Process

Measurements

• Cogeneration Plant

Real World Engineering

Process Simulation

• Flow

• Temperature

• Pressure

Life in the Day

of an Engineer:

Week 1 • Tour of Cogeneration

Facility

• Process Simulation using

HYSYS

• Homework: Heat Duty

Calculations

Economizer

Boiler

Heat Recovery Steam

Generator (HRSG)

Feed

Water from

Deaerator

Tank

To Main

Steam

LineSteam Flowmeter

HRSG SF

T

Feed Water Flow

FDWTR F

T PHRSG

SP

FDWTR

T

P

Continuous Liquid

Blow-Off

Process

Engineering

Objectives

• Unit Conversion & Dimensional homogeneity

• Engineering Equations and Calculations

• Energy balances based on readings taken in plant.

• Process Equipment Identification

• Chemical Process Simulation HYSYS

• Describe the process of cogeneration to a high

school student.

Cogeneration at the Rowan University

Central Heating Plant

• Useful thermal energy

(steam) and electricity

• Heating & Cooling

• Electricity Needs -

60% (1.5 MW)

Exp

an

sio

n

Jo

int

Ec

on

om

ize

r

Water Drum

Steam Production Drum

Heat Recovery Steam

Generator (HRSG)

Duct

Burner

Turbine Inlet Air

Compressor

Turbine for

Generation of

Electricity

Bu

rne

r

Air From

Roof Vent

Power

Generation

Da

mp

er

Vertical Columns

of Heat

Exchanger Tubes

Feed Water from

Deaerator Tank

Exhaust Gases

To Main Steam

Line

Bypass

Stack

Exh

au

st G

ase

s

T

Room Air

Exhaust Gases

to Stack

Water Injection

for NOx and

Temperature Control

Rowan Cogeneration Plant

Energy Recovery International

Reduction

Gearbox

Hot

Exhaust

Gases

Steam

Flowmeter

HRSG SF

T

FLU I

P

FLU O

T

FLU O

P

Econ

T

Econ

P

Fe

ed

Wa

ter

Flo

w

FD

WT

R F

Duct Burner Fuel

Flow

DB Oil or Gas

T W IJF

FLU I

T

T P

HRSG

SP

Tu

rbin

e F

ue

l F

low

TN

Ga

s o

r T

F O

il

FDWTR

T

Stack Gas

Emissions

CO & O2

ENG

AIR T

P

Continuous

Liquid

Blow-Off

Manually

Operated Liquid

Blow-off

Fuel Oil

M

Na

tura

l G

as

Co

mp

resso

r

Natural Gas

Overall Schematic

of Steam &

Electricity

Generation Building

A

BuildingB

BuildingC

Steam & Electricity

Generation Plant

Steam to

Buildings

Condensate Return to Plant

(Steam condensed to water)

Electricity

Generation

Fuel & Air

Exhaust Gases

N2, CO

2, H

2O,

O2, NO, CO, HC's

Brainstorm a

Process that you

are familiar with

• Flows into process

• Flows out of process

• chemical transformations within process

• Process conditions, T, P, Flowrate, Concentrations

valve

valve

gas flowmeter

liquid flowmeterva

lve

Hot

Water

Tank

Natural Gas

From Mains

Air From Room

Cold Water

from Mains

Combustion

Exhaust

Gases to Vent

Hot Water to

Faucets etc.

Ja

cu

zzi

Water Drain

to City Sewer

Pump

Process Flow Diagram of Hot Water

Production for Jacuzzi

Relief Vent for Hot

Water Tank

Relief

Valve

Air Vent to

Roof for

Sewer Line

valve valve

valve

Cold water to

faucets,etc.

check

v alv e

check

valve

Exp

an

sio

n

Jo

int

Ec

on

om

ize

r

Water Drum

Steam Production Drum

Heat Recovery Steam

Generator (HRSG)

Duct

Burner

Turbine Inlet Air

Compressor

Turbine for

Generation of

Electricity

Bu

rne

r

Air From

Roof Vent

Power

Generation

Da

mp

er

Vertical Columns

of Heat

Exchanger Tubes

Feed Water from

Deaerator Tank

Exhaust Gases

To Main Steam

Line

Bypass

Stack

Exh

au

st G

ase

s

T

Room Air

Exhaust Gases

to Stack

Water Injection

for NOx and

Temperature Control

Rowan Cogeneration Plant

Energy Recovery International

Reduction

Gearbox

Hot

Exhaust

Gases

Steam

Flowmeter

HRSG SF

T

FLU I

P

FLU O

T

FLU O

P

Econ

T

Econ

P

Fe

ed

Wa

ter

Flo

w

FD

WT

R F

Duct Burner Fuel

Flow

DB Oil or Gas

T W IJF

FLU I

T

T P

HRSG

SP

Tu

rbin

e F

ue

l F

low

TN

Ga

s o

r T

F O

il

FDWTR

T

Stack Gas

Emissions

CO & O2

ENG

AIR T

P

Continuous

Liquid

Blow-Off

Manually

Operated Liquid

Blow-off

Fuel Oil

M

Na

tura

l G

as

Co

mp

resso

rNatural Gas

Cogeneration Process Water

Flow Diagram

Economizer

Boiler

Feed

Water from

Deaerator

Tank

To Main

Steam

Line

Steam

Flowmeter

T

Feed Water Flow

FDWTR F

T PHRSG

SP

FDWTR

T

P

Feed Water

Temperature

Feed Water

Pressure

Feed Water

Mass Flowrate

Steam Mass Flowrate

Boiler Inlet Water

Temperature

Steam Pressure

Entrance of Heating Plant

Straight Ahead Right

Measurements on boiler side of

cogeneration unit

Steam Pressure

Boiler (HRSG)

Temperature

Digital Displays on “Brown Panel”

1000 pph =

multiply

reading

by 1000 to

get lbm/hr

Orifice Meters

for Flowrate

& Data Acquistion

Feed Water Flowrate

(FDWTR F)

Cogen Steam Flowrate

(HRSG SF)

Fuel Oil Flowrate

Boiler Water Treatment

Reverse Osmosis Unit Ion - Exchange Unit

Cogeneration Unit

Turbine

Duct Burner

Heat Recovery

Steam Generator

(HRSG) or boiler

Inside the

Boiler!

Boiler Tubes

Detail of bottom

of boiler tubes

Data Acquisition

System

65 Channels!

What a maze of

pipes!

Do you know where

your liquid is flowing?

Light Blue Feed water (mainly from dealkalinizer for pH control )

Red Steam

Orange Condensate (liquid water condensed from steam)

Green Feed water to boilers from deaeration unit

Yellow Natural Gas

Black Fuel Oil

Steam “Mains” Valve

Steam flows from here to the campus via underground pipes.

Conventional Boiler Unit

Condensate

return line

Deaerator Unit at the top of the steps!

Dial Temperature Gauge

Liquid Level

Indicator

Remember gh!

Economizer

Steam Orifice

Flowmeter

Best View of

an orifice

flowmeter

(fuel oil)

Steam Production Valve

Safety First!

• Pipes and Tanks may

be hot!

• Wear Hard Hats -

High Bay Area

• Eye Protection

• Hearing Protection is

optional

Walk over to

the Cogen

Plant

Turbine

Dealkali

zer Unit

Co

ntr

ol R

oo

m

Compressor

Room

Bo

ile

r #

3B

oile

r #

2

Bo

ile

r #

1

T

PFeed Pump

1st floor

Fe

ed

Wa

ter

Flo

w

FD

WT

R F

T

FDWTR

T

P

Cogeneration Unit

Deareation Tank

(second floor)

Economizer

Ste

am

Flo

wm

ete

r

HR

SG

SF W

ate

r T

rea

tme

nt

Un

its

Ste

am

Exit &

Co

nd

en

sa

te R

etu

rn

2n

d F

loo

r C

atw

alk

1

3

2

5

5

Boiler(HRSG)

HRSG

SP

Cogen

Tour

Guide

Turbine

Dealkali

zer Unit

Co

ntr

ol R

oo

m

Compressor

Room

Bo

ile

r #

3B

oile

r #

2

Bo

ile

r #

1

T

PFeed Pump

1st floor

Fe

ed

Wa

ter

Flo

w

FD

WT

R F

T

FDWTR

T

P

Cogeneration Unit

Deareation Tank

(second floor)

Economizer

Ste

am

Flo

wm

ete

r

HR

SG

SF W

ate

r T

rea

tme

nt

Un

its

Ste

am

Exit &

Co

nd

en

sa

te R

etu

rn

2n

d F

loo

r C

atw

alk

1

3

2

5

5

Boiler(HRSG)

HRSG

SP

Process Simulation

HYSYS Economizer

Boiler

Feed Water

from

Deaerator

Tank

To Main

Steam

LineSteam Flowmeter

HRSG SF

T

Feed Water Flow

FDWTR F

T PHRSG

SP

FDWTR

T

P

Homework Assignment

• Calculate duty on both

heat exchangers

• Compare hand

calculations to process

simulation results

Answers

given in the

process

simulation

results!

Engineering Equations

• Mass Balance

• Thermodynamics

Enthalpy

Heat Capacity

Vapor-Liquid

Equilibrium of

Saturated Steam

• Energy Balances

2

3

3

2 Kkg

J10885.4

Kkg

J4297.3

Kkg

J26.4788 TTC liquid

p

K

110683.2

Pa1001325.1ln

K

110075.2

1 3

5

4

steam

steam

P

T

liq

liq

inliq

liq

meconomzer mHmHQ ˆˆ

liq

liq

mgas

gas

outboiler mHmHQ ˆˆ

? steamFW mm

2K16.273ˆ TCH liquid

p

liquid

Week 2: Process

Engineering

Immersion Heater Comparision

0

20

40

60

80

100

120

0 5 10 15 20

Time (min)

Te

mp

era

ture

(°C

)

Immersion Heater (200 Watts)

West bend (1000 Watts)

RIVAL Hot Pot Express (750 watts)

Proctor Silex (1500 Watts)

Heater

Turns Off

0d

d in

liq

p Qt

TmC

• Immersion Heaters

• Rotameter Calibration

Week 3: Process Engineering

• Tank Efflux

• 2-L Soda Bottle

Implosion

Tank Efflux: Comparison of the Effect of Outlet

Drain Diameter

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

0.00 5.00 10.00 15.00

Time (min)

Liq

uid

Heig

ht

(cm

)

1/2 inch data

3/4 inch data

1 inch data

out

k mt

hA

t

m

d

d

d

d tanktan