CASE STUDY OF RECONDITIONING OF AIR

PREHEATER GEAR BOX

At
Dr SHYAMA PRASAD MUKHARJEE THERMAL
POWER STATION

Submitted by
NARENDRA PATEL
EASE KORBA


DR SHYAMA PRASAD MUKHARJEE THERMAL
POWER STATION AT A GLANCE

Dr Shyama Prasad Mukharjee thermal power station is operated by Chhattisgarh
state power Generation Company limited.
Dr Shyama Prasad Mukharjee thermal power station, Korba is situated in the heart
of the city. It is built in the place where the first power plant of Korba was built in 1958.
It has a installed capacity of 5oo megawatts consisting of two coal fired Bhel boilers of 250
megawatts each. The first unit was commissioned on 30
th
March 2007 and the second unit
was commissioned on December 11 of the same year.
Dr Shyama Prasad Mukharjee thermal power station has always welcomed new
ideas and concepts for improvising its efficiency. Reformation of process is a regular feature
at KTPS. The plants officials are always ready to adopt newer technologies and believe in
continual improvement and setting newer bench marks. EWAC Association goes hand in
hand from last 3 decades. EWAC services are regarded very high at Dr Shyama Prasad
Mukharjee thermal power station. Various technologies have been offered to the plant
which has been very well accepted by the plant













ABOUT THE JOB
The gear box is situated in the primary air fan area to reduce the rpm of electrical
motor to that required for fan. During the changing of bearing the bearing sitting area of
the gear box cracked due to miss handling.


(crack of air preheater gear box)






Application details
Nature of problem- crack developed due to improper handling
Base metal- cast iron
Recommended electrode-
Eutectrode 27 and Xuper 2240
Reason for recommending these electrodes
The gear box contains oil inside for lubrication of gears. Since the base metal is cast iron, it
soaks oil so a buffering layer of eutectrode 27 is required because it can seal the impurities
and the bonding between the base metal and required joining electrode should be perfect.

Xuper 2240 has a nodular cast iron deposit which provides improved crack resistivity.
It is highly machinable.
It provides a tensile strength of 57000 Psi which ensures a high safety of margin.
The weldability of the electrode is excellent.











STEP BY STEP WELDING PROCEDURE
1st step-
The cracked metal part is removed by grinding. The grinding is done till the complete
crack is removed.




2nd step
Dye penetration test is done to check that the crack is removed completely.


3
rd
step
The preheating is done with oxy- acetylene flame to 200 degree Celsius and welding
is started.

A single layer of eutectrode 27 is deposited to seal the contaminants inside. Due to
use of eutectrode 27 the next phase of welding become easier because it sealed all the oil and
impurities.

4
th
step
Welding current is set to as low as possible to burn the electrode to preserve the
quality of weld deposit and to prevent over heating of electrode.
Short stringer beads of Xuper 2240 are welded and after welding the bead peening is
done with a ballpin hammer to remove the internal stress and flux is removed with the help
of a chipping hammer and with the help of stainless steel wire brush. This process is done
till a complete layer is overlaid and then the weld overlay is slightly grinded to remove any
flux residues. Then temp of job is checked and preheating is done once again to bring the job
temp to again 200 degree Celsius. The process is continued till the total area is completly
buildup to required thickness.



Final view of job after welding















For Further Information Please Contact
NARENDRA PATEL
EASE KORBA
Ph-07509572413
Mail- np.ewac@gmail.com

The only way to do great work is to love what you do