Water Treatment Solutions

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COMMON WATER TREATMENT PROBLEMS

Water related problems result in Acid Cleaning of boilers, closed loop systems , heat exchangers. These problems are as follows.

COOLING AND BOILER SCALING:

Many water impurities result in deposits forming on heat transfer areas of boilers and Cooling systems. These deposits reduce system efficiency and result in high maintenance or equipment failure

BOILER AND COOLING CORROSION:

Corrosion occurs in Boilers and Cooling systems and the result is equipment failure. In Boiler systems corrosion usually occurs due to oxygen in the water attacking the tubes and pre treatment equipment forming boiler pitting. In condensate systems, condensate corrosion failures are primly due to low ph from the formation of carbonic acid. In Cooling Towers corrosion can occur from electrochemical reactions, oxygen pitting, or deposits / microbiological induced cells

BOILER CARRY OVER:

In Steam boilers, priming or foaming can cause water to be carried over with the steam. When Boiler water carries over the results can be dramatic. The problems are many, including loss of heat, higher blowdown rates, deposit forming in the condensate system and potential failure of equipment having any yellow metals.

Wet Steam is a dramatic loss in energy, and should be monitored, and rectified when found.

COOLING FOULING:

Fouling occurs in Cooling Tower systems from air born materials being sucked into the system from the fan. It can also result from uncontrolled microbiological growth in the circulating water. These materials adhere to heat transfer surfaces restricting heat transfer and flow, frequently causing serious corrosion

ENERGY AND WATER LOSS

In many Water Treatment programs, systems are treated without full consideration of Energy and Water loss. The impact is higher operating cost in Energy, Water and Chemicals. In many applications the end user is not aware of the extra operating cost.

S.P. THERMAL SYSTEMS INC. overall concern is to maintain the integrity and efficiency of your operating equipment. We will do this while minimizing your Chemical, Fuel, Water and Maintenance cost. Call us for your Free evaluation

WHY MUST YOU BE TREATING BOILER SYSTEMS

To prevent oxygen pitting in the Feed Water Systems and on Boiler metal surfaces

To prevent deposits and sludge from forming on heat exchange surfaces that will cause premature failure and high Energy cost

To protect the Condensate System from corrosion which will reduce maintenance and loss of Energy from traps malfunctioning.

To maximize operational efficiency and equipment service life

WHY MUST YOU BE TREATING COOLING TOWERS:

Cooling Towers are excellent air washers for particulate and noxious gases. This environment will cause fouling and under deposit corrosion.

Air passage through the Tower continuously saturates the circulating water with oxygen, creating a corrosive environment in the Tower system.

Since Towers contain warm water and are open to sunlight, they are excellent breeding ground for Algae, Fungi, and bacteria.

Cooling Towers also provide ideal breeding conditions for pathogenic bacteria such as Legionella Pneumophila

WHY MUST YOU BE TREATING CLOSED LOOP SYSTEMS

All so called closed loops have some make up. Oxygenated water is therefore introduced periodically resulting, in corrosion and fouling.

In many areas, waters used in closed loops are acidic. The combination of acidic water containing corrosive oxygen results in heat transfer surfaces becoming coated, resulting in plugging and loss of efficiency. System corrosion and equipment failure would soon follow.

Expansion tanks contain air. Thus oxygen is dissolved in the water and is circulated through the system resulting in corrosion.

S.P. Thermal Systems Inc. will either perform or supervise Acid Cleaning where required. Deposit removal will increase your system operating Efficiency.

When performed by experienced and professional people, chemical cleaning are safe and effective method of immediately increasing heat exchange efficiency. In most operations, chemical washes should not be routinely required with effective Water Treatment programs.

However, when deposits do develop, chemical cleaning can be justified, by Fuel Savings and associated energy cost.

With new modern Technology, a properly applied Water Management program should eliminate the need for chemical cleaning. In most applications however, old technologies in use, or system component failure, will still necessitate periodic cleaning. Small amounts of deposits may not impair the reliability or production capacity of a boiler, however deposits will affect efficiency. Efficiency losses encountered over even short periods can increase your yearly Fuel bill much more than the cost of chemical cleaning.

It is a known fact that Thermal loss from equipment which is fouled due to scale deposits or other contamination can severely reduce the efficiency of the equipment.

In the case of Boiler Systems, the Thermal loss from a deposit of as small as 1/32" is an increase in fuel of 8.5%. As most deposits are well in excess of this thickness, it is important that boilers and heat exchangers are maintained free from any deposits. Closed loops cleaning is very important.

Some boiler manufacturers of the new Low Volume Coil Tube design recommend that chemical cleaning is carried out, when deposits are found. This is important to prevent boiler tube failure, and high maintenance cost.

BOILER DEPOSITS EFFICIENCY LOSS

1/32" Scale Deposit = 8% Extra Fuel usage

1/ 8" Scale Deposit = 25% Extra Fuel usage

1/4" Scale Deposit = 40% Extra Fuel usage

They are various types of acids cleaning chemicals available on the market and used for Chemical Cleaning of Boilers or Heat Exchangers. The most common is Hydrochloric Acid. The problem of using hydrochloric acid is that is dangerous to use and it gives of toxic fumes.

TOTAL CLEAN - WM 8570

This product was formulated for use in Cooling Towers, Evaporative condensers, Boilers and Heat Exchanger cleaning. The benefit of using this product is that it is safe to handle and does not give off any fumes.

The recommended concentration varies from 20% - 30% of Volume . The application of heat to

150 F will accelerate the cleaning process.

Acid cleaning of heat exchangers can be easily be done using this chemical.

For more details please call us.

ACID CLEANING CLOSED LOOPS PROCEDURE

Closed Loops if not treated or the chemical levels are not maintained, will become dirty and loose heat transfer. The cleaning of heat exchangers is important to maintain system high efficiency.

In order to overcome heat transfer loss the system requires to be treated with a cleaner.

WM 8585 - Add to the system WM 8585 based on a 2% solution.

This is about 4 pails / 1000 IMP gallons in system.

First Flush the system to remove as much of the sediment as possible

Strainers should be removed and cleaned

Micron Filters should be removed before adding Cleaning solution

Add the correct amount of chemical WM 8585 based on system volume

Circulate the system with chemical for about 1 - 2 weeks

Check the pH of the system daily. pH should be around 5 - 5.5

If higher pH is found, you need more cleaner compound WM 8585.

Drain every 2 days small amounts of water from system at low points

After the 2 week period drain and flush the system at the same time with the circulating pump on.

While flushing check the TDS of the water to determine if it is approx. same as the make up water

When this occurs the system has been fully flushed.

Bleed air from the System

Add Closed Loop inhibitor to the system. Molybdate Blend or Sodium Nitrite with an azole.