Introduction to Thermo-fluids Systems Design

List of Figures xv

List of Tables xix

List of Practical Notes xxi

List of Conversion Factors xxiii

1 Design of Thermo-Fluids Systems 1

1.1 Engineering Design—Definition 1

1.2 Types of Design in Thermo-Fluid Science 1

1.3 Difference between Design and Analysis 2

1.4 Classification of Design 2

1.5 General Steps in Design 2

1.6 Abridged Steps in the Design Process 2

2 Air Distribution Systems 5

2.1 Fluid Mechanics—A Brief Review 5

2.1.1 Internal Flow 5

2.2 Air Duct Sizing—Special Design Considerations 12

2.2.1 General Considerations 12

2.2.2 Sizing Straight Rectangular Air Ducts 13

2.2.3 Use of an Air Duct Calculator to Size Rectangular Air Ducts 18

2.3 Minor Head Loss in a Run of Pipe or Duct 18

2.4 Minor Losses in the Design of Air Duct Systems—Equal Friction Method 20

2.5 Fans—Brief Overview and Selection Procedures 44

2.5.1 Classification and Terminology 44

2.5.2 Types of Fans 44

2.5.3 Fan Performance 46

2.5.4 Fan Selection from Manufacturer’s Data or Performance Curves 48

2.5.5 Fan Laws 51

2.6 Design for Advanced Technology—Small Duct High-Velocity (SDHV) Air Distribution Systems 54

Problems 66

References and Further Reading 72

3 Liquid Piping Systems 73

3.1 Liquid Piping Systems 73

3.2 Minor Losses: Fittings and Valves in Liquid Piping Systems 73

3.2.1 Fittings 73

3.2.2 Valves 73

3.2.3 A Typical Piping System—A Closed-Loop Fuel Oil Piping System 75

3.3 Sizing Liquid Piping Systems 75

3.3.1 General Design Considerations 75

3.3.2 Pipe Data for Building Water Systems 77

3.4 Fluid Machines (Pumps) and Pump–Pipe Matching 83

3.4.1 Classifications and Terminology 83

3.4.2 Types of Pumps 83

3.4.3 Pump Fundamentals 83

3.4.4 Pump Performance and System Curves 86

3.4.5 Pump Performance Curves for a Family of Pumps 88

3.4.6 A Manufacturer’s Performance Plot for a Family of Centrifugal Pumps 89

3.4.7 Cavitation and Net Positive Suction Head 92

3.4.8 Pump Scaling Laws: Nondimensional Pump Parameters 97

3.4.9 Application of the Nondimensional Pump Parameters—Affinity Laws 98

3.4.10 Nondimensional Form of the Pump Efficiency 99

3.5 Design of Piping Systems Complete with In-Line or Base-Mounted Pumps 103

3.5.1 Open-Loop Piping System 103

3.5.2 Closed-Loop Piping System 111

Problems 121

References and Further Reading 126

4 Fundamentals of Heat Exchanger Design 127

4.1 Definition and Requirements 127

4.2 Types of Heat Exchangers 127

4.2.1 Double-Pipe Heat Exchangers 127

4.2.2 Compact Heat Exchangers 129

4.2.3 Shell-and-Tube Heat Exchangers 129

4.3 The Overall Heat Transfer Coefficient 130

4.3.1 The Thermal Resistance Network for Plane Walls—Brief Review 132

4.3.2 Thermal Resistance from Fouling—The Fouling Factor 136

4.4 The Convection Heat Transfer Coefficients—Forced Convection 138

4.4.1 Nusselt Number—Fully Developed Internal Laminar Flows 139

4.4.2 Nusselt Number—Developing Internal Laminar Flows—Correlation Equation 139

4.4.3 Nusselt Number—Turbulent Flows in Smooth Tubes: Dittus–Boelter Equation 141

4.4.4 Nusselt Number—Turbulent Flows in Smooth Tubes: Gnielinski’s Equation 141

4.5 Heat Exchanger Analysis 142

4.5.1 Preliminary Considerations 142

4.5.2 Axial Temperature Variation in the Working Fluids—Single Phase Flow 143

4.6 Heat Exchanger Design and Performance Analysis: Part 1 147

4.6.1 The Log-Mean Temperature Difference Method 147

4.6.2 The Effectiveness-Number of Transfer Units Method: Introduction 148

4.6.3 The Effectiveness-Number of Transfer Units Method: ε-NTU Relations 149

4.6.4 Comments on the Number of Transfer Units and the Capacity Ratio (c) 151

4.6.5 Procedures for the ε-NTU Method 156

4.6.6 Heat Exchanger Design Considerations 157

4.7 Heat Exchanger Design and Performance Analysis: Part 2 157

4.7.1 External Flow over Bare Tubes in Cross Flow—Equations and Charts 157

4.7.2 External Flow over Tube Banks—Pressure Drop 162

4.7.3 External Flow over Finned-Tubes in Cross Flow—Equations and Charts 175

4.8 Manufacturer’s Catalog Sheets for Heat Exchanger Selection 202

Problems 208

References and Further Reading 211

5 Applications of Heat Exchangers in Systems 213

5.1 Operation of a Heat Exchanger in a Plasma Spraying System 213

5.2 Components and General Operation of a Hot Water Heating System 216

5.3 Boilers for Water 217

5.3.1 Types of Boilers 217

5.3.2 Operation and Components of a Typical Boiler 218

5.3.3 Water Boiler Sizing 220

5.3.4 Boiler Capacity Ratings 224

5.3.5 Burner Fuels 226

5.4 Design of Hydronic Heating Systems c/w Baseboards or Finned-Tube Heaters 227

5.4.1 Zoning and Types of Systems 227

5.4.2 One-Pipe Series Loop System 227

5.4.3 Two-Pipe Systems 229

5.4.4 Baseboard and Finned-Tube Heaters 233

5.5 Design Considerations for Hot Water Heating Systems 236

Problems 258

References and Further Reading 265

6 Performance Analysis of Power Plant Systems 267

6.1 Thermodynamic Cycles for Power Generation—Brief Review 267

6.1.1 Types of Power Cycles 267

6.1.2 Vapor Power Cycles—Ideal Carnot Cycle 268

6.1.3 Vapor Power Cycles—Ideal Rankine Cycle for Steam Power Plants 268

6.1.4 Vapor Power Cycles—Ideal Regenerative Rankine Cycle for Steam Power Plants 269

6.2 Real Steam Power Plants—General Considerations 271

6.3 Steam-Turbine Internal Efficiency and Expansion Lines 272

6.4 Closed Feedwater Heaters (Surface Heaters) 280

6.5 The Steam Turbine 282

6.5.1 Steam-Turbine Internal Efficiency and Exhaust End Losses 282

6.5.2 Casing and Shaft Arrangements of Large Steam Turbines 284

6.6 Turbine-Cycle Heat Balance and Heat and Mass Balance Diagrams 286

6.7 Steam-Turbine Power Plant System Performance Analysis Considerations 288

6.8 Second-Law Analysis of Steam-Turbine Power Plants 300

6.9 Gas-Turbine Power Plant Systems 307

6.9.1 The Ideal Brayton Cycle for Gas-Turbine Power Plant Systems 307

6.9.2 Real Gas-Turbine Power Plant Systems 309

6.9.3 Regenerative Gas-Turbine Power Plant Systems 312

6.9.4 Operation and Performance of Gas-Turbine Power Plants—Practical Considerations 313

6.10 Combined-Cycle Power Plant Systems 324

6.10.1 The Waste Heat Recovery Boiler 325

Problems 332

References and Further Reading 338

Appendix A: Pipe and Duct Systems 339

Appendix B: Symbols for Drawings 365

Appendix C: Heat Exchanger Design 373

Appendix D: Design Project— Possible Solution 383

D.1 Fuel Oil Piping System Design 383

Appendix E: Applicable Standards and Codes 413

Appendix F: Equipment Manufacturers 415

Appendix G: General Design Checklists 417

G.1 Air and Exhaust Duct Systems 417

G.2 Liquid Piping Systems 418

G.3 Heat Exchangers, Boilers, and Water Heaters 419

Index 421

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