1、PUBLIC WORKS TECHNICAL BULLETIN 420-49-052 FEBRUARY 1998INDUSTRIAL WATER TREATMENT PROCEDURESProvided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEPARTMENT OF THE ARMYU.S. Army Center for Public Works7701 Telegraph RoadAlexandria, VA 22315-3862Public Wor
2、ks Technical Bulletin 2 February 1998No. 420-49-05 FACILITIES ENGINEERINGUtilitiesINDUSTRIAL WATER TREATMENT PROCEDURES1. Purpose . This Public Works Technical Bulletin (PWTB) transmits the Industrial WaterTreatment Procedures handbook. The procedures provide information on the application,selection
3、, procurement and implementation of water treatment procedures and chemicals requiredto properly operate boiler and cooling systems and maintain the waterside surfaces. Theprocedures improve maintenance, efficiency, reliability, treatment, system life and safety of boilerand cooling systems. The boi
4、ler and cooling systems include steam boilers, hot water boilers,chilled water systems, cooling towers and other industrial systems. 2. Applicability . This PWTB applies to all U.S. Army Public Works activities responsible foroperating and maintaining boiler, cooling tower and HVAC systems.3. Refere
5、nces.a. Army Regulation 420-49, Facilities Engineering, Utility Services, April 1997.b. TM 5-650, Central Boiler Plants, October 1989. c. TM 5-642, Operation and Maintenance Small Heating Systems, August 1990. d. TM 5-671, Preventive Maintenance for Refrigeration, Air Conditioning, MechanicalVentila
6、tion, and Evaporative Cooling, August 1958. 4. Discussion .a. Many installations across the country are facing problems in industrial water systems(i.e., boiler and cooling systems). One of the most common problems is difficulty in preventingthe formation of scale or the occurrence of corrosion in h
7、eating and cooling systems. As a resultof these problems, system life, reliability, efficiency and safety are reduced. Many of theseProvided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-PWTB No. 420-49-05 2 February 19982problems are preventable through pr
8、oper boiler/cooling water chemistry maintenance andtreatment.b. Army policy requires generic chemicals for the treatment of central boiler plant systemwater. TM 5-650 provides basic guidance on the application of chemicals to steam and hot waterboiler water. This PWTB amplifies the correct chemical
9、treatment of boilers and adds requiredchemical treatment for cooling towers and chilled water systems. It also provides procedures forthe economical, safe and efficient control of heating and cooling systems while setting specificstandards for water treatment.c. This PWTB provides one consolidated g
10、uide for chemical treatment of all HVACsystems. 5. Point of contact . Questions and/or comments regarding this subject, which cannot be resolvedat the installation level, should be directed to:U.S. Army Center for Public WorksNelson Labb ATTN: CECPW-ES7701 Telegraph RoadAlexandria, VA 22315-3862Tele
11、phone: (703) 806-5202, DSN: 656-5202FAX: (703) 806-5216e-mail: nelson.c.labbecpw01.usace.army.milFOR THE DIRECTOR:EVANGELOS P. STOYAS, P.E.Acting Director of EngineeringProvided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-Public Works Technical Bulletins
12、are published by the U.S. Army Center for Public Works,Alexandria, VA. They are intended to provide information on specific topics in areas of FacilitiesEngineering and Public Works. They are not intended to establish new DA policy.Provided by IHSNot for ResaleNo reproduction or networking permitted
13、 without license from IHS-,-,-PWTB 420-49-52 February 1998 This publication may be reproduced.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-INDUSTRIAL WATER TREATMENT PROCEDURES2 FEBRUARY 1998Provided by IHSNot for ResaleNo reproduction or networki
14、ng permitted without license from IHS-,-,-iApproved for public releaseINDUSTRIAL WATER TREATMENT PROCEDURESHANDBOOKParagraph PageCHAPTER 1. INTRODUCTION TO INDUSTRIAL WATER TREATMENTSection I. Industrial Water Treatment PolicyIndustrial Water Defined 1-1 1-1Problems Encountered in Industrial Water S
15、ystems . 1-2 1-1Objective of Industrial Water Treatment . 1-3 1-1Responsibility for Treatment . 1-4 1-2Unauthorized Treatment . 1-5 1-2Protecting Health 1-6 1-2Record Keeping Requirements 1-7 1-3Support Available . 1-8 1-4Section II. Safety and First AidSafety Considerations . 1-9 1-4First Aid Infor
16、mation 1-10 1-5Section III. Disposal of Industrial Water WastesDisposal Procedures . 1-11 1-5Regulations That May Apply 1-12 1-6CHAPTER 2. MAKEUP WATERSection I. General InformationIndustrial Water . 2-1 2-1Sources of Makeup Water . 2-2 2-1Source Selection Factors to Consider . 2-3 2-1Reasons and Cr
17、iteria for Treating Makeup Water 2-4 2-1Section II. Methods of TreatmentGeneral Discussion 2-5 2-2Aeration. 2-6 2-2Filtration 2-7 2-6Lime-Soda Softening . 2-8 2-6Ion Exchange Processes-General 2-9 2-6Sodium Ion Exchange 2-10 2-7Hydrogen Ion Exchange 2-11 2-10Anion Exchange 2-12 2-11Dealkalization .
18、2-13 2-11Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-iiParagraph PageDecarbonation 2-14 2-13Evaporation 2-15 2-13Reverse Osmosis 2-16 2-13Ultrafiltration . 2-17 2-18Electrodialysis 2-18 2-18CHAPTER 3. STEAM BOILER SYSTEMSSection I. General Inform
19、ationBoiler System Defined . 3-1 3-1Components of a Steam Boiler . 3-2 3-1Total Dissolved Solids (TDS) and Alkalinity 3-3 3-2Boiler Blowdown Calculations . 3-4 3-4Determining Feedwater Requirements . 3-5 3-6Determining Makeup Requirements . 3-6 3-7Determining Chemical Treatment Required . 3-7 3-8Sec
20、tion II. Boiler Water Treatment and ControlDeposit Formation 3-8 3-9Problems Caused by Scaling . 3-9 3-10Common Scales Found in Boilers 3-10 3-10Internal Treatment of Boiler Water 3-11 3-10Water Carryover in Steam . 3-12 3-11Removal of Oxygen From Feedwater . 3-13 3-13Condensate Corrosion and Contro
21、l 3-14 3-15Section III. Putting It All TogetherGeneral Information 3-15 3-18Determining Blowdown Required . 3-16 3-18Determining Phosphate Required to Replace Blowdown Loss 3-17 3-20Determining Phosphate Required for Hardness Reaction 3-18 3-21Determining Sodium Hydroxide (Caustic Soda) Required . 3
22、-19 3-23Determining Synthetic Polymer Dosage . 3-20 3-23Determining Sulfite Dosage 3-21 3-23Determining Amine Dosage 3-22 3-24Summary of Required Calculations . 3-23 3-24Section IV. Boiler Layup RequirementsGeneral Information 3-24 3-25Dry Layup. 3-25 3-25Wet Layup. 3-26 3-26CHAPTER 4. COOLING TOWER
23、SSection I. General InformationOpen Recirculating Systems Defined 4-1 4-1Fundamental Parts of a Cooling Tower 4-2 4-1Objective of Cooling Water Treatment . 4-3 4-2Section II. Cooling Tower Operating CalculationsProvided by IHSNot for ResaleNo reproduction or networking permitted without license from
24、 IHS-,-,-iiiParagraph PagePrinciples of Cooling Tower Operations 4-4 4-2Relationship Between Evaporation, Blowdown, and Makeup 4-5 4-4Cycles of Concentration 4-6 4-4Relationship Between Blowdown, Evaporation, and Cyclesof Concentration 4-7 4-6Section III. Deposit Formation and ControlTypes of Deposi
25、ts 4-8 4-6Causes of Scale 4-9 4-6Determining Scaling Limits 4-10 4-8Use of Scaling Indices 4-11 4-9Scale Control . 4-12 4-10Causes of Fouling . 4-13 4-11Fouling Control . 4-14 4-11Section IV. Microbiological Deposits and ControlGeneral Information 4-15 4-11Microbiological Control . 4-16 4-12Legionna
26、ires Disease 4-17 4-13Section V. Corrosion in Cooling SystemsDefinition of Corrosion . 4-18 4-13Corrosion Rates . 4-19 4-15Methods of Corrosion Control 4-20 4-15Section VI. Putting It All TogetherGeneral Information 4-21 4-15Scale Control by Adjusting COC 4-22 4-18Treatment Program for Small Cooling
27、 Towers 4-23 4-18Treatment Programs for Medium and Large Cooling Towers . 4-24 4-18Treatment Chemical Calculations 4-25 4-21Use of Ozone (O 3 ) in Cooling Towers 4-26 4-23What to Look for as a Cooling Tower Operator . 4-27 4-23CHAPTER 5. OTHER INDUSTRIAL WATER SYSTEMSSection I. Hot Water Boiler Syst
28、emsDescription of Hot Water Boilers . 5-1 5-1Description of Hot Water Systems 5-2 5-1Treatment of Hot Water Boiler Systems 5-3 5-1Procedures for Layup of Hot Water Boilers . 5-4 5-4Section II. Chilled Water and Brine SystemsDescription of Systems . 5-5 5-4Treatment for Corrosion Control . 5-6 5-4Det
29、ermining Leaks in the System . 5-7 5-6Section III. Combined Hot and Chilled Water SystemsDescription of Systems . 5-8 5-6Treatment Required . 5-9 5-6Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-ivParagraph PageSection IV. Diesel Engine Jacket Cool
30、ing SystemsGeneral Information 5-10 5-7Treatment Required 5-11 5-7CHAPTER 6. SAMPLING AND TESTING OF INDUSTRIAL WATER SYSTEMSSection I. General InformationRequirement for Sampling and Testing . 6-1 6-1In-Plant Testing 6-2 6-1Section II. Sampling and Testing Cooling TowersMethods of Sampling 6-3 6-1F
31、requency of Samples . 6-4 6-2Testing Requirements 6-5 6-2Section III. Sampling and Testing BoilersMethod of Sampling . 6-6 6-4Frequency of Samples and Testing 6-7 6-4Section IV. Sampling and Testing Other Water SystemsHot and Chilled Circulating Water 6-8 6-7Ion Exchangers and Dealkalizers . 6-9 6-7
32、Section V. Testing ProceduresPurpose of Testing . 6-10 6-7Water Sample Testing Procedures . 6-11 6-9Corrosion Testing . 6-12 6-9Section VI. Interpretation of TestsGeneral Information 6-13 6-9Alkalinity Relationships . 6-14 6-10Hydrogen Ion Concentration (pH) . 6-15 6-12Conductivity and Total Dissolv
33、ed Solids 6-16 6-12Section VII. In-Plant Laboratory RequirementsGeneral Data . 6-17 6-12Laboratory Equipment Recommended 6-18 6-12Chemical Reagents . 6-19 6-13CHAPTER 7. CHEMICAL MIXING, FEEDING, AND CONTROL DEVICESSection I. General InformationChemical Mixing . 7-1 7-1Chemical Feeding . 7-2 7-1Chem
34、ical Control . 7-3 7-2Section II. Chemical Mixing ProceduresDissolving Dry Chemicals 7-4 7-2Diluting Liquid Chemicals 7-5 7-3Changing Concentration in a Tank 7-6 7-3Section III. Feeding DevicesMetering Pumps 7-7 7-4Bypass Feeders 7-8 7-5Slowly Dissolving Chemical Packages . 7-9 7-5Provided by IHSNot
35、 for ResaleNo reproduction or networking permitted without license from IHS-,-,-vParagraph PageEductor Chemical Addition Systems . 7-10 7-5Other Systems 7-11 7-5Section IV. Control DevicesConductivity Control . 7-12 7-5Controlling pH 7-13 7-5Flow Proportioning Control 7-14 7-5Timer Control 7-15 7-5C
36、HAPTER 8. CHEMICAL CLEANINGSection I. General InformationGeneral Guidance . 8-1 8-1Reason for Cleaning . 8-2 8-1Types of Deposits 8-3 8-1Section II. Cleaning ProceduresCleaning Methods 8-4 8-2Hydrochloric (Muriatic) Acid 8-5 8-2Sulfamic Acid . 8-6 8-3Preparation for Cleaning . 8-7 8-4Methods for Rem
37、oving Scale 8-8 8-5Checking Strength of Acid Solution . 8-9 8-6LIST OF APPENDICESAPPENDIX A. REFERENCES A-1APPENDIX B. PRACTICAL (PUCKORIUS) SCALING INDEX (PSI)Development of PSI B-1 B-1Calculating pH of Saturation (pH s ). B-2 B-1Calculating Equilibrium pH (pH eq ). B-3 B-7Scaling Severity Keyed to
38、 Indices . B-4 B-8APPENDIX C. CORROSION TESTING WITH COUPON TYPE TEST SPECIMENSPurpose . C-1 C-1Application C-2 C-1Installation of Coupon Type Test Specimens . C-3 C-2APPENDIX D. CORROSION TESTING WITH TEST NIPPLE ASSEMBLYPurpose . D-1 D-1Application D-2 D-1Installation of Tester . D-3 D-1APPENDIX E
39、. TESTING OF SAMPLES FROM INDUSTRIAL WATER SYSTEMSPurpose of Testing E-1 E-1Use of Portable Test Kits . E-2 E-1Testing Techniques . E-3 E-1Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-viPageAPPENDIX F. INDUSTRIAL WATER TREATMENT CHEMICALS F-1GLOSS
40、ARY. G-1LIST OF TABLESTable No. Title Page2-1. Makeup Water Treatment Methods for Removing Impurities 2-32-2. Guide for Selection of External Treatment Equipment . 2-42-3. Salt Required for Regeneration of a Commonly Used Cation Resin . 2-102-4. Carbon Dioxide Content of Water Versus pH 2-163-1. Tot
41、al Dissolved Solids (TDS) and Conductivity Limits forSteam Boilers . 3-53-2. Silica Levels Allowed in Boiler Water . 3-133-3. Deaerator Water Outlet Temperature for Boiler Systems atVarious Pressures at Sea Level 3-143-4. Levels of Sulfite to be Carried in Boiler Water . 3-153-5. Physical and Chemic
42、al Properties of Neutralizing Amines . 3-163-6. Neutralizing Amine Selection Chart . 3-173-7. Limits on Boiler Water Conditions for an Effective TreatmentProgram . 3-193-8. Phosphate, Caustic, and Polymer Addition Requirements for Boilers 3-224-1. Biocides for Cooling Towers 4-144-2. Assessing Corro
43、sion in Cooling Water Systems 4-174-3. Factors Affecting Corrosion in Cooling Towers 4-174-4. Dosages for Zinc-Phosphonate Program 4-194-5. Dosages for Zinc-Molybdate Program . 4-204-6. Dosages for Phosphonate-Polymer Program . 4-204-7. Treatment Chemicals for Cooling Towers 4-216-1. Sample Frequenc
44、y and Testing Requirements forCooling Tower Systems According to Sources of Samples . 6-26-2. Sample Frequency and Testing Requirements forBoiler Water Systems . 6-86-3. Sample Frequency and Testing Requirements for Other Systems . 6-96-4. Alkalinity Relationship Based on P and M Tests 6-116-5. Rela
45、tionship Between Causticity and pH . 6-136-6. Recommended Testing Frequency for Boiler System Water Samples 6-14B-1 Factor “A“ for Total Dissolved Solids . B-2B-2 Factor “B“ for Temperature . B-3B-3 Factor “C“ for Calcium Hardness (as ppm CaCO 3 ) B-4B-4 Factor “D“ for Alkalinity (as ppm CaCO 3 ) B-
46、6B-5 Equilibrium pH Value (pH eq ) Determined from Total Alkalinity B-8B-6 Scaling Indices Versus Condition . B-9Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-viiLIST OF FIGURESTable No. Title Page2-1. Effects of Treatment on Raw Water . 2-52-2. Ty
47、pical Ion Exchange Unit 2-82-3. Deionization Process 2-122-4. Anion Dealkalization Process 2-142-5. Split Stream Dealkalization Process . 2-152-6. Reverse Osmosis Process . 2-172-7. Photomicrograph of Hollow Fiber Membrane 2-193-1. Simple Steam Boiler . 3-33-2. Example of Boiler Feedwater, Steam Gen
48、eration,and Blowdown Relationships . 3-63-3. Example of Boiler Calculations 3-83-4. Localized Scale Formation Process . 3-93-5. Mist Formation Due to Water Boiling . 3-123-6. Wet Storage Method 3-274-1. Typical Cooling Tower 4-34-2. Simple Cooling System With Makeup and Losses 4-54-3. Effect of Cycles of Concentration on Makeup Requirements 4-74-4. Forms of Corrosion . 4-165-1. Simple Hot Water Boiler System . 5-25-2. Typical Chilled Water System . 5-56-1. Possible
