Boilers have been used in various industries for many years now.

The older versions of such pieces of

equipment have been carved from wrought iron whilst the more modern versions that we see these
days are made from steel alloys or even steel. These boilers are highly important in many applications,
the most popular of which are for food preparation, steam power generation, hot water applications and
water sanitation.

Due to the many applications with which industries depend on boilers, it is imperative that careful design
of such should be brought to mind. In order to keep them safe for your particular purpose, both
temperature and pressure switches are important in its manufacture. In line with these, here are things
you should know about such switches for steam boiler applications. Particularly, at the end of this article,
you will be familiar with the proper control for temperature and pressure in the steam generation
process.

A malfunctioning high pressure switch can trigger boiler explosion

The high steam pressure switch is one that can be triggered once the steam pressure inside the boiler
reaches a high point. This will eventually trigger the vessel’s burner to discontinue firing. If the pressure
switch is not functioning accordingly, there is a great chance that the burner will continue firing. This will
then result to more problems, including the possibilities of building higher pressure on the vessel thus
causing it to explode. Choosing a pressure switch that can handle pressure levels will be suitable for
various steam conditions.

A malfunctioning high gas pressure switch can cause the boiler to overheat

There is also a high gas pressure switch in industrial boilers. This can be seen in versions of boilers that
require natural gas combustion in order to power the heat in the vessel. When such a switch in a boiler
malfunctions, there is a great chance that too much natural gas will flow into the combustor. As a result,
the burner will leak because the fuel inside it is not mixed properly. Additionally, it will also result to an
overheating boiler. Different pressure switch models are available and are best suited for boilers that
make use of natural gas.

A malfunctioning temperature switch can be too high or too low for the boiler
Oil low as well as oil high temperature switch can both cause a problem to boilers. You have to take note
that the proper temperature switch is important in order to burn oil properly. Properly burning oil can be
achieved when the oil is heated at the proper temperature. This will ensure the appropriate vaporisation
for either the air or fuel mix. A temperature switch should be able to monitor if the oil is too high or is
falling below the requirement.

Pressure and temperature switches are with no doubt crucial to the proper functioning of steam boilers
whether for steam power generation or for the various applications with which a boiler is needed.
Industries must then look for the appropriate switches for their boilers. Start by browsing through our
pages today!

Operating Control

The operating control is the main control for the boiler. This control will be set for the desired water
temperature or steam pressure of the system. In most hydronic applications, the operating control will
be set for 1800F. The industry has adopted 1800F as the official Design Water Temperature. Heating
systems and equipment were designed to operate at full capacity using 1800F water. Be careful if the
control is set for lower than 1400F as the boiler flue gases would condense. Many manufacturers will
void their warranty if the boiler water temperature is below 1400F. When the flue gases condense, acids
are released which will attack the piping, flue and chimney.

On steam systems, the operating control is typically set for 2 psi. The controls should be installed on a
siphon or pigtail. This protects the control from live steam by using a water seal.

The operating control is an automatic reset type control. That means that the control will automatically
start once the temperature or pressure drops to a predetermined temperature or pressure.

Limit Control
The limit control has the same responsibility as the operating control but with two distinct differences.
The first is the set point. The set point for the limit control is set at a higher temperature or pressure
than the operating control. The other difference is that the limit control is a manual reset control. That
means that when the temperature or pressure reaches that point, it will open and interrupt electric
service to the burner. The control will require a button to be depressed to reset the control to allow
operation again.

Many installers wonder why the limit control is a manual reset and not an automatic reset control. Well,
consider that your operating control is set at 1800Fand the limit control is set at 2100 F. If the boiler
temperature raises high enough to trip the limit control, you can be fairly sure that the operating control
is not working. The manual reset feature is designed to get someone into the boiler room to investigate.

Modulating Control

The modulating control should be set for a temperature or pressure that is slightly lower than the
operating control. For example, it may be set for 175 degrees and the operating control is set for 180 F.
When the water temperature gets to the modulating control set point or 175 as above, the burner will
drop to low fire. When the water temperature or pressure drops, the modulating control will drive the
burner to somewhere between low fire and high fire. Modulating burners are used to better track the
temperature or pressure requirements of the building. They also reduce cycling.

Low-Water Cutoff

The low water cutoff is the leading mechanical cause of boiler accidents. The low water cutoff is
mounted at an elevation that is above the lowest possible water level of the boiler. On hydronic systems,
it is common to have one installed in the piping above the boilers. If the low water cutoff is connected to
the system piping with nipples or pipes, valves cannot be installed in the piping to allow isolation of the
low water cutoff and the system.

The older type low water cutoffs used to use an internal float that would track the water level of the
boiler. Many of the newer types of low water cutoffs use a probe type sensor for the low water cutoffs.
Commercial steam boilers require two low water cutoffs. The primary low water cutoff on a commercial
steam boiler usually has two functions. It is typically referred to as a low water cutoff / pump control.
When the water level drops in the boiler, the first set of contacts will start a boiler feed pump and / or
open a feed water valve. If the water level continues to drop, the low water cutoff will interrupt the
electrical service to the burner, shutting off the burner.

If the level continues to drop inside the boiler, the auxiliary low water cutoff will trip, cutting power to
the burner. The auxiliary low water cutoff should be a manual reset style. The auxiliary low water cutoff
will be installed at a lower elevation than the primary low water cutoff.

Flow Switch

Water tube or coil type boilers that rely on flow for proper operation use a flow switch instead of a
traditional low water cutoff. Some of these boiler types may be referred to as copper finned boilers. I
prefer a low water cutoff to be installed in the system piping for these systems even though they are not
required for code compliance.

Primary Control

The primary control or flame safeguard assures that the burner operates correctly. It will typically be
installed inside the burner control panel. Many feature a manual reset switch on the control.

Gas-Pressure Switch

Some boilers require gas pressure switches to meet code compliance. The gas pressure switches are to
verify that the gas pressure is within a safe range. If the gas pressure is too low or too high, the burner
will not operate correctly. Several years ago, a main gas regulator failed in Chicago. People were
reporting five foot tall pilot flames on their stoves. The high gas pressure switch will be located on the
burner head. The low gas pressure switch will be on the gas train downstream of the gas pressure
regulator.

Boiler Pressure and temperature controls are devices that control the operating pressure and
temperature of the boiler. Steam boilers typically operate off pressure controllers and Hot water
boiler typically operate off of temperature. They both may have components that offer both.

Some of these controllers are also safety devices that make sure that you do not go above a certain set
point and will shut down your boiler/burner in cases where you exceed that set point.