Chapter _fJ

Steam Boilers and

Steam Power Plants
Tl,is chapter covers...
on, classification and types ofsteam
► Steam Boilers, Steam Turbines and Power Plants: Introducti
rs and steam tz.rrbines. Introduction and
boilers and steam turbines. Discuss working ofsteam boile
Classification ofpower plants.

ies of the Industrial Revolutio~

The steam engine was one of the most important technolog
ted it in 1775, the steam engine began,
Scottish inventor and mechanical engineer James Watt inven
where the first engines had been used to
to be used in many industrial settings, not just in mining,
engine/turbine we need steam, which is
pump water from deep workings. For running the steam
produced by Steam generator/boiler.

~LER
l into which water is heated until
Steam generator is a boiler, whjch is basjcally a closed vesse
(generally coal) is burnt in a furnace and
the water is converted into steam at required pressure. Fuel
ct with water vessel where the heat of
hot gasses are produced. These hot gasses come in conta
is produced in the boiler. Then this
these hot gases transfer to the water and consequently steam
e are different types of boiler utilized for
steam is piped to the turbine of thermal power plant. Ther
some area, sterilizing equipment, to wann
different purposes like running a production unit, sanitizing
up the surroundings etc.
Steam Boiler Efficiency :

Heat exported by outlet steam 100

Steam boler Tl = . x
Heat supplied by fuel
 • BASIC MECHANICAL ENGINEERING ~
( 2.2 ) ffi ·
. b f10n efficiency & fuel to steam e 1c1ency. Stearn b .
It includes thermal efficiency, com us Oiler
efficiency depends upon the size of boiler used.
. 1 ffi . of steam boiler is 80% to 88%. Actually there are some losses occur 1·1.
A typtca e 1ciency . II d .c • 11\e
.mcomplete com b . d' t' 1 ss occurs from steam boiler surroundmgwa , e1ective cornbust·
ust1on, ra ta mg O 10 0
gas etc.

2.1.1 Boiler Types and Classifications

Boilers can be Classified as Follows :

1. According to the flow of water and hot gases - fire tube (or smoke tube) and water tube
boilers. In fire tube boilers, hot gases pass through tubes which are surrounded with water.
Examples: Vertical, Cochran, Lancashire and Locomotive boilers.
There may be single tube as in case of Lancashire boiler or there may be a bank of tubes as in
a locomotive boiler. In water tube boilers, water circulates through a large number of tubes and
hot gases pass around them.
Eg. Babcock and Wilcox boiler.
2. According to the axis of the shell-vertical and horizontal boilers.
3. According to location or position of the furnace - externally and internally fired boilers.
In internally fired boilers, the furnace forms an integral part of the boilers structure. The vertical
tubular, locomotive and the Scotch marine boilers are well known examples.Externally fired
boilers have a separate furnace built outside the boiler shell and usually below it. The horizontal
return tube (HRT) boiler is probably the most widely known example of this type.
4. According to the application - stationery and mobile boilers. A stationary boilers is one, which is
installed permanently on a land. A marine boiler is a mobile boiler meant for ocean cargo and
passenger ships with an inherent fast steaming capacity.
5. According to steam pressure- low, medium and high pressure boilers.
Jre-tube Boilers :

In fire-tube boilers, combustion gases pass through the inside of the tubes with water surrounding
th e outside of the tubes. The advantages of a fire-tube boiler are its simple construction and less rigid
water treatment requirements.

_The disa~vantages are the excessive weight-per-pound of steam generated, excessive time
required to_ raise steam pressure because of the relatively large volume of water, and inability to
respond qmckly to load changes, again, due to the large water volume.
The most common fire-tube b0 1·1 d· h • . . , , catch··
" . ,, . . e_rs use m eatmg applications are often referred to as 5 ,.
or scotch marme boilers, as this boiler type was commonly used for marine service because ot its
...---------______. STEAM BOILERS AND STHAM . PO WE iJ
act size (fire-box integral with b .1 . JR PLANTS • -(7.. 1
c0Jll • o1 er sechon) The .
P through tubes (Fig 2.1) that are
banneled · fire, or hot flue gases from the burner, ,s
c surrounded by the fluid to be heated.

Fig. 2.1 : Fire-tube Boiler Gas Flow

Every set of tubes that the flue gas travels through, before it makes a turn, is considered a
"pass." So, a three-pass boiler will have three sets of tubes with the stack outlet located on the rear
of the boiIer. A four-pass bo iIer will have four sets and the stack outlet at the front.
Shell and tube boilers are also referred to as fire tube or smoke tube boilers.
Fire tube bo ii ers, typically have a lower initial cost, are more fuel efficient and easier to operate.
Their capacities are up to 25 tons/hr and 17.5 kg/ cm2.
Advantages of Fire-tube Boiler :
• Relatively inexpensive
• Easy to clean
• Compact in size
• Available in sizes from 600,000 btulhrto 50,000,000 btulhr

• Easy to replace tubes

• Well suited for space heating and industrial process applications

Disadvantages of Fire-tube Boilers Include :

• Not suitable for high pressure applications 250 psig and above
• Limitation for high capacity steam generation
 --1- ----- •
( 2.4) B:ASIC MECHANICAL ENGINEERING .----_ ___
----.....
Different Types of Fire Tube Boilers : .
. .
Cormsh boiler : Th ese are the earliest form of high pressure fire
.
tube boiler. These con .
. s,~t of
. . d
Iong honzonta 1cy1m er w ith single large tube containing fire. Fuel IS added 111 the grate area, \\h
e~
it bum to produce hot gases. The hot gases transfer the heat to the water.
Lancashire boiler : The Lancashire bo_iler _is similar to the Co~1ish, but h~'j t\\.O large tubes
containing the fires. Pressure range of the boiler IS about 0. 7 MPa to~ MPa and cffic1cncy is
6510
70%. Fuel in these boilers is added into the grate wh ich heats the ga5cs.
Locomotive boiler: A locomotive boiler has th ree main components:
1. Double-wa lled fi rebox;
2. Horizontal, cylindrical "boiler barrel" containing a large number of smaII flue-tubes;
3. Smokebox with chimney. for the exhaust gases.
Fuel is burned to produce the hot gases and is feed through fire hole. Hot gases arc divertedto
fire tube with the help of fire brick arch. Steam is collected in the steam drum which is placed at the
top of the shell. The wet steam goes through inlet headers of super heater and after passing through
tubes, it returns to the outlet header of super heater and is taken out for steam en gine.
Locomotive-type boilers are al so used in traction engines, steamroll ers, portable engines etc. On the
basis of construction these can be classified wet back boilers and dry back boiler~.
Wet Back Boilers: In wet back boilers, as the name suggests the reversal chamber is completely
surrounded by water. The combustion reversal chamber is surrounded by water and therefore the
heat in the flue gases is optimally utiliLed . Radiation losses are reduced as none of the parts of the
combustion chamber are open to atmosphere instead they arc surrounded by water. That means
fewer losses, and lesser fuel bills. Most efficient modern boilers supplied are wetback type. (Reversal
Chamber)

Dry Back Boilers : The reversal chamber in dry back boilers is not completely surrounded b}
water. The posterior part is exposed to the atmosphere. This leads to the increased radiation losses.
as the radiant heat is lost to the atmosphere instead of going to the water as in wet hack boikr~.
Earlier generation boilers used to be dry back.
Thus wet back boilers ensure lesser radiation losses and hence save fuel. ·1he layout of th e
tubes involves the number of passes, the tube wm make to pass the heat from the boiler furnace
before being discharged. These can be two- pass and three pass boiler.
Water-tube Boilers : In a water-tube boiler, the water is inside the tubes and combu 5tl0. n
gases pass around the outside of the tubes. The advantages of a water-tube boiler are a lov,cr 0~11
weight-per-pound of steam generated, less time required to raise steam pressure. a greater flcxibilit)
for responding to load changes, and a greater ability to operate at high rates of steam gcncratiul1•
_________. STEAM BOILERS AN_D STEAM POWER PLANTS -•_ __.-{ 2.5 J

Steam drum

Steam to turbine
'--'A·ir heater

Brick furnace~
wall
~ .0/ll~
Stoker

..__ASH PIT

Fig. 2.2 : Water-tube Boiler

. The mdustnal
d users are better suited for the water-tub e design.
· Large steam . . v.ater-tube boiler
steam . 1process apphcations,
or hot water primarily for indus tna . . .
typ1ca
frequently for uces
11 Ypro heating applications. and ,s used less

Advantages of Water-tube Boilers:

• Are of steam in sizes far greater than a fire-tube design
houravailable u '
up to several m,·1rwn poun ds-per-

• Are able to handle higher pressures up to 5,000 psig

• Recover faster than their fire-tube cousin
• Have the ability to reach very high temperatures
Disadvantages of the Water-tube Design Include:
• High initial capital cost
• Cleaning is more difficult due to the design
• No commonality between tubes
• Physical size may be an issue
Different types of Water-tube Boilers :
Depending on layout boilers can also be classified as:
1. Longitudinal drum boiler: The feedwater is feed in drum. The drum is placed abo,e the
heat source. The cooler water goes to the inclined tubes and the water is heating e, entually in the hot
tubes. As the water boils its density decreases and there is circulation of hot \\ater and steam. Steam is
separated from water in steam drum and taken out. Longitudinal drum boilers range from 2250 I..g/h to

3600 kg/h.
 ( _ ) • BASIC MECHANICAL ENGINEE~ING ~
26
. . The drum in this type is placed tn cross to the heat sourc
2. Cross drum b011er • . e, lh ,
. d • th's type of arrangement is more urnform. When the steam loads are h,· h ~
temperature obtame m I . g thJ
th
upper tubes can become dry which cause em to fail.
of tubes is made in such a way that large numbers of tubes are made available. 'l'the
Th e layout
capacity of cross drum range from 700kh/h to 240000 kg/h I
3. Stirling boiler : A Stirling boiler has near vertical, almost
straight water tubes that zig-zag
between a number of steam and water drum. Usually there are three banks of tubes in a four drulll
layout.
The feed water enters the left upper drum, from where it falls to lower water drum. Water in
pipes and two drums is heated, the steam produced rise in upper drum from where steam is separate
and taken off.
Other Water Tube Boilers is Babcock and Wilcox Boiler, High Pressure Boilers are La-Mont
Boiler,Loeffier Boiler,Benson Boiler
Supercritical Steam Generator :
A supercritical steam generator is a type of boiler where liquid water immediately becomes
steam. (At Super critical pressure latent heat becomes zero ),hence it operates at supercritical pressure,
ie pressures above the critical pressure -3,200 psi or 22 MPa. (More than 200Bar, lBAR = 1.0197kg'
sq CM).
Contemporary, supercritical steam generators are sometimes refer as Benson boilers. In 1922,
Mark Benson was granted, a patent for a boiler designed to convert water into steam at high pressure.
(Technically, the term "boiler" should not be used for a supercritical pressure steam generator as no
"boiling" actually occurs in the device).
Safety was the main concern behind Benson's concept. Earlier steam generators were designed
for relatively low pressures of up to about 100 bar (10 MP a; 1,450 psi), corresponding to the state of
the art in steam turbine development at the time.
The main advantage and the reason for a higher pressure operation is the increase in the
thermodynamic efficiency of the Rankine cycle.Large Subcritical thermal power plants with 170 bar
and 540 / 540°C (SH / RH) operate at an efficiency of38 %. Supercritical units operating at 250 bar
and 600/615°C can have efficiencies in the range of 42 %.Ultra supercritical units at 300 bar and 6IS
! I 630°C will still increase the efficiency up to 44 %.
I

l 2.1.2 Boiler Mountings and Accessories

th
Fittings which are primarily indicated for the safety of the boiler and for complete control e
process of steam generation. These units are called mountings. The mounting from an integral part
of the boiler and are mounted on the body of the boiler itself. The following mountings are usuall)
installed on the boiler.
 - - - - - -_______. STHAM BO/ I .. FNS L~·,· '
~ .. , tN/) c, ! :AM /'( >\rf:'N I'/ IN n " •

I. Two safety valve 2 · Two water k-vd i11d1l-:1tor.s

4 F11sibh.· plug
3 . Pres sure gauge
5. Steam stop valve 6 . Feed cited, valve
7. Blow-of cock 8 Man and mud hol e
Second categories include · ·I1 are ·m s tall e d to .rn c re a se th e cf •f -1c 1c
. the component s, w Ilie • 11 cy o f· l l H.:
steam power plants a nd help 111 the power working or llrn boil e r unit. T hese fittin g a rc call e d boiler
accessories.
The following accessories are given below.
I. Air pre-heater 2. Economiser
3. Super heater 4. Feed pump and Injector

Function and Working of Mountings and Accessories

(A) Safety Valve

The function of the safety valve is to permit the steam in the boiler to escape to atmosphere
when the steam force due to boiler pressure acting under the valve exceeds the des ired p ressure, the
valve gets lifted off its seat and some of the steam rushes out until normal pressure is restored again.
The commonly used safety valves are given below:
(ii) Lever safety valve
(iii) Spring loaded safety valve
(iv) High steam-low water safety valve
(B) Water Level Indicator
The function of the water level indicator is to ascertain constantly and exactly the level of water
in the boiler shell. It is fitted in the front of the boiler from where it is easily visible to the operator.

(C) Fusible Plug

The function of the fusible plug is to extinguish the fire in the event of the boiler shell failing
below a certain specified limit. If the water is not replenished and the steam generation continues
then the parts, which have been uncovered by water may get overheated and subsequently are
melted. To safeguard against this eventuality we use fusible plug. The fusible plug is inserted at the
box crown or cover the combustion chamber at the lowest permissible water level.

(D) Pressure Gauge

Each boiler has to be provided with a pressure gauge, which record the pressure at which the
steam is being generated in the boiler. The gauge is usually mounted at the front top of the boiler shell
or drum. The gauge should to be clearly visible to the attendant so that he can easily record the
pressure reading.
 (2 )~]1-- - -- • BASIC MECHANICAL ENGINEERING
(E) Blow Off Cock
fhc blow of cock serves to drain out the water from
the boil er periodically for any one oft
fol Im, ing reasons:
( 1) To discharge mud, scale and other impurit
ies which settle down at the bottom of
boiler.
(2) To empty the boiler for internal cleaning
and inspection.
(3) To lower the water leve l rapi dly if the leve
l becomes too high.
The unit is fitted at the lowest portion of the boiler.
(F) Feed Check Valve
The feed check valve has the following two function
s to perform:
(1) To allow the feed water to pass into the
boiler.
(2) To prevent the back flow of water from the
boiler in the events of the failure ofth
feed pump.
(G) Stop Valve
The function of the steam stop valve is to shut off
or regulate the flow of steam fromthe boile
to the steam pipe or from the steam pipe to the
engine. When used for the former purp ose, it is calle
junction valve.
Usually the junc tion valve means a regulating valv
e of larger size and a stop valve refers to
regulating valve of smaller size.
The junction valve is mou nted on the highest
part of the steam space of the boiler and i
connected to the steam pipe, whi ch carries the stea
m to the engine.
(H) Man Holes
These are door to allow men to enter insi de the boil
er for the inspection and repair
accessories:
(I) Air Preheater
Air heater or air pre-heater is waste heat recovery
device in which the air on its way to th e
furnace is raised in temperature by utili zing the
heat of the exhaust gases.
(J) Economiser
The economizer is a device, which serves to
recover some of the heat being carried by
exhaust flue gases. The heat thus recovered is
utilized in raised temperature in feed wate r bein
supplied to the boiler. g

If the water is raised and thus there is a saving in

the consumption of fuel.The economi.ze r
unit is installed in the path of the flue gases betw
een the boiler and the chimney.
 • STHA M H< )JI.hN • ST EA M POWER PLANTS -- •-
-- -t (2 .9 J
· S AN D
---
1 wr I kn
tc r
Sh•HI11 S ~ 11

r in ge ne ral ly we t or at the mo st dr y sat ura ted . St ea m

ple bo ile
Til l' sk' ntn gem:ratcd by n sim st dried at the sa me tem pe rat ur
e
r in wh ich the we t ste am is fir
·r hc:1tl'r is a surface he at ex ch an ge tio n tem pe rature at co ns tan t pr es su re.
10 ra~ure ab ov e the sat ura
prL'ssur~ nnd the•~ ~-aisc~ tempe r he ate r is pla ce d in the pa th of
10 s up er he atm g the steam and as the su pe
t of llue gnsscs utt hz ed in pla nt.
u It in the inc rea sed eff ici ency and economy of the steam
nu e gasses. It rcs

Feed Pump and Injector

in pr es su re
am ing bo ile r is high an d so the feed wa ter has to be rai sed
The pressure inside a ste vic e wh ich rai sed the pre ssu re of
the boile r. Fe ed pu mp is a de
cxc its entry can be affected in
tcrand forces it into the boiler.

STEAM TURBINE
it to
t ex tra cts the rm al en erg y fro m pressurized ste am an d us es
A steam tw·bine is a de vic e tha ary motion, it is pa rti cu lar ly su
ite d to
ou tpu t sha ft. Be cau se of rot
mechanical wo rk on a rot ati ng ctr ici ty ge ne rat ion in the Un ite d St ate s
rat or - abou t 90 % of all ele
used to drive an ele ctr ica l ge ne
es.
996) is by use of ste am turbin
ted in 18 84 by Sir Ch arl es Pa rsons, wh os e first mo de l wa s
s inven
The mo de m ste am tur bin e wa of ele ctr ici ty. Pa rso ns ' de sig n
wa s
ne rat ed 7. 5 kW (10 hp )
nnected to a dy na mo th at ge
reaction type. se po we r
fac tur ing ind ust ry for ste am turbines is dominated by Ch ine
The present-day ma nu re inc lud e BHEL, Siemens, Mitsubishi
turers wi th mi no r ma rke t sha
quipment makers. Other manufac
eavy Industries, and Toshiba .

.2.1 Types
d in several different ways:
~eam turbines can be classifie
1. By details of stage desig
n - ImpuJse or reaction
densing
am sup ply an d ex ha us t co nd itions - Condensing or non-con
2. By ste
tom atic or co ntr oll ed ex tra cti on - Mixed pressure, Reheat
3. Au mpound
arr an ge me nt - Sin gle cas ing , tandem compound or cross co
4. By casing or shaft
5 · By number of exhaust stages in parallel - Tw
o flow, four flow or six flow
w or tangential flow
6 By direction o f steam flow -A xia l flows , radial flo
7· Sin gle orm ult i-A tag e
8 By steam condition - Superheated or saturated
·
(7Jo}- - - ---. BASIC MECJJANJCAL ENGINEERING -•------ .....,
Steam turbines are made in a variety of sizes ranging from small <O.?S kW used a.., 1111,;(:1, • •
· , pumps compress
dm ~s 1or ors and otI1er shaft dnven
· equipment' to l .5 GW (2 000 000 J1 ·%~~
' ' P) trrrl .
used to generate 'electricity. '"' '
•
~ Table 2.1 : Comparison of Impulse and Reaction Turbines

Impulse turbine Reaction turbine

I. It has fi\.ed nozzles that expand It makes use of the reaction force prod~
steam flow to produce force the steam
2. It has fixed nozzles on casing and It has rotating nozzles and fixed vane on casi~
moving buckets on rotor
3. Here, steam completely expands in Here, Fixed blades act as nozzles. Jr ence ~~
the nozzle itself. Hence its pressure expands both in fixed and moving blades
remains constant on both ends of the continuously as it passes over them. 'Jhus the
moving blades pressure drop occurs gradually and .
continuously over both the fi xed and moving
blades.
4. Here, Blades Passage is of constant Here, Blade passage is of variable cross-
cross section area, as there is no sectional area (converging type) due to
expansion of steam. expansion of steam.
5.
--
As pressure remains constant in In Reaction Turbine, Continuous expansion of -
moving blades, the relative velocity steam means relative velocity in the moving
of steam passing over the moving blades increases
blades remains constant
6. Here, Blades are of symmetrical In Reaction Turbine, The blade shapes are -of
profile types : hence, manufacturing aerofoil and non-symmetrical type; hence
of blade is simple. manufacturing is difficult.
7. In Impulse Turbine, Because of In Reaction Turbine, Due to small pressure -
large pressure drop, the steam speed drop, the steam speed and the running speed are
and the running speed are high. low.
8. In Impulse Turbine, Because of In Reaction Turbine, Because of small pressure
---
large pressure drop in the nozzles, drop in each stage, the number of stages are
the number of stages are less. The more for the same pressure drop. Hence the size
size of an impulse turbine for power of the reaction turbine for the same power
output is comparatively small. output is large. Reaction turbines are multi-
stage turbines only
9. Impulse Turbine Occupies less space Reaction Turbine Occupies more space per unit
per unit power power
--
10 Impulse Turbine is Suitable for Reaction Turbine is Suitable for medium
small powers higher powers.
and ----
-- ---• STEA M BOILE RS A ND STEA M POW ER PLAN TS •
• - - - , ( 2.11 )

;- - -1
( Imp ulse Turb ine ; Rea ctio n Turbin~
~ I
Movin g
bucke ts
,
'
..:a
~ - I
Rotor - - ~
Fixed _ _ , ~ ';
Rotati ng
nozzle ~ nozzle

Movin g
bucke ts ~ "'4 f ~ Rotating

Fixed
nozzle
~

~
crF: Rot~---~" ~g --:
&la;o, ~
~
c::::.././ nozzle

i
I
cffi= ! ~ I
I
~ I : "c3' ~t
Rotation

Steam Press ure

I
Steam Pressure

I
Steam Velocity Steam Velocity

Fig. 2.3 : Sche matic Diagr am Show ing Difference

High Medi um
Press ure Gene rator
Turbi ne

'\Hig h
Press ure
Steam Press ure
Steam Steam
Rehe at
Steam Wate r Cond ense r
Boile r

Fig. 2.4 : Multi Stage Turbine Generator

(2.12)- - - - - ~• H lS/c' HUCJI \NICAI~ I NC,INl:'li NINO • ---..
(. 'omkn"mg turhilll'S ,lrt' 1nost l'lmunonl) found in clcctrienl power plnnts. These turbines receive
boikr und l''\lrnust ii 10 n l'01Hkmsc1 Non,-condcnsing or back pressure turbines are
~ll\tlll from a
most" idd) used f\H. prot'l'Ss stl'atn applications. The cAhaus1 pressure is control led by a regulatin .
vah c to suit the rn..'l'ds of the process steam pressure. These are con11nonly found at refineries l

district heating units. pulp and paper plants, and desalination facilities where large amounts oflo\\
pr~ssurc pn)Cl'ss steam art' n~cded.
Reheat turbines an~ t1lso used almost exclusively in electrical power plants. In a reheat turbine
'
steam flo,, c\.its from a high-pressure section of the turbine and is retun1ed to the boiler where
additional superheat 1s added. The steatn then goes back into an intern1ediate pressure section of the
turbine and cont inucs its expansion. Using reheat in a cycle increases the work output from the
turbine and also the c\..pansion reaches full before the stean1 condenses, thereby minimizing the
erosion of the blades in last rows. In an extracting type turbine, steam is released from various stages
of the turbine, and used for industrial process needs or sent to boiler feedwater heaters to improve
overall cycle efficiency. Extraction flows may be controlled with a valve, or left uncontrolled.
Based on Casing or Shaft Arrangements :
These arrangements include single casing, tandem co1npound and cross compound turbines.
Single casing units are the most basic style where a single casing and shaft are coupled to a generator.
Tandem compound are used where two or 1nore casings are directly coupled together to drive a
single generator. A cross compound turbine arrangement features two or more shafts not in line
driving two or more generators that often operate at different speeds
~ STEAM BOILERS AND STEAM POWER PLANTS • ( 2.13 J
rhe steam turbine operates
. . on basic prin cip· Ies of· thermodynamics using the part 3-4 of
e Rankine cycle shown.m th e ~tagram. Superheated steam (or dry saturated steam, depending on
th jjcation) leaves the boil~r at high temperature and high pressure. At entry to the turbine, the steam
ap~ kinetic energy by pass mg through a nozzle (a fixed nozzle in an impulse type turbine or the fixed
aat0 5 • a react10n
0
· type turb'me) · Wh en th e steam leaves the nozzle it is moving at high velocity·
blades tI1the blades of the turbme
.
rotor. A force is created on the blades due to the pressure of the
wwards the blades causmg . them to move. A generator or other such device can be placed on the
0
vapor oand . the steam can now be stored and used. The steam leaves the
the energy that was m
shaft,
. a saturated vapor ( . ·d-vapor mix
or 11qm . depending on application) at a lower temperature
turbine a5 . .
ressure than it entered with and 1s sent to the condenser to be cooled. The first law enables us
an!Pda formula for the rate at which work is developed per unit mass. Assuming tl~ere is no heat
to 10fi to the surrounding environment and that the changes in kinetic and potential energy are
trans er . .
. 'bl compared to the change in specific enthfilpy we arrive at the follow mg equation
neg Iig1 e
W/m = h3 - h4
where,
Wis the rate at which work is developed per unit time and
mis the rate of mass flow through the turbine and
h is the specific enthalpy at state three &
3
h is the specific enthalpy at state 4 for the actual turbine
4
Isentropic Efficiency :
To measure how well a turbine is performing we can look at its isentropic efficiency. This
compares the actual performance of the turbine with the performance that would be achieved by an
ideal, isentropic, turbine. When calculating this efficiency, heat lost to the surroundings is assumed to
be zero. The starting pressure and temperature is the same for both the actual and the ideal turbines,
but at turbine exit the energy content (' speci fie enthalpy') for the actual turbine is greater than that
for the ideal turbine because of irreversibility in the actual turbine.
The specific enthalpy is evaluated at the same pressure for the actual and ideal turbines in order
to give a good comparison between the two. The isentroP ic efficiency is found by dividing the actual
work by the ideal work
r1J -h4
Efficiency ri == Is _h4~
Where
h3 .ts the specific enthalpy at state three
h, is the specific enthalpy at state 4 for the actual turbine
h ·• h . fi h · tropic turbine
e specific enthalpy at state 4s or t e isen
4.\ isl
 ( 2.1~) • BASIC MECHANICAL ENGINEERING ~
2.3 POWER PLANT
A power plant or a power generating station, is basically an industrial location that is ..
for the generation and distribution of electric power. Utilizeq
All power generating stations has an AC generator or an alternator, which is basically a r .
machine that is equipped to convert energy from the mechanical domain ( rotating turbine~t~tlllg
electrical domain by creating relative motion between a magnetic field and the conductors the in to
source harnessed to tum the generator shaft varies widely, and is chiefly dependent on th ~nergy
fuel used e Pe of
Types of Power Station :
Power plant can be of several types
1. Based On Input Energy /Fuel
(A) Coal Thennal Power Plants (B) Hydraulic Power Plants
(C) Nuclear Power Plants (D) Geothermal Power Plants
(E) Solar Power Plants (F) Wind Power Plants
(G) Biomass Power Plant
A. Coal Thermal Power Plant- The heat produce by burning fossil fuel materials, boils
water
and transfonns it into steam. The steam is then piped to a turbine. The impulses of turbine move
the turbine. Rotation of the turbine rotates the generator to produce electricity. Finally, steam is
condensed and move into the boiler to repeat the cycle.
B. Hydraulic Power Plant- The hydroelectric power plants are stations, where energy is produced
by the force of falling water. The water moves a turbine, connected to a generator that collect
the energy that water creates. Rotation of the turbine rotates the generator to produce electricity.
C. Nuclear Thermal Power Plant- The heat is produced by fission in a nuclear reactor
(a light
water reactor). By this heat, water vapor (steam) is produced. The pressurized steam is then
usually fed to a multi-stage steam turbine.
D. Geothermal Power Plant - Geothermal electricity is electricity generated from geotherm
al
energy. Technologies in use include dry steam power plants, flash steam power plants and
binary cycle power plants.
E. Solar Power Plant - These power plants creates energy by transforming the heat and r ht
ig
from the sun. Solar power plants are two types.
1. Pbotovolta1c · Energy : Is a method . g electnc
. al power by convert·og
of generatm 1 solar
radiation into direct current electricity.
2. Solar Thermal Energy : It stores the heat of the sun, which transforms water into steaJJI,
that moves turbines which are connected to a generator that collect energy
 ST'fL t,\J Hou /"p \
that is '-'ti/;~ed , ,.s I.VJ> ~ I'/'
., WindPowerPJant-Windstnr 1·l). ' · I,\/ 11<>1r1u~ , INi ·,,
,. kind of enerll.).A" ;nd forn, cons;,n ••re• lh,•" ,"''S1hn11.,.,,,,;,., 1•1·· " •-. ,..,,.,
' '· "J
101
Jly a rotat;n wer transmission net,, 0 , • • nlniosr II ht111drt1<1 )I' .1111 111d l'llL•r~ 1° 111101ht1r IINt'lilll
b. g G Biomass
po Power Plant - fhc
'•· l3io ,, . """'"111·11 · , , , 111
' •
r Ine) in to 1111 Illes l01111l'l'l1:d lo dcttnc
·s the energy .h I I . I ss 11 lL'1111n1 t'llcr1n ' . .
rubb1s 'sue 1 asp ants an1111n1s, food. It'). I • ' . <N co11s1:s1 '" h111ni11g lhu 1111111rulw11s1u 1111<1
the type of . f' · · t I llt 11 <.:cs nnturnl 11 , , . I .
which trans onns rt into stcnni, thnt I 1, . c- 0scs, t 1111 prov,dt's hcut to wall'r und
n er \V1ll 1110,l' II t ·t ·
Thermal Power
collects Station :
energy '" "'" """'""'"' In n gcneo·,uor llrn1
e A thermal
f0 power station or a coal frrcd the, I
1
. .
thod o aenerating e ectr,c Power With rcuso i•ibl I · I , ,- ·
. . rna Power Plant 1s hy lur, lho lllos( convcntionul
1nc«ncy. II uses cnnl n, fhc pdnin.-y
m to bod. the water available
fuel •
to superheated' <' Y Hg
steam forl cddvi,.g lhc steam to,,b;,. _ The""""
0 gcnccaHon
lurbine is then mechanically coupled to an altcmato, coto,, the 101aU011 of whfoh rcsulf, ;,. lhc
ofelectric power. Generally in Jnd ia, bituminous coo I o, brown coal aro used "' IUcl of boUcr wh ioh
has volatile content ranging fi-om 8 lo 33% ,,.dash confcnt 5 lo 16 %. 't\, COlha"cc lhc lhcnnal
efficiency ofthe p Ian~ the coal is used in the bo;re, in its pu lvcd1c<1 fom,.1,. coa I fo·cd lhcnnnl power
plans steam is obtained in very high pressure, ins idc the steam boilec by bum ;,,g 1110 pu lvc,i,cd coa I.
This steam is then super heated in the super hcatc, to extreme h<gh lcmpcrnfurc.
water
~mo~e Super Heated HP steam
~am1s 3-ph supply
&
cu
E Super
::,
LL heater
Air
r Boiler Drum
LP steam
Boiler Economiser
en
Exhaust gas to stack
~al
hd
Condenser
T Fig. 2.6 : Steam Power Plant
it
b super heate d steam 1s
rotated his . the turbme,
. then allowed to enter into . as the turbine blades arc
that its y th e ~ressure of the steam. The turbine is mechanically coupled with alternator in a way
pressu rotor Wlll rotate with the rotation of turbine blades. After entering into the turbine, the steam
ener r~ suddenly falls leading to corresponding increase in the steam volume. Aficr having impar1cd
c gy into the turbine rotors, the steam is made to pass out of the turbine blades into the steam
ondenser of turbine. In the condenser, cold water at ambient temperature is circulated with the
( 2.16) • /MSH' Ml!<'IIAN/Clil, liNUINl!J!NJNCJ ----------
help of' pump which lends to the l'ondcnsntion of' the low pressure wet steam. Then this co~
water is further supplied to low prcssur~ water h~ate_r where the lo~ _rrcss~re steam incre den~
temperature of this feed wntcr it is ng11111 hcuted 111 l11gh pressure. 1 his outlines the ba . ases1~,
·. • s1c\Vor .'
methodology or u thermal power plant. k1~
Atlvm,tllge.\· ()/ Tlternu,/ Power l'lmtt.,·
• Fuel used i.e coal is quite cheaper.
• Initial cost is less ns compared to other generating stations.
• It requires less space as compared to hydro-electric power stations.
Disadva11tages of Thermal P()wer Plants
• It pollutes atmosphere due to production of smoke & fumes.
• Running cost of the power plant is more than hydro electric plant.
Nuclear Power Station :
The nuclear power generating stations are similar to the thermal stations in more ways thj
one. How ever, the exception here is that, radioactive elements like uranium and thorium are used
the primary fuel in place of coal. Also in a Nuclear station the furnace and the boiler are replacedb
the nuclear reactor and the heat exchanger tubes.
Containment
Building
!Alternator I
IReactor vessel I
I Fuel rods! !Hot water
aterlI
ICooll
~
~ !Waterl !Condensorl
ICooling tower I
Fig. 2.7 : Nuclear Power Station
For the process of nuclear power generation, the radioactive fuels are made to undergo fissio.
reaction within the nuclear reactors. The fission reaction, propagates like a controlled chain reactt0
- - - - - - - -· S 'l'J!AAI JU )JJJ/NS /\NJ> S'l'/Ji\AI / 1( )W/1 /I,! l'/,;tN'/S •----Ci I 'I)
nnd is uccompanic~I by uuprccc~le11tud 11111011111 ol\.:rwrgy produ<.;cd , which is ,rw11ifo:-,ted in the forn•
of hcnL This heal IS then ti·m~slerrcd to lhu w11h.,,· pn..•sc11t i11 Ille IH..: ut, cxdui11ger lubu~. /\t.; a rc:wlt,
super heated steam ul v~-r~ I ugh IL'lllJ>~l'lll\lru is prod11ccd . <>11c<.· the process of' stc:im f OJ 111:il ion _is
ncconiplishud, the rc1_1wm111µ, fWOCL~ss 1s ox11clly si111i lm lo II flu.:nmd pnwur plunt. mi tlai :-; stc.i111 will
further drive the turb111u blades lo gc11erntu uluctricity.
Hydro-electric Power Sh1Cion :
In l lydro-clectric plants the <.mcrgy ornw
fhlli11g wnlcr is utilized to drive the turhinc which in
wrn runs the generator to produce elcctrici1y. Rain foiling upon the earth 's :,,11rfocc has potcntiul
energy relative to the occHns toward s which it flows. This cncrgy is convt:rtcd to shaft work where
the water falls through an appreciable vcrticnl cli sta ncc. 'I he hyclniulic power is thcrt:forc a m1turally
available renewable energy
Inside a H ·y dro;p ower Plant
Power house
Dam
Reservoir Power tines
' Transf,ormer
Generator
1
...... Turbine
Outflow
Control Penstock
Intake
Gate
...
Fig, 2.8 : Hydro-Electric Power Plant
This power is utilized for rotating the alternator shaft, to convert it to equivalent electrical
energy. An important point to be noted is that, the hydro-electric plants arc of much lower capacity
compared to their thermal or n uc lea r counterpart. For this reason hydro plants arc generally used in
scheduling with thermal stations, to serve the load during peak hours. ·r hey in a way assist !he
th crmal or the nuclear plant to deliver power crftciently during pcriocls of peak hours.
 ( 2.18) • BASIC M/JCIIANICA!,, JiNUINI!JiNJN(J • - - - -
Advantages of Hydro Electric Power Station
• rt requires no fuel, water is used for generation of electrical energy.
• It is neat and clean energy generation.
• Construction is simple, less maintenance is required.
• It helps in irrigation and flood control also.
Disadvantages Hydro Electric Power Statioll
~
• It involves high capital cost due to dam construction.
• Availabili ty of water depends upon weather conditions.
It requires high transmission cost as the plant is located in hi Ily areas.
Solar Power Plant :
Fig. 2.9 : Solar Power Plant
Solar energy can be turned into electricity either directly in solar cells, or in a concentrating
solar power plant by focusing the light to run a heat engine.
A solar photovoltaic power plant converts sunlight into direct current electnci · ·ty using
.n
the photoelectric effect. Inverters change the direct current into alternating current for co_nnecllO
to the electrical grid. This type of plant does not use rotating machines for energy conversion. .
Solar the_rmal powe~ plants a_re another type of solar power plant. They u_se e1t. her ~~ii. arabohc
The
troughs or hehostats to dlfect sunlight onto a pipe containing a heat transfer fluid, such a rator,
heated oil is then used to boil water into steam, which turns a turbine that drives an electrical gene din~
The central tower type of solar thermal power plant uses hundreds or thousands of mirrors,. depenstc n.
31
on size, to direct sunlight onto a receiver on top of a tower. Again, the heat is used to produce·
to tum turbines that drive electrical generators.
____________. STEAM BOILERS AND STEAM POWER PLANTS • [ ·19 )
2
wer Plant:
Wind Po
Fig. 2.10 : Wind turbines
Wind turbines can be used to generate electricity in areas with strong, steady winds,
sometimes offshore. Many different designs have been used in the past, but almost all modem turbines
being produced today use a three-bladed, upwind design. Grid-connected wind turbines now being
built are much larger than the units installed during the 1970s. They thus produce power more
cheaply and reliably than earlier models. With larger turbines (on the order of one megawatt), the
blades move more slowly than older, smaller, units, which makes them less visually distracting and
safer for birds.
Biomass Polwer Plant :
Fig. 2.11 : Biomass Power Station