PREFERRED CIRCULATING WATER CONDITION LIMITS For GALVANIZED

STEEL COOLING TOWERS - ADDENDUM

Startup

Experiences at Marley indicate that startup conditions are critical for galvanized steel cooling towers.
The initial operation will significantly affect its service life. Ideal startup conditions include circulating
tower water with neutral pH (6.5 - 8.0), calcium hardness of 100 - 300 ppm (as CaCO3), and alkalinity
of 100-300 ppm (as CaCO3) for at least 8 weeks.

If raw makeup water quality prohibits the user from meeting the recommended guidelines,
modifications to the water quality should be considered. Modifications may include pH and/or
hardness control. pH can be modified through acid treatment, while hardness can be modified through
water softening. Both methods are very effective in meeting the recommended guidelines. Potential
problems exist, however, with both methods if not properly maintained. Acid overfeed conditions
produce pH swings below 6.0 resulting in aggressive galvanized steel corrosion. Acid should be
introduced into the system in high velocity areas to avoid inadequate mixing. Softened water with
calcium hardness below 50 ppm (as CaCO3) is also very aggressive towards galvanized steel.

Besides pH, alkalinity, and hardness control, other acceptable chemical water pretreatment methods
such as inorganic phosphate passivation may be considered. These alternative methods are a logical
choice if makeup water quality cannot meet recommended guidelines and the risks associated with
other methods (e.g. acid) are deemed excessive.

Normal Tower Operation (after passivation)

Ideally, the recommended guidelines for startup should be used for normal tower operation as well.
However, once passivation of galvanized surfaces is achieved, recommended guidelines can be
relaxed since passivated surfaces are much more resistant to water quality variations. In today’s more
alkaline treatment programs, pH’s greater than 8.0 are not uncommon. As long as passivation has
occurred on galvanized surfaces, pH levels can be allowed to rise above 8.0. If the pH is maintained
at or above 8.3 or if corrosion problems develop, it may be necessary to repassivate galvanized
surfaces through water treatment chemicals and/or pH control. Periodic inspections of galvanized
surfaces in the cooling tower is recommended to confirm no problems are occurring. Generally
speaking, pH levels less than 6.0 or greater than 9.0 will increase zinc corrosion significantly.

Normal tower operation guidelines are listed on “Preferred Circulating Water Condition Limits for
Galvanized Steel Cooling Towers”.

GALVYADD.doc 4/26/96
Rev. 3, 6/16/97 MFP