EXPERIMENT NO.

AIM OF THE EXPERIMENT: To study the modern steam power-plant with

model.

EQUIPMENT: Model of steam power-plant

THEORY:
Steam Powerplant: It is the power plant which is used to generate electricity by the use of
steam turbine. The major components of these power plants are boiler, steam turbine, condenser,
and water feed pump.

Construction or Layout of Steam Power Plant:

There are so many components present in the steam power plant which performs their
specialized function for efficient working. The various component of the steam power plant
are:

1. Coal Storage:
It is the place where coal is stored which can be utilised when required.

2. Coal Handling:
Here the coal is converted into the pulverised form before feeding to the furnace. A proper
system is designed to transport the pulverised coal to the boiler furnace.
 3. Boiler:
It converts the water into high pressure steam. It contains the furnace inside or outside the
boiler shell. The combustion of coal takes place in the furnace.

4. Air-preheater:
It is used to pre-heat the air before entering into the boiler furnace. The pre heating of air helps
in the burning of fuel to a greater extent. It takes the heat from the burnt gases from the furnace
to heat the air from the atmosphere.

5. Economiser:
As its name indicates it economises the working of the boiler. It heats the feed water to a
specified temperature before it enters into the boiler drum. It takes the heat from the burnt gases
from the furnace to do so.

6. Turbine:
It is the mechanical device which converts the kinetic energy of the steam to the mechanical
energy.

7. Generator:
It is coupled with the turbine rotor and converts the mechanical energy of the turbine to the
electrical energy.

8. Ash Storage:
It is used to store the ash after the burning of the coal.

9. Dust Collector:
It collects the dust particle from the burnt gases before it is released to the chimney.

10. Condenser:
It condensate the steam that leaves out turbine. It converts the low pressure steam to water. It
is attached to the cooling tower.

11. Cooling Tower:

It is a tower which contains cold water. Cold water is circulates to the condenser for the cooling
of the residual steam from the turbine.

12. Chimney:
It is used to release the hot burnt gases or smoke from the furnace to the environment at
appropriate height. The height of the tower is very high such that it can easily throw the smoke
and exhaust gases at the appropriate height. And it cannot affect the population living near the
steam power plant.

13. Feed Water Pump:

It is used to transport the feed water to the boiler.

Working of Steam Power Plant:

 The pulverised coal is fed into the boiler where the pulverised coal is burnt into the furnace
 Due to heat from the furnace, the water present in the boiler drum changes to the high pressure
steam.
 From the boiler this high pressure steam is passed to the super heater where it is again heated
up to its dryness.
 After that this superheated steam strikes the turbine blades with a high speed and the turbine
blades starts rotating to at high speed. Here the stored potential energy of the steam is gets
converted into mechanical energy.
 A generator is coupled with the turbine rotor. As the turbine rotates, the generator also rotate
with same speed and mechanical energy of the turbine gets converted into electrical energy.
 Steam after hitting the turbines blades lost its most of the energy and leaves the turbine with
low pressure steam.
 This low pressure steam enters into the condenser. Cold water circulates in the condenser from
the cooling tower. Here the low pressure wet steam is converted into water.
 After that condensed water with the feed water passed to the economiser where it gets heated
up by the economiser. And finally the feed water enters into the boiler by a feed water pump
to repeat the cycle.
 The burnt flue gases from the furnace passes through the superheater, economiser and air pre-
heater. This heat of the flue gases is used to heat the steam in the super heater to its dryness, to
heat feed water in the economiser before entering into the boiler and to heat air form the
atmosphere in the air pre-heater before it enters into the furnace.
 The ash from the furnace is transported to ash handling plant and finally to the ash storage.

CONCLUSION: So we have successfully studied and demonstrated modern steam

powerplant.
 EXPERIMENT NO.2

AIM OF THE EXPERIMENT: To study and demonstrate the cooling tower.

EQUIPMENT: Model of cooling tower
THEORY:
Cooling tower: Cooling towers are a very important part of many chemical plants. The
primary task of a cooling tower is to reject heat into the atmosphere. They represent a relatively
inexpensive and dependable means of removing low-grade heat from cooling water. The make-
up water source is used to replenish water lost to evaporation. Hot water from heat exchangers
is sent to the cooling tower. The water exits the cooling tower and is sent back to the exchangers
or to other units for further cooling. Typical closed loop cooling tower system is shown in
Figure.

TYPES:
Cooling towers fall into two main categories: Natural draft and Mechanical draft.
Natural draft towers use very large concrete chimneys to introduce air through the media.
Due to the large size of these towers, they are generally used for water flow rates above 45,000
m3/hr. These types of towers are used only by utility power stations.
Mechanical draft towers utilize large fans to force or suck air through circulated water. The
water falls downward over fill surfaces, which help increase the contact time between the water
and the air - this helps maximise heat transfer between the two. Cooling rates of Mechanical
draft towers depend upon their fan diameter and speed of operation. Since, the mechanical draft
cooling towers are much more widely used.

COMPONENTS:
The basic components of an evaporative tower are: Frame and casing, fill, cold water basin,
drift eliminators, air inlet, louvers, nozzles and fans.

Frame and casing: Most towers have structural frames that support the exterior enclosures
(casings), motors, fans, and other components. With some smaller designs, such as some glass
fiber units, the casing may essentially be the frame.
Fill: Most towers employ fills (made of plastic or wood) to facilitate heat transfer by
maximising water and air contact. Fill can either be splash or film type.
With splash fill, water falls over successive layers of horizontal splash bars, continuously
breaking into smaller droplets, while also wetting the fill surface. Plastic splash fill promotes
better heat transfer than the wood splash fill.
Film fill consists of thin, closely spaced plastic surfaces over which the water spreads,
forming a thin film in contact with the air. These surfaces may be flat, corrugated,
honeycombed, or other patterns. The film type of fill is the more efficient and provides same
heat transfer in a smaller volume than the splash fill.
Cold water basin: The cold water basin, located at or near the bottom of the tower, receives
the cooled water that flows down through the tower and fill. The basin usually has a sump or
low point for the cold water discharge connection. In many tower designs, the cold water basin
is beneath the entire fill.
In some forced draft counter flow design, however, the water at the bottom of the fill is
channeled to a perimeter trough that functions as the cold water basin. Propeller fans are
mounted beneath the fill to blow the air up through the tower. With this design, the tower is
mounted on legs, providing easy access to the fans and their motors.
Drift eliminators: These capture water droplets entrapped in the air stream that otherwise
would be lost to the atmosphere.
Air inlet: This is the point of entry for the air entering a tower. The inlet may take up an entire
side of a tower–cross flow design– or be located low on the side or the bottom of counter flow
designs.
Louvers: Generally, cross-flow towers have inlet louvers. The purpose of louvers is to equalize
air flow into the fill and retain the water within the tower. Many counter flow tower designs do
not require louvers.
Nozzles: These provide the water sprays to wet the fill. Uniform water distribution at the top
of the fill is essential to achieve proper wetting of the entire fill surface. Nozzles can either be
fixed in place and have either round or square spray patterns or can be part of a rotating
assembly as found in some circular cross-section towers.
Fans: Both axial (propeller type) and centrifugal fans are used in towers. Generally, propeller
fans are used in induced draft towers and both propeller and centrifugal fans are found in forced
draft towers. Depending upon their size, propeller fans can either be fixed or variable pitch.
A fan having non-automatic adjustable pitch blades permits the same fan to be used over a
wide range of kW with the fan adjusted to deliver the desired air flow at the lowest power
consumption.
Automatic variable pitch blades can vary air flow in response to changing load conditions.
Tower Materials
In the early days of cooling tower manufacture, towers were constructed primarily of wood.
Wooden components included the frame, casing, louvers, fill, and often the cold water basin.
If the basin was not of wood, it likely was of concrete.
Today, tower manufacturers fabricate towers and tower components from a variety of
materials. Often several materials are used to enhance corrosion resistance, reduce
maintenance, and promote reliability and long service life. Galvanized steel, various grades of
stainless steel,glass fiber, and concrete are widely used in tower construction as well as
aluminum and various types of plastics for some components.
Wood towers are still available, but they have glass fiber rather than wood panels (casing)
over the wood framework. The inlet air louvers may be glass fiber, the fill may be plastic, and
the cold water basin may be steel.
Larger towers sometimes are made of concrete. Many towers–casings and basins–are
constructed of galvanized steel or, where a corrosive atmosphere is a problem, stainless steel.
Sometimes a galvanized tower has a stainless steel basin. Glass fiber is also widely used for
cooling tower casings and basins, giving long life and protection from the harmful effects of
many chemicals.
Plastics are widely used for fill, including PVC, polypropylene, and other polymers. Treated
wood splash fill is still specified for wood towers, but plastic splash fill is also widely used
when water conditions mandate the use of splash fill. Film fill, because it offers greater heat
transfer efficiency, is the fill of choice for applications where the circulating water is generally
free of debris that could plug the fill passageways.
Plastics also find wide use as nozzle materials. Many nozzles are being made of PVC, ABS,
polypropylene, and glass-filled nylon. Aluminum, glass fiber, and hot-dipped galvanized steel
are commonly used fan materials. Centrifugal fans are often fabricated from galvanized steel.
Propeller fans are fabricated from galvanized, aluminum, or moulded glass fiber reinforced
plastic.

CONCLUSION: So we have successfully studied and demonstrated cooling tower.

 EXPERIMENT NO.3

AIM OF THE EXPERIMENT: To study the model of jet condenser.

EQUIPMENT: Model of jet condenser
THEORY:
Condenser: A condenser is a device used in industries to convert steam into
water. Condenser removes heat from the steam and gives it to the coolants, thus converting the
hot steam into liquid know as condensate.
A condenser works on the principle of heat transfer (heat energy always flows from higher
temperature to lower temperature). It transfers heat from hot steam from the compressor to
the coolants and converts it into water.

Jet condenser: A jet condenser is a type of condenser in which steam and cooling water
are mixed up in a chamber, where the steam is converted into liquid form and known as
condensate. This condensate is then used for many other industrial purposes.

Types of Jet Condenser:

There are 3 basic types of jet condensers:

1. Low-level Jet Condenser

 Parallel Flow Jet Condenser
 Counterflow Jet Condenser
2. Barometric Jet Condenser or High-level Jet Condenser
3. Ejector Condenser

Parallel Flow Jet Condenser:

As the name suggests in a parallel flow jet condenser the steam and water enters from the top
of the condenser and hence flow parallel to each other, this is because the air pump creates a
vacuum due to which there is a flow of water and steam. During the flow of water and steam,
the heat from the steam gets transferred to the flowing water as we know heat always flows
from higher temperature to lower temperature.

The condensate produced is collected at the bottom of the condenser. The perforated trays and
air pump is used to make the process faster. There is an extraction pump located at the bottom
which is used to transfer the condensate to the hot well. After passing through the hot well
condensate is sent to the boiler. The design of a parallel flow jet condenser is quite simple when
compared to other types of the jet condenser.
Counter Flow or Low-Level Jet Condenser:
As we can see the word “counter” itself says that the flow of steam and water are opposite to
each other. In counter-flow jet condenser steam comes into the chamber from below and the
cooling water comes from the top. The air pump creates a vacuum which forces cooling water
into the condenser.

Water being heavy falls down and steam being light rises up through perforated trays. The
falling water gets stored in the perforated trays. As soon as cooling water meets steam on its
way, the process of heat transfer takes place as the result of which condensate gets accumulated
in the bottom.

This condensate is drawn out with the help of a pump into the hot well. The condensate is
drawn out from the hot well. The equipment required for the construction of the counterflow
jet condenser is less costly and simple. The quantity of cooling water required is less.
Barometric or High-Level Jet Condenser:
Barometric or high level jet condenser works much similar to counter flow jet condensers.
There are a few changes in the basic structure, there is a long discharge pipe from where the
condensate passes and accumulates in the hot well.

The air pump and injection pump forces cooling water from the top of the condenser and the
steam is forced from below, again steam being light rises up and water being heavy falls down
through perforated trays. Heat transfer between water and steam takes place producing
condensate which gets settled down.

Unlike other condensers, there’s no need for a pump to extract the condensate. The potential
energy of condensate is high enough to make it fall this is because of the long discharge pipe.
Ejector Condenser:
In the Ejector type jet condenser the steam and cooling water mixes together and pass through
few metal cones. These metal cones increase the time taken by the water to come down, thus
increasing the time of heat transfer.

The steam enters into the condenser through a non-return valve (the steam can only go in and
can’t come out of the valve).

Steam and cooling water get mixed together properly while passing through the cone where
the heat transfer process takes place. There are no pumps used as the area of cross-section does
not get narrow. The condensate gets collected into a hot well.
CONCLUSION: So we have successfully demonstrated the models of jet condensers or
each type.
 EXPERIMENT NO.4
AIM OF THE EXPERIMENT: To study the steam generators(boilers).

EQUIPMENT: Models of different boilers

THEORY:

Boiler: A boiler is an enclosed vessel in which a fluid such as water is heated to produce
steam or the vaporized form of a liquid. The steam or hot water is then circulated through a
piping system, to transfer heat for various applications such as heating, power generation and
other processes. Boilers and associated systems are efficient heat exchange systems, however
they can be dangerous if not properly maintained and operated.

Different models of boilers:

1) Lanchashire boiler: Lancashire boiler is a horizontal drum axis, natural circulation,

natural draft, two-tubular, low pressure, stationary, fire tube boiler with furnace located
internally. Its main purpose is to create steam and then this steam is used to drive steam
turbines for power generation. It has high thermal efficiency and it is about 80 to 90
percent. It is mostly used in locomotive engines and marines etc.

Working:

Now I am going to explain the working of this boiler step by step:

 Lancashire boiler consists of a horizontal cylindrical shell filled with water surrounding two
large fire tubes.
 The cylindrical shell is placed over brickwork which creates several channels for the flow of
hot flue gases.
 Solid fuel is provided by the fire door which then burnt over grate at the front end of each fire
tube.
 A small arc shape brickwork is provided at the end of the grate to deflect the flue gases
upward and prevent the entry of burning coal and ashes into the interior part of the fire tubes.
 The fire tubes are slightly conical at the rear end to increase the velocity of hot flue gases.
 When hot flue gases are allowed to pass through the downward channel at the front end of the
fire tubes. Now, these gases pass through the side channel towards the rear end of the fire
tube and finally escape out through the chimney.
 There are dampers at each side channel to regulate the airflow.
 The feed check valve is used to feed the water uniformly to the boiler shell.
 Once the boiler is at quickly, water converts into steam by absorbing the heat from the flue
gases. This steam is stored at the upper portion of the boiler where the anti priming pipe
separates the water from steam. Thus the steam stop valve receives the dry steam for various
purposes.
 A manhole is provided at the top and bottom of the shell to allow a man to enter into the
boiler and clean it.
 A blow-off valve is provided to remove the mud that has settled down. It is also used to clean
the boiler.
2) Cornish Boiler: Cornish boiler is a fire tube boiler that works is to produce steam by
the burning of fuel(coal) and further used in the steam turbine, textile or sugar mill
industry, and so on.
Working:

 Fuel is inserted through the fire door and placed over the grate, and burnt over the grate
which emits hot flue gases due to combustion.

 The grate is provided with equal spacings to ensure complete combustion of the fuel
with air.

 The hot flue gases from the grate travel through the fire tube and heat transfer take place
between the hot gases and the surrounding water.

 Then the gases move along the side flues and enter the bottom flue.

 Due to the defined flow of flue gases, the water in the shell is heated from the bottom
by the bottom flue and the side by the side flue. and also from the center of the fire tube.

 When the gases increase the temperature of the walls of the tubes due to which heat
transfer takes place between water and tube walls.

 This heat transfer increases the temperature of the water so that it starts boiling and
converts into vapors.

 The gases after passing through the bottom flue finally exit the atmosphere through a
chimney.
3) Babcock & Wilcox boiler: Babcock and Wilcox Boiler is a horizontal drum axis,
natural draft, natural circulation, multi-tubular, stationary, high pressure, solid fuel
fired, externally fired water tube boiler, used to produce high pressure steam in ships
for the function of other machineries and the production of electricity.
Working:

 The working of Babcock and Wilcox boiler is first the water starts to come in the water
tubes from the drum through down take header with the help of a boiler feed pump
which continues to feed the water against the drum pressure.

 The water present in the inclined water tubes gets heated up by the hot flue gases
produced by the burning of coal on the fire grate.

 These fuel gases are uniformly heated the water tube with the help of a baffle plate
which works deflect the flues gas uniform throughout the tubes which absorbed the
heating maximum from the flue gases.

 As the hot flue gases come in contact with water tubes, It exchanges the heat with heater
and converts into the steam.

 Continuous circulation of water from the drum to the water tubes and water tubes to the
drum is thus maintained.

 The circulation of water is maintained by convective current and it’s known as Natural
Circulation.

 The Steam generated is moved upward, due to density difference and through the up-
take header, it gets collected at the upper side in the boiler drum.
 Anti-priming pipe inside the drum which works separates the moisture from the steam
and sends it’s to the superheater.

 The superheater receives the water-free steam from an anti-priming pipe. It increases
the temperature of the steam to the desired level and transfers it to the main steam stop
valve of the boiler.

 The superheated steam stop valve is either collected in a steam drum or send it’s inside
the steam turbine for electricity generation.

4)Vertical water tube boiler:

A vertical boiler is a type of fire-tube or water-tube boiler where the boiler barrel is
oriented vertically instead of the more common horizontal orientation. Vertical boilers
were used for a variety of steam-powered vehicles and other mobile machines,
including early steam locomotives.
 Working:

 In simple vertical boilers, the first fuel is added to the furnace through
a fire hole. Fuel is placed on the furnace at the bottom of the furnace.
When the fuel burns, hot gas is produced, and the ash produced from
burning the fuel is collected into ashes.

 The hot gas produced by the burning of fuel is then sent to the cross
tubes, and the waste gases are then transported to the atmosphere
through the chimney.

 The heat from the flue gases in the cross tube is transferred to the
water, and the water is heated to produce steam. Current water due to
convection goes from the lower end of the cross tube to the higher end
by natural circulation.

 The steam produced by the heat transfer from the vapor gas to the
water is then collected at the steam location of the boiler; steam is
collected until a certain pressure is reached, and then the steam is
released to the gas turbine or engine or any other Use is passed.

CONCLUSION: Hence we have studied about boiler models successfully.