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Process

Measurements
• Cogeneration Plant
Real World Engineering
Process Simulation
• Flow
• Temperature
• Pressure
Life in the Day
of an Engineer:
Week 1
• Tour of Cogeneration
Facility
• Process Simulation using
HYSYS
• Homework: Heat Duty Boiler
Heat Recovery Steam
Generator (HRSG)

Calculations Feed
Water from
T P
Economizer
T P
HRSG
SP
To Main
Steam
Deaerator Feed Water Flow Steam Flowmeter Line
Tank FDWTR F
FDWTR
HRSG SF
T Continuous Liquid
Blow-Off
Process
Engineering
Objectives
• Unit Conversion & Dimensional homogeneity
• Engineering Equations and Calculations
• Energy balances based on readings taken in plant.
• Process Equipment Identification
• Chemical Process Simulation HYSYS
• Describe the process of cogeneration to a high
school student.
Exhaus t Gases
to Stack
Feed Water from T P
Stack Gas
Deaerator Tank Emissions

Exhaust Gases
CO & O2

Feed Water Flow


FDWTR F
Room Air Econ
Natural Gas Fuel Oil To Main Steam T
Compressor
Line Econ
Natural Gas

Cogeneration
P
Bypass

Economizer
Stack T
FLU O
T

FLU O
HRSG
Turbine Fuel Flow
Water Injection TN Gas or TF Oil
SP
P
Duct Burner Fuel
for NOx and Flow
Temperature Control DB Oil or Gas Exhaust Gases

Expansion
Steam

Joint
T W IJF Flowmeter

at the Rowan University


HRSG SF
Burner

Damper
Steam Production Drum
Reduction
Continuous
Gearbox FLU I Liquid
T Blow-Off
Hot Vertical Columns
Power of Heat
Exhaus t Exchanger Tubes
Generation

Central Heating Plant


Gas es

ENG Turbine Inlet Air FLU I


AIR T Compressor P
Duct Water Drum
Burner
Turbine for FDWTR
Air From Generation of Manually
T
T

Roof Vent Operated Liquid Heat Recovery Steam


Electricity Blow-off
Generator (HRSG)

Rowan Cogeneration Plant


Energy Recovery International

• Useful thermal energy


(steam) and electricity
• Heating & Cooling
• Electricity Needs -
60% (1.5 MW)
Overall Schematic
Exhaust Gases
Electricity N2, CO 2, H 2O,
O2, NO, CO, HC's of Steam &
Generation
Steam to
Buildings
Electricity
Building

Steam & Electricity


Generation
A

Generation Plant

Building
Fuel & Air B

Building
C

Condensate Return to Plant


(Steam condensed to water)
Brainstorm a
Process that you
are familiar with
• Flows into process
• Flows out of process
• chemical transformations within process
• Process conditions, T, P, Flowrate, Concentrations
Air Vent to
Roof for
Sewer Line

Jacuzzi
Cold water to
faucets,etc.
valve
Cold Water Combustion
from Mains Exhaust
Gases to Vent Pump
valve valve
liquid flowmeter

valve Hot Water to


check Faucets etc.
Relief
valve
Valve
check
v alv e Water Drain
to City Sewer
valve

Hot
Water
Tank

Natural Gas Relief Vent for Hot


From Mains Water Tank
valve
gas flowmeter

Air From Room

Process Flow Diagram of Hot Water


Production for Jacuzzi
Exhaus t Gases
to Stack
Feed Water from T P
Stack Gas
Deaerator Tank Emissions
CO & O2

Exhaust Gases

Feed Water Flow


FDWTR F
Room Air Econ
Natural Gas Fuel Oil To Main Steam T
Line Econ
Compressor
Natural Gas

M
P
Bypass

Economizer
Stack T
FLU O
T

FLU O
HRSG
Turbine Fuel Flow

Water Injection P
TN Gas or TF Oil

SP
Duct Burner Fuel
for NOx and Flow
Temperature Control DB Oil or Gas Exhaust Gases

Expansion
Steam

Joint
T W IJF Flowmeter
HRSG SF
Burner

Damper
Steam Production Drum
Reduction
Continuous
Gearbox FLU I Liquid
T Blow-Off
Hot Vertical Columns
Power of Heat
Exhaus t Exchanger Tubes
Generation
Gas es

ENG Turbine Inlet Air FLU I


AIR T Compressor P
Duct Water Drum
Burner
Turbine for FDWTR
Air From Generation of Manually
T
T

Roof Vent Operated Liquid Heat Recovery Steam


Electricity Blow-off
Generator (HRSG)

Rowan Cogeneration Plant


Energy Recovery International
Cogeneration Process Water
Flow Diagram
Steam Pressure

Steam Mass Flowrate


Feed Water Boiler Inlet Water
Pressure Temperature Boiler
Feed Water
Temperature
Economizer
HRSG To Main
T P T P SP
Feed Steam
Water from Line
Deaerator
Feed Water Flow Steam
Tank FDWTR F FDWTR Flowmeter
T

Feed Water
Mass Flowrate
Entrance of Heating Plant

Straight Ahead Right


Measurements
on boiler side of
cogeneration unit
Boiler (HRSG)
Temperature
Steam Pressure

1000 pph =
multiply
reading
by 1000 to
get lbm/hr

Digital Displays on “Brown Panel”


Orifice Meters
for Flowrate
& Data Acquistion
Fuel Oil Flowrate

Cogen Steam Flowrate Feed Water Flowrate


(HRSG SF) (FDWTR F)
Boiler Water Treatment

Ion - Exchange Unit Reverse Osmosis Unit


Cogeneration Unit

Heat Recovery
Steam Generator
(HRSG) or boiler

Turbine
Duct Burner
Inside the
Boiler!

Detail of bottom
of boiler tubes

Boiler Tubes
Data Acquisition
System
65 Channels!
What a maze of
pipes!
Do you know where
your liquid is flowing?

Light Blue Feed water (mainly from dealkalinizer for pH control )


Red Steam
Orange Condensate (liquid water condensed from steam)
Green Feed water to boilers from deaeration unit
Yellow Natural Gas
Black Fuel Oil
Condensate
return line

Conventional Boiler Unit

Steam “Mains” Valve


Steam flows from here to the campus via underground pipes.
Deaerator Unit
at the top of the steps!

Liquid Level
Indicator
Remember gh!

Dial Temperature Gauge


Economizer

Best View of
an orifice
flowmeter
(fuel oil)

Steam Orifice
Flowmeter
Steam Production Valve
Safety First!

• Pipes and Tanks may


be hot!
• Wear Hard Hats -
High Bay Area
• Eye Protection
• Hearing Protection is
optional
3 T

Deareation Tank
(second floor)

P
Feed Pump Dealkali
1st floor zer Unit

Walk over to

Boiler #1
2nd Floor Catwalk

the Cogen
Steam Exit & Condensate Return

Boiler #2
5

Plant
Boiler #3
Water Treatment
Feed Water

FDWTR F

2
Flow

Units

5 Compressor
Flowmeter

Room
HRSG SF
Steam
Control Room

1
T

HRSG
FDWTR
SP
Cogeneration Unit
T

Economizer Boiler(HRSG) Turbine


P
Cogen
Tour
3 T

Deareation Tank
(second floor)

Feed Pump
1st floor
P
Dealkali
zer Unit
Guide

Boiler #1
2nd Floor Catwalk
Steam Exit & Condensate Return

Boiler #2
5

Boiler #3
Water Treatment
Feed Water

FDWTR F
2

Flow

Units
5 Compressor

Flowmeter
Room

HRSG SF
Steam
Control Room

1
T

HRSG
FDWTR
SP
Cogeneration Unit
T

Economizer Boiler(HRSG) Turbine


P
Process Simulation Boiler

HYSYS Feed Water


T P
Economizer
T P
HRSG
SP
To Main
from
Steam
Deaerator
Feed Water Flow Steam Flowmeter Line
Tank FDWTR F HRSG SF
FDWTR
T
Homework Assignment
• Calculate duty on both
heat exchangers
• Compare hand
calculations to process
simulation results

Answers
given in the
process
simulation
results!
Engineering Equations
• Mass Balance m FW  m steam ?
• Thermodynamics
Hˆ liquid  C liquid T  273.16K 2

Enthalpy p

J J J
Heat Capacity C
3
liquid
p  4788.26  3.4297 T  4.885  10 T 2

kgK kgK 2 kgK 3


Vapor-Liquid
1 1  Psteam  3 1
Equilibrium of T  2.075  104 ln    2.683  10
steam K  1.01325  105 Pa  K
Saturated Steam
Qeconomzer  Hˆ mliq m
 liq  Hˆ inliq m
 liq
• Energy Balances
Qboiler  Hˆ out
gas
m gas  Hˆ mliqm liq
Week 2: Process • Immersion Heaters
Engineering • Rotameter Calibration
Heater
Turns Off Immersion Heater Comparision

120 Immersion Heater (200 Watts)

100 West bend (1000 Watts)

Temperature (°C)
80 RIVAL Hot Pot Express (750 watts)

60
Proctor Silex (1500 Watts)
40

20

0
0 5 10 15 20
Time (min)

dT
mC  Qin  0
liq
p
dt
Week 3: Process Engineering
Tank Efflux: Comparison of the Effect of Outlet
• Tank Efflux Drain Diameter

80.00
• 2-L Soda Bottle 70.00

Liquid Height (cm)


60.00

Implosion 50.00
40.00 1/2 inch data
3/4 inch data
30.00
1 inch data
20.00
10.00
0.00
0.00 5.00 10.00 15.00
Time (min)

dmtan k d Atank h 
  m out
dt dt

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