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Boiler Water Management - Boiler Water Carryover
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Boiler Water Management - Oxygen Removal for Boiler Water Treatment
Case Study - Chemical handling, System Upgrades & Common-up
Convergent Cooling Systems - pH relay upgrades
Associations:
Chemical handling, System Upgrades & Common-up
Purpose of this case study
To demonstrate CORE’s capabilities to improve site efficiencies and safety onsite by reducing chemical handling and improving robustness of onsite systems
DISADVANTAGE OF NOT COMMONING-UP
Six control systems = high probability of control / pump / probe issues each service visit
Very high level of operator / consultant time required fixing control issues, topping up small chemical drums and individually testing all towers
Individual Brominators = weekly top ups required = high chance of spills and very high level of chemical / manual handling component
20l chemical drums = weekly change over = very high chemical / manual handling component
Plastic spill pallet bunding = below specification for segregation of chemicals
No corrosion monitoring
Poor HCC & LP control
ADVANTAGES of COMMONING-UP SYSTEM:
Single controller with internet monitoring using a single set of probes / pumps = email / sms notification to consultants and operators of any out of spec parameters or low level chemical tanks
Bulk chemical supply = Chemical transfer frequency ever 4 – 6 months = minimal chemical / manual handling of chemicals
Portable bunding = segregation of acids and alkalines with sufficient spill space
Excellent HCC & LP control
Excellent corrosion monitoring and control
OLD Situation:
Individual make-up and bleed water meters for all six towers = many not operational and not recorded
Six individually controlled cooling systems
NEW Situation:
Single make-up water meter and single bleed water meter for all six towers running off a common balance tank and recirculation pump
ADVANTAGES:
Water usages trended weekly
Body of water continually circulating = greater biological and corrosion control
One body of water = one lot of testing - This has significantly reduced required testing from six systems to one system allowing more time to be spent identifying other projects and improving other systems onsite
Summary
Individual Systems
Six control systems = high probability of control / pump / probe issues each service visit
Very high level of operator / consultant time required fixing control issues, topping up small chemical drums and individually testing all towers
Individual Brominators = weekly top ups required = high chance of spills and very high level of chemical / manual handling component
20l chemical drums = weekly change over = very high chemical / manual handling component
Plastic spill pallet bunding = below specification for segregation of chemicals
No Corrosion monitoring
HCC within spec 80% - LP within spec 83% 2013
System Common - Up
Upgrade to single controller system with internet monitoring
Single make-up water meter and single bleed water meter for all six towers running off a common balance tank and recirculation pump – Water usage monitored weekly
Bulk chemical supply = Bulk Transfer every 8 – 10 weeks
Portable bunding = Segregation of acids and alkalines with sufficient spill space
Corrosion rates 2013 – 2015 Average 1.45mpy (Target <3.0mpy)
HCC & LP control 100% within spec 2014 & 2015
