DESIGN OF ae NA tL THIRD EDITION W. F. STOECKER TATA McGRAW-HILL EDITIONTata McGraw-Hill DESIGN OF THERMAL SYSTEMS Copyright © 1989, 1980, 1971 by The McGraw-Hill, Inc, All rights reserved. No part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the publisher. Tata McGraw-Hill Edition 2011 RZZDRRBGRQRYC Reprinted in India by arrangement with The McGraw-Hill Companies, Inc., New York Sales territories: India, Pakistan, Nepal, Bangladesh, Sri Lanka and Bhutan Library of Congeess Cataloguing-in-Publication Data Stoecker, W. F. (Wilbert F.), date. Design of thermal systems. Includes bibliographies and index. 1. Heat engineering. 2, Systems engineering. 3. Engineering design. [Title 73260.S775 1989 621.402 88-1328! ISBN 0-07-06 1620-5 ISBN-13: 978-1-25-900239-7 ASBN-10: 1-25-900239-X Published by Tata McGraw Hill Education Private Limited, 7 West Patel Nagar, New Delhi 110 008, and printed at Nice Printing Press, Delhi 110 051 The McGraw-Hill cfe ee SRIAREGHESecami|saunaewnye CONTENTS Pref he Third Editi Preface to the Second Edition Preface to the First Edition Engineering Design Designing a Workable System Economics Equation Fitting Modeling Thermal Equipment System Simulation Optimization Lagrange Multipliers Search Methods Dynamic Programming Geometric Programming Linear Programming Mathematical Modeling —Thermodynamic Properties Steady-state Simulation of Large Systems Dynamic Behavior of Thermal Systems Calculus Methods of Optimization Vector and Reduced Gradient Searches Calculus of Variations and Dynamic Programming Probabilistic Approaches to Design Appendix I. Comprehensive Problems Appendix II. Generalized System Simulation Program Appendix III Index 561a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.PREFACE TO THE THIRD EDITION The field of thermal system design and analysis continues to develop. The number of workers is growing, technical papers appear in greater numbers, and new textbooks are being written. The major objective of this third edition is to organize some of the new approaches that are now available and to provide more flexibility to instructors who use Design of Thermal Systems as a text. The changes to the twelve chapters of the second edition are modest and mainly constitute the inclusion of some additional end-of-chapter problems. Chapters 13 through 19, however, are all new. One possible use of the text is to cover the first twelve chapters in an advanced-level undergraduate course and the remaining seven chapters as a graduate course. In some engineering schools students already have some kind of optimization course prior to taking the thermal design course. For those classes certain chapters of the first twelve (usually the ones on search methods, dynamic programming, and linear programming) can be omitted and material can be supplemented from the new seven chapters. Several of the new chapters are extensions of the introductions offered in the first twelve chapters, especially mathematical modeling, steady-state system simulation, and search methods. Chapter 14 addresses some of the challenges that arise when simulating large thermal systems. New material appears in Chapter 15 on dynamic behavior, in Chapter 18 which introduces calculus of variations as a companion to dynamic programming, and in Chapter 19 on probabilistic approaches to design, which is exploratory. The author thanks colleagues both at the University of Illinois at Urbana-Champaign and at other engineering schools for continued input and suggestions during the past several years on how to keep the book fresh. McGraw-Hill would also like to thank the following reviewers for their many useful comments: Jghn R. Biddle, California State Polytechnic ixa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.XiV PREFACE TO THE FIRST EDITION SYSTEMS Engineering education is predominantly process oriented, while engineering practice is predominantly system oriented. Most courses of study in engi- neering provide the student with an effective exposure to such processes as the flow of a compressible fluid through a nozzle and the behavior of hydrodynamic and thermal boundary layers at solid surfaces. The practicing engineer, however, is likely to be confronted with a task such as designing an economic system that receives natural gas from a pipeline and stores it underground for later usage. There is a big gap between knowledge of individual processes and the integration of these processes in an engineering enterprise. Closing the gap should not be accomplished by diminishing the empha- sis on processes. A faulty knowledge of fundamentals may result in subse- quent failure of the system. But within a university environment, it is ben- eficial for future engineers to begin thinking in terms of systems. Another reason for more emphasis on systems in the university environment, in addi- tion to influencing the thought patterns of students, is that there are some techniques —such as simulation and optimization—which only recently have been applied to thermal systems. These are useful tools and the graduate should have some facility with them. While the availability of procedures of simulation and optimization is not a new situation, the practical application of these procedures has only recently become widespread because of the availability of the digital computer. Heretofore, the limitation of time did not permit hand calcula- tions, for example, of an optimization of a function that was dependent upon dozens or hundreds of independent variables. This meant that, in designing systems consisting of dozens or hundreds of components, the goal of achiev- ing a workable system was a significant accomplishment and the objective of designing an optimum system was usually abandoned. The possibility of optimization represents one of the few facets of design. OUTLINE OF THIS BOOK The goal of this book is the design of optimum thermal systems. Chapters 6 through 11 cover topics and specific procedures in optimization. After Chap. 6 explains the typical statement of the optimization problem and illustrates how this statement derives from the physical situation, the chap- ters that follow explore optimization procedures such as calculus methods, search methods, geometric programming, dynamic programming, and linear programming. All these methods have applicability to many other types of problems besides thermal ones and, in this sense, are general. On the other hand, the applications are chosen from the thermal field to emphasize the opportunity for optimization in this class of problems.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.CHAPTER 1 ENGINEERING DESIGN 1.1 INTRODUCTION Typical professional activities of engineers include sales, construction, research, development, and design. Design will be our special concern in this book. The immediate product of the design process is a report, a set of calculations, and/or a drawing that are abstractions of hardware. The sub- ject of the design may be a process, an element or component of a larger assembly, or an entire system. Our emphasis will be on system design, where a system is defined as a collection of components with interrelated performance. Even this definition often needs interpretation, because a large system sometimes includes subsystems. Furthermore, we shall progressively focus on ther- mal systems, where fluids and energy in the form of heat and work are conveyed and converted. Before adjusting this focus, however, this chapter will examine the larger picture into which the technical engineering activ- ity blends. We shall call this larger operation an engineering undertaking, implying that engineering plays a decisive role but also dovetails with other considerations. Engineering undertakings include a wide variety of commer- cial and industrial enterprises as well as municipally, state-, and federally sponsored projects.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.ENGINEERING DESIGN 5 FIGURE 1-2 Probability distribution curve. in the evaluation of the area beneath the curve. The area under the curve between x; and x2, for example, represents the probability P of the event's occurring between values x, and x2. Thus, 2 P= I ydx at Since the probability of the event's occurring somewhere in the range of x is unity, the integration over the entire range of x is equal to 1.0: 2 I ydx =1 «0 The equation for the probability distribution curve is = LP -a)? =—e 1.1 y VE (1.1) The maximum value of the ordinate is h//7, which occurs when x = a. This fact suggests that increasing the value of fA alters the shape of the distribution curve, as shown in Fig. 1-3. If 4; is greater than h2, the peak of the A; curve rises higher than that of the hz curve. To extend the probability idea to decision making in an engineering undertaking, suppose that a new product or facility is proposed and that the criterion for’success is a 10 percent rate of return on the investment for a 5-year life of the plant. After a preliminary design, the probability distribution curve is shown as indicated in Fig. 1-4. Since rough figures were used throughout the evaluation, the distribution curve is flat, indicating no great confidence in an expected percent of retum of investment of, say,a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.1.10 OPTIMIZATION OF OPERATION The flow diagram of Fig. 1-1 terminates with the construction or beginning of manufacture of a product or service. Actually another stage takes over at this point, which seeks to optimize the operation of a given facility. The facility was designed on the basis of certain design parameters which almost inevitably change by the time the facility is in operation. The next challenge, then, is to operate the facility in the best possible manner in the light of such factors as actual costs and prices. A painful activity occurs when the project is not profitable and the objective becomes that of minimizing the loss. 1.11 TECHNICAL DESIGN (STEP 5) Step 5 in Fig. 1-1, the product or system design, has not been discussed. ‘The reason for this omission is that the system design is the subject of this book from this point on. This step is where the largest portion of engineering time is spent. System design as an activity lies somewhere between the study and analysis of individual processes or components and the larger decisions, which are heavily economic. Usually one person coordinates the planning of the undertaking. This manager normally emerges with a background gained from experience in one of the subactivities. The manager's experience might be in finance, engineering, or marketing, for example. Whatever the original discipline, the manager must become conversant with all the fields that play arole in the decision-making process. The word “design” encompasses a wide range of activities. Design may be applied to the act of selecting a single member or part, e.g., the size of a tube in a heat exchanger; to a larger component, e.g., the entire shell-and-tube heat exchanger; or to the design of the system in which the heat exchanger is only one component. Design activities can be directed toward mechanical devices which incorporate linkages, gears, and other moving solid members, electrical or electronic systems, thermal systems, and a multitude of others. Our concentration will be on thermal systems such as those in power generation, heating and refrigeration plants, the food-processing industry, and in the chemical and process industries. 1,12, SUMMARY The flow diagram and description of the decision processes discussed in this chapter are highly simplified and are not sacred. Since almost every under- taking is different, there are almost infinite variations in starting points, goals, and intervening circumstances. The purpose of the study is to empha- size the advantage of systematic planning. Certain functions are common in the evaluation and planning of undertakings, particularly the iterations and the decisions that occur at various stages.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.DESIGNING A WORKABLE SYSTEM 13 1. The elevation of 8 m imposes a pressure difference of (8 m)(1000 kg/m>)(9.807 m/s?) = 78.5 kPa Arbitrarily choose an additional 100 kPa to compensate for friction in the 250 m of pipe. 2. According to the foregoing decision, select a pump which delivers 3 kg/s against a pressure difference of 178.5 kPa. Finally, select a pipe size from a handbook such that the pressure drop in 250 m of length is 100 kPa or less. A pipe size of 50 mm (2 in) satisfies the requirement. Appoaching the same problem with the objective of achieving an opti- mum system presupposes agreement on a criterion to optimize. A frequently chosen criterion is cost (sometimes first cost only in speculative projects, and sometimes the lifetime cost, consisting of first plus lifetime pumping and maintenance costs). In designing the optimum pump and piping system for minimum life- time cost, the pressure rise to be developed by the pump is not fixed imme- diately but left free to float. If the three major contributors to cost are (1) the first cost of the pump, (2) the first cost of the pipe, and (3) the life- time pumping costs, these costs will vary as a function of pump pressure, as shown in Fig. 2-1. As the pump-pressure rise increases, the cost of the pump probably increases for the required flow rate of 3 kg/s because of the need for higher speed and/or larger impeller diameter. With the increase in pressure rise, the power required by the pump increases and is reflected in Lifetime pumping cost First cost ‘of pump 0 50 100150, 200250 Pressure developed by pump, kPa FIGURE 2-1 Contributions to costs by pump and piping systems.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.a You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.DESIGNING A WORKABLE System 17 Within the internal design of the compression refrigeration plant, the procedure was to select reasonable temperatures and then design each component around those temperatures and resulting flow rates. When one approaches the design with the objective of optimization, all those inter- connecting parameters are left free to float and one finds the combination of values of these parameters which results in the optimum (probably the economic optimum). 2.7 PRELIMINARIES TO THE STUDY OF OPTIMIZATION Any attempt to apply optimization theory to thermal systems at this stage is destined for frustration. There are a variety of optimization techniques available, some of which are introduced in Chapters 8 to 12. The first attempts to optimize a thermal system with a dozen components, however, will be detoured by the need to predict the performance of the system with given input conditions. This assignment, called system simulation, must be Studied first and will be considered in Chapters 6 and 14, For complex systems, system simulation must be performed with a computer. For this purpose the performance characteristics making up the system could possibly be stored as tables, but a far more efficient and useful form is equation-type formulation. Translating catalog tables into equations, called component simulation or mathematical modeling, is a routine preliminary step to system simulation and will be treated in Chapters 4, 5, and 13. Finally, since optimization presupposes a criterion, which in engineer- ing practice is often an economic one, a review of investment economics in Chapter 3 will be appropriate. The sequence to be followed in the ensuing studies, then, will be (1) economics, (2) mathematical modeling, (3) system simulation, and (4) optimization. PROBLEMS 2.1, Location $ in Fig. 2-3 is an adequate source of water, and location A, B, and C are points at which water must be provided at the following rates of flow: Ls 25 3.5 1S Points $,A,B, and C are all at the same elevation. The demands for water at A and C occur intermittently and only during the working day, and they may coincide. The demand for water at B occurs only during nonworking hours and is also intermittent. Ground-level access exists in a 3-m border surrounding the building. Access is not permitted over, through, or under the building.