The initial cooling stage

The process of the initial cooling of the brine through the coolant (mother liquor)
passes through a heat exchanger with panels or strips and temperature drops
until reach 15.65 C.
The exchanger reduces the temperature of brine from 25 degrees Celsius to 15.6
degrees Celsius that temperature inside exchangers must not be less than as it is
beginning of ( glauber salt) to be crystallized that may cause the occurrence of
obstruction inside exchanges
After having heat exchangers with slides in the service for a period of time from 4
to 6 hours, obstruction may be occurring as Impurities began to form inside
exchanger
This can be distinguished through brines temperature increasing and coolants
temperature decreasing. The obstruction makes the amount of brine entering the
factory relatively decreasing .In this case you must get the exchanger out of the
service and wash it with flushing water

Washing of old exchanger
Exchanger is got out from the service by the control unit and the following points
must be in consideration
1 - Reducing relatively the amount of coolant and brine
2 - Opening valve of brine discharging and coolant before getting the old
exchanger out of service directly
3 The old exchangers are converted from the control panel and the response of
valves (SV101 & SV104 & SV103 & SV102) is monitored for conversion to position
(BY PASS)

4 - Opening the washing points for the old exchanges and monitoring
temperature measuring point TR104 & temperature measuring point TR103 until
reaching temperature higher than 40 C
5 - Closing the washing points and then entering the old exchanger to the service
through the control panel .The valves of brine discharging and coolant are locked
then valves (SV101 & SV104 & SV103 & SV102) are converted to position
NORMAL
6 - The amount of brine and coolant (ML) must be returned to its natural state.

Washing of the new exchangers
In the case of the new exchangers the following points is followed:
1 - Reducing relatively the amount of coolant and brine
2 - Opening valve of brine discharging and coolant before getting the old
exchanger out of service directly
3 - Brine and mother liquor are manually directed and the new exchangers are got
out of service by the technician of Ground Floor
4 - Opening the washing points for the new exchanges and monitoring
temperature measuring point
TR201 until it reaches higher than 40 degrees Celsius

5 - Closing the washing points and then entering the new exchanger to the service
by the technician of Ground Floor
6 - The amount of brine and coolant (ML) must be returned to its natural state.


Brine lines washing steps: -
washing of brine lines is occurring after getting out of the service through the
washing points existing on Centrifugal pump P1376 next to roller. These points
are connected with the two lines of brine ( the fly line & the old one)
every line has a manual valve and prevention of returning valve .To wash the
stopped brine line, the connection roller 1&2 and manual valve ,which is existing
among pumps on the brine line , are locked then the discharging line for plant is
opened and the desired line is isolated from other lines


The process of basic cooling for brine is occurring through two crystallizers
equipped with heat exchanger with pipes. The temperature of solution in the first
crystallizer drops to 12.15 C. cooling is done by the mother liquor before
entering to the first stage of cooling .Then the brine is transferred to the second
crystallizer where the basic cooling process is occurring at a temperature of -15
C and coolant is a solution by a mixture of ethylene glycol and water at 3:1, which
is cooled to a temperature of -10 degrees Celsius inside cooling units.





The first crystallizer
The brine enters to first crystallizer that is the first stage to form Crystals of
hydrate sodium sulfate salt where 40% of Crystals of water sodium sulfate are
formed
The first crystallizer consists of:

V1203A: - is the basic tank of crystallizer with a capacity of 115 m 3
E1204A: - a heat exchanger consists of a set of pipes installed between two
mirrors, bottom and top, through which the brine passes. The space between
these pipes and around is called Shell where the coolant solution exists. The
surface area of the heat exchanger is 880 m 2

V1221A: - It is the link between V1203A and the heat exchanger E1204A. There is
flipping pump P1205A, on the link, which pulls the solution from V1203A and
pumps it through a heat exchanger E1204A to return to the V1203A again from
the top through the V1222A. The capacity of this link is 7 m3

P1205A: - is the main flipping pump for first crystallizer which has 90 kilowatt -
engine and the volatility of 4500 m 3 / hour

P1207A: flipping- pump of coolant. Its function is to pull the solution from the
bottom of the Shell and pumping it to the top of the Shell through V1223A. The
capacity of this pump is 45 kW and the volatility of 4500 m 3 / hour.
The direction of flowing of brine is to height but the coolant solution is to bottom.
The measuring point of temperature TR113 determines the temperature of brine
inside the first crystallizer also the measuring point TR109 determine the
temperature of coolant solution inside the exchanger with slides .the measuring
point TR105 determine the temperature of coolant solution before it enters the
heat exchanger with slides and by design, the first crystallizer lowers the
temperature of the brine from 15.6 to 12.1 C which reduces temperature by 3.5
degrees Celsius and within it 40 % of hydrated sodium sulfate crystallization is
formed
After a period of time, an obstruction within the crystallizer of the first exchanger
is occurring, and this is identified when the difference of temperature degree
between measuring point of temperature TR109 and TR113 is equal to or exceeds
the limit of 8 degree. In this case the first crystallizer must be isolated and
smelted.

Melting of first crystallizer
First crystallizer is isolated by locking the valve of brines flowing and the brine
Path is directed to the second crystallizer, also the Path of coolant solution is
redirected by locking the valve controlling the entrance and exiting of coolant
solution to first crystallizer
P1232, a pump pulls brine from the top exchanger of V1222A and poured into the
bottom of the exchanger in V1221A next to centrifugal pump P1205A that is
stopped in this case.
There is a link around to V1223A next to P1207A called JACKET where steam 4 bar
on this link is opened but after opening valves of condensate discharge at the
bottom of this link.
This steam leads to raise the temperature of coolant that is being flipping by
pump P1207A and in turn raises the temperature of brine inside the pipes of
exchanger. The P1232 is flipping the brine inside the exchanger by pulling it from
the top of the exchanger and pouring it at the bottom of exchanger. This process
continues until the temperature measuring point TR109 reading reach to 40 C
VENT that exists at the top of SHELL is opened during heating to avoid pressure
inside the SHELL resulting from extended coolant with increasing of its
temperature. Steam flowing is stopped when measuring point of temperature
TR109 reaching to 40 C.
Pump P1205A is being working and the P1232 pump is being stopped then
opening its discharging valve to make the line free of salt solution, then the valves
of entrance and exiting of coolant solution to the first crystallizer are opened but
roller BYPASS is closed .
gradually cooling is occurring , and when the measuring point of temperature
TR113 reach to suitable operating temperature,the first crystallizer is Retrieved
to work by opining its brine line and closing brine path to second and third.


The second and third crystallizer
After first crystallizer to the second, the brine access to second and third
crystallizer from the first crystallized in parallel. The second and third crystallizers
represent the final stage for composition of hydrate sodium sulfate crystallization
known as (gluaber salt)

The second crystallizer consists of: -

:-V1203B is the main tank in second crystallizer with a capacity of 115 m 3.

E1204B: - is the heat exchanger for the second crystallizer .it consists of a set of
pipes installed between two mirrors, bottom and top, through which the brine
passes .The space between these pipes and around is called Shell where the
coolant solution exists. The surface area of the heat exchanger is 1675m 2.

V1221B: - It is the link between V1203B and the heat exchanger E1204B .There is
flipping pump P1205B, on the link, which pulls the solution from V1203B and
pumps it through a heat exchanger E1204Bto return to the V1203B again from the
top through the V1222B. The capacity of this link is 3 m3
P1207B: - -this Pump has a function of flipping of coolant liquid (glycol). The
capacity of this pump is 75 kW and the volatility of 4000 m 3 / hour.
the measuring point of temperature TR117 determines the temperature of
glycol coming from the old units also the measuring point TR112 determine the
temperature of glycol inside the shell.
The measuring point TR120 determines the temperature of glycol returning from
shell of the second crystallizer. The measuring point TR116 determines the
temperature degree inside the second crystallizer.


The third crystallizer consists of: -

V1203C: - is the basic tank of crystallizer with a capacity of 115 m 3
E1204C: - a heat exchanger consists of a set of pipes installed between two
mirrors, bottom and top, through which the brine passes .The space between
these pipes and around is called Shell where the coolant solution exists. The
surface area of the heat exchanger is 1675 m 2
V1221C: - It is the link between V1203C and the heat exchanger E1204C .There is
flipping pump P1205C, on the link, which pulls the solution from V1203C and
pumps it through a heat exchanger E1204C to return to the V1203C again from
the top through the V1222C. The capacity of this link is 3 m3
P1205C: - is the main flipping pump for first crystallizer which has 57 kilowatt -
engine and the volatility of 0444 m 3 / hour
The measuring point of temperature TR715 determines the temperature of
glycol coming from the new units also the measuring point TR717 determine the
temperature degree of glycol inside the shell of the exchanger . The measuring
point of temperature TR 074determine the temperature degree of glycol
returning from shell of the exchanger of the third crystallizer but the measuring
point of temperature TR216 determines the temperature degree of brine inside
the third crystallizer.
the second and third crystallizer are decreasing the temperature of brine from
12.1 degrees Celsius to a temperature of -1 C and thus the crystals of hydrate
Sodium sulfate salt are forming.

*** coolant in the second and third crystallizer is ethylene glycol mixed with
water by 30% glycol .cooling liquid come from old and refrigeration units G1227A
and new and refrigeration units G1235C.D .
Glycol passes to the second crystallizer through the control roller TCV116 where it
enters to SHELL of the exchanger through V1223B .The pump P1207B pulls from
the bottom to the top of shell.
Glycol passes to the third crystallizer through control valve TCV216 .pump P1207C
is flipping glycol inside shell of the exchanger of the third crystallizer.

* pumps P1228A.BC & P1236A.BC pull coolant from the second and third
crystallizer after exchanging and increasing in its temperature and return it to the
old and new refrigeration units.

* There is Manual valve controlling return glycol of the second crystallizer is
named blue valve between operating members .there are manual valves on
pumps P1228A.B.C.
there is an insulator roller between the pumps of P1228B, and another one
between the pumps of B, C with the knowledge that the pumps P1228A.B can run
both or one of them for the unit A, also the pumps P1228B.C can run both or one
of them for the unit B.
In the case of any stoppage of old units, any of the three pumps can run on
another unit, and taken into account reviewing the insulator valves among pumps
when running pumps of pull the coolant.
* There is Manual valve controlling return glycol of the third crystallizer is named
Violet valve between operating members .there are manual rollers on pumps
P1236A.B.C.
there is an insulator valve between the pumps of P1236B,A and another one
between the pumps of B, C with the knowledge that the pumps P1236A.B can run
both or one of them for the unit G1235C, also the pumps P1236B.C can run both
or one of them for the unit G1235D.
In the case of any stoppage of old units, any of the three pumps can run on
another unit, and taken into account reviewing the insulator roller among pumps
when running pumps of pull the coolant.

* In the case of isolation of the second and third in the cooling, it is essential to
close the manual valve located on the connection link between manual pumps
P1228 AB C and the pumps P 1236 A, B, C, as well as being closing the manual
valve located on the connection link between the expulsion of the old and new
units. In this case the valve TCV 116-2 is working BY PASS valve for only old units
and be influenced only by slot of valve TCV116-1, and the BYPASS that specific for
Chinese units is being the link that has a manual roller for units and another one
for plant.
In this case, the pumps P1228A & B & C pull glycol returning from only the second
crystallizer, but the pumps P1236A & B & C pull glycol returning from the second
crystallizer.

In the case of non-isolation of the two crystallizers in cooling, connection valves
must be opened for expulsion of the units and the roller TCV116-2 is becoming
the BYPAS valve for all units affected by the highest open of valve TCV116-1 or
roller TCV216

* After a period of time for being the crystallizers in working, it is observed that
the difference of temperature degree between measuring point of temperature
TI116 and TI120 is high and the difference of temperature degree between
measuring point of temperature TR117 and TR120 is decreasing, and this
indicates that there is an obstruction problem that occurring after 35_45 hours
from being crystallizer works.in this case the second crystallizer must be isolated
and smelted.


Melting process for the second crystallizer:

1- Firstly, close valve TCV 116-1 gradually and the technician of cooling unit is
told about that.
If the second crystallizer is insulated (in cooling process) from the third
crystallizer, valve TCV 116-2 will be opened with closing TCV 116-1.
After valve TCV 116-1is closed totally, the returning glycol valve or (blue valve) is
closed also, and then the second crystallizer is got out of service by closing Over
Flow valve between the first and second crystallizers -in condition of the first
crystallizer is in service- or closing of the valve allowing the brine to enter the
second crystallizer from the bottom (in the past the brine was not fed during the
melting process for the second crystallizer before installation of new systems).
2- The P1233 is operated (stir pump which is operated during the melting process
only) and intakes the brine from the top of the exchanger from V1222B and
pumps it above the discharge of the pump P1205B - which is closed in this case- in
the bottom of the second crystallizer after that the 4 bar steam manual valve is
opened which is connected to gasket existing around V1223B (above the
discharge of the pump P1207B).
Before opening the steam valve, the valve of discharging the cooled is opened
and heating process begins till the temperature degree TR112 reaches 40 C and
in this case the steam valve is closed, operating pump P1205B and pump P1233 is
closed and its intake, discharge valves are closed also then making a discharge to
its intake line, the blue valve is opened then the valve TCV 116-1 is opened
gradually ( it's preferable to wait after operating P1205B in order to make the
temperature degrees TR116 & TR109 converges). The cooling process begins
gradually till TR116 reaches the normal operating temperature degree and the
crystallizer begins to work when allowing the brine to enter.
If the second and third crystallizers aren't insulated in cooling process, all the
units will cool the third crystallizer (when closing TCV 116-1 and the blue valve).


The Melting process for the third crystallizer
If the workers remark increase of temperature degree TR216, reduction of TR320
and the converges between TR217 and TR320 accompanied with increase of
ampere of pump's P1205C motor, the valve TCV216 must be closed gradually, also
closing the returning glycol valve (violate valve) and the unit technician is told
about that. If the third crystallizer is insulated in cooling process from the second
crystallizer, the manual valve of Bypass -which is in the discharge of new units-,
must be opened.
Also open the manual bypass valve which is in the discharge of P1236A&B&C. In
this condition, the Chinese units are turned to NO LOAD. The violate valve &
TCV216 aren't closed 100%, after that pump P1234 is operated & P1205C is closed
and the discharge cooled valve is opened also steam valve till TR212 reaches 40 C
then the steam valve is closed, P12905C is operated, P1234 is closed, opening
violate valve and valve TCV216 is opened gradually.
The bypass manual valve is closed, loading the units and the cooling process
begins till TR116 reaches the normal operating temperature degree. The
crystallizer begins to work by entering the brine to it
In the case of the two crystallizers aren't insulated in the cooling process, the
TCV216 must be closed gradually and the returning glycol valve is closed. The
bypass manual valve must not be opened as the glycol would transport to the
second crystallizer through TCV116. The melting process continues as mentioned
before.
If the melting process is done to one of the two crystallizers during the continuous
production, the crystallizer must be cooled keeping the maximum allowable
amount of the brine. The cooling time is in consideration, also the melting process
that avoid the need of melting for the two crystallizers in one time or converge
times.
The feeding of brine to the crystallizers must be adjusted in order to make TR116
equals TR216.

Remark:
There is on the shell of each exchanger 2-inch connection linked to opened tank
(its function is to include the increase of glycol volume during the melting process
also workers can know the level of glycol in the system). There is a connection
from this tank to other tank existing in the first floor to prevent loss of glycol.


Cooling Units
The equipment which is responsible for cooling the liquid (mixture of water and
glycol) entering to the crystallizers.
There are four cooling units
1- The old units G1227A.B: 1 MWatt ability, it cools 600 m3/hr from the glycol.
TI-117 indicates the temperature degree of the outgoing glycol from the units,
TI-122 indicates the temperature degree of the cooling water outgoing from the
unit
TI-118 indicates the temperature degree of the outgoing cooling water from unit
A.
TI-119 indicates the temperature degree of the cooling water outgoing from
unit B.
F1 104 indicates the amount of the cooling water entering to unit G1227A.
FI 105 indicates the amount of the cooling water entering to unit G1227B.
FI1213 indicates the amount of glycol entering to the second crystallizer.

2- The new units G1235C.D: .5 M Watt ability, that cooling 600 m3/hr of glycol
and indicates
TI-217 temperature degree of the glycol outgoing from the units
TI-220 temperature degree of the cooling water entering to the units
TI-218 temperature degree of cooling water outgoing from unit G-1235C
TI-219 temperature degree of the outgoing cooling water from unit G1235D
FI 204 indicates the amount of entering cooling water to unit G1235C
FI 205 indicates the amount of entering cooling water to unit G1235D
FI 206 indicates the amount of entering glycol to unit G1235C
FI 207 indicates the amount of entering glycol to unit G1235D

The Brine is transported from the second and third crystallizers to V1209A&B.