understanding power production students’ laboratory manual

EEN-E1010 – Power Plants and Processes Course

Edition Author Date

V.01 Mohamed Magdeldin 11.10.2016



Understanding Power Production Students’ Laboratory Manual

Steam Turbine Electrical Generation

Course Instructors: Professor Mika Järvinen, M.Sc. Mohamed Magdeldin

EEN-E1010 – Power Plants and Processes

Laboratory Assignment Student Manual V.03

1

Contents 1: INTRODUCTION ................................................................................................. 4

1.1 Rankine Cycle ................................................................................................... 5

1.2 The Laboratory Setup ....................................................................................... 7

1.2.1 Burner ......................................................................................................... 7

1.2.2 Boiler .......................................................................................................... 8

1.2.3 Sight glass ................................................................................................... 9

1.2.4 Boiler pressure gauge ................................................................................. 9

1.2.5 Steam admission valve ............................................................................... 9

1.2.6 Steam turbine ............................................................................................10

1.2.7 Generator ..................................................................................................11

1.2.8 Cooling tower ...........................................................................................11

1.2.9 Data acquisition system ............................................................................11

1.2.10 Operator panel ........................................................................................12

1.2.11 Liquid propane cylinder ..........................................................................13

1.2.12 Flue gas temperature thermocouple ........................................................13

1.3 General Operational limitations ......................................................................14

1.3.1 BOILER ....................................................................................................14

1.3.2 BURNER ..................................................................................................14

1.3.3 GENERATOR ..........................................................................................14

1.3.4 ABNORMAL SHUTDOWN “OFF-OPEN-OFF” ...................................14

1.4 General Guidelines .........................................................................................15

2: Pre-operation Preparation (For Demo run purposes only). .................................16

3: System Operation .................................................................................................17

3.1 Prestart check ..............................................................................................17

3.2 Start operation .............................................................................................20



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3.3 Steady state operation (Experimental run) ..................................................23

3.4 Shutdown .....................................................................................................24

4: Practical Guidelines for Reporting ......................................................................27

4.1 Technical Report Guidelines ..........................................................................27

4.2 Oral presentation .............................................................................................28

4.3 RankineCyclerTM Data Run Plots ...................................................................29

4.4 System Analysis ..............................................................................................30

4.3.1 Boiler ........................................................................................................30

4.3.2 Turbine ......................................................................................................30

4.3.3 Cooling Tower ..........................................................................................31

4.3.4 Overall System ..........................................................................................31



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List of Figures Figure 1. Schematic of an ideal Rankine cycle.. ...................................................................................................... 5

Figure 2. PV and TS property diagram for the ideal Rankine cycle. ................................................................... 5

Figure 3. Temperature- Entropy diagram representation of the four processes within the Rankine cycle.. . 6

Figure 4. Image of the RankineCyclerTM laboratory setup. ................................................................................... 7

Figure 5. Boiler assembly. .......................................................................................................................................... 8

Figure 6. Steam admission valve. ............................................................................................................................. 9

Figure 7. CAD cutaway of the steam turbine........................................................................................................ 10

Figure 8. Steam turbine. ........................................................................................................................................... 10

Figure 9. Electrical generator................................................................................................................................... 11

Figure 10. Cooling tower. ........................................................................................................................................ 11

Figure 11. Screenshot of the data acquisition system of the RankineCycler..................................................... 12

Figure 12. Flue gas temperature measurement. ................................................................................................... 13

Figure 13. Schematic of the boiler tubing. ............................................................................................................. 16

Figure 14. Caster wheels closed position. .............................................................................................................. 17

Figure 15. Snapshot of Load switch and rheostat position during the prestart checkup. .............................. 18

Figure 16. Snapshot of cooling tower draining step. ........................................................................................... 18

Figure 17. Snapshot of boiler front door during prestart check. ........................................................................ 18

Figure 18. Snapshot of boiler drain check during prestart check. ...................................................................... 19

Figure 19. Snapshot of proposed beaker position for boiler fill during prestart check. .................................. 19

Figure 20. Snapshot of the location for the aluminum coupler attachment to the boiler. .............................. 20

Figure 21. Location for observation of burner operation. ................................................................................... 21

Figure 22. Steam admission valve rotation counter-clockwise and clockwise to preheat the system. ......... 22

Figure 23. Snapshot of the target operating conditions for the generator after preheating is completed. ... 22

Figure 24. Snapshot of turning off the BURNER SWITCH during Shutdown. ............................................... 24

Figure 25.Snapshot of turning off the OPERATOR PANEL GAS VALVE during Shutdown. ...................... 25

Figure 26. Snapshot of turning off the LOAD RHEOSTAT during Shutdown. ............................................... 25

Figure 27. Snapshot of turning off the LOAD SWITCH during Shutdown. .................................................... 25

Figure 28. Snapshot of turning off the MASTER SWITCH during Shutdown. ................................................ 26

Figure 29. Snapshot of turning off the FUEL SOURCE during Shutdown. ...................................................... 26



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1: INTRODUCTION

One of the most significant contributions to the development and growth of our modern technological way

of life has been the ability to extract vast amounts of energy from available natural resources. These energy

sources allowed us to generate and control work, power and heat to meet the functional demands of

societies around the world. Typical natural resources that are currently in use for energy purposes include

petroleum oil, natural gas, coal, biomass, water, wind, solar, and nuclear.

The production of heat and power is derived from man-designed thermodynamic cycles that manipulate

the existing conditions of a working fluid to extract naturally stored energy into a usable form. Several

cycles have been developed through history, however the Rankine cycle remains to be the most dominant

application in terms of market share (almost 90%), as it could be applied efficiently with a wide range of

fuels. The cycle is named after the Scottish civil engineer William Rankine (pronounced “Rang-Keene”),

who is considered one of the founding fathers in the field of thermodynamics.

In a power cycle, chemical energy of the fuel is transformed (through an intermediate step of heat

generation) into mechanical work. In a Rankine based power plant, the working fluid, which is water,

undergoes phase transformation into steam at elevated thermodynamic conditions and is used to drive a

turbine, where mechanical energy is finally transformed into the desirable or target product of electricity.

The real Rankine cycle found in existing power plants is much more complex and includes variations from

the idealized cycle, however the conceptual thermodynamic steps remain the same.

Upon completion of this laboratory assignment, as part of the course EEN-E1010 – Power Plants and

Process at Aalto University School of Engineering, a solid and fundamental understanding of the core

driving units in commercial power production is obtained. The RankineCyclerTM setup will offer an

opportunity for a hands-on experience on the operation and control of a lab-scale steam power plant. The

operational parameters of the cycle sub-processes are measured and analyzed to better understand their

performance characteristics. This knowledge will hopefully transfer very well into full-scale systems within

the power production industry.

Disclaimer: Some of the content in this laboratory students’ manual is based on the instruction and

operation manual documents provided by Turbine Technologies LTD for educational purposes of

operating the RankineCyclerTM steam turbine power system, model: RC-101.



5

1.1 Rankine Cycle

Figure 1. Schematic of an ideal Rankine cycle. Q stands for heat and W for work. (Blue lines represent water in liquid state, Red

lines represent water in elevated steam conditions, Black lines are energy streams)

The ideal Rankine cycle consists of four subsequent processes for the working fluid, for e.g. water, to

undergo for the production of electricity, as shown and numbered in Figure 1. The theoretical starting point

of the cycle, state 1 is the water in its liquid form near ambient conditions. The first process is the isentropic

compression (1-2) of the working fluid by the mechanical work from the pump to elevated pressures. The

introduction of heat is the following step in an isobaric manner (2-3), for e.g. in a boiler, where liquid water

undergoes phase change into saturated and then finally superheated steam at state 3. Then the work

production step takes place, where the pressurized steam is expanded isentropically (3-4) within the

turbine to extract mechanical work. Finally, to close the cycle, remaining heat is removed in an isobaric

manner within the condenser (4-1) for the working fluid to return to the initial state of saturated liquid. The

thermodynamic cycle is further shown on the property diagrams in Figure 2, where the phase change or

cross from liquid to vapor and vice versa along with intermediate two-phase state are illustrated.

Figure 2. PV and TS property diagram for the ideal Rankine cycle.

BoilerTurbine

Pump

2

1 4

3

Condenser

qin

qout

WtWp



6

The four main steps of the real Rankine cycle are further demonstrated in Figure 3; where (1-2) is liquid

compression, (2-3) is the isobaric heat addition, (3-4) steam expansion and finally (4-1) water condensation.

In practice, the ideal cycle is not achievable and a deviation is present due to irreversibility in the

mechanical operation of the components, such as friction or heat transfer losses. The clear variation of the

real cycle (shown in Figure 3) to the ideal cycle (shown in Figure 2) is the presence of the irreversible steam

expansion step (3-4). As the introduction of the superheated steam through the nozzles of the turbine and

the process of vapor hitting the turbine blades and moving the shaft is irrecoverable in nature. As such,

step (3-4) is not isentropic and entropy is generated in that step which leads to less work extracted and then

additional heat is needed to be removed within the condenser step.

Figure 3. Temperature- Entropy TS diagram representation of the four processes within the Rankine cycle. Note: this is not an

ideal cycle.

As such, the energy analysis for the four processes/components could be defined by the enthalpy profile

at each stage, as following:

Water pump (1-2): 𝑊𝑝 = ℎ2 − ℎ1

Boiler (2-3): 𝑄𝑖𝑛 = ℎ3 − ℎ2

Turbine/Expander (3-4): 𝑊𝑝 = ℎ3 − ℎ4

Condenser (4-1): 𝑄𝑜𝑢𝑡 = ℎ4 − ℎ1

In addition, the overall thermal efficiency of the cycle is a combination of all four equations. Where, the

cycle input is the amount of heat added and product would be the net generated work.

Rankine cycle efficiency, 𝜂𝑇 =𝑊𝑛𝑒𝑡

Q𝑖𝑛 × 100% =

(ℎ3− ℎ4) −(ℎ2− ℎ1)

ℎ3− ℎ2 × 100%



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1.2 The Laboratory Setup

Figure 4. Image of the RankineCyclerTM laboratory setup.

The RankineCyclerTM setup, shown in Figure 4, is a lab-scale power generation system specifically designed

for educational purposes. The setup resembles the operation and control of an industrial scale steam cycle,

where each component models the full size components in purpose and function. In this section, the

RankineCyclerTM components will be thoroughly introduced, including all components that make up the

actual system, its integrated data acquisition system and virtual instrument panel. From there, operating

the system allows the study of the important performance parameters such as; fuel energy density, boiler

heat flow, energy conversion efficiency, system mass flow rate, turbine work rate, generator

output/efficiency, condenser efficiency, total system efficiency.

1.2.1 Burner A forced air gas burner provides the necessary energy to vaporize the liquid working fluid as it passes

through the boiler, illustrated in Figure 5. An electrically driven centrifugal blower provides combustion

air to the burner through a blower duct. A fuel line is routed through this duct, delivering fuel to a gas



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mixing nozzle. The fuel and air are further mixed by a vortex disk that introduces turbulence to the flow.

A “hot surface" igniter located in the fixed rear boiler door and at the end of the primary flame tube

provides the ignition source. The igniter is a resistance element that glows when current is applied to it.

The fuel and air mixture combusts when it comes in contact with this glowing element producing a flame

confined within the primary flame tube. Once combustion commences, the flame is self-sustaining and the

igniter will shut off.

Figure 5. Boiler assembly: 1- burner, 2- boiler 3- sight glass and 4- boiler pressure gauge.

1.2.2 Boiler

The boiler facilitates the vaporization of the system working fluid, making it available to the turbine for

power extraction. All boilers provide for some manner of heat transfer between the heat source and the

system working fluid. The RankineCyclerTM utilizes a fire tube and shell boiler arrangement, which is

representative of over 80% of all boiler systems in use today. The shell of the boiler is an 8 in (20.3 cm)

diameter by 11.5 in (29.2 cm) long stainless steel cylinder. The cylinder holds both the working fluid of the

system as well as the high-pressure vapor prior to it exiting to the turbine.

To allow heat transfer, 17 tubes of 0.5 in diameter (1.3 cm) pass through the cylinder allowing hot

combustion gasses from the burner to “flow through" the boiler. Five of these boiler tubes lie above the full

water line. A primary flame tube 2 in (5.1 cm) in diameter also passes through the boiler and holds the

flame produced by the burner. The walls of the 17 tubes and the primary flame tube provide nearly 380 in2

(2,451.6 cm2) of surface area for heat transfer.

1

2

3

4



9

Positive pressure provided by both the blower and the expansion of the combustion gasses moves the hot

air through and out of the primary flame tube. The rear boiler door then ducts this air to the 17 through

tubes. The combined volume of the 17 through tubes is just under that of the primary flame tube, insuring

an even air flow with maximum surface area contact. The hot air exits the through tubes and is ducted by

the front boiler door through a vertical stack, exhausting the combustion gasses up and away from the

boiler.

The front boiler door is hinged, while the rear is fixed. A latch secures the front door in the closed position

while the system is operating. When the system is not operating and sufficiently cool, the front door may

be unlatched and opened for viewing. The general arrangement of the through tubes and the primary flame

tube can be seen. The rear door holds the hot surface gas igniter while the front door holds the blower unit

and the exhaust stack.

1.2.3 Sight glass

The sight glass provides an indication of the relative level of working fluid within the boiler. An upper and

lower adjustable bezel allow the extents of working fluid to be marked. These markings make it easy to

measure the amount of working fluid consumed during operation of the system. Attached to the bottom

of the sight glass is the fill fitting, connecting the sight glass to the boiler and permitting the boiler working

fluid level to show in the sight glass. At the top of the sight glass is a vent fitting that also connects back to

the boiler to equalize pressure. The sight glass is not calibrated and only provides an indication of the boiler

fluid level. Because of the curvature of the boiler cylinder and the presence of the through tubes, the level

in the sight glass is non-linear over the volume of the boiler.

1.2.4 Boiler pressure gauge

An analog pressure gauge is installed providing a direct read out of available boiler pressure. The gauge

indicates the normal range of operation with a white background. The red area of the gauge indicates

pressure conditions that exceed normal operating limitations.

1.2.5 Steam admission valve

The steam admission valve is a needle type valve that regulates steam vapor flow to the turbine. In fully

clockwise position, it is CLOSED, preventing flow. In fully counter-clockwise position, the valve is OPEN

and the full flow of steam is available to the turbine. Intermediary positions regulate accordingly. In

addition to the steam admission valve setting, steam flow is dependent on boiler pressure and temperature.

Figure 6. Steam admission valve.



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1.2.6 Steam turbine

The steam turbine provides useful work through the extraction of energy from the vaporized working fluid

provided by the boiler. High pressure steam is directed through a nozzle, forcing the steam to impinge

directly on the blades of the turbine wheel causing it to rotate. This rotation is then used to derive useful

work. The single stage turbine unit is made up of a front and rear housing, each precision machined and

fitted with a carbon bearing requiring no additional oil or lubrication.

Figure 7. CAD cutaway of the steam turbine.

The three main functional steps within the turbine are shown in Figure 7 and could be summarized as:

1. Steam enters inlet port at the bottom left.

2. Steam flow forced through slits in stator ring (purple), impinging on turbine blades, spinning

turbine wheel (red).

3. Steam exits turbine to condenser.

In addition to the inlet and outlet fittings in the front and rear housing, respectively, two other fittings

provide transducer access to turbine inlet temperature and pressure as well as turbine outlet temperature

and pressure. These values are measured by the data acquisition system and available on the computer.

Figure 8. Steam turbine.

1

2

3



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1.2.7 Generator

The generator utilizes the rotational motion of the turbine to produce electrical energy. A four-pole,

permanent magnet, brushless design, the generator is directly coupled to the output shaft of the turbine

and supported on its own set of preloaded ball bearings. Both alternating current (AC) and direct current

(DC) are available at the generator outputs.

Figure 9. Electrical generator.

1.2.8 Cooling tower

The cooling tower facilitates heat transfer between the hot vapor exiting the turbine and the relatively cool

ambient air surrounding the tower. The tower mantle, manufactured from aluminum, provides the heat

transfer interface and a condensation surface. Steam enters the cooling tower through a distribution

manifold that disperses the steam within the tower to maximize contact with the mantle. Four internal

stainless steel baffles further direct the steam along the mantle, while allowing condensate to run back to a

catchment basin at the bottom of the tower. This basin can be drained, using the attached hose and pinch-

clamp, to accurately measure the amount of condensate collected.

Figure 10. Cooling tower.

1.2.9 Data acquisition system

The RankineCyclerTM is equipped with a National Instruments 6218 precision data acquisition system,

which provides full range of system parameter measurement. This system, consists of a suite of sensors,

excitation power sources, signal conditioners, data acquisition hardware and user interface software, when

used in conjunction with an appropriate computer, allows actual run-time data to be displayed and

recorded for later analysis.



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Figure 11. Screenshot of the data acquisition system of the RankineCyclerTM.

1.2.10 Operator panel

The panel is shown in Figure 12 and consists of the following control switches:

Keyed Master Switch: The key lockable master switch controls the supply of electrical power to the

main bus that powers the indicator lights, boiler combustion boiler and the gas control module.

GREEN indicator light will illuminate when this switch is selected ON and power is available.

Burner Switch: The burner switch enables the gas control module and powers the burner blower. A

RED indicator light above the switch will illuminate when this switch is selected ON and power is

available to the burner circuits.

Low Water Indicator Light: RED indicator that shows a warning by the low water level in boiler.

Load Switch: The load switch enables the load bank. The load bank presents a true load to the

generator, allowing the operator to simulate conditions at a full scale power station when consumer

demand fluctuates.

Load Rheostat Control: The full counter-clockwise position of the control represents NO LOAD, full

clockwise position of the control represents FULL LOAD.

Operator Panel Gas Valve: Rotating the black gas valve knob counter-clockwise to the 3 o'clock

position OPENS the valve. Rotating the valve knob clockwise to the 6 o'clock position CLOSES

the valve and prevents any flow of gas through the regulator.

Amp Meter: The amp meter indicates the amount of current the load is drawing based upon the

load (as set by the Load Rheostat Control) and the available voltage (as provided by the generator;

a function of generator speed/RPM).

Volt Meter: The volt meter indicates the amount of voltage the generator is providing (a function of

generator speed/RPM).



13

Figure 12. RankineCyclerTM operator panel with illustrations of the main components.

1.2.11 Liquid propane cylinder

The cylinder contains the fuel necessary to operate the system. The fuel regulator is completely closed

during startup and then completely open when operation takes place. The Operator Panel Gas Valve in the

operator panel controls the flow of fuel to the burner, and is set to a constant value throughout the

experiments.

1.2.12 Flue gas temperature thermocouple The temperature thermocouple is inserted into the flue gas exhaust to record the outlet temperature. A

measurement device will be provided during the experiment to take sample readings, shown in Figure 13.

Figure 13. Flue gas temperature measurement.



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1.3 General Operational limitations The RankineCyclerTM is designed to be operated within the following limitations. Under no circumstances

should these limitations be exceeded by any margin. Operator safety and efficient operation of the R

RankineCyclerTM is contingent upon these limitations being followed.

1.3.1 BOILER

MAXIMUM OPERATIONAL BOILER PRESSURE . . . . . . . . . . . . . . . . . . . . . 120 psi (827 kPa)

MAXIMUM OPERATIONAL BOILER STEAM TEMPERATURE . . . . . . . . . . . 608 ±F (320 ±C)

MAXIMUM OPERATIONAL BOILER VOLUME . . . . . . . . . . . . . . . . . . . . . . 203 oz (6,000 ml)

OPERATING FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER

1.3.2 BURNER

FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .LIQUID PROPANE (LP) ONLY

1.3.3 GENERATOR MAXIMUM GENERATOR OUTPUT, Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.0 Volts

MAXIMUM GENERATOR OUTPUT, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Amps

MAXIMUM GENERATOR OUTPUT, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Watts

MAXIMUM GENERATOR SPEED, RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500 RPM

1.3.4 ABNORMAL SHUTDOWN “OFF-OPEN-OFF”

The RankineCyclerTM is designed with the necessary safety alarms and switch offs that minimize hazardous

operation and ensures operator safety. In the unlikeliness of abnormal events or accidents (Fire or electrical

malfunction) taking place during the operation, familiarize with the following ABNORMAL

SHUTDOWN procedure. CAUTION that this procedure is for the worst case scenario and will be

performed by the TEACHING ASSISTANT.

The “OFF-OPEN-OFF” procedure includes

1. OFF – Shut OFF the MASTER SWITCH, to cut off all electrical system operation.

2. OPEN – Fully OPEN the STEAM ADMISSION VALVE, to relieve system pressure.

3. OFF – Shut OFF the supply of gas to the burner.



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1.4 General Guidelines The following General Guidelines are offered as reminders of items requiring particular attention, further

details on each are mentioned throughout the manual.

Mandate the appropriate personal safety equipment for all operators and observers.

Know the facility safety policies, emergency contact numbers and location of fire extinguishers.

Read and become familiar with the RankineCyclerTM Student's Manual.

DO NOT operate RankineCyclerTM without first becoming familiar with the Student's Manual.

DO NOT operate the system unattended.

Use the provided checklists during every operation.

Lock all four caster wheels during operation.

Use only in a well ventilated area.

Continually monitor all system parameters and be attentive for out of limit readings. Immediately

consult with the teaching assistant if anything is questionable.

DO NOT exceed scale readings/limitations on any instrument or gauge.

Remember, the working fluid is high temperature, pressurized steam.

Consider all surfaces to be HOT during and for a significant time after operation. DO NOT touch

any surface during operation.

DO NOT move the system while operating or when the boiler is pressurized.

DO NOT allow the boiler water level to become less than 1.0 in (2.5 cm) as indicated on the sight

glass.

DO NOT attempt to fill the boiler while the system is pressurized.

DO NOT open the boiler doors while hot, doing so may cause permanent warp-age of the boiler

cradle.

DO NOT tighten or adjust fittings while system is under pressure.

DO NOT tap on or scratch boiler sight glass.



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2: Pre-operation Preparation (For Demo run purposes only). In preparation for the system operation and data analysis, students are advised to read the complete

laboratory manual, familiarize themselves with the setup and perform some background reading on the

Rankine cycle as well as the different operational components.

Each student present for the demo lab run is expected to present a personal data sheet answering the

following questions before taking part in the experiment.

1. Liquid propane (LP) is the current used fuel, where it is vaporized and introduced into the burner.

What is the energy content per unit volume and mass of gaseous LP? Identify both the lower and higher

heating value of LP? If we assume a flow of 6 L/min at steady state, what is the energy consumption

per hour of the system? What are the expected products in the flue gas, (assume 100% content of C3H8)

in the cases of excess, stoichiometric and deficit oxygen supplied?

2. Sketch a process flow diagram (use blocks to show components, do not need to draw each component)

of the laboratory setup, and illustrate the major input and output material and energy streams. (Hint:

Microsoft Visio® is a good tool to assist you. However, hand sketched diagrams are perfectly accepted).

3. The boiler is shell and tube style construction. Calculate the available volume for water in the boiler

given the basic construction dimensions shown in Table 1. If the boiler is filled with 5500 ml of water,

what is the fill percentage and estimate the number of flame tubes that would not be submerged within

the working fluid.

Table 1. Boiler basic dimensions.

Main Shell External Length 29.85 cm

Main Shell Wall Thickness 0.198 cm

End Plate Outside Diameter 20.32 cm

End Plate wall thickness 0.318 cm

Main Flame Tube Outside Diameter 5.08 cm

16 Return Pass Flame Tubes Outside Diameter 1.9 cm

Figure 14. Schematic of the boiler tubing.

4. What are the operating limitations for the BOILER pressure, generator voltage and ampere output.

5. State the three main steps in the ABNORMAL SHUTDOWN procedure.



17

3: System Operation This section includes the standard procedural steps for Prestart check, Startup operation, Steady state

operation and Shutdown, which allows for an efficient and safe operation of the system. Familiarity with

these procedures must be made prior to operating the RankineCyclerTM for the first time. Even experienced

operators should continue to use the checklist for each operational run to eliminate the possibility of

overlooking or inadvertently eliminating a necessary step. All steps are expected to be conducted by the

student group members, under the supervision of the teaching assistant, and should be followed exactly in

the same sequence presented here in the manual. The data acquisition system is used to capture all

operational values from startup to shutdown, however some data are required to be obtained manually:

Steady state start time.

Steady state stop time.

Initial, intermediate and final Boiler fill estimate on the sight glass.

Amount of condensate collected during experiment.

Flue gas temperature readings.

3.1 Prestart check The PRE-START checklist must be completed prior to operating the RankineCyclerTM. The checklist ensures

that all system components are ready for operation and that heat can be safely applied to the boiler.

1. THE AREA CHECK and SAFETY MEASURES- assessment to VERIFY SUITABILITY OF

THE OPERATION and the SAFETY of the operators (Each group member should present a

personal data sheet similar to that shown in Section 2). This step is to ensure all members of

the group are familiar with laboratory safety procedures, any additional equipment

requirements and an opportunity for consultation with the teaching assistant on any questions

or concerns before operation. All operators and personnel in the immediate area should know

the location of fire extinguisher equipment, circuit breakers and fuel supply valves, as well as

being familiar with existing safety policies and procedures, emergency escape routes, and

emergency services telephone numbers/points of contact.

2. CASTER WHEELS must be in the LOCKED position prior to operation, preventing movement

that may either pose a safety hazard or disrupt critical operations such as boiler filling.

Figure 15. Caster wheels closed position.



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3. Ensure the following switch positions:

a. MASTER SWITCH - OFF position: GREEN light OFF

b. BURNER SWITCH - OFF position: DOWN position

c. LOAD SWITCH - OFF position

d. LOAD RHEOSTAT – Minimum load – FULL COUNTER-CLOCKWISE POSITION

Figure 16. Snapshot of Load switch and rheostat position during the prestart checkup.

e. OPERATOR PANEL GAS VALVE – OFF positon

4. Perform a thorough VISUAL INSPECTION of each major component and the system. Verify

that no components are damaged, tampered with or missing from previous runs.

5. Drain the COOLING TOWER using the attached clear tubing and pinch-clamp. Discard any

condensate collected, and empty in drain after measurement, DO NOT RE-USE.

Figure 17. Snapshot of cooling tower draining step.

6. The FRONT BOILER DOOR must be CLOSED and LATCHED (REAR DOOR is stationary).

Figure 18. Snapshot of boiler front door during prestart check.



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7. The STEAM ADMISSION VALVE must be OPEN to allow air to vent out of the boiler

during the fill operation. Water will not enter the boiler with the valve closed.

8. The BOILER should be DRAINED completely using the fill/drain valve and beaker assembly.

Figure 19. Snapshot of boiler drain check during prestart check.

9. Fill the BOILER with 5,500 ml of clean, distilled water for the most efficient operation. Any

quantity over this recommended amount will likely degrade boiler performance and may

prevent the boiler from producing any pressure. During fill, scale the boiler level on the sight

glass, in order to be able to estimate the water consumption during steady state. With the

beaker ball valve closed, fill the beaker to the desired boiler level.

a. Place the beaker on a firm support higher than the boiler fill/drain valve at the rear of

the boiler. If this is the first run of the day or adequate time has passed that the cooling

tower is sufficiently cold, beaker can be placed on the tower.

Figure 20. Snapshot of proposed beaker position for boiler fill during prestart check.

b. Insert the aluminum coupler at the end of the beaker hose assembly into the fill/drain

valve coupling hole.



20

Figure 21. Snapshot of the location for the aluminum coupler attachment to the boiler.

c. Open the beaker ball valve to allow water to fill the boiler. At the meantime SCALE

(calibrate) the SIGHT GLASS at equal intervals. (recommended every 500 ml)

d. When all the water has emptied from the beaker, close the beaker ball valve and

remove the aluminum coupler from the fill/drain valve. If the beaker assembly was

placed into the top opening of the cooling tower while filling the boiler, remove it

before proceeding to the next step.

10. Now, put the STEAM ADMISSION VALVE back to the CLOSED position which was opened

before filling the boiler. Starting with a closed valve lets boiler pressure properly build up.

11. Now, connect the COMPUTER DAQ SYSTEM USB cable to the USB system on the left side

panel of the RankineCyclerTM. Make sure the computer is OFF prior to connecting the cable or

the DAQ Module hardware/software may not properly initialize.

12. Connect the RANKINECYCLER ELECTRICAL SERVICE to the electrical outlet.

13. Check the FUEL SOURCE line connection to the LP FUEL SUPPLY TANK.

3.2 Start operation The Start operation procedure is necessary to take the RankineCyclerTM from cold shutdown conditions

through preheating and to run-time data collection at steady state.

1. THE COMPUTER DAQ SYSTEM should be turned on. Note: ensure that the computer USB

connection is attached to RankineCyclerTM before the computer is turned on, to avoid improper

DAQ module hardware/software initialization. TURN DATA LOG ON.

2. FUEL SOURCE regulator is opened, and initial FUEL LEAK CHECK must be completed

before any further steps take place. (NOTE: LOOK OUT FOR A “HISSING” SOUND OR

FUEL ODOR)

3. OPERATOR PANEL GAS VALVE is turned to ON position.

4. MASTER SWITCH key is turned to ON position. GREEN light is illuminated, which indicates

that electrical power is now available to the system components.

5. Check if the FLUE GAS TEMPERATURE MEASUREMENT and GAS ANALYZER devices

are working.



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6. Select the BURNER SWITCH to the ON position. RED light is illuminated. Observe the

COMBUSTION BLOWER and verify if it is on. The blower motor should be heard as it begins

to rotate, drawing air into the burner and forcing it through the boiler.

NOTE: To PURGE FUEL LINES, you could allow the blower to operate for 45 seconds then

turn the BURNER SWITCH off and immediately back on (CONSULT WITH THE

TEACHING ASSISTING BEFORE PURGING).

7. VERIFY that the BURNER has LIT within 45 SECONDS of selecting the BURNER switch on.

It should be noted that the burner may occasionally burp" - producing an audible popping

noise with a small blue flame present at the blower inlet. This behavior is normal and should

NOT be considered a fire requiring the execution of the abnormal procedures.

Figure 22. Location for observation of burner operation, Blue flame is considered the first sign, in addition to a distinguishable

gas burning noise.

8. Monitor BOILER PRESSURE on the pressure gauge as well as through the DAQ system.

VERIFY POSITIVE PRESSURE within 3 MINUTES from start. If not, turn off the BURNER

SWITCH and investigate. Verify that the proper amount of water is in the boiler and the

STEAM ADMISSION VALVE is fully CLOSED.

9. Allow the indicated BOILER PRESSURE to rise to approximately 120 psi (827 kPa).

10. The system should now be PREHEATED. This allows the steam lines, valves and turbine to

come up to the proper operating temperature. The turbine bearings are also lubricated at this

time. During the preheating period, small vapor leaks and condensation droplets may be seen

around the turbine and related fittings. This is normal and should subside once the turbine

bearing clearances close due to thermal expansion. The preheating process outlined below

should take approximately 7 to 10 MINUTES to complete. This preheating process is essential

to supplying the highest quality steam available to the turbine. If preheating is omitted,

condensation will form in the steam lines degrading system performance overall. The

preheating steps are:

a. The STEAM ADMISSION VALVE should be turned counter-clockwise to OPEN.

This will allow steam to flow throughout the system. The turbine/generator may or

may not rotate at this point.

b. Monitor BOILER PRESSURE until it falls to approximately 50 psi (345 kPa). During

which the load switch (Turn ON) and rheostat knob will have to be used so the



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turbine/generator does not over speed (RPM should be below 2500) and not exceed 9

volts. (GROUP WORK IS ESSENTIAL AT THIS POINT TO SYNCHRONIZE THE

RHEOSTAT ADJUSTMENT WITH THE RESULTING GENERATOR READING

ON THE DAQ SYSTEM)

c. The STEAM ADMISSION VALVE should be turned clockwise to CLOSE. This will

stop the steam flow and allow for boiler pressure to build up again.

Figure 23. Steam admission valve rotation counter-clockwise and clockwise to preheat the system.

d. Turn the RHEOSTAT knob back to original position and shut the LOAD SWITCH off.

e. Allow BOILER PRESSURE to rise back to approximately 120 psi (827 kPa).

11. Open the STEAM ADMISSION VALVE slowly, while maintaining approximately 120 psi

(827 kPa) of BOILER PRESSURE. Once the turbine begins to rotate, the generator will produce

electricity. Monitor the turbine RPM, it should not exceed the safe limit of 2500. Generator

output will be directly indicated on the VOLT METER.

12. Turn ON the LOAD SWITCH again. Continue opening the STEAM ADMISSION VALVE

and simultaneously ADJUST the LOAD RHEOSTAT.

Figure 24. Snapshot of the target operating conditions for the generator after preheating is completed.

13. In preparation of an experimental data run, the STEAM ADMISSION VALVE and the LOAD

RHEOSTAT may continue to be adjusted to achieve a STEADY STATE CONDITION.

Satisfactory run-time results can be achieved with the following values:

a. An AMP METER indication of approximately 0.23-0.35 Amps.

b. A VOLT METER indication of approximately 8.0-9.0 Volts.

c. A BOILER PRESSURE indication according to experimental conditions (generally

120 psi (827 kPa)).



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3.3 Steady state operation (Experimental run) This section illustrates the experimental procedure for operation, as well as the necessary data acquisition

after steady state conditions are achieved. The system will be operated at two different boiler pressure

steady conditions, the first is the design (or optimal) setting of 120 psi and the second pressure level is at

the lower conditions of 85 psi. A data set will be collected for each pressure condition and a system level

analysis should be conducted for each.

1. To begin the experimental run, TIME and BOILER FILL LEVEL from the sight glass should

be noted. This is essential as data log in the DAQ is not in real time (only cumulative time) so

a comparison between the real time at which the log started and the experimental start is

needed to establish the time interval for usable data in the steady state analysis.

2. CHECK with the teaching assistant that the data log for the flue gas analyzer is also turned on.

3. SET the SIGHT GLASS UPPER BEZEL to the current, indicated WATER LEVEL. This value

will be compared to the end of the experiment level to validate your calculation for steam flow

rate through the system.

4. For the operation of the first pressure level, set the group starting TIME and continue to use

the STEAM ADMISSION VALVE to make PERIODIC ADJUSTMENTS maintaining the

STEADY STATE established in the experiment (120 psi) for a total period of 5 MINUTES.

5. The FLUE GAS TEMPERATURE reading should be periodically taken and noted every 30

seconds for the duration of the 4 minutes.

6. At the END of the 5-minute interval, NOTE the time for the 120 psi run and NOTE down the

new level of water in the BOILER from the CALIBRATED SIGHT GLASS, this data will be

used to assume the steam flow exiting the steam admission valve during the run.

7. After completion of data collection for the first run, use the STEAM ADMISSION VALVE to

make PERIODIC ADJUSTMENTS to bring the BOILER PRESSURE down to the second

pressure level and maintain steady state conditions for a total period of 3 MINUTES. The

RHEOSTAT KNOB should be adjusted accordingly to maintain the recommended operation

conditions for the generator similar to the steady state.

8. Note the TIME of start and BOILER FILL LEVEL. Then REPEAT STEPS 5 to 8 for the new

pressure level.

9. After finishing the experimental runs, the COOLING TOWER should be drained to measure

the amount of CONDENSATE collected during the whole experiment (preheating and steady

state operation). As the condensate will contain suspended turbine oil, it is suggested that a

disposable or condensate specific vessel be used. NOTE that the CONDENSATE is HOT, so

should be collected with care.

IMPORTANT NOTE: For the second run, make sure that the boiler water level does not drop too

low. If you observe that this is the case, consult with the teaching assistant immediately.



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A number of responsibilities could be delegated or shared among the group members during

the two pressure level runs. It is advised to be set and agreed upon as part of the preparation

before starting the experiment: (The arrangement below is only a suggestion).

a. Responsible for the checklist and ensure procedural sequence of the experimental run.

b. Monitor recommended operation conditions on the DAQ and liaison with other

member handling the rheostat knob.

c. Handle the steam admission valve and the rheostat knob (generator load) along with

monitoring the voltage and ampere readings of the generator from the operator panel.

d. Water level measurement in the boiler.

e. Data logging and time keeping for the two runs.

f. Flue gas measurement (temperature) recording, the analyzer data will be provided by

the teaching assistant.

g. Condensate collection and data recording.

3.4 Shutdown The SHUTDOWN checklist ceases RankineCyclerTM operation and places the system into a known, safe

condition.

1. Turn the STEAM ADMISSION VALVE to the CLOSED position.

2. SET the SIGHT GLASS LOWER BEZEL to the current, indicated WATER LEVEL. This allows

measurement of the boiler water consumed during the whole experimental run.

3. Select the BURNER SWITCH to OFF. Verify that the RED light is extinguished indicating

that no electrical power is available at the burner or the blower. The blower should

immediately stop rotating.

Figure 25. Snapshot of turning off the BURNER SWITCH during Shutdown.



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4. The OPERATOR PANEL GAS VALVE should be selected OFF.

Figure 26.Snapshot of turning off the OPERATOR PANEL GAS VALVE during Shutdown.

5. The LOAD RHEOSTAT should be turned FULL COUNTER-CLOCKWISE, resulting in

MINIMAL LOAD.

Figure 27. Snapshot of turning off the LOAD RHEOSTAT during Shutdown.

6. The LOAD SWITCH should be selected OFF.

Figure 28. Snapshot of turning off the LOAD SWITCH during Shutdown.



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7. Turn DATA LOG OFF in the computer DAQ system and the gas analyzer systems to stop

recording system measurements.

8. The MASTER SWITCH should be selected OFF. Verify that the GREEN light is extinguished.

Figure 29. Snapshot of turning off the MASTER SWITCH during Shutdown.

9. The STEAM ADMISSION VALVE should be turned to the fully OPEN position SLOWLY

as to not exceed 9 volts. This relieves all remaining boiler pressure.

10. The FUEL SOURCE valve should now be turned OFF.

Figure 30. Snapshot of turning off the FUEL SOURCE during Shutdown.



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4: Practical Guidelines for Reporting This section shows the guidelines for the final technical report and presentation for each student group, as

well as for laboratory run data acquisition and system analysis.

4.1 Technical Report Guidelines The technical report is expected to showcase the accumulated knowledge by the group members of the

fundamentals of a Rankine cycle-steam power plant for design, operation and analysis purposes. Logically

the language of the report should be in English only. All members of the group are expected to participate

actively in the laboratory run as well as in reporting. Thus, the report is expected to include a sub-section

as part of the introduction which specifies the delegated tasks and the contributions of each member. The

expected outline of the report (chapters) includes:

(Groups are free to restructure the report, this is merely a guideline for what should be included)

Cover page.

The cover page represents the title of the work, each group is free to choose the report name, which

should reflect the topic of report as well as purpose of laboratory run or the main findings from the

run. The page should include group number, list of members, and their respective information.

Abstract.

The abstract is a short summary of the report, maximum 200 words, with emphasis on the highlights

in the report. A list of 4 key words should be included at the end also.

Table of content, list of Figures and list of Tables.

Introduction.

Clearly indicate the context/background of the technical report. The objective of the laboratory run.

Group members’ contribution and designated tasks. Outline the reporting approach and content.

Theoretical background.

Use an appropriate title based on the content that is included. The chapter should include all the

necessary theory and background knowledge for the following chapters. In addition to a literature

review that lists all the sources for equations used in the calculations part.

Laboratory Setup and Procedure

Refer to the RankineCyclerTM schematic and explain the overall operation. Point out and explain the

similarities and differences between the laboratory setup and the industrial scale systems. Identify

what are the processing parameters measured and why. Provide a brief description of the experimental

procedure (Do not simply copy the Laboratory’ manual). List sets of experiments done and the range

of parameters that have been tested.



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Results.

List down and organize the laboratory run data in a coherent structure that would support the

following discussion. Select which data are relevant here and which could be rather included in the

Appendices. Present the data in a meaningful way, that major findings could be extracted from them,

thus graphs are always preferable to tables. (Note: tables are still recommended to use when listing

data such as specifications)

Discussion and Findings

Describe how the results alter along the variation of certain process parameters and how such change

would influence overall system and component performances. Identify sensitive (most impactful)

parameters and validate through comparison with what is reported in literature.

Note: This part should also include an analytical comparison between the two steady state operation

conditions.

Conclusions.

Brief summary of the main findings in the report.

References.

Nomenclature and Appendices if needed.

In general, each report should have enough detail so that the reader can comprehensively follow and

reproduce your main findings. The report is expected to list in detail the procedure and results of your

laboratory run, in addition to the discussion and analysis of the system performance. The latter two will

distinguish reports from each other and will significantly influence the final grading. The writing style is

expected to be in a technical and direct manner.

4.2 Oral presentation The schedule for the presentation is announced during the course lectures. The presentation is a group

effort where all members are expected to take part. The maximum duration of the presentation per group

is 20 minutes, with an additional 5 minutes allocated for a Q&A session. The content of the presentation

should be based around the technical report. However, complete freedom is given to the group in the

presentation design or for addition of elements to the presentation technical content deemed by the group

beneficial. The use of any support materials or tools during the presentation will be considered a bonus.

The overall grading for the presentation will be based on organization, time management, technical

content, presentation skills (language proficiency, demeanor & body language) and creativity.

The peer review process will take place after the oral presentation at which names of the group members

would be drawn anonymously, every member will be given two other member names to evaluate. The

results would be collected by the teaching instructors (only individuals to have access to that information)

and would be combined along the pre-assignment, technical report and oral presentation grading for the

overall grade.



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4.3 RankineCyclerTM Data Run Plots Graphically plot the RankineCyclerTM run data extracted from the DAQ system as a first step for the

following system analysis and performance calculations to be conducted in the following sections. Plot the

following operation parameters vs. TIME, utilizing MS-Excel, where the different operational states (the

two steady state operations and transitional states) are clearly defined and distinguished):

Fuel Flow.

Boiler Temperature.

Boiler Pressure.

Turbine Inlet/Outlet Temperature.

Turbine Inlet/Outlet pressure.

Generator DC Amps output.

Generator DC Voltage Output.

Turbine RPM.

Power produced.

From the gas analyzer data, plot the flue gas concentration of Oxygen, Carbon dioxide and Carbon

Monoxide, Propane vs. TIME, while showing the steady state conditions.

Note that steady state conditions will be the basis for your system level analysis. From the plots and the

data collected from the system run, record the following for each steady state pressure condition:

Average Fuel Flow.

Average Boiler Temperature.

Average Boiler Pressure.

Average Turbine Inlet/Outlet Temperature.

Average Turbine Inlet/Outlet pressure.

Average Power produced.

Water consumption from the Boiler.

Condensate amount collected (total operational time).



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4.4 System Analysis The objective is to conduct performance calculations using controlled volume thermodynamic

conservation laws to develop the mass and energy balance of the system and its components.

Any thermal (steam) power plant performance is mainly characterized by

Mechanical power output, 𝑊𝑡 (kW)

Electrical power output, 𝑊𝑒𝑙 (kW)

Cycle thermal efficiency, 𝜂𝑡ℎ (%)

Heat rate, 𝐻𝑅 (kJ/kWh)

Steam rate, 𝑚𝑠 (g/s)

Fuel rate, 𝑚𝑓 (g/s)

Electrical (overall) efficiency, 𝜂𝑒𝑙 (%)

Capacity factor, reliability and operating flexibility. (not included in calculation but should be

discussed in the report)

In your calculations, refer to the lecture and exercise materials along with the reference book Advanced

Energy Systems by Khartchenko for detailed formulation of the equations. Assume kinetic and potential

energy as negligible throughout the calculation for the two pressure level cases. The data needed for these

calculations come from the information plotted and recorded in the previous section. Note that steam tables

should be also used for each of the points of interest within the system.

NOTE: that although the accuracy of measurement data is an important operational consideration for

industrial application, in this laboratory assignment, the emphasis is on showing the ability to interpret the

data collected from the laboratory run and utilize it for thermal analysis of the overall plant as well as the

sub-processes.

4.3.1 Boiler

Perform the mass and energy balance for the boiler, show an illustration of the material and energy streams

on a diagram and specify the following:

Heat flow into the Boiler. (kW)

Determine the real Air to Fuel ratio, as well as Lambda.

Heat losses with the Flue gas. (kW)

Heat production from the Boiler in the product steam. (kW)

Boiler thermal efficiency. (%)

4.3.2 Turbine Calculate and specify the following:

Isentropic efficiency of the turbine. (%)

Generator efficiency. (%)

Heat losses within the steam admission valve (losses due to throttling effect). (kW)

Note: if the calculated average values are below saturation temperature, assume saturated steam

properties.



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4.3.3 Cooling Tower

Perform the mass balance only for the cooler tower, show an illustration of the water streams on a diagram

and specify the following:

Overall tower extraction efficiency. (%) Hint: (𝑚𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑎𝑡𝑒

𝑚𝑖𝑛𝑙𝑒𝑡⁄ )

Heat rejected in the condenser for each steady state. (kW)

The current cooler is air-cooled, calculate the theoretical amount of cooling medium needed if it

was water cooled. (kg/s) Hint: assume a temperature rise of 10 °C for the coolant water.

4.3.4 Overall System

Perform the overall steady state mass and energy balance, show an illustration of all material and energy

streams (with computed values) on a process flow diagram, and specify the following:

The cycle thermal efficiency. (%)

The plant electrical efficiency. (%)

Also show the T-S and H-S diagrams of the plant for the three steady state cases.

understanding power production students’ laboratory manual

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