Bicol University

College of Engineering
Mechanical Engineering Department
A.Y. 2021 - 2022

4400 kW Thermal Power Plant

Submitted to:

ENGR. AGERICO U. LLOVIDO, PME

Professor, ME 415

Submitted by:

BARQUEZ, LORD JIREH C.

CILLAN, CYRENE C.
DE LA TORRE, ADRIAN JONES C.
FERRER, MELLEGEL Y.
ORONAN, ADNEIL KYLE JOSEPH B.

1
 TABLE OF CONTENTS

Front Page 1
Schematic and T-S Diagram 3
Heat Balance and Schematic Diagrams with Flows, Temperatures and Enthalpies 4
Turbine Generator Design 14
Boiler Design 16
Condenser Design 19
Deaerator Design 24
Boiler Feed Pump Design 27
Condensate Pump Design 29
Piping Design (Steam and Condensate Water) 31
Forced Draft Fan Design 36
Stack Design 39

FIGURES AND TABLES

Plant Layout of Regenerative Cycle with One Stage of Extraction for Feedwater Heating 3
T-S Diagram with One Stage of Extraction for Feedwater Heating 3
Plate 15: Dimensions of Westinghouse, Single Automatic Extraction, Condensing, 15
3600-RPM Turbine Generator Units
Plate 13: Boiler Dimensions 18
Fig. 8-9: Heat-transfer curves for surface condensers 20
Fig. 8-11: Friction Loss for No. 18 BWG Condenser Tubes and Water Boxes 21
Fig. 8-2: Approximate Tube Lengths for Surface Condensers 23
Plate 14: Dimensions of Westinghouse Two-pass, Non-divided Water box, Radial-flow 24
Surface Condensers
Plate 9: Deaerator Dimensions 26
Plate 11: Boiler Feed Pumps Dimensions 28
Plate 1: Physical Properties of Pipes 32
Plate 10: Fan Dimensions 38

2
 The Ideal Regenerative Cycle with One Stage of Extraction for
Feedwater Heating
1

1 lb

TURBINE GENERATOR

(1-m)
3
Boiler
(Steam Generator Unit) 2
CONDENSER

7 4
6 DEARATOR 5
FEEDWATER
HEATER
1 lb

BOILER CONDENSATE
FEED PUMP PUMP
Plant Layout of Regenerative Cycle with One Stage of Extraction for
Feedwater Heater

1
Temperature, T (°F)

6 2

4 3

Entropy, S (𝑩𝒕𝒖ൗ𝒍𝒃 ∙ 𝑹)

3
 T-S Diagram with One Stage Extraction for Feedwater Heating
CONTENTS
1. Heat Balance and Schematic Diagram with Flows, Temperature and Enthalpies

A. HEAT BALANCE CALCULATION (Design A)

AT STATE POINT 1:
P1 = 650 Psig + 14. 696 (atm) = 664.696 Psia

t1 = 700 °F

From Steam Table:

P (Psia) h (BTU/lb) S (BTU/lb⋅R)

650 1348.7 1.5775
664.696 h1 S1
700 1345.6 1.5673

By Interpolation:
664.696 − 650 ℎ1 − 1348.7 𝑆1 − 1.5775
= =
700 − 650 1345.6 − 1348.7 1.5775 − 1.5673
ℎ1 = 1347.7888

𝑆1 = 1.5805 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅
AT STATE POINT 2:

P2 = 65 Psia

𝑆2 = 𝑆1 = 1.5805 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅
From Steam Table:

t (°F) P (Psia) Sf (BTU/lb⋅R) Sfg (BTU/lb⋅R) hf (BTU/lb) hg (BTU/lb)

296 63.084 0.4317 1.2082 265.6 913
t2 65 Sf2 Sfg2 hf2 hfg2
300 67.005 0.4372 1.1979 269.7 910

By Interpolation:
65 − 63.084 𝑡2 − 296 𝑆𝑓2 − 0.4317 𝑆𝑓𝑔2 − 1.2082 ℎ𝑓2 − 265.6
= = = =
67.005 − 63.084 300 − 296 0.4372 − 0.4317 1.1979 − 1.2082 269.7 − 265.6
ℎ𝑓𝑔2 − 913
=
910 − 913
𝑡2 = 297.9546 ℉

4
 𝑆𝑓2 = 0.4344 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅

𝑆𝑓𝑔2 = 1.2032 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅

ℎ𝑓2 = 267.6035 𝐵𝑡𝑢/𝑙𝑏

ℎ𝑓𝑔2 = 911.5340 𝐵𝑡𝑢/𝑙𝑏

Solving for 𝑋2 :
𝑆2 = 𝑆𝑓2 + 𝑥2 𝑆𝑓𝑔2
𝑆2 − 𝑆𝑓2 1.5805 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅 − 0.4344 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅
𝑥2 = =
𝑆𝑓𝑔2 1.2032 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅

𝑥2 = 0.9525

ℎ2 = ℎ𝑓2 + 𝑥2 ℎ𝑓𝑔2

ℎ2 = 267.6035 𝐵𝑡𝑢/𝑙𝑏 + (0.9525)(911.5340 𝐵𝑡𝑢/𝑙𝑏)

ℎ2 = 1135.8396 𝐵𝑡𝑢/𝑙𝑏

AT STATE POINT 3:
P3 = 3 in. Hg = 1.4735 Psia

S3 =S2 = 1.5805 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅

From Steam Table

P (Psia) t (°F) hf (BTU/lb) hfg (BTU/lb) Sf (BTU/lb⋅R) Sfg (BTU/lb⋅R)

1.4299 114 81.97 1029.1 0.1542 1.7938
1.4735 t3 hf3 hfg3 Sf3 Sfg3
1.5133 116 83.97 1027.9 0.1577 1.7856

By Interpolation:
1.4735 − 1.4299 𝑡3 − 114.0 ℎ𝑓3 − 81.97 ℎ𝑓𝑔3 − 1029.1 𝑆𝑓3 − 0.1542
= = = =
1.5133 − 1.4299 116.0 − 114.0 83.97 − 81.97 1027.9 − 1029.1 0.1577 − 0.1542
𝑆𝑓𝑔3 − 1.7938
=
1.7856 − 1.7938
𝑡3 = 115.0456 ℉
ℎ𝑓3 = 83.0156 𝐵𝑡𝑢/𝑙𝑏

ℎ𝑓𝑔3 = 1028.4727 𝐵𝑡𝑢/𝑙𝑏

5
 𝑆𝑓3 = 0.1560 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅

𝑆𝑓𝑔3 = 1.7895 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅

Solving for X3:

𝑆3 = 𝑆𝑓3 + 𝑥3 𝑆𝑓𝑔3
𝑆2 − 𝑆𝑓3 1.5805 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅 − 0.1560 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅
𝑥3 = =
𝑆𝑓𝑔3 1.7895 𝐵𝑡𝑢/𝑙𝑏 ∙ 𝑅

𝑥3 = 0.7960

ℎ3 = ℎ𝑓3 + 𝑥3 ℎ𝑓𝑔3

ℎ3 = 83.0156 𝐵𝑡𝑢/𝑙𝑏 + (0.7960)(1028.4727 𝐵𝑡𝑢/𝑙𝑏)

ℎ3 = 901.6799 𝐵𝑡𝑢/𝑙𝑏

AT STATE POINT 4:

P4 = 3 in. Hg = 1.4735 Psia

h4 = hf3 =hf4 = 83.0156 𝐵𝑡𝑢/𝑙𝑏

t4 = t3 =115.0456 ℉

From Steam Table:

P (Psia) v (Ft3/lb)
1.4299 0.016180
1.4735 vf4
1.5133 0.016188

1.4735 − 1.4299 𝑣𝑓4 − 0.016180

=
1.5133 − 1.4299 0.016188 − 0.016180
𝑣4 = 𝑣𝑓4 = 0.016184 𝑓𝑡 3 /𝑙𝑏

AT STATE POINT 5:
From Power Plant Theory and Design by Philip J. Potter Chapter 11 p.512

− there is an estimate of 5 % pressure loss in the turbine flanges

Emg = 100% − 5% = 95%
P5 = 65 Psia (0.95) = 61.75 Psia

6
 ℎ5 = ℎ4 + 𝑣4 (𝑃5 − 𝑃4 )

ℎ5 = 83.0156 𝐵𝑡𝑢/𝑙𝑏 + (0.016184 𝑓𝑡 3 /𝑙𝑏) (61.75 Psia

𝑙𝑏
1 2 144𝑖𝑛2 1𝐵𝑡𝑢
− 1.4735 Psia) ( 𝑖𝑛 )( )( )
1 𝑃𝑠𝑖𝑎 1 𝑓𝑡 2 778.169𝑓𝑡 ∙ 𝑙𝑏𝑓

ℎ5 = 83.1961 𝐵𝑡𝑢/𝑙𝑏
83.1961 − 83.0156
𝑡5 = 115.0456 ℉ +
1
𝑡5 = 115.2261 ℉
AT STATE POINT 6:

P6 = P5 = 65 Psia (0.95) = 61.75 Psia

From Steam Table:

P (Psia) T (°𝐅) hf (Btu/lb) vf (Btu/lb⋅R)

63.084 296 265.6 0.01738
61.75 t6 hf6 vf6
67.005 300 269.7 0.01741

By Interpolation:
61.75 − 63.084 𝑡6 − 296 ℎ𝑓6 − 265.6 𝑣𝑓6 − 0.01738
= = =
67.005 − 63.084 300 − 296 269.7 − 265.6 0.01741 − 0.01738
𝑡6 = 294.6391 ℉
ℎ6 = ℎ𝑓6 = 264.2051 𝐵𝑡𝑢/𝑙𝑏

𝑣6 = 𝑣𝑓6 = 0.01737 𝑓𝑡 3 /𝑙𝑏

AT STATE POINT 7:

P7 = P1 = 650 Psig + 14. 696 (atm) = 664.696 Psia

ℎ7 = ℎ6 + 𝑣6 (𝑃7 − 𝑃6 )

ℎ7 = 264.2051 𝐵𝑡𝑢/𝑙𝑏 + (0.01737 𝑓𝑡 3 /𝑙𝑏)(664.696 𝑃𝑠𝑖𝑎

𝑙𝑏
1 2 144𝑖𝑛2 1𝐵𝑡𝑢
− 61.75 𝑃𝑠𝑖𝑎) ( 𝑖𝑛 ) ( 2 )( )
1 𝑃𝑠𝑖𝑎 1 𝑓𝑡 778.169𝑓𝑡 ∙ 𝑙𝑏𝑓

ℎ7 = 266.1432 𝐵𝑡𝑢/𝑙𝑏
266.1432 − 264.2051
𝑡7 = 294.6391 ℉ +
1
𝑡7 = 296.5772 ℉

7
TABULATION OF STATE POINTS:

STATE PRESSURE (Psia) TEMPERATURE (℉) ENTHALPHIES (Btu/lb)

1 664.696 700 1347.7888
2 65 297.9546 1135.8396
3 1.4735 115.0456 901.6799
4 1.4735 115.0456 83.0156
5 61.75 115.2261 83.1961
6 61.75 294.6391 264.2051
7 664.696 296.5772 266.1432

CYCLE ANALYSIS:
Basis: 1 lb throttle steam

Mass of Bled Steam, m

ℎ2
2

1 𝑙𝑏 𝑚5
OPEN HEATER
ℎ6 6 5 ℎ5

Mass Balance:
𝑚𝑖𝑛 = 𝑚𝑜𝑢𝑡

𝑚5 + 𝑚 = 1
𝑚5 = 1 − 𝑚

Energy Balance:

𝐸𝑖𝑛 = 𝐸𝑜𝑢𝑡
𝑚(ℎ2 ) + 𝑚𝑠 ℎ𝑠 = 𝑚6 ℎ6

𝑚(ℎ2 ) + (1 − 𝑚)ℎ5 = 1ℎ6

𝑚ℎ2 + ℎ5 − 𝑚ℎ5 = ℎ6

𝑚ℎ2 − 𝑚ℎ5 = ℎ6 − ℎ5
𝑚(ℎ2 − ℎ5 ) = ℎ6 − ℎ5
ℎ6 − ℎ5
𝑚=
ℎ2 − ℎ5
264.2051 − 83.1961
𝑚=
1135.8396 − 83.1961
𝑚 = 0.1720 𝑙𝑏/𝑙𝑏 𝑜𝑓 𝑡ℎ𝑟𝑜𝑡𝑡𝑙𝑒 𝑠𝑡𝑒𝑎𝑚

8
Alternate method:

Heat balance:
𝑚(ℎ2 − ℎ6 ) = 𝑚5 (ℎ6 − ℎ5 )

= (1 − 𝑚)( ℎ6 − ℎ5 )
𝑚ℎ2 − 𝑚ℎ6 = ℎ6 − ℎ5 − 𝑚ℎ6 − 𝑚ℎ5

𝑚ℎ2 − 𝑚ℎ5 = ℎ6 − ℎ5

𝑚(ℎ2 − ℎ5 ) = ℎ6 − ℎ5
ℎ6 − ℎ5
𝑚=
ℎ2 − ℎ5
264.2051 − 83.1961
𝑚=
1135.8396 − 83.1961
𝑚 = 0.1720 𝑙𝑏/𝑙𝑏 𝑜𝑓 𝑡ℎ𝑟𝑜𝑡𝑡𝑙𝑒 𝑠𝑡𝑒𝑎𝑚

Turbine work:

TURBINE

2
3
2

Energy Balance:
𝐸𝑖𝑛 = 𝐸𝑜𝑢𝑡

ℎ1 = 𝑚ℎ2 + (1 − 𝑚)ℎ3 + 𝑊
𝑊 = ℎ1 − 𝑚ℎ2 − (1 − 𝑚)ℎ3
𝐵𝑡𝑢 𝐵𝑡𝑢 𝐵𝑡𝑢
𝑊 = 1347.7888 − 0.1720 (1135.8396 ) − (1 − 0.1720) (901.6799 )
𝑙𝑏 𝑙𝑏 𝑙𝑏
𝑊 = 405.8334 𝐵𝑡𝑢/𝑙𝑏
Solving for ms:
4400 𝑘𝑊
𝑚𝑠 =
𝑊

9
 𝐵𝑡𝑢
4400 𝑘𝑊 (3412 )
𝑚𝑠 = 𝑘𝑊 ∙ ℎ𝑟
405.8334 𝐵𝑡𝑢/𝑙𝑏
𝑚𝑠 = 36992.5196 𝑙𝑏/ℎ𝑟
Heat Balance in the Deaerator:

𝐸𝑖𝑛 = 𝐸𝑜𝑢𝑡
(𝑚𝑠 − 𝑚2 )ℎ𝑠 + 𝑚2 ℎ2 = 𝑚𝑠 ℎ6

𝑚𝑠 ℎ𝑠 − 𝑚2 ℎ𝑠 + 𝑚2 ℎ2 = 𝑚𝑠 ℎ6
𝑚2 ℎ2 − 𝑚2 ℎ𝑠 = 𝑚𝑠 ℎ6 − 𝑚𝑠 ℎ𝑠

𝑚2 (ℎ2 − ℎ𝑠 ) = 𝑚𝑠 (ℎ6 − ℎ𝑠 )
𝑚𝑠 (ℎ6 − ℎ𝑠 )
𝑚2 =
(ℎ2 − ℎ𝑠 )
𝐵𝑡𝑢 𝐵𝑡𝑢
36992.5196 𝑙𝑏/ℎ𝑟 (264.2051 − 83.1961 )
𝑚2 = 𝑙𝑏 𝑙𝑏
𝐵𝑡𝑢 𝐵𝑡𝑢
1135.8396 − 83.1961
𝑙𝑏 𝑙𝑏
𝑚2 = 6361.1080 𝑙𝑏/ℎ𝑟
Heat Supplied, QA

Boiler: 1

𝑄𝐴

𝐸𝑖𝑛 = 𝐸𝑜𝑢𝑡

𝑄𝐴 + 𝑚𝑠 ℎ7 = 𝑚𝑠 ℎ1
𝑄𝐴 = 𝑚𝑠 ℎ1 − 𝑚𝑠 ℎ7

𝑄𝐴 = 𝑚𝑠 (ℎ1 − ℎ7 )
𝐵𝑡𝑢 𝐵𝑡𝑢 1 ℎ𝑟
𝑄𝐴 = (36992.5196 𝑙𝑏/ℎ𝑟) (1347.7888 − 266.1432 )( )
𝑙𝑏 𝑙𝑏 3600𝑠
𝑄𝐴 = 11114.6656 𝐵𝑡𝑢/𝑠

10
Heat Rejected, QR

𝑚3 = 𝑚4
𝑚3 = 𝑚𝑠 − 𝑚2

𝑚3 = (36992.5196 − 6361.1080) 𝑙𝑏/ℎ𝑟

𝑚3 = 30631.4116 𝑙𝑏/ℎ𝑟
3

CONDENSER

4
𝐸𝑖𝑛 = 𝐸𝑜𝑢𝑡
𝑚3 ℎ3 = 𝑄𝑅 + 𝑚4 ℎ4

𝑄𝑅 = 𝑚3 ℎ3 − 𝑚4 ℎ4
𝑄𝑅 = 𝑚3 (ℎ3 − ℎ4 )
𝐵𝑡𝑢 𝐵𝑡𝑢 1 ℎ𝑟
𝑄𝑅 = (30631.4116 𝑙𝑏/ℎ𝑟) (901.6799 − 83.0156 )( )
𝑙𝑏 𝑙𝑏 3600𝑠
𝑄𝑅 = 6965.7898 𝐵𝑡𝑢/𝑠

Design of Turbine Generator:

5
Multiply or 1.25 the kW and also the flow rates
4

Turbine Design: 1

𝑚𝑠 = 36992.5196 𝑙𝑏/ℎ𝑟
𝑚2 = 6361.1080 𝑙𝑏/ℎ𝑟 TURBINE
𝑚3 = 𝑚𝑠 − 𝑚2
2
𝑚3 = (36992.5196 − 6361.1080) 𝑙𝑏/ℎ𝑟 3
2
𝑚3 = 30631.4116 𝑙𝑏/ℎ𝑟

11
Design Value (Multiply by 5/4 or 1.25)

𝑚𝑠 = 36992.5196 𝑙𝑏ൗℎ𝑟 (1.25)

𝑚𝑠 = 46240.6495 𝑙𝑏ൗℎ𝑟 1

𝑚2 = 6361.1080 𝑙𝑏ൗℎ𝑟 (1.25)

𝑚2 = 7951.385 𝑙𝑏ൗℎ𝑟 TURBINE

𝑚3 = 30631.4116 𝑙𝑏ൗℎ𝑟 (1.25)

2
3
𝑚3 = 38289.2645 𝑙𝑏ൗℎ𝑟 2

Boiler Design
1

𝑄𝐴

𝑄𝐴 = 11114.6656 𝐵𝑡𝑢/𝑠

𝑚𝑠 = 46240.6495 𝑙𝑏ൗℎ𝑟

𝑚7 = 46240.6495 𝑙𝑏ൗℎ𝑟

3
Condenser Design

CONDENSER

4
𝐹𝑙𝑜𝑤 = 𝑚3 = 𝑚𝑠 − 𝑚2

𝑚3 = 36992.5196 𝑙𝑏ൗℎ𝑟 − 6361.1080 𝑙𝑏ൗℎ𝑟

𝑚3 = 30631.4116 𝑙𝑏ൗℎ𝑟

12
Deaerator Design
2

DEARATOR
FEEDWATER
6 HEATER 5

𝑚5 = 𝑚3 = 30631.4116 𝑙𝑏ൗℎ𝑟

𝐸𝑖𝑛 = 𝐸𝑜𝑢𝑡

𝑚6 = 𝑚2 + 𝑚5

𝑚6 = 6361.1080 𝑙𝑏ൗℎ𝑟 + 30631.4116 𝑙𝑏ൗℎ𝑟

𝑚6 = 36992.5196 𝑙𝑏ൗℎ𝑟

Boiler Feed Pump Design

7 6

Boiler Feed Pump Design

𝐹𝑙𝑜𝑤 = 𝑚6 = 𝑚𝑠 = 36992.5196 𝑙𝑏ൗℎ𝑟

Condensate Pump Design

5 4

Condensate Pump Design

𝐹𝑙𝑜𝑤 = 𝑚5 = 𝑚4 = 30631.4116 𝑙𝑏ൗℎ𝑟

13
 2. Turbine Generator Design

Design Conditions for Turbine generator: 97% mechanical efficiency, 95% generator
efficiency, straight-line condition curve, design point is 5/4 load, 65-Psia automatic
extraction and 10-Psia nonautomatic extraction pressures, steam conditions 650 Psig, 700
°F, and 3 in. Hg.
𝑊1 ℎ1 − 𝑊2 ℎ2
𝑇𝑢𝑟𝑏𝑖𝑛𝑒 ℎ𝑒𝑎𝑡 𝑟𝑎𝑡𝑒 =
𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟 𝑜𝑢𝑡𝑝𝑢𝑡 𝑖𝑛 𝑘𝑊
where:

𝑊1 = 𝑠𝑡𝑒𝑎𝑚 𝑒𝑛𝑡𝑒𝑟𝑖𝑛𝑔 𝑡ℎ𝑒 𝑐𝑦𝑐𝑙𝑒, 𝑏 𝑝𝑒𝑟 ℎ𝑟,

𝑊2 = 𝑓𝑒𝑒𝑑𝑤𝑎𝑡𝑒𝑟 𝑙𝑒𝑎𝑣𝑖𝑛𝑔 𝑡ℎ𝑒 𝑐𝑦𝑐𝑙𝑒 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 ℎ𝑖𝑔ℎ𝑒𝑠𝑡 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 ℎ𝑒𝑎𝑡𝑒𝑟

ℎ1 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝ℎ𝑦 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 𝑒𝑛𝑡𝑒𝑟𝑖𝑛𝑔 𝑡ℎ𝑒 𝑐𝑦𝑐𝑙𝑒, 𝑡𝑢 𝑝𝑒𝑟 𝑙𝑏
ℎ2 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝ℎ𝑦 𝑜𝑓 𝑓𝑒𝑒𝑑𝑤𝑎𝑡𝑒𝑟 𝑙𝑒𝑎𝑣𝑖𝑛𝑔 𝑐𝑦𝑐𝑙𝑒, 𝑡𝑢 𝑝𝑒𝑟 𝑙𝑏

Solving for Turbine Heat Rate:

𝑊1 = 36992.5196 𝑙𝑏/ℎ𝑟
𝑊2 = 6361.1080 𝑙𝑏/ℎ𝑟
𝐵𝑡𝑢
ℎ1 = 1347.7888
𝑙𝑏
𝐵𝑡𝑢
ℎ2 = 1135.8396
𝑙𝑏

𝑇𝑢𝑟𝑏𝑖𝑛𝑒 ℎ𝑒𝑎𝑡 𝑟𝑎𝑡𝑒

𝐵𝑡𝑢 𝐵𝑡𝑢
(36992.5196 𝑙𝑏/ℎ𝑟) (1347.7888 ) − (6361.1080 𝑙𝑏/ℎ𝑟) (1135.8396 )
= 𝑙𝑏 𝑙𝑏
4400 𝑘𝑊
𝑩𝒕𝒖
𝑻𝒖𝒓𝒃𝒊𝒏𝒆 𝒉𝒆𝒂𝒕 𝒓𝒂𝒕𝒆 = 𝟗𝟔𝟖𝟗. 𝟐𝟗𝟔𝟔
𝒌𝑾 ∙ 𝒉𝒓

(𝑊1 − 𝑊3 )ℎ1 + 𝑊4 ℎ4 − 𝑊2 ℎ2
𝐺𝑟𝑜𝑠𝑠 𝑆𝑡𝑎𝑡𝑖𝑜𝑛 ℎ𝑒𝑎𝑡 𝑟𝑎𝑡𝑒 =
𝐸𝑏 (𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟 𝑜𝑢𝑡𝑝𝑢𝑡, 𝑘𝑊)

where:

𝑊3 = S𝑡𝑒𝑎𝑚 𝑙𝑜𝑠𝑡 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑡ℎ𝑒 𝑏𝑜𝑖𝑙𝑒𝑟 𝑎𝑛𝑑 𝑡𝑢𝑟𝑏𝑖𝑛𝑒, 𝑏 𝑝𝑒𝑟 ℎ𝑟

𝑊4 = W𝑎𝑡𝑒𝑟 𝑙𝑜𝑠𝑡 𝑎𝑠 𝑏𝑜𝑖𝑙𝑒𝑟 𝑏𝑙𝑜𝑤𝑑𝑜𝑤𝑛, 𝑏 𝑝𝑒𝑟 ℎ𝑟

ℎ4 = E𝑛𝑡ℎ𝑎𝑙𝑝ℎ𝑦 𝑜𝑓 𝑏𝑙𝑜𝑤𝑑𝑜𝑤𝑛, 𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑙𝑖𝑞𝑢𝑖𝑑 𝑎𝑡 𝑏𝑜𝑖𝑙𝑒𝑟 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒, 𝐵𝑡𝑢 𝑝𝑒𝑟 𝑙𝑏

𝐸𝑏 = B𝑜𝑖𝑙𝑒𝑟 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

14
Solving for Gross station heat rate,
(𝑊1 + 𝑊3 )ℎ1 + 𝑊4 ℎ4 − 𝑊2 ℎ2
𝐺𝑟𝑜𝑠𝑠 𝑆𝑡𝑎𝑡𝑖𝑜𝑛 ℎ𝑒𝑎𝑡 𝑟𝑎𝑡𝑒 =
𝐸𝑏 (𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟 𝑜𝑢𝑡𝑝𝑢𝑡, 𝑘𝑊)
𝐵𝑡𝑢 𝐵𝑡𝑢 𝐵𝑡𝑢
(𝟑𝟔𝟗𝟗𝟐. 𝟓𝟏𝟗𝟔𝑙𝑏/ℎ𝑟 + 30631.4116𝑙𝑏/ℎ𝑟) (1347.7888 ) + (30631.4116𝑙𝑏/ℎ𝑟) (83.0156 ) − (6361.1080𝑙𝑏/ℎ𝑟) (1135.8396 )
= 𝑙𝑏 𝑙𝑏 𝑙𝑏
(𝟎. 𝟗𝟕)(𝟎. 𝟗𝟓)(𝟒𝟒𝟎𝟎𝒌𝑾)

𝑩𝒕𝒖
𝑮𝒓𝒐𝒔𝒔 𝑺𝒕𝒂𝒕𝒊𝒐𝒏 𝒉𝒆𝒂𝒕 𝒓𝒂𝒕𝒆 = 𝟐𝟏𝟑𝟐𝟒. 𝟎𝟒𝟐𝟕
𝒌𝑾 ∙ 𝒉𝒓

(𝑊1 + 𝑊3 )ℎ1 + 𝑊4 ℎ4 − 𝑊2 ℎ2
𝑵𝒆𝒕 𝒔𝒕𝒂𝒕𝒊𝒐𝒏 𝒉𝒆𝒂𝒕 𝒓𝒂𝒕𝒆 =
𝐸𝑏 (𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟 𝑜𝑢𝑡𝑝𝑢𝑡 𝑖𝑛 𝑘𝑊 − 𝑎𝑢𝑥𝑖𝑙𝑙𝑎𝑟𝑦 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛 𝑘𝑊)
𝐵𝑡𝑢 𝐵𝑡𝑢 𝐵𝑡𝑢
(𝟑𝟔𝟗𝟗𝟐. 𝟓𝟏𝟗𝟔𝑙𝑏/ℎ𝑟 + 30631.4116𝑙𝑏/ℎ𝑟) (1347.7888 ) + (30631.4116𝑙𝑏/ℎ𝑟) (83.0156 ) − (6361.1080𝑙𝑏/ℎ𝑟) (1135.8396 )
= 𝑙𝑏 𝑙𝑏 𝑙𝑏
(𝟎. 𝟗𝟕)(𝟎. 𝟗𝟓)(𝟒𝟒𝟎𝟎𝒌𝑾 − 𝟐𝟎𝟎𝟎𝒌𝑾)

𝑩𝒕𝒖
𝑵𝒆𝒕 𝒔𝒕𝒂𝒕𝒊𝒐𝒏 𝒉𝒆𝒂𝒕 𝒓𝒂𝒕𝒆 = 𝟑𝟗𝟎𝟗𝟒. 𝟎𝟕𝟖𝟒
𝒌𝑾 ∙ 𝒉𝒓

Choose 5000 kW Rating for Turbine Generator for it is the next higher value for the assigned 4400
kW turbine capacity.
Plate 15
Dimensions of Westinghouse, Single Automatic Extraction,
Condensing, 3600-RPM Turbine Generator Units

15
 Source: Power Plant Theory and Design by P.J Potter (p.691, Appendix, Plate 15)

3. Boiler Design

There is no generally accepted method of rating the large, modem high-pressure boilers
except by giving the pounds of steam per hour together with the steam and water conditions
for which the out is designed. Units of millions of Btu per hr and kBtu per hr have been
proposed but are not generally used.

A term used for many years, and still used to some extent for small boilers, is boiler
horsepower. Originally, this term was intended to relate the output of the steam generator to
the steam requirements of a prime mover. Improvements in the design of both the prime
mover and the boilers have made this misnomer obsolete. One boiler horsepower is
equivalent to the generation of 34.5 lb of steam per hr from water at 212 F to saturated steam
also at 212 F, i.e., from and at 212 F. The energy of evaporation for steam at 212 F was taken
at 9703 Btu per 113 making the product equal to 34.5x 970.3=33,475 Btu per hr. Usually,
this figure is approximated at 33,500 Btu per hr. Thus

𝑊(ℎ1 − ℎ7 )
𝐵𝑜𝑖𝑙𝑒𝑟 ℎ𝑝 =
33,500
𝑖𝑛 𝑤ℎ𝑖𝑐ℎ,

𝑊 = 𝑠𝑡𝑒𝑎𝑚 𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 𝑏𝑦 𝑏𝑜𝑖𝑙𝑒𝑟 𝑡𝑢𝑏𝑒𝑠, 𝑒𝑐𝑜𝑛𝑜𝑚𝑖𝑧𝑒𝑟, 𝑎𝑛𝑑 𝑠𝑢𝑝𝑒𝑟 ℎ𝑒𝑎𝑡𝑒𝑟, 𝑙𝑏 𝑝𝑒𝑟 ℎ𝑟

ℎ1 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑒𝑛𝑡𝑒𝑟𝑖𝑛𝑔 𝑒𝑐𝑜𝑛𝑜𝑚𝑖𝑧𝑒𝑟, 𝐵𝑡𝑢 𝑝𝑒𝑟 𝑙𝑏
ℎ2 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 𝑙𝑒𝑎𝑣𝑖𝑛𝑔 𝑏𝑜𝑖𝑙𝑒𝑟 𝑜𝑟 𝑠𝑢𝑝𝑒𝑟ℎ𝑒𝑎𝑡𝑒𝑟, 𝐵𝑡𝑢 𝑝𝑒𝑟 𝑙𝑏

Source: Chapter 6 of Power Plant Theory and Design by Philip J. Potter, Boiler Rating and
Performance, pg. 255 – 256.

16
 Computed Properties:

𝑩𝒕𝒖
𝒉𝟏 = 𝟏𝟑𝟒𝟕. 𝟕𝟖𝟖𝟖
𝒍𝒃
𝑩𝒕𝒖
𝒉𝟕 = 𝟐𝟔𝟔. 𝟏𝟒𝟑𝟐
𝒍𝒃

𝑾 = 𝟑𝟔𝟗𝟗𝟐. 𝟓𝟏𝟗𝟔 𝒍𝒃/𝒉𝒓

Boiler HP is solved as follow:

𝑊(ℎ1 − ℎ7 )
𝐵𝑜𝑖𝑙𝑒𝑟 ℎ𝑝 =
33,500
𝐵𝑡𝑢 𝐵𝑡𝑢
36992.5196 𝑙𝑏/ℎ𝑟 (1347.7888 − 266.1432 )
𝑙𝑏 𝑙𝑏
𝐵𝑜𝑖𝑙𝑒𝑟 ℎ𝑝 =
33,500
𝐵𝑜𝑖𝑙𝑒𝑟 ℎ𝑝 = 1194.4118 ℎ𝑝
Because power boilers do not generate steam at 212 F, the actual energy change of
the water in passing through the boiler compared with the energy evaporation at 212 F is the
factor of evaporation. Thus
ℎ2 − ℎ1
𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑒𝑣𝑎𝑝𝑜𝑟𝑎𝑡𝑖𝑜𝑛 =
970.3
and

𝐸𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑒𝑣𝑝𝑜𝑟𝑎𝑡𝑖𝑜𝑛 = 𝑓 × 𝑊

and
𝑓 × 𝑊 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑒𝑣𝑎𝑝𝑜𝑟𝑎𝑡𝑖𝑜𝑛
𝐵𝑜𝑖𝑙𝑒𝑟 ℎ𝑝 = =
34.5 34.5

At the time these terms were standardized, boilers could develop 1 boiler hp with 10 sq. ft of boiler
heating surface. Therefore, the manufacturers’ boiler horsepower is defined as 10 sq ft of boiler
heating surface. Surface areas for superheaters, economizers, or air heaters are not included as boiler
heating surface. Therefore, the terms of boiler horsepower, etc. are meaningless for large, modern
steam generators.
It is common for even small, modern boilers to generate more than 1 boiler hp with 10 sq ft of heating
surface. Most boilers can develop 150% of rating – 200% is common and some units have exceeded
400% - when percentage of boiler rating is defined as:

Assumed Design:
Developed boiler rating= 250% (PPTD by Potters, p.699)

17
Solving for boiler heating surface area:
𝑏𝑜𝑖𝑙𝑒𝑟 ℎ𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 × 10
𝐵𝑜𝑖𝑙𝑒𝑟 𝑟𝑎𝑡𝑖𝑛𝑔 =
𝑏𝑜𝑖𝑙𝑒𝑟 ℎ𝑒𝑎𝑡𝑖𝑛𝑔 𝑠𝑢𝑟𝑓𝑎𝑐𝑒𝑠
𝑏𝑜𝑖𝑙𝑒𝑟 ℎ𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 × 10
𝑩𝒐𝒊𝒍𝒆𝒓 𝒉𝒆𝒂𝒕𝒊𝒏𝒈 𝒔𝒖𝒓𝒇𝒂𝒄𝒆 𝒂𝒓𝒆𝒂 =
𝑏𝑜𝑖𝑙𝑒𝑟 𝑟𝑎𝑡𝑖𝑛𝑔
1194.4118 ℎ𝑝 × 10
=
250%
1194.4118 ℎ𝑝 × 10
=
2.5
𝑩𝒐𝒊𝒍𝒆𝒓 𝒉𝒆𝒂𝒕𝒊𝒏𝒈 𝒔𝒖𝒓𝒇𝒂𝒄𝒆 𝒂𝒓𝒆𝒂 = 𝟒𝟕𝟕𝟕. 𝟔𝟒𝟕𝟐 𝒇𝒕𝟐

Referring to Appendix, Plate 13(Boiler Dimensions), p.689

Plate 13

BOILER DIMENSIONS

(Total surface includes superheater surface;

maximum design pressure 300 psi)
(Babcock &Wilcox Co.)

18
 Principal Dimensions of Boiler:
F-15 Boiler
Steam Outlet Size: 5’’
Feed Size: 2 ‘’
A. Boiler Width – Outside Casing: 10’ – 3 3/4’’
B. Furnace Width – Outside Casing: 11’ – 5 1⁄4 ’’
C. Furnace Wall Tubes: 10’ – 2 ’’
D. Face to Face 7 1/6’’ Square Headers: 9’ – 7 3/4‘’
E. Width of Dampers: 2’– 4‘’
F. Drums: 15’- 2’’
G. Drums: 9’ – 9’’
H. Overall Height: 21’ – 0’’
I. Height over Steam Outlet (West. Det. Oil): 19’-4’’
J. Overall Length: 18’ – 10 3/8 ’’
K. Drum to Outside Casing Front Wall: 6’ – 2’’
L. Inside Face Front Wall to Inside Face Bridgewall: 9’ – 0’’
M. Damper Location, Horizontal: 9 3/16’’
N. Damper Location, Vertical: 24 2/3‘’
O. Length of Dumper: 6’ – 6’’

Design of a Surface Condenser:

P = 3 in. Hg = 1.47346 Psia

𝑡𝑠𝑎𝑡 = 115.0456 ℉

4. Condenser Design

Coefficients of heat transfer for surface condensers should include conduction through the
metal wall and surface conduction or convection for the water film on the inside of the tube
and for the steam film on the outside of the tube; i.e., assuming that the tube is commercially
clean. An actual tube may have a slimy film on the inside from algae in the circulating water.
Many stations employ continuous or intermittent chlorination of the circulating water to pre-
vent formations on the tubes, as these films reduce the coefficient of heat transfer. Because
of the many uncertainties involved in calculating coefficients, the Heat Exchange Institute,
which is composed of the major manufacturers of heat-exchange equipment, has
standardized the over-all coefficients of heat transfer (U) to be used in the design of surface
condensers, Fig. 8-9. Values given on the curves are for 70 F water entering commercially
clean tubes made of No. 18 BWG Admiralty metal. Correction factors are given for other
metals and thicknesses. A temperature-surface diagram for a condenser would consist of a
constant temperature line for the steam condensing and a rising curved line for the
circulating water being heated. It was also shown in Chap. 4 that the equation for log mean
temperature difference and the quantity of energy transferred are
𝜃2 − 𝜃1 𝑡2 − 𝑡1
𝜃𝑚 = = 𝑡 −𝑡
𝜃
𝑙𝑛 2 𝑙𝑛 𝑠𝑎𝑡 1
𝜃1 𝑡𝑠𝑎𝑡 − 𝑡2

19
and
𝑄 = 𝑈𝐴𝜃𝑚

where:
𝜃𝑚 = 𝑙𝑜𝑔 𝑚𝑒𝑎𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒, 𝐹
𝜃1 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑡𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒, 𝑡𝑠𝑎𝑡 − 𝑡2, 𝐹
𝜃2 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑡𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒, 𝑡𝑠𝑎𝑡 − 𝑡1, 𝐹
𝑡𝑠𝑎𝑡 = 𝑠𝑎𝑡𝑢𝑟𝑎𝑡𝑖𝑜𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑡𝑒𝑎𝑚, 𝐹
𝑡1 = 𝑖𝑛𝑙𝑒𝑡 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒, 𝐹
𝑡2 = = 𝑜𝑢𝑡𝑙𝑒𝑡 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒, 𝐹
𝑈 = 𝑜𝑣𝑒𝑟 − 𝑎𝑙𝑙 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑏𝑎𝑠𝑒𝑑 𝑜𝑛 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑡𝑢𝑏𝑒 𝑎𝑟𝑒𝑎, 𝐵𝑡𝑢 𝑝𝑒𝑟 (𝑠𝑞 𝑓𝑡)(ℎ𝑟)(𝐹)
𝐴 = 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑡𝑢𝑏𝑒 𝑎𝑟𝑒𝑎, 𝑠𝑞 𝑓𝑡

The quantity θ1 is known simply as the terminal difference and is the difference between the
saturation temperature of the steam and the temperature of the water leaving. The coefficient

20
of heat transfer to be used in Eq. 8-2 cannot be obtained directly from Fig. 8-9 but can be
defined by

̅ 𝑥𝐹𝑡 𝑥𝐹𝑚 𝑥𝐹𝑜 𝑥𝐹𝑝

𝑈 = 𝑈

𝑤ℎ𝑒𝑟𝑒:
̅ = 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑓𝑟𝑜𝑚 𝐹𝑖𝑔. 8 − 9, 𝐵𝑡𝑢 𝑝𝑒𝑟 (𝑠𝑞 𝑓𝑡) (ℎ𝑟) (𝐹)
𝑈
𝐹𝑡 = 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑟𝑜𝑚 𝐹𝑖𝑔. 8 − 9
𝐹𝑚 = 𝑡𝑢𝑏𝑒 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑎𝑛𝑑 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑟𝑜𝑚 𝐹𝑖𝑔. 8 − .9
𝐹𝑐 = 𝑐𝑙𝑒𝑎𝑛𝑙𝑖𝑛𝑒𝑠𝑠 𝑓𝑎𝑐𝑡𝑜𝑟
𝐹𝑝 = 𝑝𝑟𝑖𝑚𝑒 𝑚𝑜𝑣𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟𝑠, 1.0 𝑓𝑜𝑟 𝑡𝑢𝑟𝑏𝑖𝑛𝑒𝑠 𝑎𝑛𝑑 0.75 𝑓𝑜𝑟 𝑠𝑡𝑒𝑎𝑚 𝑒𝑛𝑔𝑖𝑛𝑒𝑠

from Chapter 8 of Power Plant Theory and Design by Philip J. Potter, Condenser Calculations,
pg. 350 – 357.

Design of a Surface condenser:

𝑡𝑠𝑎𝑡 = 115.0456 ℉

21
 𝑡2 = 115.0456 ℉ − 8.0 = 107.0456 ℉

Solving for 𝜃𝑚:

𝜃2 − 𝜃1
𝜃𝑚 =
𝜃
𝑙𝑛 2
𝜃1
𝑡𝑠𝑎𝑡 − 𝑡1
= 𝑡 −𝑡
𝑙𝑛 𝑠𝑎𝑡 1
𝑡𝑠𝑎𝑡 − 𝑡2

107.0456 ℉ − 90℉
=
115.0456℉ − 90℉
𝑙𝑛 ( )
115.0456℉ − 107.0456℉

𝜃𝑚 = 14.9358 𝑑𝑒𝑔

From Fig. 8-9,

̅ = 714.3529 𝐵𝑡𝑢/ ℎ𝑟 ∙ 𝑠𝑞. 𝑓𝑡. ℉ × 1.05 × 1.0 × 0.85 × 1.0

𝑈

From Equation 8-3,

̅ = 637.5600 𝐵𝑡𝑢/ ℎ𝑟 ∙ 𝑠𝑞. 𝑓𝑡. ℉

𝑈

From Equation 8-2,

30631.4116 𝑙𝑏/ℎ𝑟 × 950

𝐴=
637.5600 𝐵𝑡𝑢/ ℎ𝑟 ∙ 𝑠𝑞. 𝑓𝑡. ℉ × 14.9358 𝑑𝑒𝑔

𝐴 = 3055.9136 𝑠𝑞. 𝑓𝑡

Circulating water requirements are determined from the energy rejected by the steam and
the temperature rise of the water. Assuming a specific heat of unity for the water, we compute
the flow to be

30631.4116 𝑙𝑏/ℎ𝑟 × 950

= 1707176.105 𝑙𝑏/ℎ𝑟
107.0456 ℉ − 90℉

Dividing by 500 gives a flow of 3414.3522 gpm.

1707176.105 𝑙𝑏/ℎ𝑟
= 3414.3522𝑔𝑝𝑚.
500

Regardless of the number of passes, all this water must flow through each pass. Table 8-1
indicates that each 3⁄4 in. No. 18 BWG tube will pass 1.042 gpm at 1 fps. At 6 fps, there will
be

22
 3414.3522𝑔𝑝𝑚.
= 468 𝑡𝑢𝑏𝑒𝑠 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠
1.042 × 7

The number of passes will be determined by the tube length. Also from Table 8-1, each tube
has a 0.1963 sq ft of outside surface per foot of length. Assuming one pass with 468 tubes,
the effective tube length would be

3055.9136 𝑠𝑞. 𝑓𝑡
= 33.2640 𝑓𝑡
468 𝑡𝑢𝑏𝑒𝑠 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠 × 0.1963

Consulting Table 8-2, by Potter page 354, we find this length to be unreasonable. For a two-
pass condenser, the effective length would be

33.2640 𝑓𝑡
= 16.6320 𝑓𝑡
2
which is reasonable. The total number of tubes would be 468 × 2 = 936

A condenser of this size would have 3⁄4 in thick tube sheets, so the actual tube length
would be 16.6320 ft.

From Fig. 8-11, by Potter, page 355

𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝐿𝑜𝑠𝑠 = 2 × 16.6320 × 0.40 + 2 × 1.41 = 16.1256 𝑓𝑡

23
 Plate 14

Dimensions of Westinghouse Two-pass,

Nondivided Waterbox, Radial-Flow Surface Condenser
𝟑
(Based on in. OD No. 18 BWG tubes)
𝟒

Source: Plate 14, PPTD by Potters, page 690 for Dimensions of Westinghouse Two-pass, Non-
divided Waterbox, Radial-flow Surface Condensers (Based on 3⁄4 in OD No. 18 BWG tubes)

5. Deaerator Design

Heat-Balance Calculations for Deaerators and Contact Heaters. 𝑆

ℎ𝑠
Heat-balance calculations for a deaerator are no different from those
for a contact heater. The calculations assume that the heater is perfectly
insulated, that the process is one of steady flow, and that the loss of 𝑃 𝑊1 𝑡1
energy from the vent to atmosphere or some other region is negligible.
If a vent condenser is used with the equipment, it is considered a part 𝑡𝑠𝑎𝑡 ℎ1
of the heater for heat-balance calculations. The same two laws that
define the performance of all heat-exchange equipment are used for
contact-heater calculations. The Law of Conservation of Energy applies 𝑊2
to the energy exchange and the Law of Conservation of Mass applies to
the weights flowing. Refer to Fig. 8-30. ℎ2 Fig. 8-30

24
 Energy entering = energy leaving
or 𝑆ℎ𝑏 + 𝑊1 ℎ1 = 𝑊2 ℎ2 (8 − 11)

where;

𝑆 = 𝑠𝑡𝑒𝑎𝑚 𝑓𝑙𝑜𝑤, 𝑙𝑏 𝑝𝑒𝑟 ℎ𝑟

𝑊1 = 𝑤𝑎𝑡𝑒𝑟 𝑒𝑛𝑡𝑒𝑟𝑖𝑛𝑔, 𝑙𝑏 𝑝𝑒𝑟 ℎ𝑟

𝑊2 = 𝑤𝑎𝑡𝑒𝑟 𝑙𝑒𝑎𝑣𝑖𝑛𝑔, 𝑙𝑏 𝑝𝑒𝑟 ℎ𝑟

ℎ𝑠 = 𝑠𝑡𝑒𝑎𝑚 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦, 𝐵𝑡𝑢 𝑝𝑒𝑟 𝑙𝑏

ℎ1 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑒𝑛𝑡𝑒𝑟𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟, 𝐵𝑡𝑢 𝑝𝑒𝑟 𝑙𝑏

ℎ2 = 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑙𝑒𝑎𝑣𝑖𝑛𝑔, 𝐵𝑡𝑢 𝑝𝑒𝑟 𝑙𝑏

Each product in this equation must equal Btu per hour. Regardless of the number of fluids entering
the heater, the energy balance must always hold true. The enthalpy of the water leaving should be
taken at zero terminal difference. A typical application of this equation would contain two unknowns,
S and W1. But, by applying the second of the two laws, we get
𝑆 + 𝑊1 = 𝑊2

Solving for the steam quantity,

𝑊2 (ℎ2 − ℎ1 )
𝑆=
ℎ𝑠 − ℎ1
Design conditions:

Steam enters a contact type of heater at 40 psia and 1082. 16 Btu per lb. The heater discharges
29245.19205 lb per hr of water; the entering temperature is 80F. The calculation for steam required
is as follow:

𝑡2 𝑎𝑡 65 𝑝𝑠𝑖𝑎 = 297.9546 ℉
𝐵𝑡𝑢
ℎ5 = 83.1961
𝑙𝑏
𝐵𝑡𝑢
ℎ6 = 264.2051
𝑙𝑏

𝐵𝑡𝑢 𝐵𝑡𝑢
36992.5196 𝑙𝑏ൗℎ𝑟 (264.2051 − 83.1961 )
𝑆= 𝑙𝑏 𝑙𝑏
𝐵𝑡𝑢 𝐵𝑡𝑢
1135.8396 − 83.1961
𝑙𝑏 𝑙𝑏

25
 𝑆 = 6361.1080 𝑙𝑏ൗℎ𝑟

𝑊1 = 𝑊2 − 𝑆

𝑊1 = 36992.5196 𝑙𝑏ൗℎ𝑟 − 6361.1080 𝑙𝑏ൗℎ𝑟

𝑊1 = 30631.4116 𝑙𝑏ൗℎ𝑟

Refer to PPTD by Potter, Plate 9, page 683 for Deaerator Dimensions

Plate 9

Deaerator Dimensions
(Vacuum to 50 Psig)
(Cochrane Corp.)

26
6. Boiler Feed Pump Design

Boiler Feed Pumps:

Four pumps for the plant, 100% spare

Centrifugal
Motor-driven
325-psig discharge pressure

B𝒂𝒔𝒆 𝒇𝒍𝒐𝒘 𝒓𝒂𝒕𝒆 = 𝑩𝒐𝒊𝒍𝒆𝒓 𝑴𝒂𝒙𝒊𝒎𝒖𝒎 𝑪𝒂𝒑𝒂𝒄𝒊𝒕𝒚 𝑯𝒐𝒓𝒔𝒆𝒑𝒐𝒘𝒆𝒓 × 𝟎. 𝟎𝟔𝟗 𝑮𝑷𝑴 × 𝑪

Use the boiler maximum-capacity horsepower from the boiler manufacturer’s specification.
The number 0.069 is a constant. The “C” value varies depending on whether

27
the pump will cycle on and off in intermittent operating mode (C = 1.50) or operate in a
continuous feed mode (C = 1.15).

where:

𝐵𝑜𝑖𝑙𝑒𝑟 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 = 1200 𝐵𝐻𝑃; 𝐶 = 1.50

0.069 𝐺𝑃𝑀
𝐵𝑎𝑠𝑒 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 = 1200 𝐵𝐻𝑃 ( ) × 1.50
1 𝐵𝐻𝑃
𝑩𝒂𝒔𝒆 𝒇𝒍𝒐𝒘 𝒓𝒂𝒕𝒆 = 𝟏𝟐𝟒. 𝟐 𝑮𝑷𝑴

𝑩𝒂𝒔𝒆 𝒉𝒆𝒂𝒅 𝒊𝒏 𝒇𝒆𝒆𝒕 = 𝒎𝒂𝒙𝒊𝒎𝒖𝒎 𝒃𝒐𝒊𝒍𝒆𝒓 𝒑𝒓𝒆𝒔𝒔𝒖𝒓𝒆 × 𝟐. 𝟑𝟏 × 𝟏. 𝟎𝟑 ÷ 𝒍𝒊𝒒𝒖𝒊𝒅 𝒔𝒑𝒆𝒄𝒊𝒇𝒊𝒄 𝒈𝒓𝒂𝒗𝒊𝒕𝒚

where:
𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑜𝑖𝑙𝑒𝑟 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 664.696 𝑝𝑠𝑖
𝑙𝑖𝑞𝑢𝑖𝑑 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑔𝑟𝑎𝑣𝑖𝑡𝑦 = 9.8

𝒇𝒕 𝒐𝒇 𝒉𝒆𝒂𝒅
𝑩𝒂𝒔𝒆 𝒉𝒆𝒂𝒅 𝒊𝒏 𝒇𝒆𝒆𝒕 = 𝟔𝟔𝟒. 𝟔𝟗𝟔 𝒑𝒔𝒊 × 𝟐. 𝟑𝟏 × 𝟏. 𝟎𝟑 ÷ 𝟗. 𝟖 = 𝟏𝟔𝟏. 𝟑𝟕𝟖𝟕 𝒇𝒕
𝒑𝒔𝒊

Refer to PPTD by Potters, page 687, PLATE 11, Boiler Feed Pumps Dimensions

Plate 11
Boiler Feed Pumps Dimensions

28
7. Condensate Pump

COMMON CONVERSION FACTORS

𝑀𝑢𝑙𝑡𝑖𝑝𝑙𝑦 𝐵𝑜𝑖𝑙𝑒𝑟 𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 (𝐵𝐻𝑃) 𝑏𝑦 34.5 = 𝐿𝑏. 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 (𝑤𝑎𝑡𝑒𝑟 𝑝𝑒𝑟 ℎ𝑜𝑢𝑟 (𝑙𝑏/ℎ𝑟)
𝑀𝑢𝑙𝑡𝑖𝑝𝑙𝑦 𝐵𝑜𝑖𝑙𝑒𝑟 𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 (𝐵𝐻𝑃) 𝑏𝑦 0.069 = 𝐺𝑎𝑙𝑙𝑜𝑛𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑝𝑒𝑟 𝑚𝑖𝑛𝑢𝑡𝑒 (𝑔𝑝𝑚)
𝑀𝑢𝑙𝑡𝑖𝑝𝑙𝑦 𝐵𝑜𝑖𝑙𝑒𝑟 𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 (𝐵𝐻𝑃) 𝑏𝑦 33,475 = 𝐵𝑇𝑈ൗℎ𝑟
𝑀𝑢𝑙𝑡𝑖𝑝𝑙𝑦 𝐵𝑜𝑖𝑙𝑒𝑟 𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 (𝐵𝐻𝑃) 𝑏𝑦 139 = 𝑆𝑞𝑢𝑎𝑟𝑒 𝑓𝑒𝑒𝑡 𝑜𝑓 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑑𝑖𝑟𝑒𝑐𝑡
𝑟𝑎𝑑𝑖𝑎𝑡𝑖𝑜𝑛 (𝑠𝑞 𝑓𝑡. 𝐸𝐷𝑅)

CONDENSATE PUMP SIZING

Condensate pumps are typically sized at three times normal condensing or evaporation
rate.

𝐸𝑣𝑎𝑝𝑜𝑟𝑎𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑒 𝑥 3 = 𝑃𝑢𝑚𝑝 𝐺𝑃𝑀 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑

𝑃𝑢𝑚𝑝 𝐺𝑃𝑀 𝑥 1 = 𝑅𝑒𝑐𝑒𝑖𝑣𝑒𝑟 𝑇𝑎𝑛𝑘 𝑆𝑖𝑧𝑒 (𝐺𝑎𝑙𝑙𝑜𝑛𝑠 𝑆𝑡𝑜𝑟𝑎𝑔𝑒)

𝐵𝑡𝑢
33,475
𝑂𝑢𝑡𝑝𝑢𝑡 𝑏𝑜𝑖𝑙𝑒𝑟 𝐻𝑃 = 1200 𝐵𝐻𝑃 ( ℎ𝑟 ) = 40,170,000 𝐵𝑡𝑢/ℎ𝑟
1 𝐵𝐻𝑃

29
Solving:

1 𝐸𝐷𝑅
40,170,000 𝐵𝑡𝑢/ℎ𝑟 𝑜𝑢𝑡𝑝𝑢𝑡 𝑏𝑜𝑖𝑙𝑒𝑟 ( ) = 167 375 𝐸𝐷𝑅
240 𝐵𝑡𝑢/ℎ𝑟
0.5 𝐺𝑃𝑀
167 375 𝐸𝐷𝑅 ( ) = 83.6875 𝐺𝑃𝑀
1000 𝐸𝐷𝑅
83.6875 𝐺𝑃𝑀 𝑥 3 = 251 𝐺𝑃𝑀 𝑝𝑢𝑚𝑝 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦
251 𝐺𝑃𝑀 𝑥 1 = 251 𝑔𝑎𝑙𝑙𝑜𝑛 𝑡𝑎𝑛𝑘 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑎𝑡𝑒 𝑝𝑢𝑚𝑝

Condensate Pump size is the same with Boiler Feed Pump Size

30
8. Piping Design

Design Conditions:
𝑃1 = 650 𝑝𝑠𝑖𝑔
𝑡1 = 700 ℉

𝑃𝑎𝑏𝑠 = 650 𝑝𝑠𝑖𝑔 + 14.696

𝑃𝑎𝑏𝑠 = 664.696 𝑝𝑠𝑖𝑎

P (Psia) t (°𝐅) V (ft3/lb)

650 494.89 0.70843
664.696 tsat V1
700 503.08 0.65556

By interpolation

664.696 − 650 𝑡𝑠𝑎𝑡 − 494.89 𝑉1 − 0.70843

= =
700 − 650 503.08 − 494.89 0.65556 − 0.70843

𝑡𝑠𝑎𝑡 = 497.2972 ℉
𝑓𝑡 3
𝑉1 = 0.6929
𝑙𝑏
Steam’s superheated @:
𝑡1 = 700℉ + 460
𝑇𝑠 = 1160 𝑅

For specific volume of superheated steam:

𝑉1 𝑇𝑠
𝑉𝑠 =
𝑇1
𝑓𝑡 3
(0.6929 ) (1160 𝑅)
𝑙𝑏
𝑉𝑠 =
(497.2972 + 460)𝑅
𝑓𝑡 3
𝑉𝑠 = 0.8396
𝑙𝑏
Steam Piping Design:
𝑚𝑠 = 36 992.5196 𝑙𝑏/ℎ𝑟

Solving for steam pipe diameter

From table 2-6

Superheated, over 600 psig, the range of velocity in fpm is 4000-10000.

𝑓𝑡ൗ
𝐴𝑠𝑠𝑢𝑚𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 7000 𝑚𝑖𝑛

31
 4𝑚𝑠 𝑉𝑠
𝑑=√
𝜋(𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦)
𝑓𝑡 3
4(36 992.5196 𝑙𝑏/ℎ𝑟) (0.8396 )
√ 𝑙𝑏
𝑑=
𝑓𝑡
𝜋 (7000 ൗ𝑚𝑖𝑛 ) (60 𝑚𝑖𝑛ൗℎ𝑟)
12𝑖𝑛
𝑑 = 0.3068𝑓𝑡 ( )
1𝑓𝑡
𝑑 = 3.6816 𝑖𝑛
The next higher diameter steam pipe is 4.026 in.

Condensate Piping Design

P4 = 3 in. Hg = 1.4735 Psia

𝑉𝑐 = 𝑉4 = 0.016184 𝑓𝑡 3 /𝑙𝑏

𝑚3 = 𝑚4 = 30631.4116 𝑙𝑏/ℎ𝑟

32
 From Table 2-6, condensate and boiler feed, pump discharge (350-500) fpm.
𝑓𝑡ൗ
𝐴𝑠𝑠𝑢𝑚𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 425 𝑚𝑖𝑛

Solving for condensate pipe diameter

4𝑚3 𝑉𝑐
𝑑=√
𝜋(𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦)

4(30631.4116 𝑙𝑏/ℎ𝑟)(0.016184 𝑓𝑡 3 /𝑙𝑏)

𝑑=√
𝑓𝑡
𝜋 (425 ൗ𝑚𝑖𝑛 ) (60 𝑚𝑖𝑛ൗℎ𝑟)

𝑖𝑛
𝑑 = 0.1573𝑓𝑡 (12 )
𝑓𝑡

𝑑 = 1.8880 𝑖𝑛

The next higher inside diameter condensate pipe is 2.067 in.

33
 Extraction Piping Design:

𝑃2 = 65 Psia
From Steam Table

P (Psia) 𝑉𝑓 (ft3/lb) 𝑉𝑓𝑔 (ft3/lb)

60 0.017383 7.1562
65 𝑉𝑓 𝑉𝑓𝑔
70 0.017482 6.1875

By interpolation:
65 − 60 𝑉𝑓 − 0.017383 𝑉𝑓𝑔 − 7.1562
= =
70 − 60 0.017482 − 0.017383 6.1875 − 7.1562
𝑉𝑓 = 0.01743 𝑓𝑡 3 /lb

𝑉𝑓𝑔 = 6.67185 𝑓𝑡 3 /lb

𝑥2 = 0.9525

𝑉2 = 𝑉𝑓 + 𝑥2 𝑉𝑓𝑔

𝑉2 = 𝑉𝑒 = 0.01743 𝑓𝑡 3 /lb + 0.9525(6.67185 𝑓𝑡 3 /lb)

𝑉𝑒 = 6.3724 𝑓𝑡 3 /lb

Solving for extraction pipe diameter:

𝑚2 = 6361.1080 𝑙𝑏/ℎ𝑟

𝑉𝑒 = 6.3724 𝑓𝑡 3 /lb

From Table 2-6, moist (10-100) Psig 2000-5000 fpm.

𝑓𝑡
𝐴𝑠𝑠𝑢𝑚𝑒𝑑 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 3500
𝑚𝑖𝑛

4𝑚2 𝑉𝑒
𝑑=√
𝜋(𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦)

4(6361.1080 𝑙𝑏/ℎ𝑟)(6.3724 𝑓𝑡 3 /lb)

𝑑=√
𝑓𝑡 𝑚𝑖𝑛
𝜋 (3500 ) (60 )
𝑚𝑖𝑛 ℎ𝑟

𝑖𝑛
𝑑 = 0.4958 𝑓𝑡 (12 )
𝑓𝑡

34
 𝑑 = 5.9490 𝑖𝑛

The next higher extraction pipe diameter is 6.065 in.

35
9. Forced Draft Fan Design

Data: Forced-draft Fans: 3.5-in. water static pressure

How much air is required?

In general, the following formulas have been developed to determine the amount of air
required for any boiler room with a package firetube boiler firing gas or oil fuels.

1. Combustion Air = HP* x 8 CFM/HP =

2. Ventilation Air = HP* x 2 CFM/HP =

3. Total Air Required = HP* x 10 CFM/HP =

*HP refers to the total maximum boiler HP located in the boiler room.

The above calculations are adequate for installations up to 1000 feet above sea level (fasl).
For installation above 1000 fasl, add 3% additional air for each 1000 fasl (or portion
thereof) to allow for the density change in air at higher altitudes.

What size of opening to the outside is required in a boiler room?

The size of the fresh air inlet openings and their location are very important. There should
be a minimum of two permanent air supply openings in the outer walls of the boiler room.
Whenever possible, they should be at opposite ends of the boiler room and no higher than
seven feet above the floor. This will promote thorough mixing with the air already in the
boiler room, proper cooling of the boilers and tempering of potentially colder outside air
prior to it entering the burner for combustion.

The air inlets should be provided with some type of weather protection, but they should
never be covered with a fine mesh wire screen. This type of covering results in poor air flow
characteristics and is subject to clogging by dust, dirt, paper and other small items. To
determine the net free open area of the opening, divide the total CFM required in the boiler
room by the allowable velocity at the opening.

Acceptable Air Velocities in a Boiler Room

0-7 ft. above floor 250 FPM

Above 7 ft. high 500 FPM

When sizing an opening to the outside, it should be a minimum of one square foot.

36
Care should be taken to ensure that no water, oil or steam lines are run in the direct path of
cold fresh air entering from any of the outside air opening. Heated heavy oil lines should be
protected from cold air and they should be electrically, or steam heat traced and insulated.

What about air ducting?

In some applications the boiler room is located in a building such that it has no outside
walls. Many of these applications do not have sufficient excess makeup air in the factory to
allow for combustion air requirements. In these cases, there are two solutions: The first is
ducting fresh air to the boiler room. Where this is required, the general rules for the size of
wall opening for fresh outside air can be used. The duct size to the outside and its free open
area inlet must never be smaller than the wall opening in the boiler room. In addition, the
pressure drop through the duct at maximum flow must never exceed 0.05′′ w.c. The second
is ducting fresh air directly to the boiler. In general, this method of air supply should be
avoided whenever possible. The disadvantages of this type of system far exceed any
perceived advantages. If used, the ducting becomes a part of the boiler system and can affect
the stability of combustion due to varying weather conditions, wind direction and velocity,
humidity and temperature. An outside temperature variation of -10EF in the winter to 80EF
in the summer (many areas of the country are wider) can cause a burner adjusted for 15%
excess air combustion on the coldest winter day to be 5% short of air on a warm day. This
can lead to massive CO production, soot formation, plus unstable and unsafe combustion. If
direct ducting must be used, we suggest the following minimum steps be followed:
1. Each boiler has its own, completely separate fresh air ducting and exhaust stack.
Shared air supplies and exhaust stacks will lead to combustion problems and unsafe
operating conditions.

2. Boilers directly connected to fresh outside air ducts must be checked for proper
combustion adjustment and operation every three months by a certified package fire-tube
boiler specialist.
3. The duct work supplying the fresh air to the boiler must be sized so that it has a
maximum pressure drop at maximum flow of 0.05′′wc.

4. The fresh air supply duct should have an electric, hot water, or steam heater to
temper cold outside air to at least 50EF.
5. If the application is utilizing a low emission with flue gas recirculation, do not use
direct ducted outside air. The potential problems associated with a standard burner are
intensified with a low emission burner.

37
Calculations:

Determine the CFM required of a boiler room with one 1200 HP Boilers.
𝐶𝐹𝑀
𝐴𝑖𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = (1200 𝐻𝑃) (10 ) = 12000 𝐶𝐹𝑀
𝐻𝑃
Air Horse Power - AHP
Assuming 100% efficiency AHP is the power required to move a given air volume against a
given pressure. AHP can be expressed as

𝑃𝐴𝐻𝑃 = 𝑞 𝑑𝑝𝑖𝑛. 𝑊𝐶 𝑆𝐺ൗ6356

where:
𝑃𝐴𝐻𝑃 = 𝐴𝑖𝑟 𝐻𝑜𝑟𝑠𝑒 𝑃𝑜𝑤𝑒𝑟 (ℎ𝑝)

𝑞 = 𝑎𝑖𝑟 𝑓𝑙𝑜𝑤 (𝑐𝑓𝑚)

𝑆𝐺 = 𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝐺𝑟𝑎𝑣𝑖𝑡𝑦 𝐴𝑖𝑟 (= 1.0)

𝑑𝑝 𝑖𝑛𝑊𝐺 = 𝑡𝑜𝑡𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 (𝑖𝑛. 𝑊𝐶) = 3.5 𝑖𝑛. 𝑊. 𝐺

𝑃𝐴𝐻𝑃 = 𝑞 𝑑𝑝𝑖𝑛𝑊𝐺 𝑆𝐺ൗ6356

1 ℎ𝑝
𝑃𝐴𝐻𝑃 = (12000𝐶𝐹𝑀)(3.5𝑖𝑛. 𝑊. 𝐺)(1.0) ( )
6356 𝐶𝐹𝑀 ∙ 𝑖𝑛. 𝑊𝐶
𝑃𝐴𝐻𝑃 = 6.6079 ℎ𝑝

38
NOTE: pp 686
10. STACK DESIGN

Atmospheric Dispersion Calculations

Air Pollution Control Stacks Equation Formulas

10. Stack Design

Atmospheric Dispersion Calculations

Air Pollution Control Stacks Equation Formulas

Solving for stack diameter for sub-adiabatic conditions.

𝑢 √𝑄ℎ
𝑑= (∆ℎ − 2.24 )
− 1.04𝑉𝑠 𝑢

where:

𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑤𝑖𝑛𝑑 𝑠𝑝𝑒𝑒𝑑 (𝑢)

𝑆𝑡𝑎𝑐𝑘 𝑔𝑎𝑠 𝑒𝑥𝑖𝑡 𝑠𝑝𝑒𝑒𝑑 (𝑉𝑠 )

𝑃𝑙𝑢𝑚𝑒 𝑟𝑖𝑠𝑒 (𝛥ℎ)

39
 𝑆𝑡𝑎𝑐𝑘 ℎ𝑒𝑎𝑡 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 (𝑄ℎ )

Average Wind Speed

The highest daily average wind speed in August 2021 is 7.9 miles per hour.

𝑢 = 7.9 𝑚𝑝ℎ
Stack gas exit speed (Vs)

Design of steel stacks ASME STS-1-2006. As a point of reference, quoting from section
1.3.2 Diameters, "Velocities in round stack between 2400 and 3600 ft/min are most common.
Stacks venting saturated gases sometimes limit velocities between 1800 and 2400 ft/min to
reduce entrained or condensed moisture from leaving the stack exit."
𝑉𝑠 = 3000 𝑓𝑡/𝑚𝑖𝑛

Plume Rise (Δh)

∆ℎ = 𝐻 − ℎ𝑝ℎ𝑦𝑠𝑖𝑐𝑎𝑙

where:
Effective stack height (H)

𝐻 = 100 𝑚
Physical stack height (hphysical)
ℎ𝑝ℎ𝑦𝑠𝑖𝑐𝑎𝑙 = 𝐻𝑔 = 2.5 𝐻𝑠

𝐻𝑔 = 𝑔𝑜𝑜𝑑 𝑒𝑛𝑔𝑖𝑛𝑒𝑒𝑟𝑖𝑛𝑔 ℎ𝑒𝑖𝑔ℎ𝑡 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑔𝑟𝑜𝑢𝑛𝑑 − 𝑙𝑒𝑣𝑒𝑙 𝑒𝑙𝑒𝑣𝑎𝑡𝑖𝑜𝑛 𝑎𝑡 𝑡ℎ𝑒 𝑏𝑎𝑠𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑡𝑎𝑐𝑘

𝐻𝑠 = ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑛𝑒𝑎𝑟𝑏𝑦 𝑠𝑡𝑟𝑢𝑐𝑡𝑢𝑟𝑒(𝑠) 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑔𝑟𝑜𝑢𝑛𝑑

− 𝑙𝑒𝑣𝑒𝑙 𝑒𝑙𝑒𝑣𝑎𝑡𝑖𝑜𝑛 𝑎𝑡 𝑡ℎ𝑒 𝑏𝑎𝑠𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑡𝑎𝑐𝑘

BUILDING HEIGHTS IN THE PH (not expressly stated in the National Building Code of the
Philippines):
1. LOW-RISE (from 1 - 5 storeys i.e. 4.0 m to 16.0 m, inclusive of an average 1.0 m provision
for parapet wall or roof apex; excludes maximum allowance for a 6.0 m tall antenna/ steel
tower on top of the structure (only where allowed by the Civil Aviation Authority of the Ph/
CAAP);

2. MEDIUM-RISE (from 6 - 15 storeys i.e. 19.0 m to 46.0 m, inclusive of an average 1.0 m

provision for parapet wall or roof apex; excludes maximum allowance for a 6.0 m tall
antenna/ steel tower on top of the structure (only where allowed by the Civil Aviation
Authority of the Ph/ CAAP);

3. HIGH-RISE (from 16 - 60 storeys i.e. 49.0 m to 181.0 m, inclusive of an average 1.0 m

provision for parapet wall or roof apex; excludes maximum allowance for a 6.0 m tall
antenna/ steel tower on top of the structure (only where allowed by the Civil Aviation
Authority of the Ph/ CAAP); and

40
 4. VERY TALL BUILDING (taller than 60 storeys i.e. taller than 181.0 m, inclusive of an average
1.0 m provision for parapet wall or roof apex; excludes maximum allowance for a 6.0 m tall
antenna/ steel tower on top of the structure (only where allowed by the Civil Aviation
Authority of the Ph/ CAAP).
𝐻𝑠 = 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑚𝑒𝑑𝑖𝑢𝑚 − 𝑟𝑖𝑠𝑒 𝑏𝑢𝑖𝑙𝑑𝑖𝑛𝑔𝑠 = 32.5 𝑚
ℎ𝑝ℎ𝑦𝑠𝑖𝑐𝑎𝑙 = 𝐻𝑔 = 2.5 (32.5𝑚) = 81.25 𝑚

𝛥ℎ = 100 𝑚 – 81.25 𝑚 = 18.5 𝑚

Stack Heat Emission Rate

𝐴𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒 𝑆𝑡𝑎𝑐𝑘 𝐻𝑒𝑎𝑡 𝐸𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑅𝑎𝑡𝑒 = 4,800 𝑘𝐽/𝑆

𝑄ℎ = 4,800 𝑘𝐽/𝑆

Conversions

𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑤𝑖𝑛𝑑 𝑠𝑝𝑒𝑒𝑑 (𝑢) = 7.9 𝑚𝑖𝑙𝑒/ℎ𝑜𝑢𝑟 = 3.5309 𝑚/𝑠𝑒𝑐

𝑠𝑡𝑎𝑐𝑘 𝑔𝑎𝑠 𝑒𝑥𝑖𝑡 𝑠𝑝𝑒𝑒𝑑 (𝑉𝑠) = 3000 𝑓𝑡/𝑚𝑖𝑛 = 15.2393 𝑚/𝑠𝑒𝑐

𝑝𝑙𝑢𝑚𝑒𝑟𝑖𝑠𝑒 (𝛥ℎ) = 18.5 𝑚𝑒𝑡𝑒𝑟 = 18.5 𝑚𝑒𝑡𝑒𝑟

𝑠𝑡𝑎𝑐𝑘 ℎ𝑒𝑎𝑡 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 (𝑄ℎ) = 4800 𝑘𝑖𝑙𝑜𝑗𝑜𝑢𝑙𝑒/𝑠𝑒𝑐𝑜𝑛𝑑 = 4800 𝑘𝑖𝑙𝑜𝑗𝑜𝑢𝑙𝑒/𝑠𝑒𝑐𝑜𝑛𝑑

𝑢 √ 𝑄ℎ
𝑑= (∆ℎ − 2.24 )
− 1.04𝑉𝑠 𝑢

3.5309 𝑚/𝑠𝑒𝑐 √4800 𝑘𝐽/𝑠

𝑑= (18.5 𝑚 − 2.24 )
− 1.04(15.2393𝑚/𝑠𝑒𝑐) 3.5309 𝑚/𝑠𝑒𝑐
𝑓𝑡
𝑆𝑡𝑎𝑐𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 (𝑑) = 5.6704 𝑚 (3.281 )
𝑚
𝑺𝒕𝒂𝒄𝒌 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓 (𝒅) = 𝟏𝟖. 𝟔𝟎𝟒𝟔 𝒇𝒕

41