SYSTEMS

The Best Scale Prevention

Solution for Condenser and
Heat Exchangers
SYSTEMS
Table of Contents

I
I. General
II. Type of Scale
III. Scale Effect on Heat Transfer
IV
IV. Scale Control
V. Automatic Tube Brushing System
VI. Conclusion

2
ASIA ENERGY TECH
SYSTEMS
GENERAL

T t l Cost
Total C t

Equipment Running Cost

Production Cost

Service and Maintenance Cost

Initial Equipment
q p Cost

3
ASIA ENERGY TECH
SYSTEMS
SCALE

Scale Is the biggest single factor in reducing the efficiency

Of a Chiller

Not only does it increase the energy consumption of a chiller

It also has a detrimental effect on the operation of the
Compressor

In Addition scale can become the catalyst that initiates

Condenser tube failure

4
ASIA ENERGY TECH
SYSTEMS SCALE

Scale Deposit On Condenser Tube

Sludge Deposit on Tube

Surface Anaerobic
Surface,
Corrosion will Occur
Under the deposit Result of under
(Common with River Water) Deposit corrosion

5
ASIA ENERGY TECH
SYSTEMS
TYPE OF SCALE
Typical Scale in cooling water system

Condenser
Scale Clean

S l on a cooling
Scale li T Tower Fill

6
ASIA ENERGY TECH
SYSTEMS
Scale Effect on Tube Surface
Outer Tube Fin

Wall tthickness
Wa c ess
Inner
Scale

df: ID after scale

di: Actual ID

df
di
7
ASIA ENERGY TECH
SYSTEMS
GENERAL
Where does scale come from
A portion of the Water In the Cooling Tower Evaporates as
it falls through the Tower and the Evaporation process
draws heat from the remaining Water
The Evaporation process results in an increase in dissolved
mineral solids in the remainingg water which can pprecipitate
p
out onto the surface of piping and heat exchanger tubes
Chemicals will help to keep these dissolved solids in
suspension but the required volume of chemicals increases
as the level of dissolved solids increases
The
h level
l l off dissolved
di l d solids
lid circulating
i l i in i a system is
i
referred to as the Cycle of Concentration

ASIA ENERGY TECH

SYSTEMS
GENERAL
Where does scale come from
Mostt Water
M W t usedd in i Cooling
C li Towers
T comes from
f the
th city
it mainsi andd
contains a level of dissolved mineral salts which can be referred to
as X
X, the cycle of concentration can be referred to as X
X*
Example If the make up Water contains a level of Total Dissolved
Solids ((TDS)
S S) of 150 ppm
pp then a Tower system
y operating
p g at 450
TDS would be operating at 3 cycles of concentration. (normal
operation 3 to 6 cycles)
By adding more chemicals we can increase the operating Tower
system to 6 cycles of concentration but above this the cost of
chemicals
h i l begins
b i to outweigh i h the
h cost off Water
W
As the maximum cycle of concentration is reached water must be
blown down and replaced with fresh make up

ASIA ENERGY TECH

SYSTEMS
GENERAL
Where does scale come from
Increasing the Cycle of concentration saves water because
you do not need to blow down or bleed off so much Tower
water
However precipitation will take place once the TDS level
reaches a ppoint where the chemicals in the system
y can no
longer hold the dissolved solids in suspension
When DS begin to precipitate out they will attach to the
warmest surface in the system first, which, in the case of a
water cooled condenser will be the condenser tube surface
A careful
f l balance
b l between
b Cycle
l off Concentration
i andd
water blow down or bleed off and Chemical additives,
needs to be maintained
maintained.

ASIA ENERGY TECH

 SYSTEMS
Scale Effect on Heat Transfer
Heat Flow
q = HTHeat
Medium-LT Medium
Resistance
Th: Tc: low
l
high temp
temp
Rfh Rfc Waterside Heat
Refrigerant Side Heat Rw
Resistance Scale Resistance
Heat Resistance

Rfh: high temp side liquid scale heat resistance

Rw: wall resistance
Rfc: low temp side liquid scale heat resistance

11
ASIA ENERGY TECH
SYSTEMS
Scale Effect on Heat Transfer

„ For new heat exchanger,

exchanger Rfh and Rfc equals zero.zero When
Rfc increases, it means internal scale is increasing. Total
heat resistance Rt increases,, heat transfer q will reduce.
„ To keep q stable, Th-Tc shall remain constant.
Normally, Tc is constant, then Th increases due to scale
and affects the performance of the equipment.
„ To chiller, if scales get thicker, in the early stage, chiller
efficiency will reduce, at the later stage, compressor
discharge temp will increase.
„ A 1oC iincrease in
i condensing
d i Temperature
T equates to
approx 3% increase in Compressor Power.

12
ASIA ENERGY TECH
SYSTEMS
Scale Effect on Heat Transfer

Scale Removal Required

Scale Resista

Scale Period
ance

Time
13
ASIA ENERGY TECH
SYSTEMS
Scale Effect on Heat Transfer
Fouling Effect
Fouling Factor Scale Power Increase
(M2-K)k/Kw Thickness (%)
(mm)
Clean Tube 0 0
0.0176 0.025 1.1 With ATB
system
t
0.044 0.076 3.3
0 088
0.088 0 152
0.152 55
5.5
0.176 0.305 11.0 Typical Scale
0 352
0.352 0 610
0.610 22 0
22.0 Between
Manual
0.528 0.903 33.0 Cleaning
0 704
0.704 1 219
1.219 44 0
44.0
14
ASIA ENERGY TECH
SYSTEMS
Scale Control
Chemical Method
„ Add acid to adjust PH valve (high PH increases Scale tendency
low PH increases acid erosion)
„ Add polymers to keep Dissolved Solids in Suspension
„ Use sterilizer or chlorine to reduce the fungus
„ Add dispersant to control suspended solids to sink in Tower

Disadvantage
„ Difficult to control the dosage
„ Environment contamination
„ Chillers still need periodic cleaning, at best resultant
scale is kept soft to facilitate manual scale removal

15
ASIA ENERGY TECH
SYSTEMS
Scale Control
Types of Mechanical Cleaning

„ Sponge Balls
„ ATB Brush System
„ Magnetic field cleaning
„ Electromagnetic
g scale removal equipment
q p

16
ASIA ENERGY TECH
SYSTEMS Ball Systems
Sponge Balls

z Ball strainer
z Ball recirculation pump
z Ball collector vessel
z Ball injector
z Control
C t l panell
z Cleaning balls

17
ASIA ENERGY TECH
SYSTEMS
Ball Systems
‹ 1 mm larger than ID of
How Ball Works
tube, (ball does not clean the
inner fin)

‹ Ball enters and is moved

through the heat
exchanger tubes by the water
Velocity (requires high
Velocity >1.5m/sec)

‹Number of Balls = No of
tubes x 30%

‹Laws off probability

‹L b bilit att 99%
success rate means all tubes
cleaned every 36 hours, time
period
i d is
i too long
l
18
ASIA ENERGY TECH
SYSTEMS
Ball Systems
Disadvantage • Random Cleaning－Some
tubes never get cleaned,
if more than one ball in
the tube the ball will stick

• High Maintenance Cost －

recommend balls change
every 1 to 2 months, if
replacement not done
tube will scale, cost on a
large chiller can be
>$1,000 per month.

• Limitation － only suitable

for smooth tube or large
power plant Heat
Exchangers

19
ASIA ENERGY TECH
SYSTEMS ATB SYSTEM

How Brush Wworks

ASIA ENERGY TECH

SYSTEMS ATB SYSTEM
• Each Tube has a dedicated
Brush which is held in the catch
Basket at the tube ends

• Every 4 to 6 hours the flow

Reverses for 30 seconds and
the brush Spirals forwards and
backwards Through the tube
with the Nylon Bristles cleaning
the tube surface and Fin
grooves

• Each
E h ttube
b iis guaranteed
t d tto
Be brushed even at tube
velocities Of less than 1 metre a
second

ASIA ENERGY TECH

SYSTEMS ATB SYSTEM

22
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEM
Brushes are sitting in the baskets
Normal Flow On the leaving side

Baskets are empty Brushes

Are at the other end

23
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEM
Baskets are empty Brushes
Reverse Flow Are at the other end

Brushes are sitting in the baskets

On the leaving side

24
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEM
System
y Components：
Components：
p
„ One four-way reversing flow diverter.
„ One control panel
panel.
„ One set of Brush and Basket for each tube

„ Power is usually taken from the chiller starter

or can be from separate 230v source.
source
„ Air supply of 4 to 8 Bar required or can supply
small compressor
p (40
( 0 Litres Capacity)
C p y)
„ Can integrate to Chiller Flow bypass and
Unloading
„ Can Integrate to BMS
25
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEM
„ Brush & Basket

26
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEM
Turbo End Rotates
Spiral
p Brush Design
g brush

Spiral
p Brush Design
g Spiral movement, cleans the
groove of enhanced tube
completely

27
ASIA ENERGY TECH
SYSTEMS
Tube Profiles
Different Types of Internal Enhanced Tube

28
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEM

Pneumatic
Cylinder Compressed Air
8 Bar

Control
Panel

4 Way
W
Proximity Solenoid
Switch Valve
Controller
HX Valve

29
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEM

Model Of 4 – Way Valve

Normal Flow Reverse Flow

30
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEM

Control Panel
„ NEMA 4X
„ Si
Siemens S7 PLC CController
ll
„ 4 Line HMI Panel Mounted
„ Power Indicator
„ Manual/Auto Mode
„ Normal/Reverse Flow Indicator
„ Alarm Indicator/Reset
„ Can Integrate to BMS
„ C be
Can b CConfigured
fi d as DData
t LLogger
With additional sensors

31
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEM MATERIALS
Brush, Heads Polypropylene, Bristles Du-Pont
Nylon 512 Wire, Bristle Melt Point 208oC,
512, Titanium Wire C
Max continuous Use 80oC

Baskets, Polypropylene, Tested to 150oC,

M i
Maximum C
Continuous
ti Use 104oC,
U C
Melt Point 167oC

Valve, Body of A36 Carbon Steel, Internal

Parts 304 Stainless Steel and Neoprene
Seals, Manufactured to ASME pressure
Vessel Code, Maximum Working Pressure 10 Bar
(20 Bar also available)

32
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEM INSTALLATIONS

33
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEM INSTALLATIONS

34
ASIA ENERGY TECH
 SYSTEMS
ATB SYSTEMS BENEFITS
„ Energy Saving 15～30％ Features
„ Low Maintenance Cost (quarterly inspection)
„ Brush guaranteed for 5 years, baskets guaranteed for 20 years,
Easy to replace brushes
„ Baskets protect tube end from water velocity erosion
„ Every tube guaranteed to be cleaned every 4 to 6 hours (timer)
„ Economical initial cost (payback often less than 1 year)
„ Special basket design,
design end clips allow brush to be removed
„ Automatic cleaning, no need to shut down
„ R d
Reduce th
the amountt off W
Water
t & Ch Chemicals
i l (By
(B increasing
i i COC)
„ Reduced failure of chiller by maintaining low lift
„ l pressure drop
low d (
(usually
ll less
l than
th 15 Kpa
K forf valve
l + Brush)
B h)
35
ASIA ENERGY TECH
SYSTEMS Chiller Approach
pp Performance
2* 500tr Chillers at Acer Taiwan, One with ATB, One Without
A with ATB system
y Fitted ，B Without ATB

Chiller B M
Chill Manuall Chiller B D
Chill Due
Tube Clean Tube Clean
Both Chillers 14 Months 7 Months
New
10
9 A B Compressor Energy
Approach ttemperature

8 15% Higher Than A

Chiller A Maintains
7
Approach @ Less
6
Than 1oF (0.6oC)
5
4
3
2
1
0
2002/10/30

2002/12/30
2002/1/30

2002/2/28

2002/3/30

2002/4/30

2002/5/30

2002/6/30

2002/7/30

2002/8/30

2002/9/30

2003/1/30

2003/2/28

2003/3/30

2003/4/30

2003/5/30

2003/6/30

2003/7/30

2003/8/30

2003/9/30
2002/11/30

36
ASIA ENERGY TECH
 Ch
hiller Load
Chiller
C (%
Load%)
%

0
10
20
30
40
50
60
70
80
90
100
10 20 30 40 50 60 70
7 80 90 100
2002/1/30
SYSTEMS

2002/2/28

2002/3/30

2002/4/30

2002/5/30

2002/6/30

2002/7/30

2002/8/30
Chiller B Data Logging

2002/9/30

2002/10/30
2
Load Vs Approach Relationship

2002/11/30
2

运行时间
2002/12/30
2

2003/1/30

2003/2/28

ASIA ENERGY TECH

2003/3/30
Chiller B Load Vs Approach

2003/4/30

2003/5/30

2003/6/30

2003/7/30

2003/8/30
Chiller Approach

2003/9/30
0
1
2
3
4
5
6
7
8
9

1 2 3 4 5 6 7 8 9 10
0
10

Approach
Approac
ch
temperature
temperatu
e
ure
( (oF) F)
F
Chiller Percentage Load
Chiller Approach Performance

37
 ATB SYSTEMS ROI
SYSTEMS

Return on Investment
Capacity (Tons) 500 900 1200

Power (KW/TON) 0.65 0.65 0.65

Running cost After first

year（no ATB）ARI 744,543 1,230,322 1,874,785
condition (RMB)

Running cost ( with ATB)

ARI Condition 638,574 1,055,226 1,607,962
(RMB)

R t Saved(RMB)
Rates S d(RMB) 105 969
105,969 175 096
175,096 266 823
266,823

ATB Installation cost

192,000 263,700 335,000
(RMB)
Investment on Return
1.81 1.51 1.26
(Year)

Chill running
Chiller i att 70% load,
l d 10 months
th a year, 0.6RMB/KWh
0 6RMB/KWh
38
ASIA ENERGY TECH
 ATB SYSTEMS
SYSTEMS

Regular Turndown
Cleaning
• With ATB Shut downs for
Tube Cleaning are eliminated

• Avoid
A id th
the d
downtime
ti (3 tto 4 d
days ttwice
i
a year)

• Avoid the Possibility of tube damage

From Acid or Manual Roding

• Avoid the cost of Labor

39
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEMS
ATB Systems can be Applied to New and
E i ti Chillers
Existing Chill
„ New Chillers can be fitted with brushes at
the Factory or at site
„ Existing Chillers are fitted with brushes at
site after extensive tube clean to remove all
traces of scale
„ On new installations M&E contractor fits the
valve and provides the wiring, AET provides
the terminations and the commissioning
„ On existing Chiller sites AET would include
for valve fitting and wiring and
commissioning
40
ASIA ENERGY TECH
 ATB SYSTEMS
SYSTEMS

Tube Treatment
After Tubes
Aft T b have
h been
b completely
l t l d
descaled
l d Th
The ttube
b ends
d are
scored lightly with Stainless Steel brush to provide key for epoxy

41
ASIA ENERGY TECH
 ATB SYSTEMS
SYSTEMS

Brush Installation
Brushes
B h are iinserted
t d iinto
t th
the ttube
b with
ith T
Turbo
b end
d ffacing
i
away from the normal water Flow

Turbo End

Normal Water Flow

42
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEMS
Basket Installations
Baskets are glued into the Tube ends with High Strength
Waterproof Epoxy

43
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEMS

Finished Appearance

44
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEMS

Valve Size: 50mm～

50mm～
1050mm
Standard 10 Bar (150 psi)
High Pressure 20 Bar
(300psi)
Pneumatic or Electric
Actuators

45
ASIA ENERGY TECH
 SYSTEMS
ATB SYSTEMS
Water Outlet Water Inlet
Typical
T i l IInstallation
t ll ti
Flow Switch
Arrangement
or Pressure
Differential
Butterfly valve
Switch

Vibration absorber

Service space

46
ASIA ENERGY TECH
 ATB SYSTEMS
SYSTEMS

Quotation Basics:
Basics: Required Information

„ Chiller Flow Rates

Rates, tube counts and Piping connection
size
„ Tube ID size at the tube sheet and 50mm down the tube
„ HX Valve connection type (Victaulic or flange)
„ Operating Pressure 10 Bar (150psi) or 20 Bar (300psi)
„ Pneumatic or Electric Actuator
„ Flow Switch/pressure differential switch position
„ Chiller size (to determine if unloader required)

47
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEMS

RITEK Tai Wan － 56 Systems

48
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEMS

ACER - 45 Systems
y in Asia

49
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEMS
Yi Long Electronics - 8 Systems

50
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEMS
Shanghai Expo Arts Center - 5 Systems

51
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEMS
Intel Factory Chengdu - 8 Systems

52
ASIA ENERGY TECH
 ATB SYSTEMS
SYSTEMS

Volkswagen Factory Pune India - 2 Systems

53
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEMS
Expo Axis Shanghai - 3 Systems

54
ASIA ENERGY TECH
SYSTEMS
ATB SYSTEMS
Our Major Customers
„ 3M
„ Allied Chemical
„ Amoco Oil Company
„ Baltimore Gas and Electric
„ California Energy Company
„ Coastal Corporation
„ Compaq Computer
„ D
Dow Ch
Chemical
i l
„ DuPont Company
„ Eastman Kodak
„ General Motors
„ Hilton Hotels
ASIA ENERGY TECH
„ Houston Medical Center
„ Hyatt Hotels
„ IBM
„ Johnson and Johnson
„ Mitsubishi Heavy Industries
„ Northern California Power Agency
„ Pacific Gas & Electric Company
„ Phili Morris
Philip M i
„ Phillips Petroleum
„ Philips Semi-Conductor
„ Westinghouse
„ Xerox Corporation
55
 SYSTEMS ATB SYSTEMS
ATB Reference – River Water
‹ Blue Chip Casino ‹ Caesar’s Casino – Shanghai EXPO
Michigan City,
City Elizabeth
Elizabeth, Expo Axis
4*380ton 4*450ton 3*1,000ton
Trane chillers Trane chillers Carrier
Ri
River W
Water
t Ri
River W
Water
t Ri
River W
Water
t

‹ Schlitz Office Park ‹ Pfizer Pharmaceuticals Shanghai EXPO

Milwaukee Rockford, Arts Center
1 *1100ton, 1*1200-ton, 2 *350 ton 5*800ton
Trane chillers York Chillers Trane
River Water Well Water River Water

56
ASIA ENERGY TECH
SYSTEMS ATB SYSTEMS
Some of Our Customers in China
‹ Philips Suzhou ‹ Walton Tech Suzhou
5*800ton
5 800ton
McQuay Phase I: 2*400ton
McQuay

‹ Intel Chengdu Phase II: 2*800ton

8*1300ton McQuay
Trane
‹ National Semiconductor Kunshan
‹ Intel Shanghai Phase I: 3*500ton
6*1050ton McQuay
Trane

57
ASIA ENERGY TECH
SYSTEMS
Payback Calculation
Water Technology of Pensacola, Inc.
Automatic Tube Brushing (ATB) System
Payback Calculation

Date:08-Aug-09
C t
Customer:ABC
ABC B
Business
i
Job Name:New Chiller

Chiller Information:
Manufacturer: Trane
Tonnage: 800
KW/Ton Rating at Design: 0.58

P
Power R
Requirements:
i t
Power Cost ($/KWh): $0.750
Load Factor: Months Load %Load in Hours
a. 3 90% 1944
b. 3 70% 1512
c. 2 60% 864
Total Load 4320

Adjustment for Fouling: Energy Increase:*

Average Fouling Factor:* 0.0018 19.80%
Fouling with ATB System: 0.00025 2.75%
Difference: 0.00155 17.05%
KW/Ton Increase due to Fouling: 0.68

Power Cost per Year: (Tonnage x KW/Ton Rating x Total Load x Fouling Adjustment)
Without ATB System: $1 801 025 28
$1,801,025.28

With ATB System: $1,503,735.84

Savings with ATB System:

Estimated Power Savings: $297,289.44
Estimated Maintenance Savings: $15,000.00
Total Savings: $312,289.44

System Cost:
Equipment Cost: $170,000.00
Installation Cost: $40,000.00
Total Cost: $210,000.00

Payback and ROI:

Estimated Payback: 0.67Years

Return on Investment (ROI): 148.71%

58
ASIA ENERGY TECH
SYSTEMS Conclusion
„ Automatic Tube Brush Systems is the only method of
A tomatic tube
Automatic t be cleaning recommended by
b all USA
Chiller manufacturers
„ ATB Systems are infinitely more reliable and cost
effective than ball systems
„ ATB can provide energy saving and help to extend
the operating life of your equipment
„ ATB has qqualified local support
pp from energygy
professionals both in China and Asia
„ Each application is carefully studied and we will
not promote the product unless we can achieve a
less than 2 year payback or where the use of ATB
i essential
is ti l (River,
(Ri W t Water
Waste W t or SSea WWater
t
application) 59
ASIA ENERGY TECH
SYSTEMS

Th k You
Thank Y

ASIA ENERGY TECH