COOLING WATER

SYSTEM
Prepared by:
Mohammad Shoeb Siddiqui
Senior Shift Supervisor
Saba Power Plant
 INTRODUCTION
Cooling water is the water
removing heat from a machine or
system. Cooling water may be
recycled through a re-
circulating system or used in a
single pass once-through
cooling (OTC) system. Recirculating
systems may be open if they rely
upon cooling towers or
cooling ponds to remove heat
or closed if heat removal is
Prepared by: Mohammad Shoeb Siddiqui
 Introduction
Industrial cooling towers may use river water, coastal
water (seawater), or well water as their source of
fresh cooling water. The large mechanical induced-
draft or forced-draft cooling towers in industrial
plants continuously circulate cooling water through
heat exchangers and other equipment where the
water absorbs heat. That heat is then rejected to the
atmosphere by the partial evaporation of the water
in cooling towers where upflowing air is contacted
with the circulating downflow of water. The loss of
evaporated water into the air exhausted to the
atmosphere is replaced by "make-up" fresh river
water or fresh cooling water. Since the evaporation of
pure water is replaced by make-up water containing
carbonates and other dissolved salts, a portion of the
circulating water Prepared
is by: also continuously discarded as
Mohammad Shoeb Siddiqui
 Circulating Water
System
CTF
From Bore Wells
Raw & Fire
Ambient Condition
Water Tank
Temp. 27.5 oC
Capacity Humidity 88.5 %
2155 m3
CW I/L
Temp.
30 oC

CW
Pumps CW O/L
Temp. 45 oC
Condenser
Cooling
Tower
CCW Heat Air flow
Exchanger
CT Makeup

Air flow

Prepared by: Mohammad Shoeb Siddiqui

 Background
Hot
Water
Coolin
Condense
Air g Air
r
Tower

Cooled Make-up
Water Water

Condenser:
The condenser is the most important component of the turbine
cycle that affects the turbine heat rate. The function of the
condenser is to condense exhaust steam from the steam turbine by
rejecting the heat of evaporation to the cooling water passing
through the condenser. Generally, twin shell- double pass- surface
type condensers are employed for higher capacity units

Prepared by: Mohammad Shoeb Siddiqui

COOLING TOWER

Prepared by: Mohammad Shoeb Siddiqui

COOLING TOWER

Prepared by: Mohammad Shoeb Siddiqui

TYPES OF COOLING TOWER
Different types of
cooling towers are
used in the power
plants depending upon
the location, size,
infrastructure and
water resources etc.
Close cycle – wet
cooling systems:
-Induced draft
- Forced draft
- Natural draft cooling
towers
Prepared by: Mohammad Shoeb Siddiqui
TYPES OF COOLING TOWER

Natural draft
 Large concrete chimneys
 generally used for water flow rates above 45,000
m3/hr
 utility power stations
Mechanical draft
 Lrge fans to force or suck air through circulated
water.
 The water falls downward over fill surfaces, which
help increase the contact time between the water
and the air maximising heat transfer between the
two.
 Cooling rates of Mechanical draft towers depend
upon their fan diameter and speed of operation
Prepared by: Mohammad Shoeb Siddiqui
TYPES OF COOLING TOWER
Natural Draft Cooling Towers
• Hot air moves through tower
• Fresh cool air is drawn into the
tower from bottom
• No fan required
• Concrete tower <200 m
• Used for large heat duties

Prepared by: Mohammad Shoeb Siddiqui

TYPES OF COOLING TOWER
Natural Draft Cooling Towers

Prepared by: Mohammad Shoeb Siddiqui

TYPES OF COOLING TOWER
Natural Draft Cooling Towers
• Air drawn across • Air drawn up
falling water through falling water
• Fill located • Fill located inside
outside tower tower

Cross flow Counter flow

Prepared by: Mohammad Shoeb Siddiqui
TYPES OF COOLING TOWER

Mechanical Draft Cooling Towers

• Large fans to force air through
circulated water
• Water falls over fill surfaces:
maximum heat transfer
• Cooling rates depend on many
parameters
• Large range of capacities
• Can be grouped, e.g. 4-cell tower
Prepared by: Mohammad Shoeb Siddiqui
TYPES OF COOLING TOWER

Mechanical Draft Cooling Towers

Three types
• Forced draft
• Induced draft cross flow
• Induced draft counter flow

Prepared by: Mohammad Shoeb Siddiqui

TYPES OF COOLING TOWER
Induced Draft Cooling Towers
• Two types
• Cross flow
• Counter flow
• Advantage: less recirculation than
forced draft towers
• Disadvantage: fans and motor drive
mechanism require weather-
proofinh
Prepared by: Mohammad Shoeb Siddiqui
TYPES OF COOLING TOWER
Induced Draft Counter Flow CT
• Hot water enters at the top
• Air enters at bottom and exits at top
• Uses forced and induced draft fans

Prepared by: Mohammad Shoeb Siddiqui

TYPES OF COOLING TOWER
Induced Draft Cross Flow CT
• Water enters top and passes over fill
• Air enters on one side or opposite sides
• Induced draft fan draws air across fill

Prepared by: Mohammad Shoeb Siddiqui

TYPES OF COOLING TOWER
Forced Draft Cooling Towers
• Air blown through
tower by centrifugal
fan at air inlet
• Advantages: suited
for high air resistance
& fans are relatively
quiet
• Disadvantages:
recirculation due to
high air-entry and low
air-exit velocities

Prepared by: Mohammad Shoeb Siddiqui

 Components of Cooling Tower
 Frame and casing
 Fill
 Cold water basin
 Drift eliminators
 Air inlet
 Louvers
 Nozzles
 Fans
 Pumps
 Chemical Dosing System

Prepared by: Mohammad Shoeb Siddiqui

Components of Cooling Tower
• Frame and casing: support exterior
enclosures
• Fill: facilitate heat transfer by maximizing
water / air contact
• Splash fill
• Film fill
• Cold water basin: receives water at bottom
of tower

Prepared by: Mohammad Shoeb Siddiqui

 Components of Cooling Tower

• Drift eliminators: capture droplets in air stream

• Air inlet: entry point of air
• Louvers: equalize air flow into the fill and retain
water within tower
• Nozzles: spray water to wet the fill
• Fans: deliver air flow in the tower
• Pumps: deliver the water flow in the tower

Prepared by: Mohammad Shoeb Siddiqui

Components of Cooling Tower
Tower Materials
 Wooden components included the frame, casing,
louvers, fill, and often the cold water basin
 Galvanized steel, various grades of stainless steel,
glass fiber, and concrete
 enhance corrosion resistance, reduce maintenance, and promote reliability
and long service life
 Plastics are widely used for fill, including PVC,
polypropylene, and other polymers. Plastics also find
wide use as nozzle materials
 Aluminum, glass fiber, and hot-dipped galvanized
steel are commonly used fan materials.
 Centrifugal fans are often fabricated from galvanized
steel. Propeller fans are fabricated from galvanized,
aluminum, or molded glass fiber reinforced plastic

Prepared by: Mohammad Shoeb Siddiqui

Components of Cooling Tower
Fill Media Effects
 Heat exchange
between air and water
is influenced by
surface area of heat
exchange, time of heat
exchange (interaction)
and turbulence in
water effecting
thoroughness of
intermixing. Fill media
in a cooling tower is
responsible to achieve
all of above.

Prepared by: Mohammad Shoeb Siddiqui

Assessment of Cooling Towers
Measured Parameters
• Wet bulb temperature of air
• Dry bulb temperature of air
• Cooling tower inlet water temperature
• Cooling tower outlet water temperature
• Exhaust air temperature
• Electrical readings of pump and fan
motors
• Water flow rate
• Air flow rate

Prepared by: Mohammad Shoeb Siddiqui

Assessment of Cooling Towers
Performance Parameters
1. Range
2. Approach
3. Effectiveness
4. Cooling capacity
5. Evaporation loss
6. Cycles of concentration
7. Blow down losses
8. Liquid / Gas ratio

Prepared by: Mohammad Shoeb Siddiqui

FACTORS AFFECTING COOLING
TOWER PERFORMANCE
 Capacity

 Heat dissipation (in kCal/hour) and

circulated flow rate (m3/hr) are not
sufficient to understand cooling tower
performance.
 For example, a cooling tower sized to cool
4540 m3/hr through a 13.9oC range might
be larger than a cooling tower to cool
4540 m3/hr through 19.5oC range.

Prepared by: Mohammad Shoeb Siddiqui

 Efficient System Operation
 Cooling Water Treatment
 Drift Loss in the Cooling Towers
 drift loss requirement to as low as 0.003
– 0.001%
 Cooling Tower Fans
 Flow Control Strategies

Prepared by: Mohammad Shoeb Siddiqui

Prepared by: Mohammad Shoeb Siddiqui
Assessment of Cooling Towers
1. Range Hot Water Temperature (In)
 Difference between
cooling water inlet
and outlet

Range
temperature: (In) to the Tower
(Out) from the
Tower

 Range (°C) = CW inlet

temp – CW outlet Cold Water Temperature (Out)
temp Approach

Wet Bulb Temperature (Ambient)

 High range = good
performance

Prepared by: Mohammad Shoeb Siddiqui

Assessment of Cooling Towers
2. Approach
Difference between cooling Hot Water Temperature (In)

tower outlet cold water

temperature and ambient
wet bulb temperature:

Range
(In) to the Tower
(Out) from the
Tower
Approach (°C) =
CW outlet temp – Wet bulb
temp Cold Water Temperature
(Out)

Approach
Low approach = good
Wet Bulb Temperature
performance (Ambient)

Cold Water Temperature 32.2oC – Wet Bulb

Temperature (26.7oC) = Approach (5.5oC)
Prepared by: Mohammad Shoeb Siddiqui
Assessment of Cooling Towers

3. Effectiveness
Hot Water Temperature (In)
Effectiveness in %

= Range / (Range +
Approach)

Range
(In) to the Tower
(Out) from the
= 100 x (CW temp – CW Tower

out temp) / (CW in

temp – Wet bulb temp)
Cold Water Temperature
(Out)
Approach
High effectiveness =
good performance Wet Bulb Temperature
(Ambient)

Prepared by: Mohammad Shoeb Siddiqui

Assessment of Cooling Towers
4. Cooling Capacity
Hot Water Temperature (In)
Heat rejected in kCal/hr
or tons of refrigeration
(TR)

Range
(In) to the Tower
= mass flow rate of water (Out) from the
Tower
X specific heat X
temperature difference
Cold Water Temperature
High cooling capacity = Approach
(Out)
good performance
Wet Bulb Temperature
(Ambient)

Prepared by: Mohammad Shoeb Siddiqui

Assessment of Cooling Towers
5. Evaporation Loss
Water quantity (m3/hr)
evaporated for cooling duty Hot Water Temperature
(In)

= theoretically, 1.8 m3 for

every 10,000,000 kCal heat

Range
(In) to the Tower
rejected (Out) from the
Tower

= 0.00085 x 1.8 x circulation

Cold Water Temperature
rate (m3/hr) x (T1-T2) Approach (Out)

T1-T2 = Temp. difference Wet Bulb Temperature

(Ambient)
between inlet and outlet water

Prepared by: Mohammad Shoeb Siddiqui

Assessment of Cooling Towers
6. Cycles of concentration (C.O.C.)
Ratio of dissolved solids in circulating water to
the dissolved solids in make up water

7. Cycles of concentration (C.O.C.)

Depend on cycles of concentration and the evaporation
losses

Blow Down = Evaporation Loss / (C.O.C. – 1)

Prepared by: Mohammad Shoeb Siddiqui

Assessment of Cooling Towers

8. Liquid Gas (L/G) Ratio

Ratio between water and air mass flow rates

Heat removed from the water must be equal to the heat

absorbed by the surrounding air

L(T1 – T2) = G(h2 – h1)

L/G = (h2 – h1) / (T1 – T2)

T1 = hot water temp (oC)

T2 = cold water temp (oC)
Enthalpy of air water vapor mixture at inlet wet bulb temp (h1) and outlet wet
bulb temp (h2)

Prepared by: Mohammad Shoeb Siddiqui

Energy Efficiency Opportunities

1. Selecting a cooling tower

2. Fills
3. Pumps and water distribution
4. Fans and motors

Prepared by: Mohammad Shoeb Siddiqui

 Heat Load

 The heat load imposed on a cooling tower is

determined by the process being served
 In most cases, a low operating temperature is
desirable to increase process efficiency or to
improve the quality or quantity of the
product. In some applications (e.g. internal
combustion engines), however, high
operating temperatures are desirable
 The size and cost of the cooling tower is
proportional to the heat load

Prepared by: Mohammad Shoeb Siddiqui

 Wet Bulb
Temperature
 Minimum cold water temperature to which water can be
cooled by the evaporative method
 Thus, the wet bulb temperature of the air entering the
cooling tower determines operating temperature levels
throughout the plant, process, or system.
 Theoretically, a cooling tower will cool water to the
entering wet bulb temperature, when operating without a
heat load. However, a thermal potential is required to
reject heat, so it is not possible to cool water to the
entering air wet bulb temperature, when a heat load is
applied
 The temperature selected is generally close to the
average maximum wet bulb for the summer months
whether it is specified as ambient or inlet

Prepared by: Mohammad Shoeb Siddiqui

 Range, Flow and Heat
Load
 Range is a direct function of the quantity of water
circulated and the heat load. Increasing the range as a
result of added heat load does require an increase in the
tower size. If the cold water temperature is not changed
and the range is increased with higher hot water
temperature, the driving force between the wet bulb
temperature of the air entering the tower and the hot
water temperature is increased, the higher level heat is
economical to dissipate.
 If the hot water temperature is left constant and the range
is increased by specifying a lower cold water temperature,
the tower size would have to be increased considerably.
Not only would the range be increased, but the lower cold
water temperature would lower the approach. The
resulting change in both range and approach would
require a much larger cooling tower.

Prepared by: Mohammad Shoeb Siddiqui

Saba Power
Plant Data
Prepared by: Mohammad Shoeb Siddiqui
SABA POWER PLANT DESIGN DATA
1 x 4 cell cooling tower
Design data: GEA
Type: Counter flow.
Number of cells: 4
Cell Size (ft x ft) 60 x 60.
Overall Length/ Width (ft x ft) 240 x
60.
Distribution type: Up spray.
Snow Load: 0
Design wind velocity: 100 mph.
Prepared by: Mohammad Shoeb Siddiqui
 SABA POWER PLANT DESIGN DATA

Cooling Tower Performance Data:

Water circulation: 58,558 gpm(13300

m³/hour)
Inlet water circulation temperature:
91.4ºF (33ºC)
Outlet Water Temperature: 71.42ºF (22ºC)
Design wet bulb temperature 62.96ºF
(17.2ºC)
Prepared by: Mohammad Shoeb Siddiqui
SABA POWER PLANT DESIGN DATA
2 x 100% duty mixed flow centrifugal pumps.
Capacity: 60,000 gpm.

2 x 1000 HP motors use to drive the circulating water pumps

Speed: 500 RPM.
Voltage: 6.6Kv.

4 x cooling tower with induce draft fans.

Speed: 98.3 RPM.
Number of blades: 6 per fan.

4 x cooling tower fan motors.

Speed: 1500 RPM.
Rated capacity: 200 HP.
Rated Voltage: 415 Volts.

4 x Amarillo gearboxes.
Reduction ratio: 15:1by: Mohammad Shoeb Siddiqui
Prepared
SABA POWER PLANT DESIGN DATA
1 x Condenser

Design Data: Made Ecolaire

Steam load: 588,694 LB/HR
Steam Temperature: 100.61oF
Heat rejected to circulating water: 555.5161 million BTU/HR.
Effective Tube length: 9398 mm
Effective Condenser surface: 62,462 Sq.Ft.
Circulating water flow: 55,256 gpm
Circulating water inlet temperature: 21.6oC
Cleanliness factor: 90%
Average Circulating water velocity in tubes: 7.2 FT/SEC
Absolute Pressure: 50 mm HgA
Circulating water friction loss through clean tubes and water box: 16.22 Ft.
of water.
Number of tubes: 7777
Tubes material: SS-A249 TP 304L, 22BWG
Tubes outer diameter: 25 mm

Prepared by: Mohammad Shoeb Siddiqui

SABA POWER PLANT DESIGN DATA
Bently Nevada vibration monitoring system (3300 series).

The main components of the cooling tower dosing system

are:
1 x Acid storage tank . Capacity 16.5 cubic meters

2 x Acid dosing pumps, Neptune. Capacity 125 lph, 7 kg/cm2

Motor capacity 1 KW

1 x Anti-scalant dosing tank, Capacity 190 liters

2 x Anti-scalant dosing pumps, Neptune. Capacity 5 lph, 50

kg/cm2
Motor 1 KW

Prepared by: Mohammad Shoeb Siddiqui

SABA POWER PLANT DESIGN DATA
2 x Chlorination booster pumps, Jonson March
Capacity 43.14 m3/h, 28 mlc
Motor 5.6 KW, 1,440 rpm

1 x Chlorine evaporator
Capacity 2,727 Kg/day

1 x Chlorinator
Capacity 2,727 Kg/day
2 x Ton chlorine cylinder containers for liquid chlorine

1 x Weigh scale for the chlorine cylinder container

capacity 0 to 1,800 Kg.

Prepared by: Mohammad Shoeb Siddiqui

 Working Principle
During normal operation, one circulating water pump
is in service supplying approximately 60,000
gallons of water at a temperature of 30ºC and a
pressure of 1.4 kg/cm² to the Main condenser and
the closed cooling water plate heat exchangers.
The circulated water makes two passes in the
condenser. Water enters the condenser waterbox
inlet and flows through the tubes into the return
waterbox, and then through the second set of tubes
and into the outlet waterbox.
As the circulating water flows through the tubes, the
exhaust steam thermal energy is transferred to the
circulating water. Rapid condensation of the steam
occurs and a vacuum is created in the condenser.
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 Working Principle
The heated water returns to the top of the cooling
tower via four pipe risers and into a horizontal
distribution header pipe. From there, it branches
into a system of lateral distribution pipes, where
the nozzles spray the water downward in a
predetermined pattern over the heat exchange
medium, or fill.
Before the air flow is permitted to exit through the
top of the tower, it must pass through the drift
eliminators. The shape of this material causes the
air to change directions and thus provides impact
surfaces which prevent water droplets from being
carried out of the tower with the air flow.
The cold water basin of the cooling tower catches the
falling water, Prepared
which then flows back to the
by: Mohammad Shoeb Siddiqui
 Working Principle
As this process takes place, a small percentage of water is
loss due to evaporation. Ambient temperature and
Relative Humidity also affect the rate of evaporation.
The cool water is then recirculated to the users.
When the water evaporates in the cooling tower
operations, most of the dissolve solids remain behind in
a non-evaporative state. If the ratio of these
concentrations become excessively high, scale and
deposits will form in the Main condenser tubes and other
piping. This will drastically affect the efficiency of the
condenser, which will in turn cause a high back pressure
for the steam turbine.
To reduce the amount of total dissolve solids (TDS) in the
system, blowdown is required. The operating (TDS)
range is blow (3500 PPM). Cooling tower make up is
therefore necessary to replace the water loss caused by
evaporation, blowndown, windage
Prepared by: Mohammad Shoeb Siddiquiand carryover.
 Working Principle

WATER TREATMENT
Cooling tower maintenance can
be very high unless the water is
treated to prevent corrosion,
biological growth, and deposits.
Water treatment also protects
the cooling tower wood from
chemical attack.
Prepared by: Mohammad Shoeb Siddiqui
 Working Principle
WATER TREATMENT
Due to the evaporation that takes place in the
cooling tower, the dissolved solids in the water
become concentrated. The evaporated water must
be replaced by make up water. The circulating
water becomes more concentrated than the make
up water due to this evaporation loss. The cycle of
concentration is the term applied to indicate the
degree of concentration of the circulating water
with the make up water. Some water of the cooling
tower is also lost due to wind or drift loss, this is the
loss of fine droplets of water that are carried away
by the circulating air. In mechanical draft towers,
0.1 % to 0.3 % wind losses are possible. The water
treatment process plays a vital role in the cooling
tower operation. Prepared by: Mohammad Shoeb Siddiqui
 Working Principle
WATER TREATMENT
Calcium bicarbonate which is normally
present in raw water, breaks down to form
relatively insoluble calcium carbonate.
Calcium carbonate scale is the most
common type of water formed deposits in a
cooling system. The Langlier Index
measures the tendency of CaCO3 to
precipitate under given conditions of
calcium hardness, alkalinity, pH,
temperature and total dissolved solids. A
positive index means that water will tend to
deposit scale while a negative index tends
Prepared by: Mohammad Shoeb Siddiqui
 Working Principle
WATER TREATMENT
The Saba Power Plant cooling water system
has three (3) dosing systems.

Sulfuric acid dosing

Anti-scalant dosing

Chlorination injection

Prepared by: Mohammad Shoeb Siddiqui

 Working Principle
WATER TREATMENT
Sulfuric Acid Dosing System

Chemical treatment with sulfuric acid

keeps the scale forming salts of
calcium and magnesium in solution
by lowering the pH of the circulating
system. At Saba, the pH is
controlled between 7.8 to 8.5.
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 Working Principle
Anti-scalant Dosing System

Chemical inhibitors are needed to check corrosion.

Surface active chemicals or chelating agents
such as sodium hexameta phosphate prevent
crystal growth & therefore scale formation. In
effect, they increase the solubility range of scale
forming salts. Controlled scale treatment adjusts
the composition of water so that a thin
impervious layer of calcium carbonate scale
deposits on the surface of the circulating water
system. The scale must be thick enough to
prevent any corrosion, but thin enough not to
effect the overall heat transfer.
For the Anti-scalant dosing system, there is one
dosing tank of 220
Prepared litters
by: Mohammad capacity with two
Shoeb Siddiqui
 Working Principle
Chlorination System
Microbiological growth, slimes &
algae, retard cooling, cut cooling
efficiency and increases the
maintenance cost of the cooling
system. When growth breaks loose,
it will clog pipelines, pumps &
equipment. Mechanical cleaning is
the best way to get rid of
accumulated growths. But to keep
slime & algae from getting a toehold
in the first place, chlorine gas is
Prepared by: Mohammad Shoeb Siddiqui
Saba Power Plant

Precautions,
Limitations
and Setpoints

Prepared by: Mohammad Shoeb Siddiqui

 Precautions, Limitations and
Setpoints
Before starting any circulating water pump (CW-PP-
1/2), verify that all four (4) riser isolation valves to the
distribution header at the cooling tower, are fully
opened.
The circulating water pumps (CW-PP-1-2) motors are
limited to the number of starts, depending on the
existing conditions. This limitation is designed to
protect the stator and rotor from excessive heat that
is generated from the high inrush current when a
motor is started. If the motor is in a cold condition
(standby), three (3) consecutive starts are allowed. If
the motor was running and achieved normal operating
temperature, the motor will be limited to two (2)
consecutive starts. If the number of starts is
exceeded, the IQ-1000 which is the supervisory
instrumentation Prepared
located
by: Mohammadon the respective motor
Shoeb Siddiqui
 Precautions, Limitations and
Setpoints
The circulating water pumps (CW-PP-1-2) are equipped
with temperature sensing devices (TE-1028A-J for CW-
PP-1 and TE-1031A-J for CW-PP-2) that continuously
monitor the motor bearing and winding temperatures.
If any winding temperatures exceeds 170°C an alarm
will annunciate on the DCS (TAH-1028A-F for CW-PP-1
and TAH-1031A-F for CW-PP-2) and if the winding
temperature exceeds 180°C the respective motor will
trip and an alarm will annunciate on the DCS (TAHH-
1028A-F for CW-PP-1 and TAHH-1031A-F for CW-PP-2).
If any motor bearing temperature exceeds 90°C, an
alarm will annunciate on the DCS (TAH-1028G-J for
CW-PP-1 and TAH-1031G-J for CW-PP-2) and if bearing
temperature exceeds 95°C the respective motor will
trip and an alarm will annunciate on the DCS (TAHH-
1028G-J for CW-PP-1
Preparedand TAHH-1031G-J
by: Mohammad Shoeb Siddiqui for CW-PP-2).
 Precautions, Limitations and
Setpoints
A circulating water pump (CW-PP-1-2) will be
prohibited from starting if the discharge motor
operated valve (MOV-2007, MOV-2009) is open. This
requirement is to prevents the motor from overloading
and also prevent the system from a sudden shock,
which will result if the system is rapidly pressurized.
During normal operation, one circulating pump (CW-
PP-1 or 2) will be in service and one will be in the
standby mode. The discharge MOV-2007 and 2009
controllers must be in the AUTO mode. If AUTO mode
is not selected when the pump is running, an alarm
will annunciate on the DCS (PUMP IS RUNNING and
VALVE IS NOT IN AUTO). The standby pump must be in
the AUTO mode in the event that the running pump
fails and the standby pump will start automatically.
Prepared by: Mohammad Shoeb Siddiqui
 Precautions, Limitations and
Setpoints
A low level in the cooling tower basin will
annunciate on the DCS (LAL-1036) to warn the
control room Operator. The Low level alarm is set
at –700 mm. Note that this alarm gets its signal
from the cooling tower basin level transmitter.
A low low level in the cooling tower basin will trip
the pump that is in service and annunciate on the
DCS (LALL-1004). The level switch (LSLL-1041) is
set at –800 mm.
A low press switch, (PSL-1005) is located on the
circulating water header, if this switch detects a
low pressure <1 kg/cm²>, the standby pump will
start and an alarm will annunciate on the DCS
(PAL-1005).
Prepared by: Mohammad Shoeb Siddiqui
 Precautions, Limitations and
Setpoints
All four (4) cooling tower fan gearboxes (CT-FN-1-4) are
provided with vibration monitoring instrumentation
(VE-1050A-D), that will generate an alarm on the DCS
(VAH or VAHH-1050A-D) if the respective vibration
supervisory circuit detects a Hi or Hi Hi vibration on the
fan gearbox. The Hi and Hi Hi vibration alarm is set at
0.075 in/sec. and 0.1 in/sec. respectively.

All four (4) of the

cooling tower fan gearboxes are provided with
temperature measuring devices that will generate an
alarm on the DCS (TAH-1051A-D) if the temperature
exceeds 100ºC and if temperature exceeds 111ºC, the
fan will trip.

Prepared by: Mohammad Shoeb Siddiqui

 Precautions, Limitations and
Setpoints
Sulifuric Acid
Sulfuric acid mist begins to irritate the eyes, nose and
throat at 0.5 mg/m3; the threshold limit value of 1
mg/m3 may corrode teeth, with frequent exposure.
Sulfuric acid is more irritating in a high humidity
environment. Liquid sulfuric acid will burn skin and
eyes and it will deeply burn the stomach and throat if
swallowed. Sulfuric acid is non-flammable but reacts
violently with water and organic materials. Poisonous
gas may be produced in a fire. Flammable hydrogen
gas may be produced at acid facilities. Fire fighters
should wear protective equipment when exposed to
such conditions.

Low Low level switches are provided in the sulfuric acid

and Anti- scalant dosing tanks, these switches will trip
Prepared by: Mohammad Shoeb Siddiqui
the pump and will annunciate on the DCS, when
 Precautions, Limitations and
Setpoints
Chlorine
Chlorine is known as a potential danger to
worker health. Chlorine causes irritation of the
eyes, nose, throat and lungs. Exposure to a
sufficiently high concentration of chlorine will
be fatal. Chlorine gas exhibits a sharp pungent
odor. Therefore, its presence is readily
detected and it is unlikely that anyone could
remain in a contaminated area. Fortunately,
chlorine gas does not produce a cumulative
physiological effect and complete recovery will
occur following mild exposure.

Prepared by: Mohammad Shoeb Siddiqui

 Precautions, Limitations and
Setpoints
The physiological effects of chlorine are;
detectable odor at 3.5 ppm, throat
irritation at 15.1 ppm, coughing at 30.2
ppm and extreme danger in 30-60
minutes at 40-60 ppm. The characteristic
penetrating odor of chlorine gas gives
warning of its presence in the air. Its
greenish yellow color makes it visible
when high concentrations are present.
The handling and use of both liquid and
gaseous chlorine require close attention
to safety precautions and practices.
Prepared by: Mohammad Shoeb Siddiqui
 Precautions, Limitations and
Setpoints
○ Gas masks for chlorine protection are
available at;
○ The closed cooling water pump area/green
box
○ The air heater washing basin /green box
○ The firewater foam tank /green box
○ The raw water building, north wall/green
box
○ The main control room, SCBA is also
available in the control room

Prepared by: Mohammad Shoeb Siddiqui

 Precautions, Limitations and
Setpoints
(If a chlorine ton/cylinder container develops a leak,
its contents are disposed of by placing it in
position for gas withdrawal and bubbling the gas
into the neutralization bath as describe below.)

1.4 pounds of Caustic Soda (NaOH) is required for

neutralization of one pound of Chlorine.

3.7 pounds of Soda Ash (Na2CO3) is required for

neutralization of one pounds of Chlorine.

1.3 pond of Hydrated Lime [Ca(OH)2] is required for

neutralization of one pounds of ch

Prepared by: Mohammad Shoeb Siddiqui

Precautions, Limitations and Setpoints
There are two (2) chlorine leak detectors installed
at the chlorination control room building, one
inside the chlorination room and the other at the
ton/cylinder container skid area. These leak
detectors will give a Chlorine leak alarm at the
DCS and start the strobe/horn at the Chlorination
control room building.

Two windsocks are provided in the plant to

establish the wind direction in case of a chlorine
gas leak. Personnel should check the direction of
these windsocks before rushing to fix the leak.
Note
Don’t rush in the opposite direction of the
wind Prepared by: Mohammad Shoeb Siddiqui
Precautions, Limitations and Setpoints
Chlorine
The Control Panel:
The control panel contains all the equipment
required to operate the chlorination sequence.
A programmable timer can be programmed to
control the chlorination process automatically.

The System Control Panel Alarm Lights are as

follows;
Chlorine evaporator low water level
Chlorine evaporator water temperature high
Evaporator water temperature low
Liquid chlorine manifold pressure low (2.8 Kg/cm2)

Prepared by: Mohammad Shoeb Siddiqui

Precautions, Limitations and Setpoints
Chlorine

Expansion chamber pressurized (2.8 Kg/cm2)

Evaporator discharge pressure relief valve (2.8
Kg/cm2)
Evaporator discharge pressure high (17.6 Kg/cm2)
Evaporator discharge gas temperature low
Filter exit low pressure (4.2 Kg/cm2)
Ejector pressure supply low
Booster pumps discharge pressure low (3.9 Kg/cm2)
Booster pumps suction pressure low (1.05 Kg/cm2)
Chlorinator vacuum low
Chlorinator vacuum high
Prepared by: Mohammad Shoeb Siddiqui
Startup
The purpose of starting this system is to provide
cooling water to the following users.

1. Main condenser.
2. Plate heat exchangers.
3. Chlorination booster pumps.

The following support systems should be aligned

so that they may be placed in service when
required.
Acid injection system
Anti scalant injection system
Chlorination system
Water Well pumps and raw water system

Prepared by: Mohammad Shoeb Siddiqui

 Startup

The normal operating level is (-325 mm). If filling of the

basin is required, verify on the DCS that the raw
water tank level is at normal operating level of 12
meters as indicated on (LT-1505) and the water well
pumps are in auto. Place the level control valve
(MOV-1521) in <Manual> and commence filling the
basin by giving the controller a 25% output, this will
allow water to flow by gravity from the raw water
tank to the cooling tower basin.
Note
The water well pumps will only start when the raw water
tank level drops to 3.5 meters.
Verify that the Low and Low Low level (LAL-1036 and
LALL-1040) alarms are cleared, “normal” status, as
indicated on the DCS alarm summary and also have
the field operator verify the actual level.
Prepared by: Mohammad Shoeb Siddiqui
 Startup

Once the normal operating level of the cooling tower

basin is established, verify that all the permissive are
satisfied, Proceed to start the CW pump .
The field operator should verify that the circulating water
pump discharge motor operated valve (MOV-1007 or
1009) opens to approximately 25%. When the system
is pressurized > 1 Kg/cm², the discharge MOV should
continue to open, when the valve is fully open the
valve indication on the DCS will change color from
green to red. If the valve fails to open , the valve is
provided with a hand wheel that can be used to open
the valve. In order to open the valve locally through the
motor, the field operator will have to switch from
REMOTE to LOCAL control.
The field operator must check the pump and motor for
abnormal noise and vibration. If any abnormal noise or
vibration is detected, immediately shutdown the pump
and inform the Shift
PreparedSupervisor.
by: Mohammad Shoeb Siddiqui
 Startup

 The system should be vented once circulation is

established. The high point vents (GW-GA-06, GW-GA-
07 and GW-GA-08) are located on the Main condenser
water box inlet, outlet and return respectively.
 Align and place the plate heat exchangers in service as
required.
 Check the gearbox oil level before starting the cooling
tower fans. Cooling tower fans will be started as
required to control the circulating water temperature.
Proceed to start the cooling tower fans
 Start and maintain the circulating water chemistry as
per the Plant Chemistry Manual.
 Place the Blowdown system in service by opening (CW-
GA-01) as required to control the Total Dissolve Solids
(TDS) as per the Chemistry manual.

Prepared by: Mohammad Shoeb Siddiqui

 Chemical Dosing system
Startup

Acid dosing system

 Align all the valves per procedure.
 Align all the electrical breakers as per procedure.
 Make sure that the acid storage tank level is not low.
 Start the Acid dosing pump A or B from DCS

Anti-scalant dosing system

 Align all the valves per procedure.
 Align all the electrical breakers as per procedure.
 Make sure that the acid storage tank level is not low.
 Start the Acid dosing pump A or B from DCS

Prepared by: Mohammad Shoeb Siddiqui

 Chemical Dosing system
Startup
Chlorination System
 Close the drain valves in the water piping system and
open all shutoff valves in the water supply line to the
water supply piping system.
 Fill the water chamber to the operating level, as confirmed
by water being discharged to the drain through the open
drain connection in the rear of the evaporator. Observe the
sight glass to check the water level.
 When the chamber is filled to the operating level,
gradually close the throttling valve.
 Apply 120 V. ac power to the control circuit connection
box.
 Observe the position of the indicating pointer of the
cathodic protection ammeter; turn the adjustment screw of
the potentiometer, if necessary, to bring the pointer just
within the lower portion of the green band on the scale. If
the reading in the green portion of the scale cannot be
achieved, this is indicative that the conductivity of the
water is too low to permit a sufficient flow of protection
current. In such instances, it will be necessary to increase
the conductivity by adding sodium sulfate or magnesium
sulfate to the water via the standpipe provided for this
purpose in the topPrepared
of the water chamber.
by: Mohammad Shoeb Siddiqui
 Chemical Dosing system
Startup
Chlorination System
 Set the water temperature control to 155 oF, the high
temperature control to 170 oF and the low temperature
control to 140 oF.
 Energize the immersion heater by closing the circuit
breaker in the power supply line to the heater. While the
Evaporator is warming up, leak test all piping.
 Inspect all joints in the liquid chemical supply and the gas
discharge lines to ensure that the joints are tight.
 Verify that the blow-off valve in the bypass line is closed.
 To test for leaks, open all in-line valves between the liquid
chemical supply valve and the gas dispenser, including the
valve in the bypass line around the electrically operated
pressure reducing and shut-off valve, to provide a path
around the de-energized valve.

Prepared by: Mohammad Shoeb Siddiqui

 Chemical Dosing system
Startup
 CAUTION
Do not open the header valve that is closest to the
chemical supply

 WARNING
Damaging or breaking of the chemical piping, valves
or fittings can cause a major hazardous chemical
spill. Never tighten or adjust any leaking fitting
when the chemical supply cylinder valve is open.

 WARNING
When system leaks occur, the procedures required to
find these leaks may cause exposure to hazardous
chemicals at levels that exceed the Occupational
Safety and Health Administration (OSHA) limits.

Prepared by: Mohammad Shoeb Siddiqui

Cooling Towers
THANK YOU
FOR YOU ATTENTION

Prepared by: Mohammad Shoeb Siddiqui