UNIVERSITI KUALA LUMPUR

MALAYSIAN INSTITUTE OF CHEMICAL BIOENGINEERING

TECHNOLOGY
PILOT PLANT OPERATION 2 – CPD30303

Laboratory Report
Assessment/Rubric/Marking Sheet July 2020

Experiment : Performance Of A Steam Plant

Date : 10/8/2020
Lecturer : Dr Nor Shahirah Mohd Nasir
Group no. : 2
Name of group members:
Name ID
1 NUR KHAIRUNNISA BINTI SOBERI 55102118033
2 MUHAMMAD FAIZ BIN MUHAMAD SUBRI 55102118032
3 MOHD KHAIRUL FATHY BIN M. ASRAR 55102118037
4 MUHAMMAD AL-BAIHAQI BIN MOHD RAFIDI 55102118030

No Criteria Wt. Grade Mark

1 Summary 2 1 2 3 4 5
• Brief explanation of the experiment
• Objectives / Purposes of experiment
• Brief method
• Results & significant conclusion /10
2 Introduction 3 1 2 3 4 5
• Overview of the experiment
• The theoretical study, relevancy & formula
• Sufficient information to support /15
3 Methodology 2 1 2 3 4 5
• Compact & understandable /10
4 Results 3 1 2 3 4 5
• Data and graph presentation support the objective/s
of the study (with complete labels and units)
• Data, calculations and derived results are clearly
presented /15
5 Discussion 4 1 2 3 4 5
• Relate to theory and objectives
• Explanations of the referred table and figure
• Comparison between experimental results &
theoretical/predicted/reported values
• Data accuracy/precision (personal, methodological
and/or instrumental errors)
• Discussion is clear and satisfactory /20
6 Conclusion & Recommendation 2 1 2 3 4 5
• Overall conclusion must be clearly stated
• Recommendation /10
7 General 1 1 2 3 4 5
• Neatness, written according to format, appendix /5
8 References 1 1 2 3 4 5 /5
 • Plagiarism >20% similarity
• No references or late submission (mark deduction)
TOTAL MARKS (90 MARKS)
TOTAL MARKS + PSYCHOMOTOR (100%)
VERIFICATION

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1.0 SUMMARY

The experiment conducted is Experiment Performance of a Steam Plant. The

experiment is conducted to determine the performance characteristics of a steam plant, to
demonstrate thermodynamic principles applied in a steam plant and demonstrating the
conversion of energy from one form to another added by the measurement of mechanical
power. As the name of experiment showed, the experiment is run at a laboratory scale steam
plant. In this experiment, thermodynamics principles are applied and discovered. The steam
plant introduces the first and second law of thermodynamics. This term will be further
elaborated in the introduction. The method used in this experiment fully follows the step as in
an industrial steam plant. Therefore, students will be able to analyse and understand how a
steam plant operates and how energy is formed by using mere steam. From the result, the
steam quality at the boiler, boiler efficiency, power output of engine, Rankine cycle efficiency,
thermal efficiency and a graph of flow rate vs power output is inserted. The result is then
discussed in the discussion section to achieve the agenda behind all of result obtained. One
of the discussion topics is how the force applied at the steam plant affects the outcome of the
experiment. The force manipulated in this experiment is one of the variables to the process
efficiency. To conclude the experiment, it is hypothesis of the experiment is explained and
elaborated. There is a few fluctuations in the experiment, therefore a recommendation section
is prepared to explain the turbulent of results obtained and how the fluctuations and flaws of
the steam plant affect the process. in a nutshell, the experiment is well done and achieved its
objectives optimally.
2.0 INTRODUCTION
The experiment was carried out in order to determine the performance of characteristic
of the steam plant, to demonstrate the thermodynamic principles as applied to laboratory scale
steam plant, and lastly, to show the transfer of energy from one type to another and the
mechanical power measurements. Steam plant is planned to help understanding the
thermodynamics concepts as applied to high-scale steam engine development (S.O.
Oyedepo, 2020). The first law of thermodynamics and second law of thermodynamics were
the two laws incorporated throughout this experiment. The procedure is achieved by keeping
spring load F2 at 1.0N and changing spring load F1 at 0.5N intervals from 1.0N to 3.0N. To
calculate the steam quality and boiler efficiency, the reading of the parameters that are taken
will be used. Five experiments were measured in order to achieve the experiment’s goals. The
steam quality that were recorded from test 1 to test 5 were 1.468, 0.942, 0.941, 0.940, 1.114
and 1.468 respectively. Power output was also calculated which are 0W, 4.387W, 8.075W,
11.611W, 15.857W and 19.455W respectively. The result that obtained match well with the
theory which is the higher the energy that needed to lift a load of an object, the higher power
output generated. Plus, it also calculated boiler efficiency, thermal efficiency and efficiency of
the Rankine cycle. While running this experiment, there are several machine issues that make
the reading unprecise. Due to some energy lost to other processes such as friction or
conduction, a system can never be 100 per cent efficient during a complete cycle. Next, the
thermal efficiency increased with the values of 0.0%, 0.00024%, 0.00045%, 0.00069%,
0.0009%, and 0.001% while the Rankine cycle efficiency increases as the spring load
increases with the value of 0.0%, 0.000072%, 0.00013%, 0.00020%, 0.00025%, and
0.00030% respectively. This implies that as load size grows, engines required more fuel to
generate steam. A condensate flow rate diagram (ml / min) and the power output (W) were
plotted. The plotted graph obeys line theory of the William, where it increases in linear motion.
3.0 METHODOLOGY
The experiment was started with the procedure of setup and checks. Firstly, the inlet
pipe was connected to the cooling water supply, and the outlet pipe was connected to the
appropriate drain. Next, the condensate collector outlet was connected to an appropriate drain,
or collector. The unit was then connected to the electric power supply. The filter at the end of
the boiler pump suction pipe was checked to determine whether it is in place and clean. The
pipe end was placed inside the supplied reservoir tank. The tank was at least halfway filled
with the clean soft water. The reservoir was then kept at least half full to ensure that no air
from the pump was drawn in. The upper lower valves were opened on the boiler sight gauge,
the same goes for the steam outlet valve on the boiler. The temperature display has been
switched on to ensure the display is working. The student must make sure he pulled out the
red emergency button. Then the feed pump for the mains supply and boiler was switched on.
It opened the pump bleed valve and checked whether the pump was operating or not. The
bleed valve was closed when there is no air bubble and was at a steady flow of water and the
boiler on the sight gage was filled up to the upper mark. In about 8 to 10 minutes the boiler
was filled up. Then when the boiler is full the boiler steam valve was closed. To ensure the
engine was not loaded, the band brake was slackened, and the spring balance was set at
zero.

The experiment was then started with star up procedure. Practically, during the
experiment, the boiler steam valve was opened when the boiler pressure was reached
approximately 60KN/m2 and the engine inlet pressure reached 40kN/m2 to 50kN/m2. Next, it is
necessary to pull the starting knob upwards and let it go if there was one swift motion. Then,
the engine starts turning. It is necessary to check the inlet pressure, make sure the band brake
was not very tight and try to start the knob again if the engine was not turned. The condenser
refrigerating water was turned on and adjusted to 100L / hr flow rate. The steam valve was
used to keep the engine ticking over at pressure of between 40kN/m2 and 50kN/m2 because
when the engine speed increased the steam pressure will increased. Then, the heaters were
switched on to keep the boiler pressure up to a sufficient level. 340kN/m2 was the boiler safety
valve that begun to operate but not fully open until reached 400kN/m2. The appliance must be
run for at least 10 minutes before it took the reading to stabilize the conditions. The water level
inside the boiler should be checked regularly.

The experimental procedure has been commenced. The engine was operated at a
constant speed of 2000 rpm, at varying engine load. Next, it recorded the parameter in the
data sheet. The volume of condensate flow rate was measured and collected over a period of
1 minute using the measuring cylinder. Then we analysed the result. After using the steam
plant machine, the student must disconnect the supplied electrical and water, open the boiler
drain valve and allow the boiler to cool down, drain the apparatus from any water and lastly,
the temperature display must be switched off.
4.0 RESULT

Engine
Boiler Boiler Inlet Engine Calorimeter
Spring Load Pressure Temp Pressure speed Temp Condenser Condenser Condensate Electrical Condensate
cooling cooling
F1 (N) F2 (N) P1 (bar) T1(C) P2 (bar) N(rev/min) T2(C) H2O Inlet H2O Outlet Flow rate Power,Q1 Temperature
T3(C) T4(C) ms(ml/min) (W) T5(C)
1.0 1.0 200 137.8 180 1885 106.6 30.9 31.3 122 2.6 60.0
1.5 1.0 160 132.9 140 1496 106.4 31.1 33.0 92 2.6 40.0
2.0 1.0 160 131.6 140 1337 103.9 30.1 34.3 90 2.6 45.0
2.5 1.0 160 130.9 146 1320 102.7 31.8 34.9 84 2.6 40.0
3.0 1.0 180 134.9 160 1352 104.9 31.1 34.2 94 2.8 55.0
3.5 1.0 200 135.9 180 1327 103.8 31.5 34.1 97 2.8 50.0

TABLE 4.1
SPRING LOAD, F1 QUALITY OF BOILER POWER OUTPUT RANKING CYCLE THERMAL
STEAM AT EFFICIENCY OF THE ENGINE EFFICIENCY EFFICIENCY
BOILER
0 1.468 30955.47 0 0 0
0.5 0.942 23415.09 4.387 -7.206 X 10-5 -2.432 X 10-5
1.0 0.941 23236.24 8.075 -1.337 X 10-4 -4.579 X 10-5
1.5 0.940 21833.40 11.611 -2.045 X 10-4 -6.994 X 10-5
2.0 1.114 22407.32 15.857 -2.527 X 10-4 -9.031 X 10-5
2.5 1.468 23003.12 19.455 -3.021 X 10-4 -1.034 X 10-4
TABLE 4.2

FIGURE 1
5.0 DISCUSSION
This experiment was carried out in order to determine the performance characteristics
of a steam plant, to demonstrate thermodynamic principles as applied to laboratory scale
steam plant, and lastly, to demonstrate the conversion of energy from one form to another and
the measurement of mechanical power.

The steam plant employs the thermodynamic principle. There are 2 thermodynamic
laws that are used, these are the First Law of Thermodynamics and the Second Law of
Thermodynamics. The First Law of Thermodynamics states that, while on the other hand, the
total energy in a closed system is constant. The Second Law of Thermodynamic describes
that, due to the energy being lost during friction or conduction, a system cannot achieve 100
per cent efficiency during a complete cycle. In a steam engine, the cycle of operations is based
on the Rankine cycle. Similar to the Carnot cycle the Rankine cycle provides the most precise
approximation to the operation of a real steam engine. In the Rankine process, heat is applied
at constant pressure to transform water into superheated steam in the boiler, which allows the
steam to expand at constant entropy to become pressure in the condenser, so that the water
produced is compressed into the feed pump at constant entropy.

Two separate spring loads were used which needed to be balanced to determine the
effect of the various forces exerted by the spring load on the engine's power output. The spring
load F2 was kept constant at 1.0 N for this experiment, while the spring load F1 was adjusted
accordingly by an increment of 0.5 N in intervals, from 1.0 N to 3.5 N. The readings of the
boiler pressure (P1) and boiler temperature (T1) were taken for the calculation of steam quality
and boiler efficiency during the whole experiment. The engine inlet pressure (P2) and speed,
calorimeter temperature (T2), condenser cooling water inlet (T3) and outlet (T4), condensate
flow rate (ms), condensate temperature (T5), and electrical power supply (Q1) were other
parameters recorded. The experiment was conducted until all parameters for the spring loads
were measured.

Based on Table 3.1, the F1 load was set at 1.0 N for the first trial and the boiler operating
condition was recorded at a 200 kPa pressure and 137.80C temperature. Based on the
measurement obtained from the tests, the steam quality produced at the boiler was 1.468 with
a boiler efficiency of approximately 30.95 percent. The value for the engine power output, the
efficiency of the Rankine cycle and the thermal efficiency was 0, since both F1 and F2 have
equal spring load. For spring loads of 1.5N, 2.0N, 2,5N, 3.0 and 3.5N, the pressure and
temperature measurements were 160kPa and 132.90C; 160kPa and 1131.60C; 160kPa and
130.90C; and 180kPa and 134.90C, respectively; 200kPa and 135.90C.
 Meanwhile the calculated data and results obtained are shown in Table 3.2. The steam
quality at the boiler was calculated and the values were in the range of 0.9 to 1.5 for all spring
loads which were respectively 1.468, 0.942, 0.941, 0.940, 1.114 and 1.468. Steam quality at
boiler was calculated to calculate the magnitude of damage to the components or to measure
how much liquid water is present in the produced steam. The lower steam quality means that
the steam has higher moisture content which will more easily damage the components, and
vice versa.

Other than that, it also measured the engine's power outputs. The engine's power
output decreased from the first spring load to the last one when the spring load decreased,
with the values of 0W, 4.387W, 8.075W, 11.611W, 15.857W and 19.455W. Load is the amount
of force generated by a spring at a particular distance traveled, and in this experiment the
force or load acting on the engine refers to the spring load set. This parameter was related to
the power the engine was using. The energy used at 3.5N was the highest value compared to
the other spring loads, since the motor needs to lift the heavier spring load. So, the higher the
energy needed to lift the object 's load, the higher the power output the engine will generate.

In addition, it also calculated boiler efficiency, thermal efficiency, and efficiency of the
Rankine cycle. Efficiency of boilers is related to energy output and input of the boiler. The
supposed increase in spring load lead to an increase in boiler efficiency. While running this
experiment, there are several machine issues that make the reading unprecise. Due to some
energy lost to other processes such as friction or conduction, a system can never be 100 per
cent efficient during a complete cycle. Thermal efficiency is technically a dimensionless
performance metric of a system that uses thermal energy, indicating the degree to which the
heat-added energy is transformed into network output. Based on the results of this experiment,
the thermal efficiency also increases as the load spring mass increases, with the values of 0.0
percent, 0.00024 percent, 0.00045 percent, 0.00069 percent, 0.00090 percent, and 0.0010
percent. The thermal efficiency improvements show that the engine needs more heat to
produce steam. Finally, the efficiency of the Rankine cycle, where it is known as the idealized
thermodynamic cycle of a heat engine which converts heat into mechanical work. As the spring
load increases, the efficiency of the Rankine cycle increases with the values of 0.0 percent,
0.000072 percent, 0.00013 percent, 0.00020 percent, 0.00025 percent, and 0.00030 percent
respectively.

The graph shows the relation between the condensate flow rate (ml / min) and the power
output (W) in Figure 1. The diagram is plotted to display the steam consumption on the engine
at various load levels versus the engine power output. The graph shows that it decreases and
increases that disobeys the line theory of the William, where it states that the condensate flow
rate should be increased as the load spring increases, thus also increasing the engine power
output. This is due to the rise in the load spring, because the heavier the load spring, the more
energy is needed to raise the load, thereby requiring a higher boiler pressure. The high
pressure will increase the kinetic energy of the steam molecule which is transformed to
mechanical energy instantly when it moves through the steam engine. After transfer of energy
the steam passes through the condenser where the steam condensation occurs. This was
then added to the cooling water; hence, at the outlet and inlet it would influence the cooling
water temperature of the condenser. The increase in the temperature of condenser cooling
water at outlet is due to the addition of being transferred from the steam.

Even though the experiment was conducted without any major problems, a few
problems or errors were still encountered during the experiment, which may influence the
result. The first problem that has influenced is the spring load, where it has been vibrating
throughout the experiment, which can result in deviations in the data obtained and affecting
the actual load data. Since the spring scale was also a bit unclear, the exact measurement
was inaccurate during setting up of the load. Other than that, it was measurement of the
volume of water. Since the condensate has been collected in the beaker, the accuracy on the
actual volume can affect the efficiency of the calculation.
6.0 CONCLUSION
This experiment is to determine the performance characteristics of a steam plant, to
demonstrate thermodynamic principles as applied to laboratory scale steam plant and to
demonstrate the conversion of energy from one form to another and the measurement of
mechanical power. Based on the results it is proved that a high-quality water vapor mixture
can be produced by the steam plant. From the relationship, the engine's power input is
significantly increased when the load is increased alongside the steam pressure. So, we can
conclude that the higher the load, the greater the engine power output. It also linked this direct
relationship to the boiler. The higher the load the better the efficiency, the Rankine and thermal
efficiency. Transfer of all the heat energy to mechanical energy is impossible. This is in
accordance with the second law of thermodynamics, where some energy is lost during energy
transfer to other processes, friction, or conduction. The aim of this experiment is attained as
the conclusion.

7.0 RECOMMENDATION

There have been several recommendations that can be considered to improve the
outcomes that could be achieved through the experiment. First, water use must be
demineralized to prevent erosion throughout the process that causes the disturbances.
Besides that, it is necessary to optimize the equipment well to avoid faulty which can give the
experiment a disturbance. Next, to avoid parallax error, the eye must be perpendicular to the
scale reading during condensate volume measurement. Apart from ensuring that all
machinery, tools, or components undergo periodic inspections to avoid any technical errors.
Finally, speed must be maintained to avoid significant vapor loss to the surrounding
environment.
8.0 REFERENCES

A. Sinan Karakurt, Ü. G. (2017). PERFORMANCE ANALYSIS OF A STEAM TURBINE POWER PLANT AT

PART. Journal of Thermal Engineering.

Gerhart, A. &. (2006). LABORATORY-SCALE STEAM POWER PLANT STUDY--RANKINE CYCLER

EFFECTIVENESS AS A LEARNING TOOL AND A COMPREHENSIVE EXPERIMENTAL ANALYSIS.

RankineCycler™ Steam Turbine System | Turbine Technologies. (2016). Retrieved from

Turbinetechnologies.com: https://www.turbinetechnologies.com/educational-lab-
products/steam-turbine-engine-lab

S.O. Oyedepo, O. K. (2020, 10). Dataset on thermodynamics performance analysis and optimization
of a reheat – regenerative steam turbine power plant with feed water heaters. Retrieved
from Data in Brief: https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7397695/
9.0 APPENDIX