Cooling Water PDF

UTILITY COMPLEX RELIANCE PETROLEUM LIMITED SEA WATER COOLING
UNIT 734 JAMNAGAR TOWER
1.3.2 PRINCIPLE OF OPERATION

The principle of operation of cooling tower is based on the principles of Heat
and Mass Transfer. Cooling tower is virtually a Heat Exchanger that removes a
certain amount of heat from the hot (return) cooling water from the plants. This heat is
transmitted to the atmosphere and the water is returned at a lower temperature that is
recycled back for cooling. Atmospheric air is used as a cooling medium via the
physical phenomenon of evaporation based on psychrometry. The transfer of heat
from the water to air occurs by convection and evaporation.
Cooling of water consists in placing its surface in contact with air, in order
that the latter absorbs heat from the water. This is achieved partly by sensible heat
transfer between air and water, because of the temperature difference between them.
But the amount of heat transferred in this manner is very small. The major portion of
heat transfer is done by the evaporation of a some quantity of water that takes away
the necessary latent heat of vaporisation (heat required to accomplish the phase
change of liquid water to its vapour form) – thus cooling the rest of the water. The
water vapour formed in this process is driven away by the air stream passing through
it. The cooling water is used as a cooling media while going through heat exchangers
of various equipment and thereby it gains heat before it returns back to the cooling
tower. Thus the prime function of cooling tower is to reduce the temperature gained
by the cooling water returning back to it, which is done by heat transfer with air. The
cooling water in the cooling tower can be cooled down nearest to Wet Bulb
Temperature of air entering the tower. Thus the cooling towers have been widely used
to dispose the waste heat from industrial process as it is more convenient to reject heat
to atmosphere rather than to water in a nearby river, lake, or ocean.
MECHANISM OF COOLING
The mechanism of cooling is based on Evaporation. In cooling towers, natural

or mechanical (forced or induced) draft patterns are used to create circulation of air
stream inside the tower.
Some form of energy is required for any movement or change in matter. The
molecules that break away in evaporation, first have a higher amount of heat energy
that they take with them. The molecules that remain have a lower level of heat energy
as they move slower. These slower molecules are to be accelerated. This is done by
the cooling tower, where water breaks into smaller particles, which provide larger
surface area in contact with air. Due to partial evaporation, the water gets cooled.
Higher the number of water molecules that leave the body of water at a given time,
the faster will be the rate of evaporation of the water and hence better will be the
PAGE :
REV : 00
REVIEWED BY : ARM OPERATING MANUAL ISSUE : 01
APPROVED BY : PBP DATE : 15/11/98
AUTHOR : KDR
cooling. As air acquires moisture its humidity rises. Now air can hold only a certain
amount of water molecules at a given temperature. After it becomes saturated, it will
no longer absorb water molecules. The higher the humidity of air in contact with the
water, slower will be the rate of evaporation.
The cooling is accomplished partially by raising the temperature of the

surrounding air and partially by evaporating a portion of the stream of higher
temperature cooling water returning to the cooling tower. The relative amount of heat
going into increasing the temperature of air and into evaporating the water depends on
the humidity of air entering the cooling tower. The minimum temperature, to which
the hot cooling water could be cooled in an ideal case, is the Wet Bulb Temperature
of air entering the tower. Although practically no cooling tower water is able to attain
wet bulb temperature of entering air.
Taking into account the condition of air when it enters the cooling tower, only 10 to
15 % of the heat is generally removed by convection. Evaporation is thus the pre-
dominant phenomenon. Hence the exchange surface consists either of droplets of
water themselves (splashing types) or by films of water trickling over the surfaces
(film type). The enthalpy of moist air is almost solely a function of the wet bulb
temperature. i.e., only Wet Bulb Temperature lines are ordinarily drawn on
psychometric charts. The difference in the W.B.T. for the inlet and outlet gives
measure of the enthalpy rise.
The Dry bulb temperatures are mainly significant from the standpoint of water
consumption. Hence cooling tower is considered analogous to a heat transfer matrix
with a water film surface area that depends on the water and air flow rates and on the
characteristics of the packing or fills. Heat will be given to the air by two mechanisms
as mentioned earlier Convection heat transfer and vaporisation of water.
When water is cooled by the effect of vaporisation, it transfers approximately

1000 Btu per pound of vaporised water to air. In other words, the evaporation of one
pound of water in a cooling tower, cools 100 pounds of water, with a decrement of
10 ° F .We can say as rule of thumb, that the evaporation of 1 kg of water-cools 100
kg of water, with a decrement of 5.5 ° C.
TERMS AND DEFINITIONS

Various terms / terminology used in cooling towers are explained as follows:
1. Air Flow: It is the total quantity of air including the associate water vapour flowing
through the tower expressed in cub. m. per sec or kg per sec.
PAGE :
REV : 00
AUTHOR : KDR
2. Fan Power: The power input to the fan in kilowatts.
3. Drift Loss[W]: Water loss caused by liquid drops carried away by the outlet air
stream. Drift should be minimised because the water carried by it can cause staining
on buildings at some distance from the tower. Drift is about 0.1 to 0.2% of circulation
rate. Evaporation loss[E] accounts to about 1 % of circulation rate for each 100F drop.
4. Inlet Water Flow: The quantity of hot water flow measured in m3 / sec or per
minute, flowing into the water distribution system.
5. Blowdown[B]: In cooling tower pure water is lost to the atmosphere due to

evaporation. Due to this the dissolved and suspended impurities in circulating water
get concentrated. These impurities when concentrated beyond certain desired level
will cause massive problems of scaling and corrosion. To maintain the most desired
level of impurities in circulating water, a certain amount of water is intentionally
removed from the system. This intentional removal of water is termed as blowdown.
The blowdown calculation is critical in determining cooling water treatment
chemicals’ feed rates and cost.
6. Make-up [M]: Water added to circulating water system to replace leakage,

evaporation, drift loss and blowdown.
M(m3/hr) = E + W + B + Loss in the system.
Depending upon the water quality, optimum operating parameters and selected water
treatment procedure, a certain maximum concentration of total dissolved solids
(TDS), of chloride ion (Cl-) or total hardness (TH) in circulating water is fixed. This
in turn will determine the desired cycle of concentration on which the cooling tower is
to be operated. The quantity of make up water needed for the blow down and windage
loss is then calculated using the following equations:
E = CR x R x 1.8 / 1000
B = E / (C-1)
where,
CR = Circulating rate, E= Evaporation rate, C = cycles Of Concentration.
7. Concentration: When water evaporates, dissolved solids and other impurities are
left behind leading to an increase in concentration of these impurities in circulating
water.
PAGE :
REV : 00
AUTHOR : KDR
8. Concentration Ratio: Ratio of the total mass of impurities in the circulating water to
the corresponding total mass in the make- up water. Water circulates through the heat
exchangers and over the cooling tower at a rate referred to as the recirculation rate.
Water is lost from the system through evaporation and blowdown. For all calculation
purpose blowdown is defined as all non-evaporative water losses (windage, leaks, and
intentional blowdown). As pure water evaporates minerals remains in the circulating
water, making it more concentrated than the make up water. The blowdown has the
same chemical composition as circulating water. By varying blowdown from the
cooling tower, control the degree of concentration of impurities in circulating water is
achieved. This is best defined as,
COC = Concentration of Mg hardness in circulating water (ppm)

Concentration of Mg hardness in make up water (ppm)
Cycle of concentration can also be calculated by taking ratios of chloride ion

concentration or silica. Choice of proper cycle of concentration for cooling tower is
determined by its design, water quality, operating Parameters and water treatment
Programme.i.e.,
Cycles of Concentration = Concentration in BLOWDOWN (BD)

Concentration in MAKE UP (MU)
As water dissolved solid level increases, corrosion and deposition tendencies

increase because corrosion is an electrochemical reaction, higher conductivity due to
higher dissolved solids increases the corrosion rate. It becomes progressively more
difficult and expensive to inhibit corrosion as the specific conductance approaches
and exceeds 10,000 mho.
Some salts have inverse temperature solubility i.e. they are less soluble at
higher temperature and thus tend to form deposits on heat exchanger tubes. Many
salts are less soluble at higher pH. As cooling tower water is concentrated and pH
increases, the tendency to precipitate scale increases. With or without chemical
treatment of cooling water, cycles of concentration are eventually limited by an
inability to prevent scale formation.
Increasing blow down to limit cycles of concentration is an effective way to

reduce the scaling potential of circulating water. Operating at 2 cycles of
concentration the make up water requirement for a 50,000 gpm system is 2000 gpm.
Increasing from 2 to 8 cycles decreases the make up requirement by 43 % to 1140
gpm. Make up water savings at higher than 8 cycles are negligible. The reduction of
blowdown at higher cycles is more significant because chemical treatment and waste
disposal costs relate directly to blowdown. Increasing cycles from 2 to 8 reduces the
blowdown by 86%. Further increase has a much smaller effect on the blowdown rate.
PAGE :
REV : 00
AUTHOR : KDR
9. Water Loading: Flow of water related to the cross sectional area of packing
normally expressed in kg/s or kg/min per m2 of cross section area of packing. It also
relates to amount of water to be handled for cooling per pass. It is also called
circulation rate, which relates to amount of water pumped per unit time and an
important parameter for calculation purposes. Usually it is the designed rating of the
circulation pump or pumps in the cooling water system. Generally it is expressed in
m3/ hr.
10. Wet Bulb Temperature: When water and air are in direct contact with each other
there is sensible heat transfer from air to water because of temperature difference
between the two. Similarly there is latent heat transfer from water to air because
evaporation. After a certain time of exposure, a condition of thermal equilibrium
exists where heat transfer rates from either side is same. This temperature is called as
Wet Bulb Temperature of air. In dry (unsaturated) air the wet bulb temperature
readings is always lower than the dry bulb reading. The wet bulb temperature is the
lowest temperature to which water can be cooled by evaporation. Cooling towers are
designed to cool water to a certain temperature under a given set of conditions. It is
not practical to design a tower to cool to the wet bulb temperature. Evaporation causes
cooling, cooling tower performance is lowest when wet and dry bulb temperatures are
equal. Even when air is saturated in the tower some cooling occurs by convection.
11. Ambient Air Wet Bulb Temperature: Wet bulb temperature measured on the
windward side of the cooling tower and free from the influence of the tower, or
surrounding air wet bulb temperature.
12. Inlet Air Wet bulb temperature: It is the average wet bulb temperature of the inlet
air including any recirculation effect measured at the entrance of cooling tower.
13. Nominal Inlet Air Wet Bulb Temperature: An arithmetic average wet bulb
temperature based on measurement taken within 1.5 m of the air inlets and between
1.5 m and 2.0 m above the basin kerb elevation on the both sides of the cooling tower.
14. Hot Water temperature: It is referred to as inlet hot water temperature, which is
distributed over top of the tower.
15. Re-cooled Water Temperature (Cold water temperature): It is average temperature

of water at the discharge point from the cold water basin excluding the effect of any
make up entering the basin.
16. Approach: The difference between the cold sump temperature i.e. exit water
temperature and the wet bulb temperature of the inlet air to the cooling tower is called
as approach. It is impracticable to cool the water to the inlet air level WBT. The
PAGE :
REV : 00
AUTHOR : KDR
smaller the approach the more complicated the tower design becomes. The minimum
reasonable approach temperature is 2 0C. However 4 to 6 0C is more usual. Approach
temperature varies with the entering air wet bulb temperature, the water flow rate, and
the heat load.
17. Hold Up Capacity: It is the capacity relating to the basin hold up volume which
should maintain a constant level at times and to hold all the water when the system is
under shut down. It also denotes total system capacity, which is the sum of total of
basin capacity, plus water contained in the piping and equipment. Most of the water is
in the basins or sump of the cooling tower and an extra amount of about 25 to 30% is
contained in the piping and the system.
18. Humidity: It is ratio of the weight of water vapour per unit weight of dry air. The
relative amount of heat going into increasing the temperature of the air and into
evaporating the water depends on the humidity of the air entering the cooling tower.
Humidity is expressed as a percentage of the maximum saturation by water

(Relative Humidity). If air holds all the water vapour it can hold at a particular
temperature it is called saturated. The relative humidity of air at the point of saturation
is 100%. As relative humidity increases evaporation decreases, hence performance
decreases. Thus in a cooling tower the air becomes more saturated as it moves in
contact with water and the rate of evaporation decrease. So if the air is continuously
changed by means of a mechanical draft, which employs either, induced or forced
draft, then the cooling tower efficiency increases.
19. Recirculation: It is that portion of outlet air that re-enters the tower. The
phenomenon of recirculation is almost absent in case of natural draft towers basically
because of a tall stack and the round shape of the tower. Among the mechanical draft
towers, recirculation is more pronounced in case of forced draft tower.
Recirculation is the phenomenon in which a portion of the saturated air

discharged from the tower under the influence of the force and direction of the wind
blows over and around the tower, and re-enters the tower with fresh air. The amount
of recirculation depends upon factors like the wind velocity, the stack height, the
ambient temperatures and the shape and the size of the tower. The effect of the
recirculation adulterates the ambient air entering the tower by increasing its wet bulb
temperature, thereby causing a considerable loss in cooling tower efficiency. The air
does not always recirculate, the behaviour of recirculation being erratic due to the
quick variations in the atmospheric conditions.
Recirculation is measured by means of inlet wet bulb temperature. This inlet wet bulb
temperature is higher than the ambient temperature by the amount of recirculation.
The rational value of inlet wet bulb temperature can be arrived at if we are to
PAGE :
REV : 00
AUTHOR : KDR
determine the rational values of ambient wet bulb temperature and the recirculation
allowance.
20. Heat Load: Rate of heat removal from the water flowing through the tower
expressed in kW.
1.3.3 PROCESS FLOW STREAMS
Following are the process streams in this system.
1) Sea water from seawater filtration package.

2) High Total Dissolved Solids treated effluent from Effluent Treatment Plant.
3) Blow-down from Cooling Tower No. 3 (Aromatics cooling tower Unit no. 733).
4) Water from Neutralisation Pit of Demineralisation Plant.
5) Water from storm water ponds.
A brief description of the characteristics/specifications of each stream is given as

follows.
1) Sea water from sea water filtration package.

Sea water is pumped from the filtered sea water tanks by pumps through 42”
epoxy lined CS pipes known as sea water intake lines. The water obtained
from the filtration package will be of following specification.
PARAMETER CONC. (as ppm CaCO3)

pH 7.5 – 8.0
TDS 39960
Chloride 21043
Sodium 14200
Bicarbonates 125
Calcium 461
Magnesium 1442
Sulphate 2500
Turbidity <10 NTU
Silica – Dissolved as SiO2 15
Silica – Colloidal as SiO2 2.0
TSS <5.0
The design flow rate of this stream is 1550 m3/hr.
PAGE :
REV : 00
AUTHOR : KDR
2) HTDS treated effluent.

High TDS effluent received from different plants is segregated and treated in
HTDS Effluent Treatment Plant. The treated water from the E T P will be of
following specification.
PARAMETER SPECIFICATION
pH 6.0-8.5
TSS <10 ppm
Oil <10 ppm
Phenols 1.0 ppm max.
TDS 10000 ppm max
Sulphides 0.5 ppm
BOD <15 ppm
Total Residual Chlorine <0.5 ppm
The designed flow capacity of HTDS stream from ETP is 500 m3/hr.
The operating capacity will be appx. 200 m3/hr.
3) Blow-Down from C.T. – 3 (Aromatics Complex unit no. 733).

With a view to minimise Desal. Make-up requirement and the overall treatment
cost, the make-up philosophy of all four cooling towers is devised as follows.
C.T. – 1 and C.T. – 2 will receive only Desal Water as make-up. The blow-down
from both the towers will be used as make-up to C.T. – 3, which will also receive
all LTDS treated water as make-up. Balance make-up requirement, if any will be
fulfilled by the Desal water. The blow-down from C.T. – 3 will be used as make-
up to C.T. – 4.
4) Water from the Neutralisation Pit of DM Plant.
Regeneration effluent from DM Plant and Condensate Polishing Unit is collected
in Neutralisation Pit and is used as make-up to C.T. – 4 after neutralising. The pH
of this stream will be 6.0 to 9.0.
5) Water from storm water ponds.

Water drained from different process plants are collected in storm water ponds
through the collection system. This water is pumped to C.T. – 4, to be used as
make-up.
PAGE :
REV : 00
AUTHOR : KDR
1.3.4 PROCESS UNITS
1) COOLING TOWER :
Make : Paharpur Cooling Towers Ltd.
Model No. : 674 - 4 - 010
Type: Induced Draft, cross-flow, splash bar fills
No. of cells: 10 (9 w + 1 s)
Capacity of each cell: 2331 m3/hr.
Tower Capacity: 23310 m3/hr.
Hot water temperature (return header) : 45 °C.
Cold water temperature (supply header): 32 °C.
Design wet bulb temperature : 28 °C.
Design wind velocity : 180 m3/hr.
Active tower volume : m3
Splash surface : m2
Recirculation allowance : °C.
Width of stair : 0.75 m
Slope of stair : 45°.
Tower size overall : 97.87m x 22.87m.
Height of stack / stack material : 4.19 / FRP.
Static Pumping Head Above Basin Curb : 13.6 m.
PAGE :
REV : 00
AUTHOR : KDR
Material of Construction :
Item name MOC
Frame work Treated Red wood

FC Valves CI epoxy coated
Sheathing Fire retard, FG
Partitions Treated Red wood
Filling Treated Red wood
Grids GRP (Glass reinforced polyester)
Louvers FRP (fiber reinforced polyester)
Nozzles, orifices / splash plates PP (polypropylene)
Riser pipes FRP
Fasteners SS 316
Anchor bolts SS 304
Drift eliminators PVC (poly-vinyl chloride)
Louver mould bars PVC
Hot water basin cover Plywood
For further details, refer PAHARPUR Operation And Maintenance Manual.
2) SUMP AND BASIN DATA:
Material of Construction : Reinforced Cement Concrete.
Width of the sump : 7.875 m
Height of sump : 5.1 m
Length of sump : 97.32 m
Width of basin : 15.394 m (individual basin)
Height of basin : 3.544 m
Length of basin : 9.452 m
Operating Range of sump level : 4.0 – 5.0 m (as minimum level of 4.0 m is
required for complete flooding of the circulation pump casing).
3) CHLORINATION PACKAGE:
PAGE :
REV : 00
AUTHOR : KDR
Make : Capital Controls Ltd.
Manufacturing Standard: Chlorine Institute
Motive water : Cooling water circulating pump discharge
Minimum in-take battery limit pressure required at operating flow : 4.1 kg/cm2 g.
Motive water operating flow (Available): 25 m3/hr.

Motive water temperature - Range: 32 – 45 °C.
- Normal: 32 °C.
Continuous dosing rate of chlorine: 0 – 1.8 mg/l.
(In addition to continuous chlorination, facilities shall be suitable for periodic slug
dosing at double the continuous rate)
Stream to be dosed: 22000 m3/hr.
Minimum chlorinator range: 0 – 80 kg/hr.
Chlorine gas pressure – max. at Ejector : atmospheric kgf/cm2 g.
INTERMITTENT OPERATION
Concentration of chlorine dosed: 0 – 3.6 mg/l.
Method of slug chlorination: Manually set dose rate applied using timers.
Period of slug injection : Adjustable up to max. 30 minutes
Frequency : Adjustable, max. 3 times in 24 hours.
ACCESSORIES
- 10 NO. x 5 m long horizontal sparger for injection of chlorine solution in to

the cooling tower basin. (for injection 1-3 m below the surface.)
- Automatic tank changeover to be provided to ensure gas for continuous dosing
is always available.
- Headers, connection and drum rollers for 2 on duty and 2 stand-by Toners.
For further detail refer, CAPITAL CONTROLS Operation And Maintenance

Manual.
PAGE :
REV : 00
AUTHOR : KDR
4) FAN DATA
Fan manufacturer: Paharpur Cooling Towers Ltd.
Model No.: Type HP-4 glass reinforced polyester blade fans.

289” through 336” Diameter.
Fans per cell: 1
Type: propeller type
No. of blades per fan : 8
Diameter of fan: 8.54 m
Quantity of air per fan: m3/min.
Fan speed: 992 rpm
Blade tip speed: m/s
Static differential pressure: bar
Power to drive each fan: kW
Total power air: m3/min.
Total tower power: kW
Blade material: FG
Hub material: HDGS
Manual pitch adjustment: Included
Pitch of Blades : 19.5 °.
4) GEAR DATA:
PAGE :
REV : 00
AUTHOR : KDR
Gear manufacturer: Paharpur Cooling Towers limited
Model no.: 32.2 series
Type & AGMA service factor:
Rating: kW
Speed ratio/ Mech. Efficiency:12.93 : 1.0
Coupling mfr / Model no.:
Coupling bore:
Type of oil: SAE 30
Oil capacity: 9.0 gallons i.e. 43.0 liters. Change oil every 6 months or 300 hours
of operation.
Drive shaft: 225/301 series
Coupling Type: Pin Bush type
Vibration Switch Type: MMR – 2X
Level switch for oil: MICRO Type
PAGE :
REV : 00
AUTHOR : KDR
1.3.5 EQUIPMENT SUMMARY

Sea water-cooling tower system consists of following equipment.
1) Cooling Tower
2) Cooling water circulation pump.
3) Cooling water circulation pumps motor.
4) Chlorination equipment.
5) Cooling tower fans.
6) Cooling Tower fan motors.
7) Gear-box for cooling tower fans.
8) T – type strainer in cooling water circulation pump suction line.
9) Motor operated valves in cooling water circulation pump suction and
discharge line.
The summary of the equipment is furnished as follows.
COOLING TOWER
Make : Paharpur Cooling Towers Ltd.
Model No. : 674 – 4 – 010

INDUSTRIAL CROSS-FLOW CLASS 600 COOLING TOWER
Type: Induced Draft, cross-flow, splash bar fills
No. of cells: 10 (9 w + 1 s)
Capacity of each cell: 2331 m3/hr.
Tower Capacity: 23310 m3/hr.
Hot water temperature (return header) : 45 °C.
Cold water temperature (supply header): 32 °C.
Design wet bulb temperature : 28 °C.
DESCRIPTION
GENERAL:
PAGE :
REV : 00
AUTHOR : KDR
Following are the instructions to be followed for different activities to ensure

efficient, long life from the Cooling Tower.
PRE-STARTING PROCEDURE:
CLEANING: Remove any debris, dirt and trash, which has accumulated in the hot
water distribution basins. Clean any nozzles that are clogged. Remove any
sediment from the cold water basin, sump and screens. Use a water hose to flush
cold water basins.
INSPECTION: It is imperative that all operating assemblies be inspected before

they are placed in operation. Following is a list of components to be checked
before staring the tower.
1. Check drive shaft alignment. Realign if necessary.
2. Check tightness of bolts that attach mechanical equipment support to the tower
framing. Check tightness of bolts in fan cylinder joints and fan cylinder
anchorage. Do not pull the washers into the wood.
3. Check tightness of bolts at diagonals and columns and at grits and columns in
the area between fan and cold water basin.
4. Check the tightness of the following bolted joints in the fan and drive
assemblies, i.e. fan hub clamp bolts, fan hub cover bolts, gear reducer and
motor mounting bolts and drive shaft coupling and guard bolts.
5. Check gear reducer oil for water accumulation by draining off and testing a
sample, as outlined in gear reducer service manual. Check gear reducer oil
level at “oil level” mark on the side of the case. Add oil as required. The oil
level placard must be adjusted so its ‘FULL’ mark is at the same elevation as
the ‘FULL’ mark on the side of the gear reducer case. Check oil lines to be
sure there are no leaks and all joints are tight. See Gear reducer service manual
for oil filling procedure and list of recommended lubricants.
6. Rotate fan by hand to be sure of free rotation and ample tip clearance. See fan
service manual.
7. Check motor insulation with a ‘megger’.
8. Lubricate the motor according to motor manufacturer’s instructions.
9. Test run each fan separately for a short time. Check for excessive vibration or
unusual noise. If either is present, stop the motor and rectify the problem. Fan
must rotate clockwise when viewed from above. Recheck oil level in gear
reducer.
10. Check functioning of make-up water supply.
11. Make sure that blow-down or bleed-off will carry required amount of water.
OPERATE WATER SYSTEM: Completely open all hot water flow control
valves. Start the circulation pumps. Increase the flow of circulating water
gradually to design flow rate to avoid surges of water hammer, which could
PAGE :
REV : 00
AUTHOR : KDR
damage the distribution piping. Circulate water over the tower continuously for
several days before starting any mechanical equipment any putting the tower onto
continuous operation.
STARTING PROCEDURE: Fill the cold water basin and circulating water system
until the operating level (4 Mts.) is reached. Completely open all the hot water
flow control valves of the basins to be taken in line. Then energize the pump
motor to be run and its suction and delivery MOVs. Open the suction MOV fully
and vent the pump. If required prime the pump manually. When the air is
completely vented in the pump then start the pump. Increase the flow of
circulating water gradually to design water rate to avoid surges of water hammer,
which could damage the distribution piping. Adjust valves to equalize the hot
water depth in the distribution basins. Lock valves in desired open position with
valve locking bar. Clean the sump screens several times during the first weeks of
operation. After this, clean sump screens as required.
STARTING THE FAN: Start the fan. After 30 minutes operation time, which is
required to permit the gearreducer oil to come to operating temperature and
viscosity, check the motor load with wattmeter or take operating volt and ampere
readings. Calculate motor HP. Fan blade pitch angle setting is important as it can
influence the load on the motor and also the efficiency of the fan.
OPERATION:
TOWER PERFORMANCE: Keep the tower clean and water distribution uniform
to obtain continued maximum cooling capacity. Do not allow excessive deposits
of scale or algae to build up on the filling or eliminators. Keep the metering
orifices free of debris to assure correct distribution and cooling of water. The
capacity of a tower to cool to a given cold water temperature varies with the WBT
of air entering the tower and the heat load. As the WBT drops, the cold water
temperature also drops. However, the cold temperature does not drop as much as
the WBT. A tower does not control the heat load. The quantity of water circulated
determines the cooling range for a given heat load. The hot and cold water
temperature increases with higher heat loads.
COLD WATER COLLECTING BASIN: The normal water depth in a wood basin
is 5 inches, while in concrete basin the normal water level is 8 to 13 inches below
the curb. Adjust the make-up water supply to maintain this water level. Low
operating depths of water require air baffles under the fill t prevent air bypass.
Maintain sufficient water depth to prevent cavitation.
HOT WATER DISTRIBUTION SYSTEM: Keep metering orifices clean and in

place in distribution basins. Adjust water flow to give the same depth in
PAGE :
REV : 00
AUTHOR : KDR
distribution basins of all cells. Design water depth varies from 3” to 5” depending
upon the design circulating water rate. If a major change in circulation rate is to
be made, replace the removable metering orifice with ones of new correct size to
provide adequate water break-up and maintain proper water level. The orifices
should be periodically checked for clogging.
WINTER OPERATION: During periods of low temperature operation, 2 to 7

Deg. C or below, ice will form on relatively dry parts of the tower that are in
contact with the incoming air. Primarily, this includes the louver and adjacent
structural framing.
Ice forming characteristics on any given tower will vary, depending on
velocity and direction of wind, circulating water flow rate and heat load.
Excessive ice formation may be controlled by regulating air and water flow
through the tower one or more of the following procedures.
1) Shut the fan down. This reduces the cooling rate to a minimum and increases
the quantity of warm water on the louver to a maximum. Except for excessive
cold conditions or extended freezing conditions, this procedure will normally
control ice formation. For automatic operation, a timer switch can be provided
to shut down the fan for a few minutes each hour.
2) If the tower has two-speed motors, operate the fan at half speed forward. This
reduces cooling rate and increases quantity of warm water on the louvers.
3) Under extreme cold conditions, it may be necessary to operate the fan in
reverse. This forces warm air out through the louvers, melting any
accumulated ice. Reversal may be either at full or half speed, however full
speed is recommended if adequate heat load is available. Reverse operation
should only be used to control ice, not prevent it. Reverse fan operation should
not exceed 15 to 20 minutes. Usually much than this is required to melt
accumulated ice.
4) With no heat load on the circulating water, icing cannot be controlled
effectively by air control during freezing weather. Towers must not be
operated with reduced water rate and /or no heat load during freezing weather.
If a bypass directly in to the cold water basin is used, all water must be
bypassed. Design of a bypass arrangement must include consideration of water
impact effect on tower components.
MAINTENANCE:
Well-maintained equipment gives the best operating results and the least
maintenance cost. A regular inspection schedule should be set up to ensure
effective safe operation of the cooling tower. Detailed activities to be followed on
individual equipment are described as follows.
PAGE :
REV : 00
AUTHOR : KDR
HOT WATER DISTRIBUTION BASINS: Metering orifices in the floor of the

hot water basin may be cleaned without shutting down any part of the tower.
Remove dirt, algae, leaves etc. that might get in these basins or orifices. The
metering orifices must be kept in place to assure proper water distribution.
Completely open and close flow control valves at least semi annually to remove
any scale on the threads. Grease the stainless steel stem to prevent scale forming.
Lubricate the valves at least semi annually with lithium base NLGI No.2
consistency grease. More frequent relubrication of valves and valve stems may be
dictated by circulating water conditions.
COLD WATER COLLECTING BASIN: Inspect collecting basin occasionally for

leaks and repairs if necessary. Minor leaks may appear in redwood basins when
staring with a dry basin but these generally disappear after the wood becomes
soaked. Keep cold water outlets clean and free of debris. Make-up and circulating
water controls must operate freely and maintain the desired water quantity in the
system.
TOWER FRAMEWORK: Keep framework bolts tight. Pay particular attention to

bolts in the mechanical equipment supports. Do not pull washers into the wood.
DRIVE SHAFT: Check drive shaft alignment and condition of coupling every six
months.
ELECTRIC MOTOR: Lubricate and maintain each electric motor in accordance

with the manufacturer’s instruction.
FAN: Inspect the fan blade surfaces every six months.
GEAR REDUCER: Make weekly and monthly oil checks. Inspect internal parts
during seasonal oil change.
PAINTING: Periodically clean and if necessary recoat all metal parts subjecte to
corrosion.
COOLING TOWER WOOD DETERIORATION: Untreated wood in cooling

towers can be damaged by decay anytime after the first year or two of service. If
decay is discovered and treated in early stages, serious wood damage can be
prevented. Routine inspections should be made to assure that decay is discovered
before it is heavily advanced.
Decay is generally of two types, Soft rot and Pocket rot. Soft rot is easy to
detect as it is almost always on the surface of wood members. It makes the surface
soft and weak and in its more advanced stages the decayed wood can be easily
removed. This type of rot occurs primarily in the flooded areas of the tower.
PAGE :
REV : 00
AUTHOR : KDR
Pocket rot, as the name implies, occurs in pockets inside of the wood members.
For the same reason, it is difficult to be detected than soft rot. Pocket rot most
commonly found in the heavier members in the plenum areas of the tower. One of
the best methods of inspection for pocket rot is ‘sounding’ with hammer blows.
Members which have pocket rot sound ‘dead’ while non-rotted members have a
‘ring’ or ‘live’ sound. Areas, which can sound ‘dead’, can be probed with a
screwdriver or other tool to verify the presence of pocket rot.
COOLING WATER CIRCULATION PUMP:
Applicable to: 22960-3PS-MP-002
Design data: 22960-3PS-GA-001
Vendor: KBL
Model: 24UPH3M Type : HSC
No. of Pumps: five (4 W + 1 S)
Type of Pump: Horizontal split casing, centrifugal pump
Pump capacity: 5500 m3/ hr (normal)
Discharge Pressure: 6.28 kg/cm2 abs
Suction pressure: 1.35 kg/cm2 abs (max.), 1.19 kg/cm2 abs. (rated.)
Differential pressure: 5.07 kg/cm2
NPSH available: 10.9 m
Hyd. Power: 760 kW

Differential head: 48.4 m
Impeller diameter: 740 mm (max)

660 mm (min)
689 mm (rated)
Name of liquid: Seawater
Pumping temperature: 32 °C – normal

45 °C – max.
PAGE :
REV : 00
AUTHOR : KDR
25 °C – min.
Specific Gravity @ 32 °C – 1.047
Vapour Pressure @ 32 °C – 0.051 kg/cm2 abs.
Viscosity @ 32 °C – 0.83 cP.
PERFORMANCE DETAILS:
Proposal curve no.: HA170960100/2B
Min. continuous flow: 1200 m3/hr.
Efficiency: 92 %
Rated power: 825.02 kW
Max. power @ rated impeller : 835.5 kW
Driver speed: 980 rpm
Pump speed: 980 rpm
NPSH reqd.: 7.0 m water
Max. head @ rated impeller: 63 m
Max. power @ max. impeller: 80 m
(Pressure and NPSH value are all referred to underside of base plate. NPSH
available refer to underside of base-plate at 8000 m3/hr. is 10.3 m).
CONSTRUCTION DETAILS:
Main connections:
UNIT Size Rating Facing Position

Suction 750 125 FF Side
Discharge 600 125 FF Side
Other connections:
PAGE :
REV : 00
AUTHOR : KDR
UNIT No. Size Type

Drain 1 1” Plugged
Vent 1 3/8” Valve
Press. Gauge 1 3/8” Valve
Temp. Gauge 1 3/8” Plugged
Casing mounting: Foot

Casing Split: Axial
Casing Type: Single volute
Impeller Style: Closed
Impeller Mount: Between Bearings
Shaft Rotation: (from coupling end) CCW
Sealing System: Packing
Packing Manf. / Type : CHAMPION / PTFE
Size / No. of Rings: 20 sq. mm / 10
Bearing Radial / thrust: Journal
Lubrication Type: Ring oil
Coupling Manf.: UNIQUE /
FLEXIBOX
Coupling Type: METAFLEX
GENERAL:
1) The Kirloskar make pump 24 UPH 3 MN is used for water. The pumps are
manufactured to close tolerance and are of rigid construction. However proper
installation, operation qnd maintenance are equally important to ensure trouble
free service. The following instructions should be followed carefully for
satisfactory performance of the pumping unit.
2) This is Horizontal Split Casing Centrifugal Pumps with suction dia. 750 mm
and Discharge dia. 600 mm nozzles. This construction enables to remove the
rotating unit for inspection and repairs by just removing upper half casing, oil
ring bearing upper half bearing cap and without disturbing alignment or pipe
connection.
3) Pumps when properly installed and given due care in operation and
maintenance should operate satisfactorily.
4) When the pump is received, sometimes before the actual use of pump. It
should be inspected and located in dry place. The coupling should be rotated
once in a month to prevent pitting of bearing surfaces.
INSTALLATION:
PAGE :
REV : 00
AUTHOR : KDR
The details are available in publication of KBL ‘General Instruction Manual

On Centrifugal Pumps’. Refer to Technical Data of packing and position of
lantern ring.
OPERATION:
Before staring the pump, check the following.
1) The pump rotates freely by hand.
2) Sealing connections are properly tightened and adjusted.
3) Fill oil in the bearing if not done earlier.
4) The direction of rotation of motor corresponds to direction of rotation of
pump.
5) The pump and the suction line is fully primed with liquid.
6) Valve on the delivery line is fully closed.
7) The cock for pressure gauge connection is closed.
8) Start the pump.
9) Let the prime mover pick up its full speed.
10) During running of the pump, check the following and regulate if necessary.
• The pump is running smooth.
• The flow of stuffing box sealing and oil ring bearing cooling liquid.
• Leakage through the stuffing box is normal, there should be leakage of 60
to 80 drops per minute.
• The bearing is not getting heated up excessively.
• Head and capacity developed by pump is as specified.
• Power consumption is within the limit.
• Ensure that there is no mechanical friction in the pump.
• Do not operate the pump at greatly reduced capacities or with the delivery
valve closed. Operating the pump in such a condition may be dangerous,
as the pump will get heated up due to churning of liquid. To guard against
possible damages protective devices such as liquid temperature relay, low
suction pressure control should be used.
• If the discharge through the pump increases due to reduced system
resistance, load on the motor increases heating up the motor. In such
conditions arrangements should be made to throttle the valve on delivery
side either manually or automatically to build pressure to a safe value.
• Stop the pump immediately if the defects are noticed. Do not start the
pump unless defects are rectified.
11) During stopping of the pump, following procedure is to be followed.
• Close the valve on Delivery side.
• Stop the motor.
• Close the cooling and sealing liquid connections.
• If the pump is not required to be operated for long time, drain the casing
completely.
PAGE :
REV : 00
AUTHOR : KDR
• Check the oil level periodically.
TECHNICAL DATA:
1) Direction of rotation: The direction of rotation is counter clockwise when
viewed from driving side.
2) The pumps are fitted with oil ring bearing and heavy duty deep groove ball
bearing at NDE and oil ring at DE, which are capable of carrying loads in
either direction.
The details of bearing are as follows.
DE : Oil Ring Bearing
NDE : Oil Ring Bearing with bearing no. 6322 (quantity – 01)
3) Lubrication: DE and NDE Bearings are oil lubricated. The specification of

recommended oil areas follows.
MANUFACTURER BRAND NAME

Indian Oil SERVO SYSTEM 321
Hindustan Petroleum ENCLO – 57
Caltex REGAL OIL PE
Refilling period: Appx. After every 1000 running hours.

Bearing Temperature: Allowable bearing temperature rise is 40 °C above
ambient temperature.
Quantity of oil: 1500 cc for each bearing at each filling.
4) Stuffing box: The pump is provided with a stuffing box at DE and NDE is
extra deep to reduce leakage and minimise maintenance. Split lantern ring
is provided in the stuffing box for sealing purpose. Clear cold water at 1.0
kg/cm2 is used for sealing. Stuffing box packing is of PTFE.
Size of gland packing:

Size and length: 24 sq. x 5600 mm L
No. of rings: 5
Position of Lantern ring from impeller side: 2 + L + 3
5) Coupling: The Triveni Flexibox couplings LS26 – 1800 – 1400 – 1000

(Ref. Dwg. No. 4TFC0013 Issue – 2) is used.
6) Paper packing: Paper packing of 0.4 mm thickness to be used between

upper and lower half casing (qty. 02).
MAINTENANCE:
PAGE :
REV : 00
AUTHOR : KDR
Preventive maintenance schedule is the periodical checks by which

possibilities of failure and breakdowns are made very remote. Following
are the daily and periodical checks and activities to be carried out.
Daily checks:
• Pressure gauge reading.
• Bearing temperature.
• Leakage through stuffing box.
• Noise and vibration.
• Voltage and current.
• Oil level.
• Temperature at outlet of cooling water.
Periodical Maintenance:
• Replenish the oil.
• Change the stuffing box packing.
• Check the alignment of pump set.
• Calibrate the measuring instruments.
• Check the sealing connection.
OVERHAULING:
With normal daily operating speed, the pump will be due for overhaul after
about 5000 working hours. This work should be done by skilled personnel.
Please refer to the cross sectional drawing while dismantling and reaasembly
of pump.
1) Dismantling:
• These pumps being of horizontally split casing type, it is not necessary to
disconnect the suction and delivery pipe connection for routing check ups.
• Remove coupling.
• Take out oil from chamber of oil ring bearing housing.
• Remove bearing covers at DE and NDE.
• Remove the upper half of oil ring bearing housing.
• Remove its accessories such as temperature indicator, sealing water
connection and oil level indicator etc.
• Remove split gland and clamping plate by removing gland eyebolt and
nuts.
• Remove the nuts and bolts joining the upper and lower half casing and
remove the upper half casing slowly taking enough care not to damage the
impeller, impeller ring, and casing ring. While removing the upper half
casing the release bolts provided should be tightened lowly so that top and
PAGE :
REV : 00
AUTHOR : KDR
bottom casing will be separated conveniently. The Dowel pins inserted for
location purpose should be removed before taking out the upper half
casing away from the lower half casing.
• Lift the rotating unit slowly after slinging it in correct fashion so that none
of the parts will be damaged. Take out the rotating unit and keep it in a
dry clean place for further dismantling purpose.
• Remove upper and lower half of oil ring bearing. Remove oil ring bearing.
• Start dismantling the unit further from driving end side. Remove pump
coupling and coupling key.
• Remove bearing lock nut at NDE side and take out deep groove bearing
with the help of bearing puller.
• Remove liquid deflectors, clamping plate and lantern ring from both ends.
• Unscrew the shaft sleeve nuts and shaft sleeves.
• ‘O’ ring has been provided in between the two shaft sleeves in order to
have a positive sealing against the leakage along shafts. Enough care
should be taken while refitting this ‘O’ ring. Otherwise due to negligence
it is very likely that this ring may get spoiled and thereby leakage may take
place. For some pumps flat gasket tapping is used.
• Take out the impeller gently either using suitable pullers or gently tapping
the shaft from the other end.
• Remove the impeller key.
• Take out the casing rings.
This completes the dismantling of the pump. Before proceeding for

reassembly of rotating unit and pump, following points have to be checked.
• Rotate ball bearing by hand and check if they rotate smoothly. Renew
them if they are not rotating freely or if the races are deteriorated.
• Check shaft for possible runout. Remove the same before assembly.
• Remove any dust or rust from parts, and if necessary apply new
paint/coating on the same.
• Clean all the parts thoroughly with kerosene or petrol.
• If reaasembly is not to be made immediately, apply rust preventive coating
on all machined surfaces.
• Examine all the parts for refitting, worn out etc. Damaged or corroded
parts should be either reconditioned or replaced by new ones.
• Check wearing of oil ring bearing inside diameter.
• Ensure that newly fitted parts are free from damage and burrs.
• Examine deflector, ‘O’ rings for damage or deterioration. If replaced with
new ones, make sure that they are of requisite dimensions.
PAGE :
REV : 00
AUTHOR : KDR
• Check the clearances of following parts and replace with new ones if
needed.
PART MAX. DIAM. CLEARANCE

Impeller ring and Casing ring 1.5 mm
Shaft sleeve and Stuffing box 2.0 mm
2) Reassembly:
• Fit the impeller key on the shaft. Mount the impeller on the shaft at its
middle portion. Check impeller vanes for correct direction of rotation.
• Insert packing or ‘O’ ring for shaft sleeve and impeller DE and NDE
between impeller and shaft sleeve. Mount shaft sleeve on the shaft and fit
shaft sleeve nut and shaft sleeve lock nuts with the help of suitable
spanner. Do not hammer or chisel these shaft sleeve nuts while tightening,
otherwise they will be spoiled.
• Insert clamping plate for gland and water deflector.
• Mount the bearing with the help of suitable sleeves. Do not hammer on the
bearing directly which may spoil the bearing. Tighten the bearing nuts and
locknuts.
• Mount the oil ring bearings with oil ring at DE and NDE on shaft with the
help of locating pins. Insert casing ring from both ends.
• Mount the pump coupling key and fit the pump coupling on the shaft from
DE side.
• Thus the assembly of rotating unit is completed. Lift it and insert it in
lower half casing correctly.
• Mount the upper half of oil ring bearing housing of DE and NDE side.
Tight it with oil ring bearing and bearing covers.
• Put the packing of correct size between casing halves, if it damaged. Put
the upper half casing on the lower half casing correctly, taking enough
care, otherwise the casing rings or impeller may get damaged. Tighten the
upper and lower half casings by the bolts and nuts. Rotate the unit by hand
and check whether it is rotating freely without any mechanical friction.
• Fill the gland packing along with lantern ring in the correct sequence as
given in technical data.
• Mount all the accessories such as oil level indicator, temperature indicator
and sealing connections etc.
• Fill the recommended oil in oil ring bearing housing upto the specified
level on oil level indicator.
PAGE :
REV : 00
AUTHOR : KDR
• Align the motor coupling with pump coupling.
This completes the reassembly of the pump.
CHLORINATION PACKAGE:
General: Increased fuel, operating and construction costs have forced large users
of cooling water to strive for maximum thermal and mechanical efficiency. This
requires, above all, clean heat exchanger and condenser surfaces to provide the
best possible heat transfer and cooling efficiency. Maintaining clean condenser
tubes and unrestricted cooling water flow requires careful control of mineral
scaling, corrosion, deposition of suspended matter and Biofouling.
Biofouling, in addition to restricting heat transfer, often serves as the ‘glue’
that blinds other deposits to the heat transfer surfaces. Conditions in a typical
cooling water system are close to ideal for biological and marine growth. The
water source is often a river, lake or coastal water. Each contain all the naturally
occurring organisms and nutrients that are required for biological growth. In-
organic and organic phosphates are often used for corrosion control thus adding
additional nutrients. Where towers and heat exchangers are used, chlorination is
applied to control slime and algae in the cold water basin and fills of the tower, as
well as the exchanger tubes and total pipeline network. When properly applied,
chlorine help to control zebra mussels, asiatic clams and other marine organisms
that grow in cooling water environment. Chemical dosages vary, but are generally
between 1.0 to 3.0 ppm range for continuous feed and 3.0 to 8.0 ppm for shock
treatment. Free Residual Chlorine (FRC) is measured in the hot return line to the
tower, determining the effectiveness and demand for chlorination. The amount of
chlorine required to destroy the biofouling organisms in the water and oxidise
organic and in-organic matter is called as Chlorine Demand. FRC should not
exceed 1.0 ppm over long periods of time. Keeping low FRC eliminates the waste
of chlorine and prevents damage to wooden towers.
The chlorination package is supplied by The Capitals Control Group.

The package unit consists of three major items.
1) Chlorine gas manifold skid
2) Chlorine gas feeder skid
3) Diffusers for distributing the chlorinated water inside the basins
Along with this, safety equipment like Gas mask canister type, Self-
contained Breathing Apparatus, Hand held chlorine gas detection meter with
rubber boot holder, first aid kit with eye wash bottles etc. are provided.
Maintenance tools like Hand toolkit and Emergency drum repair kits is
provided.
System description:
PAGE :
REV : 00
AUTHOR : KDR
The system is based on ejector principle. Chlorine stored in Chlorine

toners will be fed to Chlorine gas manifold skid through drum isolation valve and
flexible connectors. The manifold has vacuum regulator, pressure gauge with
HI/LO contact, drip leg heater, Y type strainer and vacuum changeover unit.
Chlorine will then be fed to Chlorine gas feeder skid. Chlorine gas feeder skid is
equipped with a isolation valve, high and low vacuum switches – one each,
manual gas flow meter, vacuum gauge, vacuum actuated valve with shock dosing
timer having manual override, a secondary check valve and an ejector on chlorine
side. On waterside an isolation valve, an NRV and an ejector are provided. The
chlorine will pass through the flow tube, shock dosing valve and fed to the ejector
where cooling water as power water will be fed at minimum press. of 4.1 kg/cm2
through 4” epoxy coated CS line. . The chlorinated water will leave the package
unit by a 4” FRP coated PVC line to the cooling tower. The chlorinated water line
is having diffusers (5.0 m long 10 nos.) for supplying chlorine to individual
basins. Isolation valve is provided on each basin line for enabling maintenance
and partial shutdown. The following table gives details of different equipment.
ITEM DESCRIPTION QTY.

1 2 Drum manifold (app. Length 1700 mm each ¾” N.B.) 2
¾” SCH 80 seamless carbon steel
1.1 Pressure gauge (4” dial) with HI/LO contact 2
(Fitted to manifold)
1.2 Flexible connector (10 ft) 4
1.3 Drip leg heater (240 V) 25W (Fitted to manifold) 2
1.4 Drum isolation valve 1.030 – 14 NGO THREAD 4
2 Drum roller trunnions (Pairs) 485 mm x 102 mm 4
3 Vacuum regulators 150 kg/hr (Fitted to manifold) 2
3.1 NPT Y strainer ¾” NPT (Fitted to manifold) 2
3.2 Drip leg heater (240 V) 25W (Fitted to manifold) 2
4 Vacuum changeover unit (chlorine 80 kg/hr) 1
(Fitted to manifold)
5 Manual floor mounting chlorine gas feeder (80 kg/hr) 1
5.1 Vacuum gauge 2 ½” (Fitted to chlorinator) 1
5.2 Low vacuum switch (Fitted to chlorinator) 1
5.3 High vacuum switch (Fitted to chlorinator) 1
5.4 1 ½” vacuum line actuated valve (110V) FPM seals 1
Man. Override (Fitted to chlorinator)
5.5 1 ½” Manual ball valve (Fitted to chlorinator skid) 2
5.6 Manual gas flow tube (Fitted to gas feeder) 1
5.7 24 hr. electronic timer (Fitted to gas feeder) 1
6 Motive water pressure gauge 0 – 10 kg/cm2 1
(Fitted to chlorinator)
PAGE :
REV : 00
AUTHOR : KDR
7 Ejector 120 kg/hr (nozzle – 1.125” , throat – 1.687” 1

(Fitted to chlorinator skid)
8 Secondary check valve (chlorine) – 1 ½” union connection 1
PVC-U (Fitted to chlorinator skid)
9 Diffuser 4” N.B. / 5.0 m long 10
The item nos. are written according to the vendor P & ID,
Drawing No. 80512 00 P 04 issue – Z
System Description:
From the 72” under ground cooling water supply header, a 4” tapping is
directed to the chlorination package. Cooling water as power water passes through
the ejector-creating vacuum in the chlorine gas vacuum line in the Chlorinator.
Chlorine gas is drawn at a rate determined by the manual gas flowrate valve on
the chlorinator to a 3” orifice ejector where it mixes with the power water to
provide a chlorine solution, which will be piped to the point of application.
There is a motorised valve in chlorine line to the ejector. Chlorine gas will
only be drawn into the system when the shock-dosing valve is OPEN and motive
water is flowing through the ejector.
. The chlorine will be dosed in each basin by a 4” diameter FRP coated PVC
pipe, which will serve as common distribution header. From the common header,
a 4” tapping for individual basins is provided. This line is having an isolation
valve provided for maintenance purposes and at the end a diffuser for distributing
the chlorinated water in basin.
Operation:
The chlorine gas manifold is made up of SCH 80 seamless steel having two
arms. Each arm is having two header valves on chlorine circuit, one pressure
gauge with HI/LO contacts, one vacuum regulator, one Y type strainer and two
drip leg heaters. Four chlorine toners can be connected to the manifold at a time.
Minimum requirement is one toner on each arm of the manifold. Both the arms
are connected to the outlet line by means of a common vacuum changeover unit.
There is an isolation valve mounted on each toner, which is connected to the
header valve by flexible link made up of Cadmium plated Copper. A container /
manifold valve is mounted on the toner, which is connected to the isolation valve
by means of a positive yoke connection which is sealed by a single lead gasket.
This lead gasket should be changed every time the connection is broken. All
chlorine calves are fitted with right hand threads. The condition of this pressure
chlorine pressure handling system is crucial to the safety and life expectancy of
the installation.
When combined with moisture, chlorine is very corrosive gas, forming
hydrochloric acid, which will corrode the surrounding equipment if even minor
leak is allowed to continue. If the gas is maintained in dry condition from the
PAGE :
REV : 00
AUTHOR : KDR
chlorine toner, very rarely corrosion will occur. When a chlorine pressure
connection is broken, chlorine is exposed to the atmosphere which, depending on
the humidity of air, will allow some moisture to combine with chlorine gas. If this
moist air is allowed to collect in the manifold, corrosion will ultimately cause the
manifold to fail. The purpose of the isolating valve is to isolate the manifold from
any moisture. Before a connection is broken, the isolating and the manifold valves
are closed. So, only limited amount of moisture will be allowed to enter the
system.
Gaseous chlorine can change to liquid state if the temperature decreases. To
combat this, keep the chlorine cylinder at constant ambient temperature. If the gas
is maintained at constant pressure, a drop in temperature, even as low as 0.56 °C
can cause liquid formation. Two drip leg heaters, each of 25W capacity are placed
on each arm of manifold. Should any chlorine liquefy, it will collect on the bottom
of the manifold and into the drip leg. The heater will vapourise the liquid. The
drip leg heaters should be made powered on at least 5 minutes prior to starting
chlorination. The heater should always be powered to help stop liquid carry-over
and minimise damage to the vacuum regulator.
The heart of the package is ejector. The ejector contains an orifice and water
supplied to the same creating a vacuum. The vacuum then moves through the
ejector check valve assembly, through vacuum tubing to the rate control valve.
The purpose of the check valve assembly is to prevent any water from backing up
into the vacuum regulator. The vacuum then moves through secondary check
valve, gets reduced across the rate valve and moves to diaphragm assembly of the
vacuum regulator. The diaphragm assembly is connected directly to the inlet valve
of the vacuum regulator. The vacuum on one side of the diaphragm is usually 20”
of water column and the other side of the diaphragm is open to atmospheric
pressure. This differential pressure causes the diaphragm to move and open the
chlorine inlet valve, allowing the gas to flow under vacuum to the point of
application. In case if the ejector is not working, the vacuum regulator will not
operate. The secondary check valve is an additional provision to avoid water entry
into the vacuum regulator.
Functions of Vacuum Regulator: There are four basic functions of vacuum
regulators, explained as follows.
1) Reduction of gas pressures to a regulated vacuum – The vacuum regulator
reduces the gas pressure entering its inlet to a constant vacuum level of 20” of
water. It does so by balancing the pneumatic forces acting on the diaphragm
(atmospheric on the vented side and vacuum on the inlet side) against the
force produced by the inlet spring. This level of vacuum is maintained as the
gas floes through the flowmeter.
2) Safety shut-off of gas pressure upon loss of vacuum – upon loss of vacuum in
the spring loaded vacuum regulator, whether from a severed vacuum line,
ejector failure, etc. the safety shut-off valve will immediately close. This
action stops the flow of gas at vacuum regulator inlet.
PAGE :
REV : 00
AUTHOR : KDR
3) Vacuum regulator pressure relief – A vent incorporated into the vacuum

regulator is used to prevent pressurisation of vacuum regulator caused by
improper seating of the safety inlet valve. Improper seating is caused by dirt
build-up on the valve seat. The dirt prevents seating of the inlet valve and
allows pressure to increase in the vacuum regulator. To relieve any pressure,
the regulator is vented to an external location. To help prevent venting, all
vacuum regulators have an inlet filter.
4) Isolation of vacuum regulator via the vacuum seating valve – The vacuum
seating valve in the vacuum regulator is designed to close when a high
vacuum condition exist in vacuum regulator (gas source is depleted or closed).
Vacuum Regulator Specification:

• Maximum allowable inlet pressure: 300 psig (20.7 bar)
• Maximum recommended inlet pressure: 150 psig (20.3 bar)
• Maximum temperature: 140 °F (60 °C)
• Minimum temperature: 40 °F (4.4 °C)
• Minimum recommended inlet pressure: 20 psig (1.4 bar)
• Operating vacuum level: 20” water column (minimum)
• Vent pressure relief setting: 3.5” to 4” water column
Depending on operation of shock dosing valve, the unit can be following modes.
1) Manual: By engaging the manual valve and moving through 90° note the
indicator will not change in this instance.
2) Local: This provides control of the shock-dosing valve by OPEN/CLOSE
pushbuttons located on the shock dosing control box fitted on the rear panel of
the chlorinator.
PAGE :
REV : 00
AUTHOR : KDR
3) Timed: A 24-hr. timer is fitted inside the shock-dosing control box. The timer
can be configured to open the valve at specific times of the day as
programmed for the unit.
4) Remote: A ‘closed’ volt free contact from a remote source can initiate the
remote open / remote close action of the valve.
The shock-dosing valve status is displayed locally and remotely by a telemetry

link. The vacuum status alarms are also provided.
PAGE :
REV : 00
AUTHOR : KDR

Cooling Water PDF

Uploaded by

Copyright:

Available Formats

Cooling Water PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Cooling Water PDF

Uploaded by

Copyright:

Available Formats

UTILITY COMPLEX RELIANCE PETROLEUM LIMITED SEA WATER COOLING

UNIT 734 JAMNAGAR TOWER

1.3.2 PRINCIPLE OF OPERATION

The mechanism of cooling is based on Evaporation. In cooling towers, natural

The cooling is accomplished partially by raising the temperature of the

When water is cooled by the effect of vaporisation, it transfers approximately

TERMS AND DEFINITIONS

2. Fan Power: The power input to the fan in kilowatts.

5. Blowdown[B]: In cooling tower pure water is lost to the atmosphere due to

6. Make-up [M]: Water added to circulating water system to replace leakage,

COC = Concentration of Mg hardness in circulating water (ppm)

Cycle of concentration can also be calculated by taking ratios of chloride ion

Cycles of Concentration = Concentration in BLOWDOWN (BD)

As water dissolved solid level increases, corrosion and deposition tendencies

Increasing blow down to limit cycles of concentration is an effective way to

15. Re-cooled Water Temperature (Cold water temperature): It is average temperature

Humidity is expressed as a percentage of the maximum saturation by water

Recirculation is the phenomenon in which a portion of the saturated air

1.3.3 PROCESS FLOW STREAMS

Following are the process streams in this system.

1) Sea water from seawater filtration package.

A brief description of the characteristics/specifications of each stream is given as

1) Sea water from sea water filtration package.

PARAMETER CONC. (as ppm CaCO3)

The design flow rate of this stream is 1550 m3/hr.

2) HTDS treated effluent.

3) Blow-Down from C.T. – 3 (Aromatics Complex unit no. 733).

5) Water from storm water ponds.

1.3.4 PROCESS UNITS

Make : Paharpur Cooling Towers Ltd.

Model No. : 674 - 4 - 010

Type: Induced Draft, cross-flow, splash bar fills

Capacity of each cell: 2331 m3/hr.

Tower Capacity: 23310 m3/hr.

Hot water temperature (return header) : 45 °C.

Cold water temperature (supply header): 32 °C.

Design wet bulb temperature : 28 °C.

Design wind velocity : 180 m3/hr.

Active tower volume : m3

Recirculation allowance : °C.

Width of stair : 0.75 m

Slope of stair : 45°.

Tower size overall : 97.87m x 22.87m.

Height of stack / stack material : 4.19 / FRP.

Static Pumping Head Above Basin Curb : 13.6 m.

Item name MOC

Frame work Treated Red wood

For further details, refer PAHARPUR Operation And Maintenance Manual.

2) SUMP AND BASIN DATA:

Material of Construction : Reinforced Cement Concrete.

Width of the sump : 7.875 m

Height of sump : 5.1 m

Length of sump : 97.32 m

Width of basin : 15.394 m (individual basin)

Height of basin : 3.544 m

Length of basin : 9.452 m

Make : Capital Controls Ltd.

Manufacturing Standard: Chlorine Institute

Motive water : Cooling water circulating pump discharge