DESIGN AND FABRICATION OF SMALL STEAM GENERATOR

A Research Partial Proposal Presented to the Faculty of the College of

Engineering and Industrial Technology

Northwest Samar State University

Main Campus, Calbayog City

As a Required for the Subject of Research 1 in Degree

Bachelor of Science in Mechanical Engineering

Presented by
Jade M. Animo
Primo M. Javate II
Clemente Ace B. Macorol
Glen L. Malanog
Jerald O. Malobo
Winlan L. Sale

School Year 2018-2019

 Chapter 1

Introduction

In the present scenario, universities are improving, levelling up and also increasing

the schools standards. The advancement in teaching makes the school better. The

providence of complete apparatus or equipment for the laboratory purposes is really good

for the students. This enables the students to learn faster and make them study easier.

Although this makes the school expensive for study, it will still be good for the students.

This is a good opportunity for those who can afford the expenses and this may be unfair

to those who cannot. In the Philippines, which is a poor country, those coming from a rich

family can afford to go to a high level university and those who are bright students can

become scholars of the university. There are students who cannot afford not because

they are not smart enough, but because they came from poor families and do not have

money for the expenses.

Our school, an improving university, lacks laboratory equipment on testing like

steam engine, boiler, and condenser. In most engineering subjects, students are solving

problems and study on equipment, yet do not know what these look like. Although these

are seen on the internet, students cannot actually figure them out and results to lack of

knowledge on these equipment. Even if the students know how to solve written problems

about those equipment, if they lack knowledge on handling them, this is disadvantageous

for them in the future. There are students who are good on actual operations or hands on

rather than written or oral. Students can fully show their intelligence if the required

equipment will be provided.

 With this problem in the university, the researchers come up with the idea to make

a prototype design of one of these lacking equipment, particularly, a prototype small

steam generator. It can be used for testing and laboratory purposes. A steam generator

is very relevant in mechanical engineering. It is but fitting and appropriate that the

students have knowledge about it, both in written and hands on operations.

A steam generator is heat exchangers used to convert water into steam from heat

produced in a nuclear reactor core. They are used in pressurized water reactors (PWR)

between the primary and secondary coolant loops. The knowledge from this steam

generator is very important to the mechanical students. The steam generator covers

many sub-topics that are encountered in the semester. The steam generator is a great

help for the students to learn.

Objectives

The main objective of this study is to develop a device that can be used for testing

and experiments. In order to achieve this, the following approach should be obtained.

1. To design and fabricate a small steam generator that can be used for testing and

laboratory purposes.

2. To test and evaluate the steaming capability of the boiler.

3. To develop a laboratory manual and experiment procedures.

Significance of the study

This study provides significant knowledge for the following beneficiaries:

Researchers. This study will attest to their acquisition of knowledge particularly

in their major field thus coming up with a generator.

Mechanical Engineering students. The result of this study will make the students

learn about how the steam generator works and they can also use this as equipment for

their laboratory.

NwSSU. The result of this study will provide the school equipment for mechanical

engineering student that is useful for experiment and laboratory purposes.

Scope and limitations of study

The researchers concentrated on the design of fabricating the steam generator

that the future mechanical engineering students can use it for their laboratory. Steam

generator generates steam. The boiler can handle up to 15-20psi. This study is limited

for laboratory purposes of the students. The main purpose of this study is for future

mechanical engineering students for them to know what the mechanism is and how does

a steam generator works.

Definition of terms

This part of the chapter discusses the definitions of the terms that used in this

research. These definition of terms are operational.

Steam- in our study this refers to the product that is being produced by the boiler

through boiling the water up to its boiling temperature.

Gate Valve- in our study this device is for controlling the flow of fluids. This is used

to open and close the system.

Water Pump- in our study this device is used to feed or deliver the water to the

boiler. It raises the water from low elevation to higher elevation from the water tank to the

boiler.

Boiler-in our study this device is used to convert water to steam through boiling

the water up to its boiling point. It produces a high pressured steam for power production

or by any means.

Boiler tubes – in our study boiler tubes are metal tubes located inside of boilers

that heat water in order to produce steam. In our study which is a fire tube boiler, the

produced heat from the furnace passes through the tubes and transfer the heat to the

water in order to boil the water inside the shell.

 Chapter 2

Related Literatures and Studies

Related Literatures

Some school universities are now lack of funds to use for the expenses like for

the laboratory equipment and some engineering students still do not know how to use it.

Some mechanical engineering students still do not know how to use these laboratory

equipment like for example the researcher’s study which is the steam generator and we,

the researchers conducted a review of related studies and literatures about steam

generator.

According to Robert Morgan (2017), the different types of steam generator are fire

tube boilers, water tube boilers, combustion heat generator, heat recovery steam

generator, nuclear power plant steam generators and solar power steam generators. Fire

tube boilers is the initial steam generators, also called boilers, required a fire box for the

fuel. The water tube boilers came about so that the steam generated could be produced

at a higher pressure. And the combustion heat generator follow a similar heat exchange

concept as the tube boilers, but can product even higher pressures for power. These are

used mainly in power plants producing electricity. While the heat recovery steam

generator or heat exchanger, recovers the high pressure hot gas steam and utilizes that

steam after running it through a chain of heat exchanges to run other lower-powered

machines. And the nuclear power plant steam generators have two types the Boiling

Water Reactor where the water is turned into steam within the nuclear reactor itself and

run to the turbine outside the containment area and Pressurized Water Reactor where
water is pressurized in excess of 100 bar and there is no water boiling process inside the

reactor. And the last type is the solar power steam generators, solar power steam

generators are the cleanest source of boiling water. The water is run through tubes inside

a solar panel.

From the study of Robert Morgan the researchers come up to decide what type of

boiler should be designed and be fabricated. This helps the researchers to identify the

different types of steam generators.

Related Studies

In addition that the study and analysis on boiler tubes for performance

enhancement with varying corrugated tube shapes by Shivasheesh Kaushik (2017) that

says heat transfer improvement through corrugated tubes has been taken into study. By

varying the influencing geometrical parameters of the corrugated tubes like rifling, height

if rifling, and length of the pitch of rifling etc. it is easy to study the performance of

geometry of corrugated tubes. Flow through the tube of heat exchanger was determined

by the effects of different geometry of the corrugated tube such as triangular etc. The

change in the shape of corrugated tubes gave the significant change in heat transfer. The

result unveils that heat transfer rate is increased when it is compared with the inner plane

wall of the water tube.

This related study, the study and analysis on boiler tubes for performance

enhancement with varying corrugated tube shapes by Shivasheesh Kaushik et al (2017)

says that the change in the shape of corrugated tubes gave the significant change in heat
transfer. This helps the researchers to determine what shape of tube that must be used.

The researchers will use cylindrical boiler tubes.

Meanwhile the study of Sung-Keun Cho et al (2006) that the steam generators in

a pressurized water reactor (PWR) are large heat exchangers that use the heat from the

primary reactor coolant to make steam on the secondary-side to drive turbine

generators. Hoop stress is known to be the main cause of fracture of inner

pressurized tubes such as the steam generator tube. However, because the steam

generator tube is too small to be manufactured to a standard tensile specimen in

the hoop direction, the axial tensile properties of the steam generator tube

(or original material properties) instead of hoop tensile properties have been

used to estimate the fracture properties of a steam generator tube. In this study,

we have conducted not only axial tensile tests but also ring tensile tests. From

these test, both the axial and hoop tensile properties of steam generator tubes

were obtained, and the reliability of the hoop tensile properties were confirmed

by burst test of a real steam generator tube.

These study the evaluation of hoop tensile properties of a steam generator by

Sung-Keun Cho et al (2006) they study the hoop stresses in the steam generator tubes.

This study helps us to choose what type of material of the boiler tubes we must use in the

fabrication of the small steam generator to avoid bursting of the tubes.

In addition with that Herminé Nalbandian Sugden (2011) that the coal quality,

which is the properties of coal, has an impact on many parts of a power plant including

the coal handling facilities, pulverizing mills, boiler, air heater, ESP, ash disposal as well

as stack emissions. Coals have different characteristics and heat content. The behavior
of a coal in a boiler is strongly influenced by its rank and by the mineral matter and other

impurities associated with it. Coal properties can affect the efficiency, reliability and

availability of both the boiler and the emissions control units. Therefore they affect the

economics as well as the short- and long-term operation of the plant. Expert systems are

used today in many aspects of power generation. The first step in the application of expert

systems for coal quality assessment is to ensure that the sampling procedures used are

as accurate and precise as is possible. This then provides a representative sample for

the subsequent analysis. Online analyzers can show variations in coal quality as they are

occurring. However, online analyzers can be expensive and their cost-effectiveness

depends on the site and application. Despite questions about the accuracy of online

analyzers being raised, their use in coal mines as well as power plants continues to

increase. The operation of coal-fired power plants involves multiple variables which have

different levels of importance. A key contributor to an overall expert system is the method

used to optimize the coal combustion in the boiler. This is affected by coal quality, boiler

cleanliness and equipment deterioration as well as by the even distribution of the

pulverized fuel to the burners. Expert systems for assessing coal quality and its

implications for power generation have been and continue to be developed.

This study Expert systems and coalquality in power generation by Herminé

Nalbandian Sugden (2011) says that coal quality mainly affects the efficiency of the boiler.

This study helps us to know what fuel and quality of fuel we must use in the operation of

the steam generator to achieve more efficient steam generator.

 Chapter 3

Materials and Methods

This chapter of the study describes the diagram of operation, materials used and

methods. A part of this chapter discusses the mechanism and operation of the fire tube

steam boiler.

Methods

The development of the design

INPUT PROCESS OUTPUT

Lacks of  Design and fabricate a Designed and fabricated

laboratory small steam generator small steam generator

equipment that that can be used for

can be use by testing and laboratory

mechanical purposes.

engineering  Test and evaluate the

students. steaming capability of

the boiler.

 Develop a laboratory

manual and experiment

procedures.
Figure 3.1 Design Process
The development of the design starts with the lack of laboratory equipment which is the

problem that the researchers are trying to solve. The purpose is to design and fabricate

a small steam generator. After the design is fabricated various test and evaluation will

be done to the boiler. If this steam generator operates properly the main goal of the

researchers is accomplished.

Research design

This study uses the experimental method of research. This helps the researchers

to come up with the design of a small steam generator. The researchers gathered data

from the internet about steam generators. The researchers collected some images and

designs of about steam generators. Through the images or models and data that have

been collected the researchers agreed the design which is a vertical fire tube boiler. The

researchers shared their ideas and come up this design. This research which is the design

and fabrication of vertical fire tube boiler will be fully functional and the results will be

known after the design is fully fabricated.

To design and develop a small steam generator

To develop the design of small steam generator through the book of Jas Tordillo

Second edition the researchers came up the possible formulas that can be used for

developing a small steam generator. The small steam generator designed by selecting

the applicable materials for construction.

For the Tensile strength of the Materials

A. Circumferential or tangential stress (hoop stress)

 Thin-wall cylinder

𝑃𝐷𝑖 𝑃𝑟1
Sy = =
2𝑡 𝑡

B. Longitudinal stress

𝑃𝐷𝑖 𝑃𝑟1
ST = =
4𝑡 2𝑡

P = internal pressure

Di = inside diameter

t = wall thickness

St = tangential (tensile) stress

r1 = inner radius

 Thick wall cylinder

𝑡
> 0.07
𝐷

 Lames equation for internal pressure

𝐷 𝑠𝑡 + 𝑃𝑖
t= [(√ ) − 1]
2 𝑠𝑡 − 𝑃𝑖

t = wall thickness

D = inside diameter

St = tangential or tensile stress

 Pi = internal pressure

These formulas helps the researchers to identify the thickness and strength of the boiler

tubes to be used to avoid bursting.

 When subjected to internal and external pressure maximum tangential stress in

the inside:

𝑃𝑖 (𝑟𝑜2 +𝑟𝑖2 )−2𝑃𝑜 𝑟𝑜2

Sti =
𝑟𝑜2 −𝑟𝑖2

 Maximum tangential stress at the outside:

2𝑃𝑖 𝑟𝑖2 −𝑃𝑜 (𝑟𝑜2 +𝑟𝑖2 )

Sto =
𝑟𝑜2 −𝑟𝑖2

Pi = internal pressure

Po = external pressure

ri = inside radius

ro = outside radius

These formulas helps the researchers to determine the maximum pressure that

the boiler can operate without failure.

 For the heat transfer at the surface of the boiler conduction through the plane wall:

𝐾𝐴 (𝑡𝑎 −𝑡𝑏 )
Q=
𝑥
 Q = heat transmitted, w

A = heat transfer area, m2

ta = surface temperature on hot side, °𝐶

tb = surface temperature on cold side, °𝐶

k = thermal conductivity, W/m - °𝐶

These formulas helps the researchers to determine the maximum amount of heat

transferred to the surface of the boiler.

Fabrication of small steam generator

To fabricate the small steam generator, the researchers used the following

materials for construction: pressure gauge, angle steel bar, bolts and nuts, label glass,

boiler tube, metal plate, water pump, valve and for installation we used the welding

machine to weld the area that is not fix. The researchers decided to use gas as fuel and

burner to produce fire for boiling the water.

Testing and evaluation for the performance of small steam generator

For the testing and evaluation of the small steam generator, the researchers will

conduct a testing of the fuels that will be used for each fuel. The researchers will collecting

the data after the test is done in the evaluation form.

The following formulas are can be used to determine some of the values in the

evaluation form:
For the FE (Factor Evaporation)

ℎ𝑠−ℎ𝑓
FE = 2257

For the thermal efficiency of the boiler

𝑚𝑠 (ℎ𝑠 −ℎ𝑓 )
Boiler thermal efficiency = 𝑚𝑓 𝑄ℎ

FE = Factor of Evaporation

𝑘𝐽
hs = enthalpy of steam; ⁄𝑘𝑔

𝑘𝐽
hf = enthalpy of feed water; ⁄𝑘𝑔

𝑘𝑔⁄
ms = rate of evaporation of steam; ℎ𝑟
𝑘𝑔⁄
mf = mass of fuel; ℎ𝑟
These formulas determine the performance of the steaming capability of the boiler.

Materials

Boiler tube - is metal tubes located inside of boilers that heat water in order to

produce steam. There are two major types of tube boilers, the water-tube boilers and fire-

tube boilers.
 Boiler plate- originally referred to the rolled steel used to make boilers to heat

water.

Bolts, Nuts and washers- are used in several applications, with a primary

function to hold things or components together. A bolt, also known as a screw, does not

always have to be used together with a nut; however, a nut is always used together with

a bolt.
 Angle steel bar- also known as “L-bar”, “L-bracket” or “angle iron, is a metal in the

form of a right angle. An angle bar is a steel material which is an angle shape with inside

radius corners that is ideal for all structural applications.

Pressure gauge- instrument for measuring the condition of a fluid (liquid or gas)

that is specified by the force that the fluid would exert, when at rest, on a unit area, such

as pounds per square inch or newton per square centimeter.

 Column Glass - a label glass is used on a steam boiler to reduce the turbulence

and fluctuation of the water level so the gage glass can provide a steady, accurate water

level reading. The use of a water column is not mandatory.

Safety Valve- A safety valve is a valve that acts as a fail-safe. An example of

safety valve is a pressure relief valve (PRV), which automatically releases a substance

from a boiler, pressure vessel, or other system, when the pressure or temperature

exceeds pre-set limits.

 Gate Valve - Gate valves are primarily designed to start or stop flow, and when a

straight-line flow of fluid and minimum flow restriction are needed. In service, these valves

generally are either fully open or fully closed.

Gas Burner - A gas burner is a device that produces a controlled flame by mixing

a fuel gas such as acetylene, natural gas, or propane with an oxidizer such as the

ambient air or supplied oxygen, and allowing for ignition and combustion.

Asbestos Gasket - Gaskets prevent pipes and machinery from leaking by sealing

the tight spaces in between metal parts, making them essential components of the

industrialized world. Modern gasket manufacturers now use a number of heat-resistant

substitutes for asbestos, but workers still commonly encounter the toxic mineral when

taking apart old engines or industrial machinery.

Pressure regulators - Pressure regulators are valves that automatically cut off

the flow of a gas when it is at a certain pressure. Regulators are also used to allow high-

pressure fluid supply tanks or lines to be reduced to a usable and safe pressure for

different applications.

Insulation Foam – Insulation foams are used to cover the shell and insulates heat,

and to avoid high temperature in a certain area.

Nipples - a small projection on a device or machine, especially one from which oil, grease,

or other fluid is dispensed in small amounts.

PVC Pipe – Pvc or polyvinyl chloride is commonly used for plumbing and drainage.

Hose - A hose is a long plastic or rubber tube that's used for moving a liquid from one

place to another, or to get water from the pump into the boiler.
 Chapter 4

This chapter discusses the presentation of data acquired during experimentation as well as

the analysis of the output in relation to the objectives presented for the verification of the

functionality and stability of the prototype.

RESULTS AND DISCUSSION

4.1 Hydro testing

The researchers conducted a hydro test to check the integrity of boiler and with the help

of this test, the pressure tightness, strength and any leakages are checked and the researchers

concluded that there is no leakage found.

4.2 Pressure test

The researchers conducted a pressure test to check the integrity of the pressure shell by

40psi pressure into the vessel and there is no leakage found.

4.3 Testing the source using LPG tank

Table 4.3.1 Testing the source using LPG tank with normal pressure regulator

The researchers tested to produce fuel into the boiler using LPG tank with normal

pressure if it is enough to boil and produce steam with a 10-15psi pressure in an earlier

time. However, the testing failed because of its insufficient produced fuel by a LPG tank

with normal pressure. So the researchers decided to provide a high pressure regulator

for LPG tank.

Table 4.3.2 Testing the source using LPG tank with high pressure regulator
 The researchers decided to use LPG tank regulator with high pressure to produce

more flame that will boil the boiler. The researchers put the pressure of regulator into

“note : to be decided”. However, the testing still failed to produce steam in an earlier time

because of the fire still did not reach boiler fuel conductor.

Table 4.3.3 Testing the source using LPG tank with high pressure regulator and

bronze tube

The researchers come up with the idea by using a bronze tube as conductor for

flow of fire. The researchers designed the bronze tube by having drilled holes for the fire.

And for this time the researchers succeed their test and produce a steam for an earlier

time with a pressure of “note: to be decided”.

Test Mass Pressure Mass flow rate of Factor Boiler

number flow steam produced Evaporation Efficiency

rate of (kg/s)

fuel

(kg/s)

3
 Appendix

Material Cost

No. Qty Unit Description Unit cost Total

1 4x8 ft BI steel 3000 3000

plate

2 4x8 ft GI steel 3850 3850

plate

3 36 pcs Nuts 3 108

4 36 pcs washers 3 108

5 6 kg Welding 107 642

rod

6 3/16x2 inches Angle bar 620 620

7 1 pc Safety 280 280

valve

8 1 pc Pressure 375 375

gauge

9 3x3 ft Insulation 256 256

10 6(120) pc(ft) GI tubes 650 3900

11

12

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