MODULE 1

Steam Generating Unit

and its auxiliaries
 INTRODUCTION

This module presents the steam boiler, boiler components and its auxiliaries. Contained in this
module are definitions, classifications and major components of boiler, basic boiler room valves and
identification, the purpose and procedure of boiler blowdown. The main purpose of this module is for
you to be familiar with different types of steam boiler and for you to learn how to operate and test the
fire tube boiler in our laboratory room.

LEARNING OUTCOMES
.

After studying the module, you should be able to:

1. Demonstrate knowledge about steam boilers by explaining the operating principle, and by
enumerating, describing and differentiating the different classification or types of steam
boiler,
2. Enumerate the boiler components and auxiliaries and describe the functions of each.
3. Identify boiler room valves and symbols.
4. Operate a firetube boiler.

 DIRECTIONS/ MODULE ORGANIZER

This module is divided into three lessons. Lesson 1 deals with the definition and classifications
of boiler, lesson 2 covers the boiler components, terminology and boiler room valves while lesson 3
presents the procedure of operating firetube boiler and troubleshooting tips. Each lesson contains an
activity or a research questions for you to accomplish. Make sure to submit the exercises on time
according to our schedule. At the end the module, you are required to report to school to conduct an
experiment where in you are going to operate and test the firetube boiler in our laboratory room.
LESSON 1: STEAM BOILER CLASSIFICATIONS

 Steam Boiler

What is steam boiler?

A boiler can be defined as a closed vessel in which water or other fluid is heated under pressure. This fluid
is then circulated out of the boiler for use in various processes or power generation. In the case of power generation
steam is taken out of the steam boiler at very high pressure and temperature.

Classification of Steam Boilers

Boiler classification can be based on many factors like usage, fuel fired, fuel firing system, type of
arrangement etc. Commonly known types are pulverized coal fired boilers, fluidized bed boilers, super critical
boilers, oil and gas fired boilers. All cater to industrial and power generation.
From 200 B.C. to date, many developments have taken place that today allow us to classify steam boilers in
different ways. Hence steam generating boilers can be classified under various categories. The main purpose of
steam boilers is to generate steam, and so the way in which the steam is generated and consumed forms the major
category. The major two groups of boiler application are Industrial steam generators and power generation boilers.
Boilers are also classified as fire tube and water tube boilers.

Fire tube Boiler. In fire-tube boilers, combustion gases pass through the inside of the tubes with water
surrounding the outside of the tubes. The advantages of a fire-tube boiler are its simple construction and less rigid
water treatment requirements. The disadvantages are the excessive weight-per-pound of steam generated,
excessive time required to raise steam pressure because of the relatively large volume of water, and inability to
respond quickly to load changes, again, due to the large water volume. he most common fire-tube boilers used in
facility heating applications are often referred to as ''scotch'' or ''scotch marine'' boilers, as this boiler type was
commonly used for marine service because of its compact size (fire-box integral with boiler section). The name
"fire-tube" is very descriptive. The fire, or hot flue gases from the burner, is channelled through tubes that are
surrounded by the fluid to be heated. The body of the boiler is the pressure vessel and contains the fluid. In most
cases, this fluid is water that will be circulated for heating purposes or converted to steam for process use.

Figure 1: 3 Pass Wetback Boiler Fig 2. 4 Pass Wetback Flue Passes

Fire-tube boilers are:

 Relatively inexpensive
 Easy to clean
 Compact in size
 Available in sizes from 600,000 btu/hr to 50,000,000 btu/hr
 Easy to replace tubes
 Well suited for space heating and industrial process applications

Disadvantages of fire-tube boilers include:

 Not suitable for high pressure applications 250 psig and above
 Limitation for high capacity steam generation

Fire tube boilers have almost become extinct; however this can be classified as
Cornish boiler. The earliest form of fire-tube boiler was Richard Trevithick's "high-pressure" Cornish boiler. This
is a long horizontal cylinder with a single large flue containing the fire. The fire itself was on an iron grating placed
across this flue, with a shallow ashpan beneath to collect the non-combustible residue.

Lancashire boiler. The Lancashire boiler is similar to the Cornish, but has two large flues containing the fires. It was
the invention of William Fairbairn in 1844, from a theoretical consideration of the thermodynamics of more efficient
boilers that led him to increase the furnace grate area relative to the volume of water.

Scotch marine boiler. The Scotch marine boiler differs dramatically from its predecessors in using a large number
of small-diameter tubes. This gives a far greater heating surface area for the volume and weight. The furnace
remains a single large-diameter tube with the many small tubes arranged above it. They are connected together
through a combustion chamber – an enclosed volume contained entirely within the boiler shell – so that the flow
of flue gas through the firetubes is from back to front.

Locomotive boilers. The locomotive boiler is an inactive boiler which is used in train engines. This type of boiler
is capable while producing steam as well as it is solid. The design of the locomotive boiler is horizontal multi
tubular. The main advantage of using this type of boiler is low cost for construction, installation and steam capacity
is high.

Vertical fire-tube boiler. A vertical fire-tube boiler (VFT), colloquially known as the "vertical boiler", has a
vertical cylindrical shell, containing several vertical flue tubes.

Horizontal return tubular boiler. Horizontal return tubular boiler (HRT) has a horizontal cylindrical shell,
containing several horizontal flue tubes, with the fire located directly below the boiler's shell, usually within a
brickwork setting.

Admiralty-type direct tube boiler. Extensively used by Britain, before and in the early days of ironclads, the
only protected place was below the waterline, sometimes under an armoured deck, so to fit below short
decks, the tubes were not led back above the furnace but continued straight from it with keeping the
combustion chamber in between the two.

Immersion fired boiler. The immersion fired boiler is a single-pass fire-tube boiler that was developed by Sellers
Engineering in the 1940s. It has only fire tubes, functioning as a furnace and combustion chamber also, with
multiple burner nozzles injecting premixed air and natural gas under pressure. It claims reduced thermal stresses,
and lacks refractory brickwork completely due to its construction.
Water tube Boiler. In a water-tube boiler ('''Figure 3'''), the water is inside the tubes and combustion gases pass
around the outside of the tubes. The advantages of a water-tube boiler are a lower unit weight-per-pound of steam
generated, less time required to raise steam pressure, a greater flexibility for responding to load changes, and a
greater ability to operate at high rates of steam generation. A water-tube design is the exact opposite of a fire-tube.
Here, the water flows through the tubes and is encased in a furnace in which the burner fires. These tubes are
connected to a steam drum and a mud drum. The water is heated and steam is produced in the upper drum. Large
steam users are better suited for the water-tube design. The industrial water-tube boiler typically produces steam
or hot water primarily for industrial process applications, and is used less frequently for heating applications. The
best gauge of which design to consider can be found in the duty in which the boiler is to perform.

Fig 3. D Type Industrial Water -tube Boiler Fig 4. Water-tube Boiler

Water-tube boilers:

 Are available in sizes far greater than a fire-tube design , up to several million pounds-per-hour of steam
 Are able to handle higher pressures up to 5,000 psig
 Recover faster than their fire-tube cousin
 Have the ability to reach very high temperatures

Disadvantages of the water-tube design include:

 High initial capital cost

 Cleaning is more difficult due to the design
 No commonality between tubes
 Physical size may be an issue

Water tube boiler can be classified depending on type of circulation used to generate steam as
Natural circulation boiler. In natural or thermal circulation type boilers, the rate of circulation depends strongly
on the density difference between the unheated water and the heated steam-water mixture. The overall circulation
rate (flow) in natural circulation systems mostly depends on the following factors: the height of the boiler,
operating pressure of the boiler, and the heat input rate of the boiler.
Forced circulation boilers. A forced circulation boiler is a boiler where a pump is used to circulate water inside
the boiler. This differs from a natural circulation boiler which relies on current density to circulate water inside
the boiler. In some forced circulation boilers, the water is circulated twenty times the rate of evaporation.

Super critical pressure boilers or zero circulation boilers. A supercritical boiler is a type of boiler that operates
at supercritical pressure, frequently used in the production of electric power. a supercritical steam generator
operates at pressures above the critical pressure – 22 megapascals (3,200 psi). Therefore, liquid
water immediately becomes steam. Water passes below the critical point as it does work in a high
pressure turbine and enters the generator's condenser, resulting in slightly less fuel use.

Depending on type of firing adopted in boilers they can be classified as

 Stoker fired.
 Pulverized coal fired.
 Down shot fired.
 Fluidized bed boilers.
 Cyclone fired.
 Chemical recovery boilers.
 Incinerators.

Boilers can be classified based on the type of fuel used as:

 Coal fired boilers

 Oil fired boilers
 Gas fired boilers
 Multi-fuel fired
 Industrial waste fired boilers
 Biomass fired boilers

Classified based on the arrangement as

 Top supported boilers

 Bottom supported
 Package boilers
 Field erected boilers
 Drum type boilers
 Tower type or single pass
 Close coupled
 Two pass boilers

Steam and Condensate Boiler System. In steam and condensate systems, heat is added to water in a boiler
causing the water to boil and form steam. The steam is piped to points requiring heat, and as the heat is transferred
from the steam to the building area or process requiring heat, the steam condenses to form condensate. In some
very low-pressure saturated steam heating applications, the steam distribution piping may be sized to slope back
to the boiler so that the steam distribution piping also acts as the condensate return piping (single-pipe system).
 Figure 5: Steam and Condensate Boiler System

In other low-pressure applications, there may be steam supply piping and condensate return piping (two-pipe
system), although the condensate system is open to the steam system. In typical packaged steam boiler operations,
the boiler system may generate steam at about 150 psig for distribution throughout the facility and may be lowered
to the operating pressure of equipment supplied through point-of-use pressure reducing stations. As heat is
transferred from the steam, condensate is formed which collects in discharge legs until enough condensate is
present to operate a trap that isolates the steam distribution system from the condensate system. In common facility
heating applications, the condensate system is at atmospheric pressure and the system is arranged to drain the
condensate to a central condensate receiver, or into local smaller receivers that pump the condensate back to the
central condensate receiver.

RESEARCH QUESTIONS

1. What are the fundamental trade-offs in the design of boiler? Discuss each.
2. What is the difference between external furnace fire tube boiler and internal furnace fire tube
boiler? Show illustration
LESSON 2. BOILER SYSTEM MAJOR COMPONENTS

Boiler systems are comprised of the major components described below and shown in Fig below:

Figure 6: Boiler Room Schematic

Feedwater Heaters. Feedwater heaters are energy recovery devices generally found only in large steam generating
plants where all of the steam generated is not reduced to condensate by the steam user. This "waste steam" is
reduced to condensate for return to the boiler in the feedwater heater. The boiler feedwater is used as
a cooling medium to reduce the steam to condensate, which increases the temperature of the feedwater and,
thereby, increases the thermal efficiency of the boiler.

Fuel Heater. Many boilers firing heavy fuel oil require fuel heaters to reduce the fuel viscosity, so the fuel can be
atomized by the burner system for complete combustion.

Deaerators. A deaerator is a special case of feedwater heater that is designed to promote the removal of non-
condensable gases from the boiler feedwater. The principal gases of concern are oxygen, carbon dioxide, and
ammonia, which are major contributors to boilers, and steam and condensate piping corrosion problems. In small
steam plants, a portion of the steam generated by the boiler is used to operate the deaerator if "waste steam" is not
available. Failure to maintain and properly operate the deaerator can lead to early failure of the boiler, steam using
equipment, and the steam and condensate piping.

Pumps. In most hot water systems, the system circulating pumps are electric motor-driven, end suction centrifugal
pumps. In steam systems, the condensate return pumps are typically electric motor-driven, end suction, centrifugal
or turbine-type pumps. Feedwater pumps are generally electric motor-driven, multiple-stage, end suction
centrifugal pumps. The shutoff head of the pump must be greater than the steam or hot water system
operating pressure.

Combustion Air Blowers. In many packaged boiler installations, the combustion air fan is designed and provided
by the boiler manufacturer and is integral with the boiler housing. In installations where a stand-alone fan is
provided, low-pressure centrifugal blowers are commonly used. An important characteristic of the blower is the
ability to maintain a relatively constant air pressure over a wide range of airflows.
Flue. Flues (boiler firebox exhaust duct or boiler discharge stack) must be large enough to conduct the products
of combustion away from the boiler with a minimum of duct friction loss. Flues may be fabricated from any
material suitable for the operating temperature and pressure. Common materials of construction associated with
packaged boiler installations are carbon steel and stainless steel.

Economizer. An economizer is an energy recovery device that uses the hot exhaust gases from the boiler (waste
heat) to heat combustion air or feedwater.

Steam Traps. Steam traps are installed throughout steam systems to remove condensate (spent steam), air, and
non-condensable gases from the steam system. There are five types of steam traps in general use today, as
described below.

Piping. Piping two-inches and smaller used in steam and hot water systems is typically Schedule 80, American
Society for Testing and Materials (ASTM) A 106, Standard Specification for Seamless Carbon Steel Pipe for
High-Temperature Service (1999), Grade B, steel pipe with threaded joints and carbon steel fittings. Piping larger
than two-inches is typically standard weight, ASTM A 106, Grade B, steel pipe with flanged joints and carbon
steel fittings.

Boiler Room Definition/Terminology

There are many terms used in a discussion of boilers, the following is a list of some of the most common
terms. There is a glossary provided that covers some of the other terms that may be also used. This section also
contains some of the basic valves that are used on boiler and boiler systems, along with some of the
common HVAC and piping symbols.

Boiler and Heating Terms

BTU – British thermal unit; the amount of energy required to raise one pound of water one degree Fahrenheit.
Boiler- An enclosed vessel in which water is heated and circulated, either as hot water or as steam, for heating
or power. A container, such as a kettle, is used for boiling liquids. In our context, a boiler is "a piece of heating
equipment that is used to heat water for use in a hot water-based heating system." Examples of hot water-based
heating systems include under-floor radiant heat, baseboard hot water, and radiator-based systems. A ''furnace''
is a piece of heating equipment that is used in a hot air-based heating system to heat the air that is circulated
through the ductwork.

Burner- One that burns, especially:

 A device, as in a furnace, stove, or gas lamp, that is lighted to produce a flame

 A device on a stovetop, such as a gas jet or electric element that produces heat
 A unit, such as a furnace, in which something is burned such as an oil burner
 An incinerator

AFUE- Annual Fuel Utilization Efficiency, a standard government rating for energy efficiency.
Anode Rod- A sacrificial metal used to protect against corrosion in a hot water heater.
Baseboard Heating - Heating elements around the perimeter of a room used to give off heat produced by hot
water circulating through them.
Blower- A unit used with a furnace to circulate air through a network of ducts.
BTU/h - (British Thermal Units per hour) a standard rating for heat transfer capacity.
Cast Iron- A durable metal with an exceptional capability to hold and transfer heat.
Chimney Venting- A vertical vent used to transfer exhaust products from a boiler or furnace to the outdoors.
Combustion - The process of converting fuel into heat; requires oxygen.
 Convective Heat- The natural circulation of air across a heat source to heat the air.
Direct Vent- A boiler design where all the air for combustion is taken from the outside atmosphere and all
exhaust products are released to the outside atmosphere, also known as sealed combustion.
Draft Hood- A device that prevents a backdraft from entering the heating unit or excessive chimney draw
from affecting the operation of the boiler or furnace.
Efficiency Rating- The ratio of heat actually generated versus the amount of heat. Theoretically possible from
the amount of fuel inputted.\
Flue- The passageway that takes combustion exhaust from the combustion chamber to the flue collector and
venting system.
Forced Hot Air- A furnace system using a blower to circulate air from within the home through the furnace
and back into the home (as opposed to gravity circulation).
Furnace- An enclosure in which energy in a non-thermal form is converted to heat, especially such an
enclosure in which heat is generated by the combustion of a suitable fuel.
Heater- An apparatus that heats or provides heat.
Heat Exchanger- The part of the boiler or furnace used for transmitting heat from the flame to air or water for
heating.
Heating Capacity- The amount of usable heat produced by a heating unit.
Hot Water Boiler- A heating unit that uses water circulated throughout the home in a system of baseboard
heating units, radiators, and/or in-floor radiant tubing.
Hot Water Heater- A unit with its own energy source that generates and stores hot water.
Hydronics- The science of heating or cooling with water.
Indirect Hot Water Storage Tank- A unit that works in conjunction with a boiler to generate and store domestic
hot water, it does not require its own energy source.
In-Floor Radiant Tubing- Tubing, typically plastic or rubber, used in conjunction with heated boiler water to
heat floors.
Low-boy- A term used to describe a furnace that has a low profile. The blower is located on the same level
plane as the heat exchanger.
Low Water Cut-off'- A device used to shut down a boiler in the event of a low water condition exists.
Natural Gas- Any gas found in the earth (e.g., methane gas) as opposed to gases which are manufactured.
Oil Heating- The production of heat by burning oil.
Propane- A manufactured gas typically used for cooking or heating.
Push Nipples- Metal sleeves used to join adjacent sections of a boiler.
Radiant Heating - The method of heating the walls, floors, or ceilings in order to transfer heat to the occupants
of a room.
Radiator- A heating element, typically metal, used in conjunction with water or steam to give off heat.
Sealed Combustion - A boiler design where all the air for combustion is taken from the outside atmosphere
and all exhaust products are released to the outside atmosphere, also known as ''direct vent.
Steam Boiler- A heating unit designed to heat by boiling water, producing steam, and circulating it
to radiators or steam baseboard units throughout the home.
Supply Tapping- Opening in a boiler by which hot water enters the heating system.
Tankless Heater- A copper coil submerged into the heated boiler water used to transfer heat to domestic water.

Basic Boiler Room Valves and Identification

The following valves are the most common valves found on boilers and boiler systems. Each type is briefly
discussed.
Butterfly Valves. A butterfly valve is composed of two semi-
circular plates hinged on a common spindle, used to permit flow
in one direction only. Butterfly valves are of the quarter-turn
family and are so designed because a 90-degree turn of the
operator fully opens or closes the valve.

The valve uses elastomer seats and seals and their surge in
popularity can be attributed to these advantages. In some cases,
they may be used for non-critical throttling applications. They
are lighter in weight than conventional valves. The position of
the lever indicates whether they are wide open, partially open,
or fully closed.

Butterfly valves are compact and space-saving and easily

installed in new piping or as replacements in existing piping. Figure. 7. Butterfly Valve
They are easily adapted to lever, manual, gear, electric, or
pneumatic operation.

Gate Valves. Gate valves are, by far, the most widely used in
industrial piping. They are used as stop valves – to fully shut off
or fully turn on flow – the only job for which gate valves are
recommended. Gate valves are inherently suited for full open
service. Flow moves in a straight line and practically without
resistance when the wedge is fully raised. There are two basic
designs of gate valves: inside screw stem and outside screw
stem.

Seating is perpendicular or at right angles to the line of flow –

meets it head on. That is one reason why gate valves are
impractical for throttling service. When throttling is
necessary, globe valves should be used. Repeated movement of
the wedge near the point of closure, under high velocity flow,
may create a drag on the seating surfaces and cause galling or
scoring on the downstream side. A slightly opened wedge may
also cause turbulent flow with vibration and chattering of the
wedge.
Figure 8. Gate Valve
A gate valve usually requires more turns to open it fully. Also,
unlike many globe valves, the volume of flow through the valve
is not in direct relation to the number of turns of the hand-wheel.

Globe Valves. Unlike the perpendicular seating in gate valves,

globe valve seating is parallel to the line of flow.

All contact between seat and disc ends when flow begins. These
are advantages for more efficient throttling of flow, with
minimum wire drawing and seat erosion. Valve disks and seats
in most globe valves can be conventionally repaired or replaced
– often without removing the valve body from the line.

Shorter disk travel, with fewer turns required to operate globe

valves, saves considerable time and work, also wear on valve
parts.
Figure 9. Globe Valve
 Check Valves. Check valves are designed to automatically
prevent the reversal of flow in a pipeline system. They control
the direction of flow, rather than throttling or isolating flow as
other valve designs do. Reverse flow may create problems or it
could cause damage to equipment. Check valves are sometimes
known as ''reflux'' valves.

Figure 10. Check Valve

Pressure Relief Valves. Pressure relief valves are designed to

open automatically at a pre-determined set pressure level of
system pressure and to achieve a rated relieving capacity at a
specified pressure and temperature above the setpoint
(overpressure) before re-closing at a pressure below the opening
point (blowdown). The simplest and most reliable type of
pressure relief valve, even some four-hundred years on from the
first design, is the spring-loaded design where a spring force
opposes the system pressure acting on the valve disc. When the
system pressure rises above the level of the spring force, the
valve opens. This valve type may also be fitted with a bellows
for better emission control performance.

Regulating Valve. Regulating valves are used in many systems

on a boiler from feed flow to fuel flow. Regulators attempt to
manage flow by adjusting the flow area available to the fluid.
Most designs incorporate a plug or similar element that occupies
a portion of a stationary orifice while throttling. In an action Figure 11. Spring-Type Pressure Relief
often called ''modulation'', the plug or similar element is shifted Valve
to increase or decrease available flow area. Flow through a
particular size of open orifice area is primarily dependent upon
the available pressure difference.

Boiler Blowdown. Blowdown of steam boilers is very often a highly neglected or abused aspect of routine boiler
room maintenance. The purpose of boiler blowdown is to control solids in the boiler water. Blowdown protects
boiler surfaces from severe scaling or corrosion problems that can result otherwise.

There are two types of boiler blowdowns: ''continuous'' and ''manual''.

A continuous blowdown uses a calibrated valve and a blowdown tap near the boiler water surface. As the name
implies, it continuously takes water from the top of the boiler at a predetermined rate. A continuous blowdown
is an optional feature and may not be included on your steam boiler; however, all steam boilers should include
a means for manual blowdown as standard equipment.

Manual blowdowns are accomplished through tapings at the bottom of the boiler. These openings allow for the
removal of solids that settle at the bottom of the boiler. Manual blowdown is also used to keep water level
control devices and cutoffs clean of any solids that would interfere with their operation. All steam boilers
require manual blowdown whether or not they are supplied with continuous blowdowns.
Frequency of Manual Blowdown. When continuous blowdown is used, manual blowdown is primarily used to
remove suspended solids or sludge. The continuous blowdown removes sediment and oil from the surface of the
water along with a prescribed amount of dissolved solids. When surface or continuous blowdown is not used,
manual blowdown is used to control the dissolved or suspended solids in addition to the sludge.In practice, the
valves of the bottom blowdown are opened periodically in accordance with an operating schedule and/or chemical
control tests. From the standpoint of control, economy, and results, frequent short blows are preferred to infrequent
lengthy blows. The length and frequency of the blowdown is particularly important when the suspended solids
content of the water is high. With the use of frequent short blows, a more uniform concentration of the pressure
vessel water is maintained. In cases where the feedwater is exceptionally pure, or where there is a high percentage
of return condensate, blowdown may be employed less frequently since less sludge accumulates in the pressure
vessel. When dissolved and/or suspended solids approach or exceed predetermined limits, manual blowdown to
lower the concentrations is required. It is generally recommended that a steam boiler be blown down at least once
in every eight-hour period, but frequency may vary depending upon water and operating conditions.

Proper blowdown is performed as follows:

1. Blowdown should be done with the boiler under a light load.

2. Open the blowdown valve nearest the boiler first. This should be a quick-opening valve.
3. Crack open the downstream valve until the line is warm. Then open the valve at a steady rate to drop the
water level in the sight glass 1/2 inch. Then close it quickly being sure that the handwheel is backed off
slightly from full close to relieve strain on the valve packing.
4. Close the valve nearest the boiler.

Repeat the above steps if the boiler has a second blowdown tapping. Water columns should be blown down at
least once a shift to keep the bowls clean. Care should be taken to prevent low water shutdown if this will affect
process load.

Blowdown Purpose. The purpose of blow down is to control the amount of solids and sludge in the boiler water.
The blow down process involves partially draining the boiler to remove sludge and to maintain pre-determined
concentration levels of solids. As the water is turned into steam, the solids remain behind. Unless there is 100%
condensate return, the solid content tends to build up when the boiler takes on make-up water. On hot water
systems, there is generally no make-up water. Therefore, the solid concentration remains constant and no blow
down is needed.

RESEARCH QUESTIONS

1. Discuss at least five types of steam traps that are generally use in boilers today.,
2. Illustrate and discuss ate least 3 basic designs of check valves.
3. Illustrate and discuss the two basic kinds of relief valves
4. Differentiate direct operated regulator and pilot operated regulator.
5. Illustrate the basic boiler room valves identification symbols
LESSON 3. STARTING UP AND SHUTTING DOWN THE BOILER

Starting up the Boiler:

1. Check water level of feed water tank. Be sure that water is sufficient in the entire system.
2. Check fuel system of burner. Mark the fuel level indicated in the Fuel tank sight glass.
3. Check valves of the entire system. Position them according to their specified positions. Valves are
labelled according to their operational use.
4. After checking all the parameters above, power on the boiler Main Control Panel (MCP).
5. Position the feed water pump switch to auto mode.
6. Position the buzzer selector switch to on position. The buzzer sounds if the water level controller
detects low water level in the boiler.
7. Be sure that the air vent valve is open. This is to expel all air from the steam shell.
Note: Before starting the burner always check the normal water level of boiler. The quality of steam
produced is low if the water level is higher than normal. Since the water day tank is installed
at a higher elevation than the boiler vessel, if the boiler is at zero pressure, water can enter into
the boiler from the day tank through gravity. Therefore, always check water level of boiler
before starting up the burner. If the water level is higher than normal, open the blow-down
valve to discharge excess water. The feed water pump starts automatically at low water level
to fill the boiler with water then automatically shuts off when normal water level is achieved.
Close the blow-down valve as soon as the feed water pump starts.
8. Switch on the burner. The burner starts running following the sequence specified in item III.
9. Record the burner starting time.
10. Verify boiler pressure setting. For example:
Boiler maximum pressure setting - 45 Psi
Initial differential setting - 15 Psi
Boiler cut-in pressure setting - 30 Psi
11. When steady flow of steam from the air vent is observed, close the air vent valve. Take note that
pressure starts to build up in the steam shell as indicates in the steam pressure gauge.
12. The burner automatically shuts off upon reaching the maximum setting pressure and automatically
starts at minimum or cut-in setting pressure.
13. Record the pressure reading, stack gas temperature reading and the time as the burner shuts off.
14. Mark the fuel level as indicated in the sight glass of the fuel tank.
15. The whole system operates continuously as specified above unless the burner switch is manually
turned off.

Shutting down the boiler:

1. Power off the burner selector switch.

2. Let the power supply of the main control panel on until no more pressure can be read from the boiler
pressure gauge. This may take more than 24 hours. This is to let the feed water pump feed the
condensate of the boiler even it is no longer running. It will also safeguard the boiler tubes.
3. If the boiler will not be used for a longer period, fill completely the boiler shell with water so that no
air space is inside the boiler. Oxygen in air causes serious corrosion on both the shell and the tubes.

Trouble Shooting. Follow the following troubleshooting tips when the identified problems are encountered.

1. Burner does not start

Solution: - Check limit controller
- Reset pressure controller
- Check water level controller
- Check warrick contact
- Push burner reset button.
2. Burner runs but not firing
Solution: - Check fuel supply, bleed the fuel pump
 - Check ignition rod spacing. Adjust if necessary
- Check ignition transformer
- Wipe flame eye with dry cloth
- Check burner controller
3. Burner runs but not stable
Solution: - Check and adjust air:fuel ratio of burner
4. High stack temperature
Solution: - Check and adjust air:fuel ratio of burner
- Reduce boiler pressure
- Reduce air opening of blower
NOTE: In adjusting air:fuel ratio, Adjust the fuel inlet and air opening one at a time.
5. Feed water pump is not pumping
Solution: - Check overload relay of FWP. Reset.
- Bleed the pump if pressure is unstable to release unnecessary air inside the pump.

 LEARNING ACTIVITY

Follow the following parts in writing your laboratory report. Use the formatted paper of the college.

I. Drawing/Set up: Draw the boiler set available in the laboratory room.Label its parts.

II. Methods and Procedures: Operate the boiler following the procedures discuss in our lesson, copy the
procedure here.

III. Data and Results: Tabulate the following data and results

Start time of burner

Cut-in setting pressure
Maximum steam pressure during the operation
Maximum stack gas temperature
Steam temperature measured at the steam exhaust
Volume of fuel consumed, Lit.
Fuel consumption, Lit./hour

IV. Discussion and Conclusion: Discuss how the experiment is conducted. Draw a conclusion base from your
findings during the experiment
V. Appendices: Attached computations and documentations.

VI. References
LESSON 4: MEASUREMENT OF STEAM QUALITY

 Steam Quality

What is Steam Quality?

Steam quality is the proportion of saturated steam (vapor) in a saturated condensate (liquid)/
steam (vapor) mixture. A steam quality of 0 indicates 100 % liquid, (condensate) while a steam quality
of 100 indicates 100 % steam. One (1) lb. of steam with 95 % steam and 5 % percent of liquid entrainment
has a steam quality of 0.95. The measurements needed to obtain a steam quality measurement are
temperature, pressure, and entrained liquid content. A high percentage (88 % or more) of industrial steam
systems use saturated steam for process applications. Saturated steam (meaning steam that is saturated
with energy) is completely gaseous and contains no liquid. The boiler operation uses chemical energy
from a fuel source to deliver energy to the boiler water. Inside the boiler, liquid gains energy from the
combustion process and changes state into saturated steam.

Why Steam Quality is Important

Manufacturing techniques of heat transfer, control, and standards are all dedicated to improving
and providing the highest quality product to the market place. To attain the highest quality, each
manufactured component of the final product is inspected repeatedly, and measured for its quality to
ensure that it meets the manufacturer’s and consumer’s expectations. Steam is a vital and critical part in
producing the final product; therefore, steam quality should be one of the main measurable points in
producing a product in today’s manufacturing facility. All heat transfer components (shell/tube,
plate/frame, plate/coil, tracing, etc.) base performance calculations on 100 % steam quality, unless the
manufacturer is informed by the end user that the steam quality is lower than 100 %.

What are the effects of Steam Quality?

Low steam quality affects steam system operations in many ways.
1. Reduced heat transfer efficiency: The major problem with low steam quality is the effect on the heat
transfer equipment and process. In some cases, low steam quality can reduce heat transfer efficiency by
more than 65 %. The liquid entrained in the steam has sensible energy (16 % estimated – varies with
pressure) which has a significantly lower amount of energy than the steam vapor’s latent energy (94 %).
Therefore, less usable energy is being delivered to the steam process equipment. Also, the additional
liquid (low steam quality) collects on the wetted surface of the heat exchanger causing an additional
build-up of a liquid which reduces the ability of the steam’s latent energy to be transfer to the product.
2. Premature Valve Failure: Liquid passing through steam control valves will erode the internals of the
valves causing premature failure.
3. Internal Turbine Component Failures: Liquid introduced with the steam in a saturated turbine
operation will reduce the life expectancy of the internal components.
4. Waterhammer. Steam systems are usually not designed to accommodate the additional liquid in steam.
Additional liquid creates the chance for waterhammer to occur. Waterhammer is a safety issue, and may
cause premature failure in the steam system.

Roadmap to ensure a High Steam Quality.

The following items will ensure a high steam quality.
1.) Insulate steam lines and components.
2.) Establish proper steam line drip leg steam trap stations.
3.) Develop proper startup procedures.
4.) Implement a proactive boiler chemical program.
5.) Implement a proactive steam system management program.
6.) Install steam separators (mechanical coalescing design), if needed.
How is Steam Quality measured?
A true measurement of steam quality can be obtained from the use of a throttling calorimeter and
Ganapathy’s steam plant calculations. Unfortunately, most industrial plants do not have the luxury or
capability of doing the testing. Another way to measure steam quality is relying on the basics of steam.
Saturated steam is a dry invisible gas and only becomes visible with the entrained air or liquid. Therefore,
opening a steam valve and allowing steam to be released into the atmosphere provides an estimate of the
steam quality in the system.

Picture number 1 indicates an acceptable steam

quality. The discharge from the valve through
the tube is almost invisible

Picture number 2 shows the discharge from the

valve off the steam line to be very visible with
liquid being discharged with the steam vapor.
Steam quality is not acceptable for the process.

Picture number 3 shows the discharge from the

valve off the steam line to be very visible with
liquid being discharged with the steam vapor.
Steam quality is not acceptable for the process.
 Steam test methods

Eric Erpenbeck, P.E., mechanical engineering manager and head of central utilities group for
Fosdick & Hilmer, recommends three different methods:

Visual Test. This involves opening a steam valve from a steam trap station and blowing steam to the
atmosphere. Good steam quality should result in very little, if any, water exiting the pipe. While there is
no cost to this method, the downside is that it is not able to quantify the magnitude of the problem.

Noncondensable Gas Kit. A second is a noncondensable gas kit. These involve multiple methods to test
for noncondensable gases. The industry offers portable steam quality test kits that utilize a condensor.
With the right test kit, the steam quality can be tested with repeatable results, therefore quantifying the
magnitude of the problem.

Dryness Value Test. A third is the dryness value test. This is intended to quantify the amount of moisture
in the steam by using calorimetry, which calculates the amount of energy in a known amount of steam
by condensing a sample in a known amount of water. "Increase in water temperature will determine the
amount of energy in the steam, and therefore the amount of moisture.

Calorimeters

The apparatus used to determine the moisture content of steam is called a calorimeter. However,
since it may not measure the heat in the steam, the name does not describe the function of the apparatus.
The first name used was the “barrel calorimeter,” but the liability of error was so great that its use was
abandoned.

Modern calorimeters are generally of either the throttling or separator type.

Throttling Calorimeter. The figure shows a typical form

of throttling calorimeter. Steam is drawn from a vertical
main through the sampling nipple. Then it passes around
the first thermometer cup, through a ⅛-in. orifice in a disk
between two flanges, around the second thermometer cup,
and to the atmosphere.
The instrument and all pipes and fittings leading to it
should be thoroughly insulated to diminish radiation
losses. Care must be taken to prevent the orifice from
becoming blocked with corrosion materials. The
discharge piping should be short to prevent backpressure
below the disk.

When steam passes through an orifice from a higher to a lower pressure, as is the case with the throttling
calorimeter, no external work has to be done in overcoming a resistance. Hence, if there is no loss from
radiation, the quantity of heat in the steam will be exactly the same after passing the orifice as before
passing.
Compact Throttling Calorimeter. This calorimeter consists of two concentric metal cylinders screwed to
a cap containing a thermometer well. The steam pressure is measured by a gauge placed in the supply
pipe or other convenient location. Steam passes through the orifice and expands to atmospheric pressure,
its temperature at this pressure being measured by a thermometer placed in the cup. To prevent radiation
losses as far as possible, the annular space between the two cylinders is used as a jacket, steam being
supplied to this space through a hole. The limits of moisture within which the throttling calorimeter will
work are, at sea level, from 2.88 percent moisture at 50 pounds’ gauge pressure and 7.17 percent moisture
at 250 pounds’ pressure.

Separating Calorimeter

The separating calorimeter mechanically separates the

entrained water from the steam and collects it in a reservoir,
where its amount is either indicated by a gauge glass or where
it is drained off and weighed. Figure 6 shows a calorimeter of
this type.

The steam passes out of the calorimeter through an

orifice of known size so that its total amount can be calculated
or it can be weighed. A gauge is ordinarily provided with this
type of calorimeter, which shows the pressure in its inner
chamber and the flow of steam for a given period, this latter
scale being graduated by trial.

The instrument, like a throttling calorimeter, should be

well insulated to prevent losses from radiation.

Steam Pressure Reducing: Testing Steam Quality

A steam pressure-reducing valve will work the same as a throttling calorimeter. A typical
installation of a steam pressure-reducing station, by adding pressure measurement upstream and
downstream with the addition of temperature measurement downstream, provides the continuous online
“calorimeter.”
REFERENCES
Knowing the plant’s steam quality. (2019, August 19). Retrieved from
https://www.achrnews.com/articles/141764-knowing-the-plants-steam-quality
Atkinson, W., & Editor, C. (2014, September 30). Evaluating the pros and cons of measuring steam
quality. Retrieved from https://www.plantservices.com/articles/2014/pros-and- cons-of-measuring-
steam-quality/
Knowing the plant’s steam quality. (2019, August 19). Retrieved from
https://www.achrnews.com/articles/141764-knowing-the-plants-steam-quality
 LEARNING ACTIVITY 3

Direction. Answer the following questions completely. Write your answer on a short bond paper and
submit through our google classroom in pdf file. (10 pts. Each)
1. What is considered good steam quality?
2. What is the best method to measure steam quality? Why?
3. What is Yarway method? How does this method perform?
4. Differentiate “steam purity” from “steam quality”.
5. What are the properties needed to obtain the quality of steam?
6. Steam quality should be one of the main measurable points in producing a product in today’s
manufacturing facility.
7. How does steam quality affects system operation? Explain and give examples.
8. Aside from temperature and pressure, do you think that steam quality is one of the most important
measurable properties in a manufacturing facility? Why?
9. Do you think that steam with a quality of 65% has a lesser energy compared to a steam with 90%
quality of the same pressure? Why? Or Why not?
10. Recommend other steam test methods used in the industry? Cite sources.
11. Compare visual test and dryness value test as a steam test method.

 MODULE SUMMARY

In module I, you have learned about steam boilers. You have learned its definitions, scope,
their uses, classifications, components and the procedure of operation. There are three lessons in
module I.
Lesson 1 focused on definition and steam boiler classifications which is according to type of
circulation, the firing adopted, the fuel used and according to its arrangement.
Lesson 2 presents the boiler main components such as the feedwater heaters, fuel heater,
dearetors, pumps, combustion air blowers, flue, economizer, steam traps and pipings.Boiler room
definitions and boiler room valves and identifications such as gate valves, globe valves, butterfly
valve, and pressure relief valves were discussed.
In lesson 3, it focuses on the procedure of starting up and shutting down the boiler in our
laboratory room.
While lesson 4 pertains to the importance and determination of steam quality.