Nalco's 3D Trasar, which includes modeling software, continuously monitors key parameters related to cooling system stress. When it detects upsets, the system automatically takes corrective action and communicates with system users.

By helping customers "utilize more variable water sources, responding to upsets faster, informing system users of potential problems and automatically taking appropriate, necessary corrective actions, [the software] provides them a real competitive advantage," said William Joyce, Nalco's chairman and CEO.

The 3D Trasar program uses a combination of technologies to monitor system stresses and detect conditions that can lead to scaling. When necessary, the program makes adjustments to chemical dosage and blowdown. It also takes into account how changes in stress levels affect the system and makes adjustments.

All aspects of cooling system operation can be viewed through the customer interface of 3D Trasar's web site. Alarms signaling out-of-spec conditions can be sent by text messages or e-mails. Cause and effect can be evaluated by reviewing all aspects of cooling system treatment and operation at a glance.

According to Nalco, field trials demonstrated potential savings to customers in several areas of their water systems. For example, chemical cleaning because of a fouled heat exchanger could cost from $5,000 to $20,000, while repair of a failed chiller could cost $50,000 to $500,000. During 3D Trasar trials, Nalco reported that customers saved up to $2,200 per day by keeping critical systems online during key production periods.

"Stresses on cooling-water systems can cause significant reductions in efficiency and interruptions in the cooling-water process," Joyce said. "3D Trasar allows managers a preemptive strike against the effects of stress to bring their systems to a level that will provide optimal efficiency."