In any steam generation system, the deaerator plays a vital role in protecting equipment, maximizing efficiency, and preventing costly downtime. By removing dissolved oxygen and non-condensable gases from boiler feedwater, the deaerator dramatically reduces corrosion, extends equipment life, and ensures reliable boiler operation.
Despite its importance, deaerator maintenance is often overlooked until performance problems or system failures occur. Poor venting, degraded spray valves, malfunctioning level and pressure controls, and unnoticed corrosion can quickly lead to elevated oxygen levels, reduced heat transfer, and premature equipment damage.
A well-structured maintenance program helps prevent these issues by identifying problems early, maintaining optimal performance, and ensuring safe, consistent operation. Packaged deaerator systems are made up of a wide variety of components that are crucial to proper system operation.
The professionals at BFS Industries recommend following a weekly, quarterly, and annual checklist for packaged deaerator maintenance. By following this guide, you will be able to detect potential issues before they become problems that can cause premature wear or operational issues with your steam system.
Weekly Maintenance
| Task | Description |
|---|---|
| Check operating pressures | Verify storage tank pressure, water inlet pressure, and pump discharge pressures. |
| Check operating temperatures | Confirm deaerator water temperature – temperature should match saturated steam temp +/- 1 degree based on operating pressure. |
| Inspect system for leaks | Check steam, water, and condensate piping. |
| Verify water level | Confirm normal operating range. |
| Inspect vent operation | Ensure proper venting with no blockage, and check the steam plume coming out of your vent discharge. |
| Listen for warning signals | Listen to the pumps for signs of cavitation or grinding, and signs of unwanted flashing across valves. |
| Inspect pumps | Look for vibration, and seal leakage. |
| Check control panel | Verify alarms, indicators, and normal operation. |
In addition to the above weekly maintenance, a more thorough quarterly maintenance plan should be followed as well.
Quarterly Maintenance
| Task | Description |
|---|---|
| Inspect relief valve | Check for proper relief valve operation, look for leaks, and ensure no blockages on relief valve discharge. |
| Inspect vacuum breaker | Check the vacuum breaker for leaks and ensure proper operation. |
| Blowdown tank columns | Drain stagnant water from tank columns. |
| Blowdown strainers | Blowing down strainers removes any debris that has built up in the strainer baskets. |
| Inspect steam pressure reducing valve | Ensure proper operation and no leaks/clogs in the sensing lines. |
| Oxygen testing | Use an oxygen test kit; Chemetrics #K7511 (0-20 ppb) to verify deaerator system performance. |
| Grease motors | If your motors are equipped with a Zerk fitting, grease your motors per the manufacturer’s recommendations. Motors not equipped with a Zerk fitting do not require grease. |
| Pump pressure test | Perform a pump discharge pressure test to see the maximum discharge pressure your pump can generate. Record this value and compare against future measurements. |
On an annual basis, it is important to complete a thorough inspection of the entire packaged deaerator system, including the inside of the tank. For annual maintenance, we recommend completely isolating the deaerator system, draining the system of all water and opening the tank manhole.
Annual Maintenance
| Task | Description |
|---|---|
| Internal vessel cleaning | Flush out all sediment in the storage section and follow with manual cleaning, if necessary. Make certain pump suction openings and piping are clean. |
| Spray type internal inspection | Inspect scrubber section for any corrosion. Flush out sediment through scrubber drain connection. |
| Tray type internal inspection | Check tray assemblies for structural integrity and flush any accumulated sediment. Be sure the trays are in place and securely held by the “Tray Hold Down Bar.” |
| Spray valve inspection | Visually inspect the internal spray valves to make sure they are secured in place, check for any damage to the spring or seat, and replace as necessary. |
| Pressure vessel inspection | Enter the vessel (confined space) and inspect all deaerating internals and pressure vessel for signs of corrosion. |
| Thickness testing | If corrosion of the pressure vessel is found, thickness testing may be required. Check with your local ASME inspector. |
| Replace gaskets | Replace manway gaskets after inspection, replace any other gaskets showing signs of wear. |
Recommended Spare Deaerator Parts Inventory
To minimize downtime of your package deaerator system, we recommend keeping an inventory of spare parts. The parts will be specific to the components supplied on your packaged deaerator system, but, in general, we recommend keeping the following parts on hand:
- Spray valves
- Replacement trays
- Gaskets – manway and flanges
- Steam pressure reducing valve pilot
- Tank level switch
- Pump mechanical seals
- Pressure gauge
- Thermometer
BFS Industries Can Help
A well-maintained deaerator system is essential to the reliability, efficiency, and longevity of any boiler plant. By implementing a structured preventive maintenance program, operators can significantly reduce corrosion, improve heat transfer efficiency, and minimize unplanned downtime. Routine inspections, timely cleaning, and detailed recordkeeping all play a crucial role in keeping your packaged deaerator system operating at peak performance.
Beyond protecting equipment, proactive maintenance also improves plant safety, lowers operating costs, and supports consistent steam quality. In today’s demanding operating environments, investing time and resources into regular deaerator maintenance is not just good practice — it’s a critical strategy for long-term operational success.
With the right procedures, tools, and commitment, your deaerator system can deliver reliable performance for decades to come, ensuring your boiler plant operates safely, efficiently, and without interruption. Reach out to our BFS team for more information or if you have any questions regarding your deaerator system.