Introduction to Thermo-Fluids Systems Design

438 Pages·2013·13.949 MB·English

by  Andre G. McDonald, Hugh L. Magande(auth.)

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Introduction to Thermo-Fluids
Systems Design
i
JWST229-fm JWST229-McDonald Printer:YettoCome August16,2012 11:29 Trim:244mm×168mm
Introduction to
Thermo-Fluids
Systems Design
Andre´ G. McDonald, Ph.D., P.ENG.
UniversityofAlberta,Canada
Hugh L. Magande, M.B.A., M.S.E.M.
RinnaiAmericaCorporation,USA
A John Wiley & Sons, Ltd., Publication
iii
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Thiseditionfirstpublished2012.
(cid:2)C 2012Andre´G.McDonaldandHughL.Magande.
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DISCLAIMER
Thecontentsofthistextbookaremeanttosupplyinformationonthedesignofthermo-fluidssystems.
Thebookisnotmeanttobethesoleresourceusedinanydesignproject.Theexamplesandsolutions
presentedarenottobeconstruedascompleteengineereddesignsolutionsforanyparticularproblemor
project.Theauthorsandpublisherarenotattemptingtorenderanytypeofengineeringorother
professionalservices.Shouldtheseservicesberequired,anappropriateprofessionalengineershouldbe
consulted.Theauthorsandpublisherassumenoliabilityorresponsibilityforanyusesmadeofthe
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LibraryofCongressCataloging-in-PublicationData
McDonald,AndreG.
Introductiontothermo-fluidssystemsdesign/AndreG.McDonald,Ph.D.,P.Eng.,HughL.Magande,
M.B.A.,M.S.E.M.
pagescm
Includesbibliographicalreferencesandindex.
ISBN978-1-118-31363-3(cloth)
1.Heatexchangers–Fluiddynamics. 2.Fluids–Thermalproperties. I.Magande,HughL. II.Title.
TJ263.M382013
(cid:3)
621.4022–dc23
2012023753
AcataloguerecordforthisbookisavailablefromtheBritishLibrary.
ISBN:9781118313633
Setin10/12.5ptPalatinobyAptaraInc.,NewDelhi,India.
iv
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Contents
Preface xi
ListofFigures xv
ListofTables xix
ListofPracticalNotes xxi
ListofConversionFactors xxiii
1 DesignofThermo-FluidsSystems 1
1.1 EngineeringDesign—Definition 1
1.2 TypesofDesigninThermo-FluidScience 1
1.3 DifferencebetweenDesignandAnalysis 2
1.4 ClassificationofDesign 2
1.5 GeneralStepsinDesign 2
1.6 AbridgedStepsintheDesignProcess 2
2 AirDistributionSystems 5
2.1 FluidMechanics—ABriefReview 5
2.1.1 InternalFlow 5
2.2 AirDuctSizing—SpecialDesignConsiderations 12
2.2.1 GeneralConsiderations 12
2.2.2 SizingStraightRectangularAirDucts 13
2.2.3 UseofanAirDuctCalculatortoSizeRectangularAirDucts 18
2.3 MinorHeadLossinaRunofPipeorDuct 18
2.4 MinorLossesintheDesignofAirDuctSystems—EqualFriction
Method 20
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vi Contents
2.5 Fans—BriefOverviewandSelectionProcedures 44
2.5.1 ClassificationandTerminology 44
2.5.2 TypesofFans 44
2.5.3 FanPerformance 46
2.5.4 FanSelectionfromManufacturer’sDataorPerformance
Curves 48
2.5.5 FanLaws 51
2.6 DesignforAdvancedTechnology—SmallDuctHigh-Velocity
(SDHV)AirDistributionSystems 54
Problems 66
ReferencesandFurtherReading 72
3 LiquidPipingSystems 73
3.1 LiquidPipingSystems 73
3.2 MinorLosses:FittingsandValvesinLiquidPipingSystems 73
3.2.1 Fittings 73
3.2.2 Valves 73
3.2.3 ATypicalPipingSystem—AClosed-Loop
FuelOilPipingSystem 75
3.3 SizingLiquidPipingSystems 75
3.3.1 GeneralDesignConsiderations 75
3.3.2 PipeDataforBuildingWaterSystems 77
3.4 FluidMachines(Pumps)andPump–PipeMatching 83
3.4.1 ClassificationsandTerminology 83
3.4.2 TypesofPumps 83
3.4.3 PumpFundamentals 83
3.4.4 PumpPerformanceandSystemCurves 86
3.4.5 PumpPerformanceCurvesforaFamilyofPumps 88
3.4.6 AManufacturer’sPerformancePlotforaFamilyof
CentrifugalPumps 89
3.4.7 CavitationandNetPositiveSuctionHead 92
3.4.8 PumpScalingLaws:NondimensionalPumpParameters 97
3.4.9 ApplicationoftheNondimensionalPump
Parameters—AffinityLaws 98
3.4.10 NondimensionalFormofthePumpEfficiency 99
3.5 DesignofPipingSystemsCompletewithIn-LineorBase-Mounted
Pumps 103
3.5.1 Open-LoopPipingSystem 103
3.5.2 Closed-LoopPipingSystem 111
Problems 121
ReferencesandFurtherReading 126
4 FundamentalsofHeatExchangerDesign 127
4.1 DefinitionandRequirements 127
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Contents vii
4.2 TypesofHeatExchangers 127
4.2.1 Double-PipeHeatExchangers 127
4.2.2 CompactHeatExchangers 129
4.2.3 Shell-and-TubeHeatExchangers 129
4.3 TheOverallHeatTransferCoefficient 130
4.3.1 TheThermalResistanceNetworkforPlaneWalls—
BriefReview 132
4.3.2 ThermalResistancefromFouling—TheFoulingFactor 136
4.4 TheConvectionHeatTransferCoefficients—ForcedConvection 138
4.4.1 NusseltNumber—FullyDevelopedInternalLaminarFlows 139
4.4.2 NusseltNumber—DevelopingInternalLaminarFlows—
CorrelationEquation 139
4.4.3 NusseltNumber—TurbulentFlowsinSmoothTubes:
Dittus–BoelterEquation 141
4.4.4 NusseltNumber—TurbulentFlowsinSmoothTubes:
Gnielinski’sEquation 141
4.5 HeatExchangerAnalysis 142
4.5.1 PreliminaryConsiderations 142
4.5.2 AxialTemperatureVariationintheWorkingFluids—Single
PhaseFlow 143
4.6 HeatExchangerDesignandPerformanceAnalysis:Part1 147
4.6.1 TheLog-MeanTemperatureDifferenceMethod 147
4.6.2 TheEffectiveness-NumberofTransferUnits
Method:Introduction 148
4.6.3 TheEffectiveness-NumberofTransferUnitsMethod:ε-NTU
Relations 149
4.6.4 CommentsontheNumberofTransferUnitsandtheCapacity
Ratio(c) 151
4.6.5 Proceduresfortheε-NTUMethod 156
4.6.6 HeatExchangerDesignConsiderations 157
4.7 HeatExchangerDesignandPerformanceAnalysis:Part2 157
4.7.1 ExternalFlowoverBareTubesinCrossFlow—Equationsand
Charts 157
4.7.2 ExternalFlowoverTubeBanks—PressureDrop 162
4.7.3 ExternalFlowoverFinned-TubesinCrossFlow—Equations
andCharts 175
4.8 Manufacturer’sCatalogSheetsforHeatExchangerSelection 202
Problems 208
ReferencesandFurtherReading 211
5 ApplicationsofHeatExchangersinSystems 213
5.1 OperationofaHeatExchangerinaPlasmaSprayingSystem 213
5.2 ComponentsandGeneralOperationofaHotWater
HeatingSystem 216
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viii Contents
5.3 BoilersforWater 217
5.3.1 TypesofBoilers 217
5.3.2 OperationandComponentsofaTypicalBoiler 218
5.3.3 WaterBoilerSizing 220
5.3.4 BoilerCapacityRatings 224
5.3.5 BurnerFuels 226
5.4 DesignofHydronicHeatingSystemsc/wBaseboards
orFinned-TubeHeaters 227
5.4.1 ZoningandTypesofSystems 227
5.4.2 One-PipeSeriesLoopSystem 227
5.4.3 Two-PipeSystems 229
5.4.4 BaseboardandFinned-TubeHeaters 233
5.5 DesignConsiderationsforHotWaterHeatingSystems 236
Problems 258
ReferencesandFurtherReading 265
6 PerformanceAnalysisofPowerPlantSystems 267
6.1 ThermodynamicCyclesforPowerGeneration—BriefReview 267
6.1.1 TypesofPowerCycles 267
6.1.2 VaporPowerCycles—IdealCarnotCycle 268
6.1.3 VaporPowerCycles—IdealRankineCycleforSteam
PowerPlants 268
6.1.4 VaporPowerCycles—IdealRegenerativeRankineCyclefor
SteamPowerPlants 269
6.2 RealSteamPowerPlants—GeneralConsiderations 271
6.3 Steam-TurbineInternalEfficiencyandExpansionLines 272
6.4 ClosedFeedwaterHeaters(SurfaceHeaters) 280
6.5 TheSteamTurbine 282
6.5.1 Steam-TurbineInternalEfficiencyandExhaustEndLosses 282
6.5.2 CasingandShaftArrangementsofLargeSteamTurbines 284
6.6 Turbine-CycleHeatBalanceandHeatandMassBalanceDiagrams 286
6.7 Steam-TurbinePowerPlantSystemPerformanceAnalysis
Considerations 288
6.8 Second-LawAnalysisofSteam-TurbinePowerPlants 300
6.9 Gas-TurbinePowerPlantSystems 307
6.9.1 TheIdealBraytonCycleforGas-TurbinePowerPlant
Systems 307
6.9.2 RealGas-TurbinePowerPlantSystems 309
6.9.3 RegenerativeGas-TurbinePowerPlantSystems 312
6.9.4 OperationandPerformanceofGas-TurbinePower
Plants—PracticalConsiderations 313
6.10 Combined-CyclePowerPlantSystems 324
6.10.1 TheWasteHeatRecoveryBoiler 325
Problems 332
ReferencesandFurtherReading 338
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Contents ix
AppendixA:PipeandDuctSystems 339
AppendixB:SymbolsforDrawings 365
AppendixC:HeatExchangerDesign 373
AppendixD:DesignProject—PossibleSolution 383
D.1 FuelOilPipingSystemDesign 383
AppendixE:ApplicableStandardsandCodes 413
AppendixF:EquipmentManufacturers 415
AppendixG:GeneralDesignChecklists 417
G.1 AirandExhaustDuctSystems 417
G.2 LiquidPipingSystems 418
G.3 HeatExchangers,Boilers,andWaterHeaters 419
Index 421
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Preface
Designcoursesandprojectsincontemporaryundergraduatecurriculahavefocused
mainly on topics in solid mechanics. This has left graduating junior engineers with
limited knowledge and experience in the design of components and systems in the
thermo-fluidssciences.ABBAutomationintheirhandbookonEnergyEfficientDesign
ofAuxiliarySystemsinFossil-FuelPowerPlantshasmentionedthatthislackoftraining
in thermo-fluids systems design will limit our ability to produce high-performance
systems. This deficiency in contemporary undergraduate curricula has resulted in
an urgent need for course materials that underline the application of fundamental
conceptsinthedesignofthermo-fluidscomponentsandsystems.
Owingtotheurgentneedforcoursematerialsinthisarea,thistextbookhasbeende-
velopedtobridgethegapbetweenthefundamentalconceptsoffluidmechanics,heat
transfer,andthermodynamicsandthepracticaldesignofthermo-fluidscomponents
andsystems.Toachievethisgoal,thistextbookisfocusedonthedesignofinternal
fluidflowsystems,coiledheatexchangers,andperformanceanalysisofpowerplant
systems.Thisrequiresprerequisiteknowledgeofinternalfluidflow,conductionheat
transfer, convection heat transfer with emphasis on forced convection in tubes and
over cylinders, analysis of constant area fins, and thermodynamic power cycles, in
particular, the Rankine and Brayton cycles. The fundamental concepts are used as
tools inanexhaustive design process tosolve various practical problems presented
in the examples. For junior design engineers with limited practical experience, use
offundamentalconceptsofwhichtheyhavepreviousknowledgewillhelpthemto
increasetheirconfidenceanddecision-makingcapabilities.
The complete design or modification of modern equipment and systems will re-
quire knowledge of current industry practices. While relying on and demonstrat-
ing the application of fundamental principles, this textbook highlights the use of
manufacturers’ catalogs to select equipment and practical rules to guide decision-
making in the design process. Some of these practical rules are included in the
text as Practical Notes, to underline their importance in current practice and pro-
vide additional information. While great emphasis is placed upon the use of these
rules, an effort was made to ensure that the reader understands the fundamental
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xii Preface
concepts that support these guidelines. It is strongly believed that this will also en-
able the design engineer to make quick and accurate decisions in situations where
theguidelinesmaynotbeapplicable.
Thetopicscoveredinthetextarearrangedsothateachtopicbuildsontheprevious
concepts.Itisimportanttoconveytothereaderthat,inthedesignprocess,topicsare
notstand-aloneitemsandtheymustcometogethertoproduceasuccessfuldesign.
Therearethreemaintopicalareas,arrangedinsixchapters.
IntroductorymaterialonthedesignprocessispresentedinChapter1.Sincethebook
focusesonthedetailed,technicaldesignofthermo-fluidscomponentsandsystems,
thechapterendswithanabridgedversionofthefulldesignprocess.
Chapters2and3dealwiththedesignofairductandliquidpipingsystems,respec-
tively.Itisintheseinitialchaptersthatabriefreviewofinternalfluidflowispresented.
Systemlayout,componentsizing,andequipmentselectionarealsocovered.
AnintroductiontoheatexchangerdesignandanalysisispresentedinChapter4.This
chapterpresentsthemostfundamentalmaterialinthetextbook.Extensivechartsare
usedtodesignandanalyzetheperformanceofbare-tubeandfinned-tubecoiledheat
exchangers. The chapter ends with a description of excerpts from a manufacturer’s
catalogusedtoselectheatingcoilmodelsthatareusedinhigh-velocityductsystems.
Chapter5continuesthediscussionofheatexchangersbyfocusingonthesizingand
selectionofvariousheatexchangerssuchasboilers,waterheaters,andfinned-tube
baseboard heaters. Various rules and data are presented to guide the selection and
designprocess.
Chapter 6 focuses on the analysis of power plant systems. Here, the reader is in-
troduced to a review of thermodynamic power cycles and various practical consid-
erationsintheanalysisofsteam-turbineandgas-turbinepowergenerationsystems.
Combined-cyclesystemsandwasteheatrecoveryboilersarealsopresented.
There are seven Appendices at the end of this book. They contain a wide variety
ofcharts,tables,andcatalogsheetsthatthedesignengineerwillfindusefulduring
practice.Alsoincludedintheappendicesare:apossiblesolutionofadesignproject,
the names of organizations that provide applicable codes and standards, and the
names of some manufacturers and suppliers of equipment used in thermo-fluids
systems.
The writing of this textbook was inspired, in part, by the difficulty to find ap-
propriate textbooks that presented a detailed practical approach to the design of
thermo-fluids components and systems in industrial environments. It is hoped that
the readers and design engineers, in particular, will find it useful in practice as a
referenceduringdesignprojectsandanalysis.
Theauthorshavemadenoefforttoclaimcompleteoriginalityofthetext.Wehave
beenmotivatedbytheworkofmanyothersthathavebeenappropriatelyreferenced
throughoutthetextbook.
Whilewefeelthatthistextbookwillbeavaluableresourcefordesignengineersin
industry,itisofferedasaguide,andassuch,judgementisrequiredwhenusingthe
texttodesignsystemsorforapplicationtospecificinstallations.Theauthorsandthe
publisherarenotresponsibleforanyusesmadeofthistext.