Monitoring and Control• Full PLC logic –DCS Integration • Managefrom central control • osemount, Yokogawa • Wet chemical analyzers or solid state probe sensors? room •

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Monitoring and Control of

Cooling Systems

Water Treatment Seminar Lake Charles, LAOctober 18, 2012

Raymond M. Post, P.E.

Collect | Calculate | Control | Communicate

y ,Director Cooling Technology

[email protected]

Fundamental Cooling Triangleg g

Corrosion

Control

BioFoulingDeposition

Best Performance at Lowest Cost Demands Excellent Control

Property of ChemTreat – do not reproduce without permission

Why Invest In Automation?

• Reduces Chemical Consumption

Manual Control

• Reduce Water Usage• Improve Program

PerformanceU ili M M• Utilize Manpower More Efficiently

• Improve Troubleshooting and Diagnostics A t ti C t land Diagnostics

• Ensure Personnel Safety• Reduce Total Operating

Costs

Automatic Control

Costs• Avoid Equipment Failures

and Lost Production


Impact of Control On Chemical Consumptionp p


Tighter Control Through Automation Closes the Cost ↔ Performance Gap

What Parameters Do We Want To Monitor and Control?and Control?

• Flow– Make‐up– Bleed

• Water Chemistry• Water Chemistry– pH– Conductivity– Temperature– Suspended Solids / Turbidity

H d (C d M )– Hardness (Ca and Mg)– Alkalinity– Silica– Corrosion

• Treatment Chemistryy– 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 MandatedProperty of ChemTreat – do not reproduce without permission

Effluent‐Related MonitoringEffluent Related Monitoring• Flow• pH

T• Temperature• Phosphorus

• < 1 ppm P likely in future NPDES permitsW t L d All ti• Waste Load Allocation

• EPA National Nutrient Reduction Program)

• Metals• Zn• Zn• Cu • Hg

• Chlorine and other halogensChlorine 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 DosingProperty of ChemTreat – do not reproduce without permission

Monitoring and Control ApproachMonitoring and Control ApproachThe approach we recommend is to use the most appropriate and cost‐effective monitoring and control equipment, which will:

• Provide minimum total cost of operation• 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 qualityEnsure highest product quality

• Reduce / Eliminate potential for forced outage

So, Where Do You Start?


What Are The Elements of A Good Cooling Water Monitoring and Control System?Monitoring and Control System?

• 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 more accurate but requires reagents• Chlorine analyzer – more accurate but requires reagents

• Historical data logging and trending capability• Centralized (Preferred)• Remote stand alone unit

• Means for Pacing the Corrosion and Scale inhibitorsMeans for Pacing the Corrosion and Scale inhibitors• Flow based or Residual based• Probe sensor or wet chemical analyzer• Feedback or Feed Forward


Chem Feed Monitoring and Control Hierarchy

FlowFlow,Chemistry,

Data Acquisition,Remote

C i iCommunications

Flow based Control With Ch i V ifi iChemistry Verification

Flow based Controlwith Proportional Chemical Feedwith Proportional Chemical Feed

Bleed and Feed


Most appropriate choice depends on the system, criticality, etc.

Monitoring and Control Considerations

• Advanced controller designs• Walchem • ProMinent/Aquatrac

• External call‐out capabilities• Cell modem or internet access?

• Remote control or Alarm only?– Ethernet – MODBUS– Integral cell modem– USB

Setup Software

• Remote control or Alarm only?

• Water quality analyzers• Hach

R Y k– Setup Software

• Custom systems• Full PLC logic – DCS Integration• Manage from central control

• Rosemount, Yokogawa

• Wet chemical analyzers or solid state probe sensors?

Manage from central control room

• New wireless technology• One‐way or two‐way

communication

• Own or Lease• Capital and Tax implications

• Proprietary Vs. Open source

• Data logging and management• Access

• Who?Off it ?

• Who owns the equip. & data?

• Can you be held hostage to one equipment or chemical

li ?• Off‐site access? supplier?


Pacing The Chemical FeedPacing The Chemical FeedFlow‐Based• ~90% of chemical is lost to blowdown

– Flow pacing can be very accurate

l l bl l d d– On‐line, reliable, simple, Feed Forward

• 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)


Treatment Chemical ControlF d F d F d B k B thFeed Forward, Feed Back, or Both

Feed BackFeed Forward• Flow• Turbidity

S li t d

Feed Back• Conductivity• ORP / Chlorine

Residual• Scaling tendency• Conductivity

• pH• Product residuals

• Actives• Fluorescence• Fluorescence

• Corrosion Rate• Biofouling


is:

• 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


• Your Solution starts with an easy to build and install control system

COLLECT | CALCULATE | MONITOR

• The CT Solutions system can be specified with sophisticated or standard control schemes

• Also with a wide range of sensors for measuring and monitoring:

– Performance‐based monitor and control

– Conductivity– pH– ORPORP– Corrosion– Fouling– Actives‐based ppm control

Fl– Fluorescence sensors


Control Systems:Collect | Calculate | Control | Communicate

Standardized but highlyStandardized but highly customizable control

systems.

Solid-state productSolid-state product residual sensor (no reagents)


Control Systems:Collect | Calculate | Control | Communicate

System Integrated and Manufactured to be “plug and play” when it arrives at

our customer’s facility


Solutions Controller with Hach CL17, MultiTrak Polymer Analyzer


Data Management Software

• You have the ability to review real time data

VERIFY | VALIDATE

time data

• Data can be integrated with DCS systems or viewed from individual PC’s or smart phones

Cl hi h i l• Clear graphics show crucial 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

CTVi t i b b d d t• CTVista is a web‐based data 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 ja few of the charts available to authorized personnel within this secure environment


Reporting structure can be scaled to meet customers needs:Reporting structure can be scaled to meet customers needs:

• Unlimited systems per facility (multiple systems w/ substantial reporting needs)U li it d f iliti t

• Unlimited systems per facility (multiple systems w/ substantial reporting needs)U li it d f iliti t• Unlimited facilities per customer (multi‐site corporate oversight)

• Unlimited facilities per customer (multi‐site corporate oversight)


Operators can manually input results using a tablet, Smartphone, laptop, or PC

Operators can manually input results using a tablet, Smartphone, laptop, or PC

orData can be automatically logged directly

from a controller

orData can be automatically logged directly

from a controller


Customized dashboards give instant snapshot of overall

system health

Customized dashboards give instant snapshot of overall

system health


Operator / Service Reports –


Visit Reports – Cooling Tower Cleaning


Lab Reports –


REPORT | COMMUNICATE


Because Better Data Means Better DecisionsBecause Better Data. Means Better Decisions.

• Real time secure data available 24/7 via PC smartControl Systems • Real time secure data available 24/7 via PC, smart phone, or tablet

• Solutions Control Systems are easy to set up and operate - all it needs is a water source

Control Systems

ope ate a t eeds s a ate sou ce

• Data input automatically from your Control System, manually from ChemTreat service, or plant personnel.

• Information is available in a number of easy to read• Information is available in a number of easy to read graphs, charts, and tables – with customized dashboards for quick review

Your Package :Your Package :

Pinpoints and corrects system inefficiencies Creates more accurate tracking and system

validation reportsp Increases productivity of plant personnel Reduces operating costs


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Better Data Better DecisionsBetter Data. Better Decisions.


Documents

Monitoring and Control• Full PLC logic –DCS Integration • Managefrom central control • osemount, Yokogawa • Wet chemical analyzers or solid state probe sensors? room •