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industrial division WATER TREATMENT CHEMICALS N ALCQ CHEMICAL COMPANY HERITAGE SQUARE 130 JAMESTOWN LAKE CHARLES, LOUISIANA 70605 AREA 31S-470-BO6O April 19, 1984 Conoco Chemical Company V. C. M. Plant Post Office Box 605 Westlake, Louisiana 70669 Attention: Mr. Michael L. Ashby Gentlemen: The enclosed report contains our findings and observa tions regarding the cooling water equipment inspection during the recent plant shut down for annual turn around. We would like to thank Conoco Chemical Company for the opportunity to inspect your equipment. We look forward to discussing this report with you and answering any questions you may have. Sincerely M. C. Mowad C >v K- ) District Representative enclosures cc:NjR. J. M. A. Conrad W. Ware C. Manion R. A. Hart - Ponca City, OK L. C. Martens - Ponca City, OK CCR 000019329 CORPORATE OFFICES: 2301 BUTTERFIELD ROAD a OAK BROOK, ILLINOIS SOB21 a AREA 312-BB7-75CO NALCO EXECUTIVE SUMMARY of INSPECTION RESULTS Generally, all cooling water exchangers exhibited deposition. The degree of deposition was slight in the new exchangers (6 months service) to moderately heavy in the majority. Several of the exchangers showed evidence of active under deposit corrosion, which can eventually lead to tube leaks and exchanger replacement or retubing. There was evidence of microbiological activity in all exchang ers. Microbio activity will aggrevate fouling and corrosion in the system. All deposits exhibited iron and silica as prime constituents. The high percentage of phosphate in the deposits is due to precipitation of your phosphate cooling water treatment with the iron and silica in the well water. Our experience indi cates such a program will aggrevate a deposition problem more than prevent deposition. CCR 000019330 IMALCO V. C. M. PLANT COOLING WATER INSPECTION During the weeks of March 12 and March 19, 1983, we had the opportunity to inspect a number of cooling water exchangers in the V. C. M. Plant. Following are our inspection findings and our laboratory deposit analyses. H-101 DIRECT CHLORINATOR COOLER This exchanger has mild steel tubes, with water on shell side. Due to the nature of the inspection ports on this exchanger we were only able to inspect cooling water side at two small locations where it showed high deposition and an indication of some under deposit corrosion. Also, 18% loss at 800 C indicates some evidence of microbio activity in the system, (please see the attached deposit analysis data). Form 1 72 CCR 000019331 NALCO CHEMICAL COMPANY 3004 tuTT|A#l|LD HQAD QAK IHQQK, ILLINQII BOB31 CONOCO V.C.M COOLING WATER DEPOSIT INORGANIC ANALSIS (WEIGHT %) H -101 IRON AS (fe2o3) rfStJ CfO* O o o o ae u o CALCIUM AS (cao) 3.1% SULFUR AS (so3) 3.1% CHLORINE AS (cl) 1% SILICON AS (sio2) PHOSPHORUS AS (p2o5) MAGNESIUM AS (mgo) 1% 3/13/84 loss at me (%) i8 0% NALCO From: CONOCO VCM Westlake, LA Sample Marked: H-101 At 180 Deg. Analysis No. Date Sampled Date Received Date Printed X 47453 3/13/84 3/19/84 3/21/84 wA - >>> COOLING WATER DEPOSIT < < < INORGANIC ANALYSIS (WEIGHT PERCENT) Iron (Fe203) Silicon (Si02) Phosphorus (P205) Sulfur (S03) Calcium (CaO) Chlorine (Cl) Magnesium (MgO) Carbonate (% C02) 63 15 12 3 3 1 1 0 Loss at 800C (%) CH2C12 Extractables (%) 18 0 THE FOLLOWING ELEMENTS WERE NOT DETECTED: NA AL K TI V CR MN CO NI CU ZN SR M0 SN BA PB * P. O. Box 220 Long Beach, CA 90801 CCft OOOOI9333 NALCO CHEMICAL COMPANY ANALYTICAL LABORATORIES 1927 Nolte Drive Paulsboro, NJ 08066 Box 87 Sugar Land, TX 77478 Form PS-108 (20M 8 82) 1801 Diehl Road Naperville, IL 60566 N INI ALGO H-109 HEAVY ENDS COLUMN - OVERHEAD CONDENSER This is two pass cooling water exchanger with admiralty tubes and mild steel shell. Cooling water is on the tube side. The exchanger exhibited a moderate amount of fouling. The physical nature of the deposit was gray-yellow in color and was very flaky in texture. There was no evidence of any corrosion in the tubes on the water side. A 37% loss on ignition (800 C) indicates heavy microbiological contamina tion in the system. Based on the result of the deposit analysis it seems that most of the deposition is in the form of iron and calcium phosphate which is typical of phosphate program used in water with high iron in the make-up, (see attached analysis for complete data). form 1 72 CCR 000019334 NALCO CHIMICAL COMPANY BBQ1 BUTTERFIELD HQAD Q A K BROOK, ILLINOIS BOB21 CCR 0 0 0 0 1 9 3 3 5 CONOCO V.C.M COOLING WATER DEPOSIT INORGANIC ANALYSIS (WEIGHT %) H -109 LOSS AT * (*) 37 % IMA LCD /^RO/SiILWDS/SitL From: CONOCO VCM Westlake, LA. Sample Marked: H-109 2nd Pass Analysis No. Date Sampled Date Received Date Printed X 48154 3/20/84 3/26/84 3/29/84 >>> COOLING WATER DEPOSIT <<< INORGANIC ANALYSIS (WEIGHT PERCENT) Iron (Fe203) Phosphorus (P205) Calcium (CaO) Silicon (Si02) Manganese (Mn02) Barium (BaO) Magnesium (MgO) Chlorine (Cl) Sulfur (S03) Carbonate {% C02) 39 30 15 7 3 2 1 1 1 0 Loss at 800C (%) CH2C12 Extractables (%) 37 3 THE FOLLOWING ELEMENTS WERE NOT DETECTED: NA AL K TI V CR CO NI CU ZN SR MO SN PB P P. O. Box 220 Long Beach, CA 90801 CCR 00001933& NALCQ CHEMICAL COMPANY ANALYTICAL LABORATORIES 1927 Nolte Drive Paulsboro, NJ 08066 Box 87 Sugar Land, TX 77478 Form PS-108 (20M 8 82) 1801 Diehl Road Naperville, IL 60566 N NALCO H-207 (EAST) VINYL COLUMN CONDENSER This is a six pass cooling water exchanger with mild steel tubes and water on the tube side. H-207 exhibited a severe amount of deposition which was very hard in nature. We also noticed some corrosion in the tubes and at the tube rolls. The deposit analysis indicated that the majority of the deposit was iron (61%) and phosphate at (17%) which indicates the formation of iron phosphate in the system. Twenty-eight percent loss at ignition (800 C) indicates microbiological contamination in the system. This exchang er is being replaced with an admiralty exchanger. This will be easier to treat and keep clean. Form 172 CCR 000019337 NALCO CHIMICAL COMPANY 2BQ1 auTTIBPllLO ROAO OAK BROOK ILLINOIS 00021 CCR 0 0 0 0 1 9 3 3 8 CONOCO V.C.M COOLING WATER DEPOSIT INORGANIC ANALYSIS (WEIGHT %) H -207 EAST 3/13/84 LOSS AT SOflfL (%) 28 NALCO From: CONOCO VCM Westlake, LA. Sample Marked: H-207 East Analysis No. Date Sampled Date Received Date Printed X 47454 3/13/84 3/19/84 3/23/84 >>> COOLING WATER DEPOSIT <<< INORGANIC ANALYSIS (WEIGHT PERCENT) Iron (Fe203) Phosphorus (P205) Silicon (Si02) Calcium (CaO) Sulfur (S03) Barium (BaO) Chlorine (Cl) Magnesium (MgO) Carbonate (% C02) 61 17 11 6 2 1 1 1 0 Loss at 800C (%) CH2C12 Extractables (%) 28 4 THE FOLLOWING ELEMENTS WERE NOT DETECTED: NA AL K TI CR MN CO NI CU ZN SR MO SN PB P. O. Box 220 Long Beach, CA 90801 NALCO CHEMICAL COMPANY ANALYTICAL LABORATORIES 1927 Nolte Drive Paulsboro, NJ 08066 Box 87 Sugar Land, TX 77478 CCR 000019339 Form PS-108 (20M 8 82) 1801 Diehl Road Naperville, IL 60566 NALCO H-207 (WEST) VINYL COLUMN CONDENSER This is a six pass cooling water exchanger with admiralty tubes and water on the tube side. The exchanger was fairly clean; however some of the tubes exhibited a thin soft layer of deposition which could be wiped off quite easily. The color of the deposition was a yellowish gray. There was no evidence of any corrosion in the tubes or on the tube rolls. Based on the deposit analysis results the majority of deposi tion was in the form of iron phosphate, calcium phosphate, and some silicate. From experience in the Lake Charles area well water silica will co-precipitate with iron any time iron is being dropped out in the system. This exchanger is new and has been in service only 6 months. Form 172 CCR 00001934-0 NALCO CHIMICAL COMPANY 39D1 auTTinrifLD AO*o OAK book, ILLINOIS booSi CONOCO V.C.M COOLING WATER DEPOSIT INORGANIC ANALYSIS (WEIGHT %) H -207 WEST IRON AS (Fe2o3) 3/13/84 % NALCO From: CONOCO VCM Westlake, LA Sample Marked: H-207 West Analysis No. Date Sampled Date Received Date Printed X 47452 3/13/84 3/19/84 3/23/84 < >>> COOLING WATER DEPOSIT <<< INORGANIC ANALYSIS (WEIGHT PERCENT) Iron (Fe203) Phosphorus (P205) Calcium (CaO) Silicon (Si02) Barium (BaO) Sulfur (S03) Chlorine (Cl) Magnesium (MgO) Copper (CuO) Manganese (Mn02) Aluminum (A1203) Carbonate (% C02) 40 26 15 7 2 2 2 1 1 1 1 0 Loss at 800C (%) CH2C12 Extractables (%) A 48 0 THE FOLLOWING ELEMENTS WERE NOT DETECTED: NA K TI V CR CO NI ZN SR MO SN PB Lab Comments: The Loss on Ignition is approximate because of limited sample. P. O. Box 220 Long Beach, CA 90801 ANALYTICAL LABORATORIES 1927 Nolte Drive Paulsboro, NJ 08066 Box 87 Sugar Land, TX 77478 CCR 00001^342 Form PS-108 (20M 8 82) 1801 Diehl Road Naperville, IL 60566 NALCO H-307 (TOP & BOTTOM) OIL COOLERS: These two pass admiralty cooling water exchangers, with water on the tube side, contained moderate amounts of deposition in the tubes. The majority of deposition was in the form of silica, iron, iron phosphate, and calcium phosphate. There was no evidence of any corrosion in the tubes, or in the channel head. 27% and 25% loss in ignition indi cates microbio contamination of the system. During our inspection we pointed out that the channel on the top oil cooler was improperly placed where the baffle plate was about 45 off. This resulted in improper cooling water circulation. One of the channel heads exhibited a different type of deposition which was white in color and was not seen in any of the other exchangers we inspected. The majority of deposit was silicon 50.5%, magnesium 20.2%, and calcium 16.2%, (see attached deposit analysis). Form 172 CCR 00001934-3 NALCO CHIMICAL COMPANY *04 UTTKHFIfLO n Q A QAK BROOK ILLINOIS BOBS! CCR 0 0 0 0 X 9 3 4 4 CONOCO V.C.M COOLING WATER DEPOSIT INORGANIC ANALYSIS (WEIGHT %) H -307 BOTC)M SIUCON AS (Sio2) IRON AS (Fe2o3) OTHERS 7% PHOSPHORUS AS (P2o5) 3/14/84 CALCIUM AS (Cao) LOSS AT 80QC (X) 27 * < NALCO Prom: CONOCO VCM Westlake, LA Sample Marked: BL 307 Oil Cooler Bottom Analysis No. Date Sampled Date Received Date Printed X 48028 3/14/84 3/23/84 3/29/84 >>> COOLING WATER DEPOSIT < < < INORGANIC ANALYSIS (WEIGHT PERCENT) Silicon (Si02) Iron (Fe203) Phosphorus (P205) < Calcium (CaO) Manganese (Mn02) Barium (BaO) Magnesium (MgO) Chlorine (Cl) Sulfur (S03) Zinc (ZnO) Carbonate (% C02) 32 27 22 12 1 1 1 1 1 1 0 Loss at 800C (%) CH2C12 Extractables (%) 27 1 THE FOLLOWING ELEMENTS WERE NOT DETECTED: NA AL K SN PB TI V CR CO NI CU SR MO P. o. Box 220 Long Beach. CA 90801 CCR 000019345 NALCO CHEMICAL COMPANY ANALYTICAL LABORATORIES 1927 Nolte Drive Paulsboro, NJ 08066 Box 87 Sugar Land, TX 77478 Form PS-108 (20M 8-82) 1801 Diehl Road Naperville, IL 60566 CCR 0 0 0 0 1 9 3 4 6 CONOCO V.C.M COOLING WATER DEPOSIT INORGANIC ANALYSIS (WEIGHT %) H -307 TOP 3/14/84 LOSS AT 0OQC (X) 25 % NALCO ilz^@bz^bv bup From: CONOCO VCM Westlake, LA. Sample Marked: BL 307 Oil Cooler Top Analysis No. Date Sampled Date Received Date Printed X 48029 3/14/84 3/23/84 3/29/84 >>> COOLING WATER DEPOSIT <<< INORGANIC ANALYSIS (WEIGHT PERCENT) Iron (Fe203) Silicon (Si02) Phosphorus (P205) Calcium (CaO) Magnesium (MgO) Manganese (Mn02) Barium (BaO) Chlorine (Cl) Sulfur (S03) Zinc (ZnO) Carbonate (% C02) 28 27 22 14 2 2 2 1 1 1 0 Loss at 800C (%) CH2C12 Extractables (%) 25 0 THE FOLLOWING ELEMENTS WERE NOT DETECTED: NA AL K TI V CR CO NI CU SR MO SN PB 000019347 OCR P. O. Box 220 Long Beach, CA 90801 NALCO CHEMICAL COMPANY ANALYTICAL LABORATORIES 1927 Nolte Drive Paulsboro, NJ 08066 Box 87 Sugar Land, TX 77478 Form PS-108 (20M 8 82) 1801 Diehl Road Naperville, IL 60566 CCR 0 0 0 0 1 9 3 A 8 CONOCO V.C.M COOLING WATER DEPOSIT INORGANIC ANALYSIS (WEIGHT %) H -307 CHANNEL HEAD SILICON AS (Sio2) CALCIUM AS (Cao) 3/14/84 LOSS AT % IMAL.CO From: CONOCO VCM Westlake, LA. Sample Marked: BL-307 Channel Head Analysis No. Date Sampled Date Received Date Printed X 48030 3/14/84 3/23/84 3/29/84 # >>> COOLING WATER DEPOSIT < < < INORGANIC ANALYSIS (WEIGHT PERCENT) Silicon (Si02) Magnesium (MgO) Calcium (CaO) Phosphorus (P205) Iron (Fe203) Sodium (Na20) Carbonate (% C02) 50 20 16 6 3 2 2 Loss at 800C (%) CH2C12 Extractables (%) 16 0 THE FOLLOWING ELEMENTS WERE NOT DETECTED: AL S CL K TI V CR MN ZN SR MO SN BA PB CO NI CU P. O. Bo* 220 Long Beach, CA 90801 CCR 000019349 NALCO CHEMICAL COMPANY ANALYTICAL LABORATORIES 1927 Nolte Drive Paulsboro, NJ 08066 Box 87 Sugar Land. TX 77478 Form PS-108 (20M 8 82) 1801 Diehl Road Naperville, IL 60566 INI ALCO H-501 PROPYLENE DISCHARGE COOLER This is a two pass admiralty exchanger with water on the tube side. It contained a moderate amount of deposition in all of the tubes, particularly on the tube outlet. There was no evidence of any corrosion in the tubes. The nature of deposits was very flakey and had a yellowishgray color similar to what we saw in the other exchangers. The majority of the deposits was in the form of iron phosphate, calcium phosphate, and some iron and silica. Also 38% loss on ignition (800 C) indicated the potential of severe microbio fouling in the system. Form 172 CC# OOoq J'3So NALCO CHIMICAL COMPANY BBOI BUTTERFIELD ROAO OAK BROOK ILLINOIS HOOB1 CONOCO V.C.M COOLING WATER DEPOSIT INORGANIC ANALYSIS (WEIGHT % ) H -501 oooot cC oo 3/21/S4 LOSS AT 803Q^C1(%) 38 * % NALCO BOP From: CONOCO VCM Westlake, LA * Sample Marked: H-501 Analysis No. Date Sampled Date Received Date Printed X 48152 3/21/84 3/26/84 3/29/84 >>> COOLING WATER DEPOSIT < < < INORGANIC ANALYSIS (WEIGHT PERCENT) Iron (Fe203) Phosphorus (P205) Calcium (CaO) Silicon (Si02) Manganese (Mn02) Barium (BaO) Chlorine (Cl) Magnesium (MgO) Sul fur ( S03 ) Carbonate (% C02) 35 28 14 8 6 3 1 1 1 0 Loss at 800C (%) CH2C12 Extractables (%) 38 0 THE FOLLOWING ELEMENTS WERE NOT DETECTED: NA AL K TI V CR CO NI CU ZN SR MO SN PB * P, 0. Box 220 Long Beach, CA 90801 NALCD CHEMICAL COMPANY ANALYTICAL LABORATORIES 1927 Nolte Drive Paulsboro. NJ 08066 Box 87 Sugar land, TX 77478 000019352 cc* Form PS-108 <20M 8-82) 1801 Diehl Road Naperville. IL 60566 INIALCO H-60 6 FREON COOLER This is a two pass admiralty exchanger with water on the tube side. It contained severe deposition in the tubes and the presence of corrosion in the channel head. There was also evidence of some slime in the tubes. The majority of deposition was iron phosphate, iron and silica, and some calcium phosphate. A 35% loss on ignition indicates the evidence of micro bio fouling in the system. Form 1 72 000019353 CCR NALCO CHIM1CAL COMPANY BBQ1 BUTTIRff IILO "OAO ' OAK BOOK, ILLINOIS BQDB1 CONOCO V.C.M COOLING WATER DEPOSIT INORGANIC ANALYSIS (WEIGHT % ) H -606 oo ot O o LOSS AT (*) 35 % NALC From: CONOCO VCM Westlake, LA Sample Marked: H-606 Analysis No. Date Sampled Date Received Date Printed X 47455 3/13/84 3/19/84 3/23/84 <) >>> COOLING WATER DEPOSIT < < < INORGANIC ANALYSIS (WEIGHT PERCENT) Iron (Fe203) Phosphorus (P205) Silicon (Si02) Calcium (CaO) Sulfur (S03) Magn esiurn (MgO) Chlorine (Cl) Barium (BaO) Manganese (Mn02) Aluminum (A1203) Copper (CuO) Carbonate (% C02) 38 22 20 10 2 2 1 1 1 1 1 0 Loss at 800C (%) CH2C12 Extractables (%) THE FOLLOWING ELEMENTS WERE NOT DETECTED: NA K TI V CR CO NI ZN PB 35 0 SR MO SN f P. O. Box 220 Long Beach, CA 90801 CCR OOOOI9355 NALCC3 CHEMICAL COMPANY ANALYTICAL LABORATORIES 1927 Nolte Drive Paulsboro, NJ 08066 Box 87 Sugar Land. TX 77478 Form PS-108 (20M 8-82) 1801 Diehl Road Naperville, IL 60566 MALCO H-610 CHLORINE RECIRCULATING COOLER This is a two pass cooling water exchanger with water on the tube side. It exhibited a severe amount of deposition in the tubes and in the channel head. There was also evidence of some under deposit corrosion. The highest percentage of deposition was iron 65%, phos phorous 14%, silicon 12%, and calcium at 4%. Loss on ignition was 17%. CCR 000019356 CONOCO V.C.M COOLING WATER DEPOSIT INORGANIC ANALYSIS (WEIGHT % ) H -610 3/20/84 % NALCO Mwom From: CONOCO VCM Westlake, LA * Sample Marked: H-610 Analysis No. Date Sampled Date Received Date Printed X 48153 3/20/84 3/26/84 3/29/84 (ft 'r >>> COOLING WATER DEPOSIT < << INORGANIC ANALYSIS (WEIGHT PERCENT) Iron (Fe203) Phosphorus (P205) Silicon (Si02) Calcium (CaO) Sulfur (S03) Manganese (Mn02) Barium (BaO) Magnesium (MgO) Carbonate (% C02) 65 14 12 4 2 1 1 1 0 Loss at 800C (%) CH2C12 Extractables (%) 17 0 THE FOLLOWING ELEMENTS WERE NOT DETECTED: NA AL CL K TI V CR CO NI CU ZN SR MO SN PB P. O. Box 220 Long Beach, CA 90801 CCR 000l9358 NALCO CHEMICAL COMPANY ANALYTICAL LABORATORIES 1927 Nolle Drive Paulsboro, NJ 08066 Box 87 Sugar Land, TX 77478 Form PS-108 (20M 8 82) 1801 Diehl Road Naperville, IL 60566