Allmech improves boiler performance and reduces capital costs at Warmbaths Forever Resort
TWO coal-fired boilers sit at the heart of daily operations at the Forever Resort in Warmbaths, South Africa. As a business known for its heated pools and guest comfort, reliable boiler performance is essential. However, the resort was battling inefficiency, high coal consumption and excessive chemical use.
Inspection revealed corrosion and scaling, with boiler restoration likely to require significant capital investment. The resort then sought a second opinion from Allmech, a leading local supplier of boilers and water treatment solutions, to review the water treatment setup.
Investigating the root cause
On assessment, Allmech found that a demineralisation plant was supplying feedwater to the mid-pressure coal-fired boiler. Allmech Managing Director Lionel Maasdorp explains that highly purified water may seem like the ideal choice, however, “clean” demineralised water absorbs mineral from whatever it comes into contact with. In a carbon steel boiler system, that can accelerate corrosion in the boiler shell, tubes and condensate lines.
“Considering the water was being used for a mid-pressure coal-fired boiler, we did not agree with the demineralised water,” Maasdorp says. “Water that clean can be corrosive in the boiler and pipes.”
Low pH levels compounded the problem, particularly in the condensate lines, where oxygen-related corrosion was evident. Steam traps were clogging with rust particles. The resort was in the process of replacing some metal pipework with PVC to mitigate the effects, but when the boiler was opened it was clear that acid wash and repairs to boiler tubes were required. Forever Resorts decided to relook their system requirements and setup and asked Allmech to step in.
After analysing the incoming raw water, Allmech recommended discontinuing the demineralisation process and instead repairing and optimising the site’s softeners. This reduced unnecessary chemical expenditure and allowed for a more appropriate treatment strategy.
The team commenced treatment using Allmech A103, a blended boiler treatment designed for mid-pressure systems, which performs several functions simultaneously:
- An oxygen scavenger removes dissolved oxygen.
- A pH booster stabilises and elevates alkalinity.
- A polymer keeps suspended solids in suspension so they can be removed through controlled blowdown.
- A vapour-phase component carries over in the steam to protect condensate lines from corrosion.
At weekly check-ins, Total dissolved solids (TDS) were monitored, blowdowns adjusted, and chlorine and pH levels in the condensate were closely tracked. Over time, test results began to shift in the right direction and pH levels increased. Rust particles in the feed tank decreased, while corrosion stabilised.
Visible results
After the first year under Almech’s treatment programme, visible corrosion had already reduced. Maasdorp says some debris remained, likely originating from previously damaged condensate lines.
On recommendation from the original equipment manufacturer, another acid wash was undertaken, although Allmech did not believe this was essential.
The most recent inspection showed that the tubes were spotless. “There was only evidence of old scale that had flaked off in a hard-to-reach area. There were no signs of excessive corrosion, and the particles that had previously been present in the feed tank were no longer there,” says Maasdorp.
A clean boiler eliminates the need for further acid washing – a harsh and destructive process – thereby extending the lifespan of the asset.
Operational impact
For Jean Nel, Boiler Manager at the Forever Resort, the improvements have been significant. “The boiler was more efficient, with less coal usage,” he explains. “There was less corrosion in the boiler and less scale detected on the inner tubes from the time Allmech took over the boiler water treatment.”
Chemical efficiency has also improved and Nel believes the risks to longevity have been effectively addressed.
Maasdorp credits the site team for their role in the turnaround. “I am always proud when a client’s team works well with our staff. A good team working together helps to look after a company’s assets and livelihood by reducing unnecessary costs.”
With the right treatment strategy and disciplined monitoring, boiler water chemistry becomes an asset protection tool rather than a recurring repair risk.
For more information, visit www.allmech.co.za, Lionel Maasdorp, Managing Director, Tel: 011 849 2731, Email: lionelm@allmech.co.za
