THE EPRI STATE-OF-THE-ART COOLING WATER TREATMENT RESEARCH

PROJECT
A TAILORED COLLABORATION PROGRAM

Babu Nott
Electric Power Research Institute David Morris
3412 Hillview Avenue Southern Company Services
P.O. Box 10412 42 Inverness Parkway
Palo Alto, California 94303-0813 Birmingham, Alabama 35242

K. Anthony Selby S.R. Pate

Puckorius & Associates, Inc. Georgia Power
P.O. Box 2440 333 Piedmont Avenue
Evergreen, Colorado 80437-2440 Atlanta, Georgia 30303

Tammy Brice Dale Smay

Entergy Operations- River Bend Station Penelec - Keystone Station
P.O. Box 220 R.D. #1 Box 269
St. Francisville, Louisiana 70775 Shelocta, Pennsylvania 15774

Don Goldstrohm Terry Spaulding

Salt River Project - Coronado Station PSI - CINergy
P.O. Box 1018 1000 East Main Street
St. Johns, Arizona 85936 Plainfield, Indiana 46168

Abstract The EPRI TailoredCollaborationState.of-the-ArtCoolingWaterTreatmentResearchProgramhas been

initiated with several electric utility participants. Started in January 1995, the programwill provide O&M cost
reduction through improvedcoolingwater systemreliabilityand operation. This effortis discussed alongwith the
objectivesand goals, the participants and projecttimetable. The programwill providethree (3) main resultsto the
participating utilities: cost effectiveoptimizationof cooling water treatment, production of a new Cooling Water
Treatment Manual and updating of two (2) EPRI softwareproducts - SEQUILand COOLJkDD. A review of the
specificobjectives,projecttimetableand resultsto datewill be presented.

Ke),words:cooling water, cost reduction, coolingwatertreatmentmanual, COOLADD,SEQUIL

1. Background

The Electric Power Research Institute (EPRI) recognized the critical role of cooling
systems in power production and began funding research on improved control of cooling
water chemistry in 1978. Since that time, EPRI's R&D efforts in this area have resulted
in a variety of valuable products. These have included:

Design and Operating Manual for Cooling-Water treatment (CS-2276, March

1982) 1. The manual was originally developed to assist zero-discharge plants with
the design and operation of recirculated cooling water systems at very high cycles of

Water, Air and Soil Pollution 90: 173-181, 1996.

1996 Kluwer Academic Publishers. Printed in the Netherlands.
174 BABU NOTT ET AL.

concentration (>10). This manual offered the utility industry the first computer code
(DRIVER) for predicting the saturation limits of potential scaling species (calcium
carbonate, calcium sulfate, calcium phosphate and silica) based on actual liquid-
liquid and solid-liquid ion pairing relationships instead of generic rules of thumb.

SEQUIL: An Inorganic Aqueous Chemical Equilibrium Micro-computer Code (GS-

6234-CCML, September 1990)2. This is an IBM PC code that is an updated version
of the earlier mainframe computer code, DRIVER. SEQUIL made it easy for plant
chemists and engineers to evaluate the impacts of changes in cooling water
chemistry and to predict system scaling potential at different operating conditions.

COOLADD: A Database of Generic Chemical Additives Usage ~n Cooling Water

Systems (CS-5133, April, 1987)3. The COOLADD database provided utilities with
the first comprehensive information on industry use of cooling water scale and
corrosion inhibitors, making it possible for power plant staff to independently review
and compare chemical treatment programs recommendedby vendors.

By today's standards, however, these EPRI products have cumbersome user interfaces
making them somewhat more difficult to use than most people would like. Equally
important, from a potential user's perspective, is the lack of integration between all three
products and with other EPRI cooling water chemistry related information, as well.
Since each product was developed independently by different EPRI contractors over a ten
year period, overall integration depended upon EPRI's continuing research and technical
staff guidance in this area.

2. Objectives

This project is sponsored by EPRI as a Tailored Collaboration (TC) program. An EPRI

TC program is cofunded by EPRI and the participating utilities. There are several EPRI
member utilities that are participating in the program.

The project has three basic objectives:

To update and enhance COOLADD and SEQUIL as EPRI software products.

To develop a new Cooling Water Treatment Manual as a state-of-the-art guidance

document by integrating EPRI research results and products with related information
from other reliable technical sources.

To demonstrate the advantages of using EPRI's revised products from improved

cooling water chemistry control and to document the industry benefit based on site-
specific case studies.
 A TAILORED COLLABORATION PROGRAM 175

Meeting these objectives will assure that EPRI's member utilities will have improved
access to cooling water research results and integrated products that encompass current
technology.

3. Task Descriptions

The tasks are designed to result in an integrated series of EPRI products that will have
tangible benefits to the program participants and other EPRI members.

SofOvare Update and Enhancement

The purpose of this task is to revise both the COOLADD database and the SEQUIL code.
The primary focus of these revisions will be incorporation of new and more current
information on cooling water additives usage, modification of the user input/output (I/O)
interface, and preparation of an internal applications interface for simultaneous access of
the two software packages. All software revisions will operate in the Microsoft Windows
3.0+ environment, which is consistent with EPRI's goal of maintaining a common "Look
and Feel" based on a visual, graphics-oriented interface (EPRI Software Guidelines -
Contractor Summary, July 1992).

COOLADD
The initial step in revising the COOLADD database has been the development of a new
survey of the utility industry to determine any changes in the information collected
during the earlier 1986 survey. This repeat survey is similar to the original survey with
two exceptions. First, some information from the existing COOLADD database will
already be complete so that respondents need only verify or correct these data. Second,
additional information (not included on the original survey) is requested, such as type of
cooling tower fill, metallurgy of auxiliary heat exchangers linked to the main steam
condenser cooling loop, and the length of time (years) the current chemical treatment
program has been in use. The survey has been sent to the plant manager at all power
plants having one or more units with a total capacity equal to or greater than 500 MW
(based on the Utility Data Institute's Power Statistics Database).

Following a response quality check, the data will be entered into a new set of data files
that can be accessed, searched and sorted using commercial database management
software (DBMS). Microsoft ACCESS will be used as the DBMS.

EPRI and the participating utilities will test the beta version of COOLADD as part of the
proposed case studies. Each party will receive a complete COOLADD package
consisting of diskettes, documentation, installation instructions and test cases. When the
beta testing has been concluded, each party will be asked to complete an evaluation form
and to provide suggestions for software / documentation revisions. The beta testing
results will be used to develop the final version of COOLADD and the associated
documentation.
176 BABU NOTr ET AL.

SEQUIL
EPRI's Inorganic Aqueous Chemical Equilibrium code has undergone extensive
technical evaluation since it was first developed as a mainframe computer code.
SEQUIL has proven to be a reliable predictor of scaling potential over a wide variation of
cooling water chemistries. Therefore, only two revisions are proposed for this code: a n
improved user I/O interface and an internal applications interface that links it with
COOLADD database.

SEQUIL's entire code is presently written in ANSI FORTRAN '77, and consequently
has severe limitations with regard to the user I/O interface. Data entry is accomplished
through a cumbersome question-and-answer format. Input corrections and file
modifications are not particularly straightforward, and output (which is typically too long
to be summarized on a screen) scrolls by quickly and cannot be conveniently viewed on a
monitor. All file and execution commands are in DOS.

All of these difficulties can be overcome by operating SEQUIL from a Windows 3.0+
environment. DOS commands can be replaced by pull-down menus. Data entry can be
simplified for the user through input screens that are mouse-activated. And output that is
more than one screen can be sectioned into multiple windows that can be viewed
simultaneously and moved about on the desktop. Therefore, without modifying any of
the technical calculations performed by SEQUIL, the code can be given a more user-
friendly "Look and Feel" by making it a Windows application.

Since both COOLADD and SEQUIL will be converted to the Windows environment,
linking the two software product will be easier. With applications software, a user will
be able to access the database and the equilibrium code without storing results and
exiting either product. For example, a user that has just used SEQUIL to determine the
calcium carbonate scaling potential for a particular cooling water may want to search
COOLADD to learn about the water treatment programs commonly used for these
conditions. The user can temporarily reduce the size of the SEQUIL window and move it
to another area of the desktop, then open the COOLADD database from the applications
software and search it for the necessary information. Through the Windows
environment, the user will be able to go back and forth between the two software
products as often as necessary by simply changing the size of the software window and
rearranging the desktop.

Following internal review of an alpha version, EPRI and the TC utilities will test the beta
version of the SEQUIL applications code as part of the proposed case studies. Each party
will receive a complete SEQUIL applications package consisting of diskettes,
documentation, installation instructions, and test cases. When the beta testing has been
concluded, each party will be asked to complete an evaluation form and to provide
suggestions for software / documentation revisions. The beta testing results will be used
 A TAILORED COLLABORATION PROGRAM 177

to develop the final version of the SEQUIL applications code and the associated
documentation.

Cooling Water Treatment Manual Development and Demonstratlon

The purpose of this task is to develop a state-of-the-art cooling water treatment manual
based on a combination of EPRI research results and products in addition to current
industry information, standards, and practices:. To achieve this goal, this task will focus
not only on the preparation of the document, but also on the demonstration of the
document's direct application to utility cooi'Jng water chemistry control through case
studies conducted for each of the TC utilities. These case studies will include
demonstration of the EPRI software updated and enhancements completed under the
software portion of the project.

The Cooling Water Treatment Manual will be application-oriented. As such, it will be

organized to help a reader:

Understand the importance of cooling water chemistry control.

Recognize problems related to cooling water chemistry and determine probable

causes.

Evaluate possible corrective actions.

Implement corrective actions and follow-up as necessary.

The draft outline for the manual has been reviewed by EPRI and the TC utilities. Based
on this initial review, the outline was revised as a basis for preparing a preliminary draft
manual.

Each TC utility has been visited to discuss and select a case study for a cooling system at
one plant. These case studies will have two goals: 1) to demonstrate EPRI software, and
2) to develop an actual site-specific cooling water treatment approach using the draft
manual as guidance and document the associated benefits. In most cases, the case
studies are being conducted for cooling systems that have experienced or continue to
experience operating problems, or for situations in which a successful cooling water
treatment program is place but program costs are high.

A typical case study began with a system audit in which historic cooling system data are
evaluated to determine the cause(s) of current/potential problem(s). The contractor
personnel are spending time on-site working with a utility staff representative(s) to
review these data, define the need for additional data, and assist in using EPRI software
and the draft manual. As a result of the on-site evaluations (in conjunction with the
utility staff) a recommended cooling water treatment program will be developed.
178 BABU NOT1r ET AL.

At this point, the participating TC utility has the option of deciding whether to continue
with their current cooling system treatment program or to change to the program
recommended by the system audit. Should the TC utility decide to change treatment
programs, the contractor will assist in implementation by:

Identifying chemical formulations and supply sources.

Specifying chemical storage and feed equipment.

Defining monitoring instrumentation needs (equipment and locations).

Participating in program startup and performance monitoring over a limited period.

Preparing a letter report evaluating the success of the new treatment program and
documenting the benefits in terms of cooling system performance and / or total
program costs.

Participation in the case study activity does not obligate a TC utility to modify an
existing cooling water treatment program or to switch to a different treatment program.

When the case studies have been completed, the preliminary draft manual will be revised
to incorporate the results. Based on review comments and suggestions from EPRI and
the TC participants the final Cooling Water Treatment Manual will be submitted to EPRI
for publication.

Technology Transfer
The purpose of this task is to assist EPRI in the introduction of new and updated products
developed as a result of this project. Such assistance will consist of preparing selected
publications, conducting a training workshop, and providing telephone consultation to
product users.

Because the new products will include software, a training workshop will be provided in
which attendees are instructed in the use of the Cooling Water Treatment Manual and
provided hands-on experience with the software. During the workshop, attendees will
review case studies presented in the Manual and evaluate new cases based on site-specific
information they provide regarding current problems and/or concerns in their systems.

In addition, telephone hotline consulting support will be provided to software users for a
period of six(6) months following product delivery to EPRI. The telephone consulting
will focus on user support for installing and applying the software.

4. Program Participants

There are currently five (5) EPRI member participants in the program. These are shown
in Table I.
 A TAILORED COLLABORATION PROGRAM 179

Table I

State-of-the-Art Cooling Water Treatment Program Participants

Utility Station Utility Contact

Entergy River Bend Tammy Brice
CINergy Gibson Station Terry Spaulding
Georgia Power Plant Bowen S. 1L Pate/David Morris*
Penelec Keystone Station Dale Smay
Salt River Project Coronado Station Don Goldstrohm

*Mr. Morris is with Southern Company Services

The intent of the program is to use the on-site evaluations and EPRI products to optimize
water treatment operations at the individual sites. For the most part, this applies to the
condenser cooling systems but service water systems may also be involved. Each site is
different, however, and the program is designed to address the needs of the individual
participants. River Bend, Plant Bowen, Keystone and Coronado all are cooling tower
systems. Of these, Plant Bowen and Keystone both have experienced problems with the
fouling of the cooling tower film fill. Program optimization will focus on this subject. A
goal of the program at River Bend and Coronado will be on minimization of water
treatment program cost while maintaining program effectiveness. Gibson Station utilizes
a cooling lake. The dynamics of condenser cooling system are therefore different. Like
the other sites, however, a primary goal is water treatment cost minimization and
optimization of program cost.

5. Results to Date

At the present time, the State-of-the-Art Cooling Water Treatment Program is only ten
months into a three year program. In spite of the short time span, tangible results to date
have been achieved:

The survey forms that will be used to update the COOLADD database have been
sent to 422 generating stations representing 128 utilities.

Work has begam on reviewing the SEQUIL source code in order to develop plans for
interface improvements.

Initial site visits have been made to all participating generating stations. In some
cases follow-up visits have also been made.

Specific initial recommendations were made at Plant Bowen regarding the on-line
cleaning and maintenance of fouled cooling tower film fill. These recommendations
180 BABU NOTT ET AL.

consisted of an aggressive chlorination program to clean up the fouled fill. A

dechlorination program was implemented in conjunction with the chlorination
program. The preliminary recommendations also included the discontinuation of
one treatment chemical which was not compatible with the dispersant program. The
treatment program has been effective in meeting the objective of full load operation
during the summer of 1995.

An evaluation has been conducted at Coronado regarding lime softener operation,

cooling system scaling characteristics and overall program economics. Initial efforts
have been on optimizing lime softener operation. The cooling system scaling issues
relate primarily to magnesium silicate. For these efforts, SEQUIL will be used
extensively and it's equilibrium calculations reconciled with other approaches to
estimating magnesium silicate deposition.

Assistance has been provided to River Bend regarding the selection of clarification
polymers. Polymer performance data was developed, screening tests were run and
bid specifications were developed. Through these efforts, the plant is expected to
achieve a cost reduction on the order of 25%.

The overall goal at Keystone is to reduce chemical and monitoring costs for the
treatment of circulating and service cooling waters without sacrificing equipment
life of efficiency. One area that has been evaluated is the development of an on-line
cleaning procedure for calcium carbonate deposits that uses carbon dioxide to reduce
pH.

The program goals at Gibson Station also are to reduce treatment costs while
protecting equipment life and efficiency. Gibson Station is an impounded lake
cooled station that has had a history of calcium carbonate deposition problems.

6. Summary

The State-of-the-Art Cooling Water Treatment Program is an EPRI Tailored

Collaboration research program designed to update existing EPRI products, develop new
products and perform site specific studies in order to assist participants with selecting
optimum chemical treatment programs for their cooling water systems. The products
will consist of a Cooling Water Manual and enhancement of the software products
SEQUIL and COOLADD. These will be used as part of the site evaluations and
recommendations for specific problem solving at the participant's sites.

The TC program is less than a year into a three year effort but has already achieved some
significant results. The problem of film fill fouling is being addressed at two (2) sites.
Initial steps have been taken to reduce water treatment program costs at other sites.
 A TAILORED COLLABORATION PROGRAM 18 ]

Even though this program is now underway ~with the initial five (5) TC participants, the
authors encourage additional participants to join. The benefits will include participation
in the development of the EPRI products, early access to the products and the direct
benefits resulting from the on-site activities. A specific target will be reduced O&M
costs through improved water treatment operations.

7. Acknowledgments

The State-of-the-Art Cooling Water Treatment Program is a team effort that has
benefited from the dedicated efforts of many individuals and their companies. The
authors wish to thank Winston Chow of EPRI for his support in initiating the project. We
also wish to thank Wayne Micheletti for his efforts in helping to establish the program as
well as handling the software aspects of the project.

References
!
Electric Power Research Institute (EPRI): 1990, SEQU,rL, An ,rnorganieAqueous ChemiealEquilibrium Code
for Personal Computers, GS-6234-CCML-q.

2
Electric Power I~.esearch institute (EPRI): 1982, Design and OperatingManualfor Cooling-WaterTreatment,
CS-2276.

3 Electric Power Research institute (EPRI): 1987, A Database of Generic ChemicalAdditives Usage in Cooling
tP'aterSystems, CS-5133.