Cooling Water Treatment http://www.marinediesels.co.uk/members/operation/cooling_water_trea...

marinediesels.co.uk - Members Section

Engine Operation
Cooling Water Treatment

Other Pages The Basics The 2 Stroke Engine The 4 Stroke Engine Operation Members

PROBLEM AREAS

There are four key areas which must be considered when treating diesel engine cooling water systems.

Scale

Scale results when a compound precipitates from the water phase because its solubility has been exceeded. Scale is a
dense, adherent deposit of minerals and is tightly bonded to itself and to metal surfaces.

One primary factor influencing scale adherence is surface roughness. The rougher the surface, the greater the probability
of adherent scale forming. Also, scale forms more readily on corroding surfaces than on non-corroding surfaces. Easily
corroded metals (mild steel) result in significantly more scale than metals that do not corrode (stainless steel).

Wildly fluctuating pH is a significant cause of scale deposition in closed loop systems. As the pH of the system increases,
so does the scaling potential for almost all common scale. This would include Calcium Carbonate, Calcium Sulphate, and
Iron Oxide. Low pH extrusions can accelerate corrosion, provide nucleating sites and increase the potential for some
forms of Silica scale.

Scale formation in diesel engine cooling water systems can be controlled by various methods. Removing scale-forming
Ions from the water before that water enters the cooling system is the most effective method (demineralization or water
softening). Almost all engine manufacturers recommend the use of distilled water. Distilled water is free of minerals.
However, distilled water has a natural affinity for carbon dioxide, which makes it acidic, and if untreated, can lead to
corrosion.

Corrosion

Corrosion is the phenomenon that returns metals to their native states as chemical compounds or minerals.

In diesel engines containing dissimilar metals, the main concern is galvanic corrosion. When exposed to water which acts
as an electrolyte, one metal becomes anodic and the other cathodic, setting up a galvanic cell. For example, when Copper
and Mild Steel are connected in water, the Mild Steel becomes the Anode, because it will give up electrons more readily
than the Copper. The metal loss occurs at the anode, so the Mild Steel corrodes. Acidic corrosion (pitting) can also occur
when the pH falls below 7. The water will contain dissolved oxygen, and if left untreated an ideal environment will exist
for all types of corrosion.
Fouling

Fouling is different from scaling in that fouling deposits are formed from material suspended in the water, while scale
deposits are formed from minerals in solution. Materials that cause fouling in cooling water systems are suspended solids
and oil leaking into the system. We must control fouling in a diesel engine cooling water system, as it interferes with the
effectiveness of corrosion inhibitors.

Microbiological activity

Nitrites act as a food source for some types of bacteria. While the presence of bacteria is not as widespread in diesel
engine cooling water systems as in other cooling water systems, it is a potential problem. The problem becomes apparent
when conducting chemical tests of the cooling water. If the personnel on the vessel are dosing Nitrites and do not get a
reading and the pH begins to fall, there is a possibility of microbiological activity. This can be verified by simple test
methods ("dip slides"). Bacteria can be introduced into a system by filling a cooling system with raw untreated water
from ashore. Bacteria can also attack rubber, so seal rings and hoses may deteriorate when bacteria is active within a
system. Biocides are used to kill these micro organisms.

TREATMENT

Nitrites (e.g. Unitor Dieselguard NB powder or Rocor NB Liquid)

1 of 2 06-02-2017 21:55
Cooling Water Treatment http://www.marinediesels.co.uk/members/operation/cooling_water_trea...

The most common form of water treatment nowadays is a nitrite borate azole inhibitor. The nitrite protects the mild steel
and cast iron by forming a protective metal oxide film on the surfaces of the metal, while the azole protects the copper
from corrosion. A reserve concentration of the agents is held within the water and this replaces any areas of surface layers
which may be removed by cavitation or vibration. Normal nitrite limits: 1000-2400 ppm nitrite (NO2). The borates act as
buffering agents to maintain pH values within suitable limits when the product is dosed as recommended. The pH should
be maintained between 8.3 and 10.0 by the treatment.

Under certain conditions because of external contamination, the pH may not fall into the range usually found with the
correct nitrite dosage. In such cases, an alkalinity control chemical (sodium hydroxide - caustic soda) is added to the
cooling water to raise the pH value when the pH is below 8.3.

Chlorides have a negative effect on the passive oxide film created by the nitrites. A chloride test should be carried out to
ensure that the chloride level in the water is below 50ppm. An increase in chlorides is an indication of sea water
contamination. If the chlorides are above 50 ppm then the reserve of nitrites should be increased to the maximum (2400
ppm) until corrective action can be taken (freshening the system).

Nitrite inhibitors are not suitable in systems containing zinc or aluminium as they will attack these metals. Therefore
galvanised piping and soldered joints should be avoided. However nitrites do not attack rubber and so sealing rings and
hoses are not affected.

Nitrite inhibitors are safe to use where a domestic fresh water generator uses the jacket cooling water as a heat source.
Where biocides are used, these must also be approved for use with a fresh water generator.

Soluble Oils (e.g. Shell Dromus B)

These are the same oils that are used for cutting fluids, although in lower concentrations (0.25 - 0.5 %). Increased water
hardness scale forming hardness salts of calcium and magnesium will require higher concentrations to maintain
corrosion inhibition properties. The oils form a greasy protective film which adheres to surfaces and prevents corrosion.
Its tenacity gives better protection against cavitation than chemical additives. Because of this and because it helps
lubricate the telescopics it is suitable for use in crosshead engines with water cooled pistons. Emulsion oils must be
maintained within close concentration limits and the system kept clean: any contamination causes deposits to build up,
with the risk of choking of passages causing overheating. The oil deteriorates in time and the system should be cleaned
and recharged. Can be subject to microbiological attack and biocides may be necessary. Safe to use with domestic fresh
water generators.

Soluble oils can attack rubber seal rings especially if the concentrations are too high.

Chromates

Although chromates are a very effective inhibitor, and do not attack zinc, they are no longer used. They are poisonous
and carcinogenic and cannot be used in systems incorporating a fresh water generator. They do not buffer the pH so a
separate pH control chemical would be necessary. Low levels of concentration promote pitting attack.

DHTML Menu / JavaScript Menu Powered By OpenCube

2 of 2 06-02-2017 21:55