Steam Generation Training Unit

(TD-014)

A Gas Fuel Pipeline B Water Tube Boiler C Steam Pipelines D Pressure Retention Valve E Steam Line F Condenser G Air Ejector Pump H Cooling water of Condenser I Feed Water Tank

Operation of a steam generator
Familiarization with safety procedures related to steam generators
Getting familiar with a variety of industrial components such as the boiler and the accumulator.
Recognition of Rankin cycle.
Calculation the total efficiency of steam generator
Calculation of the heat flux density and the overall heat transfer coefficient
Familiarization with T-S diagrams and steam charts
Calculation of
- Evaporation rate
- Combustion rate
- Energy of consumption
- Energy losses
- Combustion energy
- Steam energy

Burner
- Two gas cylinders:
  - Volume: 7.5 liters each.
- Two gas hoses.
- Two check valves:
  - ½ “thread connection
  - Material of construction: Brass material.
- Two ball valves:
  - ½ “thread connection
  - Material of construction: Stainless-steel material.
- One ball valve:
  - 1” thread connection,
  - Material of construction: Stainless-steel material.
- Accumulator:
  - 6” diameter
  - 10 mm thickness
  - Materia of construction: Steel material.
- Filter:
  - 1” thread connection
  - Material of construction: Cast iron material.
- Pressure reducing valve:
  - FRG/2MCS DN25,
  - Upstream Pressure Value Pa: 5.5 bar,
  - Downstream pressure value Pe: 60-90 mbar,
  - Designed according to EN 88-2 –EN13611(Red Colored).
- Two pressure sensors:
  - Measuring Range 0 – 100 mbar (g)
  - Material: Stainless Steel.
- Two pressure gauges:
  - Measuring Range 0 – 100 mbar (g)
- 1st gas train (Burner controller):
  - DUNGOUS, MB 405/1 – RSD20
- Forced draught gas burner:
  - RIELLO 40 FS3 TYP TYPE 565M, CODE 3756506.
- Exhaust gas temperature sensor:
  - TYPE k
  - RANGE 0 – 500-degree Celsius
  - Stainless Steel material.
Steam pipelines
- Saturation temperature sensor:
  - RTD PT100
  - 0-200-degree Celsius
  - Stainless Steel material.
- Electric heater:
  - 1 ½” Flange connection
  - Stainless steel element
  - 1 KW power (continuously adjustable).
- Superheated steam temperature sensor:
  - TYPE k
  - Measuring Range 0 – 300-degree Celsius
  - Stainless Steel material.
- Pressure safety valve:
  - operating Range 0 -10 bar
  - Phosphoric bronze material.
- Steam pressure sensor:
  - Measuring Range 0 – 10 bar (g)
  - Stainless Steel material.
- Steam pressure switch:
  - Control Range 4 – 12 bar (g).
- Drain needle valve:
  - ¼” thread connections
  - Stainless Steel material.
- Pressure retention valve:
  - Operating Range 0 – 10 bar
  - Adjusted on 6 bars
  - Phosphoric bronze material.
- Steam pipeline:
  - Standard Steam Pipelines,
  - Stainless Steel material
  - Thickness 1.5 mm.
- Steam connection:
  - Standard Steam Connections
  - Stainless Steel material.
Condenser
- Condenser temperature sensor:
  - Type k
  - Measuring Range 0 – 100 degree Celsius
  - Material: Stainless Steel.
- Condenser pressure sensor:
  - Measuring Range -1 … 1 bar (g)
  - Material: Stainless Steel.
- Level switch:
  - Switch ON or OFF.
  - Temp Rating: -10 ~ +85°C.
Cooling Water
- Two quick water connection:
  - ¾” water hoses connections
  - Material: Stainless Steel.
- Air ejector pump:
  - Stainless Steel Nozzle.
- Gate valve:
  - ½” thread connections
  - Stainless Steel material.
- Cooling water flow sensor:
  - Precise detection of flow and medium temperature, Suitable for water, coolants, oil and glycol.
  - Reliable backflow prevention with very fast response time
  - Measuring range 0....15 l/min, 0.018...0.9 m³/h
  - Process connection threaded connection G ½
  - Medium temperature [°C] -10...100
  - Pressure rating [bar] 40.
  - Cooling water inlet temperature sensor:
  - RTD PT100,
  - Range 0 – 100 degree Celsius
  - Material: Stainless Steel.
- Cooling water outlet temperature sensor:
  - RTD PT100
  - Range 0 – 100 degree Celsius
  - Material: Stainless Steel.
- Cooling water pipelines:
  - ½” Schedule pipelines.
Feed water tank
- Upper-level switch:
  - Switch ON or OFF.
  - Temp Rating: -10 ~ +85°C.
- Lower-level switch:
  - Switch ON or OFF.
  - Temp Rating: -10 ~ +85°C.
- Drain solenoid valve:
  - ½” thread Connection
  - Material: Brass
  - Normally Close, Min Pressure 0 bar.
Feeding water line
- Positive displacement pump:
  - High pressure diaphragm Pump
  - Power 1.2 KW.
- Feeding water temperature sensor:
  - RTD PT100
  - Measuring Range 0 – 100 degrees Celsius.
- Non-return valve:
  - Swing type
  - ¼” thread connection
  - Material: Stainless Steel.

Steam Generation Training Unit - (TD - 014)
Hard copy user manual

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Description
Technical Details

The steam generation training system (TD-014) provides trainees with broad aspects of theoretical and practical knowledge of steam generation processes. Trainees can also get familiar with different instrumentation that’s used in real-life industrial plants such as air ejectors, burners and condensers. Furthermore, trainees will be able to recognize the associated safety consideration with this process. The system is also supplied with data acquisition system.

This training unit is based on an industry-developed system which polishes up the student’s skills regarding this topic.
The steam generator is a standalone training unit which is divided into two sections.
The first section of the training system comprises the boiler, accumulator, and gas cylinder while the other section includes the electric heater, condenser tank, air ejector and much more.
The training system consist of a variety of real-world components allowing trainees to get familiar with these components prior exposure to work life.
The training system contains a set of control and display elements to measure the process parameters such as pressure and temperature, making it possible to monitor and control the process.
Trainees will get exposed to a variety of sensors and gauges required for the process.
Trainees will get acquainted with all of the safety measures and possible hazards concerning steam generators.
Trainees will gain the theoretical knowledge behind steam generation and will be able to detect process zone on our training unit.
The system is supplied with safety components such as level switches and emergency button.
Students will be able to perform all of the needed calculations such as Evaporation rate, combustion rate, energy of consumption, energy losses, combustion energy, steam energy and the total training unit efficiency.
Student will get familiar with reading and using different steam charts and T-S diagrams.
Within this trainer, students will be able to perform different steam connections. For an example, from and to the boiler connections and much more.
Students will be able to analyze the safe and reliable operation of boiler and steam distribution systems as well as discuss ways of improving boiler performance and efficiency of steam generation system.
The educational unit is supplied with an interactive software system to display all of the process values clearly as well as the heat transfer energy equation calculations.

Digital content (BI-01)

BI-01

Steam Generation Training Unit

(TD-014)