Many boiler problems start with the water quality. Common boiler feed water issues or problems with the condensate return water can lead to severe damage to the unit. Instead of waiting for a problem to occur, find out how the most frequent water quality issues develop and how to prevent them.
While boilers can have issues with their equipment, problems are more likely to develop from improperly balanced water. Poor water quality can subsequently cause damage to the components of the boiler. If you notice any equipment problems, consider all the causes, including possible issues with the water chemistry that require treatment to rebalance it.
Here is a look at common boiler problems with water quality.
Poor water quality can severely damage your boiler system. Minerals, like calcium and others, in the water can accumulate in the boiler and pipes as scale deposits. These deposits can slow the passage of steam through the system or block it entirely. In fact, scale is the most significant contributor to efficiency loss in your steam boiler system.
Scale buildup can reduce the effectiveness of heat exchangers and prevent hot water in the boiler from reaching the needed temperature. Therefore, by removing and preventing scale buildup, your boiler will restore its efficient operation.
Probes submerged in the water can also become encrusted with scale, just like the pipes. This coating on probes is another reason to have your tank water treated. If the probes cannot correctly measure the water temperature or pressure, the boiler may automatically shut off.
Safety controls and sensors that fail also could prevent the boiler from shutting off in a dangerous situation, such as the buildup of too much pressure. Because these safety controls prevent the system from running in dangerous conditions, regular inspections are critical for the operation of the tank and the safety of those who work around it.
Low water cutoff valves shut off the boiler if the water level drops too low. Checking the operation of these should be a part of the job of someone in the building. Drain the tank for a few seconds to test the float chamber whenever it’s not in a firing sequence. The low water control system should kick in immediately. This brief drainage examines the system while also allowing heavy sediments to flow out of the system.
One boiler problem with the water chemistry that can happen is water leaks. Improper water chemistry inside a boiler can lead to pinhole leaks in the tank, pipes or other parts of the system.
Water leaks can occur anywhere in the steam system. Look for dripping around the tank or its pipes, but leaks may also occur away from the tank. Water can also leave the system through the air vents. These hidden leaks make identifying a problem much more difficult. Using a water meter will tell you if a closed system is losing water, even from a hidden hole. If you don’t have this type of gauge on your system, consider having one installed.
A water leak in a closed system will eventually drop the water level available for the system low enough that it will cause the system to shut down. If the water level does not decrease significantly but the system leaks, atmospheric moisture may be getting into the system. This untreated water in your tank can cause premature wear. In open-loop systems, an increase in the water delivered into the tank indicates an excessive loss of water somewhere in the system.
Due to the labor required to remove leaking parts of your boiler system, replacing multiple elements at once may be more cost-effective than having the leaks fixed piecemeal. This price savings is especially true if you have numerous holes in pipes inside the walls or other hard-to-reach places. Don’t attempt to change the pipes or other parts yourself. Leave that labor-intensive task to a professional.
Sludge is similar to the more solid deposits of scale but has a softer texture. When sludge reaches the boiler tank, it has exposure to high temperatures. However, it will typically only harden if the water level drops, such as during draining. As the sludge hardens, it creates a baked-on layer onto the interior of the boiler tank. This baked-on sludge can then create similar problems to scale.
Another issue with sludge is building up in areas that have lower pressure or flow rates of water. Continued buildup without checking can increase the temperature inside the pipes by insulating that area of the boiler system. Buildup anywhere in the boiler can restrict water flow. Consequently, more sludge or scale deposits build, temperatures increase and damage to the boiler’s components occurs.
Foaming inside the boiler tank occurs when solids in the water float to the top. When the water heats, these solids foam from the steam. Some rise through the steam to the turbines or superheaters. When the solids deposit on these, the system loses efficiency. Eventually, the solids will work their way throughout the rest of the boiler, causing more damage.
Corrosion can transpire anywhere in the boiler. In fact, this boiler problem often happens starting on the inside and eventually works its way out. Therefore, signs of corrosion may not be evident until a pipe or tank leaks.
Typically, corrosion stems from a chemical reaction of the boiler water with the material of the pipes or tank. This situation may happen from too much dissolved oxygen in the boiler water, an improper pH level or dissolved solids. A qualified water treatment professional will know the type of chemicals to use to protect your boiler from this type of damage. Preventing corrosion is essential to preserving the integrity of the system. Plus, by preventingcorrosion, you also avoid leaks caused by chemical damage to your boiler system.