“PREPARATION ON #300 AREA”

IW SUPPLY SYSTEM
PREPARED BY : JAYPALSINH BORADHARA
EMPLOYEE CODE : Y00550
DEPARTMENT : UTILITY (W22)
DATE : 18--2017
 PRESENTATION OUTLINE

 SCHEMATIC DRAWING OF WATER

TREATMENT SECTION
 ABOUT #300 AREA (COOLING TOWER)
 WATER IMPURITIES & ITS EFFECT
 COOLING WATER PROBLEMS
 SUPPLY FLOW RATE & REQUIREMENTS
 MAIN SPECIFICATION OF COOLING TOWER
 SITE PICTURES
 MASS FLOW BALANCE SHEET
 SCHEMATIC DIAGRAM

300# 800#
NG
IW cooling PA Station STATION
system

100 #

Treated Water plant

UTILITY CONTROL 400#
N2 & H2
BUILDING DM WATER PLANT
STATION
WATER SYSTEM

700#

WASTE WATER TREATMENT PLANT

 COOLING TOWER

Cooling towers are heat removal devices

used to transfer process waste heat to
the atmosphere. Cooling towers may either
use the evaporation of water to remove
process heat and cool the working fluid to
near the wet-bulb air temperature or, in the
case of closed circuit dry cooling towers, rely
solely on air to cool the working fluid to near
the dry-bulb air temperature.
 TYPES OF COOLING TOWER

COOLING TOWERS

Natural Draft Mechanical Draft

Design of Cooling tower is
such that cold air at the Forced Draft Induced Draft
bottom of tower pushes the
warmer air out from top. Air is pushed in Air is pulled from
the tower with a
cooling tower by
fan at the side. a fan at the top

Counter Flow Cross Flow

 TYPES OF COOLING TOWER

Natural Draft
Forced Draft
TYPES OF COOLING TOWER
Counter Flow Cooling Tower
CSCI-COOLING TOWER
 COOLING TOWER COMPONENTS

FRAME & CASING – support the exterior enclosures

FILL- to facilitate heat transfer by maximizing water & air contact
COLD WATER BASIN- the basin usually has a sump or low point for
the cold water discharge connection.
DRIFT ELIMINATORS - these capture water droplets entrapped in the
air stream that, otherwise would be lost to the atmosphere
LOUVERS – the purpose of louvers is to equalize air flow into the fill
and retain the water within the tower. mostly used in cross flow.
NOZZLES – these provide the water sprays to wet the fill.
FANS – propeller & centrifugal are generally used in cooling tower.
propeller fan is generally used in induced draft.
 COOLING TOWER PERFORMANCE

COOLONG TOWER
PERFORMANCE :
COOLONG RANGE :-
RANGE = HOT WATER
TEMPRATURE – COLD
WATER TEMPERATURE
COOLING TOWER
APPROACH :-
APPROACH = COLD WATER
TEMPERATURE – WET BULB
TEMPERATURE
 COOLING TOWER CALCULATION
EVAPORATION E:-
E = ∆T × R × 0.00085 (T in °F)
E = ∆T × R × 0.00153 (T in °C) Where,
where, E=Evaporation
R= Recirculating Rate in (m3/hour)
Temperature drop ∆T:-
∆T= TR – TS where TR – inlet temp.
TS – outlet temp.
Make up Water MU:-
MU = E + BD where, MU = make up rate (m3/hour)
E = evaporation rate (m3/hour)
BD = blowdown rate (m3/hour)
 COOLING TOWER CALCULATION

BLOW DOWN RATE BD:-

BD= E/CR-1 Where, BD = blowdown rate (m3/hour)
E = evaporation rate (m3/hour)
CR = cycle of concentration
 CYCLE OF CONCENTRATION :-
C.O.C = TSS in recirculation water
TSS in make up water
COOLING WATER PROBLEMS

MICROBIOLOGICAL
GROWTH

FOULING
 CORROSION

 An electrochemical process in which a metal in it’s elemental

form returns to it’s native.

WATER (ELECTROLYTE)

H2 O
++ -
Fe OH
O2 O2
=
Fe(OH) O
3

Fe(OH)2
ANODE CATHODE
ELECTRON
FLOW
 CONSEQUENCE OF CORROSION

 Reduced heat transfer (lost efficiency)

 Increased cleaning (added costs and hassle)
 Equipment repair and replacement (lost revenue)
 Process or waste–side contamination (poor product
quality)
 Unscheduled shutdown (lost revenue)
 TYPES OF CORROSION

Uniform corrosion
or
Localized corrosion

Macroscopic Microscopic
• Galvanic Other • Intergranular
• Concentration Cell • Microbiological
• Corrosion Fatigue
• Pitting • Erosion Corrosion
• SCC
• Selective Leaching
 Galvanic Corrosion
 Two dissimilar metals in contact with an
electrolyte
 Anode and Cathode in different metals
 One metal is the anode, the other is the
cathode
 One metal corrodes, the other is protected

Brass Bolt
Aluminum
Electrolyte

Corroded Zones
Galvanic Corrosion
 CONCENTRATION CELL

 Anode and Cathode in same metal (c.f.

galvanic corrosion
 Anode becomes localized by some mechanism
that makes it the preferred site
 Can occur at crevices or under deposits
CONCENTRATION CELL
 PITTING
 Caused by Localized Deposition & Differential Oxygen cells.
Tuberculation leads to pitting

Tubercle

Protective Film
Water

Iron

Pit Forming
at Small Anodes(陽極)
 Selective Leaching
Selective removal of one element from an alloy
by corrosion

– Examples:

• Dezincification - removal of zinc from brass alloys

• Graphitization - removal of Fe from cast iron

• Dealuminumification - removal of Al from aluminum

bronzes

• Denickelification - removal of Ni from Cu: Ni Alloy

 Selective Leaching

Dezincification of Admiralty Brass Denickelification of Cu:Ni Alloy

 Erosion Corrosion
• Via compact(high speed water flow or
suspended solid)
• Rate of corrosion affected by:
– Velocity
– Turbulence
– Impingement
– particulate solids

 Copper alloys particularly susceptible as

soft
Erosion Corrosion
Microbiological corrosion
 STRESS CORROSION CRACKING(SCC)

 Localized attack due to a combination of surface

tensile stress, temperature and a corrosive
environment
 Either inter or transgranular
 Certain ions are particularly aggressive to certain
metals
SCC Failure
 SCALE TYPES

•sludge
•Organic and oil
•precipitation
•Corrosion product
•Microorganism product
FOULANTS

• Mud / Silts
• Organics / Oils
• Dust / dirt
• Matter precipitated in
bulk water
• Corrosion products
• Microorganisms
 FOULANTS

• Suspended Solids - settle in low flow areas

–obey Stokes Law
–shell-side coolers, plate exchangers
• Organic materials and microorganisms can act
as binding agents
• Do not form scale deposits by themselves
MICROORGANISMS POLLUTION
MICROORGANISMS FORMING
TYPES
• Algae
• Fungi
• Bacteria
ENVIRONMENT
• Water
• Temperature
• pH
 COOLING TOWER DOSING

o Corrosion inhibitors
o scaling inhibitors
o Dispersant
o H2SO4
o NaOCl
 MAIN SPECIFICATION OF COOLING TOWER

1300M3/Hour×2 cells× 45 – 35 ° C Cross flow type

× 29 ° C –W.B (Including 1 set stand by)
Flow rate = 1200 m3/hour
Cycle of concentration = 3 times
Inlet temperature = 45 ° C
Outlet temperature = 35 ° C
Windage loss = 0.22 %
 MAIN SPECIFICATION OF COOLING TOWER

• Evaporation loss = 20.7 m3/hour

• Windage loss = 0.24 m3/hour
• Blow down = 10.1 m3/hour
• Make up = 31.1 m3/hour

 Retention Time (T) for cold well = 1258 m3/hour

1200 m3/hour
T = 62.9 minutes.
 IW supply pumps = 720 CMH × 65 M × 3 sets ( Including 1 set
stand by)
 Emergency IW pump = 250 CMH × 60 M × 1 set
SUPPLY FLOW RATE & REQUIREMENT

Design Flow rate = 1200 m3/hour

Design temperature : <35°C
Design supply pressure at T.O.P = 4.5 Kg/cm2
pH = 7~8.5
Suspended solid (mg/L) : <30
Total hardness as CaCO3 (ppm) : <800
 SUPPLY FLOW RATE & REQUIREMENT

1) ACL plant requirement = 716 m3/hour

2) Compressed air supply system = 105 m3/hour
3) Utility control Building = 50 m3/hour
4) Auxiliary Building = 243 m3/day
5) Main Substation Building = 76 m3/hour
 Total flow rate = 1190 m3/day
 Design flow rate = 1200 m3/hour
 Design temperature = 45°C
 SITE PICTURES

COUNTER
FLOW
COOLING
TOWER

H2SO4
STORAGE
NaOCl TANK
STORAGE
TANK

EMERGENCY
RETURN PUMP ROOM
HEADER
 SITE PICTURES

FAN STACK

COUNTER
FLOW
COOLING
TOWER

COLD WELL
IW SUPPLY PUMP P-
3A01A/B/C
MASS FLOW BALANCE
 THANK YOU
ANY QUESTION?