drum and header are used to remove scale and other foreign matter that have settled in the lowest part of the water spaces. Boilers are also blown down to control concentration ofdissolved and suspended solids in boiler water. The water column blowdown permits removal of scale and sediments from the water column. Additionally, some boilers have what is called a surface blowdown. The surface blowdown is located at the approximate water level so as to discharge partial steam and water. The surface blowdown removes foaming on the top of the water surface and any impurities that are on the surface of the water.

FUSIBLE PLUGS

FUSIBLE PLUGS are used on some boilers to provide added protection against low water. They are constructed of bronze or brass with a tapered hole drilled lengthwise through the plug. They have an even taper from end to end. This tapered hole is filled with a low-melting alloy. consisting mostly of tin. There are two types of fusible plugs - fire actuated and steam actuated.

The FIRE-ACTUATED plug is filled with an alloy of tin, copper. and lead with a melting point of 445F to 450F. It is screwed into the shell at the lowest permissible water level. One side of the plug is in contact with the tire or hot gases, and the other side is in contact with the water (see item 9). As long as the plug is covered with water, the tin does not melt. When the water level drops below the plug, the tin melts and blows out. Once the core is blown out, a whistling noise will warn the operator. The boiler then must be taken out of service to replace the plug.

The STEAM-ACTUATED plug is installed on the end of a pipe outside the drum. The other end of the pipe. which is open, is at the lowest permissible water level in the steam drum. A valve is usually installed between the plug and the drum. The metal in the plug melts at a temperature below that of the steam in the boiler. The pipe is small enough to prevent water from circulating in it. The water around the plug is much cooler than the water in the boiler as long as the end of the pipe is below the water level. However, when the water level drops below the open end of the pipe, the cool water runs out of the pipe and steam heats the plug. The hot steam melts and blows the tin out, allowing steam to escape from the boiler warning the operator. This type of plug can be replaced by closing the valve in the piping. It is not necessary to take the boiler out of service to replace the plug.

Fusible plugs should be renewed regularly once a year. Do NOT refill old casings with new tin alloy and use again. ALWAYS USE A NEW PLUG.

WATER COLUMN

A WATER COLUMN (fig. 1-7) is a hollow vessel having two connections to the boiler. Water columns come in many more designs than the two shown in figure 1-7; however, they all operate to accomplish the same principle. The top connection enters the steam drum of the boiler through the top of the shell or drum. The water connection enters the shell or head at least 6 inches below the lowest permissible water level. The purpose of the water column is to steady the water level in the gauge glass through the reservoir capacity of the column. Also, the column may eliminate the obstruction on small diameter, gauge-glass connections by serving as a sediment chamber.

The water columns shown are equipped with high- and low-water alarms that sound a whistle to warn the operator. The whistle is operated by either of the two floats or the solid weights shown in figure 1-7.

Water Level Control

The water level control not only automatically operates the boiler feed pump but also safeguards the boiler against low water by stopping the burner. Various types of water level controls are used on boilers. At Seabee activities, boilers frequently are equipped with a float-operated type, a combination float and mercury switch type, or an electrode probe type ofautomatic water level control. Each of these types is described below.

The FLOAT-OPERATED TYPE of feedwater control, similar in design to the feedwater control shown in figure 1-8, is attached to the water column. This control uses a float, an arm, and a set of electrical contacts. As a low-water cutoff, the float rises or lowers with the water level in an enclosed chamber. The chamber is connected to the boiler by two lines, which allow the water and steam to have the same level in the float chamber as in the boiler. An arm and linkage connects the float to a set of electrical contacts that operate the feedwater pump when the water lowers the float. When the water supply fails or the pump becomes inoperative and allows the water level to continue to drop, another set of contacts operates an alarm bell, buzzer, or whistle, and secures the burners.

The COMBINATION FLOAT AND MERCURY SW ITCH TYPE of water level control shown in figure 1-8