1.

OBJECTIVES

The main objectives of this experiment are;

 To determine the performance characteristics of a steam plant.
 To demonstrate thermodynamic principles as applied to laboratory scale steam plant.
 To demonstrate the conversion of energy from one form to another and the
measurement of mechanical power.

2. INTRODUCTION

The strength of the steam engine for modern purposes is in its ability to convert raw heat into
mechanical work. Unlike the internal combustion engine, the steam engine is not particular
about the source of heat. Since the oxygen for combustion is unmetered, steam engines burn
fuel cleanly and efficiently, with relatively little pollution. One source of inefficiency is that
the condenser causes losses by being somewhat hotter than the outside world. Thus any
closed-cycle engine will always be somewhat less efficient than any open-cycle engine,
because of condenser losses.

In this experiment, the students had been exposed with the mechanism of steam engine by
using steam plant laboratory model unit. The steam plant consists of several component
include a boiler, a steam engine, a condenser and a feed pump. In large power plants, steam
turbine are used but for a small scale laboratory set up, a steam engine is used. The
applications of steam engines can be divided into 2 categories which are as stationary engines
and also as vehicles engines. For stationary engines, its applications include in winding
engines, rolling mill engines, thermal power stations engines and many others while for
vehicles engines, its applications are traction engine, steam aircraft, steam rockets, steamboat,
steamship and many others.

The steam plants of today are a combination of complex engineered systems that work to
produce steam in the most efficient manner that is economically feasible. In large power
plants, steam turbines are used but for a small –scale laboratory set up, a steam engine is
used. In every situation, the steam power plant must first obtained heat. The heat required to
produce the steam is a significant operating cost that affects the ultimate cost of end the
product.

Heat is supplied to the boiler via two immersion heaters (3 kW each). The water in the boiler
must be clean and free from minerals. The water is pumped to the boiler from a reservoir.
The boiler raises saturated steam to a maximum 4 bars.

A steam engine is a heat engine that performs mechanical work using steam as its working
fluid. The steam engine is a totally enclosed, two cylinders, and single acting trunk piston
with nominal output of 120 W at 2000 rev per min. The steam is expended in the steam
engine to produce useful work.

The condenser condenses the exhaust steam from the steam engine from saturated steam into
water. The water is then return to the reservoir and pump back into the boiler and the cycle
continues.

Figure 1: Steam motor and energy conservation test set

3. THEORY

The cycle of operations in a heat engine is based on Rankine Cycle. The Rankine cycle is a
thermodynamic cycle which converts heat into work. The heat is supplied externally to a
closed loop, which usually uses water as the working fluid. Almost all coal and nuclear
power stations use this cycle for power generation. It is named after William John Macquorn
Rankine, a Scottish polymath. It is more closely approximates to the cycle of a real steam
engine if been compared to the Carnot cycle where it predicts a lower ideal thermal efficiency
than the Carnot cycle.

In the Rankine cycle, heat is been added at constant pressure (P1), at which water is
converted in a boiler to the superheated steam condition that causes the steam expands at
constant entropy to a pressure (P2) in a condenser; the water so formed is compressed at
constant entropy to P1 by a feed pump. The cycle consists of four processes as been listed
below:

 1 to 2: Isentropic expansion (Steam turbine)

 2 to 3: Isobaric heat rejection (Condenser)
 3 to 4: Isentropic compression (Pump)
 4 to 1: Isobaric heat supply (Boiler)

Figure 2: Rankine cycle

4. METHODOLOGY

The engine was been run at the constant speed 2000 rev per min-1 at varying engine
load with:
a) The right hand spring balance was been loaded with 2 N stages to 20 N
b) The boiler pressure was varied to achieve constant speed (+ 100 rev. min-1)

The parameter was recorded in the data sheet (The volume of condensate was
collected in a measuring cylinder with 1 minute’s interval for the condensate flow
rate.)

The results were been analyzed.

After used:
a) The electrical and water supplies were disconnected
b) The boiler was allowed to cool down and the boiler drain valve was opened
c) The water from the apparatus was drained
d) The temperature display was switched off.

**Note: Never open the boiler drain valve while there is a pressure or high
temperature inside the boiler.
5. RESULTS

Table 1: Result that obtains for the different spring load.

Spring
Load Engine Condenser Condenser
Boiler Boiler Engine Calorimeter Condensate Electrical Condensate
Inlet Cooling Cooling H2O
Pressure Temp Speed Temp Flow Rate Power, Q1 Temp
Pressure H2O Inlet Outlet
F1 F2 P1 (bar) T1 (°C) N(rev/min) T2 (°C) ms (kg/s) (W) T5 (°C)
P2 (bar) T3 (°C) T4 (°C)
(N) (N)

1.5 1 2.6 129.0 1.8 2072 100.7 29.1 38.1 1.867 x 10-3 5800 36

2.0 1 2.6 132.6 2.0 2102 100.7 29.3 39.4 2.067 x 10-3 5800 38

2.5 1 3.2 138.8 2.0 2085 100.7 29.3 39.6 2.133 x 10-3 5800 38

3.0 1 3.9 144.0 2.0 2044 100.6 29.3 39.4 2.200 x 10-3 5800 38

3.5 1 2.4 131.0 2.2 2035 100.8 29.4 40.6 2.667 x 10-3 5800 38

4.0 1 2.7 133.3 2.4 2015 100.8 29.4 41.6 2.533 x 10-3 5800 40

4.5 1 3.1 137.3 2.5 2059 100.9 29.4 42.3 2.667 x 10-3 5800 40

5.0 1 3.2 139.1 2.5 2016 100.1 29.6 42.3 2.733 x 10-3 5800 42
Quality of steam in Boiler efficiency, η Power output of the Rankine cycle efficiency, Thermal efficiency, ηTh
boiler, X engine,W1 ηR

0.9914 70.99 6.075 1.475 1.047 x 10-3

0.9914 78.58 12.327 2.705 2.125 x 10-3
0.9850 79.33 18.341 3.986 3.162 x 10-3
0.9790 80.46 23.971 5.136 4.132 x 10-3
0.9940 102.13 29.830 5.036 5.142 x 10-3
0.9900 95.69 35.450 6.39 6.110 x 10-3
0.9860 99.73 42.261 7.31 7.290 x 10-3
0.9840 101.57 47.290 8.03 8.150 x 10-3
Table 2: Data calculated using the table 1.

Hf (kJ/kg) Hfg (kJ/kg) Hg (kJ/kg) H1 H3

475.38 2220.87 2677.12 2677.15 150.74
475.38 2220.87 2677.12 2677.15 159.09
517.62 2192.98 2677.12 2677.70 159.09
556.43 2166.66 2676.96 2677.59 159.09
458.42 2231.86 2677.28 2676.89 159.09
483.04 2215.86 2677.28 2676.74 167.45
511.16 2197.29 2677.44 2676.68 167.45
517.62 2192.98 2676.16 2675.51 175.81

Table 3: Data obtained from the saturated /superheated steam tables of water
 Figure 2: The graph steam flow rate vs power output.

6. DISCUSSION

This experiment purposely conducted to make a study on the steam plant operation and
performance in terms of thermodynamic and heat transfer concept. There are 2 different
spring loads that required adjusting in order to observe the significant on the power output of
the engine. For this experiment, F2 is maintaining at 1.0N while the F1 adjusted by the
increment of 0.5N in intervals. The Boiler Pressure and Temperature readings were taken
throughout the experiment for the steam quality and boiler efficiency calculation. There are
others parameters that being recorded such as Engine Inlet Pressure and speed, Calorimeter
Temperature, Condenser Cooling Water Inlet Temperature, Condensate Flow rate and
Temperature as well as the Electrical Power supply to the unit. The experiment carried out
until the engine stop running when the load increases.

For the first run, the F1 load was set at 1.5N and the Boiler operating condition recorded at
160 bars and 129ºC. By calculation, the steam quality produced was observed at 0.9914 with
the boiler efficiency of about 70.99 %. The power delivered by the engine calculated to be
6.075W with the Rankine cycle efficiency observed at 1.475 with the thermal efficiency
indicated at 1.047 x 10-3. By referring to the steam quality produced, there is almost a perfect
water vapor phase existence.

The spring load of F1 was set at 2.0N and the steam quality produced was calculated to be
0.9914 at 132.6 bars and 132.6ºC of boiler condition. The boiler efficiency was above than
perfect condition in operation, which calculated at 78.58%. However, the power generated
from the engine observed at 12.327 W with the Rankine efficiency of 2.705 and the thermal
efficiency of 2.125 x 10-3.

The third run observed the steam quality produced at 0.9850 with the boiler efficiency
calculated at 79.33% and the Rankine efficiency observed at 3.986. The engine power output
measured at 18.341 W with the thermal efficiency recorded at 3.162 x 10 -3. The fourth run
with the F1 load set at 3.0 N measured the boiler efficiency at 80.46 % with the steam quality
produced monitored at 0.9790. The power generated by the engine recorded at 23.971 W with
the thermal efficiency calculated at 4.132 x 10-3and the Rankine efficiency of5.136.

The steam quality recorded at 0.9940 with the boiler efficiency calculated at 102.13% at F1
set to 3.5 N. The power output of the engine measured at 29.830W while the efficiency of
thermal observed at 5.142 x 10-3 and the Rankine was at 5.036. The boiler efficiency
measured at 95.69% and the steam produced was calculated at 0.9900 when the F2 set at 4.0
N. This causes the engine power to produced 35.45 W with the thermal efficiency measured
at 6.110 x 10-3 together with the Rankine cycle of 6.39 efficient. The seventh run was
observed with the F1 set at 4.5 N. The efficiency of the boiler measured at 99.73% with the
Rankine recorded at 7.31 and the thermal was calculated at 7.290 x 10-3. For this run, the
steam quality generated was calculated at 0.9860with the power of the engine recorded at
42.261W.

The last run carried out with the F2 load was set at 5.0 N. The steam produced was calculated
at 0.9840 with the power delivered from the engine measured at 47.290. This experiment
recorded the efficiency of boiler at 101.57%, the Rankine efficiency at 8.03 and the thermal
efficiency at 8.150 x 10-3.
Since the increasing of the F1 and constant value of F2, the boiler efficiency is increasing.
The basic idea to increase the efficiency of the Rankine Cycle is increase the temperature at
which heat is transferred to the working fluid in the boiler or decrease the temperature at
which heat is rejected from the working fluid in the condenser. In this steam plant, there are
three ways to increase efficiency based in simple ideal Rankine Cycle which is lowering the
Condenser Pressure (Lower T low, avg ), lowering the operating pressure of the condenser which
automatically lowers the temperature of the steam and thus the temperature at which heat is
rejected. Last but not least, superheating the Steam to High Temperatures (Increase T high, avg )
and increasing the Boiler Pressure (Increases T high, avg).

From the data and results obtained, crystal clearly shows the power output from the engine is
increasing by the increment of the spring load difference. Higher load also lead to higher
boiler efficiency with a direct relation to the Rankine and thermal efficiency as well.

7. CONCLUSION

Based on the result, there is a proven that the steam plant can produced a high quality of
water vapor mixture, which is around 99.4 %. From the relationship, there is significant
increment on the power input of the engine when the load is increasing. Thus, we can
conclude that the higher the load, the higher the power output from the engine. This direct
relationship also linked to the boiler, Rankine and thermal efficiency which the higher the
load, the better the efficiency.
8. REFERENCES

A. Jack Winnick , Chapter 7, Power production, Chemical Engineering Thermodynamics

(1997), pg.169.

B. Woodruff. E. B.et.al.(2005). Steam Plant Operation. McGraw Hill.

C. Cengel.Y. A. And Turnel R.H. (2005). Fundamentals of Thermal Fluid Sciences.

McGrawHill Higher Education.

D. Potter. M. C. And Scott. E. P. (2004). Thermal Sciences: An Introduction to

Thermodynamics, Fluids Mechanics and Heat Transfer. Thomas Learning.

E. Rousseau.S.L.(2003). Steam Turbine : A Look Into How A Steam Turbine Functions.

Technical Riview
APPENDIX

A. SAMPLE CALCULATION FOR LOAD FI=3.0

Calorimeter temperature (hg)

Data from table A-4;
Temperature hg
101 2676
100.6 x
101 2677.6

x– 2676_____ = ___100.6 – 100___

2677.6 – 2676 100.1 - 100
x = 2676.96

a) Quality, X

x = 2676.96 – 556.43
2166.66
x = 0.979

h1 = 556.43 + 0.979(2166.66)
h1 = 2677.60

b) Boiler efficiency, ηB
Ms = 132 _ml_ x __1 min__ x _1kg__
Min 60sec 1000ml
= 2.2 x 10-3kg/sec

= 2.2 x 10-3kg/sec (2677.59-556.43) kJ/kg x 100

5.8 W

ηB = 80.46%

c) Engine power, W1

W1 = 2пr (0.056m) (F1-F2) N

60

= 2 x 3.1416 x 0.056m x (3.0-1.0) x 2044

60
W1 = 23.97 W

d) Rankine cycle efficiency, ηR

= _______23.97 W________
2.2 x 10-3 (2677.59-556.43)

ηR = 5.136

e) Thermal efficiency, ηTH

= _________23.97____________
5800 + (2.2 x 10-3) (556.43-159.09)

ηTH = 4.132 x 10-3