This document is a project report submitted by Mohammed Sharooq to analyze the performance of a mini steam power plant. It includes theoretical explanations of the key components of a steam power plant, such as the boiler, turbine, generator and condenser. It also provides readings and calculations taken during an experiment on a mini steam power plant, and calculations to determine the efficiency of the condenser. Finally, it discusses some examples of large power plants in India and provides details on their specifications, power production, and environmental and social impacts.

1. 1
EXPERIMENTAL ANALYSIS OF A MINI STEAM
POWER PLANT
A project report submitted to
Jawaharlal Nehru Technological University Hyderabad
in partial fulfillment of the requirements for the award of the degree of
MASTER OF TECHNOLOGY
In
THERMAL ENGINEERING
Submitted By
MOHAMMED SHAROOQ
19WJ1D2103
Under the Guidance of
Dr. G. SANKARANARAYANAN
Professor
DEPARTMENT OF MECHANICAL ENGINEERING
GURU NANAK INSTITUTIONS TECHNICAL CAMPUS
(Affiliated to JNTU, Hyderabad, Approved by AICTE, New Delhi)
Ibrahimpatnam, Ranga Reddy District -501506
Telangana, India.
2019-2021

2. 2
CERTIFICATE
This is to certify that the Mini-Project entitled “EXPERIMENTAL
ANALYSIS OF A MINI STEAM POWERPLANT” is being submitted by MR.
MOHAMMED SHAROOQ in partial fulfillment for the award of the Degree of
Masters of Technology in Thermal Engineering to the Jawaharlal Nehru
Technological University Hyderabad is a record of bonafide work carried out by
them under my guidance and supervision.
The results embodied in this Mini-Project report have not been submitted to
any other University or Institute for the award of any, Degree or Diploma
Internal Guide
Dr. G SANKARANARAYANAN
(Professor)
External Examiner Head of the Department
(MECHANICAL ENGINEERING)

3. 3
DECLARATION
We declare that this Mini-Project report titled “EXPERIMENTAL
ANALYSIS OF A MINI STEAM POWERPLANT” submitted in partial fulfillment
for the award of the Degree of Bachelor of Technology in Mechanical Engineering
to the Jawaharlal Nehru Technological University Hyderabad is a record of original
work carried out us under the guidance of DR. G SANKARANARAYANAN,
Professor, Department of Mechanical Engineering, and has not formed the basis for
the award of any other degree or diploma, in this or any other Institution or University.
In keeping with the ethical practice in reporting scientific information, due
acknowledgements have been made whenever the findings of others have been cited.
MOHAMMED SHAROOQ
19WJ1D2103

4. 4
ACKNOWLEDGEMENTS
We wish to express our sincere thanks to Dr. H.S. SAINI, Managing Director,
Guru Nanak Institutions and Dr. M. RAMALINGA REDDY, Director, Guru Nanak
Institutions Technical Campus, School of Engineering and Technology, for providing
us with all the necessary facilities and their support.
We place on record, our sincere thanks to Dr. G. SANKARANARAYANAN
and Dr. A. RAJ KUMAR, Professors and Head of the Department, Mechanical
Engineering for their whole-hearted co-operation, providing excellent lab facility,
constant encouragement and unfailing inspiration.
We would like to say sincere thanks to Dr. S. NAGAKALYAN, Professor, and
Department of Mechanical Engineering for Co-coordinating Projects
We especially thank our internal guide Dr. G. SANKARANARAYANAN
Professor, Department of Mechanical Engineering for the suggestions and constant
guidance we also like to thank all of our lecturers helping us in every possible way.
MOHAMMED SHAROOQ
19WJ1D2103

5. 5
ABSTRACT
The aim of this mini-project is to analyze the performance of mini steam power
plant, Marcet Boiler Efficiency, Nozzle efficiency and Performance, Steam turbine
efficiency (Blade efficiency), DC generator efficiency, Rate of evaporation of water,
velocity of steam jet and Condenser efficiency. And examples of some power plants in
India, overall specifications in depth, power production, their stages, Net annual
pollution, Environmental Impact, Corporate social responsibility (CSR), and
achievements at a glance.

6. 6
CONTENTS
INDEX PAGE NO
1. INTRODUCTORY OVERVIEW 7
2. THEORITICAL EXPLANATION OF STEAM POWER PLANT 8
3. MINI STEAM POWER PLANT READINGS AND 18
CALCULATIONS AS TAKEN ON 8-10-2020
4. CONDENSER EFFICIENCY CALCULATIONS 31
5. POWER PLANTS IN INDIA 32
6. CONCLUSION 41

7. 7
1. INTRODUCTORY OVERVIEW
A station thermal power is a power plant in which the prime mover is steam driven.
Water is heated, turns into steam and spins a steam turbine which drives an electrical
generator. After it passes through the turbine, the steam is condensed in a condenser
and recycled to where it was heated; this is known as a Rankine cycle. The greatest
variation in the design of thermal power stations is due to the different fossil fuel
resources generally used to heat the water. Some prefer to use the term energy center
because such facilities convert forms of heat energy into electrical energy. Certain
thermal power plants also are designed to produce heat energy for industrial purposes
of district heating, or desalination of water, in addition to generating electrical power.
Globally, fossil fueled thermal power plants produce a large part of man-made CO2
emissions to the atmosphere, and efforts to reduce these are varied and widespread.
Almost all coal, nuclear, geothermal, solar thermal electric, and waste
incineration plants, as well as many natural gas power plants are thermal. Natural gas is
frequently combusted in gas turbines as well as boilers. The waste heat from a gas
turbine can be used to raise steam, in a combined cycle plant that improves overall
efficiency. Power plants burning coal, fuel oil, or natural gas are often called fossil-fuel
power plants. Some biomass-fueled thermal power plants have appeared also. Non-
nuclear thermal power plants, particularly fossil-fueled plants, which do not use co-
generation are sometimes referred to as conventional power plants. Commercial electric
utility power stations are usually constructed on a large scale and designed for
continuous operation. Electric power plants typically use phase electrical to produce
alternating current (AC) electric power at a frequency of 50 Hz or 60 Hz. Large
companies or institutions may have their own power plants to supply heating or
electricity to their facilities, especially if steam is created anyway for other purposes.
Steam-driven power plants have been used in various large ships, but are now usually
used in large naval ships. Shipboard power plants usually directly couple the turbine to
the ship's propellers through gearboxes. Power plants in such ships also provide steam
to smaller turbines driving electric generators to supply electricity. Shipboard steam
power plants can be either fossil fuel or nuclear. Nuclear marine propulsion is, with few
exceptions, used only in naval vessels.

8. 8
There have been perhaps about a dozen turbo-electric ships in which a steam-driven
turbine drives an electric generator which powers an electric motor for propulsion.
Combined heat and power plants (CH&P plants), often called co-generation plants,
produce both electric power and heat for process heat or space heating. Steam and hot
water lose energy when piped over substantial distance, so carrying heat energy by
steam or hot water is often only worthwhile within a local area, such as a ship,
industrial plant, or district heating of nearby buildings.

9. 9
2. THEORITICAL EXPLANATION OF STEAM
TURBINE
A Rankine cycle with a two-stage steam turbine and a single feed water heater.
The energy efficiency of a conventional thermal power station, considered salable
energy produced as a percent of the heating value of the fuel consumed, is typically
33% to 48% As with all heat engines, their efficiency is limited, and governed by the
laws of thermodynamics. By comparison, most hydropower stations in the United
States are about 90 percent efficient in converting the energy of falling water into
electricity.

10. 10
The energy of a thermal not utilized in power production must leave the plant in the
form of heat to the environment. This waste heat can go through a condenser and be
disposed of with cooling water or in cooling towers. If the waste heat is instead utilized
for district heating, it is called co-generation. An important class of thermal power
station are associated with desalination facilities; these are typically found in desert
countries with large supplies of natural gas and in these plants, freshwater production
and electricity are equally important co-products.
The Carnot efficiency dictates that higher efficiencies can be attained by increasing the
temperature of the steam. Sub-critical fossil fuel power plants can achieve 36–40%
efficiency. Super critical designs have efficiencies in the low to mid 40% range, with
new "ultra-critical" designs using pressures of 4400 psi (30.3 MPa) and multiple stage
reheat reaching about 48% efficiency. Above the critical point for water of 705 °F
(374 °C) and 3212 psi (22.06 MPa), there is no phase transition from water to steam,
but only a gradual decrease in density.
Currently most of the nuclear power plants must operate below the temperatures and
pressures that coal-fired plants do, since the pressurized vessel is very large and
contains the entire bundle of nuclear fuel rods. The size of the reactor limits the
pressure that can be reached. This, in turn, limits their thermodynamic efficiency to 30–
32%. Some advanced reactor designs being studied, such as the very high temperature
reactor, advanced gas-cooled reactor and supercritical water reactor, would operate at
temperatures and pressures similar to current coal plants, producing comparable
thermodynamic efficiency.
2.1 BOILER AND STEAM CYCLE
In the nuclear plant field, steam generator refers to a specific type of large heat
exchanger used in a pressurized water reactor (PWR) to thermally connect the primary
(reactor plant) and secondary (steam plant) systems, which generates steam. In a
nuclear reactor called a boiling water reactor (BWR), water is boiled to generate steam
directly in the reactor itself and there are no units called steam generators.

11. 11
In some industrial settings, there can also be steam-producing heat exchangers called
heat recovery steam generators (HRSG) which utilize heat from some industrial
process. The steam generating boiler has to produce steam at the high purity, pressure
and temperature required for the steam turbine that drives the electrical generator.
Geothermal plants need no boiler since they use naturally occurring steam sources.
Heat exchangers may be used where the geothermal steam is very corrosive or contains
excessive suspended solids. A fossil fuel steam generator includes an economizer, a
steam drum, and the furnace with its steam generating tubes and superheater coils.
Necessary safety valves are located at suitable points to avoid excessive boiler pressure.
The air and flue gas path equipment include: forced draft (FD) fan, air preheater (AP),
boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic precipitator or
baghouse) and the flue gas stack.
2.2 WATER HEATING AND DEAERATION
The boiler feed water used in the steam boiler is a means of transferring heat energy
from the burning fuel to the mechanical energy of the spinning steam turbine. The total
feed water consists of recirculated condensate water and purified makeup water.
Because the metallic materials it contacts are subject to corrosion at high temperatures
and pressures, the makeup water is highly purified before use. A system of water
softeners and ion exchange demineralizers produces water so pure that it coincidentally
becomes an electrical insulator.

12. 12
With conductivity in the range of 0.3–1.0 micro siemens per centimeter. The makeup
water in a 500 MWe plant amounts to perhaps 120 US gallons per minute (7.6 L/s) to
replace water drawn off from the boiler drums for water purity management, and to also
offset the small losses from steam leaks in the system. The feed water cycle begins with
condensate water being pumped out of the condenser after traveling through the steam
turbines. The condensate flow rate at full load in a 500 MW plant is about 6,000 US
gallons per minute (400 L/s)
Diagram of boiler feed water deaerator (with vertical, domed aeration section and
horizontal water storage section).
The water is pressurized in two stages, and flows through a series of six or seven
intermediate feed water heaters, heated up at each point with steam extracted from an
appropriate duct on the turbines and gaining temperature at each stage. Typically, in the
middle of this series of feed water heaters, and before the second stage of
pressurization, the condensate plus the makeup water flows through a deaerator that
removes dissolved air from the water, further purifying and reducing its corrosiveness.
The water may be dosed following this point with hydrazine, a chemical that removes
the remaining oxygen in the water to below 5 parts per billion (ppb). It is also dosed
with pH control agents such as ammonia or morph line to keep the residual acidity low
and thus non-corrosive.

13. 13
2.3 SUPERHEATER
Fossil fuel power plants often have a super heater section in the steam generating
furnace. The steam passes through drying equipment inside the steam drum on to the
super heater, a set of tubes in the furnace. Here the steam picks up more energy from
hot flue gases outside the tubing and its temperature is now superheated above the
saturation temperature. The superheated steam is then piped through the main steam
lines to the valves before the high pressure turbine.
Nuclear-powered steam plants do not have such sections but produce steam at
essentially saturated conditions. Experimental nuclear plants were equipped with fossil-
fired super heaters in an attempt to improve overall plant operating cost.
2.4 STEAM TURBINE WITH GENERATOR

14. 14
Steam turbine with generator
The turbine generator consists of a series of steam turbines interconnected to each other
and a generator on a common shaft. There is a high pressure turbine at one end,
followed by an intermediate pressure turbine, two low pressure turbines, and the
generator. As steam moves through the system and loses pressure and thermal energy it
expands in volume, requiring increasing diameter and longer blades at each succeeding
stage to extract the remaining energy. The entire rotating mass may be over 200 metric
tons and 100 feet (30 m) long. It is so heavy that it must be kept turning slowly even
when shut down (at 3 rpm) so that the shaft will not bow even slightly and become
unbalanced. This is so important that it is one of only five functions of blackout
emergency power batteries on site. Other functions are emergency lighting,
communication, station alarms and turbo generator lube oil.
Superheated steam from the boiler is delivered through 14–16-inch (360–410 mm)
diameter piping to the high pressure turbine where it falls in pressure to 600 psi
(4.1 MPa) and to 600 °F (320 °C) in temperature through the stage. It exits via 24–26-
inch (610–660 mm) diameter cold reheat lines and passes back into the boiler where the
steam is reheated in special reheat pendant tubes back to 1,000 °F (540 °C). The hot
reheat steam is conducted to the intermediate pressure turbine where it falls in both
temperature and pressure and exits directly to the long-bladed low pressure turbines and
finally exits to the condenser.

15. 15
The generator, 30 feet (9 m) long and 12 feet (3.7 m) in diameter, contains a stationary
stator and a spinning rotor, each containing miles of heavy copper conductor—no
permanent magnets here. In operation it generates up to 21,000 amperes at 24,000
voltsAC (504 MWe) as it spins at either 3,000 or 3,600 rpm, synchronized to the power
grid. The rotor spins in a sealed chamber cooled with hydrogen gas, selected because it
has the highest known heat transfer coefficient of any gas and for its low viscosity
which reduces windage losses. This system requires special handling during startup,
with air in the chamber first displaced by carbon dioxide before filling with hydrogen.
This ensures that the highly explosive hydrogen–oxygen environment is not created.
The power grid frequency is 60 Hz across North America and 50 Hz in Europe,
Oceania, Asia (Korea and parts of Japan are notable exceptions) and parts of Africa.
The desired frequency affects the design of large turbines, since they are highly
optimized for one particular speed.
The electricity flows to a distribution yard where transformers increase the voltage for
transmission to its destination.
The steam turbine-driven generators have auxiliary systems enabling them to work
satisfactorily and safely. The steam turbine generator being rotating equipment
generally has a heavy, large diameter shaft. The shaft therefore requires not only
supports but also has to be kept in position while running. To minimize the frictional
resistance to the rotation, the shaft has a number of bearings. The bearing shells, in
which the shaft rotates, are lined with a low friction material like Babbitt metal. Oil
lubrication is provided to further reduce the friction between shaft and bearing surface
and to limit the heat generated.

16. 16
2.5 STEAM CONDENSING
The condenser condenses the steam from the exhaust of the turbine into liquid to allow
it to be pumped. If the condenser can be made cooler, the pressure of the exhaust steam
is reduced and efficiency of the cycle increases.
Diagram of a typical water-cooled surface condenser.
The surface condenser is a shell and tube heat exchanger in which cooling water is circulated
through the tubes. The exhaust steam from the low pressure turbine enters the shell where it is
cooled and converted to condensate (water) by flowing over the tubes as shown in the
adjacent diagram. Such condensers use steam ejectors or rotary motor-driven
exhausters for continuous removal of air and gases from the steam side to maintain
vacuum. For best efficiency, the temperature in the condenser must be kept as low as
practical in order to achieve the lowest possible pressure in the condensing steam. Since
the condenser temperature can almost always be kept significantly below 100 °C where
the vapor pressure of water is much less than atmospheric pressure, the condenser
generally works under vacuum. Thus leaks of non-condensable air into the closed loop
must be prevented. Typically the cooling water causes the steam to condense at a
temperature of about 35 °C (95 °F) and that creates an absolute pressure in the
condenser of about 2–7 kPa (0.59–2.07 inHg), i.e. a vacuum of about −95 kPa
(−28 inHg) relative to atmospheric pressure. The large decrease in volume that occurs
when water vapor condenses to liquid creates the low vacuum that helps pull steam
through and increase the efficiency of the turbines.

17. 17
The limiting factor is the temperature of the cooling water and that, in turn, is limited
by the prevailing average climatic conditions at the power plant's location (it may be
possible to lower the temperature beyond the turbine limits during winter, causing
excessive condensation in the turbine). Plants operating in hot climates may have to
reduce output if their source of condenser cooling water becomes warmer;
unfortunately this usually coincides with periods of high electrical demand for air
conditioning. The condenser generally uses either circulating cooling water from a
cooling tower to reject waste heat to the atmosphere, or once-through water from a
river, lake or ocean.
A Marley mechanical induced draft cooling tower
The heat absorbed by the circulating cooling water in the condenser tubes must also be
removed to maintain the ability of the water to cool as it circulates. This is done by
pumping the warm water from the condenser through either natural draft, forced draft
or induced draft cooling towers (as seen in the image to the right) that reduce the
temperature of the water by evaporation, by about 11 to 17 °C (20 to 30 °F)—expelling
waste heat to the atmosphere. The circulation flow rate of the cooling water in a 500
MW unit is about 14.2 m³/s (500 ft³/s or 225,000 US gal/min) at full load.
The condenser tubes are made of brass or stainless steel to resist corrosion from either
side. Nevertheless they may become internally fouled during operation by bacteria or
algae in the cooling water or by mineral scaling, all of which inhibit heat transfer and
reduce thermodynamic efficiency. Many plants include an automatic cleaning system
that circulates sponge rubber balls through the tubes to scrub them clean without the
need to take the system off-line.The cooling water used to condense the steam in the
condenser returns to its source without having been changed other than having been
warmed.

18. 18
Another form of condensing system is the air-cooled condenser. The process is similar
to that of a radiator and fan. Exhaust heat from the low pressure section of a steam
turbine runs through the condensing tubes, the tubes are usually finned and ambient air
is pushed through the fins with the help of a large fan. The steam condenses to water to
be reused in the water-steam cycle. Air-cooled condensers typically operate at a higher
temperature than water-cooled versions. While saving water, the efficiency of the cycle
is reduced (resulting in more carbon dioxide per megawatt of electricity) from the
bottom of the condenser, powerful condensate pumps recycle the condensed steam
(water) back to the water/steam cycle.
2.6 OTHER EQUIPMENTS
 REHEATER
Power plant furnaces may have a reheater section containing tubes heated by hot flue
gases outside the tubes. Exhaust steam from the high pressure turbine is passed through
these heated tubes to collect more energy before driving the intermediate and then low
pressure turbines.
 AIR PATH
External fans are provided to give sufficient air for combustion. The Primary air fan
takes air from the atmosphere and, first warming it in the air preheater for better
combustion, injects it via the air nozzles on the furnace wall. The induced draft fan
assists the FD fan by drawing out combustible gases from the furnace, maintaining a
slightly negative pressure in the furnace to avoid backfiring through any closing.
 ELECTRICITY COST
The direct cost of electric energy produced by a thermal power station is the result of
cost of fuel, capital cost for the plant, operator labour, maintenance, and such factors as
ash handling and disposal. Indirect, social or environmental costs such as the economic
value of environmental impacts, or environmental and health effects of the complete
fuel cycle and plant decommissioning, are not usually assigned to generation costs for
thermal stations in utility practice, but may form part of an environmental impact
assessment.

19. 19
 GENERATOR COOLING
While small generators may be cooled by air drawn through filters at the inlet, larger
units generally require special cooling arrangements. Hydrogen gas cooling, in an oil-
sealed casing, is used because it has the highest known heat transfer coefficient of any
gas and for its low viscosity which reduces windage losses. This system requires
special handling during start-up, with air in the generator enclosure first displaced by
carbon dioxide before filling with hydrogen. This ensures that the highly flammable
hydrogen does not mix with oxygen in the air.
The hydrogen pressure inside the casing is maintained slightly higher than atmospheric
pressure to avoid outside air ingress. The hydrogen must be sealed against outward
leakage where the shaft emerges from the casing. Seal oil is used to prevent the
hydrogen gas leakage to atmosphere. The generator also uses water cooling. Since the
generator coils are at a potential of about 22 kV, an insulating barrier such as Teflon is
used to interconnect the water line and the generator high-voltage windings.
Demineralized water of low conductivity is used.
 GENERATOR HIGH-VOLTAGE SYSTEM
The generator voltage for modern utility-connected generators ranges from 11 kV in
smaller units to 22 kV in larger units. The generator high-voltage leads are normally
large aluminium channels because of their high current as compared to the cables used
in smaller machines. They are enclosed in well-grounded aluminium bus ducts and are
supported on suitable insulators. The generator high-voltage leads are connected to
step-up transformers for connecting to a high-voltage electrical substation (usually in
the range of 115 kV to 765 kV) for further transmission by the local power grid.
The necessary protection and metering devices are included for the high-voltage leads.
Thus, the steam turbine generator and the transformer form one unit. Smaller units may
share a common generator step-up transformer with individual circuit breakers to
connect the generators to a common bus.

20. 20
 MONITORING AND ALARM SYSTEM
Most of the power plant operational controls are automatic. However, at times, manual
intervention may be required. Thus, the plant is provided with monitors and alarm
systems that alert the plant operators when certain operating parameters are seriously
deviating from their normal range.
 BATTERY-SUPPLIED EMERGENCY LIGHTING AND
COMMUNICATION
A central battery system consisting of lead acid cell units is provided to supply
emergency electric power, when needed, to essential items such as the power plant's
control systems, communication systems, turbine lube oil pumps, and emergency
lighting. This is essential for a safe, damage-free shutdown of the units in an emergency
situation.

21. 21
3. TEST RIG OR STUDY APPARATUS FOR THIS
ANALYSIS
Mini steam power plant
The designed system consists of a mini steam generator of 7 liters capacity, with 2
gm/sec mass flow rate of steam, at 2 bar absolute pressure, with steel pipe of maximum
150 mm diameter with suitable and available thickness, with level gauge, over pressure
protection, over temperature protection using electrical heater of maximum 3 kW
capacity, so that it will be tested for various heights of water inside the tank, which
shall establish mathematical model to support the experimental results of time taken to
reach have discussed in detail the basic information of steam turbine and has described
steam turbine as mechanical device that converts thermal energy in pressurized steam
into useful mechanical work.

22. 22
3.1 SPECIMEN CALCULATIONS FOR READINGS TAKEN
ON 08-10-2020
BOILER
Sr
No
P1
Kg/cm2
T1
o
C
V1 I1 V2 I2 V3 I3 L1
cm
L2
cm
t1
01 4.0 144 239 26.44 244 26.98 225 26.24 54.5 55.0 120 sec
Where P1 = Steam Pressure
T1 = Steam Temperature
V1 = Voltage in DC Volts for Heater No 1
V2 =Voltage in DC Volts for Heater No 2
V3 = Voltage in DC Volts for Heater No 3
I1 = Current in Amp DC for Heater No 1
I2 = Current in Amp DC for Heater No 2
I3 = Current in Amp DC for Heater No3
L1= Initial Level in scale of Gauge glass in mm
L2= Final Level in scale of Gauge glass in mm
t1= Time in seconds from L1 toL2
CALCULATIONS:
A. For test as MARCET BOILER readings taken at Factory
before dispatch
Sr
No
PRESSURE
P1
TEMPERATURE
T1
TIME IN
SECONDS T
1 0.00 33 0
2 0.2 97 2 min 36 sec
3 0.4 103 2 min 39 sec
4 0.6 106 2 min 40 sec
5 0.8 110 2 min 41 sec
6 1.0 113 2 min 42 sec

23. 23
7 1.2 116 2 min 43 sec
8 1.4 119 2 min 44 sec
9 1.6 121 2 min 44 sec
10 1.8 123 2 min 45.5 sec
11 2.0 125 2 min 46 sec
12 2.2 129 2 min 47 sec
13 2.4 131 2 min 48 sec
14 2.6 133 2 min 48 sec
15 2.8 134 2 min 48.2 sec
16 3.0 136 2 min48.5 sec
17 3.2 138 2 min 49 sec
18 3.4 140 2 m 49.5 sec
19 3.6 141 2 m 50 sec
20 3.8 142 2 m 50.25 sec
21 4.0 144 2 m 50.5 sec
22 4.2 144 2 m 51.15 sec
23 4.4 145 2 m 51.4 sec
24 4.6 147 2 m 52 sec
25 4.8 149 2 m 52.25sec
26 5.0 151 2 m 52 .55 sec
27 5.2 152 2 m 53 .2 sec
28 5.4 153 2 m 53 .4 sec
29 5.6 154 2 m 54 sec
30 5.8 155 2 m 54.25 sec
31 6.0 156 2 m 54.45 sec
32 6.2 156 2 m 55 sec
33 6.4 158 2 m 55.5 sec
34 6.6 159 2 m 56 sec
35 6.8 160 2 m 57 sec

24. 24
3.1 FOR SEPARATING AND THROTTLING CALORIMETER
Sr
No
Inlet
pressure
P2
kg/cm2
Pressure
after
Throttling
P3 kg/cm2
Inlet
Temperature
T2
o
C
Throttling
Temperature
T3
o
C
Moisture
collected
mml
Condensate
Collected
M ml
01 1.0 0.2 113 97 22 830
3.2 FOR NOZZLE TEST RIG
Sr
No
Outlet Valve
position
Inlet
pressure P1
Pressure in
Nozzle P2
Pressure after
Nozzle P3
01 Full open 4.4 2.2 1.0
02 Partially
Closed (50%)
4.3 4.05 4.0
03 Partially
Closed (75%)
5.2 6.0 5.75
04 Closed (90%) 7.0 8.5 8.00
3.3 FOR STEAM TURBINE TEST RIG
Sr
No
Particulars / Test No’s 1 2 3 4 5 6
01 Turbine Inlet steam Pressure P4kg/cm2
1.4 1.9 2.0
02 Turbine outlet steam Pressure P4kg/cm2
0.0 0.0 0.0
03 Turbine InletTemperatureT4
o
C 114 123 123
04 Turbine OutletTemperatureT5
o
C 93 95 95
05 Condensate Temperature T6
o
C 78 81 81
06 Cold water inlet Temperature T7
o
C 38 38 38
07 Cold water Outlet Temperature T8
o
C 46 53 56
08 Room Temperature T9
o
C 40 40 40
09 Turbine Speed N rpm 1700 1700 2000
10 Generator Output Voltage V4VDC 201.3 220 240

25. 25
11 Generator Load Current I4ADC 0.0 0.1 0.14
12 Condensate Collected Vcc 1123 600 580
13 Time to collect Vcc t3seconds 200 76 67
14 Flow meter Upstream Pressure P7
kg/cm2
6.2 5.8 5.6
15 Flow meter downstream Pressure P6
kg/cm2
6.1 5.6 5.3
16 Time t2 in sec for 10 revolution in water
meter pointer
29.7 29.7 29.7
MARCET BOILER
Steam Pressure Vs Temperature and Time required
NOZZLE TESTING
Pressure Distribution in Convergent Divergent Nozzle

26. 26
3.4 OBSERVATIONS
01. DC generator efficiency ɳg = 85 % =0.85
02. Diameter of Boiler shell D = 400 mm = 0.4m
3.5 CALCULATIONS
A. FOR SEPRATING AND THROTTLING CALORIMETER
01. Dryness Fraction of steam at Separating Calorimeter X1
X1= (M / M + m)
= (830)/(830+22) = 0.9741
02. Dryness fraction of steam at Throttling calorimeter x2
a. At inlet pressure P2 kg/sq.cm from steam table find out
hf2, hfg2 in kj/kg
At 1kg/cm2
: hf2=417.31 kj/kg and hfg2 =2257.9 kj/kg
b. for throttling pressure P2 from table find value of Hg3 in Kj/kg
At P3 =0.2kg/cm2
hg3= 2609kj/kg
c. As hf2 + ( x2 xhfg2 ) = hg3
417.31 + ( X2 x 2257.9 ) = 2609
Hence X2 = 0.97
03. Actual Dryness Fraction X = X1 x X2 = 0.9741 x0.97 = 0.945

27. 27
3.6 FOR BOILER
a. Rate of evaporation (Steam Output) Ws kg/hr at 4.0kg/cm2
Ws = [{(L1– L2) x A}/ t]x 3600 kg/hr
= [{(55.0 – 54.5) x 1256.8}/ 120]x(3600/1000) kg/hr
Ws = 18.84kg/hr
L1, L2 in cm, Area of Shell A in cm2
and Time t in seconds
Area A of shell = (π/4)xD2
= (π/4) x (40) 2
= 1256.8
cm2
Timet = 120seconds
b. Enthalpy at Entry of Boiler h1 kj/kg
At entry it will be water only. Hence dryness
Faction =0 at entry temperature of water (Room)
T9 = 35 0
C
For Temperature T9 from steam table find out hf and hfg
he=129 kj/kg and hfg is irrelevant as it will be multiplied by0
Hence h1 =hf=129 kj/kg
c. Enthalpy of Outlet Steam h2 kj/kg
For Steam pressure P1 find values from Steam Table for hf and hfg
And with calorimeter find out dryness fraction of
steam X For steam pressure of P1 = 4 kg/cm2
hf = 640 kj/kg and hfg = 2107 kj/kg and Dryness Faction X = 0.945
Hence h2 = hf + ( Xxhfg) kj/kg = 640 + ( 0.945 x 2107) = 2621 kj/kg

28. 28
d. Out Put power from Boiler B kW
B = Ws ( h2-h1)/3600 = 18.84 ( 2621- 129)/3600 = 13.03kw
e. Input power to Boiler I kW
I = {( V1 x I1 ) + ( V2 x I2 ) +( V3 xI3)}/1000 kw
= {(239 x 26.44) + (244 x 26.98) + (225 x 26.24)} /1000
I = 18.834kW
f. Boiler Efficiency ɳB %
ɳB = (B/I) x 100 = (13.03 / 18.834) x 100 = 70 %

29. 29
4. STEAM TURBINE TEST RIG
01. Turbine Output BP in Watts BP = {V4 x I4 }xɳg} Watts
Where V = Voltage in volts DC
I = Current in amps DC
ɳg = Efficiency of Generator = 85 % =0.85
For all readings:
a. Turbine Output (brake Power) BP = {(201.3 x 0.00)/0.85}
= 0Watts
b. Turbine Output (brake Power) BP = {(220 x 0.10) /0.85}
= 26.82 Watts
c. Turbine Output (brake Power) BP = {(240 x 0.14) /0.85}
= 39.52 Watts
02. Blade Velocity Vb in m/sec
Vb = ( π x DT x N )/ 60 m/sec
Where DT = Mean Diameter of Impeller = 0.178 m For all readings
a. Vb = ( π x 0.178 x 1700 )/ 60 = 15.84m/sec
b. Vb = ( π x 0.178 x 1700 )/ 60 = 15.84m/sec
c. Vb = ( π x 0.178 x 2000 )/ 60 = 18.64m/sec
03. Area of Jet Aj in sq.m
Aj = ( π /4 )xd2
sq.m
Where d = dia of nozzle = 4.2 mm = 0.0042 m

30. 30
Aj = ( π /4 ) x (0.0042)2
= 0.00001384 m2
04. Steam flow rate – With Condenser Experiment Qs Cu.m/sec
01. Condensate collected Vcc ml
02. Time t3 in sec for collection
Qsk1 = ( Vcc / t3 )/1000 Kg /sec
Also Qsk2 = Q sk1 x3600 Kg /hr
Qsv= Qsk1 xVs in m3
/sec
Where Vs = Specific Volume = 0.469
m3
/kg And flow rate Qsk1
in kg/sec
For all readings 01 to 03 :
a. Qsk1 = ( V cc /t3) /1000={(1123/1000)/200}= 0.00565kg/sec
Qsk2 = Qsk1 x3600 =0.00565x3600 = 20.214 kg/hr
Qsv = Qsk1 x Vs = 0.00565x0.469 = 0.00265m3
/sec
b. Qsk1 = ( V cc /t3) /1000={(600/1000)/76} = 0.007894kg/sec
Qsk2 =Qsk1x3600 =0.007894x3600 = 28.42kg/hr
Qsv = Qsk1xVs = 0.00789x0.469 = 0.0037 m3
/sec
c. Qsk1 = ( V cc /t3) /1000= {(580/1000)/6 = 0.008656 kg/sec
Qsk2 = Qsk1x360 =0.007894x3600=31.16 kg/hr
Qsv = Qsk1xVs = 0.008656x0.469 = 0.00405 m3
/sec

31. 31
05. Velocity of Jet V1 in m/sec
V1 = Qsv/ Aj m/sec (Here Consider Qs with m3
/sec for calculations)
a. V1= 0.00565/0.00001384 = 408.23m/sec
b. V1= 0.007894/0.00001384 =570.08m/sec
c. V1= 0.00865/0.00001394 = 620m/sec
06. Velocity Diagram
With data of V, Vb, inlet α,out letβ angle,nozzle γ angle draw VelocityDiagram
And determine values ofVw1,Vw2 in m/sec

32. 32
4.2 FOR ALL READINGS A, B AND C
Sr
No
Blade Velocity
Vb m/sec
Jet Velocity at
Inlet V1 m/sec
Velocity of whirl
Inlet Vw1 m/sec
Velocity of whirl
outlet Vw2 m/sec
a 15.84 408.23 390 370
b 18.64 570.08 554 530
c 18.64 620.00 600 582
VELOCITY DIAGRAM

33. 33
07. Blade efficiency ɳb
{ 2 (Vw1+ Vw2) Vb }x100 %
ɳb =
(V1) 2
where Vb = Linear velocity of moving
blade m/sec
V1 = Absolute velocity of inlet
steam m/sec
Vw1 = Velocity of whirl of
inlet m/sec
Vw2= Velocity of whirl at
outlet m/sec
a. ɳb = 14.49 %
b. ɳb = 12.4 %
c. ɳb = 11.4 %
09. Force on Blade Fb kg-m
Fb = Qsk1 x (Vw1+Vw2)kg m
For all readings
a. Fb = 0.00565 (390+370) =4.294 kg m
b. Fb = 0.00789 (554 +530) = 8.553 kg m
c. Fb = 0.008656 (600+582) =10.231 kgm

34. 34
10. Power Produced by Steam Turbine
PT in watts
PT =Fb x Vb watts
For all readings
a. PT = 4.294x15.84 = 68.01 watts
b. PT = 8.553x15.84 = 135 watts
c. PT = 10.231x18.64 = 190.7 watts
11. Turbine Efficiency ɳT %
ɳT = (BP/PT)x100 %
For all readings
a. ɳT = ( 0/65) x 100 = 0 %
b. ɳT = ( 26.82/135) x 100 = 19.3 %
c. ɳT = ( 39.82/190) x 100 = 20.90 %
12. Specific Steam Consumption
SSC in kg/w hr
SSC = Qsk2 /BP kg/whr
For all readings
a. SSC = Qsk2 /BP = 20.34/0 = ɷ kg/w hr
b. SSC = Qsk2 /BP = 28.404/26.82 = 1.05 kg/w hr
c. SSC = Qsk2 /BP = 31.1/39.62 = 0.784 kg/w hr

35. 35
4.3TABULAR COLUMN – CALCULATED VALUES
Sr
No
Particulars a b c
01 Inlet pressure at turbine P4 kg/cm2
1.4 1.9 2.0
02 Brake Power (power absorbed) BP watts 0.0 26.82 39.52
03 Steam Consumed(Flow) Qsk2 kg/hr 20.21 28.42 31.16
04 Specific Steam Consumption SSC kg/w hr œ 1.05 0.784
05 Blade Efficiency ɳb % 14.49 12.4 11.4
06 Force on Blade Fb kgm 4.294 8.553 10.231
07 Power Produced by Turbine PT watts 68.01 135 190.7
08 Turbine Efficiency ɳT % 0 19.3 20.9
11. Plot curves for BP vs. all other parameters
BRAKE POWER BP in watts Vs Pressure, Specific Steam Consumption,
Turbine Efficiency and Power produced by Turbine
BRAKE POWER in watts Vs Force on blades,Steam flow rate and Blade efficiency

36. 36
4.4 CONDENSER EFFECTIVENESS CALCULATIONS
For reading No 03
1. Mass flow rate of Steam or Condensate Qs kg/sec
Qsk =31.1kg/hr = 0.008656 kg/sec
2. Mass flow rate of water
Qw = (1.0 /t2 ) kg/sec
Qw = 1.0/29.7 = 0.036kg/sec
3. Heat lost by Steam while converting to condensate Hs in kw
Hs= Qsk x Cp x ( T5 - T6 )kw
= 0.008656 x 4.187 x (95-81)
=0.507 kw
4. Heat Gained by cooling water Hw in kw
Hw = Qw x Cp x ( T8– T7) kw
=0.036 x 4.187 x ( 56-38)
=2.411 kw
5. Condenser Effectiveness ε
ε = Hs/Hw = 0.507/2.411 =0.208
( Divide Lowest of above by Highest among Hs and Hw)

37. 37
5.CONCLUSION
In this experiment, I have calculated the specific steam consumption, Marcet Boiler
Efficiency, Nozzle efficiency and Performance, Steam turbine efficiency (Blade
efficiency), DC generator efficiency, Rate of evaporation of water, velocity of steam jet
and Condenser efficiency.
All the above parameters are increasing under given various subjected operating
conditions, also some examples of thermal power plants in India with overall
specifications at a glance are documented.

38. 38
6 REFERENCES
1. P.K.Nag, Engineering Thermodynamics, (Tata McGraw Hill, New Delhi)
2. R.Yadav (2011), Fundamentals of Power Plant Engineering,Conventional and
Non-Conventional, (Central Publishing House publication)
3. R.Yadav (2009), Steam & Gas Turbines and Power Plant Engineering, (7th
Revised edition, Central Publishing House publication)
4. P.C.Sharma (2010), Power Plant Engineering, (S.K.Kataria & Sons Publication)
5. R.K. Naradasu, R.K. Konijeti, and V.R. Alluru (2007), thermodynamic analysis
of heat recovery steam generator in combined cycle power plant, (Thermal
Science, vol. 11, no. 4, pp. 143-156)
6. Frutschi, H.U (1999), Highest efficiencies for electrical power generation with
combined-cycle plants, (ABB Review, No. 3, pp.12–18)