CPD 20002 : Plant Utilities &

Safety

Prime Movers
Objectives
 Able to draw a basic drawing of respective prime mover
 Able to name the important parts of the equipment
 Able to explain the function of the respective prime
mover
 Able to discuss the operational of the respective prime
mover
 Able to explain the safety aspect of the prime mover
 Able to discuss and rectify common problems of the
prime mover
Intro

 Covers electric motor,

steam turbine, gas
turbines, internal
combustion engine and
safety.
 Driver to another
equipment and
machinery.
Electric Motors
 Classified as DC Motors and AC Motors
Theory:
Theory: ….
• The winding that is static is termed a stator and that
which rotates is a rotor.
• If Iπ is the rotor current and ø the instantaneous flux,
then the force in terms of torque, T, produced by these
parameters can be expressed by
Theory: ….

N.M

# In a 3- ø winding, therefore, for the

same amount of current, the torque
developed is 50% more than in a 2-ø
winding.
Introduction to Direct motor
 The operation of a dc motor is based on the following principle:
 A current-carrying conductor placed in a magnetic field, perpendicular to
the lines of flux, tends to move in a direction perpendicular to the
magnetic lines of flux. There is a definite relationship between the
direction of the magnetic field, the direction of current in the conductor,
and the direction in which the conductor tends to move. This relationship
is best explained by using the RIGHT-HAND RULE FOR MOTORS (fig.
2-1).
 To find the direction of motion of a conductor, extend the thumb,
forefinger, and middle finger of your right hand so they are at right angles
to each other.
 If the forefinger is pointed in the direction of magnetic flux (north to
south) and the middle finger is pointed in the direction of current flow in
the conductor, the thumb will point in the direction the conductor will
move.
Introduction to Direct motor…
 Stated very simply, a dc motor rotates as a result of two magnetic fields
interacting with each other. The armature of a dc motor acts like an
electromagnet when current flows through its coils. Since the armature is
located within the magnetic field of the field poles, these two magnetic
fields interact.
 Like magnetic poles repel each other, and unlike magnetic poles attract
each other. As in the dc generator, the dc motor has field poles that are
stationary and an armature that turns on bearings in the space between the
field poles
 The armature of a dc motor has windings on it just like the armature of a
dc generator. These windings are also connected to commutator segments.
A dc motor consists of the same components as a dc generator. In fact,
most dc generators can be made to act as motors, and vice versa.
 It has two field poles, one a north pole and one a south pole. The magnetic
lines of force extend across the opening between the poles from north to
south
 DC Motors...

 The armature in this simple dc motor is

a single loop of wire, just as in the
simple armature you studied at the
beginning of the chapter on dc
generators.
 The loop of wire in the dc motor,
however, has current flowing through it
from an external source. This current
causes a magnetic field to be produced.
 This field is indicated by the dotted line
through the loops. The loop (armature)
field is both attracted and repelled by the
field from the field poles. Since the
current through the loop goes around in
the direction of the arrows, the north
pole of the armature is at the upper left,
and the south pole of the armature is at
the lower right, as shown in figure
besides, (view A).
 DC Motors...

 Of course, as the loop (armature) turns, these

magnetic poles turn with it.
 Now, as shown in the illustrations, the north
armature pole is repelled from the north field
pole and attracted to the right by the south
field pole. Likewise, the south armature pole
is repelled from the south field pole and is
attracted to the left by the north field pole.
This action causes the armature to turn in a
clockwise direction, as shown in figure
besides (view B).
 After the loop has turned far enough so that
its north pole is exactly opposite the south
field pole, the brushes advance to the next
segments. This changes the direction of
current flow through the armature loop.
Also, it changes the polarity of the armature
field, as shown in beside (view C). The
magnetic fields again repel and attract each
other, and the armature continues to turn.
 DC Motors...

 In this simple motor, the momentum of

the rotating armature carries the
armature past the position where the
unlike poles are exactly lined up.
However, if these fields are exactly
lined up when the armature current is
turned on, there is no momentum to start
the armature moving.
 In this case, the motor would not rotate.
It would be necessary to give a motor
like this a spin to start it. This
disadvantage does not exist when there
are more turns on the armature, because
there is more than one armature field.
No two armature fields could be exactly
aligned with the field from the field
poles at the same time.
 DC motors are often used in variable speed
applications.
 Can be designed to run at any speed within
the limits imposed by centrifugal forces and
commutation considerations.
 DC motors - ease which speed can be
adjusted.
 Need periodic maintenance - high cost
AC Motors
 AC motor has a current passed through the
coil, generating a torque on the coil.
 Magnetic field is produced by an
electromagnet powered by the same AC
voltage as the motor coil.
 Types; induction & synchronous
Induction Motor
 3 phase AC motor & widely used machine.
 Characteristic features;
 Simple and rugged construction
 Low cost & min maintenance.
 High reliability & sufficiently high efficiency.
 Need no extra starting motor
 2 basic assemblies
make up an
induction motor: the
stator & rotor
assembly.
 Motor "induces" current into the rotor by the
rotating magnetic flux produced in the stator.
 Torque developed from interaction of currents
flowing in the rotor bars & the stator's rotating
magnetic field.
 When a three-phase voltage is applied to the stator
winding, a rotating magnetic field of constant
magnitude is produced.
 This rotating field is produced by the contributions
of space-displaced phase windings carrying
appropriate time displaced currents.
 The rotating field induces an electromotive force
(emf).
Synchronous Motor
 Obvious characteristic - strict synchronism with
the power line frequency.
 Higher efficiency & the opportunity for the user to
adjust the motor’s power factor.
 A specially designed motor controller performs
these operations in the proper sequence and at the
proper times during the starting process.
Safety Precautions
 Jiggling the started button will cause pitting of
the contacts.
 Dust or dirt is the biggest single cause of
machine failure.
 Do not grease motors. This will be done by
the Mechanical Division.
 Keep motor dry. Moisture softens and
saturates the insulation and sets up leakage
paths for current and results in breakdown of
insulation.
 Never allow a stream of water to be
directed at an electric motor.
 Misalignment between the motor and the
driven equipment, an unbalanced rotor or
worn motor bearings can cause vibration
in a motor.
 Stop the motors in case of low voltage or
overloading.
Turbines
Turbines
 Use kinetic energy (steam, gas, water) &
convert it to mechanical energy.
 Turbine used depends on numerous
factors, including principle of operation &
type of fluid used to operate them.
 Petrochemical & refining industries are
use steam or gas turbines.
 Purposes:

 Convert compressed air or steam into

mechanical energy to operate plant
equipment.
 Drivers for rotating machinery in process
plants.
 Turbine converts the motive gas flowing
from higher to lower pressure into
mechanical energy to operate rotating
equipment.
 Common is steam turbine (condensing, non-condensing,
single stage and multi-stage) & gas turbine (using liquid
or gaseous fuels and air..
 Selection of the turbine type must consider reliability of
service, availability, reliability, quality, demand for the
motive gas
 The two basic types of blading sets used to extract energy
from a vapor and produce power are listed below:
 In general, impulse blading has been widely used in the
steam turbine industry and reaction blading has been widely
used in the gas turbine industry.
 In recent years, the steam turbine industry has been
designing a 'Hybrid Turbine' utilizing rugged impulse
blading in the initial stages and high efficiency reaction
blading in the final stages.
•The objective of any expansion turbine is to extract the maximum
possible energy from each pound of vapor to produce power.
•The inlet throttle valves control the amount (mass flow) of steam
admitted to the expansion turbine to meet the power requirements of
the driven equipment.
• However, to maximize energy extraction, the losses across the
inlet throttle valves must be minimum.
•In a backpressure turbine, the exhaust pressure is greater than atmospheric
pressure.
•A condensing turbine's exhaust pressure is equal to or less than atmospheric
pressure.
•Most condensing turbines operate at a high vacuum (3-4" Hg Vac) for
maximum efficiency and energy extraction.
Steam Turbines

 Used to drive
centrifuge pumps
or to drive
generators, fans &
compressors.
 Common; single
stage machines.
Principles
 Steam enters the governor valve after passing
through the strainer and throttle valve.
 The position of the governor valve determines
how much steam is admitted to the steam chest
and nozzles.
 As the steam passes through the nozzles, its
pressure drops and velocity becomes very high.
 The rapidly moving steam then enters the first
row of buckets where part of its energy is used to
drive the bucket wheel.
 The stationary reversing buckets serve to reverse
the direction of flow so that the steam will be
traveling in the proper direction to enter the
second row of moving buckets; more energy is
extracted from the steam.
 The steam then leaves the turbine through the
exhaust steam piping.
Gas Turbine
 Similar to the steam turbine.
 Importance in power stations, ships &
locomotives, and in form of the jet engine also
in airplanes.
Gas Turbine
 Have 3 parts:
 Compressors
 Combustion Area
 Turbine
 Compressors - Compresses the incoming air
to high pressure
 Combustion area - Burns the fuel and
produces high-pressure, high-velocity gas
 Turbine - Extracts the energy from the high-
pressure, high-velocity gas flowing from the
combustion chamber. Two types of turbine
used in gas turbines are the axial-flow and
radial inflow type.
Principles
 In this engine, air is sucked in from the
right by the compressor. The compressor is
basically a cone-shaped cylinder with
small fan blades attached in rows.
 Air at normal air pressure is then forced
through the compression stage its pressure
raises significantly. In some engines, the
pressure of the air can rise by a factor of
30.
 This high-pressure air then enters the
combustion area, where a ring of fuel
injectors injects a steady stream of fuel.
The fuel is generally kerosene, jet fuel,
propane or natural gas.
 To keep a flame burning continuously in
that environment, a piece that solves this
problem is called a "flame holder," or
sometimes a "can." The can is a hollow,
perforated piece of heavy metal.
 The compressed air then goes to turbine
section. There are two sets of turbines. The
first set directly drives the compressor.
The turbines, the shaft and the compressor
all turn as a single unit.
 At the far left is a final turbine stage (single
set of vanes). It drives the output shaft.
 This final turbine stage and the output shaft
are a completely stand-alone, freewheeling
unit. They spin freely without any connection
to the rest of the engine.
 Pc & TF

PE & TE
 Pc = HP TURBINE INLET
 TF =FIRINGTEMPERATURE
 PE = EXHAUST (POWER TURBINE)
PRESSURE
 TE = EXHAUST (POWER TURBINE)
TEMPERATURE
Maintenance
Internal Combustion Engine
 The internal
combustion engine is
a heat engine in which
combustion occurs in
a confined space
called a combustion
chamber.
 Combustion of a fuel creates high
temperature/pressure gases, which are
permitted to expand. The expanding gases are
used to directly move a piston, turbine blades,
rotor(s), or the engine itself thus doing useful
work.
 Internal combustion engines can be
powered by any fuel that can be combined
with an “oxidizer" in the chamber.
 An external combustion engine such as a
steam engine does work when the
combustion process heats a separate
working fluid, such as water or steam,
which then in turn does work.
 Jet engines, most reckets and many gas
turbines are strictly classed as internal
combustion engines, but the term internal
combustion engine is also used to refer
specifically to reciprocating engines.
 Applications; cars, motobikes, many boats,
and in a wide variety of aircraft and
locomotives, jet aircraft, helicopters and
large ships, electric generators and by
industry
The Four Stroke Cycle
INTAKE stroke
1. The piston starts at the top, the intake valve
opens, and the piston moves down to let the
engine take in a cylinder-full of air and fuel
mixture. This is the intake stroke. Only the
tiniest drop of gasoline needs to be mixed
into the air for this to work.
COMPRESSION stroke
2. Then the piston returns to the top of the
cylinder compressing the air-fuel mixture
into the combustion chamber of the
cylinder head. Compression makes the
explosion more powerful.
POWER stroke
3. When the piston reaches the top of its
stroke, the spark plug emits a spark to
ignite the compressed air–fuel mixture in a
gasoline engine. The gasoline charge in the
cylinder explodes. The resulting pressure
from the combustion of the compressed
fuel-air mixture forces the piston back
down to bottom of the cylinder.
EXHAUST stroke
4. Once the piston hits the bottom of its stroke,
the exhaust valve opens and this action expels
the spent fuel-air mixture through the exhaust
valve/s.
Additional info
Ends of Chapter 2