Hot Water Boiler Expansion Tanks - Boiler Expansion TanksHot Water Boiler Expansion Tanks – There are two types of expansion tanks used on hot water boiler systems. The steel expansion tank and the bladder type expansion tank. These expansion tanks are used to provide a cushion for the expansion of water when it is heated. Without this cushion of air the pressure in the boiler system would rise and exceed the setting on the pressure relief valve. This will cause the pressure relief valve to open and discharge water to relieve the pressure.

Hot Water Boiler Expansion Tanks – HVAC Hydronics

It is necessary to for an HVAC technician to understand how expansion tanks work. This understanding is important to properly troubleshoot hot water boiler problems which may occur as a result of an issue with an expansion tank. One of the first things to check on a hot water boiler system when the pressure relief valve discharges water excessively is the expansion tank.

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Hot Water Boiler Expansion Tanks – Bad Air and Hydronic Air Lock

As the loop is filled for the first time and subsequently by the make-up water feed little tiny bubbles of air enter the system. These bubbles leech out of the water as time goes on and build up in the system in places where the air is not wanted, needed, and may cause problems with flow. It can cause hydronic air lock and will prevent the flow of water throughout the loop or in specific zones. It becomes necessary to purge this air when hydronic air lock occurs to restore heat to the zones or part of the loop affected.

With proper air management and air control hydronic air lock can be eliminated or drastically minimized. Air inside of a hydronic system is necessary. However only if the air is in the expansion tank where it provides a cushion. A cushion for the water when the water is heated and expansion occurs. Depending on the type of expansion tank will depend on if the air is in contact with the water. Additionally, the type of air management controls and air elimination and minimization procedures are used to purge the bad air in unwanted places. This is to keep the bad air out of the hydronic loop. Additionally to leave the proper amount of good air in the right place in the hydronic loop.

Steel Expansion Tanks in a Hot Water Boiler System Loop – Hot Water Boiler Expansion Tanks

Steel expansion tanks still exist today although many newer hot water boiler systems use the bladder type expansion tank. In a steel expansion tank, the air and the water touch each other. While in a bladder type the air and the water are separated by a diaphragm. Liquid does not compress but air does compress so when the boiler system heats the water the water needs a cushion and the air, which can be compressed in the closed loop system, is compressed by the expansion of the heated water. The air inside the steel expansion tank acts like a spring and absorbs the extra pressure produced by heating the water in the boiler system. Water will expand and contract in the system, but not because of compression. Water expands and contracts when heated and cooled. Basic physics.

Hot Water Boiler Expansion Tanks – Ratio of Air to Water inside the Steel Expansion Tank

The ratio of water to air inside the steel expansion tank is optimal at 2/3rds water to 1/3 air. Tanks not equipped with a site glass need an Airtrol fitting. This fitting is located on the bottom of the expansion tank and has an air bleeder on the bottom of it. This fitting has a dip tube which goes approximately 2/3rd’s into the expansion tank. This allows you to adjust the level of water to the 2/3rd’s optimal level.

The expansion tank should be isolated from the hydronic loop before opening the vent on the bottom of the Airtrol expansion tank fitting. This means there should be a gate or ball valve in the pipe leaving the boiler system and running to the expansion tank. If the expansion tank is flooded with water the Airtrol fitting (sometimes referred to as a B&G Airdrop Expansion Tank Fitting) can be used to easily restore the proper air to water ratio inside the steel expansion tank after isolating the steel expansion tank from the loop.

A site glass, which some steel expansion tanks are equipped with, can also be used to set the proper ratio of air to water inside the steel expansion tank. If the steel expansion tank is neither equipped with a site glass or an Airtrol fitting filling the tank to the proper ratio is a guessing game and the proper ratio of air to water inside the steel expansion tank will probably never be achieved.

Sizing Expansion Tanks in Hot Water Boiler System Hydronic Loops

Steel Expansion Tank Above the boiler

Steel Expansion Tank Above the boiler

The ratio of air to water inside the steel expansion tank is as important as having the proper size expansion tank. The sizing of the steel expansion tank is based on the size of the hydronic loop. And hot water boiler system capacity. The sizing of the steel expansion tank in a hot water boiler system is done before installation. This is usually done by the Boiler System Designer based on calculations of the size of the hot water boiler and hydronic loop.

If the hot water boiler system ran for more than a year with no problems and suddenly a problem arises where the relief valve is venting on a regular basis it is unlikely that the steel expansion tank size is the problem.

Automatic Air Bleeders and Steel Expansion Tanks in Hot Water Boiler System Loops – Hot Water Boiler Expansion Tanks

It is not recommended that steel expansion tank hot water boiler systems have automatic air vents in the loop. However, there are many hot water boilers with steel expansion tanks that do have automatic air bleeders. These can typically be found in the system at the highest point in the loop. The piping for the makeup water on a hydronic loop equipped with a steel expansion tank should be directly below the steel expansion tank.

Ideally, the makeup water is fed into the boiler system. The tiny bubbles of air in the makeup water will rise. The air will end up in the tank rather than in the hydronic loop. This will reduce or prevent hydronic air lock. Because the air and the water inside the steel expansion tank touch, the water is apt to absorb some air when the water in the system cools. This is partly the reason why some steel expansion tanks flood with water and need to be drained. Steel expansion tanks with site glasses can easily be monitored for flooding simply by observing the site glass.

Bladder-Type Expansion Tank Sizing and Pressure Ratings – Hot Water Boiler Expansion Tanks

Unlike steel expansion tanks bladder type expansion tanks have a diaphragm which separates the water from the air. This diaphragm inside the bladder type expansion tank prevents the problems which occur with steel expansion tanks and the absorption of air into the water in the expansion in the hydronic hot water loop. The bladder type expansion tank serves the same purpose that the steel expansion does; it absorbs the extra pressure created in the hot water boiler hydronic loop when the water in the hydronic loop is heated.

It is very important in a hot water boiler loop to size the bladder tank properly. This will be based on the static pressure of hydronic loop and at the top of the hydronic loop. If an incorrect bladder expansion tank is used or the proper air pressure in the air side of the bladder expansion tank is not maintained then the relief valve will discharge intermittently.

Pressure on the air side of the bladder type expansion tank should not exceed 2 to 4 psi of the water pressure setting at the pressure reducer valve. Most residential pressure reducer valves are set for 12 psi. This pressure could be different depending on the lift or height of the riser in the boiler loop.

Expansion Tank Sizing in Hydronic Loops – Hot Water Boiler Expansion Tanks

Always follow the manufacturer’s recommendations for sizing the bladder expansion tank. Use the following formula to fill the air side of the bladder expansion tank to the required air pressure. This will be the static pressure needed to raise the water to the highest level and then add 4 P.S.I. (Fill pressure + 4 P.S.I. = air side of bladder expansion tank fill pressure). In most residential applications this will be 12 P.S.I. Note that it is important to isolate the tank. It should be isolated from the hydronic loop pressure before filling air side of bladder expansion tank with air pressure.

Bladder Expansion Tank Charging Issues in Hydronic Loops – Hot Water Boiler Expansion Tanks

An uncharged bladder expansion tank will allow cold water to enter the tank when the loop water is cold. An overcharged bladder expansion tank will not allow water, when heated in the loop and boiler, to expand into the expansion tank. If a problem exists with the pressure relief valve venting intermittently the pressure in the bladder expansion tank needs to be checked.

Always remember when checking this pressure to isolate the system from the bladder expansion tank. It is best to charge the tank when it is totally disconnected from the boiler loop altogether so hopefully the boiler installation crew added a ball or gate valve to the line coming from the boiler loop going to the bladder expansion tank.

Air Management and Air Control in Hydronic Loops – Hot Water Boiler Expansion Tanks

Bladder type expansion tanks also need good air management and air control to eliminate the air. Air migrates into the hot water boiler loop and air which is leached out of the water. An air separator is necessary along with an automatic air vent to get rid of air. The air that comes into the hydronic loop and hot water boiler system from the make-up water. Air also comes from separation through heating and cooling. With steel expansion tanks the air is diverted into the expansion tank. However, with bladder type expansion tanks the air must be eliminated and purged from the hydronic loop system.

The hot water boiler hydronic loop with a bladder type expansion tank is a completely sealed and hermetic system. So when air is introduced into the system by whatever means it must be eliminated. If not, hydronic air lock will occur in the hot water hydronic loop itself or in a branch hydronic loop. That will prevent heating. It is thereby very important to have good air management and air control. Especially in hydronic hot water boiler systems which utilize bladder type expansion tanks.

Expansion Tank Placement in Hot Water Boiler System Hydronic Loop

boiler water loopsAlong with other hot water boiler system and hydronic loop controls, the pressure in the hydronic loop must be maintained at appropriate levels or problems will occur. For better performance and for reducing the problem of air absorption into the system it is best to install the bladder expansion tank just before the suction side of the circulator pump in the supply side of the hot water boiler system hydronic loop.

Because the bladder expansion tank absorbs the extra pressure created in the hot water boiler system in a hydronic loop this is the area where no pressure change in the hot water boiler system hydronic loop occurs. This is the balance point or pressure of the hot water boiler system hydronic loop. This is where little to no pressure change is experienced in the hydronic loop. It is also best to introduce the make-up water for the hot water boiler system and hydronic loop at a point close to the bladder expansion tank.

Since the air side of the expansion tank is charged according to the fill pressure plus 4 P.S.I. Then the pressure reducing valve (PRV) is set to the same pressure as the bladder expansion tank air side pressure. Following this installation recommendation is optional. However, for best performance, pressure control, and air management in the hot water boiler system hydronic loop this installation scenario will offer the highest performance for the hot water boiler system hydronic loop.

Hot Water Boiler Expansion Tanks Additional resources: High Performance HVAC Boiler Page and High Performance HVAC Boiler Water Loops page.

You can learn more about expansions tanks and HVAC here.

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