Boiler Mountings

BOILER MOUNTINGS

OBJECTIVE

Upon completion of this lesson, students should be able to:

1. Identify major mountings fitted on a boiler.

2. Explain the significance of each of the mountings.
3. Interpret the relevant class regulations
4. Identify the various components of a gauge glass and safety valve.
5. Describe the constructional features of various basic types of gauge glasses
and safety valves.
6. Explain the procedure for gauge glass blowing through.
7. Explain the procedure for setting a safety valves set pressure and blowdown.
8. Discuss the maintenance procedure for safety valve assembly.

LESSON OVERVIEW

An attempt has been made to cover most of the important mountings and explain
how to maintain them in good working conditions. Mountings are crucial without
which the operation of boilers is unsafe. Proper maintenance and care of the
mountings is important for the safety of both the boiler and the personnel and to
maintain optimum operating condition of the boiler.

Relevant diagrams will be provided during lectures.

Attempt questions at the end of the lesson.

REFERENCES

Nakakita, Safety Valve Technical Manual

Morton, Thomas D, Steam Engineering Knowledge for Marine Engineers (1994),

Thomas Reed Publications

Flanagan, G T H, Marine Boilers Question & Answers (1995)

Milton, J H and Leach, Roy M, Marine Steam Boilers (1995)

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INTRODUCTION

All boilers require certain minimum number of mountings to enable the engineer to
operate the boiler safely and efficiently. In addition, these mountings also
continuously monitor the operating conditions inside the boiler and protect the boiler
by automatically shutting down the boiler in the event of serious abnormal conditions.

The following is a list of commonly fitted boiler mountings for fire-tube as well as
water-tube boilers:

Safety valves
Water level indicators
Water level controller
Water level alarms & cut-out assembly
Remote water level transmitter
Main steam outlet valve
Pressure gauge & Pressure switches
Feed water valves
Burner assembly
Air vent
Water sampling valve
Manholes, mudholes & peepholes
Bottom blowdown valve
De-foaming (scum) valve
Furnace drain valve
Soot blowers

Pressure gauge & cock

Pressure Gauge and Cock shows the steam pressure, normally has 2 red lines
marked on the dial lower line shows normal working steam pressure, the upper, the
maximum permissible pressure of the boiler. A 3 way cock on the gauge and another
cock or the boiler connected with a siphon pipe is a standard practice.

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Main Steam Stop Valve

Main steam stop valve is the steam outlet to the process. Normally this valve is fitted
at the highest point of the boiler, and is of an ordinary screw down type. The stop
valve is not designed as a throttling valve and should be fully open or close. It should
always be opened slowly to prevent sudden rise in downstream pressure and
associated water hammer.

Blowdown valve
Blowdown valve enables feed water sediment to be discharged from the bottom of
the boiler. This valve might normally be opened for a period of 5 seconds, once per
watch.

Scum valve
This valve enables contaminants from the water surface to be removed.

Feed Check Valve

A feed check valve is to be fitted to each feedwater line.One screw down isolating
and another non-return antisuction valve is fitted either in one common or separate
valve housings. Under normal steaming conditions the check valve operates in a
conventional manner to stop return flow from the boiler entering the feed line when

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feed pump is not running. When the feed pump is running, its pressure overcomes
the boiler pressure to feed the boiler.

Salinometer Cock
It is used to draw off a sample of water from the boiler which is then tested for its
quality.

Air Cock
It is provided for venting purposes and fitted on the highest point at the shell to get
vent off trapped air either in service or when filling the boiler. Care to vent is
important, to avoid corrosion in the zone where air and water lie in contact. An open
air cock also avoids vacuum condition when boiler is blown down. Air vent is closed
when the boiler pressure is 0.5bar, while raising steam in the boiler.

Name Plate
The serial number and model number uniquely identify the boiler and are used when
ordering spares from the manufacturer. It provides information on safe working
pressure, hydraulic test pressure and capacity of boiler.

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WATER LEVEL GAUGES

Regulation:
Every boiler is to be fitted with at least two independent means of indicating the
water level. One of which is to be a direct reading gauge glass. The other means
is to be either an additional glass gauge or an approved equivalent device.

Water tube boilers are to be fitted with two systems of water level detection,
which are to be independent of any other mounting on the boiler. Both the
systems are to operate audible and visible alarms and automatic shut-off device.

Glass water gauges are to be so located that the lowest visible level in the glass
is either not lower than 51 mm (2 in) above the lowest permissible water level.

The lowest permissible water level is just above (usually 25 mm or 1 in above)

the top row of tubes when cold;

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Level indicators and switches

Tubular Gauge Glass

Reflex Plate Gauge Glass
Double Plate Gauge Glass
Conductivity Probes Type Alarm and Lockout switches
Magnetic float switch

Tubular Gauge Glass

Suitable for low pressure boilers of design pressure below 17.5 bar.

Safety features include a steel ball valve on the water-side connection to shut off
the water in the event of glass breaking and a wire-insert glass cage to prevent
injury to the personnel.

Reflex Plate Gauge Glass

Suitable for boilers of design pressure below 34 bar.

Makes use of the refraction of light, so that when illuminated, the series of ribs at
the back of the glass plate cause the light rays to be reflected back from the
steam space and absorbed in the water space. This gives a bright silvery
appearance to the steam space, while the water space appears dark. The strong
contrast between the two enables the engineer to see clearly the position of water
level.

To prevent etching of the glass plate by hot steam, a sheet of mica is to be placed
between steam/water space and the glass. Due to the ribs on this glass, the
reflex type cannot make use of this form of protection, and therefore is not
suitable for higher pressures.

Double Plate Gauge Glass

This gauge assembly is suitable for use when the pressures are in excess of 34
bar as the flat glass plates can be effectively protected from erosion, by sheets of
mica.

The assembly consists of a hollow centre-piece fitted with two plates of

toughened glass held in place by means of a clamp plate. A louver plate at the
back of the glass directs the light rays at an angle to make the meniscus of the
water level glow.

Operating Instructions: Reflex Plate Gauge Glass

Valves and stopping devices to be operated slowly.

Turn the glass holder in the desired direction with the aid of rotable glass holders
on the upper and lower connection pieces.

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Whenever the boiler is put into operation after it has been cleaned, some foreign
matter could exist in the shut-off valves. Avoid eventual damage by frequently
draining the system via the drain valve.

Blowing-through procedure

Close the steam and waterside valves and open the drain valve.
Blow-through the steam side by opening the upper valve for seconds and close.
Blow-through the water side by opening the lower valve for seconds and close.
Close the drain valve.
Open both steam and water side valves by turning them slowly.

Note:

If automatic steel ball shut-off valves are fitted, the above procedure must be
followed by turning the upper and lower valves only through 45O to the left, to
avoid the actuation of the ball valves.

While blowing through the gauge glasses, always remember that there is a
chance for the glass to break due to thermal stresses. You should keep away
from the assembly throughout the operation and make use of remote handles if
fitted to the valves.

While the boiler is in operation, if one of the level gauge glasses shows normal
level and the other shows an abnormally lower, then the gauge glass which is
showing a lower level must immediately be blown-through and the correct
condition ascertained.

Replacement of Glass

Isolate the assembly by shutting-off the steam and water connections and by
opening the drain.
Take off the screws of the glass holder and remove the pressure ledges.
Remove the glass insert with gaskets
Spare glass surfaces to be cleaned thoroughly.
Install the black gasket, the spare glass with the grooves facing inwards, the red
gasket and finally the thin steel sheet.
Put on the pressure ledges and tighten the screw uniformly starting from the
middle and proceeding cross-wise up and downward.
Heat the new glass slowly by keeping the waterside valve shut, the steam side
valve crack-open and the drain fully open.
After about 30 minutes, the screws should be tightened again by applying a
torque of 2.4 kp-m.
The assembly can now be put on load by shutting-off the drain and opening the
steam and waterside valves completely.

Reasons for a false water level indication by a gauge glass

Choked valves and passages on the steam and/or water side by sediment,
scale, packing or use of a round glass, which is too long.
Leaky drain valve or proffusive steam and/or water leakages from the gauge
assembly.

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Foaming condition inside the boiler.

Sudden changes in steam demand.

HIGH LOW LEVEL ALARM and BURNER CUT-OFF SYSTEMS

All types of marine boilers must be fitted with high-low water level safeguards. All
such equipment is to be capable of operating audible and visible alarms and also of
automatically shutting off the fuel supply to the burners when the water level falls to a
predetermined low level.

Magnetic Float Switch Type

The float assembly of this detector carries a permanent magnet, which is

opposed by a similar magnet in the switch assembly. This principle is employed
to change over switch contacts with a snap action under the control of the water
level float.

In addition to its main function of fuel shut-off, the assembly can also be designed
to control water level by controlling the feed pumps.

As an improvement, a tertiary magnet is added to each switch assembly to lock

the contacts in either position.

Important: The float chamber is prone to get choked on scale and sludge, if no
blowing-through of this assembly is carried out regularly. Its operation also must be
checked at least once a week.

Conductivity Probes (Electrode) Type

The principle of operation is based on the different conductivity of water and steam.
When the electrode dips-in or dives-up, a bridge circuit in the switching amplifier is
reset. The signal is amplified and energizes the switch relay of the switching
amplifier, which with its contacts within the burner safety chain releases a
disturbance shut-down.

An additional time-lag switch of maximum 20 seconds avoids effects of fluctuations of

water level and thus prevents unintended disturbance shutdown.

Operational test procedure

Raise the water level up to the high level alarm. An alarm is given after about 10
seconds and the alarm light is lit up.

Sink the level under the low level alarm - An alarm is given after about 10
seconds and the alarm lamp is lit up.

A functional test can be carried out by depressing the test button until the alarm
lamp lights up after about 10 seconds.

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Electrodes and cables are to be tested for insulation by using a volt-meter. The
reading obtained when the water level reaches up to the electrode is 0-5 V and
the reading obtained when the level is below the electrode is 15-25V.

Tubular Gauge Glass Double Plate Gauge Glass

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Reflex Plate Gauge Glass

Vapour-Silver bright

Liquid-Dark

Conductivity Probes(Electrode) Alarm Magnetic float type switches

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SAFETY VALVES
A safety valve is a safety device designed to protect a boiler from an overpressure
event. An overpressure event refers to any condition which would cause pressure in
boiler to increase beyond the specified design pressure or maximum allowable
working pressure (MAWP).

A safety valve must be capable of operating at all times, especially during a period of
power failure when system controls are nonfunctional. The sole source of power for
the pressure relief valve, therefore, is the steam pressure.

Once a condition occurs that causes the steam pressure in the boiler to increase to a
dangerous level, the safety valve may be the only device remaining to prevent a
catastrophic failure. Since reliability is directly related to the complexity of the device,
it is important that the design of the safety valve be as simple as possible.

The safety valve must:

open at a predetermined set pressure,
flow a rated capacity at a specified overpressure, and
close when the system pressure has returned to a safe level.
designed with materials compatible with steam

Difference between safety valve and a relief valve

Safety valve
A spring-loaded safety valve which is designed to open to relieve excess pressure
and to re-close and prevent the further flow of fluid after normal conditions have been
restored.

It is characterized by a rapid-opening pop action or by opening in a manner

generally proportional to the increase in pressure over the opening pressure.

It is used for compressible fluids like steam and compressed air.

Relief valve
A pressure relief device actuated by inlet static pressure having a gradual lift
generally proportional to the increase in pressure over opening pressure.

Relief valves are commonly used in liquid systems, especially for lower capacities
and thermal expansion duty. They can also be used on pumped systems as pressure
overspill devices.

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Fig 1 spring loaded safety valve

The basic spring loaded safety valve, referred to as standard or conventional is a

simple, reliable self-acting device that provides overpressure protection.

The basic elements of the design consist of a right angle pattern valve body with the
valve inlet connection, or nozzle, mounted on the pressure-containing system. The
outlet connection may be screwed or flanged for connection to a piped discharge
system. However, in some applications, such as compressed air systems, the safety
valve will not have an outlet connection, and the fluid is vented directly to the
atmosphere.

Seat design consists of a seating ring fitted into the body, the top of which forms the
seat of the valve. The advantage of this arrangement is that the seat can easily be
replaced, without replacing the whole inlet.

The disc is held against the nozzle seat (under normal operating conditions) by the
spring, which is housed in an open or closed spring housing arrangement (or bonnet)
mounted on top of the body. The discs used in rapid opening (pop type) safety valves
are surrounded by a shroud, disc holder or huddling chamber which helps to produce
the rapid opening characteristic.

The closing force on the disc is provided by a spring, typically made from carbon
steel. The amount of compression on the spring is usually adjustable, using the
spring adjuster, to alter the pressure at which the disc is lifted off its seat.

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Standards that govern the design and use of safety valves generally only define the
three dimensions that relate to the discharge capacity of the safety valve, namely the
flow (or bore) area, the curtain area and the discharge (or orifice) area.

Although the principal elements of a conventional safety valve are similar, the design
details can vary considerably. In general, the DIN style valves (commonly used
throughout Europe) tend to use a simpler construction with a fixed skirt (or hood)
arrangement whereas the ASME (American) style valves have a more complex
design that includes one or two adjustable blowdown rings. The position of these
rings can be used to fine-tune the overpressure and blowdown values of the valve.

1. Flow area - The minimum cross-sectional area between the inlet and the seat, at its
narrowest point. The diameter of the flow area is represented by dimensiond, Figure
2.

2. Curtain area - The area of the cylindrical or conical discharge opening between the
seating surfaces created by the lift of the disk above the seat. The diameter of the
curtain area is represented by dimension d1 in Figure 2.

3. Discharge area - This is the lesser of the curtain and flow areas, which
determines the flow through the valve.

Figure 2 Standard defined areas.

Basic operation of a safety valve

Lifting
When the inlet static pressure rises above the set pressure of the safety valve, the
disc will begin to lift off its seat. However, as soon as the spring starts to compress,
the spring force will increase; this means that the pressure would have to continue to
rise before any further lift can occur, and for there to be any significant flow through
the valve.

The additional pressure rise required before the safety valve will discharge at its
rated capacity is called the overpressure. The allowable overpressure depends on

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the standards being followed and the particular application. For compressible fluids
(steam and air), this is normally between 3% and 10%.

In order to achieve full opening from this small overpressure, the disc arrangement
has to be specially designed to provide rapid opening. This is usually done by placing
a shroud, skirt or hood around the disc. The volume contained within this shroud is
known as the control or huddling chamber.

Figure 3 Typical disc and shroud arrangement used on rapid opening of (DIN) safety
valves

Reseating
Once normal operating conditions have been restored, the valve is required to close
again, but since the larger area of the disc is still exposed to the fluid, the valve will
not close until the pressure has dropped below the original set pressure. The
difference between the set pressure and this reseating pressure is known as the
blowdown, and it is usually specified as a percentage of the set pressure. For
compressible (steam and air) fluids, the blowdown is usually less than 10%.

The design of the shroud (Figure 3) must be such that it offers both rapid opening
and relatively small blowdown, so that as soon as a potentially hazardous situation is
reached, any overpressure is relieved, but excessive quantities of the fluid are
prevented from being discharged. At the same time, it is necessary to ensure that the
system pressure is reduced sufficiently to prevent immediate reopening.

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Figure 4: ASME type safety valve with

The blowdown rings found on most ASME type safety valves are used to make fine
adjustments to the overpressure and blowdown values of the valves (see Figure 4).
The lower blowdown (nozzle) ring (Lower adjusting ring) is a common feature on
many valves where the tighter overpressure and blowdown requirements require a
more sophisticated designed solution. The upper blowdown ring (upper adjusting
ring) is usually factory set and essentially takes out the manufacturing tolerances
which affect the geometry of the huddling chamber.

The lower blowdown ring is also factory set to achieve the appropriate code
performance requirements but under certain circumstances can be altered.

When the lower blowdown ring is adjusted to its top position the huddling chamber
volume is such that the valve will pop rapidly, minimising the overpressure value but
correspondingly requiring a greater blowdown before the valve re-seats.

When the lower blowdown ring is adjusted to its lower position there is minimal
restriction in the huddling chamber and a greater overpressure will be required before
the valve is fully open but the blowdown value will be reduced.

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45 bar Boiler bursting pressure

Safety Factor 45/10 = 4.5

Boiler Pressure

10.6 bar 6% Maximum Accumulation of pressure with safety valve open & steam stop valve shut

!0 bar Safety valve open= 10 bar Boiler Design Pressure 10 bar

Safety valve blow down 10.0-9.6 = 0.4 bar

9.6 bar
Safety valve close 9.6 bar

Safety valve capacity to release

steam must match the steam generation
Simulation of rise in boiler pressure, with main steam stop valve shut capacity of boiler burner
burner firing at full capacity, and subsequent operation of safety valve.
The boiler pressure is not to exceed 6% above safety valve setting.
Boiler pressure drops down to 9.6 bar, and safety valve closes.
Main Steam Stop
Valve Shut Safety Valve

Burner Firing
Important Pressures Relating To Boiler
at Full Capacity
and Accumulation of Pressure Test

Figure 5: The total relieving capacity of all the safety valves connected to a boiler
should be equal to or more than the steam generating capacity (kg/hr) of the boiler

Terminology
In addition, the BS 759 standard pertaining to safety fittings for application to boilers,
defines full lift, high lift and lift safety valves:

Ordinary lift safety valve (ordinary class) - The valve member lifts
automatically a distance of at least 1/24th of the bore of the seating member,
with an overpressure not exceeding 10% of the set pressure.

High lift safety valve - Valve member lifts automatically a distance of at least
1/12th of the bore of the seating member, with an overpressure not exceeding
10% of the set pressure.

Full lift safety valve - Valve member lifts automatically to give a discharge
area between 100% and 80% of the minimum area, at an overpressure not
exceeding 5% of the set pressure.

Set Pressure: The boiler pressure at which the safety valve begins to lift.

Closing Pressure:The boiler pressure at which the valve closes.

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Valve lift:The axial valve disc travel from closed to the open position.

Blowdown: The difference between the opening and the closing pressures.

Huddling chamber The annular pressure chamber located beyond valve

seat for the purpose of generating a popping characteristic.

Safety valve requirements

Boilers with a heating surface in excess of 50m2 must be fitted with at least Two
safety valves.
Safety valves must be set to lift within the designed pressure of the boiler. Since
marine boilers have normally two safety valves, the second valve may be
adjusted to lift at a pressure of 3% above the boiler design pressure.
Superheater safety valve(s) are to be set to lift at a lower pressure than the drum
safety valves of a water tube boiler.
Normal blowdown range of safety valves: 1 4 % of set pressure.
To prevent leaking or weeping of safety valves, the boiler operating pressure
should be lower than the design pressure.
The ideal lift for a safety valve is of the valve (throat) diameter.

Procedure for Adjustment of Safety Valves: Tank/Auxiliary Boilers

At least two pressure gauges, whose accuracy has been verified recently, must
be made available to give the reading of boiler pressure.
Screw down the compression screw on the valves a few turns more than the
previous setting.
Steam pressure in the boiler raised and the boiler put on banked fire.
Slowly bring up the boiler pressure to the desired set pressure of the safety valve
being adjusted (adjust only one valve at a time).
Slacken the compression screw of the safety valve slowly till the valve blows.
Stop firing the boiler, and note down the closing pressure of the valve.
Try out again for lifting (floating) of the safety valve to check the set pressure and
to make minor adjustments to the compression screw as may be necessary.
The valve setting is done with a bit of trial and error procedure and with practice
can be achieved fairly quickly.
On valves with blowdown control, the blowdown ring is initially set at a particular
position as per the makers instructions and fine adjustment is done during the
floating of the valve.
The safety valve adjusted should be gagged (the gag must be finger tight only!),
and the other safety valve should now be floated and adjusted.
The gag from the first valve should now be removed.
Fire the boiler to confirm the satisfactory operation of the safety valves.
Split lock rings can now be made and fitted to lock the compression screws in
place.
Fit back the easing gears and lift the safety valves manually.

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Figure 6: Safety valve gag, hand tight only

PROBLEMS ASSOCIATED WITH SAFETY VALVES

Chatter: Metallic hammering sound or vibratory noise. The reasons being bent
spindle, improper clearances, loose blowdown ring, improper position of upper and/or
lower adjusting ring positions, AND excessive back-pressure .

Simmer: The first leakage of steam before the safety valve pops open, which is
allowed within 1.5 to 2 % of popping pressure of the valve. Prolonged simmering
may be due to improper position of adjusting rings and distorted valve parts .

Leakage: Constant hissing sound. The reasons being damaged seating, defective
parts, scale or foreign matter on the sealing surfaces, distortion due to waste steam
pipe fitting, interference from easing gear and spindle.

Hang-up: Safety valve fails to re-seat. The reasons are improper blowdown,
adjustment, and mechanical interference from spindle.

Routine operation

Check for leakages daily. Do not stop the leak by over-tightening of the
compression screw or gagging the valve. Try blowing the valve with the aid of
easing gear and turn the spindle (if possible, for low pressure boilers only) along
with the disc in both directions, to dislodge foreign matter or scale from the
sealing surfaces.
Manually lift the valves (when the boiler pressure is above 75% of working
pressure), to check that the valves are operational, once a month.
Float the valves on steam every six months.
Overhaul the valves completely once a year.

QUESTIONS

1. Identify the major mountings of a boiler and explain their role.

2. Compare a round type of gauge lass with a plate type in terms of their
constructional features, safety, operational limitations and applications.

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3. Explain the procedure for blowing through of a gauge glass by taking all the
necessary safety precautions.
4. State the maintenance work involved for a gauge glass assembly.
5. Describe the constructional features of a full lift spring loaded safety valve
and state the important working clearances.
6. Explain the procedure for adjusting the set pressure and blow down of a
consolidated safety valve.
7. With respect to safety valve discuss the routine checks during operation and
after dismantling to keep the safety valve reliable and efficient.

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