LAB SHEET

DJJ20063- THERMODYNAMICS

TOPIC / EXPERIMENT:

T-1 : LAYOUT AND PIPING OF THE STEAM POWER PLANT SYSTEM

T-2 : STEAM DRYNESS FRACTION
T-3 : PETTER AA1 ENGINE TEST
T-4 : OPERATION STEAM TURBINE

MARKS:
NO. ITEM SCORE CLO
1 INTRODUCTION 1/2/3 3
2 EQUIPMENT 1/2/3 3
3 SAFETY PRECAUTIONS 1/2/3 3
4 WORKING PROCEDURES 1 / 2 / 3 /4 3
5 RESULTS & DISCUSSION 1/2/3/4/5 3
6 CONCLUSION 1/2/3/4/5 3
7 REFERENCES 1/2 3
TOTAL MARKS / 25
 POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT

EXPERIMENT T-1 : LAYOUT AND PIPING OF THE STEAM POWER PLANT

SYSTEM

1.0 LEARNING OUTCOMES

At the end of this experiment, the student should be able to ;
1.1 Introduce the equipment used in steam producing and their application.

2.0 APPARATUS/EQUIPMENT

Mini steam power plant.

3.0 SAFETY AND HEALTH:

3.1 Make sure the student follow the laboratory or workshop safety regulators.
3.2 Experiment must be conduct by lecturers or experience lab assistance.
3.3 Always know the hazards associated with the materials that are being utilized
in the lab.
3.4 Always wear appropriate protective clothing.
3.5 Never perform unauthorized work, preparations or experiments.
3.6 Be familiar with the location of emergency equipment - fire alarm, fire
extinguisher, emergency eye wash and safety shower. Know the appropriate
emergency response procedures.

4.0 THEORY

Steam power plant or thermal power station is a power plant in which the prime mover
is steam driven. Water is heated, turns into steam and spins a steam turbine which
drives an electrical generator. After it passes through the turbine, the steam is
condensed in a condenser and recycled to where it was heated; this is known as a
Rankine cycle. The greatest variation in the design of thermal power stations is due to
the different fuel sources. Some thermal power plants also deliver heat energy for
industrial purposes, for district heating, or for desalination of water as well as
delivering electrical power.

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MECHANICAL ENGINEERING DEPARTMENT

5.0 DISCUSSION

5.1 State all the components used in steam power plant and give the explanation
of their uses.

5.2 Briefly explain the work cycle of the steam power plant.

5.3 What are the advantages of using steam as a medium in generating power.

5.4 Briefly explain about the work principles of steam turbine.

5.5 Give the function of the cooling tower in cooling the water in the condenser

6.0 CONCLUSION
Deduce a conclusion from the briefing and your observation

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MECHANICAL ENGINEERING DEPARTMENT

Fuel
Storage
Tank
Ball valve Fuel
Door valve
Pipe
3 ways pipe
Insulation unit
Water & steam flow
Fuel flow Fuel
Anti backward valve Service
Tank

Supply
Tank

Drain
Main steam ducting
Balancing control

Fuel Fuel
Surface
Combustion Burner
pump condenser
condenser Supply
Water tank
Condenser

Boiler
Water
Water back

Sample ducting
valve

Pump

Separator and
Calorimeter

Throttle
Over speed Back Spray
trip valve Steam turbine Well
Wash
Pump Cooling water to cooling tower

Cooling Water from Cooling Tower

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MECHANICAL ENGINEERING DEPARTMENT

EXPERIMENT T-2 : STEAM DRYNESS FRACTION

1.0 LEARNING OUTCOMES

At the end of this experiment, the student should be able to ;
1.1 Define the meaning of steam dryness fraction (x)
1.2 Demonstrate the use of the Separator and Throttling Calorimeter to determine
steam dryness fraction(x)

2.0 APPARATUS / EQUIPMENT

Empi Separator and Throttling Calorimeter

Figure 2.1: Empi Separator and Throttling Meter Calori

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MECHANICAL ENGINEERING DEPARTMENT

3.0 SAFETY AND HEALTH

3.1 Make sure the student follow the laboratory or workshop safety regulators.
3.2 Experiment must be conduct by lecturers or experience lab assistance.
3.3 Always know the hazards associated with the materials that are being utilized
in the lab.
3.4 Always wear appropriate protective clothing.
3.5 Never perform unauthorized work, preparations or experiments.
3.6 Be familiar with the location of emergency equipment - fire alarm, fire
extinguisher, emergency eye wash and safety shower. Know the appropriate
emergency response procedures.

4.0 THEORY
Moisture from the wet steam is collected in the separator. The dry steam that has been
separated from the moisture flow to the orifice will become superheated steam.
The Bourdon Gauge will measure the pressure of steam that flows through the sampling
channel. The thermometer will measure the temperature and the U tube manometer will
measure the pressure after the throttling process. The condensers will condense the steam
that flows from the throttle.

The formulas used in the calculation are:

Enthalpy for the superheated steam after the throttling process
hpl = hg2 + cpg (T2 – Ts2)
which,
hg2 = Enthalpy for the saturated dry steam after throttling process. .
cpg = Specific heat at constant pressure
T2 = Superheated steam temperature
Ts2 = Dry saturated steam temperature.

Enthalpy for wet steam between separator and orifice

h1 = hf1 + x1hfg1
which,
hf1 = Saturated enthalpy for et steam.
x1 = steam dryness fraction after separator

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MECHANICAL ENGINEERING DEPARTMENT

hfg1= Differences of dry saturated steam enthalpy and saturated water.

4.1 Steam enthalpy after separation = wet steam enthalpy
hp1 = hf1 + x1hfg1
hp 1  hf 1
x1 =
hfg 1

4.2 Dryness fraction of steam from boiler

 ms 
x  x1  
 ms  mw 

5.0 PROCEDURES
5.1 Record the barometer pressure at the beginning and at the end of experiment.
5.2 Open the water tap to let the water flow through the condenser.
5.3 Turn to open the sampling channel valve and let the steam flow to the calorie
meter in a small amount just to heat the system and make it a steady state.
5.4 Close the valve and remove all the moisture from the separator.
(Note: let the pressure drop to zero and open the blow down valve slowly with
a glove).
5.5 Put the measurement cylinder at the end of the hose that come from the
condenser.
5.6 Open the valve for the sampling channel and observe the pressure gauge just
to make sure there is no throttle effect for the steam flow. Turn the valve until
the reading for the pressure gauge is exactly the same with the boiler pressure.
5.7 Take the reading from the Bourdon gauge for the steam supply pressure P1,
the temperature T2 and the pressure after throttling process P2 every 15
seconds. Observe the side glass at the separator and close the valve if the side
glass is full with water.
5.8 Notes the water volume that is collected from the condenser Ms.
5.9 Let the pressure from the separator to drop till zero before collecting and
measuring the volume of the moisture from the separator Mw.

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MECHANICAL ENGINEERING DEPARTMENT

5.10 Average the reading for P1, T2 and P2. Notes the average pressure for the
atmosphere.

6.0 RESULTS/DATA

Reading 1 Reading 2 Reading 3 Reading 4 Average

P1 (bar)

T2 (°C)

P2 (bar)
Atmosphere
Pressure

hg2 = _____________kJ/kg
cpg = _____________kJ/kg K
Ts2 = _____________°C
So that, hpl = _____________kJ/kg
hf1 = _____________kJ/kg
hfg1= ____________________kJ/kg

hp1 = hf1 + x1hfg1

x1 = _____________
ms = _____________liter = _____________kg
mw= _____________liter = _____________kg

 ms 
So, x  x1  
 ms  mw 
= ___________

7.0 DISCUSSION
7.1 Calculate the dryness fraction (x).
7.2 What is your assumption from the dryness fraction (x)?

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MECHANICAL ENGINEERING DEPARTMENT

8.0 CONCLUSION
Deduce a conclusion from the result shown and from your observation.

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MECHANICAL ENGINEERING DEPARTMENT

EXPERIMENT T-3 : PETTER AA1 ENGINE TEST

1.0 LEARNING OUTCOMES

At the end of this experiment, the student should be able to:
1.1 To conduct a test on the Petter AA1 engine with the fuel pump rack in the fully
open position
1.2 To determine the performance characteristics.

2.0 Apparatus

Tecquipment test-bench in Plant Engineering Laboratory.

3.0 SAFETY AND HEALTH

3.1 Make sure the student follow the laboratory or workshop safety regulators.
3.2 Experiment must be conduct by lecturers or experience lab assistance.
3.3 Always know the hazards associated with the materials that are being utilized
in the lab.
3.4 Always wear appropriate protective clothing.
3.5 Never perform unauthorized work, preparations or experiments.
3.6 Be familiar with the location of emergency equipment - fire alarm, fire
extinguisher, emergency eye wash and safety shower. Know the appropriate
emergency response procedures.

4.0 Engine Specifications

Type : Single cylinder, upright, four-stroke compression
ignition, overhead valve, air-cooled, air cell
combustion engine.
Bore : 69.85 mm
Stroke : 57.15 mm
Displacement : 219 cm3
Compression ratio : 17:1
Specific Gravity (SG) of fuel : 0.84
Calorie Value (CV) of fuel : 42400 kJ/kg
Specific heat of fuel : 1.993 kJ/kg K

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MECHANICAL ENGINEERING DEPARTMENT

5.0 Theory
Supposed the speed of an un-throttled CI engine is maintained constants as the load and fuel
pump rack position are varied. The quantity of air inducted per cycle is more or less constant,
and at low rack settings, this air is more than enough to burn off all the fuel injected. The brake
torque developed then depends solely on the fuel injected per cycle and in fact bears a linear
relation with the fuel consumption rate.

6.0 Performance Characteristics

6.1 Brake power, P (kW) = 1.046 x 10-4 x N (rev/min) x T (Nm)

24.2
6.2  f (kg/h) 
Fuel consumption rate, m
t(s)
P (mm Hg) 288
6.3 a). Ambient air density, a (kg/m3) = a x x 1.226
760 Ta (K)
b).  a (kg/h)  2.98 h (mm H 2 O) x ρ a (kg/m 3 )
Air consumption rate, m
6.4  a /m
Air-fuel ratio = m f
 f (kg/h)
m
6.5 Specific fuel consumption, SFC (kg/kWh) =
P(kW)
0.0848
6.6 Brake thermal efficiency, T =
SFC (kg/kWh)
6.7 Brake mean effective pressure, BMEP (N/m2) = 57.4 x T (Nm)
.
152 x m a (kg/h)
6.8 Volumetric efficiency, v =
ρ a (kg/m 3 ) x N (rev/min)

5.0 Procedure
a) Record the ambient pressure (Pa) and ambient temperature (Ta).
b) Check that fuel and oil levels are sufficient.
c) Start the engine and warm up the engine on a light load of about 2500 rev/min for about 5
minutes. Record the start time in the log book.
d) Open the fuel pump rack fully and adjust the dynamometer flow control valve to obtain
an engine speed of 1400 rev/min. Allow about half a minute for the engine to settle down
to the new speed.
e) Obtain readings of torque (T), time (t) for 8 cm3 of fuel to flow, manometer level
difference (h) and exhaust temperature (Te).
f) By adding the engine speed by 200 rev/min at a time, repeat the readings up to the
maximum speed of 2200 rev/min.

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MECHANICAL ENGINEERING DEPARTMENT

g) Reduce the dynamometer flow control valve and allow about 5 minutes for the engine to
run down on light load of about 1500 rev/min.
h) Shut down the engine. Note time in the log book.

CAUTION: Never run the engine for long without water flow through the dynamometer. Heat
is produced in the absence of a cooling flow and it can damage the rubber glands
at both ends of the dynamometer shaft.

6.0 Results

a) Tabulate the performance characteristics (6.1 to 6.8) into Form 3.1 (Source Test Data
Sheet).
b) Plotted with the graph paper showing the variation of the:
i. Torque (Nm) over the range of working speeds (rev/min).
ii. Brake power (kW) over the range of working speeds (rev/min).
iii. Specific Fuel Consumption (SFC) over the range of working speeds (rev/min).
iv. Brake thermal efficiency and volumetric efficiency over the range of working
speeds (rev/min).

7.0 Conclusion and Discussion

Give your comment on the results obtained from graphs (b)i to (b) iv above. In
particular, list the points of practical significance.

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MECHANICAL ENGINEERING DEPARTMENT

FORM 3.1: SOURCE TEST DATA SHEET

ENGINE TYPE: ………………………………………………….. DATE: ………………………..……

Pa = mmHg
TYPE OF TEST: …………………………………………………. BAROMETER: ……………………
AMBIENT TEMP.: T………………..
o
a= C

Engine Fuel Brake Manometer Air Exhaust

Torque Brake BMEP Time for SFC
Speed, consumption Thermal reading consumpti Air-fuel Volumetric temperature
T(Nm) Power (kN/m2) 8 cm3 (kg/kW
N rate Efficiency H (mm on rate ratio efficiency Te (oC)
P (kW) fuel jam)
(rev/min) mf (kg/jam) H2O) ma
t (s)
(kg/jam)

Note:
SFC = Specific Fuel Consumption
BMEP = Brake Mean Effective Pressure

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 POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT

EXPERIMENT T-4 : OPERATION STEAM TURBINE

1.0 LEARNING OUTCOMES

At the end of this experiment, the student should be able to illustrate the procedures in
starting and stopping the steam turbine.

2.0 APPARATUS / EQUIPMENT

Impulse Steam Turbine.

3.0 SAFETY AND HEALTH

3.1 Make sure the student follow the laboratory or workshop safety regulators.
3.2 Experiment must be conduct by lecturers or experience lab assistance.
3.3 Always know the hazards associated with the materials that are being utilized
in the lab.
3.4 Always wear appropriate protective clothing.
3.5 Never perform unauthorized work, preparations or experiments.
3.6 Be familiar with the location of emergency equipment - fire alarm, fire
extinguisher, emergency eye wash and safety shower. Know the appropriate
emergency response procedures.

4.0 THEORY

A steam turbine is a mechanical device that extracts thermal energy from pressurized
steam, and converts it into rotary motion.

An impulse turbine has fixed nozzles that orient the steam flow into high speed jets.
These jets contain significant kinetic energy, which the rotor blades, shaped like
buckets, convert into shaft rotation as the steam jet changes direction. A pressure drop
occurs across only the stationary blades, with a net increase in steam velocity across
the stage.

As the steam flows through the nozzle its pressure falls from inlet pressure to the exit
pressure (atmospheric pressure, or more usually, the condenser vacuum). Due to this
higher ratio of expansion of steam in the nozzle the steam leaves the nozzle with a
very high velocity. The steam leaving the moving blades has a large portion of the
maximum velocity of the steam when leaving the nozzle. The loss of energy due to
this higher exit velocity is commonly called the "carry over velocity" or "leaving loss".

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 POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT

5.0 PROCEDURES

5.1 Procedure to start the steam turbine

5.1.1 Ensure that all switches are in off position and the shunt field rheostat
is in minimum position.
5.1.2 Check the grease oil is enough in the bearing and in the tachometer.
5.1.3 Open all nozzle and back wash pipe at the turbine exhaust of tip.
5.1.4 Open the valve (half) at the below tip before turbine for the blow down
process.
5.1.5 Open the valve at the main steam ducting system to allow the pipe to
be hot for steam reheats.
5.1.6 Start the pump for distribution of cold water to the surface condenser.
5.1.7 Start the fans of cooling tower.
5.1.8 Open slightly over speed trip valve and close the back was pipe to
avoid blow down. Reheat the turbine until no humidity. At this time,
temperature at the turbine tip must be at least 120 degree Celsius. It
can be read at the temperature gauge.
5.1.9 Reheat the vacuum pump and open the valve to supply the water to the
extraction pump.
5.1.10 Close the back wash pipe.
5.1.11 Slowly open the trip valve.Turbine will speed on balance control speed
at 3000 rpm.
- Open the trip valve until the trip lever arrives at the trip valve bar
shoulder.
- Then turn down the wheel until it stops. Trip valve now already set
to drop the turbine speed exceeding 10% of it’s over speed.
5.1.12 Control the speed of turbine by adjusting the pirouette field rheostat.
To increase the speed, step up the ohm resistance. This will weaken
the magnetic field and to allow the angker accelerate.

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MECHANICAL ENGINEERING DEPARTMENT

Note: Open the main blocker valve slowly. Be sure there is no throttling effect to the
steam inlet. Massive opening will cause priming the carryover in the boiler water
when steam is supplied.

5.2 Procedure to stop the steam turbine

5.2.1 Shut down all the load and decrease the turbine speed.
5.2.2 Close the blocker turbine at main ducting steam.
5.2.3 When the turbine stop nearly. Close the over speed valve by pushing
the trip lever to the side.
5.2.4 Allow the vacuum pump to discard the all condenser water before stop
the operation.
5.2.5 Stop the water cool flow to the surface condenser after the temperature
drop to about 40 degree Celsius.
5.2.6 Open the backwash pipe at exhaust tip to allow the humidity expelled.

6.0 DISCUSSION
6.1 Why the steam turbine needs preheating before the operation.
6.2 What is priming and carryover.
6.3 Give the other way to control the turbine speed besides the observation in steam
turbine handling.

7.0 CONCLUSION
Deduce a conclusion from from your observation.

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MECHANICAL ENGINEERING DEPARTMENT

FORMAT OF LABORATORY REPORT

[SUBMITTED BY STUDENT]

EXPERIMENT T-1 :

1.0 LEARNING OUTCOMES :

1.1
1.2

2.0 EQUIPMENT / APPARATUS :

2.1
2.2
2.3
2.4
2.5

3.0 SAFETY AND HEALTH :

4.0 THEORY:

5.0 PROCEDURES :

5.1
5.2
5.3
5.4
5.5

6.0 RESULTS/DATA :

7.0 CALCULATION :

8.0 DICUSSION :

9.0 CONCLUSION :

10.0 REFERENCES :

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 EXAMPLE
Time (s) 15 30 45 60 AVERAGE
P1 (bar) 7.7 7.8 7.8 7.9 7.8 bar
T2 (oC) 109 110 111 110 110oC = 383 K
P2 (bar) 1.9 cm 2.0 cm 2.1 cm 2.0 cm 2.0 cm
Patm 1.014 bar

Mass of steam, ms = 0.045 liter = 0.045 kg

Mass of water, mw = 0.042 liter = 0.042 kg
Gauge pressure for P2,
P2 = ρgh
= (1000)(9.81)(0.02)
= 196.2 N/m2
= 0.001962 bar
Absolute pressure for P1 & P2 ,
P1 = 7.8 + 1.014
= 8.814 bar
P2 = 0.001962 + 1.014
= 1.016 bar

The enthalpy of superheated steam after throttling,

hpl = hg2 + cpg(T2 – Ts2)

To find hg2 ,

P2
h  2675 2680  2675
1.1 g2

1.016  1.0 1.1  1.0
1.016
1.0 hg2 = 2675.8 kJ/kg

2675 hg2 2680 hg

To find Ts2 ,
P2 T  99.6 102.3  99.6
s2

1.016  1.0 1.1  1.0
1.1

1.016 Ts2 = 100.03 oC

1.0 = 373.03 K

1
99.6 Ts2 102.3 T
To tabulate cpg (use steam tables attached at page 4)
Ts2 (oC)
c  2.01 2.03  2.01
pg

105 100.03  100 105  100
100.03
Cpg = 2.01012 m3/kg
100

2.01 cpg 2.03 cpg

So,
hpl = hg2 + cpg(T2 – Ts2)
= 2675.8 + 2.01012(383 – 373.03)
= 2695.84 kJ/kg

The enthalpy of wet steam between the septum and orifice,

hl = hf1 + x1hfg1

To find hf1 ,

P1
h  721 743  721
f1

9.0 8.814  8.0 9.0  8.0
8.814
hf1 = 738.9 kJ/kg
8.0

721 hf1 743 hf1

To find hfg1 ,

P1
h  2048 2031  2048
9.0 fg 1

8.814  8.0 9.0  8.0
8.814
8.0 hfg1 = 2034.2 kJ/kg

2048 hfg1 2031 hfg1

pg

2
Enthalpy of steam after throttling = enthalpy of wet steam
hpl = hf1 + x1hfg1
2695.84 = 738.9 + x1(2034.2)
x1 = 0.962

Therefore the dryness fraction of steam boilers,

 m 
x  x   s

m m 
1

s w

 0.045 
 0.962 
 0.045  0.042 
 0.498

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