Turnaround BP Workbook

TurnAround Best Practices
Energy Services Division
Table of Contents
Introduction – T/A Best Practices ..........................................................3
Planning the T/A ....................................................................................4
Communicating the Best Practice T/A Plans.........................................5
System Lay-Up ......................................................................................7
System Lay-up Best Practices...............................................................9

a. #1 Best Practice for Lay-up: “Keep the Water Recirculating” ...................... 9
b. #2 Best Practice for Lay-up: Wet Lay-up................................................... 10
c. #2A Best Practice for Lay-up: Drain, Dry and Purge ................................. 10
d. #3 Best Practice for Lay-up: Drain and Dry ............................................... 11
Passivation Procedures.......................................................................12
a. Chart – Passivation Options Review .......................................................... 12
b. Pre- T/A – Wet Storage Lay Up.................................................................. 13
c. Post T/A – Molybdate / PSO Passivation ................................................... 20
d. Post T/A - Nitrite/PSO Passivation Procedure............................................ 27
e. New System Passivation............................................................................ 33
f. Emergency / Hurricane Wet Lay Up Passivation........................................ 39
Exchanger Inspections ........................................................................50
Exchanger Inspection Form.................................................................51
Post T/A Start-up .................................................................................53
Post T/A Reporting ..............................................................................54
2
Nalco Company Confidential
Introduction – T/A Best Practices
Turn Arounds (T/As) are consistently the one time period where all cooling water
treatment companies are judged. This is the customer’s one chance to inspect the
equipment and directly evaluate the performance of the cooling water treatment.
You know that a successful cooling water treatment program is based on a large
number of variables. These include the Mechanical, Operational and Chemical
control of the cooling water system. Fair or not, when an exchanger is opened, its
condition is attributed directly to the water treatment company’s performance.
How Nalco personnel handle themselves before, during and after a T/A can often
be the difference between maintaining, winning or losing an account.
Professionally handling all aspects of a T/A will ensure that we are delivering value
to our customers. It will lead to improved reliability and decreased maintenance
costs. It will help determine where the customer should utilize their resources
during and after the T/A.
Our customers are looking to you as the Nalco representatives to bring to their site
Best Practices. The term “Best Practices” refers to Nalco’s best technology,
products, equipment and processes. The following is designed to help identify the
items that likely will be required at your site. These lists should help provide an
outline of the steps necessary to properly plan for any cooling water system T/A.
This document is designed to help you get fully integrated into your customer’s T/A
process. You will need to identify where the site currently operates and how this
differs from Nalco’s Best Practices. You will need to present these gaps to the
Customer management and outline how these gaps can impact their plans for their
unit’s safe and reliable operation.
Once you have agreement on implementation of Best Practices, allow your

customer management to direct your efforts in moving this forward. In order to
engrain these Best Practices into the customer’s T/A plans and culture, the site
management will have to communicate their importance to the T/A planning
organization. Then work with these customers to initiate these recommendations
into their normal T/A plans. From that point it will be about execution of these
plans. If you are successful convincing the site management on the gap between
current and Best Practices, you have the opportunity to become a part of the
customer’s T/A culture.
3
Planning the T/A

A large amount of planning goes into a T/A. Likewise, you need to plan,
communicate and get agreement on Nalco’s involvement in your customer’s T/A
plans. Although it is quite possible to never start too early, begin your planning at
least 18 months in advance. This “lead time” will vary by site and by the
complexity of the T/A plans. Planning your involvement well in advance will ensure
you are included in all T/A plans and procedures.
If Nalco has not been an integral part of your sites T/A planning activities, you will
need to back up and do an assessment of what your customer does at a T/A with
respect to the cooling water system. Then assess how these activities relate to
Nalco’s T/A Best Practices. This gap analysis will help determine what is needed
and what will or won’t be allowed by the customer.
In order to engrain these Best Practices into the customer’s T/A plans and culture,
you will have to communicate with the site management to get agreement on your
recommendations. They will then help you get these implemented by
communicating these recommendations to the customer’s T/A planning
organization. Work with these professionals to institute these recommendations
into their normal T/A plans. From that point it will be about execution of these
plans. If you perform this initial planning step with the site management
successfully, you will only have to convince the site of these Best Practices and
their value once.
Establish T/A Best Practices with Customer for site

• Determine Current T/A Practices at Site
• Identify Gaps between current site practices and Recommended Best
Practices – Utilize recommendations from the Best Practice Gap Analysis
report or the most recent MOC audit.
• Meet with Customer Management to review Gaps and present
Recommendations to move to Best Practices
• Get Agreement and set Path-Forward to Implement Best Practices for all
future T/As
• Have Customer Management set up involvement with T/A Planning Team to
Integrate Best Practices into Formal T/A Plan (Understand Scheduling,
Timing, Equipment Plans, etc.)
4
Communicating the Best Practice T/A Plans
• Communicate Best Practice T/A Plans to T/A Team, Operations, other

necessary customer groups
o Shut Down / System Lay-up
o Equipment Inspections
o Cooling Tower Basin Cleaning
o Exchanger Repair / Replacement Plans
o Exchanger Cleaning Plans
o Exchanger Hydrotesting Procedures
o Cooling Tower Repairs
o Recirculation Pump or Screen Repairs
o Individual Exchanger Repassivation Plans
o System Return to Service Plans, Timing
o Start-up CW Recirculation Procedures
o Exchanger Back flushing and return to service
o System Repassivation
o Transition back to Base Treatment Program
• Action Items to Accomplish – Near Term T/A Planning

o Determine Cooling System Volume (needed for accurate passivation
estimates on required treatment volumes and resulting economics
o Determine passivation program – Type and amount of products
needed to ensure sufficient product inventory to complete entire
repassivation
o Communicate costs to appropriate budgetary personnel
o Place chemical product orders to ensure products are on-site well
ahead of scheduled outage
o Determine T/A equipment needs (feed systems, inspection
equipment, safety equipment, PPE, camera and camera supplies,
etc.) Place orders well in advance of T/A to ensure all necessary
equipment is on-site before it is needed
o Completion of all associated MOC – chemical treatment, exchanger
cleaning, exchanger photography, etc.
o Plan Nalco manpower schedules to ensure 100% coverage
throughout the T/A
o Understand all customer paperwork requirements (safety, PPE,
MOC, permits, etc.)
o Coordinate all customer-supplied resources (forklifts, cranes, etc.
prior to T/A to ensure timely availability
o Determine schedule of process/water shutdown paying particular
attention to staggered shutdown of multiple units or unit components,
as this will possibly require multiple lay-up applications
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• Action Items to Accomplish – Long Term T/A Planning

Exchangers
o Examples of Exchanger Design Changes
o Hot Process By-pass to eliminate throttling of cooling water flow to
exchanger
o Installation of sacrificial anodes on all dissimilar metallurgy conditions
o Upgrade of exchanger metallurgy – tubes or entire exchanger
o Design improvements to meet current operational conditions –
change in # passes, tube size, installing macro-filters on water inlet,
etc.
o Installation of back flush or air-rumble connections
o Installation of strainer and/or diagonal screens for debris control
o Installation of water sample points on the inlet and outlet of
exchangers
o Installation of taps for local temperature or pressure indicators
o Installation of temperature indicators to run signal into DCS (either
process or water)
o Installation of block valves to allow isolation/by-pass of exchanger
Cooling Tower
o Issues with cooling tower (basin, tower fill, return line distribution
valves on top of deck, distribution nozzles, etc.)
o Identified issues with existing cooling water or make-up water piping
(size or location changes)
o Repair of make up water or basin level control system
o Repair / calibration of flow meter in supply header
Pumps, Piping
o Installation of Cooling Water Return Line “Gas Hat” for monitoring
and sampling for presence of light hydrocarbons
o Installation of valves to isolate or back flush sections of recirculating
water piping
o Installation or repair of blowdown piping on return header piping
Chemical Feed, Storage, Monitoring and Control

o Installation of analyzer repairs / upgrades while system is out of
service (pH / acid feed system, conductivity control of blowdown,
oxidizing biocide control, etc.)
o Chemical Storage Tank Upgrades – repair or replace tanks while
system is down to minimize potential impact on system performance
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System Lay-Up
A critical step to protecting the cooling water system during the T/A is how the
system lay-up is planned and executed. Prevention of corrosion, minimizing
microbiological growth and minimizing the amount of foulants and chip scale are
the primary focus of a good lay-up program.
In order to fully understand the Best Practice recommendations that we make, we

need to fully understand the mechanisms at work with respect to corrosion and
corrosion inhibition.
Low Flow and Corrosion Inhibition

Corrosion and corrosion control occur at the metal surface. Corrosive species and
corrosion inhibitors move to the metal surface and corrosion products move away
from the metal surface. In the corrosion/corrosion inhibition process the flow of
water across the metal surface has a direct effect on the movement of corrosion
inhibitors to the metal surface and the removal of corrosion products from the
surface.
The flowing water is broken into two parts, a thin diffusion boundary layer at the
metal surface and the bulk solution. The thin diffusion layer’s thickness varies with
flow rate. As flow increases the diffusion boundary layer’s thickness decreases and
when flow rates decrease, the diffusion boundary layer’s thickness increases.
Since the thin diffusion boundary is at the metal interface its thickness greatly
influences the corrosion control process.
Optimum flow velocities for mild steel exchangers in cooling service are generally
set at 3-6 ft/sec. As the velocities increases over 6 ft./sec. the effects of
erosion/corrosion become more pronounced. High velocity erosion/corrosion has
a substantial increase in metal loss because the turbulent water has enough
energy to destroy the protective corrosion films. When these films are destroyed
the metal’s corrosion increases substantially.
When flow velocities for mild steel exchangers decrease below 3ft/sec. corrosion
rates also begin to increase. As flow decreases below 1 ft./sec. the corrosion rates
become extremely high. This increase in corrosion is due to an increase in the
thickness of the diffusion boundary layer and its relationship to mass transfer.
Mass Transfer defines the transport of chemical species to the metal surface
(corrosion inhibitors) and from the metal surface (corrosion products). Mass
transfer brings the corrosion inhibitors through the diffusion boundary layer to the
metal surface.
Why does this flow/ boundary layer process become so important for corrosion
control? It becomes important because the boundary layer thickness regulates the
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amount of corrosion inhibitor that reaches the metal surface. As the boundary layer
becomes thicker the concentration of corrosion inhibitor at the metal surface
decreases. These mass transport values can be quantified by using Fick’s
diffusion law treatments and Nernst’s diffusion layer treatments but for the
application of corrosion inhibitors in cooling water treatments it simply means that
as flow decreases below 3 ft/sec. the corrosion inhibitor concentration decreases
at the metal surface. The metal surface in effect is “under-treated”. At flows < 1
ft./sec this under-treatment is extreme and corrosion rates are very high. Iron
tuberculation is also very severe in low flow because the corrosion products cannot
be transported from the metal surface, so they just deposit.
Modern cooling water chemistry corrosion inhibition chemicals are used in cycled
cooling water environments where there are high degrees of super-saturation,
microbiological contamination and foulants. This high degree of super-saturation
prevents most corrosion inhibitors from being increased to levels that would be
high enough to be effective at the metal surface. In addition, microbiological and
fouling control issues present additional difficulty. The “best treatment” for low flow
corrosion is to take a mechanical approach and get velocities increased to the
recommended 3-6 ft./sec.
Mass Transfer Through Diffusion Layer
N a lc o C h e m ic a l C o m p a n y
Note that the concentration of Cobulk (bulk water corrosion inhibitor concentration)
decreases to Cosurface (corrosion inhibitor concentration at metal surface)
Solid line - Fick’s treatment

Dash Dotted line – Nernst treatment
8
* More in depth reading on these treatments can be found in the Metals Handbook,
Volume 13 Corrosion, Kinetics of Aqueous Corrosion.
System Lay-up Best Practices

a. #1 Best Practice for Lay-up: “Keep the Water Recirculating”
The absolute best method of Lay-up available is to not take a system out of
service. This means keeping the cooling water recirculating with its normal
velocity and normal treatment program. If only a small portion of a system will
have to come down for a T/A, only remove from cooling water service the
minimum amount of the system required to perform maintenance.
By maintaining recirculating cooling water to the rest of the system, you remove
the two most damaging mechanisms that can adversely impact the system.
The first is stagnant water. In order for most of the normal chemical treatment
programs to perform, a vital component is the water’s velocity. The graph
below illustrates the relationship between water velocity and corrosion.
Nalco Chemical Company
In the graph, the flat “bottom of the horseshoe” is the 3-6 ft/sec (0.305 m/s)
velocity range, ideal for minimal corrosion rates. Also note that as the flow
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increases above the 6-ft./sec. corrosion increases due to erosion corrosion. As

flow decreases below the 3-ft/sec. corrosion decreases due to diffusion layer
issues (under treatment).
In order to fully protect a system when the water recirculation is stopped, the
system must be treated one of two ways. Choosing which method is largely
based on the primary problem issues associated with that system.
b. #2 Best Practice for Lay-up: Wet Lay-up

If the system suffers from fouling and chip scale issues, especially after
previous outages, this is the method your customer should use. It is also a
preferred method when there are sections of piping that cannot be fully drained
(esp. underground piping) or if your system is greater than 15 years old.
An internal, visual inspection of the recirculation piping is seldom, if ever

performed by the customer. The old saying “out of sight, out of mind” is
extremely accurate. Since this equipment is seldom visually inspected, our
customers often don’t think of protecting this piping. After all, this pipe is
usually as old as the unit itself.
We have to discuss with the customer the corrosive damage that can be done
with stagnant water. Also as discussed previously, any water that remains
stagnant in the cooling water system will become very corrosive if left
untreated. The normal chemical treatment program will not provide corrosion
inhibition during periods of stagnant water flow. The only way to minimize
corrosion during stagnant water situations is to treat the systems with very high
dosages of specific chemistries.
We also have to discuss the increased potential for fouling when a system is
allowed to sit dry for weeks at a time. What occurs is a drying out of the
existing deposits on the piping. As these become dry and brittle, they crack
and easily separate from the piping surface. These deposit pieces will become
system foulants if not removed from the system.
The proper Wet Lay-up procedure for ensuring corrosion inhibition during a
system outage is found in the Passivation Procedures Section.
c. #2A Best Practice for Lay-up: Drain, Dry and Purge

The “other” Best Practice for proper lay up of a cooling water system prior to an
outage is the Drain, Dry and Purge. This method is designed to prevent
corrosion by assuring the system is free of any water. This is the preferred
method where the system is young (< 15 years old) or if the primary issue at
the unit is corrosion.
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Younger systems will likely not have had sufficient time for the cooling water
recirculation lines to have experienced significant corrosion, deposition and
fouling. Due to these lines being relatively “clean” of these potential foulants,
these recirculation lines are not likely to be a possible source for post-T/A chip
scale and other foulants at start-up. It is also important that the system have
not had any significant problems with corrosion. This will also ensure “clean”
piping that will not be a source for post-T/A chip scale. These criteria are in-
place to prevent start-up issues with fouling at the cooling water exchangers.
If the Drain, Dry, Purge method is used on systems that do not fit these criteria,
there is an increased potential for exchanger fouling during and after startup.
When the system is allowed to dry out and sit stagnant for a period of time, the
existing metal surface will dry and become less adherent to the metal surface.
All deposits, corrosion tubercles or cracks in the piping surface will provide the
source for later foulants. When the system’s recirculation water is restarted,
these deposits and weaknesses in the piping surface will allow this material to
be dislodged from its source location. When this happens, the material
becomes migratory chip scale and will deposit and settle out in an area of low
flow. Often, this is in the first pass of a cooling water exchanger. These
migratory foulants will deposit in the low flows of the channel head, on the tube
sheet and inside the tubes. This can obstruct or completely block the water
flow through the tube, leading to future problems with heat transfer, fouling and
corrosion.
The capability to dry and purge a cooling water system is extremely site-
specific. Procedures to accomplish this will have to be developed specifically
for each cooling water system.
By performing a Drain, Dry and Purge procedure, you are protecting the metal
surfaces by keeping moisture out of the equipment. Purging the system with
either nitrogen or plant air will help ensure the equipment remains free of
moisture. It should be noted that there is often resistance to the use of nitrogen
due to the hazards associated with the use of this gas. These should be fully
discussed with the customer to ensure it is the best method for that site and
that all proper steps are taken to ensure personnel safety. The use of plant air
can also perform well if the air is also free of moisture.
d. #3 Best Practice for Lay-up: Drain and Dry

This is the least preferred lay-up method, yet most commonly employed due to
its ease of implementation. Often the customer either does not want to deal
with the time and effort of purging the system, or they are not adequately
equipped to perform a purge on the system.
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If the customer cannot perform a system purge and is not willing to perform a
wet lay-up, then this is the last available method to minimize system corrosion.
The key to this procedure is to ensure, check and recheck that all of the system
is drained and dried. Any remaining water in the system will cause localized
corrosion. If the customer wants to perform a Drain and Dry Lay-up but you are
aware of sections of the cooling water system that can not be drained (i.e.,
underground piping), then you should discuss the potential impacts on these
areas and what options are available to minimize or remove this risk.
It will also be important to ensure the customer understands the impact drying
the system will have on the post-T/A start up. Ensuring that procedures are in-
place to minimize the impact of the chip scale that will be generated is key to
avoiding future problems. These post-T/A start-up procedures are included in
the later section of this workbook (page 51).
Passivation Procedures
a. Chart – Passivation Options Review
Nalco Pretreatment Options

Pretreatment pH Range Program Requirements / Conditions Comments
MoO4/PSO based Best program overcomes issues

operating with heat load and MB
MoO4 100 ppm Time frame ~48 - 72 hours
control options (can use either bleach
No Calcium Required
#1 PSO 50 ppm or gas Cl2). Can operate over longer
7.8-8.5 Can operate with a heat load
Best time frames with good iron
Can initiate regular treatment program at
Polymer 21 ppm management. MoO4 can deactivate
any time during passivation
Pits. Compatible with all treatment
programs.
Azole 15ppm
NO2/PSO based
Good program overcomes issues with
NO2 1000 ppm Time frame ~48 - 72 hours heat load, Operating over 48 hours
#2 No Calcium Required increases microbial growth concerns,
Very PSO 50 ppm 7.8-8.5 Can operate with a heat load need non-oxidizing biocide feed
Good Can initiate regular treatment program at during passivation, cannot use gas
Polymer 21 ppm
any time during passivation Cl2 during passivation. Compatible
with all treatment programs.
Azole 15ppm
Nalprep III - 2500 ppm NO HEAT Load!! Operating over 48

PolyPO4 500 ppm hours increases Polyphosphate
Time frame 24-48 hours
reversion and precipitation of calcium or
Requires 100 ppm Ca as CaO3 minimum
#3 TT 30 ppm iron phosphates (Fe Limit <3.0 ppm),
6.5-7.5 No heat load, Acid Feed
Good not suitable for long-term operation. Not
Polymer 46 ppm Need to blowdown to <10 ppm PO4 prior
compatible with treatment programs.
to start of heat load
Only use for individual exchanger
passivations.
Surfactant 40 ppm
Notes
1) All pretreatment procedures require flushing of the system to minimize iron levels prior to addition of passivation products
2) Iron management controls the ability to cycle the system. The goal is to maintain less than 3.0 ppm during passivation stage
3) MoO4/PSO and NO2/PSO are compatible with all treatment programs and no need to blowdown prior to start of maintenance program.
4) Refer to Nalco documents on correct overall procedures, dosages and testing methods
12
PSO Dosage Chart Inhibitor (MoO4 and PSO) Dosage Chart
PH Hottest Water Temperature

Ca as CaCO3 7.0 7.5 8.0 8.5 Inhibitor level ppm <75 75-100 100-120 >120
<50 100 100 80 80 MoO4/PSO 100/50 125/60 150/75 200/100
50-100 100 80 50 50
100-200 80 60 50 50
>200 80 60 50 50
PSO as Active
PolyPO4 Dosage Guide (for Nalprep III)
PH
Ca as CaCO3 7.0 7.5 8.0 8.5
<50 N/A N/A N/A N/A
50-100 N/A N/A N/A N/A

100-200 500 500 400 300
>200 400 400 300 250

Off-Line application only, no heat load
b. Pre- T/A – Wet Storage Lay Up
Open Recirculating Cooling Systems

Significant attention is routinely given to treatment and control of operating
cooling water systems. Often, however, less focus is provided to systems once
they come down for turnaround (T/A). Unfortunately, system reliability can be
substantially compromised during these periods. Some of the related concerns
include:
• Stagnant water corrosion

• Flash (atmospheric) corrosion
• Aerobic (slime-forming) bacteria infection
• Anaerobic (corrosive) bacteria infection
• Drying/cracking of piping corrosion products – chip scale
• Iron buildup and deposit formation
The damage resulting in such situations can be very significant affecting the
long-term equipment life as well as premature heat transfer problems. The
purpose of this document is to provide Best-in-Class procedures for proper lay-
up of cooling water during T/A downtime.
Wet lay-up of system piping is preferred to “dry lay-up” where water is

evacuated from the piping. The primary reason for this is drying and
subsequent cracking of piping tuberculation which can often lead to chip-scale
fouling of exchangers upon start-up. Further, it is more difficult to protect
“moist” metal from corrosion during the lay-up period. If “dry lay-up” is required,
see Best-in-Class recommendations on this subject.
13
Passivation Product Selection

When performing the various passivation procedures, there are a large number
of products that can be used to deliver the various chemical components. This
includes both single function products and blended, multi-functional products.
Be sure you understand the products, their components and their percent
actives. This is critically important to ensure the correct dosages and
economics are calculated. Also remember that while blended products may
offer the advantage of fewer products to handle, they offer less treatment
flexibility and will likely be more expensive.
Listed below are some general product names that are commonly used around
the world. Some regions use different product names, so please consult your
region’s select product list. If you have any questions or concerns, please
consult the CPP or contact your regional ITC or marketing personnel for
assistance.
Single Function Products

• Molybdate – 7357
• PSO – 3DT180 (untraced), 3DT179 (traced)
• TSHP – 3DT190
• Azole – 3DT198, 1336, 73181 (TT); 3DT199, 73199 – BZT; 3DT197
(new azole)
• Microbio Dispersants / Detergents – 73550, 7348
• Non-oxidizing Biocides – 7338 (gluteraldehyde), 7330 (isothiazoline)
Blended, Multi-Function Product

• Moly, PSO, TT, HSP, Surfactant - 3DT701
Step 1 – System Preparation

Before high-level corrosion inhibitors and biocide are added to the open
recirculating cooling system it must have its microbiological and Total Dissolved
Solids (TDS) levels lowered as much as possible. Microbiological levels need to
be at a minimum to reduce the demand on the wet storage biocide (non-
oxidizing biocides have maximum application limits in open recirculating cooling
systems) and reduce the source for biological inoculation during TAR. The
minimal TDS levels are needed to lower the corrosion potential of the water and
also allow the system’s blowdown to be minimized or blocked prior to shutdown
(maintains the inhibitors at their applied level).
5 Days prior to shut down:

1. Begin addition of biodispersant @ 10-20 ppm (N-73550) – Slug feed if not
set up for continuous injection of the biodispersant. Note: If biodispersant is
included in the routine treatment program continue the program but adjust
feed for decreased cycles and the increased 20 ppm feed level. Caution –
remember the N-73550 can foam if overdosed, slowly increase the feed rate
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to 20 ppm or until an acceptable level of foam is generated. Increase the

free chlorine levels to 0.5 –1.0 ppm for 12-24 hours.
2. After the high level chlorine, begin increased blowdown to lower the cooling
tower cycles to 2 cycles or as close to 2 as possible (if makeup restricted).
Add 250* ppm of Nalco 7338 (Glutaraldehyde). The goal is to maximize
deposition prior to the N-7338 addition to minimize the initial demand for the
biocide so it can maintain activity longer in the system. * The maximum N-
7338 dose permitted by the label is 250 ppm.
3. Maintain routine treatment dosages during the blowdown period to and
reduce free chlorine @ 0.3-0.6 ppm. Once at 2 cycles, increase product
dosages by 50%. Additionally, it is critical to maintain oxidizing biocide
control (no loss of feed) to keep the system’s microbiological activity at a
minimum prior to system shutdown.
4. Systems that don’t used chlorine as their primary biocide need to deploy
their biocide program in a manner that will have the system prepared for wet
lay-up. Systems that use stabilized halogens and/or non-oxidizing biocides
should apply non-oxidizing biocide to the system on a daily basis. Biocide
levels going to the waste plant need to be calculated. As an example, if
there are a few small cooling systems discharging into a large waste facility
the additional biocide will not present an impact. A fast killing, rapid
hydrolyzing (detoxify) non-oxidizing biocide (DBNPA) can be used during
this system preparation phase if the normally applied biocide or
Glutaraldehyde presents a problem.
5. All biocides, oxidizing and non-oxidizing, can be deactivated by sodium
bisulfite if needed. Dosages can be calculated for the stream going to waste
along with biocide residual testing. N-7408 (uncatalyzed sodium bisulfite) is
applied based on ppm/ppm of biocide to be deactivated. The reaction(s) are
extremely fast. It is recommended that the deactivation take place as close
to the waste inlet as possible. This allows maximum deactivation of the
biocides through natural degradation prior to the point of injection.
6. There are many locations upon which have multiple processing units tied to
one cooling tower that do not go into Turn Around at the same time. The
cooling tower does not shut down but the units are down. In these cases,
the unit going into T/A still needs to go into a low corrosive condition by
lowering cycles of concentration to minimize the level of Chloride and
Sulfate in the water, increase the pH to at least 8.0 and with increased
inhibitor dosages. The ortho PO4 level may not be able to be increased due
to potential scaling conditions in the other operating units. However, the
use of PSO and MoO4 will not precipitate in the hot systems and should be
used. Other inhibitors are not recommended (i.e. like Nitrite due to MB
concerns in the other operating units or PO4 due to scale formation). At
least 50 ppm of MoO4 and 100 ppm of PSO should be slugged to the
system and adequately mixed to provide corrosion protection. Prior to
lowering the cycles of concentration, a high level shock of Cl2 with
subsequent follow up with a non oxidizing biocide is required.
15
Step 2 – System Lay-up Procedure

After system preparation, the microbiological activity and TDS concentration will
be at a minimum and the system will then be ready for wet lay-up. Once the
lay-up is started, the system blowdown will be blocked in to prevent accidental
draining of the basin. Cooling water TDS levels will begin to cycle up based on
the heat load. This is normal and expected. Conductivity should be run every
six hours, if the system doesn’t have continuous conductivity monitoring, to plot
the increase rate in TDS. If delays are experience in the shutdown process
(>24 hours) a small amount of blowdown may be needed if the system is still
under full heat load. Additional biocide feed will be required if delay is > 3 days.
If there is no heat load (or negligible load) during a delay, blowdown will not be
needed.
24 hours prior to anticipated system shutdown

1. Block in all sources of “controllable” blowdown
2. Stop Biodispersant feed
3. Stop normal phosphate inhibitor chemical feed
4. Stop Chlorine feed
5. Set pH control for 8.0-8.5 range
6. Add 400 ppm of Nalco 7338 (Glutaraldehyde)
7. Add 800 ppm of Nalco 7357 (216 ppm MoO4)
8. Add 350 ppm of Nalco 3DT-180 (105 ppm PSO)
9. Add 50 ppm of Nalco 3DT198 (25 ppm Na-TT) or 3DT199 (20 ppm Na-
BZT)
10. Continue cooling system circulation with inhibitors (minimum time 12
hours)
11. Open any dead legs or blocked-in lines just enough to displace existing
water with “lay-up” water. DO NOT ALOOW EXCESS WATER LOSS AS
THIS WILL DIMINISH CHEMICAL CONCENTRATIONS!
12. Stop normal cooling water dispersant chemical just before system
shutdown
13. Test all inhibitor chemical levels and non-oxidizing biocide levels and
adjust as needed.
14. Stop recirculation and block in cooling system
15. Loss of cooling system water must be minimized especially in exchangers.
16. Preserve treatment inhibitor concentration.
17. Prevent corrosion at the air–water interface if down for extended periods.
16
Additional Considerations
1. If the unit to be in T/A is part of a large cooling water system that will still
be in operation for other processing units, it is imperative that only the
MoO4 and PSO be dosed to the cooling water prior to shut down. While
the entire loop will see the high treatment levels, it will only add to the
current corrosion program and not produce any adverse effects. High
levels of phosphate will not be as protective as the Molybdate and PSO
and may cause an issue with fouling if added to the cooling water system
after the T/A is over. Nitrite is not as option due to the potential for the
cooling water to leak into the unit in T/A and cause increased MB growth,
especially if the unit is not clean to begin with. The addition of nitrite to the
operating cooling water system may increase MB formation if biocide
control is poor.
2. If system is to be down for >2 months, supplemental or interim steps may
be required to insure long-term protection. The nature of this supplement
will depend on the length of down-time, ability to “bump circulation, etc.
Advise your Nalco representative if an expended down-time is anticipated.
3. If sections of the system are to be blocked-in before water flow is
terminated, notify your Nalco representative. Preemptive treatment prior to
the scheduling above may be required to protect these parts of the system.
4. If parts of the system are to be drained during the T/A, contact your Nalco
representative. These parts will become subject to “atmospheric”
corrosion if not addressed. Remedies may include desiccation, nitrogen
blanketing, or other protective steps.
Step 3 – System Restart

A. Clean calibrate all control probes, detectors, i.e. pH, Trasar, Conductivity,
etc.
B. The start-up water chemistry tests prior to recirculation.
a. Molybdate - Hach Method 8036 (Mercaptoacetic Acid Method 0.3-40
ppm)
b. Azole
c. pH
d. Total microbiological count
e. Sulfate reducer counts
f. Active Glutaraldehyde level - (GLUTATECT – WT by Alden Scientific)
g. Conductivity
h. Active polymer
i. Total iron (digested)
j. Total copper (digested)
k. PSO (Hach method 8007 – UV Light method or Method 8190 acid
per sulfate digestion).
C. Active Glutaraldehyde Level (prior to recirculation once recirculation is

established)
17
a. If the active level is below the maximum established level for

discharge to waste treatment then sulfite neutralization will not be
needed.
b. If the active level is > than level for discharge then N-7408
(uncatalyzed sodium bisulfite solution) should be added at
10ppm/ppm active Glutaraldehyde. This will deactivate the
Glutaraldehyde to < 2 ppm.
c. Glutaraldehyde level should be tested prior to the waste plant and as
close as possible to waste plant inlet. This sample point monitors the
amount that would enter the waste plant, allowing for maximum
uptake prior to the waste facility
D. Total Microbiological counts (prior to recirculation and once recirculation is

established) collect sample for MB testing then add 200 ppm of N-7338
during start up, then follow the recommended treatment protocol
depending upon the results of the MB testing.
a. < 1000 – resume normal chlorine treatment with biodispersant
b. 10,000 – resume normal chlorine treatment with biodispersant +
application of 200 ppm Nalco 7338 biocide
c. 100,000 – resume normal chlorine treatment with biodispersant +
application of 200 ppm Nalco 7338 biocide. Retest in 24 hours and
reapply if > 10,000 counts.
E. Sulfate Reducers – Positive detection = application of 200 ppm Nalco 7338

biocide. Retest in 24 hours and reapply Nalco 7338 with positive detection.
F. Begin Plant cooling system startup procedures, backflush exchangers,
blowdown for iron control, etc.
G. Plan to test water chemistry routinely until equipment is back in service.
H. Begin Nalco All Soluble Startup Passivation procedure.
Note: If the unit is equipped with steam driven pumps, use these first (prior to
electric driven pumps). These pumps should be capable of ramping up to
speed in a more controlled manor than electric driven pumps. This will
minimize any shock conveyed to the system pimping that might dislodge any
chip scale or other debris that can plug the exchangers.
18
Lay-Up/Start-Up Log Sheet
Plant:
System:
Date -5 -4 -3 -2 -1 TAR TAR TAR TAR TAR TAR TAR +1 +2 +3 +4 +5

Preparation Phase
Biodispersant Feed (gals)
Nalco 7338 Feed (gals)
Free Chlorine Residual (ppm)
Cycles of Concentration
<Inhibitor 1> Feed (gals/day)
Lay-Up Phase
Water Loss Blocked In
Biodispersant Feed Discontinued
Phosphate Feed Discontinued
Chlorine Feed Discontinued
pH Level
N-7338 Feed (gals)
N-7357Feed (gals)
3DT-180 Feed (gals)
N-73181 Feed (gals)
Dead Legs Flushed
Water Circulation for 12 hrs min
Dispersant Feed Discontinued
Chemical Tests (ppm)
Glutaraldehyde
MoO4
PSO
Azole
Product Feed Adjustments
N-7338 Feed (gals)
N-7357Feed (gals)
3DT-180 Feed (gals)
N-73181 Feed (gals)
Circulation Stopped
Start-Up Phase
Circulation Started
Chemical Tests (ppm)
Glutaraldehyde
MoO4
PSO
Azole
Active Polymer
Total Bacteria Count
Anaerobic Bacteria Count
pH
Conductivity
Total Iron
Total Copper
N-7338 Feed (gals)
Blowdown Rate (gpm)
Exchangers Backwashed
Corrator Reading
Coupons Installed
19
c. Post T/A – Molybdate / PSO Passivation
After a chemical or mechanical cleaning, turnaround, or emergency or long-

term lay-up, it is important to pre-treat or passivate carbon steel heat
exchangers and supply piping to minimize flash corrosion and/or deposit
formation. Corrosion under deposits can lead to the development of localized
corrosion cells or pitting. There are 3 major areas of concern after cleanings,
lay-ups or turnarounds:
• Control of debris that can block cooling water flow

• Minimization of deposition and localized corrosion
• Minimization of microbiological fouling.
Careful attention to the procedures described below will help minimize these
problems.
Phase 1 Back flushing and high-level blowdown

Precautions must be taken after a cleaning, turnaround or lay-up event to
effectively flush accumulated debris, mud, silt, etc. from the cooling system.
This will minimize the potential for exchanger fouling and plugging as a result
of chip scale and other debris being transported throughout the system piping.
The object of the back flushing and blowdown is to ensure plant reliability by
minimizing cooling water corrosion and fouling during start-up.
In many systems, chip scale and iron deposition pose the greatest threat to
tube and tube sheet plugging during start-ups. The best method for dealing
with this issue is to use either a strainer on the inlet side of the exchangers
and/or insure each exchanger that is on the primary cooling water circuit has
the capability to be back flushed. This is particularly important for those
exchangers that sit at the end of the cooling water supply piping that can
accumulate trash.
Suggested back flushing and blowdown procedure

1. When the make-up line is put back into service, the initial slug of water
may contain high levels of chip scale, mud and iron. This initial slug should
be diverted from the tower basin. If after the initial slug, any mud or high
iron levels are introduced into the basin, the basin can be overflowed to
wash that out before recirculation begins.
2. If the unit is equipped with steam driven pumps, use these first (prior to
minimize any shock conveyed to the system piping that might dislodge any
chip scale.
20
3. As circulation begins, the water flow should be directed to exchangers that

are equipped with strainers to filter out any chip scale. If possible
exchangers should be blocked in and the flow of cooling water should be
directed through the system supply piping and flushed prior to opening any
of the blocked-in exchangers.
4. Back flush all exchangers that were exposed to the initial flow of water
vigorously for 20-30 minutes, and continue back flushing until all evidence
of chip scale has subsided.
5. The remaining exchangers (those without strainers on the primary cooling

water service) should be put into service on a staggered basis.
• Close the outlet side valve.
• Open the back flush nozzle to allow flushing of the lines up to the
exchangers.
• When that runs, clear back flush the exchangers.
• When the water runs clear, close the back flush valve and open the
inlet valve.
• If possible, install inlet and outlet pressure gauges to monitor
pressure drop.
• After all the exchangers have been put into circulation and the back
flush is complete, begin the microbial cleaning and passivation
procedures.
Phase 2 Application of the 3DTRASAR all-soluble inhibitor program

The goal of the PSO/molybdate based passivation program is to apply a high
level of inhibitor to the metal surface to inhibit flash corrosion and minimize
deposition. Deposits on new heat exchange bundles can lead to localized
corrosion and significantly shorten bundle life. Both Molybdate and PSO are
highly soluble and will not precipitate with iron-based deposits. The use of
tagged high stress polymer (THSP) will help control iron based deposits and a
high level of azole will help passivate admiralty or other copper alloy tube
bundles and chelate soluble copper in the water as the system is returned to
operational status.

When performing the various passivation procedures, there are a large
number of products that can be used to deliver the various chemical
components. This includes both single function products and blended, multi-
functional products. Be sure you understand the products, their components
and their percent actives. This is critically important to ensure the correct
dosages and economics are calculated. Also remember that while blended
products may offer the advantage of fewer products to handle, they offer less
treatment flexibility and will likely be more expensive.
21
Listed below are some general product names that are commonly used
around the world. Some regions use different product names, so please
consult your region’s select product list. If you have any questions or
concerns, please consult the CPP or contact your regional ITC or marketing
personnel for assistance.

Molybdate – 7357
PSO – 3DT180 (untraced), 3DT179 (traced)
TSHP – 3DT190
Azole – 3DT198, 1336, 73181 (TT); 3DT199, 73199 – BZT; 3DT197 (new
azole)
Microbio Dispersants / Detergents – 73550, 7348
Non-oxidizing Biocides – 7338 (gluteraldehyde), 7330 (isothiazoline)
Blended, Multi-Function Products

Moly, PSO, TT, HSP, Surfactant - 3DT701
The passivation process should proceed as follows

1. Recalibrate all analyzers (pH, conductivity, ORP, TRASAR and
3DTRASAR)
2. Collect a cooling water sample. Analyze for pH, iron, copper, total
hardness/calcium, and microbiological control with Easi-cults or
equivalent.
3. Begin circulating the water to the main lines only, and adjust the pH within
a range of 7.5 - 8.5. (In general operating at the higher end of the pH
range will help minimize corrosion and aid the passivation process).
4. Maintain free halogen residual levels with a bromine or chlorine based
chemistry at 0.2- 0.4 ppm TRO and/or use a non-oxidizing chemistry such
as 7338 at 200 ppm. If the system has been stagnant for an extended
period of time, you may need to complete a microbiological cleanup prior
to beginning the passivation procedure.
5. Dose the system with 200 ppm of N-7338 and 10 ppm of N-73550.
Monitor the N-7338 actives with the GlutatTect WT test kit, looking for a
minimum of 70 ppm active and checking on the consumption compared to
what was fed. A minimum of 48 hours with 70 ppm active should be
maintained. Chlorine should be maintained at 0.2 – 0.6 ppm free after the
initial 48 hours. Confirm both general microbiological activity is minimal
and SRB activity is nonexistent.
6. As in all pre-treatment work, addition of the passivation chemicals must
be accomplished as soon as possible after heat exchangers have been
cleaned to minimize flash corrosion.
22
7. Once the system has been pH adjusted, begin adding the chemicals
specified in Table 1 to the pump basin. Watch for foaming when adding
the 73550. You may want to have anti-foam on site. If the system is small,
you may consider using Nalco 3DT701, which is a single, drum blend of
all the chemicals given in Table 1. Feed 1250 ppm of Nalco 3DT701.
8. The initial PSO level will be measured as organic phosphate and should
be about ~15- 18 ppm (higher levels will not cause problem).
9. Open all exchangers and circulate the passivation chemicals. Maintain a
circulation velocity of at least 3 feet/sec through the heat exchangers.
10. After this treatment has been in operation, typically for 3-5 days, clean all
strainers/filters that may be in-line with the heat exchangers.
11. Resume all chemical treatments at dosages shown in Table 2 and initiate
the normal treatment program and control ranges (pH, Conductivity, etc)
When using Nalco 3DT701, the system is usually returned to normal
cooling system operation after 24-48 hours of circulation. Table 2
dosages are not used.
12. Continue this treatment regime typically for 2 to 4 weeks, shorter times
may be used. This treatment approach is compatible with all 3D
TRASAR® programs. The normal 3D TRASAR program should be
started during this period with the resumption of the heat load to the
tower.
13. Perform daily testing of the pH, iron, copper, active polymer, TRASAR,
molybdate, azole, conductivity, total/calcium hardness and microbio
activity
14. Blowdown should be adjusted to maintain iron (Fe) levels less than 2.0-
3.0 ppm while maintaining the dosages given in Table 2. This is
necessary to minimize the potential for iron fouling in the system.
15. After 2 to 4 weeks, turn off the passivation chemicals and maintain the
normal cooling tower treatment program after iron levels drop below 2
ppm. The system does not need to be drained or flushed to rid the system
of the pretreatment chemical program.
23
Table 1. Passivation Chemicals--start up dosages

Product Description Product Dosage Control Parameter
7357 Molybdate 364 ppm 100 ppm as MoO4
3DT190 Tagged HSP 60 ppm 21 ppm active polymer
3DT199 Sodium BZT 40 ppm 13.4 ppm as azole
73550 Surfactant 10 ppm 5 ppm as active
3DT180 PSO 160 50 ppm as PSO Active
3DT701 Blend of above non 1250 ppm Maintain for 24-48 hours
biocide components
TRO or 7338 biocide 0.2-0.4 TRO or 200 90 ppm active
ppm
Table 2. Passivation Chemicals--dosages after start-up

7357 Molybdate 182 ppm 50 ppm as MoO4 *
3DT199 Sodium BZT 40 13.4 ppm as azole
73550 surfactant 10 ppm 5 ppm as active
TRO or 7338 biocide 0.2-0.4 TRO or 100 45 ppm active
ppm
3DT180 PSO 160 50 ppm as PSO Active*
* Molybdate interferes with the certain iron tests. The following interference levels for various Hach
iron tests are given below.
Hach FerroVer (Method 8008) no interference at <80 ppm MoO4 (range 0.02 –3.0 ppm Fe)
Hach TPTZ (Method 8112) MoO4 at 5 ppm interferes (Range 0.012 – 1.8 ppm Fe)
Hach FerroMo (Method 8365) eliminates high MoO4 interference (Range 0.01 – 1.8 ppm Fe)
Hach 1,10-Phenanthroline (Unicells) MoO4 not listed as an interference (Range 0.1 – 5.0 ppm Fe)
Phase 3 Transition to on-going 3DTRASAR cooling water program

1. After the high-level passivation program is complete, adjust system pH to
normal operating level with return of heat load.
2. Balance the blowdown rate to keep the iron level less than 1-2 ppm .
3. If the cooling water treatment program uses orthophosphate, do not raise
the orthophosphate level up to the normal operating target until the iron
level decreases below 1-2 ppm.
4. Once the iron level is below 1 ppm, increase cycles at equal increments to
return to normal dosage levels.
5. Monitor corrosion rates on NCM during the return to heat load.
24
Literature is available from the CPP on 3DT701 and on the 3D TRASAR

Passivation Program (PR 272).
Passivation Program Contingency Guide

Good control of every cooling water treatment program is necessary to achieve
desired results. Problems, however, can arise with even the best control. The
contingency guide shown in Table 3 will assist you in correcting problems
should they occur. It should also be used in outlining what actions your
customers should take when control testing indicates a problem with the pre-
treatment program.
Table 3. Problem Contingency Guide

Problem Result Corrective Action
pH rises above 8.5 Potential for increased iron Add sulfuric acid to reduce pH to 7.5 to 8.5 or
deposition or Ca3(PO4)2 normal operating levels
formation exists if back to
normal treatment levels
Initial slug of treatment Insufficient chemical to Add additional
too low effectively complete
passivation.
Excessive foam Pump cavitation; possible Add small increments of NALCO 71D5plus or
(this is an unlikely aesthetic problem in plant similar antifoam until foam height reaches an
problem) or community. acceptable level.
Temporary system Stagnant treatment; Debris will be resuspended on system start-up.
shutdown due to settling of suspended Increase blowdown if there is highly turbid water
mechanical problems. debris.
Overfeed of sulfuric pH goes below 6.5 If the problem is caught quickly, add soda ash to
acid. elevate pH. If the problem was not noticed soon
(which should not be the case during the pre-
treatment), blowdown the tower heavily, and
add make-up to regain pH. Re-establish high-
level passivation chemistry.
Words of Caution
In the long term, successful system operation will be largely determined by your
attention to in-plant training. Properly trained plant personnel will insure that
Nalco recommended chemical/mechanical treatment programs are being
operated as prescribed. Listed below are a few areas where additional
attention is warranted.
1. Iron Levels at Start Up

It is important to note that iron will be “picked up” into the re-circulating
water at startup. The “normal” level seen at startup are usually less than 10
25
ppm. The iron is removed from the system through blowdown. Systems
with iron levels > 6 ppm will need to operate at low cycles to quickly remove
the iron from the system. Systems with heavy iron contamination will
consume more products because of the high blowdown. The product
calculations should be done assuming the system will operate @ 2 cycles
during the initial 48 hour period.
2. Highly Stressed Conditions

Some systems being returned to service may be classified as a “high
stressed” startup. A “high stressed” system is one that:
1. experienced a severe acid excursion prior to shutdown

2. contains equipment that has been sitting for long periods in the
yard (no pre-cleaning or pre-treating)
3. has contained standing water (stagnant) in system piping for
greater than 3 weeks
Greater levels of iron “pickup” (~60-100 ppm) will be expected from these
“high stressed” situations. These systems should have product
consumption calculated for 5 days operating @ 2 cycles.
3. Ensure Sufficient Passivation Chemicals Inventory

A frequently encountered problem during passivation is having insufficient
chemical inventory to properly complete the process. This compromises
the effectiveness. Prior to start up ensure adequate inventory of
chemical treatment products are located on-site.
4. Do Not Overfeed Dispersant to Supply Targeted PSO

Do not substitute the use of 3DT191 or 3DT192 as the sole source of PSO
for the pretreatment program. This causes an over-feed of polymer which
can be corrosive to both carbon steel and admiralty brass metallurgy. If
you want to use a THSP/PSO blended product, use it to supply the
targeted level of dispersant. Supplement the treatment with a PSO-only
product (3DT180) to get the PSO dosage to the targeted level.
5. When in doubt, Ask for Help!

There is no substitute for experience. When planning these system
repassivations, discuss with more experienced Nalco personnel, your
District Manager, Regional marketing or ITC personnel. They can offer
you advice and suggestions on what to watch and how to react to
unexpected events.
26
d. Post T/A - Nitrite/PSO Passivation Procedure
Phase 1 Backflushing and High Level Blowdown to Control Debris

Fouling
Precautions must be taken after a Turn Around or lay up event to effectively
flush accumulated debris, chip scale, mud, silt, etc. from the cooling system.
This will minimize the potential for exchanger fouling and plugging debris that
will be transported throughout the system piping. The object is to ensure plant
reliability by minimizing cooling water corrosion and fouling during start-ups.
In many system, chip scale and iron deposition pose the greatest threat to
tube and tube sheet plugging during start-ups. The best methods for dealing
with this issue is to use either strainers on the inlet side of the exchangers
and/or ensure each exchanger that is on the primary cooling water circuit have
the capability to be back flushed to remove any debris on the inlet tubesheet.
This is particularly important for those exchangers that sit at the end of the
cooling water supply piping that can accumulate trash, chip scale, mud and
silt, etc.
Procedure
1. When the make up line is put back into service, the initial slug of water may
contain high levels of chip scale, mud and iron. If possible, this initial slug
should be diverted from the tower basin. If even after the initial slug, any
mud or high iron levels introduced into the basin, the basin may be
overflowed to wash that out before recirculation begins.
minimize any shock conveyed to the system pimping that might dislodge
any chip scale or other debris that can plug the exchangers.
are equipped with strainers or traps to filter out any chip scale. If possible,
of the blocked in exchangers. This is of particular importance for those
exchangers that are positioned at the end of the supply piping.
4. Backflush all exchangers vigorously for a minimum of 20-30 minutes that
were exposed to the initial flow of water and continue backflushing until all
evidence of chip scale has subsided.
water service) should be put into service on a staggered basis. Close the
outlet side valve. Open the backflush nozzle to allow flushing of the lines
up to the exchangers. When that runs clear back flush the exchangers.
When the water runs clear, close the back flush valve and open the inlet
valve. If possible install inlet and outlet pressure gauges to monitor
27
pressure drop across exchangers as they are put into service. If backflush
valving does not exist, open to drain the CW supply piping for 15 minutes
before establishing flow to those exchangers.
6. Very good microbial control is needed during the passivation with Nitrite.
Stagnant water, during the TAR, can rapidly allow MB growth, and a
microbiological cleanup prior to beginning the passivation procedure is
needed.
a. Re-establish Chlorine feed and maintained at 0.5 – 1.0 ppm free for
the initial 24-48 hours of flushing. Confirm both general MB activity is
minimal and SRB activity is non-existent. To aid in MB control add 5-
10 ppm of N-73550. (Note- The addition of N-73550 may generate
some foam so dose the system slowly).
b. With the use of gas chlorination in this water it will be important to
initiate pH control maintaining a pH >7.8.
7. After all the exchangers have been put into circulation and the backflush is
complete, check the iron levels in the water, as the chlorination step is likely
to cause an increase in iron and begin heavy blowdown until iron levels are
less than 3 ppm. Prior to the addition of the Pretreatment products, stop the
chlorination and dose the system with 200 ppm of N-7338 and 10 ppm of N-
73550. Monitor the N-7338 actives with the GlutatTect WT test kit, looking
for a minimum of 70 ppm active and checking on the consumption
compared to what was fed. A minimum of 48 hours with 70 ppm active
should be maintained.
Phase 2 System Repassivation

The goal of the PSO/Nitrite based passivation program is to apply a high level
of inhibitor the metal surface to inhibit flash corrosion and minimize deposition.
Deposits on new bundles can lead to localized corrosion and significantly
shorten bundle life. Both Nitrite and PSO are highly soluble and will not
precipitate with iron-based deposits. The use of HSP will help control iron
based deposits and a high level of azole will help passivate Admiralty bundles
and chelate soluble copper in the water as the system is returned to operational
status.
The passivation process proceeds as follows:

1. Clean and Recalibrate all analyzers (pH, conductivity, ORP, TRASAR, 3D
TRASAR, etc.)
hardness/calcium, and microbiological control with Easi-cults or equivalent
and field SRB test vials. If solids were seen in the water or any sludge was
removed from the system, SRB testing is needed.
3. While circulating the water adjust the pH to 8.0. This will aid in the
repassivation and help minimize the corrosion potential of the MU water.
28
4. As in all pre-treatment work, addition of the passivation chemicals must be

accomplished as soon as possible after heat exchangers have been
cleaned and back-flushed to minimize flash corrosion. Once the system has
been pH adjusted, begin adding the chemicals specified in Table 1 to the
pump basin.
5. The initial PSO level will be measured as organic phosphate (method AP-25
or AP-70). Target maintaining 160 ppm of product (50 ppm as PSO). The
Nitrite level should be 1000 ppm as NO2.
6. Maintain a circulation velocity at a minimum of 3 feet/sec through all the
heat exchangers during the passivation.
7. After 24 hours with the passivation chemistry in the system, collect water
samples and check all water chemistry parameters: pH, Ca hardness, Total
hardness, alkalinity, iron (filtered and unfiltered), NO2, ortho phosphate
(filtered and unfiltered), organic phosphate, active polymer, conductivity,
free chlorine, copper and azole. Recheck the calibration of the 3D Trasar
controller and cell fouling
8. After this treatment has been in operation, 2 days, clean all strainers/filters
that may be in-line with the heat exchangers. Resume the flow and initiate
the high-level regular treatment program.
9. If the heat load has been started on the tower, monitor iron levels closely
and maintain a maximum of 3 cycles of concentration.
Phase 3 Transition to 3D Trasar Cooling Water Program

1. Recalibrate all analyzers (pH, conductivity, ORP/Chlorine, 3D Trasar, etc.)
2. Initiate pH and halogen control at normal levels.
3. Continue feed of the passivation product, do not blowdown the nitrite from
the system, it is compatible with the base program. Start feed of the base
program products at elevated dosages per the passivation dosage chart 2.
DO NOT slug the ortho phosphate product (feed should be restarted via the
injection pump). Transition each week to the next lower level of passivation
dosages.
4. Perform daily water testing during the entire 2 week period on the following:
pH, iron, copper, active polymer, NO2, azole, conductivity, total and calcium
hardness, M-alkalinity, SRB and Total Bacteria Dipslides.
5. Operate at cycles to maintain iron levels less than ~2 ppm. If the iron rises
above 2 ppm, increase blowdown rate while maintaining dosages given in
Table 2. This is necessary to minimize the potential for iron fouling in the
system.
6. Return to the normal program dosages and control ranges after 1 week.
Passivation Products
29

Passivation & Start Up Chemical Program
Passivation Dosages Tagged HSP PSO NO2 TT MB Disp. N.O.biocide
Suggested Product 3DT190 3DT180 73310 3DT198 73550 7338
Product Actives, % 35% 31% 25% 42.0% 50% 45%
Product Dosages, ppm 60 160 4000 36 15 200
Control Target, ppm Actives 20 50 1000 15 8 70
pH Control 8.0 – 8.5

Cycles of concentration 2-3
Table 2 Post Passivation Chemicals--Continuous dosages
Post TAR - Repassivation & Start Up Chemical Program

Repassivation Dosages Tagged HSP PSO NO2 TT Traced O-PO4 ** MB Disp. N.O.biocide
Suggested Product 3DT190 3DT180 73310 3DT198 3DT-184 73550 7338
Product Actives, % 35% 31% 25% 42.0% 34.7% 50%
Product Dosages, ppm 60 160 4000 36 Don't use if 10 200
Control Target, ppm Actives 21 50 1000 15 Fe > 3 ppm 5 70
3DTrasar Program StartUp
Post-passivation, Week 1 Actives 15 30 600 4 18 5 NA
Post-passivation, Week 2 Actives 12 15 3 12 5 NA
Post-passivation, Week 3 Actives Normal Program Dosage Range
Scale Inhibition Corrosion Inhibition Microbio Control
** Do Not Slug Feed O-PO4
PROGRAM CONTINGENCY GUIDE

Good control of every cooling water treatment program is necessary to
achieve desired results. Problems, however, can arise with even the best
control. This contingency guide (See Table 3) will assist you in correcting
problems should they occur. It should also be used in outlining what actions
your customers should take when control testing indicates a problem with the
pre-treatment program.
30
Table 3 Problem Contingency Guide

pH rises above 8.5 Potential for Add sulfuric acid to reduce pH to 7.8 to 8.5
increased iron or normal operating levels. Increase Active
deposition or polymer residual to 20 ppm.
Ca3(PO4)2 formation
exists if back to
normal treatment
levels
Initial slug of Insufficient chemical Add additional chemical to meet target
treatment too low to effectively dosage requirement
complete passivation.
Excessive foam Recirculation Pump Add small increments of NALCO 71D5
(this is an unlikely cavitation; possible Plus or similar antifoam until foam height
problem) aesthetic problem in reaches an acceptable level.
plant or community.
Temporary system Stagnant treatment; Debris will be resuspended on system
shutdown due to settling of suspended start-up. Increase blowdown if there is
mechanical debris. highly turbid water
problems.
Overfeed of sulfuric pH goes below 6.5 If the problem is caught quickly, add soda
acid. ash to elevate pH. If the problem was not
noticed soon (which should not be the
case during the pre-treatment), blowdown
the tower heavily, and add make-up to
regain pH. Re-establish high-level
passivation chemistry. Determine the root
cause of the low pH, check for draining of
diked areas into the cooling tower, acid
pump operation, proper pH measurement,
refilling of acid tank, etc.
Overall Control
In the long term, successful system operation will be largely determined by
your attention to in-plant training. Properly trained plant personnel will insure
that Nalco recommended chemical/mechanical treatment programs as being
operated as prescribed.
water at startup. The “normal” level seen at startup are ~ <10 ppm. The iron
is removed from the system through blowdown. Systems with iron levels > 6
ppm will need to operate at low cycles to quickly remove the iron from the
system. Systems with heavy iron contamination will consume more products
because of the high blowdown. The product calculations should be done
assuming the system will operate @ 2 cycles during the initial 48 hour period.
31
Some systems being returned to service may be classified as a “high

stressed” startup. A “high stressed” system will be one that has 1) experienced
a severe acid excursion prior to shutdown, 2) addition of equipment that has
been sitting for long periods in the yard (>3 weeks), exposed to the elements
and not receiving any pre-cleaning or pre-treating or 3) greater than 3 weeks
of standing water (stagnant) in system piping. Greater levels of iron “pickup”
(~60-100 ppm) will be expected from these “high stressed” situations. These
systems should have product consumption calculated for 5-15 days
operating @ 2 cycles.
A frequently encountered problem during passivation is having

insufficient chemical inventory to properly complete the process. This
compromises the effectiveness. Prior to start up ensure adequate inventory
inhibitors.
Do not substitute the use of 3DT191 or 3DT192 as the source of PSO for the
pretreatment program. This will result in overfeed of polymer and be
corrosive to both carbon steel and Admiralty brass metallurgy. For
example, to achieve a 50 ppm (active) dosage of PSO using 3DT191, 100
ppm of active polymer will be fed into the system. This level of active polymer
is likely to cause increased carbon steel and yellow metal corrosion.
Caution: The use of the Nitrite based passivation program can cause a
rapid increase in Microbial growth in the system. Microbial deposits can
lead to localized corrosion cells and fouling of exchangers. The use of
bleach and high levels of non-oxidizing biocides is required.
Recommended Iron Test Procedures (due to Mo interference):

• Hach FerroMo (Method 8365) eliminates high MoO4 interference (Range
0.01 – 1.8 ppm Fe)
Other Possible Iron Test Procedures:

• Hach FerroVer (Method 8008) –Test Range 0.02 –3.0 ppm Fe. No
interference at <80 ppm MoO4, no Nitrite interference
• Hach (1,10 Phenanthroline) (Method 8146 and Unicells) -Test range 0.01
– 5.00 ppm as Fe. MoO4 and NO2 not listed as interfering with test
results.
• Hach FerroZine (Method 8147) –Test Range 0.009 –1.400 ppm Fe.
MoO4, and Nitrite not listed as interfering with test results.
When using Nitrite, it is best to avoid systems with gas chlorination and the
chlorinators are driven by tower drive water. The combination of low pH and
high halogen levels will destroy the nitrite.
32
The use of bleach has not been seen to cause rapid degradation of nitrite
especially at pH levels >7.8.
A combination of low level halogen and non-oxidizer should control denitrifier

activity level. Additionally, denitrifying bacteria are anaerobic.
e. New System Passivation
3D TRASAR Passivation Procedure for New Cooling Systems—prior to

normal cooling operation
When a new recirculating cooling water systems is constructed, the piping,
exchangers, and tower basin may be flushed and hydrotested with water to
remove any debris, loose rust, and to ensure the systems joints don’t leak, etc.
after fabrication. The water flushing is an attempt to remove these extraneous
materials from the system prior to commissioning. No other steps are usually
employed to prepare the metal surfaces prior to applying the protective film.
Acid cleaning of new equipment has been used to remove mill scale and rust;
however, this method does not remove oils, greases and other miscellaneous
materials.
Usually, after water flushing, hydrotesting or acid cleaning operations, very little
is done in the way of protecting the metal surfaces until the entire system is put
into operation. Since protection is not available during this time, considerable
corrosion may occur due to either stagnant wet conditions or circulation of
untreated water on the metal components. Often flash corrosion is started due
to residual acid left from acid cleaning. This condition may exist for weeks
before application of a protective corrosive inhibiting film and produces a
corroded surface with considerable corrosion products (iron and copper oxides)
on the metal even before the inhibitor is applied. The corrosion products will
deposit on the exchanger surfaces setting up under-deposit corrosion cells
initiating localized corrosion.
During the start-up or first few months of operation new cooling systems,
considerable tuberculation and corrosion in the system may occur if the system
is not properly treated. Normal maintenance level dosages may not effectively
film even clean surfaces due to high initial demand for inhibitor to fill the metal
surfaces. High levels of corrosion inhibitors may be more effective in
establishing protection to metal surfaces. All metal surfaces will benefit from
pre-treatment, but they must be clean for optimum formation of a protective
film.
If no attempt is made to prepare the metal surfaces for effective film formation,
the corrosion inhibitor cannot properly react with the metal surfaces to form a
protective film. The presence of rust, oils, organic films, etc. resulting from
33
manufacture or storage or the metal prior to use prevent effective film

formation. Corrosion progresses unchecked under these foreign materials due
to the formation of localized corrosion cells similar in effect to metal surfaces
prior to painting or applying protecting coatings. We cannot emphasize too
strongly the importance of surface preparation prior to applying the protective
films or in the use of any barrier type corrosion prevention program.
Phase 1 Back flushing and high-level blowdown to remove chip scale and
debris
Suggested back flushing and blowdown procedure:

1. When the make-up line is put back into service, the initial slug of water
may contain high levels of chip scale, mud and iron. This initial slug should
be diverted from the tower basin. If even after the initial slug, any mud or
high iron levels are introduced into the basin, the basin can be overflowed
to wash that out before recirculation begins.
minimize any shock conveyed to the system pimping that might dislodge
any chip scale.
are equipped with strainers to filter out any chip scale. If possible
of the blocked-in exchangers.
4. Back flush all exchangers that were exposed to the initial flow of water
vigorously for 20-30 minutes, and continue back flushing until all evidence
• Open the backflush nozzle to allow flushing of the lines up to the
exchangers.
• When that runs, clear back flush the exchangers.
• When the water runs clear, close the back flush valve and open
the inlet valve.
• If possible, install inlet and outlet pressure gauges to monitor
pressure drop.
• After all the exchangers have been put into circulation and the
backflush is complete, begin the cleaning and passivation
procedures
34
Phase 2 Application of the 3DTRASAR all-soluble inhibitor program

The goal of the PSO/molybdate based passivation program is to apply a high
level of inhibitor to the metal surface to inhibit flash corrosion and minimize
deposition. Deposits on new heat exchange bundles can lead to localized
corrosion and significantly shorten bundle life. Both Molybdate and PSO are
highly soluble and will not precipitate with iron-based deposits. The use of
tagged high stress polymer (THSP) will help control iron based deposits and a
high level of azole will help passivate admiralty or other copper alloy tube
bundles and chelate soluble copper in the water as the system is returned to
operational status.
The passivation process should proceed as follows:

1. Recalibrate all analyzers (pH, conductivity, ORP, TRASAR and 3D
TRASAR)
hardness/calcium, and microbiological control with Easi-cults or equivalent.
3. Begin circulating the water to the main lines only, and adjust the pH within
a range of 7.5 - 8.5. (In general operating at the higher end of the pH range
will help minimize corrosion and aid the passivation process).
4. Maintain free halogen residual levels with a bromine or chlorine based
chemistry at 0.2- 0.4 ppm TRO and/or use a non-oxidizing chemistry such
as 7338 at 200 ppm. If the system has been stagnant for an extended
period of time, you may need to complete a microbiological cleanup prior
to beginning the passivation procedure.
5. Dose the system with 200 ppm of N-7338 and 10 ppm of N-73550.
Monitor the N-7338 actives with the GlutatTect WT test kit, looking for a
minimum of 70 ppm active and checking on the consumption compared to
what was fed. A minimum of 48 hours with 70 ppm active should be
maintained. Chlorine should be maintained at 0.2 – 0.6 ppm free after the
initial 48 hours. Confirm both general microbiological activity is minimal and
SRB activity is nonexistent.
6. As in all pre-treatment work, addition of the passivation chemicals must be
accomplished as soon as possible after heat exchangers have been
cleaned to minimize flash corrosion.
7. Once the system has been pH adjusted, begin adding the chemicals
specified in Table 1 to the pump basin. Watch for foaming when adding the
73550. You may want to have an anti-foam on site. If the system is small,
you may consider using Nalco 3DT701---a single drum blend of all the
chemicals given in Table 1. Feed Nalco 3DT701 at 1250 ppm.
8. The initial PSO level will be measured as organic phosphate and should be
about ~15- 18 ppm (higher levels will not cause problem).
9. Open all exchangers and circulate the passivation chemicals. Maintain a
circulation velocity of at least 3 feet/sec through the heat exchangers.
10. After this treatment has been in operation, typically for 3-5 days, clean all
strainers/filters that may be in-line with the heat exchangers.
35
11. Resume all chemical treatments at dosages shown in Table 2 and initiate
the normal treatment program and control ranges (pH, Conductivity, etc).
When using Nalco 3DT701, the system is usually returned to normal
cooling system operation after 24-48 hours of circulation. Table 2 dosages
are not used.
12. This treatment regime is typically continued for 2 to 4 weeks, shorter times
may be used. This treatment approach is compatible with all 3D TRASAR
programs. The normal 3D TRASAR program should be started during this
period with the resumption of the heat load to the tower.
13. Perform daily testing of the pH, iron, copper, active polymer, TRASAR,
molybdate, azole, conductivity, total/calcium hardness and microbio activity
14. Blowdown should be adjusted to maintain iron (Fe) levels less than 2.0-3.0
ppm while maintaining dosages given in Table 2. This is necessary to
minimize the potential for iron fouling in the system.
15. After 2 to 4 weeks, turn off the passivation chemicals and maintain the
normal cooling tower treatment program after iron levels drop below 2
ppm. The system does not need to be drained or flushed to rid the system
of the pretreatment chemical program.

7357 Molybdate 364 ppm 100 ppm as MoO4
3DT701 Blend of above non 1250 ppm Maintain for 24 to 48 hours
biocide components
TRO or 7338 biocide 0.2-0.4 TRO or 200 90 ppm as active
ppm
Table 2. Passivation Chemicals--dosages after start-up

7357 Molybdate 182 ppm 50 ppm as MoO4 *
TRO or 7338 biocide 0.2-0.4TRO or 100 45 ppm as active
ppm
* Molybdate interferes with the certain iron tests. The following interference levels for various Hach iron tests
are given below.
Hach FerroVer (Method 8008) no interference at <80 ppm MoO4 (range 0.02 –3.0 ppm Fe)
Hach TPTZ (Method 8112) MoO4 at 5 ppm interferes (Range 0.012 – 1.8 ppm Fe)
Hach FerroMo (Method 8365) eliminates high MoO4 interference (Range 0.01 – 1.8 ppm Fe)
Hach 1,10-Phenanthroline (Unicells) MoO4 not listed as an interference (Range 0.1 – 5.0 ppm Fe)
36
Phase 3 Transition to on-going 3D TRASAR cooling water program

1. After the high-level passivation program is complete, adjust system pH to
normal operating level with return of heat load.
2. Balance the blowdown rate to keep the iron level less than 1-2 ppm .
3. If the cooling water treatment program uses orthophosphate, do not raise
the orthophosphate level up to the normal operating target until the iron
level decreases below 1-2 ppm.
4. Once the iron level is below 1 ppm, increase cycles at equal increments to
return to normal dosage levels.
5. Monitor corrosion rates on NCM (Nalco Corrosion Monitor) during the
return to heat load.
3D TRASAR Passivation Program Contingency Guide

desired results. Problems, however, can arise with even the best control. The
contingency guide shown in Table 3 will assist you in correcting problems
should they occur. It should also be used in outlining what actions your
customers should take when control testing indicates a problem with the pre-
treatment program.
Table 3. Problem Contingency Guide

pH rises above 8.5 Potential for increased iron Add sulfuric acid to reduce pH to 7.5 to
deposition or Ca3(PO4)2 formation 8.5 or normal operating levels
exists if back to normal treatment
levels
Initial slug of Insufficient chemical to effectively Add additional
treatment too low complete passivation.
Excessive foam Pump cavitation; possible aesthetic Add small increments of NALCO
(this is an unlikely problem in plant or community. 71D5plus or similar antifoam until foam
problem) height reaches an acceptable level.
Temporary system Stagnant treatment; settling of Debris will be resuspended on system
shutdown due to suspended debris. start-up. Increase blowdown if there is
mechanical highly turbid water
problems.
Overfeed of pH goes below 6.5 If the problem is caught quickly, add
sulfuric acid. soda ash to elevate pH. If the problem
was not noticed soon (which should not
be the case during the pre-treatment),
blowdown the tower heavily, and add
make-up to regain pH. Re-establish
high-level passivation chemistry.
37
Words of Caution
In the long term, successful system operation will be largely determined by your
attention to in-plant training. Properly trained plant personnel will insure that
Nalco recommended chemical/mechanical treatment programs are being
operated as prescribed.
water at startup. The “normal” level seen at startup are usually less than 10
ppm. The iron is removed from the system through blowdown. Systems with
iron levels > 6 ppm will need to operate at low cycles to quickly remove the iron
from the system. Systems with heavy iron contamination will consume more
products because of the high blowdown. The product calculations should be
done assuming the system will operate @ 2 cycles during the initial 48 hour
period.
Some systems being returned to service may be classified as a “high stressed”

startup. A “high stressed” system is one that:
1. experienced a severe acid excursion prior to shutdown

2. contains equipment that has been sitting for long periods in the yard (no
pre-cleaning or pre-treating)
3. has contained standing water (stagnant) in system piping for greater
than 3 weeks
Greater levels of iron “pickup” (~60-100 ppm) will be expected from these “high
stressed” situations. These systems should have product consumption
calculated for 5 days operating @ 2 cycles.
A frequently encountered problem during passivation is having insufficient

chemical inventory to properly complete the process. This compromises the
effectiveness. Prior to start up, ensure adequate inventory of all inhibitors.
Also do not substitute the use of 3DT191 or 3DT192 as the source of PSO for
the pretreatment program. This causes an overfeed of polymer and be
corrosive to both carbon steel and admiralty brass metallurgy.
Available Literature
Confidential Product Profile 3DT701
PR-272 3DTRASAR Passivation Program
38
f. Emergency / Hurricane Wet Lay Up Passivation
Open Recirculating Cooling Systems

Open recirculating cooling systems must often be shut down very quickly during
hurricane season. Most often there is not enough time bring the system down,
as it would be for a scheduled turnaround. This puts the unit into a situation
where stagnant and/or untreated water will be extremely corrosive to the
system’s metallurgy. The Emergency Wet Storage Procedure is designed to
minimize the corrosion that occurs during these stagnant conditions.

assistance.

• TSHP – 3DT190
• Azole – 3DT198, 1336, 73181 (TT); 3DT199, 73199 – BZT; 3DT197 (new
azole)
• Nitrite - 73310

• Nitrite, TT, HSP - 8349
Step 1 – System Preparation

Before high level corrosion inhibitors and biocide are added to the open
recirculating cooling system it must have its microbiological and Total Dissolved
Solids (TDS) levels lower as much as possible. Microbiological levels need to
39
be at a minimum to reduce the demand on the wet storage biocide (non-

oxidizing biocides have maximum application limits in open recirculating cooling
systems). The minimal TDS levels are needed to lower the corrosion potential
of the water and also allow the system’s blowdown to be minimized or block
prior to shutdown (maintains the inhibitors at their applied level).
5 Days prior to anticipated hurricane strike

1. Begin addition of biodispersant @ 20 ppm (Nalco 7348 Plus or Nalco
73550) Note: If biodispersant is included in the routine treatment program
continue the program but adjust feed for decreased cycles and 20 ppm
feed level.
2. Begin increased blowdown to lower the cooling tower cycles to 2 cycles or
as close to 2 as possible (if makeup restricted).
3. Maintain routine treatment (at reduced cycles) and maintain free chlorine
@ 0.3-0.6 ppm. It is critical to maintain oxidizing biocide control (no loss of
feed) to keep the system’s microbiological activity at a minimum prior to
system shutdown.
4. Systems that don’t used chlorine as their primary biocide need to deploy
their biocide program in a manner that will have the system prepared for
wet lay-up. Systems that use stabilized halogens and/or non-oxidizing
biocides should apply non-oxidizing biocide to the system on a daily basis.
Biocide levels going to the waste plant need to be calculated. As an
example, if there are a few small cooling systems discharging into a large
waste facility the additional biocide will not present an impact. A fast
killing, rapid hydrolyzing (detoxify) non-oxidizing biocide (DBNPA) can be
used during this system preparation phase if the normally applied biocide
or Glutaraldehyde presents a problem.
5. All biocides, oxidizing and non-oxidizing, can be deactivated by sodium
bisulfite if needed. Dosages can be calculated for the stream going to
waste along with biocide residual testing. Nalco 7408 (uncatalyzed sodium
bisulfite) is applied based on ppm/ppm of biocide to be deactivated. The
reaction(s) are extremely fast. It is recommended that the deactivation take
place as close to the waste inlet as possible. This allows maximum
deactivation of the biocides through natural degradation prior to the point of
injection.
Step 2 – System Lay-up Procedure

After system preparation, the microbiological activity and TDS concentration will
be at a minimum and the system will then be ready for wet lay-up. Once the
lay-up is started, the system blowdown will be blocked in. Cooling water TDS
levels will begin to cycle up based on the heat load. This is normal and
expected. Conductivity should be run every six hours, if the system doesn’t
have continuous conductivity monitoring, to plot the increase rate in TDS. If
delays are experience in the shutdown process (>24 hours) a small amount of
40
blowdown may be needed if the system is still under full heat load. If there is no
heat load (or negligible load) during a delay, blowdown will not be needed.
24 hours prior to anticipated system shutdown

1. Block in all sources of “controllable” blowdown
2. Stop Biodispersant feed
3. Stop normal phosphate inhibitor chemical feed
4. Stop Chlorine feed
5. Set pH control for 8.0-8.5 range
6. Add 400 ppm of Nalco 7338 (Glutaraldehyde)
7. Add 800 ppm of Nalco 7357 (216 ppm MoO4)
8. Add 350 ppm of Nalco 3DT-180 (105 ppm PSO)
9. Add 50 ppm of Nalco 1336(21 ppm Na-TT) or Nalco 73199 (20 ppm Na-
BZT)
10. Continue cooling system circulation with inhibitors (minimum time 12 hours)
11. Stop normal cooling water dispersant chemical just before system shutdown
12. Test all inhibitor chemical levels and non-oxidizing biocide levels. Pull 2
retain samples. Send one to the Naperville lab for total cation and anion,
filtered and unfiltered testing. Have the proper sample containers for
collection and shipment on site.
13. Stop recirculation and block in cooling system
14. Loss of cooling system water must be minimized as much as possible prior
to restart
a. Preserve treatment inhibitor concentration.
b. Prevent corrosion at the air – water interface if down for extended
periods of time.
Step 3 – System Restart

1. The start-up water chemistry tests prior to recirculation.
a. Molybdate - Hach Method 8036 (Mercaptoacetic Acid Method 0.3-40
ppm)
b. Azole
c. pH
d. Total microbiological count
e. Sulfate reducer counts
f. Active Glutaraldehyde level - (GLUTATECT – WT by Alden Scientific)
g. Conductivity
h. Active polymer
i. Total iron (digested or ICP)
41
j. Total copper (digested or ICP)

k. PSO (need to be sent to Naperville Analytical)
l. Send a sample to Naperville lab for total cation and anion, filtered
and unfiltered testing. Have the proper sample containers for
collection and shipment on site.
2. Active Glutaraldehyde Level (prior to recirculation once recirculation is

established)
a. If the active level is below the maximum established level for
discharge to waste treatment then sulfite neutralization will not be
needed.
b. If the active level is > than level for discharge then Nalco 7408
(uncatalyzed sodium bisulfite solution) should be added at
10ppm/ppm active Glutaraldehyde. This will deactivate the
Glutaraldehyde to < 2 ppm.
c. Glutaraldehyde level should be tested prior to the waste plant and as
close as possible to waste plant inlet. This sample point monitors the
amount that would enter the waste plant, allowing for maximum
uptake prior to the waste facility
3. Total Microbiological counts (prior to recirculation and once recirculation is

established)
a. < 1000 – resume normal chlorine treatment with biodispersant
b. 10,000 - resume normal chlorine treatment with biodispersant +
application of 200 ppm Nalco 7338 biocide
c. 100,000 – resume normal chlorine treatment with biodispersant +
application of 200 ppm Nalco 7338 biocide. Retest in 24 hours and
reapply if > 10,000 counts.
4. Sulfate Reducers – Positive detection = application of 200 ppm Nalco

7338 biocide. Retest in 24 hours and reapply Nalco 7338 with positive
detection.
5. Begin Plant cooling system startup procedures (See attachment)
6. Plan to test water chemistry routinely until equipment is back in service.
7. Begin Nalco All Soluble Startup Passivation procedure (See

attachments)
8. When Nalco All Soluble Startup Passivation is completed return to

normal treatment
42
g. Off-Line, Single Exchanger Passivation
Typical chemical treatment of operating cooling water generally includes

corrosion inhibitors for carbon steel metal surfaces. However, this chemistry
and the component doses are designed to “repair” breaks in already
passivated metal. For surfaces were passivation has not been established,
these programs can take weeks or months install a complete inhibitor “film”.
During this period, rapid corrosion is experienced. In addition to the interim
damage experienced, the areas where corrosion sites have developed will be
resistant to corrosion inhibitor protection afforded by the ongoing treatment
program. Additional corrosion at these sites will continue – generally resulting
deep pitting and premature tube failure.
For this reason, it is necessary that all new or freshly cleaned exchanger tubes
be exposed for a short period upon start-up to chemical inhibitors designed to
provide very rapid metal passivation. Documented benefits from this
procedure include a 20-50% extension in tube life as well as reduction in heat
transfer problems related to tuberculation.
The two methods of passivation are on-line and off-line. Off-line passivation is
the much-preferred method as it allows the use of high levels of inhibitors
designed specifically to promote a rapid protective film without any risk to the
bulk cooling water and other operating equipment. This procedure requires
that the exchanger remain off-line and blocked-in for the period of the
passivation.
Procedure
Prior to installation and passivation, the exchanger should be inspected for
cleanliness. For new exchangers, confirm that no “flash rust” is present due to
atmospheric corrosion during storage on a ‘pad’ or in a ‘yard’. New
exchangers need to be protected from the elements to minimize/eliminate
flash rust from forming on the carbon steel exchanger tubing. For exchangers
recently cleaned, insure that the cleaning was effective removing all scale and
tuberculation. If not found satisfactory, the exchanger should be re-cleaned.
Remember, the passivation only works on bare metal and will not protect
surfaces covered by scale or corrosion products!
Upon installation, immediately perform passivation. If exchanger is left over 2-

3 days before passivation, interim corrosion becomes a concern. This
procedure is designed for passivation of in-place exchangers that allow
effective flow of water through the exchanger. Typically the reservoir for the
passivation solution is from a vacuum truck or tank that can be heated and
pumped through the exchanger.
43
Recommended Procedure:
1. After the cleaning, ensure the exchanger has been flushed with high
quality water
a. Best - condensate or BFW with soda ash to a pH>9.5
b. Good- Clean service water with soda ash to a pH >9.5, turbidity <5
NTU
c. Acceptable- clean service water, turbidity <5 NTU
d. Unacceptable – untreated fire water, untreated/untested service
water
2. Fill the passivation solution tank with high quality water typically
condensate or BFW with soda ash to a pH>9.5. The use of cycled
cooling tower water or high hardness (>50 ppm TH) is not recommended
as the high temperature of the procedure can cause scale formation and
reduce the effectiveness of the passivation.
3. Heat the solution to 150F, the N-73310 to obtain 5000 ppm of NO2 (as
NO2). This is equal to 15.4 lbs of N-73310 per 100 gallons of water. Add
soda ash to raise the pH to 9-10. Use either 3DT191 or 3DT192 to
provide 15 ppm active HSP and 7.5 ppm PSO into the system
4. Circulate the solution for 2-4 hours at 150F. The circulation rate should
be adjusted to maintain a flow velocity of 3-6 fps. For best results, heated
passivation is strongly recommended. However, if this is not possible, the
circulation time must be increased to 8-12 hours.
5. One the passivation is complete, the solution should be evacuated and

disposed of and the exchanger purged dry under a N2 blanket. Maintain a
3-5-psig N2 blanket until put into service. The option to lay up the
exchanger wet, with the passivation solution, exists but should be done
for no more than 7 days. However, ensure the exchanger is fully flooded
with solution and no air pockets exist or corrosion at the water line will
occur. This passivation solution can be flushed straight into the cooling
system when the exchanger is to be placed in service.
Additional Considerations
Ensure the pH of the passivation solution is 9-10, a low pH water < 4.5 will
decompose the NO2 to a toxic NxOy gas. It will also increase the inherent
corrosivity of the solution.
1. A surfactant like N-7308 (50-100 ppm) can be added to solution if oils

are present on the surface of the exchanger to be passivated
2. Very large exchangers may require an additional 1-2 hours of circulation

time.
44

assistance.

• TSHP – 3DT190
• Azole – 3DT198, 1336, 73181 (TT); 3DT199, 73199 (BZT);
3DT197 (new azole)
• Nitrite - 73310

• Nitrite, TT, HSP - 8349
h. Off-Line, NALPREP III Passivation
Attached below is the CPP pre-section detailing the procedure for using
NALPREP III. Although this chemistry can be used successfully, there are
many drawbacks with the use of this product. It CANNOT be used with a heat
load. Elevated soluble iron levels will cause potential for iron phosphate
precipitation. Also there are environmental disposal issues due to the
extremely high levels of phosphate in the discharge. It is highly
recommended that NALPREP III only be used for individual exchanger
passivations. Please review all of these issues carefully with your customer
prior to use.
45
NALPREP III PROCEDURES

NALPREP III is uniquely designed to pre-treat both new and older systems
that have been chemically or mechanically cleaned. It must be applied when
no heat load is present while the system is on-line or they may be applied
when the system is off-line.
NALPREP III is a liquid blends of several materials including inorganic

phosphate for mild steel corrosion protection, an organic corrosion inhibitor for
yellow metals corrosion inhibition, a polymeric dispersant to disperse foulants,
and a surfactant type oil emulsifier to remove oil and grease. It prepares
metal surfaces in the system (including supply and return lines if done in a no-
heat load, on-line application) for long-term corrosion protection. They initially
remove oil and grease from the metal surfaces to permit uniform layering of
the passivating film, and aid in the prevention of flash corrosion when the
system is most vulnerable to corrosive attack.
If the customer has not been using pre-treatment programs, you must
emphasize the importance of pre-treatment.
1. DOSAGE REQUIREMENTS
On-Line pre-treatment of new plants (without Heat Load)
1. The first step in using NALPREP III in new plant start-ups (without heat
load) is to determine the condition of the cooling tower. If the cooling tower
is new, water in the system that was used to wet the tower lumber during
construction must be removed, given the probable existence of copper,
arsenic, and chromium in the water. These elements, added as wood
preservatives, are easily leached from wood. Research has shown the
application of NALPREP III in such a leachate produces a non-protective
spongy deposit and not the adherent passivating film that is desired.
2. After blowing down the system, the tower should then be filled with a
volume of water sufficient to flush main lines and laterals. All exchangers
should be blocked in so that flush water and construction debris are not
permitted entry. As a preferred practice, the flush water should be dosed
with NALPREP III at 2700 ppm product based on the total flush water
volume. Once flushing is complete, drain the tower and clean out the basin
of all debris.
3. Next, refill the basin with water to a level sufficient to fill piping, heat
exchangers, and provide sufficient head to the recirculating pumps. Begin
circulating the water to the main lines only, and adjust the pH within a range
of 6.5 - 7.5. Once the system has been pH adjusted, start adding NALPREP
III to the pump basin. The calcium level in the system must be at least 100
ppm.
46
4. The initial total inorganic phosphate level (TIP) at its maximum should be
about 470 ppm. Ideal water temperatures are from 90-100oF [32-38oC],
although slightly lower or higher temperatures pose no problems. As the
passivating film starts to form, the phosphate level will decrease. Phosphate
uptake within the system will approximate 25-75% of total inorganic
phosphate within 24 hours.
5. Open all exchangers and circulate the NALPREP III for 24-48 hours. (24
hours is minimum; 48 hours is a recommended maximum, although going
beyond 48 hours poses no problem). After the proper circulation time, begin
tower blowdown.
6. The phosphate level must be decreased via blowdown to 10-20 ppm before
the regular corrosion program is started (failure to do this could result in
precipitation of calcium phosphate). The phosphate level should never be
allowed to reach zero before beginning the normal high-level corrosion
inhibitor program.
7. Once the correct phosphate level has been reached, the designated start-up
program for corrosion control may begin. Consult the appropriate product
CPP for start-up procedures.
On-Line pre-treatment of Existing Systems (without Heat Load)

NALPREP III may be used to pre-treat existing systems where the entire
system has been brought down for cleaning and repairs. Product is applied at
2700 ppm product based on the water volume in the system. Procedures are
identical to those for new plants with the following exceptions:
• The initial water rinse step for removal of copper, arsenic, and chromium
leachate is not necessary.
• The flushing step to rid the system of construction debris is not necessary.
As in all pre-treatment work, addition of NALPREP III must be accomplished as

soon as possible after heat exchangers have been cleaned to minimize flash
corrosion. A minimum of 100 ppm of calcium is needed to form the calcium
polyphosphate complex.
47
Off-line pre-treatment of a Single or Bank of Exchangers

Effective off-line passivation of a single exchanger or a bank of exchangers can
be accomplished at 150 oF [65oC] with 5000 ppm NALPREP III or at 130oF
[54oC] with 10,000 ppm NALPREP III in two hours. Calcium must be added if
using condensate. This off-line procedure can be done in two ways:
• With the exchanger in place, and off-line, NALPREP III is applied to

established equipment that has been thoroughly degreased.
• By pulling the bundle and immersing in a vat of heated NALPREP III.
Passivating solutions may be replenished no more than two times with

NALPREP III to reestablish a total phosphate level of 470 ppm. Thereafter, old
passivating solutions should be disposed of and fresh material used. Pre-
treatment of new equipment, which will have oil and grease on the surface,
should utilize fresh NALPREP III each time.
4. PROGRAM CONTROL
Table 1- NALPREP III. Control Guidelines
5. PROGRAM CONTINGENCY GUIDE

desired results. Problems, however, can arise with even the best control. This
contingency guide (See Table 2) will assist you in correcting problems should
they occur. It should also be used in outlining what actions your customers
should take when control testing indicates a problem with the pre-treatment
program.
48
Table 2 Problem Contingency Guide for NALPREP III.
6. DISPOSAL PROCEDURES
Some plants may be able to use the phosphate in the cooling tower blowdown as
a nutrient source in their waste treatment process. However, if phosphate removal
from the blowdown is necessary, the general procedure outlined below may be
used.
Two chemicals are used to remove phosphate from the blowdown: a solution of
ferric chloride (FeCl3) and 50% sodium hydroxide.
1. Pump the phosphate containing blowdown to suitable ponds or tanks as

quickly as line limitations permit. Establish a constant flow rate of the
blowdown to aid in optimum chemical treatment dosages.
2. As the phosphate bearing blowdown reaches the treatment site, begin adding
ferric chloride and caustic. Note that the order of addition of FeCl3 first and
NaOH second is very important for optimum phosphate removal. These two
chemicals should be added at two points at least 4-5 feet [1.2-1.5 meters]
apart.
3. Add 3.5 gallons [13 liters] of a 39% FeCl3 solution to every 1000 gallons [3785
liters] of blowdown (solutions of different strengths will require a volume that is
proportional to the strength).
4. Then add 1.4 gallons [5 liters] of 50% sodium hydroxide per 1000 gallons
[3785 liters] of blowdown. NaOH addition should generate a pH at the NaOH
mixing point of 6.0.
49
5. Samples should be taken several feet [1 meter] from the final mixing point and
at a more remote point in the waste treatment system to assess successful
phosphate removal. Feed of FeCl3 or NaOH should be adjusted as necessary
to effect adequate phosphate removal. Sampling to determine phosphate
levels should occur hourly during the blowdown process.
6. For systems where the blowdown line enters a retention pond directly, a
temporary mixing baffle constructed of plywood will aid the mixing and
phosphate removal process.
Exchanger Inspections
Once the unit has come down and exchangers are being opened for inspection
and maintenance, it is time to begin to inspect the equipment. It is very important
to inspect every cooling water exchanger that is opened. As soon as these
exchangers are opened and inspected by the customer, they will usually either
clean in-place or pull the bundle and transport to a location where they are
cleaned. Time is money during the T/A - they will not wait on you if you are not
present to inspect an exchanger when opened. To make sure you do not miss any
inspections, you will need to get a copy of the T/A exchanger schedule from the
T/A group. It is also important to identify the individual(s) who will be managing the
exchanger scheduling during the T/A. Since the planned schedule will often
change, keeping in close touch with them will help ensure you do not miss any
equipment openings.
Another area that is important is ensuring you have the needed inspection
equipment supplies ready to go once they start opening exchangers. This would
include sample deposit / whirl pack bags, tools for the inspection (camera,
flashlight, magnet, knife, screwdriver, etc). Be sure to understand the permit
requirements for using a camera on-site and make arrangements to have the
necessary permit in advance of the exchangers’ openings.
The final item of need is a pad of Nalco exchanger inspection forms. These are
available from the literature forms directory in KM as Form 968, Exchanger
Inspection Form. This form is on the following pages and should be used for all
inspections.
It is important to be thorough in each inspection. Take deposit samples and send

in for analysis to Naperville. Take multiple photos that detail the condition of the
exchanger. Be sure to have the exchanger’s name with each picture. A 3”x5” note
card & marker can allow you to make a small label for the photo. Also be sure to
take detailed notes and fill out the entire inspection form attached below for each
exchanger.
50
Exchanger Inspection Form
51
52
Post T/A Start-up

Precautions must be taken after a Turn Around or lay up event to effectively flush
accumulated debris, chip scale, mud, silt, etc. from the cooling system. This will
minimize the potential for exchanger fouling and plugging debris that will be
transported throughout the system piping. The object is to ensure plant reliability
by minimizing cooling water corrosion and fouling during start-ups.
In many system, chip scale and iron deposition pose the greatest threat to tube
and tube sheet plugging during start-ups. The best methods for dealing with this
issue is to use either strainers on the inlet side of the exchangers and/or ensure
each exchanger that is on the primary cooling water circuit have the capability to
be back flushed to remove any debris on the inlet tube sheet. This is particularly
important for those exchangers that sit at the end of the cooling water supply
piping that can accumulate trash, chip scale, mud and silt, etc.
Procedure
1. When the make up line is put back into service, the initial slug of water may
contain high levels of chip scale, mud and iron. If possible, this initial slug
should be diverted from the tower basin. If even after the initial slug, any mud
or high iron levels introduced into the basin, the basin may be overflowed to
wash that out before recirculation begins.
2. If the unit is equipped with steam driven pumps, use these first (prior to electric
driven pumps). These pumps should be capable of ramping up to speed in a
more controlled manor than electric driven pumps. This will minimize any
shock conveyed to the cooling water piping that might dislodge any chip scale
or other debris that can plug the exchangers.
3. As circulation begins, the water flow should be directed to exchangers that are
equipped with strainers or traps to filter out any chip scale. If possible,
directed through the system supply piping and flushed prior to opening any of
the blocked in exchangers. This is of particular importance for those
exchangers that are positioned at the end of the supply piping.
4. Back flush all exchangers vigorously for a minimum of 20-30 minutes that were
exposed to the initial flow of water and continue back flushing until all evidence

• Open the back flush nozzle to allow flushing of the lines up to the
exchangers.
53
• When that runs clear back flush the exchangers.

• When the back flush water runs clear, close the back flush valve and
open the inlet valve.
• If possible install inlet and outlet pressure gauges to monitor pressure
drop across exchangers as they are put into service.
• If back flush valving does not exist, open to drain the CW supply
piping for 15 minutes before establishing flow to those exchangers.
6. After all the exchangers have been put back into circulation and the back
flush is complete, begin the microbial cleaning and passivation procedures.
Post T/A Reporting

Following the completion of a T/A, it is very important that a summary report be
completed. Although the customer will have various T/ A and inspection
departmental reports, none will be as focused and detailed on the health and
condition of the cooling water exchangers and the cooling water system in general.
A T/A report provides Nalco the chance to document the tremendous amount of
work done by Nalco personnel. It also will provide an opportunity for you to
correlate the data gathered and provide observations of conditions and
recommendations for improvements. There are countless examples of good T/A
reports. However, they all will include these common items:
• Photographs with descriptions

• Deposit analysis and interpretation
• History of exchanger
• Explanation of visual inspection
• Document work performed on exchanger
• Graded Exchanger Inspection form
• MOC data that illustrates impact of system stress on exchanger (i.e., low
flow rates or high skin temperature’s impact on high level of deposition)
• Recommendations to improve system and exchanger performance
Be sure to take sufficient time to produce a professional, informative document.

Ensure that the electronic copies of this are distributed to the appropriate Nalco
internal personnel (KAM, DM, local team) as well as hard copies to your
customers. Schedule time either one on one or in a T/A review meeting to discuss
your report and make plans for projects or action items to improve the results.
Examples of a good T/A report will be posted in the Energy Services, Downstream
PAC 3 Homepage in Knowledge Management.
54

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TurnAround Best Practices

Energy Services Division

Planning the T/A ....................................................................................4

Communicating the Best Practice T/A Plans.........................................5

System Lay-Up ......................................................................................7

System Lay-up Best Practices...............................................................9

b. #2 Best Practice for Lay-up: Wet Lay-up................................................... 10

d. #3 Best Practice for Lay-up: Drain and Dry ............................................... 11

b. Pre- T/A – Wet Storage Lay Up.................................................................. 13

c. Post T/A – Molybdate / PSO Passivation ................................................... 20

d. Post T/A - Nitrite/PSO Passivation Procedure............................................ 27

e. New System Passivation............................................................................ 33

f. Emergency / Hurricane Wet Lay Up Passivation........................................ 39

Exchanger Inspections ........................................................................50

Exchanger Inspection Form.................................................................51

Post T/A Start-up .................................................................................53

Post T/A Reporting ..............................................................................54

Introduction – T/A Best Practices

Once you have agreement on implementation of Best Practices, allow your

Planning the T/A

Establish T/A Best Practices with Customer for site

Communicating the Best Practice T/A Plans

• Communicate Best Practice T/A Plans to T/A Team, Operations, other

• Action Items to Accomplish – Near Term T/A Planning

• Action Items to Accomplish – Long Term T/A Planning

Chemical Feed, Storage, Monitoring and Control

In order to fully understand the Best Practice recommendations that we make, we

Low Flow and Corrosion Inhibition

Mass Transfer Through Diffusion Layer

Solid line - Fick’s treatment

System Lay-up Best Practices

Nalco Chemical Company

increases above the 6-ft./sec. corrosion increases due to erosion corrosion. As

b. #2 Best Practice for Lay-up: Wet Lay-up

An internal, visual inspection of the recirculation piping is seldom, if ever

c. #2A Best Practice for Lay-up: Drain, Dry and Purge

d. #3 Best Practice for Lay-up: Drain and Dry

Nalco Pretreatment Options

MoO4/PSO based Best program overcomes issues

Nalprep III - 2500 ppm NO HEAT Load!! Operating over 48

PSO Dosage Chart Inhibitor (MoO4 and PSO) Dosage Chart

PH Hottest Water Temperature

<50 100 100 80 80 MoO4/PSO 100/50 125/60 150/75 200/100

PolyPO4 Dosage Guide (for Nalprep III)

<50 N/A N/A N/A N/A

50-100 N/A N/A N/A N/A

>200 400 400 300 250

b. Pre- T/A – Wet Storage Lay Up

Open Recirculating Cooling Systems

• Stagnant water corrosion

Wet lay-up of system piping is preferred to “dry lay-up” where water is

Passivation Product Selection

Single Function Products

Blended, Multi-Function Product

Step 1 – System Preparation

5 Days prior to shut down:

to 20 ppm or until an acceptable level of foam is generated. Increase the

Step 2 – System Lay-up Procedure

24 hours prior to anticipated system shutdown

Step 3 – System Restart

C. Active Glutaraldehyde Level (prior to recirculation once recirculation is

a. If the active level is below the maximum established level for

D. Total Microbiological counts (prior to recirculation and once recirculation is

E. Sulfate Reducers – Positive detection = application of 200 ppm Nalco 7338