COOLING WATER SYSTEM

1. Introduction:

A cooling tower is a heat rejection device that rejects waste heat to the atmosphere
through the cooling of a water stream to a lower temperature.

2. Scope:

These procedures set out the process for operating the cooling tower in the Utilities.

3. Responsibilities:

Water Treatment Technicians.

4. Definitions:

4.1 Cooling Towers: Cooling towers are classified by the direction of air flow
(counter-flow or cross-flow) and the type of draft (mechanical or natural). USC is
using induced draft (Counter-flow) cooling towers. Counter-flow cooling towers
have upward air flow that directly opposes the downward flow of the water
providing very good thermal efficiency because the coolest air contacts the
coolest water (in the bottom section of the tower structure).

4.2 Total Dissolved Solids (TDS): The amount of dissolved minerals present in the
water.

4.3 Blowdown: The process of removing a portion of the highly concentrated water
and replacing it with fresh make-up water.

4.4 Make-up: Water supply needed to replace all losses due to evaporation, leaks, or
discharge in cooling systems.

5. References:
5.1 MSDS
5.2 LAB Sheet Reports.

6. Job/Product Safety Requirements:

Personal protection as set out in Material Safety Data Sheets (MSDS) is required when
handling chemicals or operating chemical plant.
7. Environmental Requirements:
Operated towers should not have leaks, overflows and controlled chemicals
parameters.

8. Procedure:
8.1 General: Cooling water for the plant is supplied by a system composed of
cooling tower and a closed circuit. A chemical dosing system is implement to
prevent scaling and corrosion. A portion of the cooling water is removed by
blowdown, so that chemical concentrations do not get too high. The removed
cooling water is replaced by make-up water consisting of process water and
sweet condensate. Cooling water is supplied to users at a maximum of 34 0C at
a total flow of approximately 850 m3 / hr. Water is returned at approximately 44
0C.

9. Process Flow:

Fig. 9.1 Cooling Cell Arrangement

9.1 The cooling tower is one of the counter flow induced draft type (See Fig. 9.1)
9.2 The system contains seven separate cells, each having a capacity of 180cu.m/hr.
9.3 The number of cells in use are altered if the cooling water temperature needs to
be adjusted.
9.4 This is achieved by operating the local starters.
 9.5 Each cell has a single fan with an aluminum blade. The angle of the blade can be
changed when the unit is stopped so that air flow characteristics can be altered if
needed.
9.6 Each cell is equipped with a gate and removable trash screen.
9.7 Cooled water is collected under the tower in a concrete basin divided into seven
sections in order to allow isolation of each cell for maintenance work without
shutting down the whole tower system.
9.8 The cooling water from the pump suction basin is delivered to the main header
and then pumped to all users by cooling water pumps 82 P01 A/B (one is
standby).
9.9 The closed cooling water circuit is provided with side stream filtration to remove
suspended solids. About 5% of the through put are filtered.
9.10 In order to prevent the build-up of dissolved solid matter in the water, and
subsequent fouling of heat exchanger and other surfaces, some of the cooling
water returns are diverted to the effluent water treatment plant by ‘continuous
blowdown.
To control corrosion, scaling and biological fouling, chemical treatment of circulating
water is carried out as follows:
Chemical Description Dosing Rate
HYDREX 3919 Corrosion Inhibitor 30 L/day
HYDREX 2330 Dispersant: to prevent polyphosphate 34 L/day
HYDREX 7210 Brominating Agent 25 L/week
Calcium Hypochlorite Control of microbiological Activity 10 kg/day

9.11 An adequate supply of clean cooling water at the correct temperature must
always be available to users, especially critical ones.
9.12 Consequently, it is important to control all the main process variables of the
cooling water and these are:
 Flow rate, 82FI001
 Supply temperature (82TI002) and return temperature (82TI001)
 Temperature difference between supply and Return (ΔT 5 Deg.C, Max 8)
 Pump discharge pressure 82PT001
 Total Dissolved Solids (TDS)
 Total Suspended Solids (TSS)
 PH, 82AT002
 Chlorine concentration
NOTE: The concentration of TDS is important because it is the parameter, which
enables calculation of the concentration ratio and, consequently, the blowdown and
fresh water make-up flow rates.
10. Initial Start-up procedure:

10.1. Confirm all cooling water users are isolated (close inlet and outlet valves).
10.2. Confirm chemical dosing systems have been filled with proper chemicals.
10.3. Ensure that the sluice gates are open from only the six selected towers and
that the grids are clean and in place.
10.4. Fill the cooling tower basin to just below the overflow level via the process
water line (about 1,200 m3 is required)
10.5. Confirm pump local/remote selectors 82 HA P01 A/B are in local position.
10.6. Open valve on cooling water pumps 82 P01 A/B suction lines.
10.7. Crack open discharge valve on the selected pump to be put in operation.
10.8. Open the valve on cooling water recycle line 200-CWS-8201313
10.9. Start cooling water pump and open discharge valve to obtain discharge
pressure on gauge 82-PI-301/302 of 5 bar g.
10.10. Make up level in cooling tower basin if required.
10.11. Inform users to start cooling water circulation. After the first user is on line,
close the valve on the cooling water recycle line.
10.12. When all users are on line, pump discharge pressure will be about 4.6 bar
g.
10.13. Start cooling tower air fans at the local starter.
10.14. Open stand-by pump discharge valve and switch local/remote selector 82
HA P01 to remote.
10.15. Start chemical dosing system.
10.16. When instrument air is available, put the level controller 82 LC 001 into
auto.
10.17. Commission side stream filters 82 G02. The filter is of a self-cleaning type
designed for a capacity of 40 m3/hr. Adjust water flow rate by opening the
globe valve installed on the filter supply line and confirm on flow meter 82 FI
301 that the design flow rate is achieved.

NOTE:
The clean filter pressure drop is 0.15 bars. Filter backwashing will be performed
automatically, with the filter in operation, and will be actuated by the differential pressure
switch when the filter pressure drop reaches 0.35 bars.
11. Normal Operation:
11.1 Normal operating procedure:
11.1.1 Adjust cooling water blowdown flow rate to ensure that the conductivity is
within specification. The expected value is 8.5m3/hr., which is indicated on
flow meter 82 FI 302.
11.1.2 Confirm temperature of circulating cooling water. Normal values are 34C
supply and 420C return.
11.1.3 Start/Stop fans at local starters as required maintaining the cooling water
temperature at around 34C.
11.1.4 If there is a build-up of sand or other solids, e.g. after a sandstorm,
increase the flow through the side stream filter. Monitor cooling water return
temperature in case this rises to unacceptable levels and the flow to the side
stream filter needs to be reduced.

11.2 Description of Control System 82-PLS-001

11.2.1 Cooling water pump 82 P01 A/B is manually started.
11.2.2 In case of low pressure in the cooling header, spare pump 82 P01
A or B starts automatically by 82 PLS-001 with low pressure alarm at DCS
provided that local/remote selector id in remote position. Pumps are stopped
manually in field.

11.3 Local Control 82-LC-001

11.3.1 Water level into cooling tower basin is controlled by 82-LC-001,
which maintains normal level in 82Q01 at 2300mm, by the addition of make-
up water.
11.3.2 As the water level decreases valve 82 LV 001 tends to open. High
and low level alarm is provided on the DCS.

11.4 Control Valves Action

Item Action
82 V 001 Opens in air failure (FO)
12. List of Alarm and Set Points

Item Set Point Description

82 LAL 501 50% Low level on phosphate dosing tank
82 LAL 502 50% Low level on dispersant dosing tank
82 LAL 503 50% Low level on bromine dosing tank
82 LAL 504 50% Low level on Hypochlorite dosing tank
82 FAL 001 270 m3/hr. High temperature of cooling water
82 TAH 001 38 Deg.C Low flow rate of cooling water
82 PAL 001 2.5 bar g Low pressure at CW pump outlet
82 LAL 001 2200 mm Low level in cooling tower basin
83LAH 001 2800 mm High level in cooling tower basin

13. Analytical requirements

It is advisable that during normal operation the characteristics listed below should be
confirmed on daily analysis recorded on the Laboratory results workbook (form-09-
13250).

Analysis Unit Range Target

TDS ppm 350 max 250
TSS ppm 50 max 30
pH --- 7.0 – 8.5 7.2
M-alkalinity (methyl-orange) ppm 50 - 150 75
Residual Chlorine ppm 0.1-0.5 0.2
Fe 2+ ppm 10 5
PO4 as Na3PO4 ppm 2 - 10 5
14. Shutdown procedure

Normal Shutdown Emergency Shutdown

1. Switch local/remote selector 82 HA 1. Switch local/remote selector 82 HA
P01 on stand-by pump to local P01 of stand-by cooling water pump to
2. Close manual valve on blowdown local.
line. 2. When power supply is restored,
3. Close control valve 82 LV 001 proceed according to start-up
4. Stop chemical dosing pumps. procedure.
5. Close globe valves installed on side
stream filter (82G02) supply line and
confirm on flow meter 82 FI 301.
6. Switch local/remote selector 82 HA
P01 on duty pump to local.
7. Stop duty cooling water pump 82 P01
8. Stop fans on cooling tower

NOTE:
 The cooling water unit electrical load is critical and, therefore, can be fed by either the
steam turbine generators (during normal operation) or the main diesel generators
(when steam power plant is out of service.
 The flow and temperatures readings are shown on the utilities control room screen, and
recorded in the trend page of the ps7 control system.

15. Troubleshooting Cooling Water System:

Problem Reason Solution

HIGH PH High chemical dosing Reduce the dosing
LOW PH Low chemical or sugar Check the contamination source
contamination and dose more chemical
HIGH TDS Check the blowdown valve Increase the blowdown rate
HIGH CHLORIN High chemical dosing Reduce the dosing
LOW CHLOREN Low chemical or sugar Check the contamination source
contamination and dose more chemical
LOW FLOW Pumping issue Check the pump strainer
LOW PRESSURE Pumping issue Check the pump strainer
HIGH IRON Check the blowdown valve Increase the blowdown rate
HIGH TSS Check the makeup source Increase the blowdown rate
16. Equipment Information

Manufacturer: ILMED IMPIANTI SRL ITALY

MODEL: GTG/Q1/41/S
WORKING CONDITIONS:
Unit water flow rate 180 m3/h
Total water flow rate 900 m3/h
Inlet water Temperature 42 °C
Outlet water Temperature 34 °C
Project wet bulb temperature 29 °C
Unit heat load 1.440.000 Kcal/h
Total heat load 7.200.000 Kcal/h
Evaporation water losses 1,3 %
Drift water losses 0,005 %
Nozzles feeding head 0,1 - 0,2 bar
Table 16.1 Cooling Cells Information

Fig. 16.1 Cooling Cells General Layout