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Water Treatment How to Achieve Optimum Productivity with Comprehensive Water Treatment

| Author / Editor: Akhil Jain / Dominik Stephan

Nalco conducted a complete survey using a Mechanical-Operational-Chemical (MOC) approach, and recommended a comprehensive solution – The 3D Trasar cooling water technology reduces the total cost of operation and welding system down time for a major car manufacturer in India.

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By utilizing 3D TRASAR cooling water technology, fresh water consumption was reduced from 1300 m3 in 2010 to 990 m3 in 2012. This was a reduction of nearly 30 per cent, saving $10,000 per year.
By utilizing 3D TRASAR cooling water technology, fresh water consumption was reduced from 1300 m3 in 2010 to 990 m3 in 2012. This was a reduction of nearly 30 per cent, saving $10,000 per year.
(Picture: Nalco)

As facilities have embraced flexible manufacturing with multiple platforms produced on a single manufacturing line, there is less room for production error. Weld water as a process critical closed loop can be a major source of unnecessary downtime, and incur an additional cost if this complex water treatment system is not expertly maintained.

As overheating can cause damage to welding and electrical equipment and the process, the weld water system is used to cool weld tips and electrical components. This system is critical to maintain the welding system and avoid unexpected down time.

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Corrosion at Welds due to Water Build–Up

The previous supplier did not conduct passivation treatment at the weld water system start-up which led to major corrosion inside the pipeline and turned the water red in color, a sign of severe corrosion and high iron content in the weld water. On an average, the iron content level was 25 ppm and turbidity was 450 NTU. Because of the high iron content and turbidity levels, the weld water system required daily maintenance including water flushing of the weld guns.

Production losses resulted due to increased down time of the weld guns. The customer wanted to find a comprehensive solution that reduced the cleaning frequency of the weld water system in order to increase system availability and reduce production loss while stopping continuous system corrosion.

Differnet Solutions had to Prove their Worth

Nalco conducted a complete survey using a Mechanical Operational-Chemical (MOC) approach, and recommended a comprehensive solution that includes the following:

  • Multifunctional closed loop corrosion inhibitor (TRAC 107 Plus) with non-oxidizing biocide to prevent microbiologic growth.
  • 3D Trasar cooling water technology for fully automatic control of chemical dosing. Nalco 3D Trasar Technology provides online monitoring with the System Assurance Centre which enables stable control of the weld water system 24/7.
  • A filter aid to reduce turbidity without flushing after sand filter and minimizing Trasar interference.

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