CoolingTowerTrainingFeb09
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Transcript CoolingTowerTrainingFeb09
Investment vs Operating cost
• The average 800,000 ft² Property has
•
•
$24,000,000.00 replaceable physical plant. The
cost of water treatment is $0.02 - $0.04/ ft² to
protect this investment.
The industrial market costs are higher. A
200,000 square foot plant may have roughly
$100,000,000 in replaceable physical plant.
Water treatment cost may be in the vicinity of
$0.10-$0.20 / ft²
The owner loses $6 million per year (at 6% cost
of money) for every year of lost life as a result
of poor water treatment.
Who is in charge of your
Investment ???
• The Treatment Supplier tells you what
your problems are.
• Then they tell you what chemicals to use.
• Then they tell you how much they will
cost.
• Then they tell you when it is working.
• You know when its not working when
something fails.
Why treat the water?
Corrosion
Scaling
Deposition
Microbiological
Cooling Tower
50
100
200
250
300
400
500
600
700
750
800
1000
1250
1500
2000
2
1.5
3
6
7.5
9
12
15
18
21
22.5
24
30
37.5
45
60
3
0.75
1.5
3
3.75
4.5
6
7.5
9
10.5
11.25
12
15
18.75
22.5
30
Tons [Enter]:
Old Cycles [Enter]:
New Cycles [Enter]:
Savings (Gal./Day):
Savings (Gal./Year):
Cycles of Concentration
4
5
6
0.5
0.37
0.3
1
0.75
0.6
2
1.5
1.2
2.5
1.87
1.5
3
2.25
1.8
4
3
2.4
5
3.75
3
6
4.5
3.6
7
5.25
4.2
7.5
5.62
4.5
8
6
4.8
10
7.5
6
12.5
9.37
7.5
15
11.25
9
20
15
12
2000
4
8
16,560
6,044,400
Bleed Rt.
20
8.5
7
0.25
0.5
1
1.25
1.5
2
2.5
3
3.5
3.75
4
5
6.25
7.5
10
Gal./Day
28,800
12,240
8
0.21
0.425
0.85
1.06
1.27
1.7
2.12
2.55
2.97
3.19
3.4
4.25
5.31
6.37
8.5
Bleed Rate (Gal./min.)
Tower Tonnage
Water Savings Based on Tower Tonnage and Cycles of Concentration
Gal./Year
10,512,000
4,467,600
Economics
• General cooling economics
• Effect of scale, deposits, and Bio on
efficiency and heat transfer
POTENTIAL LOSSES
• Biofouled Condenser Tubes – 10%
• Scaled Condenser Tubes – 15%
• Scaled Boiler Tubes – 8-16%
• Equipment Losses - $ millions
• Piping Losses - $ millions
• Downtime - $ priceless
What you are Buying?
Service (70% cost of your program)
Chemicals (Only 20-30% Cost of program)
Intent
What you should Expect.
• Service Defined
• Visits
• Testing
• Recordkeeping
• Inspections
• Qualifications
• Additional Services
CORROSION CONTROL
Tower Corrosion Inhibitors
• Mild Steel
– Phosphates
• Phosphonates
• Polyphosphates
• Ortho-phosphates
– Molybdenum
– Zinc
– Silicates
– Others
– Blends
• Copper
–
–
–
–
–
Tolytriazole
BT
MBT
HRA
Others?
Closed Loop Corrosion Inhibitors
• Mild Steel
–
–
–
–
–
Molybdenum
Nitrite
Silicates
Others
Blends
• Copper
– Tolytriazole
Corrosion Control.
Corrosion Rates
Less than 1.0 mils/yr for steel and less than
0.1 mils/yr. for copper.
Less than 0.5 mils/yr. for steel and less than
0.1 mils/yr. for copper.
PHOTO MICROSCOPY REPORT
120 DAYS MILD STEEL
CHILLER 102 CW
0.62 MILS/Y
DATE INSTALLED:
6/15/98
DATE REMOVED:
10/12/98
120 DAYS MILD STEEL
CHILLER 102 COND
1.38 MILS/Y
DATE INSTALLED:
6/15/98
DATE REMOVED:
10/12/98
120 DAYS MILD STEEL
CHILLER 103 CW
0.64 MILS/Y
DATE INSTALLED:
6/15/98
DATE REMOVED:
10/12/98
120 DAYS MILD STEEL
CHILLER 103 COND
1.53 MILS/Y
DATE INSTALLED:
6/15/98
DATE REMOVED:
10/12/98
DEPOSITION CONTROL
Deposition Control.
• What is deposition.
• Control with cycles.
• Control with polymeric dispersants.
–
–
–
–
–
Polyacrylates
Sulfonated Copolymers.
Copolymers
Terpolymers
Quad Polymers
• Filtration
Microbiological Control
Microbiological Control
• Aerobic Bacteria
– slime
• Anaerobic Bacteria
– SRB, IRB
• Algae
• Legionella Bacteria
– 7 different sero groups
• Dual Alternating Biocide Program
Types of Biocides
• Oxidizing
– Chlorine
• Sodium Hypochlorite
– Bromine
• Liquid Bromine
• Sodium Bromide
– Bromine/Chlorine
Donors (solids)
• Hydantoin, Others
• Ozone, chlorine dioxide,
chlorine gas
• Non-oxidizing
–
–
–
–
–
–
Glutaraldehyde
Isothiazolone
DBNPA
Ethylene Chloride
Carbamates
Quaternary
Ammonium
Compounds
Field Testing
Bacteria Performance
• Aerobic Bacteria should at or less than
10,000 cells/ml in open condenser water
systems
• Bacteria should be at or less than 1,000
cells/ml in closed loops.
• Anaerobic Bacteria at or below 50 cells/ml
SCALE CONTROL
Scale Inhibitors and Control
• REALLY DEPENDING ON THE HARDNESS +
•
ALKALINITY TO PROVIDE THE MILD STEEL
CORROSION CONTROL.
YOU WORK ON DEPOSITON CONTROL.
• Phosphonates
– HEDP
– PBTC
• Carboxylic Acid
Industry Changes
• Companies/People
• Tubes
• Environmental
• Service Industry
ENHANCED TUBES
What you should know about enhanced
tubes and package units?
• They need flow to be protected.
• They need the correct biocide program.
• They need adequate copper protection.
• They need proper brushing.
• They need to be inspected with proper
equipment.
• They need to be eddy current tested.
Underdeposit Corrosion
ENHANCED TUBE BRUSHES
Rat Race System
Cleaning
• New Systems
– Proper Cleaning
– White Rust
– Filters
– First Year Chiller Maintenance
• Eddy current
• Corrosion
• Inspections
White Rust
“GREEN TALKING POINTS”
Water Based Systems
Water Conservation
Energy Conservation
Environmental Impact
Natural Resource Stewardship
Human Impact
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