Monitoring and Control of
Cooling Systems Water Treatment Seminar Lake Charles, LA October 18, 2012 Raymond M. Post, P.E. y , Director Cooling Technology RayP@chemtreat.com
Collect | Calculate | Control | Communicate
Fundamental Cooling Triangle g g Corrosion
Control
Deposition
BioFouling
Best Performance at Lowest Cost Demands Excellent Control Property of ChemTreat – do not reproduce without permission
Why Invest In Automation? Manual Control
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Reduces Chemical Consumption Reduce Water Usage Improve Program Performance U ili M Utilize Manpower More M Efficiently Improve Troubleshooting and Diagnostics and Diagnostics Ensure Personnel Safety Reduce Total Operating Costs Avoid Equipment Failures and Lost Production
A t Automatic ti Control C t l
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Impact of Control On Chemical Consumption p p
Tighter Control Through Automation Closes the Cost ↔ Performance Gap Property of ChemTreat – do not reproduce without permission
What Parameters Do We Want To Monitor and Control? and Control? •
Flow – Make‐up – Bleed
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Water Chemistry Water Chemistry – – – – – – – –
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Treatment Chemistryy – – – – – –
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pH Conductivity Temperature Suspended Solids / Turbidity H d Hardness (Ca and Mg) (C dM ) Alkalinity Silica Corrosion Halogen residual or ORP Total product residual applied Organic phosphate residual Ortho / Poly phosphate residual Copper corrosion inhibitor residual (Azole) Copper corrosion inhibitor residual (Azole) Polymeric dispersant residual
Performance – Corrosion Rate – Fouling / Scaling – Microbiological Activity
Some Monitoring is Mandated Property of ChemTreat – do not reproduce without permission
Effluent‐Related Effluent Related Monitoring Monitoring • • • •
Flow pH T Temperature Phosphorus • < 1 ppm P likely in future NPDES permits • Waste Load Allocation W t L d All ti • EPA National Nutrient Reduction Program)
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Metals • Zn • Cu • Hg
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Chlorine and other halogens Chlorine and other halogens Oil / hydrocarbon TOC and BOD Aquatic effects (WET test) Aquatic effects (WET test) Today’s Focus Is Automation and Control of Chemical Dosing Property of ChemTreat – do not reproduce without permission
Monitoring and Control Approach Monitoring and Control Approach The approach we recommend is to use the most appropriate and cost‐effective monitoring and control equipment, which will: • Provide minimum total cost of operation • • • •
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Water Cost Chemical Cost Labor Cost Equipment life cycle cost
Achieve all environmental constraints Ensure optimum and most reliable system performance Ensure personnel safety Ensure highest product quality Ensure highest product quality Reduce / Eliminate potential for forced outage
So, Where Do You Start? Property of ChemTreat – do not reproduce without permission
What Are The Elements of A Good Cooling Water Monitoring and Control System? Monitoring and Control System? •
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Conductivity monitor/controller • Increase or decrease blowdown to maintain conductivity • Controls “Cycles of Concentration” (COC) y ( ) • Maintains consistent water chemistry • Saves water and chemicals pH analyzer for system pH monitoring/control • Absolutely critical parameter for corrosion & scaling • pH is a log scale Chlorine analyzer or ORP • Absolutely critical for microbiological control • Too much – corrosion • Chlorine analyzer – Chlorine analyzer more accurate but requires reagents more accurate but requires reagents Historical data logging and trending capability • Centralized (Preferred) • Remote stand alone unit Means for Pacing the Corrosion and Scale inhibitors Means for Pacing the Corrosion and Scale inhibitors • Flow based or Residual based • Probe sensor or wet chemical analyzer • Feedback or Feed Forward
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Chem Feed Monitoring and Control Hierarchy
Flow Flow, Chemistry, Data Acquisition, Remote C Communications i i
Flow based Control With Ch i Chemistry Verification V ifi i Flow based Control with Proportional Chemical Feed with Proportional Chemical Feed Bleed and Feed Most appropriate choice depends on the system, criticality, etc. Property of ChemTreat – do not reproduce without permission
Monitoring and Control Considerations • Advanced controller designs • Walchem • ProMinent/Aquatrac – Ethernet – MODBUS – Integral cell modem – USB – Setup Software Setup Software
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Custom systems
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• Cell modem or internet access? • Remote control or Alarm only? Remote control or Alarm only?
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• Full PLC logic – DCS Integration • Manage from central control Manage from central control • room
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Data logging and management • Access • Who? • Off‐site access? Off it ?
Water quality analyzers • Hach • Rosemount, Yokogawa R Y k
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• New wireless technology • One‐way or two‐way communication
External call‐out capabilities
Wet chemical analyzers or solid state probe sensors? Own or Lease • Capital and Tax implications
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Proprietary Vs. Open source • Who owns the equip. & data? • Can you be held hostage to one equipment or chemical supplier? li ?
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Pacing The Chemical Feed Pacing The Chemical Feed Flow‐Based •
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~90% of chemical is lost to blowdown – Flow pacing can be very accurate – On‐line, reliable, simple, Feed Forward l l bl l d d If heat load is not constant, blowdown varies – Chemical feed pump must vary proportionally – Should pace pump with cooling tower blowdown Methods to determine blowdown flow – Measure blowdown flow directly – Makeup water flow x conductivity ratio – Time pump to MU or BD valve opening – ~Proportional to heat load or production
Residuals Based •
Can also feed back on chemical residual or tracer compound – Manual adjustments based on chemical tests (poor) Manual adjustments based on chemical tests (poor) – On‐line sensor or wet analyzer – Self contained – no wires to external sensors
Results Based • •
Corrosion rate (Corrosion rate meter) ( ) Biofouling (Neosens or BioGeorge) Property of ChemTreat – do not reproduce without permission
Treatment Chemical Control F dF Feed Forward, Feed Back, or Both d F dB k B th Feed Forward • Flow • Turbidity • Scaling S li tendency t d • Conductivity
Feed Back • Conductivity • ORP / Chlorine Residual • pH • Product residuals • Actives • Fluorescence • Corrosion Rate • Biofouling
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is: •
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a combination of our field & support staffs’ industry leading knowledge and expertise a 24/7 open web‐based water management software platform the integration of our customizable control systems with a wide range of sensors, fluorescence and actives‐based control capabilities accessible over smart phone, tablet p , or PC from virtually anywhere
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COLLECT | CALCULATE | MONITOR •
Your Solution starts with an easy to build and install control system
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The CT Solutions system can be specified with sophisticated or standard control schemes
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Also with a wide range of sensors for measuring and monitoring: – Performance‐based monitor and control – Conductivity – pH – ORP – Corrosion – Fouling – Actives‐based ppm control – Fluorescence sensors Fl
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Control Systems: Collect | Calculate | Control | Communicate
Standardized but highly Standardized but highly customizable control systems.
Solid-state product residual sensor (no reagents)
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Control Systems: Collect | Calculate | Control | Communicate
System Integrated and Manufactured to be “plug and play” when it arrives at our customer’s facility
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Solutions Controller with Hach CL17, MultiTrak Polymer Analyzer
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Data Management Software
VERIFY | VALIDATE • •
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You have the ability to review real time data time data Data can be integrated with DCS systems or viewed from individual PC’s or smart phones Cl Clear graphics show crucial hi h i l parameters that are within operational limits or out Dashboards for key performance items can be created for quick review Information in one location makes meeting validation requirements easier
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CTVista is a web‐based data CTVi t i b b dd t acquisition, reporting and advanced water management solution It logs real‐time data transmitted from the Solutions Control System or entered by your key plant personnel This data is organized and presented in easy to follow graphs, charts and reports Alarms, trends, service histories, KPI reports and test results are just p j a few of the charts available to authorized personnel within this secure environment
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Reporting structure can be scaled to meet customers needs: •
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Unlimited systems per facility (multiple systems w/ substantial reporting needs) U li it d f iliti Unlimited facilities per customer t (multi‐site corporate oversight) Property of ChemTreat – do not reproduce without permission
Operators can manually input results using a tablet, Smartphone, laptop, or PC or Data can be automatically logged directly from a controller
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Customized dashboards give instant snapshot of overall system health
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Operator / Service Reports –
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Visit Reports – Cooling Tower Cleaning
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Lab Reports –
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REPORT | COMMUNICATE
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Because Better Data Data. Means Better Decisions Decisions.
Control Systems Control Systems
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Real time secure data available 24/7 via PC PC, smart phone, or tablet
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Solutions Control Systems are easy to set up and operate ope ate - a all itt needs eeds iss a water ate source sou ce
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Data input automatically from your Control System, manually from ChemTreat service, or plant personnel.
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Information is available in a number of easy to read graphs, charts, and tables – with customized dashboards for quick review
Your
Package : Pinpoints and corrects system inefficiencies Creates more accurate tracking and system validation reports p Increases productivity of plant personnel Reduces operating costs Property of ChemTreat – do not reproduce without permission
Better Data Data. Better Decisions Decisions.
Property of ChemTreat – do not reproduce without permission