First Thank you for reading my instructable. This is a work in progress, I will be adding more and more to this instructable on how to build a steam driven turbine and power plant for your home. As always if you find any typo's or any mistakes please let me know there is a lot of information I am going to throw your way. So lets get started.
I am going to show you how I build this 45 Kilowatt Genset, or steam turbine to power my home and business. This unit was a major effort to get off the ground. I will attempt to show you how to build this beauty. Perhaps you can build one on a smaller scale. This unit is not for the amature. This build is very difficult and dangerous. There are a few things you need to be aware of when working with high power.
1. Respect the power. It will kill you in a heartbeat.
2. DO NOT ATTEMPT THE PROJECT IF YOU DON'T KNOW HOW TO WORK WITH HIGH VOLTAGE AND HIGH PRESSURE STEAM.
3. BE REALISTIC. If you don't have the equipment to build this device then send the parts out to be made.
4. What you don't know, ask. I will be happy to help anyone in any I can.
Always wear safety glasses and proper protection when working with electronics and steam.
Ok this is the turbine and generator attached together on the test stand. This is a turbine of my own design the generator portion or Technically the Alternator to be more precise is as mentioned above 45 kw 3 phase AC power output. The turbine in order to produce that level of power it required to run at an astounding 100000 rpm, thats right 100000. Now that will ruin your day if you have a major malfunction this runs at ballistic levels so if you have a destructive or catastrophic event the shrapnel will kill you. It would literally explode. This will turn you into a red mist. That said I have maintained my rpm to more respectable and safe level of around 50000 rpm my power output drops, as should be expected. Though I feel safer at that rpm. My power levels at 50k are about half of my top end of 100k so around 22 kw output 3 phase.
This is more that enough for my purposes. So here is the layout and break down of the genset. From right to left. The large cylinders are far right the alternator left of that larger alum housing is the turbine chamber, the input to the turbine is via the silver high pressure line you see entering the turbine. This LIne is rated for 10000 psi at over 800 degrees. My steam unit runs at a max of 500 degrees F so i have plenty of worry room from a potential runaway. The steam unit will be discussed later right now turbine. so after we see the input line to the left of that you will see the oil pump system I have to use turbine oil rated for aircraft turbines. 150.00 per 5 gallon drum. This is great for the protection of the bearings. I am running hydrostatic bearing at the front of the turbine and a ceramic at the rear. both rated for very high rpm. The pump is a standard 110v ac motor driving a screw pump to maintain pressure at 55 psi for the hydrostatic bearing. the oil is also use to cool the alternator during runs. the oil is returned to the bath via a radiator or heat exchanger.
just below the alternator portion on the right you can see the pressure sensor and oil filter setup, I use a standard automotive sending unit to give me my oil pressure more on that later. In the following steps I will show you more detail for the components of the system.
the top drawer housed the control panel. This is the basic layout of the genset.
Step 1: DA Build
In this drawing you see the new design of my labyrinth seal. This device is used to allow steam to flow in only one direction inside the rotor. these two pieces stack one on top of the other with the geometry facing each other.
Steam enters at the center and flows to the outside into the jets. the pressure builds and only allows the steam to flow to the od of the part and out the venturies.
This is my design I was inspired by an a similar invention by Tesla. His however had issues. I made some changes and improvements and what you see here is the first layout of my design.