MECHANICAL ENGINEERING DEPARTMENT DATE : 15 / 7 / 2013 COURSE CODE: MBB 42223

SECTION A (To be filled by students) DATE EXP # & TITLE GROUP 15/7/2013 Boiler Group 21

SECTION B (To be filled by students)

NAME

ID

TIME IN

TIME OUT

SIGN

SECTION D (by Examiner) ITEM Abstract Objectives Theory & Procedure Data collection Results Conclusions & Discussion Report Format / Style TOTAL MARKS ALLOCATED 10 10 10 20 20 20 10 100 SCORE REMARKS

ABSTRACT The Rankine cycle most closely describes the process by which steam-operated heat engines most commonly found in power generation plants generate power. This cycle is a heat engine with a power cycle. The cycle consists of four which is: a. isentropic expansion (Steam Turbine) b. isobaric heat rejection (Condenser) c. isentropic compression (Pump) d. isobaric supply (Steam Generator or Boiler). In a mini power plant consist of a boiler, super heater, condenser and turbine in its operation. In a simple Rankine cycle, it uses steam as a working fluid generated from saturated liquid (feed water). The high pressure and temperature generated will cause rotation at the shaft of turbine, thus producing work. Generally, this experiment aims to give students experience in the operation principle of an actual steam power plant. This experiment also targets the students to be able to determine and describe the processes and functionality for a steam power plant. The experiment is done in laboratory by observing the plant operates. There are important parameters which need to be recorded during the experiment which is the pressure and temperature of each equipment. This data is used later on for result and analysis. At the end of the experiment, it is expected that students are able to describe the overall operation of an actual steam power plant which most power generation companies are using this type of principle. Moreover, students are also exposed and gain knowledge about the fundamental of this steam power plant.

OBJECTIVE This experiment is arranged to give students an experience about the principle of operation of an actual steam power plant

PROCEDURE 1. Time is required for the system before it can provided stable readings. Wait for the lab instructor told us to take readings. 2. When the system was ready and all the briefing was completed, schematic diagram of the system was taken, major components of the system were identified and located. 3. The instruments of the system were located and identified. 4. The readings at the inlet and the outlet of the pump, boiler, superheater, turbine nozzle, turbine and condenser were taken. 5. In case the system operated for variable working pressures, we waited the lab instructor sets it for us before the previous step is repeated.

THEORY
Rankine Cycle

The Rankine cycle is an idealised thermodynamic cycle of a heat engine that converts heat into mechanical work. The Rankine cycle, which is a is a reversible cycle, corresponds almost nearly than the Carnot cycle to the order of states assumed by the working substance in a typical steam power plant. It was developed to make use of waters characteristics as the working fluid. Referring to Figure 1, the cycle starts when the water inside the boiler is heated until it reaches saturation point. When the saturation condition is achieved, more heat input will take place at a constant temperature so that the working fluid reaches a quality of 100% steam. By this moment, the steam is expanded isentropically through an axially bladed turbine stage to produce shaft work. After that, the steam exits the turbine in liquid state.

At the moment, the water in gas state is at a fairly high quality but low pressure, therefor it is moved through a condenser in which the steam will be condensed into liquid state again. Finally, the cycle ends by returning the liquid to the boiler, which is normally accomplished by a mechanical pump.

Figure 1 : Diagrams for simple Ideal Rankine Cycle: (a) P-V diagram, (b) T-S diagram

Figure 2 : Schematic figure of a simplified Steam Power Plant

4-1 Isobaric Heat Transfer. During this phase, the boiler is feed high pressure liquid through the mechanical pump and is heated until it reaches temperature B. Extra addition of warmth causes the vaporization of the liquid until it is fully changed to saturated steam.

1-2 Isentropic Expansion. During this phase inside the turbine, the steam is expanded in which will yield work that can be converted into electricity. The expansion is restricted by the erosion of the turbine blades by liquid entrainment in the steam as the process moves into the two-phase region. The expansion is also restricted by the temperature of the cooling medium. The exit steam quality should be greater than 90%.

2-3 Isobaric Heat Rejection During this phase, the mixture of steam-liquid exiting the turbine is condensed at low pressure. If a condenser is well-designed, the pressure of the steam should be below the atmospheric pressure.

3-4 Isentropic Compression. During this phase, the rise in pressure of the condensate cause the pressure inside the mechanical pump to increase

Energy Balance of Components and Thermal Efficiency of the Cycle

Pump (q1,2 = 0) Wpump = h2-h1 = v1 (P2 P1)

Boiler (w2,3 = 0) qin = h3 h2

Turbine (q3,4 = 0) Wturbine,in = h3 h4

Condenser (w4,1 = 0) qout = h4 h1 Basically, the net work of the cycle is defined by the difference between the turbine work and the pump work.

W W m water h1 h2 m water h4 h3 W cycle t p

If the pump work is neglected, the net work of the cycle reduces to:

m water h1 h2 W cycle
Thus, the thermal efficiency of the system is defined by the rate between the net work and the heat transfer from the boiler:

RESULTS
No. 1 Property Boiler Boiler Pressure, Pb Feedwater Temperature, Tb1 Outlet or steam temperature, Tb2 Superheater Steam inlet pressure, Psh Steam inlet temperature, Tsh1 Steam outlet temperature, Tsh2 Turbine and condenser Number of nozzle open Nozzle Throat Dia. & Exit Dia. Condensate temperature, T1 Tubine exhaust temperature, T2 Cooling water outlet temperature, T3 Condenser steam inlet temperature, T4 Cooling water inlet temperature, T5 Nozzle inlet temperature, T6 Steam line temperature, T7 Nozzle inlet pressure, P1 Steam line pressure, P2 Condenser exhaust pressure, P3 Gland seal pressure, P4 Turbine exhaust pressure, P5 Condensate Flow rate of cooling water Dynamometer Current, I Voltage, V Coupling Torque, Rotational speed, N Mass Time Unit bar C C bar C C mm C C C C C C C bar bar bar bar bar kg sec Lit/hr Amp Volt N.m R/sec Value 7.5 28 176 7.3 173 178 8 5.56 & 9.525 53 67 31 76 26 152 173 3.8 7.5 -0.7 0 -0.7 15 275 10 2.1 136 2.52 3150

No. 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Parameter Steam consumption Brake power Electric power Specific steam consumption Energy supplied to turbine Energy supllied to nozzle Energy at exhaust Energy drop through throttle valve Energy drop through turbine Energy to brake power Energy to friction/losses in turbine Energy to cooling water Energy to condensate Energy to exhaust radiation Isentropic enthalpy drop Energy supplied to the turbine set Mechanical conversion efficiency Isentropic conversion efficiency of the turbine Turbine set efficiency Electric conversion efficiency Thermal efficiency

Unit kg/min kW kW kg/kW kJ/min kJ/min kJ/min kJ/min kJ/min kJ/min kJ/min kJ/min kJ/min kJ/min kJ/min kJ/min % % % % %

Value 3.27 49.88 0.29 3.94 9049.09 9013.09 8714.95 36.00 298.15 2992.94 2694.80 3.48 725.04 7986.42 1619.27 8288.05 10.04 18.41 3.29 0.57 0.23

Enthalpy at nozzle = h@T6,P1 = 2754 kJ/kg Enthalpy turbine inlet = h3 = h@T7,P2 = 2765 kJ/kg s3 = s4 = 6.73 kJ/kg.K s3 = sf@T7 + x.sfg@T7 sf@T7 = 0.9244 kJ/kg.K sg@T7 = 7.7918 kJ/kg.K x = 0.845 hf@T2 = 282.6 kJ/kg hg@T2 = 2621.8 kJ/kg Isentropic enthalpy at exhaust = h4' = hg@T2+ x.hfg@T2= 2259.224 kJ/kg Enthalpy at exhaust = h4 = hg@T2,P5 = 2662.9 kJ/kg h1 = hf @ T1 = 212 kJ/kg h2 = h@Tb1 = 113.19 kJ/kg Wnet = Wturbine - Wpump Wturbine = h3 h4 = 506 kJ/kg Wpump = h2 h1 = -98.81 kJ/kg Qin = h3 h2 Wnet = 604.81 kJ/kg Qin= (2765 113.19) = 2651.81 kJ/kg

DISCUSSION The experiment is carried out in order to observe the simulation of a steam power plant inside a lab which is applied towards an actual power plant. The steam power plant applied the concept of Rankine cycle for the cycle to function efficiently. The boiler function as to increase water temperature until it reaches to the temperature in the state of steam or superheated vapour. This experiment consists of a turbine and a condenser. The temperatures were recorded for every inlet and outlet of both turbine and condenser which is then been compared with the T-s diagram. For the experiment to gain accurate result, the inlet temperature of turbine should be higher than the exhaust temperature. As for condenser, the outlet temperature should be higher than the inlet temperature as the pressure increases from inlet to outlet. From the results obtained, we manage to get the desired outcome or temperature reading at each part. The condenser exhaust pressure and turbine exhaust pressure were both in negative values because of the gauge pressure which is not absolute and does not contain atmospheric pressure. This condition is also known as the vacuum pressure. Based on the results obtained, every reading taken is appropriate and within the range for calculation. The mass flow rate obtained is the same throughout the cycle since it is a steady flow. The energy supplied to the nozzle is higher than the energy supplied to the turbine because nozzle has higher enthalpy than turbine. The thermal efficiency calculated give out a result around 10% which is quite low and poor in performance. The actual thermal efficiency deviates from the theoretical one due to several reasons. For this experiment, the possible explanation is irreversibility found in the turbine. As a result, the turbine is not working at 100 % isentropic efficiency. Generally speaking, the existence of fluid friction will lowers the thermal efficiency of the cycle. Fluid friction causes the pressure to decrease in components like boiler and condenser. Hence, the steam at the outlet of the boiler will be lower in pressure, as opposite to the theory. In addition, the pressure of superheated vapour entering the turbine is lower than that of superheated vapour leaving the boiler (as demonstrated in this experiment).

Heat loss to the surrounding is another source of irreversibilities that decrease the thermal efficiency of a steam power plant. The heat loss situation is depicted in this experiment; where the heat loss causes the temperature of superheated vapour entering the super-heater lower than that of superheated vapour leaving the boiler.

To increase the efficiency of the cycle, it is suggested for the condenser pressure to be lowered. As a result, the total work output will increases. As shown in the figure 3 below, the required heat input will also increases, but in a very small increment. However, this method presents some side effects- possibility of air leakage into the condenser and increment of moisture content of the steam at turbine output. The high content of moisture will decrease the turbine efficiency and promotes the erosion of turbine blades.
Figure 3 Lowering the condenser pressure

Another method to increase the thermal efficiency is to superheat the steam to higher temperature. As presented in the figure below, this method will increases in the total work output. Besides, in oppose to the method above, superheating the steam to higher temperature will decrease the moisture content in the turbine output. However, the limitation of this method is temperature, by which the specific material
Figure 4 Super-heating the steam to higher temperature

of turbine blades can withstand.

10

Increasing the boiler pressure will too, increase the thermal efficiency of Rankine cycle. When the pressure increases, the temperature of the boiler will also increases. As a result, the temperature of the steam will be higher and hence improve the respective thermal efficiency.

While carrying out the experiment, we have to avoid parallax error. Our eyes should be perpendicular to the scale in order to avoid from recording inaccurate data. Since we are using digital measurements for the temperature, we have to make sure that the reading taken is for the correct part because a slight mistake could highly affect the calculation section. There is also system error where a sensor does not function effectively by giving out error signal while reading for the temperature inside one of the instrument. As for the pressure reading, there might be some zero error due to the mistake in calibrating the instrument. As time passed by, the temperature reading might experience some drop or increase which could cause unfixed data collected. Thus, to avoid this situation, we might be able to assigned one person for each station and recorded the data needed at the same time. We also have to be extra careful while handling the instruments because there are some instrument which have hot surfaces and may cause skin irritation.

CONCLUSION In conclusion, we were able to have an experience about the principle of operation of an actual steam power plant. We have related and have better understanding about Rankine cycle towards the mini plant as well. Data collected during this experiment is use to generate result of Rankine boiler efficiency. By doing so, it require students to apply the formula for Rankine boiler and technical theory in analysing the result. Some important facts about power plant have also been explored. Thus, provide students a clear picture of a steam plant before going working in a real plant.

11