---------Apply Chemical Treatment

Module 12313
Instrumentation Trainee Task Module 12313
APPLY CHEMICAL TREATMENT-
Ob|ectves
Upon completion of this module, the trainee will be able to:
1. Identfy those devces whch requre chemca treatment.
1. 2 Identfy some of the chemcas commony used for freeze
protecton.
2. 3 Gve the basc procedure for the addton of freeze protecton
chemcas to a system.
Prerequstes
Successfu competon of the foowng Task Modue(s) s requred before
begnnng study of ths Task Modue: Instrumentaton Leve 3, Task
Modues 12307 and 12316.
Requred Tranee Materas
1. Tranee Modue
2. Requred Safety Equpment
COURSE MAP
Ths course map shows a of the Wheels of Learning task modues n the
thrd eve of the Instrumentaton currcua. The suggested tranng order
begns at the bottom and proceeds up. Sk eves ncrease as a tranee
advances on the course map. The tranng order may be ad|usted by the
oca Tranng Program Sponsor.
LEVEL 3 COMPLETE

TABLE OF CONTENTS
Section Topic ..
Page
1.0.0 Introducton
.............................. 5
2.0.0 Systems That Requre Freeze Protecton ...............
5
3.0.0 Types of Chemcas Used For Wnterzaton of Fud Systems ...
7
4.0.0 Burst Protecton vs. Freeze Protecton ...............
8
5.0.0 Preparng a System for Chemca Addton .............
9
6.0.0 Addton of Chemcas
......................... 9
7.0.0 Mantenance of Chemca Concentraton ..............
11
Trade Terms Introduced In Ths Modue
Antifreeze: Chemca souton commony used to mt corroson and
provde freeze protecton. Antfreeze soutons dffer from gyco soutons
n that they are commony used n automotve appcatons versus
ndustra appcatons.
Bffer
,
Chemcas paced n a souton n order to counteract the effects of
an acd. In order to be a buffer a chemca must have a basc Ph (greater
than 7.0)
Br!t protection: One type of wnterzaton where chemcas are added
to a system ony to mt the formaton of ce n the system, but not to
competey prevent the formaton of ce n the system.
"eionize#: Term usuay reatng to water whch has been purfed
through the use of an on rch resn bed.
"i!ti$$e#: Term usuay reatng to water whch has had the mpurtes
removed through a dstaton process. Ths process generay nvoves the
bong and subsequent condensaton of the water.
Eff$ent: Term pertanng to the water eavng a secton of ppng. The
opposte of nfuent.
%reeze protection: One type of wnterzaton whereas chemcas are
added to a system n order to competey prevent the formaton of ce.
H&AC: Heatng Ventatng and Ar Condtonng.
In'i(ite# g$)co$!: Chemca souton commony used to mt corroson
and provde freeze protecton to qud systems.
In'i(itor!: Chemcas paced n a souton n order to sow (nhbt) the
corroson process.
State: One of the physca propertes whch defne matter. The three
states of matter are sod, qud, and gas.
T(e-!'eet: That area n a she and tube heat exchanger where the fud
enters the tube. Commony consdered to be the weakest part of the heat
exchanger and most susceptbe to eakage.
&i!co!it): A measure of the thckness of a qud. The hgher the vscosty,
the thcker the qud w be.
*interization: The process of preparng a system or pece of equpment
for ncement weather, usuay pror to the wnter.
1.0.0 INTRODUCTION-
When quds change state from a qud to a sod, they expand. A seaed
contaner of water, when paced nto the freezer, w burst as the water
turns nto ce and expands beyond the dmensons of the contaner. In ths
modue the tranee w earn that one method of preventng the water
nsde of equpment from freezng s through the addton of winterization
chemcas. The varous systems requrng freeze protecton as we as the
chemcas used w be dscussed. A bref procedure for the addton of the
chemcas w aso be covered.
2.0.0 SYSTEMS THAT REOUIRE FREEZE PROTECTION-
As stated earer, ppng systems and components, need protecton from
the expanson of water as t freezes. Ths expanson can over-stress the
ppng or components causng them to weaken or burst. The frst step n
protectng components from freezng s dentfyng those components
requrng protecton.
One common ppng arrangement conssts of a compete cosed oop of
ppng contanng, among other components, a heat exchanger. If ths heat
exchanger gves up heat to another system, the qud nsde of the cosed
oop w drop n temperature, possby to the temperature at whch t w
freeze. Ths freezng w damage the system ppng, not to menton the
heat exchanger tsef, especay n the frage tube-sheet area. The addton
of freeze protecton chemcas to ths ppng system can prevent the water
from changng to ce, thus preventng the damage due to expanson. One
exampe of a cosed oop system s the coong system on the typca
automobe. The radator acts as a heat exchanger. Antfreeze s added to
the cooant to prevent t from freezng durng the wnter months. Wthout
ant-freeze, frozen cooant coud expand and burst the engne bock.
Figure 1 shows an exampe of a cosed oop system contanng a heat
exchanger.
Fgure 1. Cosed Loop System
Instrument nes commony have condensng pots nstaed n-ne wth the
nstrument tsef. The purpose of the condensng pot s to coect any
mosture present n the nstrument ne, as mosture may damage the
decate nstrument. The mosture trapped nsde of the condensng pot
can then be manuay removed through a dran vave. The probem arses
when the nstrument nes and assocated condensng pots are exposed to
ncement weather, such as mght be found n a nstrument nstaed
outsde of a protectve budng. If the ambent temperature drops beow
the 32 Fahrenhet freezng temperature of water, the mosture coected
n the bottom of the condensng pot w freeze and expand, burstng the
component. Ths w cause a break n the nstrument ne, whch w ead
to an ncorrect readng nstrument. Figure 2 ustrates the ocaton of a
condensng pot n a typca nstrument ne.
Fgure 2. Condensng Pot In An Instrument Ar Lne
Ch water nes are yet another type of component whch requres freeze
protecton. Ch water s that water whch s cooed by an ar condtonng
unt, usuay through a heat exchanger, and then crcuated throughout a
budng to provde coong to desred areas. Dependng upon the settng of
the ar condtonng unt's thermostat, ths ch water can reach
temperatures dangerousy cose to the freezng pont of water. Ths
probem s especay present n the evaporator where the water s the
codest. For ths reason freeze protecton chemcas are sometmes used n
ch water systems n order to ower the freezng pont of the water, thus
protectng the system from possbe damage.
Yet another type of system requrng freeze protecton s one where the
water fows ntermttenty. Fowng water w not freeze as evdenced by
rvers n the wnter months. In a secton of ppe, the frcton between the
qud and the was of the ppe s enough to prevent freezng. The probem
arses when the water does not fow constanty. Many heatng systems use
hot water transferred through radators n order to heat a room. The
temperature of the space s controed by the voume of ths water fowng
through the radator. If the thermostat shoud fa, the water trapped n the
ppng coud freeze, thus burstng the ppng. To prevent ths potenta
damage, freeze protecton chemcas are added, thus owerng the
freezng pont beow that whch w be seen n the ppng system.
3.0.0 TYPES OF CHEMICALS USED FOR WINTERIZATION OF FLUID
SYSTEMS-
A wde varety of chemcas are avaabe for the therma protecton of
ppng systems. The two ma|or categores are inhibited glycols and antifreeze
formuas. Usng the correct type of chemca for the ppng system s
crtca, as some of the wnterzaton chemcas used are not compatbe
wth a ppng materas.
Gycos or nhbted gycos are the most commony used wnterzaton
chemca. Inhbted gycos consst of combnatons of ethyene and gyco
or propyene and gyco. The purpose of the inhibitors (ethyene and
propyene) s to mt the corroson that occurs nsde of the ppng. If
gycos were added wthout nhbtors, a arge amount of corroson woud
occur n the meta ppng due to the acds whch are formed from the
gycos when exposed to heat and ar. The nhbtors act as a buffer for
these acds as they are formed, thus mtng the corroson. The nhbtors
aso coat the nner was of the ppng thus protectng the meta from
exposure to the corrosve agents.
In a system where heat transfer effcency s of a concern, ethyene gyco
s a much better choce than propyene gyco due to the dfference n ther
viscosity. The probem arses n the toxcty of ethyene gyco. For exampe,
f a system contaned a potabe water heat exchanger, wth ony a snge
wa of the heat exchanger separatng the heat transfer chemcas and the
potabe water, reguatons requre that propyene gyco be used. In a
cases ceanness and purty requrements, as we as manufacturer
nformaton shoud be consuted before decdng upon a wnterzaton
chemca.
Another category of therma protecton chemcas are the antfreeze
formuas contanng scates. These fuds provde both therma protecton
and corroson preventon, but are desgned soey for use n automotve
appcatons. Snce aumnum s the most common matera used n the
heat-re|ectng surface n an automobe engne, the antfreeze most
commony used s a fud contanng a scate based nhbtor. Scates
prevent aganst corroson n aumnum aoys by ayng down a vsbe,
reatvey thck protectve coatng on the meta surface. Aganst the use of
scate based soutons s the fact that the protectve coatng acts as an
nsuator, reducng heat transfer through the system. Even wth the
reduced heat transfer capabtes, the corroson preventon benefts of ths
type of therma protecton chemca can not be overooked.
The mportance of seectng the proper chemca treatment for the ppng
matera can not be overooked. Manufacturers technca nformaton, as
we as system desgn nformaton must be consuted before the addton
of chemcas to a ppng system. Many manufacturers provde a teephone
consutaton servce wth traned staff avaabe to answer questons such
as those pertanng to the compatbty of materas.
4.0.0 BURST PROTECTION VS. FREEZE PROTECTION-
The eve of protecton provded by addng wnterzaton chemcas to a
ppng system s dependent upon the concentraton of chemcas n the
fud. The eves of protecton are commony grouped nto two separate
categores by the manufacturers of these chemcas. The two categores
are Burst Protection and Freeze Protection.
Whe provdng a ower eve of protecton than freeze protecton, burst
protecton s generay suffcent n most BVAC systems. In a system
utzng chemca addtves to provde burst protecton, the concentraton
of addtve s ower, thus an ce/sush mxture s formed nsde the system
and s transported around the ppng. One unque mechansm that occurs
durng the parta freezng process s an ncrease n chemca
concentraton. Snce a porton of the water turns nto ce crystas, the rato
of chemcas to water ncreases, thus the concentraton aso ncreases,
mtng the amount of ce that can form. In order for ths to provde
adequate protecton, the system must have suffcent voume avaabe for
the expanson that occurs when the ce crystas are formed, as we as
contan components capabe of resstng the abrasve propertes of the
ce/sush mxture.
In a system utzng freeze protecton, the nta concentraton of
chemcas s hgher than n a system desgned for burst protecton. For
freeze protecton, the requred concentraton of chemca addtves n the
system depends on the operatng condtons of the system and the owest
ambent temperature. The owest expected ambent temperature whch
the system w see s determned, and chemcas are added appropratey.
Manufacturers nformaton regardng concentraton of wnterzaton
chemcas shoud be strcty foowed n order to provde adequate
protecton. Usng fuds wth excessve gycos added greaty reduces
system heat transfer effcency, so care must be taken when determnng
the correct concentraton to be used. Table 1 sts varous eves of freeze
protecton and the requred chemca concentratons requred for severa
products manufactured by Dow Chemcas.
Te+peratr
e
,%
Percent -.o$./ "0*THERM %$i# Concentration
Re1ire#
%or %reeze Protection %or Br!t Protection
&o$+e 2
"0*THERM
SR-3
&o$+e 2
"0*THER
M
4555
&o$+e 2
"0*THER
M
SR-3
&o$+e 2
"0*THERM
4555
20
10
0
16.8
26.2
34.6
17.3
27.1
35.7
11.5
17.8
23.1
11.9
18.4
23.8
-10
-20
-30
40.9
46.1
50.3
42.2
47.6
51.9
27.3
31.4
31.4
28.1
32.5
32.5
-40
-50
-60
54.5
58.7
62.9
56.3
60.6
64.9
31.4
31.4
31.4
32.5
32.5
32.5
Tabe 1. Concentraton Chart
Whether provdng freeze protecton or burst protecton, the water used to
dute the wnterzaton chemcas must be of a hgh eve of purty.
Impurtes n duton water can ncrease meta corroson, cause formaton
of scae and other deposts on heat transfer surfaces, and cause coggng
of system components. Agan, manufacturers technca specfcatons
shoud be strcty adhered to when determnng the purty of the duton
water. Table 2 gves purty requrements for the duton water as stated
by one manufacturer. Whenever possbe, deionized or distilled water shoud
be used to dute the wnterzaton chemcas.
I+prit) Le.e$
Chordes 25 ppm, max
Sufates 25 ppm, max
Cacum 50 ppm, max
Magnesum 50 ppm, max
Tabe 2. Duton Water Ouaty Requrements
5.0.0 PREPARING A SYSTEM FOR CHEMICAL ADDITION-
The snge most mportant step n preparaton to addng wnterzaton
chemcas to a system s to provde an adequate eve of system
ceanness. A nes and equpment shoud be ceaned and fushed
thoroughy pror to the addton of chemcas. It s vta that a rust, scae,
and sedment be removed from the system. Chorde ons, predomnant n
acd ceanng soutons, must be ceaned out of the system as when they
are combned wth freeze protecton chemcas, they contrbute to system
corroson. For arger systems, a company specazng n ndustra
chemca ceanng may need to be empoyed for the purpose of ceanng
the system pror to the addton of any chemcas for the purpose of
wnterzaton. In any case t s mportant that the system be fushed wth
pure water unt the effluent sampe provdes no trace of the ceanng
agents.
New systems are typcay coated wth o, grease, or some other
protectve fm durng storage and constructon. Drt, soder, fux, and
wedng by-products must a be removed from the system pror to the
chemca addton. A 1%-2% souton of trsodum phosphate can be used
for the purpose of ceanng the system, keepng n mnd that the system
must be fushed competey cean pror to the addton of wnterzaton
chemcas.
6.0.0 ADDITION OF CHEMICALS-
Once the system has been competey ceaned, and the correct
concentraton of wnterzaton chemcas has been determned usng the
manufacturers technca nformaton, the voume of chemcas to be added
to the pure water must be cacuated. In order to get the correct
percentage of wnterzaton chemcas, the voume of water present n the
system must be known. Ths number can be cacuated usng the
nformaton provded n Table 3.
No+ina
$
Pipe
Size
Inc'e!
0t!i#e
"ia+ete
r
Inc'e!
I#entification
*a$$
T'ic6ne!
!
Inc'e!
In!i#e
"ia+ete
r
Inc'e!
&o$+
e
7a$$on
!
Per
355
%eet of
pipe
Stee$ Stain$e!
!
Stee$
Iron
Pip
e
Size
Sc'
e#$
e
No.
Sc'e#$
e
N+(er
1/8
V
3/8

1
0.405
0.540
0.675
0.840
1.050
1.315
STD
STD
STD
STD
STD
STD
40
40
40
40
40
40
40S
40S
40S
40S
40S
40S
0.068
0.088
0.091
0.109
0.113
0.133
0.269
0.364
0.493
0.622
0.824
1.049
0.295
0.541
0.992
1.578
2.770
4.489
1V
1
2
2
3
3
1.660
1.900
2.375
2.875
3.500
4.000
STD
STD
STD
STD
STD
STD
40
40
40
40
40
40
40S
40S
40S
40S
40S
40S
0.140
0.145
0.154
0.203
0.216
0.226
1.380
1.610
2.067
2.469
3.068
3.548
7.769
10.58
17.43
24.87
38.40
51.36
4
5
6
8
10
4.500
5.563
6.625
8.625
10.750
STD
STD
STD
STD
STD
40
40
40
40
40
40S
40S
40S
40S
40S
0.237
0.258
0.280
0.322
0.365
4.026
5.047
6.065
7.981
10.020
66.13
103.9
150.1
259.9
409.6
Tabe 3. Gaons of Heat Transfer Fud per 100 Feet of Ppe
Exampe: A 300 ft. secton of 2" schedue 40 ppe s to have a gyco
souton added to t. What s the voume of ths secton of ppng?
Answer: (300 ft.) x (17.43 gaons/100 ft.) = 5229 gaons
After the voume of qud the system s capabe of hodng s cacuated,
the system shoud be at east partay fed wth water n order to perform
a eak check. Determnng eakage ponts and reparng them at ths stage
w prevent waste of the expensve wnterzaton chemcas.
The quantty of chemcas to be added can be cacuated usng the
formua:
A =
100
V(D)
A = the amount of chemcas (n gaons) to be added
V = the tota voume of the system
D = the desred chemca concentraton desred n the system
Once the eak check s compete, dran enough water from the system to
provde room for the wnterzaton chemcas. Add the correct amount of
chemca as we as any extra water needed to competey f the system.
It s very mportant to ensure that a of the ar s vented from the ppng
upon fng. Ar w get trapped n the system hgh ponts, thus mtng
fow, and possby preventng heat transfer. Trapped ar may aso become
entraned n the fud causng foamng, agan mtng heat transfer.
After the chemcas have been added and a of the ar vented from the
system, the fud needs to be crcuated for at east 24 hours to ensure
compete mxng. In certan equpment appcatons crcuaton n the
system may not be possbe. A condensng pot on an nstrument ne s a
good exampe of ths type of equpment. In ths stuaton, the
chemcas/duton water must be mxed n a separate contaner and then
added to the equpment.
7.0.0 MAINTENANCE OF CHEMICAL CONCENTRATION-
After the chemca souton has crcuated throughout the system for 24
hours, a sampe shoud be drawn and tested for concentraton. In addton,
the chemca content shoud be measured at east annuay usng the test
equpment provded by the manufacturer, or by sendng a sampe to the
manufacturer's testng aboratory for anayss. Over tme, eaks n the
system w ower the concentraton of the souton, therefore chemca
addtons may be necessary n order to mantan the desred eve of
protecton.
If the chemca concentraton s too weak, and the freezng pont of the
souton needs to be owered, the amount of wnterzaton chemcas to be
added (as we as the amount of souton to be draned) can be cacuated
usng the foowng formua:
A = V(D-P)/(100-P)
Where:
A = the amount of chemcas (n gaons) to be
added
V = the tota voume of the system
D = the desred chemca concentraton desred n the system
P = the chemca concentraton presenty n the
system
If the concentraton s too strong, and the freezng pont must be rased,
the amount of pure water to be added to the system (as we as the
amount of souton needng to be draned) can be cacuated usng the
foowng formua:
A = V(P-D)/P
Where: A = the amount of chemcas (n gaons) to
be added V = the tota voume of the system
D = the desred chemca concentraton desred n the system
P = the chemca concentraton presenty n the system
Exampe:
A4500 gaon cosed oop heat exchanger system s beng used to provde
heatng to a budng. Research nto the chemcas beng used has shown
that a 35% souton of chemcas and duton water s necessary to provde
an adequate eve of therma protecton to the system. A system sampe
has |ust been taken and shows the system concentraton to be 25%.
Cacuate the approprate chemca addton/duton that s necessary n
order to return the concentraton back to the desred 35% concentraton
eve.
A = V(D-P)/(100-P)
Where: A = the amount of chemcas (n gaons) to be added
V = the tota voume of the system (4500 gaons)
D = the desred chemca concentraton desred n the system
(35%)
P = the chemca concentraton presenty n the system (25%)
Therefore:
A = (4500 gaons) (35-25)/(100-25) = 600 gaons
600 gaons of chemcas must be added n order to acheve a
35% souton.
SUMMARY
In ths modue the tranee has been ntroduced to some of the varous
chemcas used n the therma protecton of ppng and equpment. The
types of equpment requrng protecton and the reasons for protecton
have been covered. Severa of the dfferent types of chemcas used, as
we as the advantages and dsadvantages of each has aso been
dscussed.
Ceanness of the system pror to the addton of chemcas, as we as the
compatbty of the chemcas wth the ppng product can not be over-
stressed. Foregn matera n the system can combne wth the
wnterzaton chemcas and provde a detrmenta effect.
The procedure for cacuatng addton of chemcas n order to mantan
the proper concentraton has been dscussed aong wth severa exampes.
Wth the wde varety of chemcas avaabe on the market, the use of the
manufacturer as a resource concernng the specfcatons for the partcuar
chemca beng used can not be over-stressed. Utzng a weak chemca
souton may not provde adequate therma protecton, whe usng a
souton that s too strong may greaty decrease the heat transfer
capabty of the system.
References
For advanced study of topcs covered n ths Task Modue, the foowng
works are suggested:
Inhibited Glycols for Corrosion and Freeze rotection in Water!"ased
#eating and Cooling $ystems% ASHRE VA-89-17-2
&ngineering and '(erating Guide for )o*therm $+!1 and )o*therm ,---
Inhibited &thylene Glycol!based #eat Transfer Fluids% )o* Chemca
Company.
SELF-CHECK REVIEW I PRACTICE OUESTIONS
1. How ong shoud chemcas be crcuated throughout a ppng
system after the nta addton?
2. Movng water w not freeze.
a. True.
b. Fase.
3. A 5000 gaon system requres a 62% concentraton of chemcas n
order to provde the adequate eve of freeze protecton. A sampe s
taken and shows that a 12% concentraton exsts. How much (n
gaons) of the wnterzaton chemca must be added n order to
brng the concentraton up to the approprate eve?
4. The dfference between freeze protecton and burst protecton s
n________________.
a. The eve of protecton aganst ce formaton that s provded.
b. The concentraton of chemcas n the ppng system.
c. The amount of corroson nhbtors present n the
ppng.
d. Both answer a and answer b.
5. Why does an nstrument ne contanng ar requre freeze
protecton?
PER%0RMANCE8LAB0RAT0RY E9ERCISES
1. Mx and add wnterzaton chemcas n accordance wth
manufacturer's specfcatons.
2. Usng test kt provded by the manufacturer, measure the
concentraton of wnterzaton chemcas n a fud sampe.
ANSWERS TO SELF-CHECK REVIEW / PRACTICE OUESTIONS
1. A mnmum of 24 hours.
2. a
3. A =V(D-P)/(100-P)
Where:
A = the amount of chemcas (n gaons) to be added
V = the tota voume of the system (5000 gaons)
D = the desred chemca concentraton desred n the system (62%)
P = the chemca concentraton presenty n the system (12%)
Therefore:
A = (5000 gaons) (62-12)/(100-12) = 2841 gaons
2841 gaons of chemcas must be added n order to acheve a 62%
souton.
4. d
5. Instrument ar nes contan condensng pots whch remove the mosture
from the ar. Ths mosture coud freeze, thus rupturng the ne.