Instructional Module: Republic of The Philippines Nueva Vizcaya State University Bayombong, Nueva Vizcaya

Republic of the Philippines
NUEVA VIZCAYA STATE UNIVERSITY

Bayombong, Nueva Vizcaya
INSTRUCTIONAL MODULE
IM No.: ME21-1S-2021-2022
College: COLLEGE OF ENGINEERING

Campus: BAMBANG CAMPUS
DEGREE Bachelor of Science in COURSE NO. ME 21

PROGRAM Mechanical Engineering
SPECIALIZATION COURSE TITLE Power Plant Engineering
th
YEAR LEVEL 4 Year TIME FRAME 6hrs WK NO. 1-2 IM NO. 02
I. UNIT TITLE/CHAPTER TITLE: Boilers and Boiler Heat Balance Calculations
II. LESSON TITLE:
1. Introduction
2. Boiler types
3. Parts of a steam generator
4. Auxiliaries and accessories of a boiler
5. Definitions from PSME CODE of 2008.
6. Boiler Calculations
III. LESSON OVERVIEW: This module gives the students an in-depth understanding on the types of Boilers
and its accessories as well as Heat Balance calculations.
IV. DESIRED LEARNING OUTCOMES:
1. Identify the types of boilers, parts, and its accessories.

2. Evaluate the performance of a Steam generator.
V. LESSON CONTENT:
1. INTRODUCTION
Steam is extensively used for various applications such as power production, industrial processes, work
interaction, heating etc. With the increasing use of steam in different engineering systems the steam
generation technology has also undergone various developments starting from 100 B.C. when Hero of
Alexandria invented a combined reaction turbine and boiler.
Boiler, also called steam generator is the engineering device which generates steam at constant
pressure. It is a closed vessel, generally made of steel in which vaporization of water takes place. Heat
required for vaporization may be provided by the combustion of fuel in furnace, electricity, nuclear
reactor, hot exhaust gases, solar radiations etc.
2. BOILER TYPES
2.1 Classification according to the contents of the tubular heating surface.
Fire-tube boilers – are those in which the products of combustion pass through the tubes and the water
lies around the outside of them.
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the copyrighted works included in this material may be reproduced for educational
purposes only and not for commercial distribution”
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IM No.: ME21-1S-2021-2022
Water-tube boilers – are those in which the water is inside the tubes while the products of combustion
surround the tubes.
2.2. Classification according to:
a. Shape of the tubes

1. Straight tube - have a parallel group of straight equal-length tubes, arranged in a uniform pattern
and joined at either end to headers.
2. Bent-tube - are header less. The drum serve the same function as the headers.
b. Drum position
1. Longitudinal
2. Cross
c. Method of Water Circulation

1. Forced
2. Natural
3. PARTS OF STEAM GENERATOR
3.1 Pressure parts
Boiler heating surface – tubes with attached drums or shells for storage of water and steam.
Superheated surface – provides more heating surface through which the steam must pass after leaving
the boiler if a final superheated state is desired.
Economizer – is a feedwater pre-heating device which utilizes steam mixed with the feedwater.
3.2 Enclosure or setting
Water walls – water tubes installed in the furnace to protect furnace against high temperature.
Furnace – encloses the combustion equipment to utilize effectively the heat generated.
3.3 Combustion equipment
Burner – used in fire-tube boilers for firing liquid and gaseous fuels.
Stoker – used in water-tube boilers for firing solid fuels
4. AUXILIARIES AND ACCESSORIES
a. Air preheater – a heat exchanger utilizing the heat of the flue gases to pre-heat the air needed for
combustion.
b. Forced-draft fan – forces air inside to support fuel combustion
c. Induced-draft fan – usually situated at the bottom of the chimney or smokestack, it is responsible in
extracting flue gases out.
d. Soot blower – removes soot around steam pipes developed because of combustion, employs the
use of extracted steam from the main steam line.
e. Blowdown valve – valve through which the impurities that settle in the mud drum are removed; also
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called blow-off valve.
f. Breeching – duct connecting boiler to chimney.
g. Baffles – direct the flow of the hot gases to effect efficient heat transfer between the hot gases and
the heated water.
h. Fusible plug – a metal plug with a definite melting point through which the steam is released in case
of temperature which is usually caused by low water level.
i. Safety valve – a safety device which automatically releases the steam in case of over-pressure.
5. DEFINITIONS FROM PSME CODE 2008
Boiler or Steam Generator – a closed vessel intended for use in heating water or for application of heat
to generate steam or another vapor to be used externally to itself.
Coal-Fired Boiler – used stoked water temperature coal or pulverized coal for water-tube.
Condemned Boiler Unfired Pressure Vessel – a boiler or unfired pressure vessel that has been inspected
and declared unsafe to operate or disqualified, stamped and marked indicating its rejection by qualified
inspecting authority.
Existing Installations – any boiler or unfired pressure vessel constructed, installed, placed in operation
but subject to periodic inspection.
External Inspection – an inspection made on the external parts, accessories and/or component even
when a boiler or unfired pressure vessel is in operation.
Gas-Fired Boiler – uses natural gas or liquefied petroleum gas (LPG) for heating boiler, fire tube or water
tube.
Heat-Recovery Steam Generator – unfired pressure vessel that uses flue gas heat.
Internal Inspection – an inspection made when a boiler or unfired pressure vessel is shut-down and
handholes, manholes, or other inspection openings are opened or removed for inspection of the interior.
Locomotive Boiler – a boiler mounted on a self-propelled track locomotive and used to furnish motivating
power for traveling on rails.
Low Pressure Heating Boiler – a boiler operated at a pressure not exceeding 1.055 kg/cm2 gage steam
water temperature not exceeding 121 C.
Medium Pressure Heating Boiler – a boiler operated at a pressure not exceeding 103.5 MPa gage steam,
or water temperature not exceeding 130 C.
Miniature Boiler – as used in this Code herein mean any boiler which does not exceed any of the following
limits:
405 mm inside diameter, 1065 mm overall length of outside of heads at center, 1.85 m2 of water
heating surface, 7.03 kg/cm2 maximum allowable working pressure.
New Boiler or Unfired Pressure Vessel Installation – include all boilers and unfired pressure vessels
constructed, installed, placed in operation or constructed for.
Oil-fired Boiler – uses Bunker C as fuel for heating boiler and power boiler.
Portable Boiler – an internally fired boiler which is self-contained and primarily intended for temporary
location and the construction and usage is obviously portable.
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Power Boiler – a closed vessel in which steam or another vapor (to be used externally to itself) is
generated at a pressure of more than 1.055 kg/cm2 gage by the direct application of heat.
Reinstalled Boiler or Unfired Pressure Vessel – a boiler or unfired pressure vessel removed from its
original setting and re-erected at the same location or erected at a location without change of ownership.
Secondhand Boiler or Unfired Pressure Vessel – as used herein shall mean a boiler or unfired pressure
vessel of which both the location and ownership have been changed after primary use.
Unfired Pressure Vessel – a vessel in which pressure is obtained from an external source, or from an
indirect application of heat.
Waste-Heat Boiler – unfired pressure vessel that uses flue gas heat from waste incinerator.
Waste Tube Boiler – a boiler where heat is applied outside the tube.
6. BOILER CALCULATIONS
(a) Heat required to form steam, Qa
Refer to figure 6.1, by energy balance
Ein = Eout
Qabsorbed + mwh1 = msh2
Qa = ms(h2 - h1), kJ Figure 6.1
m w = ms
where:
h2 = specific enthalpy of steam, kJ/kg
h1 = specific enthalpy of feedwater, kJ/kg
mw = mass of water, kg
ms = mass of steam, kg
(b) Energy received from the fuel, Qf
Qf = mf(HHV)
where:
mf = mass of fuel, kg
HHV = heating value of fuel, kJ/kg
(c) boiler thermal efficiency
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(d) equivalent evaporation of a boiler
Since some boilers can be operated under many different running conditions then, for these boilers, it is
necessary to have some standard upon which to base and compare their respective evaporation
capacities. The standard commonly adopted is that the equivalent evaporation of a boiler from and at
100 oC.
From this, the amount of water at 100 oC which could be evaporated into dry saturated steam at 100 oC,
if supplied with amount of energy is then determined. This is then called the equivalent evaporation (EE)
of the boiler from and at 100 oC.
The specific enthalpy of evaporation at 100 oC = hfg = 2257 kJ/kg
Then,
𝑚𝑠 (ℎ2 − ℎ1)
EE = = ms(FE)
2257
ℎ2 − ℎ1
FE =
2257
where:
FE – factor of evaporation
(e) Equivalent specific evaporation, ESE
ms EE
ESE = FE =
mf mf
(f) Rated Boiler Horsepower (Rated Bo Hp)
Rated Bo Hp = Total Heating Surface / k
where:
k = 12 sq ft = 1.1 sq m for fire-tube boilers
k = 10 sq ft = 0.91 sq m for water-tube boilers
(g) Developed Boiler Horsepower (Dev Bo Hp)
ms (hs − h fw ) ASME EU
Dev Bo Hp = =
c c
where:
c = 33,475 Btu/hr = 35,322 kJ/hr = 8,433 kcal/hr = 1 Bo.Hp
(h) Percent Rating Developed (% Rating Dev)
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Dev Bo Hp
% Rating Dev = 100
Rated Bo Hp
Example Problem 6.1. Determine the actual evaporation per kg of coal and the equivalent evaporation if
during boiler trial of one-hour duration following observations are made:
Feed water supply temperature: 27C
Mean steam generation pressure: 10 bar,
Dryness fraction of steam generated: 0.95
Feed water supplied: 2500 kg/hr
Coal burnt: 275 kg/hr
Mass of water in boiler after trial = 300 kg less than that at commencement of trial.
Example problem 1. A boiler is being tested for 24 hours and during this trial steam at average pressure
of 10 bar, dry saturated is produced from 15 ton of water consuming 1.5 ton of coal. Composition of coal
has 3% moisture and 4% ash. Feed water is added at 35°C. Determine,
(i) the boiler efficiency,
(ii) the equivalent evaporation per kg of dry coal, and
(iii) the equivalent evaporation per kg of combustible present in coal.
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Example Problem 2. During the boiler trial for 24 hours following observations were made.
Steam generation: 16 bar, dry saturated.
Coal consumed: 10,000 kg
Rate of steam generation: 2500 kg/hr
Feed water temperature: 27C
Total heating surface area: 3000 m2
Total grate area: 4m2
Calorific value of coal: 28000 kJ/kg
Determine:
(i) the mass of coal burnt per m2 of grate per hour
(ii) the equivalent evaporation from and at 100C per kg of coal
(iii) the equivalent evaporation from and at 100C per m2 of total heating surface per hour
(iv) the boiler efficiency
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Example problem 3. Steam is generated in a boiler at 30 bar 300C at the rate of 11 kg/s with feed water
entering economizer at 100C. During one-hour test 5000 kg fuel is used in boiler. Calorific value of fuel
is 35000 kJ/kg. For the feed water being supplied to boiler to be at 27°C determine.
(i) the equivalent evaporation per kg of fuel
(ii) the boiler efficiency
(iii) the percentage of fuel energy utilized in economizer
Example problem 4. A boiler can generate 8 kg steam per kg of fuel at 400C. Feed water is supplied at
pressure of 30 bar, 40C and leaves economizer at 150C for entering to evaporator. Steam leaves
evaporator with dryness fraction of 0.98 and enters the superheater. Fuel used has calorific value of
29000 kJ/kg. Considering no pressure loss inside the boiler determine boiler efficiency and fraction of
heat given to steam in each section of boiler.
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Example problem 5. A boiler unit generates steam at 20 bar, 300°C from feed water supplied to boiler at
50°C. Coal used in boiler has calorific value of 30,000 kJ/kg and is used at rate of 600 kg/hr for steam
generation rate of 5000 kg/hr. Determine the overall efficiency of boiler and the equivalent evaporation
of boiler unit at 100°C in kg/hr. Determine the saving of coal in kg/hr if an economizer fitted to boiler to
raise feed water temperature up to 75°C increases the overall efficiency of boiler unit by 5% for all other
things remaining same.
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Example problem 6. A boiler generates 5000 kg/hr steam at 20 bar, 0.98 dry from feed water supplied to
it at 60°C. Boiler sums on coal supplied at the rate of 600 kg/hr and air supplied at the rate of 16 kg per
kg coal. The calorific value of coal is 30000 kJ/kg and boiler room temperature is 20°C. Considering 86%
of heat being lost with flue gases. Determine temperature of flue gases leaving boiler. Take specific heat
of flue gases as 1.005 kJ/kg·K.
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Example problem 7. In a boiler installation feed water enters at 30°C and leaves economizer section at
110°C for being fed into boiler. Steam generated in boiler at 20 bar, 0.98 dry and fed to super heater
where its' temperature is raised up to 300°C. For the coal with calorific value of 30,500 kJ/kg and steam
generation rate of 10kg/kg of coal burnt determine the energy received per kg of water and steam in
economizer, boiler, and superheater section as fraction of energy supplied by coal. Take C p, feedwater =
4.18 kJ/kg·K, Cp, superheated steam = 2.093 kJ/kg·K.
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VI. LEARNING ACTIVITIES
1. What are the parts of a steam generator. Give a brief definition.

2. What are the auxiliaries and accessories of a boiler/steam generator? Give a brief definition.
VII. EVALUATION (Note: Not to be included in the student’s copy of the IM)
VIII. ASSIGNMENT
Problem solving. Solve the following problems systematically. Put your answer in a rectangle.
1. A boiler has equivalent evaporation of 1300 kg/hr from and at 100C. The fuel consumption per hour is
159.5 kg/hr and the boiler efficiency is 72%. Determine actual equivalent evaporation if feed is supplied
at 110C to generate steam at 100 kg/m2 per hour and 15 bars, 200C. Also find calorific value of coal
burnt and the grate area.
[1255 kg/hr, 25498 kJ/kg, 12.6 m2]
2. Determine equivalent evaporation per kg of coal and efficiency of boiler when it consumes coal at the
rate of 52 kg/hr and steam is generated at 7 bar, 0.907 dry, 541.7 kg/hr from feed water supplied at 40C.
[11.075 kg per kg of coal, 83.3%]
3. During a boiler trial for 24 hour the following is observed;

Steam generated = 160000 kg
Mean steam pressure = 12 bar
State of steam generated = 0.85
Feed water temperature = 30C
Coal burnt = 16000 kg
C.V. of coal = 33400 kJ/kg
Determine equivalent evaporation from and at 100_C and efficiency of boiler.
[10.45 kg/kg of coal, 70.65%]
4. Steam is generated at 100000 kg/hr from a boiler at 100 bars, 500C with feed water supplied at 160C.
The fuel burnt in boiler has calorific value of 21000 kJ/kg and boiler efficiency is 88%. Determine rate of
fuel burnt per hour and percentage of total heat absorbed in economizer, evaporator, and superheater.
[14592 kg/hr, 27.09%, 48.84%, 24.07%]
5. Compare the steam generation capacities of two boilers A and B for which operating parameters are,
Steam generation pressure = 14 bar, feed water temperature = 27C, Specific heat of feed water = 41.8
kJ/kgK, Specific heat of steam = 2.1 kJ/kgK,
For boiler A:
State of steam = 0.9 dry
Boiler efficiency = 73%
Calorific value of coal = 34000 kJ/kg
For boiler B:
State of steam = 240C
Boiler efficiency = 79.5%
Calorific value of coal = 46000 kJ/kg
[For boiler A 10 kg/kg of coal burnt, for boiler B 14 kg/kg of coal burnt]
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IX. REFERENCES
Nagpal, G.R. (2006). Power Plant Engineering (15th Edition). Nath Market, Nai Sarak Delhi: Khanna
Publisher
Nag, P.K. (2008). Power Plant Engineering (3rd Edition). New Delhi. McGraw Hill
Onkar Singh (2009). Applied Thermodynamics (3rd Edition). New Delhi: New Age International Publishers
Disclaimer: This document does not claim any originality and cannot be used as a substitute for prescribed
textbooks. This information presented here is merely a collection by the faculty member for his respective
teaching assignments. Various sources as mentioned at the end of the document as well as freely available
material from the internet were consulted for preparing this document. The ownership of the information lies
with the respective authors or institutions. Further, this document is not intended to be used for commercial
purpose and the faculty member is not accountable for any issues, legal or otherwise, arising out of use of
this document. The faculty member makes no representations or warranties with respect to the accuracy or
completeness of the contents of this document and specifically disclaim any implied warranties of
merchantability or fitness for a particular purpose.
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Republic of the Philippines

NUEVA VIZCAYA STATE UNIVERSITY

College: COLLEGE OF ENGINEERING

DEGREE Bachelor of Science in COURSE NO. ME 21

I. UNIT TITLE/CHAPTER TITLE: Boilers and Boiler Heat Balance Calculations

II. LESSON TITLE:

IV. DESIRED LEARNING OUTCOMES:

1. Identify the types of boilers, parts, and its accessories.

2.1 Classification according to the contents of the tubular heating surface.

2.2. Classification according to:

a. Shape of the tubes

c. Method of Water Circulation

3. PARTS OF STEAM GENERATOR

3.1 Pressure parts

3.2 Enclosure or setting

3.3 Combustion equipment

Stoker – used in water-tube boilers for firing solid fuels

4. AUXILIARIES AND ACCESSORIES

b. Forced-draft fan – forces air inside to support fuel combustion

called blow-off valve.

f. Breeching – duct connecting boiler to chimney.

5. DEFINITIONS FROM PSME CODE 2008

(a) Heat required to form steam, Qa

Refer to figure 6.1, by energy balance

Qabsorbed + mwh1 = msh2

Qa = ms(h2 - h1), kJ Figure 6.1

(b) Energy received from the fuel, Qf

(c) boiler thermal efficiency

(d) equivalent evaporation of a boiler

The specific enthalpy of evaporation at 100 oC = hfg = 2257 kJ/kg

(e) Equivalent specific evaporation, ESE

(g) Developed Boiler Horsepower (Dev Bo Hp)

VI. LEARNING ACTIVITIES

1. What are the parts of a steam generator. Give a brief definition.

[11.075 kg per kg of coal, 83.3%]

3. During a boiler trial for 24 hour the following is observed;

[10.45 kg/kg of coal, 70.65%]

[14592 kg/hr, 27.09%, 48.84%, 24.07%]

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