STEAM POWER by Mike Brown

Electric power generation with steam at the

individual household level is making a
comeback. At the commercial power plant
level, it never left. Even nuclear power
plants run on steam.
What is new is the fairly recent phenomenon
of household-size steam power units for
standby power generation. Unfortunately,
most people today have no idea how a steam
engine works or the things you have to keep
in mind when setting up a home steam
power system.
The easiest way to deal with a technology
unfamiliar to you is to introduce one concept
at a time. Let’s introduce the basic concept
or outline and then go back and flesh out the
details.
A home steam system consists of a boiler
with a furnace to turn water to steam, a
steam engine to convert the steam energy to
rotary motion to drive a generator, and a
system to re-circulate the water once the
steam has turned back into water. During the
re-circulation of the water utilizing the
exhaust steam heat (providing hot water
and/or heating the home itself) increases the
efficiency of the system. The design of a
home steam system is dictated by the
circumstances of the home where it will be
installed and the fuel available.
Now here is what you have to keep in mind
while designing your system.
The Furnace
The design of your furnace is based upon the
type fuel you are going to use. Fuel can be
solid, liquid, or a gas (vapor). It should be
fairly obvious that a furnace built to burn
logs and twigs is not going to work well
with used motor oil or natural gas, or vice
versa.
The Boiler
Boilers come in sizes and shapes as varied
as the colors of the rainbow. However, there
are only two basic types.
The firetube boiler is what you see on the
old farm tractors and locomotives. A
firetube boiler basically consists of a tank
full of water with hollow tubes running
through it. The hollow tubes allow more
heating surface, in order to turn the water to
steam more rapidly and efficiently.
A firetube boiler will normally not withstand
steam pressure in excess of 250 psi. This is
one of the reasons so many of these devices
went into orbit during the last century and
the early days of this one. Our metals are
much stronger now.
Once in awhile you will still hear of a
firetube boiler exploding, even when built
with modern materials. Today’s explosions
can almost always be traced back to lack of
maintenance.
Even this potential danger can be largely
eliminated by proper construction. Skip
Goebel of Sensible Steam in Branson,
Missouri, builds his boilers so that, in the
unlikely even that one of his boilers "goes,"
the inside of the boiler, the tubes, give way
first. The result is that the water goes down
and puts out the fire in the furnace.
Late in the nineteenth century some
unknown genius came up with the idea of
putting the water in the tubes instead of a
water tank. The fire in the furnace then
turned the water in the tubes into steam.
Thus was born the watertube boiler. The
watertube boiler had advantages.
The first advantage was that steam in a tube
is much more easily contained than steam in
a box or a drum. Steam pressures in a tube
can reach up to 5,000 psi before anything
gives way.
The second advantage is that water in a tube
turns to steam much more rapidly than it
does in a drum. It may take 20-30 minutes to
"get up steam" in a firetube boiler. A
watertube boiler will give you steam in 1-3
minutes.
The third advantage is that a watertube
boiler is cheaper and easier to build. The
simplest of the watertube boilers is called a
monotube boiler, which in essence is
nothing more than a coiled copper tube (like
a moonshine coil) with water in it and a fire
underneath it.
The fourth advantage to a watertube boiler is
that they are really hard to explode.
Normally, all a watertube boiler will do is
spring a leak.
There are a couple of disadvantages to
watertube boilers.
First, a watertube boiler will not allow for
the fluctuations in pressure that a firetube
boiler will. A monotube requires a fairly
constant load.
Second, if a watertube boiler springs a leak
and lets steam escape in an enclosed space,
you could have a problem. If you breathe in
300º to 400º steam, your lungs could
collapse. This is one reason you do not put a
boiler inside your home.
The Engine
A steam engine is known as an external
combustion engine. That is, the power or
energy is produced outside of the engine.
That is, the steam has power before it is
introduced into the engine.
An automobile engine, in contrast, produces
power or energy inside the engine by
inhaling a fuel-air mixture and then igniting
it with a spark.
A steam engine is also quite often lubricated
externally. A device called a hydrostatic
oiler is placed between the boiler and the
steam engine. Steam picks up the oil and
carries it into the engine.
The Steam Chest
The first part of the engine the steam enters
is called the "steam chest." The steam chest
contains the valve system. On smaller steam
engines (10 horsepower and under) the usual
valving system consists of a block of metal
that slides over ports (or holes) cut into a
portion of the interior of the steam chest. No
springs are necessary. This valve is called a
"D-valve." The D-valve uncovers a hole or
passageway to allow steam to push against
the piston head. At the other end of the D-
valve’s travel, the valve uncovers another
passageway that allows steam to push
against the bottom of the piston. The exhaust
passageway is in the middle. Such an engine
is known as a "double-acting" steam engine.
The piston is alternately pushed by steam in
both directions.
Engines of this type turn fairly slowly. 600
rpm is not an unusual or "slow" turning
speed. Don’t let the speed mislead you. 600
rpm in a steam engine isn’t comparable to
600 rpm in a gasoline engine. 600 rpm in a
gas engine is an "idle speed" that produces
very little torque (or twisting force). A steam
engine can produce maximum torque at
almost 0 rpm. If you have ever seen an old
10 to 16 horsepower steam tractor at a
"tractor pull" pulling against our modern
400+ horsepower gas engines, you will
understand. The steam tractor always wins.
The cylinder, piston, connecting rod and
crankshaft are not what you are used to in an
automobile engine. The connecting rod
doesn’t move in a circular motion: it moves
straight up and down (or back and forth).
The straight movement is changed to rotary
motion at the crosshead.
A slider moves back and forth in the
crosshead. A second connecting rod
connects the first connecting rod to the
crankshaft. Crankshaft rotation drives
whatever you want it to drive—electric
generator, water pump, grain grinder, or
other device.
An eccentric mounted on the crankshaft
operates the D-valve. The eccentric and the
D-valve are connected by a valve rod. As
the eccentric rotates the valve rod is moved
back and forth, so does the D-valve.
If you saw the movie "The Titanic" you may
recall the size of the connecting rods going
up and down in the engine room. That
illustrates just how large a steam engine can
be made as compared to one providing
standby power for a home which can weigh
as little as fifty pounds (not counting the
furnace and boiler) and be carried around on
the front seat of a pickup truck. Notice that
you’ll never see gasoline engines as large as
those powering an ocean liner.
As steam engines get larger, they become
more sophisticated (and complex). D-valves
become spool (or cylinder) valves, engines
become faster by becoming uniflow (as
opposed to double-acting), engines become
more efficient by becoming double or triple
expansion, and so on. Boilers become more
efficient as pressures and temperatures rise
and size increases.
There is a trade-off. As steam engines
become more fuel-efficient and
sophisticated, they also become more
expensive, more complicated, and harder to
maintain. The key word here is
"practicality."
An ocean-going freighter with a triple-
expansion engine is practical. The vessel
must carry enough coal to get it from point
A to point B with the lowest possible fuel
consumption. Coal must be paid for and
there are no "coal stations" in the middle of
the ocean.
A small steam engine used for home power
generation needs to be as simple as possible
to facilitate ease of operation and
maintenance, and to keep manufacturing
costs down. When your fuel economy
consists of throwing another log into the
furnace once every couple of hours, who
cares what the fuel efficiency is? This is
especially so during times when you can’t
buy gasoline or diesel fuel.

Side Bar
Alternative Energy for the 21st Century
Mike Brown Steam Engines
The Steam Car Project

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Power Generation-Steam Power
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Lesson Lessons in
Introduction ELECTRICAL
POWER
Review: Lesson 1
GENERATION
The first Lesson was
Power
an Introduction to Lesson
Generation:
the principles of #1:
Introduction
Electrical power
generation. Here are Lesson Power
#2: Generation:
some points you Steam
need to remember Power
from lesson 1. Station←
• Important You are here
electric power
generation Power
definitions Generation:
Lesson
Hydro
• Different sources #3:
Power
of energy Station
• Electrical energy Power
generation Generation:
arrangement Lesson
Diesel
Preview: Lesson 2 #4:
Power
This Lesson is about Station
Steam Power Power
station. The Generation:
student/User is Lesson
Nuclear
expected to #5:
Power
understand the Station
following at the end Lesson Power
of the lesson. #6: Generation:
 • Basics: Gasturbine
• Arrangements: Power
Station
Power
• Cooling:
Lesson Generation:
• Location:
#7: Variable
• Efficiency: load
Definition, Power
advantages & Lesson
Generation:
disadvantages. #8:
Comparison
Components that Power
make up a steam Quiz
Generation:
power station. Test:
Quiz
Wet and dry cooling Electric
methods. Course
Power
Factors influencing Formula Generation -
selection of Sheet:
Formulae
construction site.
How efficient this
power station is.
 help | edit

Part 1: Steam Power station → Basics

Figure 1:Bobov Dol Thermal Power Plant

in Bulgaria ( Click on image to view full
size image )
Introduction: Steam/Thermal Power
station
A steam/thermal power station uses heat
energy generated from burning coal to
produce electrical energy. This type of
power station is widely used around the
world.
This power station uses the Rankine cycle.
This is the cycle of the steam produced in
the boiler, then taken to the Steam turbine
(prime mover). From the turbine the steam
is cooled back to water in the Condenser,
the resulting water is fed back into the
boiler to repeat the cycle.
Because of the abundance of fuel (coal),
this kind of power station can be used to
produce large amounts of electrical energy.
In most countries these power stations are
used as base load power stations. This is
because steam power stations are slow to
start and can not be used to cater for peak
loads that generally occur for a short
duration.
These power stations (together with nuclear
power stations) are kept running very close
to full efficiency for 24 hours a day (unless
they are being maintained). They have
typical life of 30 to 40 years (although most
governments have reduced this number to
35 years).
Pros & Cons: what this power station
presents
Advantages Disadvantages
Air pollution from
Cheap coal is used
smoke fumes
Can be installed Costs more to run
anywhere near fuel compared with other
& water supply types of power stations
Requires less
construction space
Cost for
Generation is less
Future generations will have to learn to
depend less and less on this type of
electricity generating power station, due to a
fast increasing depletion of fuels (coal and
oil). As other types of power stations
become more efficient it should be possible
to completely abandon the use of this type
of power station.
help | edit

Part 2: Steam Power station → Schematic

arrangement
 Figure 2:Thermal power station schematic
diagram ( Click on image to view full size
image )
Stage 1: Coal & Ash handling
This stage is seen as the entrance and exit of
fuel( coal )used. The initial handling
treatment and storage of coal and the final
handling and disposal of Ash.
Coal & Ash Handling (key from figure 2)
*Pulve
*Coal *Coal
riser
conveyor hoppe *Ash hopper (18)
Mill
(14) r (15)
(16)

Stage 2: Steam Generating Plant

This stage is seen as the energy loss stage.
The steam creation by heat accounts for the
greater percentage of power station in-
efficiency.
Steam Generating (key from figure 2)
*Re
*Super
*Boiler heat
heater *Economiser (23)
drum (17) er
(19)
(21)
*In
duc
*Force
*preheater( ed
d d- *Chimney(27)
24) d-
fan(20)
fan(
26)

Stage 3 & 4: Steam turbine &

Alternator/Generator
This stage is seen as the energy conversion
stage. The steam turbine converts steam
energy to rotational mechanical energy,
while the Alternator/Generator converts
rotational mechanical energy into electrical
energy.
Energy conversion (key from figure 2)
*Pressure *Steam
*Boiler feed
turbines (6; 9 & govenor
pump (7)
11) (10)
*Transfor
*Generator (5) *Pylon (3)
mer (4)

Stage 5: Feed water & Cooling

This stage is seen as the recycling stage.
Steam used in boiler chamber is condensed
back to water for re-use.
Feed water & Cooling (key from figure 2)
*Wat
*Cond
*Cooling er
ensor *Precipitator (25)
tower (1) pump
(8)
(2)
This schematic diagram must be properly
understood. it is the basis upon which Steam
power station designs are done. the
individual power station complexity my
differ slightly to the shematic and yet over
and above that will use the same principle.

help | edit

Part 3: Wet Part 4: Dry cooling

cooling This is the more preffered
This is the Cooling method which is
conventional now being implemented in
Cooling most new Steam power
method used in stations. Steam is circulated
most Steam inside a radiator-like heat
power stations. exchanger and is cooled by
Steam is the natural cold air blown
cooled inside (naturally or using draught
the condenser fans) between pipes of the
and is returned heat exchanger. The
to the cooled/condensed steam is
boiler(Rankine returned to the
cycle). boiler(Rankine cycyle).
The condensor This method greatly
itself uses cold decreases water wastages
water and through evaporation by
employs the almost 84% of the wet
principle of cooling method. It is called
heat exchange. Direct dry cooling since the
As the cool condenser has been
water is eliminated completely. This
returned to the method is favored where
boiler, the hot water is scarce.
water in the
condensor is
pumped to the Water consumption
cooling tower. ≈0.4lt / 1kWh
Here water is help | edit
sprayed and
thus fall down
to the water Part 4B: Indirect Dry
pond under the Cooling B
cooling tower.
The second Indirect Dry
As the water
cooling method is called Jet
falls it is
cooled condenser.
cooled by the
natural cold Here the exhaust steam
air. The cooled leaving the low-pressure
water is turbine condensed by a jet
pumped back spray of cold water. the
to the resulting hot water collected
condeser, and is through heat exchangers in
the cycle is the cooling tower. The
repeated. This cooled water is sent back to
method wastes the boiler. Notice that water
a lot of water consumption is equal to the
through previous cooling method.
evaporation.
Water consumption
Water ≈0.8lt / 1kWh
consumption help | edit
≈2.5lt /
1kWh
help | edit Part 6: Efficiency
This type of power station
has very high energy losses
Part 4A: due to great heat loss in the
Indirect Dry boiler and condensor. the
Cooling A following equation is used to
The first calculate power station
Indirect Dry efficiency:
cooling Thermal efficiency
method is
called Wet
cooled the above can be re-written
condenser. as follows:
Here the
condenser is
still used to The above generally works
cool steam that out to ±30% for steam power
is pumped stations.
back to the you can further calculate
boiler. The hot overall efficiency as follows:
water from the
condensor is
then pumped the above can be re-written
to Heat as follows:
exchangers in
the cooling The above generally works
tower and out to ±29% ( 1% loss at the
natural generator ) for steam power
ventilation is stations.
used to cool help | edit
the water
which can then
be pumped
back to the Part 8: Example continued
condenser. help | edit
Notice that
water
consumption Part 10: Completion list
here is double Once you finish your
that consumed Exercises you can post your
in the direct score here! To post your
dry cooling score just e-mail your course
method. co-ordinator your name and
score Click Here .
Water •
consumption 1.…
≈0.8lt / 2.…
1kWh 3.…
help | edit 4.…

Part 5:
Location
The following
is a list of
factors that
influence the
selection of
site for
constructing a
Steam power
station:
1. Supply of
fuel:
• The station

must be
located
close to
coal mines
to reduce
transportati
on cost of
fuel.
2. Availability
of water:
• The station

must be
located
near a river
 bank or
canal for
continous
water
supply.
3.
Transportatio
n facilities:
• The station
must be
well
connected
to major
transport
routes eg
Rail or
Road.
4. Cost & type
of land:
• The land

must have a
 good
bearing
capacity for
heavy
equipment
and yet be
cheap
enough to
purchase.
5. Distance
from
populated
areas:
• The station

must be
located as
far away
from
populated
areas as
possible
 due to air
pollution.
help | edit

Part 7:
Example
help | edit

Part 9:
Refferences &
Exercise 2
Refferences:
1. This

resource is
prepared
from
Lecture
notes by
 Thuvack.
2. V.K Mehta

& Rohit
Mehta :-
Principles
of Power
systems
(1st ed.).
S.CHAND
.ISBN 81-
219-2496-0
Execise 2:
1.…
2.…
• Answers to

Exercise 2

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