Cooling Water - Packarious

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COOLING TOWER

PROBLEMS & SOLUTIONS

by Paul R. Puckorius

Puckorius & Associates, Inc.

www.Puckorius.com

www.watertrainingservices.comApril 13, 2011

Presented by Process Cooling
http://www.puckorius.com/http://www.puckorius.com/


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COOLING TOWER SYSTEM

PROBLEMS & SOLUTIONS Cooling Tower-Where & What

* Materials of Construction

* Fill- Splash vs High Efficiency

Heat Transfer Equipment

* Proper Initial Startup Recirculation Lines

* Initial Protection/ Stagnant Water


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NEW GALVANIZED STEEL

COOLING TOWERPROBLEM -White Rust

This is corrosion of Galvanized SteelSOLUTION -Proper Initial Startup if

a New Tower

*Follow Manufacturers GuidelinesThis takes several weeks/ months

at a controlled pH ( 6.0- 8.0 )


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a New Tower- Rapid -12-48 hours

*Use 100-150 ppm phosphate with agood phosphate scale inhibitor and

a pH of 7.0-7.5. Then maintain 3-5

ppm phosphate in tower treatment


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a New Tower- Rapid -12-48 hours

*Use 100-150 ppm poly silicate witha pH of 7.5-8.5. Then maintain a

silicate level of 20-30 ppm.


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GALVANIZED COOLING TOWERS-

POTENTIAL VENT CONTAMINATION


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OLD GALVANIZED STEEL


This is corrosion of Galvanized Steel

SOLUTION

*Clean with Citric Acid

*Use Rapid Passivation- either

phosphate or poly silicate method or

epoxy coating of water wet areas

* Consider Magnesium Anodes


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GALV. STEEL COOLINGTOWER SEVERE CORROSION


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GALV. TUBING IN TOWER

(Fluid Coolers)PROBLEM -White Rust & Leaks


a New Fluid Cooler

*Follow Manufacturers GuidelinesThis takes several weeks/ months

at a controlled pH ( 6.0- 8.0 )


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( Fluid Cooler)PROBLEM -White Rust- Leaks


SOLUTION -Proper Initial Startup if

a New Cooler- Rapid -12-48 hours

*Use 100-150 ppm phosphate with agood phosphate scale inhibitor and

a pH of 7.0-7.5. Then maintain 3-5

ppm phosphate in water treatment


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CORRODED GALV. STEEL PIPE


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(Fluid Cooler)PROBLEM -White Rust


SOLUTION

*Clean with Citric Acid

*Use Rapid Passivation- eitherphosphate or poly silicate method or

epoxy coating of water wet areas


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REBUILDING WITH TREATED

COOLING TOWER WOODPROBLEMLeaching of preservative-

copper/arsenic- can cause copper

plating on mild steel & corrosionSOLUTION

*Treat with a copper Inhibitor at

50-100 ppm to tie-up the copper

and to fix preservative in the wood

during treated wood replacement


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PROBLEMCan harbor Legionella

bacteria and add as food source

but may increase tower efficiencySOLUTIONNeed to add biocide to

the cooling tower return and to

maintain a residual through the fill-if oxidant hold 0.5 ppm free and/or

use a non-oxidant weekly till gone

COOLING TOWER WITHALGAE COATED SPLASH FILL


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SPLASH FILL WITH ALGAE


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COOLING TOWER WITH

HIGH DENSITY FILM FILLPROBLEMIf plugged or restricted

will reduce tower efficiency and

could collapse fill into tower basinSOLUTIONUsually high in biofilm-

add biocide and dispersant to the

return water to tower- if an oxidantused should be positive out of fill-

find that hydrogen peroxide works


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FOULED FILM FILL


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FOULED FILM FILL


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NEW HIGH DENSITY FILM FILL


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CYCLONECARTRIDGE

FILTERS


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STONES AND FIBERS PLUGGINGCONDENSER TUBES


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Filter Types and Sizing Dense Particles- Cyclone Type

Light Weight- Sand & Cartridge

Mixture- Sand & Cartridge & MMF* Oil- Absorbant Type

Full Flow or Side Stream

Side Stream Filters Tower Volume 3-4times per day (often 3-5% recirc. rate)

*Multi-Media Filter


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Obtaing Cleaner Cooling

Water Use Filters- On Every Cooling Tower

Use Water Agitators in Basin w/Filters

Use Chemical Dispersants w/Filters


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NEW MILD STEEL TUBED

HEAT EXCHANGERPROBLEMCorrosion and rust

deposits found after 6 months in

service- started up without initialhigh level corrosion inhibitor

SOLUTION

*Clean with Hydro-blast or Chemical*Use a Rapid Passivation with a

Phosphate-based inhibitor ( 60 ppm)


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MILD STEEL TUBES AND TUBESHEET W/ RUST DEPOSITS


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CLEANED MILD STEEL TUBESAND TUBE SHEET


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NEW MILD STEEL TUBED

HEAT EXCHANGERPROBLEMStartup needed with a

combination alkaline cleaner and a

mild steel passivation treatmentSOLUTION- If an isolated bundle:

* Clean/Passivate w/ 1.5% Phosphate

& cleaner for 2-4 hours at 120-140*F.* If not isolated use a phosphate at

40-60 ppm (PO4), ambient, for 48 hrs


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NEW COPPER TUBED

HEAT EXCHANGERPROBLEMCorrosion can occur withinone year if no initial passivation- pits

& localized attack often w/enhanced

tubes but also smooth tubes

SOLUTIONInitial Protection Needed

* Treat exchanger with 50-100 ppm ofa good copper corrosion inhibitor

* Keep high level for 24 hours- then

maintain 5 ppm copper inhibitor


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SUPER ENHANCED COPPERTUBE


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ENHANCED COPPER TUBE W/ PIT


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ENHANCED COPPER

TUBED CHILLERPROBLEM - Corrosion can occur withpits & localized attack in grooves

with low copper inhibitor (1-2 ppm)

SOLUTION

*Need to maintain 3-5 ppm copper

inhibitor (active) at all times

* If chiller shut down- restart

w/copper inhibitor at 10-20 ppm

(active) for a week


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NEW STAINLESS STEEL

PLATE & FRAME BUNDLEPROBLEMCorrosion and leaks- bundle

periodically stagnant

SOLUTION*Sulfate reducing bacteria (SRB) can

cause pits and loss of protection

*Add a good SRB biocide regularly*Eliminate stagnant water or rinse

with10% H2O2 before stagnant period


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STAINLESS STEEL PLATE &FRAME HEAT EXCHANGER


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MILD STEEL TUBE SHEET

WITH COPPER TUBESPROBLEMSevere tube sheet

corrosion due to galvanic couple

SOLUTION- Little from water treatment* Use a multi-coat epoxy (different

colors) after blasting & rebuilding

* Also coat water box and channelwith same- Inspect & repair yearly

* New chiller should be coated


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SEVERE CORROSION OF MILD STEELTUBE SHEET DUE TO COPPER TUBES


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EPOXY COATED TUBE SHEET


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ZINC SACRIFICIAL ANODE


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NEW MILD STEEL PIPING

PROBLEMOften stagnant for

weeks/months after hydrotest- can

cause serious corrosion/deposits.

SOLUTION- Initial water treated with a

combination alkaline cleaner and a

mild steel passivation treatment

* Use a phosphate/cleaner combo at50-100 ppm (PO4) and maintain till

operating then reduce to 20 ppm PO4


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FOULED STEEL PIPE


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A Complete Cooling Water

Treatment Program Proper Initial Conditioning

Scale Control

Fouling Control

Corrosion Control

Microbio ControlAll items must be controlled. If one area is

not controlled, the entire program may fail.


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Need to Know Your System-All Water Contacted Surfaces

Metals- tubes, lines, water boxes, tube

sheets, and cooling towerEquipment Design- water in tubes, water on

shell, jackets, fill type in tower

Operation- max. water temp, min. watervelocity, any stagnant periods, anycontamination from air or water or process

Water-Concentrated Tower Water


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Water Conservation for

Cooling Tower Systems Higher Cycles of Concentration

Newest Technology Currently Available

ChemicalsScale Inhibitors (Crystal Modifiers)

Softening w/blowdown Return

Non-Chemical

Filters

Several Electric/pulse/wave devices


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Water Reuse- Saving Fresh

Successful in many Industries-the nearfuture of most

Use of Internally generated used waterSoftener rinse, RO reject, boiler blow

down, chiller condensate,

Externally available recycle water

treated municipal waste water (recyclewater) and even rain water.


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Green Products Available

ChemicalsBiocides- Ozone. Chlorine Dioxide,

Peroxides, Quats

Corrosion Inhibitors- Organics, Silicates,and even Tin Salts

Deposit inhibitors- from Oysters

Non-Chemical

Filters

Devices- Pulse/Electric/Precipitators


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Measuring Results-To Verify

Equipment Protection System Inspections during outages

Monitoring Systems on-line

Corrosion by coupons & Instantaneous

Deposits by heat transfer monitors

Bio-corrosion by specific monitorsBio-deposits by ATP, DNA, Sessile

rather than Planktonic


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THANK YOU FOR LISTENING

GLAD TO ANSWER ANY AND ALLQUESTIONS

Cooling Tower

Problems & Solutions


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NEED MORE HELP?

HOW TO CONTACT US?Puckorius & Associates, Inc.

6621 West 56th Ave Suite 200 Arvada, Colorado 80002

Phone-303-674-9897 Fax-303-674-1453

Florida Office- 9005 Lake Lynn Drive Sebring, FL 33876

Phone 863-655-1036

E-mail [email protected] - www.Puckorius.com &www.watertrainingservices.com

Paul Puckorius cell- 303-638-0587
mailto:[email protected]://www.puckorius.com/http://www.puckorius.com/mailto:[email protected]


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