Steam Turbine Power Plant

ABSTRACT
The main objectives of this experiment were to firstly allow the experimenter to
become familiarized with the working of the steam turbine power plant. Secondly, one
had to be able to draw a schematic diagram of the steam turbine power plant apparatus
thereby highlighting its main components and outlining their various roles in power
generation. Thirdly, the steam turbine power plant was run at a selected load so as to
obtain the relevant measurements such as pressure and temperature at the turbine inlet,
pressure and temperature at the turbine outlet, volume flow rate of fuel and generator
voltage and amperage. Based on these readings taken at steady state, the values for
overall plant efficiency and the Rankine cycle efficiency could be determined. The
overall plant efficiency was found to be 7.89x10-3% and the Rankine cycle efficiency was
1.52%.

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Steam Turbine Power Plant

EXPERIMENTAL METHOD
APPARATUS AND MATERIALS

 Rankine Cycler Steam Turbine Power system

METHOD
1. The boiler was filled with 6000ml of distilled water and the filling
equipment was removed.
2. The steam admission valve was closed and the computer was switched on.
3. The gas regulator, operator gas valve and Master switch were put on.
4. The blower was checked to ensure that it was working properly.
5. The burner was observed and verified that it was lit within 45 seconds.
6. The boiler was observed and verified for a rise in pressure within 3
minutes.
7. The system was preheated by opening and closing the steam admission
valve.
8. The steam admission valve was next opened and the load switch was
turned on.
9. The load rheostat was adjusted so that a steady state was achieved and
values of boiler pressure, generator voltage and amperage could be recorded.
10. The data listed in the objective was then collected from the computer and
recorded.

DESCRIPTION OF APPARATUS

 1 to 2: Isentropic expansion (Steam turbine)

 2 to 3: Isobaric heat rejection (Condenser)
 3 to 4: Isentropic compression (Pump)
 4 to 1: Isobaric heat supply (Boiler)

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Steam Turbine Power Plant
Figure 1 showing the schematic arrangement of the main components in the steam turbine power
system (open cycle plant)

WORKING OF THE RANKINE CYCLER STEAM TURBINE POWER

SYSTEM
Basically, the Rankine cycler is an open cycle, where the steam is generated in the
boiler by evaporating, and superheating of water. The steam passes through a valve
where it is throttled to lower pressure and then enters the turbine where it is expanded.
The turbine drives the generator; the generator load can be controlled. After expansion in
the turbine, the steam is exhausted into the “cooling tower”, where part of the steam
condenses. Note that a condenser is not employed, and that fresh water must be filled into
the boiler after a while (no continuous operation). Pressure and temperature
measurements are taken at the boiler outlet, before the turbine, and after the turbine. This
allows to find important thermodynamic quantities, in particular enthalpies and entropies,
which are important for the evaluation of the turbine performance.

DESCRIPTION OF MAJOR COMPONENTS

 GAS VALVE
This gas valve is a simple two position valve (on or off). It is located on the far
right hand side of the slanted operator control panel. It will prevent gas flow to the
burner when in the off position regardless of any other control positions/settings.

 KEYED MASTER SWITCH

The system’s electronic master switch is key operated and is located on the left
side of the operator control panel. This key switch supplies power to all electronic
and electrically operated components. A green indicator light, located directly
above the keyed master switch, will light when master switch is selected to the on
position and power is available to the switch.

 BURNER SWITCH
IT is labelled as such and is located next to the keyed master switch. The burner
switch powers the automatic gas valve and ignition controls. A green indicator
light, located directly above the burner switch, will light when the burner switch
is selected to the on position and power is available to the switch.

 LOAD SWITCH
It functions as a generator load disconnect switch.

 LOAD RHEOSTAT CONTROL KNOB

It is connected in series with the load toggle switch and generator DC output
terminals. It provides a source of variable generator load.

 AMP METER
It indicates generator load conditions.

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Steam Turbine Power Plant
 VOLTMETER
IT indicates the generator voltage output.

 STEAM ADMISSION VALVE

It controls the steam flow rate to the steam turbine.

 BOILER PRESSURE GUAGE

It indicates the pressure of steam within the boiler.

 BOILER
A stainless steel constructed, dual pass, flame through tube type boiler, with super
heat dome, that includes front and rear doors. Both doors are insulated and open
easily to reveal the gas fired burner, flame tubes, hot surface igniter and general
boiler construction. The boiler walls are insulated to minimise heat loss. A side
mounted sight glass indicates water level.

 COMBUSTION BURNER/BLOWER
The custom manufactured burner is designed to operate on either LP or natural
gas. A solid state controller automatically regulates boiler pressure via the
initiation and termination of burner operation. This U.L. approved system controls
electronic ignition, gas flow control and flame sensing.

 TURBINE
The axial flow steam turbine is mounted on a precision-machined stainless steel
shaft, which is supported by custom manufactured bronze bearings. Two oiler
ports supply lubrication to the bearings. The turbine includes a taper lock for
precise mounting and is driven by steam that is directed by axial flow, bladed
nozzle ring. The turbine output shaft is coupled to an AC/DC generator.

 ELECTRIC GENERATOR
An electric generator, driven by the axial flow steam turbine, is of the brushless
type. It is a custom wound, 4-pole type and exhibits a safe/low voltage and
amperage output. Both AC and DC output poles are readily available for analysis.
A variable resistor load is operator adjustable and allows for power output5
adjustments.

 CONDENSER TOWER
The seamless, metal spun condenser tower features 4 stainless steel baffles and
facilitates the collection of water vapour. The condensed steam(water) is collected
in the bottom of the tower and can easily be drained for measurement of flow rate.

 DigiDAQ USB INTERFACE

It is located on the left side of the unit and it is a fully integrated data acquisition
system which includes nine sensors. The installed sensor list includes:
1. Boiler pressure
2. Boiler temperature
3. Turbine inlet pressure
4. Turbine inlet temperature
5. Turbine exit pressure

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Steam Turbine Power Plant
6. Turbine exit temperature
7. Fuel flow
8. Generator voltage output
9. Generator amperage output

The sensor outputs are conditioned and displayed in “real time” on screen. Data
can be stored and replayed. Run data can be copied off to floppy or follow-on,
individual student analysis.

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Steam Turbine Power Plant

THEORY
One of the most important ways to convert energy from such things as fossil
fuels, nuclear and solar potential energy is through processes known as vapour power
cycles. One example of the use of vapour power cycles is electrical power plants. The
ideal cycle for vapour power cycles can be modelled using the Rankine Cycle. This cycle
is composed of four components: heater (boiler), turbine, condenser and pump. The
system in this scenario was an open plant system which is simply a system that uses a
continuous fresh supply of working fluid (water). As the working fluid passes through
each of the components it undergoes a process and ends up at a new state. Keeping in
mind that the Rankine cycle is physically impossible, each process can be defined so as to
involve no internal irreversibility.

Figure 2 showing the T-s diagram for the Rankine cycle

The rest of this section will define the processes that the working fluid
undergoes as it completes the cycle. Reference can be made to Figures 1 and 2.
As the fluid ends the cycle, at state 4, it is first pumped into the boiler. In the
boiler, the working fluid is heated from sub-cooled liquid to saturated vapour.
This occurs at a constant pressure as shown in the following equation:

Q in
 h1  h4

Where Q in
is the rate of heat addition per unit mass of working fluid

passing through the boiler. The value  h  h  is the difference in outlet and
1 4
inlet enthalpies of the working fluid.

Second is the turbine. Through the turbine the vapour leaving the boiler
expands to the condenser pressure. It is said to be an isentropic expansion so that
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Steam Turbine Power Plant
no heat transfer to the surroundings is present. The equation used to describe this
process is as follows:

W out
 h1  h2

Where W out
is the rate at which work is developed per unit of mass

passing through the turbine.  h  h  is the difference in inlet and exit

1 2
enthalpies os the working fluid.

Next the working fluid enters the condenser. At this heat is rejected from the
vapour at a constant pressure. Ideally, this continues until all of the vapour
condenses to leave nothing but saturated liquid. The following equation describes
this process:

Q out
 h2  h3

Where Q out
is the rate at which heat is transferred from the working fluid

per unit of mass. The value  h  h  is the difference between inlet and outlet
2 3
enthalpies of the condenser.

Finally, the working fluid enters the pump. The fluid goes through an
isentropic compression process to reach the boiler pressure. The equation
describing this is as follows:

W in
 h4  h3

W
Where in
is the rate of power input per unit mass passing through the

pump. h  h 4 3
is the difference between the pump outlet and inlet enthalpies.

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Steam Turbine Power Plant

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RESULTS
OBSERVATIONS
 Volume flow rate  5.191L/min
 Voltage output  6.708V
 Amperage output  0.112A

Boiler Turbine Turbine Boiler Inlet Turbine Outlet Turbine

Pressure/PSIg Input Output Temperature/ Temperature/ Temperature/
Pressure/PSIg Pressure/PSIg C C C
105.762 5.219 2.328 245.69 191.70 163.20
Table 1 showing the data readings collected from the experiment

SAMPLE CALCULATIONS
 RTF the overall plant efficiency
Overall plant efficiency = Electrical power output/ Fuel power
1. RTF electrical power output
Electrical output = generator V*I
= 6.708*0.112
=0.751 W
2. RTF fuel power
Fuel power = volume flow rate*density*calorific value
Re: calorific value  50MJ / kg
density  2.2kg / m 3
RTConvert volume flow rate from L/min to m3/s
Re: 1L  1000m 3
 5.191  3
Volume flow rate   m / s
 1000 * 60 
 8.652 x 10-5 m3/s
Fuel power = 8.652 x10 5 * 2.2 * 50 x10 6 W
=9.517kW
 0.751
Hence Overall Plant Efficiency =
9.517 x10 3  *100%
= 7.89x10-3%
 RTConvert the Turbine Input Pressure from PSIg to MPa
Re: 1 PSIg  0.069bar ( g )
bar(g)  bar (add 1.013)
1 bar  1x10 5 Pa
1 MPa  1x10 6 Pa
Given Turbine Input Pressure is 5.219PSIg

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Steam Turbine Power Plant
5.219 PSIg  0.36011bar ( g )
0.36011bar ( g )  1.37311bar
1.373bar  1.373 x10 5 Pa
1.373 x10 5 Pa  0.137 MPa
Hence Turbine Input Pressure  0.137MPa

By linear interpolation using steam charts

 RTF the specific enthalpy,h1

h  h g  T Input
1

h 1
 0.137 MPa
0.13MPa  2687.0kJ / kg
0.14MPa  2690.3kJ / kg
 0.14  0.13 MPa   2690.3  2687.0 kJ / kg
3.3
0.01MPa  * 0.007  2.31kJ / kg
0.01
0.137 MPa   2687.0  2.31 kJ / kg  2689.31kJ / kg

 RTF the specific enthalpy,h3

h 3
 hw  T Output
h 1
 0.117 MPa
0.11MPa  428.8kJ / kg
0.12 MPa  439.4kJ / kg
 0.12  0.11 MPa   439.4  428.8 kJ / kg
10.6
0.01MPa  * 0.007  7.42kJ / kg
0.01
0.117 MPa   428.8  7.42 kJ / kg  436.22kJ / kg

h2 will be determined using the Mollier diagram.

 RTF the Rankine Cycle Efficiency

 h1  h2 
Rankine cycle efficiency =  
  
 h1 h3 
 2689.31  2655.0 * 100%  1.52%
Rankine cycle efficiency=  2689.31  436.22

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Steam Turbine Power Plant

CALCULATED RESULTS
Boiler Turbine Turbine h1 kJ/kg / h2/ h3/kJ/kg Rankine Overa
Pressure/ Input Output kJ/kg Cycle Plant
MPa Pressure/ Pressure/MPa Efficiency/% Efficien
MPa /%
0.831 0.137 0.117 2689.31 2655.0 436.22 1.52 7.89x10

Table 2 showing the calculated results from the experiment

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Steam Turbine Power Plant

DISCUSSION
The Rankine cycle efficiency and overall plant efficiency were found to be 1.52%
and 7.89x10-3% respectively. In order to determine these specific enthalpies values ( h1
and h3) the use of linear interpolation of the steam tables was involved. The value of h2
would have shown a bit of variation since this was obtained from the Mollier diagram
from the use of h1 and more estimation had to be made, therefore this would have led to
some inaccuracy in the experiment. The overall plant efficiency was very low and so too
was the Rankine cycle efficiency which may have been due to the fact that it was an open
system. The efficiency of the Rankine cycle is not as high when compared to the Carnot
cycle but the Rankine cycle has less practical difficulties and is more economic.
In this experiment the plant was an open system but it was treated similar to that
of a closed system when allowed sufficient time to reach a steady state. The cycle
efficiency of this system could be improved by either increasing the average temperature
during heat addition or decreasing the condenser temperature. Increasing the average
temperature during heat addition is achieved by increasing the amount of superheat but
this superheating is limited by metallurgical conditions of the turbine, however the added
benefit is that the quality of the steam at the turbine exit is higher. In addition, there are
disadvantages of increasing the boiler pressure which are that more robust equipment will
be needed and the vapour quality will be diminished. By decreasing the condenser
pressure as an alternative will increase the efficiency ,however, this too may have its
disadvantages such as possible air leakage into lines if the pressure is below atmospheric
and the vapour quality will decrease which is not good for the turbine. The most common
method so as to increase the cycle thermal efficiency is to use a two-stage turbine and
reheat the steam in the boiler after the first stage.

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Steam Turbine Power Plant
CONCLUSION

1. The overall plant efficiency was found to be 7.89x10-3%

2. The Rankine cycle efficiency was found to be 1.52%.
3. The efficiency of the Rankine cycle is not as high when compared to the
Carnot cycle but the Rankine cycle has less practical difficulties and is
more economic.

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