3.1 MECHANICAL – OPERATIONAL – CHEMICAL SURVEY CONCEPT

1CONFIDENTIAL, For Nalco Employee Use Only 2006 Nalco Company

Cooling Water Application and Best Practices Guide – Book 313 (5-06)

Section 3.1

INTRODUCTION

Whether called a total system survey or a system audit, the end result should be the same.

The goals are to gain a thorough understanding of the entire cooling system from a mechanical,

operational, and chemical (MOC) point of view. Armed with this information, we can determine

where the system stresses are so that treatment programs can be optimized and we can provide

maximum value to our customers.

The goal of this Application and Best Practices Guide is to provide:

• The “how to” for auditing different types of systems and equipment

• The calculations needed to analyze the information gathered

• Troubleshooting ideas for common problems

• Analysis to determine where value can be provided

• “Adding Value” Examples

First we will look at the MOC approach for system surveys as a whole. Subsequent sections in

this Guide will cover the specifics for cooling towers, heat exchangers, chillers, condensers,

and other types of systems, such as air washers and scrubber systems. The final section provides

examples illustrating how important the entire cost picture can be in proving value.

PURPOSE

From a technical point of view, the objective of

a plant survey is to gather facts about a system

concerning the design, function, and operation

of the system. The survey data can be used to

optimize the treatment program, create a pro-

posal for a new program, troubleshoot problems,

confirm standard operating conditions, and

identify improvements that can be made. Data

collected in the survey should be compared to

design specifications to evaluate current opera-

tion vs. initial design operation. Differences can

help point to opportunities for improvements,

areas of stress in the system, or problems that

need to be solved. Key to understanding the

operation is knowing where the stress points of

the system are, so that the treatment program can

be best optimized for those stresses. Optimizing

the treatment program for the system stress

points will provide the optimum results and the

best value for that system.

There are key reasons why this important. First,

efficiency loss in any part of the system can

cause increased costs for the entire process. This

can come from lost heat transfer capability in an

exchanger or even from the cooling tower itself.

For example, an improperly maintained cooling

tower produces warmer cooling water, which

reduces the efficiency of any system. If this

system contains a chiller, the annual cost of

electricity for the chiller is a significant part of

operating costs. These costs can be 2-3% higher

for every 1°F increase in condenser water

temperature (3-4% higher for a 1°C increase).

An annual survey to identify needed mainte-

nance on the evaporative cooling equipment

prolongs the life of the tower and can result in

significant energy savings.

Another key reason for optimizing the program

for system stresses is to maximize the safety and

reliability of plant operation. The costs associ-

ated with poor plant reliability or availability can

quickly dwarf those associated with efficiency

of operation. A process shutdown resulting from

a fouled heat exchanger causes lost production

in addition to the costs of cleaning or repair.

MECHANICAL – OPERATIONAL – CHEMICAL SURVEY CONCEPT

Section 3.1

INTRODUCTION

2 CONFIDENTIAL, For Nalco Employee Use Only 2006 Nalco Company


Sometimes, a shutdown from water-related

failures can cripple an entire plant. In large,

integrated facilities, these costs can easily reach

millions of dollars. Finally, in most cases, safety,

efficiency, and reliability are inextricably linked.

The goal of a survey is to understand the system

and processes well enough to identify areas

where the cooling system program or operation

can add value to the process. That is, demon-

strate the value of the treatment program. This is

where an engineering perspective, which makes

a detailed, thorough audit of the system, comes

in handy. To understand the system, it is neces-

sary to have relevant plant information and

water treatment history. The thorough engineer

will look at the mechanical, operational, and

chemical aspects of the entire system to collect

that information. This is the MOC concept that

will be detailed in this Guide.

SURVEY PROCESS

A thorough MOC (Mechanical – Operational –

Chemical) system audit has the following

characteristics:

• Studies the system with an engineering

perspective

• Provides mechanical details about the process

and system

• Collects operating history data, including costs

of operation

• Understands the chemistry of the system

through use of the Optimizer

• Analyzes operating control using SPC

techniques

• Validates the data and especially the costs of

the cooling system operation

• Identifies the current stresses and compares

those to optimum stress conditions to create

recommendations that manage the stresses to

maximize value

There are several ways to do a survey – from a

basic checklist (easy) to a detailed MOC evalua-

tion including heat exchanger modeling and

statistical analysis. Table 3.1.1 indicates areas of

investigation in each of the MOC survey catego-

ries. Best practice calls for the survey to paint a

baseline picture of the historical operating

condition of the process, and then update with

new information as often as necessary. There are

three areas to focus our survey efforts. Since

these areas interact in predictable and unpredict-

able ways, it is our challenge to keep on top of

changes that affect the process and document

them in our survey.

M – Mechanical Tower inspection

Heat exchanger types and

orientation

Exchanger metallurgy

Exchanger design and actual

heat loads and flows

Plant diagrams

Design cooling tower

dynamics

Exchanger lifetime

(replacement or cleaning

frequency)

O – Operational Historical control data

Performance monitoring data

Coupon data

Deposit analysis

Chemical application points

Chemical feed systems

System upsets

Automation

C – Chemical Water chemistry

Scale inhibitor(s)

Corrosion inhibitor(s)

Dispersant polymer

Oxidizing biocide

Non-oxidizing biocide

Biodispersant

Table 3.1.1 – Examples of M-O-C survey areas.



Section 3.1

INTRODUCTION

Other questions to ask should include the

following:

• What products and programs are being used?

• What are the operational costs of the

program?

• Are the volumes of product being used

consistent with initial projections?

• What level of program performance is being

obtained and does it meet the customer’s

expectation?

• What are the deficiencies in the program?

• What improvements could be made?

• What new customer goals may be achieved?

When reviewing mechanical data, it is important

to look for changes, either from design or from

the previous survey. Sometimes plants have been

significantly modified over the years such that

the duty on some exchangers bears no resem-

blance to the original specifications. In this case,

the current stresses in the system may be signifi-

cantly different than design.

Both operating history and current operational

data should be collected on the system. The

operating history involves information about

problems that have occurred and can often be

collected from service reports of the sales

representative. Examples of operational prob-

lems that may occur include:

• Temporary failure of the acid feed system

• Sour leaks

• Bleach tank empty due to delayed delivery

• Fire prevention system water periodically used

for tower makeup

Operational data would include the daily water

analyses done to monitor and control the cooling

system. Examples of historical control data that

should be collected include key operating

parameters such as the following:

• pH control data

• Concentration Ratio (CR) data

• Holding Time Index (HTI) data

• Free halogen residuals

• Product residual data

Nalco’s TRASAR® monitoring data is invalu-

able. Data from performance monitoring sys-

tems, such as heat exchanger performance or

continuous corrosion monitoring equipment are

valuable. This operational data can be evaluated

to provide information on control capability

using programs like Nalco’s VANTAGE® V100.

Recent operational data on water chemistry

should be validated with a thorough analysis

of the makeup water and cooling tower water

by one of the Nalco analytical laboratories.

Remember, a given water analysis only provides

a snapshot of the conditions at that particular

point in time. For thorough analysis of stresses

due to water chemistry, programs like the

Optimizer program can be used. Water chem-

istry conditions should be studied over an

extended period of time, and a range of analyses

should be used for these programs including an

average, the high concentration, and low con-

centration conditions for the makeup water.

Logging data into VANTAGE V100 provides

easy access to average, high and low values

for every parameter.

The audit provides an opportunity to review and

update all information available, to assess the

quality of the water treatment program, and to

Section 3.1

INTRODUCTION



take appropriate actions necessary as preemptive

measure against potential problems. It also

provides an opportunity to meet with and gather

input from a variety of plant personnel, such as

shift operators, support engineers, maintenance

mangers, environmental managers, and others.

The survey should also include information on

what the customer would like to have improved.

Obviously, the customer may have specific goals

to achieve that may be different from the previ-

ous time a survey was done. An annual survey or

audit can be part of system inspections during

turnarounds, which are opportunities to perform

troubleshooting inspections.

SYSTEM STRESSES

The concept of stress analysis is important in a

complete system audit. Understanding where the

stresses are in a system is key to defining the

optimum treatment program. The stresses can be

divided into the MOC areas as follows:

Mechanical Stresses

• Conditions in heat exchangers

• Metallurgy, such as galvanic corrosion or the

effect of surface roughness on deposition

• Any part of the cooling tower that is not

functioning at its peak

• Problem areas such as dead-legs, shell side

units, high elevation exchangers, etc.

Operational Stresses

• The impact of variability of key operational

parameters

• Halogen control and resulting variability of

microbial control or influence on corrosion of

yellow metals

Chemical Stresses

• Chemical composition of makeup and recircu-

lating water

• Impact of chemical treatment programs

Mechanical Stresses

Any stress that impacts the efficiency of heat

transfer, in heat exchangers or the cooling tower,

will impact the total cost of operation (TCO) of

the system. This can be calculated in terms

of process capacity or energy costs in many

cases. Often, deposition or corrosion in heat

exchangers are caused by three main stress

factors:

1. Skin temperature

2. Water velocity

3. Heat flux

The skin temperature in a heat exchanger is the

temperature at the metal-water interface. It is a

function of the water and process temperatures

and flows. The water velocity is the speed at

which the water passes over the exchanger

surfaces. It is determined by the amount of

water flowing through the exchanger and the

cross sectional area available for water flow in

the exchanger. The heat flux is the amount of

heat passing through the tubes per unit area and

unit time.

Higher stress conditions are caused by higher

heat flux and skin temperature. Conversely,

lower water velocity increases the system stress.

The box, Mechanical Stress Ranges gives ranges

for severity of these stresses. (Note these are

examples that may vary in different systems.)

The stress caused by high skin temperature, high

heat flux, and low water velocity can have a

common impact on the cooling system:

• Increase the potential for many mineral scale

deposits

• Increase the potential for fouling by suspended

solids

• Bake soft deposits into harder deposits that are

more difficult to remove



Section 3.1

INTRODUCTION

• Increase the corrosion rates

• Reduce the effectiveness of some treatment

chemicals

• Create a potential for under-deposit corrosion

mechanisms

Note that high water velocity can also be a

stress. High water velocity can cause erosion-

corrosion in soft metals like copper and copper

alloy heat exchanger tubes. This can be aggra-

vated by suspended material in the water.

A summary of the input and output of the

mechanical part of the audit process is shown in

Figure 3.1.1. This illustrates the information

used to identify the problem heat exchangers.

The stress points can be used later with the

chemical analyses to evaluate different treatment

options with the Optimizer.

Operational Stresses

Variation of operational and control parameters

also causes stress in a cooling system. This can

be caused by variation of water chemistry, the

control capability of the system, or other factors.

Three key examples of operational stresses are

as follows:

1. Variation of cycles of concentration (CR)

2. Variation of pH

3. Variation of holding time index (HTI)

MECHANICAL STRESS RANGES

SKIN TEMPERATURE

• Mild Stress < 120oF (< 50oC)

• Moderate Stress 120-140oF (50-60oC)

• High Stress 140-160oF (60-70oC)

• Severe Stress > 160oF (> 70oC)

HEAT FLUX

• Mild Stress < 2500 BTU/h•ft2

(< 7.5 kW/m2)

• Moderate Stress 2500-8000 BTU/h•ft2

(7.5-25 kW/m2)

• High Stress 8000-12500 BTU/h•ft2

(25-40 kW/m2)

• Severe Stress > 12500 BTU/h•ft2

(> 40 kW/m2)

WATER VELOCITY

• Mild Stress > 3 ft/s (> 1 m/s)

• Moderate Stress 2-3 ft/s (0.6-1 m/s)

• High Stress 1-2 ft/s (0.3-0.6 m/s)

• Severe Stress < 1 ft/s (< 0.3 m/s)

Figure 3.1.1 – Illustration of the results of

mechanical component of a system audit.

Section 3.1

INTRODUCTION



Variability of these control parameters causes

significant system stress. The severity of the

stress caused by cycles of concentration is

impacted by the type of control system for

blowdown, variability of system water leaks,

and variability of makeup water chemistry.

For pH control, the severity of stress is a func-

tion of the type of pH control system, variability

of the makeup water rate and alkalinity, and

system contamination. The variability of HTI

depends primarily on the control of cycles of

concentration.

The impact of poor control is directly evidenced

by poor results, although each control parameter

may have a different result. The box Operational

Stresses illustrates the severity of stress resulting

from different size variations for the three

control parameters mentioned above. The impact

of variation of control can be different depend-

ing on whether the variability is on the high side

of the control range vs. the low side of the

control range. Table 3.1.2 shows the impact of

variation in control on the high side and low side

of each control parameter.

OPERATIONAL STRESSES

VARIATION OF CONC. CYCLES (% of mean)

• Mild Stress < 20%

• Moderate Stress 20-50%

• High Stress 50-80%

• Severe Stress > 80%

VARIATION OF PH

• Mild Stress ± 0.1 unit

• Moderate Stress ± 0.2 units

• High Stress ± 0.4 units

• Severe Stress ± 0.6 units

VARIATION OF HOLDING TIME INDEX

• Mild Stress < 40 h

• Moderate Stress 40-100 h

• High Stress 100-200 h

• Severe Stress* > 200 h

*Very low HTI (<20 h) can also be a high or severe

stress condition. It can be difficult to control inhibitor

levels in this case and poor non-oxidizing biocide

performance can result from short contact time.

Note: these are typical stress ranges. For higher

concentration ratios or higher pH, the severity of

stress may increase with smaller variation than

indicated here.

Operational Stress Impact of Variation on High-side Impact of Variation onof Range Low-side of Range

Increases potential for scale formation Excessive water consumptionand deposition and excessive chemical costs

Increases corrosion potential onstainless steel as chloride ion increases

Variation of pH Increases potential for scale formation Increases potential for corrosionand deposition

Reduces efficiency of oxidizingbiocides, particularly chlorine

Variation of Holding Increases potential for product None, other than those related toTime Index (HTI) degradation through: low cycles of concentration

• Adsorption mechanisms• Undesirable reactions with halogens• Hydrolysis (particularly polyphosphates)• Precipitation (particularly with zinc or phosphate)

Increases potential for scale formationand deposition of suspended solids

Variation of

Concentration

Cycles (CR)

Table 3.1.2 – Impact of poor control for common cooling water parameters.



Section 3.1

INTRODUCTION

Finally, Figure 3.1.2 shows the input and output

of this phase of the audit. To illustrate this in

more detail, an example of analysis of opera-

tional control using the VANTAGE V100

program is shown in Figure 3.1.3. Here, a trend

chart for pH measurements is plotted above a

trend chart of calculated phosphate solubility.

The phosphate solubility can be determined

from the water chemistry operational data and

programs like the Optimizer. In the example in

Figure 3.1.3, the high pH spikes correlate

directly to low solubility of phosphate. This can

cause loss of corrosion inhibition and phosphate

scale. If continuous corrosion monitoring data

are available, a trend chart may show increases

in corrosion when the pH is at the low extremes

in this example. Thus, the operational phase of

the audit can directly show the results of vari-

ability of control and the control capability of

the system. This phase can be used to show the

value of automated control equipment like

TRASAR.

Figure 3.1.2 - Illustration of information and

analysis for operational phase of audit.

Figure 3.1.3 – Trend charts of operating data for pH and phosphate solubility show that phosphate

deposition can occur during high pH spikes. Potentially, increased corrosion can occur when the

phosphate levels are low.

Section 3.1

INTRODUCTION



Chemical Stresses

The chemical composition of the makeup water

and hence the recirculating water can create

stresses, in combination with heat exchanger

stresses and operational variation. The water

chemistry will directly impact the potential for

corrosion, scale formation, deposition, and

microbial growth. The stress placed on a system

by chemical factors is a function of a variety of

parameters:

• Chemical composition of the makeup water

• Operational variability, particularly of concen-

tration cycles, pH, and HTI

• Mechanical factors like skin temperature and

water velocity

• Treatment program chosen, the concentration

of actives, and dosage control

• System contamination

Modeling the water chemistry under different

conditions is necessary to determine the scaling

potential of the system. This is the value of

programs like the Optimizer. The impact of

different treatment programs on mineral

solubility can also be evaluated. The response

of different scaling potentials can be determined

as a function of pH, concentration ratio, and

temperature. This can yield the optimum operat-

ing conditions for a system, based on operating

control and mechanical stresses in the system.

An example is shown in Figure 3.1.4, where the

optimum operational window for a phosphate-

based program is illustrated by the circled area.

This shows the Saturation Index (SI) of a scale-

forming mineral as a function of pH and concen-

tration cycles. The medium gray bars in the

circled area represent a Saturation Index that can

be handled by the treatment program. The light

gray and dark gray bars show unacceptable

scaling tendency. The area with the very short

bars represents unnecessarily low pH or low

concentration cycles. The optimum window is a

balance between the maximum cycles possible

and the ability of the treatment program to

prevent deposition and corrosion.

This step should be repeated for other scale

forming minerals and over a variety of condi-

tions. Trends for the makeup water chemistry

over time are valuable inputs for this analysis.

This allows the full range of water chemistry to

be evaluated. The ion concentrations can be

varied to study typical conditions up to the

maximum concentrations that may occur. In

many cases, evaluating scaling tendency at the

mean concentrations plus 2 sigma would cover

most situations. (Note: 2 sigma equals two

standard deviations from the mean, which can be

calculated with simple statistics from a set of

data.) The inputs and output of this phase of the

audit are summarized in Figure 3.1.5.

Figure 3.1.4 – Example of the operating window

for system pH and concentration cycles based

on mineral solubility.



Section 3.1

INTRODUCTION

METHODS AND TOOLS

Inspection methods include a variety of tools

and techniques, and may be slightly different for

different parts of the cooling system. A variety

of spreadsheets are available for collecting the

information during an audit. Rather than recom-

mending a given spreadsheet or survey form,

this manual will include checklists to illustrate

the types of information that should be collected.

A complete survey will include photographs of

various parts of the system as well as samples

taken for analysis.

Diagnostic TRASAR can provide useful tech-

niques for accurately determining a variety of

system parameters. Most of those techniques

will be mentioned where they are applicable.

The details of how to perform the diagnostic

TRASAR techniques will be covered in the

specific section devoted to them.

The VANTAGE V100 program can be a useful

means for analyzing control data from the

system. This program allows the input of

operating data collected over time and entered

into an Excel spreadsheet. The data are evalu-

ated using SPC techniques to show the control

capability of the system.

A variety of other tools are available to help

collect system data and evaluate the perfor-

mance of the system. These include sling

psychrometers, infrared temperature guns,

ultrasonic flow meters, and vibration analyzers.

VALIDATION

It is valuable to perform a survey with plant

personnel to ensure that you are collecting the

appropriate information. Due to the time com-

mitment, your customer may not be able to

participate with you all of the time. However,

you should still validate the data that you have

collected with them to ensure that the informa-

tion is correct. This is especially important with

any cost related information to ensure that

subsequent value calculations are accurate and

agreed upon by the customer. Verification of the

information gathered in the audit is essential.

ANALYSIS AND CALCULATIONS –

STRESS MANAGEMENT

Analysis of the information collected can be as

extensive as collection of the information itself,

and is an essential part of a survey or an audit.

Aspects of this analysis were discussed in the

section on System Stresses earlier in this chap-

ter. Taking this a step further, the analysis can

also be viewed in MOC terms as identification

of the stresses in each area, analysis of the

impact to the operating cost, and managing the

system at the optimum points for stress and cost.

This is shown conceptually in Figure 3.1.6.

Assessment of the impact of various stresses

involves understanding the costs of different

operating modes. These stresses on a cooling

system are very system specific. Consequently,

to be able to demonstrate the value of stress

management, identification of the stresses with

greatest impact on cooling system performance

is essential. The next step is to understand the

extent to which these key stresses impact on the

Figure 3.1.5 – Schematic illustration of input

and output of chemical phase of a survey.

Section 3.1

INTRODUCTION



total cost of operation (TCO). By understanding

the total costs of the cooling system operation

and treatment, one is best able to determine the

return on investment (ROI).

The categorization of stresses shown in Figure

3.1.7 was designed to help facilitate this process.

Potential MOC-related stresses are listed and

assigned a mild, moderate, high, or severe rating

to quantify the impact of each stress. Then, a

rating of how each stress could impact the TCO

is assigned, for a given facility. The example

shown in Figure 3.1.7 is from an electric power

facility. In this case, mechanical stresses are

moderate, with a low impact on costs, because

the main condenser has tube-side water, high

water velocity, and alloyed tubes. However,

microbial fouling could be a high stress with a

moderate impact on costs, due to the impact of

microbial films on heat transfer. The characteris-

tics of each stress and its potential impact on

costs must be determined for each individual

cooling system. The ratings of stresses could be

extremely different in a refinery with mild steel

exchangers and shell-side water.

Having all the stress-related information in one

place should help highlight potential interrela-

tionships between the stresses, making it less

likely that any are overlooked when designing a

stress management strategy. This method also

assists in prioritizing the emphasis of the stress

management strategy by starting with the severe

stresses and working backwards. Better identifi-

cation of stresses in relation to total cost of

operation will better demonstrate the value of

stress management. This is an essential compo-

nent of the MOC approach.

Mechanical aspects of the cost impact

analysis would include some of the following

parameters:

• Establishing the frequency and cost of heat

exchanger cleaning

• Estimating the cost of lost heat transfer

efficiency due to operating beyond stress

points

• Estimating the cost of corrosion

• Establishing the system maintenance costs

Figure 3.1.6 – Representation of audit steps in terms of stress identification

and analysis.



Section 3.1

INTRODUCTION

Operational and chemical cost impact analysis is

sometimes best done together. That is because

the operational variations often impact the

chemical limits of solubility or the limits of

program performance. It is then a stepwise

process to determine the operational cost based

on chemical and operational factors shown as

follows:

Determine the limiting factor for cooling system

operation, such as:

• Calcium phosphate scaling potential

• Calcium carbonate scaling potential

• Chloride or conductivity – impact on

corrosion

• Capability for pH control – limiting variability

• Capability for control of concentration

ratio (CR)

Determine the highest concentration cycles (CR)

which will accommodate the following:

• Impact of makeup water variability on the

limiting factor

• Impact of pH variability on the limiting

factor

• Impact of CR variability on the limiting

factor

• Impact of treatment dosage variability on

the limiting factor

Determine the total operational cost at this CR:

• Makeup and blowdown costs (water,

treatment, pumping)

• Chemical treatment cost (products, acid,

chlorine)

• Maintenance or mechanical costs (cleaning,

monitoring, etc.)

• Process related costs

• Other system specific costs

Figure 3.1.7 – Example of how stresses can be categorized based on impact to the system and

impact to total operating cost for an electric utility cooling system. Each system will have a different

categorization that must be determined by evaluation of the stresses.

Section 3.1

INTRODUCTION



The final result is a treatment program that best

manages the stresses in the system at an opti-

mum cost (Figure 3.1.8). This is the result of

understanding the mechanical, operational, and

chemical stresses, as a function of operational

factors. The cost of operating well below stress

points is generally excessive water and chemical

cost. The cost of operating above stress points is

poor heat transfer, corrosion, and cleaning costs.

The optimum value is provided by operating at

the optimum level of system stress that can be

handled by the treatment program. Consistently

maintaining this optimum efficiency, reliability,

and safety requires understanding which param-

eters have the most impact and variability; then

modifying conditions based on this variability.

Programs like the Optimizer can help to do this.

FREQUENCY

A plant survey should not be a onetime

opportunity to investigate the cooling system

and evaluate the treatment effectiveness. The

survey or audit should be done periodically to

ensure that value is maintained. Normally, a

survey is done in order to make a proposal for

competitive business. However, it is valuable to

survey a cooling system on an annual basis to

ensure that the treatment program offers the best

possible approach to providing value at a given

site. An annual survey can also help to identify

new problems or changes that have occurred

since the last survey, or any potential new value-

adding opportunities. In the event that nothing

has changed, your customer gains reassurance

that current operation provides the best value for

their situation. A report of survey results can be

part of an annual business review and help to

understand what new goals the customer may

have for system operation.

The reality of cooling system operation is that

plant practices may change from time to time.

Production processes may be adjusted for

different feedstocks or different energy prices.

This can have an impact on cooling system

operation. If personnel operating the plant

change, the new people can have different goals

for the operating efficiency of a cooling system.

Therefore, an audit should not be thought of as a

quick check of current understanding, but it

should be a thorough audit to understand what is

new and what has changed.

Figure 3.1.8 – The optimum TCO is a balance

between stresses that are too high and too low.



Section 3.1

INTRODUCTION

SUMMARY

An audit or complete system survey is essential

to understand the total operation and the cost

impact of a cooling system on the process that it

serves. The concepts presented in this introduc-

tion can be summarized in a pyramid that has

ROI or Added Value at the pinnacle (Figure

3.1.9). The foundation is the use of MOC

concepts to gain understanding of the system,

and relate it to the total cost of operation (TCO).

The customer goals, opportunities for improve-

ment in system operation, and anything that

currently dissatisfies the customer can provide

direction for selecting a treatment approach.

Understanding the stresses in the system, and

how treatment programs interact with those

stresses, is essential to optimizing the total cost

of operation. These costs can be challenging to

uncover since they include much more than just

the treatment costs. Understanding the impact on

production costs, system maintenance, or utility

costs can truly show where value can be gained.

Better stress identification and relating these

stresses to TCO will lead to greater demonstra-

tion of value.

The MOC concepts provide a complete frame-

work to gather and analyze the information

needed to reach the top of the pyramid. This

manual will provide methods to survey different

types of systems and calculate the value, and

hence ROI, that an optimized program can

provide.

Figure 3.1.9 – Illustration of the steps and results of a complete MOC survey.

ROI,AddedValue

PAYOFF

Understand andoptimize stresses and TCO

IMPLICATIONS

Customer goals, opportunities andcurrent dissatisfaction

PROBLEMS

Discovering facts about the system and operation –MOC Survey Concepts

SITUATION

Section 3.1

INTRODUCTION



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