Chemical Solution, Inc.

Technical Data Sheet

CLEANING, PASSIVATION and STARTUP of NEW COOLING SYSTEMS Prior to hydraulic testing or putting a new system into service, it must be cleaned to remove oil, grease, new pipe mill scale, silts and organic debris, and general rust accumulations. It is then chemically passivated to inhibit corrosion of the various metallurgies involved. Since the system may also contain microbiological contamination, disinfection should be provided prior to allowing any aerosol emissions from any wet-type heat rejection device (WTHRD), e.g., cooling towers, and evaporative condensers. Accordingly, the cleaning and disinfection procedures presented herein also incorporate the procedural concepts and disinfection guidelines for system start-up as endorsed by The Centers for Disease Control and Prevention (CDC) and as published in the "1987 Wisconsin Guidelines" entitled, Control of Legionella in Cooling Towers, Summary Guidelines. NACE publication item number 21027 may serve as an additional reference for the initial conditioning of cooling water equipment. NOTES: This procedure cannot nor can any of the CDC/Wisconsin cleaning/disinfection procedures guarantee elimination of Legionella bacteria or any other pathogen from cooling systems. Workers should be instructed and trained in protective procedures to minimize exposure to biological and chemical agents which may occur during system cleaning. Contaminants referenced above and a poor passivation program can cause a wide variety of operating problems. Oil can aggravate corrosion by hindering the ability of chemical corrosion inhibitors to function and by contributing to the formation of corrosion cells. Silt deposits and organic debris can retard heat transfer, restrict water flow, initiate formation of corrosion cells, and enhance the corrosive actions at existing corrosion cells. This leads to additional localized corrosion and subsequent leaks. These deposits also hinder the protective action of corrosion inhibitors, and can provide a "protective home" for many types of micro-organisms including corrosive ones such as the acid producing, sulfate reducing bacteria. Open recirculating water systems are typically constructed of mild steel, zinc-galvanized steel, copper, and brass metallurgies. Some may contain stainless steel, admiralty, and/or aluminum metallurgies. Thus, highly alkaline "boil out" procedures typically prescribed by boiler manufacturer's operating manuals for "all steel" boilers are NOT acceptable. Cleaning procedures based on strong, inhibited mineral acids can be risky for some metallurgies, are hazardous to handle, and are much more difficult to dispose of. The cleaning and passivation procedures employed in systems containing a zinc-galvanized WTHRD is most important to aid initial formation of a proper zinc oxide barrier. After start-up and concentration of makeup water impurities, system operation at moderately alkaline conditions (pH 8 - 9) and with water containing high concentrations of carbonate alkalinity could lead to formation of zinc carbonate (i.e. "White Rust") if the zinc galvanize is not initially passivated. The combination of cleaning and passivation chemical formulations and procedures described below function at pH neutral to very mildly alkaline conditions, contain phosphates to aid initial passivation of the zinc, and have been proven quite successful. Initial Flushing of Newly Constructed Systems New systems must be first filled with water to check for leaks and flushed to remove construction debris and loose deposits. Dead ends and low velocity areas should be flushed/drained until all sediment has been removed. The system volume (water holding capacity) should be established to effectively estimate cleaning chemical and treatment requirements. An alternate to any initial calculation/estimation of system capacity from design data is to perform a traced ion study during the initial system filling and circulation just prior to flushing. Once flushed, the system should not be allowed to sit idle for more than a day or two before all observed leaks are repaired and the chemical cleaning, passivation, and disinfection program is performed. Additional tasks prior to circulating any water over the cooling tower or other WTHRD should include: Turn off (lock out) the tower fans to avoid formation and emission of any contaminated aerosols; i.e. water mist. Close nearby building air intakes; say intakes within 30 meters (100 feet) of the cooling tower. This step is also very important prior to conducting any high dosage chemical cleaning, passivation, and disinfection in order to protect building occupants from high levels of chlorine or bromine gas and other biologic agents that would otherwise be aerosolized during this process. Remove all loose construction materials. Inspect the tower fill, drift eliminators, and fan belts. Repair or properly install as deemed necessary. Ascertain that the makeup water fill line is positioned so that the chemically treated circulating water cannot "backup" or siphon into the water supply lines. Make sure there are no system cross connections with the potable water supply.

(continued on other side) Cleaning of Newly Constructed Systems

ALL RIGHTS RESERVED. Do not duplicate this document by any method without prior written permission from Chemical Solution, Inc.

CLEANING, PASSIVATION and STARTUP of NEW COOLING SYSTEMS (continued) Additional preparations after system flushing, repair of any leaks encountered, and estimation of system holding capacity include: Shut down the system's bleedoff conductivity controller and close bleedoff valve. Verify that the chemically treated system bleedoff water will comply with proper regulatory agency discharge requirements; i.e. an EPA/State NPDES permit for discharges to a surface stream or, if required, a local POTW permit regulating discharges into a public sanitary sewer system. they are compatible with the cleaning/passivation formulations. above referenced

Oxidizing chlorine based disinfectants such as sodium hypochlorite liquid (FORMULA 1582) or chlorinated isocyanurate powder (FORMULA 1588-G) are both good sources of chlorine that can be used prudently with the above referenced products. Maintenance of chlorine residuals at 12 ppm free chlorine should be quite sufficient to compliment the above cleaning-passivation program without necessarily hindering initial system passivation.

Add the cleaning, passivation, and disinfection chemical formulations in accordance with the specific product selections and dosage instructions provided by the water treatment specialist serving the facility. A two step process is outlined in the following paragraphs. Circulate this initial cleaning-passivation solution for 24 to 48 hours at a cleaning temperature of 50oF to 100oF. The warmer temperatures will be more effective and permit more rapid cleaning. After the initial cleaning solutions are flushed from the system, the subsequent passivation chemical program should ideally be circulated for an additional one to two weeks to optimize the passivation process. During this period of time the system may be operated at low heat load and low cycles. Microbiocides should be added in accordance with the program selected for the on-going treatment program. The chemical formulations required for this two step process are generally described in the following paragraphs. Initial Cleaning and Passivation SERIES 1960 Formulations are concentrated mixtures of chelating agents, sequestrants, and metal passivators with polymeric dispersants, an azole yellow metal inhibitor, and surfactants. These products are mildly alkaline as necessary to maintain product stability. If the system being cleaned contains zinc galvanize, the pH of the circulating water needs to be adjusted downward to pH neutral or very slightly alkaline; pH of 7.0 to 7.5. This can be best accomplished by using an organic acid-based formulation. This mild organic acid serves to lower the pH to the desired range and has mild cleaning properties to aid removal of metal oxides such as mill scale and rust.

NOTE: The CDC/Wisconsin guidelines for start-up of existing systems and emergency disinfection of systems containing objectionable concentrations of Legionella specify chlorine dosages of 25 and 50 ppm and maintenance of 10 ppm for 24 hours. After circulating the above solution for 24 to 48 hours, drain and flush the system by procedures described above and in accordance with specific system characteristics learned during initial system flushing. IMMEDIATELY refill the system with clean water and add the final passivation and disinfection formulations specified by the water treatment specialist and as generally described below. Final Passivation and Disinfection SERIES 1930 Formulations are concentrated mixtures of molybdate, complex polyphosphates, orthophosphate, and azole yellow metal-based corrosion inhibitors ideal for passivation of cooling systems. The formulations also contain phosphonates and multi-functional polymer dispersants to aid product performance during initial one to two weeks of system operation provided the system only experiences moderate heat loads and is operated at low cycles to aid in maintaining operation at pH 7.0 to 7.5. Feed microbiocides as deemed necessary and specified by the water treatment specialist serving the facility. This program could utilize the same products referenced above and selected for the initial cleaning process. The SERIES 1930 passivation program may not require system flushing. At start-up, simply initiate the automated bleedoff valve to regulate desired cycles of concentration. The SERIES 1930 passivation formulation will be removed by normal system bleedoff and replaced by the specific corrosion/scale inhibitor and dispersant formulation specified by the facility's water treatment specialist for use during the on-going treatment program

NOTE: The cleaners and surfactant contained in the SERIES 1960 Formulations are NOT designed for systems heavily fouled with oil. An alternate cleaner or supplemental addition of a SERIES 1335 or 1340 Formulation may be required. The water treatment specialist serving the facility should be consulted.

FORMULA 3218 and FORMULA 3214 are two different organic acid-based formulations available to accomplish the above mentioned objectives. FORMULA 3218 is a concentrated liquid also containing a phosphonate sequestrant. FORMULA 3214 is a powdered formulation that would be most cost-effective for large systems. FORMULAs DL-1542 through DL-1547 are glutaraldehyde based microbiocides. These non-oxidizing-type biocides are preferred for disinfection of new systems as they would not adversely effect the new, un-passivated metallurgies as would high dosages of chlorine. Once diluted in the system's waters, ALL RIGHTS RESERVED. Do not duplicate this document by any method without prior written permission from Chemical Solution, Inc.