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, discover 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, leading to more serious damage. 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.
When water is heated, minerals in the water can form scale deposits inside the surfaces of a boiler. These deposits can build up and eventually block steam through the system if left untreated, contributing to significant efficiency loss in your steam boiler.
Scale buildup can reduce the effectiveness of heat exchangers and prevent hot water in the boiler from reaching the needed temperature. Removing and preventing scale buildup on your boiler will restore its efficient operation.
Probes submerged in the water can create scale buildup without regular cleaning. The encrusted scale cannot properly measure water temperature or pressure, causing the boiler to shut down automatically.
Safety controls and sensors that fail could also prevent the boiler from shutting off in a dangerous situation, such as a buildup of too much pressure. Because these safety controls prevent the system from running in dangerous conditions, regular inspections are critical for the tank’s operation and the safety of those who work around it.
Low water is a dangerous condition for a boiler, as cutoff valves shut off if the water level drops too low. If you notice the boiler isn’t running, 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.
Internal water chemistry problems can cause pinhole leaks anywhere in the steam system. Look for dripping around the tank or its pipes, but leaks may also occur away from the tank or through the air vents. These hidden leaks make identifying a problem much more difficult. 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 loop system will eventually drop the water level available for the system low enough to cause it to shut down. If the water level does not decrease significantly but the system leaks, atmospheric moisture may be getting into the system, causing 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.
Sludge is similar to the more solid deposits of scale but has a softer texture. When sludge reaches the boiler tank, it is exposed 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 on the interior of the boiler tank, creating similar problems to scale.
Continued sludge buildup can increase the temperature inside the pipes and insulate that area of the boiler system. As a result, buildup can restrict water flow, increase temperatures and damage boiler components.
Scale can detach from the sides of the boiler tank and float to the top. As the water heats, the solids will foam from the steam. The solids can rise through the steam into turbines or superheaters, causing damage and blocking the system’s efficiency.
Over time, corrosion can form in the boiler, eventually working its way out. You may not notice the signs of corrosion before the pipe or tank leaks.
Corrosion forms during a chemical reaction between boiler water and the pipe or tank material. Some common reasons for corrosion include too much dissolved oxygen, dissolved solids or an improper pH level. 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 preventing corrosion, you also avoid leaks caused by chemical damage to your boiler system.
Boiler water treatment can prevent many issues with the system, ranging from minor to severe. The initial treatment of the water is important, in addition to filtering, monitoring water quality and adding chemicals as needed to maintain balance. To facilitate the process, have equipment set up on your boiler to monitor water chemistry and automatically dispense treatment chemicals to ensure the fresh makeup water does not contribute to imbalances.
Vital boiler water treatment equipment includes the following monitoring devices:
Additionally, boiler equipment includes controllers to meter out the appropriate levels of boiler water treatment chemicals. These pieces of equipment make the work of measuring and administering water treatment products easier, keeping the system cleaner for longer.
Types of equipment used for boiler chemical control include the following:
Having the right equipment is important to retaining water quality. That said, the chemicals added to treat the water make the biggest difference in the longevity of the boiler and the quality of the water. These chemicals play different roles, and each boiler may require a different composition of water based on its materials and operation. Therefore, trust professionals in water treatment to choose the correct chemicals for your boiler water and how much to add to keep the system clean.
The precise chemicals used will vary based on your system, but common categories of boiler chemicals include:
To troubleshoot steam boiler problems, consider the issues and the most common causes behind them. Consider the issues and the most common causes behind them for boiler troubleshooting. Look at the composition of the water before progressing to the troubleshooting process to save you time and money.
Consider water chemistry for leaks or corrosion, especially in heated portions of the boiler. Measure the water quality carefully for dissolved oxygen levels or low pH, as these factors are common causes of corrosion or damage to steam boilers.
Simply knowing your boiler has damage is often not sufficient because several types of mechanical and chemical corrosion can occur. If possible, evaluate the damage to the interior of the pipes for signs of specific chemical corrosion.
Types of chemical corrosion include the following:
The above types of damage have water chemistry as their main cause. Therefore, correcting the water to prevent scale, reduce dissolved oxygen and raise low pH can protect against future corrosion and boiler failure. Consulting with professionals to provide you with a clean boiler system can prevent corrosion and subsequent leaks.
To treat scale or sludge buildup in the boiler, you must consider your water composition. Both the makeup water and return line water need chemical treatment and will cause problems with increased water pressure or reduced flow. Plus, they prevent efficient heating of the boiler.
For severe problems, you will likely need to drain and clean the system. Then, start with properly treated and filtered water.
Scale prevention chemicals will also stop sludge from depositing inside the boiler. Therefore, ask your water experts about how to protect your boiler from scale and sludge with future use.
As with other boiler problems, clean the boiler of any contamination caused by foaming before correcting the water chemistry problem. Treating the water with anti-foaming agents prevents the chain reaction caused by foam production. The chemicals alter the surface tension to prevent any solids from creating foam in the water.
If you suspect the problem stems from poor water quality, reach out to professionals to have a water treatment system installed or to have your boiler system evaluated. You should never operate a boiler without untreated water because the damage can appear with few symptoms over time until the pipes become clogged or the system gets corroded. These situations will often require expensive repairs and professional expertise.
Once your boiler is operating again, become more vigilant about maintaining it. Because water is such an essential part of your steam boiler’s operation, water treatment is critical for the system’s longevity. With treated water, you can avoid problems such as scale buildup or blockages in the system. Use water treatment as part of regular maintenance for your boiler system. Keeping up with it will ensure your boiler continues to function appropriately, and problems can be addressed before they cause disruptions.
At Chardon Labs, we offer water treatment for boilers in a variety of applications. Everything from health care facilities to HVAC systems to industrial plants may use boilers that need water treatment. Whether the system is open or closed, scale can build up over time. We will install a customized solution to prevent boiler problems with your tank and steam system that stem from its water.
We’ve been treating water since 1965. In that time, we’ve become the place businesses turn to for results from their water treatment. Contact us to schedule a treatment for your boiler or if you have any questions about your boiler’s water. Our results and expertise have made us a leader in the water treatment industry, and we are here to help your business.
