GL1.

Z COMPLEX - SONATRACH
PROCESS OPERATING MANUAL

CLOSED COOLING WATER SECTION No 11.1~ REVISION No. 2

GL1.Z RENOVATION PROJECT

TABLE OF CONTENTS
1.0 GENERAL OVERVIEW...........................................................................................1 2.0 OPERATING PRINCIPLES....................................................................................1 2.1 Process Description...............................................................................................1 3.0 PREPARATION FOR START-UP...........................................................................2 3.1 Filling the System..................................................................................................2 4.0 NORMAL START-UP...............................................................................................2 5.0 NORMAL OPERATION...........................................................................................3 5.1 Normal Operating Parameters..............................................................................3 6.0 PROCESS CONTROL..............................................................................................3 7.0 NORMAL SHUTDOWN...........................................................................................4 8.0 PROTECTIVE SYSTEMS AND EMERGENCY SHUTDOWN.............................4 8.1 Primary Protection................................................................................................4 10.0 TROUBLESHOOTING..........................................................................................4 11.0 APPENDICES.........................................................................................................6 11.1 DCS Print-outs....................................................................................................6 11.2 Process Flow Diagrams - PFD's.........................................................................6 11.3 Process and Instrument Diagrams P&ID's......................................................6 11.4 Cause and Effect Charts......................................................................................6

CLOSED COOLING WATER

PROCESS OPERATING MANUAL

1.0

GENERAL OVERVIEW The closed cooling water system is installed to provide the cooling system for the Turbine Seal gland condensers, Turbine Ejectors, the Process Boiler areas and the Mitsubishi 400 T/hour boiler auxiliary equipment. The cooling water is distilled water with corrosion inhibitor added. Alternatively, potable water can be used as a makeup supply.

2.0 2.1

OPERATING PRINCIPLES Process Description The closed cooling water systems are located in Units 200/400/600. Each system supplies 2 Process units and may supply the Mitsubishi 400 T/hour boilers via a common header. Normal operation has only one unit supplying the Mitsubishi boiler. Two electric motor driven pumps are supplied for each system. Normal operation has one in service with the other in "Auto" standby. Water exits the discharge of pumps, X20-J370/371 and flows to "plate" exchangers, X20-E-334/335 where it is cooled by seawater from the process seawater supply system. The closed cooling water system supplies the following users: Forced draft Fan turbines (Process boilers) 7X0-D301K1T, 7X0D302K1T, 7X0-D303K1T bearings and Lubrication oil coolers. Seal cooling for BFW pump 7X0-J-349. Oil cooling for BFW pumps and turbine 7X0-J-349/369 Sample coolers for 7X0-D301/302/303 Bearing cooling for X02-K01.30R-JT1 Bearing cooling for X01-J-503 MEA pump. Bearing cooling for X04-J-07.95 C3 transfer pump. Bearing cooling for X10-J-07.47 C3 return pump. Bearing cooling for X10-J-07.37 C2 return pump. Bearing cooling for X10-J-07.57 C4 recycle pump. Bearing cooling for X10-J-07.61 C4 recycle pump. Gland condenser X05-K01.20E Ejector condenser X05-E-301 Ejector condenser X05-E-302 Gland condenser X05-K01.21E Gland condenser X03-K01.10E Gland condenser X02-K01.30E Ejector condenser X03-E-313 Ejector condenser X02-E-319 Bearing cooling for X03-K-01.10R JT1 Bearing cooling for X03-K-01.10R JT3

SECTION 11.1

Rev 2

Aug 2001

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CLOSED COOLING WATER

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The cooling water returns back to the pump suction lines. On the return header a Surge drum, (X20-G-338) is provided to maintain stable flow to the pump suction. Potable water make-up is added via LV-X20-01 as is necessary to maintain the proper water level in the system. 3.0 3.1 PREPARATION FOR START-UP Filling the System This section describes the initial cleaning and filling of the Closed cooling water circuit after a shutdown. Fill X20-G-338 to 80% with potable water via LV-X20-01. Remove the suction spools on both CCW pumps, (X20-J370/371). Open the suction valves on both pumps and flush the piping until clean. Reinstall the suction spools with temporary strainers in line. Refill X20-G-338 to 80% with potable water. Remove the inlet spools on X20-E-334/335 downstream of the valves. Ensure both pumps are primed. Start either pump, (discharge closed) and slowly open the discharge valve to flush the piping to the cooler inlet lines. Reinstall the inlets spools when the piping is clean. Refill X20-G-338 to 80%. Disconnect the inlet/outlet piping to all CCW users and install pipe spools. Flush the lines until clean using the system pumps. Repeat this process until all the piping is clean in all trains. Inventory the system with distilled water. Add the proper corrosion inhibiting chemicals, (Nalco 8539) and circulate the system. 4.0 NORMAL START-UP It is assumed that the system has been filled with distilled water and the necessary chemicals added. Set LIC-X20-01, at 60% in Automatic. Ensure the seawater is open to one of the seawater exchangers. SECTION 11.1 Rev 2 Aug 2001 Page 5 of 5

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Start one of the CCW pumps in the "HAND" position. Place the stand-by pump in "AUTOMATIC". Open the supply and return valves to each piece of equipment as is necessary for start-up. 5.0 5.1 NORMAL OPERATION Normal Operating Parameters Normal operation of the closed cooling water circuit has a system supplying Units 100/200, a system supplying Units 300/400, a system supplying Units 500/600 and one of the units supplying the 4 Mitsubishi boilers. The system has one pump and one heat exchanger in service with the other pump in Automatic standby, starting by PSLL-X2014. Normal pump discharge pressure is 4.6 Bar. Design flow from the pump discharge is 695 m3/hr with the exchanger outlet temperature of 30 C. The cooling water flow to the 4 Mitsubishi boilers is 320 m 3/hr and the flow to each process unit being 187.8 m3/hr. The cooling water return header design temperature is 35 C. 6.0 PROCESS CONTROL The closed cooling water system supplies cooling water to the various users in the Process units and the Mitsubishi boilers. A surge drum X20G-338 is provided for the pump suction and to maintain a constant level in the system. Level indication is provided locally on gage glasses, LGX20-02A/B. A level transmitter, LT-X20-01 is provided which sends a signal to LIC-X20-01, which in turn acts upon LV-X20-01 to makeup potable water into the system. LIC-X20-01 is normally set at 50% and has High and Low alarm functions on the DCS. Two circulation pumps, X20-J-370/371 are provided with local hand switches (3 position) H-O-A. Normal operation is one pump in the Hand position, the other in Auto standby. Pump running indication is provided on the DCS by JI-X20-18/19. Pump discharge pressure is indicated locally by PI-X20-15 (X20-J-370) and PI-X20-16 (X20-J-371). On the common discharge header a pressure switch, (PSLL-X20-14) is provided which sends a signal to PALL-X20-14 that automatically starts the standby pump on low header pressure. Pressure transmitter PT-X20-13 is provided with DCS indication on PI-X20-13. Temperature is indicated locally on TI-X20-12. The cooling water flows through one of the two exchangers X20-E334/335 where it is cooled by seawater. Local CCW outlet temperature is provided on TI-X20-07/08. Provisions to measure the Seawater outlet SECTION 11.1 Rev 2 Aug 2001 Page 5 of 5

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temperature are installed on each exchanger TW-X20-09/10. A local differential pressure indicator, PDI-X20-17 is installed to measure the differential pressure across the seawater inlet strainers for plugging. Common CCW outlet temperature is monitored by TE-X20-11 with DCS indication and alarm functions on TI-X20-11. 7.0 NORMAL SHUTDOWN The closed cooling water system is similar to the seawater system, as when equipment does not require CCW it can be isolated to the equipment. To shutdown the entire system: Isolate the valves from the Mitsubishi boiler supply and return header. Stop the pumps, X20-J-337/338. De-energize the electrical supply. Isolate LV-X20-01, potable water make-up supply. Isolate and drain the system as is required. 8.0 8.1 PROTECTIVE SYSTEMS AND EMERGENCY SHUTDOWN Primary Protection TSV-X20-06, X20-E-335 thermal relief set at 6 Bar. TSV-X20-03, X20-E-334 thermal relief set at 6 Bar. 10.0 TROUBLESHOOTING Effect Check List Immediate Action

Low level in X20-G- Check the level on the Ensure there is 338 sight glass. distilled & potable water available from Check the operation of utilities. LIC-X20-01 High cooling water Verify the temperature temperature on TI- locally. X20-11 Check seawater inlet strainer, PDI-X20-17 Adjust the seawater flow. Switch exchangers, isolate and clean the seawater inlet strainer.

Pump discharge Verify the standby Ensure the pump is in pressure low, PALL- pump has started. Automatic. X20-14 SECTION 11.1 Rev 2 Aug 2001 Page 5 of 5

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Check instrumentation.

SECTION 11.1

Rev 2

Aug 2001

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11.0 11.1 11.2 11.3

APPENDICES DCS Print-outs Process Flow Diagrams - PFD's Process and Instrument Diagrams P&ID's 85-X00-24.1 85-X00-24.2 85-X00-24.3 85-X00-24.4 85-X00-26

11.4

Cause and Effect Charts

SECTION 11.1

Rev 2

Aug 2001

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