As one of the UK’s leading
environmental engineering and steam boiler water treatment specialists, Water Treatment Services are able to offer a full range of
expert, hands-on solutions for the maintenance, pro-active management and
optimisation of industrial boilers and steam generating systems.
Our engineering solutions
focus on the main problems affecting steam boilers which include system
scaling, corrosion and deposition, all of which can adversely affect the
reliability and performance of steam generating systems.
Our services are delivered
by experienced boiler specialists who combine the latest high performance
boiler treatment chemicals, equipment and controllers to reduce down-time,
improve performance, cost efficiencies and reliability; increase plant and
equipment lifecycles, and operational safety.
Specialist
boiler water treatment solutions
Our
specialist steam boiler management and water treatment solutions include:
·
BOILER TREATMENT & SERVICING
In-field boiler treatment, engineering support and
pro-active maintenance services to control scaling, corrosion, deposition and
sludge.
·
MONITORING & VALIDATION
Latest water analysis equipment to monitor and validate
treatment programme performance.
·
ENERGY EFFICIENCY
Expert investigation and analysis to identify process
improvement and energy efficiencies involving boilers, steam generation and
heat transfer processes.
Full
national UK coverage
With offices in London serving the South and
South East England, Manchester (North West), Birmingham (Midlands),
Bristol (South East England and Wales), Leeds (North and North East) and
Glasgow (Scotland), supported by regional teams of specially
trained engineers, in-field water treatment service specialists and technical
experts Water
Treatment Services can offer professional, cost effective
solutions for the treatment of boilers and steam generating systems across the
whole of the UK and Ireland.
Contact us today to learn
how our expert boiler treatment and engineering solutions can help you optimise
costs and operational boiler efficiencies, reduce downtime, achieve water and
energy savings, maintain steam quality, and increase plant reliability and
safety. To speak with one of our industrial water treatment experts call us
on 0330
223 31 31 or simply use this button.
Industrial
boilers & steam generating systems
Industrial
steam boilers and generating systems are an essential component in many
commercial, industrial and process applications where their primary purpose is
to transfer energy from one part of the system to another. Such systems use
water (steam) at elevated temperatures which is a highly efficient means of
energy transfer.
What
problems affect steam boilers?
If
a boiler system is poorly maintained or the water used within it is left
untreated it can lead to a number of serious issues that will affect the
integrity and performance of the boiler and steam-raising system. The problems
associated with poor boiler water treatment and system maintenance can include
scaling, corrosion and deposition.
·
SCALING
·
CORROSION
·
DEPOSITION
Such
problems can affect steam quality, reduce heat transfer efficiencies, increase
energy costs, and reduce asset reliability and life-expectancy. In the worst
cases poor boiler maintenance can also result in catastrophic system failure
which can be very hazardous.
To
combat these problems the water used in both the boiler and the wider
steam-raising system will require suitable treatment which would typically
include the boiler together with the feed-tank, feed-lines, and steam and
condensate return systems.
Optimised
boiler water treatment solutions
Successful
boiler operation requires a holistic approach to the maintenance and protection
of both the boiler and wider steam system against the detrimental effects of
scale formation, corrosion and deposition.
A
well-managed boiler water treatment programme will help to optimise costs and
operational efficiencies, reduce downtime, achieve water and energy savings,
maintain steam quality, and increase plant reliability and safety.
Our holistic approach to the successful management of boilers
and steam generating systems typically involves the following stages:
·
PRE-TREATMENT
Suitable pre-treatment of the boiler feed water, this
may include commercial water softeners and industrial reverse osmosis units.
·
PROTECTION
Protection of the boiler and steam system.
·
DEPOSIT FREE
Maintaining clean internal surfaces free from scale and
deposition using a range of techniques for the treatment of industrial boilers
and steam generators, heritage steam and marine boilers.
·
CONDENSATE RETURN
Maximise levels of condensate return.
Controlling
scale in boilers
Scale
formation on the internal surfaces of boilers and steam systems is a
significant issue. If left untreated scale can build-up on the internal
surfaces of pipework, boiler tubes and other heat transfer surfaces to act as
an insulator and reduce boiler efficiencies significantly. It can also cause
the boiler and pipework to overheat, and in extreme circumstances catastrophic
failure can result.
Boiler
scaling occurs when high temperatures reduce the solubility of calcium and
magnesium salts commonly found in the feed water allowing them to precipitate
out and on to internal surfaces.
To control boiler scale
formation it is therefore important to pre-treat the feed water, removing as
effectively as possible any hardness salts before they enter the boiler system.
This can be achieved using a commercial water softener and specialist chemical scale
inhibitors. Reverse osmosis (RO) equipment can also be
considered for the pre-treatment of the boiler feed water.
To
ensure the steam system is kept under full control at all times the quality of
the boiler water should also be tested regularly to ensure the boiler water
treatment programme is operating effectively and the correct water conditions
are being maintained.
Corrosion
control for steam boilers
The
internal environments found within boilers and steam systems be extremely
aggressive to the materials of construction and can cause a number of serious
problems. Corrosion is one such problem and if left untreated it can increase
costs, reduce asset reliability and life-expectancy, and in the worst cases it
can cause catastrophic failure. The primary causes of corrosion in boiler
systems are dissolved oxygen, acidity and excess alkalinity. The most common of
these being oxygen associated corrosion which is caused by oxygen dissolved in
the feed water entering the boiler system.
The oxygen contained in
the water acts aggressively to create localised corrosion of the internal
surfaces in the form of oxygen pitting. These corrosion pits are generally
small but can sometimes grow, resulting in deep pinholes or pittingwhich if left to penetrate boiler tubes
and other internal surfaces can affect their integrity and result in failure.
Effective
boiler water treatment should be holistic in its approach and focus on the
removal of dissolved oxygen from the feed water, whilst controlling both pH and
alkalinity levels. This can be achieved through good system design, particularly
feed-tank and condensate return arrangements) and the use of high performance
boiler treatment technologies.
Steam
condensate corrosion
Managing condensate water
quality in your steam generating system is important as if left untreated it
can cause a number of serious issues including acid and oxygen
corrosion. This can lead
to the failure of the condensate return lines and other system components.
Problems
arise in the condensate system when steam condenses. As it does so it absorbs
carbon dioxide and oxygen from the atmosphere to create corrosive water
conditions which can be detrimental to the boiler system, but particularly the
condensate return lines, threaded joints and elbow components. Oxygen corrosion
acts aggressively on the internal condensate line surfaces to create localised
pitting and potentially deeper pinholes. Pitting and pinholing can be
controlled using boiler treatment chemicals such as oxygen scavengers including
tannin, sulphite or DEHA.
The
formation of carbonic acid in the system will lead to general corrosion
throughout the boiler system and can be controlled using specialist steam
volatile boiler treatment chemicals including film forming and neutralising
amines, or by pre-treatment of the boiler water using reverse osmosis or
de-alkalisation techniques.
Blowdown
Boiler
blowdown is an important component in the successful management of any steam
generating system as it helps to remove accumulated sludge from the boiler,
control levels of both suspended and total dissolved solids (TDS) and so
maintain boiler efficiencies and overall steam purity.
It
is also important to remember that boiler blowdown, while important should only
be performed when required as it can be very energy inefficient.
Sludge deposition
The
formation of boiler sludge occurs as the concentration of suspended solids,
primarily from corrosion by-products and the deposition of solid hardness
salts, increases in the system. If left unchecked the build-up of sludge can
reduce heat transfer efficiencies and overall boiler performance.
Total dissolved
solids (TDS)
As steam is generated in
a boiler system water naturally evaporates and is lost to the atmosphere. As this
occurs the concentration of Total Dissolved Solids in the remaining boiler water
increases and can cause a number of problems including carryover and foaming.
Carryover
(see below) can cause steam contamination issues whilst foaming can reduce the
heat transfer efficiency of boiler tubes and lead to overheating and premature
failure. To prevent carryover and unwanted foaming it is therefore important to
control TDS levels in the boiler water. This can be achieved by blowdown and
the introduction of fresh, suitably pre-treated feed water.
Carryover
Carryover
occurs when boiler water in its liquid form is “carried over” in to the gaseous
steam. This can cause solids contamination of the steam and any process
products it comes in to contact with. It can also result in damage to the
boiler, steam system and other process equipment.
To
prevent carryover and unwanted foaming it is therefore important to control the
levels of contaminants in the boiler water (total dissolved solids). This can
be achieved by blowdown and the introduction of pre-treated feed water.
Boiler
water treatment training
The industrial and
process water treatment specialists at Water Treatment Services have developed
an extensive series of professional water and wastewater treatment training
courses that includes WTS 0040 “Boiler Water Treatment & Steam Generation”.
This specialist boiler treatment training course comprises an intensive one day
course designed for boiler plant operators, plant managers, maintenance and
engineering contractors, water treatment specialists and those with
responsibility for the operation and on-going maintenance of commercial and
industrial boilers and steam generating plant… training courses →
Expert
boiler water treatment services & technical support
Contact Water Treatment Services today
to discuss your steam boiler requirements. We can provide expert advice and
support regarding the maintenance, management and treatment of commercial and
industrial boilers and steam generating systems to help you optimise costs and
operational efficiencies, reduce downtime, achieve water and energy savings,
maintain steam quality, and increase plant reliability and safety.
With offices in London serving the South and
South East England, Manchester (North West), Birmingham (Midlands),
Bristol (South East England and Wales), Leeds (North and North East) and
Glasgow (Scotland), supported by regional teams of specially
trained engineers, in-field specialists and technical experts we can offer
reliable, cost effective boiler water treatment and engineering services
throughout the UK and Ireland.
Contact
us today for more information about our industry leading boiler solutions and
how they can help you.
