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Cooling Water System

2/6/13 FSPD HYDRO ENGG. DEPARTMENT

Water requirement in industries

Water is one of the important utilities for most of the

industrial activities.

Water is required for the following purposes

Equipment Process Service/flushing Drinking Fire

cooling

Fighting

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Why cooling water system

All heat generated in the process and equipments cannot be

converted into work. A large portion of it has to be rejected.

The heat rejection is done through cooling water system

Heat is rejected to atmosphere by evaporating a portion of

cooling water in the cooling tower

Fresh water will be added to the system to compensate the

losses due to evaporation in the system.

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Cooling water
The term cooling water is applied where water is

circulated through equipment to absorb and carry away the heat. This definition includes: Industrial Air

heat exchange operations,

conditioning and refrigeration system, jacket cooling systems including power plants.

Engine

In the cooling process, temperature of the cooling

water is raised, depending on the cooling water flow.

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Cooling water systems

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Once-Through System
In this system, water passes through the equipment only once

and the warm water is usually discharged to its original source from which it is drawn.
APPLICATION

RIVER

FLOW

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Once-Through System
Advantages

System is very simple During cooling, water does not evaporate hence the cold and warmed water characteristics does not change. System has less potential for scale formation and corrosion Cooling towers, Hot water sump, etc. can be avoided in this system.

Disadvantages

Plant should be located near to the water body Discharging the warmed water to the water body raises the temperature, affecting the aquatic life and increasing the stringent restrictions on thermal discharge Contamination of large amount of water which cannot be treated efficiently or 2/6/13 FSPD HYDRO economically.

Need for Change

High competition in water demand. Scarcity of clean water. High cost of water. Increasing awareness towards water pollution Introduction of statutory regulations for waste discharge. Research & Development of water chemistry and Water

treatment technology.

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Recirculating cooling water system

In this system, same water is recirculated repeatedly after

cooling in the cooling tower

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Non Contact Open Circuit Cooling System

CONSUMER

HOT WATER SUMP

MAKE-UP

COLD WATER SUMP

COOLING TOWER

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Non Contact Open Circuit Cooling System

In this system water is circulated through

the equipment or heat exchangers to a cooling tower and then returned to the equipment or heat exchanger.
The recirulating water is always in contact

with air/atmosphere in a cooling tower where evaporation takes place. As a result

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Contact Open Circuit Cooling System

EOHT

CONSUMER

TREATMENT FACILITIES MAKE-UP SUMP COOLING TOWER

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Contact Open Circuit Cooling System

In this system the cooling water is sprayed on the

equipment/ product being cooled and it is in direct contact with the equipment/product as well as atmospheric air for heat rejection
Further cooling water will be treated to the quality to

suit the equipment requirement and recirculated.

Examples

Blast furnace gas cleaning system BOF Gas Cleaning system

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Closed Circuit Cooling System

OVER HEAD TANK
CONSUMER

HEAT EXCHANGER SOFT/DM WATER SUMP

MAKE-UP

SOFT/DM WATER PLANT CHEMICAL DOSING MAKE-UP COLD WATER SUMP COOLING TOWER

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Closed circuit recirculation system

Primary circuit

Cooling water in a closed recirculation system remains completely confined within the entire system including pipes heat exchangers.

Secondary circuit

The heat absorbed by the primary circuit fluid is transferred to secondary circuit water in the heat exchangers. The secondary water is recirculated in the cooling tower where heat is rejected by evaporation of the secondary water.

Examples

Blast Furnace Shell Cooling system BOF gas cooling system.

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Emergency water system

Any steel plant or other process plant is always susceptible

for various types of emergency.

Facilities provided for tackling emergency situations are: Emergency Diesel

Over Head Tank

Pumps

Generally, emergency water is supplied for a duration 15-20

mins at 30-40 % of the normal water circulation flow rate. 2/6/13 FSPD HYDRO

Cooling Water Treatment

Both open and closed recirculation cooling water system

experience all sorts of problems associated with cooling water like scale formation, corrosion, and micro biological fouling (only in open cooling system).
The cooling water is treated with various types of

chemical in order avoid above problems and to protect heat transfer efficiency of the system
Chlorine is one of the common Biocides used to control

biological fouling.
For prevention of scale formation and corrosion of the
2/6/13 FSPD sodium material, scale inhibitors like sulphuric acid,HYDRO

Major activities in detail engg. of water circulation system

Assignment from various technologists section indicating the

water requirement(industrial water, soft water, DM water) including pressure and temperature etc.

Based on the above water balance diagram will be prepared

indicating inflow & out flow , losses in system and fresh water requirement as make up water.

Fixing up capacity of pumps, heat exchangers, cooling towers,

filtration system, soft water/DM plant etc.

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Major activities in detail engg. of water circulation system

Preparation of layout drawings after fixing size of the pump house,

cooling tower and other units.

Issue of procurement specification for various equipment. Issue of assignments to various section for planning their facilities for

water circulation system.

Finalising the layout after receiving the input from the other sections

like size of the buildings for electrical, instrumentation, ventilation, etc.

Issue of assignments for civil and structural buildings as per the

finalised layout
Preparation of piping detail engineering drawings for execution at site. 2/6/13 FSPD HYDRO