CLB 20403 THERMODYNAMICS

MALAYSIAN INSTITUTE OF CHEMICAL AND BIOENGINEERING

TECHNOLOGY

EXPERIMENT 2
PERFORMANCE OF A
STEAM PLANT

THERMODYNAMICS
CLB 20403

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CLB 20403 THERMODYNAMICS

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

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

2.0 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.

3.0 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
in Saturated Steam from the steam engine into water. The water is then returned to the
reservoir and pump back into the boiler and the cycle continues.

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Figure 1: Steam Motor and Energy Conversion Test Set

4.0 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

W1= Q1 - Q2 - Q3 - Q5 + mhw - mh3

 The thermal efficiency of the plant is given by

th = W1
Q1 + ms(hw – h3)

 Boiler efficiency is given by the following formula

b = ms (h1-hw)
Q1

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 Rankine cycle efficiency

R = W1
ms (hw - h1)

 Steam quality
x= hg[@calorimeter temperature] – hf[@boiler pressure]
hfg[@ boiler pressure]

 Power Output of the Engine, W1 = 2R(F1-F2)N/60

Where
R= Brake radius (0.056 m)
F = spring load (N)
N= engine speed (rev. min-1)

Notes: h1 – specific enthalpy of steam leaving boiler

h3 – specific enthalpy condensate leaving boiler
hw – specific enthalpy water in boiler

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5.0 PROCEDURE
5.1 Set Up and Checks Procedure
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 on the boiler sight gauge, and the
stop valve/ 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 stop
valve/steam outlet 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.

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5.2 Start Up Procedure

1. When the boiler pressure has reached approximately 60 kN/m2 (0.6
bar), open the stop valve/ steam outlet valve until the engine inlet pressure
reaches 40 kN/m2 to 50 kN/m2 (0.4 bar to 0.5 bar).
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. 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 stop valve/steam outlet valve to keep engine ticking over at a pressure
of between 40kN/m2 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/m2.
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.

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5.3 Experimental Procedure

1. 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 0 N stages to 4 N.
b) Vary the stop valve/ steam outlet valve to achieve a constant speed
(  100 rev.min-1)
2. Record the parameters in the data sheet
(Measure the condensate temperature and condensate flow rate by measuring
the volume collected in a measuring cylinder for a period of 1 minute)
3. Analyze the results.

5.4 Shutdown Procedure

1. Disconnect the electrical and water supplies
2. Allow the boiler to cool down and open the boiler drain valve.
3. Drain any water from the apparatus
4. Switch off the temperature display
Note: Never open the boiler drain valve while there is a pressure or high
temperature in the boiler.

6.0 TASKS
1. Calculate the following for every particular load.
a) Quality of steam at boiler
b) Boiler efficiency
c) Power output of the engine, W1
d) Rankine cycle efficiency
e) Thermal efficiency
f) Plot the condenstae flow rate vs power output (Willan’s Line)
**Use the steam table to determine the enthalpy value.

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7.0 DATA SHEET

Spring Condenser Condenser

Engine Condensate
Load Boiler Boiler Engine Calorimeter Cooling Cooling Electrical Condensate
Inlet Flowrate,
Pressure Temperature, Speed,N Temperature, Water Inlet Water Outlet Power,Q1 Temperature,
F1 F2 Pressure, ,ms
,P1 (kPa) T1(°C) (rev/min) T2(°C) Temperature, Temperature, (W) T5(°C)
(N) (N) P2 (kPa) (mil/min)
T3(°C) T4(°C)

* Condenser Cooling Water flowrate ,mw = 0.0284 kg/s