ME2041-THERMODYNAMICS

Title: Steam Boiler

Objectives:

To study the operation of a steam boiler.

To study the relationship between temperature and pressure.

Apparatus:

Figure 1: Equipment and components used [1]

Introduction / Theory:
The basic definition of a boiler is, a closed vessel into which water is heated until the water is
converted into steam at required pressure. [2]
The equation for an ideal gas is consist of state that relates the pressure, specific volume
or density, and absolute temperature with mass of molecule and the gas constant, R. However, real gas
does not behave accurately to the equation. A few modifications on the ideal gas equation of state allow
its application in the properties of real gas. When energy is added within water, the increasing of
activities among the molecules caused the increase in the number of molecule escape from the surface
until an equilibrium state is reached. The state of equilibrium depends on the pressure between the water
surface and steam. The lower the pressure, the molecules may leave easily the water surface and hence
less energy is required to achieve the state of equilibrium or the boiling point. The temperature where
equilibrium occurs at a given pressure level is called saturated temperature and the pressure is called
saturated pressure.
In this experiment Marcet Boiler is used to observe the relationship between the pressure and
temperature of saturated steam. This steam is in equilibrium with water at all temperature levels between
the atmospheric pressure and a reference pressure level about 10 bars. The measured value of the slope
of the graph (dT/dP) obtained from the experiment results can be compared to the theoretical value
determined through calculation from the steam table. [3]

PV=mRT
{ P=absolute pressure
V=volume
m=mass
R=ideal gas constant
T=absolute temperature
}

Steam Boiler Efficiency (%) = (Heat exerted by outlet steam/ Heat supplied)*100%
Procedure:
General start up procedure:
First the proper working condition is ensured by performing a quick visual inspection. Then the
drain valve is closed and opened up the V1, V2 valves. Next the water is filled upto the level of the top
valve (V1). Closed the V1, V2 valves. Then the power plug is connected to the distribution load.
Experimental procedure:
First the mains on/off switch is switched on. Then the temperature is set to 2000C. Wait till
water boils and steam generation begins. As steam is being generated, the pressure quage pointer starts
to rise above the zero value. Then the steam outlet valve is opened momentarily to remove trapped air
from the boiler and closed as the steam started to come out of the valve. The temperature and pressure
values are noted down at few time intervals.
General shut down procedure:
The mains switch is switched off and the power supply is disconnected. Then the steam is
allowed to flow out by opening up the top valve, V1. The boiler is allowed to cool down and the water
is drained out.

Observations:

Steam Temperature(0C) Experimental

Steam Pressure Values Steam Temperature(0C)
Test No.
(bar) - Steam Tables
(Heating + Cooling)/2
1 0.5 (101+116)/2 108.5 81.3
2 1.0 (102+126)/2 114.0 99.3
3 1.5 (112+132)/2 122.0 111.4
4 2.0 (122+139)/2 130.5 120.2
5 2.5 (130+144)/2 137.0 127.4
6 3.0 (135+143)/2 139.0 133.5
7 3.5 (141+152)/2 146.5 138.9
8 4.0 (146+157)/2 151.5 143.6
9 4.5 (150+159)/2 154.5 147.9
10 5.0 (153+163)/2 158.0 151.8
11 5.5 (156+165)/2 160.5 155.5
12 6.0 (159+167)/2 163.0 158.8
13 6.5 (163+168)/2 165.5 161.8
14 7.0 (166+169)/2 167.5 165.0
Graphs:
Pressure vs. Temperature (Absolute and Experimental)
Discussion:
Note on introduction to boilers and types of boilers
Boilers are pressure vessels designed to heat water or produce steam. The generated steam can
then be used to provide space heating and/or service water heating to a building. In most commercial
building heating applications, the heating source in the boiler is a natural gas fired burner. Oil fired
burners and electric resistance heaters can be used as well. Steam is use than hot water in some
applications like absorption cooling, kitchens, laundries, sterilizers and steam driven equipment.
Boilers are available in several strengths. That is a common feature of using in buildings. They
have a long life, can achieve efficiencies up to 95% or greater, provide an effective method of heating
a building, and in the case of steam systems, require little or no pumping energy. However, fuel costs
can be considerable, regular maintenance is required, and if maintenance is delayed, repair can be
costly. [4]
There are many types of boilers. The main two types of boilers are Industrial steam generators
and power generation boilers. Boilers are also classified as fire tube and water tube boilers.
Fire tube boilers can be classified as
Locomotive boilers, which ruled rail transportation before diesel and electric engine came.
Industrial boilers, mainly used for green projects where initial steam is required
Domestic use boilers
Water tube boilers use in large capacity big size applications. This can be classified base on type of
circulation used to generate steam
Natural circulation boiler
Forced circulation boilers
Super critical pressure boilers or zero circulation boilers
Depending on type of firing adopted in boilers they can be classified as
Stoker fired
Pulverized coal fired
Down shot fired
Fluidized bed boilers
Cyclone fired
Chemical recovery boilers
Incinerators
In early days it has been used pulverized coal fired boilers and fluidized bed boilers by replacing high
pressure high capacity boilers. Stoker boilers are still have applications in the industries like sugar
industries, etc.
Fluidized boilers are also developing fast and can be sub classified as
Bubbling fluidized bed boilers
Pressurized fluidized bed boilers
Circulating fluidized bed boilers.
The higher capacity boilers are mainly circulating fluidized bed boilers due inherent limitations in
bubbling bed boilers.
Boilers can be classified based on the type of fuel used as
Coal fired boilers
Oil fired boilers
Gas fired boilers
Multi-fuel fired
Industrial waste fired boilers
Biomass fired boilers
Various types of arrangement are used by designers in designing the boiler for meeting the end
requirement. Hence boilers are classified based on the arrangement as
Top supported boilers
Bottom supported
Package boilers
Field erected boilers
Drum type boilers
Single drum
Bi drum
Three drums, but these are presently out of use
Tower type or single pass
Close coupled
Two pass boilers
Boilers therefore can be classified based on firing type, fuel used, construction type, circulation type,
firing system design nature, and nature of steam application. More than 125 years of experience in the
design, fabrication, and operation of water tube boilers helps the makers to keep their dependability
and safety techniques in advanced state. [5]

Explain the operation of a boiler

The boiler first ignite and start the heating process in big tanks. Steam boilers produce steam which is
allowed to flow through pipes from areas of high pressure to areas of low pressure. This does not need
any external energy source such as a pump. Steam utilized for heating can be directly utilized by steam
using equipment or can provide heat through a heat exchanger that supplies hot water to the
equipment. [4]

Discuss the safety of boilers

Boilers are large vessels which has a storage of high pressure, high temperature steam. The steam
has a large amount of energy stored. An explosion or a leakage of hot water can cause serious disasters.
All combustion equipment of the boilers need to be operated properly to prevent dangerous conditions.
Personal injury and property loss can occur due to boiler explosions. The basic cause of boiler explosions
is ignition of a combustible gas that has accumulated within the boiler. Interrupt the ignition of fuel and
air process, re-ignition of accumulated gas, attempt number of unsuccessful attempts at ignition are the
reasons.

Boiler safety is inspected by a governmental organization. This organization reports and tracks
boiler safety and the number of incidents related to boilers and pressure vessels each year. Boilers need
to be inspected regularly based on manufactures recommendations by the boiler operators prior, during
and after the usage. [4]

Discuss the relationship between the pressure and temperature of saturated steam and the experiment
Interchange of heat and work between a system and the surroundings during a process, changes
in the properties of fluid are a part of Thermodynamics studies. Most gases and vapors are often referred
as P-V-T substances. An ideal gas behaves according to the equation of state that relates the pressure,
specific volume or density, and absolute temperature with mass of molecule and the gas constant, R.
However, real gas does not perfectly behave according to the equation of state. A few modifications on
the ideal gas equation of state allow its application in the properties of real gas. When energy is added
within water, the increasing of activities among the molecules caused the increase in the number of
molecule escape from the surface until an equilibrium state is reached. The state of equilibrium depends
on the pressure between the water surface and steam. The lower the pressure, the easier the molecules
leaving the water surface and thus less energy is required to achieve the state of equilibrium (boiling
point). The temperature where equilibrium occurs at a given pressure level is called saturated
temperature. The pressure where equilibrium occurs at a given temperature is called saturated pressure.

In the experiment Marcet Boiler is used to investigate the relationship between the pressure and
temperature of saturated steam in equilibrium with water at all temperature. The conducted experiment
provides a clear image on the progressing in between pressure and temperature. The increase of the
temperature energized the molecules of the water and thus, pressure became higher until the state of
equilibrium. [7]

Introduction to steam plant

A steam plant (steam/thermal power station) uses heat energy to produce electrical energy. This
energy is generated from burning coal or many other ways. This type of power station is widely used
around the world.

This power station uses the Rankine cycle principles. This is the cycle of the steam produced in
the boiler, then taken to the Steam turbine (prime mover). From the turbine the steam is cooled back to
water in the Condenser, the resulting water is fed back into the boiler to repeat the cycle.

This kind of power station can be used to produce large amounts of electrical energy. In most
countries these power stations are used as base load power stations. This is because steam power stations
are slow to start and cannot be used to cater for peak loads that generally occur for a short duration.

These power stations (together with nuclear power stations) are kept running almost similar to
full efficiency for 24 hours a day. The life span of such plant is 30 to 40 years. [6]
Conclusion:
In conclusion, this experiment reveals that temperature and pressure is relatively proportional in
balance with water. The experimental results can be improved by conducting it under the room
temperature and repeating in both heating and cooling processes and taking an average temperature
value. Heat losses need to be reduces by insulting the apparatus.

References:
[1] Sarwan S., Marcet Boiler, 21/01/2014 [online] Available:
http://www.slideshare.net/areesalah/marcet-boiler-30868236
[2] (N.A.), Steam Boiler | Working principle and Types of Boiler, 2011 [online] Available:
http://www.electrical4u.com/steam-boiler-working-principle-and-types-of-boiler/

[3] Conor J., Marcet Boiler, 27/03/2011 [online] Available:

https://www.scribd.com/doc/51634867/Marcet-Boiler-Lab-Report
[4] (N.A.), Boilers , (N.Y.) [online] Available:
http://betterbricks.com/sites/default/files/operations/om_of_boilers_final.pdf
[5] Sathyanathan V.T. , Classification of Steam Boilers, 07/15/2009 [online] Available:
http://www.brighthubengineering.com/power-plants/42213-classification-of-steam-boilers/
[6] (N.A.), Power Generation-Steam Power, N.Y.) [online] Available:
https://en.wikiversity.org/wiki/Power_Generation-Steam_Power
[7] Kurosawa R.D., What is the relationship between pressure and temperature of saturated
steam., (N.Y.) [online] Available:
http://www.answers.com/Q/What_is_the_relationship_between_pressure_and_temperature_of_saturat
ed_steam