water treatment boot camp · 01/05/2019 · water treatment boot camp may 1, 2019 1 2 today’s...

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Water Treatment Boot Camp

May 1, 2019

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Today’sTopics:

Water Overview

Pre-treatment & Filtration Options

Cooling Towers

Steam Boilers

Water Testing Techniques

Troubleshooting & Corrective Actions

Equipment & Reporting

WATEROVERVIEWFactsIndustrial usesCharacteristics

Presenter:Rob PierickSenior Territory Manager

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Basic Water Characteristics

City of Waterloo Water Well Water

p Alkalinity (mg/L as CaCO3) 0 0

m Alkalinity (mg/L as CaCO3) 214 331

Chloride (mg/L as Cl-) 27.4 13.8

Silica (mg/L as SiO2) 17.4 35.7

Sulfate (mg/L as SO42-) 30.5 819

Ortho-Phosphate (mg/L as PO43-) < 0.1 < 0.1

Total Phosphate (mg/L as PO43-) < 1.6 < 1.6

Calcium (mg/L as Ca2+) 75.8 267

Magnesium (mg/L as Mg2+) 23.0 81.6

Calcium Hardness (mg/L as CaCO3) 190 668

Magnesium Hardness (mg/L as CaCO3) 94.3 335

Total Hardness (mg/L as CaCO3) 284 1003

Iron, Total (mg/L as Fe) < 0.1 1.8

Copper (mg/L as Cu) < 0.1 < 0.1

Sodium (mg/L as Na+) 10.4 159

Potassium (mg/L as K+) 1.2 8.8

pH 7.9 7.7

Conductivity 605 1950

Comparative example of surface and ground water characteristics

WATER OVERVIEW | Water Treatment Boot Camp 4

Why all the fuss?

WATER OVERVIEW | Water Treatment Boot Camp

Boilers will explode with improper water treatment/management

Premature equipment failures and unscheduled downtime will result if water systems are not properly maintained and chemically treated.

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Water QualityLater we will discuss why it is important to maintain consistent good high-quality water based on industry standards:

• ASME – American Society of Mechanical Engineers

• ABMA – American Boiler Manufacturers Association

• CTI – Cooling Technology Institute

WATER OVERVIEW | Water Treatment Boot Camp 6

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Pretreatment & Filtration Options

Presenter: Jeff Freitag – Director of Sales

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Why Pretreat?• Consistency of water quality

• Make-up sources and quality vary

• Chemicals can only do so much

• Needed for almost all applications

• Prevent against scaling, deposition and improved efficiencies

PRETREATMENT & FILTRATION | Water Treatment Boot Camp 8

Most Common Treatment Methods

Filtration Softening Reverse Osmosis


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Filtration


A process for separating suspended and colloidal impurities from water• Passage through a bed of granular media• Passage through spiral wound cartridge or bag.

Bag and Cartridge FiltersAdvantages / Disadvantages

ADVANTAGESLow capital cost, simple operation

DISADVANTAGESHigh operating cost, labor intensive


Media Filters

ADVANTAGES• Fine Filtration• 15 microns

• Automatic Operation• M inimal labor

• Large surface area

DISADVANTAGES• Moderate cap. Cost

• High backwash vol.• Great “bug” trap / media


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Tekleen Self-Cleaning Filtration• Automatically self-cleans using only

water pressure

• High performance screens• Flow is not interrupted during cleaning

process – means no downtime• External power is not required• Virtually Maintenance free

• Easy to install• Configurable to a wide range of

applications


Key Takeaways – Filters• Make sure not to exceed maximum pressure drop of

15 psig before changing out any type of cartridge bag filter• Track inlet and outlet pressures

• Track pressure differentials across media filters to ensure that they are backwashing properly.

• Media filters may need to be disinfected on a annual or semi annual basis to remove microbiological fouling.• Use fresh water for backwash filters instead of process or tower water.

• Automatic screen/disc filters are a good alternative to media filters as they use less water to backwash

KEYTAKEAWAYS


Softeners• Remove calcium, manganese

and iron

• What information do you need to know when sizing softeners?

• Commercial units regenerate just like the unit in your house (multiple designs)


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Ion Exchange Resin


Hard water loaded with Calcium, Magnesium and many other ions enters the softener coming in contact with millions of resin beads holding billions of sodium ions.

The Calcium, Magnesium and other ions trade places with the Sodium ions creating softened water.

How do you know the softener is working?• Perform a total hardness test on the water.• Soft water used for boiler make up should have <0.5 ppm of total

hardness. This will vary depending upon boiler pressure. As pressure goes up acceptable hardness levels go down.• Soft water used for cooling tower make up should be less than 50

ppm as a rule of thumb. This will go down as the cycles of concentration in the tower go up.

17PRETREATMENT & FILTRATION | Water Treatment Boot Camp

Key Takeaways – Softeners

• Soft water is critical to pretreatment and management of heat exchange systems

• Monitor salt usage and make sure there is salt in your brine tank

• Clean your brine tank

• Brine elusion studies will help determine efficiencies• Contact your water treater for this service

KEYTAKEAWAYS


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• Dealkalizer for alkalinity reduction

• Demineralizer for removal of both anions and cations

Dealkalizers and Demineralizer

Reverse Osmosis


• Membrane -based separation process

• Involves the separation of dissolved solids from the feedwater by means of a semi-permeable membrane• Membranes allow water to pass

through (permeate) readily, but are fairly impermeable to other constituents in the feed stream.

Reverse Osmosis


• What are the benefits to using RO water for boiler feed water?

• Cycles of concentration

• Better water quality (Total dissolved solids and alkalinity reduction) = better water quality

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Semipermeable Membranes


Chemical Treatment• RO feedwater must be carefully prepared to minimize suspended solids, scaling ions, free

halogen residuals and microbiological contamination.

• Feedwater should then be chemically treated to prevent mineral scaling, plugging and microbiological degradation of the membranes.

• Concentrate can be tested for amount of RO antiscalant present to prevent overfeed or underfeed of product.


Key Takeaways – ROs• Make-up water quality is critical

• Monitor concentrate and permeate flow and pressure

• Reduction of alkalinity and conductivity greatly increase cycles of concentration

• Permeate water must be treated to prevent corrosion and biological growth

• Soft water vs anti-scalant for chloride and water reduction practice


KEYTAKEAWAYS

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Cooling TowersFunctionGeneral DesignWater Treatment

Presenter:Jeff Freitag – Director of Sales

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Cooling TowersWhat is the purpose of a cooling tower?• Reduce water usage/ recycle water

Types of cooling towers• Induced draft

• Forced Draft

26COOLING TOWERS | Water Treatment Boot Camp

The Life Blood of the Plant

Approximately 70% of a plants water use is for cooling, 20% for process and 10% for other uses.

Cooling towers provide the most efficient means of rejecting heat from open recirculating cooling water systems.


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What Processes do you have that require cooling water?• Chillers

• Heat exchangers

• How do they work?




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Chilled Water LoopsConcerns with Chilled Water Loops• Corrosion• Scale (less likely)• Particulate•Microbiological growth

What is important to protecting chilled water loops?• Corrosion inhibitor• Filtration• Biocide


Basic Water Chemistry –Cooling Towers

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Basic Water Treatment Components• Make up and blowdown water meters

• Blowdown/Bleed valve

• Conductivity, Evirodose (ptsa), pH, ORP control

• Inhibitor pump

• Biocide pumps

• Optional• Tanks, level sensors, flow meters


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Cooling System Overview

COOLING TOWERS | Water Treatment Boot Camp

The Process of Evaporative Cooling


• Circulating cooling water, after picking up heat from the process heat exchangers , passes through the tower.

• Evaporation provides most of the cooling as the recycled water passes through the tower.

• As a result of evaporation, the dissolved solids in the water become concentrated.

• The rate of water discharge, blowdown, stabilizes the dissolved solids content of the water.

• The evaporative process also absorbs gasses from the air, particulate matte, nutrients - for biological growth-and reduces the solubilities of the solids remaining in the circulating water.

Typical Sources of Cooling Tower Make Up• Well water - scaling

• Municipal source water - scaling

• Waste water -scaling, corrosive, fouling

• Reuse water (RO concentrate) - Scaling

• Process condensate (cow water) – corrosive, fouling

• Each poses different challenges• Pretreatment may or may not be necessary• Each source of water will pose unique challenges


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Soft Water and Filtration


Pros vs. Cons of using soft water for cooling water makeup?◦ Lake Michigan vs. Waukesha water◦ Safety

What kind of Filtration should you use?

Cooling Tower Water Treatment Goals


Public Health and Safety

Cycles of Concentration

BLEE

D RA

TE

1 2 3 4 5 6 7 8 9 10 11

Control Fouling and Corrosion

Minimize Water Usage

Cycles of ConcentrationBoilers and Cooling Towers

• Build-up of the concentration of dissolved solids in recirculating water = “cycling up”

• Determine the maximum number of cycles of concentration to run w/o forming deposits or causing excessive corrosion• Your Water Treatment Supplier is responsible for this.


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What Cycling Means


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How To Control Cycles In Your Tower


Water Use and Your Recirculating Cooling Water System


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Before: Tower at 3 Cycles

AnnualMake Up

AnnualBleed

22.86 MG 7.56 MG

$43,094 $19,656

3,000 GPM Recirc Rate

30 GPM

15 GPM 45 GPM

400 uS

Controller

Setpoint

= 3 Cycles

1,200 uS

10oF T

Make Up

Evaporation


After: Tower at 5 Cycles

AnnualMake Up

AnnualBleed

19.15 MG 4.03 MG

$36,389 $10,483

3,000 GPM Recirc Rate

30 GPM

8 GPM 38 GPM

400 uS

Controller

Setpoint

2,000 uS

= 5 Cycles 10oF T

Make Up

Evaporation

Summary of Cooling Scenarios


Make Up Flow Make Up Cost Bleed Flow Bleed Cost

3 Cycles 22.86 MG $43,094 7.56 MG $19,656

5 Cycles 19.15 MG $36,389 4.03 MG $10,483

SAVINGS 3.71 MG $7,514 (-15.5%)

3.52 MG $9,173(-46.7%)

Chemical / Misc Savings = >$10,000 per year

TOTAL SAVINGS = $27,000 per year

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Effective Ways to Increase Cycles of ConcentrationRecirculating Cooling Tower

1. Automate chemical feed and tower bleed

2. Soften the makeup water

3. Feed acid to control alkalinity and pH

4. Look for a better source of makeup water

5. Install “side-stream” filtration for solids removal


Cooling Water Problem Areas

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Cooling Water System Problem Areas


• Scale – calcium, magnesium, iron, silica

• Corrosion – loss of metal

• Fouling◦ M icrobiological – bacteria, mold, fungus, algae◦ W ind blown debris, process contamination

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Cooling Water System Problem Areas

SCALING

CORROSION

FOULING


Basic Cooling Water Treatment Programs• Scale and corrosion inhibitor blend

• Biocides• Oxidizing• Non-oxidizing biocide

• Anti-foulants


Scale and Corrosion Inhibitor• Blend of polymers, sequestrants, dispersants and

corrosion inhibitors• Specific blends to handle various water qualities and

contamination issues

• Feed with or without acid• Acid for alkalinity reduction

• Soft water makeup – corrosion control issue

• Lab and direct measurement tests for monitoring• PTSA, polymer, phosphonate, molybdenum

• Feed proportional to makeup/bleed volume or direct measurement


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Microbiological ControlBiocides to control bacteria, mold, fungus, algae• Inhibit heat transfer• Inhibit flow• Increase corrosion – “mic” =

microbiologically induced corrosion

• Health and safety issue –Legionella


BiocidesOXIDIZING

1. Dosage is based on system volume

2. Different biocides have different requirements• pH, ammonia, retention time, organics

3. Requirements for effectiveness• Correct concentration

• sufficient contact time

4. Dual Biocide Program works best


BiocidesOXIDIZING

• Chlorine

• Bromine

• Chlorine dioxide

• Hydrogen peroxide, peracetic acid


NON-OXIDIZING

• Isothiazolone

• Gluteraldehyde

• DBNPA

• Quaternary amine

• Many more

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The Cooling System… What to knowConductivity control is critical to proper water chemistry • Use automation to accomplish this• Check calibration with hand held conductivity meter

Maintain proper scale and corrosion inhibitor levels• Envirodose automation, op testing and others.

Ensure biocides are being fed as prescribed• Track ORP for oxidizing biocide.• Monitor tank levels, pump flow of non-oxidizing biocides.

If pH control is in use, automated control of acid pump with pH sensor is a must!• Check calibration with hand held pH meter.• Run total alkalinity test as a back up test.

Install water meters to track make up and blowdown gallons


5 Key Cooling Takeaways –To Reduce Cost1. Know your water and be committed to your water management

program.

2. Know your pretreatment equipment and make sure it is operating properly and efficiently.

3. Install make up and blowdown water meters on all of your equipment where applicable. Know where you use and discharge water and how much

4. Understand cycles of concentration to optimize and reduce water, energy, chemical and salt usage.

5. Consider utilizing automated systems to monitor, control, alarm and trend critical water systems.


KEYTAKEAWAYS

Steam BoilersFunctionGeneral DesignChemical Treatment


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Basic Boiler System

STEAM BOILERS | Water Treatment Boot Camp

INPUTS

OUTPUTS

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Boilers


What are a boilers worst enemies?

• Scale

• Corrosion

What types of boilers are there?

• Firetube

• Watertube

DeaerationOxygen is a natural component of virtually all water supplies.

At feedwater and boiler temperatures, even small amount of oxygen greatly accelerate corrosion.

Corrosion will typically be observed in a few specific locations.• Economizer - dramatic increase in temperature• Steam drum at steam/drum interface• Condensate system

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Spray Type Deaerator Operation


Purpose of Deaeration• Primary purpose is to remove oxygen and

other dissolved gasses from the feedwater.• Preheat the feedwater to prevent thermal

shock on the boiler

Dissolved gasses that may be removed:• oxygen• carbon dioxide• ammonia• hydrogen sulfide


Dissolved Oxygen Concentration Vs. Water Temperature


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Deaerator Vs. Feedwater TankWhat is the MAJOR difference BETWEEN a deaerator AND A feedwater tank?• Much lower oxygen levels

What ARE the benefits of using a deaerator over a feedwater tank?• Reduce chemical and energy usage,

Reduce expansion and contraction


Chemical DeaerationEffluent from a properly operating deaerator contains no more than 7 ppb oxygen.

Last traces of oxygen must be chemically scavenged from the feedwater.

Two types of scavengers• Inorganic - Sulfites• Organic - DEHA, Erythorbate, etc.


Basic Boiler Treatment Programs1. Oxygen scavenger – corrosion control

2. Internal treatment program – deposit control

3. Condensate treatment – corrosion control

4. Miscellaneous – alkalinity builders, antifoam


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Typical Boiler System Chemical Feed Points


Internal Treatment &

Alkalinity Builders

Make Up Condensate

Feed Water

Blowdown

Controller

Steam

Condensate

Treatment

Oxygen Scavenger

Internal

Treatment

Heat Exchanger

Oxygen Scavengers


• Sulfite• DEHA, Erithorbate, hydrazine• Feed to storage section of the DA / Feedwater

tank below the water line

• Maintain a constant residual of oxygen scavenger

O2 Scavenger Performance Monitoring


• Monitor your DA / feedwater tank pressure and temperature

• Watch scavenger concentrations

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Internal Treatments


Internal Deposit Inhibitor• Blends of polymers, dispersants, sequestrants, phosphate, chelants• Control of deposits of hardness scales, iron, copper, silica• Feed point varies depending on the treatment program and water quality

• Various test methods to determine actual concentration in boiler water

Recommendations• Don’t rely on internal treatment to do all the work

• Properly operated Pretreatment equipment is critical

Condensate Line Corrosion Control


Carbonic Acid Attack – Low pH• From makeup water alkalinity ---- carbon dioxide = C02

• Remove the carbonate alkalinity in the makeup - proper pretreatment

Oxygen Attack

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Steam / Condensate Treatments


Carbonic Acid Attack – Low pH◦ Volatile Amines used to raise the pH of condensate to prevent acidic attack◦ Usually a blend of 2-4 different amines that provide total system coverage

Oxygen Attack• used to prevent oxygen corrosion from air intrusion into condensate system

CO2

Alkalinity

Amine + VOS

Oxygen

CO3

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Oxygen Control in Condensate Systems

• Enters through condensate receivers, vacuum pumps, process systems

• Treated using volatile oxygen scavengers (V.O.S.) such as DEHA, hydroquinone, Mekor, and filming amines

• Blended amines and V.O.S.


• Watch iron and copper concentrations

• Monitor pH levels because low pH levels and oxygen accelerate corrosion rates

• Monitor VOS concentration

CAUSES AND TREATMENTS MONITORING

Water Use and Your Boiler Water System


Cycles of ConcentrationBoilers and Cooling Towers

• Build-up of the concentration of dissolved solids in recirculating water = “cycling up”

• Determine the maximum number of cycles of concentration to run w/o forming deposits or causing excessive corrosion• Your Water Treatment Supplier is

responsible for this.


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What Cycling Means


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How To Control Cycles In Your Boiler


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Make Up Condensate

Feed Water

Blowdown

50,000 #/hrSteaming Rate

Setpoint

3,500 uS

Controller

850 uS

Steam67,925 GPD 92,455 GPD

160,380 GPD

16,495 GPD

360 uS

= 9.7 Cycles

Before58%

AnnualMake Up

AnnualBlowdown

23.77 MG 5.77 MG

$45,170 $15,010

Heat Exchanger


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Make Up Condensate

Feed Water

Blowdown

50,000 #/hrSteaming Rate

Setpoint

3,500 uS

Controller

850 uS

Steam32,120 GPD 119,565 GPD

151,686 GPD

7,801 GPD

180 uS

= 19.4 Cycles

After79%

Heat Exchanger

AnnualMake Up

AnnualBlowdown

11.24 MG 2.73 MG

$21,360 $7,098


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Make Up Flow Make Up Cost Blowdown Flow Blowdown Cost

9.4 Cycles 23.77 MG $45,170 5.77 MG $15,010

19.7 Cycles 11.24 MG $21,360 2.73 MG $7,098

SAVINGS 12.53 MG $23,810 (-52.7%)

3.04 MG $7,912(-52.7%)

Fuel Savings = $40,000 per year

TOTAL SAVINGS = $92,000 per year125 psi boiler operating at 80% efficiency, 2012 city of Milw. Water cost, $4.50/MSCF gas cost, 160oF condensate temp.,

Chemical Savings = $20,000 per year


Hot Water Boilers and Loops• Common for comfort heating applications and smaller processes in plants

• What is important to protecting the hot water boiler and piping system?


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Key Takeaways – Boilers• Feedwater hardness test is the most critical test to run and keep in range

• Conductivity control is critical to proper water chemistry• Use automation to accomplish this

• Maintain proper oxygen scavenger levels• Check deaerator, chemical feed pump, tank levels if readings are low

• Maintain proper levels of internal treatment/dispersant• Adjust chemical feed pump as needed

• Track condensate and feedwater total iron levels to monitor for corrosion byproduct concentration.

• Track condensate pH to ensure proper feed of steam and condensate treatment


KEYTAKEAWAYS

Water Testing TechniquesSamplingWork StationTesting Techniques


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General Sampling TechniquesA good sampling container• Preferably with a handle to minimize exposure to water

Wear gloves• Some of the reagents are not nice• Phenolphthalein is a carcinogen. It was a laxative first…

Always rinse the sample bottle 3 times• This removes contaminants• Both sampling bottles and test vials and cuvettes

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Where to Grab Boiler System Samples

WATER TESTING TECHNIQUES | Water Treatment Boot Camp

Boiler System Sampling


Sample Cooler• Provides a safe, cooled sample• Important for temperature sensitive tests• Sulfite, condensate

• A necessity on high pressure systems

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Testing Procedures Review – Digital


Fluorometry• Uses the fluorescence of an activated

tracer to determine concentrationInterferences• Oil in water

• Color in sample prior to readingEnvirodose• Boiler

• Cooling• Closed Loop

Digital• Multiple tests available

• Easy to read results

• Math rarely needed

• Must keep glass clean

• Requires reagents

Testing Procedures Review – Drop Test


Reagent based test• Relies on chemical reaction in sample to show endpoint

Low initial costInterferences

• Iron, pH, oxidizers, temperature

Wide range of options• Hardness, OPO4, Sulfite, alkalinity, etc

Considerations• Always hold dropper bottle straight up and down• Dropper bottles are calibrated for 0.1mL per drop

• Make sure sample cell used is rinsed 3 times

Testing Procedures Review – Titration


Reagent based test• Relies on chemical reaction in sample to show endpoint

Least expensive overall considering reagent costs• Larger upfront cost then drop tests

Interferences• Iron, ph, oxidizers, temperature

Less options but used mainly for basic tests• Hardness, sulfite, alkalinity, chlorides

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Water Testing


Break into teams and test for:• Total Hardness• Conductivity

Troubleshooting & Corrective Actions

Presenter: Jeff Freitag – Director of Sales

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Corrective Actions

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• Identify parameters out of range and the potential cause• Chemical vs mechanical-based corrections • Corrective action follow-up

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Corrective Actions


So you know what to sample, where to grab the sample, how to make sure it’s a good sample, how to run the proper test, and where to log the reading…

Now what?

Before you do anything…


Re-sampleRe-rinseRe-test!

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Trouble Shooting & Corrective ActionsPRETREAMENT

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Filters – Corrective Actions

Most common Problems with filters:• High pressure loss• Improper application• Improper micron rating• Plugging / fouling /

labor intensive

97TROUBLE SHOOTING & CORRECTIVE ACTIONS | Water Treatment Boot Camp

Filters – Corrective Actions

Most common Problems with filters:• Plugging / fouling / labor intensive• Contamination• Poor water treatment• Start up•Microbiological issues


Softeners – Corrective Actions

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Most common Problems with water softeners:• No Salt• Improper programming• Improper sizing

• Bad seals or internals

What to check:

• Re-run sample (flush)• Test right after online unit• Check status of unit online

• Check brine tank• Switch softeners / put into regen

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How do you know the softener is working?

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• Perform a total hardness test on the water.

• Soft water used for boiler make up should have <0.5 ppm of total hardess. This will vary depending upon boiler pressure. As pressure goes up acceptable hardness levels go down.

• Soft water used for cooling tower make up should be less than 20 ppm as a rule of thumb. This value should go down as the cycles of concentration in the tower go up.


Troubleshooting Softeners

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Short Runs ◦ Change in raw water hardness

◦ Poor regeneration◦ Resin Fouling◦ Loss of resin

High Hardness◦ Raw water bypassing unit

◦ Resin fouling◦ Increased raw hardness in supply water

High Pressure Drop◦ Bed fouling

◦ Poor backwash◦ Plugged under drain◦ Deteriorating Resin


Brine Elution Studies• Problems in zeolite softener systems are often due to poor regeneration practices.

• Brine elution study is often used to troubleshoot this process.• Plots the concentration of brine from a zeolite softener during regeneration using a brine salometer and

graduated cylinder


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Elution Studies


Reverse Osmosis Corrective Actions

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Most common Problems with water RO’s:• Hardness coming from softener

• Chemical feed to the ro• Pre-Filters plugging

• Bad seals• Poor pressure from pump• Chorine breakthrough

• Due for cleaning


Reverse Osmosis Corrective Actions

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If hardness or conductivity are high:

• Check the quality of the influent water first

• Check all gauges

• Check water quality on outlet of each membrane


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Monitoring and Maintenance• Ensure that the system is operating properly.

• Determine if gradual fouling, scaling or membrane degradation is occurring by observing system performance over time.


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Trouble Shooting & Corrective ActionsBOILERS

Determining Proper Control Ranges• Control Ranges

- ASME for boilers

• Boiler Plate

• Limiting factors- Iron- Silica

• EXPERIENCE!!


ASME Boiler Guidelines

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American society of mechanical engineers (ASME)

& American boiler manufacturer (ABMA) Guidelines


Water Testing – Test Procedure Guidelines


SAMPLETotal

HardnessCalcium

HardnessP

Alk.M

Alk.TDS,

mmhoOrgano

Phos SulfiteTotal

Polymer pHTotalIron

RAW WATER X X X X XSOFT WATER X X

RO PERMEATE X X XFEEDWATER X X X X X X

CONDENSATE X X X XBOILER WATER X X X X X

COOLING TOWER X X X X X X

Boiler Control Chart


Test Range Corrective Actions

Total Polymer(PP-3060M)

.6-.8

• If out of range, check conductivity of the boilers. High or low conductivity will cause high or low readings.

• If conductivity is okay, increase addition of PP-3060M if polymer is low, decrease if polymer is high.

Sulfite(WT-3462) 20-40 ppm

• Check deaerator temperature.• Check conductivity in the boilers.• If both are in range, increase feed of WT-3462 if

the reading is low and decrease the feed of the WT-3462 if the reading is high.

Alkalinity(WT-3732)

P= 300-400M= 350-650OH=200-400

• Check conductivity levels. High or low conductivity will cause high or low alkalinity.

• Check for proper feed of the WT-3732 sodium hydroxide.

• If both are correct, increase the feed of the WT-3732 to increase alkalinity levels and decrease the pump to decrease alkalinity levels.

Total Hardness(Softeners, Feedwater &

Condensate)<.5 ppm

• If hardness if present, check the softeners and condensate for possible contamination.

• Regenerate softener on line if necessary.

Boiler Conductivity(Un-Neutralized)

mmho1,800-2,300

• If conductivity is out of range, check operation of blowdown controllers.

• Calibrate as necessary

pH(WT-3516)

8.3 – 8.8

• Increase feed of the WT-3516 if pH is low. Decrease feed if pH is high.

• Wait for two days of below 8.0 readings to increase feed of the WT-3516

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Boiler Log Sheet


Deaerator Corrective ActionsMost common problems:• Temp/pressure not correlating

• Chemistries out of range

• Contamination


Deaerator Corrective ActionsIf the temperature/pressure is low:

• Check pressure

• Check accuracy of gauges

• Check vent

• Check steam heating system


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Troubleshooting Deaerators

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Deaerator performance is monitored with a dissolved oxygen analyzer and Chemetrics tests.

If effluent level of oxygen is high:• Check pressure and temperature for insufficient steam flow.• Check vent valve - Should have 18” plume

• Poor spray pattern - Check spray system• Broken scrubber or trays - Inspect


Deaerator Vents


Boiler Corrective ActionsMost common problems:

• Conductivity out of range• Chemistries out of range

• Cloudy / colored water• Boiler water carryover


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BoilerProblemB1 Low Conductivity, Alkalinity & Sulfite:• Re-run sample (flush)• Check for loss of

water or improperly operating blowdown system

• Normal???

High pH:• Related to poor boiler

readings?

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BoilerResultB1 Low Conductivity, Alkalinity & Sulfite:• Normal

• Lead/Lag program

High pH:

• Most likely steam line treatment overfeed

119TROUBLE SHOOTING & CORRECTIVE ACTIONS | Water Treatment Boot Camp119

BoilerProblemB1 High Sulfite:• Where is

conductivity?• Compare to 2nd boiler

Low conductivity:• Check for loss of

water or improperly operating blowdown system

• Check lead/lag operation?


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BoilerResultB1 High Sulfite:

• Since conductivity is low, this is likely an overfeed. Same on B2.

Low conductivity:

• Check lead/lag operation


BoilerProblemLow Conductivity:

• Related to operation?

• What about probe temperature?


BoilerResultLow Conductivity:

• Always check the blowdown valve first.

• Check all blowdown piping to see if it is hot.

• Check bypass around

blowdown valve.• Check for internal

leaks.


Check position of valve/stem

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Boiler Blowdown Valve


Boiler Blowdown Valve


BoilerProblemB2 Low Sulfite:

• Related to high conductivity?

• Related to low phosphate?

Condensate pH high:• Related to other

readings?


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BoilerResultB2 Low Sulfite:

• No chemical getting into boiler FW tank!

Condensate pH high:

• Not related to anything else. Just an overfeed.


WTH?

Never hesitate to question everything!

This was the sulfite chemical.


Condensate ProblemIntermittent High

Hardness:

• Related to boiler Water?

• Related to conductivity?


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Condensate Result B2 Low Sulfite:

• No chemical getting into boiler FW tank!

Condensate pH high:

• Not related to anything else. Just an overfeed.


Steam and Condensate – Corrective ActionsMost common problems:

• Conductivity high• pH high or low

• Total hardness high• Iron detected

• Cold condensate


Steam and Condensate – Corrective ActionsSlightly Elevated Hardness:

• Check individual return lines• Check conductivity levels

• Try to find specific source• Most likely bad heat

exchanger


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Trouble Shooting & Corrective ActionsCOOLING

Determining Proper Control Ranges• LSI, RSI indexes for cooling towers

- Fouling vs. Biocide rates- CTI?/ASHRAE


Tower Control Chart


Test Range Corrective Actions

Total Hardness 20 – 80 ppm • If hardness is present, check the softeners.• Regenerate softener on line if necessary.

Free Chlorine .2 – 1.0 ppm• If levels are out of range check to see that the pump is primed and pumping.• Check conductivity levels. High or low conductivity will cause high or low free chlorine

levels.

Cooling Tower Conductivity 2,800 – 3,000• If conductivity is high, check the operation of the blowdown solenoid.• If conductivity is low, check for uncontrolled losses or overflow of the sump.• Verify the controller is reading properly. Calibrate or replace the sensor if needed.

PTSA Tracer(CWT-766)

150 – 200 ppb

• If levels are out of range check to see that the pump is primed and pumping.• Check conductivity levels. High or low conductivity will cause high or low conductivity will

cause high or low molybdenum levels.• Check to see that the makeup water meter is turning and registering flow.

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Cooling Tower Log Sheet


Cooling Tower – Corrective ActionsMost common problems:

• Conductivity out of range• Inhibitor out of range

• Microbiological activity• Sediment and/or algae noticed in tower

• Automation issues


Cooling Tower – ProblemHigh Bacteria:

• Check conductivity level

• Check sediment build up in tower

• Check that the biocide pumps are primed

• Check for chemical in the tanks

• Turn up feed rate • Test for proper biocide residuals

• Retest bacterial levels in one week


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Cooling Tower – ResultHigh Bacteria:

• Check sediment build up in tower

• Turn up feed rate

• Test for proper biocide residuals

• Retest bacterial levels in one week


Cooling Tower – ProblemPTSA (inhibitor) Sensor Issues:

• PTSA Sensor is acting up

• Calibrated several times

• Replaced w/ new sensor

• Read perfect for 3 hours

• Dropped to near zero and stayed


80 pts out of spec

In range

Flat line

Cooling Tower – ResultPTSA (inhibitor) Sensor Issues:

• Wiring was fine

• There was chemical in the system

• Flow across sensor is good

• Faulty sensor out of the box!


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Problem: Envirodose Inhibitor levels dropping


Result: Bad Pump. Diaphragm failed and was leaking out of the weep hole.

Cooling Tower – Corrective Actions

Low or no chemical in tank.


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Cooling Tower – Corrective Actions



Clean Sensors


Flow Meters

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Strainers


Healthy ORP vs 5213 usage graph


Problem: ORP drops – 5213 feed

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Bad Diaphragm


Low ORP with Normal Chemical Feed


Chlorine Degradation

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Trouble Shooting & Corrective ActionsEXERCISE HAND-OUTS


Tower ExerciseProblem

Low Molybdenum/Inhibitor:• Check conductivity level

• Check log book for

trending data

• Check that pump is primed

• Check for chemical in the

tank

• Turn up the feed rate


Tower ExerciseResult

Low Molybdenum/Inhibitor:• Turn up the feed rate

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Tower ExerciseProblemHigh Conductivity:• Check operation of bleed

valve

• Check flow to drain when bleed valve is open

• Check conductivity sensor

• Run graph on bleed meter

vs. makeup meter

Tower Exercise ResultHigh Conductivity:

• Valve would only open partially• Actuator was bad. Ordered a new

one.



BoilerExerciseProblem– DeaeratorLow pH:• Check makeup water

quality

• Check condensate return water quality

• Check chemical feed levels

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BoilerExerciseResult– DeaeratorLow pH:• Check prime on pump


Pump That Has Lost Prime


BoilerExerciseProblem B4 High Polymer:

• Related to Conductivity?

• Compare to 2nd boiler• Chemical overfeed?

Low conductivity:• Lead/Lag?

• Lag boiler taking on condensate?

• Water Loss?

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BoilerExerciseResult

B4 High Polymer:

• Chemical overfeed

Low conductivity:• Water Loss

Equipment & Reporting

Presenter: Rob Pierick – Territory Manager

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Controllers


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Controller Installation – What Not to do.


Controller Installation• All components located in one location• Easy to access

• Isolation valves• Quick release sensors

• Sample/drain valve• Wiring


Types of Chemical Feed Pump – DiaphragmAdvantages• Wide range of capacity and pressure• Wide range of compatibility

• Proven design

Disadvantages• Can get air locked

• Can struggle with high viscosity products


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Types of Chemical Feed Pump – PeristalticAdvantages• Good for thick products• Naturally degassing

• No loss of prime

Disadvantages• Tube life

• Pressure ratings• Compatibility

• Messy when tube fails


Chemical Feed Pump Installation


Flooded Suction (Ideal) Tank/Drum Mount (Most Common)

Chemical Feed Pump Operation & Maintenance

Loss of prime• Degassing product

• Loose connections• Cracked suction tubing

Leaks• Incompatible tubing

• Old tubing• Loose connections

• Plugged injectorSiphoning

• No back pressure


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Valve Selection CriteriaRule 1: No Solenoids!


Valve Selection Criteria – Type


Valve Installation – Boiler Blowdown


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Cooling Tower Bleed ValveValve Installation

• Keep bleed line as short as possible.

• Eliminate pipe bends and reductions in pipe size.

Operation & Maintenance

• Internal limit switch failure

• Plugging

• Leaking


Water Meters


Water Meter Basic Application


Meter Type Positive Displacement

Inline Turbine Insertion Paddlewheel

Ultrasonic

Cooling Tower and Boiler Makeup

Boiler Feedwater

Cooling Tower Bleed

Process Water

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Monitoring & ReportingController Data• System optimization• Root cause analysis

Manual Data• Assist in operator training• Identify automation problems

Advanced Metrics• Cycles of concentration• Tons of Cooling• Water usage• Cost of treatment

System Performance Measurement


Key Takeaways – Equipment• Considering all inputs and outputs (current and future)

• Pumps• Materials compatibility• Flow and pressure requirements

• Viscosity

• Valves• Size, pressure and temperature

• Flow Meters• Type of water (clean/dirty, temperature)

• Installation location and configuration

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KEYTAKEAWAYS

EQUIPMENT & REPORTING | Water Treatment Boot Camp

Questions?

180

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Survey says…

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Please take a moment to fill out our survey.

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