Combination of probes, chemistry, analyzer enabled monitoring, and continuous automated control provides $200K in annual savings for operator.
Download PDFCooling tower monitoring and control outdated and prone to plugging
Louisiana
A chemical plant operator requested assistance from Halliburton to provide a superior automated cooling tower monitoring and control system. The system was outdated and prone to plugging, required frequent cleaning/calibration, and was limited to controlling two parameters: pH with acid and conductivity cycles with blowdown.
This limitation resulted in Halliburton and the operator making frequent chemical adjustments. The time between testing and adjustments led to erratic under and overfeeding conditions. These conditions were usually minor, but occasionally were much more than intended, adding to the budgeted chemical costs.
Recognizing the need for a flexible and innovative solution, Halliburton recommended an advanced cooling water system from Halliburton’s APX™ suite of digital solutions for enhanced chemical performance and monitoring. The recommended solution included implementing an industry-leading polymer analyzer and a customized polymer dispersant.
For the phosphate corrosion inhibitor, rather than use a phosphate analyzer, which is known to be problematic and maintenance intensive, Halliburton recommended a PTSA (pyrenetetrasulfonic acid, sodium salt) traced phosphate with probe monitoring. Next, since the cooling water heat exchanger system consisted of metallurgy, which contained yellow metal, a yellow metal corrosion inhibitor chemical treatment was also required. Halliburton recommended the application of a tolytriazole (TTA) corrosion inhibitor with a TTA monitoring probe. This combination of probes, chemistry, and analyzer technology-enabled monitoring and continuous automated control of five parameters: pH, conductivity, polymer, phosphate (via PTSA tracer), and TTA.
Decrease in chemical usage
Annual savings
Following the operational start-up of the advanced cooling tower system and the continued control of existing pH and conductivity parameters, Halliburton improved control of the polymer, phosphate, and TTA chemistries to less than 3% variable of the target PPM dosages. This decreased combined chemical usage by $58,000, far exceeding the skid purchase price. The overall value of energy, water, and maintenance avoidance realized by installing the advanced cooling tower system is more than $200,000 annually.
