OPERATING

INSTRUCTION
Service, Wärtsilä Finland Oy Käyttöohje Driftsinstruktion
Engine section Engine type Ref. Date Issue Document No. Page
19 Cooling water All TSu/S 28.12.2001 02 4619Q002GB 1(7)

Cooling water treatment and analysing

Background Correct cooling water treatment and follow-up of the cooling water condition
are of utmost importance for keeping the cooling water systems of the
engines in good condition. The corrosion processes that could occur due to a
bad cooling water quality may under certain circumstances be local and by
their nature proceed very rapidly. This may cause unexpected operating
problems or engine failures even within relatively short periods of time, for
example in the cylinder head exhaust valve seat pockets and other areas
prone to corrosion (see further comments in the “Worth noticing” chapter
below) in the cooling water systems of the engines.

Most of the cooling water additives which are approved by Wärtsilä are nitrite
(typically NaNO2) based and today the majority of the installations in
operation are also using nitrite based additives. There is a slow trend
towards more environmentally friendly alternatives. These operating
instructions and recommendations are mainly intended for installations using
nitrite based additives but certainly contain useful information for users of
other types of additives.

Purpose To avoid unnecessary corrosion damages and operating problems in the

cooling water systems of the engines.

Instructions & Recommendations

Raw water quality

The raw water quality for the cooling water circuits of an engine must meet
the following specification:
Property Limit
pH Minimum 6.5
Total hardness Maximum 10 °dH*)
Chlorides (Cl) Maximum 80 mg/l
Sulphates (SO4) Maximum 150 mg/l
A total hardness of 10 °dH (German degrees) ↔ 178 mg/l (as CaCO3).
*)

Soft waters (like distilled, ion exchanged, reverse osmosis and rain water)
with a total hardness close to 0 °dH have the ability to dissolve oxygen and
carbon dioxide from the air, which quite rapidly lowers the pH levels and
increases the corrosive effect of these waters. Suitable amounts of calcium
and magnesium compounds (= total hardness) participates in forming a thin,

Wärtsilä Finland Oy P.O. Box 252 (Tarhaajantie 2) Telecop. +358 10 709 7355 Tel. +358 10 709 0000 Registered in Finland No. 465.942
Service, Vaasa FIN-65101 Vaasa, Finland Telecop. +358 6 356 7339 Registered Office: Vaasa
Wärtsilä Finland Oy P.O. Box 50 (Stålarminkatu 45) Telecop. +358 10 709 3279 Tel. +358 10 709 0000
Service, Turku FIN-20811 Turku, Finland Telecop. +358 10 709 3410
Service, Wärtsilä Finland Oy Operating instruction
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02 4619Q002GB 2(7)

corrosion protective layer on the heat exchanging surfaces of the cooling

water system. Correct additive dosage and careful follow up of the dosing
levels are thus even more important with a very soft water compared to a
normal quality tap/drinking water with a total hardness of 2 – 10 °dH. The
use of raw water qualities with a too high total hardness may on the other
hand result in excessive deposit formations and reduced heat transfer
properties. Water produced by one (1) stage reverse osmosis processes
may sometimes contain too high chloride (and sulphates) contents, and are
in those cases not suitable as cooling water. Two (2) stage RO processes
usually achieve satisfactory chloride and sulphate levels.

Additive dosing

The cooling water additive dosage recommendations may vary, depending

on additive type and manufacturer. The dosage recommendations for the
cooling water additives approved by Wärtsilä are presented in table 3. There
exists no general dosage recommendation for the approved additives.
Observe that these recommendations apply for normal raw/cooling water
properties, see also the “Worth noticing” comments below. Generally a slight
overdosing is better than under dosing, but an excessive additive (nitrite)
dosage is not to be recommended economically, nor technically. Large (> 2 –
3 times the maximum recommendation) overdosing may cause corrosion on
copper, brass and other “soft alloys” in the system and possibly also
problems with precipitation and deposit formations.

Table 3 presents the currently approved cooling water treatment products,

their suppliers of these and the dosage recommendations (presented as
some different units).

Worth noticing

Aggressive compounds and conditions

Sulphates, sulphides, halides and especially chlorides are extremely

aggressive (corrosive) against iron. If there are high amounts of these
aggressive ions present in the cooling water system the nitrite dosage should
be increased accordingly. The recommendations vary slightly between
different additive manufacturers but for increased chloride and sulphate
contents the following formulas could be used as rules of thumb:

Add 100 mg/l of nitrite (NO2) / 10 mg/l of chlorides (Cl), for Cl > 50 mg/l.

Add 100 mg/l of nitrite (NO2) / 50 mg/l of sulphates (SO4), for SO4
> 150 mg/l.

It is strongly recommended to change the cooling water immediately if the

chloride content of the water exceeds ≈ 200 mg/l and if the sulphate content
exceeds ≈ 400 mg/l.

The nitrite oxidation curve in figure 1 shows a schematic graph of the

corrosion rate as a function of the nitrite dosage. Observe that the position of
the curve peak on the x-axis (= dangerous condition for corrosion) is not
Service, Wärtsilä Finland Oy Operating instruction
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02 4619Q002GB 3(7)

stable, but will shift depending on several external conditions in the cooling
water: temperature, pH, chlorides & sulphates contents, etc. That is, if the
chloride content of the cooling water is increased the additive (nitrite) dosage
also has to be increased in order to avoid the conditions of increased
corrosion rate.

Chlorides and other corrosive ions additionally have the tendency to

concentrate in cracks, under deposits etc. and may there reach considerably
higher concentrations than in the "bulk phase". It is thus extremely important
that all the surfaces of the system are cleaned properly before the corrosion
protection additive is added to the system. Both fats/oils/greases and
scale/rust should be properly removed. There are cleaning products
available on the market that combines or can be combined to provide both
degreasing and descaling properties, for example the environmentally
friendly Energy Cleaning and Combi Degreaser products provided by
Wärtsilä.

Additive characteristics

Nitrite based cooling water additives are so called anodic inhibitors and
require proper dosing and maintenance in order to protect as intended. The
nitrite of the additive is as such a salt and it will increase the electrical
conductivity of the water. The conductivity is on the other hand one of the
main parameters affecting the corrosion rate once/if a corrosion process gets
started: the higher the conductivity the higher the corrosion rate.

If the conditions (nitrite level, chlorides, pH, etc.) in the systems are such that
the additive (nitrite based) is no longer able to protect the entire surface of
the system there may occur a rapid, local (pitting) corrosion in the areas that
are not protected. The corrosion rate at the attacked areas will even be much
greater than it would be with no additive at all present in the system.

Sensitive areas for corrosion would typically be:

- In crevices and under deposits.

- Areas of very low flow (the inhibitor is not properly taken to the metal
surface).

- Areas of turbulent flow, such as a change of pipe cross-section, where a

proper protective film formation is more difficult to achieve.

- Areas that are typical problem areas for corrosion such as: welded
sections, combinations of dissimilar metals, areas of increased
mechanical stress, etc.

Powder form products

Nitrite based cooling water additives in powder form should be dissolved

properly in water before adding to the system. In order to avoid possible
dissolving problems resulting in under dosing, ensure sufficient mixing of the
powder and the water in the maintenance tank.
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02 4619Q002GB 4(7)

Prolonged stops and mechanical design

During possible prolonged stops (> several months) of the engine it is

recommended to apply proper circulation of the cooling water once in a while
and to keep the additive (nitrite) dosage at least at the maximum
recommended level and preferably at 1,5 times the normal dosage.

It is also worth noticing that the mechanical design of the cooling water
system (venting pipes to the expansion tank, expansion tank, air separator,
etc.) must be according to the recommendations and specifications in order
to avoid corrosion (cavitation) and other operational problems.

Analysing and typical levels

It is recommended to perform cooling water analysis, for example with test

kits provided by the additive manufacturer, once (1) a week. The additive
concentration may decrease quite rapidly, especially in the beginning after
the initial dosing of a new or thoroughly cleaned system. When the
properties of the cooling water are found to be stabilised the analysis interval
may, under normal conditions gradually be prolonged, for example to 2 – 4
weeks.

It is also recommended to perform a more complete cooling water analysis

2 – 4 times / year to check that the test kit analysis results are on a correct
level and also to be able to make a more complete cooling water condition
evaluation. When samples are taken and sent for analysis the sample bottles
should be filled up totally to minimize the amount of air that is left in the
bottle, a suitable sample amount is 1 litre. The cooling water samples should
be taken from circulating water. Remember to flush sampling pipes and
valves properly before taking the sample for analysis. The samples should
also be kept cool and in a dark place during transportation and storage
before the analysing. If special sample bottles are not available the best
alternative is an empty, clean mineral water bottle, since these are most
likely free from bacteria and other contaminants.

Water and cooling water samples should be analysed as soon as possible,

preferably within a week, after sampling. Some of the properties/compounds
(pH, sulphates and iron for example) of the water may react or precipitate in
the sample bottle and result in false results.

Table 1 below shows typical/guidance values for the cooling water analysis
that should be checked regularly (weekly). Observe that the values in table 1
are not “maximum or minimum allowed” levels. Sudden changes in the
trends of the analysed properties should always be investigated and possible
malfunctions and faults in the systems corrected.
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Table 1. Regularly (weekly) controlled cooling water properties.

Property Typical level
pH 8 – 11
Nitrite (NO2) 500 – 2500*) ppm
Chlorides (Cl) < 40 mg/l
Sulphates (SO4) < 100 mg/l
*)
Depending on additive type and manufacturer.

Table 2 presents typical/guidance values for the additional properties that

should be performed during the more complete cooling water analysis,
performed 2 – 4 times / year. Additional analysis may naturally be considered
from case to case, if some special problems have occurred.

Table 2. Additional properties that should be checked 2 – 4 times / year.

Property Typical level
Iron (Fe) < 1 mg/l1)
Nitrate (NO3) < ≈ 200 mg/l2)
Calcium (Ca) The total hardness
Magnesium (Mg) (Ca + Mg) < 10 °dH 3)
Copper (Cu) < 1 mg/l
1)
The iron levels may be higher in new systems, due to presence of smaller amounts
of machining and installation debris, etc. These “initially high” iron contents should
however gradually decrease to the typical levels. Observe that the total iron contents
should be analysed, not dissolved iron.
2)
Constantly/rapidly increasing nitrate (NO3) levels, especially in combination with
simultaneously decreasing nitrite (NO2) levels, indicate presence of possible
bacterial/microbial activity in the systems. Bacterial contamination may come for
example from salt water or some other dirty water contamination of the system.
A total hardness of 10 °dH (German degrees) ↔ 178 mg/l (as CaCO3) and
3)

Mg = 4,3 mg/l ↔ 1 °dH and Ca = 7,1 mg/l ↔ 1 °dH.

Alternative cooling water treatment methods

As an alternative to the approved cooling water additives treatment systems

that do not apply any chemicals to the water can also be used, for example
the Elysator, which provides a cathodic protection to the cooling water
system by applying magnesium anodes. Other similar products are currently
under approval. The quality specifications for the raw water are the same as
for normal cooling water additives.

The Texaco Havoline Xli (ex ETX 6282) is a more environmentally friendly
alternative to the traditional, nitrite based cooling water additives.
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Table 3. Approved cooling water additives, suppliers and dosage recommendations (for normal conditions)

Supplier Product designation Dosage recommendations

l of product / m3 ppm (mg/l) ppm (mg/l)
of water of NO2 of NaNO2
BetzDearborn Corrshield NT 4293 10 670 – 1000 1000 – 1500
(ex Dearborn 547)
Drew Ameroid Marine DEWT-NC powder 3 – 4.5 (kg) 1500 – 2250 2250 – 3400
Div. Drewgard 4109 16 – 29 1100 – 2000 1650 – 3000
Liquidewt 8 – 12 470 – 700 700 – 1050
Maxigard 16 – 29 1100 – 2000 1650 – 3000
Houseman Cooltreat 651 5 800 1200

RRS-Yhtiöt Korrostop KV 20 – 25 120 – 150

(as Mo)
Maritech Marisol CW 8 – 16 1000 – 2000 1500 – 3000

Nalco Chemical Company Nalco 39 (L) 16 – 36 550 – 1200 820 – 1800

Nalcool 2000 32 – 48 1000 – 1500 1500 – 2250

Nalfleet Marine Chemicals Nalcool 2000 32 – 48 1000 – 1500 1500 – 2250

Nalfleet EWT 9 – 108 2.2 - 3.4 1000 – 1500 1500 – 2250
Nalfleet CWT 9 - 131C 8 – 12 1000 – 1500 1500 – 2250
Rohm & Haas RD11 (RD11M) 5 (kg) 1250 1880
RD25 50 710 (as Mo)
Tampereen Prosessi- Ruostop XM 20 120 (as Mo)
Insinöörit

Texaco Global Products, Havoline Xli 50 – 100 1.6 - 3.2 w-% of active compounds,
LLC (ex-ETX 6282) measured with refractometer
Arteco

Unitor ASA Dieselguard NB 2 - 4.8 (kg) 1500 2250

Rocor NB Liquid 10 – 24 1500 2250
Vecom Holding Vecom 6 – 10 1500 - 2500 2250 – 3750
CWT Diesel QC-2

Note: It is recommended to start the dosage from the upper level, since the amount of the active
corrosion inhibitors (nitrites) typically decreases, especially after the initial dosing of a new or
thoroughly cleaned system.
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02 4619Q002GB 7(7)

To give full protection the Nitrite level

should be kept above X ppm. The
actual concentration is additive
supplier dependent.
A permanent lower level will lead to
an accelerated corrosion rate.

Figure 1. Corrosion rate as a function of the nitrite concentration.