Diesel Engine Cooling Water Treatment

PROBLEM AREAS
There are four key areas which must be considered when treating diesel engine cooling water systems.

1. Scale
Scale results when a compound precipitates from the water phase because its solubility has been exceeded. Scale is a
dense, adherent deposit of minerals and is tightly bonded to itself and to metal surfaces. Scale forming on metal surfaces
requires four simultaneous factors:
A. Exceeding the solubility of the compound in water.
B. Formation of small nuclear particles.
C. Adequate contact time for crystal growth.
D. Scale re-deposition exceeds the rate of dissolution.
One primary factor influencing scale adherence is surface roughness. The rougher the surface, the greater the probability
of adherent scale forming. Also, scale forms more readily on corroding surfaces than on non-corroding surfaces. Easily
corroded metals (mild steel) result in significantly more scale than metals that do not corrode (stainless steel).
In addition to the four primary factors influencing scale deposition,there are other factors that offset the formation of scale.
Wildly fluctuating pH is a significant cause of scale deposition in closed loop systems. Unitor uses Borates to buffer and
control this fluctuating pH. As the pH of the system increases, so does the scaling potential for almost all common scale.
This would include Calcium Carbonate, Calcium Sulphate, and Iron Oxide. Low pH extrusions can accelerate corrosion,
provide nucleating sites and increase the potential for some forms of Silica scale.
Scale formation in diesel engine cooling water systems can be controlled by various methods. Removing scale-forming
Ions from the water before that water enters the cooling system is the most effective method. Almost all engine
manufacturers recommend the use of distilled water. Distilled water is free of minerals. However, it is
aggressive water and, if untreated, can lead to corrosion.

2. Corrosion
Corrosion is the phenomenon that returns metals to their native states as chemical compounds or minerals. In diesel
engines containing dissimilar metals, main concern is galvanic corrosion. When exposed to water, one metal becomes
anodic and the other cathodic, setting up a galvanic cell. For example, when Copper and Mild Steel are connected in
water, the Mild Steel becomes the Anode, because it will give up electrons more readily than the Copper. The metal loss
occurs at the anode, so the Mild Steel corrodes.
Unitor recommends the use of a corrosion inhibitor containing Nitrite, Borate and Azole. Nitrite protects Mild Steel and Iron,
while Azole protect Copper from corrosion. Nitrite acts by forming a protective metal oxide (passivating film) on the metal
to be protected.

3. Fouling
Fouling is different from scaling in that fouling deposits are formed from material suspended in the water, while scale
deposits are formed from minerals in solution. Materials that cause fouling in cooling water systems are suspended solids
and oil leaking into the system. We must control fouling in a diesel engine cooling water system, as it interferes with the
effectiveness of corrosion inhibitors.

4. Microbiological activity
Nitrites act as a food source for some types of bacteria. While the presence of bacteria is not as widespread in diesel
engine cooling water systems as in other cooling water systems, it is a potential problem. The problem becomes apparent
when conducting chemical tests of the cooling water. If the personnel on the vessel are dosing Nitrites and do not get a
reading and the pH begins to fall, there is a possibility of microbiological activity. This can be verified by simple test
methods (“dip slides”), or by sending a sample of the water to Unitor.

UNITOR COOLING WATER TREATMENT PRODUCTS

Diesel engines need to be cooled and water is used for this purpose. This water must be conditioned to ensure that scale
does not deposit on the heat transfer surfaces in the cooling system.

1. The System
The water is circulated around the engine and any loss due to leaks, etc. is made up from the expansion tank. As it
circulates through the engine cooling spaces, the water picks up the engine heat, and this hot water goes to a heat
exchanger where it is cooled. The steam heater is used to warm the engine up from cold. An air separator is normally
installed to get rid of entrained air in the system. The water added to the expansion tank is termed “make-up” water.
Distilled water shall preferably be used for these cooling systems. This is normally made onboard by a fresh water
generator. A useful way of increasing the plant efficiency is to utilise the heat taken from the engine to provide a heat
source to the evaporator. If evaporated water cannot be used for make-up, then fresh shore water will have to be used.
This is normally much higher in impurities.
The engine water temperature is in the region of 65 °C to 75 °C at the inlet to the engine. It is maintained at this
temperature by controlling the cooling. The cooler is bypassed if the temperature drops.
As mentioned above, this is the main problem in diesel engine cooling systems. The water contains some oxygen, and if it
is untreated, an ideal environment will exist for all types of corrosion.

TREATMENT CHEMICALS FROM UNITOR : DIESELGUARD NB AND ROCOR NB LIQUID

How do they work?

All the information is contained in the relevant product data sheets (from Unitor, you can read when you are onboard) but
can be summarised as follows:
They provide a very thin coating to all metal surfaces to prevent the corrosion from starting. The water is also made
alkaline by the treatment to ensure that there is no acid corrosion. It is important that there is an excess of treatment in the
system to replace any breakdown in the coating and to treat the makeup water as it enters the system.

(The testing for this is quickly carried out by the Unitor’s Spectrapak 309 Cooling Water Test Kit)
(All cooling water treatments must be approved by accepted Government bodies for use where the water is used as a heat
source for an evaporator making drinking water.The treatments must also be accepted by the engine manufacturer. The
Unitor products are covered in these areas.)

Dieselguard NB dosage – (Solid chemical in powder form)

Initial dosage for an untreated system is 2 kg/1,000 liters of makeup water. This will bring the treatment level up to a
minimum level of 1000 ppm.

Rocor NB liquid dosage – (Liquid chemical)

Initial dosage for an untreated system is 9 litres/1,000 litres of distilled water. This will bring the treatment level up to a
minimum level of 1000 ppm.
Note: When initially dosing a cooling water system, it is typical that the initial dosage may vary from vessel to vessel, or system to system.Total passivation of
the cooling water system will consume more product than when making Nitrite up as maintenance dosages. The quality of make-up water will also affect initial
dosage rates.

ALL CADETS MAY NOTE THAT ONLY DIESEL GUARD NB OR ROCOR NB, ONLY ONE OF THE PRODUCTS IS TO BE USED AT A TIME. Only
difference between both are that one is in solid form while the other one is in liquid form.

TESTS FOR DIESEL ENGINE COOLING WATER TREATED WITH DIESELGUARD NB/ROCOR NB
LIQUID
The following tests are recommended to maintain cooling water within the prescribed limits when using Dieselguard
NB/Rocor NB Liquid:
1. Nitrite: 1000–2400 ppm as NO2
2. pH: 8.3–10.0
3. Chlorides 50 ppm maximum

1. Nitrite – Recommended Limits 1000–2400 ppm as NO2

The Nitrite concentration should be maintained within the above recommended limits to effectively inhibit any corrosive or
scaling action within a closed cooling system. Over-concentration should be avoided to minimise the cost of maintaining
the system. Under-dosage can set up a condition where accelerated corrosion can occur in areas which become
unprotected. Dieselguard NB/Rocor NB Liquid is dosed according to the recommended nitrite level.

2. pH – Recommended Limits 8.3–10

The effectiveness of a corrosion inhibitor is restricted to within a certain pH range. Treatment with Dieselguard NB/Rocor
NB Liquid ensures that this pH range is observed when the Nitrite level is sufficiently maintained to prevent corrosion.
Under certain conditions because of external contamination, the pH may not fall into the range
usually found with the correct Nitrite dosage. In such cases, Unitor recommends dosing 50 ml of Unitor’s Alkalinity Control
per tonne of cooling water to raise the pH value when the pH is below 8.3. Re-test pH after dosage to prove that the pH
value is being maintained between 8.3 and 10.0.

3. Chlorides – Recommended limit max. 50 ppm

The Chlorides value of the cooling water should be kept as low as possible. Any increase in value whether sudden or
gradual, will be an indication of sea water contamination. Check with the engine manufacturer
for other specified limits.
If the Chloride level exceeds 50 ppm, the possibility of corrosion in the system increases because Chlorides have a
negative effect on the passivation film created by nitrites. Therefore, until corrective action has succeeded in bringing the
Chloride level back down below 50 ppm, the nitrite level should be kept close to the upper limit (2400 ppm).

4. Sampling and testing of cooling water

Samples should be drawn, tested and results logged for each system at least of once per week and if possible six times
per month.
THE FOLLOWING INFORMATION IS FOR YOUR REFERENCE ONLY AND NOT FOR WRITING IN THE
EXAMS. FOR THOSE CURIOUS AND WANTING OVERVIEW OF HOW TESTING IS DONE

SAMPLING OF DIESEL ENGINES:

To minimise the effort in obtaining cooling water samples, a sample cock located in a position to draw a sample/having
access to draw the sample quickly and easily will make the task of drawing samples a simple one. In each case of drawing
a sample, the container should be filled with the water to be tested, then sealed and labelled. It is advisable to conduct the
appropriate tests within 30 minutes of drawing the sample, although this time limit can be extended when sample container
is completely filled and sealed.

TEST EQUIPMENT – UNITOR SPECTRAPAK 309

TEST KIT TEST PROCEDURES
Sample preparation:
A. Cool sample to 21–25 °C
B. Filter if necessary to clarify.

Spectrapak 309 content:

A. Reagents:
a. Nitrite No. 1 tablets ( Composition - NaHSO4 – Sodium hydrogen sulphate)
b. Nitrite No. 2 tablets (Composition - KMnO4 – Potassium Permangnate)
c. Chloride tablets ( Composition - Silver Nitrate + Boric acid + Potassium di-chromate + Potassium Chromate)
d. pH test strips (6.5–10.0)

B. Equipment:
a. Syringe
b. Plastic sample container

Test methods:
A. Nitrite test
a. Take a 5 ml water sample with the syringe and put into the container provided.
b. Make the sample up to 50 ml using distilled water.
c. Add two Nitrite No. 1 tablets and shake to disintegrate (or crush
with the rod provided). Sample will be white.
d. Add one Nitrite No. 2 tablet and shake to disintegrate.
e. Continue adding the Nitrite No. 2 tablets one at a time until a pink color persists for at least one minute.
Calculation:
Nitrite(ppm) = number of No. 2 tablets x 180
For example: If 9 tablets are used Nitrite = 9 x 180 = 1620 ppm.
f. Mark the result obtained on the log sheets provided against the date on which the test was taken.

B. Chloride test
a. Take a 50 ml water sample in the container provided.
b. Add one Chloride tablet and shake to disintegrate; sample should turn yellow if Chlorides are present.
c. Repeat tablet addition one at a time until the yellow colour changes to orange/brown.
Calculation:
Chloride ppm = (number of tablets used x 20) –20
For example:
If 3 tablets are used, Chloride ppm = (3 x 20) –20 = 40 ppm
d. Mark the result obtained on the log sheets provided, against the date on which the test was taken.

C. pH test
a. Dip one of the test strips into the water sample so that the colour zone is completely immersed.
b. Compare the colour obtained with the reference, and read off the printed pH value.
c. Mark the result obtained on the log sheet provided, against the date on which the test was taken.

TEST RESULTS
Recording
The test results should be recorded on the Spectrapak 309 Rapid Response log forms.

Reporting
Completed monthly log should be distributed as shown:
A. White copy – Send to Unitor Rapid Response Centre.
B. Pink copy – Vessel’s head office.
C. Yellow copy – Retain for ship’s records.

Evaluation
A. Logs will be reviewed for adherence to specification requirements by Unitor’s computerised RAPID RESPONSE system
and staff.
B. A log review indicating the status of the system, problems and recommendations will be issued to the ship’s operator.