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Closed Loop Systems Training Overview

The document discusses closed loop cooling and heating systems. It describes the advantages of closed loop systems, including high efficiency, minimized fouling, and reduced maintenance costs. It then discusses some of the major problems that can occur in closed loop systems, such as microbiological activity, corrosion, and oxygen. The rest of the document provides details on monitoring, controlling, and treating closed loop systems, including the use of various inhibitors like nitrite, molybdate, and azoles.

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Zain
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210 views18 pages

Closed Loop Systems Training Overview

The document discusses closed loop cooling and heating systems. It describes the advantages of closed loop systems, including high efficiency, minimized fouling, and reduced maintenance costs. It then discusses some of the major problems that can occur in closed loop systems, such as microbiological activity, corrosion, and oxygen. The rest of the document provides details on monitoring, controlling, and treating closed loop systems, including the use of various inhibitors like nitrite, molybdate, and azoles.

Uploaded by

Zain
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

2/24/2014

1/20/14

2014 Service Technician


Training Program
Closed Loop Systems
Daniel S. Krack, CWT

Closed Loop Cooling and Heating


The Closed Loop Cooling Advantages
High Efficiency Chillers , Heat Exchangers, and Hot Water Recirculating
Boilers Need Clean Water
Chiller Condenser Tube and boiler heat exchange surface Fouling is
Minimized
System Operates at Maximum Efficiency
Minimal Water Treatment Requirement
Reduced Cooling and Heating System Maintenance Costs

1
2/24/2014

Closed Loop Cooling


Closed Cooling Loops Operating Benefits
Water Treatment Costs are Reduced
Reduced Potential Pump Problems
Free Cooling as an Operating Strategy

CLOSED LOOPS
A closed system refers to a recirculating water system in
which there is negligible water loss 1% to 5% per day

The water is either heated or cooled through a heat


exchanger

Water may be kept in the system from weeks to years

Operating temperatures vary in closed systems, from


40 to 50F to as high as 350 400F

A TYPICAL CLOSED WATER SYSTEM


Closed Air
Evaporation Box Vent

Gauge
Glass Makeup

Heat
Exchange
Coil

Boiler or
Air Conditioner

Pump

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Cast Iron Sectional Boilers

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MAJOR PROBLEMS

Microbiological

Corrosion

Oxygen

Closed Loops
Microbiological Activity

Decreases Corrosion
Inhibitor
Decreases Heat Transfer
Efficiency
Increases Corrosion

Microbiological Activity

Bacteria can occur in systems


operating at temperatures of -0 to
160F.

Aerobic organisms can flourish in


closed loops if oxygen is present.

Anaerobic organisms, such as


sulfate reducers, can lurk under
deposits or in oxygen-free systems.

Bacteria thrive the best in 90F


water, in static conditions, and in
low flow areas
1/20/14

4
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Microbiological Control

Monitor for bacteria regularly


by use of dip slides.

1/20/14

Closed Loops
Corrosion
By-Products increase
plugging and fouling
Reduces heat transfer
efficiency
Wears pump seals and
impellors
By-Products Can Cause
Erosion

What Happens Over Time With


Corrosion By-Products?

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General Corrosion General Corrosion

With Zero Filtration With Continuous Filtration

Letting Filtration Reduce The Concentration

Filtering Contaminants

Closed Loop Corrosion


Filtered Iron Results From Several Loops

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How Can We Instantly Test The Closed Loop


To See If We Have Corrosion?

Problems
Fouling and Plugging
Because most closed systems retain
water a long time, any corrosion can
result in a gradual buildup of metals in
the system causing severe fouling and
plugging.

Oxygen pitting
Air can seep into the closed system
through valves, unions, elbows, and
pumps in addition to dissolved oxygen in
makeup water.

Deposit Control
Water added to a closed loop does not evaporate so a
deposit control program often is not required.

Polymers or surfactants sometimes are incorporated into


closed-loop programs to act as dispersants.

Polymers and surfactants can be effective in cleaning up


systems that have been previously abused and contain
high-suspended solids of metal oxides or hydroxides.

Side-stream filtration is used in conjunction with these


chemicals. When cleaning up, it is important to have bled
the system so that the cleaned deposits can be removed
from the system.

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Closed Loops
Oxygen
O2 (Oxygen) can enter a system in two ways:

1. Seep through valves, unions, elbows,


pumps, faulty air separators.

2. It also enters as dissolved oxygen in


makeup water.

Closed Loops
Expansion Tanks

They compensate as water expands


with rising temperature and permit
addition of makeup water.

They may be "open" or "closed".

Open tanks release air to the


atmosphere. They are located on the
suction side of the pump at the
highest point in the system.

Closed expansion tanks are most


commonly used in high-temperature
hot water boilers, high-temperature
systems, and chilled-water loops.

Closed Loops
Air Separators

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Closed Loops
Mechanical Pump Seals
Seals are designed to
permit minor leaks of
water.
Excessive water loss
results if they are not
maintained
High levels of inhibitors
can crystallize in the seal,
causing mechanical
degradation
Foulants such as iron can
wear mechanical seals

Closed Loop Monitoring

Monitoring should include:


Testing for the inhibitor nitrite,
molybdate, etc.
pH
Iron levels
Copper levels
Suspended solids

Types of Closed Loop


Inhibitors
Nitrite
Molybdate
Borate
Nitrate
Silicates
Phosphates
Azoles
Sulfites

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Nitrite
Interfere with the corrosion mechanism by putting
down a film or barrier on the steel surface
Typically utilized at 500 to 1,500 ppm at pH>7.5
Formulated with several other inhibitors and
buffers such as borate, nitrate, azole, or molybdate
Used in chilled water loops to hot water boilers
Residuals must be maintained to constantly repair
gaps in the film barrier
Nitrifying and de-nitrifying bacteria use nitrite for
their food/metabolism and if present contribute to
the production of nitrate, ammonia, and nitrogen
in the system

Molybdate
Molybdate (MoO4) is an anodic metal
passivating agent
Used at concentrations of 80 to 500
ppm as Mo at high pH (>8.5).
Not recommended soley in hot water
systems
Molybdate treatments are expensive
and require high concentrations in high
sulfate and chloride water
Calcium molybdate precipitation can
occur in high-hardness waters

Borate

It is used to buffer the water to a


pH above 8.5 or higher.

Used most often used with nitrite-


based programs.

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Nitrates

Nitrates at 100 to 200 ppm provide


protection to aluminum.

Aluminum must be controlled in the


7.5 to 8.5 range.

A pH above 9.0 will produce severe


corrosion of aluminum.

Silicate
Effective corrosion inhibitor for both
steel and aluminum
Produces an adsorbed silicate film on
the metal surface that is stable over a
temperature range of 80 to 140 in
low hardness or soft water
Used at concentrations of 20 to 60 ppm
as SiO2
Can be used alone or with phosphates.
Are preferred treatments for systems
with high water losses.

Phosphates
Phosphate can be used alone or with
silicate in systems with high water loss

Used where economics prohibit the use


of alternate programs

Exercise extreme caution when using


phosphates to avoid the precipitation
of calcium phosphate.

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Azoles
Add benzotriazole and tolytriazole
to closed system treatments for
the protection of yellow metals
(copper & brass)

Dosages vary from 10 to 20 ppm

Azoles form a thin, impervious,


adsorbed, organic film on yellow
metals, acting as a chemical and
physical barrier to corrosion.

Oxygen Scavengers
Oxygen scavengers work well in closed-loop
systems where the system is not truly closed and
the pH is properly controlled.
Maintain a sulfite residual of 80 to 120 ppm.
In high-temperature systems, hydrazine and
diethylhydroxyl amine (DEHA) are better because
they are also metal passivation agents.
DEHA residuals from 60 parts per billion to 150
ppb are used.
DEHA is used where there are limits on
conductivity.

Chemical Feeders

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Glycol Closed Loop Systems

Type of Glycol
The types of glycol that are commercially
available in bulk:

Propylene
Ethylene Glycol Automotive
Glycol Grade
Glycol

Type of Glycol

Automotive grade glycol must not be used


in HVAC systems because these types of
glycol contain corrosion inhibitors that are
not compatible with the materials and
operations of HVAC systems.

Automotive grade glycols


will break down quickly in a
HVAC system and cause
system corrosion.

13
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T
y
p
e

o
f

G
l
y
c
The acute oral toxicity of
propylene glycol is much
o
l
lower than that ethylene glycol.

Propylene glycol is the


preferred choice for use
in systems where
accidental ingestion
may occur.

l
o
c
y
l
G

f
o

e
p
y
Because of its higher heat transfer rate
T

ethylene glycol could be used in systems


where accidental ingestion is not a
concern.

Some municipalities also restrict the


disposal of ethylene glycol to sanitary
sewers, which may further limit its use in
certain applications.

T
y
p
e
s

o
f

G
Never dump any glycol
l to a storm sewer or
a water way withyc out approval from the
appropriate governmental
o agencies.
l

14
2/24/2014

System Cleaning
All lines and equipment of the system should be
cleaned with a cleaning solution formulated to
remove oil, grease, and mill scale
The cleaning solution must be thoroughly
flushed from the system prior to the glycol
addition.
After flushing the system, the water should be
tested to insure all of the cleaner is removed.
Corrosion inhibitors added will only protect what
it comes in contact with. If the system surface
is dirty the inhibitor cannot contact the metal to
protect it.

SYSTEM MATERIALS
The standard materials of construction (i.e. steel, cast
iron, copper, brass, bronze, solder, and most
plastics) that are found in closed loop water systems
are also acceptable for use in glycol systems.

However, aluminum, galvanized, and zinc materials


should be avoided because the corrosion inhibitors in
most glycols will not fully protect aluminum at
temperatures greater than 150F (65C). The zinc and the
zinc in the galvanized alloy will react with the alkaline
corrosion inhibitor and start to corrode.

Fresh Make-up Water


The use of automatic fresh water make-up for
glycol systems must be avoided to prevent
undetected dilution of glycol.

Fresh potable water contains oxygen. The amount


of oxygen is dependent on the temperature of the
water.

When glycol is added to water the chemical


reaction between the two will also release oxygen.

15
2/24/2014

Fresh Make-up Water


If automatic fresh water make-up is mandated, install a
water meter on the fill line to track water usage.

Fresh Make-up Water


Prevent unintended glycol
dilution by installing a
glycol feed system to replace small
fluid loses.

Expansion Tanks
Bladder type expansion
tanks are needed for glycol

16
2/24/2014

Expansion Tank
Due to the higher density of glycol, the expansion
tank for a glycol system must be capable of
absorbing approximately 4% more volume than a
closed system without glycol.

Glycol Concentration

20%Glycol Bug Poison

20% Glycol Bug Food

Volume of Glycol
The following equation may be used to calculate the
approximate amount of glycol that must be added to the
system:

G = V x (CD-CP)
(100-CP)
G = volume of fresh concentrated glycol to be added to
the system.
V = volume of the system
CD = desired glycol concentration, vol%
CP = present glycol concentration, vol%

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Dilution Water
The water which is used to mix and or dilute
glycol must be of the highest possible quality
(i.e., softened, demineralized, deionized,
boiler condensate).

Minerals in some domestic water supplies


will deplete the inhibitor concentration in the
glycol, thus making it corrosive.

Many local water supplies will exceed these


limits.

Dilution Water
The following limits are representative of most
glycol suppliers:

Chloride Sulfate
25 ppm 25 ppm
Max Max

Calcium Magnesium
50 ppm 25 ppm
Max Max

18

Common questions

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Microbiological activity in closed loop systems can lead to decreased corrosion inhibitor effectiveness, reduced heat transfer efficiency, and increased corrosion. Aerobic and anaerobic bacteria can flourish under certain conditions such as temperatures conducive to growth, presence of oxygen, or stagnant water areas. Regular monitoring using dip slides is recommended to detect bacterial presence early, and appropriate control measures should be implemented to maintain system integrity .

Oxygen can enter closed loop systems through physical breaches such as leaks at valves, unions, and pumps, or as dissolved oxygen in makeup water. This oxygen ingress can lead to corrosion within the system, impacting its efficiency and longevity by causing pitting, especially in metal components . Monitoring and employing oxygen scavengers can help mitigate these effects .

Glycol, particularly propylene glycol, is used in closed loop systems for its lower toxicity and ability to prevent freezing. However, automotive-grade glycols should not be used in HVAC systems as their inhibitors are incompatible with system materials, leading to corrosion. Improper glycol selection or concentration can lead to additional oxygen release, which induces corrosion if not managed properly .

Expansion tanks in closed loop and glycol systems manage thermal expansion of the fluid. For glycol systems, expansion tanks must accommodate an increase in volume due to glycol's higher density, approximately 4% more than a non-glycol system. This ensures system pressure stability and fluid integrity during operation .

Closed loop cooling and heating systems offer several advantages: they ensure high efficiency of chillers, heat exchangers, and hot water recirculating boilers by minimizing fouling on chiller condenser tubes and boiler heat exchange surfaces. This leads to maximized system efficiency and reduces the need for extensive water treatment, thereby cutting down maintenance costs for cooling and heating systems .

Aluminum and galvanized materials are discouraged in glycol systems because the corrosion inhibitors in most glycols do not fully protect these metals at higher temperatures, leading to corrosion. Zinc in galvanized alloys reacts with alkaline inhibitors, exacerbating the issue. Using incompatible materials can significantly reduce system lifespan and reliability .

Failure to properly flush a closed loop system prior to adding inhibitors results in ineffective protection as residual contaminants can obstruct inhibitors from contacting metal surfaces. The unprotected surfaces may then corrode, undermining system efficiency and longevity. Thorough flushing ensures inhibitors can function correctly by forming protective barriers where needed .

To test for corrosion in closed loop systems, monitoring should include checks for the concentration of inhibitors like nitrite and molybdate, pH levels, and the presence of metals such as iron and copper. These parameters help detect potential corrosion that could lead to fouling and system inefficiency. Testing is crucial to preemptively address issues that could severely impact the operational lifespan and efficiency of the system .

To prevent unintended glycol dilution, automatic fresh water make-up should be avoided unless equipped with a water meter to track usage. A glycol feed system is recommended to replace minor fluid losses, ensuring the intended glycol concentration remains consistent to maintain its protective properties against freezing and corrosion .

Polymers and surfactants can clean previously abused systems by acting as dispersants, effectively dealing with high suspended solids and metal oxides. They should be used in conjunction with side-stream filtration. It's crucial that systems are adequately bled of these materials post-cleaning to avoid unintended residues that can lead to system inefficiencies .

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