aryan (turbine technolgy

8/8/2019 Aryan (Turbine Technolgy

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INTRODUCTION

For Thriven, sugar to sugar plant & machinery was a natural diversification & Thriven sugar grow as a big name in that

field. Thriven sugar is the biggest sugar mill in whole ASIA. Thriven entered in this field in mid 60s and has been a major

player in this business area of sugar machinery & turnkey sugar plants.

This division has executed more than 35 sugar plants ranging from 1000 TCD - 10000 TCD capacity and carried out

major expansion, balancing work for over 20 sugar factories.

The mills designed by Thriven are considered by experts to be very robust and rugged, requires least maintenance and

give higher mill extractions.

Thriven got out of the business of complete new sugar units installation as it started focusing on niche technology and

equipment available because of tie up with SRI, a premier sugar research institute of Australia and industry turning to

low cost small players (at a time when sugar industry was going through bad phase) started eating away the profits

made by this division.

Now,Thriven SRI Limited (TSL), a Thriven Group Company, under a License Agreement with Sugar Research

International, offers the latest models of plants and machinery available to the Australian industry to the Indian Sugar

Industry.

PLANT EQUIPMENT

I. JUICE EXTRACTION

II. CLARIFICATION

III. EVAPORATION

IV : VACUUM PAN STATION

V. CRYSTALLISER TREATMENT AND CURING

VI. STEAM AND POWER PLANT

VII. COGENERATION

VIII. GENERAL

BRIEF CLASSIFICATION

Business Overview

With a current cane crushing capacity of 61,000 TCD, Triveni continues to be one of the largest producers of sugar in

India.
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Facilities

Using the most productive and eco-friendly processes, we can crush 61,000 tonnes of sugar cane from seven efficient

production facilities at Cataula, Disband, Ram kola, Sanitary, Chandanpur, Maniacal and Milk Narainpur.

Raw Material

We believe that in order to deliver a superior quality product, we need to have superior quality raw material too. We lay

special emphasis on procurement as well as sugarcane development to ensure this...

Plants & Process

The standard double sulphitation process of clarification and 3 1/2 massecuite boiling scheme for production of direct

plantation white sugar...

Environmental Compliance

We conduct our business in accordance with a well laid out, comprehensive environmental policy and environment

management system...

Technology

Know about our state-of-the-art technology that helps us leverage our superior manufacturing capabilities, reduce

energy consumption and improve sugar quality.

Key Strengths

Our strengths go beyond vast collection network, sound financial support, strategic location of plants and ultra modern

facilities. We strengthen our base through strong & transparent relationships with farmers.

Strategic Alliances

With a strong strategic alliance partner like Sugar Research International, we have access to the best sugar equipments

& knowledge in the world.

Milestones

We had a prosperous journey since the setup of our first sugar production unit at Khatauli in 1933. These are some ofour key milestones that we have crossed during our journey.

MILESTONES

Since the setting up of first unit at Disbands in 1932, the overall performance of our Sugar Business has been

commendable. During the last two decades we have crossed many milestones and are committed to cross many more in

the future.

Following is a glimpse of our achievements during the last two decades:

1989

Awarded "Certificate of Merit" for best performance during season 1987-88 by National Productivity Council of India. This

award was presented by Hon'ble Shri J. Vengala Rao, then Hon'ble Minister of Industries, Govt. of India and President of

NPC.
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1991

The Double Carbonation and Double Sulphitation process was converted successfully into Double Sulphitation process

having due consideration to Environmental problems.

1992

Successfully completed Expansion and Modernisation of the Plant from 5000 TCD to 10,000 TCD.

1998

Successfully completed the Expansion of the Plant from 10,000 TCD to 11,000 TCD.

2000

We exported 2.42 Lac. Qtls. of Sugar to Pakistan.

2001

Launching of the Biological Control Lab. for Soil testing and developing of biological pest control system for the benefits

of the Cane Growers of the area.

2003

In August, 2003 launched Branded Sugar "Shagun" and started packing of consumer packets.

2005

Launched "Triveni Kushali Bazaar" an Agri-business Centre at Village Ladpur near our Sugar Unit mainly for making

available agricultural implements & inputs and other domestic items under one roof for the Cane Growers of the area.

2005

We crushed 186.61 lac. Qtls. of cane during season 2004-05 which was the highest crush in India with highest

production of 19.59 lac. Qtls. of Sugar.

Expansion of the Plant from 12,500 to 16,000 TCD by adding a new Milling Tandam with complete automation system is

being done which will commence production in season 2005-06.

A new Co-generation plant of 24.0 M.W. is under installation which will commence production in October, 2005.

KEY STRENGTH

One of the Leaders in the Indian Industry

The sugar industry in India is highly fragmented with over 500 sugar factories. We are amongst the three largest

producers of sugar in India based on sugar production in Sugar Year 2003-2004 derived from ISMA Working Results of

Sugar Factories in India, 2003-2004. We manufactured 0.38 million tonnes of sugar in the Sugar Year 2005.

Strong Financial Position

We have a strong financial position, which we believe will enable us to finance our capacity expansion plans. As of March

31, 2005, we had a long-term debt to equity ratio of 0.72: 1 and total debt to equity ratio of 2.74:1. In fiscal 2005, we


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have net cash flow from operating activities of Rs. 1,414.42 million.

Strategic Location of Mills

All of our manufacturing facilities for sugar production are located in the north Indian state of Uttar Pradesh and the two

largest sugar mills at Khatauli and Disband are located in western Uttar Pradesh, which is one of the largest sugarcane

growing areas in India. As a result of our presence in the state of Uttar Pradesh, we benefit from the following

advantages.

Proximity of Sugarcane Deficient Markets

Our sugar mills are located close to the sugarcane deficient markets of Punjab, Mariana, Delhi, Madhya Pradesh,

Rajasthan, Gujarat and West Bengal. Thus, our primary markets are located close to our manufacturing facilities and we

do not rely on transporting our sugar to distant markets, which gives us a comparative advantage in distribution costs of

this bulk commodity.

Excellent Relationships with Farmers

We make timely payments to sugarcane farmers and have built excellent relationships and goodwill with them, which is

an important factor in our industry. We have a good record of payments to farmers for sugarcane despite the cyclical

nature of the sugar industry and have strong ties with approximately 167,000 sugarcane farmers.

Extensive Network for Sugarcane Collection

In order to facilitate the sale of sugarcane to us by the sugarcane farmers, we have established a extensive network of

more than 350 collection centers in the state of Uttar Pradesh, where the sugarcane is collected by us and payments are

made to farmers. These collection centers are located in our sugarcane area and hence, the farmer is not required to

bring his crop to our factory gates.

Good Product Quality

The sugar produced by our sugar mills in Khatauli and Disband is bold grained and is rated as one of the better qualities

of sugar produced in western Uttar Pradesh. This enables us to command a premium on the sugar produced by us.

SUGAR VARIETY

We actively encourage the farmers in our cane areas to grow early maturing varieties of sugarcane, which have high

sucrose content. We conduct sugar content analysis of sugarcane samples on a daily basis to have information base for

our procurements and future development of high sugared sugarcane varieties. Some of these varieties are CoJ-64, CoS-

88230 and CoS-8436, which are varieties, which have been identified as early maturing sugarcane varieties by the

government of Uttar Pradesh, and the SAP is higher than the SAP for general varieties by Rs.30-50 per metric tone for

these varieties of sugarcane. The areas on which sugarcane with high sugar content is being grown in the Cane Areas of

our sugar mills is detailed in the table below:

M.Nagar Disband

Total land under

cultivation of

% of land under

sugarcane cultivation

Total land under

cultivation of

% of land under sugarcane

cultivation

CoJ-64 17.20% CoJ-64 15.38%


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CoS-88230 10.94% CoS-88230 26.79%

CoS-8436 3.11% CoS-8436 12.33%

We are focused on using varieties of sugarcane, which have higher sugar content for crushing in our sugar mills. The

major varieties of sugarcane used in our sugar mills in Khatauli and Disband and the amount used in the last three Sugar

Years are as detailed in the table below:

Quantity (Thousand Metric Tonnes)

M.Nagar Disband 2002-03 2003-04 2004-05 2002-03 2003-04 2004-05CoJ-64 251.0 364.2 377.6 198.7 230.9 309.5

CoS-88230 293.8 230.8 266.8 150.0 222.2 352.2

CoS-8436 320.4 208.9 57.6 343.4 302.3 367.4

CoS-767 1075.9 1074.7 913.1 909.6 717.0 360.8

CoS-84212 40.2 3.0 3.0 3.0 3.0 2.2

CoS-8432 42.0 30.8 31.5 7.0 3.3 3.0

The percentage wise breakup of the use of sugarcane varieties in our sugar mills in the last three Sugar Years, are as

detailed in the table below:

Percentage of total sugarcane crushed in Sugar Year (in %)

M.Nagar Disband 2003 2004 2005 2003 2004 2005CoJ-64 15.0 21.0 22.0 12.0 16.0 22.0

Coos- 88230 17.0 13.0 15.0 10.0 12.0 25.0

CoS-8436 2.0 2.0 3.0 20.0 23.0 26.0

In the Sugar Year 2005, at Khatauli we received approximately 33.00% of the sugarcane crushed by the factory at thegate of our sugar mill and 67.00% of the sugarcane crushed was procured through 220 sugarcane collection and

purchase centers. In Disband unit, we received 47% of the total sugarcane crushed at the gate of our plant and 53%

from collection and purchase centers. At our Ram kola unit, we received 70% sugarcane at the gate of our sugar mill and

30% from the collection and purchase centers.


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WATER POLLUTIONWater pollution is a serious problem in India as almost 70% of surface water resources have serious pollution problem

and a growing number of ground water resources are already contaminated by various pollutants. In many cases these

sources have been rendered unfit for any useful consumption. This deterioration is more apparent in and around the

large urban areas. Inadequately treated industrial effluent is finding way in the water sources causing sever

contamination beyond repair through conventional means.

Rapid increase in the use of Agro-chemical and Pesticides in the agricultural fields has entered the water supply through

surface run-off or underground leaching. Adequate water pollution solutions are required for handling increased water

pollution.

Although, Industrial sector accounts for only 3% of annual water withdrawals in India, its contribution through the

effluent load is disproportionate to its consumption figures. These effluents are often contaminated with highly toxic

organic and inorganic substances which remain in the ecological systems for many years.

Although, Industrial sector accounts for only 3% of annual water withdrawals in India, its contribution through the

effluent load is disproportionate to its consumption figures. These effluents are often contaminated with highly toxic

organic and inorganic substances which remain in the ecological systems for many years.

Domestic wastewater is also one of the major pollution source causing 14 major river systems getting heavily polluted

from 50 million M3 of untreated sewage discharged into them each year. This also causes high incidence of water related

diseases. To date, only 14% of rural and 70% of urban inhabitants have access to adequate sanitation facilities.

New Integrated ApproachThe new integrated approach, we are trying to bring in for Water & Wastewater Treatment in association with US Filtercan be summarized in the following figure:


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Wastewater is used contaminated water. It includes substances such as human waste, food scraps, oils, soaps and

chemicals. In homes, this includes water from sinks, showers, bathtubs, toilets, washing machines and dishwashers.

Businesses and industries also contribute their share of used water that must be cleaned.

Wastewater also includes storm runoff. Although some people assume that the rain that runs down the street during a

storm is fairly clean, it isn't. Harmful substances that wash off roads, parking lots, and rooftops can harm our rivers and

lakes.

How Wastewater Affects Us

The water we use never really goes away. In fact, there never will be any more or any less water on earth than there is

right now, which means that all of the wastewater generated by our communities each day from homes, farms,

businesses, and factories eventually returns to the environment to be used again. So, when wastewater receives

inadequate treatment, the overall quality of the world's water supply suffers.

Locally, the amount of wastewater homes and communities produce, its characteristics, and how it is handled can greatly

impact residents' quality of life. Wastewater has the potential to affect public health, the local economy, recreation,

residential and business development, utility bills, taxes, and other aspects of everyday life

Domestic Wastewater

Although the word sewage usually brings toilets to mind, it actually is used to describe all types of wastewater generated

from every room in a house. Sewage varies regionally and from home to home based on such factors as the number and

type of water-using fixtures and appliances, the number of occupants, their ages, and even their habits, such as the


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types of foods they eat. However, when compared to the variety of wastewater flows generated by different

nonresidential sources, household wastewater shares many similar characteristics overall.

There are two types of domestic sewage: blackwater, or wastewater from toilets, and graywater, which is wastewater

from all sources except toilets. Blackwater and graywater have different characteristics, but both contain pollutants and

disease-causing agents that require treatment.

Non-domestic WastewaterNonresidential wastewater in small communities is generated by such diverse sources as offices, businesses, department

stores, restaurants, schools, hospitals, farms, manufacturers, and other commercial, industrial, and institutional entities.

Stormwater is a nonresidential source and carries trash and other pollutants from streets, as well as pesticides and

fertilizers from yards and fields.

Composition of Wastewater

Wastewater is mostly water by weight. Other materials make up only a small portion of wastewater, but can be present

in large enough quantities to endanger public health and the environment. Because practically anything that can be

flushed down a toilet, drain, or sewer can be found in wastewater, even household sewage contains many potential

pollutants. The wastewater components that should be of most concern to homeowners and communities are those that

have the potential to cause disease or detrimental environmental effects.

Major wastewater components can be liested as below:

Organisms

Pathogens

Organic Matter

Oil and Grease

Inorganics

Nutrients

Solids

Gases

Wastewater treatment is a multi-stage process to renovate wastewater before it reenters a body of water, is applied to

the land or is reused. The goal is to reduce or remove organic matter, solids, nutrients, disease-causing organisms and

other pollutants from wastewater. Each receiving body of water has limits to the amount of pollutants it can receive

without degradation. Therefore, each sewage treatment plant must hold a permit listing the allowable levels of BOD5,

suspended solids, coliform bacteria and other pollutants. The discharge permits are called NPDES permits, which stands

for the National Pollutant Discharge Elimination System.

Absolute

The micron rating of a filter. It indicates that any particle larger than a specific size will be trapped within the filter.

Absorption

When a solid takes up molecules into its structure.

Acid aerosol

Very small liquid or solid particles that are acidic and are small enough to become airborne.

Acid neutralizing capacity

Measure of the buffering capacity of water; the ability of water to resist changes in pH.


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Rain that has a flamboyantly low pH, due to contact with atmospheric pollutants such as sulphuric oxides.

Acidity

The quantitative capacity of water to neutralize a base, expressed in ppm or mg/L calcium carbonate equivalent. The

number of hydrogen atoms that are present determines this. It is usually measured by titration with a standard solution

of sodium hydroxide.

Activated coalThis is the most commonly used adsorption medium, produced by heating carbonaceous substances or cellulose bases in

the absence of air. It has a very porous structure and is commonly used to remove organic matter and dissolved gases

from water. Its appearance is similar to coal or peat. Available in granular, powder or block form; in powder form it has

the highest adsorption capacity.

Activated sludge

Oxygen dependent biological process that serves to convert soluble organic matter to solid biomass, that is removable by

gravity or filtration.

Active groups

Really fixed ions bolted on to the matrix of an ion exchanger. Each active group must always have a counter-ion of

opposite charge near itself.

Adsorption

Separation of liquids, gases, colloids or suspended matter from a medium by adherence to the surface or pores of a

solid.

Advanced oxidation process

One of several combination oxidation processes. Advanced chemical oxidation processes use (chemical) oxidants to

reduce COD/BOD levels, and to remove both organic and oxidisable inorganic components. The processes can completely

oxidise organic materials to carbon dioxide and water, although it is often not necessary to operate the processes to this

level of treatment.

A wide variety of advanced oxidation processes are available:

Chemical oxidation process using hydrogen peroxide, ozone, combined ozone & peroxide, hypochlorite, Fenton's

reagent, etc.

Ultra-violet (UV) enhanced oxidation such as UV/ ozone, UV/ hydrogen, UV/air

Wet air oxidation and catalytic wet air oxidation (where air is used as the oxidant)

Advanced water treatmentThe level of water treatment that requires an 85-percent reduction in pollutant concentration, also known as tertiarytreatment.

Advanced Wastewater TreatmentAny treatment of sewage water that includes the removal of nutrients such as phosphorus and nitrogen and a high

percentage of suspended solids.

Aerated lagoonA water treatment pond that speeds up biological decomposition of organic waste by stimulating the growth and activity

of bacteria, which are responsible for the degradation.

AerationTechnique that is used with water treatment that demands oxygen supply, commonly known as aerobic biological water

purification. Either water is brought into contact with water droplets by spraying or air is brought into contact with waterby means of aeration facilities. Air is pressed through a body of water by bubbling and the water is supplied with oxygen.


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Aeration tankA tank that is used to inject air into water.

AerobicA process that takes place in the presence of oxygen, such as the digestion of organic matter by bacteria in an oxidationpond.

Aerosol

Very small liquid or solid particles dispersed in air.

AffinityThe keenness with which an ion exchanger takes up and holds on to a counter-ion. Affinities are very much affected bythe concentration of the electrolyte surrounding the ion exchanger.

AgglomerationA process of bringing smaller particles together to form a larger mass.

Aggressive water

Water that is soft and acidic and can corrode plumbing, pipes and appliances.

AlgaeSingle- or multi-celled organisms that are commonly found in surface water, such as duckweed. They produce their own

food through photosynthesis. The algae population is divided up into green algae and blue algae, of which the blue algaeare very damageable to human health. Excessive algae growth may cause the water to have undesirable odors or tastes.

Decay of algae diminishes oxygen supplies in the water.

Algal bloomsPeriods of enlarged algal growths that affect water quality. Algal blooms indicate potentially hazardous changes in the

chemistry of water.

AliquotA measured portion of a sample taken for analysis. One or more aliquots make up a sample.

AlkalinityAlkalinity means the buffering capacity of water; the capacity of the water to neutralize itself. It prevents the water pHlevels from becoming too basic or acid. It also adds carbon to water. Alkalinity stabilizes water at pH levels around 7.

However, when the acidity is high in water the alkalinity decreases, which can cause harmful conditions for aquatic life.

In water chemistry alkalinity is expressed in ppm or mg/L of equivalent calcium carbonate. Total alkalinity of water is thesum of all three sorts of alkalinity; carbonate bicarbonate and hydroxide alkalinity.

Alluvium

Sediments deposited by erosion processes, usually by streams.

AnaerobicA process that takes place in the absence of oxygen, such as the digestion of organic matter by bacteria in a UASB-

reactor.

AnionA negatively charged ion that results from the dissociation of salts, acids or alkali's in solution.

Anode

A site in electrolysis where metal goes into solution as a cation leaving behind an equivalent of electrons to betransferred to an opposite electrode, called a cathode.

AquaticGrowing in water, living in water, or frequenting water.

AqueousSomething made up of water.

Aqueous solubility

The maximum concentration of a chemical that dissolves in a given amount of water.


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AquiferA layer in the soil that is capable of transporting a significant volume of groundwater.

AromaticsA type of hydrocarbon that contains a ring structure, such as benzene and toluene. They can be found for instance ingasoline.

AssimilationThe ability of water to purify itself of pollutants.

Assimilative Capacity

The capacity of natural water to receive wastewaters or toxic materials without negative effects and without damage toaquatic life or humans who consume the water.

Atom

The smallest unit of matter that is unique to a particular element. They are the ultimate building blocks for all matter.

Atomic numberA specific number that differs for each element, equal to the number of protons in the nucleus of each of its atoms.

Attenuation

The process of reduction of a compound's concentration over time. This can be through absorption, adsorption,degradation, dilution or transformation.

Attrition

The action of one particle rubbing against the other in a filter media or ion exchange bed that can in time causebreakdown of the particles.

Available chlorine

A measure of the amount of chlorine available in chlorinated lime, hypochlorite compounds, and other materials.

BackflowThe flow of water in a medium in a direction opposite to normal flow. Flow is often returned into the system by backflow,

if the wastewater in a purification system is severely contaminated.

Back PressurePressure that can cause water to backflow into the water supply when a user's waste water system is at a higher

pressure than the public system.

Back siphonageReverse seepage of water in a distribution system.

Backwashing

Reversing the flow of water back through the filter media to remove entrapped solids.

BacteriaMicroscopically small single-cell organisms, that reproduce by fission of spores.

TURBINE TECHNOLOGY

For human development to continue, we ultimately need to find sources of renewable or virtually inexhaustible energy.For the purpose, Turbines play a very important role. Turbine is a rotary engine that uses a continuous stream of fluid

(gas or liquid) to turn a shaft that can drive machinery. Different technologies are used by different kind of turbines forvarious applications.

Improvements in technology continue to make turbines cheaper and more efficient. Turbine technology has beenevolving over a long period of time. Further restructuring of the world turbine industry is likely in a persistentlychallenging market environment.


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STEAM TECHNOLOGY

Steam Turbine is a device for converting energy of high-pressure steam produced in a boiler into mechanical power

which can then be used to generate electricity. Steam turbines have been playing crucial role since The Industrial

Revolution. Today, steam turbines contribute to most the world's electricity.

Turbine Unit

Roughly, it is conical, steel shell enclosing a central shaft that bears a series of bladed disks arranged in a queue. The

blades are curved and extend radially outward from the rim of each disk. In some steam turbines the shaft is surrounded

by a drum to which the rows of blades are attached. Between each pair of disks is a row of stationary vanes attached to

the steel shell extending radially inward. Each set of stationary vanes and the bladed disk immediately next to it

constitutes a stage of the turbine; most steam turbines are multistage engines.

Working Principle

The basic principle of Turbine is to convert mechanical energy most probably into electrical energy. And the working

involves the force of pressurised steam that rotates the blades of turbine. The steam comes from a boiler it propels theblades to rotate, on exhaustion it is condensed and pumped back to the boiler to create a continuous cycle. Practically a

large steam turbine consists of several turbines.

Applications

These have been the most important prime-mover for power generation. Turbines mainly serve a variety of industrial

purposes comprising of large electric generators, pumps, and compressors in utilities and other process industries.

TURBINE COMPONENTS

Steam turbines are the most common and versatile prime movers used today. The capabilities and flexibility of

operation, as well as the range of power provided is unparalleled in today's power generation and process markets. The

components of Steam Turbine are:

Blades Rotors Casings Seals Nozzles.

Steam turbines consist of circularly distributed stationary blades called nozzles which direct steam on to rotating blades

or buckets mounted radially on a rotating wheel. In a steam turbine nozzles apply supersonic steam to a curved blade.

The blade whips the steam back in the opposite direction, simultaneously allowing the steam to expand a bit. A

stationary blade then redirects the steam towards the next blade. The process repeats until the steam is completely

expanded. The moving blades are mounted radially on the rotor. The stationary blades are mounted to the case of the

turbine. Typically, the blades are short in proportion to the radius of the wheel, and the nozzles are approximately

rectangular in cross section.

Several stages of expansions are obtained by using a series of nozzles and buckets, with the exhaust from the buckets of

one stage flowing directly into the nozzles of the following stage.


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A compact machine can be built economically with ten or more stages for optimum use of high pressure steam and

vacuum exhaust by mounting the wheels of a number of stages on a single shaft, and supporting the nozzles of all

stages from a continuous housing. Large axial turbines must be operated under such conditions that the exhaust steam

does not contain more than 10 to 13% of liquid since condensate droplets could seriously erode the high velocity nozzles

and blades. The moisture content of the exhaust is dependent upon the inlet steam pressure/temperature combination.

Special moisture removal stages may be incorporated in the design when the steam superheat temperature is limited.

TURBINE STANDERDS

B133.3 - 1981 (R1994) - Procurement Standard for Gas Turbine, Auxiliary Equipment

The purpose of this Stanford is to provide guidance to facilitate the preparation of gas turbine procurement

specifications. It is intended for use with gas turbines for industrial, marine, and electric power applications. 1.2 This

section covers auxiliary systems such as lubrication, cooling, fuel (but not its control), atomizing, starting, heating-

ventilating, fire protection, cleaning, inlet, exhaust, enclosures, couplings, gears, piping, mounting, painting, and water

and steam injection.

B133.7M - 1985 (R1992) - Gas Turbine Fuels

Gas turbines may be designed to burn either gaseous or liquid fuels, or both with or without changeover while under

load. This Standard covers both types of fuel. Utility applications. Included are practices for making field sound

measurements and for reporting field data. This standard can be used by users and manufacturers to write specifications

for procurement, and to determine compliance with specification after installation. Information is included, for guidance,

to determine expected community reaction to noise.

B133.8 - 1977 (R1989) - Gas Turbine Installation Sound Emissions

This standard gives methods and procedures for specifying the sound emissions of gas turbine installations for industrial,


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pipeline, and utility applications. Included are practices for making field sound measurements and for reporting field

data. This standard can be used by users and manufacturers to write specifications for procurement, and to determine

compliance with specification after installation. Information is included, for guidance, to determine expected community

reaction to noise.

B133.9 - 1994 - Measurement of Exhaust Emissions from Stationary Gas Turbine Engines

This standard provides guidance in the measurement of exhaust emissions for the emissions performance testing (source

testing) of stationary gas turbines. Source testing is required to meet federal state, and local environmental regulations.The standard is not intended for use in continuous emissions monitoring (CEM) although many of the on line

measurement methods defined may be used in both applications. This standard applies to engines that operate on

natural gas and liquid distillate fuels.

B133.10 - 1981 (R1994) - Procurement Standard for Gas Turbine

The intent of this Standard is to provide a means for rapid communication between the user and manufacturer relative to

requests for proposals by the user and the tendering of proposals by the manufacturer. The use of the restructured

forms contained in this Standard will facilitate the preparation of this information and ensure consistency of submission

by the various manufacturers who may be requested to submit proposals. The forms cross-reference the appropriate

information contained in the other sections of the Gas Turbine Procurement Standard.

B133.11 - 1982 (R1994) - Procurement Standard for Gas Turbine, Shipping and Installation

The intent of this Standard is to provide a review of shipping and installation items that should be considered in the

preparation of procurement specifications. The shipping sections of this Standard provide guidelines which the user may

find helpful in preparing a specification applicable to his specific requirements. In the preparation of the installation and

startup sections, it was found that there are a variety of suitable methods to achieve the same ultimate end, as

employed by the various manufacturers. Because of this diversity, the user is advised to consult with the manufacturer

on his use and interpretation of this Standard. This Standard should be useful in providing guidelines for items that

should be included in the user's more detailed specifications, applicable to his specific requirements.

B133.16 - 2000 - Procurement Standard for Gas Turbine, Marine Applications

(a) This procurement standard provides guidance and criteria for gas turbine systems used in marine applications. It

supplements the general gas turbine procurement standards presented in Acmes B133 series.

(b) In utilizing this procurement standard, the user should ensure that only those requirements considered necessary for

his/her application are utilized. This is a general document and its intent is to cover most marine applications. Therefore,

there is an inclusion of data for most varied applications, which may not be applicable to a specific application.

(c) Marine applications are defined as gas turbines serving as prime movers for:

Propulsion Electric power generation Gas transmission or compression

Cargo pumps

Water flood pumps(d) Emphasis should be made for machinery to be classed by International Maritime Organization (IMO) codes in the

following areas of service:

Emergency duty Essential service


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Nonessential service Process service Above or below decks

B133.12 - 1981 (R1994) - Procurement Standard for Gas Turbine, Maintenance and Safety

TDP-1-1998 - Recommended Practices for the Prevention of Water Damage to Steam Turbines Used for

Electric Power Generation

B133.4 - 1978 (R1997) - Gas Turbine, Control and Protection Systems.

TURBINE APPLICATION

Energy is an integral part of the biosphere. Technology and science have created new opportunities to conserve and

optimize the resources of energy. The use of different energy technology options are key to diversifying the energy mix

for conserving energy and reducing environmental impacts of energy production and use.

Turbines play an important role in increasing energy efficiency and using a mix of sources, that support energy security,

conservation, economic growth and environmental protection. Turbines canalize energy in various forms. Hence, they

find a wide range of applications:

Steam Turbine Applications

Steam turbines are devices which convert the energy stored in steam into rotational mechanical energy. These machines

are widely used for the generation of electricity in a number of different cycles, such as:

Ranking cycle

Reheat cycle

Regenerative cycle

Combined cycleUtility Steam Turbine Applications

Applications for utility Steam Turbines are applied for control of straight condensing, reheat and non-reheat steam

turbines up to 300MW. These upgrades may include integrated generator control for generator protection and excitation/

AVR upgrades, utilizing the latest commonly available industry-standard digital equipment.

Industrial Steam Turbine Applications

Applications of Industrial Steam Turbines cover all straight condensing, non-condensing, and automatic extraction steam

turbines. Specific design features are incorporated to address control issues often unique to process plants including

paper mills, oil refineries, chemical plants, and other industrial applications, generator and mechanical drive.

Gas Turbine ApplicationsGas turbine is a versatile source of shaft or propulsion power in a growing number of applications. In the gas industry,

turbine applications span the range from small industrial turbines to aeroderivatives to large industrial turbines. The gas

turbine applications are in the areas of power generation, marine transportation and power generation, and the

process/petrochemical industries. Large gas turbine engines have also been used to provide electric power for oilfield

operations but large turbines still require an electric transmission and distribution system because, in many cases, they

produce more power than the local site can use.


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Wind Turbines

Wind turbines convert the kinetic energy of the wind to mechanical power. This mechanical power can be used by a

generator to produce electricity.Wind turbines are used around the world for many applications. Wind turbine use ranges

from homeowners with single turbines to large wind farms with hundreds of turbines providing electricity to the power

grid. Applications include networking within wind parks and between wind parks which require longer distances than

twisted pair copper lines can provide. Data communications alongside noisy power distribution lines with fiber optics

ensures data integrity, since fiber optics is inherently immune toelectromagnetic interference.

Water Turbine

A water turbine is a rotary engine that takes energy from moving water. Turbine selection is based mostly on the

available water head, and less so on the available flow rate. In general, impulse turbines are used for high head sites,

and reaction turbines are used for low head sites. Turbines are well-adapted to wide ranges of flow or head conditions,

since their peak efficiency can be achieved over a wide range of flow conditions.

TURBINE GROSSARY

Adiabatic

Insulated; occurring with no external heat transfer.

Aspect Ratio

The ratio of the blade height to the chord.

Axial Chord

The length of the projection of the blade, as set in the turbine, onto a line parallel to the turbine axis. It is the axial

length of the blade.

Axial Solidity

The ratio of the axial chord to the spacing.

Blade Exit AngleThe angle between the tangent to the camber line at the trailing edge and the turbine axial direction.

Blade Height

The radius at the tip minus the radius at the hub.

Blade Inlet Angle:

The angle between the tangent to the camber line at the leading edge and the turbine axial direction.

Blower

A rotary machine that produces a low-to-moderate pressure rise in acompressible fluid (usually air), usually incorporated

in a duct. See "fan" and"compressor."

Bucket

Same as rotor blade.

Camber Angle:

The external angle formed by the intersection of the tangents to thecamber line at the leading and trailing edges. It is

equal to the sum of the angles formed by the chord line and the camber-line tangents.


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Camber Line

the mean line of the blade profile. It extends from the leading edge to the trailing edge, halfway between the pressure

surface and the suction surface.

CBE

Compressor-burner-expander, or the "simple" gas-turbine "cycle."

CBEXCompressor (heat exchanger)-burner-expander-heat exchanger, or the"regenerated," "recuperated," or "heat-

exchanger" gas-turbine "cycle."

Chord

The length of the perpendicular projection of the blade profile onto the chord line. It is approximately equal to the linear

distance between the leading edge and the trailing edge.

Chord Line

If a two-dimensional blade section were laid convex side up on a flatsurface, the chord line is the line between the points

where the front and the rear of the blade section would touch the surface.

Compressor

A rotary machine that produces a relatively high pressure rise (pressureratios greater than 1.1) in a compressible fluid.

Deflection

The total turning angle of the fluid. It is equal to the difference between the flow inlet angle and the flow exit angle.

Deviation Angle

The flow exit angle minus the blade exit angle.

Diffuser

Adduct or passage shaped so that a fluid flowing through it will undergo an efficient reduction in relative velocity and will

thereforeincrease in (static) pressure.

Effectiveness

A term applied here to define the heat-transfer efficiency of heatexchangers.

Efficiency

Performance relative to ideal performance. There are many types ofefficiency requiring very precise definitions (see

section 2.8).

Entropy

A property of a substance defined in terms of other properties. Its change during a process is of more interest than its

absolute value. In an adiabatic.

Process, the increase of entropy indicates the magnitude of losses occurring. Expander: a rotary machine that produces

shaft power from a flow of compressible fluid at high pressure discharged at low pressure. In this book the only types of

expander treated are turbines.

Flow Exit Angle

The angle between the fluid flow direction at the blade exit and the machine axial direction.


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Flow Inlet Angle

The angle between the fluid flow direction at the blade inlet and the machine axial direction.

Head

The height to which a fluid would rise under the action of an incremental pressure in a gravitational field.

Hub

The portion of a turbomachine bounded by the inner surface of the flow annulus.

Hub-Tip Ratio

Same as hub-to-tip-radius ratio.

Hub-to-tip-radius ratio: the ratio of the hub radius to the tip radius.

Incidence Angle

The flow inlet angle minus the blade inlet angle.

Intensive Property

A property that does not increase with mass; for instance, the pressure and temperature of a body of material do not

double if an equal mass at the same temperature and pressure is joined to it. (The energy, on the other hand, would

double.)

Intercoolers

Heat exchangers that cool a gas after initial compression and beforesubsequent compression.

Isentropic

Occurring at constant entropy.

WHAT IS GEAR

Basically, gear is a toothed wheel designed to transmit motion or to change speed or direction to another toothedcomponents or gear. Gear and its teeth are designed in a manner to minimize wear, vibration and noise, and to

maximize the efficiency of transmission.

Due to difficulty in designing high power machineries mechanical engineers sometimes rely on electronic control and

toothed belts. Whatever may be the case, gears are the optimal medium for high accuracy and low energy loss, even for

high power machinery.

According to the meshing of toothed components gears are categorized into several types like, circular spur gears, rack

and pinion spur gears, and worm gears. Helical and herringbone gears utilize curved teeth for efficient, high-capacity

power transmission. Worm gears, driven by worms transmit motion between non-intersecting right-angle axes.

HOW GEAR WORKSLaw of gearing

In working more than one pair of teeth are always in sliding contact and the rotation brings successive pairs into contact.

And the pressure between the two sliding surfaces in normal to their common tangent. This maintains the ratio of

angular velocities of the two gears to certain constant. This is the Law of Gearing. Full satisfaction of the Law of Gearing

ensures the motion to be smooth, quiet and free of vibration. If not satisfied, the gears will shake and vibrate as they

rotate, there will be loss in power. The tooth profiles of gears that satisfy the Law of Gravity is called conjugate.


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Kinetics

Number of teeth per gear and the arrangement of teeth on the gear surface determine the torque and direction. The

gear that transmits motion or directs motion is known as driver, and the other is known as driven.

If two gears have the same number of teeth then same amount of rotation is transferred to the driven gear, as one turn

of driver gear causes the driven gear to turn once. Difference in number of teeth of the two gears in contact brings

change in amount of rotation in the driven gear. If the driver gear is smaller or has less number of teeth, the driven gear

will receive less rotation but amplified torque.

For a single pair of gears where the output shaft rotates at a different speed than that of the input shaft, the torque

applied on the output shaft drives the load. The size of the teeth on the pinion should be the same as the size of the

teeth on the wheel. This module must be common to both the gears. Pitch circles contact one another at the pitch point

and the pinion's pitch line velocity must be identical to the wheels pitch line velocity. And at the pitch point develops a

tangential component of action-reaction due to contact between the gears.

The only way that the input and output shafts of a gear pair can be made to rotate in the same sense is by interposition

of an odd number of intermediate gears. These do not affect the speed ratio between input and output shafts. Such a

gear train is called a simple train. If there is no power flow through the shaft of an intermediate gear then it is an idler

gear.

OVERVIEW

Technology gives direction to innovation

Spur gear represents gear technology in the most fundamental form, i.e., contact of teeth (gear mesh), speed of rotation

and change in direction. Spur gears are widely used in instruments and control systems.

The essential features of a gear mesh are:

Center distance.

The pitch circle diameters (or pitch diameters).

Size of teeth (or module).

Number of teeth.

Pressure angle of the contacting involutes.

Constancy of angular velocities or proportionality of position transmission is a prerequisite for gears. High-speed and/or

high-power gear trains also require transmission at constant angular velocities in order to avoid severe dynamic

problems. "A common normal to the tooth profiles at their point of contact must, in all positions of the contacting teeth,

pass through a fixed point on the line-of-centers called the pitch point. (Law of Gearing)" It ensures proper and

maximum transfer of speed and direction.

GEAR STANDERDSStandards in gears is relational to certain values of parameters in figures, like length, mass, angle etc. Officially certified

measuring instruments must be checked for accuracy using such standards. Using a standard has some advantage, the

primary being an agreement to the degree of quality of gears among trading partners. They can pass on that

understanding of quality to customers.


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Metric Standards

Metric roller chain and sprockets are classified according to ISO standards 606. The number correlates to pitch in 1/16"

increments, expressed in millimeter units. An ISO 12 sprocket mates with a chain with " or 19.05mm, pitch. Number of

teeth for a specified pitch will determine sprocket size and drive ratio.

The SAE Aerospace Standard (AS) establishes the standard modules for aerospace metric involute gear teeth and

establishes the tooth dimensions of aerospace metric involute gear teeth in terms of the conjugate rack type cutter

whose counterpart reference profile is called the basic rack profile of the generated gear, having the tooth dimensionsexpressed in terms proportional to the module.

SAE also covers established metric manufacturing tolerances applicable to corrosion and heat resistant steel, iron alloy,

titanium and titanium alloy bars and wire ordered to metric dimension.

British Standards

English standards are classified according to ANSI number designations. Sprockets engage chains in many different

power transmission and conveyor system. English roller chain and sprockets are categorized according to ANSI B 29.1M.

The number can be used to identify pitch. The first digits identify the pitch in 1/8" increments and the last digit is 0 for

standard proportions, 1 for lightweight chain and 5 for roller less bushed chain.

AGMA Standards

AGMA is an accredited standards development organization with the American National Standard Institute that produces

quality consensus standards designed to meet the demand of domestic and the international markets. AGMA hold the

position of Secretariat of ISO Technical Committee and promotes a better understanding of the concerns of American

gear manufacturers, as well as wider acceptance of AGMA standards. The association also promotes the dissemination of

research and development work conducted throughout the industry related to gear design and manufacture at major

meetings and seminars.

The standard method for determining induced bending stresses in bevel gears comes from the AGMA. Gears shall be

designed in accordance with the AGMA standards 211.02 and 221.02. Bearings shall be ball or roller type and shall be

selected in accordance with AGMA standards 265.01. The aerator shall be stainless steel of adequate size to transfer the

applied torque and to resist bending. To maximize strength and performance the rotor shall be one piece moldedfiberglass of monolithic construction and internally reinforced with a steel structure.

AGMA gear quality numbers range from 3 to 15 and identify the accuracy level of the tooth element tolerances that are

permissible in the manufacture of each particular gear in terms of its specialized use. The permissible tolerances for the

different quality numbers may be obtained from AGMA standards, which show the type of gear and the permissible

tolerances and inspection dimensions.

GEAR APPLICATIONGear are omnipresent when it involves rotation and speed & motion transfer. With the advancements in science andtechnology gears have got new platforms of applications. They are inevitable in running of machines and vehicles. There

are a number of different types of gears used in different industries depending upon their properties and usage. They can

be classified under automotive gears, mining gears, wind turbines, bicycle gears, mill heads, instrumentation gears,

conveyor system, marine gears etc.

Gears are used for two basic purposes; increase or decrease of rotation speed and increase or decrease of power or


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torque. Torque is a measure of a force to produce torsion and rotation about an axis. To increase speed and reduce

torque a large drive gear is coupled to a smaller driven gear. To reduce speed and increase torque a small gear turning a

larger gear is used. They are also used for enhancement for positioning systems.

Gears, as per their application in various fields can be categorized as: Gears used in Agro Industry, Automotive Gears,

Conveyor Systems, Instrumentation Gears, Marine Gears, Mill heads, Mining Gears, Power Station Gears, Wind Turbine,

etc.

GEAR ACCESSORIESGears never work in isolation. For placement, support and running it requires gearboxes, gear motors, axle, transfer

cases, winches, etc. These are called gear accessories. A wide range of gear accessories control the working and normal

functioning of the gears.

Major gear accessories are: Geared Actuator, Gearmotors, Axle, Power Take-Offs, Right Angle Drives-Reversing, Transfer

Cases, Winches, Gearbox Housings, Gear Couplings, Gear Blank, Mandrel, etc.

There are four basic types of bevel gears-

Straight bevel gears:

These gears have a conical pitch surface and straight teeth tapering towards an apex

Zerol bevel gears:

This is similar to a bevel gear except the teeth are curved. In essence, Zerol Bevel Gears are Spiral Bevel Gears

with a spiral angle of zero

Spiral bevel gears:

The teeth are curved teeth at an angle allowing too contact to be gradual and smooth

Hypoid bevel gears:

These gears are similar to spiral bevel except that the pitch surfaces are hyperboloids rather than cones. Pinion

can be offset above or below gear center, thus allowing larger pinion diameter, and longer longer life and

smoother mesh, with additional ratios eg 6:1, 8:1, 10:1

The design of bevel gears results in thrust forces away from the apex. With the bearing limitations the gears have to be

carefully designed to ensure that they are not thrown out of alignment as they are loaded.

Straight bevel gears

These are gears cut from conical blanks and connect intersecting shaft axes. The connecting shafts are generally at 90o

and sometimes one shaft drives a bevel gear which is mounted on a through shaft resulting in two output shafts. The

point of intersection of the shafts is called the apex and the teeth of the two gears converge at the apex.
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Zerol Bevel Gears

The advantage of Zerolbevel gears compared to straight bevel gears is that operate with a smooth localised point contact

as opposed to a line contact enabling smoother operation with low vibration levels and higher speeds. Because there is

not spiral angle and no additional developed thrust these gears can be used as direct replacements for straight bevel

gears.

Spiral Bevel Gear

These are produced using a spiral gear form which results in a smoother drive suitable for higher speed higher loaded

applications. Again satisfactory performance of this type of gear is largely dependent upon the rigidity of the bearings

and mountings.

Hypoid Bevel Gear

Hypoid gears are best for the applications requiring large speed reductions with non intersecting shafts and those

applications requiring smooth and quiet operation. Hypoid gears are generally used for automotive applications.

The spur gear is is simplest type of gear manufactured and is generally used for transmission of rotary motion between

parallel shafts. The spur gear is the first choice option for gears except when high speeds, loads, and ratios direct

towards other options. Other gear types may also be preferred to provide more silent low-vibration operation. A singlespur gear is generally selected to have a ratio range of between 1:1 and 1:6 with a pitch line velocity up to 25 m/s. The

spur gear has an operating efficiency of 98-99%. The pinion is made from a harder material than the wheel. A gear pair

should be selected to have the highest number of teeth consistent with a suitable safety margin in strength and wear.

The minimum number of teeth on a gear with a normal pressure angle of 20 desgrees is 18.

Designing spur gears is normally done in accordance with standards the two most popular series are listed under

standards above: The notes below relate to approximate methods for estimating gear strengths. The methods are really


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only useful for first approximations and/or selection of stock gears (ref links below). Detailed design of spur and

helical gears is best completed using the standards. Books are available providing the necessary guidance. Software is

also available making the process very easy.

Helical gears are similar to spur gears except that the gears teeth are at and angle with the axis of the gears. A helical

gear is termed right handed or left hand as determined by the direction the teeth slopes away from the viewer looking at

the top gear surface along the axis of the gear. ( Alternatively if a gear rest on its face the hand is the direction of slope

of the teeth) . Meshing helical gears must be of opposite hand. Meshed helical gears can be at and angle to each other

(up to 90o ). The helical gear provides a smoother mesh and can be operated at greater speeds than a straight spur

gear. In operatation helical gears generate axial shaft forces in addition to the radial shaft force generated by normal

spur gears.

In operation the initial tooth contact of a helical gear is a point which develops into a full line contact as the gear rotates.

This is a smoother cycle than a spur which has an initial line contact. Spur gears are generally not run at peripheral

speed of more than 10m/s. Helical gears can be run at speed exceeding 50m/s when accurately machined and balanced

A helical gear train with parallel axes is very similar to a spur gear with the same tooth profile and proportions. The

primary difference is that the teeth are machined at am angle to the gear axis.

Designing helical gears is normally done in accordance with standards the two most popular series are listed under

standards above: The notes below relate to approximate methods for estimating gear strengths. The methods are really

only useful for first approximations and/or selection of stock gears (ref links below). Detailed design of spur and

helical gears should best be completed using the standards. Books are available providing the necessary guidance.

Software is also available making the process very easy.

Crossed Helical Gears

When two helical gears are used to transmit power between non parallel, non-interesecting shafts, they are generally

called crossed helical gears. These are simply normal helical gears with non-parallel shafts. For crossed helical gears to

operate successfully they must have the same pressure angle and the same normal pitch. They need not have the samehelix angle and they do not need to be opposite hand. The contact is nor a good line contact as for parallel helical gears

and is often little more than a point contact. Running in crossed helical gears tend to marginally improve to area of

contact

Designing crossed helical gears is normally done in accordance with standards the two most popular series are listed

under standards above: The notes below relate to approximate methods for estimating gear strengths. The methods are

really only useful for first approximations and/or selection of stock gears (ref links below). Detailed design of spur and

helical gears should best be completed using the standards. Books are available providing the necessary guidance.

Software is also available making the process very easy.

A worm gear is used when a large speed reduction ratio is required between crossed axis shafts which do not intersect. A

basic helical gear can be used but the power which can be transmitted is low. A worm drive consists of a large diameter

worm wheel with a worm screw meshing with teeth on the periphery of the worm wheel. The worm is similar to a screw

and the worm wheel is similar to a section of a nut. As the worm is rotated the wormwheel is caused to rotate due to the

screw like action of the worm. The size of the worm gearset is generally based on the centre distance between the worm


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and the wormwheel.

If the worm gears are machined basically as crossed helical gears the result is a highly stress point contact gear.

However normally the wormwheel is cut with a concave as opposed to a straight width. This is called a single envelope

worm gearset. If the worm is machined with a concave profile to effectively wrap around the wormwheel the gearset is

called a double enveloping worm gearset and has the highest power capacity for the size. Single enveloping gearsets

require accurate alignment of the worm-wheel to ensure full line tooth contact. Double enveloping gearsets require

accurate alignment of both the worm and the wormwheel to obtain maximum face contact.

Worm gears provide a normal single reduction range of 5:1 to 75-1. The pitch line velocity is ideally up to 30 m/s. The

efficiency of a worm gear ranges from 98% for the lowest ratios to 20% for the highest ratios. As the frictional heat

generation is generally high the worm box is designed disperse heat to the surroundings and lubrication is and essential

requirement. Worm gears are quiet in operation. Worm gears at the higher ratios are inherently self locking - the worm

can drive the gear but the gear cannot drive the worm. A worm gear can provide a 50:1 speed reduction but not a 1:50

speed increase....(In practice a worm should not be used a braking device for safety linked systems e.g hoists. . Some

material and operating conditions can result in a wormgear backsliding )

The worm gear action is a sliding action which results in significant frictional losses. The ideal combination of gear

materials is for a case hardened alloy steel worm (ground finished) with a phosphor bronze gear. Other combinations are

used for gears with comparatively light loads.

Involute gears have a tooth shape that is tolerant of variations in the distance between the axes, to ensure smooth

running of the gears. The velocity ratio of the gears does not depend on the exact spacing of the axes, but is fixed by the

number of teeth or by pitch diameters. Increasing the distance above its theoretical value makes the gears run easier,

since the clearances are larger. This also increases the backlash. Rack type cutters generate involute gears.

On an involute gear tooth, the contact point starts closer to one gear, and as the gear spins, the contact point moves

away from that gear and towards the other. The pitch diameter is the effective contact diameter. As the gear turns, the

contact point slides up onto the thicker part of the top gear tooth. Thus, pushes the top gear ahead. As the teethcontinues to rotate, the contact point moves further away going outside the pitch diameter. Then the contact point starts

to slide onto the skinny part of the bottom tooth, subtracting a little bit of velocity from the top gear to compensate for

the increased diameter of contact. Thus, the involute gear tooth produces a constant ratio of rotational speed.

Involute spur gears have the invaluable ability of providing conjugate action when the gears' center distance is varied

either deliberately or involuntarily due to manufacturing or mounting errors.

Bevel Gears

Spur Gears

Helical Gears

Worm Gears

Involute Gears

Crown Wheel and Pinion

Differential Gears

Fine Pitch Gears

Girth Gears

Hardened and Ground Gears

Herringbone Gears
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Miter Gears

Non-Involute Gears

Pinion Gears

Precision Gears

Rack Gears

Idler Gear

Planetary Gear

Ground Gear

Face Gear

Internal Gears

Cycloidal Gears

External Gear

Winch Gears
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aryan (turbine technolgy

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