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  Introduction | Feasibility Study |  Specifications |  Air as Feed Gas |  Drawings |  Reference BRIEF SPECIFICATIONS FOR OZONE SYSTEM FOR COOLING TOWER APPLICATION
(USE THESE SPECS FOR OZONE GENERATORS LESS THAN 6.50 LBS PER DAY)

(Text shown in Italic script is to be completed by the consultant/client)

SYSTEM SPECIFICATIONS

  1. Condenser water system shall be provided with controlled and regulated system of ozone injection to achieve scale suppression on condenser tubes and condenser water piping, corrosion inhibition, and control of microbial growth in water and in drift air from cooling tower.
  2. Ozone treatment shall be a stand alone treatment, and shall not use any form of supplementary addition of any type of chemical.
  3. Cycles of Concentration of condenser water shall be not less than 17 based on conductivity of tower basin water based on POSI less than 0.20 for available make up water. The tower water POSI shall be maintained less than 1.0.
    POSI = Practical Ozone Scaling Index

    (Provide water quality analysis. If TDS in water is high, provide softening plant)


  4. Concentration of ozone in condenser water system shall be;
    1. In the tower basin: 0.10 to 0.25 PPM.
    2. Prior to entry to condenser: 0.10 to 0.15 PPM.
    3. At entry to tower spray nozzles: 0.01 to 0.05 PPM.
  5. Microbial and algae level in the tower basin shall not be greater than 1000 CFU per milli Liter
  6. Corrosion in the system shall not be higher than: 0.3 milli In per year for copper and 5 milli In per year for steel.

    EQUIPMENT AND COMPONENT DETAILS

    OZONE GENERATOR
  7. Ozone generated shall be of maximum concentration 2 to 3% wt/wt in air, with air as feed gas. Oxygen as feed gas is not permissible, and shall not be used.
  8. Ozone generation and variation of ozone output shall be at constant line frequency of 60 (or 50 Hz). Modulation of ozone by frequency variation is not permissible.
  9. The equipment is housed indoor. The ozone generator shall be skid mounted, integrally piped and wired with external connections for wiring and piping connections on site.
  10. All pipes in contact with ozone shall be SS316L. All other devices in contact with ozone shall be SS316L, glass silicone, PVDF.
  11. All electrical component shall confirm to CSA, NEC and UL ratings. The generator shall be suitable for operation on 220 V, 3 ø, 60 Hz (380V - 410V, 3 ø 50 Hz). Power density shall not exceed 0.30 watts per sq.cm of effective dielectric surface area.
  12. All electrical components shall be integrally mounted in a high voltage electrical enclosure compartment, attached to the generator skid. All necessary power control package shall be mounted in this enclosure. This compartment shall be provided with two doors for easy access and safety . Each door shall be provided with lock and contact switch to prevent opening of door when unit is in operation. The housing shall be suitably ventilated. The power train shall be equipped with necessary components to protect against electrical surges. The transformer used shall be dry type.
  13. Ozone production rate shall be continuously variable over the operating range. The system shall be designed to operate continuously, 24 hours a day, 365 days a year. Ozone generator shall have pre wired power control system capable of modulating ozone output from between 10% and 100% of the maximum design output
  14. Minimum of 1/4" (6mm) thick PVC plate shall be used to separate the power compartment form generator compartment. All doors shall have a locking hardware and safety switch to prevent door opening when the generator is in operation.
  15. The power train shall confirm to UL and CSA ratings.
  16. Following minimum components shall be mounted in the power compartment; Circuit breaker, variable motor driven transformer for automatic and remote variation of ozone, inductor, HT transformer, voltmeter to read production rate.
  17. Control panel shall be integral to the main cabinet, and provided with switches for: Air preparation On/Off, Ozone production On/Off.
  18. Following controls shall be unit mounted: Rotometer to read air flow, Pressure regulator to control air pressure, pressure gauge to read air pressure.
  19. The generator shell shall be fabricated of SS 316, consisting cylindrical housings for the dielectrics. Dielectrics shall be mounted vertically. Acrylic view port 1" thick shall be mounted on the tube shell to view the corona. All gaskets shall be fabricated of silicone, hypalone or teflon.
  20. The generator shall be designed to operate at 15 psig on air side.
  21. All devices in contact with ozonized air shall be of SS 316, glass, silicone, pvdf, viton, or teflon.
  22. The shell shall be provided with integral cooler to cool temperature of air incoming from the compressor, prior to entry to desiccant dryer. When chilled water is used as the cooling medium, it also serves to remove moisture from entering air.
  23. The generator shell shall be cooled by chilled water, temperature 45°F (If chilled water is not available, substitute this with water temperature not higher than 65°F)

    INSTRUMENTS, CONTROLS & VALVES
  24. Pneumatically operated spring assisted back flow preventor shall be provided on the ozone pipe to prevent reverse flow of injection water to the generator, and on the air flow line to prevent reverse flow of ozone to air pipes. They shall be located in the ozone generator cabinet and shall be factory piped.
  25. Air flow transmitter output with 4 -20mA output and air flow rotameter shall be used to indicate volume of airflow.
  26. Outlet devices shall include high low air pressure safety shut down switch, pressure relief valve, ozone temperature sensor with high temperature safety shutdown, flow regulator valve, ozone sample valve, electrically operated solenoid valve, water flow rotameter, high water temperature safety shut down and low water flow switch on the cooling water circuit.

    AUTOMATION, CONTROLS, AND SAFETY DEVICES
  27. Ozone generator shall be provided with motorized powerstat to allow automatic variation of ozone output from 10% to 100% of the full capacity.
  28. Ozone generator shall be provided with microprocessor controller.
  29. Side stream injection system shall be provided with ORP sensor and controller. Based on the ORP of the water sensed, it provides 4 to 20 milli Amps signal to the micro processor, which in turn modulates the generator. The ORP controller also provides visual digital readout of the ORP in milli Volts.
  30. Conductivity sensor and controller shall be provided in the Side stream piping. It shall provide 4 to 20 milli Amps output. Based on set value of the conductivity, it automatically controls the electric solenoid valve on the blow down line of the cooling tower. Conductivity monitor also provides visual digital indication of conductivity in Micro Mho.
  31. Adjustable time delay device to delay start between compressor and generator. This is actuated by the micro processor.
  32. Pneumatic solenoid valve mounted in series with back flow preventor valve to provide rapid and positive shut off in the ozone injection line.
  33. Ozone generator shall be provided with a port with shut off valve on the air intake stream, to enable the field installation contractor to provide compressed air to operate the pneumatic solenoid valve.
  34. High low level switch in the tower basin to regulate the rate of out flow of blow down water. This is not a factory supplied item, and shall be field provided by the installation contractor.
  35. All monitors shall provide 4 to 20 milli Amps output which may be input to the BMS system, if used.
  36. Adequate electrical interlocks shall be provided between the air compressor, ozone generator, and injection water pump, as will be shown in the electrical circuit diagram.
  37. The system shall be designed for continuous operation, pre wired for modulating ozone output from between 10% and 100% of the maximum design output.
    Dew point monitor, with alarm and cut out, 4 to 20 mA shall be used to shut off the generator, in the event adequate DP temperature is not attained. This also provides digital visual indication of Dew Point Temperature (DPT). It shall be suitable for operation of DPT down to -90°F (to equivalent atmospheric pressure). This is recommended though not used for all projects
  38. Corrosion coupon rack with coupon holders for copper and steel shall be provided, with initial supply of coupons. It shall be complete with constant flow orifice device

    AIR COMPRESSOR
  39. Air compressor with ASTM receiver with pressure relief valve rated for continuous operation, sized to provide adequate air flow for generation of ozone with allowance for loss of air to purge the desiccant dryer and for reduction in volume experienced after removal of moisture. Compressor shall be reciprocating type (screw type or scroll).
  40. Air Preparation package shall comprise prefilter to 1 micron, coalescent filter to 0.01 micron particle and 0.01 micron oil removal and after filter to 1 micron, and twin tower pressure swing heatless desiccant dryer for dryness to dew point temperature of -70°C at 90 PSIG. Quality of air should meet ISO 8573-1; clause 1.1.1.

    INJECTION WATER SYSTEM
  41. Vertical Loop method shall be used to inject produced ozone into the water stream. Side stream injection water shall be raised by a vertical loop to a point where the pressure in the water is lowered sufficient to allow injection of produced ozone into the water stream. Pressure gauges shall be provided at both ends of the vertical loop. Pneumatic, quick shut off valve and back flow preventor valves shall be provided in the ozone injection line to prevent reverse flow of water into the ozone generator.

    (This applies to plants 5 Lbs/Day and larger. For plants less than 5 Lbs/Day, use the following injector)

    Injection of ozone into the water stream shall be by venturi injector. Pressure differential switch shall be provided to ensure the venturi develops the necessary pressure difference to inject ozone into the stream. In the event this is not achieved, the pressure differential switch shall shut down the pneumatic back flow preventor valve and the ozone generator to ensure injection water does not flow into the generator. Back pressure from the down stream of the venturi shall be adequate to return water to the tower basin and distribute the same in the basin

  42. Injection water pump shall be close coupled, centrifugal pump, CI casing, steel shaft with SS 316 sleeve, bronze impeller, and EPDM seal.
  43. Commissioning and balancing of the system shall be done by factory trained technicians.

    PLANT CAPACITY:

  44. Ozone Generator: xxx Lbs/Day.
  45. Side stream injection water pump: xxx US GPM at 20 psig.
    (xxx GPM at 20 psig if venturi injector is used).
  46. Air compressor: xxx Scfm at FAD discharge pressure 140 psig.

    RECOMMENDED MANUFACTURER
  47. Ozone generators shall be of make Ruks Hankin Ozone Systems, Canada


BRIEF SPECIFICATIONS FOR OZONE SYSTEM FOR COOLING TOWER APPLICATION

(USE THESE SPECS FOR OZONE GENERATORS 7 LBS/DAY AND LARGER)

(Text shown in Italic script is to be completed by the consultant/client)

SYSTEM SPECIFICATIONS
  1. Condenser water system shall be provided with controlled and regulated system of ozone injection to achieve scale suppression on condenser tubes and condenser water piping, corrosion inhibition, and control of microbial growth in water and in drift air from cooling tower.
  2. Ozone treatment shall be a stand alone treatment, and shall not use any form of supplementary addition of any type of chemical.
  3. Cycles of Concentration of condenser water shall be not less than 17 based on conductivity of tower basin water based on POSI less than 0.20 for available make up water. The tower water POSI shall be maintained less than 1.0. POSI = Practical Ozone Scaling Index

    (Provide water quality analysis. If TDS in water is high, provide softening plant)


  4. Concentration of ozone in condenser water system shall be;
    1. In the tower basin: 0.10 to 0.25 PPM.
    2. Prior to entry to condenser: 0.10 to 0.15 PPM.
    3. At entry to tower spray nozzles: 0.01 to 0.05 PPM

  5. Microbial and algae level in the tower basin shall not be greater than 1000 CFU per milli Liter
  6. Corrosion in the system shall not be higher than: 0.3 milli In per year for copper and 5 milli In per year for steel.

    EQUIPMENT AND COMPONENT DETAILS

    OZONE GENERATOR

  7. Ozone generated shall be of maximum concentration 2 to 3% wt/wt in air, with air as feed gas. Oxygen as feed gas is not permissible, and shall not be used.
  8. Ozone generation and variation of ozone output shall be at constant frequency. Modulation of ozone by frequency variation is not permissible.
  9. The equipment is housed indoor. The ozone generator shall be skid mounted, integrally piped and wired with external connections for wiring and piping connections on site.
  10. Ozone generator shell shall be fabricated of SS 316 L consisting removable head, 1" thick acrylic view port for visual monitoring of corona, vertical cylindrical housing corona tubes of SS316L. Each cylinder shall be provided with tri-clamp nozzle for air inlet. All gasket shall be fabricated of silicone, hypalon or teflon. The generators shall have ports for air inlet, ozone outlet, chilled water inlet and outlet and drain. Dielectric tubes shall be fabricated of alumina glass, and metalized with aluminum by plasma coating, to provide high efficiency dielectric. Each tube shall be independently protected by a H.T fuse.
  11. All pipes in contact with ozone shall be SS316L. All other devices in contact with ozone shall be SS316L, glass silicone, PVDF.
  12. All electrical component shall confirm to CSA, NEC and UL ratings. The generator shall be suitable for operation on 380V - 410V, 3 ø 50 Hz. Power density shall not exceed 0.30 watts per sq.cm of effective dielectric surface area.
  13. Power supply unit transformers shall be dry type , class F insulated with a high temperature cutout for each phase, suitable for operation in 104°F (40°C) ambient, with temperature rise not higher than 122°F (50°C)
  14. The PSU shall consist of the following components as a minimum, all factory wired, assembled and tested.
    1. 3 phase harmonic filter to minimize total harmonic distortion.
    2. Three phase isolating transformer.
    3. Three phase fully controlled rectifier with snubbers and MOV=s (Metal oxide Varistors) on each side
    4. DC filter bank
    5. IGBT inverter assembly complete with snubbers
    6. Medium frequency oscillating circuit with over current and over voltage protection
    7. Medium frequency dry-type transformer
  15. If operation is on medium frequency, each Power Supply Unit shall have frequency electronic protection consisting rectifiers or invertors over current protection, over voltage protection at the IGBT modules, and high voltage short circuit protection.
  16. The ozone generator shall be provided with emergency stop button with keyed lock out.

    INSTRUMENTS, CONTROLS & VALVES
  17. Pneumatically operated spring assisted back flow preventor shall be provided on the ozone pipe to prevent reverse flow of injection water to the generator, and on the air flow line to prevent reverse flow of ozone to air pipes. They shall be located in the ozone generator cabinet and shall be factory piped.
  18. Air flow transmitter output with 4 -20mA output and air flow rotameter shall be used to indicate volume of airflow.
  19. Outlet devices shall include high low air pressure safety shut down switch, pressure relief valve, ozone temperature sensor with high temperature safety shutdown, flow regulator valve, ozone sample valve, electrically operated solenoid valve, water flow rotameter, high water temperature safety shut down and low water flow switch on the cooling water circuit.

    MICROPROCESSOR CONTROL SYSTEM
  20. The system shall be provided with microprocessor based controllers with EPROM resident software, housed in NEMA 12 steel enclosure with operator controls on the front.
  21. It shall be possible to operate the generator on automatic, semi automatic or manual modes. In the automatic mode, the system shall be capable of modulating ozone production to maintain a constant set ORP level. Semi auto mode shall allow the operation to set the power level through keypad.
  22. The microprocessor shall accept one analog input signal (4-20mA). This signal can then be used by the ozone generator to control production in the automatic mode.
  23. The control unit shall be capable of showing the following status indications on a 16 character display:
    1. Gas supply, on
    2. Minimum power
    3. Maximum power
    4. High gas temperature
    5. High Dew point
    6. Low gas flow
    7. Low cooling water flow
    8. High cooling water temperature
    9. Dielectric failure
    10. Low gas pressure
    11. High temperature, ozonized air
    12. PSU fault
    13. RTD temperature sensor
    14. Power train door ajar
    15. Ozone concentration, if ozone analyzer is installed
    16. Ozone production, if ozone analyzer is installed
    17. Ozone concentration set point
    18. Automatic control set point
    19. Treated water flow rate
    20. Dew point, if DP transmitter is installed
    21. Cooling water exit temperature
    22. Ozonized gas exit temperature
    23. Gas flow rate
    24. Generator voltage
    25. Generator current
    26. Generator power

  24. The system shall be designed for continuous operation, pre wired for modulating ozone output from between 10% and 100% of the maximum design output.

    AIR COMPRESSOR
  25. Air compressor with ASTM receiver with pressure relief valve rated for continuous operation, sized to provide adequate air flow for generation of ozone with allowance for loss of air to purge the desiccant dryer and for reduction in volume experienced after removal of moisture. Compressor shall be reciprocating type (screw type or scroll).
  26. Refrigerant dryer shall be used to remove bulk of the moisture. It shall be direct expansion refrigeration unit, with environmentally acceptable refrigerant.
  27. Air Preparation package shall comprise prefilter to 1 micron, coalescent filter to 0.01 micron particle and 0.01 micron oil removal and after filter to 1 micron, and twin tower pressure swing heatless desiccant dryer for dryness to dew point temperature of -70°C at 90 PSIG. Quality of air should meet ISO 8573-1; clause 1.1.1.

    INJECTION WATER SYSTEM
  28. Vertical Loop method shall be used to inject produced ozone into the water stream. Side stream injection water shall be raised by a vertical loop to a point where the pressure in the water is lowered sufficient to allow injection of produced ozone into the water stream. Pressure gauges shall be provided at both ends of the vertical loop. Pneumatic, quick shut off valve and back flow preventor valves shall be provided in the ozone injection line to prevent reverse flow of water into the ozone generator.
  29. Injection water pump shall be close coupled, centrifugal pump, CI casing, steel shaft with SS 316 sleeve, bronze impeller, and EPDM seal.

    AUTOMATION, CONTROLS, AND SAFETY DEVICES
  30. The system shall be capable of operating automatically based on output from the microprocessor provided by ORP and Conductivity controller, or manually, at the option of the user.
  31. (The system shall be capable of operating through BMS system. Necessary transponders to communicate to BMS shall be provided by the BMS Vendor). Insert this Clause if BMS is used in the project.
  32. Side stream injection system shall be provided with ORP and conductivity sensors and controller with 4 to 20 mA signal. ORP signal shall be used to modulate ozone output, and conductivity signal to activate tower blow down, automatically.
  33. Dew point monitor, with alarm and cut out, 4 to 20 mA shall be used to shut off the generator, in the event adequate DP temperature is not attained. This also provides digital visual indication of Dew Point Temperature (DPT). It shall be suitable for operation of DPT down to -90°F (to equivalent atmospheric pressure). This is recommended though not used for all projects, as it adds to the cost. Apply this clause only if adequate safety is desired.
  34. All monitors shall provide 4 to 20 mA output which may be input to the BMS system, if used.
  35. Adequate electrical interlocks shall be provided between the air compressor, ozone generator, and injection water pump, as will be shown in the electrical circuit diagram.
  36. Commissioning and balancing of the system shall be done by factory trained technicians.
  37. Corrosion coupon rack with coupon holders for copper and steel shall be provided, with initial supply of coupons. It shall be complete with constant flow orifice device.

    PLANT CAPACITY:

  38. Ozone Generator: xxx Lbs/Day.
  39. Side stream injection water pump: xxx US GPM at 20 psig. (xxx GPM at 20 psig if venturi injector is used).
  40. Air compressor: xxx Scfm at FAD discharge pressure 140 psig.

    RECOMMENDED MANUFACTURER

  41. Ozone generators shall be of make Ruks Hankin Ozone Systems, Canada

Introduction | Feasibility Study |  Specifications |  Air as Feed Gas |  Drawings |  Reference

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