KARBALA REFINERY PROJECT

UTILITY PROCESS TRAINING - BASIC

(Course Code : ETI-PR-03B)

UNIT 33 – Cooling Water Unit

CONTENTS Page : 2 / 49

Before Start..
Please follow below rules!

1. 50 minutes class, 10 minutes break

2. Please don’t use your mobile phone. If you need, use at the
out of this class room.
3. If you have question, please ask at the end of the class
4. Please be quite during the class
5. 12:00~13:00 is lunch time
CONTENTS Page : 3 / 49

1. INTRODUCTION
1) Introduction of Training Course Contents
2) Introduction of Training Schedule

2. PROCESS OVERVIEW
1) Process Principle
2) Basis of Design
3) Process Description

3. PROCESS FLOW AND CONTROL

1) Process Variables
2) Major Equipment
3) Complex Control Logic

4. START-UP AND SHUTDOWN

1) Startup Sequence
2) Shutdown Sequence
1. INTRODUCTION Page : 4 / 49

Expected Training
JV/Vendor Unit Unit Description Training Class
Duration

30 Raw Water Treatment Unit 2 days

1
51 Waste Water Treatment Plant 2 days

31 Firewater Unit 2 1 day

33 Cooling Water Unit

34 Drinking Water Unit 3 2 days

SK-PR
43 Caustic Soda Unit

35 Condensate Collection and Treatment Unit

4 2 days
36 BFW and Steam Generation Unit

37 Power Generation Unit 5 3 days

41 Instrument and Plant Air Unit 6 1 day

42 Nitrogen Generation Unit 6 1 day

1. INTRODUCTION (Continued) Page : 5 / 49

Basic Terminologies for Cooling Water System

1. Wet bulb Temperature
(Temperature when the water saturated with air, Theoretical minimum cooling water supply
temperature)

2. Approach Temperature
(Difference between Design wet bulb temperature & Cooling water supply temperature)

3. Cooling Range
(Temperature difference between Cooling water return & Cooling water supply)

4. Evaporation Loss
(Water loss quantity by evaporation, 1.92% is considered)

5. Drift Loss and windage loss

(Water loss quantity by drift or windage, 0.01% is considered)
1. INTRODUCTION (Continued) Page : 6 / 49

Basic Terminologies for Cooling Water System

6. Blowdown
(Throw way dirty water for control water purity)

7. Cycle of Concentration (also called COC number)

(ratio of nonvolatile ion in blow down water and the ion’s concentration in make up water)

8. Make up water
(fresh water to replace the blowdown water)
1. INTRODUCTION (Continued) Page : 7 / 49

Basic Terminologies for Cooling Tower

1. Natural draft cooling tower vs Mechanical draft tower

2. Distribution pipe

3. Packing or fill

4. Eliminator
2. PROCESS OVERVIEW (Continued) Page : 8 / 49

- Reference video
1. INTRODUCTION (Continued) Page : 9 / 49

– Purpose
• The system provides cooling water with chemical treatment and bacterial
control

– Product : Cooling Water Supply (CWS)

• Supply temperature : 32 ºC
• Cycle Concentration Number of 6
• Maximum Supply Flowrate Including blowdown : 32,000m3/h
• Maximum Blowdown rate : 116 m3/h
• Minimum supply pressure at BL @ grade level : 4 kg/cm2g

– Feed : Cooling Water Return (CWR)

• Maximum return temperature : 43 ºC
• Maximum return flowrate : 30,955m3/h
• Normal pressure at CW BL @ grade level : 2.5 kg/cm2g
2. PROCESS OVERVIEW Page : 10 / 49

Process Principle
Cooling water is circulated through equipment to absorb and carry away heat.

The open recirculating system routes cooling water through the heat-exchange equipment.

Effluent warm water then is cooled by contact with air in a cooling tower. The cooling effect is
produced by evaporation of a portion of the circulating water, and this evaporation causes the
dissolved solids in the water to become concentrated. To maintain a required concentration
level, amount of water is drained from the system. Water lost by evaporation, blowdown and
drift must be replaced by makeup water.

Side stream filter package (33-PK-005) is provided for reducing the TSS (Total Suspended
Solid) at Cooing water pump discharge.

Sodium Hypochlorite package (33-PK-003) and NOB(Non oxidizing biocide) are required to
control of microbial growth in the cooling water system. To control pH in the Cooling Tower
Basin, H2SO4 injection package (33-PK-006) will supply H2SO4 because high pH can cause
violent scale inside piping for cooling water.

Cooling water will be also chemically treated to protect the equipment from corrosion and
scale phenomena: Anti-scale / Dispersant package (33-PK-001) is provided to prevent scale
and Corrosion inhibitor Package (33-PK-002) is provided to prevent corrosion.
2. PROCESS OVERVIEW Page : 11 / 49

Cooling water quality analysis target value

1) Cooling water pH
pH (33-AI-0003) control range is 7.5 (Low) ~ 8.5 (High).
 
2) Cooling water conductivity
Target conductivity (33-AIC-0002) is 1388μS/cm with the control range of 1000 ~ 2200
μS/cm. It will be controlled by controls cooling water blow down rate.
 
3) Cooling water TOC (Total Organic Carbon)
If TOC is higher than 10 ppmv (33-AI-0001), blowdown is routed to OWS through 33-XV-
0004.
 
4) Cooling water residual chlorine
Free chlorine (33-AI-0004) control range is 0.3 ~ 2.5 ppmv with on-off control of 33-PK-003.
2. PROCESS OVERVIEW (Continued) Page : 12 / 49

Basis of Design
– Circulating Capacity

• Design flow : 110% of Normal flow

FLOW RATE DUTY

 CASE △T (ºC)
(m3/h) (Gcal/h)

BASRAH BASE 25,050 7.9 196.7

MISHRIF BASE 25,178 8.2 205.0

DESIGN CASE 30,955 11 339

– Make-up Water
• Blending of River Filtered Water and Permeate Water from 1st Reverse Osmosis
• Make-up Water Requirement : 712 m3/h (Max)
• Target Quantity of TDS : 155 ppm
2. PROCESS OVERVIEW (Continued) Page : 13 / 49

Basis of Design

(3) CT losses To ATM

From Users (1) CWR

COOLING (4) Blow down To Raw Water

WATER UNIT Treatment Unit
From Raw Water (2) Make-up (UNIT 30)
Treatment Unit
(5) CWS
(UNIT 30) To Users

Major Feed (m3/h) Major Product (m3/h)

CASE
1 2 Total 3 4 5 Total

DESIGN 32,000 712 32,712 596 116 32000 32,712

BASRAH 25050 712 25762 596 116 25050 25762

MISHRIF 25178 712 25890 596 116 25178 25890

2. PROCESS OVERVIEW (Continued) Page : 14 / 49

Simplified PFD

Antiscale & Dispersant

Corrosion Inhibitor
Sodium Hypochlorite
CW Side
Solution. Filtered CW Stream Filter Package
H2SO4 Evaporation &
Drift Losses (596 m3/h)
Cooling Tower Fans
Filtered Water Cooling Water Return 39.5 ºC (Mishrif)
(18~48 m3/h) From Users 39.2 ºC
Treated Water (30955 m3/h) (Basrah)
Cooling Tower 1.5 kg/cm2g
(694~664 m3/h)

Cooling Tower Basin

32 ºC
Cooling Water Supply
4.97
To Users
kg/cm2g
(30955+116(Blowdown) m3/h)
Cooling Water
Circulation Pumps
2. PROCESS OVERVIEW (Continued) Page : 15 / 49

- Overall Plot plan

2. PROCESS OVERVIEW (Continued) Page : 16 / 49

- 3D model
2. PROCESS OVERVIEW (Continued) Page : 17 / 49

- Process Description
2.1 Cooling Water Unit
– Circulating cooling water is 30955m3/h. Circuit design flow is 110% of normal flow rate.

– Cooling maximum differential temperature is 11°C based on a cooling water supply

temperature of 32 °C and a return temperature of 43 °C.

– A continuous make-up water is provided to compensate the loss of water due to evaporation
and drift losses and blow-down water. Make-up water requirement is 712m3/hr with a cycle
concentration number of 6.

– Target quantity of TDS in cooling water make-up is 155 ppm (40 ppm of Ca++ as CaCO3
equivalent) produced as follow;
• blending of river filtered water (48 m3/h) and permeate water from 1st reverse osmosis
(664m3/h) in case of river water with 1000 ppm TDS content
• blending of river filtered water (18 m3/h) and permeate water from 1st reverse osmosis
(694 m3/h) in case of river water with 2500 ppm TDS content.

Cooling water blow-down is 116m3/hr and is normally sent to Clarified Water Basin 30-BA-001.
2. PROCESS OVERVIEW (Continued) Page : 18 / 49

- Process Description
2.2 Cooing Tower (33-CT-001)
The Cooling Tower 33-CT-001 is counter current flow induced draft type composed of nine cells,
(eight operating, one spare).

Expected design flow to each cell is 3870m3/h. (30955 / 8 cells). Each cell is provided with film fill
packing. Return water is distributed in the cooling tower where it falls through the fill and cool by
evaporation.

Induced draft is achieved by nine fans (33-FA-001 A~I), one each cell. Each fan moves air
through water to promote evaporation. The discharge air exits the top of the cell. All fans are
provided of dual speed driver for energy saving during cold periods and vibration switch to trip the
motor in the event of an unbalanced operation of the fan.

Drift eliminators are provided to minimize liquid water carry over and prevent from fallout around
the tower itself.

Reinforced concrete is used for the cooling tower structure. The fill is of inert material.
2. PROCESS OVERVIEW (Continued) Page : 19 / 49

- Process Description
2.3 Cooing Tower Basin (33-BA-001)

The Cooling Tower Basin (33-BA-001) is a cooling water collector and storage reserve: cooled
water falls through the cooling tower into the concrete basin and passes to the pumps suction
bay.

The basin area below cooling tower cells is divided into nine sections, one below each cell.

Each section will be provided with removable sluice gate valve to allow segregation from pump
suction bay without shutting down the whole tower system.

Removable vertical double screens are provided at each entry to the pump suction bay to prevent
ingress of suspended material. The two screens, in series arrangement, allow the first screen to
be cleaned while the other one is in line. A hoist is provided to remove each screen for cleaning.

Basin (except area below cooling tower cells) is covered to avoid sand entering during
sandstorm.
2. PROCESS OVERVIEW (Continued) Page : 20 / 49

- Process Description
2.4 Cooing Water Side Stream Filter Package (33-PK-005)

A side stream from the discharge of the Cooling Water Pumps (33-P-001A/B/C/D/E/F) flows
through the CW Side Stream Filter Package 33-PK-005 to remove suspended solids. Side
Stream Filters, pressurized multi-media type, are cleaned by periodic backwash. The side stream
filtration ensures in circulating cooling water a maximum TSS content of 33 ppm (in normal
conditions).

The package is composed of a Hydrocyclone (33-PK-005-CY-001) followed by eight sand filters

(33-PK-005-FL-001A~H) operating in parallel. The filters are backwash one per time, using as
backwash cooling water. Hydrocyclone is provided to reduce TSS load to filters especially during
sandstorm. Filtered water from filters flows to the Cooling Tower Basin 33-BA-001.

2.5 Side Stream Filter Back-Wash Basin (33-BA-002)

A Filter Back-Wash Basin (33-BA-002) is provided to collect the back-wash water coming from
Side-Stream Filter for the sedimentation of particles greater than 50~60μm. The basin is divided
into two independent sections with a common inlet.

Each section is provided with sluice gate to allow segregation in case of maintenance. At the end
of the basin, the water goes through a weir into a collecting pit and then discharge to the Oily
Water Sewer.
2. PROCESS OVERVIEW (Continued) Page : 21 / 49

- Process Description
2.6 Cooling Water Chemical Conditioning

– Cooling water is also chemically treated to protect the equipment from corrosion and scale
phenomena.
• 33-PK-001 (anti-scale/dispersant) with unloading pump, dosing drum and metering pumps
• 33-PK-002 (Corrosion inhibitor). with unloading pump, dosing drum and metering pumps.

– Control of microbial growth in the cooling water system.

• 33-PK-003 supplies 12% solution with with unloading pump, dosing drum and metering
pumps.
• The NaOCl (12% aqueous solution) is very common oxidizing biocide widely used and to
maintain the residual chlorine at the return line 0.3ppm (normal) ~ 0.5ppm(max) on a
continuous basis.
• However, a limitation of oxidizing biocides is that they are generally poor at penetrating and
dispersing heavy, anaerobic infestations, unlike some nonoxidizers.
• NOB (non oxidizing biocide) is a monthly slug dosed at an approx. 20 ppm on the system
volume by dumping the required quantity into the basin.

– To control pH in the Cooling Tower Basin (33-BA-001)

• 33-PK-006 supplies sulphuric acid because high pH can result in violent scale inside piping
for cooling water.
3. PROCESS FLOW AND CONTROL Page : 22 / 49

- Process Variable

1. Cooling Water level inside the Cooling Tower Basin

• Cooing water basin level (33-LI-0001) working range is 60 % (Low) to 72 % (High)

2. Cooling Water pH
• pH (33-AI-0003) control range is 7.5 (Low) ~ 8.5 (High).

3. Cooling Water Conductivity

• To maintain the correct concentration of the cooling water.
• Target conductivity (33-AIC-0002) is 1388μS/cm with the control range of 1000 ~ 2200 μS/cm.
It will be controlled by controls cooling water blow down rate.

4. Cooling Water TOC (Total Organic Carbon)

• To determine cooling water blow down destination.
• If TOC is higher than 10 ppmv (33-AI-0001), it is routed to OWS through 33-XV-0004.
Otherwise, It is routed to 30-BA-001 through 33-XV-0003 normally.

5. Cooling Water residual chlorine

• To avoid biological growth.
• Free chlorine (33-AI-0004) control range is 0.3 ~ 2.5 ppmv with on-off control of 33-PK-003.
3. PROCESS FLOW AND CONTROL Page : 23 / 49

- Process Variable (Continued)

Analyzers for TOC / Chlorine are located at Cooling Water Return Header in Unit 33.

Analyzer for pH is located at Cooling Water Supply Header in Unit 33.

Analyzers for conductivity is located at Cooling Water Blowdown line in 5D area. (IONE-AA51-PID-
0021-101-1)
3. PROCESS FLOW AND CONTROL (Continued) Page : 24 / 49

- Major Equipment

3.6 Cooling Tower Basin (33-BA-001)

 Minimum liquid level is at the top of horizontal pump suction piping into the basin.
 Low liquid level is 150 mm above the top of pump.
 Normal operating water level will be 125 mm above low water level.
 Free board for the basin will be 600 mm.
 Vertical double screens will be sized for 0.3 m/s velocity through the net free area of the screen
at design circulation rate.

3.7 Cooling water circulation pumps (33-P-001A~F)

 6 X 20% Cooling Water Pumps (33-P-001 A/B/C/D/E/F), horizontal type, are provided.
 Five (5) are in normal operation and one is spare.
 Each pump is rated at 6500 m3/hr.
 Two pumps (33-P-001 A/B) are steam turbine driven, four pumps (33-P-001 C/D/E/F) are electric
motor driven. The normal configuration is with three pumps electric motor driven and two pumps
steam turbine driven.
3. PROCESS FLOW AND CONTROL (Continued) Page : 25 / 49

- Major Equipment (Continued)

3.8 Cooling water Side stream filters (33-PK-005)

 Filters are Pressurized Multi-Media type.

 Filtration degree is 50 microns
 Solid retention efficiency is 90% in weight.
 Design capacity is 3% of Cooling Water Pumps design capacity.
 Working time is 16 hrs as minimum for each filter before backwash.
 Maximum allowed pressure drop is 2.5 kg/cm2.
3. PROCESS FLOW AND CONTROL (Continued) Page : 26 / 49

3.9 Complex Control (1) – Make up water control loop

Level in Cooling Tower Basin (33-BA-001) is maintained by Make-up water from Raw Water
Treatment Unit (Unit 30).
Blending ratio of Filtered water and First RO Permeate is controlled by Ratio controller 33-FFIC-
0013. Operator can set the target value of required ratio by 33-FHIC-0013 based on TDS content in
the river water. (30-AT-5003A)
• 30-SC-5001 for Raw (River) water
• 30-SC-5033 for RO permeate water
3. PROCESS FLOW AND CONTROL (Continued) Page : 27 / 49

3.10 Complex Control (2) – Side Stream Filter Back wash

The Cooling Water Side Stream Filter Package Systems are composed of Eight (8) filters (Seven
(7) Filters operating, One (1) Filter Stand-by) with Two (2) Blowers (One (1) is Operating, One (1) is
Stand-by) and One (1) Hydro-cyclone and it will be controlled by DCS.

The multi-media filters are depth filtration units designed to remove solid particles from cooling
water. Each filter is equipped with inlet and collection headers and filtration media comprising two
grade support media and finer sand. The multi-media have a role to catch suspended solid particle
and remove it from produced water.

1) Operating Mode (for example 33-PK-005-FL-001A)

Operating Mode Location Auto Semi-auto Manual

Remote selector (HS-5005A) Local Remote Remote Local *3

Auto mode (33-HS-5065). DCS Auto Semi-auto -

Start switch (33-HS-5000A). DCS Start *2 -

Stop switch (33-HS-5064) DCS *1 *1 -

*1: When stop switch is activated, the sequence is stopped.

*2: Operator selects a required step
*3: To open and close each XV by local panel hand switches.
3. PROCESS FLOW AND CONTROL (Continued) Page : 28 / 49

3.10 Complex Control (2) – Side Stream Filter Back wash

Local Panel & DCS signal (For Filter A)

3. PROCESS FLOW AND CONTROL (Continued) Page : 29 / 49

3.10 Complex Control (2) – Side Stream Filter

33-PK-005-FL-001A Valve Status

3. PROCESS FLOW AND CONTROL (Continued) Page : 30 / 49

3.10 Complex Control (2) – Side Stream Filter Back wash

A backwash is started when one of the following is initiated;
 Max. differential pressure: 1.3 kg/cm2
 Timer: 16 hours
 Low flow alarm: 55 m3/hr
Normally, the filter backwash will be executed automatically by time period or High DP.

Back wash flow160m3/h

3. PROCESS FLOW AND CONTROL (Continued) Page : 31 / 49

3.11 Complex Control (3) – Chemical injection pumps

1) Sodium Hypochlorite Dosing Pumps (33-PK-003-001A/B)
 When concentration of Cl2 is high (2.5 ppm) on 33-AI-0004, the pump will stop.
 When concentration of Cl2 is low (1.0 ppm) on 33-AI-0004, the pump will start.
 Control set points can be adjusted inside alarm parameters.

2) H2SO4 Storage and Dosing Pumps (33-PK-006-P-001A/B)

 When pH is high (8.5) on 33-AI-0003, the pump will start
 When pH is low (7.5) on 33-AI-0003, the pump will stop
 Control set points can be adjusted inside alarm parameters.
3. PROCESS FLOW AND CONTROL (Continued) Page : 32 / 49

- Cause and Effect Diagram

PDF Document
4. START-UP AND SHUTDOWN Page : 33 / 49

- Start up sketch at PFD

4. START-UP AND SHUTDOWN Page : 34 / 49

- Start up sketch at PFD

4. START-UP AND SHUTDOWN Page : 35 / 49

- Start up sketch at PFD

4. START-UP AND SHUTDOWN Page : 36 / 49

- Start up sketch at PFD

4. START-UP AND SHUTDOWN (Continued) Page : 37 / 49

1. Preparing chemicals

Make sure below chemicals have all been filled in their own storage tanks.
– Anti-scale/dispersant package (33-PK-001-TK-001)
– Corrosion inhibitor dosing package (33-PK-002-TK-001)
– Sodium hypochlorite dosing package (33-PK-003-TK-001)
– Sulphuric acid Storage and Dosing Unit (33-PK-006-TK-001)
– NOB is available in ware house

2. Introduce the make-up water

1) Before make-up water can be introduced, ensure that the River Water Intake Unit 60 and the
Raw Water Treatment Unit 30 are in operation.
 Check the TDS of river filtered water and adjust the flow ratio to meet target of TDS in CW.
 Fill the blended water until the correct level
 The level control (33-LIC-00002) shall be in manual mode but others (33-FFIC-0013 / 33-FIC-
0001 / 33-FIC-0002) are in auto mode.
 Maintain 10% (or smaller) output of level controller to introduce water up to normal level then
change to auto mode.

2) Start chemical treatment system to meet designed qualities of cooling water

4. START-UP AND SHUTDOWN (Continued) Page : 38 / 49

3. Start cooling water circulation pumps (33-P-001A/B/C/D/E/F) progressively

1) Start cooling water circulation pump 33-P-001C (or D/E/F) by local push button.
a) Check cooling towers and two cells are selected to receive C.W return flow and ensure the
other MOVs shall be closed position.
b) Start cooling water circulation pump 33-P-001C (or D/E/F) by local push button
c) Slowly open discharge valve 33-MOV-0008 (or 0009/ 0010/ 0018).
The MOV has inching function which allows moderated valve opening.
d) Check for unusual noises and high vibrations. And,
- Check suction and discharge pressure gauges.
- Regulate the amount of fluid circulated to mechanical seal.
- Check for excessive leakage at seal areas.
- Check for adequate flow of service water in seal chamber.
- Check oil level in bearing housing and bearing temperature.
e) Ensure CW recirculation flow through 33-HV-0002.
f) Adjust MOV (33-MOV-0008 (or 0009/ 0010/ 0018) on the pump discharge to meet discharge
pressure at rated condition. The valve opening shall be stopped at normal pump discharge
pressure of 4.9 kg/cm2g.
g) Adjust CW return MOV opening to avoid overflow in the cell.
4. START-UP AND SHUTDOWN (Continued) Page : 39 / 49

3. Start cooling water circulation pumps (33-P-001A/B/C/D/E/F) progressively

2) Start the second cooling water circulation pump

- Repeat the steps a) through e) for this pump
- Repeat the step f) for all previous running pumps
- Repeat the step g)

3) Start the remaining cooling water circulation pump(s), if required

- Repeat the all steps in 2)

4) When required pump(s) are started, the start-up bypass valve (33-HV-0001) shall be closed
gradually.

5) When steam system is available, warm up the two (2) steam turbines and then start the two (2)
steam turbines.

6) After adjusting of pump discharge pressure and adjusting flow distribution on cooling tower return
line, all the MOV shall be switched to Remote position.

7) Put a stand-by pump in Remote position. The discharge MOV opening shall be same with running
pumps.

Note: A motor pump in stand-by mode (Remote Position)

Adjust chemical injection rate if required.
4. START-UP AND SHUTDOWN (Continued) Page : 40 / 49

4. Put the cooling tower fan in service

1) Water introducing to cell

Cooling water return shall be introduced to the cooling tower cell by opening the MOV

2) Fan start up
a) Check cooling water supply temperature.
b) If it is higher than 32℃, service cooling tower fans as required.
c) The fan has two speed modes. When starting of the motor, low or high speed can be selected

• The number of fan and each fan speed can be adjusted depending on the cooling tower
condition, process operation load, circulation flow rate and weather condition (especially low
ambient temperature, no fan may be required).

• In case speed change (from high to low or vice versa), speed change is possible with time
delay (40 seconds). Operator shall stop the running fan at high (or low) speed and then push
low (or high) speed button to start the fan after 40 seconds.

Caution: Within this time period (40 seconds), the motor will not be started
Note: The cooling tower fan has two speed selections, with three push buttons
 High speed : 116 rpm
 Low speed : 76 rpm
 Stop
4. START-UP AND SHUTDOWN (Continued) Page : 41 / 49

4. Put the cooling tower fan in service

3) Operating when the ambient temperature is lower than or equal to 0℃

Generally, icing risk shall be avoided in cold weather. The cooling water supply
temperature can vary between 10℃ to 32.0℃ by adjusting the flow rate to each cell
with the following manner

• Fan speed adjustment to low speed or high speed

• Fan stop
• Adjust the MOV opening at cooling water return line
and open the MOV bypass valve to supply hot return water to cell.
4. START-UP AND SHUTDOWN (Continued) Page : 42 / 49

- Shutdown Procedure
1) Shutdown all water treatment packages
Shutdown all chemical treatment system pumps
Isolation supplying line of chemicals and drains if maintenance is required.

2) Shutdown the cooling water turbine driven pumps(33-P-001A/B)

A. Close the HP steam supply to 33-STP-001A and 33-STP-001B by push button. XHS-P001AB
and XSH-P001BB
B. The pump discharge valve shall be closed, while the suction valve normally remains open.
C. Switch off flushing and/or cooling liquid supplies
D. Isolate the pump only for maintenance by close suction valve.
E. If turbine needs to isolate, close the turbine discharge valve.

3) Shutdown the cooling water motor driven pumps(33-P-001C/D/E/F)

4) Switch off CW Side stream filter package.

5) Switch off the cooling tower fans.

4. START-UP AND SHUTDOWN (Continued) Page : 43 / 49

- Shutdown Procedure (Continued)

7) Drain Cooling Water Unit
7-1) Drain of Pump 33-P-001A/B/C/D/E/F
• Stop the pump and isolate
• Ensure drain route is free to drain
• Open vent and drain valves

7-2) Drain of Side Stream Filter Package 33-PK-005

• Stop package operation (individual stop button)
• Close inlet valves for the package and Open drain valve

7-3) Drain all water treatment packages (33-PK-001/002/003/006)

• Stop all pumps and Open all drain valves
• The chemical drain in the curbed area.
• Operator arranges vacuum truck to empty the pit.

7-4) Draining Cooling Tower Basin (33-BA-001)

• When cooling tower basin is required to empty for cleaning (or maintenance) purpose, the
cooling water shall be drained using 4” OWS line.
• For lower level of the 4” basin drain point (990 m3), it will be pumped out using portable
pumps. (Portable pumps can be entered to the basin by two (2) manholes which are located at
the both ends of 33-BA-001, near drain pit).
5. Special Procedure Page : 44 / 49

- Chemical Curbed Area

Perform periodic monitoring of liquid level in curbed area sumps.
Note that in addition to periodic monitoring, field operator is required to check sump levels after a
rainfall event.

1) If sump is liquid-filled, arrange to test the sump contents by taking a manual sample.

2) If sump contents are suitable for routing to OWS (refer to below table):
a. Open normally closed (NC) manual valve to OWS.
b. Sump level shall be monitored (visually).
c. When sump has been emptied, close the manual valve to OWS.
5. Special Procedure Page : 45 / 49

- Chemical Curbed Area (Continued)

3) If sump contents are not suitable for routing to OWS:

a. Collect sump contents via vacuum truck

b. Sump level shall be monitored (visually).
c. When sump has been emptied, stop the vacuum truck.
d. The remaining chemical shall be removed by using mop and discharged appropriately
e. Remaining chemicals (after mopping) shall be neutralized (or diluted with mass water) then
drained to OWS. (open drain valve and then the valve shall be closed)
5. Special Procedure Page : 46 / 49

- Chemical Injection Package Operating Procedure

Filling Chemical Storage Tank. (Air Operated pump is applied)

1) Check safety guidelines in MSDS.

2) Operator is to use safety gloves and glasses.
3) Open all instrument block valves, Close tank / line drain valves
4) Check plant air pressure (Operating pressure 7 Max. : 7.5 / Min. : 4 kg/cm²g, at BL)
5) Arrange Chemical Drum near the air operated pump
6) Insert the air operated pump suction line into the chemical drum and Connect tightly to drum
nozzle
7) Connect to Air operated drum pump discharge to tank inlet connection with flexible hose
8) Connect air connection to Air operated drum pump with flexible hose
9) Open chemical inlet valve to tank
10) Open air valve
11) When drum emptying, close air valve
12) Repeat step 5) through 11) until tank level is satisfied.
5. Special Procedure Page : 47 / 49

- Chemical Injection Package Operating Procedure (Continued)

Injection Pump Flow Rate Calibration

1) With the pump operating normally, both valves A and B in the full open position, the calibration
tube will fill with liquid.
2) Close valve A and wait the liquid level reaches to top of the division mark.
3) Allow liquid level to drop for a period of at least 1 minute before reopening valve A.
4) Finally, divide the number of divisions that the liquid has dropped by the number of minutes used.
5) Check the actual measured flow rate against the pump flow curve sheet.
6) When the calibration tube is not in use,
valve B have to be closed and
valve A must retain open at all the times
except while the calibration tube is in use.
5. Special Procedure Page : 48 / 49

- Noise Protection
Intermittent High Noise Areas
Below table shows the intermittent high noise areas which are created by PSVs and of which the
maximum sound pressure levels at work area are estimated to be above 110 dB(A) in some
emergency conditions.

Below table shows the intermittent high noise areas which are created by vents of PSVs and of
which the maximum sound pressure levels at work area are estimated to be above 110 dB(A) in
some emergency conditions.
5. Special Procedure Page : 49 / 49

- NOB (Non-oxidizing Biocide) Injection

Non-oxidizing biocide is required for the open recirculation type cooling water system for control of
bacteria, fungi and algae. Normally, Sodium Hypochlorite is injected to cooling water system primary
for control of bio matters. Non-oxidizing biocide is used as intermittent (shock dosing) for disturbing
tolerance metabolism of bio matters.

For the uniform distribution, the dosing point is recommended as near as possible form the cooling
water pump intake. In this plant, the recommended point is cooling water basin top manholes. NOB
product will be delivered as iso-tank (1000 liter) with bottom valve

 The normal cooling water system volume is 23,000 m3

 The required NOB is 460 - 690 liter (20-30 ppmv)
 Arrange NOB product near the cooling tower basin
top manholes with waterproof sheet
 Connect a short piece of hose at the bottom nozzle
NOB iso-tank and then extend to the manhole.
 Open the bottom valve and then
close the valve when the tank level reaches a half level.
 After shock dosing, visually check periodically tower basin
and/or cooling tower filler.
 The effect of shock dosing may take a day or more
 If the effect is minor (or no effect),
repeat the above shock dosing procedure.