ME 412 Heat Transfer Laboratory9/4/02

ME 412

Heat Transfer Laboratory

Power Plant Lecture

Electric power generation is an essential element in a modern industrialized society. In fact many of the indicators of such a society, longevity, per capita income, etc., are directly correlated with electricity production. Most electric power generation is achieved through the conversation of fossil fuel energy in a steam power system. The laboratory experience this week focuses on steam power systems and has two distinct components that are both very different from our normal experiments:

Tour of Campus Power Plant

Computer Simulation of Steam Power Systems

In planning this experiment several objectives were addressed and are listed below:

See what a "real" world thermal system looks like

{it's just not little boxes connected on a diagram}

Understand that there is a different jargon in industry vs. academia.

{examples of industry using pounds to describe anything from mass flow rate (lbm/hr) to pressure (psi)}

Recognize the importance of the tremendous knowledge base of technicians (non-degreed engineers) in industry

Utilize some calculation tools available for system analysis

Power Plant Tour

Scheduled for 7:00 pm on October 12, 13, 14 (Tuesday, Wednesday, Thursday) Begins with a 45 minutes to an hour presentation by the power plant staff, followed by a tour of the facility. Plan to spend from 2 to 2 and 1/2 hours and wear flat shoes and slacks. During the presentation you will want to collect the information needed to fill out the worksheet. You should review the worksheet questions, especially those that are going to require calculations, so you know what information you will need. Bring the worksheet with you to the tour as you are required to obtain a signature from the instructional staff to verify your attendance. The worksheet on the tour component is to be done individually and every student must submit a completed worksheet. The power plant is located as shown below. Parking is limited, so you may wish to carpool.

Map to Simon Power Plant

Worksheet I Power Plant Tour

Due Friday, October 22 by 5:00 p.m.

Turn in to your regular TA (or their mailbox)

Student Name

1. Signature of TA to verify attendance

2. Answer the following questions concerning the T.B. Simon Power Plant.

a. What are the three mass streams associated with a coal fired, steam power plant?

b. Provide three methods that are employed to reduce particulate emissions in a coal fired power plant.

c. What is the temperature in the combustion chamber?

d. Describe how the boiler works in the Simon Power Plant.

e. What is the source of the air for the combustion chamber?

f. Describe the steam (pressure, temperature, fluid phase) that is sent to campus for heating.

g. What percent of the energy provided by the coal is transformed into electricity? Into usable steam? Provide a calculation using the data from a monthly report.

Computer Simulation

The computer simulation component of the experiment has two parts and is to be done in your normal subgroups of two or three students. To perform the computer simulation you will be using the program RANKINE version 3.0, which allows for the simulation of an infinite number of steam power system layouts as specified by the user. A copy of the users manual is posted on the ME 412 web page. The most important aspect of the program is communicating to it the layout and operating conditions for the power plant of interest. This is done through the creation of an input file which is then read into the program and deciphered into the information required for the calculations. Results are then written to another file. The first part of the simulation involves running an existing input file so as to produce results for the power system layout shown below.

Figure 1. Configuration for Item #1

Transparency #2

This power plant layout is more geared to electricity production, hence it is somewhat more complicated then the Simon Power Plant which is more geared for steam production (for heating the campus buildings). The input file is called Sim1.txt and we can view it with the Wordpad or Notepad editors.

An inputs file has two distinct parts. The first part provides system information while the second part provides device information. With the file looking like below. System information includes everything up to DEVICE #1 SIMPLE BOILER. This includes the title, number of nodes, the temperature information (which is only used for second law considerations), and the generator information. Device information is then provided device by device using the Device Block format

DEVICE #?? SIMPLE ??

END DEVICE

Between these two statements is the information pertinent to the device. There is node information dealing with where the inlets and exits are located in the system, operating conditions such as temperature and pressure, and performance characteristics such as efficiencies and pressure drops. Note that all caps must be used for any text in the input file.

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ME 412 Heat Transfer Laboratory9/4/02

ECHO ON

TITLE LINE

Variation of Condensing Operating Pressure

END TITLE LINE

NUMBER OF NODES:34

HIGH TEMPERATURE RESERVOIR IS 600 DEG C

LOW TEMPERATURE RESERVOIR IS 64 DEG C

DEAD STATE TEMPERATURE IS 25.0 DEG C

DEAD STATE PRESSURE IS 101 KPA

GENERATOR MECHANICAL LOSS IS 0.0 MW

GENERATOR ELECTRICAL LOSS IS 0.0 MW

DEVICE #1: SIMPLE BOILER

BOILER INLET NODE NUMBER IS 34

BOILER EXIT NODE NUMBER IS 1

BOILER REHEAT LEG #1 INLET NODE NUMBER IS 4

BOILER REHEAT LEG #1 EXIT NODE NUMBER IS 5

BOILER REHEAT LEG #2 INLET NODE NUMBER IS 8

BOILER REHEAT LEG #2 EXIT NODE NUMBER IS 9

BOILER EXIT TEMPERATURE IS 600.0 DEG C

BOILER EXIT PRESSURE IS 20 MPA

BOILER EXIT MASS FLOW RATE IS 50.0 KG/SEC

BOILER REHEAT LEG #1 EXIT TEMPERATURE IS 600.0 DEG C

BOILER REHEAT LEG #2 EXIT TEMPERATURE IS 600.0 DEG C

BOILER PRESSURE LOSS IS 0.0 MPA

REHEAT LEG #1 PRESSURE LOSS IS 0.0 MPA

REHEAT LEG #2 PRESSURE LOSS IS 0.0 MPA

END DEVICE

DEVICE #2: SIMPLE PIPE

INLET NODE NUMBER IS 1

EXIT NODE NUMBER IS 2

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #3: SIMPLE TURBINE

INLET NODE NUMBER IS 2

EXTRACTION #1 NODE NUMBER IS 3

STAGE GROUP #1 EFFICIENCY IS 75%

EXTRACTION #1 PRESSURE IS 15.0 MPA

END DEVICE

DEVICE #4: SIMPLE PIPE

INLET NODE NUMBER IS 3

EXIT NODE NUMBER IS 4

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #5: SIMPLE PIPE

INLET NODE NUMBER IS 5

EXIT NODE NUMBER IS 6

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #6: SIMPLE TURBINE

INLET NODE NUMBER IS 6

EXTRACTION #1 NODE NUMBER IS 7

STAGE GROUP #1 EFFICIENCY IS 75%

EXTRACTION #1 PRESSURE IS 7.5 MPA

END DEVICE

DEVICE #7: SIMPLE PIPE

INLET NODE NUMBER IS 7

EXIT NODE NUMBER IS 8

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #8: SIMPLE PIPE

INLET NODE NUMBER IS 9

EXIT NODE NUMBER IS 10

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #9: SIMPLE TURBINE

INLET NODE NUMBER IS 10

EXTRACTION #1 NODE NUMBER IS 11

EXTRACTION #2 NODE NUMBER IS 13

EXTRACTION #3 NODE NUMBER IS 15

EXTRACTION #4 NODE NUMBER IS 17

STAGE GROUP #1 EFFICIENCY IS 75%

STAGE GROUP #2 EFFICIENCY IS 75%

STAGE GROUP #3 EFFICIENCY IS 75%

STAGE GROUP #4 EFFICIENCY IS 75%

EXTRACTION #1 PRESSURE IS 2.5 MPA

EXTRACTION #2 PRESSURE IS 1.0 MPA

EXTRACTION #3 PRESSURE IS 0.3 MPA

END DEVICE

DEVICE #10: SIMPLE PIPE

INLET NODE NUMBER IS 11

EXIT NODE NUMBER IS 12

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #11: SIMPLE PIPE

INLET NODE NUMBER IS 13

EXIT NODE NUMBER IS 14

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #12: SIMPLE PIPE

INLET NODE NUMBER IS 15

EXIT NODE NUMBER IS 16

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #13: SIMPLE PIPE

INLET NODE NUMBER IS 17

EXIT NODE NUMBER IS 18

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #14: SIMPLE CONDENSER

EXIT NODE NUMBER IS 19

INLET #1 NODE NUMBER IS 18

INLET #1 PRESSURE IS 0.29 MPA

END DEVICE

DEVICE #15: SIMPLE PIPE

INLET NODE NUMBER IS 19

EXIT NODE NUMBER IS 20

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #16: SIMPLE PUMP

SUCTION NODE NUMBER IS 20

DISCHARGE NODE NUMBER IS 21

PUMP EFFICIENCY IS 85%

END DEVICE

DEVICE #17: SIMPLE PIPE

INLET NODE NUMBER IS 21

EXIT NODE NUMBER IS 22

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #18: SIMPLE OFW HEATER

FEED WATER EXIT NODE NUMBER IS 23

FEED WATER INLET NODE NUMBER IS 22

EXTRACTION INLET NODE NUMBER IS 16

END DEVICE

DEVICE #19: SIMPLE PIPE

INLET NODE NUMBER IS 23

EXIT NODE NUMBER IS 24

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #20: SIMPLE PUMP

SUCTION NODE NUMBER IS 24

DISCHARGE NODE NUMBER IS 25

PUMP EFFICIENCY IS 85%

END DEVICE

DEVICE #21: SIMPLE PIPE

INLET NODE NUMBER IS 25

EXIT NODE NUMBER IS 26

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #22: SIMPLE OFW HEATER

FEED WATER EXIT NODE NUMBER IS 27

FEED WATER INLET NODE NUMBER IS 26

EXTRACTION INLET NODE NUMBER IS 14

END DEVICE

DEVICE #23: SIMPLE PIPE

INLET NODE NUMBER IS 27

EXIT NODE NUMBER IS 28

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #24: SIMPLE PUMP

SUCTION NODE NUMBER IS 28

DISCHARGE NODE NUMBER IS 29

PUMP EFFICIENCY IS 85%

END DEVICE

DEVICE #25: SIMPLE PIPE

INLET NODE NUMBER IS 29

EXIT NODE NUMBER IS 30

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #26: SIMPLE OFW HEATER

FEED WATER EXIT NODE NUMBER IS 31

FEED WATER INLET NODE NUMBER IS 30

EXTRACTION INLET NODE NUMBER IS 12

END DEVICE

DEVICE #27: SIMPLE PIPE

INLET NODE NUMBER IS 31

EXIT NODE NUMBER IS 32

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

DEVICE #28: SIMPLE PUMP

SUCTION NODE NUMBER IS 32

DISCHARGE NODE NUMBER IS 33

PUMP EFFICIENCY IS 85%

END DEVICE

DEVICE #29: SIMPLE PIPE

INLET NODE NUMBER IS 33

EXIT NODE NUMBER IS 34

PIPE PRESSURE LOSS IS 0.0 MPA

PIPE ENTHALPY LOSS IS 0.0 KJ/KG

END DEVICE

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ME 412 Heat Transfer Laboratory9/4/02

To run Rank30 software for ME 412 just double click on the Rank30 icon on the Heat Transfer Lab PC’s. The program will take a few minutes to load into RAM and then a welcome box will come up and you will be asked to enter the name of the input file. This file must reside on the desktop. After doing this the program will read in the data, process it, write an ECHO file, perform the calculations, prompt for an output files, and then write the results to an output file. The ECHO file presents the input data as the program interprets it. It is quite often useful to look at the ECHO file if the program is not functioning correctly. The results look like below.

The output is presented in three groups. First is node information that consists of the temperature, pressure, enthalpy, etc., at every node n the system. If any entry is -1, there is probably something wrong with input file since the program was unable to calculate the parameter. The second group in the output deals with device information. Work, heat transfer, irreversibilities, etc. are given for each device. Finally, system information such as thermal efficiency and second law effectiveness are given in the third group.

RANKINE 3.0: A steam power plant computer simulation

Copyright 1994

W.A. Thelen, C.W. Somerton

********************************** TITLE ***********************************

Variation of Condensing Operating Pressure

******************************** NODE DATA *********************************

NODE T(C) P(MPa) L Q S(KJ/KG/K) H(KJ/KG) V(M^3/KG) M(KG/S) A(KJ/KG)

------

1 600.00 20.0000 3 ***** 6.5052 3536.61 .01808 50.0000 1602.36

2 600.00 20.0000 3 ***** 6.5052 3536.61 .01808 50.0000 1602.36

3 554.33 15.0000 3 ***** 6.5358 3460.98 .02304 50.0000 1517.59

4 554.33 15.0000 3 ***** 6.5358 3460.98 .02304 50.0000 1517.59

5 600.00 15.0000 3 ***** 6.6756 3579.77 .02482 50.0000 1594.74

6 600.00 15.0000 3 ***** 6.6756 3579.77 .02482 50.0000 1594.74

7 498.28 7.5000 3 ***** 6.7545 3400.01 .04456 50.0000 1391.46

8 498.28 7.5000 3 ***** 6.7545 3400.01 .04456 50.0000 1391.46

9 600.00 7.5000 3 ***** 7.0495 3642.23 .05172 50.0000 1545.76

10 600.00 7.5000 3 ***** 7.0495 3642.23 .05172 50.0000 1545.76

11 453.57 2.5000 3 ***** 7.1840 3357.65 .13081 3.8043 1221.09

12 453.57 2.5000 3 ***** 7.1840 3357.65 .13081 3.8043 1221.09

13 348.68 1.0000 3 ***** 7.2959 3154.40 .28190 3.5656 984.50

14 348.68 1.0000 3 ***** 7.2959 3154.40 .28190 3.5656 984.50

15 232.57 .3000 3 ***** 7.4479 2932.15 .76890 .0881 716.95

16 232.57 .3000 3 ***** 7.4479 2932.15 .76890 .0881 716.95

17 229.50 .2900 3 ***** 7.4518 2926.31 .79067 42.5420 709.96

18 229.50 .2900 3 ***** 7.4518 2926.31 .79067 42.5420 709.96

19 132.38 .2900 4 ***** 1.6585 556.24 .00107 42.5420 66.29

20 132.38 .2900 4 ***** 1.6585 556.24 .00107 42.5420 66.29

21 132.39 .3000 1 ***** 1.6585 556.25 .00107 42.5420 66.30

22 132.39 .3000 1 ***** 1.6585 556.25 .00107 42.5420 66.30

23 133.54 .3000 4 ***** 1.6706 561.16 .00107 42.6301 67.61

24 133.54 .3000 4 ***** 1.6706 561.16 .00107 42.6301 67.61

25 133.66 1.0000 1 ***** 1.6710 562.15 .00107 42.6301 68.49

26 133.66 1.0000 1 ***** 1.6710 562.15 .00107 42.6301 68.49

27 179.87 1.0000 4 ***** 2.1351 762.23 .00113 46.1957 130.27

28 179.87 1.0000 4 ***** 2.1351 762.23 .00113 46.1957 130.27

29 180.20 2.5000 1 ***** 2.1358 764.39 .00113 46.1957 132.21

30 180.20 2.5000 1 ***** 2.1358 764.39 .00113 46.1957 132.21

31 223.94 2.5000 4 ***** 2.5472 961.70 .00120 50.0000 206.91

32 223.94 2.5000 4 ***** 2.5472 961.70 .00120 50.0000 206.91

33 228.65 20.0000 1 ***** 2.5550 987.90 .00121 50.0000 230.81

34 228.65 20.0000 1 ***** 2.5550 987.90 .00121 50.0000 230.81

********************* DEVICE DATA (DEVICE BEFORE NODE) *********************

NODE REV. WRK ACT. WRK IRREV HEAT X-FER MASS ERROR ENERGY ERROR

(KW) (KW) (KW) (KW) (KG/S) (KW)

------

1 44989.95 .00 44989.95 127435.30 .000 .000

2 .00 .00 .00 .00 .000 .000

3 4238.27 3781.70 456.57 .00 .000 .000

4 .00 .00 .00 .00 .000 -.001

5 160.61 .00 160.61 5939.89 .000 -.001

6 .00 .00 .00 .00 .000 -.003

7 10164.18 8988.03 1176.15 .00 .000 -.004

8 .00 .00 .00 .00 .000 .006

9 766.36 .00 766.36 12110.71 .000 .006

10 .00 .00 .00 .00 .000 .003

11 16233.47 14228.80 2004.67 .00 .000 .000

12 .00 .00 .00 .00 .000 .000

13 10929.38 9389.50 1539.88 .00 .000 .000

14 .00 .00 .00 .00 .000 .000

15 11405.61 9474.37 1931.24 .00 .000 .000

16 .00 .00 .00 .00 .000 .000

17 297.62 248.47 49.15 .00 .000 -.001

18 .00 .00 .00 .00 .000 .000

19 17771.18 .00 17771.18 -100827.50 .000 .000

20 .00 .00 .00 .00 .000 -.001

21 -.47 -.53 .06 .00 .000 -.001

22 .00 .00 .00 .00 .000 -.001

23 1.40 .00 1.40 .00 .000 .000

24 .00 .00 .00 .00 .000 .000

25 -37.42 -42.03 4.61 .00 .000 .000

26 .00 .00 .00 .00 .000 .000

27 412.19 .00 412.19 .00 .000 -.001

28 .00 .00 .00 .00 .000 -.001

29 -89.85 -99.62 9.76 .00 .000 -.001

30 .00 .00 .00 .00 .000 -.001

31 407.60 .00 407.60 .00 .000 -.003

32 .00 .00 .00 .00 .000 .001

33 -1194.78 -1310.24 115.46 .00 .000 .001

34 .00 .00 .00 .00 .000 .001

******************************* SYSTEM DATA ********************************

TOTAL MASS FLOW RATE EXITING SYSTEM: .0000 KG/SEC

TOTAL MASS FLOW RATE ENTERING SYSTEM: .0000 KG/SEC

TOTAL ENTHALPY FLOW RATE EXITING SYSTEM: .0000 KW

TOTAL ENTHALPY FLOW RATE ENTERING SYSTEM: .0000 KW

TOTAL HEAT AND WORK ENTERING SYSTEM: .0000 KW

BOILER HEAT (DEVICE # 1): 145485.9000 KW

TOTAL BOILER HEAT: 145485.9000 KW

TOTAL HEAT LOAD HEAT: .0000 KW

CONDENSER HEAT (DEVICE # 14): -100827.5000 KW

TOTAL PIPE ENERGY LOSSES: .0000 KW

TURBINE WORK (DEVICE # 3): 3781.7020 KW

TURBINE WORK (DEVICE # 6): 8988.0250 KW

TURBINE WORK (DEVICE # 9): 33341.1400 KW

NET WORK TO GENERATORS: 46110.8700 KW

PUMP WORK (DEVICE # 16): -.5349 KW

PUMP WORK (DEVICE # 20): -42.0316 KW

PUMP WORK (DEVICE # 24): -99.6179 KW

PUMP WORK (DEVICE # 28): -1310.2390 KW

TOTAL PUMP WORK: -1452.4230 KW

GENERATOR MECHANICAL LOSSES: .0000 KW

GENERATOR ELECTRICAL LOSSES: .0000 KW

NET ELECTRICAL POWER: 44658.4500 KW

SYSTEM HEAT RATE: 11115.4300 BTU/KW*HR

CARNOT CYCLE EFFICIENCY: 61.3975 PERCENT

1ST LAW THERMAL EFFICIENCY: 30.6961 PERCENT

2ND LAW THERMAL EFFICIENCY: 47.4019 PERCENT

2ND LAW EFFECTIVENESS: 49.9956 PERCENT

The first part of the simulation asks you to run this configuration several times changing the condenser operating pressure and graph the first law thermal efficiency versus the condenser pressure.

For the second part of the simulation you are asked to create an input file to represent the Simon Power Plant. To do this it is probably best to simply edit the Sim1.txt file. You need to specify the correct number of nodes. Eliminate all of the piping, all but one turbine, no reheat, leave only one feedwater heater, and add the heat load. Table 1 has the operating data you will use and note that you may leave it in the mixture of units as RANKINE can handle different units. Table 3 in the RANKINE users guide will tell you the appropriate abbreviations for the units. To be used as a target, I will tell you that the first law thermal efficiency for the Simon simulation should be 24.8284%.

Table 1. Data for T.B. Simon Power Plant

Turbine Data
Turbine Stage Efficiency / 91% / best estimate
Extraction #1 Pressure / 186 psig / to feedwater heater
Extraction #2 Pressure / 93 psig / to building heat load
Extraction #3 Pressure / -21 in of Hg gauge / to condenser
Extraction #2 Mass Flow / 115,000 lbm/hr / to campus buildings
Pump Data
Pump Efficiencies / 87% / best estimate
Heat Load Data
Exit Temperature / 47°C
Boiler Data
Boiler Exit Pressure / 869 psig
Boiler Exit Temperature / 854°F
Boiler Exit Mass Flow Rate / 250,000 lbm/hr

Figure 2. Layout of T.B. Simon Power Plant

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