Me 157

A Design Proposal
Presented to the Faculty of the

Mechanical Engineering Department
College of Engineering
Mindanao State University
S.Y. 2015 - 2016 General Santos City
DESIGN OF A 54.5
MW STEAM
POWER PLANT
In Partial Fulfillment of the Requirements In

ME 157 - Power Plant Engineering Design
Presented to:
Engr. Abdul Gafur S. Kudarat
Presented by:
Irene Lara M. Abad
Jaycob O. Clavel
Robijeen Jolly R. Estocapio
Allen Mae D. Valiente
December 2015
Design of a 54.5 MW Steam Power Plant
INTRODUCTION
The discovery of electricity is one of the greatest achievements of man. It became a part of
modern life and one cannot think a world without it. Its use has made our lives so comfortable that, today,
scientists in all countries are trying their utmost to use it more and more for all purposes. Electricity can
be considered as the backbone that runs a community, thus, researches, inventions and ideas
concerning the developments of electric generation processes are continuously sought to
provide consumers the best services at least possible cost.
Designing a power generating plant that could be sufficient for the needs of power consumers is
one of the tasks of mechanical engineers. Almost every problem in power plant engineering concerning
engineering physics, thermodynamics, and mathematics has been solved and the materials needed has
been identified. Power plant standards for every component have been published and can be acquired by
anyone. Thus, the design can now be easily made and used by people around the world. Improving the
technology for more sustainability is the only challenge left in the future.
In response to the challenge and in fulfillment of the course ME 157- Power Plant Engineering,
the designers design a steam power plant with a capacity of 54.5 megawatts. This design includes the
design of equipment and plant assembly. For sustainability, the designers chose bituminous coal from
Fayette County, West Virginia as its fuel for firing the steam generator.
HEAT BALANCE
CALCULATIONS
SUMMARY
Power Plant Capacity: 54.5 MW
Non- Reheat Power Plant with Cascaded Backward Feedwater Heaters

From Table 11-2 of Power Plant Theory and Design by Philip J. Potter, the following properties are
obtained for the power plant:
Throttle pressure= 1250 psig
Throttle temperature= 950
Number of extraction openings= 5
Exhaust pressure= 1.5 in. Hg
Saturation temperatures at the openings at turbine rating with all extraction openings in service (F) are
as follows:
Extraction Opening Saturation Temperature, oF

1st 180
2nd 240
3rd 290
4th 360
5th 420
From Table A.2 from Power Plant Technology by M.M El- Wakil, saturation pressures are:
Saturation Temperature, Saturation Pressure,

State Description o
F psia
1 Throttle 950 1264.696
2 Extraction 5 420 308.78
4 Extraction 3 290 58.1025
7 Exhaust 91.66 0.7367
By heat balance calculations, the summary of steam properties is as follows:
Specific Mass flow

Temperature Pressure Enthalpy Entropy
STATE Phase o
Volume Quality Rate
F psia 3
Btu/lbm Btu/lb R
ft /lb lbm/hr
1 DF 950 1264.696 0.6211 1468.283 1.6023 - 373,012.0074
2 SHV 560.5718 308.78 1.8605 1292.1651 1.6023 - 26,897.8959
3 SHV 407.6459 153.01 3.1994 1223.4338 1.6023 - 26,912.81634
4 LVM 290 58.1025 7.1853 1143.0699 1.6023 0.963 14,860.7984
5 LVM 240 24.968 14.9762 1082.2907 1.6023 0.9178 21,037.8772

6 LVM 180 7.511 43.4211 1004.6562 1.6023 0.8654 28,057.9632
7 LVM 91.66 0.7367 351.4786 879.9426 1.6023 0.7876 255,244.6564
8 SL 91.66 0.7367 0.0161 59.7067 0.1146 0 304,340.4968
9 CL 91.8335 58.1025 0.0161 59.8798 0.1146 - 304,340.4968
10 CL 175 58.1025 0.01648 143.03 0.255285 - 304,340.4968
11 CL 235 58.1025 0.01688 203.43 0.346145 - 304,340.4968

12 SL 290 58.1025 0.01735 259.45 0.42361 0 373,012.0074
13 CL 293.7685 1264.696 0.01735 263.324 0.42361 - 373,012.0074
14 CL 360 1264.696 0.01811 332.28 0.51607 - 373,012.0074
15 CL 420 1264.696 0.01894 396.84 0.59145 - 373,012.0074
16 SL 420 308.78 0.01894 396.84 0.59145 0 26,897.8959
17 LVM 360 153.01 0.238 396.84 0.5948 0.0748 26,897.8959

18 SL 360 153.01 0.01811 332.28 0.51607 0 53,810.71224
19 LVM 290 58.1025 0.6084 332.28 0.5208 0.0794 53,810.71224
20 SL 240 24.968 0.01692 208.49 0.35342 0 21,037.8772
21 LVM 180 7.511 3.0795 208.49 0.3577 0.0611 21,037.8772
22 SL 180 7.511 0.01651 148.04 0.26318 0 49,095.8404
23 LVM 91.66 0.7367 37.8577 0.2748 0.26318 0.0848 49,095.8404

SURFACE CONDENSER DESIGN
Exhaust Connection
Drain from FWH 1

Water Outlet
Hotwell Condensate Outlet

Water Inlet
Design Summary:
Condenser Heat Load: 213,697,628.1 Btu/hr

Circulating Water: 34,191.6205 GPM
Shell Diameter: 12.71 ft
Number of passes: Two- pass
Number of tubes: 7,600
Length of tube: 26.28 ft
Tube size and material: 7/8 in. 18 BWG (0.049 in. thick), Admiralty Metal
CIRCULATING WATER COOLING SYSTEM

Design Summary:
Inlet Air Conditions:
Dry- Bulb Temperature= 85F
Wet- Bulb Temperature= 60F
Outlet Air Conditions:
Wet Bulb Temperature= 76.16F
Relative Humidity= 95%
No. of Cooling Tower: 3
Tower Dimensions:
Length= 15ft
Width = 8.033ft
Height= 15ft
FEEDWATER HEATER DESIGN

Closed Feedwater Heater Design
FWH 5
FWH 4
FWH 2
FWH 1
Design Summary:
Feedwater Heater No. of Passes No. of Tubes Tube Size Tube Length
1st 6 360 7/8 in. 15.8 ft
2nd 6 360 7/8 in. 12.4 ft
4th 8 624 7/8 in. 20.1 ft
5th 8 624 7/8 in. 15.7 ft
Feedwater Heater Tube Gauge Tube Material Outside Shell Diam.

1st 18 BWG 90-10 Cu-Ni 3.6 ft
2nd 18 BWG 90-10 Cu-Ni 3.6 ft
4th 18 BWG 70-30 Cu-Ni 2.4 ft
5th 18 BWG 70-30 Cu-Ni 2.4 ft
Feedwater Heater 1
To FWH 2
From Turbine,
5th Extraction
Drain from FWH 2
Drain to Condenser From Pump 1

Feedwater Heater 2
To Deaerator
From Turbine,
4th Extraction
Drain to FWH 1 From FWH 1

Feedwater Heater 4
To FWH 5
From Turbine,
2nd Extraction
Drain from FWH5
Drain to Deaerator
From Pump 2
Feedwater Heater 5
To Steam Generator
From Turbine,
st
1 Extraction
Drain to FWH 4
From FWH 4
Open Feedwater Heater/ Deaerator
From Turbine,
3rd Extraction
From FWH 2
Drain from FWH 4
To Pump 2
Design Summary:
Total Capacity: 373,102.0074 lb/h
Volume: 37.301 cu. ft (D= 3.164 ft, H= 4.746 ft)
Storage Tank:
Volume: 215.725 cu ft. (D= 4.51 ft, H= 13.53 ft)
STEAM TURBINE
Design Summary
A steam turbine converts the heat energy of steam into useful work. The nozzles and diaphragms
in a turbine are designed to direct the steam flow into well-formed, high-speed jets as the steam expands
from inlet to exhaust pressure. These jets strike moving rows of blades mounted on the rotor. The blades
convert the kinetic energy of the steam into rotation energy of the shaft.
Classification of the Designed Turbine

Types of Blades The design employs Pressure Compounding which consists of 4 Rateau stages
in series with an additional Curtis stages at the start and end of the series of stages.
Cylinder Arrangement The turbine is one with a single cylinder with all rotating blades attached
to one shaft and the steam flow all in one direction.
Rotor Diameter
The rotor diameter can be solved using an equation from MMEH (pp9-59). In derived form, that is
D = (6.57hi x 108)0.5 N.
where,
D = rotor diameter, inch
N = angular velocity, rad/min
hi = enthalpy of the steam entering the stage, Btu/lb.
hi = 1468.283 Btu/lb.
D = (6.57 x 1468.283 x 108)0.5 7200

D = 43.422 inches.
Number of Extractions: 6
Single casing units are the most basic style where a single casing and shaft are coupled to a
generator. In this design casing is manufactured by joining half of each casing by a bolt. Designs employ
either a single- or double-shell construction. Both of these shell configurations have been used on many
applications and have accumulated years of operation. These construction methods facilitate the
accommodation of transient thermal stresses and provide a design that resists shell cracking and
alignment changes during operation. The double-shell construction prevents initial steam being in direct
contact with the outer casing joint.
Materials
Casing: 10% Cr-Mo-V-Mb Alloy Steel

Boltings: 10% Cr-Mo-V-Mb Alloy Steel
Rotor: 1% Cr-Mo-V Alloy Steel
Nozzle Block: 10% Cr-Mo-V-Mb-N Alloy Steel (Situated at every entrance of each stage)
Moving Blades: 10% Cr-Mo-V-Mb-N Alloy Steel (Inserted on rotor)
Fixed Blade: 10% Cr-Mo-V-Mb-N Alloy Steel (Inserted on circular plate, welded on casing)
Extraction Destination Mean Wheel Diameter (in.) Mass Extracted (lb/h)

1 To FWH 5 46.95 26,897.8959
2 To FWH 4 50.87 26,912.81634
3 To Deaerator 53.04 14,860.7984
4 To FWH 2 57.58 21,037.8772
5 To FWH 1 61.97 28,057.9632
Exhaust To Condenser 70.05 255,244.6564
STEAM GENERATOR DESIGN
Steam Drum Stack

Boiler Air Preheater
Superheater Economizer
Coal from
Coal Handling Unit
Hopper
Electrostatic
Fuel (Coal) Sillo Precipitator
Ash Conveying System

Boiler Design
Design Summary:
Heat Load Capacity= 399,661,104.2 Btu/h
Furnace and Furnace Water Wall Dimensions:
Height= 53 ft
Length= 20 ft
Width= 20 ft
Tubes:
Tube Material: Carbon Steel
Tube Spacing: 5 in. center spacing
No. of Tubes
Front Wall 48
Rear Wall 48
Roof 48
Side Walls 48
Total projected area of the furnace envelope tubes:

Outside Diameter
Length (ft) No. of Tubes Area (ft2)
(ft)
Front Wall 3/12 53 48 636
Rear Wall 3/12 53 48 636
Roof 3/12 20 48 636
Side Walls 3/12 53 48 (2) 1272
Steam Drum
Design Summary
Material: A387 (Chrome Molybdenum) Alloy Steel
Drum Inside Diameter: 4 ft.
Wall Thickness: 2.89 in.
Drum Length: 21.5 ft.
Superheater Design
Design Summary:
Heat Load Capacity= 107,160,008.5 Btu/h
Mass to be superheated= 121,294.8712 lb/h
Type: Horizontal Convection- Surface (with in-line arrangement)
Tube Specification:
Tube Material Carbon Steel
Tube Spacing 5 in. center spacing
Nominal Pipe Size (in) 2.0
Outside Diameter (in) 2.0
Wall Thickness (in) 0.25
Inside Diameter (in) 1.5
No. of Tube Elements: 34

Area per Element: 407.89 ft2
Length of Element: 778.42 ft
Tube Length: 20 ft
No of Pass per Element: 40
Economizer Design
Design Summary:
Heat Load Capacity: 68,544,686.48 Btu/h
Mass Admitted: 373,012.0074 lb/h
Tube Specification:
Tube Material Carbon Steel
Tube Spacing 4 in. center spacing
No. of Tube Elements: 40

Area per Element: 584.605 ft2
Length of Element: 1115.61 ft
Tube Length: 20 ft
No of Pass per Element: 56
ACCESSORIES
Air Preheater
Design Summary
Tube Specification:
Tube Material No. 14 BWG Steel Tubes
Tube Spacing 2.5 in. center spacing
Tube Arrangement Staggered tubes
No. of Air Passes: 4

Total Outside Area per Pass: 20,462.7912 ft2
Tube Length: 30 ft
No. of Tubes per Pass: 1299
Arrangement: 25 rows of 27 tubes and 24 rows of 26 tubes alternately arranged
Stack
Design Summary:
Mass of Flue Gas: 519434.2862 lb/h
Flue Gas Quantity: 177020.4 cfm
Diameter: 6.15 ft.
Height: 187.68 ft.

POWER PLANT
ASSEMBLY-
PIPING
ANALYSIS
PIPE SIZING
Line 1:
m1 = 373,012.01 lb/hr
v6 = 0.6211 f3/lb
From the recommended velocities of Table 2-6 (Potter) for superheated over 600 psig, 8 in.
diameter and larger pipes, the designer try the average value of 13000 fpm. Then, the required area of
flow is about,
(373,012.01)(0.6211)
= = = 42.77 2
(60)(13000)
From Appendix of PPTD (Plate 1), using 8 in. schedule 40 pipe with internal cross sectional area of
43.5in.2, the velocity of water flowing inside the pipe is,
(373,012.01)(0.6211)
= = = 12782.2
(60)(43.5)
Thus, this velocity is within the range of the recommended velocity.
The table below shows the summary of the piping system for the steam power plant.
The mass flow, actual velocity, pipe size, and the corresponding insulations are calculated.
Specific Assumed Nominal Final

Mass Final Area
Line Description Volume Velocity Area (in2) Schedule Pipe Size Velocity
(lb/hr) 3
(in2)
(ft /lb) (fpm) (in) (fpm)
1 Steam Generator to Turbine 373,012.01 0.6211 13000 42.77 100.00 43.5 8 12782.2
2 Turbine to 5th FWH 26,897.90 1.8605 9000 13.34 80.00 18.19 5 6602.78
3 Turbine to 4th FWH 26,912.82 3.1994 6000 34.44 80.00 45.7 8 4521.92
4 Turbine to Deaerator 14,860.80 7.1853 6000 42.71 80.00 45.7 8 5607.67
5 Turbine to 2nd FWH 21,037.88 14.9762 5000 151.23 80.00 160.9 16 4699.58
6 Turbine to 1st FWH 28,057.96 43.4211 15000 194.93 80.00 204.2 18 14319
7 Turbine to Exhaust 255,244.66 351.4786 24000 8,971.30 8 x 8 ft 23362.8
8 Pump1 Inlet 304,340.50 0.0161 250 47.04 40.00 50 8 235.194
9 Pump1 Outlet 304,340.50 0.0161 600 19.60 40.00 20.01 5 587.692
10 1st FWH to 2nd FWH 304,340.50 0.01648 600 20.06 80.00 26.1 6 461.198
11 2nd FWH to Deaerator 304,340.50 0.01688 600 20.55 80.00 26.1 6 472.392
12 Pump2 Inlet 373,012.01 0.01735 250 62.13 80.00 71.8 10 216.326
13 Pump2 Outlet 373,012.01 0.01735 600 25.89 80.00 26.1 6 595.104
14 4th FWH to 5th FWH 373,012.01 0.01811 600 27.02 80.00 28.9 6 560.989
15 5th FWH to Steam Generator 373,012.01 0.01894 600 28.26 80.00 28.9 6 586.7
16 Drain, 5th FWH to 4th FWH 26,897.90 0.01894 440 2.78 80.00 2.953 2 414.044
17 Drain, 4th FWH to Deaerator 53,810.71 0.01811 440 5.32 80.00 6.6 3 354.368
18 Drain, 2nd FWH to 1st FWH 21,037.88 0.01692 440 1.94 80.00 2.953 2 289.301
19 Drain, 1st FWH to Condenser 49,095.84 0.01651 440 4.42 80.00 6.6 3 294.754
Condenser to Header 17095810 0.016041 600 1,096.94 1134.1149 38 580.333
Header to Cooling Towers 5698603.4 0.016041 600 365.65 60.00 382 24 574.314
Header to Condenser 17095810 0.016041 600 1,096.94 1134.1149 38 580.333
Cooling Towers to Header 5698603.4 0.016041 600 365.65 60.00 382 24 574.314
POWER PLANT
MANAGENENT-
AUXILLIARIES
COAL HANDLING UNIT AND STORAGE
Coal handling systems are an integral part of a complete material flow and quality management
system. Proper management can contribute to making use of coal in a more efficient and in a more
sustainable way. Also, complete sysem optimisation is required to secure the coal supply in sufficient
quality and quantity.
Coal handling unit will not use any agriculture land and will be located at a distance of two
hundred fifty meters away from any surrounding agricultural land. Thus, a government waste land not
suitable for any agriculture purposes which meets with the requisite distance criteria will be preferred for
establishing the unit. Furthermore, the area will be five hundred meters away from residential areas,
roads and highways as well as ecological sensitive areas like forests.
On the other hand, the unit will store coal in such a way that coal heap will not be higher than five
meters and a clear distance between two adjoining heaps will be maintained at five meters, so that in
case of fire, approach is available. In addition to that, continuous water sprinkling shall be carried out on
the top of the heap at regular intervals to prevent dusting, fire and smoke. Thus, an adequate fire fighting
measure like adequate water storage facility will be provided to avoid any fire or related hazards. In
addition, an onsite emergency plan shall be prepared and implemented and the premises shall be used
exclusively for storage of coal.
Coal storage area will have a mechanized loading/unloading system from the loading/unloading
area to the stacking yards and in to the vehicles. Regular sweeping of coal dust from internal and main
road will be done to ensure that there will be an adequate space for free movement of vehicles.
Proper drainage system will be provided in the area so that water drained from sprinkling and
runoff is collected at a common tank and can be reused after screening through the coal slit or any other
effective treatment system. Also, all the engineering control measures and state of art technology
including covered conveyer belts, mechanized loading and unloading, provision of silo etc. will be provided
in addition to the measures recommended in the environmental guidelines for curbing the pollution.
EMP (Environment Management Plan) will be prepared and will be implemented in the same true
spirit in the plant to maintain overall environment of the area. It will not carry out the operation of
loading/unloading of coal/coal dust at any place, till adequate air pollution control equipment for dust
control/suppression are installed.
EMISSION CONTROL EQUIPMENT
Coal is one of the most abundant energy sources in the world. However, advanced emission
control technologies are needed to cleanly use coal for electricity generation. Environmental regulations
of coal-fired power plants in Asia cover a broad range of requirements and depending on the area within
Asia and the type of coal to be burned, different combinations of technologies are needed to meet local
regulations.
Solid and liquid matter of organic or inorganic composition, suspended in flue gas or in the
atmosphere is generally referred to as particulate. Particle size from combustion sources are usually found
between 1 to 100 microns, although particles smaller than 1 micron can occur through condensation
processes. Furthermore, these fine particles are formed in the atmosphere when gases such as SO2, NOx,
and volatile organic compounds (VOCs), emitted by combustion processes, are transformed into fine
particulate by chemical reactions in the air. Among the effects of particulate emissions are impaired
visibility such as smog and haze, soiling of surrounding areas, aggravation of the adverse effects of SO2,
impaired plant growth and human respiratory problems.
Particulate control equipment is designed to remove the particulate from the flue gas stream,
prevent the particulate from re - entering the flue gas, and discharge the collected material. There are
several types of particulate removal equipment and the selection is typically limited to electrostatic
precipitators (ESP) and fabric filters to meet high efficiency and high reliability requirements. So, for our
power plant, the former is used.
ESPs are large, industrial emission-control unit and continue to be excellent devices for control of
many industrial particulate emissions, including smoke from electricity-generating utilities (coal and oil
fired). These devices treat gas volumes from several hundred thousand in the largest coal-fired boiler
applications which is usually performed in downstream of the air preheater.
In many industrial plants, particulate matter created in the industrial process is carried as dust in
the hot exhaust gases. ESPs are designed to trap and to remove these dust particles from the exhaust gas
stream. On the other hand, precipitators function by electrostatically charging the dust particles in the
gas stream. Then, the charged particles are attracted and deposited on plates or other collection devices.
Consequently, when enough dust has accumulated, the collectors are shaken to dislodge the dust, causing
it to fall with the force of gravity to hoppers below. The dust is then removed by a conveyor system for
disposal or recycling. Furthermore, the cleaned gas passes out of the precipitator and through a stack to
the atmosphere.
Depending upon dust characteristics and the gas volume to be treated, there are many different
sizes, types and designs of electrostatic precipitators. Very large power plants may actually have multiple
precipitators for each unit and this is implemented on our power plant.
Flue Gas Recirculation (FGR) is the most effective technique for reducing NOx emissions from
industrial boilers and is applied for this steam power plant. With FGR, a portion of the relatively cool boiler
exhaust gases re-enter the combustion process, reducing the flame temperature and associated thermal
NOx formation. Furthermore, external FGR employs a fan to recirculate the flue gases into the flame, with
external piping carrying the gases from the stack to the burner. Also, a valve is employed to control the
recirculation rate. A portion of the gases travel via ductwork or internally to the air fan, where they are
premixed with combustion air and introduced into the flame through the burner. On the other hand,
Induced FGR in newer designs utilize an integral design that is relatively uncomplicated and reliable. In
addition, the physical limit to NOx reduction via FGR is 25 percent for standard fuel oils.
Flue Gas Desulfurization (FGD) is used for controlling SOx emissions in the power plant. Use of low
sulfur fuels is the most cost effective SOx control method for industrial boilers, as it does not require
installation and maintenance of special equipment. In addition, FGD systems are of two types: non-
regenerable and regenerable. The most common, non-regenerable, results in a waste product that
requires proper disposal. Regenerable FGD converts the waste product into a product that is saleable,
such as sulfur or sulfuric acid. Furthermore, SOx emissions reductions of up to 95 percent can be obtained
with FGD.
ASH HANDLING EQUIPMENT
Fly ash will be conveyed to silos through pressure systems. Pressure systems offer high-capacity
fly ash transport over long conveying distances. In addition, pressure vessels required at each collection
hopper are furnished with rugged valving with hardened seats and discs, internal aeration to provide
positive ash flow, and air flow control from the clean side of the vessel to provide uniform, controlled ash
flow to the conveying line. Several vessels are connected to one conveying line however, for different
conveying quantities, different pressure vessel sizes can be combined. Furthermore, the energy
consumption is relatively low thus, conveying distances greater than one thousand meters are possible.
The collected fly ash is then transported to central cone silo which will handle the ash. It is equipped with
a pneumatic discharge bottom and provided for metered and maintenance free discharge of material.
From being waste material, fly ash has now become a commodity. The power plant supports this
with innovative and economical technology. The collected fly ash is processed into high quality ash with
a continuous mechanical mixer. Mixers with capacities ranging between one hundred to two hundred fifty
tons per hour will be used. To satisfy the high quality requirements stipulated by the cement and concrete
standards, additional fly ash homogenisation will be done. At least two silos are required for such concept.
One silo is used to take up the fly ash during operation while homogenisation is carried out in the second
silo. In addition, the silos are equipped with so called quadrant homegenisation systems which are used
to fluidise, to circulate and to mix the contents of the silo section by section.
FUEL BURNING EQUIPMENT
For the power plant, chain grate stokers will be used which is a common type of an overfeed
stoker in which the coal is fed onto the grates above the point of air admission. It will consist of staggered
links mounted on bars which resuts to a continuous chain that is placed over sprocket wheels at each end
of the stoker. Furthermore, the grate will receive coal from the hopper at the front of the boiler. Then,
constant speed a c motors with variable speed transmissions will be used to drive the grate. Also,
primary air is supplied from below the stoker through the use of intermediate vertical baffles.
FEEDWATER REGULATOR
The basic function of feedwater regulator in power plants is to maintain enough feedwater for
the steam boiler to keep it on the range of NOWL (Normal Operation Water Level). Maintained water level
is totally important to keep steam boiler safe from both short term overheating or long term overheating
and also damage turbine generator.
This steam power plant is designed to have a thermostatic expansion regulator type of feedwater
regulator. This type of feedwater regulator which uses inclined tube and connects it between feedwater
control valve and boiler. If the water level in the boiler indicates low level, the tube will get expansion, so
the feedwater control valve will supply the feedwater to the boiler.
TURBINE LUBRICATION
Lube systems for steam turbine are not significantly different from oil supplies for centrifugal
compressors or other turbomachines. Although lube oil supply systems come in numerous layouts and
configurations, they would essentially embody the principal components shown below. The oil supply
system is designed to cope with the requirements of the turboset or equipment train. The figure below
shows the lubricating system for a turbine used to drive a generator direct.
(1) The main oil pump is driven off by the turbine shaft.
(2) The auxiliary pump is designed for 100 percent capacity supplies lubricating oil while the set is
being started up or running down. It is usually a gear oil pump like the main pump and is driven
by an AC motor.
(3) The battery-operated emergency oil pump is generally a centrifugal pump and designed to supply
40 percent of the required amount of oil. In the event of the auxiliary pump failing, it ensures that
the turboset receives sufficient oil while running down.
(4) A jacking oil pump makes sure that an oil film exists between bearing and journal or shaft surfaces
from the very instant rotation commences.
(5) (6) The oil cooler and filter are duplicated so that they can be maintained while the set is running.
APPENDIX

Me 157

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Me 157

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A Design Proposal

Presented to the Faculty of the

In Partial Fulfillment of the Requirements In

Power Plant Capacity: 54.5 MW

Non- Reheat Power Plant with Cascaded Backward Feedwater Heaters

Extraction Opening Saturation Temperature, oF

Saturation Temperature, Saturation Pressure,

By heat balance calculations, the summary of steam properties is as follows:

Specific Mass flow

4 LVM 290 58.1025 7.1853 1143.0699 1.6023 0.963 14,860.7984

5 LVM 240 24.968 14.9762 1082.2907 1.6023 0.9178 21,037.8772

8 SL 91.66 0.7367 0.0161 59.7067 0.1146 0 304,340.4968

9 CL 91.8335 58.1025 0.0161 59.8798 0.1146 - 304,340.4968

10 CL 175 58.1025 0.01648 143.03 0.255285 - 304,340.4968

11 CL 235 58.1025 0.01688 203.43 0.346145 - 304,340.4968

14 CL 360 1264.696 0.01811 332.28 0.51607 - 373,012.0074

15 CL 420 1264.696 0.01894 396.84 0.59145 - 373,012.0074

16 SL 420 308.78 0.01894 396.84 0.59145 0 26,897.8959

17 LVM 360 153.01 0.238 396.84 0.5948 0.0748 26,897.8959

20 SL 240 24.968 0.01692 208.49 0.35342 0 21,037.8772

21 LVM 180 7.511 3.0795 208.49 0.3577 0.0611 21,037.8772

22 SL 180 7.511 0.01651 148.04 0.26318 0 49,095.8404

23 LVM 91.66 0.7367 37.8577 0.2748 0.26318 0.0848 49,095.8404

SURFACE CONDENSER DESIGN

Drain from FWH 1

Hotwell Condensate Outlet

Condenser Heat Load: 213,697,628.1 Btu/hr

CIRCULATING WATER COOLING SYSTEM

FEEDWATER HEATER DESIGN

Feedwater Heater Tube Gauge Tube Material Outside Shell Diam.

Drain from FWH 2

Drain to Condenser From Pump 1

Drain to FWH 1 From FWH 1

Open Feedwater Heater/ Deaerator

Classification of the Designed Turbine

D = (6.57 x 1468.283 x 108)0.5 7200

Casing: 10% Cr-Mo-V-Mb Alloy Steel

Extraction Destination Mean Wheel Diameter (in.) Mass Extracted (lb/h)

STEAM GENERATOR DESIGN

Steam Drum Stack

Ash Conveying System

Total projected area of the furnace envelope tubes:

No. of Tube Elements: 34

No. of Tube Elements: 40

No. of Air Passes: 4

Mass of Flue Gas: 519434.2862 lb/h

Flue Gas Quantity: 177020.4 cfm

Diameter: 6.15 ft.

Height: 187.68 ft.

Thus, this velocity is within the range of the recommended velocity.

Specific Assumed Nominal Final

COAL HANDLING UNIT AND STORAGE

EMISSION CONTROL EQUIPMENT

ASH HANDLING EQUIPMENT

FUEL BURNING EQUIPMENT

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