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Boiler TDS Systems
Boiler TDS systems, also known as Total Dissolved Solids systems, play a crucial role in maintaining the efficiency and longevity of industrial boilers. These systems are designed to monitor and control the concentration of dissolved solids in the boiler water, ensuring that it falls within the recommended limits. By effectively managing the TDS levels, these systems help prevent scale buildup, corrosion, and foaming in the boiler, which can lead to decreased efficiency, increased fuel consumption, and even system failure. With their ability to accurately measure and regulate the TDS levels, boiler TDS systems are a vital component in ensuring optimal boiler performance and safety.
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Boiler TDS Explained
As a boiler generates steam, impurities found within the boiler feed water do not evaporate and begin to concentrate in the boiler. As the concentration of these impurities (known as dissolved solids) increases further, it begins to affect the phase-change process of water into steam by increasing the stability of the bubbles at the (boiling) water-steam interface.
Depending on a boiler’s capacity (kg/hr) and operating pressure (barg), stable steam bubbles start to accumulate in the steam space within the boiler chamber. If untreated, these bubbles are carried forward into the steam main, causing the raised steam to be exceptionally wet and contain boiler water and suspended solids. This leads to the steam main and ancillaries – such as control valves, steam traps and flowmeters – being contaminated with impurities, which consequently affect their service life.
Whilst the formation of stable steam bubbles (also known as foaming) can be caused by high levels of contaminants produced by oils and fats, the most common cause of carryover is due to increases in the Total Dissolved Solids (TDS) levels in the boiler water. Assuming other contaminant sources are properly managed, careful monitoring and control of boiler water TDS levels would ensure that the risks of foaming and carryover are minimised.
Boiler TDS Services
Specification & Design
Valveforce can supply and install the following solutions and equipment:
Complete TDS System inclusive of:
- Electric TDS Control valve with
- TDS Controller - panel mounted
- TDS Probe
- Spool piece
- Valves
- Sample cooler
Valveforce can also supply and install the control panels:
TDS Control Panels:
- With modulating controller for the TDS system
- With Blowdown timer for bottom blowdown
- Within Valveforce designed control panels
- Or incorporated within the existing boiler panel
Installation & Commissioning
Ensuring System Compatibility
Valveforce ensures that your TDS control system is fully compatible with your boiler. We carefully consider your boiler's operating pressure, temperature, and capacity to select the most suitable TDS control system, tailored to your specific needs.
Comprehensive Water Quality Analysis
Our experts conduct a thorough analysis of your feed water and boiler water, identifying the types and concentrations of dissolved solids present. This analysis allows Valveforce to set precise parameters for your TDS control system, maintaining optimal water quality and system efficiency.
Correct Sizing and Strategic Placement
Valveforce specifies and installs TDS control equipment, including sensors and blowdown valves, to match your boiler's capacity and the expected range of TDS levels.
Compliance with Safety and Regulatory Standards
Valveforce ensures that your TDS control system meets all local and international safety and environmental regulations. We consider the impact on blowdown discharge, ensuring compliance with regulatory requirements for wastewater.
Automated vs. Manual Control Options
Valveforce offers both automated and manual TDS control systems, helping you decide based on your boiler's size, complexity, and operational requirements. Automated systems provide precise control and rapid adjustment to changing conditions, enhancing overall efficiency.
BG03 CEA Guidelines
It is important that industrial steam users are in coherence with BGO3 CEA Guidelines. Feel free to contact Valveforce for advice.
Overhaul & Repair
Scaling
Unchecked TDS levels can lead to harmful scaling, insulating heat transfer surfaces and drastically reducing boiler efficiency. Valveforce employs advanced descaling techniques and TDS control strategies to prevent scaling, safeguarding against overheating and tube damage.
Corrosion
To combat the corrosive effects of certain dissolved solids, Valveforce implements targeted water treatment and control measures, protecting your boiler’s internal structures and preventing leaks or component failures.
Foaming and Priming
Excessive foaming and priming can severely impact your steam system's operation. Valveforce's solutions manage TDS levels effectively, reducing the risk of water hammer and ensuring the purity of your steam for reliable process outcomes.
Sensor and Probe Failures
Dependable monitoring is crucial for TDS control. Valveforce provides meticulous maintenance and replacement services for sensors and probes, ensuring accurate readings and system responsiveness.
Control Valve Issues
Valveforce addresses control valve malfunctions with precision repairs or replacements, maintaining critical control over TDS discharge to keep your boiler operating smoothly.
Blowdown Heat Recovery Issues
Enhancing efficiency, Valveforce troubleshoots and repairs blowdown heat recovery systems, resolving issues from scaling to blockages, and ensuring optimal heat conservation.
Electrical and Programming Faults
For automated TDS control systems, Valveforce offers expert electrical and programming diagnostics and repairs, correcting faults that could compromise system performance.
Improper Calibration
Regular, precise calibration is vital for accurate TDS control. Valveforce’s calibration services ensure your system measures and responds correctly, maintaining the ideal TDS balance for your boiler.
Maintenance and Service
Preparation
System Shutdown: Ensure the boiler is shut down safely and the TDS control system is isolated from the boiler and electrical supply. This is essential to prevent accidental activation during maintenance.
Drainage: Drain the boiler water to a safe level if necessary, depending on the type of TDS system and the scope of maintenance.
Lockout/Tagout (LOTO): Implement LOTO procedures to ensure the system cannot be re-energized during maintenance.
Visual and Functional Inspection
External Inspection: Inspect the external components of the TDS control system, including sensors, probes, control units, and wiring. Look for signs of wear, corrosion, damage, or leaks.
Control Panel Inspection: Inspect the control panel for any signs of malfunction, such as burnt-out displays, loose connections, or corrosion on terminals.
Probe and Sensor Check: Inspect the TDS probes or sensors for any physical damage, scaling, or fouling that could affect their accuracy.
Cleaning
Probe Cleaning: Clean the TDS probe(s) to remove any scale, fouling, or debris that may have accumulated. Use a soft brush or a non-abrasive cloth, and, if necessary, a mild cleaning solution recommended by the manufacturer. Avoid using harsh chemicals or abrasive materials that could damage the probe.
Sensor Calibration: After cleaning, check the calibration of the TDS sensors to ensure they are providing accurate readings. Recalibrate as necessary according to the manufacturer’s instructions.
Control Unit Cleaning: Clean the control unit, including the enclosure and terminals, to remove dust, dirt, and any other contaminants. Ensure all connections are clean and secure.
Component Inspection and Replacement
Probe and Sensor Inspection: After cleaning, inspect the probes and sensors for any signs of wear, corrosion, or damage. Replace them if they show signs of deterioration that could affect their accuracy or reliability.
Valve and Actuator Check: Inspect the blowdown valve and its actuator (if applicable) for proper operation. Check for leaks, corrosion, or wear, and replace any faulty components.
Wiring and Connections: Inspect all wiring and electrical connections for signs of wear, corrosion, or loose connections. Replace any damaged wires or connectors to ensure a reliable electrical connection.
System Calibration and Testing
Calibration: Recalibrate the TDS control system after cleaning and component replacement. Ensure that the system is correctly set to maintain the desired TDS levels in the boiler water.
Functional Testing: After calibration, conduct functional tests to verify that the system accurately monitors and controls the TDS levels. This includes simulating high and low TDS conditions and observing the system’s response.
Blowdown Testing: Test the blowdown function to ensure that the system correctly triggers the blowdown valve when TDS levels exceed the setpoint. Verify that the valve operates smoothly and that the blowdown process effectively reduces TDS levels.
Reassembly
Reassembly of Components: Reassemble any components that were disassembled during maintenance. Ensure all parts are securely fastened and properly aligned.
Wiring and Connection Check: Double-check all wiring and connections to ensure they are secure and correctly routed. Pay special attention to grounding and ensure that all safety protocols are followed.
Final Inspection and Documentation
Final Visual Inspection: Conduct a thorough final inspection of the entire TDS control system to ensure that all components are correctly assembled and functioning properly.
Documentation: Document all maintenance activities, including inspections, parts replaced, calibration settings, and test results. This documentation is essential for future reference and regulatory compliance.
Recommissioning
System Integration: Reintegrate the TDS control system into the boiler operation. Gradually bring the boiler up to operating pressure and temperature, monitoring the TDS system’s performance.
Monitoring: During initial operation, closely monitor the TDS levels and the system’s response to ensure it is functioning correctly. Check for any abnormal readings or unexpected blowdown events.
Post-Service Support
Operator Training: Provide training to operators and maintenance personnel on the updated operation and maintenance procedures for the TDS control system. Ensure they understand how to operate the system, interpret readings, and perform basic troubleshooting.
Scheduled Follow-Up: Arrange for a follow-up inspection after a specified period to ensure the TDS control system continues to operate correctly and to address any potential issues.
Regular Maintenance Plan
Routine Inspections: Establish a routine maintenance schedule for the TDS control system, including regular inspections, cleaning, and calibration checks.
Preventive Maintenance: Implement preventive maintenance strategies based on the operating conditions and history of the system to prevent issues before they lead to boiler performance problems.
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