I.

OBJECTIVE
THIS REPORT COVERS THE STUDENT’S FIRST TECHNICAL INSPECTION REPORT TO A STEAM
POWER PLANT WITH STEAM ENGINE

II. THEORY AND ANALYSIS

IN TODAY’S MODERN WORLD, ALL SOCIETIES ARE INVOLVED TO VARIOUS DEGREES WITH
TECHNOLOGICAL BREAKTHROUGHS THAT ARE ATTEMPTING TO MAKE OUR LIVES MORE
PRODUCTIVE AND MORE COMFORTABLE. THESE TECHNOLOGIES INCLUDE SOPHISTICATED
ELECTRONIC DEVICES, THE MOST PROMINENT OF WHICH ARE COMPUTER SYSTEMS. MANY OF
THE SYSTEMS IN OUR MODERN WORLD DEPEND ON A RELIABLE AND RELATIVELY INEXPENSIVE
ENERGY SOURCE—ELECTRICITY. IN FACT, INEXPENSIVE AND RELIABLE ELECTRICITY IS CRITICAL
TO THE SUSTAINED ECONOMIC GROWTH AND SECURITY OF THE WORLD.
THE GENERATION OF POWER IN A COUNTRY MAINLY DEPENDS ON THE UTILIZATION OF
NATURAL RESOURCES AVAILABLE IN ADDITION TO GEOGRAPHICAL LOCATION. THE MAJORITY OF
POWER GENERATED IN THE WORLD COMES FROM HYDROELECTRIC PLANTS, STEAM/ THERMAL
POWER PLANTS, AND NUCLEAR POWER PLANTS. ALTHOUGH POWER AVAILABLE BY A
HYDROELECTRIC PLANT IS SEASONAL AND DEPENDS ON THE AVAILABILITY OF NATURAL SITES
AND THE HYDROLOGICAL CYCLE, NUCLEAR POWER HAS RAISED CONCERNS ABOUT THE SAFETY,
ESPECIALLY IN THE BACKDROP OF NATURAL DISASTERS. DUE TO THIS INSTALLING A THERMAL
POWER PLANT HAS BECOME MORE ATTRACTIVE. A STEAM POWER PLANT CAN BE COMMISSIONED
IF WATER AND FUEL RESOURCES ARE AVAILABLE NEARBY.
IN A THERMAL POWER PLANT, COAL IS USED AS THE CHIEF SOURCE OF FUEL, AND BURNT
IN THE BOILER FURNACE, BY RAISING THE STEAM IN THE STEAM GENERATORS. IN THE PROCESS,
THE CHEMICAL ENERGY OF COAL IS CONVERTED INTO HEAT ENERGY. THE HIGH-PRESSURE
STEAM THUS GENERATED IS EXPANDED IN THE TURBINE. THE TURBINE IS COUPLED TO THE
GENERATORS, CONVERTING HEAT ENERGY INTO ELECTRICITY.
STEAM IS A CRITICAL RESOURCE IN TODAY’S INDUSTRIAL WORLD. IT IS ESSENTIAL FOR THE
PRODUCTION OF PAPER AND OTHER WOOD PRODUCTS, FOR THE PREPARATION AND SERVING OF
FOODS, FOR THE COOLING AND HEATING OF LARGE BUILDINGS, FOR DRIVING EQUIPMENT SUCH
AS PUMPS AND COMPRESSORS, AND FOR POWERING SHIPS. HOWEVER, ITS MOST IMPORTANT
PRIORITY REMAINS AS THE PRIMARY SOURCE OF POWER FOR THE PRODUCTION OF ELECTRICITY.
STEAM IS EXTREMELY VALUABLE BECAUSE IT CAN BE PRODUCED ANYWHERE IN THE
WORLD BY USING THE HEAT THAT COMES FROM THE FUELS THAT ARE AVAILABLE IN THE AREA.
THE MAIN SOURCES OF HEAT IN STEAM POWER PLANTS ARE FOSSIL FUELS SUCH AS COAL, OIL
AND NATURAL GAS. STEAM ALSO HAS UNIQUE PROPERTIES THAT ARE EXTREMELY IMPORTANT IN
PRODUCING ENERGY. STEAM IS BASICALLY RECYCLED, FROM STEAM TO WATER AND THEN BACK
TO STEAM AGAIN, ALL IN A MANNER THAT IS NONTOXIC IN NATURE.
STEAM IS AN IMPORTANT MEDIUM FOR PRODUCING MECHANICAL ENERGY. STEAM HAS THE
ADVANTAGE THAT IT CAN BE RAISED FROM WATER WHICH IS AVAILABLE IN ABUNDANCE. IT DOES
NOT REACT MUCH WITH THE MATERIALS OF THE EQUIPMENT OF THE POWER PLANT AND IS
STABLE AT THE TEMPERATURE REQUIRED IN THE PLANT. STEAM IS USED TO DRIVE STEAM
ENGINES, STEAM TURBINES ETC. A STEAM POWER STATION IS MOST SUITABLE WHERE COAL IS
AVAILABLE IN ABUNDANCE.
THE SIMPLEST STEAM CYCLE OF PRACTICAL VALUE IS CALLED THE RANKINE CYCLE, WHICH
ORIGINATED AROUND THE PERFORMANCE OF THE STEAM ENGINE. THE STEAM CYCLE IS
IMPORTANT BECAUSE IT CONNECTS PROCESSES THAT ALLOW HEAT TO BE CONVERTED TO WORK
ON A CONTINUOUS BASIS. THIS SIMPLE CYCLE WAS BASED ON DRY SATURATED STEAM BEING
SUPPLIED BY A BOILER TO A POWER UNIT SUCH AS A TURBINE THAT DRIVES AN ELECTRIC
GENERATOR. THE STEAM FROM THE TURBINE EXHAUSTS TO A CONDENSER, FROM WHICH THE
CONDENSED STEAM IS PUMPED BACK INTO THE BOILER. IT IS ALSO CALLED A CONDENSING
CYCLE.
AS A STEAM POWER PLANT WORKS ON RANKINE CYCLE, STEAM GENERATED IN THE BOILER
EXPANDS IN THE STEAM TURBINE. LOW-PRESSURE EXHAUST STEAM FROM THE TURBINE IS
CONDENSED IN THE CONDENSER. THE CONDENSATE IS FED BACK TO THE BOILER ALONG WITH
FEED WATER.
A THERMAL POWER PLANT MAINLY USES HOT PRODUCTS OF COMBUSTION KNOWN AS
FLUE GAS TO GENERATE STEAM IN A STEAM GENERATOR. HEAT IS GENERATED BY BURNING
COAL, OIL OR GAS. FOR THIS PURPOSE, BOILER FURNACE IS DESIGNED FOR FIRING COAL, AIR OR
GAS.
HIGH-PRESSURE STEAM GENERATED IN THE STEAM BOILER IS PASSED THROUGH STEAM
TURBINE WHERE STEAM EXPANDS IN THE NOZZLES. HEAT ENERGY OF STEAM IS CONVERTED
INTO MECHANICAL ENERGY. MECHANICAL ENERGY IS UTILIZED TO RUN THE GENERATOR, AND
HENCE TO GENERATE ELECTRIC POWER. THE LOW-PRESSURE STEAM AFTER EXPANDING IN THE
TURBINE ENTERS THE CONDENSER. HERE, STEAM CONDENSES BY REJECTING HEAT TO THE
COOLING WATER. THE CONDENSED STEAM IS SUPPLIED BACK TO THE BOILER USING
CONDENSATE EXTRACTION PUMP. THE OVERALL EFFICIENCY OF THE PLANT IS INCREASED BY
USING ECONOMIZER, AIR PREHEATER, SUPER HEATER, AND FEED WATER HEATERS.
THE TYPE OF FUEL THAT IS BURNED DETERMINES TO A GREAT EXTENT THE OVERALL
PLANT DESIGN. WHETHER IT BE THE FOSSIL FUELS OF COAL, OIL, OR NATURAL GAS, BIOMASS, OR
BY-PRODUCT FUELS, CONSIDERABLY DIFFERENT PROVISIONS MUST BE INCORPORATED INTO THE
PLANT DESIGN FOR SYSTEMS SUCH AS FUEL HANDLING AND PREPARATION, COMBUSTION OF THE
FUEL, RECOVERY OF HEAT, FOULING OF HEAT-TRANSFER SURFACES, CORROSION OF MATERIALS,
AND AIR POLLUTION CONTROL.

III. PROCEDURE
MAKE A PHYSICAL STUDY AND LAYOUT OF THE STEAM POWER PLANT TH-3134 BASED ON
AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) AND PHILIPPINE SOCIETY OF
MECHANICAL ENGINEERS (PSME) TEST CODES. INCLUDE THE FOLLOWING:
GENERAL INSTRUCTIONS
1. STEAM-PIPING LAYOUT. STARTING WITH THE SHUT-OFF VALVE ON THE BOILER, SKETCH THE
HIGH-PRESSURE PIPING TO EACH OF THE STEAM ENGINE. INDICATE THE LOCATION OF EACH
VALVE AND FITTING. GIVE THE TYPE AND PURPOSE OF EACH AND THE REASON FOR ITS
PARTICULAR LOCATION. SHOW THE STEAM SEPARATORS AND STEAM TRAPS.
2. EXHAUST STEAM, CONDENSATE, AND FEEDWATER PIPING. IN A SECOND SKETCH, INDICATE THE
PATH OF EXHAUST STEAM, OF THE CONDENSATE. OBSERVE THE GENERAL OUTLINE GIVEN FOR
THE PREVIOUS SKETCH AND, IN ADDITION, INDICATE THE FOLLOWING: SOURCE OF MAKE-UP OR
RAW WATER SUPPLY AND WHERE IT GETS TO BE ADMITTED INTO THE SYSTEM, HOW IT IS
CONTROLLED AND MEASURED.
3. MAIN UNITS. A DESCRIPTION OF THE STEAM BOILER AND STEAM ENGINE UNITS SHOULD BE
GIVEN.
A. STEAM BOILER - MANUFACTURER'S NAME, MODEL, SERIAL NUMBER, TYPE, HEATING SURFACE,
STEAM OUTPUT, FUEL CONSUMPTION, POWER CONSUMPTION, APPROXIMATE SHIPPING WEIGHT,
OPERATING PRESSURE AND LOAD, METHOD OF MEASURING OUTPUT AND RATING, AUTOMATIC
AND SAFETY CONTROLS.
B. STEAM TURBINE - MANUFACTURER'S NAME, MODEL, SIZE, POWER RATING, NORMAL RUNNING
SPEED, EMERGENCY TRIP SPEED, MAXIMUM PRESSURE, CLASSIFICATION (CONDENSING OR NON-
CONDENSING), KIND OF LOAD, BLADE DIMENSION, METHOD OF LUBRICATION, SAFETY CONTROLS
AND PROCEDURE IN STARTING, RUNNING AND SHUTDOWN.
AUXILIARIES SHOULD BE INCLUDED IN THE REPORT.
4. AUXILIARIES. A BRIEF DESCRIPTION OF THE TYPE, SIZE AND CONDITIONS OF OPERATION OF
EACH OF THE MAJOR AUXILIARIES SHOULD BE INCLUDED IN THE REPORT.
A. CONDENSER (SURFACE OR JET) - MANUFACTURER'S NAME, OVERALL DIMENSIONS,
CONDENSER TUBE SPECIFICATION (NUMBER OF TUBE, INSIDE DIAMETER AND OUTSIDE
DIAMETER), NUMBER OF PASS; SIZE OF STEAM, WATER AND AIR CONNECTION; PRESSURE AND
TEMPERATURE AT THE TIME OF OBSERVATION. AND SOURCE OF CIRCULATING WATER.
B. CONDENSER PUMP - WET OR DRY AIR PUMPS, CONDENSATE PUMPS AND CIRCULATING WATER
PUMPS SHOULD BE DESCRIBED.
C. FEED WATER SYSTEM
HEATERS (OPEN OR CLOSED) - METHOD OF PIPING, TREATMENT OF FEEDWATER AND PRESSURE
AND TEMPERATURE AT THE TIME OF OBSERVATION.
PUMPS - TYPE, SIZE AND SPEED.
CONTROL TYPE AND METHOD OF OPERATION OF FEEDWATER REGULATORS AND PUMP -
GOVERNORS.
D. OTHER AUXILIARIES - NOTE THE TYPE AND LOCATION OF EACH OF THE FOLLOWING, IF THEY
ARE PROVIDED: SUPERHEATERS, ECONOMIZERS, FORCED DRAFT FANS, INDUCED-DRAFT FANS,
SOOT BLOWERS, CARBON DIOXIDE RECORDERS, OIL PURIFIERS AND AIR COMPRESSORS.

IV. ILLUSTRATION
LAYOUT OF THE TH-3134 STEAM POWER PLANT TRAINER

1. STEAM-PIPING LAYOUT
 HIGH-PRESSURE PIPING (STEAM ENGINE)

 VALVE AND FITTING

1. STEAM CONTROL VALVE

TECHNICALLY, A VALVE IS A DEVICE WHICH WILL CONTROL FLOW OF FLUID OR

VAPOR IN ANY SYSTEM. IN CASE OF STEAM, THE MAJOR APPLICATIONS ARE TO REDUCE
THE PRESSURE OF THE INLET STEAM FOR PROCESS APPLICATION. HOWEVER, IN
ADDITION TO CONTROLLING PRESSURE, A STEAM CONTROL VALVE WILL ALSO CONTROL
TEMPERATURE.
2. OIL REGULATOR VALVE
FROM A SEPARATE SUPPLY TANK NEAR THE ENGINE, THE REGULATOR DELIVERS
ONLY THE AMOUNT OF OIL REQUIRED TO MAINTAIN A CONSTANT OIL LEVEL IN THE
ENGINE CRANKCASE. THE CYLINDERS OF STEAM ENGINES REQUIRE STEAM OIL WHICH IS
PRODUCED THROUGH FILLING OIL IN THE OIL REGULATOR TANK AND TURNING THE VALVE
PROPERLY SO THAT AN APPROPRIATE AMOUNT OF OIL CAN BE MIXED WITH STEAM. FULLY
OPENING THE VALVE CAUSES TOO MUCH OIL TO BE MIXED WITH STEAM.
3. PURGING VALVE
A PURGE VALVE IS AN INTEGRAL COMPONENT OF A VACUUM MATERIAL CONVEYING
SYSTEM THAT NOT ONLY PROVIDES AN ON/OFF FLOW OF MATERIAL INTO A CONVEYING
LINE, BUT ALSO A WAY TO PURGE THAT CONVEYING LINE WITH AIR AT THE END OF EVERY
MATERIAL LOADING CYCLE.
BOILER MOUNTINGS
BOILER MOUNTINGS ARE THE EXTERNAL FITTINGS THAT ARE REQUIRED TO ENSURE
SAFE OPERATION OF THE BOILER. THESE ARE NECESSARY TO REGULATE THE STEAM
FLOW, TO MEASURE CERTAIN PARAMETERS OF WATER AND STEAM, ETC.
4. STEAM BOILER SAFETY VALVE (SHUT-OFF VALVE)
THE FUNCTION OF THE SAFETY VALVE IS TO PREVENT THE EXCESSIVE STEAM
PRESSURE INSIDE THE BOILER DRUM EXCEEDING THE DESIGN PRESSURE. WHEN THE
PRESSURE INSIDE THE BOILER DRUM EXCEEDS THE RATED PRESSURE, THE SAFETY
VALVE AUTOMATICALLY OPENS AND DISCHARGES THE STEAM TO THE ATMOSPHERE TILL
NORMAL WORKING PRESSURE IS RETAINED. THIS SITUATION ARISES WHENEVER
FURNACE TEMPERATURE INCREASES CAUSING EXCESSIVE HEAT TRANSFER OR
WHENEVER STEAM DEMAND SUDDENLY DROPS.
5. SIGHT GLASS (WATER LEVEL INDICATOR)
SIGHT GLASS IS A TYPE OF LEVEL SENSOR, A TRANSPARENT TUBE THROUGH WHICH
THE OPERATOR OF A BOILER CAN OBSERVE THE LEVEL OF LIQUID CONTAINED WITHIN. IN
A BOILER HOUSE ONE OF THE IMPORTANT READINGS IS THE LEVEL OF WATER. THE
FUNCTION OF THE WATER-LEVEL INDICATOR IS TO INDICATE THE LEVEL OF WATER INSIDE
THE BOILER DRUM AT ANY GIVEN INSTANT.
6. THERMOCOUPLE.
A THERMOCOUPLE CONSISTS OF TWO ELECTRICAL CONDUCTORS OF DISSIMILAR
MATERIALS THAT ARE JOINED AT THE END TO FORM A CIRCUIT. IF ONE OF THE
JUNCTIONS IS MAINTAINED AT A TEMPERATURE THAT IS HIGHER THAN THE OTHER, AN
ELECTROMAGNETIC FORCE, CALLED EMF, IS GENERATED THAT PRODUCES A CURRENT
FLOW THROUGH THE CIRCUIT. THE RELATIONSHIP BETWEEN EMF AND THE
CORRESPONDING TEMPERATURE DIFFERENCE HAS BEEN ESTABLISHED BY LABORATORY
TESTS FOR COMMON THERMOCOUPLE MATERIALS FOR VARIOUS TEMPERATURE
RANGES. THE THERMOCOUPLE IS A LOW-COST, VERSATILE, DURABLE, SIMPLE DEVICE
THAT PROVIDES FAST RESPONSE AND ACCURATE TEMPERATURE MEASUREMENT.
7. EXHAUST STEAM
THE STEAM EXHAUSTED FROM THE STEAM ENGINE THAT IS TO BE CONDENSED
(CONVERT BACK INTO LIQUID FORM) IN THE CONDENSER TO BE SUPPOSEDLY SUPPLIED
AGAIN TO THE BOILER. HOWEVER, THE CONDENSATE CONTAINS LUBRICATING OIL WHICH
IS BAD FOR THE STRUCTURE AND PERFORMANCE OF THE BOILER.
8. CONDENSATE
THE CONDENSED STEAM OIL COMPOUND PRODUCED BY THE CONDENSER. THE
CONDENSATE WILL BE ONLY TRANSFERRED IN THE CALIBRATED TANK DESIGNED FOR
COLLECTING CONDENSATE INSTEAD OF BEING USED IN THE BOILER.
9. FEEDWATER PIPING AND WATER STORAGE TANK
THE WATER STORAGE TANK STORES WATER WHICH WILL BE USED AS THE BOILER
FEEDWATER. FEEDWATER IS AN ESSENTIAL PART IN THE BOILER OPERATION WHERERIN
IT IS PUT INTO THE STEAM GENERATOR (BOILER) TO GENERATE STEAM. THE WATER IS
RAISED FROM THE TANK TO THE BOILER THROUGH THE USE OF WATER PUMP.

 MAIN UNITS
10. BOILER
MANUFACTURER: INFINIT TECHNOLOGIES OPERATING PRESSURE: 4 bar
TYPE: GAS-FIRED VERTICAL BOILER
IN SIMPLE, A BOILER MAY BE DEFINED AS A CLOSED VESSEL IN WHICH STEAM IS
PRODUCED FROM WATER BY COMBUSTION OF FUEL. THE STEAM GENERATED IS
EMPLOYED FOR GENERATING THE POWER OF THE STEAM ENGINE.
ACCORDING TO AMERICAN SOCIETY OF MECHANICAL ENGINEERS (A.S.M.E.) A ‘STEAM
GENERATING UNIT’ IS DEFINED AS:
“A COMBINATION OF APPARATUS FOR PRODUCING, FURNISHING OR RECOVERING
HEAT TOGETHER WITH THE APPARATUS FOR TRANSFERRING THE HEAT SO MADE
AVAILABLE TO THE FLUID BEING HEATED AND VAPOURISED.”
11. STEAM ENGINE (INSTEAD OF STEAM TURBINE)
MANUFACTURER: INFINIT TECHNOLOGIES
TYPE: SINGLE-CYLINDER PISTON WITH GENERATOR AND RPM SENSOR
ENGINE INLET PRESSURE: 0-4 bar
A HEAT ENGINE THAT PERFORMS MECHANICAL WORK USING STEAM AS ITS
WORKING FLUID. IT CONVERTS THE ENERGY FROM THE STEAM INTO MECHANICAL
ENERGY AND UTILIZES GENERATOR TO PRODUCE ELECTRICAL ENERGY.
STEAM TURBINES ARE MORE COMPACT AND USUALLY PERMIT HIGHER
TEMPERATURES AND GREATER EXPANSION RATIOS THAN RECIPROCATING STEAM
ENGINES. THE TURBINE IS THE UNIVERSAL MEANS USED TO GENERATE LARGE
QUANTITIES OF ELECTRIC POWER WITH STEAM.
AUXILIARIES
12. CONDENSER
MANUFACTURER: INFINIT TECHNOLOGIES
CONDENSER WATER FLOW METER: 0-7 LPM
IN POWER PLANTS, CONDENSERS ACT AS A HEAT-REJECTION ENGINE WHEN
CONDENSING STEAM INTO WATER. THE USE OF CONDENSERS IN THERMAL POWER PLANT
OR STEAM POWER PLANT IMPROVES THE EFFICIENCY OF THE POWER PLANT BY
DECREASING THE EXHAUST PRESSURE OF THE STEAM BELOW THE ATMOSPHERE.
13. CONDENSER PUMP (COOLING WATER RECIRCULATION PUMP)
MANUFACTURER: AQUASPEED
MODEL: A4000 AQUASPEED SUBMERSIBLE PUMP
VOLTAGE: 220-240V.
FREQUENCY: 50/60HZ.
WATT: 24W.
F.MAX: 4000L/HOUR.
H.MAX: 3M.
THE CONDENSER PUMP IS CONNECTED TO THE CONTROL PANEL FOR THE COOLING
WATER IN. THE COOLING WATER RECIRCULATION PUMP IS A TYPICAL BOOSTER PUMP,
WHOSE DUTY IS TO COMPENSATE, THROUGH THE PUMP MANOMETRIC PRESSURE, THE
PRESSURE LOSSES OF THE HEAT REJECTION SECTION CIRCUIT, IN ORDER TO
RECIRCULATE, THE HEAT REJECT SECTION OUTLET, ROUTED TO THE DRAIN, TO THE
INLET.

FEEDWATER SYSTEM
 FEEDWATER HEATER
THERE IS NO FEEDWATER HEATER BECAUSE THE CONDENSATE IN THIS STEAM POWER
PLANT TRAINER, THE CONDENSATE MAY NOT BE USED TO SUPPLY THE BOILER. THUS, THERE IS
ONLY ONE PIPE CONNECTED TO THE BOILER ASIDE FROM THE DRAINPIPE. THIS PIPE IS
CONNECTED FROM THE FEEDWATER TANK TO RAISE THE WATER SUPPLY FROM THE WATER
STORAGE TANK. THE CONDENDATE CONTAINES LUBRICATING OIL FROM THE STEAM ENGINE.
LUBRICATING OIL IS NOT PERMITTED IN THE STEAM BOILER UNDER ANY CIRCUMSTANCES
BECAUSE IT FORMS A COATING ON THE EVAPORATOR SURFACES AND HINDERS THE TRANSFER
OF HEAT. IN THAT CASE, THE POWER OF THE BOILER DROPS, AND THE BOILER CAN OVERHEAT.
 FEEDWATER PUMP
TYPE: RECIPROCATING PUMP
SIZE: P1=440 W, P2=0.18KW
SPEED: 2-10 l/min (0.6m^3/h)
THE FEED PUMP IS A PUMP WHICH IS USED TO DELIVER FEED WATER TO THE BOILER. IT IS
DESIRABLE THAT THE QUANTITY OF WATER SUPPLIED SHOULD BE AT LEAST EQUAL TO THAT
EVAPORATED AND SUPPLIED TO THE ENGINE.
THE RECIPROCATING PUMP CONSISTS OF A PUMP CYLINDER AND A PISTON INSIDE THE
CYLINDER RECIPROCATES A PISTON WHICH DISPLACES WATER.
V. CONCLUSION
THE EXPERIMENT FOCUSES ON THE FAMILIARIZATION WITH THE COMPONENTS OF A STEAM
POWER PLANT AND HOW THEY INTERACT. THIS IS ACHIEVED THROUGH A PHYSICAL STUDY OF
THE UNIT TH-3134 STEAM POWER PLANT WITH STEAM ENGINE WHICH SERVE AS THE MINI POWER
PLANT. THIS MINI POWER PLANT, ALTHOUGH DOES NOT POSSESS THE EXACT AND COMPLETE
COMPONENTS OF AN ACTUAL POWER PLANT, CAN BE USED TO DEMONSTRATE THE BASIC LAWS
AND PRINCIPLES ON THE OPERATION OF A STEAM POWER PLANT. THE UNIT IS DESIGNED TO
PERFORM VARIOUS EXPERIMENTS SUCH AS RECORDING THE VAPOR PRESSURE CURVE,
OBSERVATION OF THE BEHAVIOR OF STEAM AND FEEDWATER, OBTAINING CHARACTERISTICS OF
THE EVAPORATION AND CONDENSATION PROCESSES, STUDYING THE EFFECT OF RE-
EVAPORATION AND BACK FEED OF COLD WATER, AND DETERMINING FUEL CONSUMPTION, STEAM
GENERATION, BOILER EFFICIENCY AND CONDENSER CAPACITY. HOWEVER, THE MAIN HIGHLIGHT
OF THIS TECHNICAL INSPECTION IS THE DEMONSTRATION OF THE FUNCTION OF A STEAM POWER
PLANT USING STEAM ENGINE.
THE SPECIFICATIONS OF THE MINI STEAM POWER PLANT UNIT INCLUDES (1) SINGLE-
CYLINDER PISTON STEAM ENGINE, (2) GAS-FIRED BOILER FOR STEAM GENERATION, (3) WATER-
COOLED CONDENSER, (4) DC GENERATOR, (5) SENSOR AND DISPLAY FOR TEMPERATURE,
PRESSURE, FLOW RATE, VOLTAGE AND CURRENT, (6) SAFETY VALVE AND TEMPERATURE
MONITORING FOR SAFE OPERATION.
A STEAM POWER PLANT CONSISTS OF A HEAT SOURCE FOR GENERATING STEAM, A
TURBINE OR STEAM ENGINE WITH A GENERATOR, AND A COOLING DEVICE FOR CONDENSING. IN A
STEAM ENGINE, THERMODYNAMIC ENERGY IN THE FORM OF VAPOR PRESSURE FROM STEAM
GENERATORS IS CONVERTED INTO MECHANICAL ENERGY. THIS CAN BE USED FURTHER
DOWNSTREAM IN THE PROCESS TO GENERATE ELECTRICITY OR TO POWER MACHINERY AND
VEHICLES.
THE TRAINER CONTAINS THE MAIN COMPONENTS OF A STEAM POWER PLANT: A GAS FIRED
STEAM BOILER, A SINGLE-CYLINDER PISTON STEAM ENGINE WITH A GENERATOR, A CONDENSER,
A FEED WATER TANK AND A FEED WATER PUMP.
 THE STEAM BOILER GENERATES WATER VAPOR AND SUPPLIES IT TO THE PISTON STEAM
ENGINE. A PISTON AND A CRANK MECHANISM CONVERT THE ENERGY FROM THE VAPOR INTO
MECHANICAL ENERGY.
A GENERATOR IN THE FORM OF A DC MOTOR GENERATES ELECTRICITY FROM THE
MECHANICAL POWER. LIGHT BULBS ARE USED AS CONSUMERS OF THE RESULTING ELECTRICAL
ENERGY. THE EXHAUST STEAM IS CONDENSED IN A WATER-COOLED CONDENSER.
SAFE OPERATION IS ENSURED BY SAFETY DEVICES THAT MONITOR THE BOILER
TEMPERATURE AND A SAFETY VALVE. SENSORS RECORD THE TEMPERATURE, PRESSURE, AND
FLOW RATE AT ALL RELEVANT POINTS. THE MEASURED VALUES CAN BE READ ON DISPLAYS.
CURRENT AND VOLTAGE FROM THE GENERATOR ARE MEASURED AND DISPLAYED IN THE
EXPERIMENTAL UNIT.

VI. RESEARCH QUESTIONS

COMPARISON OF AVAILABLE STEAM POWER PLANT TRAINER TO ACTUAL POWER PLANT GENERAL
GUIDELINES
IN A COAL-FIRED STEAM POWER PLANT, THE PULVERISED COAL IS FED INTO THE BOILER
AND IT IS BURNT IN THE FURNACE. THE WATER PRESENT IN THE BOILER DRUM CHANGES TO HIGH
PRESSURE STEAM. FROM THE BOILER THE HIGH-PRESSURE STEAM PASSED TO THE
SUPERHEATER WHERE IT IS AGAIN HEATED UPTO ITS DRYNESS. THIS SUPERHEATED STEAM
STRIKES THE TURBINE BLADES WITH HIGH SPEED AND THE TURBINE STARTS ROTATING AT HIGH
SPEED. A GENERATOR IS ATTACHED TO THE ROTOR OF THE TURBINE AND AS THE TURBINE
ROTATES IT ALSO ROTATES WITH THE SPEED OF THE TURBINE. THE GENERATOR CONVERTS THE
MECHANICAL ENERGY OF THE TURBINE INTO ELECTRICAL ENERGY. AFTER STRIKING ON THE
TURBINE THE STEAM LEAVES THE TURBINE AND ENTERS INTO THE CONDENSER. THE STEAM
GETS CONDENSED WITH THE HELP OF COLD WATER FROM THE COOLING TOWER. THE
CONDENSED WATER WITH THE FEED WATER ENTERS INTO THE ECONOMISER. IN THE
ECONOMISER THE FEED WATER GETS HEATED UP BEFORE ENTERING INTO THE BOILER. THIS
HEATING OF WATER INCREASES THE EFFICIENCY OF THE BOILER. THE EXHAUST GASES FROM
THE FURNACE PASS THROUGH THE SUPERHEATER, ECONOMISER AND AIR PRE-HEATER. THE
HEAT OF THIS EXHAUST GASES IS UTILISED IN THE HEATING OF STEAM IN THE SUPERHEATER,
FEED WATER IN THE ECONOMISER AND AIR IN THE AIR PRE-HEATER. AFTER BURNING OF THE
COAL INTO THE FURNACE, IT IS TRANSPORTED TO ASH HANDLING PLANT AND FINALLY TO THE
ASH STORAGE.
THE STEAM POWER PLANT TRAINER IS A SMALL AND RELATIVELY LOW-COST MINIATURE
POWER PLANT DESIGNED FOR EDUCATIONAL PURPOSES. THERE ARE MAJOR DIFFERENCES
BETWEEN THE ACTUAL AND THE TRAINER HOWEVER, THE TRAINER REPRESENTS THE SAME
BASIC LAWS AND PRINCIPLES OF THERMODYNAMICS AS APPLIED IN THE ACTUAL STEAM POWER
PLANTS. A STEAM POWER PLANT CONVERTS THE CHEMICAL ENERGY OF THE FOSSIL FUELS
(COAL, OIL, GAS) INTO MECHANICAL/ELECTRICAL ENERGY. IN THIS CASE, THE TRAINER USES
LIQUEFIED PETROLEUM GAS (LPG) TO FIRE UP THE BOILER WITH THE HELP OF THE BURNER FOR
THE GENERATION OF STEAM. THE MAIN REASON FOR THIS IS THAT LPG IS EASILY ACCESSIBLE
AND THE MOST SUITABLE FUEL FOR THE PURPOSE OF EXPERIMENTATION WHICH USES
EXTREMELY LOWER FUEL CONSUMPTION RELATIVE TO THE ACTUAL ELECTRICITY GENERATION.
IN THE ACTUAL POWER PLANT, THE CONVERION OF CHEMICAL ENERGY TO MECHANICAL IS
ACHIEVED BY RAISING THE STEAM IN THE BOILERS AND EXPANDING IT THROUGH THE TURBINES.
THEN, COUPLING THE TURBINES TO THE GENERATORS TO CONVERT MECHANICAL TO
ELECTRICAL ENERGY. ON THE OTHER HAND, THE BOILER IN THIS TRAINER GENERATES STEAM
AND SUPPLIES IT INTO THE STEAM ENGINE INSTEAD OF A STEAM TURBINE. A PISTON AND CRANK
MECHANISM IN THE ENGINE CONVERT THE ENERGY FROM THE VAPOR INTO MECHANICAL
ENERGY. THEN, A GENERATOR IN THE FORM OF A DC MOTOR GENERATES ELECTRICITY FROM
THE MECHANICAL POWER.
ASIDE FROM THOSE MAIN DIFFERENCES, THE TRAINER DOES NOT HAVE THE SAME LAYOUT
AS AN ACTUAL STEAM POWER PLANT. THE TRAINER ONLY HAVE FEED WATER AND STEAM FLOW
CIRCUIT, AND COOLING WATER CIRCUIT. A TYPICAL ACTUAL SUCH AS COAL-FIRED FURTHER
INCLUDES COAL AND ASH HANDLING CIRCUIT AND, AIR AND GAS CIRCUIT. MOREOVER, TO
MINIMIZE THE COMPLEXITIES OF EXPERIMENTATION, THERE ARE FEW AUXILLIARY COMPONENTS
OF AN ACTUAL POWER PLANT WHICH ARE NOT PRESENT IN THE TRAINER.
THE TRAINER HAS A GAS–FIRED BOILER, THUS THERE IS MINIMUM NEED FOR FUEL
STORAGE AND HANDLING BECAUSE THE GAS USUALLY COMES DIRECTLY FROM THE PIPELINE TO
THE BOILER. IN ADDITION, ONLY A RELATIVELY SMALL FURNACE IS REQUIRED FOR COMBUSTION.
SINCE NATURAL GAS HAS NO ASH, THERE IS NO FOULING IN THE BOILER BECAUSE OF ASH
DEPOSITS, AND THEREFORE THE BOILER DESIGN ALLOWS HEAT-TRANSFER SURFACES TO BE
MORE CLOSELY SPACED. THE COMBINATION OF A SMALLER FURNACE AND THE CLOSER SPACING
RESULTS IN A MORE COMPACT BOILER DESIGN. THE CORROSION ALLOWANCE IS ALSO
RELATIVELY SMALL, AND THE EMISSIONS CONTROL REQUIRED RELATES PRIMARILY TO THE
NITROGEN OXIDE (NOX) THAT IS FORMED DURING THE COMBUSTION PROCESS. THE BOILER
DESIGNED FOR NATURAL GAS FIRING IS THEREFORE A RELATIVELY SMALL AND ECONOMICAL
DESIGN.
THE POWER PLANT BECOMES MUCH MORE COMPLEX WHEN A SOLID FUEL SUCH AS COAL
IS BURNED. COAL AND OTHER SOLID FUELS HAVE A HIGH PERCENTAGE OF ASH, WHICH IS NOT
COMBUSTIBLE, AND THIS ASH MUST BE A FACTOR IN DESIGNING THE PLANT. A COAL-FIRED
POWER PLANT MUST INCLUDE EXTENSIVE FUEL HANDLING, STORAGE, AND PREPARATION
FACILITIES; A MUCH LARGER FURNACE FOR COMBUSTION; AND WIDER SPACED HEAT-TRANSFER
SURFACES.

AS THE TRAINER’S LAYOUT DOES NOT HAVE THE SAME CIRCUIT AS AN ACTUAL POWER
PLANT, THEN, IT FOLLOWS THAT IT DOES NOT HAVE CERTAIN COMPONENTS. THE TRAINER ONLY
HAVE THE MAIN COMPONENTS OF THE POWER PLANT AND FEW AUXILLIARIES. THOSE
COMPONENTS (AUXILLIARIES) ARE THE FOLLOWING:
14. SUPERHEATERS
THE FUNCTION OF A SUPERHEATER IS TO INCREASE THE TEMPERATURE OF THE STEAM
ABOVE ITS SATURATION POINT. THE SUPERHEATER IS VERY IMPORTANT ACCESSORY OF A
BOILER AND CAN BE USED BOTH ON FIRE-TUBE AND WATER-TUBE BOILERS. THE SMALL BOILERS
ARE NOT COMMONLY PROVIDED WITH A SUPERHEATER.
15. REHEATER
THE FUNCTION OF REHEATER IS SIMILAR TO THE SUPERHEATER IN THAT IT SERVES TO
ELEVATE THE STEAM TEMPERATURE. PRIMARY STEAM IS SUPPLIED TO THE HIGH-PRESSURE
TURBINE. AFTER PASSING THROUGH THE HIGH-PRESSURE TURBINE, THE STEAM IS RETURNED TO
THE STEAM GENERATOR FOR REHEATING (IN A REHEATER) AFTER WHICH IT IS SENT TO THE LOW-
PRESSURE TURBINE. A SECOND REHEAT CYCLE MAY ALSO BE PROVIDED.C
BOTH ARE A SET OF TUBES LOCATED IN THE BOILER. HIGH REHEATING TEMPERATURES
IMPROVE THE OUTPUT AND EFFICIENCY OF A POWER PLANT.
16. ECONOMIZER
AN ECONOMIZER IS A DEVICE IN WHICH THE WASTE HEAT OF THE FLUE GASES IS UTILIZED FOR
HEATING THE FEED WATER. ECONOMIZER ARE OF THE TWO TYPES: (I) INDEPENDENT TYPE, AND
(II) INTEGRAL TYPE. FORMER IS INSTALLED IN CHAMBER APART FROM THE BOILER SETTING. THE
CHAMBER IS SITUATED AT THE PASSAGE OF THE FLOW OF THE FLUE GASES FROM THE BOILER
OR BOILER TO THE CHIMNEY. LATTER IS A PART OF THE BOILER HEATING SURFACE AND IS
INSTALLED WITHIN THE BOILER SETTING.
17. SOOT BLOWER
THE FUEL USED IN THERMAL POWER PLANTS WITH SOLID FUELS CAUSES SOOT AND THIS IS
DEPOSITED ON THE BOILER TUBES, ECONOMIZER TUBES, AIR PREHEATERS, ETC. THIS
DRASTICALLY REDUCES THE AMOUNT OF HEAT TRANSFER OF THE HEAT EXCHANGERS. SOOT
BLOWERS CONTROL THE FORMATION OF SOOT AND REDUCE ITS CORROSIVE EFFECTS. THE
TYPES OF SOOT BLOWERS ARE FIXED TYPE, WHICH MAY BE FURTHER CLASSIFIED INTO LANE
TYPE AND MASS TYPE DEPENDING UPON THE TYPE OF SPRAY AND NOZZLE USED.
18. FEEDWATER HEATER
FEEDWATER HEATERS HAVE TWO PRIMARY FUNCTIONS IN POWER PLANTS: (1) TO PROVIDE
THE MEANS FOR INCREASING THE FEEDWATER TEMPERATURE, WHICH IMPROVES THE OVERALL
PLANT EFFICIENCY, AND (2) TO MINIMIZE THE THERMAL EFFECTS IN THE BOILER. FEEDWATER
HEATERS USE STEAM FROM SELECTED TURBINE EXTRACTION POINTS TO PREHEAT THE
FEEDWATER FROM THE CONDENSER PRIOR TO IT ENTERING THE ECONOMIZER OR BOILER DRUM.
19. FORCED- DRAFT FAN
IN A MECHANICAL DRAUGHT SYSTEM, THE DRAUGHT IS PRODUCED BY A FAN. IN A FORCED
DRAUGHT SYSTEM, A BLOWER OR A FAN IS INSTALLED NEAR OR AT THE BASE OF THE BOILER TO
FORCE THE AIR THROUGH THE COOL BED AND OTHER PASSAGES THROUGH THE FURNACE,
FLUES, AIR PREHEATER, ECONOMIZER ETC. IT IS A POSITIVE PRESSURE DRAUGHT. THE
ENCLOSURE FOR THE FURNACE ETC. HAS TO BE VERY HIGHLY SEALED SO THAT GASES FROM
THE FURNACE DO NOT LEAK OUT IN THE BOILER HOUSE.
20. INDUCED- DRAFT FAN
IN THIS SYSTEM A FAN OR BLOWER IS LOCATED AT OR NEAR THE BASE OF THE CHIMNEY. THE
PRESSURE OVER THE FUEL BED IS REDUCED BELOW THAT OF THE ATMOSPHERE. BY CREATING A
PARTIAL VACUUM IN THE FURNACE AND FLUES, THE PRODUCTS OF COMBUSTION ARE DRAWN
FROM THE MAIN FLUE, AND THEY PASS UP THE CHIMNEY. THIS DRAUGHT IS USED USUALLY WHEN
ECONOMIZERS AND AIR PREHEATERS ARE INCORPORATED IN THE SYSTEM. THE DRAUGHT IS
SIMILAR IN ACTION TO THE NATURAL DRAUGHT.
21. AIR PREHEATER
THE FUNCTION OF THE AIR PREHEATER IS TO INCREASE THE TEMPERATURE OF AIR BEFORE IT
ENTERS THE FURNACE. IT IS GENERALLY PLACED AFTER THE ECONOMIZER, SO THE FLUE GASES
PASS THROUGH THE ECONOMIZER AND THEN TO THE AIR PREHEATER. AN AIR PREHEATER
CONSISTS OF PLATES OR TUBES WITH HOT GASES ON ONE SIDE AND AIR ON THE OTHER. IT
PREHEATS THE AIR TO BE SUPPLIED TO THE FURNACE. PREHEATED AIR ACCELERATES THE
COMBUSTION AND FACILITATES THE BURNING OF COAL.
22. STEAM SEPARATOR
THE FUNCTION OF A STEAM SEPARATOR IS TO REMOVE THE ENTRAINED WATER PARTICLES
FROM THE STEAM CONVEYED TO THE STEAM ENGINE OR TURBINE. IT IS INSTALLED AS CLOSE TO
THE STEAM ENGINE AS POSSIBLE ON THE MAIN STEAM PIPE FROM THE BOILER.
23. STEAM TRAPS
STEAM TRAPS ARE A TYPE OF AUTOMATIC VALVE THAT FILTERS OUT CONDENSATE
(CONDENSED STEAM) AND NON-CONDENSABLE GASES SUCH AS AIR WITHOUT LETTING STEAM
ESCAPE.
24. AIR COMPRESSOR
AN AIR COMPRESSOR IS A PNEUMATIC DEVICE THAT CONVERTS POWER INTO POTENTIAL
ENERGY STORED IN PRESSURIZED AIR. COMPRESSED AIR AT A POWER PLANT FINDS
APPLICATION IN COAL HANDLING, OPERATING PNEUMATIC INSTRUMENTS CONNECTED WITH
BOILERS, TURBINES, GENERATORS, PRECIPITATORS, AND ASH HANDLING SYSTEM. THE AIR
SYSTEM IN A THERMAL POWER PLANT IS DIVIDED INTO INSTRUMENT AIR AND SERVICE AIR.
25. OIL PURIFIER
THE FUNCTION OF THE OIL PURIFIER IS TO SEPARATE WATER AND OTHER CONTAMINATIONS
FROM OIL. UTILIZING VACUUM DEHYDRATION TECHNOLOGY, OIL PURIFIER IS USEFUL TO MAINTAIN
TURBINE PERFORMANCE AND MAKE IT AVOID CORROSION OR WEAR ON THE ENGINE.
26. CARBON DIOXIDE RECORDER
CO2 RECORDER IS A MACHINE THAT CAN RECORD THE LEVEL OF CARBON DIOXIDE AT
DIFFERENT TIMES.
27. INJECTOR
THE FUNCTION OF AN INJECTOR IS TO FEED WATER INTO THE BOILER. IT IS COMMONLY
EMPLOYED FOR VERTICAL AND LOCOMOTIVE BOILERS AND DOES NOT FIND ITS APPLICATION IN
LARGE CAPACITY HIGH PRESSURE BOILERS. IT IS ALSO USED WHERE THE SPACE IS NOT
AVAILABLE FOR THE INSTALLATION OF A FEED PUMP.
28. EVAPORATOR
THESE ARE USED TO GIVE A SUPPLY OF PURE WATER AS MAKE-UP FEED FOR THE BOILERS.
RAW WATER IS EVAPORATED BY USING EXTRACTED STEAM AND THEN CONDENSED TO GIVE
DISTILLED AND PURE FEED WATER.
 2. Air and flue gas system
In this system, air from the air heater is supplied to the boiler furnace using forced draught
fan. The products of combustion in the form of flue gases are circulated in the furnace to heat
the water in the tubes. The heat in the exhaust flue gases is utilized by passing it first over
economizer tubes and then over air preheater tubes. After extracting maximum possible heat,
the flue gases are discharged through the chimney using an induced draught fan.
3. Cooling water system
This system mainly consists of a condenser, condensate extraction pump, cooling tower and
cooling water circulation pump. When plenty of water is not available, a cooling tower is
preferred.
Water pumped from the water clarifier plant is circulated through the condenser
tubes in order to condense the exhaust steam coming from the turbine. Water leaving the condenser
is discharged to the downward side of the river. Such a system is known as open system that is very useful
when abundant water supply is available. When there is scarcity of water,
a cooling tower is installed. This system is also known as a closed system. In this system, the
condensate water is cooled by passing it through the cooling tower. The cold water is pumped
to the hot well. The loss of water due to evaporation is compensated by supplying water directly
from the river.
4. Feed water and steam generation system
This system mainly consists of feed water pump, steam generator, condenser and hot well.
Feed water from the hot well is supplied to the steam generator by using the feed pump. Steam
generated in the boiler is superheated in super heater tubes. Superheated steam is supplied to
the prime mover to develop power. The steam exhausted in the prime mover is condensed in the
condenser. Any water that is lost in the system is compensated by supplying feed water from
an external source. Such feed water should be treated in a feed water treatment plant before
sending it to the hot well.