DESIGN AND LAYOUT PROBLEM FOR A COMBINED GAS-VAPOR

POWER PLANT

General
The power plant will consist of two identical controlled-extraction 4000-
Kw turbine generators. Steam will be extracted from each turbine for process
use and for a deaerator. Steam also will be extracted at a lower pressure for
use in a surface type of feed water heater. A by-pass, pressure reducing station
will provide process steam when the turbines are not in use. All process steam
become contaminated and is wasted.
Four identical boiler are to supply the plant steam requirements (two
boilers to carry maximum requirements of one turbine). The boiler room will be
separate from the turbine hall, and in addition to the boilers; will contain one fan
(forced draft) per boiler, coal handling equipment and ducts.
Equipment to be located in the turbine hall: turbine generators,
deaerators, low-pressure heaters, boiler feed pumps, condensers, circulating
pumps, air ejectors condensate pump, turbine control board, overhead crane.

Data

Steam Power Plant

Turbine generators: 96% mechanical efficiency, 95% generator
efficiency, design point is 5/4 load, 40-psia automatic extraction (for surface
type feed water heater) and 10-psia non-automatic extraction pressures (for
process use and deaerators). Steam conditions 400 psig, 550 oF, and 2 in. Hg.
Process Steam: 30000 lb per hour for the plant. Show connection for
safety valve after PRV.
Boilers: Single settings, Minimum distances, 10-ft between boilers, 18-ft
aisle in front of boiler setting for control board and coal handling equipment 6-
ft aisle behind boiler. Air enters at 80 oF and gases leave at 40 oF. Ash removal
from feet below aisle in back of boilers. Boiler rating 250%, Franklin County,
Illinois coal with 35% excess air.
Force draft fans. 2.5 in, water static pressure.
Condensers: Circulating water enters at 80oF, surface type, 2-pass, 18-
gage ¾ in. tubes, 6-fps water velocity, 75% cleanliness factor. Design
condenser for 2 in. Hg abs, at 4000 kW, with steam extraction from the turbines
for feed heating only. Condenser axis will be perpendicular to turbine axis.
Air Ejectors: 200 lb per hour of steam required for each unit; 1000 Btu
per lb available for feed heating in air-ejector condensers.
Condensate Pumps: Two per condenser, 100% spare, centrifugal,
motor-driven, 150-ft total head. Allow 10% extra capacity based on the low
obtained for the condenser.
 Boiler Feed Pump: four pumps for the plant, 100% spare, centrifugal,
motor-driven, 325-psig discharge pressure. Allow 10% extra flow to take care
of emergencies.

Deaerators: two for entire plant, 100% spare, Make-up waters

deaerators at 60oF.
Surface Heaters: One per turbine generator, no spare, 5 oF TD, drains
cascaded to condenser. Design on basis of heat balance data.
Turbine Control Board: One for both turbines, 8 ft high by 14 ft long, and
5 ft deep (to allow for switchgear) with 4-ft clearance.
Piping: of sufficient strength for pressures and temperatures involved,
flanged. Water piping on pump discharges designed for velocity of about 450
fpm and less than 200 fpm on suction. 10% pressure drop in low-pressure bleed
line and 5% in high-pressure bleed line. Use a hand by-pass around automatic
PRV.
Stack: To develop 1-in. static draft.

Requirements:
a. Calculate heat balance for turbine hall and make schematic
diagram with flows, temperatures, and enthalpies.
b. Calculate boiler size and select boiler
c. Calculate surface requirements of condenser and select condenser
d. Calculate size of, and select, deaerators and surface heaters
e. Calculate size of boiler feed pumps and select pumps
f. Calculate size of condensate pumps
g. Make a plan layout of equipment. Show major dimension of
equipment and building, and show centerline dimensions.
h. Layout main steam pipe (single line) on drawing and show all
fittings.
i. Calculate pipe sizes for main steam lines
j. Write a bill of material for the main steam piping
k. Calculate the maximum friction loss in the steam piping from boiler
to turbine
l. Calculate the fan horsepower and select a fan
m. Determine the diameter and height of the stack
n. Draw and end view of the plant showing equipment and piping
o. Layout the water piping from the deaerator of the boiler, showing all
fittings, and includes and automatic valve for feed water regulation
p. Determine the friction loss of the water piping
q. Determine cost of building based on 50cents per cu. ft.
 A. CALCULATE HEAT BALANCE FOR TURBINE HALL AND MAKE
SCHEMATIC DIAGRAM WITH FLOWS, TEMPERATURES, AND
ENTHALPIES.

4000 KW @ 400 psig

0.101325 𝑀𝑃𝑎
𝑃1 = (400 𝑝𝑠𝑖𝑔 + 14.7𝑝𝑠𝑖) ( ) = 2.86 𝑀𝑃𝑎 ≈ 2.9 𝑀𝑃𝑎
14.7 𝑝𝑠𝑖

The value is 73.5% ; Engine Efficiency (Fig 11-15, Morse)

2.9 MPaa @ 290 0C

For the Rankine Cycle Ratio

For Emg:

Emg = (Mechanical Efficiency)(Generator Efficiency)

= (0.96)(0.95)

Emg = 91.2%
 For RCR or Stage Efficiency :

Engineefficiency
RCR 
Emg

0.735
= 𝑥 100%
0.912
RCR = 80.59%

At Point 1 : w/ 400 psig @ 550 0F

P1 = 2.9 MPaa

T1 = 290 0C

From Steam Table ( Table 3)

For h1:
𝒌𝑱
𝒉𝟏 = 𝟐𝟗𝟕𝟏. 𝟏
𝒌𝒈

For S1:
𝒌𝑱
𝑺𝟏 = 𝟔. 𝟓𝟏𝟒
𝒌𝒈 ͦ𝐊

A point 2: w/ h1 = h2 and 4% pressure drop

𝑃2 = 𝑃1 − (4%)(𝑃1 )

= 2.9 – (0.04)(2.9)

𝑷𝟐 = 𝟐. 𝟕𝟖 ≈ 𝟐. 𝟖 𝑴𝑷𝒂

With h1 = h2;
h2 = 2971.1 kJ/kg
Solving For S2:
From steam table 3, 𝑷𝟐 = 𝟐. 𝟖 𝑴𝑷𝒂, 𝑻 = 𝟐𝟗𝟎˚𝑪

𝒌𝑱
𝑺𝟐 = 𝟔. 𝟓𝟑𝟒𝟖
𝒌𝒈 ˚𝑲
 𝒌𝑱
At Point 3: w/ P3 = 0.28 MPa and S2 = S3’ = 6.5348 𝒌𝒈 ˚𝑲

Solving for h3’:

𝒌𝑱
𝑆2 = 𝑆3′ = 6.5384 𝒌𝒈 ˚𝑲

𝒌𝑱
From steam table 2, @ 0.28 MPa and with 𝑆2 = 𝑆3′ = 6.5384 𝒌𝒈 ˚𝑲

hf = 551.48 kJ/kg sf = 1.6472 kJ/kg-K

hfg = 2170.7 kJ/kg sfg = 5.3677 kJ/kg-K

′ ′
𝑆3′ = 𝑆𝑓3 + 𝑥𝑆𝑓𝑔3

′
𝑆3′ − 𝑆𝑓3
𝑥= ′
𝑆𝑓𝑔3

6.5384 − 1.6472
=
5.3677

𝑥 = 0.9106

′ ′
ℎ3′ = ℎ𝑓3 + 𝑥 ℎ𝑓𝑔3

= 551.48 + (0.9106)( 2170.7)

ℎ3′ = 2528.1194 𝑘𝐽/𝑘𝑔

Solving for 𝒉𝟑 using RCR:

ℎ2 − ℎ3
𝑅𝐶𝑅 = 𝑠𝑡𝑎𝑔𝑒 𝑒𝑓𝑓. =
ℎ2 − ℎ3′

RCR = 80.59%
 2971.1 − ℎ3
80.59% =
2971.1 − 2528.1194

ℎ3 = ℎ2 − 𝑠𝑡𝑎𝑔𝑒 𝑒𝑓𝑓. (ℎ2 − ℎ3′ )

= 2971.1 − 0.8059(2971.1 − 2528.1194)

𝒌𝑱
𝒉𝟑 = 𝟐𝟔𝟏𝟒. 𝟏𝟎𝟏𝟗
𝒌𝒈

𝒌𝑱
At point 4: w/ 𝑺𝟐 = 𝑺′𝟒 = 𝟔. 𝟓𝟑𝟒𝟖 𝒌𝒈−𝑲 and 𝑷𝟒 = 𝟎. 𝟎𝟔𝟗 𝑴𝑷𝒂 ≈ 𝟎. 𝟎𝟕 𝑴𝑷𝒂

Solving for 𝒉′𝟒 :

From steam table 2,

hf = 376.7 kJ/kg sf = 1.1919 kJ/kg-K

hfg = 2283.3 kJ/kg sfg = 6.2878 kJ/kg-K

′ ′
𝑆4′ = 𝑆𝑓4 + 𝑥4 ′𝑆𝑓𝑔4

6.5348 − 1.1919
𝑥4 ′ =
6.2878

𝑥4 ′ = 0.8497
′ ′
ℎ4′ = ℎ𝑓4 + 𝑥4 ′ℎ𝑓𝑔4

𝑘𝐽 𝑘𝐽
ℎ4′ = 376.7 + (0.8497)(2283.3 )
𝑘𝑔 𝑘𝑔 − 𝐾

ℎ4′ = 2443.8157 𝑘𝐽/𝑘𝑔

ℎ1 − ℎ4
𝑅𝐶𝑅 = 𝑠𝑡𝑎𝑔𝑒 𝑒𝑓𝑓. =
ℎ1 − ℎ4′

ℎ4 = ℎ2 − 𝑠𝑡𝑎𝑔𝑒 𝑒𝑓𝑓. (ℎ2 − ℎ4′ )

2971.1 − ℎ4
80.59% =
2971.1 − 2316.82

𝒌𝑱
𝒉𝟒 = 𝟐𝟒𝟒𝟑. 𝟖𝟏𝟓𝟕
𝒌𝒈
Solving 𝑺𝟒 with 𝒉𝟒 = 𝟐𝟒𝟒𝟑. 𝟖𝟏𝟓𝟕 𝒂𝒏𝒅 𝑷𝟒 = 𝟎. 𝟎𝟕 𝑴𝑷𝒂

ℎ4 = ℎ𝑓4 + 𝑥4 ℎ𝑓𝑔4

ℎ4 − ℎ𝑓4
𝑥4 =
ℎ𝑓𝑔4

2443.8157 − 376.7
𝑥4 =
2283.3
𝑥 = 0.9053

𝑠4 = 𝑠𝑓4 + 𝑥4 𝑠𝑓𝑔4

𝑠4 = 1.1919 + (0.9053)(6.287)

𝑘𝐽
𝑠4 = 6.8844
𝑘𝑔 ˚𝐾

𝒌𝑱
A point 5:w/ 𝑷𝟓 = 𝟎. 𝟎𝟎𝟕 𝑴𝑷𝒂 𝒂𝒏𝒅 𝒖𝒔𝒊𝒏𝒈 𝑺𝟐 = 𝑺′𝟓 = 𝟔. 𝟓𝟑𝟒𝟖 𝒌𝒈−𝑲
From steam table 2,

hf = 163.4 kJ/kg sf = 0.5592 kJ/kg-K

hfg = 2409.1 kJ/kg sfg = 7.7167 kJ/kg-K

𝑆5 ′ = 𝑆𝑓 + 𝑥5 ′ 𝑆𝑓𝑔

𝑆5 ′ − 𝑆𝑓
𝑥5 ′ =
𝑆𝑓𝑔

6.5348 − 0.5592
𝑥5 ′ =
7.7167

𝑥5 ′ = 0.7744

For ℎ5′ :

ℎ5 ′ = ℎ𝑓 + 𝑥5 ′ℎ𝑓𝑔

ℎ5′ = 163.4 + ( 0.7744)( 2409.1)

𝑘𝐽
ℎ5′ = 2029.007
𝑘𝑔
Solving for 𝒉𝟓 :

ℎ1 − ℎ5
𝑅𝐶𝑅 =
ℎ1 − ℎ5 ′

ℎ5 = ℎ1 − 𝑠𝑡𝑎𝑔𝑒 𝑒𝑓𝑓. (ℎ1 − ℎ5′ )

= 2971.1 − ( 0.7744)(2971.1 − 2029.007)

𝒌𝑱
𝒉𝟓 = 𝟐𝟐𝟏𝟏. 𝟗𝟒𝟕𝟖
𝒌𝒈

LIST OF FINAL ENTHALPIES:

𝑘𝐽
ℎ1 = 2971.1 𝑘𝑔

𝑘𝐽
ℎ2 = 2971.1 𝑘𝑔

𝑘𝐽
ℎ3 = 2614.1019 𝑘𝑔

𝑘𝐽
ℎ4 = 2443.8157
𝑘𝑔

𝑘𝐽
ℎ5 = 2211.9478
𝑘𝑔

FOR ESTIMATING THE THROTTLE FLOW

𝐾𝑊 𝑐𝑎𝑝
𝑇𝑜𝑡𝑎𝑙 𝑜𝑢𝑡𝑝𝑢𝑡 =
𝐸𝑚𝑔

4000
=
0.912

𝑻𝒐𝒕𝒂𝒍 𝒐𝒖𝒕𝒑𝒖𝒕 = 𝟒𝟑𝟖𝟓. 𝟗𝟔𝟒𝟗 𝑲𝑾

FOR NON-BLEEDING THROTTLE FLOW

5
𝑇𝑜𝑡𝑎𝑙 𝑜𝑢𝑡𝑝𝑢𝑡 (4)
𝑇ℎ𝑟𝑜𝑡𝑡𝑙𝑒 𝐹𝑙𝑜𝑤𝑁𝐵 =
ℎ1 − ℎ5

5
4385.9649 (4)
𝑇ℎ𝑟𝑜𝑡𝑡𝑙𝑒 𝐹𝑙𝑜𝑤𝑁𝐵 =
2971.1 − 2211.9478

𝑻𝒉𝒓𝒐𝒕𝒕𝒍𝒆 𝑭𝒍𝒐𝒘𝑵𝑩 = 𝟕. 𝟐𝟐𝟏𝟖 𝒌𝒈/𝒔

FROM EQUATION (11-1.p.510). for the non-regenerative cycle

𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒1

1
[(𝑇ℎ𝑟𝑜𝑡𝑡𝑙𝑒 𝐹𝑙𝑜𝑤𝑁𝐵 + 2 𝑃𝑆)] + [𝑇ℎ𝑟𝑜𝑡𝑡𝑙𝑒 𝐹𝑙𝑜𝑤𝑁𝐵 (ℎ4 − ℎ𝑓@2𝑖𝑛𝐻𝑔 )]
=
5
(𝐾𝑊𝑐𝑎𝑝)
4

Process steam = 30, 000 lb/hr ≈ 3.7793 kg/s

1
[(7.2218 + 3.7793)(2971.1−2443.8517 )]+[7.2218(2443.8517−163.4)]
2
= 5
(4000)
4

𝑻𝒖𝒓𝒃𝒊𝒏𝒆 𝑯𝒆𝒂𝒕 𝑹𝒂𝒕𝒆𝟏 = 𝟒. 𝟐𝟓𝟒𝟔

ASSUME THAT THE FINAL TEMPERATURE OF FEED WATER IS:

𝑇𝑓𝑤 = 115 0C

𝑇𝑒𝑚𝑝@2𝑖𝑛𝐻𝑔 = 39 0C

𝐹𝑒𝑒𝑑 𝑤𝑎𝑡𝑒𝑟 𝑡𝑜𝑡𝑎𝑙 𝑟𝑖𝑠𝑒 = 115 − 39

𝑭𝒆𝒆𝒅 𝒘𝒂𝒕𝒆𝒓 𝒕𝒐𝒕𝒂𝒍 𝒓𝒊𝒔𝒆 = 𝟕𝟔 0C

From FIG. 11-7(a) p.513. The reduction in heat consumption at total rise

in Feed water temperature = 76 0C

ONE STAGE ∴ 𝟓. 𝟕%

From FIG. 11-7(e) p.515. The temperature correction to be added is

0.00426. Therefore, the load and vacuum correction will be unity,

applying this correction as indicated in EQUATION (11-5)

𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒 = 𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒1 [1 − 0.057 − 0.00426]

= 4.2546[1 − 0.057 − 0.00426]

𝑻𝒖𝒓𝒃𝒊𝒏𝒆 𝑯𝒆𝒂𝒕 𝑹𝒂𝒕𝒆 = 𝟑. 𝟗𝟗𝟒𝟎

Since the plant generates process steam & electrical energy is by

produce the turbine heat rate would be added by EQUATION (11-4 p.511)

1
𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒 = 𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒 +
𝐸𝑚𝑔

1
𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒 = 3.9940 +
0.912

𝑻𝒖𝒓𝒃𝒊𝒏𝒆 𝑯𝒆𝒂𝒕 𝑹𝒂𝒕𝒆 = 𝟓. 𝟎𝟗𝟎𝟓

At 𝑇𝒇𝒘 = 115 0C

Form steam table 1

𝒌𝑱
𝒉𝒇𝒘 = 𝟒𝟖𝟐. 𝟒𝟖
𝒌𝒈

Form Equation 11-1

𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒 (𝐾𝑊𝑐𝑎𝑝)

𝑊=
ℎ1 − ℎ𝑓𝑤
 5.0905(4000)
=
2971.1 − 482.48

𝒌𝒈
𝑾 = 𝟐. 𝟎𝟒𝟓𝟓
𝒔

𝒌𝒈
Assume that 𝒎𝑻 = 𝟏𝟎. 𝟖𝟑𝟕𝟕 . Approximately &Reduce by 0.0252 kg/s .
𝒔
For Air Ejector,

Therefore 𝒎𝑻 = 𝟏𝟎. 𝟖𝟏𝟐𝟓

HEAT BALANCE FOR DEAERATOR

𝑚2

ℎ4

1
𝑚𝑊 = 2 𝑃𝑆 + 0.02𝑚 𝑇 65 kPa 1
𝑚2 + 2 𝑃𝑆 + 0.02𝑚 𝑇

𝑚2 ℎ4 = 𝑚2 ℎ𝑓@65 𝑘𝑃𝑎 + 𝑚𝑊 (ℎ𝑓@65𝑘𝑃𝑎 − ℎ𝑓@16deg.C )

𝑚𝑊 (ℎ𝑓@65𝑘𝑃𝑎 − ℎ𝑓@16 𝑑𝑒𝑔.𝐶 )

𝑚2 =
ℎ4 − ℎ𝑓@65𝑘𝑃𝑎

1
𝑚𝑊 = 𝑃𝑆 + 0.02𝑚 𝑇
2
hf @ 65 kPa = 368.54 kJ/kg

hf @ 16 deg.C = 67.19 kJ/kg

1
𝑚𝑊 = (3.7793) + 0.02(10.8125)
2
𝒌𝒈
𝒎𝑾 = 𝟐. 𝟏𝟎𝟓𝟗
𝒔
(2.1059)(368.54 − 67.19)
𝑚2 =
2443.8157 − 368.54
𝒎𝟐 = 𝟎. 𝟑𝟎𝟓𝟖
The temperature of the feed water form heater & deaerator entering the
boiler
1
𝑚2 + 2 𝑃𝑆 + 0.02𝑚 𝑇

1
1.02𝑚 𝑇 𝑚 𝑇 = 2 𝑃𝑆 − 𝑚2

ℎ𝑓@225.96𝐹 =
224.6394

ℎ𝑓𝑤

1 1
[(𝑚2 + 𝑃𝑆 + 0.02𝑚 𝑇 ) (ℎ𝑓@65 𝑘𝑃𝑎 )] + [(𝑚 𝑇 − 𝑃𝑆 − 𝑚2 ) (ℎ𝑓@108 𝑑𝑒𝑔.𝐶 )]
2 2
= 1.02𝑚 𝑇 (ℎ𝑓𝑤 )

1 1
[(𝑚2 + 2 𝑃𝑆 + 0.02𝑚 𝑇 ) (ℎ𝑓@65𝑘𝑃𝑎 ) + [(𝑚 𝑇 − 2 𝑃𝑆 − 𝑚2 ) (ℎ𝑓@108 𝑑𝑒𝑔.𝐶 )]
ℎ𝑓𝑤 =
1.02𝑚 𝑇

1 1
[(0.3058 + 2 (3.7792) − 0.02 (10.8125)] (368.54) + [(10.8125 − 2 (3.7793) − 0.3058) (452.83)]
=
1.02(10.8125)

𝒌𝑱
𝒉𝒇𝒘 = 𝟒𝟑𝟒. 𝟑𝟗𝟖𝟎
𝒌𝒈

For 𝒎𝑪

1
𝑚𝐶 = 𝑚 𝑇 − 𝑚2 − 𝑃𝑆
2
1
𝑚𝐶 = 10.8125 − 0.3058 − (3.7793)
2
𝒎𝑪 = 𝟖. 𝟔𝟏𝟕𝟎𝟓

For 𝒎𝑾

1
𝑚𝑊 = 𝑃𝑆 + 0.02𝑚 𝑇
2
 1
𝑚𝑊 = (3.7793) + 0.02(10.8125)
2
𝒎𝑾 = 𝟐. 𝟏𝟎𝟓𝟗

HEAT BALANCE AT AIR EJECTOR

ℎ𝑓@2𝑖𝑛𝐻𝑔 = 163.4

0.0253∆ℎ

𝑚𝐶 ℎ𝐶

𝑚𝐶 (ℎ𝐶 − ℎ𝑓@2𝑖𝑛𝐻𝑔 ) = 0.0253∆ℎ

0.0235(2326.275)
ℎ𝐶 = + 163.4
8.61705
𝒉𝑪 = 𝟏𝟕𝟎. 𝟐𝟑𝟎𝟎

HEAT BALANCE AT SURFACE HEATER

Pressure @ surface heater = 250 kPa

Tsat=127.44 0C

With Temperature Difference of -15 0C

𝑇2 = 𝑇𝑠𝑎𝑡 − 𝑇𝑑

𝑇2 = 127.44 − (−15)

𝑻𝟐 = 𝟏𝟒𝟐. 𝟒𝟒 0C
 𝑚1

ℎ3

𝑚𝐶 𝑚𝐶

ℎ𝑓@𝑇2 ℎ𝐶

𝑚1

𝒉𝒇@𝟐𝟓𝟎 𝒌𝑷𝒂 = 𝟓𝟑𝟓. 𝟑𝟕

𝐸𝑖𝑛 = 𝐸𝑜𝑢𝑡

𝑚𝐶 ℎ𝐶 + 𝑚1 ℎ3 = 𝑚1 ℎ𝑓@36𝑝𝑠𝑖𝑎 + ℎ𝑓@𝑇2

𝑚𝐶 (ℎ𝑓@𝑇2 − ℎ𝐶 )
𝑚1 =
ℎ3 − ℎ𝑓@250𝑘𝑃𝑎

8.61705(452.83 − 170.2300)
=
2614.1019 − 535.37
𝒎𝟏 = 𝟏. 𝟏𝟕𝟏𝟓

FOR MASS BALANCE

Assume that the surface heater deaerator & air ejector

condenser are one heat exchanger.
1
𝑀1 𝑀2 + 0.02 + 2 𝑃𝑆

0.02𝑀𝑇

𝑀𝑇

𝑀1
 Mass entering = Mass leaving

𝑚1 =1.1715 𝑚1 = 1.1715
𝑚2 = 0.3058 𝑚 𝑇 = 10.8125
𝑚𝐶 = 8.61705
1
𝑃𝑆 = 1.88965
2

The output of the Turbine

Internal KW
1
(𝑚 𝑇 − 0.0253)(ℎ1 − ℎ3 ) + (𝑚 𝑇 − 0.0253 − 𝑚1 )(ℎ3 − ℎ4 ) + (𝑚 𝑇 − 0.0253 − 𝑚1 − 𝑚2 − 𝑃𝑆) (ℎ4 − ℎ5 )
= 2
5
4

=
(10.8125−0.0253)(2971.1−2614.1019)+(10.8125−0.0253−1.1715)(2614.1019−2443.8157)
1
+(10.8125−0.0253−1.1715−0.3058− (3.7793))(2443.8157−2211.9478)
2
5
4

Internal KW = 5767.1590

𝐾𝑊𝑐𝑎𝑝
𝑙𝑜𝑠𝑠𝑒𝑠 = − 𝐾𝑊𝑐𝑎𝑝
𝐸𝑚𝑔

4000
= − 4000
0.912

𝑳𝒐𝒔𝒔𝒆𝒔 = 𝟑𝟖𝟓. 𝟗𝟔𝟒𝟗

Therefore Net output will be:

𝑜𝑢𝑡𝑝𝑢𝑡 = 𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝐾𝑤 − 𝐿𝑜𝑠𝑠𝑒𝑠

= 5767.1590 − 385.9649

𝒐𝒖𝒕𝒑𝒖𝒕 = 𝟓𝟑𝟖𝟏. 𝟏𝟗𝟒𝟏

Correction:

𝑚𝑇
𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 = (𝑜𝑢𝑡𝑝𝑢𝑡 − 𝐾𝑊𝑐𝑎𝑝) ( )
𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝐾𝑊

10.8125
= (5381.1941 − 4000) ( )
4000

𝒄𝒐𝒓𝒓𝒆𝒄𝒕𝒊𝒐𝒏 = 𝟐. 𝟓𝟖𝟗𝟓

For Work Turbine:

= (𝑚 𝑇 − 0.0253)(ℎ1 − ℎ3 ) + (𝑚 𝑇 − 0.0253 − 𝑚1 )(ℎ3 − ℎ4 )

1
+ (𝑚 𝑇 − 0.0253 − 𝑚1 − 𝑚2 − 𝑃𝑆) (ℎ4 − ℎ5 ) − 1.917𝑚𝐶
2

(10.8125 − 0.0253)(2971.1 − 2614.1019) + (10.8125 − 0.0253 − 1.1715)(2614.1019 − 2443.8157)

= 1
+ (10.8125 − 0.0253 − 1.1715 − 0.3058 − (3.7793)) (2443.8157 − 2211.9478) − 1.917 (8.61705)
2

𝑾𝑻 = 𝟕𝟏𝟗𝟐. 𝟒𝟐𝟗𝟖

EXTRACTION FACTOR

ℎ3 − ℎ5 2614.1019 − 2211.9478
𝐹𝑅𝐼𝑆𝑇 𝐵𝐿𝐸𝐸𝐷 = = = 𝟎. 𝟓𝟐𝟗𝟕
ℎ1 − ℎ5 2971.1 − 2211.9478

ℎ4 − ℎ5 2443.8157 − 2211.9478
𝑆𝐸𝐶𝑂𝑁𝐷 𝐵𝐿𝐸𝐸𝐷 = = = 𝟎. 𝟑𝟎𝟓𝟓
ℎ1 − ℎ5 2971.1 − 2211.9478

NON-BLEEDING STEAM RATE

5
4 1.25
= =
ℎ1 − ℎ5 2971.1 − 2211.9478

𝑵𝑶𝑵 𝑩𝑳𝑬𝑬𝑫𝑰𝑵𝑮 𝑺𝑻𝑬𝑨𝑴 𝑹𝑨𝑻𝑬 = 𝟏. 𝟔𝟒𝟔𝟔 𝒙 𝟏𝟎−𝟑

For 4000 KW capacity w/ 𝟑𝟖𝟓. 𝟗𝟔𝟒𝟗 Losses. The Throttle Flow required
will be:

REPLACEMENT FLOW
Non-bleeding throttle flow

= (𝐾𝑊 + 𝐿𝑜𝑠𝑠𝑒𝑠)(𝑛𝑜𝑛 𝑏𝑙𝑒𝑒𝑑)

= (4000 + 385.9649)(. 6466 𝑥 10−3 )

𝒌𝑾 𝒌𝒈
𝑵𝒐𝒏 − 𝒃𝒍𝒆𝒆𝒅𝒊𝒏𝒈 𝑻𝒉𝒓𝒐𝒕𝒕𝒍𝒆 𝑭𝒍𝒐𝒘 = 𝟕. 𝟐𝟐𝟏𝟗
𝒔

REPLACEMENT STEAM

1st Replacement
𝐹𝑖𝑟𝑠𝑡 𝐵𝑙𝑒𝑒𝑑 = 𝑚1 (𝑓𝑖𝑟𝑠𝑡 𝑏𝑙𝑒𝑒𝑑)
= 1.1715(0.5297)

𝑭𝒊𝒓𝒔𝒕 𝑩𝒍𝒆𝒆𝒅 = 𝟎. 𝟔𝟐𝟎𝟓

2nd Replacement
1
𝑆𝑒𝑐𝑜𝑛𝑑 𝐵𝑙𝑒𝑒𝑑 = (𝑚2 + 𝑃𝑆)(𝑠𝑒𝑐𝑜𝑛𝑑 𝑏𝑙𝑒𝑒𝑑)
2
1
= (0.3058 + (3.7793)) (0.3055)
2

𝑺𝒆𝒄𝒐𝒏𝒅 𝑩𝒍𝒆𝒆𝒅 = 𝟎. 𝟔𝟕𝟎𝟕

Total Flow required when bleeding

= 7.2219 + 0.6205 + 0.6707

𝒕𝒐𝒕𝒂𝒍 = 𝟖. 𝟓𝟏𝟑𝟏
CONSIDERING THE CORRECTION

𝑇𝑜𝑡𝑎𝑙 = 8.5131 + 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛

= 8.5131 + 2.5895

𝑻𝒐𝒕𝒂𝒍 = 𝟏𝟏. 𝟏𝟎𝟐𝟔

FOR TURBINE HEAT RATE

ℎ1 (𝑚 𝑇 − 𝑚𝑊 ) − 𝑚 𝑇 (ℎ𝑓𝑤 )
𝐻𝐸𝐴𝑇 𝑅𝐴𝑇𝐸 =
𝑜𝑢𝑡𝑝𝑢𝑡

2971.1(10.8125 − 2.1059) − 10.8125(434.3980)

=
5381.1941

𝑯𝑬𝑨𝑻 𝑹𝑨𝑻𝑬 = 𝟑. 𝟗𝟑𝟒𝟑

FOR ∆𝒉

𝑚𝐶 (ℎ𝐶 − ℎ𝑓@2𝑖𝑛𝐻𝑔 )
∆ℎ =
200

8.61705(170.2300 − 163.4)
=
0.0253

∆𝒉 = 𝟐𝟑𝟐𝟔. 𝟐𝟔𝟐𝟗
 B. CALCULATE THE BOILER SIZE AND SELECT BOILER

1
𝑚𝑓𝑤 = 𝑚2 + 0.02𝑚 𝑇 + 𝑃𝑆 + 𝑚𝐶
2

1
m fw  0.3058 kg  0.02(10.8125 kg ) (3.7793 kg )  8.61705 kg
sec sec 2 sec sec
11.02875 kg
m fw  sec  5.5144 kg
2 sec

Solving for the mass Flow Rate of Blow down

𝑚𝑏𝑑 = 0.01𝑚 𝑇

mbd  0.01(10.8125 kg )
sec
mbd  0.108125 kg
sec

Solving for the mass of steam coming from the gas turbine flowing to
the boiler

𝒎𝒔𝒕𝒆𝒂𝒎𝒃𝒐𝒊𝒍𝒆𝒓 = 𝒎𝒇𝒘 − 𝒎𝒃𝒅

msteamboiler  5.5144 kg  0.108125 kg

sec sec
msteamboiler  5.40625 kg
sec

hs  h1  2971.1 KJ
kg

Solving for the boiler HP

msteamboiler x(hs  h fw )
BoilerHP 
9.81055407
*1BoilerHP  9.81055407kw  33500 HP
 5.40625 kg (2971.1  434.3980) kj
sec kg
Boiler HP 
9.81055407
Boiler HP  1397.887 Bhp
Boiler rating  250%
Boiler HP (10) 1397.887(10)
Boiler heatingsurface  
Boiler rating 2.5
Boiler heatingsurface  5591.54767

From plate 13,

Boiler size= F-15 , Turbine wide=40

Heating Surface=5392

Steam Outlet size=6 inches

Feed Size=2 1/2 inches

 C. CALCULATE THE SURFACE REQUIREMENT OF CONDENSER
AND SELECT CONDENSER:
Data:

Temperature of circulating water entering, t1 80 oF 26.67oC

2 pass
Tube Size - 18gage ¾ in 19.1 mm
Water velocity 6 fps 1.829 m/s
Cleanliness factor, Fc 75%
Condenser design 2 in Hg 0.00677 MPa
Capacity 5000 kW
Mc 68 402. 14 lb/hr 8.61705 kg/s

Saturated Temperature of 2 in Hg (0.00677 MPa)

From steam table, Table 2. Saturation:Pressure

Pressure (MPa) Temperature (oC)

0.0065 37.63
0.00677 Tsat
0.0070 39.00

by interpolation,
0.0065-0.00677 37.63-Tsat
=
0.0065-0.0070 37.63-39.00
Tsat = 38.3698 oC (101.06564oF)

From Potter, pp.356, the Institute Standard prohibits a temperature difference

of less than 5 oF (-15oC) .

Assume : TD = 5oF TD = -15oC

t2 = Tsat – TD t2 = Tsat – TD
= 101.06564 – 5 = 38.3698 – (-15)
t2 = 96.06564 oF t2 = 53.3698 oC
t1 = 80oF t1 = 26.67oC
THE LOG MEAN TEMPERATURE DIFFERENCE

t 2 − t1
θm = t − t1
ln ( sat
t sat − t 2 )

96.06564 − 80 5
= (96.06564 − 80)
101.06564 − 80 9
ln ( ) = 5
101.06564 − 96.06564 (101.06564 − 80)
ln [ 9 ]
5
(101.06564 − 96.06564)
9
𝛉𝐦 = 𝟏𝟏. 𝟏𝟕𝟎𝟔𝟏𝟔𝟏℉ 8.9254
=
11.7031
ln (
2.778 )
𝛉𝐦 = 𝟔. 𝟐𝟎𝟔𝟑℃

Since water velocity is 6 fps

From Figure 8-9 (Potter,pp. 351),using 6 fps velocity

U = Coefficient of Heat Transfer

BTU W
U = 660 U = 3747.654
hr ∙ ft 2 ∙ ℉ m2∙K
Temperature correction factor Ft = 1.05
Tube material and thickness Fm = 1.00
correction factor (admirality metal, 18 BWG, 1.00)
Cleanliness factor Fc = 0.75
Prime mover factor Fp = 1

For Overall Coefficient of Heat Transfer

Using equation 8-3 (Potter, pp. 351)

U = U ∙ Ft ∙ Fm ∙ Fc ∙ Fp U = U ∙ Ft ∙ Fm ∙ Fc ∙ Fp
BTU W
(660 ) (1.05)(1.00)(0.75)(1) (3747.654 ) (1.05)(1.00)(0.75)(1)
hr ∙ ft 2 ∙ ℉ m2∙K
𝐁𝐓𝐔 𝐖
𝐔 = 𝟓𝟏𝟗. 𝟕𝟓 𝐔 = 𝟐𝟗𝟓𝟏. 𝟐𝟕𝟕
𝐡𝐫 ∙ 𝐟𝐭 𝟐 ∙ ℉ 𝐦𝟐 ∙ 𝐊
CONSIDER CALCULATION FOR NON-REHEAT TURBINE INSTALLATION
In accordance with the standards of Heat Exchange Institute (Potter, pp. 356),
condenser calculation for non-reheat turbine installation is based on 950
BTU/lb (2209961.25 J/kg) of steam rejected.
Using equation 8-2 (Potter,pp. 351), Q = UAθm
where Q = quantity of energy
transferred = Mc

To get the Area,

Q
A=
Uθm
lb BTU kg J
(68 402. 14 hr) (950 lb ) (8.61705 s ) (2209961.25 kg)
BTU W
(519.75 ) (11.1706161℉) (2951.277 ) (6.2063℃)
hr ∙ ft2 ∙ ℉ m2 ∙K
𝐀 = 𝟏𝟏𝟏𝟗𝟐. 𝟑𝟕𝟔𝟏 𝐟𝐭 𝟐 𝐀 = 𝟏𝟎𝟑𝟗. 𝟔𝟖𝟐 𝐦𝟐

From Table 8-2 (Potter, pp.354), Approximate tube length for surface
condenser

SURFACE AREA LENGTH

10000 to 20000 18 to 24 FT

Solving for Circulating Water, Cw

BTU circulating water =
Mc ∗950
lb
circulating water = J
t2 −t1 Mc ∗2209961.25
kg
t2 −t1
kg J
lb BTU (8.61705 s ) (2209961.25 kg)
(68 402. 14 ) (950 )
hr lb
96.06564℉ − 80℉ 5
[ (96.06564℉ − 80℉ )] ℃
9
 𝐁𝐓𝐔
Cw = 4044783.339 Cw = 2133623.302 𝐖 ∙ ℃
𝐡𝐫 ℉

From Potter, pp.352, for stationary plant they are used 500 ft2 (46.475 m2)
capacity.
circulating water
gpm =
capacity
BTU
4044783.339
gpm = hr ℉
500 f𝑡 2
𝑔𝑎𝑙 3.79 𝑙𝑖𝑡𝑒𝑟𝑠 1 𝑚𝑖𝑛
gpm= 8089.5667 8089.5667 ( )( )
𝑚𝑖𝑛 1 𝑔𝑎𝑙 60 𝑠𝑒𝑐
lps = 510.99
From table8-1(Potter, pp. 353), for ¾ in tube, 18 BWG
Water quantity per gpm at 1 fps velocity = 1.042

No. of tube per pass 𝑔𝑝𝑚

=
(𝑤𝑎𝑡𝑒𝑟 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦)(𝑤𝑎𝑡𝑒𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦)
8089.5667 𝑔𝑝𝑚
=
𝑔𝑝𝑚
(1.042 ) (6 𝑓𝑝𝑠)
𝑓𝑝𝑠
No. of tube per pass = 1293. 9166
No. of tube per pass = 1300 tubes

Since there are two (2) pass, the total number of tubes are : 2600 tubes

EFFECTIVE TUBE LENGTH

From Table 8-1 (potter, pp.353)
Outside surface, ft2 /1 in.ft, for tube size 3/4 in. = 0.1963

Area
Length =
(No. of Pass )(No. of Tube per pass)(outside surface)

11192.3761 ft 2
Length =
(2 )(1300)(0.1963)
 𝐋𝐞𝐧𝐠𝐭𝐡 = 𝟐𝟏. 𝟗𝟐𝟗𝟒𝟗𝟓𝟖𝟕 𝐟𝐭
𝐋𝐞𝐧𝐠𝐭𝐡 = 𝟐𝟐𝐟𝐭
FRICTION LOSS
From Figure 8-11(Potter, pp.355), Friction loss for NO.18 BWG condenser tube
and water boxes.
Tube friction loss = 0.3
Pressure loss = 1.12

Friction loss = (Length ∙ Tube friction loss ∙ No. of Pass) +

(No. of Pass ∙ Pressure loss)
Friction loss = (22ft)(0.3)(2) + (2)(1.12)
𝐅𝐫𝐢𝐜𝐭𝐢𝐨𝐧 𝐥𝐨𝐬𝐬 = 𝟏𝟓. 𝟒𝟒 𝐟𝐭

SELECTION OF SURFACE CODENSER

Using the total number of tube = 2600
From PLATE 14 Potter, pp.690. Dimensional of Westinghouse two-pass, non-
divided water box, radial flow surface condenser
Based on ¾ in OD, NO.18 BWG tubes

FRAME Actual Tube Distance Required for Max. No.of

NO. Length Withdrawing Tubes Tubes
8500 18'-0" 21'-1" 3 100

UNIT: 2
CONNECTION: PARALLEL CONNECTION
MODEL: TWO-PASS, NON-DIVIDED WATERBOX
RADIAL FLOW SURFACE TYPE
MANUFACTURER: WESTINGHOUSE ELECTRIC AND MFG CO.
 D. CALCULATE THE SIZE AND SELECT DEAERATOR AND
SURFACE HEATER

For heater selection

Assume: 5°F TD

TD heater= -15°C
Saturation temperature of heater
Tsat temp =127.2C =260.96 °F
t2heater  Tsat.temp  TDheater
= 127.2°C =255.96°F

t1 = temperature leaving from the air ejector

t1  Tc
T1=40,02826281 °C = 104.05087306 °F

For the Log Mean Temperature Difference

t2heater  t1
m heater 
 Tsat.temp  t1 
ln  
 Tsat.temp  t2heater 
5
9(255.96 − 104.05087306)
=
5/9(260.96 − 104.05087306
𝑙𝑛 [ ]
5
9(260.96 − 255.96)

84.39395941
=
3.446228916

=24.48878512°C

SOLVING FOR Q:
Qheater  
W  hfcondense  hc

where:
Q = amount of work, Btu/hr
W = water flow, lb/hr
Mc = mass of condensate
Mc  65587.89746763
(hf.condense - hc) = enthalpy entering and leaving heater, Btu/lb
 
Qheater  Mc  hfcondense  hc 
Qheater  10005993.02271614

FOR THE FILM TEMPERATURE

From article 8-10 SURFACE CALCULATION: (Potter, pp 372)


Filmtemperature  Tsat.temp  0.8 m heater 
Filmtemperature  225.69614942

From Figure 8-23 (Potter, pp.373)

Filmtemperature  225.69614942
Watervelocity  6
Overallheattransfer.rate  780

Correction factor of Admiralty metal material, Gage 18 BWG

Correctionfactor  1

For corrected value U

Correctedvalue  Overallheattransfer.rate  Correctionfactor

Correctedvalue  780

Solving for the area of the surface heater

From equation 8-2 (Potter, pp.351)

Qheater
Areaheater 

Correctedvalue  m heater 
Areaheater  291.02201768
 E. CALCULATE SIZE OF BOILER FEED PUMP AND SELECT PUMP

Since 2 boiler feed pump should use per each turbine with 100% spare,
capacity of each pump should be flow from closed heater and deaerator with
10 % extra flow to take care of emergencies
 Mf 
BFPmass.flow  1.10   
 
2

11.02875 kg
BFPmass flow  1.10( sec )
2
BFPmass flow  6.0658 kg
sec

FROM PLATE 2, Potter

TFEEDW ATER  115 deg rees celcius

S .GBFP  0.946

BFPmass flow
BFPVOLUME FLOW 
500( S .GBFP )
6.0658 kg
BFPVOLUME FLOW  sec
(0.946)(1000 kg )
m3
3
BFPVOLUME FLOW  6.04121x10 3 m
sec

FROM PLATE 11, Potter

3
6.4121x103 m  101.6331gpm
sec
THEN USE:

Volume Flow rate  125 gal

3
 7.88625 x10 3 m
min sec
Developed Head  2757.14 Kpa
Pump Size  1.5
No. of Stage  6
Motor Hp Rating  60
 F. CALCULATE SIZE OF CONDENSATE PUMP

DATA:
Two per condenser
100% spare, centrifugal motor driven
150 ft total head
10% extra capacity based on the flow obtained for the
condenser
NOTE: there are 4 Condensate pump in the entire plant
FOR CONDENSATE MASS FLOW:
CPmassflow = 1.10 (Mc)

CPmassflow = 1.10 (8.61705 kg/s)

CPmassflow = 9.478755 kg/s

CONVERTING INTO VOLUME FLOW:

From Plate 2 (Potter, pp.678) with:

Tc = 40.02826 deg.C = 104.05087306 deg.F

Specific GravityCP = 0.992

𝐶𝑃𝑚𝑎𝑠𝑠𝑓𝑙𝑜𝑤
CPvolumeflow = 1000(𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝐺𝑟𝑎𝑣𝑖𝑡𝑦 𝐶𝑃)

9.478755 kg/s
= 1000𝑘𝑔/𝑚3(0.992)

CPvolumeflow = 9.55519 × 10-3 m3/s

FOR HYDRAULIC POWER

From Equation 3-4 (Potter, pp.92)

CPvolumeflow(H)(SGcp)
Hyraulic power = 367

H = 150ft = 45.72m
CPvolumeflow(H)(SGcp)
Hydraulic power = 367

34.38684m3/h(45.72)(0.992)
Hydraulic power = 367

Hydraulic power = 4.24956 kW

FOR SHAFT POWER

From equation 3-6 (Potter, pp.93)

Assume pump efficiency:

Pump Efficiency = 70%

Hydraulic power
Shaft power = 𝑃𝑢𝑚𝑝 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

4.24956 kW
Shaft power = 0.70

Shaft power = 6.0708 kW

 G. MAKE A PLAN LAYOUT OF EQUIPMENT. SHOW MAJOR
DIMENSION OF EQUIPMENT AND BUILDING, AND SHOW
CENTERLINE DIMENSION.

ler Feed Pump

222
6
To deaerator

Control Room

Surface Heater
5

Fire Exit

4 Boiler 1 Boiler Feed Pump

Boiler 2 Boiler Feed Pump

3

Boiler Feed Pump

Boiler 3

2
2
Boiler Feed Pump
Boiler 4

1
2
2

1
1 A B C D E F
6

Air Injection
Control Room

Fire Exit

2
2
CONDENSER

1
2
2

1
B C D E F
1 A
6

BR UNIT

Fire Exit TURBINE

2
2 DEARATOR

1
2
2

1
1 A B C D E F
H. LAYOUT MAIN STEAM PIPE (SINGLE LINE) ON DRAWING AND
SHOW ALL FITTINGS
 I. CALCULATE PIPE SIZE FOR MAIN STEAM LINE

Solving for Pipe Diameter:

From the calculations of velocity of steam, refer to Table 2 – 6 Recommended

Velocities and Pressure Drops for Fluids in Pipes pp. 72 from Power Plant

Theory and Design by Potter; Steam condition is 2758 kPag, therefore use

these values:

Fluid Velocity, meter per minute

Less than 200 mm. 200 in dia. and larger
dia.
Steam, Superheated, 914 – 2438 1524 – 4267
690 – 4137 kPag

Assuming the pipe diameter of steam line is less than 200 mm. diameter,

velocity is 914 to 2438 meter per minute. Also, assuming a diameter of 150 mm.

to solve for pipe cross-sectional area.

FOR THE SPECIFIC VOLUME OF THE PRESSURE FLOW FROM BOILER
TO JUNCTION A
2859.2558
P boiler junction A =
0.95

P boiler junction A = 3,009.742947 kPa

From Steam Table:

P boiler junction A = 3,009.742947 kPa

V1 = 0.066464 m3/kg

Using Trial and Error for Cross – Sectional Area with less than 200 mm.
diameter

Assume: 200 mm. diameter

𝜋(200)2
Area8 = 4

Area8 = 31, 415.92654 mm.2

Assume: 178 mm. diameter

𝜋(178)2
Area7 = 4

Area7 = 24, 884.55541 mm.2

Assume: 150 mm. diameter

𝜋(150)2
Area6 = 4

Area6 = 17, 671.45868 mm.2

Assume: 127 mm. diameter

𝜋(127)2
Area5 = 4

Area5 = 12, 667.68698 mm.2

Solving for the Steam Velocity of the given areas using the formula:
2 (𝑀 𝑠𝑡𝑒𝑎𝑚 𝑏𝑜𝑖𝑙𝑒𝑟) (𝑉1)
Velocity =
(𝐴𝑟𝑒𝑎)(60)

At 200 mm. diameter:

Velocity8 = 1330.011348433248 m/min

At 178 mm. diameter:

Velocity7 = 1737.157679584728 m/min

At 150 mm. diameter:

Velocity7 = 2364.464619435192 m/min

At 127 mm. diameter:

Velocity7 = 3404.6640607374256433 m/min

THEREFORE: Use the area that have the lowest minimum velocity and have
value in range of 914 – 2438. Select the diameter of 150 mm. with a velocity
of 2364.464619435192 m/min and area of 17, 671.45868 mm. 2

Solving for the Minimum Wall Thickness of Pipe:

From Equation 2-5 (Potter, pp. 34)

𝑃᛫𝐷
tm = +𝐶
2𝑠+2𝑦 ᛫ P

Where:

tm = maximum wall thickness, in.

P = maximum internal service pressure, psig

D = pipe outside diameter, in.

s = allowable stress due to internal pressure at operating temperature

From Table 2-1, pp. 33 (Potter)

C = constant as follows:

Threaded steel, ½ in. and larger, depth of thread

Plain and Steel, 1 in. and smaller, 0.05 in.

Plain and Steel, larger than 1 in., 0.065.

y = coefficient (that may be operated) that is follows:

Ferretic steels: 900 °F and below, 0.4

950 °F, 0.5

1000 °F, 0.7

From Table 2 – 1, pp. 32, psi

Material ASTM Grade Allowable Values

Specification of Stress, psi
(-20 to 650)
Carbon Steel A53 A 12, 000
*Note: ASTM specification A53 is for common type of carbon-steel pipe, more
rigid than A120 and is recognized by the codes for power plant use.

Therefore:

𝑃᛫ 𝑂𝐷𝑠𝑐ℎ.40
tm =
(2᛫12000)+(2 ᛫ 𝑦 𝑓𝑒𝑟𝑟𝑖𝑡𝑖𝑐.𝑠𝑡𝑙 ᛫ 𝑃)
+ 𝐶𝑝𝑙𝑛.

tm = 4.567632724 mm.

Note: The calculated wall thickness should be divided by 0.875 so that the
value will be increased to allow for the mill-rolling tolerance.
tm
tm.increased =
0.875

tm.increased = 5.220151612 mm.

Selection of Pipe Size from Boiler to Junction A

From Appendix Plate 1 (Potter, pp. 675) Physical Properties of Pipes,

Schedule 40

Physical Properties of Pipes Schedule 40

Nominal Outside Wall Inside Inside Internal Weight

Pipe Diameter, thickness, Diameter, Diameter, Cross- of per
Size, in. in. in. in. Fifth sectional ft-lb
power Area
D t d D5 Sq. in.
Sq. ft.
6 6.625 0.280 6.065 8,210 28.9 18.98
0.20

From Junction A to Turbine:

Assume that the pipe diameter is 200 mm. and larger with superheated
pressure of 2758 kPag. The velocity is from 1524 to 4267.2 meters per
minute.
Trial and Error for Cross-Sectional Area (8 in. and larger)

Assume 8 in. (200 mm.) diameter:

𝜋(200)2
Area8 =
4

Area8 = 31,415.92654 mm.2

Assume 9 in. (228.5 mm.) diameter:

𝜋(228.5)2
Area9 =
4

Area9 = 41,007.40526 mm.2

Assume 10 in. (250 mm.) diameter:

𝜋(250)2
Area9 =
4

Area9 =49,087.38521 mm2

Assume 11 in. (279.5 mm.) diameter:

𝜋(279.5)2
Area9 =
4

Area9 = 61,355.50087 mm2

Solving for the Specific Volume of the Pressure Flow from Boiler to
Junction A:

P1 = 2859.2558 kPa

From Steam Table:

P1 = 2859.2558 kPa

V2 = 0.083002218687 m3/kg

Solving for the Steam Velocity of the given area

2 (𝑀 𝑠𝑡𝑒𝑎𝑚 𝑏𝑜𝑖𝑙𝑒𝑟) (𝑉2)
Velocity =
(𝐴𝑟𝑒𝑎)(60)

At 200 mm. diameter:

Velocity8 = 5448.67686663 m/min

At 228.5 mm. diameter:

Velocity9 = 4305.1274008 m/min

Therefore: Use the area with a higher velocity. Assume that it has 200 mm.
diameter.

Area8 = 31,415.92654 mm.2

Velocity8 = 5448.67686663 m/min

Solving for the Minimum Wall Thickness of Pipe:

From Equation 2-5 (Potter, pp.34)

𝑃᛫𝐷
tm = +𝐶
2𝑠+2𝑦 ᛫ P

where:

tm = maximum wall thickness, in.

P = maximum internal service pressure, psig

D = pipe outside diameter, in.

s = allowable stress due to internal pressure at operating temperature

From Table 2-1, pp. 33 (Potter)

C = constant as follows:

Threaded steel, ½ in. and larger, depth of thread

Plain and Steel, 1 in. and smaller, 0.05 in.

Plain and Steel, larger than 1 in., .065.

y = coefficient (that may be operated) that is follows:

Ferretic steels: 900 °F and below, 0.4

950 °F, 0.5

1000 °F, 0.7

From Table 2 – 1, pp. 32, psi

Material ASTM Grade Allowable Values

Specification of Stress, psi
(-20 to 650)
Carbon Steel A53 A 12, 000
*Note: ASTM specification A53 is for common type of carbon-steel pipe, more
rigid than A120 and is recognized by the codes for power plant use.
 C = Plain and steel, larger than 1 in.

Cpln.stlb = 0.065

y = coefficient of Ferritic steels: 900 °F and below

yferritic.stlb = 0.4

P = maximum internal service pressure

Pb = 400

D = outside diameter of schedule 40 by 8 in pipe size

from Plate 1 (Potter, pp.675)

ODsch.40b = 8.625

Therefore:

𝑃᛫ 𝑂𝐷𝑠𝑐ℎ.40𝑏
tm414.7 =
(2᛫12000)+(2 ᛫ 𝑦 𝑓𝑒𝑟𝑟𝑖𝑡𝑖𝑐.𝑠𝑡𝑙𝑏 ᛫ 𝑃)
+ 𝐶𝑝𝑙𝑛. 𝑠𝑡𝑙𝑏

tm414.7 = 5.25420717 mm.

tm414.7
tm.increased414.7 = 0.875

tm.increased414.7 = 6.004808158 mm.

Selection of Pipe Size from Boiler to Junction A

From Appendix Plate 1 (Potter, pp. 675) Physical Properties of Pipes,

Schedule 40

Physical Properties of Pipes Schedule 40

Nominal Outside Wall Inside Inside Internal Weight

Pipe Diameter, thickness, Diameter, Diameter, Cross- of per
Size, in. in. in. in. Fifth sectional ft-lb
power Area
D t d D5 Sq. in.
Sq. ft.
8 8.625 0.322 7.981 32,400 50.0 28.56
0.347
J. BILL OF MATERIALS FOR THE MAIN STEAM PIPING

ITEM MATERIAL DESCRIPTION QUANTITY

CARBON STEEL
1 NPS 6 ASTM A106 GRADE A 117 FT
PIPE

2 90O ELBOW NPS 6 ASTM A106 GRADE A FLANGED 10

3 90O ELBOW NPS 8 ASTM A106 GRADE A FLANGED 2
4 T-ELBOW NPS 6 ASTM A106 GRADE A FLANGED 10
5 *GATE VALVE NPS 6 CLASS 600 FLANGED 4
6 *GATE VALVE NPS 8 CLASS 600 FLANGED 2
7 *CHECK VALVE NPS 6 CLASS 600 FLANGED 4
PRESSURE
8 REGULATING NPS 6 CLASS 600 FLANGED 2
VALVE
9 *SAFETY VALVE NPS 8 ASTM A106 GRADE A FLANGED 2
10 STRAIGHT TEE NPS 6 CLASS 600 FLANGED 2
6” X 8” ASTM A106 GRADE A
11 REDUCER 2
FLANGED

ANSI/MSS SP -69 & SP-58, TYPE 37

12 TEFLON TAPE 5
(B3090)

ANSI/MSS SP -69 & SP-58, TYPE 37

13 VULCASEAL 5
(B3090)

ANSI/MSS SP -69 & SP-58, TYPE 37

14 PIPE HANGER 10
(B3090)

ADJUSTABLE PIPE ANSI/MSS SP -69 & SP-58, TYPE 37

15 10
SADDLE SUPPORT (B3090)

ANSI/MSS SP -69 & SP-58, TYPE 37

16 PIPE ADJUSTER 10
(B3090)
K. CALCULATE THE MAXIMUM FRICTION LOSS IN THE STEAM PIPING
FROM BOILER TO TURBINE

Solving for steam piping pressure drop

From boiler to junction a:

From Equation 2-15 (Potter, pp.56)

Where:

Δ P = pressure loss, psi

d = pipe ID, in.
W = flow, lb/min
f = 4C = Friction factor, From Figure 2-19 (Potter, pp.61)
L = lenght, ft
V = velocity, ft/s

Assume:

For the value of f, using Table 2-3 (Potter, pp.63) Friction factor for steam
By Babcock and Wilcox (B. and W.) investigator

𝒅𝑰𝑫 𝒑𝒊𝒑𝒆 𝑩−𝑨 = 𝟔. 𝟎𝟔𝟓𝒊𝒏

From:
1
𝜌𝐵−𝐴 =
𝑉1

𝑙𝑏
𝜌𝐵−𝐴 = 0.9392
𝑓𝑡 3

Therefore:
. 001295 𝑓𝑠𝑡𝑒𝑎𝑚 𝑝𝑖𝑝𝑒𝐵−𝐴 𝐿𝑠𝑡𝑒𝑎𝑚𝑝𝑖𝑝𝑒𝐵−𝐴 𝜌𝑉 2
∆𝑃𝐵−𝐴 =
𝑑𝐼𝐷 𝑝𝑖𝑝𝑒𝐵−𝐴

𝑷𝑩−𝑨 = 𝟏𝟕. 𝟑𝟎𝟕𝟐𝟔𝟏𝟒𝟖𝒑𝒔𝒊

From junction a to boiler:

Solving for steam piping pressure drop:

From Equation 2-15 (Potter, pp.56)

. 𝟎𝟎𝟏𝟐𝟗𝟓 𝒇𝒔𝒕𝒆𝒂𝒎 𝒑𝒊𝒑𝒆 𝑳𝒔𝒕𝒆𝒂𝒎𝒑𝒊𝒑𝒆 𝝆𝑽𝟐

∆𝑷 =
𝒅𝑰𝑫 𝒑𝒊𝒑𝒆

Where:
Δ P = pressure loss, psi
d = pipe ID, in.
W = flow, lb/min
f = 4C = Friction factor, From Figure 2-19 (Potter, pp.61)
L = length, ft
V = velocity, ft/s

Assume:
𝑳𝒔𝒕𝒆𝒂𝒎 𝒑𝒊𝒑𝒆 𝑨−𝑻 = 𝟐𝟎𝟎𝒇𝒕

For the value of f, using Table 2-3 (Potter, pp.63) Friction factor for steam
By Babcock and Wilcox (B. and W.) investigator

𝑑𝐼𝐷 𝑝𝑖𝑝𝑒 𝐴−𝑇 = 7.981𝑖𝑛

𝑓𝑠𝑡𝑒𝑎𝑚 𝑝𝑖𝑝𝑒 𝐴−𝑇 = 0.01567157

3.6
𝑓𝑠𝑡𝑒𝑎𝑚 𝑝𝑖𝑝𝑒 𝐴−𝑇 = 0.1080 (1 + )
𝑑𝐼𝐷 𝑝𝑖𝑝𝑒 𝐴−𝑇
1
𝜌𝐴−𝑇 =
𝑉2

𝒍𝒃
𝝆𝑨−𝑻 = 𝟎. 𝟕𝟓𝟐𝟏𝟐𝟒
𝒇𝒕𝟑

Therefore:
. 001295 𝑓𝑠𝑡𝑒𝑎𝑚 𝑝𝑖𝑝𝑒𝐴−𝑇 𝐿𝑠𝑡𝑒𝑎𝑚𝑝𝑖𝑝𝑒𝐴−𝑇 𝜌𝑉 2
∆𝑃𝐴−𝑇 =
𝑑𝐼𝐷 𝑝𝑖𝑝𝑒𝐴−𝑇

∆𝑃𝐴−𝑇 = 2.0231248𝑝𝑠𝑖

∆𝑃𝑇𝑂𝑇𝐴𝐿 = 2∆𝑃𝐵−𝐴 + ∆𝑃𝐴−𝑇

∆𝑷𝑻𝑶𝑻𝑨𝑳 = 𝟑𝟔. 𝟔𝟑𝟕𝟔𝟒𝟕𝟕𝟔𝒑𝒔𝒊

 L. CALCULATE THE FAN HORSEPOWER AND SELECT A FAN

From Plate 10 (pg. 685, Potter)

Static Pressure = 3 in W

CFM = 10 000

From Eq (7-10) Potter

(10000)(3 𝑖𝑛)
𝐴𝑖𝑟 𝐻𝑃 = 6350

𝐴𝑖𝑟 𝐻𝑃 = 8.2192 𝐻𝑃

From Plate 10 (pg. 685)

Fan Size Type SLD = 3 ½

Motor Size = 7 ½

Speed = 1760 rpm

Limit HP = 7 ½
M. DETERMINE THE DIAMETER AND HEIGHT OF STACK

Solving for the Diameter of the stack

From:

Q=AxV

Where:

𝑚3
Q = flow rate, 𝑠𝑒𝑐

A = area of the stack, sq.m

𝑚3
V = specific volume, 𝑘𝑔

From previous solution, the flow rate flowing to the stack is the mass of
air and mass of fuel given off by the 4 boiler
The total exhaust of the 4 boiler is:

𝑴𝑻𝑶𝑻𝑨𝑳 𝒆𝒙𝒉𝒂𝒖𝒔𝒕 = 𝟕𝟗𝟑𝟑. 𝟎𝟐𝟖𝟖 𝒌𝒈/𝒔𝒆𝒄

From Article 7-4 CHIMNEY (Potter, pp.306) the outlet velocity are range
from 15.2393mps-18 2871mps represent good practice and help disperse
the gases
𝐾𝐽
𝑅𝑔𝑎𝑠 = 0. 287 𝑘𝑔 𝐾

𝑇𝑔𝑎𝑠 = 176.6667 𝑑𝑒𝑔. 𝐶 + 273 = 449.6667 𝐾

𝑻𝒈𝒂𝒔 = 𝟒𝟒𝟗. 𝟔𝟔𝟔𝟕

Assume barometric pressure is 101.6298kpa and from the given plant

elevation equal to 14.3249m.
𝑃𝑙𝑎𝑛𝑡 𝑒𝑙𝑒𝑣𝑎𝑡𝑖𝑜𝑛 = 14.33249 𝑚
 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑔𝑎𝑠 = 101.6228 𝑘𝑝𝑎 − 0.0319 𝑘𝑝𝑎
𝑷𝒓𝒆𝒔𝒔𝒖𝒓𝒆 𝒈𝒂𝒔 = 𝟏𝟎𝟏. 𝟔𝟏𝟓𝟗 𝒌𝒑𝒂

For the Volume flow rate of gas

RGAS (TGAS )(mass)

QGAS  =
Pr essuregas

kj kg
0.287 (449.6667k )(7933.0288 )
kg.k sec
KN
101.6159 2
m
3
m
QGAS  10075.1144
sec

THEREFORE:

ASSUME: Velocity outlet=18.2871m/sec

pie (d 2 )
Qgas  ( )(Velocityoutlet )
4
Qgas x 4
d
Velocityoutlet xpiex60
m3
10075.1144 x4
d sec  3.4193m
18.2871 m xpiex60
sec

SOLVING FOR THE HEIGHT OF THE STACK

From Equation 7-6 (Potter, pp.306)
2
 Qgas 
B  
 1000 
 4  Tg
Pv
0.5602  d
To get Tg: From Equation 7-5 (Potter, pp.306)

Tg 
ta  Cconst  templeaving.boiler  ta 

Where:
t.g = average gas temperature, °C
temp.leaving = temperature leaving the boiler, °k
t.a = air temperature k
C = empirical constant, ranging from 0.85 to 0.95 for chimney
height and
diameter normally used for power plant

Assume Empirical constant:

Cconst  0.95

Ta  308k

Temperature of leaving=449.6667k


Tg.  ta  Cconst  templeaving  ta 
Tg=442.5834k-273=169.5834degree celcius

B  101.6298kpa  0.0139kpa
B  101.6159kpa

SOLVING FOR VELOCITY PRESSURE:

m3
101.6159kpa(10075.1144 1000) 2
PV  sec
(3.3281)(3.4193m) 4 (169.5834 deg .celcius )
PV  0.1337kpa
SOLVING FOR THE HIGH OF STACK

P.t=P.f+P.v
P.t=0.38268698kpa

where:

P.t = total pressure

P.f = stack friction loss
P.f=0.24898698kpa

THEREFORE THE HEIGHT OF THE STACK

From Equation 7-4 (Potter, pp.305)

BXH 1 1
Pt  (  )
29.2039m t a tg
0.38268698kpa( 29.2039m)
H 
1 1
101.6159kpa(  )
308 442.5834
H  111.39795m
N. DRAW AN END VIEW OF THE PLANT SHOWING EQUIPMENT AND
PIPING
O. LAY OUT THE WATER PIPING FROM THE DEAERATOR TO THE
BOILER, SHOWING ALL FITTINGS, AND INCLUDES AN
AUTOMATIC VALVE FOR FEED WATER REGULATION.
P. DETERMINE THE FRICTION LOSS OF THE WATER PIPING

Given:

Piping: Of sufficient strength for pressure and temperature involve, flanged

and less than zero on pump discharges designed for velocity of about 450
fpm and less than 200 fpm on suction. 10 % pressure drop in low pressure
bleed line and 5% in high pressure bleed line. Use a hard by pass around
automatic PRV.

Solving for the Water Piping Diameter From Deaerator to Junction B

Qflow d-b = A(V)

From heat balance calculation:

Qdeaerator = Mw + M2

Qdeaerator = 21958.70253237 cu.ft/min

1 1
Qflow d-b = Qdeaerator (62.4)(60)

Qflow d-b = 5.86503807 cu.ft/min

Therefore

Vsunction = 200 ft/min

𝜋𝑑 2
Qflow d-b = (𝑉𝑠𝑢𝑛𝑐𝑖𝑡𝑜𝑛)
4

𝑄𝑓𝑙𝑜𝑤𝑑𝑏 (4)
d deaerator.b = √ (12)
𝜋(𝑉 𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛)
 𝑓𝑡
(5.865 𝑐𝑢.min) (4)
d deaerator.b = √ (12)
𝜋(200 𝑓𝑡/𝑚𝑖𝑛)

d deaerator b = 2.31876494 inch

Selection of Pipe Sunction

From appendix, Plate 1 Physical Properties of Pipe pp.675 Power Plant

Theory and Design by Potter

Schedule 40

Nominal Outside Wall Inside Inside Internal Weight

Pipe Diameter, Thickness, Diameter, Diameter, Cross of pipe
Size, in in in in Fifth Sectional per ft-
Power Area lb
D T d D5 Sq. Sq. ft
in
2½ 2.875 0.203 2.469 91.8 4.79 0.033 5.794

Solving for the Water Piping Discharge Diameter

Vdischarge = 450 ft/min

𝜋𝑑 2
Qflow d-b = (𝑉𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒)
4

𝑄𝑓𝑙𝑜𝑤𝑑𝑏 (4)
d discharge = √ (12)
𝜋(𝑉 𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒)

5.865𝑐𝑢.𝑓𝑡/ min(4)
d discharge = √ (12)
𝜋(450 𝑓𝑡/𝑚𝑖𝑛)

d discharge = 1.5458 inch

Nominal Outside Wall Inside Inside Internal Weight

Pipe Diameter, Thickness, Diameter, Diameter, Cross of pipe
Size, in in in in Fifth Sectional per ft-
Power Area lb
D T d D 5 Sq. in Sq. ft
2 2.375 0.154 2.067 37.73 3.356 0.023 3.653
Solving For Water Friction Loss

Friction Loss at Sunction Pipe

2
0.001295 (𝑓𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛)(𝐿𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛)(𝜌𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛)(𝑉𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛)
∆𝑃𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛 = 𝑑𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛

Assume length of sunction

Lsunction = 100 ft

For suction friction factor, f from Eq 2-18 potter, pp.58

64
𝑓=
𝑁𝑟
Solving for Reynold’s number from Eq 2-10 potter, pp.53

IDsunction = 1.610 inch

𝑉𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛(𝐷𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛)(𝜌)
𝑁𝑟 =
𝜇

𝑓𝑡 62.4𝑙𝑏
200 𝑚𝑖𝑛 (1.61 𝑖𝑛𝑐ℎ)( )
𝑐𝑢𝑓𝑡
𝑁𝑟 =
𝑠 𝑖𝑛𝑐ℎ 𝑙𝑏
(60 min)(12 )(0.00022175 )
𝑓𝑡 𝑓𝑡 − 𝑠

𝑁𝑟 = 125847.4257798

Then:

64
𝑓=
125847.4257798
𝑓 = 0.00050855

Then:

0.001295 (𝑓𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛)(𝐿𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛)(𝜌𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛)(𝑉𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛)2
∆𝑃𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛 =
𝑑𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛
𝑙𝑏
0.001295 (0.00050855)(100 𝑓𝑡)(62.4 )( 200𝑓𝑡/60𝑠)2
𝑐𝑢𝑓𝑡
∆𝑃𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛 =
1.61
∆𝑃𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛 = 0.028361 𝑝𝑠𝑖
Friction Loss at discharge Pipe:

From equation 2-15 (potter, pp.56)

∆𝑃𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛
0.001295 (𝑓𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒)(𝐿𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒)(𝜌𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒)(𝑉𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒)2
=
𝑑𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒

Assume Length of Pipe:

Ldischarge = 100ft

For discharge friction factor, f from equation 2-18 (potter, pp.58)

64
𝑓=
𝑁𝑟
Solving for Reynold’s number from Eq 2-10 potter, pp.53

IDdischarge = 1.049 inch

𝑉𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒(𝐷𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒)(𝜌)
𝑁𝑟 =
𝜇

𝑓𝑡 𝑙𝑏
(450 min)(1.049𝑖𝑛𝑐ℎ)(62.4 )
𝑐𝑢𝑓𝑡
𝑁𝑟 =
𝑠 12𝑖𝑛𝑐ℎ 𝑙𝑏
(60 )( )(0.00022175 )
min 𝑓𝑡 𝑓𝑡 − 𝑠

𝑁𝑟 = 184491.5445

Then:

64
𝑓=
184491.5445
𝑓 = 0.0003469

Therefore:

𝑙𝑏
0.001295 (0.0003469)(100 𝑓𝑡)(62.4 )( 450𝑓𝑡/60𝑠)2
𝑐𝑢𝑓𝑡
∆𝑃𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛 =
1.049 𝑖𝑛𝑐ℎ
∆𝑃𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛 = 0.150316 𝑝𝑠𝑖
The Total Friction Loss at Deaerator water Piping:

∆𝑃𝑑𝑒𝑎𝑒𝑟𝑎𝑡𝑜𝑟 = ∆𝑃𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛 + ∆𝑃𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒

∆𝑃𝑑𝑒𝑎𝑒𝑟𝑎𝑡𝑜𝑟 = 0.028361 𝑝𝑠𝑖 + 0.150316 𝑝𝑠𝑖

∆𝑃𝑑𝑒𝑎𝑒𝑟𝑎𝑡𝑜𝑟 = 0.178677

Water Piping Diameter From Surface Heater to Boiler:

From heat balance calculation

QflowSH-B = Mc (1/62.4)(1/60)

QflowSH-B = 17.51813501 cu.ft/min

QflowSH-B = A(V)

Therefore:

@VsunctionSH = 200ft/min

𝑄𝑓𝑙𝑜𝑤𝑆𝐻−𝐵 (4)
d sunctionSH-B = √ (12)
𝜋(𝑉𝑠𝑢𝑛𝑐𝑡𝑖𝑜𝑛)

17.518135 𝑐𝑢𝑓𝑡/𝑚𝑖𝑛(4)
d sunctionSH-B = √ (12)
𝜋(200𝑓𝑡/𝑚𝑖𝑛)

d sunctionSH-B = 4.00742351 inch

Selection of Pipe Suction

From Plate 1, potter, pp.675 physical properties of pipe

Schedule 40

Nominal Outside Wall Inside Inside Internal Weight

Pipe Diameter, Thickness, Diameter, Diameter, Cross of pipe
Size, in in in in Fifth Sectional per ft-
Power Area lb
D t d D 5 Sq. in Sq. ft
5 5.563 0.258 5.047 3,275 20.01 0.138 14.62
Water Piping Discharge Diameter Surface Heater of Boiler

Therefore:

𝑉𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 = 450 𝑓𝑡/𝑚𝑖𝑛

𝑄𝑓𝑙𝑜𝑤𝑆𝐻−𝐵 (4)
d dischargeSH-B = √ (12)
𝜋(𝑉 𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒)

17.51813501 cu.ft/ min(4)

d dischargeSH-B = √ (12)
𝜋(450 𝑓𝑡/𝑚𝑖𝑛)

d dischargeSH-B = 2.67161568 inch

Selection of Pipe Discharge

From Plate 1 Potter, pp.675 physical properties of pipe

Schedule 40

Nominal Outside Wall Inside Inside Internal Weight

Pipe Diameter, Thickness, Diameter, Diameter, Cross of pipe
Size, in in in in Fifth Sectional per ft-
Power Area lb
D t d D5 Sq. Sq. ft
in
3 3.500 0.216 3.068 271.8 7.39 0.051 7.58
 APPENDICES

CHART, TABLES, CATALOGS & OTHER REFERENCES

SELECTION OF BOILER

FROM APPENDIX, PLATE 13 PP. 689 POWER PLANT THEOREY AND

DESIGN BY POTTER

Tubes Wide
Size of Boiler
44

Heating Surface 6506

Steam Outlet Size 6’’
F - 15
Feed Size 2 1/2’’
A Boiler Width-Outside Casing 13’- 10 1/2’’
Furnace Width-Outside
B 15’-0’’
Casing
C Furnace Wall Tubes 13’-8 3/4’’
Face to Face 7 ¼’’ Square
D 13’-2 1/2’’
Headers
E Width of Dampers 3’-6 1/4’’
F Drums 15’-2’’
G Drums 9’-9’’
H Overall Height 21’-0’’
j Height over Steam Outlet 19’-4’’
K Overall Length 18’-10 3/8’’
Drum to Outside Casing Front
L 6’-2’’
Wall
Inside Face Font Wall to
M 9’-0’’
Inside Face Bridgewall
N Damper Location-Horizontal 9 11/18’’
O Damper Location-Vertical 24 7/8’’
P Length of Damper 6’-6’’

SELECTION OF SURFACE ACE CONDENCER

FROM APPENDIX, PLATE 14 pp.690 POWER PLANT THEORY AND
DESIGN BY POTTER
DISTANCE REQUIRED
FRAME ACTIVE TUBE FOR WITHDRAWING MAX. NO.
NO. LENGHT TUBES OF TUBE

7000 18’’-0’’ 20’’-10’’ 2580

DIMENSIONS OF WESTING HOUSE TWO-PASS, NON-DIDVIDED WATER
BOX, RADIAL-FLOW SURFACE CONDENSERS

SELECTION OD SURFACE HEATER

From appendix, plate 7 pp.682 power plant theory design by potter
Surface Heater Dimensions
Shell OD 18

Number of ¾ in. Tubes

2 pass heater 220
4 pass heater 180
A inches 22
B inches 36

C = Tube length plus____ ,inches 30

Clearance to remove shell cover, inches 14

Clearance to withdraw tube bundle, inches =

12
tube length plus____,
SELECTION OF DEAERATOR
From appendix, plate 9 pp.683 power plant theory design by potter
Deaerator Dimensions (Vacuum to 50 psi)
Capacity lb/hr at oulet 10,000 to 25,000

A 30”
B 57
C 20
D as required (storage tank diameter should be
E equal to or larger then diameter heater top)
F
G 45
H 24
J 21
K 30
M 20
N 18
O 7
Q 10
R 10
S --
2A 14 ½
2B 32
2C 9¾
2D 8
2E 7¾
2F 10
2G --
3A Drainer
3B
3C
3D
Blow off 1½
Trap return 1½
Relief connection 2
Regulating valve 1½
Pump supply 5
Overflow 3
Evaporator 5
SELECTION OF BOILER PUMP

From Appendix, Plate 11 pp. 687 Power Plant Theory and Design by Potter

Boiler Feed Pumps Dimensions

PUMP SIZE – NUMBER OF STAGES

MOTRO HP RATING
(16 ft. minimum NPSH) (3500 rpm)
Developed Head Gallon per Minute
Psi 100
#1½–6
400
60

Pum Numbe Diameter

p r Suctio Discharg A B C D E F G
Size Stages n e
1½ 6 2½ 1½ 99” 103” 30” 33” 18” 29” 19”

SELECTION OF MAIN STEAM PIPES

From Appendix, Plate 1 pp. 675 Power Plant Theory and Design

Physical Properties of Pipe (From Boiler to Junction A)

Internal
Nominal Outside Wall Inside Inside Weight
cross-
Pipe Diamete thicknes Diamet Diameter, of pipe
sectional
Size, in. r, in. s, in. er, in. Fifth power per ft-lb
area
Sq.
D t d D5 Sq. in.
ft.
Schedule 40
0.20
6 6.25 0.280 6.065 8210 28.9 18.98
0
SELECTION OF PIPE SUNCTION

From Appendix, Plate 1 Physical Properties of Pipe pp. 675 Power Plant theory

and Design by Potter

Schedule 40

Nomina Outside Wall Inside Inside Internal Weigh

l Pipe Diameter Thickness Diameter Diameter Cross t of
Size, in , in , in , in , Sectional pipe
Fifth Area per ft-
Power lb
D T d D5 Sq. Sq. ft
in
2½ 2.875 0.203 2.469 91.8 4.7 0.03 5.794
9 3

Nomin Outside Wall Inside Inside Internal Weigh

al Pipe Diamete Thicknes Diamete Diamete Cross t of
Size, in r, in s, in r, in r, Sectional pipe
Fifth Area per ft-
Power lb
D T d D5 Sq. Sq.
in ft
2 2.375 0.154 2.067 37.73 3.35 0.02 3.653
6 3

SELECTION OF PIPE SUCTION

Form Plate 1, potter, pp.675 physical properties of pipe

Schedule 40

Nomin Outside Wall Inside Inside Internal Weigh

al Pipe Diamete Thicknes Diamete Diamete Cross t of
Size, in r, in s, in r, in r, Sectional pipe
Fifth Area per ft-
Power lb
D t d D5 Sq. Sq.
in ft
5 5.563 0.258 5.047 3,275 20.0 0.13 14.62
1 8
SELECTION OF PIPE DISCHARGE

From Plate 1 Potter, pp.675 physical properties of pipe

Nomina Outside Wall Inside Inside Internal Weigh

l Pipe Diameter Thickness Diameter Diameter Cross t of
Size, in , in , in , in , Sectional pipe
Fifth Area per ft-
Power lb
D t d D5 Sq. Sq. ft
in
3 3.500 0.216 3.068 271.8 7.3 0.05 7.58
9 1
 GLOSSARY

Air ejector - a device that uses a relatively high-pressure motive steam flow
through a nozzle to create a low-pressure or suction effect

Air vent - a device that allows the release of non-condensable gases from a
steam system

Blower - is a fan used to force air under pressure, that is, the resistance to gas
flow is imposed primarily upon the discharge

Boiler - a vessel or tank in which heat produced from the combustion of fuels
such as natural gas, fuel oil, wood, or coal is used to generate hot water or
steam for applications ranging from building space heating to electric power
production or industrial process heat

Boiler horsepower - a unit of rate of water evaporation equal to the

evaporation per hour of 34.5 pounds of water at a temperature of 212°F into
steam at 212°F. One boiler horsepower equals 33,475 Btu per hour or 35,322
Kilojoules per hour

British thermal unit (Btu) - the amount of heat required to raise the
temperature of one pound of water one degree Fahrenheit; equal to 252
calories. It is roughly equal to the heat of one kitchen match.

Bunker C Oil - Residual fuel oil of high viscosity commonly used in marine and
stationary steam power plants. (No. 6 fuel oil)

By-pass - A passage for a fluid, permitting a portion of the fluid to flow around
its normal pass flow channel.

Compressor - is a machine used to increase the pressure of a gas by

decreasing its volume

Condensate - Condensed water resulting from the removal of latent heat from
steam.

Condensate pump - a pump that pressurizes condensate allowing it to flow

back to a collection tank or boiler plant

Condenser - A device that condenses steam. Surface condensers use a heat

exchanger to remove energy from the steam, and typically operate under
vacuum conditions.
Cooling Range – is the difference in temperature between the hot water
entering and cold water leaving the tower

Deaerator - a device that uses steam to strip feed water of oxygen and carbon
dioxide. It sometimes also acts as pre-heater equipment
Drift – is the water lost as mist or droplets entrained by the circulating air and
discharge to the atmosphere. It is in addition to the evaporative loss and is
minimized by good design

Dry bulb temperature - is the temperature of air as registered by an ordinary

thermometer

Exhauster - is a fan used to withdraw air under suction, that is, the resistance
to gas flow is imposed primarily upon the inlet

Fan - a machine consisting of a rotor and housing for moving air or gases at
relatively low-pressure differentials

Fan - is a machine used to apply power to a gas to increase its energy content
thereby causing it to flow or to move

Fan Power Input – is the power required to drive the fan and any elements in
the drive train which are considered as a part of the fan. Power input can be
calculated from appropriate measurements for a dynamometer, torque meter
or calibrated motor

Fan Static Pressure – is the difference between the fan total pressure and the
velocity pressure. Therefore, fan static pressure is the difference between the
static pressure at the fan outlet and the total pressure at the fan inlet.

Fan Total Efficiency – is the ratio of the fan power output to the fan power
input

Feedwater - water sent into a boiler or a steam generator. Feed water typically
meets cleanliness criteria, contains treatment chemicals, and has been stripped
of oxygen.

Foundation - is the supporting part of the structure. It is a transmission or

structural connection whose design depends on the characteristics of both the
structure and the type of the soil and rock beneath.

Fuel header system -is designed to provide fuel to multiple generators, where
there are severe regulatory restrictions to the volume of fuel that can be stored
in the generator room. The header is an 8” to 12” diameter pipe which runs the
length of the room to serve all generators. The pipe is sized to be less than the
regulatory limit for fuel storage quantities in the room.

Induced draft tower –The fan is mounted on the top (discharge) of the cell,
with consequent improved air distribution within the cell; drift eliminators reduce
make-up requirements; spray nozzles, downspouts, splash plates and splash
bars ensure ample evaporative surface for the water, with maximum volumetric
heat transfer rates.

Kilowatt-hour (kWh) - The electrical energy unit of measure is equal to one

thousand watts of power supplied to, or taken from, an electric circuit steadily
for one hour.

Make-up water - water brought into a boiler system from outside to replace
condensate not returned to the boiler plant, water used in blow down, steam
lost through leaks, or water lost through evaporation or mist

Pressure Reducing Valve (PRV) - a valve that regulates the amount of steam
allowed from a high-pressure service to a low-pressure service

Process Steam - Steam used for industrial purposes other than for producing
power.

Pump - is a machine used to add energy to a liquid in order to transfer the liquid
from one point to another point of higher energy level.

Relief Valve (Safety Relief Valve) - An automatic pressure relieving device

actuated by the pressure upstream of the valve and characterized by opening
pop action with further increase in lift with an increase in pressure over popping
pressure.

Steam - The vapor phase of water, unmixed with other gases.

Turbine - A device that converts the enthalpy of steam into mechanical work.

Wet bulb temperature - is the temperature of air as registered by a

thermometer whose bulb is covered by a wetted wick and exposed to a current
of rapidly moving air.

Wet Steam - Steam containing a percentage of moisture

 BIBLIOGRAPHY

Avallone, Eugene & Baumeister, Theodore III; "Mark's Standard Handbook for
Mechanical Engineers"; 9th Edition

Frederick T. Morse, "Power Plant Engineering" Van Nostrand KEN incorporated

Copyright 1953.

Parker Sybil P., “Mc Graw Hill Dictionary of Engineering ", “Mc Graw Hill Book
Company Inc, New York, Copyright

Philippine Society of Mechanical Engineers; “The PSME Code of 2003”; 2003

Revision of PSME Code

Phillip Potter J., "Power Plant Theory and Design" Van Nostrand KEN
incorporated Copyright 1953.

Raka, A. J.,Srivastava, Amit Prakash, Dwivedi, Manish; "Power Plant

Engineering"

Salisbury, J. Kenneth;"Kent's Mechanical Engineer's Handbook: Volume 2:

Power Volume"; 12th Edition

Steam Tables; Thermodynamics Properties of Water Including Vapor, Liquid,

and Solid Phases, Keenan Keyes & Hill