Note

This document has been made accurate to the best of our knowledge,
however there is no liability for errors. If there is an error discovered,
please notify the company with complete details. Experimental results
provided (if any) are for the sole purpose of guidance and influence of
different variables on accuracy and precision of experimental results must
be considered.
 Warning
This unit has been designed to be safe for users during operation. As with any other
sophisticated piece of equipment, danger exist if equipment is mishandled or not
maintained properly. Presence of competent personnel during the operation of
equipment is advised.

It is the user’s responsibility to exercise safe practices during the operation of

this unit.

Steam Hot Surface Electric Shock

The ESOLS Engineering Steam Power Plant (Model: SMT-SPP-04) has been designed to
demonstrate students about the operation of a steam power plant. Students can see the
operation of a rankine cycle based power plant. The power plant contains a boiler steam
turbine, condenser, and water feed system (feed tank and pump). An additional ‘Quality of
Steam’ module containing separating and throttling calorimeters, is also provided to instruct
students on the method of determination of quality of steam.

Temperature and pressure on different points in the plant are displayed on the LCD GUI. Steam
is produced by a boiler with an electric heating element. Boiler is designed to produce up-to 8
bars of pressure and has multiple safety features to render the operation completely safe for the
user.
Theory:
Steam Power plant
Steam power plant is used to generate electricity by the use of steam turbine. The major
components of these power plants are boiler, steam turbine, condenser, and water feed
pump. In a steam power plant, a steam turbine – driven by steam – generates mechanical
energy. A generator then converts this mechanical energy into electrical energy. Steam power
plants run vapor power cycles with water as the working fluid.

Thermodynamic Cycles:
Thermodynamic cycles can be divided into two general categories:
 Power cycles, which produce a net power output.
 Refrigeration and heat pump cycles, which consume a net power input.
The thermodynamic power cycles can be categorized as gas cycles and vapor cycles. In gas
cycles, the working fluid remains in the gas phase throughout the entire cycle. In vapor cycles,
the working fluid exits as vapor phase during one part of the cycle and as liquid phase during
another part of the cycle.

The steam power stations run on Rankine cycles using steam as a working fluid. The simple
ideal Rankine cycle is in fact the most basic vapor power cycle.

Rankine Cycle:
In general, the Rankine cycle is an idealized thermodynamic cycle of a constant pressure heat
engine that converts part of heat into mechanical work. In this cycle the heat is supplied
externally to a closed loop, which usually uses water (in a liquid and vapor phase) as the
working fluid.

Many substances could be used as the working fluid in the Rankine cycle (inorganic or even
organic), water is usually the fluid of choice due to its favorable properties, such as its non-toxic
and unreactive chemistry, abundance, and low cost, as well as its thermodynamic properties.
For example, water has the highest specific heat of any common substance – 4.19 kJ/kg K.
Moreover, it has very high heat of vaporization, which makes it an effective coolant and
medium in thermal power plants and other energy industry. In case of the Rankine cycle, the
Ideal Gas Law almost cannot be used (steam do not follow pV=nRT), therefore all-important
parameters of water and steam are tabulated in so called “Steam Tables “

Rankine Cycle – Processes

In an ideal Rankine cycle, the system executing the cycle undergoes a series of four processes:
two isentropic (reversible adiabatic) processes alternated with two isobaric processes:
 Isentropic compression (compression in centrifugal pumps) – The liquid condensate is
compressed adiabatically from state 1 to state 2 by centrifugal pumps (usually by
condensate pumps and then by feed water pumps). The liquid condensate is pumped from
the condenser into the higher-pressure boiler. In this process, the surroundings do work on
the fluid, increasing its enthalpy and compressing it (increasing its pressure). On the other
hand, the entropy remains unchanged. The work required for the compressor is given
by WPumps = H2 – H1.
 Isobaric heat addition (in a heat exchanger – boiler) – In this phase (between state 2 and
state 3) there is a constant-pressure heat transfer to the liquid condensate from an external
source, since the chamber is open to flow in and out.  The feed water (secondary circuit) is
heated from to the boiling point of that fluid and then evaporated in the boiler. The net
heat added is given by Qadd = H3 – H2
 Isentropic expansion (expansion in a steam turbine) – Steam from the boiler expands
adiabatically from state 3 to state 4 in a steam turbine to produce work and then is
discharged to the condenser (partially condensed). The steam does work on the
surroundings (blades of the turbine) and loses an amount of enthalpy equal to the work that
leaves the system. The work done by turbine is given by WT = H4 – H3. Again the entropy
remains unchanged.
 Isobaric heat rejection (in a heat exchanger) – In this phase the cycle completes by a
constant-pressure process in which heat is rejected from the partially condensed steam.
There is heat transfer from the vapor to cooling water flowing in a cooling circuit. The vapor
condenses and the temperature of the cooling water increases. The net heat rejected is
given by Qre = H4 – H1
Specifications:
1. Boiler
a. Material of construction: Stainless Steel
b. Electric heating element: 8 kW
2. Steam turbine
3. Separating calorimeter
4. Throttling calorimeter
5. Condenser
6. Feed Tank
a. Material of construction: Stainless Steel
b. Volume: 80 L
7. Feed Pump
a. Power supply: 12 v DC
b. Flowrate: 25 L/min
 2

4 3

.Figure 1: Process Diagram of Steam Power Plant

Objective:
To demonstrate the relationship between the pressure and temperature of saturated steam in
equilibrium.

Procedures:
 If the boiler is initially filled with water, check the water level through level gauge. Fill in
additional distilled water if necessary. Then, close the inlet valve.
 Set the pressure controller to required value.
 Open the vent valve and turn on the heater. Observe the steam temperature rise as the
water boils.
 Allow steam to come out from the vent valve for about 30 seconds, and then
close the valve. This step is important to remove air from the boiler as the
accuracy of the experimental results will be significantly affected when air is
present.
 Record the steam temperature and pressure when the boiler is heated until the
steam pressure reaches required setpoint.
 Then, turn off the heater and the steam temperature and pressure will begin to
drop. Start to record steam temperature when the boiler is cooled until the
steam pressure reaches atmospheric pressure.
 Allow the boiler cool down to room temperature.
 Record the steam temperatures at different pressure readings when the boiler
is heated and cooled.
 Tv fg
( )
dT
Plot dP SAT versus P and hfg versus P on a same graph.

Pressure, P Temperature, T
(bar) (°C) Measured Calculate
Slope, d
Gauge Absolut Increase Decrease Averag Average dT/dP Slope,
e (0C) (0C) e Tavc (K) Tvg/hfg
Tavc (0C)
Objective:
To measure the pressure and temperature at different points in rankine cycle and demonstrate
the students about the use of steam tables.

Procedures:
 If the boiler is initially filled with water, check the water level through level gauge. Fill in
additional distilled water if necessary. Then, close the inlet valve.
 Close the turbine inlet valve and open the steam vent valve.
 Turn on the heater. When steam start coming off the steam outlet, close the vent valve
as well after 30 seconds.
 Generate steam up-to 2 bar(g) pressure. Open the turbine inlet valve and direct the
steam toward condenser via throttling calorimeter.
 Note the temperature and pressure values along different points in the cycle. Determine
other relevant properties from steam table.

Observations:
Gauge Specific
Temperature Enthalpy
Location o Pressure Volume
C kJ/Kg
Bar m3/Kg
Boiler
Turbine Inlet
Turbine
Outlet
Objective:
To demonstrate power generation using a steam Rankine cycle power plant.

Procedures:
 If the boiler is initially filled with water, check the water level through level gauge. Fill in
additional distilled water if necessary. Then, close the inlet valve.
 Adjust the steam pressure setpoint at required value. Close the turbine inlet valve and
open the steam vent valve.
 Turn on the heater. When steam start coming off the steam outlet, close the vent valve
as well after 30 seconds.
 Close all the valves leading to separating and throttling calorimeters and open the steam
exhaust valve (the one located after turbine). Fill the oil vessel with oil valve and slightly
manipulate the valve to ensure a low but consist of flow of oil through the turbine.
 When the steam pressure reaches required value, open the turbine inlet valve. Once the
turbine stabilizes, push the load toggle switches down to drive the electric load using
generated electricity. Record the parameters once reasonable stability has been
achieved.
 Decrease the pressure entering the turbine by manipulating the turbine inlet valve.
Once reasonable stability has been achieved, again record the parameters.

Observations:

Electrical Power
P1 P2 P3 V I RPM
Sr. output
bar bar bar volts amps (Optional)
W
 Objective:
To determine the boiler efficiency.
Procedures:
 If the boiler is initially filled with water, check the water level through level gauge. Fill in
additional distilled water, if necessary, by turning the feed pump on. Then, close the
inlet valve.
 Set the pressure setpoint at required value. Close the turbine inlet valve and open the
steam vent valve.
 Turn on the heater. When steam start coming off the steam outlet, close the vent valve
as well after 30 seconds.
 When steam pressure reaches the requisite value, open the turbine inlet valve and
direct the exhaust steam toward condenser. Do not let the P2 exceed 0.5 bar. Collect
the condensate and measure the collected volume and the time taken for collection.
 Record the values of feed water temperature and steam temperatures.
 Calculate the boiler efficiency from the enthalpy values of feed water, steam,
condensate collected as well as the power input of the boiler heater.
 Repeat the procedure at increased values of steam pressures.

m(hs−hw)
դboiler = Qin
Observations:
Steam
Steam Feed Water Condensate Time of Volumetric
Temperature Heater Power
Sr. Pressure Temperature Collected Collection Flowrate
O (prior to (kJ/min)
(Bar g) C ml min mL/min
turbine)

Boiler
Mass Steam
Water Boiler
flowrate Enthalpy
Enthalpy Efficiency
Kg/min kJ/Kg
kJ/Kg

Objective:
To determine the dryness fraction of steam.

Procedures:
 If the boiler is initially filled with water, check the water level through level gauge. Fill in
additional distilled water, if necessary, by turning the feed pump on. Then, close the
water inlet valve.
 Set the steam pressure setpoint at required value. Close the turbine inlet valve and
open the steam vent valve.
 Turn on the heater. When steam start coming off the steam outlet, close the vent valve
as well after 30 seconds.
 When steam pressure reaches the requisite value, open the turbine inlet valve and
direct the exhaust steam toward condenser via each calorimeter consecutively.
Maintain the P2 below 0.5 bar. Collect the condensate and measure the collected
volume and the time taken for collection.
 Also collect the condensate from separating and throttling calorimeters intermittently.
Record the total condensate collected over the course of experiment from each
calorimeter.
 Record the values of all temperatures/pressures across the steam power plant.
Calculate the dryness fraction.
XS = mass of dry vapor / (mass of dry vapor + moisture)
XT = (Ht.cal. - Hf)/Hfg

Observations:
 Condensate Condensate
Collected Collected
Sr. T1 P1 T2 P2 T3 P3 T4 P4 from from Time
Separating Throttling (Min)
Calorimeter Calorimeter

Condensat
Dryness Dryness
e Collected
Ht.cal. Hf Hfg Fraction Fraction
from
T.C S.C
Condenser
Installation requirements:
 Feed water supply for boiler, deionized water with hardness level of less than 5
ppm.
 Drainage for condensate.
 Water source for cooling water circuit, preferably with hardness level less than 15
ppm.
 Well ventilated area.
 Vent for steam exhaust
 Power supply required: 380V, 15 Kw with 32A breaker.

Maintenance and Troubleshooting:

 Once every 15 days, thoroughly inspect the main power cable and industrial
connect for any sign of damage. Call competent electrician if any damage is
found.
 If values from temperature sensor do not appear on LCD, press re-set button.
 Oil tank must be filled at all times.
 In case of issues with control panel, refer to following table:

Issue Probable cause Solution

Any electrical load Since the LCD is resistive in

(pump/heater) is not working
and LED indicator is off but is
shown being ON on the LCD
Any electrical load
(pump/heater) is not working
but is being shown ON on LED
indicator and LCD
Any electrical load
(pump/heater) is not working
LCD touch pointer not pressed
appropriately
Electric load is out of order
LCD is defective
nature, it requires a gently and
limited pressure to operate.
Press the required icon again.
Call the ESOLS technician for
further assistance.
Call the ESOLS technician for
further assistance.
and is not being turned ON on
LCD and LED indicator.
Completely irresponsive GUI
Sensor is showing unrealistic
values
Sensor is showing ‘nan’
Unit is not being turned on.
Industrial power supply socket
LCD is defective
Call the ESOLS technician for
further assistance.
Programming Bug
Sensor is damaged
Call the ESOLS technician for
further assistance.
Sensor wire is damaged
Call the ESOLS technician for
Sensor wire is de-attached
further assistance.
Check the breaker at the main
power node.
Main power supply issue
Try removing the socket and
plugging it in again. Make sure
is not properly connected the power is turned off while
mounting the industrial socket
connection.
Safety Precautions
 The experiment instructions, in particular the safety instructions, must be read
thoroughly prior to starting the unit. Before commencing an experiment, all the
participants must have been guided about the safety precautions and proper
handling of the unit. All the participants must use personal protective equipment
for safety.

 It is strongly recommended that ONLY distilled or deionized water be used in this

unit. The impurities existing in tap water may cause scaling inside the column.

 Make sure there is no moisture before operating the electrical equipment and the
control panel else there is a risk of electric shock.

 Make a regular check on the steam pressure through the pressure gauge so that it
may not exceed the safe limit.

 Avoid excessively touching the unit. Do not climb the unit. In case of emergency,
press the red emergency button to shut down the unit.