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DK KURITA SDN BHD (351759D)
LOT 779, JALAN PENGHIBURAN, KG BESUT,
CHUKAI, 24000 KEMAMAN, TERENGGANU DARUL IMAN.
E-mail:[email protected]:609-850 2020
FAX:609 850 2020DATE:19th November 2006DOCU NO:
CONTRACT NO:REF. NO:
TOTAL SHEETS:14 PAGES
FORMTBE MALAYSIA SDN BHD
DOCUMENT TITLE
PHASE OVER Procedure
of the
cooling water system(with heat load)
FOR MTBE cooling watermMTBE (M) SDN BHD
Lot 111, Kawasan Perindustrian Gebeng,
Peti Surat 1, Balok, 26060 Kuantan,
Pahang Darul Makmur,
MALAYSIA
Ref. No.CTS/938-2-042(06)
Contract No.CSR MM/06/042
Eng. DisciplineCHEMICAL TREATMENT
Item Tag No.
Data Type
Supplier No.I
Issue No.ONE
ATTACHED DWGNOTITLE
DRAWING NONOTITLE
TITLENOTITLE
REVISIONDATEAPPRDCHECKDMADEDESCRIPTION
128-11-06RAAKWN/SNMMZMREVISED
019-11-06RAAKWN/SNMMZMISSUED
1. IntroductionThe following document describes the procedure for initial treatment under heat load condition.
2. Preparatory works
2.1.1 MTBE scope
1) Electrical supply outlet for transfer pumps
2) Raw water supply hose for washing when in contact with chemicals
3) Operation of cooling water and simultaneous make-up water operation.
4) Place all chemicals near to the cooling tower basin.
2.1.2 DKKSB scope
1) Transfer pump.
2) Chemical dosing and supervision
3) Water analysis and monitoring
4) Technical recommendation
5) Corrosion coupon evaluation to determine completion of initial treatment
3.0 Chemical required
Table 1: Amount of Chemical required for Initial treatment.
ChemicalFunctionDosage (mg/l)MMSB CW (kg)
Kuriroyal P-3270DKCorrosion inhibitor400640
Kuriroyal P-2380DKDispersant300480
Calcium chlorideCalcium hardness adjustment-Depends on water quality
98 % Sulfuric AcidpH adjustment-Depends on water quality
48 % Caustic SodapH adjustment-Depends on water quality
Soda AshpH adjustment-Depends on water quality
Note : The quantity above is only an estimates. It may varies according to water quality4.0 Procedure
ItemActionAction by
1Allow the cooling water to circulate through the system with heat load. Stop the injection of all the chemicals from the previous vendor.MTBE
2Check the quality of the cooling water.DKKSB
3Conduct blowdown of the cooling water from the system, if the total iron and turbidity exceeds 2 ppm and 5 NTU. Exchange the water with fresh make-up water until being close to above condition. Refer Table 3MTBE
4Check the quality of the cooling water to ensure that the above criteria are met.DKKSB
5Close all blowdown valvesMTBE
5Determine the calcium hardness in the cooling water. Dose the required amount of calcium chloride to achieve a minimum of 50 ppm of Calcium Hardness in circulating water. Use the formula in the Appendix. Slug dose manually. DKKSB
6Dose 200 ppm of KURIROYAL P-2380DK against the holding water volume of system into the cooling tower basin. Apply transfer pump to dose. DKKSB
7Dose 400 ppm of KURIROYAL P-3270DK against the holding water volume of the system into the cooling tower basin after 1 hour of dosing calcium chloride. Apply transfer pump to dose.DKKSB
8Should the calcium hardness in the cooling water is more than 100 ppm, dose 300 ppm of KURIROYAL P-3270DK instead..DKKSB
9Measure and confirm pH of circulating water is within the optimum range of 6.0 to 6.9. If pH was out of the range, adjust accordingly through the use of sulphuric acid or soda ash. Dosage shall be calculated based on the formula in the Appendix. Install test coupon in the basin once pH is within the range.DKKSB
10Analyze the KURIROYAL P-3270DK concentration 30 minutes after the water circulation. If the concentration of total phosphate was not enough, dose additional KURIROYAL P-3270DK to increase the concentration up to 80-100 ppm. Dose KURIROYAL P-2380DK at the quantity for every kg of KURIROYAL P-3270DK injected into the system.DKKSB
11Check and re-confirm at regular interval the quality of the cooling water. Should the pH and the concentration of KURIROYAL P-3270DK, additional dosing of acid and chemicals are necessary.DKKSB
12Dose 100 ppm of KURIROYAL P-2380DK against the holding water volume of system into the cooling tower basin. Apply transfer pump to dose. This should be done about 24 hour after start of initial treatment.DKKSB
13M-Alkalinity should be maintained above 50 ppm.DKKSB
14Continue circulating and monitoring the water quality as per table 3 and 4.MTBE /DKKSB
15The water circulation should be continued for another 24 hours.MTBE
16Proceed with transition treatment by carrying out blowdown to reduce the high chemical concentration in the system. DKKSB /MMSB
17Start to dose NaOCl and to control dosing to keep FRC target.DKKSB /MMSB
18Proceed with initial treatment when the total phosphate reaches 20mg/lDKKSB
19In order to switch to maintenance treatment, to adjust Ca-H until 80ppm by Calcium Chloride and to reduce blow down valve. DKKSB /MMSB
20Start to dose KURIROYAL C-3170 according to blow down rate. DKKSB
21Ca-H will achieve more than 120ppm, gradually. After that, KURIROYAL C-3170 should be adjust for target level, PO4 10-19ppm. DKKSB
DKKSB: DK KURITA SDN BHDMMSB : MTBE MALAYSIA SDN BHD5.0 Analysis and Frequency5.1 Monitoring parameter and control range of circulating water during blow down
Table 2: Control Range during blow downItemRangeFrequency
pH-twice / day (10am. 4pm)
T-Fe (ppm as Fe)Less than 2 ppmtwice / day (10am. 4pm)
Turbidity (NTU)Less than 5 NTUtwice / day (10am. 4pm)
Remark1; According to analysis result, DK KURITA may ask operator to change flow rate (twice/day).Remark2; In case DK KURITA dose CaCl2 and P3270DK at 10am, DK KURITA will analyze water quality at 9am to make sure concentration of Ca-H .5.2 Control range of circulating water during initial treatment
Table 3: Control Range during Initial Treatment
ItemRange
First 24 hoursAfter 24 hours
pH6.0 ~ 6.97.0 ~ 7.5
Calcium hardness (ppm as CaCO3)More than 50More than 50
Total phosphate (ppm as PO43-)80 ~ 10050 ~ 100
Table 4: Analysis parameter and Frequency during Initial Treatment
ItemFrequency
Make-up waterCooling water
First 24 hoursAfter 24 hrs to 4days
pHOnceOnce / 4hr3 times / day
Turbidity (degree)OnceOnce / 4hr1 times / day
Electrical conductivity ((S/cm)OnceOnce / 4hr1 times / day
Calcium hardness (ppm as CaCO3)OnceOnce / 4hr2 times / day
M-alkalinity (ppm as CaCO3)OnceOnce / 4hr2 times / day
Total iron (ppm as Fe)OnceOnce / 4hr2 times / day
Total phosphate (ppm as PO43-)-Once / 4hr2 times / day
Indispensable items are as follows. The monitoring purpose of these items is to form and control precipitate film on metal surface.
1) pH
2) Calcium hardness
3) Total phosphate
Other items are analyzed in order to reinforce monitoring of initial treatments.
1) Turbidity & Total iron; Monitor progress of formation of precipitate film.
2) Electrical conductivity; Monitor if some contamination occurs from external environmental.
3) M-alkalinity; Confirm pH reading
Remark1; In case DK KURITA dosed CaCl2 or Soda Ash/H2SO4, DK KURITA will analyze water quality after dosing. (Soda Ash/H2SO4: After 1 hour, CaCl2: After 2hour)Table 5: Control Range during Transition with high Blow downItemRangeFrequency
pH7.0-8.0twice / day (10am. 4pm)
T-Fe (ppm as Fe)Less than 5 ppmtwice / day (10am. 4pm)
Turbidity (NTU)Less than 20 NTUtwice / day (10am. 4pm)
Calcium hardness (ppm as CaCO3)40 ~ 60 ppmtwice / day (10am. 4pm)
Table 6: Control Range during Transition-Maintenance Treatment
ItemRangeFrequency
pH7.0-8.0twice / day (10am. 4pm)
Total phosphate (ppm as PO43-)10 ~ 19
19 ~ 30
twice / day (10am. 4pm)
Calcium hardness (ppm as CaCO3)80 ~ 200
40 ~ 80
twice / day (10am. 4pm)
APPENDIX
FORMULAES
1.CORROSION INHIBITOR (KURIROYAL P-3270DK)
Condition;
W: Dosage of KURIROYAL P-3270DK
(kg)
MPT: Target total phosphate in circulating water(mg/l CaCO3)
In this case, target total phosphate is 100.
MPA: Actual total phosphate in circulating water(mg/l CaCO3)
H: Holding water volume
(m3)
W = 4 * (MPT - MPA) * H / 1000
2.CALCIUM CHLORIDE
Condition;
W: Dosage of calcium chloride flake
(kg)
MCT: Target calcium hardness in circulating water(mg/l CaCO3)
In this case, target calcium hardness is 50.
MCA: Actual calcium hardness in circulating water(mg/l CaCO3)
H: Holding water volume
(m3)
W = 1.47 * (MCT - MCA) * H / 1000
3.pH ADJUSTMENT3.1 pH is higher than the desirable pH
Chemical required: Sulfuric Acid
Condition;
W: Dosage of sulfuric acid (98%)
(ltr)
MMT: Target M-alkalinity in circulating water(mg/l CaCO3)
In this case, target m-alkalinity is 6.5 to achieve pH at 6.5
MMA: Actual M-alkalinity in circulating water(mg/l CaCO3)
H: Holding water volume
(m3)
W = (MMT - MMA) * H / 1800
3.2 pH is lower than the desirable pH
Chemical required: Soda Ash or Caustic Soda
a. Soda Ash
Condition;
W: Dosage of soda ash
(kg)
MMT: Target M-alkalinity in circulating water(mg/l CaCO3)
In this case, target m-alkalinity is 6.5 to achieve pH at 6.5
MMA: Actual M-alkalinity in circulating water(mg/l CaCO3)
H: Holding water volume
(m3)
W = 1.06 * (MMT - MMA) * H / 1000
b. Caustic Soda
Condition;
W: Dosage of caustic soda (48%)
(ltr)
MMT: Target M-alkalinity in circulating water(mg/l CaCO3)
In this case, target m-alkalinity is 6.5 to achieve pH at 6.5
MMA: Actual M-alkalinity in circulating water(mg/l CaCO3)
H: Holding water volume
(m3)
W = 1.67 * (MMT - MMA) * H / 1500
The estimated relationship between M-alkalinity and pH
pHM-alkalinitypHM-alkalinity
8767.428
7.9657.324
7.8557.220
7.7467.117
7.639714
7.5336.56.5
6.0Maintenance Treatment for MTBE Cooling Water
Table (a): Treatment Chemicals (under normal condition/maintenance treatment)
Product nameFunctionDosage (mg/l)
Kuriroyal C-3170DKCorrosion Inhibitor40~80
Kuriroyal S-7180DKScale Inhibitor0~40
Sodium HypochloriteOxidizing agent For slime and bacteria control (continuously)0.2
Kuriroyal B-5410DKNon-oxidizing agent
For bacterial control50
( once per month against holding volume )
7.0Standard control range for cooling water quality for MTBE Cooling Water
The recommended water treatment programme is selected considering of the estimated cooling water quality shown in Table (a). The standard of cooling water quality control for the treatment programme is shown in Table (b).
Table (b) : Standard control range (under normal condition/maintenance treatment)
ItemControl Range
pH7.0 8.5
Electrical Conductivity((S/cm)less than 2000
M-Alkalinity(mg/l as CaCO3)80 150
Calcium Hardness(mg/l as CaCO3)120 200
Silica(mg/l as SiO2)less than 150
Chloride(mg/l as Cl-)less than 500
Total Iron(mg/l as Fe)less than 5.0
Turbidity(NTU)less than 20
Free Residual Chlorine(mg/l as Cl2)0.2 0.5
Cycle of concentration12
Total Phosphate (mg/l as PO4)10 19
8.0Water analysis
Analytical items and frequencies for cooling water quality control are shown in Table (c )
The frequency of analysis can be changed depending on the stability of make-up water quality and the operational conditions of the system.
Table (c) : Items and frequencies of water analysis (under normal condition/maintenance treatment)
ItemMake-up water Cooling water (any sampling point at the return line)
Once/weekOther times / weekOnce/weekOther times / week
pH((((
Electrical Conductivity ((S/cm)((((
M-Alkalinity (mg/l as CaCO3)((
Calcium hardness (mg/l as CaCO3)((
Chloride Ion (mg/l as Cl-)((
Silica Ion (mg/l as SiO2), 1*((
Total Iron (mg/l as Fe)((((
Turbidity (degree)((((
Total Phosphate (mg/l as PO4)-(
Free Residual Chlorine (mg/l as Cl2)-((
Bacteria Count-Once per week
ATP-Once per week
IRB-Once per month
SRB-Once per month
SFB-Once per month
Legionella Test (3rd Party)-Once per 6 months
Mild Steel Corrosion Coupon-Once per month
Note: *1 :When silica of cooling water exceeds 200 mg/l as SiO2, considerable error may be caused on the analysis because silicate ion changes to colloidal silica.
9.0 Target corrosion rate
Mild steel :Less than 2 mpy (or less than 11 mdd)
Copper
:Less than 0.2 mpy (or less than 1.2 mdd)10.0 Target deposition rate
Langelier Index
: less than 2.0
Ryzner index
: less than 8.0
Calcium Phosphate Deposition Index : 0.2 ~1.5
11.0 Bacteria Control Target Value
a. Bacterial numbers
: Below 104 col./ml (after stoppage of chlorine injection)
b. Slime adhesion degree : Below 10 degrees
c. ATP
: Below 80 RLU
d. Sulfate Reducing Bacteria: Below 103
e. Iron Related Bacteria
: Below 103
f. Fungi/Mould count
: Below 103
g. Legionella Bacteria
: