Heating Boiler Feedwater Controls

Learning Outcome
When you complete this module you will be able to:
Describe the various feedwater control methods and devices used on low-pressure
steam boilers.

Learning Objectives
Here is what you will be able to do when you complete each objective:
1. Describe the operation of a feedwater float switch operating a valve and float
switch operating a pump.
2. Describe how condensate is collected and returned to the boiler.
3. Explain the purpose and function of heating boiler feedwater and condensate
piping connections.

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INTRODUCTION
In low-pressure steam boilers there are several ways in which feedwater is
controlled to the boiler and many ways condensate is collected and returned to the
boiler. This module will cover some of the common methods that are in use today.

LOW-WATER FUEL CUT-OFF WITH COMBINED FUNCTIONS

Combination Low-Water Fuel Cut-Off and Feedwater Supply Switch
The feedwater supply to most steam heating boilers is usually controlled by a
float switch; the float following the fluctuations of the boiler water level. Rather
than using a separate float and housing, the feedwater control switch is commonly
operated by the low-water fuel cut-off float. This arrangement is shown in Fig. 1.

Figure 1
Basic Diagram of a Float Operated Low-Water Fuel Cut-Off
The three-wire (double-pole) switch (Fig. 2(a)) is used as a cut-off switch for the
fuel valve and as an alarm switch; the two-wire (single-pole) switch (Fig. 2(b))
controls the operation of either the feedwater pump or the feedwater control
valve.

Figure 2
Mercury Switches
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Fig. 3 shows how a combined low-water fuel cut-off and feedwater control switch
controls the water level in a steam boiler.

Figure 3
Control of Water Levels in a Steam Boiler

At level A, the highest operating level of the water in the boiler, the feedwater
supply switch opens, stopping the power supply to either feedwater pump or
control valve, thus stopping feedwater supply to the boiler. When the water level
drops to level B, the control switch closes again and feedwater supply resumes.
Should the pump fail to start or should the water supply be insufficient to
maintain the level, the water level in the boiler would continue to drop. When it
reaches level C, the cut-off switch opens and cuts off the power to the fuel valve.
At the same time the alarm circuit is energized.
The boiler cannot be started up again unless the water is raised above level C, the
operating level of the cut-off switch.
The cut-off switch should open when the level in the glass (level C) shows at least
20 mm (approx. 3/4") of water. Levels B and A, the cut-in and cut-out levels of
the feedwater control switch, may vary depending on type and size of boiler used.

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A basic sketch of a small steam boiler plant is shown in Fig. 4. The boiler supplies
steam to the various parts of the heating system where the steam gives up its heat
in the radiators, convectors, etc., and condenses. This steam condensate returns
from the heating system to the boiler room through the condensate return main
and collects in the condensate receiver from where it is pumped into the boiler by
the boiler feed pump. The diagram shows the combination low-water fuel cut-off
and pump control mounted at the right side of the boiler. The boiler is also
equipped with a second low-water cut-off device, which is required by code.

Figure 4
Basic Steam Plant

Combination Low-Water Fuel Cut-off and Feeder Valve

Float operated low-water fuel cut-offs are often combined with a valve assembly
that is used to control the flow of feedwater to the boiler. A cut-away view of this
combination cut-off is shown in Fig. 5.

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Figure 5
Float-Operated Low-Water Cut-Off with Feeder Valve

Since control of the feedwater supply is now the primary function of the cut-off
device, a second cut-off is again required by code.

Low-Water Fuel Cut-Off Controlling Secondary Supply of Feedwater

When a heating plant contains only a single boiler and the low-water cut-off stops
the firing of this boiler due to a low water condition, the heating system will soon
stop the supply of heat to the building. A boiler shut-down could result in
damaging freeze-ups during cold weather if the water level is not restored and
operation resumed within a short time. This is particularly true in buildings that
are not occupied during nights or week-ends, where a boiler shut down may go
unnoticed for a long time. For this reason, many heating boilers are equipped with
a second source of water supply (usually city water) that starts feeding water into
the boiler when the normal source of supply is either insufficient or fails
altogether.
This second source of supply is controlled by the low-water fuel cut-off device in
one of the following ways.

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Electric Feeder Valve

Besides the cut-off switch in the power supply to the burner, the low-water fuel
cut-off device is also equipped with a second switch which controls the power
supply to an electric valve in the city water supply line. When the water level in
the boiler drops well below the normal level, but before the level is reached at
which the cut-off switch opens the burner circuit, the float closes the second
switch energizing the electric valve, which then opens to allow the flow of city
water into the boiler. This arrangement is illustrated in Fig. 6.

BH1_fig6.gif

Figure 6
Low-Water Cut-Off Operating Electric Valve in Secondary Feedwater Supply
After the water level is raised, the switch breaks the circuit and the valve is closed
again. Should the supply of make-up water fail or be insufficient, the low-water
cut-off will stop the burner before the level drops to a dangerous point. A second
low-water cut-off device would also be required on this boiler.

Float Operated Mechanical Feeder Valve

In Fig. 7 the float of the low-water fuel cut-off operates a feeder valve which
controls the city water supply.
When the water level drops below the normal operating level, the float will open
up the feeder valve by means of a lever system allowing the auxiliary water
supply to enter the boiler. As the water level rises, the float will close off the
feeder valve again.
If the auxiliary supply is not able to maintain a safe water level in the boiler and
the level continues to drop, the low-water cut-off switch will break the circuit to
the fuel valve.
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Note that the auxiliary water supply should not open until the water level has
dropped well below the cut-in level of the feedwater pump. This allows for ample
space for fluctuations in water level without the necessity of feeding any make-up
water. The feeder valve should merely act as a stand-by for low water conditions.

BH1_fig7.gif

Figure 7
Feeder Valve On Secondary Water Supply Operated by Low-Water Cut-Off

FEEDWATER SUPPLY
In a steam heating system the boiler supplies the steam to the heating system. In
this system consisting of various pieces of heat exchange equipment (radiators,
convectors, unit heaters etc.) connected by supply and return piping, the steam
gives up its heat and condenses back to water forming what is commonly called
steam condensate. This condensate is then returned to the boiler to be converted
to steam again.
In this module, whenever mention is made of feedwater supplied to a lowpressure steam heating boiler, it should be understood that most, if not all, of the
feedwater is actually steam condensate returned from the heating system.

Gravity Feed With Hartford Loop

In older, small steam heating systems the condensate from the various parts of the
heating system is piped to a common condensate return line or return main which
feeds the condensate directly back into the boiler by gravity.

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The condensate is fed into the boiler through a return or Hartford loop, Fig. 8. If
the condensate return line would be directly connected to the feed connection in
the lower part of the boiler, the possibility would exist that the steam pressure
would force the boiler water back into the return line should the check valve fail
to close, and the water level in the boiler could drop below the safe minimum
level.

Figure 8
Hartford or Return Loop

The Hartford loop prevents this. The return line is connected to the loop at the
height of the lowest safe water level. At that level the heights of the water in the
boiler and in the loop will be equal and the steam pressure above the water in
boiler and loop will be the same. Since water height and steam pressure in both
boiler and loop are balanced, no water can be forced out of the boiler and
sufficient water will cover the heating surfaces to prevent overheating.

Feedwater Supply by Pump

In larger systems, all the condensate is returned to a common condensate receiver
or tank from which it is returned to the boiler by a boiler feedpump.
In a well balanced system the amount of condensate returning from the heating
system is equal to the amount of steam leaving the boiler, and the water level in
the boiler can be kept fairly constant. For this system a simple feedwater supply
arrangement, as shown in Fig. 9 would work reasonably well. The condensate or
boiler feedpump is controlled by a float-operated switch mounted on the receiver.
The boiler is equipped with a combination feeder valve low-water cut-off to
maintain a safe minimum water level in case of a failure of the boiler feed pump
or to shut off the burner should the level drop below safe limits.

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BH1_fig9.gif

Figure 9
Feedwater Control by Float Switch in Condensate Tank

The system in Fig. 9 is not suitable for systems where the condensate return is not
steady. Heating systems with long horizontal condensate return lines, such as
those found in large shopping centres and warehouses, or systems with irregular
steam consumption have a tendency to accumulate large amounts of condensate,
since the steam supply is faster than the condensate return. This would cause a
low level in the boiler, the feeder valve would open up, and extra water would
flow into the boiler to make up for the condensate hung up in the system. But
when the condensate returns to the receiver, the pump will feed it all into the
boiler, since the float switch maintains a fairly steady level in the receiver. As a
result of the extra water fed into the boiler previously, the level in the boiler will
now become excessively high.
It should be noted that the boiler in Fig. 9 is also fitted with a Hartford loop. This
loop is also used on boilers equipped with non-positive displacement feedpumps,
such as a centrifugal pump, since failure of the check valve in the feed line could
allow the steam pressure to force the boiler water back into the tank via the pump,
creating a low water condition.

Fig. 10 shows a feed system commonly used to maintain a steady boiler water
level in spite of an irregular condensate return. The boiler is equipped with a
combination pump control low-water cut-off.

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BH1_fig10.gif

Figure 10
Feedwater Control by Float Switch on Boiler

The float will follow the water level in the boiler and start and stop the feed pump
as required. This will assure a steady water level within close limits. Fluctuations
in the condensate return will only affect the level in the condensate receiver. A
make-up feeder is installed on the receiver to ensure that sufficient water is
available at all times to maintain the boiler water level and to prevent the pump
from running dry.
Although this system is quite reliable, there is still the possibility of developing a
low water condition in the boiler due to failure of the pump or its power supply
resulting in a shut-down by the low-water cut-off. This can be prevented by
installation of a secondary means of water supply controlled by a float-operated or
electrically controlled feeder valve as discussed earlier in this module.

In multiple boiler heating plants, the control of the water level in each boiler is
independent from the other boilers but the feedwater is usually supplied through a
common feedline by a single pump (Fig. 11). When one of the boilers requires
water, its float operated control switch closes, energizing the motorized valve in
the feedwater branch line to the boiler. As soon as this valve reaches the open
position, it closes an attached pump starting switch, and the condensate starts
flowing from the receiver to the boiler. When the water in the boiler reaches its
maximum level, the pump control switch opens the circuit, the motorized valve
closes and the pump stops.

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Figure 11
Multiple Boiler System with Feedpump and Motorized Valves
If any of the other boilers requires feedwater while the pump is already feeding
into one boiler, its pump control switch will energize the motorized feedwater
valve on that boiler and the pump will then supply both boilers. Since the second
motorized valve also closes an attached pump starting switch, it will be the valve
closing last that will shut the feedwater pump down.

FEEDWATER CONNECTIONS
Condensate Receiver Tank Level Controllers
An important requirement of a well-designed boiler feedwater system is a
condensate receiver of adequate size together with a reliable method of make-up
water supply to the receiver. An undersized receiver may cause loss of
condensate, while an unreliable make-up feeder could result in boiler shut-downs
due to low water conditions if the boilers are not equipped with feeder valves.
As a general rule, the size of the receiver should be sufficient to hold a volume of
condensate equivalent to the water evaporated by the boiler in a 1/3 to 1/2 hour
period at normal load. The smaller size receiver may be used when the condensate
returns easily as in heating systems used in high-rise buildings. In systems
extended over a large area (factories, warehouses, etc.), condensate return will be
lengthy and the larger size tank should be used.
The make-up valve should have sufficient capacity to supply the water required at
the normal firing rate of the boiler. If a make-up valve of smaller capacity is used,
the valve is commonly installed in the upper part of the receiver, leaving a small
volume available for accumulation of condensate. Enough water will be stored in
the receiver to supply the feed to the pump during its operating cycle.
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Two arrangements of make-up water feeders and controls are shown in

Figs. 12 and 13. The float mechanism of the feeder shown in Fig. 12 is mounted
directly in the tank. The disadvantage of this arrangement is obvious. The water
level in a condensate receiver can be subjected to violent fluctuations due to the
return of the condensate in slugs which will affect the float control, resulting in a
very unsteady valve operation.

Figure 12
Receiver with Internal Float Make-Up Valve
An externally mounted float controller feeder valve is preferred on most
installations (Fig. 13). The float chamber is attached to the receiver by equalizing
lines which dampen the level fluctuations in the chamber resulting in a smooth
flow of make-up water.

Figure 13
Receiver with External Float Make-Up Valve

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A large capacity receiver serving a multiple boiler plant requires a higher volume
of make-up water and thus a larger size feeder valve. The float controlled feeder
valve, as used in Fig. 13, serves then as a pilot valve actuating a high capacity
diaphragm valve in a make-up water line, as shown in Fig. 14.

Figure 14
Receiver with Float-Controlled Hydraulically Operated Make-Up Valve
City water is supplied on top of the diaphragm of the make-up valve and to the
float controlled valve through a small diameter control line which has a needle
valve to control the water flow. When the level in the receiver is normal and no
make-up is required, the float control valve is closed. The full pressure of the city
water will act on the diaphragm of the make-up valve keeping it closed. When the
level drops slightly below normal, the float control valve will open slightly,
bleeding some of the water out of the control line. With a restricted flow of water
through the needle valve, the bleed-off will cause the pressure in the control line
to drop which reduces the force on the diaphragm, allowing the make-up valve to
open slightly.
The lower the level in the receiver drops below normal, the more water the
control valve will bleed out of the control line and the lower the pressure in this
line will drop. This, in turn, allows the make-up valve to open more.

Fig. 15 shows an electric float control actuating a motorized valve in the make-up
water line to the receiver. This control is modulating, which means that it opens
up the make-up valve in proportion to the drop in water level in the receiver.

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Figure 15
Receiver with Float-Controlled Electrically Operated Make-Up Valve

Some condensate receivers are equipped with a low-water cut-off switch. Should
the level in the receiver drop so low that the pump could lose suction, the switch
will cut off the power supply to the motor preventing damage to the pump.

IMPURITY PROBLEMS IN CONDENSATE

Oxygen and carbon dioxide can both be present in condensate. The oxygen will
not cause problems until it reaches the high temperature boiler where it produces
a corrosion phenomenon called pitting. The carbon dioxide however will cause a
low temperature corrosion phenomenon called grooving in the condensate return
lines due to the formation of carbonic acid.
Corrosion caused by carbon dioxide can be prevented by using filming amines
which will coat the metal to prevent the attack of the acid or by neutralizing
amines which will neutralize the acid.
Corrosion caused by oxygen is either treated in the boiler or in a deaerator.

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References and Reference Material

For more information on this topic, the following are recommended:
1. ASME. Boiler and Pressure Vessel Code Section IV, 1992. Rules for
Construction of Heating Boilers, New York: The American Society of
Mechanical Engineers; 1992.
2. ASME. Boiler and Pressure Vessel Code, Section VI, SI Edition, 1983.
Recommended Rules for the Care and Operation of Heating Boilers, New
York: The American Society of Mechanical Engineers: 1983.
3. CSA. CSA Standard, B51-M 1992, Code for the Construction and Inspection
of Boilers and Pressure Vessels, Rexdale: Canadian Standards Association:
1992.

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Notes:

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