REPORT IN STEAM GENERATORS

DEFINITION
The modern steam generator is an integrated assembly of several essential
components. Its function is to convert water into steam at a predetermined
pressure and temperature.
The steam generator is a closed pressure vessel into which liquid water is
pumped at the operating pressure. After the heat has vaporized the liquid, the
resulting steam is then ready either for delivery to the user or for further
heating in a superheater. Heat transfer and the containment of a fluid pressure
are the chief functions of a steam generator.

PARTS OF A STEAM GENERATOR

1. Enclosure or Setting - It is a wall, or casing, suitably shaped, to enclose and

direct the flow of combustion gases, to support the other components and to
insulate against the flow of heat from the interior to the boiler room
atmosphere.
2. Boiler
3. Boiler Accessories and Mountings
4. Combustion Equipment

Schematic Diagram of a Boiler System

Boiler Accessories

Steam drum - It is a reservoir of water or steam at the top end of the water tubes.
The drum stores the steam generated in the water tubes and acts as a phase-
separator for the steam/water mixture.

Headers - It is a drum beneath a boiler, into which sediment and mud in the water
can settle for removal. It is related with "bottom" blow down which reduces the
quantity of un-dissolved solids (sludge) which collect in the lower parts of the boiler
(mud drum).

Mud drum - It is a drum beneath a boiler, into which sediment and mud in the
water can settle for removal. It is related with "bottom" blow down which reduces
the quantity of un-dissolved solids (sludge) which collect in the lower parts of the
boiler (mud drum).

Water Walls - This consists of tubes which form the walls of the boiler where water
is evaporated to steam.

Superheater - A superheater is a device used to convert saturated steam or wet

steam into dry steam used in Steam turbines or in processes, such as steam
reforming.

Stack/Chimney - A chimney is a structure that provides ventilation for hot flue

gases or smoke from a boiler, stove, furnace or fireplace to the outside atmosphere.
Chimneys are typically vertical, or as near as possible to vertical, to ensure that the
gases flow smoothly, drawing air into the combustion in what is known as the stack,
or chimney, effect.

Re-Heater - Steam from the exhaust of the first stage turbine goes back to the
boiler for reheating and is returned to the second stage. Reheater coils in the flue
gas path does the reheating of the returned steam.

Air preheater System - In this type of preheater, heat is transferred from the flue
gases to a matrix, which is then cooled by the combustion air, thereby preheating
the air.

Economizer - Economizer coils are used in the downstream of the boiler bank to
preheat the feed water absorbing heat from hot exhaust gases.

Soot Blowers - A soot blower is a system for removing the soot that is deposited
on the furnace tubes of a boiler during combustion.

Downcomers - Downcomers are pipes leading from the top to the bottom of the
boiler. They carry the water from steam drum to the bottom part of the boilers.

Furnace - A furnace is a chamber for combustion. It provides support or enclosure

for the combustion equipment burners or stokers.
 Burners - Burners are combustion equipment for firing liquid and gaseous fuels
(used in fire-tube boilers).

Stokers - Stokers are combustion equipment for firing solid fuels (used in water-
tube boilers).

Feedwater Pump - It is 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.

Baffles - They direct the flow of the hot gases to effect efficient heat transfer
between the hot gases and the heated water.

Steam Separators - The function of a steam separator is to remove the entrained

water particles from the steam conveyed to the steam engine or turbine.

Draft Fans They supply air needed for combustion and create the draft required
for the flow of gases in the boiler.

Boiler Mountings

Gage Glass- indicates the water level inside the boiler vessel

Pressure gauge indicates the pressure of the steam in the boiler

Safety valve a safety device which automatically releases the steam in case of
over-pressure.

Stop valve regulates the flow of steam from boiler to the steam pipe or from
one steam pipe to another.

Blow off cock - discharges mud and other sediments deposited in the bottom
most part of the water space in the boiler while the boiler is in operation. It is
mounted at the lowest part of the boiler.

Feed check valve works as non-return valve; prevents the back flow of water
from the boiler when the feed water pump fails or is not working.

Fusible plug a metal plug with a definite melting point through which the steam
is released in case of excessive temperature which is usually caused by low
water level.

Blowdown valve - valve through which the impurities that settle in the mud
drum are removed.

Boiler Vents also called drum vents or air cocks remove air from the steam and
water drum while filling and during warm-up, prior to putting the boiler into
 service. They prevent a vacuum from developing within the boiler drum when
the boiler is removed from service, or when draining the boiler.

Mud and Man Holes allow men to enter into the boiler for inspection and repair.

BOILER TYPES

1. Low Pressure Steam Boilers

A low pressure steam boiler has a maximum allowable working pressure
(MAWP) of 15 psi. It is used primarily for heating buildings such as schools,
apartments, warehouses, and factories, and for heating domestic water.
2. High Pressure Steam Boilers
A high pressure steam boiler operates at pressures above 15 psi and over 6
boiler horsepower. It is used in generating electricity and in processing
operations in industry.
3. Fire Tube Boilers
In a fire tube steam boiler, heat and gases of combustion pass through tubes
surrounded by water. The heat produced by gases of combustion pass
through the tubes while the water surrounds the tubes. Fire tube boiler tubes
are always measured by their outside diameter (O.D.). Fire tube boilers are
designed for pressure up to a maximum of 250 psi and approximately 750
boiler horsepower. Modern Fire tube boilers with improved design and heat
transfer rates have achieved thermal efficiency rates as high as 80% to 85%.

Three types Fire Tube Boiler of fire

tube boilers:

a) Horizontal Return Tubular Boiler

 The HRT boiler is fired with fuel oil, gas or coal. It consist of a drum
suspended over a firebox. The tube sheets of an HRT boiler are supported
with through stays and diagonal stays (braces).The feedwater pipe extends
approximately three-fifths of the length of the drum. It enters the front tube
sheet. The location of the feedwater pipe helps increase water circulation in
the boiler. The HRT boiler is also equipped with a dry pipe to ensure a higher
quality of steam. The drum is riveted and since its bottom is in the firebox,
leaks often develop around the rivets.

HRT Boiler

b) Scotch Marine Boiler

Scotch Marine boilers were used on ships for many years. These boilers have
a corrugated furnace, combustion chamber, and tubes passing through the
boiler to the front tube sheet. The furnace is completely surrounded by water.
This increases the boiler heating surface, therefore increasing boiler
efficiency. In a scotch marine boiler, the gases of combustion will make many
passes before leaving the boiler. By increasing the number of passes, more
heat can be absorbed by the water, therefore increasing thermal efficiency.
 Two Pass Dry Back Scotch Marine Boiler

c) Vertical Fire Tube Boiler

Vertical fire tube boilers are one-pass boilers. The gases of combustion
cannot be retained in the boiler by the use of baffles. Vertical fire tube boilers
are designed as dry-top or wet-top boilers. The dry-top boiler produces
steam that is slightly superheated. The wet-top boiler does not produce
superheated steam because the upper tube sheet is surrounded by water.
Vertical fire tube boilers are commonly used on steam pile drivers.

4. Water Tube Boiler

 A water tube steam boiler has water inside the tubes. The heat and gases of
combustion pass around these tubes. As with fire tube boilers, the boiler
tubes are measured by their outside diameter. Water tube boilers have been
designed to operate at pressures as high as 3206 psi, also known as the
critical pressure of steam.

The two types of water tube boilers are:

a) Straight-tube Boiler
 Straight-tube boilers have inclined tubes to increase circulation. Water is
introduced to the boiler through an internal feedwater pump.

b) Bent-Tube Boiler
Bent-tube boilers operate at higher pressures and steam capacities than
straight-tube boilers, and their design provides for improved water
circulation.
Bent-tube boilers operate at higher pressures and steam capacities than
straight-tube boilers, and their design provides for improved water
circulation.

5. Package Boilers
A package boiler is preassembled before installation. It self-contained unit
complete with feedwater pump, fuel pump, burner assembly, and combustion
 controls. It requires connecting only the feedwater lines, steam lines, fuel
lines, electrical connections, and a tie into the breaching and chimney. It can
either be fire tube or water tube type.
6. Field Erected Boilers
Field erected boilers are used to generate electricity or large amounts of
steam and must be built on site. Some of these boilers are five to six stories
high. Field erected boilers require very careful quality control during
construction.
7. Electric Boilers
Electric Boilers operate similarly to boilers fired by fuel oil, gas or coal. The
primary difference is that electric boilers have heat produced by electric
resistance coils, or electrodes. Conductivity of the boiler water will affect the
flow of electricity and the amount of heat generated.

FUEL BURNING EQUIPMENT

Burners
The burner is the device that permits controlled burning of fuel inside the furnace.
The burner mixes the fuel with the required amount of air and directs the flame into
the combustion area. The burner comprises of gas burner and oil burner with
atomizing steam connection.

The burner consists of:

Air Register: used to give an enough quantity of air to the burner for good
combustion.
Ignition Gun: used to give ignition spark to the burner for firing.
Flame Detector: used to monitor the flame.

Oil Burners
Oil burners deliver fuel oil to the furnace in a fine spray, which mixes with air to
provide efficient combustion.

Types of Oil Burners:

a) Pressure jet burners
A pressure jet burner is simply an orifice at the end of a pressurized tube.
Typically the fuel oil pressure is in the range 7 to 15 bar. In the operating
range, the substantial pressure drop created over the orifice when the fuel is
discharged into the furnace results in atomization of the fuel. Putting a thumb
over the end of a garden hosepipe creates the same effect. Varying the
pressure of the fuel oil immediately before the orifice (nozzle) controls the
flowrate of fuel from the burner.
Advantages of pressure jet burners:
Relatively low cost.
Simple to maintain.
 Disadvantages of pressure jet burners:
If the plant operating characteristics vary considerably over the course
of a day, then the boiler will have to be taken off-line to change the
nozzle.
Easily blocked by debris. This means that well maintained, fine mesh
strainers are essential.
b) Rotary cup burner
Fuel oil is supplied down a central tube, and discharges onto the inside
surface of a rapidly rotating cone. As the fuel oil moves along the cup (due to
the absence of a centripetal force) the oil film becomes progressively thinner
as the circumference of the cap increases. Eventually, the fuel oil is
discharged from the lip of the cone as a fine spray. Because the atomization
is produced by the rotating cup, rather than by some function of the fuel oil
(e.g. pressure), the turndown ratio is much greater than the pressure jet
burner.
Advantages of rotary cup burners:
Robust.
Good turndown ratio.
Fuel viscosity is less critical.
Disadvantages of rotary cup burners: More expensive to buy and maintain.
c) Gas burners
Being a gas, atomization is not an issue, and proper mixing of gas with the
appropriate amount of air is all that is required for combustion. Two types of
gas burner are in use 'Low pressure' and 'High pressure'.
Low pressure burner These operate at low pressure, usually between
2.5 and 10 mbar. The burner is a simple venturi device with gas
introduced in the throat area, and combustion air being drawn in from
around the outside. Output is limited to approximately 1 MW.
High pressure burner These operate at higher pressures, usually
between 12 and 175 mbar, and may include a number of nozzles to
produce a particular flame shape.
d) Dual fuel burners
The attractive 'interruptible' gas tariff means that it is the choice of the vast
majority of organizations in the world. However, many of these organizations
need to continue operation if the gas supply is interrupted. These burners are
designed with gas as the main fuel, but have an additional facility for burning
fuel oil. The notice given by the Gas Company that supply is to be interrupted
may be short, so the changeover to fuel oil firing is made as rapidly as
possible, the usual procedure being: Isolate the gas supply line. Open the oil
supply line and switch on the fuel pump. Purge and re-fire the boiler. On the
burner control panel, select 'oil firing' (This will change the air settings for the
different fuel). This operation can be carried out in quite a short period. In
some organizations the changeover may be carried out as part of a periodic
drill to ensure that operators are familiar with the procedure, and any
necessary equipment is available.
 e) Pulverized Coal Burners
Pulverized coal is highly expensive so care must be taken when burning it. A
flame must be maintained in the furnace at all times. Also, the furnace must
have a negative pressure. If the pressure in the furnace becomes positive, the
flame could travel back to the pulverizer and cause an explosion. Pulverized
coal systems are most suitable for use with bituminous coals.

TESTING FOR CAPACITY AND PERFORMANCE

Boiler Capacity
Boiler loads, or the capacity of steam boilers, are often rated in boiler
horsepower (BHP), lbs of steam delivered per hour, or BTU.
Large boiler capacities are often given in lbs of steam evaporated per hour
under specified steam conditions.

Boiler Horsepower
The Boiler Horsepower (BHP) is the amount of energy required to produce 34.5
pounds of steam per hour at a pressure and temperature of 0 Psig and 212 oF, with
feed water at 0 Psig and 212 oF. A BHP is equivalent to 33,475 BTU/hr or 8430
Kcal/hr and it should be noted that a boiler horsepower is 13.1547 times a normal
horsepower.
1boiler horsepower = 35,322 kJ/hr

Performance Parameters

Rate of Evaporation (ms) is the rate of evaporation of steam or mass flow rate
of steam measured in kg/hr or lbs/hr.
Heating surface is equal to the total surface area through which the heated
water and hot gases exchange heat.
Heat generated by fuel = mass flow rate of fuel x higher heating value of fuel
Factor of Evaporation = (hs-hf)/2257
ms (hshf )
Thermal Efficiency=
mf Qh

ms
Actual Specific Evaporation=
mf

Equivalent Evaporation=ms FE at 100 o C

- the rate in kg per hour at which water would be vaporized in a given steam
boiler if supplied and evaporated at the normal boiling point and normal
atmospheric pressure.
 ms
Equivalent Specific Evaporation= FE at 100 o C
mf

Performance Test

The performance test in a boiler evaluates the practically achievable boiler

efficiency.

Direct Method: This is also known as input - output method due to the fact
that it need only the useful output (steam) and the heat input (i.e. fuel) for
evaluating the efficiency.
ms (hshf )
Boiler Efficiency=
mf Qh

Boiler efficiency =Heat output / Heat input

Parameters to be monitored for the calculation of boiler efficiency by direct method
are:
a) Quantity of steam generated per hour (Q) kg/hr.
b) Quantity of fuel used per hour (q) in kg/hr.
c) The working pressure [in kg/cm(g)] and superheat temperature (C), if any.
d) The temperature of feed water (C)
e) Type of fuel and gross calorific value of the fuel (GCV) in Kcal/kg of fuel.

Disadvantages of direct method:

Does not give clues to the operator as why the efficiency of the system is lower.
Does not calculate various losses accountable for various efficiency levels.

Indirect Method: It is also called as heat-loss method or heat balance

method. Subtracting the heat loss fractions from 100 can arrive at the
efficiency. The standard do not include blow down loss in the efficiency
determination process.

The principle losses that occur in a Boiler are:

Loss of heat due to dry flue gas.

Loss of heat due to moisture in fuel and combustion.

Air loss of heat due to combustion of hydrogen.

Loss of heat due to radiation

Loss of heat due to unburnt carbon.

The data required for calculation of boiler efficiency using indirect method are:
 Ultimate analysis of fuel (H2, O2, S, C, moisture content, ash content).
Percentage of oxygen or CO2 in flue gas
Flue gas outlet temperature in C
Ambient temperature in C and humidity of air in kg/kg of dry air.
GCV of fuel in Kcal/kg.
Percentage combustible in ash
GCV of ash in Kcal/kg

Some Provisions for Boilers (PMC)

Power Boilers :
Boiler Rooms :
(1) Clearance around the boiler to the boiler room wall or any equipment shall be at
least 100 cm (3.28 ft). Boiler room shall have two independent doors for easy
access.
a. in separate buildings of fire-resistant materials used for no other purpose and
situated
not less than 3m (10 ft) away from buildings not forming part of the factory, or
b. in structure of fire resistant materials if situated in the same factory buildings or
in close proximity to other factory buildings.

(2) Where power boiler room adjoins workrooms in which flammable or explosive
substances are manufactured, used, handled, or liberated, there shall be no exits or
other wall openings in the intervening walls.

(3) Power boiler rooms, blow-offs, ash pits or high pressure steam line tunnels and
other places where there is danger or workers being trapped in the event of
explosion or rupture of steam lines, shall be provided with not less than (2)
adequate exits which shall be kept clear of any obstructions.

(4) Rails, walls, runways and stairs of iron or steel construction with non-slip surface
shall be provided for convenient and safe access to overhead valves, water
columns, feed water regulators and other fittings.

(5) Runways located on top or alongside a battery of power boilers shall be provided
with not less than two (2) means of descent.

(6) Power boiler rooms shall be of sufficient height to permit installation and
operation of all valves and safety devices with a minimum clearance of 90 cm (3 ft)
above the highest valve fitting or levers.

(7) Pits in power boiler rooms shall be covered or guarded by standard railings and
toe-boards.

(8) Where power boilers are supported by structural steel work, the support shall be
located or insulated that the heat from the furnace cannot impair the strength of
the steel.
(9) Power boiler settings shall be provided with suitably packed openings or sleeves
of sufficient size to permit the expansion and contraction of the pipes.
(10) Wet-bottom stationary boiler shall have a space of not less than 30 cm (12 in)
between the bottom of the boiler and the floor line to provide access for
maintenance or inspection.

(11) Clearance around the boiler to the boiler room wall or any equipment shall be
at least 90 cm (3 ft). Boiler room shall have two independent doors for easy access.

Access and Inspection :

Power boiler or parts thereof shall be equipped with suitable manholes or other
openings for inspection, examination and cleaning.

(1) Hand-hole openings in heads or shells of power boilers shall not be less than 70
mm x 90 mm (2 in x 3 in).

(2) Each power boiler shall be equipped with at least one (1) safety valve if the
heating surface is 46.5 sq. m (500 sq. ft) or less and two (2) or more if the heating
surface is over. The safety valves shall be:
a.) placed as close as possible to the boiler;
b.) connected to the boiler independent of any other steam connection; and
c.) placed between the boiler and the discharge point when installed in the pipeline.

(3) The safety valve or valves on power boilers shall be of sufficient capacity to
discharge all the steam generated by the boiler without allowing the pressure to rise
to more than
a.) six percent (6%) above the maximum allowable working pressure; or
b.) six percent (6%) above the highest pressure to which any valve is set.

(4) Seats and discs of safety valve for power boilers shall be of suitable corrosion-
resistant materials and the seat shall be secured on the valve body to avoid the
possibility of the seat lifting off.

(5) Safety valves for power boilers shall be constructed, tested and maintained in
the following manner:
a.) the failure of any part will not obstruct the free and full discharge of steam from
the
valves;
b.) no shock injurious to the valves or to the boiler shall resort from its operations;
and
c.) the valve can be turned on its seat.

(6) Safety valves for power boilers shall be:

a.) capable of being adjusted and set to operate without chattering.
b.) sealed or otherwise protected to prevent tampering by any unauthorized person;
c.) provided with a special means for lifting the valve for testing purposes; and
d.) located to enable the boiler attendant to hear readily the discharge.

(7) Safety valves discharge outlets for power boiler shall be located or piped out
away from running boards and platforms, preferably not less than 3 meters (10 ft)
above the platforms.
(8) When the discharge pipes are used on safety valves for power boilers, they shall
be:
a.) not less in cross-sectional area than the full area of the valve outlets, and
b.) fitted with open drains to prevent water lagging in the upper part of the valves
or in the pipes.

(9) When mufflers are used on safety valves for power boilers, they shall:
a.) have sufficient outlet area to prevent back pressure from interfering with the
proper
operation and discharge capacity of the valves; and
b.) be constructed to avoid any possibility of obstruction of the steam passage due
to
deposits.

(10) Superheaters arranged in a manner that they can be isolated from power
boilers shall be located near the steam outlet. However, valve or valves maybe
located anywhere in the lengths of the outlet heater if there is a uniform flow of
steam through the superheater tubes and heater.

(11) Economizers used on power boilers shall be equipped with at least one (1)
safety valve provided with seats and discs of corrosion resistant materials, if there is
an isolating valve between the drum and economizer.

(12) Miniature boilers shall be equipped with sealed safety valves connected directly
to the boiler. Miniature boilers with no extraction of steam (closed system), may in
addition to safety valves, be provided with a rupture disc relieving device.

Stop Valves:
(1) Steam discharge outlets on boilers, except safety valves, shall be equipped with
stop valves located at an accessible point in the steam delivery line and as near the
boiler as practicable.

(2) Quick and convenient means of manipulating the principal stop valves on power
boilers shall be provided.
a.) by extending the valve spindles so that the valves wheels may be operated:
i. from the floors of the boiler rooms by means of chains, gears or other mechanical
devices, or
ii. from outside the boiler rooms in case of emergency.
b.) by installing remote control stations for electrically operated valves in a
protected space where they may be operated without danger.

(3) When two or more power boilers are connected to a common steam main, the
steam connection from each boiler equipped with a manually opened valve shall be
fitted with two stop valves having between them an ample free-flow drain. The
discharge shall be visible to the operator while manipulating the valves.

(4) When stop valves on power boilers are located where water may accumulate,
ample drain shall be provided.
Water Column Pipes:

(1) Pipes connecting water columns to power boilers shall not be less than 25 mm (1
in) pipe size, and as short and direct as possible.

(2) Horizontal return to water columns shall be taken from the top of the shell in the
upper part of the head and the water connections from a point not less than 15 cm
(6 in) below the lowest center line of the shell.

(3) On the fire box type of power boilers, the water connections shall be taken from
a point not less than 25 cm (10 in) below the lowest water line or as near thereto as
possible, and no case less than 45 cm ( l8 in) above the mud ring.

(4) Whenever practicable, water connection from power boilers to water column
shall be provided with a cross at each right angle turn, to facilitate cleaning.

(5) Water columns on power boilers shall be fitted with drain cocks or drain valves
with suitable connections to a safe point of disposal.

(6) No outlet connection allowing the escape of an appreciable amount of steam or

water shall be placed on pipes connecting water column to medium and high
pressure boilers, except for damper regulators or feed water regulators, drain,
steam gauges or apparatus of similar form.

Steam Gauges:
(1) Each power boiler shall be equipped with steam pressure gauge, placed as
follows:
a.) free from vibrations;
b.) conveniently adjusted; and
c.) afford a clear and unobstructed view to the attendant from the usual operating
position, in front or at the side.
(2) Steam gauges, in satisfactory working condition for power boilers, shall be
connected to the steam space or to the water column on its steam connection by
siphons or equivalent devices which shall be:
a.) of sufficient capacity to keep the gage tube with water; and
b.) arranged that the gauge cannot be shut-off from the boiler, except:
i. by a cock placed near the gauge and provided with the level handle fitted parallel
to the pipe when the cock is open, or
ii. by a cock or shut-off valve of 35kg/cmg (500 psig.) rating or over.
(3) Steam gauges connection for power boilers shall be as short as practicable.
(4) Dials for steam gauges for power boilers shall:
a. be of size and marked that the graduations of the pointer can be clearly
determined by a person with normal vision from a distance equal to one and one
half (11/2) times the width of the boiler front;
b. be graduated to not less than 1 times the pressure at which the safety valve is
set,
preferably to about double such pressure. The graduation shall be so arranged that
the
pointer will be at nearly vertical position when indicating the working pressure; and
c. have the working pressure indicated in red on the dial.
(5) All steam gauges in any power boiler room shall be of the same type, size and
graduation.

(6) Each power boiler shall be provided with a valve connection near the regular
connection of the steam gauges for the exclusive purpose of attaching gauge set.

Water Gauge Glasses:

(1) Each power boiler, except once-through boilers with no fixed steam and water-
lines, shall be equipped with at least one (1) water gauge glass, which shall be:
a.) located within the range of vision of the boiler attendant;
b.) fitted at top and bottom with quick closing valves easily closed from the floor in
case the glass breaks;
c.) connected to the water column or directly to the boiler by piping of not less than
12 mm (15/32 in) diameter;
d.) equipped with a valve drain piped to a safe point of disposal; and
e.) provided with a wire glass or other suitable guard for the protection of workers
from
flying glass or escaping hot water in case of breakage, and such guard shall not
obstruct free observation of water level.

(2) Water gauge glasses on power boilers shall be located in such a way that when
the visible water level is at its lowest reading in the glass, the reading should not be
less than:
a. 75 mm (3 in) of water over the highest point of the tubes, flues or crown sheets in
horizontal fire tube power boilers; or
b. 50 mm (2 in) of water above the lowest permissible level in water tube power
boilers.

(3) Miniature boilers operating on the closed system, where there is insufficient
space for the usual water gauge glass, may be provided with water level indicators
of the glass bull's eye type.

Fusible Plugs :
(1) Fusible plugs, when used on power boilers, as additional low water alarms, shall
be renewed at intervals not exceeding twelve (12) months. Casings, which have
been used, shall not be refilled.

(2) Fusible plug, after inspection, should be replaced with the same or equivalent
specifications of the original plug.

(3) Fusible plugs shall not be used on power boilers operating at pressures
exceeding 17.5 kg/cmg (250 psig).

(4) Steam actuated fusible plugs, when used in power boilers, shall be located that
they can be operated when the water level is at a point where a fire actuated fusible
plug is located.
Feed Water Systems:
(1) The discharge end of feed water pipes for boilers shall be:
a. located that the feed water at no time will discharge:
i. directly against surfaces exposed to direct radiation of the fires or to gases at high
temperature, and
ii. close to any riveted joints of the furnace sheets or to the shell.

(2) Feed pipes for power boilers shall be provided with a check valve near the
boilers and a valve or stop cock between the check valve and the boiler.

(3) When two or more power boilers are fed from a common source, the main feed
pipe shall also be provided with a check valve between the water supply to prevent
the water from backing out from one boiler to another.

(4) Power boilers equipped with duplicated feed water arrangements shall conform
to the requirements of 1163.09 on water supply source.

(5) Where economizers or other feed water heating devices are connected directly
to power boilers without intervening valves, the required feed and check valves
shall be placed on the inlets of the economizers of water heaters.

(6) Miniature boilers shall be provided with at least one (1) feed pump or other
feeding device except on closed system boilers where a suitable connection or
opening shall be provided to fill the boiler when cold or when the water main has
sufficient pressure to feed the boiler at any time while under pressure.

References:

1. High Pressure Boilers, Steingress & Frost, 2nd ed

2. Powerplant Engineering, Morse, 3rd ed
3. Energy Solution Center
Inc. :http://www.energysolutionscenter.org/BoilerBurner/
4. Alkan Murray Corp. : http://www.alkenmurray.com/Boilerworks.html
5.