Boilers are indispensable in the process and manufacturing industries. Steam is essential for the heating, drying, sterilizing, and power generation process. The steam produced from steam boilers must be of high quality for a hassle-free and superior outcome. To ensure that, plant managers must address any boiler issues that may hinder the process operation. Many boiler issues arise from poor quality of boiler water and lack of proper water treatment before utilizing it for combustion. Boiler water issues can cause severe damage to the steam boiler and its parts. Therefore, it is necessary to ensure that the boiler feedwater is treated appropriately to prevent the failure of boiler parts. Here are some of the common problems caused by the poor quality of boiler water,
Scale Deposits:
Poor quality of boiler water can cause damage to boiler components with the presence of minerals like calcium. These minerals accumulate in the boiler and pipes as scale build-up. It results in constraining the passage of steam through the system or completely restricting it. Scale deposition is one of the major causes of the reduced efficiency of steam boilers. Scale formation also impacts the effectiveness of heat exchangers and impedes the boiler water to reach a certain temperature for heating. Dispensing scale build-up helps in retaining the efficiency of the boiler system.
Damaged Water and Safety Probes due to Scale Formation:
Similar to pipes, scaling also impacts the probes that are immersed in water. The encrusted scale on the probes requires regular treatment of boiler water. Failure in probes affects the measurement of water temperature or pressure, leading to shutting off boilers.
Scaling on safety controls and sensors fail to prevent shutting off steam boilers in hazardous situations. Therefore, regular assessment of steam boilers is vital to ensure efficient operation and safety of operating personnel. It is also important to examine the low water cutoff valves that shut off the boiler when the water level drops too low.
Excess Amount of Sludge:
Sludge is similar to scaling but softer in texture. As the sludge reaches the tank of the steam boiler, it is exposed to high temperatures. It starts hardening once the water level drops with draining. Once hardened, the sludge forms a baked-on layer in the interior of the boiler tank causing similar problems to scaling.
Sludge formation in areas of low pressure and water flow rate increases the temperature inside the pipes by insulation of that particular boiler component. Sludge damages the steam boiler components by hindering the water flow.
Water Leaks:
Inappropriate water chemistry in a steam boiler results in pinhole leaks in the tank, pipes, and other boiler parts. Water leaks take place anywhere in the boiler, including the air vents. Such leaks are difficult to detect and require a water meter to inspect if the boiler system is losing water, even externally or from hidden pinholes.
Water leak in the steam boiler system would drop the water level to an extent that it causes the boiler to shut down. Atmospheric moisture entering the boiler system leads to leakage in the steam boiler without significantly decreasing the water level. In some cases, replacing the leaking components is more cost-effective than getting them fixed.
Foaming in Steam Boiler:
Foaming in steam boilers is a phenomenon that occurs when the solids in the water start floating to the top. As the water starts heating, the solids foam from the steam and accumulates on the turbines or superheaters. It reduces the efficiency of the system due to the solids that would eventually reach the rest of the steam boiler and cause further damage.
Corrosion in Steam Boiler System:
Corrosion develops from the chemical reaction of boiler water and the metal of pipes and tanks and can take place in any part of the boiler. Corrosion is caused due to excessive dissolved oxygen, improper pH level, or dissolved solids. Preventing corrosion is important to maintain the efficiency of the steam boiler and avoid leakages in boiler components.
Prevention of Water Issues in Steam Boiler:
Proper boiler water treatment helps in preventing various boiler issues that may cause damage to the system. Additionally, filtering, monitoring water quality, and introducing chemicals ensure the efficiency of the steam boiler operations.
- For Corrosion and Leaks:
Proper water chemistry is essential for preventing leaks and corrosion, particularly in pipes or heated parts of the boiler. Water quality must be carefully examined for dissolved oxygen levels or low pH, which are common causes of corrosion in boilers.
- For Scale or Sludge Formation:
Proper water composition is necessary for treating scale or sludge build-up. Makeup water and return line water require chemical treatment to prevent boiler problems with increased water pressure or decreased flow. In severe cases, it is important to drain and clean the system.
- For Foaming:
Regular cleaning of any contaminants in the boiler, along with proper water chemistry prevents foaming. Anti-foaming agents are vital for water treatment preventing the consequent reactions caused by foaming.
Conclusion:
With 38+ years of experience in boiler manufacturing and thermal solutions, Rakhoh Boilers is a trusted name for boiler manufacturers in India by installing more than 3000 boilers globally. We manufacture efficient industrial steam boilers and provide the best boiler services in over 20 process industries.
Learn more about our products and services at www.rakhoh.com