Technical directive – Water Treatments of Closed

Circuits
Date : 03/09/15

T&P Contact: GREGOIRE Sebastien

T&P Department - Energy

Disclaimer :
This document has been recovered from Dalkia document database and is provided as it is. Please
note that information and data were valid at the document issuing date. This document will be
updated if needed.
For further information, please get in touch with the T&P contact above.
 Technical Directive

Water Treatment
of Closed Circuits
 Technical Directive

Water Treatment
of Closed Circuits

Document for internal use only

Publication date:
Table of content
1. PRIMARY CAUSES OF FAILURE IN CLOSED WATER
October 12, 2011
SYSTEMS ............................................................................ 4
Scope:
1.1. Corrosion ................................................................... 4
Operations technicians
1.2. Scaling....................................................................... 5
Versions: 1.3. Silting........................................................................ 5
English and French 1.4. Microbiological growth .................................................. 5
Written by: 2. TREATMENT OF CLOSED CIRCUITS .................................. 5
Jean-Philippe Puibaraud
2.1. Best practices ............................................................. 5
Visa: 2.1.1. Equipment ...........................................................5
Bertrand Guillemot 2.1.2. Operation ............................................................6
2.1.3. Checks ................................................................6
Reference: 2.2. Preventive chemical treatment ....................................... 6
DTGP / Technical Directive / 2.2.1. Main active reagents...............................................6
Water treatment of closed 2.2.2. Parameters to comply with in steel circuits treated
circuits / October 2011 / with a phosphate-sulfite base....................................7
version a 2.2.3. Table of water treatments for closed systems set out in
On the following page: the framework contract of Dalkia France / Veolia
- Updated records Water STI ............................................................8
- Other documents on this 2.3. Curative chemical treatment .........................................10
subject 2.3.1. Fast desilting ...................................................... 10
2.3.2. Slow desilting ..................................................... 10
2.3.3. HYDREX products ................................................. 11
3. FRAMEWORK AGREEMENTS ............................................ 11

4. CIRCUITS EQUIPPED WITH CAST ALUMINIUM

BOILERS ........................................................................... 12
4.1. Implementation of a cast aluminium boiler in an existing
network ....................................................................12
4.2. Operation of a facility with a cast aluminium boiler ............12
4.3. Taking over of a facility with a cast aluminium boiler ..........12

Directive technique / Traitement d'eau des circuits fermés/ July 20, 2011 / Creation Page
Internal use only 2/12
 Technical Directive

Water Treatment of Closed Circuits

Updated records

Initial version
July 20, 2011

Version “a” update

October 12, 2011

Version “b” update

March 08, 2012

Version “c” update

Other documents on this subject

Title
Description

Title
Description

Title
Description

Directive technique / Traitement d'eau des circuits fermés/ July 20, 2011 / Creation Page
Internal use only 3/12
 TECHNIQUE Technical Directive

1. PRIMARY CAUSES OF FAILURE IN CLOSED WATER SYSTEMS

Corrosion, scale, silting and microbiological growth are the main problems of operating water systems. In
general, in closed water systems corrosion is considered as a major risk.
Besides, even if in semi-open systems (e.g. a recirculated cooling system in a cooling tower) such phenomena
are easy to detect, this is not the case for closed systems where most of the time problems are only detected if
there is a perforation.
1.1. CORROSION
Corrosion is an electrochemical phenomenon where the development of a corrosion battery translates into a
loss of metal. Any metal put in contact with water tends to dissolve in it. Steel is one of the most unstable metals
with regard to water under standard conditions.
Main factors favouring corrosion:
 Galvanic phenomena when coupling different metals (e.g. steel/copper or copper/aluminium couplings).
 Presence of dissolved oxygen which accelerates corrosion of steel without necessarily forming a
protecting insoluble oxide. This oxygen can come either by unexpected make up water supplies, or by
air takes at the circulation pumps or valves level; or by the porosity condition of some gas synthetic
material or of the expansion system (in the case of outdoor expansion tanks).
 Differential concentration batteries (e.g. differential aeration under deposits).

 Some factors that due to the physical means applied may cause the metal wearing (cavitation
phenomenon, erosion).

 An inappropriate and out of the metal passivation ranges pH. Hereafter passivation pH ranges for
information only:
- Steel 9.5 < pH < 12.5
- Copper 7 < pH < 10
- Aluminium 6 < pH < 8.5
Out of these ranges, the aforementioned metals have a high corrosion risk.
In networks using several metals (steel, copper and aluminium) treatments using specific inhibitors shall
be applied (nitrites, molybdate, benztriazoles, etc.).

Acid corrosion of a
Corrosion by cavitation of a Generalised corrosion of Alkaline corrosion of an
steam condensate return
copper collar a DHW circuit aluminium-made tube
network

Technical Directive / Water Treatment of Closed Circuits / October 12, 2011 / version a Page
Internal use only 4/12
 TECHNIQUE Technical Directive

1.2. SCALING
Scaling consists in the precipitation of a salt (supposed to be soluble) on metallic surfaces. Such deposits
appear when the ionic product of the considered cations (positive ions) and anions (negative ions) is higher than
the solubility product of the salt considered.
In closed systems scaling is mainly due to the decomposition of the soluble calcium bicarbonate in insoluble
calcium carbonate as per the chemical reaction hereafter:
Ca(HCO3)2  CaCO3 + H20 + CO2
(Calcium bicarbonate) (scale) (carbonic gas)

The higher the hardness and the complete alkalinity titration of raw water and make up
water supplies, the greater the scaling.
This scaling mainly appears in hot spots, i.e. boilers, and leads to a reduction in thermal
transfers (this is the reason why there is an overconsumption of energy) and the break of
structures due to overheating.
3
Remember: 1m of water with a hardness of 30 °f and a complete a lkalinity titration of 25 °f may generate 250g
of scale, expressed in calcium carbonate (CaCO3).
1.3. SILTING
Most of the time, closed network silting is due to corrosion or scaling phenomena due to the lack of treatment or
to an inappropriate treatment, or to uncontrolled supplies of make up water, or to construction or refurbishment
residues of the network, for example: cutting oil, sand, rust of tubes stored outdoors, etc.
1.4. MICROBIOLOGICAL GROWTH
Due to high temperatures, lack of light, low oxygen rate and few nutritive elements, i.e. parameters that do not
favour life, the growth of microbiological elements should be reduced. However, it is important to be careful with
chilled water systems, networks where water sits stagnant (sprinkler) and glycol loops, because bacteria growth
of anaerobic organisms may appear.
This growth may carry fouling phenomena and so, the reduction of transfer ratios and corrosion of the structures
(corrosion due to sulfate-reducing bacteria or the drop of pH due to nitrifying bacteria).

2. TREATMENT OF CLOSED CIRCUITS

2.1. BEST PRACTICES
As a minimum, overheated water networks (100 to 180°C) shall be fed with softened water. For all close d
systems it would be convenient to reduce water make-up supplies as much as possible in order to avoid the
aforementioned failures. For closed circuits < 100°C softening shall be recommended depending on the
magnitude of the make up supplies.
The recommendations hereafter are considered best practices:

2.1.1. Equipment
- Installing a make up water metering. A maximal renewal of 5% could be considered
as normal. This metering must be read on regular basis and water consumption
assessed to tailor the treatment and explain any possible extra consumption.

- Installing filters bypassing the circuit (preferably magnetic filters with fabric bags to
retain non-magnetic particles, if possible); the recommended cutting threshold is 50
µm. A framework contract has been agreed with our chemical products suppliers
to desilt closed systems.

Technical Directive / Water Treatment of Closed Circuits / October 12, 2011 / version a Page
Internal use only 5/12
 TECHNIQUE Technical Directive

- Installing a water make up softener (it is recommended to feed low temperature

heating circuits with softened water if annual make up is > 10% of the network
volume).
WARNING: during softening, calcium bicarbonate becomes bicarbonate and
sodium carbonate and later, under the effects of high temperatures, it becomes
soda after loosing the CO2. The pH will rise and so, become incompatible with
aluminium-based elements (aluminium-made heaters or cast aluminium/silicon
boilers). In some cases, especially with high-hardness water, it would be
necessary to use water treated by osmosis or demineralised water to feed the
circuits.

- Installing a chemical reagent injection system (displacement feeder for small

systems or dosing pumps for greater networks).

- Consider an analysis kit for controlling physical and chemical parameters.

2.1.2. Operation
Once the network has been fed with water, it is recommended to limit water make up:
- Finding and fixing leakages as soon as possible.
- Fitting the pumps packings in order to allow the lowest leakage flow.
- Making sure pumps with mechanical seals have no leakages.
- Avoiding interseasonal network blow-downs and refilling.
- Reducing water leakage during maintenance operations as much as possible.
- Write technical specification for maintenance jobs, make up water volumes, addition of chemical
products, etc.

2.1.3. Checks
The water purifier has often been hired to provide technical assistance in addition to in situ regular checks
(monthly, bimonthly or quarterly). This does not mean that the operator does not need to treat water or to
monitor the parameters.
- Given the high risks due to temperature in superheated water networks, controls on hardness, pH,
O2 reducer and concentration of corrosion regulation products must be carried out at least once a
month.
- For low pressure water networks, make up water consumptions are in general less important and
parameters vary just a little bit. Therefore, controls can be carried out every quarter.
- WARNING: when installing a new cast aluminium/silicon-made boiler parameters shall be measured
every week during the first quarter account taken of their high sensibility degree of these metals to
high pHs.

2.2. PREVENTIVE CHEMICAL TREATMENT

2.2.1. Main active reagents

Since corrosion is an electro-chemical phenomenon there is always the presence of a cathode (reduction of
a chemical element) and of an anode (oxidation of a chemical element) where corrosion appears. If one of
these two reactions is blocked, the corrosion phenomenon is stopped.

Technical Directive / Water Treatment of Closed Circuits / October 12, 2011 / version a Page
Internal use only 6/12
 TECHNIQUE Technical Directive

This is how it is possible to find:

- Cathodic inhibitors that block cathodes reactions. These cathodic inhibitors are electric insulators
that refuse electron transfers and so, avoid corrosion.
- Anodic inhibitors that block anodic reactions by reacting along with corrosion products to generate a
stable component.
However, it is easier to control anode reactions and this is the reason why most of the inhibitors have an
anodic nature.
Corrosion inhibitor molecules to be used will depend on the type of circuit to protect:
 Nitrite-based
Nitrites are good anodic inhibitors for ferrous metals with a pH ranging between 8 and 9, but not good
enough to protect copper and aluminium alloys properly.
They are used to protect heating, chilling and engine cooling networks with a dose of 1,000 mg/l.
 Molybdate-based
Molybdates are very efficient to protect closed circuits. Associated to specific inhibitors (e.g. triazole
compounds for copper) they are well adapted to closed circuits made up with different type of metals
(Fe/Cu/Al).
Furthermore, unlike nitrites, molybdates are not toxic and can be used for heating networks supplying
DHW with a single exchanger.
The parameter to meet in circuits is about 50 mg/l of molybdate (MoO4).
One of the main drawbacks is molybdates high cost.
 Tannate-based
In an hot and alkaline medium (pH > 8) tannates along with iron produce black insoluble iron tannates
which ensure a proper protection of ferrous metals. Nowadays, they are highly used in steam boilers, in
fact, they were used to treat steam locomotive boilers.
 Phosphate-based
Some phosphates in solution immersed in water at a rate of 20 to 30 mg/l expressed in phosphoric
anhydride (P2O5) provide enough alkalinity as to fight the thermodynamic instability of the iron in an aqueous
medium (pH near 10). Furthermore, if by accident there is calcium hardness due to the lack of softening,
these phosphates will avoid scaling at the hot spots of the boiler.
 Sulfite-based
Oxygen is often a corrosion source and it is necessary to neutralise it. The most used product is sodium
sulfite which after reacting with oxygen will become inert sodium sulfate.
2 Na2SO3 + O2  2 Na2SO4

2.2.2. Parameters to comply with in steel circuits treated with a

phosphate-sulfite base

pH: from 9.5 to 10.5 P2O5: from 10 to 30 mg/L of phosphate

hardness: < 0.5 °f Na2SO3: from 30 to 50 mg/L of sulfite
Alkalinity titration: from 5 to 15 °f

IMPORTANT: if there is aluminium present in the network, the pH must be < 8.5,
and a specific treatment shall be implemented. This treatment will especially consist in products
with high buffering conditions that will fight against the pH rise.

Technical Directive / Water Treatment of Closed Circuits / October 12, 2011 / version a Page
Internal use only 7/12
 TECHNIQUE Technical Directive

2.2.3. Table of water treatments for closed systems set out in the framework contract of Dalkia France /
Veolia Water STI
SRB + If total
Annual checks
total flora >
Type of facility recommended Reagent Technology Control Dosage If SRB
flora 1,000
(1)
(2) BT/ml
H2992 Molybdate 500 ppm H7310 H7990
Chilled water, raw water or pH = 9.5 ± 0.5 and 30 to 60 ppm of (dosage (dosage
softened water
4 or 4
MoO4 from 100 from 100
H2993 Molybdate 1,000 ppm to 200 to 200
Chilled water network (or ppm) ppm)
Equal to chilled water networks
condensers) without anti-frost
between
30% and
Chilled water network (or
40%
condensers) with MPG-based 4 H2903 Molybdate pH > 9.0 4
depending
anti-frost
on the PI
wished
Chilled water network (or
condensers) with MEG-based or pH = 9.5 ± 0.5 and 30 to 60 ppm of
4 H2993 Molybdate 1,000 ppm 4
MPG-based anti-frost without MoO4
inhibitor
Heating network T < 90°C with or No treatment required if the 1st analysis confirms that the physical and chemical parameters
2 checks (one
without aluminium and ARR < are good and if the 2nd analysis confirms that there is no variation. Otherwise, follow
every quarter)
30% recommendations of networks with an ARR > 30%
H2909 1,000 ppm
Heating network T < 90°C with Molybdate + pH = 8.5 ± 0.5 and 20 to 50 ppm of
aluminium and ARR > 30%
4 or silicate MoO4
4

H2992 350 ppm

Heating network T < 90°C Phosphate + pH = 9.5 ± 0.5 and 10 to 30 ppm of

H1310 1,000 ppm
without aluminium, ARR > 30%, Sulfite PO4 and 30 to 50 ppm of SO3
softened water make up and 4 Depending 4
expansion tank protected from H1908 if need
Sulfite If SO3 < 30 ppm on
air be
analyses

Technical Directive / Water Treatment of Closed Circuits / October 12, 2011 / version a Page
Internal use only 8/12
 TECHNIQUE Technical Directive

Heating network T < 90°C

without aluminium, ARR > 30%,
pH = 9.5 ± 0.5 and 30 to 60 ppm of
softened water or raw water 4 H2993 Molybdate 1,000 ppm 4
MoO4
make up and expansion tank
exposed to air

Between
Phosphate + pH = 10 ± 0.5 and 10 to 30 ppm of
H1906 100 and
Dispersant PO4
300 ppm
H1992:
Between
recommended
Overheated networks 110-180°C Carbohydrazide 0.5 at 1 ppm in N2H4 50 and 75
for networks at
shall be fed by at least softened 4 ppm 4
180°C
water (hardness < 0.5°F)
or
H1908:
Depending
recommended
Sulfite 30 at 50 ppm in SO3 on
for networks at
analyses
110°C

(1) The amount of checks is FYI only; they will be set according to the criticality level of the facility.
(2) The amount of controls will be set depending on the checks agreed.
ARR: Annual Renewal Rate.
Note: Another product from the Hydrex array could be proposed if Veolia Water STI's responsible considers it is technically necessary.

Technical Directive / Water Treatment of Closed Circuits / October 12, 2011 / version a Page
Internal use only 9/12
 TECHNIQUE Technical Directive

2.3. CURATIVE CHEMICAL TREATMENT

Lack of treatment or improper treatment may produce mud that will deposit in the heaters and make their
efficiency fall or, overall, in the boilers and make their exchanges scarce which could even make the heating
elements collapse. Many damages on boilers are caused by an important silting.
There are two techniques to remove mud from the circuits:

2.3.1. Fast desilting

Fast desilting requires the facility to be shut down and mechanic means to be applied in addition to
chemical means (HP pumps, human action during blow-downs, fullers, etc.). In general, this kind
of jobs is carried out during one or several days by specialised companies, especially when there
is need to replace the boiler during the heating plant refurbishment.

2.3.2. Slow desilting

This kind of jobs is carried out with the facility operating and it can last several months. Slow
desilting can be conducted in anticipation of the replacement of the boiler or just to improve the
facility performance. The company VEOLIA WATER STI/AQUABELLEC owns a Technical Notice
(ATEC 19/09-104) issued by the CSTB (http://www.cstb.fr/evaluations/atec-et-dta/). The company
associates a chemical treatment (Hydrex 5900B) and a bag filter equipped with magnetic
cartridges to catch magnetisable particles.

Characteristics of the filter

proposed by VEOLIA
WATER STI

WARNING: since these desilting operations imply products with a high pH they are not compatible
with networks made up of aluminium elements (cast aluminium boilers or aluminium heaters). If
the boiler is replaced by a cast aluminium boiler, this desilting action must be done before
installing the new boiler.

Technical Directive / Water Treatment of Closed Circuits / October 12, 2011 / version a Page
Internal use only 10/12
 TECHNIQUE Technical Directive

2.3.3. HYDREX products

In general, filtration is not enough to remove deposits properly. Depending on the type of deposit
(incrusting mud or not) and the material in contact (steel, stainless steel, aluminium, etc.), curative
treatment products will be often necessary.

HYDREX washing products proposed by Veolia Water STI:

Washing
Role Dosage Comments
products
To degrease the new facility before its commissioning, before
H5900 Desilt 1 at 5 % changing the treatment or when applying the slow desilting
technique
Powdered product - For soft cleaning for scaled equipment.
H5202 Scale remover 2 at 10 % Compatible with ferrous and non-ferrous metals - Sulfamic acid
based
Black steel scaling remover. Fast action. Do not use on
H5204 Scale remover 2 at 10 %
aluminium or galvanic steel - Hydrochloric acid based
Scaling remover
To remove scale from sensitive metals (stainless steel,
H5901 for sensitive 2 at 10 %
galvanised steel, aluminium) - Phosphoric acid based
metals
Passivating agent
Neutralisation after acid scaling remove + passivation of the
H5902 (1) / neutralising 2 at 10 %
metal elements
agent
Scaling remover
To remove scale from sensitive metals (stainless steel,
H5903 for sensitive 2 at 10 %
galvanised steel, aluminium) - formic acid based
metals
Solubilisation of iron oxide deposits in the circuits made up of steel,
Rust remover / de-
H5904 2 at 10 % stainless steel, galvanised steel and copper - Phosphoric acid based +
oxidant citric acid based
Stripping of new networks or desilting of old networks - Amine citrate
H5905 Desilt / de-oxidant 2 at 10 % based

(1): Product to be used after an acid scaling removal.

Note: Products shall be chosen depending on the facility to be treated and they shall be technically validated by Veolia
Water STI's responsible.

3. FRAMEWORK AGREEMENTS
The Purchasing and Technical Departments contacted three suppliers of water treatment proposing preventive
and slow curative water treatment solutions for heating networks account taken of framework agreements:
- Nalco
- Permo
- Veolia Water STI / Aquabellec
These agreements were signed in January 2010 for a 3-year period and they can be renewed twice, per tacit
agreement, for 1-year period.

Technical Directive / Water Treatment of Closed Circuits / October 12, 2011 / version a Page
Internal use only 11/12
 TECHNIQUE Technical Directive

4. CIRCUITS EQUIPPED WITH CAST ALUMINIUM BOILERS

It is important to implement precautionary measures account taken of the boilers sensitivity to high pH and
circulating mud.

4.1. IMPLEMENTATION OF A CAST ALUMINIUM BOILER IN AN EXISTING

NETWORK
Before the installation of such equipment:
 Check that the features of the tap water match with the manufacturer’s guaranteed conditions
(chlorides, pH and conductivity).
 Desilt the existing facility according to the aforementioned procedure: desilting product + bag filter
and magnetic cartridges.
 Rinse the circuits.
 Fill in the circuit with softened water or demineralised water according to the characteristics of the
raw water.
Plan a water treatment tailored to the coating of the steel pipeline. Keep the pH at < 8.5.
If it is not possible to carry out the desilting operation before the new boiler commissioning, it is
recommended to install an exchanger between the boiler and the heating network.

4.2. OPERATION OF A FACILITY WITH A CAST ALUMINIUM BOILER

After the boiler commissioning:
 Every two weeks: measure the pH the first two months to make sure this parameter is stable.
 Every month: read the metering of water make up and interpret the values recorded; wash the
filter installed during the desilting (to be adapted according to the clogging degree).
 Every quarter: analyse the main parameters: pH, hardness, alkalinity titration, corrosion inhibitor
and suspended solids (SS).
 Record the results of the analyses in the logbook of the heating plant.
 Comply with the recommendations of the water purifier.

4.3. TAKING OVER OF A FACILITY WITH A CAST ALUMINIUM BOILER

 Conduct a comprehensive analysis of the network water and the make up water
 Identify with the water purifier the water treatment implemented and set out its compatibility with all
different materials of which the facility is made up of.
 Set out the taking over report with the adapted reservations, give it to the customer and propose
him/her, if need be, a tailored treatment (desilting, rinsing, conditioning, frequency of analyses,
etc.).
 Make the customer approve the action plan.

Technical Directive / Water Treatment of Closed Circuits / October 12, 2011 / version a Page
Internal use only 12/12