SERVICE EXCELLENCE

FYI
GROUP

TRANE INTERN,ATIONAL

FOR YOUR INFORMATION

ATTENTION: SERVICE DEPARTMENT

THIS IS AN INFORMAL DISCUSSION ISSUED BY THE INTERNATIONAL TECHNICAL SERVICE DEPARTMENT OF THE TRANE WORLDWIDE APPLIED SYSTEMS GROUP. IT IS INTENDED TO BE USED ONLY BY TRANE SERVICE COMPANIES.

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HILLER

Y TEM WATER TREATMENT

This bulletin discusses water problems in condenser and evaporator water piping systems. It also discusses the responsibility for water treatment. This bulletin does not discuss the application of seawater as a condensing medium. GENERAL WATER QUALITY:

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Setting guidelines for acceptable water chemistry for use in Trane chillers is a very difficult task, and we are well aware that there are many locations throughout the world where it is simply not practical, or even possible, to supply water that meets the guidelines we set. However, it is water that exceeds our guidelines that is most likely to have scaling or corrosion occur. The customer/owner should be aware that if the water they wish to apply in his chiller exceeds one or more of our guidelines, then they should be very concerned about the possibility of corrosion or fouling. is the customer/owner's responsibility to protect his water using systems by applying a proper water treatment program. _Ite_m_ Trane Basic Guideline

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pH
Total Dissolved Solids (TDS) Chlorides Sulfates Total'Suspended Solids (TSS) Total Hardness Iron

7.5 - 8.5
1500 ppm max 100 ppm max 35 ppm max 10 ppm max 400 ppm max 1 ppm max

The above guidelines are NOT a guarantee against corrosion or scaling. AJso, some items or specifications not proVided by us may be of more importance in the customer's application. In ALL cases a water treatment specialist should be consulted to determine the condition of the water and what treatment is required to prevent corrosion or scaling.

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OPEN TYPE WATER SYSTEMS: Most Trane water-cooled condensers used with comfort cooling and industrial processes are applied with a type of system that is cal!~d an "open system". They are "open" because they use a cooling tower to reject the heat from the condenser water. The cooling tower uses fans to draw air directly thru the water, which is falling as droplets thru the cooling tower. The use of a cooling tower makes a condenser water system VERY vulnerable to corrosion and fouling~ The air contacting the water in a cooling tower will contain a wide variety of dust and dirtp?rticles, depending on the local environment. The re-circulating water to the condenser then becomes contaminated with this debris, and depending on the type and severity of the debris you can get scale, corrosion, and organic contamination of the system. SCALE: Scale is the dissolved solid matter that reappears in its solid state after water is heated or evaporated. At I1jgher temperatures water can hold I~ss scale forming compounds than water at lower temperature can. This is why warm condensers can form scale very quickly. Scale or fouling on the inside surfaces of a condenser will create a loss of heat transfer efficiency, and can also lead to under-deposit corrosion. SCALE REMOVAL: Scale in a condenser tube can usually best be removed by mechanical cleaning using a powered rotating brush. Some types of scale (calcium etc.) may be more difficult to remove and may require the use of chemicals or acids to loosen them. The type and amount of acid required should be determined by a qualified water treatment specialist after their analysis of the scale and water from the system. After a chemical or acid method of tube cleaning is used, it MUST be followed immediately with a mechnical tube cfeaning, flushing, and inspection. ~ Some types of scale (usually silica type fouling) may be difficult to remove by mechanical or chemical means, in these cases a "Hydro-Blast" (high-pressure water jet) cleaning may be effective. A contractor specializing in this type of cleaning procedure should be consulted. SCALE PREVENTION:

1. Ensure the tower 'bleed-off is correctly operating and is correctly adjusted.

The amount of tower bleedJequired may vary according to local water conditions. A water treatment specialist should be consulted to determine the amount of bleed required. Tower bleed-off is also called "blow-down". Implement a properly designed chemical treatment program. A water treatment specialist should analyze the local conditions in which the system will operate (for example: raw water quality, air quality, air temperature and humidity, materials of construction, etc.), and should recommend the appropriate chemicals and treatment method that will keep the contaminants suspended in solution and prevent scale from forming . . . Regular testing of the condenser water and observation of the condition of the equipment is necessary to maintain adequate chemical levels and to ensure prompt action in case problems occur.

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CORROSION: Corrosion in a condenser can occur as a direct result of acidic attack on the materials. Low pH in water is an .indication of acid caused by gases, particularly oxygen, dissolved in the water. The cooling tower . continually introduces dissolved oxygen into the water, which makes the water conditions Ideal for corrosion to occur. Cooling towers are also very effective "air-scrubbers and will catch large portions of city or industrial air pollution contaminants including dirt, soot, fly-ash, and sulfur dioxide. Sulfur dioxide in water causes an aggressively low pH value. The dirt and soot partic:es collected by the cooling tower can end uo as suspended solids in the system, and can lead to a failure type called "erosion-corrosion". The dirt and soot can also deposit in the condenser tubes. causing severe under-deposit corrosion.
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Excessive scale formation in condenser tubes can also result in the formation of under-deposit corrosion. Under-deposit corrosion is also frequently found under algae, fungi, or bac:eria deposits inside the condenser system. As part of their method of propagation, some organisms can also directly attack and consume the iron in tubesheets and water boxes, giving the appearance and effect of corrosion. See the following discussion on organic contaminants. PREVENTING 1. CORROSION:

Start with a clean system. Before commissioning, most condenser loops contain dirty water and large amounts of rust, slag, and mill scale. Clean, flush, and inhibit the system using a purging compound designed for the purpose by your water treatment company. Implement a properly designed chemical treatment program. A water treatment specialist should analyze the local conditions in which the system will operate (for example: raw water quality, air quality, air temperature and humidity, materials of construction, etc.), and should recommend the appropriate corrosion inhibitors. The correct corrosion inhibitors should be maintained at a constant level at all times.

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Regular testing of the condenser water and observation of the condition of the equipment is necessary to maintailJ adequate chemical levels and to ensure prompt action in case problems occur.

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The installation of a sidestream fiiter can be effective at reducing the amount of suspended solids in circulation in the condenser water. This can reduce the amount of tube fouling, under-deposit corrosion, and erosion-corrosion that occurs. Back-washable sand filters are most common for cooling tower applications. Drain and clean the cooling tower on a regularly scheduled basis, at least annually. More often if environmental conditions at the site are poor. Wear proper protective gear when "Yorking in the tower sump.

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ORGANIC CONTAMINATION: Since towers contain warm water, are open to sunlight, and easily trap a variety of life forms and nutrient sources, they are perfect breeding grounds for algae, fungi, and bacteria. Some of these forms circulate throughout the condenser system, while others attach themselves to surfaces like the condenser tubes and the cooling tower sump. Corrosion is frequently found under these deposits as a result of underdeposit corrosion or as a result of a direct attack from a species that consumes iron in order to propagate.

Because cooling towers are excellent breeding grounds for bacteria, serious diseases such as "Legionella Pneumophila" (Legionnaires Disease) can be formed. This is 3 oetentially fatal disease thought to be transmitted to humans via airborne water droplets. The forced air design of cooling towers creates droplets of small size that can be easily drawn into fresh air- ducts and transported to the occupied spaces. PREVENTING ORGANIC

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CONTAMINATION:

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Implement a properly designed chemical treatment program. A water treatment specialist should analyze the local conditions in which the system will operate (for example: raw water quality, air quality, local vegetation, air temoerature and humidity, materials of construction, etc.), and should recommend the appropriate biocides. While corrosion and scale inhibitors should be maintained at constant levels at all times, biocides may work best if applied in "slug" doses and if alternated with another type of biocide. Drain and clean the cooling tower on a regularly scheduled basis, at least annually. More often if environmental conditions at the site are poer. Wear proper protective gear wnen working in the tower sump ..

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GENERAL

CONDENSER MAINTENANCE:

At least once a year, or more often if indicated by measurements of :~e condenser performance, remove the water boxes and visually inspect the piping, water boxc::s, ~ube sheets, and tubes for corrosion, fouling, and debris. Brush dean or chemically clean the tubes [f required. Remember that whenever a chemical method of tube cleaning is used, it MUST be followed immediately with a mechanical tube cleaning, flushing, and inspection. Once every three years, have a non-destructive tube test (Eddy Current) performed to detect signs of condenser tube pitting or corrosion.

COOLING TOWER MAINTENANCE: Drain and clean the cooling tower on a regularly scheduled basis, at least annually. often if environmental conditions at the site are poor. Clean the tower more

Pressure Wash all accumulated dirt and organic fouling from the sump, walls, baffies, and distribution decks. Wear rubber boots, rubber gloves, and a filter mask when working in the cooling tower, to protect against organic contamination that may be present. If the condenser water is discolored or cloudy, drain and purge the system. Check the fan system as per the tower manufacture's recommendations. Lubricate all bearings, motors etc. Check belts for condition and tightness. Check all electrical connections for tightness and corrosion. Check fan blades for cleanliness and condition.

If the tower is to be left off for an extended period of time, like for a winter shutdown, it can be left dry. Temporary covers can be fitted to the tower openings to prevent dust and dirt from entering. If the tower and condenser water system is to be placed back in immediate operation, it should be re-filled and immediately chargedwith scale and corrosion inhibitor and with a biocide.

Condensers and cooling towers that are to be inactive but still charged with water are very vulnerable to corrosion damage. This is because the concentration of inhibitor is quickly depleated in areas where corrosion is active; resulting in corrosion that grows much ~aster. To prevent this, it is important that the COr"8ct concentration of corrosion inhibitor is present in the condenser water, AND the condenser water must be circulated frequently. Even on a system that is off, the condenser pumps should :::e run for 5 ~ minutes"a day to keep the inhibitor equally distributed thru the system. CLOSED SYSTEM REQUIREMENTS: Most of the water systems that Trane evaporators (and some condensers) are installed in use a design called a "cioseC system". A closed system is sealed off from the atmosphere and circulares the same body of ftuid all of the time. However, because it is sealed does not mean that it does not need water treatment. Much of the water used in the world to fill closed loops contains large amounts of dissolved oxygen and may be acidic. These two age:;ts will quickly cause the iron and steel in the chiller and water piping to corrode. If uncorrected, the corrosion will release small abrasive rust partic!es into the circulating water system, causing general erosion of the chiller and water piping system and quickly damaging pump shaft seals etc. In an ideal closed system the acid and oxygen would quickJy be used up and the corrosion damage would stop or become very slow to occur. However, most chilled water systems are NOT truly closed. To compensate for pressure changes and water losses most systems have an expansion tank and relief valve, and are connected to a make-up water supply with a pressure reducing valve (PRV). By their design, expansion tanks usually have a volume of air trapped above the water. The oxygen in the air dissolves in the water and is then circulated throughout the system. Also, if the system has any water leaks, or if air is being bled from the system, make-up water to replace it will be provided by the PRY. The make-up water from the PRY is a small but consistent source of fresh acid and dissolved oxygen, and the corrosion will continue: As an example, a simple leak in a pump seal that allows 1 gallon (3.78 liters) per hour to leak out can result in a requirement for up to 8,700 gallons (33,000 liters) per year of oxygen-rich make-up water from the PRY. Because the PRY function is usually automatic, even large leaks or problems may go unnoticed by the customer for a long time, allowing the C0rrosion to become severe. As corrosion in the loop continues, heat transfer surfaces in the evaporator can become coated and efficiency losses will occur. Excessive corrosion debris in the system can cause under-deposit corrosion, which can quickly cause pitting or other damage to the evaporator tubes. The impact of debris in the system can also cause "erosion-<;orrosion" in softer metals in the system, typically in the copper evaporator tubes. How can a technician tell if an evaporator has a water problem? 1. Check the color and clarity of the evaporator water from the evaporator water box. It should Qe clear and colorless. Dark brown or black water indicates there is a corrosion problem. There should be very few solid particles collecting at the bottom of the sample container. Have the water treatment company test a sample of the water. _If the sample contains more tan 1 ppm of dissolved iron the system is corroding. ~ Once a year, remove the water boxes and visually inspect the piping, water boxes, tube sheets, and tubes for corrosion and debris. Brush clean the tubes if rec;uired. Once every three years, have a non-destructive signs of evaporator tube pitting or corrosion .. tube test (Eddy Current) performed to detect

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To protect a typical closed evaporator system we recommend: ~ 1. Start with a clean system. Before commissioning, most evaporator loops contain dirty water and large amounts of rust, slag, and mill scale. Clean and flush the system using a purging compound designed for the purpose by your water treatment company. Install a filter. In addition to the strainer that is normally installed on a piping system, we recommend the use of a "sidestream" filter to help remove smaller corrosion debris from the closed loop. Inspect the filter element regularly. 3. Check the system often for leaks. Installation of a water meter on the make-up water line to the PRY can provide early indication of leaks. 4. Inspect the equipment. A defective expansion tank, relief valve, bleed valve, PRY, etc. could let oxygen into the system. They should be repaired or replac-..ad quickJy as possible. as Maintain a pH between 7.5 and 8.5. Have the water treatment company sample the water and recommend a suitable pH adjustment additive. Use an oxygen scavenger. Have the water treatment company sample the water and recommend a suitable oxygen scavenger additive. v Use a corrosion inhibitor. The internal surfaces of the equipment should be coated by a protective film. Have the water treatment company sample the water and recommend a suitable corrosion inhibitor. Most chiller evaporators are constructed of copper, cast iron, and steel. 8. Measure the chemical concentrations in the evaporator loop regularly. The inhibitors or additives cannot do their jobs if they are being continually diluted by system leaks or by draining parts of the system for maintenance.

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SACRIFICIAL ANODES: Sacrificial anodes may be desired if the water within a system is determined to have the properties of a corrosive electrolyte. This is most common with the use of seawater as a condensing medium (not covered here), but
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occur elsewhere in extreme applications.

When correctly applied, the introduction of the anode to the system will create a galvanic cell in which the magnesiufll or zinc will go into solution (be corroded) faster than the surrounding metals of the water box and tubesheet. This sacrificial action imparts a cathodic (negative) charge to the surrounding metals, and prevents or slows their corrosion. Again, consult your water treatment specialist to determine if sacrificial anodes, and what type of sacrificial anodes, are needed in a system.

RESPONSIBll TIES: It is the equipment owner's responsibility to protect his water using systems. The sales engineer or service engineer should simply advise the owner or the consulting engineer of why water treatment is needed and stress the importance of its continuation during the life of the equipment~ Water treatment is an added maintenance cost item that must be sold to the owner. However, this cost is generally much less than the cost of correcting troubles or replacing damaged equipment. Also remember the statement as made in the unit installation manuals: The use of improperly treated or untreated water in this equipment may result in scaling, erosion, corrosion, algae, or slime. The services of a qualified water treatment specialist should be engaged to determine what treatment, if any, is advisable. The Trane Company warranty specifically excludes liability fer corrosion, erosion, or deterioration of Trane equipment. Trane assumes no respol1sibiiity for the results of the use of untreated water, or saline or brackish water.

Trane W ASG International Technical Service Department Phone: 608-787-4477, This memo is intended to be informational only. No warranty is expressed or implied. No action or compensation is authorized. This memo is not intended for distribution outside of Trane service companies.