3rd Episode

1. Introduction
During my Bachelor of Mechanical Engineering, final year project was of utmost importance. In this
episode, I have explained the key areas of my project and the role and responsibilities as a leader of
my group. I was a part of project group of five students with diverse skills. The project aims towards
the “designing of Waste Heat recovery system from gas turbine exhaust” whose purpose was to
fulfill electric, cooling heating demand of Masters Textile. Our internal Advisor was Mr. Ahmed Raza,
from Masters textile Miss Amber Naz provided us the required assistance.

1.1 Chronology:
Idea Submission date:

Project Start date:

Project completion date:

Project Duration:

1.2 Geographical Location:

Ahmedabad, India

1.3 University:
Gujrat Technological University

2. Background
I was enrolled in Bachelor of Mechanical Engineering program at Sal Engineering & Technical
Institute, Gujrat Technological University, Ahmedabad. During my bachelors’ program I did multiple
designing projects. This project was a bit different as it required extensive literature review. This was
the final year project and had significant importance.

2.1 Nature of Engineering Project:

The project was for master’s Textile who are leaders in their industry decided to build a
cogeneration plant. My main aim in this project was to utilize the exhaust gases of Gas turbine. Since
turbine exhaust normally have higher temperature, the exhaust gases have sufficient energy which
can be utilised by deigning appropriate heat recovery system. Based on the requirement of the
industry I had to design the HRSG, Chiller and cooling coil system accordingly.

2.2 Objectives of Project:

The key objectives of my project were as follows:

1. To design the waste heat recovery steam generator (approximately 10 tph of steam).
 2. To design the absorption chiller system (598 Refrigeration tons)
3. To design the cooling coil system for compressor intake
4. To obtain the required 3.8MW of electricity.
5. To perform cost benefit analysis for the project.

2.3 Nature of My Work:

Since I was the team leader, I had to design the complete Waste Heat recovery steam generator.
Apart from that duty, it was my responsibility to address any challenges that my group might face
during the project. I applied project management principles to gauge the performance of the group
and to establish key milestones for this project.

2.4 Organisational Structure:

The structure of my University is shown below:

Gujrat
GujratTechnological
Technological
University
University External Body

SAL
SALEngineering
Engineering&&
Masters
MastersTextile
Textile
Technical
TechnicalInstitute
Institute

Supervisor:
Supervisor:Prof.
Prof.Sasmita
Sasmita
Mr.
Mr.Jayesh
JayeshPatel
Patel
Patnaik
Patnaik

Akash
AkashGandhi
Gandhi

Bhavsar
BhavsarAkshat
Akshat Gandhi
GandhiKrunal
Krunal Patel
PatelBrijesh
Brijesh Patel
PatelDarshan
Darshan

2.5 My Duties and Responsibilities:

Following were my key duties and responsibilities as a leader of the project.

 To develop the timeline of the project and identify key milestones

 To keep track of the progress of project
 To perform design calculations of Waste heat recovery steam generator.
 To make sure that all group members are engaged and are working towards a common
objective.
  To perform all the coordination within the faculty and be the focal person of the group to
avoid any ambiguity in external communication.

3. Personal Engineering Activity

3.1 Application of Engineering Knowledge and Skills:

Master textile had encountered a problem for which I had to provide cost effective solution. The
solution should fulfill all the requirement for master textile of 3.8MW of electric demand, 598
refrigeration tons of cooling, and 6.2 tph of steam for process heating.

This problem requires the learnings of heat and mass transfer and powerplant engineering. These
two courses cover all the aspects of power plant and different types of generation systems. The
course of material and metallurgy is also important as the design part covers the material
requirement as well.

3.2 Tasks delegated and My approach:

Since I am the leader of the group, so I delegated the tasks within my team mate as follows:

 Akash Gandhi (Team lead) WHSRG design and Project management

 Bhavsar Akshat Design of absorption chiller
 Gandhi Krunal Improvement in performance of Gas turbine
 Patel Brijesh Cooling coils design
 Patel Darshan Cost benefit analysis, market survey.

Since it was the final year project and carries significant importance, so I implemented all the
principles of project management to avoid any delays in project completion.

3.2.1 Development of Project Charter

This is the very first stage of any project. I developed the project Charter and identified the key
stakeholders of the project. I developed the level IV timeline on MS Projects and mentioned key
deadlines as directed by my University supervisor. I also Identified the role and responsibilities of
each team member.

3.2.2 Literature Review:

Since this project required significant amount of calculations, so all group members mutually
concluded that first stage should be the literature review.

3.2.3 Visit to Master Textile:

I performed all the coordination to plan this visit, With the help of my external advisor Miss Amber
naz I was able to get all the design parameters and condition for the existing gas turbine installed.
Along with the existing parameters, I also gathered the requirement of cooling and steam for
process heating applications at Master textile.

3.2.4 Designing of Waste Heat Recovery Steam Generator:

This was the core responsibility of me for this entire project. The starting point for designing of
waste heat recovery steam generator was the Gas turbine exhaust. I made my visit useful by
gathering the required data. This also implies that the importance of the literature review as without
prior knowledge of all the parameters involved, I would have not been able to make visit useful.

The Natural gas composition was obtained from Karachi gas company, once again to avoid any
ambiguity all the external communication was handled by me.

Once I had the composition of natural gas, I performed calculations regarding the actual and
stoichiometric ratios of reaction.

For any heat recovery steam generator, following parameters are of key importance:

 Temperature of exhaust gas from Gas turbine.

 Mass flow rate of exhaust gas
 Temperature of entering feed water
 Required steam pressure

I gathered the required values from the Master textile representative and performed the
calculations based on these values.

The methodology I opted in calculation is as follows, at first, I calculated the evaporative duty by
heat and mass balance equations. Once I had this information, I evaluated the thermo physical
properties of gas for economizer.

After getting the thermo physical properties and heat and mass numbers, I moved towards the
equipment designing part. Since I had decided to opt for Firetube heat exchanger and based on the
surface area requirement bare tubes were used. Please note here that the cost of finned tubes is
approximately 2 to 2.5 times the cost of bare tubes. So, considering the cost optimization I selected
bare tubes for heat exchanger.

The tube thickness and tube diameter were calculated and allowable working pressure on that
diameter and thickness was calculated. I used Rohsenow’s Correlation for calculating the difference
between the wall and saturation temperature.

Moreover, I performed calculations for both fire tube and water tube economizer and evaporator
and summarized the results as follows, its up to the Master Textile to decide which type to install in
their plant.

S. Variable Water tube Fire tube

No. 2 x 0.10 in tubes with 3 solid 2 x 0.1 in tubes
fins/in, 1 inch height of fine,
0.06 in thickness
Economizer Evaporator Economizer Evaporator
1 Gas flow lb/hr 136311.8 136311.8 136311.8 136311.8
2 Gas inlet temperature deg F 392.77 973.4 392.77 973.4
3 Gas exit temperature deg F 303.799 392.77 303.799 392.77
 4 Water temperature deg F 185 313.574 185 313.574
5 Steam pressure, psig 117.6 117.6
6 Steam temperature deg F 338.77 338.77
7 Duty Btu/hr 2.979 x 10^6 20.24 x 10^6 2.979 x 10^6 20.24 x 10^6
8 Steam flow lb/hr 22992.49 22992.49
9 Heat flux, Btu//ft2 hr 2393.973 3656.206
10 Tube wall temperature deg F 468.854 fin 348.865
tip temp 595
11 No of tubes 12 in wide 7 12 in wide, 150 600
in deep 16 in deep
12 Length of tubes 10.5 10.5 15.358 20.46
13 U, Btu/ft2.hr.degF 6.717 6.953 25.291 10.619
14 Surface area ft2 4541.747 10906.608 1085.61 6427.67
15 Gas delta P in Wc 1.317 3.196 41.11 4.349

All the design parameters and calculations can be found in the technical report of the project.

3.2.5 Design of Absorption chiller, Gas turbine performance improvement, cooling

coils and Cost benefit analysis:
Bhavsar Akshat was responsible for this part and after literature review and calculation he proposed
steam chiller package of model BYS200. Gandhi calculated the increase in gas turbine performance
and Patel calculated the requirements for cooling coils. All these calculations together sum up our
project. In last phase Patel brijesh performed cost benefit analysis and calculated the payback period
to be of 1.8 years.

3.3 Difficulties faced during project:

I being the team leader had to manage the overall decorum of the time and to distribute the tasks
accordingly. Following table summarizes the difficulties and my approach towards the problem.

Technical Problems faced Solution proposed

Use of relevant literature
Design calculations review
Our Internal guide referred to the relevant books to
go through and it saves a lot of time
To check whether I was headed in right direction I
planned fortnightly meeting with advisor and he
reviews all my calculations.

Management Problems faced Solution proposed

Achieving milestones decided Tasks delegation and performance of activities in
parallel to reduce the time of project
Stakeholders management Regular updates to all the bodies regarding the
progress of project were shared.
3.4 Collaboration among Team:
I planned the frequency of team meetings such that no member of the team feel disengaged, we
helped each other and then discuss our queries with our advisor in fortnightly meeting, I also issues
monthly progress update flyer to keep all the stakeholders updated.

4. Summary
This project was very different as it has direct industrial application and I got to know the industrial
norms and practices. Learning from book is one thing and application in industry is a whole new
world. By this project I and my team got understanding of powerplant engineering in a practical way.
The solution was very attractive and had payback period of only 1.8 years on capex of 177.5 Million
PKR.

I presented this report to internal and external advisor and they all applauded my efforts and took
this business case to the management of Master Textile for necessary approvals.