Circulating Water System

1
 1.Introduction
• Circulating Water is one of the important systems that
affects the availability and operational efficiency of a
thermal power plant.
• Bulk requirement of water is used in thermal plants for the
purpose of cooling the steam in condensers. The requirement of
water for this purpose is of the order of 150-to 200(m3 /hr)/MW
of installation.
• It also decides the location of a power plant.
• The steam exiting from the steam turbine condenses in a
condenser and then is reused in the steam cycle.
• Almost all thermal power plants use a surface condenser for
cooling the steam.
• In a surface condenser, the steam flows over a tube bundle. The
condenser cooling water flows through the inside of these tubes.
In a large power plant, the condenser will have about 15,000
tubes.
• The heat transfer takes place through the surface of these tubes.

• Where sufficient water is available once through system is used.

• Where water supply is not consistent, closed loop cooling system

with cooling tower is used.

3
 2.Circulating water scheme

• Intake channel
• A chlorination plant
• A circulating water pump house
• Connecting pipe line to condenser
• Outlet channel
• A cooling tower
• ACW system

4
Intake Channel

 If it is open loop system intake is directly taken from cannel/

reservoir

 In Closed loop makeup is taken from Cannel/ Reservoir using

makeup pumps to trench.

 The intake level is normally 10-15 ft. above from flood

 level of the water source and 10 m in depth and varies

depending on Design
• Trash rack to avoid entering wood, tree branches, animal,
plastic, floating object.
• provides uniform flow/suction to the CW pump 5
Traveling Water Screen
•leaves
It catches small pieces of coal, sand, gravel, wood, plastic, herbs,

•which can go into the impeller and may choke/damage the pump.
A chlorination plant
Chemical dosing done for disabling micro organism development
inside the tube.

A circulating water pump house

It houses the main CW pumps. Vertical submergible pump with
operating pressure around 2 Kg/ cm2.

The pump house resides on the fore bay.

The fore bay is flooded through intake system. 6

CW PUMP LAY OUT
COARSE SCREEN (TRASH RACK)
TWS
Cooling Tower
• A cooling tower is an air and water management device, which
consists of fan stacks, fans, drift eliminators, fill and water/air
distribution systems.

• It uses principle of evaporation of water in unsaturated air.

11
Auxiliary Cooling water (ACW system)
• TG/SG DMCW pumps are in service to cool and Turbine and
Boiler Auxiliaries

• Heat added to TG/SG DMCW to be removed

• HE are provided to exchange b/w TG/SG DMCW to

circulating water

• Additional pumps are provided to take water from circulating

water to HE and then return it back to CW return line

12
Make up PUMPS
• In closed loop system make up required due to
Evaporation losses

• Blow down provided to Maintain COC (Cycle of

Concentration)

• So Make up Pumps are provided to Maintain ForeBay

level

• Evaporation loses are those occurred when cooling in

Cooling tower

13
What is COC?
• COC is the ratio of Dissolved solids in circulating water to
make up water

• COC to be maintained depends on Type and Design of

Cooling tower

• Normally Cooling tower are designed for COC in range

less then 3

• To maintain COC below 3 Blow down done

14
Condition Monitoring Basin:
Blow down water can be used for Ash disposal system

If any left it has to be in CMB for further Utilization/

treatment/Disposal outside boundary

15
3. TYPES OF CW SYSTEM

1. Open Cycle System

2. Closed Cycle System

1. Open Cycle system
In an open circulating water system, water from a large water
body like the sea, or a river or a lake is pumped to the
condenser and is returned back to the same source. Since the
sea is a free and large open source of water, we see many power
plants located on the seacoast.

Advantages of an open system are:

• Large quantity water is freely available.
• The water temperature is almost constant. Ambient
temperatures do not affect the cooling capacity.
 Types of CWCT systems
Open Loop system:
Water is abundant…
Reduction in the APC..

Steam from Turbine

Cold Water
Condenser
Pump
Hot water

River Flow

18
Disadvantages of an open system are:

• That plants can be located only near the sea.

• Organic and aquatic growth can plug the condenser tubes
reducing the efficiency. This requires the use of chemicals like
Sodium Hypochlorite to kill the organisms. This also requires
methods to clean the tubes mechanically.
• The large quantity of water used can destroy aquatic life
sucked into the system. Higher temperature water discharge
also destroys many smaller species and fish eggs. Since the
natural ecosystem is interdependent, destruction of one
species can lead to eventual destruction of the entire
ecosystem.
• Seawater is corrosive. This requires special materials like
Titanium tubes in the condenser, rubber lining for the piping,
and corrosion resistant impellers for the pumps.
• It requires a properly designed intake and an outfall to
eliminate environmental impact.
Closed Cycle system:
• In the closed cooling system where Circulating water is in a
closed circuit. The Circulating water removes the heat from the
condenser and flows to cooling towers. In the cooling towers an
airflow, natural or forced, cools the water and the water returns
to the condenser. Power plants located away from large sources
of water utilise this type. The large concrete hyperbolic towers
that you see near thermal power plants are used for cooling the
circulating water.
Advantages of a closed system are:
• The raw water requirement is considerably less. It requires only
about 5% of the water requirement of the open cycle system.
This is to make up for losses due to evaporation and blow down.
Closed Loop System

Reservoir/ River Canal Intake

Trash rack
Cooling tower

TWS
CT pumps

Hot Pond CW pumps

21
Condenser
Disadvantages of a closed system are:

• The system requires higher capital investment, increased

operating costs for the cooling towers, and more
maintenance requirements and spares.
• Since air is the secondary cooling medium, ambient wet
bulb temperature is a limiting factor in achieving the
cooling water temperature. This will affect the
performance of the power plants.
Hot Pond:
•Hot Water from the condenser discharged to hot pond
and provide source for the CT pump.

CT Pump

•It takes suction from the Hot pond and discharged

the water to the riser tubes of Cooling towers

23
 Hasdeo Barrage RBC
Darri Gate open
Open Cycle CT- II
Pragati
Nagar
Regulator
Stage-II Stage-I
3X500 MW 3 X 200 MW

CWPH-I

CWPH-II

Hot pond

CT- I

Charpara Cross Regulator

Emergency Exit
open
 Hasdeo Barrage
RBC Darri Gate
partially open.
Partial Closed Cycle CT- II

Pragati Nagar
Regulator
Stage-II Stage-I
3X500 MW 3 X 200 MW

CWPH-I

CWPH-II

Hot pond

CT- I

Emergency Exit Charpara Cross Regulator

Partially open
 Hasdeo Barrage
RBC Darri Gate
Total Closed Cycle CT- II open for makeup
Pragati
Nagar
Regulator
Stage-II Stage-I
3X500 MW 3 X 200 MW

CWPH-I

CWPH-II

Hot pond

CT- I

Emergency Exit Charpara Cross Regulator

totally closed
4. CW PUMPS

27
 CW PUMP SYSTEM
CW MOTOR CW P/P
VOLTAGE – 6.6 KV VERTICAL MIXED FLOW
RATING – 1500 KW DISCHARGE - 33,000 M3/HR
SPEED – 295 RPM FROM Sump/Forebay SPEED – 295 RPM
FULL LOAD CURRENT – 181 A

1A 1B 2A 2B 3A 3B

CW GATE
TWS O/S P/P HOU

MAIN P/P

BFV

TO CW SCREEN ICV - 1 ICV - 2 ICV - 3

WASH P/P

U#1 U#2 U#3 R/C TO O/L OF

ST-I CT
SPECIFICATION
 TRAVELLING WATER SCREEN (TWS )
Capacitance type of level indicator are used for
level difference detection. When ever level
difference across TWS shows 150 mm WC the
auto sequence starts. The sequence of operation
is as below.

1) The selected screen wash pump start.

2) The motorized control v/v will open for the
corresponding CW pump.
3) TWS will start at the speed of 3 m/ min only when
pressure of spray header is > 3 Ksc.
4) TWS will stop when the level difference drops to
50 mmWC.
5) Screen wash p/p will stop.
• If more than 3 level switches indicates a difference of
150mmWC or when more than three TWS are running the
second screen wash pump will take auto start. When the
running TWS are less than three the lag selected screen wash
pump will stop ( senses from the screen wash control v/v
closed).
• During TWS operation if control v/v closes TWS will trip.
• When ever TWS is started it will complete 1.33 revolution till
the level drops to 50 mmWC. TWS will stop only after
completing 1.33 revolutions.
• There are two rows of spray water lines for each TWS, one is
having 15 jets and other 16 jets.
 Lub Water System

• Lub water supplies cooling water for

1. Gland Sealing in Stuffing Box.

2. Cooling for pump tilting & thrust bearing oil.
3. Lubricating for Rubber line Shaft Guide Bearing .

 Supply of water is very important for continuous operation

of pump. Pump should not run with Lub water supply .
 LWP TANK CAPACITY-15000 LITRE
LWP-1 TO LWP-7
TANK-1 TANK-2
FLOW-7 M3 / HR, KW – 3.7
LWP-8
FLOW-18 M3/ HR, KW – 7.5
MIN FLOW FOR CW / CT = 30 LITRE/ MIN FROM DM
PLANT
MOTOR

CW P/P
LWP-1
LWP-7 LWP-8
F S VG
S/B SOL

ROM SCREEN WASH P/P DIS. HDR FROM ST-I CLARIFIED TO TANK-1
 Starting Procedure of CW / CT Pump
1. Check that CW motor top and bottom bearing oil level is normal in
g/g glass. If not then use Servo Prime-46 turbine oil. Gauge glass
drain valve should be in closed condition.
2. Open vent valve in pump casing.
3. Open vent valve at discharge pipe before CW pump discharge
valve.
4. Check that discharge butterfly valve is closed.
5. Select to ‘Normal’ the oil pump of the butterfly valve oil unit.
6. Check the 6.6KV power supply to main pump motor, 415V power
supply for hydraulic unit oil pump motor, 415V supply to lube
water pump, A/C control supply and 220V DC control supply to
solenoid are established.
7. Check that oil unit accumulator pressure is not less than 150
kg/cm2. Hydraulic unit oil tank level is normal and drain valve is
tightly closed.
8. Open the vent valve after the discharge valve.
9. Normalize electrical supply to the pumps and associated lube water
pumps.
10. Select the pump normal.
11. Release the Emergency stop push button of main pump and LWP-1 to
8.
12. Give start command to CW pump from PIP and check that the
following happens in sequence.
a) Lube water pump will take start in auto.
b) Lube water flow and pressure should be normal.
c) Hydraulic unit oil pump will start on recirculation.
d) After 7 seconds, SOL-1 and SOL-7 energies i.e. SOL-1 closes and
SOL-7 opens.
e) Discharge butterfly valve will start opening.
f) When BF valve open 6 to 8 deg from full close main CW pump
will take start.
Note: If within 15 seconds, butterfly valve does not open 6 to 8 deg, then
auto trip alarm will come and BF valve will close fully and pump will get a
trip command at 5 deg open of BF valve.
g) Butterfly v/v open fully and oil p/p stops at oil unit pr. of 205
kg/cm2
h) Pump discharge pressure builds upto 0.5 kg/cm2 after
sometime.
13. Butterfly valve will full open
14. When oil pressure increases to 205 ksc oil pump will stop. SOL-7 and
SOL-1 energies i.e. SOL-7 closes and SOL-1 opens.
 TRIPPINGS / PROTECTIONS

 Bearing (upper thrust pads, lower thrust pads, upper guide bearing,
lower guide bearing) temperature hi-h. Total 4 temperature switches
for this protection.. Alarm = 85 Deg Cel. Trip = 95 Deg Cel.

 Suction duct level lo-lo ( 6 meter)

 Pump running and discharge v/v closed. (50 open from full close or 5.5%
open from fully closed condition.)

 Pump running and lube/cooling water floe lo-lo. (<30 lpm, time delay of
45 seconds)

 Hydraulic emergency trip. (Pull button)

 Push button trip. (Local EPB).

CW Pumps PIP Alarms & Status
 Routine Checks in CW / CT System
• Status of CW / CT pumps in service and status of standby CW /CT
pumps.
• Note the level of Forebay & Hot Pond..
• Note the pumps loading current in Amperes, discharge pressure
and lube water pressure.
• Note the level of oil bath, oil temperature, pressure of oil unit,
accumulator in service and oil level in the tank, temperature of guide
bearing/ thrust bearing and motor winding temperature.
• Check the lube water return flow in all the pumps.
• Ensure the lube water overflow from lube water tank.
• Ensure availability of lube water from Screen Wash Pump discharge
header in case of emergency.
• Availability of standby lube water pumps (LWP).
• Touch the lube water solenoid valves whether these are energized or
not.
• Check for reverse rotation of any standby CW / CT pumps.
•Status of interconnection valves and recirculation valve.
• Status of screen wash pumps, their strainers, NRVs and discharge line
interconnection with stage-I.
• Check on the TWS viz water isolating valve, nozzles, shear pin, oil level,
covers, and difference of water level at both sides of screen.
• Status of inlet gate of CW pumps and accumulation of debris etc. if any.
• Any water accumulation in CW (-) mtr level and cable trench sump and
availability of sump pumps.
• Status of roof exhausters and lighting.
• Any abnormality like abnormal sound, seepage, fire alarm and safety
aspects etc.
• Any alarm in local control panel.

•Check the status of CT fans.

 Nos. of fans in service.
 Nos. of fans not in service and reason there upon.
 Oil level, vibration in foundation, condition of earthing strips, position
of push button and riser valves, any abnormal sound from gear box and
condition of inspection doors meant for the purpose
TROUBLE SHOOTING in CW / CT
5. COOLING TOWER

42
 Cooling Tower - Introduction
• Cooling tower is the most important equipment for
closed cycle water recirculation system.
• The efficiency of cooling tower has direct effect on
condenser vacuum and in turn, the heat rate of the
station.
• 1oC rise in cold water temperature in a 200MW unit
corresponds to 5mm vacuum loss leading to 7.5
Kcal/kwh loss in heat rate and in 500MW, 5.74
Kcal/kwh loss in heat rate..

43
 Why Cooling water Temp to
kept low?
• The steam turbine itself is a device to
convert the heat in steam to mechanical
power.
• Enthalpy drop across the turbine decides
the work output of the turbine. For
increasing this enthalpy drop across the
turbine we need effective condenser vacuum
system.

44
• By condensing the exhaust steam of
turbine, the exhaust pressure is brought
down below atmospheric pressure,
increasing the steam pressure drop
between inlet and exhaust of steam turbine.
This further reduction in exhaust pressure
gives out more heat per unit weight of
steam input to the steam turbine, for
conversion to mechanical power.

45
 Types of cooling Tower
• Wet type
• Dry type

• Wet type cooling towers are two type

• 1.natural draft
• 2.mechanical draft

• Mechanical draft may be devided in to two type

• 1.forced draft
• 2.induced draft
• Both of these can be counter flow type or cross flow
type. 46
 NATURAL DRAFT C.T.
• It produces air flow through utilisation of stack or
chimney effect.pressure diff. causing air flow is
given by p=(douter-dinner)H.g
• The fill is located in the lower portion of shell with
upper 85 to 90% of shell empty which is used to
create chimney effect.
• They are more suitable in the area of high relative
humidity ratio and low temp.
• They may be of cross flow or counter flow.

47
48
 MECHANICAL DRAFT C.T.
• Forced draft
• Advantage:-fan is subjected to less severe
condition
• Disadvantage:-recirculation more (why?)

• Induced draft
• Advantage:-min recirculation (why?)
• Disadvantage:-fan is subjected to warm humid
condition.

49
 MECHANICAL DRAFT C.T.
• Counter flow :-fill is arranged over entire tower
plan.fill is typically film type.
• Advantage:-more thermal efficiecy,smallest
tower,lower capital cost, lower pumping head
• Disad:-increased pressure drop requires more
horse power of fan.
• Cross flow:-fill is arranged at the outer perimeter.
• Advantage:-large air inlet area hence pressure drop
is less.
• Disad:-high pumping head due to more height of fill.
50
51
52
Types of Cooling Towers

53
A BIRD’s EYE VIEW OF NDCTs OF DADRI-Coal (4 X 210 MW) 54
Cooling Tower Thermal Design
Parameters are used to develop the tower design :

• Water flow rate

• Cooling range
• Design Heat load
• Design Wet-bulb temperature.
• Recirculation and interference
• DBT and relative humidity

55
 Design Wet-bulb
Temperature
• The impact the design wet-bulb temperature has on the
size and power requirements of a cooling tower is critical
to optimizing the cooling tower economics.
• In the majority of applications, the design duty of an
evaporative cooling tower is based upon an
acceptable/required cold water return temperature
• If investment and operational costs were not a concern,
the ideal design wet-bulb temperature would be equal to,
or higher than, the highest local wet-bulb temperature
recorded.
• In this way, the returned water temperature would never
be higher than the acceptable/required cold water
temperature.
• Design W.B.T.=DESIGN AMBIENT
D.B.T.+RECIRCULATION ALLOWANCE.
56
 Component Design : Fills
• The component most likely to provide improvement
in tower performance is the fill packing.
• The earliest and most common designs utilized
splash type fills
• Film type counter flow designs using relatively low
cost PVC materials.
• The new film type designs provide energy savings
both in fan power and pump head through the high
surface areas per cubic feet of fill.

57
 TYPES OF FILLS

• Splash type consisting of splash

Bars used for crossflow and
Counterflow.

• Film type consisting of thin film of

Sheets used mostly for counterflow

58
 SPLASH FILLS
In splash fill, the hot water strikes the bar and
breaksup into many smaller drops.

59
 FILM FILLS
Film fill consists of flat or formed sheets to provide
a surface upon which water and air come in
contact for heat exchange.

60
 Drift Eliminators
• A cooling tower drift eliminator is a low pressure,
momentum filter.
• Components are arranged to force the air leaving the fill
section to make a series of directional changes.
• Water droplets, which cannot negotiate these turns,
impinge on the surface of the eliminator, from which they
are collected and drained back into the wet side of the
tower.
• The designer's goal is to provide the maximum drift
elimination at reasonable cost and minimum pressure
loss.
• The design o drift eliminators has undergone
tremendous improvement in the last decade.
• New eliminator configurations accomplish this
improvement while actually reducing eliminator pressure
losses 61
 Fan Design
• Each fan has only one design point which is
established by a specific air flow, total pressure,
air density, and fan speed.
• The factors that must be known when replacing
a fan on an existing installation are:

1. Fan diameter.
2. Installed motor horsepower.
3. Gear reduction ratio of gear reducer.
4. Shaft size or gear reducer model.
5. Some estimate of elevation above sea level of
installation.
62
Cooling Tower Performance

63
 Cooling Tower Performance
 Cooling Tower Effectiveness =
Range/(Range+Approach)

 Cooling Tower Capacity = mass flow rateXspecific

Heat x Temperature Difference

 Evaporation Loss in cub mtr/Hr =

0.00085x1.8xcirculation ratexTemperature Diff.

 Cycle of Concentration = Dissolve solid in circulating

water/Dissolve solid in make up water

 Blow Down = Evaporation Loss/(C.O.C.-1)

64
THANK YOU

65