Industrial Water Treatment Operation and Maintenance - index
Chapter 1 Introduction Industrial Water Treatment
Deposits
Water Conservation
Protection of Potable Water
Operations Logs
Industrial Wastewater - ufc_3_240_13fn0024
Water Discharge Restrictions
Chapter 2 Makeup Water
Makeup Water Treatment Methods
External Treatment
Table 2-1. Makeup Water Treatment Methods for Removing Impurities
Figure 2-1. Effects of Treatment on Raw Water
Table 2-2. External Treatment Equipment Selection Guide for Steam Boiler Makeup Water
Aeration - ufc_3_240_13fn0033
Sand Filters
Cold and Hot Processes
Figure 2-3. Duplex Softener
Regeneration Cycle
Table 2-3. Salt Required for Regeneration of a Commonly Used Cation Resin
Fast Rinse
Resin Replacement
Equipment Requirements
Figure 2-4. Demineralization Process
Exchange Process Result
Figure 2-5. Anion Dealkalization Process
Figure 2-6. Split-Stream Dealkalizer
Table 2-4. Carbon Dioxide Content of Water vs. pH
Figure 2-7. RO Schematic
Figure 2-8. RO Unit
Biological Fouling - ufc_3_240_13fn0049
Electrodialysis
Chapter 3 Steam Boiler Systems
Figure 3-1. Fire Tube Boiler
Boiler Capacity Rating
Figure 3-3. Components of a Simple Steam Boiler System
After-Boiler
Measuring Equipment
Figure 3-5. Scaled Boiler Tube
Figure 3-6. Impact of Scale on Heat Transfer
Figure 3-8. Failed Boiler Tube
Blowdown
Relationship Between Feedwater, Blowdown, Steam Generation, and COC
Figure 3-9. Simplified Boiler System Water Balance
Makeup Water Rate
Difference Between Amount of Steam Produced and Amount of Condensate
Boiler Water Treatment and Control
Figure 3-10. Localized Scale Formation Process
Calcium Sulfate
External Water Treatment for High-Pressure Boilers
Precipitating Water Treatment Programs
Determining Chemical Treatment Feed Rates
Preventing Sludge Deposits
Table 3-1. Summary of Phosphate Treatment Programs
Table 3-2. Deaerator Water Outlet Temperature for Boiler Systems at Various Sea Level Pressures
Figure 3-11. Mechanical Deaerator Schematic (Spray Type)
Figure 3-12. Mechanical Deaerator Schematic (Tray Type)
Table 3-3. Levels of Sulfite to be Carried in Boiler Water
Condensate Corrosion and Control
Figure 3-13. Effect of pH on Mild Steel and Copper Corrosion
Control of Carbon Dioxide by Neutralizing Amines
Table 3-4. Physical and Chemical Properties of Neutralizing Amines
Morpholine
Control of Carbon Dioxide and Oxygen by Specialty Volatile Amines
Food Preparation
Figure 3-14. Water Boiler Mist Formation
Table 3-7. Silica Levels Allowed in Boiler Water
Developing A Steam Boiler System Water Treatment Program
Cooling Systems Treatment
Program Content
Table 3-8. Suggested Feedwater Limits for Industrial Water Tube Boiler
Table 3-9. Suggested Feedwater Limits for Industrial Water Tube Boiler
Table 3-11. ASME Feedwater Limits for Industrial Water Tube Boilers
Table 3-12. ASME Suggested Feedwater Limits for Marine Propulsion Water Tube Boiler
Table 3-13. ASME Suggested Boiler Water Limits for Industrial Water Tube Boiler
Table 3-14. ASME Boiler Water Limits for Industrial Water Tube Boilers
Table 3-15. ASME Boiler Water Limits for Industrial Fire Tube Boilers
Table 3-17. NAVSEASYSCOM Shore-To-Ship Steam Purity Requirements
Table 3-18. Treatment Guidelines for Low-Pressure Steam
Table 3-19. Treatment Guidelines for Medium- and High-Pressure Steam
Table 3-20. Treatment Guidelines for Very-High-Pressure Steam
Start-up of New Boilers and Condensate Systems or Repaired Boilers
Table 3-21. Troubleshooting Boiler System Water
Chemical Requirement for Boiler Layup
Quicklime or Silica Gel Layup Method
Wet Layup of Drained Boilers
Figure 3-15. Inspection Gauge for Wet Boiler Layup
Commonly Asked Questions and Answer on Boiler Water Treatment
Commonly Asked Qustions and Answer on Boiler Water Treatment
Chapter 4 Cooling Water Systems
Figure 4-2. Evaporative Fluid Cooler and Evaporative Condenser Diagram
Figure 4-3. Open Recirculating Cooling Tower Water System Diagram
Figure 4-4. Cooling Tower Water System
Figure 4-5. Hyperbolic Natural-Draft Cooling Towers
Figure 4-6. Cross-Flow Cooling Tower
Figure 4-8. Counter-Flow Cooling Tower Diagram
Figure 4-10. Induced-Draft Cross-Flow Cooling Tower Components
Figure 4-11. High-Efficiency Cooling Tower Film Fill
Common Cooling Water System Problems
Figure 4-12. Super-Enhanced Copper Tubes
Figure 4-14. Heavily Fouled Cooling Tower Film Fill
Cooling Tower Water Calculations
Calculating COC by Volume
Controlling COC
Figure 4-15. Effect of COC on Makeup Requirement
Relationship Between Blowdown, Evaporation, and COC
Objectives of Cooling Water Treatment
Calcium Carbonate Scale
Silica Scale
Calcium Carbonate Scaling Indices
Practical (Puckorius) Scaling Index (PSI)
Calcium Carbonate Scale Control Using Solubilizing Chemicals
Calcium Sulfate Scale Control Using Solubilizing Polymers
Table 4-1. Summary of Scale Control Methods
Algae
Table 4-3. Bacterial Types and Problems Created
Fungi
Figure 4-16. Halogen Species vs. pH in Water
Table 4-5. Bromine Release Agents
Table 4-6. Guidelines for Oxidizing Microbiocide Effectiveness
Non-Oxidizing Biocides
Table 4-7. Guidelines for Non-Oxidizing Microbiocide Selection
Algae Control
Corrosion Cooling Systems
Figure 4-17. Forms of Corrosion
Figure 4-18. Galvanic Series of Common Metals and Alloys Found in Cooling Water Systems
General Corrosion
Table 4-9. Assessing Corrosion Rates in Cooling Water Systems: 90-Day Corrosion Coupon Test
Figure 4-19. Effect of pH on Corrosion Rate of Unprotected Mild Steel in Water
Table 4-10. Criteria for Corrosion Inhibitor Selection
General Inhibitors
Table 4-11. Guidelines for Passivation Film Formation and Subsequent Maintenance
Water Quality - ufc_3_240_13fn0151
Table 4-12. Small Cooling Tower Treatment Program
Table 4-13. Treatment Programs for Medium and Large Cooling Towers
Cooling Tower Distribution Deck
Cooling Water System Start-Up and Layup Requirements
Start-up of New Cooling Water Tower Systems
Table 4-14. Required Chemical Technology
Table 4-15. Supplemental Chemical Technology
Chapter 5 Closed Industrial Water Systems
Figure 5-1. Hot Water Boiler
Figure 5-2. Typical Closed Chilled Water System Schematic
Figure 5-3. Chillers
Water-Cooled Diesel Engine Cooling Systems
Table 5-1. Makeup Water Requirements for Closed Systems
Table 5-2. Selection Guidelines for Closed System Treatment
Nitrite-Azole Treatment Program
Molybdate-Nitrite-Azole Treatment Program
Treatment and Control of Microbiological Growth
Procedures for Layup of Hot and Chilled Water Systems
Chapter 6 Water Sampling and Testing of Water Systems
Table 6-1. Recommended Water Sample Frequency and Testing Requirements for Cooling Tower Systems
Frequency of Cooling Water Sampling and Testing
Figure 6-1. Typical Water Sampling Points for an Open Recirculating Cooling Water System
Figure 6-2. Boiler or Condensate Water Sample Cooling Coil
Sampling Locations
Figure 6-3. Typical Locations for Water Sampling in a Steam Boiler Water System
Table 6-2. Water Sampling Frequency and Testing Requirements for Boiler Water Systems
Boiler Feedwater Sample
Table 6-3. Water Sampling and Testing Requirements
Water Testing
Water Sample Testing Methods
Interretation of Results From Water Tests
Figure 6-4. Acidity, Alkalinity, and pH Ranges
Table 6-4. Alkalinity Relationship Based on P and M Tests
pH (Hydrogen Ion Concentration)
Table 6-5. Relationship Between Causticity and pH
In-Plant Laboratory Water Testing Requirements
Chapter 7 Water Treatment Chemical Feed and Control
Table 7-1. Cooling System Controller Functions
Chemical Pumps
Chemical Feed Methods
Figure 7-1. Chemical Pot Feeder
Figure 7-3. Automatic Chemical Feed System
Figure 7-4. Automatic Neat Chemical Feed
Safety and General Information
Handling Caustic Soda (Sodium Hydroxide)
Chemical Storage
Chapter 8 Non-Chemical/Non-Traditional Water Treatment Devices
Electrical Impressed Current Devices
Magnetic and Electromagnetic Devices
Copper and Silver Ionizing Devices
Chapter 9 Chemical Cleaning of Water Systems
Remedial Cleaning
Remedial Cleaning Procedures
Example Procedure for 10% Solution
Phosphate Deposits
Cleaning Preparation
Methods for Removing Scale
Circulating Method Without Heat
Fill and Soak Method
Checking Acid Solution Strength
Chapter 10 Developing A Water Treatment Program
Generic Chemical Water Treatment Programs
Qualifications
Service Requirements - ufc_3_240_13fn0215
Glossary - ufc_3_240_13fn0216
Glossary - Cont'd - ufc_3_240_13fn0217
Glossary - Cont'd - ufc_3_240_13fn0218
Glossary - Cont'd - ufc_3_240_13fn0219
Glossary - Cont'd - ufc_3_240_13fn0220
Glossary - Cont'd - ufc_3_240_13fn0221
Glossary - Cont'd - ufc_3_240_13fn0222
Glossary - Cont'd - ufc_3_240_13fn0223
Glossary - Cont'd - ufc_3_240_13fn0224
Glossary - Cont'd - ufc_3_240_13fn0225
Appendix B Practical (Pukorius) Scaling Index (PSI)
Table B-1. Factor "A" for TDS
Table B-2. Factor "B" for Temperature
Table B-3. Factor "C" for Calcium Hardness (as ppm CaCO3) Zero to 200 ppm
Table B-4. Factor "C" For Calcium Hardness (as ppm CaCO3) 200 to 990 ppm
Table B-5. Factor "D" for Alkalinity (as ppm CaCO3) Zero to 200 ppm
Table B-6. Factor "D" for Alkalinity (as ppm CaCO3) 200 to 890 ppm
Scaling Severity Keyed to Indices
Table B-8. Scaling Indices vs. Condition
Appendix C Corrosion Testing With Coup-type Test Speciments
Installation of Coupon-Type Test Specimens
Figure C-1. Bypass Piping for Corrosion Testing Cooling Water and Condensate Systems
Table C-1. Flow Rate
Appendix D Corrosion Testing With Test Nipple Assembly
Installation of Tester
Figure D-1. Condensate Corrosion Tester
Appendix E Testing Industrial Water System Samples
Testing Procedures
Appendix F Nonproprietary Industrial Water Treatment Chemicals
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0247
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0248
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0249
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0250
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0251
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0252
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0253
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0254
Chapter 1 Introduction Industrial Water Treatment
Deposits
Water Conservation
Protection of Potable Water
Operations Logs
Industrial Wastewater - ufc_3_240_13fn0024
Water Discharge Restrictions
Chapter 2 Makeup Water
Makeup Water Treatment Methods
External Treatment
Table 2-1. Makeup Water Treatment Methods for Removing Impurities
Figure 2-1. Effects of Treatment on Raw Water
Table 2-2. External Treatment Equipment Selection Guide for Steam Boiler Makeup Water
Aeration - ufc_3_240_13fn0033
Sand Filters
Cold and Hot Processes
Figure 2-3. Duplex Softener
Regeneration Cycle
Table 2-3. Salt Required for Regeneration of a Commonly Used Cation Resin
Fast Rinse
Resin Replacement
Equipment Requirements
Figure 2-4. Demineralization Process
Exchange Process Result
Figure 2-5. Anion Dealkalization Process
Figure 2-6. Split-Stream Dealkalizer
Table 2-4. Carbon Dioxide Content of Water vs. pH
Figure 2-7. RO Schematic
Figure 2-8. RO Unit
Biological Fouling - ufc_3_240_13fn0049
Electrodialysis
Chapter 3 Steam Boiler Systems
Figure 3-1. Fire Tube Boiler
Boiler Capacity Rating
Figure 3-3. Components of a Simple Steam Boiler System
After-Boiler
Measuring Equipment
Figure 3-5. Scaled Boiler Tube
Figure 3-6. Impact of Scale on Heat Transfer
Figure 3-8. Failed Boiler Tube
Blowdown
Relationship Between Feedwater, Blowdown, Steam Generation, and COC
Figure 3-9. Simplified Boiler System Water Balance
Makeup Water Rate
Difference Between Amount of Steam Produced and Amount of Condensate
Boiler Water Treatment and Control
Figure 3-10. Localized Scale Formation Process
Calcium Sulfate
External Water Treatment for High-Pressure Boilers
Precipitating Water Treatment Programs
Determining Chemical Treatment Feed Rates
Preventing Sludge Deposits
Table 3-1. Summary of Phosphate Treatment Programs
Table 3-2. Deaerator Water Outlet Temperature for Boiler Systems at Various Sea Level Pressures
Figure 3-11. Mechanical Deaerator Schematic (Spray Type)
Figure 3-12. Mechanical Deaerator Schematic (Tray Type)
Table 3-3. Levels of Sulfite to be Carried in Boiler Water
Condensate Corrosion and Control
Figure 3-13. Effect of pH on Mild Steel and Copper Corrosion
Control of Carbon Dioxide by Neutralizing Amines
Table 3-4. Physical and Chemical Properties of Neutralizing Amines
Morpholine
Control of Carbon Dioxide and Oxygen by Specialty Volatile Amines
Food Preparation
Figure 3-14. Water Boiler Mist Formation
Table 3-7. Silica Levels Allowed in Boiler Water
Developing A Steam Boiler System Water Treatment Program
Cooling Systems Treatment
Program Content
Table 3-8. Suggested Feedwater Limits for Industrial Water Tube Boiler
Table 3-9. Suggested Feedwater Limits for Industrial Water Tube Boiler
Table 3-11. ASME Feedwater Limits for Industrial Water Tube Boilers
Table 3-12. ASME Suggested Feedwater Limits for Marine Propulsion Water Tube Boiler
Table 3-13. ASME Suggested Boiler Water Limits for Industrial Water Tube Boiler
Table 3-14. ASME Boiler Water Limits for Industrial Water Tube Boilers
Table 3-15. ASME Boiler Water Limits for Industrial Fire Tube Boilers
Table 3-17. NAVSEASYSCOM Shore-To-Ship Steam Purity Requirements
Table 3-18. Treatment Guidelines for Low-Pressure Steam
Table 3-19. Treatment Guidelines for Medium- and High-Pressure Steam
Table 3-20. Treatment Guidelines for Very-High-Pressure Steam
Start-up of New Boilers and Condensate Systems or Repaired Boilers
Table 3-21. Troubleshooting Boiler System Water
Chemical Requirement for Boiler Layup
Quicklime or Silica Gel Layup Method
Wet Layup of Drained Boilers
Figure 3-15. Inspection Gauge for Wet Boiler Layup
Commonly Asked Questions and Answer on Boiler Water Treatment
Commonly Asked Qustions and Answer on Boiler Water Treatment
Chapter 4 Cooling Water Systems
Figure 4-2. Evaporative Fluid Cooler and Evaporative Condenser Diagram
Figure 4-3. Open Recirculating Cooling Tower Water System Diagram
Figure 4-4. Cooling Tower Water System
Figure 4-5. Hyperbolic Natural-Draft Cooling Towers
Figure 4-6. Cross-Flow Cooling Tower
Figure 4-8. Counter-Flow Cooling Tower Diagram
Figure 4-10. Induced-Draft Cross-Flow Cooling Tower Components
Figure 4-11. High-Efficiency Cooling Tower Film Fill
Common Cooling Water System Problems
Figure 4-12. Super-Enhanced Copper Tubes
Figure 4-14. Heavily Fouled Cooling Tower Film Fill
Cooling Tower Water Calculations
Calculating COC by Volume
Controlling COC
Figure 4-15. Effect of COC on Makeup Requirement
Relationship Between Blowdown, Evaporation, and COC
Objectives of Cooling Water Treatment
Calcium Carbonate Scale
Silica Scale
Calcium Carbonate Scaling Indices
Practical (Puckorius) Scaling Index (PSI)
Calcium Carbonate Scale Control Using Solubilizing Chemicals
Calcium Sulfate Scale Control Using Solubilizing Polymers
Table 4-1. Summary of Scale Control Methods
Algae
Table 4-3. Bacterial Types and Problems Created
Fungi
Figure 4-16. Halogen Species vs. pH in Water
Table 4-5. Bromine Release Agents
Table 4-6. Guidelines for Oxidizing Microbiocide Effectiveness
Non-Oxidizing Biocides
Table 4-7. Guidelines for Non-Oxidizing Microbiocide Selection
Algae Control
Corrosion Cooling Systems
Figure 4-17. Forms of Corrosion
Figure 4-18. Galvanic Series of Common Metals and Alloys Found in Cooling Water Systems
General Corrosion
Table 4-9. Assessing Corrosion Rates in Cooling Water Systems: 90-Day Corrosion Coupon Test
Figure 4-19. Effect of pH on Corrosion Rate of Unprotected Mild Steel in Water
Table 4-10. Criteria for Corrosion Inhibitor Selection
General Inhibitors
Table 4-11. Guidelines for Passivation Film Formation and Subsequent Maintenance
Water Quality - ufc_3_240_13fn0151
Table 4-12. Small Cooling Tower Treatment Program
Table 4-13. Treatment Programs for Medium and Large Cooling Towers
Cooling Tower Distribution Deck
Cooling Water System Start-Up and Layup Requirements
Start-up of New Cooling Water Tower Systems
Table 4-14. Required Chemical Technology
Table 4-15. Supplemental Chemical Technology
Chapter 5 Closed Industrial Water Systems
Figure 5-1. Hot Water Boiler
Figure 5-2. Typical Closed Chilled Water System Schematic
Figure 5-3. Chillers
Water-Cooled Diesel Engine Cooling Systems
Table 5-1. Makeup Water Requirements for Closed Systems
Table 5-2. Selection Guidelines for Closed System Treatment
Nitrite-Azole Treatment Program
Molybdate-Nitrite-Azole Treatment Program
Treatment and Control of Microbiological Growth
Procedures for Layup of Hot and Chilled Water Systems
Chapter 6 Water Sampling and Testing of Water Systems
Table 6-1. Recommended Water Sample Frequency and Testing Requirements for Cooling Tower Systems
Frequency of Cooling Water Sampling and Testing
Figure 6-1. Typical Water Sampling Points for an Open Recirculating Cooling Water System
Figure 6-2. Boiler or Condensate Water Sample Cooling Coil
Sampling Locations
Figure 6-3. Typical Locations for Water Sampling in a Steam Boiler Water System
Table 6-2. Water Sampling Frequency and Testing Requirements for Boiler Water Systems
Boiler Feedwater Sample
Table 6-3. Water Sampling and Testing Requirements
Water Testing
Water Sample Testing Methods
Interretation of Results From Water Tests
Figure 6-4. Acidity, Alkalinity, and pH Ranges
Table 6-4. Alkalinity Relationship Based on P and M Tests
pH (Hydrogen Ion Concentration)
Table 6-5. Relationship Between Causticity and pH
In-Plant Laboratory Water Testing Requirements
Chapter 7 Water Treatment Chemical Feed and Control
Table 7-1. Cooling System Controller Functions
Chemical Pumps
Chemical Feed Methods
Figure 7-1. Chemical Pot Feeder
Figure 7-3. Automatic Chemical Feed System
Figure 7-4. Automatic Neat Chemical Feed
Safety and General Information
Handling Caustic Soda (Sodium Hydroxide)
Chemical Storage
Chapter 8 Non-Chemical/Non-Traditional Water Treatment Devices
Electrical Impressed Current Devices
Magnetic and Electromagnetic Devices
Copper and Silver Ionizing Devices
Chapter 9 Chemical Cleaning of Water Systems
Remedial Cleaning
Remedial Cleaning Procedures
Example Procedure for 10% Solution
Phosphate Deposits
Cleaning Preparation
Methods for Removing Scale
Circulating Method Without Heat
Fill and Soak Method
Checking Acid Solution Strength
Chapter 10 Developing A Water Treatment Program
Generic Chemical Water Treatment Programs
Qualifications
Service Requirements - ufc_3_240_13fn0215
Glossary - ufc_3_240_13fn0216
Glossary - Cont'd - ufc_3_240_13fn0217
Glossary - Cont'd - ufc_3_240_13fn0218
Glossary - Cont'd - ufc_3_240_13fn0219
Glossary - Cont'd - ufc_3_240_13fn0220
Glossary - Cont'd - ufc_3_240_13fn0221
Glossary - Cont'd - ufc_3_240_13fn0222
Glossary - Cont'd - ufc_3_240_13fn0223
Glossary - Cont'd - ufc_3_240_13fn0224
Glossary - Cont'd - ufc_3_240_13fn0225
Appendix B Practical (Pukorius) Scaling Index (PSI)
Table B-1. Factor "A" for TDS
Table B-2. Factor "B" for Temperature
Table B-3. Factor "C" for Calcium Hardness (as ppm CaCO3) Zero to 200 ppm
Table B-4. Factor "C" For Calcium Hardness (as ppm CaCO3) 200 to 990 ppm
Table B-5. Factor "D" for Alkalinity (as ppm CaCO3) Zero to 200 ppm
Table B-6. Factor "D" for Alkalinity (as ppm CaCO3) 200 to 890 ppm
Scaling Severity Keyed to Indices
Table B-8. Scaling Indices vs. Condition
Appendix C Corrosion Testing With Coup-type Test Speciments
Installation of Coupon-Type Test Specimens
Figure C-1. Bypass Piping for Corrosion Testing Cooling Water and Condensate Systems
Table C-1. Flow Rate
Appendix D Corrosion Testing With Test Nipple Assembly
Installation of Tester
Figure D-1. Condensate Corrosion Tester
Appendix E Testing Industrial Water System Samples
Testing Procedures
Appendix F Nonproprietary Industrial Water Treatment Chemicals
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0247
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0248
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0249
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0250
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0251
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0252
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0253
Appendix F Nonproprietary Industrial Water Treatment Chemicals - Cont'd - ufc_3_240_13fn0254
