COMMON COOLING

SYSTEM PROBLEMS

CWT-64
 Cooling System Problems
Left unchecked these
problems cause
• Loss of heat transfer
• Reduced equipment life
• Equipment failures
• Lost production
MICROBIO
• Lost profits
• Increased maintenance
costs
CORROSION
• Plant shutdown

CWT-65
 MINERAL SCALE

CWT-66
 Mineral Scale

• Cooling Water contains many different

minerals -- normally these minerals are
dissolved in the water
• Under certain conditions minerals can
come out of solution and form into hard,
dense crystals called SCALE

CWT-67
 Mineral Scale
CaCO3
Common Scales
• Calcium Carbonate
• Magnesium Silicate
• Calcium Phosphate
• Calcium Sulfate
• Iron Oxide
• Iron Phosphate
CaPO4 • Others...
Scaled Heat Exchanger Tubes
CWT-68
 Mineral Scale

The Following Factors Affect

Scale Formation...
Mineral Concentration
Water Temperature
Water pH
Suspended Solids
Water Flow Velocity

CWT-69
 Temperature & Scale Tendency
Temperature

Scaling Tendency

CWT-70
 Mineral Scale

• Scale forms in hot areas of cooling

systems
• Reduces heat transfer efficiency
• Mechanical/Chemical cleaning
• Under deposit corrosion (pitting)
• Plant shutdown
• Equipment replacement

CWT-71
 Preventing Mineral Scale

• Limit concentration of scale forming

minerals: Blowdown, clarify/filter MU
• Feed acid to reduce pH & alkalinity:
Reduces scaling -- increases corrosion
• Mechanical design changes: Increase
HX water velocity, backflush, air rumble
• Apply chemical scale inhibitors

CWT-72
 Mineral Scale

Three Classifications Of Scale

Inhibiting Chemicals Are…

• Crystal Modifiers
• Sequestrants
• Dispersants

CWT-73
 Crystal Modifiers
Minerals do not align in
a tight matrix

Organophosphates & organic dispersants

distort the crystal structure of scale so that it
does not become tightly adherent

CWT-74
 Sequestrants

Treated Untreated

Polyphosphates & anionic dispersants form a

complex with troublesome minerals to
prevent them from forming scale

CWT-75
 Dispersants

Compounds such as polyacrylates are

large molecules that impart a charge
causing scale forming minerals to repel
each other
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- - -
-
- - - -
Particle
Particle
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- - -
- - -
- - -
CWT-76
 CORROSION

CWT-77
 CORROSION

Corrosion is the mechanism by which

metals are reverted back to
their natural “oxidized” state

CWT-78
 Corrosion
e-
Battery Analogy
• Anode
• Cathode
Cathode • Electrical Circuit
Anode

• Metal lost at anode

Electrolyte

CWT-79
 Simplified Corrosion Cell
STEP 4 OH-
O2 O2
STEP 1
Water with
Dissolved STEP 3
Fe 2+
Minerals
Base Metal CATHODE

e- e-
ANODE e- e-
STEP 2

CWT-80
 Four Step Corrosion Model
• Step 1: At the anode, pure iron begins to break down
in contact with the cooling water. This step leaves
behind electrons.
• Step 2: Electrons travel through the metal to the
cathode.
• Step 3: At the cathode, a chemical reaction occurs
between the electrons and oxygen carried by the
cooling water. This reaction forms hydroxide.
• Step 4: Dissolved minerals in the cooling water
complete the electrochemical circuit back to the
anode.

CWT-81
 Factors Influencing Corrosion

• pH
• Temperature
• Dissolved Solids
• System Deposits
• Water Velocity
• Microbiological Growth

CWT-82
 Corrosion Vs. pH
100
Corrosion Rate, Relative Units

10

0
5 6 7 8 9 10
pH

CWT-83
 Corrosion Vs. Temperature
Temperature

In general, for every 18°F in

water temperature, chemical
reaction rates double.
Corrosion Rate

CWT-84
 Other Causes of Corrosion

Dissolved Solids
• Complete circuit from cathode to anode
System Deposits
• Anodic pitting sites develop under deposits
Water Velocity
• Too low = deposits
• Too high = Erosion
Microbiological Growth
• Deposits; Produce corrosive by-products
CWT-85
 Types of Corrosion
All cooling system metallurgy experiences some degree
of corrosion. The objective is to control the corrosion
well enough to maximize the life expectancy of the
system...

1. General Corrosion
2. Localized Pitting Corrosion
3. Galvanic Corrosion

CWT-86
 General Corrosion
Water
• Preferred
Thickness
Original

Base Metal
situation
• Take a small
General Etch Uniform Attack
amount of metal
evenly throughout
the system
• Anode very large

CWT-87
 Pitting Corrosion
Water
• Metal removed at
Thickness
Original

same rate but from

Base Metal a much smaller area
Localized Pitting Attack • Anode very small
• Often occurs under
deposits or weak
points
• Leads to rapid
metal failure

CWT-88
 Galvanic Corrosion
Active End
Magnesium
• Occurs when two Galvanized Steel
Mild Steel
different metals are Cast Iron
18-8 Stainless Steel Type 304 (Active)
in the same system 18-12-3 Stainless Type 316 (Active)
Lead Tin
• More reactive metal Muntz Steel
Nickel (Active)
will corrode in 76-Ni-16 Cr-7 Fe Alloy (Active)
Brass
presence of less Copper
reactive metal 70:30 Cupro Nickel
67-Ni-33 Cu Alloy (Monel)
• Potential for galvanic Titanium
18-8 Stainless Steel Typ 304 (Passive)
corrosion increases 18-12-3 Stainless Steel Type 316 (Passive)
Graphite
with increasing Gold
distance on chart Platinum
Passive End

CWT-89
 Galvanic Corrosion

CWT-90
 Affects of Corrosion
• Destroys cooling system metal
• Corrosion product deposits in heat exchangers
• Heat transfer efficiency is reduced by deposits
• Leaks in equipment develop
• Process side and water side contamination occurs
• Water usage increases
• Maintenance and cleaning frequency increases
• Equipment must be repaired and/or repaired
• Unscheduled shutdown of plant

CWT-91
 Methods To Control Corrosion

• Use corrosion resistant alloys: $

• Adjust (increase) system pH: Scale
• Apply protective coatings: Integrity
• Use “sacrificial anodes”: Zn/Mg
• Apply chemical corrosion
inhibitors

CWT-92
 Anodic Corrosion Inhibitors
• Stop corrosion cell Anodic Inhibitors
by blocking the • Chromates
anodic site • Nitrites
• Severe localized • Orthophosphates
pitting attack can
occur at an • Silicates
unprotected anodic • Molybdates
sites if insufficient
inhibitor is present

CWT-93
 Cathodic Corrosion Inhibitors
• Stop corrosion cell Cathodic Inhibitors
by blocking the • Bicarbonates
electrochemical • Polyphosphates
reaction at the
cathode • Polysilicates
• Corrosion rate is • Zinc
reduced in direct
proportion to the
reduction in the size
of the cathodic area.
CWT-94
 General Corrosion Inhibitors
• Protect metal by General Inhibitors
filming all surfaces • Soluble Oils
whether they are • Tolyltriazoles
anodic or cathodic
• Benzotriazoles

CWT-95
 FOULING

CWT-96
 Fouling

FOULING is the accumulation of solid

material, other than scale, in a way that
hampers the operation of equipment or
contributes to its deterioration

CWT-97
 Common Foulants
Suspended Solids
• Silt, Sand, Mud and Iron
• Dirt & Dust
• Process contaminants, e.g. Oils
• Corrosion Products
• Microbio growth
• Carryover (clarifier/lime softener)

CWT-98
 Factors Influencing Fouling
• Water Characteristics
• Water Temperature
• Water Flow Velocity
• Microbio Growth
• Corrosion
• Process Leaks

CWT-99
 Affects of Fouling
• Foulants form deposits in hot and/or low flow
areas of cooling systems
• Shell-side heat exchangers are the most
vulnerable to fouling
• Deposits ideal for localized pitting corrosion
• Corrosive bacteria thrive under deposits
• Metal failure results

CWT-100
 Economic Impact of Fouling
• Decreased plant efficiency
• Reduction in productivity
• Production schedule delays
• Increased downtime for maintenance
• Cost of equipment repair or replacement
• Reduced effectiveness of
chemical inhibitors

CWT-101
 Fouling

Three Levels Of Attack Can Be Employed

To Address The Effects Of Fouling...

1. Prevention
2. Reduction
3. Ongoing Control

CWT-102
 Preventing Fouling
Prevention
• Good control of makeup clarification
• Good control of corrosion, scale, & microbio
Reduction
• Increase blowdown
• Sidestream filter
Ongoing Control
• Backflushing, Air rumbling, Vacuum tower basin
• Chemical treatment

CWT-103
 Fouling

Chemical Treatment
• Charge Reinforcers
• Wetting Agents

CWT-104
 Charge Reinforcement Mechanism

• Anionic polymers increase strength of charge

already present on suspended solids
• Keep particles small enough so they do not
settle out
Highly
Anionic
Slightly anionic Chemical Suspended Solid
suspended which has adsorbed
particle highly anionic
chemical

CWT-105
 Wetting Agents

• Surfactants Particle Build-up

• Penetrate existing
deposits
• Wash away from
metal surfaces

With Wetting Agent

CWT-106
 MICROBIOLOGICAL
GROWTH

CWT-107
 Microbiological Growth
• Water treatment is The microbial fouling
about managing process is...
three fouling • The most complex
processes... • The least understood
• The hardest to measure
Corrosion
and monitor
Scale • Controlled using the
Microbio least desirable, most
expensive, & potentially
hazardous products

CWT-108
 Microbiological Growth

Three Kinds Of Troublesome

Microorganisms In Cooling Water...

1. Bacteria
2. Algae
3. Fungi

CWT-109
 Bacteria
• Bacteria extremely small

• Compared to a
human, a bacteria is
like a grain of sand
to the Sears Tower
• Size allows many
(millions) to fit into a
small volume of
Sears
water... Tower

CWT-110
 Bacteria
• There are as many
bacteria in 12 oz. of
cooling water as there
are people living in the 12oz.
United States Cooling Water

• There are 40,000 times

as many bacteria in a
50,000 gallon cooling
system as there are 40,000 X
people in the world! 50MGAL
Cooling System

CWT-111
 Bacteria

Types of Bacteria
1. Slime Forming
2. Anaerobic Corrosive
3. Iron Depositing
4. Nitrifying
5. Denitrifying

CWT-112
 Bacteria

Typical Rods Slime Formers

Anaerobic Iron Depositing

CWT-113
 Bacteria
• Produce acidic waste that lowers pH and
causes corrosion
• Produce large volumes of iron deposits that
foul
• Produce acids from ammonia that increase
corrosion & lower pH
• Form sticky slime masses that foul & cause
reduced heat transfer

CWT-114
 Two Classifications of Bacteria
Planktonic:
• Free-floating bacteria in bulk water

Sessile:
• Bacteria attached to surfaces
• Over 95% of bacteria in a cooling system are
sessile and live in BIOFILMS

CWT-115
 Biofilms
• Contribute to all cooling
water problems 
• Underdeposit corrosion 
• Trap silt & debris which
foul heat exchangers 
and tower fill
• Provide nucleation sites
for scale formation
Biofilm Formation

CWT-116
 Biofilms
Thermal
• More insulating than Foulant Conductivity
Common
most common scales  CaCO3 1.3-1.7
biofilms are 4
CaSO4 1.3
• Reduce heat transfer CaPO4 1.5
times more
insulating
efficiency MgPO4 1.3 than CaCO3
Fe Oxide 1.7 scale!
• Increase dP across Biofilm 0.4
heat exchangers &
reduce flow
• Health risks (legionella) FLOW

P P

CWT-117
 Algae

• Require sunlight to grow

• Found on tower decks & exposed areas
• Form “algae mats”
• Plug distribution holes on tower decks
• Plug screens/foul equipment
• Consume oxidants
• Provide food for other organisms

CWT-118
 Fungi
• Use carbon in wood
fibers for food
• Destroy tower
lumber by either
surface or internal
rotting (deep rot)
• Loss of structural
integrity of tower

CWT-119
 Factors Affecting Growth of
Microorganisms
• Microorganism Sources: Air or Makeup water
• Cooling systems provide the ideal
environment for microbiological growth
• Nutrients: Ammonia, oil, organic contaminants
• Temperature: 70-140°F acceptable
• pH: 6.0 - 9.0 ideal
• Location: Light/No Light
• Atmosphere: Aerobic/Anaerobic

CWT-120
 Controlling Microbiological
Growth
Water Quality
• Eliminate organic contaminants (food)
• No food = No bugs
System Design Considerations
• Clean basin, plastic, cover decks
Chemical Treatment with Biocides

CWT-121
 Microbiological Growth

Chemical Treatment With Biocides

• Oxidizing Biocides
• Non-oxidizing Biocides
• Biodispersants

CWT-122