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EXPERIMENTAL STEAM TURBINE TEST RIG (1KW Capacity)

Introduction Altech steam turbine is a single stage DeLaval type impulse turbine. Steam from the boiler is expanded down to the existing backpressure in a nozzle. The resulting high velocity steam jet enters one side of the bucket and exits on the other side. Due to the change in the direction of the steam jet, a change in the momentum and hence a tangential force is applied to the wheel. The tangential force due to the steam jet imparts a torque on the wheel and to the output shaft. Description of the test rig The test rig consists of a steam turbine with two nozzles. Both nozzles are connected through individual valves and piping to a common steam pipe/manifold to the boiler. Steam from the boiler is supplied to these nozzles through these pipelines and valves. A single nozzle or both the nozzles can be opened depending upon the steam flow available both nozzles for larger flow and single nozzle for smaller flow. Exhaust steam from the turbine is led directly from the bottom of the turbine casing into a water cooled condenser. To provide cooling for the turbine bearings, a water cooled jacket surrounding the bearings is provided as an integral part of the turbine casing. Cooling water for this water jacket is tapped from the condenser cooling water supply line through braided hoses and is drained away after cooling the bearings. Suitable taps are provided in the main steam line from the boiler to sample the steam and determine its quality and to measure its pressure and temperature. A main valve is used to control the flow rate from the boiler.

Altech Industries, Coimbatore 641 006

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The steam turbine output shaft drives an AC alternator 220V, 1 phase, 3000rpm. The turbine output is calculated from the alternator output and assuming an alternator efficiency. Turbine speed is measured with a proximity probe and a panel mounted rpm indicator. A panel board with digital ammeter, voltmeter, multi channel temperature indicator, and the rpm indicator is provided to make the experimental measurements. A set of electrical bulbs with individual switches are fixed in the board to act as the resistance loading and absorb the electrical power produced by the alternator.

Altech Industries, Coimbatore 641 006

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Separating and Throttling calorimeter: This consists of three parts, the separator, the throttling chamber and finally the condenser(see Fig.1 for a layout). In the separator moisture is mechanically separated from steam sample and is collected in a reservoir. In the throttling part, steam is allowed to expand through a small orifice into a chamber that is close to atmospheric pressure. In the condenser, cooling water is circulated continuously and steam from the throttling chamber is condensed. In the throttling chamber, the excess of heat liberated due to throttling serves first to evaporate any moisture present and then to superheat the steam at a lower pressure. With the aid of steam tables, from the observed pressure and temperature the percentage of moisture in the original sample can be calculated. Since the limit of the throttling calorimeter is only about 5% moisture at 10 Bar, for steam containing greater moisture, the separating calorimeter also has to be used. The water separated here is collected periodically and its quantity measured. The quantity of steam that passes into the throttling chamber is determined by measuring the condensate from the condenser or alternatively, by using Napier's rule (procedure described in sample calculations). Condenser: The condenser is a shell and tube type heat exchanger. Coolant water is supplied to the condenser by a separate pump. An orificemeter is provided to measure the coolant flow rate. Thermometers are provided at inlet and outlet to measure the temperature rise of the coolant through the condenser.

Altech Industries, Coimbatore 641 006

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OPERATING INSTRUCTIONS Preparation of Calorimeter (Refer Fig.1): 1. Drain any water present in the separating chamber using V2 and then close it fully. 2. Open fully V3, valve connecting calorimeter condenser to atmosphere. Operating procedure 1. Keep the main steam control valve and the valves of the calorimeter (as described above) fully closed initially. 2. Supply the power to the main control panel to the digital voltmeter, ammeter, tachometer and temperature indicator. 3. Start the condenser cooling water pump and circulate cooling water through the condenser. Ensure that cooling water flows freely through the turbine casing bearing cooling water jacket the braided hoses. 4. Open the steam main valves and crack open one of the steam nozzle control valves to observe the turbine start spinning. 5. Apply some initial load (switch on a few load bulbs) first. Continuously monitoring the turbine speed, open the nozzle valve such that the turbine speed reaches about 2800rpm. Note: Do not exceed 3000rpm under any circumstances as the alternator is rated only for 3000rpm and any overspeed will damage the coil windings. 6. Observe the operating parameters rpm, spring balance load, pressure, alternator output voltage, current. 7. The turbine can be loaded further by switching on more bulbs and opening the second nozzle valve also. Alternatively, both nozzles can be opened partially. If the turbine speed tends to increase beyond the permissible speed, more bulbs are to be switched on. 8. Initially some steam may come out of the condenser along with condensate. After a few minutes, it will stop and only water will flow. If steam continues to come out, it indicates that either the cooling water flow rate is not sufficient or the cooling water temperature is too hot for the condenser to be effective.

Altech Industries, Coimbatore 641 006

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The condensate is to be measured directly to determine the exact steam flow rate through the condenser and turbine.

10. Monitor the coolant water inlet and exit temperatures. Once steady state is reached, note down the temperatures and the orificemeter pressure gauge readings (to determine the flow rate) 11. Steam quality measurement: Open the needle valve V1 and outlet valve V3 and let the steam purge any air present inside the two chambers. Allow cooling water through the calorimeter condenser. Now, adjust the valve V1 such that a small quantity of steam flows through the separating calorimeter at first and then through the throttling calorimeter and finally is condensed. If steam pressure is increasing in the separating chamber, it implies that the condenser cooling is insufficient. So, increase the cooling water flow rate and/or close the valve V0 slightly. Once steady conditions are reached, note the pressure and temperature at the throttling calorimeter chamber. After a certain period of time (say 5 minutes), close V1 and measure the water collected in the separating chamber by opening valve V2 at its bottom. Also measure the water condensed in the condenser. 12. Repeat the experiment for other loads.

Caution: Never run the turbine without any load. This may cause overspeed and damage the alternator which is rated for 3000rpm.

Altech Industries, Coimbatore 641 006

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CALCULATIONS Calorimeter calculations: P1 - Pressure in separating chamber P2 and T2 - Pressure and temperature in throttling chamber m be the mass flow rate of steam sampled by the calorimeter mt be steam throttled to the throttling chamber ms be moisture separated in separating chamber h1 is the enthalpy at P1 and h2 is the enthalpy at P2 and T2 X1 is the steam quality in separating chamber (Note: Steam condition 1 is normally wet and 2 is superheated due to the throttling - hf1 and hfg1 are obtained from saturated steam tables and h2 from superheated steam tables) We have the following relations m = mt + ms .... 1 h2 = h1 =hf1 + X1hfg1 .... 2 X1 = (h2 - hf1)/hfg1 .... 3 For steam throttled through an orifice, mass flow rate = 51.4 PA lbs/hour (Napier's Rule) (where P is pressure in psia and A is orifice area in sq.in) For an orifice of d mm dia, flow rate into throttling chamber mt = 0.4 P1d2 kg/hour (P1 - kg/sq.cm) for 2.5mm dia orifice, mt = 2.5 P1 kg/hour (P1 - kg/sq.cm)

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Alternatively, mt is determined directly by measuring the condensate from the calorimeter condenser. If t is the sampling time in minutes and mc is the quantity of water collected in the separating chamber in cc, ms = (mcx60)/(tx1000) kg/hour .... 6 mw be total moisture in steam sample mw = [ms + (1-X1) mt] Steam Quality X = [1 - mw/(ms+mt)]x100 %

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Altech Industries, Coimbatore 641 006

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Calculation of Isentropic work: P0, T0, X are inlet steam pressure, temperature and quality. Corresponding enthalpy and entropy h0 and s0 are determined form steam tables. h0 = hf0 + X.hfg0 s0 = sf0 + X.sfg0 For isentropic expansion to exit pressure PE, sE = s0 and hence, exit steam quality XE is determined from the relation XE = (s0 -sfE)/sfgE .... 9 isentropic enthalpy drop is h s= const = h0-( hfE + XE.hfgE) .... 10 (hfE+XE.hfgE = hE is the exit enthalpy for isentropic expansion) Isentropic work W = M.( hs=const) kcal/hr = M.( hs=const)/642.2 HP = M. (hs=const)/860.6 KW

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Altech Industries, Coimbatore 641 006

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Calculation of Output Power: Voltmeter reading = V volts Ammeter reading = A amps Alternator Output Power = VxA/1000 kW Steam turbine output Power = Alternator output/Eff. KW where, Eff the assumed alternator efficiency = 0.7 = VxA/(1000x0.7) KW Calculation of isentropic efficiency of turbine: Isentropic efficiency Calculation of condenser effectiveness: Coolant water flow rate The orificemeter has been calibrated Orificemeter pressure gauge reading 1= OP1 kg/sq.cm Orificemeter pressure gauge reading 2= OP2 kg/sq.cm Difference in pressure = (OP1-OP2) kg/sq.cm OP = 10(OP1-OP2) m of water Coolant water flow rate Q = 0.00204 OP m3/sec Coolant water mass flow rate MC = 60,000xQ kg/min Coolant water inlet temperature = TC1 deg C Coolant water exit temperature = TC2 deg C Heat removed by coolant water H = MCx(TC1-TC2) Kcal/min Heat exchanger effectiveness of condenser = (TC2-TC1)/(TE-TC1) = Turbine Power/Isentropic work .... 14

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Altech Industries, Coimbatore 641 006