MechChem Africa May-June 2025

⎪ PowerGen,PetroChem and Sustainable energy management ⎪ From steam to scrap – the effects of poor boiler maintenance When it comes to industrial equipment, few systems work harder than boilers. But when maintenance is overlooked – especially water treatment – the consequences can be severe. Theo Boshoff of Allmech, a South African boiler and associated water treatment specialist, explains. D uring a service trip to the Kingdom

of Saudi Arabia. Theo Boshoff, se nior boiler technician at Allmech, encountered a situation where ignoring OEM water quality recommenda tions led to the premature and costly decom missioning of a boiler. Boshoff explains that Allmech had in stalled the boiler at a facility in Saudi Arabia and was returning to undertake an inspection. “At the time of installation, our specialists emphasised the importance of maintain ing strict water quality standards, specifi cally for feedwater conductivity of between 200 µS/cm and 350 µS/cm, and boiler water conductivity of below 1 200 µS/cm,” he says. “These thresholds are critical to ensuring efficient and safe operation, particularly in electrode boilers where conductivity directly influences performance.” However, despite initial improvements made by the client to upgrade their feedwater treatment system, further deviations from these guidelines occurred. “Over time, poor quality water led to an aggressive internal environment, ultimately causing severe cor rosion to the boiler shell. The damage reached a point beyond repair, forcing the client to decommission the boiler entirely. “Ironically, the attempt to save money by delaying proper treatment ended up costing significantly more in the long run,” Boshoff says. Why conductivity matters in boilers Water conductivity is a measure of how well water carries electric current. This ability de pends on the number of dissolved ions – from salts, chlorides and sulphates, for example – in the water. These are referred to as total dis solved solids (TDS). The higher the TDS, the higher the conductivity. In electrode boilers, excessive conductivity can result in uncontrol lable current flow, posing a risk to the system and the safety of personnel. Unchecked conductivity leads to pitting corrosion and compromised structural in tegrity; increased energy consumption due to reduced efficiency; and frequent break downs and costly repairs. “As we saw in the Saudi Arabian example, high TDS damages the boiler shell,” says Boshoff. “That’s why the

When water treatment is overlooked in a boiler, the consequences can be severe.

recommended TDS levels in the Allmech elec trode boiler at any time had to be kept below 1 200 µS/cm. The recommended conductivity levels in the feed water tank must also be as low as possible to allow smooth operation of the boiler, usually within a range of 200 and 350 µS/cm.” Preventing high conductivity High conductivity is preventable through routine blowdown procedures, correct dos ing of treatment chemicals, and investment in reverse osmosis or demineralisation systems. However, many boiler operators underestimate the importance of maintain ing optimal water conditions, choosing to cut costs by skipping preventative maintenance, until it’s too late. “As we often remind our clients, a boiler is not a ‘set-and-forget’ machine,” says Boshoff. “Regular maintenance, inspections, and water testing are vital and can significantly extend the lifespan of a boiler, and ensure it continues to operate at optimal efficiency. This delivers savings on energy bills and helps to prevent costly repairs.” The most common mistakes Allmech sees boiler operators making include ignoring water quality recommendations, delaying corrective actions despite early warnings, and underestimating the long-term costs of poor maintenance. “Our advice is to stick to the OEM service

schedule, to dose feed water with the correct treatment chemicals (such as A101+), and to never skip annual inspections,” says Boshoff. “In South Africa, an inspection by an Approved Inspection Authority (AIA) is required every 36 months – something many clients overlook until it’s too late.” Regular servicing allows issues to be iden tified and addressed before they become ma jor problems, reducing the risk of unexpected breakdowns. Boshoff suggests working with a supplier who can assist with a holistic boiler maintenance solution. “At Allmech, we don’t just install boil ers. We partner with clients throughout the lifecycle of their systems,” he says. “We offer expert advice during commissioning, provide tailored water treatment solutions, conduct thorough servicing and fault-find ing, and follow up with regular check-ins to ensure ongoing efficiency. “The lessons from Saudi Arabia are clear: don’t cut corners when it comes to conductivity and boiler maintenance. In this industry, the price of neglect is always higher than the cost of prevention,” con cludes Theo Boshoff. Allmech, one of South Africa’s leading boiler manufacturers and suppliers of boiler water treatment solutions, offers a compre hensive range of electrode, gas and oil-fired boilers with water treatment to suit. www.allmech.co.za

May-June 2025 • MechChem Africa ¦ 17