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4-Stroke Engines 4619Q002

Technical Services Issue 11, 11 February 2020

Cooling water treatment and

For your information
analysing
Distribution to operators and owners of installations Engines concerned
concerned This bulletin is valid for:
· Sulzer Z40, ZA40, ZA40S, ZA50S
· Wärtsilä Vasa 32, 32LN
· Wärtsilä 16
· Wärtsilä 20, 20DF
· Wärtsilä 200, 220SG
· Wärtsilä 28SG
· Wärtsilä 26
· Wärtsilä 31, 31DF, 31SG
· Wärtsilä 32, 32DF, 32GD, 32LNGD
· Wärtsilä 34DF, 34LPG, 34SG
· Wärtsilä 38A, 38B, 38C
· Wärtsilä 46, 46GD
· Wärtsilä 46F, 46FDF
· Wärtsilä 50, 50DF, 50SG
· Wärtsilä 64
Reference
Cooling water system
Introduction
Correct cooling water treatment and follow-
up of the cooling water condition are of
utmost importance for keeping the cooling
water systems of the engines in good
condition.
Validity
Until further notice. Replacing issue 10,
dated 27 September 2019.
In this issue, the following has been added
in Table 2:
· Condemning values.
· Requirement for water hardness.
Before taking any action, always check the
available online systems for the latest
revision of this document. Any locally stored
or printed version is considered to be an
uncontrolled document.

Wärtsilä Finland Oy Tel: +358 010 709 0000 www.wartsila.com

P.O. Box 244 (Järvikatu 2-4)
FIN-65101 Vaasa
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4619Q002, Issue 11, Page 2 / 10

Contents
Page
1 Background 2
2 Purpose 2
3 Instructions 3
3.1 Raw water quality 3
3.2 Additive dosing 3
3.3 Analysis and recommended levels 4
4 Worth noticing 5
4.1 Aggressive compounds and conditions 5
4.2 Additive characteristics 6
4.3 Powder form products 7
4.4 Prolonged stops and mechanical design 7
4.5 Alternative cooling water treatment additives and treatment systems 7
4.6 Mixing of different cooling water additives 7
4.7 Warning for Aluminium parts 8
4.8 Use of glycol 9
5 Validated cooling water additives 9
6 Contacts 10

1 Background
Correct cooling water treatment and follow-up of the cooling water condition are of utmost
importance for keeping the cooling water systems of the engines in good condition. The
corrosion processes that could occur due to a poor cooling water quality may under
certain circumstances be local and by their nature proceed very rapidly. This may cause
unexpected operating problems or engine failures even within relatively short periods of
time, for example in the cylinder head exhaust valve seat pockets and other areas prone
to corrosion (see further comments in chapter 4) in the cooling water systems of the
engines.
Most of the cooling water additives which are validated by Wärtsilä are nitrite based
(typically NaNO2) and today, most of the installations in operation are also using nitrite-
based additives. Although there is a trend towards more environmentally friendly
alternatives. These operating instructions and recommendations are mainly intended for
installations using nitrite-based additives but certainly contain useful information also for
users of other types of additives.

2 Purpose
To avoid unnecessary corrosion damages and operating problems in the cooling water
systems of the engines.

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4619Q002, Issue 11, Page 3 / 10

3 Instructions
3.1 Raw water quality
The raw water quality for the cooling water circuits of an engine must meet the following
specification:

Table 1, Raw water quality

Property Unit Limits for Limits for Test method reference

chemical use WWCU*) use
pH 1) - 6.5 - 8.5 6.5 - 8.5 ASTM D 1287 or D 1293
Hardness °dH Max. 10 Max. 10 ASTM D 1126
Chlorides 1) mg/l Max. 80 Max. 40 ASTM D 512 or D 4327
Sulphates mg/l Max. 150 Max. 100 ASTM D 516 or D 4327
*)
Wärtsilä Water Conditioner Unit
1)
If a Reverse Osmosis (RO) process is used, min. limit for pH is 6.0 based on the RO process
operational principle. The use of water originating from RO process further presumes that for
chloride a max. content of 80 mg/l when using chemicals and max. content of 40 mg/l when using
WWCU is achieved.
Soft waters (like distilled, ion exchanged, reverse osmosis and rain water) with a total
hardness close to 0 °dH (German degrees) can dissolve oxygen and carbon dioxide from
the air, which quite rapidly lowers the pH levels and increases the corrosive effect of
these waters. Thus, it is essential that additives are added as soon as possible after
filling the cooling water system.
Suitable amounts of calcium and magnesium compounds (= total hardness) participates
in forming a thin, corrosion protective layer on the heat exchanging surfaces of the
cooling water system. Correct additive dosage and careful follow-up of the dosing levels
are thus even more important with a very soft water compared to a normal quality
tap/drinking water with a total hardness of 2 – 10 °dH.
The use of raw water qualities with a too high total hardness may on the other hand result
in excessive deposit formations and reduced heat transfer properties. Water produced
by one (1) stage reverse osmosis processes may sometimes contain too high chloride
(and sulphates) contents and are in those cases not suitable as cooling water.
Sometimes, it is possible to achieve a lower chloride level by using a two (2) stage RO
process, but the outcome also depends on the RO process technology being used.

3.2 Additive dosing

The cooling water additive dosage recommendations may vary, depending on additive
type and manufacturer. The dosage recommendations for the cooling water additives
validated by Wärtsilä are presented in section 5. There is no general dosage
recommendation for the validated additives. Note that these recommendations apply for
normal raw/cooling water properties, see also section 4 for further information. Generally,
a slight overdosing is better than under-dosing, but an excessive additive (nitrite) dosage
is not recommended economically or technically. Large (>2 – 3 times the maximum
recommendation) overdosing may cause corrosion on copper, brass and other “soft
alloys” in the system and possibly also problems with precipitation and deposit
formations.

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4619Q002, Issue 11, Page 4 / 10

3.3 Analysis and recommended levels

It is recommended to perform cooling water analysis, for example with test kits provided
by the additive manufacturer, once (1) a week. The additive concentration of nitrite-based
products may decrease quite rapidly, especially in the beginning after the initial dosing
of a new or thoroughly cleaned system. When the properties of the cooling water are
found to be stabilised, the analysis interval may under normal conditions gradually be
prolonged, for example to 2 – 4 weeks.
It is also recommended to perform a more complete cooling water analysis 2 – 4 times /
year to check that the test kit analysis results are correct and to be able to make a more
complete cooling water condition evaluation. When samples are taken and sent for
analysis, the sample bottles shall be fully filled up to minimise the amount of air in the
bottle, and a suitable sample amount is 1 litre. The cooling water samples shall be taken
from circulating water. Remember to flush the sampling pipes and valves properly before
taking the sample. The samples should be kept in a cool and dark place during
transportation and storage before the analysing. If special sample bottles are not
available, the best alternative is an empty, clean drinking water bottle, since these are
most likely free from bacteria and other contaminants.
Water and cooling water samples shall be analysed as soon as possible, preferably
within a week after sampling. Some of the properties/compounds (pH, sulphates and iron
for example) of the water may react or precipitate in the sample bottle and give false
results.
Table 2 below shows the recommended values for the cooling water analysis to be
checked regularly (weekly). Sudden changes in the trends of the analysed properties
shall always be investigated and possible malfunctions and faults in the systems
corrected.

NOTE:
If the recommended levels are exceeded, please contact Wärtsilä for further instructions.

Table 2, Regularly (weekly) controlled cooling water properties

Property Recommended levels for optimal performance 1)

Condemning limits
Chemical use WWCU use
pH 8 – 11 < 7.5 and > 11.5
2)
Nitrite (NO2) 470 – 2500 ppm < 470 and > 2500
ppm 2)
Chlorides (Cl) < 50 mg/l < 40 mg/l > 80 mg/l
Sulphates (SO4) < 100 mg/l > 150 mg/l
Hardness (°dH) < 10 °dH > 10 ⁰dH
1)
For normal cooling water conditions, see also chapter 4.1 for recommendations for aggressive
compounds and conditions.
2)
The required nitrite content range is product specific and the additive dosage always has to fulfil
the requirements included in Table 4.

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4619Q002, Issue 11, Page 5 / 10

Table 3 gives recommended values for the additional properties that shall be performed
during the more complete cooling water analysis, performed 2 – 4 times / year. Additional
analysis may naturally be considered from case to case, if special issues have occurred.
Table 3, Additional properties that shall be checked 2 – 4 times / year

Property Recommended levels for optimal performance

Iron (Fe) < 1 mg/l1)
Nitrate (NO3) < » 50 - 200 mg/l2)
Calcium (Ca) The total hardness (Ca + Mg)
Magnesium (Mg) < 10 °dH 3)
Copper (Cu) < 1 mg/l
1)
The iron levels may be higher in new or recently overhauled systems, due to presence of smaller
amounts of machining and installation debris, etc. These “initially high” iron contents should
however gradually decrease to the typical levels. Observe that the total iron contents should be
analysed not dissolved iron.
2)
Constantly/rapidly increasing nitrate (NO3) levels, especially in combination with simultaneously
decreasing nitrite (NO2) levels, indicate presence of possible bacterial/microbial activity in the
systems. Bacterial contamination may come for example from salt water or some other dirty water
contamination of the system. Nitrate (NO3) content in cooling water can vary significantly, since
some products contain nitrate also as an original ingredient.
3)
A total hardness of 10 °dH (German degrees) « 178 mg/l (as CaCO3) and
Mg = 4.3 mg/l « 1 °dH and Ca = 7.1 mg/l « 1 °dH

NOTE:
There are some chemical processes (deposition, corrosion and evaporation) in the
cooling water system that can decrease or increase the concentration of certain elements
(e.g. Ca, Mg, Cl). This can be one of the reasons for higher/lower levels found in the
cooling water system compared to the raw water quality used.

4 Worth noticing
4.1 Aggressive compounds and conditions
Elevated amounts of sulphates, sulphides, halides and especially chlorides are
extremely aggressive (corrosive) on iron. If there are high amounts of these aggressive
ions present in the cooling water system, the nitrite dosage must be increased
accordingly. The recommendations vary slightly between different additive
manufacturers, but for increased chloride and sulphate contents the following formulas
can be used as rules of thumb:
· Add 100 mg/l of nitrite (NO2) / 10 mg/l of chlorides (Cl), for Cl > 50 mg/l.
· Add 100 mg/l of nitrite (NO2) / 50 mg/l of sulphates (SO4), for SO4 > 150 mg/l.

CAUTION:
It is strongly recommended to change the cooling water immediately if the chloride
content of the water exceeds 200 mg/l or if the sulphate content exceeds 400 mg/l.

The nitrite oxidation curve in Figure 1 shows a schematic graph of the corrosion rate as
a function of the nitrite dosage. Observe that the position of the curve peak on the
x-axis (= dangerous condition for corrosion) is not stable, but will shift depending on
several external conditions in the cooling water, such as temperature, pH, chlorides and
sulphates contents, etc. That is, if the chloride content of the cooling water is increased

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4619Q002, Issue 11, Page 6 / 10

the additive (nitrite) dosage also must be increased to avoid the conditions of increased
corrosion rate.

To give full protection the Nitrite level

must be kept above X ppm. The
actual concentration is additive
supplier dependent.
A permanent lower level will lead to
an accelerated corrosion rate.

Figure 1, Corrosion rate as a function of the nitrite concentration

Chlorides and other corrosive ions tend to accumulate in cracks, under deposits etc. and
may there reach considerably higher concentrations than in the "bulk phase". It is thus
extremely important that all the surfaces of the system are cleaned properly before the
corrosion protection additive is added to the system. Both oils/greases and scale/rust
must be properly removed. There are cleaning products available on the market that
combines or can be combined to provide both degreasing and descaling properties, such
as the environmentally friendly BioCleaner products provided by Wärtsilä.

4.2 Additive characteristics

Nitrite based cooling water additives are so called anodic inhibitors and require proper
dosing and maintenance to protect as intended. The nitrite of the additive is a salt and it
will increase the electrical conductivity of the water. The non-additive originated
conductivity is on the other hand one of the main parameters affecting the corrosion rate,
if a corrosion process starts: the higher the conductivity, the higher the corrosion rate.
From conductivity trend follow-up point of view, it is important to know the normal
conductivity level of un-treated and treated cooling water. If the conditions (nitrite level,
chlorides, pH, etc.) in the systems are such that the additive (nitrite based) is no longer
able to protect the entire surface of the system, a rapid, local (pitting) corrosion in the
unprotected areas may occur. The corrosion rate at the attacked areas will even be much
higher than it would be with no additive at all present in the system.
Sensitive areas for corrosion would typically be:
· In crevices and under deposits.
· Areas of very low flow (the inhibitor is not properly taken to the metal surface).
· Areas of turbulent flow, such as a change of pipe cross-section, where it is more
difficult to form a proper protective film.
· Areas that are typical problem areas for corrosion, such as welded sections,
combinations of dissimilar metals, areas of increased mechanical stress, etc.

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4619Q002, Issue 11, Page 7 / 10

4.3 Powder form products

Nitrite based cooling water additives in powder form must be dissolved properly in water
before adding to the system. To avoid possible dissolving problems resulting in under
dosing, ensure enough mixing of the powder and the water in the maintenance tank.

4.4 Prolonged stops and mechanical design

During possible prolonged stops (> several months) of the engine, it is recommended to
occasionally establish circulation of the cooling water and to keep the additive (nitrite)
dosage at least at the maximum recommended level and preferably at 1.5 times the
normal dosage.
It is also worth noticing that the mechanical design of the cooling water system (venting
pipes to the expansion tank, expansion tank, air separator, etc.) must be according to
the recommendations and specifications to avoid corrosion (cavitation) and other
operational problems.

4.5 Alternative cooling water treatment additives and treatment systems

Organic Acid Technology (OAT) based products are more environmentally friendly
alternatives to the traditional, nitrite-based cooling water additives. These are advisable
to be used when aluminium and its alloys are present as engine parts.
As an alternative to the validated cooling water additives, the Wärtsilä Water Conditioner
Unit (WWCU) can also be used to treat cooling water of engines’ closed water circuits.
WWCU is based on the Enwamatic EMM cooling water treatment system but includes
several new features based on Wärtsilä design. The WWCU protects the engine from
corrosion without any chemicals. It acts as a side stream filtration and water treatment
unit and includes the following functions: corrosion protection, scale control, filtration,
control of bacterial growth and air separation. The stricter raw water quality requirements
compared to what is specified when cooling water additives are used shall be taken into
account, see Table 1 in chapter 3.1. Due to a severe corrosion risk WWCU cannot be
used in the cooling water systems containing aluminium or aluminium alloys as a
construction material.
The WWCU can be a sensible alternative for the installations in which environmentally
friendly solutions are appreciated.
The assembly, installation, operation and maintenance instructions of Wärtsilä shall
always be followed. For more information about the WWCU, contact Wärtsilä and refer
to solution name WWCU.

4.6 Mixing of different cooling water additives

Different cooling water additives shall not be mixed with each other. If it is desired to start
to use another cooling water additive, the one being used shall be drained from the
system before filling with another product. If the cooling water system is dirty, it shall be
flushed with good quality water or if needed use additionally chemicals to remove
possible deposits, like grease, oil, rust, etc. Many additives are chemically compatible
with each other, but mixing can lead to e.g. polymers starting to loosen existing deposits
from cooling water system, which can then drift in the system and stick to other surfaces,
e.g. at the cylinder head and cause heat transfer decline, clogging of small bore channels
and deposit formation leading to corrosion.

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4619Q002, Issue 11, Page 8 / 10

4.7 Warning for Aluminium parts

When aluminium alloys are present as engine parts, Sodium Nitrite/Borate based
products are typically not good for protection (though some products can contain other
inhibitors giving protection to Al as well). Neither molybdate based products nor
metasilicate technology are good in this respect, since at the elevated temperatures in
the HT-circuits, silicates can start to crystallize, resulting in a loss of Al protection and
causing e.g. leakage in mechanical pump sealings. Organic acid technology is the only
acceptable cooling water additive if Al alloys are used as construction material.

NOTE:
In recently manufactured engines, the cooling water system does not have aluminium
parts, but older engines may have. If in doubt, or if a change of additive type is planned,
please contact Wärtsilä for advice. Additionally, it shall be checked that there are no
aluminium / aluminium alloy components present in the external cooling water system
when choosing a nitrite-based cooling water additive.

Aluminium has a very high resistance to corrosion. One reason for this is that aluminium
is covered spontaneously by a thin but effective coating of oxide which protects the part
from further oxidation. The aluminium oxide is impermeable and is integral with the base
metal. If the coating of oxide is mechanically damaged, the coating will be renewed
immediately. The conditions for thermodynamic stability of the oxide film are expressed
by the Pourbaix diagram (potential versus pH) in Figure 2.
The diagram shows that aluminium is passive (protected by the oxide film) in the pH
range of about 4 and 8.5. The limits of this range, however, vary somewhat with
temperature, with the specific form of oxide film present, and with the presence of
substances that can form soluble complexes or insoluble salt with aluminium.

Figure 2, Pourbaix diagram for Aluminium with an Al2O3∙3H2O film at 25°C. Potential
values are for the standard hydrogen electrode (SHE) scale
The most frequent types of corrosion are Galvanic Corrosion, Pitting and Crevice
Corrosion. Galvanic corrosion takes place when two different metals are in contact with
each other in the presence of an electrolyte. The less noble metal (anode) of the
combination corrodes, while the noble (cathode) will be protected.
A small surface of the cathode and a large surface of the anode lead to a low corrosion.
In a reverse case, the Aluminium will be attacked quickly. In most combinations with
other metals, Aluminium is the less noble. Aluminium is therefore at greater risk of
galvanic corrosion than that of the other materials.

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4619Q002, Issue 11, Page 9 / 10

4.8 Use of glycol

NOTE:
Do not use glycol in the cooling water unless it is necessary.

If a risk of freezing exists, glycol needs to be added to cooling water. Since glycol alone
does not protect the engine and cooling water system against corrosion, additionally a
validated cooling water additive must always be used. All the validated cooling water
additives are compatible with glycol.
Ready-to-use mixtures containing both glycol and corrosion inhibitors are not allowed to
use, since those are normally designed to be used as strong (30 –) 50% / 50% mixtures.,
Normally, a much lower glycol concentration is adequate to protect the cooling water
system against freezing. But when decreasing the glycol amount, simultaneously also
the concentration of corrosion inhibitors will decrease to too low level resulting in an
increased risk of corrosion.
The amount of glycol in closed cooling water system shall always be minimised since
glycol decreases the heat transfer capability of water. The engine may be subject to
additional output derating when using glycol in the cooling water.
There are two types of glycol qualities, monopropylene glycol (MPG) and
monoethyleneglycol (MEG) commercially available. Industrial qualities of both glycol
types can be used, but MPG is the more environmentally friendly alternative.

5 Validated cooling water additives

Table 4 below presents the currently validated cooling water treatment products and the
dosage recommendations.
Table 4, Validated cooling water additives and dosage recommendations (for normal conditions)
Dosage per 1 m³ of Concentration of active
Manufacturer Product designation Additive type
system capacity corrosion inhibitor
Alm International Diaprosim RD11 (RD11M) 5 kg 1250 ppm as NO2 NaNO3 + borate
Arteco Havoline XLI 50 – 100 litres 1.8 – 3.7 Brix° of A.C* OAT**
Liquidewt 8 – 12 litres 470 – 700 ppm as NO2
Drew Marine NaNO3 + borate
Maxigard 16 – 30 litres 640 – 1200 ppm as NO2
Delo XLI Corrosion Inhibitor
Chevron (Texaco +
Concentrate 50 – 100 litres 1.8 – 3.7 Brix° of A.C* OAT**
Caltex)
XL Corrosion Inhibitor Concentrate
CorrShield NT 4293
GE Water and Process 10 litres 670 – 1000 ppm as NO2 NaNO3 + borate
CorrShield NT 4200
Korves Oy Pekar J 20 litres 30 ppm as Mo OAT**
Kuwait Petroleum
Q8 Corrosion Inhibitor Long-Life 50 – 100 litres 1.8 – 3.7 Brix° of A.C* OAT**
(Danmark) A/S
Marine Care B.V. Caretreat 2 Diesel 6 – 10 litres 1500 – 2500 ppm as NO2 NaNO3 + borate
Maritech AB Marisol CW 6 – 9 litres 1000 – 1500 ppm as NO2 NaNO3 + borate
Motul HD Cool Power Ultra 50 – 100 litres 1.8 – 3.7 Brix° of A.C* OAT**
Nalco Chemical TRAC102 32 – 48 litres 1000 – 1500 ppm as NO2
NaNO3 + borate
Company TRAC118 2.25 – 3.40 litres 670 – 1000 ppm as NO2
Solenis Drewgard 4109 16 – 30 litres 640 – 1200 ppm as NO2 NaNO3 + borate
Total WT Supra 50 – 100 litres 1.8 – 3.7 Brix° of A.C* OAT**
Vecom Marine Alliance Cool Treat NCLT 6 – 10 litres 1500 – 2500 ppm as NO2 NaNO3 + borate
Cooltreat AL 50 – 100 litres 1.8 – 3.7 Brix° of A.C* OAT**
Dieselguard NB 2.0 – 4.8 kg 1000 – 2400 ppm as NO2
Wilhelmsen Chemicals Engine Water Treatment 9-108 2.25 – 3.40 litres 670 – 1000 ppm as NO2
NaNO3 + borate
Nalfleet 2000 32 – 48 litres 1000 – 1500 ppm as NO2
Rocor NB liquid 9.5 – 24 litres 1000 – 2400 ppm as NO2
* Brix° of active compounds (A.C), measured with a supplier’s refractometer.
** Organic Acid Technology

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4619Q002, Issue 11, Page 10 / 10

Note 1: For many products the recommended minimum and maximum limits are listed in the table above. Since
the amount of active corrosion inhibitors, especially nitrites, is decreasing during the service of engines,
the engine manufacturer recommends starting the dosage from the upper level of indicated range.
Note 2: The nitrite content of nitrite-based cooling water additives tends to decrease in use. The risk of local
corrosion increases substantially when nitrite content goes below the recommended limit.
Note 3: Cooling water additive manufacturers can indicate the required nitrite content measured either as sodium
nitrite, NaNO2 or as nitrite, NO2. 1 mg/l as NO2 equals to 1.5 mg/l as NaNO2.
Note 4: Nitrite based cooling water additives are not offering a good protection against corrosion for aluminium
and its alloys and thus the use of such products can’t be recommended for cooling systems containing
those construction materials.

6 Contacts
If technical support is needed, please create a TechRequest in Wärtsilä Online.
For services, spare parts and/or tools, please contact your nearest Wärtsilä
representative or the Customer Support Centre (CSC):
www.wartsila.com/csc

© 2020 Wärtsilä Finland Oy – All rights reserved

No part of this publication may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying, recording,
taping or other information retrieval systems) without the prior written permission of the copyright holder. Wärtsilä Finland Oy makes no
representation, warranty (express or implied) in this publication and assumes no responsibility for the correctness, errors or omissions for
information contained herein. Information in this publication is subject to change without notice. Wärtsilä does not assume any liability for the
consequences of the owner’s/operator’s actions, inactions, and/or decisions made or based upon the information provided herein.
Unless otherwise expressly set forth, no recommendation contained in this document or any of its appendices is to be construed as provided
due to a defect of the product, but merely as an improvement of the product and/or the maintenance procedures relating thereto. Any actions
by the owner/operator as a result of the recommendations are not covered under any warranty provided by Wärtsilä and such actions will
thus be at the owners/operators own cost and expense.
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE
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