Circulating Water System

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Cooling Water requirement

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 1.5-to2.0 cusecs/MW of installation. 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.

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Circulating water scheme

A circulating water pump house Intake channel Trash rack A chlorination plant Traveling water screen Connecting pipe line to condenser Outlet channel A cooling tower
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Circulating water scheme

We shall discuss the open loop system first.

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Function of each component

A circulating water pump house It houses the main CW pumps. Vertical submergible pump with operating pressure around 1 Kg/ cm2. The pump house resides on the fore bay. The fore bay is flooded through intake system.

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Intake

It is RCC open trench from where Raw water is taken through canal/reservoir. The intake level is normally 10-15 ft. above from flood level of the water source and 12 m in depth.

Trash Rack

Trash rack to avoid entering wood, tree branches, animal, plastic, floating object. provides uniform flow/suction to the CW pump
Traveling Water Screen

It catches small pieces of coal, go intogravel, wood, and sand, plastic, herbs, leaves which can the impeller
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may choke/damage the pump.

Once through system

Condenser is fitted with 4 way valve to enable

Chemical dosing done for disabling micro organism development inside the tube. reverse flow through condenser when required.

Hot water coming out from condenser iscool downto allowed pass through long outlet channel to get

before meeting the main stream of water. Performance of condenser mainly depends on Inlet temp. to the condenser, Condenser tube fouling, Air ingress in condenser etc.
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Types of CW systems
Open Loop system:
Water is abundant Reduction in the APC..

Steam from Turbine

Cold Water

Condenser

Pump
Hot water

River Flow

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CW scheme
Reservoir/ River Canal Intake

Trash rack Cooling tower TWS CT pumps

Hot Pond
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CW pumps Condenser
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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
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Cooling Tower - Introduction

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.

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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..
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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.
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Cooling Tower in NTPC Ltd.

There are 75 cooling towers in operation in NTPC. Induced Draught Cooling Towers Cross flow type Counter flow splash bar fill type Counter flow film fill type Natural Draught Cooling Towers Natural draught type.
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NATURAL DRAFT C.T.

It produces air flow through utilization of stack or chimney effect.pressure diff. causing air flow is given by p (pr head developed)=(p outer-p inner).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 and low temp. They may be of cross flow or counter flow.
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MECHANICAL DRAFT C.T.

Forced draft Advantage:-fan is subjected to less severe condition Disadvantage:-recirculation more Induced draft Advantage:-min recirculation Disadvantage:-fan is subjected to warm humid condition.

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MECHANICAL DRAFT C.T.

Counter flow :-fill is arranged over entire tower plan.fill is typically film type. Advantage:-more thermal efficiency, 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.
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Types of Cooling Towers

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A BIRDs EYE VIEW OF NDCTs OF DADRI-Coal (4 X 210 MW) 22

ARRANGEMENT OF C.T.
1.Rectangular type:-each cell indentical, more long area required, low capital cost,for plant upto 250mw. 2.Round type:-less recirculation, more capital cost,for plant more than 250mw.

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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
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DESIGN HEAT LOAD

Condenser and c.t. are designed on the basis of MCR load point.

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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.
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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.

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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

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

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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.

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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 of drift eliminators has undergone tremendous improvement in the last decade. New eliminator configurations accomplish this improvement while actually reducing eliminator pressure losses 24 December 2012 31

Drift Eliminators
Cellular eliminators are typically constructed of PVC sheets vacuum formed into very precise, compound shapes, with an integral honeycomb strength. The compound shape allows significant improvements in drift eliminations and the use of cellular structure appreciably reduces the pressure losses through the eliminator when compared to either the wood lath or wave form eliminators. The net free are of well-designed, modern cellular eliminators is in excess of 95%.
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Air-Water Distribution System Design

1) Water Distribution:
Assured performance is a function of nozzle design, nozzle installation pattern, nozzle distance, and the structural cleanliness of the spray chamber.
To provide the primary function of precise water distribution, the nozzle must be designed with other considerations in mind: The location of counter flow nozzles and the potential for poor quality circulating water demands that the nozzle system be designed to minimize fouling. The nozzle must be capable of providing uniform distribution over a wide range of flows, without significant loss in nozzle performance. The nozzle must be capable of efficient operation while consuming a minimum of expensive pump energy. 24 December 2012 34

Air-Water Distribution System Design

2) Air Distribution: Three variables control the distribution of air to

the fill in a counter flow configuration. The first is the air inlet geometry. Pressure Ratio : The pressure ratio reflects the ratio of resistance to available entering air energy. The higher the ratio, the better entering air will be spread out before entering the fill. The lower the pressure ratio, the less uniform, and less stable the distribution of air flow becomes. The degradation of air flow uniformity is readily apparent, particularly at the inlet. (Pressure Ratio = Static Pressure / Velocity Pressure at Air Inlet) The third is the fan coverage over the eliminators
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Fan Design
1. 2. 3. 4. 5. 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: Fan diameter. Installed motor horsepower. Gear reduction ratio of gear reducer. Shaft size or gear reducer model. Some estimate of elevation above sea level of installation.

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Cooling Tower Performance

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Cooling Tower Performance

Cooling Tower Effectiveness=Actual Cooling/Maximum Cooling Possible =Range/(Range +Approach) Cooling Tower Capacity = mass flow rate X specific Heat x Temperature Difference Evaporation Loss in cub mtr/Hr = 0.00085x1.8xcirculation rate x Temperature Diff. Cycle of Concentration = Dissolve solid in circulating water/Dissolve solid in make up water Blow Down =1-1.5 percent of total water flow To replenish the losses make up water 2-2.5% of water flow is added
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COOLING TOWER(BTPS)
Intake Channel Level (Normal)---------- 202 mtrs C.T.PUMP Nos Discharge Head Speed Make

2 for each 210 MW unit 4160 L/sec or 15000 m cube per hour 17.855 mwc 405 rpm KIRLOSKAR BROTHERS LTD.(U5)
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MOTOR
Type Speed KW Current Volts Make Induction Motor 421 rpm 930 108.5 amps 6600 volts, 3 Ph. 50 C/S BHEL

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COOLING TOWER
Make Gammon(U4)/ Paharpur(U5) Number 1 for each unit of 210 MW No. of cells/tower 16 Rate of flow/unit 27000 m cube per hour per tower Cooling Range 10 degree C Max operating inlet water temperature 50 degree C

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COOLING TOWER FANS

Fan Type No of fans/Tower No of blades/fan No of row of fan Dia. Reduction gear Ratio Fan Speed Induced Draft 16 9 2(8 in each row) 7315 mm 10:1 L.X. 151 rpm

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MOTORS
Make Volts Current K.W. Speed N.G.E.F 415 V 130 amps 75 1475 rpm

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THANK YOU

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