What Is Boiler Mounting?

Boiler mountings are mechanical devices that are considered necessary to

operate the boiler smoothly & safely, which are usually mounted on surfaces
of the boilers.

1. Main steam Stop Valve

2. Auxiliary steam Stop Valve
3. Safety valve
4. Water level indicator (gauge glass)
5. Air release valve or boiler vent
6. Feed check and control valve
7. Pressure gauge valve / connection
8. Air purge valve.
9. Air Vent
10. Pressure gauge & Pressure switches.
11. Main steam outlet valve
12. Blow down valve
13. Scum blow down valve
14. Sample connection
15. Whistle valve
16. Low Level alarm
17. Soot blowers
18. Manholes, Mudholes & peepholes.
19. Automatic feed water regulator
What are Boiler Accessories?
Boiler accessories are devices and plants that are installed with boilers to
improve the operating condition and overall efficiency of the boiler plant.
Boiler Accessories

1. Air pre-heater
2. Superheater
3. Economiser
4. Feed pump
5. Soot blower
6. Injector
7. Reducing valve
8. Steam separator
What Is Boiler Mounting?
Boiler mountings are mechanical devices that are considered necessary to
operate the boiler smoothly & safely, which are usually mounted on surfaces
of the boilers.

1. Main Steam Stop Valve

It is usually applied to the highest part of the shell through the flanges. To control the flow of
steams from the boilers to the main steam pipe. The steam produced in the boilers is
provided by this valve to the ship’s system to completely shut off the steam when required. It
is typically a non-return valve type installed directly at the steam location of the boiler shells.
The body is made of cast irons, & the valve seat is made of gunmetal.

2. Auxiliary Steam Stop Valve

A separate steam line provided by the boilers for the small auxiliary system is supplied to
most steam systems on ships through this valve. The valve is small in size and is generally a
non-return type.
3. Safety Valve

Location It is attached to boiler mounting steam chests. Function To blow off steam to
prevent explosions when the steam pressure inside the boiler exceeds the working pressure.
Commonly used safety valves are spring-loaded safety valves. In case of unsafe excess
pressures inside the boilers, a safety valve is used to release the excess pressure. Before
installation, the lifting pressure of the valve is set & locked in the presence of surveyors so
that it does not change later. In generals, safety valves are fitted in pairs.

4. Scum Blowdown Valves

Location: It is mounted in the crown plate of a boiler mounting furnace or firebox.

Functions: To extinguish a fire in a boiler furnace when the water level in the boiler falls to an
unsafe limit, and thus the explosion caused by overheating of the furnace plate is avoided.

A shallow dish types systems equipped at ordinary water level enables floating impurities, oil
foaming, etc., to float from the surface of the water.

5. Salinometer valve

Location: The sampling water cock system is usually equipped with a cooler in order so that
water samples can be collected at any time for testing the feed water.

Functions: To test the salinity of the water.

6. Whistle Valve

If a steam whistle is applied to the ship, the steam is supplied directly from the boiler, in the
form of a small non-return valve known as the whistle valve.

7. Soot Blower

Function: Required for soot blowing & pipe surface combustion products. It is operated by
steams or compressed air.

8. Automatic Feed Water Regulator

Location: A device that is important and fit into the feed line

Functions: Automatic feed water regulator is one of the important boiler mountings to
ensure a proper level of water under all load conditions. In boilers with high evaporation
rates, several feed element water control systems are used.
9. Manhole

Function: The boiler consists of several manhole gates which enable inspection, cleaning,
and maintenance of boiler tubes and internal components by the crew.

Location: Usually fitted in a gate steam drum and a water drum.

10. Mud box

Function: Earthen cans are used in boilers to collect mud (dirty impurities) from water drums.

Location: Fitted underwater drum.

11. TDS Sensor and Sample

Functions Most modern boilers are now equipped with this system for continuous
monitoring of total dissolved solids in the boiler water. The sensor compares the actual value
to the setpoint, and if the value is higher, then an audio-visual alarm is given. A manual
blowdown introduces fresh feedwater into the system to reduce total dissolved solids
content.

12. Water Level Gauge Glass

Location: This fitting can be seen in front of the boiler.

Function: This boiler mounting is fitted to indicate the water level inside the boiler. Gauge
glasses are also fitted in pairs to manually monitor the water level inside the boiler tank. The
construction of gauge glass is chosen based on the pressure of the boiler.

13. Air vent cock

Location: It is fitted in valve headers, boiler drums, etc.

Function: To protect the boiler from bursting when depressurized or when steam pressure
increases internally.

The word explosion is the opposite of explosion. In this situation, the pressure inside the
boiler will be sufficiently reduced by atmospheric pressure to prevent the shell from bending
inward; this boiler mounting is required.

14. Feed Check Valves and Controls

Location: It is fitted in the shell slightly below the normal water level of the boiler. It is a non-
return valve fitted into a screw spindle to control the lift.

Functions: To regulate the water supply, which is pumped into the boiler by a feed pump.
This valve controls the supply of steams as required & is installed after the stop valves in
both main and aux steam lines. They are non-return valves that have visible signs of open
and near position.

15. Pressure Gauge Connection

Location: It is fixed on the fronts of the boilers.

Functions: To measure the pressure of steam inside a steam boiler.

This pressure gauge can be installed in superheaters, boiler drums, and wherever necessary
to read pressure readings. Commonly used pressure gauges are the Bourdon type.

16. Blowdown Valve

Location: Blowdown is an important boiler mounting, which is located below the boiler.

Work: To evacuate the boiler whenever necessary and to remove soil, scale, or sediment
deposited on the bottom of the boiler.

It is used when the chloride level becomes too high for thorough cleaning of the boiler or for
water treatment of the boiler.

What are Boiler Accessories?

Boiler accessories are devices and plants that are installed with boilers to
improve the operating condition and overall efficiency of the boiler plant.

1. Feed Pump

Feed Pumps Are Used to Feed High-Pressure Water in Boilers. The Steam Pressure Inside the
Boiler Is High, So the Feed Water Pressure Must Be Increased for Smooth Operation Before
Reaching the Boiler. in General, the Feed Water Pressure Is 20% Higher Than the Boiler
Pressure. The Feed Pump May Be of a Centrifugal or Reciprocating Type.

2. Soot Blower

During combustion, soot accumulates on the inner tubes of the furnace, and the gas passes
are plugged in. Ultimately, soot deposited inside the furnace reduces the efficiency of the
boiler. A soot blower is used to remove the soot from the tubes to prevent the gas pass from
being plugged.
3. Injector

The function of the injectors is the same as that of the feed pumps; It is used where space is
not available for the installation of the feed pump. The kinetic energy of steam in an injector
is used to increase the pressure and velocity of feed water in a convergent-diverging nozzle.

Advantage of Injector

 Simplicity,
 Density,
 High thermal efficiency,
 Lack of dynamic part.

Disadvantages of Injector

 Low pumping efficiency,

 Difficulty in operation under extreme variations in steam pressure.

4. Superheater

The superheater raises the temperature of saturated steam without increasing its pressure. It
consists of a small bundle of tubes. It is set in the path of the hot flue gas of the furnace.
Saturated steam passes inside the heater tubes, and hot flue gases pass outside the tubes.
Thus the transfer of heat takes place in saturated steam from hot flue gases and raises its
temperature without increasing the pressure of steam.

For this purpose, convection superheaters and radiation superheaters are used. The change
in steam temperature depends on the position of the superheater, the temperature of the
hot flue gases, the configuration of the superheater, and the flow of steam. If the
temperature of the saturated steam rises to 100C with the help of a superheater, then a 1
percent saving of fuel can be achieved.

Advantage of Superheater

 Steam consumption reduced.

 Protection from turbine corrosion.
 The losses from the condensation of steam in cylinders and pipes are reduced.
 Increases efficiency of plants.

5. Air Preheater

The air preheater is used to recover heat from the exhaust flue gases. It is established
between the chimney and the economist. Through the preheater, air passes for combustion
purposes. This increases the temperature of the combustion air with the help of exhaust flue
gases. The air passes through the heater tubes, and the flue gas passes through the outside
of the heater tubes.
Thus, heat is transferred from the flue gases to the air required for combustion. If the
temperature of the combustion air rises to 1000F with the help of an air preheater, 2.3 to 2.6
percent of fuel can be saved. In some situations, 5% to 10% of fuel savings can also be
achieved.

Advantage of Air Preheater

 The evaporative capacity per kilogram of fuel increases.

 For every 35-400C increase in air temperature, the boiler increases 2 percent of efficiency.
 It Burns better with less smoke, soot, and ash.
 Allows low-grade fuel to burn with less excess air.

6. Pressure Reducing Valve

The function of a pressure-reducing valve is to maintain constant pressure on the distribution

side of the boiler regardless of its pressure.

7. Steam Separator

In turbines, the use of wet steam is unviable; Therefore, a steam separator, also known as a
moisture separator, is used. The function of the steam separator is to remove water droplets
from the steam. It is installed on the main steam pipe in the boiler. It is important to remove
steam that is in the water because water droplets in the steam reduce thermal efficiency.

Water can accumulate in the cylinder and cause a hydrostatic lock which damages the
engine. In thermal power plants, water droplets of high-speed steam from the nozzle
damage the turbine blades.

According to operating principles, they are classified as Impact or Baffle Type, Reverse
Current Type, Centrifugal Type.
Difference between the boiler mountings and
accessories:
Sr. Boiler Mountings Boiler Accessories
No.
1 The component that ensures boiler safety Components improve the boiler efficiency

2 An essential part of a boiler Boiler Accessories are not essential

3 Mounted on the boiler surface Integral parts of the boilers, but not mounted on
it
4 Boiler Mountings control fluid parameters Boiler Accessories control fluid parameters
insides of the boiler shell outside of the boiler

5 Examples: Pressure gauges, Blow-off cocks, Examples: Superheater, Air preheaters, Feed
Safety valves, Water level indicator, Stop pump, Economizer, Injector, Steam Separator
valve, Fusible plug

6 Boiler mountings are an integral part of the Boiler Accessories are not an integral part of the
boiler. boiler.

7 The boiler mounting function is to save the Boiler Accessories function is to increase the
boiler efficiency of the boiler

8 Boiler mounting increases boiler life. Boiler Accessories not increased boiler life; they
increased boiler efficiency.

9 Boiler mountings are commonly mounted on Boiler Accessories is not mounted on boiler
boiler shells. shell.

10 Boiler mounting is important for the safety of Boiler Accessories is important for
boiler Purposes. boiler performance purposes

11 Boiler mounting is controlled by the Fluid Boiler Accessories are fluid control parameters
parameters inside the boiler. outside the boiler.

12 The boiler is not Operated without the The boiler is run without the use of
Mountings. boiler Accessories.

13 Boiler mounting is an essential part of the Boilers Accessories are not an essential part of
boiler. the boilers.

14 Boiler mounting reduces boiler Accidents. Boiler Accessories is

increased boiler performance.
15 Boiler mounting is an Internal part of the Boiler Accessories are an extra part of the boiler.
boiler.
16 When boiler mounting is used, the output of when boiler Accessories used in the boiler, then
the boiler is not increased. the output of the boiler is increased

The function of various boiler mountings and accessories are:

1. Water Level Indicator

 It is fitted in front of the boiler and generally present two in number.

 It is used to indicate the water level inside the boiler. It shows the instantaneous
level of water that is present inside the steam boiler which is necessary for its
proper working.
2. Pressure gauge

 It is also present in front of the boiler.

 It is used to measure the pressure of the steam inside the boiler.
 The pressure gauges generally used are of Bourden type
3. Safety Valves

 Safety valves are attached to the steam boiler chest.

 It is used to prevent explosion due to excessive internal pressure. When the
internal pressure inside the boiler exceeds its working pressures than the safety
valves blow off the steam and maintains the internal pressure.
 Generally two safety valves are present on a boiler.
4. Stop Valve (steam stop valve)

 It is usually fitted on the highest part of the boiler with the help of a flange.
 The main function of the stop valve is
1. To control the flow of steam from the boiler to the main steam pipe.
2. To completely shut off the steam supply when required.
5. Blow Off Valve

 It is fitted at the bottom of the boiler drum.

 The functions of blow-off Valve is
1. To empty the boiler whenever required.
2. To discharge the scale, mud and sediments which gets collected at the bottom of the
boiler.
6. Feed Check Valve

 It is non-return valve and fitted to a screwed spindle to regulate the lift.

 It is fitted to the shell slightly below the normal water level of the boiler. A
boiler must have its spindle lifted before the pump is started.
 It regulates the supply of water which is pumped into the boiler by feed pump.

7. Fusible Plug

 It is fitted to the crown plate of the furnace or firebox.

  Its function is to extinguish fire in the furnace when the water level in the boiler
falls to an unsafe limit. This avoids the explosion that may take place because of
the overheating of the furnace plate.

Boiler accessories: the boiler accessories are the integral parts of the boiler. They are
used in the boiler to improve its efficiency.
1. Air preheater

 It is installed between the economiser and the chimney.

2. Superheater

 It is placed in the path of hot flue gases from the furnace.

 A superheater is an important accessory used in the boiler. Its main function is
to increase the temperature of saturated steam without raising its pressure.
3. Economiser

 It is used to heat the feedwater by the utilization of heat from the hot fuel gases
before it leaves the chimney.
 A economiser improves the economy of the steam boilers.
4. Feed pump

 It is used to deliver water to the boiler.

1) Main steam Stop Valve: The steam generated in the boiler is supplied to the
main system through this valve. It is normally non-return type of valve.

2) Auxiliary steam Stop Valve: If there is separate steam line provided for small
auxiliary system, it is supplied through this valve. The valve is smaller in diameter
and usually of a non-return type.

3) Safety valve: In the event of excessive pressure inside the boiler, the safety
valve comes in action to release the over pressure. The lifting pressure of the valve
is set before its installation and locked in the presence of a surveyor so that it not
changed later on. Safety valves are generally installed in pairs with one valve set at
a little higher pressure to ensure boiler does not explode of over pressure in the
event of failure of any one boiler safety valve.
4) Water level gauge glass: Gauge glasses are also installed in pairs for manually
checking the water level inside the boiler drum. Construction of the gauge glass is
decided on the basis of boiler pressure.

5) Air release valve or boiler vent: This valve is fitted in the headers, boiler drum
etc, to avoid collapsing of boiler when it is depressurized or when initially raising the
steam pressure.

6) Feed check and control valve: This valve controls the flow of steam as per the
demand and is fitted in both main and auxiliary steam line after the stop valve. They
are non return valves with a noticeable indication of open and close position.

7) Pressure gauge connection: This pressure gauge can be fitted in super heater,
boiler drum and wherever it is necessary to read the pressure reading.

8) Blow down valve: It is used to empty the boiler completely for maintenance
purpose or for water treatment of boiler when the chloride level becomes very high.

9) Scum blow down valve: It’s a shallow dish type arrangement fitted at the
normal water level which allows the blow down of floating impurities, oil foaming etc
from the water surface.

10) Sample connection: A sample water cock is also fitted in series so that water
sample can be collected at any time for feed water analysis.

11) Whistle valve: If there is a provision for steam whistle in the ship, then steam
is supplied directly from the boiler through a small bore type non-return valve
known as whistle valve.

12) Low Level alarm: An alarm is used to initiate audible warning at low water
level condition.

13) Soot blowers: It is required to blow the soot and the combustion products from
the tube surfaces. It is operated by steam or compressed air.
14) Automatic feed water regulator: It is a device which is essential to ensure
appropriate water level in all load conditions and is fitted in the feed line. Multiple
element feed water control system is fitted in boilers with high evaporation rate.