International Journal of Research in Engineering and Applied Sciences (IJREAS)

PERFORMANCE ANALYSIS OF SEPARATING AND

THROTTLING CALORIMETER TO DETERMINE
QUALITY OF STEAM ON THERMAX DIESEL
FIRED WATER TUBE BOILER

*R.G.Bodkhe, Y. Y. Nandurkar, S. S. Akant, S. L. Bankar

*r_bodkhe@rediffmail.com
Department of Mechanical Engineering,
Yeshwantrao Chavan College of Engineering, Nagpur (India)

Abstract
In present study the Separating & Throttling Calorimeter set up is developed on Thermax diesel fired water tube Boiler (Three pass Reverse
Flue coil type steam generator) in Thermal Power Laboratory and experimentation is carried out to determine the quality of steam (The
percentage by weight of steam in a mixture of steam and water) passing through the steam main. The limitation of our experimentation is
the wet steam. The calorimeter results are not applicable to dry and superheated steam. The analytical analysis is also carried out using
steam table. The effect of parameters like steam temperature, steam pressure, water outlet temperature of economizer, Fuel pressure,
exhaust gas temperature, water and fuel flow rate on quality of steam is a recorded.
Keywords : Steam, Dryness Fraction, Boiler Efficiency, Separating and Throttling Calorimeter

1. Introduction 2.1 Separating calorimeter

Steam is the major source for power generation in steam engines
or steam turbine. Steam is produced from water by combustion
of fuel in a boiler and employed for heating the building in cold
weather, in the textile industries for sizing and bleaching, sugar
industries, chemical industries etc. The primary requirements of
steam generators or boilers are (i) Water must be contained
safely. (ii)The steam must be safely delivered in desired
condition as regards its pressure, temperature, quality and
required rate. The presence of moisture in steam causes a loss of
heat from the feed water temperature to the steam temperature.
The boiler consists of a membrane coil fitted in a shell which in
turn is enclosed by an air jacket. The coil forms the combustion
chamber (furnace). Burning fuel generates heat which produces
steam. High pressure pumps supply water and fuel to the boiler
and air is supplied by a blower fan. Steam is generated within a
few minutes after firing the unit[1].
2. Construction of test set up
The boiler is bolted on a bottom chassis. Blower, control panel
and other panels are also bolted on the chassis. The structure is
supported from above by a top chassis. On both sides are hinged
doors. Ladder is in the front, adjacent to the control panel. The
utility valves are on the rear side. At the center of the boiler is the
coil made of boiler quality carbon steel tubes. The coil is
enclosed by a pair of concentric shells. This pair of shells forms
an air jacket around the coil[1].
The separating calorimeter is a vessel used initially to separate
some of the moisture from the steam, to ensure superheat
conditions after throttling. The steam is made to change direction
suddenly; the moisture droplets, being heavier than the vapor,
drop out of suspension and are collected at the bottom of the
vessel.
It consists of two concentric chambers, the inner chamber and
the outer chamber, which communicates with each other through
an opening at the top. As the steam discharges through the metal
basket, which has a large number of holes, the water particles due
to their heavier momentum get separated from the steam and
collect in the chamber. The comparatively dry steam in the inner
chamber moves up and then down going through the annular
space between the two chambers and enters the Throttling
Calorimeter [3].
2.2 Throttling calorimeter
The throttling calorimeter is a vessel with a needle valve fitted on
the inlet side. The steam is throttled through the needle valve and
exhausted to the condenser. Suppose M kg of wet steam with a
dryness fraction of x (state A) enters the separating calorimeter.
The vapor part will have a mass of xM kg and the liquid part will
have a mass of (1-x)M kg. In the separating calorimeter part of
the liquid, say M1 kg will be separated from the wet steam.
Hence the dryness fraction of the wet steam will increase to x1
(state B) which will pass through the throttling process valve.
After the throttling process the steam in the throttling

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 International Journal of Research in Engineering and Applied Sciences (IJREAS)
calorimeter will be in superheated state (state C).It consist a
narrow throat (Orifice). Steam Pressure and temperature are
measured by pressure gauge and thermometer. The steam after
throttling process passes through the heat exchanger and
condensate is collected. Steam Generator is also provided to
supply the saturated steam (Max) at 5 kg/cm² pressure[3].
Fig. 1 - Schematic diagram for the separating and
throttling Calorimeter
Fig. 2 - T-S diagram of the separating and throttling calorimeter
From the steady flow energy equation; Q – W = hC - hB
Since throttling takes place over a very small distance, the heat
transfer is negligible, i.e., Q = 0. Then the steady flow energy
equation for the throttling process becomes, hC = hB
Hence, enthalpy after throttling = enthalpy before throttling
hC = hf1 + x1 hfg1
If the pressure of the steam before throttling, the pressure and
temperature of the steam after throttling, are known the value of
x1 can be calculated using steam tables.
Using the average values, obtain the specific enthalpy of steam at
(state C) hence calculate the dryness fraction of incoming steam.
Also calculate the specific enthalpy of incoming steam.
ISSN : 2249-9210
3. Principle of working
“Chemical energy in the fuel is released in the form of heat
during combustion. The products of combustion, the flue gases,
transfer this heat to the coil carrying water by radiation and
convection. Residual heat in the flue gases is absorbed in the
economizer, where feed water is heated to expel dissolved gases.
Air is supplied for the combustion by the blower which imparts
velocity and pressure to the air by its centrifugal action of its
rotating blades. For maximum efficiency correct amount of air
has to be supplied. More air than necessary results in wastage of
heat because of a larger quantity of hot gases escaping from the
chimney”.
“Lesser air results in incomplete combustion and soot formation.
Soot gets deposited on heat transfer surfaces. To use minimum
possible excess air requires vigorous mixing of air and fuel, so
that air is available to each fuel particle. Before the fuel can burn,
it has to evaporate into gaseous form. To achieve this, it is
atomized into a fine mist by passing it through swirler in the
nozzle under pressure. Atomization produces very large surface
area from which fuel can evaporate. Fuel cannot be properly
atomized if it is too viscous. Light Diesel Oil (LDO) has a low
viscosity so that it can be easily atomized, except in very cold
wheather. Furnace oil (FO) or low sulfur heavy stocks (LSHS)
are too viscous at room temperature and have to be heated to
reduce their viscosity”[1].
In the operation of the boiler it is of primary importance to have
water in the proper condition.
l
Make sure that the boiler feed water is soft. If the water is
not soft, regenerate the water softener.
l
To ensure that the water behaves as a proper cooling
medium.
It is essential to see that
l
The water continuously wets the heating surface.
l
The water does not corrode the heating surfaces.
l
The water does not erode the heating surfaces.
l
The water has necessary chemicals within it such that a
protective oxide layer is formed on the surfaces.
4. Experimental procedure
“The trials were conducted on Thermax diesel fired water tube
Boiler (Three pass Reverse Flue coil type steam generator)
coupled with Separating & Throttling Calorimeter set up to
evaluate the performance of system. The performances
parameters were compared with Separating & Throttling
Calorimeter and without Separating & Throttling Calorimeter
for same boiler output conditions. Known quantity of steam is
circulated into the Separating & Throttling Calorimeter. and is
controlled with valve manually . The dry steam comes out at very
high temperature and pressure. It is pulsating in nature. The
experimental Separating & Throttling Calorimeter set up is
shown in figure (2). Several components of this set up have been
designed and fabricated”.
42 © IJREAS, Vol. 02, Issue 01, Jan 2014
 International Journal of Research in Engineering and Applied Sciences (IJREAS)

“A cylinder is designed and fabricated to collect the high 5.4 Boiler efficiency
temperature & pressure steam. Gate valve is used to control the
It is the ratio of heat actually utilized in generation of steam to the
flow of steam. Valves are used to control the inlet and outlet
heat supplied by the fuel in the same period. It is denoted by
steam supply from the boiler and water from main tank. Digital
symbol ç
Temperature Indicator is used to measure the temperature of
steam. A Bourdon's pressure gauge is used to measure the ma ( h – hf)
pressure and it is mounted on control panel. Digital control panel ç=
is provided to acquire data such as blower down, steam C.V.
temperature, steam pressure, water level, fill-off-fire and
control. Temperature gauges are provided at the intake, exhaust Where ma – Mass of water actually evaporated into steam per Kg
manifold and other test points along the boiler route. of fuel at the working pressure

Rota meter is used to measure the steam flow rate in litre per hour h – Enthalpy of steam
(LPH) hf - Enthalpy of feed water temperature in KJ/Kg
The following procedure adopted for the experimentation on C.V. – calorific value of the fuel in KJ/Kg.
separating and throttling calorimeter.
1. Start the boiler and supply steam to the separating and 5.5 Dryness fraction of steam
throttling calorimeter unit.
Dryness Fraction = Mass of dry steam
2. Start the cooling water flow through the condenser. Mass of mixture
3. Open steam valve and allow the steam to flow through the
calorimeters to warm through the steam. x1 M 2
Therefore, X=
4. Open the throttle valve and adjust to give a pressure at M1 + M2
exhaust of about 5cm Hg measured on the manometer.
Where,M1 is the Quantity of Separated water. (in Kg)
5. Drain the separating calorimeter. M2 is the mass of condensate. (in Kg)
6. Start the test and take readings at 2-3 minutes intervals. P1 is the steam pressure before throttling in bar
P2 is the Steam pressure after throttling in bar
7. When a reasonable quantity of condensate is collected
T1 is the steam temperature before throttling in 0C
measure the quantity of separated water and the quantity of
condensate. T2 is the steam temperature after throttling in 0C
Pa is atmospheric pressure in bar measured using aneroid
5. Performance parameters of boiler barometer.
5.1 Evaporative capacity Alternate Method
The evaporative capacity of a boiler may be expressed in terms
of: It is related with wet steam. It is defined as the ratio of the mass of
actual dry steam to the mass of steam containing it. It is usually
(i) Kg of steam/h (ii) Kg of steam/h/m2 of heating surface expressed by the symbol ‘X’
(iii) Kg of steam /Kg of fuel fired. Let X1 = Dryness fraction of steam considering
Separating calorimeter
5.2 Equivalent evaporation X2 = Dryness fraction of steam entering the
Throttling calorimeter
It is defined as the amount of water evaporated from water at
Now, the actual dryness fraction of steam in the steam main,
1000 C to dry and saturated steam at 1000 C. It is denoted by
X = X1 * X2
symbol me
ma (h – hf) M
me = x 1 =s
2257.
Ms +Mw
Where: MS = mass of dry steam (Kg)
5.3 Factor of evaporation Mw = mass of water separated out (Kg)

It is defined as the ratio of heat received by 1 Kg of water under Thus if in 1 Kg of wet steam 0.9 Kg is the dry steam and 0.1 Kg
working conditions to that received by 1 Kg of water evaporated water particles then X = 0.9
from and at 1000 C. It is denoted by No steam can be completely dry and saturated, so long as it is in
contact with the water from which it is being formed [1] .
(h – hf)
Fe =
2257 h f1 +
x 2 h fg1 = Cp (
h g2 + t sat )
t sup -
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 International Journal of Research in Engineering and Applied Sciences (IJREAS)

6. Specifications and Observations

Table 1 - Specifications of Test Set up

MAKE REVOMAX
Type Three Pass Reverse Flue
Coil type Steam Generator
Steam output at 100 0C 200 kg/hr LDO
Heat output 451.44 MJ/Hr
Steam pressure and 10.5 bar , 185 0C
temperature
Efficiency @88%
Fuel Consumption 12 kg/hr, C.V.= 42.7 MJ/kg
Boiler heating surface area 3.5 m²
Economizer heating surface 0.9 m²
area
Fig. 2.-Typical T-S diagram for steam
Electric Supply 415 volt, 50 Hz , 3 phase
Blower motor (3000 rpm) 735 W , 1 H.P.
7. Result & Discussions
Water Pump (100 rpm) 550 W, 0.75 H.P
Total connected load 1.9 KW If the steam whose dryness fraction is to be determined is very
Softener (Maxi. W orking 3.5 Kg/cm2 wet then throttling to atmospheric pressure is not sufficient to
Pressure) ensure superheated steam at exit. In this case it is necessary to
The following observations recorded during experimentations. dry the steam partially, before throttling. This is done by passing
the part of steam from the steam main through separating
Table 2 - Observations from Boiler control panel calorimeter as shown in figure. The steam is made to change
direction suddenly, and the water, being denser than the dry
Sr. Steam Steam Exhaust gas Fuel steam is separated out is measured at the separator, the steam
No. Pressure Temperatur Temperature Pressure remaining, which now has dryness fraction, is passed through
P1 in bars e in 0C 0
C in Kg/cm2 the throttling calorimeter.
With the combined separating and throttling calorimeter it is
1. 1.5 105 150 2.1 necessary to condense the steam after throttling and measure the
2. 2.5 115 165 2.3 amount of condensate (Ms).
3. 3.6 120 180 2.5
4. 4.3 137 195 3.0 It was observed that with increasing the boiler steam pressure
5 5.2 150 258 3.3 there is increase in steam temperature and when the part of the
6. 6.5 160 310 3.5 steam enters into the separating calorimeter steam pressure
7. 8.0 180 336 3.6 before throttling is higher than steam pressure after throttling. It
is also observed that steam pressure decreases after throttling.
Table 3 - Observations from separating and throttling Corresponds to the steam pressure after throttling, from steam
calorimeter Test set up table it was noted that steam temperature measured is greater
P1 in P2 T1 T2 in M1 M2 Pa in Manomet
than the saturation temperature. Therefore the steam becomes
bar in in bar er superheated steam. From the measured values the various
bar 0
C 0
C (kg) (kg) reading parameters like dryness fraction of steam, enthalpy of
in cm of superheated steam, equivalent evaporation and factor of
Hg evaporation and boiler efficiency calculated.

1.5 1.2 101 90 10 7 0.98 5 8. Conclusion

Performance analysis on separating & throttling calorimeter was
2.5 2.0 105 95 10 7 0.98 5 carried out. The following parameters were measured: Steam
Temperature, Steam Pressure, Exhaust Gas Temperature, Fuel
3.6 3.1 112 100 10 7 0.98 5
Pressure, and Water Temperature after Economizer at various
conditions. Dryness fraction of steam was calculated. The
4.3 3.5 125 112 10 7 0.98 5
following conclusions were drawn under various parameters
like boiler steam temperature; boiler steam pressure; steam
5.2 4.5 135 120 10 7 0.97 5
pressure before throttling; Steam pressure after throttling; steam
temperature after throttling; steam flow rate measured. Water
6.5 5.2 148 132 10 7 0.97 5
particles from wet steam can fully separated, thus resulting in
8.0 6.5 169 140 10 7 0.98 5
precise value. The actual Dryness fraction of steam calculated.
Boiler efficiency improved by 10 %.

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 International Journal of Research in Engineering and Applied Sciences (IJREAS)

References Author's Bibliography

[1] Instruction Manual for Thermax Boiler, Thermax Limited, Pune.
Prof. Rajesh G. Bodkhe presently working
[2] S. M. Elonka, A. L. Kohan, Standard Boiler Operators ( New Delhi, India: as a assistant professor in the Department of
McGraw Hill, 2009)
Mechanical Engineering, YCCE, Nagpur.
[3] Rajput R. K. Thermal Engineering, Laxmi Publications (P) Ltd. New His area of interest in the field of Thermal
Delhi (India).
Engineering. He has attended several
[4] Khurmi R. S., Gupta J.K., Thermal Engineering (Mechanical workshops under national mission (Govt. of
Technology), S. Chand & Company Limited New Delhi (India). India) through ICT , conducted by I.I.T.
[5] Khurmi R. S., Gupta J.K., Steam Table with Mollier Diagram, S. Chand & Bombay at YCCE Nagpur. He has 12 years
Company Limited, New Delhi (India). teaching experience.
[6] Indian Boiler regulation act [www.indianboiler.co.in/ibr.htm]
[7] Water and Steam in the Power Cycle, American Society of Mechanical Prof. Yogesh Y. Nandurkar presently
Engineers , New York, NY 10017
working as a assistant professor in the
[8] Bureau of Energy Efficiency[www.beeindia.in/] Department of Mechanical Engineering,
Appendix YCCE, Nagpur. His area of interest in the
field of Thermal Engineering.

Prof. Sunil S. Akant presently working as a

associate professor in the Department of
Mechanical Engineering, YCCE, Nagpur.
His area of interest in the field of Thermal
Engineering. He has attended several
workshops under national mission (Govt. of
India) through ICT , conducted by I.I.T.
Bombay at YCCE Nagpur. He has 25 years
Fig. 3 - Line Diagram of Test set up teaching experience.

Prof. Sanjeev L. Bankar presently working

as a associate professor in the Department of
Mechanical Engineering, YCCE, Nagpur.
His area of interest in the field of Thermal
Engineering. He has attended several
workshops under national mission (Govt. of
India) through ICT , conducted by I.I.T.
Bombay at YCCE Nagpur. He has 25 years
teaching experience.

Fig. 4 - View of Thermax (Revomax) Boiler Test Set up

Fig. 5 - View of Separating & Throttling Calorimeter Set up

ISSN : 2249-9210 45 © IJREAS, Vol. 02, Issue 01, Jan 2014