A proper water treatment program, administered under the supervision
of a competent water treatment specialist, is an essential part of routine
maintenance to ensure the safe operation and longevity of evaporative cooling
equipment, as well as other system components.
In evaporative cooling products, cooling is accomplished by evaporating a
small portion of the recirculating water as it flows through the unit. As the
water evaporates, the dissolved solids originally present in the water remain
behind and if not controlled, the concentration of dissolved solids will increase
rapidly. This can lead to corrosion, scale or biological fouling which may
negatively affect heat transfer as well as the longevity of system components.
s Corrosion – Red rust on steel components and white rust on galvanized
surfaces may affect the longevity of system components.
s Scale formation – Scale, typically a calcium or magnesium based build-
up, not only reduces heat transfer and system efficiency, but may also
lead to under deposit corrosion. If scale is not controlled, it may contiunue
building on critical components such as the fill, and severely impact thermal
performance.
s Biological Fouling – Slime and algae formations may reduce heat
transfer, promote corrosion, and harbor pathogens such as Legionella.
Each of these aspects of water quality is discussed in greater detail below.
Since the quality of the ambient air and make-up water varies significantly
from job site to job site, BAC strongly recommends obtaining the services
of a competent water treatment agency prior to the initial start-up of the
evaporative cooling equipment. Additionally, to protect against the risk of
Legionella contamination, the cooling equipment should never be operated
without adequate biological control.
Corrosion and Scale Control
To control corrosion and scale, maintain the water chemistry
of the recirculating water within the parameters listed in
Table 1 on the following page. The specific measures required vary from system
to system and are dependent on the chemistry of the make-up water, the
metallurgy of the piping and heat transfer devices exposed to the recirculating
water, and the temperatures at which the system will be operating. Bleed/
blowdown, the continuous flow of a small portion of the recirculating water
to a drain, is used to control the concentration of dissolved solids. On rare
occasions, this may be adequate to control scale and corrosion. More often,
chemical scale and corrosion inhibitors are necessary, which raise the
allowable level of dissolved solids without the risk of scale and corrosion.
Keep the chemically treated water within the guidelines given in Table 1 .
In cases where bleed/blowdown alone is being employed for corrosion and
scale control without chemical treatment your water treatment specialist may
recommend more conservative limits than those shown in Table 1 .
Chemical Treatment Requirements
Chemical treatment programs must meet these requirements:
9
The chemicals must be compatible with the unit materials of
construction as well as other materials used in the system (pipe, heat
exchanger, etc.).
9
BAC discourages acid dosing as means of scale control except for
open circuit cooling towers with remote sump applications or towers
constructed from stainless steel. This should be done at a point in
the system where total mixing and dilution occur before reaching
the evaporative cooling equipment. The preferred injection point for
chemical scale and corrosion inhibitors is on the discharge side of the
system circulating pump(s). These chemicals should not be batch fed
directly into the unit’s cold water basin or water distribution system,
as this can severely damage areas directly contacted.
9
When chlorine is added to the system, free residual chlorine should
not exceed 1 ppm, except as noted in start-up and shutdown section.
Exceeding this limit may accelerate corrosion.
Passivation
When new systems are first commissioned, special measures should be taken
to ensure that galvanized steel surfaces are properly passivated to provide
maximum protection from corrosion. Passivation is the formation of a protective,
passive, oxide layer on galvanized steel surfaces. To ensure the galvanized steel
surfaces are passivated, the pH of circulating water should be kept between 6.5
and 8.2 and calcium hardness between 50 and 600 ppm (as CaCO
3
) for four
to eight weeks after start-up, or until new zinc surfaces turn dull gray in color.
If white deposits form on galvanized steel surfaces after the pH is returned to
normal service levels, it may be necessary to repeat the passivation process.
In case the pH can’t be kept below 8.2, a secondary approach is to conduct a
chemical passivation using inorganic phosphate or film-forming passivation
agents. Consult your water treatment specialist for specific recommendation.
Biological Control
The warm, oxygen and nutrient rich environment inside evaporative cooling
equipment provides an ideal environment conducive to the growth of algae,
slime, and other micro-organisms. Uncontrolled, this can reduce heat trans-
fer, promote corrosion, and promote the growth of potentially harmful organ-
isms such as Legionella. To avoid biological contamination and minimize
the risk of Legionella, initiate the biocide treatment program at start-up and
continue on a regular basis thereafter in accordance with the treatment sup-
plier’s instructions. Bleed/blowdown or chemical treatment used for corrosion
and scale control alone is not adequate for control of biological contamina-
tion. Introduce solid or granular biocides through a chemical “pot” feeder
installed in parallel with the system circulating pump. Diluted liquid biocides
may be added directly to the cold water basin.
Water Quality Guidelines
NOTE:
Since the quality of the ambient air and make-up water
varies significantly from job site to job site, BAC strongly
recommends obtaining the services of a competent water
treatment specialist prior to the initial start-up of the
evaporative cooling equipment. Additionally, to protect
against the risk of Legionella contamination, never operate
the cooling equipment without adequate biological control.
NOTE: Stainless steel cold water basins and basins protected by the
TriArmor
®
Corrosion Protection System or thermosetting hybrid polymer
do not require passivation. However, if the upper structure is galvanized
steel, passivation is required. Closed circuit cooling towers and
evaporative condensers with galvanized coil require passivation.
50 BALTIM ORE A IRC OIL COMPANY