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Introduction to Thermo-Fluids Systems Design PDF

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JWST229-fm JWST229-McDonald Printer:YettoCome August16,2012 11:29 Trim:244mm×168mm 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 JWST229-fm JWST229-McDonald Printer:YettoCome August16,2012 11:29 Trim:244mm×168mm Thiseditionfirstpublished2012. (cid:2)C 2012Andre´G.McDonaldandHughL.Magande. Registeredoffice JohnWiley&SonsLtd,TheAtrium,SouthernGate,Chichester,WestSussex,PO198SQ,UnitedKingdom Fordetailsofourglobaleditorialoffices,forcustomerservicesandforinformationabouthowtoapply forpermissiontoreusethecopyrightmaterialinthisbookpleaseseeourwebsiteatwww.wiley.com. Therightoftheauthortobeidentifiedastheauthorofthisworkhasbeenassertedinaccordancewiththe Copyright,DesignsandPatentsAct1988. Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,or transmitted,inanyformorbyanymeans,electronic,mechanical,photocopying,recordingorotherwise, exceptaspermittedbytheUKCopyright,DesignsandPatentsAct1988,withoutthepriorpermissionof thepublisher. Wileyalsopublishesitsbooksinavarietyofelectronicformats.Somecontentthatappearsinprintmay notbeavailableinelectronicbooks. Designationsusedbycompaniestodistinguishtheirproductsareoftenclaimedastrademarks.Allbrand namesandproductnamesusedinthisbookaretradenames,servicemarks,trademarksorregistered trademarksoftheirrespectiveowners.Thepublisherisnotassociatedwithanyproductorvendor mentionedinthisbook.Thispublicationisdesignedtoprovideaccurateandauthoritativeinformationin regardtothesubjectmattercovered.Itissoldontheunderstandingthatthepublisherisnotengagedin renderingprofessionalservices.Ifprofessionaladviceorotherexpertassistanceisrequired,theservices ofacompetentprofessionalshouldbesought. DISCLAIMER Thecontentsofthistextbookaremeanttosupplyinformationonthedesignofthermo-fluidssystems. Thebookisnotmeanttobethesoleresourceusedinanydesignproject.Theexamplesandsolutions presentedarenottobeconstruedascompleteengineereddesignsolutionsforanyparticularproblemor project.Theauthorsandpublisherarenotattemptingtorenderanytypeofengineeringorother professionalservices.Shouldtheseservicesberequired,anappropriateprofessionalengineershouldbe consulted.Theauthorsandpublisherassumenoliabilityorresponsibilityforanyusesmadeofthe materialcontainedanddescribedherein. 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 JWST229-fm JWST229-McDonald Printer:YettoCome August1,2012 7:44 Trim:244mm×168mm 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 v JWST229-fm JWST229-McDonald Printer:YettoCome August1,2012 7:44 Trim:244mm×168mm 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 JWST229-fm JWST229-McDonald Printer:YettoCome August1,2012 7:44 Trim:244mm×168mm 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 JWST229-fm JWST229-McDonald Printer:YettoCome August1,2012 7:44 Trim:244mm×168mm 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 JWST229-fm JWST229-McDonald Printer:YettoCome August1,2012 7:44 Trim:244mm×168mm 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 JWST229-fm JWST229-McDonald Printer:YettoCome August1,2012 7:44 Trim:244mm×168mm 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 xi JWST229-fm JWST229-McDonald Printer:YettoCome August1,2012 7:44 Trim:244mm×168mm 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.

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Most books are stored in the elastic cloud where traffic is expensive. For this reason, we have a limit on daily download.