51314-4291-Improving Reliability of Closed Loop Cooling Water Systems a Lessons Learnt Approach

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Product Number: 51314-4291-SG

ISBN: 4291 2014 CP

Author: Muhammed Santuraki

Publication Date: 2014

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Oil & gas industries utilize fresh cooling water as a cooling medium for many of their process equipment. Quality of the water is very important in order to ensure the continued integrity and reliability of these systems.This paper discusses on various corrosion issues in Heat Exchangers within the closed loop cooling water system due to water quality. A detailed study was performed to determine the root cause of the corrosion failures which was validated by metallurgical analysis water chemistry analysis microbiological study sludge analysis and inspection of the exchangers.The paper further discusses on trouble shooting and mitigation methods such as improvements in chemical treatment system monitoring inspection strategy and system operation which resulted in significant improvement in Cooling water integrity and overall system reliability. It also details the importance of cleaning and passivation of the system prior to commissioning.The paper concluded that inadequate system cleaning during system start-up chemical treatment and monitoring are the root cause of corrosion issues. The recommendations of the study includes corrosion control methods such as optimizing corrosion inhibitor and biocide dosages and frequency improvement in fresh cooling water monitoring programme by means of monitoring key process parameters and improvement in laboratory analytical techniques including microbial analytical techniques by more accurate ATP analysis.Recommendation includes incorporating lessons learned in future cooling water systems such as requirement for proper cleaning and passivation of cooling water system prior to commissioning improvements in chemical treatment and monitoring periodic use of side-stream filtration and regular inspection of heat exchangers.The major contributions to technical knowledge are: (1) Use of close system monitoring to compliment chemical treatment. (2) Use of more accurate microbial analytical techniques like ATP to detect microbial activity (3) Use of inert tracer to measure accurate system volume.