PP LAB Report

Lab Session # 1-7

2015-ME-08
SHAYAN AHMED RAGHIB
Experiment No -1 Power Plants

Name: ____Shayan Ahmed Raghib ___ Regd. No.___2015-ME-08______ Date: _12-02-2019 _

Objective:

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

Theory:

Block Diagram of Plant:

Figure 1 Block Diagram of Mini Steam Turbine Power Plant

Description of Parts:

Economizer
Economizers are used to preheat a fluid before intake into the steam generator.
The temperature of the fluid (water) is raised to the saturation temperature in the economizer.

Boiler/Steam Generator
The fluid then moves to the steam generator where it absorbs latent heat to change
its phase to steam.

Super heater
The vapors are then heated more before intake of turbine in the super heater. All
of the three (economizer, steam generator and super heater) are heat exchangers.

Turbine
The steam is then used to rotate the panes of a turbine. The steam provides the
kinetic energy for the motion of the turbine. This turbine is connected to a generator assembly
for electric generation.

Condenser
The steam after losing its energy is then sent to the condenser where it changes its
phase back to water. Condensers are also heat exchangers.

Pump
Water is then sent to a feed pump to increase its pressure before entering into the
boiler.

Comments:

 The plant was explained and understood theoretically but not operated during the visit.
Experiment No -2 Power Plants

Name: ____Shayan Ahmed Raghib ___ Regd. No.___2015-ME-08______ Date: _12-02-2019 _

Objective:
To determine the thermal efficiency (ηth) of a steam boiler and measure the
evaporating rate

Apparatus:
Boiler (Steam generating device)
Theory:

Classifications of Boilers:
Boilers can be classified with respect to the following parameters:

 Relative position of fluids

o Water tube boiler: The flue gases are in the tank and the water flows in tubes.
o Fire tube boiler: The flue gases are in the tube and water is outside in the tank
.
 Axis of Shell
o Vertical
o Horizontal

 Position of Furnace
o Internally Fired
o Externally Fired

 Moveability
o Stationary
o Portable

 Pressure
o High
o Low

 No. of turns

 No. of passes
Specification:

Maximum Pressure 10 kg/cm2

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

Procedure:

Boiler Starting up
Open water Supply valve. Turn 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.

Specimen Calculation

Thermal efficiency of the boiler is given by

ηth=ms(h1-h6)/mf x C.V
where
ms= mass flow rate of steam generated =ρwVw/ t

mf = mass flow rate of fuel consumed = ρfVf/ t

C V = 42700(kj/kg)

ρf= 820 kg/m3

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

ηth= 74.1%

TABLE:

h4

h6

h4

h6
Quality of Steam (x)

mf
Observation Number

Load

C.V

ηth. Boiler
Number of Heater On

ms
P1

Tw1

kW MPa (ºC) (s) (kg/s) (kg/s) (kJ/k (kJ/kg (kJ/kg (kJ/kg (%)
g) ) ) )

with Without Witho

Economizer Economizer ut

1 2 0.15 0.29 19.8 0.98 4270 0.0167 0.0020 83.08 2697.3 714 2766 40.02
1 0 85 15 83

2 4 0.3 0.3 19.9 0.98 4270 0.0178 0.0023 83.5 2706.5 710 2765 36.14
5 0 91 83 44

3 6 0.45 0.29 20.1 0.99 4270 0.0294 0.0022 84.34 2715.7 710 2765 64.18
0 0 15 06 23

4 6 0.45 0.49 20.8 0.96 4270 0.0180 0.0021 87.27 2677.6 710 2765 40.85
3 0 74 3 71

5 4 0.3 0.51 20.8 0.97 4270 0.0201 0.0020 2694.2 719 2768 46.26
0 0 35 89 87

6 2 0.15 0.5 21.1 0.97 4270 0.0192 0.0018 88.52 2700.1 706 2764 50.38
3 0 37 38

7 4 0.3 0.21 21.4 0.97 4270 0.0192 0.0022 89.78 2681.7 701 2763 41.51
9 0 9 44 09

8 3 0.22 0.21 21.5 0.98 4270 0.0192 0.0019 90.2 2702.1 727 2769 46.56
5 9 0 9 81 77

9 2 0.15 0.21 21.7 0.99 4270 0.0262 0.0019 91.03 2709.6 727 2769 64.83
 2 0 91 39 87

10 1 0.07 0.21 21.8 0.98 4270 0.0098 0.0019 91.45 2697.8 706 2764 24.54
5 7 0 57 36 66

Load vs Effeciency
70
65
60
55
Effeciency

50
45
40
35
30
0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
LOAD kW

GRAPHS:
Graph 1

With economizer
 Pressure vs Effeciency
65

60

55
Effeciency

50

45

40
0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Pressure

Graph 2
Experiment No –3 Power Plants

Name: ____Shayan Ahmed Raghib ___ Regd. No.___2015-ME-08______ Date: _12-02-2019 _

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

Theory:

Calorimeter:
Calorimeter is basically used to measures the different heats (heat of combustion,
heat of formation) of a reaction. But for steam, calorimeters are used to measure the dryness
fraction of the steam. If the steam is sufficiently dry to enable it to reach a supersaturated state by
throttling process, then a solitary throttling calorimeter can serve the purpose. If on the other
hand, the steam is very wet, then a separating calorimeter is used. When the dryness fraction of
the steam is somewhere in between, then a combined setup of Throttling and Separating
Calorimeter is used.

Throttling Calorimeter:
Using a needle valve for the throttling process, wet steam is dried and then passed
on to the super heater.

Separating Calorimeter:
Separating calorimeter contains a configuration of plates which are designed to
make the steam lose water droplets on collisions and energy transmission.

Apparatus:
Steam generating device
Throttling calorimeter.

Specifications:
Pressure gauge 10kg/cm2, 2kg/cm2
Throttle type Needle Valve type
Procedure:

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 = mg/mg + mf
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

TABLE:
P1

P2

T2

hf1

h2
Observations

hfg1
Load

Quality of
Steam (x)
Number of

  kW MPa MPa ℃ kJ/kg kJ/kg kJ/kg  

                 

1 0.15 0.3 0.025 114 605.236 2132.97 2698.58 0.981422

2 0.3 0.3 0.075 122.2 605.236 2132.97 2706.54 0.985154

3 0.45 0.2 0.125 121.7 562.099 2163 2703.49 0.99001

4 0.45 0.52 0.025 105.4 676.545 2081.2 2680.15 0.962716

5 0.3 0.5 0.075 114.5 670.876 2085.36 2693.51 0.969921

6 0.15 0.47 0.125 119.2 662.234 2091.77 2697.73 0.973097

7 0.3 0.2 0.025 105.4 562.099 2163 2680.15 0.979219

8 0.225 0.19 0.075 117 557.188 2166.35 2699.05 0.988696

9 0.15 0.17 0.125 121.6 546.95 2173.32 2703.26 0.992173

10 0.075 0.16 0.125 133 552.9 2166.23 2718.23 0.9834

GRAPHS:

Load vs Quality of Steam

1
0.99
0.99
0.98
0.98
Quality x

0.97
0.97
0.96
0.96
0.95
0.95
0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Load kW

Graph 3
 Pressure vs Quality
1
0.99
0.99
0.98
0.98
Quality x

0.97
0.97
0.96
0.96
0.95
0.95
0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55
Pressure MPa

Graph 4
Experiment No - 4 Power Plants

Name: _Shayan Ahmed Raghib_ Regd. No._2015-ME-08_ Date: 22-02-2019__

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

Apparatus:
Steam Super Heater

Specifications:

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

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

Procedure:

Close respective valves of super heater and wait for steam generation from steam.
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 power switch ON. Burner starts function and steam is super-
heated. Note the readings of pressure and temperature before and after the super heater.
Note the reading of the volume of the fuel consumed in super heater by the integral flow
meter on the panel.

Department of Mechanical Engineering

Theory:
Types of Superheater:
1) Radiant Superheater:
 It is positioned in the boiler’s combustion chamber.
 It enables the pipes of the superheater to instantly absorb the radiant heat from the
combustion inside the furnace.
 These pipes are placed over furnace’s top in water-tube boilers.
 They absorb the second greatest heat energy, following the raiser/evaporator tubes.
 The steam output decreases with the increase in steam flow through radiant
superheater pipes.
2) Convective Superheater:
 Here the pipes are placed in the flow of the flue gases that still contain heat.
 The pipes absorb heat from combustion exhaust gases conventionally.
 This enables maximization of heat absorption from combustion.
 In this superheater, the steam output temperature increases with increase in steam
flow in pipes.
3) Separately Fired Superheater:
 It is placed separately from the main boiler, having its own separate combustion
system with the main boiler.
 This design puts additional burners in the area of superheater pipes.
 It is not popularly used.
 Its infamy is due to the fact that as its efficiency of combustion ratio with steam
quality gives no edge to it in comparison to other superheater types.
4) Combination Radiant and Convection Superheater:
 It’s the most popular.
 It combines the opposite characteristics between radiant and convection superheater.
 The result is that for the steam output temperature is more homogeneous for various
steam flows.
 This superheater gives best output in comparison with the individual superheater.
 The boiler performance increases.

Calculations:
ɳth= ms(h3-h2) / mfx CV

= 43.8(2812.25 – 2687.25) / 0.44 x 42700

= 29.14%
TABLE:
P1

P3

T2

ms

T3

mf

nth
No. of

Quality of

h2

h3
Steam or
dryness
Observation

Fraction (x)
MPa MPa ℃ kg/s ℃ kg/s kJ/kg kJ/kg

1 0.31 0.3 169 0.01678 190 0.00059 0.98142 2697.3 2840. 9.4664
5 6 2 8 9 8

2 0.29 0.3 168 0.01789 185 0.00052 0.98515 2706.5 2831. 9.8791
5 1 9 4 4 2 5

3 0.29 0.29 168 0.02941 185 0.00051 0.99001 2715.7 2831. 15.641
5 2 5 0

4 0.49 0.5 168 0.01807 185 0.00051 0.96271 2677.6 2819. 11.639
4 7 6 7 7 6

5 0.5 0.51 170 0.02013 187 0.00047 0.96992 2694.2 2823. 12.796
5 6 1 8 5 1

6 0.5 0.51 167 0.04208 183 0.0005 0.97309 2700.1 2814. 22.560
2 7 3 6 0

7 0.21 0.19 166 0.01929 184 0.00058 0.97921 2681.7 2833. 11.870
9 0 9 4

8 0.22 0.21 172 0.01929 187 0.00059 0.98869 2702.1 2839. 10.379
8 6 7 6 6

9 0.23 0.21 172 0.02629 183 0.00061 0.99217 2709.6 2830. 12.092
5 1 7 3 8 7 9

10 0.23 0.21 167 0.00985 187 0.00060 0.9868 2698.0 2839. 5.3554
7 8 8 0 4
GRAPHS:

Boiler Exit Temperature vs Efficiency

19
17
15
Efficiency

13
11
9
7
5
165 166 167 168 169 170 171 172 173
Temperature

Graph 5

Boiler Pressure vs Efficiency

19
17
15
Efficiency

13
11
9
7
5
0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55
Pressure

Graph 6
 LAB SESSION # 5

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

TABLE:

No. of Heaters Pin Tin Pou Tou ms VI ng hin hout nt

On t t

MP ℃ MP ℃ kg/s kW kJ/kg kJ/kg %

a a

2 0.1 12 0.0 103 0.01678 0.126 0. 2720.7 2680.4 37.4401

7 1 5 5 5 3 7 1

4 0.1 14 0.0 103 0.01789 0.253 0. 2713.2 2680.4 71.9874

7 4 1 1 6 1 7 1

6 0 15 0.0 100 0.02941 0.297 0. 2765.2 2674.1 -

0 1 5 7 7 9 0.53939

6 0.2 13 0.0 103 0.01807 0.237 0. 2716.7 2680.4 72.3989

2 1 1 4 5 5 7 7 6

4 0.2 12 0.0 114 0.02013 0.253 0. 2703.4 2703.1 6980.62

3 6 1 5 6 9 9 8

2 0.1 12 0.0 106 0.04208 0.22 0. 2713.2 2686.7 28.1718

9 8 1 2 7 2 1 3

4 0.1 15 0.0 115 0.01929 0.268 0. 2773.3 2705.2 40.9177

8 5 1 8 5 5 4 4

3 0.1 14 0.0 112 0.01929 0.207 0. 2757.0 2699.0 30.8410

7 7 1 6 8 9 5

2 0.1 14 0.0 113 0.02629 0.168 0. 2764.8 2701.1 14.3285

 8 1 1 7 5 4 8

1 0.0 14 0.0 112 0.00985 0.096 0. 2761.0 2699.0 31.4379

7 5 1 7 5 5 9 6

GRAPHS:

Comaprison of Pressure and Efficiecny

80
70
Steam Turbine effieciny

60
50
40
30
20
10
0
0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22
Pressure Drop Across Turbine

Graph 7
 Mass Flow rate of steam vs Efficiency
80
70
Steam Turbine Efficiency 60
50
40
30
20
10
0
0.01 0.01 0.02 0.02 0.03 0.03 0.04 0.04 0.05
Mass flow rate of Steam

Graph 8

COMMENTS: Exp 2-5

 From the results we can see that with increase in the power output. The thermal efficiency
increases.
 The steam temperature must be high and have min moisture content while entering the
turbine, to get the max output from system.
 Obviously, with increase in power output, the generator efficiency also increases.
 In a real (non-ideal) case, the whole process is irreversible which explains the reduced
thermal efficiency.
 The heat loss due to improper insulations and the frictional effects between the parts, the
efficiency is decreased.
 The boiler pressure can be increased to get better efficiency, as it is related with an increase
in the max cycle temperature
 Graph 1 shows that the efficiency of the boiler is evidently high as with economizer as
compared to without economizer. The reason is that the economizer is reheated with the
 help of flue gases from the turbine and therefore less heat is required to heat the
economizer.
 As we increase, the boiler pressure the thermal efficiency should ideally increase linearly
but this is not the actual case in Graph 2.
 In the lab session # 2, we measured the quality of steam using a throttling calorimeter. It is
evident in Graph 4, that the dryness factor decreases with the increase in pressure.
 Similarly, with the increase in load, the steam quality decreases. As shown in Graph 3.
 The efficiency is greatly increased by using a super heater.
 According to Graph 7, the pressure drop across turbine also has a direct affect on the
efficiency of the system.

Experiment No - 6 Power Plants

Name: _Shayan Ahmed Raghib_______ Regd. No.__2015-ME-08________ Date: __2/4/2019_____

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

Apparatus: Condenser heat exchange

Theory:
Condenser:

Condenser is a vital part of the steam turbine power plant. After the steam passes through the
turbine portion it loses its heat in the condenser and is converted to water state. This enthalpy
drop leads to an increase in efficiency. This water is then reused in the cycle by pumping it into
the boiler.

Specification:

Type Shell and tube type

Exchange heat quantity 105,000 kcal/h
Steam flow rate 180 kg/h
Heat transmission area 1.0 m2
Water receiving tank 100L
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.

Department of Mechanical Engineering

Observations

Tw2 Qw heat
No of Obs. Tw1 (ºC) (m3/h) mw exchnage
(ºC) (kg/h) rate
(Mj/h)
1 10.2 67.7 0.479 479 115.13

2 9 54.6 0.832 832 158.58

 3 8.5 59.7 0.878 878 187.91
4 9 66.8 0.891 891 215.27

Specimen Calculations:
Condenser heat exchange rate = mW * CW * ∆TW
⸫ CW = 4.18 kJ/kg℃
= 0.891 * 4.18 * (59.7-8.5)
= 115.13 MJ/hr

Graphs:

Flow Rate Vs Heat Exchange Rate

230
210
190
Heat Exchange (MJ/h)

170
150
130
110
90
70
50
0.4 0.5 0.6 0.7 0.8 0.9 1
Flow Rate (m3/h)

Inlet Temp Vs Heat Exchange Rate

230
210
190
Heat Exchange (MJ/h)

170
150
130
110
90
70
50
8 8.5 9 9.5 10 10.5
Temperature (oC)
Experiment No –7 Power Plants

Name: Shayan Ahmed Raghib Regd. No. 2015-ME-08 Date: 01/04/2019 .

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 = ρfVf/ t

C V = 42700(kj/kg)

ρf= 820 kg/m3

Observations:

Total % Useful % Useful % Total % % % % Unaccounted

Input energy Energy Useful Energy Output Energy Energy losses
extracted extracte Energy lost to work lost to lost in
in boiler d in S.H in exhaust output fric. in cond.
boiler in boiler in turbine
& S.H turbine
kW % % % % % % % %
111.51 39.35 2.16 41.51 58.49 0.23 0.38 0.05 34.13
124.32 37.75 1.79 39.54 60.46 0.34 0.67 0.04 23.79
115.97 66.74 2.94 69.68 30.32 0.37 0.71 0.04 63.72
112.99 41.44 2.27 43.71 56.29 0.42 0.16 0.04 35.77
109.57 49.54 2.38 51.98 48.09 0.39 0.38 0.04 47.28
99.79 110.13 4.83 114.96 -14.96 0.31 0.8 0.05 113.77
120.58 41.47 2.44 43.9 56.1 0.45 0.64 0.03 31.24
110.14 45.75 2.41 48.16 51.84 0.31 0.7 0.04 41.84
109.15 63.08 2.92 66 84 0.22 1.31 0.04 61.32
108.62 4.31 20.62 24.93 75.07 0.18 0.39 0.03 17.87
Comments:

The main factors that the power generated from the plant are dependent on the flow rate of
turbine and enthalpy drop. The generated power decreases, despite the increasing amount of the
specific work, because of the decrease of flow rate with variation to load at the high pressure
turbine.
 Total Energy content Distribution

Useful energy that extracted in

Boiler
Energy (useful) extracted in Supr.
Heater
Energy lost due to friction and
39% 40% exhaust in boiler of power plant
work extracted from turbine
Energy lost due to friction in
turbine
Energy eliminated in condenser
0%
0% cooling water
2% unaccounted losses after
18% expansion in turbine