FACULTY OF ENGINEERING

OIL AND GAS ENGINEERING (HK88)

KG22501 LABORATORY 1
SEMESTER 1 2019/2020
LAB REPORT

NO. NAME MATRIC NO.

1. NURLILIYANA SIEN-SIEN BINTI BK18110246

KARIM

2. VANESSA KANDU ANAK CHALIE BK18110063

3. CALVIN JAMES BK18110059

4. MOHAMAD AL FATEH BIN BK18110078

MUSTAFA

NAME OF EXPERIMENT: BOILER SIMULATION (TD3)

GROUP NO. : GROUP 1
DATE OF EXPERIMENT: 17th OCTOBER 2019
NAME OF LECTURER: MADAM HAFEZA BINTI ABU BAKAR
NAME OF LAB ASSISTANT: MR. SAIYFUL SAFIC
VENUE: MAKMAL KIMIA BUKAN ORGANIK, BLOK B FKJ
1.0 ABSTRACT

Nowadays, performing experiment on real boiler or laboratory boiler requiring high cost.
Thus, using a boiler simulator may reduce cost and also help the students to be familiar with
real life boiler system. Boiler simulation is a helpful tool for controls design, analysis and
performing experiments. In this experiment is carried out by using Cussons P7667 boiler
simulation software which allows students to learn the operation of a steam generation plant.
Changing the system properties allows the user to simulate a wide range of boiler systems for
periods up to 24 hours and adjustments to the operating parameters may be made whilst the
simulation is running to allow the investigation of transients on the system. The experiment
is conducted observe parameters in boiler using the boiler simulation software, to investigate
the change in efficiency of boiler when the burner fuel rate varied, learn the process of
generating power plant with steams produced by the boiler and to learn the effect of TDS
removal over an extended period of operation. Graph were plotted for parameters against
time for burner fuel flow rate (10kJ/hr, 20kJ/hr and 30kJ/hr) such as efficiency vs time, burner
fuel flow rate vs time, boiler temperature vs time and boiler temperature vs efficiency.
2.0 INTRODUCTION

2.1 OBJECTIVE
The main objectives of this experiment are to observe parameters in boiler
using the boiler simulation software, to investigate the change in efficiency of boiler
when the burner fuel rate varied, learn the process of generating power plant with
steams produced by the boiler and to learn the effect of TDS removal over an extended
period of operation.

2.2 INTRODUCTION
Cussons P7667 boiler simulation has been designed to provide complete
investigation of a steam power plant. Cussons P7667 boiler simulation has been
specifically designed to allow institutes of education to study the principles and
operations of an industrial steam power plant. The plant can operate as a steam boiler,
turbo-generator or complete power plant. The energy input to the plant mainly comes
from the fuels but the incoming feedwater and the superheater provides energy input
as well. The energy outputs of the plant are composed of the energy output from the
turbine, heat transferred to the condenser cooling water and other losses such as heat
loss and friction loss. The relationship between the energy input and the energy output
can be generalized by the formula:

𝜮 𝑬𝒊𝒏 = 𝜮 𝑬𝒐𝒖𝒕
Equation 1: Energy Balance

The control system of the unit provides the control and timing for all boiler
system functions. The electronic control system can basically be considered 4 sections
which is feed pump control, Burner Control, boiler simulation and fault simulation, front
panel drive and ancillaries. This boiler simulation is provided with the control and
timing for all boiler system functions. The simulation is run for periods up to 24 hours
and the system properties can be altered to allows the user to simulate a wide range
of boiler systems and adjustments to the operating parameters may be made while
the simulation is running to allow the investigation of transients on the boiler system.
3.0 EXPRERIMENT PROCEDURE

3.1 EQUIPMENT

 Cusson P7665 Boiler Control Demonstration Unit.

 Computer with boiler simulation software.

Figure 1: Cusson P7665 Boiler Figure 2: Computer with boiler

Control Demonstration Unit simulation software

3.2 EXPERIMENTAL PROCEDURE

Experimental setup

1. The interface cables between the P7665 and the PC were connected.
2. The PC was switched on and allowed to boot up.
3. The simulation program was started and whilst the introductory screen was
displayed,then switched on the P7665.
4. Start button on the introductory screen was pressed. Before the units will operate
5. together, the Low Water Lockout and the Flame Failure on the P7665 was reset and
the
6. cut-in control was rotated clockwise.
7. The properties window will be displayed.
Starting the simulation

1. The properties for each parameter was set to be as shown in the table below.
Feedwater/TDS
Make up water temperature (℃) 15
Feed tank nominal capacity (L) 40
Make-up water TDS content (ppm) 100
Feed pump flow rate (kg/hr) 54
TDS blowdown flow rate (L/hr) 10.8
 Initial feed tank/noiler TDS (ppm) 250
Feedwater control On-off
Fuel Burner
Burner fuel calorific value (KJ/kg) 43500
Burner fuel flow rate (kg/hr) 3.1
Excess air (%) 80
Boiler
Max pressure (kPa abs) 600
Pressure differential (kPa) 100
Upper water level (L) 50
Lower water level (L) 40
Low water cutout (L) 35
Max boiler TDS (ppm) 350
Initial boiler water content (L) 45
Bottom blowdown flow rate (L/hr) 360
Plant
Steam consumption (kg/hr) 28.8
Plant return water ratio 0.90
Pressure for steam consumption (kPa abs) 450

2. After entering all the parameter, the simulation was started right after OK button
was pressed.

Running simulation/Properties

1. Main graphical window was displayed on the screen. A box appeared with the name
of that part when the mouse pointer was positioned over the boiler parts. After clicking
the part, a box showing measurements associated with that part of the Boiler system.
The displayed pressures were all absolute pressures.
2. The speed of the simulation was adjusted by selecting the required speed from the
Speed menu of the window in step 1 above. Normal speed was selected to run the
simulation in real time.
3. The Reset Total menu from the window in step 1 was clicked to reset all the totalisers
and restart the efficiency calculation from that time.
4. Properties from the View menu of the window in step 1 was selected to display the
properties page, which allowed appropriate properties to be changed during the
simulation. When the History system was active, it was being reset when any of the
properties were changed to prevent viewing of the earlier events.
 5. Show List from the View menu was selected to display a comprehensive list of
simulation variables. The list view were resized and repositioned to suit the user and
remainained open until closed by the user.
Saving results

1. Manual Results was selected when the simulation was started. The File menu showed
with a Save option to allow the user to store a set of values to the results file.
2. The first time this option was chosen the user was requested to enter a filename and
Location for a set of results to be stored to the Results file.
Ending simulation and viewing results

1. The simulation was terminated by pressing the Close box in top right corner of the
window or Exit from the File menu was selected.
2. Once terminated, the results, start a new simulation or exit the program can be shown
or started.
3. View Results that was selected to open a window on a spreadsheet containing all the
recorded results.
Printing results

1. Print option was selected from the File menu and format it if necessary, prior to
printing.
2. Right mouse button was clicked to reveal options to format aspects of the spreadsheet
prior to printing and allowed the view to be zoomed in or out.
3. Steps 3.4.2 to 3.4.6 were repeated by changing the Burner fuel flow rate to 10 kJ/hr,
20 kJ/hr and 30 kJ/hr.
The final results of the simulation for burner fuel flow rate of 10kJ/hr,20kJ/hr and 30kJ/hr
were obtained through the experiment and recorded.
4.0 RESULT

Efficiency of Boiler(%)

Time (hr) 10KJ/hr 20KJ/hr 30KJ/hr

0 0 0 0

2 52.9 44.7 38.6

4 54.0 45.2 38.8

6 55.7 46.2 39.6

8 56.5 46.8 40.1

10 56.8 47.1 40.4

12 57.5 47.7 40.8

14 57.6 47.8 40.9

16 57.9 47.9 41.4

18 58.2 48.2 41.2

20 58.1 48.1 41.2

22 58.3 48.3 41.4

24 58.4 48.4 41.4

Table 1 : Efficiency of Boiler of 10 kJ/hr, 20kJ/hr and 30 kJ/hr

Efficiency of Boiler vs. Time

70
58.2 58.1 58.3 58.4
60 54 55.7 56.5 56.8 57.5 57.6 57.9 10KJ/h
52.9
Efficiency of Boiler (%)

47.1 47.7 47.8 47.9 48.2 48.1 48.3 48.4 r

50 44.7 45.2 46.2 46.8 20KJ/h
41.2 41.2 41.4 41.4
38.6 38.8 39.6 40.1 40.4 40.8 40.8 40.9 r
40 30KJ/h
30 r

20

10
0
0
0 5 10 15 20 25 30
Time (hr)

Graph 1: Graph of efficiency of boiler(%) against time(hr)

 Burner Fuel Flowrate (Kg/hr)

10KJ/hr 20KJ/hr 30KJ/hr

0 0 0 0

2 0 20 0

4 0 0 0

6 0 0 0

8 10 0 0

10 10 0 0

12 0 0 0

14 10 0 0

16 0 0 0

18 10 0 0

20 0 0 0

22 10 0 0

24 0 0 30

Table 2: Burner Fuel Flowrate of 10 kJ/hr, 20 kJ/hr and 30 kJ/hr

Burner fuel flow rate vs. Time

35
30
30 10KJ/h
r
Burner fuel flow rate (Kg/hr)

25 20KJ/h
20
20 r
30KJ/h
15 r
10 10 10 10 10
10

5
0 0 0 0 0 0 0 0 0 0 0 0 0
0
0 2 4 6 8 10 12 14 16 18 20 22 24
Time (hr)

Graph 2: Graph of Burner fuel flow rate(Kg/hr) against Time (hr)

 Boiler Temperature (℃)

10KJ/hr 20KJ/hr 30KJ/hr

0 0 0 0

2 156.5 152.1 153.1

4 155.6 151.0 157.4

6 152.2 155.1 158.1

8 152.4 157.6 155.9

10 155.4 153.9 156.1

12 156.0 150.7 156.1

14 153.7 153.2 151.1

16 152.7 154.6 150.7

18 154.7 152.4 155.5

20 156.8 156.9 152.9

22 155.3 151.1 153.0

24 155.2 150.7 153.0

Table 3: Boiler Temperature of 10KJ/hr, 20kJ/hr and 30kJ/hr

Boiler Temperature (°C) VS Time(hr)

180
160
Boiler Temperature (°C)

140
120
100 10KJ/hr
GG
80 2 20KJ/hr
60
3 30KJ/hr
40
20
0
0 5 10 15 20 25 30
Time (hr)

Graph 3: Graph of Boiler Temperature (℃) against time(hr)

 Efficiency of Boiler(%) Boiler Temperature(℃)
10kJ/hr
0 0
52.9 156.5
54.0 155.6
55.7 152.2
56.5 155.4
56.8 156.0
57.5 153.7
57.6 152.7
57.9 154.7
58.2 156.8
58.3 155.3
58.4 155.2
Table 4: The efficiency of boiler for boiler temperature in 10kJ/hr

Efficiency of Boiler (%) Boiler Temperature(℃)

20 kJ/hr
0 0
44.7 152.1
45.2 151.0
46.2 155.1
46.8 157.6
47.1 153.9
47.7 150.7
47.8 153.2
47.9 154.6
48.2 152.4
48.1 156.9
48.3 151.1
48.4 150.7
Table 5 : The efficiency of boiler for boiler temperature in 20 kJ/hr
 Efficiency of Boiler (%) Boiler Temperature (℃)
30 kJ/hr
0 0
38.6 153.1
38.8 157.4
39.6 158.1
40.1 155.9
40.4 154.5
40.8 156.1
40.9 151.1
41.4 150.7
41.2 155.5
41.2 152.9
41.4 153.0
41.4 153.0
Table 6: The efficiency of boiler for boiler temperature in 30 kJ/hr

Boiler Temperature vs Effiency

170
Boiler Temperature(⁰C)

140

110

80

50

20

-10
0 38.6 38.8 39.6 40.1 40.4 40.8 40.9 41.4 41.2 41.2 41.4 41.4
Efficiency

10 KJ/hr 20 KJ/hr 30KJ/hr

Graph 4: The boiler temperature against efficiency of the boiler

 5.0 DISCUSSION

Boiler efficiency is a combined result of efficiencies of different components of a

boiler. Based on the first graph which was the efficiency of the boiler against time, there was
a significant increase of the efficency of boiler from 0 to 2 hours. The efficiency of boiler was
continuously increase over the time from the 2nd hour up till 24th hour. As shown on the graph
1, the efficiency of the boiler of 10 kJ/hr burner fuel flow rate was higher compared to 20
kJ/hr of burner fuel flow rate, followed by 30 kJ/hr of burner fuel flow rate. The highest
efficiency for 10KJ/hr was 58.4%, for 20KJ/hr was 48.4% and for 30KJ/hr was 41.4%. Refer
to data given, starting from 2nd hour until 24th hour, almost all the time the system boiler
efficiency starting to stabilize. This can be seen where during the period, the efficiency of
boiler for burner fuel flowrate for 10KJ/hr, 20kJ/hr and 30kJ/hr was constantly increased as
time increased. For 10KJ/hr, the efficiency of boiler started stabilizing at time 2nd hour to 24th
hour where the data recorded from 52.9% until 58.4%. For 20KJ/hr, the efficiency of boiler
started to stabilize at 2nd hour to 24th hour which was 44.7% until 48.4%. For 30KJ/hr, the
efficiency of boiler started to maintain its efficiency at the time from 2nd hour to 24th hour
which was 38.6% to 41.4%.

For the second graph was the burner fuel flow rate against time, the burner fuel
flowrate for 10KJ/hr remained 0kg/hr started from 0 hour until 6th hour. Next, the burner fuel
flowrate increased from the 8th hour until 10th hour which was 10kg/hr and then dropped to
0kg/hr at 12th hour. Then, the burner fuel flow rate increased and decreased simultaneously.
At 14th hour, the burner fuel flow rate raised up to 10kg/hr, then falled to 0 kg/hr at 16th hour.
At 18th hour, the burner fuel flow rate increased again to 10kg/hr and decreased back to
0kg/hr at 20kg/hr, followed by 0kg/hr at 22nd hour. At last, the burner fuel flow rate decreased
to 0kg/hr at 24th hour. On the other hand, the burner fuel flowrate of 20kJ/hr was 0kg/hr at
0 hour, then the value increased to 20kg/hr at 2nd hour. However, the burner fuel flow rate
declined to 0 kg/hr at the 4th hour and remained the same until 24th hour. For the burner fuel
flow rate of 30kg/hr, the value was 0kg/hr started from 0th hour until 22nd hour, however it
increased to 30kg/hr at the last hour(24th hour).

Based on the third graph which was boiler temperature against time, there was a
significant increased from 0th to 2nd hour in the boiler temperature. The boiler temperature
was slightly increasing or decreasing for the all fuel flow rate which are 10KJ/hr, 20KJ/hr and
30KJ/hr. The highest temperature for the burner fuel flow rate of 10KJ/hr was 156.8°C at 20th
hour, meanwhile for 20KJ/hr was 157.6°C at 8th hour , followed by 30KJ/hr the higher
temperature achieve was 158.1 at 6th hour.
 Based on the fouth group which was boiler temperature against efficiency, there was
a significant increased from 0 to 38.6% for the boiler flow rate of 10kJ/hr, 20kJ/hr and
30kJ/hr. For 10KJ/hr at 155.2℃, the efficiency boiler was 58.4% which shown the highest
efficiency. On the other hand, for 20KJ/hr at 150.7℃, the highest efficiency boiler was 48.4%.
For 30KJ/hr at 153.1℃, the highest efficieny of boiler was obtained which was 41.4%. Based
on the three datas which were 10,KJ/hr,20KJ/hr and 30KJ/hr, the efficiency of the boiler varies
which only slightly increased and decreased along the temperature from 150.7℃ to 157.1℃.

There are some precaution steps that need to be taken in order to increase the
accuracy of the results. First and foremost, the readings of the data such as the efficiency of
the boiler, the boiler temperature, burner fuel flow rate in each time should be observed
carefully. Since there are a lot of data together, thus the readings of the data should be read
and made sure by more than one observer.
6.0 QUESTIONS
1) Plot the diagram for various parameters against time for every burner fuel flow rate.

Efficiency of Boiler vs. Time

70
58.2 58.1 58.3 58.4
55.7 56.5 56.8 57.5 57.6 57.9
Efficiency of Boiler (KJ/hr)

60 52.9 54 10KJ/h
47.1 47.7 47.8 47.9 48.2 48.1 48.3 48.4 r
50 44.7 45.2 46.2 46.8
41.2 41.2 41.4 41.4 20KJ/h
38.6 38.8 39.6 40.1 40.4 40.8 40.8 40.9
40 r
30KJ/h
r
30

20

10
0
0
0 5 10 15 20 25 30
Time (hr)

Graph of Efficiency of Boiler against time

35
30
30 Burner fuel flow rate vs. Time
25 10KJ/h
20
r 20KJ/h
20
Burner fuel flow rate (Kg/hr)

r
30KJ/h
15 r
10 10 10 10 10
10

5
0 0 0 0 0 0 0 0 0 0 0 0 0
0
0 2 4 6 8 10 12 14 16 18 20 22 24
Time (hr)

Graph of Burner fuel flow rate against time

 Boiler Temperature (°C) vs Time(hr)
180
160
Boiler Temperature (°C)

140
120
100
80
60
40
20
0
0 5 10 15 20 25 30
Time (hr)

Graph of Boiler Temperature against time

Boiler Temperature vs Effiency

170
Boiler Temperature(⁰C)

140

110

80

50

20

-10
0 38.6 38.8 39.6 40.1 40.4 40.8 40.9 41.4 41.2 41.2 41.4 41.4
Efficiency

10 KJ/hr 20 KJ/hr 30KJ/hr

Graph of boiler temperature against efficiency

2) Draw the system featuring the main equipment in the boiler simulation.

7.0 CONCLUSION

In conclusion, the efficiency of boiler increases when the time increase but decreasing
when the burner fuel flowrate increasing. The boiler temperature against time graph also
shows that it does not consistently increase or decrease. Therefore the objectives of this
experiment has been achieved.
REFERENCES

Cusson P7665 Boiler Control Demonstration Unit operation manual, Cussons Technology Ltd,
United Kingdom.

Elmegaard, B. (1999). Simulation of boiler dynamics: development, evaluation and application

of a general energy system simulation tool. Technical University of Denmark, Department of
Energy Engineering.

Laboratory Manual KG22501 Laboratory I Semester 1 2019/2020.

Walter H., Ponweiser K. (2017) Boiler Simulation—Simulating the Water and Steam Flow. In:
Walter H., Epple B. (eds) Numerical Simulation of Power Plants and Firing Systems. Springer,
Vienna
APPENDIX