Field Evaluation Summary
Sentinel for Cooling Water Field Evaluation Study | Ammonia Plant | 5 Exposure Periods “Two Year Process of Cooling Water Performance Improvement”
“Sentinel represents a quantum shift in how we test for corrosion and scale because it is the first technology to use a heated surface and actually give us accurate results.” - Brian Bloxam | Ammonia Superintendent, CF Industries
21st Century Cooling Water Performance Monitoring
Sentinel Field Evaluation Study Sentinel by Knew Value is an improved method of monitoring cooling water performance. • On-line monitoring through visual inspection • Scale & Deposition • Corrosion • Bacteria fouling Knew Value has been monitoring the cooling water performance at the CF Industries, Courtright Nitrogen Complex since March 2015 with the objective of improving cooling water results. As of April, 2017 the 5th exposure has been completed. Objective: • What is Sentinel for cooling water and how does it work • Summary of results over the past 24 months • For you to think about how this will benefit your plant.
Sentinel for Cooling Water “If you only knew” What do we know? • • • •
Coupon results do not match exchanger results You do not have a tool to visually watch your cooling water treatment performance online. Visual inspections have been our report card for decades. Currently available tools are inaccurate and produce inconsistent or unrealistic results. There is no way to evaluate dosage changes or overlays without system wide changes.
If you only knew...(using Sentinel for Cooling Water) • • • •
The first heated corrosion coupon is now available. Results can be observed online. Program changes can be evaluated head to head. Sentinel uses the similar, but improved, technology that is employed by R&D for program development and customer program evaluations.
Sentinel for Cooling Water Various Uses for this tool •
Scale monitoring
•
Corrosion monitoring • • •
Same metallurgy, different exchanger conditions Different metallurgy, same exchanger conditions Independent exchanger modeling (metallurgy, skin temp, velocity)
•
Bacteria monitoring
•
Monitoring system clean-up following: • •
Bacteria excursion Clean-up of deposition
•
Passivation effectiveness during start-up
•
Efficacy of program dosage changes
•
Efficacy of program overlays
Sentinel for Cooling Water
Annular Exchanger
Sentinel for Cooling Water
Power: 120V 30 Amp Placement: Unclassified area (Air purge available) Input/Output: 6/gpm cooling water (supply water preferred) and drain.
Pump Heater
Dimensions: 30”x30”x12”
Sentinel for Cooling Water 120V Annular Test Heat Exchanger Skid Simplified Flow Customer Cooling Water Outlet
Customer Cooling Water Inlet
Process Heater Process Pump
Sentinel for Cooling Water 120V Annular Test Heat Exchanger Modeling Capability 220.0
9.00 8.00
200.0 7.00 6.00 5.00
fps
Deg F
180.0
160.0 4.00 140.0
3.00 2.00
120.0
Skin Temperature Modeling Zone at
1.00
100.0
0.00 1
2
3
4
5
SKIN TEMP
6
7
8
FT. PER SEC
Exchanger Operating Capability GPM Velocity (fps)
0.5 0.7
1 1.3
1.5 2.0
2 2.6
2.5 3.3
3 3.9
3.5 4.6
4 5.2
4.5 5.9
5 6.5
5.5 7.2
Dimensions – 30”x30”x12”. Power - 120V 30amp Power Supply. Unclassified area (air purge available), 6/gpm cooling water (supply water preferred) and drain.
6 7.8
Sentinel for Cooling Water Historical Evaluation Summary •
The first evaluation study was requested by the Ammonia Superintendent in March 2015 to assist in improving the results of the cooling water program.
•
The plant had historically experienced scale and under deposit corrosion, primarily due to the frequent swings in pH following contamination of the system with ammonia.
•
Initial results following a first run of 46 days were identical to the results observed by the Ammonia Superintendent in the ammonia condenser which was modeled by Sentinel for Cooling Water. It mirrored scale and under deposit corrosion with pit depths in excess of 20 mils.
•
Corrosion coupon results in the same period did not indicate any signs of performance problems.
•
Chemical program changes were started to improve results: • The dispersant was changed to a new product • Dosage was increased • An overlay of pyrophosphate was introduced
Sentinel for Cooling Water Historical Evaluation Summary (cont.) •
Overall results significantly improved • Iron phosphate scale was eliminated • Under deposit corrosion and associated pitting stopped
•
In addition to overall program improvements, Sentinel was used during the 2 year field evaluation as a tool to: • Monitor the recovery from bacteria excursions and insure system clean-up • Monitor the effectiveness of system passivation following a turn around
Sentinel for Cooling Water Field Evaluation Run Summary Runs
Exposure Period (Days)
Velocity (fps)
Skin Temp. (degF)
Tube Metallurgy
1
46
4.0-4.5
115 125
Carbon Steel
2
51
4.0-4.5
115 125
Carbon Steel
3
133
4.0-4.5
115 125
Carbon Steel
4
126
3.0
130
Carbon Steel
5
84
3.0
130
Carbon Steel
Sentinel for Cooling Water Overall Corrosion Summary of all Exposure Periods RUN
COUPON RESULTS
EXCHANGER TUBE RESULTS
COMMENTS
1
1.32, 1.9 MPY
>20 MIL PITS
2
2.4, 1.7, 3.9 MPY
>30 MIL PITS
3
1.1,1.1,1.3,1.6,1.2, 1.5,0.7,0.7,0.9 MPY
14, 24 MIL PITS
Isolated localized corrosion observed with
“Sentinel represents a quantum shift in how we test for corrosion and scale because it is the first technology to use a heated surface and actually give us accurate results.” - Brian Bloxam | Ammonia Superintendent, CF Industries
21st Century Cooling Water Performance Monitoring
Sentinel Field Evaluation Study Sentinel by Knew Value is an improved method of monitoring cooling water performance. • On-line monitoring through visual inspection • Scale & Deposition • Corrosion • Bacteria fouling Knew Value has been monitoring the cooling water performance at the CF Industries, Courtright Nitrogen Complex since March 2015 with the objective of improving cooling water results. As of April, 2017 the 5th exposure has been completed. Objective: • What is Sentinel for cooling water and how does it work • Summary of results over the past 24 months • For you to think about how this will benefit your plant.
Sentinel for Cooling Water “If you only knew” What do we know? • • • •
Coupon results do not match exchanger results You do not have a tool to visually watch your cooling water treatment performance online. Visual inspections have been our report card for decades. Currently available tools are inaccurate and produce inconsistent or unrealistic results. There is no way to evaluate dosage changes or overlays without system wide changes.
If you only knew...(using Sentinel for Cooling Water) • • • •
The first heated corrosion coupon is now available. Results can be observed online. Program changes can be evaluated head to head. Sentinel uses the similar, but improved, technology that is employed by R&D for program development and customer program evaluations.
Sentinel for Cooling Water Various Uses for this tool •
Scale monitoring
•
Corrosion monitoring • • •
Same metallurgy, different exchanger conditions Different metallurgy, same exchanger conditions Independent exchanger modeling (metallurgy, skin temp, velocity)
•
Bacteria monitoring
•
Monitoring system clean-up following: • •
Bacteria excursion Clean-up of deposition
•
Passivation effectiveness during start-up
•
Efficacy of program dosage changes
•
Efficacy of program overlays
Sentinel for Cooling Water
Annular Exchanger
Sentinel for Cooling Water
Power: 120V 30 Amp Placement: Unclassified area (Air purge available) Input/Output: 6/gpm cooling water (supply water preferred) and drain.
Pump Heater
Dimensions: 30”x30”x12”
Sentinel for Cooling Water 120V Annular Test Heat Exchanger Skid Simplified Flow Customer Cooling Water Outlet
Customer Cooling Water Inlet
Process Heater Process Pump
Sentinel for Cooling Water 120V Annular Test Heat Exchanger Modeling Capability 220.0
9.00 8.00
200.0 7.00 6.00 5.00
fps
Deg F
180.0
160.0 4.00 140.0
3.00 2.00
120.0
Skin Temperature Modeling Zone at
1.00
100.0
0.00 1
2
3
4
5
SKIN TEMP
6
7
8
FT. PER SEC
Exchanger Operating Capability GPM Velocity (fps)
0.5 0.7
1 1.3
1.5 2.0
2 2.6
2.5 3.3
3 3.9
3.5 4.6
4 5.2
4.5 5.9
5 6.5
5.5 7.2
Dimensions – 30”x30”x12”. Power - 120V 30amp Power Supply. Unclassified area (air purge available), 6/gpm cooling water (supply water preferred) and drain.
6 7.8
Sentinel for Cooling Water Historical Evaluation Summary •
The first evaluation study was requested by the Ammonia Superintendent in March 2015 to assist in improving the results of the cooling water program.
•
The plant had historically experienced scale and under deposit corrosion, primarily due to the frequent swings in pH following contamination of the system with ammonia.
•
Initial results following a first run of 46 days were identical to the results observed by the Ammonia Superintendent in the ammonia condenser which was modeled by Sentinel for Cooling Water. It mirrored scale and under deposit corrosion with pit depths in excess of 20 mils.
•
Corrosion coupon results in the same period did not indicate any signs of performance problems.
•
Chemical program changes were started to improve results: • The dispersant was changed to a new product • Dosage was increased • An overlay of pyrophosphate was introduced
Sentinel for Cooling Water Historical Evaluation Summary (cont.) •
Overall results significantly improved • Iron phosphate scale was eliminated • Under deposit corrosion and associated pitting stopped
•
In addition to overall program improvements, Sentinel was used during the 2 year field evaluation as a tool to: • Monitor the recovery from bacteria excursions and insure system clean-up • Monitor the effectiveness of system passivation following a turn around
Sentinel for Cooling Water Field Evaluation Run Summary Runs
Exposure Period (Days)
Velocity (fps)
Skin Temp. (degF)
Tube Metallurgy
1
46
4.0-4.5
115 125
Carbon Steel
2
51
4.0-4.5
115 125
Carbon Steel
3
133
4.0-4.5
115 125
Carbon Steel
4
126
3.0
130
Carbon Steel
5
84
3.0
130
Carbon Steel
Sentinel for Cooling Water Overall Corrosion Summary of all Exposure Periods RUN
COUPON RESULTS
EXCHANGER TUBE RESULTS
COMMENTS
1
1.32, 1.9 MPY
>20 MIL PITS
2
2.4, 1.7, 3.9 MPY
>30 MIL PITS
3
1.1,1.1,1.3,1.6,1.2, 1.5,0.7,0.7,0.9 MPY
14, 24 MIL PITS
Isolated localized corrosion observed with
