Professional Documents
Culture Documents
Centre for Power Efficiency & Environmental Centre for Power Efficiency & Environmental Protection Protection
CenPEEP
Prepared on 16th March, 2010 All data on annual basis
Installed Capacity 24400 MW, GCV 3500 kcal/kg , Coal Cost Rs 1400 per Ton, PLF 90%, FC 34%
1 % Eff. Improvement
67 kcal//kWh Improvement
500 MW Unit
500 MW Unit
Same as above
5 kcal//kWh Improvement
You could check this directly using an electric kettle. Put in 1 liter of water (1 Kilocalorie will heat this by 1 deg celsius) Note the kettle wattage, and the cold water temperature, then note how many seconds to reach boiling temp (100 celsius). The number of kilocalories is just the temperature rise in degrees C, the number of Kwseconds is the wattage times the time to reach boiling in seconds.
10 mmHg Improvement in Condenser Vacuum Leads to 20 Kcal/kwh Improvement in Heat Rate for a 210 MW Unit
CenPEEP Condenser Performance Monitoring Factors affecting Condenser Performance Tube fouling Air ingress into the system High Condenser heat load CW Inlet temperature CW Flow
CenPEEP Cooling Tower Thermal Performance Testing Importance of Cooling Tower Performance Cooling water system plays a vital role in dissipation of waste heat in power station. More than 60 % of total heat input to the plant is finally dissipated as waste heat. The waste heat from the power plant is carried away by circulating water and ultimately gets dissipated in cooling tower.
Monitoring
For a 200 MW Unit : Cooling Tower Heat Duty is equivalent to approx. 275 MW For a 500 MW Unit : Cooling Tower Heat Duty is equivalent to approx. 700 MW
CenPEEP
Wet Bulb Temperature (WBT) at Tower inlet Cold Water Temperature Hot Water Temperature CW Flow to each Tower Fan Motor Power
CenPEEP
Difference between the Cold Water Temperature at CT outlet and Inlet air Wet Bulb Temperature Range Difference between the Hot Water Temperature (inlet to CT) and Cold Water Temperature (outlet of CT)
CenPEEP Cooling Tower Performance Salient Terms Used in CT Testing Tower Capability The most reliable means to assess the cooling tower thermal performance. It is defined as the percentage of water that the tower can cool to the design cold water temperature when the inlet wet-bulb, cooling range, water flow rate and fan motor power are all at their design value.
Predicted Water Flow Rate =Calculated from Manufacturer graphs and actual test conditions i.e. WBT, Range and Cold water temperature.
Where : QT = Measured water flow rate, t/hr Predicted water flow rate, t/hr No. of cells for design water flow rate No. of cells in operation during test Fan motor power design, kW Fan motor power measured, kW
CT Performance Test
TEST DATA
Average Hot Water Temperature Average Cold Water Temperature Average Inlet Air WBT Average Wind Velocity Actual KW of Fans during Test (Average) T HOT WATER T COLD
WATER
CenPEEP
UNITS
C C C Meter / sec kW
TEST VALUE 46.30 36.10 28.50 2.97 36.59 18 26100 29000 31900 32.00 11.00 4.40 18
P Des
No.
T/Hr T/Hr T/Hr C C C
No.
kW meter
WATER - 90%
From CT [90%] Characteristic curve From CT [100%] Characteristic curve From CT [110%] Characteristic curve T/Hr
WATER - 100%
WATER - 110%
CT Performance Test
CenPEEP
CT Performance Test
FIELD TEST PARAMETERS Average Hot Water Temperature Average Cold Water Temperature Average Inlet Air WBT Average Wind Velocity COMPUTATION OF EXPECTED COLD WATER TEMPERATURE Average Inlet Air WBT Average CW Cooling Range Expected Cold Water Temperature : 90% Flow Expected Cold Water Temperature : 100% Flow Expected Cold Water Temperature : 110% Flow UNITS C C C m/sec C C C C C
CenPEEP
TEST VALUE 46.30 36.10 28.50 2.97 28.50 10.20 32.25 32.93 33.53
CORRECTION IN EXPECTED COLD WATER TEMPERATURE DUE TO WIND Correction factor due to Wind Velovity C Expected Cold Water Temp C RESULTS DESIGN EXPECTED Cold Water Temperature (C) 32.00 32.95 Cooling Range of Cooling Tower (C) 11.00 13.35 Approach of Cooling Tower (C) 4.40 4.45 Cooling Tower Effectiveness (%) No. of Cells Design No. of Cells in Service during Test TOWER CAPABILITY Measured CW Flow (T/Hr) Predicted CW Flow corres.to Test Cold Water Temp. Design KW of Fans Actual KW of Fans during Test (Average) Adjusted CW Flow (T/Hr) Tower Capability 71.43 18 75.02
18 Q Meas Q Pred. P P
Des Act
Q Adj %
CT Performance Test
Design CWT HWT WBT CW Flow Fan Power (Average) Range Approach Effectiveness (Actual) Effectiveness (EXP) Capability 100 32 44 27.7 2222 47.81 12 4.3 73.62 CT Cell (19mm flute) 31.33 40.51 24.52 2520 45.65 9.18 6.81 57.4 63.22 87.13
CenPEEP
CT Cell (17mm flute) 31.84 41.13 24.42 2515 43.84 9.29 7.42 55.59 64.4 80.04
CenPEEP Cooling Tower Performance Performance Analysis CT degradation to be assessed based on Capability test Deviation to be derived from actual temperature and predicted cold water temperature
Deposition in the fills comes from the turbidity of make up water air borne dust from the atmospheric air being drawn into the cooling tower precipitates of dissolved silica
Damage of fills. Chocking of nozzle. Falling of nozzle. Damage of splash bars. Algae formation on splash bars Damaged drift eliminators Unequal water flow in different cells. Recirculation of vapors Poor air flow due to less blade angle.
Hot water distribution pipe damage Annular clearance between distribution pipe and hot water channel Growth of trees/plants/bushes near cooling tower Overflow of cold water basin. Improper quality of water
Control of COC Control of Turbidity
By plugging all air path that do not pass through the fill zone
i ii iii iv v Sealing shaft hole of fan. Sealing door openings of fan chamber. Sealing the fan hub area. Maintaining blade tip clearances Reducing drift handled by fan
Cleaning of fills with water jets Cleaning of fills manually by removing from tower Cleaning of cold water basin during overhauls. Regular cleaning/checking of nozzles. Continuous Chlorination & Shock dozing to maintain required FRC
46.7 53.4 46.5 54.5 Predicted Cold Water Temp calculated at 100% flow 31.6 31.5 31.3 31.6 5.8 4.1 6.0 4.0
Remarks : Fill cleaning started in Jan 2006 and completed in May 2007.
Study of variation in CT Fan power and air flow due to change in Liquid/Gas ratio Study of variation in CT performance due to change in Liquid/Gas ratio
Liquid/Gas Ratio (L = water; G = air), of a cooling tower is the ratio between the water and air mass flow rates Low L/G ratio indicates that cooling tower is under utilized. High L/G ratio indicates availability of less air for actual cooling water flow CT Characteristic (KaV/L) is dependent on designed L/G ratio Heat removed from the water must be equal to the heat absorbed by the surrounding air
Measured L/G ratio was higher than the design L/G ratio of 1.44 CT fan air flow and power consumption varied proportionately with change in blade angle The test indicates that by changing the L/G ratio ( increasing the fan blade angle by 1 ) , the effectiveness of cell varied by more than 1% Cooling tower capability varied by more than 2.5 % with change in L/G ratio Higher capability observed with low L/G ratio i.e. high air flow for same CW flow
Increase in power consumption by 4 Kw in a single cell with increase in 10 blade angle Decrease in cold water temperature by 0.4 deg C in a single cell with increase in 10 blade angle Decrease in L/G ratio by 3.2% increases capability by 2.5% (typically running one additional CT fan in a tower decrease L/G ratio by 6.3%) Increase in power consumption by around 64 Kw in a tower can improve HR by 2 kcal/kwh (for a typical 200 MW unit)
Improvement in HR by 2 kcal/kwh is equivalent to improvement in unit load by around 205 Kw (for a typical 200 MW unit) Improvement in HR by 2 kcal/kwh is equivalent to annual savings of around 11 lacs (for a typical 200 MW unit)
38.9
9 2 3
10
1.66
80.4
77.8 2
1.60 3
81 80 79 78 77 76
CenPEEP
L < 2 Meters,
X Measurement Station.
L < 2 Meters,
X Measurement Station.
CenPEEP Cooling Tower Thermal Performance Testing Wet Bulb Temp. measurement setup
CenPEEP
CenPEEP Cooling Tower Thermal Performance Testing Grid setup for Cold Water Temp. measurement
CenPEEP Cooling Tower Thermal Performance Testing Grid setup for Cold Water Temp. measurement of single cell
CenPEEP Cooling Tower Thermal Performance Testing Grid setup for Cold Water Temp. measurement of single cell
CenPEEP
Grid of 48 probes
CW Flow Measurement
CenPEEP
CW Flow Measurement
CenPEEP
CenPEEP
On-line CW Flow Monitoring using Elbow Tap dp
Measurement of CW flow using Pitot traverse and calibrating Elbow Tap dp for on-line monitoring.
CW outlet duct
Elbow Tap
Elbow DP
Circulating Water
Out let WB
Cond enser
Benefits On-line measurement of CW flow available in control room Helps in assessing Condenser performance
Measured Flow at CT end (t/hr) using 3-hole Pitot ACW Flow (t/hr) CW Flow at Condenser Outlet (t/hr) dP at condenser end (mmWC) Elbow Tap Method
12950
10054
7513
6385
8269
6582
4982
450 12500 -
CW Pass I (LHSRoad side) CW Flow at Condenser Outlet (t/hr) Elbow tap dP ( mmwcl)
431.59
C-8.8C
B-11.0C
A- 13.25C
C-8.8C
B-11.0C
A- 13.25C
37.0 36.0 35.0 34.0 33.0 32.0 31.0 30.0 29.0 28.0 27.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0
C-8.8C
B-11.0C
A- 13.25C
COOLING RANGE (C) 90% Flow 100% Flow 110% Flow Test Range
30.6 30.4 30.2 30.0 29.8 29.6 80 85 90 95 100 105 110 115
Test Cold Water Temp 35.9 C Predicted Flow 77,000 t/hr, Actual Flow - 30,977 t/hr
DEPOSITS IN FILL
CenPEEP
ALGAE FORMATION
CenPEEP
CenPEEP
CenPEEP
SEALING OF AIR PASSAGE THROUGH SHAFT OPENING
CenPEEP
CenPEEP
CenPEEP