Ppe Exp.3 ROLLNO 1

POWER PLANT ENGINEERING
Experiment No.3
AIM- Experiments are conducted on Boiler to determine efficiency of boiler and generate heat balance
sheet
OBJECTIVES
1. To Determine Dryness fraction of Steam.
2. To determine boiler efficiency.
3. To conduct Heat Balance test.
I. INTRODUCTION:
Steam is one of the energy sources, by virtue of which thermal power plants are running. It finds its
application in process industry. It is very important to study thermodynamic properties of steam to
design all these plants. Basically steam is generated in a boiler by heating water above boiling
temperature. Combination of pressure and temperature along with rate of flow has to be decided for
all process.
Hence DEVALE’s Steam lab is a package with boiler, turbine, steam flow meter, steam calorimeter,
all instrumentation, steam line, insulation, all mounting, safety devises, heat exchanger, pumps,
etc,.which gives comprehensive training in steam lab also known as MINI POWER PLANT.
DEVALE’s NON IBR Steam lab package comprises following:
01. Steam boiler – fully automatic, oil fired,400 kg/hr, non IBR with all mountings
02. Diesel tank with accessories
03. Separating and Throttling calorimeter
04. Steam Flow meter
05. Steam Turbine coupled to Eddy current Dynamometer
06. Steam turbine control panel
07. Surface condenser
08. Pumps
09. Collection tanks
10. Chimney
11. Water pipelines, water softener
12. Steam line with insulation
13. All gauges, cables, thermocouples
14. Other instrumentation
A. STEAM BOILER : TECHNO THERM - DEVALE
This boiler is Non IBR, oil fired, fully automatic - 600 kg/ hr, four pass, vertical with following:
Department of Mechanical Engineering, BVDUCOE, Pune

a) Steam output (from and at 100 oC) - 400 kg/hr

b) Working pressure - 12 kg/sq.cm
c) Design pressure - 17.5 kg/sq.cm
d) Hydraulic test pressure - 26.25 kg/sq.cm
e) Efficiency - 90 +/- 2 % *
f) Fuel and consumption - LDO about 36 kg/hr *
g) Burner control - ON/OFF
h) Electric supply - AC 3 phase,4 wire,415 V
i) Blower motor - 2/1.5 Hp/kw
ACCESSORIES :
Chimney - 200 mm dia, about 20 ft height

Fuel Tank - about 100 liters, made from MS, with stand, piezometer, valve, pipes etc,
Economizer - Shell and tube type, MS
Water meter - 1 inch to measure flow rate of water to boiler
SEPARATING AND THROTTLING CALORIMETER:
It is complete with separator and throttling unit, gauges, valves, pipes, etc, All the parts are insulated.
Sampling pipe is connected, to main steam pipe.
Pressure gauge : 2 nos, one at inlet and another at throttling unit.
Thermowells : 2 nos, for temp measurement.

Condenser : Shell and coil type, with water circulation in Shell and steam in copper coil pipe.
PROCEDURE :
PRESETTING, PRECAUTIONS AND OBSERVATIONS:
1. Fill up water in overhead tank.

2. Fill up diesel in fuel tank and close the lid.
Check electrical connections, and observe rotation of direction of pump motor, blower motor and
feed water pump motor
3. Ensure all three phase power with neutral .This is indicated by Glowing of 3 lamps – R,Y ,B along
with Control
4. RTD sensor to be placed in its location.
EXPERIMENTAL PROCEDURE :
a. Open water valve and fuel tank valve.

b. Open auxiliary valve and close main steam valve.
c. Put on Mains and observe lamp glow for all three phase and control circuit.

d. Put the controller rotary switch to WATER position( 1) .Now pump starts and water flows inside
coil and comes out of boiler through auxiliary valve.
e. Once water comes out freely(Observed Outside lab),set valve at about 4 bar
f. Now change control switch position to FIRE.(2)
g. Now boiler starts with all its sequence of operations and after 3-4 minutes steam comes out. Wait
until pressure raises to 10 bar and temperature to say 170 degree.
h. Boiler may stop as it would have triggered pressure switch, at this point open the valve completely.
Now boiler is ready for test.
i. Adjust pressure to say 6 bar, and see that boiler is running without stop.
j. Note down water meter reading with respect to time, note down fuel consumption with respect to
time. Note down all temperatures, pressure readings.
k. Repeat experiment for different valve openings and pressure
l. If difficulty is faced in maintaining low pressure, main steam valve may be opened, and open pipe
and valves fitted for calorimeter. Here close needle valve of calorimeter.
SAFETY MEASURES AND PRECAUTIONS FOR STEAM LAB :

1. Do not run boiler without soft water, it may choke coil, by formation of scale, and efficiency will
drop.
2. If by any default boiler stops, a hooter comes into action, this time open panel cover, and push
reset button.
3. Run boiler at least once a week, run turbine also.
4. Drain out all condensate from pipe line, turbine, steam trap after use.
5. Daily check water, fuel levels
6. Check oil level in feed water pump , turbine periodically.
SEPARATING AND THROTTLING CALORIMETER :

1. Once boiler trial is over, close auxiliary valve and open main steam valve, completely. Adjust
steam valve along with needle valve of calorimeter to get pressure say 1.5-2.0 bar. Now sample is
taken from continuous flowing steam. allow water to the condenser.
2. Now wait for 5 minutes, so that systems comes to thermal equilibrium.
3. Observe sufficient condensate flows out, and collected in measuring jar(2 liters) Throw this
condensate collected.
4. Mark level of water in separator and keep measuring jar below condenser to collect condensate
simultaneously.
5. After about 2 minutes or sufficient condensate is collected in jar, close needle completely. Allow
complete conversion into condensate and collected in the jar.
6. Note down all readings of temperature and pressure.
7. Now boiler is stopped fully.
8. Allow entire remaining steam in pipes to go outside through this bypass valve at calorimeter.
9. After completely letting out steam ,open needle valve of calorimeter
10. Measure quantity of condensate collected from condenser and note down it as M cc
11. Empty the jar and hold it below drain valve of gauge glass set of separator unit.
12. Open drain valve, now moisture collected start filling jar
13. Open valve until water level in the gauge glass reaches marked level.
14. Measure quantity of moisture collected in the jar and note it down as m cc

15. Calculate DRYNESS FACTION of the steam, using formulae.
OBSERVATIONS FOR DRYNESS FRACTION :

01. Pressure at inlet to calorimeter P1 = 2.5 Bar
02. Pressure after throttling P2 = 0.5 Bar
03. Temperature at inlet T4 = 125 OC
04. Temperature after throttling T5 = 103 OC
05. Moisture collected from separator m cc = 180 ml
06. Condensate collected M cc = 1000 ml
OBSERVATIONS :
A. BOILER:
01. Initial reading of water meter : w1lts

02. Final reading of water meter : w2lts
03. Time for above :t1 sec
04. Initial level in diesel tank : L1 cm
05. Final level in diesel tank : L2 cm
06. Time for above :t2 sec
07. Steam pressure : P1 bar
08. Boiler room Temperature : Tr C
09. Feed water inlet temperature : Tr C
10. Feed water Temp after economizer : T1 C
11. Flue gases temperature entering Economiser: T2 C
12. Flue gases temperature leaving Economiser: T3 C
13. Steam temperature : Ts C
14. Calorific value of Diesel : CV = 41,870 kJ/kg
15. Maximum flow of Air from blower : 1200 cfm
16. Opening of Blower suction : ….. % = …..
CALCULATION




CONCLUSION- In this experiment we learnt about the boiler and calculated the efficiency of boiler and
generate heat balance sheet.

Ppe Exp.3 ROLLNO 1

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POWER PLANT ENGINEERING

DEVALE’s NON IBR Steam lab package comprises following:

A. STEAM BOILER : TECHNO THERM - DEVALE

Department of Mechanical Engineering, BVDUCOE, Pune

a) Steam output (from and at 100 oC) - 400 kg/hr

Chimney - 200 mm dia, about 20 ft height

SEPARATING AND THROTTLING CALORIMETER:

Pressure gauge : 2 nos, one at inlet and another at throttling unit.

Thermowells : 2 nos, for temp measurement.

PRESETTING, PRECAUTIONS AND OBSERVATIONS:

1. Fill up water in overhead tank.

a. Open water valve and fuel tank valve.

Department of Mechanical Engineering, BVDUCOE, Pune

SAFETY MEASURES AND PRECAUTIONS FOR STEAM LAB :

SEPARATING AND THROTTLING CALORIMETER :

Department of Mechanical Engineering, BVDUCOE, Pune

15. Calculate DRYNESS FACTION of the steam, using formulae.

OBSERVATIONS FOR DRYNESS FRACTION :

06. Condensate collected M cc = 1000 ml

01. Initial reading of water meter : w1lts

Department of Mechanical Engineering, BVDUCOE, Pune

Department of Mechanical Engineering, BVDUCOE, Pune

Department of Mechanical Engineering, BVDUCOE, Pune

Department of Mechanical Engineering, BVDUCOE, Pune

Department of Mechanical Engineering, BVDUCOE, Pune

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