Boiler Water Test Procedures Complete
Boiler Water Test Procedures Complete
Boiler Water Test Procedures Complete
OFFERED BY
S.P. THERMAL SYSTEMS INC. offers the following services to our customers at no
additional cost other than the purchase of chemicals.
START UP ASSISTANCE: We will set up your system chemical change over and monitor
your program to make sure that recommended parameters are being maintained.
We will train your staff in the basic requirements of control and administration of the
program.
We will provide control charts, MSDS, testing procedures and reporting manuals
SERVICE VISITS: We will provide a minimum monthly service visits and perform testing
analysis, to detect how the program is being maintained. We will report our findings and
review reports with your staff. Our reports will be forwarded to all personal directly involved.
On each service visit we will review operators plant records and report back on control and
treatment levels. Our report will emphasise Energy Management and utility savings by
maintaining proper control.
Our service report will show chemical usage and feed rate calculations based on plant data.
It will report on chemical control and Chemical Management control.
DEPOSIT AND CORROSION ANALYSIS: We will provide testing and deposit analysis as
required on your system using laboratory equipment
.
S.P. THERMAL SYSTEMS INC.
PH. 905 563 8651 FAX 905 563 6234
BOILER SYSTEM CONTROL VALUES PROGRAM
MAKE UP WATER
Use a softener where possible to prevent scale deposits from forming in the boiler
SOFTENER ( Record all test values and make up gallons from water meter)
Maintain softener to produce hardness levels of
‘ Hardness < 0.5 ppm as CaCo3 (Water Test will show BLUE) - Normal expected condition
‘ Hardness > 0.5 ppm as CaCo3 (Water Test will show RED )
When Water Test show RED MANUALLY regenerate the softener.
If hardness leakage persists after softener is regenerated, check the following
1. Check salt level daily in the brine tank. Maintain salt level 3/4 full at all times
2. Check to see if softener valves are functioning properly, and no hard water by pass is open
3. Check softener resin. If the resin is dirty use a resin cleaner. If the resin is low add. If the resin is
more than 10 years old have the resin replaced.
4. If Hardness persist call your Water Treatment Supplier and have softener serviced immediately
FEED WATER
# Maintain hardness level < 0.5 ppm. BLUE COLOUR. EXPECTED. If RED COLOUR check
softener and condensate for hardness. Record Feed water TDS, Hardness & Tank Temp..
BOILER WATER Sample of boiler water must be at room temperature before testing.
‚ Maintain Sulphite levels during normal Boiler Operating Period at 50 - 80 ppm ( 10 - 16 drops).
‚ On Fridays before shutting down for week end raise the sulphite values to 100 ppm ( 20 drops) in
the boiler. This will protect boiler over week end when it is not operating.
Note: 1 drop = 5 ppm.
If Sulphite value is low increase pump setting / timer. If Sulphite value is high reduce pump setting
‚ If on a Molybdate Program maintain Molybdate value at 100 - 150 ppm in boiler water
CONDENSATE
‚ Check for Hardness. Maintain values of hardness as BLUE. If water turns RED look for source of
hardness leakage. (Leaking heat exchanger / Hard water by pass)
‚ Check TDS in condensate for steam purity. If values are > 60 mmhos inform your water treatment
supplier.
‚ Check pH of condensate by adjusting amine feed to maintain pH around 8.6 - 9
EQUIPMENT REQUIRED
Advantage Controls Conductivity tester or similar
Sample jar or similar to take hot boiler water sample.
SAMPLE POINTS
UNITS: mmhos
FEED WATER
Take from the Feed Water Tank or deaerator a water sample and cool.
Take a sample of the water and rinse 3 times the cup holder of the conductivity meter
Then pour into the cup holder the water and press READ and record the value shown.
The conductivity units of measure should be set at mmhos.
BOILER WATER
Take from the Boiler Surface Blowdown Water a water sample and cool.
Take a sample of the water and rinse 3 times the cup holder of the conductivity meter
Then pour into the cup holder the water and press READ and record the value shown.
The conductivity units of measure should be set at mmhos.
CONDENSATE WATER
Take sample from condensate and apply same procedure and record reading.
Values < 50 mmhos is good quality steam
Value > 50 mmhos try to correct why steam quality is not good.
S.P. THERMAL SYSTEMS INC
Ph 905 563 8651 Fax 905 563 6234 Cell 416 876 0684
HARDNESS DROPPER TEST
REAGENTS REQUIRED
WR 8255 Hardness Buffer 30 ml
WR 8238 Hardness Indicator liquid 30 ml
WR 8269 Hardness Titration Solution 30 ml
Sample jar 25 ml or similar to take water sample.
Example: If 6 drops of WR 8269 is added to change color from RED to BLUE then
(Drops added x 2) = ppm hardness as CaCO3 = ( 6 x 2 ) = 12 ppm hardness
Record ppm Value found in Log Book, AND proceed to rectify problem immediately
pH TEST PROCEDURE
When collecting sample for testing condensate pH, please carry out the following
procedure.
2) The pH meter should be calibrated with pH 7 and pH 10 buffer solution at least once /
week.
2 B) If using pH Test strip, please dip strip into water sample and match to colour on
box, to arrive at pH.
6) Monitor condensate TDS . If the sample of condensate TDS is higher than 50 mmhos then
there is a good possibility, that the condensate is contaminated from poor steam quality.
Boiler Water is carry overing with steam. If this is the case reduce TDS in boiler to
<4000 mmhos
7) Determine what is causing carry over and rectify. High TDS in boiler or high Alkalinity
could cause carry over.
DAILY DAILY FD WATER DAILY BOILER FEED WT DAILY COND. COND COND TOTAL
SOFTENER FD WATER TDS POLISHER MOLY TEMP F BOILER PH TDS HARD BOILER MU
DATE HARD - PPM HARD PPM MMHOS HARD TEST TDS US GALL/ CU M
1
2
3
4
5
6
7
8
9
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11
12
13
14
15
16
17
18
19
20
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23
24
25
26
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Value to RED - BAD RED - BAD Record RED - BAD 100 - 150 + 180 F 3500 - 4000 7.6 - 8.6 < 100 RED - BAD
Control BLUE - GOOD BLUE - GOOD BLUE - GOOD ppm MMHOS mmhos BLUE - GOOD
MONTHLY SYSTEM REVIEW
S.P. THERMAL SYSTEMS INC. YEAR Verification Comments:
4504 GREEN MEADOW BLVD. MONTH
BEAMSVILLE ONT. Verification Signature / Date:
PH 905 563 8651 FAX 905 563 6234 Water Treatment Test Log Sheet CUSTOMER
Email: spthermal@cogeco.ca ATTENTION
BOILER
Hardness Test Feed Tank Boiler Condensate
F Boiler Surface Manual pH Hardness
TESTING Softener Polisher Feed Tank TDS Feed Tank Oxy Scav TDS Blowdown Blowdown
DATE mmhos Temp. Drops mmhos Working Done
1
2
3
4
5
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7
8
9
10
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Value to Blue - Good Blue - Good Blue - Good Record Maintain Daily 3500 - 4000 Yes / No Yes / No 7.6 - 8.6 Blue - Good
Control Red - Bad Red - Bad Red - Bad Value + 180 F 10 - 16 drops mmhos Red - Bad
Deviation / Corr Review Action to take shown Lower check Week end Review Action to take shown Record Log book
Action in Boiler Water Test Procedure Steam injector 20 drops in Boiler Water Test procedure for TSSA
Your Water Treatment program should be considered just as critical, as operating your car without the
necessary oil changes.
For a good Water Treatment Program to be effective, the following Standard equipment should be part
of your system.
SOFTENER TEST:
This is one of the most essential tests and should be done at least once per day on the preboiler system
Water samples should be taken from the softener and the polisher. A sample should also be taken from
the Feed Water tank or deaerator. A minimum of three (3) Test areas for Hardness should be monitored.
A. Flush sample lines and rinse the sample jar properly before taking a sample.
B. Collect the correct sample amount, based on the test procedure used. Sample amount ----- mls
C. Add Hardness Indicator to the sample ----- drops
D. Add Hardness Buffer to the sample ---- drops
E. Sample should turn SEA BLUE , if water is SOFT. If hardness is present , sample will turn RED
F. If RED, titrate with appropriate solution, until sample turns BLUE. Record hardness value.
G. If Hardness is present, always determine the reason and rectify the problem.
Solenoid
SULPHITE TEST: If using this product.
To protect the boiler and feed water tank from oxygen corrosion, the use of sodium sulphite is
a common treatment program.
A. Flush and collect a sample of water from the boiler gauge glass, or off the surface blowdown line.
B. Cool the sample enough for safe handling.
C. Measure appropriate sample, based on test procedure into a jar . Sample size ---- mls
D. Add 1 scoop of Acid Powder Starch reagent to sample.
E. Titrate, using Potassium Iodide Iodate solution until sample turns BLUE.
F. The value to maintain is - ppm in the boiler. ( ---- to ---- drops depending on size of sample)
G. Less than ----- ppm (---- drops), in boiler, increase feed rate of chemical pump or increase
chemical timer setting.
H. Higher > ---- ppm (---- drops) in the boiler, reduce feed rate of chemical pump or reduce timer
setting.
I. If the Feed Water Tank is cold < 180 F, the feed rate of the chemical will be higher. Increase
Feed Water temperature of Tank to 180 F, to reduce chemical usage.
J. If pH of Feed Water is < 8.4, the consumption of sulphite will be increased. Adjust pH in feed
water tank, to achieve a level higher than 8.4 to reduce chemical usage & protect the boiler.
K. If Boilers are not operating 24 hours / day, 7 days / week you may have to increase the feed rate
of sulphite, to achieve protection of the boiler during idle periods, where the boiler loses heat.
Sodium Sulphite consumption is temperature dependant and will be consumed, as the
temperature in the water gets colder. If you are having problems maintaining control, discuss this
with your Water Treatment Supplier for other options available.
Check valve
Check valve
Pump Stroke
Chemical Pump
Chemical Timer and
Accumulator Check valve
Strainer
pH TEST of Condensate
A. Flush and collect a sample of water from the condensate
B. Cool sample to room temperature
C. Using pH meter, check pH of sample
D. Control range to maintain is 7.6 - 8.6 pH
E. Less than 7.6 pH increase feed rate of amine
F. Higher than 8.6 pH reduce feed rate of amine
TROUBLE SHOOTING: Follow same procedure shown above with a sulphite, Item # 1 - 6 only.
NOTE: If you are getting Boiler carryover, you will also get false high pH readings. Carryover of boiler
water will damage a steam system. In addition, you lose energy and contaminate heat exchangers, and
process. This condition is also dangerous and could cause water hammer and break steam lines.
DISPERSANT FEED :
If chemical dispersant is being used separately, control dispersants based on the feed rate
recommended.
Note: Feed rate will depend on make up, boiler cycles and feed water quality.
If feeding dispersants separately, by separate pump, follow same Trouble shooting procedure shown for
chemicals.
DEAERATOR
If you have a deaerator to mechanically remove oxygen, you will still need to use an oxygen scavenger.
The deaerator functions well, operating at a pressure of 5 psig. The storage tank temperature of a
deaerator, should run about 228 F, if the deaerator pressure is 5 psig.
In addition, the deaerator must have a vented gas plume, to remove the gasses. This plume should be
about 2 - 3 feet high. It can be observed from outside the building. If the gases are not being vented
properly, corrosion may occur in the deaerator.
Solenoid valve
BOILER BLOWDOWN TANK for cold water
Boilers of steam pressure >15 psig, require in Ontario to be blowndown into Thermostat
a blowdown tank, designed for this operation. In addition the water exiting
the blowdown tank to sewer, needs to be controlled below a specified
temperature, based on the local regulations.
To do this, boiler blowdown tanks should be outfitted with a temperature
thermostat, to control the exit water temperature to the sewer. Adjust
thermostat to suit. This will inject cold city water into the tank. Furthermore,
care should be taken to protect drain lines, by making drain lines of tile or
Blowdown Tank
steel construction and not PVC due to the temperatures. PVC drains will fail with
high heat in a very short time.
BLOWDOWN CAUTION
When blowing down boilers under pressure, the valves must be opened slowly. Any quick action could
result in the pipe breaking, resulting in injury or death.
In addition, caution should be to have a get away path, in the event of the pipe breaking.
Make sure to have a good clear access path all round the boiler, at all times.
Follow all TSSA rules and procedures, as they are the Governing Body responsible for the safety
operation of boilers in Ontario.
S. P. THERMAL SYSTEMS INC.
4504 Green Meadow Blvd. Beamsville Ontario L0R1B5 Canada
Phone: 905 563 8651 Fax: 905 563 6234
NOTE: This article is provided as a Guide Only. S.P. Thermal Systems Inc. is not
responsible for training of Boiler Safety and does act as an agent in training personnel on
boiler safety. This is done in Ontario by TSSA and all companies having boilers should
consider getting this training
Many boiler plants today, are operated by maintenance and production staff who have been assigned
boiler care responsibility as part of their duties. This is due to the introduction of Coil Tube and Low
Volume Boilers, which by code in Ontario, have relaxed restrictions, if these boilers meet certain
guidelines.
It should be noted that TSSA has provided rules, that must be followed for the operation of these boilers.
These rules are specified in the attached, and include daily monitoring and recording using a Log Book
# 471
BOILERS: Boilers are classified as Low Pressure Steam (< 15 psig), High Pressure Steam (> 15 psig)
or Hot Water Design Boilers.
CAUTION: Any type of Boiler, is a pressure vessel and should be handled with caution, and care
should be exercised at all times, when operating these units.
DISCLAIMER
S.P. Thermal Systems Inc. is not responsible for any action regarding Safety or Operation of your Boiler.
The information provided, is only a general guide to help the owner in the operation of the boiler. We accept
no responsibility regarding Boiler Safety, or Boiler operation. All safety regulations on boilers come under
the “Operating Engineers Regulations” It is available at www.tssa.org
The proper Safety of your boiler, falls under the responsibility of the Owner and Management of the
Equipment, to take the necessary steps and training.