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

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

1
 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.

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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.

2
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.

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IV. QUESTIONS AND ANSWERS:
A. What is a steam boiler?
- A steam boiler is a container in which water is heated to produce steam.
Steam turbines generally require high-pressure steam boilers, so you have the
maintenance of the boiler system as well as their turbine to consider. A steam
boiler is a container in which water is heated to produce steam.
B. What is the difference between a fire-tube boiler and a water-tube boiler?
- The main difference between fire tube and water tube is that in fire tube boiler
the flue gases flow in the tubes and water flows from the shell and in water tube
boiler, water flows from the tubes and the flue gases from the shell or passes over
the tubes. This is the key difference between these boilers.

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

Advantage:
 Fire tube boiler is in simple design and has a low maintenance cost.
 Less skilled operation are sufficient for efficient operation.
 Fire tube boiler can be used in small industry.
 Treatment of feed water is not very essential in fire tube boiler.
 No pure feed water is required in FTB, So cost can be minimized because pure
feed water is costly.
 For the same power output, the cost of a fire tube boiler is less as compared to a
water tube boiler.

Disadvantage:
 The maximum working pressure of fire tube boiler is up to 20 bar.
 Overall efficiency is up to 75%
 It requires more floor area for a given output.
 Load fluctuation cannot be easily handled.
 The rate of steam generation and quality of steam for suitable power generation
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are not much better than the water tube boiler.

 This is used in small power plants.

D. What are the advantages and disadvantages of wate r-t u be boilers?

(BOILER AND LOEFFLER BOILER.)
Advantage:
 The maximum working pressure of water tube boiler is 250 bar.

4
  Overall efficiency is up to 90% with an economizer.
 It requires less floor area for a given output.
 Load fluctuation can be easily handed.
 The rate of steam generation and quality of steam for suitable power generation
are much better.
 This can be used in large power plants.
 The direction of water circulation is well defined.

Disadvantage:
o Complex design and High maintenance cost.
o A skilled operator is required for operation.
o This is used in large power plants and it is uneconomical for use in small industry.

o For the same power output, the cost of a water tube boiler is high.
o Treatment of feed water is very essential in water tube boiler as small-scale
deposits inside the tube can cause overheating and bursting.

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

1. Furnace - A furnace is a device used for high- temperature heating.
2. Dry pipe - A dry pipe sprinkler system is one in which pipes are filled with
pressurized air or nitrogen, rather than water. This air holds a remote valve,
known as a dry pipe valve; in a closed position Water then enters the pipe,
flowing through open sprinklers onto the fire.
3. Super heater - A super heater is a device used to convert saturated steam or wet
steam into superheated steam or dry steam. Superheated steam is used in steam
turbines for electricity generation, steam engines, and in processes such as
steam reforming. There are three types of super heaters: radiant, convection,
and separately fired.
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4. Safety valve - a valve opening automatically to relieve excessive pressure,

especially in a boiler.
5. Soot blower - A soot blower is a device for removing the soot that is deposited
on the internal furnace tubes of a boiler during combustion to prevent plugging
of the gas passes and maintain boiler efficiency.
6. Steam gage - is a Python-based web app driven by Flask.

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7. Fusible plug - is a threaded metal cylinder usually of bronze, brass or gunmetal,
with a tapered hole drilled completely through its length.
8. Gas baffles - Baffles are flow-directing or obstructing vanes or panels used in
some industrial process vessels (tanks), such as shell and tube heat exchangers,
chemical reactors, and static
9. Damper - A damper is a valve or plate that stops or regulates the flow of air
inside a duct, chimney, VAV box, air handler, or other air -handling equipment.
10. Economizer - Economizers, or economizers, are mechanical devices intended to
reduce energy consumption, or to perform useful function such as preheating a
fluid. The term economizer is used for other purposes as well. Boiler, power
plant, heating, refrigeration, ventilating, and air conditioning uses are discussed
in this article.
11. Gage glass - A sight glass or water gauge is a type of level sensor, a transparent
tube through which the operator of a tank or boiler can observe the level of
liquid contained within.
12. Steam and water drum - A steam drum is a standard feature of a water-tube
boiler. It is a reservoir of water/steam at the top end of the water tubes. The
drum stores the steam generated in the water tubes and acts as a phase
separator for the steam/water mixture.
13. Mud drum - a drum beneath a boiler, into which sediment and mud in the water
can settle for removal.
14. Main steam stop valve - A main steam stop valve is a valve usually connected
directly to the boiler for the purpose of shutting off the steam from the main
steam line.
15. Bottom blow valve - Bottom blow down involves periodically opening valves in
the mud drum to allow boiler pressure to force accumulated sludge out of the
boiler. Similar blow down connections at the bottom of water wall headers are
blown down less frequently.
16. Headers - In automotive engineering, an exhaust manifold collects the exhaust
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gases from multiple cylinders into one pipe. The word manifold comes from the
Old English word manigfeald and refers to the folding together of multiple inputs
and outputs.
17. Hydrokineter - A device for circulating the water in a steam-boiler while the fire
in the furnace is being started, or when natural circulation or convection is
inadequate.

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 18. Salinometer cock - A valve fitted to the water drum to allow samples to be taken.
Cooling coil fitted for high pressure boilers.
19. Try cocks - one of two or more cocks arranged one above the other to ascertain
the water level in a steam boiler
20. Auxiliary steam stop valve - Certain fittings are necessary on a boiler to ensure its
safe operation. They are usually referred to as boiler mountings.
21. Water walls - are membrane walls that are made of tubes welded together with
or without a strip of metal in between. Water wall tubes are also referred to as
the evaporator section; they contain water mostly in liquid form which gradually
evaporates as it rises in the boiler.
22. Desuperheater - is used to take out the excess heat from superheated steam to
bring down the steam temperature to saturation level.
23. Air -preheater - is any device designed to heat air before another process (for
example, combustion in a boiler) with the primary objective of increasing the
thermal efficiency of the process. They may be used alone or to replace a
recuperative heat system or to replace a steam coil.
24. Steam trap - is a device used to discharge condensates and non-condensable
gases with a negligible consumption or loss of live steam. Most steam traps are
nothing more than automatic valves. They open, close or modulate automatically
.
25. Day tank - Day tanks are designed to reliably provide fuel oil storage for
emergency generators or boilers. The day tanks are a complete package with all
the required instrumentation and pumping equipment mounted to the day tank

REFERENCES:
Practical Marine Engineering 2nd edition
By: Reno C. King

Marine Engine Room Blue Book

7
Page

By: William B. Paterson

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 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.
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The boiler is equipped with automatic ignition and low-water level switch that operates
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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:

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 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

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
9
Page

Practical Marine Engineering

By: Reno C. King

9
 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
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temperatures.
Page

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:

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 Marine Engineering FT Boiler
Measuring tape
Vernier caliper

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

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Fire-tubes
Page

Furnace

End Plates

Total Surface Area

Boiler Horsepower

11
CONCLUSION:

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
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Steel rule
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Pressure gages
Tachometer
Test drum
Multi tester
Thermometer
Clamp-on ammeter

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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:
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8. Capacity of fuel tank:

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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:

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 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:
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Republic of Philippines

14
 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
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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

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 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

26. Pounding
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27. Crank pin

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28. Valve travel

29. Flywheel
30. Relief valve

III. Define the following steam engineering terminologies:

1. Steam line

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 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:

3. Horizontal Corliss steam engine

Bore diameter:
Length of stroke:
Piston rod diameter:
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OBSERVATION:

CONCLUSION:

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

College of Engineering and Architecture

Mechanical Engineering Department
18

REPORT NO. 06
Page

STEAM ENGINE OPERATION

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

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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

DATA RESULTS:

Trial 1 Trial 2

Gross weight

Tare weight

Speed

Pressure
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TABULATED RESULTS:
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Table 6.1 Indicated Power

LHE LCE AHE AHE Pmi IpHE IpCE
Trial
(mm) (mm) (mm2) (mm2) (kpa) (KW) (KW)
1

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 2

Average

Table 6.2 Brake Power

Gross Brake Rotational
Tare weight, Brake power,
Trial weight, Fg in weight, FB in speed, N
Ft in kg KW
kg kg (rpm)
1

Average

Table 6.3 Mechanical Efficiency

Indicated Power Brake Power Mechanical
Trial
KW KW Efficiency
1

Average

COMPUTATIONS:
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OBSERVATIONS:
Page

CONCLUSIONS:

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 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
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pressure and temperature. Heat is nevertheless a difficult quantity to measure or even define.
Page

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

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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

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
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Clamp ammeter
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U tube manometer
Voltmeter
Graduated cylinder
Barometer

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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.

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.
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2. Type of compressor valve.

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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

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9. Number of cylinder
10. Rated displacement
11. Plant output, TOR

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
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33. Wet bulb temperature of Atmospheric Air

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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

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40. Temperature of brine entering brine cooler

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
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64. Water HP of cooling water pump

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65. Overall efficiency of cooling water pump

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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

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