Problems in the operation of warm and hot water boilers and steam generators
Operating problems:
» Corrosion in the boiler, steam and condensate system » Accumulation of sludge in pipes, circulating pumps and fittings » Reduced heat transmission » Defective radiators
Causes:
» Scale formation » Low pH-levels » High temperatures » Oxygen in the boiler water » Incorrect boiler operation » Soda-splitting
The problem: Untreated
drinking water is only partly suitable for use as boiler supply water.
The different operating conditions in boiler systems present their own
particular problems, with the distinction being made between closed
warm and hot water systems and steam generators.
Scale formation (all boiler types) During heating of the water, the carbonate hardness in the supply water precipitates out, forming so-called boiler scale. This impairs the heat transmission and can lead to local destruction of the material due to over-heating.
Corrosion on the water side (all boiler types) Low
pH-levels and high temperatures promote the corrosion of metallic
materials. Under such conditions, even low oxygen contents lead to
corrosion and erosion of the metallic boiler and piping materials. This
becomes apparent from the increasing discoloration of the boiler water
and/or accumulation of sludge in the system. Oxygen gets into the
system in the fresh water supply and can also enter the system through
leaks, under-pressure zones or non-diffusion-tight pipe materials.
Soda-splitting (steam generators) The
minimum treatment of the fresh water supply for steam generators is the
softening process. This ion-exchange process converts calcium and
magnesium hydrogen carbonate. Through heating, sodium hydrogen
carbonate is converted into sodium carbonate (soda). Under
the conditions in steam generators (high pressures and temperatures),
the soda is partly broken down into caustic soda and carbonic acid. The
caustic soda normally remains at the water-steam phase boundary area,
where it can attack the boiler material. The carbonic acid escapes with
the steam, leading to so-called carbonic acid corrosion in the
subsequent piping. The lower the proportion of condensate in the steam
produced, the more serious are the effects of the soda-splitting. In
many cases, subsequent softening of the fresh water supply is no longer
sufficient, making it necessary to resort to more complex processes
such as partial desalination or reverse osmosis.
Incorrect operation (steam generators) Inadequate
desalination leads to increased salt concentrations in the boiler
water. This can cause so-called "foaming" and "spitting" in the boiler,
in which boiler water containing salts is carried into the steam area,
where it causes corrosion.
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21.05.2012 / 23:15 
