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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NEW GALVANIZED STEEL
COOLING TOWERPROBLEM -White Rust
This is corrosion of Galvanized SteelSOLUTION -Proper Initial Startup if
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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NEW GALVANIZED STEEL
COOLING TOWERPROBLEM -White Rust
This is corrosion of Galvanized SteelSOLUTION -Proper Initial Startup if
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
COOLING TOWERPROBLEM -White Rust
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
This is corrosion of Galvanized SteelSOLUTION -Proper Initial Startup if
a New Fluid Cooler
*Follow Manufacturers GuidelinesThis takes several weeks/ months
at a controlled pH ( 6.0- 8.0 )
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GALV. TUBING IN TOWER
( Fluid Cooler)PROBLEM -White Rust- Leaks
This is corrosion of Galvanized Steel
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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GALV. TUBING IN TOWER
(Fluid Cooler)PROBLEM -White Rust
This is corrosion of Galvanized Steel
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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