2500 Chemical Injection System
Design
Abstract
This section discusses the process control and design of a chemical injection system
for a cooling tower. Included are discussions of automatic controls; design consider-
ations; types of containers for feeders and storage; location of facilities; chlorine
injection facilities, with sizing, piping, and location; system commissioning; and
safety requirements.
Contents Page
2510 Process Control 2500-2
2520 Automatic Controls 2500-2
2521 Instrumentation
2522 Packaged Controls
2530 Chemical Injection System Design 2500-3
2531 Introduction
2532 Chemical Entry
2533 Design Considerations
2540 Chlorine Injection Facilities 2500-6
2541 Introduction
2542 Nature of Chlorine
2543 Design and Process Considerations
2544 System Commissioning
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2510 Process Control
Figure 2500-1 shows the common components of a typical cooling tower process
control scheme. The mechanisms of corrosion and fouling and how they are
controlled are discussed in Section 2400. Consult the ETD Monitoring and Control
Systems Division for help in this area.
Fig. 2500-1 Typical Cooling Tower Process Control
2520 Automatic Controls
2521 Instrumentation
Automatic units ensure control of critical variables at the optimum values, resulting
in an efficient system at a minimum operating cost. Close regulation of parameters
is also important for minimizing waste disposal. Many practical features can be
built into the instrumentation to achieve maximum dependability. Such features
include:
1. Sensing units located at the cooling tower to minimize response time.
2. Preamplification of the signal at the sensing point so it can be transmitted any
distance without interference.
3. Instruments located in the control room or other locations where personnel are
available.
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4. Dependable, solid-state electronic recorders to observe trends.
Generally, an automatic system provides a package to measure and control the
inhibitor level (chromate or nonchromate), conductivity for blowdown control, pH,
and, in many cases, corrosivity. The corrosivity device serves as a backup or as an
override on the system to provide an alarm or perform certain functions that are
programmed in for rapid restoration of normal conditions.
Chlorination programs can be automated by using ORP (oxidation reduction poten-
tial) instruments. Liquid nonoxidizing biocides are frequently injected into the
cooling system automatically by timing devices which operate proportioning feed
pumps.
2522 Packaged Controls
Both Uni-Loc and Magna Corporation offer packaged control systems for pH, blow-
down, and inhibitor addition. Controls should be designed so that they may be
expanded to use the various control options available. As environmental consider-
ations restrict, and probably eliminate, the discharge of chromates, more sophisti-
cated cooling tower controls will be needed.
2530 Chemical Injection System Design
2531 Introduction
This section discusses the design, equipment selection, and installation of chemical
injection facilities for additives injected from:
• Drums
• Semibulk portable containers
• Bulk storage tanks
The discussion applies to facilities used for purchased-outside products typically
intended as additives to process plant streams, such as antifoulants, antifoams, anti-
oxidants, corrosion inhibitors, boiler feed water additives, acids, caustics and
cooling tower additives.
2532 Chemical Entry
We are legally required in many locations to document and provide specific mate-
rial hazard information for all personnel who might be exposed to the hazardous
materials. These requirements include:
• Reviewing and approving all chemicals which are used in a plant
• Posting the identity of the material and the appropriate hazard warning on the
container
• Providing a Material Safety Data Sheet before the material is used
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The engineer is responsible for verifying that all of the local rules and regulations
have been complied with. Consult the local safety and environmental specialists for
the most up-to-date rules and regulations.
2533 Design Considerations
Richmond Refinery Drawings D-253080, B-603003, and B-603005 are Standard
P&IDs for bulk, semibulk, and barrel chemical injection facilities. These drawings
are attached at the end of this section as Figures 2500-2, 2500-3, and 2500-4. Full
size prints and CAD files are available from the Richmond Refinery Drafting
Department.
Note that the attached P&IDs were generated at the Richmond Refinery for their
Process Hazard Safety Committee. Consequently, some of the information, such as
references to refinery instructions, is specific to Richmond.
Types of Containers
The choice of containers for feeding chemicals, such as acid, caustic, inhibitor,
dispersant, biocide, etc., depends on the type of controls, the desired inventory, ease
of replenishing stock, handling problems, cost of chemicals in bulk and drum lots,
and, most importantly, the safety and environmental considerations involved.
Bulk Storage Tanks (see Figure 2500-2 drawing D-253080)
For large quantities and where tank truck deliveries are required, bulk storage tanks
are the best option. Often vendors will supply the tank; however, the tank must
sometimes be upgraded to meet local standards.
Steel storage tanks should be designed to UL-142 or equal (unless a pressure vessel
is required, then use ASME Code, Section VIII, Division 1). All connections to the
vessel must be 3/4-inch minimum size and must be seal-welded or flanged. Vessels
containing flammable material require a bottom fill nozzle and a vent system sized
for emergency venting (per NFPA 30 and API STD-2000).
High-density polyethylene (HDPE) storage tanks may be used if they are compat-
ible with the material stored (HDPE should not be used to contain combustibles).
HDPE tanks should be designed to Poly Cal Plastics’ specification PCPP48614, or
equal, for cross-linked polyolefin tanks.
Semibulk, Portable Returnable Container (see Figure 2500-3 drawing B-
603003)
Semibulk containers offer the advantages of returnable containers supplied by the
vendor and are easily handled by a forklift or crane. Skid-mounted standard units
with attached pumps offer great convenience at low first cost and eliminate or
reduce capital expenditures. Material unit cost is usually cheaper than for drums.
However, not all vendors offer this option. Note that some upgrade of vendor-
proposed piping and equipment is usually required to meet local standards.
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Drums (see Figure 2500-4 drawing B-603005-0)
Use of drums should be avoided unless the quantity to be used is very small and
returnable, or bulk facilities cannot be justified. Drums may be an acceptable alter-
nate, however, for temporary uses (test runs). Drums are costly to dispose of, waste
chemicals because they do not empty completely, and may result in higher
employee exposure. Drum handling is difficult and can cause injuries.
Location of Facilities
The facilities should be located in an easily accessible area, preferably around the
perimeter of the plant. Give consideration to the access of the truck delivering the
bulk shipment, ease of operator access on normal rounds, and to the nature and
potential hazard of the material (i.e., decomposition of the material if near a fire).
Injection Pumps
The injection pump(s) should be located as close as possible to the vessel while still
maintaining the proper clearances. For bulk storage facilities, if possible, elevate
the pump(s) approximately 3 feet for ease of operation and maintenance. Milton
Roy, Pulsafeeder, or Williams pumps may be used, depending on the application.
Instrumentation
A combination level gage/rate meter is allowable; however, it should be heavy duty
to avoid spills resulting from mechanical damage. The suggested model is a
KENCO calibration gage (or equal). Since each facility’s pump flow rate is
different, the KENCO model number must be obtained from the vendor.
Piping
Consider seal welded or socket welded piping 3/4-inch minimum. The type of
chemical may require a material other than steel. The ETD Materials Division or
the material vendor should be consulted. Some injection quill designs are shown on
the referenced P&ID. To facilitate pump hookup or to decrease costs in long
discharge runs, stainless steel tubing (or another alloy) is acceptable (1/2-inch O.D.,
0.065-inch minimum wall).
Lighting
Provide adequate lighting for the operating and maintenance activities required.
Consult the local safety engineer for the level of lighting required.
Berms
The decision to berm the facilities should be based on the volume, and on the
impact on the effluent treatment system in the event of a spill. The intent is to
contain any spills to a confined area and to keep the material out of the drainage
system. Berms should be large enough to hold all contents of the largest tank in
case of rupture and should contain any slight spillage from the loading spot and
from taking the facilities out of service for maintenance. A 2-inch minimum gate
valve (normally closed) should be provided in the berm, through which rainwater
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can be drained from the bermed area. Adequate washdown facilities should be
provided near the facilities.
Safety Requirements
Each facility must be evaluated to determine if the following safety equipment is
needed:
• Safety showers and eyewash stations a minimum of 10 feet from any potential
leak source and a maximum of 50 feet (unobstructed) from the facility for
corrosive chemicals
• Safety signs
• Barriers or guard posts around the perimeter per Standard Drawing GA-
S99975 (located in the Civil and Structural Manual)
• Scott Air-Pak
• Posting of instructions for the driver of the bulk delivery truck
2540 Chlorine Injection Facilities
2541 Introduction
This section gives guidance on the design of cooling tower chlorine injection
systems. In order to complete a detailed design, you must understand the hazards,
regulations, and safe handling guidelines for chlorine. These subjects are discussed
in detail in the Piping Manual, Section 1500, and in general terms in this section.
2542 Nature of Chlorine
Chlorine is a nonflammable gas which is liquified under pressure. It will react
chemically (often vigorously) with almost all elements and with many inorganic
and organic substances, usually with the evolution of heat. The gas has a character-
istic odor and a greenish-yellow color, and is about two and one-half times as heavy
as air. Thus, if it escapes from a container, it will seek the lowest level in the
building or area where the leak occurs. Although dry chlorine will not corrode most
metals, it is very corrosive (forms HCl) when moisture is present. Therefore, never
use water on a chlorine leak because resulting corrosive conditions always make the
leak worse.
There are potential health hazards associated with the use of chlorine. Chlorine gas
is primarily a respiratory irritant. In sufficient concentration the gas irritates
mucous membranes, respiratory system, and skin. In extreme cases, the difficulty of
breathing may increase to the point where death can occur from suffocation. Never
attempt a rescue without adequate respiratory protection. Liquid chlorine, in contact
with skin or eyes, will cause burns. Consult the Material Safety Data Sheet for addi-
tional information.
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2543 Design and Process Considerations
The primary use for chlorine is for cooling water treatment. Chlorination reduces
the growth of algae and fungi which, left untreated, can cause severe deposition
problems and cell attack on metals.
Chlorine normally comes in 150-pound or 1-ton containers. Drawings D-603001
and D-603002 are standardized P&IDs that can be used as a basis for designing
chlorine facilities for cooling water treatment. These drawings are attached at the
end of this section as Figures 2500-5 and 2500-6. Full-size prints and CAD files
can be obtained from the Richmond Refinery Drafting Department.
Sizing of the Facilities
The dependable continuous discharge rate of chlorine gas from a single 100-pound
or 150-pound cylinder without frosting under normal conditions (70°F) is about
1.75 pound/hr against a 35 psi back pressure. The rate for a 1-ton container is about
15 pound/hr under similar conditions.
If the gas discharge rate from a single container will not meet requirements, two or
more can be connected to a manifold and discharged simultaneously, but all
containers should be at the same temperature to prevent transfer of gas from a warm
container to a cool container. If a container becomes completely filled with liquid
and the container valve is then closed, the container may burst from hydrostatic
pressure.
Minimize the number of chlorine cylinders that are hooked up to the system. Addi-
tional cylinders and associated piping increase the risk of having a chlorine release.
Normally a 4-week supply should be adequate.
Where to Inject Chlorine
Chlorine should be injected into the tower basin on the opposite side of the tower
from the forebay to maintain a sterile condition in the tower basin. If chlorine is
added to the forebay, it will not reach the basin because it evaporates through aera-
tion as the water cascades down over the tower fill. In order to efficiently sweep the
basin, a chlorine distributor that extends the full length or width of the basin is
normally employed. This distributor should be located approximately 2 feet below
the basin water level.
Piping
Piping arrangements should be as simple as possible. Joints should be flanged or
welded with the number of flanged joints held to a minimum. Piping systems
should be well-supported and adequately sloped to allow drainage; low spots
should be avoided.
Construction materials and ratings for Monel pipe are shown on the attached
P&IDs for cooling water chlorination facilities. The cylinders are connected to the
piping system by a Chlorine Institute transfer hose. A pressure-reducing valve
should be installed between the cylinder and the regulator.
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Piping Expansion and Protection
Suitable allowance should be provided for pipe expansion due to changes in temper-
ature. Liquid chlorine has a high coefficient of thermal expansion. If liquid chlorine
(containing no gas bubbles) is trapped between two valves, high pressure will
develop with an increase in the temperature of the chlorine and a rupture could
occur. For this reason the standard designs shown on the P&IDs have only one pair
of isolation valves (one main plus backup).
Preventing Liquid to the Chlorinator
No liquid chlorine can enter the chlorinator, as this usually damages the chlorinator
components. The following methods can be used to reduce the chances of liquid
chlorine entering the chlorinator:
• Install a pressure reducer (as shown on the P&IDs) to flash any residual liquid
• Have a 120 volt heater installed in the chlorinator (most can come factory-
equipped)
• Install a liquid trap in the piping just upstream of the chlorinator
Chlorinator Design
Chlorinators are usually sized to provide 1 ppm of chlorine continuously to the
circulating water. For example, for a system with a circulation rate of 13,000
gallons per minute (156 million pounds per day) the chlorinator should be sized to
deliver approximately 156 pounds per 24 hours. A margin of 20 to 25% should be
added to the chlorinator design capacity.
Chlorinators are typically automated by equipping them with timers that permit
either a daily or several times weekly application. These timers should also permit
complete flexibility for the length of each application. However, the typical dura-
tion is somewhere between 2 and 8 hours. The timer is usually connected to a sole-
noid valve on the water supply to the chlorinator. Since a flow of water is necessary
to operate a chlorinator, interrupting this flow with a suitable automatic, full-
opening valve provides a simple and reliable method of turning the equipment on
and off.
Vacuum Eductor
The chlorinator is actuated by an inducted vacuum from an eductor. The eductor
uses the flow of water to pull a slight vacuum on the chlorine system. The chlorine
flow can be controlled by a variable rate rotameter.
Where to Locate Chlorine Containers
Exposure of containers to flame, intense radiation heat, or steam lines must be
avoided. If the fusible plug reaches 158°F the plug will melt and chlorine will
escape to the atmosphere. For cooling water treatment, the cylinders can be stored
outdoors but they should be located at least 50 feet from the tower or from any
other flammable materials. If they must be located closer than this, a building or
fire wall should be designed and constructed to protect all elements of the chlorine
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system from fire hazards. Positive hold-down clamps should be provided for all
chlorine containers.
Miscellaneous Safety Equipment
The chlorine facilities should be well lighted and identified by “Cl2 Hazard” and
“No Parking” signs around the perimeter. Barriers of guard posts should also be
installed around the perimeter. An eyewash, Scott Air-Pak, protective clothing, and
shower should be located within 50 feet of the chlorine.
2544 System Commissioning
Cleanup After Fabrication
It is especially important to clean all portions of a chlorine system before use
because chlorine may react violently with cutting oil, grease, or other foreign mate-
rials. Cleaning may be accomplished by pulling a cloth saturated with trichloreth-
ylene (or other suitable chlorinated solvent) through each length of pipe.
Chlorinated solvents can produce serious physiological effects if not used in
strictest compliance with the solvent manufacturer’s safety recommendations.
Never use hydrocarbons or alcohols because residual solvent may react with chlo-
rine.
Pressure Testing
After hydrostatic testing, the piping must be dried. This can be done by passing
steam through the lines from the high end until the lines are thoroughly heated.
While steaming, allow condensate and foreign matter to drain out. While the line is
still warm, nitrogen (or dry air) should be blown through the line until it is dry; this
may require several hours.
After drying, the system should be pressurized to 150 psi with dry air or nitrogen
and tested for leaks by application of soapy water to the outside of joints. Chlorine
gas may then be introduced gradually and the system tested for leaks. Never
attempt to repair leaks by welding until all chlorine has been purged from the
system. When all detectable leaks have been repaired, the system should be retested.
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Fig. 2500-2 Engineering Drawing D-253080-0
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Fig. 2500-3 Engineering Drawing B-603003-0
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Fig. 2500-4 Engineering Drawing B-603005-0
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Fig. 2500-5 Engineering Drawing D-603001-0
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Fig. 2500-6 Engineering Drawing D-603002
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