S.
No
Parameters
Deviation Range
Cause
Insufficient acid dosing.
Effect
High
Increased CO3 and HCO3 in water.
Scaling
>150 ppm
Ammonia leakage.
Over dosing of acid.
Alkalanity
Low
<100 ppm
Decreased CO3 and HCO3 in water.
Corrosion
Increased Nitrites.
Inaccurate reading at 3DTRASAR.
High
>8.1
Insufficient acid dosing.
Ammonia leakage.
Scaling, effectiveness of NaO
biocide decreases as pH rise
Inaccurate reading at 3DTRASAR.
pH
Over dosing of acid.
Low
<7.8
Corrosion
Acid leakage from NA plant.
Calcium
High
Chlorides
High
>750 ppm Increased Calcium concentration.
Increased scaling and fouling
Crevice corrosion, stress corr
>220 ppm Increased Chloride Concentration
pitting, affects on Zn passivat
High
>4000 s/cm
Low
<3000 s/cm
Conductivity
Fe
High
SiO2
High
Zinc
Low
Phosphates
High
10
Polymer reserves
11
CT Heat Load
Low
High
No
Shut down
Inaccurate reading at 3DTRASAR.
Increased TDS concentration
Insufficient treatment chemic
Decreased TDS concentration
Circulating water
Increased Fe in makeup water
Combines with phosphates to
>3 ppm
Decreased pH
Deactivates polymers used to
Increased NaOCl dosing
phosphate scaling
Increased TDS concentration
Magnesium silicate scale in h
Increased SiO2 in makeup water formation of hard scale
>130 ppm
Increased SiO2 due to wind
storm
<3 ppm
Increased chlorides and sulfates Increased mild steel corriosio
Can combine with calcium to
>5 ppm
Increased dosing of 3DT-190
phosphate scaling, acts as nu
<15 ppm
Scale formation due to lack o
>35 ppm
Inaccurate reading at 3DTRASAR.
Multiple reasons
12
Ammonia
High
13
OM
Free Chlorine
High
Low
High
Suspended Solids
High
Leakage from heat exchanger
Wind prevailing from EP to
> 1 ppm
Cooling tower, Due to ammonia
with the wind from vents
>30 ppm From supply water
<0.2 ppm Increased biological growth
>0.9 ppm Decreased biological growth
SSF out of service
>20 ppm Due to sand storm and rain
Sulphates
High
>800 ppm Increased dosing of H2SO4
14
15
16
Corrosion, Scaling
No cooling water supply to th
Promotes formation of biofilm
copper alloys, Combines with
form chloramines which can
impact of hypochlorite as disi
Act as fertilizer for microorga
Increased biological growth.
Can cause dezincification at
Can adhere to biofilms and c
deposit corrosion, also cause
erosion in heat exchangers.
Consumed by sulfate reducing b
that can cause severe pitting i
Can combine with calcium to form
17
18
NO2
NO3
High
High
>1 ppm
>20 ppm
Due to consumption of ammonia Lowers system's pH by HNO
by nitrifying bacteria
hence cause corrosion
Effect
Scaling
Corrosion
Scaling, effectiveness of NaOCl as a
biocide decreases as pH rises above 8.0
Corrosion
Increased scaling and fouling
Crevice corrosion, stress corrosion cracking,
pitting, affects on Zn passivation layer
Corrosion, Scaling
Insufficient treatment chemicals in
Circulating water
Combines with phosphates to form foulants
Deactivates polymers used to inhibit calcium
phosphate scaling
Magnesium silicate scale in heat exchanger,
formation of hard scale
Action
Check for acid injection and increase pump strokes.
Check for COC, if >5 increase blowdown.
Check for ammonia contamination.
Check for acid injection and reduce pump strokes.
Check for COC, if <5 decrease blowdown.
Use biocide.
Check reading at 3DTRASAR and send check sample.
Check for acid injection and increase pump strokes.
Check for ammonia contamination.
Check reading at 3DTRASAR and send check sample.
Check for acid injection and reduce pump strokes.
Check pH in CWS and CWR of NA plant for any acid
leakage, Isolate the exchanger and attend leakage.
Increase Blow down and add hypo if pH reduces to 7.2
check Nitrites and use biocide if needed.
Check for COC and increase blowdown
Check for COC, hypo addition and blowdown, Increase
blow down.
Check reading at 3DTRASAR and send check sample
Check for COC, if >5 increase blowdown
Check reading at 3DTRASAR and send check sample
Check for COC, if <5 decrease blowdown
Check Fe in make up water, check pH and 3DT-129
dosing and take actions accordingly.
Check for COC, if >5 increase blowdown
Check Concentration No. and blow down. Increase
blowdown to reduce T.S.S <20 ppm
Increased mild steel corriosion and pitting.
Can combine with calcium to form calcium
phosphate scaling, acts as nutrient for biofilms
Scale formation due to lack of polymer reserves
No cooling water supply to the complex
Promotes formation of biofilm, corrosive to
copper alloys, Combines with chloride to
form chloramines which can negate the
impact of hypochlorite as disinfectant.
Act as fertilizer for microorganisms
Increased biological growth.
Can cause dezincification at low pH
Can adhere to biofilms and cause under
deposit corrosion, also cause fouling and
erosion in heat exchangers.
.Check Concentration No. and blowdown.
Check 3DTRASAR reading for 3DT-129, if >20 ppm
reduce strokes, if <15 ppm increase pump strokes.
.Check Concentration No. and blowdown.
Check 3DTRASAR reading for 3DT-129, if >35 ppm
Stop Acid Injection
Stop blow down
Isolate the heat exchanger and plug the tube
Increase chlorine and bromine dosing to achieve free
Cl2= 0.3 ppm
Use Nalco 7330 if Nitrites go beyond 20 ppm.
Increase blow down and hypo+bromine dosing
Increase hypo dosing
Decrease hypo dosing
Employ side stream filtration
Dose N8506
Consumed by sulfate reducing bacteria to form
that can cause severe pitting in heat exchangers Increase dosing of 3DT-129
Can combine with calcium to form calcium sulfa
Lowers system's pH by HNO3 formation,
hence cause corrosion
Increase hypo+bromine dosing
