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Innovative liquid vaporizing and gas mixing solutions

All Horizontal and Vertical Waterbath

Vaporizers and Packaged Mixers

Operations & Maintenance Manual

Supplement for Heat Transfer Fluid
Maintenance

2019.03.0
MANUAL PN 51852 AQUAVAIRE SUPPLEMENT REV 02-27-19 4 09:46:16
-08'00'
 DISCLAIMER and WARNING
Read the OPERATION MANUAL before operating this equipment.

DISCLAIMER
Algas-SDI International, LLC (ASDI) shall not be liable for technical
and/or editorial errors or omissions in this manual. ASDI makes no
warranties, express or implied, including the implied warranties of
merchantability and fitness for a particular purpose with respect to
this manual.

 NOTE: Algas-SDI reserves the right to use alternate

manufacturers’ components as vendor delivery applicability
dictates. Vendors have supplied literature contained in the
Operation Manual. Please check to be sure supplied data
matches your configuration. Contact Algas-SDI if any questions
exist.
■ This equipment uses LPG-a flammable fuel, or NH3-a toxic gas,
(depending on the model), handled under pressure. Inherent
hazards exist, and a thorough understanding of the equipment is
required to allow safe operation and maintenance.
■ Allow only a TRAINED and FULLY QUALIFIED PERSON to service
this equipment.
■ Any time a component must be replaced, use the same type,
model, etc. DO NOT SUBSTITUTE! The consequence from such
actions are unpredictable and may lead to dire consequences.
When components are replaced with components not approved
for use in our FM listed equipment, the FM listing becomes void
for that unit.
DISCLAIMER and WARNING

Read this Operation and Maintenance Manual before operating the QH, QV or
QM systems.

DISCLAIMER
Algas-SDI International, LLC (ASDI) shall not be liable for technical and/or
editorial errors or omissions in this manual. ASDI makes no warranties, express
or implied, including the implied warranties of merchantability and fitness for a
particular purpose with respect to this manual. In no event shall ASDI be liable
for any special or consequential damages including, but not limited to loss of
production time, or loss of profits.

Product names used in the manual are for the manufacturer or supplier
identification only and may be trademarks, or registered trademarks, of these
companies.

In accordance with the manufacturer’s policy of continual product improvement,

Algas-SDI reserves the right to use alternate manufacturer’s components as
vendor delivery applicability dictates. Literature contained in the Operation
Manual has been supplied by vendors. Please check to be sure supplied data
matches your configuration. Contact Algas-SDI if any questions exist.
 CORROSION PROTECTION

Waterbath vaporizers contain all the ingredients for metallic corrosion. In order
to minimize this corrosion, certain steps must be taken. Grounding the vaporizer
skid and adding a rust-inhibiting antifreeze and/or rust inhibitor to the heat
transfer fluid (HTF) will help minimize this corrosion.

An ELECTRICAL GROUND must be connected to the vaporizer frame. The

vaporizer frame must be grounded using 4 AWG or larger wire to a copper or
galvanized grounding rod driven at least 4 ft into the ground to minimize galvanic
corrosion. The earth ground can be tested by performing an ohmmeter check
with the system power off. Test continuity between an unpainted metal surface
of the QV/QM/QH water-jacket and the nearest earth ground. This should read
less than 1000 ohms (1.0 kohm).

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Algas-SDI Operations and Maintenance Manual Supplement – P/N – 51852 1-1
Waterbath Freeze and Corrosion Protection
The QV/QM/QH is an unpressurized, closed-loop waterbath vaporizer, meaning its heat transfer section is vented
to atmosphere and requires slightly different maintenance than a sealed and pressurized closed-loop system.
This is accomplished by increasing the frequency of testing the heat transfer fluid (HTF) to once every 30 days.

The QV/QM/QH is cleaned at the factory with a liquid alkaline cleaner to remove loose mill scale, oil,
contaminants and corrosion that occurred during the manufacturing process. After testing, and prior to shipment,
the vaporizer was drained and a vapor phase corrosion inhibitor (VPCI), in powder form, was introduced into the
boiler section of the vaporizer. The vent cap of the vaporizer was then sealed. The VPCI will remain active for a
period of 24 months as long as it remains sealed. The VPCI will NOT need to be washed from the system before
adding the HTF products when the system is activated.

NOTE
The AQUAVAIRE QV/QM/QH system must have either corrosion
inhibitors or both corrosion inhibitors and freeze protection added
to the waterbath heat transfer fluid (HTF).

RECOMMENDED WATER SPECIFICATION

Distilled or de-ionized water is recommended for both initial fill and make up due
to evaporation. Tap water should not be used because of dissolved solids and
gases, which can interfere with corrosion inhibitor effectiveness and even
increase inhibitor depletion rate. If distilled or de-ionized water is not available,
water quality should meet the minimum quality requirements in the table below.

Chlorides 25 PPM (max)

Sulfates 25 PPM (max)
Calcium 50 PPM (max)
Magnesium 50 PPM (max)
Total PPM 100 PPM (max)

WATERBATH FILL LEVEL

The Cold Fill Line on the sight gauge is for filling at 60°F (15.6°C). However, the
waterbath will only vary 1/2 inch to 3/4 inch below the fill line from 60°F (15.6°C)
to -20°F (-28.9°C) and a total of 2 to 2-1/2 inches from -20°F (-28.9°C) to 170°F
(76.7°C). Because of this, for the initial fill, we recommend filling to the Cold Fill
Line regardless of the temperature. The waterbath level will then be 1 to 2
inches above the fill line at operating temperature. Final fill should be done once
waterbath reaches operating temperature. Fill to the Hot Fill line as marked on
the expansion tank sight gauge.

FREEZE PROTECTION
If freeze protection is required, Algas-SDI recommends DOWFROST HD as the
preferred freeze protection product. DOWFROST HD is a heavy duty industrial
inhibited PROPYLENE GLYCOL based product and is preferred because the low
acute toxicity is more environmentally friendly than an ethylene glycol-based
product. DOWFROST HD also contains corrosion protection chemicals so none
need to be added.

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1-2 Algas-SDI Operations and Maintenance Manual Supplement – P/N – 51852Q
Calculating Freeze Protection

FREEZE PROTECTION TABLE 1

To calculate gallons of DOWFROST HD to
add for freeze protection: FREEZE BOILING
POINT POINT %VOL.
 Select a temperature at least 5°F (3°C) DOWFROST
below the lowest ambient temperature the (F) (F) HD
waterbath will reach. 15 217 25.6
 Determine the % volume of HTF required 10 218 29.8
in the final mix from Table 1. 5 220 34.7
0 221 38.6
 Determine total waterbath gallons -5 221 41.5
required from Table 2. -10 222 44.4
 Multiply the total waterbath gallons by % -15 223 47.0
volume/100 to determine gallons of anti- -20 224 49.2
freeze product required. -25 224 51.7
-30 225 53.7
-35 226 55.7
EXAMPLE: -10°F ( -23.3OC ) IS THE LOWEST OPERATING -40 226 57.5
TEMPERATURE FOR A Q640V USING DOWFROST HD. -45 227 59.3
-50 228 60.8
 Freeze protection required:
-15° F (-26.1°C)

 Percent volume DOWFROST HD TABLE 2 – QV(QM) & QH VOLUMES

required at -15° F ( -26.1°C ):
PV = 47% (Table 1) Total Waterbath
QV(QM) Models Gallons
 Total Coolant Gallons (TCG) for
Q320V 116
Q640V: TCG = 237 (Table 2)
Q480V 136
 Gallons DOWFROST HD Q640V 237
required: Q800V 294
Q960V 294
 GALHD Q1120V 505
Q1375V 505
TCG X PV = GALHD
Q1650V 505
237 X 0.47 = 111 GALHD

TCG – GALHD = GALWater

Total Waterbath
237 – 111 = 126 GALWater
QH Models Gallons
 Circulate waterbath for 24 Q1650H 1050
hours and refer to page 1-11 of Q2200H 1190
this supplement to record Q3300H 1444
corrosion protection Q4400H 2450
concentrations in your Q5500H 3500
waterbath maintenance log. Q7500H 4550
Q10000H 6000
Q12500H 6800
Q15000H 7500

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Algas-SDI Operations and Maintenance Manual Supplement – P/N – 51852 1-3
CORROSION PROTECTION WITHOUT FREEZE PROTECTION

When freeze protection is not required, corrosion protection must still be used.
Algas-SDI recommends the use of CH2O 6431 HYDRO-TREAT when only
corrosion protection is required. Add this material at the rate of 1 gal to 500
gallons of distilled or deionized water as described in RECOMMENDED WATER
SPECIFICATION on page 1-2.

EXAMPLE: Q640V CORROSION PROTECTION

 Q640V TCG = 237 gal (Table 2)

 237/500 x 1 gallon (128 oz) = 61 oz CH2O 6431 HYDRO-TREAT

 Circulate waterbath for 24 hours and refer to page 1-11 of this supplement to
record corrosion protection concentrations in your waterbath maintenance
log.

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1-4 Algas-SDI Operations and Maintenance Manual Supplement – P/N – 51852Q
ORDERING INFORMATION

 DOW CHEMICAL

The Dow Chemical Company

Larkin Lab
C/O Thermal Fluids Testing Lab
1691 North Swede Road
Midland, Michigan 48674

Phone: 1-800-447-4369
Web Site: http://www.dow.com/heattrans/gss/inhibited/

 CH20 HYDROTREAT, LLC.

CH20
8820 Old Hwy 99 SE
Olympia, WA 98501

Phone: 1-800-562-6184
Fax: 1-360-352-4813
Web Site: www.ch20.com/ch20

 Algas-SDI

Algas-SDI International, LLC

151 South Michigan Street
Seattle, WA 98108

Phone: 1-206-789-5410
Fax: 1-206-789-5414
Web Site: www.algas-sdi.com

OPTIONAL FREEZE PROTECTION AND CORROSION PROTECTION PRODUCTS

If you choose to use a generic brand of freeze protection with corrosion

protection in lieu of DOWFROST HD or corrosion protection in lieu of CH2O 6431
HYDRO-TREAT it must have the following properties:

Freeze Protection: Inhibited propylene or ethylene glycol with adequate buffers

and industrial corrosion protection chemicals suitable for protecting steel, cast
iron, and small amounts of brass and copper (pump bushings, thermowells and
miscellaneous).

Corrosion Protection With or Without Freeze Protection: Sodium nitrite

and/or sodium molybdate and/or other chemicals capable of protecting steel, cast
iron, and small amounts of brass and copper (pump bushings, thermowells and
miscellaneous fittings.

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Algas-SDI Operations and Maintenance Manual Supplement – P/N – 51852 1-5
Maintenance Checklist

Check these items weekly to ensure safe and proper operation:

 Check for leaks in the entire gas and liquid train.

 Heat transfer fluid level.

 Verify water pump operation.

 Gas valve operation.

 Flame safeguard status.

 Smooth light-off and smooth burner operation.

 Solenoid operation.

Check heat transfer fluid pH, freeze protection and inhibitor levels on a monthly
schedule.

Check heat transfer fluid for algae, fungi and bacteria on a yearly basis.

VAPORIZER SAFETY CHECK

1. START AND STOP THE BURNER several times to insure proper operation.
Check for proper functioning of low-water cutoff, high limit and operating
control.

2. CHECK OPERATION OF FLAME SAFEGUARD by simulating a flame

failure by shutting off the MAIN GAS SUPPLY VALVE in the gas train,
making certain the burner locks out on safety within the time limits of the
control. Refer to the flame safeguard section in the Appendix of
equipment Operating Manual.

3. START THE BURNER in accordance with the step by step operating

sequence procedure. As the burner enters the flame safeguard sequence,
verify each burner function at the timing indicated. Refer to the flame
safeguard section in the Appendix of equipment Operating Manual.

HOW TO FIND INFORMATION

 To locate a component on the QV/QM/QH system, See equipment

Operating Manual.

 For an overview of component operation in a system and minor adjustments,

Consult equipment Operating Manual.

 For more specific information on a component, See Appendix in equipment

Operating Manual.

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1-6 Algas-SDI Operations and Maintenance Manual Supplement – P/N – 51852Q
 CAUTION
Whenever any component or fitting in the system is removed,
replaced or reinstalled, the complete system must be leak tested.
NO LEAKS ARE TOLERABLE!

HEAT TRANSFER FLUID (HTF) MAINTENANCE

In addition to maintaining proper heat transfer fluid (HTF) level, pH and corrosion
inhibitor control is also necessary. Water loss by evaporation is natural and
depends on system use and ambient conditions. Monitor water loss for a month
when in use to determine a pattern of loss. Also, check HTF level before using if
the vaporizer has been idle for over 30 days.

pH control is important because glycol can oxidize into acidic end products which
are very corrosive. Dow products contain additives to neutralize these acids
which may become depleted over time. pH should be checked with a pH monitor
or indicating paper. Test kits are provided with each QV/QM/QH, located in the
instrument panel box. Replacement kits can be ordered from Algas-SDI (See
Ordering section for address information).

Test the HTF after treatment and circulating 24 hr, once per week for the
first month and monthly thereafter following the test procedures in the
following section and record the data in the maintenance log shown on page 1-
11. If the pH, freeze protection or corrosion inhibitors (if appropriate to your HTF)
are out of specification, submit two samples to a lab to test for all active
ingredients, pH, conductivity (μS) and the presence of iron. Provide the test
results and a copy of your maintenance log to the supplier of your HTF to
determine the proper corrective action.

Dow provides a free fluid analysis to determine inhibitor condition for systems
containing 250 gallons or more of DOWFROST or DOWTHERM, and a small fee
for lesser amounts. The kit consists of several 4-ounce containers and labels to
fill with fluid samples to send to Dow. It is recommended that you order the kit in
time to take a sample after the vaporizer has been initially filled and circulated for
24 hours. The test results from Dow will include inhibitor and glycol levels and
any necessary recommendations.

The inhibitor used in CH20 HYDRO-TREAT is both molybdenum and nitrite

based and can be checked using the Algas-SDI test kit provided inside the
control panel of the QV/QM/QH vaporizer.

Check your HTF for biological activity (i.e. bacteria, algae, and fungi) at least
once per year. A dip slide test kit is provided inside the control panel of your
QV/QM/QH vaporizer.

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Algas-SDI Operations and Maintenance Manual Supplement – P/N – 51852 1-7
 NOTE___________________________________________________

Purchase heat transfer fluid (HTF) from a supplier that is

competent and can provide instructions, water analysis and follow-
up service necessary for complete and satisfactory results. Do not
be misled by vendors offering low-cost HTF(s) or solutions without
fully understanding these products, their application and how to
properly maintain them.

The standard Algas-SDI warranty covers only original defects and

does not cover repairs resulting from poor water or HTF conditions
leading to corrosion, scale buildup or poor vaporizer performance.
It is the sole responsibility of the customer to see that a proper
water and/or HTF maintenance program is always correctly
followed.
________________________________________________________

HEAT TRANSFER FLUID (HTF) TEST PROCEDURES

TESTING FOR FREEZE PROTECTION AND CORROSION INHIBITORS

Test heat transfer fluid (HTF) before maintenance is performed. The test
strips should be used by the date on the packaging. These test strips are for
maintenance screening for HTF problems. If the HTF is out of acceptable
range, submit additional samples to your test lab to determine the proper
corrective action. This kit will test for products such as molybdate and nitrite
that are not present in DOWFROST HD but are present in CH2O 6431
HYDRO-TREAT. Determine what products are in your HTF before testing.
For best results:
• Start with clean, dry hands and utensils.

• Circulate fluid for 24 hours before testing.

• Run test in a well-lit area, natural light if

possible.

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1-8 Algas-SDI Operations and Maintenance Manual Supplement – P/N – 51852Q
 • Collect HTF samples from both the top and bottom of the waterbath
tank. HTF must be between 50° F (10° C) and 110° F (43° F) when tested.
Room temperature is preferred.

• Remove one strip from the bottle. DO NOT touch the pads on the end of
the strip. DISCARD STRIP IF NITRITE TEST PAD HAS TURNED BROWN.

• Dip strip in HTF sample for one second, remove, and shake strip briskly
to remove excess liquid.

• 45 SECONDS after dipping the strip, compare and record results in the
following order: (1) Compare FREEZEPOINT (end pad) to color chart and
record the result. (2) Next compare MOLYBDATE (middle pad) to color chart
and record the result which must be between 200 – 300 ppm. (3) Then
compare NITRITE test to color chart and record result which must be
between 250 – 350 ppm. (4) Finally compare pH test to color chart and
record result.

• All four readings must be completed NO LATER THAN 75 SECONDS

after dipping the strip.

• It is okay to estimate a value BETWEEN color blocks, but if uncertain

about the color match, pick the LOWER numbered block.

• For best results follow test times carefully. Use a stopwatch or clock with
a sweep second hand. Comparing the test strips to the color chart too soon
or too late may result in incorrect readings and improper treatment and could
result in heat exchanger tubing pitting and vaporizer damage.

• FOR DOW FLUIDS ONLY: Control of pH between 8 and 10 is important

to minimize corrosion and glycol degradation. The desirable pH range
should fall between 8.0 and 10.0. Adjustments can be made by adding a
50% solution of sodium hydroxide or potassium hydroxide until the pH has
returned to normal. Any fluid with a pH below 7.0 should be replaced. Also,
you can quickly determine the condition of your fluid by examining its
appearance and odor. Any drastic variation from the initial fluid
specifications, such as a black or dark-grey color, presence of an oily layer,
burnt odor, or any heavy sludge in the fluid may indicate the need for fluid
replacement.

• Test for biological activity at least once per year. Dip slides and
instructions are provided inside the control box of your QV/QM/QH vaporizer.
Spare test kits can be ordered from Algas-SDI.

• All readings should be recorded on the vaporizer maintenance log for

future reference.

• If your HTF components are out of specification, submit samples from

top and bottom of tank, as previously mentioned, to either DOW or an
appropriate test lab to test for all active ingredients, pH, conductivity (μS) and
the presence of iron. Send or fax test results along with a description of your
HTF and a copy of your test log to your HTF supplier to determine the proper
course of corrective action. Failure to do so may result in damage to your
vaporizer and poor heat transfer performance.

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Algas-SDI Operations and Maintenance Manual Supplement – P/N – 51852 1-9
TESTING FOR BIOLOGICAL CONTAMINATION

1. If ANY fungal or bacteria growth is present, consult HTF supplier for corrective action.
Unscrew the cap and remove the paddle from the vial. Be careful not to touch either of the
paddle’s surfaces.
2. Immerse the paddle into the sample for 2-3 seconds so that both surfaces are covered with
the liquid.
3. Allow excess fluid to drain from the paddle by touching the tip to an absorbent piece of paper
(such as a paper towel).
4. Empty vial of liquid, screw cap back on and incubate in a upright position between 77o – 86o F
(25 – 30o C) for 24 – 36 hr. At that time bacterial side can be read. Fungal growth, if heavy, can
be read at 36 hr. For sparse fungal growth, up to 5 days of incubation may be required.
5. Compare the growth on the paddle to the conversion chart below for a quantitative
interpretation of the results.

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Algas-SDI Operations and Maintenance Manual Supplement – P/N – 51852 1-11
Algas-SDI International, LLC
151 South Michigan Street
Seattle, Washington 98108
USA
Ph.: 1.206.789.5410
Fax.: 1.206.789.5414
www.algas-sdi.com