SIMPLE STEAM POWER

PLANT
REHEAT-REGENERATIVE SYSTEM
UNIVERSAL STEAM PRIME MOVER TESTER
BOILER

Boiler is a closed vessel in

which water is converted into
steam by the application of
heat. Thermal energy
released by combustion of
fuel is transferred to water,
which vaporizes and gets
converted into steam.
 UNIVERSAL STEAM PRIME MOVER TESTER
BOILER

SPECIFICATIONS
Calorific value – 80000 kCal/h,
Nominal steam pressure- 6 kg/𝑐𝑚2
Heating Surface Area -2.8 𝑚2
Fuel Consumption (Kerosene) – 10.9 l/h
Equivalent Evaporation - 150 kg/h
Maximum working pressure – 7 kg/𝑐𝑚2
UNIVERSAL STEAM PRIME MOVER TESTER
CONTROL BOX
UNIVERSAL STEAM PRIME MOVER TESTER
BOILER FEED PUMP

Boiler Feed Pump

is used to feed the
water to be
steamed in the
boiler of the
thermal power
plant.
UNIVERSAL STEAM PRIME MOVER TESTER
SUPERHEATER

A superheater is a
device used to
convert saturated
or wet steam into
superheated steam
or dry steam.
 UNIVERSAL STEAM PRIME MOVER TESTER
SUPERHEATER

SPECIFICATIONS
Heating surface approx. 1.1 𝑚2
Superheating pipe: seamless drawn steel boiler
tube (Outside diameter 34 mm, thickness 3.2 mm)
UNIVERSAL STEAM PRIME MOVER TESTER
STEAM PIPE

A pipe designed to
carry pressurized
steam from a boiler
to the working
components (steam
engines or
turbines).
UNIVERSAL STEAM PRIME MOVER TESTER
WATER PIPE
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BURNER

A burner is a
mechanical device that
supplies required
amount of fuel and air
and creates a condition
of rapid mixing and
produce flame.
UNIVERSAL STEAM PRIME MOVER TESTER
CISTERN

A tank for storing

water.
UNIVERSAL STEAM PRIME MOVER TESTER
WATER SOFTENER

A water softener is
a device that is used
to soften water, by
removing the
minerals that cause
the water to be
hard.
 UNIVERSAL STEAM PRIME MOVER TESTER
WATER SOFTENER

SPECIFICATIONS
Water Softening Capacity – 0.1 to 0.2 𝑚3 /h
Required quantity of salt per regeneration- 1 kg
Quantity of water softened per regeneration cycle
– 4 to 8 𝑚3
UNIVERSAL STEAM PRIME MOVER TESTER
GENERATOR

The turbine is linked by

an axle to a generator, so
the generator spins
around with the turbine
blades. As it spins, the
generator uses the kinetic
energy from the turbine
to make electricity.
UNIVERSAL STEAM PRIME MOVER TESTER
TURBINE

Turbine changes the heat

energy contained in the
steam into rotary motion.
Steam with high pressure
and temperature were
directed to push turbine
blades mounted on the
shaft, so the shaft rotates.
 UNIVERSAL STEAM PRIME MOVER TESTER
TURBINE

SPECIFICATIONS
Single Curtis type, two speed step, axial flow type
Running speed : 3000 rpm
Working steam pressure :
5.5 – 6.0 kg/𝑐𝑚2 (exhaust pressure)
Atmospheric temperature
 UNIVERSAL STEAM PRIME MOVER TESTER
TURBINE

SPECIFICATIONS
Working steam temperature :
180-250˚C (superheated steam)
Required quantity of steam: approx. 100 kg/h
Nozzle (Divergent type)
Turbine wheel diameter ; first rotor vane 270 mm
second rotor vane 290 mm number of blades 75
each
UNIVERSAL STEAM PRIME MOVER TESTER
GOVERNOR

Governor varies the

water flow through the
turbine to control its
speed or output.
 UNIVERSAL STEAM PRIME MOVER TESTER
CONDENSER
The use of a condenser in a power plant is to improve
the efficiency of the power plant by decreasing the
exhaust pressure of the steam below atmosphere.
 PERFORMANCE TESTING OF BOILER
PURPOSE

• To find out the Efficiency of the

Boiler

• To find out the Evaporation Ratio

 PERFORMANCE TESTING OF BOILER
REFERENCE STANDARD

British Standards, BS845: 1987

The British Standard BS845: 1987
describes the methods and conditions
under which a boiler should be tested
to determine its efficiency.
 PERFORMANCE TESTING OF BOILER
REFERENCE STANDARD

British Standards, BS845: 1987

Part One deals with standard boilers, where
the indirect method is specified.
Part Two deals with complex plant where
there are many channels of heat flow. In this
case, both the direct and indirect methods are
applicable, in whole or in part.
 PERFORMANCE TESTING OF BOILER
REFERENCE STANDARD

ASME PTC 4.1

This consists of

Part One: Direct Method (Input - Output

Method)
Part Two: Indirect Method (Heat Loss
Method)
 PERFORMANCE TESTING OF BOILER
REFERENCE STANDARD

IS 8753: Indian Standard for Boiler Testing

Basically Boiler efficiency can be tested by the
following methods:
1) The Direct Method: Where the energy gain of the
working fluid (water and steam) is compared with
the energy content of the boiler fuel.
2) The Indirect Method: Where the efficiency is the
difference between the losses and the energy input.
 PERFORMANCE TESTING OF BOILER
DIRECT METHOD TESTING

This is also known as ’input-output method’ due

to the fact that it needs only the useful output
(steam) and the heat input (i.e. fuel) for evaluating
the efficiency. This efficiency can be evaluated
using the formula:
 PERFORMANCE TESTING OF BOILER
DIRECT METHOD TESTING

HEAT INPUT

The measurement of heat input requires

knowledge of the calorific value of the
fuel and its flow rate in terms of mass or
volume, according to the nature of the
fuel.
 PERFORMANCE TESTING OF BOILER
DIRECT METHOD TESTING

HEAT INPUT

For gaseous fuel: A gas meter of the

approved type can be used and the
measured volume should be corrected for
temperature and pressure.
 PERFORMANCE TESTING OF BOILER
DIRECT METHOD TESTING

HEAT INPUT

For liquid fuel: Heavy fuel oil is very

viscous, and this property varies sharply
with temperature.
 PERFORMANCE TESTING OF BOILER
DIRECT METHOD TESTING

HEAT INPUT

For solid fuel: The accurate measurement

of the flow of coal or other solid fuel is
very difficult. The measurement must be
based on mass, which means that bulky
apparatus must be set up on the boiler-
house floor.
 PERFORMANCE TESTING OF BOILER
DIRECT METHOD TESTING

HEAT OUTPUT

There are several methods, which can be

used for measuring heat output. With
steam boilers, an installed steam meter can
be used to measure flow rate, but this must
be corrected for temperature and pressure.
PERFORMANCE TESTING OF BOILER
DIRECT METHOD TESTING
 PERFORMANCE TESTING OF BOILER
INDIRECT METHOD TESTING

The efficiency can be measured easily by measuring all

the losses occurring in the boilers using the principles
to be described. The disadvantages of the direct
method can be overcome by this method, which
calculates the various heat losses associated with boiler.
An important advantage of this method is that the
errors in measurement do not make significant change
in efficiency.
 PERFORMANCE TESTING OF BOILER
INDIRECT METHOD TESTING

The following LOSSES are applicable to liquid, gas

and solid fired boiler.
L1 Loss due to dry flue gas
L2 Loss due to hydrogen in fuel
L3 Loss due to moisture in fuel
L4 Loss due to moisture in air
L5 Loss due to carbon monoxide
L6 Loss due to surface radiation, convection and other
unaccounted*.
 PERFORMANCE TESTING OF BOILER
INDIRECT METHOD TESTING

The following LOSSES are applicable to liquid, gas

and solid fired boiler.
L1 Loss due to dry flue gas
L2 Loss due to hydrogen in fuel
L3 Loss due to moisture in fuel
L4 Loss due to moisture in air
L5 Loss due to carbon monoxide
L6 Loss due to surface radiation, convection and other
unaccounted.
 PERFORMANCE TESTING OF BOILER
INDIRECT METHOD TESTING

The following LOSSES are applicable to solid fuel

fired boiler in addition to others
L7 Unburnt losses in fly ash
L8 Unburnt losses in bottom ash
 PERFORMANCE TESTING OF BOILER
INDIRECT METHOD TESTING

Measurements Required for Performance Testing

A. Flue Gas Analysis
-Percentage of CO2 or O2 in flue gas
-Percentage of CO in flue gas
-Temperature of flue gas
Instrument: Flue gas analyzer
Type: Portable or fixed
Measurements: % CO2 , O2 and CO
 PERFORMANCE TESTING OF BOILER
INDIRECT METHOD TESTING

Measurements Required for Performance Testing

B. Flow Meter Measurements for
-Fuel -Condensate Water
-Steam -Combustion Air
-Feed water
Instrument: Flow Meter
Type: As applicable
Measurements: Steam, water, air, fuel flow
 PERFORMANCE TESTING OF BOILER
INDIRECT METHOD TESTING

Measurements Required for Performance Testing

C. Temperature Measurements for
-Flue Gas -Condensate Return
-Steam -Combustion Air
-Make-up Water -Fuel
Instrument: Temperature Indicator
Type: Thermocouple, Liquid in Glass
Measurements: Temperature
 PERFORMANCE TESTING OF BOILER
INDIRECT METHOD TESTING

Measurements Required for Performance Testing

D. Pressure Measurements for
-Steam -Draft
-Fuel -Combustion Air
Instrument: Draft Gauge
Type: Manometer, Differential Pressure
Measurements: Amount of draft used or
available
 PERFORMANCE TESTING OF BOILER
INDIRECT METHOD TESTING

Measurements Required for Performance Testing

E. Water Condition
-Total Dissolved Solids
-pH
-Blowdown rate and quantity
Instrument: TDS Meter
Type: Conductivity
Measurements: Boiler Water TDS, Feedwater
TDS, Make-up Water TDS
 PERFORMANCE TESTING OF BOILER
INDIRECT METHOD TESTING

Measurements Required for Performance Testing

E. Water Condition
-Total Dissolved Solids
-pH
-Blowdown rate and quantity
Instrument: TDS Meter
Type: Conductivity
Measurements: Boiler Water TDS, Feedwater
TDS, Make-up Water TDS