Innovas Technologies http://innovastechnologies.com Mon, 20 Nov 2017 06:00:00 +0000 en-US hourly 1 https://wordpress.org/?v=4.8.3 Full Cooling Season Review: George Mason University http://innovastechnologies.com/full-cooling-season-review-george-mason-university/ http://innovastechnologies.com/full-cooling-season-review-george-mason-university/#respond Mon, 16 Oct 2017 21:03:27 +0000 http://innovastechnologies.com/?p=1099168 Its commonly understood that adopting new technologies and processes can be difficult for some organizations.  However, in today’s “technology tsunami” environment, new innovations are key to all organizations’ competitiveness.  The cycle of innovation is now so rapid that it is creating a new leadership perspective focused on harnessing the opportunities brought by new technology instead […]

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Its commonly understood that adopting new technologies and processes can be difficult for some organizations.  However, in today’s “technology tsunami” environment, new innovations are key to all organizations’ competitiveness.  The cycle of innovation is now so rapid that it is creating a new leadership perspective focused on harnessing the opportunities brought by new technology instead of managing the diminishing stability of the status quo.  George Mason University is taking the lead in this arena as demonstrated by the University’s adoption of new chiller optimization tools.

In May, 2017 we highlighted GMU’s employment of the Helios Tube Cleaning Systems (Helios TCS) in one of their chilled water facilities as it worked side by side with a traditionally run chiller.  The season is now coming to conclusion and the results are profound.  Following is a chart that highlights the approach temperature differences between the Helios TCS operated chiller and the non-Helios chiller.   The differences speak volumes. The cost savings are clear.

Helios TCS Operating on GMU 1400 Ton Chiller

Actual GMU 2017 COndenser Approach Comparison – Helios TCS vs. Non-Helios TCS

The above chart shows chiller 9 (Non-Helios) handicapped with progressively growing approach temperatures (Increased inefficiency & Cost) due to fouling compared with chiller 10 that employs the Helios TCS. Chiller 10 demonstrates “Flatline” approach temperatures maintaining at less than .5 degrees because of the automated Helios.  Obviously, chiller 10 has clean tubes and chiller 9 has developed fouling accumulation during the season.  It’s clear that the costs to operate chiller 9 are dramatically higher due to traditional fouling not to mention the increased potential for Microbiological Induced Corrosion (MIC) and the burdens of manual cleaning.  Regarding manual cleaning?  Seems an ineffective and costly habit.

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Innovas Project Update: George Mason University http://innovastechnologies.com/innovas-project-update-george-mason-university/ http://innovastechnologies.com/innovas-project-update-george-mason-university/#respond Tue, 30 May 2017 17:22:45 +0000 http://innovastechnologies.com/?p=916182 The first Helios TCS automatic tube cleaning system installation was completed at George Mason University (GMU) during the first quarter of 2017.  GMU has taken an aggressive approach towards efficiency and innovation, and in their investigative process realized that their chillers were a great opportunity for obtaining cost saving improvement.  Encouraged by observing the success the […]

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The first Helios TCS automatic tube cleaning system installation was completed at George Mason University (GMU) during the first quarter of 2017.  GMU has taken an aggressive approach towards efficiency and innovation, and in their investigative process realized that their chillers were a great opportunity for obtaining cost saving improvement.  Encouraged by observing the success the University of Virginia has achieved with the Helios TCS condenser tube cleaning systems, GMU installed a single Helios TCS on a 1400-Ton chiller in their central cooling plant.

Chiller Automatic Tube Cleaning SystemHelios TCS Installed on 1400 Ton Trane Chiller at George Mason University

The early results have been very good with improved approach temperatures compared to previous year’s operation and better than design values.  Considering the successes already observed and the path to a 2.3-year simple project payback, GMU has decided to add an additional Helios TCS immediately to the neighboring 1400-ton chiller and is pressing forward with benchmark-related initiatives focused on optimizing chiller efficiency and quality of chilled water plant operations.

                             Helios TCS Skid Installed at GMU                     Helios TCS Collector Installed at GMU

Initially, GMU studied the Helios concept very thoroughly as it represented a profoundly different approach than periodic manual cleaning, and they wanted to ensure that no undue operational risk was present with the automatic tube cleaning system.  To the contrary, they have discovered that in the old-fashioned status quo habit of manual cleaning they were wasting significant amounts of time, money and maintenance effort.  As an added benefit, GMU anticipates increased cooling capacity as the months turn warmer.   Innovation leads to success in many ways and GMU is leading they way into the future as a successful innovator.

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Innovas Technologies Gets A Write-up In The Corridor Business Journal http://innovastechnologies.com/innovas-technologies-gets-write-corridor-business-journal/ http://innovastechnologies.com/innovas-technologies-gets-write-corridor-business-journal/#respond Thu, 27 Apr 2017 12:54:31 +0000 http://innovastechnologies.com/?p=877358 The post Innovas Technologies Gets A Write-up In The Corridor Business Journal appeared first on Innovas Technologies.

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Great article about Innovas Technologies in the Corridor Business Journal by staff reporter Dave DeWitte. The article outlines a bit of our history and financing and looks into our efforts to develop an intelligent sensor ball for monitoring the internal environment of heat exchanger systems. Read the article here or download a PDF below.

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IDEA Campus Energy 2017 Trade Show & Conference http://innovastechnologies.com/idea-campus-energy-2017-trade-show-conference/ Tue, 10 Jan 2017 17:28:02 +0000 http://innovastechnologies.com/?p=731985 JOIN US FEBRUARY 20 – 24, 2017 AT THE HYATT REGENCY MIAMI FOR INTERNATIONAL DISTRICT ENERGY ASSOCIATION’S CAMPUS ENERGY 2017 CONFERENCE, “A SUSTAINABLE FUTURE”  WE LOOK FORWARD TO SEEING YOU IN MIAMI, FL! Innovas Technologies will be attending the International District Energy Association’s Campus Energy 2017 conference in Miami, FL, and we are excited to […]

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JOIN US FEBRUARY 20 – 24, 2017 AT THE HYATT REGENCY MIAMI FOR INTERNATIONAL DISTRICT ENERGY ASSOCIATION’S CAMPUS ENERGY 2017 CONFERENCE, “A SUSTAINABLE FUTURE”  WE LOOK FORWARD TO SEEING YOU IN MIAMI, FL!

Innovas Technologies will be attending the International District Energy Association’s Campus Energy 2017 conference in Miami, FL, and we are excited to have the opportunity to deliver a presentation alongside the University of Virginia about their experiences with the Helios Tube Cleaning System and how it has become “Best Practice” in their campus chilled water plants.  Our presentation is titled, “Optimizing Chiller Efficiencies via Innovative Tube Fouling Prevention” and is scheduled for Thursday, February 23rd.  The full conference schedule can be found here.

 

Innovas will also be exhibiting at the conference, so please be sure to stop by table #71 to visit with us and see our latest product demonstrations and project updates.  We hope to see you there!

 

About IDEA Campus Energy Conferences: For more than 100 years, IDEA conferences have been at the vanguard of the district energy industry. With a focus on peer exchange, best practices and sustainable solutions, the IDEA Campus Energy Conference has proven invaluable for connecting like-minded campus utility professionals and keeping pace with new information. Since campus professionals face many of the same challenges in planning and operating efficient, reliable campus utilities, this conference provides an atmosphere of open exchange and collaboration that is focused and unique, yet maintains an incredible scope.

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Innovas Project Update: Memorial Hospital of South Bend http://innovastechnologies.com/innovas-project-update-south-bend-memorial-hospital/ Mon, 09 Jan 2017 20:40:56 +0000 http://innovastechnologies.com/?p=730673 Innovas recently commissioned Helios Tube Cleaning Systems at Memorial Hospital of South Bend, servicing eight Trane chillers, including four new 900-ton chillers and retrofits to four existing chillers.  The chilled water plant provides more than 5,600 tons of cooling capacity for Memoral Hospital of South Bend and the adjacent Memorial Children’s Hospital. As part of the […]

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Innovas recently commissioned Helios Tube Cleaning Systems at Memorial Hospital of South Bend, servicing eight Trane chillers, including four new 900-ton chillers and retrofits to four existing chillers.  The chilled water plant provides more than 5,600 tons of cooling capacity for Memoral Hospital of South Bend and the adjacent Memorial Children’s Hospital.

As part of the chilled water plant expansion and upgrade project, geothermal capability was added to the energy center, allowing the chillers to utilize either ground source cooling or existing cooling towers.  This enables the facility to leverage the local groundwater cooling source and greatly reduce chilled water plant energy consumption.

2nd-floor-helios-tcs

As pictured above, the four new Trane 900-ton chillers are serviced by a single Helios TCS skid, with each chiller having an independent collector and ball trap. The chillers are equipped with head pressure control and variable condenser water flow to enable the use of geothermal cooling from local groundwater.  Accordingly, the Helios TCS controls were integrated with the building automation system (BAS) and chiller controls to ensure coordinated chiller and Helios TCS operation.

1st-floor-helios-tcs

In the existing mechanical room, a second Helios TCS skid was installed as part of the project and services the four existing chillers.  Two 900-ton Trane centrifugal chillers and two 140-ton Trane screw chillers were retrofit with independent collectors and ball traps.   Geothermal cooling capability was added to these chillers as part of the chilled water plant expansion project.

The project was engineered by Heapy Engineering of Dayton, OH with general construction management and oversight by Balfour Beatty Construction, and the Helios TCS were bundled with chillers supplied by Solid Blend Technologies and Trane of South Bend.  Close coordination and communication by all parties involved was a crucial component in this incredibly successful project.

 

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Innovas Technologies LLC Awarded Competitive Grant from the National Science Foundation http://innovastechnologies.com/innovas-technologies-awarded-grant-from-the-national-science-foundation/ Fri, 06 Jan 2017 02:36:25 +0000 http://innovastechnologies.com/?p=724368 Coralville, Iowa  – Innovas Technologies has been awarded a National Science Foundation (NSF) Small Business Innovation Research (SBIR) grant for $225,000 to conduct research and development (R&D) work on developing mobile micro-sensors to identify degradation, fouling and enable remote failure detection and isolation in operating shell and tube heat exchangers. Innovas Technologies will develop a […]

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Coralville, Iowa  – Innovas Technologies has been awarded a National Science Foundation (NSF) Small Business Innovation Research (SBIR) grant for $225,000 to conduct research and development (R&D) work on developing mobile micro-sensors to identify degradation, fouling and enable remote failure detection and isolation in operating shell and tube heat exchangers.

Innovas Technologies will develop a mobile, submersible micro-sensor system designed to address fouling and failure in shell and tube heat exchangers.  This new technology aims to enable optimal efficiency and maximize heat exchanger operating life by continuously detecting tube failure, capturing unusual vibration signatures, and providing finite speed and temperature readings inside an operating heat exchanger.  The research conducted as a result of this grant will lead to products designed to eliminate more than $40B in unnecessary waste attributed to damaged or fouled heat exchangers.   Industries served will include power generation, oil and gas, industrial manufacturing, and commercial cooling.

“The National Science Foundation supports small businesses with the most innovative, cutting-edge ideas that have the potential to become great commercial successes and make huge societal impacts,” said Barry Johnson, Director of the NSF’s Division of Industrial Innovation and Partnerships. “We hope that this seed funding will spark solutions to some of the most important challenges of our time across all areas of science and technology.”

“Shell and tube heat exchangers represent one of the unseen foundations of our economy,” said Chuck Dirks, President of Innovas Technologies. “We aim to eliminate tens of billions in unnecessary costs and greatly improve environmental health by developing transformational micro-sensor technology that continuously monitors conditions inside of an operating heat exchanger.”

Once a small business is awarded a Phase I SBIR/STTR grant (up to $225,000), it becomes eligible to apply for a Phase II grant (up to $750,000). Small businesses with Phase II grants are eligible to receive up to $500,000 in additional matching funds with qualifying third-party investment or sales.

NSF accepts Phase I proposals from small businesses twice annually in June and December. Small businesses with innovative science and technology solutions, and commercial potential are encouraged to apply. All proposals submitted to the NSF SBIR/STTR program undergo a rigorous merit-based review process.

To learn more about the NSF SBIR/STTR program, visit: www.nsf.gov/SBIR.

About the National Science Foundation’s Small Business Programs: The National Science Foundation (NSF) awards nearly $190 million annually to startups and small businesses through the Small Business Innovation Research (SBIR)/Small Business Technology Transfer (STTR) program, transforming scientific discovery into products and services with commercial and societal impact. The non-dilutive grants support research and development (R&D) across almost all areas of science and technology helping companies de-risk technology for commercial success. The NSF is an independent federal agency with a budget of about $7 billion that supports fundamental research and education across all fields of science and engineering.

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Press Release: New ATCS Strainer Patent http://innovastechnologies.com/press-release/ Thu, 01 Dec 2016 22:17:23 +0000 http://innovastechnologies.com/?p=667271 The post Press Release: New ATCS Strainer Patent appeared first on Innovas Technologies.

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Coralville, IA., November 15, 2016

New Automatic Tube Cleaning System Strainer Patent improves preventing unnecessary cost due to condenser fouling.

Shell and Tube Heat Exchanger fouling costs the US economy over $80B annually despite the long established preventive maintenance habit of periodic manual cleaning. The Iowa manufacturing company Innovas Technologies develops state of the art solutions to eliminate this problem in shell and tube heat exchangers through the full spectrum of heavy industry all the way down to comfort cooling by its Helios Automatic Tube Cleaning System (Helios TCS).

The award winning Innovas Technologies recently completed the filing of a new patent that enables a new benchmark of effectiveness in cleaning media capture rates. The new technology titled, “Strainer for Collection of Heat Exchanger Cleaning Projectiles in Continuous Tube Cleaning Systems” allows for a much smaller footprint of our ball collection trap making it very appealing for large industrial applications as well as smaller comfort cooling scenarios with confined areas. Furthermore, the new strainer technology allows for high flow rates (7 to 10 Feetp/s) yet provides a very small pressure drop of less than 1 psi.

This new design was developed using ISO 9001 Quality Standards and Best Practice engineering design procedures. To validate the new product the innovative trap design was thoroughly tested at the University of Iowa Hydraulics laboratory and will be built under strict ISO 9001 quality standards as well as ASME B31.1 Power Piping Code. The ultimate result will be another step in the march to eliminate shell and tube related fouling completely through automated condenser cleaning systems.

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Condenser Tube Cleaning System Custom Design & Fabrication http://innovastechnologies.com/condenser-tube-cleaning-system-custom-design-fabrication/ Wed, 30 Nov 2016 17:47:11 +0000 http://innovastechnologies.com/?p=645580 Dominion Power is one of United States’ largest producers and transporters of energy, with a portfolio of approximately 25,700 megawatts of generation and 6,500 miles of electric transmission lines. Dominion serves more than 5 million utility and retail energy customers in 14 states. Dominion’s Mount Storm Power Station is the largest coal-fired power station managed […]

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Dominion Power is one of United States’ largest producers and transporters of energy, with a portfolio of approximately 25,700 megawatts of generation and 6,500 miles of electric transmission lines. Dominion serves more than 5 million utility and retail energy customers in 14 states.

dominion-mt-storm

              Dominion Mt. Storm Power Station

Dominion’s Mount Storm Power Station is the largest coal-fired power station managed by Dominion Resources. Its 3 units can generate nearly 1,600 megawatts of electricity – as much in one hour as 160 average homes use in one year.  Despite excellent operating processes, during the summer months Mt. Storm’s turbines can lose 2-4% of output capacity (20-40 MW) due to condenser tube fouling.  Dominion expressed interest in evaluating possible replacements or upgrades to existing tube cleaning systems in order to recover this lost power generation capacity.

In 2015, Dominion contracted Innovas Technologies to provide optimized performance over a competitor’s existing condenser tube cleaning system on Mt Storm Unit 3B Condenser, and to expand the automatic tube cleaning system from treating one condenser to two condensers.  The existing competitor’s ball trap had demonstrated exceptionally high operating pressure drop and a propensity to pin sponge cleaning balls inside it.

The overall goals of the project were to:

  • Reduce operating pressure drop across ball trap
  • Improve sponge cleaning ball return rates
  • Reduce overall physical footprint of the ball trap
  • Expand the condenser tube cleaning system capability to treat two condensers rather than one
  • Demonstrate reliable & effective tube cleaning system performance for further deployment

For the project, Innovas Technologies employed best-practice engineering techniques to develop custom ball trap designs and completed performance testing on a 1/6 scale model of the competitor’s 36” ball trap and custom Innovas ball trap designs.  Innovas then performed detailed design and fabrication of two 36” diameter ball traps utilizing the optimal ball trap configuration.   Additionally, Innovas designed and fabricated the necessary piping and PLC digital control systems to expand the tube cleaning system to provide condenser tube fouling prevention for two surface condensers.

Hydraulic Modeling, Testing, and Optimization

As an essential element of design validation, hydraulic modeling and testing was conducted at the University of Iowa Hydraulic Laboratory (IIHR) in Iowa City, IA, and was supported by IIHR hydraulic engineers and fabrication shop technicians.

img_20150728_135611655

              The 6″ pipe test apparatus at the hydraulic lab.

Innovas successfully recreated the field performance of the competitor’s existing ball trap, both in terms of clean ball trap pressure drop and in ball return rates.  Innovas was also successful in designing a ball trap alternative that provides vastly superior performance in both the clean ball trap pressure drop and ball return rate parameters, as demonstrated in the charts below.

Innovas Ball Traps Demonstrated Significantly Improved Pressure Drop

     Innovas Ball Traps Demonstrated Significantly Improved Pressure Drop

The competitor’s existing as-built ball trap exhibited the highest clean ball trap pressure drop at all three fluid velocities.  At higher fluid velocity (~10 ft/s) the clean ball trap pressure drop became excessive (>7.5 psi) and would negatively impact cooling water pumping system performance.   The existing as-built design also pinned significant numbers of cleaning balls in several areas, which caused the pressure drop across the ball trap to further increase.

ball-trap-ball-return-rates

        Innovas Ball Traps Demonstrated Superior Cleaning Ball Return Rates

Innovas Technologies Develops & Tests Custom Design Options

The Innovas Option 1 ball trap design exhibited good clean ball trap pressure drop across the full range of fluid velocities, with pressure losses lower than published pressure drops for typical industrial y-strainers.  The Option 1 design also returned all cleaning balls on collection, with no pinning across the fluid velocity range.

The Innovas Option 2 ball trap design exhibited the lowest clean ball trap pressure drop at all three fluid velocities.  However, the Option 2 design also demonstrated the lowest rate of cleaning balls return on collection, with cleaning balls pinning at both the 7 ft/s and 10 ft/s fluid velocities.

With excellent test results in hand, Innovas initiated detailed design of the Option 1 ball trap in the full-scale 36” diameter version for Mt. Storm power station.

Custom Design & Fabrication of 36” Diameter Ball Traps

The Innovas Option 1 design demonstrated superior performance in terms of pressure drop and cleaning ball retention and return rates, and did so in a more compact physical package.  Innovas initiated detailed design utilizing 3D CAD tools to turn the test concept into full-size production equipment.

ball-trap-3d-to-shop

        Innovas equipment is manufactured in a state of the art                                                       fabrication facility.

Fabrication of the ball traps and equipment was performed by ASME certified welders and subjected to verification in accordance with the ASME B31.1 Power Piping Code and Innovas’ ISO9001 Certified Quality Management System.

ball-trap-shop-photo-3

                                      Innovas ball traps ready for shipping preparation.

The fabrication of ball traps and associated equipment, including internal and external anti-corrosion coatings, was completed in six weeks and the equipment was shipped ahead of schedule.

Condenser Tube Cleaning System Installation & Operation

The installation configuration of the existing condensers required that the two 36” ball traps be installed in a very tight location, with a concrete mezzanine overhead and butterfly valve for isolation immediately downstream of the traps.  By all accounts the installation and fit-up process for Innovas-provided equipment was smooth and straightforward due to precise fabrication tolerances and quality control.

Installed Innovas Ball Trap

                                     Installed Innovas Ball Trap.

Innovas commissioned the tube cleaning systems and field results matched precisely with the hydraulic laboratory performance results—all cleaning balls were returned without pinning, and a pressure drop of well under 1 psi was measured across the ball traps.

Innovas vs. Competition

Competitor's Ball Trap After Removal.

                               Competitor’s Ball Trap After Removal.

The competitor’s old ball trap was inspected in the site’s equipment graveyard after removal.  Even in a quick visual inspection of the traps the advantages of the Innovas ball trap design are readily apparent.  In the competitor’s ball trap extensive areas of the main pipeline were blocked off with solid plates in order to get the cleaning balls routed to the ball exit.  The Innovas design achieves perfect ball return rates without occluding the open area for flow in the main pipeline.

Competitor's Ball Trap Entrance. Innovas Ball Trap Entrance.

        Competitor’s Ball Trap Entrance vs. Innovas Ball Trap Entrance.

The Path Forward

The optimized condenser tube cleaning system has been well received at the Mt. Storm facility, with excellent reliability and system performance.

The next level of performance achievement would require use of Innovas’ patent-pending design in retrofitting the site’s 108” and 120” nominal diameter condenser piping systems to improve power generation output.

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Continuous Robotic Tube Cleaning Eliminates Condenser Fouling – Entirely. http://innovastechnologies.com/continuous-robotic-tube-cleaning-eliminates-condenser-fouling-entirely/ Tue, 11 Oct 2016 17:33:30 +0000 http://innovastechnologies.com/?p=592739 Shell and tube heat exchanger fouling causes an $80B waste in the US alone, and almost all chiller operators are paying into this waste account. The Helios TCS provides work-reducing, reliable and simple automation for any organization seeking operational excellence in cost performance and energy efficiency

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Shell and tube heat exchanger fouling causes an $80B waste in the US alone, and almost all chiller operators are paying into this waste account.  The Helios TCS provides work-reducing, reliable and simple automation for any organization seeking operational excellence in cost performance and energy efficiency.

The Helios Tube Cleaning System enables continuous cleaning of condenser tubes to prevent fouling and optimize chiller performance.  Scale and biofilm typically takes several days to weeks to begin to take up residence on the inside of tubes.  The Helios TCS automatically sends cleaning media through the tubes every 20 minutes via computer-controlled injections.  The cleaning media, specially made sponge balls, clean and prevent micro-level biofilm and scale from getting established. The Helios TCS uses state of the art digital PLC controls and mechanical design philosophy to ensure world-class reliability and performance.

Whether it’s a surface condenser in a power station, overheads condenser in a chemical plant, or water-cooled chiller condenser or evaporator, Helios TCS technology can improve process performance and energy efficiency, while reducing maintenance requirements.

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Sponge Ball Tube Cleaning System Saves the Day! http://innovastechnologies.com/sponge-ball-cleaning-system-saves-day/ Tue, 11 Oct 2016 17:21:32 +0000 http://innovastechnologies.com/?p=592733 Facing a unique set of challenges associated with water treatment. The PeaceHealth facilities team in Springfield, Oregon employed sponge ball tube cleaning innovation to their front lines……with game-changing success!

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Facing a unique set of challenges associated with water treatment. The PeaceHealth facilities team in Springfield, Oregon employed sponge ball tube cleaning innovation to their front lines……with game-changing success!

PeaceHealth was restricted from using chemical water treatment due to their proximity to a blue ribbon trout stream. Their non-chemical water treatment program was struggling and they experienced out of control biological growth in their 6,000 ton chiller system. After each chiller tube cleaning the chillers would quickly return to a fouled state, resulting in approach temperatures exceeding 10 degrees. Looking for a solution Pat Lamb of PeaceHealth turned to sponge ball tube cleaning technology.

“Once we turned on the sponge ball tube cleaning systems, our fouling problems disappeared.” states Lamb, manager of the central utility plant. Since implementation, approach temperatures have remained at or below design levels and manual cleaning has not been required for four years. Additionally, with the additional capacity available from the first three chillers, their fourth chiller (trim) is often no longer required to run at all!

Calling the ball system at PeaceHealth a success would be a world class understatement!

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