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Design Calculations of Shell and Tube Steam Generator For Steam Turbine

This document provides design calculations for a shell and tube steam generator used in a steam turbine. It details the input parameters for the hot and cold fluids, calculates the heat transfer and surface area required. It then sizes the tubes and shell based on the calculations, checking design parameters like pressure drop and heat transfer coefficients to validate the assumptions made.

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Ashlesh Dahake
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Download as PDF, TXT or read online on Scribd
359 views

Design Calculations of Shell and Tube Steam Generator For Steam Turbine

This document provides design calculations for a shell and tube steam generator used in a steam turbine. It details the input parameters for the hot and cold fluids, calculates the heat transfer and surface area required. It then sizes the tubes and shell based on the calculations, checking design parameters like pressure drop and heat transfer coefficients to validate the assumptions made.

Uploaded by

Ashlesh Dahake
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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DESIGN CALCULATIONS OF SHELL AND TUBE

STEAM GENERATOR FOR STEAM TURBINE.

GIVEN DATA:-

HOT Fluid COLD Fluid


(DOWTHERM) VALUES Unit (water) VALUES Unit

Inlet Temperature Th1 300 ⁰C Inlet Temperature Tc1 60 ⁰C

Outlet Temperature Th2 150 ⁰C Outlet Temperature Tc2 205 ⁰C

∆Th 150 ⁰C ∆Tc 145 ⁰C


3 3
ρ 883 kg/m ρ 933.446 kg/m
Cp 2148 J/kg-K Cp 4269.51 J/kg-K
AMT 225 ⁰C AMT 132.5 ⁰C

µ 0.00033 Pa-s µ 0.0002089 Pa-s


k 0.1059 W/m-K k 0.6845 W/m-K

ṁ 7.1 kg/min
Amount of Heat Energy obtained from HOT Fluid
Q = ṁCp∆T
Q = 38127 W

Heat required to convert water at 60:C to steam at 205:C


Q = ṁwCp∆T + ṁwhfg
ṁw = Q/ ( Cp∆T + hfg)
ṁw = 54.06 Kg/hr

For 1 Shell And 2 tube passes


FT (Correction factor) normally should be greater than 0.75 [2] for the steady
operation of the exchangers. After calculation we obtained the value for FT as
FT = 0.8863
LMTD = 81.9661 :C

Value of Overall Heat Transfer Coefficient is assumed to be


U = 300 W/m²K ……..[2]

Therefore Heat Transfer Area is A = Q/(U*LMTD* FT)

A = 1.7495 m2
do = 20 mm di = 16.698 mm t = 1.651mm
A = 3.14*d*L = 1.7495 m2

Therefore Total Tube Length is L = 29.25 m


Now for 2 pass i.e. np = 2
Length of one pass is 14.6 m
Hence, We can consider 20 Tubes of .75 meter length each nt = 20(single pass)
Tubeside Reynolds number:- (4*m*(Np/Nt))/(3.14*di*µ)

Re=4556.54......i.e. >2300
Therefore the flow is turbulent.

For turbulent flow,


Nu = [(f/2)(Re-1000).Pr]/[(1+12.7*(f/2).5 *(Pr(2/3)-1)]

hi = 231.23 W/m²K

From Reference ……[2][3]

Pitch = 1.25do = 1.25*20 mm = 25 mm


Bundle Diameter Db = do(Nt/K1)(1/n1)
For Square arrangement K1 = 0.156 n1 = 2.291
Therefore Db = 211.31mm

For 40 tubes with 1inch pitch, the suggested shell diameter is 10inch. ……..[1]

For Outside heat transfer Co-efficient:- …………[2]

Assume that h(assm) = 2500 W/m²K for water.


Now, re-determine hcal (latent heat transfer) from the Figure corresponding to
(Tw-t.) (t is the cold fluid boiling temperature).

Caloric Temperature = 150 + .46*(300-150)


= 219o C
hio = 202.51 W/m²K Tavg = 225 o C

1st Iteration :-

h(assm) = 2500 W/m²K Twall = 222.5

(Tw-t.)= 17.55 o C , from this the calculated value of h is =3600 W/m²K.

As h(assm) and hcal are not comparable we have to do more iterations.

2nd Iteration :-

h(assm) = 4000 W/m²K Twall = 224.71

(Tw-t.)= 19.71 o C , from this the calculated value of h is =3974 W/m²K.

As h(assm) and hcal are comparable we don’t have to do more iterations.

ho = 3974 W/m²K
Fouling Co –eff Dowtherm = (0.0002) m² K/W
Water = (0.0025) m² K/W

Ao = 3.14*do*L = 1.16239

Ai = 0.9706
Ao/Ai = 1.19761

Therefore, Uo = 351.527922 W/m²K

As assumed Overall heat transfer coefficient was 300 W/m²K

If difference between assumed and calculated overall heat transfer is between 0


to 30%

Then the assumption is correct

ie (Uo - Uassum )*100/Uassum = 5100/300 = 17.17%

Hence the assumption is correct.

References:-

1. D Q kern, “PROCESS HEAT TRANSFER”.


2. NPTEl, “Process design of heat exchanger”.
3. Reyad Awwad Shawabkeh, University of Jordan,“Step by step for heat
exchanger design”, September 1915 RG 2.1.4959.6644
4. The DOW CHEMICAL COMPANY, “Dowtherm a :- heat transfer fluid”.

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