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These are design issues. Sometimes you can compensate via operational control changes, other times you just have to bite the bullet and make the necessary mechanical modifications. Case in point: I had a client that used the bow thruster on a large vessel for operational steerage control. They...

Steamchick, Your suggestion of an O2 sensor in the boiler exhaust is a good one. It looks to me like Toymaker is setting up his burner control as an exclusively feed-forward algorithm. While you can do this in theory, in the real world there are just too many variables to compensate for. I...

Troll, Hot spot tube failures in a water tube boiler are rarely caused by fire side issues - rather they are overwhelmingly the result of water side issue - either scaling that inhibits heat transfer from the metal to the water, allowing the metal under the scale to overheat, or corrosion due...

I agree. In water tube boilers, the feed water is typically injected about 1/3 from the bottom of the steam drum. In fire tube boilers, the injection point is typically near the mid-drum level. To minimize thermal shock, fabricate a simple economizer tubing coil that is located in the boiler...

This information is incorrect. 1. DI water in and of itself is by definition neutral - it is neither an acid nor a base. That said, because of it's lack of ions (low ionic strength), it can be corrosive to some materials by leaching ions. It can also become very slightly acidic in some...

Did a quick look - the minimum recommended sulfite concentration in the boiler water is 20ppm. Minimum pH should never be less than 8.5, 9.0-9.5 is better.

Even in a sealed system you're probably going to have some leakage losses. The majority of potential contaminants come from the makeup water. If you're using DI water, that shouldn't be an issue, and you won't have to worry about blowdown. Na2SO3 as an oxygen scavenger is usually injected into...

Actually, pure water is neither an acid nor a base - it has a neutral pH. It also has a very low conductivity/high resistivity due to it's extremely low ionic strength. That said, it is a very good solvent. Corrosion in steam systems is mostly due to the presence of oxygen, which will react...

There are a number of things that can cause what you are experiencing. Check to make sure that both the combustion air inlet and the exhaust are clear and unobstructed. Also check the condensate drain system to make sure it is functioning correctly, as issues with condensate removal can cause...

Since he is using DDC, I'd suggest adding some type of an external watchdog timer circuit that has to be reset by the control board or it will cut the mains power. It's relay should be N.O. and can be initially energized when the system is started. I would never let the system auto-ignite - it...

In the industry we call that DDC - direct digital control.

I never believed in letting the DCS, or analog control systems for that matter, handle flame safeguard functions. We would typically use a dedicated Fireye system that interfaced with the boiler combustion control system. Once all the basic safety interlocks, pre-purge timers, main fuel valve...

It's actually not that tough - it's been done for many years in industrial boiler systems. How complex the controls have to be depends on the characteristics of the system. For base loaded systems it is relatively straightforward for both the basic control strategy, and to add feedback trim...

If you find yourself needing to restrict combustion air, the most energy efficient method (depending on blower design) is usually to damper the combustion air blower inlet, not the outlet. Water entrainment (wet stream) can be minimized a couple of ways. Most boilers are designed with a steam...

Actually, under normal circumstances, with the increase of excess air the temperature of boiler exhaust gas increases. Reducing the excess air to the minimum achievable to ensure complete combustion will reduce the exhaust gas temperature. This of course assumes that the boiler has been properly...

Yup, these are screw jacks - used for leveling.

Steamchick - re: post #25 Good info. I agree that fuel tanks can be successfully welded with proper cleaning and purging to keep vapors below the LEL. For smaller tanks, you can additionally flood the interior with N2 gas at a couple inches WC to scavenge any O2 - this also helps reduce weld...

Lloyd, I'm late to this thread - lots of good info here in the various posts. Sounds kike you have found some issues and are dealing with them. One thing you might look at is the vibration signature of the various rotating elements to help ID sources. If you know someone with a vibration...

Phosgene (COCl2) breaks down into carbon monoxide and chlorine gases, both of which are highly toxic. Section 10 of the MSDS also states: NORMALLY STABLE? (CONDITIONS TO AVOID): The product is normally stable. Avoid sources of ignition such as sparks, hot spots, welding flames and lighted...

https://refrigerants.com/wp-content/uploads/2019/12/SDS-R123.pdf see specifically sections 5, 6, 8 & 10 The flame temperature of your burner will be well above the auto ignition temperature of R123. Also R123 will decompose at temperatures above 250C, generating HCl, HF, and carbonyl halides...