Chemical Treatment Manual

Technical Guidelines on
Cooling Water Treatment

Ion Exchange Ltd
©Ion Exchange Ltd
G.C.C Operation: P.O Box: 49247, Hamriyah Free Zone, Sharjah, United Arab Emirates. Tel: +971 6 5261606 Fax: +971 6 5261607
Web: www.ionexchangeglobal.com; Email: uaesales@ionexchangeglobal.com
Offices: - USA, UAE, Canada, India, Malaysia, Singapore, South Africa, Thailand, Bangladesh, Bahrain, Indonesia, KSA, Kenya, Nigeria, Oman.
Document Title Technical Guidelines on Chemical Treatment of Cooling Water Systems
Document No. IEH/CHD/TS/CW-01/16 Revision No. 01 Dtd. 15-09-2016 Page 2 of 42
Executive Profile
Ion Exchange Ltd. is a leading Company in the field of Water Treatment Products and Services having
operations in India, Middle East, Asia Pacific, Africa and SAARC Countries. Ion Exchange is among very
few companies in the world having virtually all types of water treatment processes and technologies
under one roof. This gives us a tremendous competence to provide total water management solutions
to our Customers. To build this competence, we had several arrangements / tie ups with various water
treatment leaders in their respective fields.
We are headquartered at Mumbai - India with 5 manufacturing facilities at various locations. Our state
of the art chemical manufacturing facilities are located in Bahrain and India with R&D facilities at India
We have 4 major product lines:
◢ Water Treatment Chemicals
◢ Water Treatment Equipment
◢ Consumer Products for Homes and Communities
◢ Services
The technological base of Water Treatment Chemicals was inherited from WR Grace – Dearborn, USA
during our collaboration and further built up strongly by our Research and Development facilities in
India. We have a team of well-trained water treatment professionals who are able to work out the
most appropriate solutions for your water treatment needs.
OUR BACK-UP FACILITIES
We are backed by diagnostic tools, which are used to evaluate Corrosion rates, trends of Deposits and
Bio-fouling at site. We are backed by unique facilities of Easy test Kits for even the finest tests which
are accurate enough to carry out investigation at the site.
Basic water testing of water samples can be performed at laboratory facility from Hamriyah Free Zone
UAE. We have state of art laboratory facilities at, Patancheru for a thorough testing of water and
deposit samples. We are backed up with a simulation laboratory and test rig facilities here. We can
simulate client Specific cooling water quality and have a pilot test run for evaluating different products
and the same facility is also used for solving any site related problems. Our application laboratory has
following facilities:
◢ Simulations of water quality and evaluation of water performance on a test rig
◢ Testing of deposit samples
◢ Testing of complete range of parameters for water analysis even at micro level.
◢ A range of sophisticated equipment as atomic absorption spectro photometer,

chromatographs and IR facilities.
We are backed up by experienced technologists and experts and the services of microbiologists. We
have a Central Technical Services group in our Chemical Division to provide spontaneous services back
up to our Customers.
We have developed an expertise in treating variety of cooling water systems from all areas in the
industry and from core sectors like fertilizer, steel, refineries, petrochemicals, synthetic fiber and
chemical etc. We are treating over 3000 boilers and cooling systems in across the globe.
QUALITY ASSURANCE
Ion Exchange Ltd – specialty Chemical Division has commitment to the quality of its products. Our
manufacturing facilities are been awarded with ISO 9002, OHSAS 18001 and ISO 14001 certification.
An up to date R & D center is attached to our factory where there is constant up gradation of latest
technologies and continuous development. We have a robust quality assurance system and a well-
equipped laboratory at our works.
Section 1: - Closed Loop/Chilled Water Systems Water management
Part 1:- Introduction

A closed recirculating water system uses water continually in a cycle. First, the water absorbs heat
from process fluids, and then releases it in another heat exchanger. True closed systems neither lose
nor gain water during service.
Closed cooling systems are generally very straight forward to treat because of the high quality of the
water used for make-up and because of the low level of water losses
Part 2:- Products
A. Cleaning Chemicals
INDION 9020 is a neutral pH cleaning chemical which is capable of removing oil, grease, mill scales and
rust from metal surfaces of system.
INDION 9020 includes:
 Low foaming non-ionic surfactant for penetrating oily and greasy deposit surfaces.
 Dispersant for dissolving rust.
 Reducing agent for corrosion control.
B. Chemical for Passivation

INDION 3591 is a corrosion inhibitor which is used for Passivation of metal surfaces. INDION 3591
provides a silicious film for the protection of metal surfaces.
C. Corrosion and scale inhibitors
 INDION 5547C/INDION5543 (Nitrite Based Corrosion Inhibitors)
INDION 5547C/5543 is a unique product used as a corrosion & scale inhibitor, which provides
superior corrosion and scale protection to all types of closed systems. INDION 5547C/5543 contains a
complete corrosion inhibitor system that protects the yellow metals and iron
INDION 5547C/5543 is a unique formulation which consists of the following
 Sodium Nitrite – For Ferrous metals corrosion prevention.
 Borate Buffer – To maintain pH between 8.5 to 10.5
 Benzo Triazole – To prevent Non Ferrous metal Copper corrosion.
 Polymeric Dispersants and phosphonates for Scale Control even in high

hardness waters.
 INDION 9018 (Molybdate Based Corrosion Inhibitor)
INDION 9018 is a specially developed synergistic blend of sodium molybdates and polymers which
forms an effective corrosion inhibitor film on metal surfaces. It reduces expensive downtime and
maintenance costs. INDION 9018 prevents the deposition of airborne foulants and water caused
deposits.
D. Biocide
 INDION 9040/9042 (Isothiazolinone based biocide)
INDION 9040/9042 is an isothiazoline based broad spectrum microbicide, slimicide and bio-
dispersant effective against wide spectrum of bacteria algae/fungi/moulds/slimes. They are
effective against aerobic and anaerobic bacteria, algae and bio-films commonly associated with
Cooling or Fire water systems. The product is highly effective in the control of Pseudomonas and
helps to control microbiologically induced corrosion.
Part 3:- Chemical cleaning of chilled water system
Clean chilled water system to remove oil, grease, silt, and rust and leave metal surfaces well
passivated.
Part 3.10 Cleaning Procedure
The process of pre-commission cleaning is designed to remove surface rust, mill scale and light debris,
which may have entered the systems during their construction. Pebbles, welding slag and small pieces
of metal and wood cannot be dissolved by any chemical, which may be safely used, and although one
would expect the majority of such debris to be removed by the flushing process. Prior to
commencement of works, all system should be filled, vented and fully circulated
Cleaning and Flushing procedure for Chilled Water
Procedure for cleaning the chilled water circuits consists of the following stages:
Stage 1 - Flushing with clean water
Stage 2 - Flushing with Chemical Removal of surface oxides.
Stage 3 – Final flushing and removal of cleaning chemicals

Stage 4 - Passivation treatment of the system
Stage 5 – Initial Fill

The purpose of this stage is to remove inert suspended matter such as iron pieces, welding slags, and
foreign particles etc. this flushing will be continued until all suspended solids are removed from the
system.
1. The chilled water system is first filled with fresh water and the water is circulated in the system
using the system pump, at low speed, for a period of 2 - 3 hours.
2. The system is then drained from the lowest point and this is done with a view to take away the
large debris which would be accumulated in the pipes, during manufacturing, transportation
etc.
3. The system will again be filled with fresh water and then circulated for up to 24 hours and
drained from the lowest point. The process is repeated until the suspended solids in the system
are taken out and the water is relatively clear.
4. The water quality required at this stage in order to inject INDION 9020 program is as below:
Parameter Control parameter after plain flushing stage

pH Same as water used
Total dissolved solids Same as water used
Conductivity Same as water used
Total iron <5ppm as Fe
TSS < 50 PPM
Table 1: control parameter after stage 1
Stage 2 - Flushing with Chemicals
1. This process involves the use of chemical INDION 9020 which is manufactured by M/s Ion
Exchange.
2. INDION 9020 is a synthetic antifoulant and it inhibits the deposition of fouling materials on heat
transfer surfaces. Fouling caused by hardness scales, phosphates, metal oxides, silt and other
air-borne materials can be eliminated. INDION 9020 removes oil and grease from all metal
surfaces. It acts to keep surface clean, maintain a high rate of heat transfer and aid the
formation of corrosion inhibitor film. It is particularly useful in systems with higher iron
concentration.
3. The INDION 9020 should be injected at the rate of 500-750 ppm based on system volume. The
product shall circulate in the system for a minimum 24 hours and to a maximum of 48 hours,
water samples should be taken every three hours to monitor the total iron level in the system.
This procedure should be carried out until satisfactory results
4. The iron level should increase until reaching a steady value that will not differ from 0.5 to 1 ppm
from the previous value. Three consecutive values stable with difference not more than 0.5 to 1
ppm lead to the completion of this phase.
Stage 3- Final Flushing and removal of Chemicals
1. The purpose of final flushing is to take out all the left over suspended particles, mill scale,
debris, and metal oxides which are accumulated in the system.
2. In this phase the water should be supplied to the system and the system pressure should be
stabilized and the water will be drained from the chilled water system at the same time.
3. This phase should be carried on without interruption in order not to disturb the flushing
sequence progress, plus the iron decrease until the iron value level will reach the acceptable
recommended limits below 2 ppm.
4. The water quality needed before the addition of the Passivation chemicals is as below:
Parameters Water parameters after final flushing
pH 7.0 to 8.2
Conductivity Same as water used for flsuhing
Total iron <2 ppm as Fe
TSS <30 ppm
Stage 4– Passivation of the system
Once Stage-3 has been completed the system is then filled with passivation chemicals INDION 3591 @
rate 0.2 Kg/m3 as per System volume. Circulate water for 24 hours.
The system then comes to a rest and is finally monitored and inspected upon commissioning.
Parameters Water parameters after Passivation
pH 7.8 to 8.5
TSS <30 ppm
INDION 3591 (ppm) 5 to 10
Stage 5- Initial Fill of Biocide and Corrosion Inhibitor
After completion of Passivation initial fill of corrosion inhibitor and biocide is performed to ensure
adequate protection of system against corrosion, scaling and microbiological growth.
Based on the corrosion inhibitor selected dosage will vary as per the following table
Sl No Chemical Name Active ingredient Dosage
1.0 INDION 5547C Nitrite Based corrosion 3.5 Kg/Cubic Meter on

inhibitor system volume
2.0 INDION 5543 Nitrite Based Corrosion 2.5 Kg/Cubic Meter on

inhibitor system volume
3.0 INDION 9018 Molybdate Based 0.3 kg/ cubic meter on

system volume
4.0 INDION 9447 Molybdate/Nitrite based 0.8 kg/ cubic meter on

corrosion inhibitor system volume
Table 4.0 Dosage requirement for various corrosion inhibitors for closed loop system
INDION 9040 should be dosed at the rate of 0.1 Kg per cubic meter (0.05 Kg/Cubic meter for INDION
9042) of water based on the system volume and should be circulated for at least 6 hours.
Sample shall be taken to confirm that the chemical is circulated throughout the system.
Sequence of operation:
 Micro-bio control should be added to the system, INDION 9040 at the dosage rate of 0.1 kg / m3
(0.05 Kg/Cubic meter for INDION 9042) based on the system volume, circulate the system for six
hours.
 Select suitable corrosion inhibitor based on system metallurgy and design as per Table 1. Dose
corrosion inhibitor as per the dosage Table 1 and circulate for six hours
 Random samples shall be taken from the index branch in the system (for AHU, & FCU) for testing
to confirm the amount of corrosion inhibitor reserve.
 The system should circulate for at least 12 hours and sample shall be taken to confirm the water
parameters as below:
Parameters Control parameters for systems using INDION 5547C/5543

after initial addition of chemicals
pH 8.5 to 10.5
Conductivity <3000 µSiemens/cm
Nitrite 800-1000
Total Suspended solids <20 ppm
Table 5 - Water parameters for systems using INDION 5547C/5543
Part 3.20 Regular treatment
Once a “tight” closed water system is treated, it should rarely require addition of corrosion inhibitors.
However, water losses from leaking pump seals and valve packing will also cause a loss of chemical
treatment that will necessitate replacement. The need is determined by testing the system on a
regular basis. The frequency of testing is based on experience but should be done no less than
monthly for most systems. However, where experience shows the systems to have virtually no water
losses, a test frequency of once per quarter may be sufficient.
Although extensive microbiological growth is not usually encountered in a closed recirculating system,
its presence can adversely affect a corrosion control program. Biological growth can impede effective
heat transfer and cause blockage. Microbial under deposit corrosion can create intense localized
pitting and corrosion resulting in leaks. This is particularly costly if it occurs on evaporator tubes. Ion
Exchange recommends quarterly addition of biocides to prevent such microbiological growth. INDION
9040 is added to system on a quarterly basis through pot feeder or automatic dosing system, dosage is
0.1 kg/Cubic meter (0.05 kg/Cubic meter for INDION 9042)
Sl.No Parameters Control parameters to be

maintained in systems during
regular operation
1.0 Chemical Parameters
a pH 8.5 to 10.5
b Conductivity <3000 µSiemens/cm

c Total iron <2 ppm as Fe
Corrosion Inhibitor INDION 5547C/INDION 5543, ppm
d.1 800-1200 ppm
as NaNO3
d.2 Corrosion Inhibitor INDION 9018, ppm as Molybdate 150-300 ppm
Corrosion Inhibitor INDION 9447, ppm as Molybdate +

d.3 100-200 ppm each
Nitrite
e Soluble Copper, as ppm 0.20 ppm as maximum
f “OH” or Free Caustic Alkalinity 20 ppm Maximum
g Tolytriazole, Copper corrosion inhibitor, ppm 5-10 ppm
h Total Suspended solids <20 ppm

2.0 Microbial Parameters
a Total Aerobic Plate Count, CFU/ml <1,000
b Total Anaerobic Plate Count CFU/ml <10
c Nitrite Reducers, CFU/ml <10
d Sulfate Reducing Bacteria, CFU/ml 0

3.0 Performance Parameter
a Mild Steel Corrosion Rate, MPY <1.0 MPY
b Copper Corrosion Rate, MPY <0.2 MPY
Table: 6 Properties to be maintained during normal operation
Part 3.30 Automatic Dosing Controller
Cooling System performance for operational efficiency, asset preservation, water conservation, and
environmental compliance is more critical now than ever before. Keeping up with this Ion exchange
has come up with ‘Indion Autochem’. Indion Autochem is a valuable automation and data
management platform that enables our best-in-class field engineers to provide a superior water
treatment program.
Features and Benefits:
◢ Continuous monitoring and proportional control for pH and conductivity variables

◢ Data logging for pH, Conductivity, Temperature and 13 other variables
◢ Special inhibitor and dispersant dosing features
◢ Flexible non ox biocide dosing program
◢ Remote Access via secure website - No software installation or upgrades required
◢ Alarms & events sent via SMS and/or e-mail
◢ Online dashboard with Graphs and Plots
◢ 24 x 7 remote monitoring from centralized expert team
Scope of Supply
◢ Indion Autochem Inclusive of
 Controller
 Chemical Dosing Pumps
 Modem for wireless communication (Optional)
 Online Web Access (Optional)
 pH Sensor
 Conductivity Sensor with RTD sensor
 Flow switch
 Dosing Tank
Site Requirements
A. 230 V, 50 HZ Power Supply – Preferable UPS Supply Power point should be within 1 meter from
the controller. Normal 10A power point is fine.
B. 1” or 3/4” Tapping for sample water inlet from recirculation pump discharge header or chilled
water return header
C. 2.5 m x 2.5 m space along with proper shed for Autochem Skid for protection from sunlight/ rain
and dusty environment.
Part 3.31 Equipment Specification
A. INDION Autochem Dosing Controller
INDION Autochem is a complete automatic condenser/chilled water treatment and control system of
modular plug-in construction. The system is included with a conductivity controller, pH controller,
corrosion inhibitor dosing controller and biocide programmer. INDION Autochem is a microprocessor
based controller with alpha numeric LCD display capable of being programmed by operator and
monitored in a BMS system. Dosage of corrosion inhibitor can be controlled based on the makeup
water rate, biocide dosing pump can be operate manually since the dosage comes once in three
months.
The system can be connected to local BMS on view only access mode. The system will provide four 4-
20 mA output for pH, Conductivity and return water temperature. It will also provide 9 NPN Open
Collector Transistors to signal output of pump running status, flow status, solenoid valve status, Power
failure status, and alarm status only. The system can be connected remotely using GSM protocol and
can be controlled remotely through standard internet browsers. The controller enclosure is IP65
protected. The make-up water totalized reading can be viewed online by using standard web browser.
Engineering Data
Controller
Enclosure : NEMA 4X / IP65

Power Supply : 230 V/ 50Hz
Control Output : Line Voltage @240VA per Relay
(2 Amps @ 120VAC)
Display : LCD
pH Sensor
Range : 0.01-13.99pH
Accuracy : 0.4% of Range
Resolution : 0.01pH
Conductivity Sensor
Range : 0-9999 μS/TDS

Temperature Compensation : Yes
Resolution : 1 μS / 1 ppm TDS
B. Water meter
An impulse type water meter in the makeup water lines to control inhibitor dosing and for makeup
flow monitoring purpose; water meter shall be capable of transmitting the flow rate to Autochem
Controller
C. Inhibitor Dosing System

The dosing pump will be of diaphragm type leak proof dosing pumps capable of handling the corrosion
inhibitor. The pumps will be provided with dry run automatic protection system (low level switch).
Specification of dosing pump and tank is as given below.
(i) Dosing Tank
Quantity : 1 No.
Chemical : Corrosion Inhibitor
Dosing Tank Material : Polyethylene tanks
Make : Prominent/Seko/Equiv.
(ii) Dosing Pump
Quantity : 2 No. (1 Duty+1 Stand By)

Power Supply : 230 VAC, 1 Ph, 50-60 Hz
Manufacturer : Asia LMI/ Pulsa Feeder/
Prominent/JESCO/Equiv.
Type : Electronic Diaphragm type pump
Liquid end Material

Pump Head : PVDF
Diaphragm : PTFE
Balls : Ceramic
Seals (O-ring) : PTFE/Viton
Control : Dual control through stroke and speed
Fittings : Supply to include:
- Foot Valve with strainer
- Injection Check Valve
- Suction and Injection Tubing
D. Biocide Dosing System

The dosing pump will be of diaphragm type leak proof dosing pumps capable of handling the
aggressive chemical. The pumps will be provided with dry run automatic protection system (low level
switch). Specification of dosing pump and tank is as given below.
(i) Dosing Tank
Quantity : 1 No.
Chemical : Biocide
Dosing Tank Material : Polyethylene
(ii) Dosing Pump

Chemical : Biocide
Prominent/JESCO/Equiv.
Liquid end Material
Pump Head : PVDF

Diaphragm : PTFE
Balls : Ceramic
Section 2 Condenser Water System/Open Cooling Water Systems
Part 1 Introduction
Cooling towers reject heat to environment by evaporating a small part (1 – 2%) of re-circulating water.
As a result, salt concentration in cooling water increases progressively to cause scaling and corrosion.
A cooling water system can have problems of:
 Corrosion
 Scaling and fouling
 Microbiological Growth with consequent bio-fouling and Microbiologically Induced Corrosion.
Corrosion: This is an electro-chemical phenomenon where a metal reacts with water and
dissolved oxygen to revert to its parent oxide state.
Fe  Fe 2+ + 2 e- Anodic Reaction, metal goes into solution

2e- + ½ O2 + H2O  2 (OH)- Cathodic Reaction, electrons consumed at cathode
Fe + ½ O2 + H2O  Fe(OH)2 Net Reaction
The Fe(OH)2 in turn is oxidised to form Fe2O3, a porous deposit that allows further corrosion to
continue underneath the deposit.
Scaling: Scaling is the precipitation and deposition of hard crystalline salts on heat transfer surfaces.
Scales form when the concentration of scaling salts (typically Ca3(PO4)2, CaCO3) in cooling water
exceed the solubility limit. Normal treatment programmes require dosing of acid to lower pH of cooling
water and thereby suppress scaling. By using a low PO4 programme, we are able to operate the system
without acid dosing. Scale formation is controlled by using polymeric dispersants that increase
solubility of these salts.
Microbiology: A cooling water system is an ideal incubator for bacteria to grow. The slightly
alkaline pH, warm temperature and availability of nutrients allow bacteria to grow without hindrance.
Addition of biocides on a regular basis destroys these bacteria and prevents problems of slime
formation. A more difficult problem is microbiologically induced corrosion due to anaerobic bacteria
such as Sulphate Reducing Bacteria (SRB). These bacteria consume SO4 ions in CW and convert them to
the acidic H2S that causes pitting corrosion.
Dosing a biodispersant ensures that anaerobic bacteria are constantly flushed out and do not form
localised colonies that cause pitting corrosion.
Operating the cooling water system at alkaline pH reduces effectiveness of chlorine / sodium
hypochlorite. For better effect, it is necessary to supplement chlorine with bromine. Bromine retains its
effectiveness up to a pH of almost 9.0 and is better suited for systems.
Part 2 Goals of programs
The purpose of a water treatment program is to provide heat-exchange surfaces that are sufficiently
intact and free of deposits so that design specifications are met. Cooling systems that are corroded
with loss of piping, tube bundles, or pumps do not meet specifications. Cooling systems with scale do
not meet specifications. (Calcium carbonate is a frequent example; other scales such as magnesium
hydroxide, calcium phosphate, or scales containing silica can occur.) Cooling systems containing
deposits of sand, silt, or organic material blown into the system by the wind do not meet specifications
if these materials clog piping, strainers, cooling tower distribution holes, or tower fill or pumps. Profuse
growth of microorganisms can prevent a cooling system from meeting heat-transfer specifications and
may increase risk of legionellosis and other diseases.
Part 3 Calculations for designing a treatment program
Water circulates through the process exchangers and over the cooling tower at a rate referred to as
the "recirculation rate." Water is lost from the system through evaporation and blowdown. For
calculation purposes, blowdown is defined as all non evaporative water losses (windage, drift, leaks,
and intentional blowdown).
Makeup is added to the system to replace evaporation and blowdown.
Make Up (M), m3/h = Blow Down (B), m3/h+ Evaporation (E),m3/h + Drift
Evaporation loss is the water quantity evaporated for cooling duty and, theoretically, for every
10,00,000 kCal heat rejected, evaporation quantity works out to 1.8 m3. The following equation
describes this relationship between evaporation, recirculation rate, and temperature change:
Evaporation Loss (m3 /hr) = T.F x 1.8 x circulation rate (m3 /hr) x Delta T(oC) / 1000
(Reference: Perry’s Chemical Engineers Hand Book)
T.F = evaporation factor/tower factor
The evaporation factor, F, equals 1 when all cooling comes from evaporation. For simplicity, this is
often assumed to be the case. In reality, F varies with relative humidity and dry bulb temperature. The
actual F value for a system is generally between 0.75 and 1.0, but can be as low as 0.6 in very cold
weather.
Operating cycles of concentration are selected based on makeup water reaching the cooling system.
Cycles of concentration is defined to be the ratio of impurities in cooling water compared to its levels
in the makeup water system. Concentration of salts in cooling water increases operational problems
like scaling, corrosion and fouling.
Cycles of concentration (COC) = Impurities in cooling water/Impurities in makeup water
As many impurities tend to precipitate, it is often suggested to compare the level of chloride. Chloride
is chosen because it is soluble and does not form precipitates as do calcium, magnesium, carbonate,
phosphate, silicate, and occasionally other ions. Conductivity or any dissolved compound could
theoretically be used in the calculation of the ratio, but chloride is chosen because of its high solubility.
An exception to the use of chloride ion as the measure of cycles of concentration occurs if high levels
of chlorine are used as a biocide. In this case, the cycles of concentration ratio would be high, and
another parameter should be selected.
To control cycles of concentration, a conductivity meter continuously measures a moving side stream
of system water. The conductivity meter is connected to the bleed valve. As water evaporates and
conductivity increases above a set point the bleed valve opens. Cycled water goes to drain, which may
lower the level of water in the cooling tower basin. The float valve in the basin opens to replace the
cycled bleed water with makeup water at one cycle of concentration. When conductivity decreases
below another set point, the bleed valve closes.
Periodic laboratory/On site testing of the water constituents, such as hardness, alkalinity, chloride, and
conductivity, are done to check that the conductivity meter and bleed control valve are working and
appropriately calibrated. The ratio of chloride in system to chloride in makeup should be about the
same as the ratio for hardness in the system and in the makeup. If differences are substantial and
occur consistently, someone should be looking for a reason.
Calculation of bleed off requirement at a particular COC
Bleed off (m3/hr), B = Evaporation Rate (m3/hr) E/Cycles of Concentration (C)-1

[B=E/(C-1)]
The calculated value will give the quantity of water to be discharged from the cooling tower to
maintain a a definitive value of COC
Part 4 Cooling Water System Problems & Solutions
Poor water maintenance will create certain and predictable problems in open cooling loops. These
problems are detailed below:
A. Scale formation:
Scale formation is the creation of a precipitated solid. Scale is a dense coating of predominantly
inorganic material formed from the precipitation of water-soluble constituents. Some common scales
are:
• Calcium carbonate
• Calcium phosphate
• Magnesium silicate
• Silica
Scale results when dissolved ions in the water exceed the solubility of a given mineral.
Four principal factors determine whether or not water is scale forming:
 Temperature
 Alkalinity or acidity (pH)
 Amount of scale-forming material present
 Influence of other dissolved materials, which may or may not be scale-forming
By coating heat-exchange surfaces, this solid material interferes with efficiency of the system’s heat
exchange surface and also blocks water flow at the cooling tower’s basin or fill, thus reducing the
efficiency of the cooling system.
Scaling potential indices have been developed to predict the likelihood of calcium carbonate
precipitation. These indices are convenient, easy to use, and provide a reasonable estimate of the
likelihood of scaling in water sources. The most widely used indices in the water treatment industry are
the Langelier Saturation Index (LSI), Stiff and Davis Stability Index (S&DSI), the Ryznar stability index
(RSI), Puckorious Saturation Index (PSI) and the Larson-Skold Index etc.
Scale Index Values

LSI RSI PSI Indication
+3.0 3.0 3.0 Extremely severe scaling
+2.0 4.0 4.0 Very Severe scaling
+1.0 5.0 5.0 Severe Scaling
+0.5 5.5 5.5 Moderate Scaling
+0.2 5.8 5.8 Slight Scaling
0.0 6.0 6.0 Stable Water
-0.2 6.5 6.5 Slightly Corrosive
-0.5 7.0 7.0 Moderately Corrosive
-1.0 8.0 8.0 Severe Corrosion
-2.0 9.0 9.0 Very Severe Corrosion
There are four basic means to control scale:
• Limit the concentration of scale forming minerals by controlling concentration ratio or by removing
the minerals before they enter the system.
• Feed acid to keep the common scale forming minerals (such as calcium carbonate) dissolved.
• Make mechanical changes in the system to reduce the chances for scale formation.
• Treat with chemicals designed to prevent scale.
Acid dosing converts less soluble calcium carbonate into more soluble one. pH is reduced leading to
reduction in LSI thereby reducing scaling tendency.
Ca (HCO3) 2 + H2SO4 – CaSO4 + 2H2O + 2CO2
Sulphuric acid is most commonly used due to low cost but difficult to handle. Use of hydrochloiric acid
induces high chlorides and should not be used in systems having stainless steel. High chloride built up
should be avoided in all systems.
Enough care is required in maintaining uniform & continuous acid dosing to keep pH within range. Acid
should not be used in systems where enough care on dosing and control cannot be given.
B. Corrosion
Corrosion is the process of metal dissolution, usually by oxidation, resulting in substantial material
breakdown and premature degradation of system equipment.
The most important factors that result in corrosion are:
• Oxygen and other dissolved gases

• Dissolved and suspended solids
• Alkalinity or acidity (pH)
• Velocity
• Temperature
• Microbial activity
For corrosion to occur, a corrosion cell, consisting of an anode, a cathode, and an electrolyte must
exist. Metal ions dissolve into the electrolyte (water) at the anode. Electrically charged particles
(electrons) are left behind.
These electrons flow through the metal to other points (cathodes) where electron consuming reactions
occur. The result of this activity is the loss of metal and often the formation of a deposit. This process
degrades the metal, reduces its strength, thickness, and in some extreme cases, creates pits and then
holes in the material
Typical Corrosion cell
Chemical inhibitors reduce corrosion by interfering with the corrosion mechanism. Inhibitors usually
affect the corrosion reactions at either the anode or the cathode.
C. Fouling
Fouling is the accumulation of solid material, other than scale, in a way that hampers the operation of
plant equipment or contributes to its deterioration.
Examples of common foulants are:
• Dirt and silt

• Sand
• Corrosion products
• Natural organics
• Microbial masses
• Aluminum phosphates
• Iron phosphate
The most important factors influencing fouling are:
• Water characteristics
• Temperature
• Flow velocity
• Microbial growth
• Corrosion
• Contamination
Fouling can be controlled mechanically or by the use of chemical treatments. The best method of
control depends upon the type of fouling. Control of fouling in the cooling system involves three major
tactics:
Prevention The best approach is to prevent foulants from entering the cooling system. This may
include mechanical changes or addition of chemicals to clarify makeup water.
Reduction Take steps to remove or reduce the volume of foulants that unavoidably enter the system.
This may involve sidestream filtering or periodic tower basin cleaning.
Ongoing Control Take regular action to minimize deposition of the foulants in the system like adding
dispersants, back flushing exchangers etc.
D. Biological Problem
a. Microbiological Problem
Microbiological activity is micro-organisms that live and grow in the cooling water systems. Cooling
towers present the perfect environment for biological activity due to the warm, moist environment.
There are two distinct categories of biological activity in the tower system. The first being plank tonic,
which is bioactivity suspended, or floating in solution. The other is sessile biogrowth, which the
category is given to all biological activity, biofilms, or biofouling that stick to a surface in the cooling
system.
Microbial growth can result in the following problems in cooling systems
• Slime formation (biofilm)

• Bio-fouling (biomass)
• Biodegradation (wood rot)
• Microbiologically induced corrosion (MIC)
• Accelerates scale formation
• Human Health concerns (Legionellosis)
Legionella is a group of bacteria present in all natural waterways and biofilms. About half of the
Legionella species can produce pneumonia like infection in humans (Legionellosis)
Preventing Microbial Problem
Three general classes of chemicals used in microbial control are:
• Oxidizing biocides
• Non-oxidizing biocides
• Biodispersants
Each class functions uniquely to provide effective microbiological control.
Oxidizing biocides oxidize important cellular components in microorganisms, resulting in death of the
organisms. They can be applied continuously or on a slug basis. Chlorine gas, hypochlorites and
bromine are examples of oxidizing biocides
Non-oxidizers perform differently than oxidizers. They are organic compounds that react with specific
cell components within a microbe to ultimately destroy that cell.
Biodispersants do not kill organisms. They loosen microbial deposits, which upon detachment from a
metal surface, are flushed away with the bulk cooling water. They also expose new layers of microbial
slime or algae to the attack of oxidizing biocides. In addition to removing biodeposits, biodispersants
are also effective in preventing biofilm formation from taking place.
b. Macro biological Problem
Macrofouling is the attachment of complex organisms like clams and mussels to piping and other
surfaces of a cooling system. It is most common in once-through cooling systems or water intakes using
surface water, like lakes, rivers, or oceans. This can result in plugged lines, reduced water flow, under-
deposit corrosion, damage to pumps, and the high cost of mechanical cleaning.
Macrofouling is very difficult to control completely. Local environmental regulations are a key factor
when choosing a control approach. The two general strategies to treat macrofouling are prevention
and eradication
Part 5 Total Treatment Program
A successful cooling water treatment program requires all of the following elements.
• Optimized chemical treatment and automated system control programs and must be combined.
• All concerned persons must understand the value of the cooling water system in relation to
production and must be committed to maintain and control the program.
• Implementation of performance monitoring program to evaluate heat transfer efficiency,

corrosion control, deposition control, and microbial control.
• Use of analytical testing
• Monitoring and control must be continuous and must utilize the proper techniques, equipment,
and supplies.
Part 6 Ion Exchange Cooling Water Management Program
Ion Exchange Advanced Cooling Solution is an innovative offering that can help you monitor, control
and maintain your cooling systems with greater efficiency, reliability, and predictability. It lowers your
total cost of ownership and minimizes the environmental impact of your operation.
Ion Exchange technology is customized to meet specific needs with the support of simulated software
and our application laboratory. This enable us to provide a solution that is tailor made for each cooling
water system.
Ion Exchange cooling water system management program includes
a. INDION Cooling System Chemicals

b. INDION Autochem Dosing and Control Systems
c. Monitoring and Evaluation of systems
 Corrosion Rate Studies (Corrator & Coupon studies)
 Microbial Monitoring
 Periodic testing of water samples for KPIs
 Deposit Analysis
d. Data Management
 In depth survey prior to design and start of treatment
 Data logging and interpretation
 Service and Consultation reports for comments and action
 Trend analysis reports for KPIs (Yearly/ Quarterly)
 Periodic reviews with plant personnel
 Failure and pareto analysis
Part 6.10 - Objectives of Ion Exchange Cooling Water Management Program
Objectives of a PEFECT cooling water treatment shall be as follows:

◢ Control of corrosion rates at less than 3 mills per year.
◢ Control of Scaling and sedimentation fouling.
◢ Microbiological control to prevent bio-fouling.
◢ Keep heat transfer surfaces fairly clean to operate system consuming optimum energy,
better productivity at low cost and lesser rates of replacements, maintenance and
downtime. The benefit amount to manifold of actual investment on treatment.
◢ Ensure better plant and equipment life.
◢ Conserve ENEGY and WATER.
◢ No pollution hazard
◢ Flexible treatment with relatively less dependency on controls.
Part 6.20 Ion Exchange Cooling Water Management Program
Cooling Water Treatment is broadly classified as follows

◢ External Treatment
◢ Internal Chemical Treatment
Part 6.21 Ion Exchange External Treatment Program
External treatment involve use of WATER TREATMENT EQUIPMENTS before using for cooling system
and it’s main objective is to treat water to operate within control limits and make it fit for use, make
internal treatment more flexible and economical and conserve water by operating at higher cycles of
concentration.
Various processes with their benefits and treatment requirements are briefly discussed here below.
A. Softening
Replaces Ca and Mg ions with Na ions. No change in total dissolved solids, hardness reduces to less
than 5 ppm as CaCO3 (commercial zero). However, residual hardness concentrate in cooling water and
the SCALING tendency may still exist, although with much less SCALING POTENTIAL, as only calcium is
reduced out of 5 factors responsible for scale formation (pH, temperature, alkalinity, TDS, Ca and M
alkalinity). Corrosive tendency of cooling water increase after elimination of calcium. No effect on
sedimentation and microbiological fouling. INTERNAL chemical treatment with use of scale retardants,
corrosion inhibitors, antifoulants and biocides essentially required. Can help conserve water by
operating at higher cycles of concentration provided alkalinity, TDS, chlorides and silica allows it.
B. Dealkalization
Is used to remove alkaline hardness (temporary hardness) when total alkalinity is higher than hardness.
It involves use of cation exchanger and degasser (cooling tower also may be used). DEALKALIZATION
removes almost complete carbonate or dealkaline hardness (Ca & Mg alkalinity) and partial TDS. No
change in chlorides, sulfate and silica. DEALKALIZATION offer excellent benefits.
◢ Allows operating at higher cycles of concentration by removing hardness, alkalinity and
partially TDS provided chlorides and silica are within limits.
◢ Cost of internal chemical treatment is substantially reduced
◢ No separate acid dosing in cooling water is required. The pH also does not fluctuate.
Dealkalised water is more corrosive than soft water due to elimination of hardness, alkalinity and TDS.
It must be supplemented with INTERNAL CHEMICAL TREATMENT from day one.
C. Demineralization
All water soluble impurities are removed. It is preferred in cooling system only when reduction in
chloride and silica is required to operate at higher cycles of concentration.
◢ Cost of demineralised water is usually high.
◢ Excellent conservation of water as make up water requirement becomes very low.
Complete internal chemical treatment should be implemented from day one as water is highly
corrosive.
D. Reverse Osmosis
Demineralization becomes uneconomical if raw water TDS is above 600 ppm. The RO systems are used
for brackish water/TSE systems and educing all dissolved solids by appx. 90%. The water at low cycles
of concentration is usually corrosive and at high cycles predominantly scales. RO systems are capital
intensive but reduce cost of INTERNAL CHEMICAL TREATMENT which is a MUST.
E. Side Stream Filtration
Undissolved impurities contaminate cooling water due to ingress of suspended impurities through
make up water and across cooling water though air current and atmospheric conditions. Make up
water most essentially be filtered to use water with total suspended solids less than 2-5 ppm. The side
stream filtration in every cooling system is preferred to keep TSS below 25 ppm.
Part 6.22 Ion Exchange Internal Chemical Treatment Program
Through comprehensive research and development, we have successfully established the INDION
cooling system chemicals range that enhances the system operations along with the most complete
portfolio of filtration and products for side stream softening, filtering, and wastewater reuse.
INDION Cooling System chemicals range include:-
 Inhibitors to control scale, corrosion and fouling in all types of cooling water systems with
makeup waters including zero hardness RO product, river water, brackish waters, high hardness
borehole water, treated effluent water etc.
 A comprehensive range of pre-commission cleaning, flushing and passivating agents for open
and closed recirculating cooling water systems of all metallurgies
 A wide range of oxidizing and non-oxidizing biocides and bio dispersants.
 INDION easy test kits for on the spot water analysis to monitor key parameters.
A. INDION Scale & Corrosion Control Program
a) INDION Scale Retardants
We offer programs including; all-organic, orthophosphate, polyphosphate, zinc phosphonate, zinc-

phosphate, zinc replacement technology molybdate etc.
Internal chemical treatment provides SCALE RETARDANTS, which are usually organic SEQUESTRANTS.
These additives provide “THRESHOLD STABILIZATION” at use dosage which is a mechanism to inhibit
crystal growth and educe scale formation. The use of polymeric antifoulants also helps to distort crystal
structure making them non- adherent thereby preventing overall deposition
b) INDION Corrosion Inhibitors
The principal method of controlling corrosion in cooling water systems is by means of chemical
corrosion inhibitors. Their function in preventing corrosion lies in their ability to insulate the electrical
current between the anode and cathode. If the insulation affect occurs at the anodic site, then the
inhibitor is classified as an anodic inhibitor. If the cathodic site is insulated the inhibitor is classified as a
cathodic inhibitor.
When anodic and cathodic inhibitors are used in isolation corrosion protection is limited, as they have
various limitations as described below. The most effective proprietary corrosion inhibitor for open
recirculating cooling systems are formulations based upon bends of cathodic and anodic corrosion
inhibiting compounds.
The most effective proprietary corrosion inhibitor for open recirculating cooling systems are
formulations based upon bends of cathodic and anodic corrosion inhibiting compounds.
Ion Exchange offers specially formulated corrosion and scale inhibitors which use certain proprietary
additives to overcome the limitations associated with traditional corrosion and scale inhibitors. Various
formulations are designed based on the synergies of various concentrations of corrosion and scale
inhibitors.
Ion Exchange have following principal technologies, which covers the entire spectrum of scaling and
corrosive tendencies taking place with various types of water qualities under various system
conditions.
B. INDION Microbiological Control Program (INDION Biocides)
An effective microbiological control is achieved by using specially developed biocides which are
toxicants and kill microorganisms when used intermittently. The excessive microbiological growth is
thus curtained. The biocides should be biodegradable to avoid pollution hazard.
1. INDION Oxidizing Biocides
Oxidizing biocides include those chemicals that have the ability to kill microorganisms through an
electrochemical process of oxidation. The oxidizing agent such as chlorine gains electrons in the
process while the substance becoming oxidized loses electrons. Depending upon the oxidizer being
used, a new compound is created and in the case of microorganisms, some life function is changed that
causes the organism to die or at least to not proliferate. Some oxidizing biocides used in cooling tower
systems include:
Chlorine, Bromine, Iodine, Chlorine dioxide, Ozone, Hydrogen peroxide
CHLORINE is most effective and cheap oxidising biocide and is used as continious/ intermittent
chlorination.
But its use is limited owing to following factors:
◢ It lacks penetrating ability. Hence biodispersent should be used with it to increase its penetrating
ability.
◢ It is hardly effective at pH above 8.0. Use of INDION bromine based compounds will help to
overcome this limitation.
◢ Handling problems.
◢ Adequate care is required to maintain FREE CHLORINE RESIDUAL in cooling water.
2. INDION Non-Oxidizing Biocides
Non-oxidizing biocides function by interference with the metabolism of the organism in a variety of
ways which, by preventing normal processes, kills the organism. Due to the large variety of organisms,
those that are immune to a particular non- oxidizing biocide will rapidly replace those that are killed by
a single dosage. Following doses will become progressively less effective as the organism population
shifts to those varieties that are immune to the particular biocide employed. Due to this natural effect,
the typical recommendation is that at least two different non-oxidizing biocides, or a oxidizing and a
non- oxidizing biocide, be utilized in biological control programs on an alternating basis.
INDION Non-oxidizing biocides even function in the presence of process contamination, no effect on
corrosivity is evident from their use, corrosion and scale control chemicals are usually not affected by
them, often they can be targeted at a specific class of problematic organism like Legionella
pneumophila, and several have a definite dispersant effect for removal of dead microbiological growth
Selection of a nonoxidizing biocide depends upon water pH, available retention time, efficacy against
various bacteria, fungus, and algae, biodegradability, toxicity, and compatibility with the other
chemistry.
3. INDION Biodispersants
Chemicals that can penetrate and loosen the complex matrix of biofilms allow biocides to reach the
organisms for more effective kill and control. These chemicals are typically shot fed at dosages that
break down polysaccharides, emulsify oils, release minerals and foulants, or disperse the biopolymers
C. INDION Precleaning & Passivation Chemicals
1. INDION 9020
INDION 9020 is a synthetic antifoulant and it inhibits the deposition of fouling materials on heat
transfer surfaces. Fouling caused by hardness scales, phosphates, metal oxides, silt and other air-borne
materials can be eliminated. INDION 9020 removes oil and grease from all metal surfaces. It acts to
keep surface clean, maintain a high rate of heat transfer and aid the formation of corrosion inhibitor
film. It is particularly useful in systems with higher iron concentration.
2. INDION 3591
INDION 3591 is a corrosion inhibitor which is used for Passivation of metal surfaces. INDION 3591
provides a silicious film for the protection of metal surfaces.
PART 6.3 Chemical cleaning of Condenser water system
Clean condenser water system to remove oil, grease, silt, and rust and leave metal surfaces well
passivated.
CLEANING PROCEDURE
The process of pre-commission cleaning is designed to remove surface rust, mill scale and light debris,
which may have entered the systems during their construction. Pebbles, welding slag and small pieces
of metal and wood cannot be dissolved by any chemical, which may be safely used, and although one
would expect the majority of such debris to be removed by the flushing process. Prior to
commencement of works, all system should be filled, vented and fully circulated
Cleaning and Flushing procedure for Condenser Water

Procedure for cleaning the chilled water circuits consists of the following stages:
Stage 2 - Flushing with Chemical Removal of surface oxides.
Stage 3 – Final flushing and removal of cleaning chemicals
Stage 4 - Chemical treatment of the system (Passivation).

The purpose of this stage is to remove inert suspended matter such as iron pieces, welding slags, and
foreign particles etc. this flushing will be continued until all suspended solids are removed from the
system.
◢ The condenser water system is first filled with fresh water and the water is circulated in the
system using the system pump, at low speed, for a period of 2 - 3 hours.
◢ The system is then drained from the lowest point and this is done with a view to take away the
large debris which would be accumulated in the pipes, during manufacturing, transportation
etc.
◢ The system will again be filled with fresh water and then circulated for up to 24 hours and
drained from the lowest point. The process is repeated until the suspended solids in the
system are taken out and the water is relatively clear.
◢ The water quality required at this stage in order to inject INDION 9020 program is as below:
Parameter Control parameter after plain flushing stage
pH Same as water used
Total dissolved solids Same as water used
Conductivity Same as water used
Total iron <5ppm as Fe
TSS < 50 PPM
Stage 2 - Flushing with Chemicals
◢ This process involves the use of chemical INDION 9020 which is manufactured by M/s Ion
Exchange.
◢ The INDION 9020 should be injected at the rate of 500-750 ppm based on system volume. The
product shall circulate in the system for a minimum 24 hours and to a maximum of 48 hours,
water samples should be taken every three hours to monitor the total iron level in the system.
This procedure should be carried out until satisfactory results
◢ The iron level should increase until reaching a steady value that will not differ from 0.5 to 1
ppm from the previous value. Three consecutive values stable with difference not more than
0.5 to 1 ppm lead to the completion of this phase.
Stage 3 Final Flushing and removal of Chemicals
◢ The purpose of final flushing is to take out all the left over suspended particles, mill scale,
debris, and metal oxides which are accumulated in the system.
◢ In this phase the water should be supplied to the system and the system pressure should be
stabilized and the water will be drained from the chilled water system at the same time.
◢ This phase should be carried on without interruption in order not to disturb the flushing
sequence progress, plus the iron decrease until the iron value level will reach the acceptable
recommended limits below 2 ppm.
◢ The water quality needed before the addition of the Passivation chemicals is as below:
Parameters Water parameters after final flushing
pH 7.0 to 8.2
Conductivity Same as water used for flsuhing

TSS <30 ppm
Stage 4– Addition of sequestering agent
◢ Once Stage-3 has been completed the system is then filled with passivation chemicals INDION
3591 @ rate 0.2 Kg/m3 as per System volume. Circulate water for 24 hours.
◢ The system then comes to a rest and is finally monitored and inspected upon commissioning.
Parameters Water parameters after Passivation
pH 7.8 to 8.5
TSS <30 ppm
INDION 3591 (ppm) 5 to 10
Stage 5– Passivation of System
After completion of initial fill, Passivation of system is performed by using double the normal dosage
concentration of corrosion & scale inhibitor on blow down for 48-72 hours continuously for
establishing protective film.
Most methods of corrosion control involve the formation of a film to act as a barrier to corrosion. The
effectiveness of the treatment depends largely on the rate at which the barrier film is formed.
Materials that do not allow rapid film formation permit corrosion to take place before a complete film
layer has been created. Incomplete film formation contributes to continued corrosion. The rate at
which the film forms is related to the concentration of the inhibitor.
Prefilming permits the rapid formation of a uniform film that immediately stifles the corrosion
reaction. Once the film has been established, it can be maintained through continuous, low treatment
levels to deter the accumulation of corrosion products.
INDION 9040 should be dosed at the rate of 0.1 Kg per cubic meter (0.05 Kg/Cubic meter for INDION
9042) of water based on the system volume on day one.
Sample shall be taken to confirm that the chemical is circulated throughout the system.
Part 6.40 INDION Regular Treatment Chemicals
Through continuous development VERSATILE formulations have been developed using latest
technologies. Few are illustrated below:
Regular Treatment
Scale Corrosion & Fouling Control
Make Up Water Technology Dosing Method
Polished TSE, Softened , INDION Alkaline Zinc & Non –
dealkalised and demineralised ( Zinc Programmes
Carefully maintained)
Dosage is proportional to bleed
UAE Municipality Water INDION All Organic Treatment
off from the system/Make up
Supplies (LSI + 0.8 to + 3.0) Programme
water flow to the system.
Direct TSE Water Combination of proprietary Dosing is performed though
INDION Corrosion Inhibitors and dosing control system
INDION Scale Inhibitors &
Dispersants based on system
metallurgy
Microbiological Control
INDION Biodispersants Dosage is performed on system
INDION Non Oxidizing Biocide Series volume. Dosing is preferred
though dosing control system
INDION Oxidizing Biocide Series
CAUTION: Expert advice of company must be taken before selecting treatment programme.
Part 6.50 Implementation, Monitoring & Evaluation of treatment
The success of treatment cannot be achieved without exercising control on treatment implementation
and monitoring. The treatment should also be evaluated to guage system response to enable modify
treatment, if necessary.
A. Implementation:-
Chemical treatment programs must meet the following requirements:
◢ The chemicals must be compatible with the unit materials of construction as well as other
materials used in the system (pipe, heat exchanger, etc.)
◢ Chemical scale and corrosion inhibitors, and particularly acid (if used) will be introduced into
the circulating water through INDION Auotchem, fully automated dosing controller at a point
in the system where total mixing and dilution occur before reaching the evaporative cooling
equipment. The preferred injection point for chemical scale and corrosion inhibitors is on the
discharge side of the system circulating pump(s).
◢ The quantity dosed will be proportional to the makeup water entering the system, which will
be metered through impulse water meter installed on makeup water line.
◢ These chemicals should not be batch fed directly into the unit’s cold water basin or water
distribution system, as this can severely damage areas directly contacted.
◢ When chlorine is added to the system on a continuous basis, free residual chlorine should not
exceed 1 ppm. Exceeding this limit may accelerate corrosion. INDION Autochem with ORP
controller will helps to maintain sufficient chlorine levels in the system; this shall be used for
proper dosing of oxidizing biocides without damaging the system.
◢ To avoid biological contamination and minimize the risk of Legionella, initiate the biocide
treatment program at start-up and continue on a regular basis as per recommendations.
◢ Liquid biocides shall be fed using INDION Autochem automated dosing system. INDION
Autochem is a dual, alternating Biocide Dosing Controller with 28 day timer to automatically
feed up to two (2) different biocides on a scheduled, intermittent basis. During biocide
addition Bleed-off will be “locked out” for a period of six hours.
◢ To protect against the risk of Legionella contamination, the cooling equipment should never be
operated without adequate biological control.
◢ If ozone water treatment is used, at no point should concentrations exceed 0.5 ppm.
B. Monitoring
i. Monitoring of Water Chemical Parameter using analytical methods
The success of any treatment programme depends on monitoring and maintaining the various
parameters within limits. Ion Exchange’s expert advice should be taken to work out a detailed
programme of monitoring and evaluations for each system; following details provided are for general
maintenance.
The following parameters to be monitored continuously and during every shift are as follows
a. pH
b. TDS/Conductivity
c. Water level in sump
d. Blow down rate
e. Make-up water rate
f. Residual chlorine (if applicable)
g. Temperature
The complete analysis of circulating water and make-up water should be carried out periodically and
should include following (at least once in a month)
a. pH
b. TDS/Conductivity
c. Alkalinity
d. Turbidity
e. Total Suspended Solids
f. Calcium and Magnesium Hardness
g. Chlorides
h. Silica
i. Iron
j. Treatment Chemical Residuals
k. Any frequent pollutants Expected
The following are the guidelines for maintaining the quality of recirculating type of cooling water for
trouble free operation However, if there is practical difficulty in achieving the same because of too
much variation in the quality of the source water itself, attempts should be made either to treat the
source water suitably.
Ion Exchange Manufactures INDION Easy Test kits for the regular monitoring of cooling water
parameters, these test kits offers simple drop test and standard color comparison methods which can
be easily carried out by site operators, making monitoring and preventive action very quick and
convenient
Sl.No Parameters Control parameters to be maintained in systems during

regular operation
1.0 Chemical Parameters
a pH Depends on treatment program selected (8.0 to 9.0 for
alkaline programs
b Conductivity <2000 µSiemens/cm (Depends on makeup water quality)
c Total iron <2 ppm as Fe
d Corrosion Inhibitor, ppm 5.0 to 6.0
e Calcium Hardness, ppm as CaCO3 <350.00
f Total Hardness, ppm as CaCO3 <500.00
g M Alkalinity, ppm as CaCO3 <250.00
h Chlorides, ppm <300.00

i Total Suspended Solids, ppm <10
j Oxidizing Biocides, ppm <1.0

H Silica, ppm <75
I Turbidity, NTU <20
2.0 Microbial Parameters
a Total Aerobic Plate Count, CFU/ml <1,000
b Total Anaerobic Plate Count CFU/ml <10
c Nitrite Reducers, CFU/ml <10
d Sulfate Reducing Bacteria, CFU/ml 0

3.0 Performance Parameter
a Mild Steel Corrosion Rate, MPY <3.0 MPY
b Copper Corrosion Rate, MPY <0.2 MPY
Note: Companies expert advice should be taken to work out a detailed control parameter as these
parameters vary with respect to make up water & system design
ii. Monitoring & Controlling of Treatment program using INDION Autochem Controller
INDION Autochem is a robust automation platform that provides system-wide monitoring and dosing.
INDION Autochem can offer conductivity/blowdown control, pH control, real-time dosing, continuous
corrosion monitoring, web-enabled reporting, and alarm relays. The benefits of INDION Autochem is
tightened control of the various control points of the water treatment program, and also help in
eliminating excessive water use and high cycle conditions.
Indion Autochem is a valuable automation and data management platform that enables our best-in-
class field engineers to provide a superior water treatment program.
Features and Benefits:
◢ Continuous monitoring and proportional control for pH and conductivity variables

◢ Data logging for pH, Conductivity, Temperature and 13 other variables
◢ Special inhibitor and dispersant dosing features
◢ Flexible Oxidizing & non oxidizing biocide dosing program
◢ Remote Access via secure website - No software installation or upgrades required
◢ Alarms & events sent via SMS and/or e-mail
◢ Online dashboard with Graphs and Plots
◢ 24 x 7 remote monitoring from centralized expert team
Scope of Supply
◢ Ion Exchange can supply the following materials as part of the INDION AUTOCHEM Dosing
system,
◢ Controller
◢ Chemical Dosing Pumps
◢ Modem for wireless communication (Optional)
◢ Online Web Access (Optional)
◢ pH Sensor
◢ Conductivity Sensor with RTD sensor
◢ ORP Sensor
◢ Flow switch
◢ Dosing Tanks
◢ Impulse water meter for makeup water and bleed line
◢ Solenoid Vales
Site Requirements
◢ 230 V, 50 HZ Power Supply – Preferable UPS Supply Power point should be within 1 meter
from the controller. Normal 10A power point is fine.
◢ 1” or 3/4” Tapping for sample water inlet from recirculation pump discharge header or
chilled water return header
◢ 2.5 m x 2.5 m space along with proper shed for Autochem Skid for protection from
sunlight/ rain and dusty environment.
Equipment Specification
A. INDION AUTOCHEM Controller
INDION Autochem is a complete automatic condenser/chilled water treatment and control system of
modular plug-in construction. The system is included with a conductivity controller, pH controller,
corrosion inhibitor dosing controller and biocide programmer. INDION Autochem is a microprocessor
based controller with alpha numeric LCD display capable of being programmed by operator and
monitored in a BMS system. Dosage of corrosion inhibitor can be controlled based on the makeup
water rate, biocide dosing pump can be operate manually since the dosage comes once in three
months.
The system can be connected to local BMS on view only access mode. The system will provide four 4-
20 mA output for pH, Conductivity and return water temperature. It will also provide 9 NPN Open
Collector Transistors to signal output of pump running status, flow status, solenoid valve status, Power
failure status, and alarm status only. The system can be connected remotely using GSM protocol and
can be controlled remotely through standard internet browsers. The controller enclosure is IP65
protected. The make-up water totalized reading can be viewed online by using standard web browser.
Engineering Data
Controller
Enclosure : NEMA 4X / IP65

Power Supply : 230 V/ 50Hz
Control Output : Line Voltage @240VA per Relay
(2 Amps @ 120VAC)
Display : LCD
pH Sensor
Range : 0.01-13.99pH
Resolution : 0.01pH
Conductivity Sensor
Range : 0-9999 μS/TDS

Temperature Compensation : Yes
Resolution : 1 μS / 1 ppm TDS
B. Water meter
An impulse type water meter in the makeup water lines to control inhibitor dosing and for makeup
flow monitoring purpose; water meter shall be capable of transmitting the flow rate to Autochem
Controller
C. Inhibitor Dosing System
The dosing pump will be of diaphragm type leak proof dosing pumps capable of handling the corrosion
inhibitor. The pumps will be provided with dry run automatic protection system (low level switch).
Specification of dosing pump and tank is as given below.
(i) Dosing Tank
Quantity : 2 No. ( 1 W+1 S)

(ii) Dosing Pump

Prominent/JESCO/Seko Italy Equiv.
Liquid end Material
Pump Head : PVDF

Diaphragm : PTFE
Balls : Ceramic
D. Oxidizing Biocide Dosing System
(i) Dosing Tank
Quantity : 1 No.
Chemical : Biocide
(ii) Dosing Pump

Chemical : Biocide
Prominent/JESCO/Seko Italy/Equiv.
Liquid end Material
Pump Head : PVDF
Diaphragm : PTFE
Balls : Ceramic
E. Non-Oxidizing Biocide Dosing System
(iii) Dosing Tank
Quantity : 1 No.
Chemical : Biocide
(iv) Dosing Pump

Chemical : Biocide
Prominent/JESCO/Seko Italy/Equiv.
Liquid end Material
Pump Head : PVDF

Diaphragm : PTFE
Balls : Ceramic

Part 6.60 Evaluation of Ion Exchange Treatment Program
The treatment programme should be regularly evaluated for
a) Corrosion control - It is done by reassuring corrosion rate normally by corrosion meter which
takes into account the corrosion rate due to electrochemical corrosion, but does not take into
account the corrosion due to micro organisms while the Coupon tests indicate both. Corrosion
coupons are installed in the return header and are exposed for a minimum period of 30 days.
After that, average corrosion for the period is noted Coupon material should be as close in
composition to the metal in the system and the mount along with nut and bolt should be of
laminated phenol formaldehyde resin or similar plastic rods
b) Scale and fouling control — exact extent of scaling and fouling is difficult to measure. However,
assessment may be made indirectly to heat transfer data and periodic inspection of the
exchanger which can be isolated for opening without disturbing plant operation.
c) Microbiological control — Regular Microbiological analysis of the circulating water should be

carried out, using dip slides. Legionella & aerobic colony count analysis should be carried as per
UAE Govt. guidelines through approved third party labs.

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Technical Guidelines on

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◢ Consumer Products for Homes and Communities

OUR BACK-UP FACILITIES

◢ Simulations of water quality and evaluation of water performance on a test rig

◢ Testing of deposit samples

◢ A range of sophisticated equipment as atomic absorption spectro photometer,

Section 1: - Closed Loop/Chilled Water Systems Water management

Part 1:- Introduction

Part 2:- Products

INDION 9020 includes:

B. Chemical for Passivation

C. Corrosion and scale inhibitors

 INDION 5547C/INDION5543 (Nitrite Based Corrosion Inhibitors)

 Polymeric Dispersants and phosphonates for Scale Control even in high

 INDION 9018 (Molybdate Based Corrosion Inhibitor)

 INDION 9040/9042 (Isothiazolinone based biocide)

Part 3:- Chemical cleaning of chilled water system

Part 3.10 Cleaning Procedure

Stage 3 – Final flushing and removal of cleaning chemicals

Stage 1 - Flushing with clean water

Parameter Control parameter after plain flushing stage

Stage 2 - Flushing with Chemicals

Stage 3- Final Flushing and removal of Chemicals

Parameters Water parameters after final flushing

Conductivity Same as water used for flsuhing

Total iron <2 ppm as Fe

TSS <30 ppm

Table 2: control parameter after stage 3

Stage 4– Passivation of the system

Parameters Water parameters after Passivation

Total iron <2 ppm as Fe

TSS <30 ppm

INDION 3591 (ppm) 5 to 10

Table 3: control parameter after stage 4

Stage 5- Initial Fill of Biocide and Corrosion Inhibitor

Sl No Chemical Name Active ingredient Dosage

1.0 INDION 5547C Nitrite Based corrosion 3.5 Kg/Cubic Meter on

2.0 INDION 5543 Nitrite Based Corrosion 2.5 Kg/Cubic Meter on

3.0 INDION 9018 Molybdate Based 0.3 kg/ cubic meter on

4.0 INDION 9447 Molybdate/Nitrite based 0.8 kg/ cubic meter on

Parameters Control parameters for systems using INDION 5547C/5543

Table 5 - Water parameters for systems using INDION 5547C/5543

Part 3.20 Regular treatment

Sl.No Parameters Control parameters to be

b Conductivity <3000 µSiemens/cm

d.2 Corrosion Inhibitor INDION 9018, ppm as Molybdate 150-300 ppm

Corrosion Inhibitor INDION 9447, ppm as Molybdate +

f “OH” or Free Caustic Alkalinity 20 ppm Maximum

g Tolytriazole, Copper corrosion inhibitor, ppm 5-10 ppm

h Total Suspended solids <20 ppm

a Total Aerobic Plate Count, CFU/ml <1,000

b Total Anaerobic Plate Count CFU/ml <10

c Nitrite Reducers, CFU/ml <10

d Sulfate Reducing Bacteria, CFU/ml 0

a Mild Steel Corrosion Rate, MPY <1.0 MPY

b Copper Corrosion Rate, MPY <0.2 MPY

Table: 6 Properties to be maintained during normal operation

Part 3.30 Automatic Dosing Controller