APPLICATION TIPS

North America HVAC Systems & Services

Date Subject Department

5/4/2018 Water Quality Guidelines CCS Chiller Marketing

Bulletin Number Product Model Number(s) Author Name/Phone/Email

19XR(V), 19DV, 23XRV, 30XV,

Kevin DiSanto / 704-494-2594 /
WC-CHLR-18-03 30XW, 30XA, 30HX, 30MP, 30RB
[email protected]
& 30RAP

Water Quality Guidelines

Water quality, as it applies to mechanical systems, can be defined as a measure of the condition of
water relative to the requirements of human need or purpose.i Depending on the quality of application
water, the waterside of a chiller’s heat exchanger can develop excessive scale, accelerated rates of
corrosion, or significant biological growth. These three fouling categories can lead to degradation of
heat transfer across the chiller, and in extreme cases mechanical failure of the unit. Therefore, proper
tube selection and or treatment should be considered for waters that are not chemically balanced.

Because of the sensitivity of certain mechanical systems, it is important that chiller end users be
familiar with typical water chemistry in their area, as well as the effect of such additives to their
mechanical systems. Additionally, common treatment plans, and their effect and cost should be
understood by those operating & servicing mechanical chillers.

The ability to mechanically filter or clean the heat exchanger of a particular chiller depends mostly on
the type of heat exchanger used. Carrier uses three (3) types of heat exchangers in packaged or
applied chillers. Because of the varying sensitivity of a chiller to water quality issues, each type of heat
exchanger has different guidelines.

Open vs. Closed Loop Systems

Closed loop systems are systems that are sealed from their environment during normal operations.
One aspect of closed loop systems is that the head that system pumps must overcome is only the sum
of frictional flow losses in the piping.

Open loop systems are systems that are not closed; they are open to the atmosphere. Pumps in such
a system must overcome the frictional flow losses in the piping, as well as the static head associated
with the system’s net change in height.

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 Water Quality Guidelines

In typical comfort cooling applications, the chilled water loop is closed, while the condenser water loop
is open. Often, service & water treatment specialists are more concerned with open loop system than
closed loop systems. This is because of the higher probability of getting debris into an open loop,
exposed to the atmosphere. Therefore, the mechanical filtration recommendations for an open versus
a closed loop may differ.

Brazed Plate Heat Exchangers

30RAP, 30MPA & 30MPW

Brazed plate evaporators consist of a series of plates brazed together with every second plate turned
180 degrees. This creates two highly turbulent fluid channels that flow in opposite directions, resulting
in high heat transfer coefficients over the relatively small surface area. The plates are stacked so they
form a multi-layered design for two independent paths of fluid to travel. Brazed-plate evaporators
require chemical cleaning since the waterside is not mechanically cleanable.ii

Figure 1 - Brazed Plate Heat Exchanger

Brazed plate heat exchangers are utilized as the evaporator for the 30RAP, 30MPA & 30MPW.
Additionally, a brazed plate heat exchanger is used at the condenser in the 30MPW. Brazed plate heat
exchangers exhibit sensitivity to poor water quality because of their lack of ability to be mechanically
cleaned, as well as the torturous flow path created by their design. For this reason, explicit water
quality guidelines are published directly in the product data for chiller models that utilize such heat
exchangers.

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 Water Quality Guidelines

Figure 2- Brazed Plate Heat Exchanger Water Quality Guidelines1

1
These requirements can be found in: 30MP Product Data: 30MP-10PD, Carrier Corporation 2015, Application Data section

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These water quality specifications are in place to ensure continuous advertised-efficiency operation
throughout the life of the chiller. Most items are in place to prevent accelerated rates of corrosion or
wear. In addition to chemical water quality, mechanical filtration is an important application concern.
To that end, strainers of a certain mesh size are specified to be used, either as an option or factory
standard. For the 30RAP, a 40-mesh strainer is installed in the cooler fluid inlet line, just ahead of the
cooler. For the 30MPA/W a bronze 40-mesh strainer is also required. However, its selection is
optional. This discretion allows for those in the field to select exactly the type of strainer they want,
depending on the pipe size, and threaded or flanged preference. The 30MPA/W selection software
explicitly informs field personnel that use of a strainer is required and that it is their responsibility to
ensure a strainer is installed at the application. Additional caution is advised when using a 30MPW with
an open loop system, as additional mechanical filtration may be required.

Figure 3 - Packaged Chiller Builder 30MP Strainer Warning

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 Water Quality Guidelines

Direct Expansion (DX) Heat Exchangers

30RB & 30XA (Optional)

This heat exchanger is a shell-and-tube design, where the refrigerant flows through the tubes and the
water flows around the tubes inside the shell section. The shell (water) side must be chemically
cleaned.

Figure 4 - DX Heat Exchanger

Direct expansion heat exchangers are standard for the evaporator of the 30RB and an option for the
evaporator for the 30XA. The water quality guidelines for DX coolers are not as explicitly stated as they
are for Brazed Plate Heat Exchangers. A corrosion-resistant inhibitor suitable for the water for the area
is recommended. Additionally, consultation with a local water treatment specialist for characteristics of
system water and a specific inhibitor is recommended. For both the 30RB & 30XA, open loop system
applications require that an additional field-supplied strainer with a minimum size of 20 mesh be
installed within 10 feet (3.05m) of and ahead of the cooler inlet to prevent debris from damaging internal
tubes of the cooler.

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 Water Quality Guidelines

Flooded Shell-and-Tube Heat Exchangers

30XA (Standard), 30XV, 30HXA, 30HXC, 30XW, 23XRV, 19DV (Condenser) & 19XR(V)

In larger capacity chillers, shell and tube heat exchangers with water in the tubes and refrigerant in the
shell are most frequently used. The advantage of such heat exchanger use is that the tubes can be
mechanically cleaned.

Figure 5 - Flooded Shell-and-Tube Heat Exchanger

Due to the applied nature of the products that utilize flooded shell-and-tube the recommendations
written into product literature are less prescriptive than for brazed plate or DX units. This is due to the
amount & variety of temperatures & tube combinations available. For all applied chillers, the best
course of action is consultation with local water treatment specialists for the characteristics of the
application water, and maintenance, chemical & cleaning schedule.

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Falling Film Heat Exchangers

19DV (Evaporator)

Rather than flood the evaporator with refrigerant, falling film technology provides a thin film of
refrigerant that is constantly falling across the tube bundle. This thin film wets & replenishes the tube
surfaces with saturated liquid refrigerant, ensuring even heat transfer across a chiller’s operating
profile. As the refrigerant picks up heat from the water, it evaporates and escapes as vapor into the
compressor. A small pool boiling section at the bottom of the bundle ensures that any liquid refrigerant
that did not evaporate in the falling section eventually does.

Figure 6 – Falling Film Heat Exchanger

Similar to flooded shell and tube heat exchanges, the recommendations written into product literature
for falling film heat exchangers are less prescriptive than for brazed plate or DX units. This is due to
the amount & variety of temperatures & tube combinations available. For all applied chillers, the best
course of action is consultation with local water treatment specialists for the characteristics of the
application water, maintenance, chemical & cleaning schedule.

Corrosion Resistant Measures

Carrier offers the following options as additional corrosion preventive measures. Such options include:
 Zinc Anodes (Evaporator & Condenser)
 Copper Nickel Tubes & Clad Tube Sheets
 Titanium Tubes & Clad Tube Sheets
 Stainless Steel Tube Sheets
 Coated Water Boxes
Please note that not all of the above options are available on all heat exchangers. Prior to selection in
the respective chiller’s selection programs, Sales Engineers are encouraged to discuss the specifics of
the application with their customers. While the above listed options do make the chiller more robust in
the face of corrosive elements, their addition adds cost to the chiller. Therefore, Sales Engineers
should ensure such options are strongly desired by their customers prior to inclusion in submittals.

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Zinc Anodes

Zinc anodes work to mitigate the impact of galvanic corrosion. When metals with different electrical
potentials, and both are in contact with an electrolyte, the anode metal dissolves into the electrolyte and
the deposit collects on the cathode. This exchange between anode & cathode is galvanic corrosion.
Zinc has a high electrochemical potential, therefore it will serve as the anode in the galvanic corrosion
reaction, rather than the components in the chiller. The relatively cheap zinc anode will preferentially
corrode, leaving the chiller materials unchanged. After sufficient time, the zinc anode can be replaced
at significantly lower cost than the chiller itself.

Copper-Nickel (CuNi) Tubes & Clad Tube Sheets

Copper-nickel alloys were developed specifically for use in applications more corrosive than typical
fresh water. Copper-nickel alloys chosen for commercial use contain either 10% or 30% nickel.
Copper-nickel 90/10 alloy exhibits superior corrosion resistance with low general corrosion rates, and
good resistance to pitting. The addition of nickel improves the alloy’s strength and durability and also
the resistance to corrosion, erosion and cavitations in all natural waters including seawater and
brackish, treated or polluted waters.

The additional corrosion resistant properties of Cu-Ni tubes, (compared to standard copper tubes) must
be weighed against two factors.
1. The additional cost of the copper-nickel tubes against the cost of standard copper tubes.
The cost of nickel as a commodity is traditionally higher than that of copper. Therefore, it is
likely that Cu-Ni tubes will add to the overall cost of the chiller.
2. The efficiency penalty. The heat transfer characteristics of Cu-Ni are not as good as that of
copper alone. Therefore, when using Cu-Ni condenser tubes, the approach temperatures
across the tube wall will increase. These higher approach temperatures raise the lift across
the compressor. This higher lift means the compressor must work harder than it would for a
chiller containing standard copper tubes.

Titanium Tubes & Clad Tube Sheets

Titanium is extremely corrosion resistant compared to stainless steel, copper, and aluminum.
Titanium’s corrosion resistance is due to a stable, protective, strongly adherent oxide film. This film
forms instantly when a fresh surface is exposed to air or moisture. The film is only attacked by a few
substances.

The tradeoff between cost and efficiency penalty for titanium tubes would be the same for copper-
nickel, only magnified. This is because while Titanium’s corrosion resistance properties are greater
than that of copper-nickel, so too are its relative cost & degradation of heat transfer across the tube
wall.

Stainless Steel Tube Sheets

Stainless steel differs from carbon steel by the amount of chromium present in the alloy. Stainless steel
provides additional corrosion resistance (compared to carbon steel) by the formation of a passive oxide
film of chromium oxide.

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 Water Quality Guidelines

Coated Water Boxes

Carrier offers corrosion resistant coating as on option to several models’ shell & tube heat exchanger
water boxes. The coating forms a barrier between the potential corrosive water & the metal of the
water box. Coating can be used instead of or in conjunction with the corrosion resistance alloys
discussed previously in this document.

Summary

Water quality is an important variable in determining both the yearly operating cost of a chilled water
plant, both for its impact on chiller efficiency & the cost of preventative maintenance. Because of the
variability of water quality in Carrier’s global markets, completely prescriptive guidelines are impractical.
Instead, general engineering knowledge and reliance on local experts must be relied upon.

Chiller marketing cannot determine if any specific corrosion resistant measure is sufficient for a
particular application. This is best left to local experts that know the constituents of application water.
Additionally, an accelerated maintenance, treatment, & service schedule could be agreed upon,
however the additional cost determination can only be made by the chiller’s end user.

i
Johnson, D.L., S.H. Ambrose, T.J. Bassett, M.L. Bowen, D.E. Crummey, J.S. Isaacson, D.N. Johnson, P. Lamb, M. Saul, and A.E. Winter-
Nelson (1997). "Meanings of environmental terms." Journal of Environmental Quality.
ii
Technical Development Program, Carrier Corporation, Commercial HVAC Chiller Equipment, Water-Cooled Chillers, page 7, Syracuse NY,
2005

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