Spring 2019 MECH 2102 Elements of Mechanical Engineering Lab Manual

Experiment No. - 2

1. Title
To study mountings and accessories of boilers.

2. Objectives
a) To study the working procedure and constructional features of boiler mountings
b) To study the working procedure and constructional features of boiler accessories

3. Apparatus
a) Mountings
I. Model of Safety Valves
 Dead weight safety valve
 Spring loaded safety valve
II. Steam stop valve
III. Model of water level indicator (WLI)
IV. Model of pressure gauges (PGs)
V. Model of fusible Plug
VI. Model of blow-off cock
b) Accessories
I. Model of economizer
II. Model of super heater
III. Model of air preheater
IV. Model of steam separator
V. Model of steam trap
VI. Model of Injector

4. Theory
4.1 Boiler Mountings
Boiler mountings are devices which are required for proper operation, safety and control of the boiler.
 Boiler mountings are components used for ensuring the safety of boiler operation.
 These are generally mounted on the surface of the boiler.
 Control fluid parameters at the inside of the boiler shell.
 The mountings are an essential part of a boiler, without which boiler operation is
impossible.

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Examples are:
 water level indicator (WLI)
 pressure gauges (PGs)
 steam stop valve
 safety valves
 fusible plug
 feed-check valve
 blow-off cock
 manhole and
 mudhole, etc.

4.1.1 Safety Valves

Function: To release the excess steam when the pressure of steam inside the boiler increases higher than the
safe pressure (maximum pressure). Safety valve are used to maintain safe pressure inside the boiler. As soon as
pressure of steam inside the boiler increases higher than the safe pressure, safety valve automatically opens and
excess steam rushes out into the atmosphere still pressure drops down to normal value.
Location: Safety valve is generally mounted on the top of the shell. All boiler should have at least two safety
valves.
The safety valve may be classified as
a) Dead weight safety valve
b) Lever safety valve
c) Spring loaded safety valve
d) High steam and low water safety valve

4.1.1.1 Dead Weight Safety Valve

Construction: A valve is placed upon a valve seat which is fixed upon a long vertical pipe having a flange at
the bottom for fixing at the top of the boiler.
Working Principle:
When the steam pressure exceeds the normal limits, this high pressure steam creates upward force on valve,
thus valve lift with its weights and the excess steam escapes through the pipe to the outside.
Advantages:
 The construction of valve is simple.
 It gives satisfactory operation for low pressure and stationary boilers.
Disadvantages:

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 It is not suitable for moving boilers as the force of the weights should always work vertically
downward.
 It is not suitable for high pressure boiler as the weight becomes too large.

4.1.1.2 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. 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.

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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.

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.b) till the pressure falls back to the working
pressure.

4.1.2 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 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.

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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. (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. (b) and steam flow from the boiler to
the steam pipe stops.

4.1.3 Water level Indicator (WLI)

Function: It is indicates the water level inside the boiler to an observer.

Number and Location: Normally two water level indicators/water
gauge are fitted in front of the boiler.
Working Principle:
The water of the boiler comes into the glass tube through the lower tube
and the steam through the upper tube.
The water then stands in the glass tube at the same level as in the boiler.
Two cocks are used to control the passage of between the boiler and the
glass tube while the third cock is in used to discharge some of the water
from inside the boiler to see whether the gauge is in proper order or not.

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4.1.4 Pressure gauges (PGs)

Function: It is an instrument measure the pressure of steam in boiler.

Location: The gauge is usually mounted on the front top of the shell or the
drum. It is designed to read pressure in kgf/cm2 or bar, above atmosphere.
Number: All boilers must be fitted with at least one pressure gauge. There
are two types of pressure gauges:
 Bourdon tube pressure gauge and
 Diaphragm type pressure gauge.
Construction: The circular bent bourdon tube of oval-cross section is
closed at one end and the other end is connected with steam space of boiler
through siphon (U-tube).
Working: When pressure is applied to inside of oval tube, It cross section
tends to becomes circular, and free end of tube try to becomes straight, so
turning the spindle and needle by the links and gearing.

4.1.5 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.

Working Principle:
In the normal working conditions of the boiler, the fusible plug is
fully submerged under water. When the water level falls below the
fusible plug, the plug gets uncovered from water. The upper portion

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of the plug gets exposed to the steam space. The steam cannot keep the plug cool. This will over heat the
fusible metal. The plug falls down along with the fusible metal making a hole. The steam and water, being
under pressure immediately reach the firebox and extinguish the fire.

4.1.6 Blow-off cock

Function: The blow off cock serves three purposes: —

i. To discharge a portion of water when the boiler is in operation to blowout mud, scale or sediment
periodically
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 Figure. 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. 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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4.2 Boiler Accessories

Boiler accessories are devices which are used to increase the efficiency of a boiler.
 Accessories are the auxiliary items required for proper operation of boiler and improve the Boiler
efficiency of it.
 These are integral parts of the boiler, but not mounted on it
 Control fluid parameters at outside of the boiler.
 These are not essential parts of the boiler, without which boiler can operate through at lower
efficiency.
Examples are
 air preheater
 economizer
 superheater
 feed-pump
 injector,
 baffles, etc.

Boiler with the Accessories

4.2.1 Economizer

A device, which utilizes the waste heat, carried by the exhaust gases before leaving the boiler through chimney
or exhaust steam or utilized steam for heating feed water is called feed water heater or economizer. It is
generally used for stationary boilers. It consists of a large no. of vertical cast iron pipes which are connected
with 2 horizontal pipes, one at the top & the other at the bottom. The feed water is pumped into the economizer
through the bottom pipe. From the bottom pipe the water comes into the top pipe through the vertical pipes &
finally comes into the boiler. The water is allowed to pass in a direction opposite to that of the furnace gas. At
the rear end of the vertical pipes, a blow-off valve is fitted through which any mud or sediment deposited in the
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bottom boxes may be discharged. The soot of the flue gases deposits on the outer surface of the vertical pipes
& this reduces the efficiency of the boiler. A system of scrapers is, therefore, adopted to clean the outer surface
of vertical pipes. Each vertical pipe is fitted with a scraper which moves up & down automatically &
continuously by means of a gear & belt arrangement. A safety valve is also provided at the end of the pipe for
the safety of the pipes.

4.2.2 Super heater

The function of a super heater is to increase the temperature of steam with the supply of additional heat. They
are located in the path of the furnace gases so that heat is recovered by the super heater from the exhaust gases.
It consists of 2 mild steel boxes or headers. Group of solid drawn steel tubes bent to U form is hanged from the
headers. The ends of these tubes are expanded into the headers. C & D are external & internal covers. For
inspection & cleaning, the space is provided between the headers. The covers close this space. Any tube may
be taken out & replaced without disturbing the super heater the branches on the headers for the inlet & outlet
of the steam are forged on the headers. The steel flanges have been screwed on to the header. A balanced
damper is provided in the super heater to prevent the overheating of the super heater tubes. The handle
operates this damper. By turning the damper upwards into the vertical position the gases pass directly into the
bottom flue without passing over the super heater tubes. By placing the damper in intermediate position, part
of the gases will go over the super heater tubes & the remaining will pass directly to the bottom flue. Varying
degrees of superheat may be thus, possible to obtain.

4.2.3 Air preheater

The air preheater heats the air before it enters in to the boiler by using the heat of flue gases, which are coming
out from the economizer. Now as we suppose supply this preheated air to the boiler it saves some amount of
fuel. As we need some amount of heat in removing the moisture from the fuel, the preheated air will supply
this heat. Thus that much amount of the heat we have to supply less in to the boiler in form of fuel.

4.2.4 Steam Separator

The steam separators separate the steam and water before the steam enters in to the steam turbine. There is a
typical requirement of the steam turbine that the steam, which is entering to it, it should be dry. There should
not be any water particles in it.

4.2.5 Steam trap

The steam traps are used in the steam power plant in order to remove the water particles from the steam.

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4.2.6 Feed pump

The feed pump increases the pressure of feed water, which is coming out from the condenser. As we all knows
the pressure inside the boiler is higher than the atmospheric pressure and the condenser pressure, so the water
will not flow from condenser or from atmosphere automatically. So Because of this we are forced to use the
feed pump.

4.2.7 Injector

The injector injects the water in to the boiler. Injectors can be used alternatively in place of feed pumps. As the
function of both is same, which is to increase the pressure of feed water in order to enter it in to the boiler.

4.3 Question for report writing:

a) What is boiler mounting? Write the functions of each boiler mountings.
b) Explain working principle, construction with a neat sketch of any two boiler mountings.
c) What is boiler accessories? Write the functions of each boiler accessories. Draw a neat sketch of boiler
with accessories.

5. References
 https://thermodyneboilersblog.wordpress.com/2017/02/06/what-is-difference-between-boiler-
accessories-and-boiler-mountings/
 Lab annual from Smt. S. R. PATEL ENGINEERING COLLEGE Dabhi, unjha- 384 170
 Lan manual from RPS group of institute
 Slide Share- Steam Boilers

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