GENERAL SIR JOHN KOTELAWALA DEFENCE UNIVERSITY
DEPARTMENT OF MECHANICAL ENGINEERING
CONTROL MECHANICS LABORATORY
PERFORMANCE EVALUATION OF
A STEAM POWER PLANT UNDER
SATURATED AND SUPERHEATED
LOW FLOW CONDITIONS
INSTRUCTOR MR. MAHOGA GROUP NO ME 03
DEWASUNDARARACHCHI
GROUP BMJC BALASURIYA
NAME NH JAYAWARDENA MEMBERS NND PERERA
THMCN BANDARA
BRPN BASNAYAKE
INDEX NO D/ENG/0057/ME
INTAKE 40 DATE OF 02/04/2024
PERFORMANCE
STREAM MECHANICAL DATE OF 16/04/2024
ENGINEERING SUBMISSION
Declaration:
I solemnly declare that the readings recorded are authentic and have been solely conducted by
me. I affirm that no data has been manipulated or altered in any manner. By signing this
declaration, I acknowledge my responsibility to uphold the principles of academic integrity
and honesty in all aspects of my work.
……...……………..
Signature
INTRODUCTION
Electricity is produced in many forms using such as hydro, wind, coal, solar, geothermal etc.
The basic principle of these power plants is to utilize the thermal energy generated by burning
fuel or other energy sources to heat up water and produce steam. This steam is then used to
rotate a turbine, which generates power by converting the kinetic energy of steam into
mechanical energy which turns the turbine blades. The practical is conducted to evaluate the
performance of TH 136 Compact steam power plant. In this steam power plant, a feed water
system, a small industrial boiler, a steam turbine, a generator and lamp load, a condenser with
a condensate tank with pump, and a cooling tower are operating cooperatively to generate
power. By this TH 136 Steam power plant a energy of 1KW can be produced. In the practical
evaluating of steam power plant in different conditions, components, improving efficiency of
the power plant by improving the efficiency of components will be discussed.
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AIM
To gain a comprehensive understanding of the operation of a steam power plant, with a
specific focus on optimizing its applications.
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PRE-LAB QUESTIONS
1. What is the basic principle behind a steam power plant?
In a steam power plant, the boiler generates the steam using heat gained burning a fuel at high
temperature and high pressure. Then steam is flown to the turbine and generated electricity and
steam is condensed into water using condenser. The above cycle happens in the steam power
plant.
2. What are the main components of a steam power plant and their functions?
Boiler – Provide heat energy by burning a fuel to generate steam by water.
Turbine – Generates mechanical energy which is gained by the steam that is fed by the boiler.
Generator – The turbine is connected to generator, which helps to produce electrical energy.
Condenser – Condensing the steam which was fed into the turbine. The remaining heat energy
of the steam is extracted by condenser.
Cooling System – Maintain the heat transfer of whole steam power plant using a cooling tower
or any other heat exchange methods.
3. What is the common thermodynamic cycle used to explain a steam power plant
operation? Explain with clear diagrams.
The most common thermodynamics cycle which is used in the steam power plant is Rankine
Cycle. In the stage 1-2 the water is pumped from the reservoir to the boiler. From 2-3 stage the
water is evaporated to form saturated steam at constant pressure. In the 3-4 process the steam
is expanded isentropically while a work is given to the surrounding by the turbine. From 4 to
1 process, the steam is condensed and released to the reservoir with heat rejection in constant
pressure. This cycle is called the Rankine Cycle.
Figure 1: Rankine Cycle Steam Power Plant Diagram
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THEORY
A steam power plant uses steam as its primary working fluid and uses to produce electricity
using thermodynamic principles. Heat energy is first transformed into mechanical work and
then into electrical energy. Boiler, turbine, condenser, and generator are important parts.
• Boiler: Heats water to generate high-pressure steam using fossil fuels or nuclear energy.
• Turbine: Receives high-pressure steam and converts its energy into rotational
mechanical energy through turbine blades.
• Generator: Connected to the turbine, it transforms mechanical energy into electrical
energy by inducing an electric current in wire coils within a magnetic field.
• Condenser: Cools and condenses steam back into water after it passes through the
turbine, releasing latent heat and enabling water reuse.
• Cooling System: Decrease excess heat from the condenser, often involving cooling
water from external sources or cooling towers.
Boiler Principles
Boiling water to a temperature of 100°C in a closed boiler produces steam. Compression raises
the temperature of the contained vapor above 100°C. Saturated steam is heated further to
produce dry steam, which is devoid of water and has a higher energy content. Usually measured
at zero-gauge pressure or steam temperature of 100°C, the boiler's steam rate indicates the
amount of steam produced per hour. The horsepower output of a boiler indicates how much
steam it can create. Fire-tube and water-tube boilers are the two most common types of boilers;
water-tube boilers are more common. These boilers heat water for the production of steam by
means of hot gas that passes through water tubes after combustion takes place in the furnace.
Figure 2: Cross section of a water tube boiler.
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The Rankine Cycle
We are able to understand how the cycle works in a closed loop where the working fluid is
recycled by looking at its component parts. To understand how the Rankine cycle works, let's
look at the P-v and T-s diagrams along with the h-s diagram.
Figure 2 shows the following ideal thermodynamic processes on the T-s and p-V diagrams:
• Process Line C-D illustrates the boiler's feed water pumping phase.
• Process Lines D–E handle the boiler's feed water heating, which is the system's labor
input.
• Evaporation is represented by Process Line E-A.
• It is assumed that Process Lines A–B in the steam turbine represent isentropic
expansion, a process with constant entropy.
• The steam is heated from A to A' if a super heater is used, and isentropic expansion
changes A to B.
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6
Low Flow Saturated/ Superheated Steam Test
Average Flow Rate
Boiler Efficiency
Superheater Efficiency
In this case, h2 is based on the average pressure for p1.
Boiler and Superheater Efficiency
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Turbine Indicated Power Input
Turbine-Generator Electrical Power Output
Turbine Mechanical Power Output
Turbine-Generator Efficiency
Thermal Efficiency of the Steam Turbine
Turbine Mechanical Efficiency
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Overall Power Plant Efficiency
Theoretical efficiency of the ideal Rankine cycle can be obtained by,
Condenser Heat Transfer Efficiency
Cooling Efficiency of Cooling Tower
Energy Balance
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APPARATUS
Figure 3: TH 136 Compact Steam Power Plant
The purpose of the TH 136 small steam power plant is to replicate a present-day steam power
plant. A feed water tank, a small industrial boiler, a steam turbine, a generator, and a lamp load
make up the major parts. Additionally provided is a condenser with a cooling tower, a pump,
and a tank. Included are accessories such a fuel tank, feed water meter, flow meter, and stack.
The instruments needed to measure the output voltage, current, temperature, and pressure were
available.
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PROCEDURE
Starting the boiler
Closure of the outlet valve V5, manual throttle valve V6, and optionally electric throttle valve
V6A was ensured. Water and fuel levels were checked. The main ELCB breaker and other
necessary switches were activated. The boiler water level was confirmed to be within the
specified range. Feed water and chemical dosing pumps were started. The "Combustion" toggle
was switched on. Burner activity and pressure levels were monitored. Functionality of pressure
and fuel gauges, water level, and smoke emission was verified. For superheated steam tests,
saturated steam flow was ensured before activating the superheater. (Maximum temperature of
superheater is 215 °C)
Boiler Test
Cooling water valves were opened, and the steam outlet was vented. Steam pressure was
adjusted, and condensate was drained. The system was stabilized, and results were recorded.
Optionally, exhaust gas properties were measured. Tests were repeated at varying steam rates.
Steam flow rate adjustment.
Throttle valves and pressure regulators were utilized. For low flow rates, the pressure regulator
was set, and the throttle valve was adjusted accordingly.
Turbine Generator/ Dynamometer Test
Proper equipment setup was ensured before commencing tests. Tests were initiated by
adjusting steam flow and following prescribed procedures. Data was recorded at each stage of
load adjustment. Tests were safely concluded by reducing load and steam outlet pressure.
Condenser and cooling tower Test
System readiness and stable conditions were confirmed before proceeding. Data was recorded
while varying cooling water flow rates.
Boiler shut down.
All switches were powered down and fuel and feed water valves were closed. The steam
blowdown valve was opened, and the boiler was drained. The public water supply was closed,
and the feed water tank was drained.
Superheater shut down.
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Power was deactivated and the superheater was drained.
For turbine shutdown
The condensate tank drain valve was opened.
For blowdown condenser
The cooling water inlet and outlet valves were closed, and the blowdown condenser drain valve
was opened.
For air pump
After the turbine is turned off, wait at least 5 minutes before turning off all power at the
instrument panel. For long shutdowns, if the boiler is not in use for an extended period, it is
necessary to maintain the boiler drum carefully to prevent corrosion. There are two methods
according to the boiler manufacturer’s recommendations: keeping the interior dry (Dry
method) or filling the interior with water (Wet method) while maintaining the pH value
between 11 and 11.8.
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DISCUSSION
1. Discuss the operation of the steam power plant.
Steam power plant is an energy generating facility which operates using steam as the main
working fluid. This power plant runs under principle of Rankine cycle in thermodynamics,
using the conservation of energy theory. Conversion of heat energy of steam into mechanical
energy by the turbine and subsequently converting into electrical energy by the generator.
There are main components of steam power plant as water pumping system, boiler, turbine,
generator, condenser, and cooling system. Here’s a breakdown of the components in the steam
power plant and how do they work collectively to generate electricity.
Water Pumping System – In this system, a water pump, reservoir (water source), and pipe
system are included. By the water pumping system, water is pumped from the water source by
the water pump though the pipeline into the boiler to generate steam. By this water pumping
system, the water condensed in the condenser tank is suctioned and transferred into the water
source making it more efficient and ecofriendly and cost effective.
Boiler – After water is transferred from the water source it gets heated to form steam with high
temperature and high pressure. The energy required to produce steam is gained by burning
fossil fuel such as diesel or gasoline. It is better to have a fuel with high calorific value, so the
input energy is maximized.
Steam Turbine – The high pressurized steam is directed to the steam turbine. The pressurized
steam get contact with the turbine blades. This creates a force which starts the turbine blades
rotate. The turbine inlet gets steam and it get contact with the blades and exits from the turbine
outlet. In this stage the steam gets expanded isentropically due to the energy flow from steam
to the turbine blades. Here the high pressurized energy converts into rotatory mechanical
energy.
Generator – The generator is coupled with Steam turbines shaft to transfer the rotatory motion.
The generator, which consists of coil windings with a magnetic field generates electricity when
the winding is rotated. This rotation input is gained by coupling the generator with the turbine.
Condenser – The condensation of steam is processed in the condenser. The high temperature
steam which was released from the turbine outlet is directed to the condenser to cool down. By
using a water pipe cooling system, the steam is condensed and turned into water with
approximately 30-35 °C.
Cooling System – The steam power plant is required to have a cooling system to release the
excess heat from the condenser. This cooling system can consist of water bodies, cooling
towers or any other heat exchanger. Most of the time the condenser is operated by a water-
cooling pipe. The cooled water is run into the pipes and the hot water is runed outer side of the
pipe to absorb the heat from the hot water. Then the hot water is released from the power plant
to the cooling tower to cool down the hot water by releasing the heat energy to the environment.
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2. Compare the results obtained under both low frow saturated and superheated
conditions.
In this practical we evaluate the steam power plant in two different conditions as low flow
saturated steam and low flow superheated steam. For each of the two conditions the efficiency
of the whole power plant and component wise efficiencies were calculated. In saturated
condition the boiler efficiency was 46.10% and in superheated condition boiler efficiency was
52.54%. In both conditions the efficiencies should be run at same but the due to heat losses and
different fuel flow rates. The boiler and superheater efficiency are 49.51% in superheated
conditions. In both cases same amount of power input is generated valuing 1.070KW at
superheated and 1.039KW in saturated conditions. The high energy output in superheated
conditions the mechanical power output at superheated condition is nearly twice the amount as
in the saturated condition valuing 405.34W and 256.19W. The thermal efficiency of the turbine
was higher in the superheat condition at 0.92% and 0.72% at saturated conditions. All the
efficiencies are greater when the power plant is operated in superheated conditions. The turbine
mechanical efficiency, Turbine-generator efficiency and overall electrical, mechanical, and
theoretical Rankine cycle efficiency are valued high when the power plant is operated in low
flow superheated conditions.
3. Heat losses in the steam power plant.
The overall efficiency of the steam power plant is lower than most of the commonly used power
plants as hydropower, wind power and solar power. Mainly there are two ways of heat loss in
the steam power plant. First one is heat which is released in the condensation process and other
way is heat loss at the components of the power plant (stages). The boiler is where a large
amount of heat is losses due to incomplete combustion of the fuel and exhaust gas which carries
a considerable amount of heat. This phenomenon is called dry flue gas/ stack loss in a fuel
combustion. The heated surface of boiler contributes to a considerable loss of heat by radiation.
In the steam turbine the heat is lost due to frictional forces acted on the shafts and the impeller.
In the condensation process a huge amount of heat is released as waste to the environment
affecting the efficiency of the power plant on a large scale. The heat energy which is not
convertible to mechanical energy exists in the steam and water mixture, this energy is released
to environment as waste make a huge drop in efficiency of the power plant. Also, another
considerable amount of heat energy is lost due to the pipes which transport the steam from
component to component. Due to radiation and convection the heat is lost to the environment
by the pipes. By the other components as pumps, pressure valves, fans and other auxiliary
components, the heat is loss to the environment.
4. Different methods to optimize the steam powerplant efficiencies.
As we discussed above, by minimizing heat losses we can increase the efficiency of the steam
power plant. Firstly, by optimizing the components and insulating the piping system the
minimizations of heat loss can be achieved. Using different methods to modify the Rankine
Cycle such as reheat cycle, Regenerative cycle, Economizer and Air-preheater we can improve
the efficiency of the steam power cycle. By addressing these methods, we can minimize the
heat loss in the steam power plant and increase the overall efficiency of the steam power plant.
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Optimizing Components
Insulating the boiler and the pipe system the heat loss to the environment can be minimized.
Using improved combustion technologies, furnace design and heat transfer methods the boiler
efficiency can be optimized. Minimizing the friction in the turbine shaft and the impeller the
energy lost can be reduced and efficiency will be increased. By absorbing more heat energy of
the steam passing through turbine will decrease the condensation water temperature apparently
decrease the energy waste to the environment. Using auxiliary components such as pump and
fans with minimum losses and maintaining and cleaning all the components and pipe system
regularly will increase the efficiency of the power plant.
Optimization of Rankine Cycle
The Rankine cycle can be optimized in many different ways as mentioned above.
In reheating cycle, the work output is increased by installing two turbines and reheating the
steam by sending it through another bank of tubes in the boiler or superheater when it passes
through one. With two turbines there are two work outputs which also use the heat loss in the
superheater to reheat the steam.
Figure 4: Reheat Cycle schematic diagram and T-S diagram.
In the Economizer, the feed water is passed through the exhausting gas which is released by
the boiler to increase the temperature of the feed water. This increases the boiler efficiency and
recovers some waste heat which is released to the environment. Thus, it will also reduce the
heat of hot flue gases which is released by the power plant making it more eco-friendly.
Figure 5: Economizer which is installed in a steam power
plant.
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The Air Pre-heater is also similar to the economizer which reduces the heat released to the
environment by the exhaust gas. Pre heating the feed water increases the efficiency of the boiler
and increase the combustion rate and reduces the stack loss in the fuel.
Other than these methods Back-pressure Turbines, Extraction or Pass-out Turbine and
Feed water heater methods can be used to improve the efficiency of steam power plants.
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CONCLUSION
In conclusion, the performance evaluation of a steam power plant under saturated and
superheated low flow conditions was conducted using the TH 136 Compact Steam Power plant
as the apparatus. The steam power plant was operated under two conditions as low flow
saturated and superheated conditions. The power plant was operated under these conditions
and data was gathered. Then the calculations were done to find the efficiency of each
component and overall efficiency of the power plant was calculated. Then the experimental
data of two conditions were compared and we observed that when the power plant is operated
in the superheated condition all the efficiencies were higher than the saturated conditions. Then
the operation of a steam power plant was briefly discussed and the heat losses of in the steam
power plant were detected. Finally, the steps which can be taken to minimize the heat losses
and ways of improving the efficiency of the power plant were discussed. By this experiment
we exceeded the aim to evaluate the performance of the steam power plant and it was successful
and further understanding about the theories and principles were gained by us.
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