COOLING SYSTEMS WATER TREATMENT TRAINING

A and W TECHNOLOGIES

COOLING SYSTEMSCOOLING SYSTEMS

WATER TREATMENTWATER TREATMENTTRAININGTRAINING

Presented byPresented by

Plant Refrigeration CostsPlant Refrigeration Costs

59%

20%

13%

5%2%

1%

Electricity

EquipmentDepreciation

Labor

Makeup Cost

Sewer Cost

Water Treatment

NUMBER 1 PRIORITYNUMBER 1 PRIORITY

SAFETYSAFETYTHINK

COOLING WATER COOLING WATER IMPURITIESIMPURITIES

TYPICAL IMPURITIESTYPICAL IMPURITIES– IonsIons

Calcium, Magnesium, Sulfate, Silica, chloridesCalcium, Magnesium, Sulfate, Silica, chlorides

All can react to form harmful depositsAll can react to form harmful deposits

– pHpH

Increasing pH - increased scale potentialIncreasing pH - increased scale potential

Decreasing pH - increased corrosion potential Decreasing pH - increased corrosion potential

COOLING WATER COOLING WATER IMPURITIESIMPURITIES

CharacteristicsCharacteristics City WaterCity Water WellWell

– pHpH 7.27.2 7.37.3

– M alkalinityM alkalinity 0 ppm0 ppm 7171

– ChoridesChorides 12 ppm12 ppm 2.32.3

– HardnessHardness 17 ppm17 ppm 6868

– SilicaSilica 4.2 ppm4.2 ppm 2323

– IronIron .05 to .5 ppm.05 to .5 ppm .5.5

– ConductivityConductivity 60 mmhos60 mmhos 160 - 185160 - 185

– CopperCopper .1 ppm.1 ppm .1.1

EVAPORATION

MAKEUP water meter WELL & CITY

Recirculation pumps

Blowdown line to drain

Solenoid valve

3 Chillers

FORCED DRAFT TOWERCondenser Water

FANHOT WELL

Fill

COLD WELL

Forced Draft TowerA and W TECHNOLOGIES

MAKEUP

Water Meter

PROCESS74*F 90*F

Blowdown

NATURAL DRAFT TOWERNATURAL DRAFT TOWER

500’

500,000 GPM10* F Delta T - ApproachPower Generating Station

Evaporative Condensor

Makeup waterTo chemical feed center

Chillwaterin the tubesor ammonia

Water distribution

Heywhat the

heck is that?

?

Evaporati

on

Recirculation pump

•BAC Evaporative condensor Chicken plants and food manufacturers

COOLING WATERCOOLING WATER

OPERATIONAL FACTORSOPERATIONAL FACTORS– Evaporation Evaporation = (Recirc. Rate x Delta T x .001) = GPM= (Recirc. Rate x Delta T x .001) = GPM

Pure water leavesPure water leaves

Solids concentrateSolids concentrate

Requires fresh water makeup to be addedRequires fresh water makeup to be added

– BlowdownBlowdown *Makeup = *Makeup =

Equal to Equal to Evaporation Evaporation Evap + BDEvap + BD Cycles - 1Cycles - 1

– CyclesCycles Equal to Equal to Conductivity in TowerConductivity in Tower

Conductivity in MakeupConductivity in Makeup

Typical SpecificationsTypical Specifications

EvaporationEvaporation» 5000 x 10 x 70% x 24 x .06 = 5000 x 10 x 70% x 24 x .06 = 50,400 GPD50,400 GPD

BlowdownBlowdown» 50,400 / 5-1 = 50,400 / 5-1 = 12,600 GPD 12,600 GPD

Makeup = Evap + BDMakeup = Evap + BD» 50,400 + 12,600=50,400 + 12,600= 63,000 GPD 63,000 GPD

Typical SpecificationsTypical Specifications

Evaporation CreditsEvaporation Credits» 4220 x 10 x 60% x 24 x .06 = 4220 x 10 x 60% x 24 x .06 = 36,461 GPD36,461 GPD

At 365 days per year this is 13,308,265 GPYAt 365 days per year this is 13,308,265 GPY

Sewer charge is $2.75 per 1000 gallonsSewer charge is $2.75 per 1000 gallons

13,308,265/1000 = 13,308 x $2.75 = 13,308,265/1000 = 13,308 x $2.75 = $36,597$36,597

Optimizing CyclesOptimizing Cycles

0

5

10

15

20

25

30

35

40

1 2 3 4 5 6 7Cycles

To

wer

Blo

wd

ow

n

Saves WaterSaves Water

0

5

10

15

20

25

30

35

40

1 2 3 4 5 6 7Cycles

To

wer

Blo

wd

ow

n

COOLING WATER COOLING WATER PROBLEMSPROBLEMS

CORROSIONCORROSION– Tendency for metal to revert to its Tendency for metal to revert to its

natural statenatural state– Electrochemical reactionElectrochemical reaction– Anode, cathode, source of electron Anode, cathode, source of electron

flow and an electrolyteflow and an electrolyte– General thinning and/or pittingGeneral thinning and/or pitting– Galvanic corrosionGalvanic corrosion

One end of the “battery”One end of the “battery”

AnodeAnodeFeFe++++

ee- - ee- - ee- - ee- - ee--

Fe = FeFe = Fe++++ + 2e + 2e--

At the Anode

At the Cathode At the Cathode The other end completes the circuit!The other end completes the circuit!

CathodeCathode

OHOH-- OO22

11//22OO22 + H + H22O + 2eO + 2e-- = 2OH = 2OH--

HH22OO

ee- - ee- - ee- - ee- - ee--

Fe(OH)Fe(OH)22

AnodeAnode

Result:Result:Corrosion Products FormCorrosion Products Form

OHOH--FeFe++++

OHOH--

CathodeCathode

FeFe++++ + 2OH + 2OH- - = Fe(OH) = Fe(OH)22

Fe(OH)Fe(OH)22

AnodeAnode

COOLING WATER COOLING WATER TREATMENTTREATMENT

CORROSION CONTROLCORROSION CONTROL– Without it....Without it....

Destruction of equipmentDestruction of equipment

Plant downtime due to Plant downtime due to equipment failureequipment failure

Decreased efficiency / decreased Decreased efficiency / decreased heat heat transfertransfer


CORROSION CONTROLCORROSION CONTROL– Anodic inhibitorsAnodic inhibitors– Cathodic inhibitorsCathodic inhibitors

Continuous feed must be maintained to Continuous feed must be maintained to keep the protective film in place !!keep the protective film in place !!

Control of blowdown / pH critical to Control of blowdown / pH critical to success!!success!!

A and WA and WCooling Cooling ProductsProducts

A and W TechnologiesA and W Technologies

Three-Part Corrosion ProtectionThree-Part Corrosion Protection Deposit ProtectionDeposit Protection Molybdate TracerMolybdate Tracer Medium to High pHMedium to High pH

A and W InhibitorsA and W Inhibitors. . .. . . Passivates Anodic SitesPassivates Anodic Sites

Protects Cathodic SitesProtects Cathodic Sites

Shields Copper SurfacesShields Copper Surfaces

Reliable Corrosion ProtectionReliable Corrosion Protection

A and WA and WTo ProtectTo Protect

and to Serveand to Serve

1. Anodic Protection1. Anodic Protection

A and W Inhibitors Passivate the SteelA and W Inhibitors Passivate the Steel

------------------------ -iron oxide-----------------------

OO22

OO22

ee-- ee--

With A and W . . .With A and W . . .


SCALESCALE– Crystalline structureCrystalline structure– Combinations of cations and anionsCombinations of cations and anions– Water analysis can provide scaling indices Water analysis can provide scaling indices

to determine scale forming potentialto determine scale forming potential– Inversely solubleInversely soluble

» As temperature increases solubility decreases As temperature increases solubility decreases (scale can come out of solution)(scale can come out of solution)


FOULINGFOULING– Accumulation of organic / inorganic materialAccumulation of organic / inorganic material– Examples:Examples:

Biological slimesBiological slimes

AlgaeAlgae

Corrosion productsCorrosion products

Airborne dirt and debrisAirborne dirt and debris– Subject to flow velocitiesSubject to flow velocities– Organic fouling can be found throughout Organic fouling can be found throughout

A and W Inhibitors . . .A and W Inhibitors . . .Technology

Suspends Contaminants

A and W Inhibitors . . .A and W Inhibitors . . .

Patented TechnologySuspends Contaminants

Inhibits Scale Formation



Allows High Cycles




Allows High Cycles

Maintains Heat Transfer Efficiency


CHEMICAL FEEDCONDENSER WATER

CONTROLLER

A and W

3/4 INCH SCH. 80 PVC

USE SCREWED TEES AT INJECTIONSSupply line

Return to Tower

CORROSION COUPON RACK3/4 inch PVC pipe and screwed tees.Notice orientation, with flow. Can be constructed on site.*Presently No Coupon Studies!

All pumps plug into controller. Blowdown solenoid also plugs into controller. Signal from water meter back to controller if used. Power needs to be supplied to the controller. 110VAC @ 10 amps.

Awc 310 M-1015 M-1202 CL-1 & M92

AWC AWC AWC

A and W TECHNOLOGIES

AWC


BIOLOGICAL CONTROLBIOLOGICAL CONTROLCooling water systems provide an Cooling water systems provide an

excellent environment for microbio excellent environment for microbio activityactivity

Fouling and underdeposit corrosionFouling and underdeposit corrosion

Toxicant evaluations can determine the Toxicant evaluations can determine the most effective biocidemost effective biocide

BUGSALGAE


BIOLOGICAL CONTROLBIOLOGICAL CONTROL– Oxidizing biocides -Oxidizing biocides -

““BURNS THE BUGS”BURNS THE BUGS”

Chlorine, bromine, sodium hypochloriteChlorine, bromine, sodium hypochlorite

Provides quick killProvides quick kill

Fed at a rate exceeding the chlorine Fed at a rate exceeding the chlorine demand plus 0.5 to 1 ppm free demand plus 0.5 to 1 ppm free

chlorine chlorine residual for one to four residual for one to four hourshours


BIOLOGICAL CONTROLBIOLOGICAL CONTROL– Nonoxidizing biocides – Nonoxidizing biocides –

““POISONS OR STARVES ‘EM”POISONS OR STARVES ‘EM”

Used where chlorine demand is high Used where chlorine demand is high or...or...

Supplemental biocide for chlorineSupplemental biocide for chlorine

Remain in the system longer than Remain in the system longer than oxidizing biocidesoxidizing biocides

Provides longer contact time for killProvides longer contact time for kill

TESTING AND CONTROLTESTING AND CONTROL

SYSTEM TESTSSYSTEM TESTS– Conductivity (All systems)Conductivity (All systems)– pH (City, Tower, All closed loops)pH (City, Tower, All closed loops)– Molybdenum (Tower, All closed loops) Molybdenum (Tower, All closed loops) – Cycles (Tower)Cycles (Tower)– Microbiological (Tower)Microbiological (Tower)

Data should be entered in log book or Data should be entered in log book or monitored with computer trendingmonitored with computer trending

TROUBLESHOOTINGTROUBLESHOOTING

Low levelsLow levels Algae in towerAlgae in tower Tower losing waterTower losing water Closed loops losing waterClosed loops losing water High head pressure on chillersHigh head pressure on chillers Leaks on chemcialsLeaks on chemcials Bugs in ChillwaterBugs in Chillwater

Cooling Service ProgramCooling Service Program

Lab Analysis – Water– Deposit– Metallurgical

Test HX Equipment

Corrosion studies Chiller efficiency studies Micro-biological studies Cooling tower wood analysis LSI Calculations

Quality AssuranceQuality Assurance

A and W TechnologiesThank you for the opportunity

AT&T AT&T

COOLING SYSTEMS WATER TREATMENT TRAINING

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