Coal Feeder Mechanism

The coal feeding process under the coal handling plant in where the coal is taken from the yard crushed and screened and then fed to the coal bunkers.

The coal that is present in the yard at a pre-defined ratio between Indian and Imported coal is moved to the reclaim hopper 261.10 using dozers. These reclaim hoppers have a rack and pinion gate (RPG), which allows a controlled flow of the coal. The coal is passed on to the electro magnetic vibrating feeder, which is of hanging type. This feeder is connected to the conveyor 261.05, which has a suspension magnet situated in the middle to the conveyor to eliminate iron particles. This is then passed on to the next conveyor 261.40, which also has a suspension magnet. The coal then moves on to a flap gate 261.62, before the installation of the impactors the crushers were used. The coal was crushed and screened and then sent to the boiler bunkers. But the new fluidized bed combustion type (FBC) boiler needs the coal particles not to be more than 8 mm in size. This is the reason why the crushers were changed to impactors, and hence a flap gate arrangement with a bypass directly to the conveyor 261. ISA.

From the conveyor 261. ISA the coal is taken to the two way chute and towards the two impactors. The crushed coal from the impactor in sent for screening to the filter, here coal particles of size till 8 mm in passed on to the conveyor C1. The uncrushed coal from the filter is carried by the conveyor C2 to the oversize coal conveyor C4. This C4 conveyor takes the uncrushed coal back to the impactor thus reducing wastage. The impacted and screened coal is carried on the conveyor 261.12 and passed on to the conveyor 261.13. Here a dust fan 261.44 in placed. The last conveyor in the feeding process is the flight conveyor 261.14, which is also called a plate conveyor. This one fills the boiler bunkers through the RPG, thus each bunker in filled with the same amount of coal.

3.2. NEED FOR MODIFICATION

The over-size coal conveyor C4, also known as the reject conveyor is used for the transfer of uncrushed coal back to the impactor. We observed that this conveyor could be used for feeding coal, there by making the process less complex and more effective.

By extending the C4 conveyor on its tail-end and there by reducing its height and then installing a new feeding system we can directly feed coal using a front loader. The new feeding system is a mechanically vibrating one, so that it doesn't obstruct the front loader while feeding coal. By installing this system, we can save a considerable amount of energy and cost.

3.3 DETAILS OF MODIFICATION

The modification on the C4 conveyor was carried out mainly for energy conservation and for reducing the chute maintenance. The conveyor system in the coal feeding process is made simpler and more effective, by-passing two conveyor systems on the coal feeding process.

The conveyor is extended to around 3 meters from the middle of the existing end column. This is for reducing the height of the feeding system that is being installed at the tail-end. The height is a major criterion when we use a front loader for loading coal. For better strength an ISMC 150 is used from the middle of the existing column, this is because it will be dealing with a much bigger load than the earlier one. Four new 400x400 columns are constructed; this would be the platform for the conveyor roller and its driving arrangements.

The side view of the conveyer modification shows the existing and proposed columns with the roller in position. The idlers are also clearly shown in here. Another detailed view shows the tail end side that gives us an idea of the specifications of the roller, the idlers, and the channel sections used in here. The different bolts are also specified. The plan of the modification gives us an idea of the channel sections. The column can be seen with its MS plate on top. Another important view is the front view, or elevation. Here we have specified the channel sections that are not visible on the side view and elevation. A sectional view of the idler shows us the way the impact idlers are supported on the conveyor belt and the way the return idlers are supported. The way impact idlers are kept in an inclined manner is also clearly shown.

The new system is installed at the right side of the conveyer C4. The system is mounted on 3 ISMC columns. On the top of the columns, a support plate is placed. A conical slide is placed on the support plate by means of four open coiled springs. The arrangement is such a way that the slide is free to vibrate on the springs in the longitudinal direction. The springs are strong enough to carry the entire load. The detailed dimensions of the springs are given in the design section. The vibrating motion to the slide is given from the back portion of the slide by means of two cams. These cams are mounted on a shaft which is driven by a motor. This shaft is mounted on two ball bearings. The power is transferred from the motor to the shaft is by means of belt - pulley arrangements. The forward motion is given by the cams and backward motion is given by means of two closed coiled springs. One end of the springs is fitted on a rigid plate which is placed at certain distance from the back portion of the slide and the other end is on the slide itself. The coal feeding rate is 8 ton per hour. The stroke given by the cam is 8 mm. The speed of rotation of the shaft can change according to the need by means of stepped pulleys. The slide is made up of cast iron with 10mm thickness and also has a mild steel liner with thickness 6mm. The liner is fitted on the slide by using screws. The advantage of liner is that, wearing is takes place on this liner and thus the slide is safe from the damage. We can easily change the liner with lower cost. The area of cross section of the slide is continuously decreasing when move towards the front. The slide is placed at an angle 12o from the horizontal level to the downward direction for the smooth flow of the coal through the slide. The detailed design of shaft, cams, springs, motor etc. are given in the design section. The entire arrangements are covered for avoiding the damage due to the dusts during the loading. The coal is loaded from the back portion of the slide by means of a front loader. The slide is continuously vibrating along the longitudinal direction at a constant speed. Due to this vibration the coal is directed to the conveyer. By installing this system we can save the energy required for the working of two extra conveyers.

RESULTS

In our project, we designed a new coal feeding system. Our views and the design procedures are shown in following pages. The working model of the advanced coal feeder mechanism was also developed to get a better perspective of the same.

ADVANTAGES OF THE NEW COAL FEEDER MECHANISM.

Ø If there is any break down in any of the conveyors 261.05, 261.40 we can by pass all of them by feeding coal on the new installed coal feeding mechanism.

Ø No complicated mechanisms.

Ø Coal is directly loaded the feeder by using a front loader.

Ø Only one motor is required for the system instead of using two large motors in the case of existing feeder.

Ø Can have a considerable saving of energy and man power.

Ø There is a cost benefit on this new modification, as we need to run only the C4 conveyor instead of the other 2 conveyors.

Ø The chute maintenance on the conveyor 261.40 is considerably high, so this can be brought down.

Ø Parts are of less cost and can be changed easily.



Feeders

When materials in drawn from a hopper or bin to a conveyor, an automatic feeder should be used (unless the material in dry and free running e.g. grain). The satisfactory operation of any conveyor depends on the material being fed to it in an even and continuous stream. The automatic feeder not only ensures a constant and controlled feed, irrespective of the size of material, but saves the expense of a man who would otherwise be required at the feeding point. A commonly used simple feeder would be a reciprocating plate feeder consisting of a plate mounted only wheels and forming the bottom of the hopper. The plate is moved by connecting rods from cranks or eccentrics. But a negative point of this feeder is that it is not self clearing.

Vibrating Feeders

These type of feeders consists of an inclined downward slight and vibrated

• By a high speed unbalanced pulley

• By electro magnetic vibration from one or more solenoids

• By the slower pulsating secured by mounting the plate on reward incline real springs.

Electric Vibrating Feeders

These operate magnetically with a large number of short strokes (7200 /min from on AC in small sizes and 3600/min from a pulsating DC in the larger sizes). It is built to feed a few pounds per min to 1250 tones per hour and will handle any material that doesn't adhere to the pan. It is self cleaning, instantaneously adjustable for capacity and controlled from any point near or remote. It is usually supported from above with spring shocks absorbers or from below with similar spring foot supports. A modified form can be set to free a weighed constant amount hourly for process control.

The Ratio Feeder

It is a fight-conveyor type of unit having 2 converging sets of flight moving lengthwise along its bed. At the inlet end, the flights provide a wide carrying surface, but as they approach the narrow outlet throat section they meet together to reduce the carrying width. This construction in possible in the use of welded link chain, which is flexible horizontally to permit the converging and flexible vertically to permit the driving over the pocket wheel that propels the chain. Such a feeder will accept a large, sudden surge of material will carry it away from the delivery means and will then "ration" it out onto a belt at a uniform rate.

Conveyors


The early development of this type of conveyors is reputed to have originated in the pork packing houses in the mid-west of USA in latter part of 19th century. Starting from a series of trolleys/hooks mounted on an overhead track to carry the animals from the killing to dismembering stages, the trolleys were linked to a hauling chain which later become the endless chain of a conveyor loop and was finally mechanically driven.

The basic constituents remain namely:

The track: This usually is a rolled steel hoist of size varying from approximately 75 x 40 mm to 150 x 75 mm with popular standard 100 x 75 mm for loads of around 350kg/single trolley.

The chain: For the standard, most frequently of forged links and pins or of plate link type of internationally acceptable 458 pattern with a pitch of approximately 100 mm and breaking strain in region of 20 tones.

The drive unit: Either the sprocket type or more modern eater-pillar type which has advantage that it can be inserted at almost any point in track as required by pull in the chain and does not involve diverting the line of the conveyor to accommodate a sprocket.

Twin Track Conveyors

The twin track or 'Dual duty' conveyors were developed during 1930's by Donald. M. King. In this application the loads were no longer attached directly to endless conveyor chain but where suspended from four wheel trolleys running on a parallel track below the chain track. The chain track was fitted with hinged dogs capable of driving or retaining load trolleys this was a great advance for the loads could now be diverted from main track onto sidings or Dead line where painting or inspection operations could be undertaken or could be held for storage. The full advantages of this new system were not utilized for some 20 years, due mainly to war-time activities, but in 1950 further development permitted the dead lines to be driven as separate conveyors.

An overhead conveyor is particularly suited to the provision of loading and unloading devices which utilizes the motion of conveyor for their operation. These often incorporate roller conveyor, ramps or air-operated rams, for diversion of the loads and can be made selective by limit switches actuated by pegs on suspension members on the carriers for load.

Floor Mounted Chain Conveyors

This type of conveyor with its twin chain and wood or metal slats falls into two categories.

Ø The service conveyors: This is used for moving goods from one position to another in a straight line in a level or inclined plane.

Ø The process conveyors: This application is arranged so that work may be carried out on goods while they are in motion.

The service conveyor is much simpler and straight forward; chains are driven by two, usually octagonal, sprockets mounted on a common shaft driven by a worm or train of spur gears, the final drive being roller chain in most cases to ensure compactness. The material of slats is normally dictated by duty requirements. A tractive effort for this type of conveyors is usually around 5%. The structural member consists of angles for track supported on intermediate channels forming legs to suit the application. The advantage of the slat over the belt conveyor for this type of use is primarily the rigidity of the continuous working surface which can support jigs and fixtures and is readily adaptable to the incorporation of automatic processes. With frames of appropriate height, the slats can become a travelling work bench. The height can be varied at appropriate locations along run of conveyors as in case of cake stand conveyors of motor car assembly plants. Here the car frames and transmission unit are set up on a single slat conveyor and when the wheels and tires are added they are easily transferred to a twin slat line were chocks act on the car wheels up and inclined to a higher level. The vehicle is now on the cake stand track where the operators can work on the platforms carried by the conveyor structure or inside the car or beneath it from the ground level. Care is required on such conveyors to ensure that the chock referred to above are protected where they descend below ground level in order to avoid workers feet being trapped. For flat ground level conveyors run carrying wheeled vehicles. The level of slats at pre-arranged pitches can be lowered so that vehicles are duly spaced.

As an alternative to beach type conveyors a more recent development is for slats to run at floor level and support work-carrying pedestals. This enables the operator to have all round access to his job and when necessary. The head of work carrier can provide a swivel unit.

· Floor conveyors without slats:

When it is required to convey pallets, work carrying skids or fixtures, slats are not needed and carrying unit is mounted directly on chain. Alternatively, if wheeled trucks are involved, dogs are provided on chain to engage the abutments on the trucks. This provides two further classifications namely double strand floor conveyors and drag link floor conveyors.

· Double strand conveyors

These could be also described as slat conveyors without slats. The chains are often of the raised link type where rollers provided at each end of links are offset to ensure that the links neither drag on the track nor rub on loads. This greatly reduces the chain pull, allows for longer length and smoother running on Drag link conveyors.

Drag link conveyors are normally of single strand chain often of the 458 or 678 pattern as used for overhead conveyors, mounted on floor in a box type truck with guide channel rails for trucks. The conveyors are ideal for paint plants because, there is no chance of dust or grease being dropped from an overhead track. The trucks however must be accurately made and constantly maintained and checked particularly where automatic painting is involved.

· Floor conveyors (carrousel)

This type of conveyors is frequently used for store services and small part assembly. The layout is a continuous loop with shaped slats driven by the chain mounted centrally. The slats may require overlapping to prevent screws and small work pieces falling between them which would result in jamming on bends.

Belt Conveyors

There are two classes of belt conveyors, flat belt and troughed belt. Flat belt is used for unit handling and troughed belt type for bulk handling. Both are driven from the far-end by a head-drum usually crowned to minimize the danger of belt tracking or drifting to one side. Self aligning roller sets are also available to assist tracking for long conveyors. The calculation for drive unit is based on normal belt drive formula and demands the determination of effective tension required to more the empty belt, to move the load and to raise or lower the load. Belts are normally rubber or plastic covered textile material, ranging from cotton, doubled cotton/nylon, rayon, rayon/nylon to all terylene and terylene / nylon of varying plies. The covering is obtainable in differing thickness as demanded by the duty. Rubber tired idler rollers are also obtainable to suit impact duty. Belting of stainless steel is frequently used in food industry and woven wire belts are normal where high temp service is required.

Belt conveyors have a good record of trouble free running even though high speeds some time in excess of 3m/s are common with high long gradients, and heavy and sharp materials are dealt with. The electrical equipment is usually quite straight forward but interlocks should be provided in any continuous run of conveyors to ensure that if any one of these stops, or develops serious belt slips, the whole series will stop together with any automatic loading mechanism.

Troughed belt, however, preset a more difficult problem, which can be solved by a tipper. This device incorporates a gradually inclined track with troughed idler pulleys. The conveyor belt is carried up a ramp and over a drum at a highest point so that material being conveyed tips onto a built in chute. The built is then fed over a further drum at conveyor level and hence to its normal operating position. Trippers are mounted on four rails, wheels, fitted with locking device to retain them in positions. The installation of belt conveyors is extremely important, particularly of long runs. The drive and tension units must be carefully aligned and all idlers positioned and set up accurately if good belt tracking is to be assured.

Pneumatic Conveyors

Pneumatic ducting can be routed along walls and ceilings and enable saving of floors space. Operators can transmit materials between in accessible points without radical structural alterations to existing premises.

Bulk purchasing is made practicable for smaller firms, with resultant saving of expense.

Improved house keeping, Pneumatic handling virtually eliminates wastage and spillage and is clean and economical.

Lower running cost. Few working parts and involved and reduced maintenance costs are thus achieved.

Positive overall plant efficiency over more usually methods of bulk handling can be achieved.

Many different systems are available. The simple pressure method with a blower pack induces the pressure into the ducting, the material to be conveyed being fed from hopper via a rotary valve. The final storage bin is fitted with filters to clean the exhaust air. The simple vacuum system uses a similar layout except that no rotary valve is required and the blower pack is fitted at the end of the line connected to the filter on the storage bin. The air involved can be then recycled. Various combinations of the two systems are built up to suite the particular requirements. It is important that the purchaser should ensure that the supplier has the facility to run test of samples of this material to make sure that this system is the best for the particular material and no damage will be done to the material in this rotary valves etc.

Pneumatic conveyor systems lend themselves quite easily to automation and process control. As a bonus it is frequently possible to arrange for actual processing during conveying.

Level control in hoppers has been a problem. This has been overcome by use of rotating paddle controllers which are insensitive to dust and pressure but give positive control. It can be expected that this type of bulk handling will be increasingly used for heavier work such as the conveying of pulverized fuel, for quarry work and in iron and steel industry.

Screw and 'En Masse' Conveyors

These conveyors can be used for either horizontal or vertical transport or run under mill bore condition. The screw conveyor which has been called an animated mincing machine certainly employs the same principle. The 'En Masse' type conveyor consists of a special endless chain with H-shaped attachments at frequent pitches housed in rectangular ducting. The forces exerted by the attachments and the chain exceed the friction force on material on the sides of the housing.

Both these types of conveyors, being totally enclosed, tend to be dust free, which strongly recommends them to the food and chemical industries. The material conveyed is normally of powdered or granular nature

Space Station

THE INTERNATIONAL SPACE STATION (ISS)

In 1984, President Ronald Reagan proposed that the United States, in cooperation with other countries, build a permanently inhabited space station. Reagan envisioned a station that would have government and industry support. The U.S. forged a cooperative effort with 14 other countries (Canada, Japan, Brazil, and the European Space Agency -- United Kingdom, France, Germany, Belgium, Italy, The Netherlands, Denmark, Norway, Spain, Switzerland, Sweden). During the planning of the ISS and after the fall of the Soviet Union, the United States invited Russia to cooperate in the ISS in 1993; this brought the number of participating countries to 16. NASA is taking the lead in coordinating the ISS's construction.

ISS Facts

Length: 290 ft (88m)
Width: 356 ft (109 m)
Height: 143 ft (44 m)
Volume: 46,000 ft3 (1300 m3); living space will be about the cabin size of two 747 jets
Mass: 1,000,000 lb (454 metric tons)
Orbit: 217 to 285 miles (362 to 476 km), inclined 51.6 degrees relative to the equator

The assembly of the ISS in orbit began in 1998. The ISS has more than 100 components and will require 44 spaceflights by at least three space vehicles (space shuttle, Soyuz and Russian Proton rocket) to deliver the components into orbit. One-hundred sixty spacewalks, totaling 1,920 man-hours, will be required to assemble and maintain the ISS, which is scheduled for completion in 2010 and will have an anticipated life of 10 years at a projected total cost of $35 to $37 billion. When completed, the ISS will be able to house up to seven astronauts. It will have the following major components:

• Control Module (Zarya) or Functional Cargo Block - contains propulsion (two rocket engines), command and control systems
• Nodes (three) - connect major portions of the ISS
• Service Module (Zvezda) - contains living quarters and life support for early parts of the ISS, docking ports for Progress resupply ships and rocket engines for attitude control and re-boost
• Scientific Laboratories (six) - contain scientific equipment and a robotic arm to move payload on an outside platform
• Laboratory Module - shirt-sleeve environment facility for research on microgravity, life sciences, Earth sciences and space sciences
• Truss - long, tower-like spine for attaching modules, payloads and systems equipment
• Mobile Servicing System - robotic system that will move along the truss; equipped with remote arm for assembly and maintenance activities
• Transfer Vehicles - a Soyuz capsule and a Crew Return Vehicle (X-38) for emergency evacuation
• Electrical Power System - solar panels and equipment for generating, storing, managing and distributing electrical power

ISS in orbit showing (top to bottom) Node-1, Control Module, Service Module and a Progress supply ship (September 2000).


On October 31, 2000, the first crew of the ISS was launched from Russia. The three-member crew spent almost five months aboard the ISS, activating systems, and conducting experiments.
To sustain a permanent environment in outer space where people can live and work, the ISS must be able to provide the following things:

• Life support
• Atmosphere control, supply and recycling
• Water recycling
• Temperature control
• Food supply
• Waste removal
• Fire protection
• Propulsion - move the station in orbit
• Communications and tracking - talk with ground-based flight controllers
• Navigation - find its way around
• Electrical power
• Computers - coordinate and handle information
• Resupply - methods of getting new supplies and removing waste
• Emergency escape route


LIFE SUPPORT

ATMOSPHERE CONTROL, SUPPLY AND RECYCLING
Astronauts on board the ISS need to have the following:
• Atmosphere similar to Earth's
• Carbon dioxide that they exhale removed
• Contaminating or trace gases removed
• Normal humid environment
Our atmosphere is a mixture of gases -- 78 percent nitrogen, 21 percent oxygen, 1 percent other gases -- at a pressure of 14 lbs/in2 (1 atm). The ISS astronauts will need a similar atmosphere. To achieve this, oxygen and nitrogen will have to be supplied:
1. The Russian Elektron generator will make oxygen by splitting water into hydrogen and oxygen (electrolysis).
2. Solid fuel oxygen generators or oxygen candles will be burned to make additional oxygen, if required.
3. The space shuttle or Progress supply ships will bring nitrogen from Earth, and store it in external tanks on the station.
4. In later phases of construction, external tanks will supply oxygen; these tanks can be refilled by the space shuttle. In the final stage, an additional electrolysis oxygen generator will be added to the station.
5. The pressure control assembly (a system of pumps and valves) will mix the nitrogen and oxygen in the right percentages, monitor the atmospheric pressure and depressurize the station when necessary to prevent overpressure or to extinguish a fire during an emergency.
A carbon dioxide removal assembly (a series of beds of special material) will absorb carbon dioxide and release it into outer space. In addition, backup chemical carbon dioxide canisters can remove carbon dioxide by reacting it with lithium hydroxide.
The trace contaminant control system will filter cabin air to remove trace odors and volatile chemicals from leaks, spills and outgassing. As a backup, the harmful impurities filter will also be used.
The station's heating system will control the humidity and circulate the atmosphere throughout the station.
Finally, the major constituent analyzer will constantly monitor the amount and type of gases in the cabin air, and control the atmosphere supply and recycling systems.
WATER RECYCLING
Besides air, water is the most important element aboard the ISS. Initially, the space shuttle and Progress supply vehicles will bring water from Earth. On the ISS, water will be highly conserved. There will be no long, luxurious showers. In fact, most astronauts get by with sponge baths. The water recovery and management subsystem will collect, recycle and distribute water from various sources including:
• Sink
• Shower
• Urine - from the astronauts and from laboratory animals onboard
• Spacesuit wastewater
• Heating and cooling systems
• Cabin air - moisture exhaled by astronauts and laboratory animals
• The space shuttle's fuel cells
The water recovery and management subsystem consists of various condensers, filters and water purifiers. The water will be used for drinking and cooling electrical systems. This system is not 100 percent efficient, and water will be lost through the Elektron oxygen generator, airlocks and carbon dioxide removal systems. Water will be periodically replenished from Earth. However, this system will greatly reduce the amount of water needed from Earth.
TEMPERATURE CONTROL
Outer space is an extremely cold environment, and temperatures will vary drastically in different parts of the ISS. You might think that heating the ISS would be a problem. However, the electronic equipment generates more than enough heat for the station. The problem is getting rid of the excess heat. So the temperature control system has to carry out two major functions -- distributing heat where it is needed on the station and getting rid of the excess. To do this, the ISS has two methods to handle temperature control:
• Passive methods - generally simple; handle small heat loads and require little maintenance
 insulating materials, surface coatings, paints - reduce heat loss through the walls of the various modules, just like your home insulation
 electrical heaters - use electrically-heated wires like a toaster to heat various areas
 heat pipes - use liquid ammonia in a pipe to transfer heat from a warm area to a cold area over short distances. The ammonia evaporates at the warm end of the pipe, travels to the cold end and condenses, giving up heat; then the liquid travels back to the warm end along the walls of the pipe (capillary action).
• Active methods - more complex; use fluid to handle large heat loads; require maintenance
 cold plates - metal plates that collect heat by direct contact with equipment or conduction
 heat exchangers - collect heat from equipment using fluid. The equipment radiates heat to a fluid (ammonia), which in turn passes heat on to water. Both fluids are pumped and recirculated to remove heat.
 pumps, lines, valves - transport the collected heat from one area to another
 heat rejection units - large, winged structures, similar to solar panels, that radiate the collected heat to outer space
For cabin air, the temperature and humidity control system circulates and filters air, removes water (humidity) and maintains a constant temperature range. Any collected water goes to the water recovery and management system.
FOOD SUPPLY
The space shuttle and Progress supply ships will bring food to the ISS. Food comes in several forms (dehydrated, low moisture, heat-stabilized, irradiated, natural, fresh). The ISS has a galley (kitchen) equipped with the following:
• Food storage compartments
• Food warmers
• A food preparation area
• Table with restraints (straps, footholds) so the astronauts do not float away
• Metal trays that stop the food packages and utensils from floating away
TheUnited States and Russia have each agreed to supply half of the food for the crew.
WASTE REMOVAL
Like any home, the ISS must be kept clean. This is especially important in space, where floating dirt and debris could present a hazard. Wastes are made from cleaning, eating, work and personal hygiene. For general housecleaning, astronauts will use various wipes (wet, dry, fabric, detergent, disinfectant), detergents and wet/dry vacuum cleaners to clean surfaces, filters and themselves. Trash will be collected in bags, stowed in a Progress supply ship and returned to Earth for disposal. Solid waste from the toilet is compacted, dried and stored in bags, where it is returned to Earth for disposal (burning). Water reclaimed from solid waste is processed and purified for drinking purposes.
FIRE PROTECTION
Fire is one of the most dangerous hazards in space. During astronaut Jerry Linenger's stay on Mir, a fire broke out. The Mir crew extinguished the fire, but not before the station was damaged. The ISS has a fire detection and suppression subsystem that consists of the following:
• Area smoke detectors in each module
• Smoke detectors in each rack of electrical equipment
• Alarms and warning lights in each module
• Nontoxic portable fire extinguishers - foam or liquid extinguishers that are either carbon dioxide (from the United States) or nitrogen-compound-based (from Russia)
• Personal breathing apparatus - mask and oxygen bottle for each crew member
After a fire is extinguished, the atmosphere control system will filter the air to remove particulates and toxic substances.

POWER
All of the onboard systems of the ISS will require electrical power. Eight large solar arrays will provide electrical power from the sun. Each array is 109 feet (33 m) long and covers an area of 27,000 ft2 (approximately 2508 m2), or about one acre. On each array are two blankets of solar cells. Each blanket is on one side of a telescoping mast that can extend and retract to fold or form the array. The mast turns on a gimbal, so that it can keep the solar cells facing the sunlight. The Russian modules also have 72- to 97-foot (22- to 30-m) solar arrays that provide power.
Like a power grid on Earth, the arrays will generate primary power -- approximately 160 volts of DC electricity. The primary power will be converted by a secondary transformer to provide a regulated 124-volt DC current to be used by the station's equipment. There are also power converters onboard to meet the different currents required by U.S. and Russian equipment. The primary power will also be used to charge the ISS's three nickel-hydrogen battery stations, which will provide power when the ISS passes through the Earth's shadow in each orbit.

RE-SUPPLY

In the ISS, they have to call for "home-delivery." Progress supply ships will be used to ferry new supplies (food, water, medicines,oxygen, nitrogen, fuel, equipment, clothing, personal items) to the ISS. Progress ships will also remove solid waste from the ISS. The space shuttle can bring new supplies to the ISS as well, along with equipment for construction. In addition to Progress and the space shuttle, two new supply vehicles are being developed by the European Space Agency (ESA) and National Space Development Agency of Japan. The ESA's vehicle will be like Progress, capable of supplying nine tons of cargo, including food, clothing, fuel, water, oxygen and nitrogen; the vehicle will also be able to reboost the ISS. The Japanese craft, called the Hope Transfer Vehicle, will be capable of delivering pressurized cargo (food, water, clothing), but not fuel, oxygen or nitrogen.


Living and Working Aboard the ISS

The first space station crew members will spend a lot of their time setting up the station, building its components and conducting various scientific experiments and Earth observations. The crew will live in the service module at first. This module has spartan living quarters, but provides everything the crew needs -- personal sleeping quarters, a toilet, hygiene facilities, a kitchen with a table, a treadmill and a stationary bicycle. Astronauts will have to exercise frequently to keep from losing bone and muscle mass, which happens with prolonged weightlessness.
Sleeping
Sleeping in space is quite different from sleeping on Earth. Instead of a bed, you have a wall-mounted sleeping bag that you slip into and zip up. The bag is also equipped with arm restraints to prevent your arms from floating above your head while you sleep.
Bathing
While stations such as Skylab and Mir have been equipped with a shower, most astronauts take sponge baths using washcloths or moistened towelettes. This reduces the amount of water consumed. Each astronaut will also have a personal hygiene kit with a toothbrush, toothpaste, shampoo, razor and other basic toiletries.
Eating
The food on the ISS will be mainly frozen, dehydrated or heat-stabilized, and drinks will be dehydrated. Astronauts will collect food trays and utensils, locate their individually-packaged meal from a storage compartment, prepare the items (rehydrate if necessary), heat the items (microwave, forced-air convection oven), place them in the tray and eat. After the meal, they will place the used items in a trash compactor, and clean and stow the utensils and trays. Interestingly, astronauts get to select their menus approximately five months before their flight.
Exercising
In weightless conditions, the body loses bone and muscle mass. To counter these losses, astronauts will have to exercise daily. The service module is equipped with a treadmill and a stationary bicycle. Astronauts must strap themselves onto these devices so that they do not float away while exercising.
Working
Once the ISS is completed, work will involve maintaining the station (fixing broken equipment, repairing structures, etc.) and conducting scientific experiments and observations. The station will have six scientific laboratories. Closet-sized racks along the walls of the laboratory module will hold the equipment, and the astronauts will use footholds and restraints so they won't float away while working. The experiment racks will also have remote video and data links so that scientists on the ground will be able to monitor the experiments on-board the ISS continuously. The Japanese laboratory module will have a platform open to space, for determining the effects of the space environment on materials.
Moving Around on the ISS
Working in weightlessness, or microgravity, is very different from what we are used to. For example, as I write this article at my computer, I do not have to worry about floating off of my chair, or having the papers on my desk float away. This is not the case in the ISS. As we have mentioned above, many places (experiment racks, kitchen area, crew quarters) will have restraints to keep the astronauts and equipment from floating away. And while I can walk the corridor in my office with no trouble, astronauts on the ISS will have to use handholds mounted on the walls of the station to keep themselves stable as they move around.
Spacewalks
The crew will have to perform spacewalks during construction and maintenance of the ISS. Initially, the crew will perform spacewalks from the Russian service module using Russian spacesuits. Because spacesuits operate at lower pressures than the station, the astronauts will have to reduce the air pressure of the entire station prior to the spacewalk, so that the spacewalker's body can adjust; otherwise, the spacewalker might get the bends.
Once the Joint Airlock Module (JAM) arrives at the ISS, the crew will be able to use both Russian and American spacesuits, and the entire station will no longer have to be depressurized prior to a spacewalk. To prepare for a spacewalk, the spacewalkers will have to do the following:

• Enter the JAM with their spacesuits and equipment
• Reduce the pressure in the airlock from 14.7 lb/in2 (1 atm) to 10.2 lbs/in2 (0.7 atm)
• "Camp-out" overnight in order to:
 adjust to the low pressure used in spacesuits -- 4.3 lbs/in2 (0.3 atm)
 eliminate nitrogen from the space walker's body, thereby reducing the chance of decompression sickness
• Put the spacesuit on
• Pre-breathe pure oxygen (spacesuits use pure oxygen) for a few minutes prior to the space walk
• Open the airlock doors
• Conduct the spacewalk
The spacesuits used on the ISS will be enhanced versions of those used on the shuttle. They will have the following modifications:
• Internal parts that are more easily replaced
• Carbon-dioxide absorption cartridges that are reusable and removable
• Metal sizing rings that adjust the fit for individual users
• New gloves with increased flexibility and dexterity
• Enhanced radio with more channels, so more people can talk at once
• New heaters, and a cooling system shut-off (ISS spacewalkers will have to work in shadows, where it is colder; shuttle spacewalkers were able to work in the sun, because the shuttle could be turned easily toward sunlight)
• Helmet-mounted flood lights and spot lights
• Jet-pack that allows an untethered astronaut to fly back to the station in an emergency (if he should slip away from the ISS)
The spacesuits will have to be returned to the ground for maintenance after every 25 spacewalks.
Photo courtesy NASA
Astronauts training for the many space walks that will be involved in ISS construction and maintenance.
The ISS will have robotic arms to assist spacewalkers and move large items such as construction modules and some supply ships.
Leisure Time
All work and no play makes for cranky astronauts. This has been observed on space shuttle, Skylab and Mir missions. Crews do need to have leisure time. What can you do with free time on the ISS? You can read, play games or e-mail your friends. However, most astronauts say that what they like to do most is look out the window at the Earth below.
Habitation Module
The United States will provide an additional habitation module, the trans-hab module, for extra crew quarters.

The proposed U.S. trans-hab module.
This habitation module will be able to sleep four astronauts. Each cabin will have a sleeping bag (note that it is upright on the wall), a desk with a computer, and footholds.

Crew quarters of trans-hab module.
The module will also have a wardroom with a galley, table and storage area. This will be a place for the astronauts to eat and gather for meetings.

The wardroom of the trans-hab module.
The module will also contain a level for crew health care, which includes exercise and medical equipment as well as storage space.

The exercise area of the trans-hab module

Porting Device Drivers for the Solaris

The capabilities of the Solaris platform continue to expand to meet customer needs. The Solaris 10 release is designed to fully support both 32-bit and 64-bit architectures. The Solaris OS supports machines based on both 32-bit and 64-bit SPARC processors as well as 32-bit and 64-bit x86 platforms.

The primary difference between the 32-bit and 64-bit development environments is that 32-bit applications are based on the ILP32 data model, while 64-bit applications are based on the LP64 model. The primary difference between applications for SPARC and x86-based systems, from the driver developer's point of view, is big-endian versus little-endian translation.

To write a common device driver for the Solaris OS, developers need to understand and consider these differences.

Note: This document addresses topics related to x86 platforms only. In this document, references to 64-bit operating systems refer to the Solaris OS on machines with AMD Opteron processors.

The Solaris OS runs in 64-bit mode on appropriate hardware, and provides a 64-bit kernel with a 64-bit address space for applications. The 64-bit kernel extends the capabilities of the 32-bit kernel by addressing more than 4 Gbyte of physical memory, by mapping up to 16 Tbyte of virtual address space for 64-bit application programs, and by allowing 32-bit and 64-bit applications to coexist on the same system.

This document discusses the differences between 32-bit and 64-bit data models, provides guidelines for cleaning 32-bit device drivers in preparation for the 64-bit Solaris OS kernel, and addresses driver-specific issues with the 64-bit Solaris OS kernel.

Conclusion


This document describes issues that you need to be aware of when you write 32-bit and 64-bit safe drivers for the Solaris OS on x86 platforms. These issues include multiple C language data models, the use of system-derived types that have changed, and changes to some of the DDI interfaces. Also, you need to address some driver-specific issues. Finally, you need to consider performance issues such as the use of DMA.

This article lists and describes these issues, and it provides solutions and recommendations for these issues. This guide should help you write clean code for 32-bit and 64-bit device drivers for the Solaris OS on x86 platforms.

For further information on device drivers in the Solaris OS, see Writing Device Drivers. To see examples of some basic device drivers, see Device Driver Tutorial (PN 817-5789, Sun Microsystems). If you are new to development in the Solaris OS or are unfamiliar with the range of information on the Solaris OS, see the Introduction to the Solaris Development Environment.

References


Writing Device Drivers, Appendix C: "Making a Device Driver 64-Bit Ready," PN 816-4854, Sun Microsystems, 2004

Solaris 64-Bit Developer's Guide, PN 816-5138, Sun Microsystems, 2004

STREAMS Programming Guide, PN 816-4855, Sun Microsystems, 2004

Software Optimization Guide for AMD Athlon 64 and AMD Opteron Processors (pdf), PN 25112, Advanced Micro Devices, 2004

Pressure Vessel Design

DESIGN OF PRESSURE VESSEL TO CODE SPECIFICATION

American, Indian, British, Japanese, German and many other codes are available for design of pressure vessels. However the internationally accepted pressure vessel code is American Society Of Mechanical Engineers (ASME).
Various codes governing the procedures for the design for fabrication, inspection, testing, and operation of pressure vessels have been developed, partly as a safety measure. These procedure furnish standards by which, any state can be assured of the safety of the pressure vessel installed within its boundaries. The code used for unfired pressure vessel is section 8 of the ASME boiler and pressure vessel code. It is usually necessary that the pressure vessel equipment be designed to a specific code in order to obtain insurances on the plant in which the vessel is to be used. Regardless of the method of design, pressure vessels within the limits of the ASME code specifications are usually checked against the specifications.


DEVELOPMENT AND SCOPE OF ASME CODE

In 1911, American society of mechanical engineers, established a committee to formulate standard specifications for the construction of steam boilers and other pressure vessels. This committee reviewed the existing Massachusetts and Ohio rules and conducted an extensive survey among superintends of inspecting departments, Engineers, fabricators and boiler operators. A number of preliminary reports were issued and revised. A final draft was prepared in 1914 and was approved as a code and copyrighted in 1915.
The introduction to the code started that public hearings on the code should be held every two years. In 1918, a revised edition of the ASME code was issued in 1924,the code was revised with the addition of the new section 8, which represented a new code for unfired pressure vessels.

THE API-ASME CODE

In 1931 a joint API-ASME committee on unfired pressure vessels was appointed to prepare a code for safe practice in the design, construction, inspection and repair of unfired pressure vessels.


SELECTION OF THE TYPE OF VESSEL

The first step in the design of any vessel is the selection of the type best suited for the particular service in question. The factors influencing this choice are:

1. The operating temperature and pressure.
2. Function and location of the vessel.
3. Nature of the fluid.
4. Necessary volume for storage or capacity for processing.
It is possible to indicate some generalities in the existing use of the common type of vessels. For storage of fluids at atmospheric pressure, cylindrical tanks with flat bottoms and conical roofs are commonly used. Spheres or spheroids are employed for pressure storage where the volume required is large. For smaller volume under pressure cylindrical tanks with formed heads are more economical

TYPE OF VESSELS
OPEN VESSELS

Open vessels are commonly used as urge tanks between operations , as vats for batch operations where materials may be mixed and blended as setting tanks, decanters, chemical reactors, reservoirs and s on. Obviously this type of vessel is cheaper than covered or closed vessel of the same capacity and construction. The decision as to whether or not open vessels may be used depends upon the fluid to be handled and the operation.

CLOSED VESSELS

Combustible fluids, fluids emitting toxic or obnoxious fumes and gases must not be stored in closed vessels. Dangerous chemicals such as caustic are less hazardous if stored in closed vessel. The combustible nature of petroleum and its products associates the use of closed vessels and tanks throughout the petroleum and petrochemical industries. Tanks used for the storage of crude oils and petroleum products and generally designed and constructed as per API specification for weld a silo storage tanks.

CYLINDRICAL VESSEL WITH FLAT BOTTOMS AND CONICAL OR DOMED ROOFS

The most economical design for a closed vessel operating of atmospheric pressure is the vertical cylindrical tank with a conical roof and a flat bottom resting directly on the bearing soil of the foundation composed by sand, gravel or crushed rock. In case where it is desirable to use a gravity feed, the tank is raised above the ground, and the flat bottom may be supported by columns and wooden joints or steel beams.

CYLINDRICAL VESSELS WITH FORMED ENDS
Closed cylindrical vessels with formed heads on both sides used where the vapour pressure of the stored liquid may dictate a stronger design , codes are developed through the efforts of the American petroleum institute and the ASME to govern the design of such vessels . These vessels are usually less than 12 feet in diameter. If a large quantity of liquid is to be stored, a battery of vessels may be used.

SPHERICAL AND MODIFIED SPHERICAL VESSELS

Storage containers of large volumes under moderate pressure are usually fabricated in the shape of a sphere or spheroid. Capacities and pressures used in this type of vessel vary greatly for a given mass; the spherical type of tank is more economical for large volume, low pressure storage operation..


VERTICAL Vs HORIZONTAL VESSELS

In general functional requirements determine whether the vessel shall be vertical or horizontal. e.g.: distilling columns, packed towers which utilize gravity require vertical installation.
Heat exchangers and storage vessels are either horizontal or vertical. If the vessel to be installed outdoor wind loads etc are to be calculated to prevent overturning, thus horizontal is more economical. However floor space, ground area and maintenance requirements should be considered.


VESSELS OPERATING AT LOW TEMPERATURE RANGES

Pressure vessels constructed in such a manner that a sudden change of section producing a notch effect is present, are usually not recommended for low temperature range operations. The reasons are that, they may create a state of stress such that the material will be incapable of releasing high localized stress by plastic deformation. So the material used for low temperature operations are tested for notch ductility.
Carbon steels can be used down to 60 C. notch ductility is controlled in such materials through proper composition steel making practice, fabrication practice and heat treatment. They have an increased manganese carbon ratio. Aluminum is usually added to promote fine grain size and to improve notch ductility.
Ductility of certain materials including carbon and low alloy steels is considerably diminished when the operating temperature is reduced below certain critical value. This critical value is usually described as the transient temperature. It depends up on the material, method of manufacture, previous treatment and stress system present. Below transition temperature fracture may take place in a brittle manner with little or no deformation, whereas at temperatures above the transition temperature, fracture occurs only after considerable plastic strain or deformation.

VESSELS OPERATING AT ELAVATED TEMPERATURES

Embitterment of carbon and alloy steel may occur due to service at elevated temperatures. In most instances brittleness is manifest only when the material is cooled to room temperature. This is inhibited by the addition of molybdenum and also improve tensile and creep properties. Two main criteria in selecting steel for elevated temperatures are metallurgical strength and stability. Carbon steels are reduced in their strength properties due to rise in temperature and are liable to creep. So the use of carbon steel is generally limited to 500 c.
The SA-283 steels cannot be used in applications with temperatures over 340 C .The SA-285 steels cannot be used for services with temperatures over 482 C. However both SA-285 and SA-212 steels have very low allowable stress, at the higher temperatures.

MATERIAL SPECIFICATION

Plain carbon and alloy steel plates are usually used where service conditions permit because of the lesser cost and greater availability of these steels. Such steels may be fabricated by fusion welding and oxygen cutting if the carbon content does not exceed .35%. Vessels may be fabricated of plate steels meeting the specifications of SA-7,SA-113 grade c and SA-283 grade A,B,C and D provided that

1. The operating temperature is between –28 and 360 C.
2. The plate thickness does not exceed 1.5 cm.
3. The vessels do not contain lethal liquids and gases.
4. The steel is manufactured by the electric furnace or open hearth process.
5. The material is not used for unfired steam boilers.

One of the most widely used steel for general purpose in the construction of pressure vessels is SA-283, grade C. This steel has good ductility and forms welds and machines easily. It is also one of the most economical steel suitable for pressure vessels. However its use is limited to vessels with plate thickness not exceeding 1.5 cm.
For vessels having shells of greater thickness, SA-285 grade C is most widely used in moderate pressure applications. In the case of high pressure or large diameter vessels, a high strength steel may be used to advantage to reduce the wall thickness. SA –212, grade B is well suit for such applications and requires a shell thickness of only 79% of that required by SA-285, grade C. This steel also is fabricated but is more expensive than other steels.
Now many new series of materials like low alloy, high alloy steels, high temperature and low temperature materials are available which can be selected to suit the requirements of every individual need of the process industry
The important materials generally accepted for the construction of pressure vessels are indicated here. Metals used are generally divided into 3 groups as

A) Low cost: - Cast iron, cast carbon and low alloy steel, wrought carbon and low alloy steel.
B) Medium cost: - high alloy steel (12% chromium and above) aluminum, nickel, copper and their alloys, lead.
C) High cost: - platinum, tantalum, zirconium, titanium silver.

Materials mentioned in b and c group are sometime used in the form of cladding or bonding for materials in group a. Non metallic linings such as plastics, rubber etc can also be used.

Vessels with formed heads are commonly fabricated from low carbon steel wherever corrosion and temperature considerations will permit its use because of the low cost, high strength, ease of fabrication and general availability of mild steel. Low and high alloy steel and nonferrous metals are used for special service.

Steels commonly used fall into two general classifications.

1) Steel specified by ASME code.
2) Structural grade steels, some of which permitted by the ASME

CLOSURES FOR PRESSURE VESSELS


All formed heads are fabricated from single circular flat plate by spinning or by drawing with dies in a press. Although the cost of heads formed from flat, plates involves additional cost of forming, the use of formed heads as closures usually more economical than the use of flat plates as closures except for small diameters.
A variety of formed heads are used for closing the ends of cylindrical vessels. These include flanged only heads, flanged and shallow dished, Toro spherical, elliptical, hemispherical and conical shaped heads. For spherical purposes flat plates are used to close a vessel opening, however flat heads are rarely used for large vessels.
For pressures not covered by the ASME code, the vessels are often equipped with standard dished heads, whereas vessels that require code construction are usually equipped with standard dished heads whereas vessels that require code construction are usually equipped with either the ASME dished or elliptical dished heads. The most common shape for the closure of pressure vessels is the elliptical dish. Most chemical and petrochemical processing equipments such as distilling columns, disrobers, absorbers, scrubbers , heat exchangers, pressure-surge tanks and separators are essentially cylindrical closed vessels with formed ends of one type or the other.
As mentioned above , the most common types of closures for vessels under internal pressure are the elliptical dished head( ellipsoidal head) with a major to minor axis ratio equal to 2.0:1.0 and the Toro spherical head in which the knuckle radius is equal to 6% or more of the inside crown radius(ASME standard dished head)