Information  About Boilers Introduction Blow-down Technology Steam Boilers Trouble Shooting Steam Boilers Introduction Steam boilers represent a financial investment in terms of initial capital outlay and daily fuel and operating costs. The company or institution that owns and operates the boiler is vitally interested in the maximum return on their investment. In today's unstable market for fuel, energy conservation is one of the most important methods of controlling costs. It is the least expensive cost factor associated with the boiler. Water, which is the cause of the major problems encountered in boiler treatment must be tested and treated on an on-going basis. Water causes corrosion of the metal components, scale accumulation inside the boiler results in wasted energy, loss of heat efficiency and therefore, loss of money in the form of increased fuel consumption. The ultimate result of the chemical effect of the water is an expensive re-tubing of the boiler or replacement of the whole unit. All of these problems caused by a cost factor most of us neglect because it is so small compared to the other factors ..... water. IDEAL has developed a group of products and a system for their usage that helps fight and control these energy wasting effects. These systems are based primarily on providing a single chemical treatment along with periodic, laboratory monitoring of the systems to assure that high efficiency is being maintained. Top Blow-down Technology for Boilers Getting rid of water that has high concentrations of dissolved and suspended solids is the primary method of controlling the accumulation of scale forming impurities. Regardless of the sophistication of the water treatment program and the formulations used, continued concentration of impurities, "cycling up", the saturation point will eventually be reached resulting in the precipitation of solids. Some of these solids may be scale-forming minerals. Although chemical additions to the system can, in effect, increase the saturation point for these impurities and increase the tolerance of the system to precipitation, the continued build up will result eventually in trouble for the efficient working of the system. Getting rid of the charges water is the only way to reduce total impurities being carried. Top Steam Boilers There are various ways of getting rid of charged water from a boiler. This process is referred to as blow- down. By law in many countries, each steam boiler must be blown down at least once each day of operation, from the bottom blow-down valve. In addition good practice includes blowing-down at least once each day from the 11-Miller sensor valve each day to make sure that, that important piece of equipment stays clear of any build-up of impurities. Knowing the pressure of the boiler and the openings for blow-down, blow-down schedules are often given in relation to the time the blow-down valve is open during boiler operation. At pressure, if the valves are open too long and too much water is blown out, the boiler may shut down because the low water sensor would sense that the safety limit for operation was not met. This could easily happen if the valve was left open for longer than several seconds at a time. It is important, then that the valve can be open for a few seconds at a time. Bottom blow-down works best also for several short seconds at a time rather than one long opening which also would result in diminishing the pressure. Several short "Blasts" also help to disrupt and stir up the sludge deposited on the bottom thus helping to get rid of the solids load much better than just a stream of escaping of escaping water and steam. Top Trouble-Shooting Steam Boilers; Up to 150psig In steam boilers, which have at least 70% condensate return and operate at less than 150psgi good, efficient operation depends on: 1. The operator  2. Burner operator and setting  3. Preventative maintenance practices 4. Fuel used 5. Water treatment program 6. Regular and efficient blow-down Care of the waterside of the boiler is very important. Once steam is formed, the impurities brought into the boiler with the boiler feed water from the boiler feed tank remain in the boiler. Thus, the impurities become concentrated as more and more are brought in. As this concentration continues, at some point, the impurities will exceed their solubility limits. Unless their concentration is reduced or their solubility limits altered, the excess concentration will be precipitated out as a solid material. Under many conditions, this will result in the accumulation of scale. The dissolved gases which, unless otherwise, will cause corrosion or pitting of the boiler walls, tubes and steam-line system. Symptoms of inadequate water treatment practices include: 1. High stack temperatures  2. Foaming or "bumping" of the boiler 3. Long heat-up periods before reaching operating pressure at start-up 3. Pitting and rusting Stack temperature is determined by the operating pressure; the higher the pressure the higher the steaming temperatures for some pressures. Boiler Pressure (inches)  Steam Temp. (0F)  25 268  50 298  75 320 100 337 125 353 150 367 If stack temperatures are more than about 50 degrees higher than steam temperature, then the heat exchange tubes may be coated with deposits either on the waterside or on the fire side. The analysis of the water may expose the problem if scaling is indicated. If scaling is indicated, then it can be assumed that the boiler burners are heating the atmosphere instead of the water. Top