My day job is a controls tech working on commercial HVAC systems. I've got an issue with a some steam humidification boilers. The boilers are Fulton 40hp steam boilers (I think around 1200lb/hr), running at 11psi, they have a 5:1 turn down ratio. They serve several large air handlers for humidification. The issue I've observed is that at high fire with the humidifier valves open past 70% the steam quality seems to suffer. I observe a lot of water pouring out of the remote traps to drain, and my steam meter (I think it's a vortex) reading goes crazy. The remote condensate goes to drain (there is some tempering valves to add cold water).
The feed water has multiple softeners and de-alkalizers, and some sort of water treatment chemical systems. The boiler manufacture rep and the water quality rep both say everything looks good as far they are concerned.
If I run both boiler simultaneously and limit the valve position to 70% the problem goes away. Since this is commercial steam at 11psi the best practices might be a bit different, but I wondered if any could comment on any red flags they see in the pictures. I could go back and talk to the mechanical contractor.
Two things I wonder about. 1. There is some sort of swing valve above each boiler (is it some sort of check valve?), is this ok and necessary? 2. The steam outlet goes up from each boiler, over to the left and down to a header. The two big pipes to the right on the header are the inlets from the boilers, the pipes to the left are takeoffs to feed the humidifiers. My concern is the condensate outlet (bottom right). It appears to go thru a trap, and then up and then into the feedwater tank. Is it ok to push the condensate up like this?