This document summarizes a presentation about managing water systems for cost control and reliability. It discusses managing water for sustainability, cost control, and system reliability. Specific strategies are presented for increasing cycles of concentration in cooling towers and boilers to reduce water and chemical usage. Automating chemical treatment and improving makeup water quality through advanced treatment are effective ways to increase cycles of concentration and lower costs. Case studies show potential savings of over $20,000 per year from optimizing boiler water systems and over $27,000 per year from cooling tower improvements.

1. Manage Your Water Systems for
Cost Control and System Reliability
Presented by:
Tom Christman, Vice President
Watertech of America, Inc.
March 1, 2012

2. Why Manage Water?
• Sustainability
• Cost Control
• System Reliability

3. Why Manage Water?
Sustainability
The ability of the earth to continue to
support human life. The responsible use of
natural resources - Water.

4. Why Manage Water? Sustainability
 Water Stressed Areas of the World

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 world's (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.

7. Wisconsin Water Use by Category

8. Wisconsin Population and Water Use

9. Wisconsin Water Use by Source

10. Wisconsin Water Use by Source

11. Why Manage Water?
Cost Control
 Water Costs –
• Relatively inexpensive but going up at record rates
 Chicago's 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

12. Why Manage Water? Cost Control
Rates for large industrial users
Location Water cost Sewer cost Total Water &
US $/1000 gallons US $/1000 gallons Sewer Cost
US $/1000 gallons
Seattle, WA $6.19 $13.74 $19.93
Portland, OR $3.65 $9.42 $13.07
Los Angeles, CA $3.00 $4.00 $7.00
Cincinnati, OH $1.84 $4.93 $6.77
Wausau, WI $1.54 $3.45 $4.99
Green Bay, WI $2.65 $2.31 $4.96
Milwaukee, WI $1.58 $2.69 $4.27
Madison, WI $1.82 $2.31 $4.13
Spokane, WA $0.95 $2.19 $3.14

13. 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

14. Why Manage Water? Cost Control

15. Why Manage Water? Cost Control
Boiler 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

16. Why Manage Water?
System Reliability
 Fewer failures
 Reduced downtime
 Extended asset life
 Reduced Liability

17. Why Manage Water? System Reliability
Without a proper chemical treatment
program, Scaling and Corrosion will occur =
equipment failures, increased downtime, shortened
equipment life

18. Why Manage Water? System Reliability
 Public health and safety
• Legionella

19. 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”

20. Managing My Water – Flow Diagram

21. 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!

22. Percent Boiler/Cooling Water use as
Total Water Usage
80%
70%
60%
50%
40%
30%
20% Cooling
10%
0% Boilers

23. Managing my Water
Automation

24. 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

25. Managing my Water

26. 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.

27. Water Use and Your Recirculating Cooling
Water System

28. Controller
Before: Tower @ 3 Cycles
30 GPM
Annual Make Annual
Up Bleed
Setpoint 22.86 MG 7.56 MG
1,200 uS $43,094 $19,656
= 3 Cycles
45 GPM 15 GPM
400 uS 3,000 GPM Recirc Rate

29. Controller
After: Tower @ 5 Cycles
30 GPM
Annual Make Annual
Up Bleed
Setpoint 19.15 MG 4.03 MG
2,000 uS $36,389 $10,483
= 5 Cycles
38 GPM 8 GPM
400 uS 3,000 GPM Recirc Rate

30. Summary of Cooling Scenarios
Make Up Flow Make Up Cost Bleed Flow Bleed Cost
3 Cycles 22.86 MG $43,094 7.56 MG $19,656
5 Cycles 19.15 MG $36,389 4.03 MG $10,483
Savings 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

31. Effective Ways to Increase Cycles of Concentration
Recirculating Cooling Water
1.Automate chemical feed and tower bleed
2.Soften the makeup water
3.Feed acid for control alkalinity and pH
4.Look for a better source of makeup water
5.Install “side-stream” filtration for solids
removal

32. Water Use and Your Boiler Water System

33. 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
GPD
Controller
Annual Make Annual
Up Blowdown
Setpoint = 9.7 Cycles 23.77 MG 5.77 MG Blowdown
$45,170 $15,010 16,495 GPD
3,500 uS

34. 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 GPD
Controller
Annual Make Annual
Up Blowdown
11.24 MG 2.73 MG
Setpoint = 19.4 Cycles Blowdown
$21,360 $7,098
7,801 GPD
3,500 uS

35. Make Up Flow Make Up Cost Blowdown Flow Blowdown Cost
9.4 Cycles 23.77 MG $45,170 5.77 MG $15,010
19.7 Cycles 11.24 MG $21,360 2.73 MG $7,098
Savings 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 year
125 psi boiler operating at 80% efficiency, 2012 city of Milw. Water cost, $4.50/MSCF gas cost, 160oF condensate temp.,

36. 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

37. Questions?
For a copy of this presentation, see
Tom Christman or contact him at
tom@watertechusa.com
www.watertechusa.com