Republic of Philippines

Iloilo Science and Technology University

Burgos St., La Paz Iloilo City

College of Engineering and Architecture

Mechanical Engineering Department

Table of Contents

Report No. Title Page

Report No. 01 Steam Generating Unit 2

Report No. 02 Boiler Nomenclature 5

Report No. 03 Heating Surfaces and 7

Boiler Horse Power

Report No. 04 Boiler Operation 9

Report No. 05 Steam Engine Nomenclature 12

Report No. 06 Steam Engine Operation 16

Report No. 07 Test on Refrigeration Unit 19

References

.
.
1
Page

1
 Republic of Philippines
Iloilo Science and Technology University
Burgos St., La Paz Iloilo City

College of Engineering and Architecture

Mechanical Engineering Department

REPORT NO. 01

STEAM GENERATING UNIT

INTRODUCTION:
The most important single piece of equipment in any steam power plant is the

boiler. Without the boiler, there would be no means to transfer the energy in the fuel to
useful work output.

Boilers have been in existence since man first discovered the use of fire. However,

until the introduction of the first steam engine, there was a need for an efficient steam
generator. Since the days of Newcomen and Watt, the development of engines and

boiler have proceeded side by side with an improvement in one demanding, or

following, an improvement in the other.

The earliest practical boilers were of the fire-tube type. This type of boiler is still

use today in low-pressure heating plants. In 1856, the Wilcox water-tube boiler was
invented. One of the advantages of water-tube boiler is that higher pressuresare

attainable. This is the reason why most steam power plants utilize the use of water tube
boiler as their steam-generating unit.
2
Page

2
REPORT PROPER:

I. Draw the condensing steam and water cycle and label the machinery involved.
Discuss how steam and water flows through the simple condensing steam power

plant.
II. Draw the front and side view of scotch Fire-tube boiler.

III. Draw the front and side view of Babcock and Wilcox water-tube boiler. Label the
parts.

IV. QUESTIONS AND ANSWERS:

A. What is a steam boiler?

B. What is the difference between a fire-tube boiler and a water-tube boiler?

C. What are the advantages and disadvantages of fire-tube boilers?

D. What are the advantages and disadvantages of water-tube boilers?

E. Define the following parts of a steam generating units:

1. Furnace
2. Dry pipe

3. Super heater
4. Safety valve

5. Soot blower
6. Steam gage

7. Fusible plug
8. Gas baffles

9. Damper
10. Economizer

11. Gage glass

12. Steam and water drum

13. Mud drum

14. Main steam stop valve

15. Bottom blow valve

16. Headers

17. Hydrokineter
18. Salinometer cock
3
Page

3
 19. Try cocks
20. Auxiliary steam stop valve

21. Water walls

22. Desuperheater

23. Air-preheater
24. Steam trap

25. Day tank

REFERENCES:
Practical Marine Engineering 2nd edition

By: Reno C. King

Marine Engine Room Blue Book

By: William B. Paterson

4
Page

4
 Republic of Philippines
Iloilo Science and Technology University
Burgos St., La Paz Iloilo City

College of Engineering and Architecture

Mechanical Engineering Department

REPORT NO. 02

BOILER NOMENCLATURE

INTRODUCTION:
WVCST boiler is a fire-tube boiler. It was first installed in the Mercado Hall in

1970 as part of the laboratory equipment of the Mechanical Engineering Department.

The boiler is equipped with automatic ignition and low-water level switch that
operates the pump whenever the water goes below the critical limit. It is also equipped

with safety valve that blows off steam if the pressure of the steam inside the boiler ie
above the desired working pressure.

REPORT PROPER:
A. Draw the USA boiler in three views, left-side view, right-side view, and front view.
Label the parts as show in the drawing.

B. Make a brief description of the following:

1. Steam pressure gage

2. Flu gas temperature gage

3. Fuel pressure gage

4. Water column
5. Gage glass

6. Tri-cocks
7. Gage-glass blow-off valve

8. Water-column blow-off valve

9. Feed water pump

10. Feed stop valve

5
Page

5
 11. Feed check valve

12. Blow-down valve

13. Fuel pump

14. Fuel filter

15. Air cock

16. Safety valve

17. Forced draft fan

18. Main switch

19. Water level switch

20. Electric motor

REFERENCES:
Boiler Room Question and Answer

By: Elonka
Practical Marine Engineering

By: Reno C. King

6
Page

6
 Republic of Philippines
Iloilo Science and Technology University
Burgos St., La Paz Iloilo City

College of Engineering and Architecture

Mechanical Engineering Department

REPORT No. 03
HEATING SURFACES AND BOILER HORSEPOWER

OBJECTIVES:

To study the inner construction of the boiler and to determine the horsepower
based on the heating surfaces.

THEORY AND ANALYSIS:

Steam generators are now being rated by kg per hr of actual steam generating
capacity and ASME units of evaporation and at the same time specifying operating

pressure and temperatures.

Another capacity unit of long standing is the boiler horsepower. This is based
mainly in the heating surfaces of the boiler that 10 ft2 of heating surfaces was needed to

generate steam to produce one boiler horsepower.

INSTRUMENT AND EQUIPMENT:

Marine Engineering FT Boiler

Measuring tape
Vernier caliper
7
Page

7
PROCEDURES:

1. Remove the back cover of the boiler.

2. Measure the diameters and lengths of the furnace.

3. Measure the inside diameters of the fire tubes, furnace, and diameters of the end
plates.

4. Compute the heating surface of the boiler.

ILLUSTRATIONS:
Draw the pictorial cut-away view and front sectional view of the boiler.

COMPUTATIONS:

TABULATED RESULTS:

Description Heating Surface Area

Fire-tubes

Furnace

End Plates

Total Surface Area

Boiler Horsepower

CONCLUSION:
8
Page

8
 Republic of Philippines
Iloilo Science and Technology University
Burgos St., La Paz Iloilo City

College of Engineering and Architecture

Mechanical Engineering Department

REPORT NO. 04

BOILER OPERATION

OBJECTIVES:
To study how the HRT boiler operates.

THEORY AND ANALYSIS:

Test for stationary steam generator maybe conducted for the purpose of
determining the capacity of the boiler, its developed boiler horsepower, its efficiency

and any information necessary in connection with the actual performance.

EQUIPMENT AND APPARATUS:

HRT Boiler

Measuring tape
Steel rule

Pressure gages
Tachometer

Test drum
Multi tester

Thermometer
Clamp-on ammeter
9
Page

9
PROCEDURES:
1. Check main switch for fuses of proper rating and leave switch open.

2. Place the selector switch in the “off” position or center position.

3. Close the boiler blow down value, water column blow-off and gage glass blow-

off valve.
4. Open the feed water suction gate, feed water discharge gate valve, main steam

valve, tri-cocks, gage glass control valve.

5. Allow the water to fill the boiler automatically. The water level should come up

then close the feed water gate valve as soon as it reaches two (2) inches above
the water gage glass.

6. Check and close tri-cocks and main steam gate stop valve.
7. Close the main switch.

8. Place selector in the “on” position.

A. The fuel and fan motor will be energized immediately.

B. The flame and its sound should be recognized by the flare eye.

DATA AND RESULTS:

1. Length of the fuel tank:

2. Width of the fuel tank:

3. Height of the fuel tank:

4. Height of the fuel before operation:

5. Height of the fuel after operation:

6. Operation time:
7. Current consumption:

8. Capacity of fuel tank:

9. Operating steam pressure:

10. Temperature of flue gas:

11. Fuel oil pressure:

12. Volume of water inside the boiler:

13. Volume of fuel consumed:
10
Page

10
 14. Cost of fuel consumed:

15. Cost of electricity used:

16. Steam rate:

17. Fuel rate:

18. Boiler efficiency:

19. Enthalpy of steam:

20. Enthalpy of feed water:

21. Developed boiler horsepower:

22. Factor of evaporation (F.E.);

23. Equivalent evaporation (E.E.):

24. Weight of steam flow rate tank before entrance of steam:

25. Weight of steam flow rate tank after entrance of steam:

26. Trial time:

27. RPM of fan motor:

28. Temperature of feed water:

29. Specific gravity of fuel:

30. Voltage reading:

31. RPM of fan:

COMPUTATIONS:

OBSERVATIONS:
11
Page

11
 Republic of Philippines
Iloilo Science and Technology University
Burgos St., La Paz Iloilo City

College of Engineering and Architecture

Mechanical Engineering Department

REPORT NO. 05
STEAM ENGINE NOMENCLATURE

OBJECTIVE:

To study the different types of steam engine, its nomenclature and the function
of each parts.

THEORY AND PRINCIPLES:

Steam engine is the first type of engine that was developed and used in various
types. It was developed by Newcomen in 1698 for the purpose of pumping of water,

with refinement made by James Watt in about 1763, the real steam power prime mover
begun.

Considering only efficiency in the use of heat, the diesel engine is superior to the

steam engine but by improved design in the action of steam and balanced poppet
valves for high pressure and temperature, increase in the economics of steam engine

could be attained.

ILLUSTRATIONS:
1. Draw a Vertical Steam Engine

2. Draw a Corliss Steam Engine

3. Draw a Horizontal Steam Engine
12
Page

12
QUESTIONS AND ANSWERS:
I. Discuss briefly how the reciprocating steam engine operates from the admission

of steam up to the rotary motion of the crankshaft.

II. Define the following steam engine nomenclature:

1. Piston
2. Cylinder liner

3. Crosshead
4. Crosshead pin

5. Guide
6. Piston ring

7. Piston rod
8. Connecting rod

9. Main bearing
10. Throttle valve

11. Governor
12. Shims

13. Columns
14. Crankshaft

15. Crankweb
16. Piston rod packing

17. Piston type valve

18. D-slide valve

19. Corliss type valve

20. Steam lap

21. Exhaust lap

22. Steam lead

23. Exhaust lead

24. Steam chest

25. Indicator rod

13
Page

13
 26. Pounding
27. Crank pin

28. Valve travel

29. Flywheel

30. Relief valve

III. Define the following steam engineering terminologies:

1. Steam line

2. Steam trap
3. Steam

4. Steam engine
5. Steam turbine

6. Saturated steam
7. Superheated steam

8. Dry steam
9. Wet steam

10. Quality of steam

IV. Discuss how to measure the brake power on the steam engine being developed.

V. Factors affecting the starting of steam engine.

DATA AND RESULTS:

1. Vertical steam engine

Diameter of the bore:

Length of stroke:

Piston rod diameter:

Clearance:

2. Horizontal D-slide steam engine

Bore diameter:

Length of stroke:
Piston rod diameter:
14
Page

14
 3. Horizontal Corliss steam engine
Bore diameter:

Length of stroke:
Piston rod diameter:

OBSERVATION:

CONCLUSION:

15
Page

15
 Republic of Philippines
Iloilo Science and Technology University
Burgos St., La Paz Iloilo City

College of Engineering and Architecture

Mechanical Engineering Department

REPORT NO. 06

STEAM ENGINE OPERATION

OBJECTIVE:
To operate the steam engine in order to determine its indicated power, brake

power and mechanical efficiency.

PRINCIPLES:
Steam engine was the first practical steam prime mover developed by James

Watt in 1763. It is the most widely used prime mover, although its field if usefulness has
been encroached upon in recent years by gas engine.

Steam engine operates more economical than gas engine but it needs more

space to occupy and more time for maintenance.

INSTRUMENTS AND APPARATUS:

Boiler

Steam engine
Tachometer

Prony Brake Assembly

Stop watch

Weighing Scale
Steel rule
16
Page

16
DATA RESULTS:

Trial 1 Trial 2

Gross weight

Tare weight

Speed

Pressure

TABULATED RESULTS:

Table 6.1 Indicated Power

LHE LCE AHE AHE Pmi IpHE IpCE

Trial
(mm) (mm) (mm2) (mm2) (kpa) (KW) (KW)

Average

Table 6.2 Brake Power

Gross Brake Rotational

Tare weight, Brake
Trial weight, Fg weight, FB in speed, N
Ft in kg power, KW
in kg kg (rpm)

Average
17
Page

17
 Table 6.3 Mechanical Efficiency

Indicated Power Brake Power Mechanical

Trial
KW KW Efficiency

Average

COMPUTATIONS:

OBSERVATIONS:

CONCLUSIONS:

18
Page

18
 Republic of Philippines
Iloilo Science and Technology University
Burgos St., La Paz Iloilo City

College of Engineering and Architecture

Mechanical Engineering Department

REPORT NO. 07
TEST ON REFRIGERATION UNIT

OBJECTIVE:

To be able to determine the performance of a vapor compression system.

THEORIES AND PRINCIPLES:

The story of refrigeration is the story of heat, its effects on substances, its effects

on pressure and temperature. Heat is nevertheless a difficult quantity to measure or

even define. Off hand we might say that heat and temperature are the same, but this is

not true. In fact, the refrigeration process is based on the premise that temperature is
not only the indicator of heat.

Refrigeration is defined as a thermodynamic process of removing heat from s

substance at a temperature below that on its immediate surroundings. This

characteristic gives refrigeration a wide range of applications, which have revolutionized

the lives of man and his convenience.

Major Uses of Refrigeration:

1. Food storage and distribution industry

2. Food processing-dairy products, beverages, etc.

3. Chemical process industry-separation of gases, condensation of gases,

solidification of substances, etc.

4. Drinking fountain

5. Dehumidifiers
19
Page

19
 6. Ice making

7. Ice skating rinks

8. Construction

9. Desalting sea water

10. Air-conditioning

INSTRUMENT AND APPARATUS:

Pressure gages
Temperature gages

Refrigerant flow meter

Calibrated tank

Platform scale
Stopwatch

Hydrometer
Revolution counter

Clamp ammeter
U tube manometer

Voltmeter
Graduated cylinder

Barometer

PROCEDURE:

1. Check and fill-up water in cooling tower.

2. Check and fill-up all ice cans inside brine tank.

3. Check all electrical systems.

4. Check oil level in the compressor sight glass.

5. Check and open valve in cooling water lines.

6. Switch ON main breaker.
20
Page

20
 7. Run cooling water pump and observe if water is circulating in condenser, by

watching if water is flowing from the top of the cooling tower.

8. Check if cock valve at manometer topping in brine discharge piping is closed.

Then run brine pump motor.

9. Check if brine is circulating by opening simultaneously both cock valve at

manometer topping or if done, open the approach cock valve through the
discharge cock valve. Observe if mercury level in manometer changes.

10. Open all valves, service valves at refrigerant piping system. These are valves SV1,
SV2, SV3. (SV-normally closed; TEX-normally opened)

11. Run compressor motor and observe for any unnecessary noise while a brine plant
is in operation.

12. Allow one-hour operation before actual testing to ensure stabilized and uniform
condition.

13. Get necessary data and record.

14. Record all readings in the log sheet every 30 or 60 minute interval.

DATA AND RESULTS:

1. Type of compressor and kind refrigerant.

2. Type of compressor valve.

3. Method of driving compressor.

4. Method of volume control.

5. Discharge gage pressure.

6. Diameter of compressor cylinder.

7. Stroke of piston
8. Rated speed

9. Number of cylinder
10. Rated displacement

11. Plant output, TOR

21
Page

21
12. Type of condenser

13. Area of condenser surface on refrigerant side

14. Type of evaporator

15. Area of evaporator surface on refrigerant side

16. Type of water pump

17. Size of water pump

18. Type of brine pump

19. Size of brine pump

20. Types of cooling tower

21. Composition of brine

22. Specific gravity of brine

23. Specific gravity of water used

24. Duration of test

25. Barometer pressure

26. Pressure by gage in discharge pipe near cylinder

27. Condenser pressure by gage

28. Pressure inlet of cooling water pump

29. Pressure outlet of cooling water pump

30. Pressure inlet of brine pump

31. Pressure outlet of brine pump

32. Dry bulb temperature of Atmospheric Air

33. Wet bulb temperature of Atmospheric Air

34. Temperature of liquid from condenser

35. Temperature of condenser cooling water, in

36. Temperature of condenser cooling water, out

37. Temperature of water to cooling tower

38. Temperature of water from cooling tower

39. Temperature of brine out of brine cooler

40. Temperature of brine entering brine cooler
22
Page

22
41. Amount of brine circulation
42. Amount of cooling water, condenser

43. Refrigerating effect

44. Tons of refrigeration

45. Total number of revolutions of compressor

46. Average piston speed

47. Brake power supplied by motor

48. Theoretical power to compress adiabatically

49. Theoretical power to compress by formula

50. Volumetric efficiency

51. Compression efficiency

52. Mechanical efficiency

53. Heat removed by cooling water in condenser

54. Heat removed from refrigerant by condenser

55. Log mean temperature difference of condenser

56. Coefficient of heat transfer of condenser

57. Heat removed per minute from brine

58. Log mean temperature difference of evaporator

59. Coefficient of heat transfer of condenser

60. Gross or Bhp of brine pump

61. Water HP of brine pump

62. Overall efficiency of brine pump

63. Gross or Bhp of cooling water pump

64. Water HP of cooling water pump

65. Overall efficiency of cooling water pump

23
Page

23
REFERENCES

Practical Marine Engineering by Reno C. King 2nd Edition

Marine Engine Room Blue Book by Paterson 2nd Edition

Power Plant Testing by Moyer 4th Edition

PSME CODE 2003

KENT’S Mechanical Engineers Handbook by Salisbury 14th Edition

Steam Boiler Operation by James J. Jackson 2nd Edition

Boiler Rooms Questions and Answers by Stephen Elonka 2nd Edition

24
Page

24