Location: Tangerang (Indonesia)
Installation Area: One of 7 cooling towers servicing the Mall's water cooled air-conditioning systems
The cooling tower selected is a 408TR system containing 45 m3 water volume with a water flow rate of 318 m3/h in an open circuit system.
Period: February 2014 - February 2018 (4 Years)

Significant findings as a result of a 4-year field test:

• Scale build-up did not take place. During this 4-year trial period, no scale formation was found on the condenser heat exchanger copper tubes of the system.
• No system maintenance was required.
• We have found conclusively that EC (Electric Conductivity) levels of up to 10,000 μS/cm can be safely ignored. Similarly, high TDS, metals, anions and many other substances in cooling tower water can be ignored when Vulcan is used.
• Cooling tower water blow downs are vastly reduced because with the Vulcan the maximum EC limit increases from 1,200 μS/cm in chemically treated cooling tower water systems to the much higher limit of EC 10,000 μS/cm for the electronic method of cooling tower water treatment. At the new 10,000 μS/cm EC limit, the need for cooling tower water blow down will likely be reduced from almost daily to once or twice per year.
• All AC compressors ran entirely at clean condenser efficiencies.
• R22 refrigerant gauges on all condensers remained at constant hot gas head pressure.

Summary of Benefits:

• Large savings on chemicals. The complete elimination of chemicals in this cooling tower operation during the field test supports the fact that Vulcan is “ecofriendly” and would meet the Leeds and Green Mark Building Criteria required for “Green Building” designation anywhere in the world. Enjoy the benefits of a world class, sustainable and “Green” Cooling Tower
• Rust prevention in iron pipes is an added benefit of the Vulcan system.
• Scale formation was eliminated. Refrigeration compressors operated at peak efficiency due to no scale in the condensers.
• Huge savings on blow down water consumption. Significant energy and water savings due to clean condenser tubes and no need for water blow downs below electric conductivity 10,000 μS/cm levels with the electronic cooling tower water treatment system – representing alone a saving of virtually all previously wasted water due to blow downs.
• Savings on payroll – no operational stoppages required for condenser cleaning, less testing and fewer inspections needed.
• Savings on supervision – engineers appreciate the “set and forget” of this automatic water treatment system. Frequency of inspections and laboratory expenses for cooling tower water testing are reduced due to the safety and reliability of the electronic systems.

Inspections:

The images below show the refrigeration condenser tubes from the beginning to the end of the trial period in "as clean as new" condition.

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At each inspection, the following procedures were followed:

1. One of the refrigeration "Shell and Tube" condensers was opened and the tubes inspected.
2. Condenser tubes were photographed.
3. Cooling tower water sample was sent to lab.
4. Refrigeration hot gas pressure gauges were checked.


Showing copper tubes of AC condenser heat exchanger on dates indicated: