COOLING WATER SYSTEM

AND
NET WORK

PREPARED BY M. IQBAL BAIG

In Pak Arab Fertilizer we are
using cooling water as a
source of heat rejection.
Pakarab Fertilizer divided into
two wings known as West
side and East side .Both sides
has its own cooling water
system.
 WEST SIDE

This side including following plants,

1- Ammonia Plant
2- Urea plant
3- Utility Plant
4- Nitric acid plant
5- CO2 PLANT

Cooling water supplied to these plants

from new cooling tower except Urea.
 EAST SIDE

This side including following plants.

1- Nitro Phosphate plant
2- Calcium ammonium Nitrate plant.
3- Nitric acid Line C
Cooling water supplies to these plants
from dirty cooling tower, balcke
cooling tower and old cooling tower.
Supply to urea is also from this side.
Cooling water
New cooling tower
The cooling tower is an induce draft cross flow
type and it fulfills in house and Ammonia and
Nitric Acid plants cooling water needs. The
cooling tower holds 10000 m3 and circulates
30000 m3/hr.
Old cooling tower : meets cooling water
needs of Urea, Nitric acid Old, NP & CAN/CN
plant. It is induced draft type; Circulation
capacity : 6000 m3 /hr
Balcke cooling tower is dedicated for NP
modification circuit only. It is induced type
tower and has wooden structure; Circulation
capacity : 2157 m3 /hr
7/3/2019 Utilities Plant 5
NEW COOLING TOWER
 Cooling Tower
 A cooling tower is a
heat rejection
device, which
extracts waste heat
to the atmosphere
through the cooling
of a water stream to
a l o w e r
temperature.
 How a Cooling Tower
Works
In cooling tower, warm water from the heat
source is evenly distributed directly over a
heat transfer surface called “fill” while air is
simultaneously forced or drawn through the
tower. This causes a small percentage of the
water to evaporate. The evaporation process
removes heat and cools the remaining water.
Rate of evaporation depends upon
1 -Sur f a c e c o nt act ar e a b/ w wat er & ai r
2 - H u m i d i t y o f a i r
3 - T e m p e r a t u r e o f w a t e r
4 - V e l o c i t y o f a i r
Cooling Tower
 TYPES OF COOLING WATER
SYSTEM
 1-NON EVAPORATIVE
 This system includes once through
cooling & closed loop system.
 2-EVAPORATIVE / CIRCULATING

 This is used for water conservation

& environmental impact.
TYPES OF COOLING TOWER
1-Atmospheric cooling tower
2-Natural draft cooling tower

3-Mechanical draft cooling tower

 It has two types

1- Forced draft
2-Induced draft
Counter Flow Cooling Tower
Cross Flow Cooling Tower
 UFM-A/B/C/D/E/F

F E D C B A

RAW WATER IN
THROUGH TUBEWELL #
5-A

COOLING WATER BASIN

SLIP STREAM FILTERS
4X

HIGH PRESSURE CW LOW PRESSURE CW FIRE WATER PUMPS

PLANT AIR IN
2208-J/JS 2201J/JS/JAT/JBT/JCT 2203-J/2205-J/JDM
RAW WATER IN
6 Kg/cm2 CW SUPPLY THROUGH HEADER
TO NITRIC ACID PLANT
FIRE WATER SUPPLY

3 Kg/cm2 CW SUPPLY TO
AMMONIA, POWER HOUSE AND
NITRIC ACID PLANTS
New Cooling Tower
 Designed by Societe Hamon France
 Capacity 30,000 m3/hr
 Basin capacity 10,000 m3
 Type Double cross flow induced
draft
 No. of cells 6
 Inner dimension of each cell 12.92 x 20.50 m
 Fan blades 6
 Height of fan stack 6.44 m
 Return water temperature 43 0C
 Supply water temperature 34 0C
 Range 9 0C
 Wet bulb temperature 29 0C
 Basin depth 4m
 Pump head above basin curb 12 m
IMPORTANT SPECIFICATION OF WEST & EAST
SIDE COOLING TOWER
NEW C.T OLD C.T BALCKE DIRTY C.T
C.T
System 10000 3000 500 500
volume
(m3)
Supply 34 34 34 47
Temp.(c)

Return 43 43 43 57
Temp.(c)

Temp. 9 9 9 10
Diff(c)

Circulation 30000 6000 2100 1920

(m3/hr)
Evaporation 450 97 20
Rate
 SPECIFICATION OF MAJOR EQUIPMENT
AT NEW COOLING TOWER
Discharge
Capacity Speed Power
pressure
Pump Name Tag Manufacturer

M3/Hr RPM KW Kg/Cm2

2201
LP steam driven pump 6500 580 750 3.2 Sigmond Pulsometer
JAT/JBT/JCT

LP motor driven pump

2201
6500 580 750 3.2 Sigmond Pulsometer
JDM/JSM

HP motor driven pump

2208
4570 992 990 6.5 KSB
J/Js

Jockey fire water pump

2203 J 45 2900 75 11 Sigmond Pulsometer

HP fire water pump

2205 JA 570 2900 350 12.3 Sigmond Pulsometer

Diesel fire water pump

2205 JD 570 2900 350 12.3
 SPECIFICATION OF EAST SIDE PUMP
PUMP NAME MANUFACTURE SPEE CAPACITY DISH.PRE
R D SS
RPM Kg/cm2
H.T Cold water SUZLER 960 902L/S 3.4
pump#1,3
H.T cold water SUZLER 960 975L/S 3.7
pump #2
HOT WATER SUZLER 725 890 m3/hr 1.2
PUMP#1,2
HOT WATER SUZLER 960 890m3/hr 1.2
PUMP#3
L.T PUMP#1,2 KSB 1490 1079m3/hr 3.5
Balcke HALBERG 1450 1400m3/hr 6
pump#1,2
Dirty C.W KSB 1450 1920m3/hr 8.9
pump 2202J/JS
 TUBEWELL
In Pak Arab fertilizer we are using
tubewells for making the cooling
tower basin level. We have following
tubewells:
1)KSB-1
2)KSB-2
3)KSB-3
They are used for making the new
cooling tower basin level
Following tubewells are used to supply cooling
water to east and west side.
1)Tubewell -1
2)Tubewell – 6
3)Tubewell – 8
4)Tubewell- 10
5)Tubewell – 7
6)Tubewell - 4
7)Tubewell – 11
8)Tubewell – 12
9)Tubewell – 13

Tube well – 10,7,4,12 are not in service and

remaining are in working condition.
PROBLEMS IN COOLING
WATER SYSTEM
AND
CHEMICAL TREATMENT
 Make up Water
The chemistry of the make up water including the
amount of the dissolved minerals can vary widely.
Make up water low in dissolved minerals such as
those from surface water supplies (Lakes, Rivers
etc.) tend to be aggressive to metals (corrosive).
Make up water from ground water supplies
(wells) are usually higher in minerals and tend to
cause scaling( deposit minerals). Increasing the
amount of minerals present in the water by
cycling can make water less aggressive to piping
however excessive levels of minerals can cause
scaling problems.
Raw Water Common Impurities
 All water supplies contain some impurities in the
form of dissolved gases and solids in solution and
suspension so water treatment is necessary.
 Dissolved gases: CO2,O2,H2S and they are
corrosive.
 Suspended solids: sand,slit,decaying plants may
be present in varying amounts in water.
 Living Organisms such as natural water bacteria,
soil bacteria, sewage bacteria as well as algae are
also present in all water.
 Dissolved solids: Bi carbonate, sulphates,
chlorides, nitrites of calcium ,magnesium and
sodium in varying proportions together with silica
and some times small amounts of
iron,alluminium,mangnese are always present in
water.
 Calcium and magnesium salts are
the cause of hardness in water and
may be divided in two groups
– Bi-carbonates of calcium and
magnesium, they are easily
decomposed by heat cause alkaline
hardness also known as temporary
hardness or carbonate hardness
– The sulphates, chlorides, nitrates
CaCl2,MgCl2,CaSO4,MgSO4,Ca(NO3)2,
Mg(NO3)2 which are not decomposed
by heating and cause non alkaline
hardness, also known as permanent
hardness or non-carbonate hardness.
 Raw Water Analysis
pH 7.6-8.0 Sulphate 92-174 ppm

Conductivity 690-960 u s/cm Chloride 14.9-40.5 ppm

Calcium 36-46 ppm Bi-carbonate 211-245 ppm

Magnesium 13.2-30 ppm Silica 19.5-21.6 ppm

Sodium 86-120 ppm TDS 380-532 ppm

 Factors affecting
Cooling Tower Performance

 Fouling

 Biological growth

 Corrosion

 Scaling
 Chemical Treatment
Besides treating the circulating
cooling water in large industrial
cooling tower systems to minimize
scaling and fouling, the water should
be filtered and also be dosed with
biocides and algaecides to prevent
growths that could interfere with the
continuous flow of the water.For
closed loop evaporative towers,
corrosion inhibitors may be used, but
caution should be taken to meet local
environmental regulations as some
 COOLING TOWER CHEMICALS
Product Concentrati Function Dosing
on Scheme
Continuum 6ppm Mild steel Cotinuuous
AEC3192 corrosion inhibitor Based on blow
Flogard MS6208 6ppm down

Depositrol BL5300 15ppm Scale inhibitor

dispersant

Spectrus OX1201 Dependent on Oxidizing biocide Continuous based

Halogen precursor on recirculation
demand rate halogen
Chlorine gas Oxidizing biocide demand and
activator retention across
the cooling tower

Spectrus BD1500 10ppm Biocide Enhancer Intermittent based

on system volume
Spectrus NX1104 60ppm Non-Oxidizing
Biocide
 Chemicals for Cooling Water
Treatment

 SODIUM DICHROMATE ( Na2 Cr2 O7

)
 Hexa-valent Chromium Compound:

 It is used as anodic corrosion inhibitor.

 PFL maintain chromate level from 15-

20 ppm in cooling water system.
 ( Dosage: 1200 kg / month,

 (Packing: 25 kg Bags )
 Chemicals for Cooling Water
Treatment
 BIOCIDE: SYNCEM 387)
 It is a 50% aqueous solution of Tetra-
alkyl phosphonium chloride. It is a
broad spectrum biocide used to control
microbiological fouling in cooling water
systems. It is effective slims & can also
be used to clean badly fouled system.
Recommended dosage range to clean a
fouled system is 20-60 ppm twice a
week. Routine treatment 10-30 ppm
o n c e a w e e k
 (Dosage: 120 kg / 15 days, Packing: 30
 COOLING WATER
CONSUMPTION AT PLANTS
 CW Consumption

Plant Name Design flow Current Flow

Utility 8040 6940

Ammonia
13800 13800

Nitric Acid
8470 7330

LCO2
74 70

Urea
1375 1750

NP
2750 2750

CAN
3102 2232

LINE C
565 500
 COOLING WTER SUPPLY TO UREA PLANT AT
FOLLOWING EQUIPMENTS
COOLING WATER OPERATING PRESSURE 3.2 Kg
COOLING WATER SUPPLY TEMPERATURE 34C
COOLING RETURN TEMPERATURE 43C

1. C.W to CO2 –compressor jackets + inter stage cooler E23,24,25

2. E-7 M.P condenser
3. E-8 L.P condenser
4. E-9 NH3 condenser
5. E-33,34,35 exchanger
6. E-17 Distillation tower over head condenser
7. NH3 storage compressor jackets + condenser
8. P-1, P-2 pumps lube oil cooler
If cooling water failure occur, vacuum at tower disturb,
condensation in exchanger effect so we reduce the plant load or
stop the plant.
 COOLING WTER SUPPLY TO HNO3
PLANT AT FOLLOWING EQUIPMENTS
At HNO3 plant C.W supply with two pressures
High pressure C.W supply 6.5Kg/cm2
Low pressure C.W supply 3.2Kg/cm2
C.W supply temperature 34C
C.W return temperature 43C

High pressure C.W supply to following equipments

 Absorption tower 1

2 NH3 evaporator

3 Cooler condenser
 COOLING WTER SUPPLY TO HNO3
PLANT AT FOLLOWING EQUIPMENTS
Low pressure C.W supply to following equipments

1 Steam/surface condenser
2 BFW pump bearing and glands
3 B.W circulation pumps and bearing oil jacket
4 Lube oil cooler of compressor set i. e AEG steam
turbine and tail gas turbine
5 Seal air cooler (labyrinth seal of tail gas turbine

In case of C.W water failure occur flow of cooling

water to line A and B decrease and If it become
1000m3/hr at line A and 1500m3/hr at line B, the
lines tripped.
3Kg/cm2 can also enter into cooler condenser to boost
up the 6Kg/cm2 C.W pressure.
 COOLING WTER SUPPLY TO UTILITY
PLANT AT FOLLOWING EQUIPMENTS
COOLING WATER PRESSURE 3.2Kg/cm2
COOLING WATER SUPPLY TEMPERARURE 34C
COOLING WATER RETURN TEMPERATURE 43C

1 P.A COMPRESSOR
A Lube oil cooler
B Inter stage cooler
2 I.A COMPRESSOR
A Lube oil cooler
B inter stage and after stage cooler
C First and second stage jackets
 COOLING WTER SUPPLY TO UTILITY
PLANT AT FOLLOWING EQUIPMENTS
3 TURBINE HALL
A Condenser of turbines
B lube oil cooler
C Generator air cooler
D lube oil cooler and control oil cooler of KK turbine
4 BIOLER HOUSE
A FD fan, KK turbine, Lube oil cooler
B BFW Pump lube oil cooler

Incase of C.W failure vacuum of turbine condenser

drop so pressure of condenser rises due to which blow
off valve open, hence efficiency of turbine decrease.
Generator winding temperature was high. However we
have an opportunity to run 2001-JS Instt. Air
compressor of raw water supply.
 COOLING WTER SUPPLY TO AMMONIA
PLANT AT FOLLOWING EQUIPMENTS
COOLING WATER PRESSURE 3.2Kg/cm2
COOLING WATER SUPPLY TEMPERARURE 34C
COOLING WATER RETURN TEMPERATURE 43C

Cooling water supply to following equipments at Back

End

1 103-L surface condenser for 101JT (air comp),

105JT(refrigeration comp), 103-JBT(synthesis comp)
2 127-CA/CB ammonia condenser of 105JT
3 128-C inter stage cooler 105J
4 134-C ammonia desuperheater
5 145-CA/CB/CC/CD inter stag cooler of 101JT for air
cooling.
6 124-C, 147-C, 116-C inter stage cooler 103JBT
7 Main lube oil cooler of all compressor and all KK turbine.
 COOLING WTER SUPPLY TO AMMONIA
PLANT AT FOLLOWING EQUIPMENTS
Cooling water supply to following equipments at Front End
1 104-L surface condenser for Elliot condensing turbines of Semi
lean, lean, BFW pumps and ID fan turbines.
2 142-C (exit gases from methenator 106D goes to this
exchanger)
3 132-C and 133-C (CO2 cooling system i. e CO2 cooler)
4 All turbines lube oil cooler

In case of cooling water failure, refrigeration loop pressure will

increase and production will suffer. So we should have to stop
the Back End, if Cooling water pressure goes to below
1.8Kg/cm2.
 COOLING WTER SUPPLY TO NITRO
PHOSPHATE PLANT AT FOLLOWING
EQUIPMENTS
At NP plant we supply cooling water from D.C.T, B.C.T, O.C.T
D.C.T pressure 8.9Kg/cm2
Cooling water temperature difference 10 C
B.C.T pressure 6Kg/cm2
Cooling water supply temperature 34C
Cooling water return temperature 43C
O.C.T pressure 3.2Kg/cm2
Cooling water supply temperature 34C
Cooling water return temperature 43C

DIRTY COOLING TOWER SUPPLY WATER TO

1 Evaporator condenser
2 Scrubber at reactor top
If cooling water supply failure occur evaporator vacuum break
so we hold the evaporators. Acid fumes, fluorides and P2O5
contents becomes high in exit gases from reactor.
 COOLING WTER SUPPLY TO NITRO
PHOSPHATE PLANT AT FOLLOWING
EQUIPMENTS
BALCKE COOLING TOWER SUPPLY WATER TO

1 New phosphate solution cooler

2 1045 & 1055 NH3 compressor refrigeration circuit
Consisting lube oil cooler + ammonia condenser.
3 Acid pre heater
In case of cooling water failure, 1045 ammonia compressor trip.
Phosphate solution temperature become high from 45-C to 65-C.
But here we have an opportunity to connect phosphate solution
cooler with cooling water supply from old cooling tower.

OLD COOLING TOWER SUPPLY WATER TO

1 Phosphate solution cooler old

2 1035 ammonia compressor of old circuit
3 Turbines lube oil cooler
COOLING WTER SUPPLY TO CO2 PLANT
AT FOLLOWING EQUIPMENTS
COOLING WATER PRESSURE 3.2Kg/cm2
COOLING WATER SUPPLY TEMPERARURE 34C
COOLING WATER RETURN TEMPERATURE 43C

Cooling water supply to

1. Inter cooler to CO2 compressor (High stage CO2 compressor)

2. Lube oil cooler of all compressor i. e 2 NH3 compressor and 3
CO2 compressor.
3. Evaporative condenser (NH3 condenser)
COOLING WTER SUPPLY TO CAN PLANT
AT FOLLOWING EQUIPMENTS
COOLING WATER OPERATING PRESSURE 3.2 Kg/cm2
COOLING WATER SUPPLY TEMPERATURE 34C
COOLING RETURN TEMPERATURE 43C

C.W supplied to CAN plant at following equipments

CN-SECTION

1- CN Reactor

2- Surface Condenser
COOLING WTER SUPPLY TO CAN PLANT
AT FOLLOWING EQUIPMENTS
CAN SECTION

1- Surface Condenser

2- Process Condensate Cooler

3- NH3-Evaporator
 COOLING WTER SUPPLY TO HNO3
LINE-C PLANT AT FOLLOWING
EQUIPMENTS
COOLING WATER OPERATING PRESSURE 3.2 Kg/cm2
COOLING WATER SUPPLY TEMPERATURE 34 C
COOLING RETURN TEMPERATURE 43 C

C.W supplied to following equipments

1 - Reactor Jacket
2 - Cooler Condenser
3 - Absorption Tower
4 - Air Compressor interstage cooler
5 - Lube oil cooler
6 - Air chamber of 6KV motor
THANK YOU