The document summarizes work done by Michael Postler and Craig Guenette on a process cooling water system from September 2009. It includes updating as-built drawings, analyzing the existing system for head losses, and making suggestions to improve efficiency. It also evaluates options for upgrading the system to handle increased flow, including replacing pumps and heat exchangers. The proposed design is analyzed and shown to reduce operating pressure from 130.9 psig to 95 psig.

1. Group: Facilities Services Department
Team Members: Michael Postler and Craig Guenette
Start Date: September 08, 2009
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2.  The System
 Commencement
 As-Built Updates LPL
 As-Built Updates FAB
 Setup for Calculations
 Existing Calculations
 Existing Suggestions
 Problems to be Solved
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 Solutions
 New Design
 New Pipe Routes
 Proposals
 Proposals (continued)
 New Calculations
 Selection
 Questions?
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3.  What is Process Cooling Water?
 What is this system used for?
 How does it differ from Chilled Water?
 Why is it advantageous?
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4.  Initial assignment
 Update As-Built drawings
 Calculate existing head loss
 Make design suggestions
 New condition 250 GPM  330 GPM
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5.  Briefed on the “potential” hazards in ML
 Field surveyed in Lower Process Level
 Updated As-Built drawings
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6.  Coordinated a visit to the clean room
 Field surveyed in upper process level
 Updated As-Built drawings
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7.  Assigned numerical values for equipment
 Verified all pipe dimensions and pipe fittings
 Documented all pressure and flow readings
at equipment
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8.  Identified critical areas (greatest head loss)
 Created spreadsheets for problem areas
 Interpreted results with present system
(Ideal operating pressure: 106 psig)
Pipe Pipe Equiv. Friction Loss Section Accum.
Item Size GPM Length Fitting Length Velocity (per 100 ft.) dP dP
(in.) (ft.) Qty. (ft.) (fps) (ft.) (ft.) (ft.)
PCW Return 4 245 5 1 6.404 4.059 0.2029 208.5385
Ball Valve 4 245 1 2.5 6.404 4.059 0.1015 208.6400
PCW Return 2 245 1 1 25.617 103.003 1.0300 209.6700
Union 2 245 1 0.45 25.617 103.003 0.4635 210.1335
90° Elbow 2 245 1 12 25.617 103.003 12.3603 222.4938
PCW Return 2 245 1 1 25.617 103.003 1.0300 223.5238
Pumps 2 245 1 25.617 103.003 0.0000 223.5238
+10 % SAFETY FACTOR 245.8762
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9.  Evaluated critical friction losses
 Manipulated pipe diameters on spreadsheet
 Suggestions were made to save head loss
 Example: Existing LPL tool #34 has 260.7 ft.
of head loss (112.8 psig). With suggestions the
updated system will have 180.9 ft. of head loss
(78.3 psig). This suggestion will save 79.8 ft. of
head loss (34.5 psig).
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10.  Losing 21 psig (102-81 psig) across filters
 Discrepancy of 16 psig between the pressure
gauges and the controls system
 In bay 11 - equipment would occasionally
shut down during operation
 Cracked 45° elbow on riser 11
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11.  Pressure analysis performed, controls –
calibration issue
 After recalibration pump supply went from
102 psig to 86 psig
 In bay 11 – there was not enough pressure
at the equipment and pump output pressure
was increased
 The cracked 45° elbow on riser 11, will be
replaced during the next shutdown
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12.  250 GPM  330 GPM
 Existing system HL = 302.4 ft. (130.9 psig)
requiring 65 HP
 Existing pumps will not handle flow increase
 Existing heat exchanger must be
modified/replaced
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13.  Four different options for main headers
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14.  Two main 4” headers off 5” SS Main
 Filters to be moved to accommodate new
header design
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15.  28 Plates to be added to the Heat
Exchangers (65-93)
 Pumps and motors on VFD to be replaced
 Automatic air vents to be installed on all
risers
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16.  Incorporated new flows, piping and fittings
 Assigned new critical equipment
 New operating pressure: 95 psig (42 HP)
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Pipe Pipe Equiv. Friction Loss Section Accum.
Item Size GPM Length Fitting Length Velocity (per 100 ft.) dP dP
(in.) (ft.) Qty. (ft.) (fps) (ft.) (ft.) (ft.)
PCW Return 5 330 5 1 5.521 2.488 0.1244 193.7651
Ball Valve 5 330 1 3.1 5.521 2.488 0.0771 193.8422
PCW Return 5 330 1 1 5.521 2.488 0.0249 193.8671
Union 5 330 1 0.65 5.521 2.488 0.0162 193.8833
90° Elbow 5 330 1 15 5.521 2.488 0.3732
Suction Diffuser 5X4 330 1 1.850 1.8500 195.7333
PCW Return 4 330 1 1 8.626 7.046 0.0705 195.8037
Pumps 4 330 1 8.626 7.046 0.0000 195.8037
+10 % SAFETY FACTOR 215.3841
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17.  Close coupled, stainless steel 40 HP pumps
 Heat exchangers to be upgraded to 93
plates and reconditioned
 Stainless steel suction diffuser and triple
duty valves
 Relocation of filter housings with 20 micron
filters to be installed
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