Republic of the Philippines

Laguna State Polytechnic University

Province of Laguna
ISO 9001:2015 Certified
Level I Institutionally Accredited

LSPU Self-paced Learning Module (SLM)

Course
Sem/AY
Module No. 3
Lesson Title Steam Generator
Week
Duration
Date
This lesson will cover the method of solving Simultaneous Linear Equations using
Description Gaussian Elimination.
of the
Lesson

Learning Outcomes
Intended Students should be able to meet the following intended learning outcomes:
Learning 1. Solve problems using numerical methods for Linear Equations.
Outcomes 2. Be able to use different techniques and methods for Linear Equations.
Targets/ At the end of the lesson, students should be able to:
Objectives 1. Explain the steps involved in using Gaussian Elimination.
2. Solve Root-Finding Problems Using Gaussian Elimination.

Student Learning Strategies

Online Activities A. Online Discussion via Google Meet

(Synchronous/ You will be directed to attend in a 3-Hour class discussion on the nature
and types of educational technologies. To have access to the Online
Asynchronous) Discussion, refer to this link: ____________________.

The online discussion will happen on November 21, 2020, from

10:30am-1:30pm.

(For further instructions, refer to your Google Classroom and see the
schedule of activities for this module)

B. Learning Guide Questions:

1. What is the algorithm of Gaussian Elimination?
2. Cite benefits and drawbacks of using the techniques

LSPU SELF-PACED LEARNING MODULE: TECHNOLOGY FOR TEACHING AND LEARNING

Prepared by: ALBERTO D. YAZON, PhD
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna
ISO 9001:2015 Certified
Level I Institutionally Accredited
Note: The insight that you will post on online discussion forum using Learning Management
System (LMS) will receive additional scores in class participation.

Lecture Guide

STEAM GENERATOR

Introduction
Steam Generator is a combination of apparatus for producing, furnishing, or
recovering heat, together with apparatus for transforming to a working fluid the
heat thus available.

Types of Boiler

1. Fire-tube boilers – are those having the heat gases of combustion inside
the tubes. Limited only to a working pressure of 1.7 Mpag.
a. Horizontal-Return-Tubular (HRT) Boiler

Offline Activities b. Packaged Fire-Tube Boiler

(e-Learning/Self- c. Vertical Tubular Boiler
Paced)
2. Water-Tube-Boilers – are those having the hot gases of combustion
outside the tubes.
a. Horizontal Straight-Tube Boiler
b. Central Station Steam Generators
c. Marine Steam Generators
d. Forced-circulation Steam Boilers

Water-Tube Boiler Circulation Principle

o Figure 1 below illustrates the principle of water-tube boiler

circulation

Figure 1. Water-Tube Boiler Circulation Principle

LSPU SELF-PACED LEARNING MODULE: TECHNOLOGY FOR TEACHING AND LEARNING

Prepared by: ALBERTO D. YAZON, PhD
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna
ISO 9001:2015 Certified
Level I Institutionally Accredited

o Dryness Factor (or fraction) or Quality of steam – refers to the

amount of steam in the mixture of water and steam at the riser.
o Top Dryness Factor – applies to the mixture leaving the tubes.

Boiler Ratings and Performance

• Boiler Hp = equivalent to the generation of 34.5 lb/hr (15.44 kg/hr) from

water at 212 °F (100 °C) to saturated steam also at 212 °F (100 °C).
• Energy of Evaporation
lb Btu
Energy of Evaporation = (34.5)(hfg @ 212 °F) = (34.5 hr) (970.3 lb ) ≈
33 500 Btu/hr
Energy of Evaporation = (15.46)(hfg @ 100 °C) =
kg kJ
(15.646 hr) (2257 kg) ≈ 35 314 kJ/hr
Btu
Where, hfg = enthalpy of evaportion at 212 °F (100 °C) = 970.3 =
lb
2257 kJ/kg
Therefore, 1 Bo Hp = 33 500 Btu/hr = 35 314 kJ/hr
• Boiler Horsepower, Bo Hp
ms (h2 − h1 ) ms (h2 − h1 )
Bo. Hp = =
35 314 33 500

Where, ms = mass flow rate of steam, kg/hr, lb/hr

h1 = enthalpy of feed water, kJ/kg, Btu/lb
h2 = enthalpy of steam leaving the boiler, kJ/kg, Btu/lb
• Factor of Evaporation, FE
kJ Btu
Boiler Ouput, , h2 − h1 h2 − h1
kg lb
FE = = =
2257 or 970.3 2257 970.3

• Equivalent Evaporation, Eq. Evap.

Boiler Output, kJ/hr Boiler Output, Btu/ Hr
Eq. Evap. = (F. E. )ms = =
2257 970.3

LSPU SELF-PACED LEARNING MODULE: TECHNOLOGY FOR TEACHING AND LEARNING

Prepared by: ALBERTO D. YAZON, PhD
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna
ISO 9001:2015 Certified
Level I Institutionally Accredited

• Rated Boiler Horsepower

Heat Transfer Area or Surface, m2 , or ft 2
Rated Bo. Hp =
k

Where, k = 0.91 m2 /Bo. Hp = 10ft 2 /Bo. Hp → For water-tube boiler

m2
K = 1.10 Bo . Hp = 12ft 2 /Bo. Hp → For fire-tube boiler

• Developed Boiler Horsepower

∑ ms (∆h) Boiler Output, kJ/hr Boiler Output, Btu/hr
Dev. Bo. Hp = = =
35 314 or 33 500 35 314 33 500

(F. E. )(ms ) Eq. Evap. (F. E. )(ms ) Eq. Evap.

Dev. Bo. Hp = = = =
15.646 15.646 34.5 34.5

Where, ∑ ms (∆h) = total heat transfer to cycle fluid in steam generator

(boiler, superheater, heater, Economizer, reheater), kJ/hr, Btu/hr.
• Percent Rating
Dev. Bo. Hp
Percent Rating =
Rated Bo. Hp

• Rating for Modern Steam Generators

Steam Generated at Rated Capacity, kg/hr

kW Rating =
Over − all Station Steam Rate, kg/kw ∙ hr

where, Steam Generated = kg/hr of steam at a given pressure and

temperature and feed water temperature.
• Boiler Performance – the measure of boiler heat output, QB , in kJ/hr or
Btu/hr
a) QB = Based on the flow diagram
b) QB = mF (HHV)EB
c) QB = (Dev. Bo. Hp)( 35 314) or QB = (Dev. Bo. Hp)(33 500)
d) QB = (Eq. Evap.)(2257) or QB = (Eq. Evap.)(970.3)
% Rating
e) QB = (Rated Bo. Hp. ) ( 100 % ) (35 314) or
% Rating
QB = (Rating Bo. HP) ( ) (33 500)
100%
Where, QB = Boiler Output, kJ/hr, Btu/hr
HHV =higher heating value of the fuel, kJ/kg, Btu/lb
EB = boiler efficiency
mF = mass flow rate of fuel, kg/hr, lb/hr

LSPU SELF-PACED LEARNING MODULE: TECHNOLOGY FOR TEACHING AND LEARNING

Prepared by: ALBERTO D. YAZON, PhD
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna
ISO 9001:2015 Certified
Level I Institutionally Accredited

• Boiler Over-all Efficiency

QB
EB = ( ) (100 %)
QA
Where, QB = Boiler output, kJ/hr, kJ/kg, Btu/hr, Btu/lb
QA = heat added or heat from the fuel, kJ/hr, Btu/hr = mF (HHV)

• New Over-all Boiler Efficiency

QB ′ ∑ ms (∆h)
ƞB = (100%) = (100%)
mF (HHV) mF (HHV)

Where, QB ′ = heat absorbed by the boiler fluid less the amount of heat used
for the boiler auxiliaries.

• Boiler and Furnace Efficiency

QB
⁄(1 − M − A − C )
ub
EBF = [ ] (100 %)
HHV⁄
(1 − M − A)

Where, M = moisture content of the fuel

A = ash content of the fuel
Cub = unburned carbon

• Grate Efficiency

kg combustible burned / kg fuel fired 1 − M − A − Cub

EG = (100 %) = [ ] (100 %)
kg combustible / kg fuel fired 1−M−A

STEAM GENERATOR HEAT BALANCE

• The fuel supplied to a furnace when completely burned releases its heating
value. The energy primarily changes the feedwater pumped to the boiler into
steam. All the heating value does not go to this useful purpose. These are
some losses in the form of incomplete combustion, of flue gases leaving at
high temperature, and of radiated and convected heat from the outside of the
steam generator. An energy balance shows the distribution of the heating
value of the fuel to the formation of steam and to the various losses.

• Figure 2 below illustrates the energy balance of a steam generator.

Figure 2. Boiler Heat Balance

LSPU SELF-PACED LEARNING MODULE: TECHNOLOGY FOR TEACHING AND LEARNING

Prepared by: ALBERTO D. YAZON, PhD
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna
ISO 9001:2015 Certified
Level I Institutionally Accredited

Useful Energy
1. Energy Absorbed by the steam generator fluid (or Useful Energy)

Q1 = Ws (hg2 − hf1 ) + Wr (hg4 − hg3 ) + WB (hf2 − hf1 )

Where, Q1 = energy absorbed by the boiler fluid or the useful energy,

kJ/kg fuel, Btu/lb fuel
hg2 = enthalpy of steam leaving the boiler, kJ/kg, Btu/lb
hf1 = enthalpy of feed water, kJ,kg, Btu/lb
hf2 = enthalpy of water at boiler pressure, kJ/kg, Btu/lb
hg4 = enthalpy of reheat steam leaving the steam generator,
kJ/kg, Btu/lb
hg3 = enthalpy of reheat steam entering the steam generator,
kJ/kg, Btu/lb
Ws = mass of steam from feedwater per unit mass fuel, kg/kg
fuel, lb/lb fuel
Wr = mass of reheated steam per unit mass fuel, kg/kg fuel, lb/lb
fuel
WB = mass of blowdown per unit mass fuel (often negligible),
kg/kg fuel, lb/lb fuel
Energy Losses
2. Energy Loss due to mechanical moisture in fuel (or energy loss due to
evaporating and superheating moisture in fuel)

English Units:
Q2 = W(1066 + 0.5t g − t a ) when t g > 575 °F
Q2 = W(1089 + 0.46t g − t a ) when t g < 575 °F
SI Units:
Q2 = W(2479.81 + 20.935t g − 4.187t a ) when t g > 302 °C
Q2 = W(2533.31 + 1.92602t g − 4.187t a ) when t g < 302 °C
Where, Q2 = energy loss due to moisture content of the fuel as fired,
kJ/kg fuel, Btu/lb fuel
W = moisture content of the fuel, kg/kg fuel, lb/lb fuel
t g = temperature of flue gas after passing all heat-transfer
surfaces, °C, °F
t a = temperature of air entering for combustion to the furnace or
air heater, if the latter is used, °C, °F

LSPU SELF-PACED LEARNING MODULE: TECHNOLOGY FOR TEACHING AND LEARNING

Prepared by: ALBERTO D. YAZON, PhD
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna
ISO 9001:2015 Certified
Level I Institutionally Accredited

3. Energy loss due to moisture from hydrogen in the fuel (or energy loss
due to evaporating and superheating moisture formed by combustion of
hydrogen)

English Units:
Q3 = 9H2 (1066 + 0.5t g − t a ) when t g > 575 °F
Q3 = 9H2 (1089 + 0.46t g − t a ) when t g < 575 °F

SI Units:
Q3 = 9H2 (2479.81 + 20.935t g − 4.187t a ) when t g > 302 °C
Q3 = 9H2 (2533.31 + 1.92602t g − 4.187t a ) when t g < 302 °C

4. Energy Loss due to moisture from air

English Units:
Q4 = 0.47 WAV (t g − t a )

SI Units:
Q4 = 1.96789WAV (t g − t a )

Where, WAV = mass of moisture content n supp air per unit mass fuel,
kg/kg fuel, lb/lb fuel
WAV = (1 + e) Wa (g)
Wa = theoretical air-fuel ratio, kg/kg fuel, lb/lb fuel
g = humidity ratio of supply air, kg/kg d.a. , lb/lb d.a.
5. Energy Loss due to dry flue-gas sensible heat

English Units:
Q5 = WDG cp (t g − t a ) = 0.24WDG (t g − t a )

SI Units:
Q5 = WDG cp (t g − t a ) = 1.005WDG (t g − t a )

Where, WDG = mass of dry flue gas per unit mass fuel, kg/kg fuel, lb/lb
fuel
44 𝐶𝑂2 + 32 𝑂2 + 28(𝐶𝑂 + 𝑁2 ) 11 𝐶𝑂2 + 8 𝑂2 + 7(𝐶𝑂 + 𝑁2 )
𝑊𝐷𝐺 = 𝐶𝑎𝑏 = 𝐶𝑎𝑏
12(𝐶𝑂2 + 𝐶𝑂) 3(𝐶𝑂2 + 𝐶𝑂)
But 𝐶𝑂 + 𝑁2 = 100 − 𝐶𝑂2 − 𝑂2

11 𝐶𝑂2 + 8𝑂2 + 7(100 − 𝐶𝑂2 − 𝑂2 ) 11 𝐶𝑂2 + 8 𝑂2 + 700)

𝑊𝐷𝐺 = 𝐶𝑎𝑏 = 𝐶𝑎𝑏
3(𝐶𝑂2 + 𝐶𝑂) 3(𝐶𝑂2 + 𝐶𝑂)

LSPU SELF-PACED LEARNING MODULE: TECHNOLOGY FOR TEACHING AND LEARNING

Prepared by: ALBERTO D. YAZON, PhD
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna
ISO 9001:2015 Certified
Level I Institutionally Accredited
Where, 𝐶𝑎𝑏 = actually burned carbon, lb/lb fuel, kg/kg fuel
Note: 𝐶𝑂2, CO, 𝑂2, 𝑁2 are Orsat Analysis by volume.
Actually Burned Carbon
𝐶𝑎𝑏 = 𝐶 − 𝐶𝑢𝑏 = 𝐶 − 𝑊𝑟 + 𝐴
Where,
𝐴
𝐶𝑢𝑏 = 𝑊𝑟 − 𝐴 = −𝐴
1 − 𝐶𝑟
𝑊𝑟 = dry refuse, lb/lb fuel, kg/kg fuel
𝐴 = ash, lb/lb fuel, kg/kg fuel
𝐶𝑟 = Combustible in refuse, lb/lb refuse, kg/kg refuse

ASME Formula for 𝑾𝑫𝑮 Correcting for the Amount of 𝑺𝑶𝟐

11𝐶𝑂2 + 8𝑂2 + 7(𝐶𝑂 + 𝑁2 ) 𝑆 𝑆
𝑊𝐷𝐺 = (𝐶𝑎𝑏 + )+
3(𝐶𝑂2 + 𝐶𝑂) 267 160
Where, S = sulfur from fuel analysis, kg/kg fuel, lb/lb fuel

Air Actually Used During Combustion

𝑂2
𝑊𝑎𝑎 = 𝑊𝐷𝐺 + 8 (𝐻2 − ) − 𝐶𝑎𝑏 − 𝑆 − 𝑁2
8
Where, 𝐻2 , 𝑂2, S, 𝑁2 = elements from fuel analysis, lb/lb fuel, kg/kg fuel

Note:
• To derive 𝑊𝑎𝑎 as given in ASME Code, Apply the law of conservation of
mass to the combustion process.
Compositions of Dry Flue Gases (𝑾𝑫𝑮 ) Leaving the Boiler
1. All the carbon actually burned
2. Nitrogen in the fuel
3. Sulfur in the fuel
4. Excess oxygen from the air
5. Oxygen used to burn the carbon and sulfur
6. Oxygen supplied with the fuel
7. Nitrogen in the air supply

Note:

LSPU SELF-PACED LEARNING MODULE: TECHNOLOGY FOR TEACHING AND LEARNING

Prepared by: ALBERTO D. YAZON, PhD
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna
ISO 9001:2015 Certified
Level I Institutionally Accredited

• The quantity 𝑊𝐷𝐺 does not include the oxygen used to burn hydrogen in
the fuel, 8𝐻2 .
• Subtracting items 1, 2, 3, and 6 from the 𝑊𝐷𝐺 and adding 8𝐻2 will give
the actual weight of air supplied for combustion.

6. Energy Loss due to incomplete combustion

English Units:
28 CO
Q6 = ( ) (10187)
44CO2 + 28CO + 28N2 + 32O2

CO
Q6 = 10160Ci = 10160Cab ( )
CO2 + CO

SI Units:
28 CO
Q6 = ( ) (4380)
44CO2 + 28CO + 28N2 + 32O2

CO
Q6 = 23 631Ci = 23 631Cab ( )
CO2 + CO

Note: CO and CO2 in the second equation must be an Orsat analysis (%

by Volume)

7. Heat Loss due to Unburned Carbon

English Units:

Q7 = 14 600 (C − Cab )

Q7 = Wr (HHV)r

SI Units:

Q7 = 33 964 (C − Cab )

Q7 = Wr (HHV)r

Where, Wr = mass of refuse, kg/kg fuel, lb/lb fuel

(HHV)r = heating value of refuse

8. Heat Loss Due to radiation and Unaccounted-for

LSPU SELF-PACED LEARNING MODULE: TECHNOLOGY FOR TEACHING AND LEARNING

Prepared by: ALBERTO D. YAZON, PhD
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna
ISO 9001:2015 Certified
Level I Institutionally Accredited

Q8 = HHV − ∑ Q1−7 = HHV(Q1 + Q2 + Q3 + Q4 + Q5 + Q6 + Q7 )

Performance Tasks

EXERCISES 3

Solve the following.

1. In a water-tube boiler with 186 m2 of boiler heating surface and operating at 1.75 MPaa, water is fed
at the rate of 2 268 kg/hr. Water enters the economizer at 56 °C and leave therefrom at 112 °C, while
steam with 5 % moisture enters the superheater and leaves therefrom as superheated at the same
pressure. Coal with a heating value of 28 000 kJ/kg is burned at a rate of 250 kg/hr. The gross over-
all boiler efficiency is 80 %. The generated steam flows to a steam turbine through a well-insulated
pipe along which the pressure drop is 0.10 Mpa and the steam temperature becomes 250 °C. in the
turbine, steam expands to a dry and saturated at 0.065 MPaa.
Determine:
a) The temperature of steam leaving the superheater
b) The boiler heat losses per hour
c) The equivalent evaporation
d) The percent rating
e) The weight of fuel saved in using the economizer per hour
f) The weight of additional fuel used per hour in the superheater
g) The energy loss per hour in the piping line
h) The power plant generator output if the turbine generator combined efficiency is 88 %
i) The power plant gross thermal efficiency.

2. A steam boiler has an actual evaporation rate of 8.23 kg/kg coal fired. Coal as fired contains 2 %
moisture. Dry coal contains 5 % ash and has a heating value of 29 776 kJ/kg. During the test 12 % of
coal fired is delivered from the ashpit as refuse. The steam leaving the boiler is saturated at a
pressure of 0.70 MPaa and the temperature of feed water is 49 °C. Determine a) the boiler efficiency;
b) the boiler-furnace efficiency; c) the grate efficiency.
3. A water-tube boiler having a heating surface of 325.23 m2 evaporates 6349.21 kg of water in an hour
from a feed temperature of 66 °C. Boiler pressure is at 1.04 MPaa and the steam quality at the boiler
outlet is 99 %. What percent of its rated Bo. Hp was the boiler developing?

LSPU SELF-PACED LEARNING MODULE: TECHNOLOGY FOR TEACHING AND LEARNING

Prepared by: ALBERTO D. YAZON, PhD
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna
ISO 9001:2015 Certified
Level I Institutionally Accredited

4. A condenser receives 11 338 kg of steam per hour at 89 % dryness factor. Steam temperature in the
condenser is 33 °C and free air at 101.325 kPaa and 15.56 °C leaks into the condenser at the rate of
0.51 𝑚3 /min. Determine the pressure in the condenser.

Understanding Directed Assess

Rubric for Exercises 3
CRITERIA EXEMPLARY SATISFACTORY DEVELOPING BEGINNING RATING
4 3 2 1

Comprehensive The score of the The score of the SAQ The score of the The score of the
Ability SAQ and and Activities is SAQ and SAQ and
Activities is around 70% to 89% Activities is Activities is
around 90% to Correct. around 40% to around 0% to
100% Correct. 69% Correct. 39% Correct.

Workmanship The neatness of The neatness of the The neatness of The neatness
the solution for solution for the SAQ the solution for of the solution
the SAQ and and Activities is the SAQ and for the SAQ
Activities is very good quality. Activities is and Activities
good quality. standard needed
quality improvement

Accuracy The submitted The submitted work The submitted

work manifests manifest the work
qualities which required qualities partiall
go beyond the y manifest the
requirements required
qualities.
Certain aspects
are
either
incomplete or
incorrect.
Total

Learning Resources
Francisco, Jose R. (2014). Lecture Notes in Power Plant Design

LSPU SELF-PACED LEARNING MODULE: TECHNOLOGY FOR TEACHING AND LEARNING

Prepared by: ALBERTO D. YAZON, PhD
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna
ISO 9001:2015 Certified
Level I Institutionally Accredited

LSPU SELF-PACED LEARNING MODULE: TECHNOLOGY FOR TEACHING AND LEARNING

Prepared by: ALBERTO D. YAZON, PhD