Industrial downtime savings during waterside maintenance
Water scale on any heat transfer surface reduces the effectiveness of that heat transfer, this results in reduced equipment efficiency while increasing :
- Energy consumption
- Plant downtime, which causes man hours, inclusive of overtime, production time
The Domino Effect
When the cooling side of an equipment is not maintained, all other parts will eventually breakdown which cost million.
When your WCPU (Water Chilled Package Unit) starts producing warm air it is normally because the condensers are full of scale, rust. Most of the time the technician will tell you to change the compressors which cost million.
This Is What Happens ….
- Due to the sedimentation, heat transfer does not take place, therefore condensation of R22 gas does not occur.
- R22 goes back to the receiver tank in mainly gas form, which will eventually damage the compressor
- Then it will be have to change the compressor which cost million; and keep changing it frequently because the condensers are still not cleaned.
Regular cleaning and maintaining the condensers will not only keep the air cool but prolong the lifespan of the compressors and save you for million
Fouling in Heat Exchangers
Fouling is generally defined as the accumulation of unwanted materials on the surfaces of processing equipment. It has been recognized as a nearly universal problem in design and operation and affects the operation of equipment.
The fouling layer has a low thermal conductivity. This increases the resistance to heat transfer and reduces the effectiveness of heat exchangers – increasing temperature.
Fouling can be very costly in refinery and petrochemical plants since it increases fuel usage, results in interrupted operation, production losses, and increases maintenance costs
The total fouling-related cost can be broken down into four main areas:
- Capital expenditure, which includes excess surface area (10-50%, with an average around 35%),
- Costs for stronger foundations,
- Provisions for extra space,
- Increased transport and installation costs.
Extra fuel costs, which arise if fouling leads to extra fuel burning in furnaces or boilers or if more secondary energy such as electricity or process steam is needed to overcome the effects of fouling.
Production losses during planned and unplanned plant shutdowns due to fouling.
These are often considered to be the main costs of fouling and are very difficult to estimate.
According to Pritchard and Thackery (Harwell Laboratories), about 15% of the maintenance costs of a process plant can be attributed to heat exchangers and boilers, and of this, half is probably caused by fouling.
Panchal (Argonne National Laboratory), based on the study of Van Nostrand, re-estimated the energy and economic penalties associated with heat exchanger fouling for the US refineries, as more than $2 billion per year. The maintenance costs in the USA were revised because they have increased significantly due to recent environmental regulations.
Removing the scale build up allows your equipment to operate more efficiently with less down time
A good proactive/predictive maintenance program, with regards to waterside fouling,
- Reduces unplanned shutdowns,
- Maintaining optimum operating efficiency in equipment.
- Reduces astronomical energy and operational costs,
- Lower maintenance budgets
Plainly stated, the growing cost of maintenance is a serious business problem. According to DuPont, “Maintenance is the largest single controllable expenditure in a plant: in many companies it often exceeds annual net profit.”
Due to the:
- Introduction of new water continuously,
2. Existing fouling in the piping system,
Fouling cannot be avoided in everyday situations, it can only be minimized.
Two basic and effective ways to reduce energy costs that apply to all energy production, distribution and end-use categories are:
- To reduce the load or need for energy
- Increase the operating efficiency of energy-using equipment
Prolongs The Lifespan Of Your Equipment
In the past removing scale has been a major problem.
- Mechanical removal requires extensive downtime while the item of equipment is disassembled, then re-assembled.
- And corrosive acid cleaners, such as concentrated hydrochloric acid, raise occupational health and safety concerns and disposal problems.
- Also with the significant risk of long-term detrimental impact on plant life from metal loss. Therefore, to prolong the life of your equipment, it’s important to use a descaler with a low corrosion rate.
Dynamic Descaler has the lowest corrosion rate of any descaler. Thorough surface cleanse without pitting, suitable for hard metal
With Dynamic Descaler your equipment is up and running in hours, while all conventional methods takes days.. Imagine the downtime cost that you will save
- Prevents costly shutdowns
- Prevents expensive repairs
- Reduces energy and operational costs
- Dynamic Descaler will extend the lifespan of your equipment , especially when used as a part of a regularly scheduled maintenance program.
Energy Cost of Waterside Fouling In Industrial Equipment Energy is by far the largest component of the total life cycle cost of most energy-using equipment
Beebe, Ray (1995) Machine Condition Monitoring MCM Consultants (1995 Reprint) ISBN 0646250884
Beebe, Ray (1998) Condition Monitoring by Performance Analysis to Optimise Time for Overhaul of Centrifugal Pumps Mfptsociety 52nd Conference
Eryurek, E and Warrior, J (1997) Smart Field Devices Improve Process Anomaly Detection Rosemount Inc Technical Paper
Haynes, C J and Fitzgerald, M A (1986) Scheduling Power Plant Maintenance Using Performance Data ASME Paper 86-jpgc-pwr-63
Pritchard and Thackery (Harwell Laboratories
Panchal (Argone National Laboratory)
Air Compressors – lime, water scale, rust remover