Support the Technical and Financial

Sustainability of the Renewable Energy

and Energy Efficiency Sectors
EuropeAid/138795/DH/SER/EG
{Course 3}

{course date} This project is

This project is funded
by
Cairo & Alexandria, Egypt implemented by a
The European Union Consortium led by DAI/
Human Dynamics
 Calculation and Verification of
Energy Consumption of
Significant Energy Using (SEUs)
Equipment

2
 About the trainer

Reda Ragab, PhD

Assistant Professor,
Mechanical Power Engineering Dept., Zagazig University
rragab@zu.edu.eg, rragab@hotmail.com
Phone: +2(010) 22831010
www.linkedin.com/pub/reda-ragab/78/101/1b8/

Education
▪ Ph.D. Mechanical Engineering, Univ. of New Orleans, New Orleans, Louisiana,
USA, December 2013, GPA: 3.9/4.0.
▪ M.Sc. Mechanical Engineering, Zagazig Univ., Egypt, 2008.
▪ B.Sc. Mechanical Engineering, Zagazig Univ., Egypt, 2000.

Expertise
▪ Gas Turbine Cooling (Wet compression and Mist/Air film cooling,
Turbomachinery, CFD, Multiphase flow, Wind Farm Design, Hybrid
Renewable Energy Systems, Energy Auditing & Efficiency
 Professional History& Teaching
Experience
Professional History
2017- Present Assistant Professor, Mechanical Power Engineering Dept., Zagazig University, Egypt.
2016-2017 Postdoctoral Researcher, Mechanical Eng. Dept., Univ. of New Orleans, LA, USA.
2015-2016 Postdoctoral Researcher, Mechanical Eng. Dept., Univ. of Memphis, Memphis, TN., USA (J. LSU).
2014-2015 Postdoctoral Researcher, M&I Eng. Dept., Louisiana State University (LSU), B. Rouge, LA, USA.
2009-2013 Research Assistant, Mechanical Engineering, Univ. of New Orleans, LA, USA.
2010-2011 Maintenance Engineer (Part time), S&I Automotive Inc., Metairie, Louisiana, USA.
2003-2009 Research/Lecturer Assistant, Mechanical Engineering, Zagazig University, Egypt.

Teaching and Training Experience ( 18 Years)

(Zagazig Univ., Nile Univ., Heliopolis Univ. , and University of New Orleans, USA)
❑ Power Plant Tech., Energy Auditing & Efficiency, CFD, Fluid Mechanics I & II , Heat Transfer,
HVAC, Thermodynamics I & II, Internal combustion Engines, Thermodynamics I & II,
Renewable Energy Intro, Turbomachinery, Adv. Renewable Energy System Design, and
Engineering LABs

PhD Dissertation : “Experimental Investigation of Mist Film Cooling and Feasibility Study of Mist
Transport in Gas Turbines,” (Advisor Dr. Ting Wang, University of new Orleans).

MS. Thesis: “Numerical Simulation for the Impact of Wet Compression on the Performance and
Erosion of an Axial Compressor” (Advisor Dr. Hafez A. El-Salmawy, Zagazig University).
 About the Trainees

Name:

Job Title:
Work location:
Question: What are energy consuming devices you deal with
in your current job?

5
Policy

6
 Activity Time
Activity
▪ Trainees are divided in 3
groups (A,B, and C)
▪ Each group suggests a
design, a modification, an
idea for efficiency A C
improvement for one of the
devices studied.
▪ Activity is 10 minutes with
another 15 minutes
presentation. B
▪ The winner group is marked
for finals. 7
 Contents
▪ Day 1: Significant Energy Users (SEUs) in Oil and Gas Plant
and their Datasheets
Introduction to Energy Efficiency
Fired Heaters
Steam Boilers
Combustion Turbines
Steam Turbines
Compressors
Pumps
Electric Motors

8
 Contents (Cont.)
▪ Day 2: Combustion Process and Fired Equipment Efficiency
Combustion Principles
Fired Heaters Efficiency Calculations
Steam Boilers Efficiency Calculations
Combustion Turbines Efficiency Calculations

▪ Day 3: Rotating Equipment Efficiency

Compressors Efficiency Calculations
Pumps Efficiency Calculations
Electric Motors Efficiency Calculations

9
 TC3: Day 1
Significant Energy Users
(SEUs) in Oil & Gas Plants
and their Datasheets

10
Introduction to Energy
Efficiency

11
 Motivation

▪ Investments in energy efficiency (EE) in homes,

businesses, and other production facilities are a
proven and cost-effective strategy for meeting
electricity and thermal demands and avoiding
generation that would otherwise occur at
electricity generating units (EGUs) or usage of
extra fossil fuel resources.

12
• SEUs in Egypt’s Oil & Gas Sector

13
Typical Manufacturing Unit
Sankey Diagram – Energy Balance
(Example: Reheating Furnace)
 Energy Efficiency
▪ Energy Efficiency - involves reducing energy
consumption per unit of production (Specific Energy
Consumption or SEC).
▪ Energy Efficiency leads to:
Improved profitability
increased availability of energy sources for
incremental
production output in terms of avoided energy
consumption.
lower GHG emissions.
16
Benefits of Energy Efficiency
 Typical Energy Efficiency
▪ Approaches
Retrofit – addition of new technology features in existing systems

e.g. lamps in a lighting

fixture

▪ Replacement – complete refurbishment of the system

e.g. complete lighting

fixtures

18
Retrofitting vs. Replacement
Typical Energy Efficiency Methodology
 Energy Equipment

Thermal energy equipment

Electrical energy equipment
Monitoring equipment

21
Significant Energy Users (SEUs)
Establishing a Baseline for EE Activities
 Preliminary Assessment
▪ 10 MCQ to be solved online in 10 minutes.
▪ Link: https://forms.gle/5m6meTXTT7TZzBmp6

Purpose:
▪ Measure the background information related SEUs
(Boilers, Fired Heaters, turbines, pumps, compressors,
…)
▪ Pinpoint the strengths and weaknesses
▪ Deciding the pace of transition and the level of detail.

24
 Fired Heaters
Fired Heaters for General Refinery Service
ANSI/API STANDARD 560 (4th Ed., Aug. 2007)

Types in terms of Energy Efficiency; direct (fired box, with convection section, with air preheater), indirect;
Heater treater and Typical efficiency for each type
Datasheet and energy data that could be extracted from it (efficiency, fuel flow rate, operating parameters and
duty)

25
 Direct Type vs. Indirect Type Fired
❑Heaters
In a fired heater, heat liberated by the combustion of fuels is transferred
to fluids contained in tubular coils within an insulated enclosure.
Based on the way the output heat is transferred to the process user:
▪ Direct heating to a coil where process medium is circulated to consume
the heat, by sensible energy (temperature rise) or Latent heat (boiling or
changing process medium )
▪ Indirect type utilizes intermediate heating bath of heating fluid such as
saline water, heating oil, which is heated by a fired tube where fuel is
burnt as injected into the coil with air. This bath transfer heat to another
coil where the process medium is circulated to absorb the heat.
▪ Indirect type heater is slightly less efficient but provides better safety
because it eliminates the inevitable burning of process medium as it
leaks from its coil by the direct heating fuel flames.
26
Direct Heater (more efficient)

27
Indirect Heater (Heater Treater)

28
Indirect Heater

29
Energy Efficient Designs
with air preheater with convection section

30
 Operational advantages of APH
systems
Air preheat systems typically provide the following
operational advantages:
reduced fuel consumption;
improved control of combustion air flow;
reduced oil-burner fouling;
better flame-pattern control;
more complete combustion of difficult fuels.

▪ What about the disadvantages ?

31
Further Classification
▪ Classified by Based on structural configuration: cylindrical,
box, cabin and multi-cell box,
▪ Classified by Radiant tube coil configuration: vertical,
horizontal, helical and arbor.
▪ Classified by Burner arrangement: up-fired, down-fired and
wall-fired. The wall-fired arrangement can be further classified
as sidewall, endwall and multilevel.
▪ Classified by fluid-flow design: Balanced-draught APH
system, Forced-draught APH system, Induced-draught APH
system
▪ Fired Heaters classified by APH (exchanger) design: Direct
APH systems, Indirect APH systems, and External Heat Source
32
systems.
Typical heater types

33
Typical burner arrangements.

34
Heater Components
Key
1 access door
2 arch
3 breeching
4 bridge wall
5 burner
6 casing
7 convection section
8 corbel
9 crossover
10 tubes
11 extended surface
12 return bend
13 header box
14 radiant section
15 shield section
16 observation door
17 tube support
18 refractory lining
19 end-tube sheet
20 pier
21 stack/duct
22 platform
23 process in
24 process out 35
Link: https://www.youtube.com/watch?v=jtYZPtbJSH4

36
Burners for Fired Heaters
Burners for Fired Heaters in General Refinery Services
API 535 (3rd Ed., XXXXX 2012)

37
Low NOx Staged Fuel Gas Burner

38
Data Sheet of Fired Heaters

▪ From the fired heater datasheet both, fuel efficiency and guaranteed
fuel efficiency could be identified.

▪ The guaranteed Fuel efficiency could be used as typical efficiency

value

SOR: Start of run

EOR: End of run 39
Data Sheet

Datasheets
Datasheets of Fired Heaters
Source 1

Datasheets
Source 2

40
Burner Data sheet

41
 Steam Boilers
(Fired Steam Generator)

42
 Classification of Steam Generators
▪ Application (Utility or industrial)
▪ Basic Design (Water tube or Fire tube)
▪ Operating pressure (sub-critical, super-critical or
multi-pressure)
▪ The firing system (Fired , Electric, Heat recovery
boilers or Heat recovery with supplementary firing)
▪ Energy Saving Components: Economizer, Air
Pre-Heater, boiler blow down

43
Fire Tube Boilers
▪ Heat transfer surfaces are basically those of the fire and
the smoke tubes. The hot surfaces usually form two or
three passes with wet or dry back.
▪ Mainly used in industrial or HVAC applications
▪ Usually has a cylindrical shape
▪ Limited capacity and operating pressure (20 ton/hr and
18 bar)
▪ Can be either horizontal or vertical.
▪ Low response for load changes

44
Fire Tube Boilers

45
Water Tube Boiler

▪ Can Provide high operating pressure as well as steam

flow rate.
▪ High response for load changes
▪ Consists of at least one steam drum, down comer and
raiser. Some designs may include lower drum (mud
drum) and more than one steam drum.
▪ Water circulation inside the boiler can be natural,
controlled or once through (no circulation).

46
View For a Water Tube Boiler

47
Waterwall and Internal
Components

48
 Energy Saving Boiler
▪ Components
Economizers: are used to recover heat from the boiler
flue gases and thereby increase boiler efficiency. The heat
absorbed by economizer is transferred to the boiler
feedwater flowing through the inside of the economizer
tubes.
▪ Air Pre-heaters: The purpose of the air preheater is to
recover the heat from the boiler flue gas which increases
the thermal efficiency of the boiler by reducing the useful
heat lost in the flue gas.
▪ Boiler Blowdown Control System: The removal of some
quantity of water from the boiler in order to achieve an
acceptable concentration of dissolved and suspended 49
solids in the boiler water.
 Energy Saving Boiler Components

Economizers

Economize 50
Economizers

51
Boiler Efficiency Improvement
▪ For natural gas-fired boilers, the
lowest temperature to which flue
gas can be cooled is about 250°F
to prevent condensation and
possible stack or stack liner
corrosion.
▪ The condensing economizer
improves waste heat recovery by
cooling the flue gas below its dew
point, which is about 135°F for
products of combustion of NG.
▪ The economizer reclaims both
sensible heat from the flue gas
and latent heat by condensing
flue gas water vapor (see Table 1)
52
53
 Video: Water Tube Boiler
Link:
https://www.youtube.com/watch?v=dVBoZ4PfZmE

54
 Boiler Blowdown (Bd)
▪ Boiler blowdown is water
intentionally wasted from a boiler to
avoid high TDS concentrations in the
boiler drum.
▪ The water is blown out of the boiler
with some force by steam pressure
within the boiler
▪ Bottom blowdown & Surface Manual Bd

blowdown. Automatic & manual BD.

▪ It is most effective to remove water
with the highest level of impurities;
and such water is found where
steam separates in the steam drum
at the top of the boiler. 55
Tubular Vs. Rotary Air Pre-heater

56
Water wall

57
Burner Location

58
Tangentially Fired Boilers

59
60
 Boiler Terminology (1/3)
▪ MCR (Maximum Continuous Rating)
Steam boilers rated output is also usually defined as MCR (Maximum
Continuous Rating). This is the maximum evaporation rate that can be
sustained for 24 hours and may be less than a shorter duration
maximum rating (e.g. Shoubra P. Station: 1072 ton/hr)

▪ Boiler Rating
Conventionally, boilers are specified by their capacity to hold water and
the steam generation rate. Often, the capacity to generate steam is
specified in terms of equivalent evaporation (kg of steam / hour at 100°
C).

61
Boiler Terminology (2/3)
▪ Boiler turndown
Boiler turndown is the ratio between full boiler output and
the boiler output when operating at low fire. Typical boiler
turndown is 4:1. The ability of the boiler to turndown
reduces frequent on and off cycling. Fully modulating
burners are typically designed to operate down to 25% of
rated capacity

▪ Balanced draught
The condition achieved when the pressure of the gas in
a furnace is the same as or slightly below that of the
atmosphere in the enclosure or building housing. 62
 Boiler Terminology (3/3)
▪ Blow down
The removal of some quantity of water from the boiler in order
to achieve an acceptable concentration of dissolved and
suspended solids in the boiler water.

▪ Oxygen trim sensor

measures flue gas oxygen and a closed loop controller
compares the actual oxygen level to the desired oxygen level. The
air (or fuel) flow is trimmed by the controller until the oxygen level is
corrected. Oxygen Trim maintains the lowest possible burner excess
air level from low to high fire. Burners that don’t have Oxygen Trim
must run with Extra Excess Air to allow safe operation during
variations in weather, fuel, and linkage.
63
Typical Boiler Efficiencies

64
Typical Boiler Efficiencies (cont.)

▪ Oil-fired boilers are inherently more efficient than

natural gas- or coal-fired boilers, because of different
hydrogen contents and different flame characteristics
and their effect on heat transfer.

▪ Also, unburned fuel losses are normally higher with

coal-fired boilers.

65
Boiler Data Sheet
Boiler Data Sheet

67
Boiler Data Sheet

68
 Gas Turbines
Types in terms of energy efficiency (open cycle, combined cycle and
cogeneration) and typical efficiency for each type.
Datasheet and performance curve and energy data that could be
extracted from it

69
New Capital CC Power Plant

70
Stationary Gas Turbines
▪ It can be used to drive generators, compressors and
pumps.
▪ It can be used in ships and small compact units are
available for automobiles.
▪ Suitable for utility either for base or peak loads.
▪ Energy in exhaust gases of a gas turbine can be
recovered in Heat Recovery Steam Generator (HRSG)
to raise steam for either power generation (combined
cycle) or process heating (cogeneration).

71
Gas Turbine Classifications
▪ Regarding the application :
Micro gas turbine (small power range)
Aero-derivative (gas turbine originally designed for air craft
propulsion or derived from unit designed for air jets
Industrial gas turbines
Heavy duty gas turbine
▪ Regarding the design:
Single shaft
Two shaft turbines (eliminates the need of a gear box; suitable
for driving compressors and pumps).
▪ Regarding Energy Efficiency:
Open cycle,
Combined cycle
Cogeneration 72
 According to Gas Turbine:
design
Combustion Chamber Combustion Chamber

Load Load

Inlet Air Exhaust Gases Inlet Air Exhaust Gases

Single Shaft Gas Turbine Two Shafts Gas Turbine

73
Simple Open Cycle (Brayton Air
Cycle) Gas Turbine
▪ Regeneration, intercooling, and
reheat sometimes are not
practical.
▪ Energy in exhaust gases can
be recovered in Heat Recovery
Steam Generator (HRSG) to
raise steam for either power
generation (combined cycle)
or process heating
(cogeneration).
74
 Link:
https://www.youtube.com/watch?v=KjiUUJdPGX0

75
Combined Cycle Gas Turbine

HRSG

76
HRSG Design

77
Cogeneration
(aka: CHP, Combined Heat & Power)

78
 Link:
https://www.youtube.com/watch?v=W1hSFLXADQ0

79
 Types of Cogeneration Cycle
Fuel Bottoming Cycle
Heat Industrial Use
Source (e.g. Furnace)

Engine Generator

Electrical
Energy

Topping Cycle
Thermal Energy
Heat Exchanger
Fuel (Hot gases, Steam, Hot
water)
Engine Generator
Electrical Energy
80
 Advantages of Gas Turbines
▪ Wide power range form fraction of Megawatts up to
hundreds of Megawatts
▪ High power to weight ratio
▪ Compact
▪ Fuel flexibility where it can use gaseous as well as liquid
fuels
▪ No need for cooling water
▪ No vibration due to its rotatory design.
▪ Suitable for combined cycle and cogeneration
▪ Minimum environmental impact due to combustion at very
lean conditions
▪ Short delivery and quick to install
81
Disadvantages of Gas Turbines
▪ What do you think???

▪ Relatively low thermal efficiency when used as simple

cycle
▪ Not suitable for solid fuels
▪ Power output as well as efficiency are sensitive to site
conditions

82
Efficiency Range

▪ Simple open cycle

efficiency ≈ 22 %
▪ Combined Cycle
efficiency ≈ 60 %
▪ New Capital CCPP is
H-Class with efficiency >
60 %
83
Combined Cycle Data Sheet

84
New Capital CCPP (Siemens)

85
86
87
Activity
 Workshop Activity : 15 minutes
Reflect upon efficiency improvement in
studied technologies
Activity
▪ Split into groups A, B, and C
▪ Each group select a topic of
the 3 covered today (Fired
Heater, Boiler, Combustion
Turbine)
▪ Discuss with your group some A C
proposed techniques to
improve energy efficiency in
the selected equipment.
▪ List down your suggestions
▪ Present your group work in B
front of the whole audience.
 Steam Turbines
Classification and typical efficiency .
Datasheet and performance curve and energy data that could be
extracted from it

90
Steam Turbines

91
 Steam Turbines
There are three basic types of steam turbines:
▪ Condensing turbines, in which all the steam that enters
the turbine expands to the high-vacuum condensing
pressure.
▪ Back-pressure turbines, which operate with an exhausts
pressure equal or greater than, atmospheric pressure to
meet the process steam requirements.
▪ Extraction turbines, in which steam is extracted at one or
more intermediate stages, often at comparatively high
pressures, either to meet process load or to heat boiler
feed water. Extraction can be applied to condensing or
back-pressure turbines.
92
93
 More Classifications
▪ Operating Principles: ▪ Exhaust Direction:
Impulse: axial
• Velocity Compound (Curtis Turbine) Upward
• Pressure Compound Downward
Reaction
▪ Intermediate Steam
▪ Number of Stages: Supply/Extraction
Induced turbine
Single stage (De-laval impulse Extraction turbine (i.e. controlled
turbine) and un-controlled extraction)
Multistage (Rateau for impulse and
Parsons for reaction turbines)

▪ Exhaust Pressure:
Above atmospheric pressure (back
pressure turbines)
Below atmospheric pressure
(condensing turbine)
94
 Video: Steam Turbines
Link: https://www.youtube.com/watch?v=SPg7hOxFItI

95
96
Industries Served (GE’s Oil and Gas
Business)

97
98
Data Sheet (Design Parameters)

99
Steam Turbine Data Sheet (Design Parameters)

100
Data Sheet (Maintenance)

101
Specific Steam Consumption

Specific Steam Consumption most/kWh [kg/kWh] 102

Compressors

103
• Functions of Compressors
• Compression of gases and vapours is an important operation in chemical
and petrochemical plants.
• Compressor is a mechanical device used to increase the pressure of
compressible fluid, either gas or vapour, by reducing the fluid specific
volume during passage of the fluid through compressor.
• As gases are compressible, the compressor reduces the volume of the
gas and transports the fluid through pipes.
• The benefits of operating the gas at higher pressures includes the
ability to transmit larger volumes of gas through a given size of a
pipeline, lower transmission losses due to friction, and the scapability to
transmit gas over long distances without additional boosting stations.

104
• Classification of Compressors

105
Positive Displacement Compressors
• In a positive displacement compressor, a fixed amount of
the working fluid (gas or vapour) is positively contained
during its passage through the machine and undergoes
changes of pressure energy by means of variation in
the volume of container.

106
• Reciprocating Compressors

107
• Reciprocating Compressors

108
• Rotary Screw Compressors

109
• Rotary Screw Compressors

110
• Rotary Vane Compressors

111
• Rotary Vane Compressors

112
 Dynamic Compressors
• Dynamic compressors are used for converting mechanical
energy into fluid energy (pressure or enthalpy rise),
dealing with compressible fluids.
• They are based on a dynamic principle where kinetic
energy is imparted by a rotating impeller to a gas in order to
keep it continuously flowing, while a suitable diffuser
converts this kinetic energy into pressure energy.
• For very low pressure ratios, these machines are called fans
or blowers where most of the mechanical energy input is
converted into kinetic energy.
• For high pressure ratio compressors, the pressure rise may
be achieved in more than one stage; i.e., in a multistage 113
• Centrifugal Compressors

114
115
• Multistage Centrifugal Compressor

116
• Multistage Centrifugal Compressor

117
• Multistage Centrifugal Compressor

118
• Axial Compressors

119
• Turbo-Jet Application

120
• Compressor Performance Characteristics

121
• Compressor Performance Characteristics

122
• Compressor Performance Curves

123
• Compressor Capacity Regulation
Exit Valve Throttling Inlet Valve Throttling Variable Speed Drive

124
Off-Design Conditions
• At the design point, the minimum energy loss takes
place.
• At off-design conditions, the energy loss will be higher.
• So, the shape of characteristic curve deviates from the
straight line relation ship.
• Taking into consideration effect of leakage loss the curve
is shifted to the lift.
• Surge effects will limit the relationship at a certain
minimum value which represents the stability limit of
operation.
• Choking limits flow rate to a certain maximum value 125
126
 Surge
• The general shape of the characteristic curve for pressure
ratio as a function of mass flow rate at constant rotational
speed is a descending line.
• But, incidences increase with decreasing flow rate.
• So, boundary layer separation occurs below a certain flow
rate.
• The flow is then said to be stalled, meaning that the
compressor does not function properly anymore.
• During surge, a noisy and often violent flow process can occur
causing cyclic periods of backflow through the compressor.
• Operation in surge not only drastically reduces the
performance of the compressor but can damage the 127
compressor and its installation.
• In stalled flow, the
tangential force of the
blade drops.
• This causes a
maximum in the
characteristic curve for
pressure ratio as a
function of flow rate.
• This maximum may be
very sharp.

128
Cell Propagation Mechanism

129
 Choking
• By reduction of the backpressure of a subsonic flow
compressor, the flow rate increases and all velocities
increase until sonic speed is attained in some
through-flow section.
• With further reduction of the backpressure, the flow rate
then stays blocked.
• This phenomenon is called choking.
• The choking flow rate depends on the rotational speed,
both for choking within the rotor blade passages as for
choking in the stator vane passages.
130
Choking
Boundary

131
• Inlet Conditions
• It’s very important to note that the performance curves for a
particular compressor are valid ONLY for the inlet condition
specified in the performance diagram for that compressor.

(Pressure Transducer Designation)

132
• Operating Range

133
134
135
• Changing Operating Point

136
• Field Activity Normally Rated Varios Type of
Compressor

137
• Compressor Range Chart

138
• Compressor Datasheets – Centrifugal Type

139
• Compressor
Datasheets – Screw
Type

140
• Summary of Typical Operating Characteristics
of Compressors

141
• Specific Power Consumption

142
 Pumps
• Pumps are fluid machines that convert mechanical
energy into fluid energy and handle incompressible
fluids (liquids).
• Positive displacement pumps are either reciprocating or
rotary types.
• Dynamic pumps include radial-flow (centrifugal) pumps,
axial-flow (propeller) pumps and mixed-flow (screw)
pumps.

143
• Pump Types

144
• Examples of Positive Displacement
Pumps

145
• Examples of Centrifugal Pumps

146
• Pump Applications

147
 Dynamic Pumps
• Most of the centrifugal
pumps are shrouded,
while the screw and
the propeller pumps
are generally not
shrouded as shown in
the Figure.

148
• Energy Transfer in the Impeller

149
• Pump Specific Speed

150
 Volute Casing and Diffuser

• The function of stator (diffuser) in pumps is to convert

the exit kinetic energy into useful pressure energy.
• Most single-stage centrifugal and screw pumps have a
stator of the volute casing type, while multi-stage pumps
have diffuser blades.

151
152
153
• Double Inlet (Suction) Single-Stage
Pumps

154
• Double Suction Pumps

155
• Multistage Pumps

156
• A typical three-stage pump

157
• A Multistage Centrifugal Pump

158
• Suction & Discharge Nozzles

159
• Series & Parallel Pump Connections

New operating point

160
New operating point

161
• Axial Flow Pumps

162
 Cavitation & NPSH
•

163
• Cavitation Factor

164
• Cavitation Damages

165
 Pump Performance
•

166
• Typical Pump Performance Curves

167
• Typical Pump Performance Curves

168
• Typical Pump Performance Curves

169
• Reciprocating Pump Performance

170
• Centrifugal Pump Performance

171
 Pump Capacity Regulation
• The discharge of pumps may be controlled by different
methods depending on application:
❑ Discharge Throttling: the cheapest and most common
method.
❑ Speed Regulation: by changing the speed of pump
driver and is mainly used with centrifugal pumps.
❑ Adjustable Guide Vanes: The vanes angles produce
pre-whirl of flow at inlet to the impeller, hence for the
same speed, the head, capacity and pump efficiency
may be changed.
❑ Rotor-Blade Pitch Adjustment: by changing the
stagger angle of rotor blades while running and is used 172
only with axial and diagonal rotors.
• Discharge Throttling

173
• Speed Regulation

174
• Adjustable Guide Vanes

175
• Rotor-Blade Pitch Adjustment

176
• Pump
Datasheets –
Centrifugal Type

177
• Efficiency of
Centrifugal
Pumps

178
• Performance Comparison of Pump Types

179
180
Activity
 Workshop Activity : 15 minutes
Reflect upon working principles and performance
enhancements
Activity

▪ Each group select a topic of

the 3 covered today (Steam
Turbines, Compressors,
Pumps)
▪ Discuss with your group some A C
proposed techniques to
improve energy efficiency
and performance in the
selected equipment.
▪ List down your suggestions
B
▪ Present your group work in
front of the whole audience.
 Electric Motors
• An electric motor is an electrical machine that
converts electrical energy into mechanical energy. Most
electric motors operate through the interaction between
the motor's magnetic field and electric current in a wire
winding to generate force in the form of torque applied
on the motor's shaft.
• Electric motors can be powered by direct current (DC)
sources, such as from batteries, or rectifiers, or
by alternating current (AC) sources, such as a power
grid, inverters or electrical generators.
183
• Motor Systems’ Energy Use

184
• Motor Lifecycle Costs

185
• Motor Types

186
• Motor types and applications

187
• The Motor System

188
• Typical Torque Speed Curve – Induction
Motor

189
• Motor Losses

190
• Energy Efficient Induction Motors

191
• Energy Efficient Induction Motors

192
• Efficiency Classification Standards in the World
– IEC 60034-30-1

193
• Typical Power Factor vs. Motor Load%

194
 Typical Motor Nameplate Data

• Motor service factor (SF) is an indication of the ability to exceed the

mechanical power output rating on a sustained basis.
195
Electric Motor Datasheets

196
197
 Day 1 Assessment

• 15 MCQ to be solved online in 10 minutes.

• Link: https://forms.gle/dQcKn9AW3mmqF4Xd7

Purpose:
• Measure the ILOs of Day 1
• Pinpoint the strengths and weaknesses

Results and Conclusions

Conclusion of Day 1

Thank You !
Backup Slides

200
Fired Heaters classified by Fluid-Flow design

201
 Fired Heaters classified by preheater
(exchanger) design

Key

1 fired heater
2 air
3 air preheater
4 induced-draught fan
5 flue gas
6 forced-draught fan
7 separate stack (alternative)

Balanced-draught APH system with

direct exchanger 202
 Fired Heaters classified by preheater
(exchanger) design

Key
1 flue gas
2 induced-draught fan
3 fired heater
4 air
5 air preheater
6 forced-draught fan
7 heat medium

Balanced-draught APH
system with indirect
exchangers
203
 Fired Heaters classified by preheater
(exchanger) design

Key
1 fired heater
2 air
3 air preheater
4 forced-draught fan
5 process or utility stream

Forced-draught APH system with

external-heat-source exchanger
204
 Sub-critical vs. Super critical

Drum Type Once-Through

Boilers Boilers
• Pcr = 3206.2 psia (221.2 bar) , Tcr =705.40oF (374.15oC)