[DEETAF COLLEGE OF ENGINEERING]

PLANT MAINTENANCE AND WORK SERVICE - PRACTICE March 9, 2021

BOILER MOUNTINGS

Boiler mountings are the fitting and devices which are mounted on the boiler for the safety of the
boiler and for complete control of the process of steam generation.

The mountings which must be fitted on the boilers according to the boiler regulations are
described below:-

(a) Safety valves    

(b) Water level indicators/Water Gauge     
(c) Pressure gauge
(d) Fusible plug      
(e) Steam stop valve or Junction Valve     
(f) Feed check valve
(g) Blow off cock
(h) Manhole and Handhole
(i)Steam Scrubbers/Anti-priming pipe
(j) Air vents and vacuum breakers
(k) Soot blowers

Safety Valve

Function: The function of a safety valve is to prevent excessive pressure from building up in a
steam boiler. If the steam pressure in the boiler drum exceeds the working pressure, it permits the
steam in the boiler to escape to the atmosphere until the safe working pressure in the boiler is
reached again. The safety valve also warns the boiler attendant as the steam escape through the
safety valve. .

Principle: The principle of operation of safety valve depends on the fact that a valve is pressed
against a seat through some external force. When the steam force corresponding to boiler
pressure acting under the valve exceeds the external force, the valve gets lifted off its seat
allowing some of the steam to escape until the working pressure is restored again.

Types: There are four types of commonly used safety valves as given below:

(i)   Dead weight safety valve,      (ii) Spring loaded safety valve,

(iii) Lever safety valve and           (iv) High steam and low water safety valve.

29.1.1.  Dead Weight Safety Valve:

In this valve, the steam pressure in the upward direction is balanced by the downward force of
the dead weights acting on the valve.

Construction:

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Refer Fig 29.1. It consists of a vertical cast iron or steel pipe through which the steam pressure
acts on the valve. At the lower end of vertical pipe, a bottom flange is provided to bolt safety
valve to the seating block on the boiler shell. At the upper end of the vertical pipe, a gun metal
valve seat is screwed to it. Under normal working condition, the gun metal valve rests on this
valve seat. This valve is free to move in discharge pipe and secured to a large weight carrier
which hangs freely over the vertical pipe. To balance upward force of steam pressure, the dead
weights of cast iron rings are placed on the weight carrier. Further, the dead weights and weight
carrier are covered by a cast iron cover plate just to avoid any mishandling of the weights. A
discharge pipe is used to discharge the steam to the atmosphere after the valve is lifted.

            (a)                                                                                                                   (b)

 Fig. 29.1. Dead Weight Safety Valve  in (a) closed and (b) open position

Operation:

 When steam pressure in side the boiler is below or equal to working pressure:

The upward force exerted by boiler steam on the valve is balanced by the downward force due to
total weight of the valve, weight carrier, dead weights and cover plate.  Under these normal
conditions, the valve lies on its seat and the steam will not escape from the boiler as shown in
Fig. 29.1 (a).

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 The upward force exerted by boiler steam on the valve is over powered the downward force due
to total weight of the valve, weight carrier, dead weights and cover plate.  Under this condition,
the valve along with weight carrier is lifted up from its seat and the steam escapes through the
discharge pipe as shown in Fig. 29.1 (b).

Uses:

This type of valve is used only on stationary boilers such as Lancashire boilers, or other low
capacity boilers.

29.1.2.  Spring Loaded Safety valve:

In this valve, the steam pressure in the upward direction is balanced by the downward force of
the spring.

Construction:

Fig. 29.2 (a) shows a Ram’s Bottom spring loaded safety valve. It has a cast iron body which is
provided with two channels for the flow of steam to the atmosphere when the steam pressure in
the boiler exceeds the working pressure. These two channels are connected to a valve chest, the
flange of which is bolted to the seating block on the boiler shell. Each channel has separate
valve. The necessary thrust for keeping the valves on their valve seat against the steam pressure
is provided by pivot of the lever which is held down by the helical spring. During steam
generation operation, the working of the valve is checked by pulling the projected end of the
lever.

Operation:

 When the steam pressure in the boiler is equal to the working pressure:

The upward force exerted by boiler steam on the valve is balanced by the downward force of
spring.  Under this condition, the valve lies on its seat tightly and the steam will not escape from
the boiler as shown in Fig. 29.2 (a).

 When the steam pressure in the boiler is more than the working pressure:

The upward force exerted by boiler steam on the valve is overpowered the downward force of
spring.  Under this condition, the valve automatically opens and the steam escapes to the
atmosphere(Fig. 29.2 (b)) till the pressure falls back to the working pressure.

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Fig. 29.2. Ram’s Bottom spring loaded safety valve in (a) closed  (b) open position.

Uses:  These valves are suitable for

 both low and high pressure boilers

 stationary and non-stationary boilers

Advantage:

 Elimination of heavy weight.

 Easy maintenance and examination.
 Not effected by jerks and vibrations.

29.1.3.  Lever Safety Valve:

In this valve, the steam pressure in the upward direction is balanced by the downward force of
the lever system.

Construction:

Figure 29.3 shows the arrangement of a lever safety valve. It has a cast iron valve body of
diameter ‘d’, the flange of which is bolted to the seating block on the boiler shell. On the
opposite end of valve body, it has a valve seat on which the valve is held tightly by downward
force of a lever having fulcrum at one end and movable weight at the other end. To prevent side
movement of the lever, a guide is provided between the lever and the valve body. This guide also

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limits the lift of the valve. According to required steam working pressure in boiler, the position
of the movable weight on the lever is adjusted.

Operation:

When the steam pressure in the boiler is equal to or under the normal limit of working pressure:
The upward force exerted by boiler steam on the valve is balanced by the downward force of
lever system.  Under this condition, the valve remains on its seat tightly and the steam will not
escape from the boiler as shown in Fig. 29.3 (a).

When the steam pressure in the boiler exceeds above the normal limit of working pressure: The
upward force exerted by boiler steam on the valve is overpowered the downward force of lever
system. Under this condition, the valve automatically lifts off from its seat and escapes the steam
to the atmosphere (Fig. 29.3 (b)) until the pressure falls back to the working pressure.

 Fig. 29.3.  Lever Safety Valve (a) closed  (b) open position.

The position of movable weight ‘W3’ suspended on the lever for a given steam pressure can be
calculated as described under:-

Let,     W1, W2 and W3  are the weight of the valve through its center of gravity, weight of lever
through its C.G. and weight of movable weight, respectively and L 1, L2, L3 are their respective
distances from fulcrum.

F is the upward force due to steam pressure ‘p, N/m 2’ acting at the center of the valve at a
distance L1 from the fulcrum

29.1.4.  High Steam and Low Water Safety Valve:

This valve has a combined safety arrangement against

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a)      high steam pressure in the boiler and

b)      low water level in the boiler.

A commonly used high steam low water safety valve consists of two valves, namely valve ‘U’
and valve ‘V’ as shown in Fig. 29.4 (a). Under normal condition, the valve ‘U’ rests upon its
valve seat and the valve ‘V’ rests on valve ‘U’ which act as seat for valve ‘V’.

When valve act as safety against high pressure steam in the boiler:

Construction:

High steam and low water safety valve acts like a simple lever safety valve when it acts as safety
against high steam pressure in the boiler. A lever ‘L1’,hinged at one end and loaded at the other
end by a weight ‘W’, forces valve ‘U’ upon its seat through pivot ‘P’ as shown in Fig. 29.4 (a).

Operation:

When the steam pressure in the boiler is under normal limit of working pressure: The upward
force exerted by boiler steam on the valve ‘U’ is balanced by the downward force of lever
system through pivot ‘P’.  Under this condition, the valve ‘U’, having valve ‘V’ seated on it,
remains on its seat tightly and the steam will not escape from the boiler as shown in Fig. 29.4 (a).

When the steam pressure in the boiler exceeds above the normal limit of working pressure: The
upward force exerted by boiler steam on the valve ‘U’ is overpowered the downward force of
lever system. Under this condition, the valve ‘U’ having valve ‘V’ seated on it, lifts off
automatically from its seat and escapes the steam through the passage between the valve ‘U’ and
its valve seat to atmosphere as shown in Fig. 29.4 (b)until the pressure falls back to the normal
working pressure.

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Fig. 29.4. High Steam Low Water Safety Valve acts as safety against high pressure steam

When valve act as safety against low water level in the boiler:

Construction:

For prevention against low water level the high steam and low water safety valve is operated by
a lever ‘L’ which is hinged at the fulcrum ‘F’ inside the boiler as shown in Fig. 29.4 (a). A
weight ‘W1’ is attached to one end of the lever ‘L’ and a large floating earthware ‘E’ to the other
end. By hanging a dead weight ‘W2’  on the lower end of the spindle ‘S’ of valve ‘V’, the
hemispherical shaped valve ‘V’ is forced downwards on valve ‘U’ which act as a seat for valve
‘V’. The knife edge ‘K’ of lever ‘L’ is provided to push collar ‘C’ of spindle ‘S’ for lifting valve
‘V’ from its seat. 

Operation:

When the water level in the boiler is at normal level: The floating earthen ware ‘E’ remains in
water and whole level system ‘L’ with its weights is balanced. Under this condition, the valve
‘V’ is seated tightly on valve ‘U’ due to the downward force of dead weight ‘W2’ and the steam
will not escape from the boiler as shown in Fig. 29.4 (a).

When the water level in the boiler go down below the normal level: When the level of the water
falls, the floating earthen ware ‘E’ is partly uncovered thus its weight increases due to decrease
in buoyancy force on partly uncovered earthenware ‘E’. With this increase in weight of earthen
ware ‘E’ as compared to Weight ‘W1’, the lever system ‘L’ becomes unbalanced and the earthen
ware float ‘E’ moves in a downward direction. With this movement of lever the knife edge ‘K’
provided on lever push the collar C with the spindle and valve ‘V’ in the upward direction

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leaving valve ‘U’ on its seat and the steam gets the passage to escape to atmosphere between the
valve ‘V’ and valve ‘U’ as shown in Fig. 29.5. The escaping of steam causes a loud noise as it
passes through a specially constructed passage and alert the boiler attendant regarding low water
level. 

Fig. 29.5. High Steam Low Water Safety Valve in open position due to low water level

Uses:

This valve is used in internally fired boilers such as Lancashire and Cornish in which there is
always a chance of overheating of the fire tubes.

29.2. Water Level Indicator/Water Gauge

Function: The purpose of this fitting is to indicate the level of water in the boiler and to enable
the attendant to regulate the supply of feed water in the boiler to maintain correct level.

Number and Location: Normally two water level indicators/water gauge are fitted in front of
the boiler.

Construction and operation: A commonly used water level indicator is shown in Fig. 29.6. It
consists of a gauge glass tube having guard cover fitted between two hollow gun metal casting

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tubes of which one of it is fixed with steam space and the other with water space of the boiler. As
steam comes from upper tube and water comes from lower tube in gauge glass, so the water level
inside the boiler will be the same as seen in the gauge glass tube. It has a steam cock and a water
cock to keep or shutoff the glass tube in connection with steam space and water space in the
boiler, respectively. It has also one drain cock to discharge water at regular intervals to avoid
accumulation of foreign element in the path from boiler to glass tube. During operation, for the
observation of the water level in the boiler, the steam and water cocks are opened (in vertical
position) and drain cock is closed (in horizontal position) as shown in Fig. 29.6. The various
screw caps provide access to different passages for cleaning purposes.

Safety against if gauge glass tube gets broken:

An arrangement of hollow metal tube and two small metal balls inside the upper and lower metal
casting tubes, as shown in Fig. 29.6, is used for an automatic shut off the steam and water supply
to the gauge glass in case the gauge glass tube gets broken.

Under normal condition: The balls are at rest as pressure exerted on all side of it remains the
same, as shown by Fig. 29.6 (a).

Under condition when the glass tube breaks: Then the pressure at the gauge glass tube will be
much less than the pressure in the boiler. This pressure difference causes the both ball to move
towards the ends of the gauge glass tube and fit into the steam and water openings as shown in
Fig. 29.6 (b) and thus closes the gauge glass tube ends. As a result steam and water may not
escape any more. Now by closing the steam cock and water cock (in horizontal position), the
glass tube may be replaced.

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Fig. 29.6. Water Level Indicator/Water gauge (a) under normal condition (b) under
condition when the glass tube breaks

29.3. Pressure Gauge

Function: With pressure gauge steam pressure of boiler can be measured.

Number and Location: All boilers must be fitted with at least one pressure gauge and it is 
usually mounted at the front top of the boiler shell or drum so that attendant can easily read the
pressure reading .

There are two types of pressure gauges:

 Bourdon tube pressure gauge and

 Diaphragm type pressure gauge.

The common type of pressure gauge for steam boilers is Bourden’s pressure gauge, construction
and operation of which is described as follows:

Construction:

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The Bourden type pressure gauge, as shown in Fig. 29.7, consists of a C shaped spring tube ‘C’
of elliptical in cross-section.  One end ‘A’ of this spring tube is closed and movable while the
other end is fixed to a hollow block ‘D’. To have link with steam space of a boiler, the hollow
block of Bourden tube is connected to the boiler through a water filled U-shaped siphon tube.
The water in the siphon tube prevents the steam from entering and coming in contact with the
spring tube when for pressure measurement three way lever handle cock ‘S’ is opened to the
boiler pressure otherwise without U-tube steam from boiler could overheat the spring tube which
may ultimately spoil the accuracy of pressure gauge. To have reading of pressure in bar on the
dial of the gauge, the dial mechanism is attached to the movable closed end of the spring tube. In
this mechanism, the closed end of tube is connected to a toothed sector wheel ‘T’ through a link
‘R’. Further, the toothed sector hinged at point ‘H’ is meshed with a pinion ‘P’ fixed to the
spindle of the pointer ‘N’.

The accuracy of the pressure gauge during working of boiler can be tested by connecting the
inspector’s steam pressure test gauge to normally plugged connection ‘Q’ provided on U-tube
siphon. Three way lever handle cock ‘S’ is used to isolate the gauge from the boiler when the test
gauge is to be attached/removed. The three way cock ‘S’ is also used to isolate the gauge from
the boiler in the event of repair or replacement of the gauge. For cleaning the siphon, plug ‘Z’ is
provided on U-tube.

Operation:

When the three way lever handle cock ‘S’ is opened to sense the steam pressure of boiler, the
water in U-tube fills the spring tube ‘C’ and cause the spring tube straightens out depending upon
steam pressure in the boiler as the steam pressure acting through water on the inside of the spring
tube tries to change the cross-section of elliptical spring tube ‘C’ to circular. Since one end of the
spring tube is fixed, this makes closed end ‘A’ of tube to move in outward direction. The
movement of closed end of spring tube is magnified considerably through the dial mechanism
attached at the closed end and the pointer rotates over a circular graduated dial and pressure can
be easily read against the pointer on the circular graduated dial in bars.

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Fig. 29.7. Bourden’s pressure gauge with water filled U-tube siphon attachment

29.4.  Fusible Plug

Function: The function of the fusible plug is to protect heating surface area of the boiler against
damage of overheating when the water level in the boiler falls below the safe limit.

Location: The fusible plug is generally inserted in the crown of the furnace or in the combustion
chamber at the lowest permissible water level. (Refer Figures 27.4, 28.1 and 28.2)

Construction:

A fusible plug as shown in Fig. 29.8 is made from three parts which plug the whole in crown
plate of the furnace and thus stop the steam or water of boiler from entering into the furnace.
First part of it consists of a hollow gunmetal body ‘A’ which is screwed into the crown plate of
the furnace with the help of a hexagonal flange. The second part consists of another hollow gun
metal plug ‘B’ which is screwed into the upper portion of the hollow gunmetal body ‘A’ and the
third part consists a solid copper plug ‘C’ which is kept and held firmly in the hole of plug ‘B’ by
setting low melting point fusible metal between plug ‘A’ and plug ‘B’. The fusible metal may be
of tin or lead which has a lower melting point than plug ‘A’ and plug ‘B’.

Operation:

Under normal water level condition: Under this condition, the fusible plug fixed on furnace is
always covered with water. As for hot gases in furnace the water is always available for heat
transfer, the temperature of fusible metal remains below its melting point. This keeps the solid
copper plug in its position as shown in Fig. 29.9 (b) and normal steam generation process is
carried out in boiler.

Under condition when the water level falls below the lower limit in the boiler:In this condition,
the fusible plug gets uncovered out of water and is exposed to steam only. As now the water is
not available as heat transfer medium for hot gases of furnace, the both plugs ‘B’ and ‘C’ gets
overheated. The overheating of plugs result melting of fusible metal first which make the copper
plug ‘C’ is released and falls as shown in Fig. 29.9 (b). This opens a way between steam space
and furnace and steam rush into the fire box and extinguish the fire and stop the steam generation
process.

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Fig. 29.8. A fusible plug (a) Under normal condition (b) Under condition when water level
low

Before starting the steam generation process again in the boiler, the plug ‘C’ is fixed back in plug
‘B’ with fusible metal.

29.5.Steam Stop Valve or Junction Valve

Function: The function of the steam stop valve or junction valve is to stop or regulate the flow
of steam from the boiler to the steam pipe or from one steam pipe to another steam pipe or from
the steam pipe to the turbine/engine.

Location: This valve is usually mounted over the boiler drum (Fig 29.1), in the steam pipe
leading to-the steam turbine/engine, and between the steam pipes to stop or regulate the flow of
steam.

When this valve is mounted over the boiler drum it is called a junction valve. If this valve is
mounted in the steam pipe leading to-the steam turbine/engine or between the steam pipes, it is
called a steam stop valve. The steam stop valve and junction valve are basically the same valves.

Construction:

It consists of a valve body made of cast iron having two flanges at right angles as shown in Fig.
29.9. When the valve is used to stop or regulate the flow of steam from the boiler to the steam
pipe, its inlet end flange is attached to the seating block at the highest point of the steam space of
the boiler shell while its outlet end flange is bolted to the steam pipe. It also consists of a gun
metal valve in the form of disc and a valve seat made of gun metal. The valve seat is screwed on
the valve body whereas the valve seat is connected to hand wheel through a spindle. To prevent

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any leakage of steam from valve body to atmosphere, the spindle is passed through a gland. Due
to rotation of hand wheel, the valve may move in downward or upward direction to close or open
the passage fully or partially for the flow of steam.

Its flange is attached to the delivery end of the feed pump is attached to the pipe which leads to
the boiler.

Operation:

Under normal working condition of boiler: The valve is open and steam flows from the boiler to
the steam pipe as shown in Fig. 29.9 (a).

Under conditions when boiler is shut down or steam is not required from boiler: The valve is
closed by operating the hand wheel as shown in Fig. 29.9 (b) and steam flow from the boiler to
the steam pipe stops.

 Fig. 29.9: Steam stop valve (a) open and (b) close positions

29.6.Feed Check Valve

Function: The function of the feed valve is

 To control the supply of feed water to the boiler from the feed pump and
 To prevent any water escaping back from the boiler in the event of failure
of the feed pump or the pump pressure less than the boiler side.

Location: It is fitted over the boiler shell slightly below the normal water level of the boiler.

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Construction:

It consists of a valve body having two flanges at right angles as shown in Fig. 29.10. Its inlet end
flange is attached to the delivery end of the feed pump while its outlet end flange is attached to
the pipe which leads to the boiler. The body of feed check valve contains two valves, one is the
feed valve to control the supply of feed water to the boiler and other is the check valve to prevent
any water escaping back from the boiler.

The feed valve is operated manually by a hand wheel similar to steam stop valve and it may
move in downward or upward direction to close or open the passage fully or partially for the
flow of water. While the check valve operates automatically due to pressure difference of water
on the pump side and the boiler  of the check valve and it may either in open or close position to
allow the feed water flow in one direction only i.e. from feed pump to boiler side only.

Operation:

Under normal working condition of boiler when the feed pump is working properly: The supply
of water in the boiler is controlled by manually raising or lowering the feed valve from its seat by
means of a hand wheel as shown in Fig. 29.10 (a). In this condition, the more water pressure on
feed pump side of the check valve cause the check valve to lift from its seat and allow the water
to enter into the boiler to maintain a constant water level.

Under conditions when there is failure of the feed pump or less pump pressure than the boiler
side: The feed valve is in open position as shown in Fig. 29.10 (b). But due to failure of feed
pump or less pump pressure than the boiler side, the less water pressure on feed pump side of the
check valve cause the check valve to press on its seat and prevents the back flow of water from
the boiler to water pump.

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Fig. 29.10. Feed check valve (a) under normal condition (b) under condition when there is
failure of the feed pump

29.7. Blow-off Cock

Function: The blow off cock serves three purposes:—

(i)  To blow out sediments, precipitated sludge, loose scale or other impurities periodically when
the boiler is in operation.

(ii)  To empty the boiler when necessary for cleaning, repair and inspection.

(iii) To permit rapid lowering of water level in the boiler if accidentally it becomes too high.

Location: The blow off cock is fitted at the lowest water space of a boiler shell.

Construction:

Blow-off Cock consists of a casing having two flanges at their ends as shown in Fig. 29.11. One
of the flanges of the casing is attached to the boiler while the other flange is attached to a pipe
which takes the blow off water out of the boiler. It also consists of a conical plug which fits
perfectly into a matching hole in the casing. For the discharge of water from boiler a rectangular
hole is provided in the plug.

Operation:

During working of boiler when blow out of sediments is not desired: The position of plug is such
that the solid part of plug comes in line with the hole in the casing as shown in Fig. 29.11 (a). In
this position, there is no discharge of water from boiler.  

During working of boiler when blow out of sediments is desired: The plug of blow off cock is
turned in such a way that the hole in the plug comes in line with the hole in the casing. In this
position, the water from boiler rushes out of the boiler.

After required time of blow out, the discharge of water is again stopped by turning plug in
previous position.

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 Fig. 29.11. Blow off cock (a) close (b) open

29.8.Manhole and Handhole

Function: Man holes and hand holes are required for cleaning, inspection and repairing of the
boiler. The manhole is provided for the entrance of a man inside the boiler shell whereas hand
hole is for a hand.

Location: The manhole is provided on the boiler shell at a convenient place.

Construction: Generally they are elliptical in shape and cover is provided. The size of the man
hole is usually 400 mm x 300 mm.

29.9.Steam Scrubbers/Anti-priming pipe

Function: The steam in contact with the water surface always contains water particles. A steam
scrubber also known as steam drier is used in a boiler to remove the water particles contained in
steam.

Location: It is fitted inside the boiler drum or shell just before steam outlet of boiler.

Construction and operation:

Refer Fig. 29.12. Anti-priming is a cast iron box which is fitted under the mounting block on
which the steam stop valve is to be bolted. When the steam with water particles passed between
closely fitted corrugated plates or the perforation made in the upper half of the anti-priming pipe,
the heavier water particles separate out and are collected at the bottom of the anti-priming pipe.
The water thus collected is later on drained to the boiler through the small holes ‘O’ provided at
the bottom of the anti-priming pipe. 

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Fig 29.12: Anti-priming pipe mounted in boiler

29.10. Air vent/Vacuum breaker:

Function: It is used to eliminate air from steam space of the boiler.

Location: Air vent/vacuum breaker is located above the steam space in the boiler Fig 29.12.

Construction and operation:

When a boiler is started from cold, the steam space is full of air. As this air blankets the heat
exchange surfaces and it has no heat value, the performance of steam plant is adversely affected.
This air also gives rise to corrosion in the condensate system, if not removed adequately.

So, to increase the performance and reduce the corrosion of boiler, the air is purged from the
steam space by air vent using a simple cock during start up of boiler.  Normally this is done by
leaving the air vent open until a pressure of about 0.5 bar is achieved inside the boiler.

29.11.    Soot blowers:

Function: It is used to blow soot and the combustion products from the tube surfaces.

Location: It is located near the water tubes inside the boiler as shown in Fig 29.13.

Construction and operation:

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The soot layer on the tubes and shells of the furnace of the boiler acts as a heat insulator. This
not only causes the boiler efficiency to be lowered, but a more serious problem can also occur.
The soot can also catch fire. Therefore it is important to remove the soot without stopping the
steam generation process of the boiler. This is done by soot blower as shown in Fig. 29.13. It is
operated by steam or compressed air.

Fig. 29.13. Soot blower

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