EXPERIMENTAL STEAM POWER PLANT
(STEAM TURBINE TEST RIG -1.0KW CAPACITY)

The test rig consists of suitable equipment for performing experiments to measure the steam turbine efficiency, steam quality, and flow rate and condenser effectiveness. The turbine is suited for operation with a 300kg/hour, 10bar saturated steam supply.

  1. Steam turbine: The turbine is a single stage impulse turbine with two stainless steel nozzles. The blades are also made of stainless steel to ensure high reliability. The turbine is of vertical split case design to provide easy serviceability.
  2. Separating and throttling calorimeter: Consists of well insulated separating and throttling chambers made of MS pipes with suitable piping, valves, thermometer and pressure gauges. A condenser is included to condense the sampled steam and measure its actual mass.
  3. Condenser assembly: Consists of a shell and tube type condenser and a 3.0HP monoblock pump set (440Volts, 3 phase, 50Hz) to circulate the cooling water. An orificemeter with pressure gauges and thermometers are fixed in the cooling water pipeline to measure the flow rate and temperature rise. Suitable piping and valves are provided to connect the turbine exhaust to the condenser and atmosphere. The steam flow rate is determined by measuring the condensate.
  4. Other accessories: Suitable 25mm piping (not exceeding 3.0m) and control valve to connect the turbine with the calorimeter and to the boiler. Necessary pressure gauge is provided to measure turbine steam inlet conditions. A digital tachometer is provided to monitor the turbine speed.
  5. Loading Device: The steam turbine is coupled to a 3000 rpm, 1KW, 220 Volts, generator on a strong base plate. A panel board consisting of ammeter, voltmeter and a row of bulbs is provided.
With a steam flow rate of 300 kg/hour 10 kg/sq.cm saturated conditions, the turbine will produce
Boiler Details:
Steam Boiler of capacity 300 kg/hr., (made by Elite Boilers, Pune or equivalent) with working pressure of 15 kg/cm2 model “STEAMPACK- 300” (f & a 30° C) LDO/HSD fired. As per
ERECTION OF 300Kg/hour Boiler and Supply of accessories.
  1. Suitable Water Tank (sintex tank)–1000 ltrs
  2. Suitable Fuel Tank (MS tank) - 100 ltrs
  3. Suitable Chimney – 1 No (4 Meters Long)
  4. Suitable Water Softener – 1 No.
  5. Water Line from Softener to Tank, water tank to boiler
  6. Fuel Line from Fuel Tank to Burner and back
  7. Steam Line to Steam Turbine
  8. Condensate Drain Line
  9. Softener and water Pump
Other accessories required for the steam turbine test rig:
1. A suitable sump tank of capacity at least 10,000 liters is required for the condenser cooling
water supply. Existing lab sump if it is of sufficient capacity can be used for this purpose.
Necessary GI piping to connect the condenser pump to the sump and the condenser and return
trenches are to be provided by the college.
2. Necessary foundation for the turbine, condenser, and boiler.
Optional: Cost of cooling tower (instead of the sump tank) – Rs.55,000
(Rs. fifty five thousand only)
BOILER SPECIFICATIONS:
1) STEAM BOILER
1.1. TYPE : 3 Pass, Forced
1.2. Capacity F & A 100 deg.C : 300Kgs/hr
1.3. Maximum Working Pressure : 12.5 kg/cm2
1.4. Fuel : L.D.O/H.S.D
1.5. Fuel Consumption : 24 kgs/hr
1.6. Electrical Load : 2.5HP (415V, 3Ph)
Feed Pump Motor, Blower Motor and oil Pump
2) STEAM BOILER CONSTRUCTION
It is designed on forced circulation Heat Exchange principle fabricated out of high
temperature resistant seamless tubes, once through spiral coil nest is arranged to give 3 clear
passes of flue gases forms combustion zone. It ensures for optimum rate of heat release and
maximum heat transfer and low stack temperature. It is ultimately placed in double shell on
study steel frame for quick and easy installation.
3) SHELL AND COIL ASSEMBLY
Inner & Outer shell, Aluminium foil in between two shells to act as heat retarder, Nest
of once through spiral coil to give 3 clear pass and Top & Bottom refractory block.
4) BURNER, BLOWER & OIL PUMP ASSEMBLY
Centrifugal Blower coupled with motor, vertically downward position placed burner
complete with nozzle, nozzle holder, diffuser plate, ignition electrodes, photocell, sight glass
& solenoid valve. Gear oil pump coupled with motor, Oil filter and Pressure gauge.
5) FEED WATER ASSEMBLY
Positive displacement type piston pump coupled with motor, pulley, V-Belt, Pump
safety valve & Non-return Valve.
6) MOUNTINGS, FITTINGS & INSTRUMENTATION
· Main steam stop valve
· Steam Auxiliary valve
· Safety Valve
· Blow down valve
· Steam trap
· Non return valve
· Strainer
· Oil, water & steam pressure gauge with isolating valves
· Temperature Indicator cum controller
· Flue gas controller
· Steam pressure switch
· Audio Alarm
· Oil filer
· Ignition Transformer
7) ELECTRICAL PANEL
It is mounted on the front side of the boiler at a convenient height, is prewired and
complete with starters, push buttons indicating lamps all duly labeled, fuses, O/L relays,
contactors and sequence controller.
8) ACCESSORIES

  •  Air blower
  • Water pump (Feed Water)
  • Fuel pump
  • Pressure control : Through HP/LP cutout, Solenoids, pressure switches

9) INSULATON
The steam line connecting the Turbine will be well insulated.
10) FINISH
Red oxide primer and one coat of enamel paint
11) BASE
Strong Channel Base, Houses all parts of boiler
12) SOFTENER
Water softener suitable for softening raw water up to 200 PPM of CaCO3 complete with
inter connection piping, valves, Filter, Resin, Pressure Gauge, Ejector & brine tank
13) Fuel Tank: 100 liter capacity MS fuel tank
14) Feed water tank: 1000 liter capacity sintex tank
15) Piping: Water line, fuel line, steam line (blow down line and line to connect boiler with
turbine, etc)
16) Thermal lagging for steam pipes
17) Flue gas arrangement - Chimney 4 m height chimney

 

steam turbine lab setup from Jagajeet Marketing
 steam turbine lab in actual operation from Jagajeet Marketing