Section 3.

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.

MECHANICAL OPERATIONAL CHEMICAL SURVEY CONCEPT

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 proposal 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 operation 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 1F increase in condenser water temperature (3-4% higher for a 1C increase). An annual survey to identify needed maintenance 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 associated 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.

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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, demonstrate 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 necessary 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. There are several ways to do a survey from a basic checklist (easy) to a detailed MOC evaluation including heat exchanger modeling and statistical analysis. Table 3.1.1 indicates areas of investigation in each of the MOC survey categories. 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 unpredictable ways, it is our challenge to keep on top of changes that affect the process and document them in our survey.
Table 3.1.1 Examples of M-O-C survey areas. 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

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

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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 customers 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 resemblance to the original specifications. In this case, the current stresses in the system may be significantly 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 problems 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 The audit provides an opportunity to review and update all information available, to assess the quality of the water treatment program, and to 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 Nalcos TRASAR monitoring data is invaluable. Data from performance monitoring systems, 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 Nalcos 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 chemistry 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 concentration conditions for the makeup water. Logging data into VANTAGE V100 provides easy access to average, high and low values for every parameter.

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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 previous 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. 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

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 recirculating water Impact of chemical treatment programs

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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 erosioncorrosion in soft metals like copper and copper alloy heat exchanger tubes. This can be aggravated 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.

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 Moderate Stress High Stress Severe Stress

< 2500 BTU/hft2 (< 7.5 kW/m2) 2500-8000 BTU/hft2 (7.5-25 kW/m2) 8000-12500 BTU/hft2 (25-40 kW/m2) > 12500 BTU/hft2 (> 40 kW/m2)

WATER VELOCITY Mild Stress Moderate Stress High Stress Severe Stress

> 3 ft/s (> 1 m/s) 2-3 ft/s (0.6-1 m/s) 1-2 ft/s (0.3-0.6 m/s) < 1 ft/s (< 0.3 m/s)

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)
Figure 3.1.1 Illustration of the results of mechanical component of a system audit.

2. Variation of pH 3. Variation of holding time index (HTI)

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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 function 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 depending 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 Moderate Stress High Stress Severe Stress 0.1 unit 0.2 units 0.4 units 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.

Table 3.1.2 Impact of poor control for common cooling water parameters. Operational Stress Variation of Concentration Cycles (CR) Variation of pH Impact of Variation on High-side of Range Increases potential for scale formation and deposition Increases corrosion potential on stainless steel as chloride ion increases Increases potential for scale formation and deposition Reduces efficiency of oxidizing biocides, particularly chlorine Variation of Holding Time Index (HTI) Increases potential for product degradation through: Adsorption mechanisms Undesirable reactions with halogens Hydrolysis (particularly polyphosphates) Precipitation (particularly with zinc or phosphate) Increases potential for scale formation and deposition of suspended solids None, other than those related to low cycles of concentration Increases potential for corrosion Impact of Variation on Low-side of Range Excessive water consumption and excessive chemical costs

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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 operational 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 variability 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.

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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 concentration 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 operating 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 phosphatebased program is illustrated by the circled area. This shows the Saturation Index (SI) of a scaleforming mineral as a function of pH and concentration 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
Figure 3.1.4 Example of the operating window for system pH and concentration cycles based on mineral solubility.

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 conditions. 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.

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A variety of other tools are available to help collect system data and evaluate the performance of the system. These include sling psychrometers, infrared temperature guns, ultrasonic flow meters, and vibration analyzers.

Figure 3.1.5 Schematic illustration of input and output of chemical phase of a survey.

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 recommending 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 techniques 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 evaluated using SPC techniques to show the control capability of the system.

VALIDATION It is valuable to perform a survey with plant personnel to ensure that you are collecting the appropriate information. Due to the time commitment, 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 information 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 chapter. 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

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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 characteristics 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 interrelationships 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 identification of stresses in relation to total cost of operation will better demonstrate the value of stress management. This is an essential component 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.

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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.

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

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The final result is a treatment program that best manages the stresses in the system at an optimum 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 parameters 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 valueadding 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.

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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 introduction 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 improvement 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 demonstration of value. The MOC concepts provide a complete framework 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.

ROI, Added Value PAYOFF Understand and optimize stresses and TCO IMPLICATIONS Customer goals, opportunities and current dissatisfaction PROBLEMS Discovering facts about the system and operation MOC Survey Concepts SITUATION

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

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For your notes:

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