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DESIGN AND LAYOUT PROBLEM FOR A COMBINED GAS-VAPOR POWER PLANT

General
A single Gas Turbine Power Plant topping the steam power plant that will
contain two identical controlled-extraction 5000-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/heat exchangers are to supply the plant steam
requirements (two boilers to carry maximum requirements of one turbine). The
boiler/heat exchanger room will be transferring it to the steam in a heat exchanger that
serves as the boiler.
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. A separate building shall be
provided for gas turbine power plant.

Data
Gas Turbine Power Plant
Compressor mechanical efficiency: 99%
Turbine and compressor adiabatic efficiencies: 85%
Generator electrical and mechanical efficiency: 98%
Burner efficiency: 95%
Turbine mechanical efficiency: 99%
Fuel: Natural gas with lower heating value of 20270 Btu/lb
Air enters the compressor suction at 95oF and 14.7 psia, and the gas turbine at
2060oF. The pressure ratio is 14. The exhaust gasses leave the heat exchanger at 350 oF.

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, 550oF, and 2 in. Hg.
Process Steam: 35000 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.
Condensers: Circulating water enters at 80oF, surface type, 2-pass, 18-gage ¾ in.
tubes, 6-fps water velocity, 75% cleanliness factor. Design 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 obtaine 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 60
oF.
 Page |2

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 % in high-
pressure blee 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 centreline 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 feedwater regulation
p. Determine the friction loss of the water piping
q. Determine the power penetrated by the gas turbine power plant
r. Determine amount of fuel consumed per hour]
s. Draw a TS diagram for the combined gas-vapor power plant
Page |3
 Page |4

A. Calculate heat balance for turbine hall and make schematic diagram with
flows, temperatures, and enthalpies.

5000 KW @ 400 psig

The value is 73.1% ; Engine Efficiency (Table 8 p. 8-61)

400 psig @ 550 0F

For the Rankine Cycle Ratio

For Emg:

Emg = (Mechanical Efficiency)(Generator Efficiency)

= (0.96)(0.95)

Emg = 91.2%
 Page |5

For Engine Efficiency :

Engine Efficiency = 73.1 x 1.0 x 0.98

Engine Eff. = 71.638%

For RCR or Stage Efficiency :

Engineefficiency
RCR 
Emg

RCR = 78.5504%

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

P1 = 400 psig + 14.7 = 414.7 psia

T1 = 550 0F

From Steam Table ( Table 3)

P h s

410 1276 1.5570

4.7 x1 x2

5 414.7 0.6 ℎ1 1.7x 10−3 𝑠1

415 1275.4 1.5553

For h1:

4.7 𝑥1 𝑥2
= =
5 0.6 1.7𝑥10−3

𝑥1 = 0.564

ℎ1 = 1276 + ( −0.564)

𝒃𝒕𝒖
𝒉𝟏 = 𝟏𝟐𝟕𝟓. 𝟒𝟑𝟔
𝒍𝒃

For S1:
 Page |6

𝑥 4.7
−3
=
1.7x 10 5

𝑋 = 1.598 𝑥 10−3

𝑆1 = 1.5570 − ( 1.598 𝑥 10−3 )

𝒃𝒕𝒖
𝑺𝟏 = 𝟏. 𝟓𝟓𝟓𝟒𝟎𝟐 ͦR
𝒍𝒃

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

𝑃2 = 𝑃1 − (4%)(𝑃1 )

= 414.7 – (414.7)(4%)

𝑷𝟐 = 𝟑𝟗𝟖. 𝟏𝟏𝟐 𝒑𝒔𝒊𝒂

With h1 = h2;

h2 = 1275.436

Solving For S2:

By double interpolation @ 395 psia and 400 psia

@ 395 psia

ℎ S t

1271.3 1.5562 540

4.136 X3 X4

6.2 1275.436 6.1𝑥10−3 s 10 t

1277.5 1.5623 550

 Page |7

S = 1.5562 + x3

(4.136)(6.1𝑥10−3 )
= 1.5562 +
6.2

𝑠 = 1.5603

@ 400 psia

ℎ S t

1270.8 1.5544 540

4.6 X X

6.2 1275.4 6.1𝑥10−3 s 10 t

1277.0 1.5605 550

S = 1.5544 + x

(4.636)(6.1𝑥10−3 )
= 1.5544 +
6.2

𝑠 = 1.55896

By interpolating the computed S values:

𝑃2 𝑆2

395 1.5603

3.112 X

5 398.112 1.34𝑥10−3 𝑆2

400 1.55896
 Page |8

𝑋 3.112
−3
=
1.34𝑥10 5

𝑋 = 8.34016 𝑥 10−4

𝑆2 = 1.5603 − 𝑥

𝑆2 = 1.5602 − (8.34016 𝑥 10−4 )

𝒃𝒕𝒖
𝑺𝟐 = 𝟏. 𝟓𝟓𝟗𝟒𝟕
𝒍𝒃 ˚𝑹
At Point 3: w/ P2 = 40 psia and S2 = S3’ = 1.55947

Solving for h3’ by interpolation:

Since 𝑆2 = 𝑆3′ = 1.55947 is beyond the values found in the Tables 3, we will use Table 2

@ 40 psia and with 𝑆2 = 𝑆3′ = 1.55947

hf = 236.16 sf = 0.39214

hfg = 933.8 sfg = 1.2845

′ ′
𝑆3′ = 𝑆𝑓3 + 𝑥𝑆𝑓𝑔3

′
𝑆3′ − 𝑆𝑓3
𝑥= ′
𝑆𝑓𝑔3

1.55947 − 0.39214
=
1.2845

𝑥 = 0.9087816271

′ ′
ℎ3′ = ℎ𝑓3 + 𝑥 ℎ𝑓𝑔3

= 236.16 + (0.9087816271)(933.8)

ℎ3′ = 1084.780283 𝑏𝑡𝑢/𝑙𝑏

 Page |9

Solving for 𝒉𝟑 using RCR:

ℎ2 − ℎ3
𝑅𝐶𝑅 = 𝑠𝑡𝑎𝑔𝑒 𝑒𝑓𝑓. =
ℎ2 − ℎ3′

RCR = 78.5504%

ℎ2 − ℎ3
78.5504% =
ℎ2 − ℎ3′

ℎ3 = ℎ2 − 𝑠𝑡𝑎𝑔𝑒 𝑒𝑓𝑓. (ℎ2 − ℎ3′ )

= 1275.436 − 0.785504(1275.436 − 1084.7803)

𝒃𝒕𝒖
𝒉𝟑 = 𝟏𝟏𝟐𝟓. 𝟔𝟕𝟓𝟐
𝒍𝒃

Solving 𝑆3 w/ ℎ3 = 1125.6752 𝑎𝑛𝑑 𝑃𝟑 = 40 𝑝𝑠𝑖𝑎

ℎ3 = ℎ𝑓3 + 𝑥ℎ𝑓𝑔3

ℎ3 − ℎ𝑓3
𝑥=
ℎ𝑓𝑔3

1125.6752 − 236.16
𝑥 =
933.8

𝑥 = 0.9525757121

𝑆3 = 𝑆𝑓3 + 𝑥𝑆𝑓𝑔3

𝑆3 = 0.39214 + (0.9525757121)(1.2845)

𝑏𝑡𝑢
𝑆3 = 1.61572
𝑙𝑏 ˚𝑅
 P a g e | 10

At point 4: w/ 𝑺𝟐 = 𝑺𝟒 ′ and 𝑷𝟒 = 𝟏𝟎𝒑𝒔𝒊𝒂

Solving for ℎ4′ :

hf = 161.23 sf = 0.28356

hfg = 982.1 sfg = 1.5041

′ ′
𝑆4′ = 𝑆𝑓4 + 𝑥𝑆𝑓𝑔4

′
𝑆4′ − 𝑆𝑓4
𝑥= ′
𝑆𝑓𝑔4

1.55947 − 0.28358
𝑥=
1.5041

𝑥 = 0.8482747158

′ ′
ℎ4′ = ℎ𝑓4 + ℎ𝑓𝑔4

ℎ4′ = 161.23 + (0.8482747158)(982.1)

ℎ4′ = 994.3206 𝑏𝑡𝑢/𝑙𝑏

ℎ1 − ℎ4
𝑅𝐶𝑅 = 𝑠𝑡𝑎𝑔𝑒 𝑒𝑓𝑓. =
ℎ1 − ℎ4′

ℎ4 = ℎ2 − 𝑠𝑡𝑎𝑔𝑒 𝑒𝑓𝑓. (ℎ2 − ℎ4′ )

ℎ4 = 1275.436 − (0.785504)(1275.436 − 994.3206)

𝒃𝒕𝒖
𝒉𝟒 = 𝟏𝟎𝟓𝟒. 𝟔𝟐𝟐𝟗𝟕
𝒍𝒃

Solving 𝑆4 with ℎ4 = 1054.62297 𝑎𝑛𝑑 𝑃4 = 10𝑝𝑠𝑖𝑎

ℎ4 = ℎ𝑓4 + 𝑥ℎ𝑓𝑔4

ℎ4 − ℎ𝑓4
𝑥=
ℎ𝑓𝑔4
 P a g e | 11

1054.62297 − 161.23
𝑥=
982.1

𝑥 = 0.9096761735

𝑠4 = 𝑠𝑓4 + 𝑥𝑠𝑓𝑔4

𝑠4 = 0.28358 + (0.9096761735)(1.5041)

𝑏𝑡𝑢
𝑠4 = 1.65182
𝑙𝑏 ˚𝑅

𝒃𝒕𝒖
A point 5:w/ 𝑷𝟓 = 𝟐𝒊𝒏. 𝑯𝒈. 𝒂𝒏𝒅 𝒖𝒔𝒊𝒏𝒈 𝒔𝟐 = 𝟏. 𝟓𝟓𝟗𝟒𝟕 𝒍𝒃 ˚𝑹

P ℎ𝑓 ℎ𝑓𝑔 𝑆𝑓 𝑆𝑓𝑔

0.90 66.25 1038.0 0.12642 18604

0.0797

0.1 0.9797 𝑋1 3.49 𝑋2 2 𝑋3 6.24𝑥10−3 𝑋4

0.0151

1.0 69.74 1036.0 0.13266 1.8453

(3.49)(0.0797)
𝑋1 = ℎ𝑓 = 66.25 + = 69.0.3153
0.10

(2)(0.0797)
𝑋2 = ℎ𝑓𝑔 = 1038.0 − = 1036.406
0.10

(6.24𝑥10−3 )(0.0797)
𝑋3 = 𝑆𝑓 = 0.12642 + = 0.13139328
0.10

(0.0151)(0.0797)
𝑋4 = 𝑆𝑓𝑔 = 1.8604 − = 1.8483653
0.10
 P a g e | 12

𝑆1 = 𝑆𝑓 + 𝑥 𝑆𝑓𝑔

𝑆1 − 𝑆𝑓
𝑥=
𝑆𝑓𝑔

1.555402 − 0.13139323
𝑥=
1.8483653

𝑥 = 0.7704151988

For ℎ5′ :

ℎ5 ′ = ℎ𝑓5 ′ + 𝑥 ℎ𝑓𝑔5 ′

ℎ5′ = 69.03153 + ( 0.7704151988)(1036.406)

𝑏𝑡𝑢
ℎ5′ = 867.494
𝑙𝑏

Solving for ℎ5 :

ℎ1 − ℎ5
𝑅𝐶𝑅 =
ℎ1 − ℎ5 ′

ℎ5 = ℎ1 − 𝑠𝑡𝑎𝑔𝑒 𝑒𝑓𝑓. (ℎ1 − ℎ5′ )

= 1275.436 − ( 0.7704151988)(1275.436 − 867.494)

𝒃𝒕𝒖
𝒉𝟓 = 𝟗𝟓𝟒. 𝟗𝟗𝟓𝟗𝟑
𝒍𝒃
 P a g e | 13

LIST OF FINAL ENTHALPIES:

𝑏𝑡𝑢
ℎ1 = 1275.436 𝑙𝑏

𝑏𝑡𝑢
ℎ2 = 1275.436 𝑙𝑏

𝑏𝑡𝑢
ℎ3 = 1125.6752 𝑙𝑏

𝑏𝑡𝑢
ℎ4 = 1054.62297
𝑙𝑏

𝑏𝑡𝑢
ℎ5 = 954.99593
𝑙𝑏

FOR ESTIMATING THE THROTTLE FLOW

𝑲𝑾 𝒄𝒂𝒑
𝑻𝒐𝒕𝒂𝒍 𝒐𝒖𝒕𝒑𝒖𝒕 =
𝑬𝒎𝒈

𝟓𝟎𝟎𝟎
=
𝟎. 𝟗𝟏𝟐

𝑻𝒐𝒕𝒂𝒍 𝒐𝒖𝒕𝒑𝒖𝒕 = 𝟓, 𝟒𝟖𝟐. 𝟒𝟓𝟔𝟏𝟒𝟎𝟑𝟓

FOR NON-BLEEDING THROTTLE FLOW

5
𝑇𝑜𝑡𝑎𝑙 𝑜𝑢𝑡𝑝𝑢𝑡 (4) (3413)
𝑇ℎ𝑟𝑜𝑡𝑡𝑙𝑒 𝐹𝑙𝑜𝑤𝑁𝐵 =
ℎ1 − ℎ5

5
5,482.45614035 (4) (3413)
𝑇ℎ𝑟𝑜𝑡𝑡𝑙𝑒 𝐹𝑙𝑜𝑤𝑁𝐵 =
1275.436 − 954.99593

𝑻𝒉𝒓𝒐𝒕𝒕𝒍𝒓 𝑭𝒍𝒐𝒘𝑵𝑩 = 𝟕𝟐𝟗𝟗𝟏. 𝟖𝟗𝟔𝟕𝟔𝟒𝟖𝟖

 P a g e | 14

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

1
[(𝑇ℎ𝑟𝑜𝑡𝑡𝑙𝑒 𝐹𝑙𝑜𝑤𝑁𝐵 + 2 𝑃𝑆)] + [𝑇ℎ𝑟𝑜𝑡𝑡𝑙𝑒 𝐹𝑙𝑜𝑤𝑁𝐵 (ℎ4 − ℎ𝑓@2𝑖𝑛𝐻𝑔 )]
𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒1
5
(𝐾𝑊𝑐𝑎𝑝)
𝟒

[(72991.89676488+17500)(1275.436−1054.62297)]+[72991.89676488(1054.62297−69.03153)]
5
(5000)
4

𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒1 = 14707.51656895

ASSUME THAT THE FINAL TEMPERATURE OF FEEDD WATER IS:

𝑇𝑓𝑤 = 239.0583772

𝑇𝑒𝑚𝑝@2𝑖𝑛𝐻𝑔 = 100.9895

𝐹𝑒𝑒𝑑 𝑤𝑎𝑡𝑒𝑟 𝑡𝑜𝑡𝑎𝑙 𝑟𝑖𝑠𝑒 = 239.0583772 − 100.9895

𝐹𝑒𝑒𝑑 𝑤𝑎𝑡𝑒𝑟 𝑡𝑜𝑡𝑎𝑙 𝑟𝑖𝑠𝑒 = 138.0688772

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

temperature = 138.0688772

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]

= 14707.51656895[1 − 0.057 − 0.00426]

𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒 = 13806.53410394

 P a g e | 15

Since the plant generates process steam & electrical energy is by produce the turbine

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

3413
𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒 = 𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒 +
𝐸𝑚𝑔

3413
𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒 = 13880.91834407 +
0.912

𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒 = 17,548.85866534

At 𝑇𝒇𝒘 = 239.0583772

Form steam table

T hfw

238 206.42

1.0583772

239.0583772 x 2.02

240 208.44

1.0583772(2.02)
𝑥=
2
𝑥 = 1.068960972

ℎ𝑓𝑤 = 206.42 + 1.068960872

ℎ𝒇𝒘 = 207.48896096

Form Equation 11-1

𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒 (𝐾𝑊𝑐𝑎𝑝)

𝑊=
ℎ1 − ℎ𝑓@239.053772

17,623.24290547(5000)
=
1275.436 − 207.48896096

𝑾 = 𝟖𝟐, 𝟏𝟔𝟏. 𝟔𝟓𝟐𝟑𝟐𝟖𝟑𝟓

 P a g e | 16

𝑰𝒃
Assume that 𝒎𝑻 = 𝟖𝟔𝟎𝟑𝟎. Approximately &Reduce by 200𝒉𝒓 . For Air Ejector

Therefore 𝒎𝑻 = 𝟖𝟓𝟖𝟑𝟎

HEAT BALANCE FOR DEAERATOR

𝒎𝟐

𝒉𝟒

𝟏
𝒎𝑾 = 𝟐 𝑷𝑺 + 𝟎. 𝟎𝟐𝒎𝑻 9 psia 𝟏
𝒎𝟐 + 𝟐 𝑷𝑺 + 𝟎. 𝟎𝟐𝒎𝑻

𝒎𝟐 𝒉𝟒 = 𝒎𝟐 𝒉𝒇@𝟗𝒑𝒔𝒊𝒂 + 𝒎𝑾 (𝒉𝒇@𝟗𝒑𝒔𝒊𝒂 − 𝒉𝒇@𝟔𝟎𝑭 )

𝒎𝑾 (𝒉𝒇@𝟗𝒑𝒔𝒊𝒂 − 𝒉𝒇@𝟔𝟎𝑭 )
𝒎𝟐 =
𝒉𝟒 − 𝒉𝒇@𝟗𝒑𝒔𝒊𝒂

𝟏
𝒎𝑾 = 𝑷𝑺 + 𝟎. 𝟎𝟐𝒎𝑻
𝟐

(𝟏𝟕𝟓𝟎𝟎 + 𝟎. 𝟎𝟐(𝟖𝟓𝟖𝟑𝟎))(𝟏𝟓𝟔. 𝟐𝟕 − 𝟐𝟖. 𝟎𝟖)

𝒎𝟐 =
𝟏𝟎𝟓𝟒. 𝟔𝟐𝟐𝟗𝟕 − 𝟏𝟓𝟔. 𝟐𝟕

𝒎𝟐 = 𝟐𝟕𝟒𝟐. 𝟏𝟎𝟐𝟓𝟑𝟐𝟑𝟕
 P a g e | 17

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@9𝑝𝑠𝑖𝑎 )] + [(𝑚 𝑇 − 𝑃𝑆 − 𝑚2 ) (ℎ𝑓@225.96𝐹 )]
2 2
= 1.02𝑚 𝑇 (ℎ𝑓𝑤 )

1 1
[(𝑚2 + 2 𝑃𝑆 + 0.02𝑚 𝑇 ) (ℎ𝑓@9𝑝𝑠𝑖𝑎 ) + [(𝑚 𝑇 − 2 𝑃𝑆 − 𝑚2 ) (ℎ𝑓@225.96𝐹 )]
ℎ𝑓𝑤 =
1.02𝑚 𝑇

[(2742.10253237 + 17500 + 0.02(85830)(156.27)] + [(85830 − 17500 − 2742.10253237)(22

=
1.02(85830)

ℎ𝑓𝑤 = 207.49017735

For 𝒎𝑪

𝟏
𝒎𝑪 = 𝒎𝑻 − 𝒎𝟐 − 𝑷𝑺
𝟐
𝒎𝑪 = 𝟖𝟓𝟖𝟑𝟎 − 𝟐𝟕𝟒𝟐. 𝟏𝟎𝟐𝟓𝟑𝟐𝟑𝟕 − 𝟏𝟕𝟓𝟎𝟎

𝒎𝑪 = 𝟔𝟓𝟓𝟖𝟕. 𝟖𝟗𝟕𝟒𝟔𝟕𝟔𝟑

For 𝒎𝑾

𝟏
𝒎𝑾 = 𝑷𝑺 + 𝟎. 𝟎𝟐𝒎𝑻
𝟐
𝒎𝑾 = 𝟏𝟕𝟓𝟎𝟎 + 𝟎. 𝟎𝟐(𝟖𝟓𝟖𝟑𝟎)

𝒎𝑾 = 𝟏𝟗𝟐𝟏𝟔. 𝟔
 P a g e | 18

HEAT BALANCE AT AIR EJECTOR

ℎ𝑓@2𝑖𝑛𝐻𝑔 = 69.03153

200∆ℎ

𝑚𝐶 ℎ𝐶

𝑚𝐶 (ℎ𝐶 − ℎ𝑓@2𝑖𝑛𝐻𝑔 ) = 200∆ℎ

200(1000)
ℎ𝐶 = + 69.03153
65587.89746763

ℎ𝐶 = 72.08087306

HEAT BALANCE AT SURFACE HEATER

Pressure @ surface heater = 36 psia

Tsat=260.96 0F

With Temperature Difference of 5 0F

𝑇2 = 𝑇𝑠𝑎𝑡 − 𝑇𝑑

𝑇2 = 260.96 − 5

𝑇2 = 255.96
 P a g e | 19

𝑚1

ℎ3

𝑚𝐶 𝑚𝐶

ℎ𝑓@𝑇2 ℎ𝐶

𝑚1

T hf

254 222.65

1.96

2 255.96 X 2.03

256 224.68

By interpolation:
255.96−254
𝑥= (224.68 − 222.65)
256−254

ℎ𝑓@36𝑝𝑠𝑖𝑎 = 229.75

𝐸𝑖𝑛 = 𝐸𝑜𝑢𝑡

𝑚𝐶 ℎ𝐶 + 𝑚1 ℎ3 = 𝑚1 ℎ𝑓@36𝑝𝑠𝑖𝑎 + ℎ𝑓@𝑇2

𝑚𝐶 (ℎ𝑓@𝑇2 − ℎ𝐶 )
𝑚1 =
ℎ3 − ℎ𝑓@36𝑝𝑠𝑖𝑎

65587.89746763(224.6394 − 72.08087306)
=
1125.6752 − 229.73
𝑚1 = 11168.08597525
 P a g e | 20

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 = 11225.23684584 𝑚1 = 11225.23684584

𝑚2 = 2743.04431587 𝑚 𝑇 = 86160

𝑚𝐶 = 65916.95568

1
𝑃𝑆 = 17500
2

96998.08597525 96998.08597525

The output of the Turbine

Internal KW=
1
(𝑚𝑇 −200)(ℎ1 −ℎ3 )+(𝑚𝑇 −200−𝑚1 )(ℎ3 −ℎ4 )+(𝑚𝑇 −200−𝑚1 −𝑚2 − 𝑃𝑆)(ℎ4 −ℎ5 )
2
5
(3413)
4

=
(85630)(149.7608)+(74461.91402475)(71.05223)+(54219.81149237)(97.8349525)−1.917(65587.89746763
5
(3413)
4

Internal KW = 5482.73769105
 P a g e | 21

𝐾𝑊𝑐𝑎𝑝
𝑙𝑜𝑠𝑠𝑒𝑠 = − 𝐾𝑊𝑐𝑎𝑝
𝐸𝑚𝑔

5000
= − 5000
0.912

𝐿𝑜𝑠𝑠𝑒𝑠 = 482.4561404

Therefore Net output will be:

𝑜𝑢𝑡𝑝𝑢𝑡 = 𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝐾𝑤 − 𝐿𝑜𝑠𝑠𝑒𝑠

= 5482.1779944 − 482.73769105

𝑜𝑢𝑡𝑝𝑢𝑡 = 5000.28155069
Correction:

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

86160
= (5000.28155069 − 5000) ( )
5000

𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 = 4.40756015

For Work Turbine:

1
= (𝑚 𝑇 − 200)(ℎ1 − ℎ3 ) + (𝑚 𝑇 − 200 − 𝑚1 )(ℎ3 − ℎ4 ) + (𝑚 𝑇 − 200 − 𝑚1 − 𝑚2 − 𝑃𝑆) (ℎ4 − ℎ5 )
2
− 1.917𝑚𝐶

= 12824017.304 + 5290685.04152648 + 5401759.3283433 − 125731.99944544

𝑊𝑇 = 23390729.67
FOR CHECKING

5
3413 (4) (𝐾𝑊𝑐𝑎𝑝)
𝑂𝑢𝑡𝑝𝑢𝑡 =
𝐸𝑚𝑔

5
3413 (4) (5000)
𝑂𝑢𝑡𝑝𝑢𝑡 =
0.912

𝑂𝑢𝑡𝑝𝑢𝑡 = 23389528.51
 P a g e | 22

CHECKING THE CAPACITY

𝑜𝑢𝑡𝑝𝑢𝑡(𝐸𝑚𝑔 ) 𝑊𝑇 (𝐸𝑚𝑔 )
𝐾𝑊𝑐𝑎𝑝 = 5 𝐾𝑊 = 5
3413(4) 3413( )
4

23389528.51(0.912) 23390729.67(0.912)
𝐾𝑊𝑐𝑎𝑝 = 5 𝐾𝑊 = 5
3413(4) 3413(4)

𝐾𝑊𝑐𝑎𝑝 = 5000 𝐾𝑊 = 5000.256774

EXTRACTIO FACTOR

ℎ3 − ℎ5 1125.6752 − 954.99593
𝐹𝑅𝐼𝑆𝑇 𝐵𝐿𝐸𝐸𝐷 = = = 0.53264022
ℎ1 − ℎ5 1275.436 − 954.99593

ℎ4 − ℎ5 1054.62297 − 954.99593
𝑆𝐸𝐶𝑂𝑁𝐷 𝐵𝐿𝐸𝐸𝐷 = = = 0.31090693
ℎ1 − ℎ5 1275.436 − 954.99593

NON-BLEEDING STEAM RATE

5
(3413) 1.25(3413)
=4 =
ℎ1 − ℎ5 1275.436 − 954.99593

𝑁𝑂𝑁 𝐵𝐿𝐸𝐸𝐷𝐼𝑁𝐺 𝑆𝑇𝐸𝐴𝑀 𝑅𝐴𝑇𝐸 = 13.31372197

For 5000 KW capacity w/ 482.4561404 Losses. The Throttle Flow required will be:

REPLACEMENT FLOW

Non-bleeding throttle flow

= (𝐾𝑊 + 𝐿𝑜𝑠𝑠𝑒𝑠)(𝑛𝑜𝑛 𝑏𝑙𝑒𝑒𝑑)

= (5000 + 482.4561404)(13.31372197)

𝑁𝑜𝑛 − 𝑏𝑙𝑒𝑒𝑑𝑖𝑛𝑔 𝑇ℎ𝑟𝑜𝑡𝑡𝑙𝑒 𝐹𝑙𝑜𝑤 = 72991.89676488

 P a g e | 23

For 5000 KW capacity w/ 482.4561404 Losses. The Throttle Flow required will be:

REPLACEMENT FLOW

Non-bleeding throttle flow

= (𝐾𝑊 + 𝐿𝑜𝑠𝑠𝑒𝑠)(𝑛𝑜𝑛 𝑏𝑙𝑒𝑒𝑑)

= (5000 + 482.4561404)(13.31372197)

𝑁𝑜𝑛 − 𝑏𝑙𝑒𝑒𝑑𝑖𝑛𝑔 𝑇ℎ𝑟𝑜𝑡𝑡𝑙𝑒 𝐹𝑙𝑜𝑤 = 72991.89676488

REPLACEMENT STEAM

1st Replacement
𝐹𝑖𝑟𝑠𝑡 𝐵𝑙𝑒𝑒𝑑 = 𝑚1 (𝑓𝑖𝑟𝑠𝑡 𝑏𝑙𝑒𝑒𝑑)

= 11225.23684584(0.53264022)

𝐹𝑖𝑟𝑠𝑡 𝐵𝑙𝑒𝑒𝑑 = 5948.57179239

2nd Replacement

1
𝑆𝑒𝑐𝑜𝑛𝑑 𝐵𝑙𝑒𝑒𝑑 = (𝑚2 + 𝑃𝑆)(𝑠𝑒𝑐𝑜𝑛𝑑 𝑏𝑙𝑒𝑒𝑑)
2

= (2742.10253237 + 17500)(0.31090693)

𝑆𝑒𝑐𝑜𝑛𝑑 𝐵𝑙𝑒𝑒𝑑 = 6293.41005535

Total Flow required when bleeding

= 72991.89676488 + 5948.57179239 + 6293.41005535

𝒕𝒐𝒕𝒂𝒍 = 𝟖𝟓𝟐𝟑𝟑. 𝟖𝟕𝟖𝟔𝟏

CONSIDERING THE CORRECTION

𝑇𝑜𝑡𝑎𝑙 = 85233.87861 + 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛

= 85566.86534 + 4.40756015

𝑇𝑜𝑡𝑎𝑙 = 85571.2729
 P a g e | 24

FOR TURBINE HEAT RATE

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

1275.436(85830 − 19216.6) − 85830(207.49017735)

=
5000.28155069

𝐻𝐸𝐴𝑇 𝑅𝐴𝑇𝐸 = 13429.71395558

FOR ∆𝒉

𝑚𝐶 (ℎ𝐶 − ℎ𝑓@2𝑖𝑛𝐻𝑔 )
∆ℎ =
200

65587.89146763(72.08087306 − 69.03153)
=
200

∆ℎ = 1000

B. CALCULATE THE BOILER SIZE AND SELECT BOILER

1
𝑚𝑓𝑤 = 𝑚2 + 0.02𝑚 𝑇 + 𝑃𝑆 + 𝑚𝐶
2

= 2742.10253237 + 0.02(85860) + 17500 + 65587.89146763

87546.6
𝑚𝑓𝑤 = = 43773.3
2

Solving for the mass Flow Rate of Blow down

𝑚𝑏𝑑 = 0.01𝑚 𝑇

𝑚𝑏𝑑 = 0.01(85830)

𝑚𝑏𝑑 = 858.3
 P a g e | 25

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

𝒎𝒔𝒕𝒆𝒂𝒎𝒃𝒐𝒊𝒍𝒆𝒓 = 𝒎𝒇𝒘 − 𝒎𝒃𝒅

= 𝟒𝟑𝟕𝟕𝟑. 𝟑 − 𝟖𝟓𝟖. 𝟑

𝒎𝒔𝒕𝒆𝒂𝒎𝒃𝒐𝒊𝒍𝒆𝒓 = 𝟒𝟐𝟗𝟏𝟓

Solving for 𝒉𝑺 enthalpy of steam

ℎ5 = ℎ1 = 1275.436

Enthalpy o Blow down, 𝒉𝒃𝒅

ℎ𝑏𝑑 = ℎ𝑓@400𝑝𝑠𝑖𝑔 + 14.7

𝑃 = 414.7 𝑝𝑠𝑖𝑎

DIVIDED BY 0.95 ONE TO 5% PD IN HIGH PRESSURE; BLEED LINE

414.7
𝑃= = 436.5261579
0.95

FOR 𝒉𝒃𝒅 by interpolation

P hf

430 432.2

6.52631579
10 436.52631579 x 2.6

440 434.8

6.52631579(2.6)
𝑥=
10

𝑥 = 1.69684211

ℎ𝑏𝑑 = 432.2 + 1.69684211

ℎ𝑏𝑑 = 433.89684211
 P a g e | 26

FOR THE GAS TURBINE CYCLE

DATA:

𝑷𝟏𝑮 = 𝟏𝟒. 𝟕

𝑻𝟏𝑮 = 𝟗𝟓 + 𝟒𝟔𝟎 = 𝟓𝟓𝟓

𝑻𝟑𝑮 = 𝟐𝟎𝟔𝟎 + 𝟒𝟔𝟎 = 𝟐𝟓𝟐𝟎

𝑻𝒃𝒐𝒊𝒍𝒆𝒓𝒆𝒙𝒉𝒂𝒖𝒔𝒕 = 𝟑𝟓𝟎 + 𝟒𝟔𝟎 = 𝟖𝟏𝟎

𝑪𝒐𝒎𝒑𝒓𝒆𝒔𝒔𝒐𝒓𝒎𝒆𝒄𝒉𝒂𝒏𝒊𝒄𝒂𝒍𝒆𝒇𝒇 = 𝟎. 𝟗𝟗

𝑻𝒖𝒓𝒃𝒊𝒏𝒆𝒄𝒐𝒎𝒑𝒂𝒅𝒊𝒂𝒃𝒂𝒕𝒊𝒄𝒆𝒇𝒇 = 𝟎. 𝟖𝟓

𝑮𝒆𝒎𝒆𝒇𝒇 = 𝟎. 𝟗𝟖

𝑩𝒖𝒓𝒏𝒆𝒓𝒆𝒇𝒇 = 𝟎. 𝟗𝟓

𝑻𝒖𝒓𝒃𝒊𝒏𝒆𝒎𝒆𝒄𝒉𝒆𝒇𝒇 = 𝟎. 𝟗𝟗

𝑷𝒓𝒆𝒔𝒔𝒖𝒓𝒆𝒓𝒆𝒕𝒊𝒐 = 𝟏𝟒

FUEL: Natural Gas

𝑳𝑯𝑽 = 𝟐𝟎𝟐𝟕𝟎

At point 1 of the gas cycle:

From the table of properties of air

𝑻𝟏𝑮 = 𝟓𝟓𝟓

𝑷𝟏𝑮 = 𝟏𝟒. 𝟕
 P a g e | 27

By interpolation from the given table

T h Pr

540 129.06 1.3860

555 Xh XPr

560 133.86 1.5742

For the enthalpy of point 1

𝟓𝟓𝟓−𝟓𝟒𝟎
𝑿𝒉 = 𝟓𝟔𝟎−𝟓𝟒𝟔 (𝟏𝟑𝟑. 𝟖𝟔 − 𝟏𝟐𝟗. 𝟎𝟔)

𝑿𝒉 = 𝟑. 𝟔

𝒉𝟏𝑮 = 𝟏𝟐𝟗. 𝟎𝟔 + 𝑿𝒉

𝒉𝟏𝑮 = 𝟏𝟑𝟐. 𝟔𝟔

𝟓𝟓𝟓 − 𝟓𝟒𝟎
𝑿𝑷𝒓 = (𝟏. 𝟓𝟕𝟒𝟐 − 𝟏. 𝟑𝟖𝟔𝟎)
𝟓𝟔𝟎 − 𝟓𝟒𝟎

𝑿𝑷𝒓 = 𝟎. 𝟏𝟒𝟏𝟏𝟓

𝑷𝒓𝟏𝑮 = 𝟏. 𝟑𝟖𝟔𝟎 − 𝑿𝑷𝒓

𝑷𝒓𝟏𝑮 = 𝟏. 𝟓𝟐𝟕𝟏𝟓
 P a g e | 28

At point 2 the gas cycle

For P2

𝑷𝟐𝑮
= 𝑷𝒓𝒆𝒔𝒔𝒖𝒓𝒆𝒓𝒂𝒕𝒊𝒐
𝑷𝟏𝑮

𝑷𝟐𝑮 = 𝑷𝒓𝒆𝒔𝒔𝒖𝒓𝒆𝒓𝒂𝒕𝒊𝒐 (𝑷𝟏𝑮 )

For Pr2

𝑷𝟐𝑮 𝑷𝒓
= 𝑷𝒓𝟐𝑮
𝑷𝟏𝑮 𝟏𝑮

𝑷
𝑷𝒓𝟐𝑮 = 𝑷𝟐𝑮 (𝑷𝒓𝟏𝑮 )
𝟏𝑮

𝑷𝒓𝟐𝑮 = 𝟐𝟏. 𝟑𝟖𝟎𝟏

For the temperature and enthalpy of point 2 in the gas cycle

From the table of properties of air:

Using 𝑷𝒓𝟐𝑮 = 𝟐𝟏. 𝟑𝟖𝟎𝟏

Pr h2G T2G

21.18 281.14 1160

21.3801 Xh2 XT2

24.01 291.30 1200

 P a g e | 29

For the ideal enthalpy of point 2

𝟐𝟏.𝟑𝟖𝟎𝟏−𝟐𝟏.𝟏𝟖
𝑿𝒉𝟐 = (𝟐𝟗𝟏. 𝟑𝟎 − 𝟐𝟖𝟏. 𝟏𝟒)
𝟐𝟒.𝟎𝟏−𝟐𝟏.𝟏𝟖

𝑿𝒉𝟐 = 𝟎. 𝟕𝟏𝟖𝟑𝟖𝟎𝟐𝟏

𝒉𝟐𝑮𝒊𝒅𝒆𝒂𝒍 = 𝟐𝟖𝟏. 𝟏𝟒 + 𝑿𝒉𝟐

𝒉𝟐𝑮𝒊𝒅𝒆𝒂𝒍 = 𝟐𝟖𝟏. 𝟖𝟓𝟖𝟑𝟖𝟎𝟐𝟏

For the actual enthalpy of point 2

𝒉𝟐
𝑮𝒊𝒅𝒆𝒂𝒍 −𝒉𝟏𝑮
𝒉𝟐𝑮𝒂𝒄𝒕𝒖𝒂𝒍 = 𝒉𝟏𝑮 + 𝑻𝒖𝒓𝒃𝒊𝒏𝒆𝒄𝒐𝒑𝒎
𝒂𝒅𝒊𝒂𝒃𝒂𝒕𝒊𝒄𝒆𝒇𝒇

𝒉𝟐𝑮𝒂𝒄𝒕𝒖𝒂𝒍 = 𝟑𝟎𝟖. 𝟏𝟖𝟕𝟓𝟎𝟔𝟏𝟑

For the temperature of point 2

𝟐𝟏.𝟑𝟖𝟎𝟏−𝟐𝟏.𝟏𝟖
𝑿𝑻𝟐𝑮 = (𝟏𝟐𝟎𝟎 − 𝟏𝟏𝟔𝟎)
𝟐𝟒.𝟎𝟏−𝟐𝟏.𝟏𝟖

𝑿𝑻𝟐𝑮 = 𝟐. 𝟖𝟐𝟖𝟐𝟔𝟖𝟓𝟓

𝑻𝟐𝑮 = 𝟏𝟏𝟔𝟎 + 𝑿𝑻𝟐𝑮

𝑻𝟐𝑮 = 𝟏𝟏𝟔𝟐𝟐. 𝟖𝟐𝟖𝟐𝟔𝟖𝟓𝟓

 P a g e | 30

At point 3 of the gas cycle

Using the given temperature at point 3

𝑻𝟑𝑮 = 𝟐𝟓𝟐𝟎

From the table of the properties of air

T h3G Pr3G

2500 645.78 435.7

2520 Xh3G XPr3G

2550 660.12 473.3

For the enthalpy of point 3

𝟐𝟓𝟐𝟎−𝟐𝟓𝟎𝟎
𝑿𝒉𝟑𝑮 = 𝟐𝟓𝟓𝟎−𝟐𝟓𝟎𝟎 (𝟔𝟔𝟎. 𝟏𝟐 − 𝟔𝟒𝟓. 𝟕𝟖)

𝑿𝒉𝟑𝑮 = 𝟓. 𝟕𝟑𝟔

𝒉𝟑𝑮 = 𝟔𝟒𝟓. 𝟕𝟖 + 𝑿𝒉𝟑𝑮

𝒉𝟑𝑮 = 𝟔𝟓𝟏. 𝟓𝟏𝟔

 P a g e | 31

For the Pr of point 3

𝟐𝟓𝟐𝟎−𝟐𝟓𝟎𝟎
𝑿𝑷𝒓𝟑𝑮 = 𝟐𝟓𝟓𝟎−𝟐𝟓𝟎𝟎 (𝟒𝟕𝟑. 𝟑 − 𝟒𝟑𝟓. 𝟕)

𝑿𝑷𝒓𝟑𝑮 = 𝟏𝟓. 𝟎𝟒

𝑷𝒓𝟑𝑮 = 𝟒𝟑𝟓. 𝟕 + 𝑿𝑷𝒓𝟑𝑮

𝑷𝒓𝟑𝑮 = 𝟒𝟓𝟎. 𝟕𝟒

At point 4 of the gas cycle

𝑷𝒓𝟒𝑮 𝟏
=
𝑷𝒓𝟑𝑮 𝑷𝒓𝒆𝒔𝒔𝒖𝒓𝒆𝒓𝒂𝒕𝒊𝒐

𝟏
𝑷𝒓𝟒𝑮 = 𝑷𝒓𝒆𝒔𝒔𝒖𝒓𝒆 (𝑷𝒓𝟑𝑮 )
𝒓𝒂𝒕𝒊𝒐

𝑷𝒓𝟒𝑮 = 𝟑𝟐. 𝟏𝟗𝟓𝟕𝟏𝟒𝟐𝟗

From the table properties of air

By interpolation

Using Pr4G=32.1957143

Pr4G h4G T4G

30.55 311.79 1280

32.19571 Xh4G XT4G

34.31 322.11 1320

 P a g e | 32

For the ideal enthalpy of point 4

𝟑𝟐.𝟏𝟗𝟓𝟕𝟏.𝟑𝟎.𝟓𝟓
𝑿𝒉𝟒𝑮 = (𝟑𝟐𝟐. 𝟏𝟏 − 𝟑𝟏𝟏. 𝟕𝟗)
𝟑𝟒.𝟑𝟏−𝟑𝟎.𝟓𝟓

𝑿𝒉𝟒𝑮 = 𝟒. 𝟓𝟏𝟔𝟗𝟒𝟖𝟕𝟐

𝒉𝟒𝑮𝒊𝒅𝒆𝒂𝒍 = 𝟑𝟏𝟏. 𝟕𝟗 + 𝑿𝒉𝟒𝑮

𝒉𝟒𝑮𝒊𝒅𝒆𝒂𝒍 = 𝟑𝟔𝟔. 𝟓𝟖𝟖𝟑𝟎𝟔𝟒𝟏

For the temperature at point 4

32.19571  30.55
XT4g   ( 1320  1280)
34.31  30.55

XT4g  17.50755319

T4g  1280  XT4g

T4g  1297.50755319

FOR THE WEIGHT OF FUEL

Wf = weight of fuel

h3g  h2gactual
Wf 

LHV  Burner eff. 
Wf  0.01782923

FOR WORK OF THE COMPRESSOR

h2gactual  h1g
Workcompressor 
Compressormechanicaleff.

Workcompressor  177.30051124
 P a g e | 33

FOR WORK OF GAS TURBINE


Workgasturbine  Turbinemecheff.  h3g  h4gactual  1  Wf  
Workgasturbine  287.10765654

WORK NET OF THE GAS CYCLE

Worknetgas  Workgasturbine  Workcompressor

Worknetgas  109.80714529

WEIGHT OF AIR REQUIRED TO PRODUCE A GIVEN OUTPUT

From equation 12-5 (potter, pp.559)

5
capacity  ( 3413) 
4
Wair.required 

GEMeff.  Worknetgas 
Wair.required  198225.54874894

HEAT BALANCE AT THE BOILER

For the enthalpy of the exhaust:

Boiler temperature exhaust = 350+460 = 810R

Using the table of properties of air
Tboilerexhaust  810

T5exhaust hboilerexhaust

800 191.81
810 Xexhaust

820 196.69

810  800
Xexchaust   ( 196.69  191.81)
820  800

Xexchaust  2.44
 P a g e | 34

hboilerexhaust  191.81  Xexchaust

hboilerexhaust  194.25
FOR MASS OF THE EXHAUST

  
Mfeedwater  hf.feedwater  Me  1  Wf h4    
Msteamboiler  h1  Mb  hb  Me  1  Wf  h  
Me 
   
Msteamboiler  h1  Mb  hb  Mfeedwater  hf.feedwater 
 
1  Wf  h4gactual  hboilerexhaust 
Me  262384.92784404

SINCE THERE ARE 4 BOILER IN THE PLANT

 
Mtotalexhaust  4  Me

Mtotalexhaust  1049539.71137614

CYCLE NET OUTPUT

 h2gactual  h1g 
 
Cyclenet.output  0.99 h3g  h4gactual  1  Wf     0.99


Cyclenet.output  109.80714529

FOR GAS TURBINE OUTPUT

Gasturbine.output 

Mtotalexhaust  0.98 Cyclenet.output  
3413

Gasturbine.output  33091.71414836

FOR THE NET OUTPUT OF THE ENTIRE PLANT

Since there is a 2 steam turbine:

Capacitysteam.turbine  5000  2

Capacitysteam.turbine  10000
 P a g e | 35

THEREFORE:

NEToutput.plant  Gasturbine.output  Capacitysteam.turbine

NEToutput.plant  43091.71414836

FOR TOTAL MASS OF FUEL

Mfuel  Wf  Mtotalexhaust

Mfuel  18712.48089537

FOR BOILER HP
From eqution 6-9 (potter, pp.255)

BoilerHP

Msteamboiler  hs  hffeedwater 
33500

Where: Msteamboiler = steam generated by boiler

hs = enthalpy of steam leaving the boiler
hffeedwater = enthalpy of water entering the boiler

BoilerHP 

Msteamboiler  hs  hf.feedwater 
33500

BoilerHP  1368.0856444

FOR BOILER HEATING SURFACE

From article 6-11 (potter, pp. 256)
Assume:
Boilerrating  2
BoilerHP  10
Boilerheating.surface 
Boilerrating

Boilerheating.surface  6840.42822201
 P a g e | 36

FACTOR OF EVAPORATION

From equation 6-10 (potter, pp.255)

hs  hf.feedwater
Factorevaporation f
970.3
hs  hf.feedwater
f 
970.3

f  1.10063405
EQUIVALENT EVAPORATION

From equation 6-11 (potter, pp.256)

Equivalentevaporation  f  Msteamboiler

Equivalentevaporation  47233.71028289

EQUIVALENT EVAPORATION

From plate 13: Principal dimension (potter, pp.689), with heating surface of
6840.42822201 sq.ft

Therefore:

SIZE OF BOILER TUBE WIDE

F-15 Heating surface= 44

Steam outlet size= 6506 sq.ft

Feed size= 2 ½ ft

C. CALCULATE THE SURFACE REQUIREMENT OF CONDENSER AND SELECT

CONDENSER:

Data:
Temperature of circulating water entering = 80 F
2 Pass
18 gage – ¾ in. tube
6 fps velocity of water
75% cleanliness factor
Condenser design for 2in. Hg abs
5000 KW capacity
Mc =65587.89746763
Pressure = 2 in Hg = 0.9796734 psia
From previous solution in air ejector:
To get the temperature saturation of 2 in.Hg
Tsat = 100.9895
From the institute standard Prohibit temperature less that 5 F. potter, pp.356
 P a g e | 37

Assume: TD  5
t2  Tsat  TD

t2  95.9895

t1  80

THE LOG MEAN TEMPERATURE DIFFERENCE: θ m

t2  t1
m 
 Tsat  t1 
ln  
 Tsat  t2 
m  11.1457367

SINCE WATER VELOCITY IS 6 FPS:

From Figure 8-9 (Potter, pp.351), Using 6 fps velocity
Ū = Cofficient of heat transfer = 660 Btu/hr.sq.ft.°F

U  660
Temperature Correction Factor = 0.92 = ft

ft  1.05

Fm = Tube material and Thickness correction factor

From Figure 8-9 (Potter, pp.351)

Fm = 1 (admiralty Metal, 1.00, 18 BWG)

Fm  1
Fc = Cleanliness factor = 0.75
Fc  0.75

Fp = Prime mover factor = 1

Fp  1

FOR OVER-ALL COEFFICIENT OF HEAT TRANSFER

From Equation 8-3 (Potter, pp.351)

U  U  ft  Fm  Fc  Fp

U  519.75
 P a g e | 38

CONDENSER CALCULATION FOR NON-REHEAT TURBINE INSTALLATION

Based on 950 Btu/lb of steam rejected:

From Equation 8-2 (potter, pp.351)

Q U A  m

Q  Mc

Q  65587.89746763
Q  ( 950)
Area 
U  m

Area  10755.83266436

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

SURFACE AREA LENGHT

10000 to 20000 18 to 24 ft

SOLVING FOR CIRCULATING WATER

Mc  ( 950)
Circulatingwater 
t2  t1

Circulatingwater  3896838.71254558

From potter, pp.352. For stationary plant they are used 500 sq.ft capacity

Circulating water
gpm 
500
gpm  7793.67742509
For 3/4 in tube, No. 18 BWG (From Table 8-1,potter.pp.353)

gpm at 1 ft/sec velocity=1.042

Velocity  6

NUMBER OF TUBE PER PASS

gpm
Notube.per.pass. 
1.042  6
Notube.per.pass.  1246.58947938

Notube.per.pass  1250
 P a g e | 39

EFFECTIVE TUBE LENGHT

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

Outsidesurface  0.1963
2 pass condenser or heater

Area
Length 
 
2 Notube.per.pass  Outsidesurface 
Length  21.91713228
Length22ft  22

Therefore: the lenght 21.91713228 ft is in the range of 16-22 ft

gpmwater  Notube.per.pass  ( 6)  ( 1.042)

gpmwater  7815

TOTAL NUMBER OF TUBE

Totalno.tube  Notube.per.pass  2

Totalno.tube  2500

FOR FRICTION LOSS OF THE CONDENSER

From Figure 8-11. Friction loss for NO.18 BWG condenser tube and water
boxes. (Potter, pp.355).

Watertube.velocity  6

Tubefriction.loss  0.3

Pressureloss  1.12

Nopass  2

   
Frictionloss  Length22ft  Tubefriction.loss  Nopass  Nopass  Pressureloss

Frictionloss  15.44
 P a g e | 40

SELECTION OF SURFACE CODENSER

Using the total number of tube = 1400
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 NO. ACTUAL TUBE LENGHT DISTANCE REQUIRED MAX. NO.

FOR WITHDRAWING TUBES OF TUBE

7000 18'-0" 20'-10" 2580

NO. OF UNIT: 2
CONNECTION: PARALLEL CONNECTION
MODEL: TWO-PASS, NON-DIVIDED WATERBOX
RADIAL FLOW SURFACE TYPE
MANUFACTURER: WESTINGHOUSE ELECTRIC AND MFG CO.

PRICES OF CONDENSER MATERIAL DESIGN

For No. 18 BWG

Material: Admiralty metal for lower cost
Cost: 1.45 dollar per sq.ft
49 pesos per 1 dollar

Cost  Area  1.45  49

Cost  764201.91080249

D. CALCULATE THE SIZE AND SELECT DEAERATOR AND SURFACE HEATER

FOR HEATER SELECTIO

FOR HEATER SELECTION

Assume: 5°F TD
TDheater  5
Saturation temperature of heater:
Tsat.temp  260.96

t2heater  Tsat.temp  TDheater

t2heater  255.96
 P a g e | 41

t1 = temperature leaving from the air ejector

t1  Tc

t1  104.05087306
FOR THE LOG MEAN TEMPERATURE DIFFERENCE
t2heater  t1
m heater 
 Tsat.temp  t1 
ln  
 T sat.temp  t2heater 
m heater  44.07981322

SOLVING FOR Q:

Qheater 
W  hfcondense  hc 
where:
Q = amount of work, Btu/hr
W = water flow, lb/hr
= mass of condensate, Mc

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
 P a g e | 42

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

SOLVING FOR TUBE PER PASS

From Table 8-1 (Potter, pp.353).

3/4 in tube, NO. 18 BWG

Watervelocity  6

gpmat.1ft.per.secvelocity  1.042
Mc
Notube.per.pass.heater 
 
500  gpmat.1ft.per.secvelocity  Watervelocity 
Notube.per.pass.heater  20.98141314

Approximate:
Notubeper.pass.heater  12
 P a g e | 43

SOLVING FOR THE TUBE EFFECTIVE LENGHT FOR THE HEATER

From Table 8-1 (Potter, pp.353) Physical properties of condenser and
Feedwater heater tubes
OD.surface, sq.ft/ 1 in. ft

ODsurface  0.1963

Assume 2 pass heater:

Areaheater
Effectivelenght 
 
2  Notubeper.pass.heater  ODsurface 
Effectivelenght  61.77237597

From Plate 7 (Surface heater Dimension), (Potter, pp.682), It is obvious

that it is very long size, Now try 4 pass heater

Assume 4 pass heater:

Areaheater
Effectivelenght.4pass 
 
4  Notubeper.pass.heater  ODsurface 
Effectivelenght.4pass  30.88618799

SOLVING FOR THE FRICTION LOSS

From Figure 8-24 (Potter, pp.374)

Averagewater.temp  Tsat.temp  m heater

Averagewater.temp  216.88018678

From Figure 8-24 (Potter, pp.374).

F1 with 6 fps water velocity
F1  0.082

F2 with average temperature 216.88018678

F2  0.8
From Table 8-1 (Potter, pp.353)

The oustside Diameter of NO.18 BWG is 0.652 for 3/4 in tube size

ODNo.18.BWG  0.652

ThicknessNo.18.BWG  0.049


IDNo.18.BWG  ODNo.18.BWG  2  ThicknessNo.18.BWG 
IDNo.18.BWG  0.554
 P a g e | 44

FRICTION LOSS, Δ P

P 
 F2  F1  Effectivelenght.4pass  5.5   ODNo.18.BWG  4
1.24
ODNo.18.BWG

P  15.373249
FOR CIRCULATING WATER

From Plate 2 (Potter, pp.678)

Using Average temperature = 216.88018678°F

Specificgravity.heater  0.956
Mc
gpmheater 

500  Specificgravity.heater 
gpmheater  137.21317462

SELECTION OF SURFACE FEEDWATER HEATER

From Plate 7 (Potter, pp.682) Surface Heater Dimension
For 3/4 in tube with 4 pass heater

SHELL OD: ShellOD  18

NO. OF 3/4 IN. TUBE: 4 PASS HEATER

Fourpass  180
MANUFACTURER: Westinghouse Electric and MFG. Co.

FOR DEAERATOR

SOLVING WATER FLOW:

From Equation 8-11 (Potter, pp.382)

Ein = Eout
S  hsentering  W1  h1 W2  h2
where:
hs.entering  h4

hs.entering  1054.62297

h.1 = hf at 60°F

h1.entering  hfat60

h1.entering  28.08
 P a g e | 45

h.2 = hf at 9 psia

h2.leaving  hfdeaerator

h2.leaving  156.27

S = steam flow, lb/hr

W1 = water entering, lb/hr
W2 = water leaving, lb/hr

From Equation 8-12 (Potter, pp.383)

S  W1 W2

where:

S = steam from the second extraction = M2, lb/hr

M2  2742.10253237
W.1 = mass of make-up water = 1/2 process steam + 0.02MT

Mw  19216.6

THEREFORE:

W2 
  
M2  hs.entering  Mw  h1.entering 
h2.leaving

W2  21958.70253237

SELECTION OF DEAERATOR

From Plate 9 (Potter, pp.683)

CAPACITY lb/hr at Outlet 10,000 to 25,000

NUMBER OF UNITS 2

MANUFACTURER Cochrane Corp

 P a g e | 46

E. CALCULATE SIZE OF BOILER FEED PUMP AND SELECT PUMP

Since 2 boiler feed pump should used 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 
BFPmass.flow  48150.63

CONVERTING INTO VOLUME FLOW:

From Plate 2 (Potter, 678) Using saturation temperature at Feed water

Tempfeedwater  239.0583772

Specificgravity.BFP  0.946
BFPmass.flow
BFPvolume.flow 

500  Specificgravity.BFP 
BFPvolume.flow  101.79837209

FROM PLATE 11(@125 GALLONS PER MINUTE:

DEVELOPED HEAD 400psi

PUMP SIZE-NUMBER OF STAGES #1.5-6

MOTOR HP RATING 60

DIMENSIONS:

Pipe Number Suction Discharge A B C D E F G

size stages Diam. Diam.

1.5 4 2.5 1.5 91” 95” 30” 33” 18” 29” 19”
 P a g e | 47

F. CALCULATE SIZE OF CONDDENSATE 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:

CPmass.flow  1.10  Mc  
CPmass.flow  72146.68721439

CONVERTING INTO VOLUME FLOW:

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

Tc  104.05087306

Specificgravity.CP  0.992
CPmass.flow
CPvolume.flow 

500  Specificgravity.CP 
CPvolume.flow  145.45703067

FOR HYDRAULIC HP
Frrom Equation 3-4 (Potter, pp.92)

HYDRAULICHp 

CPvolume.flow  ( 150)  Specificgravity.CP 
3960

HYDRAULICHp  5.46565812

FOR SHAFT Hp or BHp

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

Assume pump efficiency:

Pumpefficiency  0.70

HYDRAULICHp
SHAFTHp 
Pumpefficiency

SHAFTHp  7.80808303
 P a g e | 48

G. MAKE A PLAN LAYOUT OF EQUIPMENT FIRST BY TEMPLATES AND THEN

BY PENCIL ON TRACING PAPER. SHOW MAJOR DIMENSION OF
EQUIPMENT AND BUILDING, AND SHOW CENTRELINE DIMENSIONS
P a g e | 49
P a g e | 50
 P a g e | 51

H. LAYOUT MAIN STEAM PIPE (SINGLE LINE) ON DRAWING AND SHOW ALL
FITTINGS
 P a g e | 52

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 400 psig, therefore use these values:

Fluid Velocity, fpm

Less than 8in dia. 8in dia. and larger
Steam, Superheated, 3,000 – 8,000 5,000 – 14,000
100 – 600 psig

Assuming the pipe diameter of steam line is less than 8 in. diameter, velocity is 3,000

to 8,000 fpm. Also, assuming a diameter of 6 in. to solve for pipe cross-sectional area

Solving for Pipe Cross-Sectional Area:

 P a g e | 53

FOR THE SPECIFIC VOLUME OF THE PRESSURE FLOW FROM BOILER TO JUNCTION A

414.7
Pboiler.junctionA 
0.95
Pboiler.junctionA  436.52631579

From steam table:

P V
1.0809
430
X.V
436.5263158
1.0562
440
436.5263158  430
XV   ( 1.0809  1.0562)
440  430

XV  0.01612

V1  1.0809  XV

V1  1.06478

TRIAL AND ERROR FOR CROSS-SECTIONAL AREA (less than 8 in. diameter)

Assume: 8 in. diamter 2

 8 

 
Area8 
 12 
4

Area8  0.34906585
Assume: 7 in. diameter
2
 7 

 
Area7 
 12 
4

Area7  0.26725354
 P a g e | 54

Assume: 6 in. diameter 2

 6 

 
Area6 
 12 
4

Area6  0.19634954

Assume: 5 in. diameter

2
 5 

 
Area5 
 12 
4

Area5  0.13635385
SOLVING FOR THE STEAM VELOCITY OF THE GIVEN AREA:

Velocity
 Msteamboiler  2  V1
Area  60

At 8 in diameter:

Velocity8 
 Msteamboiler  2  V1
Area8  60

Velocity8  4363.55429276

At 7 in. diameter:

Velocity7 
 Msteamboiler  2  V1
Area7  60

Velocity7  5699.33621911

At 6 in diameter:

Velocity6 
 Msteamboiler  2  V1
Area6  60

Velocity6  7757.42985379

At 5 in. diameter:

Velocity5 
 Msteamboiler  2  V1
Area5  60

Velocity5  11170.69898946
 P a g e | 55

THEREFORE: Use the area have a lowest minimum velocity and it is in the range of 3,000 - 8,000. Therefo
the diameter of 6 in. with velocity of 7757.42985379 fpm and area of 0.19634954 sq.in

Diameter6.in.  6

Area6  0.19634954

Velocity6  7757.42985379

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), psi
C = constant as follows:
Threaded steel, 1/2 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 in
Plain end nonferrous,0.000 in.
y = coefficient (that may be operated) that is as follows:
Ferritic steels: 900 and below, 0.4;
950°F, 0.5;
1000°F and above, 0.7

From Table 2 – 1 pp 32, psi

Material ASTM Specification Grade Allowable Values of

Stress,psi
-20 to 650
Carbon Steel A53 A 12,000

*Note: ASTM specification A53 is for a common type of carbon-steel pipe, more rigid

than A120 and is recognized by the codes for power plant use.
 P a g e | 56

THEREFORE:

tm 

P  ODsch.40   Cpln.stl

( 2  12000)  2  yferritic.stl  P
tm  0.17982806
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  0.20551778

SELECTION OF PIPE SIZE FROM BOILER TO JUNCTION A

From Appendix Plate 1 (Potter, pp.675) Physical properties of pipe

SCHEDULE 40

Physical Properties of Pipe

Nominal Outside Wall Inside Inside Internal cross- Weight of

Pipe Size, Diameter thickness Diameter Diameter, sectional area pipe per
in. , in. , in. , in. Fifth power ft-lb
D t d D5 Sq. in. Sq. ft.
Schedule 40
6 6.625 0.280 6.065 8,210 28.9 0.200 18.98

FROM JUNCTION A TO TURBINE

Assume that the pipe diameter is 8 in. and larger
with superheated pressure of 400 psig
The velocity is from 5,000-14,000
TRIAL AND ERROR FOR CROSS-SECTIONAL AREA ( 8 in. diameter and larger)

Assume 8 in diameter:

Area8  0.34906585
 P a g e | 57

2
Assume 9 in diameter:  9 

 
Area9 
 12 
4

Area9  0.44178647
Assume 10 in diameter: 2
 10 

 
Area10 
 12 
4

Area10  0.54541539
Assume 11 in diameter: 2
 11 

 
Area11 
 12 
4

Area11  0.65995262

SOLVING FOR THE SPECIFIC VOLUME OF THE PRESSURE FLOW FROM BOILER TO
JUNCTION A:

P1  414.7

From steam table:

P V2

1.3463
410

414.7 XV2

415 1.3285

414.7  410
XV.2   ( 1.3463  1.3285)
415  410

XV.2  0.016732

V2  1.3463  XV.2

V2  1.329568
 P a g e | 58

SOLVING FOR THE STEAM VELOCITY OF THE GIVEN AREA:

Velocity
 Msteamboiler  2  V2
Area  60
At 8 in diameter:

Velocity8. 
 Msteamboiler  2  V2
Area8  60

Velocity8.  5448.67686663

At 9 in diameter:

Velocity9 
 Msteamboiler  2  V2
Area9  60

Velocity9  4305.1274008
THEREFORE: Use the area with higher velocity
Assume that it is 8 in diameter
Area8  0.34906585

Velocity8.  5448.67686663

Diameter8.in  8

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), psi
C = constant as follows:
Threaded steel, 1/2 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 in
Plain end nonferrous,0.000 in.
y = coefficient (that may be operated) that is as follows:
Ferritic steels: 900 and below, 0.4;
950°F, 0.5;
1000°F and above, 0.7
 P a g e | 59

From Table 2-1 (Potter, pp.33). Allowable stresses for some seamless pipe materials

Material ASTM Specification Grade Allowable Values of

Stress,psi
-20 to 650
Carbon Steel A53 A 12,000

*Note: ASTM specification A53 is for a common type of carbon-steel pipe, more rigid

than A120 and is recognized by the codes for power plant use.

C = Plain end 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 diamter of schedule 40 by 8 in pipe size From Plate 1 (Potter, pp. 675)

ODsch.40b  8.625

THEREFORE:

tm414.7 

Pb  ODsch.40b   Cpln.stlb
 
( 2  12000)  2  yferritic.stlb  Pb

tm414.7  0.20685855

tm414.7
tm.increased414.7 
0.875

tm.increased414.7  0.23640977

SELECTION OF PIPE SIZE FROM BOILER TO JUNCTION A

From Appeendix Plate 1 (Potter, pp.675) Physical properties of pipe

SCHEDULE 40

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
 P a g e | 60

SELECTION OF PIPE SIZE FROM BOILER TO JUNCTION A

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

Physical Properties of Pipe

Nominal Outside Wall Inside Inside Internal cross- Weight of

Pipe Size, Diameter thickness Diameter Diameter, sectional area pipe per
in. , in. , in. , in. Fifth power ft-lb
D t D D5 Sq. in. Sq. ft.
Schedule 40
8 8.625 0.322 7.981 32,400 50.0 0.347 28.56
 P a g e | 61

J. BILL OF MATERIALS FOR THE MAIN STEAM PIPING

ITEM MATERIAL DESCRIPTION QUANTITY

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

NPS 6 ASTM A106 GRADE A

2 90O ELBOW 10
FLANGED
NPS 8 ASTM A106 GRADE A
3 90O ELBOW 2
FLANGED
NPS 6 ASTM A106 GRADE A
4 T-ELBOW 10
FLANGED
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 NPS 6 CLASS 600 FLANGED 2
REGULATING VALVE
NPS 8 ASTM A106 GRADE A
9 *SAFETY VALVE 2
FLANGED
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)
 P a g e | 62

K. CALCULATE THE MAXIMUM FRICTION LOSS IN THE STEAM PIPING FROM BOILER TO
TURBINE

FROM BOILER TO JUNCTION A:

SOLVING FOR STEAM PIPING PRESSURE DROP:

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

2
0.001295  fsteam.pipe  Lsteam.pipe    V
 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 = lenght, ft
Assume: V = velocity, ft/s

Lsteam.pipeB.A  300
For the value of f, using Table 2-3 (Potter, pp.63) Friction factor for steam
By Babcock and Wilcox (B. and W.) investigator

IDpipeB.A  6.065

fsteam.pipeB.A  0.01080 1 
 3.6 

IDpipeB.A 

fsteam.pipeB.A  0.01721055

From:
1
 B.A 
V1

 B.A  0.93916114
 P a g e | 63

THEREFORE:

2
 Velocity6 
0.001295  fsteam.pipeB.A  Lsteam.pipeB.A   B.A   
 60 
 PB.A  ID pipeB.A

 PB.A  17.30726148

FROM JUNCTION A TO BOILER:

SOLVING FOR STEAM PIPING PRESSURE DROP:

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

2
0.001295  fsteam.pipe  Lsteam.pipe    V
 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 = lenght, ft
Assume: V = velocity, ft/s
Lsteam.pipeA.T  200

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

IDpipeA.T  7.981

fsteam.pipeA.T  0.01080 1 
 3.6 

IDpipeA.T 

fsteam.pipeA.T  0.01567157

From:
1
 A.T 
V2

 A.T  0.752124
 P a g e | 64

THEREFORE:

2
 Velocity8 
0.001295  fsteam.pipeA.T  Lsteam.pipeA.T   A.T   
 60 
 PA.T  ID pipeA.T

 PA.T  2.0231248

P total   PB.A  2   PA.T

P total  36.63764776
 P a g e | 65

M. DETERMINE THE DIAMETER AND HIGHT OF THE STACK

SOLVING FOR THE DIAMETER OF THE STACK

From:

Q A V

where: Q = flow rate, cfm

A = area of the stack, sq.ft
V = specific volume, cubic ft./lb

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:

Mtotalexhaust  1049539.71137614

From Article 7-4 CHIMNEY (Potter, pp.306) the outlet velocity are range from 50-60 fps
represent good practice and help disperse the gases

Rgas  53.3

T°R  350  460

T°R  810

Plantelevation  47

where: Vgas  20.4001322

Rgas = gas constan
T.°R = temperature of gas leaving the boiler

Assume barrometric pressure is 30.01 in.Hg and from the given plant elevation equal to 47
ft.

Pgas   30.01 
0.01 
 47   0.4898
 100 
Pgas  14.69659594

For velocity:

Rgas  T°R
Vgas 
Pgas  144
 P a g e | 66

For flow rate:

1
Qgas  Mtotalexhaust  Vgas 
60

Qgas  356845.81427518

THEREFORE:
Assume:
Velocityoutlet  60

Qgas A  Vgas

2
d
 

Qgas  Velocityoutlet
4

2 Qgas  4
d
Vgas  

Qgas  4
d 
Velocityoutlet    60

d  11.23425073

SOLVING FOR THE HEIGHT OF THE STACK

From Equation 7-6 (Potter, pp.306)

2
 Qgas 
B  
 1000 
 4  Tg
Pv
0.5602  d

where:
P.v = velocity pressure, in. of water
B = barrometric pressure, in.Hg
Qgas = gas flow, cfm
d = stack diameter, ft
Tg = absolute gas temperature, °R

To get Tg: From Equation 7-5 (Potter, pp.306)

Tg 
ta  Cconst  templeaving.boiler  ta 
 P a g e | 67

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

Cconst  0.95

ta  95

templeaving  350


Tg.  ta  Cconst  templeaving  ta 
Tg.  337.25

Tg  Tg.  460

Tg  797.25
0.01
B  30.01   47
100

B  30.0053
SOLVING FOR VELOCITY PRESSURE:

2
 Qgas 
B  
Pv 
 1000 
4
0.5602  ( d)  Tg

Pv  0.53708757

SOLVING FOR THE HEIGHT OF THE STACK:

Pt Pf  Pv

where:
P.t = total pressure
P.f = stack friction loss
Pf  1

Pt  Pf  Pv

Pt  1.53708757
 P a g e | 68

THEREFORE THE HEIGHT OF THE STACK:

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


0.256  B  H  
1

1 
Pt 
 ta  460 Tg 

Pt
Height 
0.256  B   1 1 
  t  460  T 
  a g 

Height  365.49748975
 P a g e | 69

N. DRAW AN END VIEW OF THE PLANT SHOWING EQUIPMENT AND PIPING

 P a g e | 70

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 a g e | 71

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 FROMDEAERATOR TO JUNCTION B

Qflow.d.B A V

where:
Q = volume flow rate, cu.ft/min
A = cross sectional area, sq.ft
V = velocity of fluid, ft/min

From heat balance calculation:

Qdeaerator  Mw  M2

Qdeaerator  21958.70253237
1 1
Qflow.d.B  Qdeaerator  
62.4 60

Qflow.d.B  5.86503807
 P a g e | 72

THREFORE

Vsunction  200
2
  ( d)
Qflow.d.B  Vsunction
4

Qflow.d.B  4
ddeaerator.B   ( 12)
  Vsunction

ddeaerator.B  2.31876494

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 Cross Weight of

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

SOLVING FOR WATER PIPING DISCHARGE DIAMETER

Vdischarge  450
2
  ( d)
Qflow.d.B  Vdischarge
4
Qflow.d.B  4
ddischarge   ( 12)
  Vdischarge

ddischarge  1.54584329

Nominal Outside Wall Inside Inside Internal Cross Weight of

Pipe Diameter, Thickness, Diameter, Diameter, Sectional Area pipe per
Size, in in in in Fifth ft-lb
Power
D T d D5 Sq. in Sq. ft
2 2.375 0.154 2.067 37.73 3.356 0.023 3.653
 P a g e | 73

SOLVING FOR WATER FRICTION LOSS

FICTION LOSS AT SUNCTION PIPE

2
0.001295  fsunction  Lsunction   suction  Vsunction
P sunction dsunction

Where:

Δ P = suction pressure loss, psi

d = suction inside diameter, in
L = suction lenght, ft
V = suction velocity, fps
f = suction friction factor
ρ = suction density, lb/cu.ft

Assume length of suction

𝑳𝒔𝒖𝒄𝒕𝒊𝒐𝒏 = 𝟏𝟎𝟎

For suction friction factor, f

From Eq. 2-18 potter, pp.58

𝟔𝟒
𝒇=𝑵
𝑹

Solving for Reynod’s number

From Eq. 2-10 potter, pp.53

Vav  D  
NR


Where

Nr = Reynold's number
V = average velocity, fps
D = internal pipe diameter, ft
ρ = fluid density or reciprocal of specific volume (1/v), lb-
mass/cu.ft
μ = fluid absolute viscosity, lb-mass/ft-sec
 P a g e | 74

DsunctionID  1.610

Vsunction  DsunctionID  62.4

NR 
60  12  0.00022175

NR  125847.42577978

Then:
64
fsunction 
NR

fsunction  0.00050855

THEREFORE: 2
 200 
0.001295  fsunction  Lsunction  62.4   
P sunction 
 60 
Dsunction ID
P sunction  0.028361

FRICTION LOSS AT THE DISCHARGE PIPE:

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

2
0.001295  fdischarge  Ldischarge   discharge  Vdischarge
P discharge ddischarge

Assume lenght of sunction

Ldischarge  100

For discharge friction factor, f:

From Equation 2-18 (Potter, pp.58)

64
f
NR
where:
f = discharge friction factor
Nr = Reynold's number

Solving for Reynold's number:

From Equation 2-10 (Potter, pp.53)

Vav  D  
NR


DdischargeID  1.049
 P a g e | 75

Vdischarge  DdischargeID  62.4

NRdischarge 
60  12  0.00022175

NRdischarge  184491.54453213

Then:
64
fdischarge 
NRdischarge

fdischarge  0.0003469

THEREFORE: 2
 Vdischarge 
0.001295  fdischarge  Ldischarge  62.4   
P discharge 
 60 
Ddischarge ID

P discharge  0.15031589
THE TOTAL FRICTION LOSS AT DEAERATOR WATER PIPING:

P deaerator  P sunction  P discharge

P deaerator  0.1786769

WATER PIPING DIAMETER FROM SURFACE HEATER TO BOILER

Fro heat balance calculation

1 1
Qflow.SH.B  Mc  
62.4 60

Qflow.SH.B  17.51813501

Qflow.SH.B A V

where:
Q = volume flow rate, cu.ft/min
A = cross section area, sq.ft
V = velocity of fluid, ft/min
 P a g e | 76

THEREFORE

𝑽𝒔𝒖𝒄𝒕𝒊𝒐𝒏.𝑺𝑯 = 𝟐𝟎𝟎

2
  ( d)
Qflow.SH.B  Vsunction.SH
4
Qflow.SH.B  4
dSH.B   ( 12)
  Vsunction.SH
dSH.B  4.00742351

SELECTION OF PIPE SUCTION

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

Schedule 40

Nominal Outside Wall Inside Inside Internal Cross Weight of

Pipe Diameter, Thickness, Diameter, Diameter, Sectional Area pipe per
Size, in in in in Fifth ft-lb
Power
D t d D5 Sq. in Sq. ft
5 5.563 0.258 5.047 3,275 20.01 0.138 14.62

WATER PIPING DISCGARE DIAMETER SURFACE HEATER TO BOILER

THEREFORE:

Vdischarge  450
2
  ( d)
Qflow.SH.B  Vdischarge
4
Qflow.SH.B  4
ddischarge.SH.B   ( 12)
  Vdischarge

ddischarge.SH.B  2.67161568
 P a g e | 77

SELECTION OF PIPE DISCHARGE

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

Schedule 40

Nominal Outside Wall Inside Inside Internal Cross Weight

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

SOLVING FOR WATER FRICTION LOSS

FRICTION LOSS AT SUCTION LOSS

From Eq. 2-15 potter, pp.56

2
0.001295  fsunction.SH  Lsunction.SH   suction.SH  Vsunction.SH
P sunction.SH dsunction.SH

Δ P = suction pressure loss, psi

d = suction inside diameter, in
L = suction lenght, ft
V = suction velocity, fps
f = suction friction factor
ρ = suction density, lb/cu.ft

Assume length of suction

𝑳𝒅𝒊𝒔𝒄𝒉𝒂𝒓𝒈𝒆.𝑺𝑯 = 𝟏𝟎𝟎

For discharge friction factor, f:

From Eq. 2-18 potter, pp.58

64
f
NR

Where

f = discharge friction factor

Nr = Reynold's number
 P a g e | 78

Solving of Reynold’s number

From Eq. 2-10 potter, pp.53

Vav  D  
NR


𝑫𝒅𝒊𝒔𝒄𝒉𝒂𝒓𝒈𝒆𝑰𝑫.𝑺𝑯 = 𝟐. 𝟒𝟔𝟗

Vdischarge  DdischargeID.SH  62.4

NRdischarge.SH 
60  12  0.000155

NRdischarge.SH  621232.25806452

Then:

64
fdischarge.SH 
NRdischarge.SH

fdischarge.SH  0.00010302

Therefore

2
 Vdischarge 
0.001295  fdischarge.SH  Ldischarge.SH  62.4   
P discharge.SH 
 60 
Ddischarge ID.SH
P discharge.SH  0.01896626
 P a g e | 79

THE TOTAL FRICTION LOSS AT SURFACE HEATER TO BOILER WATER PIPING

P surface.heater  P sunction.SH  P discharge.SH

P surface.heater  0.02304827

FOR TOTAL FRICTION LOSS

P total.loss  P deaerator  P surface.heater

P total.loss  0.20172517

Q. DETERMINE THE POWER GENERATED BY THE GAS TURBINE POWER PLANT

𝒉𝟑𝒈 −𝒉
𝟐𝒈𝒂𝒄𝒕𝒖𝒂𝒍
𝑾𝒇 = 𝑳𝑯𝑽(𝑩𝒖𝒓𝒏𝒆𝒓 )
𝒆𝒇𝒇

𝟔𝟓𝟏.𝟓𝟏𝟔−𝟑𝟎𝟖.𝟏𝟖𝟕𝟓𝟎𝟔𝟏𝟑
= 𝟐𝟎𝟐𝟕𝟎(𝟎.𝟗𝟓)

𝑾𝒇 = 𝟎. 𝟎𝟏𝟕𝟖𝟐𝟗𝟐𝟑

FOR WORK OF THE COMPRESSOR

𝟐𝒈𝒂𝒄𝒕𝒖𝒂𝒍 𝒉 −𝒉𝟏𝒈
𝑾𝑶𝑹𝑲𝒄𝒐𝒎𝒑𝒓𝒆𝒔𝒔𝒐𝒓 = 𝑪𝒐𝒎𝒑𝒓𝒆𝒔𝒔𝒐𝒓
𝒎𝒆𝒄𝒉𝒂𝒏𝒊𝒄𝒂𝒍 𝒆𝒇𝒇.

𝟑𝟎𝟖.𝟏𝟖𝟕𝟓𝟎𝟔𝟏𝟑−𝟏𝟑𝟐.𝟔𝟔
= 𝟎.𝟗𝟗

𝑾𝑶𝑹𝑲𝒄𝒐𝒎𝒑𝒓𝒆𝒔𝒔𝒐𝒓 = 𝟏𝟕𝟕. 𝟑𝟎𝟎𝟓𝟏𝟏𝟐𝟒

FOR WORK OF GAS TURBINE

𝑾𝒐𝒓𝒌𝒈𝒂𝒔𝒕𝒖𝒓𝒃𝒊𝒏𝒆 = 𝑻𝒖𝒓𝒃𝒊𝒏𝒆𝒎𝒆𝒄𝒉𝒆𝒇𝒇 (𝒉𝟑𝒈 − 𝒉𝟒𝒈𝒂𝒄𝒕𝒖𝒂𝒍 )(𝟏 + 𝑾𝒇 )

= 𝟎. 𝟗𝟗(𝟔𝟓𝟏. 𝟓𝟏𝟔 − 𝟑𝟔𝟔. 𝟓𝟖𝟖𝟑𝟎𝟔𝟒𝟏)(𝟏 + 𝟎. 𝟎𝟏𝟕𝟖𝟐𝟗𝟐𝟑)

𝑾𝒐𝒓𝒌𝒈𝒂𝒔𝒕𝒖𝒓𝒃𝒊𝒏𝒆 = 𝟐𝟖𝟕. 𝟏𝟎𝟕𝟔𝟓𝟔𝟓𝟒

WORK NET OF THE GAS CYCLE

 P a g e | 80

𝑾𝒐𝒓𝒌𝒏𝒆𝒕𝒈𝒂𝒔 = 𝑾𝒐𝒓𝒌𝒈𝒂𝒔𝒕𝒖𝒓𝒃𝒊𝒏𝒆 − 𝑾𝒐𝒓𝒌𝒄𝒐𝒎𝒑𝒓𝒆𝒔𝒔𝒐𝒓

= 𝟐𝟖𝟕. 𝟏𝟎𝟕𝟔𝟓𝟔𝟓𝟒 − 𝟏𝟕𝟕. 𝟑𝟎𝟎𝟓𝟏𝟏𝟐𝟒

𝑾𝒐𝒓𝒌𝒏𝒆𝒕𝒈𝒂𝒔 = 𝟏𝟗𝟖𝟐𝟐𝟓. 𝟓𝟒𝟖𝟕𝟒𝟖𝟗𝟒

R. DETERMINE AMOUNT OF FUEL CONSUMPTION PER HOUR

For fuel required:

𝑴𝒇𝒖𝒆𝒍 = 𝑾𝒇 (𝑴𝒕𝒐𝒕𝒂𝒍𝒆𝒙𝒉𝒂𝒖𝒔𝒕 )

= 𝟎. 𝟎𝟏𝟕𝟖𝟐𝟗𝟐𝟑(𝟏𝟎𝟒𝟗𝟓𝟑𝟗. 𝟕𝟏𝟏𝟑𝟕𝟔𝟏𝟒)

𝑴𝒇𝒖𝒆𝒍 = 𝟏𝟖𝟕𝟏𝟐. 𝟒𝟖𝟎𝟖𝟗𝟓𝟑𝟕

For duel required for 4 boiler

𝒕𝒐𝒕𝒂𝒍 𝒇𝒖𝒆𝒍 = 𝟒 ∗ 𝑴𝒇𝒖𝒆𝒍

= 𝟒 ∗ 𝟏𝟖𝟕𝟏𝟐. 𝟒𝟖𝟎𝟖𝟗𝟓𝟑𝟕

𝒕𝒐𝒕𝒂𝒍 𝒇𝒖𝒆𝒍 = 𝟕𝟒𝟖𝟒𝟗. 𝟗𝟐𝟑𝟓𝟖𝟏𝟒𝟖

 P a g e | 81

S. DRAW A TS DIAGRAM FOR THE COMBINED GAS-VAPOR POWER PLANT

 P a g e | 82

APPENDICES

DRAWING, CHART, TABLES, CATALOGS & OTHER REFERENCES

P a g e | 83
P a g e | 84
P a g e | 85
P a g e | 86
 P a g e | 87

SELECTIO 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’’

B Furnace Width-Outside Casing 15’-0’’

C Furnace Wall Tubes 13’-8 3/4’’

D Face to Face 7 ¼’’ Square Headers 13’-2 1/2’’

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’’

L Drum to Outside Casing Front Wall 6’-2’’

Inside Face Font Wall to Inside

M 9’-0’’
Face Bridgewall

N Damper Location-Horizontal 9 11/18’’

O Damper Location-Vertical 24 7/8’’

P Length of Damper 6’-6’’

 P a g e | 88

SELECTION OF SURFACE ACE CONDENCER

FROM APPENDIX, PLATE 14 pp.690 POWER PLANT THEORY AND DESIGN BY POTTER

DISTANCE REQUIRED
FOR WITHDRAWING MAX. NO.
FRAME NO. ACTIVE TUBE 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 = tube

12
length plus____,
 P a g e | 89

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
E should be equal to or larger then
F diameter heater top)
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
 P a g e | 90

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

Pump Number Diameter

A B C D E F G
Size Stages Suction Discharge

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)

Nominal Outside Wall Inside Inside Weight of

Internal cross-
Pipe Size, Diameter thickness Diameter Diameter, pipe per
sectional area
in. , in. , in. , in. Fifth power ft-lb
D t d D5 Sq. in. Sq. ft.
Schedule 40
6 6.25 0.280 6.065 8210 28.9 0.200 18.98
 P a g e | 91

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 Cross Weight of

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

Nominal Outside Wall Inside Inside Internal Cross Weight of

Pipe Diameter, Thickness, Diameter, Diameter, Sectional Area pipe per
Size, in in in in Fifth ft-lb
Power
D T d D5 Sq. in Sq. ft
2 2.375 0.154 2.067 37.73 3.356 0.023 3.653

SELECTION OF PIPE SUCTION

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

Schedule 40

Nominal Outside Wall Inside Inside Internal Cross Weight of

Pipe Diameter, Thickness, Diameter, Diameter, Sectional Area pipe per
Size, in in in in Fifth ft-lb
Power
D t d D5 Sq. in Sq. ft
5 5.563 0.258 5.047 3,275 20.01 0.138 14.62

SELECTION OF PIPE DISCHARGE

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

Nominal Outside Wall Inside Inside Internal Cross Weight

Pipe Diameter, Thickness, Diameter, Diameter, Sectional Area of pipe
Size, in in in in Fifth per ft-lb
Power
D t d D5 Sq. in Sq. ft
3 3.500 0.216 3.068 271.8 7.39 0.051 7.58
 P a g e | 92

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
 P a g e | 93

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.
 P a g e | 94

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

 P a g e | 95

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