Drew Marine Division

SHIPBOARD WATER
TREATMENT MANUAL
4.1 Edition

ENGINE EVAPORATOR/ BOILER EXHAUST

COOLING DISTILLER SYSTEM SYSTEM
SYSTEM SYSTEM

TM-WT-1 (11/01)R7
 SHIPBOARD WATER
TREATMENT MANUAL
4.1 EDITION
 Marine Chemical Products
BOILER WATER TREATMENT
ADJUNCT® B phosphate boiler water treatment
AGK® 100 boiler and feedwater treatment
AMERZINE® corrosion inhibitor
CATALYZED SULFITETM corrosion inhibitor
DREWTM BWT-3 boiler water treatment
DREW BWT-4 boiler water treatment
GCTM concentrated alkaline liquid
SLCC-ATM condensate corrosion inhibitor
LIQUID COAGULANTTM boiler sludge conditioner
PERFORMANCE BOILER WATER TREATMENT
DREWPLEX® AT boiler water treatment
DREWPLEX OX corrosion inhibitor
EVAPORATOR TREATMENT
AMEROYAL® evaporator treatment
AMEROYAL® CF concentrated evaporator treatment
AMEROYAL CF/HG concentrated evaporator treatment
COOLING WATER TREATMENT
AMERSPERSE® 280 seawater cooling treatment
DEWT® NC diesel engine water treatment
DREWSPERSE® SWD seawater dispersant
FERROFILM® corrosion and erosion inhibitor
MAXIGARD® diesel engine water treatment
LIQUIDEWTTM cooling water treatment
FUEL ADDITIVES
AMERGIZE® deposit modifier/combustion improver
AMERGY® 222 fuel oil conditioner
AMERGY 1000 combustion improver
AMERGY 5000 combustion improver
AMERGY 5800 PLUS deposit modifier/combustion improver
AMERSTAT® 25 microbiocide fuel treatment
DREWCLEAN® EST economizer soot treatment
F.O.T.TM fuel oil treatment
LT SOOT RELEASETM low temperature soot remover
SOOT RELEASETM soot combustion catalyst
MAINTENANCE CHEMICALS
ACC-9TM air cooler cleaner
ACC/ME® air cooler cleaner
AMEROID® DC disc cleaner
AMEROID® OSC one-step cleaner
AMEROID® OWS quick separating degreaser
AMEROID® RSR rust stain remover
CARBON REMOVERTM solvent cleaner
CILTM corrosion inhibitor
DESCALE-ITTM liquid acid descaler
DREW FC filter cleaner
DREWCLEAN EOSD enviro oil spill dispersant
ENVIROMATE® 2000 general purpose cleaner
MAINTENANCE CHEMICALS (cont'd)
FERROCLEAN® cleaning agent
HDE-777TM heavy duty emulsifier
NEVAMELTTM wire rope conditioner
O&GRTM oil and grease remover
OSD/LTTM oil spill dispersant
SAF-ACIDTM descaling compound
ENVIRONMENTAL CHEMICALS
DREW ELECTRICTM 2000 motor and parts cleaner
DREWCLEAN 2000 quick breaking degreaser
SNCTM 2000 carbon remover
SANITATION PRODUCTS
AMEROID® MSD-PAK organic waste treatment
BIOTAL1 MDS 2000 shipboard waste treatment
BIOTAL MDS 2000C shipboard waste systems
treatment concentrate
TANK CLEANERS
DREW ABD alkaline based degreaser
DREW AF air freshener
DREW BC buffering cleaner
DREW CTC coal tar cleaner
DREW LPA liquid pickling agent
DREW NBD neutral based degreaser
DREW PL passivating liquid
DREW TC SEA tank cleaner
EDGE® heavy duty cleaner
LACTM liquid alkaline cleaner
TC#4TM tank cleaner
SPECIALTY PRODUCTS
MUD CONDITIONERTM ballast tank water treatment
TECHNICAL PRODUCTS
DREWFRESH® 2000 heavy duty cleaner
CORROSION COATINGS
DREWTANTM RC rust converter
DREW PD anticorrosion coating
MAGNAKOTE® rust preventative
MAGNAKOTE PLUS rust preventative
MISCELLANEOUS
MOTORGARDTM total motor vessel protection program
ULTRAMARINESM water treatment program
 FOREWORD

This manual is intended for use by persons who are
concerned with the chemical testing, dosing, and control
of a shipboard water treatment program. Included are
explanations of why water treatment is required and a
description of the methods used in modern marine prac-
tice. The purpose and application of each of the Drew
Marine water treatment chemicals is explained. This
edition has been updated to include the newest treat-
ments and tests in our line.
The power plants of modern steam and motor vessels are
more efficient today than at any other time in history.
Boilers and diesel engines are designed to extract the
greatest possible amount of energy from the fuel and to
turn that energy into work. Turbines, generators and
auxiliary equipment are designed to make the most effec-
tive use of the steam or mechanical energy that is supplied
to them. Efficient operation of the marine power plant
depends significantly on the quality of the water that it
receives. Contaminants such as dissolved minerals, gases,
oil, and even the water itself can cause serious damage to
power plant equipment unless proper control steps are
taken.
Testing is an important part of any water treatment pro-
gram because the test results are the primary means of
controlling the program and of detecting problems. All test
procedures are described in this manual after discussion
of the applicable treatment program. We refer the reader
to the section entitled "General Information" which should
be read before conducting tests. Here, recommendations
are provided for proper sampling, general testing and
recording techniques.

CREDITS FOR ILLUSTRATIONS

We wish to acknowledge the sources of some of the illustrations used in this manual.

Reference Page(s)

CHEMetrics, Inc., Calverton, VA

46, 48, 49, 55, 56, 57, 58, 63
MARINE ENGINEERING, Roy L. Harrington, ed.,
The Society of Naval Architects and Marine Engineers, NY, NY 1971 12

Nirex, Alfa-Laval Group, Fort Lee, NJ 13

Riley-Beaird, Inc., Shreveport, LA 12, 13

i
 Table of Contents

FOREWARD ................................................................................................................... i

GENERAL INFORMATION ............................................................................................. 1

• Introduction ............................................................................................................ 1
• Water Sampling Procedures .................................................................................. 2
• Analytical Techniques ............................................................................................ 4
• Expression of Chemical Results ............................................................................ 7

BOILER WATER SYSTEMS AND TREATMENT ............................................................ 9

• Introduction ............................................................................................................ 9
• Production of High Quality Distillate ....................................................................... 10
• Boiler Water System Circulation ............................................................................ 14
• Corrosion of Metals ................................................................................................ 16
• Chemical Treatment ............................................................................................... 19
• Composition and Formulation of Deposits .............................................................. 21
• Special Operating Conditions ................................................................................. 24
• Boiler Water Treatment Chemicals ........................................................................ 25
• Boiler Water Treatment Chemical Applications and Controls ................................. 26
• Introduction to Water Treatment Control Tests ...................................................... 34
Alkalinity:
• Hydrate (AGK® 100 and DREWPLEX® AT) ......................................................... 35
• Medium to Low Pressure .................................................................................... 36
• High Pressure ..................................................................................................... 37
• Conversion Table (high, medium and low pressure) ........................................... 38
Ammonia (condensate, high pressure) .................................................................. 39
Chloride:
• HP Test Kit ......................................................................................................... 40
• Mercuric Nitrate Burette Titration ........................................................................ 41
• LMP Test Kit ....................................................................................................... 42
• Silver Nitrate Burette Titration ............................................................................. 43
• Conversion Table (high, medium and low pressure) ........................................... 44
Conductivity (all pressures) .................................................................................... 45
DEHA/DREWPLEX OX corrosion inhibitor Ampoule Test ...................................... 46
Hardness:
• Ampoule Method (high pressure) ........................................................................ 47
• Titret2 method ..................................................................................................... 48
HYDRAZINE/AMERZINE:
• (High to low pressure) ......................................................................................... 49
pH:
• Colormetric (high pressure boilers) ..................................................................... 50
• Meter (high pressure boilers) .............................................................................. 51
• Condensate (AGK 100 and DREWPLEX AT) ..................................................... 52
• Condensate (standard treatment) ....................................................................... 53
• Condensate (high pressure) ............................................................................... 54

ii
 Phosphate:
• (High Pressure) .................................................................................................. 55
• (Medium to low pressure) ................................................................................... 56
Silica (high pressure) ............................................................................................. 57
Sulfite (medium to low pressure) ............................................................................ 58

COOLING WATER SYSTEMS AND TREATMENT ......................................................... 59

• Introduction ............................................................................................................ 59
• Cooling Water System Circulation .......................................................................... 59
• Corrosion of Metals ................................................................................................ 60
• Composition and Formation of Deposits ................................................................ 61
• Cooling Water Treatment Chemicals ..................................................................... 62
• Cooling Water Treatment Chemical Applications and Controls .............................. 62
• Cooling Water Treatment Control Tests
and Dosage Requirements ................................................................................. 62
CWT Test (Titret2 Method) ...................................................................................... 63
DEWT® NC ............................................................................................................ 64-65
Reference Tests:
Chloride (treated water) ...................................................................................... 42
Chloride Sample Pretreatment ......................................................................... 66
Hardness ............................................................................................................ 47

iii
 GENERAL INFORMATION
INTRODUCTION

Proper testing techniques are necessary to assure a well using the correct units of mass, volume and concentration
controlled water treatment program. This section describes measurements, a section entitled "Expression of Chemical
the best methods for obtaining water samples and conduct- Results" has been included for your reference.
ing chemical tests. Because test results must be recorded

PROPER RECORD KEEPING

An important part of an analytical program is the keeping of
legible and accurate logs. Complete information is essential
for an accurate evaluation of the progress of the treatment
program. When recording the test data, remember the
following pertinent points:
• Use the proper Onboard Graphing Logs for the system
being treated.
• Record all information legibly.
• Distribute copies to Drew's Technical Department, owner's
office and ship's records as indicated in the instructions on
the log. All Drew Onboard Graphing Logs are printed on
NCR paper so that carbon paper is not needed.
• Record test results and treatment dosages, marking
proper units of measurement on the Onboard Graphing
Log. The colored band will indicate the satisfactory range
for each control test. Reference test results should be
recorded in the appropriate boxes.
IMPORTANT: Decimal points must be placed correctly to
eliminate misunderstandings and inaccurate evaluations.
• Any additional relevant information relating to the condi-
tion of the vessel, the equipment being treated, or the
treatment program should be recorded in the appropriate
space.

• Fill in all required information to identify the ship, the ship's

operating company, the voyage number, the equipment
being tested, the date of the the review period, the boiler
type and pressure, and inport or full steaming conditions.

EXPRESSION OF CHEMICAL DOSAGES

CONVERSIONS (M = METRIC, E = English)*

UNITS MEASUREMENT SYMBOL MULTIPLY BY TO FIND SYMBOL

MASS (weight)

M to M kilogram kg 1000 gram gm

M to M gram gm 1000 milligram mg
E to E pound lb 16 ounce oz
M to E gram gm 0.035 ounce oz
M to E kilogram kg 2.2 pound lb
E to M ounce oz 28 gram gm
E to M pound lb 0.45 kilogram kg

VOLUME

M to M liter ltr 1000 milliliter ml

E to E cup c 8 fluid ounce fl oz
E to E pint pt 2 cup c
E to E quart qt 2 pint pt
E to E gallon gal 4 quart qt
M to E milliliter ml 0.03 fluid ounce fl oz
M to E liter ltr 2.1 pint pt
M to E liter ltr 1.06 quart qt
M to E liter ltr 0.26 gallon gal
E to M fluid ounce fl oz 30 milliliter ml
E to M cup c 0.24 liter ltr
E to M pint pt 0.47 liter ltr
E to M quart qt 0.95 liter ltr
E to M gallon gal 3.785 liter ltr

*NOTE: The U.S. version of the English units is used in these calculations.

1
 WATER SAMPLING PROCEDURES
The main purposes of routine water testing are:
1. To ensure that the proper residuals of treatment chemi-
cals are maintained at all times.
2. To detect the presence of contaminants in the water that
may be injurious to the boiler, diesel engine, and other
equipment.
Test results are meaningful and useful only when the samples
tested are representative of the water in the system at the
time of testing. Recommended procedures for obtaining
representative samples of boiler water, condensate, makeup
water, feedwater, and cooling water circuits are discussed in
the following sections.
RECOMMENDED LOCATION
FOR SAMPLING CONNECTIONS
Boiler Water Sampling
Normally you can use the sampling connections provided by
the boiler manufacturer. The sampling line is usually located
in the steam drum, just above the generating tubes. In order
to get proper results, it should be as far as possible from the
internal feedwater line and the chemical feed line.
Samples drawn for routine boiler water tests should be tested
ONBOARD THE VESSEL. Boiler water samples for labora-
tory analysis should be taken only in special cases. Boiler
water samples are not normally submitted for iron and
copper analyses since results are not representative of the
corrosion rate in the system. This is because of the boiler
water alkalinity conditions and the tendency to collect iron
and copper deposits from other parts of the system than in
the boiler.
Condensate and Feedwater Sampling
Stainless steel sampling lines should be installed at three
locations:
• Directly after the Main Condensate Extraction Pump. This
line is to be used when the plant is under normal steaming
conditions.
• Directly after the Auxiliary Condensate Extraction Pump.
This line should be used only when the plant is under port
operating conditions.
• The deaerator outlet line or from the suction or discharge
of the main feedwater pump.
The latter is the best position for samples drawn for iron and
copper tests; these samples will give a direct indication of the
amounts of metal oxides entering the boiler with the feedwater.
These connections may be used for obtaining samples for
dissolved oxygen tests if they are ever required.
On motor vessels or for LPSG's, condensate samples should
be taken after the condensor or condensate cooler and
before the feed or cascade tank to avoid recirculation from
the feed pump. See page 31.
2
Makeup Water Sampling
The sampling line for this water may be located in one or two
positions:
• In the line between the distilled water storage tank and the
point of entrance of makeup water to the condensate
system.
• Directly from the distillate condenser.
SAMPLING EQUIPMENT
Before testing, boiler water, hot condensate and feedwater
samples must be cooled to 25OC (77OF) by collecting through
a sample cooler for safety and to prevent flashing which
concentrates the sample. Stainless steel sample coolers
should be used except where seawater is used for cooling.
Where seawater is the only coolant, contact your Drew
Marine representative for proper handling procedures or a
special coil.
Stainless steel piping or tubing used for sample lines should
be installed with the least possible number of fittings and/or
sharp bends. This is a precaution against plugging the lines
with solid contaminants. The stainless steel sampling lines
must meet international pressure code requirements. Tubing
size should be 1.0 cm (3/8 in.) O.D.; nominal pipe size should
be 1.0 cm or 1.27cm (3/8 in. or 1/2 in.). Stainless steel is
recommended to prevent contamination of sample by corro-
sion from the lines.
OBTAINING SAMPLES FOR SHIPBOARD TESTS
1. Allow the sample stream to run for 5-10 minutes in order
to thoroughly flush out the line before taking a sample for
testing.
2. A convenient and desirable procedure is to open the
sample valve and allow the stream to run throughout the
testing period. Appropriate samples for each individual
test may be taken from the sample stream as needed.
Test equipment, graduated cylinders, evaporating dishes,
etc., should be clean and rinsed with the water to be
tested and thoroughly drained.
3. If analysis of a sample must be delayed for any reason,
the sample should be kept tightly capped in a clean
sample bottle which has been thoroughly rinsed with
water from the sample stream. After a long delay,
resample. Test results for pH, alkalinity, hydrazine,
sulfite or ammonia will be less accurate if testing is
delayed because of the effect of air on these treatments.
OBTAINING SAMPLES FOR
LABORATORY TESTING
The following special procedures are to be followed when
obtaining samples for testing at shoreside laboratories:
1. A boiler water sample for laboratory analysis should be
collected in a glass bottle. Minimum sample volume for
boiler water analysis is 1,000 ml (one U.S. quart).
2. Condensate and feedwater samples for iron and copper
analyses must be collected in special high purity plastic
bottles. The minimum sample volume required for iron
and copper analyses is 120 ml (4 oz.)
4. Draw samples while boilers are operating under full or
normal steaming conditions.
5. Flush the sample line for 5-10 minutes prior to obtaining
a sample for testing. Flush for a longer time if the line is
rarely used.
6. The sample container should be thoroughly rinsed with
the water being tested and completely filled to overflowing
so there will be no air space at the top of the sample bottle.
However, if there is a danger of freezing, leave some
freeboard in the bottle for expansion; otherwise, the bottle
will burst. Tightly seal and properly label the sample bottle
with the following information: vessel name, source of the
sample, date of sampling, and information which de-
scribes the reason for sampling and any existing prob-
lems. This information is essential in order to determine
what tests should be conducted and in the evaluation of
results.
Request for Analysis Forms
In addition, fill in the line(s) that ask for sample identification
(e.g., Port boiler water, Main engine jacket cooling, etc.)
Check the box that is appropriate for the sample:
MBW - Boiler water analysis
MCW - Cooling water analysis
MBAL - Ballast water analysis
MPD - Boiler deposit sample analysis
MCD - Cooling deposit sample analysis
MFD - Fireside deposit analysis
MHP - High purity feed and/or condensate analysis
In Sections I through IV, please fill out the particulars of the
equipment, symptom of the problem, if applicable, and
anything else that can help us in interpreting the analysis
results.
Reports will be issued to the Account Executive responsible
for your owner or manager. Distribution of these reports will
be left to the discretion of your owner or manager.

In order to assure that the samples you are taking are

analyzed promptly, Drew Marine has developed ISO 9002
forms that accompany the Sample Paks. The instructions for
filling out the form follow:

Please print clearly the following information in the space

provided:

• Vessel Name
• Owner or Manager Name
• Date Sample was drawn or collected
• Date Sample was landed to be sent to Laboratory
• Port where Sample was landed

3
 ANALYTICAL TECHNIQUES

Accurate analytical testing procedures are essential for READING CALIBRATED GLASSWARE
proper control of chemical treatment programs. This section
briefly describes the basic information common to all treat-
ment programs and the procedures which should be fol-
When filling or reading liquid
lowed for each of the analytical control tests. levels in calibrated glassware
Meniscus
such as burettes and graduated
PREVENT CONTAMINATION Line of cylinders, read the level where
AND STORE REAGENTS PROPERLY Measurement the bottom of the concave liquid
surfaces reaches the line of
measurement. The concave
To ensure accurate test results, the analyst should take the surface of a water solution is
necessary precautions to prevent contamination of the test-
Calibrated called the meniscus.
ing equipment before, during and after each test. It is Glassware
imperative to have clean hands, a clean working surface,
and, most important, clean test equipment and uncontami-
nated reagents within their normal shelf life. BURETTE TITRATION

CARE OF REAGENTS Proper titration technique is important to assure accurate test

Reagents by their nature are reactive. Care must be taken to
prevent contamination and deterioration.Closeall reagent
bottles tightly with their original stoppers or caps. Use sepa-
rate clean, dry spoons or droppers for each reagent to
prevent cross-contamination of reagents. Never return ex-
cess reagent solution or powder to storage bottles.
results. The titrating solution should be slowly added to the
sample while stirring until the desired endpoint is reached.
Addition of titrant should be slowed to one drop at a time as
the endpoint approaches to avoid overshooting the endpoint.
The approaching endpoint is signaled by temporary color
change where the titrant enters the sample. The first perma-
nent color change throughout the sample is the endpoint.

To ensure freshness, periodically replace reagents. Store MEASURING SPOON

spare chemical supplies in a clean, cool cabinet, preferably
outside of hot, humid areas. Air-conditioned rooms are a
good environment for reagents. Powdered reagents can
absorb moisture if stored in refrigerators so storage in an air-
conditioned area is preferable.
Some reagents are light sensitive so it is a good general rule
to store them in the original bottles in which they are supplied
in closed closets.
The brass measuring spoon has been specially selected to
make the addition of reagent easy. It is used for delivering a
specified amount of reagent to a cooling water sample when
running the DEWT® NC test procedure. It is also used for
adding Gallic Acid to neutralize boiler water when testing
conductivity.

USE OF COLORIMETRIC EQUIPMENT

Code: 0224-01-4
For accurate results using the color comparator slides, the
path of light through the viewing tubes must be free of dirt or Description: Measuring Spoon, Brass
other obstructions. Before inserting the viewing tubes into the
comparator, gently tap the tubes against the palm of your
hand to dislodge any gas bubbles from the test solution.
Clean the outer surface of each tube to remove water
droplets and fingerprints. The outside surface of the com-
parator slide and color standards should also be clean.

There should be sufficient lighting behind the comparator

when running the test to obtain accurate color comparison
and uniform results. Daylight fluorescent light is preferred.

4
WATER ANALYZER BASE 6. Move the slide back and forth, while observing the
GENERAL INSTRUCTIONS colored ovals that will appear in the mirror. Continue
until the color of the middle oval matches that of one of
the side ovals. Note that the comparison can be made
The Water Analyzer is used to determine boiler pH in the only when one of the arrows on the slide is opposite the
ULTRAMARINESM program. middle tube.

The Water Analyzer consists of a base structure (A), three 7. When a color comparison is obtained, read the test
glass tubes (B)(C)(D), and one or more comparator slides (E) result (in pH) from the numbers on the slide.
fitted with transparent color standards (F). The tubes are
modified "Nessler" tubes, and each has an etched mark (G)
at 150 mm or 250 mm above the bottom. The base has a
compartmented holder (H) for the tubes, which supports
them at a 45O angle above a mirror (J) set into the base. The
slides move in a slot in the base (K) above the mirror and
beneath the tubes.

USE OF THE WATER ANALYZER

1. Set the appropriate comparator slide for the desired test
in the slot in the base. The row of numbers on the slide
(corresponding to pH values, ppm silica or ammonia,
etc.) should be visible when the slide is viewed from
above the mirror.

2. Fill the two outer tubes (B & D) to the etched mark with
reference blanks according to the instructions for the
particular test. Place these tubes in the two outer
compartments in the base.

3. Add reagent chemicals to another portion of the sample,

according to the instructions for the particular test.

4. Fill the middle tube (C) to the etched mark with the
treated sample and place it in the middle compartment
in the base.

5. Set the base on a flat surface so that the mirror faces the
operator and a light shines into the open ends of the
tubes.

5
FILTER PAPER

Filtration is required in some test procedures. This is es- Some filter papers are specially prepared to minimize
pecially true if suspended solids appear in the sample. contaminanats. (Drew specifies a Whatman #5 filter paper).
Failure to filter a sample when required or the repeated use
of the same filter will result in an incorrect value. There is one The most simple technique for folding filter paper is:
exception to this rule. If a sample remains cloudy after the first
filtering, the sample should be refiltered through the same
filter paper since the filter becomes more retentive on the
second filtration.

Fold the paper in half (Step 1) and

then in half again (Step 2).

Step 1

Step 2

Step 3
Pull three-quarters of the paper
to one side and crease to hold
the cone shape (Step 3). Insert the
tip of the cone into the funnel (Step
4).

Step 4

Pour the sample into the center of the cone. Do not fill the
funnel above the upper surface edge of the filter paper.
Sample which flows between the paper and funnel will add
unwanted materials to the filtered sample.

6
 EXPRESSION OF CHEMICAL RESULTS
REPORTING OF QUANTITY
When reporting the results of an analysis, it is necessary to
express the quantity of each constituent that is determined.
In the analysis of most materials, the quantity of each
constituent is given in terms of percent--the amount of each
constituent per 100 parts of the material. For example, an
analysis of a metallic sample may show 60 percent copper
which would mean that every 100 parts of the sample contain
60 parts of copper.
Reporting by percent is not practical in water analysis since
the amounts of the materials determined are extremely
small. For example, the silica content of natural waters, if
expressed in percent, would be in the range from 0.0001%
to 0.01%. To avoid the use of very small numbers, the terms
"parts per million" (ppm) and "parts per billion" (ppb) are used
in water analysis. The terms ppm and ppb are utilized by
Drew Marine in its publications and reports.
Parts Per Million (ppm)
One part per million (ppm) is an expression of the relationship
of one part of a substance to one million parts of another. As
examples, if a water contains one ppm of silica, there would
be one part of silica in 1,000,000 parts of the sample. In a
1 gram silica
1,000,000 grams (1 metric ton) = 1 ppm silica
million grams (1 metric tonne) of this water, there would be
one gram of silica; or in a million pounds of water, there
would be one pound of silica. Expressing results in terms of
parts per million is a simple method to use, and for most
determinations, the results are given in whole numbers.
Parts Per Billion (ppb)
One part per billion (ppb) is used to express the relationship
of one part of a known substance to one billion parts of
another. For example, a sample of water may contain one
part of silica to one billion (1,000,000,000) parts of water. As
indicated above for "ppm", "ppb" may be applied to quanti-
ties expressed in any unit of measure.
Values below 7.0 are increasingly acidic, and those above
7.0 are increasingly alkaline. In common practice, pH can be
determined by electrical instruments, color indicators, or
specially treated test paper.
Alkalinity is defined as the state of being alkaline or "basic".
The alkalinity is determined by the concentrations of hydrox-
ide, carbonate, and certain other chemicals, such as phos-
phate and silicate.
Phenolphthalein ("P") Alkalinity is a measure of the alkalinity
above a pH of 8.2-8.3. All of the hydroxide, one-half of the
carbonate, and one-third of the phosphate, plus all other
alkali-producing materials present in a water sample such as
silicate are included in the Phenolphthalein Alkalinity.
Total ("T") Alkalinity is a measure of the alkalinity above a pH
of 4.2-4.3. All of the hydroxide, all of the carbonate, and two-
thirds of the phosphates, plus all other alkali materials are
included in the Total Alkalinity.
REPORTING OF DISSOLVED SOLIDS
CONCENTRATION AS CONDUCTIVITY
In boiler water, dissolved salts consist of contaminants,
treatment chemicals, and naturally occurring chemical con-
stituents. Dissolved salts ionize and conduct an electric
current. The amount of current that a water sample carries
from one electrode to another at a specific temperature is
termed its conductivity. The concentration of ionized dis-
solved solids in any water is proportional to its electrical
conductance. For example, distilled water has a very low
conductivity; in contrast, seawater has a very high conduc-
tivity. Therefore, the amount of dissolved solids can be
estimated by the water's conductivity. A conductivity meter,
which records conductance in micromhos (µmhos), is used
to measure this characteristic of the water.

REPORTING OF pH
Acidity, Neutrality, Alkalinity

An aqueous solution can be either acidic, neutral or alkaline.

The accepted manner of expressing this condition is pH. pH
is the reciprocal of the logarithm of the hydrogen ion (H+)
concentration in solution, -log[H+] on a scale of 0 to 14. The
midpoint pH at 7.0 is considered "neutral".

7
(Neutralization is required before testing the conductivity of
boiler water samples because strong bases (or strong acids)
conduct more than a proportional amount of electricity)
based on their actual solids concentration, giving a false high
reading.
Dilution of a sample should always be done with distilled
water. If a sample is diluted, the test result must be
multiplied by the appropriate factor. Examples follow:
EXAMPLE: Phosphate Test

The sample should be a cooled sample, its temperature 1.Draw a 25 ml sample of water.
taken and the temperature compensation dial on the meter,
if there is one, should be properly set before taking the 2.Dilute sample with 25 ml of distilled water.
conductivity reading. (Total volume = 50 ml)

DILUTION OF WATER SAMPLES 3.Conduct phosphate test. (Result = 45 ppm phosphate)

There are two conditions under which dilution of a sample 4.Multiply test result by a factor of 2. (45 ppm x 2 = 90 ppm
may be necessary: phosphate)

• When a sample is highly colored, even after filtration, which
would make it impossible to determine a colorimetric end
point.
• When the initial test result is exceedingly high or beyond
the normal range of the test procedure.
5.Final test result = 90 ppm phosphate
*Avoid dilution of a sample when testing for an oxygen
scavenger. When testing for oxygen scavenger, the water
used to dilute the sample should be deoxygenated.

The following dilution and multiplication factors can be used for any sample. The accuracy of the result, however, is dependent
upon the care taken in making the dilution.

MULTIPLE TEST
DISTILLED WATER RESULT BY
WATER SAMPLE + DILUTION = TOTAL VOLUME FACTOR OF:

25 ml 25 ml 50 ml 2
50 ml 50 ml 100 ml 2
10 ml 40 ml 50 ml 5
20 ml 80 ml 100 ml 5
10 ml 90 ml 100 ml 10

8
 BOILER WATER SYSTEMS AND TREATMENT
INTRODUCTION
A boiler converts the chemical energy in fuel to heat energy
in steam for the purpose of doing work. There are many types
of boiler plants, but all of them function on the same basic
principles of thermodynamics. A complete discussion of
either plant design or thermodynamics is beyond the scope
of this presentation. However, some basic concepts will be
presented here to introduce the systems which we will
discuss in the sections below.
In the world fleets today, we see some ships which operate
boilers for propulsion (some at pressures over 60 kg/cm2,
(850 psig) and motor vessels equipped with auxiliary oil-fired
and waste heat boilers which operate at lower pressure
levels (7-24 kg/cm2, 100-350 psig).
All boilers operate on the common premise that heat is
transferred to water to create steam which is then used to do
work onboard. Diesel engines depend on scale-free heat
transfer surfaces for cooling. They share common problems
of scale formation and corrosion, although some forms of
corrosion will be more evident in high pressure boilers and
others are more often seen in engines.
The water used onboard, for whatever purpose, comes
primarily from the sea. In order for seawater to be safely used
for steam production, the salts and other contaminants must
be removed from the water. An evaporator or distiller is
generally installed for the purpose of purifying the water until
it contains only trace levels of minerals. Seawater also
9
contains dissolved gases which have been absorbed from
the air or formed by decaying organic matter. They can be
mechanically removed by deaeration, thermally reduced by
increased feedwater temperature and/or chemically scav-
enged.
An effective water treatment program minimizes scale and
corrosion in the boiler system. Since distillation and
mechanical/thermal deaeration cannot remove all of the
contaminants, routine chemical treatment programs are
necessary for the efficient maintenance of all steam gener-
ating and cooling system equipment.
The primary goals of a controlled water treatment program in
any power generating plant are:
• To maintain clean, scale-free waterside heat transfer
surfaces in steam generating and cooling water systems.
• To prevent metal loss due to corrosion.
• To ensure efficient production of steam in boiler systems
without priming, foaming, or carryover contamination.
• To prevent formation of deposits in steam/condensate
systems.
• To minimize heat loss from the system due to excessive
blowdown from boilers.
• To keep all power generating and auxiliary equipment, and
associated water and steam systems at their most efficient
levels and thereby minimize costs.
 PRODUCTION OF HIGH QUALITY DISTILLATE

The water used on ships, for whatever purpose, comes
primarily from the sea. In order for seawater to be used for
steam production, the salts and other contaminants must be
separated from the water to minimize scale formation and
corrosion in boiler water and steam circuits. Mechanical and
chemical technology is used in combination to do both. This
section will discuss the production of high quality water,
corrosion and scale mechanisms, mechanical and chemical
corrections for these conditions before moving on to the test
procedures used to control the chemical treatments and
monitor the contamination.
Distillation, ion exchange, and reverse osmosis (RO) are
processes which may be used for the desalination of seawa-
ter. In the marine industry, distillation is the most widely used
method because of its relative simplicity and cost effective-
ness. Brief descriptions of the other methods follow.
Ion exchange: Cation ion exchange units will effectively
remove hardness constituents (calcium and magnesium)
from water but not the anions, i.e., chloride and sulfate ions
or other contaminants. The extremely high concentrations of
the salts in seawater pose a challenge to these units. The
most common ion exchange units must be regenerated with
sodium chloride brines which can contribute chloride ions to
the contamination. Ion exchange resin beds must be de-
signed in such a way to prevent channels which will allow
water to flow through untreated.
Reverse osmosis is an effective means of desalination.
However, a single pass unit will not produce water of suffi-
cient quality for use in marine systems and further deminer-
alization is necessary. A number of units in series could
theoretically produce an effluence of acceptable quality and
quantity for boiler feedwater.
The normal process of osmosis involves two solutions of
different dissolved solids concentration that are in a single
container, separated by a semipermeable membrane. The
common solvent in both solutions is water. The water flows
from the more dilute solution through the membrane to the
more concentrated solution. In time, the equalizing effect
creates equal dissolved solids concentration in both com-
partments.

SOLUTION WILL RISE TO THIS

POINT WHICH IS HEAD EQUAL
TO APPARENT OSMOTIC PRES-
SURE

SEMI-PERMEABLE
MEMBRANE

MORE LESS
CONCENTRATED CONCENTRATED
SOLUTION SOLUTION

WATER FLOW

OSMOSIS

PRESSURE

SEMI-PERMEABLE
MEMBRANE

MORE LESS
CONCENTRATED CONCENTRATED
SOLUTION SOLUTION

WATER FLOW

REVERSE OSMOSIS

10
The reverse osmosis process is created when pressure is
exerted upon the more concentrated solution so that the
water flows in the reverse direction through the semiperme-
able membrane from the concentrated side to the dilute side,
leaving the majority of the dissolved solids behind.
When reverse osmosis is used to produce fresh water from
seawater, a reverse osmotic pressure is created to force the
water from the brine (seawater side) into the fresh water
compartment. Theoretically, the only energy required is that
which is needed to overcome the osmotic pressure and
pump the feed water. In practice, much higher pressure
(between 60-70 kg/cm2, 850-1000 psig) are required to
produce useful volumes of water per unit area of membrane.
Generally, the reverse osmosis process is not as widely used
onboard ship as distillation.
DISTILLATION (EVAPORATION PROCESS)
A marine evaporator is normally used to provide high quality
distillate from seawater for the vessel's water systems. There
are many types of evaporators, but they are all designed for
the same purpose. Hot cooling water or auxiliary steam is
often used as a heat source increasing cost effectiveness.
In some type of evaporators, seawater is heated or flows over
a series of coils or tubes through which auxiliary steam is
passed. Heat is transferred to the seawater under vacuum,
vaporizing a major portion of the water. The resulting vapor
is scrubbed by a mist eliminator as it leaves the evaporator
unit to remove entrained moisture which contains a small
amount of dissolved solids.
The vapor is then cooled in a condenser to produce pure
distillate. It is pumped to storage tanks for use as boiler water
makeup, engine cooling water, potable water and other
domestic purposes.
The majority of dissolved solids are left behind, accumulated
and concentrated in the brine section of the unit for overboard
discharge. The purified water now contains only traces of
minerals which can be easily handled with boiler and cooling
water treatment chemicals.
Evaporator Scaling
During the evaporation process, the solubility of most of the
dissolved minerals, which remain in the evaporator brine, is
exceeded and precipitation occurs, forming scale deposits
on heat transfer surfaces. The three most common scales
formed in an evaporator are calcium sulfate, calcium carbon-
ate, and magnesium hydroxide. These are effecient heat
transfer barriers. Reduced heat transfer results in reduced
water production. Eventually, distillers must be shut down
and cleaned to remove the insulating scale.
Evaporator Foaming and Carryover
The higher concentration of dissolved solids in the brine
increases the surface tension of the water, acting like an
elastic skin at the water level. The increased surface tension
hinders the release of vapor bubbles and gases and pro-
motes foaming.
11
When the bubbles burst, droplets containing concentrated
salts are thrown into the vapor space and are carried over into
the distillate. This results in reduced water quality.
Foaming also may be caused by "organic" substances in the
water, which are formed by the decay of organic materials or
contamination with petroleum products.
Mechanical Control
Foaming and carryover from evaporators can be minimized
by proper management of the water level and salinity (brine)
control.
• Improper water level control is often due to the malfunction
of the automatic controls and alarms. Automatic equip-
ment and alarms should be maintained in good operating
condition.
• Salinity control is an important factor in the prevention of
scale deposits as well as carryover. Salinity management
refers to the continuous removal of concentrated brine
from the evaporator in order to control the amount of
dissolved solids buildup. Normally the brine concentration
should be maintained at 1.5 (1.5/32nds) concentrations,
although some vapor compression units operate at 2.0
(2.0/32nds) concentrations or more.
Chemical Treatment
The problems of scale formation and foaming can be mini-
mized by the addition of chemical treatments containing
polymeric scale inhibitors and antifoams. The polymer mol-
ecules attach themselves to the scale-forming minerals to
disrupt the densely packed crystalline structure. This pre-
vents hard scale from building up on the heat transfer
surfaces. Instead, nonadherent, suspended crystals are
formed which will easily flow overboard with the brine dis-
charge.
Polymer treatments can remove existing scale from heat
transfer surfaces by the same action. If treatment is used,
water production can be maintained, and acid cleaning to
remove scale can be minimized.
Modern formulations include an antifoam ingredient which
reduces the surface tension of the water and allows vapor to
escape without the formation of foam. This helps to maintain
water quality.
Drew Evaporator Treatments
AMEROYAL® evaporator treatment is a liquid combination of
an active polymer with a highly effective antifoam agent. It is
effective in seawater and brackish water. The antiform agent
in AMEROYAL treatment reduces surface tension and,
thereby, prevents foaming and carryover. AMEROYAL treat-
ment is the most widely used evaporator treatment in the
marine industry.
AMEROYAL CF concentrated evaporator treatment is a
concentrated liquid formulation of active polymers and
antifoam agents developed specifically to prevent scale
deposition and carryover in high temperature, high produc-
tion multi-stage evaporators. AMEROYAL CF treatment has
been proven capable of significantly reducing the amount of
acid cleaning required to maintain design distillate produc-
tion.
EXAMPLES OF EVAPORATOR UNITS

LOW-PRESSURE SUBMERGED
HEATING ELEMENT DISTILLER
AMEROYAL

VAPOR-COMPRESSION DISTILLER

AMEROYAL CF

12
 TWO-STAGE VACUUM-FLASH DISTILLER
AMEROYAL

Air Ejectors After Condenser

Steam Supply
Steam Supply
to Air Ejectors Condensers to Feed Heater
Distillate Cooler

Salinity
Indicator Drain Sea Feed Heater
Sea Water Pump

Vacuum Vacuum
Chamber #2 Chamber #1
Reject Water to Waste

Drain Return
Brine
Steam
Distillate Distillate Condensate Pump
Distillate to Storage Brine Overboard
Pump
Brine Pump Sea Water Temperature Control Valve

LOW PRESSURE THIN-FILM DISTILLER

IN CONDENSER
SEA WATER

OUT

DEMISTER

OUT
JACKET WATER

IN EVAPORATOR
AMEROYAL

ELECTRIC
PANEL ORIFICE
SALINO-
METER OVER
BOARD
FRESH BRINE EJECTOR
W. PUMP

AIR EJECTOR

TO
BILGE
TO FRESH W.
TANK FROM
SEA
EJECTOR PUMP

13
 BOILER WATER CIRCULATION
A boiler is designed to convert the chemical energy con-
tained in fuel to heat energy in the steam. This steam is then
available to do work in a variety of systems onboard. The
figure below illustrates the circulation pattern of a water tube
boiler system. (While only one design is shown, all marine oil-
fired boilers function in a similar pattern).
In a water tube boiler, the furnace is surrounded by tube tanks
which are connected through headers to the upper and lower
drums. The fuel is burned in the furnace and the heat is
passed by radiation to the surrounding generating tubes. The
heat energy is passed by conduction to the recirculating
boiler water in the tubes. In this way, the tube metal is cooled
and steam is generated.
As the water is heated, its density decreases and it tends to
rise. Colder heavier water tends to sink. As the hot water/
steam rises in the generating tubes and the colder water
sinks in the downcomer tubes, a natural circulation results in
the boiler curcuit.
As the steam/water mixture reaches the upper drum (steam
drum), it separates. The steam passes to the upper half of the
drum, then leaves the top of the drum to the superheater or
directly to where it is needed as saturated steam. The
recirculating water remains in the lower half of this drum,
mixes with incoming feedwater and again passes through
the complete water circuit.
In boilers fitted with superheaters, the steam which is re-
leased into the top of the steam drum passes out of the boiler
through the steam line to the superheater where more heat
STEAM OUT
HEAT
14
is added, increasing the energy in the steam. The super-
heated steam is then passed through a high pressure turbine
and possibly a low pressure turbine where a major portion of
steam's thermal energy is converted to mechanical energy.
Before the steam is condensed and returned to the feed
system, part of it may be bled off from the turbine system for
feedwater heating and similar processes so that its thermal
energy can be fully utilized.
After passing through any auxiliary systems, the steam
enters the condenser where it is condensed to form water
which is pumped back to the feed line, completing the boiler/
feed system circuit.
In systems operating at lower pressure levels without super-
heaters, the steam simply leaves the boiler from the steam
drum and passes throughout the steam system before being
condensed and returned as condensate to the feed equip-
ment.
On motor vessels, there are usually two steam generating
systems: a waste heat economizer drawing its heat energy
from the diesel engine exhaust gases and an auxiliary oil fired
boiler. The waste heat economizer functions when the
engine is in operation, and the auxiliary boiler functions when
the ship is in port and the main engine secured. Although their
design is different from the boilers used for propulsion, these
boiler systems function under the same principles of heat
transfer and are subject to many of the same problems due
to scale and corrosion.
WATER IN
15
 CORROSION OF METALS
Ferrous and non-ferrous alloys are commonly used metals
of construction in marine power plants although other metals
are also being used. All of these metals will corrode slowly in
contact with water, unless the water is properly treated. High
temperatures and pressures increase the rate of corrosion.
The purpose of any complete water treatment program is to
protect all the preboiler, boiler and afterboiler auxiliary equip-
ment and systems against corrosion, both during operation
and during out-of-service periods.
CHARACTERISTICS AND TYPES OF CORROSION
Corrosion is defined as the deterioration of a metal or alloy or
its properties due to reaction with its environment. Character-
istics of the damage caused by corrosion include the follow-
ing:
• Pitting - A selective, localized metal attack characterized
by the formation of rounded deep cavities in a metal
surface. Pitting is considered to be one of the most serious
forms of corrosion and often associated with oxygen
attack.
• General corrosion - Thinning or metal loss in which the
thickness of the metal is evenly reduced over a large
surface area.
• Underdeposit - Accelerated corrosion that takes place
under scale or sludge deposits. Underdeposit corrosion is
accelerated since alkalinity left behind can become ex-
tremely concentrated.
• Caustic Cracking - A localized form of corrosion or physical
destruction in which a facturing of the metal following grain
boundaries occurs due to stress.
• Embrittlement - An effect of corrosion that changes the
physical properties of a metal, its crystalline and inter-
crystalline structure, causing the metal to lose its strength
and ductility, thereby becoming brittle and weak.
• Dealloying - The selective dissolution of one metal from an
alloy.
CAUSES OF CORROSION REACTION
AND PREVENTATIVE MEASURES
Corrosion is a result of chemical and electrolytic action of
water or air on a metal. The corrosion rate is influenced by the
impurities in the metal and the water. Properly treated high
purity water and metals reduce the rate of corrosion. All of
these metals will corrode in water unless the water is properly
treated.
The most common causes of corrosion in boiler systems are
dissolved gases, improper pH levels, chloride ion, and
mechanical conditions. Brief discussions of the specific
corrosion reactions follow.
16
GASEOUS CORROSION
Three gases are of primary concern in a water treatment
program: oxygen, carbon dioxide and ammonia.
Oxygen gas is one of the most undesirable contaminants
which enters the preboiler/boiler/afterboiler water system.
Oxygen dissolves in water and causes corrosion at an
excessive rate. The severity of the oxygen attack depends on
the concentration of the dissolved oxygen, pH value, and
temperature of the water.
Oxygen reacts with the ferrous metal surfaces to form red
iron oxide (Fe2O3). Because this red iron oxide (ferric oxide)
or rust is porous and does not protect the metal surface, the
corrosion process continues. Ultimately, the entire metal
structure will be converted to ferric oxide unless corrective
measures are taken.
The corrosion is often localized which results in pitting.
Unless stopped by chemical or thorough mechanical clean-
ing, the corrosion reaction will proceed beneath a cap of
porous oxide until it pierces the metal.
Carbon Dioxide: Most of the carbon dioxide in marine power
plant water systems is formed in the evaporators. Heat
causes carbonate (CO3=) and bicarbonate (HCO3-), which
are dissolved in the seawater, to break down to carbon
dioxide gas (CO2).
Carbon dioxide gas leaves the evaporator with the vapor and
dissolves in the distillate. The carbon dioxide reacts with
water to form carbonic acid which reduces the pH of the water
and accelerates general corrosion in the feedwater and
ultimately in the boiler steam-condensate system.
The carbonic acid (H2CO3), a weak acid, attacks the steel in
the feed and condensate lines to form ferrous bicarbonate
(Fe(HCO3)2). Ferrous bicarbonate is a highly soluble com-
pound that has no protective or passivating effect.
Carbonic acid produces a general type of corrosion, which is
typified by grooving along the bottom of a pipe, overall metal
thinning and, particularly, loss of metal at stressed areas
such as pipe bends and threaded sections.
Ammonia: The cooper-based metals are subject to attack
by ammonia in the presence of oxygen. It is only the
combined action of these gases which is corrosive. By
eliminating the oxygen, the corrosive potential of ammonia is
minimized.
Ammonia is formed by the decomposition of organic material
or the breakdown of excessive hydrazine.
Mechanical Removal of Gases: Air naturally dissolved in
the makeup water, in-leakage and the breakdown of other
compounds introduces oxygen, carbon dioxide, and ammo-
nia. Air can enter through any opening such as makeup, drain
or cascade tanks and especially systems under vacuum
such as turbine seals and condensers.
To deal with this problem, marine steam systems are equipped
with air ejectors, hot wells and sometimes, deaerating heat-
ers. The efficient operation of this equipment is essential for
the removal of a high percentage of the non-condensible
gases which enter the system.
The following is a list of the main points to check in plant
operation to reduce the entry of corrosive oxygen (O2) and
carbon dioxide (CO2) gases:
• Check all points of possible air in-leakage in the con-
densing and vacuum sections of the plant (i.e., defective
flanges, condensing and vacuum sections of the plant,
(i.e., defective flanges, gaskets, valve packing, cracked
valve bonnets, open return line drain valves, insufficient
steam pressure on gland seals, malfunctioning steam
traps, etc.)
• Check the temperature of the water in tanks operating at
atmospheric pressure. Since O2 and CO2 gases readily
dissolve in cool water, the water in all atmospheric water
tanks should be heated to the highest temperature posssible
without creating a vapor lock at the pump suction.
NOTE: In motor vessel systems without deaeration equip-
ment, the feed-cascade-hot well tanks must be kept at as
high a temperature as possible (90OC) in accordance with
boiler manufacturers' recommendations to liberate the
maximum amount of dissolved oxygen. Tanks which are
covered must have vent lines fitted to carry away vented
gases. Many ship systems have feed pumps functioning
continuously with feedwater excess recirculated back to
the feed tank. As the returning water may be simply
dumped into the tank, any volatile chemicals which may
have been dosed to the feedwater before the recirculation
off-take can be lost from the system. To minimize this
condition, the treatment chemicals are often dosed "down-
stream" of the off-take point by means of a dosing pump.
• Avoid piping drains with high oxygen concentrations to
drain tanks or to any point where they may be used as
boiler makeup.
17
• Check for inefficient operation of the deaerating heater.
One thermometer should be installed in the steam space
and another in the water space of the deaerator. When the
unit is operating efficiently, the temperatures in the water
space and in the steam space should be within one to two
degrees Centigrade of each other. If not, check thermom-
eters for accuracy and replace if necessary. If the tempera-
ture difference is confirmed, the unit should be opened and
inspected at the first opportunity to determine the cause of
the problem. (See "Pressure/Temperature Table for
Deaerator Checks," which follows).
• Provide adequate venting of gases from the deaerating
heater directly to the atmosphere. The vent line must be
open; and if an orifice is installed, it must be large enough
to adequately remove the noncondensate gases. If the
vent line is run to the gland seal exhauster, the fan on this
unit must be in operation continually while the vessel is in
port and when at sea. If the fan should fail, the auxiliary vent
to the atmosphere on the deaerating heater must be
opened until the fan is again in operation.
• Check for clogged, worn, or broken spray nozzles or
springs in the deaerator. Poor atomization will result in poor
deaeration regardless of the temperature.
• When taking on extra feed water:
a) Take on feed as slowly as possible. If the feed is taken
on too quickly, the deaerating heater may be over-
loaded, making it impossible to efficiently minimize the
O2 and CO2 concentrations.
b) A higher water temperature in the makeup feed tank
will reduce the absorption of O2 and CO2.
• Use chemical treatment for maximum protection against
the remaining O2 and CO2. While mechanical deaeration of
the feed water is a major step in eliminating dissolved
oxygen and other corrosive gases such as ammonia and
carbon dioxide, it needs the assistance of chemical treat-
ment.
 Pressure/Temperature Table for Deaerator Checks
Malfunction of the deaerating heater will allow gases to
remain in the feedwater which will result in fluctuations in the
oxygen scavenger residual in the boiler water and cause
condensate pH control difficulties. An indication of proper
deaerator operation is provided by the operating tempera-
tures and pressures. The steam and water space tempertures
should be nearly equal. If the temperature difference is
greater than 1OC or 2OF, the thermometers should be
checked for accuracy and, if necessary, repaired or re-
placed. At the same time, the system should be checked for
malfunctioning atomizing nozzles, steam inlet valves, vents,
etc.

DEAERATOR SHELL PRESSURES

AND
CORRESPONDING SATURATION TEMPERATURES

Deaerator Shell Pressures Correct Saturation Temperatures

kg/cm2 psig O
C O
F

0.0 0 100 212

0.11 2 103 218
0.28 4 107 224
0.43 6 110 230
0.58 8 113 235
0.69 10 115 239
0.86 12 118 244
0.99 14 120 248
1.12 16 122 252
1.26 18 124 255
1.41 20 126 259
1.56 22 128 262
1.72 24 130 265
1.83 26 131 268
1.97 28 133 271
2.10 30 134 274
2.25 32 136 277
2.34 34 137 279
2.54 36 139 282
2.68 38 140 284
2.82 40 141 287
2.96 42 143 289
3.10 44 144 291
3.24 46 145 294
3.38 48 146 296
3.52 50 148 298
3.80 54 150 302
3.94 56 151 304
4.08 58 152 305
4.22 60 153 307

18
 CHEMICAL TREATMENT
Removal of Oxygen
Any dissolved oxygen remaining after deaeration can be
completely scavenged by the addition of a chemical oxygen
scavenger, such as hydrazine, diethylhydroxylamine or
sodium sulfite, to the boiler feed water.
The reaction produts of the hydrazine treatment are water
and nitrogen gas which is inert and will not attack the metal
in the system. These reaction products will not add solids
to the boiler water as do the reaction products of other
oxygen scavengers such as sodium sulfite.
N2H4 + O2 → 2H O + N
2 2
Hydrazine has added benefits. After a boiler system has
been operating for a short time with proper chemical
control and adequate hydrazine concentrations, a protec-
tive film of black magnetic iron oxide (Fe3O4, magnetitite)
forms. At the same time, any non-protective red iron oxide,
(Fe2O3, hematite), is slowly converted to magnetite. This
magnetite film passivates the metal surfaces.
If the hydrazine residual is allowed to be depleted, oxygen
will not be removed from the system. At this point the
magnetite film will be converted to hematite, and corrosion
of the base metal will begin.
Since hydrazine is volatile, some of it will carry over with
the steam. In this way, the metals of the condensate
system also can be protected. In a series of reactions
similar to those described above for ferrous metals, non-
ferrous metals are rendered less sussceptible to corro-
sion. For example, cupric oxide (CuO) is converted to a
protective form, cuprous oxide (Cu2O)
4CuO + N2H4 → 2Cu2O + 2H2O + N2
The most recent volatile oxygen scavenger introduced to
the marine industry is diethylhydroxylamine, also known
as DEHA. In addition to oxygen scavenging, DEHA forms
a passive magnetite film providing a protective barrier
against corrosion.
The oxidation reaction products of DEHA are acetic acid,
nitrogen and water. In a boiler water environment, the
hydroxide alkalinity neutralizes the acetic acid and is
removed by blowdown as sodium acetate.
4(C2H5)2NOH + 9O2 → 8CH3COOH + 2N2 + 6H2O
Another feature of DEHA is its volatility, which is similar to
morpholine. It extends throughout the feedwater, boiler
and into the condensate system where it scavenges
oxygen, passivates metal surfaces and any remaining
DEHA contributes to condensate pH neutralization.
19
An alternative oxygen scavenger is sodium sulfite (Na2SO3).
This compound readily combines with oxygen in solution
to form a more stable compound, sodium sulfate (Na2SO4).
This process efficiently removes oxygen from solution, but
it does add dissolved solids to the water. As a result, it is
not generally recommended for high pressure boilers
where minimum dissolved solids levels are critical.
Sulfite is not volatile and it is not a metal passivator. It
remains in the boiler water and does not offer protection
for the condensate system.
Na2SO3 + 1/2 O2 → Na2SO4
(Sodium Sulfite) + (Oxygen) (Sodium Sulfate)
Control of Condensate pH
As discussed above, CO2 gas reacts with the condensate
to form carbonic acid. Without chemical treatment, this
acid reduces the pH of the condensate. The pH can be
controlled within a specified non-corrosive range by the
continuous dosage of a neutralizing amine, such as
morpholene or cyclohexylamine.
ACIDIC CORROSION - ACID ATTACK
Acid attack of boiler tubes and drums is usually in the form
of general thinning of all metal surfaces.
Acidic conditions, exclusive of those created by the pres-
ence of CO2, occur when the boiler feed water becomes
contaminated by evaporator carryover or seawater in-
leakage at the condenser. When magnesium chloride
(MgCl2), a seawater salt, is introduced to a boiler water
system, it dissociates into ions of magnesium (Mg+2) and
chloride (Cl-). The chloride ions (Cl-) react with the
hydrogen ions, which lowers the pH of the water and
attacks the metal surfaces.
The magnesium ions (Mg+2) react with the phosphate
(PO4-3) and hydroxyl ions (OH-), if these treatments are
present, to form sludge. Magnesium ions may react only
with the phosphate ions to form magnesium phosphate, a
soft, adherent deposit which tends to bind all other depos-
its to the tube surfaces.
Any deposits on metal surfaces can be heat transfer
barriers and can lead to overheating and increasingly
destructive conditions. Water trapped beneath these de-
posits on high heat transfer surfaces will concentrate the
acid or caustic. When this occurs, the corrosion rates
become extremely high and serious localized damage
occurs in a very short time.
HYDROGEN ATTACK
This type of corrosion results in embrittlement or cracking
of the tube metal, damaging of the internal structure of the
metal.
Hydrogen ions are generated by the concentration of
acids under a hard dense deposit. The hydrogen ions (H+)
are the smallest of all elements and can penetrate the
grain boundaries of the tube metal. They react with carbon
atoms present in the steel to form methane.
Methane (CH4) is a large gas molecule which exerts
pressure within the metal. The high pressure combined
with the weakening caused by degraphiting forces the
grains of steel to separate. Eventually, cracks in the metal
develop.
Hydrogen attack can occur very rapidly. Tube metal fails
and ruptures when the section can no longer withstand the
internal pressure.
CAUSTIC CORROSION
Caustic attack is characterized by irregular patterns of
gouging of the metal. It is often referred to as "caustic
gouging".
Caustic corrosion results from the presence of an excess
of free hydroxide (OH) in the boiler water, indicated by a
very high pH.
Much like an acid, caustic corrosion may occur beneath
layers of deposits which have formed on heat transfer
surfaces allowing the hydroxide to concentrate and thereby
causing severe localized corrosion.
Caustic corrosion also will occur in the horizontal or
inclined tubes when the interior surfaces become steam
blanketed because of excessive boiling (hot spots) or
separation of steam and water. Boiler water containing
hydroxide can splash onto the steam blanketed surface,
and as the water flashes off, the hydroxide remains and
concentrates on the metal.
CAUSTIC CRACKING CORROSION
Corrosion caused by caustic cracking is a type of
intercrystalline cracking. When highly caustic (alkaline)
water comes in contact with steel under stress,
intercrystalline cracking can result. (Metals can be stress
relieved, that is reheated at low temperatures to relieve
internal stresses). This type of corrosion occurs along the
crystal boundaries of a metal or an alloy.
20
CORROSION FATIGUE
Corrosion fatigue manifests itself as a series of fine cracks
in the tube wall. These cracks are aggravated by other
corrosive conditions within the boiler which will ultimately
result in tube failure.
This form of corrosion usually attacks the tube walls of
high pressure boilers. It occurs generally in the high
temperature areas of the tubes where irregular water
circulation has been experienced and alternating stresses
have been set up in the tube material.
MECHANICAL CORRECTION
The evaporator should be operated properly to avoid
carryover which will introduce contaminants as described
above. Condenser piping must be maintained to prevent
leaking condenser tubes which will introduce seawater.
The boiler should be operated within the design specifica-
tions in order not to overload the steam production capac-
ity which leads to steam blanketing.
Proper burner alignment and correct atomization of the
fuel oil are essential to avoid flame impingement of hot
spots.
CHEMICAL TREATMENT
Acidic corrosion can be prevented by the maintenance of
a proper boiler water alkalinity. Adequate dosages of an
alkaline material such as sodium hydroxide (GCTM con-
centrated alkaline liquid) will maintain the recommended
alkalinity range and eliminate the possibility of acid attack.
Please note: The alkalinity level may be measured directly
in "ppm" or indirectly using the corresponding pH ranges.
Maintain the recommended range of alkalinity or pH
according to the treatment program.
Caustic corrosion readily takes place in ultra high pres-
sure boilers (60 kg/cm2, 850 psig and over) in the presence
of free caustic. The Drew ULTRAMARINESM coordinated
phosphate-pH boiler water treatment program used in
high pressure boilers eliminates free hydroxide (OH-) in
the boiler water. (This program will be described in detail
later in this book). Maintain the balance of treatment
chemicals to minimize free caustic.
The application of the ULTRAMARINE coordinated
phosphate-pH boiler water treatment will also assist in
inhibiting hydrogen embrittlement, primarily by the buffer-
ing action of the phosphate and the pH control in the boiler
water.
 COMPOSITION AND FORMATION OF DEPOSITS
Since water is a universal solvent, it dissolves practically all
materials which it contacts to a certain extent. However,
materials have differing solubilities in water depending upon
the temperature, pressure, pH, mineral composition, and
contact time. Solubilities are grouped into three general
categories: very soluble solids, slightly soluble solids, and
relatively insoluble solids. Under certain operating condi-
tions, any one of these may produce undesirable deposits
which will reduce operating efficiency.
DISSOLVED INORGANIC SOLIDS are materials which
dissociate in water into their ionic parts (cations and anions).
Most organic materials are not highly ionized (see discussion
later in this section). The major minerals encountered in
seawater are combinations of the following dissolved (ion-
ized) constituents:
Positive Ions (Cations) Negative Ions (Anions)
Calcium+2 Carbonate-2
Magnesium+2 Bicarbonate-1
Sodium+1 Sulfate-2
Potassium+1 Silicate-2
Chloride-1
Salts may enter the boiler system as poor quality evaporator
distillate, seawater in-leakage, or shore water makeup. Some
are very soluble and cause few problems because of their
relative solubility. For example, sodium salts are very soluble
compounds. However, contaminants can volatilize and carry
over with the steam and deposit on superheater tubes or on
turbine blading.
Slightly soluble solids are soluble at atmospheric condi-
tions; however, an increase in the temperature and pressure
will cause precipitation and/or deposition. The primary ex-
amples of this type of solid are salts of calcium and magne-
sium. For example, the solubility of calcium sulfate increases
up to approximately 38OC (100OF) but then decreases rapidly
as the temperature is increased above this level.
Only a very small quantity of the so-called insoluble solids
will dissolve in water. Suspended solids, which do not
dissolve, will deposit or disperse and circulate with the water.
Following is a list of these materials that are most likely to be
found as boiler water suspended solids:

Material Composition Source

Red iron oxide Fe2O3 Corrosion of feed or return lines or boilers.

Magnetic iron Fe3O4 Corrosion of return lines or boilers or conversion of
suspended Fe2O3.
Copper metal and copper oxides Cu, Cu2O and CuO Corrosion of condenser tubes and evaporators.
Clay Complex silicates of Introduced by contamination of feed water with
Al, Fe, and Mg seawater, low quality shore or brackish water.
Calcium carbonate CaCO3 Introduced by seawater contamination as a reaction
product formed by heating water that contains calcium
bicarbonate.
Calcilum silicate CaSiO3 Reaction product from water that contains calcium and silica
Tricalcium phosphate Ca3(PO4)2) Formed when water is overtreated with phosphate and
undertreated with sodium hydroxide, and this material is
very likely to adhere to metal surfaces.
Calcium hydroxyapatite* 3Ca3(PO4)2•Ca(OH)2 Formed when proper treatment controls are maintained.
Magnesium hydroxide* Mg(OH2) Formed when proper treatment controls are maintained.
Magnesium silicate* 3MgO•2SIO2•2H2O Formed in water that contains silica when proper treatment
("Serpentine") controls are maintained.
Magnesium phosphate Mg3(PO4)2 Formed when water is overtreated with phosphate. This
material is very likely to adhere to metal surfaces.
Oily sludge Organic Mixtures Formed when any of the above solids absorb oil present
in the system.

*Starred items are minerals that may be produced as a result of normal chemical water treatment and which are the least likely
to form adherent sludge deposits. Of the suspended solids in the boiler water, these substances are preferred since they easily
can be removed by blowdown.

21
In addition to the above, there are metallic oxides and salts
of iron and copper which enter the boiler as corrosion
products. The sources of iron may be from corrosion in steam
systems and in return lines. Some oxides are from internal
corrosion in boiler generating tubes, the drum surfaces or
feed line. Corrosion of the main and auxiliary condensers or
of evaporator condensers is one of the sources of the copper
and copper oxide materials. (See the previous section on
"Formation of Oxides").
Organic contamination may enter the boiler system via leaks
in the cargo or fuel heating coils or other auxiliary feed lines.
Types of organics include petroleum products (e.g., oil or
lubes), cargo liquids (e.g., organic chemicals), or microor-
ganisms (e.g., bacteria). Organic materials tend to decom-
pose and can act as binders for the suspended solids so that
they adhere to the interior tube metal walls.
DEPOSIT FORMATION AND
PREVENTATIVE MEASURES
Scale: A "true" scale is a crystalline solid which is found at the
point in the boiler system at which it is formed. Scale materials
are formed by oversaturation and precipitation of hardness
constituents (calcium and magnesium) on heat transfer
surfaces.
Metal oxide deposits are formed by the reaction of an
aggressive solution or gas in contact with the metal surface
at the point where the oxide is found. It may come from
another part of the system and accumulate at that location.
Metal oxides can combine with other contaminants to form
deposits. This is another reason why corrosion should be
controlled by mechanical as well as chemical methods. (See
previous section on "Corrosion of Metals").
Sludge is generally a mixture of loose fluid particles com-
posed of organic, inorganic and/or corrosion products. The
sludges that result from water treatment reactions are pre-
ferred to the scale that would otherwise form.
Sludges must be removed on a regular schedule or the
accumulation of sludges at the low flow points may block the
water flow patterns. Restriction of this flow may cause
"starvation" of some areas and ultimately the overheating of
metal.
Scales and baked-on sludges in any heat transfer area can
act as "insulators". Interference with heat transfer results in
reduced fuel efficiency and potentially tube failure.
Mechanical Correction
Blowdown is the method used to remove the dissolved and
suspended solids from the boiler systems, and blowdown
procedures should be based on boiler manufacturers' in-
structions. There are three types of blowdown--bottom,
header and continuous--each used for a specific purpose.
Bottom blowdown (blowdown from the bottom of the boiler)
removes suspended solids and residual sludges that have
settled out of the water. If these contaminants are not
removed regularly, they will build up until they hinder circula-
tion patterns.
22
Continuous or surface blowdown (blowdown from the upper
areas of the boiler) removes circulating boiler water which
contains a high percent of the dissolved solids. This blowdown
location keeps the concentration of dissolved solids under
control.
Header blowdown (an intermittent blow from a header loca-
tion) reduces accumulated, suspended or floating solids, and
also removes high dissolved solids concentrations.
Chemical Treatment
Not all contaminants can be removed naturally by blowdown
but require chemical assistance. The formation of undesir-
able deposits can be prevented by treating the water with
chemicals that convert the undesirable dissolved hardness
constituents to harmless suspended solids. These solids
gradually settle out in the mud drum of the boiler as a
nonadherent fluid sludge which can be removed by blowdown.
The standard treatment used is a combination of soluble
phosphate (ADJUNCT® B phosphate boiler water treatment)
and an alkaline liquid (GCTM concentrated alkaline liquid).
Some one drum combination products, such as AGK® 100
boiler and feedwater treatment, combine phosphate, alkali,
oxygen scavenger amines and other water conditions into a
complete treatment. AGK 100 treatment is not a "one-shot"
treatment but rather a complete package which must be fed
continuously to provide complete protection. (Also, see the
section on "Coordinated Phosphate-pH Treatment" that
follows).
Any existing hardness scales are not rapidly removed by the
boiler water treatment chemicals and special chemical clean-
ing methods should be employed. (See the section entitled
"Chemical Cleaning").
If the water treatment program is controlled within the limits
set for the phosphate and alkalinity, the sludges which will
develop will not be sticky and will not adhere to the metal
surfaces.
If feedwater becomes contaminated by oil, LIQUID
COAGULANTTM boiler sludge conditioner should be dosed
to the boiler to coagulate the oil droplets. These conditioned
suspended solids will settle to the low points of the boiler
where they are removed by blowdown, thus preventing
foaming and carryover and lowering deposit adherence
characteristics.
Coordinated Phosphate-pH Program (ULTRAMARINESM)
Caustic corrosion is one of the most frequent and most
serious causes of metal damage in high pressure boilers
(over 60 kg/cm2, 850 psig). This type of corrosion results from
the action of "free caustic" at heat transfer surfaces causing
severe corrosion and metal loss. The caustic conconcentrates
in crevices or localized areas beneath porous metal oxide
deposits or where thin films of steam are formed leaving
concentrated caustic behind on the metal surface. This
localization of caustic can cause severe corrosion and may
be the result of some physical features of the boiler such as
design or the mode of operation.
The Drew ULTRAMARINESM program has been specifi- The alkalinity or pH range is controlled so that it protects the
cally designed to minimize "free caustic" conditions in high boiler steel in a passivated state and coordinates with the
pressure boilers by adjusting and controlling the chemical phosphate concentration to insure the formation of fluid
balance of pH and phosphate in the boiler water. The Drew non-adherent sludges. These levels are coordinated in a
ULTRAMARINE Program is a coordinate phosphate-pH balance that will prevent a condition of excess or "free
boiler water treatment program. The addition of Drew GCTM caustic". (See the graph of coordinated phsophate-pH
concentrated alkaline liquid and ADJUNCT® B boiler water control below).
treatment establishes an equilibrium in the boiler water as
shown in the equation below: All the other water treatment controls must be monitored
closely because high pressure boilers have lower toler-
Na2HPO4 + NaOH Na3PO4 + H2O ances for variations in chemical levels and total dissolved
disodium + sodium trisodium + water solids. This lower tolerance for chemicals and solids does
(ortho) hydroxide (ortho) not distinguish between treatment chemicals and contami-
phosphate phosphate nants so overall control of all critical boiler water chemistry
is a necessity.

PPM PO4 (DERIVED FROM TSP)

ULTRAMARINE COORDINATED PHOSPHATE-----pH CURVE

23
 SPECIAL OPERATING CONDITIONS
Special attention must be given to operating conditions
which are unusual or those which are not directly related
to normal steaming conditions. The water treatment pro-
cedures which are employed during "slow-speed" steam-
ing are just as important as the chemical treatment pro-
gram during the normal boiler operations. The following
situations should be given full consideration.
LOW SPEED STEAMING
If a boiler is to be operated at substantially reduced loads,
the correct water treatment chemical concentrations must
be maintained at all times. This is because excessive
corrosion and deposition conditions may be exaggerated
by the decreased water circulation rates especially in high
heat input areas and reduced efficiency of pre-boiler
equipment such as deaerations.
If the boiler has been drained, the AMERZINE inhibitor
should be added as it is filled to the normal level and fired
up. The boiler must be operated long enough to provide
sufficient circulation to obtain a uniform concentration of
the oxygen scavenger throughout the boiler water to
eliminate the oxygen.
If the boiler has been in operation, dose 1.3 liters of
AMERZINE inhibitor for each ton of boiler capacity at the
test level (100% full).
After inspection or cleaning, a boiler should not be allowed
to stand open or wet since atmospheric corrosion or "flash
rusting" will occur. In addition, boilers should not be
returned to service if residual corrosion products or de-
posits are present. They should be cleaned before their
return to service.

A potentially more serious situation occurs when firing CHEMICAL CLEANING

rates are reduced, which disrupts temperature gradients
across all of the boiler sections. In effect, some generating
tubes which normally are risers may become stagnant or
even downcomers.
At extremely reduced steaming conditions, many tubes
can become stagnant since they are in a transition zone
where they are neither risers nor downcomers but rather
"percolate" in a static condition. If percolation occurs, the
lack of circulation in high heat input areas tends to permit
steam blanketing and tube overheating, thereby concen-
trating the dissolved solids at the metal-water interfaces.
To help alleviate this condition in a two boiler system, it
may be advisable to put one boiler in standby and operate
the other at a more normal load condition.
STANDBY AND IDLE BOILERS
Boiler water chemical levels (non-volatile) in standby
boilers should be kept within the same ranges that are
indicated for the full steaming conditions.
Efficient operation of the boiler system, as with all equip-
ment, is dependent upon cleanliness and freedom from
obstructions in the water or gas pass circuits.
Precommission cleaning of new equipment is required to
remove oils, corrosion products, millscale and debris
which may have accumulated during construction.
Carefully controlled treatment programs can keep most
systems trouble-free; however, in certain conditions an
emergency cleaning action may be necessary because of
accidental contamination, tube failure, or accumulations
of deposits and oxide deposits.
All chemical treatment programs require strict adherence
to the recommended procedures to produce the desired
results. Chemical cleaning solutions, their byproducts,
and residuals must be removed before returning the
system to service, thereby avoiding any additional con-
tamination or corrosion.

When any boiler is off-line for extended periods of time,

proper dry or wet layup procedures are essential to
prevent corrosion.

Successful dry layup procedures depend upon the elimi-

nation of all moisture from inside the boiler. Corrosion will
not occur if moisture is eliminated. However, it is almost
impossible to eliminate all moisture; therefore, the use of
"wet" layup procedures is the most practical and preferred
corrosion control method for all but very extended layup
periods.

Boilers placed in "wet" layup are not maintained under

pressure. During these periods adequate protection against
oxygen gas corrosion must be employed by introducing a
high concentration of AMERZINE® corrosion inhibitor
(approximately 150-200 ppm or 1.3 liter/ton).

24
 BOILER WATER TREATMENT CHEMICALS
ADJUNCT® B phosphate boiler water treatment:
ADJUNCT B treatment is a specially formulated powdered
phosphate used in conjunction with GCTM liquid in both high
and low pressure boilers to control scale formation due to
hardness. The soluble phosphate from ADJUNCT B treat-
ment in alkaline boiler water combines with the incoming
hardness to form a soft, nonadherent sludge.
GCTM concentrated alkaline liquid: GC liquid neutralizes
acid and controls corrosion. GC liquid provides a suitable pH
environment for the efficient reaction of the phosphate treat-
ment with the hardness constituents to maintain the resulting
sludges in a fluid state.
AMERZINE® corrosion inhibitor: AMERZINE inhibitor is a
liquid catalyzed oxygen scavenger used to minimize oxygen
corrosion in boiler steam and condensate systems.
AMERZINE (hydrazine) prevents the corrosion of iron and
copper by oxygen and promotes the formation of protective
iron and copper oxide films.
SLCC-ATM condensate corrosion inhibitor: SLCC-A in-
hibitor is a volatile liquid organic amine designed to minimize
corrosion in steam and condensate systems. SLCC-A inhibi-
tor condenses with the steam, providing a pH environment
which neutralizes the corrosive effects of carbon dioxide
(Carbonic Acid).
25
LIQUID COAGULANTTM boiler sludge conditioner:
LIQUID COAGULANT conditioner is a colorless, high mo-
lecular weight solution used in both medium and low pres-
sure boilers to prevent sludge deposits. It is especially useful
when feedwater becomes contaminated by oil. Dosing
LIQUID COAGULANT conditioner to the boiler coagulates
the oil droplets, causing these suspended solids to settle to
the low points of the boiler where they are removed from
blowdown.
AGK® 100 boiler and feedwater treatment: AGK 100
treatment is a unique multi-functional liquid formulation of
organic sludge conditioners, coagulants, oxygen scaven-
gers, and inorganic contaminant dispersing and precipitating
agents. AGK 100 treatment controls waterside scale and
sludge deposits and corrosion conditions in low pressure
boilers using distilled water as makeup (up to 32 kg/cm2, 450
psig). The single multi-functional production formulation of
the Drew AGK 100 treatment program can replace multi-
product conventional water treatments in these systems.
DREWPLEX® AT 100 boiler water treatment: DREWPLEX
AT treatment is a phosphate-based treatment combined
with synthetic polymers providing the ultimate in simplicity,
system flexibility and treatment control for all motor vessel
auxiliary and exhaust gas economizer boilers. DREWPLEX
AT boiler water treatment provides a cleaner boiler by
allowing greater tolerance of feedwater quality fluctua-
tions.
DREWPLEX OX corrosion inhibitor: DREWPLEX OX
corrosion inhibitor is a safe-to-use, unique, and fast-acting
catalyzed oxygen scavenger for use in low, medium and
high pressure steam generating systems. Because
DREWPLEX OX corrosion inhibitor is volatile, excess in
the feedwater will be carried through the boiler with the
steam and into the condensate system, thereby protecting
the entire boiler system from oxygen corrosion. The
catalyst in DREWPLEX OX corrosion inhibitor acceler-
ates the rate of oxygen removal in the feedwater, thereby
improving corrosion protection in the preboiler section.
 BOILER WATER TREATMENT CHEMICAL APPLICATIONS AND CONTROLS

Control Limits for Boiler Water and Condensate

ULTRAMARINESM program: Boiler Pressure 60-84 kg/cm2 (850-1200 psig)

Boiler Water Tests Treatment Control Limits

Phosphate ADJUNCT® B 15 - 25 ppm

pH GCTM 9.8 - 10.2
HYDRAZINE/AMERZINE® AMERZINE 0.03 - 0.10 ppm
Chloride Blowdown 16 ppm max.
Conductivity Blowdown 120 µmhos max.
Silica Blowdown 6 ppm max.

Condensate Tests
pH SLCC-ATM 8.6 - 9.0
Ammonia Deaeration 0.5 ppm max.

STANDARD: Boiler Pressure 32-60 kg/cm2 (450-850 psig)

Boiler Water Tests Treatment Control Limits

Phosphate ADJUNCT B 20 - 40 ppm

P. Alkalinity GC 90 - 130 ppm
T. Alkalinity GC Less than 2 x P. Alkalinity
HYDRAZINE*/AMERZINE AMERZINE 0.03 - 0.10 ppm
Sulfite CATALYZED SULFITE 10 - 15 ppm
Chloride Blowdown 36 ppm max.
Conductivity Blowdown 700 µmhos max.

Condensate Tests

pH SLCC-A 8.3 - 8.6

STANDARD: Boiler Pressure 0-32 kg/cm2 (0-450 psig)

Boiler Water Tests Treatment Control Limits

Phosphate ADJUNCT B 20 - 40 ppm

P. Alkalinity GC 100 - 150 ppm
T. Alkalinity GC Less than 2 x P. Alkalinity
HYDRAZINE*/AMERZINE AMERZINE or 0.03 - 0.10 ppm
Sulfite CATALYZED SULFITE 20 - 30 ppm
Chloride Blowdown 300 ppm max.
Conductivity Blowdown 700 µmhos maximum

Condensate Tests

pH SLCC-A 8.3 - 8.6

NOTE: Hardness tests of boiler water are not necessary when the phosphate is above the lower limit of the control range.

*Use of either hydrazine or sulfite is recommended for oxygen scavenging. Use of both scavengers is not necessary.

26
 BOILER WATER TREATMENT

PHOSPHATE: Dosage of ADJUNCT® B phosphate boiler water treatment per ton boiler water.

P r e s s u r e R a n g e
Phosphate 0-32 kg/cm2 32-60 kg/cm2 60-84 kg/cm2
Test Results (ppm) (0-450 psig) (450-850 psig) (850-1200 psig)

Dosage Requirements

0 30 gm (1 oz.) 30 gm (1 oz.) 30 gm (1 oz.)

3 30 gm (1 oz.) 30 gm (1 oz.) 30 gm (1 oz.)
6 30 gm (1 oz.) 30 gm (1 oz.) 26 gm (1 oz.)
9 30 gm (1 oz.) 30 gm (1 oz.) 22 gm (1 oz.)
12 15 gm (.5 oz.) 15 gm (.5 oz.) 18 gm (1 oz.)
15 15 gm (.5 oz.) 15 gm (.5 oz.) 14 gm (1 oz.)
18 15 gm (.5 oz.) 15 gm (.5 oz.) 9 gm (1 oz.)
20 - 25 Satisfactory Satisfactory Satisfactory
25 - 40 Satisfactory Satisfactory Satisfactory
40+ Blowdown Blowdown Blowdown

CAUSTIC: Dosage of GCTM concentrated alkaline liquid per ton boiler water

P r e s s u r e R a n g e
P. Alkalinity 0-32 kg/cm2 32-60 kg/cm2
Test Results (ppm) (0-450 psig) (450-850 psig)

Dosage Requirements

0 - 20 0.15 liter 0.15 liter

30 - 50 0.10 liter 0.10 liter
60 - 80 0.05 liter 0.05 liter
90 - 130 -- Satisfactory
100 - 150 Satisfactory --
130+ -- Blowdown
150+ Blowdown --

CAUSTIC: Dosage of GCTM concentrated alkaline liquid per ton boiler water

Pressure Range
pH Boiler Water 60-84 kg/cm2
Test Results (850-1200 psig)

Dosage Requirements
8.6 or less 14 ml
9.0 13 ml
9.0 - 9.3 12 ml
9.4 - 9.5 11 ml
9.6 10 ml
9.7 9 ml
9.8 8 ml
10.0 7 ml
10.1 5 ml
10.2 Satisfactory
10.3 or above Blowdown

27
 SULFITE: Dosage of CATALYZED SULFITETM corrosion inhibitor

BOILER PRESSURE RESIDUAL RANGE DOSAGE

PSI kg/cm2 (ppm as SO3) REQUIREMENTS

(a) Up to 450 Up to 32 20-30 Satisfactory

(b) 450-850 32-60 10-15 Satisfactory

(a) or (b) Below satisfactory, Increase 25%

(a) or (b) Above satisfactory, Decrease 25%

HYDRAZINE/AMERZINE: Continuous Dosage of AMERZINE® corrosion inhibitor

Treatment Pressure Range Hydrazine Test Result AMERZINE Dosage

Standard 0-60 kg/cm2 less than 0.03 Increase dosage by 25%

(0-850 psig) 0.03 - 0.10 Maintain
greater than 0.10 Decrease dosage by 25%
Initial dosage is 0.15 liters per ton of boiler water.

ULTRAMARINE 60-84 kg/cm2 less than 0.03 Increase dosage by 25%

(850-1200 psig) 0.03 - 0.10 Maintain
greater than 0.10 Decrease dosage by 25%
Initial dosage is 0.10 liters per ton of boiler water.

CONDENSATE pH: Continuous Dosage of SLCC-ATM condensate corrosion inhibitor

Treatment Pressure Range Condensate pH SLCC-A Dosage

Standard 0-60 kg/cm2 less than 8.3 Increase dosage by 25%

(0-850 psig) 8.3 - 8.6 Maintain
greater than 8.6 Decrease dosage by 25%
Initial dosage is 0.15 liters per ton of boiler water.

ULTRAMARINE 60-84 kg/cm2 less than 8.6 Increase dosage by 25%

(850-1200 psig) 8.6 - 9.0 Maintain
greater than 9.0 Decrease dosage by 25%
Initial dosage is 0.10 liters per ton of boiler water.

28
AGK® 100 treatment Supplemented with AMERZINE® treatment

AGK 100 Treatment

Initial Dosage: 2.5-5 liters per ton of water in the boiler system

Continuous Dosage: Maintain 40-65 ppm hydrate alkalinity and 10-20 ppm phosphate in the boiler water.

AGK 100 Dosage Adjustment

Hydrate Alkalinity is the primary parameter for adjusting AGK 100 Dosage

HYDRATE ALKALINITY HYDRATE ALKALINITY HYDRATE ALKALINITY

<40 ppm 40 - 65 ppm >65 ppm

PO4 Increase dosage by 25% Dosage adjustment may be Reduce dosage by

<10ppm and check for seawater or necessary. Check for 10%. Check for
shore water or in-leakage. possible hardness in-leakage. shore water in-leakage.

PO4 Increase dosage by 20% Normal condition. No dosage Reduce dosage by 20%
10 - Check condensate for adjustment necessary. Check for shore water
20 ppm acidic material in-leakage. adjustment in-leakage.

Increase dosage by 20% Dosage adjustment may be Reduce dosage by 25%.

Check condensate for
acidic material in-leakage.
PO4 Make up and/or feedwater
>20ppm volume may be low or
quality may be better
than usual.
necessary. Check for acidic Feedwater quality may be
material in-leakage. better than usual.
Alkalinity may be destroyed
by acid contamination. Make
up and/or feedwater volume
may be low or quality may be
better than usual.

NEUTRALIZED
CONDUCTIVITY
in µmhos BLOWDOWN ADJUSTMENT

Up to 700 Satisfactory Normal maintenance blowdown is sufficient. Regular flash blowdown to

remove suspended solids should be carried out a minimum of once per
week.

Above 700 High Increase frequency of blowdown.

Boiler Water AMERZINE DOSAGE ADJUSTMENT

Hydrazine Dosage is necessary only when HYDRAZINE test results are low
in ppm with AGK 100 dosage alone.
Initial Dosage: 100 ml/day

Above 0.10 High Decrease

0.03 - 0.10 Satisfactory No Change
Below 0.03 Low Increase

29
DREWPLEX® AT boiler water treatment and DREWPLEX OX corrosion inhibitor for Motor Vessels

DREWPLEX AT/DREWPLEX OX Treatment

Initial Dosage: 2.5-5 liters per ton of water in the boiler system

Continuous Dosage: Maintain 40-65 ppm hydrate alkalinity and 10-20 ppm phosphate in the boiler water

DREWPLEX AT Dosage Adjustment

Hydrate Alkalinity is the primary parameter for adjusting DREWPLEX AT Dosage
HYDRATE ALKALINITY HYDRATE ALKALINITY HYDRATE ALKALINITY
<40 ppm 40 - 65 ppm >65 ppm

Increase dosage Dosage adjustment Reduce dosage by

PO4 by 25% and check may be necessary. 10%. Check for
<10ppm for seawater or Check for possible shore water in-leakage.
shore water hardness
or in-leakage. in-leakage.

Increase dosage by Normal condition. Reduce dosage by

PO4 20%. Check No dosage 10%. Check for
10 - condensate for acidic adjustment shore water in-leakage.
20 ppm material in-leakage. necessary.

Increase dosage Dosage adjustment Reduce dosage by

by 10%. Check may be necessary. 25%. Feedwater
condensate for Check for acidic quality may be better
PO4 acidic material material in-leakage. than usual.
>20ppm in-leakage. Alkalinity may be
Make up and/or destroyed by acid
feedwater volume contamination.
may be low or Makeup and/or
quality may be feedwater volume may
better than usual. be low or quality may
be better than usual.

NEUTRALIZED CONDUCTIVITY
in µmhos BLOWDOWN ADJUSTMENT

Up to 700 Satisfactory Normal maintenance blowdown is sufficient.

Regular flash blowdown to remove suspended
solids should be carried out a minimum of
once per week.

Above 700 High Increase frequency of blowdown.

Feedwater DOSAGE ADJUSTMENT

DEHA DREWPLEX OX Continuous Dosage
in ppm Initial Dosage: 0.4 liters/ton of water
in the boiler system

Above 0.8 High Decrease

0.4 - 0.8 Satisfactory No Change
Below 0.4 Low Increase

30
DREWPLEX® AT boiler water treatment/AMERZINE® corrosion inhibitor for Motor Vessels

DREWPLEX AT/AMERZINE treatment

Initial Dosage: 2.5-5 liters per ton of water in the boiler system

Continuous Dosage: Maintain 40-65 ppm hydrate alkalinity and 10-20 ppm phosphate in the boiler water

DREWPLEX AT Dosage Adjustment

Hydrate Alkalinity is the primary parameter for adjusting DREWPLEX AT Dosage
HYDRATE ALKALINITY HYDRATE ALKALINITY HYDRATE ALKALINITY
<40 ppm 40 - 65 ppm >65 ppm

Increase dosage Dosage adjustment Reduce dosage by

PO4 by 25% and check may be necessary. 10%. Check for
<10ppm for seawater or Check for possible shore water in-leakage.
shore water hardness
or in-leakage. in-leakage.

Increase dosage by Normal condition. Reduce dosage by

PO4 20%. Check No dosage 10%. Check for
10 - condensate for acidic adjustment shore water in-leakage.
20 ppm material in-leakage. necessary.

Increase dosage Dosage adjustment Reduce dosage by

by 10%.Check may be necessary. 25%. Feedwater
condensate for Check for acidic quality may be better
PO4 acidic material material in-leakage. than usual.
>20ppm in-leakage. Alkalinity may be
Make up and/or destroyed by acid
feedwater volume contamination.
may be low or Makeup and/or
quality may be feedwater volume may
better than usual. be low or quality may
be better than usual.

NEUTRALIZED CONDUCTIVITY
in µmhos BLOWDOWN ADJUSTMENT

Up to 700 Satisfactory Normal maintenance blowdown is sufficient.

Regular flash blowdown to remove suspended
solids should be carried out a minimum of once
per week.

Above 700 High Increase frequency of blowdown.

Boiler Water DOSAGE ADJUSTMENT

Hydrazine AMERZINE Continuous Dosage
in ppm Initial Dosage: 0.15 liters/ton of water
in the boiler system

Above 0.10 High Decrease

0.03 - 0.10 Satisfactory No Change
Below 0.03 Low Increase

31
Dosage of LIQUID COAGULANTTM
boiler sludge conditioner

LIQUID COAGULANT boiler sludge conditioner is "slug-
fed" daily at a dosage of 30 mls (1 oz.) per ton of boiler
water capacity to minimize the effects of oil contamination.
When dosing LIQUID COAGULANT conditioner, both
bottom flash blowdowns and fast surface blowdowns are
recommended.
Do not continue to operate a boiler system with severe oil
contamination.
For systems experiencing severe oil contamination,
locate and secure the leak. Then an off-line cleaning is
recommended. Consult your Drew Marine representative
for specific maintenance chemicals.
After the equipment is cleaned, LIQUID COAGULANT
conditioner should be dosed at 30 mls (1 oz.) per ton of
boiler water capacity per day for two weeks or until
complete oil removal is accomplished.

LIQUID COAGULANT conditioner should not be used in

high pressure boilers.

MAKEUP
TURBO
ALTERNATOR
AUX.
CONDENSER

L.O. COOLER

BOILER MAIN
H.P. L.P.
CONDENSER
TURBINE TURBINE

DISTILLER

GLAND EXHAUST
CONDENSER
L.P. HEATER

FEED
PUMP DEAERATOR
H.P. HEATERS

DRAINS
RETURN
HEATING TANK
SERVICES

OBSERVATION
TANK

STEAM PROPULSION SYSTEM

1. AMERZINE

2. SLCC-A INJECTION POINTS

3. ADJUNCT B INJECTION POINTS

4. GC INJECTION POINTS

32
33
Boiler Water Treatment Control Tests
In Alphabetical Order
(pages 35-58)

Cooling Water Treatment Control Tests

In Alphabetical Order
(pages 63-66)

34
 HYDRATE ALKALINITY TEST
FOR AGK 100 and DREWPLEX® AT TREATMENTS
®

Before testing, boiler water, hot condensate, and feedwater samples must be cooled to 25OC (77OF) by collecting
through a sample cooler for safety and to prevent flashing which concentrates the sample. Read MSDS before running
these tests.

NOTE: If the sample is colored or turbid, filter before running the test. If the sample remains cloudy after the first
filtering, the sample should be refiltered through the same filter paper since the filter becomes more retentive on the
second filtration. (Filter paper is supplied separately).

HYDRATE ALKALINITY TEST KIT (PCN #0388-01-8)

APPARATUS REAGENTS

1 Plastic Titration Vial Marked at 12ml 7 x 60ml Barium Chloride 10%

1 Dropper Pipette Marked at 0.5 and 1.0ml 3 x 60ml Sulfuric Acid N/10
1 x 30ml Phenolphthalein

PROCEDURE 1. Rinse and fill the plastic titration vial to the line (12 ml) with cooled boiler
water sample.

2. Pipette 2 ml of Barium Chloride 10% into the vial and swirl to mix.

12 ml 3. Add 2 drops of Phenolphthalein Indicator and swirl. IF THE SAMPLE

DOES NOT TURN PINK, the Hydrate Alkalinity level is zero. Record zero
on the Onboard Graphing Log and adjust dosage to increase hydrate
1 alkalinity. IF THE SAMPLE TURNS PINK, counting the drops, add
2 Sulfuric Acid N/10 until the sample is colorless (disregard the eventual
reappearance of a pink color). Swirl the vial between drops.

4. Calculate the Hydrate Alkalinity concentration as follows:

Number of drops of Sulfuric Acid N/10 x 5 = ppm Hydrate Alkalinity as OH.

5. Record the Hydrate Alkalinity level on the Onboard Graphing Log. Make
3
dosage adjustments as needed.

CONTROL LIMITS

Hydrate Alkalinity Dosage

Below 40 ppm Increase

40-65 ppm No change
Above 65 ppm Decrease

35
 ALKALINITY TITRATION
FOR MEDIUM TO LOW PRESSURE BOILER SYSTEMS

Read the MSDS before performing this test procedure.

Before testing, samples must be cooled to 25OC (77OF) by collecting through a sample cooler for safety and to prevent flashing
which concentrates the sample.

APPARATUS REAGENTS

LP Alkalinity Titration Assembly PCN 0380-01-4 N/10 Sulfuric Acid, 500 ml PCN 0319-09-6
Graduated Cylinder, 50 ml PCN 0237-02-5 Phenolphthalein Indicator, 120 ml PCN 0311-01-9
Evaporating Dish PCN 0218-01-7 Total Alkalinity Indicator GP, 120 ml PCN 0355-19-9
Plastic Stirring Rod PCN 0417-01-5

PROCEDURE
1. Fill the burette by squeezing the plastic bottle of N/10 Sulfuric Acid. Allow the solu-
tion in the burette to settle to the 0.0 mark.
2. Measure 50 ml of cooled sample using a graduated cylinder.
3. Transfer the measured sample into an evaporating dish.
Phenolphthalein Endpoint
4. Add 4 drops of Phenolphthalein to the sample. If the solution turns pink, proceed to
step 5. If the solution does not turn pink, record Phenolphthalein Alkalinity as 0.0
on the Onboard Graphing Log and refer to the GC Dosage Chart for immediate
dosage of GC.

2 5. Turning the stopcock on the burette, add N/10 Sulfuric Acid to the sample drop by
1 drop while stirring continuously until the pink color disappears and the sample is
back to its original color. This is the Phenolphthalein Endpoint. NOTE: Do not
dispose of the sample in the evaporating dish or refill the burette. This same
sample is used for the Total Alkalinity Test and the total amount of acid added
must be measured.
6. Read the level of the N/10 Sulfuric Acid solution on the burette. Refer to the Medium
to Low Pressure Alkalinity Conversion Table on Page 36 and find the number which
3 corresponds to the burette reading. Beside this number you will find the equivalent
Phenolphthalein (P) Alkalinity expressed in parts per million (ppm). The parts per
million Phenolphthalein Alkalinity can also be calculated as follows:
ppm Phenolphthalein Alkalinity = mls of N/10 Sulfuric Acid x 100
7. Record the Phenolphthalein (P) Alkalinity as ppm on the Onboard Graphing Log.

Control Limits: 0-32 kg/cm2 100-150 ppm

32-60 kg/cm2 90-130 ppm
Total Alkalinity Endpoint
8. Using the same water sample in the evaporating dish, add 4 drops of Total Alkalinity
Indicator GP. The sample will turn a blue green color.
9. Without refilling the burette, turn the stopcock and add N/10 Sulfuric Acid drop by
drop stirring continuously. A pinkish purple color will begin to form around the drops
4&8 as they fall into the sample. Continue titrating and stir until a permanent pinkish
purple color develops throughout the sample. This is the Total Alkalinity Endpoint.
10. Read the level of the N/10 Sulfuric Acid solution on the burette. Refer to the Medium
to Low Pressure Alkalinity Conversion Table and find the number closest to the
burette reading. Beside this number you will find the equivalent Total (T) Alkalinity in
the sample expressed in parts per million (ppm). The parts per million Total Alkalin-
ity can also be calculated as follows:
ppm Total Alkalinity = mls of N/10 Sulfuric Acid x 100
11. Record the Total (T) Alkalinity as ppm on the Onboard Graphing Log.
12. Refer to the Control and Dosing Chart for instructions on dosing GCTM concentrated
alkaline liquid. The total alkalinity endpoint test is only a reference test and should
determine GC dosage adjustment only if the T. Alkalinity is out of balance.

5&9 6 & 10 Control Limits: 0-60 kg/cm2 < 2 P Alkalinity

36
 ALKALINITY TITRATION
FOR HIGH PRESSURE BOILER SYSTEMS
Read the MSDS before performing this test procedure.
Before testing, samples must be cooled to 25OC (77OF) by collecting through a sample cooler for safety and to prevent
flashing which concentrates the sample.

APPARATUS (included in PCN 0441-04-8) REAGENTS (included in PCN 0437-04-7)

HP Alkalinity Titration Assembly PCN 0379-01-7 N/50 Sulfuric Acid, 1000 ml PCN 0485-01-2
Graduated Cylinder, 50 ml PCN 0237-02-5 Phenolphthalein Indicator, 60 ml PCN 0311- -- -
Evaporating Dish PCN 0218-01-7 Total Alkalinity Indicator GP, 60 ml PCN 0355- -- -
Plastic Stirring Rod PCN 0417-01-5

PROCEDURE 1. Fill the burette by squeezing the plastic bottle of N/50 Sulfuric Acid. Allow the
solution in the burette to settle to the 0.0 mark.

2. Measure 50 ml of cooled sample using a graduated cylinder.

3. Transfer the measured sample into an evaporating dish.

Phenolphthalein Endpoint

4. Add 4 drops of Phenolphthalein to the sample. If the solution turns pink,

2 proceed to step 5. If the solution does not turn pink, record Phenolphthalein
1 Alkalinity as 0.0 on the Onboard Graphing Log and proceed to step 8.

5. Turning the stopcock on the burette, add N/50 Sulfuric Acid to the sample
drop by drop while stirring continuously until the pink color disappears and
the sample is back to its original color. This is the Phenolphthalein Endpoint.
NOTE: Do not dispose of the sample in the evaporating dish or refill the
burette. This same sample is used for the Total Alkalinity Test and the
3 total amount of acid added must be measured.

6. Read the level of the N/50 Sulfuric Acid solution on the burette. Refer to the
High Pressure Alkalinity Conversion Table on Page 36 and find the number
which corresponds to the burette reading. Beside this number you will find
the equivalent Phenolphthalein (P) Alkalinity expressed in parts per million
(ppm). The parts per million Phenolphthalein Alkalinity can also be
calculated as follows:

ppm Phenolphthalein Alkalinity = mls of N/50 Sulfuric Acid x 20

7. Record the Phenolphthalein (P) Alkalinity as ppm on the Onboard

Graphing Log.

Total Alkalinity Endpoint

4&8
8. Using the same water sample in the evaporating dish, add 4 drops of Total
Alkalinity Indicator GP. The sample will turn a blue green color.

9. Without refilling the burette, turn the stopcock and add N/50 Sulfuric Acid
drop by drop stirring continuously. A pinkish purple color will begin to form
around the drops as they fall into the sample. As the titration continues a
slate gray color will be observed. Continue titrating and stir until a permanent
pinkish purple color develops throughout the sample. This is the Total Alka-
linity Endpoint.

10. Read the level of the N/50 Sulfuric Acid solution on the burette. Refer to the
High Pressure Alkalinity Conversion Table and find the number closest to the
burette reading. Beside this number you will find the equivalent Total (T)
Alkalinity in the sample expressed in parts per million (ppm). The parts per
million Total Alkalinity can also be calculated as follows:
5&9 6 & 10
ppm Total Alkalinity = mls of N/50 Sulfuric Acid x 20

11. Record the Total (T) Alkalinity as ppm on the Onboard Graphing Log.

12. The alkalinity tests are conducted only as reference tests for high pressure
boiler systems.

37
 ALKALINITY TESTS

HIGH PRESSURE BOILERS

(Pressure Range: 60-84 kg/cm2 (850-1200 psig)

Titrated with N/50 Sulfuric Acid

Phenolphthalein and Total Alkalinity Control Tests

Conversion Table
mls of titrant ppm
(N/50 Sulfuric Acid Alkalinity as CaCO3

0.1 2
0.2 4
0.3 6
0.4 8
0.5 10
0.6 12
0.7 14
0.8 16
0.9 18
1.0 20
1.2 22
1.4 28
1.6 32
1.8 36
2.0 40
2.4 48
2.6 52
2.8 56
3.4 68
4.0 80
4.6 92
5.2 104

MMEDIUM TO LOW PRESSURE BOILERS

(Pressure Range: Up to 60 kg/cm2 (850 psig)
Titrated with N/10 Sulfuric Acid
Phenolphthalein and Total Alkalinity Control Tests

Conversion Table
mls of titrant ppm mls of titrant ppm
(N/10 Sulfuric Acid) Alkalinity (N/10 Sulfuric Acid) Alkalinity as CaCO3

0.1 10 2.6 260

0.2 20 2.7 270
0.3 30 2.8 280
0.4 40 2.9 290
0.5 50 3.0 300
0.6 60 3.1 310
0.7 70 3.2 320
0.8 80 3.3 330
0.9 90 3.4 340
1.0 100 3.5 350
1.1 110 3.6 360
1.2 120 3.7 370
1.3 130 3.8 380
1.4 140 3.9 390
1.5 150 4.0 400
1.6 160 4.1 410
1.7 170 4.2 420
1.8 180 4.3 430
1.9 190 4.4 440
2.0 200 4.5 450
2.1 210 4.6 460
2.2 220 4.7 470
2.3 230 4.8 480
2.4 240 4.9 490
2.5 250 5.0 500

38
 AMMONIA TEST
(CONDENSATE)
FOR HIGH PRESSURE BOILER SYSTEMS

Not a Required Test for Medium to Low Pressure Boilers

AMMONIA TEST AMPOULES (PCN 0384-01-6) INCLUDES:

30 Ampoules
1 Snapping Cup
1 Color Comparator Card

Included in the ULTRAMARINESM 6-Month Reagent Set (PCN 0437-04-7)

PROCEDURE

Before testing, samples must be cooled to 25°C (77°F) by collecting through a sample cooler for safety and to prevent
flashing which concentrates the sample.

1. Fill the snapping cup completely with cooled condensate.

SNAPPING
CUP FILL
COM- 2. Place the tapered tip of an ammonia ampoule into one of
PLETELY
the holes in the snapping cup. Keeping the tip immersed in
the sample, break the tip by tilting the ampoule towards the
opposite wall of the snapping cup and allow the ampoule to
1
fill completely.
2

3. Remove the ampoule from the snapping cup. Mix the

3 contents by inverting the ampoule back and forth several
times for 30 seconds.

Ashland Specialty Chemical 4. Wait 15 minutes for full color development.

15:00 Drew Marine Division
AMMONIA, ppm

4 5. Compare the color of the ampoule with the color standards.

0 0.1 0.3 0.5 0.7 Report the ammonia level on the ULTRAMARINE Onboard
Graphing Log as ppm ammonia.
5

Control Limit
60-84 kg/cm2
(850-1200 psig)
0.5 ppm maximum

39
 CHLORIDE TEST
FOR HIGH PRESSURE BOILER SYSTEMS

DREW CHLORIDE HP TEST KIT (PCN 0372-01-1) INCLUDES:

1 Glass Flask for Sample

1 Plastic Dropper Plug for Mixed Chloride Indicator
1 White Plastic Bottle Cap for Mixed Chloride Indicator
2 x 60 ml (2 oz.) Mercuric Nitrate
1 x 30 ml (1 oz.) Nitric Acid N/5
1 x 30 ml (1 oz.) Mixed Chloride Indicator Solution
1 Glass Vial Powder Indicator
This test kit is included in the ULTRAMARINESM 6 Month Reagent Set (PCN 0437-04-7).

...
...
...
...

Prepare the Mixed Chloride Indicator as follows:

Mixed
Chloride b Mixed
a. Unscrew the black caps of the small glass vial and the 1 oz. plastic
a Indicator Chloride
Indicator
bottle labeled "Mixed Chloride Indicator".
Dropper
Plug b. Pour the powder contents of the small glass vial into the liquid
contents of the 1 oz. plastic bottle.

Mixed c c. Screw the black cap back onto the Mixed Chloride Indicator bottle
Chloride d Mixed
Indicator
Chloride
Indicator and mix for 5 seconds.

d. Remove the black screw cap. Insert the plastic dropper plug into the
mouth of the plastic bottle and screw the white cap onto the bottle.
Mixed Proceed with the test.
Chloride
Indicator

PROCEDURE
1
1. Prepare the sample flask by rinsing the glass flask and fill to the
2
mark (24 ml) with the water to be tested.

2. Adjust the color of the sample by adding 6 drops of Mixed Chloride

Indicator and swirl to mix. The resulting color will be light red.
Nitric
Acid 3. Adjust the pH by adding Nitric Acid N/5 dropwise, swirling between
drops until the sample is yellow. Add 1 more drop.

4. Counting the drops, hold the glass flask in a vertical position and
3 Mercuric
add Mercuric Nitrate dropwise with swirling until the color turns to a
Nitrate
permanent purple.

4 5. Calculate the chloride concentration

Number of drops of Mercuric Nitrate x 1 = ppm chloride as Cl

6. Record results as ppm chloride on the Onboard Graphing Log.

Control Limit
16 ppm maximum

40
 CHLORIDE TITRATION
FOR HIGH PRESSURE BOILER SYSTEMS

Read MSDS before performing this test procedure.

Before testing, samples must be cooled to 25°C (77°F) by collecting through a sample cooler for safety and to prevent
flashing which concentrates the sample.

Note: If the sample is colored or turbid, it should be filtered before testing. If the sample remains cloudy after the first
filtering, the sample should be refiltered through the same filter paper since the filter becomes more retentive
on the second filtration.

This procedure is preferred for systems which are expected to contain low chloride levels because it is more sensitive
than the method for medium to low pressure boiler systems.

THIS TEST IS NOT RECOMMENDED FOR USE ON TREATED COOLING WATER.

APPARATUS REAGENTS

HP Chloride Titration Assembly PCN 0382-01-0 Mercuric Nitrate, 500 ml PCN 0475-09-6
Graduated Cylinder, 50 ml PCN 0237-02-5 N/5 Nitric Acid, 120 ml PCN 0479-19-7
Evaporating Dish PCN 0218-01-7 Mixed Chloride Indicator Solution, 100 ml PCN 0477-19-1
Plastic Stirring Rod PCN 0417-01-5 Mixed Chloride Indicator Powder, 5 caps PCN 0478-01-7

PROCEDURE
1. At least every four weeks prepare fresh Mixed Chloride Indi-
cator Solution. Discard any Mixed Chloride Indicator So-
lution that is more than four weeks old. Prepare new solution
as follows:
a. Empty a capsule of Mixed Chloride Indicator Powder into
the bottle of Mixed Chloride Indicator Solution.
b. Cap and mix by swirling or shaking the bottle gently.
1 2. Fill the burette by squeezing the plastic bottle of Mercuric Ni-
2 trate. Allow the solution in the burette to settle to the 0.0
mark.
3. Measure 50 ml of cooled sample using a graduated cylinder.
50 ml
4. Transfer the measured sample into an evaporating dish.
4
5. Add 10 drops of prepared Mixed Indicator Solution and stir.
3
6. Add N/5 Nitric Acid, drop by drop, stirring continuously until
the sample just turns yellow. Add 5 more drops of acid.
7. Turning the stopcock on the burette, add Mercuric Nitrate to
the sample drop by drop while stirring continuously. The end-
point is reached when the color changes to a permanant vio-
5&6 let.

8. Read the level of the Mercuric Nitrate solution on the burette.

Refer to the Chloride/Mercuric Nitrate Conversion Table on
Page 42 and find the number which corresponds to the burette
reading. Next to this number you will find the equivalent chlo-
ride content expressed in parts per million (ppm). The parts
per million chloride can also be calculated as follows:
ppm chloride = mls of Mercuric Nitrate x 10

9. Record results as ppm chloride on the Onboard Graphing Log.

7
Control Limit: 16 ppm maximum

41
 CHLORIDE TEST
FOR MEDIUM TO LOW PRESSURE BOILER SYSTEMS

DREW CHLORIDE LMP TEST KIT (PCN 0373-01-9) INCLUDES:

1 Plastic Vial (10 ml mark)

1 Glass Tube (1 ml mark)
2 x 60 ml (2 oz.) Silver Nitrate
1 x 30 ml (1 oz.) Sulfuric Acid N/10
1 x 30 ml (1 oz.) Phenolphthalein
1 x 60 ml (2 oz.) Potassium Chromate
This test kit is included in the Alkalinity/Chloride Reagent Set (PCN 0301-02-8).

PROCEDURE

1. For samples less than 100 ppm chloride

Rinse the plastic vial and fill to the mark (10 ml) with sample to be tested.
1 or
For samples greater than 100 ppm chloride
Rinse the tall glass test tube and fill to the mark (2 ml) with sample to be
plastic vial glass tube tested.

2. Neutralize the sample by adding 3 drops of Phenolphthalein Indicator to

the sample. Swirl to mix.
If the sample turns pink, add Sulfuric Acid N/10 dropwise with swirling
until the sample turns clear. Add 1 more drop.

If the sample does not turn pink, add 1 drop of Sulfuric Acid N/10.

3. Adjust the color of the sample by adding 6 drops of Potassium

Chromate. The sample will be yellow.

4. Counting the drops, add Silver Nitrate N/10 dropwise. Swirl between
2, 3, 4, 5
drops until the sample turns orange.

5. Calculate the Chloride Concentration

If the plastic vial was used in Step 1:
Number of drops of Silver Nitrate x 10 = ppm chloride

If the glass test tube was used in Step 1:

Number of drops of Silver Nitrate x 50 = ppm
chloride as Cl

6. Record results as ppm chloride on the Onboard Graphing Log.

NOTE: This test can be used to detect chloride in makeup water and
Control Limits
cooling water treated with DEWT® NC diesel engine water treatment. THIS
0-32 kg/cm2 32-60 kg/cm2
METHOD IS NOT RECOMMENDED FOR COOLING WATER TREATED
(0-450 psig) (450-850 psig)
WITH MAXIGARD® diesel engine water treatment or LIQUIDEWTTM
cooling water treatment WITHOUT SAMPLE PRETREATMENT. See
300 ppm max. 40 ppm max.
page 66 for sample pretreatment procedure.

42
 CHLORIDE TITRATION
FOR MEDIUM TO LOW PRESSURE BOILER SYSTEMS

Read MSDS before performing this test procedure.

Before testing, samples must be cooled to 25°C (77°F) by collecting through a sample cooler for safety and to prevent
flashing which concentrates the sample.

Note: If the sample is colored or turbid, it should be filtered before testing. If the sample remains cloudy after the first
filtering, the sample should be refiltered through the same filter paper since the filter becomes more retentive on the
second filtration.

This procedure is generally recommended for chloride determinations on all waters. An accurate chloride determination can
be made only with water having a pH below the Phenolphthalein Alkalinity Indicator end point (pH 8.3).

APPARATUS REAGENTS

LP Chloride Titration Assembly PCN 0381-01-2 N/10 Silver Nitrate, 500 ml PCN 0315-09-4
Graduated Cylinder, 50 ml PCN 0237-02-5 Potassium Chromate, 120 ml PCN 0313-19-7
Evaporating Dish PCN 0218-01-7 Phenolphthalein, 120 ml PCN 0311-19-1
Plastic Stirring Rod PCN 0417-01-5 N/10 Sulfuric Acid, 120 ml PCN 0319-19-5

PROCEDURE
1. Fill the burette by squeezing the plastic bottle of Silver
Nirate. Allow the solution in the burette to settle to the
0.0 mark.
1
2. Measure 50 ml of cooled sample using a graduated
50 ml cylinder.

3. Transfer the measured sample into an evaporating

dish.
Step 2 3
4. Add 4 drops of Phenolphthalein to the sample. If the
sample turns pink, add N/10 Sulfuric Acid dropwise
until the pink disappears. If the sample does not turn
pink, proceed to step 5.

5. Add one dropperful of Potassium Chromate to the

sample. This will turn the sample a yellow color.

6. Turning the stopcock on the burette, add Silver

6 Nitrate to the sample drop by drop while stirring
continuously. The endpoint is reached when the color
4&5 changes to a permanent light red. Do not "overtitrate"
to a "brick red" color as this will result in an errone-
ously high determination.

7. Read the level of the Silver Nitrate solution on the

burette. Refer to the Chloride/Silver Nitrate Conver-
sion Table on Page 42 and find the number which
corresponds to the burette reading. Next to this
number you will find the equivalent chloride content
expressed in parts per million (ppm).
8. Record results as ppm chloride on the Onboard
Graphing Log.
Control Limits

0-31 kg/cm2 32-60 kg/cm2

(0-450 psig) (450-850 psig)

300 ppm max 40 ppm max

43
 CHLORIDE TESTS

HIGH PRESSURE BOILERS

Pressure Range: 60-84 kg/cm2 (850-1200 psig)
Titrated with Mercuric Nitrate

Conversion Table
mls of Titrant ppm
(Mercuric Nitrate) Chloride
0.1 1
0.2 2
0.3 3
0.4 4
0.5 5
0.6 6
0.7 7
0.8 8
0.9 9
1.0 10
1.2 12
1.4 14
1.6 16
1.8 18
2.0 20
2.4 24
2.6 26
2.8 28
3.0 30
4.0 40
4.6 46
5.2 52

MEDIUM TO LOW PRESSURE BOILERS

Pressure Range: Up to 60 kg/cm2 (850 psig)
Titrated with Silver Nitrate

Conversion Table
mls of Titrant ppm mls of Titrant ppm mls of Titrant ppm
(Silver Nitrate) Chloride (Silver Nitrate) Chloride (Silver Nitrate) Chloride
0.1 7 2.5 178 4.8 341
0.2 14 2.6 185 4.9 348
0.3 21 2.7 192 5.0 355
0.4 28 2.8 199 5.1 362
0.5 36 2.9 206 5.2 369
0.6 43 3.0 213 5.3 376
0.7 50 3.1 220 5.4 383
0.8 57 3.2 227 5.5 390
0.9 64 3.3 234 5.6 398
1.0 71 3.4 241 5.7 405
1.1 78 3.5 248 5.8 412
1.2 85 3.6 256 5.9 418
1.3 92 3.7 263 6.0 426
1.4 99 3.8 270 6.1 434
1.5 107 3.9 277 6.2 440
1.6 114 4.0 284 6.3 447
1.7 121 4.1 291 6.4 455
1.8 128 4.2 298 6.5 461
1.9 135 4.3 305 6.6 468
2.0 142 4.4 312 6.7 476
2.1 149 4.5 319 6.8 483
2.2 156 4.6 326 6.9 490
2.3 163 4.7 334 7.0 497
2.4 170

44
 CONDUCTIVITY TEST
FOR HIGH TO LOW PRESSURE BOILER SYSTEMS

CONDUCTIVITY KIT (PCN 0173-01-3) INCLUDES:

APPARATUS REAGENTS

Conductivity Meter PCN 0156-01-9 Gallic Acid, 100 gm PCN 0309-01-4

Low Range Cell (White Band) PCN 0117-01-1 Phenolphthalein Indicator, 480ml (16 oz.) PCN 0311-01-9
High Range Cell (Black Band) PCN 0116-01-3 (Not provided in PCN 0173-01-3)
Conductivity Cylinder, Plastic PCN 0232-02-5
Dial Thermometer PCN 0143-02-4
Brass Spoon, 0.2gm PCN 0224-01-4

PROCEDURE

NOTE: Neutralization (Steps 3 and 4) is necessary for boiler water. It is not necessary for high purity waters such as condensate
or for feedwater. The other steps of the procedure are the same.
Before using the meter, be sure the voltage switch is set for the proper voltage.
CAUTION: ALWAYS DISCONNECT THE METER FROM THE POWER SOURCE BEFORE OPENING THE CASE.

1. Press the power switch and allow the meter to warm up for one minute.

2. Connect the conductivity cell for the appropriate testing range.

• White band (inner scale) for condensate and low conductivity waters.
• Black band (outer scale) for boiler water and other high conductivity solutions.

3. For a boiler water sample, add two drops of Phenolphthalein Indicator to the
sample and stir. If the sample remains clear, go to Step 5.
3
4. a. If the sample turns pink, neutralize by adding Gallic Acid, one level spoonful at
a time, stirring after each spoonful, until the pink color just disappears. NOTE:
Do not add excess Gallic Acid, Failure to neutralize sample or addition of
Gallic excess acid beyond the end point will cause erroneously high conductivity
Acid readings.
4

b. If Liquid Neutralizing solution is being used, the first drops will turn the solution
pink. Continue to add solution dropwise until the pink color disappears.

5. Submerge the cell in the water sample to a depth to cover the vent holes. Agitate
the cell to vent all trapped air bubbles from the cell interior.

6. Measure the temperature of the sample and set the temperature knob to this
value.

7. Rotate the conductivity knob until both the red and the green indicator lamps are
lighted at the same time.
7
8. Read the conductivity value on the appropriate scale.

9. Record the test result on the Onboard Graphing Log (µmhos).

10. Remove the cell from the sample and rinse it with clean water.
Control Limits
0-60 kg/cm2 60-84 kg/cm2 11. Press the power switch to shut off the meter.
(0-850 psig) (850-1200 psig)
12. Compare results to the Control and Dosing charts and adjust blowdown schedule
700 µmhos max 120 µmhos max as required.

45
 DEHA/DREWPLEX® OX corrosion inhibitor
Ampoule Test

DREWPLEX OX Ampoule Test Kit (PCN 0387-01-0) INCLUDES:

APPARATUS REAGENTS

1 Comparator Activator Solution PCN 0387-03-6

1 Snap Cup Ampoule Refill PCN 0387-02-8

PROCEDURE

Read MSDS before performing this test procedure.

NOTE: Before testing, samples must be cooled to 25OC (77OF) by collecting through a sample cooler for safety and to
pevent flashing which concentrates the sample. If the sample is colored or turbid, filter before running this test.

mL
25
20
1. Fill the sample cup to the 25 ml mark with cooled
15 feedwater sample.
10
5 2. Add 2 drops of Activator Solution. Stir gently with the tip
of an ampoule from the DREWPLEX® OX corrosion
1 inhibitor Ampoule Test Kit to mix the contents of the
3
2 sample cup.

3. Immediately snap the tip of the ampoule by pressing the

ampoule against the side of the sample cup. The
10:00 sample will fill the ampoule and begin to mix with the
reagent, leaving a small bubble to facilitate the mixing.

5 4. Remove the ampoule from the cup. Mix the contents of

4 the ampoule by inverting it several times, allowing the
small bubble to travel from end to end each time.

5. Wipe all liquid from the exterior of the ampoule and

WAIT EXACTLY 10 MINUTES for full color develop-
ment.

6. When using the comparator, be sure it is illuminated by a

6 white light directly above the comparator. The filled
DEHA ampoule should be placed between the color
standards for viewing. It is important that the DEHA
7 ampoule be compared by placing it on both sides of the
standard tube before concluding that it is darker, lighter
or equal to the standard.
CONTROL LIMITS
7. Record the results on the Onboard Graphing Log and
0-32 kg/cm2 adjust the DREWPLEX OX corrosion inhibitor dosage as
0-450 psig necessary.
0.4 - 0.8 ppm in feedwater

46
 HARDNESS TEST, TOTAL
FOR HIGH PRESSURE BOILER SYSTEMS
(MAKEUP and FEEDWATER)

HARDNESS TEST AMPOULES INCLUDES:

2 boxes of 30 Ampoules (PCN 0365-01-6)

This test material is included in the ULTRAMARINESM 6-Month Reagent Set (PCN 0437-04-7).

PROCEDURE

SNAPPING 1. Rinse and fill the snapping cup with the sample to be tested.
CUP FILL
COM-
PLETELY

1
2. Place the tip of the hardness ampoule into one of the holes in the bottom of
the snapping cup.

3. While applying downward pressure, break the tip by tilting the ampoule
toward the edge of the snapping cup. Keep the tip immersed in the water
while drawing sample.

4. Mix by inverting the hardness ampoule back and forth to dissolve the
3 reagent.

5. Wait 30 seconds.

6. Place the ampoule in front of a white background and view the color. A pure
blue color indicates less than 0.1 ppm hardness. A pink color indicates
hardness is present.

7. To confirm a pure blue color, run a zero standard by performing the test on
distilled water.

8. Record results on the Onboard Graphing Log.

Control Limit
60-84 kg/cm2
(850-1200 psig)
<0.1ppm

47
 HARDNESS TEST
TITRET2 METHOD

This test may be used on treated waters as well as makeup water.

TOTAL HARDNESS TITRETS2 (PCN 0378-01-9) INCLUDES:

50 Titrets 1 Sample Cup

30 Valve Assemblies

PROCEDURE

NOTE: If the sample is colored or turbid, it should be filtered before

testing.

1. Fill the sample cup to the 25 ml mark with sample (Figure 1).

1 2. Slide the open end of the valve assembly over the tapered tip of the
Titret so that it fits snugly to the Reference Line (Figure 2).

3. Snap the tip of the Titret at the Score Mark (Figure 3).
Valve
Assembly 4. With the tip of the valve assembly immersed in the sample, squeeze
the bead valve briefly to add a small amount of sample to the Titret
(Figure 4). The red indicator in the valve assembly will also be added
Bead to the Titret.
← Valve
CAUTION: Do not squeeze the bead valve unless the tip of the valve
Score Mark is immersed below the surface of the liquid.
3
Reference Line
5. Rock the Titret to mix the contents. The contents of the Titret will turn
Ampoule 2 a BLUE color.

6. Continue to add small amounts of sample until the liquid in the Titret
turns from BLUE TO PINK. Be sure to rock the Titret to mix the
contents after each addition of sample. When the color of the liquid
in the Titret changes to PINK, the end point has been reached. Stop
the test, hold the Titret with its tip pointed upward and read the scale
opposite the liquid level to obtain the test results in ppm total hardness
4 as calcium carbonate, CaCO3 (Figure 5).

7. Record results on the Onboard Graphing Log.

Read
Here →

Hardness should not exceed 170 ppm in waters used as makeup to diesel engine cooling systems treated with MAXIGARD®
diesel engine water treatment or LIQUIDEWTTM cooling water treatment.

48
 HYDRAZINE/AMERZINE TEST
FOR HIGH TO LOW PRESSURE BOILER SYSTEMS

AMERZINE® CORROSION INHIBITOR AMPOULE TEST KIT (PCN 0369-01-8) INCLUDES:

1 Cylindrical Comparator
1 Sample Cup
1 Set of Instructions
30 Ampoules

AMERZINE CORROSION INHIBITOR AMPOULE REFILL (PCN 0369-02-6) INCLUDES:

30 Ampoules

This test kit and refills are included in the ULTRAMARINESM 6 Month Reagent Set (PCN 0437-04-7)

PROCEDURE

1. To insure accurate results, the sample should be collected with

minimum contact to air and tested promptly. A sample cooler
should be used for sampling boiler water.

2. Fill the sample cup to the 25ml mark with sample.

1&2

3. Place the AMERZINE corrosion inhibitor ampoule's tapered tip into

one of the four depressions in the bottom of the sample cup. Snap the
tip by squeezing the ampoule toward the side of the cup. Keep the tip
3 immersed in the water while drawing sample. The sample will fill the
ampoule and begin to mix with the reagent.

4. Remove the AMERZINE corrosion inhibitor ampoule from the cup. Mix
the contents of the ampoule by inverting it several times, allowing the
bubble to travel from end to end each time.

5
5. Wipe all liquid from the exterior of the ampoule and wait 10 minutes for
full color development.

6. Place the AMERZINE corrosion inhibitor ampoule, flat end downward

into the center tube of the comparator. Direct the comparator toward a
source of bright white light while viewing from the bottom. Hold the
comparator in a nearly horizontal position and rotate it until the color
standard below the AMERZINE corrosion inhibitor ampoule shows the
Control Limit closest match.
0-84 kg/cm2
(0-1200 psig) 7. Record the AMERZINE level on the Onboard Graphing Log. Results
are expressed as ppm hydrazine.
0.03-0.10 ppm

49
 pH TEST (COLORMETRIC)
FOR HIGH PRESSURE BOILER SYSTEMS

Not a Required Test for Medium to Low Pressure Boilers.

APPARATUS

Included in the ULTRAMARINESM Glassware Set (PCN 0441-04-8)

Water Analyzer Base PCN 0427-01-4
Phthalein Red Comparator Slide PCN 0422-01-4
(8.6 to 10.2 pH range)
Tolyl Red Comparator Slide PCN 0425-01-8 REAGENTS
(10.0 to 11.6 pH range)
Nessler Tubes, 3 Short, 150mm PCN 0423-01-2 Included in the Ultratest® 6 Month Reagent Set
Graduated Cylinder, 100ml, Plastic PCN 0410-01-9 (PCN 0437-02-1)
Dropper Pipettes, Plastic, marked at 0.5ml (cc) PCN 0411-01-7 1 x 500ml Phthalein Red PCN 0481-01-0
and 1.0ml (cc) 1 x 500ml Tolyl Red PCN 0486-01-0
Stirring Rod, 150 mm, Plastic PCN 0417-01-5
Bottle, 60ml (2 oz.), Glass, with dropper PCN 0433-01-1
(for Phthalein Red Indicator)
Bottle, 60 ml (2 oz.), Glass, with dropper PCN 0434-01-9
(for Tolyl Red Indicator)

PROCEDURE

1. Fill the two outside Nessler Tubes (end tubes B&D) to the 150 mm mark with
untreated sample water and place in the outside compartments of the Water
Analyzer Base.

2. Rinse the center Nessler Tube (C) with a small amount of boiler water.

3. Measure exactly 75 ml of sample in the 100 ml graduated cylinder, and add

to this exactly 0.5 ml (cc) of the appropriate pH indicator (using dropper
3 pipette). Stir thoroughly with the stirring rod to obtain uniform color through-
out.
U
Conntreate ed
den d reat te 4. Put treated sample (from Step 3) into the center Nessler Tube (C), adding
sate Untndensa
Co
only enough to bring the level in the tube to the 150 mm mark. Place this tube
D in the center compartment.

1&4 5. Place the appropriate pH comparator slide in the slot in the support base.
Determine the pH according to the General Instructions for the Water
Analyzer on page 5.

6. Record the pH value on the Onboard Graphing Log.

7. Compare test results to those on the Control and Dosing Chart. Adjust the
pH of the boiler water with GCTM concentrated alkaline liquid as necessary.

Control Limits
60-84 kg/cm2
(850-1200 psig)

9.8-10.2 boiler water

50
 pH TEST (METER)
FOR HIGH PRESSURE BOILER SYSTEMS

Not a Required Test for Medium to Low Pressure Boilers

APPARATUS REAGENTS

PORTABLE pH METER PCN 0246-01-8 pH Buffer 7 (500ml) PCN 6255-09-6

Low Maintenance Triode pH Electrode PCN 0246-02-6 pH Buffer 10 (500 ml) PCN 6444-09-5
pH Electrode Storage Solution PCN 0246-03-4
(500ml)

PROCEDURE (Boiler Water)

Two Point Autocalibration (Weekly)

1. Attach the pH Electrode to the meter.

2. Press the "power" button to turn the meter on.
3. Place the electrode into pH buffer 7 solution.
4. Press the "mode" button until CALIBRATE is displayed.
5. Press the "no" button until the buffer sequence 7-10 is displayed and then press the "yes" button.
6. The buffer chosen will be displayed in the main field, P1 will be displayed in the lower field, and an arrow in the bottom
of the display will point to "7".
7. When ready is displayed, press the "yes" button. P2 will then be displayed in the lower field and an arrow in the bottom
of the display will point to "10". This indicates that the meter is ready for the second buffer
calibration using a pH buffer 10 solution.
8. Rinse the electrode with distilled water and place into pH buffer 10 solution.
9. When ready is displayed, press the "yes" key. The meter will automatically advance to the MEASURE mode.

Sample pH Measurement (Daily)

1. Rinse the electrode with distilled water.

2. Place the electrode into the sample.
3. Record the reading when ready is displayed.
4. Both the temperature corrected pH reading and temperature reading are displayed.

Electrode Storage

For short-term (up to one week) electrode storage, soak the electrode in pH Electrode Storage Solution.

For long-term (greater than one week) electrode storage, rinse the electrode with distilled water and remove any salt
buildup or deposits. Cover the end of the electrode with the protective cap and store dry.

Consult the Orion Instruction Manual for more information.

Control Limits
60-84 kg/cm2
(850-1200 psig)

9.8-10.2 boiler water

51
 pH TEST
CONDENSATE
MEDIUM AND LOW PRESSURE BOILER SYSTEMS
USING STANDARD TREATMENT

This test can be performed with the indicators and acids already available in the testing program. The procedures
differ slightly because of acid strengths.

The desired pH in a condensate system is 8.3-8.6 because this is the least corrosive pH for nonferrous metals of
construction. This pH is in the same range as the endpoint of phenolphthalein. If the addition of phenolphthalein
turns the sample pink, then it is sufficiently alkaline. To be sure that the water is not excessively alkaline, we back
titrate with acid. If a very small amount of acid is needed to reach the endpoint in these titrations, then we can say
that the pH of the condensate is in the proper range.

APPARATUS REAGENTS

LP Alkalinity Titration Assembly PCN 0380-01-4 N/10 Sulfuric Acid, 500 ml PCN 0319-09-6
Graduated Cylinder, 50 ml PCN 0237-02-5 Phenolphthalein Indicator, 120 ml PCN 0311-01-9
Evaporating Dish PCN 0218-01-7
Plastic Stirring Rod PCN 0417-01-5

PROCEDURE

1. Collect 50ml cooled condensate sample and pour into

evaporating dish.
1

2. Add 3 drops phenolphthalein. Sample should turn pink.

3. Add sulfuric acid N/10 drop by drop until pink color

disappears.

4. Record results on the Onboard Graphing Log and adjust

2 SLCC-ATM treatment dosage as necessary.

Control Limit
0-60 kg/cm2
(0-850 psig)

1-2 drops or
pH 8.3-8.6

53
 pH TEST
CONDENSATE
FOR HIGH PRESSURE BOILER SYSTEMS

APPARATUS REAGENTS

(1) Beaker, 100ml , PCN 0247-01-6 (1) Phenolphthalein, 120ml, PCN 0311-19-1
(1) Stirring Rod, PCN 0417-01-5 (1) N/50 Sulfuric Acid, 1000ml, PCN 0485-01-2

PROCEDURE

1. Obtain a cooled 50ml condensate sample and add

2-3 drops of phenolphthalein.

1
2. Add N/50 Sulfuric Acid dropwise, counting drops,
until the pink color disappears.

3. Record results on the Onboard Graphing Log.

4. Record results on the Onboard Graphing Log and

3 adjust SLCC-ATM treatment dosage as necessary.

Control Limit
60-84 kg/cm2
(850-1200 psig)

1-2 drops or
pH 8.6-9.0

54
 PHOSPHATE TEST
FOR HIGH PRESSURE BOILER SYSTEMS

PHOSPHATE VACU-VIALS2 TEST KIT (PCN 0390-01-3) INCLUDES:

1 Photometer
30 Vacu-Vials (PCN 0390-02-1)
1 Sample Cup
1 Light Shield
1 Test Tube
1 Blank Vacu-Vial

PROCEDURE

Read Material Data Sheet before using. Do not snap the ampoule tip in air or in any liquid except water.
NOTE: Filter a cooled boiler water sample before running this test. Filter paper and funnel are supplied separately.

1. Fill the sample cup to the 25 ml mark with cooled, filtered

boiler water.

2. Place the phosphate VACU-VIALS ampoule in the sample

cup. Snap the tip by pressing the ampoule against the
side of the cup. The ampoule will fill, leaving a small
bubble to facilitate mixing.
1
2 3. Mix the contents by inverting the ampoule, showing the
bubble to travel from end to end. Wipe all liquid from the
exterior. Wait 5 minutes.
05:00
4. Press ON. When the display shows “---”, the photometer
is ready.
3
3
5. Zero the photometer by inserting the VACU-VIALS blank
ampoule into the cell compartment, aligning the vertical
line on the ampoule with the water droplet on the photom-
eter. Cover the ampoule with the light shield. Press the
ZERO button. The display will show “S1P” momentarily,
then it will read “-0.0-”.

6. After the 5 minute wait required in step 3, insert the

4 5 phosphate VACU-VIALS ampoule with proper cell align-
ment into the cell compartment. Cover the ampoule with
the light shield. Press the READ button. The meter will
show “S1P” momentarily, then it will display the test result
in ppm ortho phosphate as PO4.

7. Record the results on the Onboard Graphing Log and

Control Limit adjust the ADJUNCT® B treatment dosage as necessary.
60-84 kg/cm2
(850-1200 psig)
15-25 ppm

55
 PHOSPHATE TEST
FOR MEDIUM TO LOW PRESSURE BOILER SYSTEMS

Before testing, sample must be cooled to 25OC (77OF) by collecting through a sample cooler for safety and to
prevent flashing which concentrates the sample.

NOTE: Filter the boiler water sample before running this test. Filter paper and funnel are supplied separately.

APPARATUS

Boiler Phosphate Ampoule Test Kit (Product Code #1AA0003) contains:

• 1 comparator • 1 set of instructions
• 1 snap cup • 30 ampoules

Boiler Phosphate Ampoule Refill (Product Code #1AA0004) contains:

• 30 ampoules

Filter Paper, box of 100 sheets P/C #0225-01-2

Funnel, Plastic P/C #0221-01-0

PROCEDURE
1. Fill the sample cup to the 25 ml mark with sample (Figure 1).

mL 2. Place the Boiler Phosphate ampoule’s tapered tip into one of

25 the four depressions in the bottom of the sample cup. Snap
20 the tip by squeezing the ampoule toward the side of the cup.
15
The sample will fill the ampoule and begin to mix with reagent
10
(Figure 2).
5

Figure 1
3. Remove the Boiler Phosphate ampoule from the cup. Mix the
contents of the ampoule by inverting it several times allowing
the bubble to travel from end to end each time (Figure 3).
Figure 2
4. Wipe all liquid from the exterior of the ampoule and wait 5
minutes for full color development (Figure 4).

5. When using the comparator, be sure it is illuminated by a

white light directly above the comparator. The filled Boiler
Figure 3 Phosphate ampoule should be placed between the color
05:00 standards for viewing. It is important that the ampoule be
compared by placing it on both sides of the standard tube
Figure 4 before concluding that it is darker, lighter or equal to the
standard (Figure 5).

6. Record the results on the Onboard Graphing Log and adjust

product dosage as necessary.

Figure 5
Control Limits
AGK® 100 & DREWPLEX® AT Programs
10-20 ppm
Standard Treatment Programs
0-60 kg/cm2
(0-850 psig)
20-40 ppm

56
 SILICA TEST
FOR HIGH PRESSURE BOILER SYSTEMS

Not a Required Test for Medium to Low Pressure Boilers.

SILICA AMPOULE TEST KIT (PCN 0376-01-3) INCLUDES:

30 Ampoules
2 x A-9000 Neutralizer Solution
2 x A-9001 Activator Solution
1 Cylindrical Comparator, 0-1 ppm
1 Flat Comparator, 1-10 ppm
1 Sample Cup

Included in the ULTRAMARINESM 6 Month Reagent Set (PCN 0437-04-7)

PROCEDURE

NOTE: If the sample is colored or turbid, it should be filtered before testing.

1. Fill the sample cup to the 15 ml mark with sample

(Figure 1).

2. Add 10 drops of A-9001 Activator Solution (Figure 2). Cap

the sample cup and shake it to mix the contents well. Wait 4
minutes.
3. Add 5 drops of A-9000 Neutralizer Solution (Figure 2). Cap
the sample cup and shake it to mix the contents well. Wait 1
minute.

4. Place the silica ampoule's tapered tip into one of the four
1 depressions in the bottom of the sample cup. Snap the tip by
2 squeezing the ampoule toward the side of the cup. The
sample will fill the ampoule and begin to mix with reagent
(Figure 3).

5. Remove the silica ampoule from the cup. Mix the contents of
the ampoule by inverting it several times allowing the bubble
to travel from end to end each time.

6. Wipe all liquid from the exterior of the ampoule and wait
2 minutes for full color development.
3 4
7. After 2 minutes, use the comparator to determine the level of
silica in the sample.

a. When using the lower range comparator (0-1.0 ppm),

place the silica ampoule, flat end downward into the
center tube of the comparator. Direct the comparator
toward a source of bright white light while viewing from
the bottom. Hold the comparator in a nearly horizontal
position and rotate it until the color standard below the
silica ampoule shows the closest match (Figure 4).
5 b. When using the high range comparator (1-10 ppm), be
sure it is illuminated by a white light directly above the
comparator. The filled silica ampoule should be placed
between the color standards for viewing. It is important
Control Limit that the silica ampoule be compared by placing it on both
60-84 kg/cm2 sides of the standard tube before concluding that it is
(850-1200 psig) darker, lighter or equal to the standard (Figure 5).
6 pm maximum
8. Record the results on the Onboard Graphing Log.

57
 SULFITE
FOR MEDIUM AND LOW PRESSURE BOILER SYSTEMS

DREW MARINE SULFITE TITRETS2 (P/C #0377-01-1) INCLUDES:

• 30 Titrets • 1 Sample Cup

• 30 Valve Assemblies • 1 Set of Instructions
• 1 A-9600 Neutralizer Solution

PROCEDURE

NOTE: If the sample is colored or turbid, it should be filtered

before testing.

1. Fill the sample cup to the 25 ml mark with sample (Figure 1).

2. Add 5 drops of A-9600 Neutralizer Solution (Figure 2). Stir

lightly and briefly. Wait 30 seconds. Figure 1

3. Slide the open end of the valve assembly over the tapered tip of
the Titrets1 so that it fits snugly to the Reference Line (Figure 3).
Valve →
4. Snap the tip of the Titrets at the Score Mark (Figure 4). Assembly Figure 2
← Bead
5. With the tip of the valve assembly immersed in the sample, Score
Valve
Mark →
squeeze the bead valve briefly to add a small amount of Reference →
sample to the Titrets (Figure 5). The colorless indicator in the Line

valve assembly will also be added to the Titret.

CAUTION: Do not squeeze the bead valve Figure 3
unless the tip of the valve assembly is immersed below the
surface of the liquid.

6. Rock the Titrets to mix the contents. The contents of the

Titrets will turn a DEEP BLUE color. Wait 30 seconds.

7. Continue to add small amounts of sample until the liquid in

Figure 4
the Titrets turns from BLUE TO COLORLESS. Be sure to
rock the Titret to mix the contents after each addition of
sample. When the color of the liquid in the Titrets changes to
COLORLESS, the end point has been reached. Stop the
test, hold the Titrets with its tip pointed upward and read the
scale opposite the liquid level to obtain the test results in ppm
sulfite as SO3 (Figure 6).

8. Record the results on the Onboard Graphing Log and adjust Figure 5
product dosage as necessary.
Figure 6
Control Limit
0-32 kg/cm2 36-60 kg/cm2
(0-450 psig) (450-850 psig)

20-30 ppm 10-15 ppm

58
 COOLING WATER SYSTEMS AND TREATMENT
INTRODUCTION
Cooling water circuits on motor vessels encompass sev-
eral different types of systems. Of primary concern to us
are the cooling water systems for main and auxiliary en-
gines and air conditioning systems. While we will mention
refrigeration brine systems briefly in our discussions, we
will not include them or seawater cooling systems except
to say that fouling of these units will lead to overheating
and ultimate system failure. Chemical and mechanical
treatments* of these systems are available, but will not be
discussed at this time.
Marine diesel engines have continually undergone im-
provement in performance ratings and power to weight
ratios. These design changes often increase the com-
plexity of the system. Where ferrous and some cuprous
metals were the standard of the past construction for me-
dium and slow speed engines, today’s designs are begin-
ning to utilize a wider variety of metals including alumi-
num components.
Improved performance characteristics have subjected the
cylinder liners, covers and pistons to higher temperatures,
pressures and heat transfer rates. These factors in com-
COOLING WATER SYSTEM CIRCULATION
The importance of an efficient engine cannot be overstated.
The temperature of the gases produced during combus-
tion exceed the melting point of case iron and, without
cooling, the piston and other metal parts would fuse and
eventually seize. This is the result of overheating in the
extreme. However, even if actual melting does not occur
there can be substantial loss of the metal’s strength and
ductility which can lead to premature failure. Lube oil films
also can be destroyed by overheating, leading to wear,
deposits and premature system failure.
Diesel engines can be cooled with water or air heat ex-
change equipment. The most commonly used medium in
the commercial marine market is water. Its treatment is of
primary concern to us.
There are three main systems in a diesel engine which
require cooling: the engine jacket, the piston areas and
the fuel valves. The cooling water system can be one large
closed loop with main circulating pumps and a common
head tank or there can be three separate cooling water
circuits employed to independently cool the cylinder jacket,
piston, and fuel valve. The systems can be cross-con-
nected in the event of equipment failure so that the cool-
ing load can be picked up by another system. Conversely,
cooling circuits also can be isolated if contamination is
encountered. Consideration of each system design and
the metals of construction is important in deciding on the
type of treatment to be used and how and where it should
be dosed.
59
bination with the variety of metals in use have created a
challenge for the efficiency of the cooling water systems
and the capability of chemical treatments formulated for
them.
The higher engine temperatures result in accelerated min-
eral deposition rates on the water side. Because of the
design of diesel engines, the use of high quality makeup
water is the best means of controlling scale formation. As
a result, the use of distilled water as the coolant has be-
come essential. However, untreated distilled water is many
times more corrosive to metals than a water with a degree
of contamination and it has therefore become an opera-
tional and economic necessity to treat the engine cooling
water with a corrosion inhibitor.
Testing of treated cooling water is a vital part of the treat-
ment program and the required test procedures will be
discussed at the end of this section.
Contact your local Drew representative for more informa-
tion about the use of corrosion inhibitors and
AMERSPERSE® 280 seawater cooling treatment in these
systems.
The cooling water enters at a low point in the cooling cir-
cuit and flows upward to exit at the top of the engine. This
arrangement minimizes the formation of air pockets which
prevent the proper wetting of metal surfaces. This inter-
rupts proper heat transfer and allows overheating to oc-
cur.
The hot water is extracted and passed through a heat
exchanger system where the heat energy is passed to a
secondary coolant, often seawater. The cooled water is
then recirculated back to the engine to complete the
“closed” circuit.
This heat exchange process also can provide heat for
evaporators and auxiliary systems. Many modern motor
vessels are equipped with evaporators that use the diesel
engine cooling water as a primary heat source to gener-
ate distilled water at minimum cost. After passing through
the evaporator, the cooling water may continue through
another heat exchanger to further utilize the energy avail-
able and control the water inlet temperature to the diesel
engine systems. Because of the space considerations
and economic factors, the design of marine plants often
interrelates a number of systems to maximize the efficiency
which could be discussed at length. However, that is not
the central topic of this discussion. Instead, the preven-
tion of scale and corrosion in these various systems is.
 CORROSION OF METALS
TYPES OF CORROSION
AND PREVENTATIVE MEASURES
Distilled water is desirable for scale prevention but it is
very aggressive in itself. In addition, other corrosion
mechanisms are at work in the system.
Oxygen Pitting: Dissolved oxygen is a primary cause of
corrosion and is involved in practically all corrosion pro-
cesses.
Cooling water is not deaerated. Although there are air
release units in the circuit, the water usually contains a
much higher concentration of dissolved oxygen than does
boiler feed water. The cooling water is exposed to the air
while in open head tanks and air contains 20% (200,000
ppm) oxygen.
The amount of oxygen that the water contains is depen-
dent upon the temperature of the water since cold water
will dissolve more oxygen than hot water. Some oxygen is
brought in by makeup water additions and inleakage at
seals or other points throughout the mechanical system.
Cavitation: Because of engine vibrations and high im-
pingement flow conditions, metal parts of the cooling sys-
tem can be damaged by cavitation corrosion/erosion. Cavi-
tation damage appears as shallow pitting or gouging of
the metal surface, but, unlike oxygen attack it is caused
by mechanical as well as chemical conditions.
High frequency vibration, high velocity flow conditions, or
changes in temperature which cause a localized reduc-
tion in water pressure below the vapor pressure can lead
to cavitation/erosion. In these areas of low pressure,
bubbles of vapor will form next to the metal surface. As
the pressure returns to normal, the bubble collapses strik-
ing the metal with great force (hundreds of kilograms/cen-
timeter2 or thousands of pounds/inch2). The protective
film is destroyed leading to further corrosion. This action
is repeated in a cycle that erodes the metal surfaces.
Acid Attack: Acid attack is brought about by low pH wa-
ter. Some minerals and gases can, when dissolved in the
water, produce acid which lowers the pH and causes cor-
rosion. Not only will the acidic water be more corrosive to
the metal, it will not be an environment in which the mod-
ern cooling water corrosion inhibitors will be effective.
60
Chemical Treatment
Inhibitors are chemicals that protect metals by creating a
barrier between the water and the metal or by reacting
with the metal surface to form a thin protective or passiva-
tion film which makes the metal underneath more resis-
tant to attack.
Soluble oil is a barrier type inhibitor which functions well
up to the point of breakdown when deposits may form.
Other barrier-type inhibitors, such as silicates which func-
tion well in ambient temperatures, interfere with heat trans-
fer and are not applicable in engine cooling systems.
Most protective films are so thin that they cannot be seen
and they do not interfere with heat transfer. They are
formed by the chemical combination of the inhibitor and
the metal surface and tightly adhere to the metal. The film
can be damaged or torn away by water flow. However, a
residual of inhibitor is maintained in the water so that if the
protective film is damaged in any way, the film is rapidly
repaired.
Modern chemicals are normally a nitrite-borate-organic
mixture. Nitrite is a film forming inhibitor. The nitrite pri-
marily protects against corrosion of the ferrous metals in
a cooling water system. Other inhibitors are included in
the formulation designed to minimize corrosion of nonfer-
rous metals. Borate is included to adjust pH to aid in cor-
rosion inhibition and to provide the proper environment for
the reaction of nitrite.
Where cavitation erosion is known to exist, there is some
evidence that large doses of corrosion inhibitors will re-
duce the erosion.
Special formulations are available for medium and high-
speed diesel engines which combine nitrite-borate organic
corrosion inhibitors and polymeric scale inhibitors.
In the past, buffered chromate treatment was the primary
inhibitor but this approach has lost favor due to environ-
mental concerns and the toxicity of chromate. Chromate
is still used in refrigeration brine systems where other in-
hibitors are not very effective.
In systems where glycol antifreezes are needed, nitrite
borate treatments should be used because they are com-
patible with the glycol. Chromate should not be used with
glycol because of a reaction which forms a “curd-like” pre-
cipitate.
 COMPOSITION AND FORMATION OF DEPOSITS
DEPOSIT FORMATION
AND PREVENTATIVE TREATMENT
Scale Deposits: The diesel engine has a very low toler-
ance for mineral scale buildup. Calcium and magnesium
compounds will form scale in high heat transfer sections
of the cooling water system. Calcium carbonate and sul-
fate salts are the first to deposit because their solubility
decreases as the water temperature increases.
Mineral scales are hard and dense and are excellent in-
sulators. Their presence drastically reduces heat trans-
fer. For example, one mm of calcium sulfate (CaSO4) scale
is equivalent as a heat transfer barrier to 40 mm of metal.
The effect of scale on heat transfer characteristics is illus-
trated in the following diagram.
Effect of Scale
Scale often allows corrosion to progress underneath the
deposits which can ultimately lead to system failure. This
type of corrosion is more fully described in the Boiler Wa-
ter Systems and Treatment section.
Scale-forming minerals may be introduced by seawater
inleakage or by the use of poor quality makeup. Distilled
water is the recommended makeup to minimize scale for-
mation. On ships which do not produce or have an inad-
equate supply of distilled water, fresh water from a shore
supply is used. Shore water is not preferred because it
contains varying amounts of scale-forming constituents
and other contaminants.
Oil Deposits: Soluble oils are used as treatments in some
cooling systems, especially in the piston cooling circuits.
If overheating occurs due to reduced circulation or over-
load conditions, the soluble oil may decompose and can
form deposits. These oils are not truly “soluble,” but are
emulsions which breakdown in time with the same unde-
sirable result as any oil contamination would cause in a
cooling system.
WATER
COMBUSTION SIDE
SIDE
TEMP
GRADIENT
ACROSS
25 MM
LINER
270OC
70OC
(A) Clean Cylinder Wall
The cooling water may become contaminated by fuel or
lubricating oils. The insulating effects of oil deposits on
heat transfer surfaces are the same as mineral scale de-
posits.
As with all other contaminants, the source of oil inleakage
should be located and eliminated. The entire cooling sys-
tem should be cleaned with a solvent cleaner at the earli-
est opportunity. HDE-777TM heavy duty emulsifier is an
effective cleaner for the purpose. Light to medium oily
deposits combined with scale and oxide deposits can be
removed using AMEROlD® OSC one-step cleaner. (There
are other maintenance chemical cleaner choices. Con-
sult your local Drew Marine representative for specific rec-
ommendations.)
Mechanical Correction
The only means of mechanically preventing scaling is by
removing minerals before the makeup water enters the
engine system. The evaporator, a bank of reverse osmo-
sis units or a demineralizer must be operated efficiently to
provide high quality make up. Shore water can be used if
the needed volume of high quality water is not available,
but, as stated above, it is not preferred because its quality
is poor and so variable around the world. However, if it is
used, an analysis of the water should be obtained from
the supplier and/or a local governmental office.
Chemical Correction
The antiscalant chemicals used in boiler water treatment
are not applicable for diesel engine systems because there
is no practical method to blow down a diesel cooling water
system to remove the normal sludges formed by a boiler
water treatment process. The sludges can block small
cooling passages in the system restricting water flow and
compounding the problems of overheating.
Treatments are now available which contain polymeric
antiscalants which can sequester and disperse a certain
amount of hardness. Unlike the phosphate-alkalinity treat-
ments common to boiler water treatments, the polymers
in modern cooling water treatments will hold hardness con-
stituents in suspension until they can be removed by bleed
off.
WATER
SIDE
570OC
COMBUSTION TEMP
TEMP GRADIENT
SIDE
GRADIENT ACROSS
ACROSS 1 MM
25 MM SCALE
LINER
(B) 1mm Mineral Scale on
Waterside
61
 COOLING WATER TREATMENT CHEMICALS
DEWT® NC diesel engine water treatment is a nitrite-
borate type corrosion inhibitor used in closed cooling water
systems. This low toxicity product is particularly applicable
in diesel engine cooling water circuits, where the jacket
water is the heat source for the evaporators which produce
potable water. DEWT NC treatment has no deleterious
effects on glands, seals, rubber hoses, valve packing, etc.
It is compatible with antifreeze materials and will not form
objectionable sludges.
MAXIGARD® diesel engine water treatment is a multi-
functional liquid blend of nitrite-borate-organic corrosion
inhibitor and mineral deposit modifiers. MAXIGARD treat-
ment is specially formulated for the closed cooling water
systems in medium and high speed diesel engines. It is
suitable for distilled or fresh water systems with or without
antifreeze chemicals. MAXIGARD treatment is safe for
use in systems where jacket water is the heat source for
the evaporators which product potable water supplies.
LIQUIDEWTTM cooling water treatment is a multi-
functional liquid blend of nitrite-borate-organic corrosion
inhibitor and mineral deposit modifiers for scale preven-
tion. LIQUIDEWT treatment is formulated for use in
medium speed diesel engines. This product can be used
in both distilled and shore waters. It has low toxicity and
is compatible with glycol antifreezes. Glycol is used as an
antifreeze only--it is not a corrosion inhibitor.

COOLING WATER TREATMENT

CHEMICAL APPLICATIONS AND CONTROLS

SYSTEM APPLICATION CONTROL LIMITS

High and medium speed
diesel engines
MAN/B&W Medium Speed
4-Stroke Engines
(L&V32/40; L40/54; L&V48/60; L58/64)
MAXIGARD cooling water treatment to 20,000 ppm
minimize corrosion and prevent deposition
compatible with glycol antifreeze.
40-43,000 ppm

Medium and slow speed DEWT NC cooling water treatment to 3,000 - 4,500 ppm
diesel engines minimize corrosion compatible with
glycol antifreeze.
MAN/B&W Medium Speed
4-Stroke Engines 4,500-4,900 ppm
(L&V32/40; L40/54; L&V48/60; L58/64)

Medium and slow speed
diesel engines
MAN/B&W Medium Speed
4-Stroke Engines
(L&V32/40; L40/54; L&V48/60; L58/64)
LIQUIDEWT cooling water treatment to 10,000 ppm
minimize corrosion and prevent deposition.
Compatible with glycol antifreeze.
15-17,000 ppm

COOLING WATER TREATMENT CONTROL TESTS AND DOSAGE REQUIREMENTS

Because the cooling water system is an essential part of
the diesel engine, a carefully controlled water treatment
program is essential for the efficient operaton of the
engine. The water treatment program is monitored by
means of a few simple tests. The control tests are the
basis on which the chemical dosage is adjusted.
The following pages outline the test procedures which are
used in conjunction with the Drew cooling water treat-
ments. In some instances, an additional chloride determi-
nation of the water may be desirable. The chloride test
procedure on page 42 can be used for DEWT NC treated
systems. This method is not recommended for cooling
water treated with MAXIGARD diesel engine water treat-
ment or LIQUIDEWT cooling water treatment without
Sample Pretreatment. See page 66 for Sample Pretreat-
ment procedure.
As in the steam generating system, the accuracy of the
test results is dependent upon proper sampling, testing,
and recording procedures as well as the corrective action
62
taken. Refer to the General Information section before
proceeding with any of the tests.
Testing Frequency
Testing and chemical dosing should be done on a regular
basis. The test should be conducted 24 hours after the
initial dosage and once a week thereafter unless a prob-
lem is suspected.
If abnormal water loss and makeup or other problems are
known to exist, then the test results will probably be low
and should be used compared with a control and dosing
chart to increase treatment levels. Dose, allow time for
circulation (approximately 30 minutes) and retest until
treatment levels are satisfactory.
If treatment levels are high, suspend dosage. Although
not normally necessary, you may wish to bleed off some
cooling water and makeup with untreated water to dilute.
 CWT TEST
2
TITRET METHOD

For use with LIQUIDEWTTM cooling water treatment, MAXIGARD® diesel engine water treatment, and
DEWT® NC diesel engine water treatment.

CWT TITRETS (PCN 0367-01-2) INCLUDES:

1 Titrettor3
30 Titrets (contains reagent)
1 Sample Vial
1 Instruction Sheet
30 Valve Assemblies (contains reagent)

PROCEDURE
1. Slide the open end of the valve assembly over the tapered tip of the
Titret so that it fits snugly to the Reference Line.

Valve
2. Snap the tip of the Titret at the Score Mark and proceed with the regular
Assembly Snap the test instructions below or use the Titrettor assembly as covered on
tip at the page 5.
score mark

3. With the tip of the sample pipe immersed in the sample, squeeze the
bead valve briefly to pull in a small amount of sample. CAUTION: Do
not squeeze the bead valve unless the sample pipe is immersed below
Score Mark the surface of the liquid or vacuum will be lost and the test ruined.
Reference Line 2
4. Rock the Titret to mix the contents. The first addition of sample will pull
Ampoule 1 in the reagent in the ampoule. The contents of the ampoule will turn a
GREEN color.

5. Continue to add small amounts of sample water until the liquid in the
Titret turns from GREEN to a bright ORANGE.* When the ORANGE
color appears, the end point has been reached. Stop test, hold the Titret
with its tip pointed upward and read liquid level. Check the control and
dosing chart below for the appropriate product concentrations.

*NOTE: Immediately before the end point is reached, the contents will
turn BLUE. Make further additions with care.
To test makeup water for hardness using the Titret method, see page 48.

Satisfactory Ranges Control and Dosing Chart

Product Scale PPM, Product Initial Dosage

LIQUIDEWT 1.2-1.8 10,000-15,000 8 ltr/ton (2.13 gal/ton) Below Satisfactory Increase Dosage
MAXIGARD 1.6-3.5 20,000-40,000 16 ltr/ton (1.6 gal/ton) Satisfactory Maintain Dosage
DEWT NC 3.5-5.0 3,000- 4,500 3.2 kg/ton (7 lbs/ton) Above Satisfactory Decrease Dosage

MAN/B&W Medium-Speed 4-Stroke Engines

Models: L&V32/40 L40/54 L&V48/60 L58/64

Satisfactory Ranges
Product Scale PPM, Product Initial Dosage

LIQUIDEWT 1.8-2.0 15,000-17,000 3.0 ltr/ton

MAXIGARD 3.3-3.6 40,000-43,000 3.3 ltr/ton
DEWT NC 5.6-5.8 4,500 - 4,900 4.5 kg/ton

63
 TEST FOR DEWT® NC
diesel engine water treatment

DEWT NC TEST KIT (PCN 0302-01-8) INCLUDES:

Graduated Cylinder, with Stopper, 50 ml PCN 0236-01-9 DEWT NC Reagent No. 1, 100 gms PCN 0306-01-0
Brass Measuring Spoon, 0.2 gm PCN 0224-01-4 DEWT NC Reagent No. 2, 100 gms PCN 0307-01-8

PROCEDURE
1. Draw a cooling water sample from a full flowing part of the system
into the graduated mixing cylinder to the 25 ml mark.

2. Add 5 level measuring spoons of DEWT NC Reagent No. 1 and mix

until all of the reagent is dissolved.

3. Add 1 level measuring spoon of DEWT NC Reagent No. 2, stopper

the mixing cylinder, and thoroughly mix.

4. If the sample turns purple-red and the color lasts for at least 30
seconds, the test indicates that the treatment level is below 50 ppm.

However, if the color disappears within 30 seconds, add additional

Reagent No. 2, one level measuring spoon at a time (counting
spoonfuls) with thorough mixing until the purple-red color persists
for over 30 seconds.

5. To determine the concentration of DEWT NC, count the total

number of measuring spoons of Reagent No. 2 added and convert
to ppm.

Calculation: ppm DEWT NC = (number of spoons -1) x 500

6. Record results as pm DEWT NC on the onboard graphing log.

7. Determine the dosage of DEWT NC diesel engine water treatment

required per ton of circulating water as indicated on the Dosage
Requirement Chart which follows:

DOSAGE REQUIREMENT CHART - DEWT NC

TOTAL NUMBER OF ppm
MEASURING SPOONS OF OF DEWT NC DOSAGE REQUIREMENT PER
REAGENT NO. 2 USED RECORDED TON OF CIRCULATING WATER

1 None 3.2 kg (7 lbs.)

2 500 2.7 kg (6 lbs.)
3 1000 2.3 kg (5 lbs.)
4 1500 1.8 kg (4 lbs.)
5 2000 1.4 kg (3 lbs.)
6 2500 0.9 kg (2 lbs.)
7 3000 Satisfactory - No Dose Required.
8 3500 Satisfactory - No Dose Required.
9 4000 Satisfactory - No Dose Required.
10 4500 Satisfactory - No Dose Required.
11 5000 High - No Dose Required.

64
 TEST FOR DEWT® NC
diesel engine water treatment
(continued)

DEWT NC TEST KIT (PCN 0302-01-8) INCLUDES:

Graduated Cylinder, with Stopper, 50 ml PCN 0236-01-9 DEWT NC Reagent No. 1, 100 gms PCN 0306-01-0
Brass Measuring Spoon, 0.2 gm PCN 0224-01-4 DEWT NC Reagent No. 2, 100 gms PCN 0307-01-8

MAN/B&W Medium-Speed 4-Stroke Engines

Models: L&V32/40 L40/54 L&V48/60 L58/64

DOSAGE REQUIREMENT CHART - DEWT NC

TOTAL NUMBER OF ppm
MEASURING SPOONS OF OF DEWT NC DOSAGE REQUIREMENT PER
REAGENT NO. 2 USED RECORDED TON OF CIRCULATING WATER

1 None 4.5 kg (10.0 lbs.)

2 500 4.0 kg (8.8 lbs.)
3 1000 3.5 kg (7.7 lbs.)
4 1500 3.0 kg (6.6 lbs.)
5 2000 2.5 kg (5.5 lbs.)
6 2500 2.0 kg (4.4 lbs.)
7 3000 1.5 kg (3.3 lbs.)
8 3500 1.0 kg (2.2 lbs.)
9 4000 0.5 kg (1.1 lbs.)
10 4500 Satisfactory - No Dose Required.
11 5000 Satisfactory - No Dose Required.
12 5500 High - No Dose Required.
13 6000 High - No Dose Required.
14 6500 High - No Dose Required.

65
 Chloride Sample Pretreatment

SAMPLE PRETREATMENT SHOULD BE USED WHEN TESTING FOR CHLORIDE IN COOLING WATER
TREATED WITH MAXIGARD® DIESEL ENGINE WATER TREATMENT OR LIQUIDEWTTM COOLING WA-
TER TREATMENT.

APPARATUS AND REAGENTS

Drew Chloride LMP Test Kit PCN 0373-01-9
Sample Pretreatment, 50 gm PCN 0374-02-5
(includes 0.5 gm scoop)
Filter Paper, Box of 100 PCN 0225-01-2
Funnel, Plastic PCN 0221-01-0
Stirring Rod, Plastic, 150mm PCN 0417-01-5

PROCEDURE
1. Add one scoop (0.5 gm) of Sample Pretreatment to approximately 70 ml of cooling water and stir well.

2. Let stand for two minutes to allow precipitate to settle.

3. Filter the sample and proceed with the chloride determination using the Drew Chloride LMP Test Kit as shown on
page 42.

66
All statements, information and data presented herein are believed to be accurate and reliable One Drew Plaza
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©2001 Inc. All Rights Reserved. Emergency Safety #: (1-800-ASHLAND) U.S.
®
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1
Registered trademark of Biotal, Inc. Printed in U.S.A.
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