
All the data is oaptured in an Lxoel
workbook and the neoessary faotors are
also oaloulated. Laoh faotor oaloulated is
then plotted on a graph to represent the
variation in the struotural quantity with
respeot to building physioal parameters.
3inoe, the physioal building parameters
are area and volume, it is quite possible
that different oombination of building
dimensions would yield same floor area
and volume for more than one building.
1his would yield two values of ordinate
for one typioal value on absoissa.
1herefore, in order represent a unique
paramet er, a paramet er oal l ed
representative volume was established
against whioh only one ordinate oould be
represented.
Representative volume = (4xLxBx(Bf/
1f)
2
x(Bf+1f)
2
) m
3

ere L, B, are length and breadth of
bay respeotively while Bf and 1f are
depth of foundation and top of roof
respeotively as shown in lig. 1 earlier ln
order to estimate the oonorete quantity
for oorner footing, ohart shown in lig 4 is
used.

C0NCLu3l0N3 C0NCLu3l0N3 C0NCLu3l0N3 C0NCLu3l0N3
lrom the database produoed and
oharts following oonolusions oan be
drawn:
1. 1he estimation of preliminary sizes
of various struotural oomponents
oan be easily made with the help of
oharts produoed. 1his will help in
qui ok and reasonabl y good
estimation of framing element sizes
and aooelerate the design prooess.
2. 3ignifioant attention has been paid
to establish a database whioh helps
in estimating struotural oonorete
quantities for quiok estimate during
proposal making and even during
detailed engineering.
3. 1his database oan be kept in the
oompany's repository and oan be
extended by adding data of
buildings aotually designed in
various future projeots.
"Ood doesnt nake ozange juIce, Ood nakes ozanges" -]esse ]ackson
An Applioation to Lstimate Conorete uantities in Balanoe of An Applioation to Lstimate Conorete uantities in Balanoe of An Applioation to Lstimate Conorete uantities in Balanoe of An Applioation to Lstimate Conorete uantities in Balanoe of
Plant 3truotures for lossil Power Plants Plant 3truotures for lossil Power Plants Plant 3truotures for lossil Power Plants Plant 3truotures for lossil Power Plants
Contributed by: Raja l. Bagga & 1ignesh v. Chokshi, L&1 Contributed by: Raja l. Bagga & 1ignesh v. Chokshi, L&1 Contributed by: Raja l. Bagga & 1ignesh v. Chokshi, L&1 Contributed by: Raja l. Bagga & 1ignesh v. Chokshi, L&1- -- -3&L, Baroda 3&L, Baroda 3&L, Baroda 3&L, Baroda
APkIl 2000 PA0 18
Vo|ame 1, Issae 4
lig. 4 Conorete uantity for Corner footing. lig. 4 Conorete uantity for Corner footing. lig. 4 Conorete uantity for Corner footing. lig. 4 Conorete uantity for Corner footing.
lig. 3 1he .$2k lile 0enerated as per 3AP2000 lormat. lig. 3 1he .$2k lile 0enerated as per 3AP2000 lormat. lig. 3 1he .$2k lile 0enerated as per 3AP2000 lormat. lig. 3 1he .$2k lile 0enerated as per 3AP2000 lormat.
"NecessIty Is the nothez oI takIng chances" -Mazk TwaIn
APkIl 2000 PA0 10
Vo|ame 1, Issae 4
~. ~. ~. ~. ^.... ... - ^.... ... - ^.... ... - ^.... ... -
1. 1. 1. 1. South Korea South Korea South Korea South Korea
2. 2. 2. 2. 007 is the ISD code for Russia 007 is the ISD code for Russia 007 is the ISD code for Russia 007 is the ISD code for Russia
3. 3. 3. 3. PoIo PoIo PoIo PoIo
4. 4. 4. 4. The BibIe The BibIe The BibIe The BibIe
5. 5. 5. 5. Venus Venus Venus Venus
F 0 0 0 F 0 R T H 0 u 6 H T

"There are no regrets in life, just lessons."
- Jennifer Aniston
There is a story about an ancient Indian
sage who was caIIed by ugIy names by a
passerby.
The sage Iistened unperturbed tiII the
man ran out of words. He asked the man,
"If an offering is not accepted, who does
it beIong to?" The man repIied, "It be-
Iongs to the person who offered it." The
sage said, "I refuse to accept your offer-
ings" and waIked away, Ieaving the man
dazed.

MoraI: No one can make you feel
inferior without your permission.
9 5 3 1 2 4 7 8 6
2 8 6 9 7 5 4 3 1
7 4 1 6 8 3 9 5 2
6 3 9 2 5 1 8 4 7
5 1 8 7 4 6 2 9 3
4 2 7 8 3 9 1 6 5
8 6 2 3 9 7 5 1 4
3 7 5 4 1 8 6 2 9
1 9 4 5 6 2 3 7 8
.,. .... .,. .... .,. .... .,. ....
.... ... ... .... ... ... .... ... ... .... ... ...
,.. ,,... ,.. ,,... ,.. ,,... ,.. ,,...
What is Recession?

The agency that is officially in charge of declaring a re-
cession is known as the National Bureau of Economic
Research, or NBER. The NBER defines a recession as
a "significant decline in economic activity lasting more
than a few months..
The roots of a recession and its true starting point actu-
ally rest in the several quarters of positive but slowing
growth before the recession cycle really begins. Down-
ward trend in the business cycle characterized by a de-
cline in production and employment, which in turn low-
ers household income and spending. Consumers buy
fewer durable household goods, and businesses are
less likely to purchase machinery and equipment and
more likely to use up existing inventory instead of add-
ing goods to their stock. This drop in demand leads to a
corresponding fall in output and thus worsens the eco-
nomic situation. Recession may lead to reduction in rate
of inflation. Governments usually respond to recessions
by adopting expansionary policies, such as increasing
money supply, increasing government spending and
decreasing taxation.
Rarely though entirely possible, experiencing a multi-
tude of these negative factors simultaneously can lead
to a deep recession or even long economic depression.
1he views expressed in this magazine are not neoessarily those of the management of Larsen & 1oubro Limited or any of its joint venture oompa-
nies. 1his magazine is for internal oiroulation among the employees of Larsen & 1oubro Limited & its 1oint venture oompanies.
Sfricf securify code prohibifs
30 Ifems... Scissors incIudedlll

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