CLB 2O403: Thermodynamics Exp.

1: Performance of a steam plant

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EXPERIMENT NO: 2
(PERFORMANCE OF A STEAM PLANT)










CLB 2O403: Thermodynamics Exp. 1: Performance of a steam plant


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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 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.
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.



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CLB 2O403: Thermodynamics Exp. 1: Performance of a steam plant


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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

W
1
= Q
1
- Q
2
- Q
3
- Q
5
+ mh
w
- mh
3


The thermal efficiency of the plant is given by

th
= W
1

Q
1
+ m
s
(h
w
- h
3
)

Boiler efficiency is given by the following formula

b
= m
s
(h
1
-h
w
)
Q
1



CLB 2O403: Thermodynamics Exp. 1: Performance of a steam plant


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Rankine cycle efficiency

R
= W
1

m
s
(h
w
- h
1
)

Steam quality
x= h[enthalpy after throttling calorimeter] h
f
[@boiler pressure]
h
fg
[@ boiler pressure]
Power W = 2R(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:
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.

CLB 2O403: Thermodynamics Exp. 1: Performance of a steam plant


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4. Open the upper and lower valves 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 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.

2.2 Start Up
1. When the boiler pressure has reached approximately 60 kN/m2 (0.6 bar), open
the boiler steam 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.

CLB 2O403: Thermodynamics Exp. 1: Performance of a steam plant


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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/m
2
.
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/m
2
(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
)
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

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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
2. Boiler efficiency
3. Power output of the engine, W
1

4. Rankine cycle efficiency
5. Thermal efficiency
6. Plot the steam flow rate vs power output ( Willans Line)

Use the steam table to determine the enthalpy values



CLB 2O403: Thermodynamics Exp. 1: Performance of a steam plant


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Experiment 1 Data Sheet :

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














* Condenser Cooling Water flowrate ,m
w
= 0.0284 kg/s