Thermal Systems Design

Richard J. Martin, PhD, PE, is the President and Principal Engineer of Martin Thermal Engineering, a mechanical and thermal consulting firm that specializes in system failure analysis and engineering safety, and is an Adjunct Lecturer at California Polytechnic State University – San Luis Obispo where he teaches Air Pollution and Programming Methods in Engineering and an Adjunct Lecturer at Santa Clara University where he teaches Thermal Systems Design and Heat Transfer. He has previously taught at the University of Southern California, California Polytechnic State University – Pomona, and California Baptist University.

• Preface to the First Edition (A Most Practical Guidebook) xiAcknowledgments xiPreface to the Second Edition (Fundamentals and Projects) xiiiAcknowledgments xvAbout the Author and the Textbook xviiAbout the Companion Website xix1 Thermodynamics 11.1 Units of Measure 11.2 Mass/Force Unit Conversion 21.3 Standard Temperature and Pressure 31.4 Control Mass, Control Volume 31.5 Laws of Thermodynamics 51.6 Conservation Laws 61.7 Thermodynamic Variable Categories 71.8 Ideal Gas Law 101.9 History of Temperature 111.10 Thermodynamic States 121.11 Internal Energy, Enthalpy, Entropy 131.12 Availability (Exergy) 151.13 Homework Problems 16Cited References 172 Fluid Mechanics 192.1 Viscosity, Shear, Velocity 192.2 Hydrostatics, Buoyancy 202.3 The Continuity Equation 212.4 Mass, Volume, Mole Flows 222.5 Reynolds Number, Velocity Profiles 232.6 The Momentum Equation 272.7 Bernoulli’s Equation 272.8 Stagnation, Static, Dynamic Pressure 282.9 Friction Factor, Hydraulic Diameter 292.10 Moody Chart, Chen Equation 312.11 Modified Bernoulli Equation 332.12 Alternate Moody Charts 332.13 Entry Effects, Minor Losses 352.14 Porous Media Pressure Drop 362.15 Homework Problems 37Cited References 383 Heat Transfer 413.1 Fourier’s Law 413.2 Newton’s Law of Cooling 433.3 The Stefan–Boltzmann Law 433.4 The Energy Equation 443.5 The Entropy Equation 453.6 Electricity Analogy for Heat 453.7 Film, Mean Temperature 473.8 Nusselt, Prandtl Numbers 483.9 Flows Across Tube Banks 493.10 “Gotcha” Variables 523.11 Radiation and Natural Convection 533.12 Radiant Exchange 543.13 Types of Heat Exchangers 583.14 Heat Exchanger Fundamentals 593.15 Overall Heat Transfer Coefficient 593.16 LMTD Method 603.17 Effectiveness-NTU Method 613.18 Porous Media Heat Transfer 633.19 External Convection to Individual Spheres and Cylinders 653.20 Homework Problems 67Cited References 684 Introduction to Combustion 714.1 Fuels for Combustion 714.2 Air for Combustion 724.3 Atomic and Molar Mass 734.4 Balancing Chemical Equations 734.5 Stoichiometry and Equivalence Ratio 744.6 The Atom Equations 764.7 Sensible and Chemical Enthalpies 784.8 Thermochemical Property Tables 824.9 Enthalpy of Combustion 834.10 Enthalpy Datum States 854.11 Adiabatic Combustion Temperature 864.12 Equilibrium and Kinetics 884.13 Pollutant Formation and Control 934.14 Combustion Safety Fundamentals 954.15 Other Topics in Combustion 964.16 Homework Problems 97Cited References 985 Process Flow Diagrams 1015.1 Intelligent CAD 1015.2 Equipment 1025.3 Process Lines 1055.4 Valves and Instruments 1055.5 Nonengineering Items 1055.6 Heat and Material Balance 1065.7 PFD Techniques 1075.8 Homework Problems 111Cited References 1136 Advanced Thermodynamics 1156.1 Equations of State 1156.2 Thermodynamic Property Diagrams 1176.3 Gibbs, Helmholtz, and Maxwell 1186.4 Equations of State 1216.5 Boiling and Condensation 1246.6 Psychrometry 1266.7 Liquid–Vapor Equilibrium for NH3 + H2O Mixtures 1336.8 Efficiency vs Effectiveness 1376.9 Space vs Time 1396.10 Homework Problems 141Cited References 1427 Burners and Heat Recovery 1457.1 Burners 1457.2 Combustion Safeguarding 1477.3 Thermal Oxidizers 1497.4 Destruction Efficiency 1517.5 Recuperators and Regenerators 1527.6 Packed-bed Heat Storage 1567.7 Heat Exchanger Discretization 1577.8 Thermal Destruction of Airborne Pathogens 1597.9 Special Atmosphere Heat Treating 1607.10 Burner and Heat Exchanger Failures 1617.11 Homework Problems 163References 1668 Boilers and Power Cycles 1698.1 Rankine Cycle 1698.2 Boiler Terminology 1718.3 Efficiency Improvement 1748.4 Controls and Safeguards 1778.5 Blowdown and Water Treatment 1798.6 Air Pollutant Reduction 1818.7 Organic Rankine Cycle 1858.8 Boiler Failure Analysis 1868.9 Homework Problems 189Cited References 1919 Combustion Turbines 1939.1 Turbomachinery 1939.2 Brayton Cycle 1949.3 Polytropic Processes 1969.4 Isentropic Efficiency 1979.5 Gas Property Relationships 2009.6 Reheating, Intercooling 2019.7 Recuperation 2029.8 Homework Problems 204Cited References 20610 Refrigeration and Heat Pumps 20710.1 Vapor Refrigeration Cycle 20710.2 Gas Refrigeration Cycle 21010.3 Heat Pump Efficiency 21110.4 Sizing and Energy Usage 21210.5 Refrigerants 21410.6 Compressors 21710.7 Air Handlers 21910.8 Refrigeration Control 22210.9 Coil Defrost 22410.10 Compressorless Refrigeration 22510.11 Thermoelectric Coolers 23410.12 Refrigeration System Failures 23510.13 Homework Problems 238Cited References 24211 Other Thermal Systems 24511.1 Solar Fluid Heating 24511.2 Fluid Heaters 24811.3 Evaporative Cooling 25111.4 Geothermal Heat Sink 25211.5 Thermal Energy Storage 25411.6 Thick-layer Product Dehydration 25711.7 Desalination 25911.8 Steam Sterilization 26111.9 Espresso Machine 26211.10 Hot Air Balloon 26611.11 Homework Problems 269Cited References 27212 Pipe and Fluid Mover Analysis 27512.1 Fluid Mover Categories 27512.2 Conveying Means Categories 27712.3 Leak Prevention 27812.4 Pressure Rise and Drop 27912.5 Electricity Analogy for Flow 28012.6 Piping Network Rules 28212.7 Blower and System Curves 28312.8 Pump and Blower Work 28712.9 Compressibility in Long Pipes 29112.10 Chimney Effect 29212.11 Homework Problems 295Cited References 29713 Thermal Protection 29913.1 Refractory Ceramics 29913.2 Refractory Metals 30113.3 Thermal Insulation 30113.4 Radiative-Convective Insulation Systems 30413.5 Skin Contact Burns 30413.6 Protection Against Thermal Expansion 30513.7 Protection Against Thermal Shock 30813.8 Homework Problems 309Cited References 31014 Piping and Instrumentation Diagrams 31114.1 Design Packages 31114.2 Temperature Sensors 31314.3 Pressure Sensors 31514.4 Flow Sensors 31714.5 Level Sensors 31914.6 Exhaust Gas Analyzers 32114.7 Combustion Safety Instruments 32314.8 Valves and Actuators 32514.9 ISA Tag Glossary 32914.10 P&ID Techniques 33114.11 Homework Problems 332Cited References 33315 Control of Thermal Systems 33515.1 Control Nomenclature 33515.2 Thermostatic Control 33515.3 PID Control 33815.4 Safety Controls and Interlocks 34115.5 Sequencing Control 34215.6 Ladder Logic 34315.7 Homework Problems 345Cited References 34616 Process Safety 34716.1 Safety Terminology 34716.2 Safety Hierarchy 34916.3 Safeguards and Warnings 35016.4 History of Safety Standards 35116.5 Process Hazard Analysis 35216.6 Homework Problems 354Cited References 35517 Process Quality Methods 35717.1 Quality Terminology 35717.2 Advanced Statistical Methods for Quality in Thermal Processes 35817.3 Management of Change for Quality, Stewardship, and Safety 36217.4 Homework Problems 364Cited References 36618 Procurement, Operation, and Maintenance 36718.1 Engineering Design Deliverable 36718.2 Engineering Data Sheets 36718.3 Construction and Commissioning 36818.4 Inspection, Maintenance, and Training 37118.5 Operation and Maintenance Manual 37318.6 Homework Problems 375Cited References 375Appendix A Property Tables 377Appendix B Excel (VBA) Custom Functions 449Index 511