DK KURITA SDN BHD (351759D)

LOT 779, JALAN PENGHIBURAN, KG BESUT,

CHUKAI, 24000 KEMAMAN, TERENGGANU DARUL IMAN.

E-mail:whkurita@tm.net.myTEL: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

: