WO2001083384A1 - Use of control matrix for cooling water systems control - Google Patents
Use of control matrix for cooling water systems control Download PDFInfo
- Publication number
- WO2001083384A1 WO2001083384A1 PCT/US2001/010639 US0110639W WO0183384A1 WO 2001083384 A1 WO2001083384 A1 WO 2001083384A1 US 0110639 W US0110639 W US 0110639W WO 0183384 A1 WO0183384 A1 WO 0183384A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- cooling water
- treatment
- control
- water
- controller
- Prior art date
Links
Classifications
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D21/00—Control of chemical or physico-chemical variables, e.g. pH value
- G05D21/02—Control of chemical or physico-chemical variables, e.g. pH value characterised by the use of electric means
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/008—Control or steering systems not provided for elsewhere in subclass C02F
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F2101/00—Nature of the contaminant
- C02F2101/10—Inorganic compounds
- C02F2101/20—Heavy metals or heavy metal compounds
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F2103/00—Nature of the water, waste water, sewage or sludge to be treated
- C02F2103/02—Non-contaminated water, e.g. for industrial water supply
- C02F2103/023—Water in cooling circuits
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F2303/00—Specific treatment goals
- C02F2303/08—Corrosion inhibition
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F2303/00—Specific treatment goals
- C02F2303/20—Prevention of biofouling
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F5/00—Softening water; Preventing scale; Adding scale preventatives or scale removers to water, e.g. adding sequestering agents
- C02F5/08—Treatment of water with complexing chemicals or other solubilising agents for softening, scale prevention or scale removal, e.g. adding sequestering agents
Definitions
- This invention is in the field of cooling water systems. Specifically, it is in the field of control of cooling water systems.
- a cooling water system comprises a cooling tower, heat exchangers, pumps and all necessary piping to move water through the system. Control of a cooling water system is based on the balancing the desire to run the cooling water system at the highest concentration cycles possible without incurring detrimental scaling, corrosion, fouling or microbiological control patterns.
- a concentration cycle is defined for a specific species as :
- the specific species is the calcium ion (hereinafter either Ca +2 " or "Ca +3 " depending on what context it is used in)
- the cooling water system is running at 3.3 concentration cycles.
- the maximum concentration cycles for a cooling water system are limited by the undesirable events, such as scaling and corrosion, which occur when the amount of specific species in the cooling water tower reaches a certain level, such that the species contributes to these problems .
- Controlling the concentration cycles is typically done by controlling the flow rate of "fresh" water (from one or more sources) known as make-up water into the system and by controlling the main flow rate out of the system, referred to as blowdown.
- a pump or valve controls the flow of make-up water into the cooling tower and a level controller is typically used in the cooling tower reservoir or "sump".
- the level controller is linked to the make-up water pump or valve and when the water in the sump decreases to a point lower than the setpoint for the level controller the make-up water pump is activated.
- Conductivity is the typical method of control of blowdown. Conductivity is the measuring of electrical conductivity of water with electrical conductivity being present in the water due to ionic species being present in the water. Conductivity can be used to control bleed of blowdown because conductivity can readily be used to estimate the overall amount of ionic species present in the water, and a simple controller can be set to open a valve or pumpand start blowdown when the conductivity of the reservoir water reaches above a certain setpoint . There are limits to how useful conductivity is for control of a cooling water system as conductivity is nothing more than an indirect measure of the amount of ionic species present.
- conductivity cannot provide information about scaling tendency or actual scaling and use of conductivity can cause "catastrophic failure" , where scaling causes the cooling water system to overcycle and scale further.
- a timer can control bleed of blowdown without actually measuring any of the ingredients in the water.
- water flow meters on the makeup and blowdown can be used, sometimes in conjunction with a microprocessor controller to do an overall cooling water mass balance.
- a problem with these known control schemes is that when the blowdown is controlled by conductivity and the make-up is controlled by the level controller, if the composition of the usual make-up water is variable, or if there are alternate sources of make-up water that are significantly different from the usual make-up water source, level controllers and conductivity cannot account for everything that is occurring in the system. In these cases, the cooling water system is typically controlled by the operator being conservative with the conductivity setpoint which thus causes extra undesirable expense due to non-optimal use of treatment chemicals and water.
- cooling water systems use treatment products to control undesirable events such as scaling, corrosion, fouling and microbiological growth. These treatment products comprise polymers and other materials and are known to people of ordinary skill in the art of cooling water systems.
- a cooling water system can be set up to feed treatment product based on either a bleed/feed mechanism where the action of blowdown triggers a chemical feed pump or valve that feeds treatment product; or, in the alternative, the cooling water system feeds treatment product based on timers using a "feeding schedule" or flow meters on the make-up water line trigger the pumping of treatment product based on a certain amount of make-up water being pumped.
- a limitation of these control methods is that none of these systems measure the treatment product concentration directly online, so if there is a mechanical problem, for example, if a pump fails, a drum empties, or high, low or unknown blowdown occurs, system volume changes or makeup water quality changes; the correct treatment product concentration is not maintained. Because this problem is common, typically cooling tower systems are either overfed to ensure the level of treatment product in the system does not drop too low as a result of high variability in product dosage or the treatment product is unknowingly underfed. Both overfeeding and underfeeding of treatment product are undesirable due to cost and performance drawbacks .
- TRASAR ® is a registered trademark of Nalco Chemical Company One Nalco Center, Naperville IL 60563 (630) 305-1000).
- the fluorescent signal of the inert fluorescent chemical is then used to determine whether the desired amount of treatment product is present in the cooling tower (and to control blowdown) .
- Cooling towers that use both inert tracer (s) and conductivity typically use the following types of information in order to control the tower.
- a cooling tower with typical makeup water having: 150 ppm Ca +2 , 75 ppm Mg +2 , and 100 ppm "M alkalinity"; with a conductivity of 600 ⁇ S/cm (Note that conductivity is expressed in units of microsiemans per centimeter)
- the system is set to run at 500 ppm Ca +2 .
- the cycle of concentration for this cooling water system is 3.3 (calculated by dividing
- Running the system at 500 ppm Ca +2 corresponds to a conductivity setpoint of 3.3 times 600 or 1980 ⁇ S/cm. When the conductivity exceeds this setpoint the system is configured to automatically blowdown a portion of "concentrated" water
- freshness makeup water (where “fresh” is defined as having a lower level of scaling ions than the “concentrated” cooling water) .
- This decreases the conductivity and hardness (Ca +2 and Mg +2 ) ions via dilution. Dilution also reduces the amount of inert tracer and treatment chemical in the system. Decreasing the amount of inert tracer in the system, decreases the fluorescent signal from the inert tracer.
- the tracer control system is set up to feed a fresh mixture of treatment product and inert tracer chemical to compensate for the decrease in inert fluorescent tracer and treatment chemical that was lost in the blowdown.
- a known method of control of product feed to a cooling water system involves the use of another aspect of tracer technology. This involves using a treatment product containing a polymer that has been "tagged" with a fluorescent moiety. These tagged treatment polymers, are not inert, rather, they are supposed to be consumed as they function to treat whatever performance-related condition it is that they are designed to treat. Thus, by measuring the fluorescent signal of the tagged treatment polymer it is possible to determine the amount of consumption of the tagged treatment polymer. By knowing the amount of consumption of the tagged treatment polymer it is possible to use that information to control the feeding of new treatment product containing tagged treatment polymer.
- the instant claimed invention is a method of controlling a cooling water system in which control is based on information from a control Matrix applicable to the specific operating parameters of said cooling water system comprising:
- step (iv) determining the pattern of changes in the readings from step (iii) over time;
- Figure 1 shows a control Matrix for a cooling water system treated with a "Stabilized Phosphate" treatment program.
- Figure 2 shows the General Trends for the manner of consumption for the components consumed in a "Stabilized Phosphate" treatment program.
- Figure 3 shows a control Matrix for a cooling water system treated with a "Zinc Containing" treatment program.
- Figure 4 shows the General Trends for the manner of consumption for the components consumed in a "Zinc Containing" treatment program.
- Figure 5 shows a control Matrix for a cooling water system treated with an "All Organic" treatment program.
- Figure 6 shows the General Trends for the manner of consumption for the components consumed in an "All Organic" treatment program.
- Figure 7 is a typical "Recommended Program Limits" chart for an "All-Organic", “Zinc”, and “Stabilized Phosphate” treatment program.
- the invention is a method of controlling a cooling water system in which control is based on information from a control Matrix applicable to the specific operating parameters of said cooling water system comprising: operating parameters of said cooling water system comprising:
- the fluorometer described and claimed therein is capable of measuring anywhere from one to sixteen separate fluorescent signals.
- the controller described therein is capable of using input from the fluorometer and other analytical devices, processing this input according to program and applying control signals to the pumps and valves of a cooling water system.
- Sufficient analytical devices are the number of analytical devices required to analyzed those system factors known to persons of ordinary skill in the art of cooling water systems as being important. Those system factors include, but are not limited to: pH;
- Oxidation-reduction potential or "ORP" additional chemical monitors of water quality for such factors including, but not limited to, calcium, magnesium, total hardness, iron, copper, chloride, sulfate, manganese, aluminum, silica, alkalinity, ammonia, phosphate, turbidity, total suspended solids; process leaks; free residual & total oxidant/halogen/chlorine; non-fluorescent or fluorescent-based monitors of treatment actives such as dispersant polymer, zinc, molybdate, phosphate, condensed inorganic phosphates, phosphonates, and triazoles; water temperatures; process-side temperatures, taken at various places in the system to help determine exchanger efficiency and fouling; treatment actives; fluid flowrates; fluid velocities; fluid pressures and differential pressures; chemical inventories and depletion thereof; pumping rates; blowdown rates; makeup water flowrate; corrosion monitors; fouling/deposit monitors; microbiological indicators; and light absorbance of substances in
- Figure 1 shows the control Matrix for a cooling water system where a "Stabilized Phosphate" treatment program is being used.
- a "Stabilized Phosphate” treatment program is recognized by people of ordinary skill in the art of cooling water systems to be a treatment formulation comprising dispersant polymer, orthophosphate, pyrophosphate, phosphonate, triazole and an inert fluorescent tracer.
- Figure 3 shows the control Matrix for a cooling water system where a "Zinc Containing" treatment program is being used.
- a "Zinc Containing" treatment program is recognized by people of ordinary skill in the art of cooling water systems to be a treatment formulation comprising zinc cation, dispersant polymer, phosphonate, orthophosphate, organic triazole and an inert fluorescent tracer.
- Figure 5 shows the control Matrix for a cooling water system treated with an
- An “All Organic” treatment program is recognized by people of ordinary skill in the art of cooling water systems to contain only organic-based treatment actives. Therefore, an All Organic treatment program would comprise organic polymers, organic phosphonates and organic triazoles, and would not include actives based on heavy metals, such as molybdate and inorganic ions such as ortho phosphate. This type of program is also typically used under high-pH conditions (8.5 or higher) and with minimal control of pH with acid.
- the left-hand columns in Figures 1, 3 and 5 are a list of System Conditions Leading to Stress that could occur in the cooling water system.
- “Over-Chlorination” (high residual) refers to excessive levels of chlorine gas (or bleach) or other halogen-based oxidizing biocides, which are higher than is needed for microbiological control and can react with and degrade treatment actives. This also refers to biocide feedpoints where excessive localized concentrations of oxidizing biocides can exist.
- Merobiological Upsets refers to formation of biofilm and excessive levels of planktonic bacteria that exceed specified limits (e.g. >10 3 CFUs/mL) .
- variable P04 refers to changes in make-up water composition or changes between makeup water source.
- High P04 refers to levels of orthoP04 in MU which would cause treatment program or performance limits to be exceeded when the P04 cycles up in cooling tower.
- Loss of treatment feed refers to when product supply runs out or product decreases to the point at which performance is adversely affected. Product decreases, or low product dosages, mean lower than specified by product application recommendations or by the cooling water system operator for level of chemical feed equipment .
- High/Variable HTI refers to excessive holding time index (“HTI").
- HTI is the time required for 50% removal/replacement of substance from the system. Treatment programs often have HTI limit recommendations.
- Overfeed of product refers to levels of product which are higher than specified by program recommendations or by the cooling water system operator.
- Low alkalinity refers to "M-alkalinity" in Figure 7.
- Process leaks refer to contaminants from the process that is being cooled by the cooling water, which inadvertently enter the cooling water.
- Recirculation water as chlorinator drive water refers to mixing cooling tower water with high levels of chlorine.
- High alkalinity refers to high concentration of HC0 3 ⁇ and C0 3 " above a prescribed range; for example 50- 200 ppm as CaC0 3 .
- High heat flux, high skin or water temperature is related to the temperature which can occur on the metal heat-exchange surfaces on the waterside of the exchangers. Refer to Highest H20 Temp @ H-E outlet (deg F) in Figure 7. " Iron contamination in MU water” refers to Fe
- Al carryover refers to contamination of cooling water in the system due to Al +3 from make-up water or from improper clarification with Al-containing coagulant . See Figure 7.
- Low Cycles refers to low cycles of concentration resulting from excessive blowdown or excessive addition of make-up water.
- control Matrices can be used to program a controller that acts to automatically implement the desired corrective action, upon registering that a listed condition or a combination of listed conditions have occurred.
- Figure 2 shows the manner of consumption for the components consumed in a "Stabilized Phosphate" treatment program. This information is the basis for certain parts of the logic expressed in the control Matrix for the cooling water system being treated with a stabilized phosphate program
- Figure 4 shows the manner of consumption for the components consumed in a
- Figure 6 shows the manner of consumption for the components consumed in an
- Figure 7 is a "Recommended Program Limits" chart for an "All-Organic", “Zinc”, and “Stabilized Phosphate” treatment program. This information is the basis for certain of the limits used to program the controller using information from the control Matrix and using measured analytical results .
- control Matrix method of control of a cooling water system provides a comprehensive control scheme for automatic control of a cooling water system.
- a stabilized phosphate-type treatment program is being used.
- the treatment contains an inert fluorescent tracer (for product dosage control and as a reference point) , orthophosphate, dispersant polymer, pyrophosphate, phosphonate, and triazole.
- the cooling water system uses sulfuric acid for pH control and has a water chemistry that is controlled at or near the following conditions .
- the water also contains sulfate, chloride, small amounts of M-alkalinity, and other dissolved ions.
- the dosage levels of the treatment program and the active components of the treatment program are measured. Under typical to moderately stressed operating conditions, the dosage of the treatment program is controlled using the inert tracer readings. The consumption of each active treatment component is also measured by comparing the inert tracer readings and the dosages of active treatment components .
- a system upset occurs where the feed of sulfuric acid used to control pH of the cooling tower is interrupted. During that high pH upset, an increase in the scaling potential of the system occurs and increased consumption of some of the treatment actives (dispersant polymer, orthophosphate, and phosphonate) occurs.
- the expected increase in consumption of certain treatment actives is designated by the symbol "1" in Figure 1 showing consumption of treatment actives versus upset/stress condition in system operation. The symbol
- the performance problem is minimized, the treatment chemistry/actives consumption and water chemistry return to normal and the problem is fixed and the actives consumption/matrix results confirm the treatment problem is corrected.
- Each and every one of these processes occur much quicker and better with this analysis and corrective action and programming technique as compared to separate analysis and manual measurements, connections or other available techniques.
- a zinc program known as an "alkaline-zinc" type program is being used.
- the treatment contains an inert fluorescent tracer (for product dosage control and as a reference point) , orthophosphate, dispersant polymer, phosphonate, zinc, and triazole.
- the cooling water system uses sulfuric acid for pH control and has a water chemistry that is controlled at or near the following conditions . pH 8.5
- the water also contains sulfate, chloride, M- alkalinity, and other dissolved ions.
- the dosage levels of the treatment program and the active components of the treatment program are measured using standard analytical techniques. Under typical operating conditions, the dosage of the treatment program is controlled using the inert tracer readings. The consumption of each active treatment component is also measured by comparing the inert tracer readings and the dosages of active treatment components .
- a system upset occurs when the blowdown rate increases significantly, which results in low cycles of concentration in the cooling water system feed. During that low cycles upset, a decrease in the scaling potential of the cooling water system occurs and also the analytical readings indicate:
- Treatment dosage is decreased to compensate for low cycles of concentration and high levels of actives which can occur from dissolution of scale and deposition.
- an "All Organic” type treatment program is being used.
- the treatment contains an inert fluorescent tracer (for product dosage control and as a reference point) , dispersant polymer, phosphonates and triazole.
- the cooling water system often does not use acid for pH control and has a water chemistry that is controlled at or near the following conditions.
- the water also contains sulfate, chloride, M- alkalinity, and other dissolved ions.
- the dosage levels of the treatment program and the active components of the treatment program are measured. Under typical operating conditions, the dosage of the treatment program is controlled using the inert tracer readings . The consumption of each active treatment component is also measured by comparing the inert tracer readings and the dosages of active treatment components .
- An additional analysis probe e.g., turbidimeter
- turbidimeter can be used to further substantiate the root-cause of the problem as being high suspended solids. Based on the analytical results and the matrix pattern, corrective actions are taken to solve the problem as follows :
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- Engineering & Computer Science (AREA)
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Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
MXPA02009727A MXPA02009727A (en) | 2000-05-01 | 2001-04-03 | Use of control matrix for cooling water systems control. |
AU2001253081A AU2001253081B2 (en) | 2000-05-01 | 2001-04-03 | Use of control matrix for cooling water systems control |
EP01926551A EP1284935A4 (en) | 2000-05-01 | 2001-04-03 | Use of control matrix for cooling water systems control |
CA2403274A CA2403274C (en) | 2000-05-01 | 2001-04-03 | Use of control matrix for cooling water systems control |
AU5308101A AU5308101A (en) | 2000-05-01 | 2001-04-03 | Use of control matrix for cooling water systems control |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/562,397 US6315909B1 (en) | 2000-05-01 | 2000-05-01 | Use of control matrix for cooling water systems control |
US09/562,397 | 2000-05-01 |
Publications (1)
Publication Number | Publication Date |
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WO2001083384A1 true WO2001083384A1 (en) | 2001-11-08 |
Family
ID=24246129
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2001/010639 WO2001083384A1 (en) | 2000-05-01 | 2001-04-03 | Use of control matrix for cooling water systems control |
Country Status (9)
Country | Link |
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US (1) | US6315909B1 (en) |
EP (1) | EP1284935A4 (en) |
AR (1) | AR028544A1 (en) |
AU (2) | AU5308101A (en) |
CA (1) | CA2403274C (en) |
MX (1) | MXPA02009727A (en) |
TW (1) | TW482885B (en) |
WO (1) | WO2001083384A1 (en) |
ZA (1) | ZA200207642B (en) |
Cited By (1)
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US6668568B2 (en) * | 2001-01-05 | 2003-12-30 | General Electric Company | Flexible sealed system and fan control algorithm |
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US20050025660A1 (en) * | 2003-07-31 | 2005-02-03 | Hoots John E. | Method of tracing corrosive materials |
US7282101B2 (en) * | 2003-08-19 | 2007-10-16 | Mccurdy Brent K | Method for dissolving a solid material in a liquid |
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US6929749B2 (en) * | 2004-01-09 | 2005-08-16 | Water & Enviro Tech Company, Inc. | Cooling water scale and corrosion inhibition |
US7095500B2 (en) | 2004-01-30 | 2006-08-22 | Nalco Company | Interchangeable tip-open cell fluorometer |
US7632412B2 (en) * | 2006-11-03 | 2009-12-15 | Nalco Company | Method for chemistry control in cooling systems |
US7708939B2 (en) * | 2007-04-24 | 2010-05-04 | Water Conservation Technology International, Inc. | Cooling water corrosion inhibition method |
US20130233796A1 (en) | 2012-03-06 | 2013-09-12 | Narasimha M. Rao | Treatment of industrial water systems |
US9284205B2 (en) | 2013-12-24 | 2016-03-15 | Donald S. Hofmann | Apparatus providing softened makeup water for cooling system |
US9612221B2 (en) | 2014-10-14 | 2017-04-04 | Chem-Aqua, Inc. + Pyxis Lab, Inc. | Opto-electrochemical sensing system for monitoring and controlling industrial fluids |
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- 2001-04-03 WO PCT/US2001/010639 patent/WO2001083384A1/en active IP Right Grant
- 2001-04-03 CA CA2403274A patent/CA2403274C/en not_active Expired - Lifetime
- 2001-04-03 AU AU5308101A patent/AU5308101A/en active Pending
- 2001-04-03 EP EP01926551A patent/EP1284935A4/en not_active Ceased
- 2001-04-03 AU AU2001253081A patent/AU2001253081B2/en not_active Expired
- 2001-04-03 MX MXPA02009727A patent/MXPA02009727A/en active IP Right Grant
- 2001-04-23 TW TW090109653A patent/TW482885B/en not_active IP Right Cessation
- 2001-04-24 AR ARP010101894A patent/AR028544A1/en unknown
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2002
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US8724956B2 (en) | 2009-10-09 | 2014-05-13 | Dsm Ip Assets B.V. | D1451 radiation curable supercoatings for multi-mode optical fiber |
US8731366B2 (en) | 2009-10-09 | 2014-05-20 | Dsm Ip Assets B.V. | D1451 radiation curable supercoatings for single mode optical fiber |
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CA2403274A1 (en) | 2001-11-08 |
EP1284935A4 (en) | 2004-08-18 |
MXPA02009727A (en) | 2004-09-06 |
AU5308101A (en) | 2001-11-12 |
AU2001253081B2 (en) | 2005-06-16 |
EP1284935A1 (en) | 2003-02-26 |
AR028544A1 (en) | 2003-05-14 |
US6315909B1 (en) | 2001-11-13 |
TW482885B (en) | 2002-04-11 |
CA2403274C (en) | 2011-11-08 |
ZA200207642B (en) | 2003-09-23 |
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