Subj ect: ORB-II COOLING TOWER SYSTEM

BYCO purchased three pumps and 5 fans of a cooling water system from Milford Haven UK
along with Refinery. There were four pumps at Milford Haven, two motor driven while two
turbines driven. One Large capacity motor driven pump was missing during the time of
purchase. Bosicor purchased new cells along with partial piping, side stream filters + pump.
At first stage BYCO will run with three cells commissioned along with three pumps (one
motor and two turbines driven). Specs of pumps and fans are given below:
Milford Haven Refinery cooling water system was designed to reject 160.8MMBtu/h heat
with its temperature change of 30
o
F (110- 80
o
F). So, the water circulation rate was around
11000 gpm. Design conditions were as follows:

Sr.No Parameter Summer
1. Supply temperature,
o
F 80
2. Return temperature,
o
F 110
3. Ambient temperature (avg),
o
F 85
4. Wet Bulb temperature, (avg),
o
F 75
5. Relative Humidity, % 65 -

At Milford Haven, there were two cooling towers. One cooling tower had two cells while the
other had three cells. Two cells cooling tower had 16ft dia, 6 blades of GRP fans with 60hP
motors while three cells cooling tower had 16ft dia, 4 blades of FRP fans with 50hP drivers.
Two cells tower was feeding to VDU and Isomerization unit & Plat splitter unit while other
process units were with 3 cells tower.

1. Cooling Water pumps, Flow (5160gpm), head (175.4ft) and power 320 hp Motor/Turbine
(1/1)
2. Cooling Water pumps, Flow (6000gpm), head (161.7ft) and power 400 hp Motor/Turbine
(1/1). Pump with motor is missing.

3. Fans, 16 ft dia, 6 blade FRP 60 hP Motor 3
4. Fans, 16 ft dia, 4 blades FRP 50 hP Motor 2



Ambient conditions in Pakistan are hotter than that at Milford Haven and they are as
follows:
Sr.No Parameter Summer
1. Supply temperature,
o
F 90
2. Return temperature,
o
F 120
3. Ambient temperature (avg),
o
F 95
4. Wet Bulb temperature, (avg),
o
F 85
5. Relative Humidity, % 65

So hot weather would require higher water circulation rate and/or increase in heat transfer
area. To have more water circulation rate, provision has been taken to add 3 more cells.
Only one additional pump will handle the future additional requirement of the water.
However, current piping network, along with available differential head of pumps, will not
be able to handle the additional water circulation rate and piping network debottlenecking
would be required.
For initial Refinery operation, 5 cells (induced draft counter flow) of each capacity 540
m3/hr have been selected in order to achieve heat rejection of 160 MM BTU/HR.
BYCO is installing 4 cells in first phase with refurbished rotating equipment (Fan motors,
gear drives, shafts, fan blades & complete fan assembly), provided by BYCO while rest of
cooling tower parts are in scope of supplier.
Side Stream Filtration
Side stream Filtration system has been designed to keep the turbidity level below 1 NTU by
removing suspended solids. The design flow rate of the system is 600 gpm. Filtration
system has two filters and one pump. It has been provided with line from main cooling
water supply pumps.
Filters are sand filled units which will operate at certain pressure drop. At specified
pressure drop one of the filters will be taken off the line and will go on regeneration /
backwashing while the other will be on line.
Details & operational sequence of Side stream filter package is given in attached doc# SP-J-
001.

Chemical Dosing System:-


Chemical dosing system requirements are given in attached doc# 1197-22-CH-1502.



COOLING TOWER DESIGN PARAMETERS
Circulation rate m3/hr 2160
No. of cells No. 4
Summer Case
Supply temperature
0
C 32
Return temperature
0
C 47
Range
0
C 15
Wet bulb temperature(Avg)
0
C 29
Approach
0
C 3
Relative Humidity % 65


COOLING TOWER BASIN DIMENSIONS
Length m 12.825
Width m 8.7
Depth 2.35
Volume m
3
262.2
No. of basin 2
Total Volume m
3
524



SYSTEM VOLUME
ONE HEADER
Pipe dia inch 20
Length m 1000
2nd HEADER
Pipe dia inch 16
Length m 1000



2
ND
header will



2nd header will be in operation in future when
cooling tower capacity would be 2700 m3/hr



LABORATORY RESULTS MAKE UP WATER COOLING WATER

Target Target

pH 7.00 8 - 9



TDS ppm (as CaCO3) 300 - 350 < 1500

NaCl ppm (as CaCO3) 50 - 70 < 500

T.HARD ppm (as CaCO3) 89 - 150 < 800

Ca HARD ppm (as CaCO3) 70 - 110 < 500

M. ALK ppm (as CaCO3) 90 - 150 < 700

ZINC - 1 - 2
TO be
maintained
FREE HALOGEN (B) -

CONC. FACTOR (NaCl) - 5.0 - 6.0

CONC. FACTOR (TDS) - 5.0 - 6.0



RYZNAR INDEX: <6 is scaling



LANGELIER INDEX:
positive value is
scaling


Anti scal.&Corr.
kg/day
?

NaOCl
Lit/Day
?

Biocide oxidizing
Lit/Day
?




Bromine Before PPM ?


Bromine After PPM ?


Please find below the procedures of Cooling & Boiler system passivation.

Cooling Tower
Good system passivation is essential to achieve optimum treatments benefits
at most cost effective treatment levels. At the Plant start up double dose of
SCgon...345 will be given for three to seven days in order to maintain 2-3
ppm Zinc which will promote uniform layering of the corrosion inhibitors on
the heat transfer surfaces. This would also help the fulfillment of system Zinc
demand.
In case of the installation of new bundles (Retubing) and to help reduce the
flash corrosion a high level slug dose (30 kg) is essential to passivate the new
heat transfer surfaces to establish a barrier for pitting corrosion
prevention. This high level slug dosages will continue for two days along with
passivation dose.
Maintain 2-3 cycle for at least 02 - 03 days to flush out the mud/clay and mill
scale.
You may experience high level of iron contents after startup of the plant, such
low cycles will help us to minimize the iron contents in system water.
In view of our experience, we hope that all parameters will be normalized in
on week time after the start up of the plant.


As soon as all parameters are normalized, normal dosages of the chemicals
shall be followed, and a corrosion coupon shall be installed in corrosion
coupon assembly, corrosion coupon is lying with our rep. at site.
We are already conducting biological counts test at site, you may ask your
engineer to coordinate with our rep. for timing schedule.
Cooling Tower is operated at high CF and TDS level, therefore, Turbidity has
no significant role in cooling water chemistry, however monitoring of
suspended solids in cooling water circuit can help to address and resolve
the sludge accumulation issue.