Sizing and Selection of Steam Turbine :

Classification of Steam Turbine and its Application

Basic Type Operating Condition Steam Condition Application
Drivers for electric
High-Pressure turbine (with 6.89 – 165.36 Bar,
generators, blowers,
Condensing or without extraction for saturated, 565.6 C, .
compressor, pumps,
feed water heating) 033 – .17 Bar abs.
marine propulsion, etc.

0 – 6.89 Bar, Drivers for electric

Low-Pressure turbine saturated, 398.89 C, . generators, blowers,
033 – .17 Bar abs. compressor, pump, etc.

99.97 – 241.31 Bar,

Reheat turbine saturated, 398.89 C, . Electric-utility plants
033 – .17 Bar abs.

6.89 – 165.36 Bar, Drivers for electric

Automatic extraction saturated, 565.6 C, . generators, blowers,
033 – .17 Bar abs. compressors, pump etc.

6.89 – 165.36 Bar, Drivers for electric

Mixed-Pressure(induction)
saturated, 565.6 C, . generators, blowers,
turbine
033 – .17 Bar abs. compressors, pump etc.

Cross-compound
turbine(with or without 27.6 – 99.97 Bar,
extraction for feed water 750 – 1050 C, & Marine propulsion
heating, with or without .033 – .17 Bar abs.
reheat)
41.36 – 241.32 Bar,
Drivers for electric
Non – 315.56 – 565.55 C,
Straight – through turbine generators, blowers,
Condensing Atmospheric, 6.89
compressors, pump, etc.
Bar
41.36 – 241.32 Bar,
Automatic extraction 315.56 – 565.55 C,
turbine Atmospheric, 41.36
Bar
 Chart 1 - Mechanical Efficiency (MeEff) vs. Rated Power (KW)

Chart 2: Speed (RPM) vs. Turbine Work (KW) and Type of TurbineStages

Fig. 6.1 Stem Turbine

Preliminary sizing of a steam turbine condensing type – single stage given the power plant coal -fired
water-tube boiler generating steam of 113636.4Kg/Hr(Ws) and an operating pressure at P1 = 31 Bar
and temperature atT1 = 350C The steam is condensed at P2 = .103Bar.Determine the following:
1. Draw the T- S diagram with labels
2. Ideal turbinework (iKW)
3. Ideal turbinesteam rate (iTSR)
4. Using iKW as the basis, what are the following efficiencies:
a. Mechanical efficiency (ME_Eff)
b. Isentropicefficiency (Isen_Eff)
c. Break Engine Efficiency (BE_Eff)
d. Generator Efficiency (GE_Eff)
5. Turbine Potential generation Capacity KW
6. Steam Turbine Specs
Solution:
1. T-s diagram with labels

fromMollier Chart
h1 = 3100 Kj/Kg at P1=31 Bar and T1 = 350C
h2 = 2125 Kj/Kg at P2 = .103 Bar
2. Ideal Turbine Work (Wti)
Wti = h1 – h2 = (100 – 2125) = 975 Kj/Kg
3. Ideal Turbine Steam Rate (ISR) and Ideal KW
ISR = 3600/Wti =(3600/975) =3.69 Kg/KW-Hr
iKW = Ws / IRS = 113636.4Kg/Hr/ ISR = 30796 KW
4. Using iKW as the basis, what are the following efficiencies:
Let us make use iKW (instead of the rated capacity) so that we compute for the following efficiencies:
a. Mechanical efficiency (ME_Eff)
ME_Eff = 1.00 – [ .04/(rated KW/1000).50] = 1.00 – [ .04/(iKW/1000).50]
 ME_Eff = 1.00 – [ .04/(30796/1000).50] = .993 (99.3%)
For checking purposes, use Chart 1 = .997 (99.7%)
b. Isentropic efficiency (Isen_Eff)
65% (2 – 5 MW), 70% (5.1 – 10 MW), 75% (10.1 – 25 MW), 80% (25.1 – 50 MW) 84% (>50 MW)
from the above data relating iKW to Isentropic efficiency therefore, Isen_Eff = 80%
c. Break Engine Efficiency (BRK_Eff)
50% (<= 74.6 BKW), 58% (373 BKW), 63% (746 BKW), 72% (3730 BKW), 76% (7460 BKW),
82% (14,920 to 74,600 BKW)
again, from the above data relating iKW to Break Engine Efficiency therefore, BRK_Eff = 82%
d. Generator Efficiency (GE_Eff)
using iKW instead of rated KW
GE_Eff = .96 – [.025/(rated KW/1000).333] = .96 – [.025/(iKW/1000).333]
GE_Eff = .96 – [.025/((30796/1000).333] = .952 (95.2%)
5. Turbine Potential generation Capacity KW(PGC) or Combined Steam Turbine Work
PGC = (Isen_Eff * Brk_ Eff * GE_Eff) *iKW = .80 * .82* .952* 30796 = 19232.5 KW
Say 20,000 KW
6. Steam Turbine Specs:
a. Using Chart 2 the range of speed is from a maximum 10000 RPM and a minimum5000 RPM.
getting the average of the range, use 7500 RPM.
b. Using the same Chart 2 given the average 7500 RPM use Rateau stages + Reaction single stage.
c. Use air as medium for generator cooling system. Given the following guide:
1. Air cooling system for generator: <=25,000 KW or
2. Hydrogen cooling system for generator =>30,000 KW
d. Use SCSF and non-reheat Type
SCSF – Single case, single flow exhaust ( < = 50,000KW), non-reheat units
TCDF – Tandem compound double flow exhaust (50,000 < KW < = 100,000),non-reheat units
– Tandem compound double flow exhaust 100,000 KW, reheat unit
TCSF – Tandem compound single flow exhaust (60,000 KW & 75,000 KW) reheat units
Design and Sizing of Condenser
Exhaust steam of the above power plant has a dryness quality of x = .80, which enters the surface
condensers at an absolute pressure of .103 Bar and condensing temperature of 45 C. The circulating
cooling H2O enters the condenser at 30 C and leaves at 40 C. Design the condenser and cooling tower
using the closed loop system type. Design, size and determine the following:
1. Process Diagram and steam properties
2. Overall Heat Transfer Coefficient (Ucon) and LMTD
3. Condenser Heat Transfer Surface Area (Acon)
4. Mass of cooling water and Single or Two way Pass
Solution:
1. Process Diagram:

Fig. 7.1 Schematic Diagram of a Wet cooling System Operating as Closed Loop
(Universally Applied)
Condenser Design: Steam and water thermo-physical properties from steam table -2
Ws = 31.6 Kg/s Design WB (Phil) = 27.45 CVw = 2 – 2.5 m/s use 2.3 m/s
Pcon = .103 Bar TW1 = 30 C TW2 = 40 C
x2 = .80 Tcon = 45 T w = .5(30 + 40) = 35 C
hfg = 2394 Kj/ Kg
2. Overall Heat Transfer Coefficient (Ucon)
Ucon =2.15*Vw^.50*(.7586 + .0135*Tcon – .0001*Tcon^2)
Ucon = 2.15*2.3^.50*(.7586 + .0135*45 – .0001*45^2) = 3.794 KW/m^2 – C (3794 W/m^2)
Log Mean Temperature Difference LMTD
LTD = (45 – 30) = 15 C
STD = (45 – 40) = 5 C
 LMTD = (LTD – STD)/ln(LTD/STD)
LMTD = (15 – 5)/ Ln (15/ 5) = 10/ 1.0986 = 9.103 C
3. Condenser Heat Transfer Surface Area ( Ssc)
Acon= [(x2) (hfg)* Ws]/ (Uo*LMTD)
Acon= [(.8* 2394)* 31.6]/ ( 3.794 *9.103) = 1752.34m^2

4. Mass of Cooling Tower Flow Rate (Mw)

@.103 Bar, Tsat = 45 C

Mw = (Ws*x2*hfg)/[Cpw*(Te1 – Te2)]
Mw = (31.6* .80* 2394)/(4.19*10) = 1444.4Kg/s
Preliminary Foot Print and Power Dimensioning of Cooling Tower:
Table 8.1a – Cooling Tower Dimensional Sizing Parameters

Table 8.1b – Cooling Tower Total Fan KW Required

Table 8.1c – Cooling Tower Fan Capacity Required

a. If cooling tower flow, H2O spray and gravity type

Mw = 1484 kg/s (including make-up water supply)
Vw = Ww* Svw at Tw = 35 C, Svw = .001
Vw = 1484 Kg H2O/s* .001 m^3/Kg H2O = 1.484 m^3/s (5342.4m^3/hr)
Xa = RNGE/APRCH = 10/2.5 = 4 - - -
using Table 8.1a for preliminary cooling tower sizing
Ya = 2.5 m^3 /Hr per m^2from Table A.1 in Table 8.2a (Large cooling tower
Type = Counter - Flow w/ water distribution by water spray and gravity
Fan Deck height = 13.2 m
Inlet H2O height = 11m
CT_A = Cooling tower foot print area
= Vw/ (Ya*2.445) = 5342.4/ (2.5*2.445) = 874 m^2
from the same source computing for the number of cell CT_NCL using Table A.1 in Table 8.1a
CT_NCL = Vw/2000 = 5342.4/2000 =2.67, use 3 cells in one cooling tower
CT_W = 13 m width
CT_L = CT_A/CT_W tower total length = 874/13 = 67.23 m
from the same table computing for total fan power using Table B.1 in Table 8.1b
CT_KW = Vw (Yb) / 100/NCL/no. fans per cell
CT_KW = 5342.4* 9.75/100/3/2/.746 = 116.4 Kw per fan
fromTable 8.1c computing for the fan capacityusing Table C.1
CT_Q = Vw*(Yc)*170/ NCL/ no. fans per cell = 5342.4*(6.4)*170/3/2 = 269.1 m^3/s per fan
Section - 8: Design and Sizing of Cooling Tower
Design and Size the cooling tower for the said coal fired thermal power plant, as given below:
DB1 = 33 C WB = 27.45 C design WB for Philippine application
RH1 = 65%
Tw1 = 40 C
Tw2 = 30 C
Determine the following:
1. Process Diagram:

a. Inlet air conditions (using psychrometric chart):

HR1 = .0208 Kg H2o/kg air
SV1 = .8958 m^3/kg air
Ha1 = 86.4 kj/kg
Ha2 = 97 kj/kg @ WB = 27.45& RH = 100%
b. Outlet air condition (using equation)
DB2 = .5752 + .4785 (Tw1 + Tw2) * 50 = .5752 + .4785 (40 + 30) * 50 = 34.1 C
RH2 = Design range (80 - 100%) use ave. = 90%
DB2PS = 14097400 * exp[-3928.5 / (DB2 + 231.667 )]
DB2PS = 14097400* exp[-3928.5 / (265.767)] = 5.364 Kpa
PWVP2 = RH2* DB2PS= .90*5.364 = 4.83 Kpa
HR2 = .622*PWVP2/(101.325– PWVP2) = .622* 4.83/(96.495) = .0311 Kg H2o/kg air
WB2 = 30 C
Ha2 = 1.005*DB2+HR2*(2500+1.82*DB2) = 1.005*34.1+ HR2(2500+1.82*34.1)= 113.95 kj/kg air
2. Cooling tower approach & range:
APRCH = (Tw2 – WB) = (30 –27.45) = 2.5 C
RNGE = (Tw1 –Tw2) = (40 – 30) = 10 C
3. Cooling tower Effectiveness or Efficiency
CT_Efv = RNGE/(RNGE + APRCH)= 10/(10+2.5) = .80 or 80%
4. Cooling Duty, Air Volume and mass flow rate:
CT_Qc = Mw(cpw)(Tw1 – Tw2) heat gain from air = 1444.4 (4.19)(40-30) = 60520.4 kj/s
CT_Va = (CT_Qc *SV1)/[(Ha2 – Ha1)– (HR2 –HR1)*Cpw*Tw2]
 CT_Va = (60520.4*.8958)/[(113.95 – 86.4) – (.0311 – .0208)*4.19*30]
= 54214.17 / [27.55 – 1.295] =2065 m^3/s
CT_Ma = CT_Va/SV1 = 2065/.8958 = 2305.2 kg/s
5. Cooling Tower Different types of H2O losses:
a. Drift loss
DRFT_L = .002 of Mw = .002*1444.4 = 2.89 kg/s
b. Evaporation loss
EVAP_L = .00085(Mw) * 1.8 *(RNGE)= .00085(1444.4)(1.8)(10) = 22.1 kg/s
c. Windage loss
WND_L = .005 * Mw = .005 * 1444.4 = 7.22kg/s
d. Blow down loss
MB = WND_L+EVAP_L+DRFT_L (mass balance) = 7.22 +22.1 + 2.89 = 32.21 kg/s
CYLE = MB/(MB – EVAP_L)=32.21 /(32.21 – 22.1) = 3.19 - - -
BLW_L = EVAP_L/(CYLE – 1) = 22.1 /(3.19 – 1) = 10.1kg/s
e. Make-up H2O for Mw
MH2O = (EVAP_L+WND_L+BLW_L)
= (22.1 + 7.22 +10.1) = 39.42 kg/s
therefore design Mw = 1444.4 + 39.42 = 1484 kg/s
specific volume of water at 35C is .001 m^3/Kg steam, therefore the volume flow
rate is, Vw = Ww* Svw at Tw = 35 C, Svw =.001
Vw= 1484 Kg H2O/s* .001 m^3/Kg H2O = 1.5 m^3/s
it must be noted that when cooling H2O volume flow rate is less than 12.62 m^3/s use
forced draft cooling tower else it would be natural draft type cooling tower.
6. Optimum Liquid to gas mass flow ratio
a. Average cooling a water temperature difference
Tw = (Tw1+Tw2)* .5 = (40+30)* .5 + 273 = 35 C (308 K)
b. Computing for the optimum L/G
L/G = 77.5 - .555*Tw + .001*Tw^2 = 77.5 - .555*(308) + .001*308 2 =1.424
7. Constructing the numerical integration table for K (a) V/L using Chebyshev-method
a. first column will indicate Tw_n = (Tw2+dn*range) where dn = .1, .4, .6, .90, Tw2 = 30 (colder),
range = 10 C (Tw1-Tw2) and also n=1, 2, 3, & 4 Therefore;
Tw_n = Tw2 + (dn)* range
Tw_1 = Tw2 + (d1)* range = 30 + .1 * 10 = 31 C
Tw_2 = Tw 2+ (d2)* range = 30 + .4 * 10 = 34 C
Tw_3 = Tw2 + (d3)* range = 30 + .6 * 10 = 36 C
Tw_4 = Tw2 + (d4)* range = 30 + .9 * 10 = 39 C
b. Second column will indicate Hsw_n = Tw_n @ RH100% and also n=1, 2, 3, & 4,
Therefore;
 Hsw_n = Tw_n @ RH100%
Hsw_1 = Tw_1@RH100% = 31 @ RH100% = 105.1 kj/kg
Hsw_2 = Tw_2@RH100% = 34 @ RH100% = 122.7 kj/kg
Hsw_3 = Tw_3@RH100% = 36 @ RH100% = 135.8kj/kg
Hsw_4 = Tw_4@RH100% = 39 @ RH100% = 158 kj/kg
c. Third column will indicate Ha_n =Ha2 + L/G*dn*range where Ha2 =97 kj/kg @ WB = 29.444 C
w/ RH = 100% , L/G = 1.4 dn= .1, .4, .6, .90, and also n=1, 2, 3, & 4,
Therefore;
Ha_n =Ha2 =L/G*dn*RNGE
Ha_1 = Ha2 + L/G*d1*RNGE = 97+1.4*(.1)10 = 98.4 kj/kg
Ha_2 = Ha2 + L/G*d2*RNGE = 97+1.4*(.40)10 = 102.6 kj/kg
Ha_3 = Ha2 + L/G*d2*RNGE = 97+1.4*(.60)10 = 105.4kj/kg
Ha_4 = Ha2 + L/G*d2*RNGE = 97+1.4*(.90)10 = 109.6kj/kg
d. Fourth column will indicate dhn = (Hsw_n - Ha_n), where n = 1, 2, 3 and 4,
Therefore;
dhn = (Hsw_n–Ha_n)
dh1 = (Hsw_1 – Ha_1) = (102.1 – 98.4) = 6.676kj/kg
dh2 = (Hsw_2 – Ha_2) = (122.7 – 102.6) = 20.004kj/kg
dh3 = (Hsw_3 – Ha_3) = (135.8 – 105.4) = 30.256kj/kg
dh4 = (Hsw_4 – Ha_4) = (158 – 109.6) = 48.184 kj/kg
e. fifth column will indicate 1/dhn, where n=1, 2, 3, and 4
1/dhn
1/dh1 = 1/6.7 = .1498kj/kg
1/dh2 = 1/20.1 = .0499kj/kg
1/dh3 = 1/30.4 = .0331kj/kg
1/dh4 = 1/48.4 = .0208kj/kg
summation 1/dhn = .25336kj/kg
summation 1/dhn(ave) = .0631kj/kg
K (a) V/L= (Tw1 – Tw2)* [summation1/dhn (ave)] = 10* .06315 = .634
Determination of K (a) V/L or NTU @ 100% Water Flow Rate
Water side Air side Dh_n
Tw_n Hsw_n Air Operating Line Ha_n dh_n = (Hsw_n – Ha) 1/dhn
Tw_n = Tw2 *dn*RNGE
C Kj/Kg Ha_n =Ha2 + L/G*dn*range KJ/Kg KJ/Kg
Tw_1 = 30 + .1 *10 31 105.1 Ha_1 = 97 + 1.4*(.1)10 98.424 dh_1 = 6.676 .1498
Tw_2 = 30 + .4 *10 34 122.7 Ha_2 = 97 + 1.4*(.40)10 102.696 dh_2 = 20.004 .0499
Tw_3 = 30 + .6 * 10 36 136.8 Ha_3 = 97 + 1.4*(.60)10 105.544 dh_3 = 31.256 .0319
Tw_4 = 30 + .9 *10 39 158 Ha_4 = 97 + 1.4*(.90)10 109.816 dh_4 = 48.184 .02075
where: dn = .1, .4, .6 & .9 Total 25235
Total/4 (Average) .0631
K(a) V/L= (Tw1 – Tw2)* [summation1/dhn (ave)] =10* .0631
 L/G = 77.5 - .555*Tw + .001* Tw^2 (where: Tw in K)

Chart 8.1 - Optimum L/G(Kg water/Kg air vs mean water Tw)

f. Using mass and heat transfer coefficient from the above item # 7
K (a) V/ (mw_L) = .6315
Using the above “Cooling Tower Design Parameters” optimum L/G can be obtain from Chart 8.1
L/G = 1.4 or by an equation 1.424
Design typical values for cooling tower are as follow:
mw_L = 2.935 Kg H2O/s per m^2 water loading
ma_L = 2.445 Kg air/s per m^2 air flow loading
K (a) = .534 Kg air/s per m^3
therefore:
CT_A = Cooling tower area occupied or cooling tower foot print
= (Mw/mw_L) = (1484/2.935) = 505.62 m^2
CT_Hf = Cooling tower fill material = [K (a) V/mw]* [ mw_L/K(a) ] = .6315*2.935/.534 = 3.47 m,
say 3.5m
CT_Vf = Cooling tower fill material volume
= CT_A* CT_Hf = 505.62*3.5 = 1770 m^3
HDU = Height of diffusion units
= CT_Hf/ [K (a) V/mw] = 3.47/ .6315 = 5.495 m
Total Cooling Tower Height is
CT_H = CT_Hf + HDU = 3.47 + 5.495 = 8.965 say 9m