WATER MANAGEMENT
develop gradually, they can significantly affect system performance over time. For estates engineers responsible for maintaining reliable steam plant, managing these risks is an important part of protecting critical infrastructure. Scale formation is one of the most common operational
challenges encountered in steam boiler systems. When water containing dissolved minerals such as calcium and magnesium carbonate is heated under pressure, these minerals can precipitate and form deposits on heat transfer surfaces. Over time, these deposits accumulate on boiler tubes and other internal surfaces. Even a thin layer of scale acts as an insulating barrier, reducing heat transfer efficiency. As a result, the boiler must burn more fuel to produce the same quantity of steam. Across large healthcare estates operating multiple boilers, this loss of efficiency can lead to significant increases in energy consumption.
Scale deposits may also create localised hot spots
Above: Scale build-up on a steam generator coil caused by poor control of solids in the feed water.
Above right: Severe pitting corrosion on a steam boiler tube caused by inadequate oxygen control.
facilities professionals. Guidance such as BG01 – Safe Operation of Steam Boilers, BG02 – Safe Operation of Hot Water Boilers, and BG04 – Boiler Water Treatment emphasises the importance of monitoring, operator competence and proactive management in maintaining safe boiler operation. While steam systems remain essential for applications such as sterilisation and humidification, many healthcare estates also rely heavily on closed-loop hot water boiler systems for heating and domestic hot water generation. Guidance such as BG02 – Guidance on the Safe
Operation of Hot Water Boilers recognises that these systems operate under different conditions from steam boilers but still require careful monitoring and competent supervision. In closed-loop systems the circulating water is retained within the system rather than discharged as steam. Because of this, maintaining stable water chemistry is essential to prevent corrosion, sludge formation, and fouling of heat exchangers, pumps, and distribution pipework. Poor water quality within closed heating systems can lead to corrosion, blocked strainers, and reduced heat transfer efficiency. Over time these issues can affect both system performance and energy consumption. For healthcare estates teams managing mixed heating infrastructure, understanding the differences between steam boiler water treatment and closed-loop system management is an important part of maintaining reliable and efficient plant operation.
Why boiler water management matters Water used in steam generation is rarely chemically pure. Natural water supplies typically contain dissolved minerals, gases, and suspended solids that influence how water behaves when heated under pressure. As water is heated within a boiler, these impurities can concentrate and interact with internal surfaces. Without effective treatment and monitoring, three common issues may develop: scale formation, corrosion, and carryover. Although these problems often, but not always,
within boiler tubes. As heat cannot dissipate effectively through the insulating scale layer, metal surfaces beneath the deposits may become overheated, potentially leading to tube distortion or failure.
Corrosion within steam systems While scale deposits are often visible during inspection, corrosion can develop more gradually and may remain undetected until damage becomes significant. Corrosion within boiler systems commonly results from dissolved gases such as oxygen or carbon dioxide and inadequate pH control. These conditions typically originate in the feedwater and can affect components throughout the boiler system. Over time, they react with metal surfaces and gradually weaken system materials. Corrosion may affect several parts of a steam system including boiler shells and tubes, feedwater pipework, condensate return systems, and steam distribution pipework. Within large hospital estates where steam networks
extend across multiple buildings, corrosion damage can lead to leaks, contamination risks, and costly repairs. Chemical treatment programmes, deaeration systems, and effective condensate management are typically used to control corrosion. Maintaining correct water chemistry through routine monitoring is therefore essential for protecting system integrity.
Maintaining reliable steam generation is not simply an engineering task – it forms part of the wider resilience of healthcare infrastructure.
44 Health Estate Journal April 2026
The importance of condensate return systems Condensate return systems play a significant role in the overall performance of steam plant. When steam transfers its heat energy to a process or heating system it condenses back into water, known as condensate. Returning this condensate to the boiler house allows both heat and treated water to be recovered. Efficient condensate recovery offers several advantages. Because condensate is already heated, returning it to the boiler reduces the amount of energy required to raise feedwater to boiling point. It also reduces the volume of fresh make-up water required, lowering the demand for chemical treatment. However, condensate systems can also present challenges. As steam condenses, carbon dioxide can dissolve into the condensate, forming carbonic acid. This can create acidic conditions within return pipework and potentially lead to corrosion if not properly controlled. Regular monitoring of condensate quality is therefore an important part of steam system management. Identifying contamination or changes in condensate chemistry early can help prevent corrosion and protect the wider system. For healthcare estates teams, maintaining effective
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