Thermo Lecture 2 - Boiler Mountings & Accessories PDF

Iswor Bajracharya, PhD
Department of Mechanical Engineering

Pulchowk Engineering Campus
1.4 Boiler Mountings and Accessories
Boiler Mountings
Different devices and fittings that are used for the control,
safety and efficient operation of boiler are known as boiler
mountings. Different mountings are:
1. Safety Valve
2. Water Level Indicator
3. Fusible Plug
These devices are used for the safe operation of boiler.
1. Pressure gauge
2. Feed check valve
3. Blow-off Cock
4. Steam Stop Valve
These fittings are essential for the operation of boiler .
Boiler Mountings & Accessories Iswor Bajracharya 2
1.4 Boiler Mountings and Accessories
Fig: Boiler mountings and Accessories (Source: www.brighthubengineering.com )

Safety Valve
Function of Safety Valve
When there is a sudden drop in steam requirement, the
steam pressure increases in the boiler. The main function
of this valve is to prevent the steam pressure from
exceeding a limiting maximum pressure value. Safety
valve operates automatically by releasing excess steam
and bring pressure down within safe limits. Safety valve is
fitted at the top of boiler shell.

Safety Valve
Different Types of Safety Valve
Different types of safety valve which are commonly used
are :
1. Spring-Loaded Safety Valve
2. Dead Weight Safety Valve
3. High Steam Low Water Safety Valve

Safety Valve
Spring Loaded Safety Valve
This type of safety valve is very common for stationary as
well as mobile boilers where vibration is likely to occur.
It is loaded with spring instead of weight. So vibration
does not affect it.
It is generally used in locomotive boilers.
It consists of two valves which rest over a valve seat.
A lever is attached with the spring which pushes the valve
and keeps the valve in closed position at normal condition.
When the steam pressure exceeds the working pressure,
the valves are lifted against the spring force and allows the
steam to escape from the boiler.

Safety Valve
Fig: Spring Loaded Safety Valve

Safety Valve
Fig: Spring Loaded Safety Valve

Safety Valve
Dead Weight Safety Valve
This valve is used for low pressure, low capacity
stationary boilers. Not suitable for high pressure boilers
and locomotive boilers.
It has a large vertical pipe on the top of which a valve
seat is fixed. Valve rests upon this valve seat.
A weight carrier is hung on the top of valve upon which
cast iron weight are placed as dead weight. This weight
keeps the valve in closed position in normal condition.
When the pressure of steam exceeds the total weight
of valve, it is lifted up and the excess pressure is released
and falls back as steam pressure gets reduced.
Safety Valve
Fig : Dead Weight Safety Valve

Safety Valve
High Steam Low Water Safety Valve
This valve performs two functions against the high
steam pressure and low water level in the boiler.
This valve is a combination of two valves: one of which
is a lever safety valve which blows off steam when the
working pressure of steam exceeds the normal pressure.
The second valve operates when the water level in boiler
falls below the predetermined level by blowing off the
steam . This triggers the alarm so that corrective action
can be taken by pumping water.
This valve is generally used in Lancashire boiler.

Safety Valve
It has two valves as shown in the figure.
When the pressure inside the boiler increases goes
beyond limiting value, then high steam valve gets lifted
up and excess pressure of steam is released.
When the water level goes below critical level, low
water valve gets raised up as it is fulcrumed and is
linked to float on one end and balance weight on other
end. With raising of low water valve, it moves up from
valve seat and steam escapes out with hissing sound.
This hissing sound is loud enough to warn the boiler
operator.

Safety Valve
Fig: High Steam Low Water Safety Valve

Water Level Indicator
Function
Water level indicator shows the water level inside the boiler
shell to the operator and warns the operator if the water
level falls below a certain limit to take corrective action.
Construction
It consists of two tubes one is front glass tube and
other is a metal tube. Water level is seen through glass
tube which is made strong enough to withstand high
steam pressure and temperature.
Two control cocks are provided for regulating steam
and water passage from boiler to glass tube.
For blow off purpose a blowing cock is also provided.

In case of breakage of glass tube, the possibility of
accident is prevented by providing two balls. As glass
tube breaks, the rush of water and steam carries the
two balls with it and closes the openings for glass tube,
and thus water and steam flowing out can be
prevented.

Fig: Water Level Indicator

Pressure Gauge
Function
Pressure gauge is used to measure the pressure of steam
generated inside the boiler.
Construction
Commonly used pressure gauge is the Bourdon Tube Type
pressure gauge. It consists of an elastic metallic tube with
elliptical cross-section and is bent in the form of circular
arc. One end of the tube is connected to the steam pipe
and the other end is connected to a sector wheel and
pinion through a link. The pinion is connected to a
pointer which indicates the pressure.

Pressure Gauge
Working of Bourdon Tube Pressure Gauge

When the high pressure steam enters the tube, the
tube section tries to become circular which causes the
other end of the tube to move outward. This movement
of tube is transmitted and magnified by the link and
sector. The magnitude of the movement is indicated by
the pointer on the dial.

Pressure Gauge
Fig: Bourdon Tube Pressure Gauge

Fusible Plug
Function
It is a safety device used in a boiler. It prevents the
overheating and burning of tubes in case of water level
falls below a predetermined level. If the water level in a
boiler falls below a predetermined level, the boiler shell
and tubes will be overheated. If it is continued, the
tubes may burn. Fusible plug prevents this accident.
When the temperature of the shell increases above a
particular level , the fusible plug which is mounted
above the grate melts and forms an opening. The high
pressure steam pushes the remaining water through
this whole on the furnace and the fire is extinguished.
Fusible Plug
Working of Fusible Plug
Fusible plug is fitted over the crown of furnace or over
the combustion chamber. Under normal water level
condition in a boiler, this plug is covered with water and
therefore, its temperature is below the melting point.
But when the water level in a boiler falls low enough to
uncover the plug, the temperature of the plug increases
which causes the plug to melt and an opening appears.
High pressure steam and water rushes out of this hole
and extinguish the fire.

Fusible Plug
Fig: Fusible Plug

Feed Check Valve
Function
The function of this valve is to allow the supply of water to
the boiler at high pressure continuously and to prevent the
back flow of water from boiler when the pump pressure is
less than the boiler pressure of when pump fails. This is
one way or non-return valve.
Operation of Valve
During normal operation, the valve is lifted due to the
pressure of water from the pump and water is fed to the
boiler. But when the pump pressure falls below the boiler
pressure or if the pump stops, no-return valve is closed
automatically due to the pressure of water from the boiler
& prevents the back flow from boiler.
Feed Check Valve
Fig: Feed Check Valve

Blow-Off Cock
Function
This valve is also called Blow-down valve. It has the
following functions:
To empty the boiler for cleaning, repair and
inspection.
To discharge the mud and sediments carried with
the feed water and accumulated at the bottom of the
boiler.
By periodic blow-off, the salt concentration in the
boiler is also reduced.

Blow-Off Cock
Working of Blow-Off Valve
This valve is fitted at the lowest part of the boiler either
directly with the boiler shell or to a pipe connected with
the boiler.
It consists of conical plug fitted accurately into a similar
casing. The plug has a rectangular opening. When the
plug is rotated, the rectangular opening will align with
the pipe opening. This causes the water to be discharged
from the boiler. The discharging water may be stopped
by rotating the plug again.
This valve should be operated only when the boiler is
running.
Blow-Off Cock
Fig: Blow-Off Cock

Steam Stop Valve
Function
The function of this valve is to regulate the flow of steam
from the boiler as per the requirement and shut off the
steam flow when not required. It is the largest valve on the
steam boiler and usually fitted to the highest part of the
boiler.
Construction
The main body is made of cast steel. The valve, valve seat
and nut are made of brass for smooth working. The spindle
is passed through the gland to prevent the leakage of
steam. The spindle is rotated by means of a hand wheel.
When the hand wheel is rotated, the valve may move up or
down and accordingly the flow of steam.
Steam Stop Valve
Fig: Steam Stop Valve

Boiler Accessories
Devices and fittings which are mounted and fitted on the

boiler to increase the overall efficiency of the system is
called boiler accessories. These are the auxiliary
equipments. The important accessories are:
1. Economizer
2. Air Preheater
3. Superheater
4. Feed Water Heater
5. Steam Separator

Boiler Accessories
Fig: Boiler and Accessories (www.brighthubengineering.com )

Economizer
Function
An economizer is an accessory in a boiler which extracts
the waste heat of the flue gases before it enters the
chimney and is used to preheat the water before it is fed
into the boiler. Economizer is located before the air
preheater and after the evaporator.
Advantages
1. There is a saving of fuel as waste heat from the flue
gases is used for heating the feed water.
2. Dissolved gases as air and CO2 are removed by
preheating the feed water which reduces the
corrosion and pitting of boiler.
Economizer
4. This improves the overall efficiency of the boiler by

reducing the fuel consumption.
5. Circulation of water is well maintained as quick
evaporation is possible because of the hot feed water.
6. Higher feed water temperature reduces the thermal
stress on boiler which increases the boiler life.
Disadvantage
1. Economizer is placed at the passage of flow of flue
gases. So there will be a draught pressure loss.

Economizer
Construction and Working of Economizer
It consists of large number of vertical or horizontal
cast iron pipes which are fitted with two headers,
one at the bottom and other at the top.
The feed water enters from the bottom header,
then flows through the economizer pipes and finally
exits from the top header and enters the boiler.
The hot flue gases pass over the external surface
of economizer water tubes which transfer the heat
to the water.
A safety valve is fitted at the top of the header for
the safety of pipes.
Economizer
Fig: Economizer
Air Pre-Heater
Function
Air preheater, like economizer , recovers some portion of
waste heat of the flue gases . Air supplied to the
combustion chamber is preheated by using the heat of
the waste flue gases. Air preheater is fitted after the
economizer but before the gases enter the chimney.
Advantages
1. Waste heat from the flue gases is recovered for
heating the air. Heated air improves the fuel
combustion.
2. Inferior grade of coal can be burnt efficiently with
preheated air.
Air Preheater
Construction and Working

Tubular preheaters consist of straight tube bundles
which is installed between the economizer and
chimney.
The hot flue gases coming out from the economizer
pass through these tubes and the ambient air is forced
to flow over these tubes.
Air is forced to be deflected by using baffles and
compelled to move in a zigzag path for a number of
times. This increases the period of contact between the
air and hot surface. In this process, heat is transferred
from the flue gases to the ambient air very effectively.
Air Preheater
Ambient air is forced by a fan through ducting at one

end of the preheater tubes and at other end the heated
air comes out from the preheater and enters the boiler
furnace for combustion.
The soot and other material carried with the flue gases
are collected in the hopper at the bottom and removed
periodically through the soot gate.

Air Preheater
Fig: Tubular Type Air Preheater

Superheater
Function
Superheater is a device used in boilers to convert the
saturated or wet steam into superheated steam by
increasing the temperature above its saturation
temperature. This is done by passing the steam through
a small set of tubes and hot gases over them.
Superheated steam is essential for power generation.
The advantages are:
1. Reduces the specific steam consumption in engine
and turbine.
2. Reduces the condensation losses in the pipe.
3. Increases the efficiency of the steam plant.
Superheater
This
superheater
is used in
Lancashire
boiler.
Fig: Smooth tube hairpin type superheater

Superheater
Fig: Superheater in red circle

Deaerator
Function
Feedwater for steam generating boilers contains
dissolved gases such as oxygen and carbon dioxide. If
these gases are not removed, following damage may
occur:
1. They can cause serious corrosion damage by
attaching to the walls of pipes and other metallic
components and forming oxides (rust).
2. Dissolved carbon dioxide combines with water to
form carbonic acid that causes further corrosion.
Because these gases cannot be condensed out, a
different procedure must be used.
Types of Deaerator
There are two types of deaerator
1. The tray-type (also called the cascade-type) includes a
vertical domed deaeration section mounted on top of
a horizontal cylindrical vessel which serves as the
deaerated boiler feedwater storage tank.
2. The spray-type consists only of a horizontal (or
vertical) cylindrical vessel which serves as both the
deaeration section and the boiler feedwater storage
tank.

Deaerator
Fig: Tray type deaerator

Deaerator
Fig: Spray type deaerator

Feed Pump
Function
Boiler feed pump is a specific type of pump which is
used to pump the water to feed into the boiler by
increasing the pressure of the water above the boiler
shell.
Raises the feed water pressure to a value higher
than the boiler operating pressure.
Delivers feed water in excess to the maximum
evaporation rate of boiler.

Feed Pump
Types of Feed Water Pump
Two types of pumps are used to supply water to the
boiler:
1. Reciprocating feed pump
2. Centrifugal feed pump
Due to the inherent problems in reciprocating

pump, it has become obsolete and not used so
much.
Instead, multistage centrifugal pumps are used as a
feed pump. These pumps are cheaper and easy to
maintain than reciprocating pump.
Feed Pump
Fig: Reciprocating Feed Pump

Feed Pump
Fig: Centrifugal Feed Pump

Steam Separator
Function
It is a device for separating water moisture from the
steam. It is necessary to separate the water moisture from
steam because:
1. Wet steam reduces the thermal efficiency of engines.
2. In piston engines, water can accumulate in the
cylinders and cause a hydraulic lock which will damage
the engine
3. Water droplets in high velocity steam coming from
nozzles (or vanes) in a steam turbine can impinge on
and erode turbine internals such as turbine blades.
4. Creates corrosion problem on metal parts.
Steam Separator
Types of Steam Separator

There are three types of steam separator in common
use:
1. Baffle type
2. Cyclonic type
3. Coalescence type

Steam Separator
Baffle Type Steam Separator
It consists of a number of baffle plates, which cause the flow
to change direction a number of times as it passes through the
separator body.
The suspended water droplets have a greater mass and a
greater inertia than the steam. So, when there is a change in
flow direction, the dry steam flows around the baffles and the
water droplets collect on the baffles.
Furthermore, as the separator has a large cross-sectional
area, there is a resulting reduction in the speed of the fluid.
This reduces the kinetic energy of the water droplets, and most
of them will fall out of suspension. The condensate collects in
the bottom of the separator, where it is drained away through a
steam trap.
Steam Separator
Fig: Baffle type steam separator

Steam Separator
Cyclonic Type Steam Separator
The cyclonic or centrifugal type separator uses a series
of fins to generate high-speed cyclonic flow.
The velocity of the steam causes it to swirl around the
body of the separator, throwing the heavier, suspended
water to the wall, where it drains down to a steam trap
installed under the unit.

Steam Separator
Fig: Cyclonic type steam separator

Steam Separator
Coalescence Type Steam Separator
It consists of a wire mesh pad (demister pad) upon
which water molecules become entrapped. These water
molecules tend to coalesce, producing droplets that are
too large to be carried further by the gas system. As the
size of the droplets increases, they become too heavy
and ultimately fall into the bottom of the separator.
It is common to find separators, which combine both
coalescence and cyclonic type operations. By combining
the two methods, the overall efficiency of the separator
is improved.

Steam Separator
Fig: Coalescence type separator

END

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Iswor Bajracharya, PhD

Department of Mechanical Engineering

Fig: Boiler mountings and Accessories (Source: www.brighthubengineering.com )

Boiler Mountings & Accessories Iswor Bajracharya 4

Boiler Mountings & Accessories Iswor Bajracharya 5

Boiler Mountings & Accessories Iswor Bajracharya 6

Fig: Spring Loaded Safety Valve

Fig: Spring Loaded Safety Valve

Fig : Dead Weight Safety Valve

Boiler Mountings & Accessories Iswor Bajracharya 11

Boiler Mountings & Accessories Iswor Bajracharya 12

Fig: High Steam Low Water Safety Valve

Boiler Mountings & Accessories Iswor Bajracharya 14

Boiler Mountings & Accessories Iswor Bajracharya 15

Fig: Water Level Indicator

Boiler Mountings & Accessories Iswor Bajracharya 17

Working of Bourdon Tube Pressure Gauge

Boiler Mountings & Accessories Iswor Bajracharya 18

Fig: Bourdon Tube Pressure Gauge

Boiler Mountings & Accessories Iswor Bajracharya 19

Boiler Mountings & Accessories Iswor Bajracharya 21

Fig: Fusible Plug

Fig: Feed Check Valve

Boiler Mountings & Accessories Iswor Bajracharya 25

Fig: Blow-Off Cock

Boiler Mountings & Accessories Iswor Bajracharya 27

Fig: Steam Stop Valve

Devices and fittings which are mounted and fitted on the

Boiler Mountings & Accessories Iswor Bajracharya 30

Fig: Boiler and Accessories (www.brighthubengineering.com )

4. This improves the overall efficiency of the boiler by

Boiler Mountings & Accessories Iswor Bajracharya 33

Construction and Working

Ambient air is forced by a fan through ducting at one

Boiler Mountings & Accessories Iswor Bajracharya 38

Fig: Tubular Type Air Preheater

Fig: Smooth tube hairpin type superheater

Fig: Superheater in red circle

Boiler Mountings & Accessories Iswor Bajracharya 44

Fig: Tray type deaerator

Fig: Spray type deaerator

Boiler Mountings & Accessories Iswor Bajracharya 47

Due to the inherent problems in reciprocating

Fig: Reciprocating Feed Pump

Fig: Centrifugal Feed Pump

Boiler Mountings & Accessories Iswor Bajracharya 50

Types of Steam Separator

Boiler Mountings & Accessories Iswor Bajracharya 52

Fig: Baffle type steam separator

Boiler Mountings & Accessories Iswor Bajracharya 55

Fig: Cyclonic type steam separator

Boiler Mountings & Accessories Iswor Bajracharya 57

Fig: Coalescence type separator

Boiler Mountings & Accessories Iswor Bajracharya 59

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