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Details of Water-CoolingDetails of Water-Cooling
SystemSystem
• Cooling towers and ReservoirsCooling towers and Reservoirs
• Direct cooling to DiesDirect cooling to Dies
• Indirect cooling to oil through HeatIndirect cooling to oil through Heat
ExchangersExchangers
• Pre-treatment of Water through WaterPre-treatment of Water through Water
SoftenerSoftener
• No Blowdown facility from bottom of waterNo Blowdown facility from bottom of water
reservoirsreservoirs
WHY DO COOLING WATER PROBLEMWHY DO COOLING WATER PROBLEM
EXIST ?EXIST ?
If cooling water left untreated , cooling waterIf cooling water left untreated , cooling water
system provide an environment where thesystem provide an environment where the
four main cooling problems will exist:four main cooling problems will exist:
• CORROSIONCORROSION
• SCALESCALE
• FOULINGFOULING
• MICRO BIOLOGICAL CONTAMINATIONMICRO BIOLOGICAL CONTAMINATION
WHAT ARE THE EFFECTS OF THOSEWHAT ARE THE EFFECTS OF THOSE
PROBLEMS ?PROBLEMS ?
• Increased maintenance costIncreased maintenance cost
• Reduced heat transfer efficiency andReduced heat transfer efficiency and
therefore greater energy lossestherefore greater energy losses
• Possible production cutbacks orPossible production cutbacks or
shutdownsshutdowns
• Direct loss or abandon of plant &Direct loss or abandon of plant &
machineriesmachineries
Methods of Prevention and Control ofMethods of Prevention and Control of
ScaleScale
• Removal of scale forming minerals by pre-Removal of scale forming minerals by pre-
treatment of makeup water.treatment of makeup water.
• Limiting the concentration of scale formingLimiting the concentration of scale forming
minerals by bleed control.minerals by bleed control.
• Replacing scale-forming minerals withReplacing scale-forming minerals with
soluble salts by acid dosing.soluble salts by acid dosing.
• Controlling the scale forming processControlling the scale forming process
using scale-inhibiting chemicals.using scale-inhibiting chemicals.
Corrosion ControlCorrosion Control
ConceptsConcepts
The rate of attack by circulating coolingThe rate of attack by circulating cooling
water on steel is a function of temperaturewater on steel is a function of temperature
and pH. It increases with temperature andand pH. It increases with temperature and
depression of pH.depression of pH.
Corrosion protection follows two rules:Corrosion protection follows two rules:
High pH promotes scale and inhibitsHigh pH promotes scale and inhibits
corrosioncorrosion
Low pH inhibits scale and promotes corrosionLow pH inhibits scale and promotes corrosion
WHAT TYPE OF WATER CHARACTERISTICS AFFECTWHAT TYPE OF WATER CHARACTERISTICS AFFECT
CORROSIONCORROSION
• Oxygen and other dissolved gasesOxygen and other dissolved gases
• Dissolved or suspended solidsDissolved or suspended solids
• Alkalinity or acidityAlkalinity or acidity
• VelocityVelocity
• TemperatureTemperature
• Microbial activityMicrobial activity
WHAT METHODS ARE USED TO PREVENTWHAT METHODS ARE USED TO PREVENT
CORROSION ?CORROSION ?
• When designing a new system chooseWhen designing a new system choose
corrosion resistant material to minimizecorrosion resistant material to minimize
• The effect of an aggressive environment.The effect of an aggressive environment.
Adjust pHAdjust pH
• Apply protective coatings such as paints,Apply protective coatings such as paints,
metal plating etcmetal plating etc
• Add Protective Film Forming ChemicalAdd Protective Film Forming Chemical
InhibitorsInhibitors..
THE EFFECTS OF SCALE ON HEAT TRANSFER ANDTHE EFFECTS OF SCALE ON HEAT TRANSFER AND
ENERGYENERGY
• EFFECT OF CaCO3 SCALE (OF VARYING THICKNESS) ONEFFECT OF CaCO3 SCALE (OF VARYING THICKNESS) ON
OVERALL HEAT TRANSFER  COEFFICIENTOVERALL HEAT TRANSFER  COEFFICIENTScale Thickness, InchesScale Thickness, Inches Overall heat transfer coefficient, BTU per sq ft perOverall heat transfer coefficient, BTU per sq ft per
deg Fdeg F
Percent loss in BTU per sq ft per degPercent loss in BTU per sq ft per deg
FF
0.0000.000 92.7792.77 00
0.0120.012 73.6873.68 20.5820.58
0.0240.024 61.1261.12 34.1234.12
0.0360.036 52.2052.20 43.7343.73
0.0480.048 45.6045.60 55.8355.83
0.0600.060 40.4640.46 56.3956.39
0.0625 (1/16 in.)0.0625 (1/16 in.) 39.5239.52 57.4057.40
THE EFFECTS OF SCALE ON HEAT TRANSFER ANDTHE EFFECTS OF SCALE ON HEAT TRANSFER AND
ENERGYENERGY
EFFECT OF CaSO4 (OF VARYING THICKNESS) ON OVERALL HEAT TRANSFER EFFECT OF CaSO4 (OF VARYING THICKNESS) ON OVERALL HEAT TRANSFER 
COEFFICIENTCOEFFICIENT
Overall heat transfer scale thickness, inchesOverall heat transfer scale thickness, inches Coefficient, BTU per sq ft per deg FCoefficient, BTU per sq ft per deg F Percent loss in BTU per sq ft per deg FPercent loss in BTU per sq ft per deg F
0.0000.000 92.7792.77 00
0.0120.012 63.1063.10 31.9831.98
0.0240.024 47.8147.81 48.4648.46
0.0360.036 38.4938.49 58.5158.51
0.0480.048 32.2032.20 62.0062.00
0.0600.060 27.6927.69 70.0070.00
0.0625 (1/16 in.)0.0625 (1/16 in.) 26.8926.89 71.071.0
PROBLEMS CAUSED BYPROBLEMS CAUSED BY
MICROORGANISMSMICROORGANISMS
• HEAT TRANSFER EFFECTSHEAT TRANSFER EFFECTS
• FLUID FLOW EFFECTSFLUID FLOW EFFECTS
• CORROSION EFFECTCORROSION EFFECT
Parameters to Assess Water QualityParameters to Assess Water Quality
• pHpH
• TDSTDS
• Total HardnessTotal Hardness
• Calcium HardnessCalcium Hardness
• Total AlkalinityTotal Alkalinity
• LSILSI
• RSIRSI
What is pH?What is pH?
• pH is a measure of the acidity or basicity apH is a measure of the acidity or basicity a
solution. Solutions with a pH less than seven aresolution. Solutions with a pH less than seven are
considered acidic, while those with a pH greaterconsidered acidic, while those with a pH greater
than seven are considered basic. pH 7 isthan seven are considered basic. pH 7 is
defined as neutral because it is the pH of puredefined as neutral because it is the pH of pure
water at 25 °Cwater at 25 °C
• It should be between 7 and 8.5 for cooling-waterIt should be between 7 and 8.5 for cooling-water
system.system.
What is TDS?What is TDS?
• It means density of “Total DissolvedIt means density of “Total Dissolved
Solids” in water. To avoid carryover andSolids” in water. To avoid carryover and
deposition (due to super saturation) indeposition (due to super saturation) in
system, TDS should be maintained withinsystem, TDS should be maintained within
1000 ppm. This can be controlled by blow1000 ppm. This can be controlled by blow
down only.down only.
What is ‘Total Hardness’?What is ‘Total Hardness’?
• Technically, it is the sum of all polyvalentTechnically, it is the sum of all polyvalent
cationscations
• Practically, it is the amount of calcium andPractically, it is the amount of calcium and
magnesium ions, which are themagnesium ions, which are the
predominant minerals in natural waterspredominant minerals in natural waters
• This will indicate the amount of scalingThis will indicate the amount of scaling
load going to system for internalload going to system for internal
treatment.treatment.
What is ‘Calcium Hardness’?What is ‘Calcium Hardness’?
• Calcium Hardness is caused by theCalcium Hardness is caused by the
presence of calcium ions in the waterpresence of calcium ions in the water
• Calcium salts can be readily precipitatedCalcium salts can be readily precipitated
from water and high levels of calciumfrom water and high levels of calcium
hardness tend to promote scale formationhardness tend to promote scale formation
in the water system.in the water system.
What is ‘Total Alkalinity’?What is ‘Total Alkalinity’?
• Alkalinity is a water's acid-neutralizingAlkalinity is a water's acid-neutralizing
capacitycapacity
• Alkalinity measures the total amount ofAlkalinity measures the total amount of
base present and indicates a waterbase present and indicates a water
reservoir’s ability to resist large pHreservoir’s ability to resist large pH
changes, or the “buffering capacity.” changes, or the “buffering capacity.” 
• The most important components ofThe most important components of
alkalinity are carbonates andalkalinity are carbonates and
bicarbonates.bicarbonates.
Langelier Saturation IndexLangelier Saturation Index
• The Langelier Saturation Index (LSI;also called LangelierThe Langelier Saturation Index (LSI;also called Langelier
Stability Index) is a calculated number used to predictStability Index) is a calculated number used to predict
the calcium carbonate stability of water; that is, whetherthe calcium carbonate stability of water; that is, whether
a water will precipitate, dissolve, or be in equilibrium witha water will precipitate, dissolve, or be in equilibrium with
calcium carbonatecalcium carbonate
• If LSI is negative: No potential to scale, the water willIf LSI is negative: No potential to scale, the water will
dissolve CaCO3dissolve CaCO3
• If LSI is positive:  Scale can form and CaCO3If LSI is positive:  Scale can form and CaCO3
precipitation may occurprecipitation may occur
• If LSI is close to zero: Borderline scale potential. WaterIf LSI is close to zero: Borderline scale potential. Water
quality or changes in temperature, or evaporation couldquality or changes in temperature, or evaporation could
change the index.change the index.
Ryznar Stability IndexRyznar Stability Index
(RSI)(RSI)
• The Ryznar stability index (RSI) attempts to correlate anThe Ryznar stability index (RSI) attempts to correlate an
empirical database of scale thickness observed in waterempirical database of scale thickness observed in water
systems to the water chemistry. Like the LSI, the RSIsystems to the water chemistry. Like the LSI, the RSI
has its basis in the concept of saturation levelhas its basis in the concept of saturation level
• RSI << 6 the scale tendency increases as the indexRSI << 6 the scale tendency increases as the index
decreasesdecreases
• RSI >> 7 the calcium carbonate formation probably doesRSI >> 7 the calcium carbonate formation probably does
not lead to a protective corrosion inhibitor filmnot lead to a protective corrosion inhibitor film
• RSI >> 8 mild steel corrosion becomes an increasingRSI >> 8 mild steel corrosion becomes an increasing
problem.problem.
Chemical TestingChemical Testing
Chemicals /Chemicals /
ParametersParameters
DensityDensity
(kg/litre(kg/litre
))
ColourColour OdourOdour pHpH Increase inIncrease in
TDS ofTDS of
water (1kg)water (1kg)
on 1 mlon 1 ml
additionaddition
AST - 6600AST - 6600 1.09 to1.09 to
1.111.11
Light GreenLight Green PungentPungent 0.1 to 0.30.1 to 0.3 660 to 710660 to 710
AST - 6602AST - 6602 1.12 to1.12 to
1.131.13
Coca ColaCoca Cola Pungent,Pungent,
PhenolicPhenolic
0.5 to 0.70.5 to 0.7 170 to 190170 to 190
AST - 7711AST - 7711 1.04 to1.04 to
1.051.05
Light BrownLight Brown
PhenolicPhenolic
10 to 10.510 to 10.5 4.2 to 4.64.2 to 4.6
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Aqua sai ppt

  • 1.
  • 2. Details of Water-CoolingDetails of Water-Cooling SystemSystem • Cooling towers and ReservoirsCooling towers and Reservoirs • Direct cooling to DiesDirect cooling to Dies • Indirect cooling to oil through HeatIndirect cooling to oil through Heat ExchangersExchangers • Pre-treatment of Water through WaterPre-treatment of Water through Water SoftenerSoftener • No Blowdown facility from bottom of waterNo Blowdown facility from bottom of water reservoirsreservoirs
  • 3. WHY DO COOLING WATER PROBLEMWHY DO COOLING WATER PROBLEM EXIST ?EXIST ? If cooling water left untreated , cooling waterIf cooling water left untreated , cooling water system provide an environment where thesystem provide an environment where the four main cooling problems will exist:four main cooling problems will exist: • CORROSIONCORROSION • SCALESCALE • FOULINGFOULING • MICRO BIOLOGICAL CONTAMINATIONMICRO BIOLOGICAL CONTAMINATION
  • 4. WHAT ARE THE EFFECTS OF THOSEWHAT ARE THE EFFECTS OF THOSE PROBLEMS ?PROBLEMS ? • Increased maintenance costIncreased maintenance cost • Reduced heat transfer efficiency andReduced heat transfer efficiency and therefore greater energy lossestherefore greater energy losses • Possible production cutbacks orPossible production cutbacks or shutdownsshutdowns • Direct loss or abandon of plant &Direct loss or abandon of plant & machineriesmachineries
  • 5. Methods of Prevention and Control ofMethods of Prevention and Control of ScaleScale • Removal of scale forming minerals by pre-Removal of scale forming minerals by pre- treatment of makeup water.treatment of makeup water. • Limiting the concentration of scale formingLimiting the concentration of scale forming minerals by bleed control.minerals by bleed control. • Replacing scale-forming minerals withReplacing scale-forming minerals with soluble salts by acid dosing.soluble salts by acid dosing. • Controlling the scale forming processControlling the scale forming process using scale-inhibiting chemicals.using scale-inhibiting chemicals.
  • 6. Corrosion ControlCorrosion Control ConceptsConcepts The rate of attack by circulating coolingThe rate of attack by circulating cooling water on steel is a function of temperaturewater on steel is a function of temperature and pH. It increases with temperature andand pH. It increases with temperature and depression of pH.depression of pH. Corrosion protection follows two rules:Corrosion protection follows two rules: High pH promotes scale and inhibitsHigh pH promotes scale and inhibits corrosioncorrosion Low pH inhibits scale and promotes corrosionLow pH inhibits scale and promotes corrosion
  • 7. WHAT TYPE OF WATER CHARACTERISTICS AFFECTWHAT TYPE OF WATER CHARACTERISTICS AFFECT CORROSIONCORROSION • Oxygen and other dissolved gasesOxygen and other dissolved gases • Dissolved or suspended solidsDissolved or suspended solids • Alkalinity or acidityAlkalinity or acidity • VelocityVelocity • TemperatureTemperature • Microbial activityMicrobial activity
  • 8. WHAT METHODS ARE USED TO PREVENTWHAT METHODS ARE USED TO PREVENT CORROSION ?CORROSION ? • When designing a new system chooseWhen designing a new system choose corrosion resistant material to minimizecorrosion resistant material to minimize • The effect of an aggressive environment.The effect of an aggressive environment. Adjust pHAdjust pH • Apply protective coatings such as paints,Apply protective coatings such as paints, metal plating etcmetal plating etc • Add Protective Film Forming ChemicalAdd Protective Film Forming Chemical InhibitorsInhibitors..
  • 9. THE EFFECTS OF SCALE ON HEAT TRANSFER ANDTHE EFFECTS OF SCALE ON HEAT TRANSFER AND ENERGYENERGY • EFFECT OF CaCO3 SCALE (OF VARYING THICKNESS) ONEFFECT OF CaCO3 SCALE (OF VARYING THICKNESS) ON OVERALL HEAT TRANSFER  COEFFICIENTOVERALL HEAT TRANSFER  COEFFICIENTScale Thickness, InchesScale Thickness, Inches Overall heat transfer coefficient, BTU per sq ft perOverall heat transfer coefficient, BTU per sq ft per deg Fdeg F Percent loss in BTU per sq ft per degPercent loss in BTU per sq ft per deg FF 0.0000.000 92.7792.77 00 0.0120.012 73.6873.68 20.5820.58 0.0240.024 61.1261.12 34.1234.12 0.0360.036 52.2052.20 43.7343.73 0.0480.048 45.6045.60 55.8355.83 0.0600.060 40.4640.46 56.3956.39 0.0625 (1/16 in.)0.0625 (1/16 in.) 39.5239.52 57.4057.40
  • 10. THE EFFECTS OF SCALE ON HEAT TRANSFER ANDTHE EFFECTS OF SCALE ON HEAT TRANSFER AND ENERGYENERGY EFFECT OF CaSO4 (OF VARYING THICKNESS) ON OVERALL HEAT TRANSFER EFFECT OF CaSO4 (OF VARYING THICKNESS) ON OVERALL HEAT TRANSFER  COEFFICIENTCOEFFICIENT Overall heat transfer scale thickness, inchesOverall heat transfer scale thickness, inches Coefficient, BTU per sq ft per deg FCoefficient, BTU per sq ft per deg F Percent loss in BTU per sq ft per deg FPercent loss in BTU per sq ft per deg F 0.0000.000 92.7792.77 00 0.0120.012 63.1063.10 31.9831.98 0.0240.024 47.8147.81 48.4648.46 0.0360.036 38.4938.49 58.5158.51 0.0480.048 32.2032.20 62.0062.00 0.0600.060 27.6927.69 70.0070.00 0.0625 (1/16 in.)0.0625 (1/16 in.) 26.8926.89 71.071.0
  • 11. PROBLEMS CAUSED BYPROBLEMS CAUSED BY MICROORGANISMSMICROORGANISMS • HEAT TRANSFER EFFECTSHEAT TRANSFER EFFECTS • FLUID FLOW EFFECTSFLUID FLOW EFFECTS • CORROSION EFFECTCORROSION EFFECT
  • 12. Parameters to Assess Water QualityParameters to Assess Water Quality • pHpH • TDSTDS • Total HardnessTotal Hardness • Calcium HardnessCalcium Hardness • Total AlkalinityTotal Alkalinity • LSILSI • RSIRSI
  • 13. What is pH?What is pH? • pH is a measure of the acidity or basicity apH is a measure of the acidity or basicity a solution. Solutions with a pH less than seven aresolution. Solutions with a pH less than seven are considered acidic, while those with a pH greaterconsidered acidic, while those with a pH greater than seven are considered basic. pH 7 isthan seven are considered basic. pH 7 is defined as neutral because it is the pH of puredefined as neutral because it is the pH of pure water at 25 °Cwater at 25 °C • It should be between 7 and 8.5 for cooling-waterIt should be between 7 and 8.5 for cooling-water system.system.
  • 14. What is TDS?What is TDS? • It means density of “Total DissolvedIt means density of “Total Dissolved Solids” in water. To avoid carryover andSolids” in water. To avoid carryover and deposition (due to super saturation) indeposition (due to super saturation) in system, TDS should be maintained withinsystem, TDS should be maintained within 1000 ppm. This can be controlled by blow1000 ppm. This can be controlled by blow down only.down only.
  • 15. What is ‘Total Hardness’?What is ‘Total Hardness’? • Technically, it is the sum of all polyvalentTechnically, it is the sum of all polyvalent cationscations • Practically, it is the amount of calcium andPractically, it is the amount of calcium and magnesium ions, which are themagnesium ions, which are the predominant minerals in natural waterspredominant minerals in natural waters • This will indicate the amount of scalingThis will indicate the amount of scaling load going to system for internalload going to system for internal treatment.treatment.
  • 16. What is ‘Calcium Hardness’?What is ‘Calcium Hardness’? • Calcium Hardness is caused by theCalcium Hardness is caused by the presence of calcium ions in the waterpresence of calcium ions in the water • Calcium salts can be readily precipitatedCalcium salts can be readily precipitated from water and high levels of calciumfrom water and high levels of calcium hardness tend to promote scale formationhardness tend to promote scale formation in the water system.in the water system.
  • 17. What is ‘Total Alkalinity’?What is ‘Total Alkalinity’? • Alkalinity is a water's acid-neutralizingAlkalinity is a water's acid-neutralizing capacitycapacity • Alkalinity measures the total amount ofAlkalinity measures the total amount of base present and indicates a waterbase present and indicates a water reservoir’s ability to resist large pHreservoir’s ability to resist large pH changes, or the “buffering capacity.” changes, or the “buffering capacity.”  • The most important components ofThe most important components of alkalinity are carbonates andalkalinity are carbonates and bicarbonates.bicarbonates.
  • 18. Langelier Saturation IndexLangelier Saturation Index • The Langelier Saturation Index (LSI;also called LangelierThe Langelier Saturation Index (LSI;also called Langelier Stability Index) is a calculated number used to predictStability Index) is a calculated number used to predict the calcium carbonate stability of water; that is, whetherthe calcium carbonate stability of water; that is, whether a water will precipitate, dissolve, or be in equilibrium witha water will precipitate, dissolve, or be in equilibrium with calcium carbonatecalcium carbonate • If LSI is negative: No potential to scale, the water willIf LSI is negative: No potential to scale, the water will dissolve CaCO3dissolve CaCO3 • If LSI is positive:  Scale can form and CaCO3If LSI is positive:  Scale can form and CaCO3 precipitation may occurprecipitation may occur • If LSI is close to zero: Borderline scale potential. WaterIf LSI is close to zero: Borderline scale potential. Water quality or changes in temperature, or evaporation couldquality or changes in temperature, or evaporation could change the index.change the index.
  • 19. Ryznar Stability IndexRyznar Stability Index (RSI)(RSI) • The Ryznar stability index (RSI) attempts to correlate anThe Ryznar stability index (RSI) attempts to correlate an empirical database of scale thickness observed in waterempirical database of scale thickness observed in water systems to the water chemistry. Like the LSI, the RSIsystems to the water chemistry. Like the LSI, the RSI has its basis in the concept of saturation levelhas its basis in the concept of saturation level • RSI << 6 the scale tendency increases as the indexRSI << 6 the scale tendency increases as the index decreasesdecreases • RSI >> 7 the calcium carbonate formation probably doesRSI >> 7 the calcium carbonate formation probably does not lead to a protective corrosion inhibitor filmnot lead to a protective corrosion inhibitor film • RSI >> 8 mild steel corrosion becomes an increasingRSI >> 8 mild steel corrosion becomes an increasing problem.problem.
  • 20. Chemical TestingChemical Testing Chemicals /Chemicals / ParametersParameters DensityDensity (kg/litre(kg/litre )) ColourColour OdourOdour pHpH Increase inIncrease in TDS ofTDS of water (1kg)water (1kg) on 1 mlon 1 ml additionaddition AST - 6600AST - 6600 1.09 to1.09 to 1.111.11 Light GreenLight Green PungentPungent 0.1 to 0.30.1 to 0.3 660 to 710660 to 710 AST - 6602AST - 6602 1.12 to1.12 to 1.131.13 Coca ColaCoca Cola Pungent,Pungent, PhenolicPhenolic 0.5 to 0.70.5 to 0.7 170 to 190170 to 190 AST - 7711AST - 7711 1.04 to1.04 to 1.051.05 Light BrownLight Brown PhenolicPhenolic 10 to 10.510 to 10.5 4.2 to 4.64.2 to 4.6