Cooling PDF

Cooling Basics
The Basics
Hydrologic Cycle
Properties of Water
pH and Alkalinity
Langelier Saturation Index
Analytical Expressions
Water Analysis/Deposit Analysis
Corrosion and Deposition & Monitoring
Chemical Feed
Hydrologic Cycle
Water
PureWater -- can be very boring
Combination of 2 gases - Hydrogen and Oxygen
Colorless
Tasteless
Odorless
Nonconductive
Wet
Water
-- but it has several very special properties
Is attracted to itself
Can dissolve every substance on crust of earth or in
the atmosphere ( to some degree )
Possesses unusual heat capacity
Dissolved Minerals
Called IONS
Cations (+): Na+1, Ca+2, Fe+2
Anions (-): Cl-1, SO4-2, PO4-3
All ions are water impurities
Ions...
React with each other to form salts
Cations and anions can recombine as insolubles
Conduct electrical currents
React with metal to cause corrosion

Carry electrical charges between metals
Special Ions
pH
Hydrogen, H+
Hydroxide, OH-
Alkalinity
Bicarbonate, HCO3-
Carbonate, CO3--
Hydroxide, OH-
pH
Hydrogen Ion Concentration
Logarithmic Scale
pH = -log [H+]
How Does pH Apply to Us?
pH < 7: Acidic (corrosion)
pH > 7: Alkaline (deposition)
Alkalinity Relationships
P-Alkalinity = OH- + CO3--
Titration to pH 8.3 (phenolphthalein)
M-Alkalinity = HCO3- + CO3-- + OH-

Known as Total
Titration to pH 4.3 (methyl orange)
pH vs M-Alkalinity
9.5
9.0
8.5
8.0
pH
7.5
7.0
6.5
6.0
50 100 150 200 250 300 400
M-Alkalinity, ppm as CaCO3
Alkalinity Adjustment
pH Adjustment with 93% Sulfuric Acid (66o Be) H2SO4

(1 ppm H2SO4 neutralizes 1 ppm alkalinity)
To adjust alkalinity down by 50 ppm you need to add 50

ppm of H2SO4
Conductivity
Inverse of Resistance [mho]
Measure of concentration of ions in solution
LSI (Calcium Carbonate Solubility)
pH
Calcium
M-alkalinity
Conductivity
Temperature
LSI = pH - pHs where pHs is the pH at which

the water is saturated in calcium carbonate
Acceptable Ranges: TS (50 - 6000); Temp (32 - 176 F); Ca (3 - 990); M-Alk (1 - 990)
Measured pH (pHa) : 8.2 pH

Conductivity (TS): 400 mhos
Calcium Hardness (Ca) : 500 ppm as Calcium Carbonate
Operating Temperature (T) : 70 Deg. F
M-Alkalinity (MAlk) : 500 ppm as Calcium Carbonate
LSI (Process Engineering) : 1.654197 LSI = pHa - (9.3 + (LOG(LOG(TS)) / 2.3)+(3.05*EXP(-0.00557 * T)) - (LOG(0.4 * Ca)) - (LOG(MAlk)))
LSI (Internet) : 1.546975 LSI = pHa - (9.4 - (LOG(Ca)) - (0.94 * LOG(MAlk)) + ((LOG(TS)) / 10.7) + 3.24 * EXP(-T/191))
LSI (InfoCalc) : 1.667648 LSI = pHa - (9.59 + ((0.1026 * LOG(TS)) - (1.001 * LOG(Ca)) - (LOG(MAlk)) + (10 ^ (-0.002445 * T) * 3.0788))
LSI (Internet) : 1.574604 LSI = pHa - (9.3 + ((LOG(TS) - 1) / 10) + ((-13.12 * LOG((T - 32) * 5 / 9 + 273)) + 34.55) - ((LOG(Ca)) - 0.4) - (LOG(MAlk)))
LSI (Permutit) : 1.68 LSI = pHa - (9.3 + A + B - C - D) Where factors A, B, C & D are located in Tables A, B, C & D
LSI (CoolCalc) : 1.5550 LSI = pHa - (16.58 - LOG(Ca) - LOG(MAlk) + 0.1 * LOG(TS) - 2.6 * LOG(T))
LSI Benchmarks
LSI Condition
+3.0 Extremely Severe Scaling

+1.0 Severe Scaling
0.0 Stable Water
-0.5 No Scaling; Slight Tendency
to Dissolve Scale
-2.0 No Scaling; Strong Tendency
to Dissolve Scale
-3.0 No Scaling; Very Strong
Tendency to Dissolve Scale
Types of Solubility
Normal: Increases with Temperature
Table Salt (NaCl)
Sugar
Retrograde: Decreases with Temperature

Calcium Carbonate
Calcium Phosphate
LSI = +2.5
(LSI = +2.5)
How Do We Quantify What Is in the
Water?
Concentration
units of solute per unit of solvent:
PPM (parts per million)
parts of solute per million parts of solvent
mg/l (milligrams per liter)
1 gram solute/1,000,000 grams solvent
Different Conventions
GE uses ppm as CaCO3
ppm ppm
as substance factors as CaCO3
Ca 50 2.5 125
Mg 20 4.1 82
M-Alk 100 0.82 82 82
Equivalent weight
Convenient way of comparing ionic compounds
Derived from molecular weight and molecular charge
Allows quantities on water analysis to be easily
combined
Mg as CaCO3
Magnesium expressed as its Equivalent
weight in Calcium Carbonate
100 (MW CaCO3) = 4.1

24 (MW Mg)
Water Analysis
What Does It Tell Us?
Water characteristics
MU and cycled
Cycles
actual and theoretical
Is treatment there?
Is it sufficient?
Is there corrosion or deposition?
Makeup and Tower Waters
SAM PLING POINT
MU CT1 CT2
pH 7 .4 8 .5 9 .1
Specific Conductance 425 2210 1691

2 5 Deg C, UM HOS
Alkalinity, "P" 0 0 0
as CaCO3 , ppm
Alkalinity, "M " 106 250 390
as CaCO3 , ppm
Sulfur, Total 68 620 251
as SO4 , ppm
Chlorides, as CL, ppm 35 250 344
Hardness, Total, 145 725 538

as CaCO3 , ppm
Calcium Hardness, 90 450 333
Total, as CaCO3 , ppm
M agnesium Hardness, 55 275 205
Copper, Total, < 0 .0 5 < 0 .0 5 < 0 .0 5
as CU, ppm
Iron, Total, 0 .0 3 0 .1 2 3 .5 0
as Fe, ppm
Sodium, as Na, ppm
Phosphate, Total, 1 .0 8 .0 4 .0
as PO4 , ppm
Inorganic, as PO4 , ppm
Phosphate, Ortho- 1 .0 8 .0 4 .0
as PO4 , ppm
Silica, Total, 8 .3 2 1 .9 3 1 .3
as SiO2 , ppm
Solids, Total Suspended 10 27 35
M G/L
Aluminum, < 0 .0 5 < 0 .0 5 < 0 .0 5
as Al, ppm
Cycles
SAM PLING POINT
MU CT1 CT2 CT1 CT2
pH 7 .4 8 .5 9 .1
Specific Conductance 425 2210 1691 5 .2 4 .0

2 5 Deg C, UM HOS
Alkalinity, "P" 0 0 0
as CaCO3 , ppm
Alkalinity, "M " 106 250 390 2 .4 3 .7
as CaCO3 , ppm
Sulfur, Total 68 620 251 9 .1 3 .7
as SO4 , ppm
Chlorides, as CL, ppm 35 250 344 7 .1 9 .8
Hardness, Total, 145 725 538 5 .0 3 .7

as CaCO3 , ppm
Calcium Hardness, 90 450 333 5 .0 3 .7
M agnesium Hardness, 55 275 205 5 .0 3 .7
Copper, Total, < 0 .0 5 < 0 .0 5 < 0 .0 5
as CU, ppm
Iron, Total, 0 .0 3 0 .1 2 3 .5 0 4 .0 1 1 6 .6
as Fe, ppm
Sodium, as Na, ppm
as PO4 , ppm
Inorganic, as PO4 , ppm
Phosphate, Ortho- 1 .0 8 .0 4 .0
as PO4 , ppm
Silica, Total, 8 .3 2 1 .9 3 1 .3 2 .6 3 .8
as SiO2 , ppm
Solids, Total Suspended 10 27 35
M G/L
Aluminum, < 0 .0 5 < 0 .0 5 < 0 .0 5
as Al, ppm
Possible Signs of Corrosion
Iron (Fe)
above that in cycled MU
Copper (Cu) > 0.2 ppm
Aluminum (Al)
Check Makeup Water
Possible Signs of Deposition
Ca cycles < Cl or Cond
Mg cycles < Cl or Cond
SiO2 cycles < Cl or Cond
LSI >2.5 & Temp > 115o or
LSI >3.0, Temp < 115o
Limiting Cycles
LSI
MgSiO2
CaMgSiO2 (pH > 8.8)
SiO2 > 200 PPM (Reactive)
Conductivity
Chlorides - SS, Cu, Al
Uncontrolled losses prevent these limits from being
exceeded
Treatment Components Open System
Corrosion Inhibitors
Ortho-PO4 (Mild Steel)
Zinc (Mild Steel)
Azoles (Yellow Metal - Copper & Brass)
Scale Inhibitors
Phosphonate (Calcium Carbonate)
Polymers (Calcium Carbonate, Calcium Phosphate, Iron, TSS)
Biological Control
Oxidizers (All MB)
Non-Oxidizers (Specific MB)
TIP
TP -TIP
TP
Molybdate MoO4 (Mo X 1.67) (Mild Steel)
Nitrite (Mild Steel)
Azoles (Yellow Metals Copper & Brass)
Scale Inhibitors
Typically not needed
Biological Control
Non-Oxidizers (Specific MB)
Deposit Analysis
Deposit Analysis
Nature of deposit
organic/inorganic
Composition of deposit
elemental analysis
Theoretical compounds
Determining Theoretical Deposit
Composition Inorganic Deposit Analysis
Ve rsion 1.2
Compa ny: H a ppy Custome r D a te : 2-31-03

City, Sta te : Antwhe re , U SA
Account #: D a te of D e posit Sa mple d:
Loca tion of D e posit:
Data from Inorganic Analysis Report Ca lcula te d hypothe tica l compounds
LOI 9 CaCO3 59.0%

CO2 26 CaSiO3 17.6%
CaO 42 LOI 9.0%
P2O5 1 MgSiO3 5.0%
ZnO 1 Al2SIO5 4.8%
SiO2 14 Fe2O3 2.0%
Fe2O3 2 Zn3(PO4)2 1.6%
SO3 Ca3(PO4)2 0.9%
MgO 2 SiO2 0.2%
Al2O3 3
CuO
PbO
BaO
Na2O
Other
T OT AL 100
Trivia
LOI = dry weight - ash weight
LOI does not include water!
Analysis gives weight of oxidized species

P2O5, CaO, MgO etc.....
Hypothetical composition
Based on relative solubility, kinetics, etc.....
compounds are deduced not analyzed
Limitations
Does not distinguish between phosphate and phosphonate
Analyzes as P2O5
Does not give detailed organic analyses
Consider source and quantity
Use COMMON SENSE

Coupon Rack
MS ADM
SS /Cu
Al
Direction of Flow
Coupon Placement
Align edges (not

faces) with direction
of flow
System Considerations
Use nylon screws and nuts or match coupon metallurgy
Ensure pressure differential (drop) between inlet and
outlet for proper flow
Use established procedures and guidelines (CTI Code
STD-149(00))
Coupons
Match system metallurgy
Place in 1 rack on hot return
PROPER ORDER!
30, 60, 90 day results
Pretreated vs. non-treated???
What do they indicate?
Galvanized Coupons?
Corrosion Rates
Electrochemical Reaction
Corrosion rates generally increase as:
Temperature increases
pH decreases
Alkalinity decreases
Conductivity increases
LSI decreases
Corrosion Rates
Industry Standards for Cooling Systems
Mild Steel < 3 mpy

Copper < 0.2 mpy
Aluminum < 1 mpy
Stainless Steel < 1 mpy
Factors for Correlation
Established baselines
Water Analyses
Equipment Inspections
Treatment Programs
The Key to a Successful Treatment
Program
Get the Right amount of the Right chemical
fed to the Right place in the system
Product Feed
Lbs
____________
PPM =
MM Lbs (H2O)
Lbs = PPM x MM Lbs (H2O)
Lbs
_____
MM Lbs (H2O) =
PPM
1 MM lbs (H20) = 1,000,000 Lbs (H20)
Lbs
_______
Gallons =
Density
Lbs = Gallons x Density
Density = Lbs/Gal
Given the following:
Product ABC (Density 11 lbs/gal)
Water (Density 8.34 lbs/gal)
A cooling Tower has a blowdown rate of 120,000

gallons a day. You want to maintain 100 ppm of
Product ABC in the system.
Calculate the gallons of Product ABC needed.

How Many Million Pounds of Water
Are to Be Treated?
120,000 gal x 8.34 lbs/gal
______________________ = 1 MM lbs
1,000,000
Lbs = PPM x MM Lbs (H2O)
100 PPM x 1 MM Lbs (H2O) = 100 lbs
Lbs
_______
Gallons =
Density
100 lbs
___________ = 9.1 gallons
11 lbs/gal
Inhibitor Feed
Controlled feed (not slug)
High mix area
Away from biocide/acid
Best fed neat
dont mix chemicals
dilution water
Away from controller sensors
Biocide Feed
Shot Feed
Away from inhibitor
Best fed neat
watch common lines
Do NOT blend w/surfactant (prod. separation)
Proper materials of construction
Safety when handling
Acid Feed
Dilution water/static mixer
High mix area
Proper materials of construction
Away from inhibitor/biocides
In Summary
Hydrologic Cycle
Properties of Water
pH and Alkalinity
Water Analysis/Deposit Analysis
Corrosion and Deposition & Monitoring
Chemical Feed
* Trademark of the General Electric Company and
may be registered in one or more countries.
Cooling Equipment
Topics
HVAC Equipment
How a Cooling Tower Works
Cycles of Concentration
Cooling Tower Calculations
Major components of a Chiller
HVAC Equipment
Heating Ventilation & Air Conditioning
Cooling Tower
Makeup
Blowdown
Cooling Tower Water Loop
Condenser
Compressor Expansion
Refrigeration Loop
Valve
Evaporator
Chilled Water Loop
Expansion Makeup
Tank
Chilled Water
(Air Coils)
Cooling Towers
Cooling Tower Basic Energy Balance Equations
(mh)out (mh)in = 0
ma1 + mw3hw3 = ma2hm2 + mw4hw4
ma1(ha1 + w1hv1) + mw3hw3 = ma2(ha2 + w2hv2) + mw4hw4
ma[cp,a(T1 T2) + w1hg1 w2hg2] = mw4hf4 mw3hf3
mw4 = mw3 ma(w2 w1)

Assuming Adiabatic conditions; changes in kinetic & potential energy is negligible; fan work is negligible
m = mass; h = enthalpy; T = temp (oC); w = mass flow rate; cp,a - 1.005kJ/(kg)(oC)
Source: Thermodynamic (Fourth Edition) by: Kenneth Wark (ISBN 0-07-068284-4) Page 437
Cooling Towers
What makes a cooling tower really cool?
Evaporation !!!
Sensible Heat - Heat energy stored in a substance as a result of an

increase or decrease in temperature. (Water = 1 BTU/Lb/F)
Latent Heat - Heat which flows to or from a substance without a
change in temperature. The heat will only change the structure or
phase of the substance (i.e. melting or boiling of pure material).
(Water = 1000 BTU/Lb)
Cooling Towers
Equal Volumes
VS
Sheets or Film
(1) 12 Inch Cube (96) 1/8 x 12 Inch Square
Surface Area 864 Square Inches Surface Area 28,224 Square Inches
Small surface area Large surface area

Cooling Towers Air / Condensing Water Vapor
Hot Water Hot Water

Return Return
Drift Eliminator
Air / Water
Vapor
Tower Tower
Fill Fill
Outside Outside
Air (Dry) Air (Dry)
Cold Water
Tower Sump
Cooling Towers
Cycles of Concentration Demonstration

What Does Cycling Up Mean?
Makeup
Blowdown
Cooling Towers
Useful Calculations
MAKEUP = EVAPORATION + BLOWDOWN
CYCLES = MAKEUP / BLOWDOWN
EVAPORATION (GPM) = T x RECIRCULATION RATE (GPM) x (0.9) / 1000
BLOWDOWN = EVAPORATION / (CYCLES 1)
% LOAD = AVG. OPERATING TONNAGE / TOTAL TONNAGE * 100

RECIRCULATION RATE FOR CENTRIFIGAL MACHINE
(10F DESIGN T) = 3 GPM / TON AC
Cooling Towers
E = RR x T (oF) x Ef
1,000
D E
MU = E + BD _____
E
C = X ppm Recirc BDi =
MU = BD x C X ppm MU (C-1)
C = MU
BD RR
L
BD = Total Non-Evaporative Losses
BD = Intentional Blowdown (BDi) + Windage (W) + Drift (D) + Leaks (L)
Cooling Towers
Questions?
Next topic
Chillers -How they work
HVAC / Chillers
Cooling Tower

Condenser
Refrigeration Loop
Valve
Evaporator
Chilled Water Loop
Chilled Water
(Air Coils)
What the Components Are & Do
Condenser
Refrigeration Loop
Device
Evaporator
Compressor
Condenser
Expansion Valve
Evaporator
What the Compressor Does
Compressor Compresses vapor refrigerant which increases the
pressure and temperature of the vapor. Additional heat is added
by compression.
Highest Pressure
Highest Temperature
Vapor Phase
Compressor
What the Condenser Does
Condenser Condenses vapor refrigerant to a liquid when
cooling. The heat is transferred from the refrigerant to the
cooling media. The liquid refrigerant is still at a high pressure.
Highest Pressure
Highest Temperature
Vapor Phase
Compressor
Condenser
High Pressure High
Temperature Liquid
Phase
What the Expansion Valve Does
Expansion device The pressurized liquid refrigerant is
expanded which lowers the pressure and lowers the
temperature.
Highest Pressure
Highest Temperature
Vapor Phase
Compressor
Condenser
High Pressure High
Temperature Liquid Expansion Valve Low Pressure
Phase Low Temperature
Mostly Liquid Phase
What the Evaporator Does
Evaporator Evaporation of the liquid to a vapor by boiling.
High Pressure High

Temperature Vapor Lowest Pressure
Vapor Phase
Compressor
Condenser
Evaporator
High Pressure High
Temperature Liquid Expansion Valve Low Pressure
Mostly Liquid Phase
The Refrigerant Inside
Liquid, Vapor, Pressure & Temperature
Highest Pressure Lowest Pressure

Highest Temperature Low Temperature
Vapor Phase Vapor Phase
Compressor
Condenser Evaporator
Expansion Valve
High Pressure High Low Pressure Lowest

Temperature Liquid Temperature Mostly
Phase Liquid Phase
Closed Loops
Cooling Tower

Condenser
Refrigeration Loop
Valve
Evaporator
Chilled Water Loop
Chilled
Water
(Air Coils)
Closed Loops
Chilled Water Loop
Evaporator
Meter
Shot Pot
Feeder Makeup
(Air Coils)
Expansion
Tank
Chemical Treatment and Control
Treatment Programs
Corrosion Historical Review

Neutral pH Programs
Alkaline pH Programs
Deposition Whats New
Evolution of Cooling Treatment
Chromate (50's to early 60's)
Zinc Phosphate (late 60's)
Polynodic (early 70's)
Dianodic BAT / Zinc

(late 70s to present) (early 80s to present)
Polynodic Treatment Program
Orthophosphate
Pyrophosphate
Polymer
Historical Break-Through
Polymeric Dispersant
Effective Treatment Must:
Inhibit Corrosion
Minimize Deposition
Operate Under Broad Conditions
Be Economical
Have a Low Environmental Impact
Cooling Water Programs Components
Corrosion Inhibitors &
Deposit Control Agents
(Dispersants)
Cooling Water Program
Components:
Steel Corrosion Inhibitor
Cu/Alloy Corrosion Inhibitor
Polymeric Dispersant(s)
Maintain corrosion inhibitor soluble
Disperse Particulate
Calcium Carbonate Inhibition
Allow operation at positive saturation
Program Classification
6.5 7.0 7.5 8.0 8.5 9.0
Neutral pH Programs (6.8 to 7.8)

Corrosion Inhibitor Intensive
Primarily Anodic Inhibitors
Alkaline pH Programs (> 7.8)
Dispersant Intensive
Primarily Cathodic Inhibitors Used
Conventional Cooling Programs
Components
Neutral pH Alkaline pH
Steel Inh. o-PO4, poly-PO4,Zinc o-PO4, Zinc
(phosphonate)
Copper Inh. TTA, BZT TTA, BZT
Dispersant Co & Terpolymer Co & Terpolymers
CaCO3 Inh. HEDP,PBTC HEDP, PBTC

Neutral pH Programs
Steel Corrosion Protection
Orthophosphate: 10 - 18 ppm
Polyphosphate: 0 - 6 ppm
Zinc: 0 - 3 ppm
Copper Alloy Protection
Azole (TTA): 1.5 - 5+ ppm
Deposition Control
Copolymer/Terpolymer
Neutral pH Programs
Stabilized Phosphate Mechanism
Passive Iron Oxide Layer Formed at Anode
Polymer Allows Sufficient o-PO4 Dosage
Neutral pH Programs
Function of Polymer
Maintain Corrosion Inhibitors Soluble
Inorganic Phosphate / Zinc
Prevent Scaling of Hot Surfaces
Ca3(PO4)2, Zn(OH)2, Zn3(PO4)2, CaSiO2, ZnSiO2
Prevent Particulate Fouling
Silt, iron oxide/hydroxide, Alum (Aluminum
hydroxide), Manganese oxides
Neutral pH Programs
Challenges:
High Temp. and/or Low Flow
Calcium Phosphate Scaling
Low Flow Steel Exchangers
Excessive Corrosion
Iron Phosphate Fouling
High Calcium Water
Iron and Alum (aluminum) Contamination
Precipitation/Deposition of Phosphate
Neutral pH Programs
Advantages
Passive Film at Anode
Easy to Recover from Upsets
Scaling Potential Minimized
Disadvantages
High Levels Phosphate Required (Scaling)
Copper Corrosion Inhibition is Difficult
Susceptible to pH Excursions
Well Buffered
pH vs. Alkalinity
400 115
350
M-Alkalinity
300
250
200
150 28
100
50
0
6.5 7 7.5 8 8.5 9
pH
Corrosion Potential Minimized

Higher Buffering Capacity
pH Control Simplified
Capitalize on Calcium Carbonate Film
Acid Reduction or Elimination

CaCO3...The Free Inhibitor
+2
Ca CO3-2
-
OH
HCO3 -
CaCO3 CaCO3 CaCO3

Anode
Cathode
-
HCO3 + OH
- CO3-2 + H2O
Ca+2 + CO3-2 CaCO3
Deposition Control
Phosphonate(s) for CaCO3
Polymer for Inhibition & Dispersion
Deposition Control
Phosphonate(s) for CaCO3
Polymer for Inhibition & Dispersion
Steel Corrosion Control
CaCO3 - Maintain + LSI
Orthophosphate: 3 to 8 ppm
Phosphonate: 4 - 8 ppm
Zinc: 0.5 - 2 ppm
Azole (TTA): 1 to 3 ppm
Alkaline Phosphate
Deposition/Precipitation Control
Phosphonate (HEDP) - CaCO3
Copolymer /Terpolymer - Ca3(PO4)2 , Ca-
Phosphonate, & Particulate Matter
Alkaline Phosphate
Copolymer /Terpolymer - Ca3(PO4)2 , Ca-
Phosphonate, & Particulate Matter
Corrosion Inhibition:
Orthophosphate - Primarily Cathodic
Phosphonate - Anodic and Cathodic
TTA - Copper & Alloys
Alkaline Zinc
Copolymer/Terpolymer - Ca-Phosphonate,
Ca3(PO4)2, Zn(OH)2 & Zn2(PO4)3 & TSS
Alkaline Zinc
Copolymer/Terpolymer - Ca-Phosphonate, Ca3(PO4)2,
Zn(OH)2 & Zn2(PO4)3 & TSS
Corrosion Inhibition
Phosphonate - Anodic and Cathodic
Zinc - Cathodic Inhibitor
TTA - Copper & Alloys
Common Phosphonates
CaCO3 Scale Control
PO3H2
HEDP
CH3 - C - OH HydroxyEthylidine
DiPhosphonic acid
PO3H2
CH2 COOH
PBTC
H2O3P C COOH
2-PhosphonoButane
CH2
1,2,4 TriCarboxylic acid
CH2 COOH
Common Phosphonates
CaCO3 Scale Control
PO3H2
HEDP
CH3 - C - OH HydroxyEthylidine
DiPhosphonic acid
PO3H2
CH2 COOH
PBTC
H2O3P C COOH
2-PhosphonoButane
CH2
1,2,4 TriCarboxylic acid
CH2 COOH
Problem with Phosphonates & Halogen
Phosphonate + Halogen ---->
ortho-PO4
+
Ineffective
Chlorinated Organics
Advantages
Buffering Reduces pH Swings
Corrosion Potential Minimized
Acid Feed Reduced / Eliminated
Disadvantages
Phosphonate Instability with Halogen
Phosphonate Precipitated by Calcium
Upset Recovery Difficult
Conventional Neutral and Alkaline pH
Technology
Limits Cycles of Concentration
Calcium Hardness & Retention Time
Halogen Instability
Limits use of Halogen for disinfection
Loss of copper corrosion protection
Pitting of Steel due to copper plating
Approaches to Limitations of
Conventional Programs
Develop Friendly Halogen
Stabilized Bromine
Develop Halogen and Calcium Stable Programs

Whats New from GE?
Dianodic PLUS
Halogen Stable Cooling Technology
Halogen Stable Technology
Dianodic PLUS
6.8 7.5 7.8 8.5 9.0 9.5
Dianodic III Continuum AEC

Dianodic II Treatment
Orthophosphate & Pyrophosphate
Phosphonate (optional) - CaCO3
Azole (TTA)
Dispersant
Copolymer (HPS-1)
Inhibits: Ca3(PO4)2
Disperses: Iron Oxide, Silt, Clay, etc.
Dianodic II Treatment
Whats new?
HRA
Polymer Dispersant Package
HPS-1, TMPS, CAPS
Copper Corrosion Inhibitors
Azoles
(Adsorbed Films)
Conventional Azoles
Copper Corrosion Inhibitors
Benzotriazole (BZT) R= H
Tolyltriazole (TTA) R=CH3
R
N
N
N
H
Problems with Conventional Azoles
Destroyed By Halogen - chlorine/bromine
Increased copper corrosion
Increased steel corrosion
Limit Free Halogen Residual
Cannot use halogen to greatest advantage
Odor Issues - TTA
Copper Discharges Issues
HRA
Halogen Resistant Azole
CH3
N
N N
H
Cl
Chlorotolyltriazole
HRA
Copper Corrosion Inhibitor
Advanced Technology (1998)
Halogen Stable
Benefits Steel Corrosion
Highlights of HRA
Prolong Life of Copper Equipment
Minimize Copper Throw

Pitting of Steel Equipment
Copper Discharge Issues
Cu Coupons - 3 ppm TTA
From left: 1, 5, 6, 6 days exposure
Cu Coupons - 3 ppm HRA
Low Carbon Steel Coupons
3 ppm TTA
Low Carbon Steel Coupons
3 ppm HRA
HRA Prolongs The Life of Steel
Equipment !
TTA HRA
Continuous Chlorination Trial
5.0
Azole Fed
4.0 Azole
Recovered
3.0
ppm
2.0
1.0
0.0
TTA HRA
Mixed Metallurgy Protection -
HRA Vs TTA 5 ppm TTA
Continuous Chlorination 5 ppm HRA
2.5 ppm TTA
2.5 ppm HRA
3.0
2.5
2.0
mpy
1.5
1.0
0.5
0.0
ADM Cu:Ni LCS
Cu Corr Rate (mpy)
0.0
0.2
0.4
0.6
0.8
1.0
1.4
1.6
1.2
05/07/1996
05/09/1996
05/10/1996
TTA
05/11/1996
05/13/1996
05/14/1996
05/16/1996
05/17/1996
05/19/1996
05/20/1996
Shot Feed Chlorination
05/21/1996
05/23/1996
05/24/1996
05/26/1996
05/27/1996
05/28/1996
HRA
05/30/1996
05/31/1996
06/02/1996
06/03/1996
HRA Performance
Chlorine Stability
In Solution
Inhibitor Film
Prevents Copper Plating
pitting of steel surfaces
Environmental
No Odor
Dianodic III
(Neutral pH Stabilized Phosphate)
Calcium Phosphate Inhibitors & Dispersants
Neutral pH
Stabilized Phosphate
#1 Concern:
Polymer Dispersant Package
Improved Deposit Control:
Up to Three Dispersants
Custom Blended Based on System
All Are Halogen Stable
All Are Calcium Stable

HPS-I
Sulfonated Co-Polymer
Excellent Calcium Phosphate Control
Inhibitor
Dispersant
Excellent Dispersant for TSS
TMPS
Sulfonated Ter-Polymer
Improves Calcium Phosphate Control
High Temperature
Iron
Aluminum
CAPS
Sulfonated Co-Polymer
Good CaCO3 Inhibitor
Aids HPS-I
Control Of Calcium Phosphate
Iron Dispersion
GE Polymers Summary
HPS-1 Most Commonly Used Ca-PO4 Inhibitor
Excellent Particulate Dispersant
TEMPS Excellent High Temp. Ca-PO4 Inhibitor

Efficacy not Affected by Iron or luminum
CAPS Calcium Phosphate Inhibitor

Calcium Carbonate Inhibitor
Newest Polymer Development
(2003)
APES
APES
(Ethoxylated Acrylic Acid Copolymer)
Superior Deposit Control Efficacy
Twice as effective as current polymers
APES
Excellent For Stressed Applications
High Hardness
Cation Contamination
High Temperature/Elevated Flux
Suspended Solids
APES
High Hardness
Suspended Solids
Halogen Stable
APES
High Hardness
Suspended Solids
Halogen Stable
Calcium Stable
Phosphate Inhibition
In the Presence of 3 ppm Total Fe APES
HPS I
Competitive Copolymer
Competitive Terpolymer
Competitive Copolymer
100
80
Percent Inhibition
60
40
20
0
5 10 12 15
Polymer Dosage (mg/L)
Continuum AEC
Alkaline pH Program
Continuum AEC
AEC - CaCO3
Copolymer (HPS-1)
Continuum AEC
AEC - CaCO3
Copolymer (HPS-1)
Corrosion Inhibition:
Orthophosphate
AEC - Primarily Anodic
HRA - Copper & Alloys
AEC Alkyl Epoxy Carboxylate
Threshold CaCO3 Inhibitor
First Major Advance in >25 Years
Non-Phosphorus - Not a Phosphonate
Halogen Stable
No Precipitation with Calcium
AEC Alkyl Epoxy Carboxylate
CaCO3 Scale Control
AEC = Poly Epoxy Succinic Acid (PESA)
CO2H R
HO ----- C ------ C ---- O ----- H
R CO2H
n
Calcium Tolerance
10 ppm Inh. - 880 Ca - pH 9 - 158 F
100
90
80
% Soluble
70
60
50
40
30
20
10
0
AEC PBTC HEDP
AEC Stability
5 ppm Inh. - pH 8.5 - 10 ppm Cl2
80
%
70
D
E 60
G
50
R HEDP
A 40
D
A 30
T
I 20
O
N 10 AEC
0
3 6 20 48
TIME (Hrs.)
AEC Stability
5 ppm Inh. - pH 8.5 - 10 ppm Cl2
80
%
70
D
E 60
G
50
R HEDP
A 40
D
A 30
T
I 20
O
N 10 AEC
0
3 6 20 48
TIME (Hrs.)
Customer Fouling Study
182 F Wall Temp. , 1.5ft/sec Velocity
AEC D-II HEDP-PO4 HEDP-ZN

40
35
30
Fouling Rate
25
20
15
10
5
0
0 12 24 36 48 60 72
Hours
Continuum AEC Programs
Low to No PO4
Applicable to 2,000 ppm Ca
Extends LSI Limit
+ 2.85 Hot
+ 3.0 or more Warm
Alkaline Programs Components
Conventional Continuum AEC
Steel Inh. o-PO4, Zinc o-PO4, Zinc
(HEDP, PBTC) (AEC)
Copper Inh. TTA, BZT HRA
Dispersant Co & Terpolymer Copolymer (HPS-1)
CaCO3 Inh. HEDP,PBTC AEC

(phosphonate)
Dianodic PLUS
(Dianodic III & Continuum AEC)
Excellent Performance Under Stressed Conditions
Prolongs Equipment Life
Maintains System Cleanliness
Dianodic PLUS
Allows High Cycle operation
Reduced Operating Cost
Dianodic PLUS
Allows High Cycle operation
Reduced Operating Cost
Exploits Benefits of Halogen For Biological Control
Halogen Stable Programs
No Loss of Corrosion Protection
No Loss of Scale Control
Dianodic II Treatment 1979
Phosphonate (optional) - CaCO3
Azole (TTA)
Dispersant
Copolymer (HPS-1)
Inhibits: Ca3(PO4)2
Disperses: Iron Oxide, Silt, Clay, etc.
Cleaning Technologies & Ferroquest
GE Technologies
CLEANING
GE Technologies
CLEANING
GE Technologies
CLEANING
GE Technologies
CLEANING
GE Technologies
CLEANING
GE Technologies
CLEANING
GE Technologies
Ferroquest and
Kleen
Cleaning
General Cleaning Solutions
Ferroquest Cleaning Technology
FQ Series for Iron
LP Series for Calcium Carbonate
Kleen Cleaning Technology
AC Series for Fe, Cal, PO4, etc.
New Cleaning Technologies
Cleaning Goals
Improve Production
Reduce Operation & Maintenance Costs
Equipment Life
Return Heat Transfer
Minimize Effects of Deposits
Safety
Environment
Value
General Cleaning Solutions
Mineral Acids
Lower pH / Very Corrosive
Safety Concerns
Deposit formation / Chip Scale
Fast and Cost effective
Organic Acids
Slower / Expensive
Less Corrosive
Chelants
Sequester / Costly
GE Cleaning
Cleaning Applications
Preoperational
Rust Removal
Reactor Jacket
Biofilm Removal
Calcium Carbonate Removal
On-line and Off-line Cleanings
Technical Services for Cleaning
Developmental Cleaners
Preoperational Cleaning
Remove mill scale and rust deposits
Oils provide food for MB and anodic sites when partially
removed
Ant Nest Corrosion in Enhanced Tubes
Deposits or coatings prevent passivation
Ferroquest Technology
Circulate for a 24 hrs to 72 hours & Purge
New equipment placed into service without

pre-cleaning can have shorter life-spans
GE Iron Cleaning
Benefits
Uncleaned
Removes Iron
Neutral pH
Passivates
On-Line
Ferroquest FQ
Cleaned
Compare to Acids
Acid Advantages Acid Disadvantages
Quick Attacks deposits and
equipment
Low chemical cost
High Disposal Cost
Hazardous conditions
Safety
Does Not Leave a Passive
Surface
Cleaning Comparisons
Traditional Acid Ferroquest FQ
pH cleaning - near 1.0 pH cleaning - neutral
Required neutralization No neutralization required
Cleaned iron oxide quickly, also Cleaned iron oxide in 36 hours no
etched base metal etching of base metal
2 step process for passivation 1 step process, cleaning and
passivation
Flash rust problems
No flash rusting
Acid Cleaning Process
Fouled Pipe
Acid
Passive Rust Base Metal

Ferroquest FQ
FQ Advantages FQ Disadvantages
Neutral Cleaner Slower Reaction
Safe to Handle and Low
Environmental Impact
Leaves a Passive Surface
Low Total Cost
On-line After 3 weeks
Copper Corrosion Inhibitor After 2 weeks
Ferroquest FQ
Wet with Surfactant

Reduce
Insoluble Fe Soluble
+3
Fe +2
Disperse
With Polymer
Monitoring Ferroquest FQ
Maximum Iron of 10,000 ppm as Fe2O3
Special Iron Testing
pH 6.5 to 7.2
Reducing Agent
Conductivity
8,500 mhos
Ferroquest Performance
Before After
Iron Levels (ppm)
6000
5000
4000
3000
2000
1000
10:30 AM
Ferroquest Cleaning on Closed Loop Cooling System
9:30 AM
8:30 AM
7:30 AM
6:30 AM
Iron (ppm)
5:30 AM
4:30 AM
pH
3:30 AM
Ferroquest Performance
2:30 AM
1:30 AM
12:30 AM
Time
11:30 PM
10:30 PM
9:30 PM
8:30 PM
7:30 PM
6:30 PM
5:30 PM
4:30 PM
3:30 PM
2:30 PM
1:30 PM
12:30 PM
0
pH
Frequently Asked Questions
Will Ferroquest clean a Will the cleaning remove the
plugged tube? rust that is plugging all the
pin holes and cause leaks?
No This is a possibility with
What about chip scale? any cleaning! Acid
amplifies the risk!
The average particle If the tube is that bad it
size is 1.5 microns. should be plugged or
Largest particles are replaced.
5 microns in a typical
cleaning.
Welder Water System Cleaning
Glass Lined Reactors OptiTherm
Safely removes rust deposits to increase
jacket efficiency by an average of 15%.
BioFilm Removal
Cause Severe Corrosion Problems
Prevent Protection
Prevent Cleaning
Potential Legionella
Cleaning Technology
Apply Spectrus Technology
New Biofilm Cleaner - Spectrus BD1550
Use of Halogen with proper System Protection
Circulate On-line
GE Ferroquest LP
Removes Calcium Carbonate
Removes Minor Phosphate Deposits
Compatible with system metals
On-line and Off-line
Environmental
Safe
GE Hardness Scale Remover
Ferroquest LP Technology
Cleans 15 - 20 times faster than H2SO4 at pH 5
Easier than hydroblasting
Low Toxicity
Applications
Open or closed recirculating systems
Cleans heat exchangers
Cleans condensers
Cleans cooling tower fill
Avoid galvanized systems
Depositrol SF502
Cleans Calcium Carbonate
Great for galvanized towers On-line
May take 60 days
Cleans Film Fill
Cleans Enhanced Chiller Tubes
Foaming tendency
Kleen Technology
Inhibited Acids
Selection based on Scale
Great on a variety of deposits
Fast
Off-line applications typically
Developed for Food Industry
Kleen AC9500 / Kleen AC9502 / Kleen AC9507

Technical Services
Cleaning Consulting
Cleaning Application Experiences
Water Analysis
Inorganic Deposit Analysis
Microbiological Analysis
Organic Analysis
Scanning Electron Microscopy
Corrosion Coupon Testing
Development Projects
R&D - Clean Team
Large On-line Cleaning Technology

Manganese Cleaning Technology
Carbonate cleaning on Galvanized
New Chelant Based Technology
Silica Cleaners
Industry Cleaning Specialization
Closed Systems
Discussion Topics
Closed Systems
Primary Inhibitors
Additives
Biocides
Typical Closed Systems
HVAC Systems
Bearing Cooling
Welder Water Systems
Thermal Energy Storage Systems
Plastic Injection Molding
Lube Oil Coolers
Closed Recirculating System
To
Cooling
Tower Heat Process
Exchanger
Heat
Makeup
Load
From
Cooling
Surge
Tower Tank
What Is a Closed System?
Extremely low water losses, < 5% of system volume
per day
High quality makeup.
High inhibitor levels.
pH 9.5 (Ideal).
Temperature ranges as high as 350 F.
Uses water, glycol, or brine systems.
Primary Closed System Treatment
Nitrite
Molybdate
Non Oxidizing Biocides
Oxygen Scavengers-Boiler Products

Nitrite
Mechanism
Anodic Passivator
Promotes Passive Iron Oxide Film
Advantages
Low Cost
Very Effective on Carbon Steel
Independent of Oxygen
Stable to 350 F
Nitrite Problems
Effective Only On Carbon Steel

Oxidized to Nitrate by MB, Chlorine, and Oxygen
Passivation Reaction Produces Ammonia
Aquatic Toxicity
Brass Stress Corrosion Cracking (O2 Present)
Aggressive to Solder
High Dosages Required
200- 1,200 ppm as NO2 (700 Typical)
Molybdate
Mechanism
Forms passive anodic film
Advantages
Excellent MS Corrosion Inhibitor
Mildly Effective on Cu, Al, Solder
Excellent Stability
Compatible With Oxidizers
Molybdate
Disadvantages
Higher Cost
Slow Passivation, Especially in Low D.O.
Not allowed by some discharge permits
Dosage
150 - 500 ppm as MoO4
Molybdate / Nitrite Blends
Synergistic Combination
Provides Excellent MS Performance
Low and High D.O.
Stagnant Conditions
Disadvantages
Cost
Still prone to MB reversion
Biocide Selection
Iso BNPD DBNPA Glut Quat MBT
High pH X X X
Low pH X X X X X X
Low/No
Foam
X X X X
Rapid Kill X X X X X
Long-Term
Activity
X
Cl2
Compatible
X X X X X
Cu/Fe Free X X X X X
What Is a Nearly Closed System?
High water losses, > 5% of system volume per day
Normal quality makeup.
Treated like an open recirculating system or a once
through system.
Neutral pH range.
Uses Water only.
Primary Nearly Closed System Inhibitors -
Ortho/Pyrophosphate
Mechanism
Cathodic inhibitor at lower levels, metal passivator at
higher dosage levels
Requires hardness in MU
Requires oxygen
Matching Inhibitor to System
Infinite residence time MB stability
High temperature Temperature stability non -

scaling, low Cl -
Copper Need azole
Aluminum components Not compatible with Cu,

maintain pH 7.0 8.5
Low conductivity Avoid nitrite based products
Demineralized makeup Buffer to 9.0 9.5

Enhanced Chiller Tubes
New systems should be
thoroughly precleaned.
Minimum velocity of 3.5 ft/sec.
Circulate idle machines as
frequently as possible. Target 5
minutes/hour with a minimum of
30 minutes/day. Treat with non-
oxidizing biocides.
Filter to remove suspended
solids.
Secondary Inhibitors / Additives
Azoles - Copper Alloy Corrosion Inhibitors
Tolyltriazole (TTA)
Benzotriazole (BZT)
Sodium or Potassium Silicate / Polysilicate

Works by adsorption
Best Cast Iron Corrosion Inhibitor
Useful on Copper Alloys and Aluminum
Polymeric Dispersants
PAA, HPS1, Others
Disperse Corrosion Products
Nitrate
Aluminum Corrosion Inhibitor
Bug Food
pH Buffers
Borates / Boric Acid
Amines
Carbonate / Bicarbonate
Caustic Soda, Caustic Potash - not buffers
Red Dye
Spot Leaks
Eyeball Treatment Concentration
Questions ?
Thank you for your attention
Cooling Systems Design and Operation
Cooling System Design
Types of Systems
Cooling Towers
Terms & Balances
Components
Objective...
Remove Heat (BTUs)

Water & Heat Transfer
Two Mechanisms:
Temperature Change
Cp = 1 BTU/lb oF
Q = m x Cp x (Th -Tc)
Evaporation
LH = 1,000 BTU/lb
Q = m x LH
Cooling Water Systems
Two Types:
Temperature Change
Once-Through
Closed Recirculating
Evaporation
Open Recirculating
Once - Through System
Cooling Water
Supply
Process
Heat Load
Cooling Water
Discharge
Closed Recirculating System
To
Cooling
Tower Heat Process
Exchanger
Heat
Makeup
Load
From
Cooling
Surge
Tower Tank
Open Recirculating System
Evaporation
Blowdown
Cooling
Tower
Heat
Load
Makeup
Recirculating Pump(s)
Factors Influencing Efficiency:
Water Flow Rate
Air Flow Rate
Water/Air Distribution (L/G)
Ambient Conditions
Percent Tower Capacity Usage
Cooling Tower Types
Natural Draft Mechanical Draft

Natural Draft
Hot Air
(Convection Current)
Water Water
Ambient Ambient
Air Air
Natural Draft
Mechanical Draft
Induced Draft - Cross Flow
Hot Air
Water Water
Air Air
Cross-Flow Tower
Mechanical Draft
Induced Draft - Counter Flow
Hot Air
Water
Air Air
Counter-Flow Tower
Cooling Tower Terms
Top 10 List!
Evaporation
Approach vs. Range
Hot Water TR
to Tower
Cold Water
from Tower TS
Approach
(TS-T WB)
Wet-Bulb T WB
Temperature
Evaporation Blowdown
RH
Tdb
Twb Return
Heat Load = Sum of Qs
TR
Supply
Makeup
TS Recirc. Pump(s)
Cooling Tower Balances
In - Out = Accumulation
Energy (Heat)
Qin = Qout
Mass (Water and Components)
Makeup = Evaporation + Blowdown
Conventional Terms: gal/min (gpm)
Nomenclature
Heat Load (Q) (BTU/hr)
Evaporation (E) (gpm)
Latent Heat (LH) (BTU/lb)
(gpm)
Blowdown (BD)
(gpm)
Makeup (MU) (gpm)
Recirculation Rate (RR)
Cycles of Concentration (C)
Energy (Heat) Balances
QR = RR * Cp * (TR - TS)
QA = E * LH
QA = QR * f
RH E T1 T2
TR
Tdb
Twb TS RR
Evaporation Factor (f)
1.1 20% RH
Evaporation Factor
1.0 40% RH
60% RH
0.9 80% RH
100% RH
0.8
0.7
0.6
0.5
20 30 40 50 60 70 80
Wet Bulb Temperature (F)
Mass Balances
E = [RR * (TR - TS) * f]/1,000
BD = E/(C - 1)
MU = BD + E
BD
C = MU/BD (metered values)
C = [X]BD/[X]MU E
TR
TS RR
MU
Effect of Cycles on MU & BD
Makeup Blowdown
600
RR = 10,000 gpm
500
T = 20F
400
E = 180 gpm
300
200
100
0
1.5 2 3 4 5 6 7 8 9 10
Cycles
Cooling Tower Components
Distribution Multi-Blade Air Flow
Area Fan
End Wall
Splash Casing
Bar Grid
And
Supports
Air Flow Air Flow
Louvers
Longitudinal
Drift Eliminators Partition
Efficiency Components
Water : Air Distribution (L/G)
Air Flow
Water Distribution System
Tower Fill
Splash
Film
Fan Stacks
Deck - Cross Flow
Distribution - Cross Flow
Distribution - Counter Flow
Splash Fill
Film Fill
Film Fill - Fouled
Tower Screens
Cooling System Design
Wrap Up:
Water & Heat Transfer
In - Out = Accumulation
Optimum Efficiency
> (L/G)
> Intimate Contact
Distribution Deck & Tower Fill
What Will Be Covered
Classic Corrosion Cell
Types of Corrosion
Factors That Affect Corrosion
Cooling Water
Treatment Advances
Water Treatment Concerns
Biofouling
Corrosion Products
Under-Deposit Corrosion Deposition
Corrosion
Water Treatment Goals
Protect Equipment
Fouling
Corrosion
Achieve Target Run Lengths
Avoid Unplanned Outages
Minimize Down Time
Cleaning
Repairs
Maximize Unit Profitability
Production
Utilities
Safety
Environmental Compliance
Biofouling
Corrosion
$
Asset protection
Unit reliability
Health & safety
Corrosion Products
Water Treatment Tools
Biofouling
Oxidizers
Nonoxidizers
Biodispersants
Corrosion Corrosion Products Deposition

Phosphates Under-Deposit Corrosion Polymers
Zinc Phosphonates
Azoles AEC
pH control pH control
Water Treatment Essentials
CHEMISTRY
SUCCESSFUL
WATER TREATMENT
MONITORING Residuals & Results CONTROL

Advances In Water Treatment
Chemistry
AEC
Non-Phosphate CaCO3 Inhibitor
HRA
Halogen stable corrosion inhibitor
APES
Fourth Generation CaPO4 dispersant
The Corrosion Cell
O2 -
Fe +2 OH H 2O
= O2
Fe(OH) O
3
Fe(OH) 2
Electron
Flow Cathode
ANODE
e-
Anode: Oxidation Cathode: Reduction

Feo Fe2+ + 2e- In neutral or alkaline water
2Fe(OH)2 + 1/2 O2 + H2O 1/2 O2 + H2O + 2e- 2OH-
2Fe(OH)3
Phosphonate Programs
Phosphonates Degrade/Precipitate
Loss of Scale Control
Increased Ca-PO4 Fouling Potential P
Increased Polymer Demand
Halogens Consumed/Biocontrol Compromised
Marginal results in stressed systems
Higher treatment costs
The Corrosion Cell
Alkaline pH Treatment
CaCO3 Little or no acid; bulk water pH 7.8 9.0
Phosphonate LSI +1 - +2.5
PO4?, Zn? ppt.
Polymer for CaPO4,
CaPhosphonate & TSS control
Electron
Flow Cathode
ANODE pH 10+
e-
Anode: Oxidation Cathode: Reduction

Feo Fe2+ + 2e- In neutral or alkaline water
2Fe(OH)2 + 1/2 O2 + H2O
2Fe(OH)3 1/2 O2 + H2O + 2e- 2OH-
1984 Betz Labs
Balanced Alkaline Technology
Barrier film protection at cathode
CaCO3 saturated bulk water (+ LSI)
CaPhosphonate
5 10 ppm PO4?
1-5 ppm Zn?
4 6 ppm HEDP
Limit CaCO3 ppt. to cathode only
Balance scaling Vs corrosion
2ndary ppt. of CaPhosphonate at cathode
Polymer for CaPhosphonate, TSS etc.
3-6 ppm TTA
Yellow metal protection
Mild steel pitting protection
Phosphonate Chemistry
OH OH OH
HEDP O P C P O
35 YRS
OH CH3 OH
O
P
PBTC
C CH2 CH CH CH2 C
25 YRS C
Limitations of Phoshphonate-based
Alkaline Technology
Phosphonate insolubility
pH >8.3
Ca hardness >500 CaCO3
Temperature >125F.
Low flows <2 fps
LSI >2.5
Phosphonate instability
Halogens
System Retention Time
Cycles
Phosphonate Solubility
100 ppm Inhibitor 0.1M CaCl2 - pH 9 158oF
% Transmittance
100
90 Lab
80
70 Data
60
50
40
30
20
10
0
PBTC HEDP
Chlorine Stability Studies
Nalco Patent & Drew Tech Paper
% Degradation
100
90 Lab
80
70
60 N D Data
50
40
a r
30
20
l
c
e
10
0
o w Drew
HEDP HEDP PBTC
10 ppm Cl2 - 48 hrs 7 ppm Cl2 - 2 hrs

AEC
Alkyl Epoxy Carboxylate
Threshold Scale Inhibitor
Carboxylated organic
Low molecular weight
No phosphorous
First new scale control agent in over 25 years
Replaces phosphonates
AEC
Alkyl Epoxy Carboxylate
Primary Function:
Control CaCO3 precipitation (cathode only)
Prevent gross CaCO3 fouling
Secondary Function:
Steel corrosion inhibition
(Anodic Inhibitor)
AEC
Key Properties
Solubility
Remains soluble
In high hardness waters
In high alkalinity waters
In high iron waters
Stability
Compatible with all halogens
Cl, Br, ClO2 etc.
Does not revert or degrade
AEC
Calicum Tolerance Test
Test Conditions
Inhibitor level 100 ppm

CaCl2 0.1 M
pH 9.0
Temperature 158oF
AEC
Calicum Tolerance Test
% Transmittance
100
90 Lab
80
70 Data
60
50
40
30
20
10
0
AEC PBTC HEDP
AEC
CaCO3 Inhibition Test #1
Test Conditions
Calcium (as CaCO3) 1102 ppm
Carbonate (as CaCO3) 1170 ppm
pH 9.0
Temperature 158oF
LSI 3.2
AEC
% Inhibition
100
90
80
70
60
50
AEC PBTC HEDP
AEC
Test Conditions

Carbonate (as CaCO3) 1170 ppm
pH 9.0
Temperature 158oF
LSI 3.2
AEC
100
95
90
AEC
85
HEDP
80
75
70
4 4.5 5 5.5 6 6.5 7
ppm Actives
AEC
Halogen Stability Test #1
Test Conditions

Calcium (as CaCO3 1250 ppm
pH 8.5
Halogen (Free Cl2) ~10 ppm
AEC
80
%
70
D
E
60
G
50
R
A HEDP
40
D
A 30
T
I 20
O
N 10 AEC
0
3 6 20 48
TIME (Hrs.)
AEC
Test Conditions

pH 9.0
Temperature 158oF
Halogen (Free Cl2) 0 - 10 ppm
AEC
CaCO3 Inhibition in the Presence of Cl2
100
90
80
% inhibition
70
AEC
60
HEDP
50
0 2 5 10
ppm Cl2
Continuum AEC
Program Components
Steel Corrosion Inhibitor
Cooling water alkalinity
2-7 ppm Phosphate &/or
1-3 ppm Zinc
Calcium Carbonate Control
6-10 ppm AEC
Ca3(PO4)2 Control/Solids Dispersion
HPS I Polymer
Copper Corrosion Inhibitor
1-3 ppm HRA (1998)
Continuum AEC
Alkaline Program Capability
pH >7.8
Calcium 100 2000 ppm (as CaCO3)
Temp. >160oF. (HX outlet water)
LSI +2.85 (hvy. industrial conditions; i.e., low flow,
high temperatures)
LSI +3.25 (hi flows, low temps.)
Silica Limits unchanged
Silicate Limits unchanged
Continuum AEC
High Temperature Scale Control
DATS Fouling Studies

182oF. Wall Temp. 1.5ft/sec Velocity
35 HEDP-PO4
R Factor x 0.00001
30
D-II
25
HEDP-ZN
20
15
10
5 AEC
0
0 12 24 36 48 60 72
Hours
Continuum AEC
Successfully Treats Stressed Systems

High Calcium / High Alkalinity Waters
Hot Equipment / Shell-Side Equipment
High Cycles / Long Retention Times
Poor Chlorination Control
Other Control Problems
Avoids Economic Penalties

Protection of Copper
and Copper Alloys
Protection of Copper and Copper Alloys
Azoles
BZT
MBT
TTA
HRA
Azole Reactions
Corrosion Inhibitor
on the metal surface
Complex with Copper
in the bulk water
Why Protect Copper?
Prolong life of copper equipment
Prevent premature steel bundle failures
Avoid mild steel pitting
Avoid copper discharge violations
Critical with High Levels of Free Halogen

Copper Corrosion
CuII
CuII
CuII
CuII
CuI CuI CuI CuI CuI CuI CuI CuI CuI
Copper Surface (Cuo)

Azole Surface Reactions
N N N
Cu I + N N
N
Azole Cu I
H
H+
Azole - Cu
Complex
Azole Reactions in Solution
Cu II
Cu II
Cu II
Cu II
Pit Steel
MILD
Surface STEEL
1998 Betzdearborn
HRA Performance Advantages
Corrosion Protection
Film persistence
Copper complexation
Environmental Benefits
Reduced copper
No odor
1998 Betzdearborn
Reasons for HRA Performance
Activity Level
Halogen Stability
In solution
On the surface
Dissociation of Azoles
In Solution
N N
N N
N N
H Deprotonated Form
Azole H+ Active Azole
Comparison: HRA vs TTA
100
>90% Anion
80
Per Cent Azole as Anion
60 TTA
40
HRA
~25% Anion
20
0
4 5 6 7 8 9 10 11 12
pH
HRA vs TTA
Azole Protection in Presence of Halogen
LAB DATA
Pre-treat 18 hours with 3 ppm azole
Add 5 ppm bleach with azole present
Track corrosion rates
Corrosion Rate (mpy)
2.5
TTA
2 HRA
1.5
1
0.5
0
0 5 10 15 20
Time (hours)
HRA vs TTA
Azole Film Persistency
LAB DATA
Remove azole; No bleach
Track corrosion rates over 22 hours
Copper Corrosion Rate (mpy)
2
1.8
1.6
1.4
1.2 TTA
1 HRA
0.8
0.6
0.4
0.2
0
0 10 20 30 40 50
Time (hours)
HRA vs TTA
Unaided Film Persistency with Halogen
LAB DATA
Remove azole; Add 5 ppm bleach
Track corrosion rates over 22 hours
Copper Corrosion Rate (mpy)
8
7
6
5
TTA
4 HRA
3
2
1
0
0 10 20 30 40 50
Time (hours)
LCS Corrosion
After Halogen Exposure
TTA HRA
HRA vs TTA Halogen Stability
Field Trial - Intermittent Bleach Feed
3.5
Azole Fed
3.0
Azole Recovered
2.5
2.0
ppm
1.5
1.0
0.5
0.0
TTA HRA
Continuum AEC with HRA
Protects Under Adverse Conditions
35 Day Sour Leak Exposure
Periodic 5 ppm Free Cl2 Spikes
3 Days @ 10 - 16 ppm Free Cl2
Biofouling
Biofouling
Corrosion Products
Corrosion
New Criteria For Success
INTEGRATED TREATMENT
Corrosion
Simultaneous Control
Deposition
No Adverse Impact
Biofouling & Avoid Economic Penalties

Legionella
Control
Dianodic PLUS
6.8 7.0 7.8 8.0 8.5 9.0+

Dianodic Continuum
III AEC
Spectrus Biocontrol
Open Recirculating Cooling
6.8 7.0 7.8 8.0 8.5 9.0+

Neutral pH Alkaline pH
Anodic Cathodic
Biocontrol Program
LCS Corrosion
After Halogen Exposure
TTA
Corrosion Theory and Control
Factors Necessary For Corrosion
Anode
Cathode
Electrolyte
Electron Flow
Classic Corrosion Cell
WATER
(ELECTROLYTE) O2
Fe(OH)3 Fe2+ OH-

FERRIC H2O
ELECTRICAL POTENTIAL e-
Fe(OH)2
FERROUS ELECTRON FLOW
ANODE (-) CATHODE (+)

CARBON STEEL
ANODIC REACTIONS CATHODIC REACTIONS

CHEMICAL OXIDATION CHEMICAL REDUCTION
Fe
o
Fe
++
+ 2e
- 1/2O2 + H2O + 2e - 2OH-
Types Of Corrosion
Uniform
Localized
Macroscopic
Microscopic
Microbiological
Erosion
Uniform Corrosion
Least Damaging
Cathodic and Anodic Sites

Continuously Changing
Even Metal Loss
Long Time Before Failure

Localized Corrosion
Very Detrimental
Small Amount of Metal Loss
Short Time Before Failure
Can Be:
Macroscopic
Microscopic
Microbiological
Erosion
Macroscopic Corrosion
Galvanic Corrosion
Concentration Cell
Pitting
Leaching
Galvanic Corrosion
Brass Bolt
( Small Cathode )
Electrolyte Aluminum
( Large Anode )
Corroded Zones
Galvanic Corrosion
Galvanic Series
Magnesium Anodic -
More Easily
Zinc
Corroded
Aluminum
Mild Steel
Cast Iron
Brass
Copper
Bronze
Cathodic - Copper Nickel Alloys

More Easily Titanium
Protected Stainless Steel (Passive)
Graphite
Galvanic Corrosion
Stainless Steel Tubes
Mild Steel Tube Sheet

Sacrificial Anodes
Concentration Cell
OH-
Cl- M+
Cl- M+ O2
O2 O2
M+ M+ OH- M+
OH- OH-
Concentration Cell
OH-
O2
O2 OH-
M+
Cl- M+ M+
O2 M+ Cl-
O2 Cl-
O2 Cl-
M+ Cl-
M+ M+
OH- OH- OH- O H-
e-
Pitting
Tubercle
Water
Protective
Film
Pit Forming
Iron at Small
Anodes
Pitting
O2 O2 O2 Cl- O2 O2 O2
Cl- O2
Cl- Cl-
OH- OH- OH- OH-
Cl- M+
M+ M+
e- M+ M+ e-
e- e-
e- e-
Pitting
Pitting
Leaching
Selective Removal Of One Element From A
Solid Alloy By Corrosion
Examples:
Dezincification- Removal Of Zinc From Brass Alloys
Graphitization- Removal Of Fe From Cast Iron
Dealuminumification- Removal Of Al From Aluminum
Bronzes
Dezincification
Admiralty
Coupon
Dezincification
Microscopic Corrosion
Intergranular
Transgranular
Stress Corrosion Cracking
Residual or Induced Stress
And a Corrosive Environment
Intergranular Or Transgranular
Alloy Environment Cracking
Al-Mg Cl- Intergranular

Brass NH4+ Intergranular
Steel NH3- , OH- Intergranular
300 Series Stainless Cl- , OH- Transgranular
Steels
MONEL alloy 400 Mercury, Chromic Intergranular and
Acid, Aerated Hydro- Transgranular
fluoric Acid Vapor
INCONEL alloy 600 Fused Caustic Intergranular
Nickel 200 and 201 Mercury, Molten Intergranular
Metals
Other Types Of Corrosion
Erosion Corrosion
Microbiological Corrosion
Erosion Corrosion
MB Attack Metal
Sulfate Reducing Bacteria
Sulfur Bacteria
Iron And Manganese Bacteria
Film Formers: Bacteria, Fungi, Algae
Factors Affecting Corrosion
pH
Conductivity
Oxygen
Temperature
Effect of pH
Corrosion Rate
4 10
pH
Effect of Conductivity
Corrosion Rate
Dissolved Solids
(Conductivity)
Effect of Oxygen & Temp
120 F
90 F
Corrosion Rate
48 F
PPM Oxygen
Types Of Inhibitor Films
Anodic
Cathodic
Adsorbed Layer
WATER (ELECTROLYTE)
ANODIC INHIBITORS CATHODIC INHIBITORS
O=
O
2 Fe(OH)3 Fe++ - O
OH 2
Fe(OH)2 ELECTRON
CATHODE
ANODE
ANODE FLOW
Anodic Inhibition
Orthophosphate
High Concentration
Primarily Anodic Inhibitor
Passive Iron Oxide Film
Requires Calcium
Neutral to Alkaline pH Range
Molybdate
Primarily Anodic Inhibitor
High Levels in Closed Systems
Low Levels in Open Systems
Does Not Require Calcium
Requires Oxygen
Nitrite
Promotes Anodic Films
No Oxygen Required - Generally Used in Closed
Systems
Used at High Levels
Susceptible to Biodegradation
Cathodic Inhibition
Polyphosphates
Primarily Cathodic
Reverts to Orthophosphate
Orthophosphate
Low Concentration
Primarily Cathodic Inhibitor
Requires Calcium
Calcium Phosphate Forms (Cathode)
Zinc
Cathodic Inhibitor
Used at Low Concentrations
Usually Used with Other Inhibitors
Discharge Considerations
Organic Phosphates (Phosphonates)
Considered Both Anodic and Cathodic
Normally Used in Combination with Other Inhibitors
Used in Alkaline pH Range
Adsorbed Layer
Az = Azole
Az Az (TTA, BZT or HRA)
Az
++
Az Cu Az
++
Cu
Az
Az
Az
Az Az Az Az Az Az Az Az
Az Az Az Az Az Az Az Az
Copper Metal Surface

Silicate
Adsorbed Film
Slow Development for Protection
Does Not Require Calcium
Environmentally Acceptable
Azoles
Adsorbed Films
Primarily for Copper Protection
Fed on a Continuous Basis
Deposition/ Fouling
Theory and Control
Types Of Deposition
Scaling
Mineral Scale
Fouling
Suspended Matter
Transient Corrosion Products
Process Leaks
Deposition Problems
Production Losses
Turnarounds
Emergency Shut Downs
Shortened Equipment Life
Reduced Flow
Cleaning Costs
Deposition
Deposition
Total Resistance Of Heat Exchanger
Tubes
Temperature 5X
Gradient
Shell
Tube
Total Tube-Side Tube-Side Tube Shell-Side Shell-Side

Resistance Fluid Deposition metal Deposition Fluid
l = rt + r tf + rm + rsf + rs
U
Effect on Heat Transfer
100
% Reduction in U-Coefficient
90 SiO2
80 Clay (Kaolin)
70
60 CaSO4
50
40
30 CaCO3
20
10 Al2O3
0
0.001 0.010 0.100
Scale Thickness (inches)
Scale Formation
+
- - + - CALCIUM
MAGNESIUM
+ +
SODIUM
BICARBONATE
- + - CHLORIDE
+ - +
SULFATE
Scale Formation
Concentrate Twice
+
- - + -
+ + + -
- + -+ -
+
- + - -+ - + +
+ - +
Scale Formation
Concentrate Four Times
+
- - + -
+ +
- + - --++-++-++-
+ - + +- - -
Scale Formation
Solubility Exceeded
Scale Potential Depends On:
Temperature
pH
Concentration Of Ions
Velocity
Agitation
Addition Of Solid Seeding Material
Mineral Scales
Inverse Solubility
Increasing
Solubility
Temperature
Mineral Scales vs Temperature
(Process)
HEAT
Ca+ CO3- Ca+ CO3- Ca+ CO3-
Ca+ CO3- Ca+ CO3- Ca+
CO3-
Ca+
CO3-
Ca+
Ca+
CO3-
Ca+ CO3- Ca+ CO3- Ca+
Ca+ CO3- Ca+ CO3- Ca+ CO3-
METAL SURFACE
HEAT
(Process)
Decreasing
Solubility
Mineral Scales
pH
Common Scales
CaCO3 Calcium Carbonate
CaSO4 Calcium Sulfate
Ca3(PO4)2 Calcium Phosphate
MgSiO3 Magnesium Silicate
Al2O3.SiO2 Aluminum Silicate
Zn3(PO4)2 Zinc Phosphate
FePO4 Iron Phosphate
CaO.MgO.2(SiO2) Calcium Magnesium Silicate

Calcium Carbonate
Most Common Scale in Cooling Water Systems
Degree of Scaling Depends on:
Calcium Hardness
Alkalinity
Total Dissolved Solids
pH
Temperature
Solubility
Calcium Carbonate
Calcium Carbonate Indices

L.S.I. = pHa - pHs
Where:
pHa = Actual pH
pHs = Saturation pH
pHs is a function of Ca, M-Alk, TDS, and Temperature
Calcium Carbonate Indices
L.S.I. Guidelines:
Positive (+) scale is likely to form
Negative (-) scale is not likely to form

GE Guidelines
Standard Technology +2.5
AEC Technology +2.85 - 3.0+
CaCO3 Solubility
LSI +2.5
1200
110F
1000
Calcium, ppm CaCO3
125F
800
140F
600
CaCO3 Deposition Expected
(even with treatment)
400
200 No CaCO3 Deposition Expected

(with treatment)
0
150 200 250 300 350 400 450 500 550 600 650 700
Alkalinity, ppm CaCO 3 ; 4,000 umhos
Calcium Phosphate
Less Soluble At High pH And Temperature
Sources
River Water
Partially Treated Sewage Waters
Phosphate-Based Programs
Calcium Phosphate
600
500
Calcium, as ppm CaCO3
400
300 pH = 7.0
200
100
pH = 8.2
0
0 1 2 3 4 5 6 7 8 9 10
-2
Orthophosphate, as ppm PO 4
Silica
Solubility Increases With Increasing pH And
Temperature
Dissolved Silica Exists In Natural Water
GE Normal Maximum
<200 ppm SiO2 (molybdate reactive)
Silicates
Solubility Decreases With Increasing pH and
Temperature
Solubility Affected By Calcium and Magnesium

Concentrations
Magnesium Silicate Saturation Index
(Soluble field test SiO2 x Mg) x cycles
Magnesium Silicate (MgSiO3) Solubility
Magnesium Silicate Product
500K
400K
300K
Deposition Expected
200K
100K
0
7.0 7.5 8.0 8.5 9.0
pH
Manganese
Source - Well Water
Metallurgy Dependent
Stainless Steel
Copper
Difficult to Remove
Severe Under-deposit Corrosion
Foulants
Mud / Silts
Organics / Oil
Dust / Dirt
Matter Precipitated In Bulk Water
Corrosion Products
Microbiological Forms
Foulants
Mechanisms:
Baked-on
Binding Agents
Do Not Form a Scale Deposit
Settle in Low Velocity Areas
Suspended Solids
Obey Stokes Law
Larger and Heavy
Many Amorphous Structures
Deposit Control
2 Types
Mechanical Chemical
Removal Inhibition
Process Dispersion
Adjustments
Mechanical
Categories
Removal Process Adjust

Softening Increase Velocity
Clarification Increase BD
Filtration Design Equip
Side Stream Reduce Temp
Cleaning Adjust pH
Chemical
Chemicals
Inhibition Dispersion
Threshold Synthetic Polymer
Sequestration Natural Polymers
Deposit Control
SOLUBLE VS INSOLUBLE
INHIBITION VS DISPERSION
Types of Inhibitors
SOLUBLE Sequestrant or Chelant
Threshold (Crystal Modifiers)

INHIBITION
Crystal Modifiers
Calcium Carbonate Crystal Modifier Modified CaCO3
Particle Particle
+ =
Metal
Surface
No Modifier Used With Modifier

Untreated
Treated
Organic Phosphates
Phosphonates
Calcium Carbonate
Threshold Inhibitor
Inhibit Scale by Adsorption
Sub-Stoichiometric
Can Precipitate
Affected by Iron and Chlorine
Organic Inhibitor
Alkyl Epoxy Carboxylate (AEC)
Calcium Carbonate
Non-Phosphorus
Superior Solubility
Superior Stability
Higher Cycles
Effective on CaSO4, BaSO4, CaF2
Inorganic Phosphates
Generally Act As Sequestrants
Pyro- And Meta- Phosphates
Unstable (Revert Or Hydrolyze)
Pyro - Is The Most Stable
Precipitation Can Occur
Dispersants
Control Particle Size
Imparting Excess Negative Charges
Particles To Repel
Polymers Adsorb onto Suspended
Solids...
...Imparting Negative Charges

Which Repel
Polymers Adsorb onto Suspended
Solids...
Repulsion
...Imparting Negative Charges

Which Repel
Polyacrylates
Effective for CaCO3 and CaSO4
Good on Suspended Solids
Not Easily Degraded
React with Cationic Materials
Nonoxidizing Biocides
Flocculants
Copolymer/Terpolymer
Effective for:
Phosphate / Phosphonate / Zinc
Suspended Solids
CaCO3
Iron
Inhibitors and/or Dispersants
Can React with Cationic Materials
Surfactants
Wetting Agents:
Oils & Greases
Biological Deposits
Removal of Deposited Materials

Applied with Dispersants
Have Polar and Non-Polar Region
Oil Dispersion With A Surfactant
SURFACTANT
WATER
MOLECULES
OIL
NON-POLAR
POLAR
Surfactants
Nonionic
Long Chain Hydrocarbon Oils
Microbes
Biocide or Chlorine Enhancer
Anionic
Ringed Hydrocarbons
Surfactants
Bio-Surfactant
Specifically Designed for Microbes
Does Not Work as Well on Oils
Blended with Nonionics for Leaks
Biocide Enhancers
Oxidizers
Nonoxidizers
Iron Based Scales
Exhibit Low Solubilities
Oxide Films Vary
Hard, Dense, Highly Adherent Scales
Loose, Highly Porous Deposits
Soluble Iron Oxidizes Readily

HVAC Inspections
& Cleaning Basics
Just the Facts!
Agenda
Typical Inspection
The Cleaning Process
Deposit Analysis
Cleaning Products
Centrifugal System
Compressor Evaporator
Condenser
Expansion Device
(Orifice)
Centrifugal System
Tube Fouling
Tube Fouling & Brushing
Clean Tube
Fouled Tube
Tube Fouling
Pipe Fouling
Tower Fill Fouling
Tower Fill Fouling
Documentation
Document each inspection
Document before and after each cleaning
Pictures
Water Analysis
Deposit Analysis
Corrosion Coupon Results
Performance Data
Chiller Log Sheet
LOG SHEET
Building:______________________________________________ - Chiller:______________________________________________
DATE: / / / / / / / / / / / / / / / / / / / / / / / /
COND TEMP & PRESS
Water In (F)
Water Out (F)

Refrig Liquid (F)
Refrig (PSI)
Water In (PSI)
Water Out (PSI)
Water In (F)
EVAP TEMP & PRESS
Water Out (F)

Refrig Liquid (F)
Refrig (PSI)
Water In (PSI)
Water Out (PSI)
COMPRESSOR
Oil Diff. (PSI)

Oil Sump (F)
Oil Sump Level (%)
Run Time (Hrs)

Phase 1 (Amps)
Phase 1 (Volts)
POWER
Phase 2 (Amps)
Phase 2 (Volts)
Phase 3 (Amps)
Phase 3 (Volts)
Cleaning
Corroded Mild Steel Tube

Dipped in a Cleaning Solution
Iron Desposit from

Corrosion
Is the Steel Protected after the Cleaning

???
Did it Attack the Steel ???
BUT What Happened to the Steel ???
Desposit is Removed
Ideal Cleaning Process
Dissolve the Deposit - ONLY

Passivate the Base Metal Immediately
Protective Deposit
Barrier
Tube
Questions To Ask
What is the Deposit?
What conditions are present (Mechanical / Chemistry / Other)
What will remove this deposit without removing the base metal?
How do I protect the base metal after the cleaning?

What Is The Deposit?
Company: Date:
City, State:
Account #: Date of Deposit Sampled:
Location of Deposit:
Data from Inorganic Analysis Report Calculated hypothetical compounds
LOI 5 CaCO3 45.4% Print

CO2 20 Ca3(PO4)2 21.8%
CaO 45 CaSO4 8.5%
P2O5 10 MgSiO3 8.3%
ZnO LOI 5.0% Return to
SiO2 5 Fe2O3 5.0% Input Sheet
Fe2O3 5 CaO 4.3%
SO3 5 MgO 1.7%
MgO 5
Al2O3
CuO
PbO
BaO
Na2O
Other
TOTAL 100
Company: Date:
City, State:
LOI 6 Fe2O3 56.9% Print

CO2 2 MgSiO3 10.0%
CaO 3 Fe2(SO4)3 10.0%
P2O5 4 FePO4 7.7%
ZnO LOI 6.0% Return to
SiO2 6 CaCO3 4.5% Input Sheet
Fe2O3 65 Na2O 4.0%
SO3 6 Ca3(PO4)2 0.9%
MgO 4
Al2O3
CuO
PbO
BaO
Na2O 4
Other
TOTAL 100
WHAT IS THE DEPOSIT
Company: Date:
City, State:
LOI 8 Ca3(PO4)2 16.0% Print

CO2 5 Fe2O3 15.0%
CaO 15 MgSiO3 14.9%
P2O5 12 CaCO3 11.4%
ZnO 4 Na2O 9.0% Return to
SiO2 9.5 LOI 8.0% Input Sheet
Fe2O3 20 Fe2(SO4)3 6.7%
SO3 4 Zn3(PO4)2 6.3%
MgO 12 MgO 6.1%
Al2O3 1 FePO4 4.3%
CuO 0.5 Al2SIO5 1.6%
PbO Cu3(PO4)2 0.8%
BaO
Na2O 9
Other
TOTAL 100
What Conditions?
On-Line or Off-Line Cleaning
What are the base metals
What are the wetted materials (compatibilities)
What is the water temperature
What is the time frame for the cleaning
What are the disposal/discharge issues

What Removes The Deposit?
Product CaCO3 CaSO4 CaPO4 Mn Silt Fe2O3 CuO MgSiO2
FQ7101 2 X X 1 2 1 X X
LP7200 1 X 2 X X 2 X X
LP7202 1 X 2 X X 2 X X
IEC2 1 X 2 1 X 1 1 X
AC9500 1 X 1 2 X 1 1 X
AC9507 1 1 1 1 X 1 1 X
SF502 1 X X X X X X X
Table 1:Effectiveness of Ferroquest, Kleen, and Depositrol products for various mineral deposits.
Scale Key
1 = Effective 2 = Has some Efficacy (special handling) X= Not Recommended
What Metals Are Safe?
Product Mild Steel Admiralty Copper Cu/Ni SS Titanium Galv. Aluminum
FQ7101 Y Y Y Y Y Y N Y
LP7200 Y Y Y Y Y Y N N
LP7202 Y Y Y Y Y Y N N
IEC2 Y Y Y Y Y Y N Y
AC9500 Y Y Y Y Y Y Y N
AC9507 Y Y Y Y N Y N N
SF502 Y Y Y Y Y Y Y Y
Table 2:Compatiblity of Ferroquest, Kleen, and Depositrol products for metallurgies. (As the cleaning solutions).
Scale Key
Y = Compatible N = Not Recommended
Protection After Cleaning
Corrosion Inhibitors during or immediately following Cleaning
Blended Cleaning Products may Include Corrosion Inhibitors
Multiple Products for Specialized or Unique Cases

Summary
Typical Inspection
The Cleaning Process
Deposit Analysis
Cleaning Products
* Trademark of the General Electric Company and
may be registered in one or more countries.
Legionella
Defining Terms
Legionella BACTERIA
a genus of bacteria
Legionellosis
Legionella
disease caused by Legionella
Legionnaires Disease
Pontiac Fever
LDB
Legionnaires Disease Bacterium
Legionella Bacteria
Legionella Bacteria
Rod-shaped (bacillus)
Aerobic Bacteria
Prefer sessile lifestyle - biofilms
Parasitic on amoebae
Require amino acid and iron
Widespread aquatic organism
Natural and man-made habitats
Legionella Reservoirs
Evaporative Condensers
Cooling Systems
Humidifiers
Produce Misters
Ornamental Fountains
Whirlpools
Spas
Potable water systems
Showers / Faucets
Hot water tanks
Respiratory Therapy Equipment
A Progressive Pneumonia
2-10 day incubation period
Cough Fever
Dyspnea Chest Pain
Headache Myalgia
Diarrhea Confusion
Fatality Rates
General Population 15%
Hospital Environment 40%
Treatable with Erythromycin
CDC estimates in US...
more than 25,000 cases/year
more than 4000 fatalities
Only 1000/year reported to CDC

Legionnaires Outbreaks
Cruise Ships
Exhibition Centers
Grocery Stores
Homes
Hospitals/Nursing Homes
Hotels
Industrial Facilities
Office Buildings
Legionellosis Risk Factors
2 Conditions:
Compromised Host Virulent Strain
3 Steps:
Transmission
Dissemination
Amplification
Step 1: Amplification
Natural Habitats: 10 Cells/Liter
Man-made Habitats: 106 Cells/Liter
68 - 113o F. (20 - 45o C.)
Sediment/Scale/Stagnation
Biofilms/Algae/Amoebae
Step 2: Dissemination
Simple Presence Not Enough
Must Be Virulent
Must Have Sufficient Numbers
Infectious Dose - Not Determined
Must Be Aerosolized
Droplets <5 micron
Step 3: Transmission
Must Be Inhaled (Deepest Part of Lung)
Not by Physical Contact
Not by Drinking Infested Water
Systems Conducive to 3 Steps:
Showers/Faucets/Water Heaters
Cooling Towers/Evaporative Condensers
Vegetable Sprayers
Humidifiers/Whirlpools/Spas
Condition 1:
Compromised Host
Weakened Immune System
Immunosuppressed
Underlying Illness
Cancer / Diabetes / AIDS
Elderly
Smokers
Condition 2:
Virulent strain
Capable of causing disease
Capable of evading host defenses
Improper diagnosis
Not all Legionella cause disease
41 species
61 serogroups
~ 20 species
human disease
Legionella pneumophila
14 serogroups
62 genetic variants Lp group 1
80% of cases
Legionella pneumophila serogroup 1
Managing the Risk

Risk Reduction
Location
Design
Mechanical maintenance
Water treatment
Record keeping
Employee awareness
Risk Reduction
February 2000 CTI Guideline
Day-to-Day Operations $
Preventative Measures $$
Emergency Disinfection $$$$
CTI Guidelines
Day-to-Day Operations
Preferred program
Continuous Halogen
0.5 - 1.0 ppm as Free Residual Chlorine
Recommended by regulatory agencies
Supercedes traditional 0.2 - 0 .5 FRC
CTI Guidelines
Preferred program
Continuous Halogen
2nd Choice - not preferred

Intermittent Halogen
CTI Guidelines
Nonoxidizing biocides and biodispersants
Supplement halogens
Intermittent halogenation
Wastewater makeup
Process contamination
Biofouling
Sulfate Reducers
CTI Guidelines
Prevenatative Measures
Periodic Hyper-halogenation
5 ppm FRCl2 for at least 6 hours
Leaks
Wastewater MU
High Counts
Biofouling
Precedents:
OSHA, ASHRAE, Wisconsin
CTI Guidelines
Prevenatative Measures
Take tower off-line
50 ppm Free Chlorine with biodispersant
Maintain
10 ppm FRCl2 in return 24 hrs
pH 7.5 - 8.0 Lost
Drain and repeat Production =
Major
Drain, inspect, repeat if needed Economic
Penalty
Emergency Disinfection
Other reasons to avoid it
High corrosion rates
Yellow metal
Mild steel
Tower wood delignification
mAlk 300+
pH 9+
Free residual chlorine >1.0
Safety When Cleaning
Minimize aerosols
Fans OFF !
Wear respirators
Half-face, filter for 1micron particles
Other protective equipment
Tyvek suit, hood, gloves
Close air intakes
Personal Protection
GE Recommendation
Aerosol risk?
Non-compliant system?
Personal health risk factors?
3M 8210 N95 3M 8511 N95

N95 Disposable Respirators
NIOSH: Natl. Institute for Occupational Safety and Health
N95: Filters out 95% particles .3 microns
Risk Reduction
February 2000 CTI Guideline
Preventative Measures
Avoid Emergency Disinfection
New Criteria For Effective Water
Treatment
Corrosion
Simultaneous control
Deposition
No Adverse impact
Biofouling & Avoid unnecessary costs

Legionella
Control
Dianodic PLUS
6.8 7.5 7.8 8.5 9.0 9.5
Dianodic III Continuum AEC

No Guarantees
GUARANTEE
.....
.
ERADICATE
LEGIONELLA
PREVENT
LEGIONELLOSIS
MAKE YOUR
SYSTEM SAFE
Local Sales Rep
Risk Reduction For Legionellosis
Risk Reduction For Legionellosis
Assessing the risk

Managing the risk
Developing a Legionella policy
Assessing the Risk
Biofouling
Biofouling
Corrosion Products
Corrosion Under-Deposit Corrosion Deposition
Legionellosis
Pontiac Fever
Pontiac Fever
Non-Pneumonia Flu-like Illness
1-3 day incubation
Fever
Headache
Myalgia
Non-Fatal
Recovery
2-5 days
without antibiotic
The Bellevue Stratford

Philadelphia, Pennsylvania
A Progressive Pneumonia
2-10 day incubation period
Cough Fever
Dyspnea Chest Pain
Headache Myalgia
Diarrhea Confusion
Fatality Rates
General Population 15%
Hospital Environment 40%
Treatable with Erythromycin
Legionella Bacteria
Rod-shaped (bacillus)
Motile
Widespread aquatic organism
Infected Macrophage
Legionnaires Pneumonia
Legionnaires Disease in Context
CDC estimates in US...

more than 25,000 cases/year
more than 4000 fatalities
Only 1000 cases/yr reported to CDC

Death from various causes...
120,000
100,000
Hospital Error *
80,000
60,000
A
g
MV
in
s'
on
ire
40,000
ois
g
na
nin
ion
ls
dP
ion
Fal
ow
iat
Foo
20,000
Leg
Av
Dr
329 3959 4000 5000 14,986 43,649 120,000

US Cooling Towers: 350,000 !
Not the only reservoir
Legionella Reservoirs
Evaporative Condensers
Humidifiers
Produce Misters
Whirlpools
Spas
Potable water systems
Showers / Faucets
Hot water tanks
Respiratory Therapy Equipment
Legionellosis Outbreaks
Cruise Ships
Exhibition Centers
Grocery Stores
Homes
Hospitals/Nursing Homes
Hotels
Industrial Facilities
Office Buildings
Conditions For Legionnaires Disease
Amplification
Dissemination
Virulence
Susceptibility
Amplification
Natural habitats: 10 cells per liter
Man-made: 106 cells per liter
68 - 113F. (20 - 45C.)
80 - 108F. (27 - 42C.)

Amplification
Natural habitats: 10 cells per liter
Man-made: 106 cells per liter
68 - 113F. (20 - 45C.)
80 - 108F. (27 - 42C.)
Stagnation/Sediment/Scale/Corrosion
Biofilms/Algae/Amoebae
Outbreak
Legionella
Amoeba
Legionella
Biofilm
Amplification
Simple presence not enough
Must have sufficient numbers...
BUT !...
Infectious dose - not determined
10/ml? 100/ml? 1000/ml?

Legionella Monitoring
Routinely? ...NO
Poor control method
Assume they are there !
Gone today, Here tomorrow
Infectious density - unknown
Pathogenic type?
High risk environments? ...MAYBE
Outbreak? ...YES
Identify source
Verify decontamination
OSHA Recommended Responses To
Legionella
Action Cooling Domestic
Tower Water Humidifier
Prompt
Cleaning &/or
Treat w/Biocide
100 10 1
Immediately
Clean &/or Treat
w/Biocide;
Prevent 1000 100 10
Exposure
Legionella Colony Forming Units per mL
Recommended Targets
General Aerobic Bacteria
PARAMETER DIPSLIDES PLATE COUNT

Bulk water <10,000 CFU/ml <10,000 CFU/ml
Surfaces <100,000 <100,000

CFU/cm2 CFU/cm2
Do plate counts correlate to Legionella risk?

What Routine Monitoring Should Be
Done?
Monitor System Cleanliness
Visual Inspection
Bioscan ATP-Based Biomonitoring
Bulk Water
Surfaces
Bioscan
ATP-Based Biomonitor
Dissemination
Aerosols
Inhaled
< 5 micron
Deepest part of the lung
Virulence
Species
Sero-group
Passage through amoeba
Legionella Bacteria
41 species
61 serogroups
~ 20 species
human disease
Legionella pneumophila
14 serogroups
62 genetic variants Lp group 1
80% of cases
Legionella pneumophila serogroup 1
Conditions For Legionnaires
Disease
Susceptibility
Weakened immune system
Immunosuppressed
Underlying illness
Cancer
Diabetes
AIDS
Elderly
Smokers
Elements of Risk
Tepid Water 68-113F. Untreated System
pH 5 - 9 Low/No Halogen
Stagnant Conditions
Reclaimed makeup
Dead Legs
Organics/Nutrients
Aerosol Generator
Scale/Corrosion Worker Exposure
Biofilms (Slime) Worker Health
Algae Down Wind Sites
Bulk Water Counts

Biofouling
Biofouling
Corrosion Products
Recent Outbreaks
Norway - 8/01
17 cases/2 dead
Cooling tower outlet near bus terminal
Spain - 7/01 - 420 cases min./4 dead
Source unknown
Brook Park, OH - 3/01
4 cases/2 dead
Ford casting plant; source?
Melbourne - 3/01
5 cases/2 dead
Cooling tower on building
Spain - 10/00
28 cases/3 dead
Community acquired; Towers at Hospital?
If You Do Monitor...
HAVE A PLAN!!!
How to interpret the numbers
What you will do in response

Managing The Risk
Biofouling
Biofouling
Corrosion Products
Treatment Concerns
Biofouling
Biofouling
Corrosion Products
No Guarantees
GUARANTEE
.....
.
ERADICATE
LEGIONELLA
PREVENT
LEGIONELLOSIS
MAKE YOUR
SYSTEM SAFE
Local Sales
Rep
Risk Reduction
Not Just
Chemicals
Risk Reduction
Key Elements
Design
Mechanical Maintenance
Water Treatment
Record Keeping
Employee Awareness
Risk Reduction By Design
Cooling tower placement
Away from air intakes
Away from sources of organics, nutrients
Downwind of outdoor public areas
Future construction?
Effective drift eliminators
Avoid dead legs
Control system temperatures
(<68F. or >140F.)
Provisions for cleaning
Risk Reduction Through Maintenance
Repair/Replace drift eliminators
Minimize process leaks
Remove sediment
Treat the water
Keep air filters dry
Responses to the Legionellosis Risk
CDC
OSHA
State of WISCONSIN
JCAHO
ASHE
ASHRAE
Cooling Technology Institute (CTI)
Risk Reduction
General Guidelines
High efficiency mist eliminators
Maintain system cleanliness
Apply water treatment program
Corrosion, Scale, and Biocontrol
Minimize Bio-growth
Process leaks
Water stagnation
Keep records
Risk Reduction
CTI Guidelines
Day-to-Day Operations $
Preventative Measures $$
Emergency Disinfection $$$$
Bacteria
Two Lifestyles:
Planktonic
Free-floating
Sessile
Unprotected Planktonic
Sessile
Attached to a Surface
Protected
Preferred Lifestyle!
Biofilm
Diffusion Limited Transport

High Demand
Non-livingfor
Demand
Halogens
Reduced Environment
10,000 x
Biofilm
Block Heat Transfer

Cause Corrosion
Economic- MIC
Penalties
Reduce Water Flow
10,000 x
CTI Guidelines
Preferred Program
Continuous Halogen
CTI Guidelines
Preferred Program
Continuous Halogen
2nd Choice - not preferred
Intermittent Halogen
1.0 ppm FRCl2
Hold at least 1 hour per day
CTI Guidelines
Use with halogens
Non-potable makeup
Leaks Target system cleanliness
Biofilms
with the right biocides
Sulfate Reducers
Oxidizers + Nonoxidizers
Critical for Intermittent Halogen
Select based on Toxicant Evaluation
Aerobic Heterotrophic Bacteria
CTI Guidelines
Preventative Measures
Periodic Hyper-halogenation
5 ppm FRCl2 for at least 6 hours
Leaks
Wastewater MU
High Counts
Biofouling
Precedents:
OSHA, ASHRAE, WISCONSIN
CTI Guidelines
Emergency Disinfection
Take tower off-line
50 ppm Free Chlorine with Biodispersant
Maintain
10 ppm FRCl2 in return 24 hrs
pH 7.5 - 8.0
Drain and Repeat
Drain, inspect, repeat if needed
Lost Production = Major Economic Penalty

New Criteria For Effective Water
Treatment
Corrosion
Simultaneous Control
Deposition
No Adverse Impact
Biofouling & Avoid Unnecessary Costs

Legionella
Control
Safety When Cleaning
Minimize aerosols
Fans OFF !
Wear respirators
Half-face, filter for 1 micron particles
Other protective equipment
Tyvek suit, hood; gloves
Close air intakes
Personal Protection
GE Recommendation
Aerosol risk?
Non-compliant system?
Personal health risk factors?
3M 8210 N95 3M 8511 N95

N95 DISPOSABLE RESPIRATORS
NIOSH: Natl. Institute for Occupational Safety and Health
N95: Filters out 95% particles .3 microns
Developing a Legionella Policy
Avoid Legionellosis Lawsuits Over Cooling Towers
W. Craig Meyer, Pierce College
Chemical Engineering, Sept. 2000
Who Should be Responsible for Legionella?

Jay S. Gregory, Esq.
ASHRAE Journal
May 2000
Whos Responsible For Legionella
Risk Minimization?
Lawsuit targets:
System designer
Installation contractors
Facility (building) owner
Maintenance personnel
Contractors
What Is The Risk To My Company?
Liability vs Negligence
Failure to warn
Damages awarded
Assess Your Risk
Type of facility
Health care, apartment building, school, industrial etc.
Age of facility
Systems involved
Size of systems
Types of potential exposure

Aerosol generators
Activities
Physical status
Current water treatment
Results of treatment
Assess Your Risk
Who might be exposed to suspect systems?
General population
Older work force, potential health issues
High risk situations - health care facilities
Is there a history?
At your facility or a sister facility?
Known previous cases?
Suspected cases?
Who Are The Policy Makers?
Senior Management
Employee Health and Safety
Facility engineering and maintenance
Medical staff
Labor representatives
Water treatment provider
Consultants
Where Do We Start?
Site audit of systems
Risk assessment
Aerosols
Location - exposure potential
Design
Physical condition
Operating parameters
Treated or forgotten?
Where Do We Start?
Water treatment review
Products
Residuals
Frequency
Results
Compare to guidelines and recommendations
Where Do We Start?
Water treatment review

Is your provider capable?
Can they work with you
Do they have appropriate products
Can they provide guidance
Are current results acceptable?
Develop and Implement Plan

Action plan
1)Corrective action
Budget picture - cost vs. risk analysis
Prioritize - crucial fixes vs. $$$$
Address with Engineering/Maintenance
2)Normal day-to-day operations
3)Emergency response (what if?)
4)Employee education
Develop and Implement Plan
Document, document, document!!!!

Facility upgrades & maintenance
Water treatment program
Chemicals and applications
Chemical residual testing
Performance
Microbiological monitoring
Corrosion and deposit control
Employee awareness vehicles
By the way.
How many facilities?
Are you global?
Summary
Assess your risk
Systems review
Aerosols
Favorable growth conditions
Cleanliness
Compliance
Exposure potential
Numbers
Demographics
Time
Summary
Develop proactive measures
Design
Maintenance
Treatment
Repair/Remediation
Develop emergency response plans
Summary
Educate
Risk minimization
Understanding risk
PPE
Response plans
Document
Policy
Maintenance/Repairs
Disinfection residuals
Biomonitoring results
Employee awareness vehicles
Summary
Risk of Legionella outbreaks can be managed
Be proactive
Be aggressive
Plan ahead
Responsibility is a facility wide issue
Balance costs against overall improvements in system
performance
Consult with experts
Work with your water treatment provider
Resources
CTI Position Statement
281-583-4087 www.cti.org
ASHRAE
404-636-8400 www.ashrae.org
Guideline 12P
Reprint: Who Should Be Responsible for Legionella
OSHA Technical Field Manual
www.osha.gov
Section III Chapter 7 Legionnaires Disease
GE
Legionella Q&A Capability Profile 25
Best Practice Recommendations Technical Bulletin 73
HC Resources
Microbiological Problems, Monitoring and Control
Cooling Water Microbiology
Problems
Factors Favoring Microbial Growth In
Cooling Systems
Sources
air
makeup
Water
Temperature
< 32oF. - > 212oF.
mesophiles 68 - 113oF.
Factors Favoring Microbial Growth In
Cooling Systems
pH
< 2 - > 10
5 - 9 most common
Nutrients
air
makeup
process contamination
Microorganisms
Small size
1 u = 1/1000 mm = ~4/100,000 inch
Rapid growth potential
100/ml x 224 hrs. = 1,677,721,600/ml
Large populations
105 - 106/ml in water; 109 1012/g in deposits
Environmentally flexible
Nutritionally versatile
Primary Biofouling Organisms
Algae
Fungi
Bacteria
Algae
Photosynthetic
CO2 fixers
Pioneer colonizers
Algae
Problems Caused by Algae
Physical/mechanical
Chemical
Biological
Environmental
Fungi
Plant-like but lack chlorophyll
Degrade wide variety of organics
Forms
Filamentous, i.e., molds
Unicellular, i.e., yeasts
Fungi
Problems Caused by Fungi

Degrade Tower Wood
External attack soft rotDegrade cellulose
Internal attack deep rot
Brown rot: degrade cellulose
White rot: degrade lignin & cellulose
Bacteria
Most common
Grow throughout cooling systems
Extremely diverse
Bacteria Types
Heterotrophs
Organics for energy and carbon
Autotrophs
Inorganics for energy
H2, Sulfur, Ammonia, Nitrite, Iron, Manganese
Fix CO2 for carbon
Bacteria
Bacteria
Bacteria Types
Aerobes
Aerobic respiration
Oxidize nutrients with free O2
Facultative Anaerobes
Fermentation
Coupled oxidation-reduction of molecule
Obligate Anaerobes
Anaerobic respiration
Oxidize nutrients with combined O2
CO2, SO4-2, NO3-
Sulfate Reducing Bacteria (SRB)
System Cleanliness Indicators
Anaerobic
Cannot Survive in Bulk Water
Thrive Under Biofilms
Reduce Sulfate (SO4) to Sulfide (S-2)
Strongly Implicated in Corrosion
Bacterial Growth
Two Lifestyles:
Planktonic
Free-floating
Sessile
Unprotected
Planktonic
Sessile
Attached to a Surface
Protected
Preferred Lifestyle!
Biofilms
Formed by sessile organisms
Cells immobilized at a substratum ...frequently

embedded in an organic polymer matrix of microbial
origin. (Characklis and Marshall)
A tissue of microorganisms coating submerged

surfaces
10,000 X
Biofilms
Not passive deposits
biochemically active
generate gradients
Biofouling Problems
Reduced heat transfer
Reduced water flow
Increased corrosion rates
Increased health risk
Impact On Heat Transfer
Cooling Water Flow
Biofilm - Stagnant Water Layer

(25 - 80 Times < Conductive Than Steel)
Impact On Water Flow
Cooling Water Flow
Roughness
& Drag
Biofilm...Visco-Elastic Layer
Impact On Corrosion
Block corrosion inhibitors
Create concentration cells
Generate corrosive by-products
Depolarize corrosion cell
Resulting Penalties
Lost production
Higher maintenance costs
Reduced equipment life
Higher operating costs
Reduced profitability
Biofouling Control
Must not be a secondary consideration
Essential for
Maximum equipment life
Optimum equipment performance
Unit reliability
Critical to profitability
Questions?
Monitoring
Why Monitor?
Assess system cleanliness
Warn of fouling
Guide application of biocides
Comply with best practice guidelines
Be proactive, not reactive
What To Monitor?
Bulk Water or Surfaces?
Bulk water contains planktonic forms
Free-Floating Organisms
Easy to gather
Easy to analyze
Do bulk water
Broadly accepted
samples
Useful water quality indicator, but reflect surface
conditions?
What To Monitor?
Do bulk water samples reflect surface conditions?

Planktonics easily controlled
10 - 100 x lower biocide level than sessiles
Sessiles protected within film
Sloughing releases planktonic organisms
Overwhelms control program
Planktonics: Last to
show, first to go.
What To Monitor?
Planktonic counts can mislead
Program efficacy
False security
Sudden loss of control
System cleanliness
Equipment fouled despite
Free Cl2
Low bulk water counts
What To Monitor?
Bulk Water or Surfaces? Sessile
Monitor surfaces Planktonic
Organisms prefer surfaces
Sessiles cause problems
Sessiles generate planktonics
Sessile monitoring gives direct info.
System cleanliness
Biocide effectiveness
Where To Monitor?
Heat Exchangers
Critical/High heat flux equipment
Air-bumped or Back-washed HXs
Opened exchangers
Corrosion or deposit coupons
Areas of Low Water Velocity
Tower Fill
Tower Deck
but not the tower sump

When To Monitor?
ROUTINELY ! ..and Trend the Data
Frequency for Industrial Systems:
Planktonic: 1x - 2x per week
Sessile: 1x 2x per month
Dependent on:
Plant process
System operating history
Available personnel
Monitoring Tools
Culture-based
Dipslides, PetrifilmTotal aerobic bacteria
SRB Check Kite Recers (anaerobes)
Indirect methods
delta T
delta P
Biochemical markers
ATP, Protein, DNA
Bioscan
ATP-based Biomonitoring
Bioscan 2
Bioscan 2
Why monitor ATP?
ATP = Adenosine Triphosphate
High Energy Phosphate Bonds
Primary Carrier of Biologically Useful Energy
Energy Currency of the Cell
Produced Only in Living Cells
Proportional to Cell Activity and Numbers
~10-15 gram ATP / Bacterial Cell
Decreases When Cells Die
Bioscan
How is ATP detected?
Chemistry
ATP + Luciferase + Luciferin(reduced)
Luciferin(oxidized) + AMP + Light (Photon)
Light is Detected by Photometer

> Light is Directly Proportional to ATP
> Result is Expressed as Relative Light Units
RLU ~ Light ~ ATP ~Cells and Activity

Bioscan Procedure
STEP 1
Micro-organisms
Lysing ATP released
+ Into buffered
Agent
Solution
STEP 2 STEP 3
Measure
Emitted
Enzyme
+ 110 Light in
Reagents
Betz Dearborn
BIOSCAN
Rlus
ATP MONITOR
ATP (RLU) vs Plate Count (cfu/mL)
ATP vs CFU/ml from Field Studies, 1995
8.00
7.00
6.00
5.00
Observation
4.00
3.00
2.00
1.00
0.00
1.00 2.00 3.00 4.00 5.00 6.00
Microbial ATP - Log (RLU)
Bioscan
ATP advantages over culture-based methods?
ATP Culture-based
Detects ALL microbes Detect only those that grow on
Bacteria, Fungi, Algae, et al media
Detects ALL bacteria classes and Requires many growth media
types and conditions
Time: 1 to 5 Days before colonies
Results in <10 Minutes form
Allows immediate response to Response delayed until colonies
problem are visible
The View With Culture Based Monitoring
Only 0.1 - 10% Recovery
of Total Microbes
The View Using Atp
Monitoring
100% of Total Microbes
Bioscan
What do the numbers mean?
A qualitative indicator
Safe Bulk Water
Caution <100 RLU
Danger 100 500 RLU
A semi-quantitative tool >500
+/- 32% coefficient of variation
Use for trending
Results From Any Mb Monitoring
Procedure
What do the numbers mean?
No absolute guidelines for microbial cleanliness
Data is a relative indicator of changes within the
system
Develop a history to establish site-specific guidelines
Questions?
Control
Cooling Water Biocontrol
What are the options?
Oxidizing biocides
Non-oxidizing biocides
Supplemented with
Biodispersants
Biocide enhancers
Kill ~ C x T x Lc
Mode Of Action
Oxidizers & Nonoxidizers
Nutrients
The Microbial Cell Membrane
Waste
Energy
Synthesis
Oxidizing Biocides
Oxidizers
Chlorine gas
Sodium hypochlorite
Bromine
BCDMH
NaBr
Stabilized liquid bromine
Chlorine dioxide
Ozone
Peroxygens
Oxidizing Biocides
Mode of Action:
Burns Reduced Compounds

Proteins, Lipids, Fatty Acids, etc.
Damages Cell Membrane
Damages Essential Cell Machinery
Oxidizing Biocides
Reaction with demand:
Reduced Inorganic Species
Organic Materials
Aqueous Ammonia
Mode Of Action
Oxidizers
DEMAND
Biofilms
10,000 X
Oxidizers
Chlorine gas
Sodium hypochlorite
Bromine
BCDMH
NaBr
Stabilized liquid bromine
Chlorine dioxide
Ozone
Peroxygens
Non-oxidizing Biocides
Non-oxidizing Biocides
Surface Active Agents
Metabolic Inhibitors
Quaternary Amines (ADBAC)
DGH (Dodecyl Guanidine Hydrochloride)
R2
|
(C12 - C16) - N+ - R3 Cl-
|
R4
The Micrbial Cell
Osmotic Pressure
Nutrients H2O
H2O
H2O
H2O
Nutrients
H2O
H2O
H2O H2O
Nutrients
H2O
H2O
Nutrients
H2O H2O
Bronopol
DBNPA
Glutaraldehyde
Isothiazolone
Terbuthylazine
Microbial Respiration
O2
2H+
2H+
2H+
2H+ H2O
2H 0
2e-
2e- 2e- ENERGY
Mode Of Action
M.I.
2H+ 2H+
2e- X
2e- ENERGY
Why Use Nonoxidizers?
Trouble Spots for Oxidizers
Slime Penetration
High Efficiency Film Fill
Intermittent Feed
Open Decks
Raw/Waste H2O MU
Process Contamination
Why use nonoxidizers?
Supplement halogens
Intermittent halogenation
Wastewater makeup
Process contamination
Biofilm penetration
Sulfate Reducers
Biofouling cleanup
Chloride limits
Multiple Active Formulations
Synergism
1+1=3
Better control at lower dosages
Expand the kill spectrum
Broader control
Minimize number of products needed
Slow the selection of resistant strains
Improve the duration of biocontrol
Extend useful life of product
Which product is right to use?
EPA Registration
System operating parameters
Retention time
pH
Type of bio-problem
Toxicant evaluation results
Discharge environment
Performance Monitoring
Monitor & Control
Cooling Tower
Treatment Program
Water Chemistry
Performance
Tower Inspection
Components
Screens Distributors
Mist Eliminators Buildup On Surfaces
Deck Air Flow Louvers
Fill Basin
Screens
Mist Eliminators
Tower Deck
Fill
Fill
Fill
Distributors
Basin Nozzles Louvers
Treatment Program
Monitoring
Inhibitor Residuals
Dispersant Residuals
Tracers
Feed Rates
Consistent (Desired Control Range)
Treatment Program
Controlling
Controllers
Chemical Pumps
Specialized Feed
Equipment
Chemical Pump
Treatment Program
Automation
Continuous Monitoring
Continuous pH Control
Blowdown Control
Chemical Feed Control
Alarm Capabilities
Tower Chemistry
Monitoring
pH
Water Chemistry
Cycles
Oxidizer Residuals
Scaling Tendencies
Tower Chemistry
Controlling
Dissolved Solids
Calcium Levels
Silica
Other Specific to Potential Limitations
Suspended Solids
pH
Oxidizer
Aquatrack Controllers
Smart AS & FLEX
Smart Automated Systems
Smart AS Controllers
Moderate Level of Sophistication
1 Cooling Tower or up to 4 Boiler Systems
with Single Product Feed
Smart FLEX Controllers

Complex Level of Sophistication
1 Cooling Tower and up to 3 Boilers with 4
Chemical Feeds
Smart AS
Monitor / Control Sensors

Conductivity, pH, ORP, Temperature
Up to 4 Level Sensors
3 Water Meter Inputs
Such as: M/U, BD, Closed Loop M/U
Smart AS
Control Outputs
Blowdown Solenoid Control
4 Configurable Output Relays
Inhibitor Pump
Acid or Caustic Pump
Biocide Pumps
Control Algorithm
Water Meter Proportional
Setpoint Control
Tower Cycle Control
Smart FLEX
Monitor / Control Sensors

Conductivity, pH, ORP, Temperature
Up to 8 Level Sensors
6 Water Meter Inputs
Such as: M/U, BD, Closed Loop M/U
Smart AS & FLEX
Security
3 Levels of Security
Data Acquisition and Alarm Management
Maintains 5 Weeks of Hourly Data
Maintains Previous 2 Years of Flow Data
User-Selectable Alarm Call-Out (Telephone or Pager System)
Direct Communication Link via Telephone Modem
Smart AS & FLEX
Controller Networking
One Telephone Line Talks to Many Controllers
Connects to up to 16 SMART AS & FLEX Controllers
Complete Remote Command & Control
From on-site PC or off-site Modem w/ auto-switching
Adjust Setpoints
Set Alarms & Dial-outs
Modify Treatment Programs
Revise Biocide Timing
Review Water Usage
Results
Monitoring
Corrosion Rates
Deposition Control
Heat Transfer
Tower Performance
Flows
Equipment Inspection
Coupons
Petrifilm
BioScanTM 2
Luminometer
Heat Exchanger Monitoring
Why Monitor??
Early Detection
Treatment Program Modifications

What Needs To Be Monitored?
Critical Exchangers = Process Critical And
Exchangers with . . .
Low Velocities <2.0 ft/s
High Skin Temperatures >160F
High Heat Flux (>10,000 BTU/hr ft2)
Shell Side Cooling
Vertical Alignment
Throttled Inlet Valves
Monitoring Techniques
U-Coefficients
Approach Temperatures
Terminal Temperatures
Vacuum Pressure
Pressure Drop (C Factor)
U-Coefficient
Most Popular
Compare Actual To Design
Compare Actual To Clean
Effective BUT Requires Intensive Data

Collection
U-Coefficient
Function of Flow Rates on Process and Water Side, All
Temps, Water & Process Side Fouling
Instrumentation is Mandatory - Calibrated
Instrumentation Must Be Sensitive
Must Be Evaluated at Identical Conditions
Simplified U-Coefficient Measurement
Minimal Instrumentation
Simple
Countercurrent HX: Condenser:

Approach Temp = TTD = TPo - T Wo
TPo - T Wi
TPi TPi TPo
T Wo TPo T Wo
Heat T Wi T Wi Heat
Transfer Transfer
T1 Length T2 T1 Length T2
Monitoring Recommendations
Establish Frequency and Check Accuracy of
Instrumentation
Trend Data
Charts
InfoCalc
Monitoring Recommendations
Quantity (More is Better) -- Combine Methods
MonitAll
Coupons
U-Coefficients/Approach Temperatures
InfoCalc
Microbial fouling - BioScan
Equipment Inspection
Monitor & Control
Results
Chemistry
Program
Conductivity Controller
pH Controller
Chlorine Analyzer
Corrosion Rate Meters
GE MonitAll
Temperature Heated Test

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Cooling Basics

Conduct electrical currents

React with metal to cause corrosion

M-Alkalinity = HCO3- + CO3-- + OH-

pH Adjustment with 93% Sulfuric Acid (66o Be) H2SO4

To adjust alkalinity down by 50 ppm you need to add 50

LSI = pH - pHs where pHs is the pH at which

Measured pH (pHa) : 8.2 pH

+3.0 Extremely Severe Scaling

Retrograde: Decreases with Temperature

100 (MW CaCO3) = 4.1

Specific Conductance 425 2210 1691

Hardness, Total, 145 725 538

MU CT1 CT2 CT1 CT2

Specific Conductance 425 2210 1691 5 .2 4 .0

Hardness, Total, 145 725 538 5 .0 3 .7

Compa ny: H a ppy Custome r D a te : 2-31-03

Loca tion of D e posit:

Data from Inorganic Analysis Report Ca lcula te d hypothe tica l compounds

LOI 9 CaCO3 59.0%

Analysis gives weight of oxidized species

Does not give detailed organic analyses

Consider source and quantity

Use COMMON SENSE

Align edges (not

Industry Standards for Cooling Systems

Mild Steel < 3 mpy

Water (Density 8.34 lbs/gal)

A cooling Tower has a blowdown rate of 120,000

Calculate the gallons of Product ABC needed.

100 PPM x 1 MM Lbs (H2O) = 100 lbs

Chilled Water Loop

ma1 + mw3hw3 = ma2hm2 + mw4hw4

ma1(ha1 + w1hv1) + mw3hw3 = ma2(ha2 + w2hv2) + mw4hw4

ma[cp,a(T1 T2) + w1hg1 w2hg2] = mw4hf4 mw3hf3

mw4 = mw3 ma(w2 w1)

Sensible Heat - Heat energy stored in a substance as a result of an

Small surface area Large surface area

Hot Water Hot Water

Cycles of Concentration Demonstration

EVAPORATION (GPM) = T x RECIRCULATION RATE (GPM) x (0.9) / 1000

BLOWDOWN = EVAPORATION / (CYCLES 1)

% LOAD = AVG. OPERATING TONNAGE / TOTAL TONNAGE * 100

Cooling Tower Water Loop

Chilled Water Loop

High Pressure High

Highest Pressure Lowest Pressure

High Pressure High Low Pressure Lowest

Cooling Tower Water Loop

Chilled Water Loop

Chilled Water Loop

Corrosion Historical Review

Zinc Phosphate (late 60's)

Polynodic (early 70's)

Dianodic BAT / Zinc

6.5 7.0 7.5 8.0 8.5 9.0

Neutral pH Programs (6.8 to 7.8)

Copper Inh. TTA, BZT TTA, BZT

Dispersant Co & Terpolymer Co & Terpolymers

CaCO3 Inh. HEDP,PBTC HEDP, PBTC

Corrosion Potential Minimized

Acid Reduction or Elimination

CaCO3 CaCO3 CaCO3