The following is a list of mountings found on a typical

boiler.
Safety valve 2/3
Water gauge glass 2
Feed water check valves 2 sets
Stop valves
Vent cock
Blow down valve/scum valve 1 each
Water sampling connection. Pressure gauge connection.
Boiler Mountings
Boiler Mountings
Feed Check Configuration
Feed Check Configuration
Blow Down Valve Configuration Blow Down Valve Configuration
Blow Down Valve Configuration
Boiler
shell
Blow Down
Discharge Screw lift
valve
Screw down non
return valve
Blow down
Blow down
To avoid damage to the valves and the blow down line it is
important to open the valves in the sequence 1, 2 & 3.
Gauge Glasses
Gauge Glasses
All boilers must be fitted with at least two independent
means of reading the level of water within the boiler
shell or drum.
One of the two devices must be a glass water gauge
attached, by means of isolating cocks, to the boiler
drum. The other device can be an additional glass water
gauge or an approved equivalent device.
The water gauges are to be readily accessible and placed
so that the water level is clearly visible.
The lowest visible part of the glass is to be aligned to the
point of the lowest safe working water level.
Rules
Rules
There are two basic glass water gauges tube and plate.
The glass tube type is made from toughened borosilicate
round glass tube and is capable of withstanding pressures
up to about 34 bar.
The plate glass type is made from toughened soda-lime
glass flat plate and is capable of withstanding pressures up
to about 79 bar.
At the high temperatures experienced at these pressures, the
boiler water has a corrosive effect on the glass, which has
to be protected from direct contact with the water.
Basic Design
Basic Design
Gauge glasses should always be fitted with isolating cocks
rather than valves, the reason being:-
A straight-through passage can be obtained.
Valve lids sometimes become detached from their
spindles.
Sediment is more likely to accumulate in a valve chest.
It is easier to see if a cock is open or shut.
Basic Design
Basic Design
Tube Type
Gauge Glass
Tube Type
Gauge Glass
Note position of cocks, which
must always be installed with
handles hanging vertically when
steam & water cocks are open
and drain shut.
Position of cock (open/shut)
can be easily seen.
Cocks can not vibrate to non-
working position.

Gauge Glass Protection
Gauge Glass Protection
High Pressure
Plate Gauge
Glass
High Pressure
Plate Gauge
Glass
Glass
Joint Mica
Clamping
plate
Glass plates protected from
the corrosive effect of the
boiler water by thin
translucent mica sheets.
Lighting box positioned
behind the gauge.
Blowing Down a Gauge Glass
Blowing Down a Gauge Glass
1 2 3 4 5
Boiler Level
Sensor
Boiler Level
Sensor
High level
alarms
Low level
alarms
Magnet
Simple float device used to
activate magnetic reed
switches to indicate high and
low level and open/shut feed
control valve.
Boiler
Level
Sensor
Boiler
Level
Sensor
Weir
Condensing
chamber
Fixed
leg
Variable
leg
D.P.cell
Boiler drum
Isolating &
balance
valves
Boiler Level Control
Boiler Level Control
P + I
Controller
Desired
value
Diaphragm
control valve
I/P
converter
Level
detector
Feed water
Single element boiler water level control system
An increase in firing rate will cause a rapid increase of
steam bubbles which will displace water and cause the
level within the drum to suddenly rise.
The controller will thus shut the feed valve at a time when
the water supply needs to be increased.
The reverse will happen when the steam demand
decreases, the water level will suddenly drop and the
controller will, therefore, increase the feed water supply.
Swell & Shrinkage
Swell & Shrinkage
Secondary
Controller
P + I +D
Desired
value
Diaphragm
control valve
I/P
converter
Level
detector
Feed water
Two element boiler water level control system
D/P cell
D/P cell
Primary
Controller
P + I +D
Two Element Control
Two Element Control
A two element controller receives signals both from the
level sensor and also from a steam flow sensor.
As the steam demand increases, the flow sensing
secondary controller will over-ride the level sensing
primary controller and cause the feed control valve to
open.
Two Element Control
Two Element Control
Three Element Control
Three Element Control
Desired
value
Diaphragm
control valve
Level
detector
Feed water
D/P cell
D/P cell
Primary
Controller
P + I +D
D/P cell
Ratio
Relay
Steam flow
detector
Feed flow
detector
Secondary
Controller
P + I +D
A three element controller receives signals both from the
level sensor, a steam flow sensor and also a feed flow
sensor.
Under steady steaming conditions, the feed will be
supplied to the boiler in direct ratio to the steam flow. As
the steam flow increases the feed flow will immediately
respond to match.
The level control signal will over-ride the ratio element if
the level changes.
Three Element Control
Three Element Control
Safety Valves
Safety Valves
Two safety valves have to be fitted to the main steam
drum or shell of the boiler.
Both valves may be fitted to the same chest and
mounting but it must be separate from any chest or
mounting used for other purposes.
For boilers fitted with superheaters a third safety valve
must be fitted to the main steam outlet from the
superheater.
Safety valve seat bores must never be less than 38mm in
diameter
Rules
Rules
Standard spring loaded safety valves designs are described
according to the amount that the valve will lift against the
spring pressure:-
Ordinary spring loaded.
High lift spring loaded.
Improved high lift spring loaded.
Full lift spring loaded.
Full bore relay operated valves are of a different design.
Safety Valve Types
Safety Valve Types
Blow-down: The difference between the set pressure and
the pressure at which the valve closes after releasing the
excess pressure (Usually about 10%)
Easing gear: A means of manually opening the valve to the
maximum effective lift.
Safety Valve Terminology
Safety Valve Terminology
Flat seats: Greater steam escape edge, easier machining.
Spring protection: Regulations require the loading spring
of any safety valve to be protected from steam escaping
from the valve.
Valve chest: The bore of the valve chest connecting valve
to boiler must be at least equal to the area through the
seating of the valve in mm. multiplied by 1.5.
Basic Safety Valve Design
Basic Safety Valve Design
Waste steam pipe: The waste steam pipe and the steam
passage from the valves must have a cross-sectional area of
at least the area through the seating of the valve in mm.
multiplied by 1.1 for ordinary, high lift and improved high
lift valves and 2 for full lift valves
Drain pipe: A drain pipe must be fitted to the lowest part
of the valve chest on the discharge side of the valve. There
must be no isolating valve or cock fitted to the line and
there must be a straight fall from the valve to a safe venting
position.
Basic Safety Valve Design
Basic Safety Valve Design
An ordinary relief valve (e.g. an
air bottle) is restricted in the
amount that it can open by the
increasing force of the spring as it
is compressed.
A boiler safety valve has to lift
further and stay open, in order to
cope with the greater thermal
energy present in the steam.
Safety Valve Theory
Safety Valve Theory
Spring force
Pressure
The area of the bore of the valve governs the theoretical
maximum amount of steam that can pass through a valve of
any design.
Safety Valve Theory
Safety Valve Theory
Bore area of valve
The bore area A can be calculated from the diameter of
the valve seat i.e.
A = D
2
4
Safety Valve Theory
Safety Valve Theory
Bore area of valve
As the valve lifts it forms a cylindrical area between the
valve and the seat i.e : -
x D x lift of valve L
Safety Valve Theory
Safety Valve Theory
Lift area
If the lift area and the bore areas
of the valve are equated then:-
x D x L = D
2
4
this can then be resolved to:-
L = D
2
= D
x D x 4 4
If the valve lifts by the bore
diameter of the valve seat divided
by 4 then maximum steam can
escape through the valve.
Safety Valve Theory
Safety Valve Theory
Bore area of valve
Lift area
Using the maximum effective lift of D/4 as an ideal, typical
lifts for each type of valve are: -
Ordinary spring loaded. D/24
High lift spring loaded. D/16
Improved high lift spring loaded. D/12
Full lift spring loaded. D/5
Full bore relay operated. D/4
Safety Valve Theory
Safety Valve Theory
Safety Valve Theory
Safety Valve Theory
CP
HE
A =
Safety valve bore must never be less that 38mm
Lift area for specific valve application is derived from:-
Where:-
A = Area through the seating of valve in mm
P = Working pressure of valve in MN/m
2
H = Total heating surface of boiler in m
2
E = Evaporative rate in kg of steam/m
2
of heating surface/hour
C = Discharge co-efficient whose value depends on type of safety valve
Safety Valve Theory
Safety Valve Theory
Discharge co-efficient C for each type of valve is: -
Ordinary spring loaded. 50
High lift spring loaded. 75
Improved high lift spring loaded. 100
Full lift spring loaded. 200
Full bore relay operated. 320
CP
HE
A =
Safety Valve Theory
Safety Valve Theory
For Superheater Safety Valve the area A
s
is calculated as :-
Where:-
A = saturated area through seating of valve in mm.
T
s
= Degree of superheat temperature in
o
C.

+ =
556
1
s
s
T
Use can be made of the kinetic energy of the velocity of the
steam as it starts to escape from the opening valve lid. If the
steam is directed underneath the valve lid it will supply
force to increase the compression of the spring and give
extra lift. This will increase the effective lift to D/24.
Pressure energy
Velocity energy
Force
Increasing Valve Lift
Increasing Valve Lift
Ordinary Safety Valve
Ordinary Safety Valve
Lipped valve lid
(to increase lift to D/24)
Valve lid fitted with location wings
to hold lid in alignment on the seat
Clearance between valve lid
and spindle guide bush D/4
to allow valve to lift fully on
easing gear.
Lid a loose fit on spindle
Ordinary Safety Valve Features
Ordinary Safety Valve Features
Design problems
Wings on valve lid can restrict steam flow and cause
jamming of the valve.
Valve can jam in guide bush.
Valve lift limited to D/24.
Waste steam will accumulate above the valve and act
downwards on the lips of the valve lid. (Can be an
advantage - assists blow-down)
This type of valve is now rarely used.
Ordinary Safety Valve
Ordinary Safety Valve
High Lift Safety Valve
High Lift Safety Valve
High Lift Safety Valve Features
High Lift Safety Valve Features
Design problems
Wings on valve lid can restrict steam flow and cause
jamming of the valve.
Piston and cylinder ring can jam.
Note: Due to the loose nature of the piston on the spindle,
valve will still lift to D/24 if jamming occurs.
This type of valve has now been superseded by the
Improved High Lift Valve
High Lift Safety Valve
High Lift Safety Valve
Improved High Lift Safety Valve
Improved High Lift Safety Valve
Improved High Lift Features
Improved High Lift Features
Normal pressure
Valve at rest
Boiler pressure
3% above normal
Valve starting to lift
Steam acting
on valve lid
and piston lifts
valve to D/12
Valve Operation
Valve Operation
Valve chest Cast steel
Valve body Cast steel
Valve seat Stainless steel, Monel metal
Valve lid Stainless steel, Monel metal
Spindle Stainless steel
Guides/bushes Bronze
Spring Tempered steel
Valve Materials
Valve Materials
Hopkinson
HyLif
Safety
Valve
Hopkinson
HyLif
Safety
Valve

Valve lid, or head, now
forms a piston held within
an adjustable valve guide
Valve head now fixed
to spindle and thrust carried
via a shaped recess in the
valve lid
Lipped on valve lid lifts lid
into valve guide where steam
pressure acting on piston
increases lift to D/5
Blow-down
controlled by height
of valve guide
Hopkinson HyLif Features
Hopkinson HyLif Features
Dewrance Consolidated
Safety Valve
Dewrance Consolidated
Safety Valve
Steam passing through a valve at high temperature can
cause distortion. This can cause leakage, leading to scoring
and cutting of the seat.
Thermo-disk Valve Head
Thermo-disk Valve Head
Reduced section in way of seat
The thermodisk valve head is designed with the contact
area reduced in section to allow the valve head to flex to the
profile of the seat. The seat acts as a heat sink, removing
thermal stress from the thin sectioned valve head.
Some form of adjustable blow-down ring is a common
feature in other designs of high capacity safety valve.
Lowering the ring reduces the reaction forces to give a
more rapid blow-down.
Raising the ring increases the reaction forces and and slows
the blow down.
Consolidated Blow-down Ring
Consolidated Blow-down Ring
Full Bore Safety Valve
Full Bore Safety Valve
It is important that the relative
dimensions of the lid and seat
are maintained if the seating
faces have to be machined. The
seating width (B A & D C )
must remain the same, but will
widen as material is removed
from the seat faces.
Valve Seat Maintenance
Valve Seat Maintenance
Material must also be removed from faces H and G to compensate.
Opening E will also diminish and must be restored in order to
maintain the blow-down feature of the valve.
Parts for each valve must be kept separate.
The springs and spindles should be hung-up and sounded.
Check springs for distortion and the free length.
Check that drains are clear and that the easing gear is free.
Check chests and vent pipes for corrosion and cracking.
Check faces of the seats and lids/valve heads for damage.
Following re-assembly, the easing gear should remain
disconnected until the valve settings have been adjusted.
Valve Overhaul
Valve Overhaul
National legislation and classification society rules require an
approved surveyor to be in attendance when adjusting any
safety valves fitted to a boiler which is heated by fuel.
Safety valves fitted to boilers or economisers that are ONLY
heated by exhaust gases from the main engines or generators,
may be adjusted by a fully qualified engineer, holding a first
class certificate, sailing in the rank of chief engineer.
In this case, the engineer in question MUST inform an
approved surveyor, in writing, at the next port of call
following the adjustment of the valves.
Valve Setting Rules
Valve Setting Rules
With the easing gear removed, gag one of the valves to
prevent it lifting.
Screw down the compression screw on the other valve
about one turn tighter than its previous setting and raise the
boiler to the required lift pressure. (Approved design
pressure plus 3%)
Screw back compression screw until valve lifts and then
screw down the compression screw carefully, tapping the
valve spindle very lightly until the valve returns to its seat
and remains closed.
Valve Setting
Valve Setting
The distance between the lower land of the compression
screw and the top spindle guide should be carefully
measured and the compression split ring adjusted to give a
neat fit. The compression screw should then be hardened
down onto the compression ring.
Note: Some safety valve designs have a locking nut fitted
instead of the compression ring.
Repeat for the other valve, gagging the first valve
accordingly.
Fit both sets of easing gear, hoods, locking keys and
padlocks. Finally check and operate easing gear.
Valve Setting
Valve Setting
Securing Adjustment
Securing Adjustment
Classification societies require that safety valves be
subjected to an accumulation of pressure test to ensure the
valves are of the correct discharge capacity for the boiler.
With boiler isolated and maximum firing rate applied, the
accumulation of pressure within the boiler must not exceed
10 per cent of the approved design pressure. The duration
of test (water permitting) is not to exceed 15 minutes for
smoke tube boilers and 7 minutes for water tube boilers.
Accumulation of Pressure
Accumulation of Pressure