Nalco Company

Cooling Water Presentation 6-24-04

TVWD Cooling Tower
Stress Management for Cooling
Systems Seminar and Workshop
November 29, 2005
 Agenda

„ Introduction
„ Fundamentals of Cooling Water
„ Cooling System Problems (Stresses)
„ Treatment Programs
„ The Engineering Approach
„ Microbiological Control and
Monitoring
„ Stress Management
THE COOLING PROCESS
„ The purpose of cooling
systems is to transfer
heat from one substance
to another
„ The substance that
gives up its heat is
“cooled”
„ The substance that
receives the heat is the
“coolant”
 Open Recirculating Systems
Open recirculating systems are open to the atmosphere
at the tower. As the water flows over the tower, heat
picked up by the process is released by evaporation.
The cooling water then returns to the heat exchangers
to pick up more heat.
 Open Recirculating System Blowdown

Makeup Heat Exchanger

Water

Cooling Tower
Pump

EXAMPLES CHARACTERISTICS
y Spray Ponds y Avg. Temp. Change: 20-30°F [11.1-16.7°C]
y Cooling Towers y Amount of Water Used: Moderate
y Evaporative Condensers
 Open Recirculating Systems

Heat Transfer Evaporation

„ Process in which heat „ Process by which
is transferred from the hot cooling
one substance to water releases its
heat to the
another. atmosphere so
that it can return
cool water back to
the heat
exchangers
Open Recirculating Systems
A cooling tower provides two conditions
that enhance the evaporation process...

„ Break water into tiny droplets, thus

providing more escape routes for water
molecules to evaporate.
„ Fans provide rapid flow of air through
the tower which removes evaporated
water molecules and allows even more to
escape.
Why Use Water for Cooling?

„ Plentiful; Readily Available; Cheap

„ Easily Handled: Pumpable
„ Can carry large amounts of heat
„ Does not expand/contract much at
normally encountered temperatures
„ Does not decompose
Why Use Water for Cooling?

„ Specific Heat: Measure of how well

a substance absorbs heat
„ Water can absorb more heat than
virtually any other substance that
would be considered for industrial
cooling
„ Minor increases in temperature
„ Minimal environmental impact
Why Isn’t Water Perfect for
Cooling?

„ Dissolves everything it touches:

Metal; earth; stone; gasses
„ Unique dissolving ability has earned
water the title...
 Two Sources of Water
Surface Water
„ Low in dissolved solids
„ High in suspended solids
„ Quality changes quickly with seasons & weather

Ground Water
„ High in dissolved solids
„ Low in suspended solids
„ High in iron & manganese
„ Low in oxygen, may contain sulfide gas
„ Relatively constant quality & temperature
What Chemical Properties of
Water Are Important?
Important Properties of Water
1. Conductivity
2. Hardness
3. Alkalinity
4. pH
5. Silica
6. Other impurities
-- Iron, Manganese,
Chlorides, Phosphate, etc.
 Evaporation

Each 10°F [6°C] drop in temperature results

in an avg. 0.85% evaporation of
recirculated cooling water
ER = (RR)*(dT/10)*(.0085)
Where:
„ ER: Evaporation Rate [gpm]
„ RR: Recirculation Rate [gpm]
„ dT: Temp drop across tower [DegF]
 Concentration of Dissolved
Solids
„ Only pure water can evaporate
– Excluding volatile chemicals
Constant
like bleach Evaporation
„ No dissolved solids leave the 6
5
liquid water 4
„ If there are no other water 3
2
losses from the system, the 1
evaporation process causes an
increase in the concentration
of dissolved solids in the
recirculating cooling water.
Concentration of Dissolved
Solids

„ Mineral scale will form if the

dissolved solids concentration in the
cooling water becomes too high
„ Supersaturation
 Impact of Blowdown on
Concentration Ratio
Constant Evaporation
6
With
Zero 5
Blowdown:
Blowdown 4
3
„ Deliberate
2 discharge of
1
water to prevent
Constant Evaporation
With 6
the dissolved
Continuous 5 solids from
Blowdown 4
Maintaining 3 getting to high
4 Cycles 2
1
 Makeup Water
„ Amount of water
required to Evaporation
replace water lost
by evaporation
and blowdown
Makeup
Makeup =
Evaporation +
Blowdown Blowdown
 Concentration Ratio
Make-up Flow
CR =
Blowdown Flow

CR
MU = Evaporation x
(CR – 1)
COMMON COOLING
SYSTEM PROBLEMS
 Cooling System Problems

Left unchecked these

problems cause
„ Loss of heat transfer
„ Reduced equipment
FO
E

life
AL

„ Equipment failures
LIN
SC

MICROBIO „ Lost production

„ Lost profits
„ Increased
CORROSION maintenance costs
„ Plant shutdown
MINERAL SCALE
 Mineral Scale

„ Cooling Water contains many

different minerals -- normally these
minerals are dissolved in the water
„ Under certain conditions minerals
can come out of solution and form
into hard, dense crystals called
SCALE
 Mineral Scale

CaCO3
Common Scales
„ Calcium Carbonate
„ Magnesium Silicate
„ Calcium Phosphate
„ Calcium Sulfate
„ Iron Oxide
„ Iron Phosphate
„ Others...
CaPO4
Scaled Heat Exchanger Tubes
 Mineral Scale

The Following Factors Affect

Scale Formation...
× Mineral Concentration
× Water Temperature
× Water pH
× Suspended Solids
Ø Water Flow Velocity
 Mineral Scale

„ Scale usually forms in hot areas of

cooling systems
„ Reduces heat transfer efficiency
„ Mechanical/Chemical cleaning
„ Under deposit corrosion (pitting)
„ Plant shutdown
„ Equipment replacement
Preventing Mineral Scale

„ Limit concentration of scale forming

minerals: Blowdown, clarify/filter MU
„ Feed acid to reduce pH & alkalinity:
Reduces scaling -- increases corrosion
„ Mechanical design changes: Increase HX
water velocity, backflush, air rumble
„ Apply chemical scale inhibitors
 Mineral Scale
Three Classifications Of Scale
Inhibiting Chemicals Are…

„ Crystal Modifiers
– Prevent scale from “laying down”
„ Sequestrants
– Prevent scale from agglomerating
„ Dispersants
– Affect mineral charge so that scale
formers repel each other
 Normal Operations

Impact of pH
Parameters 7.6 7.9 8.1 8.4 8.7 8.9 9.2 Constants
Calcite 0.4 1.3 3.9 10.9 29 68 96 pH
Tricalcium Phosphate 1 1 1 1 1 1 1 Temp 120
Magnesium Silicate 0.1 0.3 1 3.2 10 28 72 PO4 2
Silica 0.6 0.6 0.55 0.53 0.5 0.44 0.36 Cycles 8

Comments:

Impact of Cycles
Parameters 6 7 8 9 10 11 12 Constants
Calcite 6 6.5 7 7.4 7.7 8 8.3 pH 8.3
Tricalcium Phosphate 1 1 1 1 1 1 1 Temp 120
Magnesium Silicate 1.3 1.6 2.1 2.5 3 3.5 0.8 PO4 2
Silica 0.4 0.5 0.55 0.6 0.7 0.75 0.8 Cycles
PGE Beaver Condenser Scale Analysis
Calcium Carbonate Scale
 High Silica, Minimum Blowdown

Impact of pH and High Silica

Parameters 7.6 7.9 8.1 8.4 8.7 8.9 9.2 Constants
Calcite 0.67 1.9 5.5 15 38 89 187 pH
Tricalcium Phosphate 1 1 1 1 1 11 1 Temp 120
Magnesium Silicate 0.2 0.8 2.8 9 28 81 203 PO4 2
Silica 1.08 1.07 1.05 1 0.9 0.8 0.7 Cycles 15

Comments: 15 cycles, 230 PPM Silica

Impact of pH and High Silica

Parameters 7.6 7.9 8.1 8.4 8.7 8.9 9.2 Constants
Calcite 0.4 1 3 9 24 60 136 pH
Tricalcium Phosphate 1 1 1 1 1 11 1 Temp 80
Magnesium Silicate 0.1 0.1 0.3 1.1 3.6 11 31 PO4 2
Silica 1.8 1.8 1.8 1.78 1.73 1.64 1.5 Cycles 15

Comments: 15 cycles, 230 PPM Silica

CORROSION
 CORROSION

Corrosion is the mechanism by which metals

are reverted back to
their natural “oxidized” state
 Corrosion
-
e
Battery Analogy
„ Anode
„ Cathode
Cathode „ Electrical Circuit
Anode

„ Metal lost at anode

Electrolyte
 Simplified Corrosion Cell
STEP 4 OH-
O2 O2
STEP 1
Water with
Dissolved STEP 3
Fe 2+
Minerals
Base Metal CATHODE

e- e-
ANODE e- e-
STEP 2
Four Step Corrosion Model
„ Step 1: At the anode, pure iron begins to break
down in contact with the cooling water. This
step leaves behind electrons.
„ Step 2: Electrons travel through the metal to the
cathode.
„ Step 3: At the cathode, a chemical reaction
occurs between the electrons and oxygen carried
by the cooling water. This reaction forms
hydroxide.
„ Step 4: Dissolved minerals in the cooling water
complete the electrochemical circuit back to the
anode.
Factors Influencing Corrosion

„ pH
„ Temperature
„ Dissolved Solids
„ System Deposits
„ Water Velocity
„ Microbiological Growth
 Corrosion Vs. pH
100
Corrosion Rate, Relative Units

10

0
5 6 7 8 9 10
pH
 Corrosion Vs. Temperature
Temperature

In general, for every 18°F in

water temperature, chemical
reaction rates double.
Corrosion Rate
Other Causes of Corrosion

× System Deposits
• Anodic pitting sites develop under deposits
Ù Water Velocity
• Too low = deposits
• Too high = Erosion
× Microbiological Growth
• Deposits; Produce corrosive by-products
 Types of Corrosion

All cooling system metallurgy experiences some

degree of corrosion. The objective is to control
the corrosion well enough to maximize the life
expectancy of the system...

1. General Corrosion
2. Localized Pitting Corrosion
3. Galvanic Corrosion
 General Corrosion
Water
„ Preferred situation
Thickness
Original

Base Metal „ Take a small

amount of metal
General Etch Uniform Attack evenly throughout
the system
„ Anode very large
 Pitting Corrosion
Water
Thickness

„ Metal removed at
Original

same rate but from a

Base Metal much smaller area
„ Anode very small
Localized Pitting Attack
„ Often occurs under
deposits or weak
points
„ Leads to rapid metal
failure
 Galvanic Corrosion
Active End
„ Occurs when two Magnesium
different metals Galvanized Steel
Mild Steel
are in the same Cast Iron
18-8 Stainless Steel Type 304 (Active)
system 18-12-3 Stainless Type 316 (Active)
„ More reactive Lead Tin
Muntz Steel
metal will corrode Nickel (Active)
76-Ni-16 Cr-7 Fe Alloy (Active)
in presence of less Brass
reactive metal Copper
70:30 Cupro Nickel
„ Potential for 67-Ni-33 Cu Alloy (Monel)
Titanium
galvanic corrosion 18-8 Stainless Steel Typ 304 (Passive)
increases with 18-12-3 Stainless Steel Type 316 (Passive)
Graphite
increasing distance Gold
on chart Platinum
Passive End
 Affects of Corrosion

„ Destroys cooling system metal

„ Corrosion product deposits in heat exchangers
„ Heat transfer efficiency is reduced by deposits
„ Leaks in equipment develop
„ Process side and water side contamination
occurs
„ Water usage increases
„ Maintenance and cleaning frequency increases
„ Equipment must be repaired and/or repaired
„ Unscheduled shutdown of plant
Methods To Control Corrosion

„ Use corrosion resistant alloys: $

„ Adjust (increase) system pH: Scale
„ Apply protective coatings: Integrity
„ Use “sacrificial anodes”: Zn/Mg
„ Apply chemical corrosion
inhibitors
 Anodic Corrosion Inhibitors

„ Stop corrosion
cell by blocking Anodic Inhibitors
the anodic site „ Chromates
„ Severe localized „ Nitrites
pitting attack can
„ Orthophosphates
occur at an
unprotected „ Silicates
anodic sites if „ Molybdates
insufficient
inhibitor is
present
Cathodic Corrosion Inhibitors
„ Stop corrosion cell
by blocking the Cathodic Inhibitors
electrochemical „ Bicarbonates
reaction at the
cathode „ Polyphosphates
„ Corrosion rate is „ Polysilicates
reduced in direct „ Zinc
proportion to the
reduction in the size „ PSO
of the cathodic area.
General Corrosion Inhibitors

„ Protect metal by General Inhibitors

filming all „ Soluble Oils
surfaces whether „ Tolyltriazoles
they are anodic or
„ Benzotriazoles
cathodic
Nalco Corrosion Monitor

„ Linear Polarization Resistance (LPR)

„ Effective in Low Conductivity Waters –
Soft Water, Condensate
„ Probes and Tips are one unit
„ Battery Powered
„ Internal Data Logger – PDA/Computer
Down Load
„ Inexpensive
Unit 2 Circ Water Corrosion Rates

9/6/03 to 9/17/03

Unit 2 NCM 100 Data

2.50 Start Trial

Startup

2.00

1.50
MPY

Chlorine Shock Normal Operations

1.00

0.50
Unit Shutdown
0.00
4-Sep 6-Sep 8-Sep 10-Sep 12-Sep 14-Sep 16-Sep 18-Sep 20-Sep
Date
FOULING
 Fouling

FOULING is the accumulation of solid

material, other than scale, in a way that
hampers the operation of equipment or
contributes to its deterioration
 Common Foulants
Suspended Solids

„ Silt, Sand, Mud and Iron

„ Dirt & Dust
„ Process contaminants, e.g. Oils
„ Corrosion Products
„ Microbio growth
„ Carryover (clarifier/lime softener)
Factors Influencing Fouling

„ Water Characteristics
„ Water Temperature
„ Water Flow Velocity
„ Microbio Growth
„ Corrosion
„ Process Leaks
 Affects of Fouling

„ Foulants form deposits in hot and/or low

flow areas of cooling systems
„ Shell-side heat exchangers are the most
vulnerable to fouling
„ Deposits ideal for localized pitting
corrosion
„ Corrosive bacteria thrive under deposits
„ Metal failure results
Economic Impact of Fouling

„ Decreased plant efficiency

„ Reduction in productivity
„ Production schedule delays
„ Increased downtime for maintenance
„ Cost of equipment repair or replacement
„ Reduced effectiveness of
chemical inhibitors
 Fouling

Three Levels Of Attack Can Be

Employed To Address The Effects
Of Fouling...

1. Prevention
2. Reduction
3. Ongoing Control
 Preventing Fouling
Prevention
„ Good control of makeup quality
„ Good control of corrosion, scale, & microbio

Reduction
„ Increase blowdown
„ Sidestream filter

Ongoing Control
„ Backflushing, Air rumbling, Clean tower basin
„ Chemical treatment
 Preventing Fouling

Prevention
„ High Efficiency Multimedia Filters
– Capable of 80% removal of 0.5 micron
– Typical multimedia depth filters capable of
80% removal only down to 10 micron
– Most (greater than 90%) of particles found in
a cooling tower are less than 10 micron

„ Do not overlook sidestream filtration and

choose wisely!
 Fouling
Chemical Treatment

„ Charge Reinforcers
– Anionic polymers increase strength of
charge already present on suspended
solids
– Keep particles small enough so they
do not settle out
„ Wetting Agents
– Surfactants
– Penetrate existing deposits
– Wash away from metal surfaces
MICROBIOLOGICAL
GROWTH
Microbiological Growth
„ Water treatment is
The microbial fouling
about managing process is...
three fouling „ The most complex
processes... „ The least understood
Ö Corrosion „ The hardest to
measure and monitor
Ö Scale
„ Controlled using the
Ö Microbio least desirable, most
expensive, &
potentially hazardous
products
Microbiological Growth

Three Kinds Of Troublesome

Microorganisms In Cooling Water...

1. Bacteria
2. Algae
3. Fungi/Mold/Yeast
 Bacteria
„ Bacteria extremely
small
„ Compared to a
human, a bacteria is
like a grain of sand to
the Sears Tower
„ Size allows many
(millions) to fit into a
small volume of
water... Sears
Tower
 Bacteria
„ There are as many
bacteria in 12 oz. of
cooling water as
there are people
living in the United 12oz.
States Cooling Water

„ There are 40,000

times as many
bacteria in a 50,000
gallon cooling
system as there are 40,000 X
people in the world! 50MGAL
Cooling System
 Bacteria

Types of Bacteria
1. Slime Forming
2. Anaerobic Corrosive
3. Iron Depositing
4. Nitrifying
5. Denitrifying
 Bacteria

Typical Rods Slime Formers

Anaerobic Iron Depositing

 Bacteria

„ Produce acidic waste that lowers pH and

causes corrosion
„ Produce large volumes of iron deposits
that foul
„ Produce acids from ammonia that
increase corrosion & lower pH
„ Form sticky slime masses that foul &
cause reduced heat transfer
Two Classifications of Bacteria

Planktonic:
„ Free-floating bacteria in bulk water

Sessile:
„ Bacteria attached to surfaces
„ Over 95% of bacteria in a cooling system
are sessile and live in BIOFILMS
 Biofilms
c
„ Contribute to all
cooling water
problems d
„ Underdeposit
corrosion
„ Trap silt & debris e
which foul heat
exchangers and
tower fill
„ Provide nucleation
sites for scale
formation Biofilm Formation
 Biofilms
„ More insulating Thermal
Foulant Conductivity
than most CaCO3 1.3-1.7 Common
common scales Ö CaSO4 1.3
biofilms are 4
times more
CaPO4 1.5 insulating
„ Reduce heat MgPO4 1.3 than CaCO3
transfer efficiency Fe Oxide 1.7 scale!
Biofilm 0.4
„ Increase dP across
heat exchangers &
reduce flow FLOW
„ Health risks
(legionella)
P P
 Algae

„ Require sunlight to grow

„ Found on tower decks & exposed areas
„ Form “algae mats”
„ Plug distribution holes on tower decks
„ Plug screens/foul equipment
„ Consume oxidants
„ Provide food for other organisms
Fungi

„ Use carbon in
wood fibers for
food
„ Destroy tower
lumber by either
surface or internal
rotting (deep rot)
„ Loss of structural
integrity of tower
Factors Affecting Growth of
Microorganisms
„ Microorganism Sources: Air or Makeup
water
„ Cooling systems provide the ideal
environment for microbiological growth
– Nutrients: Ammonia, oil, organic
contaminants
– Temperature: 70-140°F acceptable
– pH: 6.0 - 9.0 ideal
– Location: Light/No Light
– Atmosphere: Aerobic/Anaerobic
Controlling Microbiological
Growth

Water Quality
– Eliminate organic contaminants (food)
– No food = No bugs
» Bugs are carniverous – A forest feeds
itself
System Design Considerations
– Clean tower and sumps, cover decks
Chemical Treatment with Biocides
 Microbiological Growth

Chemical Treatment With Biocides

„ Oxidizing Biocides
„ Non-oxidizing Biocides
„ Biodispersants
 What About Dipslides?

Simple, quick, and inexpensive.

However, only gives bacteria

levels from the bulk water.

There is more to this picture!

 Monitoring Tools for
Planktonic Microorganisms
- Dipslides
„ Dipslides only measure selected
aerobic planktonic microorganisms
„ Total aerobic bacterial counts
determined from dipslides are useful
for tracking trends
Aerobic Plate Counts
 Microbiological Monitoring

Sessile Monitoring Bio Box

Tracide, ATP
DIVERSITY
of different kinds….
the state of being unlike or different

refers to the KINDS of microorganisms

present
Differential Microbiological
Analysis (DMA)
Testing designed
to differentiate
From: Analysis No. MB 207310
ABC Plant Date Sampled 9/ 9/97
Date Received 9/10/97
Date Completed 9/15/97
Sample Marked: Date Printed 9/15/97

the
Cooler Outlet

microbiological
>>> Microbiological Evaluation <<<

PHYSICAL APPEARANCE Liquid with Floc

content within a
TOTAL AEROBIC BACTERIA 4,000
Enterobacter <100
Pigmented <100
Mucoids <100
Pseudomonas <100
Spores <10

system.
TOTAL ANAEROBIC BACTERIA
Sulfate Reducers 2
Clostridia <10
TOTAL FUNGI
Yeasts <10
Molds 20
IRON-DEPOSITING
Gallionella None
Sphaerotilus None
ALGAE
Filamentous None
Nonfilamentous None
OTHER ORGANISMS None
Lab Comments:
All counts express colony forming units per ml.
Microscopic examination: few crystals and very few diatoms.
The goal in microbial fouling
control ...

is almost never to “sterilize” the

system, but rather,

...it is to MANAGE the fouling

control process to a level that
causes no operational problems
How do I measure
biofilms?
 Sessile monitoring is an
integral part of the microbial
monitoring program
„ Planktonic results have a weak
correlation to the sessile population
„ The sessile population, or biofilms, are
the true microbial control target
Surface Microbial
Monitoring Test Kit
 Monitoring Tools for
Sessile Microorganisms
„ Surface Microbial Monitoring Test Kit
– Applied Services C0243
– SBIO is test code
„ Kit contains supplies necessary to
sample a surface
„ Measures microorganisms on surfaces,
i.e., sessile population
Sessile Monitoring
Swab

Coupon

Sterile
Buffer

BioBox Surface Microbial

Test Kit
 Bio Box

„ Visual indicator

„ Removable Slides
for Microscopic
Analysis
BioManageTM Best Practices
Recognizing The Problem

• Planktonic counts don’t often correlate with sessile

counts.
• Use microbial types, numbers, and locations as clues to
current conditions, trends, and improvements.
• Be creative with sample point locations, timing with
cleanup events, etc.. to provide powerful diagnostic
information.
• Establish criteria for success
 THANK YOU -

Any questions on
any topics we
covered?
 Every system … under
stress
„ High Stress Causes:
– Scale
– Corrosion
– Fouling
„ Low Stress Causes
– High water costs
– High energy costs
– High chemical costs
 Stress: varies by system
operation
„ High temperatures
„ Long holding time indices (HTI’s)
„ Biological/Organic contamination
– Size, type and diversity of bio-
populations
„ Low flow rates
„ High oxidant concentrations
„ Water chemistry
 Stress: varies by system
design

„ Erratic feed systems

„ Problematic equipment
– Blowdown valves, make-up
systems, etc.
„ Monitoring problems
– How does the rest of your facility
work?
„ System design limitations
„ System location
 Stress: varies by industry

Semiconductor Institutional Food & Beverage

Equipment often idle Long HTI’s System
for long periods Contamination

Regulatory Needs Regulatory Needs Nutrient-rich

environments
Variable water Aggressive water Capacity limitations
chemistry chemistry
 Stress: varies by location
Naperville, IL

Minneapolis, MN Westchester, IL

Sandy, UT

r
y te
High water cost

tr a
is W
Gray water use Sioux City, IA

m le
he b
Martinez, CA

C aria
Critical Systems

V
Variable Water Chemistry
Rahway, NJ
High Hardness
El Segundo, CA High Alkalinity

Phoenix, AZ Morris, IL

Lo ow
L
w Al
Environmental Concerns Beaumont, TX

Ha ka
High Bio-Activity Tiger Bay, FL

rd lini
ne t y
ss
Houston, TX
San Diego, CA
High Temperatures
Variable Water Chemistry

Texas City, TX
 Stress: constantly varying…

Control Based on System Stress

80

70

60
Concentration (ppm)

50

40

Low Stress! High Stress!

30

20 As system stress varies, 3D TRASAR adjusts dosage to compensate. At times of high stress,
more inhibitor is fed. When stress decreases, less inhibitor is fed.
10

-
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89

Time (each interval = 4 hours)

Active Concentration (ppm)

Treatment Concentration (ppm)
 Stress: unpredictable

3D TRASAR Optimizes System Stress

1,800

1,600

1,400

1,200
3D TRASAR detects low stress
Conductivity

and increases conductivity to

1,000 minimize operating cost. 3D TRASAR detects low stress and
increases the conductivity to
minimize operating cost.
800
3D TRASAR detects high stress
and decreases conductivity to
600 prevent operational problems.
In this case, a bleach feed system failed. When the system was
400 repaired at 10:50 PM, high concentrations of bleach were fed into
the system, increasing system stress. 3D TRASAR detected the
stress and decreased the conductivity to prevent an operational
200
problem.

-
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61
Time (Each Division = 4 hours)
 Stress: undiscovered
Before 3D Bio-Control, ORP-based
control was erratic and copper 3D Bio-Control Started
1,000 3.0
corrosion rates were high.
900
2.5
800

Copper Corrosion Rate (mpy)

700 After 3D Bio-Control was
2.0
implemented, ORP levels were
600
ORP (mV)

reduced, variability was reduced

and copper corrosion rates
500 improved. 1.5

400
1.0
300

200
0.5
100

- -
Time (each division = 1 day)

ORP Copper
 Stress: many sources
Bio-activity stresses
Average Daily Nalco Bio-Index
cooling systems.
25.0 Bringing idle
Monday
Monday equipment online
20.0
increases system
15.0 stress.
Nalco Bio-Index

Monday
Monday
10.0
Monday

5.0

0.0

-5.0
1-Jun

2-Jun

3-Jun

4-Jun

5-Jun

6-Jun

7-Jun

8-Jun

9-Jun

10-Jun

11-Jun

12-Jun

13-Jun

14-Jun

15-Jun

16-Jun

17-Jun

18-Jun

19-Jun

20-Jun

21-Jun

22-Jun

23-Jun

24-Jun

25-Jun

26-Jun

27-Jun

28-Jun

29-Jun

30-Jun
Date
 Stress: requires dynamic
response
June 16
Nalco Bio-Index and Pump On Time

35 5
When 3D TRASAR detects a change in the rate of bio-
population increase, it responds by feeding less biocide,
30
controlling the bio-population, but preventing a biocide
overdose. 4
25
3D TRASAR detects a change in
the bio-population and starts

Pump On (minutes)
20
Nalco Bio-Index

applying more oxidizing biocide 3

to compensate.
15

Nalco Bio-Index Set- 2

10
Point

5
1

(5) -
0:00 3:00 5:40 8:40 11:40 15:00 18:20 21:28
Time (Hours:Minutes)

Pump On (minutes) Nalco Bio-Index

 Stress: intermittent

9.0 10.0

9.0

8.0
8.0

7:17 PM: acid upset 7.0

Mild Steel Corrosion Rate (mpy)

7.0 causes pH to drop.
11:24 PM, pH returns
to normal 6.0
pH

6.0 5.0

4.0
5.0
3.0

2.0
4.0
In spite of extremely low
pH, corrosion rate is 1.0
unaffected.
3.0 0.0
12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM
Date/Time

pH MS Corrosion Rate
 Stress: interrelated causes
2.30

2.25

Average Silica = 8 ppm

2.20

2.15
Exchanger Efficiency

Average Silica = 26 ppm

2.10

2.05

2.00 Prior to 3D TRASAR control,

phosphate upsets put stress on
1.95 the system which caused
significant fouling. In this case,
the overfeed caused a 14%
1.90 efficiency loss.
Average Silica = 7 ppm
1.85

1.80
Date (Each Division = 10 days)
 Stress: interrelated causes
2.30

2.25

2.20

2.15
Efficiency Factor

2.10
Even with a significant phosphate overfeed,
efficiency loss due to fouling was only 3%.
2.05

Average Silica = 8 ppm

2.00

1.95
Average Silica
4 = 7 ppm
1.90
Average Silica = 26 ppm
1.85

1.80
Date (Each Division = 10 days)

4
4
Stress: unique to every
system
Stress: highly visible
 Stress: highly visible
minimize increase
onsite throughput
inventory extend time
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between
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water usage
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Manage Control energy usage
Risks Stress Costs
reduce operating reduce
liability maintenance

Reduce Cost improve operator

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