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Boiler Feed Water Tank
A boiler feed water tank plays an integral role within a steam system. Boiler feed water (a combination of return water and make-up water) is essential for efficient steam boiler operation. It must be carefully managed and controlled and of the highest quality available to ensure a long and efficient life for industrial boilers and steam distribution pipework.
Valveforce can assist with a range of services around Boiler Feed Water Tanks from design and specification, installation, repair services through to maintenance contracts for peace of mind.
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Boiler Feed Water Tank Explained
Purpose
Feedwater must be treated and heated to remove impurities and oxygen and then correctly stored in a boiler feedwater tank before use.
A boiler feedwater tank (or hotwell tank) is an essential part of the steam system, yet often one of the last items to be considered during the Energy Centre design process. However, the feed tank’s design can increase the reliability of the steam boiler and steam system significantly and lead to substantial energy and water treatment savings being made.
The feed tank is where make-up water, steam boiler condensate return and blowdown flash steam come together and are stored; and the process of heating the feedwater begins. Essentially, properly maintained feed water from a well-designed boiler feedwater tank will help to:
- minimise the content of dissolved solids
- avoid damage to the steam boiler from thermal shock, oxygen pitting and corrosion
- maintain the desired steam output of the boiler
- reduce costs on water treatment chemicals
Boiler Feedtank Services
Specification & Design
At Valveforce, we understand that the foundation of a safe, efficient, and compliant steam system begins with meticulous design and sizing. Our engineering team ensures your boiler feedtank is perfectly sized and designed to manage the incoming cold water, returning condensate streams and steam injection line. We also specify and supply your boiler feedtank peripherals and accessories.
Available in standard capacities from 1,815 to 29,040 litres (400 to 6,400 gallons), Valveforce’s steam boiler feed tank benefits from all-welded construction using 5mm thick austenitic 304L stainless-steel plate, with all wetted parts (including connection sockets and flanges, internal pipework and sparges, manhole fittings and covers) we can also construct using austenitic stainless-steel.
Valveforce can provide a turnkey solution for its boiler feed water tanks, including:
- site surveys
- bespoke feed tank design and construction
- installation
- commissioning
- servicing/maintenance contracts
Temporary feedwater tanks are available when a site or project requires a bespoke feed water solution. During the design and build process of bespoke hotwell tanks, temporary Valveforce tanks ensure process continuation and uptime.
Valveforce can reverse engineer boiler feed tanks to be fabricated on a like-for-like basis. This ensures modifications and on-site works are minimised and the project delivered as effortlessly as possible.
If you’re looking for a new or replacement boiler feedwater tank, we can work together to manage your projects. Contact Valveforce now to discuss your requirements
Installation & Commissioning
Timely Installation
After our thorough sales and design consultation, we will ensure that your custom boiler feedwater tank is installed in the ideal location for your facility. Proper placement and precise configuration of peripheral piping are essential for seamless maintenance, monitoring, and operation, maximizing uptime for your plant.
Our experts carefully size the inlet and outlet piping to minimize pressure drops and prevent erosion, incorporating isolation valves for easy and safe maintenance. We also ensure that your system is equipped with effective drainage solutions, addressing blowdown discharge and condensate formation to keep your operations running smoothly.
Safety and Compliance Assurance
At Valveforce, your safety is our highest priority. Boiler feedwater tanks play a crucial role in your boilerhouse, and we ensure they meet all relevant local legislation and industry standards, including ASME and PED in Europe, to guarantee full compliance. To enhance safety, we strategically place warning signage to keep operational and maintenance personnel informed.
For systems with deaerators, we optimise feedwater tank temperatures to 107°C, effectively minimizing dissolved oxygen content and safeguarding your boiler. Our team ensures that condensate return and steam preheat are delivered safely, reducing the risk of thermal shock and system disturbance. If your existing vessels face these challenges, we also provide sparging solutions tailored to your needs.
Advanced Control and Instrumentation
Valveforce integrates advanced level controls for condensate management, along with temperature and pressure monitoring instruments to maintain optimal operating conditions. Our systems feature interlocks and alarms, seamlessly integrating with your boiler control systems for automated operation and immediate alerting in abnormal situations.
Dedicated Maintenance and Inspection
Recognising the importance of precision in installation and the value of ongoing maintenance, Valveforce provides services that not only correct existing issues but also prevent future failures, extending the lifespan of your boiler feedtank.
Overhaul & Repair
Internal and External Corrosion
Battling the dual threats of internal and external corrosion, Valveforce can employ cutting-edge treatments and coatings to protect your feedtank from the damaging effects of dissolved gases and environmental exposure, preserving tank integrity and prolonging service life. If a short-term fix is not possible then a replacement can be arranged.
Thermal Stress
Valveforce's experts mitigate the risks of thermal stress with strategies that ensure smooth temperature transitions, preventing cracking or warping of your feedtank due to rapid temperature changes. We would also look at the system more closely to establish the root cause and avoid reoccurrence.
Contamination
Ensuring your feedwater remains pure, Valveforce's service includes comprehensive checks and repairs on water treatment systems and tank integrity to prevent contamination that could harm your boiler. This can easily go unnoticed, so there is a need to carefully monitor water quality.
Mechanical Failure
From level controls to feedwater pumps and valves, mechanical components can be susceptible to failure. Valveforce's meticulous maintenance and repair services keep these essential parts in top condition, preventing issues like overfilling or inadequate feedwater supply.
Leakage
Addressing leaks with precision and care, Valveforce identifies the root cause, whether it be corrosion, faulty welds, or physical damage in the form of pin holes and cracks, applying expert repairs or replacements to prevent water loss and protect surrounding equipment and areas.
Erosion
Erosion is usually caused by the steam injection and can be quite violent. To protect against the erosive force of steam injection, Valveforce reviews the tank design to avoid this happening.
Maintenance & Service
Preparation
Shutdown and Isolation: Ensure the boiler system is shut down and depressurised. Isolate the feed tank from the boiler and any connected systems to prevent accidental feedwater flow.
Drainage: Drain the feed tank completely to remove all water and ensure safe access to internal components.
Safety Precautions: Implement lockout/tagout (LOTO) procedures and ensure all safety protocols are followed. Provide appropriate personal protective equipment (PPE) for all personnel.
Visual and Functional Inspection
External Inspection: Inspect the exterior of the feed tank for signs of corrosion, leaks, or physical damage. Pay special attention to the tank’s surface, welds, and joints.
Internal Inspection: If possible, access the interior of the tank to inspect for corrosion, scaling, sediment build up, or any structural damage. Use appropriate lighting and inspection tools to ensure thorough coverage.
Support Structures: Check the support structures and mounting brackets for integrity and any signs of wear, corrosion, or loosening.
Cleaning
Sediment Removal: Clean out any sediment, sludge, or scale that has accumulated at the bottom of the tank. This can be done manually or using appropriate tools like high-pressure water jets or vacuum systems.
Internal Surface Cleaning: Clean the internal surfaces of the tank, removing any remaining scale or rust. If the tank is heavily corroded, consider using chemical cleaning agents following safety and environmental guidelines.
External Surface Cleaning: Clean the external surfaces to remove any dirt, rust, or contaminants that could contribute to external corrosion.
Component Inspection and Replacement
Inspection of Internal Components: Inspect all internal components, such as baffles, heating coils, and level sensors, for wear and corrosion. Replace any components that show signs of significant deterioration.
Valve and Fitting Check: Inspect all valves, fittings, and connections for leaks, corrosion, and proper operation. Replace any damaged or worn parts.
Gaskets and Seals: Check gaskets and seals on access ports, manways, and other openings. Replace any gaskets that are degraded or no longer sealing properly.
Corrosion Protection
Corrosion Assessment: Assess the level of corrosion within the tank and determine if any parts need to be repaired or replaced. If the corrosion is extensive, consider re-lining the tank or applying protective coatings.
Protective Coating Application: If required, apply a protective coating or lining to the interior surfaces of the tank to prevent future corrosion. This might involve epoxy coatings or other specialized materials suitable for feedwater tanks.
Anode Inspection and Replacement: If the tank uses sacrificial anodes for corrosion protection, inspect and replace them as necessary.
Pressure and Leak Testing
Hydrostatic Testing: Perform a hydrostatic pressure test after reassembly to check for leaks and ensure the structural integrity of the tank. This test involves filling the tank with water and pressurising it to a level above normal operating pressure.
Leak Detection: During the pressure test, carefully inspect all welds, joints, valves, and fittings for any signs of leaks or pressure loss.
Reassembly
Careful Reassembly: Reassemble any disassembled parts of the tank, ensuring that all components are correctly installed and secured. Pay attention to gasket placement and proper sealing of all access points.
Torque Specifications: Tighten all bolts and fasteners to the manufacturer’s recommended torque specifications to ensure proper sealing and structural integrity.
Final Inspection and Functional Testing
Final Visual Inspection: Conduct a thorough final inspection of the entire feed tank, both internally and externally, to ensure all work has been completed correctly and there are no remaining issues.
Functional Testing: Gradually reintroduce the tank into the system and perform functional tests. Monitor water levels, temperature, and pressure to ensure the tank is operating properly and efficiently.
Performance Verification: Verify that the tank is properly preheating the feedwater and that all associated controls and sensors are functioning correctly.
Documentation and Reporting
Service Report: Prepare a detailed service report outlining all maintenance and overhaul activities performed, including inspection findings, parts replaced, test results, and any recommendations for future maintenance.
Record Keeping: Update the maintenance records for the boiler feed tank, ensuring that all actions taken during the service are documented for future reference.
Recommissioning
System Integration: Once the feed tank has passed all tests and inspections, reintegrate it back into the boiler system. Gradually increase the load and monitor the tank and associated equipment for any issues.
Monitoring: Closely monitor the tank during the initial hours of operation post-overhaul for any signs of leaks, abnormal noises, or performance issues.
Post-Service Support
Operator Training: Provide training to the maintenance team and operators on any new components or updated procedures, ensuring they understand how to operate and maintain the feed tank properly.
Scheduled Follow-Up: Arrange for a follow-up inspection after a specified period to ensure the tank is functioning correctly and to address any potential issues that may arise.
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