Combined Heat and Power

I just completed a webinar refresher on combined heat and power systems.  If you don’t know or have never heard of a combined heat and power system just picture a jet engine that doesn’t move.  The heat coming out of the exhaust is used to make steam.  On the other end, the rotating fan is connected by shaft to a generator and produces power.  Another type of system uses a boiler to make steam.  The waste heat from the flue gas is reclaimed using a heat exchanger to make additional steam.  The primary steam is then routed to a turbine which in turn, turns a generator and makes electric power.  The secondary steam is sent to whatever process will utilize the steam, such as an absorption chiller, for air conditioning.  Most CHP systems are well suited for industrial applications where large quantities of steam and power are required. However, smaller systems are also made and suited for light commercial applications.  Advertised efficiencies run between 70 and 75% depending on manufacturer.  These machines are fairly reliable and so, in the course of my practice, I have only encountered one instance where a gas turbine (jet engine) failed to perform as required.  Two engines were installed in a university setting and used to provide steam and power to various campus buildings.  Shortly after installation, it was noted that one of the gas turbines was not performing as warranted by the manufacturer.  After review of the design of the entire system, it was determined that one of the gas turbines was not performing according to its design specifications. The claim was finally resolved when the manufacturer agreed to replace the machine with a new gas turbine.

Veteran’s Day Appreciation

The above photo of a special dessert was given to me after a Veteran’s Day dinner at a local Restaurant.   While I am very appreciative of the gesture, I would also like to say thank you to those who are appreciative of those of us who have proudly served.

Lathe Chuck Injury Due to Faulty Lathe Operation

One of the more interesting cases that we have been assigned had to do with a personal injury suffered as a result of an airborne chuck.  The injury occurred after an individual purchased a chuck and spindle adapter for use with a Shop Smith lathe that was manufactured back in the late 40s or early 50s (see photos below).

 

Chuck and pin wrench used to tighten chuck onto spindle adapter

Antique Shop Smith Lathe

After attaching the spindle and mounting the chuck, the owner started the lathe and tested the operation.  Everything went well until the machine was turned off.  As soon as it was, the spindle shaft stopped but the chuck kept spinning and spun itself off the adapter.  The chuck went airborne, bounced off parts of the lathe and hit the owner’s hand causing severe injury.  The investigation came about as a result of the owner’s allegation of a defective product, ie, the chuck was defectively designed and had no means of stopping if it separated from the spindle adapter.  The chuck is designed to be tightened against the spindle adapter using special wrenches.  According to the owner, he claimed that he “tightened the chuck as tight as he could” before starting the lathe.  During the examination of the lathe, the lathe was started and run without the chuck attached.  When the lathe was turned off, it immediately became clear that there was something wrong when the spindle shaft did NOT coast to a stop.  It was also clear that the abrupt stop provided the torque necessary to cause the chuck to spin off the spindle adapter.  In addition, it was also noted that if the chuck was to stay attached to the spindle adapter, the torque applied during tightening had to be greater than the torque causing separation.  After working the math, it was determined that the owner could not have tightened the chuck was much as he claimed.  As a result, it was further determined that the owner unfortunately caused his own injury by ignoring the problem of abrupt stopping of the spindle shaft.  The lawsuit was subsequently dismissed.