Area Specific Course of Cooling Tower

AREA SPECIFIC COURSE
COOLING TOWER & FIRE FIGHTING AREA
Nozzles Top Deck
Louvers
Packing
Atmosphere Air
Drift Eliminator
Reviewed by MSS Page 1 of 76

INTRODUCTION:
Removal of unwanted heat is common in industrial manufacturing processes and air conditioning
systems. Water is the most commonly used medium for removing unwanted heat because it is
readily available and can be easily handled. It can carry large amount of heat per unit volume and
does not expand or compress within temperature range normally encountered. As a result, large
quantities of water are used for cooling purposes and it is anticipated that water consumption
will continue to increase with industrial growth.
Cooling tower is very important part of many chemical plants. The primary task of cooling tower
is to cool hot water for recycling by rejecting heat to the atmosphere. Cooling tower reduces the
temperature of water stream by extracting heat from water and emitting it to atmosphere.
Cooling towers make use of evaporation whereby some of water is evaporated into a moving air
stream and subsequently discharged into atmosphere. As a result, the remainder of the water is
cooled down significantly. It is the most useful device available in industry for dissipating large
heat loads at a reasonable cost.
PRINCIPLES:
Normally water is used for removing unnecessary process heat. For this heat transfer, there must
be a temperature gradient which is achieved by cooling water. There are different methods but
the common factor of all these methods is the exposure of water to air by this exposure
evaporation is achieved and causes cooling.
There are different processes by which evaporation is achieved. Some are slow, such as cooling
water on the surface of a pond and others are comparatively fast, such as spraying of water into
the air. In all such processes, heat is transferred from water to air by exposure of water to air by
different ways. This unit operation of heat transfer involves;
1. Latent heat transfer owing to vaporization of a small portion of the water.

2. Sensible heat transfer owing to the difference in the temperature of water and air, nearly 80
% of this heat transfer is due to latent heat and 20% by sensible heat. Theoretically
speaking, this transfer of heat manually depends upon the following.
a) Temperatures of both air and water to be cooled
b) Moisture content (humidity) of the air
c) Wet bulb temperature
Wet bulb temperature is an indication of the moisture content of the air. It is the lowest
theoretical temperature to which the water can be cooled. The cold water temperature approaches
but does not equal the air wet bulb temperature in a cooling tower. It is because content of all the
water with the fresh air is imposable the magnitude of approach to the wet bulb temperature is
dependent on tower design. The important factor is air to water contact time, amount of fill
surface, and break-up of water into droplets.

IMPORTANT TERMS:
1. DRY BULB TEMPERATURE:
Temperature of air read on an ordinary thermometer.
2. WET BULB TEMPERATURE:
It is the lowest theoretical temperature, to which the water can be cooled. This temperature
can be obtained by covering the bulb of an ordinary thermometer with wet silk gauze, then
putting the instrument in a moving air system. Some water in gauze evaporates taking heat
from the removing water and dropping its temperature. Amount of this drop depends on
dryness of the air as well as initial temperature. When equilibrium is reached, thermometer
is indicating wet-bulb temperature.
3. RELATIVE HUMIDITY:
Water vapors are always present in atmospheric air. Amount of vapors present per unit
volume of air is known as humidity. With rise in air temperature more moisture can be
accumulated is the same volume of air. Relative humidity is the ratio of water vapor present
to the maximum quantity of vapors that can be accommodated per unit volume of air at
given temperature. When humidity of air is 100% wet bulb temperature equal to dry bulb
temperature. The difference between wt bulb and dry bulb temperature is the most
important variable affecting the performance of cooling towers. Cooling tower performance
decreases with increase in RH.
4. RATE OF HEAT TRANSFER:
Rate of heat transfer in evaporative cooling depends upon.
a) Area of water transfer in contact with air.
b) Relative velocity of air and water during contact.
c) How long the air is in contact with the water.
d) Difference between wet bulb temperature of air and inlet temperature of water.
Cooling tower design primary aim is to reduce hot water temperature to near wet
bulb temperature while keeping initial and operating costs with in the economic
frame work of the overall project.
5. COOLING RANGE:
Difference between hot and the cold water temperatures. For our system the range is 11°C.
6. APPROACH:
Difference between cold water and surrounding air wet bulb temperatures. For our system
approach is 4°C.

CONTROL OF COOLING WATER LOSS:
Make up, Evaporation losses, Drift loss, Blow down and Cycle of concentration.
1. EVAPORATION:
The evaporation is based on the fact that 970 BTU (540 Kcal) are require to evaporate 1LB
(1kg) of water when 1% of circulation water evaporates the temperature difference become
5.8 °C or 10°F.
2. DRIFT: (Liquid water loss)
Water lost from the tower as liquid droplets entrained in the exhaust air it is independent of
water lost by evaporation. Mist eliminators control this loss in cooling towers. It depends
upon air velocity drift eliminators health in cooling towers.
3. BLOW DOWN:
Water intentionally discharged from the system to control concentration of the salts or any
other impurities in the circulating cooling water. Evaporation of water in the tower
increases its dissolved solids concentration. Blow down removes enough of this water to
keep concentration below maximum allowable limits for trouble free operation.
4. MAKE-UP:
Water required placing normal system losses caused by evaporation, drift and blow down
and small leaks. Therefore, the make up water quantity is equivalent to
M= E+D+B,
M=makeup (m3/hrs)
E=Evaporation loss (m3/hrs)
D=Draft loss,
B=Blow down (m3/hrs).

Evaporation loss Blow down water
Wind age
loss Fan
Return Water
Tower Process
Air fluid
packing Heat
exch
ange
r
Make-up
Circulation
water Cooling tower pump
Basin
Supply Water
5. CYCLE OF CONCENTRATION: (C.O.C)

This is the ratio of dissolved solids in circulating water to the dissolved solids in make up
water. In our system COC reported on silica basis. This factor helps to determine water
losses and chemicals consumption control.
Blow down losses depend upon cycles of concentration and the evaporation losses and is
given by formula:
Blow down = Evaporation loss / (C.O.C. – 1)

STRUCTURAL DETAIL
The basic components of a cooling tower include the fill, cold-water basin,
Drift eliminators, air inlet, louvers, nozzles and fans. These are described below.
Fill. Most towers employ fills (made of plastic or wood) to facilitate heat transfer by
Maximizing water and air contact. There are two types of fill:
a. Splash fill: waterfalls over successive layers of horizontal splash bars, continuously
breaking into smaller droplets, while also wetting the fill surface. Plastic splash fills
promote better heat transfer than wood splash fills.
b. Film fill: consists of thin, closely spaced plastic surfaces over which the water spreads,
forming a thin film in contact with the air. These surfaces may be flat, corrugated,
honeycombed, or other patterns. The film type of fill is the more efficient and provides
same heat transfer in a smaller volume than the splash fill. The filling is of splash type its
material is black polypropylene
Cold-water basin
The cold-water basin is located at or near the bottom of the tower, and it receives the cooled
water that flows down through the tower and fills.
The basin usually has a sump or low point for the cold-water discharge connection. In many
tower designs, the cold water basin is beneath the entire fill. In some forced draft counter
flow design, however, the water at the bottom of the fill is channeled to a perimeter trough
that functions as the coldwater basin. Propeller fans are mounted beneath the fill to blow the
air up through the tower. With this design, the tower is mounted on legs, providing easy
access to the fans and their motors.
Drift eliminators: These capture air entrapped water droplets that otherwise would be lost to
the atmosphere. The separation of droplets is achieved forcing air to pass thorough a path
with direction changments in such a way to change the droplets with centrifugal force that
makes droplets hit against drift eliminator blades droplets fall back by gravity inside the
cooling tower.
a. Reduce water loss
b. In case of an induced draft cooling tower to protect the surrounding machines,
equipments, civil structures mainly the fan blades against fouling which can easily
unbalance on the rotor.
c. To assure work security in area during winter.
d. Drift losses increases inlet air humidity and reduce cooling performance.
Air inlet: This is the point of entry for the air entering a tower. The inlet may take up an entire
side of a tower (cross-flow design) or be located low on the side or the bottom of the tower
(counter-flow design).
Louvers: Generally, cross-flow towers have inlet louvers. The purpose of louvers is to equalize air
flow into the fill and retain the water within the tower. Many counter flow tower designs do
not require louvers.
Nozzles: These spray hot water for uniform water distribution at the top of the fill to achieve
proper wetting of the entire fill surface. Nozzles can either be fixed and spray in a round or
square patterns, or they can be part of a rotating assembly as found in some circular cross-
section towers. Our cooling tower nozzles are of turbo type and anti clogging to avoid any

problem during normal running. Under each nozzle are placed several splash plates of
polypropylene will perform a perfect spraying of water.
Fans: Both axial (propeller type) and centrifugal fans are used in towers. Generally, propeller
fans are used in induced draft towers and both propeller and centrifugal fans are found in
forced draft towers. Depending upon their size, the type of propeller fans used is either fixed
or variable pitch. A fan with non-automatic adjustable pitch blades can be used over a wide
kW range because the fan can be adjusted to deliver the desired air flow at the lowest power
consumption. Automatic variable pitch blades can vary air flow in response to changing load
conditions.

TYPES OF COOLING TOWERS
NATURAL DRAFT MECHANICAL DRAFT
(Air is supplied by convectional currents) (Air is supplied by fan)
Forced Draft
Induced Draft
 The fan is located at bottom.  The fan is located at top.
High air entrance velocity and low exit
velocity.  High air exit velocity this improves the
 The tower has lower performance heat dispersion and reduces potential for
recirculation of air.
due to recirculation of air.
 The fan can be subjected icing under  High efficient than forced draft.
low ambient temp & high humidity.  Inspection & maintenance is difficult
 Easy Inspection & maintenance
Cross flow Counter flow

Air flow horizontally across the Air moves up ward through tower
down ward of water packing and vertically across the down
ward of water
TYPES OF COOLING TOWER / PONDS

Cooling towers can be classified according to airflow. Each one employs either natural or
mechanical draft. In the natural draft category we include atmospheric towers in which airflow
depends on local wind conditions and the hyperbolic chimneys. Mechanical draft designs use one
or more fans to move air
NATRUAL DRAFT
a. Cooling pond
b. Spray pond
c. Atmospheric Towers
d. Hyperbolic
e. Fan assist natural draft
a. Pond:
Is one of the simplest methods of cooling water although it is the least efficient? Warm inlet
water is introduced at one end of the pond and cold water supply is drawn from the other.
Water is cooled as air contacts the pond’s relatively large surface area.
Heat dissipated from a still pond averages only 13.5 Btu per hours per Sq feet of surface per
degree temperature difference between surface of water and air. A still pond must have
about 20 times the area of a spray pond, from 500 to 1000 times the area of a cooling tower.

Spray Ponds:
Handles as much as 120,000 g/pm of water, because of low head requirements, pumping
costs is less than for cooling towers. Properly designed spray pond exposed to prevailing
winds of 3 to 5 mph velocity, produce overall cooling efficiency up to 60%.
b. Atmospheric Towers:
They are relatively simple, consisting of little more than a louvered enclosure containing a
water spray system. Air enters through the long louvered walls passes horizontally over the
fill and exits from the opposite louvered wall. The long louvered wall is exposed to
prevailing winds for maximum airflow. The tower is relatively narrow in the direction of
airflow, so that this path of the air is short with low resistance. The use of atmospheric
towers has declined because of high initial costs of the structure and pumping system,
dependence on wind velocity and direction, difficulty in controlling water temperatures and
the needs for large open sites. The atmospheric cooling tower was the earliest design used
in 1920 but is seldom built today for small air conditioning systems.
c. Hyperbolic:
Hyperbolic tower works much like a chimney, with airflow induced by convention, which is
the result of difference in air density. As the warmer moisture containing air rises out of the
top of this tower, cooler dry air enters at the bottom. Most of the structure is a hollow shell
made from reinforced concrete. The counter flow design has fills occupying the lower
portions (10 feet to 30 feet) of the tower interior. The base of the tower is mainly open
space containing supporting legs through which the cooling air enters. The height of the
tower may be over 400 feet and is shaped like a chimney, which consists mostly of empty
spaces.
MECHANICAL DRAFT
Mechanical draft towers rely on fans for air movement through the cooling tower fill. Higher
air velocity permits better cooling under more controlled conditions and usually results in a
more economical first cost installation when compared to natural draft towers. Mechanical
draft towers are usually equipped with more than one fan to provide a greater flexibility in
temperature control for those periods of the year when the wet bulb temperature is lower
than that set by design conditions.
Air movement may be controlled by multiple speed motors, variable speed drivers or
variable pitch fans. Mechanical draft towers are divided into two categories: -
a. Forced draft.
b. Induced draft.
a. Forced Draft:
The fans on a forced draft tower are located at the air intake and force or push the air
through the fills, water and drift eliminators to the atmosphere. Since the exit leaves at such
a velocity, recirculation very frequently occurs; this may reduce efficiency as much as 20 %.
Many small air conditioning towers are still being used, utilizing the forced draft design with
centrifugal and propeller fans.

FORCED DRAFT TYPE
Air outlet
Water inlet Tower packing
Fan
Air inlet
Water out
b. Induced Draft:
The fans on induced draft towers are located on top of the tower. Air is pulled up through
the fills and water, this arrangement is called induced draft.
Inlet warm water distribution system is a header lateral type, located just under drift
eliminators. Fan and its drive mount on the top deck. Packing may be of non-splash design
wood or plastic packing. Structure is basically made of wood, with either wood or concrete
water basin. Wind load is taken by diagonal bracing, which transmits it to the columns.
Bracing and structure are usually designed to withstand 100 mph wind load.
These towers are generally classified according to the direction of movement of the air and
water: -
a. Counter flow design
b. Cross flow design
a. Counter Flow Design:
The air and water are flow is in opposite direction. The water falls by gravity through the
fills and the air flows vertically upward through the fills and water.
The main advantages here are that the coldest water contacts the driest air and warmest
water to the most humid air.
Cross Flow Design:
The water falls by gravity through the falls and air flows horizontally across the fill and
water. Cross flow designs usually provide a low resistance to air flow in a horizontal
directions thus enabling the tower to pass more air for a given amount of ground area. This
greater air movement compensate for this less efficient heat exchange contact between air
and water. Urea-III cooling tower is of induced draft cross flow design.

Induced drafts cross flow
Air outlet
Fan
Water inlet
Tower packing louvers
Air inlet Air inlet
Water out let

Drift eliminators

UTILITIES COOLING TOWER
At the plant commissioning there was only one cooling tower of eight cells. This tower is splash
type cross flow induced air cooling tower. It consists of cells separated by gates. Each cell consists
of six louvers and the space between two consecutive louvers is filled with layers of
polypropylene filling. Each cell comprises of three portions with a fan on the top. The motor
driven fan is located in the centre of the cell. Inside the two portions there are polypropylene drift
eliminators. After startup of plant it was observed that performance of the cooling tower is not
according to the design. Therefore two more cells constructed later on whose design is slightly
different than the others. Both towers are inter connected.
OPERATION;
Hot water from unit returns to the cooling towers in 70” dia pipe line. From this return header
three lines 42” dia each enter to the hot water channel of 8 cell cooling tower and rises up
through the concrete risers located in the center of each cell. Hot water is then led to the top of
the cooling tower through 28” dia pipe 16 in numbers. Flow of water to each cell can be
controlled by diffuser valve on 28” dia pipe. Similarly one line of 42” dia goes to top of 2 cell
cooling tower and hot water is led to the top of cooling tower with the help of 28” dia pipe line 4
in numbers.
Water from top of the cooling tower fell through down spots by gravity. There are four thousands
down spots in eight cell tower and spots in two cell tower. the down spots of 2 cell tower are
equipped with splash type nozzles at their lower ends while 8 cell tower are equipped with turbo
jet + static nozzles from which water is sprayed on a series of polypropylene fills due to which
surface area of water in contact with air increases. This results in better and efficient cooling of
water. The cold water falling down is collected in cold basin and is supplied to different units of
the project with the help of five pumps in which four are turbine driven and one motor driven.
Cooling of water is achieved by atmospheric air drawn by the fans on the top of each cell. The air
enters from the sides of cooling tower, passes between the polypropylene filling and is drawn up
by the fan.
An efficient system of drift eliminators is provided at the passage of fans to eliminate the
entrained water from air known as cooling tower drift. And thus minimizes the water loses. Drift
eliminators provide maximum removal of entrained water in the outgoing air.

DESIGN DATA:
UTILITY-III COOLING TOWER, E-800, DESIGN DATA
Manufacturer FAVRA ITALY
Type Induced draft / cross flow
Flow rate in circulation 31000 m3/h
Capacity of basin 6900 m3
No. of cells 08 / 02 Total = 10
Ambient air temp (Min) 7 °C
Design C.W inlet/out temp. 32 / 43 °C
Wet bulb air temperature 28 °C
Dry bulb air temperature 47.8 °C
Heat load 341 Gcal/h
Air relative humidity 80 %
Cooling tower makeup 803 m3/h
Cooling tower blow down 158 m3/h
Drift losses 0.1% (31m3/h)
Evaporation losses 2 % (614m3/h)
Drift eliminators/filling material Polypropylene
Packing Splash type
Nozzles Static +turbo
STRUCTURAL DETAIL
Cells dimension
Internal upper side width = 23.6 m
Internal down side width = 20 m
Inside basin dimension
Width = 21.0 m
Length = 86.4 m
Height = 3.2 m
Tower height above plant 0 level = +21.85 m
Water inlet height above plant 0 level = +13.2 m
Stack height = 8.65 m
Stack opening = 9.78 m
Fan diameter = 8.54 m
Tower total volume = 27370 m3
Cooling section total volume = 13686 m3

FAN DATA SHEET
Number of Fan : 08+02
Diameter : 8.54 m
No. of blade : 7&5
Air flow rate per fan : 13, 95,000 m3/h
Speed : 132 rpm
Pitch angle : 10.3°
Gear reduction ratio : 11.3:1
Motor power : 160 kW
Motor Amperes : 250 Amps (On Avg)
Motor speed : 1485 rpm
Blade material : Glass reinforced plastic (GRP)
COOLING TOWER PLANNED SHUT DOWN
1. Stop make up of cooling tower and decrease the level of cooling tower basin 2~ 2.5
meter one day before the shut down of cooling water supply system by opening blow
down valve fully.
2. If the suspended solids are > 20 ppm in cooling water, then add shock dose of 5ppm
Biodispersant, BULAB-8006 in cooling water one day before the shut down of cooling
water system.
3. Continue dosing of all chemicals till the cooling water system is in service (from high to
low load) to maintain the chemical level in cooling water.
4. Stop the dosing of all chemicals as well as blow down as soon as heat transfer
requirement is finish and there is no evaporation in cooling water system or when
CWS/CWR temperatures become equal.
5. Take sand filters out of service by closing water supply to them.
6. Stop turbo pump one by one and close suction valve.
7. Stop vacuum system of the condenser, E-801.
8. Open steam drains of all turbines.
9. Stop fan motors.
10. Drain the cooling water if necessary.

COOLING WATER SYSTEM START UP AFTER TA
1. Close cooling tower drain valves.
2. Ensure C B D valve is in close position.
3. Check cooling tower basin cleaning is completed.
4. Confirm cooling tower basin cleaning from inside and no foreign material present.
5. Install cooling tower basin strainers 09 Nos.
6. Start filling in E-800 basin.
7. Start chemical dosing (Bulb -9067, 9063, 7024, 8006) at the 50% level of basin or as per
recommendation of Buck man supervisor.
8. Fill the basin level up to over flow.
9. Open P-800A~E suction and discharge valve for filling of header.
10. Open air bleeders on supply header & also discharge header valve of P-800 A-E.
11. Open 14”Ø CWS header priming valve & close this valve when water start coming from
bleeders of P-800A-E.
12. Open all H.S & L.S header drains in crack position.
13. When dry steam is coming then close H.S & L.S Steam header drains.
14. Prepare E-801 and start MP -801- A.
15. Pull and maintain Vacuum in E-801.
16. Put TP-800 on heating & take them in service as per WI.
17. Change E-801 CWS from clarified water to cooling water.
18. Check level of E-800 basin & start make up.
19. Start TP-815 of that turbine which is in service.
20. Put MP-813 on auto S/B.
21. Put TP-801B in service as per WI.
22. Put MP-801A on auto S/B mode.
23. Put acid ejector, Ej-802 in service as per WI.
24. Start acid injection & maintain PH of Cooling water 7.5 – 8.2.
25. Change fire hydrant from well water to cooling water as per procedure.
26. Start MP-1702 after rack in.
27. Normalize P-1701 A /B.
28. Take MV -800 A-F in service.

TANK DATA SHEET
ACID TANK V-802
Tag : V-802
Capacity : 25 m3
Length : 5660 mm
Diameter : 2500 mm
Material of construction : CS
Shape : Horizontal cylindrical
Dip / Level (cm) Weight (Tons)

10 0.70
20 1.90
30 3.50
40 5.40
50 7.35
60 9.70
70 12.10
80 14.40
90 17.10
100 20.0
110 22.70
120 25.30
130 27.80
140 30.30
150 33.00
160 35.20
170 38.30
180 41.0
190 43.60
200 45.50
210 47.70
220 49.60
230 51.10
240 52.35
250 52.50

STEAM TURBINES TP-800A~D FOR COOLING WATER PUMPS P-800A~D
There are five cooling water pumps four are turbine driven while one is motor driven. Turbine is
condensing, multi stage impulse type.
PUMPS DATA SHEET
PUMPS:
Tag No. : P-800 A/B/C/D/E
Service : Cooling water
Manufacturer : WORTHINGTON ITALY
Driver type : Turbine (04)/Elec. Motor (1)
No of stages : one
Discharge pressure : 4.5 Kg/cm2a
Suction pressure : 1.0 Kg/cm2a
Capacity : 8100 m3/h
Minimum continuous capacity : 2340 m3/h
Efficiency : 90 % (Normal)
Pump speed : 590 rpm
NPSH : 3.3m
Impeller : Closed (double suction)
Impeller Dia : 975mm
TURBINE:
Tag : TP-800A~D
Manufacturer : WORTHINGTON ITALY
Turbine Power (normal/max) : 1300~1500 HP
Type : Impulse, Condensing
Speed : 7500 rpm
Steam consumption : 6600 kg/hr
Steam temperature : 370 °C
Exhaust pressure : 0.25 Kg/cm2a
No of stages : 02 (HP+LP)
No of blades : HP (02) +LP (04) =06

STARTUP PROCEDURE OF STEAM TURBINES TP-800A~D
Pre start up
1. Check oil level of console (90%).
2. Check oil level in governor of TP-815 and P-800 I/B, O/B bearings.
3. Check control oil pressure 1.5 Kgs/cm2.
4. Check ∆P of FT-801/802 is less than 0.5kgs/cm2.
5. Check all condensate drains are opened.
6. Check T.T.V (SD-150V) is in closed position.
Start up
1. Crack open isolating valve of 08-2-SD 1AV to 4AV.
2. Put the turbine on L.S heating.
3. Maintain temperature up to 150 0C.
4. Start Ej-808 A-D.
5. Open cooling water to E-811 A-D.
6. Close all condensate drains.
7. Full open isolating valve of 08-2 SD 1AV to 4AV.
8. Maintain DMW level in 08-PSV 103-106.
9. Open Sealing steam to glands of TP-800 A-D.
10. Open body condensate draintoV-805.
11. Open exhaust valves to E-801 Condenser.
12. Put the turbine L.S rolling.
13. After half an hour trip the turbine through T.T.V (SD-150V)
14. Open main condensate drain TP-800 A-D.
15. Open 08-2 SD 1BV to 4BV and Crack open isolating valve for HS heating.
16. Maintain the temperature up to 250 0C.
17. Close main drain valve and full open isolating valve of 08 2-SD 1BV-4BV.
18. Put the turbine on HS rolling with 08-SD-150V (TTV).
19. After half an hour, open pump body discharge header priming valves.
20. Open 50% discharge valve P-800 A-D.
21. Speed up turbine slowly and cross critical speed 3500-4500 RPM rapidly.
22. Open cooling water to E-805/806 if required.

SHUT DOWN PROCEDURE OF CW PUMPS TURBINE TP-800A~D
1. Close discharge valve 50%.
2. Reduce turbine speed slowly up to 5000 rpm then rapidly decrease speed from knob
2000~2500 rpm.
3. After half an hour, stop the turbine, TP-800 A-D with T.T.V (SD-150V).
4. Close body condensate draintoV-805.
5. Close 08-SD-1Bv -4Bv.
6. Close exhaust valves to E-801 Condenser.
7. Close DMW to 08-PSV 103-106.
8. Isolate sealing steam to turbine.
9. Stop EJ-808 A-D Sealing steam ejector.
10. Open turbine all body drains.
11. Put breaker off, MP 813A-D.
12. Stop & isolate TP 815 A-D after ½’ hour of TP – 800A-D
START UP OF MP-800E
1. Inform Co-ordination Engineer & 06/07 shift engineer.
2. Check level of C.W basin and maintain if it is low.
3. Check oil level in pump and motor bearings.
4. Open suction valve & open about 60 %( 20% on gear indication) discharge valve of the
pump.
5. Open pump casing bleed valve & also open the bleed valve on D/S discharge valve of the
pump for priming...
6. Open sealing water valves of glands.
7. Start MP-800E by local ON/OFF switch.
8. Check any abnormality, if no, open slowly discharge valve, keeping eye on motor amperes &
C.W.S header pressure.
9. Check bearing temperature, vibration, oil leakages & glands leakage etc.
Keep motor and pump under observation, monitor and log the conditions after every 15 minutes
for one hour
SHUT DOWN OF MP-800E
1. Inform Co-ordination Engineer and 06/07 areas shift engineer also.
2. Slowly close the discharge valve of MP-800E.
3. Give ‘STOP’ signal to MP-800E by local ‘ON/OFF’ switch.
4. Close C.W valve for gland packing.
5. Put the breaker ‘OFF’ from S.S # 1.
6. Close suction valve as per requirement.
NOTE: pump discharge valve opening is fixed at about 65% opening (at gear box indicator 17%)
to keep ampere at 125.

LUBRICATION SYSTEM OF TP-800A~D
Correct lubrication is essential for satisfactory operation of a machine. T-46 oil is being used for
TP-800A~D. this system comprises of oil tank T-800 having a capacity of 2000 liters, oil coolers,
E-805/806. Oil filterFT-802/3 and two lube oil pumps. One is motor driven and other is turbine
driven. Turbine driven usually remains in service while motor driven on auto stand by. Both
pumps are positive displacement rotary screw pumps. Oil pump, TP-815/MP-813 takes oil from
the sump (oil console). PSV-150/151 is installed at discharge of MP-813 and TP-815 respectively
to release excess oil to the sump and to deliver oil at pressure 2.8 kg/cm2. An NRV at discharge
line prevents the return of oil to oil tank through this line when main pump is in operation and
stand by pump is stopped. Oil at temperature about 60 0C passes from coolers E-805/806 and
cool down to 45 °C. This oil then passes to oil filters, FT-802/803 to remove the contamination
from oil .Oil pressure after the filter is maintained at 1.5 kg/cm2 by self actuating valve, 08-3-PCV-
150 and excess oil drains to sump before entering in oil coolers
This oil now performs two separate functions (1) oil for lubrication purposes know as lube oil
(11) oil which used for the protection system of the turbine is called control oil.
Lube oil is divided into four streams for lubrication of
1. Gear box.
2. Front Bearing.
3. Rear bearing.
4. Gear coupling
Each stream is provided with restricted orifice and after lubricating, each stream returns to oil
sump. Control oil having orifice is also divided into three streams
1. Solenoid operated oil dump valve, SD-151 (operates when condenser vacuum breaks and
pressure reaches to 0.3 kg/cm2g but this system is isolate since plant commissioning).
2. Low lube oil trip security 08-3-LLPS-154 (set point 0.8 kg/cm2).
3. Over speed trip security 08-3-LLPS-155.
LLPS-154 hydraulic switch actuate at oil pressure 0.8 kg/cm2 causing the de-latching of the
turbine resulting in closing of the emergency stop valve 08-3-SD-150V where as LLPS-155 will
actuate in case of over speed causing stoppage of steam due to low oil pressure. Similarly
whenever solenoid operated oil dump valve or it’s by pass is opened it will cause tripping of the
turbine due to low oil pressure.
A test valve is provided in the pump control oil line for testing of auto start of stand by pump.
Opening the test valve releases the oil pressure on the switch LPSA-151 by draining oil into oil
sump. The selected auto stand by pump will start immediately when lpsa-151 reaches to 1.1
kg/cm2 and remains in service to maintain the oil pressure.
START UP PROCEDURE OF LUBE OIL PUMP TURBINE, TP-815A~D

1. Check lubes oil level in lube oil level glass of TP-815 (T-46) it should be 70%.
2. Ensure that cooling water is opened to water jacket of TP-815 A-D.
3. Check that all instruments and steam traps of TP-815 A-D are working properly.
4. Check that exhaust valve of TP-815 A-D is closed and vent valve is full open.
5. Ensure that discharge valve of pump P-815 A-D is open.
6. Ensure that all condensate drains of TP-815 A-D are open.
7. Give open signal to 08-SD-1-4V.
8. Crack open U/S condensate drain valve of 08-SD-1-4V.
9. Crack open block valve of 08-SD-1-4V for HS heating of TP-815
10. Continue the heating till temperature approaches to 250OC or when dry steam appears
from condensate drain.
11. Close all condensate drain valve of TP-815 A-D when required temperature achieved.
12. Full open 08-SD-1-4V block valve and speed up the turbine.
13. Now get turbine exhaust in LS-header by opening the exhaust valve and closing vent valve
simultaneously.
14. Check discharge pressure of pump P-815 A-D.
15. If there is no abnormality stop MP-813 and put on auto from WTCR.
SHUT DOWN OF TP-815A~D
1. Inform WTCR board man.
2. Start MP-813 by opening drain of 08-LPSA-151 or put the pump on remote from WTCR &
start with local ON/OFF switch.
3. Close 08- SD -1-4V valve from ON/OFF switch.
4. Close block valve.
5. Close exhaust valve.
6. Open drain between block valve & SD valve.
7. Open all condensate drain.
8. Open vent valve.
9. Close main condensate out let valve.
10. Close Cooling water to oil cooler if required.
11. Close cooling water to bearing jackets of turbine.

CONDENSER FOR TP-800A~D
Tag No. : E-801
Steam design flow : 26100 kg/hr
Maximum flow : 27649 kg/hr
Heat injected to circulated water : 550 kcal/kg
Condensing pressure : 0.13 kg/cm2
CHLORINE BOOSTER PUMP P-802A/B :

Type : centrifugal
Manufacturer :
Suction pressure : 4.2 kg/cm2
Discharge pressure : 11.2 kg/cm2
Discharge flow : 75 m3/hr
EJECTOR FOR V-802, Ej-802

Manufacturer : WILLIAN BURTON LTD
Motive water pressure : 3~8 kg/cm2
Motive water quantity : 80 m3/hr
Suction lift : 0.5 m
Discharge head : 4.0 m
Material of ejector : polypropylene
PUMPS DATA SHEET
PUMP:
Tag No. : P-805 C
Service : Sulphuric Acid Unloading
Manufacturer : KSB
Driver type : Electric Motor
Capacity : 30 m3/h
Head at rated capacity : 30 m
Pump Speed : 2940rpm
MOTOR:
Tag : MP-805 C
Manufacturer : SIEMENS
Power : 11 KW
Voltage : 380 V AC

PUMPS DATA SHEET
PUMP:
Tag No. : P-806 A/B
Service : Dewatering Pit pump
Driver type : Electric Motor
Capacity : 200 m3/h
MOTOR:
Tag : MP-806 A/B
Manufacturer :
Power : 18.5 HP
Voltage : 380 V AC
FAN START UP PROCEDURE:

1. All maintenance jobs completed and work permits returned.
2. Check fan gear box oil level.
3. Gear box vibration switch is reset.
4. Ensure that fan motor breaker is on.
5. Put ON the fan after rotating motor shaft in clock wise direction and check its amperes.
6. Observe oil level and for any abnormal sound from fan after start up.
7. Open diffuser valves of both sides of cell.
Note: After Electrical job has been done on motor, Check motor rotation in discouple position.

SAND FILTERS, MV-800 A/B/C/D/E/F.
From feed pump
To Basin
Concrete work
Filtered water
Water to be filtered 200 M3 / hr.
Back Wash
Gravel (Silica Grit) 0.5 to 1.0 mm, 10 M3 or 15000 Kg

SAND FILTER DATA
Manufacturer Rossetti Italy

Capacity 200 m3/hr
Bed height 500 mm
Sand volume 10 m3
Sand weight 15000 Kg
Nozzles 1340
Sand size 0.5 mm
Nozzle opening < 0.23 mm
The sand filters are put in cooling water circuit to reduce suspended Particles in cooling water.
One part of the cooling water remains in filtration circuit. These are six filters, each of 200-m3/h
capacities. All sand filters operate in parallel. The back washing of the sand filters is automatic by
siphon and it dose not involve any instrumentation or manual operation. The system is provided
with such an arrangement that only one sand filter is back-washed at a time.
Each sand filter is filled with ten 10 cubic meter (15000 Kg) sand of 0.5 mm size.
1. STARTUP AND OPERATION OF FILTERS:
- Check that vacuum breaker valves (5 nos) are open.
- Check drain valve of the filter is close.
- Open water inlet valve the water level in the tank starts rising. After some time the filtered
water overflows into water outlet line.
- Check that the flow into the filter is 200 m3/hr. This is checked on the measuring stick near
overflow.
- Note: Same procedure for all filters.
2. BACK WASH OF FILTER:

The back washing of filters is automatic. These suspended matter in the water are retained
by the filtering sand. With the passage of time the deposits on sand increases. This increases
the resistance to flow through the sand bed. Consequently, the water level rises in feed line
and backwash outlet line. The water comes from the 3” dia drain line. By suction of air
through 1” line this promotes the siphoning action in the filter. The level of water rises more
in the backwash 30 Ø line and is drained through 10” Ø drain line.
The drainage rate of water is higher than the feed rate. A reverse flow in the filter starts
water goes down though risers & flow through nozzles intothe bed. This causes back
washing of the filter bed. The filters are so designed that sand from the filter dose not go out
into the drain and only light particles are drained.
As a result of back washing, the level in the filter decreases and vacuum breaks by I” Ø line
installed at top of 30” Ø line. The siphoning action stops and back washing in finished. Again
the level in the filter rises and normal operation starts.

3. SHUTDOWN OF A FILTER
If one of the filters is to put out of service, the following procedure should be adopted.
- Close the inlet valve.
- Close the inter link valves 05 nos.
- Open the drain valve.
Pumps MP-806 A and B are used to pump out water to canal or open evaporation pond.
NOTES:
All the filters are interconnected by vacuum system.
When one filter is on back-was, it is not possible to make vacuum in any of the other filters,
so at a time more than one filter cannot be backwashed.

EMERGENCY HANDLING
Cooling water high pH
1. At first, check the operating behavior of 08-PHIC-1V if it is O.K then flush the acid I/L line
to 08-PHIC-1V.
2. If 08-PHIC-1V is faulty then isolate it.
3. Take 08-PHIC-1V by pass in service and control the pH as per requirement.
4. Check Ej-102 is working properly.
5. If the pH is still not getting lower, take the acid dosing pump in service if not running.
6. Start chlorination of the system. This will help in lowering down pH.
7. If pH still high inform Co-ordination Engineer to check NH3 contamination due to
exchanger leakage or venting in atmosphere.
Cooling water low pH
1. Check the operating behavior of 08-PHIC-1V, if it is O.K then put it on manual in ‘WTCR’
& close it manually.
2. For further satisfaction, close I.V of 08-PHIC-1V.
3. Stop chlorination if in progress.
4. Open well water in C.W basin & decrease the make up through P-926 A/B.
5. Increase CBD & increase the flow to MV-800 A-F.
If still pH is decreasing then inform Co-ordination Engineer to check urea plant CO2 compressor
interstage coolers leakage
High Cooling Water Temperature:
1. Fan is stopped. Check and rectify the fan.
2. High humidity and high atmospheric temperature.
3. Improper water distribution at top basins. All hot basins must have same level of water.
Basin low level:

Causes
1. Malfunctioning of make up valve, 08-LC-1V
2. Heavy leakage of cooling water.
3. Malfunctioning of BMR cooling tower inter connecting valves.
Actions:
1. Inform shift Engineer/Boardman.
2. Open MOV 08-HS-1V.
3. Take both MP-926A /B in service with full discharge valve opening.
4. Confirm full opening of 08-LIC-1V.
5. Open motorized valve.
6. Open well water to E-800.
7. Close CBD and isolate side stream filters.
8. If the cause of low level was malfunctioning of BMR cooling tower interconnecting valves
then inform to 01 area shift Engineer/Co-ordination Engineer through shift engineer
utility and take steps 1 to 5.

Basin high level:
Causes
1. Malfunctioning of make up valve, 08-LC-1V
2. Malfunctioning of motorized make up valve, 08-HS-1V.
3. Malfunctioning of BMR cooling tower inter connecting valves.
Actions:
1. Inform shift Engineer/Boardman.
2. Check the operating or controlling behavior of 08- LC-1Vand motorized valve, 08-HS-1V. If
abnormal,
3. Isolate the make up water supply to cooling water basin locally or from 09 area, P-
926A/B.
4. Isolate well water make up supply if it is being done.
5. Increase CBD as per conditions.
6. Manually back wash the filters MV-800 A-F.
7. Rectify problem and normalize the level.
8. Control C.W quality and adjust chemical dosing as per standard procedures.
9. If the cause of high level was malfunctioning of BMR cooling tower interconnecting valves
then inform to 01 area shift Engineer/Co-ordination Engineer through shift engineer and
take steps 1 to 7.

COOLING WATER TREATMENT
Water caused corrosion, deposition, and microbiological growth can reduce operating
efficiency and increase plant maintenance costs. An effective, well designed water treatment
program can reduce many of the problems incurred. So the purpose of cooling water treatment is,
1) Corrosion control
2) Microbiological control
3) Scale/deposit control
1 CORROSION
Corrosion is an electrochemical process in which a difference in electrical potential develops
between two metals or between different parts of a single metal. This voltage can be measured
when a metal is electrically connected to a standard electrode. The electrical potential of a metal
may be more or less than the standard, in which case the voltage is expressed as either ”positive”
or “negative”. This difference in potential allows current to pass through the metal causing
reactions at anodic and cathodic sites. These sites constitute the corrosion cell as shown in below:
Reduction of ions Metal ions e.g. Fe ++

or oxygen
Ionic migration
Cathode Anode
Electron migration
Simple corrosion cell
The anode is the region of lower potential. Conversely, the cathode is the region of higher
potential. At the anode, metal ions go into solution. In general, the lower the potential of the
anode, the greater the amount of metal dissolution would be and more serious the corrosion
problem. The extent of corrosion is also a function of the capability of ions and electrons to travel
through the water phase and participate in chemical reactions. Water having high dissolved
solids is more conductive and cause more severs corrosion problems. Thus seawaters are
generally more corrosive than surface supplies. Any metal immersed in water will soon develop a
measurable potential, those of lower potential can be expected to corrode more easily and
extensively than those of higher potential. Theoretically we can assume that if two metals are
coupled, the one with lower potential will become the anode and actively corrode.

2. CORROSION CONTROL
2.1 CATHODIC POLARIZATION

Process of changing the anodic or cathodic potential or both to reduce the driving force of
the corrosion reaction is called “polarization”. Polarization reduces the driving force of the
corrosion reaction and minimizes metal loss by changing the potential of either the anode or
the cathode or both so that the difference in potential between them is reduced to a
minimum.
2.2. ANODIC POLARIZATION
Anodic surfaces can be polarized by formation of an oxide layer. This film formation is
accomplished by a mechanism known as chemisorption. Stainless steel naturally forms such
films. This unfortunately is not always the case with all metals. Most metals must be aided
by the addition of such anodic corrosion inhibitors as chromate, nitrite, etc.
2.3 PASSIVITY
When corrosion reactions are completely polarized, the metal is said to be at “passive state”
At this point there is no difference in potential between the anode and cathode areas, and
corrosion ceases. When polarization is disrupted in a passive metal at a given point, a very
active anodic site is set up, with resultant accelerated local corrosion, particularly if the
metal was strongly anodically polarized.
2.4 CORROSION INHIBTORS
The principal method of controlling corrosion in cooling water system is by means of
chemical corrosion inhibitors. Their function in preventing corrosion lies in their ability to
insulate the electric current between the cathode and anode. If the insulation effect occurs
at the anodic site, then the inhibitor is classified as an anodic inhibitor and if the cathodic
site is insulated then the inhibitor is classified as a cathodic inhibitor.
Corrosion inhibitors are classified as anodic, cathodic or both depending upon the corrosion
reaction each controls. Inhibition usually results from one or more of three general
mechanisms.
2.4.1 Anodic inhibitors:
Build a thin protective film along the anode increasing the potential at the anode and
slowing the corrosion reaction, the film is initiated at the anode although it may
eventually cover the entire metal surface. Because this film is not visible to the naked
eye so the appearance of the metal will be left unchanged.
2.4.2 Cathodic inhibitors:
These are generally less effective than the anodic type. But they often form a visible
film along the cathode surface, which polarizes the metal by restricting the access of
dissolved oxygen to the metal substrate. The film also acts to block hydrogen evolution
sites and prevent the resultant depolarizing effect.

2.5 INHIBITOR SELECTION
It is often difficult to make a proper choice between the many cooling water corrosion
inhibitors unless there is some understanding of their properties. Choice of the proper
inhibitor is determined by the cooling system design parameters and water composition,
the type of metals in the system, stress conditions, cleanliness and design water velocity all
effect inhibitor selection. In addition, other factors to be considered include treatment level
required, PH, dissolved oxygen content, and salt and suspended matter composition.
2.5.1 CHROMATES
The single most effective inhibitor available today is probably the chromate or
dichromate molecule. This anodic inhibitor forms a highly passive film of “ferric and
chromic oxides, similar in composition to that naturally found on stainless steel
at the anode surface”. Protection For example a zinc-chromate formulation used at
40~50 ppm in a cooling tower system, gives better protection than 200 ppm or more
of chromate alone.
2.5.2 ZINC
Salts of the zinc are the most commonly used cathodic inhibitors in cooling water
systems. They rapidly form a film on the metal surface. Zinc operates as a corrosion
inhibitor by rapidly forming a film of zinc hydroxide and zinc carbonate at the mild
steel cathodic site. This film serves as a barrier to oxygen, thus effectively suppressing
the corrosion reaction.
2.5.3 PHOSPHATES
Poly phosphate and ortho phosphate forms of phosphate act as corrosion inhibitors. A
minimum flow rate of 3 ft/sec is generally required when phosphate is present in
cooling water.
2.5.4 POLYPHOSPHATE
Is a cathodic inhibitor, which forms a durable polarizing film on the cathodic surface of
most metals by an electro-deposition mechanism? The molecule adsorbs or bonds with
calcium ions to form a colloidal particle. These positively charged particles migrate to
the cathode and form a film, which suppress the cathode reaction. Polyphosphates are
most often used in combination with Chromates or Zinc.
2.5.5 ORTHO-PHOSPHATE
Ortho phosphate is an anodic site corrosion inhibitor by forming a complex with
calcium and then forming a barrier film of iron phosphate, which promotes a gamma
iron oxide layer that is passive. Other corrosion inhibitors are Nitrites, Nitrates,
Silicates, Benzoates, Lime, Molybdates and synergistic blends etc
2.5.6 SYNERGISTIC BLENDS
Use of only one corrosion inhibitor in a cooling water system is rare. Usually two or
more inhibitors are blended to utilize the advantages of each and to minimize their
respective limitations.

3 MICROBIOLOGICAL CONTROL
Microorganisms are found every where in nature. They are distributed in air water and soil
and play a number of vital roles in the health of man and animal. Some microorganisms are
beneficial while others called pathogens, cause diseases such as typhoid fever, cholera or
hepatitis. Microbial life affects many industrial processes. The nature of the particular
microorganism and industrial process will determine whether the relationship is beneficial
or destructive.
3.1 COOLING WATER MICROORGANISMS
3.1.1 ALGAE
Algae growth usually occurs in sections of the cooling tower exposed to sunlight.
Algae’s are unicellular very uniform in structure and very identical to each other.
There life cycle is only 14 to 16 days. Dead algae provide food to other bacteria and
algae. They produce slime, which is the source of production of more micro-organisms.
There are three basic requirements for algal growth; air water and sunlight.
Elimination of any one of these three factors will hamper growth. The distribution
decks and sidewalls of a cooling tower provide all three requirements and therefore
represent an excellent growth environment for algae. For this reason algae are all too
often seen floating as free green masses on the top deck or attached to the cooling
tower structure itself. All algae produce oxygen, which can depolarize the corrosion
reaction and accelerate system destruction.
3.1.2 FUNGI
Fungi include all simple plants not containing chlorophyll. More advanced forms are
yeast and moulds, with the highest form including mushrooms. Advanced forms of
fungi require moisture for growth but they do not usually grow under water because
they also require atmospheric oxygen. In industrial water systems therefore fungal
growths are generally encountered the water line.
3.1.3 BACTERIA
The smallest, yet most prolific and troublesome forms of life in cooling water systems
are bacteria. Bacteria multiply at an awesome rate by cell division. Under ideal
conditions and with division occurring as often as once an hour, descendants from a
single bacterium would number 281500,000,000 bacteria with in two days. In three
days the weight of this progeny would amount to 7000 tons.
Such phenomenal growth does not actually occur because the supply of food and
nutrients becomes depleted. Microorganisms can be chocked to death by the products
of their own metabolism or by the products of other microbes living in close proximity.
However sufficient bacterial growth can and does occur to create real problems in
cooling systems. Bacterial life forms can survive in a variety of environments. Some
need air called aerobic bacteria, other prosper without it. They will grow in any water
system containing organic matter. Some will oxidize sulphur or use iron for their
growth Thus they are called sulphate reducing bacteria. Bacteria may develop
resistance to treatment used to control or kill them. So bacteria control is difficult
because agents toxic to one species may have a little effect on another. Bacteria derive
energy from the oxidation of inorganic materials.
3.2 PROBLEM CAUSED BY MICROBIAL ACTIVITY

Continued accumulation and growth of microorganisms in a cooling water system causes a
number of problems. Good corrosion and deposit control programs are incumbent upon a
successful microbial control program. A plant unable to control microbial growth will
experience increased difficulty in controlling corrosion and deposition. Another problem
associated with microbial growth is the deterioration of cooling tower lumber this reduces
the efficiency of the cooling tower operation and increases operating cost of the plant.
Microbiological growth also causes environmental pollution.
3.3 CORROSION PROBLEMS DUE TO MICROBIOLOGICAL GROWTH
Any corrosion initiated or propagated by the action of microorganisms either directly or
indirectly is called MIC. Sulfate reducing bacteria produce extremely dangerous hydrogen
sulfide gas, which corrodes metals by low PH attack and by the formation of ferrous sulfide.
Sulfate oxidizing bacteria

Produce sulfuric acid and produce localized low PH areas in the system. Corrosion proceeds
very rapidly in these low PH areas. Nitrifying bacteria nullify the effectiveness of nitrite
corrosion inhibitors by oxidizing nitrite to nitrate. This is the most serious in closed
recirculating systems which commonly use nitrite as a corrosion inhibitor in the systems
where NH3 is present in water.
3.3.1 DEPOSIT PROBLEMS
Deposit of microbial matter may lead to physical problems in the system, culminating
in loss of efficiency, heat transfer and production. The accumulation of biomatter on
the internal sections of cooling towers can seriously reduce the unit’s efficiency
3.3.2 WOOD DETERIORATION
Cooling tower wood can be attacked in several ways falling into three basic categories;
biological, chemical and physical first two causes of deterioration are linked to
microorganisms. Other problems may include the environmental effects of toxic micro
biocides used to control microbiological growth.
3.4 MICRO BIOCIDES THEORY OF ACTIVITY
Micribiocides inhibit microorganisms in a variety of ways. Some alter the permeability of
the cell walls, thereby interfacing with the vital life processes of the microbe. Heavy metals
penetrate the cell wall and enter the cytoplasm, destroying protein groups essential for life.
Surfactants damage the cell by reducing its permeability disrupting the normal flow of
nutrients into the cell and the discharge of its wastes; this deneutralizes the protein causing
the organism to die.
Oxidizing chemicals irreversibly oxidize protein groups, resulting in a loss of normal
enzyme activity, and subsequently the rapid death of the cell.
Micro biocides are divided into three categories
3.4.1 METABOLIC POISONS (BULAB-6057 etc)
They are slower acting biocides require at least 6 hours contact time,
 Act more rapidly against active cells,
 Rapid degradation by plants, sunlight, etc.
 Effective against wide variety of microbes,
 High human toxicity.
3.4.2 SURFACE ACTIVE AGENTS (BULAB-6011 etc)
They are medium/fast acting biocides require 2~4 hours contact time, they rupture
the cell’ walls and are;
 Effective over a broad PH range
 Effective against bacteria, and algae.
 Most frequently used in alkaline systems
 Low human toxicity
 Rapid degradation
3.4.3 OXIDIZING AGENTS (CHLORINE, BROMINE, OZONE, ClO2)
Oxidizing biocides oxidize cell components such as:
 The organisms cell walls
 Components of the cell’s protoplasm
 Cellular enzymes
3.5 CHOICE OF MICRO BIOCIDES
A number of factors will determine the proper choice of micro biocide or combination of
micro biocides, oxidizing and non-oxidizing micro biocide. The selection of a micro biocide
involves several factors. The operating parameters of the cooling water system will affect
the choice of a micro biocide. Temperature, PH and system design are fundamental
considerations in a decision involving oxidizing or non oxidizing toxicants.
3.6 OXIDIZING TOXICANTS
3.6.1 CHLORINATION
The most commonly used oxidizing micro biocide is Chlorine. It is the most effective of all
halogens. Chlorine is an excellent algaecide and sporicide. It is also an excellent bactericide
in most circumstances. Free residual chlorine at levels of 0.5 ppm and slightly above are
usually enough to control most microbial growth. A number of factors determine the
amount of chlorine required in an open cooling water system. These include chlorine
demand, contact time, pH, and temperature of the water.
When chlorine gas is fed to water, it hydrolyzes to form two acids, hypochlorous acid
(biocide) and hydrochloric acid, respectively.
Cl2 + H2O  HOCl + HCl
Hypochlorous acid is very weak acid but an extremely powerful oxidizing agent. It easily
diffuses through the cell walls of microorganisms, and reacts with the cytoplasm to produce
chemically stable nitrogen chlorine bonds with the cell proteins.

Some quantity of Hypochlorous acid will ionize into hypochlorite ions according to this
reversible reaction.
HOCl H+ + OCl-
The PH of the cooling water is directly responsible for the extent of ionization of
hypochlorous acid. The acid state is favored by low pH .At pH 7.5 there will be
approximately equal amounts of acid and hypochlorite ion. Chlorine becomes ineffective as
a micro biocide at pH 9.5 or greater as a result of total ionization. A, pH range of 6.5~7 is
considered practical for chlorine based microbial control programme. Hypochlorous acid is
estimated to be twenty times more reactive (effective) as a micro biocide than the
hypochlorite ions.
If ammonia is present in cooling water then chlorine reacts with ammonia to form
chloramines (NH2Cl etc) due to which there is a decrease in the residual chlorine with in the
system. Chloramines are poor biocides and are more harmful environmentally than chlorine
itself due to very long half life.
Because the amount of chlorine added to the system is directly proportional to the alkalinity
reduction. Many plants find it necessary to suspend acid feed during chlorination periods in
order to avoid low pH excursions. Chlorine is destroyed by sunlight and by aeration so, its
dosing is preferred at night to prolong its effect.
Note that
 Every kg of chlorine gas fed will generate 0.74 kg of HOCL and 0.51 kg of HCL.
 0.72 ppm of HCL will reduce 1 ppm of M-alkalinity.
 1 ppm chlorine will reduce 1.12 ppm M-alkalinity.
Other oxidizing biocides include ozone, chlorine dioxide and hypo chlorites.
Hypochlorites are salts of hypochlorous acid. They are composed of sodium hypochlorite
(NaOCl) and calcium hypochlorite (Ca (OCl) 2) when they are added to cooling water system
function in much the same way as chlorine gas.
Chlorine dioxide is a gas produced at site from sodium chlorite with chlorine gas. It does
not form hypochlorous acid in water like chlorine it exists as dissolved chlorine dioxide in
solution and is generally less reactive as a micro biocide but more effective than chlorine at
higher pH ranges.
Ozone is a powerful and naturally unstable gas. As a micro biocide it reacts in much the
same manner as the other oxidizers” by combining with protein and inactivating enzymes
that are essential to cell respiration”.
3.6.2 BROMINATION
For systems, operating at above 7.0 pH i.e. alkaline media like Phosphate treatment system,
bromine is more efficient than chlorine as a biocide. Because 50 % of hypochlorous acid,
HOCl (biocide) formed due to chlorination, ionize into hypochlorite ions (OCl -) at pH 7.5.
Hypochlorite ions as a biocide are twenty times less effective than HOCl. At pH 8.0,
Chlorination will yield only 20 % HOCl & 80 % OCl ions. But at this pH bromination will
yield 80 % HOBr (micro biocide) & 20 % OBr ions-. That is why at alkaline pH bromination
is more effective than chlorination in the control of microbiological growth. At pH (8~9.3),
only a small percentage of chlorine is available as the active toxicant, hypochlorous acid.
Target bromination is one of the most effective oxidizing biocide treatments for cooling
water systems. This is achieved by feeding sodium bromide with a chlorine- based oxidant
in a 1:1 molar ratio to achieve bromination.
Bulab-6040 used at FFC for bromination is a sodium bromide salt. It has no oxidizing
capability until it is activated by reacting it with hypochlorous acid to yield hypobromous
acid. Hypochlorous acid is generated through addition of sodium hypochlorite or chlorine in
water as,
Cl 2+ H2 O  HOCl + HCl
NaOCl l (bleach) + H2O  HOCl + NaOH
This HOCl reacts with NaBr as,
HOCl + NaBr (bulab-6040) → HOBr + NaCl
In the presence of NH3 bromamines are formed which are more effective than chloramines
in the control of bacteria. Also bromamines breakdown more quickly than chloramines in
the environment and has lower long- term environmental toxicity.
3.7 NON OXIDIZING BIOCIDES
Non-oxidizing biocides can be more effective than oxidizing biocide because of their overall
control of algae, fungi, and bacteria. They have also greater persistence, as many of them are
PH independent. They are used in conjunction with oxidizing micro biocides for broad
control. Most of plants chlorinate intermittently and add a non -oxidizer once or twice a
week or as per requirement. Their mode of activity is to inhibit cell growth by preventing
the transfer of energy or life sustaining chemical reactions occurring within the cell.
Organic sulfur compounds include a wide variety of different biocides, Methylene
bisthiocynate` (MTB) is most common, which is effective in controlling algae, Fungi and
bacteria.
Isothiazoline is a relatively new sulfur containing biocide. It is very effective in controlling
both algae and bacteria. Bulab-6057, Biocide used at FFC is also a combination of two
isothiazoline derivatives that can provide broad spectrum micro-organism control in
cooling water applications.
3.8 OXIDATION REDUCTION POTENTIAL (ORP)

ORP is not a word; it is a set of initials, like PIA, FFC. ORP stands for Oxidation-Reduction
Potential. In practical terms, “it is a measurement to oxidize contaminants”. In some
parts of the world, Oxidation-Reduction Potential is also known as Redox Potential. “It is
the potential (voltage) at which oxidation occurs at the anode and reduction occurs at
the cathode of an electrochemical cell”.
We can see examples of oxidation all the time in our daily lives. They occur at different
speeds. When we see a piece of iron rusting, or a slice of apple turning brown, we are
looking at examples of relatively slow oxidation. When we look at a fire, we are witnessing
an example of rapid oxidation. We know that oxidation involves an exchange of electrons
between two atoms. The atom that loses an electron in the process is said to be "oxidized."
The one that gains an electron is said to be "reduced." In picking up that extra electron, it
loses the electrical energy that makes it "hungry" for more electrons.
We also know that matter can be changed, but not destroyed. We can alter its structure, and
can increase or decrease the amount of energy it contains but we can't eliminate the basis
building blocks that make things what they are.
“Chemicals like chlorine, bromine, and ozone are all oxidizers. It is their ability to
oxidize i.e., to "steal" electrons from other substances that makes them good water
sanitizers (disinfectant), because they kill and “burn up” unwanted plants and animals
(microorganism), by altering their chemical makeup leaving a few harmless chemicals
as the by-product. In simple an oxidizing chemical pulls electrons away from the cell
membrane, causing it to become destabilized and leaky. Destroying the integrity of cell
membrane leads to rapid death of the microorganism
Oxidizers area of Activity

Typical Cell _ _ _
Cell Membranes
_ _ _ _ _
_ _ _
_ Cytoplasm _
_ _
_
Nucleus _
_
_
_
_ _
_ _ _
_ _ _ _
_ _ _
Of course, in the process of oxidizing, all of these oxidizers are reduced so they lose their
ability to further oxidize things. They may combine with other substances in the water or
their electrical charge may simply be "used up." To make sure that the chemical process
continues to the very end, you must have a high enough concentration of oxidizer in the
water to do the whole job.
But how much is "enough?" That's where the term potential comes into play.
"Potential" is a word that refers to ability rather than action. Potential energy is energy that
is stored and ready to be put to work. It's not actually working, but we know that the energy
is there if and when we need it. Another word for potential might be pressure. Blow up a
balloon, and there is air pressure inside. As long as we keep the end tightly closed, the
pressure remains as potential energy. Release the end, and the air inside rushes out,
changing from potential (possible) energy to kinetic (in motion) energy.
In electrical terms, potential energy is measured in volts. Actual energy (current flow)
is measured in amps. When we put a voltmeter across the leads of a battery, the reading
we get is the difference in electrical pressure “the potential between the two poles”. This
pressure represents the excess electrons present at one pole of the battery (caused, by a
chemical reaction within the battery) ready to flow to the opposite pole.
“When we use the term potential in describing ORP, we are actually talking about
electrical potential or voltage. We are reading the very tiny voltage generated when a
metal is placed in water in the presence of oxidizing and reducing agents. These
voltages give us an indication of the ability of the oxidizers in the water to keep water
free from contaminants (microorganism)”.
We can say that continuous measurement of ORP values provides a trend that can be related
to the oxidant residual in the water system because ORP is a measure of the ‘Oxidizing
potential” or “Reducing potential” of the water in mill volts.
Most well waters posses an “Oxidizing potential” that relates to an ORP reading in the range
of 100 to 150 mV. When an oxidant like Sodium hypochlorite is added to a water system the
ORP increases with the increase in dosage There is direct correlation between oxidant
residual, “oxidizing potential” of the water and the ORP mV. Likewise when a de-
chlorinating agent like Sodium bisulfate ( reducing agent) is added to the water the ORP
reading will drop back down to a low mV level. Research has shown that an ORP value of
650 to 700 mV is enough to kill the bacteria within 30 seconds.
ORP MEASUREMENT:
When a metal is immersed in a solution, electric potential is detected according to that
solution. This electric potential represents the oxidation or reduction force of the solution.
This force (potential difference) is called the oxidation-reduction potential (ORP) of the
solution, from which the oxidation or reduction ability of the solution can be obtained.
To measure the ORP, noble metals such as platinum and gold are used. Since the potential
difference cannot be detected by using a metal electrode, a reference electrode is used in
combination with the metal electrode.
An ORP probe is really a mili volt meter, measuring the voltage across a circuit
formed by a reference electrode constructed of silver wire (in effect, the negative pole
of the circuit), and a measuring electrode constructed of a platinum band (the
positive pole), with the pool water in between.
The reference electrode, usually made of silver, is surrounded by salt (electrolyte) solution
that produces another tiny voltage. But the voltage produced by the reference electrode is
constant and stable, so it forms a reference against which the voltage generated by the
platinum measuring electrode and the oxidizers in the water may be compared. The
difference in voltage between the two electrodes is what is actually measured by the meter.
Modern ORP electrodes are almost always combination electrodes that are both electrodes
are housed in one body, so it appears that it is just one "probe."
WHAT DOES AN ORP METER TELLS US:
Let see how changes in the oxidizer level in the water will effect the measurement.
Oxidizing agents are the "good guys" in the water; reducing agents are contaminants and
therefore are the "bad guys."
If we have water in which the concentration of oxidizers exactly equaled the concentration
of reducers, then the amount of potential generated at the measuring electrode would be
exactly zero. As we add oxidizer to the water, it "steals" electrons from the surface of the
platinum measuring electrode. Electrons are negatively charged particles. When we remove
these negatively charged things from this electrode, the electrode becomes more and more
positively charged. As we continue to add oxidizer to the water, the electrode generates a
higher and higher positive voltage.
EFFECT OF pH ON ORP:
Sanitizer effectiveness can vary significantly with changes in pH particularly in regards to
chlorine, which is the most commonly used chemical as a biocide.
When chlorine gas is fed to water, it hydrolyzes to form two acids, Hypochlorous acid
(biocide) and hydrochloric acid, respectively.
Cl2 + H2O  HOCl + HCl
We know that the killing form of chlorine is Hypochlorous acid (HOCI), which, is very week
acid but an extremely powerful oxidizer. Some quantity of Hypochlorous acid will ionize
into hypochlorite ions according to this reversible reaction.
HOCl H+ + OCl-
Hypochlorous acid is estimated to be twenty times more reactive (effective) as a micro
biocide than the hypochlorite ions. The percentage of Hypochlorous acid depends directly
on the pH, because the pH of the water is directly responsible for extent of ionization of
Hypochlorous acid. The acid state is favored by low pH as we can see from the above
equation that H+, the chemical symbol for acid plays an important role in determining the
nature of Chlorine in the water. If the pH of water is below 7 (acidic) the H + concentration
will be high. This will cause H +and OCL- to combine, to form more HOCl (the biocide).
Conversely if the pH of the water is above 7 (alkaline or basic), the H + concentration will be
low. This will cause the HOCl in the water to dissociate into H+ and OCL- the non biocidal
form of chlorine.
Three to five ppm free chlorine will provide more than adequate microbial control for free
floating bacteria in a very short contact time. This water quality will likely result in
measurements of 650 to 700 mV ORP, if the water pH is 6.5 to 7.0. Lowering the pH to 6.0
will raise the ORP as more Hypochlorous acid becomes available (because at a pH of 6.0,
96.5 percent of the free available Chlorine in the water is in the form of HOCI). Raising the
pH to 8.5 will lower the ORP value as more hypochlorite ions are present (because at a pH of
8.5; only 10 percent of the free available Chlorine in the water is in the form of HOCI). It is to
be noted that an ORP value of 700 mV at a pH 6.5 has the same killing potential as an ORP
value of 700 mV at pH 8.5 but it would require a much higher dose of chlorine due to
conversion of HOCl into OCL- at this pH.
Although ORP does not specifically tell you the chlorine concentration in parts per million
but it indicates the effectiveness of the chlorine as an oxidizer. ORP values accurately define
the antimicrobial potential of the water for free floating microbes. Conventional systems of
measuring parts per million using titration kits or paper test strips can give the same
information but it must be combined with a measurement of water pH and correlated with a
table of Hypochlorous acid availability.

An ORP reading will vary as pH fluctuates. As the pH goes up, the mili volt reading on an
ORP meter will go down, indicating that the sanitizer is not as effective. Bringing the pH
down or adding more sanitizer will raise the mill volt reading.
That is why most ORP instruments also incorporate an electronic pH meter which measures
the difference in electrical potential between the pool water and a sample of known pH that
is contained in the probe in a small glass bulb. At FFC-3 we are using bromonation instead of
chlorination as antimicrobial because it is more efficient than chlorine as a biocide in
alkaline media. At pH 8.0, Chlorination will yield only 20 % HOCl & 80 % OCl ions. But at this
pH bromination will yield 80 % HOBr (micro biocide) & 20 % OBr ions so effect of pH on
ORP is minor as compared to chlorination.
ADVANTAGES OF ORP SYSTEM:
It is the only practical method to electronically monitor sanitizer (disinfectant)
effectiveness.
ORP sensors allow us to electronically monitor and control sanitizer residual automatically.
ORP monitoring system provides the operator, with a rapid and single value assessment of
the disinfection potential of water.
The operator is able to asses the activity of the applied disinfectant rather than the applied
dose.
DISADVANTAGES OF ORP SYSTEM:
The potential disadvantages of ORP based systems are largely operational issues related to
equipment maintenance, calibration and cross checking of fixed position sensors.
Always have a back up system of calibrated hand held ORP probes and standard ppm kits
when using ORP based system.
Sensors become fouled and need periodic cleaning and calibration.
ORP probes may become temporarily saturated by over injection of disinfection and it can
take several minutes or longer for a sensor to come back to equilibrium with the
surrounding water which can limit the response time.
ORP relationships are not uniform for all oxidizing disinfectants.
ORP is not a practical method for monitoring the anti microbial potential of water treated
with hydrogen peroxide or peroxyacetic acid.
A combination of ORP and chemical indicator monitoring for ozone concentration is
necessary to ensure proper water disinfection.
It is observed at FFC-3, that ORP meter becomes out of order in the presence of hydrogen in
the water due to leakage of synthesis gas cooler at ammonia plant.

4 DEPOSIT CONTROL
A cooling water system is subject to a number of different deposits from a variety of sources.
These deposits typically consist of mineral scales (i.e.CaCO3. CaSO4, Ca3(PO4)2, CaF2, etc),
corrosion products (i.e. Fe2O3, Fe3O4, CuO etc), particular matter (i.e. clay, slit), and
microbiological mass. An effective cooling water treatment program must control scale,
Particulate matter, corrosion, and biological growth because, a poor deposit control
programme may result in sever operating problems and considerable operating and capital
expense to a plant.
4.1 TYPES OF DEPOSITS
4.1.1 WATERBORNE SALTS
Precipitated salts of calcium and magnesium often form dense scales and sludge’s which are
usually quite adherent and therefore difficult to remove. In addition they are effective heat
insulators, which reduce process efficiency. Calcium carbonate, calcium sulphate, calcium
and magnesium silicates and calcium phosphate are some of the more prevalent compounds
found in cooling water systems.
Calcium Carbonate
Calcium carbonate is probably the most commonly recognized type of scale found in cooling
water systems. It forms an extremely tenacious deposit.
Calcium and bicarbonate alkalinity are found in almost all cooling waters. The addition of
heat or sharp rise in pH will cause calcium bicarbonate to decompose and form carbon
dioxide and calcium carbonate.
Ca(HCO3)2  CaCO3 + CO2 +H2O
Although the bicarbonate salt is moderately soluble, the carbonate salt has very low
solubility. Deposition of calcium carbonate is found along heat transfer surfaces where
cooling water is subjected to the most heat. The precipitation of calcium carbonate from the
water phase often results in the entrainment of suspended matter into the scale layer. This
creates a deposit of large volume although one, which may be less dense.
Calcium Sulphates
Various forms of calcium sulphate scale are found in cooling water systems. The most
important is Gypsum, which contains two waters of hydration. The solubility of gypsum
increases until the temperature reaches approximately 100 oF and then gradually decreases.
Silicate scales
Calcium and magnesium silicate scales are very difficult to remove by chemical means.
Silicate scales can be prevented by limiting silica in the circulating water. If magnesium is
present with sufficiently high concentrations of silica, magnesium silicate forms.
Silica
Pure silica scales are not often found in cooling water systems. However, once formed, they
are extremely difficult to remove.

Calcium Orthophosphate
The solubility product of calcium and orthophosphate is very low. As a result if
orthophosphate is present in the water phase, it can react with calcium to form mono
hydrogen, dihydrogen and tricalcium phosphate.
Magnesium salts
The concentration of magnesium salts in a system is considerably lower than that of
calcium. In addition magnesium salts are usually more soluble than those of calcium, with
the result that calcium will precipitate first. This combination of factors results in reduced
scaling potential.
Iron salts
Soluble iron is present in many make up water supplies, especially in well water. In cooling
water it quickly oxidizes and deposit as a ferric hydroxide or ferric oxide floc. Iron corrosion
products are probably the single largest cause of deposit problems in cooling water systems.
4.1.2 WATERBORNE FOULANTS

A variety of such materials as suspended mud, sand, silt, clay, biological matter or even oil
may enter a cooling water system through its make up supply. They usually accumulate in
low flow areas, or in locations at which an abrupt change in flow velocity occurs. Therefore
the most sedimentation is found in such places as cooling tower basins and heat exchangers.
To control sedimentation it is necessary to control the suspended particulate matter. The
control of particle size and density is accomplished by use of modern deposit control
materials.
4.1.3 AIRBORNE FOULANTS
The air in contact with open cooling water systems contains many of the same suspended
materials found in the make up water. Sand, slit, clay, dirt, bacteria etc. entering with the air
add to the overall fouling of the system. Airborne contamination by gases also helps in
deposition.
4.1.4 SYSTEM RELATED DEPOSITS
Deposits formed by corrosion of elements in the system’s construction materials can quickly
plug distribution lines or exchanger tubes. Their presence leads to added corrosion and
fouling. Iron oxide is most prevalent of deposit found in cooling water systems. Process
contamination by oil, certain gases, organic material or any material, which reacts with
chemicals in the water phase, all may lead to deposition. Organic materials may be nutrients
for microbes and often reduce oxidizing corrosion inhibitors. This is particularly common in
refinery and petrochemical plants in which hydrocarbon contamination is possible.

5 DEPOSIT CONTROL METHODS
a) Conventional treatments
Softening (sodium or hydrogen zeolite exchange, lime softening and demineralization all
remove the ions that cause scale formation)
Acid feed (acid neutralizes alkalinity in the water, thereby preventing carbonate
formation)
Side stream filtration (Side stream filters are used in some cooling tower applications,
with 1 to 5 % of the cooling water flow passing through the filter.
b) Use of Polymeric Deposit Control Agents
A polymer is defined as macromolecule consisting of a number of repeating units of
“building blocks”. These units are referred to as monomers. Modern technology has made it
possible to build chains of various lengths and compositions by varying the polymerization
conditions and the monomer groups incorporated into the structure.
These polymeric deposit control agents include, Scale inhibitors, Dispersants, Flocculants
5.1 Scale Inhibitors
Scale inhibitors are important to the performance of many treatment programs. Scale
inhibitors function by adsorbing on to suspended solids/scaling particles and adsorbing on
to solids/ surfaces in the system, thereby acting to prevent growth of scale/deposits and
enhancing performance of corrosion inhibitors.
These polymers have the ability of adsorbing on active sites of the crystal to prevent any
further growth of crystal. Some of the functional groups of the scale inhibitor adsorbed on
the crystals but the rest of them are free from the adsorption and give electrical charge to
the crystals. Thus, the static electrical repelling force of the crystals is increased and the
crystals are kept in a dispersed condition.
Certain polymers can distort scale crystals by disrupting their lattice structure and normal
growth patterns. The inclusion of a relatively large irregularly shaped polymer in the scale
lattice tends to prevent the deposition of a dense uniformly structured crystalline mass on
the metal surface. These crystals can develop internal stresses which increase as the crystal
grows, with the result that deposit breaks away from the metal surface. Anionic polymers
such as polyacrylates, polymethacrylates and maleic anhydride derivatives are excellent
scale control agents. Also polyphosphate, phosphate esters and phosphonates can control
scale.
5.2 Dispersants
“The principal role of a dispersant is to reduce the tendency for small particles to
agglomerate”.
Dispersants are polymers, which control particles by increasing charge on the particle
surface, thereby keeping the particles repelled and suspended. A polymer can be adsorbed
on foulant surface imparting a like charge to them and thereby causing the particles to
remain in suspension because of charge repulsion.
Dispersant polymer is a common component of cooling water treatment programs. These
polymers prevent deposit because they keep suspended particles from adhering to pipes,

tubes, or other surfaces in the cooling systems and are removed with the water by blow
down.
5.3 Flocculants
A high molecular weight polymer can attach itself to many foulant particles creating a low
density floc. With an increase in the overall size of suspended material, there is a
corresponding decrease in the surface area available for attachment, which reduces the
extent of deposition possible.
Much of suspended matter found in cooling water has a negative surface charge. This charge
keeps the suspended matter separated. If the surface charge of the particles can be reduced,
the particle will agglomerate into light, fluffy flocs with little tendency to adhere to metal
surfaces. This can be accomplished by adding a long chain oppositely charged (cationic)
polymer to the cooling water, which neutralizes the negative charge of the suspended
material.
6. ZINC-CHROMATE/ ZINC-PHOSPHATE TREATMENT
At FFC-III Switch over of cooling water treatment from Zn-Chromate to Zn-Phosphate took
place in October, 2004 at 01 area and in 08 area in December 2004.
Phosphate based programs are the most common non-chromate type treatments. Phosphate
based treatment provides superior corrosion protection equal to that of chromate, if
properly applied. Polyphosphate and Ortho-phosphate forms of phosphate act as corrosion
inhibitors. Ortho-phosphate is an anodic corrosion inhibitor and act like chromate to
promote the formation of a passive gamma iron oxide (Fe2O3) film on the metal surface.
Additionally phosphate based corrosion treatment programs operate better in alkaline

conditions; unlike chromate based programs that operate better in neutral to slightly acidic
conditions. Alkaline conditions create higher scaling potential for carbonate, sulfate,
phosphate and silicate compounds; which will cause reduced heat exchange surfaces. Under
deposit corrosion mechanism is also more of a concern with phosphate based treatment
than with chromate based treatment. Also this program does not provide protection against
micrflora problem and corrosion related with the bacteria growth. In the presence of
ammonia in cooling water, the microbiological control become a very serious issue as this
provide sufficient nutrients for a large burst of nitrifying bacteria which convert ammonia
into nitrite and nitrate. Thus the pH of cooling water dips very rapidly and become <6.6 in
cooling water.
Chromate based treatment programs offer excellent microbiological control by them, as
chromate is a very toxic material. Phosphate based treatment programs do not offer any
microbiological control. In fact phosphates encourage microbiological growth in cooling
systems, as phosphate is an essential nutrient for microbiological organism, including algae.
Chromate operates primarily as an anodic corrosion inhibitor by forming a very passive
film of ferric and chromic oxides at anodic sites on mild steel. To a less degree chromate

will also absorb on to the mild steel surface cathodic sites and prevent the diffusion of
dissolved oxygen to the metal, there by inhibiting general corrosion.
The chromate treatment program being an anti precipitation scale control does not
contribute suspended solids in water and it does remain low. Thus prohibiting the
environment for the growth of anaerobic that caused corrosion to the metal surface
6.1 REASONS OF SWITCH OVER
 Carcinogenic nature of Chromate.
 Environment restriction on discharge of blow down.
 Unavailability of standard chromate removal plant.
 Apprehension of restriction on production and use of chromate by EPA.
 Worldwide trend of use of environment friendly treatment program.
 Efficient use of blow down water.

6.2 COMPARISON OF CHROMATE/PHOSPHATE TREATMENT
ZINC-CHROMATE TREATMENT ZINC-PHOSPHATE TREATMENT
SCALING SCALING
 Operate in pH range 6.5 to 6.8.  Operate in pH range 7.5 to 8.2, which is
alkaline.
 Calcium carbonate/phosphate, Zinc-
hydroxide and phosphate are very  Calcium carbonate/phosphate, Zinc-
soluble. hydroxide and phosphate precipitate and
form scale
 Low suspended solids in cooling water.
 High suspended solids in cooling water.
 Iron also precipitate as iron oxide or iron
phosphate.
 Carry over of iron also causes deposition.
MICROBIOLOGICAL CONTROL MICROBIOLOGICAL CONTROL
 Chromate itself is toxic to bacteria in  Phosphate is itself food for bacteria.
cooling water.  Chlorination is not very effective at high pH.
 At low pH (6~7) the chlorination is very  Biocide controlling MIC is not very effective
effective. at this pH.
 The efficiency of biocide to control  The growth of nitrifying bacteria is
bacteria causing MIC is very high at this increased at this pH.
low pH.
 High suspended solids provide
 The growth of nitrifying bacteria is very environment for the growth of anaerobic
low at this pH. bacteria.
CORROSION CONTROL CORROSION CONTROL
 Excellent corrosion protection.  Very good corrosion protection.
 Chromate forms a passive film at anode  PO4 forms passive film at anode site.
site at low pH.  Zinc forms Zn (OH)2 film at cathodic site.
 Zinc forms Zn (OH)2 film at cathode site.  CaCO3 form protective film at cathode.
No chance for the precipitation of chromate, Chances for Ca/Zn/PO4 precipitation/
Zinc and phosphate at low pH. deposition/microbiological fouling are very
high.

7. BULAB CHEMICALS FOR PHOSPHATE TREATMENT
BULAB-6040 BULAB-6057
BULAB-7024
7.1 BULAB-6040 (Activator)
1t is an aqueous solution of Bromide recommended for use as a precursor in the generation
of hypo-bromous acid (HOBr). In the cooling water system the bromide ion when mixed
with chlorine or a hypochlorite species, is converted to hypo-bromous acid. Hypo-bromous
acid is preferred over hypochlorous acid due to greater efficiency at high pH and because of
its lower environmental impacts. Bulab-6040 provides a simple and low cost means of
generating HOBr on site.
Sodium bromide is a salt and has no oxidizing capability until it is “activated”. Bulab-6040
is not an oxidizer. It must be activated to provide active bromine to a cooling water system.
It is activated by reacting it with Hypochlorous acid (HOCL) to yield hypobromous acid
(HOBr) which is a strong oxidizing biocide. Hypochlorous acid is generated through addition
of sodium hypochlorite. Or chlorine.
Cl 2 + H2O  HCl + HOCl
HOCl + NaBr  HOBr + NaCl
OR
NaOCl + H2O  HOCl + NaOH
HOCl + NaBr  HOBr + NaCl
7.2 BULAB-6057 (Non-oxidizing Biocide)
It is a biocide and a combination of two isothiazoline derivatives that can provide broad-
spectrum micro-organism control in cooling water applications. It is a non foaming water
based product that is readily biodegradable. It is a spectrum anti microbial product
designed specifically for control of bacteria, fungi and algae in open recirculating cooling
water systems. Bulab-6057 is very effective in controlling the growth of nitrifying bacteria,
which convert nitrite into nitrate and dip the PH of cooling water. It contains dispersing
agents that ensure good distribution through the system and efficient penetration of the
slime masses. Addition of Bulab-6057 depends upon daily Nitrite (NO2) / Nitrate (NO3) test.
If these are greater than 30 ppm then shock dose of bulab is fed to the cooling water.
7.3 BULAB-7002 (Phosphonates & polymer based CaCO3 Scale inhibitor)
It is a scale inhibiter. It is used for the preventation of calcium carbonate scale. It inhibits
mineral scale formation, disperses slit and suspended solids, compatible with bulab
corrosion inhibitors. It is a combination of organic phosphate (Phosphonates) and anionic
polyelectrolyte used to inhibit the formation of scale and other deposits in industrial water
systems. Phosphonates have the ability of adsorbing on the active sites of the crystal to
prevent any further growth of crystal. Some of the functional groups of the scale inhibitor
adsorbed on the crystals but the rest of them are free from the adsorption and give electrical
charge to the crystals. Thus, the static electrical repelling force of the crystals is increased
and the crystals are kept in a dispersed condition.

7.4 BULAB-8006(Specialized amide based inorganic Bio-dispersant & Bio-penetrant)
“Dispersants are polymers which control particles by increasing charge on
the particles surface thereby keeping the particles repelled and
suspended’. BULAB-8006 is a dispersant and penetrant for microbial and organic
deposits. It prevents organic and inorganic fouling, clean industrial water system online and
reduces cleaning requirements and down time. It is designed as dispersant for slit, mud,
organics and biomass. It consists of three functional groups, an ionic polymer for general
dispersancy, DMAD (Di-methyl Amide) for dispersing organic and biomass, and a surfactant
package to hold the product together. Bulab-8006 performs best in systems that have
problems with suspended solids tied to surface by organics. It is used to remove the slime in
order to expose the bacteria colonies for the biocide to act effectively. Slime produces sticky
material that attracts the suspended solids that forms a coating on it. So when biocide is
added in cooling water, it does not directly come in contact with the organic matter and it is
wasted. So for biocide to work effectively, this product is very vital.
Common areas for this to occur are petrochemical industries, refineries where high biofilm
formation complicates the problem of control of suspended solids. In general, ant time the
deposits are a combination of organics and inorganic, Bulab-8006 will provide the best type
of treatment.
7.5 BULAB-9063 (Corrosion inhibitor)
It is an in-organic corrosion inhibitor that provides corrosion protection of mild steel piping.
It provides both anodic and cathodic protection. It is zinc-phosphate {Zn3(PO4)2} based
corrosion inhibitor in which zinc is used for cathodic corrosion inhibitor while
orthophosphate is used as anodic corrosion inhibitor. Zinc forms a passive film of zinc-
hydroxide, Zn(OH)2 and zinc carbonate at cathodic side while phosphate forms a
passive gamma iron oxide (Fe2O3) film on anodic side of the metal surface.
7.6 BULAB-9067 (Ca3 (PO4)2 Scale inhibitor)
The efficiency of a phosphate and phosphonates in stabilized cooling water treatment
program is predicted on the ability of a polymeric inhibitor. The polymer serves a dual
function. It controls the thickness of the calcium phosphate on the metal surface and also
prevents precipitation of the calcium phosphate salts in the recirculating water.
Bulab-9067 is a high performance co-polymer providing exceptional calcium phosphate
deposition control. It is effective in the control of other deposits that results from iron,
manganese and slit. It is a high performance slit dispersant which stabilizes calcium
phosphate, and zinc and maintain clean heat transfer surfaces.
7.7 BULAB-7024 (scale/deposit inhibitor)
It is a combination of scale inhibiting and dispersing compounds for control of scale and
suspended solids. It functions by several scale inhibiting mechanisms including metal ion
sequestration, threshold inhibition, crystal distortion, and anionic dispersion. Thus it is
effective in controlling a variety of scale forming substances, such as calcium carbonate,
calcium sulfate. Barium sulfate and manganese oxides.
It is highly resistant to hydrolytic decomposition, even at elevated temperatures and both
high and low pH.

7.8 ZINC-PHOSPHATE CHEMICALS DOSING SYSTEM
Chemicals dosing skid is located in chemical section near cooling water return header.
Dosing system consists of a dosing tank called ISB tank having capacity of 1000 liters and
dosing pump. There are four ISB tanks T-821, T-822, T-823, and T-824 for dosing Bulab-
9063, Bulab-7024, Bulab-9067 and Bulab-8006 with the help of dosing pumps, MP-821, MP-
922, MP-923, and MP-924 respectively. These are positive displacement pumps with
variable speed and strokes. Each pump takes suction from its dosing tank through flexible
tubing and discharges into CW basin through PVC lines. At the suction of each dosing pump,
there is a measuring column for adjustment of dosing rate according to required COC. Each
ISB tank has an isolating valve at bottom and a measuring tape is provided for measuring
chemicals level in tank. For monitoring of cooling water treatment pH meter, ORP meter and
a conductivity meter is installed at cooling water return line near dosing skid. Bulab-9067
dosing is now carried out from urea plant while dosing of remaining three from utility.

8 TROUBLE SHOOTING
8.1 HIGH/LOW PH
pH is essentially an indicator of the degree of acidity or alkalinity of a solution. It is not a
measure of the actual acidity or alkalinity. It is similar to the measurement of temperature
which is an indicator of the degree of hotness rather than a measure of the actual heat
energy content.
The main effecting parameter for phosphate treatment system is pH. Best operating range is
7.6~7.8. If pH is low then cause may be excess acid dosing or nitrifying bacteria. Nitrifying
bacteria grow rapidly at 11~15 hrs due to sunlight, which is favorable for their growth, also
chlorine contents reduces due to evaporation. If pH decreases and reaches to 6.5 then
passivation layer will damage/dissolve and corrosion rate will be very high. In such
condition increase phosphate dosing.
At high pH, M-alkalinity increases so there is increase of carbonate ions (CO3). Solubility of
these carbonate ions is less so scaling will occur. Similarly there is formation of Ca3 (PO4)2. If
pH is high then
 Increase satellite dosing of Bulb-9067.
 If pH increases beyond 8.5 then stop dosing Zn-phosphate, bulab-9063 and increase
polymer dosing bulab-9067 because Zn will also precipitate which is not controllable by
chemicals.
8.2 PRESENCE OF NH3
Phosphate system is very sensitive to NH3.
 In the presence of NH3 in cooling water, the microbiological control become a very
serious as this provide sufficient nutrients for a large burst of nitrifying bacteria which
converts NH3 into nitrite, nitrate and produces nitric acid. Thus the PH of cooling water
dips very rapidly and at low PH corrosion rate increases due to damage of passivation
layer;
 Chlorine reacts with ammonia to form chloramines (NH2Cl etc) due to which there is a
decrease in the residual chlorine with in the system. Chloramines are poor biocides and
are more harmful environmentally than chlorine itself due to very long half life.
 When NH3 is greater in cooling water then increase the chlorine dosing and biocide
(Bulab-6057) to kill these nitrifying bacteria's.
 Free halogen should be 0.2~0.5 ppm for 24 hours, If NH3 is 30~40 ppm otherwise it is
sufficient for 8 hours.
 NH3 effect will increase PH at start but due to nitrifying bacteria growth, it will decrease
after some time.
8.3 HIGH SUSPENDED SOLIDS
Effect of high suspended solids is,
 De-activation of scale inhibitors and may result in fouling of exchangers.
 Provide sites for growth of microorganisms and result in high consumption of biocides.
 Require blow down of additional 1~15 m3/hr. this cause high consumption of chemicals
due to lower cycle of concentration (COC).
 Increase bio-dispersant dosing if suspended solids are more.
MONITORING STEPS FOR CONTROL OF MICROBIOLOGICAL GROWTH.
 Daily analysis of Nitrite and Nitrates.
 Weekly analysis of bacteria count.
 Monthly monitoring of sulfate reducing bacteria.
 Installation of bio-fouling plate.
FOUR IMPORTANT THINGS TO CONTROL SCALING IN PHOSPHATE TREATMENT

 Keep cooling water quality in the range of Ryzner Index 5 to 7 by controlling PH and m-
alkalinity. To convert calcium carbonate into calcium sulfate to minimize the precipitation of
calcium carbonate.
 Use of threshold scale inhibitor (phosphonates), which prevent scale formation by keeping
the calcium carbonate in soluble form and not allowing deposits to form.
 Use of scale conditioner polymer dispersants to modify the crystal structure of scale creating
bulky transportable sludge instead of hard deposits.
 Balance cooling water Orthophosphate levels to system PH and alkalinity to provide mild
steel corrosion levels without forming phosphate scales.

9. COOLING WATER LIMITS FOR NORMAL TREATMENT
Following are the control limits of each parameter that would have to be monitored as and
controlled recommended.
PARAMETER UNIT RANGE ACTION FREQUENCY
< 7.5 reduce acid dosing

pH 7.5~8.2 Daily
> 8.2 increase acid dosing
Micromhos/c >1200 increase blow
Conductivity < 1200 Daily
m down
200~30
Ca Hardness PPM CaCO3 < 200 reduce blow down Daily
0
M. Alkalinity PPM CaCO3 Based on PH &RSI Daily
Iron PPM of Fe <2 > 2 increase blow down Daily
< 3 reduce blow down or

increase bulab-9063
dosing
Ortho PO4-3 PPM PO4-3 3.0~4.5 Daily
> 4.5 increase blow down
or reduce bulab-9063
dosing
< 1 reduce blowdown or
increase bulab-7002
Organic PO4- dosing
3
PPM PO4-3 1~2.0 Daily
> 2 increase blow down
or reduce bulab-7002
dosing
Total Zinc PPM Zn < 1.5 Daily
Suspended Target 10 to 15 ppm in

PPM < 20 Daily
solids CW
Free Adjust bromination
PPM Cl2 0.2~0.5 Daily
Halogen accordingly
Corrosion Mills per Continuousl
< 3 MPS
rate year y
Bacteria
Count/ml < 104
count
Nil or
SRB
Negligible

COOLING WATER ANALYSIS
PARAMETER MINIMUM MAXIMUM
UNITS
LIMIT LIMIT
Total hardness ppm CaCO3
Calcium hardness ppm CaCO3 300
Magnesium hardness ppm CaCO3
Zinc non filtered ppm Zn
Zinc filtered ppm Zn 0.5 1.5
P-alkalinity ppm CaCO3
M-alkalinity ppm CaCO3
Dissolved Fe ppm Fe+2
Total Fe ppm Fe+2 2.0
Sulphate ppm SO-2
Ortho Phosphate ppm PO4-3 3.0 4.5
Ortho Phosphate filter 3.0 4.5
Total phosphate ppm PO4-3 4.0 6.5
Organic phosphate ppm PO4-3 1.0 2.0
COC (SiO2) Cycles 5 7
Chloride ppm Cl 175
PH 7.5 8.2
Conductivity microS/cm 1200
RSI at 30 oC 5.5 8.0
RSI at 70 oC 5.5 8.0
Total dissolved solids ppm
Suspended solids ppm 20
Turbidity FAU 30
Nitrates ppm NO-3
Nitrites ppm NO-2 30
Ammonia ppm NH3 25
Total aerobic bacteria CFU / ml 104

10-CHEMICALS RECOMMENDED DOSE ON VARIOUS COC
Blow-down at various
AT 5 COC AT 6 COC AT 7 COC
COC
5 6 7
Chemical Ppm Kg/day Ml/min Kg/day Ml/min Kg/day Ml/min
COC COC COC
BULAB-
13 35 38 29 31 23 25 113 94 75
9063
BULAB-
14 38 41 32 35 25 28 113 94 75
7002/7024
BULAB-
5 14 16.7 11 14 9 11.2 113 94 75
8006
BULAB-
20 97 285 90 264 90 264 113 94 75
6040
BULAB-
13 35 101 29 86 23 69 113 94 75
9067
BULAB-
80 600
6057

MSDS OF BULAB CHEMICALS
BULAB- BULAB- BULAB- BULAB- BULAB- BULAB- BULAB-

6040 6057 7002 7024 8006 9063 9067
Slight
Clear
Clear to Hazy Clear hazy Clear
Clear colorless
light off yellow (water yellow
Appearance liquid to yellow
green white liquid white liquid
liquid
liquid)
Pungent
Odor Slight Slight Slight Slight Slight Slight
strong
Easily Easily Easily Easily Easily Partially

soluble soluble soluble Miscible in soluble soluble
Solubility in cold in cold in cold water in cold in cold soluble in
and hot and hot and hot and hot and hot cold and
water water water water water hot water
pH 6~8 2.5~5 11~13 4~5 12 <1 3~5
1. 43 1. 02 1. 27 1.10~1.13 1.12 1. 3 1.18~1.22

Density
g/ml g/ml g/ml g/ml g/ml g/ml g/ml
Eye
Flush immediately with plenty of tap water (minimum 15 minutes)
exposure
Skin Wash exposed area with plenty of water. Repeat washing, remove contaminated clothing
exposure and wash thoroughly before use.
Inhalation Immediately move exposed individual to fresh air.
Ingestion Dilute stomach contents by slowly drinking plenty of water or milk.

11 PROCEDURE FOR SET POINT CHANGE OF PH / CONDUCTIVITY
/ORP/ANALYZERS
1) PRESS MENU
2) GO TO PROGRAMME PRESSING DOWN ARROW.
3) ENTER
4) GO TO ALARM PRESSING RIGHT ARROW
5) ENTER
6) ALAM SETPOINT WILL BLINK
7) ENTER
8) ALAM-1 WILL BLINK
9) ENTER
10) SELECT HIGH
 ALAM-1 SET POINT MUST BE AT HIGH FOR ACID PUMP AND CONDUCTIVITY WHILE
LOW FOR “ORP”
 THIS WILL SHOW SET POINT. CHANGE SET POINT AS REQUIRED BY USING, UP, DOWN,
LEFT AND RIGHT ARROWS. THIS WILL BE THE SET POINT FOR START OF ACID PUMP.
FOR STOPPAGE OF PUMP GIVE THE DEAD BAND WIDTH AS
12 BAND WIDTH SET POINT CHANGE

a) PRESS MENU
b) GO TO PROGRAMME PRESSING DOWN ARROW.
c) ENTER
d) GO TO ALARM PRESSING RIGHT ARROW.
e) ENTER
f) ALAM SETPOINT WILL BLINK GO TO CONFIGURATION PRESSING
g) ENTER
h) ALAM1 WILL BLINK
i) ENTER
j) MEASUREMENT WILL BLINK
k) ENTER
l) SELECT HIGH
m) ENTER
o THIS WILL SHOW BAND WIDTH VALUE. CHANGE SET POINT BY USIG UP, DOWN, LEFT
AND RIGHT ARROWS FOR EXAMPLE IF SET POINT IS 7.2 AND DEAD BAND IS 0.2 THEN
PUMP WILL START WHEN PH IS 7.2 AND WILL STOP WHEN IT REACHES TO 7.0
o IN CASE OF “ORP” ANALZER SELECT ALARM-1 “LOW “ THIS MEANS PUMP WILL START
WHEN ORP VALUE IS LOW AND STOP WHEN IT IS HIGH.
o THERE ARE THREE POSITIONS ON CONTROLL PANNEL FOR OPERATION OF EACH
PUMP, AUTO, OFF, ON. ON AUTO POSITION PUMP WILL FOLLOW ANALYSER SET
POINT WHILE ON MANUAL IT FOLLOW TIMER EST POINT.

13 CHEMICAL DOSING RATE PER CENTIMETER DROP OF DOSING TANK
Change in level of
Bulab 9063 Bulab 7002 BLS 9067 Bulab 8006 Bulab 6040
ISB tank
0.1 centimeter 1.51 kg 1.48 kg 0.28 kg 1.30 kg 1.66 kg



14 FEW IMPORTANT DEFINITIONS
Alkalinity:
An expression of the total basic anions (hydroxyl groups) present in a solution .It also represents,
particularly in water analysis, the bicarbonate, carbonate, and occasionally, the borate, silicate
and phosphate salts, which will react with water to produce the hydroxyl groups.
OR
The acid neutralizing capacity of water. It is usually expressed as “M” alkalinity (the methyl
orange end point at a pH =4.3, methyl orange indicator change color) and “P” alkalinity (the
phenolphthalein endpoint pH=8.3, phenolphthalein indicator change color into pink). Several
ions contribute to alkalinity, but it is generally due to bicarbonate (HCO3-1, CO3-2) and hydroxyl
(OH-1) ions.
Conductivity:
The ability of water to conduct an electrical current. It is opposite to the resistivity and related to
the concentration of dissolved (ionizable) solids in the water. The measure of conductivity is
conductance (the reciprocal of resistance), whose units are normally Micromhos equal to
1,000,000/ohms.
Total Hardness:
Total concentration of Calcium and Magnesium ions present in the water is called total hardness.
It is normally expressed as ppm CaCO3.
Total Dissolved Solids:
Concentration of all the soluble solids in water which will remain as such if all the water is
evaporated.
P-Value
P-Value is the measure of hydroxyl and Carbonate alkalinity.
M-Value
M-Value is the measure of total alkalinity.
Turbidity
Reduction of transparency of water due to presence of particulate matter.
OR
A suspension of fine inorganic, organic & other suspended impurities in water that cause
cloudiness.
Nephelometric turbidity:
An empirical measure of turbidity based on a measurement of the light scattering characteristics
(Tyndall effect) of the particulate matter in the water.
Part per million (ppm):
It is the most common unit used in expressing water analysis results. It is a measure of
proportion by weight and equivalent to a unit weight of solute per million unit weights of
solution. A part per million is generally considered equivalent to a milligram per liter but this is
not precise. A part per million is equivalent to a milligram of solute per kilogram of solution.
Part per billion (ppb):
A measure of proportion by weight equivalent to a unit weight of solute per billion (10 9) unit
weights of solution.
Langelier’s index:

A technique of predicting whether water will tend to dissolve or precipitate calcium carbonate. If
the water precipitates calcium carbonate, scale formation may result. If the water dissolves
calcium carbonate, it has a corrosive tendency. To calculate Langelier’s index the actual pH
value of the water and Langelier’s saturation pH value (pHs) are needed. Langelier’s saturation
pH value (PHs) is determined by the relationship between the calcium hardness, the total
alkalinity, the total solid concentration and the temperature of the water by using relation
PHs = (9.3+A+B)-(C+D)
Langelier’s index is then determined from the expressions pH –pHs. A chart is used for
determining Langelier’s index. pH is measurement of the acidity or alkalinity of a system.
Reference temperature for pH is 25 oC and pH runs from 0 (highly acidic) to 14 (highly basic)
with pH =7 being neutral. The interpretation of the results obtained is shown below:
Langelier’s index (pH –pHs) Tendency of water
Positive value(>1) Scale forming
negative value(<1) corrosive
Neither scale forming nor

zero
corrosive
Also note that the presence of dissolved oxygen in the water may cause water with a “zero”
Langelier’s index to be corrosive rather than “neutral.”
Caution must be observed in employing Langelier’s index for controlling corrosion or deposit
formation since there are factors that may make its. These include temperature differences
within a system, changing operating conditions, or the presence of chemical treatment in the
water.
Ryzner Stability Index:
An empirical method for predicting scaling tendencies of water based on a study of operating
results with water of various saturation indices.
Stability index=2pHs-pH
Where pHs =Langelier’s Saturation pH.
This index is often used in combination with the Langelier’s index to improve the accuracy in
predicting the scaling or corrosion tendencies of a water. The following chart illustrates how to
use this index.

Ryzner Stability Index
(2pHs-pH) Tendency of water
4.0~5.0 Heavy scale

5.0~6.0 Light scale
6.0~7.0 Little scale or corrosion
7.0~7.5 Corrosion significant
7.5~9.0 Heavy corrosion
9.0 and higher Corrosion intolerable

SULPHURIC ACID
Toxicity:
TLV-1 milligram per cubic meter of air.
Safety Hazards:
Highly corrosive, contact results in rapid destruction of tissues, causing deep and painful burns.
Extremely hazardous for eyes. Inhalation of mist/vapors is injurious to respiratory system.
PERSONAL PROTECTION:
Chemical splash goggles face shield, gloves, gum shoes and protective suit. If necessary, use
respiratory equipment.
FIRST AID:
Take patient immediately under safety shower and wash with plenty of water for at least 15
minutes. Seek medical help.
FIRE HAZARDS:
It is flammable, but it is highly reactive and capable of igniting combustibles. On contact with
metals will produce hydrogen, which may form an explosive mixture with air.
FIRE FIGHTING:
Use dry chemical. Fine spray of water is also effective.
CHLORINE
PROPERTIES:
 Chlorine is non-flammable, non-explosive, however, it supports combustion.
 It is slightly soluble in water.
 It has a characteristic penetrating odour and greenish yellow color.
 Liquid chlorine is clear and amber in color.
 Chlorine gas is 2.5 times as heavy as air; where as liquid chlorine is 1.5 times as heavy as
water.
 One volume of liquid yields 460 volumes of gas.
 At atmospheric pressure, it boils at 30 °F and freezes at – 150 °F.
 Dry chlorine (no more than 150ppm water) is not corrosive, but when moisture is mixed, it
becomes very strongly corrosive, due to the formation of hydrochloric and hypo-chlorous
acid.
HAZARDS:
 The gas irritates mucous membrane, respiratory system and skin. In extreme condition death
may occur due to suffocation.
 Liquid chlorine in contact with eyes or skin will cause burn. The longer the exposure to the
gas or higher the concentration, the more serious will be the effects.
 Like oxygen, Chlorine supports combustion.
 At elevated temperature, it reacts vigorously with most metals.
 With the increase in temperature, the volume of liquid Chlorine expands considerably; this
may cause hydrostatic rupture of cylinder.

PERSONAL PROTECTIVE EQUIPMENTS:
In order to handle chlorine leakage safely following personal protective equipment is required:-
EQUIPMENT
1. Resuscitator
2. Self contained breathing apparatus
3. Rubber Gloves
4. Chemical splash suit
5. Rubber Boots
6. Air Masks
7. Chlorine Masks
FIRST AID TIPS
Prompt treatment of anyone overcome or seriously exposed to chlorine is of the utmost
importance. First aid tips, mentioned below have been proved very useful.
1 Remove the victim from the contaminated area at once.
2 Loosen all constrictive clothing around his neck.
3 If breathing is stopped, start artificial respiration or use manual resuscitation. Continue this
process until the patient is breathing normally.
4 Call physician.
5 Keep the patient warm (21 °C room temperature) and quiet. Wrap him in blanket.
6 Never give anything by mouth to an unconscious person.
7 If the victim gets panicky, reassure him.
8 Remove contaminated clothing.
9 Flush with copious amount of water (From showers) and soap, skin areas that have been
exposed to either gas or the liquid chlorine.
10 Never attempt to neutralize the chlorine chemically.
11 If eyes have been exposed to even minute quantity of chlorine keep flushing with water (from
eye fountain) till medical assistance arrives.
12 During eye flushing, keep eyelids apart forcibly.

INSTRUMENTATION
LOGICS/ALARM/ SWITCHES
08-3 LPSA-151 A-D

Located with control oil pressure gauge (Pl-153). It is responsible to start the selected auto
standby pump (MP-813) at 1.1 kg/cm2 to maintain control oil pressure of the system.
08-3-LPA-152-A-D
Located on front panel. Actuate alarm in WTCR at low lube oil header pressure at 1.2 kg/cm2.
08-3-HDPA-153-A-D
Located with differential pressure gauge (P-153). Actuate alarm in WTCR when P of FT-
802 and 803 reaches beyond 0.5 kg/cm2.
08-3-LLPS-154-A-D
Located with latching system. Actuates at low lube oil pressure (0.8 kg/cm 2) and open oil
damp valve 08-3-SD-151; control oil drains to sump and turbine trip due to low control oil
pressure.
08-3-LLPS-155-A-D
Located with TTV. Actuates at 0.8 kg/cm2 of low lube oil header pressure and stop turbine by
closing the trip throttle valve.
08-3-HPA-156-A-D
Located at discharge line of TP-815. Actuates alarm in WTCR at high discharge pressure of
TP-815 at 4.0 kg/cm2.
08-3-HTA-150-A-D
Located with discharge pressure gauge of TP-815 and MP-813. Actuate alarm in WTCR at high
temperature of oil in sump T-800 at 70 oC.
08-3-HTA-151-A-D
Located with FT-802/803 at outlet side. Actuates alarm in WTCR at high temperature of lube
oil after coolers at 65 oC.
08-3-HTA-152-A-D
Located with 3-way valve of lube oil coolers. Actuates alarm in WTCR at high temperature of
thrust bearing at 75 oC.

08-3-HTA-100,101,102,103 A-D
Located with FT-802/803. Actuate alarm at high exhaust steam temperature of TP-800 A-D at
140 oC.
08-3-LLA-150-A-D
Located near MP-813. Actuates alarm in WTCR when lube oil level in sump T-800 A-D
decreases to 70 %.
08-3-SD-150-A-D
Located on HS steam line at inlet of turbine TP-800 A-D. It is drain valve. Actuates at low
control oil discharge pressure at 0.8 kg/cm2 or in case of over speed of turbine (7700 Rpm).
In both cases this valve open and drain control oil to sump and trip turbine.
08-3-SE-151-A-D
Located with discharge pressure gauge of TP-815 A-D. It is tachometer which shows the Rpm
of turbine TP-800 A-D.
08-3-HSS-150-A-D
It actuates at high speed of turbine TP-800 A-D at 7700 rpm, and trip the turbine by opening
oil damp valve 08-3-150-A-D.

ALARM AND SWITCHES OF E-801
08-2-HPA-101
Located at east side of E-801. Actuate alarm in WTCR at high pressure 0.23kg/cm2g .
08-2-HLSA-102
Located at west side of E-801 near TP-801B. This switch start selected auto standby pump
MP-801/TP-801 at 90% level.
08-2-HPSA-103
Located at discharge line of TP-801B. Gives running indication in WTCR, at discharge
pressure 2.0 kg/cm2.
08-2-HLA-100
Located on V-805. Actuates alarm in WTCR at 65% level.
08-2-LPA-104
Located on common condensate discharge line after E-810B. Actuate alarm in WTCR at low
condensate pressure at 2.0 kg/cm2.
08-2-HPS-105
Located at discharge line MP-801A. Only give running indication of pump MP_801 in WTCR.
When discharge pressure develops at 2.0 kg/cm2.
08-2-HPSA-102 A/B/C
Located at top of E-801. When pressure increases up to 0.3 kg/cm2g, oil damp valve 08-3-SD-
151 opens which drains control oil in sump and trip T-800 A-D turbine.
08-2-LLA-103
Located near MP-801A. Actuates alarm in WTCR at low level of E-801 at 20%.
08-2-LC-101 AV
Located at common discharge line of condensate. It is condensate outlet valve of E-801 and
responsible to control level of condenser at 50 %.
08-2-LC-101 BV
Located at recycle line of condensate. It is the level make up valve of E-801.
08-2-LZS-101-104 A-D
Located at exhaust valve of turbine. These limit switches allow opening of HS steam valve of
turbine 08-2-SD-1-4 BV.

ORIFICIES IN LUBE OIL CIRCIT OF TP-800 A-D
08-3-RO—150
Located at bypass line of E-805/806 oil cooler.
08-3-RO-151
Located at bypass line of FT-802/803 lube oil filter.
08-3-RO-152
Located with latching system of turbine TP-800 A-D.
08-3-RO-153
Located with trust side bearing of turbine TP-800 A-D.
08-3-RO-154
Located with rear side bearing of turbine TP-800 A-D.
08-3-RO-155
Located at the gear coupling lubrication line of turbine TP-800 A-D.
08-3-RO-156
Located at the gear box line of turbine TP-800 A-D.
08-3-RO-157
Located on the control oil pressure gauge line of turbine TP-800 A-D.
SWITCHES OF COOLING TOWER BASIN (E-800)
08-1-LLA
Located near suction line of MP-800 E. it actuates alarm in WTCR at low level of E-800 at
2600mm.
08-1-LLLA
Located overhead 08-LC1V on basin. Actuates alarm in WTCR at very low level of E-800 at
2400mm.
08-1-HLA
Located near suction line of MP-800 E. Actuate alarm in WTCR at high level of E-800 at
2900mm.
08-1-PHIC-1V
Located at acid line before EJ-802. Control acid dosing according to pH of cooling water.
08-1-LPSA-1
Located at supply cooling water header. Low discharge pressure switch operate at 2.9 kg/cm 2
and operate 1-40 in WTCR. Its function to open the HS valve 08-SD-1BV-4B. Turbine which is
on auto selection in WTCR, will automatically speed up if it is on rolling.

08-XT-151A~D
TP-800A~D thrust indication. 0.4 mills is alert value while 0.6 mills danger.
08-VT-152A~D.
TP-800A~D governor side vibration indication. 3.0 mills is alert value while 5.0 mills danger
08-VT-153A~D.
TP-800A~D gear box side vibration indication. 3.0 mills is alert value while 5.0 mills danger.
PRESSURE SAFETY VALVES
Sr. Tag No. Location Set point
# kg/cm 2
1 08-PSV-100 E-801 0.35

2 08-PSV-101 EJ-807A 2.5
3 08-PSV-102 EJ-807B 2.5
4 08-PSV-103 Exhaust line of TP-800A 0.25
5 08-PSV-104 Exhaust line of TP-800B 0.25
6 08-PSV-105 Exhaust line of TP-800C 0.25
7 08-PSV-106 Exhaust line of TP-800D 0.25
8 08-PSV-107 A/B C.W outlet of E-801 5.0
9 08-PSV-108 Exhaust line of TP-801B 4.5
10 08-PSV-150 A~D On discharge line of MP-813 A~D 4.0
11 08-PSV-151 A~D On discharge line of TP-815 A~D 4.0
12 08-PSV-152 A~D Exhaust line of TP-815 A~D 4.5

FIRE FIGHTING SYSTEM
Introduction.
The fire fighting system & protection of the urea ammonia complex is ensured by a series of
stationery and mobile units. The equipments system can be split into two parts.
1- Protection with water.
2- Protection with special extinguishing products, chemical powder & CO2 from stationery
and mobile extinguisher.
Water protection system.
The water protection is achieved by the hydrant system consisting of water storage (cooling
water basin), pressurization and distribution. Storage of water is cooling tower having capacity
6900m3. This water will be used to feed the fire fighting pumps. Make up (tube well /canal water)
can also be used for additional requirements or in non availability of cooling water.
Pressurization system.
Pressurization of lines is ensured by an electric motor driven jockey pump which take water from
cooling water basin and sent it into the same through recycling line. This pump has a flow rate of
50 m3/hr and differential head of 60 meters to ensure a pressure in the system not lower than
6Kg/cm2.
Distribution system.
The distribution system consists of two fire fighting pumps one is motor driven and the other is
diesel driven, each of having capacity of 500m 3/hr .The pumps shall ensure minimum pressure of
6 ata at the most remote hydrant under the worst operating condition. Incase of fire ,the pressure
drop in the net work following the toping of fire water automatically start-up the electric motor
pump, where as this motor pump and diesel pump can be started up manually and automatically.
Distribution net work.
The fire water distribution net work consists of carbon steel pipes, partially buried and partially
over head. The net work runs mainly along the roads of the units and consists of rings connected
in series and parallel. This net work is cut in several points by gate valves normally open,
installed in pits and indicated by signals. The purpose of these valves is to divide the net work
into sections, so that urgent operation can be carried out in case of break down or for
maintenance. The fire fighting lines are equipped with stationary above ground hydrant of a self
draining type with 6 inch connecting flange; the hydrants are positioned at a distance of 40 to 50
meter from each other.
Operation.
There are three pumps for pressurization of fire hydrants.
1- Jockey pump P-1702
2- Motor pump P-1701A
3- Diesel pump P-1701B
Jockey pump is for continuous in operation during normal operation this pump pressurized the
fire header. Incase of pressure drop to 4.5Kg/cm2, the motor pump P-1701A will come in
services. In case of electric failure or high consumption of water, if pressure drops and reaches to
3.5 Kg/cm2, the diesel pump P-1701B will come in services automatically. The speed of diesel
pump can be adjusted accordingly. During the normal operation of P-1702 a line from this pump

discharge goes to cooling water basin which is called bleed off line. This line valve should be open
to ovoid pressure build up in the pump.
STAT-UP OF JOCKEY PUMP (MP-1702)
1- Check oil level in pump bearings.
2- Check pump is free in rotation
3- Check pressure gauge ion the discharge
4- Open suction completely.
5- Close discharge valve completely.
6- Open priming valve.
7- After priming take pump p in services.
8- Open the discharge valve slowly.
AIR COMPRESSORS K-1701A/B.
There are two air compressors for starting air of diesel engine. One compressor is motor driven
and the other is petrol engine driven. Motor driven compressor automatically come in service
when air pressure drop to 5.5Kg/cm2 and stop when pressure build up to 7.0Kg/cm2.
Incase of power failure Mk1701A will not start to maintain the air pressure required for starting
of diesel engine, the take Pk1701B in service immediately to start Dp1701B to met the
emergency.
START UP AND SHUT DOWN
1- Check that air receiver drain valves are closed.
2- Check that main out let pressure reducing valve is closed.
3- Check that all other manual operated valves are open.
4- Start either motor or engine driven compressor or both allow running until the complete
system pressurized. When the maximum working pressure 7.0Kg/cm2 has been reached, the
motor compressor will switch off automatically but engine driven compressor will have to be
stop manually.
5- Open the main pressure reducing valve.
6- Should the pressure drop in the4 system to 5.5Kg/cm2, Mk1701A will start on auto and
recharge the system and stop on auto again after the working pressure reach.
START UP OF MP-1701A:
1. Check pumps oil level in bearings is normal.
2. Check local ON/OFF switch is at OFF position.
3. Check all valves and P/G are OK.
4. Get the motor breaker ON.
5. Open suction valve and close discharge valves.
6. Start the MP-1701A from local ON/OFF switch.
7. Observe for any abnormality /variation in sound, amperes and pressure. If the
conditions are normal then open discharge valve gradually.
8. Adjust recirculation valve opening.
SHUT DOWN OF MP-1701A:
1. Start MP-1702 as per procedure.
2. Close discharge valve of P-1701A.
3. Wait until 17-PCV-1V maintains the fire water header pressure upto 6 kg/cm2.
4. Stop MP-1701A.

TROUBLE SHOOTING OF COMPRESSOR K1701A/B.
PROBLEM CAUSES
1- Knock or rattle A- Loose belt wheel or motor pulley
Or Excessive Play in shaft.
B- Carbon on the top of the piston.
C- Restricted air pressure.
2- Air delivery has dropped off. A- Air leaks in the piping.
B- Closed intake failure
3- Trips motor over load. A- Oil viscosity to high.
B- V-belts very tight,
4- Petrol engine not start. A- Incorrect armature air gap
B- Loose spark plug.
C- Breaker plunger stuck or work.
SPECIFICATION OF DIESEL ENGINE (DP1701B).
Number of cylinders 08
Bore of cylinder 6.250 inches
Cubic capacity. 1590 m3.
Lube oil system pressure oil pump positive driven gear type.
System capacity of lube oil 68.3 liters.
Electric system voltage 24 volts.
Fuel injection pressure 180 atm
Rotation anti clock wise.
Power 407 hp
Fuel capacity 5 to 8 gallons/hr
PETROL ENGINE
Type 4 cycles, single cylinder L-head & air cooled
Bore 3 inches.
Displacement 22.97 cubic inches.
Horse power. 9.0 hp max at 3600 rpm.
Torque (ft-Lbs) 15.75 max at 2000 rpm.
MP1701A
Capacity 500 m3/hr.
Type of impeller double suction eye closed impeller
Motor power 320 Kw.
COMPRESSORS K1701A/B.
Type 30n u.k rating two, stage single acting air cooled.
RPM 500
Piston displacement. 0.567 m3/min.
Maximum discharge pressure, 14 Kg/cm2.
MOTOR 1701A
Horse power 7.5 hp
RPM 1440.

SWITCHES AT 17 AREA
1- 17-LPSA-1
Located on DP-1701-B. It is responsible to start the diesel engine when fire header pressure
decreased up to 3.5 kgs/cm2.
2- 17-LPSA-2
Located on MP-1701-A. It is responsible to start the fire pump when fire header pressure
decreased up to 4.5 kgs/cm2.
3- 17-LPA-3
Located on out let line of V-1702-A it actuates alarm on the panel of DP-1701-B when V-1702-
A air pressure decreases up to 4.5 kgs/cm2.
4- 17-LPA-4
Located on outlet line of V-1702-B. It is actuated alarm on the pannel of DP-1701-B when V-
1702-B air pressure decreased up to 4.5 kgs/cm2.
5- 17-LPSA-5
Located on V-1701-A. it is responsible to start MK-1701-A, when vessel air pressure
decreased up to 5.5 kgs/cm2 & stop MK-1701-A, when vessel air pressure maintained up to
7.0 kg/cm2.
List of PSVs in 17 area

Sr. Tag No. Location Set point
# kg/cm2
1 17-PSV-1 Discharge of MK-1701A 8
2 17-PSV-2 Discharge of PK-1701B 8
3 17-PSV-3 At V-1701A 8
4 17-PSV-4 At V-1701A 8
5 17-PSV-5 At V-1701B 8
6 17-PSV-6 At V-1701B 8
7 17-PSV-7 At V-1702A 8
8 17-PSV-8 At V-1702B 8

DIESEL ENGINE DRIVEN PUMP, DP-1701B
Diesel engine is of 407 hp and has 08 cylinders. It drives the fire water pump in case of total
power failure or in case of non availability of other two fire water pumps. It remains on auto
stand by.
Following are the main components of the diesel engine;
Starting Air System:

Air is used for starting of diesel engine. Starting air is supplied to the pneumatic motor which in
turns rotates the turbine connected with the main shaft. Starting air is supplied from the air
storage vessels; V-1702A/B. Air is stored in these vessels at a pressure of 7.0 kg/cm2 with the
help of two air compressors, MK-1701A and PK-1701B. MK-1701A maintains pressure in these
vessels up to 7.0 kg/cm2. If pressure decreases up to 5.5 kg/cm2 then low pressure switch (17-
LPSA-5) starts the MK-1701A and stops when pressure reaches to 7.0 kg/cm2. In case of power
failure, pressure can be maintained with the help of PK-1701B by manual start. In case of low
pressure up to 4.5 kg/cm2, switches 17-LPA-3/4 installed at V-1702A/B are responsible for alarm
and indication at panel.
Air from V-1702A/B first passes through moisture trap and then from oil cup. As this air is not
the instrument air so it is passed through oil to save the instruments from corrosion. After
passing through SOV operated isolating valve, it is applied for rotating pneumatic motor for
starting the engine. These SOVs are redundant and in case of failure of one SOV, the other can
operate the valve.
The function of pneumatic motor is to rotate the turbine which is connected with crankshaft for
start up of diesel engine. Under inlet air hose, there is a relief valve to release air if pneumatic
motor does not starts due to any reason.
De Mineralized Water Circuit:

DMW is provided for cylinder jackets cooling. Use of ordinary water is not recommended due to
chemical actions resulting in corrosion, rust, furring up of the cooler. DMW from the radiator
comes into the shell side of a cooler where it is cooled by the water from the discharge of P-
1701B.
DMW level in the radiator should be 37mm (1.5in.) below the top of the copper overflow pipe.
The cooling system is pressurized and do not remove the filler cap while the engine is hot.
DMW after cooling is sent to piston jackets with the help of two pumps for cooling purposes. One
pump feeds DMW to north side jackets and other pump to south side jackets. North side DMW is
used for cooling of lube oil before entering into the jacket. There are two high temperature
switches on both north and south side water jackets. These switches are meant for tripping of
engine on water jacket high temperature up to 900C. After cooling, the piston jacket water goes to
the radiator and then shell side of the cooler for cooling with cooling water. DMW cooler bypass
line valve can be opened at high temperature of DMW outlet or if auto valve is not operative due
to any reason.
Cooling water used to cool DMW passes through isolating valves, strainer, NRV and an SOV
operated valve. This valve normally remains close but opens when DMW temperature reaches to
800C.
Lube Oil System:
Oil console of diesel engine is filled with lube oil, Rotella C-30. Oil console has the capacity of 68.3
liters. Console has a dip stick to check oil level. There are two marks at the base of the dip stick,
the lower mark shows the minimum and higher mark shows the maximum level. An air breather
is also provided. On oil console, there is a switch that put the oil sump heater On or Off at
temperature <40 and >450C respectively.
There are three lube oil filters. A gear pump present at east side bottom of the engine takes
suction from console and send to oil cooler. DMW is used for cooling of Oil. Oil enters the cooler
from east side with the help of a gear pump operated by crank shaft and leaves from the west
side. There are two outlet pipes, one goes to the oil filters while in case of chocking of oil filters,
and oil goes to sump with the help of three way valve (relief valve). After oil cooler, oil passes
through from three oil filters and finally returns back to the console. Oil filter is the lubrication’s
system biggest ally. It is constantly cleaning and keeping it free from dirt which is biggest enemy
of the engine. Always try to operate the engine within lube oil temperature range of 80~900C.
Diesel Fuel System:
Diesel oil is stored in the tank, T-1701 having capacity of 140 gallons. Minimum 20 gallons and
maximum of 120 gallons should be filled. There is a level indicator, overflow line and recycle line.
A 2” dia permanent line is used for transferring diesel oil from T-1901. A low level alarm of T-
1701 appears on panel in case of low level.
Fuel is injected with the help of injection pump. Fuel injection pressure is 180 atm. On fuel
injection system, there is a solenoid valve. When we press stop push button, this solenoid valve
operates and closes the stop lever on fuel injection pump and this lever holds in closed position
by a relay on solenoid valve until the engine stops.
There are four fuel oil filters which are responsible to prevent ingress of any dirt into the fuel.
Near these fuel oil filters, there is a rpm adjusting knob and speed accelerator. Speed increases by
pressing accelerator down and vice versa. An over speed trip device is also connected with the
shaft.
Combustion Air System:
Air filter is provided at suction line of air supply for pistons. Air filters keep dirt out of the engine.
It is most important that these filters work efficiently. They must feed large quantities of clean air
to the engine. If neglected, they will clog up with dirt and either feed loss or dirty air. Dirty air is
bad for engine and engine starved of air will be down on power, will struggle to keep going, will
use a lot more fuel, with smoke and overheat. A turbo charger is provided to boost up the air
positively for combustion. It is operated with flue gases coming from combustion chamber.
Control Panel of Engine:
Control panel of diesel engine was energized all the times by means of two batteries in past but at
present there is only one battery of 24 Volts (12+12V) available. These batteries are recharged by
two chargers provided in the panel. When battery voltages drop from 22 Volts, these chargers
automatically recharge the batteries up to 24 Volts and stop itself. Due to presence of one battery,
one charger is in service only.
When diesel engine is running then these batteries are recharged by denmo operated by crank
shaft. Batteries at all times must be kept clean as much as possible. Dirt and damp allowed to
accumulate between the connectors and top of the battery can cause current leakage. Time to

time cover the level of the electrolyte, it should just cover the plates and be level with the
separators.
Moreover, a panel consisting of RPM indicator, lube oil and DMW temperatures and oil pressure
indicators is mounted on the engine. Maximum rpm of the engine are 1450 rpm while normally
engine runs at 1100 rpm.
Start up of DP-1701B:
There are two options for starting the engine, from low pressure starting switch and from manual
crank. In first case, water in the sensing line of the 17-LPSA-1 switch is drained which gives signal
to open the SOV and supply air to the pneumatic motor. In second method, low pressure starting
switch is by passed and air is supplied to pneumatic motor which rotates the turbine and engine
starts. If auto starting is failed then “fail to start indication” is appeared on panel along with
pump on demand, in this case push auto cycle reset button and again start engine from low
pressure switch.
PRESTART –UP OF DIESEL PUMP.
1- Check oil level in sump with dip stick, level should be on maximum point.
2- Check cooling (DM) water in radiator is maximum, below the overflow line.
3- Check the fuel system, fuel level, if priming required then prime the system.
4- Check the batteries are fully charged, specific gravity is 1.27 to 1.28 7 volts are 24.
5- Check air pressure vessel is above 5.5Kg/cm2.
6- Check oil level in the bearings if pump.
START-UP
1- Open suction and discharge valves of the pump.
2- Open air valves to engine air turbine.
3- Open fuel valve to engine.
4- Push Drain Button several times till indication for pump on demand appear and engine will
start automatically
5- In emergency start the engine through manual crank button.
6- Adjust the speed of engine accordingly
AFTER START-UP.
1- Check starting air turbine is stopped.
2- Check rpm of engine 900 in initial.
3- Check lube oil pressure is > 2.8 Kg/cm2.
4- Check lube oil temperature is <104 deg C.
5- Check coolant temperature is < 90 deg C.
6- Check discharge pressure of pump is <6.8Kg/cm2.
7- Observe any abnormal, sound and leakages.
SUTDOWN.
1- An electrically stop, simply press the shut down button until engine stops.
2- Manually push the stop lever vertically up-ward until the engine, then normalize the lever.
In case of emergency the engine is stopped by turning off the fuel supply.

Area Specific Course of Cooling Tower

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Area Specific Course of Cooling Tower

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AREA SPECIFIC COURSE

COOLING TOWER & FIRE FIGHTING AREA

Nozzles Top Deck

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1. Latent heat transfer owing to vaporization of a small portion of the water.

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5. CYCLE OF CONCENTRATION: (C.O.C)

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Cross flow Counter flow

TYPES OF COOLING TOWER / PONDS

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Water inlet Tower packing

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Tower packing louvers

Air inlet Air inlet

Water out let

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COOLING TOWER PLANNED SHUT DOWN

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Dip / Level (cm) Weight (Tons)

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START UP PROCEDURE OF LUBE OIL PUMP TURBINE, TP-815A~D

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CHLORINE BOOSTER PUMP P-802A/B :

EJECTOR FOR V-802, Ej-802

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FAN START UP PROCEDURE:

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From feed pump

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Manufacturer Rossetti Italy

2. BACK WASH OF FILTER:

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Basin low level:

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Reduction of ions Metal ions e.g. Fe ++

Simple corrosion cell

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2.1 CATHODIC POLARIZATION

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3.2 PROBLEM CAUSED BY MICROBIAL ACTIVITY

Sulfate oxidizing bacteria

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3.8 OXIDATION REDUCTION POTENTIAL (ORP)

Oxidizers area of Activity

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4.1.2 WATERBORNE FOULANTS

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