COOLING TOWER AND PLANT-WIDE WATER SYSTEMS
TECHNICAL SPECIFICATIONS

The following information has been prepared for your use in planning and evaluating a HYDROLATOR DEMONSTRATION installation. Before you start, please watch our sound/slide CD presentation.

SYSTEMS DESCRIPTION

(1) HYDROLATOR's high intensity magnetic fields are produced by specially formulated ceramic type permanent magnetic blocks of extreme strength and long life. In rack mounted configurations for cooling towers, the scheme involves capturing water flow directly through the racks which creates the desired charge for either once through or re-circulating water. These racks are housed in custom fabricated dams which raise water level in the cooling tower a few inches to allow fast flow through the racks. Alternatively, a holding frame can be fitted at the exit of the cooling tower leading to the pumps. In some cooling towers, water is supplied to distribution pans where HYDROLATOR racks can be installed without interfering with uniform flow requirements.  A water box unit is also available for insert into the entry pipe.  All systems are configured for maximum, safe electrical charge generation to meet the requirement of the application.

(2) CONSTRUCTION - The number of units used and the field strength are computed according to flow characteristics, type and quality of water systems to be treated. Also, plant operating requirements and characteristics are taken into consideration. Magnetic rack assemblies are mounted in stainless steel of sufficient gauge and strength to facilitate fabrication and long service life. Exterior magnetic blocks are clad in galvanized covers fitted to pipe size. These covers are fabricated to enhance magnetization of steel piping while providing for a quick and easy installation. All HYDROLATOR equipment is Life-Of-Plant guaranteed for performance as well as workmanship.

(3) EXTERNAL POWER REQUIREMENTS - None. Energy for proper function is supplied by plant pumps which force the water through the permanent magnetic field which induces the required voltage.

(4) CAPACITY - All HYDROLATOR magnetic systems are designed to provide the correct amount of electrostatic charge to the water to insure more than adequate protection to plant. For proprietary reasons, no magnetic material composition, design characteristics, energy information nor field strength data are available.

INSTALLATION PROCEDURE FOR COOLING TOWER

(1) SITE SURVEY - Before installation, a HYDROLATOR representative will trace and spec out the water distribution system(s). In addition, water analysis and flow rates will be noted. Plant operation conditions such as water source and water quality changes will be taken into account.

(2) INSTALLATION - HYDROLATOR systems are shipped or brought to the job site where they are to be installed. No welding or piping changes are necessary except where inserts are used, an anchoring tack weldment may be necessary. For the racks mounted in cooling tower distribution pans or exit flumes pipe installations, HYDROLATOR Systems are of such design as to allow installation while the plant is operating. Installation time varies with size of plant, configuration and system conditions, usually 2 to 4 hours for small plants, longer for large plants and where special fittings are required. For overhead application, a man-lift and/or ladder(s) are necessary. Two customer employees should be available to assist during installation. Location of installed HYDROLATOR systems in a re-circ system is irrelevant, since the entire bulk water system develops the same charge. For once-through, the HYDROLATOR insert unit is installed at the entry pipe opening to the condenser water box.

COOLING WATER SYSTEMS - OPERATION AND MAINTENANCE

(1) CHEMICALS - All chemicals such as corrosion inhibitors, descalers should be discontinued with the exception of bromine and/or chlorine compounds for bio-fouling control in cooling tower water or industrial water. Experience has shown that after clean-up a reduction of up to 80% or more in the cost of biocides is possible due to the enhancement of the biocidal effect when used in conjunction with the HYDROLATOR system. After clean-up, inexpensive chlorine or bleach can be fed as needed, but occasional shocking with bromine may be necessary, especially during clean-up, to avoid resistant strain formations. Bleach or chlorine should continue to be fed for faster clean-up of a biological and chemically fouled system. The HYDROLATOR electrical charge inhibits corrosion 5 to I over expensive buffered biocide use.

(2) VISUAL MONITORING - In the first 30-60 days, recirculating bulk water may change color indicating that the HYDROLATOR system is cleaning up former scale deposits and bio-fouling. These old scale deposits are then dispersed by the HYDROLATOR influence and broken down to minute crystals which settle out in the areas of low flow velocity such as the cooling tower basin. Depending on the amount of scale and bio-fouling in the system, the clean-up can take months. Operators may notice lowered operating temperatures during later stages of clean-up. However, clean-up time will be lengthened by high content of chemical residue or heavy bio-fouling which could take months to produce results. If plant is heavily fouled, operators should be prepared for "crud bursts" or avalanche effect of scale or bio-fouling dissolution. If your cooling tower supplies your service water loop, then components must either be protected with screens (which need to be cleaned more often) or an aggressive blow-down schedule maintained until the system is clean of the old chemical/mineral scale then converted to loose, purgeable sludge by the HYDROLATOR action. At installation time, you may want to scrape a test patch to monitor the de-scaling process.

(3) OTHER CHANGES TO EXPECT - Turbidity readings will rise immediately after installation indicating aggressive dissolution of deposits.  Turbidity will rise and fall, indicating crud bursts and cleaning of the system. If you use corrosion coupons or in-line electronic monitoring, you will probably see a sharp increase in corrosion early in the clean-up phase. This is due to the interaction of de-scaled chemical residue with the electrical charge in the water. This is common and not cause for alarm. Any bare (new) metal sample will show corrosive attack in HYDROLATOR descaled systems. Tests show no corrosion activity for plant surfaces. (Ask for our Virginia Power Study)

(4) SURFACE TENSION - (more accurately: inter-molecular tension) appears to be weakened by the HYDROLATOR charge! Proof: On a still day, swimming pools and "quiet" cooling tower basins (BAC type, etc.) lose boundary or margin and water surface becomes invisible. In order to see where the surface is, one must actually touch the water !! This is often seen phenomenon explains why solids drop out faster in HYDROLATOR controlled systems. Also, the wetter water provides more effective direct contact heat transfer between water and metal surface. Finally, nucleation of aragonite and other minerals have been seen to occur on clean tube surfaces. This phenomenon increases turbulence at the water/metal junction, which action is known to further enhance heat transfer.

(5) COOLING TOWERS - From our experience, all cooling towers are fouled to some degree by use of chemicals. Usually a black or green slime or algae grows on clean or scaled surfaces. This is because chemical treatment, however well performed, cannot remove scale and bio-fouling while at the same time inhibiting corrosion! The HYDROLATOR Electric Water Treatment System is the only known technology able to control both in large industrial water systems! All water flowing surface areas of your cooling tower will clean to bare surface and remain clean for the life of your plant, provided biocide is fed as needed.

(6) CONDENSERS - For power plant operators, lower fuel costs and/or increase in production will be noted because of cleaner tube surfaces and wetting action provided by the HYDROLATOR charge. Condensers and cooling towers get cleaner than possible even with the best chemical treatment program.

(7) HEAT EXCHANGERS - If already fouled, heat exchangers, condensers, and component coolers should all show an increase in heat transfer. If already clean, they should remain clear and require no additional cleaning. All of the other heat exchangers in the same cooling water stream are cleaned/protected as well. Further, users see better performance from heat exchangers and condensers they thought were clean at the outset! HYDROLATOR systems are applied externally along smaller diameter (6" or less) piping or by placing rack mounted magnets directly into the water stream. Externally mounted systems are clad with covers along the length of piping to generate an electrostatic charge along whole portions of the loop or component section as required. An alternate method is to insert a magnetic assembly into the pipe on the discharge or suction side of the pump.

(8) OPERATING RANGE OF THE HYDROLATOR SYSTEM - In actual tests, the HYDROLATOR system has shown substantial control of corrosion and fouling in ph range extremes of 3-11, and conductivity ranges from 5-20,000 micro-mhos, well beyond the fragile "window" of chemical treatment. The electrostatic charge-up time for bulk water varies but usually takes several hours to several days depending on the foulant mass. If the HYDROLATOR system should be removed or bypassed for any reason, the plant will still operate with protection because even though the impressed voltage decays over time(3-15 days) the, "passivated" surfaces will continue to be protected. Specifically, if pumps are shut off, the electrostatic protection will continue for several weeks even though no voltage is being generated. However, lay-up times are usually of short duration and monitoring of short term laid-up systems have shown negligible corrosion activity during these times.

(9) ENGINEERING SUPPORT - HYDROLATOR has representation in each market it serves world-wide. All engineering design construction, installation, training and support are provided wherever customer assistance is required.  For further information contact Ted Light (410) 352-5524.