(Aromatics - Operations)

1. INRODUCTION.

2. PARTS OF COOLING TOWER.

3. WORKING PRINCIPLE AND THEORY.

4. SYSTEM DETAIL OF COOLING TOWER.

5. CYCLE OF CONCENTRATION AND WATER BALANCE.

6. COOLING WATER TREATMENT.

7. MONITORING & CONTROL OF COOLING WATER

TREATMENT.

8. CHEMICALS USED FOR WATER TREATMENT.

9. TROUBLE SHOOTING OF SYSTEM UPSET.

 1 - COOLING TOWERS
Cooling towers are the most common method used to dissipate heat in
open recirculating cooling systems. They are designed to provide
intimate air/water contact. Heat rejection is primarily by evaporation
of part of the cooling water. Some sensible heat loss (direct cooling of
the water by the air) also occurs, but it is only a minor portion of the
total heat rejection.

Types of Towers
Cooling towers are classified by the type of draft (natural or
mechanical) and the direction of airflow (crossflow or counterflow).
Mechanical draft towers are further subdivided into forced or induced
draft towers.

Natural draft towers. Sometimes called "hyperbolic" towers due to

the distinctive shape and function of their chimneys, natural draft
towers do not require fans. They are designed to take advantage of the
density difference between the air entering the tower and the warmer
air inside the tower. The warm, moist air inside the tower has a lower
density, so it rises as denser, cool air is drawn in at the base of the
tower. The tall (up to 500 ft) chimney is necessary to induce adequate
airflow. Natural draft towers can be either counterflow or crossflow
designs. The tower in Figure 31-1 is a crossflow model. The fill is
external to the shell forming a ring around the base. In a counterflow
model, the fill is inside the shell. In both models, the empty chimney
accounts for most of the tower height.

Mechanical Draft Towers. Mechanical draft towers use fans to move

air through the tower. In a forced draft design, fans push air into the
bottom of the tower. Almost all forced draft towers are counterflow
designs. Induced draft towers have a fan at the top to draw air through
the tower. These towers can use either crossflow or counterflow air
currents and tend to be larger than forced draft towers.

Counterflow Towers. In counterflow towers, air moves upward,

directly opposed to the downward flow of water. This design provides
good heat exchange because the coolest air contacts the coolest water.
Headers and spray nozzles are usually used to distribute the water in
counterflow towers.

Crossflow Towers. In crossflow towers, air flows horizontally across

the downward flow of water. The crossflow design provides an easier
path for the air, thus increasing the airflow for a given fan
horsepower. Crossflow towers usually have a gravity feed system–a
distribution deck with evenly spaced metering orifices to distribute the
water. Often, the deck is covered to retard algae growth.
 2 - PARTS OF COOLING TOWER.
Fill Section. The fill section is the most important part of the tower.
Packing or fill of various types is used to keep the water distributed
evenly and to increase the water surface area for more efficient
evaporation. Originally, fill consisted of "splash bars" made of
redwood or pressure-treated fir. Splash bars are now available in
plastic as well. Other types of fill include plastic splash, ceramic
brick, and film fill.

Film fill has become very popular in recent years. It consists of

closely packed, corrugated, vertical sheets, which cause the water to
flow down through the tower in a very thin film. Film fill is typically
made of plastic. Polyvinyl chloride (PVC) is commonly used for
systems with a maximum water temperature of 130 °F or less.
Chlorinated PVC (CPVC) can withstand temperatures to
approximately 165 °F.

Film fill provides more cooling capacity in a given space than splash
fill. Splash fill can be partially or totally replaced with film fill to in-
crease the capacity of an existing cooling tower. Because of the very
close spacing, film fill is very susceptible to various types of
deposition. Calcium carbonate scaling and fouling with suspended
solids has occurred in some systems. Process contaminants, such as
oil and grease, can be direct foulants and/or lead to heavy biological
growth on the fill. Any type of deposition can severely reduce the
cooling efficiency of the tower.

Louvers. Louvers are used to help direct airflow into the tower and
minimize the amount of windage loss (water being splashed or blown
out the sides of the tower).

Drift Eliminators. "Drift" is a term used to de-scribe droplets of

water entrained in the air leaving the top of the tower. Because drift
has the same composition as the circulating water, it should not be
confused with evaporation. Drift should be minimized because it
wastes water and can cause staining on buildings and autos at some
distance from the tower. Drift eliminators abruptly change the
direction of airflow, imparting centrifugal force to separate water from
the air. Early drift eliminators were made of redwood in a herringbone
structure. Modern drift eliminators are typically made of plastic and
come in many different shapes. They are more effective in removing
drift than the early wood versions, yet cause less pressure drop.
 3 - COOLING TOWER THEORY

The transfer of sensible and latent heat transfers heat from water drops to the
surrounding air
•Heat and Mass transfer
•1 kg of water on evaporation removes approximately 530 kcals of heat
•The heat given up by the water falling inside the tower equals the heat
gained by the air rising through the tower
•The hot water entering the tower is distributed within the structure in a
manner that exposes a very large water surface to the air passing through.
•Water distribution is accomplished by means of spray nozzles or
distribution pans and by means of various types of “fill.”
•This fill increases the exposed water surface to maximize contact with the
air, increasing the rate of heat transfer

Approach to Wet Bulb, Cooling Range

Cooling towers are designed to cool water to a certain temperature under a

given set of conditions. The "wet bulb temperature" is the lowest
temperature to which water can be cooled by evaporation. It is not practical
to design a tower to cool to the wet bulb temperature. The difference
between the cold sump temperature and the wet bulb temperature is called
the "approach." Towers are typically designed with a 7—15 °F approach.
The temperature difference between the hot return water and the cold sump
water is referred to as the "cooling range" (DT). Cooling range is usually
around 10—25 °F but can be as high as 40 °F in some systems.
 4 - STSTEM DETAIL OF PROCESS COOLING TOWER

Recirculation rate M3/Hr : 18000

Delta T Deg.C : 8

Evaporation M3/Hr : 175

Recommended cycles : 2

Blow down M3/Hr : 225

Make up M3/Hr : 350

System Volume M3 : 3600 (Average Operating Level)

System Volume M3 : 4500 (Maximum)

Material of Construction :

i. Cooling Tower Structure

& Packing : Pressure Treated Wood
ii. Piping and Valves : Carbon Steel & Carbon Steel with
Cement lining inside.
iii. Coolers & Condensors : Tube-Admirality brass,
Cupronickel & SS
Shell & Channel Box - Carbon Steel.
 5.CYCLES OF CONCENTRATION & WATER BALANCE

1. Hold up Capacity of the system: (V)

Hold up capacity of the system equals summation of water contained in
basin, sump of cooling tower and water contained in piping and equipments.

2. Blow down: (B)

•Due to evaporation, concentration of Impurities / dissolved solids takes
place.
•Part of water is removed from system as a blowdown to control
concentration of impurities / dissolved solids in water.

3. Drift / Windage loss : (D)

Some water droplets escape along with air and water vapors. A usual drift
loss in conventional cooling towers is in the range of about 0.05 -0.2% of the
recirculation rate.
4. Evaporation Losses: (E)
• Water lost to the atmosphere in the cooling process is evaporation.
• The rate of evaporation depends upon the temperature differential
• 1% of the circulation rate evaporates for each 5.6 Delta T.

5. System Losses: (S)

Circulating water is lost in the plant through
pumps, valves or leakages in plant etc.

6. Concentration Cycle: (C)

Mg or Silica in cooling water

C = -- ----------------------------------
Mg or Silica in makes up water

Blow down E
& Windage losses = -----
C-1
Where E = Evaporation rate.
C = Cycle of Concentration.
7. Make-up Water: (M)
This is the water, which is to be added to replace the water lost by
evaporation, blow down, drift and leakage.
M=E+B+D+S
8. Holding Time Index:
Time required to reduce the concentration
of any constituent in cooling water to half.

0.693 x (Hold up capacity)

HTI = --------------------------------
Blow down

Each programmed has maximum allowable HTI beyond which chemical

lose its effective.
9. Approach:
Indicate efficiency of cooling tower.
Lesser is approach better is cooling tower efficiency.

Approach = Supply of C. W. temperature - Wet bulb temperature

Water circulates through the process exchangers and over the
cooling tower at a rate referred to as the "recirculation rate." Water is
lost from the system through evaporation and blow down. For
calculation purposes, blow down is defined as all nonevaporative
water losses (windage, drift, leaks, and intentional blow down).
Makeup is added to the system to replace evaporation and blow
down.
Approximately 1000 Btu of heat is lost from the water for every
pound of water evaporated. This is equal to evaporation of about 1%
of the cooling water for each 10 °F temperature drop across the
cooling tower. The following equation describes this relationship
between evaporation E, recirculation rate RR, and temperature
change:

RR X (Delta T ) X f
E = ------------------------------
560
Where:
E = evaporation, m3/hr
RR = recirculation rate, m3/hr
Delta T = cooling range, °C
f = evaporation factor

The evaporation factor, F, equals 1 when all cooling comes from

evaporation. For simplicity, this is often assumed to be the case. In
reality, F varies with relative humidity and dry bulb temperature. The
actual F value for a system is generally between 0.75 and 1.0, but can
be as low as 0.6 in very cold weather.
As pure water is evaporated, minerals are left behind in the
circulating water, making it more concentrated than the makeup
water. Note that blow down has the same chemical composition as
circulating water. "Cycles of concentration" (or "cycles") are a
comparison of the dissolved solids level of the blow down with the
makeup water. At 3 cycles of concentration, blow down has three
times the solids concentration of the makeup.
Cycles can be calculated by comparison of the concentrations of a
soluble component in the makeup and blowdown streams. Because
chloride and sulfate are soluble even at very high concentrations, they
are good choices for measurement. However, the calculation results
could be invalid if either chlorine or sulfuric acid is fed to the system
as part of a water treatment program.
Cycles based on conductivity are often used as an easy way to
automate blowdown. However, cycles based on conductivity can be
slightly higher than cycles based on individual species, due to the
addition of chlorine, sulfuric acid, and treatment chemicals.
 6. COOLING WATER TREATMENT

As circulating water dissolved solids levels increase as a result of

evaporation, corrosion and deposition tendencies increase. Because
corrosion is an electrochemical reaction, higher conductivity due to higher
dissolved solids increases the corrosion rate. Some salts have inverse
temperature solubility; i.e., they are less soluble at higher temperatures and
thus tend to form deposits on hot exchanger tubes. Many salts also are less
soluble at higher pH. As cooling tower water is concentrated and pH
increases, the tendency to precipitate scale-forming salts increases. Because
it is one of the least soluble salts, calcium carbonate is a common scale
former in open recirculating cooling systems. Calcium and magnesium
silicate, calcium sulfate, and other types of scale can also occur. Scale
formation in a cooling system can be controlled by:

 Minimizing cycles of concentration through blowdown control.

 Adding acid to prevent deposition of pH-sensitive species.
 Using scale inhibitors to allow operation under supersaturated conditions.

The reduction of blowdown is significant because raw water and chemical

treatment costs relate directly to blowdown. It is therefore desirable to keep
blowdown to an absolute minimum. Acid treatment removes bicarbonate
alkalinity from the water by the following reaction:

2HCO3+ H2SO4 = SO42- + 2H2O+ 2CO2

Bicarbonate sulfuric sulfate water carbon
acid dioxide

The CO2 formed is vented across the cooling tower, while sulfate remains as
a by-product. Lowering pH through acid feed also reduces the scaling
tendencies of other pH-sensitive species such as magnesium silicate, zinc
hydroxide, and calcium phosphate. There are also advantages to operating a
cooling system in an alkaline pH range. The water is inherently less
corrosive than at a lower pH and the feed of sulfuric acid can often be
minimized. pH is more easily controlled at higher pH, and the higher
alkalinity provides more buffering capacity in the event of acid overfeed.

Cooling systems can be operated at higher cycles of concentration (lower

blowdown) and/or higher pH when appropriate scale inhibitors are applied.
These materials interfere with crystal growth, permitting operation at
"supersaturated" conditions. Organic phosphates, also called phosphonates,
are commonly used to inhibit calcium carbonate scale. Phosphonates or
various polymeric materials can also be used to inhibit other types of scale,
such as calcium sulfate and calcium phosphate.

Species that do not form scale (iron, mud, silt, and other debris) can also
cause deposition problems. Because these materials are composed of solid
particles, their deposition is often more flow-related than heat-related.
Suspended solids tend to drop out in low-flow areas, such as the tower sump
and heat exchangers with cooling water on the shell side. In addition to
serving as a water reservoir, the tower sump provides a settling basin. The
accumulated solids can be removed from the sump periodically by vacuum
or shoveling methods. Polymers of various types can be used to minimize
fouling in heat exchangers.

There are many factors that contribute to corrosion and fouling in cooling
water systems. The choice and application of proper treatment chemicals is
only a small part of the solution. Monitoring programs are also needed to
identify potential problems so that treatment programs can be modified.
Effective control of product feed and monitoring of chemical residuals is
needed to fine-tune treatment programs. Continued monitoring is necessary
to confirm treatment results and determine system trends.

Corrosion rates can be monitored by means of corrosion coupons,

instantaneous corrosion rate meters, or the Betz Monitall ®, which measures
the corrosion rate on heat transfer surfaces. Elevated iron or copper levels in
the circulating water can also be an indication of corrosion. Deposition
tendencies can be observed on corrosion coupons or heated apparatus, such
as test heat exchangers or the Betz Monitall.

An open recirculating cooling system provides a favorable environment for

biological growth. If this growth is not controlled, severe biological fouling
and accelerated corrosion can occur. Corrosion inhibitors and deposit
control agents cannot function effectively in the presence of biological
accumulations. Chlorine and/or chlorine replacement products are necessary
to control microbiological growth (biofouling), which causes loss of
production, increased energy usage, shortened equipment life, and potential
health risk. Some of the major impacts of microbiological contamination are
listed below.
 Microbiological fouling reduces heat transfer rates in cooling
systems.
 Microbiological fouling increases resistance to water flow, thereby
increasing pumping cost.
 Microbiological-induced corrosion (MIC) reduces equipment life and
increases inorganic fouling by producing iron oxide.
 Microbiological problems pose a potential health risk from
contaminated cooling tower aerosol, most notably Legionella.

Chlorine gas would provide the least expensive means of biological control,
but may cause SARA Title III or OSHA concerns. Betz believes that a well-
controlled hypochlorite based program designed to maintain 0.2-0.5 ppm
free chlorine in the circulating water is a very effective microbiological
control method. Since higher free chlorine levels provide little additional
efficacy, corrode copper alloys and may, in some cases, adversely affect the
performance of the cooling tower dispersant and inhibitor, Betz does not
recommend the use of shock chlorination control methods.

The Dianodic Continuum treatment program is designed to promote the

formation of a persistent gamma iron oxide film on mild steel surfaces. The
polymeric component in the program inhibits the precipitation of calcium
phosphate, thus enabling maintenance of high levels of soluble
orthophosphate to effect passivation. The program is also designed to
control fouling due to suspended solids and inorganic scales such as calcium
carbonate. The treatment does not include zinc for cathodic protection as the
water chemistry of the circulating water is used for cathodic protection.
Calcium, and alkalinity play a major role in this mechanism.

 CORROSION CONTROL:

At a pH range of 8.4 to 8.6 combined with calcium levels of 200ppm at LSI

of +1.3 requires 7ppm of ortho-phosphate and about 4-5ppm of Organic
phosphate for excellent corrosion protection and CaCO 3 inhibition.. The
following figure illustrates corrosion protection mechanism:
 BETZ DIANO DIC CO NTINUUM
THE ANTIC O RRO SIVE ACTIO N O F O F PH O SPHA TES
IS M A IN LY AN OD IC

CO RR O SIO N: NO INHIB ITIO N

ANODE Fe Fe ++ + 2e -
CATHODE
O 2 + 2H 2 O + 4e - 4O H -

BETZ DIAN O DIC C O NTIN UU M

R

80% ANODE Fe + o-PO 4  Fe 2 O 3 Prim ary

20% CATHODE Ca + o-PO 4 Ca-oPO 4
Ca + p-PO 4 Ca-pPO 4
Controlled Precipitation at Cathode -
secondary

 DEPOSIT CONTROL:
Effective dispersant and deposit control agents provide excellent scale
control due to carbonates, sulfates and phosphates of Ca, Magnesium
silicates, iron and silt.

How Betz Dispersant Works?

Scaling due to dissolved solids in water is a common problem in cooling

water systems because of following phenomenon:

High Salinity High Temperature

(Supersaturation) (Reverse Solubility)
 Salt Precipitation

Scaling Corrosion

With the improvement in understanding of the salt precipitation mechanism

and the improved technologies in scale control now there are ways to
mitigate cooling water system scaling & fouling by the use Organic
polymeric Deposit Control Agents (DCA).

1. CRYSTAL MODIFICATION: The DCA molecule distorts the crystal

formation thereby preventing crystal buildup. Hence scale formation is
controlled.

non-distorced lattice distorced lattice

UNDISTORTED CRYSTAL DISTORTED

CRYSTAL

2. DISPERSION: The DCA molecule keeps the precipitating salts crystals

well dispersed so that the crystals do not bind together and grow into
crystalline scale.

GROWTH WITH No DCA

 O
GROWTH WITH DCA
NO GROWTH

Such a scale control mechanism using DCA’s can be achieved effectively

over a wide range of pH.

The treatment program is designed to operate at a pH of approximately 8.4.

The treatment is designed to limit the maximum pH to 8.6 under the
specified chemical dosages. However, by suitably adjusting the chemical
feed rates and concentration, the treatment can handle lower pH of 7.8 for
short durations. Sulfuric acid will be used for pH adjustment.

 MICROBIOLOGICAL CONTROL:
Chlorine gas, available through commodity chemical suppliers, will provide
the least expensive means of biological control and is recommended in this
system. We recommend you to continuously dose chlorine gas, as you are
doing now, to maintain a Free Residual between 0.2 to 0.5 ppm.

Non-Oxidizing Biocide

With a properly controlled microbiological control program, using gas

chlorine, a frequent application of supplemental non-oxidizing biocide will
not be necessary. In the event that a change in operating conditions,
hydrocarbon contamination, loss chlorination, or an unexpectedly lengthy
outage occurs, Betz has provided a recommendation for a non-oxidizing
biocide to be used, if necessary at the frequency of once in a month.
 7 - MONITORING AND CONTROL OF
COOLING WATER TREATMENT

There are many factors that contribute to corrosion and fouling in

cooling water systems. The choice and application of proper treatment
chemicals is only a small part of the solution. Sophisticated
monitoring programs are needed to identify potential problems so that
treatment programs can be modified. Effective control of product feed
and monitoring of chemical residuals is needed to fine-tune treatment
programs. Continued monitoring is necessary to confirm treatment
results and determine system trends.

Monitoring of Treatment Results

Corrosion. Corrosion rates can be monitored by means of corrosion
coupons, instantaneous corrosion rate meters, which measures the
corrosion rate. Elevated iron or copper levels in the circulating water
can also be an indication of corrosion.
Deposition. Deposition tendencies can be observed on corrosion
coupons or heated apparatus, such as test heat exchangers or the Betz
Monitall®. A comparison of various mineral concentrations and
suspended solids levels in the makeup water to those in the blowdown
may indicate the loss of some chemical species due to deposition.
Biological Fouling. Many techniques are avail-able to monitor
biological fouling. Those that monitor biological growth on actual or
simulated system surfaces provide a good measure of sys-tem
conditions. Bulk water counts of various species may be misleading.
PARTS PER MILLION (PPM)
 Water analysis involves the detection of minute amounts of a variety
of substances. The expression of results in percentage would require
the use of cumbersome figures. For this reason, the results of a water
analysis are usually expressed in parts per million (ppm) instead of
percentage. One part per million equals one ten-thousandth of one
percent (0.0001%), or one part (by weight) in a million parts–for
example, or 1 kg in 1,000,000 kg of water. It makes no difference
what units are used as long as both weights are expressed in the same
units.
Working formula :
For water systems, x ppm in y m3 = ( x X y ) /1000 kg

WATER IMPURITIES AND IT’S EFFECT :

Impurity Effect

Total Hardness Scale formation

(Calcium + Magnesium)

M-Alkalinity Corrosion - Low Alk.

Scale/Deposition. –

Chlorides Corrosion / SCC of SS

Suspended Solids Deposition

Sulphate Corrosion / Scale

Formation

SiO2 Scale

Organic Matters Fouling

Iron and Magnesium Deposition

Micro-Organisms Fouling / Corrosion

Ammonia Nitrifying bacteria / fouling

 8.BRIEF OF CHEMICALS USED FOR WATER TREATMENT
PROGRAM

Various chemicals are used to achieve the common goal of a lesser corrosive
environment in cooling water systems. All the chemicals used have a
definite role to play in maintaining the water quality of the cooling water
system. Generally a treatment program incorporates the use of corrosion
control agents, deposit control chemicals, dispersants and biocide.
The program used here is BetzDearborn Continuum, which is based on
phosphate chemistry. It operates in alkaline range of pH. A brief of the
chemicals used in Betz Dianodic Continuum treatment program with their
relevance and function is listed below:

PROCESS COOLING TOWER & TPS COOLING TOWER

REGULAR DOSING CHEMICALS

These chemicals are for regular dosage under normal working conditions.

1. BD Inhibitor
It is a orthophosphate based corrosion control agent functioning as a anodic
inhibitor & cathodic inhibitor. Functional levels of orthophosphate induce
carbon steel passivation which acts as a protective coating. It also has zinc as
a cathodic inhibitor to control pitting corrosion.

2. BD 22K
It is a patented Betz product. It is an excellent, polymeric
dispersant ,primary function is to keep orthophosphate in suspension and
prevent its diposition under operating conditions. It also disperses all
suspended & colloidal matter in water. It is a very good silt & iron
dispersant.

3. BD 40K 1501
Also known as 40 K - it is a general dispersant aimed at keeping CaCO3
level in suspension. This is because at pH > 8.2 (operating pH of PCT &
TPS) CaCO3 spicies in water are predominant and tend to deposit.

4. BD 445

It is a microbial dispersant allowing penetration of treatment chemicals and

biocide across microbial films and colonies if any. This also helps chlorine
to penetrate into areas hidden/ covered by slime.

Other chemicals that complete the program are :

1. Chlorine

Chlorine is the most effective and economical biocide during normal

operation. The active species responsible for the biocidal action is HOCl,
(Cl2 + H2O ----> HOCl + HCl) which has a strong oxidising potential.
Recomended levels of FRC for effective microbial control is from 0.2 pm to
0.5ppm. But during process leaks the chlorine demend shoots up, and higher
dosage of chlorine to achieve FRC levels is not desirable because feeding
high levels of chlorine, even with no appreciable FRC aggravates system
corrosion.

2. Sulphuric Acid

Sulphuric acid is used to control pH of the cooling water. It the best agent
for the purpose.
These chemicals are used only during contingencies, as a corrective action
for any upset in the cooling water system due to process leaks or any other
reason. Their use is restricted only to tide over the crisis generated because
of the contingengy and not on a regular basis.

1. Betz 409:
It is oil dispersant used only when there is oil ingress into the system, and
when the oil cannot be eliminated by any other means. On every occasion
of use of Betz 409 the system has to be given a blowdown to elimnate
some amount of the oil from the system. Oils being sticky in nature stick
to surfaces and considerably reduce HTC. Oils provide an exccelent source
of nourishment for microbes, and also consume chlorine, hence give a
positive feed back for increased microbial growth in the system, because of
all this it should be eliminated at the earliest.

2. Betz C 74:
It is a non-oxidising biocide. Use of non-oxidising biocide assume
importance when even after increased rate of dosage of Cl2 (the most
economical and effective biocide) microbial activity is not contained.
Increasing Cl2 dosing beyond a certain level, when no FRC is available is
detrimental to the system as it increases corrosion rate in general, attacks
yellow metal,pitting in paticular and attacks cooling tower wood.

3. Betz Bromo 118:

This chemical is used specially when there is NH3 ingress into the system
and when FRC does not appear even after increased rate of Cl2 dosage. This
is basically a Sodium Bromide formulation and is to be dosed only along
with Cl2 at a proper ratio with Cl2. Use of Bomo118 during NH3 ingress is
done to employ Bromine chemistry for the cooling water system which is
more effective in controlling microbial action during such conditions.
 9. TROUBLE SHOOTING
FOR ANTICIPATED OPERATION SYSTEM UPSETS

Here we have outlined operating steps required to be taken incase of

deviations from normal operations including

1. Fall in ortho phosphate level

2. Hydrocarbon or oil leak
3. High turbidity and suspended solids
4. Higher iron levels
5. Microbiology out of control/ no FRC in RR water
6. PH upset
7. Corrosion
8. Increase in makeup

(1) Fall in Ortho phosphate level (or Total Phosphate) :

Operating levels of total phosphate must be between 3.5 - 7 ppm as P2O5.

Drop in levels of phosphate can be possibly due to increased makeup,
increased system losses and, precipitation of phosphate. Lower levels of
phosphate means lesser corrosion protection and if precipitation is there then
fouling would occur.

Check:

 Levels of phosphate.
 Feed rate of Inhibitor.
 22K feed rate.
 Makeup rate.
 System losses.

Corrective Action:

 Increase speed of dosing pump of BD inhibitor (by 25 %) and 22 K (by

5%).
(2) Hydrocarbon or oil leak

These contaminants are not soluble and can coat heat transfer surfaces
reducing efficiency and restricting the flow of cooling water. They increase
the microbiological activity two fold by providing food source for the bugs
and consuming chlorine intended to kill them.

Check:

 Extent of oil ingress by testing - Laboratory.

Corrective Action:

 If contaminant is heavy oil, try skimming to remove floating oil.

 Locate source of leak and arrest it.
Shot dose BD 409 at the rate of 54-kgs/ day till oil level decreases.

(3) High Turbidity and Suspended Solids

This increases the fouling potential.

Check:

 Turbidity and suspended solids content of makeup streams.

Corrective action:

 Increase feed rate of BD 22K based on water analysis and system

inspection.
 Isolate the polluting source

(4) High iron levels

This increases the fouling potential and may be indicative of increased

microbial activity in the system.
Check :

 Iron levels in the makeup streams to verify if the has been any surge in iron
levels of make up.

Corrective action:

 Additional feed rate of BD 22K based on water analysis and system

inspection.

(5) Microbiology out of control / No FRC in RR water

When microbiological activity goes out of control then various complications

could arise depending upon the cause of such raise in activity. It promotes
Microbiologigally Induced Corrosion, in the form of severe pitting corrosion.
The best indication of extent of microbiological activity in the system is by
inspecting the condition of the cooling tower decks.

Check:

 Chlorination system and ensure proper chlorine dosing.

 Concentration of H2S and/or NH3 in the RR water.
 Process leaks mainly for H2S and NH3
 Marginally increase the Chlorination rate for 1-2 days and observe any
change.
 Monitor sessile activity in the Biofilm fouling monitor.

Corrective Action :

 Use of Bromine chemistry by dosing BD Bromo 118 at 2.5 times the feed
rate of chlorione dosing, with chlorine being fed at 8 kg/hr depending upon
the severity of the problem. That means Bromo 118 @ 20 kgs/hr &
chlorine @ 8 kgs/hr.
 Addition of non-oxidising biocide BD C74 at 55 ppm i.e., 200 kg/shot.
 Repair of leaking exchanger responsible for the leak.
(6) PH upset

a) Low pH

Low pH may occur due to over dose of acid feed, chlorine or process
contamination. Low pH upsets program and treatment chemicals could get
deactived. At lower pH corrosion rates are increased.

Check :

 Feed rate of acid and chlorine

 Process leaks

Corrective Action :

 Stop or reduce acid feed.

 If cause is determined then give blowdown and allow pH to increase
naturally.
 Addition of BD 22K
 If low pH conditions last for more than 3 days passivation to be done.

b) High pH

High pH beyond program limits will boost deposition of suspended species

and render program ineffective. HTC is severly affected and fouling increases.
If problem is severe water could become milky.
Check :

 Acid feed
 Process contamination
 Filtered OPO4 and unfiltered OPO4

Corrective Action :

 Increase acid feed

 Increase blowdown and subsequently adjust (increase) feed rate of
chemicals.
(7) Corrosion

If there is a increase in iron level (increase) or observed corrosion in the

equipment openings then it could indicate a change in the water quality or
chemistry.

Check:

 To see if there is any changes in system chemistry or inhibitor usage.

 If program guidelines are being met.
 Chlorination practise, FRC < 0.5 ppm
 Iron and copper levels in recirculation water - also check if there is an
increase in the iron level in the raw water.
 For contamination from process.

Corrective Action :

 Closely follow program guidelines.

 Follow trouble guidelines to analyze the problem.
 Consult BetzDearborn personnel.