EXPERIMENT 1: STEAM BOILER OPERATION AND BOILER

MOUNTING

1.0 LEARNING OUTCOMES:

At the experiment, the student should be able to;

1.1 To demonstrate the procedures involved in of starting up and shutting down a

boiler
1.2 To introduce various type of boiler
2.0 EQUIPMENT / APPARATUS
2.1 Fire Tube Boiler (Fulton 10E)
3.0 SAFETY AND HEALTH
3.1 Read and fully understand the working instruction in the lab.
3.2 Wearing suitable clothes during practical such as lab jacket.
3.3 Following the rule and regulation of lab practice.
3.4 Avoid fooling around with friend in the practice area.
3.5 Make sure that the health is in good condition.
3.6 Fully aware of IEE (Electric working regulation and work safety)
3.7 Turn off electric supply when lightning strikes.
3.8 Avoid working with wet hand.
4.0 THEORY BACKGROUND
4.1.1 Boiler mounting are device connected to the boiler which aid in its safe
and efficient operation.
4.1.2 Type of mounting
4.1.2.1 Water gauge:
The function of water gauge is to show boiler water level for maintenance.
According about specification B.S 759:1967,each steam boiler shall have
at least two independent means of indicating level can be observed, expect
that:
4.1.2.1.1 For boiler with all the drum safety valve set at or above
62bar , two independent compensated manometer
remote. Water level indicators be used in place of one
the water gauges.
4.1.2.1.2 For boiler of less than 300Ib hour evaporative capacity
one water gauge is sufficient.
4.1.2.1.3 For once-though boilers no water gauges are required.
 4.1.2.2 Water column

Water column is a hallow casting or forging connected by pipes at the top

and bottom water spaces . the steam pipe connection to top of water column must
not be lower than top of gauge glass and the water pipe connection to the column
must not be higher than bottom of glass.

Minimum size of these connection pipes must not be less than 1 in.
Plugged tees of crosses are used wherever practicable at right – angle turns so that
all parts of piping may be easily examined and cleaned by removal of plugs.

Cast iron water column may be used for pressure not exceeding 350psig
(15 bar) ,and malleable-iron column must be used. Water column and water gauge
must be test to prove that all passages are clear while the boiler is in operation.

4.1.2.3 Pressure gauge

The most common form is the bounder gauge. The gauge is

connected to the boiler drum through a siphon. The main feature is the
bourdon tube, segment gear, pinion gear and calibrated scale

4.1.2.3.1 Principle work:

The main feature is the elliptical section bourdon spring tube . The
siphon contain water of condensed steam which enter the bourdon tube.
The pressure of water makes the section more nearly circular and flattens
the curve. The movement of the tip is practically between the internal and
external pressure on the tube. Since the tube is surrounded by atmosphere,
absolute pressure is the gauge pressure plus atmospheric pressure.

The movement of the tip is magnified by the mechanism consisting

of the adjustable link, the segment lever, pivoted, hairspring and calibrated
scale.

The gauge is generally made to indicate up to twice the maximum

working pressure so that the pointer is vertical when the safety valve is
about to blow off. B.S 759 states “the graduation shall be from zero to not
less than one and one-half times and not more than twice the operating
pressure.” Each dial shall have marked upon it the boiler operating
pressure in red and the maximum permissible working pressure in purple.
 4.1.2.4 Safety valve

All except small boiler should have at least two safety valve which
will open when the boiler pressure exceeds the safe work pressure. These
valves are almost all of the disc type with narrow flat or conical seats.
They should be large enough to discharge the whole of the steam as
rapidly as it is generated when the boiler is working at full power.

B.S 759 state: “it is recommended that at least two safety valves,
one of which may be of the high ‘high steam and low water’ type, be fitted
to each boiler but it not case shall a boiler with more than 50 m². Heating
surface be fitted with less than two safety valve. Every super heater shall
have at least one safety valve on the outlet side.

4.1.2.5 Blow-off valve:

Periodically it is necessary to empty the boiler in order that it may

be cleaned and incepted internally. It also a common practice periodically
to discharge a portion of the water from the bottom of the boiler in order
that any sediment which may be deposited may be carried away. Soft
scale, or sludge, may form as a result of water treatment and has to be got
rid of. For these purposes a blow-off valve or cock is fitted to the lowest
part of the boiler.

4.1.2.6 Fusible plug:

The crown of the furnace or combustion chamber should be fitted with a

plug held in position by a fusible metal or alloy. This plug under normal condition
is covered with the water in the boiler with keep the temperature of the fusible
metal below is melted point. But should the water in the boiler fall below the
“low-water” level, the fusible metal is melted by the heat of the furnace, the plug
drop out the steam rushes into the furnace and puts out the fire or gives warning to
the stoker that the furnace or combustion chamber crown is in danger of being
overheated.
6.0 RESULT AND QUESTION

6.1 Why must we check the valve when start up the boiler?

In the period just after commissioning the boiler, the boiler might require slight adjustments. One
of the common problems is dirty water fouling the probes, as discussed above. Also the pump
strainers or the Feed water check valve might not be seating properly due to dirt. These are the
normal conditions that might occur if Low water problems occur. Wrong pump rotation also will
cause Low water conditions. The correct pump NPSH is required to operate the pump efficiently.
Certain pumps also may require a certain discharge pressure to achieve maximum efficiency.
High water can be a cause of water entering the boiler through the pump, when the boiler shuts
off for extended periods of time. This usually happens when the boiler cools off, creating a
vacuum. This can be prevented, by installing a vacuum a breaker at the highest point on the
piping that holds the Pressure controls at the front of the boiler. Chemical pumps should also be
adjusted as required