Trouble Shooting and Corrective Actions – FAQ

General Troubleshooting

What’s the first step when troubleshooting a water treatment system issue?

First, identify parameters that are out of range. Confirm results by rinsing sampling cups, grabbing fresh samples, and rerunning tests before deep troubleshooting.

What is pretreatment and why is it important?

Pretreatment systems like filters and softeners are the foundation of water treatment. They prevent scale, corrosion, and fouling in downstream equipment like boilers and cooling towers.

Filters

What are common issues with water filtration systems?

Common issues include high pressure loss due to infrequent filter changes, incorrect filter type selection, wrong micron ratings, plugging, fouling, contamination, and microbiological issues.

How can improper filter choice affect system performance?

Using inappropriate filter types (e.g., bag filters instead of twin-disc filters on large cooling systems) or incorrect micron ratings (too fine or too coarse) can cause plugging and reduced efficiency.

How often should filters be changed?

Follow your PM schedule, but excessive changes may indicate upstream water treatment or mechanical problems.

Water Softeners

How do I know if a softener is working?

Run a total hardness test. For boilers, you should see ≤0.5 PPM hardness; for cooling towers, <20 PPM is acceptable.

What are typical problems encountered with water softeners?

• Bridging: Crust forms at the top of the brine tank; use a broom or rubber mallet to break it.
• Improper programming: Causes short runs or excessive salt use. Reassess regeneration cycles.
• Empty brine tank: Check salt levels regularly and avoid overfilling (keep ~70% full).
• Resin issues: Channeling or resin loss may require testing or replacement.

What causes salt bridging, and how can it be corrected?

Salt bridging occurs when salt forms a crust above the water level. Remedy this by periodically breaking up the salt crust with a rod.

How often should brine tanks be cleaned?

At least once a year to remove sediment and impurities that accumulate at the bottom of the tank.

Reverse Osmosis (RO) Systems

What are common issues with reverse osmosis systems?

• Hardness from failing softeners
• Fouled or degraded membranes
• Improper chemical feed (e.g., antiscalants, dechlorinators)
• Plugged prefilters
• Chlorine breakthrough

How can I detect issues in an RO system?

• Monitor conductivity and pressure gauges
• Visually inspect membranes and pre-filters periodically
• Rotate membranes if dual systems exist
• Calibrate sensors and chemical feeds regularly
• Perform clean-in-place (CIP) as needed

Cooling Tower Systems

What causes poor performance in cooling towers?

• Improper conductivity control
• Microbiological growth
• Algae and sediment buildup
• Insufficient inhibitor feed
• Flow distribution issues
• Plugged strainers and nozzles
• Automation failures
• Uncontrolled water losses

Why is consistent water flow critical in cooling towers?

Inconsistent flow leads to uneven chemical distribution and increased scaling and biological growth, notably on the tower’s leading edge.

How do you manage microbial issues in cooling towers?

Ensure adequate biocide levels, frequently test residuals after chemical feed events, and maintain regular cleanings to reduce microbiological activity.

Boilers

What common boiler issues should I monitor closely?

• Watch for conductivity outside recommended ranges
• Improper chemical levels
• Cloudy or colored water (indicating hardness or contamination)
• Boiler water carryover

• Conductivity
• Alkalinity
• Hardness (only in feedwater, not boiler water)
• Oxygen levels (use deaerators + scavengers)
• Polymer and sulfite levels

What causes boiler water carryover?

Carryover may result from excessive conductivity, high alkalinity, rapid load changes, contaminated feedwater, or oily residues.

How often should boiler blowdown valves be checked?

Regular checks for proper operation are essential. Valves should be inspected for leaks, correct operation, and appropriate positioning, especially when unexpected water losses are detected.

What are common boiler issues and troubleshooting steps?

• Low conductivity: May indicate excessive blowdown or leaks.
• High pH in condensate: Often due to overfeeding steam line treatment.
• Water carryover: Could be due to high alkalinity, oils, or undersized boilers

Condensate Systems

What issues frequently affect condensate systems?

• High conductivity
• Incorrect pH
• Presence of hardness or iron
• Cold condensate return due to insufficient system sizing or malfunctioning pumps

How do you identify contamination sources in condensate systems?

Perform periodic condensate profiling to pinpoint problematic areas. Check heat exchangers, particularly in facilities where chemical processes like CIP (clean-in-place) systems are in use.

Chemical Feed Systems

What are signs of chemical pump failure?

• Leaking fittings or injection quills
• Loss of prime
• Improper diaphragm function
• Excess chemical build-up on fittings

How can I prevent chemical feed issues?

• Inspect and clean sensors regularly
• Calibrate pumps and sensors
• Replace pump heads and diaphragms annually if possible

New Technologies

What is Aquassist and how does it help?

Aquassist includes handheld devices and apps for automated titration and spectrophotometric testing (e.g., hardness, iron, PTSA), saving time and increasing accuracy

What are PTSA and Trace Polymer?

These are fluorescent tracers used in cooling tower inhibitors and boiler polymers, allowing fast, accurate measurement with a colorimeter or handheld device

Sustainability Initiatives

What is Aquafilm?

A single-treatment steam boiler additive that reduces gas consumption and eliminates the need for separate sulfite and steam line treatments

What is Endotherm?

An additive for closed-loop systems that improves heat transfer efficiency, leading to reduced natural gas usage

Maintenance Best Practices

What proactive measures can reduce water treatment issues?

Regular maintenance including filter replacements, brine tank cleaning, membrane inspections, sensor calibrations, and proper system programming significantly reduce operational issues.