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Chemical handling, System Upgrades & Common-up

Purpose of this case study

To demonstrate CORE’s capabilities to improve site efficiencies and safety onsite by reducing chemical handling and improving robustness of onsite systems 

DISADVANTAGE OF NOT COMMONING-UP 

Six control systems = high probability of control / pump / probe issues each service visit

Very high level  of operator / consultant time required fixing control issues, topping up small chemical drums and individually testing all towers

Individual Brominators  = weekly top ups required = high chance of spills and very high level of chemical / manual handling component

20l chemical drums = weekly change over = very high chemical / manual handling component

Plastic spill pallet bunding = below specification for segregation of chemicals

No corrosion monitoring

Poor HCC & LP controlCommoning_Up_-_before.png


ADVANTAGES of COMMONING-UP SYSTEM:

Single controller with internet monitoring using a single set of probes / pumps = email / sms notification to consultants and operators of any out of spec parameters or low level chemical tanks 

Bulk chemical supply = Chemical transfer frequency ever 4 – 6 months = minimal chemical / manual handling of chemicals

Portable bunding = segregation of acids and alkalines with sufficient spill space

Excellent HCC & LP control

Excellent corrosion monitoring and controlCommoning_Up_-_after.png

Meter_-_before.png

 

OLD Situation:

Individual make-up and bleed water meters for all six towers = many not operational and not recorded

Six individually controlled cooling systems



 


 NEW Situation:

Single make-up water meter and single bleed water meter for all six towers running off a common balance tank and recirculation pump

Meter_-_after.pngTank.png

controller.png

ADVANTAGES:

Water usages trended weekly

Body of water continually circulating = greater biological and corrosion control

One body of water = one lot of testing  - This has significantly reduced required testing from six systems to one system allowing more time to be spent identifying other projects and improving other systems onsite 


Summary

Individual Systems

Six control systems = high probability of control / pump / probe issues each service visit

Very high level  of operator / consultant time required fixing control issues, topping up small chemical drums and individually testing all towers

Individual Brominators  = weekly top ups required = high chance of spills and very high level of chemical / manual handling component

20l chemical drums = weekly change over = very high chemical / manual handling component

Plastic spill pallet bunding = below specification for segregation of chemicals

No Corrosion monitoring

HCC within spec 80% - LP within spec 83% 2013

System Common - Up

Upgrade to single controller system with internet monitoring

Single make-up water meter and single bleed water meter for all six towers running off a common balance tank and recirculation pump – Water usage monitored weekly

Bulk chemical supply = Bulk Transfer every 8 – 10 weeks

Portable bunding = Segregation of acids and alkalines with sufficient spill space

Corrosion rates 2013 – 2015 Average 1.45mpy (Target <3.0mpy)

HCC & LP control 100% within spec 2014 & 2015


CORE Water Management Solutions "always part of your savings not your costs"