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International Engineering Research Journal (IERJ) Volume 1 Issue 3 Page 89-93, 2015, ISSN 2395-1621
Energy Generation Solution Using
Steam Turbine
ISSN 2395-1621
Mayuresh V. Savargaonkar #1, Pratik S. Sakpal #2, Atharva D. Sathe #3,
Prof. Aniruddh Bulbule #4
1
[email protected]
2
[email protected]
3
[email protected]
4
[email protected]
University Of Pune (UG), Department of Mechanical Engineering, P.V.P.I.T.
#1234
#5
Assistant Professor, Department of Mechanical Engineering, P.V.P.I.T,
Pune, Maharashtra, India.
ABSTRACT
ARTICLE INFO
The increase in the demand for electricity in commercial areas is going up by the day.
The recent few years have shown a lot of growth in the commercial –express feeder
consumers. Consequently, the need for energy is going up. Thus to satiate the demand,
the utility company needs to produce more electricity, hence increasing the economics.
To cope up with the rising cost and escalating demand of electricity we have come up
with an indigenous solution. This solution aims at fulfilling electricity demand of the
stated consumers by domestically generating electricity. Along with satisfying the
demand for electricity of the consumer, a solution for exporting excessively generated
electricity to the power grid has also been developed. The power thus generated is at a
lower cost as compared to the commercial utility company tariff. This is accomplished
with the use of micro steam turbine, its accessories and boiler. Conclusively providing a
self-sufficient and profit path to the stated consumer .
Article History
Received : 5th April, 2015
Received in revised form :
6th April, 2015
Accepted : 12th April, 2015
Published online :
13th April 2015
Keywords— commercial-express feeder, economics, indigenous solution, micro steam
turbine, self-sufficient.
I.
INTRODUCTION
We plan on providing a solution that is economically
and technically viable, which will help make the system
self-sufficient and export the surplus electrical energy
developed. The system when and if developed further will
be a first of its kind that provides HVAC and Electrical
energy alternatively.
The above figure shows a concise idea of the actual setup of
the system that will be implemented The turbine and the
chiller unit (if required) are connected in parallel
configuration. A butterfly valve is connected to the boiler
output line for controlling the flow. The boiler is completely
automated state of the art unit. The steam turbine also
adheres to this capability making the system a remote
operated one, reducing human labour [8]..
II. LITERATURE SURVEY & THEORY
Fig 1
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a Selecting the right steam turbine and the power generation
cycle need some basic parameters such as output power and
speed of the turbine [1]. In an Extraction Steam Turbine,
steam for the thermal load is obtained by extraction from
one or more intermediate stages at the appropriate pressure
and temperature. The remaining steam is exhausted to the
pressure of the condenser, which can be as low as 0.05 bar
with a corresponding condensing temperature of about
33°C [7]. In order to assure optimal electricity production
and the best conditions of efficiency and security, a thermal
power plant (TPP) is brought to choose an effective and
robust choice of facilities [4].
Page 1
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International Engineering Research Journal (IERJ) Volume 1 Issue 3 Page 89-93, 2015, ISSN 2395-1621
The project as a whole is divided in three major parts
namely- Boiler, Turbine and Electricity Tariff.
A. Boiler
(Thermax CB 20)
Here, the „Thermax Combloc-20‟ is considered as a
definitive boiler for steam generation. Combloc, the steam
boiler offers customers who are forced to choose between a
particular boiler design and a solid fuel option, a way out.
This versatile fully packaged boiler launched by Thermax
Heating SBU combines the fuel flexibility of a hybrid boiler
and the inherent ruggedness and compactness of an integral
furnace boiler.
Combloc provides customers various options for fuel
combustion - imported coal, Indian coal, pet coke, wood
chips, rice husk, pellets, wood logs, dry biomass, etc.
Without making expensive and time consuming boiler
modifications industries can switch between these fuels,
depending on their cost and availability. Combloc's compact
design helps clients avoid the hassles of site civil work,
longer installation time and higher investments. In a small
foot print, the boiler offers one of the highest thermal
efficiencies. This boiler is available in the range of 1.5 to 6
TPH.
Technical Specifications: Boiler type - Horizontal Multi-tubular Shell Type
Smoke Tube with Water Wall Furnace.
 Max steam output - 2000 kg/hr
 Design Pressure - 10.54/17.5 kg/sq. cm
 Temperature - 185/208 °C
 Dryness - 98%
 Steam / Fuel ratio- 4.55
 Efficiency- 85.5% (for wood)
 Fuel type- wood chips ( 7 to 20 mm)
 Fuel moisture content- 15% to 25%
 Ash content - ≤ 8%
 Net Calorific Value of „Wood Chips‟ - 2950 kcal/kg
B. Micro Steam Turbine
(CTMI- PS902C)
The steam turbine considered is manufactured by „Chola
Turbo Machinery International Pvt ltd‟. The condensing
turbines take high pressure steam, expand it in turbine
nozzles and blades, and exhaust it to a condenser at lower
than atmospheric pressure. It is principally used when power
must be generated with minimum steam consumption [3].
The condensing turbine may also have bleed points
(uncontrolled extractions) to satisfy steam demands at
medium intermediate pressures.
SALIENT FEATURES OF PS 902C
 Condensing Single Stage Steam Turbine
 Woodward TG-13 oil relay governor
 Positive over speed trip
 Antifriction ball bearings throttle valve
 Ball thrust with minimum 48,000 L10 rating
 Horizontally split case with metal to metal joint for
ease of maintenance
 Multiple carbon ring gland seals with stainless steel
spacers
 Foot mounted support system
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









Large bearing housing with constant level oilers and
integral cooling water jackets
Wheel with stainless steel blades
Large efficient monel nozzles
Balanced, cage guided throttle valve
Stainless steel turbine shaft
Simplicity of design assures reliability and low
maintenance
Positive seating tight shutoff valve
Stainless steel strainer
Sentinel warning valve
Optional exhaust location
Technical Specifications: Maximum Inlet Gauge Pressure (PSI/Bar)- 640/45
 Maximum Inlet Temperature (°F/°C)- 840/450
 Maximum Exhaust Gauge Pressure (PSI/Bar)150/10
 Speed Range (RPM)- 1000-5000
 Overall Efficiency - 59.29%
 Bearing Type- Ball and/or sleeve
 Wheel Pitch Diameter (IN/mm)- 17.7450
 Approx. Maximum Rating (HP/KW)- 405/300
 Approx. Shipping Weight (LB/kg)- 1100/500
 API 611 compliant
C. Tariff
The utility company for providing electricity to the
consumers is MSEDCL. The following category is
considered for further calculations.
HT II (A): EXPRESS FEEDERS
Applicability Applicable for use of electricity / power supply at High
Tension on Express Feeders in all non-residential, nonindustrial premises and/or commercial premises for
commercial consumption meant for operating various
appliances used for purposes such as lighting, heating,
cooling, cooking, washing/cleaning, entertainment/leisure,
pumping in following (but not limited to) places [9]:
 Non-Residential, Commercial and Business premises,
including Shopping Malls / Show Rooms
 Film Studios, Cinemas and Theatres including
Multiplexes, Hospitality, Leisure, Meeting / Town
Halls and Places of Recreation & Public
Entertainment
 Marriage Halls, Hotels / Restaurants, Guest Houses,
Internet / Cyber Cafes, Mobile Towers, Microwave
Towers,
Satellite
Antennas
used
for
telecommunication activity, Telephone Booths, Fax /
Xerox Shops
 Automobile, Any Other Type of Workshops, Petrol
Pumps & Service Stations including Garages, Tyre
Re-treading / Vulcanizing units
 Sports Club, Health Club, Gymnasium, Swimming
Pool
Page 2
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International Engineering Research Journal (IERJ) Volume 1 Issue 3 Page 89-93, 2015, ISSN 2395-1621
TABLE I
COMMERCIAL EXPRESS FEEDERS TARIFF CHART
Time
Slot
Tariff
(Rs./
KWh)
A-Zone
22000600
Hrs
B-Zone
06000900
12001800
Hrs
C-Zone
09001200
Hrs
D-Zone
18002200
Hrs
.
12.82
Discounte
d/penalise
d tariff
(Rs/KWh
)
10.32
Demand Cost
(Rs/KVA/mont
h)
9
4658
1030
4.52
10
4347
974
4.46
To calculate the actual electrical consumption of the
boiler room it is necessary to carry out a brief survey of
equipment‟s used in the room .The following components
are considered as major electricity consuming equipment‟s
in the boiler.
190
TABLE III
BOILER COMPONENT RATINGS
12.82
12.82
190
Sr.
No
1
12.82
13.62
190
12.82
13.92
190
2
3
4
5
6
7
8
9
10
III. ACTUAL WORK
A. Field Study
Initially, the boiler was under observation and periodic
readings were taken and noted down. The study of boiler
performance was carried out for a period of five months.
The observation(s) included monitoring electrical energy
consumption at full load for varying atmospheric conditions.
It also comprised of steam to fuel ratio monitoring and
steam flow at various conditions. The average per day
operation is 8 hrs (0900hrs to 1700hrs). The given readings
are fortnightly averages.
The readings are tabulated as below,
TABLE III
PERIODIC BOILER READINGS
Sr.
no
1
2
3
4
5
6
7
8
Boiler Observations
Steam
Fuel
Consumption
Consumptio
(kg/day)
n (kg/day)
(FOR JULY ‟14)
8547
1882
8193
1817
(FOR AUGUST)
7320
1637
7998
1797
(FOR
SEPTEMBER)
7176
1584
6717
1348
(FOR OCTOBER)
6563
1464
6317
1406
(FOR DECEMBER)
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Steam/fue
l ratio
4.54
4.51
4.47
4.45
4.53
4.98
4.48
4.49
11
12
13
14
15
Boiler Components Ratings
Component
Wattage Voltage/Current
Name
(kw)
(volt/amp)
Feed water pump
15
415/27
x2
F.D. fan
2.2
415/2.16
I.D. fan
18.5
415/33
Heat recov. Unit
0.37
415/1.3
RAV TMC filter
0.37
415/1.36
Fuel feeder x2
1.1
220/4.76
Grate hyd. Power
3.7
415/7
pck
Grate air cooling
2.8
415/0.85
fan
Moving floor hyd. 18.5
415/33
Power pack
Moving floor air
2.8
415/0.85
cooling fan
Submerged ash
2.2
240/8.66
conveyor
Fuel conveyor
1.5
415/3.5
Bucket elevator
1.5
415/3.5
Bag filter motor
0.37
415/1.05
x2
RAV spark
0.37
415/1.3
arrestor
Using the above data and observing the energy
consumption of the boiler unit the electrical energy
consumption of the boiler was pin pointed at an average of
190kw for 8 hours at full load, using the energy meter. Here,
the concept full load corresponds to boiler output of
2000kg/hr at a pressure of 17.5bar.
B. Survey
a) Details
City Pride Multiplex (Kothrud, Pune.) is a four screen
movie theatre with a restaurant and stores. The purpose of
this survey is to get an overview of the power consumption
and study electrical tariff of this building. Air conditioning
system is a major power consumer in this building.
The average footfalls of the multiplex per week are
considered to be 38,000 persons/week. The HVAC system
currently in operation has a capacity of 9000 CFM (AHU
capacity). The chillers installed are of capacity 95 TR
(Standby) and 110 TR respectively. The complex includes 8
shops and 7 stalls.
b) Tariff skeleton
TABLE IV
DISTRIBUTION OF POWER CONSUMPTION
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TOD
International Engineering Research Journal (IERJ) Volume 1 Issue 3 Page 89-93, 2015, ISSN 2395-1621
Consu
mption
(KWh)
20740
Deman
d
(KVA)
Rate
(Rs./
KWh)
Cost
(Rs.)
A-Zone
82.5
10.30
213622
2200-0600
Hrs
B-Zone
60105
110.6
12.82
770546.1
0600-0900
1200-1800
Hrs
C-Zone
22122
111
13.62
301301.6
0900-1200
4
Hrs
D-Zone
35769
87
13.92
497904.4
1800-2200
8
Hrs
The above table is considered on the basis of mean power
consumption of three months, based on proof given by
MSEDCL (Utility Company) and values in Table I
c) Calculations for survey [5]
 The Total cost for 4-zones
= 22,70,606.2/(Including Service tax (7%), Electricity duty (17%)
and Demand Charge for 200 KVA at the rate of
190 Rs/KVA/Month)
 Considering a gross subsidy of 26.7%
 Total amount
= 16,64,354 Rs/Month
 Average Unit Consumption For 3 months
≈ 138268 KWh
 Average Unit Cost = 1664354/138268
= 12.03 Rs/Unit
IV. CALCULATIONS
Considering the above details related to the survey and
the tariff calculations [2], [6], [3] the following power
generation solution is obtained.
a. Boiler Running Cost
1. For cost of fuel
 Average unit cost = 12.03 Rs/KWh
 Fuel cost
= 4.2Rs/kg
 S/f ratio
= 4.54 (Ref. „Table II‟)
 fuel consumption
= 16000/4.54
= 3524.22 kg/8hrs
= 440.52 kg/hr
 fuel cost
= 440.52*4.2
≈1850.220 Rs/hr
2. For cost of electricity
 Consumption
= 190kw/8hrs
 Unit Costs
= 23.75*12.03
= 285.71Rs/hr
 Demand and unit cost
≈ 300 Rs/hr
3. Fuel cost + Cost of electricity
= 1850.22+300
= 2150.22 Rs/hr
b. Surplus Power Generation
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The power generation is 180kw from the system.
Subsequent calculations are done to find out the surplus
generation using tariff in “Table I”.
Break Even Points for power generation „D-Zone‟ B.E.P
= 2150.22 / 13.92
= 154.46 Kw/hr
Surplus for „D-Zone‟
= 180 - 154.46
= 25.54 Kw/hr
 „C-Zone‟ B.E.P
= 2150.22 / 13.62
= 157.87 Kw/hr
Surplus for „C-Zone‟
= 180 - 157.87
= 22.13 Kw/hr
 „B-Zone‟ B.E.P
= 2150.22 / 12.82
= 167.72 Kw/hr
Surplus for „B-Zone‟
= 180 - 167.72
= 12.28 Kw/hr
 „A-Zone‟ B.E.P
= 2150.22 / 10.32
= 208.35 Kw/hr
Surplus for „A-Zone‟
= 180 - 208.35
= (-28.35) Kw/hr
As the calculations show, profitable solution is only
viable in zones ‘D’, ‘C’, ‘B’. Hence we consider them
V. RECOVERY AND PROFITABILITY
aPayback Period‟ is defined as the length of time
required for an investment to recover its initial outlay in
terms of profits or savings. Now, from above calculations
we observe that there is a surplus electrical power
generation in the three specified zones, from the system.
i.
„D-Zone‟ is of four hours viz. 1800hrs to 2200hrs
respectively.
 Excess power generated
=102.16kw/4hrs
 Cost Recovered
≈1229Rs/4hrs
ii.
„C-Zone‟ is of three hours viz. 0900hrs to 1200hrs
respectively.
 Excess power generated
=66.39kw/3hrs
 Cost Recovered
≈799Rs/3hrs
iii.
„B-Zone‟ is of nine hours viz. 0600hrs to 0900hrs
and 1200hrs to 1800hrs respectively.
 Excess power generated
=110.52kw/9hrs
 Cost Recovered
≈1330Rs/9hrs
Hence, the total recovery after running in above three
zones i.e. 16hrs per day
≈ 3358 Rs/day
Net total recovery for 1 year (30*12 days)
= 3358*30*12
≈ 12,08,880Rs/annum
VI. EQUATIONS [6]






Average Unit Cost (Rs)
= (total amount/ Total consumption)
Fuel consumption (kg/hr)
= {total steam generated in 8 hrs/(s/f ratio)}
Demand and unit costs (Rs/hr)
= (demand per hour * rate per unit)
Fuel cost (kg/Rs)
= (fuel consumption * rate per kg of fuel)
Zone wise generation (KWh)
= (total running cost per hr / unit rate per zone)
Breakeven point of power generation (KWh)
= (power generated per hr - demand per hr)
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
International Engineering Research Journal (IERJ) Volume 1 Issue 3 Page 89-93, 2015, ISSN 2395-1621
Surplus power
=180-(Power required for B.E.P)
Cost recovered
={surplus power* cost per kwh(12.03)}
VII. CONCLUSION
After analysing the calculations and observations we are
able to deduce for a fact that the solution obtained is
commercially viable and can be put to effect. As the rates of
electricity are going up in the newest revision, the solution
becomes more attractive. The costs of electricity considered
in this paper are current and not the revised ones. This
situation of rising rates of electricity can be used as a
profitable business idea by selling the excess to the grid or
any potential consumer. As there is no standardization in the
manufacturing of steam turbines, the turbine can further be
developed to harness the full potential of the system.
Acknowledgement
The Authors of this paper are thankful to „Thermax India
Pvt. Ltd, Pune‟ and „Chola Turbo Machinery Pvt. Ltd‟.
REFRENCES
[1 ] Michael A. Cerce, Vinod P. Patel, “Selecting Steam
Turbine for Pump Drives”
[2] ASME “Theoretical Steam Rate Tables”, 1969, New
York.
[3] S. M Yahya, “Turbines, Compressors and Fans”.
„Chapter 1, 2, 4‟.
[4] M.N Lakhoua, “Casual analysis and calculation of steam
turbine power plant”, IJPS vol.7 (39), pp5493-5497.
[5] MSEDCL, MERC, “Case 121 of 2014”, Tariff Proposal .
[6] Steam and Combustion, “Common Boiler Formulae
2006”.
[7] Bureau of Energy Efficiency, “Cogeneration Handbook,
1982”.
[8] Dimeo R and Lee K.Y. “Boiler-turbine control system
design using a genetic algorithm”, IEEE, 6th august 1992,
volume 10, issue 4.
[9] MSEDCL, “Approved tariff schedule” (With effect from)
1st august, 2012, (Annexure “A”) .
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