BATANGAS STATE UNIVERSITY

College of Engineering, Architecture, Fine Arts &

Computing Sciences
Gov. Pablo Borbon Campus II, Alangilan, Batangas City, Philippines 4200
www.batstate-u.edu.ph Telefax: (043) 300-4404 locs. 106-118

Chemical and Food Engineering Department

ChE 423: Equipment Design
Written Report

DRIVER FOR MOVING

EQUIPMENT

PREPARED BY:
ANDAL, KATHERINE LEI
MENDOZA, EUNICE MAE
ChE-4202
INTENDED LEARNING OUTCOMES:
 To be able to know the working principles govern in motors, steam, gas expanders,
etc.
 To identify the Rules of Thumb in the Drivers for Moving Equipment.
 To understand the principles to be consider in designing Drivers for Moving
Equipment.
 To be able to solve problems that is related in this study.

INTRODUCTION

Powered chemical processing equipment includes pumps, compressors, agitators

and mixers, crushers and grinders, and conveyors. Drivers are electric motors, steam or gas
turbines, and internal combustion engines.

MOTORS
Three Main Classes of Motors:
1. Induction Motors - AC electric motor in which the electric current in the rotor
needed to produce torque is obtained by electromagnetic induction from the
magnetic field of the stator winding.
2. Synchronous Motors - an electric motor having a speed exactly proportional to the
current frequency.
3. Direct Current Motors - any of a class of rotary electrical machines that converts
direct current electrical energy into mechanical energy.

Efficiency is greater for larger machines. Motors are 85-95%; steam turbines are 42
78%; gas engines and turbines are 28-38%. For under 100 HP, electric motors are used
almost exclusively.

INDUCTION MOTORS
 also known as Asynchronous Motors
 The most popular and frequent in use because of their simple and rugged
construction, and simple installation and control.
 constant speed devices available as 3600 (two-pole), 1800, 1200, and 900rpm
(eight-pole)
 Two speed models with special windings with 2: 1 speed ratios are sometimes used
with agitators, centrifugal pumps and compressors and fans for air coolers and
cooling towers
 Capacities up to 20,000 HP are made
 With speed increasing gears

SYNCHRONOUS MOTORS
 are made for speeds from 1800 (two-pole) to as low as 150rpm (48-pole)
 Suited for example for low speed reciprocating compressors, but are not made
smaller than 50 HP or so.
 operate at constant speed without slip, costs of control equipment are higher than
for the induction types
 efficiencies are 1-2.5% higher than that of induction motors
 drive large low speed reciprocating compressors requiring speeds below 600 rpm
 not suitable when severe fluctuations in torque are encountered

DIRECT CURRENT MOTORS

 used for continuous operation at constant load when fine speed adjustment and
high starting torque are needed
 wide range of speed control is possible
  Have some process applications with centrifugal and plunger pumps, conveyors,
hoists, etc.

STEAM TURBINES AND GAS EXPANDERS

Turbines - utilize the expansion of steam or a gas to deliver power to a rotating
shaft. Features of such equipment are:
 flexibility with regard to inlet and outlet pressures
 high speed rotation
 adjustable speed operation,
 non sparking and consequently nonhazardous operation
 simple control
 low first cost and maintenance

Steam turbines
• are competitive above 100 HP
• are speed controllable
• frequently employed as spares in case of power failure

Gas Expanders
• equipment used when gases other than steam are employed as motive fluids
• are used to recover energy from high pressure process gas streams in a plant when
the lower pressure is adequate for further processing.
• Usually several hundred horsepower must be involved for economic justification of
an expander

Combustion Gas Turbines and Engines

• When a low cost fuel is available, internal combustion drivers surpass all others in
compactness and low cost of installation and operation.
• Process applications of combustion gas turbines are chiefly to driving pumps and
compressors, particularly on gas and oil transmission lines where the low thermal
efficiency is counterbalanced by the convenience and economy of having the fuel on
hand.

WORKING PRINCIPLES

I. MOTORS

INDUCTION MOTORS
In a DC motor, supply is needed to be given for the stator winding as well as the
rotor winding. But in an induction motor only the stator winding is fed with an AC supply.

BASIC WORKING PRINCIPLE OF AN INDUCTION MOTOR

• Alternating flux is produced around the stator winding due to AC supply and
revolves with synchronous speed. The revolving flux is called as "Rotating Magnetic
Field“.
• The relative speed between stator RMF and rotor conductors causes an induced emf
in the rotor conductors, according to the Faraday’s law of electromagnetic induction.
The rotor conductors are short circuited, and hence rotor current is produced due to
induced emf. That is why such motors are called as induction motors.
• As the cause of production of rotor current is the relative velocity between rotating
stator flux and the rotor, the rotor will try to catch up with the stator RMF. Thus the
rotor rotates in the same direction as that of stator flux to minimize the relative
velocity. However, the rotor never succeeds in catching up the synchronous speed.
This is the basic working principle of induction motor of either type, single phase of
3 phase.
SYNCHRONOUS MOTORS
The speed of the rotor of this motor is same as the rotating magnetic field. It is
basically a fixed speed motor because it has only one speed, which is synchronous speed,
and therefore no intermediate speed is there or in other words it’s in synchronism with the
supply frequency. Synchronous speed is given by

120𝑓
𝑁𝑆 =
𝑝
Where, f = supply frequency and p = number of poles.

DIRECT CURRENT MOTORS

A motor is an electrical machine which converts electrical energy into mechanical
energy. The principle of working of a DC motor is that "whenever a current carrying
conductor is placed in a magnetic field, it experiences a mechanical force". The direction of
this force is given by Fleming’s Left hand rules and it's magnitude is given by F = BIL.
Where, B = magnetic flux density, I = current and L = length of the conductor within the
magnetic field.

II. STEAM TURBINES

 Steam turbine is the engine, where the energy of working fluid is used
directly to rotate the turbine blades. In the turbine, the working fluid
undergoing a process of expansion, namely the pressure drop and flow
continuously.
 In general, the steam turbine system consists of several components, such as:
compressors, pumps, boilers, combustion chamber, condenser and turbine.
Turbine is much in use for power generation, aircraft, in the industry, and
others.

Steam turbine is one of machine types that use a method of external combustion engine.
The heating of working fluid (steam) is done outside the system. In brief the working
principle of steam turbine as follows:
 Heat energy from steam is converted into kinetic energy and the steam is expanding.
 The steam gushing out of the nozzle is directed to the turbine blades with arches
shaped and fitted around the wheel turbines.
 If the steam still has velocity when it leaves the turbine blades means that only some
of the kinetic energy of steam is taken by the turbine blades which are running.
 Row blades motion is mounted one line fixed blade (blade guide) that allows you to
change the direction of the steam velocity.
 Velocity of steam when it leaves the last blade motion should be made as small as
possible.

III. GAS TURBINES

Gas turbine engines derive their power from burning fuel in a combustion
chamber and using the fast flowing combustion gases to drive a turbine in much the
same way as the high pressure steam drives a steam turbine. A simple gas turbine is
comprised of three main sections a compressor, a combustor, and a power turbine.
The gas-turbine operates on the principle of the Brayton cycle, where compressed
air is mixed with fuel, and burned under constant pressure conditions. The resulting
hot gas is allowed to expand through a turbine to perform work.

RULES OF THUMB
a broadly accurate guide or principle, based on experience or practice rather than
theory.
 1. For under IOOHP, electric motors are used almost exclusively. They are made for up
to 20,000 HP.
2. Steam turbines are competitive above 1OOHP. They are speed controllable.
Frequently they are employed as spares in case of power failure.
3. Gas expanders for power recovery may be justified at capacities of several hundred
HP; otherwise any needed pressure reduction in process is effected with throttling
valves.
4. Efficiency is greater for larger machines. Motors are 85-95%; steam turbines are 42-
78%; gas engines and turbines are 28-38%.
5. Synchronous motors are made for speeds as low as 150rpm and are thus suited for
example for low speed reciprocating compressors, but are not made smaller than
50HP. A variety of enclosures is available, from weather-proof to explosion-proof.
6. Combustion engines and turbines are restricted to mobile and remote locations.

DESIGN PRINCIPLES
sets of generally applicable laws, guidelines, human biases and design
considerations, all of which reflect the accumulated knowledge and experience of
practitioners and researchers.

PRINCIPAL COMPONENTS OF STEAM TURBINES

The main parts of a steam turbine are:
• the rotor that carries the blading to convert the thermal energy of the steam into the
rotary motion of the shaft
• the casing, inside of which the rotor turns, that serves as a pressure vessel for
containing the steam (it also accommodates fixed nozzle passages or stator vanes
through which the steam is accelerated before being directed against and through
the rotor blading)
• the speed-regulating mechanism, and the support system, which includes
the lubrication system for the bearings that support the rotor and also absorb any
end thrust developed.

DESIGN CONSIDERATION

BLADING DESIGN
The turbine blading must be carefully designed with the correct aerodynamic shape
to properly turn the flowing steam and generate rotational energy efficiently. The blades
also have to be strong enough to withstand high centrifugal stresses and must be sized to
avoid dangerous vibrations. Various types of blading arrangements have been proposed,
but all are designed to take advantage of the principle that when a given mass of steam
suddenly changes its velocity, a force is then exerted by the mass in direct proportion to the
rate of change of velocity.

GAS TURBINES

DESIGN CONSIDERATIONS

1. NUMBER OF BEARINGS
The two-bearing design is preferred in single-shaft gas turbines. Three-bearing
solutions can cause some problems

2. ORIENTATION
The preferred gas-turbine casing is a horizontally split design that allows for
easy access. Vertically split casings are used in high-pressure machinery designs
3. SPEED LIMITATION
As the speed of a gas turbine increases, the centrifugal forces on the rotating
components increase. These forces increase the stress on the rotating components,
particularly in the disks, blades and blade attachment to the disk

4. INTERNAL DESIGN
Some problems arise when there is a major change in the number of blades
between stages.

PROBLEM SOLVING

STEAM TURBINES

Steam is fed to a turbine at 614.7 psia and 825°F and is discharged at 64.7 psia.
a. Find the theoretical steam rate, Ib/kWh, by using the steam tables.
b. If the isentropic efficiency is 70%, find the outlet temperature.
c. Find the theoretical steam rate if the behavior is ideal, with C,/C, = 1.33.

PERFORMANCE OF A COMBUSTION GAS TURBINE

Atmospheric air at 80°F (305K) is compressed to 5 atm, combined with fuel at the rate
of 1 kg/s, and then expanded to 1 atm in a power turbine. Metallurgical considerations
limit the temperature to 1700°F (1200K). The heat capacities of air and combustion
products are C, = 0.95 + 0.00021T (K) kJ/kg, the heat of combustion is 42,000 kJ/kg,
the furnace efficiency is 0.975, the isentropic efficiency of the compressor is 0.84, and
that of the expander is 0.89. Find:
a. The required air rate.
b. The power loads of the compressor and expander.
c. The overall efficiency as a function of the temperature of the exhaust leaving a
steam generator.

REFERENCES

Rules of Thumb for Chemiccal Engineers

Chemical Process Equipment: Selection and Design by Stanley M. Walas
http://www.electricaleasy.com/2014/02/working-principle-and-types-of.html
https://www.electrical4u.com/synchronous-motor-working-principle/
http://www.electricaleasy.com/2014/01/basic-working-of-dc-motor.html
http://steamofboiler.blogspot.com/2011/10/working-principle-of-steam-turbine.html
https://www.britannica.com/technology/turbine/Steam-turbines
http://www.chemengonline.com/gas-turbines-design-operating-
considerations/?printmode=1
 Solution:

Steam Turbines

a. The expansion is isentropic. The initial and terminal conditions are identified in the
following table and on the graph. The data are read off a large Mollier diagram
(Keenan et al., Steam Tables, Wiley, New York, 1969).

POINT P T°F H S
1 614.7 825 1421.4 1.642
2 64.7 315 1183.0 1.642
3 64.7 445 1254.5 1.730

∆𝐻 = 𝐻2 − 𝐻1 = −238.4 𝐵𝑡𝑢/𝑙𝑏

Theoretical steam rate = 3412/238.4 = 14.31 lb/kWh.

b. 𝐻3 − 𝐻1 = 0.7(𝐻2 − 𝐻1 ) = −166.9 𝐵𝑡𝑢/𝑙𝑏

𝐵𝑡𝑢
𝐻𝑠 = 1421.4 − 166.9 = 1254.5
𝑙𝑏
The corresponding values of T3 and S3 are read off the Mollier diagram, as tabulated.
c. The isentropic relation for ideal gases is
𝐾−1
𝑘 𝑃
∆𝐻 = 𝑘−1 𝑅𝑇1 [((𝑃2 ) 𝐾 ) − 1]
1
1.987(1285) 64.7 0.25
= [( ) − 1]
0.25 614.7

= −4396 Btu/lbmol, -244 Btu/lb

Performance of a Combustion Gas Turbine

POINT P TS T
1 1 305
2 5 483 517
3 5 1200
4 1 802 846
5 1 400

a.
Compression:
k=1.4, k/(k-1)=3.5
𝑃2 1 1
𝑇2𝑆 = 𝑇1 ( )3.5 = 305(5)3.5 = 483𝐾
𝑃1
483 − 305
𝑇2 = 305 + = 517𝐾
0.84
Combustion:
m’a = flow rate of air, kg/kg fuel
1200 1200
0.975(42000) = ∫ 𝐶𝑝 𝑑𝑇 + 𝑚′𝑎 ∫ 𝐶𝑝 𝑑𝑇
305 517
= 991682 + 771983 𝑚′𝑎
m’a=51.8

b.
Expansion:
k=1.33, k/(k-1)=4.0
𝑃4
𝑇4𝑆 = 𝑇3 ( )0.25 = 1200(0.2)0.25 = 802𝐾
𝑃1
𝑇4 = 1200 − 0.89(1200 − 802) = 846𝐾

Power Calculation:
Compresion:
517
𝑤′𝑐 = −𝑚′𝑎 ∆𝐻 = −51.8 ∫ 𝐶𝑝 𝑑𝑇
305
= −51.8(216.98) = −11.240 𝑘𝐽/𝑠

Expansion:
517
𝑤′𝑐 = −51.8 ∫ 𝐶𝑝 𝑑𝑇 = 52.8(412.35) = 21,771 𝑘𝐽/𝑠
1200
c.
Steam Generator:
517
𝑄′ = 52.8 ∫ 𝐶𝑝 𝑑𝑇
𝑇
21772−11380+𝑄′
Ƞt = overall efficiency = 42000

The tabulation shows efficiency with three different values of the exhaust temperature.
T Q’ Ƞt
846 0 0.247
600 14311 0.588
500 19937 0.722