1

EXPERIMENT # 01

To study the boiler by using the Boiler Model

TH 101
 2

EXPERIMENT # 01
Objective:
To study the boiler by using the Boiler Model TH 101

Apparatus:
• TH 101 Training Boiler
Theory:
Training Boiler System
A boiler may be used in power generation industry where the steam is used on a
prime mover such as a steam turbine for power generation. The boiler may also used in other
industries where the steam is used in a process such as a heat exchanger.

The exhausted steam can be then exhausted to atmosphere or recovered by using a

condenser and a cooling tower.

For a training boiler set, at least a resin filter is required for the feed water to the
boiler. Steam from the boiler can be used in many ways depending on optional equipment:

• A super heater
• A prime mover
• A process or a condenser for heat exchange
 3

Boiler Principles
Some important terminologies are as follows:

Steam
Changing the property of water from a liquid state into a vapor state when
boiling creates steam. The steam created by the boiling of water in an open space will have a
temperature of 100 °C (212 °F).

But if the boiling is done in an enclosed space, the created vapor has no way
to escape and it will compress itself causing pressurization. The temperature will increase likewise
and become higher than the original temperature.

Dry or superheated steam

Dry or superheated steam is the steam without any water mixture by further
heating of saturated steam resulting in the transformation of water mixture completely into vapor.
This vapor is called dry or cold vapor that has higher temperature than before, but the pressure
remains the same.

Steam rate
Steam rate is a capacity of boiler to produce steam in one (1) hour when the
gauge pressure reading is zero (0) or when the steam has a temperature of 100 OC (212 °F). One-
ton boiler is the boiler with evaporation capacity to produce steam of one ton per hour.

Main boiler components

Although boilers of all types may have different structures of construction, they
consist mainly of three sections namely furnace, water space and steam space as shown in Figure
2-2.
 4

A. Furnace: A furnace is an area in which combustion of fuel takes place. It is a

space which has the highest temperature within the boiler.

B. Water space: A water space is a water storage area in the boiler where the
evaporation into stream takes place. The water level in the boiler should change more than two
centimeters particularly for a fired-tube boiler. In the case of two boilers of the same capacity, the
boiler which has less water space will be able to produce steam faster, therefore it is suitable for
use in work requiring stream in short interval and not suitable for 24 hour application. This is due
to less volume of storage water and it is likely to dry out.

C. Steam space: Steam space is a steam storage area/section normally located

above the water space section in the boiler. Steam produced by the boiler will be stored in this
space. A boiler generally produces steam at all time but is steam demand is not constant. Therefore
when the rate of steam usage is less than the production rate of the boiler, the remaining stream
will be kept in the stream storage section of the boiler. The size of this storage section will be more
or less depending upon the design of the boiler. However, for the boiler designed as manual control
on the water level inside the boiler, the boiler operator will carry a very important function of water
level control by regulating the inlet water going into the boiler.

Classification
Boilers can be classified as the fire-tube or water-tube boiler. Fire-tube boiler is
normally used in industrial applications while the water-tube boiler is for power plants.

Water-tube boiler
In water-tube boiler, the fuel is ignited and the combustion takes place in
the furnace. The hot flue gas flows through the water wall, consisting of many water tubes. The
hot water is then flows to the upper drum where it is evaporated. The steam generated in the upper
drum can be delivered to steam utilizing devices or to the super heater.

Horizontal fire-tube boiler

In this type of boiler, the fuel is ignited and the combustion takes place in
the combustion chamber. The hot flue gas flows through the big fired tube and /or small fired
tube(s). The flow may be either 1, 2, 3 or 4 passes depending on the design as shown in Figure 2-
3 below.
 5

Today, the horizontal tube boiler is very widely used in the general industry.
There are many kinds of construction in this type of boiler. Package boiler is a popular boiler in
this type for small-scale industry located in the city or urban area with good infrastructure due to
the requirement for transportation of fuel such as diesel oil, furnace fuel and gas. It is very strong
in construction structure consisting of all necessary equipment for a boiler and is completely built
at the factory.

Thermodynamics of Training Boiler

The thermodynamic process diagram of the training boiler is as per Figure 2-4.

The thermodynamic processes are as follows:

• Feed water is at atmospheric pressure pa, Temperature T1 and has an

enthalpy of ho.
• After the feed pump, the water pressure increases to p1 at temperature T1
and has an enthalpy of h1.
• Heat is supplied to the boiler by fuel. The saturated steam pressure is p1,
temperature T2 and has an enthalpy of h2.
• When the saturated steam is further heated in a superheater, its pressure
remains at p1, temperature increases to T3, and enthalpy increases to h3.
• When the steam is throttled before the turbine, its enthalpy is assumed to
remain unchanged at h3 but the pressure and temperature change to p2 and
 6

T4. At this point, the super heated steam becomes further super heated or
the saturated steam becomes super heated.
• When the steam is used to drive a steam turbine or steam engine, there is a
power output Wo and the steam pressure, temperature and enthalpy reduce
to p3 (or pa), T5 and h4 respectively. The pressure p3 may now be
atmospheric pressure pa or below depending on the condenser position.
• When the condenser is cooled by water from the cooling tower, the steam
is condensed to an atmospheric pressure pa, temperature T6 (the actual
temperature is about 100o or slightly below), and the enthalpy is h5.
• When the condensate is returned to the feed water tank, it is mixed with
incoming feed water from the filter and the temperature becomes T1 and
enthalpy ho at pressure pa.

Symbols
h0 = Enthalpy of the feed water kJ/kg
h1 = Enthalpy of water after the feed pump kJ/kg
h2 = Enthalpy of saturated steam leaving the boiler kJ/kg
h3 = Enthalpy of steam leaving the superheater kJ/kg
h3 = Enthalpy of steam entering the steam turbine or engine kJ/kg
h4 = Enthalpy of steam leaving the turbine or engine kJ/kg
h5 = Enthalpy of the condensate kJ/kg
h6 = Enthalpy of cooling water entering the condenser kJ/kg
h7 = Enthalpy of cooling water leaving the condenser kJ/kg
hlb = Enthalpy loss of radiation, convection kJ/kg
hle = Enthalpy loss of radiation, kJ/kg
hlc = Enthalpy loss of radiation, convection at the condenser kJ/kg
pa = Atmospheric pressure kg/cm2
p1 = Boiler pressure kg/cm 2
p2 = Steam turbine/engine inlet pressure kg/cm2
p3 = Steam turbine/engine outlet pressure kg/cm2
T1 = Feed water temperature oC
T2 = Saturated steam temperature oC
T3 = Super heated steam temperature oC
T4 = Temperature of steam entering the prime mover oC
T5 = Temperature of steam leaving the prime mover oC
T6 = Temperature of condensate oC
T7 = Temperature of cooling water inlet to condenser oC
T8 = Temperature of cooling water outlet from condenser oC
T9 = Stack temperature oC
Tw = Wet bulb temperature oC
qf = Volume flow rate of the fuel lpm
qw = Volume flow rate of cooling water lpm
mf = Mass flow rate of the fuel kg/min
mc = Flow rate of the condensate (=feed water flow rate, Ws) kg/min
mw = Flow rate of cooling water kg/min
Qf = Low heating value of the fuel kJ/kg
 7

Ws = Feed water flow rate = mc kg/min

F = Dynamometer load N
Pi = Indicated power Watt
Pom = Mechanical power Watt
Tq = Dynamometer torque= F x r N-m
R = Radius of the dynamometer m.
N = Engine speed rpm
Nd = Dynamo speed rpm
Poe = Electrical power Watt
I = Generator current A
V = Generator voltage V
ηb = Boiler efficiency %
ηth = Thermal efficiency of the steam engine %
ηm = Engine efficiency of the steam engine %
ηom = Overall power plant efficiency (mechanical) %
ηoe = Overall power plant efficiency (electric) %
ηc = Condenser heat transfer efficiency %
ηct = Cooling tower efficiency
 8

EXPERIMENT # 02

Determine the efficiency of water tube

saturated boiler by using the Boiler Model
TH 101
 9

EXPERIMENT # 02
Objective:
Determine the efficiency of water tube saturated boiler by using the Boiler Model
TH 101

Apparatus:
• TH 101 Training Boiler
Procedure:
a) Softener tank
First close all valves.

Operation

i. Open valves no.1, no.5 and no. 11 until water is observed coming out from over
flow valve no.11.
ii. Close valve no.11 and open valve no.10 to release water for a few minutes.
iii. Close valve no.10 to allow the tank to fill with water.

Cleaning
iv. Close valves no.5, no.8 and then open valves no.6 and no.7 slowly for a few minutes
until clear water is observed.
v. Close valves no.6, no.7 after then open valves no.10 and no.11 to drain water from
the softener tank until it is empty dry and then close valve no.10.

Clean the softener tank with salt

vi. To add some sodium chloride in water and stir until it becomes a saline. After that
connect the saline by rubber tube to valve no. 4.
vii. Open valves no. 2 and no. 3 and close valve no.1 to fill the softener tank with saline
and open valve no.4 to allow saline solution to flow through valve no.2 to the
softener tank until it is full and then observe the over flow from valve no.11.
viii. Open valve no.10 and close valve no.11 to allow the saline to over flow through
valve no. 10 then close valves no.10, no.2, no.3 and no.4 so the tank absorbs saline
for about 3-5 minutes.
 10

Washing the saline is done as follows

ix. Open valves no.10 and no.11 to drain the saline then turn off valve no.10.
x. Open valves no.1 and no.5 to fill the tank until water flows out from valve no.11.
xi. Open valves no.6 and no.7 slowly then close valve no.5 and valve no.11 to drain
water for a few minutes.
xii. Close valves no. 7, no.6 and then open valves no.5, no.11 until the tank is full and
water flow from valve no. 11.
xiii. Open valve no. 10 and close valve no. 11 to release saline around 5-10 minute or
until no salt can be tasted.

To check water hardness

xiv. Use a solution to check water hardness at valve no.10.
xv. If water coming out is violet, it is not useable.
xvi. If water coming out is green, sky blue, or blue, it is useable.
xvii. Open valve no.8 close valve no.10 to deliver water to next process.

Feed Water System

xviii. Close all valves at water tank.
xix. Open valves no.12 and no.13 and observe water level in the water tank to ensure
there is sufficient water to operate the boiler.
xx. Open valve no.15 and start the pump to deliver water to steam boiler.
b) Fuel Supply System
i. Close all valves of fuel supply.
ii. Open valves no. 44 and no. 45 and observe the fuel level in the fuel storage tank to
ensure enough fuel.
iii. Fuel is distributed 3 ways:

o Firstly to burner of steam boiler via an oil meter by turning on valves no. 46,
no. 50 and close valve no. 47.
o Secondly to burner of steam boiler by-passing oil meter by closing off valves
no.47and no. 50 and close valve no. 47.
o Thirdly to burner of superheated steam boiler via oil meter by opening on valves
no. 46 and no. 49.

c) Steam Boiler
The boiler maximum pressure is 10 kg/cm2 gauge. However, for safety and long service,
the working pressure is set at the factory to operate between 6 and 7 bar gauge.

i. Close all valves of the steam system.

 11

ii. On the Main Breaker and Circuit Breaker, inside the control panel.
iii. Open valve no.16 to operate feed water pump by turning the switch to “AUTO”
and observe the water level at the sight glass of the steam boiler.
iv. To release fuel to fuel supply system, see the previous section above.
v. Start the burner by turning on switch at burner to “ON” (automatic operation).
vi. Wait until pressure rises to the required level.
vii. Steam can be distributed 3 ways:

o To superheater by turning on valve no. 18.

o To condenser by turning on valve no. 19.
o To blow down by turning on valve no. 20.

d) To Start the Boiler

i. Close the feed water tank outlet valve and the fuel tank outlet valve.
ii. Open the boiler outlet valve to relief vacuum, if any, and then close the valve.
iii. Start the boiler.
iv. Open the resin filter valves to allow softened water to the feed water tank. (see
4.1.1)
v. Open the fuel tank outlet valve.
vi. Open the feed water tank outlet valve.
vii. Wait until boiler set pressure is reached before slowly open the boiler outlet valve
to obtain required steam rate, e.g. 50 kg/hr.
e) Boiler Test
i. Ensure that the steam outlet is connected to a prime mover or a heat exchanger
(condenser) or vented to atmosphere.
ii. Slowly open the steam outlet valve to a steady condition with steam rate of a bout
50 kg/hr
iii. Record: - Feed water temperature oC.
iv. Steam pressure. (Both steam pressure and temperature can be used as a reference
for determining steam enthalpy. However, steam pressure is more reliable.)
v. Fuel flow rate (lpm) (see relevant theory 3.3).
vi. Feed water flow volume (l) and time (s) (see relevant theory 3.4).
vii. Repeat at different steam rate and/or pressure.
viii. Calculate: - Power input from fuel consumption.
ix. Power gained by the steam.
f) Boiler efficiency
i. To Start the Superheater
ii. Close the superheater steam outlet valve.
iii. When the boiler set pressure is reached, start the superheater.
iv. Open the boiler outlet valve in full.
v. After the superheater set temperature is reached, open the superheater outlet valve
slowly to obtained required steam rate, e.g. 50 kg/hr.
vi. The super-heater is now ready for the test.
 12

g) Shut Down
i. Boiler shut down.
ii. Close the feed water and fuel valves to the boiler.
iii. Turn off the boiler.
iv. Condenser and cooling tower.
v. Close the condenser steam inlet valve and condenser cooling water inlet valve.
vi. Turn off the cooling water pump
vii. Turn off the cooling tower circulating water pump.
Observation:

Calculation:

Boiler Efficiency

Enthalpy of saturated steam from the boiler − Enthalpy of feed water

ηb = × 100
Heat from fuel

h1 can be determined from the equation below:

h1 = h0 + (p1-pa) × v0

v0 = specific volume of saturated feed water at T1

 13

EXPERIMENT # 03

Determine the efficiency of water tube

superheated boiler by using the Boiler Model
TH 101
 14

EXPERIMENT # 03
Objective:
Determine the efficiency of water tube superheated boiler by using the Boiler
Model TH 101

Apparatus:
• TH 101 Training Boiler
Procedure:
a) Softener tank
First close all valves.

Operation

i. Open valves no.1, no.5 and no. 11 until water is observed coming out from over
flow valve no.11.
ii. Close valve no.11 and open valve no.10 to release water for a few minutes.
iii. Close valve no.10 to allow the tank to fill with water.

Cleaning
iv. Close valves no.5, no.8 and then open valves no.6 and no.7 slowly for a few minutes
until clear water is observed.
v. Close valves no.6, no.7 after then open valves no.10 and no.11 to drain water from
the softener tank until it is empty dry and then close valve no.10.

Clean the softener tank with salt

vi. To add some sodium chloride in water and stir until it becomes a saline. After that
connect the saline by rubber tube to valve no. 4.
vii. Open valves no. 2 and no. 3 and close valve no.1 to fill the softener tank with saline
and open valve no.4 to allow saline solution to flow through valve no.2 to the
softener tank until it is full and then observe the over flow from valve no.11.
viii. Open valve no.10 and close valve no.11 to allow the saline to over flow through
valve no. 10 then close valves no.10, no.2, no.3 and no.4 so the tank absorbs saline
for about 3-5 minutes.
 15

Washing the saline is done as follows

ix. Open valves no.10 and no.11 to drain the saline then turn off valve no.10.
x. Open valves no.1 and no.5 to fill the tank until water flows out from valve no.11.
xi. Open valves no.6 and no.7 slowly then close valve no.5 and valve no.11 to drain
water for a few minutes.
xii. Close valves no. 7, no.6 and then open valves no.5, no.11 until the tank is full and
water flow from valve no. 11.
xiii. Open valve no. 10 and close valve no. 11 to release saline around 5-10 minute or
until no salt can be tasted.

To check water hardness

xiv. Use a solution to check water hardness at valve no.10.
xv. If water coming out is violet, it is not useable.
xvi. If water coming out is green, sky blue, or blue, it is useable.
xvii. Open valve no.8 close valve no.10 to deliver water to next process.

Feed Water System

xviii. Close all valves at water tank.
xix. Open valves no.12 and no.13 and observe water level in the water tank to ensure
there is sufficient water to operate the boiler.
xx. Open valve no.15 and start the pump to deliver water to steam boiler.
b) Fuel Supply System
i. Close all valves of fuel supply.
ii. Open valves no. 44 and no. 45 and observe the fuel level in the fuel storage tank to
ensure enough fuel.
iii. Fuel is distributed 3 ways:

o Firstly to burner of steam boiler via an oil meter by turning on valves no. 46,
no. 50 and close valve no. 47.
o Secondly to burner of steam boiler by-passing oil meter by closing off valves
no.47and no. 50 and close valve no. 47.
o Thirdly to burner of superheated steam boiler via oil meter by opening on valves
no. 46 and no. 49.

c) Steam Boiler
The boiler maximum pressure is 10 kg/cm2 gauge. However, for safety and long service,
the working pressure is set at the factory to operate between 6 and 7 bar gauge.

i. Close all valves of the steam system.

 16

ii. On the Main Breaker and Circuit Breaker, inside the control panel.
iii. Open valve no.16 to operate feed water pump by turning the switch to “AUTO”
and observe the water level at the sight glass of the steam boiler.
iv. To release fuel to fuel supply system, see the previous section above.
v. Start the burner by turning on switch at burner to “ON” (automatic operation).
vi. Wait until pressure rises to the required level.
vii. Steam can be distributed 3 ways:

o To superheater by turning on valve no. 18.

o To condenser by turning on valve no. 19.
o To blow down by turning on valve no. 20.

d) Superheated Steam System

The superheater maximum pressure is 10 kg/cm2 gauge. However, it is to operate at the

same operating pressure as the boiler.

i. Turn off all valves on the superheated steam boiler.

ii. On the Main Breaker and Circuit Breaker, inside the control panel.
iii. Reset the Emergency Switch by pressing and turning it clockwise. Press the Control
Voltage Lamp Switch.
iv. Open valves no. 40, no. 41, no. 42 and no. 43 so observe and control pressures of
steam inlet and outlet of superheated steam boiler (P2 and P3).
v. To release fuel to fuel supply system, see the previous section above.
vi. Set the superheated steam temperature to 270 oC by using the Temperature
Controller.
vii. Set the Stack temperature to 300 oC by using the Temperature Controller.
viii. Open valve no.18 to start.
ix. To adjust temperature of superheated steam by adjusting the controller at control
panel.
x. To operate the burner, turn on the switch of the force draft fan to the “ON” position
after that turn on the burner switch to “FULL LOAD” position (OFF, PAR, FULL)
for automatic operation.
xi. Superheated steam can be distributed in 2 ways:

o To condenser, open valve no. 21.

o To blow down, open valve no. 22.

e) To Start the Boiler

i. Close the feed water tank outlet valve and the fuel tank outlet valve.
ii. Open the boiler outlet valve to relief vacuum, if any, and then close the valve.
iii. Start the boiler.
iv. Open the resin filter valves to allow softened water to the feed water tank. (see
4.1.1)
 17

v. Open the fuel tank outlet valve.

vi. Open the feed water tank outlet valve.
vii. Wait until boiler set pressure is reached before slowly open the boiler outlet valve
to obtain required steam rate, e.g. 50 kg/hr.
f) Boiler Test
i. Ensure that the steam outlet is connected to a prime mover or a heat exchanger
(condenser) or vented to atmosphere.
ii. Slowly open the steam outlet valve to a steady condition with steam rate of about
50 kg/hr
iii. Record: - Feed water temperature oC.
iv. Steam pressure. (Both steam pressure and temperature can be used as a reference
for determining steam enthalpy. However, steam pressure is more reliable.)
v. Fuel flow rate (lpm) (see relevant theory 3.3).
vi. Feed water flow volume (l) and time (s) (see relevant theory 3.4).
vii. Repeat at different steam rate and/or pressure.
viii. Calculate: - Power input from fuel consumption.
ix. Power gained by the steam.
g) Boiler efficiency
i. To Start the Superheater
ii. Close the superheater steam outlet valve.
iii. When the boiler set pressure is reached, start the superheater.
iv. Open the boiler outlet valve in full.
v. After the superheater set temperature is reached, open the superheater outlet valve
slowly to obtained required steam rate, e.g. 50 kg/hr.
vi. The super-heater is now ready for the test.
h) To Start the Super heater
i. Close the super heater steam outlet valve.
ii. When the boiler set pressure is reached, start the super heater.
iii. Open the boiler outlet valve in full.
iv. After the super heater set temperature is reached, open the super heater outlet valve
slowly to obtained required steam rate, e.g. 50 kg/hr.
v. The super heater is now ready for the test.
i) Super heater Test
i. Record data as in 5.4.2 and also temperature and pressure for both boiler and super
heater.
ii. The increase in fuel consumption from boiler test alone is attributed to super heater.
iii. Repeat 5.5.1 at different steam rate, pressure and super heater temperature
iv. Calculate:

o Power input from additional fuel consumption.

o Power gained by the superheated steam.
o Super heater efficiency.
 18

j) Shut Down
i. Boiler shut down.
ii. Close the feed water and fuel valves to the boiler.
iii. Turn off the boiler.
iv. Condenser and cooling tower.
v. Close the condenser steam inlet valve and condenser cooling water inlet valve.
vi. Turn off the cooling water pump
vii. Turn off the cooling tower circulating water pump.

Observation:
 19

Calculation:

Boiler Efficiency

Enthalpy of saturated steam from the boiler − Enthalpy of feed water

ηb = × 100
Heat from fuel

h1 can be determined from the equation below:

h1 = h0 + (p1-pa) × v0

v0 = specific volume of saturated feed water at T1

Super Heater Efficiency

Super heater efficiency is determined in the same manner as the boiler efficiency. In this case, the
steam rate is assumed to be the same as boiler, and the fuel consumption is determined the same
manner as the boiler if there is a separate fuel meter or determined from the increase in fuel
consumption in the case that the superheater uses the same fuel meter as the boiler.
 20

EXPERIMENT # 04

By using the water tube steam boiler Model

TH 101, determine the following
a) Energy Input to Condenser.
b) Energy Output from Condenser.
c) Energy Loss in Condenser due to Radiation.
d) Efficiency of Condenser
 21

EXPERIMENT # 04
Objective:
By using the water tube steam boiler Model TH 101, determine the following

a) Energy Input to Condenser.

b) Energy Output from Condenser.
c) Energy Loss in Condenser due to Radiation.
d) Efficiency of Condenser

Apparatus:
• TH 101 Training Boiler
Procedure:
a) Softener tank
First close all valves.

Operation

i. Open valves no.1, no.5 and no. 11 until water is observed coming out from over
flow valve no.11.
ii. Close valve no.11 and open valve no.10 to release water for a few minutes.
iii. Close valve no.10 to allow the tank to fill with water.

Cleaning
iv. Close valves no.5, no.8 and then open valves no.6 and no.7 slowly for a few minutes
until clear water is observed.
v. Close valves no.6, no.7 after then open valves no.10 and no.11 to drain water from
the softener tank until it is empty dry and then close valve no.10.

Clean the softener tank with salt

vi. To add some sodium chloride in water and stir until it becomes a saline. After that
connect the saline by rubber tube to valve no. 4.
vii. Open valves no. 2 and no. 3 and close valve no.1 to fill the softener tank with saline
and open valve no.4 to allow saline solution to flow through valve no.2 to the
softener tank until it is full and then observe the over flow from valve no.11.
 22

viii. Open valve no.10 and close valve no.11 to allow the saline to over flow through
valve no. 10 then close valves no.10, no.2, no.3 and no.4 so the tank absorbs saline
for about 3-5 minutes.

Washing the saline is done as follows

ix. Open valves no.10 and no.11 to drain the saline then turn off valve no.10.
x. Open valves no.1 and no.5 to fill the tank until water flows out from valve no.11.
xi. Open valves no.6 and no.7 slowly then close valve no.5 and valve no.11 to drain
water for a few minutes.
xii. Close valves no. 7, no.6 and then open valves no.5, no.11 until the tank is full and
water flow from valve no. 11.
xiii. Open valve no. 10 and close valve no. 11 to release saline around 5-10 minute or
until no salt can be tasted.

To check water hardness

xiv. Use a solution to check water hardness at valve no.10.
xv. If water coming out is violet, it is not useable.
xvi. If water coming out is green, sky blue, or blue, it is useable.
xvii. Open valve no.8 close valve no.10 to deliver water to next process.

Feed Water System

xviii. Close all valves at water tank.
xix. Open valves no.12 and no.13 and observe water level in the water tank to ensure
there is sufficient water to operate the boiler.
xx. Open valve no.15 and start the pump to deliver water to steam boiler.
b) Fuel Supply System
i. Close all valves of fuel supply.
ii. Open valves no. 44 and no. 45 and observe the fuel level in the fuel storage tank to
ensure enough fuel.
iii. Fuel is distributed 3 ways:

o Firstly to burner of steam boiler via an oil meter by turning on valves no. 46,
no. 50 and close valve no. 47.
o Secondly to burner of steam boiler by-passing oil meter by closing off valves
no.47and no. 50 and close valve no. 47.
o Thirdly to burner of superheated steam boiler via oil meter by opening on valves
no. 46 and no. 49.

c) Steam Boiler
The boiler maximum pressure is 10 kg/cm2 gauge. However, for safety and long service,
the working pressure is set at the factory to operate between 6 and 7 bar gauge.
 23

i. Close all valves of the steam system.

ii. On the Main Breaker and Circuit Breaker, inside the control panel.
iii. Open valve no.16 to operate feed water pump by turning the switch to “AUTO”
and observe the water level at the sight glass of the steam boiler.
iv. To release fuel to fuel supply system, see the previous section above.
v. Start the burner by turning on switch at burner to “ON” (automatic operation).
vi. Wait until pressure rises to the required level.
vii. Steam can be distributed 3 ways:

o To superheater by turning on valve no. 18.

o To condenser by turning on valve no. 19.
o To blow down by turning on valve no. 20.

d) Superheated Steam System

The superheater maximum pressure is 10 kg/cm2 gauge. However, it is to operate at the
same operating pressure as the boiler.

i. Turn off all valves on the superheated steam boiler.

ii. On the Main Breaker and Circuit Breaker, inside the control panel.
iii. Reset the Emergency Switch by pressing and turning it clockwise. Press the Control
Voltage Lamp Switch.
iv. Open valves no. 40, no. 41, no. 42 and no. 43 so observe and control pressures of
steam inlet and outlet of superheated steam boiler (P2 and P3).
v. To release fuel to fuel supply system, see the previous section above.
vi. Set the superheated steam temperature to 270 oC by using the Temperature
Controller.
vii. Set the Stack temperature to 300 oC by using the Temperature Controller.
viii. Open valve no.18 to start.
ix. To adjust temperature of superheated steam by adjusting the controller at control
panel.
x. To operate the burner, turn on the switch of the force draft fan to the “ON” position
after that turn on the burner switch to “FULL LOAD” position (OFF, PAR, FULL)
for automatic operation.
xi. Superheated steam can be distributed in 2 ways:

o To condenser, open valve no. 21.

o To blow down, open valve no. 22.

e) Condenser System
i. Close all valves at the condenser unit and condensate tank.
ii. Transfer cooling water to condenser system by opening valve no.33 and drain
transfer water out by open valve no. 35.
iii. Switch on cooling water pump.
 24

iv. Cooling water used should be from mains water supply and hot cooling water after
the condenser should be discharge to the drain valve (identify). To save cooling
water used, a cooling tower is recommended (not supplied) for recirculation of
cooling water.
v. To release steam to the condenser from the boiler or superheater, see previous
above sections.
vi. Open air vent at condensate tank by valve no. 30.
vii. The condensate tank should have level gauge to observe condensate level in the
tank.
viii. Open valves no. 23, no. 24, no. 26, no. 27 and no. 29 after that switch on condensate
pump until condensate level is low.
ix. Steam in the condenser will condense to water after transferring heat to the cooling
water.
x. Steam and/or condensate is distributed in two ways:

o Blow down by opening valve no. 36.

o To steam trap and condensate tank by opening valves no. 23 and no. 24.

f) To Start the Boiler

i. Close the feed water tank outlet valve and the fuel tank outlet valve.
ii. Open the boiler outlet valve to relief vacuum, if any, and then close the valve.
iii. Start the boiler.
iv. Open the resin filter valves to allow softened water to the feed water tank. (see
4.1.1)
v. Open the fuel tank outlet valve.
vi. Open the feed water tank outlet valve.
vii. Wait until boiler set pressure is reached before slowly open the boiler outlet valve
to obtain required steam rate, e.g. 50 kg/hr.
g) Boiler Test
i. Ensure that the steam outlet is connected to a prime mover or a heat exchanger
(condenser) or vented to atmosphere.
ii. Slowly open the steam outlet valve to a steady condition with steam rate of about
50 kg/hr
iii. Record: - Feed water temperature oC.
iv. Steam pressure. (Both steam pressure and temperature can be used as a reference
for determining steam enthalpy. However, steam pressure is more reliable.)
v. Fuel flow rate (lpm) (see relevant theory 3.3).
vi. Feed water flow volume (l) and time (s) (see relevant theory 3.4).
vii. Repeat at different steam rate and/or pressure.
viii. Calculate: - Power input from fuel consumption.
ix. Power gained by the steam.
 25

h) Boiler efficiency
i. To Start the Superheater
ii. Close the superheater steam outlet valve.
iii. When the boiler set pressure is reached, start the superheater.
iv. Open the boiler outlet valve in full.
v. After the superheater set temperature is reached, open the superheater outlet valve
slowly to obtained required steam rate, e.g. 50 kg/hr.
vi. The super-heater is now ready for the test.
i) To Test the Condenser

i. Start the cooling tower water circulating pump.

ii. Close the condenser cooling water inlet valve and open the outlet valve.
iii. Start condenser cooling water pump; slightly open the inlet valve to condenser.
iv. Open the (exhausted) steam to the condenser to full (about 50 kg/hr steam).
v. Adjust the condenser cooling water flow rate such that the condenser outlet
temperature is below 80oC.
vi. The condenser is now ready for the test.

j) Condenser and Cooling Tower Test

i. Data can be taken only after conditions in the condenser are steady. This includes
measurement of steam rate from the condensate collection. Alternatively, steam
rate can be calculated from the feed water pump run after one completes cycle of
the run.
ii. Record data as in 5.4.2 or 5.6.1 if superheater is used.
iii. Record flow rate of cooling tower, temperature of cooling water in and out from
cooling tower and wet bulb temperature.

k) Shut Down
i. Boiler shut down.
ii. Close the feed water and fuel valves to the boiler.
iii. Turn off the boiler.
iv. Condenser and cooling tower.
v. Close the condenser steam inlet valve and condenser cooling water inlet valve.
vi. Turn off the cooling water pump
vii. Turn off the cooling tower circulating water pump.
 26

Observation:
 27

Calculation:

Boiler Efficiency

Enthalpy of saturated steam from the boiler − Enthalpy of feed water

ηb = × 100
Heat from fuel

h1 can be determined from the equation below:

h1 = h0 + (p1-pa) × v0

v0 = specific volume of saturated feed water at T1

Super Heater Efficiency

Super heater efficiency is determined in the same manner as the boiler efficiency. In this case, the
steam rate is assumed to be the same as boiler, and the fuel consumption is determined the same
manner as the boiler if there is a separate fuel meter or determined from the increase in fuel
consumption in the case that the superheater uses the same fuel meter as the boiler.

Condenser Heat Transfer Efficiency

Cooling Efficiency of Cooling Tower

 28

EXPERIMENT # 05

To verify the pressure and temperature

relationship for saturated steam and draw a
graph between pressure and temperature at
water tube steam boiler Model TH 101
 29

EXPERIMENT # 05
Objective:
To verify the pressure and temperature relationship for saturated steam and draw a
graph between pressure and temperature at water tube steam boiler Model TH 101

Apparatus:
• TH 101 Training Boiler
Procedure:
a) Softener tank
First close all valves.

Operation

i. Open valves no.1, no.5 and no. 11 until water is observed coming out from over
flow valve no.11.
ii. Close valve no.11 and open valve no.10 to release water for a few minutes.
iii. Close valve no.10 to allow the tank to fill with water.

Cleaning
iv. Close valves no.5, no.8 and then open valves no.6 and no.7 slowly for a few minutes
until clear water is observed.
v. Close valves no.6, no.7 after then open valves no.10 and no.11 to drain water from
the softener tank until it is empty dry and then close valve no.10.

Clean the softener tank with salt

vi. To add some sodium chloride in water and stir until it becomes a saline. After that
connect the saline by rubber tube to valve no. 4.
vii. Open valves no. 2 and no. 3 and close valve no.1 to fill the softener tank with saline
and open valve no.4 to allow saline solution to flow through valve no.2 to the
softener tank until it is full and then observe the over flow from valve no.11.
viii. Open valve no.10 and close valve no.11 to allow the saline to over flow through
valve no. 10 then close valves no.10, no.2, no.3 and no.4 so the tank absorbs saline
for about 3-5 minutes.
 30

Washing the saline is done as follows

ix. Open valves no.10 and no.11 to drain the saline then turn off valve no.10.
x. Open valves no.1 and no.5 to fill the tank until water flows out from valve no.11.
xi. Open valves no.6 and no.7 slowly then close valve no.5 and valve no.11 to drain
water for a few minutes.
xii. Close valves no. 7, no.6 and then open valves no.5, no.11 until the tank is full and
water flow from valve no. 11.
xiii. Open valve no. 10 and close valve no. 11 to release saline around 5-10 minute or
until no salt can be tasted.

To check water hardness

xiv. Use a solution to check water hardness at valve no.10.
xv. If water coming out is violet, it is not useable.
xvi. If water coming out is green, sky blue, or blue, it is useable.
xvii. Open valve no.8 close valve no.10 to deliver water to next process.

Feed Water System

xviii. Close all valves at water tank.
xix. Open valves no.12 and no.13 and observe water level in the water tank to ensure
there is sufficient water to operate the boiler.
xx. Open valve no.15 and start the pump to deliver water to steam boiler.
a) Fuel Supply System
iv. Close all valves of fuel supply.
v. Open valves no. 44 and no. 45 and observe the fuel level in the fuel storage tank to
ensure enough fuel.
vi. Fuel is distributed 3 ways:

o Firstly to burner of steam boiler via an oil meter by turning on valves no. 46,
no. 50 and close valve no. 47.
o Secondly to burner of steam boiler by-passing oil meter by closing off valves
no.47and no. 50 and close valve no. 47.
o Thirdly to burner of superheated steam boiler via oil meter by opening on valves
no. 46 and no. 49.

b) Steam Boiler
The boiler maximum pressure is 10 kg/cm2 gauge. However, for safety and long service,
the working pressure is set at the factory to operate between 6 and 7 bar gauge.

i. Close all valves of the steam system.

 31

ii. On the Main Breaker and Circuit Breaker, inside the control panel.
iii. Open valve no.16 to operate feed water pump by turning the switch to “AUTO”
and observe the water level at the sight glass of the steam boiler.
iv. To release fuel to fuel supply system, see the previous section above.
v. Start the burner by turning on switch at burner to “ON” (automatic operation).
vi. Wait until pressure rises to the required level.
vii. Steam can be distributed 3 ways:

o To superheater by turning on valve no. 18.

o To condenser by turning on valve no. 19.
o To blow down by turning on valve no. 20.

c) Superheated Steam System

The superheater maximum pressure is 10 kg/cm2 gauge. However, it is to operate at the

same operating pressure as the boiler.

i. Turn off all valves on the superheated steam boiler.

ii. On the Main Breaker and Circuit Breaker, inside the control panel.
iii. Reset the Emergency Switch by pressing and turning it clockwise. Press the Control
Voltage Lamp Switch.
iv. Open valves no. 40, no. 41, no. 42 and no. 43 so observe and control pressures of
steam inlet and outlet of superheated steam boiler (P2 and P3).
v. To release fuel to fuel supply system, see the previous section above.
vi. Set the superheated steam temperature to 270 oC by using the Temperature
Controller.
vii. Set the Stack temperature to 300 oC by using the Temperature Controller.
viii. Open valve no.18 to start.
ix. To adjust temperature of superheated steam by adjusting the controller at control
panel.
x. To operate the burner, turn on the switch of the force draft fan to the “ON” position
after that turn on the burner switch to “FULL LOAD” position (OFF, PAR, FULL)
for automatic operation.
xi. Superheated steam can be distributed in 2 ways:

o To condenser, open valve no. 21.

o To blow down, open valve no. 22.

d) Condenser System
i. Close all valves at the condenser unit and condensate tank.
ii. Transfer cooling water to condenser system by opening valve no.33 and drain
transfer water out by open valve no. 35.
iii. Switch on cooling water pump.
 32

iv. Cooling water used should be from mains water supply and hot cooling water after
the condenser should be discharge to the drain valve (identify). To save cooling
water used, a cooling tower is recommended (not supplied) for recirculation of
cooling water.
v. To release steam to the condenser from the boiler or superheater, see previous
above sections.
vi. Open air vent at condensate tank by valve no. 30.
vii. The condensate tank should have level gauge to observe condensate level in the
tank.
viii. Open valves no. 23, no. 24, no. 26, no. 27 and no. 29 after that switch on condensate
pump until condensate level is low.
ix. Steam in the condenser will condense to water after transferring heat to the cooling
water.
x. Steam and/or condensate is distributed in two ways:

o Blow down by opening valve no. 36.

o To steam trap and condensate tank by opening valves no. 23 and no. 24.

e) To Start the Boiler

i. Close the feed water tank outlet valve and the fuel tank outlet valve.
ii. Open the boiler outlet valve to relief vacuum, if any, and then close the valve.
iii. Start the boiler.
iv. Open the resin filter valves to allow softened water to the feed water tank. (see
4.1.1)
v. Open the fuel tank outlet valve.
vi. Open the feed water tank outlet valve.
vii. Wait until boiler set pressure is reached before slowly open the boiler outlet valve
to obtain required steam rate, e.g. 50 kg/hr.
f) Boiler Test
i. Ensure that the steam outlet is connected to a prime mover or a heat exchanger
(condenser) or vented to atmosphere.
ii. Slowly open the steam outlet valve to a steady condition with steam rate of a bout
50 kg/hr
iii. Record: - Feed water temperature oC.
iv. Steam pressure. (Both steam pressure and temperature can be used as a reference
for determining steam enthalpy. However, steam pressure is more reliable.)
v. Fuel flow rate (lpm) (see relevant theory 3.3).
vi. Feed water flow volume (l) and time (s) (see relevant theory 3.4).
vii. Repeat at different steam rate and/or pressure.
viii. Calculate: - Power input from fuel consumption.
ix. Power gained by the steam.
g) Boiler efficiency
i. To Start the Superheater
 33

ii. Close the superheater steam outlet valve.

iii. When the boiler set pressure is reached, start the superheater.
iv. Open the boiler outlet valve in full.
v. After the superheater set temperature is reached, open the superheater outlet valve
slowly to obtained required steam rate, e.g. 50 kg/hr.
vi. The super-heater is now ready for the test.
h) Shut Down
i. Boiler shut down.
ii. Close the feed water and fuel valves to the boiler.
iii. Turn off the boiler.
iv. Condenser and cooling tower.
v. Close the condenser steam inlet valve and condenser cooling water inlet valve.
vi. Turn off the cooling water pump
vii. Turn off the cooling tower circulating water pump.

Observation:
 34

Graph:

Pressure & Temperature Relationship

0.016

0.014

0.012
Pressure (bar)

0.01

0.008

0.006

0.004

0.002

0
0 2 4 6 8 10 12 14

Temperature (C)
 35

EXPERIMENT # 06

Determine the heat balance at water tube

steam boiler Model TH 101
 36

EXPERIMENT # 06
Objective:
Determine the heat balance at water tube steam boiler Model TH 101

Apparatus:
• TH 101 Training Boiler
Procedure:
b) Softener tank
First close all valves.

Operation
xxi. Open valves no.1, no.5 and no. 11 until water is observed coming out from over
flow valve no.11.
xxii. Close valve no.11 and open valve no.10 to release water for a few minutes.
xxiii. Close valve no.10 to allow the tank to fill with water.

Cleaning

xxiv. Close valves no.5, no.8 and then open valves no.6 and no.7 slowly for a few minutes
until clear water is observed.
xxv. Close valves no.6, no.7 after then open valves no.10 and no.11 to drain water from
the softener tank until it is empty dry and then close valve no.10.

Clean the softener tank with salt

xxvi. To add some sodium chloride in water and stir until it becomes a saline. After that
connect the saline by rubber tube to valve no. 4.
xxvii. Open valves no. 2 and no. 3 and close valve no.1 to fill the softener tank with saline
and open valve no.4 to allow saline solution to flow through valve no.2 to the
softener tank until it is full and then observe the over flow from valve no.11.
xxviii. Open valve no.10 and close valve no.11 to allow the saline to over flow through
valve no. 10 then close valves no.10, no.2, no.3 and no.4 so the tank absorbs saline
for about 3-5 minutes.
 37

Washing the saline is done as follows

xxix. Open valves no.10 and no.11 to drain the saline then turn off valve no.10.
xxx. Open valves no.1 and no.5 to fill the tank until water flows out from valve no.11.
xxxi. Open valves no.6 and no.7 slowly then close valve no.5 and valve no.11 to drain
water for a few minutes.
xxxii. Close valves no. 7, no.6 and then open valves no.5, no.11 until the tank is full and
water flow from valve no. 11.
xxxiii. Open valve no. 10 and close valve no. 11 to release saline around 5-10 minute or
until no salt can be tasted.

To check water hardness

xxxiv. Use a solution to check water hardness at valve no.10.
xxxv. If water coming out is violet, it is not useable.
xxxvi. If water coming out is green, sky blue, or blue, it is useable.
xxxvii. Open valve no.8 close valve no.10 to deliver water to next process.

Feed Water System

xxxviii. Close all valves at water tank.
xxxix. Open valves no.12 and no.13 and observe water level in the water tank to ensure
there is sufficient water to operate the boiler.
xl. Open valve no.15 and start the pump to deliver water to steam boiler.
l) Fuel Supply System
iv. Close all valves of fuel supply.
v. Open valves no. 44 and no. 45 and observe the fuel level in the fuel storage tank to
ensure enough fuel.
vi. Fuel is distributed 3 ways:

o Firstly to burner of steam boiler via an oil meter by turning on valves no. 46,
no. 50 and close valve no. 47.
o Secondly to burner of steam boiler by-passing oil meter by closing off valves
no.47and no. 50 and close valve no. 47.
o Thirdly to burner of superheated steam boiler via oil meter by opening on valves
no. 46 and no. 49.

m) Steam Boiler

The boiler maximum pressure is 10 kg/cm2 gauge. However, for safety and long service,
the working pressure is set at the factory to operate between 6 and 7 bar gauge.

viii. Close all valves of the steam system.

ix. On the Main Breaker and Circuit Breaker, inside the control panel.
 38

x. Open valve no.16 to operate feed water pump by turning the switch to “AUTO”
and observe the water level at the sight glass of the steam boiler.
xi. To release fuel to fuel supply system, see the previous section above.
xii. Start the burner by turning on switch at burner to “ON” (automatic operation).
xiii. Wait until pressure rises to the required level.
xiv. Steam can be distributed 3 ways:

o To superheater by turning on valve no. 18.

o To condenser by turning on valve no. 19.
o To blow down by turning on valve no. 20.

n) Superheated Steam System

The superheater maximum pressure is 10 kg/cm2 gauge. However, it is to operate at the
same operating pressure as the boiler.

xii. Turn off all valves on the superheated steam boiler.

xiii. On the Main Breaker and Circuit Breaker, inside the control panel.
xiv. Reset the Emergency Switch by pressing and turning it clockwise. Press the Control
Voltage Lamp Switch.
xv. Open valves no. 40, no. 41, no. 42 and no. 43 so observe and control pressures of
steam inlet and outlet of superheated steam boiler (P2 and P3).
xvi. To release fuel to fuel supply system, see the previous section above.
xvii. Set the superheated steam temperature to 270 oC by using the Temperature
Controller.
xviii. Set the Stack temperature to 300 oC by using the Temperature Controller.
xix. Open valve no.18 to start.
xx. To adjust temperature of superheated steam by adjusting the controller at control
panel.
xxi. To operate the burner, turn on the switch of the force draft fan to the “ON” position
after that turn on the burner switch to “FULL LOAD” position (OFF, PAR, FULL)
for automatic operation.
xxii. Superheated steam can be distributed in 2 ways:

o To condenser, open valve no. 21.

o To blow down, open valve no. 22.

o) Condenser System
xi. Close all valves at the condenser unit and condensate tank.
xii. Transfer cooling water to condenser system by opening valve no.33 and drain
transfer water out by open valve no. 35.
xiii. Switch on cooling water pump.
xiv. Cooling water used should be from mains water supply and hot cooling water after
the condenser should be discharge to the drain valve (identify). To save cooling
 39

water used, a cooling tower is recommended (not supplied) for recirculation of

cooling water.
xv. To release steam to the condenser from the boiler or superheater, see previous
above sections.
xvi. Open air vent at condensate tank by valve no. 30.
xvii. The condensate tank should have level gauge to observe condensate level in the
tank.
xviii. Open valves no. 23, no. 24, no. 26, no. 27 and no. 29 after that switch on condensate
pump until condensate level is low.
xix. Steam in the condenser will condense to water after transferring heat to the cooling
water.
xx. Steam and/or condensate is distributed in two ways:

o Blow down by opening valve no. 36.

o To steam trap and condensate tank by opening valves no. 23 and no. 24.

p) To Start the Boiler

viii. Close the feed water tank outlet valve and the fuel tank outlet valve.
ix. Open the boiler outlet valve to relief vacuum, if any, and then close the valve.
x. Start the boiler.
xi. Open the resin filter valves to allow softened water to the feed water tank. (see
4.1.1)
xii. Open the fuel tank outlet valve.
xiii. Open the feed water tank outlet valve.
xiv. Wait until boiler set pressure is reached before slowly open the boiler outlet valve
to obtain required steam rate, e.g. 50 kg/hr.
q) Boiler Test
x. Ensure that the steam outlet is connected to a prime mover or a heat exchanger
(condenser) or vented to atmosphere.
xi. Slowly open the steam outlet valve to a steady condition with steam rate of about
50 kg/hr
xii. Record: - Feed water temperature oC.
xiii. Steam pressure. (Both steam pressure and temperature can be used as a reference
for determining steam enthalpy. However, steam pressure is more reliable.)
xiv. Fuel flow rate (lpm) (see relevant theory 3.3).
xv. Feed water flow volume (l) and time (s) (see relevant theory 3.4).
xvi. Repeat at different steam rate and/or pressure.
xvii. Calculate: - Power input from fuel consumption.
xviii. Power gained by the steam.
r) Boiler efficiency
vii. To Start the Superheater
viii. Close the superheater steam outlet valve.
ix. When the boiler set pressure is reached, start the superheater.
 40

x. Open the boiler outlet valve in full.

xi. After the superheater set temperature is reached, open the superheater outlet valve
slowly to obtained required steam rate, e.g. 50 kg/hr.
xii. The super-heater is now ready for the test.
s) To Test the Condenser

vii. Start the cooling tower water circulating pump.

viii. Close the condenser cooling water inlet valve and open the outlet valve.
ix. Start condenser cooling water pump; slightly open the inlet valve to condenser.
x. Open the (exhausted) steam to the condenser to full (about 50 kg/hr steam).
xi. Adjust the condenser cooling water flow rate such that the condenser outlet
temperature is below 80oC.
xii. The condenser is now ready for the test.

t) Condenser and Cooling Tower Test

iv. Data can be taken only after conditions in the condenser are steady. This includes
measurement of steam rate from the condensate collection. Alternatively, steam
rate can be calculated from the feed water pump run after one completes cycle of
the run.
v. Record data as in 5.4.2 or 5.6.1 if superheater is used.
vi. Record flow rate of cooling tower, temperature of cooling water in and out from
cooling tower and wet bulb temperature.

u) Shut Down
viii. Boiler shut down.
ix. Close the feed water and fuel valves to the boiler.
x. Turn off the boiler.
xi. Condenser and cooling tower.
xii. Close the condenser steam inlet valve and condenser cooling water inlet valve.
xiii. Turn off the cooling water pump
xiv. Turn off the cooling tower circulating water pump.
 41

Observation:

Calculation:

Boiler Efficiency

Enthalpy of saturated steam from the boiler − Enthalpy of feed water

ηb = × 100
Heat from fuel

h1 can be determined from the equation below:

h1 = h0 + (p1-pa) × v0
v0 = specific volume of saturated feed water at T1

Super Heater Efficiency

Super heater efficiency is determined in the same manner as the boiler efficiency. In this case, the
steam rate is assumed to be the same as boiler, and the fuel consumption is determined the same
manner as the boiler if there is a separate fuel meter or determined from the increase in fuel
consumption in the case that the superheater uses the same fuel meter as the boiler.

Condenser Heat Transfer Efficiency

 42

Cooling Efficiency of Cooling Tower

Energy Balance
• At the boiler

• At the condenser
 43

EXPERIMENT # 07

To determine the fuel to fluid efficiency of fire

tube boiler at miniature steam power plant
 44

EXPERIMENT # 07
Objective:
To determine the efficiency of fire tube boiler at miniature steam power plant

Apparatus:
• Miniature Steam Power Plant
• Match box
Theory:
Combustion Efficiency
Combustion efficiency is indicates a burner ability to burn fuel measured by
unburned fuel and excess air in exhaust.

Thermal Efficiency
Thermal efficiency indicates the heat exchangers effectiveness to transfer heat from
the combustion losses.

Fuel to Fluid Efficiency

Fuel to fluid efficiency indicates the overall efficiency of the boiler inclusive
thermal efficiency of the heat exchanger, radiation and convection losses - output.

Procedure:
xli. First the boiler with appropriate amount of water.
xlii. Ignite the boiler and start the stopwatch at constant flow rate of gas. Make sure that
gas flow rate remains constant, throughout the experiment.
xliii. Wait until the pressure of boiler increase to 1 bar.
xliv. Allow the steam to pass through condenser and condense. Collect the condensate.
xlv. Continue the experiment the boiler seems to be empty of steam.
xlvi. Switch off the gas supply and top the stopwatch, wait for condensate to collect.
xlvii. Measure the amount of condensate collected.
 45

Observation:
Amount if gas supplied = gas flow rate X time

= volume of gas

Mass of gas gas cousumed = volume * Density = mgas

Califoric value of gas = X (KJ/Kg)

Heat provided by fuel = Mgas * KJ

Amount of condensate collect = Y (mL)

Mass of condensate = mcon = Y X density (Kg)

Heat taken by water = Sensible heat effect + Latent Heat effect

= mcon Cpcon (T2 – T1) + mco λcon

Where

T1 = Temperature of saturated liquid at pressure at 1 bar

T2 = Temperature of boiler feed water

λcon = Latent Heat of vaporization for steam 1 bar

Fuel to Fluid boiler efficiency = heat taken by water / heat produce by fuel
 46

EXPERIMENT # 09

By using miniature steam power plant find

out the
• Energy Input to Condenser.
• Energy Output from Condenser.
• Energy Loss in Condenser Due To Radiation.
• Efficiency Of Condenser
 47

EXPERIMENT # 09
Objective:
By using miniature steam power plant find out the
• Energy Input to Condenser.
• Energy Output from Condenser.
• Energy Loss in Condenser Due To Radiation.
• Efficiency Of Condenser

Apparatus:
• Miniature Steam Power Plant
• Match Box
• Beakers.
Procedure:
i. Set the flow rate of cooling water to 400cm3/min.
ii. Ignite the boiler and increase its pressure upto 1.6 bar.
iii. Note inlet temperature of cooling water.
iv. Open steam valve and collect condensate.
v. Note the time which has been taken to collect condensate.
vi. Note the water outlet temperature and steam condensate temperature.
vii. Find temperature and latent heat of steam against pressure.
viii. Energy input to Condenser.
ix. Energy output from Condenser.
x. Energy loss in Condenser due to radiation.
xi. Efficiency of Condenser.
 48

Observation:
Cooling water flow rate =

Steam condensate flow rate =

Cooling Water Cooling Water Steam

Exhaust Steam
Inlet Outlet Condensate
Temperature
Temperature Temperature Temperature
T1 (oC) T2 (oC) T3 (oC) T4 (oC)

Energy Input to Condenser =

Energy Output from Condenser =

Energy Loss in Condenser Due To Radiation =

Efficiency of Condenser =
 49

EXPERIMENT # 10

To verify the Pressure and Temperature

relationship for Saturated steam and draw a
graph between pressure and temperature.
 50

EXPERIMENT # 10
Objective:
To verify the Pressure and Temperature relationship for Saturated steam and draw
a graph between pressure and temperature.

Apparatus:
• Miniature Steam Power Plant

Procedure:
i. Set the Flow rate of Natural gas and fire up boiler.
ii. Note the temperature when gauge pressure is zero.
iii. When pressure start increasing note temperature for every 0.2 bar increment in
pressure.
iv. Note temperature up to pressure of 3 bar.
v. Convert gauge pressure to absolute pressure by adding atmospheric pressure.
vi. From steam table note the temperature against these pressures.
vii. Draw a graph between pressure against actual temperature and steam table
temperature

Observation:

Absolute Temperature From Steam

Gauge Pressure
Sr. Pressure (Experimental) Table
#
(Bar) (kPa) (kPa) (oC) (oC)