Knowledge Hub
TES Knowledge Base
A central reference for engineers, chemistry teams, operations staff, and station leadership evaluating the Thermal Efficiency Solution (TES) for wet-cooled units. Everything you need to understand, deploy, and verify TES performance.
New
TES Engineering Playbook
A structured, engineering-first guide covering fundamentals, readiness, troubleshooting, and compliance. Built for audit-ready evaluation.
A. TES Methodology
Baseline → Intervention → Review. Every TES deployment follows a strict, repeatable, engineering-centred process aligned with Eskom verification protocols.
Baseline (3–4 weeks)
A clean, non-intervention period that establishes how the condenser and cooling-water system currently behaves.
Required measurements:
- Cooling-water inlet & outlet temperatures
- Temperature Rise (TR)
- Terminal Temperature Difference (TTD)
- Condenser vacuum stability
- ΔT across cooling towers
- Plant load profile (min/avg/max)
- Make-up water quality
- Operating constraints & excursions
Purpose of baseline:
- • Quantify fouling as a variable, not background noise
- • Understand TR/TTD behaviour relative to load
- • Confirm operational stability before intervention
- • Build a defendable dataset for GM/engineering decision-making
Intervention (4–6 weeks)
The TES system is implemented using:
Mexel®432
(chemistry)
Thingy:91X dosing skid
(IoT)
Performance view
(cooling-water)
What happens during intervention:
- Mexel®432 forms a microscopic surface film
- Existing biofilm, suspended solids, mud/ash loosen and detach
- Tube-side heat-transfer improves
- TR and TTD begin moving toward engineering targets
- Dosing events are automatically logged for transparency
Station involvement: minimal. TES does not interfere with turbine, boiler, chemistry program or operations.
Review (2–3 weeks)
Post-intervention analysis where performance data is compared against baseline conditions at matched load and ambient temperature.
Review deliverables:
- Baseline vs intervention comparison reports
- TR/TTD improvement quantification
- Heat rate and efficiency gain calculations
- Dosing event log and chemistry compliance summary
- Recommendations for ongoing TES deployment
Success criteria:
Measurable improvement in condenser performance, validated against baseline data with full transparency of dosing events and operational conditions. All findings are audit-ready and suitable for engineering/GM review.
B. Engineer FAQ
Common technical questions regarding implementation, compatibility, and operations.
Does TES require plant shutdown for installation?
No. The dosing skid involves a simple tap-in to the cooling water inlet line. Installation can be performed while the unit is online or during a short outage. The cleaning process itself happens entirely while the unit runs.
How does it affect my existing chemistry program?
Mexel®432 is a "single-product" replacement for biocides and dispersants in the condenser circuit. You typically stop dosing your previous biocide during the TES intervention. It is compatible with most anti-scalants if required, though usually Mexel®432 replaces them.
Is it safe for condenser tube metallurgy?
Yes. Mexel®432 serves as a corrosion inhibitor by forming a molecular film on the metal surface. It is compatible with Admiralty Brass, Titanium, Stainless Steel, and Copper-Nickel alloys.
What about high-solids or high-turbidity water?
TES is designed for variable water quality. The emulsion prevents suspended solids from settling and adhering to tube walls. However, it does not dissolve large physical debris (rocks, wood); primary screening is still required.
How do we verify the results?
We use the ASME PTC 12.2 methodology. We track TTD (Terminal Temperature Difference) and condenser particulate fouling at matched loads. Success is defined by a measurable, sustained reduction in TTD toward design specifications.
Is the dosing automated?
Yes. The TES skid is IoT-enabled, controlling dosage timing and volume precisely. Dosing events are logged to the cloud for full transparency and compliance reporting.
C. Industry Standards & Compliance
The TES approach is built on rigorous engineering standards to ensure safety, verifiability, and regulatory compliance.
ASME PTC 12.2Methodology
"Steam Surface Condensers" Performance Test Code. We adhere to Section 5 for data collection and result computation, ensuring our "Lost Megawatts" calculations are engineering-grade, not estimates.
Environmental & SDSCompliance
Mexel®432 is biodegradable and non-bioaccumulating. It reduces the plant's overall chemical footprint by replacing multiple hazardous compounds (chlorine gas, acids) with a single safe emulsion. Safety Data Sheets (SDS) are available in the Resources section.
Evidence Library
Request access to our detailed compliance documentation.
- Verification Protocol (Tutuka/Kriel)
- WRC Independent Reports
- Full Toxicology Reports
- Corrosion Inhibition Studies
D. Advanced Technical Guidance
Deeper integration details for station chemists and systems engineers.
Dosing Logic
TES uses a pulsed dosing strategy (e.g., 20 mins per day) rather than continuous feed. This targets the surface interface specifically, reducing chemical usage by up to 90% compared to traditional oxidizing biocides.
IoT Integration
The Thingy:91 dosing skid operates autonomously but can integrate with plant DCS via SCADA/Modbus if required. Note: We prefer independent cloud logging for audit-trail verification.
Troubleshooting
High TTD is not always fouling. Our protocol helps distinguish between fouling, air ingress, and passing valves. The baseline phase is critical to rule out non-fouling mechanical issues before dosing begins.
Ready to explore TES for your operation?
Whether you're evaluating TES for a power station unit, industrial cooling system, or process application, we're here to answer your questions and discuss pilot readiness.