An inability to properly manage boilers, especially neglecting water treatment can lead to extensive operational issues, including decreased efficiency, increased energy consumption, safety hazards and potential boiler failure, highlights boiler manufacturer and fluid management specialist Allmech CEO Lionel Maasdorp.

He highlights that poor boiler maintenance could result in the loss of efficiencies leading to excessive repair costs if industrial water treatment plants are improperly maintained.

In outlining the consequences of poor boiler maintenance, Maasdorp says that it could lead to a boiler explosion, which could harm civilians, in addition to destroying equipment and buildings.

Predictive maintenance, skills development and experience are outlined by Allmech as an effective way of improving boiler efficiency.

“As is the case in all industries, there are some people who have entered the boiler industry who do not have the necessary skills to give the correct advice to their clients, and this inevitably results in negative outcomes and costly fixes.”

He adds that water treatment for boilers is a specialised field, therefore, having the benefit of years of experience “always helps”. Further, if companies invest in “clean” water they need to make sure that the supplier has a good track record.

“They should also have a look at how long these companies have been in the industry and ask to speak to some of their customers with the same boiler setup,” Maasdorp explains.

Water Conductivity

Boiler water conductivity is important as it reflects the level of dissolved solids, which can impact on boiler efficiency, prevent corrosion and ensure steam quality.

Instead of relying on traditional combustion methods, electrode boilers use the conductive properties of water to create heat and generate steam, and the electric current flows through the water, causing it to heat up owing to its resistance, Maasdorp notes.

“This indicates that, when the conductivity of the water is too low, the water is very resistant and very little electricity will pass through it but if the conductivity of the water is too high then it is easy for the electricity to pass through the water, which causes electrical arcing – a continuous, luminous discharge of electric current that occurs when electrons flow between two conductors. This removes material from the boiler scrolls and the boiler shell which reduces the thickness,” Maasdorp continues.

Allmech conducts a variety of water treatment tests on the water feeding into all the boilers it manufactures to reduce the corrosiveness of the water and protect the boiler shell from scale development. This typically involves using softened water, adding scale inhibitors and chemical treatments and performing regular inspections.

Maasdorp highlights the importance of assessing the efficiency of the softener, adding that while the chemical dosing system keeps the internal components of a boiler clean, servicing boilers at a least once a year allows Allmech to thoroughly clean its boilers and maintain efficient operations.

Allmech is the exclusive South African agent for global control valve manufacturer Runxin and it tests all valves and spares on a testbench. Consequently, Allmech can also test and repair the softeners and filters that have been supplied, while testing the shell thickness of the electrode boilers that it builds, implementing repairs when needed.

The company aims to continue developing its product range to provide an increase in boiler functionality at a large scale.