PERFORMANCE, HEAT BALANCE,
AND EFFICIENCY TEST OF A SIMPLE
STEAM TURBINE POWER PLANT
ME143L
MECHANICAL ENGINEERING 3
(LAB)
WEEKS 1-2
2T/2023-2024
Prepared by:
Engr. Manuel B. Rustria
December 15, 2023
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 to familiarize with the equipment arrangement in steam power
plant.
 to conduct calculations on steam power plant heat and mass
balances.
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INSTRUCTION MANUAL TH136 COMPACT
STEAM TURBINE POWER PLANT
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 The unit is designed to simulate modern steam power plant.
 Main components consist of a feed water system, a small
industrial boiler, a steam turbine, a generator and lamp load, a
condenser with a condensate tank and a pump, and a cooling
tower.
 Accessories such as fuel tank, fuel flow meter, feed water meter,
and a stack are also included. Instruments are provided for
measurement of pressures, temperatures, output voltage and
currents.
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Typical Experiments
 Measurement of feed water and fuel flow rates.
 Boiler efficiency, turbine generator efficiency, and overall power
plant efficiency.
 Condenser heat transfer efficiency.
 Cooling tower efficiency.
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Technical Data
The boiler set consists of:
1. Boiler Unit: TH101A
2. Steam Turbine: TH 101-011 Steam Turbine
3. Generator and Lamp Load
4. Condenser: TH 102-013 Condenser
5. Cooling Tower: TH 102-014 Cooling Tower
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1. Boiler Unit: TH101A
a. Type
:
Vertical, water tube.
b. Rated heat output
: 125 kW (107,000 kcal/h)
c. Equivalent evaporation
: Approx 200 kg/h steam at 0
kg/cm2 gauge.
d. Maximum working pressure : 10 kg/cm2 gauge.
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e. Measuring instruments
: A pressure gauge for steam
outlet.
: Temperature sensors and an
indicator with a selector
switch for feed water, boiler
outlet, and exhaust stack.
f. Safety devices
: A safety valve.
: A level gauge and switch at
boiler.
: A safety alarm.
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g. Boiler accessories
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: Steam separator
: Steam pressure regulator to
maintain constant steam outlet
pressure.
: Feed water pump.
: Stack, 6 m stainless steel with
elbows.
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h. Burner
- Type
- Control
- Fuel
: Forced draft, pressure atomized.
: On-Off.
: Diesel or kerosene. (LPG is
available as an option.)
i. Fuel system:
- A fuel tank
- A fuel meter
- An oil strainer
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: 60 l.
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j. Feed water system
- A resin filter for public water
- A soft water tank
: 150 l. stainless steel.
- A water meter for steam rate monitoring
- A temperature gauge
k. Power supply
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: 220V. 3Ph. 50Hz. Other power
supply is available on
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2. Steam Turbine: TH 101-011 Steam Turbine
a. Description
 This is an educational unit for studying of a steam turbine
characteristics.
 The equipment includes a step down hydraulic
dynamometer and measuring instruments.
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b. Technical data
- Type
: Single stage, twin nozzle impulse
turbine.
- Construction
: Vacuum cast in cornel wheel.
: Stainless steel casing shaft and
nozzle.
: Ceramics and steel bearings.
- Maximum output
: Over 1.0 kW.
- Maximum speed
: Approx 33,000 rpm.
- Exhaust pressure
: Atmospheric
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b. Measuring instruments
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: 2 speed sensors and an indicator
with a selector switch for
turbine and dynamometer.
: A torque sensor and an indicator
for dynamometer.
: Temperature sensor for steam
outlet.
: Pressure gauge for steam inlet
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3. Generator and Lamp Load
a. Type
: AC generator, 2 kVA.
b. Voltage
: 220v. , 1 ph 50 Hz at 1500 rpm
c. Load lamps
: 5 x 100 + 5 x 50 W.
d. Measuring instruments : A generator speed sensor and an
indicator.
: A volt meter and an ammeter. 1
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4. Condenser: TH 102-013 Condenser
a. Description
 The unit allows a study of heat transfer in a heat exchanger
as well as recover condensate for reuse.
 The unit consists of a counter flow steam tube heat
exchanger and instruments for measurement of
temperatures, cooling water flow rate
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b. Technical data
- Type
: Steam tube
- Heat transfer area
: 7,500 cm2
- Accessories and instruments :
:
:
:
A cooling water pump
0.75 kW.
A water meter.
A condensate tank.
: 150 l. stainless steel.
: A strainer, a safety valve.
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: Temperature sensors for
cooling water inlet and
outlet.
: A pressure gauge, a
strainer, and a safety
valve.
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2. Cooling Tower: TH 102-014 Cooling Tower
a. Description
 This is an educational unit for recovering of condenser
cooling water as well as studying of cooling tower
efficiency.
 A cooling tower is recommended to recycle cooling water in
the case TH101-013 condenser is used. The unit consists of
a cooling tower unit, a storage tank, a circulating pump and
temperature gauges.
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b. Technical data
- Storage tank.
: 300 l.
- Cooling tower capacity : Up to 25 RT.
- Induction fan.
: 0.37 kW.
- Circulating pump.
: 1.1 kW.
- Wet bulb temperature sensor.
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Optional Equipment
1. TH 101-010E Super Heater, Electric.
2. TH 101-012 Reciprocating Steam Engine.
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Optional Equipment
1. TH 101-010E Super Heater, Electric
a. Description
 The unit provides super heated steam for other use such as
a steam turbine.
 Saturated steam from the boiler is further heated in the
super heater by electric heaters.
 Instruments are provided for measurement of
temperatures and pressure.
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b. Typical experiment
 Super heater efficiency
 Effect of super heated steam on prime mover efficiency.
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c. Technical data
 Capacity
- Steam rate
: Up to 150 kg/hr
- Temperature
: Up to 270 °C from 10 kg/cm2
saturated steam.
 Measuring instruments
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: A temperature sensor for
steam outlet.
: A pressure gauge for steam
outlet.
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2. TH 101-012 Reciprocating Steam Engine
a. Description
 This is an educational unit for study of steam engine
characteristics.
 The unit includes step-up a dynamometer and measuring
instruments.
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b. Typical experiment
 Steam engine input, output, and efficiency
 Power output Vs speed
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c. Technical data
 Steam engine
: Bore x stroke = 50 x 50 mm.
 Maximum power
: 0.37 kW. for 5 kg/cm2 saturated
steam at 40 kg/hr.
 Maximums speed
: Approx. 800 rpm
 Exhaust pressure
: Atmospheric.
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d. Measuring instruments : 2 speed sensors and an indicator
with a selector switch for turbine
and dynamometer.
: A torque sensor and an indicator
for dynamometer.
: Temperature sensors and an
indicator with a selector with for
steam inlet and outlet.
: Pressure gauge for steam inlet.
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e. TH 101-021 Sand filter for water with suspension materials.
f. TH 101-022 Carbon filter for water with odour or rust.
g. TH 101-031 Pressure sensor.
h. TH 101-032 Fuel flow totalizer.
i. TH 101-033 Feed water flow totalizer.
j. TH 101-035 Cooling water flow sensor.
k. TH 101-052 Computer Interface
This includes sensors, analog to digital signal converter, and software for
data display and analysis by computer (separately supplied).
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Steam turbine power plant
 A boiler may be used in power generation industry where the
steam is used on a prime mover such as a steam turbine for
power generation.
 The boiler may also used in other industries where the steam is
used in a process such as a heat exchanger.
 The exhausted steam can be then exhausted to atmosphere or
recovered by using a condenser and a cooling tower.
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Steam turbine power plant
 For a training boiler set, at least a resin filter is required for the
feed water to the boiler.
 Steam from the boiler can be used in many ways depending on
optional equipment:
a. A super heater or
b. A prime mover, or
c. A process or a condenser for heat exchange
 Diagrams for a steam power plant with optional accessories are
as per below.
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Figure 2-1 Training
Boiler System
Diagram
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Boiler Principles
 Steam
 Changing the property of water from a liquid state into a
vapor state when boiling creates steam.
 The steam created by the boiling of water in an open space
will have a temperature of 100 °C (212 °F).
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Boiler Principles
 Steam
 But if the boiling is done in an enclosed space, the created
vapor has no way to escape and it will compress itself causing
pressurization.
 The temperature will increase likewise and become higher
than the original temperature. The steam temperature can
be found from the following Table 1:
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Boiler Principles
 Steam
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Boiler Principles
 Dry or superheated steam
 Dry or superheated steam is the steam without any water
mixture by further heating of saturated steam resulting in the
transformation of water mixture completely into vapor.
 This vapor is called dry or cold vapor that has higher
temperature than before, but the pressure remains the same.
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Boiler Principles
 Steam rate
 Steam rate is a capacity of boiler to produce steam in one (1)
hour when the gauge pressure reading is zero (0) or when the
steam has a temperature of 100 OC (212 °F).
 One-ton boiler is the boiler with evaporation capacity to
produce steam of one ton per hour.
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Boiler Principles
 Boiler capacity
a. The boiler output is measured by the heat absorbed by water
and steam, therefore:
(2.1)
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Boiler Principles
 Boiler capacity
where 𝑚𝑠= mass of steam delivered by boiler (or superheater,
if used), kg/s
ℎ
= enthalpy of steam at observed pressure and
quality or temperature, kJ/kg
ℎ𝑓 = enthalpy of the liquid of feed water at observed
condition as the water reaches the boiler, kJ/kg
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Boiler Principles
 Boiler capacity
b. Boiler horsepower is the measurement capacity unit of the
boiler.
c. A one horsepower boiler is the boiler with evaporation
capacity to produce 34.5 pounds of steam per hour.
d. The boiler horsepower is:
(2.2)
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Boiler Principles
 Boiler capacity
where 𝑚𝑠, ℎ and ℎ𝑓 are previously defined, the unit of 𝑚𝑠 is
lb/hr and the enthalpy is Btu/lb
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Boiler Principles
 Main boiler components
 Although boilers of all
types may have different
structures of
construction, they consist
mainly of three sections
namely furnace, water
space and steam space as
shown in Fig. 2-2.
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Figure 2-2 Three main boiler component
sections
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Boiler Principles
 Main boiler components
a. Furnace:
 A furnace is an area in which combustion of fuel takes
place.
 It is a space which has the highest temperature within
the boiler.
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Boiler Principles
 Main boiler components
b. Water space:
 A water space is a water storage area in the boiler where
the evaporation into stream takes place.
 The water level in the boiler should change more than
two centimeters particularly for a fired-tube boiler.
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Boiler Principles
 Main boiler components
b. Water space:
 In the case of two boilers of the same capacity, the
boiler which has less water space will be able to produce
steam faster, therefore it is suitable for use in work
requiring steam in short interval and not suitable for 24
hour application.
 This is due to less volume of storage water and it is likely
to dry out.
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Boiler Principles
 Main boiler components
c. Steam space:
 Steam space is a steam storage area/section normally
located above the water space section in the boiler.
Steam produced by the boiler will be stored in this
space.
 A boiler generally produces steam at all time but is
steam demand is not constant.
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Boiler Principles
 Main boiler components
c. Steam space:
 Therefore when the rate of steam usage is less than the
production rate of the boiler, the remaining steam will
be kept in the steam storage section of the boiler.
 The size of this storage section will be more or less
depending upon the design of the boiler.
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Boiler Principles
 Main boiler components
c. Steam space:
 However, for the boiler designed as manual control on
the water level inside the boiler, the boiler operator will
carry a very important function of water level control by
regulating the inlet water going into the boiler.
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Boiler Principles
 Main boiler components
c. Steam space:
 Boilers can be classified as the fire-tube or water-tube
boiler.
 Fire-tube boiler is normally used in industrial
applications while the water-tube boiler is for power
plants.
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Boiler Principles
 Water-tube boiler
 In water-tube boiler, the fuel is ignited and the combustion
takes place in the furnace.
 The hot flue gas flows through the water wall, consisting of
many water tubes.
 The hot water is then flows to the upper drum where it is
evaporated.
 The steam generated in the upper drum can be delivered to
steam utilizing devices or to the super heater.
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Boiler Principles
 Horizontal fire-tube boiler
 In this type of boiler, the fuel is ignited and the combustion
takes place in the combustion chamber.
 The hot flue gas flows through the big fired tube and /or
small fired tube(s).
 The flow may be either 1, 2, 3 or 4 passes depending on the
design as shown in Fig. 2-3 below
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Boiler Principles
 Horizontal fire-tube boiler
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Figure 2-3 Flow of hot flue gas in the fired tubes
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Boiler Principles
 Horizontal fire-tube boiler
 Today, the horizontal tube boiler is very widely used in the
general industry.
 There are many kinds of construction in this type of boiler.
 Package boiler is a popular boiler in this type for small-scale
industry located in the city or urban area with good
infrastructure due to the requirement for transportation of
fuel such as diesel oil, furnace fuel and gas.
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Boiler Principles
 Horizontal fire-tube boiler
 It is very strong in construction structure consisting of all
necessary equipment for a boiler and is completely built at
the factory.
 Thus, it is very convenient for installation. (Some models of
the small water tube boiler may be called “package boiler”
also).
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Boiler Principles
 Water for the boiler
a. The properties of water suitable for boiler:
 The feed water use should be pure, and contain no
impurity.
 As a matter of fact there is no water with 100% purity.
 Although there is now a many modern facilities and
equipment involved with the water purification, but they
still cannot produce pure water.
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Boiler Principles
 Water for the boiler
a. The properties of water suitable for boiler:
 Thus there exists an allowable content of impurities in
the boiler feed water. However the important properties
of feed water that should be known properly are:
1) Hardness and dusty should be minimum.
2) The pH value should be in the range of 10 – 11 (as
measured in the boiler).
3) The total dissolved solid substance (TDS) should be
less than 3,500 ppm.
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Boiler Principles
 Water for the boiler
b. Treatment of boiler feed water:
 Although the treatment of water is done once before
feeding into the boiler, the water inside the boiler is
continuously boiling and evaporating into steam causing
the intensity of various impurities to increase.
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Boiler Principles
 Water for the boiler
b. Treatment of boiler feed water:
 It is therefore necessary to inspect the quality of the
water in the boiler on a regular by taking water sample
from the blow-down valve for the laboratory analysis.
 This is to find out weather the amount of impurities
exceeding the allowable limit.
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Boiler Principles
 Water for the boiler
b. Treatment of boiler feed water:
 There are two methods of treatment as follows:
1) By adding chemical compounds The chemicals
commonly employed are soda ash, sodium
phosphate, sodium aluminate, and also, under
general practices, colloidal compounds in
combination with the other chemicals.
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Boiler Principles
 Water for the boiler
b. Treatment of boiler feed water:
 There are two methods of treatment as follows:
2) By Blow-Down Operation The blow-down operations
is a method of removing water from the bottom of
the boiler and replenishing it with new feed water.
If done regularly, it will help in removing some of the
impurities that are precipitated as sludge before the
reaction of scale formation.
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Thermodynamics of a steam power plant
 The thermodynamic process diagram of a power plant is as per
Fig. 2-4.
Figure 2-4
Typical
Thermodynamic
Process Diagram
of a steam power
plant
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Thermodynamics of a steam power plant
 The thermodynamic processes are as follows:
1. A feed water is at atmospheric pressure 𝑝𝑎, Temperature 𝑇1
and has an enthalpy of ℎ𝑜.
2. After the feed pump, the water pressure increases to 𝑝1 at
temperature 𝑇1 and has an enthalpy of ℎ1.
3. Heat is supplied to the boiler by fuel. The saturated steam
pressure is 𝑝1, temperature 𝑇2 and has an enthalpy of ℎ2.
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Thermodynamics of a steam power plant
 The thermodynamic processes are as follows:
4. When the saturated steam is further heated in a
superheater, its pressure remains at 𝑝1, temperature
increases to 𝑇3, and enthalpy increases to ℎ3.
5. When the steam is throttled before the turbine, its enthalpy
is assumed to remain unchanged at ℎ3 but the pressure and
temperature change to 𝑝2 and 𝑇4. At this point, the super
heated steam becomes further super heated or the
saturated steam becomes super heated.
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Thermodynamics of a steam power plant
 The thermodynamic processes are as follows:
6. When the steam is used to drive a steam turbine or steam
engine, there is a power output 𝑊𝑜 and the steam pressure,
temperature and enthalpy reduce to 𝑝3 (or 𝑝𝑎), 𝑇5 and ℎ4
respectively. The pressure 𝑝3 may now be atmospheric
pressure 𝑝𝑎 or below depending on the system.
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The Thermodynamics of the Rankine Cycle
 For thermodynamic theoretical consideration, the ideal Rankine
cycle, as shown in Figure 2-5, is generally used by engineers as a
standard of reference for comparing the performance of actual
steam engines and steam turbines.
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The Thermodynamics of the Rankine Cycle
 The system contains the following apparatus:
1) A steam generating unit.
2) A prime mover (a steam engine or steam turbine)
3) A condenser and cooling tower.
4) A boiler feed water pump.
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The Thermodynamics of the Rankine Cycle
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Figure 2-5 T-S Diagram
69
The Thermodynamics of the Rankine Cycle
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Figure 2-6 p-V Diagram
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The Thermodynamics of the Rankine Cycle
 On the T-S and p-V diagrams, Figures 2-5 and 2-6 show the
following ideal thermodynamic processes:
• Process Line C-D shows the phase of pumping feed water
into the boiler,
• Process Line D-E is the process of heating of feed water in
the boiler representing the work input into the system.
• Process Line E-A represents evaporation.
• Process Line A-B is assumed to be isentropic expansion, a
constant entropy process, in the steam turbine
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The Thermodynamics of the Rankine Cycle
• Process Line B-C is a condensation of vapor in the condenser
at constant pressure.
If a super heater is used, the steam is heated from A to A′ then
isentropic expansion becomes A′ to B′
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The Thermodynamics of the Rankine Cycle
 The following assumptions are made for the Rankine cycle:
1) Steady flow conditions; that is, at a given point in the
system, the conditions of pressure, temperature, flow rate,
etc., are constant.
2) There is no heat loss at any point, that is:
• All of the heat is added in the steam-generating unit.
• All of the heat that is rejected from the condenser by
the cooling water is transferred in the condenser.
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The Thermodynamics of the Rankine Cycle
• There is no heat transfer between the working fluid and
the surroundings at any place except in the steamgenerating unit and the condenser.
• Heat rejected in the prime mover, Q = 0.
3) There is no pressure drop in the piping system.
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The Thermodynamics of the Rankine Cycle
4) Expansion in the prime mover occurs without friction or
heat transfer. In other word it is a frictionless adiabatic or
isentropic expansion process in which the entropy of the
fluid leaving the prime mover equals to the enthalpy of the
fluid entering the prime mover.
5) The working fluid leaves the condenser as liquid at highest
possible temperature, which is saturated temperature
corresponding to the exhaust pressure.
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The Thermodynamics of the Rankine Cycle
 If ℎ𝐴, ℎ𝐵, ℎ𝐶 , ℎ𝐷 and ℎ𝐸 represent the enthalpy in kJ per kg of
steam in the five states at 𝐴, 𝐵, 𝐶, 𝐷 and 𝐸, respectively for
boiler without superheater (In case of testing with superheater,
hA′ and ℎ𝐵′replaceℎ𝐴 and ℎ𝐵)
 Then the change of enthalpy in the boiler or heat supplied in the
steam-generating unit to produce 1 kg of steam is
(2.3)
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The Thermodynamics of the Rankine Cycle
 In the prime mover, which is usually a turbine, the steam is
assumed to expand at a constant entropy, (𝑠4 = 𝑠5) work done
in the steam turbine in kJ per kg. of steam is
(2.4)
Where, 𝑊𝑡= work done in the turbine, N-m per kg of steam
ℎ𝐴
= enthalpy of steam entering the turbine, k J per kg
ℎ𝐵
= enthalpy of steam leaving the turbine after
isentropic expansion, 𝑠𝐴 = 𝑠𝐵
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The Thermodynamics of the Rankine Cycle
 The enthalpy of the exhaust steam, ℎ𝐵, after isentropic
expansion, can be found most easily by using the Mollier
diagram or steam table.
 The condensate leaving the condenser and entering the boiler
feed water pump is always assumed to be saturated water at
condenser pressure, and its enthalpy, ℎ𝑓𝐶 , can be found from
steam tables at the condenser pressure.
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The Thermodynamics of the Rankine Cycle
 The heat rejected in the condenser, 𝑄𝑟 , in kJ per kg of steam is
then given by the equation
(2.5)
 For horizontal flow through the pump without change in water
velocity or specific volume, 𝑣𝑓𝐶 , the actual work done by the
feed water pump on 1 kg. of water and added into the system in
kJ per kg of steam :
(2.6)
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The Thermodynamics of the Rankine Cycle
 Where 𝑝𝐶 and 𝑝𝐷 are expressed in 𝑁/𝑚2 absolute and 𝑣𝑓𝐶 is
specific volume of saturated water supplied to the pump.
 Since for the ideal Rankin cycle it is assumed that there is no
heat transfer from the water to its surroundings in the pump,
the energy supplied by the pump is stored in the high-pressure
water and the enthalpy of the boiler feed water is
 Then
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(2.7)
80
The Thermodynamics of the Rankine Cycle
 The heat supplied in the steam-generating unit 𝑄𝑖𝑛 to produce 1
kg of steam is:
(2.8)
The net work of the cycle is
(2.9)
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The Thermodynamics of the Rankine Cycle
Hence, the Rankine cycle efficiency is:
(2.10)
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The Thermodynamics of the Rankine Cycle
 Where the boiler pressure is low, under 400 psia (27.6 bar abs.),
the amount of energy supplied to the pump, Wp, is rather small
and may be negligible and equation 2.10 reduces to
(2.11)
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Figure 4-1
Schematic Diagram
for TH136 Compact
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Steam
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Equipment Set up
 Ensure that the following are connected
 Raw water supply to the resin filter.
 Stacks are installed.
 Blow-down and safety valve pipes are connected to outside
building.
 Dynamometer discharge water to drain.
 Cooling water supply and drain lines.
 Power supply to the boiler and the cooling tower.
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Equipment Set up
 As the test unit is large and many data are to be taken, it is
recommended that several students are to be coordinated
during the test, e.g. one for feed water flow, one for fuel flow,
one for condenser cooling water, one for boiler and superheater
(optional) pressure and temperatures (after pressure regulator),
one for the turbine generator or turbine dynamometer, and one
for steam separator if required; etc. 4
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Guide Lines for Training Boiler Test
1. Before the boiler is started, it must be decided where the
generated steam is to be used.
2. The boiler can be run with steam vented to atmosphere and
boiler efficiency can still be measured. The same principles apply
to the superheater running at the same pressure and steam rate.
The additional fuel consumption can be attributed to the
superheater.
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Guide Lines for Training Boiler Test
3. If the steam is to be used on a prime mover such as a steam
turbine or a steam engine. The turbine or engine power output
can be measured by a dynamometer where the prime mover
efficiency can be determined. The steam from the prime mover
can be exhausted to the atmosphere or recovered by a
condenser and a cooling tower.
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Guide Lines for Training Boiler Test
4. A condenser and cooling tower may be used for a study of
condenser heat transfer efficiency and cooling tower efficiency
as well as for recovering of the exhausted steam. In the case the
prime mover is not used, the generated steam from the boiler
can still be directed to the condenser.
5. It should be noted that the boiler pressure varies between the
minimum and maximum set pressures. In this case, the average
pressure may be used as the boiler pressure. If a constant boiler
pressure is required, a steam pressure regulator must be used.
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To Start the Boiler
 It is important that the equipment manual including those of
addenda e.g. boiler, turbine etc. must be studied before running
the equipment.
1. Inspect the following before running the boiler:
a. Analyze the water from the resin filter using a hard water
indicator. (See Chapter 3 Quality Control of Water Supply in
Addendum 1).
b. Check that the steam pressure gauge and the fuel gauge
are normal.
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To Start the Boiler
c. Check that there is enough water in the feed water tank
and fuel in the fuel tank.
d. Check that there is enough chemical in the dosing tank.
e. Open Valve 4 (feed water inlet valve) and Valve 2 (fuel inlet
valve).
f. Close valve 5 (steam outlet valve from boiler)
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To Start the Boiler
2. Switch on ELCB (See Addendum 8).
3. Check and prepare the boiler per Addendum 1 items 2.1 and
2.2
4. Start the boiler (modify Addendum 1 item 2.3 as per below)
a. Turn on the running switch dosing pump switch.
b. Check water level of the boiler to ensure that the level is
between minimum and maximum. If the water is above the
maximum, drain the water from the boiler.
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To Start the Boiler
c. Turn on combustion switch. Turn on the burner switch. The
air within the furnace will be purged when the water level
meets the preset value.
d. The burner will fire at low effective combustion after 10-16
seconds. The system is transferred to high effective
combustion 20 seconds later. The transfer process should
be executed under the adjustable range of pressure and
the pressure in the boiler must be maintained.
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To Start the Boiler
e. Wait until boiler set pressure is reached, e.g. 8 bar, before
slowly opening Valve 5 (boiler steam outlet valve) about 1
turn (fully open = 2 turns), to use steam as required.
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Boiler Test
1. Ensure that the steam outlet is connected to a prime mover or a
heat exchanger (condenser) or vented to atmosphere by
connecting a steam outlet pipe from Valve 12.
2. Slowly open Valve 5 (boiler steam outlet valve) about 1 turn
(fully open = 2 turns) and observe that steam pressure (p2) is in
a steady condition. (see relevant theory)
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Boiler Test
Record: - Feed water temperature °C.
- Steam pressure (p2) and temperature (T4) after the
pressure regulator. Normally this steam is in a
slight super heated condition.
- Fuel flow rate (lpm) (see relevant theory 3.3).
- Feed water flow volume (l) and time (s) (see
relevant theory 3.4).
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Boiler Test
3. Repeat 4.4.2 at different steam rate and/or pressure.
4. Calculate: - Power input from fuel consumption.
- Power gained by the steam.
- Boiler efficiency.
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Turbine Generator Test
1. Remove the belt guard.
2. Connect the turbine to the generator by a belt. This is done by
loosening screws of the generator base plate (see Addendum 3),
then move the plate until the belt is properly fit and then
retightening all four screws. Ensure that the belts are not too
tight.
3. Make sure that all lamps are switched off.
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Turbine Generator Test
4. Turn on both upper and lower instrument box and note that all
readings are zero, including volt meter and ammeter, except
temperature.
5. Run the cooling tower and the condenser by following steps in
4.7.
6. Start the air pump (vacuum pump).
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Turbine Generator Test
7. Direct steam to the turbine by open Valve 6 (Turbine steam inlet
valve). The turbine will now start running. Open Valve 6 as
required by observing the turbine or generator speed. For safety
and other reasons, the turbine speed should not exceed 30,000
rpm for the test.
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Turbine Generator Test
It should be noted that
a. The steam pressure regulator is set at the factory for a steam
outlet pressure 5 kg/cm2
b. If the generator speed exceed 1,900 rpm or the turbine speed
exceeds 33,000 rpm, the solenoid valve will release steam to
blow down.
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Turbine Generator Test
8. Record
Steam turbine speed
Generator speed
Voltage
Current
Turbine inlet temperature, 𝑇4
Turbine outlet temperature, 𝑇5
Steam inlet pressure, 𝑝2
Feed water flow volume per boiler cycle
Feed water cycle time
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rpm
rpm
Volt
Ampere
°C
°C
kg/cm2
1
min’ sec”
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Turbine Generator Test
9. At constant steam flow rate, increase the load by turning on one
or two lamps. At this point the speed will reduce. Once the
turbine run is steady, record data as per 4.5.7.
10.Repeat 4.5.8 by turning on one more lamp load at each step
until the turbine speed is low but not stop or until all lamps are
turned on.
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Turbine Generator Test
11. Calculate:
a. Steam flow rate (see feed water flow rate 4.4.2).
b. Energy input to the turbine
c. Turbine-generator power output and efficiency.
12. Plot a graph of turbine-generator output vs. speed for constant
steam rate.
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Turbine Dynamometer Test
 In this case a hydraulic dynamometer is used.
1. Remove the belt guard.
2. Connect the turbine to the hydraulic dynamometer by a belt.
This is done by loosening screws of the dynamo base plate (see
Addendum 3), then move the plate until the belt is properly fit
and then retightening all four screws. Ensure that the belts are
not too tight.
3. Turn on both upper and lower instrument box and note that all
readings are zero except temperature.
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Turbine Dynamometer Test
4. Run the cooling tower and the condenser by following steps in
4.9.
5. Open Valve 10 (Dynamo water outlet valve) full, close Valve 9
(vent valve) and open Valve 8 (Dynamo water inlet valve) slightly
– just enough to observe at the water discharge line that there is
a very small water flow.
6. Direct steam to the turbine by opening Valve 6 (Turbine steam
inlet valve). The turbine will now start running. Adjust Valve 6 to
vary steam flow rate.
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Turbine Dynamometer Test
7. If high speed of turbine is needed, open valve V6 more or slightly
open Valve 9 (vent valve) to increase speed to a required speed,
e.g. 30,000 rpm.
If should be noted that
a. The steam pressure regulator is set at the factory for a
steam outlet pressure of 5 kg/cm2
b. The solenoid valve will release steam to blow down if
turbine speed exceeds 35,000 rpm.
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Turbine Dynamometer Test
8. Record
Steam turbine speed
Dynamometer speed
Dynamometer torque
Turbine inlet temperature, 𝑇4
Turbine outlet temperature, 𝑇5
Steam inlet pressure, 𝑝2
Feed water flow volume per boiler cycle
Feed water cycle time
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rpm
rpm
Nm
°C
°C
kg/cm2
1
min’ sec”
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Turbine Dynamometer Test
9. At constant steam flow rate, increase dynamometer torque by
opening Valve 8 a little more to increase the cooling water flow
rate, hence the load. At this point the speed will reduce. Once
the turbine run is steady, record data as per 4.8.8.
10. Repeat 4.8.9 at a speed decrease of 5,000 rpm approximately
until the turbine speed is below 10,000 rpm.
11. Repeat 4.8.7 to 4.8.10 for other steam rates.
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Turbine Dynamometer Test
12. Calculate:
a. Steam flow rate (see feed water flow rate 4.4.2).
b. Energy input to the turbine
c.
Turbine-dynamo power output and efficiency.
13. Plot a graph of turbine-dynamo output vs. speed for constant
steam rate.
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Condenser and Cooling Tower Test
 This test must be carried out at the same time as turbinegenerator test or turbine-dynamometer test.
1. Preparation before the test
a. Switch on the cooling tower fan power breaker at the
power box (See Addendum 8). Make sure that the fan
rotates in right direction by observing that air is blowing
out of the top of the cooling tower. If not, reverse two of
the three power lines of the 3 phase at customer’s site
(consult your electrician).
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Condenser and Cooling Tower Test
b. Switch on the cooling tower pump power breaker at the
power box (See Addendum 8). The pump M3 will now start
running. Normally open the valve at discharge of this pump
only half is enough.
c. Close the condenser cooling water inlet valve.
d. Switch on the circulating pump power breaker at the
power box (See Addendum 8). The pump M2 will now start
running; slightly open the inlet valve to condenser.
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Condenser and Cooling Tower Test
e. Adjust the condenser cooling water flow rate such that the
condenser outlet temperature is below 75 °C. The
condenser is now ready for the test.
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Condenser and Cooling Tower Test
2. Begin the test
a. Data can be taken only after conditions in the condenser are steady. This
includes measurement of steam rate from the condensate collection.
Alternatively, steam rate can be calculated from the feed water pump run
after one completes cycle of the run.
b. Record the following data - Feed water flow (see relevant theory 3.4) - Steam
outlet temperature from the turbine - Cooling water flow rate - Cooling water
inlet and outlet temperatures - Wet bulb temperature at the cooling tower
c. Vary the cooling water flow rate and record data as per 4.7.2.2
d. Calculate : - Condenser heat transfer efficiency as per 3.10 - Cooling efficiency
of cooling tower as per 3.11
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1. A cyclic steam power plant is to be designed for a steam temperature at turbine
inlet of 360 °C and an exhaust pressure of 0.08 bar. After isentropic expansion of steam
in the turbine, the moisture content at the turbine exhaust is not to exceed 15%.
Determine (a) the maximum allowable steam pressure at the turbine inlet, and (b) the
Rankine cycle efficiency for these steam conditions. Estimate also the mean
temperature of heat addition. (Ans. (a) 16.83 bar, (b) 31.7%, 187.5 °C)
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2. A steam power station uses the following cycle: Boiler outlet steam pressure and
temperature at 150 bar, 550 °C. Reheat at 40 bar to 550 °C. Condenser pressure at 0.1
bar. Assuming ideal processes, find (a) the quality at turbine exhaust, (b) the cycle
efficiency, and (c) the steam rate. (Ans. (a) 0.88, (b) 43.9%, (c) 2.18 kg/kWh)
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3. In a single-heater regenerative cycle, the steam enters the turbine at 30 bar, 400 °C
and the exhaust pressure is 0.10 bar. The feed-water heater is a direct contact type
which operates at 5 bar. Find (a) the efficiency and the steam rate of the cycle, and
, (b) the increase in mean effective temperature of heat addition, the efficiency and
steam rate as compared to the Rankine cycle (without regeneration)
(Ans. (a) 35.36%, 3.93 kg/kWh, (b) 27.4 °C, 1.18%, 0.47 kg/kWhr)
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4. A simple steam power cycle uses solar energy for the heat input. Water in the cycle
enters the pump as a saturated liquid at 40 °C, and is pumped to 2 bar. It then
evaporates in the boiler at this pressure, and enters the turbine as saturated vapor.
The turbine exhaust conditions are 40 °C and 10% moisture. The flow rate is 150 kg/hr.
Determine (a) the turbine isentropic efficiency, (b) the net work output, (c) the cycle
efficiency, and (d) the area of the solar collector needed if the collectors pick up 0.58
kW/m2 (Ans. (a) 76.7%, (b) 15.5 kW, (c) 12.78%, (d) 182 m2)
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5. In a reheat cycle, steam the initial steam pressure and the maximum temperature
are 150 bar and 550 °C, respectively. If the condenser pressure is 0.1 bar, the moisture
at the condenser inlet is 15%, and assuming ideal processes, Determine (a) the reheat
pressure, (b) the cycle efficiency, and (c) the steam rate. (Ans. (a) 13.5 bar, (b) 43.6%,
(c) 2.05 kg/kWhr)
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6. A regenerative cycle operates with steam supplied at 30 bar and 300 °C and the
condenser pressure is 0.08 bar. The extraction points for two heaters (one closed and
one open) are 3.5 bar and 0.7 bar, respectively. Calculate the thermal efficiency of the
plant neglecting pump work. (Ans. 36%)
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7. The net power output of an ideal reheat regenerative steam cycle is 80 MW. Steam
enters the h.p. turbine at 80 bar, 500 °C and expands till it becomes saturated vapor.
Some of the steam then goes to an open feed-water heater and the balance is
reheated to 400 °C, after which it expands in an l.p. turbine to 0.07 bar. Compute (a)
the reheat pressure, (b) the steam flow rate to the h.p. turbine, (c) the cycle efficiency,
(d) the rate of cooling water in the condenser if the temperature rise of water is 8 °C,
(e) if the velocity of steam flowing from the turbine to the condenser is limited to 130
m/s, find the diameter of the connecting pipe. (Ans. (a) 6.5 bar, (b) 58.4 kg/s, (c)
43.7%, (d) 3, 146.5 kg/s, (e) 2.97 m)
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8. Steam is generated at 70 bar, 500 °C and expands in a turbine to 30 bar with an
isentropic efficiency of 77%. At this condition, it is mixed with steam twice its mass at
30 bar, 400 °C. The mixture then expands with an isentropic efficiency of 80% to 0.06
bar. At a point in the expansion where the pressure is 5 bar, steam is bled for feedwater heating in a direct contact heater, which raises the feed-water to the saturation
temperature of the bled steam. Calculate the mass of steam bled per kg of high
pressure steam and the cycle efficiency. Assume that the l.p. expansion condition line
is straight (Ans. (a) 0.53 kg, 31.9%)
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9. A 10 MW steam turbine operates with steam at 40 bar, 400 °C at the inlet and
exhausts at 0.1 bar. 10, 000 kg/h of steam at 3 bar are to be extracted for process work.
The turbine has 75% isentropic efficiency throughout. Find the boiler capacity
required. (Ans. (a) 13.74 kg/s or 49.46 t/h)
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10. A coal fired power plant has a turbine generator rated at 1, 000 MW gross. The
plant requires 9% of this power for its internal operations. It uses 9, 800 tonnes of coal
of heating value 26 MJ/kg per day. The steam generator efficiency is 86%. Calculate the
gross and net station heat rates and efficiencies. (Ans. 10.62 MJ/kWhr, 11.67
MJ/kWhr, 33.9%, 30.86%)
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Instruction Manual TH136 Compact Steam Turbine Power Plant , Essom Co. Ltd.
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Righteousness exalts a nation, but sin is a reproach to any people. (Prov. 14:34, NKJV)
END.
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