CARRAGA Region. We Select To Build Our Steam Power Plant in Agusan Del Norte and Our

INTRODUCTION
Both the historical and the present day civilization of mankind closely interwoven
with energy, and there is little reason to doubt but that in the future our existence will be ever
more dependent upon this things called energy. Mere existence requires that even an animal
produce and expend it. Until man found ways to utilize energy from source outside and beyond
his own physical efforts, his status on earth was quite animal-like.
So as this subject is making us design power plant steam and we select our
alternative sources of power. First we select what location we are going to build our power plant.
In our mind we select the place that we can also enjoy the fruits of our labor, so we selected to
build power plant in our home place in Agusan. This plant can supply power over entire
CARRAGA region. We select to build our steam power plant in Agusan Del Norte and our
source of renewable plant in case steam is not available is hydro power plant which will build in
the Macalang Buenavista.
Energy probably was the original stuff of creation. As we encounter it about us, energy
appears in many dorms, but has one thing in common-energy is possessed of the ability to
produce a dynamic, vital effect, if a person has a good and comprehensive idea of energy, it is
quite simple for him to understand the technical meaning of power, for power is the rate at which
energy is produce and consumed,. However, it is in connection with the mechanical and
electrical forms of energy and, to a certain extent of radiation energy is not ordinarily thought of
as power. Power is primarily associated with mechanical work of electrical energy.
In common usage, a machine or assemblage of equipment that produces and delivers a
flow of mechanical and electrical energy is a power plant. However, what we generally mean by
terms is that assemblage of equipment, permanently locate in some chosen site, which receive
raw energy in the form of a substance capable of being operated on in such way as to produce
electrical energy for delivery from the power plant.
A steam power plan is basically an external-combustion engine. The combustion takes
place outside the engine, and the thermal energy released during this process is transferred to the
steam as heat. Steam power plants are rather effective and can be used in more ways than one.
The figure below depicts a basic steam power plant design. First, water is pumped form a
reservoir. Fuel, like waste coal (coal that has been used), are dumped into the boiler and heated at
amazingly hot temperatures. The pump then pumps water into the water where it is heated and
steam is generated. The steam is then ran through a turbine where is then produced. This power
is sent to companies which send electricity to communities, businesses, etc. The extra steam is
then sent to condenser, where it is cooled and returns the steam to a water/gas state. The watery
remains are pumped back through the system and process start over again .While the gas state is
exhausted into the air. Some plants do not returns the water/gas state into the system at all just
exhaust all of it into either a river or into the air.
A steam power plan continuously convert the energy stored in the fossil fuels (coal, oil,
natural gas) or fossil fuel (uranium, thorium) into shaft work and ultimately into electricity. The
working fluid is water which is sometimes in the vapor phase during its cycle operations. Energy
released by the burning of fuel is transferred to water in the boiler to generate steam at a high
pressure and temperature, which then expands in the turbine in a low pressure to produce shaft
work. The steam leaving the turbine is condensed into water in the condenser where cooling
water from the river or a sea circulates carrying away the heat released during condensation. The
water (condensate) is then fed back the boiler bay the pump and the cycle do on repeating itself.
Hydro-power is a natural resource, available wherever a sufficient volume of steady
water flow exists. The development of large-scale of hydro-power today requires extensive
construction, including storage lakes, dams: bypass canals, and the installation of large turbine
and electric generating equipment. Because the development of hydroelectric power requires a
large capital investment, it is often uneconomical for a region where coal or oil is cheap, even
though the cost of fuel for steam-powered generating plant is higher than the cost of running a
hydroelectric plant.
Hydropower converts the energy of flowing water into electricity or hydroelectricity. The
amount of electricity generated is determined by the volume of water and the amount of head
(the height from the turbines in the power plant to the water surface) created by the dam. The
greater the flow and head, the more electricity is produced.
Hydropower machine is the designation used for a machine that directly converts the
hydraulic power in water in a water fall to mechanical power on the machine shaft. This power
conversion involves losses that arise partly in the machine itself and partly in the water conduits
to and from the machine. The utilization of the power in the waterfall is evaluated by the socalled power plant efficiency a, which is the ratio between the mechanical power plan outputs
from the machine shaft and the gross hydraulic power of the power plant. The plant efficiency
a is a variable quantity that depends on the design of the water conduits to and from the
hydropower machine and the operating conditions. The conduits are normally made with flow
cross according to optimal design criteria.
Hydroelectricity is produced in a hydroelectric power plant. In this plant, the water is
released from a high location. The potential energy present in the water is converted into kinetic
energy, which is then used to rotate the blades of a turbine. The turbine is hooked to the generator
which produces electricity.
CHAPTER
I
I. HEAT BALACE
From Table 11-2, page 527, Power Plant Theory and Design by Potter.
Table Data
Turbine rating, kw
Generator rating, kva
Power factor
Short-circuit ratio
Throttle pressure, psig
Throttle temperature, F
Number of extraction openings
Saturation temperature at openings
at turbine rating with all extraction
opening in service, F
1st
2nd
3rd
4th
5th
Values
66,000
70,588
0.85
0.80
1250
950
5
STEAM
POWER
PLANT
Exhaust pressure, in.Hg. abs

Generator capacity at 0.85 power
Factor and 15-psig hydrogen
Pressure, kva
Generator capability at 0.85 power
Factor and 30-psig hydrogen
Pressure, kva
180
240
290
360
420
1.5
81,176
88,235
Table 1 Preferred standard for large 3600 rpm, 3-phase, 60 cycles, and condensing
steam turbine generators. For a turbine generator rating of 50 MW.
II. ENTHALPIES @ ACTUAL CASES
From section 8-4, p.228 of Frederick T. Morse, the pressure loss due to pipe friction
and throttling at extraction nozzle from 5% to 7% pressure drop and the temperature difference
can be increased by 1.7 to 2.8. Used 2.8 for design puposes.
From section 8-4, p.227 of Frederick T. Morse

Extraction Pressure=saturation pressure @ (+ t) +
Where =outgoing water temperature
=temp. Difference
=pressure drop
Extractio
n
1
2
3
4
5
Satn Pressure
82.22
115.56
143.33
1182.22
215.56
2.8
2.8
2.8
2.8
2.8
0.0028941
0.009424
0.02776402
0.05625292
0.1489193
0.05788354
0.1884983564
0.4288403113
1.125058566
2.252285
Extraction
Pressure
0.06151044
0.197923
0.45660433
1.198863466
2.401478015
From Steam table:

@ State 1
P1=8.7174 Mpa
h1=3414.6912
T1=5100C
s1=6.70798
v1=0.0387078
@ State 2
P2=2.401478 Mpa
s1 =s1=6.70798
@ P=2.40 Mpa
v
105.64
v
107.91
s
6.7079
6.7079862
6.7479
h
3035.7
h
3059.2
t
310
t
320
@P=2.45 Mpa
v
103.34
v
105.57
s
6.6966
6.7079862
6.7368
h
3034.3
h
3057.9
t
310
t
320
@ P=2.401478015 Mpa
h2=3035.901476 kj/kg
t2= 310.102 0C
v2=105.595 m3/kg
@P =2.362
@ P=2.408
@ P=2.401478015
Sf = 2.5270
Sf =2.5363
Sf =2.534979
Sfg = 3.7519
Sfg =3.7355
Sfg =3.737821
Since,
S2=Sf2+x2Sfg2
Then,
X2=1.11963 (superheated)
From eqtn 11-12 & 11-13, pp.385-386 of power plant engineering by Frederick T.
Morse. The stage efficiency is
s=(h1- h2)/(h1-h2)
s=0.94 x blade eff. -2% to 5% rotating leakage allowance
From table 11-4, p.386 of power plant engineering by Frederick T. Morse.
Blade eff. = 0.9
Assume 5% rotational leakage allowance
By substitution,
s=79.9%=(h1- h2)/(h1-h2)
h2=3112.0402 kj/kg
x2=1.179281 (superheated)
@ P= 2.40 Mpa
h
310.6
3112.0402
3128.4
s
t
6.8248
340
6.83523
343.28973
6.8618
350
@ P=2.45 Mpa
v
112.37
110.663
114.56
h
3104.4
3112.0402
3127.4
s
6.8138
6.826102
6.8509
v
109.95
110.663
112.11
t
340
343.28973
350
By Interpolation,
v2=112.9140833 m3/kg
S2=6.83496
t2=342.8099 0C
@ State 3
P3=1.198863466 Mpa
S2= S3= 6.83496
@ P= 1.198863466
Sf3=2.216184519
sfg3=4.30744903
since,
S3=Sf3+x3Sfg3
then,
x3=1.0722762(superheated)
@ P=1.15 & S=6.83496

s
6.8301
6.83496
6.8518
h
2925.6
2928.12699
2936.9
t
245
246.1111
250
v
198.82
199.33
201.1
@ P=1.2 & S=6.83496

s
6.8294
6.83496
6.8721
h3=2937.7097 kj/kg
Since,
h
t
2935.0
250
2937.933
251.28
2957.6
260
By interpolation,
v3=193.05m3/kg
then,
s=(h2- h3)/(h2-h3)
h3=2957.447 kj/kg
v
192.34
192.906
196.73
t3=251.161310C
@ P=1.15 & h=2957.447

h
2936.9
2957.447
2959.4
s
t
6.8518
250
6.887643
259.1164
6.8943
260
@ P=1.2 & h=2957.447
v
201.1
205.297
205.7
h
2935.0
2957.447
2957.6
s
6.8294
6.87297
6.8721
v
192.34
196.6999
196.73
t
250
260.21
260
By interpolation,
v3=196.89m3/kg
s3=6.8733 kj/kg-k
t3=260.1850C
@ State 4
P=0.4566043 Mpa
s4=s3=6.8733 kj/kg-k
@ P= 0.4566043 Mpa
Sf4=1.82618
sfg4=5.02533
since,
S4=Sf4+x4Sfg4
then,
@P=0.44 & s=6.8733

s
6.8526
6.8733
6.8797
h
2738.1
2746.803
2749.5
t
145
148.803
150
v
420.3
424.8753
426.3
@P=0.46 & s= 6.8733

s
6.8560
6.8733
6.9088
h
2747.8
2755.1845
2770.4
t
150
153.21
160
v
407.0
410.733
418.5
By interpolation,
h4=2753.759647 kj/kg
v4=413.1m3/kg
t4=152.4530C
Since,
then,
s=(h3- h4)/(h3-h4)
h4=2790.734 kj/kg
@ P=0.44 & h=2790.734

h
2771.9
2790.734
2794.0
s
6.9321
6.97503
6.9825
t
160
168.484
170
v
438.3
448.3364
450.1
@ P=0.46 & h=2790.734

h
2770.4
2790.734
2792.6
s
6.9088
6.95522
6.9595
t
160
169.136
170
v
418.5
428.84
429.8
By interpolation,
v4=432.09m3/kg
S4=6.958563 kj/kg-k
t4=169.02510C
@ State 5
P=0.197923 Mpa
S5=s4=6.958563 kj/kg-k
@ P= 0.197923 Mpa
Sf5=1.526521673
sfg5=5.604097
since,
S5=Sf5+x5Sfg5
then,
@P=0.197923 Mpa
h5=2624.6 kj/kg
v5=868.04m3/kg
Since,
s=(h4- h5)/(h4-h5)
Then,
h5= 2669.11014 kj/kg
t5=129.8620C
t5=120.1
v5=606.682m3/kg
s5=7.03408165kj/kg-k
@ State 6
P=0.060777Mpa
S6=7.03408165kj/kg-k
@P=0.060777Mpa
Sf=1.14901563
vf=1.033331
hf=361.196
Sfg=6.378693602
vfg=2700.382098
hfg=2292.521581
Then,
x6=0.92261(saturated)
h6=2476.2993kj/kg
v6=2492.4328588m3/kg
t6=86.257410 0C
Since,
s=(h5- h6)/(h5-h6)
Then,
h6= 2515.0542 kj/kg
t6=95.0219320C
v6=2113.396m3/kg
s6=7.2103kj/kg-k
@ State 7
P=0.050132Mpa
S7=7.2103kj/kg-k
@P=0.050132Mpa
Sf=1.0917378
hf=340.7515
vf=1.030042
Sfg=6.501290193
hfg=2305.23875
vfg=3232.393363
Since,
then,
S7=Sf7+x7Sfg7
Therefore,
h7=2510.281895kj/kg
t7=81.39220C
v7=3043.132408m3/kg
@ State 8
Assume a condensate depression CD=3.50C
t8=81.3922-3.5=77.89220C
h8=hf @ t8=326.055711kj/kg
p8=0.04348677241Mpa
vf8=1.027735303m3/kg
@State 9
Wp1=vf8=(p9-p8)
=1.02773(0.19723=0.043486)
Wp=0.158768kj/kg
Then,
WP1=h9-h8
h9=326.21448kj/kg
From p. 487 , potter. The efficiency of the condensate pump is in the range of 70% to
75%, use 75% for design purpose.
Then,
p(h9-h8)= h9- h8
h9=326.2674kj/kg
v9=1.028m3/kg
t9=77.90C
@ State 10
From p. 59 of power plant engg of PK Nag. The temperature terminal difference on
the water tube closed feed water heaters are of order 3-60c, used 4.50C.
t10=82.22-4.5=77.720C
v10=1.027631m3/kg
p10=197.9273kpa
h10=325.33133kj/kg
@ State 11
t11=119.90189-4.5=115.4018850C
v11=1.060211995m3/kg
p11=197.923kpa
h11=503.292992kj/kg
@State 12
Wp2=vf11(P12-P11)
Wp2=
=1.060211995(456.60433-185.39)
h12- h11
h12=787.657kj/kg
Wp2=284.364kj/kg
Then,
p1(h12-h11)= h12- h11
Therefore,
h12=882.44505kj/kg
V12=1.06022m3/kg
t12=119.920C
@State 13
t13=143.33-4.5=138.830C
v13=1.078529935m3/kg
p13=456.60433kpa
h13=584.09846kj/kg
@State 14
t14=148.4629294-4.5=143.96290C
v14=1.08881m3/kg
p14=456.60433kpa
h14=625.561432 kj/kg
@State 15
t15=215.56-4.5=2110C
v15=1.174401931m3/kg
p15=456.60433kpa
h15=902.59354 kj/kg
@State 16
Wp3=vf15(P16-P15)
=1.1744019(8.717-0.4566043)
Wp3=
h16=912.2950403kj/kg
Wp3=9.7014kj/kg
Then,
h16- h15
Therefore,
p1(h16-h15)= h16- h15
h16=915.5288706kj/kg
t16=294.440C
@State 17
t17=221.86210C
v17=1.193359m3/kg
p17=2.4015Mpa
h17=952.23 kj/kg
@State 18
t18=187.946730C
v18=1.13844315m3/kg
p18=1.198863Mpa
h18=798.458 kj/kg
@State 19
t19=148.464450C
v19=1.088794306m3/kg
p19=456.60433kpa
h19=625.5659 kj/kg
@State 20
t20=86.258741040C
v20=1.0333329m3/kg
p20=60.7777kpa
h20=361.196537 kj/kg
III. CALCULATIONS OF MASS FLOW RATES

Assumption: 1kg/s of total Mass Flow Rate
Consider the fifth heater
Using the energy balance or second law of thermodynamics

Energy in =Energy out
h4+uh2= uh17+ h15
u
u
h h
h h
15
14
17
902.5935 625.5652
3112.0402 952.2386
u 0.128265624
Consider the second heater

uh17+vh3+ h13= (u+v)h18+ h14
v
h uh uh h
h h
14
18
3
17
13
18
625.5651 (0.128265624)( 798.45811 952.2386) 584.09846

2957.447 798.45811
v 0.02834261482
Consider the third heater

(u v) h18 w h4 h12 (u v w) h19 h13
w
(u v) h19 h13 h12 (u v) h18
h h
4
19
(0.1566)( 625.5659) 584.0984 503.8586 (0.1566)(798.45811)

2790.734 625.5659
w 0.0245546199
Consider the fourth heater

x h5 (1 u v w) h10 (u v w) h19 h11
x
11
(1 u v w) h19 (u v w) h10
h h
5
10
x 0.0527227
Consider the fifth heater

(1 u v w x y ) h9
yh
(1 u v w x ) h10
yh
(1 u v w x )(h10 h9)
h h h
6
20
y 0.075795
Calculating for the work Output of the turbine
Wt (h1 h2 ' ) (1 u )( h2 ' h3 ' ) (1 u v)( h3 ' h4 ' )

(1 u v w)( h4 ' h5 ' ) (1 u v w x)(h5 ' h6 ' )
(1 u v w x y )( h6 ' h7 )
w 1022.25549kj / kg
t
(Work output of the turbine)
From Equation 8-10, page 228 of the Power Plant Engineering by Morse;
20
098
Generating Efficiency
0.055
xRatingLoad
RatedKw
1000
For full Load,

Rating Load =1
gen 0.98
0.055
x1 96.65%
50000
3
1000
Solving for the pump work;
w
w
w
w
w
p1
0.1943
p2
0.274257
p3
9.7014
net
wt w p1 w p 2 w p 3
net
1012.085533kj / kg
w
w
net
t
t 99%
Capability Rate of Generator: %

To solve the power input to the generator, the following equation is used where
the rated Gen is 50,000kW and the generator efficiency is solved above.
RatedGen gen ( Pin )

Pin
RatedGen
gen
50,000
0.99
Pin 50502.42577 KW
Pin
EXTRACTION MASS-FLOW RATES
u=0.128265 x 49.4 kg/s x 3600 s/hr = 22810.75857 kg/hr

v=0.028342 x 49.4 kg/s x 3600 s/hr = 5040.45062 kg/hr
w=0.024554 x 49.4 kg/s x 3600 s/hr = 4366.7936 kg/hr
x=0.052722 x 49.4 kg/s x 3600 s/hr = 9376.2049 kg/hr
y=0.075795 x 49.4 kg/s x 3600 s/hr =134793828 kg/hr
Exhaust = 0.705387 x 49.4 kg/s x 3600 s/hr = 125446.0241kg/h
For the total mass flow rate required to drive the turbine
50502.42577 KW
1022.25549 KJ / Kg
49.4029 Kg / s
IV. CONDENSER DESIGN

The following data are used for the design of condenser:
Pc=5.0796 Kpa
m7=32.67353 kg/s = 117623.693 kg/hr
hc=2136.9152 Kj/kg
ts=33.150572 0C
hfc=138.955 Kj/Kg
td=4.5 0C
vw=2.286 m/s
t0=ts-td=28.651 0C
ti=240C
From the table 11-8 of the book of Morse, the following data are obtained for
condenser tubes of 22.3 (tube size) and 18(BWG).
Dv=tube size (External Diameter)=22.2mm
dt=Wall thickness =1.24mm
Dw=Internal Diameter =19.74mm
aw=Cross Section of Bore = 3.06x10-3 m2
av=External Surface =0.069806
Vw=Water Velocity = 7.5 ft/sec = 2.134 m/sec
The water velocity was recommended base on an article of the Book of Potter.
From equation 9-13, Power Plant Engineering by Morse,
= LMTD (Log Mean Temperature Difference)
t t
In t t

t t
o
6.553
Uv
111910
q A
v
Ut
0.188
Equation 9-22, page 276, Morse.
dt
Where; kt=93.7 from table 9-1, page 267, Morse.

Ut
t
93.7
75,565
d t = 1.24 x10 3
Using equation 9-20, page 276, Morse.

U w 1379.7
J 0.24 0.73
V
0.27
Dw
Where J=0.938 based on the table 14-8 of Morse
Substituting the values above,

Uw=7088.83
From the book of Morse, the value of could also be solved using the
equation 9-19 provided on the said book,
let
q
Av
1
2 Dv
Dv
Dv
U v U t ( Dw Dw ) U s Dw U w Dw
q
x
Av
Substituting Values obtained,
x 0.188
2.494 x10 4
111910
1.188
x
27.9 x 733346.23
6.553 x
By trial and error or iteration using Gauss-Seidel or just using a calculator,

X= 21,302.441241
Where;
q=m11(hc-hfc)
q= 65,280.413 Kg/hr
q= 15,595.684 Kcal/hr
Substituting the Values;
A
q
x
A = 2347.32 m2
Solving for the flow of the feed water,
q=mwCp(to-ti) ; Cp=1
m t
w
q
o ti
Substituting the value,

mw 12,072.59kg / hr 26615,508.97 Kcal / hr
Dividing by 500 the mw, the flow could then be 128,793.5 GPM this value
represent condensing water needed.
To solve for number of tubes per pass,
mw=3600x103 nawVw
Substituting the values,
n 4,794.01 4794(Tubes / pass )
For the length of the tube per pass,

L
n
i
L 7.015m
Referring to the table 8-2 of Morse, it is suggested to use a specified tube

length of 7.5m which is reasonable. With this, it is suggested that a one pass surface type
condenser will used.
V. EVAPORATOR DESIGN
1. EVAPORATOR AND WATER TREATMENT
Evaporator
Within a downstream processing system, several stages are used to further isolate and
purify the desired product. The overall structure of the process including pretreatment, solid
-liquid separation, concentration, and purification and formulation. Evaporation fall into the
concentration stage of downstream processing and is widely used to concentrate foods,
chemical, and salvage solvent. The goal of evaporation is to vaporize most of the water from
a solution will usually still contain 85-98% water. This is not suitable for industry usage
because of the cost associated with processing such a large quantity of solution, such as the
need for large equipment.
Water can be removed from solution in ways other than evaporation, including
membrane process, liquid-liquid extraction, crystallization and precipitation. Evaporation can
be distinguished from some other drying methods in that the final product of evaporation is a
concentrated liquid, not a solid. It is also relatively simple to use and understand since it has
been widely used on large scale. In order to concentrate a product by water removal, an
auxiliary phase is used which allows for easy transport of solvent rather than the solute.
Heat is needed to provide enough energy for the molecules of the solvent to leave the
solution and move into air surroundings the solution. The energy needed can be expressed as
an excess thermodynamic potential of the water in the solution. Leading to on big problem in
industrial power plan.
When designing evaporator engineers must quantify the mount of steam needed for
every mass unit of water removed when a concentration is given. An energy balance must be
used based on an assumption that a negligible amount of heat is lost to the system
surroundings. the heat that need to be and vaporized the water. Another consideration is the
size of the heat exchanger which effects the heat transfer rate.
Q=UA (T1-T2) where
U=overall heat transfer coefficient
A=heat transfer area
q=overall heat transfer rate
Referring to the table of mass bled in chapter 1 where the mass flow is 2% if the total
steam flow entering the turbine, the heat transfer (q) is found to be; q=3394.5KW =
11583000Btu/hr.
From equation 8-2, pp.351 by POTTER, the heat transfer area; A=q/Um where (qm)
is the heat head and is equal to 27.8 a 50 as obtained in chapter 1.
Looking at the fig. 8-34, pp. 391 by POTTER, for a saturation temperature =285 the
heat transfer coefficient U is founded to be U= 555 Btu/fthr- knowing these value, the
resulting heat transfer area is A=39.
B. Make-up Water treatment
The make-up water is treated in a demineralizing plant capable of producing

46.32kg/s of treated water. The raw water should pass coagulation after which is filtered by
stages of mechanical filters; this is to make sure that it is free from impurities. By then it is
ready for cationic and anionic filtration.
The result should have the following quality.
Total hardness not more than 1 ppm;

Total salt content not more than 1 ppm;
Total alkalinity not more than 3 ppm;
Silica content not more than 3 ppm;
These limits of tolerance are based on the table 13-5, pp.527 by the book of MORSE.
VI. FEED WATER HEATER DESIGN

The feed water used in the steam boiler is a means of transferring heat energy from
the burning fuel to the mechanical energy of the spinning steam turbine. The total feed water
consists of recirculate condensed steam, referred to as condensate, from the steam turbine
plus purified make-up water. Because the metallic materials it contacts are subject to
corrosion at high temperature and pressure, the makeup water is highly purified before use.
A system of water softeners and ion exchanger demineralizer produces water pure
that it coincidentally becomes an electrical insulator, with conductivity in the range of 0.31.0 micro Siemens per centimeter. The make-up water in a 500Mwe pant amounts perhaps 20
Us gallons per minutes (1.25 L/s_) to offset the small losses from steam leaks in the system.
The feed water cycle begins with condensate water being pumped out of the condenser after
kilometer through the steam turbine. The condensate flow rate at full load in a 500 Mw plant
is about 6000 US gallons per minutes (0.38/s). The water flows through a series of six or
seven intermediate feedwater heaters, heated up at each point with the steam extracted from
an appropriate duct on the turbines and gaining temperature at each stage. Typically, the
condensate plus the makeup water then flows through a dearator that removes dissolve air
from the water, further purifying and reducing its corrosivity. The water may be dosed
following this point with hydrazine, a chemical that removes the remaining oxygen in the
water to below 5 parts per billion(ppb). It is also with pH control agents such as ammonia or
morpholine to keep the residual acidity low and non-corrosive.
Feed water heaters are basically small condenser, in designing a feed water heater, the
method is analologous to the design of the condensers except that the feed water heaters are
never less than two-pass, and maybe four or six pass, while the condensers are generally one
or two-pass.
Closed Feed Water Heater 1:

The following Data are used for the design of the feed water heater:
P2=2.401478Mpa
ts= ts@ P2=216.5050C
h2=3112.0402kj/kg
td=4.50C
t0=ts-td=216.5050C
ti= t2=172.20C
m2=3.172823 kg/s =11,422.1623 Kcal
hf@P2=927.543 Kcal
From table 11-8, pp.418 of Morse,

Use 15.9mm as tube size 15.9 x 18 BWG
D0=15.9mm (external dia)
Di=13.39mm (internal dia)
Dt=1.24mm (wall thickness)
ai=1.408 cm2
ar=0.049857 m2 external surface 0.5 m/s
v=8 fps or 2.4384 m/s
*From the book of Potter, it is recommended that the water velocity would be 8 fps
From equation 9-13, Power Plant Engineering by Morse (Morse),

t t
In t t

t t
o
17.40474
Uv
111910
q A
0.188
(Equation 9-22, page 276, Morse)
Ut
dt
Where from table 9-1, page 67, Morse,

Kt=93.7
Ut
t
93.7
75,565
d t = 1.24 x10 3
Using equation 9-20, page 276, Morse,

U w 1379.7
J 0.24 0.73
V
0.27
Dw
;Where J(In centepoises) is in table 14-18.
Since there is no available value of J for the given temperature, the designers
used the Helmholtz equation, by finding the viscosity of the water,
(in _ poise )
t
0.01779
1 0.03368t 0.000221t 2
ti t o
192.1025
2

J 0.11396
U w 1379.7
J 0.24 0.73
0.113960.24
V
1379
.
7
2.44 0.73
0.27
3 0.27
Dw
13.39 x10
U w 29295 Kcal / m hr C
2
From the book of Morse, the value of

9-19 provided on the said book,
could be also be solve using equation
q 1
2 Dv
Dv
Dv
Av U v U t ( Dw Dw ) U s Dw U w Dw
let
q
x
Av
x 0.188
2.661x10 4
111910
1.188
x
29776 x 1,947,764.789
6.553 x
By trial and error or iteration using Gauss-Seidel or just using a calculator,

X= 51,971.979
Where;
q m hm h fm
Substituting the values

q 5913393.897 Kcal / hr
Then,
Av 113.78m 2
For mass flow of feed Water;

q mw C p t o t i
mw
q
t o ti
mw 148,559.729kg / hr
Solving for the number of tubes per pass using the formula used on the
previous heater and substituting the values,
mw 3600 x103 nawVw
n 121tubes / pass
Therefore there are 484 the four pass heater.

L
Av
av n
L 4.72m

P3=1.198863466Mpa
ts= ts@ P3=182.680C
h3=3035.904176kj/kg
td=4.50C
t0=ts-td=178.1740C
ti= t3=136.6Kg/hr
m3=11,173.6kg/hr
hf@P3=775.04587Kj/kg=185.161Kcal

ai=1.408 cm2
v=8 fps or 2.4384 m/s
t t
In t t

t t
o
18.0027
1
2 Dv
Dv
Dv
q
Av
Uv
111910
q A
v
Ut
dt
0.188
93.7
75565
1.24 x10 3
U s 29295kcal / m 3 hr o C
U w bV 0.73
J 0.73 0.73
U w 1379.7 0.27 V ; whereJ 0.152at _ t 157.137 o C
Dw
U w 5386.057 kcal / m 2 hr oC
With the same process as the solution for the previously solved heater and substituting
the appropriate values the following equation is obtained and further simplification, the
following equation is obtained.
x1.188 28.72 x 2,014,682.157
x 52,279.35991
Then;
q m3 (hs hf )
q 5,817,077.933kcal / hr
Av 111.269
q mwC p (to ti ); C p 1
mw
q
(t o t i )
mw 138,258.2577 kg / hr
mw 3600 x103 na wVw
n 112
n 448( For _ Four _ pass _ heater )
A
L v
av n
L 4.98m _ or _ 5m

P4=0.45660933Mpa
ts= ts@ P4=146.03210C
h4=3112.0402kj/kg
td=4.50C
t0=ts-td=141.53210C
ti= t4=117.940C
M4=11,173.6kg/hr
hf@P4=615.0795Kj/kg=146.95Kcal

ai=1.408 cm2
v=8 fps or 2.4384 m/s

t t
In t t

t t
o
12.9
1
2 Dv
Dv
Dv
q
Av
Uv
111910
q A
v
Ut
dt
0.188
93.7
75565
1.24 x10 3
U s 29295kcal / m 3 hr o C
U w bV 0.73
J 0.73 0.73
U w 1379.7 0.27 V ; whereJ 0.199at _ t 129.134o C
Dw
U w 5,752.61kcal / m 2 hr oC
With the same process as the solution for the previously solved heater and substituting
the appropriate values the following equation is obtained and further simplification, the
following equation is obtained.
x1.188 28.72 x 2,014,682.157
x 52,279.35991
Then;
q m4 (hs hf )
q 2,222,966.99kcal / hr
Av 42.521
mw
q
(t o t i )
mw 94,207.089kg / hr
mw 3600 x103 na wVw
n 76.22
A
L v
av n
L 3.57 m _ or _ 3.6m

P6=0.0607777Mpa
ts= ts@ P6=146.0321oC
H6=2476.2993kj/kg
td=4.50C
t0=ts-td=141.5321oC
ti= t4=117.94oC
m6=11,173.6 kg/hr
hf@P6=615.0795Kj/kg=146.95Kcal

ai=1.408 cm2
v=8 fps or 2.4384 m/s
t t
In t t

t t
o
20.241
q
Av
Uv
1
2 Dv
Dv
Dv
111910
q A
v
0.188
Ut
dt
93.7
75565
1.24 x10 3
U s 29295kcal / m3 hr oC
U w bV 0.73
U w 1379.7
J 0.73 0.73
V ; whereJ 0.50513at _ t 55.09o C
0.27
Dw
U w 7182.383kcal / m 2 hr oC
x1.188 28.72 x 2,014,682.157

x 52,279.35991
Then;
q m6 (hs hf )
q 6,248,899.98kcal / hr
Av 90.41
mw
q
(to ti )
mw 123,096.35kg / hr
mw 3600 x103 na wVw
n 99.56
A
L v
av n
L 4.534m
VII. PIPE SCHEDULING

Within industry, piping is a system of pipes used to convey fluids from one
location to another. The engineering discipline of piping design studies the best and most
efficient manner of transporting fluid to where it is most needed.
Industrial process piping (and accompanying in-line components) can be
manufactured from wood, glass, glass, steel, aluminum, plastic and concrete. The in-line
components known as fittings valves and other devices typically sense and control the
pressure, flow rate and temperature of the transmitted fluid, and usually are included when
one discussion the concept of piping design, Piping system are documented in the piping and
instrumentation diagram. If necessary pipes can be cleaned by the tube cleaning process.
Plumbing is a piping system that the most people are familiar with, as it
constitutes the form of fluid transportation that is used to provide potable water and fuels to
their homes and business. Plumbing pipes also remove waste in the form of sewage, and
allow venting of sewage gases to the outdoors. Fire sprinkler systems also use piping and
many transport potable or non-potable water or other fire-suppression fluids.
Piping also has many other industrial applications, which are crucial for
moving raw and semi-processed fluids for refining into more useful products. Some of the
more exotic materials of construction are titanium, chrome-molly and various other steel
alloys.
1. Turbine Mainline and Super-heater Line:
The following Data is used for the design of the pipe mentioned:
Temperature: 5100C (Maximum Temperature on the pipeline mentioned)
Pressure (P):87.9 kg/cm2
With allowance on the pressure for the pipe safety purpose,
P=87.9(1.1)=96.69 kg/cm2 gauge

Mt=46.32kg/s (Total Mass-Flow Rate)
V=0.039182 m3/kg
From table 14-1, p.574, Power Plant Engineering by Morse @510 0C the
recommended pipe is Cr-Mo steel A-158 seamless-high chrome alloy having working stress
S=513.2 kg/ cm2
Using Equation 14-1, page 573, Power Plant Engineering by Morse, the schedule No.
(SN) can be obtained;
P
S
96.69
SN 1000
188.31
513.2
Sn 1000
From table 15-6, Morse, high pressure super-heated steam, the velocity (v)
Ranges from 3048-4572 m/min. The designers used 3500m/min.
To get the diameter of the pipe, equation 14-9, from the Power Plant
Engineering by Morse, page 603 which states that the weight flowing is equal to the
velocity of the steam (v) multiplied by the area of the pipe (A) will be used;
Qw AV
AV mt v
D 2V
4
3000D 2V
60( 4)
D 0.19903m _ or _ 199.03mm
0.039182(46.32)
From Figure A-6, Pipe Standards, page 665 of the power plant Engineering by Morse,
the standard dimension for the pipe were used:
Nominal Diameter=254mm
Outside Diameter-266.7mm
SUMMARY:
Pipe Material: Cr-Mo Steel A-158 Seamless-High Chrome-Alloy
Nominal Diameter: 254mm
Outside Diameter: 266.7mm
Wall Thickness:12.7 mm
Schedule Number: 200
2. Turbine First Extraction Line

The following Data is used for the design of the pipe for the said line:
Temperature = 332.855oC
Pressure: (2.167-0.101325)x 10.172=21.064 kg/cm2
v=0.1234 m3/kg
Mm=3.173 kg/s (Mass-flow rate through the first extraction)
From the table 14-1, p.574 @332.86oC the recommend pie is carbon steel A-135
Fusion welded for type RW-B having working stress S=896.4kg/cm 2
P
S
21.064
SN 1000
23.499
896.4
Sn 1000
Having the velocity(V) based on the table 14-6 Power Plant Engineering by Morse,
V=4500 m/min, solving for the weight flow rate and the diameter with the same process
above,
Qw AV
AV mt v
D 2V
4
0.123567(3.76126)
3000D 2V
60( 4)
D 81.51mm
Nominal Diameter=88.9mm
Outside Diameter=94.64mm
SUMMARY:
Pipe Material: Carbon Steel A-135 Fusion welded type RW-B
Nominal Diameter: 88.9mm
Schedule Number: 40
3. Turbine Second Extraction Line

Pressure: (1.0653-101.325)x 10.172=10.863 kg/cm2
v=0.221 m3/kg
Mm=3.10378 kg/s (Mass-flow rate through the second extraction)
From the table 14-1, p.574 @256.334oC the recommend pie is carbon steel A-135
Fusion welded for type RW-B having working stress S=896.4kg/cm 2
P
S
10.863
SN 1000
12.12
896.4
Sn 1000
above,
Qw AV
AV mt v
D 2V
4
0.221(3.10378)
4500D 2
60(4)
D 107.85mm
Nominal Diameter=127mm
Outside Diameter=133.55mm
SUMMARY:
Nominal Diameter: 127mm
Schedule Number: 40
4. Turbine Third Extraction Line

Pressure: 0.42735 MPa = 4.3578 kg/cm2
v=0.4301174 m3/kg
For the Carbon Steel A-139, Fusion Welded, S = 742.4 kg/cm 2 (Table 14-1, page 574, Power
Plant Engineering by Morse)
P
S
4.3578
SN 1000
5.87
742.4
Sn 1000
above,
Qw AV
AV mt v
D 2V
4
0.4301174(12283)
1850D 2
60(4)
D 147.7 mm
Nominal Diameter= 203.2mm
Outside Diameter= 209.55mm
SUMMARY:
Schedule Number: 20
5. Turbine Fourth Extraction Line

v=0.90781 m3/kg
P
S
1.89045
SN 1000
2.54641
742.4
Sn 1000
above,
Qw AV
AV mt v
D 2V
4
0.90781(2.6818)
1850D 2
60(4)
D 317.07 mm
Nominal Diameter= 203.2mm
SUMMARY:
Schedule Number: 20
6. Turbine Fifth Extraction Line

v=2.680711 m3/kg
P
S
0.5674721
SN 1000
0.859
660.9
Sn 1000
above,
Qw AV
AV mt v
D 2V
4
2.680711(3.4596)
1250D 2
60(4)
D 752.86mm
Nominal Diameter= 820mm
SUMMARY:
Pipe Material: Carbon Steel A-139 Fusion welded
Nominal Diameter: 820 mm
Wall Thickness; 7.92 mm
Schedule Number: 10
7. Condenser Input Pipe

v=0.0010042 m3/kg
M11=32.674 kg/s (Mass-flow rate through the second extraction)
P
S
0.042450
SN 1000
0.097
490.4
Sn 1000
above,
Qw AV
AV mt v
D 2V
4
0.0010042(32.674)
100D 2
60(4)
D 158.32mm
Nominal Diameter= 203.2 mm
Outside Diameter= 209.55 mm
SUMMARY:
Pipe Material: Carbon Steel A-120 Fusion welded
Nominal Diameter: 203.2 mm
Outside Diameter: 209.55 mm
Schedule Number: 20
8. Boiler Feed Line

Temperature = 300.324 oC
v=0.00140488 m3/kg
M16=46.319544kg/s (Mass-flow rate through the second extraction)
For the Carbon Steel A-120, Fusion Welded, S = 1054.6 kg/cm 2 (Table 14-1, page 574,
Power Plant Engineering by Morse)
P
S
87.89954
SN 1000
83.35
1054.6
Sn 1000
above,
Qw AV
AV mt v
D 2V
4
0.00140488(46.319544)
1000D 2
60(4)
D 176.268mm
Nominal Diameter= 203.2 mm
Outside Diameter= 211.38 mm
SUMMARY:
Pipe Material: Carbon Steel A-120, General Purpose Wrought Pipe Welded and Seamless
Type S-B
Nominal Diameter: 203.2 mm
Outside Diameter: 211.38 mm
Schedule Number: 40

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INTRODUCTION

Exhaust pressure, in.Hg. abs

II. ENTHALPIES @ ACTUAL CASES

From section 8-4, p.227 of Frederick T. Morse

From Steam table:

S2= S3= 6.83496

@ P=1.15 & S=6.83496

@ P=1.2 & S=6.83496

@ P=1.15 & h=2957.447

@P=0.44 & s=6.8733

@P=0.46 & s= 6.8733

@ P=0.44 & h=2790.734

@ P=0.46 & h=2790.734

p1(h12-h11)= h12- h11

p1(h16-h15)= h16- h15

III. CALCULATIONS OF MASS FLOW RATES

Consider the fifth heater

Using the energy balance or second law of thermodynamics

Consider the second heater

Using the energy balance or second law of thermodynamics

625.5651 (0.128265624)( 798.45811 952.2386) 584.09846

Consider the third heater

Using the energy balance or second law of thermodynamics

(u v) h19 h13 h12 (u v) h18

(0.1566)( 625.5659) 584.0984 503.8586 (0.1566)(798.45811)

Consider the fourth heater

Using the energy balance or second law of thermodynamics

Consider the fifth heater

Using the energy balance or second law of thermodynamics

Calculating for the work Output of the turbine

Wt (h1 h2 ' ) (1 u )( h2 ' h3 ' ) (1 u v)( h3 ' h4 ' )

(Work output of the turbine)

For full Load,

Solving for the pump work;

Capability Rate of Generator: %

RatedGen gen ( Pin )

EXTRACTION MASS-FLOW RATES

u=0.128265 x 49.4 kg/s x 3600 s/hr = 22810.75857 kg/hr

IV. CONDENSER DESIGN

= LMTD (Log Mean Temperature Difference)

Equation 9-22, page 276, Morse.

Where; kt=93.7 from table 9-1, page 267, Morse.

Using equation 9-20, page 276, Morse.

Substituting the values above,

Substituting Values obtained,

By trial and error or iteration using Gauss-Seidel or just using a calculator,

Substituting the value,

For the length of the tube per pass,

Referring to the table 8-2 of Morse, it is suggested to use a specified tube

B. Make-up Water treatment

The make-up water is treated in a demineralizing plant capable of producing

Total hardness not more than 1 ppm;

VI. FEED WATER HEATER DESIGN

Closed Feed Water Heater 1:

ts= ts@ P2=216.5050C

m2=3.172823 kg/s =11,422.1623 Kcal

From table 11-8, pp.418 of Morse,

Di=13.39mm (internal dia)

Dt=1.24mm (wall thickness)

ar=0.049857 m2 external surface 0.5 m/s

v=8 fps or 2.4384 m/s

From equation 9-13, Power Plant Engineering by Morse (Morse),

(Equation 9-22, page 276, Morse)