Académique Documents
Professionnel Documents
Culture Documents
Background
Hot HotWater Water Condenser Air Cooling Tower
Air
CW Pump
Cooled Water
Make-up Water
Condenser: The condenser is the most important component of the turbine cycle that affects the turbine heat rate. The function of the condenser is to condense exhaust steam from the steam turbine by rejecting the heat of evaporation to the cooling water passing through the condenser. Generally, twin shell- double pass- surface type condensers are employed for higher capacity units
Background
Cooling towers: Different types of cooling towers are used in the power plants depending upon the location, size, infrastructure and water resources etc. Close cycle wet cooling systems: -Induced draft -Forced draft - Natural draft cooling towers
Background
Cooling water pumps: Circulating water pumps supply cooling water at the required flow rate and pressure to the power plant condenser and the plant auxiliary cooling water heat exchangers. These pumps are required to operate economically and reliably over the life of the plant. For once through systems, vertical wet pit pumps are in common usage. For re-circulating cooling systems, vertical wet pit and horizontal dry pit are used about equally, with occasional use of vertical dry pit pumps.
Data Collection
Specifications of cooling towers:
Data Collection
Specifications of cooling towers- contd:
Data Collection
Specification of water pumps and motors- contd:
Instruments Required
Power Analyzer: Used for measuring electrical parameters of motors such as kW, kVA, pf, V, A and Hz Temperature Indicator & Probe Pressure Gauge: To measure operating pressure and pressure drop in the system Stroboscope: To measure the speed of the driven equipment and motor Ultra sonic flow meter or online flow meter Sling hygrometer or digital hygrometer Anemometer In addition to the above calibrated online instruments can be used PH meter
The energy consumption of cooling water : kWh/day and associated system Total auxiliary power consumption : kWh/Day
Flow Distribution
Measure the flow at the individual pump discharge side, main header, at the users (for the major and large users) along with the pressure and velocity. Depict these values in schematic diagram Ensure Line adequacy by measuring the velocity in the major pipe lines Pressure drop in the distribution network Specific water flow rate
CONDENSERS
Performance of Condensers
Parameters for condenser performance
Performance of Condensers
Parameters for condenser performance- contd
Performance of Condensers
The following needs to be computed: 1. Condenser heat load = Q x T x Cp
Parameter Q T Cp Details Water flow rate Average CW temperature rise Specific heat Unit Kg/h oC kcal/kg oC
2. Calculated condenser vacuum = Atmospheric pressure Condenser back-pressure 3. Deviation in condenser vacuum = Expected condenser vacuum - Measured condenser vacuum 4. Condenser TTD = Saturation temperature Cooling water outlet temperature
Performance of Condensers
5. Condenser Effectiveness = Rise in cooling water temperature Saturation temperature - Cooling water inlet temperature 6. Condenser heat duty in kcal/h = Heat added by main steam + heat added by reheater + heat added by SH attemperation + heat added by RH attemperation + heat added by BFP - 860 x (Pgen + Pgen losses + heat loss due to radiation) 7. Condenser tube velocity (m/s) = Cooling water flow rate (m3/h) x 106 3600 x tube area (mm2) x ( no. of tubes per pass - no. of tubes plugged per pass )
Performance of Condensers
8. Determination of actual LMTD Tout - Tin LMTD = Tsat -Tin Ln Tsat - Tout 9. LMTD expected = LMTD test x ft x fw x fq ft: Correction for cooling water inlet temperature ft = Saturation Temperature during test LMTD during test Saturation Temperature design LMTD design Tube velocity during test Tube velocity design Condenser design duty
0.50 0.25
fw = fq =
fw: correction for water flow rate fq: correction for cooling water heat load
COOLING TOWERS
4. Fan actual airflow (Nm3) / cell = Fan rated airflow (Nm3) / h x ( Fan input kW actual ) ( Fan input rated )
1/3
Evaporation losses
(COC 1)
The above readings may be taken on daily basis for three days on different atmospheric conditions say during mid summer, winter & monsoon period. Once in the mid day and once in the mid night time and a record duly maintained. Collect unit load (MW), frequency, and condenser vacuum condition while taking the cooling tower measurement
Turbine heat rate Reduction possibilities Improving the effectiveness of condenser and TTD Cooling water flow adequacy and flow optimization Air ingress Increasing the TTD of the condenser
Improvement of systems and drives Use of energy efficient pumps Correcting inaccuracies of the Pump sizing / Trimming of impellers Use of high efficiency motors Integration of variable speed drives into pumps: The integration of adjustable speed drives (VFD) into compressors could lead to energy efficiency improvements, depending on load characteristics High Performance Lubricants: The low temperature fluidity and high temperature stability of high performance lubricants can increase energy efficiency by reducing frictional losses Improvements in condenser performance Improvement in cooling tower performance Application potential for energy efficient fans for cooling tower fans Measuring and tracking system performance
Measuring water use and energy consumption is essential in determining whether changes in maintenance practices or investment in equipment could be cost effective In this case it is advised to monitor the water flow rate and condenser parameters, cooling tower parameters periodically i.e. at least once in a three months and energy consumption on daily basis. This will help in identifying the - Deviations in water flow rates - Heat duty of condenser and cooling towers - Measures to up keep the performance
Equipment cannot perform at its optimum capacity if fans, pumps, and blowers have poor inlet and outlet conditions Correction of system effect factors (SEFs) can have a significant effect on performance and energy savings Elimination of cavitation: Flow, pressure, and efficiency are reduced in pumps operating under cavitation. Performance can be restored to manufacturers specifications through modifications. This usually involves inlet alterations and may involve elevation of a supply tank
Internal Running Clearances: The internal running clearances between rotating and non-rotating elements strongly influence the turbo machine's ability to meet rated performance. Proper set-up reduces the amount of leakage (re-circulation) from the discharge to the suction side of the impeller Reducing work load of pumping: Reducing of obstructions in the suction / delivery pipes thereby reduction in frictional losses. This includes removal of unnecessary valves of the system due to changes. Even system and layout changes may help in this including increased pipe diameter. Replacement of components deteriorated due to wear and tear during operation, modifications in piping system