Chapter 2 Unfinished

CHAPTER 2
STEAM POWER PLANT

Table 1. Operating conditions data Based in Khoms Steam Power plant, (GECOL,
2008; NSPP, 2010)
Data Units Value

No. of units -- 5
Design Load MW 125
Operating load MW 100
Fuel Type -- H.F.O.
Steam flow rate T/hr 375
Steam Exit temperature oC 540
from turbine
Steam Exit pressure from Bar 128
C.C.
Temperature of C.C. oC 1000
Fuel flow rate for C.C. T/hr 25.34
Heat of combustion of Kcal/kg 10636
Fuel
Table 2. Comparison of suggested configurations of Khoms steam power plant cycle
Data Net Overall Thermal Heating Turbine Q

Configuratio Power Efficienc Efficienc Rate Exit condense
n out y y Quality r losses
MW % % Btu/ Vap. F. MW
hr.KW
No. 1 100.828 32.16158 32.75488 10148.04 0.897 213
8 3 3
No. 2 129.067 33.11488 33.58927 10148.04 1 260.7234
2 5 3
No. 3 95.8769 34.79238 35.51164 9563.698 0.89184 179.692
8 1 8 6
No. 4 95.7887 34.77512 35.45099 9580.058 0.89184 179.6632
5 8 7 6
No. 5 97.3717 34.67888 35.34155 9609.726 0.89184 184.9913
4 1 7 6
No. 6 106.209 33.73156 34.32249 9895.046 1 208.6579
8 2 2
i. Initial Data Overview
Based on the provided data, the following operational parameters are specific to the
Khom’s Steam Power Plant:
Number of Units: 5
Design Load: 125 M
Operating Load: 100 MW
Fuel Type: Heavy Fuel Oil (H.F.O.)
Steam Flow Rate: 375 T/hr
Steam Exit Temperature from Turbine: 540 °C
Steam Exit Pressure from Condenser: 128 Bar
Temperature of Condenser: 1000 °C
Fuel Flow Rate for the Combustion Chamber: 25.34 T/hr
Heat of Combustion of Fuel: 10,636 Kcal/kg
1.1 Calculate Boiler Efficiency

According to Powerhouse. (n.d.). Boiler Efficiency. Retrieved November 4,
2024, The average values for Fuel-to-Steam efficiency are typically between 80-
85%. To achieve the upper end of this metric, manufacturers have incorporated
advanced computational fluid dynamics (CFD) modeling to optimize the design
of components such as boiler tubes, furnace shape, and more.
𝜂=0.85
1.2 Calculate Heat Input Required
To determine the heat input required for the boiler, we employ the formula:
𝑄= Design Load/𝜂
Substituting the design load:
𝑄=125MW/0.85≈147.06MW
𝑄=147.06 MW×860Kcal/hr/MW
Converting MW to Kcal/hr (1 MW = 860 Kcal/hr):
≈126.065 Kcal/hr
ii. Required Heat Input Calculation From Steam Flow
2.1 Determine Enthalpy Values
To calculate the required heat input 𝑄 using the steam flow rate and enthalpy values,
we need the enthalpy values from steam tables at the conditions specified:
 Enthalpy of steam at 128 Bar and 540 °C =1,200 Kcal/kg
 Enthalpy of water at 100 °C =420 Kcal/kg

2.2 Calculate Mass Flow Rate
𝑚=375T/hr=375×1000kg/hr= 375,000kg/hr
2.3 Calculate Required Heat Input
Q=m (h steam – h water)
𝑄=375000kg/hr×(1200−420)kcal/kg
𝑄=375,000×780=292,500,000kcal/hr
Convert to MW
292,500,000kcal/hr×(4.184Kj/1kcal)(1kWh/3,600kJ)(1MW/1000kW)
𝑄 =339.95MW
iii. Fuel Requirement Calculation

3.1 Calculate Required Fuel Input
Using the heat of combustion for the fuel (10,636 Kcal/kg), the required fuel flow rate 𝑚fuel
can be determined by:
Heavy Fuel Oil (H.F.O.), the heat of combustion is given as 10,636 Kcal/kg. This means that
when 1 kg of H.F.O. is combusted, it releases 10,636 Kcal of energy.
Q
mfuel=
GCV
mfuel =( 292,500,000kcal/hr)/ (10,636kcal/kg)

m fuel= 27,500.55 kg/hr
i. Boiler Types and Dimensions
4.1 Typical Steam Boiler Dimensions
Steam Output: The capacity of steam boilers is often measured in

horsepower or kilograms per hour. It is crucial to size them according to the
steam output requirements.
Physical Design: Most industrial boilers can measure several feet in height
and width, depending on their design load specifications.
4.2 Specific Considerations for Sizing
Steam Output Capacity: Steam boilers are sized based on the steam demand,
represented in square feet of radiation connected to the steam system. This
is crucial for ensuring the boiler can meet peak loads.
Heat Transfer Surface Area: The size of the heat transfer area (the surface
area inside the boiler where heat is exchanged) significantly impacts
efficiency and performance. Larger surface areas can result in better heat
transfer but require larger boiler dimensions.
Boiler Height and Width: While specific dimensions were not provided in the
gathered data, industrial steam boilers typically range from:
 Key Parameters
Steam Flow Rate: 375 T/hr (375,000 kg/hr)
Design Load: 125 MW
Boiler Efficiency: 85%
4.3 Heating Surface Area Calculation

Heating Surface Area (m^2) = (boiler capacity(kg/hr))/(18m²/(kg/hr ))
Heating Surface Area ( m )=

2
boiler capacity ( kghr )
2
m
17
kg
hr

2
boiler capacity ( kghr )
2
18 m
kg
hr
 Calculating Heating Surface Area
Using 17

2
375,000 ( kghr )
17m
2 = 22,058.82 m 2
kg
hr
4.4Boiler Dimensions Calculation
Then 𝐻=5𝐷
 Aspect Ratio of 5:1 (Height:Diameter)

Surface Area=𝜋𝐷(H+D)
Substituting 𝐻:
Surface Area=𝜋𝐷(5𝐷+𝐷) = 6 π D2
 Setting this equal to the estimated heating surface area:
For 22,058.82 m 2
2 2
6 π D =22,058.82 m
=116.93 m 2
2 ( 22,058.82 m2 )
D=
(6 π )
=√'116.93 m 2
2 ( 22,058.82 m2 )
√'D =
(6 π )
D = 10.81 m
H= 5D =54.05m
H=54.05m
Based on these calculations, the estimated dimensions for the boiler at

Khom's Steam Power Plant would be
Diameter: 10.81 m
Height : 54.05 m


4.5 Area of the boiler shell
Diameter (D) = 10.81 m
Height (L) = 54.05 m
A=πDL
A= π(10.81 m)( 54.05 m)
A= 1,833.94 m2
4.6 Volume of boiler shell
π 2
V= D L
4
V= (10.81 m) (54.05 m)
π
4
V= 4,955.27 m³
4.7 Thickness of the boiler
-ASME Section II, Part D for the material's allowable stress values
-ASME Section I for the weld joint efficiency
-Allowable stress for Carbon steel (e.g., SA-516 Grade 70),
P= 16.992 Mpa
R=D/2= 10.81m/2= 10,810mm
S=137 Mpa
E=87.05%
PR
T=
S E+ 0.6 P
T=
2
(16.992 N /mm )(10 , 810)
(137 N /mm 2)(0.8705)+0.6 (16.992 N /mm2)
T= 1418.91 mm
4.8 For the diameter of tubes inside the boiler
* For the thickness of the tubes inside the boiler
-ASME Boiler and Pressure Vessel Code (BPVC)
PD
T=
2 S E+ P
P = 16.692 MPa
D = 0.038 m
S = 137 MPa
E=1
2
(16.692 N /mm )(38 mm)
T=
2(137 N /mm2 )(1)+16.692 N /mm 2
T= 37.4mm
 Volume of the tube
Vtube = DL
D=38mm
L= 54.05 m
Vtube = ( 0.038 m ) ( 54.05 m)
π 2
4
Vtube = 0.061 m3
 Number Of tubes
VBoiler
N=
Vtube
3
4,955.27 m
N= 3
0.061 m
N= 81,234 TUBES

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CHAPTER 2

STEAM POWER PLANT

Data Units Value

Table 2. Comparison of suggested configurations of Khoms steam power plant cycle

Data Net Overall Thermal Heating Turbine Q

1.1 Calculate Boiler Efficiency

Substituting the design load:

2.2 Calculate Mass Flow Rate

2.3 Calculate Required Heat Input

Q=m (h steam – h water)

iii. Fuel Requirement Calculation

mfuel =( 292,500,000kcal/hr)/ (10,636kcal/kg)

i. Boiler Types and Dimensions

4.1 Typical Steam Boiler Dimensions

Steam Output: The capacity of steam boilers is often measured in

4.2 Specific Considerations for Sizing

Steam Flow Rate: 375 T/hr (375,000 kg/hr)

Design Load: 125 MW

Boiler Efficiency: 85%

4.3 Heating Surface Area Calculation

Heating Surface Area ( m )=

Heating Surface Area ( m )=

Heating Surface Area ( m )=

 Setting this equal to the estimated heating surface area:

Based on these calculations, the estimated dimensions for the boiler at

Diameter (D) = 10.81 m

Height (L) = 54.05 m

4.6 Volume of boiler shell

4.7 Thickness of the boiler

-ASME Section I for the weld joint efficiency

-Allowable stress for Carbon steel (e.g., SA-516 Grade 70),

R=D/2= 10.81m/2= 10,810mm

4.8 For the diameter of tubes inside the boiler

* For the thickness of the tubes inside the boiler

-ASME Boiler and Pressure Vessel Code (BPVC)

 Volume of the tube

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