ME 522 - Power Plant Engineering - Review Problems

Aurora State College of Technology
Engineering Department
Zabali Campus Baler, Aurora
STEAM POWER PLANT

(Summary)
POWER PLANT ENGINEERING
Course Code: ME 522

Course Units: 3 Units ( Lec.- 3 hours, Lab.- 0 hour)
Prerequisite: ME 421 (ME Lab 2) & ( ME 517 )-Safety Engineering for M.E.
ENGR. ALKING B. GOROSPE, PhD

Instructor/Professor
Image: Power Plant Characteristics and Costs by Stan Kaplan

Engineering Department, Aurora State College of Technology
STEAM POWER PLANT (Formulas)

STEAM CYCLES
Rankine Cycle: is the ideal cycle used as the standard of comparison for
steam power plants.
QA
1 Processes of Rankine Cycle
1-2: Isentropic expansion
2-3: P=C pressure heat rejection
3-4: adiabatic pumping
4-1: P=C heat addition
turbine
2 generator T
H2O in
boiler 1
4
H2O out 4
3
condenser
3 2
pump
s
Rankine Cycle Plant Layout T-S Diagram of Rankine Cycle
Power Plant Engineering


STEAM CYCLES h1
Analysis of Rankine Cycle:
 Boiler (Heat added, QA)

QA
𝑘𝐽
𝑄𝐴 = ℎ1 − ℎ4 ,
𝑘𝑔
𝑄𝐴 = 𝑚 ℎ1 − ℎ4 , (𝐾𝑊)
h4 h1
 Turbine (Work, Wt)
Wt
𝑘𝐽
𝑊𝑡 = ℎ1 − ℎ2 = ℎ1 − ℎ2 + Δ𝐾𝐸,
𝑘𝑔
𝑊𝑡 = 𝑚 ℎ1 − ℎ2 + 𝐾𝐸1 − 𝐾𝐸2 , (𝑘𝑊)
𝑚 = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 𝑖𝑛

𝑘𝑔
𝑠
h2


STEAM CYCLES
Analysis of Rankine Cycle: h2
 Condenser (Removed, QR)
𝑄𝑅 = ℎ2 − ℎ3 ,
𝑘𝐽 QR
𝑘𝑔
h3
𝑄𝐴 = 𝑚 ℎ2 − ℎ3 , (𝐾𝑊)
 Pump (Work, Wp)

Wp
𝑊𝑝 = ℎ4 − ℎ3 𝑊𝑝 = 𝑉𝑓3 𝑃4 − 𝑃3 , 𝑘𝑊 h4
h3
𝑊𝑝 = 𝑚 ℎ4 − ℎ3 𝑊𝑝 = 𝑚𝑉𝑓3 𝑃4 − 𝑃3 , 𝑘𝑊
(Exact work) (Approximate work)


STEAM CYCLES
Analysis of Rankine Cycle:
 Net Cycle (Work, Wnet)  Steam rate (SR)
𝑊𝑛𝑒𝑡 = 𝑊𝑡 − 𝑊𝑝 = 𝑄𝐴 − 𝑄𝑅 3600 𝑘𝑔
𝑆𝑅 = =
𝑊𝑛𝑒𝑡 𝑘𝑊 − ℎ𝑟
𝑊𝑛𝑒𝑡 = ℎ1 − ℎ2 − 𝑊𝑝
 Thermal efficiency (eth)
𝑊𝑛𝑒𝑡 ℎ1 − ℎ2 − 𝑊𝑝 𝑄𝑅
𝑒𝑡ℎ = = =1−
𝑄𝐴 ℎ1 − ℎ3 − 𝑊𝑝 𝑄𝐴


Sample Problems: Rankine Cycle
In a Rankine cycle, saturated liquid water at 1 bar is compressed isentropically to
150 bar. First by heating in a boiler and then by superheating at constant
pressure of 150 bar, the water substance is brought to 750 K. After adiabatic
reversible expansion in a turbine to 1 bar, it is then cooled in a condenser to a
saturated liquid. How much work is generated in the turbine?
150 bar
750 K
T
1 bar 1
150 bar 4
3 2
1 bar
saturated s

Solution: Solving for h2:

𝑊𝑡 = ℎ1 − ℎ2 𝑠1 = 𝑠2
𝑠1 = 𝑠𝑓 + 𝑥𝑠𝑓𝑔
At 150 bar (15 MPa) and 750 K (477 oC) 2
6.2549 = 1.3026 + 𝑥 (6.0568)
ℎ1 = 3, 240.5 𝑘𝐽/𝑘𝑔
𝑥 = 0.8176 = 81.76%
𝑘𝐽
𝑠1 = 6.2549 𝑘𝐽
𝑘𝑔 − 𝐾 ℎ2 = 2,263.6
𝑘𝑔
At 1 bar (0.10 MPa) 𝑘𝐽 𝑘𝐽
𝑊𝑡 = 3, 240.5 − 2, 263.6
𝑘𝐽 𝑘𝐽 𝑘𝑔 𝑘𝑔
ℎ𝑓 = 417.46 𝑠𝑓 = 1.3026
𝑘𝑔 𝑘𝑔 − 𝐾
𝑘𝐽
𝑘𝐽 𝑘𝐽 𝑊𝑡 = 976.9
ℎ𝑓𝑔 = 2,258 𝑠𝑓𝑔 = 6.0568 𝑘𝑔
𝑘𝑔 𝑘𝑔 − 𝐾


Sample Problem:
A coal-fired power plant has a turbine –generator rated at 1,000 MW gross. The
plant required about 9% of this power for its internal operations. It uses 9,800
tons of coal per day. The coal has a heating value of 6,388.9 kCal/kg, and the
steam generator efficiency is 86%. What is the net station efficiency of the plant
in percent?
100 MW
Solution:
𝑁𝑒𝑡 𝑜𝑢𝑡𝑝𝑢𝑡
𝑁𝑒𝑡 𝑠𝑡𝑎𝑡𝑖𝑜𝑛 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
𝑁𝑒𝑡 𝑖𝑛𝑝𝑢𝑡
𝑁𝑒𝑡 𝑜𝑢𝑡𝑝𝑢𝑡 = 1, 000 (1 − 0.09)
𝑁𝑒𝑡 𝑜𝑢𝑡𝑝𝑢𝑡 = 910 𝑀𝑊 = 910, 000 𝑘𝑊
9,800 (907)
𝑁𝑒𝑡 𝑖𝑛𝑝𝑢𝑡 = 𝑚𝑓 𝑄ℎ = 6,388.9 (4.187) = 2,752,001.534 𝑘𝑊
24 (3600)
910,000
𝑵𝒆𝒕 𝒔𝒕𝒂𝒕𝒊𝒐𝒏 𝒆𝒇𝒇𝒊𝒄𝒊𝒆𝒏𝒄𝒚 = = 0.3307 = 𝟑𝟑. 𝟎𝟕%
2,752,001.534


STEAM CYCLES
Reheat Cycle: The efficiency of the plant sometimes can be increased by
withdrawing the steam from the turbine after it has partially expanded and
piping the steam back to the steam generator for reheating. This also has an
effect of reducing the moisture content of the steam in the turbine limiting the
amount of moisture to 10 or 12%. This is important because water can
cause increased turbine-blade corrosion.


STEAM CYCLES Processes of Rankine Cycle
1-2: Partial S=C expansion in the turbine
Reheat cycle 2-3: P=C pressure re-superheating in the re-heater
3-4: Complete S=C expansion in the turbine
4-5: P=C rejection of heat in the condenser
5-6: Adiabatic pumping
6-1: P=C addition of heat in the boiler
1
turbine
2 3 4
generator T
H2O in
re-heater 1 3
condenser
6
6 H2O out 2
5
5 4
pump
s
Reheat Cycle Plant Layout T-S Diagram of Reheat Cycle


STEAM CYCLES h1
Analysis of Reheat Cycle:
 Boiler (Heat added, QA)

QA
𝑘𝐽
𝑄𝐴 = ℎ1 − ℎ6 ,
𝑘𝑔
𝑄𝐴 = 𝑚 ℎ1 − ℎ6 , (𝐾𝑊)
 Turbine (Work, Wt) h6
𝑘𝐽
𝑊𝑡 = ℎ1 − ℎ2 + ℎ3 − ℎ4 ,
𝑘𝑔
𝑊𝑡 = 𝑚(ℎ1 − ℎ2 + ℎ3 − ℎ4 , ) 𝑘𝑊


STEAM CYCLES
Analysis of Reheat Cycle: h4
𝑄𝑅 = ℎ4 − ℎ5 ,
𝑘𝐽 QR
𝑘𝑔
h5
𝑄𝐴 = 𝑚 ℎ4 − ℎ5 , (𝐾𝑊)
 Pump (Work, Wp)

Wp
𝑊𝑝 = ℎ6 − ℎ5 𝑊𝑝 = 𝑉𝑓5 𝑃6 − 𝑃5 , 𝑘𝑊 h6
h5
𝑊𝑝 = 𝑚 ℎ6 − ℎ5 𝑊𝑝 = 𝑚𝑉𝑓5 𝑃6 − 𝑃5 , 𝑘𝑊
(Exact work) (Approximate work)


STEAM CYCLES
Analysis of Reheat Cycle:
𝑊𝑛𝑒𝑡 = 𝑊𝑡 − 𝑊𝑝 3600 𝑘𝑔
𝑆𝑅 = =
𝑊𝑛𝑒𝑡 = ℎ1 − ℎ2 + ℎ3 − ℎ4 − 𝑊𝑝
 Thermal efficiency (eth)
𝑊𝑛𝑒𝑡
𝑒𝑡ℎ =
𝑄𝐴


Sample Problems: Reheat Cycle
A reheat steam has 13, 850 kPa throttle pressure at the turbine inlet and a 2,800
kPa reheat pressure, the throttle and reheat temperature of the steam is 540oC,
condenser pressure is 3.4 kPa, engine efficiency of high pressure and low
pressure is 75%. Find the cycle thermal efficiency.
13.85 kPa 1
540oC
turbine
2 3 4 0.0034 MPa
generator T
QA H2O in
2.8 MPa
re-heater 1 3
540oC condenser
6
6 H2O out 2
5
5 4
pump

Solution: 𝑣5 = 𝑣𝑓 @ 0.0034 𝑀𝑃𝑎

𝑊𝑡 − 𝑊𝑝 𝑚3
𝑒𝑡ℎ = 𝑣5 = 0.0010032
𝑄𝐴 𝑘𝑔
At 13.85 MPa and 540 oC Solving for h6:
ℎ6 − ℎ5 = 𝑣5 𝑃6 − 𝑃5
𝑘𝐽
ℎ1 = 3,434.1 (𝑏𝑦 𝑖𝑛𝑡𝑒𝑟𝑝𝑜𝑙𝑎𝑡𝑖𝑜𝑛) ℎ6 − 109.84 = 0.0010032 13,850 − 3.4
𝑘𝑔
𝑘𝐽
At 2.8 MPa and 540oC ℎ6 = 123.73
𝑘𝑔
𝑘𝐽
ℎ3 = 3,548.50 𝑊𝑡 =
3,434.1 − 2,974.9 + 3,548.5 − 2,204.5 (0.75)
𝑘𝑔
𝒌𝑱
From Steam Table 𝑾 𝒕 = 𝟏, 𝟑𝟓𝟐. 𝟒
𝒌𝒈
𝑘𝐽
ℎ2 = 2,974.9 ℎ5 = ℎ𝑓 @ 0.0034 𝑀𝑃𝑎 𝑊𝑝 = ℎ6 − ℎ5
𝑘𝑔
𝑘𝐽 𝑘𝐽 𝒌𝑱
ℎ4 = 2,204.5 ℎ 5 = 109.84 𝑊 𝑝 = 123.73 − 109.84 = 𝟏𝟑. 𝟖𝟗
𝑘𝑔 𝑘𝑔 𝒌𝒈

Solution:
𝑄𝐴 = ℎ1 − ℎ6 + (ℎ3 − ℎ2 )
𝒌𝑱
𝑄𝐴 = 3, 431.1 − 123.73 + 3,548.5 − 2, 974.9 = 𝟑, 𝟖𝟖𝟑. 𝟗𝟕
𝒌𝒈
1,352.4 − 13.89
𝒆𝒕𝒉 = = 0.3446 = 𝟑𝟒. 𝟒𝟔%
3, 883.97


STEAM CYCLES
Regenerative Cycle: Cycle efficiency can be increased by bleeding a fraction
of steam from the turbine and using this steam for regenerative heating of
the feedwater. This steam may be fed either to an open heater in which the
bled steam comes into direct contact with the feedwater to be heated or to a
closed heater that is a shell and tube type heat exchanger.


Processes of Regenerative Cycle
STEAM CYCLES 1-2: Partial S=C expansion in the turbine
Regenerative cycle 2-6: P=C rejection of heat in the open heater
3-4: P=C rejection of heat in the condenser
4-5: Adiabatic pumping in pump 1
m
Stage 2 6-7: Adiabatic pumping in pump 2
boiler 1 Stage 1
turbine
m1 X m2 3 generator T
H2O in 1
2
7 condenser
7 m
H2O out m1
6 5 5 6 m = m-m
2
4 2 1
4 3
Pump 2 Open Pump 1
heater
s
Regenerative Cycle Plant Layout T-S Diagram of Regen Cycle


STEAM CYCLES
Analysis of Regenerative Cycle:
 Boiler (Heat added, QA) h1

𝑘𝐽
𝑄𝐴 = ℎ1 − ℎ7 ,
𝑘𝑔 QA
𝑄𝐴 = 𝑚 ℎ1 − ℎ6 , (𝐾𝑊)
 Turbine (Work, Wt) h7
𝑊𝑡 = 𝑚 ℎ1 − ℎ2 + 𝑚 − 𝑚1 ℎ2 − ℎ3 , 𝑘𝑊


STEAM CYCLES
Analysis of Regenerative Cycle: h3
𝑄𝑅 = (𝑚 − 𝑚1 ) ℎ3 − ℎ4 , (𝐾𝑊)
QR
 Pump (Work, Wp)
h4
𝑊𝑝 = 𝑊𝑝1 − 𝑊𝑝2 Wp1
𝑊𝑝 = 𝑚 − 𝑚1 ℎ5 − ℎ4 + 𝑚 ℎ7 − ℎ6 , 𝑘𝑊 h5 h4
(Exact total pump work) Wp2
h7 h6
𝑊𝑝 = 𝑉𝑓4 𝑃5 − 𝑃4 + 𝑉𝑓6 𝑃7 − 𝑃6 , 𝑘𝑊
(Approximate total pump work)


STEAM CYCLES
Analysis of Regenerative Cycle:
𝑆𝑅 = =
𝑊𝑛𝑒𝑡 = 𝑄𝐴 − 𝑄𝑅
 Thermal efficiency (eth) m1

 Mass of extracted steam, (m1)
2
𝑊𝑛𝑒𝑡 𝑚1 ℎ2 + 𝑚 − 𝑚1 ℎ5 = 𝑚ℎ6
𝑒𝑡ℎ =
𝑄𝐴 𝑚 ℎ6 − ℎ5
m m2 𝑚1 =
ℎ2 − ℎ5


Try this one!
Steam enters the turbine of a cogeneration plant at 7.0 Mpa and 500oC. Steam
at a flow rate of 7.6 kg/s is extracted from the turbine at 600 kPa pressure for
process heating. The remaining steam continues to expand to 10 kPa. The
recovered condensate are pumped back to the boiler. The mass flow rate of
steam that enters the turbine is 30 kg/s. Calculate the cogeneration efficiency in
percent.
T
1
7 MPa
m
7
m1
600 kPa
2
5 6 m = m-m
2 1
10 kPa
4 3


STEAM CYCLES
Reheat - Regenerative Cycle: combination of both the reheat and
regenerative is done to further improved the overall thermal efficiency and
further reduced the moisture content of steam to minimize corrosion.


Processes of Reheat-Regen Cycle
STEAM CYCLES 1-2: Partial S=C expansion in the turbine
Reheat - Regenerative cycle 2-3: Intermediate S=C expansion in the turbine
2-8: P=C rejection of heat in the open heater
3-4: P=C re-superheating in the re-heater
m2 5-6: P=C rejection of heat in the condenser
6-7: Adiabatic pumping in pump 1
m 4 Stage 2
7-8: P=C addition of heat in the open heater
boiler 1 Stage 1 8-9: Adiabatic pumping in pump 2
turbine
m2
3 5
2 m1
generator T
H2O in 1
9
X
2 condenser 4
9 m
2
H2O out 8 m1
8 7 7 3
6 m2 = m-m1
6 5
Pump 2 Open Pump 1
heater
s
Reheat-Regen Cycle Plant Layout T-S Diagram of Reheat-Regen Cycle


STEAM CYCLES
Analysis of Reheat - Regenerative Cycle:
 Boiler (Heat added, QA) h1

𝑘𝐽
𝑄𝐴 = ℎ1 − ℎ9 ,
𝑘𝑔 QA
𝑄𝐴 = 𝑚 ℎ1 − ℎ9 , (𝐾𝑊)
h7
 Turbine (Work, Wt)
𝑊𝑡 = 𝑊1−2 + 𝑊2−3 + 𝑊3−4 + 𝑚 − 𝑚1 ℎ4 − ℎ5 , 𝑘𝑊
𝑊𝑡 = 𝑚 ℎ1 − ℎ2 + 𝑚 − 𝑚1 (ℎ2 − ℎ3 ) + 𝑚 − 𝑚1 ℎ4 − ℎ5 , 𝑘𝑊


STEAM CYCLES
Analysis of Reheat-Regenerative Cycle: h5
𝑄𝑅 = (𝑚 − 𝑚1 ) ℎ5 − ℎ6 , (𝐾𝑊)
QR
 Pump (Work, Wp)
h6
𝑊𝑝 = 𝑊𝑝1 − 𝑊𝑝2 Wp1
𝑊𝑝 = 𝑚 − 𝑚1 ℎ7 − ℎ6 + 𝑚 ℎ9 − ℎ8 , 𝑘𝑊 h7 h6
(Exact total pump work) Wp2
h9 h8
𝑊𝑝 = 𝑉𝑓6 𝑃7 − 𝑃6 + 𝑉𝑓8 𝑃9 − 𝑃8 , 𝑘𝑊
𝑊𝑝 = 𝑉𝑓6 𝑃9 − 𝑃6
(Approximate total pump work)


STEAM CYCLES
𝑆𝑅 = =
𝑊𝑛𝑒𝑡 = 𝑄𝐴 − 𝑄𝑅
m1
 Thermal efficiency (eth)  Mass of extracted steam, (m1)
𝑊𝑛𝑒𝑡 𝑚1 ℎ2 + 𝑚 − 𝑚1 ℎ7 = 𝑚ℎ8
𝑒𝑡ℎ =
𝑄𝐴 𝑚 ℎ8 − ℎ7
m m2 𝑚1 =
ℎ2 − ℎ7


STEAM CYCLES
4
 Re-heater (Heat added, QRH)
QRH
𝑄𝑅𝐻 = (𝑚 − 𝑚1)(ℎ4 − ℎ3 ) 3
Note: For all steam cycles the actual efficiencies
Actual turbine work Actual pump work
𝑊𝑡𝑎 = 𝑒𝑡 𝑊𝑡 𝑊𝑝
𝑊𝑝𝑎 =
𝑒𝑝


Try this one!
A Batangas based industrial company operates a steam power plant with reheat and
regeneration. The steam enters a turbine at 300 bar and 900 K and expands to 1 bar.
Steam leaves the first stage at 30 bar and part of it entering a closed heater while the rest
reheated to 800 K. Both section of the turbine have adiabatic efficiency of 93%. A
condensate pump exist between the main condenser and the heater. Another pump lies
between the heater and the condensate outlet line from the heater (condensed extracted
steam). Compute for the extracted fraction of the total mass flow to the heater.
30 bar, 800 K
300 bar, 1 kg
30 bar
1 bar
QA


STEAM GENERATOR (BOILER)
Is an integrated assembly of several essential components the function of which
is to produce steam at a predetermined pressure and temperature.
Classification of Boilers:
 Water Tube Boiler

Is a steam boiler in which water circulates within tubes and heat is applied
from outside the tubes to generate steam.
 Fire Tube Boiler
Is a steam boiler in which hot gaseous products of combustion pass
through tubes surrounded by boiler water.


Definitions:
 Power boiler
A closed vessel in which steam or other vapor (to be used externally to
itself) is generated at a pressure of more than 1.055 kg/cm2 gage by the
direct application of heat.
 Portable boiler
Is an internally fired boiler which is self-contained and primarily intended for
temporary location and the construction and usage is obviously portable.
 Locomotive boiler
Is a boiler mounted on a self-propelled track locomotive and used to furnish
motivating power travelling on rails. It does not include locomotive cranes,
tractors, or other self-propelled apparatus. Locomotive boilers, however, if
dismantled from locomotive and reinstalled for stationary use are not
included in this definition.


Definitions:
 Miniature boiler
Is any boiler which does not exceed any of the following limits: 405 mm
inside diameter, 1,065 mm overall length of outside to outside of heads at
center 1.85 mm of water heating surface, 7.03 kg/cm2 maximum allowable
working pressure
 Low pressure heating boiler

Is a boiler operated at pressure not exceeding 1.055 kg/cm2 gage steam,
or water temperature not exceeding 121oC.
 Hot water supply boiler

Is a boiler furnishing hot water to be used externally to itself
 Unfired pressure vessel

Is a vessel in which pressure is obtained from an external sources of from
an indirect application of heat.


Definitions:
 Reinstalled boiler
Is a boiler removed from its original setting and re-erected at the same
location or erected at location without change of ownership.
 Second hand boiler
Is a boiler of which both the location and ownership have been changed
after primary use.
 Condemed boiler
Is a boiler that has been inspected and declared unsafe to operate or
disqualified stamped and marked indicating its rejection by qualified
inspecting authority.


BOILERS AND ITS ACCESSORIES
 Air preheater
Is a heat exchanger which utilizes the heat of the flue gases to preheat the
air needed for combustion.
 Baffles
A device that direct the flow of the hot gases to effect efficient heat transfer
between the hot gases and the heated water.
 Blowdown valve
Is a valve through which the impurities that settle in the mud drum are
removed.
 Breeching
Is the duct that connects the boiler and chimney
 Breeching
Is the duct that connects the boiler and chimney


 Burner
Is the combustion equipment for firing liquid and gaseous fuels.
 Draft fans (Induced and Forced Draft)
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.
 Feed water heater
Is the free heating device which utilizes steam mixed and the feed water.
 Feed water pump

Is a device used to deliver water into the boiler.


 Furnace
A device that encloses the combustion equipment so that the heat
generated will be utilized effectively.
 Fusible plug
Is a metal plug with a definite melting point through which the steam is
released in case of excessive temperature which is usually caused by low
water level.
 Gage Glass (water column)
A device that indicates the water level existing in the boiler.
 Pressure gage
A device that indicates the pressure of the steam in the boiler.
 Safety valve
Is a safety device which automatically releases the steam in case of over-
pressure.

 Soot blower
Is a device which uses steam or compressed air to remove the soot that
has accumulated in the boiler tubes and drums.
 Temperature gage
A device that indicates the temperature of the steam in the boiler.
 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.


PERFORMANCE OF STEAM GENERATOR (BOILER) hs
Steam
 Heat Supplied by Fuel, Qs ms
𝑄𝑠 = 𝑚𝑓 𝑄ℎ 𝑚𝑓 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑓𝑢𝑒𝑙
𝑄ℎ = ℎ𝑖𝑔ℎ𝑒𝑟 ℎ𝑒𝑎𝑡𝑖𝑛𝑔 𝑣𝑎𝑙𝑢𝑒 Fuel
Qh
 Boiler Heating Surface, HS mf
The boiler heating surface is the total area in
m2 through which the heated water and hot
hf
gases exchange heat.
1 2 ms
𝐻𝑆 = 𝐴1 + 𝐴2 + 𝐴3 − 𝐴4
𝐴1 = 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙 = π𝐷𝐿 2 3
Feed water
𝐴2 = 𝑖𝑛𝑠𝑖𝑑𝑒 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑎𝑙𝑙 𝑡𝑢𝑏𝑒𝑠 = π𝑑1 𝐿𝑛
𝐷 = 𝑠ℎ𝑒𝑙𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
π𝐷 2 𝑑1 = 𝑖𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒
𝐴3 = 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑒𝑎𝑟 ℎ𝑒𝑎𝑑 =
4 𝑑𝑜 = 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒
π𝑑𝑜 2 𝑛 𝐿 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡𝑢𝑏𝑒
𝐴4 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 = 𝑛 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠
4


PERFORMANCE OF STEAM GENERATOR (BOILER)
 Rated Boiler Horsepower
The rated boiler Horsepower is the Manufacturer’s Rating equivalent to the
heating surface in m2 divided by 0.91 for water tube and 1.1 for Fire tube.
a.) For water tube boiler: 𝐻𝑆 (𝑚2)
𝑅𝑎𝑡𝑒𝑑 𝐵𝑜𝑖𝑙𝑒𝑟 𝐻𝑝 =
0.91
a.) For fire tube boiler: 𝐻𝑆 (𝑚2)

𝑅𝑎𝑡𝑒𝑑 𝐵𝑜𝑖𝑙𝑒𝑟 𝐻𝑝 =
1.1
 Developed Boiler Horsepower
The actual heat absorption divided by 35,322
𝑚𝑠 (ℎ𝑠 − ℎ𝑓 ) 1 𝐵𝑜 𝐻𝑃 = 35,322 𝑘𝐽/ℎ𝑟

𝐷𝑒𝑣𝑒𝑙𝑜𝑝𝑒𝑑 𝐵𝑜𝑖𝑙𝑒𝑟 𝐻𝑝 = 𝑚𝑠 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 𝑖𝑛 𝑘𝑔/ℎ𝑟
035,322
ℎ𝑠 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 𝑖𝑛 𝑘𝑔/ℎ𝑟
ℎ𝑓 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑓𝑒𝑒𝑑𝑤𝑎𝑡𝑒𝑟 𝑖𝑛 𝑘𝑔/ℎ𝑟


 Percent Rating
The ratio of the developed boiler Hp to rated boiler Hp.
𝐷𝑒𝑣𝑒𝑙𝑜𝑝𝑒𝑑 𝐵𝑜𝑖𝑙𝑒𝑟 𝐻𝑝
𝑃𝑒𝑟𝑐𝑒𝑛𝑡 𝑟𝑎𝑡𝑖𝑛𝑔 =
𝑅𝑎𝑡𝑒𝑑 𝐵𝑜𝑖𝑙𝑒𝑟 𝐻𝑝
 ASME evaporation units

is the heat output of the boiler or the rate at which heat is transformed.
𝐴𝑆𝑀𝐸 𝐸𝑣𝑎𝑝𝑜𝑟𝑎𝑡𝑖𝑜𝑛 𝑢𝑛𝑖𝑡𝑠 = 𝑚𝑠 (ℎ𝑠 − ℎ𝑓 )
 Factor of evaporation, FE
The actual heat absorption per kg of steam generated divided by 2,257 (hfg
from and at 100oC)
ℎ𝑠 − ℎ𝑓
𝐹𝐸 =
2,257


 Equivalent Evaporation
The product of the rate of evaporation of steam and factor of evaporation
𝐸𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑒𝑣𝑎𝑝𝑜𝑟𝑎𝑡𝑖𝑜𝑛 = 𝑚𝑠 (𝐹𝐸)
 Actual Specific Evaporation or Boiler Economy

The actual specific evaporation or boiler economy is the ratio of the mass
of steam to the mass of fuel
𝑚𝑠
𝐵𝑜 𝑒𝑐𝑜𝑛𝑜𝑚𝑦 =
𝑚𝑓
 Equivalent Specific Evaporation (Boiler Economy)

Is the product of the actual specific evaporation and the factor of
evaporation
𝑚𝑠
𝐸𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑒𝑣𝑎𝑝𝑜𝑟𝑎𝑡𝑖𝑜𝑛 = 𝐵𝑜. 𝐸𝑐𝑜𝑛𝑜𝑚𝑦 𝐹𝐸 = (𝐹𝐸)
𝑚𝑓


 Boiler Efficiency or Overall Thermal Efficiency
Is the measure of ability of a boiler or steam generator to transfer the heat
given it by the furnace to the water and steam
𝑚𝑠 ℎ𝑠 − ℎ𝑓 + 𝑚𝑟𝑠 ℎ𝑟𝑜 − ℎ𝑟𝑖 + 𝑚𝑏𝑜 (ℎ𝑏𝑜 − ℎ𝑓 )

𝑒𝑏𝑜 =
𝑚𝑓 𝑄ℎ
Note: if no re-heater and no boiler blowdown

𝑚𝑠 = 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚
𝑚𝑠 ℎ𝑠 − ℎ𝑓
𝑒𝑏𝑜 = 𝑚𝑟𝑠 = 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑟𝑒ℎ𝑒𝑎𝑡𝑒𝑑 𝑠𝑡𝑒𝑎𝑚
𝑚𝑓 𝑄𝐴 𝑚𝑏𝑜 = 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑏𝑙𝑜𝑤𝑑𝑜𝑤𝑛 𝑎𝑡 𝑏𝑜𝑖𝑙𝑒𝑟 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
ℎ𝑠 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚
ℎ𝑓 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑓𝑒𝑒𝑑𝑤𝑎𝑡𝑒𝑟
ℎ𝑟𝑜 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 𝑙𝑒𝑎𝑣𝑖𝑛𝑔 𝑡ℎ𝑒 𝑟𝑒ℎ𝑒𝑎𝑡𝑒𝑟
ℎ𝑟𝑖 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 𝑒𝑛𝑡𝑒𝑟𝑖𝑛𝑔 𝑡ℎ𝑒 𝑟𝑒ℎ𝑒𝑎𝑡𝑒𝑟
ℎ𝑏𝑜 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑠𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑙𝑖𝑞𝑢𝑖𝑑 𝑎𝑡 𝑏𝑜𝑖𝑙𝑒𝑟 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒


 Net Boiler Efficiency
Is the boiler efficiency less the energy consumed by accessories.
𝑚𝑠 ℎ𝑠 − ℎ𝑓 − 𝑒𝑛𝑒𝑟𝑔𝑦 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑 𝑏𝑦 𝑎𝑐𝑐𝑒𝑠𝑠𝑜𝑟𝑖𝑒𝑠
𝑒𝑏𝑜 𝑛𝑒𝑡 =
𝑚𝑓 𝑄ℎ
 Boiler and Furnace Efficiency

𝑚𝑎𝑠ℎ = 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑎𝑠ℎ 𝑟𝑒𝑓𝑖𝑟𝑒𝑑
𝑚𝑠 ℎ𝑠 − ℎ𝑓
𝑒𝑏𝑓 = 𝑄𝑎𝑠ℎ = ℎ𝑒𝑎𝑡𝑖𝑛𝑔 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑎𝑠ℎ
𝑚𝑓 𝑄ℎ − 𝑚𝑎𝑠ℎ 𝑄𝑎𝑠ℎ
 Grate Efficiency
1 − 𝑚𝑐 𝑄𝑐 𝑚𝑐 = 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑐𝑎𝑟𝑏𝑜𝑛 𝑖𝑛 𝑟𝑒𝑓𝑢𝑠𝑒 𝑜𝑟 𝑎𝑠ℎ
𝑒𝑔𝑟𝑎𝑡𝑒 = 𝑄𝑐 = ℎ𝑒𝑎𝑡𝑖𝑛𝑔 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑐𝑜𝑚𝑏𝑢𝑠𝑡𝑖𝑏𝑙𝑒 𝑖𝑛 𝑟𝑒𝑓𝑢𝑠𝑒 𝑜𝑟 𝑎𝑠ℎ
𝑄ℎ


STEAM PRIME MOVERS
Machine which originates mechanical motion using some of natural force. All
heat engines are prime movers such as steam engines and turbine.
 Steam Turbine
Is a prime mover for the conversion of heat energy of steam into work on a
revolving shaft, utilizing fluid acceleration principles in jet and vane
machinery.
h1 Turbine Generator
output output
steam
h2
H2O in
condenser
H2O out
hf2


PERFORMANCE OF STEAM TURBINES
 Ideal Turbine Work  Electrical or Generator Efficiency
𝑊𝑡𝑖 = 𝑚𝑠 ℎ1 − ℎ2 𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟 𝑜𝑢𝑡𝑝𝑢𝑡
𝑒𝑔 =
𝑡𝑢𝑟𝑏𝑖𝑛𝑒 𝑜𝑢𝑡𝑝𝑢𝑡
 Actual Turbine Work  Brake Thermal Efficiency

𝑊𝑡𝑎 = 𝑚𝑠 ℎ1 − ℎ2𝑎 𝑡𝑢𝑟𝑏𝑖𝑛𝑒 𝑜𝑢𝑡𝑝𝑢𝑡 ℎ1 − ℎ2 𝑒𝑡
𝑒𝑡𝑏 = =
𝑚𝑠 ℎ1 − ℎ𝑓2 𝑚𝑠 ℎ1 − ℎ𝑓2
𝑊𝑡𝑎 = 𝑚𝑠 ℎ1 − ℎ2𝑎 𝑒𝑠
ℎ2𝑎 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑎𝑓𝑡𝑒𝑟 𝑎𝑐𝑡𝑢𝑎𝑙 𝑒𝑥𝑝𝑎𝑛𝑠𝑖𝑜𝑛
𝑒𝑠 = 𝑠𝑡𝑎𝑔𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
 Combined/Overall Thermal Efficiency
𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟 𝑜𝑢𝑡𝑝𝑢𝑡 ℎ1 − ℎ2 𝑒𝑡 𝑒𝑔
𝑒𝑡𝑏 = =
 Turbine Power Output 𝑚𝑠 ℎ1 − ℎ𝑓2 𝑚𝑠 ℎ1 − ℎ𝑓2
𝑃𝑡 = 𝑚𝑠 ℎ1 − ℎ2 𝑒𝑡
𝑒𝑡 = 𝑡𝑢𝑟𝑏𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦


PERFORMANCE OF STEAM TURBINES
 Ideal Rankine Thermal Efficiency
ℎ1 − ℎ2
𝑒𝑡𝑟 =
ℎ1 − ℎ𝑓2
 Brake Engine Efficiency

𝐵𝑟𝑎𝑘𝑒 𝑃𝑜𝑤𝑒𝑟
𝑒𝑒𝑏 =
𝑚𝑠 ℎ1 − ℎ2
 Combined or Overall Engine Efficiency

𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟 𝑂𝑢𝑡𝑝𝑢𝑡
𝑒𝑒𝑏 =


 Steam Engine
A device for the conversion of heat in steam into work, generally in the
form of a positive displacement, piston and cylinder mechanism.
steam h1 h
d
h1
D
actual
h2a ideal
h2
h2
Indicated power H2O in
condenser
s
H2O out Brake Power

hf2


 Volume displacement  Brake Power, Pb
If Piston rod is neglected: 𝑃𝑏 = 𝑃𝑚𝑏 𝑉𝐷
π𝐷 2 π𝐷 2 𝐿𝑁
𝑉𝐷 = 2 𝐿𝑁 = 𝑃𝑏 = 2π𝑇𝑁
4 2
 Friction Power, Pf
If Piston rod is considered:
𝑃𝑓 = 𝑃𝑖𝑛𝑑 − 𝑃𝑏
π𝐷2 π 2
𝑉𝐷 = 𝐿𝑁 + 𝐷 − 𝑑 2 𝐿𝑁
4 4
 Mechanical Efficiency, emech
π𝐷 2 π𝑑 2
𝑉𝐷 = 2 𝐿𝑁 − 𝐿𝑁 𝑃𝑏
4 4 𝑒𝑚𝑒𝑐ℎ =
𝑃𝑖𝑛𝑑
 Indicated Power, Pind
𝑃𝑖𝑛𝑑 = 𝑃𝑚𝑖 𝑉𝐷


 Indicated Thermal Efficiency, eti  Brake Engine Efficiency, eeb
𝑃𝑖𝑛𝑑 𝑃𝑏
𝑒𝑡𝑖 = 𝑒𝑒𝑏 =
𝑚𝑠 ℎ1 − ℎ𝑓2 𝑚𝑠 ℎ1 − ℎ2
 Brake Thermal Efficiency, etb  Equivalent Rankine Cycle Efficiency, erc

𝑃𝑏 ℎ1 − ℎ2
𝑒𝑡𝑏 = 𝑒𝑟𝑐 =
𝑚𝑠 ℎ1 − ℎ𝑓2 ℎ1 − ℎ𝑓2
 Indicated Engine Efficiency, eei
𝑃𝑖𝑛𝑑
𝑒𝑡𝑖 =


 Steam Condenser
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.
CLASSIFICATION OF STEAM CONDENSERS

 Surface Condenser: is a heat transfer device used to condense a steam
under vacuum, absorbing its latent heat in cooling fluid, ordinarily water.
It is a device in which the steam and cooling water do not mix
 Contact Condenser: is a heat transfer device in which the steam is

brought into direct contact with a cooling liquid such as water and is
condensed by giving up its latent heat to the liquid.
Heat Balance in the Condenser

𝐻𝑒𝑎𝑡 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑 𝑏𝑦 𝑤𝑎𝑡𝑒𝑟 = ℎ𝑒𝑎𝑡 𝑟𝑒𝑗𝑒𝑐𝑡𝑒𝑑 𝑏𝑦 𝑠𝑡𝑒𝑎𝑚
𝐸ℎ = ℎ𝑒𝑎𝑡 𝑒𝑥𝑡𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟
𝑚𝑤 𝐶𝑝𝑤 𝑡2 − 𝑡1 = 𝑚𝑠 ℎ𝑠 − ℎ𝑓 𝐸ℎ

Vacuum Efficiency:
𝑃𝑎𝑡𝑚 = 𝑎𝑡𝑚𝑜𝑠𝑝ℎ𝑒𝑟𝑖𝑐 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒

𝑃𝑎𝑡𝑚 − 𝑃𝑠𝑎𝑡
𝑒𝑣 = 𝑃𝑠𝑎𝑡 = 𝑠𝑎𝑡𝑢𝑟𝑎𝑡𝑖𝑜𝑛 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑎𝑡 𝑎 𝑔𝑖𝑣𝑒𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑖𝑛𝑠𝑖𝑑𝑒 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟
𝑃𝑎𝑡𝑚 − 𝑃𝑡𝑜𝑡𝑎𝑙
𝑃𝑡𝑜𝑡𝑎𝑙 = 𝑡𝑜𝑡𝑎𝑙 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒


 Feed water Pump
A device used to pump boiler feedwater.
ℎ2
 Pump Work, Wp 𝑚
𝑊𝑝 = 𝑚(ℎ2 − ℎ1 ) ℎ1
𝑊𝑝 = 𝑚𝑉1 (𝑃2 − 𝑃1 )
 Power Input of the Pump:

𝑝𝑢𝑚𝑝 𝑤𝑜𝑟𝑘 𝑚 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑙𝑜𝑤
𝑊𝑝𝑖𝑛 = 𝑉1 = 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑣𝑜𝑙𝑢𝑚𝑒
𝑝𝑢𝑚𝑝 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝑃1 = 𝑒𝑛𝑡𝑟𝑎𝑛𝑐𝑒 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝑚(ℎ2 − ℎ1 ) 𝑃2 = 𝑒𝑥𝑖𝑡 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒

𝑊𝑝𝑖𝑛 =
𝑒𝑝

SUMMARY
-End-
SUMMARY
References:
 Power Plant Engineering, R. S. Capote and J. A. Mandawe, JRT
Publishers, 2001

ME 522 - Power Plant Engineering - Review Problems

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Aurora State College of Technology

STEAM POWER PLANT

POWER PLANT ENGINEERING

Course Code: ME 522

ENGR. ALKING B. GOROSPE, PhD

Image: Power Plant Characteristics and Costs by Stan Kaplan

STEAM POWER PLANT (Formulas)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

 Boiler (Heat added, QA)

𝑊𝑡 = 𝑚 ℎ1 − ℎ2 + 𝐾𝐸1 − 𝐾𝐸2 , (𝑘𝑊)

𝑚 = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 𝑖𝑛

Power Plant Engineering

STEAM POWER PLANT (Formulas)

 Pump (Work, Wp)

(Exact work) (Approximate work)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

 Net Cycle (Work, Wnet)  Steam rate (SR)

 Thermal efficiency (eth)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

Solution: Solving for h2:

Power Plant Engineering

STEAM POWER PLANT (Formulas)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

 Boiler (Heat added, QA)

 Turbine (Work, Wt) h6

Power Plant Engineering

STEAM POWER PLANT (Formulas)

 Pump (Work, Wp)

(Exact work) (Approximate work)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

 Net Cycle (Work, Wnet)  Steam rate (SR)

 Thermal efficiency (eth)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

Solution: 𝑣5 = 𝑣𝑓 @ 0.0034 𝑀𝑃𝑎

Power Plant Engineering

STEAM POWER PLANT (Formulas)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

Power Plant Engineering

STEAM POWER PLANT (Formulas)

 Boiler (Heat added, QA) h1

 Turbine (Work, Wt) h7

Power Plant Engineering

STEAM POWER PLANT (Formulas)

Power Plant Engineering

STEAM POWER PLANT (Formulas)