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Low water levels in your boiler can happen for several reasons, some of which may be out of your control in some ways. Many of the common causes of low boiler water can be prevented with proper maintenance and adequate monitoring. Understanding these common causes can also help you understand how to fix and prevent low water issues:

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Boilers can fail even with LWCO systems in place, so maintaining your boiler is essential to further helping prevent damage and keeping the boiler in efficient condition. Consistent steam boiler maintenance can extend your unit’s life and keep it working effectively for a long time. Here are a few maintenance tips to keep your steam boiler in optimal condition and prevent low water damage.

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Water levels within your boiler will fluctuate as it evaporates and is refilled. When it gets low, water needs to be added to the boiler through feed pumps or similar operations, depending on the boiler. As the controls sense low water levels, the pumps will kick in and feed water into the boiler until it reaches normal levels. When these systems fail to replenish low water, you’ll be at high risk of boiler damage. Fixing and maintaining low water levels is relatively simple with the right features.

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Understanding common steam boiler issues like low water conditions can better equip you and your team to handle concerns that arise. Adequate water levels are vital to boiler operation and safety. Low water conditions in your boiler occur when it fails to replace the water as it evaporates.

Older boilers may not have a low water light — instead, your boiler may have a sight glass that allows you to see into the boiler and determine where the water level sits. The sight glass offers another way to visually gauge the water level, so check it regularly. You and your team should be familiar with what the normal water level looks like through the sight glass so it’s easy to tell when it falls.

Safety should be a top priority when working with any industrial equipment, including boilers. Since boilers involve chemicals, high temperatures, high pressure, combustion, moving parts and other safety hazards, you should use a boiler with high safety ratings. Choosing a boiler that’s been designed and built with safety standards in mind can help reduce risks while working with the boiler.

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While you should only have trained individuals monitor and service your boiler, even the most knowledgeable people can overlook potential concerns. Some modern boilers feature advanced controls and monitoring capabilities that can help you effectively monitor and address boiler issues. Boilers with monitoring and smart controls are beneficial because they can help your team catch issues that may be difficult to identify. Boiler monitoring can also send alerts when potential issues are detected, notifying you and your team before the problem escalates.

26 Sept 2012 — The fresh water feed regulator for my boiler system is stuck shut. I kept very close tabs on the water pressure all last year and will do so again this year.

Low water is especially dangerous because it creates conditions where the boiler vessel can overheat and potentially explode. Adding cool water to overheated components will create steam, which expands significantly and creates too much pressure inside the boiler, causing the vessel to burst. A boiler explosion is a risk to lives, property and operations, and will cost you and your company significant time and money to recover from. Maintaining adequate water levels in your boiler is essential to safe operations.

Some boilers have indicator lights that can visually tell you when your boiler’s water level is too low. If your boiler has a low water light, check it regularly. Make this part of your daily or pre-shift checklists to ensure your team monitors it. If you notice the light come on, you know water needs to be added to the boiler immediately.

Even with the best preventive care and maintenance, boilers don’t last forever, and a time may come when you need a replacement. Look for signs that your boiler may need to be replaced, including odd or loud noises, decreased efficiency or expensive upkeep. Whether your boiler simply aged out or there’s a sudden break, knowing when to replace it and what to consider when doing so is essential.

The repairs you’d need after low water damage can be costly, sometimes requiring a new boiler altogether. LWCOs are a simple preventive measure that can save you money in the long run.

Keep in mind that your boiler water can be contaminated with other particles like oil. High concentrations of contaminants can lead to water carrying over into the steam lines. Maintaining consistent water treatments helps prevent boiler issues related to water impurities and contaminants.

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Look for important low-water features that will help you monitor water levels. Boilers with built-in LWCOs help reduce the risks of low boiler water immediately upon installation, saving you time and resources to install them later. Many boilers also feature blowdown systems, allowing you to conveniently perform this necessary maintenance routine.

The primary purpose of water in a boiler is to protect metal components from the high temperatures produced in the unit. While metal surfaces like steel can withstand high temperatures, boiler temperatures highly exceed steel’s limits. When water levels get too low, the metal components are exposed to extreme heat, which can cause them to melt and warp. In addition to melting metal components, boiler low water conditions can also crack or loosen tubing, leading to water leaks.

When deciding whether to buy a boiler, be sure to consider price as a major deciding factor. While you may be able to cover the purchase, be sure to also consider the price of installation, maintenance and operational costs. Investing in maintenance for your boiler may be most cost-efficient than another replacement, though you should be prepared to cover those costs.

For example, consider if a boiler has any safety features or components that help reduce the likelihood or severity of common boiler issues. Some boilers won’t start if you try to bypass their built-in safety measures, reducing the risk of small issues becoming major problems. Also, consider whether certain components like tubing are designed to withstand high temperatures and pressure. Most are, though this is a necessity, so you wouldn’t want to sacrifice this.

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Like any machine, boilers require professional inspections to operate properly. While your team should conduct visual inspections daily, professional inspections should be scheduled annually. Professionals can identify weaknesses in the boiler system and areas that pose potential threats before they become major problems. Professional inspection also ensures every aspect of your boiler is inspected, even the hard-to-reach or see components.

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Renting can be a more convenient option for some facilities. Boiler rentals are ideal for emergency situations. Let’s say your primary boiler is undergoing extensive maintenance or repairs and must be shut down for a week. Rather than pause operations and lose money, you could temporarily rent a boiler to continue operations while your boiler is out of commission. Boiler rentals also offer more flexibility and lower costs, allowing you to plan for the long term and save money, all while continuing operations.

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Highly reliable pressure control technologies help you regulate and isolate your processes with certainty in natural gas and industrial applications.

Accurate control of tank pressures prevents moisture and other contaminants from entering the tank and reduces product loss and prevents toxic venting to the atmosphere. Our fit-for-purpose tank blanketing regulators can help mitigate risks associated with normal and unexpected pressure changes in storage tanks.

Purchasing a new or refurbished steam boiler may make sense for your facility if you already own a boiler or have consistently high needs for it. For example, if your production line always needs the boiler, you may be better off owning one — or multiple depending on the size of your operation.

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Whether you need a cost-effective boiler option or a temporary fix in an emergency, boilers from Smith Hughes are your most reliable option. Our comprehensive packages can include everything from installations and start-ups to boiler training and more. Our team will work closely with you to find a solution for your time and space needs. We also offer numerous boiler service packages, including 24-hour emergency boiler room services.

Timely maintenance can make a huge difference in your boiler’s performance. Create a boiler maintenance schedule and checklist to stay on track and ensure maintenance tasks are done consistently. Some tasks should be done before and after each shift — like checking water levels — while others can be done daily or weekly. Indicate which tasks should be completed and when, and keep a log that tracks completed maintenance so you know for sure when tasks were completed and what’s needed next.

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Blowdown is a process that involves emptying your boiler’s water tank and refilling it. This process helps you determine a few things, including:

You also have the option to rent or buy a replacement boiler depending on your needs and budget. Both choices have pros and cons, so weighing your options will help you make the best decision for your facility.

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A pump that's pumping the cold water out of the hot water pipes and the crossover valve at the furthest, end of the system.

Boiler water must be treated to remove minerals that can cause buildup, encourage overheating or cause other damage. For example, oxygen in the water can cause corrosion like pitting and rusting on your boiler’s metal components. As the metal corrodes, it will become weak, thin and more susceptible to breakage. Various chemicals and treatments can be added to the boiler water to remove oxygen and other elements or particles so the water has fewer impurities.

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A typical low water cutoff (LWCO) is a floating system within the boiler that rises and falls with the water levels. When the water level falls too low, LWCOs will automatically shut the boiler off to prevent damage. LWCOs are typically triggered when the water level falls within a few inches of the boiler’s tubes, as exposure can lead to several tubing issues.

Regularly scheduling professional steam boiler inspections is the best way to catch potential issues before they become major setbacks.

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LWCO systems may also use probes or a combination of floaters and probes. The probes sit in the water and shut off the boiler when the water reaches a certain level. While most boilers today come standard with LWCOs, your older boilers may not have them. In this case, you should have a professional install them for peace of mind.

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Managing low water in a steam boiler is an important element of boiler maintenance that impacts everything from safety and wear to boiler effectiveness.

Fisher and Tartarini direct and pilot-operated regulators are part of Emerson's pressure management portfolio. Explore safe and reliable innovations for compressed air, natural gas, steam, fuel, propane, specialty gases, water, hydrogen, renewable natural gas, and other process fluids.