University of Bolton

Study World Lanka Campus

BEng (Hons) Mechanical Engineering

AME6015 Advanced Thermofluids and control

Designing and Controlling of Steam Power Plant

Table of Contents

TASK 1 – DESIGNING OF FLUID SYSTEMS AND MAIN EQUIPMENT.

1.Introduction to the steam power plant 1

2 Coal power plant working configuration2

3.Feed pump piping system for water 5

3.1 Boiler max capacity 6

3.2 Pump flow rate 6

3.3 Mass flow rate through feed pump 6

3.4 velocity of flow 7

3.5 Actual boiler pressure 7

4 Design of boiler 8

4.1 Rankine cycle 10

4.2 Calculations 12

4.2.1 Work done by the turbine 15

4.2.2 Generator capacity 16

4.2.3 Work done by the feed pump 16

4.2.4 Heat supplied by the boiler 17

4.2.5 Heat rejected by the condenser 17

5. Super-heated steam circuit 18

6. Cooling tower and piping system 19

7. Summary 21

8. Conclusion and the recommendation 22

TASK 2 – INTERGRATING COMBINED HEAT POWER SYSTEM FOR PROCESS

HEATING

9.Introduction to the combine heat power 23

10. Discussion and the calculation 24

11.Summary 28

12. Conclusion and recommendation 29

TASK 3 – PID based control system

13.Introduction to the PID system 31

14. Advanced strategies of PID based control systems 31

14.1 Turbine and the generator 31

14.2 Boiler 32

14.2.1 Temperature controller 32

14.2.2 Boiler water level controller 33

14.2.3 Tuning the boiler by identification of fuel ratio 33

15. Conclusion and recommendation 33

16. References 36
TASK 1 – DESIGNING OF FLUID SYSTEMS AND MAIN EQUIPMENT.

1. Introduction to the steam power plant

Produce electricity steam power plants are being used globally. Approximately 80% of

electricity is produced by the fired thermal power plant and the rest is depends on the alternative

methods such as solar, biogas, nuclear and etc. (Rashidi, Aghagoli, and Ali, 2013).

Water is transformed into steam by the combustion of fuel such as coal and other carbon based

fuels to gain heat energy. Turbine blades are rotated by high temperature and steam pressure

while turbine shaft is joined to the generator. With this, generator transforms the kinetic energy

into electric energy. (Cold handling plants, 2021)

Importantly, thermal or steam power plants emphasis on the medium of steam and temperature.

It can be pointed as follows;

 Saturation of temperature - it is the process of fluid converts to the steam at the boiling

point for a corresponding pressure.

 Unsaturated steam or wet steam - When steam is generated, non-vaporized water

molecules and water droplets are mixed. Most efficient boiler emit 2% and 4% of steam

and wetness.

 Saturated steam or dry steam - vapor becomes saturated when the water is heated up to

the boiling point. at the temperature of saturation dry steam is passed out and doesn’t

contain water in suspension

1
  Super-heated steam - it takes place at the higher temperature of the boiling point and

where water is removed from the system.

 Condensate - steam, or gas is being condensed to produced liquid or water.

2. Coal power plant working configuration

Four main working circuits can be identified in coal based thermal power plants,

1. Coal and Ash circuit

Figure 1

When the coal reach the coal handling plant, it’ll go through the necessary operations.

Then it proceeds through the furnace in pulveriser and fuel feeding device. Ash formed

by the combustion of coal gathers behind the boiler and an ash handling plant separates it

to the ash storage.

2. Air and Gas Circuit

2
 Figure 2

A Forced draught fan is operated to grasp the air in atmosphere and to progress it to a

furnace by the air preheater. With the combustion of coal in the boiler Flue gases are

made. Then the flue gases will pass in boiler tubes and superheated tubes in furnace, next

to an economizer and lastly to air preheater and released to the atmosphere through an

electro static precipitator.

3. Feed water and steam flow circuit

Figure 3

Distillation occurs in the water and steam circuit, leaving and flowing through the

deaerator and economizer used to heat up the feed water to the boiler by flue gas.

Purification and softening process is taking place before it enters to the boiler and it

3
 avoids scaling of tubes. Water circulation in the boiler is then occurred due to the

differences of the temperature and density. Steam is superheated by the assistance of the

drum before entering to the turbine.

4. Cooling water circuit

Figure 4

To maintain a low pressure cool water is supplied to the condenser and then cool water is

absorbed by the heat emitted from the turbine and gets warm inside the condenser.

Thereafter, hot water flows through the cooling tower to get cool and pressure is applied

in circulating the water pump again to the condenser. The amount of water wasted in the

cooling tower is indemnified by using the water resources like lake, see and river.

3. Feed Pump piping system for water

Ball valve is used for on/off control without pressure drop at the feed pump. Cast iron grade 316

is used for feed pump piping. Total length is 60m and diameter is 150mm

4
Friction coefficient λ = 0.00085 (Engineering toolbox 2001)

Figure 5 Feed pump piping circuit

Assumptions and the calculations are made according to the (Carver pump, 2020).

Feed pump flow rate is given by the formula: boiler maximum capacity horsepower x 0.069 x C.

The value of C is based on how your pump will cycle: either in intermittent mode or in

continuous feed mode. If the pump is an intermittent mode, C =1.50. If it’s continuous, C = 1.15.

Pump flow rate = boiler maximum capacity horsepower x 0.069 x C. (C = 1.15)

3.1 Boiler maximum capacity

Boiler maximum capacity = 9.14 x 1000 kW

= 9.14 x 1000/0.7355 (0.7355Kw = 1hp)

5
3.2 Pump flow rate

Covert gallons into liters

750 4.5
(1 gallon = 6 x l=4.5 l= =¿45 x 10-4 m3)
1000 1000

Pump flow rate = (9.14 x 1000/0.7355) x 0.069 x 1.15. (c = 1.15)

= 986 gpm (gallons per min.) = 986 x (45 x 10-4)/60 m3 / s = 0.074 m3 / s

Pump flow rate = 0.074 m3 / s.

Volumetric flow rate through Feed Pump V̇ = 0.074 m3/s

3.3 Mass flow rate through Feed Pump

V̇
Mass flow rate through Feed Pump ṁ = ( )
vf

1
∴ = 0.074×
1.0052× 10−3

= 73.62 kg/s

3.4 Velocity of flow

Q
Velocity of flow v = ( )
A

0.074
= 2
π × 0.15 /4

6
= 4.19m/s

3.5 Actual boiler pressure

2
2
0.00085 ( 60 ) 4.19
∴ Friction head loss hf = λLV = = 0.3m
2 gD 2(9.81)(0.15)

Assume suction + delivery head to the boiler = 10m

∴ Total head loss = 10m + 0.3m = 10.3m

1
Pressure loss: P = h ρg ; ρ =
vf

1
That is the pressure loss = [10.3 × × 9.81¿ /¿105 = 1.0 bar (Assume 1.0 bar = 10 5
1.0052× 10−3

N / m2)

∴ Actual boiler pressure = 120 – 1.0 = 119 bar

4. Design of boiler

Boiler designing and calculations are made according to the (Raphael, Joseph and Gruscinshi,

2014) research paper and engineering consultancy software (Red-Bang, 2020)

Material type – A-106-6RB (Which is Carbon – MN steel)

7
According to – ASME. Dutch rule

Inside diameter – 950.06 mm

Nominal required thickness – 26.95 mm

Volume enclosed (V) – 1.054 m3

Height (L) – 1.5 m

Type of the boiler – Fire tube type

Figure 6 Fire tube boiler

Saturated steam flow rate – 2.5kg/s

2.5 kg/ s
Feed pump flow rate (according to EN 12952- 7) -
1.15
8
 = 2.174 kg/s

4.1 Rankine cycle

Figure 7 Rankine cycle with superheated

9
Rankin cycle is known as the idealized thermodynamic cycle which expresses the operation and

procedure of heat engines or reciprocating steam engines. Further it extracted mechanical energy

by the fluid and work on heat sink and heat source. Rankine cycle is commonly used in thermal

steam power plants to produce electricity.

There are four steps in the process of rankine cycle.

1 – 2 [Isentropic compression] in this stage working fluid is saturated water and it is being

pumped from lower to higher pressure in a reversibly and adiabatically.

2 – 3 [Isobaric heat addition] High pressure saturated water from the compressor is pumped to

the boiler and it is heated at a constant pressure.

3 – 4a [Isentropic expansion] in this process super-heated steam is expanded by the turbine and

work is done by the turbine. Further, pressure and the temperature of vapor steam will decreased.

Final state of steam will be in partially saturated state.

4a – 1 [Isobaric heat rejection] partially saturated steam enters for the condensing process and

it is condensed at a constant pressure, where it becomes saturated water.

10
4.2 Calculations

As mentioned by Dr. Whitefoot in 2018 and power engineering in 2008, calculations for the

steam power cycle are as follows;

11
 Table 1 Properties of super-heated water vapor

h3 and S3 values are calculated by using the above table 1 and interpolation

(3858.4−3709)
hg at 120 bar ( 12MPa ) & 650 °C h3 = 3709 + (700−640)
×(650−640)

= 3733 KJ/kg

12
 (7.0749−6.9164)
Sg at 120 bar ( 12MPa ) & 650 °C S3 = 6.9164+ (700−640)
×(650−640)

= 3733 KJ/kg K

Table 2 Saturated water (liquid – vapor) pressure table

By interpolation;

0.4226+0.5210
Sf at 0.05 bar =
2

= 0.4718 KJ/ Kg K

13
 121.46+151.53
hf at 0.05 bar =
2

= 136.495 KJ / kg

2554.4+2567.4
hg at 0.05 bar =
2

= 2560.9 KJ /Kg

8.4746+8.3304
Sg at 0.05 bar =
2

= 8.4025 KJ / kg K

The state 4a means actual state of steam in the condenser while state 4s means the state of steam

in the condenser if it is assumed the turbine process is fully isentropic. Then s 3 = s4s .by this, it

can be used to calculate dryness fraction at state 4s: x4s.

Applying,

S3 = S4s S3

= 0.4718 + X4s (8.4025 – 0.4718)

= 6.9428

To find the dryness fraction (X4S)

6.9428−0.4718
∴ X4s =
8.4025−0.4718

14
= 0.816

Using x4s h4s can be calculated as follows.

h4s = 136.445 + 0.816 (2560.9 – 136.495)

= 2114.84 KJ/kg

Isentropic efficiency of the turbine is 90%;

From the equation of turbine’s efficiency h4a can be calculated as follows.

Actual work
Efficiency of the turbine = =
Isntropic work

3733−h 4 a
0.9 =
3733−2114.81

= h4a 3733 – 0.9 (3733 – 2114.81)

= h4a = 2276.629 KJ / kg

4.2.1 Work done by the turbine

The process isentropic expansion

WT = h3 – h4a = 3733 – 2276.629

= 1456.371 KJ / kg

4.2.2 Generator capacity

Generator capacity = work done by the turbine × 95%

= {1456.371 × 2.5} × 0.95

15
3.45 MW

Saturated temperature values from the table 2

(28.96+ 36.16)
Saturated temperature at 0.05 bar =
2

= 32.56 °C

4.2.3 Work done by the feed pump

Work done by feed pump on the system

Wf =vf × (P2 – P1) This will be the isentropic work done. No heat transfer in work done.

By SFEE ; Q+W = h2s - h1 ⇒ 0 + Wf = h2s - h1 ⇒ Wf = h2s - h1

But the feed pump has isentropic efficiency, using this h2a is calculated.

hf = Vf at 0.05 bar {(120 – 0.05) × 100}

= 1.0052 × 10-3 × 119.95 × 100

Wf = 12.06 KJ/kg

h1 = hf at 0.05 bar = 136.495 KJ/kg

but Wf = h2s – h1s

12.06 = h2s – 136.495

h2s = 148.455 KJ/kg

Efficiency of the feed pump =

Isentropic work
Actual work
16
 h 2 s−h1
0.82 =
h 2 a−h 1

h 2 s−h 1
h2a = + h1
0.82

12.06
h2a = + 136.495
0.82

h2a 154.43 KJ/kg

4.2.4 Heat supplied by the boiler

Qin = h3 – h2a = 3733 – 154.43

= 3578.57KJ/kg

4.2.5 Heat rejected by the condenser

According to the first law of thermodynamics,

Qin – Qout = WT – Wf

Qout = Qin – WT + Wf

= 3578.57 – 1456.371 + 12.06

= 2134.259 KJ/kg

5. Super-heated steam circuit

A 100mm schedule 40 pipe has an outside diameter of 114.30mm, a wall thickness of 6.02mm
giving a bore of 102.26mm (according to code BS 1600) is used for steam transport from the
boiler to turbine. Assumes length is 10m (Engineering toolbox, 2001).

17
 Figure 8 Super-heated steam circuit

6. Cooling tower and piping system

18
 Figure 9 Piping system diagram

Total length of the circuit is 50m and assumed average velocity throughout the system as 4.19

m/s. Globe valve is design to stop or regulate the fluid flow and use to control the flow according

to the requirement by the system. Globe valve is known as a best shut off valve in the working

environment compared to gate valve.

Figure 10 Friction losses in pipe fittings

19
 2
fL V
Friction head loss hf =
2 Dg
2
0.00085 ×50 × 4.19
=
2 × 9.81× 0.15
=0.25 m
2
V
Minor head loss = k
2g
2
4.19
Globe valve loss = 10
2× 9.81
= 8.94 m
Total minor losses in globe valves = 3 × 8.94
=26.82 m
2
4.19
90° Standard elbow = 0.9
2× 9.81
= 0.80 m
Total minor losses in elbows = 4 × 0.80
=3.2 m
Total losses in the system = 3.2 + 26.82 + 0.25
= 30.27 m

7. Summary

20
Heat supplied by the boiler = 3578.57 KJ/kg

Heat supplied rate by the boiler = 3578.57 x 2.5 = 8.946 MW

Heat rejected by the condenser = 2134.259 KJ/kg

Heat rejected rate by the condenser = 2134.259 x 2.5 = 5.336MW

Work done by the turbine = 1456.371 KJ/kg

Work done rate by the turbine = 1456.371 x 2.5 = 3.641 MW

Generator capacity = 1383.55 kJ/kg

Work done rate by the generator = 3.45 MW

Work done on feed pump = 12.06 KJ/kg

Work rate in feed pump = 12.06 x 2.5 = 30.15 KW

8. Conclusion & recommendation

To make the system more efficient and to save the environment, bag filters and the dust

collectors can be installed. Dust from the exhaust gas particles can be collected into the bags and
21
disposed in an environment friendly. Further, preventive maintenance should be carried out

annually such as Non-Destructive testing for Boiler and the fire tubes. Liquid penetrate (LP),

ultrasonic, magnetic particles (MP) and X –ray test methods are commonly used to analyze the

defect factors such as corrosion and cracks. It is important to do preventive maintenance to

eliminate sudden break downs and hazards.

Major and minor losses should be concern to minimize the pressure drop. Therefore, pipe and

fittings in the system should be reducing the minor and major losses. Compared to globe valve,

gate valve has a small K – factor (Coefficient of fluid resistance) and 45° standard elbow is

better in use compared to 90° standard elbow due to lesser K- factor.

Efficiency of the steam power plant can be improved by increasing the pressure and the

temperature of incoming steam to the turbine and by reducing the pressure of the condenser.

However, efficiency of the turbine section can increase by reheating the steam in different stages

such as low pressure turbine, intermediate turbine and high pressure turbine.

Task 2 – Integrating combined heat power system

9. Introduction to combine heat power

Heat engines are used to generate mechanical power and convert to thermal energy by

combustion of fuel for thermal power plant. Water is heated to produce stream and it is used to

22
drive the electrical generator. As the first step boiler is produced the steam and passes through

the turbine and it condensed in the condenser where it is being recycled to the primary stage.

According to the second law of thermodynamics thermal energy can be transformed in to

mechanical but there will be a heat lost to the atmosphere. Therefor Combined Heat Power cycle

is introduced to minimize the heat loss.

CHP is a productive and advance system for electricity generation and in capturing the heat that

can get unused when dispensing thermal energy including steam or hot water. Hot water utilized

for domestic purposes, industrial procedures and space heating are some of its usages. CHP is

identified in buildings, unoccupied residential units or in networks of energy systems and utility

resource. CHP is mainly found in provisions where electricity and thermal energy are needed.

Approximately two thirds of energy produced by giving rise to conventional electricity, are

squandered as heat discharged to the atmosphere. Further, more energy is wasted when

electricity is distributed for users for final consumption. CHP can achieve a productivity of more

than 80%, by seizing and averting losses on distribution using heat that'll get wasted, in

comparison to 50% for typical technologies such as on site boiler. (Carbon trust, 2014)

10. Discussion and the calculation

23
 Figure 11 Rankine cycle for combined heat power

1 is the boiler outlet, 2 and 3 is the inlet of the PRV (Pressure Released Valve) and turbine

respectively. It is Assumed that the same steam, flows through the above mentioned inlets. And

neglected the minor pressure lost. Point 4 is the outlet of the PRV and take it as an adiabatic

where no heat transfer and no work done is being placed. Purpose of the PRV is to regulate the

pressure.5 and the 6 are the inlet and the outlet of the turbine. Point 11 is the inlet of the boiler

from the mixing and pumps 1 and 2.

The assumptions of Eurostat energy statistics in 2017 and Bali and Aras in 2007 were considered

in the following combined heat power system as below;

24
h2 = hg (at 119.003 bar 650°C) = 3733 kJ/kg..

Applying Steady Flow Energy Equation

for 2 → 4 process; Q + W = h4 – h2 : here Q = 0 & W = 0.

Assume the PRV has no heat transfer. And there is no work done on the system.

0 + 0 = h4 – h2 ⇒ h4 – h2 = 0 ⇒ h4 = h2

Then h4 = h2 = 3733 kJ/kg. Assume 20% of steam is taken off for 2 → 4 process. Then the

remain 80% of steam flows though the turbine.

h4 = 3733 kJ/kg. From steam tables 1

Table 3 Properties of super-heated water vapor

By interpolation

(700−600)
T4 = 600 + (3925.9−3701.7) ×(3733−3701.7)

25
= 600.45 °C and P4 = 5.0 bar.

As the turbine is not fully isentropic and its isentropic efficiency is 90 %, then remain 10 % 0f

energy is dissipated as heat and assume this heat is transferred in 5 → 7 process.

Heat collected from node 4 and 5 are used for industrial food heating process.

10 80
Heat is transferred in 5 → 7 process; Q5 →7 = (h3 – h4s) × ×
100 100

Heat is transferred in 5 → 7 process; Q5 →7 = (3733 – 2114.81)×0.1×0.8 = 129.5 kJ/kg of

original steam.

Assume at node 7, there is pure water at 1.0 bar coming from outside (atmosphere), which was

used for the purpose of food processing.

From steam tables; h7 = hf at 1.0 bar = 417.46 kJ/kg

∴ Heat is used for food processing purpose

Q4 ,5 →7 (Process Heater) = (h4 + Q5 →7 ¿ – H7

20 20
H4 = h4× & H 7 = h7×
100 100

Q4 ,5 →7 (Process Heater) = (3733×0.2 + 129.5 - 417.46 ×0.2)

= 792.61 kJ per kg of original steam.

80
Heat in condensing = (h4a – h1) ×
100

26
Heat in condensing = (2276.629 – 136.495) × 0.8 = 1712.12 kJ per kg of original steam. This

will be the heat waste.

Vf at 1.0 bar = 1.0432×10-3m3/kg (from the saturated water steam tables)

Work done by Pump WP = Vf (m / kg) × (P2 – P1)( bar) × 100× mass(kg )/η c ; 100 is used to
3

convert units into kN/m2.

200
Work done by Pump2 WP2 = (Vf at 1.0 bar)× (119 bar – 1.0 bar) × 100× /0.82 (0.82 isη c)
1000

200
= 1.0432×10-3× (119 – 1.0) × 100× /0.82
1000

= 3 kJ per kg of original steam.

800
Work done by Pump1 WP1 = (Vf at 0.05 bar)× (119 bar – 0.05 bar) × 100× /0.82
1000

800
= 1.0052×10-3× (119 – 0.05) × 100× /0.82
1000

= 11.67 kJ per kg of original steam

∴. Work done by two pumps Wf =3.00 + 11.67 = 14.67 kJ /kg.

As net heat supplied to the system is equal to the net work done by the system (neglecting heat

exchanges in pumps);

∴ QBoiler – QProcess heater – QCondenser = WTurbine – WPumps

QBoiler – 792.61 – 1712.12 = 1165.1 – 14.67

27
 ∴ QBoiler = 3655.16 kJ/kg

Work done by the Turbine; WT = 1456.371×0.8 = 1165.1 kJ/ per kg of original steam.

11. Summary

Heat supplied by the boiler = 3655.16 kJ/kg

Heat supplied rate by the boiler = 3655.16 × 2.5 = 9.14 MW

Heat rejected by the condenser = 1712.12 kJ per kg of original steam

Heat rejected rate by the condenser = 1712.12 × 2.5 × 80% = 3.42 MW

Work done by the turbine = 1165.1 kJ/ per kg of original steam

Power produced by the turbine = 1165.1 × 2.5 ×80% = 2.33 MW

Work done by the feed pump = 14.67 kJ /kg

Power absorbed by the feed pump = 14.67 × 73.62 = 1.08 MW

Heat supplied by the process heater = 792.61 kJ per kg of original steam

Heat supplied rate by the process heater = 792.61 × 2.5 × 20% = 396.31 kW

12. Conclusion & recommendation

28
In comparison with typical steam power plants, the energy loss has minimized in combined heat

power plants. In here, the heat loss has considerably decreased in heat supplied and the heat

rejection. CHP power plants has supplied 1% more power to the boiler than steam power plant.

Further, the heat rejection in the condense has reduced by 10.97% which is a significant decline

when compared with a normal power plant. Additionally conventional coal fire steam power

plants efficiency is approximately around 32%.with the advanced technology, ultra supercritical

plants able to operate above the critical point of water to maximize the efficiency of the system.

It can be illustrated as operating temperature and the pressure beyond the critical point of water.

Chemically in this process water and the gas coexist in equilibrium due to temperature and the

pressure, at this point there will be no difference with the liquid water and gas. According to the

research studies expresses that efficiency would be higher than the conventional coal power

steam.

In practical working condition, standard pressure of water boils at 100 °C in 1.01 bar and the

temperature of the boiling water also increases. When the pressure is increasing up to 22,120,000

Pascal at the 374 °C, water is transform directly to steam without reaching the boiling phase.

This affect is known as the critical point and above the critical pressure is called the supercritical

pressure. Ultra supercritical pressure is the temperature equal or above 593 °C and while

maintaining supercritical pressure (Mitsubishi Power, 2021).

29
 Figure 12 Advanced ultra-supercritical technology rankine cycle

Task 3 – PID based control system

13. Introduction to PID system

30
PID stands for Proportional-Integral-Derivative device. It controller is a device utilize for

industrial control purposes to maintain pressure, flow, temperature and many other variables.it

uses a loop feedback mechanism to administer the variables related to the process precisely and

steadily. In addition, 95% of the industrial automation applications are being used closed-loop

operations (Electronic project focus, 2013).

PID is designed according to the conditions and the requirements of the system parameters.

Further, it treated as the block box of the system, where it tracked the errors in the system wisely.

In general, PID based controller balance whole system such as oscillation, overshooting and

setting time. In the present context, PID controllers uses the microprocessors.

14. Advanced strategies of PID base control systems

14.1 Turbine and the generator

Entire system is dependent on the steam flow of the turbine and it has to be controlled.

Frequency should be maintained at the generator to produce power. Sensors at the output of the

generator measures the frequency and the speed to control the process quality. Steam input is to

be controlled to maintain constant frequency and speed. Steam flow is called as manipulation of

variable because of process variable can control by manipulating this quality.

Furthermore, it is known as the final control element because of it holds the control across the

valves. Important part of this system is the controller. Sensor is designed to collect data and the

variables. From the received data controller will decide how far it should open the valves.

(Electronics Hub, 2015)

31
 Figure 13 PID controller for turbine – generator

14.2 Boiler

14.2.1 Temperature controller

Thermocouple use to read the temperature in the boiler, according to the requirement and the

design features of boilers, temperature is set in the controller. For example of boiler cut off is

given as 1200 Celsius and all the fans and the air valves will off when it reaches the temperature.

When set temperature reach, valves will be activated in sequence. PID calculated value is set and

it works according to the data receive by the thermocouple as feedback. As a strategy, PID is

used in control loop feedback to read the temperature at the process (Realpars, 2021). Basically,

calculated value is set at the design temperatures min 1000°C to max 1200°C and the designed

temperature is set in the middle of it. PID controller working as a switch to the system

commanding ON / OFF by controlling and heat tracing.

32
 Figure PID Control working as an ON/OFF controller

14.2.2 Boiler water level controller

Boiler water level is set by assist of PID and level of boiler is divided into main parts such as

Boiler low water level and the extra low water level. This feature is used to increase the safety of

the system. When the water level is fail to maintain the minimum water level in the boiler

(Boiler extra low level) boiler will automatically switch off transmitter will send signal

correspondingly to stop the boiler.

14.2.3 Tuning the boiler by the identification of fuel ratio

PID is used to maximize the efficiency of the combustion by alarming the combustion

temperature and the energy of fuel. In addition to that boilers must need to be tuned get the

highest quality steam. Tuning of the boiler depends on the input fuel ratios for the combustion as

well. Therefore, disposable and bio degradable tea is used as a fuel for boiler due to its low cost

and high energy (measured in Giga joules) fuel with cashew debris per the rate of 3:1. Ratio of

the fuel is given by the PID and its giving the feedback value at the combustion process. All the

33
values are given by the PID and if output need a higher temperature without a quality steam, PID

value is indicated the input fuel value as 4:1.

Waste tea is unique and alternative thermo-chemical biomass fuel. This strategy is to overcome

the cost incurred on wooden chips used and also to find a highly inflammable fuel material and

sufficient temperature with advanced feature of PID and PLC system configurations.

15. Conclusion and recommendation

PID is one of the best and the excellent operation for automation. It can retain speed, temperature

or flow at a constant value. Boilers, generators and turbines are comprised with PID process to

maximize the efficiency, safety and reduce the cost for the operation. PID is very useful

especially in steam power plants as fuel, water levels, moisture position levels and valves are

controlled by PID loops. It can illustrated in many forms such as stand along units and PLC

programming. PID can be set by the programmable logic controller and software.

Turbine plays a significant role in steam power plant when generating electricity. Quality of

steam, temperature and pressure should be maintained throughout the system. Practically,

degradation takes place in the turbine due to inlet design condition. As a key component, turbine

and the system efficiency is getting reduced due to this condition in the power plant.

Furthermore, Ideal steam turbine with 100% efficiency is not practically to be made in the real

world working conditions because of the frictions in the parts of the steam turbines. Turbine

34
efficiency is based on the angle of guide vanes and blades on the rotor, rotor speed and the

velocity of the input steam (Turbines info, 2019). Therefore, changing blades angle according to

the requirement is needful. Hence turbine blade angle can vary by employing actuators and it can

be managed by PID controller, according to the feedback speed error.

Figure 14 PID controller block diagram

16. References

35
Balli, O. and Aras, H (2007) Energetic analyses of the combined heat and power (CHP) system .

Energy exploration & exploitation, [Online] Volume 25, pp. 39-62. Available from:

https://journals.sagepub.com/doi/pdf/10.1260/014459807781036412. [Accessed 5 July 2021].

Breeze, P. (2018) Combined heat and power. 1st ed.

Carbon trust. (2014) Introducing combine heat and power. [Online] Available from:

https://www.carbontrust.com/. [Accessed 10 June 2021].

Carver pump. (2020) 17 steps you need to know to find the best boiler feed pump. [Online]

Available from: https://www.carverpump.com/17-steps-you-need-to-know-to-find-the-best-

boiler-feed-pump/. [Accessed 9 July 2021].

Cold handling plants. (2021) Thermal power plant. [Online] Available from:

https://www.coalhandlingplants.com/thermal-power-plant/.[Accessed 15 June 2021].

Dr. Whitefoot, J. (2018) Design a steam power plant [Online] Available from:

http://www.pitt.edu/~sts106/Design_of_a_Steam_Power_Plant.pdf. [Accessed 9 July 2021].

Electronics Hub. (2015) PID controller working and tuning methods. [Online] Available from:

https://www.electronicshub.org/pid-controller-working-and-tuning-methods/. [Accessed 25 June

2021].

36
Electronic project focus. (2013) what is a PID controller: working and applications. [Online]

Available from: https://www.elprocus.com/the-working-of-a-pid-controller/. [Accessed 10 July

2021].

Engineering toolbox (2001) Tools and basics information for design, engineering and

construction of technical applications [Online] Available from:

https://www.engineeringtoolbox.com/. . [Accessed 19 July 2021].

Eurostat energy statistics (2017) Combined heat power (CHP) generation, [Online]. Available

from:

https://ec.europa.eu/eurostat/documents/38154/42195/Final_CHP_reporting_instructions_referen

ce_year_2016_onwards_30052017.pdf/f114b673-aef3-499b-bf38-f58998b40fe6. [Accessed 5

July 2021].

Mitsubishi Power. (2021) Steam power plants. [Online] Available from:

https://power.mhi.com/products/conventional. [Accessed 10 June 2021].

Power Engineering. (2008) Steam power thermodynamics. [Online] Available from:

https://www.power-eng.com/coal/steam-generation-thermodynamics-101/#gref. [Accessed 15

July 2021]

Raphael., Joseph and Gruscinshi. (2014) Thermodynamic design of a fire-tube steam boiler.

Department of biological Engineering, College of Engineering. Ohio state university

Rashidi, M., Aghagoli, A. and Ali, M. (2013) Thermodynamics analysis of a steam power plant

with double reheat and feed water heaters, pp 1-3.

37
Realpars (2021) What is a PID controller. [Online] Available from:

https://www.elprocus.com/the-working-of-a-pid-controller/. [Accessed 19 July 2021].

Red-Bang. (2020) Engineering consultancy software. [Online] Available from: https://www.red-

bag.com/shell-thickness-calculation.html. [Accessed 2 July 2021]

Turbines info. (2019) Steam turbine efficiency. [Online] Available from:

https://www.turbinesinfo.com/steam-turbine-efficiency/. [Accessed 26 July 2021].

Xie, W., Ding, J. and Wei, X. (2018) Corrosion resistance of stainless steel and pure metal in
ternary molted nitrate for thermal energy storage, [Online]. Available from:
https://www.sciencedirect.com/. [Accessed 25 July 2021].

38