It can bring down your costs

For any plant owner or HVAC manager, the operating cost of an evaporative cooling system is often viewed as the most crucial deciding factor. However, the quality of the available makeup water and the operating cost of the cooling system are interconnected with each other. With a proactive water treatment program, you can keep your cooling towers and chiller condenser tubes free of scaling, bioaccumulation and corrosion. This way, you end up reducing the maintenance cycle, saving more water than ever and ensuring zero downtime that can lead to a lower total cost of ownership.

It can increase the lifespan of your cooling equipment

When you ignore available makeup water quality and choose not to implement a water treatment program, you leave your equipment more vulnerable to water-based problems. Water is a universal solvent that can dissolve many substances, including gases like oxygen and carbon dioxide. As a result, water can cause corrosion of metals, which can cause unwanted side effects for industrial uses, such as equipment damage. Hence, bad water conditions alone can cause a cooling system to lose as little as two to seven years. However, the same system could last for 15 to 20 years if the makeup water quality is consistently maintained. Hence, a water quality checkup has to be a part of your equipment selection process so you can invest in a water treatment system.

It can prevent water-related problems

As water continues to concentrate in an evaporative cooling system, the dissolved ions in makeup water end up exceeding the solubility of minerals, causing scaling and bioaccumulation. It can lead to harmful bacteria entering your cooling system from the makeup water supply. These bacteria may grow in number, creating more equipment-related problems or an outbreak of airborne microbes like Legionella. However, an automatic water treatment system like SBR continues to clean the makeup water without using harmful chemicals, thus preventing the growth of bio-organisms and keeping you free of worries.

It can bring down your costs

For any plant owner or HVAC manager, the operating cost of an evaporative cooling system is often viewed as the most crucial deciding factor. However, the quality of the available makeup water and the operating cost of the cooling system are interconnected with each other. With a proactive water treatment program, you can keep your cooling towers and chiller condenser tubes free of scaling, bioaccumulation and corrosion. This way, you end up reducing the maintenance cycle, saving more water than ever and ensuring zero downtime that can lead to a lower total cost of ownership.

It can increase the lifespan of your cooling equipment

When you ignore available makeup water quality and choose not to implement a water treatment program, you leave your equipment more vulnerable to water-based problems. Water is a universal solvent that can dissolve many substances, including gases like oxygen and carbon dioxide. As a result, water can cause corrosion of metals, which can cause unwanted side effects for industrial uses, such as equipment damage.
Hence, bad water conditions alone can cause a cooling system to lose as little as two to seven years. However, the same system could last for 15 to 20 years if the makeup water quality is consistently maintained. Hence, a water quality checkup has to be a part of your equipment selection process so you can invest in a water treatment system.

It can prevent water-related problems

As water continues to concentrate in an evaporative cooling system, the dissolved ions in makeup water end up exceeding the solubility of minerals, causing scaling and bioaccumulation. It can lead to harmful bacteria entering your cooling system from the makeup water supply. These bacteria may grow in number, creating more equipment-related problems or an outbreak of airborne microbes like Legionella. However, an automatic water treatment system like SBR continues to clean the makeup water without using harmful chemicals, thus preventing the growth of bio-organisms and keeping you free of worries.
To summarize, water treatment solutions to maintain water quality are the crucial building blocks for all evaporative cooling systems. Implementing an effective treatment program will help you ensure efficient operation of cooling water systems and appropriate service life for the equipment they serve. An automatic non-chemical water treatment system like SBR is the most sustainable option capable of reducing chemical usage while increasing water efficiency. By combining innovative cooling efficiency technologies, this system can effectively tackle challenging water quality while reducing the dependence on chemicals, thereby reducing environmental impacts.
For more information about SBR water treatment, click here.

Trend#1: Tracking Down Water Losses

Evaporation is the chief cause of water loss from cooling towers, followed by blowdown. Cooling towers typically store lots of water, leading to bacterial growth and solid buildups. Hence, that water must be replaced with fresh water regularly to prevent corrosion, scaling and let it run efficiently. And when a system is more efficient, less water circulates and less water needs to be flushed out, reducing the bleed-off quantity and the need for blowdown.
The other way to save water is through chillers operations. When chillers function more efficiently, they transfer less heat into the plant’s condenser system and thus reduce evaporation. By improving plant efficiency from 1.0 to 0.75 kilowatt per ton of cooling, facility operators can cut water usage by 10 per cent or more. The result is cost savings, reduced chemical usage, and a decreased carbon footprint. Non-Chemical water treatment technologies for Cooling tower, such as SBR can provide huge savings in maintenance costs.

Trend #2: Reduced Energy Consumption

With more focus on sustainable growth, most HVAC operators are looking for products and solutions that reduce their negative impact on the environment. According to recent studies, 40 per cent of energy consumption in the commercial sector are caused by heating and cooling. However, chillers are the single largest individual user of electricity in commercial and institutional HVAC facilities.
And when the performance of heat exchangers deteriorates due to the accumulation of deposits, biological growth, corrosion on heat transfer surfaces, the energy costs also go up. At some point in the operating cycle, the increased cost of power will be offset by the cost of cleaning.
To prevent this, maintenance and engineering managers need round-the-clock cleaning of chiller tubes, which is only possible through the Automatic Tube Cleaning System (ACCS).
It's an automatic system that continuously cleans heat exchanger tubes while the equipment remains in operation and in full production. With automated maintenance and high-efficiency HVAC units running smoothly, HVAC operators get to reduce their energy consumption and take control of their energy costs. This leads right into our next HVAC trend: long-term energy cost savings.

What is Water Treatment?

Water treatment is to eliminate undesirable components and to reduce their concentration to make the water useful for the end-use. The treated water can be used for industrial purposes and other things as well. Such as using that processed water in a water cooler condenser to make air cool within a building. However, this process took a little longer to clean water and there are other ways too. That will help you to clean the water within your water cooling condenser using four chemicals. These chemicals are corrosion inhibitor solution, antiscalant, dispersant and biocide.

SBR Technology For Water Treatment

Scale and Bio Remover or SBR is a non-chemical water treatment for cooling towers. That you are looking to use for your own water cooler tower. Using this technology of scale and bio remover will meet all your requirements. However, wastage of water in the industries is one of the dangerous things for all types of lives. The earth is 71% of water but only 1% of it is usable for drinking, washing, and using for food wash. Being sustainable is another important task for all of us. If we choose to be in a traditional way this will lead us to end lives. Therefore being green eco-friendly is something that will help us meet the target of sustainability. There is no chance of surviving without water and industries have to think of it, in order to be sustainable.

You have been looking for the innovative SBR that deploys an electrolysis reaction with a cathode and anode in the reaction tank. This generated at the cathode creates a high PH environment in its walls; the result of this reaction is the precipitation of calcium. Magnesium ions in the water reduce scaling and corrosion on the anode site chlorine and other strong oxidizers are generated. Inhibiting bacterial and any biological growth in the cooling tower thus countering biofouling.

SBR treated water is free of hazardous chemicals and can be used for alternate purposes like irrigation. SBR comes with site stream filtration to reduce any suspended solids in the cooling system. Another integral part of

The system is automatic blowdown control equipped with an accurate conductivity sensor. SBR can increase the speed cycles of concentration accordingly reducing your blowdown. By as much as 66% a breakthrough in the cooling tower water management.

Scale and bio remover (SBR) from CET Enviro is a complete package that offers a myriad of benefits and comes with an expert on-site service guarantee 24×7.

What Are the Advantages of SBR

• Save more than 50% of blowdown water
• Zero chemicals
• Environment-friendly
• Reduce STP
• Treatment cost
• Reduce operational cost
• Improve workplace safety
• Eliminate risk due to chemicals
• Reduce Maintenance downtime
• Enhanced cooling system performance

Do not use chemicals for your cooling tower system. All the hazardous chemicals will decrease the life of your water cooling tower system and you can avoid these problems by using non-chemical water treatment for cooling towers technology. Scaling bio remover is an eco-friendly system and worth ROI.

Common Cooling Tower Problems

However, every cooling tower has common cooling problems which are occurring. The CEO of Cet Enviro: Tsure Ben David has given the solution to all these problems. You can eliminate this problem of a water cooling tower easily and simply. We are working to make things easy, simple and to find new solutions to all these problems. That is making things hard for your industry to maintain a cooling condenser working smoothly for a long time. Here are three common cooling tower problems that you must be working on and keep your cooling system maintained well.

• The high amount of blowdown.
• A low cycle of concentration.
• Noise emissions from cooling towers.

These three problems are common that you will find in every cooling tower. Therefore, you must be maintaining your cooling tower continuously so that you can avoid this problem.

Final thought

This has become an integral part of everyone to work according to the environment. However, water is one of the most important parts of our life and therefore, we have to be sustainable enough. Being part of sustainability is our responsibility and goal. So, natural resources are limited to survive on the earth. To avoid such damage to the natural resources is like blasphemy. Therefore, SBR (Scaling Bio Remover) is one of the solutions that meet the requirements of sustainability and make your system environmentally friendly. Be a part of sustainability and be green to save the environment.

What temperature is required?

Medical equipment requires accurate temperature control to maintain a precise temperature at +/- 1°F.

What flow rate is required?

Medical chillers require a specialized high-pressure pump to ensure fluids flow through the system effectively as the component is operating.

What is the heat load variation?

When medical imaging equipment is scanning, chillers need to handle 100% heat load at 100% for elongated run times.

What is the desired capacity output?

Shifting from a single to a dual circuit medical chiller system can cut capacity output by as much as half. So select an efficient medical chiller that will help you get the most uptime.

What level of redundancy is required?

Medical chillers require additional redundancy options, such as a city water bypass apparatus, to help keep the systems up and running.

How’s the maintenance?

There was always a concern over the use of hazardous treatment chemicals in medical chillers. Our modern technology for round-the-clock cleaning of condenser tube cleaning is Automatic Tube Cleaning System (ACCS). It automatically cleans the heat exchanger tubes in chillers while the equipment remains in operation. It also eliminates downtime while optimizing energy utilization of water-cooled heat exchangers, including chillers. Sharing his thoughts, Mr Tsur Ben David, CEO, CET Enviro said, “In the medical industry, sustainability remains a priority in choosing any powered equipment. However, the best choice depends on the decisions criteria set by the user. So, consider all factors to make sure the chiller that ultimately gets specified balances all the objectives over the long term”

Air-cooled chillers:

Used in both commercial and personal facilities, Air-cooled chillers cool fluids, exchange heat and dehumidify the air. They actively absorb heat from the processed water and then transfer this heat into the air around the chiller unit.

Used in both commercial and personal facilities, Air-cooled chillers cool fluids, exchange heat and dehumidify the air. They actively absorb heat from the processed water and then transfer this heat into the air around the chiller unit.

In this process, heat is absorbed from the chilled water circulating through the evaporator. Then, the compressor pumps the refrigerant vapour to the condenser, thus increasing temperature and pressure. To complete the cycle, the refrigerant flows over the chilled water coils and absorbs more heat.

Air-cooled chillers were mostly popular in areas where additional heat discharge is not an issue but instead works as a benefit. They are also compact and highly efficient heat exchangers, which make them ideal for supplemental, temporary applications. But now they are in a wide variety of settings including hotels, corporate events, restaurants, large-scale construction, industrial and manufacturing plants, etc.

Water-cooled chillers:

Used for large installations, water-cooled chillers are connected with a cooling tower and use a water-cooled condenser to remove excess heat. They use recirculating water from a cooling tower to condense the refrigerant. This water absorbs heat from the process and the heated water returns to the chiller.

The processed water works as a medium for heat transfers which is why water-cooled chillers can often operate more efficiently than an air-cooled chiller. They ensure more consistent performance because of the relative independence to fluctuations of the ambient temperature. Even if water-cooled chillers are more efficient than air-cooled chillers, this is only true if you look exclusively at heat exchange.

Performance: Air-cooled chillers are typically available in compact sizes, ranging from 7.5 to 500 tons. Due to their small size and output, air-cooled towers work only for small areas and facilities. Water-cooled chillers are available from 10 to 4,000 tons with output performance ranging from 35 kW to 14,000 kW. So before choosing your cooling tower, make sure to check for the surface area that needs to be cooled.

Maintenance: Air-cooled chillers do not require cooling towers to operate because they use air to remove excess heat. Water-cooled chillers require cooling towers, which increases maintenance demands such as water treatment, tube cleaning, and tower mechanical maintenance.

To overcome these challenges, systems operators use automated water treatment solutions such as SBR, which prevents fouling, biofouling, reduces downtime, cuts maintenance costs and saves water. While air-cooled towers are easier to maintain, water-cooled chillers are more sustainable and deliver higher cooling capacity with fewer units and a smaller footprint.

Durability: Air-cooled chillers are mostly outdoors and operate at higher condenser pressure while Water-cooled chillers are typically installed indoors. They are less prone to damage and operate at lower condenser fluid pressure. However, they still have a shorter lifespan of 15 to 20 years. But with innovative technology solutions like SBR water treatment and ACCS condenser cleaning system, water-cooled chillers last up to 30 years.

While cost & sustainability remains a priority in choosing any powered equipment, the above factors have to be considered too. While the water-cooled chillers are more energy-efficient, air-cooled chillers have a lower maintenance cost and several other aspects.

Yet, the best choice for the project depends on the decisions criteria that are set by you. So take all factors into consideration to make sure the chiller that ultimately gets specified balances all the objectives over the long term.

These types include mechanical-draft and natural-draft hyperbolic cooling towers:

Natural-draft cooling towers:

With hyperbole shaped cooling towers, this cooling technology utilizes shape and pressure to move up the air naturally. Typically located outside the buildings, these cooling towers induce a pressure difference between heated air and the surrounding air. Due to this pressure difference, air enters into the cooling tower while the water doesn’t come into contact with the air, which is only possible with a heat exchanger.

The heat exchanger separates the cooling tower water and cools down from the evaporation water while avoiding contact between the process water and the air. By enclosing the heated air in the chimney, it creates a pressure between heated air and surrounding air which then enters into the cooling tower. Due to their sizes, the capital cost of these cooling towers is a little higher from other alternatives. However, its operating and maintenance cost is low because of the absence of electrical fans.

Mechanical draft cooling tower:

 While the process is still the same with a mechanical-draft cooling tower, the only difference is the fan in the cooling tower. In this cooling technology, cooling towers use a propeller or centrifugal fan to circulate the air into the tower and move it up and out in the opposite direction of the warm condenser water of the top of the unit.

 Due to the evaporation of a small quantity of the water, heat transfer occurs between air and the water. The air will carry the heat through evaporating water from the cooling tower into the atmosphere. It allows the water to cool down from a delta of the high-temperature point to the final temperature.

 Unlike natural draft towers, these are enclosed structures and can be located anywhere inside the building. They are much smaller in size than other cooling towers which is why they are mostly used in hotels, hospitals and commercial buildings. Capacity control is also easy in these types of towers since the speed of the fan can be controlled.

 Cooling towers are essential for temperature control and cooling in several industries but it may vary in size, shape and type depending on the building’s needs. From big industries like oil refineries and manufacturing plants to a commercial complex, most facilities have a cooling tower as a part of their HVAC system. Based on your business needs, you can easily choose the right cooling technology and cooling tower type which can help you lower cooling costs, minimize downtime, and improve operational efficiency.

Data & Insights

Cooling tower operators and building managers are now using data analytics to make educated decisions about system maintenance, cutting costs and wasting less energy associated with unnecessary equipment operation, inefficient strategies, and faulty equipment. It can help them choose which HVAC systems will be the most energy- and cost-efficient and provide options for them based on their prior use and other factors.

With detailed data generation and analysis reports, HVAC operators can manage energy and operating costs on a routine basis. The data is collated in a specialized Control Panel to calculate the specific power consumption of chillers in ikW/TR. These values are automatically retrieved and updated for real-time, so our consumers can perform an energy load calculation of their residence and select the proper size of equipment needed to cool the home efficiently. It significantly helps in improving the performance potential of chillers.

Smart HVAC Technologies

Artificial Intelligence is at the forefront of many emerging trends because it’s accessible and a lot smarter. The HVAC contractors too can implement this technology to control and manage more efficiently. These systems can also track the conditions outdoors, such as temperature, humidity, brightness, and position of the sun.

HVAC commands produced by the AI “algorithms” and delivered to the thermostat would ultimately control the HVAC unit. For instance, if one part of a building isn’t in direct sunlight, then the system will blow less AC during the summer and more heat during the winter months. If there are smart blinds installed, the system can open and close the blinds based on the position of the sun.

The HVAC industry can now achieve sustainability and efficiency by becoming more environmentally friendly, using automation and smart tech, and analyzing data for peak performance. With software-enabled HVAC systems like ACCS, which is the only online condenser tube cleaning system in India, they’re set to implement innovation into their business strategy and future-proof your company.

Challenges of Scale Buildup:

Scaling is a hard layer of mineral deposits precipitated from the cooling water and builds on the chiller surfaces. The precipitation of these mineral deposits is more prevalent at higher temperatures. Therefore, scale build-up usually occurs first on heat transfer tubes of chillers.

While some of the symptoms will be seen over time because scale deposits build up over time, small changes in equipment efficiencies can be the first sign of scale growth. Here are some efficiency problems that remind you to tackle your limescale problem:

In this process, heat is absorbed from the chilled water circulating through the evaporator. Then, the compressor pumps the refrigerant vapour to the condenser, thus increasing temperature and pressure. To complete the cycle, the refrigerant flows over the chilled water coils and absorbs more heat.

• Rise in operational costs (including tube or pump failures or the chiller shutting down due to high head pressure)
• Increased equipment downtime
• Increase in heating and cooling energy costs
• Loss in performance, including high head pressures or pump reading more elevated than usual

“By understanding how these issues affect your HVAC systems, and their associated cost drivers, you can make informed decisions on the proper scale and biological fouling control”. Shared Mr Tsur Ben David.

So let’s take a closer look into these signs:

A rise in operational costs

When your energy consumption is rising with no change in facility operational hours, there’s a good chance you’ve got scaling in your chillers. Scale deposits reduce the heat transfer surface on chiller systems, leading to significant increases in energy costs.

When scaling is impeding the energy coefficients, more energy is required to achieve the same level of heating or cooling. Also, the build-ups in condenser tubes mean your pumps work harder to move the same amount of fluid.

It not only increases electricity costs but may lead to premature pump failure. Increased fuel costs mean increased building operating and maintenance costs, which affect the profitability of your business.

Increase in equipment downtime

Without regular cleaning, scale deposits will eventually require complete removal for the equipment to function. And the equipment may be out of operation for days or weeks, depending on the volume of build-ups.

Unexpected downtimes van quickly cut into the operational capability of a building. If all HVAC systems serving a business are down, the business may have to shut down its operation entirely until the problem is fixed. That’s why preventing equipment downtime is one of the most significant concerns for facility managers.

All equipment experience some sort of downtime for maintenance, but when equipment downtime sharply increases for cleaning, it may be evidence of a larger scale build-up problem. You need to realize that practising correct preventative maintenance plans on chillers can prevent downtime.

Loss in performance

The performance of HVAC systems depends on the efficiency of boilers, chillers, heat exchangers or cooling towers. That’s why any performance loss is first noticed by monitoring the key performance indicators of these systems.

Scale build-up inside the chiller or heat exchanger is the main cause behind the loss of performance. It not only leads to inadequate heating or cooling results but also ends up costing too much in maintenances costs and replacement. Inadequate performance and efficiency of HVAC systems can also increase the heating and cooling costs.

While there are different methods for controlling scale build-up, they generally fall into two categories – chemical and mechanical. However, both require regular checks and will not prevent scale deposits entirely. So vigilant monitoring of system performance is required.

Said Mr Tsur Ben David, “With CET Enviro’s ACCS, you can automatically clean heat exchanger tubes while the equipment remains in operation and full production. It’s an online method that infuses some slightly oversized elastomer balls periodically into the Condenser tubes and keeps the tubes free of fouling 24×7”.

“We have designed this system to suit the specific requirements of Water Cooled chillers, with R&D done in Israel and already have more than 1000 installations across the globe” said Mr David.

Why Is Legionella a Concern for cooling tower operators?

Legionnaires disease is a severe type of pneumonia that affects the lungs and is caused by legionella. It’s generally present in local water sources in benign amounts. The health risk arises when these bacteria are allowed to grow and spread without being treated, particularly in industrial cooling systems. It can rapidly grow in stagnant water and multiply to dangerous levels if left untreated.

These microbes are capable of colonizing in warm water environments, including domestic HVAC systems and cooling towers. In cooling towers, the outdoor air intakes are located downwind of the towers. While transferring heat to cool down the warm water, the vapour is released into the air. This moist air can carry the Legionella bacteria and expel them into the air and ventilation. The expelled Legionella bacteria can be inhaled by the building occupant and cause a massive Legionnaires outbreak.

What leads to legionella growth in cooling towers?

 There are various factors in play that become a cause of legionella growth in cooling towers and can become a breeding ground for it. Some of the main causes of Legionella are:

scaling: Scaling is the deposition and accumulation of unwanted materials and minerals from the water, collected inside the water system. It%E2%80%99s a layer of solid build-up, which interferes with the efforts of heating or cooling the water. It can lead to unpredictable or higher water temperature and serve as a breeding ground for bio-growths. As a result, legionella and other bacteria proliferate due to scale build-up in the cooling water systems.

sediment: Sediment is the left-over solids of minerals and natural material that is left down in water sources from the processes of erosion. It grows in unfiltered water that is not properly treated and may grow in a protected environment due to poor maintenance. When sediment builds up, it leads to more germ build-up including legionella and also compromises the heating and cooling systems.

Stagnation & pH: When water is stagnant without proper care and maintenance, it gives an opportunity to biofilm for growth. The other reason for stagnant water may also include pipes that have low to no flow of water. As a result, this sitting water gets warmer, creating an ideal environment for bacteria, like legionella. Which is why it's essential to maintain a required level of pH balance of the water is between 6.5 and 8.5. The chemicals, changes in the environment due to pollution, and the amount of plant or organic material in water influence also helps bio growths in the water sources

Unfortunately, many facility managers still undermine the importance of cooling tower maintenance in preventing Legionella growth. Oftentimes, facility managers and even some cooling tower suppliers don’t schedule maintenance and inspection works until a major problem occurs. With a proper water management system, you will not only guarantee efficiency, reliability, and longevity but also prevent costly repairs and replacements as well as bacteria growths.

Importance of cooling tower water treatment

A proper cooling tower water treatment like SBR can help you with the prevention of Legionnaires disease in the long run. Cooling towers hold large amounts of water, which makes them an ideal environment for the growth of Legionella bacteria. To avoid the growth of Legionella bacteria, SBR performs regular and proper cleaning and maintenance, as well as effective cooling tower water treatment.

With our innovative cooling tower water treatment, you can ensure that the water in your cooling system is always in pristine condition. With SBR, you will not only prevent untimely downtime, but also the growth and production of Legionella bacteria within your cooling system.

Increase CoC:

 For heat transfer, fresh makeup water is used in the cooling towers, which is only usable before the dissolved minerals build up to an extent where they drop out of the solution. CoC is the number of times a cooling tower recycles water before the blow down.

Typically, a CoC of three is considered best for optimal efficiency. However, the water quality and the water treatment determine the number of cycles a cooling tower system can endure. To increase the cycle, you can minimize chemical use or invest in a non-chemical water treatment system. It can reduce the potential for corrosion, scaling and biological growth, which allow the towers to operate safely at higher concentration ratios.

scaling:

 It occurs within a cooling tower when the concentration of dissolved solids becomes greater than their solubility in the water. Calcium sulfate, calcium phosphate and other calcium salts commonly cause scale which impacts the heat transfer surfaces in your tower and lower your cooling efficiencies. Scale Remover STSR is a cooling tower descaler chemical that has been used for cooling tower cleaning and cooling tower maintenance. Without cleaning and maintenance, equipment may need costly repairs, shutdowns or even replacing.

Reduce blow down:

 With no treatment in place to prevent scaling and biological growth, many cooling tower operators increase blow down. This strategy, however, can also increase corrosion by lowering the pH and water loss.

Instead, you can try careful monitoring, establishing and adhering to set points and installing a conductivity meter to reduce water wastage. You not only save lots of water but also reduce sewage, another potentially significant cost savings.

Monitor water levels and install flow meters:

 When the water level is too high, it can lead to water loss. It can cause strong airflow in the sump that tends to leak and set off water overflow. That’s why you must replace the ballcock-style fill valves with more reliable fill valves. Also, keep checking the water level to ensure that it is adequately below the overflow outlet.

For effective water management, It is essential to keep track of makeup and blow down quantities. That’s why you must install flow meters on both makeup and blow down water lines. They will help you check the ratio between blow down water and makeup water. The proportions have to match the target cycles of concentration. If it isn’t matching then, it will help you catch the performance degradation timely.

Invest in a water treatment system:

 While a water treatment reduces the cost to treat makeup water, it will also maintain an optimal recommended system water cycle of concentration.

That’s why it’s vital to achieve water efficiency in industrial cooling towers. At CET-Enviro, we offer SBR, a non-chemical automatic water treatment that continuously cleans the cooling tower water and augments the cooling performance.

These are some of the basic measures to reduce water loss from your industrial cooling tower system. To start saving, implement them and invest in systems that efficiently minimize water wastage.

Data Centre Cooling System Options:

There are multiple ways to cool data centers, depending on the size, computer capacity that must be cooled, regional energy costs, water availability, data load, and density. Popular options include:

If you compare, water cooling with air cooling, you may find air cooling a more popular option but water cooling is a better and more cost-effective option. The air has poor heat conductivity, meaning that the amount of energy required to chilling down air to the required temperatures to remove the heat and move it is becoming somewhat expensive. Water has much more capacity to remove heat than air and can therefore be far more effective to cool hotspots if it’s engineered and implemented correctly. Surprisingly, water-cooled systems can also reduce water consumption. Because the water used in a power plant to generate the additional power required by the air system needs is greater than the amount of water that would be used locally by a water-cooled system.

The benefits of water cooling systems include:

In reality, cooling towers do not keep things cool as much as they reject heat, which they do by transferring heat from the water source to the atmosphere through the process of evaporation (latent) and sensible heat transfer, thereby reducing the water temperature. The industries use cooling water for various jobs and, as a result, there are also various types of cooling towers.

A properly chosen and maintained cooling tower can help organizations avoid problems in their operation. Choices must be made based on size, efficiency, dynamics, and other factors.

Scale and Bio-Removal System from Cet-Enviro:

Our Scale and Bio-Removal System (SBR) provides non-chemical treatment of cooling towers to get rid of cooling tower problems like biofouling, scaling, and corrosion.

Cooling system water quality directly affects the reliability and operating cost of cooling towers in data centers. The SBR solution is a fully automatic online technology that continuously cleans cooling tower water without any chemicals and increases the cooling performance.

Also, learn about the importance of energy management systems in cooling towers

Advantages with SBR are:

The sole purpose of data center cooling technology is to maintain environmental conditions suitable for information technology equipment (ITE) operation. In most data centers, the operators expect the cooling system to operate continuously and reliably, and with SBR technology, you can be well assured of your cooling system working at its optimal performance.

Automatic Condenser Cleaning System for Chillers – the ultimate system to keep the condenser tubes in chillers free of fouling 24/7.

In this new era of COVID-19, the idea of dealing with yet another deadly illness is a scary thought. Read on to learn more about Legionella disease and why you should be aware of it and, how to mitigate the associated risks?

Why Legionella is a concern now?

After months of no operation, many buildings and sectors have started to operate in half or partial capacity. This also implies that they have started to function building cooling systems and water heating systems to showers that had remain inactive during the time building was closed for operation and on pretext on winter season. When properties are closed for an extended period, for any reason, unsafe conditions can develop in building Cooling system. These can pose serious health risks.

Harmful microorganisms, particularly Legionella bacteria, can grow in the stagnant or standing water supply, which is a concern for safely reopening Cooling towers, and reopening floors at hotels and long unused rooms. For all maintenance managers, the risk of Legionella could pose yet another big problem as it is as deadly and dangerous as Covid-19, and hence the ignorance may turn fatal.

The legionellae were originally transitory contaminants of environment but have since been recognized as natural components of freshwater ecosystems.

Fresh water used for air conditioning and plumbing systems has been left stagnant in many industrial buildings and businesses that were closed for COVID-19. When water is stagnant, hot water temperatures can decrease to the Legionella growth range (25–42°C, 77–108°F). Stagnant water can also lead to low or undetectable levels of disinfectant, such as chlorine.

The risk presented by Legionella is one of the tough challenges that facility and maintenance teams face on routine basis to keep their facility and surrounding area safe.

How is Legionella disease like Covid-19?

Like Covid-19, Legionella bacteria attacks lungs and is mostly caused by breathing in water containing legionella germ. Infection is acquired through breathing in aerosols (very fine droplets of water) which contain the bacteria.

Like Covid-19, people those are older or those who have weakened immune system are more prone to Legionella disease. Going by reports, both diseases have similar symptoms.

However, unlike Covid-19, Legionella is not a pandemic disease. It is not passed from person to person, nor is it acquired by drinking water contaminated with Legionella. Also, Legionella is a bacteria, while Covid-19 is a virus. None-the-less, both poses high risk to life and need prevention.

Those at risk of exposure of Legionella, include not only those who work in the premises but also others in the vicinity. Facility team involved in handling Cooling tower may be at increased risk.

Most of legionella outbreaks could be prevented with effective water management and effective cooling tower water treatment techniques.

The most critical industry at helm of risk is Hotel and Hospitality sector and Hospitals. All buildings where Cooling Tower is situated at roof, or where people can be exposed to spray from the cooling towers pose very high risk of transmitting Legionella bacteria.

Hot water distribution pipe network via showers are also potential risk points as temperature is ideal for expended grow of the Legionella bacteria.

It will remain important for people to continue to take prudent steps to protect themselves and follow the recommendations specific to reopening after prolonged shutdowns.

Exposure to the droplets falling from Cooling tower can be avoided completely by paying close attention to the mechanical design of the Cooling Tower equipment or by treating the cooling tower water with new effective technologies.

In some countries it the legal requirement to carry out frequent risk assessments on cooling towers, to identify and assess any Legionella risk presented by the system, or any work associated with it.

Check to mitigate the risk of Legionella!

Ensure that your water system is safe to use after a prolonged shutdown to minimize the risk of Legionnaires’ disease and other diseases associated with water.

4 steps to follow before reopening buildings after prolonged period of inactivity!

• Ensure that cooling towers are clean and well-maintained!
• Ensure that the tower and basin are free of visible slime, debris, and biofilm before use
• Treat stagnant water
• Take monthly test for the Legionella bacteria
• Old prevention techniques involve harmful chemical dosing in the Cooling Tower to prevent Legionella and other ills.

But how dangerous is it, exactly?

Is normal chemical treatment effective to destroy the Legionella bacteria ?

Handling & storing Chemicals for Cooling tower water treatment always remain a challenge. User is normally unsure on amount of chemicals to be added to get the best desired results. Normal oxidation of chlorine and other halogen-based chemicals at normal levels do not impose risk on equipment or risk of exposure in shower water, however studies shows that they are not 100% effective on destroying the Legionella bacteria. Super shock treatments are practically difficult to handle when the busing is occupied.

One proactive (and preventive) measure would be to choose the most advanced techniques to help minimize legionella growth. In recent years, the electrolytic disinfection process has gained popularity to offer a wide applicability in prevention of legionella bacteria and to treat Cooling Tower water for other ailments.

SBR – by CET ENVIRO is an Electrolysis treatment that comes with side-stream filtration. It is your cooling tower’s and hot water first line of defense against many issues. Without filtration, the solid buildups, airborne dirt, and pollen have the potential to foul and possibly halt the inner operation of any cooling tower water treatment. This type of scaling and fouling also gives room for bacteria such as Legionella to grow.

The electrolysis reaction is known to produce super oxidation power that is found to be very effective in prevention of the Legionella bacteria.

Amazingly, SBR Electrolysis system produces a mixture of oxidizers!

This includes free chlorine Ozone, Chlorine-dioxide, and free radicals. This is a strong combination to actually sterilize the water.

A water filtration system removes suspended and settled solids, which can help improve energy efficiency of cooling system and prevent health risks posed by waterborne bacteria. The use of electrolysis filtration system can also help in trouble-free operation and savings in maintenance costs. SBR does it all, without using any chemicals.

Click here for more information about SBR electrolysis technology!

NEW CONCERNS FOR LEGIONELLA AFTER CORONAVIRUS: Reopening Buildings

Going by the reports, the cases and outbreaks due to legionellae are expected to grow in 2021 even as the world gets ready with Corona Vaccine. Especially due to building closures or reduced operations with fewer people returning to full-time building operations is expected during year 2021. The reduced consumption of water can cause water stagnation in building water systems, increasing the risk for growth and spread of Legionella.

COVID-19 is an emerging, rapidly evolving situation. Legionella is perpetual. As we look forward to life and work after the coronavirus pandemic, we should remain vigilant about Legionella disease and take preventive measures to reduce the extent of waterborne respiratory disease.

SBR Electrolysis system in action.

Top 5-star hotel chains in India implemented SBR technology in their top-line properties and it showed amazing results. Similar results were seen in other installations including leading mall chains, top IT hubs, pharma sector and hospitals.

If you want to immediately protect your Cooling Towers, hot water systems and the employees handling these systems from the HARMFUL LEGIONELLA BACTERIA, contact us for more information.

Click here to know more information on the Legionella preventive programs that we offer!

Keep reading to learn about the benefits of energy management systems and why you need one, and how you can effectively put one into effect at your organization:

To understand Your Power Factor:

 Power factor represents the difference between the total input of power and utilized power. All industrial processes that involve machines may draw inefficient currents of power to process. Your power factor helps you identify the amount of power they’re using to produce results.

A low power factor means that your utility company is drawing more power than required and electricity companies may charge you for this wasted power. With an energy management system, you will be able to identify a low power factor and take the steps to reduce your energy costs significantly.

To identify your energy needs:

 The benefits of an energy management system also include understanding the consumption patterns. It will help you identify the sessions and processes that are using your energy most intensely. It can also pinpoint the reason for energy waste with advanced data analytics while identifying the best mode of actions to increase efficiency and reduce consumption.

Besides, if your business has operations in different locations, energy management systems will provide benchmarks across all your operations. You will then understand your impact on the power grid and be able to determine which business operations use the most energy. Hence, reduction in your electricity consumption will transform costs to savings and better your consumption patterns.

To prepare for a sustainable future:

 If you want your business to be sustainable, you need it to keep evolving. The biggest benefit of an energy management system is that it can help you identify room for continuous improvement. It always keeps an eye on whether your business’s energy consumption is as efficient as it can be.

By tracking your energy consumption, it assesses the quality of your power so that you always have the right amount of power when you need it. With this information, you can prevent maintenance downtime, eliminate risks while ensuring the best outcomes across your energy portfolio. Then you can continually benefit from the energy management system in the future too.

Problem: High amount of blowdown

Cooling towers remove excess heat by evaporation, and in turn use lots of water to make up the difference. Due to the makeup water being added into the cooling tower, solid deposits can remain in the cooling tower. This increases the need for a “blowdown” which removes solid waste and dissolved solids buildup to prevent scaling or corrosion in the equipment. When blowdown occurs, a huge amount of circulation water is also lost along with the solid waste, so it’s important to monitor this closely.

Solutions: If your cooling towers require a higher-than-normal amount of blowdown, you need to invest in an efficient water treatment solution for your cooling towers. Depending on the issue, some other solutions to prevent excess cooling tower blowdown include:

• Water filtration
• Side-stream filtration
• Increased cycle of concentration
• Maintain quality of makeup water by removing scale forming and corrosion causing impurities.

Problem: Low Cycle of Concentration

In cooling towers, CoC helps measure how much concentrated buildup is in the cooling tower water compared to the ratio of makeup water. The higher cycle of concentration means the lesser need for makeup water and blowdown, thus saving water and cost. The ideal ratio is at least three to six cycles of concentration which is 3 to 6 times the concentration of deposits in the water cycle than the makeup water. In systems operating at a low cycle of concentration, water consumption can increase rapidly, causing excess costs.

Solutions: In many water treatment systems, the quality of the water cycle, makeup water, and type of cooling tower being used will dictate the necessary treatments to achieve the best cycle of concentration for your facility. However, some solutions that can help in increasing your cycles of concentration are:

• Better cooling tower control by a water treatment system
• Minimizing blowdown monitoring conductivity
• pH/alkalinity control to minimize scale formation
• Decreasing feed hardness, iron, and silica
• Managing microbial growth

Problem: Noise emissions from cooling towers

Cooling towers can produce high levels of noise, which might be problematic in certain applications that produce huge out loads where sound reduction is imperative, such as hospitals, residential areas, hotels and commercial buildings. There are also stringent noise regulations and laws in place to prevent unnecessary noise pollution. Therefore, cooling towers have to abide by these rules and make sure the noise they produce is in check.

Solutions: The primary sources of noise from cooling towers are fans, fan motors, and the airflow. There are some noise control solutions that can be implemented in cooling towers. With a proper aerodynamic design and using optimised blade profiles and inserts, you can reduce the noise in cooling tower fans where it is generated, without reducing the efficiency of the fan.

Conclusion:

Every good business stands on an efficient operation that includes keeping the overhead down. Being aware of any potential problems in cooling towers and knowing how to solve them is essential to the success and efficiency of your process.

To ensure that the cooling towers work without any error, they have to be maintained regularly and operated with care. Even with the cooling tower water treatment, you need to take care of it in a proper manner. This will not only increase the lifespan of the equipment, but it will reduce expenses and also prevent any serious issues in your cooling system.

While it’s understandable that the filtered water will be cleaner, how can this help in running your cooling system more efficiently? To answer your question, here are the main reasons why filtering cooling tower water treatment makes sense:

1. Less blockage & downtime

With a proper type of filtration system, particulate matter, biological growth and suspended solids will be removed from the cooling tower water. It will also decrease solid deposits in the cooling tower, as well as reduce blockages in heat exchangers, tubes, and other critical process equipment. This, in turn, can improve the operational efficiency of your cooling system with less unscheduled downtime.

2. Extend equipment life

  Solid buildups of dirt particles, precipitates and biological deposits in cooling water may require higher cycles of cleaning and maintenance. Combined with scaling and fouling, this will end up damaging your cooling tower equipment. Thus, filtering suspended solids and microorganisms from your cooling tower water is a simple preventive step to extend the life of your equipment.

3. Save water & chemicals

Minerals in unfiltered water may increase blowdown in your cooling towers. This lost water then has to be replenished, which can amount to thousands of gallons. By filtering out those particles, an effective filtration system can help you reduce the blowdown and increase water savings. By preventing scaling and biofouling, it can also eliminate the dependence of water treatment chemicals, which are required to clean your cooling system.

4. Reduce maintenance and energy costs

With the installation of the right water filtration system, you can achieve significant savings in energy and maintenance costs. Less buildup in cooling towers means less time for cleaning. Cleaner water in cooling towers with fewer deposits requires less reactive maintenance overall. Furthermore, a well-maintained cooling tower will continue to function at the original optimum efficiency, thus reducing energy costs.

5. Improve operating efficiency

A cooling tower filled with dirty water can not work efficiently. All that buildup clogs tubes and coats heat transfer surfaces, forcing the cooling system to consume more energy. An effective filtration system not only minimizes those deposits but also increases the effectiveness of the corrosion inhibitor that is utilised.

Conclusion

A water filtration system is an integral part of a cooling tower water treatment program as they can greatly benefit the operation of a cooling tower. Proper filtration is also important for water savings in cooling towers. Hence, it is important to consider water filtration in your plans to keep your cooling system operating more efficiently.

Why is condenser tube cleaning important?

Clean condenser tubes and effective heat transfer are essential for the condenser temperature, pressure, and overall efficiency of the cooling system. To ensure the optimum heat transfer through the condenser tubes, suitable measures and regular maintenance cycles must be added to minimize the extent of fouling. That’s why condenser tube cleaning is an essential part of keeping your chillers unit running as efficiently as possible.

What are the best methods for condenser tube cleaning?

Up until now, chemical-based water treatment was used to minimize these buildups and other scaling problems, but the difference was minimal. Even though the makeup water was softened and cycles of concentration (CoC) were kept low, deposits and blockages still accumulated in the condenser tubes. Additionally, there was always a concern over the use of hazardous treatment chemicals, and the plant still faced difficulties in treating some of the chemicals used and discharged in the blowdown.

Most modern technology used today for round-the-clock cleaning of condenser tube cleaning is our Automatic Tube Cleaning System (ACCS). This automatic method of cleaning heat exchanger tubes occurs while the equipment remains in operation and full production. It also eliminates downtime while optimizing energy utilization of water-cooled heat exchangers, including chillers.

What is an automatic tube cleaning machine?

This is an automatic tube cleaning machine that infuses some slightly oversized elastomer balls periodically to the condenser tubes and keeps the tubes free of fouling 24×7. A ball collector is fitted at the water piping from the condenser to collect the balls for re-circulation in the system. With this ball trapping technology, there is absolutely no need for system shutdown for descaling and as a result, the chiller operates at top performance and efficiency.

How does condenser cleaning balls work?

Condenser cleaning balls technology in an automatic tube cleaning machine is the process started by injecting the balls from the ACCS ball collector to the mainline connected with a heat exchanger. ACCS balls travel along the mainline to reach the condenser’s main header. The balls are randomly distributed across the condenser tubes, automatically keeping heat exchanger tubes perpetually free from effects of scaling and particulate fouling.

The system water pushes the ball through the tubes and these balls clean up any residual like scale, dirt, or biofilms attached to the tube before they have a chance to stick to the tube walls. Once the balls exit the condenser they are collected in the uniquely designed ball trap that does not allow balls to escape. The controller directs the collection valves to open and the balls are pushed back to the ball collector where they are rinsed well and wait for the next cycle to start.

The entire cycle takes less than three minutes and cycles are programmed to take place automatically every 20 to 30 minutes. The process assures that fouling does not develop on the internal tubes allowing optimization of the heat transfer process, as a result, the heat exchanger operates at top performance, contributing to the prevention of unnecessary energy loss and low total-cost-of-use.

Conclusion

The growing environmental effects of global warming demand more green technologies to ensure the efficient operation of HVAC systems in the years ahead. This calls for the maintenance of condenser performance since condensers have an enormous impact on power generation efficiency and with our automatic tube cleaning machine, we can help you mitigate or reduce the negative impact and loss of production due to fouling and scaling.

Q: What is a cooling tower?

A cooling tower is a specialized heat exchanger, which extracts waste heat to the atmosphere through the cooling of a water stream to a lower temperature. When water comes in contact with air, it starts to reduce temperature; as a result, a small amount of water is evaporated, thereby removing the heat and humidity from the building.

Q: Why are water cooling towers better?

Evaporative heat rejection devices such as cooling towers are commonly used to provide significantly lower water temperatures than achievable with “air-cooled” or “dry” heat rejection devices. They achieve more cost-effective and energy-efficient operation of systems in need of cooling because the cooling potential of a wet surface is much better than a dry one.

Q: Why should I get a water cooling tower?

Factories, commercial buildings, and manufacturing units usually generate a tremendous amount of heat. That heat needs to be extracted so the building can be cooled down for operating efficiently. Therefore, the most cost-effective way of maintaining temperature in huge structures is by installing a cooling tower.

Q: How many types of cooling towers are there?

There are 3 types of water cooling towers:

• Cross Flow Cooling Tower
• Rectangular/Square Cooling Tower
• Round/Bottle Cooling Tower

Q: How to select the most suitable tower type for your building?

Each tower type is suitable for various buildings and operations. In the crossflow water cooling tower, air flows via the fills in the horizontal direction, and water flows down in the vertical direction. They also have splash type fillings that hold the higher suspended particles, perfect for chemical plants, big factories and processing/manufacturing plants.

Square/rectangular water cooling towers operate according to the counterflow principle. In a rectangular cooling tower, an induced draught fan is attached to the motor which pulls in air to draft it upwards leading to faster cooling of the air thus less pressure and circulation required for cooling. These types of cooling towers are perfect for light to medium industrials, pharmaceutical plants and commercial hubs.

In round water cooling towers, the airflow inside the cooling tower is uniformly distributed. The Bottle or Round cooling tower stands apart from the rest because of compact design and varying flute sizes to offer maximum heat transfer. Round water cooling towers are best suited for malls, office complexes and hospitals.

Q: How do I get my water cooling towers to run more efficiently?

Lubricating fan shaft bearings every three months and regular cleaning of the towers are required to maintain the proper functioning of the cooling system. A well-maintained and properly cleaned water cooling tower will work with original optimum efficiency, keeping energy costs low and water savings high.

Q: Why should I use SBR non-chemical water treatment for cooling towers?

The innovative SBR deploys an electrolysis reaction that breaks down and controls the elements that pollute water quality. It also enables the ongoing flow of clean quality water, using relatively little water resource and all in an eco-friendly manner. This program can reduce monthly wastewater bills for the amount of evaporated water from cooling towers that are not returned to the wastewater system.

SBR technology is a fully automatic online system that offers a myriad of benefits such as:

• The operating efficiency of your water cooling tower remains optimal.
• The cooling tower continues to operate as a new system.
• The cooling tower holds its cooling capacity.
• Save more than 50% of blowdown water.
• Allows the operation of the cooling towers at optimum 4500-5000 ?s conductivity.
• Zero chemicals mean no maintenance, storage, and discharge of chemicals.

Maximize the CoC:

The cycle of concentration or CoC is the number of times a tower recycles water before it gets dumped which is also known as water blowdown. The quality of the water and the type of water treatment usually determines the actual number of cycles a water cooling tower system can handle. However, a cycle of concentration of three is generally considered minimum efficiency.

You can take some significant steps such as minimize chemical use to treat the water in cooling towers. It reduces the potential for corrosion, scaling and biological growth, which allows the towers to operate safely at higher concentration ratios. Using SBR water treatment, for instance, reduces cooling tower make-up water by 20% and cooling tower blowdown by 50% with higher cycles of concentration.

Reduce blowdown by automatic monitoring systems:

To minimize scaling and biofouling, some cooling tower operators may increase blowdown water, which in retrospect, ends up causing water loss. It can also increase the possibility of corrosion due to the lower pH levels.

Automatic systems such as SBR water treatment determine the right amount of blowdown water automatically. By carefully monitoring, establishing, and adhering to set points, it can help reduce water waste and sewage, another potentially significant cost savings.

Monitor water levels in cooling towers:

Ballcock-style fill valves that are prone to leakage and frequently get out of adjustment. An additional source of water loss is possible when the fill level is set too high. You can replace the ballcock-style fill valves with more reliable fill valves. You should regularly check the water level to ensure that it is adequately below the overflow outlet to avoid excessive water use.

Use flow meters on make-up and blowdown pipes:

Flow meters are used to check the ratio of makeup flow to blowdown flow. You can install the flow meters on both lines and compare it with the ratio of conductivity of blowdown water and the makeup water. The ratios should match the target cycles of concentration. If that’s not the case, check the cooling tower for leaks or other unauthorized draw-off.

When the system does not function at your target cycles of concentration, check system components along with conductivity controller, makeup water fill valve, and blowdown valve. Keep tracking makeup and blowdown quantities, conductivity, and cycles of concentration to see any performance degradation if it occurred.

Select the right cooling tower water treatment:

To save water, it is vital to select a cooling tower water treatment that cleans the water efficiently and sustainably. A water treatment system selection should be based on the cost to treat make-up water and maintaining a cooling tower to the highest recommended system water cycle of concentration.

At CET-enviro, we offer SBR water treatment, which is a fully automatic online technology that continuously cleans the cooling tower water and augments the cooling performance, and treats cooling water without any chemicals. It uses a green technology that saves water without any unexpected chemical feeds or discharge from the cooling towers.

SBR water treatment enables the ongoing flow of clean quality water, using relatively little water resource and all in an eco-friendly manner. It also decreases the water usage by recycling and reusing it for irrigation while preventing scaling or corrosion build-up in the system, thus cutting down blowdown by 50% and water wastage by 40% – 50%.

Makeup = Evaporation + Blowdown + Drift

Makeup: To maintain the cooling system in proper working order, all water leaving the system must be replaced. This incoming water is referred to as makeup.

Evaporation: Water that evaporates in the cooling tower and is rejected to the atmosphere as vapour. Evaporation provides the necessary cooling for the system.

Blowdown: When water evaporates from the system, the dissolved solids and minerals are left behind. Blowdown is water that is purposefully drained from the system to remove dissolved or suspended solids and prevent scale and corrosion problems in the cooling system.

Drift: A very small amount of water will escape the water cooling tower as mist or water droplets in the air, and is referred to as drift. Compared to evaporation or blowdown, water loss due to drift is insignificant but can be a factor at the highest levels of water conservation efforts.

These factors are the most neglected regimens of cooling systems operation with water cooling towers generally the most neglected component in the mechanical system. That’s why sustainable water treatment is the most important factor in the life and energy-efficient operation of evaporative cooling equipment.

Accumulation of foulants on the tower will inhibit the cooling efficiency of the tower and can reduce the energy efficiency of the overall cooling system by 5% or more. Therefore, water cooling towers should be periodically cleaned to ensure the tower fill media and heat transfer surfaces are free from scale, biological growth, corrosion, and particulate deposits.

There must be regular inspection of the tower on your maintenance log, and if your water treatment is unable to effectively control these issues, consider alternative treatment options that can do these functions automatically like SBR.

SBR is a fully automatic and green technology that continuously cleans the cooling tower water and augments the cooling performance without the use of chemicals. The energy-saving, chemical-free, low maintenance system combats scaling and corrosion using electrolysis.

This process provides a clean, eco-friendly alternative for keeping systems free from harmful fouling. The new generation system delivers an affordable, reliable, and safe alternative to chemical usage when you’re looking to improve the water and energy efficiency in water cooling towers.

WHAT IS COOLING TOWER FOULING?

Fouling is the clogging of any surfaces or pipes with debris, dirt, and dust. Fouling is defined as a scale deposit layer such as the formation of calcium carbonate on heat transfer surfaces and occurs more rapidly when the concentrated water is circulated in the cooling towers and heat exchangers.

The economic loss due to the fouling is one of the biggest problems in all industries dealing with heat-transfer equipment. Besides, as the fouling deposited on the heat transfer surfaces reduces the cross-sectional areas of the flow passages, the flow rate of the coolant decreases, and the pressure loss of the system increases.

Impact of Cooling Tower Fouling

In cooling towers, fouling can generally be defined as a buildup of material or deposits on the heat exchange surfaces that can degrade heat exchange performance. When water cannot make it into and pass through the fill as designed, the air is not cooled properly. This means that the system must work longer to achieve the same results. Which means it is using more electricity.

Consider that for each degree that condenser supply temperature is above design specifications, chiller efficiency is reduced by two percent. This, in turn, promotes the deposit and growth which may corrode both tower fill and the tower itself, eventually requiring costly and time-consuming replacement.

Types of Fouling

Fouling can occur in different areas of your cooling tower system. There are several types of fouling that are commonly occurring in cooling towers. Here are some of the common one:

Precipitation Fouling or Scaling – These may typically be mineral-based scales that form due to exceeding the saturation point of the scaling species. The most common forms of scale are usually from calcium-based salts such as calcium sulfate or calcium carbonate. This phenomenon is strictly temperature related and is difficult to be removed by hydro-blasting or typical scrubbing. The compound created from this reaction of the free ions is called scale and the action itself is called scaling

Microbiological Fouling or Biofouling – Microbiological fouling that may occur from poor or inadequate biocide feed and control. Cooling towers by nature are places that are hot and humid. Along with the common and plentiful nutrients that most water sources contain it is an ideal place for the growth of unwanted biological growth, such as bacteria. Even very thin layers can reduce the thermal efficiency dramatically.

Particulate Fouling or Deposition (including corrosion products) – Suspended solids such as dirt or corrosion products that settle out in the cooling system. The chief causes of corrosion of metals by water are dissolved oxygen and dissolved carbon dioxide. The latter lowers the pH, permitting general acid attack but even if the water is alkaline the metal of the system can be affected by oxygen corrosion.

In addition to the reduction in water flow and heat transfer also damages the equipment and corrosion reduces the effectiveness of the work. This can lead to expensive repairs or even replacement of equipment.

SBR Technology: Combating three major ailments of Cooling Tower

Other water treatments require several separate activities and costly chemicals, which lower water quality and raise costs. SBR technology is a multi-purpose solution performs one sophisticated integrated process that is clean, inexpensive and environmentally friendly. Major Problems in cooling towers explained above are biological growth, scaling due to TDS and corrosiveness due to PH of water and under deposit corrosion in the system. These three problems are avoided by SBR in the following manner: –

Anti-Scaling: – Due to electrolysis (Cathode and Anode Reaction) all the TDS (Salts like Calcium, magnesium, Iron) are attracted to the Cathode(-) and are stuck and precipitated to the smooth surface of the Cathode Drum. As the water becomes soft the salts are dissolved and the capability of the water to dissolve the salts increases and some precipitation takes place in the drum which is automatically removed.

Anti-Corrosive:– Since the Chemicals are not added into the system there is no chance of the corrosion to take place as due to electrolysis the water becomes soft and tries to accommodate all the salts in itself and also removes the existing salts deposited in the system. So, the chances of under deposit corrosion due to scale is also avoided.

Biological Growth: – Due to anodic(+) reaction Free chlorine, Hydrogen Peroxide, Carbon Dioxide, Ozone, Oxygen is evolved which kills bacterial growth and also kills the algae in the cooling tower. Since the free chlorine is available in the water it will stop the algae growth in the cooling tower.

As a fully automatic online system, SBR technology continuously cleans the cooling tower water and augments the cooling performance, and treats cooling water without any chemicals. Solutions like SBR are ideally poised to help: In three simple steps, plants can clear fouling and restore system performance.

How does it work?

Energy Monitoring System (EMOS) is installed in each chiller with highly efficient flow –meters which specializes to measure instant flow. Further, Temperature Sensors (PT100) are installed in both inlet and outlet of Evaporators and Condensers. Instant data values are collected from the Flowmeters and temperature sensors which are sent to the Control Panel through communication cables.

Also, a kWh meter is installed to measure the instant electrical power consumption of each chiller and values are recorded in the control panel. The data is then collected from flow meters, temperature sensors and kWh meters in a specially designed control panel to calculate the specific power consumption of chillers in ikW/TR. The values are automatically retrieved and can be seen in real-time. Further, daily/monthly trend analysis and report analysis on the cloud-based server.

Features and Advantages

EMOS is a revolutionary product which is specially designed to record relevant information at a server which can be used to manage energy and operating cost daily to analyze the performance of the chillers. The readings obtained from flow meters, temperature sensors and kWh meters can be seen in real-time while simultaneously being saved into a cloud-based server, making it easier to obtain through multiple user accounts via an internet facility integrated into the EMOS system.

The whole ecosystem is built to deliver automated email alerts in case of a malfunction. Its multiple user access makes it easy to operate for consumers. Further, the dashboards are made in such a way that it is easy to understand and operate for individuals with minimum skilled resources.

EMOS is deliberately designed in such a way that it is compatible with any building HVAC system. As per the industry claims, integration of an EMOS with the above-mentioned controls can produce energy savings, varying from 10% to 40% on a case-to-case basis, while increasing the life cycle of chiller systems.

Install systems to measure the overall Coefficient of Performance:

Before you do anything, the first and foremost step towards energy saving is to monitor the consumption in chiller units and cooling towers. This will help you establish the COP for each unit and tower by measuring the flow rate, the inlet and outlet temperature and the electricity consumption. More importantly, it can help you to construct an overall COP that includes the distributor pumps, the auxiliary pumps, and the consumption of the cooling towers, and factors in the climatic conditions.

Energy Monitoring System (EMOS) from CET-Enviro is the most effective and reliable solution for energy management system that automatically records specific power consumption of chillers in the most accurate way 24×7. It continuously collects, analyzes, and reports on chiller operating data through the internet facility integrated into the system and connected to a cloud-based server. Ideally, you would be able to compile a data history for an entire year to cover all of the seasons and as many production conditions as possible.

This critical information collected at the server can be used to manage energy and operating costs on a routine basis and this significantly helps in improving the performance potential of the chiller that saves up to 15% in chiller energy consumption.

Invest in a new refrigeration technology:

The latest HVAC units are particularly efficient, thus achieving a COP of at least 7 or 8. These refrigeration units are highly modular and do not become less efficient, because they contain several small compressors that start-up in a staggered sequence. They are, however, very expensive and not very easy to maintain. If your budget doesn’t stretch that far, similar improvements in energy consumption can be achieved by adding variable power control units such as EMOS to your existing energy management system.

Ignore peak load for chiller efficiency:

  Many engineers and facility managers compare chiller efficiency based on a single number — peak load kW/ton. However, the typical chiller plant in a commercial building will never operate at these peak conditions. For office buildings, it would be better to ignore the peak kW/ton and instead compare the IPLV (integrated part-load value) or NPLV (non-standard part-load value) ratings.

  Even though each building’s load profile is unique, these numbers are meant to be a better metric for comparison since they attempt to simulate a more typical load and operational profile for an office building in a moderate climate. These small differentials can help you achieve huge energy savings in the long run.

Take advantage of cool outdoor temperatures:

  Most chillers can benefit from condenser water temperature reduction during cooler weather. A chiller and cooling towers are needed for the very few very hot and humid hours of the year. For the rest of the year, the towers can easily and efficiently provide cooler water.

  When the climatic conditions allow, adding passive outside-air heat exchangers can reduce the need for cooling towers and the associated consumptions. However, these savings may depend on climate, load profile, and equipment sizing, so analysis must be present to determine the proper control strategy.

  As we have cleared, there are a variety of solutions for optimizing your energy management system. However, the most crucial solution might be the Energy Information System. So the more your Energy Monitoring System is well-documented, the more effective these solutions will be.

Get the right system & maintenance in Place

Industrial cooling systems require a good filtration and cleaning system to be energy efficient. Different factors will make an HVAC system more energy-efficient. From the type of system, you have to how it is maintained can all affect energy efficiency. Because of this, even small changes to an existing system can help make it more energy-efficient.

So if you plan on saving in the same system for a long time, you may want to consider installing a whole new energy efficient system with some energy-efficient equipment. These systems allow regular cleaning and maintenance to be automated while taking some of the workloads off of the HVAC system itself.

CET-Enviro offers several integrated solutions that provide the maximum energy-efficiency requirements for whatever building you’re trying to cool. Not only should you be complying with the regulations, but it can help you run a more efficient cooling tower if that’s ever a concern to you.

1. Set a benchmark with EMOS

Energy Monitoring System (EMOS) is the most effective and reliable system that automatically collects & analyzes data collected from the several sensors such as Flow-meters, Temperature sensors, kWh meter, and then records it to the cloud storage.

It continuously collects, analyzes and reports on chiller operating data through the internet facility integrated into an open system, which is essential to getting more visible data of the current electricity consumption and setting the benchmarks for expected system efficiency.

The information collected at the server can be used to manage energy and operating costs on a routine basis and this significantly helps in improving the performance potential of the chiller that saves at least 20% to 40% in energy consumption.

2. Start descaling of chillers with ACCS

  CET-Enviro offers the most modern technology available today for round-the-clock cleaning of Chiller tubes. ACCS (Automatic Tube Cleaning System) is an automatic method of cleaning heat exchanger tubes while the equipment remains operational. There is absolutely no need for system shutdown for descaling and as a result, Chiller operates at top performance and efficiency.

  This is an online method that infuses some slightly oversized elastomer balls periodically to the Condenser tubes and keeps the tubes free of fouling 24×7. A strainer or ball collector is installed at the water piping exiting the condenser that collects the balls for re-circulation in the system.

  Automatic Condenser Cleaning System provides a huge difference in approach temperature before and after descaling, which shows the need and potential of the ACCS system in maintaining Chiller Efficiency. By keeping tubes free of corrosion & scaling, it improves heat transfer efficiency and reduces energy consumption, saving up to 30% in energy consumption.

3. Invest in non-chemical water treatment for cooling towers with SBR

  Cooling system water quality directly affects the reliability and efficiency of industrial or institutional cooling systems. CET-Enviro provides a sustainable and eco-friendly system that augments the cooling tower performance and continuously cleans cooling water without any chemicals. It gets rid of cooling Tower water treatment problems like biofouling, scaling, and corrosion and increases the efficiency of the cooling system.

  SBR is a green technology that saves water without any unexpected chemical feeds or discharge from the cooling towers. It also decreases water usage by recycling and reusing it for irrigation while preventing scaling or corrosion build-up in the system, thus cutting down the energy cost by 10% – 15% and water wastage by 20% – 40%.

  These days there is an emphasis on energy efficiency in every aspect of life. Having the most energy-efficient HVAC system is one of the best things you can do for your business. With our proven combo of green solutions for HVAC systems, you do not have to invest in a whole new system to increase energy efficiency. Just add these 3 solutions for some money-saving adjustments that can make a huge difference in your utility bills and overall HVAC energy consumption.

What is condenser/heat exchanger

A heat exchanger does exactly what its name suggests: exchanges heat. In the context of a chiller, a heat exchanger is a series of tubes or coils that run through the HVAC system. Different models feature different shapes and sizes of tubes based on fuel type but they all perform the same task—the tubes heat up and, in doing so, exchange and transfer the heat to the air. Heat exchangers are either given a hot fluid to provide heating or a cold fluid to provide cooling.

How it works

The way a heat exchanger works is rather simple. Heat exchangers are designed to optimize the temperature as per system needs. Coil heat exchangers in their simplest form use one or more tubes which run back and forth several times. When water flows inside the chiller tubes, heat is transferred from the tube wall via convection, it then conducts through the pipe wall to the other side, thus exchanging the heat from the system.

Why the need for maintenance?

Fouling in heat Exchangers is an undesirable piled deposit formed inside a condenser, sometimes described as a thermal resistance on the heat path in the condenser. Degraded heat exchanger performance from fouling or ageing results in extra operating and energy costs to compensate for gaps in the target temperature.

Product or chemical deposits on heat-transfer surfaces weaken an exchanger’s heat-transfer capacity and must be cleaned away regularly to maintain high performance and prevent disruption of processing. Heat exchanger fouling, or the unwanted accumulation of deposits on heat-transfer surfaces, can result in huge loss.

The maintenance of heat exchangers is therefore important to keep systems running efficiently. Regular maintenance ensures equipment is in working condition and helps prevent emergency repairs. The cost of cleaning a heat exchanger is small compared to the cost of lost production should a heat exchanger require an unscheduled shutdown.

Why Cleaning-In-Place (CIP)

The most common condenser cleaning method is scrubbing propelled through the heat exchanger tubes to remove deposits however this method required shutdown and loss of production hours. However, a proper Cleaning-In-Place (CIP) equipment can automatically clean heat exchangers without the need for a manual shutdown. CIP cleaning of heat exchangers typically includes several goals:

• Cleaning lime deposits
• Passivating surfaces to reduce susceptibility to corrosion
• Neutralizing cleaning chemicals before draining.

How ACCS helps in the maintenance

Most modern technology used today for round-the-clock cleaning of Chiller tubes is Automatic Tube Cleaning System or ACCS. This automatic method of cleaning heat exchanger tubes occurs while the equipment remains in operation and full production.

ACCS is a remarkably simple system in which recycled cleansing balls are flushed through the cooling system via a natural water flow, ensuring that unwanted deposits and residue are cleaned before fouling occurs. A strainer or ball collector is installed at the water piping exiting the condenser that collects the balls for re-circulation in the system.

This system can be controlled online while infusing some slightly oversized elastomer balls periodically to the Condenser tubes and keeps the tubes free of fouling 24×7. There is absolutely no need for system shutdown for descaling and as a result, hence chiller operates at top performance and efficiency.

With the installation of ACCS, the internal surface of the cooling tubes are guaranteed to remain clean, resulting in improved heat transfer and reduced energy consumption. The ACCS is fully automatic and works continuously while the heat exchanger is operational, eliminating the need for inconvenient shutdowns or costly maintenance.

Benefits Of ACCS

To ensure optimum performance from the system, heat exchangers must work with 100% efficiency. For this to happen we must use an automated solution that reduces maintenance cost and increases efficiency. ACCS fulfils these criteria with ease while providing some benefits too:

• Eco-friendly (Save energy up to 30%)
• Optimize heat transfer
• Eliminates downtime
• Extends equipment life
• Zero Ball loss

Challenges with Chillers & Cooling Towers

The cooling towers need regular maintenance and if left untreated it causes organic growth, fouling, scaling, and corrosion which reduces productivity causes plant downtime and requires costly equipment replacements.

Scale Deposits:

Cooling tower works by evaporation which results in periodic buildups of scale deposits on the fill. Minerals in the water can create these deposits, especially if there’s not a water treatment solution in place. These scale buildup decreases the efficiency and performance of your HVAC system and can lead to premature deterioration of your unit.

Tubes Corrosion:

Contaminants like slime, algae, and scale can build up within the condenser tubes and cause a partial or total clog which can lead to unit inefficiencies and breakdowns. Every HVAC unit experiences buildup of some kind, however clearing the chiller tubes regularly will prevent total blockages and make debris removal easier.

Water Problems:

Maintenance is about more than just keeping HVAC system components like chillers and cooling towers in adequate shape. Water quality also plays an important role in determining the efficiency of the system. Untreated water can lead to major scum and scale buildup, contributing to the breakdown of your system.

Chiller & Cooling Tower Maintenance:

Chillers and cooling towers are crucial for a safe, reliable and efficient HVAC system. Failure to inspect, maintain and repair and/or replace every part of the system can have serious consequences for your business.

Properly maintained cooling towers and chillers keep condenser temperatures lower than un-maintained systems. This results in better energy efficiency, lower utility bill costs, and a more comfortable facility. That’s why a comprehensive maintenance plan is not only a smart business investment for your facility and employees, but it’s a requirement.

Introducing SBR & ACCS to Increase your System Efficiency:

SBR (Scale and Bio-Removal system) is a Non-Chemical treatment of cooling tower water. Specially designed by CET ENVIRO, it reduces corrosion, prevents blowdown and discharges, thus reducing your environmental footprint and increasing the efficiency of the system.

ACCS or Automatic Condenser Cleaning System is an automatic cleaning system for chillers that deals with basic problems that occur in tubes such as rusting, fouling, bioaccumulation in shells and tubes. To overcome these problems, CET-Enviro has equipped ACCS with specially designed ball traps that clean the tubes more efficiently.

Combo features of ACCS & SBR:

Green Technology:

SBR is a sustainable and eco friendly technology that treats cooling water without any chemicals. ACCS, on the other hand, is a fully automatic tube cleaning system that yields optimum efficiency of the chillers and great energy savings while reducing the carbon footprint.

Low maintenance and higher savings:

SBR and ACCS both are built to reduce the high operational and maintenance cost of cooling towers and chillers. SBR decreases dependability on chemicals to 100%, decreases water usage to 20-40%, lowers energy costs by 15%, lowers the labour costs up to 50%. Similarly, ACCS prevents heat exchanger tubes from accumulating mud, scale, or biological fouling which optimizes heat transfer and saves energy up to 30%.

No fouling and corrosion problems:

Corrosion, bioaccumulation and fouling are some of the major problems that arise in chillers and cooling towers. Over a period of time, it can lead to reduced efficiency, manual shutdown which can be avoided with the installation of ACCS & SBR. These solutions can operate 24*7 without any oversight which further decreases the maintenance cost of the system.

Better performance from the system

For the proper functioning of a cooling tower, the entire component must work in unity with 100% efficiency. For this to happen we must use an automated solution which reduces manual maintenance from time to time.

Since cooling towers are one of the major components of HVAC systems, it is almost essential that it should be cleaned properly from time to time. SBR prevents problems like Biofouling, scaling, and corrosion that reduces the efficiency of your cooling system.

Further, ACCS runs automatically and continuously cleans the tubes by specially designed ACCS balls which prevent corrosion regularly. Hence, the elimination of corrosion and fouling results in an extended life cycle of the equipment.

Hassle-free maintenance of cooling towers and chillers with ACCS and SBR combo

Today every industrial sector requires a product that is cost-effective, efficient, environment friendly, and automatic solution to reduce maintenance cost for better performance. Using SBR with ACCS gives you just that. It is a revolutionary product that provides excellent performance, zero maintenance cost, and fully automatic operations.

Problems that arise with Cooling Systems

Water-based cooling systems suffer from fouling and scaling. This fouling reduces the heat transfer in the condenser tubes leading to increased energy consumption and reduced efficiency of your chiller system.

Corrosion is one of the major problems that arise in a condenser. It is equivalent to cancer for condenser tubes. Over a period of time, it can lead to puncture of tubes which cause damage to capital equipment as well.

Further, you may have to use harsh chemicals which further increase the maintenance cost and downtime. ACCS is the ultimate solution to prevent all these problems as it keeps condenser tubes free of fouling 24*7.

How does it work

Specialized ACCS balls are designed for cleaning tubes that are injected at set intervals into the cooling water flow. Also, the condition of the balls can be easily monitored through the window of the ball collector. Further, under the motive force of all water, ACCS balls travel along the mainline to reach the condenser tubes where the cleaning of internal tubes starts.

The tubes are kept clean by scrubbing and wiping action of the ACCS balls that prevent any kind of buildup of deposits on the tube surface. Then, all the tubes are routed to the ball trap and system water runs as usual. These system balls continue to move to the ball collector where they are rinsed well and prepared for the next ACCS cycle.

Benefits of Installing Automatic Condenser Cleaning System

Improved efficiency: ACCS prevents heat exchanger tubes from accumulating mud, scale, or biological fouling which accumulates over time and degrades the performance of the heat exchanger. This leads to lower energy consumption and cost reduction. The automatic tube cleaning system provides up to 30% energy saving to the organization.

Increase life cycle of chillers: The ACCS runs automatically and continuously cleans the tubes by specially designed ACCS balls which prevent corrosion regularly. Hence, the elimination of corrosion and fouling results in an extended condenser life cycle. So the chiller continuously operates at optimum efficiency without any wear and tear.

Eliminates downtime The newly designed ACCS eliminates downtime and maintenance costs. Since the system works automatically, any dependability on chemicals or manual cleaning is reduced.

Zero ball loss: Innovative ACCS ball trap design installed at the water piping exiting the condenser collects the balls for re-circulation in the system. So that there is absolutely no need for system shutdown for descaling and as a result, Chiller operates at 100% efficiency.

Lower water treatment costs: Water treatment is only required to prevent scaling of ancillary equipment, leading to cost savings of as much as 50% of the cost of chemicals used for water treatment.

Environment friendly: The automatic tube cleaning system uses no chemicals. Most of the maintenance techniques used for fouling mitigation uses chemical inhibitors which are very costly and harms the environment.

Everything from keeping a daily record of the chiller output and using most innovative maintenance solutions will yield optimum efficiency of the chillers and great energy savings in a short time. Now, when most of the organizations are switching to green technology, ACCS provides fully automatic and eco-friendly chillers for its conscious consumers.

What is a cooling tower water treatment system?

A cooling tower water treatment system is an advanced system of technologies that are designed to remove impurities from cooling tower intake water, circulation water and blowdown. The general cooling tower water treatment includes clarification, filtration, softening, chemical feed, and automated monitoring.

The system works with the combination of adsorption, turbulence and galvanic action while subduing the scale built up in the cooling tower, pipeline, and heat exchange.

What does a cooling tower water treatment system control?

Cooling tower water treatment system is created using the required technologies to regulate the level of chlorides, iron, alkalinity, TDS, silica, and other elements. These elements increase the scale built up in both cooling towers and heat exchangers and combined with phosphate, iron can damage equipment to failure. Organic matter in the water promotes microorganisms, which leads to corrosion, fouling, and other system-related issues.

A cooling tower water treatment completely removes the liquid and solid waste from the tower and allows treated water to be reused. It also regulates the level of:

• Alkalinity
• Chlorides
• Iron
• Microorganisms
• Silica
• Sulfates
• TDS & TSS

How does the cooling tower water treatment system work:

The process of cooling tower water treatment systems works based on the specific needs of the cooling tower, the chemistry of the feed and water circulation. However, a general water treatment system includes the following steps.

Filtration and ultrafiltration:

It includes running the cooling tower water through a system of filtration which removes particles such as turbidity, sediment, and certain types of organic matter.

Ion exchange/water softening:

It removes the hardness in the source or makeup water, which can often lead to scale deposits and rust.

Side-stream filtration:

If the cooling tower water is to be recirculated in the system, then a side-stream filtration unit will be required in removing all sorts of problematic contaminants that have entered the system through a leak or drift contamination.

Blowdown treatment:

In this last step, cooling tower water treatment completely removes the liquid and solid waste from the tower and allows treated water to be reused.

SBR (Non-chemical Water Treatment) — A Better Solution

Cet provide a much better solution because it doesn’t involve adding chemicals into your water supply. SBR water treatment is our top-selling product and is available for residential, commercial and industrial use. It’s a fully automatic online technology that continuously cleans the cooling tower water and augments the cooling performance.

It reduces the buildup in the pipes and will make the water softer, which will prolong the lifespan of your pipework and is a much better solution than hiring cooling tower treatment companies after every few months.

SBR does not come with any sort of harmful chemicals and does not require a whole lot of maintenance, so you don’t have to worry about anything at all. Just install it with the water supply and you are good to go!

SBR provides comprehensive cooling tower water treatment solutions to safeguard equipment, protect people and the environment, and ensure optimal ROI.

AI in Homes & Buildings Estimated to Garner Revenues of Nearly $9 Billion by 2030

Frost & Sullivan’s recent analysis, Artificial Intelligence in the Global Homes & Buildings Industry, forecast to 2030, finds that the deployment of artificial intelligence (AI) in the homes and buildings space is gaining rapid momentum across the globe as the industry is estimated to witness an approximately 15-fold increase by 2030. Increasing at a compound annual growth rate of 27.7%, the industry is likely to garner revenues of $8.98 billion by

2030, compared to $610.2 million in 2019.

Introducing SBR: Non-chemical water treatment for cooling towers

Understanding the need of the hour, CET-enviro presents a compelling opportunity to incorporate a sustainable green-technology that treats cooling tower water in an environmentally friendly manner. SBR is a fully automatic online technology that continuously cleans the water cooling tower without any chemicals.

SBR is an environmentally friendly, safe, alternative method for water treatment that provides operational savings and longer equipment life while also contributing to a more sustainable future. It immediately reduces the environmental footprint and increases your savings by eliminating toxic water treatment chemicals.

The major concerns for all corporations with the purpose of thermal transfer are cost-effectiveness in terms of energy and water Savings. SBR meets all these criteria for effective water treatment through control of scale/corrosion/biological growth for thermal transfer efficiency.

The SBR Advantages are:

Eliminates all chemical costs.

Significant savings of water and

Dramatically reduces maintenance and down-time

Dramatically reduces the volume of blowdown loss.

With your system operating free of chemicals, your facility will use considerably less water and less electrical power. Since the SBR System will also clean out the existing scale from your system, the heat transfer process of your system will improve so there will be less loading of the chillers and there will be less wear and fewer breakdowns.

With the sole intent of giving building owners and facility managers an eco-friendly alternative for providing operational savings, SBR water cooling tower system should be your go-to solution for a more sustainable future.

Automatic Condenser Cleaning System (ACCS):

Chillers are the single largest individual user of electricity in commercial and institutional HVAC facilities that need round-the-clock maintenance. Without proper cleaning, the performance usually deteriorates with time because of the accumulation of deposits, biological growth, and corrosion on heat transfer surfaces.

It is estimated that a build-up of a 0.6 mm thick layer of fouling on the condenser water tubes will reduce chiller efficiency by a minimum of 20%.

Most modern technology used today for round-the-clock cleaning of Chiller tubes is our Automatic Tube Cleaning System or ACCS. The ACCS gets rid of all these issues and that too, in a very small amount of time. This is an online method that infuses some slightly oversized elastomer balls periodically to the Condenser tubes and keeps the tubes free of fouling 24×7.

It also optimizes heat transfer performance while removing downtime. This automatic method of cleaning heat exchanger tubes occurs while the equipment remains operational. There is absolutely no need for system shutdown for descaling and as a result, Chiller operates at top performance and efficiency while providing up to 30% energy savings.

NON-Chemical Water Treatment for Cooling Tower (SBR):

Cooling system water quality directly affects the reliability, efficiency, and operating cost of industrial or institutional cooling systems. Depending on the quality of water added to the cooling tower and the operation efficiency of the unit, large amounts of solids can remain after evaporation occurs, causing an increased need to blowdown.

SBR is a fully automatic online “Green” technology that continuously cleans the cooling tower water and augments the cooling performance and treats cooling water without any chemicals.

It helps you get rid of Cooling Tower water treatment problems like Biofouling, scaling, and corrosion that reduces the efficiency of your cooling system. No chemical feeds or discharge means 100% savings on chemicals, 20% – 40% decrease in water usage, 5% – 15% lower energy costs, and 10% – 50% reduction in labour costs.

Speak to our team of experts today to know more about this solution.

How is the HVAC industry foreseeing sustainable development in this pandemic?

This pandemic has served as a wake-up call for industries to invest in sustainable practices. As we progress, we learn more facts guiding us towards taking practical decisions. One thing we know for certain that it’s not going to be with us forever. Therefore, we have to start making decisions that are in everyone’s best interests.

In the coming future, the HVAC industry will not only help with economic sustainability but also aim towards developing a nontoxic environment that can indirectly help in balanced business interest.

Regular Cleaning

The automatic tube cleaning system cleans your equipment regularly and automatically. This means you no longer need to worry about the cleanliness of the same. When the equipment isn’t cleaned regularly, it develops multiple issues such as fouling. Using the ACCS will help you in avoiding those issues. As your equipment will remain clean, it will perform with optimum efficiency too. ACCS is an eco-friendly solution. It can help reduce energy consumption by 30%. This means you can reduce your operation costs with the help of this solution too.

The automatic tube cleaning system cleans your equipment regularly and automatically. This means you no longer need to worry about the cleanliness of the same. When the equipment isn’t cleaned regularly, it develops multiple issues such as fouling. Using the ACCS will help you in avoiding those issues. As your equipment will remain clean, it will perform with optimum efficiency too. ACCS is an eco-friendly solution. It can help reduce energy consumption by 30%. This means you can reduce your operation costs with the help of this solution too.

No Ball Loss

A common problem many operators face in cleaning condenser systems is of ball loss. The balls installed inside the condenser tubes get trapped or lost, which can lead to obstruction and plenty of other issues. ACCS solves that problem too through its innovative ball trap design. All the balls sent in the condenser tubes return without causing any issues. Balls that get stuck inside condenser tubes can lead to several issues. They hamper the productivity of the system and decrease the life of the equipment.

Increased Equipment Life

The automatic tube cleaning system keeps your equipment in pristine condition. It helps you in avoiding corrosion of the tubes and other components of the equipment. When your equipment remains free from corrosion; its life increases. This means you don’t have to replace your equipment more often than required. This is another significant advantage of using ACCS. You can save a substantial through this method.

An Advanced Solution

The automatic condenser cleaning system is certainly one of the most innovative solutions in the market. It helps you in enhancing productivity, increasing equipment life, and reducing costs. That’s why it’s so popular in multiple industries.

What do you think of ACCS? Let us know.

Using Automatic Tube Cleaning System (ACCS)

As the name suggests, Automatic Tube Cleaning System is an advanced measure of cleaning condenser tubes. A dirty condenser faces many issues including fouling and depreciation of the tube’s material. The ACCS gets rid of all these issues and that too, in a very small amount of time. It optimizes the heat transfer performance and removes downtime. This helps you in getting effective results with maximum efficiency. If you’d ask us, we’d suggest going with ACCS.

Cleaning with a Brush

The oldest method of cleaning condensers is through brushes. In this method, you’d attach a brush on a long rod, making sure that the brush’s bristles are longer than the radius of the tube. Then you’d use the rods to clean the interior of the tubes after throwing in some water for lubrication. It’s an obsolete method and has been discarded by many organizations. Its main issue is it leaves a lot of residue inside the tube and takes up a lot of time and energy.

Cleaning with TCGs

TCG stands for Tube Cleaning Gun. These guns project high-pressure water in the tubes and target the dirt. Like the ‘brush method’, this method is also old and obsolete. The primary issue with this procedure is the consumption of time. And it has the risk of increasing the clog inside the tubes as the high-pressure water may not be able to get rid of all the dirt.

Cleaning with Chemicals

In this method, one adds acid solutions and circulates them through the tube bundles. This softens the scale deposits which are then cleaned with brushes. Chemicals are quite costly, and that’s why this method is also discarded in modern operations. Moreover, to perform this procedure effectively you’d need a highly trained expert.

Using COLTS

COLTS stands for Condenser Tube Cleaning System. In this method, specialized sponge rubber balls are inserted in the Condenser. They prevent the build-up of any scaling or fouling. After the passage, the system retrieves the balls and pumps them into inlets. It’s an automatic system. This means you won’t have to worry about its operation and efficiency. This is another favored method of multiple industries.

What’s your Choice?

Which method would you prefer for your condenser’s cleaning? Let us know through your comments. We’d love to hear from you. You can find out more about ACCS and COLTS.

Regular Inspection

The fundamental method to maintain your industrial cooling tower is to inspect it regularly. From the gearbox to the water pump, you should do regular inspection to ensure there are no loose components.

Regular inspection will also allow you to spot corrosion, scaling and other similar adverse issues.

When you’ll find these issues before they escalate, you can get rid of them and keep your chiller in optimum condition.

Removing Deposits of Impurities

Impurities present in the water of the cooling tower gets collected in the system. They hinder the temperature of the chiller. Impure water requires more energy for changing its temperature.

So if you don’t use a cleaning system for your cooling tower, it’s necessary that you clean the tubes regularly and check the chiller for any sedimentation.

The collected impurities can damage the life of your chiller too. So you should remove those deposits regularly for keeping the tower free from any issues.

Improving Airflow

  The fans of the chiller should be working properly. Due to some loose components or damaged fan blades, the airflow of the chiller could be disturbed.

  Presence of debris in the tower can also result in the formation of sludge which hinders proper airflow.

  Formation of algae in the windpipes can also damage the airflow, resulting in blockage and reduced efficiency.

Using SBR for Water Treatment

  The water present in the cooling tower plays a crucial role in its operation. However, the presence of various impurities such as dust, minerals, etc. can cause several issues to develop in your chiller.

  Scale and Bio-Removal system can help you in treating your water and remove those impurities without hampering the productivity of your chiller.

  It keeps the water pure and free from any harmful microbes as well, ensuring that your chiller works with maximum efficiency.

Conclusion

  By following the above 4 tips, you can keep your chiller in perfect condition, increase its life and ensure that it takes as low energy as possible.

  If you have any questions regarding these tips and topic, feel free to let us know.

  And if you liked this article, then don’t forget to share it with others who might find it useful.

In this exclusive article, Mr. Rothin Banerjee, Director of Engineering at Taj Palace, New Delhi gives us an insight on how the CET ENVIRO’s ACCS helped Taj Palace, New Delhi to earn high energy savings…

THE PROBLEM

“We at the Taj Group, have always believed in society and environment being integral stakeholders in our business and we consistently adopt measures to reduce our energy consumption. In this aspect, we did a study of our chillers last year and we found out that the performance of chiller is effecting due to high condenser approach temperature, even though we were regularly doing the decaling activity. The reason was primarily due to substandard water quality leading to formation of scale. We had to limit the descaling activity as it leads to tube deterioration. We wanted a permanent solution to this problem”

CET ENVIRO ACCS – The total solution

“In hotel industry, the focus of engineering department is always to adopt new technologies to cut energy consumption, and to reduce HLP (heat, light, power) expense which is almost 7-8% of the total revenue. In this initiative, we had installed a new set of Chiller and Cooling tower last year in our hotel with chiller optimizers equipped with ACCS system.

The ACCS system is working remarkably ever since it is installed, and it has supported the Chiller system us to maintain an approach temperature of less than 3 degrees Celsius for the entire year. The cooling tubes remain clean, resulting in improved heat transfer and reduced energy consumption.

This complete package of new Chiller, cooling tower and ACCS has already given us savings worth INR 99 lakhs approx. in nine months.”

EFFICIENT CUSTOMER SERVICE

“It is worth to mention the high quality and an effective customer service provided by CET ENVIRO team. The ACCS system is duly monitored and checked on regular intervals by CET ENVIRO representatives to ensure that the system is working fine and effectively. We are considering to install similar system at our other chillers as well.”

So, what was really the problem that the utility team was facing?

“Even after manual descaling, the approach of our condenser was going up by 3 degrees in few days. Approach Temperature is one of the important criteria for analyzing the performance and efficiency of Water-cooled Chiller. And it is directly proportional to Chiller performance and plant operating expenses” said Mr. Ananthakrishnan.

So, an increase in approach temperature can lead to potential loss of Chiller efficiencies and reduced performance output.

This is one of the important projects for us at Perfetti. This product will further bring us closer to our goal to reduce energy consumption.

Why ACCS from CET Enviro?

After doing a deep analysis of the market and evaluating all products exiting in the market, we had shortlisted CET Enviro for ACCS. We received a very good feedback from our other plant where ACCS is already working successfully. Looking at the product quality and after sales service, CET Enviro was an obvious choice for us!

ACCS system is a very good product that maintains the approach temperature very efficiently. Even in 90% load, it is rarely moving around 0.2-0.3 only.
– Mr R.Ananthakrishnan

“The services and delivery are as per our expectation. My engineering team is very happy and excited to experience a huge energy saving. We are expecting around INR 1.6 million worth energy savings per annum.”
– Shared Mr R.Ananthakrishnan.

We have dedicated programs and initiatives in reduce our energy consumption and we are ACCS surely illustrates a good example. We are happy to recommend you further!

Biofouling, scaling, and corrosion

These problems lead to water wastage and deteriorate the internal pipes and system of the complete cooling system. This naturally makes maintenance a costly hassle and reduces the overall efficiency of the cooling system.

Water Wastage

Considering the massive amount of water that is flushed frequently, Cooling towers are one of the causes behind water wastage in commercial and industrial setups. They also have detrimental consequences if not maintained properly or left untreated.

Water is scarce. Thus, there is an imminent need to use water efficiently and treat it within the parameters of environment i.e without using any Chemicals, to make it sustainable

Rise in Operational costs

Fouling slows down cooling processes and results in increased operating costs due to:

• Reduced cooling Flow & Increased Pressure on cooling systems leading to Loss of Energy
• Equipment Damage
• Cleaning and Disposal of Toxic Waste
• Increased Safety Hazards
• Ongoing Use of Costly Chemical Additives

The table below shows the potential impact of calcium scale deposit on a 500-tonne chiller running at full load, 24 hours per day. Actual increased energy use depends on compressor type, actual operating condenser head pressure, and percent operating load.

Improve Energy Efficiency by up to 25%

The ACCS prevents the heat exchanger tubes to accumulate mud, scale, or biological fouling. Earlier, these deposits used to get accumulated over time and would eventually degrade the performance of the heat exchanger. With the introduction of ACCS, many clients are able to gain around 10-15% of energy and can save up to as much as 25%.

Case study:

How we were able to save energy worthed INR 3 Million for Dr. Reddy’s?

Rapid Monetary Returns

  Not just the ACCS results in the improvement of energy efficiency, the entire tube cleaning system tends to eliminate the manual task of condenser cleaning. Also, with this, the life expectancy of the heat transfer equipment also increases rapidly which results in low cost of investment as well. The ACCS can be of great value if you put it to use regularly and would work well for the longest possible time.

Below listed are some reasons why energy efficient chillers will help attract more tenants in a mall.

Low Operating Cost

With the chillers being installed in a mall, one can easily expect a decrease in utility bills by as much as 21%. Since every business and retail shop aims to churn as much profit as possible, it will get attracted to the prospect of low operating costs.

Saves Electricity

  In the present-day world, every unit of electricity saved is electricity earned. Not only does this have huge monetary benefits, but also proves to be extremely valuable when it comes to contributing towards a greener earth. With chillers coming into play, a store in the mall that would otherwise be using 1,000 units of electricity, will end up using just 7,900 units, ensuring astounding benefits of chillers.

Tenants Prefer Greener Energy

  Ask any real estate agent who works closely with prospective tenants, and it will be clear that more and more tenants are now preferring energy-efficient offices and malls as against conventional ones. While tenants may not be ready to pay higher rent, but the fact remains that the tenants will readily choose such a space and the mall will get occupied at an exceptionally fast pace!

Case study: How our solution helped 5 star hotel save 20% on their electricity?

Eventually, the progression of fouling & scaling tends to unacceptably lower the overall performance. As a result, the guests at your hotel start complaining because of the overall failing of the cooling system. Vast amounts energy gets wasted between such cleaning interruptions due to the activity of the compressor. As such, an advanced Automatic Tube Cleaning System – ACCS or an on-line tube cleaning system can help in easily lowering this energy wastage as it will aid in keeping the condenser tubes clean throughout during operation without any human intervention. Moreover, a high-tech ACCS unit also helps in keeping the overall energy consumption per cooling unit at its lowest possible rate –throughout the year.

  With an average energy saving of around 20 percent on the overall electricity consumption by the compressor in your hotel unit, you can bring about effective cost minimization for ensuring top-notch operation. The total savings of the energy over the functional lifespan of the chiller unit in your hotel (around 10 years) will be equal to the investment needed for the next brand-new chiller unit.

How do Chillers Function?

Chillers are nothing but an extended version of a spilled unit air conditioner, which works on the principle of absorption of heat through an evaporator and releasing of the same via a condenser. The only difference here is that a chiller condenser is cooled by water, that flows to the cooling tower.

The Good

Chillers are highly preferred over conventional air-conditioners, since they help achieve the goal of maintaining the desired temperature in all types of spaces, at a significantly low cost.

The Bad

  Unlike regular air-conditioners, water-cooled air-conditioning systems are susceptible to build-up caused due to various pollutants and mineral deposits. This has a negative impact on both, their performance as well as their energy efficiency. As a matter of fact, when working inefficiently, the chillers can consume a whopping 20-40% more electricity per cooling unit.

The Solution

  Conventionally, service contractors used mechanical or chemical cleaning techniques to clear the cleaning system. This, however, resulted in undue interruptions in the functioning of the cooling system, which is rather impractical. Moreover, this process only ensures efficient functioning of the cooling system for a few days, after which the new build-up starts forcing it to decline gradually.

  The contemporary and more efficient solution to this problem is CET Enviro On-Line Cleaning System. Working on the principle of consistent cleaning, this system ensures that the condenser tubes are cleaned day-in and day-out. The cleaning sponge balls and the technique play a pivotal role in the cleaning process. As a result of this continual cleaning process, the energy consumption per cooling unit remains as low as possible.

  What makes the On-Line Cleaning System so promising is the fact, that it ensures that the chillers remain energy efficient all throughout the year, without any glitch.

  Overall, this system can help achieve an increased energy efficiency of up to 30%, thus offering great value for your money! And on the upside, it offers you an unparalleled opportunity to do your bit for the conservation of the environment and its resources!

Major items of concern:

Refrigerant

First of all, it is quite essential to maintain the refrigerant so as to decrease the load on the compressor. This minimized compressor load will itself increases the system efficiency.

Tube Cleaning

  It is the matter of fact that chiller typically has several miles of tubing and thus it is important to keep these tubes as clean as possible. Chiller efficiency is greatly affected by the cleanliness of the heat transfer surfaces than any other factor. Efficiency declines rapidly if contaminants are present on the chiller tube surfaces. Their presence can increase thermal resistance and chiller finds it hard to meet the demands.

Water Treatment

  Some sort of water treatment is required when condensers use an open cooling source so as to control scale, biological growth, and corrosion which can lead to the fouling of the condenser. Chiller condenser tube cleaning is very much important so as to enhance the life of this potential energy saving source. One should keep in the mind the fact that the more the condenser becomes fouled, the more energy it takes to satiate the demand placed on it.

Lubrication

Lubrication is yet another item of concern while talking about chiller tube cleaning. Basically, it is the lab test which should be done annually so as to keep the track for moisture content, acids and other contaminants that can affect its performance.

Motors and other electrical equipment

Chiller motor is the largest consumer of energy and probably the most important part of this energy source and hence its maintenance is quite important. Make sure that cooling air vents are properly cleaned the shaft seals should be checked on the regular basis. In order to achieve peak performance, wiring and other electrical connections should be checked from time to time.

Rod and Brush Method

Perhaps it is the oldest chiller tube cleaning methods. This usually involves the length of the rod along with nylon or wire brush larger than the tube’s inner diameter. Basically, the tube is flushed with water from a hose and then brush is manually pushed through the tubes. This method is very cheap and requires little training or expertise.

Tube cleaning Guns

This is the latest method to clean the chiller tubes. It makes the use of compressed air or water or high-pressure water alone to propel the cleaning projectile through the tubes to eliminate deposits. With its fast speed, the tubes are cleaned within little or no time. Like the previous method, it also requires little expertise or training.

Chemical cleaning

  Cleaning of the chiller tubes with the help of chemicals is yet another method to remove the contaminants from the surface of the tube and thus increases its efficiency. It employs the use of an acid solution which is circulated through the tube bundle so as to break down or soften the scale deposits in the tube. Though this method is quite costly but can clean the tubes completely.

Rotary Tube Cleaners

  This chiller tube cleaning machine uses either an electric or air motor in order to rotate the flexible shaft. It is encased in the plastic casing and transport the water to the cleaning tool. These cleaning tools are capable of cleaning all sorts of deposits including hard scales. This tube cleaning method is affordable and quite simple to perform. Apart from this, it requires only one operator and thereby reduces the cost of the laborers. These rotary tube cleaners range from simple to more advanced models with variable speed and bi-directional rotation. Also, it is the most effective method of cleaning new chillers that use internally enhanced tubes.

Here are 3 reasons why condenser tube cleaning is important:

1. For optimum performance:

Your HVAC system is a complex machine that is composed of several parts. Your condenser is one of the most important parts that work like the heart of the system. If it doesn’t work well, then the whole system will be affected. Residue and debris in condenser tubes can impede the efficiency of your chillers. That’s why it is important to have regular tube cleaning from time to time to make sure that the chillers are performing at their best.

2. To reduce zero heat loss:

  One large potential challenge to desired chiller performance is to prevent heat loss from condenser tubes. HVAC system efficiency deteriorates as tubes become fouled, when mud, algae, sludge, scale or contaminants accumulate on the waterside of heat-transfer surfaces. Chiller performance and efficiency relate directly to its ability to transfer heat, which begins with clean evaporator and condenser tubes. Large chillers contain several miles of tubing in their heat exchangers, so keeping these large surfaces clean is essential to reduce heat and energy loss through condenser tubes.

3. Extent life cycle with no downtime:

  Regular maintenance is the best way to maximize the life of your air conditioner. It extends chiller life and increases ROI because the compressor never operates beyond its design limits and condenser tube corrosion is eliminated. The automatic tube cleaning system keeps the condenser tubes permanently clean while the chiller is operating thus eliminating the need for manual cleaning while lowering your maintenance and energy bills.

  Given the current economic situation of the HVAC industry today, companies need to be investing in solutions that can increase profitability with sustainability. Estimates have shown that additional revenues from annual cleanings of the main condenser can net upwards of $250,000 per year.

  Automatic Condenser Tube Cleaning (ACCS) is clearly one of the maintenance solutions that can quickly and easily clean the condenser tubes. Therefore, it is important to regular and automated clean condenser coils…even if they may seem clean, dirt and grease are building