DESIGN AND LAYOUT PROBLEM FOR A POWER PLANT

General
The power plant will contain two identical, controlled-extractions, 4,000-kw turbine generators.
Steam will be extracted from each turbine for process use and for a deaerator. Steam also will be
extracted at a lower pressure for use in a surface type of feedwater heater. A by-pass, pressure-reducing
station will provide process steam when the turbines are not in use. All process steam becomes
contaminated and is wasted.
Four identical boilers are to supply the plant steam requirements (two boilers to carry maximum
requirements of one turbine). The boiler room will be separated from the turbine hall, and in addition to
the boilers, will contain one fan (forced draft) per boiler, coal-handling equipment and ducts.
Equipment to be located in the turbine hall: turbine generators, dearators, low-pressure heaters,
boiler feed pumps, condensers, circulating pumps, air ejectors, condensate pumps, turbine control
board, overhead crane.

Data
Turbine generators: 96% mechanical efficiency, 95% generator efficiency, straight-line condition
curve, design point is 125% load, 40 psia automatic extraction and 10-psia. nonautomatic
extraction pressures, steam conditions 400 Psig, 550.0°F, and 2 in. Hg.
Process Steam: 30,000 lb per hour for the plant. Show connection for safety valve after PRV.
Boilers: Single settings, Minimum distances, 10 ft between boilers, 18 ft. aisle in front of boiler
setting for control board and coal-handling equipment, 6 ft. aisle behind boiler. Air enters at 80
°F and gases leave at 450 °F. Ash removal from pit below aisle in back of boilers. Boiler rating,
250%.Frankin County, Illinois, coal with 35% excess air.
Forced draft Fans: 2.5 in. water static pressure.
Condensers: Circulating water enters at 80 °F, surface type, 2-pass, 18-gage ¾ in. tubes, 6-fps water
velocity, 75% cleanliness factor. Design condensers for 2 in. Hg abs, at 4,000 kw, with steam
extraction from the turbines for feed heating only. Condenser axis will be perpendicular to
turbine axis.
Air Ejectors: 200 lb. per hour of steam required for each unit; 1000 Btu per lb available for feed
heating in air-ejector condensers.
Condensate Pumps: Two per condenser, 100% spare, centrifugal, motor-driven, 150-ft total head.
Allow 10% extra capacity based on the flow obtained for the condenser.
Boiler Feed Pumps: Four pumps for the plant, 100% spare, centrifugal, motor-driven, 325-psig
discharge pressure. Allow 10% extra flow to take care of emergencies.
Deaerators: Two for entire plant, 100% spare. Make-up water enters deaerators at60 °F.
Surface Heaters: Two per turbine generator, no spare, 5 °F TD, and drains cascaded to condenser. Design
on basis of heat balance data.
Turbine Control Board: One for both turbines, 8 ft. high by 14 ft. long, and 5 ft. deep (to allow for
switchgear) with 4 ft. clearance.
Piping: Of sufficient strength for pressures and temperatures involved, flanged. Water piping on
pump discharges designed for velocity of about 450 fpm and less than 200 fpm on suction. 10% pressure
drop in low-pressure bleed line and 5% in high-pressure bleed line. Use a hand by-pass around
automatic PRV.
Stack: To develop 1 in. static draft.

Requirements:
a. Calculate heat balance for turbine hall and make schematic diagram with flows, temperatures,
pressures and enthalpies.
b. Calculate boiler size and select boiler.
c. Calculate surface requirements of condenser and select condenser.
d. Calculate size of, and select, deaerators and surface heaters.
e. Calculate size of boiler feed pumps and select pumps.
f. Calculate size of condensate pumps.
g. Make a plan layout of equipment. Show major dimension of equipment and building, and show
centerline dimensions.
h. Lay out main steam pipe (single line) on drawing and show all fittings.
i. Calculate pipe sizes for main steam lines.
j. Write a bill of material for the main steam piping.
k. Calculate the maximum friction loss in the steam piping from boiler to turbine.
l. Calculate the fan horsepower and select a fan.
m. Determine the diameter and height of the stack.
n. Draw an end view of the plant showing equipment and piping.
o. Layout the water piping from the deaerator to the boiler, showing all fittings, and include an
automatic valve for feed water regulation.
p. Determine the friction loss of the water piping.
q. Draw an isometric or perspective view of the plant with pipes, valves and fittings connected to
equipments.
1.0 6000 kW (35,000) , (30,000) , ( 25,000), (20, 000)
2.0 5500 kW (33,000), (28,000), (24,000), (22,000)
3.0 7000 kW (40,000), (25,000), (15,000), (35,000)
4.0 4000 kW (30,000), (25,000), (20,000), (15,000)
5.0 4500kW (35,000), (33,000), (30,500), (23,000)
6.0 2500kW (15,000), (10,000), (12,000), (13,000)
7.0 3000kW (8,000), (10,000), (12,000), (15,000)
8.0 5000kW (35,000) , (37,000), (30,000), (25,000)
9.0 6500kW (25,000), (40,000), (35,000), (30,000)
10.0 2000kW (8,000), (10,000), (12,000), (15,000)