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isentropic (or reversible adiabatic) expansion isobaric (or reversible constant-pressure) heat rejection isentropic (or reversible adiabatic) compression isobaric (or reversible constant-pressure) heat addition
Wp
mv 3 (p4 p3 )
where: t = turbine efficiency p = pump efficiency b = boiler efficiency Boiler efficiency is meant the measure of ability of a boiler or steam generator to transfer the heat given it by the furnace to the water and steam. Thermal Cycle Efficiency For Rankine Cycle Wt Wp (h1 h2 ) Wp (h1 h2 ) (h4 h3 ) = ecycle = = (h1 h3 ) Wp Qb h1 h4 For Rankine engine or turbine (combination with condenser) h h eengine = 1 2 h1 h3 For plant thermal efficiency electrical power output EP ep = = heat supplied by fuel m f HV 3. Methods used in increasing the thermal efficiency of a Rankine cycle a. For the same throttle pressure and condenser pressure, increase the throttle temperature. b. For the same throttle temperature and condenser pressure, increase the throttle pressure. c. For the same throttle temperature and pressure, decrease the condenser pressure. d. Using reheat cycle e. Using regenerative cycle f. Using reheat-regenerative cycle 2
Turbine work Wt = m(h1 h2 ) + m(h3 h 4 ) Heat added in the boiler QAb = m(h1 h6 ) Heat added in the reheater QArh = m(h3 h2 ) Pump work Wp = m(h6 h5 ) mv 5 (p6 p5 ) Heat rejected in the condenser QR = m(h4 h5 ) Thermal efficiency of reheat cycle W Wp W Wp ecycle = t = t QA QAb + QArh 5. Regenerative Cycle Regenerative cycle to improve the cycle efficiency, decrease turbine power, decrease heat addition.
7. Steam Generators (Boilers) Steam generators commonly referred to as boiler is an integrated assembly of several essential components the function of which is to produce steam at a predetermined pressure and temperature.
8. Boiler Types 8.1 Classification according to the contents of the tubular heating surface. 8.1.1 Fire-tube boilers Fire-tube boilers are those in which the products of combustion pass through the tubes and the water lies around the outside of them. a. Horizontal or vertical axes b. External or internal furnaces c. Fully cylindrical or partially cylindrical shells 4
9. Parts of Steam Generator 9.1 Pressure parts 9.1.1 Boiler heating surface tubes with attached drums or shells for storage of water and steam. 9.1.2 Superheated surface provides more heating surface through which the steam must pass after leaving the boiler if a final superheated state is desired. 9.1.3 Economizer is a feedwater pre-heating device which utilizes steam mixed with the feedwater. 9.2 Enclosure or setting 9.2.1 Water walls water tubes installed in the furnace to protect furnace against high temperature. 9.2.2 Furnace encloses the combustion equipment to utilize effectively the heat generated. 9.2.2.1 Factors to be considered in furnace design a. Air supply b. Character of fuel used c. Degree of pre-heating d. Draft equipment available 9.2.2.2 Types of furnace walls a. Air-cooled masonry walls b. Partially water-cooled walls c. Solid masonry d. Water-jacketed furnace 5
9.2.4
10. Definitions from PSME Code 2008 Boiler or Steam Generator a closed vessel intended for use in heating water or for application of heat to generate steam or other vapor to be used externally to itself. Coal-Fired Boiler used stoketed water temperature coal or pulverized coal for water-tube. Condemned Boiler Unfired Pressure Vessel a boiler or unfired pressure vessel that has been inspected and declared unsafe to operate or disqualified, stamped and marked indicating its rejection by qualified inspecting authority. Existing Installations any boiler or unfired pressure vessel constructed, installed, placed in operation but subject to periodic inspection. External Inspection an inspection made on the external parts, accessories and/or component even when a boiler or unfired pressure vessel is in operation. Fire Tube Boiler a boiler where heat is applied inside the tube. Fusion Welding a process of welding metals in a molten and vaporous state, without the application of mechanical pressure or blows. Gas-Fired Boiler uses natural gas or liquefied petroleum gas (LPG) for heating boiler, fire tube or water-tube. Heat-Recovery Steam Generator unfired pressure vessel that uses flue gas heat. Internal Inspection an inspection made when a boiler or unfired pressure vessel is shut-down and handholes, manholes, or other inspection openings are opened or removed for inspection of the interior. 6
11.1
Factor of Evaporation, FE h s h fw FE = h fg where: hfg = latent heat of vaporization or evaporation at standard atmospheric conditions. hfg = 970.3 Btu/lb or hfg = 2257 Btu/lb or hfg = 539 kcal/kg Equivalent Evaporation, EE EE = ms FE where: ms = amount of steam generated. Equivalent Specific Evaporation, ESE m EE ESE = s FE = mf mf where: mf = amount of fuel burned in the furnace.
11.2
11.3
11.4
ASME Evaporation unit, ASME EU ASME EU = ms (hs h fw ) Rated Boiler Horsepower (Rated Bo Hp) Rated Bo Hp = Total Heating Surface / k where: k = 12 sq ft = 1.1 sq m for fire-tube boilers k = 10 sq ft = 0.91 sq m for water-tube boilers Also Package Fire-Tube Boiler have a heating surface of 5 sq ft per boiler horsepower.
11.5
11.7
11.8
Over-all Boiler Efficiency or Steam Generator Efficiency, eo. ms (hs h fw ) + mrs (hro hri ) + mbo (hbo h fw ) eo = m f HHV where: mrs = amount of steam reheated hro = enthalpy of steam leaving reheater hri = enthalpy of steam entering reheater mbo = amount of water blowdown at boiler pressure hbo = enthalpy of saturated liquid at boiler pressure if there is no reheater and no boiler blowdown. ms (hs h fw ) eo = m f HHV
11.9
Boiler and Furnace Efficiency, ebf ms (hs h fw ) ebf = m f HHV mr HVr where: mf = amount of ash refired HVr = heating value of ash
11.10 Net Efficiency of Steam Generating Unit, enet (ms maux )(hs hfw ) enet = m f HHV where: maux = amount of steam used for SGU auxiliaries. 11.11 Gross Station (Power Plant) Heat Rate, GSHR - Defined as the amount of heat required per unit power developed . Gross heat supplied by fuel GSHR = Gross work output 11.12 Net Station (Power Plant) Heat Rate, NSHR Heat supplied by fuel , m f HHV NSHR = (kW hr generated) (kW hr used by auxiliaries )
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12.2.3 12.2.4
12.2.5
12.2.6
13. Power Rating Mechanical drive turbines are rated in horsepower; turbine-generator units, in kilowatts. Internal power is the product of torque and rotor speed. Nominal rating is a declared power capacity expected to be the maximum load. Capability is the manufacturers guaranteed maximum continuous output for a clean turbine, operating under specific throttle and exhaust conditions, with full extraction at any openings, if provided. Overload capacity is the difference between capability and rating. 14. Willans Line Willans line is a straighlt line which shows the relation between the steam consumption in lb per hr and the load in kW of a steam turbine generator unit.
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y = throttle steam flow, lb per hr a = no-load steam consumption, lb per hr b = slope of the curve, lb per kwhr x = load, kw
15.1
15.3 15.4
15.4
16. Steam Condensers Steam condenser a heat exchanger where steam enters at the top and the condensate is collected in the hot well at the bottom while cooling water flows through the tubes. 17. Functions of Steam Condenser a. To convert steam to liquid before entering the steam-generating unit. b. To create a vacuum at turbine exhaust thereby increasing turbine power. 18. Classification of steam condensers a. Surface condenser where steam and cooling water are not allowed to mix; commonly shell and tube design.
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mw c p (t 2 t1 ) = ms (hs h f )E
20. Vacuum Efficiency, hvac p p vac = atm cond patm psat where: patm atmospheric pressure pcond absolute condenser pressure psat saturation pressure
21. Feedwater Heater Terminal difference is the difference between the saturation temperature of the steam in the heater and the temperature of the water leaving the heater. Subcooling the reduction below saturation temperature. 14
Pump Work = m(h2 h1 ) Pump Work mv1 (p2 p1 ) Pump Work = mgH where: m = mass flow rate, kg/s v1 = specific volume, m3/kg p1 = entrance pressure, kPa p2 = exit pressure, kPa H = head, m
23. Steam Engines Steam engines where steam is admitted to the engine cylinder at throttle pressure during the first part of the working stroke, then cut off by closure of the steam valve. The steam so trapped in the cylinder expands adiabatically to the release pressure, then is exhausted from the cylinder during part of the return stroke. Steam engines are double-acting and the process is isentropic.
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23.2
Piston Volume Displacement Piston rod neglected: VD = 2 D 2 LN 4 Piston rod considered: VD = D 2 LN + D 2 d 2 LN 4 4 Indicated Power IP = pmiVD pmi = indicated mean effective pressure Area of Diagram pmi = Spring Scale Length of Diagram
23.3
23.4
Brake Power BP = 2TN where: T = torque, kN-m N = speed, rev/s Using brake mean effective pressure, pmb BP = pmbVD
23.5
Friction Power Friction Power = Indicated Power Brake Power FP = IP BP Mechanical Efficiency Brake Power m = Indicated Power
23.6
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23.9
24. Combined Cycle Power Plant Combined gas turbine-steam cycle is employed to transfer heat carried by the flue gas in the gas turbine cycle to the feedwater in the steam cycle; the heat exchanger performs the function of a boiler.
Schematic Diagram
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Gas Turbine Cycle: Net Work of the Cycle, Wnet = ma [(hc hd ) (hb ha )] = ma c p [(Tc Td ) (Tb Ta )] Heat Added in the Combustion Chamber, QA = ma (hc hb ) = ma c p (Tc Tb ) Heat Loss in the Heat Exchanger, QL = ma (hd hc ) = ma c p (Td Tc ) Steam Cycle: Net Work of the Cycle, Wnet = ms [(h1 h2 ) v 3 (p4 p3 )] Heat Gained in the Heat Exchanger, QG = m fw (h1 h4 ) = ms (h1 h4 )
Thermal Efficiency of the Combined Cycle, W W + WnetS ek = net = netG QA QA Energy balance in the heat exchanger, Heat lost by exhaust gases = heat gained by feedwater ma c p (Td Tc ) = ms (h1 h4 )
ms =
ma c p (Td Tc ) h1 h4
25. Binary Mercury-Steam Cycle Power Plant Binary mercury-steam cycle - is employed to transfer heat carried by the mercury in the mercury vapor cycle to the feedwater in the steam cycle; the heat exchanger performs the function of a boiler.
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Schematic Diagram
Overall Turbine Work, Wt = Whgt + Wst = mhg (ha hb ) + ms (h1 h2 ) Overall Pump Work, Wp = Whgp + Wsp = mhg (hd hc ) + ms (h4 h3 )
Wp = mhg v c (pd pc ) + ms v 3 (p4 p3 )
Heat Added in the Mercury Boiler, QA = mhg (ha hd ) Thermal Efficiency of Binary Cycle, W Wp W eb = net = t QA QA
Energy Balance in the Heat Exchanger, Heat lost by the mercury heat gained by water mhg (hb hc ) = m fw (h1 h4 )
m fw = ms
Thus,
mhg =
m fw (h1 h4 ) hb hc
where: ms = steam mass flow rate mfw = feedwater flow rate mhg = mercury flow rate
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