Francis Albert R.

Ilagan BSME-5

ME 512 EXPIREMENT NO. 1 08/22/2013 Engr.Ignacio Tocayon (instructor)

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TITLE : Boilers OBJECT: to study the construction and operation of a steam boiler and its auxiliaries, be able to obtain a relationship between the building up pressure and length of time needed, and measure its fuel consumption. THEORY: the function of a boiler is to convert water ibto steam at a desired pressure and temperature by transferring the heat envolved in consists of 1. Pressure section 2. The enclosure or setting 3. Combustion equipment and controls, and 4. The auxiliaries boilers are generally classified as 1. Fire- tube boiler or 2. Water-tube boiler. APPARATUS: 1. Boiler 2. Feed water tank 3. Measuring can 4. Weighing scale 5. Stopwatches 6. Measuring rule 7. Beaker and graduated cylinder PROCEDURE: A. Physical study of boiles and its auxiliaries B. Calibration of the feed water tank 1. Fill the tank with water and measure the height of water level in the sight glasses. 2. Drain a volume of water from the tank into a measuring can until the water level drops by approximately one centimeter. 3. Measure the final weight of the water level exactly in the sight glass. 4. Weigh the measured volume which was drained. 5. Get the equipment weight of water per change of height of water level. 6. Repeat this for 4 trials or more. TABULATED DATA/RESULTS: TRIAL INITIAL FINAL CHANGE WEIGHT WATER EQUIV. EQUIV. WATER WATER IN OF TEMPERATURE WEIGHT WEIGHT LEVEL LEVEL WATER WATER (C) OF OF (cm) (cm) LEVEL (kg) WATER WATER (cm) (kg/cm) AT 80C 1 16.3 14.8 1.5 8.2 26C 5.47 5.33 2 15.2 13.2 2 7.8 26C 3.9 3.80 3 13.7 11.2 2.5 6.4 26C 2.56 2.5 4 11.5 10.1 1.4 6.2 26C 4.43 4.32

Working formula: 1. Change in water level = initial water level final water level 2. Equivalent weight of water at (tw), 3. Equivalent weight of water at 80C, I. C. OPERATION OF THE BOILER: Measurement of steam pressure build-up time. 1. Prepare the boiler for operation by checking the fuel and fuel system; feed water and feed water system; combustion air system; boiler trim be sure that there are no air entertainment in the fuel line and that all flows are not obstructed. 2. Close the main throttle valve and open the vent valve a little. 3. Switch on power supply. The feed pump will automatically run of the water level in the boiler is below what is required. 4. Switch on parallel control. This will run the forced- draft fan. The firing sequence is now taken cared by the combustion control system automatically. 5. When firing is started (this can be seen from the peephole of the rear end of the boiler) press the stop watch and start timing the pressure build up. 6. Record the time elapsed when the pressure has reached 20psi, then record the time for the next 10psi increments until the boiler will cut off at desired steam pressure limit. 7. Press the stopwatch of, then discharge the steam by fully pressing the header drain valve, then slowly opening the main throttle valve until steam appears going to out of the header drain. 8. Record the time. 9. Plot a graph of the steam pressure and build-up time. Using pressure as your ordinate and time as your abscissa. STEAM FIRST CYCLE SECOND CYCLE THRID CYCLE PRESSURE(Psi) 20 12.35 30 13.25 40 15.60 50 16.34 run Cut-off cut-off 17.34

D. MEASUREMENT FOR FUEL CONSUMPTION: 1. Before firing starts switch the combustion control to test position. This will suspend the carrying out of the combustion program and the boiler will not fire for an indefinite period of time. 2. Open the fuel tank, and for a 10-second time interval collect the amount of fuel coming out from the return line. Measure the volume collected using a graduated cylinder. This volume divided by time is the rate of fuel recirculated during the no. of firing condition. Make three measurements and enter the average value in the table. 3. Switch the combustion control to normal to allow it to carry out the combustion program. 4. Referring to step 1-6, at 20psi, collect the amount of fuel from the return line a 10second interval and measure the volume as in (2) above. Calculate the rate of fuel recirculated when the pressure is 20psi. 5. Do the same procedure when the steam pressure reaches 30,400 psi, until the boiuler reaches cut-of. 6. Enter the results in the table.

Working formula : 1. 2.

CONCLUSION/INTERPRETATION: A boiler is a closed vessel, made out of steel and iron suitable in heating water and producing steam. It is used in many applications like food processing, heating and generating steam for other purposes. It is commonly used as the source of steam for generating power in most industry. It has two major classifications; 1. Water-tube boiler, 2. Fire-tube boiler. Water-tube boiler is a classification of boiler in which the water is placed inside the tubes and surrounded by hot gasses to produce steam. Fire-tube boiler is another classification of boiler in which a properly insulated tube or hole is fired and surrounded by water. It has many accessories like safety valve, steam gauge, water column, siphon, and so on. This accessories insures that the boiler will work properly, this also protects the boiler and the operator. This type of boiler uses fuel as a source of heat. Fuel is stored in an iron tank or container that is placed either below or set on suitable supports above the ground. Combustion of fuel will not takes place if there is no presence of air as it is common to all combustion engines. Adequate percentage of air is required to jump start the system. One of the most important components or accessories of a boiler is the feed water, feed water prevents the boiler from running out of water or taking place of dry fire. This supplies water to the boiler when the water in the boiler drops to specified level.

EXPERIMENT NO. 2 I. II. TITLE: DIESEL ENGINE PERFORMANCE TEST OBJECT: to determine the characteristics of a diesel engine in terms of torque, speed, power output, and thermal efficiency based in maximum load and at part loads, and interpret the results. THEORY: the use of diesel engine for power production is widespread. A full understanding of its operation and performance is therefore necessary for better and more economical operation. Basically, the main function of an internal combustion engine is to convert heat energy supplied from fuels into the desired from which is mechanical as tapped from the engine shaft. Fuel is burned inside the engine cylinder and develops pressure that moves the piston which in turn transmits the mechanical motion to the shaft output maybe determine by the use of a dynamometer which gives a torque reading at a given shaft speed. For the same available energy, greater torque is developed at lower speed while smaller torque developed in higher speed. In other words, it is the degree and extent at which the heat supplied is converted to useful shaft output that determine whether the engine is operating economically or not. This point is concerned on fuel cost. The factor that evaluates this engine performance is called thermal efficiency this is described as.

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The electric dynamometer is essentially a DC machine which runs as a motor or generator. The housing of dynamometer is made to float or free to move about its axis by suspending its shaft ends with bearing. A fuel and air flow meter kit added to the set up records the fuel and air consumption of the engine respectively.

CALCULATION OF POWER OUTPUTS: a. b. Where: Tb = Brake Torque

N = Engine Spedd, rpm CALCULATION OF AIR-FUEL RATIO:

Where: mf = fuel rate, lb/min m = mass flow rate equivalent to centimeter reading at 70 calibration, grams/min.

as obtained from

Where: mfb = brake specific fuel consumption mfc = combined specific fuel consumption )( ma = (ACFM)( Where: ACFM = actual cu.ft. per min. flow ma = actual mass of air supplied, lb/min FR = flowmeter reading SCFN = standard cu.ft. per hour volume flow ta = actual air temperature Pa = actual air pressure mass density of air, lb/ft

The air-fuel ratio:

CALCULATION OF VOLUMETRIC EFFICIENCY:

Where: P.D = piston-displacement of the engine D = engine bore, mm L = engine stroke, mm Np = no. of suction stroke/min = N/2 for the engine Volume efficiency =

CALCULATION OF THERMAL EFFICIENCY: a. b. Where: Qh = from bureau of standards formula = 22,320-3780(S.G), Btu/lb B.T.E = brake thermal efficiency C.T.E = combined thermal efficiency Qh = higher heating value of fuel S.g = Sp.Gr. of diesel fuel at 60

CALCULATION OF GENERATOR EFFICIENCY:

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PROCEDURE: A. MEASUREMENT AT MAXIMUM LOAD: 1. With the speed control lever in the maximum position, turn the operating made to load range 3, now slowly increase the field. 2. Increase further the field loads so that the engine speed drops off several hundred rpm. Record the value of the torque, speed, air flow and fuel flow. 3. Calculate the value of the hp for each set-up torque and speed add either it in the table. 4. Compute the thermal efficiency corresponding to each set of torque and speed by using the correct heating value of the fuel. B. MEASUREMENT AT PART LOADS: 1. Referring to the data at maximum power multiply all the torque values by 0.75 and enter the results along with the corresponding rpm in the 75% load table. 2. Make a 50% load table by multiplying the torque values at maximum power by 0.50. 3. Make a 25% load table by multiplying the torque values at maximum load by 0.25. TABULATED DATA AND RESULT: A. FUEL AND AIR CONSUMPTION: Table 1 Maximum consumption: TRIAL SPEED(rpm) cm. g/min Lb/min reading 1 2970 13.2 61.5 0.136 2 2969 13.7 63 0.139 3 2850 13.9 64 0.141 4 2840 13.81 65 0.150 5 2780 13.85 66 0.160

Lb/kwhr 10.54 7.20 5.86 4.80 3.90

SCFH ACFM Lb/min A/F ratio 560 8.9 0.71 5.22 540 8.59 0.69 4.96 520 8.27 0.66 4.68 500 7.95 0.636 4.24 480 7.63 0.611 3.8

B. MAXIMUM AND EFFICIENCIES: TRIAL SPEED BRAKE BRAKE VOLTS AMPER Kw PISTON GEN.EFF. VOLUMETRIC BTE CTE in TORQUE HP in DISP. EFF. rpm (in-lb) Bhp 1 2970 22.5 12.72 18 43 0.774 14.71 8.16 60.5 1.2 1.7 2 2910 42.5 23.55 22 54 1.188 14.5 6.76 59.2 1.8 2.4 3 2850 55 29.8 24 60 1.44 13.9 6.48 59.5 2.2 2.9 4 2810 60 32.10 26 68 1.77 13.4 7.4 59.3 2.7 3.6 5 2790 65 34.52 28 74 2.1 12.9 8.15 59 3.3 4.5

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CONCLUSION:

High oil consumption are because of high cylinder oil feed rate, high crankcase vacuum, high crankcase oil level, leakage, worn or stuck piston rings, ineffective oil control ring, worn pistons or cylinders, excessive bearing clearance, high oil pressure and low oil viscosity. Causes of lack of power are improper combustion, insufficient air, high back pressure, low fuel heat content, low compression pressure, leaking exhaust valves, tight bearings, improper lubrication, leaking injectors and late timing. Causes of improper combustion are unbalanced cylinder load, unsuitable fuel, low injection pressure, incorrect injection timing, sticking, leaking or plugged injection, insufficient air, low compression pressure, low load, low jacket water temperature, leaking or sticking intake or exhaust. The variation of brake torque, brake horsepower, volumetric efficiency, BTE, combined thermal efficiency and generator efficiency in relation to the speed is directly proportional, meaning to say that as the speed decreasing the variation of brake torque, brake horsepower, volumetric eff., BTE, CTE and gen. eff. Decreasing.

EXPERIMENT NO. 3 I. II. TITLE: CENTRIFUGAL PUMP PERFORMANCE TEST OBJECT: to determine the performance of a centrifugal pump in terms of its head or discharged characteristics, power requirements and efficiencies when operated. a. With a fixed input, supply to the pump motor b. At different running speeds THEORY: A centrifugal pump is a rotodynamic basically consisting of a rotating impeller and a casing to surround it and direct liquid flow. The liquid left into the center or eye of the impeller with velocity and pressure more than it had the eye. This naturally creates a force on the impeller opposing rotation, accounting for the torque which must be continuously supplied to the impeller shaft by its driver. This driver maybe an internal combustion engine, a steam turbines or an electric motor. A centrifugal pump being a velocity machine require first, production of liquid velocity and second, the conversion of velocity head to pressure head. The velocity is given by the rotating impeller, the conversion accomplished by diffusing guide valves or in a volute casing surrounding the impeller. A centrifugal pump is expected to develop the head, deliver the capacity and meet the efficiency at which it is designed and guaranteed. To check this performance it is necessary to conduct a test done either before installation, as in the case of large units. This test is made to confirm to existing accepted standards especially when the pumps under consideration are for purchase, in order to assure the customer of good product quality. In this laboratory, a test similar to those made according to standards is conducted on a small centrifugal pump described as follows: Make ------------------------------------------stuart turner, type 12, England Capacity--------------------------------------50 L/min. against 3 meters head at 5000 rpm Maximum head----------------------------16 meters of water at zero flow Power supply------------------------------220/240 volts 50/60 Hz, standard Pumpspeed-------------------------------0 to 84 rps Basically, the purpose of this test is to determine the characteristics of the given pump in terms of head-capacity, power capacity and efficiency-capacity relationship. The

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capacity of the pump is made to vary by the adjustments of its discharge. And it is measured by letting a volume of water accumulate in a measuring tank at a given duration of time. The volume flow rate is then obtained as

Where: V = volume collected liters t = time duration, second

For A certain running speed, the head develop by the pump is determined by taking reading of suction and discharge pressures, and adding the effects of velocity and elevation heads as well as the friction losses. Thus, +Hld Where: H = developed head, m Ps = suction pressure, bars Pd = discharge pressure, bars = sp. Wt. of water at measured temp, w/L Vs = suction velocity Vd = discharge velocity Zs = elevation of suction gage from pump centerline Zd = elevation of discharge gage from pump centerline Hls = suction head loss, m Hld = discharge head loss, m The power output of the pump is the power absorbed by water, called water horsepower which is:

Where: Q = flow rate, L/s = sp.wt. of water at measured temp, W/L H = pump head developed, m Whp = water horsepower hp Finally the overall performance of the pump and motor unit is determined by its overall efficiency.

Where: Whp = water hp Motor input = the voltage reading of the meter in watts. Note: If even at maximum position of the speed control knob, the speed does not reach 70 rev/s, partially close the flow regulator vlave until a reading of 70 rev/s is displayed.

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PROCEDURE: 1. Repeat procedures B1 to B9 and obtain fixed trials under the speed of 70rev/s, the last trial being at shut-off condition. Tabulated results. 2. Turn the flow regulator valve c back to full open position and adjust speed control knob to give a reading of 80rev/s if at maximum clockwise position of the speed control knob the speed does not reach 80 rev/s, partially close the flow control valve c until such speed is displayed in the read out. 3. Repeat procedure B, to B9 and obtain five trials , the last trial being at shut-off condition. Tabulated results under the speed of 80 rev/s 4. Shut-off the speed control unit slowly by turning its controls knob clockwise. Close the flow regulator valve c, then switch off the power supply. Consolidate all valaves in a single table and compute all items required.

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TABULATED DATA AND RESULT: FOR FIXED INPUT SUPPLY TO PUMP MOTOR TRIALS NO LOAD(pressure and speed) 1 0,3453rpm 2 1 kg/cm,3471rpm 3 0, 578 rpm (phelton wheel)

WITH LOAD(pressure and speed) 1kg/cm,3480rpm 1.1kg/cm,3523rpm 1.2kg/cm,3527rpm

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CONCLUSION: I conclude that to determine the performance of centrifugal pump, it is better to subject it to different conditions like alternating speeds, loads and heads.