Department of Mechanical Engineering

Laboratory Manual
POWER PLANTS LAB

List of Experiments:

EXPERIMENT NO. 1
Visit to Mini Steam Turbine Power Plant (Model PC-TMS-400A)
[Demonstration]

EXPERIMENT NO. 2
To determine the dryness fraction (x) of steam with the help of throttling calorimeter
[Demonstration + Analysis]

EXPERIMENT NO. 3
To determine the thermal efficiency (ηth) of a steam boiler and measure its evaporating rate
[Demonstration + Analysis]

EXPERIMENT NO. 4
To determine the thermal efficiency of a super heater and evaluate its performance
[Demonstration + Analysis]

EXPERIMENT NO. 5
To analyze different types of valves used in Power Plants
[Analysis]

EXPERIMENT NO. 6
To determine the thermal efficiency of a steam turbine and evaluate its performance
[Demonstration + Analysis]

EXPERIMENT NO. 7
To determine the condenser heat exchange rate and evaluate its performance
[Demonstration + Analysis]

EXPERIMENT NO. 8
To determine the overall efficiency of Steam Turbine Experimental Apparatus
[Demonstration + Analysis]
Experiment No - 1 Power Plants

Name: __________________________ Regd. No.___________________ Date: ___________

Objective:

Visit to Mini Steam Turbine Power Plant (Model PC-TMS-400A)

 Figure 1: Photograph & Block Diagram of Mini Steam Turbine Power Plant

The basis of operation of the Mini Steam Turbine Power Plant is through Rankine Cycle. There
are multiple components attached to the whole system as shown in Figure 1. Some important
ones and their details are mentioned below:

 Boiler:
It is a vessel in which fuels are burnt to convert water or any other type of liquid into
superheated steam or vapors, respectively. Primarily it can be divided into two types which is
the fire tube and water tube boilers. This classification is utterly based on the medium present
inside the tubes of boiler. It utilizes both latent and sensible heat content. One can say that
without a boiler, a thermal power plant cannot exist.

 Calorimeter:
This instrument functions to determine the amount of heat involved in a process. In the
power plant mentioned above, a throttling calorimeter is used. This type of calorimeter
consists of an orifice.

 Superheater:
The primary purpose of this device is to generate dry steam from wet steam. It provides
further heat to the steam to make it superheated. It utilizes only the sensible heat content for
increase in temperature.
 Condenser:
A device that converts matter from gaseous state to liquid state. It functions with the
extraction of latent heat from the fluid.

 Generator Turbine Mechanism:

This mechanism will convert thermal energy to mechanical energy with the help of
mechanical drives that consist of a generator and turbine. Further additions to the mechanism
will result in storage and transfer of this energy in a suitable form. A pump is placed at the
end of condenser to draw the steam that was used to drive the mechanical drive back to the
boiler.
Experiment No - 2 Power Plants

Name: __________________________ Regd. No.___________________ Date: ___________

Objective:
To determine the Dryness Fraction of steam (x) with the help of Throttling
calorimeter.

Apparatus:
Steam generating device
Throttling calorimeter.

Specifications:

Pressure gauge 10 kg/cm2, 2 kg/cm2

Throttle type Needle Valve type

Procedure:

The dryness fraction of the steam tells us about the amount of water vapors in the
steam. It can be measured with the help of a throttling calorimeter which uses isenthalpic
expansion in a throttling mechanism to expand the steam after an orifice or a small opening. The
sudden drop in pressure causes the temperature and pressure to be in the superheated region and
enthalpies are matched to get the fraction.
Open needle valve to induce steam to the throttling calorimeter. Then reduce the
pressure after expansion by means of needle valve and valve down to designated pressure.
‘Designated pressure’ means the value where the steam becomes superheated steam in
combination with the temperature after the throttle. After the temperature becomes steady, note
the pressure before and after the throttle on the respective pressure gauge and note the
temperature of outlet superheated steam.
Specimen Calculation:

Dryness fraction = ms/(ms + mw)

For throttling h 1 = h2

h1 = hf1 + x hfg1

h2 = h (at p2, T2 ) from superheated steam table

x = (h2-hf1)/hfg1

= (2682.85– 730.213) / 2025.71

= 0.964

Observations:

Prerecorded
p1 p2 T2 h1 = h2 X
No. of
(MPa) (MPa (ºC) (kJ/kg)
Obs.
)
0.28 0.125 111. 2696.87 0.9885
1
7
0.275 0.125 111. 2695.62 0.9884
2
1
0.255 0.125 109. 2693.12 0.9889
3
9
4 0.62 0.125 106 2684.96 0.6551
Experimental
p1 p2 T2 h1 = h2 X
No. of
(MPa) (MPa (ºC) (kJ/kg)
Obs.
)
0.27 0.060 106. 2694.81 0.9884
1
9
0.24 0.100 110. 2697.95 0.9924
2
8
0.2 0.130 115. 2703.14 0.9986
3
0
0.22 0.170 116. 2701.49 0.9958
4
4
0.28 0.125 109. 2691.45 0.9861
5
1
Results:
Graph for Prerecorded Values:

Dryness fraction vs Inlet pressure

0.995
0.99
0.985
Dryness fraction

0.98
0.975
0.97
0.965
0.96
0.955
0.95
0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65
Inlet pressure(MPa)

Graph for Experimental values:

Dry Frction vs Inlet pressure

1

0.995
Dry Fraction

0.99

0.985

0.98

0.975
0.19 0.2 0.21 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29
Inlet pressure(MPa)

Comments:

Give remarks on the following graph(s) for pre-recorded and experimental results:
1. Dryness Fraction (X) vs. Calorimeter Inlet Pressure (p1)
Experiment No – 3 Power Plants

Name: __________________________ Regd. No.___________________ Date: ___________

Objective:
To determine the thermal efficiency (ηth) of a steam boiler

Apparatus:
Boiler (Steam generating device)

Specification:

Maximum Pressure 10 kg/cm2

Equivalent evaporative quantity 150 kg/h
Heat transmission area 3.06 m2
Rated heat output 80,850 kcal/h
Potential water quantity 54 L
Fuel consumption 10.8 L/h (kerosene oil)
Fuel tank 90 L
Pressure gauge 15 kg/cm2

Procedure:

For starting the boiler open water supply valve. Turn the main power On. Open
air purging valve. Open drain valve. After total blow-off, close drain valve and air purging valve.
Open fuel valve and press feed water switch. Press combustion switch.
Steam pressure goes up and when it gets set value, combustion stops
automatically. Open main steam valve gradually. Note feed water inlet temperature from panel
and note pressure of generated steam from the outlet pressure gauge. Note the volume of feed
water fed to the boiler and fuel consumed in specific time interval, from integral flow meters on
control panel, to determine their volume flow rates.
 The enthalpy at Feed Water Inlet comes from the Boiler Feed Water Inlet
Temperature and the Enthalpy at Feed Water Outlet comes from the Boiler Outlet Pressure.

Specimen Calculation:

Thermal efficiency of the boiler is given by

ηth = ṁs(h1-h6)/ṁf x C.V

where
ṁs = mass flow rate of steam generated = ρw Vw / t

ṁf = mass flow rate of fuel consumed = ρf Vf / t

C.V. = 42700 (kJ/kg)

ρf = 820 kg/m3

ηth = 0.0134(2682.85 – 89.8)/0.0011 x 42700

ηth = 74.1%

Observations:

p1 Tw1 X V̇w V̇f

No of Obs. (MPa) (ºC) (Dryness (L/s) (L/s)
fraction)
1
2
3
4

ṁs ṁf h1 h6 ηt
(kg/s) (kg/s) (kJ/kg) (kJ/kg) (%)
Thermal Efficiency of Boiler (ηt) vs. Mass Flow Rate of Steam (ṁs)

Efficiency of boiler vs Mass flow rate of

steam(prerecorded)
90
80
70
Efficiency of boiler(%)

60
50
40
30
20
10
0
0.008 0.01 0.012 0.014 0.016 0.018 0.02 0.022 0.024 0.026 0.028
Mass flow rate of steam(kg/s)

Efficiency of boiler vs Mass flow rate of

steam(Experimental)

100
90
Efficiency of boiler(%)

80
70
60
50
40
30
20
10
0
0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04 0.045 0.05 0.055
Mass flow rate of steam(kg/s)

Thermal Efficiency of Boiler (ηt) vs. Mass Flow Rate of Fuel (ṁf)
 Efficiency of boiler vs Mass flow rate of
fuel(prerecorded)

90
Efficiency of boiler(%) 80
70
60
50
40
30
20
10
0
0.001 0.0015 0.002 0.0025 0.003 0.0035
Mass flow rate of fuel(kg/s)

Efficiency of boiler vs Mass flow rate of

fuel(Experimental)
100
90
80
(Efficiency of boiler(%)

70
60
50
40
30
20
10
0
0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.01
Mass flow rate of fuel(kg/s)

Comments:

Give remarks on the following graph(s) for pre-recorded and experimental results:
1. Thermal Efficiency of Boiler (ηt) vs. Water Inlet Temperature of Boiler (Tw1)
2. Thermal Efficiency of Boiler (ηt) vs. Mass Flow Rate of Steam (ṁs)
3. Thermal Efficiency of Boiler (ηt) vs. Mass Flow Rate of Fuel (ṁf)
Experiment No - 4 Power Plants

Name: __________________________ Regd. No.___________________ Date: ___________

Objective:
To determine the efficiency of superheater and evaluate its performance

Apparatus:
Steam Super Heater

Specifications:

Inlet Pressure & Temperature 5 kg/cm2, Saturated Steam 158 ºC

Outlet Temperature 250 ºC
Fuel Kerosene Oil
Pressure gauge 15 kg/cm2

Procedure:

A superheater is used to add a degree of superheat to the steam. The greater the
superheat, less is the effect of vapors on the turbine rotors due to rusting and wearing.
Before starting it, close respective valves of super heater and wait for steam
generation.
Induce steam which goes up to designated pressure by opening valve of super
heater inlet. Open drain valve of super heater. After drained thoroughly and steam comes out,
close drain valve. Turn the power switch ON. The burner starts functioning and steam is super-
heated. Note the readings of pressure and temperature before and after the superheater. Note the
reading of the volume of the fuel consumed in superheater by the integral flow meter on the
panel.
Specimen Calculation:
ηth = ṁs (h3-h2) / (ṁf x CV)

= 0.01350 (2818.7 – 2758) / 0.00012 x 42700

= 16.0 %

Observations:

p1 p2 T2 ṁs T3 ṁf x h2 h3 ηth
No. of
(MPa (MPa) (ºC) (kg/s) (ºC) (kg/s) (kJ/kg) (kJ/kg) (%)
Obs.
)
1
2
3
4

Results:
Efficiency of supar heater vs mass flow rate of steam

Efficiency of supar heater vs mass flow rate of

steam (prerecorded)
Efficiency of supar heater ηth(%)

18
16
14
12
10
8
6
4
2
0
0.008 0.01 0.012 0.014 0.016 0.018 0.02 0.022 0.024 0.026 0.028
mass flow rate of steam
(kg/s)
 Efficiency of supar heater vs mass flow rate of
steam (Experimental)

Efficiency of supar heater ηth(%)

14
12
10
8
6
4
2
0
0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
mass flow rate of steam
(kg/s)

Efficiency of Supar heater vs Mass flow rate of fuel:

Efficiency of Supar heater vs Mass flow rate of

fuel(prerecorded)
Efficiency of supar heater ηth(%)

14
12
10
8
6
4
2
0
0.00046 0.00048 0.0005 0.00052 0.00054 0.00056 0.00058 0.0006 0.00062 0.00064
mass flow rate of fuel
(kg/s)
 Efficiency of Supar heater vs Mass flow rate of
fuel(Experimental)

Efficiency of supar heater ηth(%)

18
16
14
12
10
8
6
4
2
0
0.0002 0.00025 0.0003 0.00035 0.0004 0.00045 0.0005 0.00055
mass flow rate of fuel
(kg/s)

Comments:

Give remarks on the following graph(s) for pre-recorded and experimental results:
1. Efficiency of Superheater (ηth) vs. Mass Flow Rate of Steam (ṁs)
2. Efficiency of Superheater (ηth) vs. Mass Flow Rate of Superheater Fuel (ṁf)

Experiment No - 5 Power Plants

Name: __________________________ Regd. No.___________________ Date: ___________

Objective:

To analyze different types of valves used in Power Plants

Comments:

In terms of temperature and pressure characteristics analyze

1. Gate Valve
2. Globe Valve
3. Rotary Valve
Experiment No – 6 Power Plants

Name: __________________________ Regd. No.___________________ Date: ___________

Objective:
To determine the thermal efficiency of a steam turbine and evaluate its
performance

Apparatus:
Steam turbine

Specification:

Out Put Maximum 0.6 kW

Rotational Speed 3000 rpm
Governor Electromagnetic rotational speed
detector Digital PID Controller

Inlet/outlet Pressure gauge 10 kg/cm2, 5 kg/cm2

Procedure:

Turbine is one of the main components of the whole power plant and is the
primary part which extracts energy and allows it to be converted to electricity. The input being
the superheated steam from the superheater and output being the rotation of the rotor on the
turbine which rotates in a generator to produce electricity. Output is not measured directly from
the torque of the rotor as it requires a dynamometer which is not present in our setup. Instead, it
is measured using electrical output from the generator. The important thing here is that the
generator itself has an efficiency limit and needs to be considered.
Start boiler and set steam pressure to the turbine by means of reducing valves.
The designed steam condition of turbine is approximately 5 kg/cm2 (read value on the pressure
gauge) and 200 ºC of superheated steam. Turbine output can be obtained by varying the
generators load resistance. But, at that time, do not set steam pressure higher than 8 kg/cm 2 and
steam flow must not be more than 120 kg/hr. Note the readings of the turbine inlet pressure and
temperature, turbine outlet pressure and temperature, voltage and current of the generator.

Specimen Calculation:

ηt = V I/ ηg/ ṁs(hin - hout)

= 0.107 / 0.517 / 0.1216(2739.4 – 2711)

= 59.6%

Observations:

No of pin Tin hin Pout Tout hout ṁs VI ηg ηt

Obs. (MPa) (ºC) (kJ/kg) (bar) (ºC) (kJ/kg) (kg/h) (kW) (%) (%)
1
2
3
4

Comments:

Give remarks on the following graph(s) for pre-recorded and experimental results:
1. Efficiency of Turbine (ηt) vs. Turbine Inlet Pressure (pin)
Experiment No – 7 Power Plants

Name: __________________________ Regd. No.___________________ Date: ___________

Objective:
To determine the Condenser heat exchange rate and evaluate its performance

Apparatus:
Condenser heat exchange

Specification:

Type Shell and tube type

Exchange heat quantity 105,000 kcal/h = 439,882.7 kJ/h
Steam flow rate 180 kg/h
Heat transmission area 1.0 m2
Water receiving tank 100 L
Cooling water flow rate Screw type flow meter

Procedure:
Measure inlet and outlet temperature of cooling water. Measure the volume flow
rate of the cooling water from the flow meter on the control panel.

Specimen Calculation:

dQ/dt = ṁw Cp (Tw3 – Tw2)

Cp = 4.2 (kJ/kg.ᵒC)

= 620 x 4.2 x (96.4 – 31.3)

= 169.5 MJ/h
Observations:

Heat
No of Obs. Tw2 Tw3 Qw ṁw Exchange
(ºC) (ºC) (m3/h) (kg/h) Rate
dQ/dt
(MJ/h)
1
2
3
4

Comments:

Give remarks on the following graph(s) for pre-recorded and experimental results:
1. Heat Exchange Rate (dQ/dt) vs. Condenser Cooling Water Flow Rate (ṁw)
Experiment No – 8 Power Plants

Name: __________________________ Regd. No.___________________ Date: ___________

Objective:
To determine overall efficiency of steam power plant.

Apparatus:
Steam Turbine Power Plant

Specifications:

Work Output Maximum 0.6 kW

Fuel Kerosene Oil

Specimen Calculation:
ηt = Wout / mf .CV

mf = mass flow rate of fuel consumed = ρf Vf / t

C.V. = 42700 (kJ/kg)

ρf = 820 kg/m3

Observations:

No. of Obs. Wout mf ηt

1
2
3
4
Comments:

Give remarks on the Efficiencies of Boiler, Superheater and Turbine and conclude their effect on
overall efficiency of the steam turbine by drawing suitable graph(s) for pre-recorded and
experimental results.