40.6 MW Regenerative Thermal Power Plant

40.
6 MW REGENERATIVE THERMAL POWER PLANT
Contents
INTRODUCTION ..................................................................... 1
VARIABLE LOADING .......................................................... 10
SCHEMATIC DIAGRAM ...................................................... 23
GENERATOR AND TURBINE SIZING .............................. 25
MASS AND ENERGY BALANCE ...................................... 32
DESIGN OF STEAM TURBINE .......................................... 40
DESIGN OF THE PUMPS.................................................... 49
FUEL ANALYSIS .................................................................. 53
BOILER DESIGN .................................................................. 62
DESIGN OF CONDENSER ................................................. 70
DESIGN OF HEATERS ........................................................ 76
DESIGN OF FURNACE ....................................................... 91
DESIGN OF CHIMNEY ........................................................ 96
DESIGN OF MACHINE FOUNDATION ........................... 100
COST ANALYSIS ............................................................... 107
REFERENCE ....................................................................... 113
40.6 MW REGENERATIVE THERMAL POWER PLANT
INTRODUCTION
1
INTRODUCTION
In thermodynamic power cycles, an efficiency increases of even 0.5% in
cycle is an important gain. One of the more common ways to improve the
efficiency of a steam cycle is to use regeneration, a process where heat is taken
from steam between turbine stages and used to heat water as it goes through
pump stages.
The idea behind regeneration is that we split the turbine into high-pressure
and low-pressure stages and do the same for the pump. Then, we can divert
some of the heat in the fluid as it leaves the high-pressure turbine and add it to
the cool fluid leaving the low-pressure pump, thereby sending fluid with a higher
temperature to the boiler.
BACKGROUND OF THE STUDY
The Regenerative Rankine cycle is so named because after emerging
from the condenser (possibly as a subcooled liquid) the working fluid is heated
by steam extracted from the steam turbine.
Another variation sends bleed steam from between turbine stages to
feedwater heaters to preheat the water on its way from the condenser to the
boiler. These heaters do not mix the input steam and condensate, function as
an ordinary tubular heat exchanger, and are named "closed feedwater heaters".
Regeneration increases the cycle heat input temperature by eliminating
the addition of heat from the boiler/fuel source at the relatively low feedwater
2
temperatures that would exist without regenerative feedwater heating. This
improves the efficiency of the cycle, as more of the heat flow into the cycle
occurs at higher temperature.
STATEMENT OF THE PROBLEM
Electricity is considered a necessity in this modern-day time. But still
some isolated areas are left behind by the advancement of the technology. As
time flies, power demand is increasing, thus giving us a huge problem in power
generation. As a mechanical engineer it is our job to build and design power
generation system that will help us cope up to the ever-increasing load demand.
3
Design consideration
The following are the fundamental parameters identified for the basis in
analysis and computation:
Name of City: Dipolog city, Zamboanga del norte
Ambient Temperature: 29 °C
Ambient Temperature: 101.325 Kpa
Plant Design Operation: 8760 hours per year
Plant design: Regenerative Thermal Power Plant
Plant Capacity: 40.6 MW
Fuel: Propane (𝐶3 𝐻8 )
Households: 23165
Industrial: 42
Commercial: 128
4
OBJECTIVES
The researcher aims to:
Design a Regenerative Thermal Power Plant (w/ 2 open and 2 close
feedwater heaters) that will supply the demand of Dipolog City.
Determine the load requirement and demand of the community.
SCOPE AND LIMITATIONS
The research focuses on designing an Thermal Regenerative Power
Plant running on Regenerative Rankine cycle using 2 open and 2 closed
feedwater heaters. Variable load calculations where made beyond the data
gathered about the chosen community.
The Plant location and Schematic diagram will be also shown in this
research. All of the chosen machineries where existent and merely based on
the theoretical and technical standards from books or articles.
5
DEFINITION OF TERMS
Air pre-heater – a device used in steam boilers to transfer heat from the
flue gases to the combustion air before the latter enters the surface
Boiler Drum – is a standard feature of a water-tube boiler. It is a reservoir
of water/steam at the top end of the water tubes. The drum stores the steam
generated in the water tubes and acts as a phase-separator for the
steam/water mixture.
Boiler Efficiency – it is the measure of ability of a boiler or steam generator
to transfer the heat given by the furnace to the water and steam.
Boiler Heating Surface – is the total area in 𝑚2 through which the heated
water and hot gases exchange heat.
Breeching – is the duct that connects the boiler and chimney.
Closed Heater – is a preheating device which does not allow steam to mix
with feed water.
Coal Burner Assembly – is a burner assembly including a housing having
an air inlet.
Coal Conveyors – are used to move coal around efficiently.
Coal Pulverizer – is a mechanical device for the grinding of many different
types of materials.
Commercial Load – is the kilowatt-hour energy output of the commercial
establishments.
6
Condensate Pump – is a specific type of pump used to pump the
condensate (water) produced in the condensing boiler furnace or steam
system.
Cooling Towers – this are heat removal devices used to transfer process
waste heat to the atmosphere.
Critical Point – Represents the highest pressure and highest temperature
at which liquid and vapor can coexist in equilibrium.
Draft Fans – are devices used to supply air needed for the combustion and
create the draft required for the flow of gases in the boiler.
Economizer – is a feed water preheating device which utilizes the heat of
the flue gases.
Energy Balance - A calculation used in designing industrial processes in
which all energy flows and transformations, such as changes in
temperature, heats of reaction, use of steam or other sources of heat, etc.,
are accounted for.
Feed Water - water preheated and supplied to a boiler (as for steam).
Feed Water Pump – is a device used to deliver water into the boiler.
Fire Tube Boiler – is a steam boiler in which hot gaseous products of
combustion pass through tubes surrounded by boiler water.
Flue Gas - the mixture of gases resulting from combustion and other
reactions in a furnace, passing off through the smoke flue, composed largely
of nitrogen, carbon dioxide, carbon monoxide, water vapor, and often sulfur
7
dioxide, and sometimes serving as a source from which carbon dioxide or
other compounds are recovered.
Fuel – is any material that stores energy that can later be extracted to
perform mechanical work in a controlled manner.
Furnace – a device that encloses the combustion equipment so that the
heat generated will be utilized effectively.
Generator – converts the mechanical energy produced by the turbine into
an electrical energy.
Heater – is an object that emits heat or causes another body to achieve a
higher temperature.
Industrial Load – is the kilowatt-hour energy output of the industrial
Open Heater – is a preheating device which utilizes steam mixed and feed
water. Power Plant - A plant, including engines, dynamos, etc., and the
building or buildings necessary for the generation of power.
Residential Load – is the kilowatt-hour energy output of the residences
Saturated Liquid – is a liquid at saturations (saturation temperature or
saturation pressure) which has temperature equal to the boiling point
corresponding to existing pressure. It is pure liquid, has no vapor content
Saturated Temperature – is the temperature at which liquids start to boil or
the temperature at which vapors begin to condense.
Saturated Vapor – is a vapor at the saturation conditions (saturation
temperature or pressure). It is 100 % vapor, has no liquid or moisture
content.
8
Steam Boiler – also called as “steam generator”. It is an integrated

assembly of several essential components the function of which is to
produce steam at a predetermined pressure and temperature.
Steam Condenser –a is a device used to maintain vacuum conditions on
the exhaust of a steam prime mover by transfer of heat to circulating water
or air at the lowest ambient temperature.
Steam Cycles – includes Rankine cycle, reheat cycle, regenerative cycle
and reheat regenerative cycle.
Steam Trap – is a device used to discharge condensate and non-
condensable gases with a negligible consumption or loss of live steam.
Steam Turbine – is a prime mover for the conversion of heat energy of
steam into work and revolving shaft, utilizing fluid acceleration principles
inject and vane machinery.
Superheated Vapor – a vapor having a temperature higher than saturation
temperature corresponding to existing pressure.
Surface Condenser – is a heat transfer device used to condense a steam
under vacuum, by absorbing its latent heat in cooling fluid ordinary water. It
is a device in which the steam and cooling water does not mix.
Water Walls – are water tubes installed in the furnace to protect the furnace
against high temperature and also serve as extension of heat transfer area
for the feed water.
Wet Vapor – is a combination of saturated vapor and saturated liquid.
9
VARIABLE
LOADING
10
VARIABLE LOAD
General Variable Load (Daily)

Time Residential Commercial Industrial Total
(W-hr) (W-hr) (W-hr) (W-hr)
12mn 23341303 183070 4500 23528873
1am 23531267 126030 4500 23661797
2 20891564 114430 4500 21010494
3 23429339 126030 4500 23559869
4 20752564 114430 4500 20871494
5 21200815 123630 4500 21328945
6am 30341082 512325 22380 30875787
7 19143759 607805 25800 19777364
8 22891875 656965 22200 23571040
9 14436295 678749 24180 15139224
10 20482795 625089 64700 21172584
11 27988675 638289 68300 28695264
12nn 29957575 623909 64700 30646184
1pm 30652575 639249 68940 31360764
2 26482575 581589 65340 27129504
3 23586875 659209 67140 24313224
4 18953795 688697 65340 19707832
5 28544795 742225 67140 29354160
6pm 24879687 734620 65340 25679647
7 34609687 682520 47000 35339207
8 30671087 358042 56180 31085309
9 28586087 329222 47000 28962309
10 28331267 192702 56180 28580149
11 23392267 197902 4500 23594669
12mn 23341303 183070 4500 23528873
Total= 597079605 10936728 929360 608945693
11
Base Load: 15139224 W-hr

Peak Load: 35339207 W-hr
Average Load: 25372737.21 W-hr
Plant Capacity: 40,513.58805 KW
12
RESIDENTIAL LOADS
Low class
Residential (low class) = .55 * 23165=12741 households
Appliances Ratings No. of Units Total (W) Hrs. Used Total

(W-Hr)
Electric Fan 200 2 400 10 4000
Television 200 1 200 10 2000
fluorescent Lamp 32 1 32 4 128
Radio 20 1 20 2 40
Cellphone charger 4 3 12 3 36
Total 79045164
13
MEDIUM CLASS
Residential (medium class) =.30*23165=6950 households
Appliances Ratings No. of Units Total Hrs. Used Total

(W) (W-Hr)
Electric Fan 200 2 400 10 4000
Television 200 1 200 10 2000
Fluorescent Lamp 32 2 64 5 320
Radio 20 1 20 2 40
Washing Machine 300 1 300 1 300
Flat Iron 500 1 500 3 1500
Refrigerator 500 1 500 24 12000
Wi-Fi router 7 1 7 24 168
DVD Player 30 1 30 1 30
Stereo Speaker 200 2 400 1 400
Total= 144685100
14
High Class
Residential (High class) =.15*23165=3475 households

(W) (W-Hr)
Electric Fan 200 2 400 10 4000
Television 200 2 400 6 2400
Radio 20 1 20 2 40
Washing Machine 300 1 300 1 300
Spin dryer 3000 1 3000 1 3000
Flat Iron 500 1 500 3 1500
Wi-Fi router 7 1 7 24 168
DVD Player 30 2 60 1 60
Stereo Speaker 200 4 800 1 800
Refrigerator 500 1 500 24 12000
Personal Computer 500 2 1000 10 10000
Oven toaster 750 1 750 1 750
air conditioner 1000 2 2000 24 48000
Microwave Oven 600 1 600 1 600
Blender 300 1 300 1 300
Vacuum cleaner 700 1 700 1 700
Electric Stove 1500 1 1500 3 4500
Water Dispenser 500 1 500 24 12000
Coffee Maker 800 1 800 1 800
Total= 357153550
15
COMMERCIAL LOADS
Public Prepatory school (25)

(W) (W-Hr)
Ceiling fan 35 2 70 12 840
Stand Fan 25 1 25 12 300
Total= 33300
Private preparatory School (22)

Appliances Rating No. of Total Hrs. Total (W-
s Units (W) Used Hr)
Ceiling fan 35 2 70 12 840
Stand Fan 25 2 50 12 600
Fluorescent 32 2 64 3 192
Lamp
Television 200 1 200 1 200
Total= 40304
Public Elementary School (38)

Ceiling fan 35 30 1050 12 12600
Stand Fan 25 15 375 12 4500
Fluorescent 32 30 960 3 2880
Lamp
Air-conditioner 750 1 750 6 4500
Television 200 1 200 1 200
Total= 937840
16
High School (13)

Ceiling fan 35 20 700 12 8400
Stand Fan 25 10 250 12 3000
Fluorescent 32 20 640 5 3200
Light
Computer 300 5 1500 4 6000
Water dispenser 500 2 1000 12 12000
Projector 300 1 300 6 1800
Total= 447200
College (12)
Ceiling fan 35 80 2800 15 42000
Stand Fan 25 10 250 15 3750
Fluorescent 32 80 2560 4 10240
Lamp
Computer 300 20 6000 8 48000
Water dispenser 500 4 2000 15 30000
Projector 300 2 600 6 3600
Air Conditioner 750 4 3000 15 45000
Total= 2191080
17
Hospitals (4)
Fluorescent 32 10 320 12 3840
light
air conditioner 800 5 4000 24 96000
Television 200 5 1000 8 8000
Computer 300 3 900 24 21600
Water 300 8 2400 24 57600
Dispenser
Telephone 300 2 600 4 2400
total= 757760
Banks (23)
Air Conditioner 1200 2 2400 24 57600
Atm Machine 250 4 1000 24 24000
Light
Television 200 2 400 12 4800
CCTV Camera 50 5 250 24 6000
Computer 300 4 1200 12 14400
Ceiling Fan 35 4 140 12 1680
Total= 2518592
18
Eatery (44)
(W) (W-Hr)
Refrigerator 500 2 1000 24 24000
Airconditioner 800 1 800 16 12800
Ceiling Fan 35 4 140 16 2240
Exhaust Fan 60 2 120 16 1920
Television 200 1 200 16 3200
Fluorescent Light 32 4 128 8 1024
Water Dispenser 300 1 300 16 4800
Total= 2199296
INDUSTRIAL LOADS
Public Market (2)
Appliances Ratings No. of Units Total (W) Hrs. Used Total (W-Hr)
Freezer 800 5 4000 12 48000
Ceiling Fan 35 10 350 12 4200
Fluorescent light 32 10 320 6 1920
Coconut grater 150 6 900 4 3600
Total= 115440
Hardware (26)
Ceiling Fan 35 2 70 9 630
Air-conditioner 750 1 750 9 6750
Telephone 200 1 200 9 1800
Computer 300 1 300 9 2700
light
Total= 315536
19
Malls (5)
Central Air 3500 2 7000 12 84000
Conditioner
Mall Lights 150 10 1500 12 18000
Total= 510000
Food Manufacturing (9)

Air 1000 1 1000 12 12000
conditioner
Television 200 1 200 6 1200
Refrigerator 500 1 500 24 12000
Telephone 20 1 20 4 80
Total= 227520
20
1. Reserve Over Peak (ROP)
= 15% PL = 0.15 PL = 0.15 (35229.207 kW) = 5284.38105 KW
2. Plant Capacity
= ROP + PL = 5284.38105 + 35229.207 kW = 40,513.58805 ≈40.6 MW
3. Average Load
𝐸𝑛𝑒𝑟𝑔𝑦 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑 (𝑖𝑛 𝑘𝑤−ℎ𝑟) 608,945.693 KW−hr

= = = 25372.73721 KW
𝑛𝑜.𝑜𝑓 ℎ𝑜𝑢𝑟𝑠 24 ℎ𝑟𝑠
4. Load Factor
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑙𝑜𝑎𝑑 25372.73721 𝑘𝑤

= = 𝑥 100%= 72.0219%
𝑃𝑒𝑎𝑘 𝑙𝑜𝑎𝑑 35229.207 𝑘𝑤
5. Capacity Factor
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐿𝑜𝑎𝑑 𝐴𝐿 25,372.73721 𝐾𝑊

= = = 𝑥 100%= 62.6277%
𝑃𝑙𝑎𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑃𝐶 40,513.58805 𝐾𝑊
6. Use Factor
𝐴𝑛𝑛𝑢𝑎𝑙 𝑘𝑊−ℎ𝑟𝑠
=
𝑃𝐶 𝑥 𝑛𝑜.𝑜𝑓 ℎ𝑜𝑢𝑟𝑠 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛
(608,945.693𝑘𝑤−ℎ𝑟)
= 𝑥 100% = 62.6277%
(24)(40,513.6 𝑘𝑤)
7. Demand Factor
𝐴𝑐𝑡𝑢𝑎𝑙 𝑀𝑎𝑥 𝐷𝑒𝑚𝑎𝑛𝑑 𝑃𝐿 35399.207𝑘𝑤

= = = 𝑥 100%= 87.23%
𝐶𝑜𝑛𝑛𝑒𝑐𝑡𝑒𝑑𝐿𝑜𝑎𝑑 𝑃𝐶 40,513.6𝑘𝑤
21
8. Utilization Factor
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑑𝑒𝑚𝑎𝑛𝑑 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚 𝑃𝐿

= =
𝑅𝑎𝑡𝑒𝑑 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚 𝑃𝐶
35,399.207𝑘𝑤
= 𝑥 100%
40,513.6𝑘𝑤
= 83.33%
9. Operation Factor
𝐷𝑢𝑟𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑠𝑒𝑟𝑣𝑖𝑐𝑒

=
𝑇𝑜𝑡𝑎𝑙 𝑑𝑢𝑟𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑛𝑠𝑖𝑑𝑒𝑟𝑒𝑑 𝑝𝑒𝑟𝑖𝑜𝑑
8760ℎ𝑟𝑠−288 ℎ𝑟𝑠
=
8760 ℎ𝑟𝑠
𝑥 100%
= 96.7123%
10. Plant Factor
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐿𝑜𝑎𝑑 𝐴𝐿
= =
𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑟𝑎𝑡𝑖𝑛𝑔 𝑠𝑢𝑝𝑝𝑙𝑦𝑖𝑛𝑔 𝑡ℎ𝑒 𝑙𝑜𝑎𝑑 𝑃𝐶
25,372.72721𝐾𝑊
= 𝑥 100%
40,513.6 𝐾𝑊
= 62.6277%
11. Annual Capacity Factor
𝐴𝑛𝑛𝑢𝑎𝑙(𝐾𝑊−ℎ𝑟)
=
𝑃𝐶(8760)
(353)(608945.693 KW−hr)
= 𝑥 100%
40,513.6 KW(8760)
= 60.5687%
22
SCHEMATIC
DIAGRAM
23
24
GENERATOR AND
TURBINE SIZING
25
GENERATOR SIZING
TURBINE RATING
Turbine Generator Rating: 40,513.58805 KW ≈ 40.6 MW
Turbine Capability: 44,662.9469. Kw
GENERATOR RATING
Generator Capability: 47,662.2364 kVa
Generator Capability: 54,811.85902 kVa
Specs: 3600 rpm
3-phase
60 cycles
Power Factor: 0.85
Type of Cooling: Hydrogen Cooling
*from Power Plant Engineering in MKS Unit by Frederick T.
Morse, P.381, Fig. 11-15

𝑘𝑔
Considering 3600 rpm, 40.6 MW and 59.8 we get;
𝑐𝑚2
Generator efficiency: 98.35 %
26
ENTHALPY CALCULATION
Throttle Temperature,𝑇1 = 482 ℃
𝒌𝒈
Throttle Pressure, 𝑃1 = 𝟓𝟗. 𝟖 = 𝟓. 𝟖𝟔𝟒𝟑𝟕𝟔𝟕 𝑴𝑷𝒂
𝒄𝒎𝟐
Exhaust Pressure, 𝑃6 = 𝟑𝟖. 𝟏 𝒎𝒎𝑯𝒈 = 𝟎. 𝟎𝟎𝟓𝟎𝟕𝟗𝟔 𝑴𝒑𝒂
For 𝑇6 : *from steam table 2
P, MPa T, ℃
0.0050 32.88
0.0050796 𝑇6
0.0055 34.58
*by interpolating the values given above we get:
𝑇6 = 𝟑𝟑. 𝟏𝟒𝟏𝟓℃
No. of Extraction: 4
*from Power Plant Engineering in MKS Unit by Frederick T. Morse, P.378, Table
11-3
Considering 40.6 MW generator output:
Extraction Temperatures:
𝑇2 = 210℃ 𝑇4 = 140.6℃
𝑇3 = 176.7℃ 𝑇5 = 112.8℃
27
TEMPERATURE BEFORE ENTERING HEATERS
*There is a ± 5.6 °C difference in the temperature of water leaving
each heater and temperature of steam entering each heater.
From Power Plant Engineering in MKS Unit by Frederick T. Morse,
P. 378
𝑇2′ = 𝑇2 + 5.6 = 210 − 5.6 = 𝟐𝟎𝟒. 𝟒℃
𝑇3′ = 𝑇3 + 5.6 = 176.7 − 5.6 = 𝟏𝟕𝟏. 𝟏℃
𝑇4′ = 𝑇4 + 5.6 = 140.6 − 5.6 = 𝟏𝟑𝟓℃
𝑇5′ = 𝑇5 + 5.6 = 112.8 − 5.6 = 𝟏𝟎𝟕. 𝟐℃
FINAL FEED WATER TEMPERATURE
* From Power Plant Engineering in MKS Unit by Frederick T. Morse,
P.225, Fig. 8-11
Consider throttle pressure, 59.8 kg/cm2 and 4 extractions
𝒌𝒈 T, ℃
P, 𝒄𝒎𝟐
63.28 195
59.8 𝑇13
56.25 190
*by interpolating the values above we get:
𝑻𝟏𝟑 = 𝟏𝟗𝟐. 𝟓𝟐𝟒𝟗 ℃
28
TEMPERATURE BETWEEN HEATERS
*From Power Plant Engineering in MKS Unit by Frederick T. Morse, P.229
𝑇13 − 𝑇6
𝑇𝑖𝑛𝑐𝑟𝑒𝑎𝑠𝑒 =
2
192.5249 − 33.1415
=
2
= 𝟑𝟗. 𝟖𝟒𝟓𝟗 ℃
TEMPERATURE LEAVING THE HEATER
*since increase in Temperature is 39.8459 ℃
𝑇9 = 𝑇6 + 𝑇𝑖𝑛𝑐 = 33.1506 + 39.8459 = 𝟕𝟐. 𝟗𝟖𝟕𝟒 ℃
𝑇10 = 𝑇9 59 + 𝑇𝑖𝑛𝑐 = 72.9942 + 39.84 = 𝟏𝟏𝟐. 𝟖𝟑𝟑𝟑 ℃
𝑇12 = 𝑇10 + 𝑇𝑖𝑛𝑐 = 112.8378 + 39.8459 = 𝟏𝟓𝟐. 𝟔𝟕𝟗𝟐 ℃
𝑇13 = 𝑇13 + 𝑇𝑖𝑛𝑐 = 152.5814 + 39.8459 = 𝟏𝟗𝟐. 𝟓𝟐𝟒𝟗 ℃
TEMPERATURE OF WATER LEAVING THE PUMP
*there is a 0.01 rise in temperature of water leaving the pump
𝑇8 = 𝑇6 + .01 = 33.1506 + .01 = 𝟑𝟑. 𝟏𝟓𝟏𝟓 ℃
𝑇11 = 𝑇10 + .01 = 72.9942 + .01 = 𝟏𝟏𝟐. 𝟖𝟒𝟑𝟑 ℃
𝑇14 = 𝑇13 + .01 = 152.6814 + .01 = 𝟏𝟗𝟐. 𝟓𝟑𝟒𝟗 ℃
29
TEMPERATURE AFTER CLOSE HEATERS
*From Power Plant Theory and Design Philip J. Potter, page 371
There is a reduction below saturation temperature known as sub-cooling
that may amount to 5-10 °C for large heaters.
𝑇15 = 𝑇3′ − 10 = 204.4 − 10 = 𝟏𝟔𝟏. 𝟏℃
𝑇16 = 𝑇4′ − 10 = 135 − 10 = 𝟏𝟐𝟓℃
30
STEAM PROPERTIES AT EACH POINT
POINT TEMPERATURE,℃ PRESSURE,MPa ENTHALPHY, 𝑲𝑱 ENTROPY, 𝑲𝑱

𝒌𝒈 𝒌𝒋−𝑲
1 482 5.8644 3380.836 6.8362
2 210 0.8422 2859.8805 6.8362
3 176.7 0.62 2759.43 6.8362
4 140.6 0.3682 2698.6067 6.8362
5 112.8 0.1573 2549.4528 6.8362
6 33.1415 0.0051 2085.0065 6.8362
7 33.1415 0.0051 138.9551 0.4801
8 33.1515 0.1973 139.1081 0.4779
9 72.9874 0.0354 305.3096 0.9912
10 112.8333 0.1574 473.3015 1.4497
11 112.8433 0.1575 474.0234 1.4516
12 152.6792 0.5111 643.7841 1.8690
13 192.5249 1.3254 818.8763 2.2599
14 192.5349 1.3257 824.8285 2.2601
15 161.1 0.6353 680.335 1.9537
16 125 0.2321 524.99 1.5813
2’ 204.4 0.8001 2848.4 6.8362
3’ 171.1 0.5871 2785.4 6.8362
4’ 135 0.3134 2669.2 6.8362
5’ 107.2 0.1305 2521.7 6.8362
31
MASS AND
ENERGY
BALANCE
32
FOR OPEN HEATER 1
m2 h2’
1kg
m h12
h13
1 = 𝑚2 + 𝑚
𝑚 = 1 − 𝑚2
ℎ10 = 𝑚2 (ℎ2 ) + 𝑚(ℎ12 )
818.8963 = 𝑚2 (2859.8805) + (1 − 𝑚2 )(643.7841)
𝒎𝟐 = 𝟎. 𝟎𝟕𝟗𝟎𝟐 𝒌𝒈
33
FOR CLOSE HEATER 1
m3 h3’
1-m2 m
h12 h11
m3 h15
(1 − 𝑚2 ) + 𝑚3 = 𝑚3 + 𝑚
𝑚 = 1 − 𝑚2
(1 − 𝑚2 )(ℎ12 ) + 𝑚3 (ℎ15 ) = (1 − 𝑚2 )(ℎ11 ) + 𝑚3 (ℎ3′ )
(1 − 0.07902)(643.7841) + 𝑚3 (680.335)
= (1 − 0.07902)(474.0234) + 𝑚3 (2785.4)
𝒎𝟑 = 𝟎. 𝟎𝟕𝟒𝟑 𝒌𝒈
34
FOR CLOSE HEATER 2
m4 h4’
1-m2 m
h10 h9
m4 h16
(1 − 𝑚2 ) + 𝑚4 = 𝑚4 + 𝑚
𝑚 = 1 − 𝑚2
(1 − 𝑚2 )(ℎ10 ) + 𝑚4 (ℎ16 ) = (1 − 𝑚2 )(ℎ9 ) + 𝑚4 (ℎ4′ )
(1 − 0.07902)(473.3015) + 𝑚4 (524.99)
= (1 − 0.07902)(305.3096) + 𝑚4 (2669.2)
𝒎𝟒 = 𝟎. 𝟎𝟕𝟐𝟐 𝒌𝒈
35
FOR OPEN HEATER 2
m5 h5’
‘‘’5
1-m2 m
H9 h8
𝑚 + 𝑚5 = 1 − 𝑚2
𝑚 = 1 − 𝑚2 − 𝑚5
𝑚ℎ8 +𝑚5 ℎ5 = (1 − 𝑚2 )(ℎ9 )
(1 − 𝑚2 − 𝑚5 )(ℎ8 ) + 𝑚5 ℎ5 = (1 − 𝑚2 )(ℎ9 )
(1 − 0.07902 − 𝑚5 )(138.10812) + 𝑚5 (2549.4528)

= (1 − 0.07902)(305.3096)
𝒎𝟓 = 𝟎. 𝟎𝟔𝟑𝟓 𝒌𝒈
36
FOR TURBINE WORK
1kg
h1
WT
m2 h2
m3 h3 (1kg- m2 – m3 – m4- m6 )h6
m4 h4
m5 h2
𝑊𝑇 + 𝑚2 ℎ2 + 𝑚3 ℎ3 + 𝑚4 ℎ4 + 𝑚5 ℎ5 + ( 1𝑘𝑔 − 𝑚2 − 𝑚3 − 𝑚4 − 𝑚5 )ℎ6 = (1𝑘𝑔)ℎ1
3380.8359 = (0.0790)(2859.8805) + (0.0743)(2795.43) + (0.0648)(2698.6067)

+ (0.0635)(2549.4527) + (0.7148)(2085.0065) + 𝑊𝑇
3380.8359 = 225.9306 + 207.7005 + 184.5847 + 161.8902 + 𝑊𝑇
𝒌𝑱
𝑾𝑻 = 𝟏𝟏𝟏𝟎. 𝟑𝟔𝟕𝟒
𝒌𝒈
FOR FRICTION LOSS/POWER, 𝐹𝐿
. 05
𝐹𝐿 = 𝑥 𝑊𝑇
√𝑟𝑎𝑡𝑒𝑑 𝑘𝑤
1000
. 05 𝑘𝐽
𝐹𝐿 = 𝑥 1110.3674
𝑘𝑔
√40,513.6
1000
𝒌𝑱
𝑭𝑳 = 𝟖. 𝟕𝟐𝟐𝟒
𝒌𝒈
37
FOR ACTUAL TURBINE WORK, 𝑊𝑡′
𝑊𝑡′ = 𝑊𝑇 − 𝐹𝐿
𝑊𝑡′ = 1110.3674 − 8.7224
𝒌𝑱
𝑾′𝒕 = 𝟏𝟏𝟎𝟏. 𝟔𝟒𝟒𝟗𝟖
𝒌𝒈
FOR MASS OF THE STEAM, 𝒎𝒔
𝑡𝑢𝑟𝑏𝑖𝑛𝑒 𝑐𝑎𝑝𝑎𝑏𝑖𝑙𝑖𝑡𝑦
𝑚𝑠 =
𝑊𝑇′ ( %𝑔)
𝑘𝐽 3600 𝑠
(40,513.6 𝑆 )( 1 ℎ𝑟 )
𝑚𝑠 =
𝑘𝐽
(1101.64498 𝑘𝑔)( 0.9835)
𝒌𝒈
𝒎𝒔 = 𝟏𝟑𝟒, 𝟔𝟏𝟑. 𝟎𝟗𝟔𝟓
𝒉𝒓
MASS OF EXTRACTED STEAMS
For open heater 1:

𝑚2 = 𝑚2 (𝑚𝑠 )
𝑘𝐽
𝑚2 = (0.0790)(134,613.0965 )
ℎ𝑟
𝒌𝒈
𝒎𝟐 = 𝟏𝟎, 𝟔𝟑𝟒. 𝟒𝟑𝟒𝟔
𝒉𝒓
For close heater 1:
𝑚3 = 𝑚3 (𝑚𝑠 )
𝑘𝐽
𝑚3 = (0.0743)(134,613.0965 )
ℎ𝑟
𝒌𝒈
𝒎𝟐 = 𝟏𝟎, 𝟎𝟎𝟏. 𝟕𝟓𝟑𝟏
𝒉𝒓
38
For close heater 2:
𝑚4 = 𝑚4 (𝑚𝑠 )
𝑘𝑔
𝑚4 = (0.07215)(134,613.0965 )
ℎ𝑟
𝒌𝒈
𝒎𝟒 = 𝟗𝟕𝟏𝟑. 𝟏𝟐𝟏𝟔
𝒉𝒓
For open heater 2:
𝑚5 = 𝑚5 (𝑚𝑠 )
𝑘𝑔
𝑚5 = (0.0635)(134,613.0965 )
ℎ𝑟
𝒌𝒈
𝒎𝟓 = 𝟖𝟓𝟒𝟕. 𝟗𝟑𝟏𝟔
𝒉𝒓
For condenser:
𝑚𝐶 = 𝑚𝑆 − 𝑚2 − 𝑚𝑠
𝑚𝐶 = 134,613.0965 − 10,001.7531 − 8547.9316
𝒌𝒈
𝒎𝑪 = 𝟏𝟏𝟓, 𝟒𝟑𝟎. 𝟕𝟑𝟎𝟐
𝒉𝒓
39
DESIGN OF
STEAM TURBINE
40
DESIGN OF STEAM TURBINE
1kg
h1
WT
m2 h2
m3 h3 (1kg- m2 – m3 – m4- m6 )h6
m4 h4
m5 h2
Turbine Generator Rating: 40,513.6 MW
Turbine Capability :44,564.9469 kW
𝑘𝑔
Throttle Pressure : 59.8 𝑐𝑚2 𝑔𝑎𝑔𝑒
Throttle Temperature : 482 ℃
41
OVERALL ENGINE EFFICIENCY:
𝑘𝑔
At 59.8 𝑐𝑚2 and 40.6 MW
For engine efficiency: 77.36% (uncorrected)
Correction Factor : 0.99
𝑢𝑛𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝑒𝑛𝑔𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 77.36%

Turbine Engine efficiency = =
𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 0.99
= 78.14% (corrected)
OVERALL ENGINE EFFICIENCY
𝜂𝑡 + (1 + 𝜂𝑓 )
𝜂𝑜𝑒 =
𝜂𝑔
For 𝜼𝒇 :
5%
=
40,513.6
√
1000
= 𝟎. 𝟕𝟖𝟓𝟓
0.7814 + (1 + 0.7855)
𝜂𝑜𝑒 =
0.9835
𝜼𝒐𝒆 = 𝟖𝟎. 𝟎𝟕𝟓𝟎 %
42
ENGINE EFFICIENCIES:
Indicated:
𝑊𝑇 ′
𝜂𝑖 = 𝑥 100%
𝑊𝑇
1101.64498
𝜂𝑖 = 𝑥 100%
1110.3674
𝜼𝒊 = 𝟗𝟗. 𝟐𝟏𝟒𝟓 %
Brake:
%𝑒𝑜
𝜂𝑏 = 𝑥 100%
%𝑔
0.80075
𝜂𝑏 = 𝑥 100%
0.9835
𝜼𝒃 = 𝟖𝟏. 𝟒𝟏𝟖𝟒%
Mechanical Efficiency:
For Brake Work, Wb
𝑊𝑏 = 𝜂𝑏 (𝑊𝑇 )
𝑊𝑏 = (0.814184)(1110.3674)
𝑲𝑱
𝑾𝒃 = 𝟗𝟎𝟒. 𝟎𝟒𝟑𝟒
𝒌𝒈
𝑊𝑏
η𝑚𝑒 = x 100%
𝑊𝑇 ′
904.0434
η𝑚𝑒 = x 100%
1101.64498
𝛈𝒎𝒆 = 𝟖𝟐. 𝟎𝟔𝟑𝟎𝟒%
43
For Combined Work, Wc
𝑊𝑐 = %𝑔(𝑊𝑏 )
𝑊𝑐 = (0.9835)(904.0434)
𝑲𝑱
𝑾𝒄 = 𝟖𝟖𝟗. 𝟏𝟐𝟔𝟔
𝒌𝒈
STEAM RATES:
Ideal:
𝑠
3600
𝑚= ℎ𝑟
𝑊𝑇
𝑠
3600
𝑚= ℎ𝑟
1110.367381
𝒌𝒈
𝒎 = 𝟑. 𝟐𝟒𝟐𝟑
𝒌𝑾 − 𝒉𝒓
Indicated:
𝑠
3600
𝑚𝑖 = ℎ𝑟
𝑊𝑇 ′
𝑠
3600
𝑚𝑖 = ℎ𝑟
1101.64497
𝒌𝒈
𝒎𝒊 = 𝟑. 𝟐𝟔𝟕𝟖
44
Brake:
𝑠
3600
𝑚𝑏 = ℎ𝑟
𝑊𝑏
𝑠
3600
𝑚𝑏 = ℎ𝑟
904.0434
𝒌𝒈
𝒎𝒃 = 𝟑. 𝟗𝟖𝟐𝟏
Combined:
𝑠
3600
𝑚𝑐 = ℎ𝑟
𝑊𝑐
𝑠
3600
𝑚𝑐 = ℎ𝑟
889.1267
𝒌𝒈
𝒎𝒄 = 𝟒. 𝟎𝟒𝟖𝟗
HEAT RATES:
𝑄𝐴 = ( ℎ1 − ℎ14 )
𝑄𝐴 = ( 3380.8359 − 824.8285)
𝒌𝑱
𝑸𝑨 = 𝟐𝟓𝟓𝟔. 𝟎𝟎𝟕𝟓
𝒌𝒈
45
Ideal:
𝐻𝑅 = 𝑚(𝑄𝐴 )
𝑘𝑔 𝑘𝐽
𝐻𝑅 = (3.2423 ) (2556.0075 )
𝑘𝑊 − ℎ𝑟 𝑘𝑔
𝑲𝑱
𝑯𝑹 = 𝟖𝟐𝟖𝟕. 𝟑𝟒𝟐𝟗
𝒌𝒘 − 𝒉𝒓
Indicated
𝐻𝑅𝑖 = 𝑚𝑖 (𝑄𝐴 )
𝑘𝑔 𝑘𝐽
𝐻𝑅𝑖 = (3.2678 ) (2556.0075 )
𝑲𝑱
𝑯𝑹𝒊 = 𝟖𝟑𝟓𝟐. 𝟓𝟐𝟏𝟐
Brake:
𝐻𝑅𝑏 = 𝑚𝑏 (𝑄𝐴 )
𝑘𝑔 𝑘𝐽
𝐻𝑅𝑏 = (3.9821 ) (2556.0075 )
𝑲𝑱
𝑯𝑹𝒃 = 𝟏𝟎𝟏𝟕𝟖. 𝟑𝟎𝟑𝟗
46
Combined:
𝐻𝑅𝐶 = 𝑚𝐶 (𝑄𝐴 )
𝑘𝑔 𝑘𝐽
𝐻𝑅𝐶 = (4.0489 ) (2556.0075 )
𝑲𝑱
𝑯𝑹𝑪 = 𝟏𝟎𝟑𝟒𝟗. 𝟎𝟔𝟗𝟕
THERMAL EFFICIENCIES:
Ideal:
𝑊𝑇
𝜂𝑡 = 𝑥 100%
𝑄𝐴
1110.3674
𝜂𝑡 = 𝑥 100%
2556.0075
𝜼𝒕 = 𝟒𝟑. 𝟒𝟒𝟏𝟓 %
Indicated:
𝑊𝑇 ′
𝜂𝑡𝑖 = 𝑥 100%
𝑄𝐴
1101.64498
𝜂𝑡𝑖 = 𝑥 100%
2556.0075
𝜼𝒕𝒊 = 𝟒𝟑. 𝟏𝟎𝟎𝟐 %
47
Brake:
𝑊𝑏
𝜂𝑡𝑏 = 𝑥 100%
𝑄𝐴
904.0434
𝜂𝑡𝑏 = 𝑥 100%
2556.00775
𝜼𝒕𝒃 = 𝟑𝟓. 𝟑𝟔𝟗𝟒%\
Combined/Overall:
𝑊𝑐
𝜂𝑡𝑐 = 𝑥 100%
𝑄𝐴
889.1266
𝜂𝑡𝑐 = 𝑥 100%
2556.0075
𝜼𝒕𝒄 = 𝟑𝟒. 𝟕𝟖𝟓𝟖 %
48
DESIGN OF THE
PUMPS
49
FOR PUMP NO.1
ms h14 ms h13
𝑊𝑝1 = 𝑚𝑠 ( ℎ14 − ℎ13 )
𝑘𝑔
𝑊𝑝1 = (134613.0965 ) ( 824.8285 − 818.8763)
ℎ𝑟
𝑘𝑔 𝑘𝐽
𝑊𝑝1 = (134613.0965 )(5.9522 )
ℎ𝑟 𝑘𝑔
𝒌𝑱
𝑾𝒑𝟏 = 𝟖𝟎𝟏𝟐𝟒𝟒. 𝟎𝟕𝟑 = 𝟐𝟗𝟖. 𝟒𝟔𝟖𝟑 𝑯𝑷
𝒉𝒓
SOLVING FOR THE ACTUAL WORK OF THE PUMP, 𝑾𝒑′𝟏
*Consider 70-80% pump efficiency
𝑊𝑝1
𝑊𝑝1′ =
. 80
298.4683 𝐻𝑃
𝑊𝑝1′ =
. 80
𝑾𝒑′𝟏 = 𝟑𝟕𝟑. 𝟎𝟖𝟓𝟒 𝑯𝑷
50
FOR PUMP NO.2
(ms – m2) h11 (ms – m2) h10
𝑊𝑝2 = ( 𝑚𝑠 − 𝑚2 )( ℎ11 − ℎ10 )
𝑘𝑔
𝑊𝑝2 = ( 123978.6619 ) ( 474.0234 − 473.3015)
ℎ𝑟
𝑘𝑔 𝑘𝐽
𝑊𝑝2 = ( 115430.7302 ) (0.7219 )
ℎ𝑟 𝑘𝑔
𝒌𝑱
𝑾𝒑𝟐 = 𝟖𝟗𝟓𝟎𝟎. 𝟏𝟗𝟔 = 𝟑𝟑. 𝟑𝟑𝟗𝟒 𝑯𝑷
𝒉𝒓
SOLVING FOR THE ACTUAL WORK OF THE PUMP, 𝑾𝒑′𝟐
Consider 70-80% pump efficiency
𝑊𝑝2
𝑊𝑝2′ =
. 80
33.3394 𝐻𝑃
𝑊𝑝2′ =
. 80
𝑾𝒑′𝟐 = 𝟒𝟏. 𝟔𝟕𝟒𝟐 𝑯𝑷
51
FOR PUMP NO.3
(ms – m2 – m5 )h8 (ms – m2 – m5 )h7
𝑊𝑝3 = ( 𝑚𝑠 − 𝑚2 − 𝑚5 )( ℎ8 − ℎ7 )
𝑊𝑝3 = ( 115430.7302)( 139.1081 − 138.9551)
𝑘𝑔 𝑘𝐽
𝑊𝑝3 = ( 115430.7302 ) ( 0.153 )
ℎ𝑟 𝑘𝑔
𝒌𝑱
𝑾𝒑𝟑 = 𝟏𝟕𝟔𝟔𝟎. 𝟗𝟎𝟏𝟕 = 𝟔. 𝟓𝟕𝟖𝟖 𝑯𝑷
𝒉𝒓
SOLVING FOR THE ACTUAL WORK OF THE PUMP, 𝑾𝒑′𝟑
Consider 70-80% pump efficiency
𝑊𝑝3
𝑊𝑝3′ =
. 80
6.5788 𝐻𝑃
𝑊𝑝3′ =
. 80
𝑾𝒑′𝟑 = 𝟖. 𝟐𝟐𝟑𝟓 𝑯𝑷
52
FUEL ANALYSIS
53
Data:
Fuel: Utah, Carbon: Bituminous
*from Power Plant Theory and Design by Philip Potter, P.172 Table 5-1
Ultimate Analysis
Element Percentage,
%
Carbon 69.12
Hydrogen 6.09
Oxygen 17.18
Nitrogen 1.35
Sulfur 5.62
Ash 7.49
Moisture 7.49
Correction Analysis
Consider: 𝐻2 𝑂
2𝐻2 + 𝑂2 → 2𝐻2 𝑂
2𝐻2 + 𝑂2 → 2𝐻2 𝑂
𝐻 = 1 𝑂 = 16
1
𝐻2 + 𝑂2 → 𝐻2 𝑂
2
2𝐻2 + 16𝑂2 → 18𝐻2 𝑂
1 8
𝐻2 + 𝑂2 → 𝐻2 𝑂
9 9
Element Percentage,% Corrected,%

Carbon 69.12 69.12
Hydrogen 1 5.2578
6.09 - (7.49)(9)
Oxygen 1 10.5222
17.18 - (7.49)( )
9
Nitrogen 1.35 1.35
Sulfur 5.62 0.64
Ash 7.49 5.62
Moisture 7.49 7.49
Total = 99.9999
54
Moisture Free Analysis

*percentage from correction analysis will be multiplied by “(1-0.0749)” to remove
the moisture
Element Percentage, %
Carbon 74.7162
Hydrogen 5.6735
Oxygen 11.3741
Nitrogen 1.4593
Sulfur .6918
Ash 6.0750
Total= 99.9999
Ash-free Analysis
*percentage from moisture-free analysis will be multiplied by “(1-0.060750)”
Carbon 74.7162
Hydrogen 5.6735
Oxygen 11.3741
Nitrogen 1.4593
Sulfur .6918
Total= 99.9999
Sulfur-free analysis
*percentage from Ash-free analysis will be multiplied by “(1-0.007365)”.
Carbon 74.7162
Hydrogen 5.6735
Oxygen 11.3741
Nitrogen 1.4593
Sulfur .6918
Total= 99.9999
55
Heating Value:
Using “Dulong’s Formula”
𝑂
𝑄ℎ = 35820𝐶 + 144212 (𝐻 − ) + 9304𝑆
8
. 105222
𝑄ℎ = 35820(.6912) + 144212 (. 052578 − ) + 9304(.0064)
8
𝑲𝑱
𝑸𝒉 = 𝟑𝟎𝟓𝟎𝟑. 𝟗𝟐𝟑𝟖
𝒌𝒈
Air to Fuel ratio

𝐴 𝑂
= 11.5𝐶 + 34.5 (𝐻 − ) + 4.3𝑆
𝐹 8
𝐴 . 105222
= 11.5(.6912) + 34.5 (. 052578 − ) + 4.3(.0064)
𝐹 8
𝑨 𝒌𝒈𝒂𝒊𝒓
= 𝟗. 𝟑𝟑𝟔𝟓
𝑭 𝒌𝒈𝒄𝒐𝒂𝒍
Actual air to fuel ratio (𝑾𝒂𝒂 ):
For perfect combustion, use excess air (𝑒) = 18%
𝐴
𝑊𝑎𝑎 = (1 + 𝑒)
𝐹
𝑘𝑔𝑎𝑖𝑟
𝑊𝑎𝑎 = (9.3365 )(1 + 0.18)
𝑘𝑔𝑐𝑜𝑎𝑙
𝒌𝒈 𝒐𝒇 𝒂𝒊𝒓
𝑾𝒂𝒂 = 𝟏𝟏. 𝟎𝟏𝟕𝟎𝟕
𝒌𝒈 𝒐𝒇 𝒄𝒐𝒂𝒍
56
Composition of flue gases:
*from moisture free:
Composition Oxygen
𝑪 0.747162 32 = 1.9924
×
12
𝑯𝟐 0.056735 8 = 0.4539
×
1
𝑶𝟐 0.113741 = −0.113741
𝑺 0.014593 = 0.014593
𝑵𝟐 0.006918
𝑨 0.00032331
1.00 𝑙𝑏 2.3472 𝑙𝑏
𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑎𝑖𝑟 = 2.3472 𝑙𝑏 𝑜𝑓 𝑜𝑥𝑦𝑔𝑒𝑛 𝑝𝑒𝑟 𝑙𝑏 𝑜𝑓 𝑓𝑢𝑒𝑙 ÷ 0.21
𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑎𝑖𝑟 = 11.17691429 𝑙𝑏 𝑜𝑓 𝑜𝑥𝑦𝑔𝑒𝑛 𝑝𝑒𝑟 𝑙𝑏 𝑜𝑓 𝑓𝑢𝑒𝑙
57
Wet products of combustion (including water vapor) at 0% excess air.
𝒍𝒃 𝑹𝑻 𝒇𝒕𝟑
𝐖𝐞𝐢𝐠𝐡𝐭( ) 𝑽𝒐𝒍𝒖𝒎𝒆( )
𝒍𝒃 𝑷 𝒍𝒃
𝑪𝑶𝟐 0.747162 + 1.9924 = 2.7396 × 35.1034 × 2710 = 123.1192
144 × 14.7
𝑯𝟐 𝑶 0.056735 + 0.4539 = 0.5106 × 85.8134 × 2710 = 56.0952
144 × 14.7
𝑺𝑶𝟐 0.014593 + 0.014593 = . 029186 × 24.1413 × 2710 = 0.90203
144 × 14.7
𝑵𝟐 0.006918 + 8.8298 = 8.8367 × 55.1602 × 2710 = 624.0299
144 × 14.7
𝑇𝑂𝑇𝐴𝐿 = 804.1463
Using 18% excess air.
9 % of excess air supplied to the combustion chamber is an addition of
0.09 × 11.01707 × 0.21 = 𝟎. 𝟐𝟎𝟖𝟐 𝒍𝒃 𝒐𝒇 𝒐𝒙𝒚𝒈𝒆𝑛
0.09 × 11.017076 × 0.79 = 𝟎. 𝟕𝟖𝟑𝟑 𝒍𝒃 𝒐𝒇 𝒏𝒊𝒕𝒓𝒐𝒈𝒆𝒏
0.2082 × 48.3138 × 2710 𝒇𝒕𝟑

𝑉𝑂2 = = 𝟏𝟐. 𝟖𝟕𝟕𝟖
144 × 14.7 𝒍𝒃 𝒐𝒇 𝒇𝒖𝒆𝒍
0.7833 × 55.1602 × 2710 𝒇𝒕𝟑

𝑉𝑁2 = = 𝟓𝟑. 𝟑𝟏𝟓𝟏
144 × 14.7 𝒍𝒃 𝒐𝒇 𝒇𝒖𝒆𝒍
58
Therefore, the total volume of gas with 18% excess air will be:
𝑪𝑶𝟐 𝒇𝒕𝟑
= 𝟏𝟐𝟑. 𝟏𝟏𝟗𝟐
𝒍𝒃 𝒐𝒇 𝒇𝒖𝒆𝒍
𝑯𝟐 𝑶 𝑓𝑡 3
= 56.0952
𝑙𝑏 𝑜𝑓 𝑓𝑢𝑒𝑙
𝑺𝑶𝟐 𝑓𝑡 3
= 0.90203
𝑵𝟐 624.0299 + (2 × 53.3151) 𝑓𝑡 3
= 730.6601
𝑶𝟐 2 × 12.8778 𝑓𝑡 3
= 25.7556
𝑇𝑂𝑇𝐴𝐿 𝑓𝑡 3
= 936.53213
Percent of 𝑪𝑶𝟐 in flue gas:
𝑓𝑡 3
123.1192
𝐶𝑂2 = × 100 = 𝟏𝟑. 𝟏𝟒𝟔𝟑%
𝑓𝑡 3
936.53213
Percent of 𝑯𝟐 𝑶 in flue gas:
𝑓𝑡 3
56.0952
𝐻2 𝑂 = × 100 = 𝟓. 𝟗𝟖𝟗𝟕%
𝑓𝑡 3
936.53213
Percent of 𝑺𝑶𝟐 in flue gas:
𝑓𝑡 3
0.90203
𝑆𝑂2 = × 100 = 𝟎. 𝟎𝟗𝟑𝟒%
𝑓𝑡 3
936.53213
59
Percent of 𝑵𝟐 in flue gas:
𝑓𝑡 3
730.6601
𝑁2 = × 100 = 𝟕𝟖. 𝟎𝟏𝟕𝟔%
𝑓𝑡 3
936.53213
Percent of 𝑶𝟐 in flue gas:
𝑓𝑡 3
25.7556
𝑂2 = × 100 = 𝟐. 𝟕𝟓𝟎𝟏%
𝑓𝑡 3
936.53213
It must be free from moisture:
𝑭𝒍𝒖𝒆 𝒈𝒂𝒔 𝒄𝒐𝒎𝒑𝒐𝒔𝒊𝒕𝒊𝒐𝒏 𝑷𝒆𝒓𝒄𝒆𝒏𝒕
𝑪𝑶𝟐 (0.131463 ÷ (1 − 0.059897)) = 𝟏𝟑. 𝟗𝟖𝟑𝟗%
× 100
𝑺𝑶𝟐 (0.000934 ÷ (1 − 0.059897)) = 𝟎. 𝟎𝟗𝟗𝟒%
× 100
𝑵𝟐 (0.780176 ÷ (1 − 0.059897)) = 𝟖𝟐. 𝟗𝟖𝟖𝟒%
× 100
𝑶𝟐 (0.027501 ÷ (1 − 0.059897)) × 100 = 𝟐. 𝟗𝟐𝟓𝟑%
𝑇𝑂𝑇𝐴𝐿 = 𝟏𝟎𝟎%
CARBON ACTUALLY BURNED, Cab
𝐶𝑎𝑏 = 𝐶 − 𝑊𝐷 + 𝐴
𝐶𝑎𝑏 = 0.6912 − 0.1084 + 0.0749
𝑪𝒂𝒃 = 𝟎. 𝟔𝟔𝟏𝟑 𝒌𝒈
60
WEIGHT OF DRY REFUSE, WD

*from Power Plant Theory and Design Philip J. Potter, page 195
𝑎𝑠ℎ
𝑊𝐷 =
𝑐𝑎𝑟𝑏𝑜𝑛
7.49
𝑊𝐷 =
69.12
𝑾𝑫 = 𝟎. 𝟏𝟎𝟖𝟒 𝒌𝒈
WEIGHT OF DRY GASES,𝑾𝒅𝒈
11𝐶𝑂2 + 8𝑂2 + 7(𝐶𝑂 + 𝑁2 ) 𝑆 𝑆

𝑊𝑑𝑔 = (𝐶𝑎𝑏 + )+
3(𝐶𝑂2 + 𝐶𝑂) 267 160
*Carbon dioxide, oxygen, carbon monoxide, nitrogen, and sulfur must be in
percentage for.
For perfect combustion:
𝑪𝑶 = 𝟎%
11(13.9839) + 8(2.9253) + 7(0 + 82.9884) 5.62 5.62

𝑊𝑑𝑔 = (0.6613 + )+
3(14.4771 + 0) 267 160
𝒌𝒈 𝒐𝒇 𝒅𝒓𝒚 𝒈𝒂𝒔
𝑾𝒅𝒈 = 𝟏𝟏. 𝟗𝟒𝟔𝟑
𝒌𝒈 𝒐𝒇 𝒇𝒖𝒆𝒍
61
BOILER DESIGN
62
DATA:
Feedwater Temperature;
𝑇14 = 192.5349 ℃
Steam Flow:
𝑘𝑔
𝑚𝑠 = 134,613.0965 ℎ𝑟
Pressure and Temperature of steam leaving the Boiler:
𝑇1 = 482 ℃
𝑃1 = 5.86438 𝑀𝑃𝑎
Percent Rating:
PR = 500 %
Type of Boiler:
Water Tube Boiler
Developed Boiler Horsepower, 𝑫𝑩𝑯
𝑚𝑠 (ℎ1 − ℎ14 )
𝐷𝐵𝐻 =
𝐾𝐽
35322
ℎ𝑟 − 𝐻𝑃
𝑘𝑔
(134,613.0965 )(3380.835978 − 824.828521)
𝐷𝐵𝐻 = ℎ𝑟
𝐾𝐽
35322
ℎ𝑟 − 𝐻𝑃
𝑫𝑩𝑯 = 𝟗, 𝟕𝟒𝟏. 𝟎𝟏𝟑𝟒𝟖𝟗 𝑯𝑷
Rated Boiler Horsepower, 𝑹𝑩𝑯

DBH
𝑅𝐵𝐻 =
𝑃𝑒𝑟𝑐𝑒𝑛𝑡 𝑅𝑎𝑡𝑖𝑛𝑔
9741.013489
𝑅𝐵𝐻 =
5
𝑹𝑩𝑯 = 𝟏, 𝟗𝟒𝟖. 𝟐𝟎𝟐𝟔 𝑯𝑷
63
Heating Surface of the Boiler, 𝑯𝑺

*use 0.91 for water tube boilers
𝐻𝑆 = 0.91(𝑅𝐵𝐻)
𝐻𝑆 = 0.91(1948.202698)
𝑯𝑺 = 𝟏, 𝟕𝟕𝟐. 𝟖𝟔𝟒𝟒𝟓𝟓 𝒎𝟐
Factor of Evaporation, 𝑭𝑬
(ℎ1 − ℎ4 )
𝐹𝐸 =
𝐾𝐽
2257
𝑘𝑔
(3380.835978 − 824.828521)
𝐹𝐸 =
𝐾𝐽
2257
𝑘𝑔
𝑭𝑬 = 𝟏. 𝟏𝟑𝟐𝟓
Equivalent Evaporation, 𝑬𝑬
𝐸𝐸 = 𝑚𝑠 (𝐹𝐸)
𝐸𝐸 = (134613.0965)(1.1325)
𝒌𝒈
𝑬𝑬 = 𝟏𝟓𝟐, 𝟒𝟒𝟔. 𝟔𝟒𝟓𝟑
𝒉𝒓
ASME Evaporation Units, 𝑨𝑬𝑼
𝐴𝐸𝑈 = 𝑚𝑠 (ℎ1 − ℎ14 )
𝐴𝐸𝑈 = (134613.0965)(3380.835978 − 824.828521)
𝒌𝒈
𝑨𝑬𝑼 = 𝟑𝟒𝟒, 𝟎𝟕𝟕𝟐, 𝟎𝟕𝟖. 𝟓
𝒉𝒓
64
Boiler Efficiency, 𝛈𝑩
(ℎ1 −ℎ4 )
𝛈𝑩 = (100 %)
ℎ1
(3380.835978−824.828521)
𝛈𝑩 = (100 %)
3380.835978
𝛈𝑩 = 𝟕𝟓. 𝟔𝟎𝟐𝟖 %
Mass of Fuel, 𝒎𝒇
𝑚𝑠 (ℎ1 − ℎ4 )
𝒎𝒇 =
(η𝐵 )𝑄ℎ
(134613.0965)(3380.835978 − 824.828521)
𝒎𝒇 =
(0.756028)(30503.92375)
𝒌𝒈
𝒎𝒇 = 𝟏𝟒𝟗𝟏𝟗. 𝟓𝟓𝟒𝟏𝟐
𝒉𝒓
Actual Specific Evaporation, ASE
𝑚𝑠
𝐴𝑆𝐸 =
𝑚𝑓
134613.0965
𝐴𝑆𝐸 =
14919.55412
𝒌𝒈𝒔𝒕𝒆𝒂𝒎
𝑨𝑺𝑬 = 𝟗. 𝟎𝟐𝟐𝟔
𝒌𝒈𝒄𝒐𝒂𝒍
65
Equivalent Specific Evaporation, ESE
𝐸𝑆𝐸 = 𝐴𝑆𝐸(𝐹𝐸)
𝐸𝑆𝐸 = (9.0226)(1.1325)
𝒌𝒈𝒔𝒕𝒆𝒂𝒎
𝑬𝑺𝑬 = 𝟏𝟎. 𝟐𝟏𝟖𝟏
𝒌𝒈𝒄𝒐𝒂𝒍
Heat Generated by Boiler
𝑄𝑔 = 𝑚𝑓 (𝑄ℎ )
𝑄𝑔 = (14919.55412)(30503.92375)
𝑲𝑱
𝑸𝒈 = 𝟒𝟓𝟓, 𝟏𝟎𝟒, 𝟗𝟒𝟏. 𝟑
𝒉𝒓
*from steam table 3 by interpolating at 5.8644 MPa and 482 ℃
we get:
𝒎𝟑
v = 0.0564 𝒌𝒈
and from steam table 2, by interpolating at 5.8644 and 482 ℃
we get:
𝒎𝟑
vf = 0.0013144 𝒌𝒈
66
VOLUME OF STEAM DRUM, VSD
𝑉𝑆𝐷 = 𝑉𝑠 + 𝑉𝑤
𝑚3 𝑚3
𝑉𝑆𝐷 = 0.0564 + 0.0013144
𝑘𝑔 𝑘𝑔
𝒎𝟑
𝑽𝑺𝑫 = 𝟎. 𝟎𝟓𝟕𝟕𝟏
𝒌𝒈
ACTUAL VOLUME OF STEAM DRUM, VSD’
𝑉𝑆𝐷 ′ = 𝑚𝑠 (𝑉𝑆𝐷 )
𝑘𝑔 𝑚3
𝑉𝑆𝐷 ′ = (134613.0965 )(0.05771 )
ℎ𝑟 𝑘𝑔
𝒎𝟑
𝑽′𝑺𝑫 = 𝟕𝟕𝟔𝟗. 𝟎𝟗𝟗𝟔𝟗𝟑
𝒉𝒓
BOILER HEAT BALANCE
Energy absorbed by the boiler (𝑸𝟏 ):
𝑚𝑠 (𝐻𝑠 − 𝐻𝑓 )
𝑄1 =
𝑚𝑓
𝑘𝑔 𝑘𝐽 𝑘𝐽
(37.3925 𝑠 )(3380.836 − 767.1023 )
𝑘𝑔 𝑘𝑔
𝑄1 =
𝑘𝑔
4.1443 𝑠
𝒌𝑱
𝑸𝟏 = 𝟐𝟑𝟓𝟖𝟐. 𝟕𝟔𝟏𝟐𝟑
𝒌𝒈
67
Energy loss due to dry flue gases (𝑸𝟐 ):
𝑄2 = 0.24𝑊𝑑𝑔 (𝑡𝑔 − 𝑡𝑎 )
𝐵𝑇𝑈 𝑡𝑔 = 378.5628℉ 𝑡𝑎 = 77℉

𝐿 = 0.24
𝑙𝑏 · 𝐹
𝐵𝑇𝑈 𝑙𝑏 𝑜𝑓 𝑑𝑟𝑦 𝑔𝑎𝑠
𝑄2 = (0.24 )(11.9463 )(378.5628℉ − 77℉)
𝑙𝑏 · 𝐹 𝑙𝑏 𝑜𝑓 𝑓𝑢𝑒𝑙
𝐵𝑇𝑈 1.05506 𝑘𝐽 2.205 𝑙𝑏 𝒌𝑱

𝑄2 = 249.1230 × × = 𝟐𝟎𝟏𝟏. 𝟒𝟒𝟓𝟏
𝑙𝑏 1 𝐵𝑇𝑈 1 𝑘𝑔 𝒌𝒈
Energy loss due to moisture in fuel (𝑸𝟑 ):
𝑄3 = 𝑀𝑓 (1089 + 0.46𝑡𝑔 − 𝑡𝑓 ) 𝑡𝑔 < 557℉
𝑀𝑓 = 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒 𝑖𝑛 𝑓𝑢𝑒𝑙, 𝑙𝑏 𝑝𝑒𝑟 𝑙𝑏 𝑜𝑓 𝑓𝑢𝑒𝑙
𝑡𝑔 = 378.5628℉
𝑡𝑓 = 77℉
𝑄3 = (0.0749)(1089 + 0.46(378.5628℉) − 77℉)
𝐵𝑇𝑈 1.05506 𝑘𝐽 2.205 𝑙𝑏 𝒌𝑱

𝑄3 = 88.8418 × × = 𝟐𝟎𝟔. 𝟔𝟖𝟐𝟐
Energy loss due to evaporating and superheating moisture formed by
combustion of hydrogen (𝑸𝟒 ):
𝑄4 = 9𝐻2 (1089 + 0.46𝑡𝑔 − 𝑡𝑓 ) 𝑡𝑔 < 557℉
𝑄4 = (9)(0.0609)(1089 + 0.46(378.5628℉) − 77℉)
𝐵𝑇𝑈 1.05506 𝑘𝐽 2.205 𝑙𝑏 𝒌𝑱

𝑄4 = 650.1227 × × = 𝟏𝟓𝟏𝟐. 𝟒𝟓𝟎𝟐
68
Energy loss due to incomplete combustion of carbon to 𝑪𝑶 (𝑸𝟓 ):
𝐶𝑂
𝑄5 = 10160𝐶𝑎𝑏
𝐶𝑂2 + 𝐶𝑂
0.00
𝑄5 = 10160(0.6613)( )
0.16 + 0.00
𝐵𝑇𝑈 𝒌𝑱
𝑄5 = 0 =𝟎
𝑙𝑏 𝒌𝒈
Energy loss due to combustible in refuse (𝑸𝟔 ):
𝑄6 = 14600(𝐶 − 𝐶𝑎𝑏 )
𝑄6 = 14600(0.6912 − 0.6613)
𝐵𝑇𝑈 1.05506 𝑘𝐽 2.205 𝑙𝑏 𝒌𝑱

𝑄6 = 436.54 × × = 𝟏𝟎𝟏𝟓. 𝟓𝟔𝟗𝟖
Energy loss due to radiation and unaccounted for (𝑸𝟕 ):
𝑄7 = 𝑄ℎ − 𝑄6 − 𝑄5 − 𝑄4 − 𝑄3 − 𝑄2 − 𝑄1
𝑘𝐽 𝑘𝐽 𝑘𝐽 𝑘𝐽 𝑘𝐽
𝑄7 = 30503.92375 − 1015.5698 −0 − 1512.4502 − 206.6822
𝑘𝑔 𝑘𝑔 𝑘𝑔 𝑘𝑔 𝑘𝑔
𝑘𝐽 𝑘𝐽
− 2011.4451 − 23582.76123
𝑘𝑔 𝑘𝑔
𝒌𝑱
𝑸𝟕 = 𝟐𝟏𝟕𝟓. 𝟎𝟏𝟓𝟐
𝒌𝒈
69
DESIGN OF
CONDENSER
70
.6
.15 +.16
DATA: QR
.7
Tube Size
External Diameter 19.1 mm
Internal diameter 16.57 mm
Wall thickness
BWG 18
mm 1.24
Cross section
Bore area 2.156 cm2
Ext. surface
av 0.059847 m2
Water Velocity
vw 𝑚
7.0 𝑓𝑝𝑠 = 2.3141
𝑠
Pass
No. 2
Flow
Qw 𝐿
6.468
𝑚𝑖𝑛
Tube material Admirality Metal

Correction Factor 1.00
71
FOR HEAT REJECTED, 𝑸𝑹

𝑄𝑅 = 𝑚3 ℎ15 + 𝑚4 ℎ16 + (𝑚𝑠 − 𝑚2 − 𝑚3 − 𝑚4 − 𝑚5 )(ℎ6 ) − (𝑚𝑠 − 𝑚2 − 𝑚5 )(ℎ7 )
𝑄𝑅 = 1890.1507 + 1416.4699 + 55435.6056 − 4455.4689
𝑸𝑹 = 𝟓𝟒, 𝟐𝟖𝟔. 𝟕𝟒𝟕𝟒 𝑲𝑾
PROPERTIES OF COOLING WATER,
𝑇𝐷 = 5.6℃
𝑇𝑚𝑖𝑥 (𝑚𝑠 − 𝑚2 − 𝑚5 ) = 𝑇15 (𝑚3 ) + 𝑇16 (𝑚4 ) + 𝑇6 (𝑚𝑠 − 𝑚2 − 𝑚3 − 𝑚4 − 𝑚5 )
𝑇𝑚𝑖𝑥 (32.0891) = 447.5784 + 248.6035 + 885.8119
𝑻𝒎𝒊𝒙 = 𝟒𝟗. 𝟑℃
FOR OUTGOING WATER
𝑇𝑏 = 𝑇𝑚𝑖𝑥 – 𝑇𝐷
𝑇𝑏 = 49.3℃ – 5.6℃
𝑻𝒃 = 𝟒𝟑. 𝟕 ℃
FOR INCOMING WATER
∆𝑡𝑎 = 20℉ = 11.1111℃
𝑇𝑎 = 𝑇𝑚𝑖𝑥 – 11.1111℃
𝑇𝑎 = 49.3℃ – 11.1111℃
𝑻𝒂 = 𝟑𝟖. 𝟏𝟖𝟖𝟗 ℃
FOR MASS OF WATER
𝑄𝑅 = 𝑚𝑤 𝐶𝑃 ∆T
54,286.7474 𝐾𝑊 = 𝑚𝑤 (4.187)(43.7 − 38.1889)
𝒌𝒈 𝒌𝒈
𝒎𝒘 = 𝟐𝟑𝟓𝟐. 𝟔𝟐𝟒𝟑 = 𝟖, 𝟒𝟔𝟗, 𝟒𝟒𝟕. 𝟐𝟗𝟐
𝒔 𝒉𝒓
72
LOGARITHMIC MEAN TEMPERATURE DIFFERENCE
Data:
𝑇𝑎 = 38.1889 ℃
𝑇𝑏 = 43.7 ℃
𝑇𝑚𝑖𝑥 = 49.3℃
𝑻𝒚 = 𝟒𝟗. 𝟑 − 𝟑𝟖. 𝟏𝟖𝟖 = 𝟏𝟏. 𝟏𝟏𝟏𝟏℃
𝑻𝒙 = 𝟒𝟗. 𝟑 − 𝟒𝟑. 𝟕 = 𝟓. 𝟔℃
𝑇𝑦 − 𝑇𝑥
𝐿𝑀𝑇𝐷 =
𝑇𝑦
ln( 𝑇 )
𝑥
11.1111℃ − 5.6℃
𝐿𝑀𝑇𝐷 =
11.1111℃
ln( )
5.6℃
𝑳𝑴𝑻𝑫 = 𝟖. 𝟎𝟒𝟑𝟑℃
OVER ALL COEFFICIENT OF HEAT TRANSFER

𝑈 = 𝑢̅ 𝑥 𝐹𝑇 𝑥 𝐹𝑚 𝑥 𝐹𝑒 𝑥 𝐹𝑝
For:
𝑢̅ = 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑓𝑟𝑜𝑚 𝑓𝑖𝑔. 8 − 9
3
𝑢̅ = 𝑐 √𝑣 𝑐 = 𝑓𝑜𝑟 4 " 𝑡𝑢𝑏𝑒 𝑠𝑖𝑧𝑒 = 270
𝐵𝑇𝑈
𝑢̅ = 270√7𝑓𝑝𝑠 = 714.3529
𝑓𝑡 2 − ℎ𝑟 − ℉
73
𝐹𝑇 = 1.00
𝐹𝑚 = 1.00
𝐹𝑐 = 0.85
𝐹𝑝 = 1.0 𝑓𝑜𝑟 𝑡𝑢𝑟𝑏𝑖𝑛𝑒𝑠
𝑈 = 𝑢̅ 𝑥 𝐹𝑇 𝑥 𝐹𝑚 𝑥 𝐹𝑐 𝑥 𝐹𝑝
𝐵𝑇𝑈
𝑈 = 714.3529 (1.00)(1.00)( 0.85)(1.0)
𝑓𝑡 2 − ℎ𝑟 − ℉
𝐵𝑇𝑈 𝐾𝐽 𝑓𝑡 2 9℉
𝑈 = 607.1999 2 (1.085 ) (3.28 ) ( )
𝑓𝑡 − ℎ𝑟 − ℉ 𝐵𝑇𝑈 𝑚 5℃
𝑲𝑱
𝑼 = 𝟏𝟐, 𝟒𝟎𝟓. 𝟐𝟏𝟔𝟗
𝒎𝟐 − 𝒉𝒓 − ℃
HEAT TRANSFER AREA, HTA
𝑄𝑅
𝐻𝑇𝐴 =
𝑈(𝐿𝑀𝑇𝐷)
𝐾𝐽
195,432,290.5
𝐻𝑇𝐴 = ℎ𝑟
𝐾𝐽
12,405.2169 ( 8.0433℃)
𝑚2 − ℎ𝑟 − ℃
𝑯𝑻𝑨 = 𝟏𝟗𝟓𝟖. 𝟔𝟓𝟏𝟒 𝒎𝟐
74
NUMBER OF TUBES PER PASS, Np
*from Power Plant Engineering in MKS Unit by Frederick T. Morse, P. 420 eqn.
11-20
𝑚𝑤
𝑁𝑝 =
𝐴𝑤 𝑣𝑤 𝜌𝑤
𝑘𝑔
2352.6243 𝑠
𝑁𝑝 =
𝜋 𝑚 𝑘𝑔
(0.01657 𝑚)2 (2.1336 )(1000 3 )
4 𝑠 𝑚
𝒕𝒖𝒃𝒆𝒔
𝑵𝒑 = 𝟓𝟏𝟏𝟑. 𝟑𝟑𝟗𝟗 (𝟐 𝒑𝒂𝒔𝒔) = 𝟏𝟎, 𝟐𝟐𝟔. 𝟔𝟕𝟗𝟗 ≈ 𝟏𝟎, 𝟐𝟐𝟕 𝒕𝒖𝒃𝒆𝒔
𝒑𝒂𝒔𝒔
LENGTH OF TUBES, 𝑳
1958.6514 𝑚2
𝐿=
𝑎𝑉 𝑁𝑇
1958.6514 𝑚2
𝐿=
(0.059832)(10,227)
𝑳 = 𝟑. 𝟏𝟗𝟕𝟕𝒎
75
DESIGN OF
HEATERS
76
CLOSE HEATER 1:
Tube Size
Wall thickness
BWG 16
mm 1.65
Cross section
Bore area 1.948 cm2
Ext. surface
av 0.059847 m2
Water Velocity
vw 𝑚
7.0 𝑓𝑝𝑠 = 2.3141
𝑠
Pass
No. 2
Flow
Qw 𝐿
5.844
𝑚𝑖𝑛
Tube material 80/20 Cu-Ni

77
m3 h3’
1-m2 m
h12 h11
m3 h15
LOGARITHMIC MEAN EFFECTIVE TEMPERATURE
𝑇3′ = 171.1 ℃ 𝑇11 = 112.8433 ℃

𝑇15 = 161.1 ℃ 𝑇11 = 152.6792 ℃
*from Power Plant Theory and Design Philip J. Potter, page 350 eqn. 8-1
∆𝑇𝐴 = 171.1 ℃ − 112.8433 ℃ = 58.2567 ℃
∆𝑇𝐵 = 161.1 ℃ − 152.6792 ℃ = 8.4208 ℃
∆𝑇𝐴 − ∆𝑇𝐵
𝐿𝑀𝑇𝐷 =
∆𝑇
ln( ∆𝑇𝐴 )
𝐵
58.2567 ℃ − 8.4208 ℃
𝐿𝑀𝑇𝐷 =
58.2567 ℃
ln( 8.4208 ℃ )
𝑳𝑴𝑻𝑫 = 𝟐𝟓. 𝟕𝟔𝟔𝟑 ℃ = 𝟒𝟔. 𝟑𝟕𝟗𝟑 ℉
78
AVERAGE FILM TEMPERATURE, FT
From Power Plant Theory and Design Philip J. Potter, page 372
𝐹𝑇 = 𝑇′3 − 0.8(𝐿𝑀𝑇𝐷)
𝐹𝑇 = 339.98 ℉ − 0.8(46.3793 ℉)
𝑭𝑻 = 𝟑𝟎𝟐. 𝟖𝟕𝟔𝟔 ℉
Since 𝐹𝑇 > 250℉, use the curve 250 ℉
COEFFICIENT OF HEAT TRANSFER, U
Consider 𝐹𝑇 > 250℉ 𝑎𝑛𝑑 𝑣𝑤 = 7𝑓𝑝𝑠
𝐵𝑇𝑈 𝑲𝑱
𝑈 = 870 2
= 𝟏𝟕𝟖𝟖𝟐. 𝟗𝟒𝟔𝟗
ℎ𝑟 − 𝑓𝑡 − ℉ 𝒉𝒓 − 𝒎𝟐 − ℃
CORRECTED COEFFICIENT OF HEAT TRANSFER, U’
𝑈 ′ = 𝑈 𝑥 𝑐𝑓
𝐾𝐽
𝑈 ′ = 17882.9469 (.88)
ℎ𝑟 − 𝑚2 − ℃
𝑲𝑱
𝑼′ = 𝟏𝟓𝟔𝟒𝟖. 𝟗𝟗𝟑𝟐
𝒉𝒓 − 𝒎𝟐 − ℃
HEAT TRANSFER BETWEEN STEAM AND FEEDWATER
𝑄 = 𝑄𝐴𝐷𝐷𝐸𝐷 𝑊𝐴𝑇𝐸𝑅 = 𝑄𝑅𝐸𝐽𝐸𝐶𝑇𝐸𝐷 𝑊𝐴𝑇𝐸𝑅

𝑄 = 𝑚3 (ℎ3′ − ℎ15 )
𝐾𝐽
𝑄 = 10001.7531( 2785.4 − 680.335)
𝑘𝑔
𝑲𝑱
𝑸 = 𝟐𝟏𝟎𝟓𝟒𝟔𝟎𝟕. 𝟓𝟐
𝒉𝒓
79

𝑄
𝐻𝑇𝐴 =
𝐾𝐽
21054607.52
𝐾𝐽
15648.9932 (25.7663 ℃)
ℎ𝑟 − 𝑚2 − ℃
𝑯𝑻𝑨 = 𝟓𝟐. 𝟐𝟏𝟔𝟕 𝒎𝟐
MASS OF FEED WATER, mw
𝑄 = 𝑚𝑤 (ℎ12 − ℎ11 )
𝐾𝐽
21,054,607.52 = 𝑚𝑤 (643.7841 − 474.0234 )
ℎ𝑟
𝒌𝒈
𝒎𝒘 = 𝟏𝟐𝟒, 𝟎𝟐𝟓. 𝟐𝟎𝟗𝟔
𝒉𝒓
*from Power Plant Engineering in MKS Unit by Frederick T. Morse, P. 420 eqn. 11-20
𝑚𝑤
𝑁𝑝 =
𝑘𝑔 1ℎ𝑟
124,025.2096 ( )
𝑁𝑝 = ℎ𝑟 3600𝑠
𝜋 𝑚 𝑘𝑔
(0.01575 𝑚)2 (2.1336 )(1000 3 )
4 𝑠 𝑚
𝑵𝒑 = 𝟖𝟐. 𝟖𝟕𝟗 ≈ 𝟖𝟑
𝒑𝒂𝒔𝒔
80
NO. OF TUBES, 𝑵𝑻
𝑁𝑇 = 𝑝𝑎𝑠𝑠(𝑁𝑝 )
𝑡𝑢𝑏𝑒𝑠
𝑁𝑇 = (2)(83 )
𝑝𝑎𝑠𝑠
𝑵𝑻 = 𝟏𝟔𝟔 𝒕𝒖𝒃𝒆𝒔
𝐻𝑇𝐴
𝐿=
𝑎𝑉 𝑁𝑇
52.2167 𝑚2
𝐿=
(0.059847)(166)
𝑳 = 𝟓. 𝟐𝟓𝟔𝟎 𝒎
TOTAL LENGTH, 𝑳𝑻
𝐿𝑇 = 𝐿 + 2𝑡
𝐿𝑇 = 5.2560 + 2(0.00165)
𝑳𝑻 = 𝟓. 𝟐𝟓𝟗𝟑 𝒎
81
CLOSE HEATER 2:
Tube Size
Wall thickness
BWG 16
mm 1.65
Cross section
Bore area 1.948 cm2
Ext. surface
av 0.059847 m2
Water Velocity
vw 𝑚
7.0 𝑓𝑝𝑠 = 2.3141
𝑠
Pass
No. 2
Flow
Qw 𝐿
5.844
𝑚𝑖𝑛
Tube material 80/20 Cu-Ni

82
m4 h4’
1-m2 m
h10 h9
m4 h16
LOGARITHMIC MEAN EFFECTIVE TEMPERATURE
𝑇4′ = 135 ℃ 𝑇16 = 125 ℃

𝑇9 = 72.9874 ℃ 𝑇11 = 112.8333 ℃
*from Power Plant Theory and Design Philip J. Potter, page 350 eqn. 8-1
∆𝑇𝐴 = 135 ℃ − 72.9874 ℃ = 62.0126 ℃
∆𝑇𝐵 = 125 ℃ − 112.8333 ℃ = 12.1667 ℃
∆𝑇𝐴 − ∆𝑇𝐵
𝐿𝑀𝑇𝐷 =
∆𝑇
ln( ∆𝑇𝐴 )
𝐵
62.0126 ℃ − 12.1667 ℃
𝐿𝑀𝑇𝐷 =
62.0126 ℃
ln( 12.1667 ℃ )
𝑳𝑴𝑻𝑫 = 𝟑𝟎. 𝟔𝟎𝟓𝟗 ℃ = 𝟓𝟓. 𝟎𝟗𝟎𝟕 ℉
83
AVERAGE FILM TEMPERATURE, FT
𝐹𝑇 = 𝑇′4 − 0.8(𝐿𝑀𝑇𝐷)
𝐹𝑇 = 275 ℉ − 0.8(55.0907 ℉)
𝑭𝑻 = 𝟐𝟑𝟎. 𝟗𝟐𝟕𝟓 ℉
Since 𝐹𝑇 < 250℉, use the curve to find the rate of heat transfer
COEFFICIENT OF HEAT TRANSFER, U
Consider 𝐹𝑇 = 230.9275 ℉ 𝑎𝑛𝑑 𝑣𝑤 = 7𝑓𝑝𝑠
𝐵𝑇𝑈 𝑲𝑱
𝑈 = 835.8 2
= 𝟏𝟕𝟎𝟖𝟑. 𝟖𝟗𝟑𝟏
ℎ𝑟 − 𝑓𝑡 − ℉ 𝒉𝒓 − 𝒎𝟐 − ℃
CORRECTED COEFFICIENT OF HEAT TRANSFER, U’
𝑈 ′ = 𝑈 𝑥 𝑐𝑓
𝐾𝐽
𝑈 ′ = 17083.8931 (.88)
ℎ𝑟 − 𝑚2 − ℃
𝑲𝑱
𝑼′ = 𝟏𝟓𝟎𝟑𝟑. 𝟖𝟐𝟓𝟗
𝒉𝒓 − 𝒎𝟐 − ℃
HEAT TRANSFER BETWEEN STEAM AND FEEDWATER
𝑄 = 𝑄𝐴𝐷𝐷𝐸𝐷 𝑊𝐴𝑇𝐸𝑅 = 𝑄𝑅𝐸𝐽𝐸𝐶𝑇𝐸𝐷 𝑊𝐴𝑇𝐸𝑅

𝑄 = 𝑚3 (ℎ4′ − ℎ16 )
𝐾𝐽
𝑄 = 9713.1216( 2669.2 − 524.99)
𝑘𝑔
𝑲𝑱
𝑸 = 𝟐𝟎, 𝟖𝟑𝟏, 𝟖𝟐𝟖. 𝟗𝟔
𝒉𝒓
84

𝑄
𝐻𝑇𝐴 =
𝐾𝐽
20,831,828.96
𝐾𝐽
15033.8259 (30.6059 ℃)
ℎ𝑟 − 𝑚2 − ℃
𝑯𝑻𝑨 = 𝟒𝟓. 𝟐𝟕𝟒𝟑 𝒎𝟐
MASS OF FEED WATER, mw
𝑄 = 𝑚𝑤 (ℎ10 − ℎ9 )
𝐾𝐽
20,831,828.96 = 𝑚𝑤 (473.3015 − )
ℎ𝑟
𝒌𝒈
𝒎𝒘 = 𝟏𝟐𝟒, 𝟎𝟎𝟒. 𝟗𝟑𝟖𝟔
𝒉𝒓
*from Power Plant Engineering in MKS Unit by Frederick T. Morse, P. 420 eqn. 11-20
𝑚𝑤
𝑁𝑝 =
𝑘𝑔 1ℎ𝑟
124,004.9386 ( )
𝑁𝑝 = ℎ𝑟 3600𝑠
𝜋 𝑚 𝑘𝑔
(0.01575 𝑚)2 (2.1336 )(1000 3 )
4 𝑠 𝑚
𝑵𝒑 = 𝟖𝟐. 𝟖𝟕𝟗 ≈ 𝟖𝟑
𝒑𝒂𝒔𝒔
85
NO. OF TUBES, 𝑵𝑻
𝑁𝑇 = 𝑝𝑎𝑠𝑠(𝑁𝑝 )
𝑡𝑢𝑏𝑒𝑠
𝑁𝑇 = (2)(83 )
𝑝𝑎𝑠𝑠
𝑵𝑻 = 𝟏𝟔𝟔 𝒕𝒖𝒃𝒆𝒔
𝐻𝑇𝐴
𝐿=
𝑎𝑉 𝑁𝑇
45.2743 𝑚2
𝐿=
(0.059847)(166)
𝑳 = 𝟒. 𝟓𝟓𝟕𝟐 𝒎
TOTAL LENGTH
𝐿𝑇 = 𝐿 + 2𝑡
𝐿𝑇 = 4.5572 + 2(0.00165)
𝑳𝑻 = 𝟒. 𝟓𝟔𝟎𝟓 𝒎
86
OPEN HEATER 1:
m2 h2’
1kg
m h12
h13
SOLVING FOR VOLUME FLOW RATE, 𝑉

𝑚𝑠
𝑉̇ ′ =
𝜌𝑤
𝐾𝑔
134,613.0965
𝑉̇ ′ = ℎ𝑟
𝐾𝑔
1000
𝑚3
𝒎𝟑
𝑽̇ ′ = 𝟏𝟑𝟒. 𝟔𝟏𝟑𝟏
𝒉𝒓
SOLVING FOR VOLUME, V
𝑉 = 𝑉′̇ 𝑥 𝑡
𝑚3
𝑉 = 134.6131 (24 ℎ𝑟𝑠)
ℎ𝑟
𝑽 = 𝟑𝟐𝟑𝟎. 𝟕𝟏𝟒𝟒 𝒎𝟑
87
ASSUME:
𝐷 = 0.75 𝐿
𝜋
𝑉 = 𝐴 𝐿 = ( 𝐷2 ) (𝐿)
4
𝜋 𝐷 𝜋
𝑉 = ( )(𝐷2 ) ( ) → 𝐷3
4 0.75 3
𝜋
𝑉 = (3 ) (𝐷3 ) = 3230.7144 𝑚3
SOLVING FOR DIAMETER, D
3 (3)( 3230.7144 )
𝐷=√
𝜋
𝑫 = 𝟏𝟒. 𝟓𝟓𝟕𝟔 𝒎 ≈15 m
SOLVING FOR LENGTH, L

𝐷 14.5576
𝐿 = =
0.75 0.75
𝑳 = 𝟏𝟗. 𝟒𝟏𝟎𝟏 𝒎 ≈ 20 m
88
OPEN HEATER 2:
m5 h5’
‘‘’5
1-m2 m
H9 h8
SOLVING FOR VOLUME FLOW RATE, 𝑉

𝑚 5 + 𝑚𝐶
𝑉̇ ′ =
𝜌𝑤
𝑘𝑔 𝑘𝑔
8547.9316 + 115430.7302
𝑉̇ ′ = ℎ𝑟 ℎ𝑟
𝐾𝑔
1000 3
𝑚
𝒎𝟑
𝑽̇ ′ = 𝟏𝟐𝟑. 𝟗𝟕𝟖𝟕
𝒉𝒓
SOLVING FOR VOLUME, V
𝑉 = 𝑉′̇ 𝑥 𝑡
𝑚3
𝑉 = 123.9787 (24 ℎ𝑟𝑠)
ℎ𝑟
𝑽 = 𝟐𝟗𝟕𝟓. 𝟒𝟖𝟕𝟗 𝒎𝟑
89
ASSUME:
𝐷 = 0.75 𝐿
𝜋
𝑉 = 𝐴 𝐿 = ( 𝐷2 ) (𝐿)
4
𝜋 𝐷 𝜋
𝑉 = ( )(𝐷2 ) ( ) → 𝐷3
4 0.75 3
𝜋
𝑉 = ( ) (𝐷3 ) = 𝟐𝟗𝟕𝟓. 𝟒𝟖𝟕𝟗 𝒎𝟑
3
SOLVING FOR DIAMETER, D
3 (3)( 𝟐𝟗𝟕𝟓. 𝟒𝟖𝟕𝟗 )

𝐷=√
𝜋
𝑫 = 𝟏𝟒. 𝟏𝟔𝟑𝟗 𝒎 ≈15 m
SOLVING FOR LENGTH, L

𝐷 14.1639
𝐿 = =
0.75 0.75
𝑳 = 𝟏𝟖. 𝟖𝟖𝟒𝟗 𝒎 ≈ 19 m
90
DESIGN OF
FURNACE
91
AVAILABLE ENERGY, 𝑨𝑬
𝐴𝐸 = (𝑄ℎ (1 − 𝑄𝑅𝐿 ) + 0.24𝑊𝑎𝑎 (𝑡𝑎ℎ − 𝑡𝑎 ) − 1040(9𝐻2 ) − 14600(𝐶 − 𝐶𝑎𝑏 ))(𝑚𝑓 )
Using equivalent evaporation (𝐸𝐸):
𝒌𝒈
𝑬𝑬 = 𝟏𝟓𝟐, 𝟒𝟒𝟔. 𝟔𝟒𝟓𝟑
𝒉𝒓
*from page 353 of Power Plant Design by Frederick J. Morse;
Radiation loss (𝑄𝑅𝐿 ) = 0.625%
𝐵𝑇𝑈 𝑘𝑔 𝑜𝑓 𝑎𝑖𝑟
𝐴𝐸 = (13112.0306 (1 − 0.00625) + 0.24(11.0171 )(77℉ − 77℉)
𝑙𝑏 𝑘𝑔 𝑜𝑓 𝑐𝑜𝑎𝑙
𝑙𝑏
− 1040(9 × 0.0526) − 14600(0.6912 − 0.6613 ))(32891.9844 )
ℎ𝑟
𝑩𝑻𝑼
𝑨𝑬 = 𝟑𝟗𝟖, 𝟎𝟑𝟐, 𝟔𝟐𝟔
𝒉𝒓
92
Enveloped surface area:
Approximate furnace dimensions, from Elements of Electrical Power Station
Design by Deshpande, page 112.
Rating Approx. plan Width of Length Height Steam Bottom Vertical
of dimensions, furnace of of drum drum distance
boiler (𝑳 × 𝑾),(𝒎𝟐 ) , (𝒎) furnace furnace diameter, diameter, between
steam , (𝒎) , (𝒎) (𝒄𝒎) (𝒄𝒎) two
flow, drums,
𝑻𝒐𝒏𝒔 (𝒎)
( )
𝒉𝒓
11 8.2x3.2 2.4 4.1 5.2 107 92 4.25
22 8.2x4.1 3.3 4.1 6.9 122 92 5.5
34 8.5x5.4 4.4 4.6 7.6 122 92 6.0
45 9.3x5.4 4.7 5.1 8.2 137 92 6.75
68 9.6x6.7 6.1 5.7 9.3 152 92 7.3
90 10x7.6 7.2 5.9 9.6 152 92 8.0
114 10.7x8.2 7.7 6.4 10.4 152 92 8.5
93
𝑇𝑜𝑛𝑠
By extrapolation, using 𝑚𝑠 = 134.6 ℎ𝑟
Approx. plan dimensions, (𝑳 × 𝑾),(𝒎𝟐 ) 11.3x8.7
Width of furnace, (𝒎) 8.13
Length of furnace, (𝒎) 6.83
Height of furnace, (𝒎) 11.09
Steam drum diameter, (𝒄𝒎) 152
Bottom drum diameter, (𝒄𝒎) 92
Vertical distance between two drums, 8.93
(𝒎)
𝐹𝑟𝑜𝑛𝑡 𝑤𝑎𝑙𝑙 𝑎𝑟𝑒𝑎 = 11.09𝑚 × 8.13𝑚 = 90.16𝑚2
𝑆𝑖𝑑𝑒 𝑤𝑎𝑙𝑙 𝑎𝑟𝑒𝑎 = 2 × 11.09𝑚 × 6.83𝑚 = 151.49𝑚2
𝑅𝑒𝑎𝑟 𝑤𝑎𝑙𝑙 𝑎𝑟𝑒𝑎 = 11.09𝑚 × 3.87𝑚 = 42.92𝑚2
𝑅𝑜𝑜𝑓 𝑎𝑟𝑒𝑎 = 8.13𝑚 × 6.83𝑚 = 55.53𝑚2
𝑆𝑐𝑟𝑒𝑒𝑛 𝑡𝑢𝑏𝑒 𝑎𝑟𝑒𝑎 = 11.09𝑚(8.13𝑚 − 3.87𝑚) = 47.24𝑚2
𝐸𝑛𝑣𝑒𝑙𝑜𝑝𝑒𝑑 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑟𝑒𝑎
= 90.16𝑚2 + 151.49𝑚2 + 42.92𝑚2 + 55.53𝑚2 + 47.24𝑚2
𝐸𝑛𝑣𝑒𝑙𝑜𝑝𝑒𝑑 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑟𝑒𝑎 = 387.34𝑚2 = 4169.7 𝑓𝑡 2
𝐵𝑇𝑈
𝐴𝐸 = 398,032,626 ÷ 4169.7 𝑓𝑡 2 ÷ 1000
ℎ𝑟
94
𝐵𝑇𝑈
𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒 𝐸𝑛𝑒𝑟𝑔𝑦 = 95.4583
ℎ𝑟 · 𝑓𝑡 2
*from page 261 of Power Plant Theory and Design by Phillip Potter:
𝑻𝒈 = 𝟐𝟐𝟓𝟎℉ = 𝟏𝟐𝟑𝟐. 𝟐𝟐℃
HEAT RELEASE, HR
𝑊𝑓
𝐻𝑅 = (𝑄ℎ + 0.24𝑊𝑎𝑎 (𝑡𝑎ℎ − 𝑡𝑎 ) − 1040(9𝐻2 ) − 14600(𝐶 − 𝐶𝑎𝑏 ))( )
𝑉
𝐵𝑇𝑈 𝑘𝑔 𝑜𝑓 𝑎𝑖𝑟
𝐻𝑅 = (13112.0306 + 0.24 (11.01707 ) (77℉ − 77℉)
𝑙𝑏 𝑘𝑔 𝑜𝑓 𝑐𝑜𝑎𝑙
𝑙𝑏
32891.9844
− 1040(9 × 0.0526) − 14600(0.6912 − 0.6613 ))( ℎ𝑟 )
21746.9275𝑓𝑡 3
𝑩𝑻𝑼
𝑯𝒆𝒂𝒕 𝑹𝒆𝒍𝒆𝒂𝒔𝒆 = 𝟏𝟖, 𝟒𝟐𝟔. 𝟖𝟖𝟓
𝒉𝒓 · 𝒇𝒕𝟐
*from page 228 of Power Plant Theory and Design by Phillip Potter
Type of Furnace: Dry bottom Furnace
95
DESIGN OF
CHIMNEY
96
FOR DENSITY OF AIR,𝝆𝒂
𝑃𝑎
𝜌𝑎 =
𝑅𝑎 𝑇𝑎
101.325 𝑘𝑃𝑎
𝜌𝑎 =
𝑘𝐽
(0.28708 ) (25 + 273)𝐾
𝑘𝑔 · 𝐾
𝒌𝒈
𝝆𝒂 = 𝟏. 𝟏𝟖𝟒𝟒
𝒎𝟑
FOR MASS FLOW RATE, 𝒎𝒈
𝑚𝑔 = (𝑊𝑑𝑔 )(𝑚𝑓 )
𝑘𝑔 𝑜𝑓 𝑑𝑟𝑦 𝑔𝑎𝑠 𝑘𝑔 𝑜𝑓 𝑓𝑢𝑒𝑙 1ℎ𝑟

𝑚𝑔 = (11.9463 )(14919.55412 )( )
𝑘𝑔 𝑜𝑓 𝑓𝑢𝑒𝑙 ℎ𝑟 3600𝑠
𝒌𝒈
𝒎𝒈 = 𝟒𝟗. 𝟓𝟎𝟗𝟑
𝒔
FOR VOLUME FLOW RATE OF THE GAS, 𝑸𝒈
𝑄𝑔 = (𝑉𝑑𝑔 )(𝑚𝑓 )
𝑓𝑡 3 1 𝑚 3 2.205 𝑙𝑏 𝑚3
𝑉𝑑𝑔 = 936.53213 ×( ) × = 58.5207
𝑙𝑏 𝑜𝑓 𝑓𝑢𝑒𝑙 3.28 𝑓𝑡 1 𝑘𝑔 𝑘𝑔 𝑜𝑓 𝑓𝑢𝑒𝑙
𝑚3 𝑘𝑔 𝑜𝑓 𝑓𝑢𝑒𝑙
𝑄𝑑𝑔 = (58.5207 )(4.1443 )
𝑘𝑔 𝑜𝑓 𝑓𝑢𝑒𝑙 𝑠
𝒎𝟑
𝑸𝒈 = 𝟐𝟒𝟐. 𝟓𝟐𝟖𝟓
𝒔
97
FOR THE GAS DENSITY, 𝑸𝒈
𝑚𝑔
𝜌𝑔 =
𝑄𝑔
𝑘𝑔
49.5093 𝑠
𝜌𝑔 =
𝑚3
242.5285 𝑠
𝒌𝒈
𝝆𝒈 = 𝟎. 𝟐𝟎𝟒𝟏
𝒎𝟑
CHIMNEY DIAMETER, 𝑫
*Actual velocity of gas (𝑉𝑔 ) = 50 𝑓𝑝𝑠 𝑡𝑜 60 𝑓𝑝𝑠, from page 306 of Power
Plant Theory and Design by Phillip Potter.
𝜋 2
𝑄𝑔 = 𝐷 𝑉𝑔
4
𝑚3 𝜋 2 𝑓𝑡 1𝑚
242.5285 = 𝐷 (55 × )
𝑠 4 𝑠 3.28 𝑓𝑡
𝑫 = 𝟒. 𝟐𝟗𝟏𝟑 𝒎
Actual velocity of gas (𝑉𝑔 ) = 30% 𝑡𝑜 50% of theoretical velocity of gas(𝑉).
*for theoretical velocity of gas (𝑉), use 40%
𝑓𝑡 1𝑚
60 𝑠 ×
3.28 𝑓𝑡
𝑉=
0.40
𝒎
𝑽 = 𝟒𝟏. 𝟗𝟐𝟎𝟕
𝒔
98
DRAFT HEAD, 𝒉𝒘
2𝑔ℎ𝑤
𝑉=√
𝜌𝑔
𝑚
𝑚 2(9.8066 2 )(ℎ𝑤 )
41.9207 =√ 𝑠
𝑠 𝑘𝑔
0.2041 3
𝑚
𝒌𝒈
𝒉𝒘 = 𝟏𝟖. 𝟐𝟖𝟕𝟒
𝒎𝟐
CHIMNEY HEIGHT, 𝑯
ℎ𝑤
𝐻=
𝜌𝑎 − 𝜌𝑔
𝑘𝑔
18.2874
𝐻= 𝑚2
𝑘𝑔 𝑘𝑔
1.1844 3 − 0.2041 3
𝑚 𝑚
𝑯 = 𝟏𝟖. 𝟔𝟓𝟒𝟗𝒎
*Standard height of chimney is 30 𝑚𝑒𝑡𝑒𝑟𝑠, to make the height 30 𝑚𝑒𝑡𝑒𝑟𝑠 we
need to adjust the diameter of the chimney.
𝜋 𝜋
(𝐷𝑜𝑟𝑖𝑔𝑖𝑛𝑎𝑙 )2 𝐻𝑜𝑟𝑖𝑔𝑖𝑛𝑎𝑙 = (𝐷𝑎𝑑𝑗𝑢𝑠𝑡𝑒𝑑 )2 𝐻𝑎𝑑𝑗𝑢𝑠𝑡𝑒𝑑
4 4
𝜋 𝜋
(4.2913 𝑚)2 (18.6549𝑚) = (𝐷𝑎𝑑𝑗𝑢𝑠𝑡𝑒𝑑 )2 (30 𝑚)
4 4
𝑫𝒂𝒅𝒋𝒖𝒔𝒕𝒆𝒅 = 𝟐. 𝟔𝟔𝟖𝟓 𝒎
𝑯𝒂𝒅𝒋𝒖𝒔𝒕𝒆𝒅 = 𝟑𝟎𝒎
99
DESIGN OF
MACHINE
FOUNDATION
100
Machine foundations are subjected to the dynamic forces caused by the
machine. These dynamic forces are then transferred to the foundation supporting
the machine. Though the moving parts of the machine are generally balanced,
there is always some unbalance in practical field which causes an eccentricity of
rotating parts. This produces an oscillating force. The machine foundation must
satisfy the criteria for dynamic loading in addition to that for static loading.
For this design I’m going to use SST-300:
Based on their catalogue:
WEIGHT 100 t (100000 kg)
MAX. OUTPUT 50 MW
LENGTH 12m (39 ft.)
WIDTH 3m (12.1 ft.)
HEIGHT 5m (16.4 ft.)
101
FOUNDATION WEIGHT, 𝑾𝒇
*for design purposes, the weight of the foundation (𝑊𝑓 ) is 3 to 5 times the
weight of the machine. Use 5 times the weight of the machine.
𝑊𝑓 = 5 × 100000 𝑘𝑔
𝑾𝒇 = 𝟓𝟎𝟎𝟎𝟎𝟎 𝒌𝒈
There should be a clearance between the machine edge dimensions and
the foundation edge dimensions, the clearance should be 10% of the length of the
bed plate of the machine.
𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = 0.10 × 12 𝑚 = 𝟏. 𝟐 𝒎
Therefore, the length (𝐿) and the upper width (𝑎) of the machine foundation
is:
𝐿 = 12 𝑚 + (2 × 1.2 𝑚) =
= 𝟏𝟒. 𝟒 𝒎
𝑎 = 5 𝑚 + (2 × 1.2 𝑚) =
= 𝟕. 𝟒 𝒎
102
The type of soil in Dipolog city in Zamboanga del norte is fine clayey sand,
𝑙𝑏
so the soil bearing capacity (𝑆𝑏 ) should be 3000 .
𝑓𝑡 2
𝑆𝑏 𝑊𝑓 + 𝑊𝑚
=
2 𝑏𝐿
𝑙𝑏 3.28𝑓𝑡 2 1𝑘𝑔 𝑘𝑔
𝑆𝑏 = 3000 2
×( ) × = 14637.2789 2
𝑓𝑡 1𝑚 2.205𝑙𝑏 𝑚
𝑘𝑔
14637.2789
𝑚2 = 500000 𝑘𝑔 + 100000 𝑘𝑔
2 (𝑏)(14.4 𝑚)
𝒃 = 𝟓. 𝟔𝟗𝟑𝟐 𝒎
103
MACHINE FOUNDATION VOLUME, 𝑽𝒇
500000 𝑘𝑔
𝑉𝑓 =
𝑘𝑔
2406 3
𝑚
𝑘𝑔
𝜌𝑐𝑜𝑛𝑐𝑟𝑒𝑡𝑒 = 2406
𝑚3
500000 𝑘𝑔
𝑉𝑓 =
𝑘𝑔
2406 3
𝑚
𝑽𝒇 = 𝟐𝟎𝟕. 𝟖𝟏𝟑𝟖 𝒎𝟑 = 𝟐𝟕𝟏. 𝟖𝟏𝟎𝟑 𝒚𝒅𝟑
FOUNDATION HEIGHT, 𝒉
𝑎+𝑏
𝑉𝑓 = ( ) ℎ𝐿
2
7.4 𝑚 + 5.6932 𝑚
207.8138 𝑚3 = ( ) ℎ(14.4 𝑚)
2
𝒉 = 𝟐. 𝟐𝟎𝟒𝟒 𝒎
104
For class A type mixture that is (1:2:4), 1-part cement, 2 parts sand, and 4
parts gravel. Therefore, to produce 1 𝑦𝑑3 of concrete, we need 6 𝑠𝑎𝑐𝑘𝑠 of cement,
0.44 𝑦𝑑3 of sand, and 0.88 𝑦𝑑3 of gravel.
NO. OF SACK SEMENT
271.8103 𝑦𝑑3 𝑛𝑜. 𝑜𝑓 𝑠𝑎𝑐𝑘𝑠

=
1 𝑦𝑑3 6 𝑠𝑎𝑐𝑘𝑠
𝒏𝒐. 𝒐𝒇 𝒔𝒂𝒄𝒌𝒔 = 𝟏𝟔𝟑𝟎. 𝟖𝟎𝟕𝟖 𝒔𝒂𝒄𝒌𝒔
≈ 𝟏𝟔𝟑𝟏 𝒔𝒂𝒄𝒌𝒔
SAND VOLUME, 𝑽𝒔𝒂𝒏𝒅
271.8103 𝑦𝑑 3 𝑉𝑠𝑎𝑛𝑑
3
=
1 𝑦𝑑 0.44 𝑦𝑑3
𝑽𝒔𝒂𝒏𝒅 = 𝟏𝟏𝟗. 𝟓𝟗𝟔𝟒 𝒚𝒅𝟑 = 𝟗𝟏. 𝟒𝟑𝟕𝟓 𝒎𝟑 ≈ 𝟗𝟐 𝒎𝟑
GRAVEL VOLUME, 𝑽𝒈𝒓𝒂𝒗𝒆𝒍
271.8103 𝑦𝑑 3 𝑉𝑔𝑟𝑎𝑣𝑒𝑙
=
1 𝑦𝑑3 0.88 𝑦𝑑3
𝑽𝒈𝒓𝒂𝒗𝒆𝒍 = 𝟐𝟑𝟗. 𝟏𝟗𝟑𝟏 𝒚𝒅𝟑 = 𝟏𝟖𝟐. 𝟖𝟕𝟔𝟐 𝒎𝟑 ≈ 𝟏𝟖𝟑 𝒎𝟑
105
STEEL BAR WEIGHT, 𝑾𝒔𝒕𝒆𝒆𝒍
*weight of steel bar reinforcements needed should be about 0.5% to 1% of
the weight of the foundation. Use 0.75% of the weight of the foundation.
𝑊𝑠𝑡𝑒𝑒𝑙 = 0.0075 × 500000 𝑘𝑔
𝑾𝒔𝒕𝒆𝒆𝒍 = 𝟑𝟕𝟓𝟎 𝒌𝒈
STEEL BAR VOLUME, 𝑽𝒔𝒕𝒆𝒆𝒍
𝑘𝑔
𝜌𝑠𝑡𝑒𝑒𝑙 𝑏𝑎𝑟 = 7850
𝑚3
𝑘𝑔 3750 𝑘𝑔
7850 =
𝑚3 𝑉𝑠𝑡𝑒𝑒𝑙
𝑽𝒔𝒕𝒆𝒆𝒍 = 𝟎. 𝟒𝟕𝟕𝟖 𝒎𝟑
FOR STEEL BAR NO.
For design purposes, we will use Rebar #9 which has a diameter of 29 𝑚𝑚
that is designed for industrial purposes. The average length of steel bar on the
market is 20 𝑓𝑡.
𝜋 2 𝐿𝑛𝑒𝑒𝑑𝑒𝑑
𝑉𝑠𝑡𝑒𝑒𝑙 = 𝐷 𝐿𝑛𝑒𝑒𝑑𝑒𝑑 𝑛𝑜. 𝑜𝑓 𝑠𝑡𝑒𝑒𝑙 𝑏𝑎𝑟𝑠 =
4 𝐿𝑎𝑣𝑒𝑟𝑎𝑔𝑒
𝜋
0.4778 𝑚3 = (0.029𝑚)2 𝐿𝑛𝑒𝑒𝑑𝑒𝑑 2373.2599 𝑓𝑡
4 𝑛𝑜. 𝑜𝑓 𝑠𝑡𝑒𝑒𝑙 𝑏𝑎𝑟𝑠 =
20 𝑓𝑡
𝑳𝒏𝒆𝒆𝒅𝒆𝒅 = 𝟕𝟐𝟑. 𝟑𝟔𝟗𝟔

𝒏𝒐. 𝒐𝒇 𝒔𝒕𝒆𝒆𝒍 𝒃𝒂𝒓𝒔 = 𝟏𝟏𝟖. 𝟔𝟔𝟐𝟗
= 𝟐𝟑𝟕𝟑. 𝟐𝟓𝟗𝟗 𝒇𝒕 ≈ 𝟏𝟏𝟗 𝒃𝒂𝒓𝒔
106
COST ANALYSIS
107
MATERIALS AND EQUIPMENT COST:

Equipment/Material Quantity Price (PHP) Total Price (PHP)
Boiler 1 5,000,000 5,000,000
Steam turbine-generator set 1 75,000,000 75,000,000
Condenser 1 350,000 350,000
Condensate pump 1 75,000 75,000
Surface heater 2 230,000 460,000
Contact heater 2 173,000 346,000
Boiler feed water pump 1 172,500 172,500
Feedwater Pump 2 103,000 206,000
Chimney 1 146,144 146,144
Furnace 1 3,750,000 3,750,000
Gate valve 2 35,000 70,000
Check Valve 11 19,000 209000
Throttling Valve 1 47,000 47,000
Steam trap 2 24,000 48,000
Pipes and Fittings 3,000,000 3,000,000
𝑻𝒐𝒕𝒂𝒍: 88,878,644
108
MACHINE FOUNDATION COST:

Material Quantity Price (PHP) Total Price (PHP)
Cement 1631 sacks 240 per sack 391,440
Sand 92 𝑚3 700 per 𝑚3 64,400
Gravel 183 𝑚3 700 per 𝑚3 128,100
Steel bar 119 pcs. 1113 per pc. 132,447
𝑮𝒓𝒂𝒏𝒅 𝑻𝒐𝒕𝒂𝒍: 716,387
LAND COST
The average price per square meter of land in Zamboanga is ₱ 3,500. The
estimated land area of the power plant is 30625 𝑚2 .
₱ 3,500
𝑐𝑜𝑠𝑡 𝑜𝑓 𝑙𝑎𝑛𝑑 = 30625 𝑚2 ×
𝑚2
𝒄𝒐𝒔𝒕 𝒐𝒇 𝒍𝒂𝒏𝒅 = ₱ 𝟏𝟎𝟕, 𝟏𝟖𝟕, 𝟓𝟎𝟎
CONSTRUCTION COST
According to the Philippine Statistics Authority, the average cost of building
construction in the Philippines was estimated at ₱ 9,605 per square meter the estimated
floor are of the power plant is 14400 𝑚2 .
₱ 9,605
𝑐𝑜𝑠𝑡 𝑜𝑓 𝑐𝑜𝑛𝑠𝑡𝑟𝑢𝑐𝑡𝑖𝑜𝑛 = 14400 𝑚2 ×
𝑚2
𝒄𝒐𝒔𝒕 𝒐𝒇 𝒄𝒐𝒏𝒔𝒕𝒓𝒖𝒄𝒕𝒊𝒐𝒏 = ₱ 𝟏𝟑𝟖, 𝟑𝟏𝟐, 𝟎𝟎𝟎
109
TOTAL INVESTMENT:
*An addition of 10 – 20% to the total investment should be made to care for contingencies
which may arise from unforeseen complications.
Materials and equipment 88,878,644
Machine foundation 716,387
Engineering Fee 10,000,000
Cost of land 107,187,500
Cost of building and construction 138,312,000
𝑮𝒓𝒂𝒏𝒅 𝑻𝒐𝒕𝒂𝒍: 345,094,531(1.2)
414,113,437.2
MAINTENANCE AND OPERATION COST:
Quantity Price (PHP) Total Price (PHP)
Fuel (Coal) 𝑡𝑜𝑛𝑠 1945 per ton 250,741,620

10,743 𝑚𝑜𝑛𝑡ℎ
Water 𝑚3
6194923.5 𝑚𝑜𝑛𝑡ℎ 18.69 per 𝑚3 1,240,719,279
Labor cost
Plant Manager 1 75,000 per month 900,000
Plant Engineer 3 40,000 per month 1,440,000
Operator 6 22,000 per month 1,584,000
Office Staff 8 20,000 per month 1,920,000
110
Maintenance
Machine 12 25000 per month 300,000
Building 12 20000 per month 240,000
Auxiliaries 12 30000 per month 360,000
𝑮𝒓𝒂𝒏𝒅 𝑻𝒐𝒕𝒂𝒍: 1,498,204,899
ANNUAL INCOME:
For the annual income of the plant, using the total load produced per day of
627180.281 𝑘𝑊 − ℎ𝑟, the profit per year is:
𝑐𝑜𝑠𝑡 𝑜𝑓 𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 365 𝑑𝑎𝑦𝑠

𝑎𝑛𝑛𝑢𝑎𝑙 𝑖𝑛𝑐𝑜𝑚𝑒 = × 𝑡𝑜𝑡𝑎𝑙 𝑙𝑜𝑎𝑑 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑 𝑝𝑒𝑟 𝑑𝑎𝑦 ×
𝑘𝑊 − ℎ𝑟 1 𝑦𝑒𝑎𝑟
𝑐𝑜𝑠𝑡 𝑜𝑓 𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝑝𝑒𝑟 𝑘𝑊 − ℎ𝑟 = ₱4.8
₱ 8.74 608,945.693 𝑘𝑊 − ℎ𝑟 365 𝑑𝑎𝑦𝑠

𝑎𝑛𝑛𝑢𝑎𝑙 𝑖𝑛𝑐𝑜𝑚𝑒 = × ×
𝑘𝑊 − ℎ𝑟 𝑑𝑎𝑦 1 𝑦𝑒𝑎𝑟
𝒂𝒏𝒏𝒖𝒂𝒍 𝒊𝒏𝒄𝒐𝒎𝒆 = ₱ 𝟏, 𝟗𝟒𝟐, 𝟓𝟗𝟕, 𝟔𝟓𝟓
PAYBACK PERIOD:
𝑡𝑜𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
𝑝𝑎𝑦𝑏𝑎𝑐𝑘 𝑝𝑒𝑟𝑖𝑜𝑑 =
𝑎𝑛𝑛𝑢𝑎𝑙 𝑖𝑛𝑐𝑜𝑚𝑒 − 𝑎𝑛𝑛𝑢𝑎𝑙 𝑐𝑜𝑠𝑡
₱ 414,113,437.2
𝑝𝑎𝑦𝑏𝑎𝑐𝑘 𝑝𝑒𝑟𝑖𝑜𝑑 =
₱ 1,942,597,655 ₱ 1,498,204,899
−
𝑦𝑒𝑎𝑟 𝑦𝑒𝑎𝑟
𝒑𝒂𝒚𝒃𝒂𝒄𝒌 𝒑𝒆𝒓𝒊𝒐𝒅 = 𝟎. 𝟗𝟑𝟏𝟗 𝒚𝒆𝒂𝒓𝒔 = 𝟏𝟏 𝒎𝒐𝒏𝒕𝒉𝒔
111
RATE OF RETURN:
𝑛𝑒𝑡 𝑝𝑟𝑜𝑓𝑖𝑡
𝑟𝑎𝑡𝑒 𝑜𝑓 𝑟𝑒𝑡𝑢𝑟𝑛 = × 100
𝑡𝑜𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
₱ 444,392,756
𝑦𝑒𝑎𝑟
𝑟𝑎𝑡𝑒 𝑜𝑓 𝑟𝑒𝑡𝑢𝑟𝑛 = × 100
₱₱ 414,113,437.2
𝒓𝒂𝒕𝒆 𝒐𝒇 𝒓𝒆𝒕𝒖𝒓𝒏 = 𝟏𝟎𝟕. 𝟑𝟏 % 𝒑𝒆𝒓 𝒚𝒆𝒂𝒓
112
REFERENCE
113
BOOK REFERENCE
Power Plant Design & Theory, Second Edition, Philip J. Potter
Power Plant Engineering, Frederick T. Morse
Fluid Mechanics, Daugherty
Elements of Electrical Power Station Design by Deshpande
LINK REFERENCE
https://m.alibaba.com/
https://m.indiamart.com
https://m.made-in-china.com/
http://www.1stresourcesolutions.com/rebar-size-9l
https://www.eia.gov/state/print.php?sid=WV
https://psa.gov.ph/content/construction-statistics-approved-building-permits-
firstquarter-2017-preliminary-results
https://www.affordablecebu.com/load/business/list_of_construction_supplies_pric
es_in_philippines/6-1-0-30422
https://www.globalpropertyguide.com/Asia/philippines/square-meter-prices
114

40.6 MW Regenerative Thermal Power Plant

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40.6 MW Regenerative Thermal Power Plant

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40.

6 MW REGENERATIVE THERMAL POWER PLANT

In thermodynamic power cycles, an efficiency increases of even 0.5% in

efficiency of a steam cycle is to use regeneration, a process where heat is taken

temperature to the boiler.

BACKGROUND OF THE STUDY

The Regenerative Rankine cycle is so named because after emerging

by steam extracted from the steam turbine.

Another variation sends bleed steam from between turbine stages to

Regeneration increases the cycle heat input temperature by eliminating

temperatures that would exist without regenerative feedwater heating. This

occurs at higher temperature.

STATEMENT OF THE PROBLEM

Electricity is considered a necessity in this modern-day time. But still

generation. As a mechanical engineer it is our job to build and design power

analysis and computation:

Name of City: Dipolog city, Zamboanga del norte

Ambient Temperature: 101.325 Kpa

Plant Design Operation: 8760 hours per year

Plant design: Regenerative Thermal Power Plant

Plant Capacity: 40.6 MW

Fuel: Propane (𝐶3 𝐻8 )

The researcher aims to:

Design a Regenerative Thermal Power Plant (w/ 2 open and 2 close

feedwater heaters) that will supply the demand of Dipolog City.

Determine the load requirement and demand of the community.

SCOPE AND LIMITATIONS

The research focuses on designing an Thermal Regenerative Power

Plant running on Regenerative Rankine cycle using 2 open and 2 closed

gathered about the chosen community.

the theoretical and technical standards from books or articles.

Boiler Drum – is a standard feature of a water-tube boiler. It is a reservoir

generated in the water tubes and acts as a phase-separator for the

Boiler Efficiency – it is the measure of ability of a boiler or steam generator

water and hot gases exchange heat.

Breeching – is the duct that connects the boiler and chimney.

with feed water.

Coal Burner Assembly – is a burner assembly including a housing having

Coal Conveyors – are used to move coal around efficiently.

Coal Pulverizer – is a mechanical device for the grinding of many different

Commercial Load – is the kilowatt-hour energy output of the commercial

Condensate Pump – is a specific type of pump used to pump the

condensate (water) produced in the condensing boiler furnace or steam

waste heat to the atmosphere.

Critical Point – Represents the highest pressure and highest temperature

at which liquid and vapor can coexist in equilibrium.

Economizer – is a feed water preheating device which utilizes the heat of

the flue gases.

Energy Balance - A calculation used in designing industrial processes in

which all energy flows and transformations, such as changes in

temperature, heats of reaction, use of steam or other sources of heat, etc.,

are accounted for.

Fire Tube Boiler – is a steam boiler in which hot gaseous products of

combustion pass through tubes surrounded by boiler water.

dioxide, and sometimes serving as a source from which carbon dioxide or

other compounds are recovered.

perform mechanical work in a controlled manner.

Furnace – a device that encloses the combustion equipment so that the

heat generated will be utilized effectively.

Generator – converts the mechanical energy produced by the turbine into

Heater – is an object that emits heat or causes another body to achieve a

Industrial Load – is the kilowatt-hour energy output of the industrial

building or buildings necessary for the generation of power.