VALVE COOLING SYSTEM

Engineer Master
M Abuzar Naeem Gou Qingshuai
Habib Ullah
PURPOSE

 Converter valve is an electronic device

that has very low thermal capability and
it gets damaged with excessive heat
produced during its operation.
 The valve cooling system is installed for
the cooling of converter valves that runs
24/7 for DC/AC power conversion.
COMPONENTS

 The Lahore converter station has a total of two

valve halls, each valve hall is independently
equipped with a closed-loop valve cooling
system produced by Guangzhou Gaolan
Company.
 The valve cooling system is divided into the
cooling circulation system inside the valve
(including the main circulation equipment,
water treatment equipment and nitrogen
pressure stabilization system), the cooling
circulation system outside the valve and the
water treatment system.
 Valve cooling system is designed for
1MPa rated pressure.
MAIN RATED PARAMETERS
Equipment Parameters

Rated cooling capacity 500 kW

Main circulation flow rate 105.8 L/s

Maximum inlet valve temperature 49°C (alarm), 52°C (trip)

Maximum outlet temperature 60.5°C

Cooling designed pressure 1.0 Mpa

Main loop filter precision 100 μm

Deionized water filtration accuracy 10 μm

INTERNAL VALVE
COOLING SYSTEM
Main Circulation System
MAIN CIRCULATING PUMP (P01,P02)

 Two induction motors are installed in each cooling system

with redundant system. Main circulating pump provides
driving force required for cooling fluid to bring heat
generated by converter valves. Heat exchange is carried out
and fluid returns back to form a closed circulating loop after
it is cooled.
 The main circulating pump is designed with a leak detection
tank, and a liquid level switch is installed in the tank to
detect slight water leakage in time. Valves are installed
before and after the main circulating pump, so that the main
pump can be repaired when the internal cooling system of
the valve is not shut down.
 Each pump runs for 168hrs and switch to othe rpump
automatically in normal conditions while pressure and flow
remains the same. Manual switch-over functio is also
availabel.
MAIN CIRCULATING PUMP (P01,P02)

 If the running pump fails or cannot provide rated pressure or flow,

immediately switch to the standby pump and issue an alarm
signal.
 Power rating: 110kW, 380V, 200A, 50Hz
 Flow rate: 388 m3/h
 Speed: 1485 rpm
 Running time: 168 hrs (7 days)
 Efficiency: 84.2%
 Power factor: 0.87
MAIN PUMP FILTER (Z01,Z02)
 Rated flow rate: 440m3/h
 Main filter blocks any rigid particles that
can be washed off in the rapid flow of
cooling water and prevent from entering
into valve body. Two parallel main filters
are placed in series of water inlet of
converter valve with redundancy.
 The filter is equipped with differential
pressure switches (dPS01 and dPS02) to
indicate the dirt level of the filter
element and remind the operator to
clean it, which can be cleaned manually
online.
DEGASSING TANK (C31)

 Effective volume: 580L

 Degassing tank is placed at the inlet of the

main circulation pump, and the top of the
tank is equipped with an automatic exhaust
valve, which can completely discharge the
gas (oxides of nitrogen) in the cooling water.

 The degassing tank is also used as a heating

tank.
ELECTRIC HEATER
(H01,H02,H03,H04)
 The electric heater is placed in the degassing tank of the main
circulating cooling water circuit for the temperature adjustment of
the cooling water.
 Heater starts to work to maintain certain temperature when:
 temperature is extremely low in winter,
 the valve body is out of operation,
 when the temperature of the cooling medium is close to the dew
point (where water condensation occurs) temperature of the valve
hall,
 When there is danger of condensation on the surface of pipes and
devices.
ELECTRIC HEATER
(H01,H02,H03,H04)

 It is prohibited to shutdown cooling

system when the electric heater is
running, and the flow of cooling water in
the pipeline must be maintained to
prevent heating tank temperature gets
high from dry burning of heater.
 Four electric heaters are set up according
to the ambient temperature of the project
location and they are started in two
groups in sequence.
INTERNAL VALVE
COOLING SYSTEM
Deionized Water Treatment System
ION EXCHANGER (C01,C02)

 Effective volume: 190L

 Deionization circuit is installed in parallel of
main circulation circuit and composed of
mixed bed ion exchanger, precision filter, flow
and conductivity meters.
 The anions and cations of part of the cooling
medium in the attached inner cooling circuit
pass through the cooling water that will cause
electrolytic corrosion of metal wetted
materials and electrical breakdown.
 Ion exchanger absorbs these ions to prevent
adverse situation under log term operating
conditions.
PRECISION FILTER (Z11,Z12)

 Rated flow rate: 10m3/h

 The precision filter is set at the outlet of

the ion exchanger to intercept the resin
particles that may be broken and flowed
out.

 There are 2 sets in total, 1 for use and 1

for backup, with an accuracy of 10μm,
and a replaceable filter element is
adopted.
INTERNAL VALVE
COOLING SYSTEM
Nitrogen Pressure Stability System
EXPANSION TANK (C11,C12)

 Effective volume: 560L

 Expansion tank is installed to buffer the
volume change of valve cooling system due
to temperature changes in main circulating
circuit to maintain the constant pressure in
the pipeline. Valve cooling return water
pressure is 0.3MPa.
 Expansion tank is linked with supplementary
water system, nitrogen stabilizer and
deionized circuit to buffer volume change in
main pipeline. In other words, pressure of
main pipeline depends upon expansion tank
and nitrogen pressure stabilizer.
EXPANSION TANK (C11,C12)

 An aeration device is installed at the bottom of expansion tank to

increase the solubility of nitrogen gas so that it can take away more
oxygen during degassing.
 Different alarms generated when expansion tank water level is:
 ≥ 90% : water level is high.
 ≤ 15% : water level is low and water replenishment starts.
 ≤ 5% : water level is ultra low and DC blocking command
occurs.

 During normal operation, expansion tank liquid level should be

50%.
NITROGEN SYSTEM (C41,C42)

 New Nitrogen cylinder pressure: 12MPa

 It consists of nitrogen cylinder, pressure reducing valve,
nitrogen pipeline, supplement / exhaust solenoid valve,
etc. Cooling system is equipped with 2 circuits with 2
nitrogen cylinders each. When one circuit fails, it can
automatically switch to the other circuit for operation.
 When the cooling medium is lost due to a small amount
of extravasation or electrolysis, the nitrogen will
automatically expand, and the cooling medium will be
pressed into the circulating pipeline system to keep the
cooling medium. The pressure of the pipeline is
constant and the cooling medium is filled.
 Nitrogen cylinder is replaced when its pressure drops to
1.5MPa.
RAW WATER TANK (C21)

 Effective volume: 560L

 Designed pressure: 0.1MPa
 The raw water tank is sealed to maintain the stability of the
supplementary water quality. The raw water tank is equipped with
a magnetic flap level gauge. When the liquid level of the raw water
tank is lower than the set value, the operator is prompted to start
the raw water pump to make up water to keep the fill of the raw
water tank.
 The raw water tank is equipped with an automatic switch solenoid
valve, which is usually closed, and automatically opens when the
make-up water pump and the raw water pump are started to
maintain the purity of the raw water.
RAW WATER TANK (C21)

 When water level drops to 30%, start raw-water pump to refill up-
to stop pump level.
MAKE-UP WATER PUMP (P11,P12)

 Rated flow: 2m3/h

 Two make-up water pumps are installed with

redundant system (1 for use and 1 for backup) to
replenish water level in the expansion tank
(C11/C12) and equipped with local/manual start
functions.

 Make-up pump starts when the liquid level of the

expansion tank drops to the replenishment level and
stops when water level reaches stop pump level.
RAW WATER PUMP (P21)

 Rated flow: 4m3/h

 It consists of a motor, pump, flow meters and filter

that links it to raw-water tank. Y-type filter (Z21) blocks
the particles to enter the main pipeline through raw-
water tank.

 When the liquid level of the raw water tank drops to

the replenishment level, an alarm will be issued to
prompt manual replenishment, and the single
configuration will automatically stop when the
replenishment reaches the stop pump level.
EXTERNAL VALVE
COOLING SYSTEM
Outdoor Heat Exchange System
CLOSED COOLING TOWERS (G01-
G06)
 Three cooling towers are installed outside for each
set of equipment and each tower has 2 fans with
redundancy. These fans are equipped with power
frequency and variablr frequency modes. As the
outdoor heat exchange equipment of the converter
valve cooling system, the closed cooling tower
transfers the heat loss of the converter valve to
the spray water and the atmosphere.
 In normal condition, 1 fan of each tower can be put
into operation running at 50Hz. But in case of a
cooling tower is out of operation, other two sets of
cooling towers will increases fans frequency
depending on temperature to ensure cooling
effect.
SPRAY WATER PUMPS (P31-P36)

 Pumps label: P31, P32, P33, P34, P35, P36

 Each cooling tower is equipped with 2×100% capacity
spray water pumps, which are made of stainless steel.
These six spray pumps share one water inlet pipe.
 Each cooling tower spray pump is provided with a
butterfly valve at the inlet, and a check valve, a
butterfly valve and a pressure gauge at the outlet. Set
up drainage branch pipes and valves on the outlet
pipe to the cooling tower.
 A drain valve is set at the lowest point of the spray
water pipe to drain the water in the pipe to prevent
the spray water from freezing when the operation is
shut down in winter and the outdoor temperature is
low .
SPRAY POOL

 An underground pool is setup outdoor to ensure the

stability and reliability of the spray water of the cooling
tower and the liquid level sensor of the pool is set in the
pump pit. Spray pool is also known as sprinkler pool.

 When the liquid level is low, a signal is sent out in time to

start the industrial water pump and start the spray water
treatment. The system replenishes the pool, stops
automatically when it reaches the design level, and
sends a signal to stop the industrial water pump. The
capacity of the spray pool can meet the 24 -hour water
consumption.
EXTERNAL VALVE
COOLING SYSTEM
Water Treatment System
EXTERNAL WATER TREATMENT

 In order to prevent the scaling phenomenon on the

outer surface of the heat exchange coil caused by long-
term spraying, the spray water needs to be treated
first. The main equipment of the water treatment
system includes: quartz sand filter, activated carbon
filter, reverse osmosis device, reverse osmosis cleaning
device, spray water dosing device (bactericide and
scale inhibitor), pipelines and valves, power distribution
and control equipment.
QUARTZ SAND FILTER (C65)

 Quartz sand filter is used for turbidity removal treatment of raw water,
using the interception ability of quartz sand to effectively remove larger
suspended solids and colloids in water, so that the turbidity of effluent is
less than 1mg/l , so as to ensure the normal operation of subsequent
treatment.
ACTIVATED CARBON FILTER (C46)

 The activated carbon filter uses granular activated carbon to further

remove impurities such as residual chlorine, organic matter and
suspended solids in the quartz sand filter to further purify the water. The
activated carbon filter is mainly composed of nut shell activated carbon
and quartz sand filtration, and the effective filtration speed is 8 ~ 12m/h.
MEDICINE TANKS (C901,C902,C904)

 In order to prevent the proliferation of bacteria and algae

microorganisms and the scaling of the closed cooling tower coil, it
is necessary to add corrosion and scale inhibitors and bactericidal
and algaecide to the spray pool.

 Corrosion and scale inhibitor can inhibit and interfere with the
normal growth of calcium carbonate crystals, so that it can not be
deposited to form scale and dispersed in the water body.

 Bactericidal and Algaecide can prevent organic matter, fungi, algae

and the slimy sludge grows into activated sludge and adheres to
the outer surface of the coil.
REVERSE OSMOSIS DEVICE (C60)

 Reverse osmosis unit desalination rate: 99.5%

 Water production of a single set of equipment: 12m3/h

 Reverse osmosis is the process of producing pure water by cross-flow

filtration with help of a high-pressure pump. The liquid flows through the
permeable membrane surface placed in vertical direction and most of the
retentate is taken out of the membrane by the concentrate components.

 Two high pressure pumps (P55,P56) are linked with reverse osmosis unit
with redundant system.
REVERSE OSMOSIS DEVICE (C60)

 The function of the high pressure pump is to provide sufficient water

inlet pressure for the reverse osmosis body device to ensure the
normal operation of the reverse osmosis membrane.
CHEMICAL CLEANING TANK (C62)

 The chemical cleaning device includes cleaning

tank, cleaning pump (P57), cleaning filter (5µm),
electric heating (3kW) and its pipes, valves,
instruments, etc. The material of the cleaning unit
is suitable for all cleaning fluids.
 Long-term RO membrane accumulates pollution
due to long-term peration and this pollution is
difficult to washout, such as long-term trace salt
scaling and accumulation of organic matter. It will
reduce the cause the performance of the
membrane module. Therefore, it must be cleaned
with chemicals to restore its normal state of
desalination capacity.
CHEMICAL CLEANING TANK (C62)

 Set up a sump in the spray pump pit to collect various faults and
leaks in the system. A high and low liquid level switch is set in the
sump to detect the liquid level in the pit.
 When the liquid level value reaches a high value, the submersible
pump configured in the pit starts to pump out the water in the pit.
When the low liquid level is reached, the submersible pump stops
automatically, and the two pumps run alternately. The submersible
pump can also be started manually.