BOILER MOUNTINGS

&
ACCESSORIES

1
Mountings:
The items which are used for safety of
boiler are called mountings

Accessories:

The items which are used for increasing

the
boiler efficiency are called accessories

2
 MOUNTINGS
1. Water Level indicator
2.Pressure Gauge
3.Safety valves
A. Dead weight
safety valve
B. Spring loaded
safety valve
C. Lever
controlled
safety valve
D. High steam &
low water
safety valve 3
Water Level
indicator
For indicating water
level inside boiler

Usually 2 Nos.

Steel balls are

provided to prevent
loss of steam in case of
glass breakage

4
Pressure Gauge
To indicate
level of
steam
pressure
inside the
boiler

5
 Safety
• valves
Safety valve releases steam outside of boiler in case of excess
pressure inside

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.
A. Dead weight safety valve

B. Spring loaded safety valve

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C. Lever controlled safety valve
 -

Spring loaded safety valve

Slotted lover
guldo

Lever

Boilershel

Lever control safety valve

7
 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.
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.
(previous).
•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.) till the
pressure falls back to the working pressure.
 
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:
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.
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.
For equilibrium condition,

             where W = total weight of the valve, weight carrier, dead weights and cover
plate, N;     d = diameter of the vertical pipe, m; p = upward steam pressure on the
valve, N/m2
•When steam pressure inside the boiler is above the working pressure:
 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.

This type of valve is used only on stationary boilers such as Lancashire boilers, or other low
capacity boilers.
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 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 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.
•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.) until the
pressure falls back to the working pressure.
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
By taking the moment about the fulcrum i.e. clockwise moment of the weights is equal to
anticlockwise moment of the steam pressure, we have
        W1L1+ W2L2 +W3.L3  = F.L1
or     W1L1+ W2L2 +W3.L3 =                                              

Calculate the position of movable weight ‘L3’ from above equation from other
parameters of known values.
 High steam & low water safety
valve
Actuates in 2 situations
1. Water level lowers 2. steam pressure
increases

Prof. S.R.
1
Khandagale,JJMCOE,Jaysingpur,Mahrashtr 5
When valve act as safety against high pressure steam 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. . 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’.
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.
•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. until the pressure falls back to the normal working
pressure.
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. 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 ‘W 2’  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.

•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
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. 
FUSIBLE PLUG
Function is to
extinguish (switch off )
fire when
water level in boiler
falls below certain limit

Fusible material is
having low MP

e.g. brass, gunmetal

2
0
Location: The fusible plug is generally inserted in the crown of the furnace or in the
combustion chamber at the lowest permissible water level.

Construction:
A fusible plug as shown in Fig. 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’.
BLOW OFF
COCK • To drain out water
from the boiler for
internal cleaning
inspection or other
purposes

• Fitted at lowest
part of boiler

10
STEAM STOP
VALVE Regulates the flow of a
steam

Function : to shut off or

regulate the flow of
steam from the boiler to
the steam pipe or steam
from the steam pipe to
the engine
2
4
FEED CHECK
VALVE • To allow the feed
water to pass in
to the boiler

• To prevent the
back flow of water
from the boiler in
the event of the
failure of the feed
pump

2
5
 ACCESSORIES

1.Economizer
2. Preheater
3.Superheater
4.Steam
separator
5.Injector
6. Feed pump

2
6
Economizer ,Preheater &
Superheater
Use to recover some heat being carrying by exhaust
flue gases.
Heat recovered is utilized in --> Economizer
raising the temperature of
the feed water

Heat recovered is utilized in --> air preheater

raising the temperature of
the fresh air

Heat recovered is utilized in --> super heater

raising the temperature of
the (saturated steam)

2
7
 To

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Gases
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· ,.. Superheat
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er miser •,. Prehea mey
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. Vl •• p
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a r Ai
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-, Ai rer
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2
8
SUPERHEATER

2
9
AIR PREHEATER

3
0
ECONOMISER

18
STEAM
SEPERATOR
• Separates
moisture
contain in
steam and
makes it
dry

1
 STEAM
INJECTOR

A steam injector is a typical application of the principle used to deliver cold water to
a boiler against its own pressure, using its own live or exhaust steam, replacing any
mechanical pump.

2
An injector is a system of ducting and nozzles used to direct the flow of a high-pressure
fluid in such a way that a lower pressure fluid is entrained in the jet and carried through
a duct to a region of higher pressure. It is a fluid-dynamic pump with no moving parts,
excepting a valve to control inlet flow. A steam injector is a typical application of the
principle used to deliver cold water to a boiler against its own pressure, using its own
live or exhaust steam, replacing any mechanical pump.

A- Steam from boiler, B- Needle valve, C- Needle valve handle, D-

Steam and water combine, E- Water feed, F- Combining cone, G-
Delivery nozzle and cone, H- delivery chamber and pipe, K- Check
valve, L- Overflow
 FEED PUMP
• Used to deliver feed water to the boiler.

• It is desirable that the quantity of water supplied

should be at least equal to that evaporated and
supplied to the engine

• Two types of which are commonly used as feed

pumps are

• (1) reciprocating pump

• (2) rotary pump

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RECIPROCATING TYPE BOILER FEED
PUMP

36