Henniges Automotive: Closed Loop Chilled Water Treatment

Henniges Automotive: Closed Loop Chilled Water Treatment

Henniges Automotive: Closed Loop Chilled Water Treatment

Project: Henniges Automotive
Location: New Haven, MO
Scope of Work: Closed Loop Chilled Water Treatment
EasyWater Equipment: (1) CLC-1000-S – Series C Closed Loop Treatment System

Problem

Henniges Automotive is a leading global supplier of highly engineered automotive sealing and anti-vibration solutions. Their New Haven, MO, facility has 8 closed loop chilled water systems with vented tanks used for process cooling. The vented tanks cause high levels of dissolved oxygen, creating major corrosion to equipment, piping and other components.

Steve Cronin, Finishing Engineer at Henniges, said the dissolved oxygen caused:

  • “sludge, sediment and corrosion problems”
  • “clogging of thermal control units and heat exchangers”
  • “piping [to be] lined with deposits”
  • “the water will turn to a brown sludge if not flushed often”
EasyWater Series C Closed Loop Treatment System installed at Henniges Automotive
Laboratory results of dissolved oxygen level in closed loop before Series C installation
Despite chemically treating the loops and salt softening the makeup water, the maintenance team had to drain and flush their most troublesome loops weekly. On their worst loop, the thermal control units were clogging every three days.

Deposits and dissolved oxygen in the water were tested at a certified third party lab. The EDS analysis of the deposit was found to be “composed primarily of zinc and iron [from the Closed Loop System].” Dissolved oxygen was 9.13Mg/L. The lab results confirmed the problem to be corrosion caused by dissolved oxygen.

Solution

EasyWater Series C Model CLC-1000-S (Closed Loop Chilled – Skid-Mounted). This automatic backwashing, skid-mounted system provides cost effective, low maintenance, non-chemical treatment for closed loops. This unique, three-part solution contains:

  • Proprietary filtration media that continuously removes dissolved oxygen
  • Sub-micron, self-backwashing filter for the removal of sediment, debris, and bacteria
  • EasyWater No-Salt Conditioners to prevent and remove insulating deposits, as well as biofilm
    and bacteria
Front and side views of the EasyWater Series C Closed Loop Treatment System at Henniges Automotive

RESULTS

An EasyWater CLC-1000-S arrived on November 11, 2020 to treat Henniges Automotive’s “worst loop” that required flushing every three days. According to Steve Cronin, the system took less than two hours to install. Before the installation, Steve tested the dissolved oxygen level and it was 11 ppm.

Three weeks later, the dissolved oxygen was dramatically lower, and there wasn’t a single clogged thermal control unit despite the loop never having been flushed.

BEFORE – Exterior view of clogged prefilter for thermal control unit

AFTER – Clean prefilter for thermal control unit after one month of EasyWater Series C installation

BEFORE – Interior view of clogged prefilter for thermal control unit

AFTER – One month after adding EasyWater Series C Closed Loop Treatment System

Since installation of the Series C System:

  • The dissolved oxygen level has been extremely low
  • Henniges hasn’t had a single thermal control unit clog
  • They haven’t had to flush the system

Henniges is so pleased with the results, they installed a second CLC-1000-S for another closed loop at their New Haven facility. They are also obtaining quotations for treating additional closed loops with Series C, as well as cooling towers with EasyWater’s CTF System.

 

Are you looking for cooling tower or closed loop water treatment for your facility?

We manufacture and offer a complete line up of industrial water treatment solutions. Please give us a call at 1-888-766-7258, or use the form below to reach out to us, so one of our experts can help you with your project. 

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CocoWalk Lifestyle Center: Cooling Tower & Closed Loop Water Treatment

CocoWalk Lifestyle Center: Cooling Tower & Closed Loop Water Treatment

CocoWalk Lifestyle Center: Cooling Tower & Closed Loop Water Treatment

Project: CocoWalk Lifestyle Center
Location: Coconut Grove, FL
Scope of Work:
  • 2-Cell, 720 Ton Cooling Tower System
  • Less Than 4000 Gallon Closed Loop
EasyWater Equipment:
  • CTF – Cooling Tower Treatment (Model CTF-100)
  • Series C – Closed Loop Treatment
    (Model CLC-1000)

Problem

CocoWalk is an upscale lifestyle center located in the Coconut Grove neighborhood of Miami, Florida. This large complex has 30+ stores and services, including shops, restaurants and a movie theater.

This facility has a cooling tower system and plate and frame heat exchangers providing water for a heat pump system. The equipment provides air conditioning for all tenants. Like many cooling towers, CocoWalk was plagued with ongoing problems from:

  • Hard water scaling in there piping system and heat pumps
  • High bacteria counts
  • Hard water scaling in the cooling tower fill
EasyWater CTF System: Model CTF-100 Installation at CocoWalk

2 Cell Cooling Tower at CocoWalk

Solution

CocoWalk purchased (1) EasyWater CTF-100 Treatment System for the cooling tower and (1)
EasyWater CLC-1000 to treat the closed loop heat pump system.

EasyWater’s CTF System is a unique, three-part solution

  • EasyWater SedimentShield—a sub-micron, backwashing filter for the removal of sediment and bacteria
  • Ultraviolet chamber for bacterial sanitization
  • EasyWater No-Salt Conditioners to prevent and remove hard water scale deposits, biofilm, and bacteria. Our No-Salt Conditioners have the added benefit of preventing the hot UV lamps from scaling.

EasyWater CTF System: Model CTF-100 Installation at CocoWalk

EasyWater’s Series C System is an advanced closed loop treatment system that eliminates the need for chemical treatment:

  • Proprietary filtration media that continuously removes dissolved oxygen
  • Sub-micron, self-backwashing filter for the removal of sediment, debris,
    and bacteria
  • EasyWater No-Salt Conditioners to prevent and remove high iron content and hard water deposits.

EasyWater Series C System: Model CLC-1000 Installation at CocoWalk

RESULTS: COOLING TOWER WITH CTF SYSTEM

Our CTF Treatment System has continuously maintained low bacteria count, clear water, and no scale. A small amount of oxidizing biocide is used and properly maintained as a precautionary measure for Legionella.

CocoWalk is now seeing an impressive 80+% reduction in chemical use. There has also been significant savings in energy consumption through eliminating limescale build-up. In addition to these savings, CocoWalk no longer has to deal with the hazard of having multiple types of chemicals on site to treat their cooling towers.

AFTER Treatment – Bacteria dip slides continue to register 100 on a monthly basis.
Top of cooling tower with no scale after (1) year
Side of cooling tower with no scale after (1) year

RESULTS: Closed Loop with Series C System

The Series C Closed Loop Treatment System has continuously maintained low dissolved oxygen and corrosion rates in the system while removing dirt debris, and deposits that were in the system.

Dirt and debris being removed during backwashing
Latest corrosion coupons lost only .1155 mils/yr for steel and .0371 for copper which is beyond EXCELLENT according to the chart below!

Before – Dissolved oxygen test results 5-6ppm

After 8 Months – Dissolved oxygen maintained at <1ppm

During the latest (10) month period the closed loop had steel corrosion rates of and .1155 mils per year and a copper corrosion rate of .0371.
Source: Bennett P. Boffardi, Ph.D., FNACE. “Standards for Corrosion Rates”, AWT Analyst, Spring 2000

 

Based on the chart above, the Series C System at CocoWalk provided results that were considerably better than EXCELLENT for both carbon steel and copper!

This test confirms that Series C provides superior corrosion control without using chemicals.

 

Are you looking for cooling tower or closed loop water treatment for your facility?

We manufacture and offer a complete line up of industrial water treatment solutions. Please give us a call at 1-888-766-7258, or use the form below to reach out to us, so one of our experts can help you with your project. 

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Tallahassee Community College: Closed Loop Treatment Systems

Tallahassee Community College: Closed Loop Treatment Systems

Tallahassee Community College: Closed Loop Treatment Systems

Customer: Tallahassee Community College
Job Facts: 270-acre community college in Tallahassee, FL, with over 40,000 students enrolled
Scope of Work Closed loop treatment for chilled and hot water systems
EasyWater Equipment
  • 3 x Series C 4,000-Gal Closed Loop Treatment Systems
  • 1 x Series C 25,000-Gal Closed Loop Treatment System
  • 1 x Series C 40,000-Gal Closed Loop Treatment System

“I’m very impressed with the very low iron and copper levels. This indicates great corrosion control in the system.”
– Chem-Aqua Consultant

Problem:

For years, Tallahassee Community College (TCC) battled and experienced a range of problems in their closed loop hot water and chilled water systems. They had a contract to add traditional chemicals and have water tests conducted on a regular basis but continued to fight leaks, sediment and iron oxide deposits in their piping and heat exchangers, which significantly reduced heat transfer and increased energy consumption by more than 12 percent. Traditional chemicals were not protecting their closed loops properly and were costing them a lot of money, so TCC turned to EasyWater for help.

EasyWater Treatment Test / Results:

TCC purchased three Series C Closed Loop Treatment Systems to treat three small (less than 4,000 gallons) closed loop hot water systems as a trial. The results were excellent, and they found the Series C Closed Loop Treatment Systems cleaned up the loose metal and sediment in the water, reduced the dissolved oxygen levels to less than 1ppm and removed the existing iron oxide deposits in the systems.

The results were so positive that they decided to purchase a larger Series C System for their 25,000-gallon central closed loop hot water system. This Series C System provided the same results for their larger closed loop hot water system, so they purchased an even larger Series C System for their 40,000-gallon central closed loop chilled water system.

TCC continues to be very pleased with the results and even had their previous chemical company test the water in their central closed loop hot water system to give an opinion of EasyWater’s performance.
Below is the email and water test results from their previous chemical company regarding EasyWater’s performance:

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IUPUI: Steam Humidifiers, Ice Machines and Closed Loop Water Treatment

IUPUI: Steam Humidifiers, Ice Machines and Closed Loop Water Treatment

IUPUI: Steam Humidifiers, Ice Machines and Closed Loop Water Treatment

  • Project:  IUPUI (Indiana University-Purdue University Indianapolis)
  • Scope of Work: Ice machine water treatment In Chemistry building, steam humidifier water treatment in Medical Science building and closed loop hot water treatment in Cavanaugh Hall
  • EasyWater Equipment:
    • 3 x EasyWater SmartGuard RO Systems treating 3 Nortec Steam Humidifiers
    • 1 x EasyWater No-Salt Conditioner treating commercial ice machine
    • 1 x EasyWater Series C Closed Loop Treatment System treating all of the closed loop hot water in Cavanaugh Hall

Problem

For years, IUPUI battled scale build-up in their Nortec Steam Humidifiers and could not find a practical solution to eliminate the problem. IUPUI looked into reverse osmosis before hearing about SmartGuard RO, but the RO systems that were quoted took up too much space and required salt softener pretreatment.

Testing EasyWAter Treatment

EasyWater’s first SmartGuard RO installation with IUPUI was in December of 2015. SmartGuard RO not only eliminated scale in the Nortec Steam Humidifiers, but also provided RO water at a 65–75 percent recovery rate without softener pretreatment. This led to IUPUI purchasing more SmartGuard RO Systems.

Expanding Treatment to Closed Loop

Backwash water from Cavanaugh Hall after 7 days of treatment

The performance and results of SmartGuard RO led to IUPUI testing EasyWater’s Series C Closed Loop Treatment System for their closed loop hot water system at Cavanaugh Hall. The system was installed on June 9, 2017. On June 15, 2017, an EasyWater representative and an IUPUI technician met at Cavanaugh Hall to check on the Series C and review the installation.

They tested the dissolved oxygen onsite and also looked at the backwash water that was sent into a bucket. The dissolved oxygen was 1ppm or less after just seven days of treatment. The dissolved oxygen level was 10+ ppm before the Series C was installed. The dissolved oxygen was originally so high because of the amount of makeup water that was recently introduced into the system and because the heat had not been running, which will naturally drive the dissolved oxygen level down to 4–6ppm.

Overall, IUPUI has been very pleased with the results and continues to contact EasyWater about additional water treatment applications.

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Water Treatment for Indiana State Museum & IMAX Theatre

Water Treatment for Indiana State Museum & IMAX Theatre

Water Treatment for Indiana State Museum & IMAX Theatre

  • Project: Indiana State Museum & IMAX Theatre
  • Customer: State of Indiana (Owner), Sexson Mechanical (Contractor) and Applied Engineering Services (Engineer)
  • Job Facts: 270,000 Sq. Ft., 3 floors, 1 restaurant,
  • Scope of Work: Domestic Water, Steam Boiler and Kitchen
  • EasyWater Equipment:
    • 6 x No-Salt Conditioners treating domestic water for Museum/IMAX
    • 2 x Series C Closed Loop Treatment Systems treating 9,000-gallon closed loop hot water system
    • 1 x Revitalife Pro Reverse Osmosis System treating kitchen Steamer and Ice Machine
    • 1 x SimplySoft Hot Water Softener treating kitchen dishmachine

Problem

The 9,000-gallon closed loop hot water system at the Indiana State Museum & IMAX Theatre had a history of corrosion, which caused the water to look black and dirty due to a high level of dissolved oxygen in the water. The dissolved oxygen in the closed loop water was 4ppm. The facility also battled scale build-up problems in their domestic water heaters, ice machines and kitchen steamers.

Testing EasyWAter Treatment

In March of 2016, the State of Indiana decided to test EasyWater’s water treatment solutions to see if they could resolve the ongoing issues with water-using equipment. This included No-Salt Conditioners for domestic water, Series C Closed Loop Systems for a 9,000-gallon closed loop hot water system, a RevitaLife Pro Reverse Osmosis System for their kitchen steamer and ice machine, and a SimplySoft Hot Water Softener for treating their dishmachine.

Brian Benson, the Facility Engineering Manager at the Indiana State Museum & IMAX, diligently tested the dissolved oxygen level and examined the clarity of the water in their closed loop hot water system after the EasyWater Series C Closed Loop Treatment System was installed.

Results

Closed loop DO test results from October 2017

The water was clean and dissolved oxygen level was 1ppm or less within one month of Series C being installed. Their domestic water equipment, such as water heaters, ice machines and steamers, has also stayed clean after installing EasyWater No-Salt Conditioners and a Revitalife Pro Reverse Osmosis System.

The Indiana State Museum led to many other projects with the State of Indiana, such as the Indiana Government Center and Capitol Building. Brian Benson has been so pleased with the results that he has welcomed other potential EasyWater customers to visit his facility as a showcase for EasyWater products.

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The GEO Group: South Florida Evaluation & Treatment Center

The GEO Group: South Florida Evaluation & Treatment Center

The GEO Group: South Florida Evaluation & Treatment Center

  • Customer: The GEO Group
  • Project: South Florida Evaluation & Treatment Center
  • Scope of Work: Cooling tower treatment, closed loop chilled and hot water treatment and domestic water treatment
  • EasyWater Equipment:
    • 1 x SmartGuard RO Model 60000 treating the cooling tower
    • 1 x CTF100 System treating the cooling tower
    • 5 x EasyWater No-Salt Conditioners treating the domestic water
    • 1 x EasyWater Series C Closed Loop Treatment System treating the closed loop chilled water

Problem

The GEO Group’s South Florida Evaluation & Treatment Center had a water hardness of about 18 grains and a very warm climate. For years, the facility struggled with:

  • Scaling in domestic water heaters, mixing valves, plumbing, etc.
  • Scaling in the cooling tower and chiller condenser tubes
  • Excessive particulate in cooling tower water and high bacteria counts
  • High chemical usage/cost in cooling tower system
  • Corrosion-related high-iron content deposits in their closed loop chilled water system

Complete Treatment Solution

EasyWater installed their No-Salt Conditioners on the hot and cold domestic water system, SmartGuard RO and CTF (Cooling Tower Filtration) Systems to treat the cooling tower, and Series C Closed Loop Treatment System on the closed loop chilled water system.

On the domestic water side, the No-Salt Conditioners slowly removed existing scale from piping, water heaters and mixing valves, and have saved considerable maintenance throughout the facility.

SmartGuard RO and CTF Systems removed existing scale deposits in the cooling tower and condenser tubes, as well as provided protection from future scale build-up. The CTF System cleaned the cooling tower water to very low particulate and bacteria levels while using only a small fraction of the biocide chemicals used previously.

The Series C Closed Loop Treatment System provided excellent results, removing existing high- iron content deposits and allowing GEO to operate without chemicals at very low corrosion rates.

This is one of many successful EasyWater projects with GEO Group.

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