ENERGY AUDIT OF CONDENSER AND

CONDENSER COOLING WATER

SYSTEM
Presented By
M.V.Pande
Dy.Director
NPTI, Nagpur
Background
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
CW Pump
Hot Water
Condenser
Cooled
Water
Cooling
Tower
Air Air
Make-up
Water
Hot
Water
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.

Specifications of Typical Cooling Water Pump
Steps Involved in Energy Audit
The major energy consuming equipments in the CW
systems are:
Cooling towers and fans
Cooling water pumps
Make up water pumps
Condensers

The steps involved in conducting energy audit of cooling
water and cooling tower are:
Data collection
Observations and Analysis
Exploration for energy conservation measures
Report preparation
Data Collection
Specifications of cooling towers:
Data Collection
Specifications of cooling towers- contd:
Specification of water pumps and motors:
Specification of water pumps and motors
Specification of water pumps and motors- contd:
Data Collection
Rated kW of the pump
Data Collection- Other Information
Performance characteristics of all pumps and motors
Compile design, P. G. Test, previous best and last energy
audit value with respect to cooling tower and cooling water
system along with the condensers
If the pumps are operated in parallel then it is advised to
collect the performance curve for the parallel operation
Schematic diagram of Water pumping network (which
depict the source, pumps in operation & stand by, line sizes
and users)
Water and pressure equipments at the users as per the
design requirements
Brief description of the system with the key specifications in
which pumps are used (for example, if pumps are used for
supplying water to condenser, then add a brief write up
about the cooling water system)
Data Collection- Condenser Specifications
Heat load considered for design
Design inlet cooling water temperature/ Design TTD
Cleanliness factor/ Cooling water temperature raise
Condenser back pressure
Cooling water flow/ Cooling water side pressure drop
No of cooling water pass/ Total heat transfer area
No. of tubes - Condensing zone - Air cooling zone
Tube dimensions: - Tube OD x thickness - Length of
tube
Tube material: - Condensing zone - Air cooling zone
Water box design pressure
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
Measurements & Observation
Energy consumption pattern of pumps and cooling tower
fans
Motor electrical parameters (kW, kVA, Pf, A, V, Hz, THD)
for pumps and cooling tower fans
Pump operating parameters to be measured/monitored for
each pump are: - Discharge, - Head (suction & discharge) -
Valve position Temperature - Load variation, Power
parameters of pumps - Pumps operating hours and
operating schedule
Pressure drop in the system (between discharge and user
point)
Pressure drop and temperatures across the users (heat
exchangers, condensers, etc)
Cooling water flow rate to users - Pump /Motor speed
Actual pressure at the user end
User area pressure of operation and requirement
Measurements & Observation
Cooling tower parameters to be monitored
Inlet temperature
Outlet temperature
Dry bulb temperature
Wet bulb temperature or relative humidity
Water flow to cooling tower
Air flow rate of cooling tower
Range, oC
L/G ratio
Approach, oC
Fan speed, rpm
Fan power consumption (kW/cell)

Observations and Analysis
System familiarization and operational details
Energy consumption Pattern
The energy consumption of cooling water : kWh/day and
associated system
Total auxiliary power consumption : kWh/Day
Operating Efficiency and Performance
Evaluation of the Pumps
Water flow rate and pressure of pumps / headers
Velocity in the main headers and pumps and major lines (to
verify adequacy of line sizes)
Power consumption of pumps (for estimating the operating
efficiency of the pumps)
Monitor present flow control system and frequency of
control valve variation if any (for application of variable
speed drives)
Fill up the following data sheet for every pump for
comparison with the design / PG test values

Operating Efficiency and Performance
Evaluation of the Pumps
Operating Efficiency and Performance
Evaluation of the Pumps

Investigations & Recommendations
Compare the actual values with the design / performance
test values if any deviation is found, investigate for the
contributing factors and arrive at appropriate suggestions
The investigations for abnormality are to be carried out for
problems. Enlist scope of improvement with extensive
physical checks / observations.
Based on the actual operating parameters, enlist
recommendations for action to be taken for improvement, if
applicable such as
Replacement of pumps/ Impeller replacement/ trimming
Variable speed drive application, etc
Compare the specific energy consumption with similar type
of pumps and latest energy efficient pumps
Cost analysis with savings potential for taking improvement
measures.
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 Details Unit
Q Water flow rate Kg/h
T Average CW temperature rise oC
Cp Specific heat 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 (m
3
/h) x 10
6

3600 x tube area (mm
2)
x ( no. of tubes per pass - no. of
tubes plugged per pass )

Performance of Condensers
8. Determination of actual LMTD



Tsat - Tout
Ln
LMTD =
Tout - Tin
Tsat -Tin
9. LMTD expected = LMTD test x ft x fw x fq
(
Saturation Temperature during test LMTD during test
Saturation Temperature design LMTD design
)
ft =
0.25
fw =
Tube velocity during test
Tube velocity design
( )
0.50
fq =
Condenser design duty
Condenser duty during test
( )
fw: correction for
water flow rate
fq: correction for
cooling water heat load
ft: Correction for cooling water inlet temperature
Observations During Condenser Energy Audit
Tubes in operation Vs total installed
Cleaning system operation
Filtering system for cooling water
Regular monitoring system for performance
Comparison of LMTD, TTD, heat load, condenser vacuum, flow,
temperatures, pressures with design / PG test- arriving the factors
causing deviation
Modifications carried out in the recent past
Cooling water flow
Pressure drop on water side and choking
Affect of present performance of cooling tower
Accurate metering of vacuum
Absolute back pressure deviation from expected value
Sub cooling of air steam mixture and condensate
Circulation water temperature raise
Effectiveness of cleaning the tubes
Circulating water velocity in tubes
COOLING TOWERS
Performance of Cooling Towers
Performance of Cooling Towers
While conducting the cooling tower, visual observations
need to be made with respect to:
Adequate water level in the trough
Cross flow air from other cooling towers (which are under
maintenance)
Nozzle condition and operation
Fill condition
Change of blade angles during change of seasons
The CT airflow shall be measured using an anemometer
and compared with calculated airflow derived from fan
characteristic curves of CT fans with actual power
measurements.
Calculate range, approach, L/G (Liquid to gas) ratio and
effectiveness for design and operating conditions for each
tower

Performance of Cooling Towers
1. C.T. Range = Water inlet temperature Water outlet temp.

2. C.T. Approach = Water outlet temperature Wet bulb temp.


3. Effectiveness % =
Range x 100
( range + approach )
Fan actual airflow (Nm3) / cell =
Fan rated airflow (Nm3) / h x ( Fan input kW actual )
( Fan input rated )
1/3
1/3
4.
5. Air mass flow / cell = flow x density of air
Performance of Cooling Towers




5. Evaporation losses =
CW flow (m
3
/ h) x CT range in
0
C
675
6. Makeup water consumption =
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
Performance of Cooling Towers
Power consumption of CT fans


Exploration of Energy Conservation Possibilities:
Condenser
Possibility of Improvement in condenser vacuum
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
Fouling of tubes
Exploration of Energy Conservation Possibilities
Water pumping and cooling tower
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
Exploration of Energy Conservation Possibilities
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

Exploration of Energy Conservation Possibilities
System Effect Factors
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

Exploration of Energy Conservation Possibilities
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