Boiler Maintenance

Gasket

Fireside Boiler gaskets

Waterside boiler gaskets
Metallic
Rope
Topog-e boiler Gaskets
Spiral Wound
Standard Style M

Boiler gaskets are used throughout a boiler as a sealing material. They can bi both the
waterside and the fireside of the heat exchanger. Ideal gaskets share common traits:

Seal upon installation

Seat at low compressive stress
Stabilize immediately (without any relaxation over time)
Resist against creep and hot/cold flow
Low compression set
Seal fugitive emissions
Withstand high pressurization
Constructed of high temperature material
Chemically resistant to feed-in treatments.

There are two types of gaskets used in boilers, which can be labeled soft and Hard
Gaskets. Soft Gaskets are

Constructed of low temperature materials

Extremely high compression set
Not impervious to all feed-water chemicals
Can extrude during installation or high pressure service
Susceptible to shearing if misaligned
Creeps overtime
Woven designs are not impermeable
Not fire safe

Hard Gaskets are

Very difficult to obtain initial stress loading

Very little recovery due to density
Low flexibility to conform to strength
Potential to spring during hard impact
High relaxation/ Low stability

Geometry allow relaxation

Storage Tips
At some point in time you may wish take your boiler off line and store it for an extended
period of time. Be very cautious. Boilers that sit idle will corrode leaving you with a quite
a mess when you want to place the boiler back in service.
Here are two ways you can store your boiler. The first is wet storage, which is generally
better for shorter periods of time. In fact, we would recommend wet storage for anybody
that needs a boiler for emergency stand-by. A word of caution, make sure the
temperatures in your boiler room do not dip below freezing.
For wet storage we recommend the following steps:

Inspect the boiler and clean it if needed

Fill the boiler with deaerated feedwater to the normal levels

Contact your water treatment company for the chemicals needed to condition the
water

An alternative would be using a nitrogen blanket throughout the entire boiler. Make sure
the vents are closed and that the nitrogen pressure is greater than atmospheric pressure.
The dry storage method is preferred for boilers that will be out of service for an extended
period of time or where the temperatures can go below freezing.

Again, inspect and clean your boiler

Drain all the water and make sure that the boiler is completely dried. Remember,
any moisture left on boiler surfaces will eventually corrode

Next make sure that moisture cannot enter the boiler. Close off any steam lines,
feed lines and any points of entry for air

Then place moisture absorbent material, such as quicklime or silica gel inside the
boiler. This should be placed on trays inside the boiler. We suggest 2 pounds of
quicklime or 5 pounds of silica gel per 30 cubic feet of boiler volume.

Close up all manways and handholes

Next place a sign on the boiler so that nobody makes the mistake of firing it
without removing the absorbent material. This sign might read as follows:
Attention - moisture absorbent material has been placed in the water side
and furnace of this boiler. This material must be removed before water is
placed in the boiler and before the boiler is fired.

Finally, inspect the boiler every two or three months and replace the absorbent
materials with new or regenerated materials.

Water Hardness
Since water is the key ingredient used in a boiler system, it is important to understand just
exactly what is in the water you will be using. We recommend that customers have a
water analysis performed so they have a true picture of what they are dealing with.

One of items that will be quantified in the analysis is the hardness. This is really the
amount of mineral contamination that is found in your water. This degree of
contamination can be measured by either a chemical analysis or by measuring the water's
ability to conduct (or resist) an electrical current.
Hardness can be reported in one of three different expressions:
Mg/l - milligrams per liter
Ppm - parts per million
Gpg - grains per gallon
We normally work with the grains per gallon expression as it is the easiest for all to
understand. Imagine if you took a pill that weighed 8 grains and dissolved it in 1 gallon
of pure water. The result would be 8 grains per gallon. Simple and easy to understand,
however, other like to express water hardness as mg/l or ppm. Here is a table that can
help you make the conversion:
Gpg X 17.1 = ppm
Gpg X 17.1 = mg/l
Ppm X .05833 = gpg
Mg/l divided by 17.1 = gpg
Water hardness becomes an issue as soon as heat is applied in the boiler system. The most
common problem is that of scale formation, a problem that will rob your system of the
efficiency it was designed to deliver. The following formula demonstrates scale
formation. To protect your boiler system, invest in an ion exchange water softener.

Points to consider when buying a boiler

Buying a packaged boiler is kind of like buying a new car. You need something that will
get the job done within a given price range. There are some features that you must have
and others that you would like to include if it fits that budget. Style counts for a lot in the
purchase of a car; not a real critical factor in the boiler world. Whether your boiler is to
be used for process duty or for heating purposes there are some basic points that you must
consider. This listing was adapted from HVAC Systems and Components Handbook
edited by Nils R. Grimm and Robert C. Rosaler. (McGraw-Hill Companies, 1998)

We have included some additional points that we believe should also require careful
consideration.

Just exactly what do you want the boiler to produce? Low Pressure Steam, High
Pressure Steam, Hot Water, High Temperature Hot Water.

How big a boiler do you need? How much steam or hot water is required to
satisfy your needs?

What duty will the boiler serve? Will it be used for space heating, process steam,
humidification or any other number of duties?

How critical is it to have the boiler on-line? If it were extremely critical it would
be advisable to have built in redundancy included in your plans.

How about the type of fuel you have available? Natural Gas, Fuel oil (no. 2, 4 or
6) Propane, Coal, Wood or a combination of fuels. What is readily available and
what is economical for your application?

What type of combustion air system would you like? Forced draft systems are
inherently more efficient and also more expensive than the atmospheric burners.
Outside influences such as emission controls, boiler location and space
availability will all contribute to this selection.

How will you vent the boiler and how will you bring in fresh combustion air?
These are two key points that will influence your burner selection. You may wish
to consider including an Exhaust to fan assist system in your design.

Who will take care of the boiler after it has been installed? After sale support is a
critical factor to consider. This includes the availability and price of aftermarket
parts.

Get your Boiler ready for cold weather

Get Ready! The time is fast approaching when you will need to have your boilers back
on-line. Yes, winter is coming and so are the demands placed upon your boilers.
To make sure you are operating safely and at peak efficiency we recommend that you, or
a qualified boiler service technician, open your boiler for an inspection. Clean both the
fireside and waterside. If you haven't had your boiler inspector out, call him so that he
can take a look.
When you reassemble your boiler use new gaskets. Also clean and inspect your low water
cutoff. Check all safety devices, including a pop test on the safety relief valves, flame
safeguard checks and a leak test on safety shut-off valves.
Here is a checklist of items to inspect, clean, repair or replace as required:

All refractory
Replace all fireside gaskets
Refractory baffle gaskets
Burner gaskets
Handhole gaskets
Manhole gaskets
Low water cut-offs
Oil gun assembly
Pilot electrode and pilot tube
Flame detector
Scanner tube
Programmer
Damper motor
Cam assemblies
Linkages
Ignition transformer
Ignition cable
Operating limit controls
Pilot Valves

Main gas valves

Main gas regulator
Gas butterfly valve
Blower motor
Air proving switch
Atomizing air pump
Air cleaner
Strainers
Air and oil hoses
Oil valves
Oil metering stem
Back pressure orifice
Stem packing
Gauges
Stack thermometer
Water column assembly
Tyrcocks
Safety Valves
Sight ports

Firetube vs. Watertube

Boilers come in many different sizes, shapes and designs. This creates quite a challenge
for those of us that do not purchase boilers on a regular basis. The choice between a
firetube design and a water tube design can become very confusing for novice boiler
buyers.

Firetube
The name firetube is very descriptive. The fire, or hot flue gases from the burner, is
channeled through tubes that are surrounded by the fluid to be heated. The body of the
boiler is the pressure vessel and contains the fluid. In most cases this fluid is water that
will be circulated for heating purposes or converted to steam for process use.
Every set of tubes that the flue gas travels through, before it makes a turn, is considered a
"pass". So a three-pass boiler will have three sets of tubes with the stack outlet located on
the rear of the boiler. A 4-pass will have four sets and the stack outlet at the front.
Firetube Boilers are:

Relatively inexpensive
Easy to clean
Compact in size
Available in sizes from 600,000 btu/hr to 50,000,000 btu/hr
Easy to replace tubes
Well suited for space heating and industrial process applications

Disadvantages of Firetube Boilers include:

Not suitable for high pressure applications 250 psig and above
Limitation for high capacity steam generation

Watertube
A Watertube design is the exact opposite of a fire tube. Here the water flows through the
tubes and are incased in a furnace in which the burner fires into. These tubes are
connected to a steam drum and a mud drum. The water is heated and steam is produced in
the upper drum. Large steam users are better suited for the Water tube design. The
industrial watertube boiler typically produces steam or hot water primarily for industrial
process applications, and is used less frequently for heating applications.
Watertube Boilers are:

Available in sizes that are far greater than the firetube design. Up to several
million pounds per hour of steam.
Able to handle higher pressures up to 5,000 psig
Recover faster than their firetube cousin
Have the ability to reach very high temperatures

Disadvantages of the Watertube design include:

High initial capital cost

Cleaning is more difficult due to the design
No commonality between tubes
Physical size may be an issue

The best gauge of which design to consider can be found in the duty in which the boiler is
to perform. Fortunately most boiler sales agencies offer a number of boiler designs and
can help you make the correct choice. Ask these professionals what they would
recommend and have them explain why.

Boiler Water
Quality Recommendations
Refer to the following table for recommended boiler water quality for Total Dissolved
Solids (TDS), Alkalinity and Hardness.

Proper Feedwater Treatment is an absolute necessity! Unless your boiler receives water
of proper quality, the boiler's life will be needlessly shortened. A steam plant's water
supply may originate from rivers, ponds, under ground wells, etc. Each water supply
source requires a specific analysis. Depending upon this analysis, various pretreatment
methods may be employed to prepare makeup water for your boiler feedwater system.

General Information

Suspended solids represent the undissolved matter in water, including dirt, silt,
biological growth, vegetation, and insoluble organic matter.

When minerals dissolve in water, ions are formed. The sum of all minerals or ions
in the water in the total dissolved solids or the TDS.

Iron can be soluble or insoluble. Insoluble iron can clog valves and strainers and
can cause excessive sludge build up in low lying areas of a water system. It also
leads to boiler deposits that can cause tube failure. Soluble iron can interfere in
many processes, such as printing or the dying of cloth. In domestic water systems,
porcelain fixtures can be stained by as little as 0.25 ppm of iron.

Water Hardness is the measure of calcium and magnesium content as calcium

carbonate equivalents. Water Hardness is the primary source of scale in boiler
equipment.

Silica in boiler feedwater can also cause hard dense scale with a high resistance to
heat transfer.

Alkalinity is a measure of the capacity of water to neutralize strong acid. In

natural waters, the capacity is attributable to bases, such as bicarbonates,
carbonates, and hydroxides; as well as silicates, borates, ammonia, phosphates,
and organic bases. These bases, especially bicarbonates and carbonates, break
down to form carbon dioxide in steam, which is a major factor in the corrosion of
condensate lines. Alkalinity also contributes to foaming and carryover in boilers.

Boiler Maintenance
When it comes to boiler maintenance ARE YOU PROACTIVE OR REACTIVE?

By far the worst strategy is reactive maintenance. This may be defined as repairs
made only when there is a failure. There is no planning, no anticipation of repairs
that may be required to prevent a failure. It is only when the equipment fails that
the operators will evaluate the cause and then try to make the repairs.
The costs associated with these repairs are typically high both in labor, much of
which is done on an overtime basis, and the associated downtime. By far this is the
least desirable approach to boiler maintenance.
On the other end of the boiler maintenance spectrum is a proactive maintenance
program. This type of maintenance approach uses scientific testing techniques and
analysis to anticipate and correct, by either repair or replacement, problems before
they arise. Real time monitoring has contributed greatly to the ability to view and
respond to changes in boiler operation and overall process performance. Operators
can compare past baseline results against current readings to determine if a
problem may be forth coming.
A proactive maintenance program pays dividends in not only peak boiler
performance but also in the overall safety of those working in the boiler plant.
The key to properly analyzing boiler room conditions is having accurate data
available. Boiler room logs are an important part of this process. Critical
predetermined readings, such as fuel consumption and flue gas temperatures, are
recorded on a daily or even a per shift basis. These recorded readings then give the
operator a base line to compare present readings against. As an example, if the flue
gas temperature of a boiler has gradually increased over the course of a month the
operator will be able to evaluate the system. He might then determine that there has
been a build up of scale reducing heat transfer.
Keep in mind that every boiler operation is different. Some will require more
extensive logs as opposed to others. This is an area that management and boiler
operators must review and jointly decide upon.
Following is a suggested list of points that we feel require daily recordings:

Water Level

Condensate Temperature

Low Water Cut Off Tested

Blowdown Water Column

Blowdown Boiler

Visual check of Combustion

Boiler Operating Pressure/Temperature

Feedwater Pressure/Temperature

Feedwater Pump Operation

Flue Gas Temperature

Gas Pressure

Oil Pressure and Temperature

General Boiler/Burner Operation

Boiler Room Support Equipment

There are some basic pieces of boiler room support equipment that should be considered
for a complete boiler installation. This equipment is designed to protect your boiler from
harmful water conditions.
Here are some of the basic pieces and the functions they serve:
CHEMICAL FEED SYSTEM
A chemical feed system is used to feed the appropriate amount of chemicals into your
system to combat scaling and corrosion. A chemical feed system is comprised of a tank,
stand, pump, motor and agitator. The feed system is wired so that it will operate in unison
with the boiler feed water system or de-aerator. This ensures that the proper amounts of
chemicals are being fed on a consistent basis.

WATER SOFTENER SYSTEM

A water softener is used to remove hardness from the boiler make-up water. They are
available in a wide range of sizes and configurations. By removing hardness in the water
you will protect your boiler from the formation of scale that can rob your boiler of its
ability to transfer heat efficiently.
BLOW DOWN SYSTEMS
There are two types of blow down systems. A surface blow down/heat recovery and
bottom blow down system. A Bottom Blow Down System is used to forcibly remove
sludge and sediment from the bottom of your boiler. This is an intermittent process and is
dependent upon the boiler operator to perform. It consists of a tank, stand and aftercooler
assembly that is used to temper the water before it is sent to the drain. A surface Blow
Down System continually removes dissolved solids from the top level of the boiler water
and recovers a great deal of the heat which is then returned used to pre-heat boiler feed
water.
DEAERATORS
Deaerators are used to remove non-condensable gases from boiler feed water. This is
done by heating and aggressively agitating the incoming make-up water. This process
reduces the oxygen content of the water to .005 cc/liter and protects your boiler from
oxygen pitting and corrosion.
FEED WATER SYSTEMS
A feedwater system is used to store and return preconditioned make-up water and hot
condensate into your boiler. A feedwater system includes a tank, pumps and a stand.
Some Feedwater systems include a steam sparge tube, which is used to pre-heat make-up
water. This helps to eliminate some of the oxygen in the make-up water.
CONDENSATE RETURN UNITS
A condensate return unit is used to reclaim used treated condensate to be used again in
your boiler. Not only will you reclaim the water but also the chemicals that were used to
treat the water. The result is a significant savings in make-up and the associated
chemicals. A Condensate return unit consists of a small tank with small pumps that are
used to feed into the boiler.

Boiler Fireside Care and Boiler Maintenance

There are two sides to every firetube boiler and we dont mean the inside and outside of
the boiler. We are really referring to the Water Side and the Fire Side of the boiler. Both

require inspection and the appropriate maintenance in order to keep your equipment
running at peak efficiency.

A visual inspection should be conducted twice a year

The fireside of your boiler will include all refractory, tubes, tube sheets and the furnace.
A visual inspection should be conducted twice a year to determine the condition of this
side of the boiler heat exchanger. Open the boiler up and use a strong light to visually
inspect the condition of these surfaces.
Do you see any blistering or pock marks? This is an indication that there is corrosion due
to condensation of flue gasses. This condensation creates an acidic solution that can eat
away at your furnace and tubes. Should you find this occurring you may correct the
situation by maintaining a minimum water temperature of 170 deg. F. Another solution is
to keep your boiler on for a longer period of time. This avoids short cycling that, which
allows for the formation of condensation.
If you run a properly adjusted boiler you may only need to clean your tubes once a year.
Next take a close look at the boiler tubes keeping an eye out for soot deposits. Soot is a
byproduct of combustion and can seriously reduce heat transfer in your boiler. Poor heat
transfer means poor efficiency. If there is soot present make arrangements to have the unit
cleaned. How often you clean the tubes will be determined by how you run your boiler. If
you run a properly adjusted boiler you may only need to clean your tubes once a year.
If you are experiencing heavy sooting it could be an indication that you are trying to fire
too much fuel. Have your burner adjusted by a qualified boiler technician.
Another way to check on sooting is to install a stack thermometer. When the stack
temperature rises above normal operating conditions you can be fairly certain it is time to
clean the tubes.
While you have your boiler open take a look at the tube sheet. Look for any evidence of
leaking tube ends. You can pin point these by a whitish deposit that streaks down from
the tube end. If you find this occurring, contact a boiler service company that can re-roll
your tubes.
Also check the gaskets used to seal the boiler up. If they are at all suspect, replace them.
It is easier to do this now than later when you are firing the boiler.

The last item to check on the fireside is the refractory. Make sure it is all tight and repair
any cracks that may have appeared. Use a wash coat to seal these up. If you find any
loose refractory brick replace it.
Boiler Blowdown
Blowdown of steam boilers is very often a highly neglected or abused aspect of routine
boiler room maintenance. The purpose of boiler blowdown is to control solids in the
boiler water. Blowdown protects boiler surfaces from severe scaling or corrosion
problems that can result otherwise.

There are two types of boiler blowdowns - continuous and manual. A continuous
blowdown utilizes a calibrated valve and a blowdown tap near the boiler water surface.
As the name implies, it continuously takes water from the top of the boiler at a
predetermined rate
A continuous blowdown is an optional feature and may not be included on your steam
boiler. However, all steam boilers should include a means for manual blowdown as
standard equipment.
Manual blowdowns are accomplished through tapings at the bottom of the boiler. These
openings allow for the removal of solids that settle at the bottom of the boiler. Manual
blowdown is also used to keep water level control devices and cutoffs clean of any solids
that would interfere with their operation. All steam boilers require manual blowdown
whether or not they are supplied with continuous blowdowns.
Proper blowdown is performed as follows:
Blowdown should be done with the boiler under a light load. Open the blowdown valve
nearest the boiler first. This should be a quick opening valve. Crack open the downstream
valve until the line is warm. Then open the valve at a steady rate to drop the water level
in the sight glass V2 inch. Then close it quickly being sure that the hand wheel is backed
off slightly from full close to relieve strain on the valve packing. Close the valve nearest
the boiler.

Repeat the above steps if the boiler has a second blowdown tapping. Water columns
should be blown down at least once a shift to keep the bowls clean. Care should be taken
to prevent low water shutdown if this will affect process load.
Please keep in mind that all blowdown piping should be checked once a year for
obstructions.

Boiler Refractory Care and Maintenance

According to the Refractory Institute, Refractories are heat-resistant materials that
constitute the linings for high-temperature furnaces and reactors and other processing
units. In addition to being resistant to thermal stress and other physical phenomena
induced by heat, refractories must also withstand physical wear and corrosion by
chemical agents. Refractories are more heat resistant than metals and are required for
heating applications above 1000F (538C).
In a boiler the refractory protects the metal surfaces at critical points such as the rear door
and in the furnace. This refractory should be inspected periodically to insure protection.
Here is a list of what to look for and possible maintenance solutions:

Visually inspect refractory. Look for large cracks or broken pieces. Small hairline
cracks are to be expected.

Wash coat the refractory with a high temperature bonding, air dry mortar.

Face all cracks and joints with hi-temp bonding cement.

If any bricks have fallen out or show signs of excessive wear, replace them.

Remember, once the repair is complete it is important to follow the manufacturers

recommendation for curing the refractory.

We also suggest that you inspect the refractory of your brand new boilers when they
arrive on site. Check to be sure that the refractory has not been damaged in shipment.
Report any defects to your boiler supplier immediately.
Need more information or refractory repair materials? Please contact our parts
department.

Combustion Air Fan

Fan problems can seriously affect combustion efficiency. To fire your boiler at peak
efficiency it is necessary to strike the correct balance between fuel and combustion air.
These ratios must remain constant throughout the entire firing range so that either fuelrich or fuel-lean mixtures are avoided.
With an atmospheric burner, air is introduced at the bottom of the burner using natural
draft. The fuel/air ratios are then determined by regulating only the gas pressure for the
correct mix.

For a full modulating forced or induced draft burner designs, air and fuel ratios are
controlled through linkages, fans, dampers and the increase or decrease of gas pressure.
As demand is placed on the boiler, the burner will respond by introducing a greater
amount of fuel and combustion air. This results in more energy introduced into the heat
exchanger.
As a general rule of thumb, it takes about 9.5 cubic feet of air for every one cubic foot of
natural gas for ideal combustion to occur. At 10% excess air this ratio will be about 10.5
cubic feet of air to 1 cubic foot of natural gas.
The air and gas must not only be in the correct proportions but also introduced at the
proper time to assure complete mixing. Gas pressure is controlled through a pressure
regulator and a fan controls the volume of combustion air.
Fan problems can seriously affect combustion efficiency. Here is a list of common fan
problems and some possible causes that you may wish to look at. Fan capacity or
pressure is below rating:
1. Dampers or variable inlet vanes are not adjusted properly
2. Fan inlet or outlet conditions are impaired
3. Multiple air leaks within the system
4. Damage sustained to the blower wheel
5. Direction of rotation is incorrect
Fan vibrates or makes noise:
1. Worn bearings
2. Unstable foundation
3. Foreign material in the fan causing an imbalance
4. Misalignment of bearings, couplings, wheel or v-belt drive
5. Damaged wheel or motor
6. Bent shaft
7. Worn coupling
8. Loose dampers or variable inlet vanes
9. Speed too high or incorrect fan rotation
10. Vibration to fan transmitted from another source
11. Uneven blade wear
12. Loose or broken bolts or set screws

Overheated Bearings:
1. Improper lubrication
2. Poor alignment
3. Damaged wheel or driver
4. Bent shaft
5. Abnormal end thrust
6. Dirt in bearings
7. Improper belt tension
Overload on Driver:
1. Speed too high
2. Direction of rotation is incorrect
3. Bent shaft
4. Poor alignment
5. Improper lubrication
6. Wheel wedging or binding on fan housing

Addressing Alkalinity & Feedwater Pretreatment

All boilers, regardless of their design, require some degree of feedwater pretreatment.
This pretreatment process addresses the three specific areas: water hardness, Total
dissolved solids and alkalinity levels. Since we discussed water hardness and TDS in
previous boiler tips we felt is was time to address alkalinity.
Acceptable Levels of Alkalinity
Alkalinity, like hardness and TDS, is expressed as parts per million (ppm). The
acceptable level of alkalinity in a boiler depends largely upon the pressure that the boiler
will be operating at. In a low pressure boiler, this level should not exceed 700 ppm. If the
alkalinity level exceeds 700 ppm it may result in a breakdown of the bicarbonate
producing carbonate and liberate free carbon dioxide with the steam. This presence of
carbon dioxide will corrode steam and return lines.
Max allowable concentration of alkalinity within a low pressure boiler is 700 ppm.
Dealkalization
Dealkalization is the process in which softened water is passed through a treatment tank
that contains an anion resin. This anion resin removes anions such as sulfate, nitrate,
carbonate and bicarbonate. These anions are then replaced by chloride. Sodium chloride
(salt) is then used to regenerate the unit with the anion exchange resin.

Hard water has the ability to precipitate calcium carbonate and magnesium hydroxide
within a dealkalizer, therefore it is necessary to have softened water fed to the system. In
addition, the anion exchange bed is susceptible to fouling due to suspended solids.
dealkalizer. The resin in a dealkalizer is lighter than that found in a water softener. This
means that the backwash rate will be much slower and insufficient to remove any
suspended material.

Proper sizing of Boiler Feedwater Systems

One of the most important factors in keeping your boiler on-line is to keep enough water
in it. Otherwise the boiler will shutdown on a low water condition. This is especially true
with firetube boilers that are fired automatically. That is why it is so important to size a
feedwater system so that it has the capability of maintaining the proper water level in
your boiler.
Properly Sized
A properly sized feedwater system will have a tank adequately sized to feed your boiler
and pumps selected to deliver that water at the correct rate and pressure.

Calculate the storage tank needed

In most cases ten minutes of water should be readily available for your boiler. One boiler
horsepower = 34.5 lbs/hr of steam (or water) from and at 212o F. We also know that onegallon of water weighs 8.37 lbs. To calculate the storage tank needed use the following
formula:
BHP X 34.5 8.33 7 lbs 60 mm. X 10 = minimum useable capacity in gallons.
For example, if you have a 500 HP boiler the calculation will be as follows
500x34.58.33760X 10=345 gallons
Now, it stands to reason that you cant operate your tank totally flooded so you have to
allow for some extra room. A safety factor of 1.5 is generally the accepted rule of thumb.
We then take the 345 gallons and multiply by 1.5 to get 517.5 gallons and choose a tank
size of 500 gallons (one of the standard tank sizes available).
Keep in mind that your boiler system requirements might demand a larger reserve
especially if you have a process steam load that returns large slugs of water intermittently.
In this case you may need a larger tank.
The next step is to select the correct pump for your application. There are three areas that
must be considered. The correct flow rate in GPM, the correct pressure needed and the
NPSH (net Pump Suction Head).

To calculate the flow rate in GPM, use the following formula:

BHPX34.58.33760X1.5=gpm
(Please note that the 1.5 is, once again, a safety factor.)
For the example we have been using the calculation will look like this:

500 BHP X 34.5 8.337 60 X 1.5 = 52 gpm

Another quick rule of thumb is that 1/10 of a gallon is needed for every boiler
horsepower. So a 500 HP boiler will need a pump capable of delivering 50 gpm.
An 800 HP boiler will need an 80 gpm pump.
The next step is to determine the proper discharge of the pump. ASME code requires that
you furnish feedwater to your boiler at 3% higher than what the relief valve setting is on
the boiler. In addition, you must take into consideration any pressure drops between the
pump and the boiler. This would include any valves and piping.
For this example we will say that our relief valve is set at 150 psig and there is a 5 lb.
pressure drop. The calculation will look like this:
150 x 1.03 + 5 lb drop = 160 psig required.
The last piece of the puzzle is the correct NPSH, net positive suction head. This is the
amount of liquid, in feet, required at the pump suction to prevent cavitation and insure the
pump is working correctly. This will help determine the tank stand height you will need
To chose the correct NPSH refer to the pump selection tables. These tables are based on
the pumps having the lowest possible NPSH needed. This is done to ensure the lowest
tank stand and thus reduce the overall height of the boiler feed system. NPSHA is the feet
available under the tank and NPSHR is the feet required by the pump. Check the pump
curve for the NPSHR and then add one foot.

Boiler Feed Pumps

Boiler feed pumps are an important part of any boiler operation. They control the amount
of water fed to the boiler and the manner in which it is fed.

Centrifugal - Continuous

Turbine - Intermittent

In order to properly select a boiler feed pump five key points must be considered:

Will the pumps operation be continuous or intermittent?

This is an operational question and is often answered by the type of level control found
on the boiler that the pump will be servicing. As a general rule of thumb, boilers with a

capacity of 10,000 lbs./hr. or less utilize a float type switch that starts and stops the boiler
feed pump to satisfy a predetermined water level within the boiler. This is a classic
intermittent operation.
Boilers with capacities exceeding 10,000 lb./hr. typically employs a modulating feed
water regulator and will continuously feed water to the boiler at various rates depending
upon the water level in the boiler.
By knowing which operation you are to satisfy, you can determine which pump design is
best suited for your application. As a general rule of thumb a turbine pump is used in an
on-off situation and a centrifugal pump is used for continuous operation. But remember,
this is a general rule and is some cases a centrifugal could be used for an on-off
application and a turbine for continuous.
What is the temperature of the water being pumped?
It is also important to know the temperature of water you intend to pump. Most pumps
can usually handle 215 oF to 2300 F, other pumps are available that can handle higher
temperatures by using external water-cooling. Keep in mind that a deaerator pump must
be able to handle higher temperatures because they operate a 5 psi or 227o F.
What is the required capacity?
How much water you intend to pump is dependent upon the evaporation rate of the boiler
the pump will service. A safe figure for an on-off application would be 2 times the
evaporation rate of the boiler. With a modulating level control, a factor of 1.3 times the
evaporation rate plus recirculation is recommended.
What is the desired discharge pressure?
When you pump directly into the boiler you will need to overcome the pressure in the
boiler as well as any piping losses. You can chose the right pump by looking at the pump
curves to determine which will accomplish this task. Should you have a modulating valve
in the discharge line, the minimum you will need to add to the boiler operating pressure
will be 20 to 25 lbs. Make sure that the pump can handle the pressure along with the flow
rate needed. With an on-off level control the pumps should be designed for the relief
valve pressure.
What is the NPSH or net positive suction head required?
This is the last piece of information that you will need. This is the minimum absolute
pressure at the suction nozzle at which the pump can operate. To avoid pump cavitation,
the NPSHA of the system must be greater than the NPSHR of the pump. In other words,
the available NPSH must be higher than the required. We have always sized our deaerator
stands to be two feet higher than the NPSH needed for the pump selection. Remember,
the water level in the storage tank adds to the safety margin.
Deaeration of Boiler Feedwater
Pour yourself a tall glass of cold water. Place it in front of you and read on.
The water you have just poured for yourself is much like the feedwater you may be
sending directly into your boiler.

It contains among other things, dissolved gases such as oxygen and carbon dioxide that
can be particularly destructive to feed lines, condensers and to your boiler.
The oxygen in this raw feedwater is released within the boiler as a result of heat and rises
in the form of bubbles. These bubbles attach themselves to the boiler tubes, water legs
and the sides of the boiler drum shell at the water line.
The oxygen along with the carbon dioxide attacks the iron and set up chemical musical
chairs in which the steel in your system will always lose. This destructive game will
continue until either all the oxygen is entirely removed from the water or the steel or iron
is dissolved.
A deaerator will prevent the game from ever starting. This piece of equipment removes
corrosive gases from boiler feedwater and preheats the water prior to entrance into the
boiler.
A deaerator should be considered if any of the following situations occur:

Your boiler plant operates at 75 psig or greater.

Your boiler plant has limited standby capacity.

Production depends on your continuous boiler operation.

Your boiler plant uses 25% or more cold water makeup.

Now take a good look at that glass of wat er you poured earlier. Those little bubbles that
have formed on the inside of the glass are just what we have been describing. Imagine the
inside of your boiler system with high temperatures and high pressures.If you dont have
a deaerator, maybe it is time to consider one.
COMMON WATER IMPURITIES

Impurity Source Effect

Algae organic growth fouling

Calcium mineral deposits scale

Carbon dioxide dissolved gases conosion

Chloride mineral deposits corrosion

Free acids Indus. Wastes corrosion

Hardness mineral deposits scale

Magnesium mineral deposits scale

Oxygen dissolved gases corrosion

Silica mineral deposits scale

Suspended solids undissolved matter fouling/scale

There are five major problems directly associated with water quality that will effect boiler
performance. These are:

Scale formation

Corrosion

Fouling

Foaming

Embrillement

SCALE is a very hard substance that adheres directly to heating surfaces forming a layer
of insulation. This layer of insulation will decrease heat transfer efficiency. Scale also
results in metal fatigue/failure from overheating, energy waste, high maintenance costs
and unnecessary safety risks. A one-sixteenth inch thickness of scale in a firetube boiler
can result in a 12.5% increase in fuel consumption.
CORROSIONis defined as the destruction of a metal by chemical or electromechanical
reaction with its environment. The metal is eaten away in much the same manner as
fender rusts on a car. Corrosion dramatically increases maintenance costs and can cause
unnecessary safety risks. It will occur when levels of oxygen or carbon dioxide are high,
where pH values are low, where contact occurs between dissimilar metals and in damp
environment or corrosive atmospheres.
Corrosion is an electrochemical process in which electricity flows through a solution of
ions between areas of metal. Deterioration occurs when the cunent leaves the negatively
charged metal or anode and travels through the solution to the positively charged metal or
cathode, completing an electrical circuit in much the same manner as a battery cell. The
anode and the cathode can be different metals or areas of the same metal. Corrosion
occurs when there is a difference in the electrical potential between them.
FOULING occurs when a restriction develops in piping and equipment passageways and
results in inefficient water flow. The fouling of boiler room equipment directly impacts
energy efficiencies and cost of operations.
FOAMING is a condition in which concentrations of soluble salts, aggravated by grease,
suspended solids or organic matter, create frothy bubbles or foam in the steam space of a
boiler. When these bubbles collapse it creates a liquid that is carried over into the steam
system. Foaming degrades steam quality and in some cases can create a water slug that is
discharged into the steam lines.
CAUSTIC EMBRITTLEMENTwi11 occur when there is a high concentration of alkaline
salts (a pH value of 11 or greater) that will liberate hydrogen absorbed by the iron in the
steel. Caustic embrittlement will be more evident in high temperature areas of the boilers
waterside and manifests itself in the form of hairline cracks.

Deaeration Systems
Deaerators are used to remove oxygen from boiler feedwater.
Industrial Steam designs and manufacturers a complete line of Boiler pre-treatment
equipment including:

Deaeration Systems

Boiler Feedwater Systems

Blowdown Systems (Intermittent and Continuous)

Heat Recovery Systems

Deaeration designs include:

Atmospheric Deaerators

. Pressurized Deaerators

Tray type Deaerators

Atmospheric Deaerators
The Spray Flow II (SP5II) Atmospheric Deaerators offers a Guaranteed performance of .
005 cc/i from 0-100% load.

Split-section receiver with integral recycle pump

Unique design eliminates the threat air re-entry

Eliminates high vent losses common to other atmospheric designs

How it works:
Modulated make-up water is sprayed through a stainless steel spring-loaded nozzle into a
stainless steel internal vent condenser located in the scrubbing section. The nozzle
produces a thin conical sheet of water, which condenses the vapors while permitting
oxygen to exit through the unrestricted atmospheric vent. Pumped low temperature
returns are also sprayed through the nozzle. Gravity returns flow unrestricted to the
scrubbing section.
The combined make-up and returns in the scrubbing section is heated with steam and
recycled deaerated water from the deaerating section. Both the steam and the deaerated
water enter the scrubbing section through separate stainless steel manifolds. The
perforated steam manifold provides jets of steam to vigorously scrub the major portion of
the dissolved oxygen from the make-up, pumped returns, and gravity returns. The
temperature in the scrubbing section is controlled at 208oF at sea level, which assures the
release of the majority of the dissolved oxygen without flash loss.

Atmospheric Deaerators
The scrubbing section water, which is nearly fully deaerated, is continuously recycled to
the deaerating section where it is sprayed through stainless steel, wide angle, full cone
nozzles. Steam enters the deaerating section in response to the temperature in the
scrubbing section. Since the cycle is continuous, pure steam is always available for final
deaeration. The last traces of oxygen are removed at the point of contact with the purest
steam. Excess, fully deaerated water flows continuously from the deaerating section to
the scrubbing section through the stainless steel recycle manifold. Trapped returns are
piped to the deaerating section where flash steam is prefentially used for final deaeration.

Since the recycle pump capacity exceeds the deaerator capacity by at least 25%, the
deaerator is able to meet 0.005 cdl, from zero to 100% load. This same feature also
enables the deaerator to supply fully deaerated water to the boiler on start-up. Rapid load
changes and on-off boiler feedwater controls. which are very troublesome for other
atmospheric Deaerators, will not affect the Spray Flow IIs performance or operation.
Pressurized Deaerator
How it works:
Water flow
Incoming undeaerated water and pumped returns enter the deaerator through a springloaded stainless steel nozzle, which directs the flow in conical sheets into the steam
atmosphere of the direct contact vent condenser. At this point, the water temperature is
raised to within a few degrees of steam temperature and most of the corrosive, noncondensable gases are removed. The water is directed by a stainless steel tray section into
the Jet Spray atomizing valve. Here a high velocity of incoming pure steam literally
atomizes the water into minute particles. This violet scrubbing action removes the last
traces of dissolved gases. The hot, deaerated water then falls to the storage compartment
for boiler use.

Pressurized Deaerator
Steam Flow - Steam initially enters the deaerator through a special, stainless steel Jet
Spray atomizing valve. This valve is designed to fully atomize and provide complete

deaeration under all load conditions. This design insures that the purest steam comes in
contact with the purest water. Once this high velocity steam mechanically shakes out the
last traces of non-condensable gases from the water, it flows upward into the preheater
area where it meets the incoming make-up water and pumped returns. This water
continuously condenses the steam, which preheats and releases the non-condensable
gases into the internal vent condenser where they are metered harmlessly to the
atmosphere. This action causes more steam to be drawn into 6the system to complete the
cycle.
Vortex Damper
Vortex dampers are used at the fan inlet to give the entering air a spin in the direction of
fan wheel rotation. This spinning air allows for a better fuel air mixture within the burner.
The other advantage of a Vortex damper is greater air control at the lower firing ranges.
This control directly impacts the efficiency of the burner.
Many customers have contacted us for assistance with the vortex dampers supplied on
Kewanee boilers. We are now offering a Vortex Damper rebuild service. Save yourself
the time and expense of converting from round flues to square.

Votex dampers