4.

THEORY BACKGROUND

4.1

Boiler Mountings:

4.1.1

Boiler mountings are devices connected to the boiler which aid in its safe and efficient operation.

4.1.2

Types 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, except that:

4.1.2.1.1

For boilers with all the drum safety valves set at or above 62 bar, two independent compensated manometer remote water level indicators be used in place of one of the water gauges.

4.1.2.1.2

For boilers of less than 300 lb per hour evaporative capacity one water gauge is sufficient.

4.1.2.1.3

For once-through boilers no water gauge are required.

4.1.2.2

Water Column

The column is a hollow casting or forging connected by pipes at 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 connecting pipes must not be less than 1 in. Plugged tees or 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 columns may be used for pressures not exceeding 250 psig (15 bar) , and malleable-iron columns for pressures not exceeding 350 psig (25 bar). Above that, steel columns 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 Bourdon 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 contains water of condensed steam which enters the Bourdon tube. The pressure of the water makes the section more nearly circular and flattens the curve. The movement of the tips 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

valves which will open when the boiler pressure exceeds the safe working pressure. These valves are almost all of the

disc type with narrow flat or cornical 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 steam and low water type, be fitted to each boiler but in no case shall a boiler with more than 50m2. Heating surface be fitted with less than two safety valves. Every super heater shall have at least one safety valves 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 inspected 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 carries away. Soft scale, or sludge, may form as a result of water treatment and has to be got rid of. For these purpose a blowoff 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 conditions is covered with the water in the boiler which keeps the temperature of the fusible metal below its melting point. But should the water in the boiler fall below the low-water level, the fusible metal is melted by the heat of the fires or gives warning to the stoker that the furnace or combustion chamber crown is in danger of being overheated.