BOILER CARRYOVER

Tuning the combustion on your boiler is kind of a big deal. Otherwise, it’ll end up operating outside of the
manufacturer’s target values, and that can translate to real problems. An improperly-tuned boiler generates more
carbon dioxide and soot, which can compromise performance and safety over time. But the biggest factor at stake
here is fuel use, especially if you use a lot of it. Optimizing your boiler combustion can translate to real energy
savings. And that translates to your bottom line.

WHAT IS BOILER CARRYOVER?

Boiler carryover is when something other than clean steam leaves the boiler through the header. This often
includes things like liquid, contaminants in vapor and even solids. Low pressure boilers are generally more
susceptible to carryover but high-pressure systems can have these issues as well.

WHAT CAUSES BOILER CARRYOVER?

Carryover can be caused by either mechanical or chemical means.

Types of Mechanical Carryover

1. Improper boiler construction/ design

2. High water levels
3. Surge firing, on-off firing, or on-off feedwater addition
4. Running the boiler in excess of boiler steam capacity
5. Improper blowdown

https://youtu.be/75UxpL-p8ho

info@combustiontechnology.co.za
Head Office +27 21 715 3171
www.combustiontechnology.co.za
 Types of Chemical Carryover
1. Improper chemical cleaning of new boilers
2. High solid concentration (Creates increased surface tension)
3. Organic Contaminants (Oil, grease, soap, fat, milk solids etc.)
4. High alkalinity
5. Improper water treatment

https://youtu.be/VgJH_HYlyDQ

Luckily the science behind chemical carryover is pretty simple. Surface tension of boiler water rises as the
alkalinity and conductivity or TDS increases. The higher the surface tension the more difficult it is for bubbles to
burst at the surface of the water cleanly. This is what causes small droplets, or foam, to be carried into the
header.

ISSUES WITH CARRYOVER

When water is leaving with the steam, this creates two BIG
issues. One, boiler water requirements will commonly exceed
feed pump capacity, causing water levels in the boiler to fall.
This can confuse operators because it appears like you have a
boiler feedwater pump issue. In these situations, your boiler will
generally shut down as it hits the low water cut out.
The second issue is that as that water get up into the header, it
causes water hammer. In extreme cases this causes steam pipes
to rip apart, an obvious and deadly serious safety hazard.
When carryover is mild, it can have some pretty detrimental side
effects on the system as well. As small amounts of water enter
the system, the water flashes to steam when pressure is
reduced in a regulator or control valve. This causes the dissolved
solids and chemicals in the boiler water to precipitate into the
steam piping. Eventually, this causes traps, strainers and control
valves to clog. It can also cause process steam to become
An extreme example of water hammer damage.
contaminated resulting in negative effects on product quality.

info@combustiontechnology.co.za
Head Office +27 21 715 3171
www.combustiontechnology.co.za
 HOW TO TEST FOR CARRYOVER
There are a number of ways to test for boiler carryover, including condensate conductivity testing, Alkalinity
testing, or chloride testing. Comparing boiler water conductivity to condensate conductivity is the simplest way to
gauge carry-over and where the water is going. However, this method isn’t as accurate. Chlorides testing is often
the most accurate way to determine if you have boiler carryover. This is because boiler conditions do not
chemically affected chlorides.

According to Viking Water Technology: “Chloride ions … are extremely soluble and do not precipitate or
decompose when subjected to boiler conditions. Therefore, chlorides are used as a measure of boiler water
concentrations.”

In systems that don’t have condensate returns, you can check for carryover in the main steam line drip legs. This
involves taking samples and can often be done from trap discharges or condensate receivers. From the sample
you will be able to compute your carryover percentage.

info@combustiontechnology.co.za
Head Office +27 21 715 3171
www.combustiontechnology.co.za