SUPER-WATER® improves cleaning by 2 to 50 times - Chevron U.S.A.
- SUPER-WATER® in Cleaning Applications
- Types of Applications
- Benefits of SUPER-WATER®
SUPER-WATER® in Cleaning Applications
SUPER-WATER® solution has been used for cleaning in the pressure range 3,000 - 20,000 psi after dilution of SUPER-WATER® concentrate by a factor of 333 prior to an appropriately sized holding tank. This diluted SUPER-WATER® in the U.S.A and Canada costs 18¢ U.S./gallon.
SUPER-WATER® is a tested, reliable additive that greatly increases the efficiency of high-pressure water blasting. It reduces job time and achieves effectiveness in otherwise impossible situations: this results in real-time savings of maintenance and production dollars. For example: Shell and tube sides of heat exchangers, so badly fouled they were scheduled for replacements, were cleaned by SUPER-WATER® and put back into service.
A 15 to 30 fold increase in effective stand-off distance was achieved when plugged slots in water-submerged oil well liners were cleaned with SUPER-WATER® solution.
Types of Applications
SUPER-WATER® increases the efficiency of high-pressure water blasting in:
- underwater operations
In these and other applications, SUPER-WATER® achieves results that are otherwise impossible.
Benefits of SUPER-WATER®
1. Line Pressure
Data for flexlance (100 ft x ¼ inch) fitted with 0.024 inch diameter tip.
2. Focussed Water Jet
Pressure: 9000 psi
Nozzle: #8 (0.067 inch diam.)
Flow Rate: 12 gpm
Note SUPER-WATER® solution extends the focussing more than 10 feet.
3. Macromolecular Polymer Bombardment
Red Brick 11½" x 3½" x 3½"
Firebrick 9" x 4½" x 2½"
6 Traversals at 1ft/sec.
During high pressure blasting SUPER-WATER® macromolecules and their associated aggregates of water do not have sufficient time for complete stretching, bending or twisting. As a result the water jet's effectiveness on the target is enhanced by bombardment with molecules that are "rigid".
The photographs show materials first blasted with water, then with 0.3% SUPER-WATER® solution under identical conditions and demonstrate the remarkable effectiveness of this product. Pump pressure was 9000 psi with a 12 gpm flow rate through a #8 nozzle (0.067 inch diam.) at a stand off distance of 9 inches.
Salt Block 10" x 9" x 9"
1 Traversal at 1ft/sec.
Oolitic Indiana Limestone 12" x 12" x 5"
4 Traversals at 1ft/sec.
Note: Using water alone, it was necessary to make several traversals across the bricks and limestone before any photographically significant etching occurred.
Other materials, including block ice, rubber sheeting, concrete slab, plywood, volcanic rock and asphalt were tested and showed the same striking difference between water and a solution of 0.3% SUPER-WATER®.
Utah Water Jet Consulting
Phone/Fax - (801) 731-7048
E-mail - JessKeopke@aol.com
I just wanted to take a moment to write you a short note to let you know how much your product (SUPER-WATER®) has helped me and my customers over the years. As you know, I have been using SUPER-WATER® since 1974 when you first introduced it for use as a water-blasting additive. This product has proven to be very valuable to me and my customers over the years. I thought you may want to know where I have used it, and the successes that I've had by using your product.
Chevron Richmond Refinery
My first project where SUPER-WATER® proved to be very cost effective, was when I used it for the cutting and removal of very hard scale deposits from reactor bundles at the Isomax unit. The scale deposits were so hard, and seemed to be fused to the tube surfaces. Chevron personnel, and outside contractors had already spent thousands of dollars, and over 3 months trying to remove the scale. They were unable to remove the scale deposits by using normal water-blasting methods, and were about to order new replacement bundles that would have cost Chevron hundreds of thousands of dollars, but were needed in order to keep the Isomax unit operating. As a last resort, and I might say, just in the nick of time, your product was being introduced to the industry for use as a water-blasting additive that could cut very hard scales such as the fused scale in the bundles at the Isomax unit. I was the first, and only contractor at the time that had any experience in using your product, and was called on to try it on the Isomax bundles. After a short period of operating our equipment on the project, it was evident that SUPER-WATER® was doing the job, and was doing it much faster than anyone had thought possible. We were able to clean the tube-side, shell-side of the bundles in about 24 hours each. Your product saved the day for my customer, and saved them hundreds of thousands of dollars in replacement costs, and downtime.
Chevron Hawaii Refinery
After the success at the Chevron Richmond, California refinery, the word got out to the other Chevron refineries. I soon found myself at Chevron's refinery in Kapolei, Hawaii where they also had a problem with very hard silica deposits in the tube-side of the exchanger bundles throughout the refinery. Chevron had been unable to get the exchanger bundles clean since the refinery was built. They were trying to cut the scale by using normal water-blasting equipment, chemical cleaning, drilling, and the list goes on. None of the methods that Chevron tried worked until I used your product ( SUPER-WATER®) to water-blast the inside diameter of the tubes. I used the same contractor that had been unable to cut the silica in the past, the same equipment, same method and pressure, only I added SUPER-WATER® to the feed water supply to the water-blasting unit. Again, it wasn't long after starting the project that we could all see that SUPER-WATER® was doing a good job in cutting the silica. This success with your product saved Chevron thousands of dollars in downtime, heat transfer, and labor costs. Chevron cut some of the tubes in half in order to inspect the results of our tests, and found the tubes to be clean, and silica free.
Salt Lake City Refinery
I opened an industrial cleaning service business in Utah back in 1979, and owe some of the success of that company to SUPER-WATER®. Chevron Salt Lake was one of my first customers in the region, and was using other contractors to perform the water-blasting work in the refinery at the time. I asked them to give me a try, and to give me the hardest cleaning job in the refinery, one that no other contractor was able to clean. They did, and it was a good test for SUPER-WATER®, the bets were on that I could not cut what they had in mind. The project turned out to be the cleaning of coke feed lines in the coker unit. In the past, they could only get the lines clean by using intensive labor, and the old rattling method. I was able to clean various size pipes that had very hard coke build up, and I was able to clean them in about 24 hours time by using SUPER-WATER®. The old method used to take about 7 to 8 days to perform the same work, and cost Chevron a lot more money than the method I used. After that, I was in the refinery on a regular basis, and Chevron was giving me more and more work. Chevron Salt Lake Refinery turned out to be my best customer in the region.
In the summer of 1978, I had the opportunity to visit a company in Utah that was the prime government contractor for building, and testing the Space Shuttle Booster Rockets. The company had a washout facility that was setup to refurbish the booster rockets for reuse after test firing, and later after the shuttle orbiter was launched. The washout facility was a high tech automated water blasting facility using high volume, high pressure water blasters to cut the motor liners from the inside diameter of the rocket motors. I ran some test using SUPER-WATER® to cut and remove the thick inner liner which was very dense rubber like material. The material was anywhere from 5 inches to 1 inch thick, and very time consuming, and hard to remove. I was able to cut the rubber like material with one hand held control gun, and one nozzle twice as fast as the automated system using three to four cutting heads. After that test, I then tested SUPER-WATER® on several other motor parts, and was also successful in cutting various types of materials such as carbon, fiberglass, rubber, and epoxy based paints. All tests proved to be two to three times faster in cutting, and removing these materials.
Nuclear Energy Industry:
Nuclear Power Plants
In 1988, I was contracted by Babcock & Wilcox of Toronto, Canada, for demonstrating the use of SUPER-WATER®. The company was trying to find a way to clean condensers that were being used in nuclear power plants. The condensers were large diameter, very expensive, (over 80 million dollars each), and were being used in most nuclear power plants around the world. The condensers were designed with very tight tube patterns, which were almost impossible to clean. The design of the tube pattern was so tight, that normal high-pressure water jets wouldn't penetrate between the tubes to remove normal buildup of scale deposits on the outside tube surfaces. By using SUPER-WATER®, I was able to maintain a focussed high-pressure water jet that would penetrate through the tight tube pattern, and remove the scale buildup. SUPER-WATER® proved to be the most effective method for cleaning these condensers, and was reported by Ontario Hydro's research personnel at a conference in Holland back in 1990.
As you can see, I have had very good success in using your product SUPER-WATER®. I have used your product in several different industries over the years, the above mentioned are just a few of them. I can honestly say that SUPER-WATER® has helped me to provide a better service to my customers, and is a product that I will continue to use for years to come.
I have also found that when I use SUPER-WATER®, I use substantially less water to get the job done, this is a big issue with some customers. Also I've found that my packing, plungers, valves, and valve seats last 2 to 3 times longer than running with straight water. This is a great cost saving to me, and means less down time for equipment repairs during projects.
As you know, I have started to do more Consulting work, and less contracting work. If you have any customers that are having cleaning difficulties or need help in using SUPER-WATER®, please have them contact me at the above mentioned address and phone number. Thanks again for all your help, I look forward to talking to you again soon.
Goldsmith Painting & Cleaning, Inc.
425 Forest Avenue
Sheboygan Falls, WI 53085
Our contracting business has utilized pressure washing/waterblasting for nearly 40 years, the last 20+ years of which the use of SUPER-WATER® has been an integral part of the equation.
Getting familiar with the proper use of SUPER-WATER® was probably the most difficult step in our eventual full time use of the product. It is extremely important to properly mix SUPER-WATER® into the blast stream and at the proper concentration. Once we mastered these two facets of the system, SUPER-WATER® became a very important tool in our waterblasting operations.
We use it in virtually every type of cleaning situation where it is necessary to enhance both the cutting power and/or the standoff distance of the blast stream. We have found that in both cases where one or both of these are required, the effectiveness is increased many times. In many instances, cleaning/cutting can be done very effectively with SUPER-WATER®, whereas, with plain water the job could not be done at all.
I could give many examples of cleaning/cutting jobs we have done through the years where SUPER-WATER® either greatly increased productivity or even made it possible, but suffice it to say, we have been and continue to be, very much reliant on SUPER-WATER® in our daily waterblasting work.
Goldsmith Painting & Cleaning, Inc.
LETTERS TO THE EDITOR OF THE WJTA
Dear Jet News,
Dr. Glenn Howells, of Berkeley Chemical Research, recently provided me with a preprint of his paper submitted for publication in the forthcoming International Journal of Waterjet Technology.
In this paper, mention is made that I use hot water when carrying out waterblasting with SUPER-WATER (polymerblasting) and also of my success in removing 20,000 sq. ft. of adhesive-attached cork from a concrete ceiling by polymerblasting where plain waterblasting was ineffectual because the cork merely absorbed the water.
A point that was not included in Glenn's letter, and one that will be of interest to your readers, is that I am having success in polymerblasting when using 0.1 percent SUPER-WATER as well as the 0.3 percent concentration which is usually recommended for maximum productivity.
Some situations do not require 0.3 percent concentrations of SUPER-WATER because production can be enhanced by a smaller percent of polymer.
Plain water is at the the bottom of the productivity scale and the addition of SUPER-WATER increases that factor as concentration increases to higher levels.
The ideal concentration levels must be experimentally determined for each application to reach a point where increased productivity balances the cost of the polymer.
Different cutting situations dictate different maximum concentrations of SUPER-WATER to arrive at the point of greatest efficacy.
Thus, use of 0.1 percent concentration reduces the cost of polymerblasting to approximately 3 cents/gallon as opposed to 9 cents/gallon indicated in Glenn's paper.
I am now writing to let you know of other applications of polymerlasting with which I have had success (In every case, use of plain water was either too slow or ineffective).
They include the following:
1. We were asked to clean 10-inch sewer lines that were almost totally plugged with phenolic resin at a plastics plan.
With plain water, we were only able to break off chunks of resin and cut a 2-inch hole along the bottom of the pipe.
With SUPER-WATER, however, we were able to virtually pulverize the hardened resin and clean out the pipe entirely.
2. We were required to remove polyester resin that had built up to a depth of 4 feet in a reactor.
Waterjets bounced off the resin and were incapable of cutting it, although the waterjet sometimes broke the bond between the resin and the outside wall.
With SUPER-WATER we were able to cut the resin like a knife and totally clean the vessel.
3. Slag and refractory material had accumulated in a coal-fired power plant boiler and plain-water blasting had proved incapable of removing it.
The water was able to cut the slag, but it had no effect upon the harder refractories which were embedded in and around steel studs welded to the boiler tubes.
With SUPER-WATER we were able to cut the refractory 5 times faster than with the only other alternative method which involved blasting with abrasives and which was very slow and quite costly.
4. We found in installing vents and pipes, that we could cut through a 10-inch concrete wall at 10,000 psi with precision and accuracy.
The SUPER-WATER decreased the cutting time over water by at least a factor of 3 and perhaps more.
This technique appears to work best when dealing with concrete that contains smaller aggregate stones in the mix. The water stream can cut the sand and cement mix, but cannot cut through larger aggregate stones. The stream must cut around the larger stones until they become dislodged and are blown away. The addition of a very hard aggregate into the water stream would readily solve this problem, however, and those injection devices are available in the market place.
5. We were able to obtain 100 percent removal of paint from a block building where, with water alone, only 25 percent was removable.
Additionally, the SUPER-WATER increased the production rate by 3 to 4 times over plain water. In fact, the SUPER-WATER is so effective that we tend to remove too much coating that is still bonded properly. We would tend to lose money on the blasting part of the operation prior to painting until we began using SUPER-WATER on a regular basis. For this application, SUPER-WATER is absolutely cost-effective.
6. We were asked to clean a 12-inch-diameter pipe about 1,200 foot long that carried a slurry made of pulverized coal slag and water. Following the accidental closing of a valve in very cold weather, the contents of the pipe (which is above ground) froze solid.
We cleaned this pipe using SUPER-WATER and self-propelled moles in about 12 hours.
We found with the SUPER-WATER that we could reach double the length of pipe obtainable with plain water and that there was much more pulling power on the self-propelled sewer-cleaning lance than with water alone.
This is because the pressure drop is much less through a long line using SUPER-WATER and, therefore, allows for better cleaning power at much greater distances from the pump in all types of cleaning applications.
7. We normally draw on our experience in using SUPER-WATER - when we use it and at what concentration at which we obtain its greatest efficiency (i.e., reduction in cleaning time versus cost of SUPER-WATER).
Probably 80 percent of the time we start out with SUPER-WATER in lower concentrations and work up to higher concentrations, if needed, until the most cost-effective concentration is achieved.
Sometimes when cost is not a factor, but time is critical, we will immediately use SUPER-WATER because we know that is the fastest way to get any job completed.
Most of our real challenges are in power plants and paper mills where there are various and many types of cleaning situations to deal with and which are almost always under a very tight time schedule.
Clearly excessive downtime costs money.
Such things as coal slag, fly ash, lime scale and other mineral deposits, by-products from production of green and brown wood liquor, salt cake, magnesium slag, recovery boiler ash, etc., are all amenable to removal with SUPER-WATER.
Goldsmith Painting & Cleaning, Inc.
425 First Avenue
Sheboygan Fall, WI 53085
12, June 1990
Mr. Bob Thomson
RMT Industrial Sales
Just a note to express our appreciation for your product; SUPER-WATER®. This water blasting additive has made us look good and raised our profile with an important customer.
I refer to the use of SUPER-WATER® for waterblast removal of coked deposits from heat exchangers. Used properly, your product enabled us to successfully clean a difficult exchanger that had previously defeated all efforts.
In my opinion, the product worked for us in two ways. It increased nozzle pressure by reducing flow friction and line loss. SUPER-WATER® also enhanced deposit removal by focusing jet quality and adding weight to the impact.
SUPER-WATER® delivers! We've stocked it ever since.
Aquaprep Pty Ltd.
During my very extensive search for the latest technology in water jet applications, I read your chapter entitled 'Enhancing Waterjetting by use of Soluble Additives'. This sparked my interest in SUPER-WATER®, and much detailed communication followed before I was sufficiently convinced enough to use it in my own operation.
Although my initial trial of SUPER-WATER® was not up to expectation due to my use of an inappropriate static mixer, in hydroblasting for surface preparation now, we produce blast standards with a 15OO bar pump which are equal to that produced by a 25OO bar pump.
SUPER-WATER® has provided us with a multi purpose pump without the investment expense of a UHP pump and the associated high running costs.
The many benefits of using SUPER-WATER® are evident by our ability to take on many jobs which we were previously unable to perform.