Process EfficiencyProducts , Inc.322 Rolling Hill Rd.Mooresville, NC 28117-99201 (800) 24-FILTER(704) 662-3133FAX (704) 662-3155pepusa@pepfilters.comwww.pepfilters.com

TalkBy Barry A. Perlmutter,Director, Marketing & Sales

The Birmingham Airport Authorityserves over 10,000 people/day throughits terminals. The Airport was undergo-ing a modernization of the majorcomponents of the cooling system. Theobjectives of the modernization were toimprove cooling and to reduce theoperating and maintenance costs.

Cooling System EvaluationPhase I of the evaluation examined thecurrent cooling towers. The Airport hadexisting Wood Towers installed inside ofthe parking deck in an open environ-ment. Jim Loftin, of the AirportAuthority staff read about the benefitsof sand media filtration in a trade publi-cation and wrote a general specificationthat incorporated a filter into the entireproject. Mr. Jim Dowdy, of Dowdy &Associates in Birmingham, AL was suc-cessful in putting together a competi-tive bid for Carrier and their 530-tonchiller. Dowdy’s proposal includedpumps, an Evapco 672-ton coolingtower, Model SST 12-818, and the PEPsand filter. The photograph belowshows the tower installation.

Operating & MaintenanceCost EvaluationAccording to Jim Loftin, the Airport wasspending significant amounts of themaintenance budget to keep the coolingtower and associated equipment cleanfrom airplane and airport dirt anddebris. The basin of the cooling towerhad to be cleaned about 15 times peryear. It required two men, up to fourhours, to drain, clean and refill thetower basin. The Airport MaintenanceDepartment was also periodically rod-ding out the chiller tubes. Finally, theAirport was using different types ofvery expensive biocides to control thebiological and algae growth. In summa-ry, cooling system maintenance was anarea of major cost.

Solving the SystemCleaning ProblemsIn order to solve the cleaning problems,Jim Dowdy explained that it is impor-tant to remove the particulates at thesource. The cooling tower is a big airscrubber. Airborne contaminants enterthe cooling tower and deposit into thebasin. These contaminants cause heatexchanger fouling, condenser tube plug-ging and have a severe impact on theability of the water treatment chemicalsto perform effectively. Analysis by inde-pendent water labs indicated thatgreater than 90% of the particles were inthe 1-10 micron range.

Jim Dowdy further explained the theo-ries of filtration and that the use of side-stream sand filters is effective in remov-ing these size particles. Centrifugal sep-arators which remove particles basedupon weight rather than size and inline

strainers do not remove particles in the1-10 micron range. The site agreed withthe analysis and installed sidestreammedia filters.

System Sizing & InstallationIn order to size a sidestream filtrationsystem for the cooling tower, the totalsystem volume had to be estimated. JimDowdy completed this calculation bytotaling the volumes in the coolingtower basin, system piping and con-denser. The recommended filtrationrate is a system volume turnover ofonce per hour. The selected filter was aPEP SMF-FG-20 Sand Filter System witha flow rate of 43 gpm, shown below.

The SMF FG-20 is a skid-mounted pack-age with system-matched pump,pre-strainer and an automated controlsystem. Three-way bronze ball valveswith electric actuation direct the fluidflow for automatic backwashing to self-clean the media.

— CONTINUED ON PAGE 2WITH THE RESULTS & BENEFITS

FollowThe Stream

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Volume 3, Issue 2, June, 1999

Visit our new web site, opening in July, at www.pepfilters.com� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

PEP Media Filter Improves Cooling Efficiency and ReducesOperating Costs at the Birmingham InternationalAirport

Evapco SST 12-818 Cooling TowerInstalled Inside the Parking Deck

PEP SMF-FG-20 Sand FilterInstalled in the Mechanical Room

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IndustrialManufacturing

ChemicalPlants

Pharmaceutical Hospitals Universities/Schools

CommercialAirports

Electronic Computer/InstrumentationCommunication

EnergyFood &Beverage

Parks,Zoos,Hotels,

Aquariums

USETHE RAPIDRESPONSE FAXTOCONDUCTAWATER

ANALYSIS OFYOUR SYSTEM.

Results & BenefitsJim Loftin was very pleased with theinstallation and performance of the fil-ter. The benefits that were realized areshown in Table 1.

With the benefits of the PEP installationon the first phase, for the Phase IIexpansion, the installation was dupli-cated. The units have been in operationsince 1996/1997 and are user-friendlyrequiring little operator attention.Payback for the PEP filters areapproximately 1 year.

— CONTINUED FROMTHE COVER

A major automotive assembly plant inOntario, Canada uses welder water in aclosed loop application for cooling thewelding tips used to manufacture carbodies. According to the plant mainte-nance manager, the operators wouldclean out the weld tips every othershift, water saver valves would plugroutinely from solids in the water andwelding efficiencies were suffering.

Manurep Sales Inc. of Pickering,Ontario was contacted about thisclosed-loop water quality problem. Awater analysis was conducted and

determined that 90% of the particleswere below 10 microns (um) with 95%in the 1-5 um range. The plant con-curred with the analysis and installedthree PEP media filters, model HMF 42systems with 0.5 um media.

The HMF 42 has a flow rate of 198 gpmand was installed as a sidestream filteroff of the closed loop system. The HMFis a skid-mounted package with an auto-mated control system that communi-cates with the plant distributed controlsystem (DCS). Three-way bronze ballvalves with electric actuation direct the

fluid flow for automatic backwashing toself-clean the media. No pump is includ-ed as the closed loop system pressureis used for filtration.

The clean water for this facility haseliminated the need for weld tip clean-ing, improved the performance of thewater saver valves and has resulted inimproved productivity of the welders.In fact, the engineer has commentedthat “he has never seen the water look-ing so clean.”

Handy Notes From Our CustomersCarAssembly Plant Realizes ImprovedWeldingFrom the Installation of Three PEP Media Filters

TABLE 1:

BENEFITS OF THE PEP MEDIA FILTER

• Tower cleaning was reduced by over 90%

• Basin cleaning time was reduced to 1 1/2 man-hours from8 man-hours

• Chiller efficiency improved

• Chiller cleaning was reduced to every two years

• Biocide usage was decreased

• Conductivity set point was increased seven-fold

• Set point increase resulted in less blowdown, less chemical usageand greater water savings

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Sand Filtration (Cooling tower application)

� DRAWING CHECKLIST:

YES N/A�� �� Equipment designation on drawing.�� �� Equipment scheduled and specified in construction

documents.�� �� Plumbing data (floor drains) coordinated with plumbing

engineer.�� �� Housekeeping pad coordinated with architect.�� �� Coordinate location with project flow diagram.�� �� Access around equipment.�� �� Direction of flow (arrows indicated).�� �� Reference to applicable detail indicated on drawing.�� �� Control devices indicated on detail.

� DESIGN CHECKLIST:

YES N/A�� �� Layout based on one-line diagram.�� �� Coordinate sequence of operation with flow diagram.�� �� Electric data coordinated with electrical engineer.�� �� Take suction from lowest point of tower basin sump

(tower side-stream application).�� �� Connect supply and return from condenser pump

suction line (inline side-stream application).�� �� Take into consideration system backwash; coordinate

floor drain size and city water makeup (if required) withplumbing engineer.

�� �� Select filter (filter flow rate) based on manufacturer’srecommendations.

� VALUE ENGINEERING TIPS::

YES N/A�� �� Equipment scheduled and specified with return on

investment (ROI).�� �� Installation of sand filter increases performance.

longevity of mechanical equipment and reduces fouling(e.g. condenser tubes, pump seals, heat exchangers,and valves).

�� �� Sand filter installations can result in better heat transfer,resulting in lower energy consumption (hence, lowercost of operation).

�� �� Reduction of fouling in system results in reduced use of chemicals for control scalingand algae. It also saves on maintenance hoursand/or cleaning of cooling tower basins, sump,condenser tubes, and dirt from heat exchangers.

Note: Clean water is the key to operating an hvac system atthe most economical kWh per ton, In addition, water treat-ment is improved, maintenance costs reduced, and equipmentlife is extended. Cooling water filtration can provide all ofthese benefits.

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If you have any comments, suggestions, or questionsregarding this checklist, contact Amanda McKew,mechanical engineer, R.G. Vanderweil EngineersCorp. (Boston); amckew@hvac.vanderweil.com(e-mail).

44 Engineered Systems April 1999 For subscription information, please contact Business News Publishing at248.362.3700

BY AMANDA McKEW________________________________

h v a c rdesigner tips™

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Technology, EngineeredSkid Systems & ServicesTECHNOLOGY

Filtration• Sand and Multimedia Backwashable Filters• BGFS Bag Filters• Cartridge Filters: Disposable and Cleanable

Separation• LMF Hydrocyclone Separators

Adsorption• Activated carbon• Organo-clays• Diatomite,perlite• Specialized adsorption media

ENGINEERED SKID SYSTEMSSkid systems with PEP Technologies includingpumps,motors, instrumentation and PLC ControlFully customized applications,designand innovationsASME Code ManufacturingUL and C-UL Certified Panel ShopUnique Approval Packages and Documentation

SERVICESWater analysis and recommendationsRental filters for on-site testingTechnical seminarsPre-shipment testing of all technologies and systemsOn-site start-up and trouble shooting

EXPERT APPLICATION KNOWLEDGECooling Tower and HVACWaterProcess fluids and waterWastewater treatment

Process Efficiency Products, Inc.

4

Gehl Guernsey Farms is a 100 year-old dairy inGermantown, Wisconsin. Gehl manufacturers specialtyproducts such as cheese sauce for nachos and nutrition-al drinks such as Gehl Cappuccino.

Cooling System ProblemsCooling for the food products is done with cooling towersand heat exchangers. Water flow rates vary from 8 to 1200gpm. Michael Sowieja, VP of Engineering, and SteveSadowski, Plant System Coordinator watched as theircost of maintaining good water quality was increasing.Their cooling towers were showing as much as 18 poundsof dirt and debris and the operating people had to drainthe towers and shovel out the dirt 3 times per year. Inaddition, using dip slide tests to check the bio-counts,Gehl was using 6 drums of biocide chemicals per year ata cost of $1,500 per drum.

SolutionMike and Steve analyzed several types of equipment tosolve the dirt problem including screen filters, disposablecartridges, centrifugal separators and media filters. Theparticle size distribution of the contaminants in the sys-tem was 90% at 10 microns and less so the selected equip-ment had to be able to remove this size of particles. Whilecartridge filters could clean up the problem, they wereextremely costly in terms of operating and maintenance.Centrifugal separators were not selected, as this technol-ogy does not have the required removal efficiency. Mikeand Steve worked with Dave Hammer of Chipley andZeman in Milwaukee, Wisconsin to select and install a PEPSMF-FG-24 media filter, on the remote sump.

ResultsWithin the first month of operation, the bio-counts werelowered by 50% and Gehl lowered its use of biocides. Infact, Gehl reduced the usage to 2 drums/year from 6drums at a savings of over $6,000 for the chemicals alone.The June bug problem that helps to drive up the use ofbiocides was reduced by the PEP media filters.

PEP Media FIlters Reduce Biocide Costs atGehl Guernsey Farms

Mike and Steve stated that “cold water is very impor-tant to cooling the cheese and that the cost ofmaintenance to keep the water cold can be veryexpensive.” In other words, water is cheap, but totreat it can be expensive. Gehl has now installed twoadditional filters on the other cooling tower sumps.According to Steve Sadowski, “if we use lesschemicals in the water, we are helping the envi-ronment... and our futures.”

PEP SMF-FG-24 Sand Filter Installed at Gehl Guernsey Farmsfor Cleaning of a Remote Sump

Process Efficiency Products , Inc.322 Rolling Hill Rd., Mooresville, NC 28117-99201 (800) 24-FILTER • (704) 662-3133 • FAX (704) 662-3155pepusa@pepfilters.com • www.pepfilters.com