Manage Your Water Systems forCost Control and System Reliability                 Presented by:          Tom Christman, Vic...
Why Manage Water?• Sustainability• Cost Control• System Reliability
Why Manage Water?     Sustainability           The ability of the earth to continue tosupport human life. The responsible ...
Why Manage Water? Sustainability Water Stressed Areas of the World
Why Manage Water? Sustainability • More than one-third of all counties in the lower 48 states will likely be facing   very...
Wisconsin Water Use by Category
Wisconsin Population and Water Use
Wisconsin Water Use by Source
Wisconsin Water Use by Source
Why Manage Water?  Cost Control Water Costs –     •   Relatively inexpensive but going up at record rates            Chi...
Why Manage Water? Cost ControlRates for large industrial usersLocation          Water cost          Sewer cost          To...
Why Manage Water? Cost Control Related Costs  • Reduced electricity & fuel      •     Better heat transfer and reduced us...
Why Manage Water? Cost Control
Why Manage Water? Cost ControlBoiler Energy Loss Due to Scaling                                                           ...
Why Manage Water?System Reliability     Fewer failures     Reduced downtime     Extended asset life     Reduced Liabil...
Why Manage Water? System ReliabilityWithout a proper chemical treatmentprogram, Scaling and Corrosion will occur =equipmen...
Why Manage Water? System Reliability    Public health and safety       •    Legionella
How Do I Begin Managing My Water?System-Wide Audit  – Conducting a survey is extremely important    because every facilit...
Managing My Water – Flow Diagram
Managing my Water   In some industries, Boilers and Cooling water   systems can account for up to 90% of the water use.   ...
Percent Boiler/Cooling Water use as               Total Water Usage80%70%60%50%40%30%20%                                  ...
Managing my WaterAutomation
Managing my Water Automated Data Collection                           www.wteservice.com                    Data Logging ...
Managing my Water
Cycles of Concentration             Boiler and Cooling Towers• Build-up of the concentration of dissolved  solids in recir...
Water Use and Your Recirculating Cooling            Water System
Controller             Before: Tower @ 3 Cycles                          30 GPM                                           ...
Controller               After: Tower @ 5 Cycles                         30 GPM                                           ...
Summary of Cooling Scenarios           Make Up Flow   Make Up Cost   Bleed Flow   Bleed Cost3 Cycles     22.86 MG       $4...
Effective Ways to Increase Cycles of Concentration        Recirculating Cooling Water1.Automate chemical feed and tower bl...
Water Use and Your Boiler Water System
850 uS             Make Up    Condensate                                       Heat                                       ...
850 uS             Make Up    Condensate                                        Heat                                      ...
Make Up Flow             Make Up Cost            Blowdown Flow             Blowdown Cost9.4 Cycles                    23.7...
Effective Ways to Increase Cycles of Concentration            Boiler Water Systems 1. Automate chemical feed and blowdown ...
Questions?For a copy of this presentation, see Tom Christman or contact him at     tom@watertechusa.com             www.wa...
Manage your water systems for cost control & reliability
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Manage your water systems for cost control & reliability

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This presentation was given at the 2012 PFMA Expo in Milwaukee, WI. The presenter was Thomas Christman, the Vice President at Watertech of America, Inc.

The purpose of the presentation is to serve as brief discuss about why it is important to manage the water used in boiler and cooling tower applications.

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Manage your water systems for cost control & reliability

  1. 1. Manage Your Water Systems forCost Control and System Reliability Presented by: Tom Christman, Vice President Watertech of America, Inc. March 1, 2012
  2. 2. Why Manage Water?• Sustainability• Cost Control• System Reliability
  3. 3. Why Manage Water? Sustainability The ability of the earth to continue tosupport human life. The responsible use ofnatural resources - Water.
  4. 4. Why Manage Water? Sustainability Water Stressed Areas of the World
  5. 5. Why Manage Water? Sustainability • More than one-third of all counties in the lower 48 states will likely be facing very serious water shortages by 2050. Natural Resources Defense Council • The average American uses 150 gallons of water per day, while residents of the U.K. only use 40 gallons per day and residents of China use just 22 gallons per day. CBS News • In northern China, the water table is dropping one meter per year due to over-pumping • Every single day Arizona and parts of New Mexico use 300 million gallons more water than they get in renewable supply. • The Great Lakes hold one fifth of the worlds (and 95% of the United States) fresh surface water .The Great Lakes Compact includes the 8 states surrounding the Great Lakes and two Canadian provinces and bans the export of water to outsiders - even to other U.S. states. • Worldwide demand for fresh water tripled during the last century, and is now doubling every 21 years.
  6. 6. Wisconsin Water Use by Category
  7. 7. Wisconsin Population and Water Use
  8. 8. Wisconsin Water Use by Source
  9. 9. Wisconsin Water Use by Source
  10. 10. Why Manage Water? Cost Control Water Costs – • Relatively inexpensive but going up at record rates  Chicagos city council unanimously passed the 2012 budget which included a 70% rate hike over the next four years • Conservation efforts = Catch 22 -per unit costs go up • Trend to raise prices to encourage conservation by environmental groups • Change in pricing structure – higher rates for higher use  Rather than encourage usage with lower rates for more usage
  11. 11. Why Manage Water? Cost ControlRates for large industrial usersLocation Water cost Sewer cost Total Water & US $/1000 gallons US $/1000 gallons Sewer Cost US $/1000 gallonsSeattle, WA $6.19 $13.74 $19.93Portland, OR $3.65 $9.42 $13.07Los Angeles, CA $3.00 $4.00 $7.00Cincinnati, OH $1.84 $4.93 $6.77Wausau, WI $1.54 $3.45 $4.99Green Bay, WI $2.65 $2.31 $4.96Milwaukee, WI $1.58 $2.69 $4.27Madison, WI $1.82 $2.31 $4.13Spokane, WA $0.95 $2.19 $3.14
  12. 12. Why Manage Water? Cost Control Related Costs • Reduced electricity & fuel • Better heat transfer and reduced usage • Pretreatment costs – Salt, etc. • Water Treatment Chemicals • Wastewater chemicals • Labor
  13. 13. Why Manage Water? Cost Control
  14. 14. Why Manage Water? Cost ControlBoiler Energy Loss Due to Scaling Energy Loss 120% 100% 80% Efficiency Loss 60% 40% 20% 0% 1/64" 1/32" 1/16" 1/8" 1/4" 1/2" 3/4" 1" Scale Thickness
  15. 15. Why Manage Water?System Reliability  Fewer failures  Reduced downtime  Extended asset life  Reduced Liability
  16. 16. Why Manage Water? System ReliabilityWithout a proper chemical treatmentprogram, Scaling and Corrosion will occur =equipment failures, increased downtime, shortenedequipment life
  17. 17. Why Manage Water? System Reliability  Public health and safety • Legionella
  18. 18. How Do I Begin Managing My Water?System-Wide Audit – Conducting a survey is extremely important because every facility is different!!! – Do you know how much water your facility is using??? Do you know how much water each process uses??? “You Can’t Manage What You’re Not Monitoring”
  19. 19. Managing My Water – Flow Diagram
  20. 20. Managing my Water In some industries, Boilers and Cooling water systems can account for up to 90% of the water use. There is a tremendous potential for water savings in these areas that converts directly to dollars saved to your bottom line!
  21. 21. Percent Boiler/Cooling Water use as Total Water Usage80%70%60%50%40%30%20% Cooling10% 0% Boilers
  22. 22. Managing my WaterAutomation
  23. 23. Managing my Water Automated Data Collection www.wteservice.com Data Logging and Communications Access to reports from anywhere via Multiple security levels for various the internet users Real time availability of operator logs Secure data storage creating a and service reports permanent record Immediate access to MSDS, Graphing package for tests and logging equipment inspections, test Time and date stamp test results procedures, and training materials Ability to export test data Detailed E-mail alarm notifications
  24. 24. Managing my Water
  25. 25. Cycles of Concentration Boiler 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 – Your Water Treatment Supplier is responsible for this.
  26. 26. Water Use and Your Recirculating Cooling Water System
  27. 27. Controller Before: Tower @ 3 Cycles 30 GPM Annual Make Annual Up Bleed Setpoint 22.86 MG 7.56 MG1,200 uS $43,094 $19,656 = 3 Cycles 45 GPM 15 GPM 400 uS 3,000 GPM Recirc Rate
  28. 28. Controller After: Tower @ 5 Cycles 30 GPM Annual Make Annual Up BleedSetpoint 19.15 MG 4.03 MG2,000 uS $36,389 $10,483 = 5 Cycles 38 GPM 8 GPM 400 uS 3,000 GPM Recirc Rate
  29. 29. Summary of Cooling Scenarios Make Up Flow Make Up Cost Bleed Flow Bleed Cost3 Cycles 22.86 MG $43,094 7.56 MG $19,6565 Cycles 19.15 MG $36,389 4.03 MG $10,483Savings 3.71 MG $7,514 3.52 MG $9,173 (-15.5%) (-46.7%)Chemical / Misc Savings = >$10,000 per year Total Savings = ~$27,000
  30. 30. Effective Ways to Increase Cycles of Concentration Recirculating Cooling Water1.Automate chemical feed and tower bleed2.Soften the makeup water3.Feed acid for control alkalinity and pH4.Look for a better source of makeup water5.Install “side-stream” filtration for solids removal
  31. 31. Water Use and Your Boiler Water System
  32. 32. 850 uS Make Up Condensate Heat Steam 67,925 GPD 92,455 GPD Exchanger 58% Before 50,000 #/hr Steaming Rate 360 uS Feed Water 160,380 GPDController Annual Make Annual Up BlowdownSetpoint = 9.7 Cycles 23.77 MG 5.77 MG Blowdown $45,170 $15,010 16,495 GPD3,500 uS
  33. 33. 850 uS Make Up Condensate Heat Steam 32,120 GPD 119,565 GPD Exchanger 79% After 50,000 #/hr Steaming Rate 180 uS Feed Water 151,686 GPDController Annual Make Annual Up Blowdown 11.24 MG 2.73 MGSetpoint = 19.4 Cycles Blowdown $21,360 $7,098 7,801 GPD3,500 uS
  34. 34. Make Up Flow Make Up Cost Blowdown Flow Blowdown Cost9.4 Cycles 23.77 MG $45,170 5.77 MG $15,01019.7 Cycles 11.24 MG $21,360 2.73 MG $7,098Savings 12.53 MG $23,810 3.04 MG $7,912 (-52.7%) (-52.7%) Fuel Savings = $40,000 / year Chemical Savings = $20,000 / 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.,
  35. 35. Effective Ways to Increase Cycles of Concentration Boiler Water Systems 1. Automate chemical feed and blowdown 2. Return as much condensate as possible 3. Improve makeup water quality through advanced treatment  Reverse Osmosis, Demineralizer, Dealkalizers
  36. 36. Questions?For a copy of this presentation, see Tom Christman or contact him at tom@watertechusa.com www.watertechusa.com

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