The Key to Boiler Efficiency: Controlling Conductivity with Surface Blowdown Systems

What is the Surface Bluffing System and Why is it Vital?

Even with proper conditioning, water used in steam boilers will begin to accumulate dissolved solids as it evaporates. This condensation increases the water's electrical conductivity , leading to critical problems.

A surface blowdown system is designed to release this high conductivity concentration in a controlled and regular manner from a point close to the boiler water level (from the surface).

⚠️ Dangers of High Conductivity Levels (Carryover Risk)

When the conductivity level in the boiler water exceeds acceptable limits, the following serious problems arise:

• Foaming: High conductivity and solid concentration cause dense foam to form on the water surface.
• Carryover: Foam and solid particles mix with the generated steam and are carried into the steam line. This damages turbine blades, control valves, and condensate traps .
• Reduced Heat Transfer: Undissolved solids adhere to the inner surface of boiler tubes, forming scale deposits that reduce heat transfer and increase fuel consumption.

Surface blowdown aims to keep the conductivity level within an acceptable range to eliminate these risks.

Energy Saving with Controlled Bluffing

The water discharged during blowdown is boiler water at high pressure and high temperature. Uncontrolled or excessive discharge of this water results in significant energy and water loss .

An ideal surface bluffing system should be designed to minimize this loss:

• Continuous Conductivity Monitoring: In modern systems, conductivity sensors continuously monitor boiler water quality and automatically adjust the blowdown amount.
• Heat Recovery: The heat from the discarded high-temperature blowdown water should be redirected to preheat the boiler feedwater using a blowdown tank and flash steam system to achieve energy recovery.

ORFA Industrial: Precise Blowdown Control Solutions

For surface blowdown to be efficient and energy-saving, the equipment used in the blowdown line must be resistant to high temperatures, high pressures, and corrosive effects, and must provide very precise control.

As ORFA Industrial Products Industry and Trade Inc., we offer the following reliable solutions for your boiler surface blowdown lines:

• High-Pressure Blow-Off Valves: Specifically designed for continuous or intermittent blow-off, these wear-resistant, long-lasting valves are ideal for continuous or intermittent blow-off applications.
• Control Valves: Control valves that integrate with signals from automatic conductivity control systems, providing fast and precise flow control .
• Steel Filters and Strainers: Protective equipment that prevents solid particles from damaging valves during blowdown.

With correctly sized and high-quality valves, you can maximize the safety and efficiency of your boiler by optimizing the blowdown rate.