During commissioning of Industrial Cooling Water Systems, when make-up water is
first circulated through equipments, the initial damage which occurs on metallic heat transfer
surface is corrosion or flash corrosion. The flash corrosion must be controlled to prevent
uneven growth of corrosion products else these will promote, in chains, layers of uneven
corrosion product deposit, scale, foulants and microbiological foulants leading to choking and
under deposit corrosion. The corrosion or flash corrosion in open recirculating cooling systems
is prevented by a rigid, impervious and protective film. The concept of film formation versus
film maintenance prevails since long in the field of Cooling Water Treatment Programme. Film
formation (Pretreatment) is achieved by high level of chemical inhibitors/additives and film
maintenance by low level of inhibitors (Regular Treatment). Based on experimental and field
data new phosphate based Pretreatment and Regular Treatment have been developed and
applied successfully to several Industrial Cooling Water Systems. The paper describes the
Pretreatment and Regular Treatment process and field experience on their performance.