EXPERIMENT 1

(PERFORMANCE OF A STEAM PLANT)

CPD 30302: Pilot Plant Operation 2 Performance of a steam 1plant

 OBJECTIVE:
 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.

KEYWORDS
Steam plant, steam engine, boiler, condenser, Rankine cycle

OVERVIEW:

A steam plant demonstrates the principles of thermodynamics. The first law of

thermodynamics suggests that in a closed system, the energy is conserved, even when it is
transferred from one form to another. The second law suggests that in any transfer of energy
some energy will be lost to other processes, friction or conduction.

1. INTRODUCTION

The steam plant helps the students understand some principles of thermodynamics using a
laboratory scale steam plant. The steam plant consists of several components: a boiler, a
steam engine, a condenser and a feed pump. In large power plants, steam turbines are used
but for a small- scale laboratory set up, a steam engine is used.

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 of 4 bars.

The steam engine is a totally enclosed, two cylinders, single acting trunk piston with nominal
output of 120 W at 2000 rev per min. The steam is expanded 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 returned to the reservoir and pump back into the boiler and the
cycle continues.

CPD 30302: Pilot Plant Operation 2 Performance of a steam 2plant

 Figure 1: Steam Motor and Energy conversion Test Set

THEORY

 For the energy balance, consider the complete system of boiler, steam engine,
condenser surrounded by the control surface shown by the dotted line. The steady
flow energy balance is given by
Q-W = ∆ h +∆ ke +∆ Pe

The thermal efficiency of the plant is given by

th = W1
Q1+ms (hw-h3)
W1=Engine power (work)
Q1=Electrical power (heat)
ms =Condensate flow rate
hw =specific enthalpy of water in boiler@ calorimeter temperature
h3 =specific enthalpy of the condensate@ condensate temperature

CPD 30302: Pilot Plant Operation 2 Performance of a steam 3plant

  Boiler efficiency is given by the following formula

b = ms (h1-hw)
Q1
h1 =specific enthalpy of steam leaving generator@ calorimeter temperature
h1 = hf +x (hfg)

 Rankine cycle efficiency

R = W1
ms (hw-h1)

 Steam quality
x= hg[enthalpy after throttling calorimeter] – hf[@boiler pressure]
hfg[@ boiler pressure]
 Power W = 2R (F1-F2)N/60
R= Brake radius (0.056 m)
F = spring load (N)
N= engine speed ( rev. min-1)

2. Operation

2.1 Set Up and Checks:

CPD 30302: Pilot Plant Operation 2 Performance of a steam 4plant

 1. Connect the cooling water supply to the inlet pipe of the condenser and connect
the outlet pipe to a suitable drain. Connect the outlet from the condensate
collector to a suitable drain or container.

2. Connect the unit to the electrical supply.

3. Check that the filter on the end of the boiler pump suction pipe is in place and
clean. Place the end of the pipe into the reservoir tank supplied. Fill the tank with
clean soft water to at least half way. Make sure the reservoir is kept at least half
full to ensure no air is drawn in to the pump.

4. Open the upper and lower valves (anti clock wise) on the boiler sight gauge, and
the steam outlet valve on the boiler.

5. Switch on the temperature display, making sure that the displays work, they will
self test with the words: 'TQ' and TE5'.

6. Make sure that the red emergency stop button is pulled out. Switch on the mains
supply and then the boiler feed pump.

7. Open the pump bleed valve, and check that the pump is operating. When there is
a steady flow of water, with no air bubbles, close the bleed valve and begin to fill
the boiler to the upper mark on the sight gauge. The boiler should fill in 8 to 10
minutes. When the boiler is full, close the pump and close the boiler steam valve.

8. Slacken the band brake to ensure that the engine is not loaded. Zero the spring
balances.

9. Switch on both heaters, the indicator lamps will light up to show the heaters are
working. The boiler pressure will rise as indicated on the boiler pressure gauge.
Make sure that the calorimeter valve is fully closed (clockwise).

2.2 Start Up

1. When the boiler pressure has reached approximately 200 kN/m 2 (not more than
340 kN/m2) , open the boiler steam valve until the engine inlet pressure
reaches over 100 kN/m2.

Note : The pressure in the boiler may be higher than 60 kN/m2 before

steam is produced. Check the boiler temperature, if it is higher than 100 °C,
then it is likely that steam is available.

2. In one swift movement, pull upwards on the starting knob and let go. The engine
should start to turn.

CPD 30302: Pilot Plant Operation 2 Performance of a steam 5plant

 If the engine does not turn:

a) Try the starting knob again

b) Check the inlet pressure is correct

c) Check that the band brake is not too tight

d) Check that the steam engine is not seized - watch the pulley at the
front of the engine and see if it turns as you pull the starting knob
upwards.

3. Turn on the condenser cooling water and adjust to a flow rate of about 100
litres/ hour. As the steam pressure rises, the engine speed will increase, use the
steam valve to keep engine ticking over at a pressure of between 40kN/m 2 and
50 kN/m2.

4. To keep the boiler pressure up to a sufficient level, switch the heaters on when
necessary. The boiler safety valve will begin to operate at approximately 340
kN/m2 (3.4 bar) but will not be fully open until 400kN/m 2. The safety valve may
vent a little steam constantly at a higher boiler pressure.

5. Before taking a set of readings, run the apparatus for at least 10 minutes for
conditions to stabilize. Regularly check the level of the water in the boiler. Switch
on the feed pump when necessary to make sure that the level lies between the
permitted limits.

Note:

Take results when the feed pump is not in operation, the apparatus will run
at full power for about 25 minutes while the water level falls from maximum
to minimum. When the pump is operating steam pressure and power output
falls.

3. EXPERIMENTS

3.1 Procedure

 Run the engine at a constant speed 2000 rev per min-1 at varying engine load
To do this:
a. Load the right hand spring balance in 2 N stages to 20 N.
b. Vary the boiler pressure valve to achieve a constant speed (
 100 rev.min-1)

CPD 30302: Pilot Plant Operation 2 Performance of a steam 6plant

  Record the parameters in the data sheet
(Measure the condensate flow rate by measuring the volume collected in a measuring
cylinder for a period of 1 minute)
 Analyze the results
 After use:
a. Disconnect the electrical and water supplies
b. Allow the boiler to cool down and open the boiler drain valve.
c. Drain any water from the apparatus
d. Switch off the temperature display

Note: Never open the boiler drain valve while there is a pressure or high
temperature in the boiler.

4. TUTORIALS

Calculate the following for every particular load.

1. Quality of steam at boiler;x

2. Boiler efficiency
3. Power output of the engine, W1
4. Rankine cycle efficiency
5. Thermal efficiency
6. Plot the steam flow rate vs power output , W( Willan’s Line)

*Please summarize all the calculation for every particular load in one table
*Use the steam table to determine the enthalpy values

CPD 30302: Pilot Plant Operation 2 Performance of a steam 7plant

Experiment 1 Data Sheet :

Boiler Engine Inlet Calorimeter

Spring Load Pressure Boiler Temp Pressure Engine speed Temp Condenser Condenser Condensate Electrical Condensate
cooling H2O cooling H2O
F1 (N) F2 (N) P1 (bar) T1(C) P2 (bar) N(rev/min) T2(C) Inlet Outlet Flow rate Power,Q1 Temperature
T3(C) T4(C) ms(ml/min) (W) T5(C)
                       
                       
                       
                       
                       
                       
                       
                       
                       
                       
                       
                       
                       
                       
* Condenser Cooling Water flowrate ,mw = 0.0284 kg/s

CPD 30302: Pilot Plant Operation 2 Performance of a steam plant8