Steam Power Plant Lab

Steam Boiler Bench

The boiler, with its attendant mains water make up tank, feed pump, steam main, blowdown, drain and feedwater connections is housed in a self-contained unit. Steam Boiler Bench consists of a sturdy framework and panels of all steel construction, fitted with a student work surface, interconnecting back panel and adjustable feet. Adjacent and connected to the framework is an electric steam boiler of 36 kW rated output. The student desk unit contains a control box with an electric power supply isolator and instrumentation to read steam and water temperatures and also to display the electrical energy consumed in kWh. All piping and wiring required to connect the boiler to the steam benches is supplied. The heat input to the boiler is provided by specially designed electrical resistance immersion elements run at a low power density in order to give a long operational life.

Experimental Capability:
To assess the heat loss from a boiler at a given steam output pressure
To determine the boiler evaporation capacity and equivalent evaporation  
Boiler efficiency trial.

Pressure and Temperature Vessel Bench

The steam bench includes a 2- pen chart recorder to provide a continuous recording of the process variables, namely temperature and pressure and gives students the opportunity to become familiar with the presentation of such data on a typical process recorder used in industry. Pressure and Temperature Steam Bench consists of a sturdy framework and panels of all steel construction, fitted with a student work surface, interconnecting back panel and adjustable feet.

Experimental Capability:
To compare the experimental observations with published data such as in steam tables.
To investigate the relationship between the temperature and pressure of saturated steam.

Steam Power Plant 1,5kW with Process Control System

The Steam Power Plant is specifically designed for training purposes in the field of power plant engineering with process control systems. The system operates very similarly to real large-scale plants due to the high degree of complexity.
The entire system is monitored, actuators regulated and controlled, measurements recorded and displayed via the process control system. Large process engineering systems, such as steam power plants, are managed with process control systems (PCS). 

Features:
Plant monitored and controlled via touch screen control station 
Complete laboratory-sized steam power plant
Process control system based on Ethernet and PLC.

Steam Power Plant 20kW with Process Control System

Due to the size and complexity of the system, in many aspects the operating behaviour corresponds to that of actual large-scale plants, thereby enabling training that is as close to the real thing as possible. The Steam Power Plant is specifically designed for training purposes in the field of power plant engineering with process control systems. The plant consists of four separate modules and can therefore be flexibly adapted to the space available in the laboratory:
The feed water circuit is equipped with a water treatment system with ion exchangers and chemical dosing. Module A steam generator assembly: a gas/oil-fired once-through steam boiler and a downstream electric super heater generate superheated steam.

Features:
Plant monitored and controlled via touch screen control station
Complete steam power plant with process control system based on Ethernet and PLC.

Steam Power Plant 1,5Kw

A steam power plant essentially consists of a heat source for generating steam, a turbine with load, and a cooling mechanism for condensing the steam. In steam power plants, thermal energy is first converted into mechanical energy and then into electrical energy.

Features:
Closed steam-water circuit
Complete laboratory-sized steam power plant.

Rankine Cycle Steam Turbine

Rankine Cycle Steam Turbine Includes instrumentation to record all relevant temperatures, pressures, cooling water and gas flows, turbine speed and turbine brake load. A bench top Rankine Cycle Steam Turbine with electric fired boiler, throttle valve, impulse turbine, sub-atmospheric water cooled condenser and boiler feed pump.

Experimental Capabilities:
Investigation of turbine torque/speed and power/speed characteristics.
Investigation of steam quality by throttling.
Investigation of a true Rankine Cycle Steam Plant.
Determination of friction losses at various exhaust pressures.
With the optional power generation module demonstration of electrical power generation.
Determine of cycle thermal efficiency based on shaft power. 

Process Plant Steam Bench

Incorporates a low pressure steam feed line including a VeeReg isolating valve, a 1 to 3 bar pressure reducing valve, a pressure relief valve set at 3.5 bar and temperature and pressure measuring points; a process fluid circuit constructed from high strength borosilicate glass components, including a reboiler equipped with a temperature measuring point, a separator with a rubber filler stopper and outlet baffle plate, a condenser, a drain valve, joint couplings and joint gaskets, reboiler blowdown pipework fitted with a flexible stainless steel braided hose complete with boiler joint adaptor flange and including a Vee-Reg isolating valve, steam trap and non-return valve; condenser cooling water feed line complete with control valve and pressure measuring point and cooling water drain line with non-return valve and pressure safety valve, set to vent at 2.5 bar. Process Plant Steam Bench consists of a sturdy framework and panels of all steel construction, fitted with a student work surface, interconnecting back panel and adjustable feet.

Experimental Capability:
Demonstration of cumulative effect on thermosyphon reboiler boiling rate, and of the boiling off of process fluid lighter fractions.
Demonstration of a thermosyphon reboiler, using water as the process fluid and steam as heating fluid.  

Reciprocating Steam Engine Bench

The steam engine is supplied with steam from a steam header at a reduced pressure via an overspeed trip solenoid valve and a displacement lubricator from which oil is displaced by droplets of condensed steam into the steam supply to lubricate the engine. Steam Engine Steam Bench consists of a sturdy framework and panels of all steel construction, fitted with a student work surface, interconnecting hack panel and adjustable feet. Engine inlet and outlet steam pressures are indicated on 0-16 bar and -1 to 3 bar Bourdon tube pressure gauges respectively. A control cubicle surmounted by resistive load elements within a separate ventilated enclosure, contains electrical control circuits and is fitted with the control switches and the indicating instruments for engine speed, dynamometer output current and voltage and analogue temperatures which can be selected by an associated multi-position switch. The steam bench comprises a robust single cylinder, double acting reciprocating steam engine driving a dynamometer which enables a calculable, variable resistive load to be easily imposed on the engine. Exhaust steam is cooled by a water cooled, coiled tube type condenser.

Ejector Steam Bench

Incorporating a typical commercially available steam ejector instrumented for the measurement of temperature and pressure at the steam inlet, suction inlet and delivery outlet. The apparatus is supplied complete with service facilities relating to water supply, blowdown and drainage together with a set of four stainless steel flexible hoses which enable the bench to be connected to other steam benches to form a comprehensive system. Ejector Steam Bench consists of a sturdy framework and panels of all steel construction, fitted with a student work surface, interconnecting back panel and adjustable feet. Two water tanks acting as a suction tank and a delivery tank respectively, are inter-connected in such a way that water can be returned to the suction tank to permit experiments with suction water at varying temperatures. Water supply to the suction tank is via a flow meter.

Experimental Capability:
To investigate the overall efficiency of the ejector.
To investigate the efficiency when used as a pump.
To investigate the efficiency when used as a feed water heater. 

Condenser Steam Bench

The steam bench includes a water-cooled multi-tube condenser; a steam feed line to supply a regulated supply of steam at reduced pressure and a condensate tank complete with a sight glass. Cooling water flow rate is metered in the supply line and regulated by a control valve in the drain line. Steam Bench Consists of a sturdy framework and panels of all steel construction, fitted with a student work surface, interconnecting back panel and adjustable feet. Bourdon type pressure gauges are provided from pressure indications and thermocouples are used to measure temperature, which may be individually selected for display on an analogue temperature meter.

Features:
Compact modular design
Easy Installation
Comprehensive instrumentation
Low capital cost
Pressure test certificates supplied for major components engine
Utilises industrial standard horizontal shell and tube type condenser.

Lagging Efficency Steam Bench

The steam bench incorporates four similar mild steel tubes, each connected to a common steam supply via an inlet regulating valve and a common blowdown line via an outlet valve. Two of the tubes are unlagged but have differing finishes, namely a painted finish and a chromium plated finish respectively. Lagging Efficiency Steam Bench consists of a sturdy framework and panels of all steel construction, fitted with a student work surface, interconnecting back panel and adjustable feet. The measured temperatures are displayed on an analogue temperature meter via a selection switch. From measurements of temperature and condensate levels over a period of time, students are able to calculate the lagging efficiency and the coefficient of thermal conductivity of the lagging. The remaining two tubes are lagged, one with glass fibre webbing tape and the other with a pre-formed fibre glass insulation jacket. Each tube is fitted with a sight glass and scale to enable condensate to be measured.

Features:
Pressure test certificates supplied for major components
Easy installation
Comprehensive instrumentation
Dividing panels so radiation does not affect thermocouple readings
Compact modular design
Low capital cost.

Separating and Throttling Calorimeter Bench

The steam bench includes an insulated separating calorimeter, equipped with a water level sight glass, connected via fixed orifice to a lagged throttling calorimeter which exhausts to a water cooled steam condenser. Separating and Throttling Steam Bench consists of a sturdy framework and panels of all steel construction, fitted with a student work surface, interconnecting back panel and adjustable feet. A manometer is provided for measuring the pressure inside the throttling calorimeter and thermocouples are provided for measuring steam supply and temperatures which may be individually selected for display on an analogue temperature meter.

Experimental Capability:
To determine the dryness fraction of steam i.e. The quantity of dry vapour present in any wet vapour mixture.

Nozzle Rig Bench

Steam passes from the inlet chamber, through the test nozzle, into the exhaust chamber and finally into the surface condenser via a back pressure control valve. Nozzle Steam Bench consists of a sturdy framework and panels of all steel construction, fitted with a student work surface, interconnecting back panel and adjustable feet. Steam supply to the inlet chamber first passes through a steam separator to remove excess water content and the chamber is fitted with a throttling facility to enable the dryness of the inlet steam to be determined. The steam chest consists of an inlet chamber and an exhaust chamber with a test nozzle positioned in the wall common to the two chambers.

Experimental Capability:
Determination of critical pressure ratio for choked flow
Calculation of velocity through length of nozzles of various forms  
The variation of pressure along a nozzle profile as a function of back pressure  
The effect of back pressure on the mass rate of flow
Measurement of state at entry to the nozzle and subsequent calculation
A comparison of theoretical and actual throat pressures on rates of flow  
Study of shock wave formation within nozzle divergence and at nozzle outlet  
Study of the effects of friction in a parallel nozzle.

Double Effect Evaporator Bench

The steam bench includes two evaporator vessels with interconnecting pipework and valves to allow single or double effect evaporation. The steam feed line includes a pressure reducing valve and safety relief valve. Double Effect Evaporator consists of a sturdy framework and panels of all steel construction, fitted with a student work surface interconnecting back panel and adjustable feet. Bourdon type pressure gauges are provided for pressure indications and thermocouples are used to measure temperature, which may be individually selected for display on an analogue temperature meter. The steam used is measured by sub cooling the condensate and using collecting beakers.

Experimental Capability:
Comparison of the relative efficiencies of a single effect and double effect evaporator.
Determination of the performance of a double effect evaporator.

Water Treatment Studies Bench

A panel with tubular supports is provided for storing filter columns not in use. Dosed or untreated water is transferred from the sample tank to the filter system by a centrifugal feedwater pump at reduced pressure and a metered rate; treated filtered water is either collected in a portable 25 litre storage tank or passed to the Steam Boiler Bench, depending on the use of the unit. Water Treatment Studies Bench consists of a sturdy framework and panels of all steel construction, fitted with a student work surface, interconnecting back panel and adjustable feet. These are fitted with top and bottom quick release couplings. Two of the columns may be used at any one time in a system of inter-connecting pipework and selection valves, set to allow the columns to be circulated with dosed or untreated water either independently, in parallel, in series or in reverse, and with a backwash connection from the service water line. The studies bench comprises five interchangeable, clear filter columns, each of which can be filled with a sand filter or ion exchange medias. A variable chemical dosage system, comprising a dosage pump and a chemical additive mixing vessel, is supplied to inject diluted additive at a controlled rate to either a portable 25 litre sample tank or the boiler feedwater tank on the Steam Boiler Bench. A control box, suitable for either 110V or 240V a.c. supplies, provides separate ON-OFF switches and associated indicator lamps for each pump and a switch to select the pumps for either Water Treatment Studies or Feed Water Service to the Steam Boiler Bench. Pressures at the inlet and outlet of either filter column are indicated on separate 0-2.5 bar Bourdon tube pressure gauges. Sample cocks are included in the system to enable water samples to be collected for analysis by test kits supplied with the unit.

Experimental Capability:
To demonstrate the abilities and combined effects of the base exchange, de-alkalinising and demineralisation units.

Manual Batch Reaction Plant

Electronic conductivity meter with automatic temperature compensation
Circuit for connection with a vacuum pump including check valve
Electronic rpm indicator for the stirrer
Distillation column packed with stainless steel mesh
Overhead condenser
Reactor with a capacity of 3 litres and 1.0 kW electric heater
Stirrer for the reactor, 0 to 400 rpm, with a mechanical seal that is lubricated with silicone oil
Tanks for adding reagents with a capacity of 1 litre
Tanks for collection of distillate with 2 litres capacity
2 electronic temperature indicators
2 thermocouples with pt100 probes protected by stainless steel shield sleeves
Vacuum gauge range 1 to 0 bar .
Emergency stop button
Electrical control panel in main cabinet
Pipe work and valves manufactured from stainless steel.