C. BOILER MOUNTINGS AND ACCESSORIES Eg smonvcrion | Boiler Mountings. These are different fittings and devices which are necessary for the operation and safety of a boiler. Usually these devices are mounted over boiler shell. Tn accordance with the Indian boiler regulation the following mountings should be fitted to the boilers. ‘Two safety valves(_—~ ‘Two water level indicators A pressure gauge e A steam stop valve A feed check valve A blow-off cock — ~ ‘An attachment for inspector's test gauge A man hole: © Mud holes or sight holes. / Boilers of Lancashire and Cornish type should be fitted with a high pressure and low water safety valve. ‘All land boilers should have a fusible plug in each furr.ace. Boiler Accessories. These are auxiliary plants required for steam boilers for their proper cperation ant for the iserease of their efficiency. Commonly used boiler accessories are : © Feed pumps © Injector Scanned with CamScanner© Economiser © Air preheater © Superheater © Steam separator ° gd BOILER MOUNTINGS ‘The various boiler mountings are discussed as follows : 30.1. Water Level Indicator The function of a water level indicator is to indicate the level of water in the boiter Itis also called ‘eter gauge Normally two water level indicators ae ited at the he cadre A= Fd plate of boiler B aud C» Hollow gun metal eas, Winios Dend = Cocke ings J = Two balls F= Gauge glass G = Hollow metal column P15 59, Wator evel in cate” Scanned with CamScannerjer, Where the boiler drum is situated at consid floor, the water BauBe ee jnclined to make the water level visible from rable height Fe ‘the water being heated in one taller transforms into steam the level of water in the boiler shell goes decreasing. For the ~ working of the boiler, the water must be kept at safe-level, If the water evel falls below the safe level wana the boiler goes on producing steam without the addition of feed water, great damage sah crack ond leak can occur to the parts ofthe boiler which get uncoys from water. This can Ute in the stoppage of steam generation and boiler operation. Fig. 39 shows a Hopkinson’s water gaus ‘a common form of glass tube water-level gauge, Ais the front ond plate of the oiler F is very hard glass tube a es water level and gMennected to the boiler plate through stuffing boxes in hollow gun metal castings (B, C) having flanges X, Y for bolting the plate. "For controlling the passage of steam and water cocks D and E are provided. When these cocks are opened the water stands in the glass tube at the same level 3s in the boiler, K is the drain Jow out water at intervals so as nell ag saints to accumulate PPE Soe Jower stuffing boxes ‘are connected hy a hallow metal column G. Balls “J and H rest if the position Bi fie posit shi sa he caube. When the glass tube breaks due trash of water ine bottom. wn in the normal w £ due to Se GrTh lle me totes postions and alt gi tga and Sea the cocks peeve safely closed and broken glass tube replaced. M, N, P and K are ‘serewed caps for ‘internal cleaning of the passage after dismantling. L is the guard glass ; it is tough and does not give splinters on breaking. Thus when the gauge glass breaks, and this guard glass ‘which normally HT eld flying pieces, also gives way, the pieces will not fly one and hurt the attendant. 30.2. Pressure Gauge The function of a pressure gauge is to measure the pressure exerted inside the vessel. The gauge is usually mounted on the front top of the shell or the drum. It is ‘usually construt Vndieate upto double the maximum working pressure. its dial is gradvaved to read pressures 1S in gle (pres “are two types of pressure gauges : (i) Bourdon Tube pressure gauge and (ii) Diaphragm type pressure gauge. A pointer, which rotates over circular graduated scale, indicates the pressure. Fig. 40, Bourdon pressure gauge, Scanned with CamScannersure gauge is known as_co! Z co as to pene passes abnva and helo the atmosohiere onthe same dal Fig. 40. shows a Bourdon pressure gauge (single tube) a common type } me y Ye of py tial feature of thi is the elliptical spring tube which ig mor%u wrheeeteete _ is solid drawn. One end A is closed by a plug and the other stage a block C the block is connected with syphon tube (which is full of condensed wajcn'*ety be (whnebl va pressure-forces-the-water-from_the syphon tube ii and this The become circular is cross-section, As the Tube is fixed at C, the other end A 8 the ee . . Moves oy outward movement is magnified by the rod R sind transmitted to toothed sector 7. ov. Ne sector is hinged at the point H and meshes with the pinion P fixed to the spindle of ‘the pe het Thus the pointer moves and registers the pressure on a graduated dial. Pointer y. The movement .of the free end of pi clliptigel ke is ncoportional to the diffe external and ihc pe le. Sie the outside pressure on the tube jg Aetna mal apd i is " the movement of the free end 14 measure of the boiler pressure above atmoephee ie a pressure, M = Connection pressure gauge R= Plug for testing pressure gauge 2 = Plug for, cleaning Syphon ‘S= Three way cock ube Fig. 41. U-tube, syphon. Syphon which co, . Space of the boiler ad ont aE to the boiler. The U-tube syphon < T transmits s from entering the pressure Pressure to the nsed steam which enters the gauge and reading obtained will be fale 122° steam Passes ine at at the same time prevents steal ne inspector's standard gauge and ¢, ™Metal ma; eenuse tube it will expand the tube Z is employed for cleaning the Soph He traey eh afta, Plug Ris used for connedtig is AY cock § ig ees Gauge while in service. Plug used for either i boiler irdon, Te ga connecting the and portable boilers. foute lo more rigid thes Thesis space, ‘and more suitoble for locomotive Scanned with CamScanneryr AOPERTIES OF STEAM AND STEAM GENERATORS 30.3. Safety Valves The function of a safety valve is to,selease the excess steam when the pressure of steam inside the boiler exceeds the rated pron) As soon as the pressure of steam inside the boiler cxceods the rated pressure the safety val automatically opens and excess steam rushes out into the atmosphere till the pressure drops down to the normal value. A safety valve is generally tpounted on the top of the shell. As per boiler regulations every boiler must be fitted at least with two safety valves. ‘The various types of safety valves are enumerated and discussed as follows : 1, Dead weight safety valve, 2, Lever safety valve. 3, Spring loaded safety valve. 4, High steam and low water safety valve. 30.8.1. Dead Weight Safety Valve Fig. 42 shows a dead weight safety valve. A is the vertical cast iron pipe through which steam pressure acts. B is the bottom flange directly connected to seating block on the boiler shell communicating to the steam space. V is the gun metal valve and VS is the gun metal valve seat. Dis another cast iron pipe for discharge of excess steam from the boiler. W are the weights in the form of cylindrical dise of east iron. WC is the weight carrier carrying the weights W. The cover plate C covers these weights. The steam pressure acts in the upward direction and is balanced by the force of the dead weights W. The total dead-weights consist of the sum of the weights W, weight of the valve V, weight of the weight carrier and weight of the cover plate C. we A= Castiron pipe B = Bottom flange VS = Gun metal valve seat V = Gun metal valve C= Cover plate W = Cast iron weights WC = Weight carrier Fig. 42. Dead weight safety valve, Scanned with CamScanner70 APPLIED THERMODYNAMicg When the steam pressure is greater than the working pressure it lifts the valve with it, weights. So the steam escapes from the boiler and the steam pressure thereby decreases. Merits of dead weight safety valve : 1. Simplicity of design. 2. Gives quite a satisfactory performance during operation. ; 3. It cannot be easily tempered from the pressure adjustment view-point. Demerits : . 1. Unsuitable for use on any boiler where extensive vibration and movement are experienced (eg., locomotive and marine work). oe 2. It is not suitable for high pressure boilers because a large amount of weight is required to balance the steam pressure. , | Uses. It is mainly used for low pressures, low capacity, stationary boilers of the Cornish and Lancashire types. 30.3.2. Lever Safety Valve Refer Fig. 43. It consists of a lever and weight W. The valve (made of gun metal) rests on the valve seat (gun metal) which is screwed into the valve body ; the valve seat can be replaced if required. The valve body is fitted on the boiler shell. One end of the lever is hinged while at the other is suspended a weight W. The strut presses against the valve on seat against the steam pressure below the valve. The slotted lever guide allows vertical movement to the lever. Slotted lever guide Boiler shell Fig. 43. Lever safety valve. When the steam pressure becomes greater than < lied with the lever and the weight. Consequently, the rte noel WOrRINg Pressure, the valve i the valve and seat and the steam pressure decreases, P&S through the passages between Fig. 44 shows the losding arrangement on the ; e iever. Scanned with CamScannerLet p = Steam pressure (gauge), d = Diameter of the valve, W = Weight suspended on the lever, W, = Weight of the lever acting at the centre of gravity G, ', = Weight of the valve, and A = Area of the valve. Steam pressure Fig. 44. Loading arrangement on the lever. ‘Taking moments about the fulcrum F, we get x Wx AF + W, x GF + W, x VF =pxax VF, wherea = 4 d*. From the above equation we can find the weight W or length of lever for a given pressure of steam (p). 30.3.3. Spring Loaded Safety Valve For locomotives and marine engines both the lever and dead-weight types are unsuitable for abvious reasons, and the valve must be spring loaded, as such valve is unaffecter! by vibration or deviations from the vertical. Fig. 45. Ramsbottom springloaded safety valve, Scanned with CamScannerAPPT] ~ SS i i bottom spring | ig. 45 illustrates what is known as Rams! spring loaded oq y two igen valves and seatings having one lever, bearing on the two st Valve, ing the spring being placed between the valves. The tension on th? “Alvee anal the nuts, By pulling of raising the lever the operatoridriver can reliene the 82 be ih valve separately, and ascertain it is not sticking on the seating, Prom One disadvantage ofthe spring-loaded safety valve is that the loag on the x the valve lifts, so that pressure required just to lift the valve is less than 1 rau, fully. From this reason is some cases it is arranged that the area acted on by thetic ety when the valve is open than the valve is closed. Steam my 80.4. High Steam and Low Water Safety Valve ms The high steam and low water safety. valve serves the follow automatically escapes out when the level of water falls below a ure of the steam ri: NE Purposes « Sertain level. (i) 1 gy hy ses above a corte : © tated pressure, top valve acts as a lever own in Fy 'S the fulcrum, W, is the weight suspended on ont end of the lever L.. Fie 4, ‘The most i 30.5. Fusible Plug \ low Pay Hane fee fas ble lug is t0 protect the boiler against damage due to overheating fr appropriate place, m the fire box crown plate or over the combustion chamber at its Screwed into the gun metal body, There is another Ty olue by an annulus of fusible metal ‘The fle ow gun. metal plug. phe ‘n-the-boiler shell is normal, the fusible I at an’ the heat from the fusible plug is being conducted ™ the water level falls belon almost temperature and below its mes he i it gets uncovered from wat F ble plig hon he fusible plug to steam i very little compared eae hole. Treated and it melts with the result that the bl ately rush to fire box and extinguigy fire. “"°4™ and water being under pressure immed The fusible plugs should generally .- ro z n ; are liable to become defective over a long Period of use 7 concn tio of about two years as i ae and scale deposits on the other), ey are subjected to heat Scanned with CamScanner\ \ Ml UUSSS SESS SSS W,= Counter weight Ly Ly= Levers V= Valve Us Hemispherical valve VS = Valve seat F,= Fulerum (upper lever L,) Fig. 46. High steam N Li NL F, = Fulerum (lower level L,) E-= Float K= Knife edge C= Spindle w = Dead weight W= Balance weight and low water safety valve. 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When all the water is discharged and steam enters the trap, the increased temperature converts the liquid in the tube B into the gas, the curved tube tends to straighten itself and consequently the valve V is closed. By adjusting the screw S the trap can be arranged to discharge either continuously. or intermittently. The end C of the tube is held against the adjusting screw by the spring, one end of which presses against the lugs L fixed to the casing. Scanned with CamScanner