COOLING WATER

TREATMENT PROGRAM
REVIEW

Prepared by : SAMI TAIMURI

Purification Plant 1
 Cooling Tower Design Data
Parameters Units CT - 10 CT - 11 CT - 12/13
In Service Since year 1987 1991 1998
System Volume m3 91 145 1550
Recirculation Rate m3/hr 824 682 3170
Cooling Water Return
F 109 120 97
Temp.
Cooling Water Supply
F 81 88 79
Temp.
Temperature Difference F 28 32 18
Evaporation m3/hr 18.4 17.2 44.4

Cycle of Concentration 5 5 5

Bleed off m3/hr 4.6 4.3 11.10

Make up m3/hr 23 21.5 55.5
Purification Plant 2
 Cooling Water Network
Cooling Tower Cooling Tower Cooling Tower Cooling Tower
11 10 12 13
Dehydration Units
01 To 06

Bank 11 Bank 10 Bank 09 Bank 08 Bank 07 Bank 06

Bank 13

Bank 12

Purification Plant 3
 Treatment Program
Original Program
Previous Current
Chemicals Description Dosage Dosage
kg/day kg/day
CWT P55 Corrosion and Scale Inhibitor 13.0 25.0
Drewsperse 2675 Antifouling Reagent 5.0 7.5
Drewsperse 738 Dispersant 11.5 18.5
Drew WPD 11-66 Corrosion Inhibitor 0.3 0.3
Biocide - 250 Non Oxidizing Biocide 97.5 97.5
Sodium Hypo Oxidizing Biocide 350 770
Sulphuric Acid For pH control 200 420
Additional Chemicals
Drewsperse 794 Iron Despersant .. 22.5
Drewguard 189-C Zinc Supplement .. 150
Biosperse 227 Non Oxidizing Biocide (Monthly) .. 150
Biosperse 280 Non Oxidizing Biocide (Monthly) .. 145
Purification Plant 4
 Problems
Hard scale / sludge deposits on plates of plate-
frame heat exchangers.
Under deposit corrosion and deep pitting on
shell side of secondary coolers (bank 12/13)
Hard scale in bearing housing of MEA pumps.
White deposits on cooling towers.
Dispersant 2675 has high chemical affinity for
iron therefore major portion of dispersant was
consumed by iron and formed a complex

Purification Plant 5
Bank 12 Secondary Cooler No. 3

Purification Plant 6
Bank 12 Secondary Cooler No. 3

Purification Plant 7
Bank 13 Secondary Cooler No. 1

Purification Plant 8
Bank 11 Secondary Cooler No. 1

Purification Plant 9
Bank 11 Secondary Cooler No. 2

Purification Plant 10
 Corrective Actions
Revision of controlling parameters.
Monthly co-ordination meetings at site.
Cross test of OWS results by PP lab.
Joint inspection of equipments before cleaning /
corrective actions.
Increase backwashing frequency.
Side stream filtration (CT 10 and 11)
Addition of Iron dispersant 794.
Suggest to replace Hypo with Non oxidizing biocide.
In house training by OWS and lab personals.
Automation on cooling tower for close monitoring.

Purification Plant 11
 Revised Limits
OLD LIMITS NEW LIMITS
Parameters CT - 10, CT -
For All CT CT 6/7 CT- 11 12/13
pH 7.0 - 7.5 7.0 - 7.8 7.0 - 7.8
Calcium Hardness, ppm as CaCO3 50 - 400 <550 <550
M - Alkalinity, ppm as CaCO3 <200 50 - 100 50 - 100
Chloride, ppm <550 <500 <300
Silica, ppm as SiO2 <100 <100 <100
Total Inorganic Phosphate, ppm as
(PO4) .. 13 - 17 13 - 17
O-PO4, ppm as PO4 8 - 12 .. ..
Delta O-PO4, ppm as PO4 .. 0.5 - 2.0 0.5 - 2.0
Zinc, ppm as Zn 1.5 - 2.5 1.5 - 2.5 1.5 - 2.5
Total Iron, ppm Fe < 1.0 <3.0 <3.0
ORP mv .. >450 >450
TPC, cft / ml <104 <104 <104
SRB, sulphate reducing bictriea Nil Nil Nil
5.0 - 6.5 (Chloride
Cycle of Concentration base 5.0(Silica base) 3 - 4 (Silica base)
Langlier Saturation Indox (LSI) 0.5 - 0.5 0.5 - 0.5 0.5 - 0.5
Purification Plant 12
 Trends of July 2008

Zinc and Phosphate

CT-06/07 PO4 Zinc CT-10 PO4 Zinc

4.5 4
1.7 4 1.7 3.5

Zinc (ppm)

Zinc (ppm)
PO4 (ppm)

PO4 (ppm)
3.5
3 3
1.2 2.5 1.2 2.5
2
0.7 1.5 0.7 2
1 1.5
0.5
0.2 0 0.2 1

CT-11 PO4 Zinc CT-12/13 PO4 Zinc

4
1.7 3.5 1.7 4
Zinc (ppm)

Zinc (ppm)
PO4 (ppm)

PO4 (ppm)

3 3
1.2 2.5 1.2
2
0.7 2 0.7
1.5 1
0.2 1 0.2 0

Purification Plant 13
 Trends of July 2008

TIP and LSI

CT-06/07 TIP L.S.I CT-10 TIP L.S.I

0.5 0.5
26 26
0.3

TIP (ppm)
0.3
TIP (ppm)

22 22 0.1

LSI
0.1

LSI
18 18 -0.1
-0.1
14 -0.3 14 -0.3
10 -0.5 10 -0.5

CT-11 TIP L.S.I CT-12/13 TIP L.S.I

0.5 0.9
26 26
0.3 0.7
TIP (ppm)

TIP (ppm)

22 0.1 22 0.5
LSI

LSI
0.3
18 -0.1 18 0.1
14 -0.3 14 -0.1
-0.3
10 -0.5 10 -0.5

Purification Plant 14
 Trends of July 2008

Calcium Hardness and Chloride

CT-06/07 Calcium Chloride CT-10 Calcium Chloride

350 350
300 400 300 400

Chloride

Chloride
Calcium

Calcium
250 300 250 300
200 200
200 200
150 150
100 100 100 100

CT-11 Calcium Chloride CT-12/13 Calcium Chloride

350 350
300 400 300 400
Chloride

Chloride
Calcium

Calcium

250 300 250 300

200 200
200 200
150 150
100 100 100 100

Purification Plant 15
 Trends of July 2008

COC and ORP

CT-06/07 COC ORP CT-10 COC ORP

700 5 700
6 600 600
4

ORP

ORP
COC

COC
500 500
5 3
400 400
4 300 2 300

CT-11 COC ORP CT-12/13 COC ORP

700 5 700
6 600 600
4
ORP

ORP
COC

COC

500 500
5 3
400 400
4 300 2 300

Purification Plant 16
 Agenda of Meeting
Effectiveness of Zinc / PO4 program in H2S atmosphere.
Iron Oxide deposits / under deposits corrosion in shell side of shell
and tube heat exchangers.
Difference in corrosion result of corrosion coupon and the system.
Reaction of iron with Dispersant 2675 polymer forming an anionic
iron complex resulted in low iron in cooling water system.
White deposits (Scale) in oil coolers of MEA pumps.
Trail run of non oxidizing biocides (BS 227, BS 280). Effectiveness
and cost comparison with previous program[ Sodium Hypo + Non
oxidizing biocide 250 (monthly shock dose)]
How to estimate the effectiveness of Iron dispersant 794.The ratio of
iron in raw/cooling water does not reflect according to revised COC.
Additional cost of chemicals being used against initial
recommendations by M/s OWS.
Excessive chemical dosing of CWT P55, Hypo and H2SO4.
Short comings of automation.

Purification Plant 17
THANKS
.

Purification Plant 18