Low-Water Fuel Cutoffs

Learning Outcome
When you complete this module you will be able to:
Discuss the designs, operation and testing of low-water fuel cutoffs.

Learning Objectives
Here is what you will be able to do when you complete each objective:
1. Describe the construction and operation of boiler low water level fuel cutoff
equipment.
2. List the ASME and CSA code regulations regarding low water fuel cutoffs.
3. Describe the testing and maintenance of boiler low water level fuel cutoffs.

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INTRODUCTION
The main cause of heating boiler failure is overheating of the heating surfaces due
to low water conditions. Normally, the water covering these surfaces will keep the
temperature of the metal at a safe value. A low water level, however, allows the
boiler metal temperature to increase to a point where it weakens and is not able to
withstand the internal boiler pressure. This may result in the boiler metal
rupturing and a massive release of pressurized steam and hot water.
The ASME Code and CSA B51 require that every automatically fired boiler that
is not under continuous attendance by a certified operator shall be equipped with
an automatic low-water fuel cutoff device, which automatically shuts off the fuel
supply when the water level drops to about 25.4 mm (1 in) in the gage glass. This
corresponds to a level approximately 76.2 mm (3 in) above the lowest permissible
water level as specified by the manufacturer. The installation shall be such that
the device cannot be rendered inoperative and can be tested under operating
conditions. Under certain circumstances, which will be discussed later, boilers
may be required to be equipped with two low-water fuel cutoff devices.
There are many different types of low-water fuel cutoff devices used on boilers,
but only the most common types will be described.

Float Operated Low-Water Fuel Cutoff

The low-water fuel cutoff device illustrated in Fig. 1 is often used on low
capacity, cast-iron heating boilers. This device consists of a float chamber
connected to the same boiler openings as the directly connected water gage glass.
Therefore, the water level in the float chamber is the same as that in the boiler and
in the gage glass. The float inside the chamber, which follows the changes in
water level in the boiler, is directly connected to an electric switch attached to the
float chamber. The switch is separated from the water chamber by a flexible
diaphragm, which acts as a seal.
When the water in the boiler is above the lowest permissible level and still visible
in the gage glass, the float keeps the electrical switch in the closed position,
allowing power to pass through to an electrically operated (solenoid type) fuel
valve. Should the boiler water drop below the minimum safe level, the float opens
the switch to the solenoid of the fuel valve, causing the valve to close, thus
stopping the fuel supply to the burner.

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Figure 1
Float Operated Low-Water Fuel Cutoff (McDonnel)

Although different in design, the low-water fuel cutoff shown schematically in

Fig. 2 is similar in operation to the one described previously.

Figure 2
Basic Float Principles

The float chamber is connected directly to the steam and water space independent
of the gage glass. The water level in this chamber will follow the level in the
boiler very closely. A float, which follows the fluctuations in water level, is
connected to a rod which pivots in the upper part of the chamber. Movement of
the short end of the rod is transmitted through the bellows assembly to a lever
system which tilts the mercury switch. The bellows assembly forms a flexible,
steam and water tight seal between the float housing and the electrical junction
box.

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Figure 3
Mercury Switch

The mercury switch, used in the low-water fuel cutoff and many other controls,
consists of a small glass bulb similar to those in Fig. 3. Electrical contacts, that
form part of an external wiring circuit, are mounted inside the bulb at either one
end or both. The bulb also contains a small quantity of mercury, which is used to
open or close the electrical contacts inside the bulb. By tilting the bulb to one side
or the other, the mercury, being an electrical conductor, will open or close the
circuit.
Fig. 3(a) shows a single pole mercury switch in the closed position, which is the
position when the water in the boiler is above the lowest permissible level.
As the water level drops in the boiler, the float follows the corresponding change
in level in the float housing, and tilts the mercury switch to the opposite side by
means of the rod and lever system. At a predetermined level, the bulb will be
tilted sufficiently to shift the mercury to the opposite end of the bulb and the
circuit will be opened as shown in Fig. 3(b). The interior of the bulb is under a
high vacuum to prevent corrosion of the electrical contacts.
Fig. 3(c) shows a three-wire mercury switch instead of a two-wire switch as
described previously. When this bulb is tilted by a float due to a drop in water
level, the mercury will move to the left end of the bulb. This will open the
electrical circuit to a solenoid valve in the fuel line and close electrical contacts at
the opposite or left end of the bulb. This energizes an electrical alarm circuit to
warn the operator when the burner shuts down due to a low water condition.

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Figure 4
Pump Control/Low-Water Fuel Cutoff

Fig. 4 illustrates a float arrangement that combines a feedwater pump control

switch with a low-water fuel cutoff and alarm. In this design, one bulb contains a
two-wire switch that controls the feedwater pump circuit while the bulb with the
three-wire switch contains a low-water fuel cutoff and an alarm. As the boiler
water level drops, the float will close the two-wire switch to start the feedwater
pump when the water is still above the lowest permissible level. If the pump fails
to start, or some other problem causes the drum level to continue dropping when
the feedwater pump is running, the bulb containing the three- wire switch will act
as a boiler emergency shutdown. The electrical circuit to the solenoid valve in the
fuel line will be opened to shut off the burner when the water in the boiler reaches
the lowest permissible level. An alarm is also energized.

Fig. 5 illustrates a float controlled feedwater valve arrangement with a low-water

fuel cutoff. If the boiler drum level drops, the float in the chamber moves to a
lower position to open the feedwater valve further and admit more water into the
boiler. As the water level rises, the float will move up to decrease the valve
opening.
If the water level continues to drop when the float moves downward to open the
feedwater valve, the switch will open the burner electrical circuit to shut down the
burner as explained previously.

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Figure 5
Feeder Valve/Low-Water Fuel Cutoff

Some boilers have the float chamber of the low-water fuel cutoff combined with
the water column as shown in Fig. 6(a). Its operation is similar to those shown in
Figs. 2 and 4.

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Figure 6
Column with Low-Water Fuel Cutoff

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Fig. 6(b) is an exterior view of the water column and float chamber shown in Fig.
6(a) that combines a pump control and a low-water cutoff control. When the water
level reaches point A, the float tilts the bulb for the pump circuit so that the
mercury flows to the opposite end of the bulb and stops the power supply to the
pump. When the level drops to B, the switch closes and the pump starts again.
If the pump fails to start, or the water level drops to point C for some other
reason, the bulb with the three-wire switch will tilt over and cut off the power
supply to the burner, which will shut down. An alarm switch will also be closed.
The boiler cannot be started unless the water level is raised above point C, the
operating level for the cutoff switch. In some cases, the switch may also have to
be manually reset.

Magnetic Low-Water Fuel Cutoff

The sketch in Fig. 7 illustrates the operating principle of a low-water fuel cutoff
which is actuated by a float and magnet. At normal water levels, the permanent
magnet, attached to the pivoted mercury switch, is drawn toward the magnetic
plunger and the mercury switch is tilted so contacts 5 & 6 [Fig. 7(a)] are closed to
maintain the burner in operation.

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Figure 7
Magnetic Low-Water Fuel Cutoff

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As the water level drops, the float is lowered together with the plunger, until, at
the cutoff point, the plunger drops entirely outside of the field of the permanent
magnet [Fig. 7(b)]. At this point, the tension spring pulls the permanent magnet
away and the three-wire mercury switch is tilted to the opposite position so
contacts 4 & 5 are closed. This opens the burner circuit to shut off the fuel supply,
and the alarm circuit is energized.

Electric Probe Type Low-Water Fuel Cutoff

This cutoff usually consists of two electric probes or electrodes immersed in the
water. These probes may be mounted directly on the boiler shell, on the water
column, or in a special probe housing. The schematic of one design is shown in
Fig. 8.

Figure 8
Electric Probe Type Low-Water Fuel Cutoff

As long as water covers both probes, a small current will flow through the water
between the probes. This closes the electric circuit that energizes an electromagnetic coil or solenoid switch in the power circuit to the fuel valve, keeping the
switch in the closed position. This allows the fuel valve to be in an open position.
When the water level drops below the upper probe, the current flow to the
solenoid will cease so the switch opens, and the power supply to the fuel valve is
interrupted, shutting off the fuel.
Another design of the probe type low-water fuel cutoff has a single probe and the
boiler shell or probe housing acts as a second probe. These are used mainly on hot
water boilers.
The advantage of the electric probe type cutoff is its simplicity. It contains no
moving parts so the possibility of mechanical failure is eliminated.

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It is necessary to check and clean the probes at regular intervals. Scale or

sediment on the probes reduces or completely stops the current flow, resulting in a
boiler shutdown.

Low-Water Fuel Cutoff For Hot Water Heating Boilers

Hot water boilers are completely filled with water, and are usually equipped with
an automatic fill valve connected to the city water supply, which keeps the system
filled at all times.
It would be a misconception to believe that a low water condition could not
develop as easily as in a steam boiler. Unfortunately, due to human error or
mechanical failure, low water conditions can develop in hot water heating boilers.
The construction of hot water boilers does not differ greatly from steam boilers,
so the effects of a low water condition can be just as disastrous.
The same type of cutoff device that is used on steam heating boilers can be
applied to hot water heating boilers, provided the pressure rating of the device is
high enough. Hot water boilers may operate at a higher pressure than steam
heating boilers. Fig. 9 shows a float operated low-water fuel cutoff device
installed on a hot water heating boiler.

Figure 9
Low-Water Fuel Cutoff on a Hot Water Boiler
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There is considerable freedom in the arrangement of the low water cutoff on hot
water heating boilers. Since no normal water level has to be maintained, the
control may be installed at any point above the lowest permissible water level
specified by the manufacturer.
Even though the low-water fuel cutoff opens the circuit to the fuel valve when the
level drops below the safe minimum level, there is always a possibility that the
fuel valve will stick in the open position and firing will continue. The boiler
temperature and pressure will continue to rise until the relief valve opens,
allowing water and steam to escape. The water level could drop to the point where
overheating of the heat transfer surfaces could occur. To safeguard against this
overheating due to an overfiring condition, a combination low water cutoff and
feeder valve offers the best protection.

POSSIBLE CAUSES of LOW WATER LEVEL

Some reasons for low water in a hot water or steam boiler:
1. Leaks in piping or boiler caused by breakage or corrosion.
2. Excessive blowoff.
3. Relief valve discharge caused by overfiring on hot water boilers, even
though the automatic fill valve is operational.
4. Boiler feedpump failure.

ASME CODES AND CSA REGULATIONS

1. CSA-B51, states that every steam boiler not under continuous attendance
by a certified operator shall be equipped with a low-water fuel cutoff that
serves no other purpose. Its installation shall be such that it can be tested
when the boiler is in operation. Every automatically fired hot water boiler,
with forced circulation and not under continuous attendance by a certified
operator, shall also be equipped with a low-water fuel cutoff device.
2. CSA-B51, also states that a low-water fuel cutoff must serve no other
purpose. If a boiler is equipped with a combination pump control/low
water cutoff (Fig.4), it should also be equipped with a separate low water
cutoff that serves no purpose except for cutting off the fuel.

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A malfunction of such a combination device consisting of a low-water fuel

cutoff and feedwater supply control switch, may stop the feedwater supply
to the boiler, and so create a low water condition. It may also prevent the
fuel cutoff switch from shutting down the burner once the minimum safe
level is reached. Overheating of the heating surfaces will result.
3. Since the cutoff devices described previously are all mounted outside the
boiler, either in a special chamber or in the water column connected to the
boiler by piping, no shutoff valves may be installed in the connecting
piping. (ASME Code, Section IV).
4. The minimum size of piping connecting a water column to a steam boiler
shall not be less than 25.4 mm (1 inch). The column drain pipe and valve
shall not be less than 19 mm (3/4 inch).
TESTING AND MAINTENANCE OF LOW-WATER
FUEL CUTOFF DEVICES
Low-water fuel cutoff devices are automatic devices. Some operators have a
mistaken idea that these devices do not require any attention. This idea could not
be further from the truth. These devices require regular attention to keep them in
proper operating condition.

1. Testing of Low-Water Fuel Cutoff on Steam Boilers

(a) Daily
Make routine checks for leaks and abnormal conditions. Repair any defects
immediately.
(b) Weekly
To check the low-water fuel cutoff mechanism, open the drain on the float
chamber while the burner is in operation. The water level should drop
enough for the float to open the mercury switch and shut down the burner.
Carefully observe the water level at which the fuel cutoff switch shuts down
the burner. If this cutoff level is not at or slightly above the lowest
permissible level specified by the manufacturer, the low-water fuel cutoff
should be serviced immediately or replaced if necessary.

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After completion of the test, the boiler should be started again, and the
automatic startup controls should be checked for proper operation.

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Opening the column drain will also clear any sediment in the float chamber.
When the column drain valve is closed, the water level in the column
chamber and gage glass should quickly return to normal. If not, all the
passages must be checked and any obstructions removed.
Steam heating boilers may use a combination boiler feedwater control and
low-water fuel cutoff. The feedwater control may activate a valve, or control
a feed pump.
By closing the feedwater valve to the boiler and opening the blowdown
valve, the water level in the boiler and column can be rapidly lowered.
Operation of the pump control can be checked by observing the levels at
which the pump starts and stops. It is advisable to mark these levels on the
gage glass and record them in a log book for future reference. A change in
levels during later checks could indicate possible control problems.
By lowering the water level further, the low-water fuel cutoff should be
activated. This level should also be recorded.
Some steam heating boilers are equipped with direct makeup valves in case
the feedwater pump fails.
The operation of the makeup valve, which is connected directly to a float,
can be checked by shutting down the feed pump. The makeup valve should
open somewhat below the cut-in level of the pump and should be able to
maintain proper level when the boiler is at full load.
The valve should be checked for tight closure. With the boiler shut down, an
increase in water level with the makeup closed may indicate a leaking valve.
(c) Monthly

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Simulate a low water condition in the boiler by shutting down the feed pump
and feedwater supply valve. On steam heating boilers, the valve on the
condensate return line should be closed so the boiler will not get any
replacement water. Allow the boiler water level to drop and note the level at
which the cutoff switch shuts down the burner. The blowoff valve can be
opened to hasten the operation. The burner should be shut down when the
level is approximately 1 cm to 2.5 cm above the bottom of the gage glass.
Restore the water level to normal and resume boiler operation if everything is
satisfactory.
If the cutoff does not function properly during the test, the problem must be
corrected immediately.

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(d) Annually
The low water cutoff on high- and low-pressure steam boilers and water
feeders on heating boilers should be dismantled annually by qualified
personnel. It should be checked for any obstructions, and proper operation of
all the parts must be verified. Any leaks in the connecting lines to the boiler
should be repaired. Connecting lines must be inspected for sediment and
scale, and cleaned if necessary.
The insulation on all visible wiring must be checked for any deterioration,
and the wiring replaced if necessary. All electrical contacts must be
examined for cleanliness and tested for proper operation by moving the float
up and down manually. If a mercury bulb is used as a switching device, the
bulb must be checked for any cracks, and the mercury for any separation or
discoloration. All soldered connections on the bellows and float, if used,
must be checked. The float should also be checked for leaks and any signs of
collapsing. Complete maintenance instructions are generally provided by the
manufacturer.

2. Testing of Low-Water Fuel Cutoff On Hot Water Boilers

Since a hot water boiler and its heating system are completely filled with water,
the float chamber of the cutoff is directly connected to the boiler, with no
intervening valves.
Opening the drain valve on the float chamber will not empty it so it is not possible
to test the low-water fuel cutoff during normal boiler operation. Testing of this
fuel cutoff would require complete isolation of the boiler from the heating system.
This can only be done by closing the valves in the supply and return lines before
the water level in the boiler can be lowered to the cutoff level.
(a) Daily
As with steam boilers, make routine checks for leaks and abnormal
conditions. Repair any defects immediately.
(b) Weekly
The amount of makeup water added in a closed hot water heating system is
usually negligible. The amount of sediment formed will also be very small so
the possibility of fouling the cutoff devices will be much smaller than on
steam boilers. It is recommended, however, that the drain on the float
chamber be opened once a week to flush any sediment that may collect.

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(c) Monthly
The monthly tests, as applied to the low-water fuel cutoff on steam boilers,
should not be done on hot water boilers.
(d) Annually
Preferably before the start of the heating season, isolate the boiler and lower
the water level to that of the cutoff device. Note the level at which the fuel
cutoff operates. Correct if necessary. Its care and maintenance would be
similar to that of a cutoff on a steam boiler. The manufacturers instructions
should be followed closely.

References and Reference Material

1. ASME. Boiler and Pressure Vessel Code - Section IV, SI Edition, Heating
Boilers. New York, NY: The American Society of Mechanical Engineers;
1983.
2. ASME. Boiler and Pressure Vessel Code - Section VI, SI Edition,
Recommended Rules for the Care and Operation of Heating Boilers. New
York, NY: The American Society of Mechanical Engineers; 1983.
3. CSA. B51-M1989 Boiler, Pressure Vessel, and Pressure Piping Code.
Rexdale, ON: Canadian Standards Association; 1989.

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