Thermal Power Plant Introduction

A thermal power plant is a facility that generates electricity by burning fossil fuels, such as coal,
natural gas, or oil, to produce steam and drive a turbine connected to a generator. The heat energy
from the fuel is converted into mechanical energy, which is then transformed into electrical energy.
These power plants are a significant source of electricity in many parts of the world, but they also
raise environmental concerns due to greenhouse gas emissions and other pollutants.
Turbine auxillary system such as governing ,feed heating,reheating ,
flange heating,and gland leakage
Turbine auxiliary systems are an essential part of a steam turbine power plant. They support the
main turbine in various ways to ensure its efficient and safe operation. Here are some key turbine
auxiliary systems:

 Governor System:

The governor system is responsible for controlling the speed and load of the turbine. It adjusts the
steam flow to the turbine based on changes in electrical load or grid frequency to maintain a
constant speed. This system helps ensure stable and reliable power generation.

 Feed Heating System:

Feed heating systems are used to preheat the water before it enters the boiler. This increases the
thermal efficiency of the power plant by recovering some of the waste heat from the turbine
exhaust and using it to heat the feedwater. There may be multiple stages of feed heating to optimize
efficiency.

 Reheating System:

In some power plants, particularly those with multiple stages of steam expansion, a reheating
system is used. After the initial steam expansion in the high-pressure turbine, the steam is
condensed and then reheated before entering the low-pressure turbine. This increases overall plant
efficiency by reducing the moisture content of the steam.
  Flange Heating System:

Flange heating is used to maintain the temperature of critical flange connections in the steam and
water piping. It prevents condensation or freezing of steam or water at these connections, which
could lead to corrosion or other issues.

 Gland Leakage System:

Steam turbines often have multiple stages with rotating and stationary blades. Gland sealing is
crucial to prevent steam leaks between these stages. Gland leakage systems maintain a controlled
flow of steam or sealing gas (such as nitrogen) to create a barrier that prevents air from entering the
turbine and steam from escaping.

These auxiliary systems are essential for the efficient and safe operation of steam turbines in power
plants. They help optimize performance, maintain equipment integrity, and ensure reliable power
generation. The specific configuration and design of these systems can vary depending on the type
and size of the power plant.

operation and maintenance of steam power plant

The operation and maintenance of a steam power plant are critical to ensuring its safe, efficient, and
reliable performance. Steam power plants typically consist of several key components, including
boilers, turbines, generators, condensers, and auxiliary systems. Here's an overview of the operation
and maintenance processes involved:

Operation of a Steam Power Plant:

Start-Up Procedure:

 Begin with a pre-startup inspection to ensure all equipment is in proper condition.

 Light up the boiler and gradually increase the steam pressure.

 Start the turbine and generator, synchronizing with the electrical grid if necessary.

Normal Operation:

 Monitor key parameters such as steam pressure, temperature, flow rates, and electrical
output.

 Control the turbine speed and load using the governor system.

 Continuously monitor safety systems and alarms.

 Maintain proper water treatment to prevent boiler scale and corrosion.

Load Changes:

 Adjust the steam flow and load as needed to meet fluctuations in electrical demand.

 Ensure proper coordination between the boiler and turbine controls.

  Shutdown Procedure:

 Gradually reduce the load and shut down the turbine.

 Cool down the boiler and other components safely.

 Conduct post-shutdown inspections and maintenance.

Maintenance of a Steam Power Plant:

Scheduled Maintenance:

 Perform routine inspections, cleaning, and maintenance tasks based on a maintenance

schedule.

 This includes checking and lubricating moving parts, inspecting safety systems, and cleaning
heat exchangers.

Boiler Maintenance:

 Regularly inspect and clean boiler tubes, ensuring they are free of scale and deposits.

 Perform non-destructive testing (NDT) on critical boiler components to detect defects.

 Replace or repair damaged or worn-out boiler parts.

Turbine Maintenance:

 Inspect turbine blades for damage, erosion, or fouling.

 Balance and align the turbine rotor.

 Check and maintain the governor system.

Generator Maintenance:

 Inspect and maintain the generator stator and rotor windings.

 Test insulation resistance and perform electrical tests.

 Monitor and maintain the excitation system.

Condenser Maintenance:

 Clean and inspect condenser tubes to maintain heat exchange efficiency.

 Check and repair condenser cooling water systems.

Auxiliary System Maintenance:

  Maintain and test auxiliary systems such as feedwater heaters, gland sealing, and flange
heating.

 Replace worn seals and gaskets in gland sealing systems.

Safety and Regulatory Compliance:

 Ensure compliance with safety standards and regulatory requirements.

 Conduct regular safety drills and training for plant personnel.

Record Keeping:

 Maintain detailed records of maintenance activities, equipment condition, and any issues
encountered.

Effective operation and maintenance practices are essential to maximize the efficiency and lifespan
of a steam power plant while ensuring safety and compliance with regulations. Regular inspections,
preventive maintenance, and a well-trained staff are crucial components of successful operation and
maintenance programs.

Selecting the site for a steam power plant

Selecting the site for a steam power plant involves several important factors:

1. Proximity to Water Source:

Steam power plants require a consistent and reliable water source for cooling and steam
generation. Being near a river, lake, or ocean is often ideal.

2. Fuel Availability:

Consider the availability and transportation logistics of the primary fuel source, whether it's coal,
natural gas, or another fuel.

3. Grid Connection:

Access to the electrical grid is essential for distributing power generated by the plant.

4. Environmental Impact:

Assess the potential environmental impact of the plant, including emissions, noise, and visual
aspects. Compliance with environmental regulations is crucial.

5. Land Availability:

Sufficient land should be available for the power plant, cooling systems, and any potential future
expansions.
6. Geological and Geotechnical Factors: Evaluate the soil stability and geological conditions to ensure
the plant's foundation and structures can withstand seismic activity or other natural events.

7. Transportation Infrastructure: Adequate roads, railways, and ports for fuel and equipment
transportation are necessary.

8. Population and Zoning: Consider the proximity of residential areas and zoning regulations that
may affect the plant's operation.

9. Water Discharge: Ensure there's a suitable method for discharging heated water back into the
water source without harming the environment.

10. Environmental Permits: Identify and acquire the necessary permits and approvals from local and
national authorities.

11. Security and Safety: Assess the security needs of the plant to protect against potential threats.

12. Economic Factors: Evaluate the overall cost-effectiveness of the chosen site, including
construction and operational costs.

13. Availability of Skilled Labor: Check if the site has a skilled workforce or if additional training will
be required.

14. Future Expansion Potential: Consider whether the site allows for future capacity expansions if
needed.

Site selection is a complex process that involves a balance between these factors to ensure the
efficient and sustainable operation of a steam power plant. Consulting with experts in engineering,
environmental science, and regulatory compliance is often necessary to make an informed decision.

STEAM TURBINE GOVERNING SYSTEM

Steam turbine governing system is a method, used to maintain a constant steady speed of turbine.
The importance of this method is, the turbine can maintain a constant steady speed irrespective of
variation of its load. A turbine governor is provided for this arrangement. The purpose of the
governor is to supply steam into the turbine in such a way that the turbine gives a constant speed as
far as possible under varying the load. So, basically Steam turbine governing system is a process
where turbine maintains a steady output speed irrespective of variation of load. The different types
of steam turbine governor of are:

1. Throttle Governing Of Steam Turbine

2. Nozzle Control Governing Of Steam Turbine

3. Bypass Governing Of Steam Turbine

1. Throttle Governing Of Steam Turbine:-

Throttle Governing of steam Turbine is most popular and easiest way to control the turbine speed.
When steam turbine controls its output speed by varying the quantity of steam entering the turbine
is called Throttle Governing. It is also known as Servomotor methods.

In this system, a centrifugal governor is driven from the main shaft of turbine by belt or gear
arrangement. A control valve is used to control the direction of oil flow which supplied by the pipe
AA or BB. The servomotor or relay valve has a piston which moves towards left or right depending
upon the pressure of oil flow through the pipes AA or BB. This cylinder has connected a needle which
moves inside the [Link] the turbine is running at normal speed, everything in the turbine such
as such control valve, servomotor, piston position, fly balls of centrifugal governor will be in their
normal position as shown in the figure. The mouth of both pipes AA or BB is closed into the control
valves.

load increase in throttle governing of steam turbine

Assume that the turbine's load increases. It will decrease its speed which will decrease the
centrifugal force of the turbine. Now fly balls of the governor will come down thus decreasing their
amplitude. These fly balls also bring down the sleeve. The sleeve is connected to a control valve rod
through a lever pivoted on the fulcrum. This down word sleeve will raise the control valve rod. Now
oil is coming from the from the oil sump, pumped by gear pump is just stay at the mounts of both
pipes AA or BB which are closed by the two wings of control valves. So, raise of control valve rod will
open the mouth of the pipe AA but BB is still closed. Now the oil pressure is coming from the pipe
AA. This will rush from the control valve which will move the right side of the piston. As a result, the
steams flow rate into the turbine increases which will bring the speed of the turbine to the normal
range. When speed of the turbine will come to its normal range, fly balls will come into its normal
position. Now, sleeve and control valve rod will back to its normal position.

load decrease in throttle governing of steam turbine

2. Nozzle Control Governing Of Steam Turbine:-

It is another interesting method by which turbine's speed can be controlled. Nozzle control
governing of steam turbine is basically used for part load condition. Some set of nozzles are grouped
together (may be two, three or more groups) and each group of the nozzle is supplied steam
controlled by valves. Every valve is closed by the corresponding set of nozzle. Steam's flow rate is
also controlled by these nozzles. Actually, nozzle control governing is restricted to the first stage of
turbine whereas the subsequent nozzle area in other stage remains constant. According to the load
demand, some nozzles are in active and other inactive position. Suppose turbine holds ten numbers
of nozzles. If the load demand is reduced by 50% then five numbers of nozzles are in open condition
and rest is closed. This method is suitable for SIMPLE IMPULSE TURBINE. It is a process where rate of
steam flow is regulated depending on the opening and closing of set of nozzles rather than
regulating its pressure.

3. Bypass Governing Of Steam Turbine:-

Bipass governing of steam turbineis a method where a bypass line is provided for the steam.
Especially this is used when turbine is running in overloaded condition. The bypass line is provided
for passing the steam from first stage nozzle box into a later stage where work output increase. This
bypass steam is automatically regulated by the lift of valve which is under the control of the speed of
the governor for all loads within its range. Bypass valve is open to release the fresh stem into the
later stage of the turbine. In the later stage output, work is increased and the efficiency is low due to
the throttle effect.
Difference Between Subcritical and Supercritical Boiler
Key Difference – Subcritical vs Supercritical Boiler

Boilers are closed vessels in which a fluid is heated, most of the times, it is water. Even though the
name of this is a boiler, the fluid does not necessarily boil in this. The heated fluid is used in various
applications including water heating, central heating, cooking, etc. Subcritical and supercritical
boilers are such steam generating systems. The key difference between a Subcritical and
supercritical boiler is that Subcritical boilers work at a subcritical pressure of the fluid whereas
supercritical boilers work at a supercritical pressure of the fluid.

Critical Point

The critical point of a substance is the temperature and pressure at which that substance can behave
like a gas and a liquid at the same time, hence indistinguishable gas and liquid phases occur. That is
because the density of the gas phase and the liquid phase is equal at this point. A substance that
exists at temperature and pressure, above its critical point is known as a supercritical fluid. A
substance that exit below its critical point is known as a subcritical fluid. In a phase equilibrium
curve, the critical point is the end point of the curve.

Supercritical Boiler

The term supercritical in supercritical boilers refers to the pressures above the critical point of water
that the boiler is being operated. The critical point of water is at 647 K temperature and 221 bar
(22.1 MPa) pressure. Pressures below 221 bar are known as “subcritical pressure” and above 221 bar
is “supercritical pressure” of water.

Subcritical Boiler

Subcritical boilers are boilers that work at temperatures up to 374°C and at a pressure of 3,208 psi
(the critical point of water). These boilers compose a system with constant evaporation endpoint. A
typical example for a subcritical boiler is the drum-type steam generator.

Inside the boiler, the natural circulation of the fluid is generated by heating the risers. The water and
steam mixture that is leaving this riser is then separated into water and steam in the drum. Water is
circulated, water returns to the evaporator inlet through down corners while steam flows into the
super-heater chamber.

If the fluid is allowed to undergo natural circulation, the application range is limited to about 190 bar
as the maximum drum pressure. But if the circulation is done using a circulating pump, (known as
forced circulation), this range can be extended. This extension happens because of the fixing of the
endpoint of evaporation in the drum. And also, it sets the size of the heating surface in the
evaporator and in the super-heater. A major drawback of the subcritical boiler is, in these boilers,
bubble formation can occur.

Supercritical Boiler

Supercritical boiler (supercritical steam generator) is a type of boiler that works under supercritical
pressure conditions. This type of boilers is often used in generating electricity. Unlike in subcritical
boilers, there is no bubble formation in supercritical boilers, and liquid water immediately converts
into steam.

Supercritical boiler works at temperatures around 538–565°C and pressures above 3,200 psi. A
supercritical boiler has a system with variable evaporation endpoint. These boilers are drum-less.
Hence, the evaporation takes place at a single pass through the evaporator. The flow of fluid, most
of the times; water, is induced by the feed pump. This makes the system to be operated at any
desired pressure, enabling it to operate the system at either subcritical conditions or supercritical
conditions. As a result, the evaporation endpoint varies. And also, in order to maintain these
conditions, the evaporator and super-heater areas automatically adjust according to the
requirements.

This boiler is named as supercritical boiler because it is operated above the critical pressure of water
which is 221 bar. Since above the critical point, there is no distinction between steam and water,
water acts as a fluid.

Beyond the critical point of water, the latent heat of vaporization is zero, and hence there is no
considerable distinction between the liquid phase and vapor phase of water. one of the major
advantages of supercritical boilers is less fuel consumption. This causes less production of
greenhouse gases. and also, due to no bubble formation, less water consumption can be observed.

What are the similarities Between Subcritical and Supercritical Boiler?

The basic operational mechanism/cycle of both Subcritical and Supercritical Boiler is same.

Except for the drum-less evaporators in supercritical boilers, other constructional features are also
same.

The techniques of both Subcritical and Supercritical Boiler use similar equipment and strategies in
operation. i.e. air preheater, economizer, turbines, condensers, boiler feed pumps, etc.

What is the Difference Between Subcritical and Supercritical Boiler?

Subcritical vs Supercritical Boiler

Subcritical boilers are boilers that work at temperatures up to 374°C and at a pressure of 3,208 psi
(the critical point of water). Supercritical boiler (supercritical steam generator) is a type of boiler
that works under supercritical pressure conditions.

Temperature

[Link] boilers are operated at [Link] boilers are operated

temperatures up to 374°C. temperatures around 538–565°C.

Pressure

[Link] boilers are operated at a pressure of 3,208 [Link] boilers are operated at a

pressure above 3,200 psi.

Drums

[Link] boilers are composed of drums. [Link] boilers are drum-less.

Bubble Formation

[Link] formation is a major drawback in subcritical boilers. [Link] is no bubble formation

supercritical boilers.

Summary – Subcritical vs Supercritical Boiler

Subcritical and supercritical boilers are two forms of steam generators that are used for electricity
generation. These are categorized as such, based on their operating conditions. The difference
between a Subcritical and supercritical boiler is that Subcritical boilers work at a subcritical pressure
of the fluid whereas supercritical boilers work at a supercritical pressure of the fluid.
BOILER MOUNTINGS
INTODUCTION TO BOILER

Definition:
 A boiler is a closed vessel in which water is converted in to steam by burning of fuel in presence
of air at desired temperature, pressure and at desired mass flow rate.
 According to the Indian Boiler Act 1923, a boiler is a closed pressure vessel with capacity more
than 23 liters and used for generating steam under pressure and includes all the mountings fitted
to a closed vessel.
 According to American society of Mechanical Engineers (A.S.M.E.), a steam generator or a
boiler is defined as "a combination of apparatus for producing, finishing or recovering heat
together with the apparatus for transferring the heat so made available to the fluid being heated
and vaporized.

PRINCIPAL OF WORKING

In case of boiler, any type of fuel burn in presence of air and form flue gases which are at very high
temperature (hot fluid). The feed water at atmospheric pressure and temperature enters the system from
other side (cold fluid). Because of exchanges of heat between hot and cold fluid (water) temperature
raises and it form steam. The flue gases (hot fluid) temperature decreases and at lower temperature hot
fluid is thrown in to the atmosphere via stack/chimney.

FUNCTION OF A BOILER

The steam generated is employed for the following purposes:

 Used in steam turbines to develop electrical energy.
 Used to run steam engines.
 In the textile industries, sugar mills or in chemical industries as a cogeneration plant.
 Heating the buildings in cold weather.
 Producing hot water for hot water supply.

IBR AND NON-IBR BOILERS

 Boiler generating steam at working pressure below 10 bar and having water storage capacity less
than 22.75 liters are called non-IBR boilers. (INDIAN BOILER REGULATION).
 Boilers outside these limits are covered by the IBR and have to observe certain specified
conditions before being operated.
CLASSIFICATION OF BOILERS

The different ways to classify the boilers are as follows

1. According to location of boiler shell axis
 Horizontal (Lancashire boiler, Locomotive boiler, Babcock and Wilcox etc.)
 Vertical (Cochran boiler, vertical boiler etc.)
 Inclined boilers
When the axis of the boiler shell is horizontal the boiler is called horizontal boiler. If the axis is vertical,
the boiler is called vertical boiler and if the axis of the boiler is inclined it is known as inclined boiler.

2. According to the flow medium inside the tubes

 Fire tube (Lancashire, Locomotive, Cochran and Cornish boiler.)
 Water tube boilers (Simple vertical boiler, Babcock and Wilcox boiler.)
The boiler in which hot flue gases are inside the tubes and water is surrounding the tubes is called fire
tube boiler. When water is inside the tubes and the hot gases are outside the boiler is called water tube
boiler.

3. According to boiler pressure

According to pressure of the steam raised the boilers are classified as follows
 Low pressure (Below 80 bar) [Cochran and Cornish boiler, Lancashire and locomotive boiler]
 High pressure boilers (> 80 bar) [Babcock and Wilcox boiler]

4. According to the draft used:

 Natural draft (Simple vertical boiler, Lancashire boiler.)
 Artificial draft boilers (Babcock and Wilcox boiler, Locomotive boiler.)
Boilers need supply of air for combustion of fuel. If the circulation of air is provided with the help of a
chimney, the boiler is known as natural draft boiler. When either a forced draft fan or an induced draft fan
or both are used to provide the flow of air in the boiler is called artificial draft boiler.

5. According to method of water circulation:

 Natural circulation (Babcock and Wilcox boiler, Lancashire boiler.)
 Forced circulation (Velox boiler, Lamont boiler, Loffler boiler.)
If the circulation of water takes place due to difference in density caused by temperature of water, the
boiler is called natural circulation boiler. When the circulation is done with the help of a pump the boiler
is known as forced circulation boiler.

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6. According to furnace position:
 Internally fired (Simple vertical boiler Lancashire boiler, Cochran boiler.)
 Externally fired boilers (Babcock and Wilcox boiler.)
When the furnace of the boiler is inside its drum or shell, the boiler is called internally fired boiler. If the
furnace is outside the drum the boiler is called externally fire boiler.

7. According to Fuel Used.

 Solid
 Liquid
 Gaseous
 Electrical
 Nuclear energy fuel boilers
The boiler in which heat energy is obtained by the combustion of solid fuel like coal or lignite is known
as solid fuel boiler. A boiler using liquid or gaseous fuel for burning is known as liquid or gaseous fuel
boiler. Boilers in which electrical or nuclear energy is used for generation of heat are respectively called
as electrical energy headed boilers and nuclear energy heated boiler.

8. According to number of tubes

 Single tube (Cornish boiler, Vertical boiler.)
 Multi-tube boiler (Lancashire boiler, Locomotive boiler, Babcock and Wilcox.)
A boiler having only one fire tube or water tube is called a single, tube boiler. The boiler having two or
more, fire or water tubes is called multi-tube boiler.

9. According to boiler mobility

 Stationary (Lancashire, Babcock and Wilcox boiler, Vertical boiler.)
 Portable (Locomotive boiler, Marine boiler)
 Marine boilers
When the boiler is fixed at one location and cannot be transported easily it is known as stationary boiler.
If the boiler can be moved from one location to another it is known as portable boiler. The boiler which
work on surface of water are called marine boilers.

3
FACTORS AFFECTING THE SELECTION OF A BOILER

One has to send the technical details to the manufacturer to purchase a boiler. The technical details that
are used to give information about a particular boiler include the following things:
 Size of drum (Diameter and Length)
 Rate of steam generation (kg/hr)
 Heating surface (Square meters)
 Working pressure(Bar)
 Number of tubes /drum
 Type of boiler
 Manufacture of boiler
 Initial cost
 Quality of steam
 Repair and inspection facility

BOILER MOUNTINGS

The boiler mountings are the different fittings and devices which are mounted on a boiler shell for proper
functioning and safety.
(A) Mountings for safety
1. Safety valve (02 Nos.)
2. High pressure and low water safety valve on Lancashire and Cornish boiler (01 each)
3. Water level indicator (02 Nos.)
4. Fusible plug (01 No.)
(B) Mountings for controls
1. Pressure gauge (01 No.)
2. Steam stop valve (01 No.)
3. Feed check valve (01 No.)
4. Blow off cock (01 No.)
5. Man hole (01 No.)
6. Mud box (01 No.)

SAFETY VALVE

Safety valve is located on the top of the boiler. They guard the boiler against the excessive high pressure
of steam inside the drum. If pressure exceeds the working pressure then the safety valve allows to blow
off a certain quantity of steam to the atmosphere, and the pressure falls in the drum.
There are four types of safety valves.

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 1. Dead-weight safety valves
Figure 01 shows the schematic of a dead weight safety valve. It is similar to dead weight (whistle) loaded
on a pressure cooker and functions in a similar way. A gunmetal valve rests on gunmetal seat. The
gunmetal seat is mounted on a steel steam pipe. The valve is fastened to a weight carrier. The dead weight
is in the form of cylindrical discs are placed on the carrier so it acts downward. When the force due to
steam pressure exceeds the total dead weight acting downward, the valve lifts up from the seat and some
quantity of steam left the atmosphere, thus reducing the steam pressure in the boiler shell, and the valve is
again closed. The dead weight safety valve is used on stationary boilers.

Fig.01: Dead weight safety valve

2. Spring- loaded safety valve

The dead weight safety valve cannot be used on locomotive and marine boilers. The spring
loaded safety valve is used on locomotive marines and on high –pressure valve. Fig shows the
valve close the steam passages under the action of a central helical spring. When the upward
force of steam exceeds the down ward spring tension, the valves open and some steam escape to
the atmosphere. Thus lower the steam pressure in the boiler and the valves are closed again under
the spring force.

5
 Fig.02: Spring –loaded safety valve

3. Lever-loaded safety valve

The fig. shows the lever- loaded spring safety valve, the body of valve is fastened on the top of
the boiler shell. A gunmetal valve is placed on the steam passage formed in the casing. A cast
iron lever attached to a fulcrum on one end and loaded by weight on the other end keeps the valve
on the seat in a closed position.
When the upward force due to steam pressure exceeds the load on the valve, the valve opens, and
allows some quantity of steam to escape. The pressure of steam in the boiler falls and the valve
again rests on the seat.

6
 Fig.03: Lever-loaded safety valve

4. High steam and low water safety valve

This valve is combination of two valves as shown in fig 4. It is used in Cornish and Lancashire
boilers. One of the valves is lever loaded and is operated when steam pressure in the boiler
exceeds the working pressure. The second valve operates and blows off steam with a louder
noise, when water level in the boiler falls below the normal level.

Fig.04: High steam and low steam safety valve

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WATER LEVEL INDICATOR

The water level indicator is located in front of the boiler in such a position that the level of water can
easily be seen by the attendant. Two water level indicators are used on all boilers. A water level indicator
consists of a metal tube and a strong glass tube with markings. The upper and lower ends are connected to
two gunmetal hollow pipes. The drain cock is to ensure the water and steam cock are clear. During
operation steam cock and water cock remains open while the drain cock remains close. During the normal
operation, the two balls provided inside the gunmetal pipe remains in position as shown in figure , hence
the water can reach the glass gauge and its level can be seen.
In case the glass gauge breaks accidently, the water and steam simultaneously rush out through the
gunmetal pipes. The force is exerted on two balls and they are carried away by water and steam and the
passage are closed. The water and the steam cocks are then closed and the glass gauge is replaced.

Fig.05: Water level indicator.

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PRESSURE GAUGE

A pressure gauge is fitted in front of the boiler in such a position that the operator can conveniently read
it. It read the pressure of steam in the boiler and is connected to the steam space by a siphon tube.
The most commonly used gauge is the bourdon pressure gauge. Fig 6. Illustrates the bourdon pressure
gauge. It consists of an elliptical spring bourdon tube. One end of the tube is connected to the siphon tube
and other end is connected by levers and gears to pointer.
When fluid pressure acts on the bourdon tube, it tries to make its cross section change from elliptical to
circular. In this process, the lever end of the tube moves out as indicated by an arrow. The tube movement
is magnified by the mechanism and given to pointer to move over a circular scale indicating the pressure.
The siphon tube is shown in Fig.07. It connects the steam space of the boiler to the bourdon gauge is
filled with water in order to avoid the effect of high temperature steam on the gauge components. The
steam pressure is transferred by water to the bourdon gauge.

Fig.06: Bourdon pressure gauge

Fig.07: pressure gauge with siphon tube.

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FUSIBLE PLUG

It is very important safety device which protect the fire tube boiler shell against overheating. It is located
just above the furnace in the boiler. It consists of a gun metal body with a fusible molten metal as shown
in fig.
During the operation the fusible plug is covered by water and its temperature does not raise melting state.
When water level falls it uncovers the fusible plug. It heats up and falls down the water and steam rush
through the hole and extinguish the fire before any major damage.

Fig. 08: Fusible plug

BLOW-OFF COCK

The function of the blow off cock is to discharge mud and other sediments deposited in the bottom most
part of the water space in the boiler, while the boiler is in operation. It can also be used for drain off boiler
water. It consists of conical hollow gunmetal plug type of valve. The flow of water through the cock can
be stopped by rotating the plug valve in such a way that its solid side comes in the line of the hole in the
casing as shown in figure.

Fig. 09: Blow-off cock

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FEED CHECK VALVE

The feed check valve is fitted to the boiler, slightly below the working level in the boiler. It is used to
supply high pressure feed water to the boiler. It also prevents the returning of feed water from the boiler if
the feed pump fails to work. A feed check valve consists of two valves feed valve and check valve as
shown in figure. In normal working pressure, the feed water pressure is more the boiler pressure, thus the
check valve remains open. But in case of its failure, the boiler pressure become more than the feed water,
the valve rests on its seat and closes the water passage and prevents its reverse flow.

Fig.10: Feed check valve

STEAM STOP VALVE

The steam stop valve is located on the highest part of the steam space. It regulates the steam supply for
use. The steam stop valve can be operated manually or automatically. It is hand operated.

Fig.11: Steam stop valve

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MAN HOLE AND MUD HOLE

The man hole is provided on the boiler shell at a convenient position so that a person can enter through
it, inside the boiler for cleaning and inspection purposes.
The mud hole is placed at the bottom of the boiler to collect mud discharge through the blow off cock.
Therefore, it is connected with blow off cock.

Sr. No. Mounting Function Location

1 Safety Valve
2 Steam Stop Valve
3 Feed Check Valve
4 Blow Off Valve
5 Water Level Indicator
6 Fusible Plug
7 Pressure Gauge

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