Lab Name: Demonstration and operation of 5KW steam power plant

Course title: Power Plants (Lab) Total Marks: 20

Practical No. 8 Date of experiment performed:
Course teacher/Lab Instructor: Engr. Syed M Kashif Shah Date of marking:
Student Name:
Registration no.

Evaluation Sheet

Knowledge components Domain Taxonomy Contribution Max. Obtained

level mark marks
s
1. Student is aware
with requirement Set (P2) 3
and use of apparatus
involved in
Experiment. Psychomotor
2. Student has conducted the
experiment by practicing 70%
the hands-on skills as per
Instructions. Guided Response 11
3. Student has achieved required (P3)
accuracy in performance.

4. Student is aware of discipline

& safety rules and followed Receiving (A1) 2
Affective
the rules during experiment.
20%

5. Student has responded well

Respond (A2) 2
and contributed affectively in
Respective lab activity.

6. Student familiar with Comprehension

Cognitive 10% 2
operation of 5KW steam power (C2)
plant

Total 20

Signed by Course teacher/ Lab Instructor

 Experiment No. 8

Demonstration and Operation of 5 kW Steam Power Plant.

Objective
Demonstration and Study the all parts of 5 kW Steam Power Plant and its process.

Introduction
In steam power plants, thermal energy is first converted into mechanical energy and then into
electrical energy. A steam power plant essentially consists of a heat source for generating steam,
a turbine with load, and a cooling mechanism for condensing the steam.
ET 830 has been designed specifically for engineering education in the field of power plant
technology, and driving and driven machines. It offers a wide range of experiments to learn
about the operational processes in a steam power plant.
An oil-fired once-through steam boiler produces wet steam that is turned into superheated steam
by means of a superheated. The boiler’s short heat-up time means rapid steam generation is
possible. Load is applied to the turbine with a generator. The turbine output is determined by
speed and torque. Downstream of the turbine, the steam is condensed and returned to the boiler.
The feed water circuit is fitted with a complete water treatment system, which consists of a
generable ion exchanger and chemical dosing. Sensors record the temperature, pressure, speed,
and flow rate at all relevant points. The measured values can be read on digital displays. At the
same time, the measured values can also be transmitted directly to a PC via USB. The data
acquisition software is included. The control panel includes a clear process schematic of the
plant. The system is monitored and controlled by a programmable logic controller (PLC).
The experimental plant is built in accordance with statutory safety regulations and includes the
mandatory safety facilities. The steam generator is type tested and does not require specific
permissions.
The plant can optionally be operated with the cooling tower ET 830.01 or ET 830.02 to supply
cooling water.
Power plants, thermal energy is first converted into mechanical energy and then into electrical
energy. A steam power plant essentially consists of a heat source for generating steam, a turbine
with load, and a cooling mechanism for condensing the steam.
ET 830 has been designed specifically for engineering education in the field of power plant
technology, and driving and driven machines. It offers a wide range of experiments to learn
about the operational processes in a steam power plant.
An oil-fired once-through steam boiler produces wet steam that is turned into superheated steam
by means of a superheated. The boiler’s short heat-up time means rapid steam generation is
possible. Load is applied to the turbine with a generator. The turbine output is determined by
speed and torque. Downstream of the turbine, the steam is condensed and returned to the boiler.
The feed water circuit is fitted with a complete water treatment system, which consists of a
generable ion exchanger and chemical dosing. Sensors record the temperature, pressure, speed,
and flow rate at all relevant points. The measured values can be read on digital displays. At the
same time, the measured values can also be transmitted directly to a PC via USB. The data
acquisition software is included. The control panel includes a clear process schematic of the
plant. The system is monitored and controlled by a programmable logic controller (PLC).
The experimental plant is built in accordance with statutory safety regulations and includes the
mandatory safety facilities. The steam generator is type tested and does not require specific
permissions.
The plant can optionally be operated with the cooling tower ET 830.01 or ET 830.02 to supply
cooling water.
Boiler
Boiler, also called Steam Generator, apparatus designed to convert a liquid to vapor. In a
conventional steam power plant, a boiler consists of a furnace in which fuel is burned, surfaces to
transmit heat from the combustion products to the water, and a space where steam can form and
collect. A conventional boiler has a furnace that burns a fossil fuel or, in some installations,
waste fuels. A nuclear reactor can also serve as a source of heat for generating steam under
pressure.

Boilers were built as early as the 1st century AD by Hero of Alexandria but were used only as
toys. Not until the 17th century was serious consideration given to the potential of steam power
for practical work. The first boiler with a safety valve was designed by Denis Papen of France in
1679; boilers were made and used in England by the turn of the 18th century. Early boilers were
made of wrought iron; as the advantages of high pressure and temperature were realized,
manufacturers turned to steel. Modern boilers are made of alloy steel to withstand high pressures
and extremely high temperatures.
Most conventional steam boilers are classed as either fire-tube or water tube types. In the fire-
tube type, the water surrounds the steel tubes through which hot gases from the furnace flow.
The steam generated collects above the water level in a cylindrically shaped drum. A safety
valve is set to allow escape of steam at pressures above normal operating pressure; this device is
necessary on all boilers, because continued addition of heat to water in a closed vessel without
means of steam escape results in a rise in pressure and, ultimately, in explosion of the
boiler. Fire-tube boilers have the advantage of being easy to install and operate. They are widely
used in small installations to heat buildings and to provide power for factory processes. Fire-tube
boilers are also used in steam locomotives.
In the water tube boiler, the water is inside tubes with the hot furnace gases circulating outside
the tubes. When the steam turbo generator was developed early in the 20th century, modern
water tube boilers were developed in response to the demand for large quantities of steam at
pressures and temperatures far exceeding those possible with fire-tube boilers. The tubes are
outside the steam drum, which has no heating surface and is much smaller than in the fire-tube
boiler. For this reason, the drum of the water tube boiler is better able to withstand higher
pressures and temperatures. A wide variety of sizes and designs of water tube boilers are used in
ships and factories. The express boiler is designed with small water tubes for quick generation of
steam. The flash boiler may not require a steam drum, because the tubes operate at such high
temperatures that the feed water flashes into steam and superheats before leaving the tubes. The
largest units are found in the central-station power plants of public utilities. Units of substantial
size are used in steel mills, paper mills, oil refineries, chemical plants, and other large
manufacturing plants.

Block Diagrams of plant

Apparatus Pictures
Specification of System
Feed Water Tank
Feed Water Tank Capacity: 500 Lt
Tank Type: Open Tank
Feed Water Temperature: Up to Max 90 C
Feed Pump:
Reciprocating Feed Pump (WX45C1)
FP Operating Temperature: 90 C
Type: Belt and Pulley drive
Pump Operating Pressure: 11 Bar
Suction Pressure = Atmospheric Condition
Steam Generator
Type: Package Type Water Tube Boiler
Design Code: ASME
Burner: Gas Fired with burner Pressure maximum up to 0.9 bar (12 Psi)
Draught: Force Draught fan
Steam Flow Rate: 300 kg/hr
Steam Type: Saturated
Design Pressure: Maximum up to 12 Bar
Working Pressure Maximum Up to 10 Bar
Maximum Steam Temperature: 180 C
Safety Valve Pressure setting: 10.5 Bar
Maximum Stack Temperature: 250—280 C
Steam Turbine:
Type: Impulse Type Steam Turbine with Single Wheel Rotor
Coupling: Rigid Coupling
RPM: 1500 (Rated)
Condenser
Type: Shell & Tube Water Condenser
Flow: Counter Flow
Condenser Pressure: less than 0.85 bar
Condenser Water Temp: 90
Electric Generator
Model: Anglo
Made: Majeed Qayyoum Ltd
Type: Air Cooled Generator
Power = 5 kW (Rated)
Voltage: 220 Volt
Amp= 45.5 Amp
RPM= 1500
Hz= 50

Plant Startup
The startup of power plant is as follows:
1. Complete inspection of plant before startup
2. Check the valves are free to open and close
3. First open the Main Gas line valve
4. ON the main breaker of control panel
5. Reset whole panel to avoid any fault alarm activation during startup command
6. Feed pump should be in healthy position and should be as standby
7. The boiler should be filled up to half gauge glass.

Operation
1. Select the selector switches i.e., Should be ON position
2. ON the blower and Boiler Pilot valve will be open after complete purging of Gases from
the Boiler
 3. When the pilot burner ignited it will turn to ignite the main boiler burner
4. When main burner will ON then observe and inspect boiler completely
5. Open the vent valve from the top of the boiler when the pressure of the boiler greater than
1 bar to raise the temperature
6. Open drain bypass valve of steam turbine to raise the temperature of line
7. When the temperature of steam increases up to 150- 160 C with pressure of 7-8 bars then
opens the main steam valve of steam turbine. The flow of steam from steam turbine
casing should be slowly by considering the boiler pressure.
8. The boiler should be tripped at high pressure and start at low pressure again. The start
and tripping of boiler will be in auto sequence
9. When the casing temperature of steam turbine increase almost 100 C then close the
bypass valve for complete diversion of steam towards steam turbine
10. Check the Electrical generator and its connection point should be clean
11. Increase the load on Electrical generator slowly up to maximum by considering the boiler
temperature and pressure
12. When the temperature and pressure become constant then hold the load on Gen.
13. Continuous monitor the temperature of bearings and Electrical Generator body to avoid
any problem.
Observation
Boiler Outlet Steam Region

Sr. Time Pressure Temperature Sub Cooled Saturated Super-

heated
1
2
3
4
5

Shut down
1. Shut down the plant by removing the load slowly
2. Switch off the burner and flow the steam from steam turbine casing for 2- 3 min then
close all valves
3. If the pressure of boiler raises then open drain valve for a while and then close it again
when pressure starts dropping.
4. Close the main Gas line valve and electrical supply breaker when required.
Observations:

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 LAB REPORT

Prepare the Lab Report as below:

TITLE:

OBJECTIVE:

APPARATUS:

PROCEDURE:
(Note: Use all steps you studied in LAB SESSION of this lab to write procedure and to
complete the experiment)

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DISCUSSION:

Q1.: Write 3 basic steps of Operation of 5kw steam power plant?

Q2.: What is the function of reciprocating feed pump?

Conclusion /Summary

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