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Anodes in Cooling Water Exchangers PDF
Anodes in Cooling Water Exchangers PDF
01
1.0 SCOPE
These are guidelines for the design, installation, and maintenance of sacrificial anodes in
cooling water heat exchangers. They are meant to protect the channel section of heat
exchangers with cooling water on the tube side.
Designers can use this when designing new exchangers or protecting existing exchangers.
Reliability personnel, such as inspectors can use this to spot problems with anodes systems or
to know when anodes may be needed (Section 7 and flow chart pg. 2). Maintenance
personnel can learn how to avoid past installation mistakes (Section 6 and 7).
Anodes in the channel section are not likely to protect the tubes from corrosion.
2.0 GOALS OF GUIDELINES (What these guidelines can help you do)
Give background on the engineering principles used for determining the number of anodes
required (Section 3).
Decide under what conditions is it appropriate to use anodes (Section 4 and Flow chart Page
1)
Decide how many anodes are needed and where to place them (Section 4 and excel
spreadsheet)
Understand how to change the anode system to reduce the number required (Section 5.0).
Maintain and troubleshoot the anode system (Section 4 and flow chart page 2)
Current density is a characteristic of the cooling water, which includes the effects of
temperature and aeration (how much oxygen is dissolved in the system). Typical units are
mA/ft2.
Conductivity is how well the cooling water conducts electricity. Units are usually given in
micro mhos/cm. Among other things, chloride content and temperature can affect this
parameter.
Two anode properties that measure the anodes performance are anode current capacity and
driving voltage.
Current capacity is a measure of how much charge an anode can put out per pound. It is
usually expressed as Amp*hrs/lb. For example, if an anode must be used at 0.100 Amp for
10,000hrs and the current capacity is 500Amp*hr/lb, then about 2lbs of anode will be
required. The higher the current capacity, the longer the anode tends to last.
Magnesium has become the standard for cooling water service, so zinc and aluminum alloys
will not be discussed in much detail here.
Magnesium alloys are the most commonly used anode materials for cooling water service.
Two common alloy compositions are specified in ASTM B843 (See Table I for the different
grades and their properties)
They are especially effective where conductivity is relatively low (<5000micro mhos /cm)
Aluminum by itself does not usually corrode as would be required of an anode, but when
activated with elements such as tin, indium, and mercury they tend to corrode uniformly.
At the Richmond Refinery in both 1998 and 2000, portions of a scale containing aluminum
were found plugging the tubes. When an analysis of the anode was done it was found to be
aluminum and not magnesium as specified. The reason for decomposition of the anode is
unclear.
They are most useful where sparking, caused by dropping the anode, cannot be tolerated.
Recommended anode shape and costs
The current locknut design shown in Figure 1 (Appendix A) should be used. Two
companies that supply anodes of this type are HARCO and Farwest. Richmonds supplier is
currently HARCO, a Corrpro company. A supplier that the El Segundo refinery is
considering is Farwest. The prices as of Aug. 2000 are listed in Table II. Other sizes may be
available but only on special order.
TABLE II. ANODE SIZES AND PRICES FOR ASTM B843 GRADE M11636
Supplier Shape Dimensions, inches Weight Potential Cost, $ Cost /lb.
vs.
Cu/CuSO4
Harco Cylindrical 5 diameter, 2 thick 3 1.5 12 4.00
Harco Square block 8X8, 2 thick 7.5 1.5 36 4.80
Harco Square block 8X8, 4 thick 15 1.5 69 4.60
Farwest Square block 8X8, 4 thick 15 1.5 70 4.67
...Personnel Approval
If you still believe anodes are
needed, but the appropriate
personnel do not approve, provide
the following to the materials
engineer:
1. Reason for disapproval
2. Contact information for person
who does not approve.
Depending on the problem, the
materials engineer might be able to
suggest an alternative (e.g. coating)
12 Decision Determine whether the appropriate The appropriate personnel are the
personnel approve of installing materials engineer, whoever is
anodes. responsible for cooling water
chemistry (e.g. NALCO), and your
immediate supervisor.
13 End point Install anodes per engineering
drawings.
TROUBLESHOOTING AND MAINTENACE OF ANODES, Page 2 of flow chart
14 Task Inspect anodes when the channel is
opened to determine if the anodes
need to be replaced because of either
damage or deterioration.
15 Decision Decide whether the majority of If so, all anodes should be replaced,
anodes are at or below half size. because size.xls is intended for anodes
to be fully effective until they reach
quarter size.
16 Decision Inspect to see whether one or two If so, this could suggest that only a
anodes appear to be much smaller few anodes are bearing the electrical
than the others are. load.
17 Decision Decide if anodes have severe They may have defects (e.g. from
localized corrosion casting) that might cause large pieces
to spall off and plug exchanger tubes.
18 End point Continue to use anode until the
anodes design life is exceeded.
19 End point Replace all the anodes, their design
life will be exceeded soon.
20 End point Replace the anodes in this chamber
and send the anodes removed to your
materials engineer for analysis. Be
sure to provide a picture or sketch of
the anode layout in the channel.
21 End point Replace anodes that have defects Anodes such as these should be
that are 1/8 or greater in size. replaced, and the remnants should be
1. Be sure that the following are available: grit blasting and stud welding equipment, anode
accessories (stud, rubber washer, hex nut, lock washer, flat washer).
2. Grit blast metal surface of partition plate until bare metal is showing. If the partition plate is
not cleaned of rust, dirt, or scale, the stud will not make good electrical contact with the
anode, hindering weldability and potentially preventing the anode from functioning.
3. Lightly scribe marks into the partition plate where the studs are to be attached.
4. Place rubber washer down around stud.
5. Place anode on top of washer such that stud fits through the core of the anode. Anode should
not come in direct contact with the partition plate (See section 7).
6. Tighten nut on stud such that a tight seal is formed between the anode, washer, and partition
plate
7.2 Miscellaneous
If in the future both aluminum and magnesium anodes are purchased, purchase aluminum in
square shapes and magnesium in cylindrical shapes to avoid mistaking one for the other. It is
difficult to distinguish between the two materials because they have similar weights and
appearance. Stamps in the cast material can be difficult to read.
Note the rubber washer/plastic spacer detail in Figure 1. From experience, we find that anode
corrosion products can build up under the anode and break off chunks of it if this spacer is
not used. The spacer also promotes uniform decay of the anode by preventing corrosion at
the channel interface.
Do not use modified anode configurations without checking with your local materials
engineer or CRTC.
Do not screw the magnesium anode into the threaded stud as this will cause preferential
corrosion at the threads and could potentially lead to heat exchanger plugging.
8.0 REFERENCES
APPENDIX A.
Additional Baffles
m e
A
B
h
Partition plate