SlideShare une entreprise Scribd logo
1  sur  42
A PRACTICAL APPROACH
                   to
ENERGY AUDIT IN CW, CT & CONDENSER SYSTEM
                   in
         THERMAL POWER STATIONS

             D.Pawan Kumar
                  And
               R.Virendra
1.0   BACKGROUND
      Cooling Water Circuit and System performance,
      holds the key in maintaining optimum vacuum in a
      thermal or a GT combined cycle plant. In current
      times, there is an increasing demand on power
      plant professionals, to address concurrently,
      complex tasks like ; Cooling water Consumption
      optimization, Achieving vacuum conditions and
      Optimizing power consumption in CW pumps and
      CT fans, despite plant side variations, like
      frequency, cooling water quality, availability, load
      variations, O & M demands, etc.        While it is a
      challenge, experiences show that with the level of
      infrastructure and information available at most
      sites, it should be possible to conduct a reasonably
      detailed and functional energy audit, deploying in-
      house resources, to bring out improvement options.
2.0   AUDIT FOCUS
      CW / CT system and condenser vacuum being focal
      points for energy audit study, the various
      improvement issues addressed in the CW audit
      include ;

2.1   Condenser Related
       Cleanliness of tube surfaces
       Tube leakages
       High inlet water temperature
       CW flow adequacy
2.2   CW Pump Related
       Efficiency of CW pumps
       Fore bay level inadequacy
       Mains frequency related
       CW flow tapping for other purposes
       Parallel operations and effects

2.3   Cooling Tower Related
       Approach, range of cooling towers
       L/G ratio of cooling towers
       Tuning scope in cooling towers, with seasonal
        variations with regard to water load, CT fan
        blade angle, etc.
       Maintenance of fills
       Quality of Cooling Water and COC improvement
       CT fan blade material such as FRP/GRP, etc.
2.4   Overall Optimization related such as ;

         Optimize CW pump operations with
          respect to thermal load
         Optimizing L/G ratios during various
          seasons
         Optimize CW pump efficiency through
          need based maintenance, retrofit,
          replacement options.
         Optimize condenser operations through
          O & M
3.0 Based on experiences at various
    plants

   The following steps are envisaged as
   illustrative help tools for the CW / CT
   audit teams in conduct of energy audit in
   thermal power plants and GT based
   combined cycle plants.
3.1 Scope of Audit
The scope of audit pertains to Energy Audit of Cooling Water System
including Cooling Towers & Condenser is made into systems as given below :

 CW System     :       Audit for water consumption
 Cooling Tower :       Audit for CT effectiveness
 Condenser     :       Audit for condenser heat load, CW flow & Vacuum

The energy audit on above system will be carried out to determine main
features such as :

1. Consumption of circulating water flow
2. Performance of CW pumps w.r.t. CW flow
3. CT effectiveness and L/G ratio
4. Performance of condenser w.r.t. heat load and vacuum and CW pressure
   drop across condenser.
5. Comparison of measured performance with reference to designed / rated
   values.
6. Recommendations based on the performance of the above system.
3.2 Methodology for Energy Audit

1.   Discussion with operation, Electrical Maintenance,
     Mechanical Maintenance, C&I and Chemistry
2.   Selection of equipments and instruments for power
     measurement for CW pumps & CT fans
3.   Data collection based on power measurement, DBT / WBT
     measurement for cooling performance, UCB data collection
     for heat load calculation
4.   Analysis of data
5.   Calculation of performance to determine key indicators for
     assessing the performance of various systems.

                                                          Contd..
3.3 Preparations for Audit

   Selection of appropriate time for conducting audit.
   Selection of units for audit.
   Selection of equipments & instruments for
    measurement.
   Calibration of instruments for pressure & temperature
    measurement in DAS.
   Assistance from O & M personnel.
   Design / rated parameters from technical operating
    manuals, equipments name plates, etc.
3.4    DESIGN DATA COLLECTION
3.4.1 DESIGN DATA – CONDENSER
 S.                    DESCRIPTION   DATA
 NO
 1.    Tube Material
 2.    Tube Outside dia (mm)
 3.    Tube Thickness (mm)
 4.    Total Number of Tubes
 5.    Tube Length (Meters)
 6.    No. of Plugged Tubes
 7.    No. of Passes
 8.    Design Surface Area (SQM)

3.4.2 DESIGN DATA – STEAM SIDE
 9.    Back Pressure (kg / sq. cm)
 10.   Condenser Duty
3.4.3 DESIGN DATA – WATER SIDE
 S.              DESCRIPTION                 DATA
 NO
 11. Cooling Water Flow
 12. CW Inlet Temperature
 13. CW Outlet Temperature
 14. Design Water Velocity
 15. CW Pressure Drop
 16. CW Source
 17. Design Cleanliness Factor

3.4.4 DESIGN DATA – GENERATOR
 S.              DESCRIPTION                 DATA
 NO
 18. Design Heat Rate kCal / kWh at ….. MW
 19. Gross Power Generated MW
3.4.5 WATER CHEMISTRY - DESIGN VALUES

 S.             DESCRIPTION      DATA
 NO
  1. PH at 250C
 2.   Conductivity
 3.   T.D.S
 4.   Total hardness
 5.   Calcium Hardness
 6.   Magnesium Hardness
 7.   P-Alkalinity
 8.   M-alkalinity
 9.   Chloride
 10. Sulphate
 11. Cycle of Concentration
 12. L.S.I
3.5     Equipments & Measurements
The following instruments are typically used for measuring various
parameters in the context of energy audit of CW, CT & Condenser
performance.

Intake air DBT & WBT at each cell (ground level)    Psychrometer
CW inlet temperature common) (risers or CT top)     Hg in glass thermometer
CW outlet temperature (common) (fills bottom)       Hg in glass thermometer
CW sump / basin temperature (overall)               - Do -
UCB Data : MW load, frequency, condenser, inlet /   DAS
outlet temperature, condenser vacuum, extraction
steam flow from heaters, etc.
CW pump elect. Data : Motor amps, volts, power      Measurement by power
factor, kilo watt                                   analyser
CT pump house fore-bay level                        Physically measured
CW pump readings for TDH
CT fans : Amps                                      Tong tester
CT transformer – Amp., Volts, PF, kW                Power analyser
Lab analysis data of CW (inlet), OAC and makeup     Lab water analysis
water
3.6    AUDIT DATA COLLECTION

The following parameters are typically chosen for spot
observations.
1.    UCB Parameters : MW load, frequency, main steam flow, extraction
      steam flow for various heaters, LPT exhaust steam flow, steam
      temperatures & pressures, condenser vacuum etc., for calculation of
      condenser heat load & CW flow.
2.    ELECTRICAL Parameters : Measurement of voltage, power factor
      & kW for CW pumps, CT transformer & CT fans.
3.    MECHANICAL Parameters CW PUMPS : Measuring data for TDH
      of CW pumps and Fore bay level.
4.    CHEMICAL / THERMAL Parameters : Measurement of DBT /
      WBT of air at cooling tower, CT basin water temperature, CW quality
      I.e., TDS & COC for CT performance & CW system water consumption.
SAMPLE DATA SHEET – 1
S.                Parameters            Unit      Design      Unit Data
No                                                Value
 .
1.    Unit Load                          MW           210.0        211.0
2.    Frequency                          Hz            50.0         51.2
3.    M.S. Temperature                   0
                                             C        535.0        530.0
4.    M.S. Flow                         T/Hr.         651.3        730.0
5.    HRH Pr.                         Kg/Sq. Cm        24.8         24.5
6.    HRH Temperature                    0
                                             C        535.0        535.0
7.    CRH Pr.                         Kg/sq. Cm        28.8         30.3
8.    CRH Temperature                    0
                                             C        328.0        324.0
9.    Feed Water Flow                   T/Hr.         651.3        689.0
10    F.W. Temperature at Inlet of
      HPH 5                              0
                                             C        167.0        164.0
      HPH 6                              0
                                             C        182.0        185.0
      HPH 7                              0
                                             C        225.0        220.0
11.   F.W. temperature at outlet of
      HPH 5                              0
                                             C        182.0        185.0
      HPH 6                              0
                                             C        225.0        220.0
      HPH 7                              0
                                             C        248.0        257.1
                                                                 Contd..
SAMPLE DATA SHEET – 1                    Contd..

S.                Parameters                  Unit       Design      Unit Data
No                                                       Value
 .
12.   Drip Temperature from
      HPH 5                                    0
                                                   C         177.0        171.8
      HPH 6                                    0
                                                   C         192.0        202.6
      HPH 7                                    0
                                                   C         235.0        236.1
13.   Ex. Steam temperature at inlet to
      HPH 5                                    0
                                                   C         440.0        455.9
      HPH 6                                    0
                                                   C         328.0        323.7
      HPH 7                                    0
                                                   C         378.0        415.5
14.   Ex. Steam pressure at inlet to
      HPH 5                                Kg / sq. cm        12.7         12.3
      HPH 6                                Kg / sq. cm        28.8         28.9
      HPH 7                                Kg / sq. cm        42.2         40.7
15.   Condensate temperature at inlet of
      LPH 1                                    0
                                                   C          44.0         58.0
      LPH 2                                    0
                                                   C          66.0         59.0
      KPH 3                                    0
                                                   C         105.0         97.0
      LPH 4                                    0
                                                   C         127.0        119.0
                                                                        Contd..
SAMPLE DATA SHEET – 1                 Contd…

S.N                 Parameters              Unit    Design Value   Unit Data
 o
16.   Condensate temperature at outlet of
      LPH 1                                 0
                                                C           63.0          59.0
      LPH 2                                 0
                                                C          105.0          97.0
      KPH 3                                 0
                                                C          127.0         119.0
      LPH 4                                 0
                                                C          159.0         156.0
17.   Drip temperature from
      LPH 1                                 0
                                                C           66.0          59.0
      LPH 2                                 0
                                                C          102.0         105.0
      KPH 3                                 0
                                                C          115.0         117.0
      LPH 4                                 0
                                                C          150.0         158.0
18.   Ex. Steam Temperature at inlet to
      LPH 1                                 0
                                                C           95.0          97.0
      LPH 2                                 0
                                                C          177.0         169.0
      KPH 3                                 0
                                                C          252.0         261.0
      LPH 4                                 0
                                                C          352.0         388.0
19.   Ex. Steam pressure at inlet to
      LPH 1                                 0
                                                C            0.3           0.2
      LPH 2                                 0
                                                C            1.5           1.8
      KPH 3                                 0
                                                C            3.0           3.3
                                            0
SAMPLE DATA SHEET – 1                    Contd…
S.N                Parameters                 Unit      Design Value   Unit Data
 o
20.   CW inlet temperature                     0
                                                   C            30.0          32.5
      Pass – A                                 0
                                                   C            30.0          32.6
      Pass – B                                 0
                                                   C            30.0          32.4
21.   CW outlet temperature                    0
                                                   C            38.4          44.2
      Pass – A                                 0
                                                   C            38.4          44.2
      Pass – B                                 0
                                                   C            38.4          44.1
22.   LPT exhaust temperature                  0
                                                   C            43.2          50.4
      Pass – A                                 0
                                                   C            43.2          50.8
      Pass – B                                 0
                                                   C            43.2          50.0
23.   CEP suction temperature                  0
                                                   C            43.0          48.9
24.   Condenser vacuum (as per DAS)         Kg/Sq Cm.          0.911         0.871
25.   Con. Vac (Kinetometer)                 Cm Hg.            66.95         64.60
      Con. Vac (Kinetometer)                Kg/Sq. Cm          0.911         0.879
      Con. Vac (as per LPT exhaust)         Kg/Sq. Cm          0.911         0.872
26.   Air / Steam mixture temp. (Ejec-A)       0
                                                   C                          46.0
      Air / Steam mixture temp. (Ejec-B)       0
                                                   C                          42.0
27.   Ejector steam pressure                Kg/Sq. Cm                        19.19
28.   CW pressure at condenser inlet        Kg/Sq. Cm                         N/A
29.   CW pressure at condenser outlet       Kg/Sq. Cm                         N/A
      CW pressure drop across cond. Tubes   Kg/Sq. Cm          0.370               --
SAMPLE DATA SHEET – 2
CT FAN DUTY
 Item Ref.    Units   Design   Fan-    Fan     Fan-    Fan-    Fan-    Fan-    Fan-    Fan     Fan     Sum
                                A      - B      C       D       E       F       G       -H      -I
Voltage        V       415     418     418     418     418     418     418     418     418     418
(measured)

Current        A       113      90      88      98      0       85      88      90      85      90     714
(measured)

Motor                          0.897   0.897   0.897   0.897   0.897   0.897   0.897   0.897   0.897

power
factor
Motor                           0.9    0.9     0.9             0.9     0.9     0.9     0.9     0.9
efficiency
(Ref.)
Fan input      kW       67     52.60   51.43   57.27           49.67   51.43   52.60   49.67   52.60   52.16

power

CT fan air    Kg /     2654    2448    2430    2519            2402    2430    2448    2402    2448    19528

flow × 1000    hr
SAMPLE DATA SHEET – 3
CHEMICAL DATA FOR CIRCULATING WATER
         Month           TDS           Na            COC           pH         Turbidity
                         ppm          ppm                                       NTU
 March                    150          9.8            1.5          8.3           22
 April                      174        11.5           1.64        8.31            8.5
 May                        161        11.5           1.55        8.48           13.0

 S.N        Quality of Water                         Effect of Quality
  o
   1.      Low COC = 1.6 to 1.8   Less corrosive effect
   2.      High COC > 2.0         Scale deposition increases
   3.      Acidic pH              Very corrosive
   4.      pH > 8.5               [A ]. Copper pick increases
                                  Material of Condenser tube = Cu 95 % Ni 5 %
                                  [B ] Chlorine effect reduces
   5.      COC V. Low = < 1.3     No scale deposition (because less TDS in CW system); but
                                  metal pick increases fast
   6.      Turbidity              MU water turbidity = 20 NTU (make-up water)
   7.      TDS Values             Raw MU Water TDS = 100 / 110 PPM
FORMULAE USED FOR CALCULATIONS - A

1. Condenser heat load calculation :
   The following data is required for heat load calculation :

   a) LPT exhaust flow
   b) Enthalpy of exhaust steam
   c) Enthalpy of condensate

   a) LPT exhaust flow

   = [Main steam flow – Extraction steam flow – Aux. Steam
   flow – D/A steam flow – ESV leak-off – Seals leakage]


                                                          Contd..
FORMULAE USED FOR CALCULATIONS - A

 Extraction steam flow is calculated by heat balance i.e.,

Extraction Steam Flow = Feed Water flow (FW I/L temp. - FW O/L temp.
                        Enthalpy of exhaust steam −Drip temperatur e
                                                                    
                                                                    




 Condenser heat load
 = [ LPT exh. Steam enthalpy – Condensate enthalpy] × Exhaust Steam flow rate


 CW flow can be calculated by heat balance

             CW Flow = Condenser heat load (k Cal / Hr.)
                          CW temperatur e rise (0 C)
FORMULAE USED FOR CALCULATIONS - B
2. CW flow calculation as per power measurement :

           Power input to motor = 3 V I × PF kW
                                   1000

  Power input to pump = Motor efficiency × Power input to motor
  LKW = Pump efficiency × Motor efficiency × Power input to motor


      CW pump discharge flow = LkW × 3600 M3 / Hr.
                               TDH× 9.81

  Actual CW flow thro’ condenser = less than 100 % of CW
  discharge flow as

   Part of CW flow is often used for cooling purposes in turbine
    side boiler side, ash slurry, etc.
FORMULAE USED FOR CALCULATION - C
3. CT fan air flow calculation :

   Power input to motor = 3 V I × PF kW
                           1000

   Power input to fans = Motor efficiency × Power input to motor kW

                                                      3
                           
                             Fan input power    
   Fan air flow actual =                                × Fan rated CMH
                           Rated fan input power 
                                                 


   Air flow per fan

   G/L Ratio = Air flow per cell (by wt.)
              CW flow per cell (by wt.)


   Evaporation losses = CT Flow × CT Range M3/Hr.
                               675


   Makeup water = Evaporation loss          M3/Hr.
                     (COC- 1)

                                                                            Contd..
FORMULAE USED FOR CALCULATION - D

4.   COC is defined as the ratio of total dissolved solids in
     basin water to TDS in makeup water.

     Water Consn.   = (Evaporation Losses + Makeup water) M3/Hr.

     CT Range       = CW temp. at CT inlet – CW temp. at bottom fills

     CT approach    = CW temp. at CT outlet – WBT at ground level


                               Range       
 % CT effectiven ess =    
                          
                                            
                                            
                                                    × 100
                           Range + Approach
                                           


                           CWT Inlet - CWT Outlet 
                        =                          × 100 %
                          
                             CWT Inlet - WBT      
                                                   
SAMPLE CALCULATION SHEET FOR
        CONDENSER HEAT LOAD CALCULATION
Steam parameters at salient points :

S.               Parameters                Unit     Design     Unit Data
No                                                  Value
 .
1.   Enthalpy of LPT exhaust steam        kCal/kg      585.7       619.3
2.   Enthalpy of condenser at CEP         kCal/kg       43.2        48.9
     suction
3.   Enthalpy of ex. Steam at HPH 5 I/L   kCal/kg      799.2       807.4
4.   Enthalpy of ex. Steam at HPH 6 I/L   kCal/kg      733.0       730.2
5.   Enthalpy of ex. Steam at HPH 7 I/L   kCal/kg      754.6       776.4
6.   Enthalpy of ex. Steam at LPH 1 I/L   kCal/kg      615.9       640.1
7.   Enthalpy of ex. Steam at LPH 2 I/L   kCal/kg      675.4       670.3
8.   Enthalpy of ex. Steam at LPH 3 I/L   kCal/kg      709.7       713.4
9.   Enthalpy of ex. Steam at LPH 4 I/L   kCal/kg      756.9       774.7


                                                                 Contd.
SAMPLE CALCULATION SHEET FOR
         CONDENSER HEAT LOAD CALCULATION
Steam parameters at salient points :
S.                   Parameters               Unit     Design Value   Unit Data
No.
1.    Extraction steam flow at HPH 5          T/hr.            16.4         22.8
2.    Extraction steam flow at HPH 6          T/hr.            53.1         45.7
3.    Extraction steam flow at HPH 7          T/hr.            28.6         47.3
4.    Extraction steam flow at LPH 1          T/hr.            16.6          0.8
5.    Extraction steam flow at LPH 2          T/hr.            31.2         31.7
6.    Extraction steam flow at LPH 3          T/hr.            18.1         17.4
7.    Extraction steam flow at LPH 4          T/hr.            25.3         28.3
8.    Auxiliary steam flow                    T/hr.            17.0         17.0
9.    HPT seal leakage                        T/hr.            12.0         12.0
10.   HPT ESV leak off                        T/hr.             2.0          2.0
11.   Ext. to deaerator                       T/hr.             4.0          4.0
12.   LPT exhaust flow (calculated)           T/hr.           436.7       501.1
13.   Av. CW temperature rise                  0
                                                   C            8.4         11.7
14.   Condenser heat load                    kCal/kg          542.5       570.4
15.   Condenser heat load × 1000             kCal/kg        236910       285831
16.   CW flow (CMH) CW Flow = (Heat load /    T/hr.        28203.5      24534.8
      CW Temperature difference)
SAMPLE CW PUMP DUTY ASSESSMENT
Total diff. Head calculation :

  S.            Item Reference     Unit   Design   Unit
  No.                                     Value    Data
  1.    Fore bay level             MSL              279.4

  2.    Fore bay to floor          mWC               4.25

  3.    Bowl loss (Reference)      mWC               0.20

  4.    Height of pressure gauge   mWC               1.33

  5.    Discharge pressure         mWC    21.8 –    22.00
                                           22.6
  6.    Velocity head @ 1.89 m/s   mWC               0.18

  7.    Total differential head    mWC              27.96
SAMPLE FLOW BALANCE OF CW PUMP BY MOTOR
a)                           LOADING
      Power measurement by power analyser (Accuracy – Class-I (0.1 %)
b)    CW flow calculation based on power measurement
     S.             Item Reference         Unit   Design         Unit Data
     No.                                          Value      Pump-A     Pump-B

     1.    Voltage (measured)               V      6600         6681          6502
     2.    Current (measured)               A       205        173.98        175.43
     3.    Power factor (measured)          -       0.85       0.6418         0.675
     4.    Power input to motor            kW      2000         1292          1334
     5.    Power input to pump             kW                   1221          1260
           (@ 94.5% motor efficiency)
     6.    Average pump input power        kW                                 1241
     7.    LKW (@ 87 % pump efficiency)           2 × 1130                    2159
     8.    Total CW discharge flow         CMH     32350                     28332
     9.    Cooling water for Aux. (15 %)   CMH     4850                       4250
     10.   CW flow through condenser       CMH     27500                     24082
     11.   CW taken for HP/LP pumps        CMH      410                        570
     12.   CW going back to CT             CMH     30000                     27479
     13.   CW fans in service              CMH       8                           8
     14.   CW flow per cell                CMH     3750                       3435
SAMPLE CT FAN DUTY ASSESSMENT
Power Measurement by Power Analyser Accuracy Class-I (0.1 %)

 S.           Item Reference          Unit    Design    Unit Data
 No.                                          Value
  1.   Voltage (measured)               V        6600       6509

  2.   Current (measured)               A                  45.86

  3.   Motor power factor               --                0.8969

  4.   Motor efficiency (Ref.)          --                    0.9

  5.   CT Xmer input power             kW         603     417.33

  6.   Ct fan motor input power        kW          67      52.16

  7.   CT fan flow per tower × 1000   Kg/hr     21229      19530

  8.   Air flow per cell × 1000       Kg/hr      2654       2441
SAMPLE CT PERFORMANCE
              ASSESSMENT
S.                                            Design    Unit
No.           Item Reference          Unit    Value     Data

1.    Water inlet temperature to CT   0
                                          C       43       45

2.    Water outlet temperature from   0
                                          C       33     31.5
      CT
3.    Wet Bulb temperature @ CT       0
                                          C      28.4    24.5
      bottom
4.    Dry bulb temperature ambient    0
                                          C        --      32
SAMPLE CT SYSTEM KEY INDICATORS

S.             Item Reference         Unit    Design  Unit Data
No.                                           Value
1.    CT range                        0
                                          C        10      13.5
 2.   CT approach                     0
                                          C       4.6         7
 3.   CT effectiveness                          0.685     0.659
 4.   Water / Air ratio (L/G Ratio)              1.41      1.41
 5.   Air / Water Ratio (G/L Ratio)              0.71      0.71
 6.   Evaporation losses              CMH         444      550
 7.   TDS                             PPM         174      174
 8.   C.O.C.                                     2.50      1.64
 9.   Makeup water                    CMH         296      859
10.   Water consumption               CMH         741     1408
11.   % water consumption              %         2.29      4.97
SAMPLE OVERALL SYSTEM KEY INDICATORS
S.             Item Reference              Unit     Design     Unit Data
No.                                                 Value
 1.    Unit load                           MW           210          211
 2.    Frequency                           Hz           50.0        51.2
 3.    M.S. flow                           T/hr        651.3         730
 4.    F.W. flow                           T/hr        651.3         689
 5.    Total C.W. flow                     T/hr       32350        24535
 6.    C.W. flow thru condenser            T/hr       27500        24535
 7.    Average CW temperature rise          0
                                                C        8.4        11.7
 8.    Condenser heat load               kCal/hr     236910       285831
                                         × 1000
 9.    Terminal temperature difference      0
                                              C          4.8         6.2
 10.   LMTD                                 0
                                                C       8.30       11.04
 11.   Condenser vacuum                  Kg/sq.cm      0.911       0.871
 12.   CW pump pressure drop              Meter         3.70        Not
       (across condenser)                                      Measurabl
                                                                      e
ILLUSTRATIVE COMPARISON : CONDENSER
VACUUM AND CW FLOW CHARACTERISTICS
                                                                           Exhaust
       Design Value    Actual Steam   Actual CW    Actual    Condenser   Hood Steam
                          Flow to      Flow to    Condense    Vacuum      Tempera-
                        Condenser     Condenser    r Heat                   ture
                                                    Load
Case                      T / Hr.       T / Hr.    kCal/hr    T / Hr.        0
                                                                                 C


 1.        Reference     436.7         28203      236910       0.91        43.2
                                                   × 1000

 2.        Reference      440          27500                   0.91         44

 3.        Reference      480          27500                   0.91         45

 4.        Reference      480          25000                   0.9          46

 5.        Reference      500          25000                   0.9         46.1
ILLUSTRATIVE COMPARISON :
             CW PUMP PERFORMANCE

S.          Item Reference          Unit   Design    Unit
No.                                        Value     Data
1.    Average CW pump motor input   kW        1335     1313

2.    Average CW pump LKW           kW        1130   1079.5

3.    CW discharge flow             CMH      32350    28332
      (16175 CMH each Pump)

4.    CW flow thro’ condenser       CMH      27500    24082

5.    CW flow per cell              CMH       3750     3445

6.    CT fans on line               Nos.         8          8
ILLUSTRATIVE COMPARISON :
             CT FAN PERFORMANCE

S.          Item Reference           Unit     Design       Unit
No.                                           Value        Data
1.    Fan input power kW              kW             67     52.17

2.    CT fan air flow per tower     Kg/hr ×     21229       19530
                                     1000
3.    CT fan air flow per cell      Kg/hr ×      2654        2441
                                     1000

4.    CW flow per cell              Kg/hr ×      3750        3445
                                     1000
5.    Water/Air ratio (L/G ratio)                   1.41     1.41


      Dry air density               Kg/M 3    1.0555
      CT fans in operation            No        8
      (for design performance)
ILLUSTRATIVE COMPARISON :
         COOLING TOWER PERFORMANCE
DESIGN DATA

                   HP         KW       CW FLOW          30,000 CMH

FAN BHP           76.4        57.0
                                     Hot Water Temp.    109.4    43 C
MOTOR HP           90         67.1                        F

                                     Cold Water Temp.   91.4 F   33 F

Fan air flow    21229 kg/hr × 1000   Wet Bulb Temp.     83.1 F   28.4 C

CT fans in           8 Nos.                             22 F     12.2 C
operation

CT air flow /   2654 kg/hr × 1000                       18 F     10 C
cell

                                                        14 F     7.8 C

                                                                 Contd..
ILLUSTRATIVE COMPARISON :
     COOLING TOWER PERFORMANCE
DESIGN DATA


                           Units      Unit
       Item Reference                 Data
  CT Range                  0
                             C         13.5

  Wet bulb temperature      0
                             C         24.5
  (measured)
                                   76.1 F
  Cold water temperature    0
                             C
                                        31.5
  (measured)
  Cold water temperature    0
                             C         32.5
  (design)
ILLUSTRATIVE COMPARISON :
      COOLING TOWER PERFORMANCE

CW FLOW (M 3 / Hr)



S.         Item Reference     Design   Unit
No.                           Value    Data

 A.   By process parameters   28203    24535

 B. By CW pump motor          27500    24082
    loading
 C. By LMTD calculation       28728    24000
SAMPLE SCAN OF CW PUMPS –
                                    ENERGY AUDIT OBSERVATIONS

 Eqpt.      kW Drawn                     Flow                   Pressure (kg/cm2) Pumps (mmWc) for Fans               Liquid kW         Combined               S.C.E                         Unit
 Ref.                                                                                                                 of Air kW        Efficiency (%)        (kWh/Ton)      Motor
                  Kw                     TPH               Suction*           Discharge          Differential                                                               Loadin   Gen.           Freq.
                                                                                                                                                                             g%      (MW)           (Hz)

         Design        Actual   Design          Actual   Desi    Actu     Design    Actual     Desi       Actual   Design   Actual   Design     Actual   Design    Actual
                                                          gn      al                            gn



CWP –    1377          1021     15000           13295     0        0       2.5      1.90       2.5        1.90     1021     688.3    74.18      67.43    0.092    0.0768    74.24    189.6          47.91
1
CWP –    1377          1014     15000           13274     0        0       2.5      1.90       2.5        1.90     1021     687.2    74.18      67.76    0.092    0.0764    73.78    186.2          47.85
2
CWP –    1377          1018     15000           13422     0        0       2.5      1.90       2.5        1.90     1021     694.9    74.18      68.23    0.092    0.0759    74.07    191.6          48.36
3

CWP –    1377          1078     15000           13310     0        0       2.5      1.75       2.5        1.75     1021     634.7    74.18      58.89    0.092    0.0810    78.39    193.9          48.20
4

CWP –    1377          983      15000           13159     0        0       2.5      1.85       2.5        1.85     1021     663.4    74.18      67.50    0.092    0.0747    71.47    194.5          47.81
5

CWP –    1377          1104     15000           13197     0        0       2.5      1.80       2.5        1.80     1021     647.3    74.18      68.64    0.092    0.0838    80.28    194.1          47.90
6

CWP –    1377          1143     15000           13183     0        0       2.5      1.95       2.5        1.95     1021     700.5    74.18      61.31    0.092    0.0867    83.09    194.7          47.84
7
CONCLUSIONS
The audit conclusions are site specific and situation
specific. The menu of recommendations substantiated
adequately are most likely to include ;
 Timely descaling of condensers
 Ensuring adequacy of CW flow through condensers
 Improving operational energy efficiency of CW pumps by
  maintenance or retrofit or replacement options
 Tuning of CT operations for achieving best CT range, L/G
  ratio, approach for given loading, ambient conditions.
 Water   quality     improvements     and    design   COC
  improvements.
 Debottlenecking of any O & M constraints
 Fill replacement/replenishment in cooling towers
 Improvements in instrumentation and MIS for enabling
  continuous efforts by O & M and O & E teams.
Ea of cw, ct & cond. system

Contenu connexe

Tendances

Hydrogen Purge and Fill
Hydrogen Purge and FillHydrogen Purge and Fill
Hydrogen Purge and FillShad Edwards
 
INTRODUCTION TO GOVERNING
INTRODUCTION TO GOVERNINGINTRODUCTION TO GOVERNING
INTRODUCTION TO GOVERNINGSURAJ KUMAR
 
Steam Turbine Performance in TPS
Steam Turbine Performance in TPSSteam Turbine Performance in TPS
Steam Turbine Performance in TPSManohar Tatwawadi
 
Hrsg startup proceudre
Hrsg startup proceudreHrsg startup proceudre
Hrsg startup proceudrekamaraprasad
 
Energy adudit methodology for boiler
Energy adudit methodology for boilerEnergy adudit methodology for boiler
Energy adudit methodology for boilerKongkiert Tankayura
 
POWER PLANT SIMULATOR 210 MW
POWER PLANT SIMULATOR 210 MW POWER PLANT SIMULATOR 210 MW
POWER PLANT SIMULATOR 210 MW Manohar Tatwawadi
 
STEAM TURBINES Governing System & TROUBLE SHOOTING
STEAM TURBINES Governing System & TROUBLE SHOOTINGSTEAM TURBINES Governing System & TROUBLE SHOOTING
STEAM TURBINES Governing System & TROUBLE SHOOTINGAshish Kumar Jain
 
THERMAL POWER PLANT OPERATIONS
THERMAL POWER PLANT OPERATIONSTHERMAL POWER PLANT OPERATIONS
THERMAL POWER PLANT OPERATIONSManohar Tatwawadi
 
Turbine cycle heat rate calculation
Turbine  cycle heat rate calculationTurbine  cycle heat rate calculation
Turbine cycle heat rate calculationSHIVAJI CHOUDHURY
 
210 mw LMZ Turbine rolling and its GOVERNING
210 mw LMZ Turbine rolling and its GOVERNING 210 mw LMZ Turbine rolling and its GOVERNING
210 mw LMZ Turbine rolling and its GOVERNING Nitin Patel
 
210 mw turbine cycle heat rate
210 mw turbine cycle heat rate210 mw turbine cycle heat rate
210 mw turbine cycle heat rateManohar Tatwawadi
 
660 mw supercritical boiler
660 mw supercritical boiler660 mw supercritical boiler
660 mw supercritical boilerAshvani Shukla
 
METHODS OF IMPROVING STEAM TURBINE PERFORMANCE
METHODS OF IMPROVING STEAM TURBINE PERFORMANCEMETHODS OF IMPROVING STEAM TURBINE PERFORMANCE
METHODS OF IMPROVING STEAM TURBINE PERFORMANCEVanita Thakkar
 
Air Heater and PF Boiler Performance Indices
Air Heater and PF Boiler Performance IndicesAir Heater and PF Boiler Performance Indices
Air Heater and PF Boiler Performance IndicesManohar Tatwawadi
 
Performance calculation for feed water heater
Performance calculation  for feed water heaterPerformance calculation  for feed water heater
Performance calculation for feed water heaterSHIVAJI CHOUDHURY
 

Tendances (20)

Power Plant Operations.pdf
Power Plant Operations.pdfPower Plant Operations.pdf
Power Plant Operations.pdf
 
Safe Operation and Explosions in Boilers
Safe Operation and Explosions in BoilersSafe Operation and Explosions in Boilers
Safe Operation and Explosions in Boilers
 
Hydrogen Purge and Fill
Hydrogen Purge and FillHydrogen Purge and Fill
Hydrogen Purge and Fill
 
INTRODUCTION TO GOVERNING
INTRODUCTION TO GOVERNINGINTRODUCTION TO GOVERNING
INTRODUCTION TO GOVERNING
 
Steam Turbine Performance in TPS
Steam Turbine Performance in TPSSteam Turbine Performance in TPS
Steam Turbine Performance in TPS
 
Hrsg startup proceudre
Hrsg startup proceudreHrsg startup proceudre
Hrsg startup proceudre
 
Energy adudit methodology for boiler
Energy adudit methodology for boilerEnergy adudit methodology for boiler
Energy adudit methodology for boiler
 
POWER PLANT SIMULATOR 210 MW
POWER PLANT SIMULATOR 210 MW POWER PLANT SIMULATOR 210 MW
POWER PLANT SIMULATOR 210 MW
 
Heat balance diagram
Heat balance diagramHeat balance diagram
Heat balance diagram
 
STEAM TURBINES Governing System & TROUBLE SHOOTING
STEAM TURBINES Governing System & TROUBLE SHOOTINGSTEAM TURBINES Governing System & TROUBLE SHOOTING
STEAM TURBINES Governing System & TROUBLE SHOOTING
 
THERMAL POWER PLANT OPERATIONS
THERMAL POWER PLANT OPERATIONSTHERMAL POWER PLANT OPERATIONS
THERMAL POWER PLANT OPERATIONS
 
Turbine cycle heat rate calculation
Turbine  cycle heat rate calculationTurbine  cycle heat rate calculation
Turbine cycle heat rate calculation
 
210 mw LMZ Turbine rolling and its GOVERNING
210 mw LMZ Turbine rolling and its GOVERNING 210 mw LMZ Turbine rolling and its GOVERNING
210 mw LMZ Turbine rolling and its GOVERNING
 
210 mw turbine cycle heat rate
210 mw turbine cycle heat rate210 mw turbine cycle heat rate
210 mw turbine cycle heat rate
 
Boilers
BoilersBoilers
Boilers
 
660 mw supercritical boiler
660 mw supercritical boiler660 mw supercritical boiler
660 mw supercritical boiler
 
METHODS OF IMPROVING STEAM TURBINE PERFORMANCE
METHODS OF IMPROVING STEAM TURBINE PERFORMANCEMETHODS OF IMPROVING STEAM TURBINE PERFORMANCE
METHODS OF IMPROVING STEAM TURBINE PERFORMANCE
 
Boiler light up & loading
Boiler light up & loadingBoiler light up & loading
Boiler light up & loading
 
Air Heater and PF Boiler Performance Indices
Air Heater and PF Boiler Performance IndicesAir Heater and PF Boiler Performance Indices
Air Heater and PF Boiler Performance Indices
 
Performance calculation for feed water heater
Performance calculation  for feed water heaterPerformance calculation  for feed water heater
Performance calculation for feed water heater
 

En vedette

En vedette (19)

Design brief
Design briefDesign brief
Design brief
 
Engineering design guidelines cooling towers - rev01
Engineering design guidelines   cooling towers - rev01Engineering design guidelines   cooling towers - rev01
Engineering design guidelines cooling towers - rev01
 
Working of Continuous Distillation Column
Working of Continuous Distillation Column Working of Continuous Distillation Column
Working of Continuous Distillation Column
 
Design Brief - Problem Solving Exercise
Design Brief - Problem Solving ExerciseDesign Brief - Problem Solving Exercise
Design Brief - Problem Solving Exercise
 
Steam Condenser performance and loss diagnostic
Steam Condenser performance and loss diagnosticSteam Condenser performance and loss diagnostic
Steam Condenser performance and loss diagnostic
 
PPT On Steam Condenser
PPT On Steam Condenser PPT On Steam Condenser
PPT On Steam Condenser
 
Selection and Design of Condensers
Selection and Design of CondensersSelection and Design of Condensers
Selection and Design of Condensers
 
Condenser in thermal power plants
Condenser in thermal power plantsCondenser in thermal power plants
Condenser in thermal power plants
 
Steam Condensers
Steam CondensersSteam Condensers
Steam Condensers
 
Methanol Plant - Theory of Distillation
Methanol Plant - Theory of DistillationMethanol Plant - Theory of Distillation
Methanol Plant - Theory of Distillation
 
Condenser and its types
Condenser and its types Condenser and its types
Condenser and its types
 
Design of condenser
Design of condenserDesign of condenser
Design of condenser
 
Packed tower
Packed towerPacked tower
Packed tower
 
STUDY OF CONDENSER AND ITS DIFFERENT TYPES
STUDY OF CONDENSER  AND ITS DIFFERENT TYPESSTUDY OF CONDENSER  AND ITS DIFFERENT TYPES
STUDY OF CONDENSER AND ITS DIFFERENT TYPES
 
PLC SCADA
PLC SCADAPLC SCADA
PLC SCADA
 
Full report gas absorption
Full report gas  absorptionFull report gas  absorption
Full report gas absorption
 
Presentation on cooling tower
Presentation on cooling towerPresentation on cooling tower
Presentation on cooling tower
 
Design of packed columns
Design of packed columnsDesign of packed columns
Design of packed columns
 
ppt on PLC
ppt on PLCppt on PLC
ppt on PLC
 

Similaire à Ea of cw, ct & cond. system

Case study Energy Audit for Chiller Plant
Case study Energy Audit for Chiller PlantCase study Energy Audit for Chiller Plant
Case study Energy Audit for Chiller PlantHina Gupta
 
ENERGY AUDIT METHODOLOGY FOR TURBINE CYCLE IN A POWER PLANT
ENERGY AUDIT METHODOLOGY FOR TURBINE CYCLE IN A POWER PLANTENERGY AUDIT METHODOLOGY FOR TURBINE CYCLE IN A POWER PLANT
ENERGY AUDIT METHODOLOGY FOR TURBINE CYCLE IN A POWER PLANTManohar Tatwawadi
 
IRJET- CFD Analysis of Double Pipe Heat Exchanger with Different Inner Se...
IRJET-  	  CFD Analysis of Double Pipe Heat Exchanger with Different Inner Se...IRJET-  	  CFD Analysis of Double Pipe Heat Exchanger with Different Inner Se...
IRJET- CFD Analysis of Double Pipe Heat Exchanger with Different Inner Se...IRJET Journal
 
H&MProject_TylerLenzen_Spring2014
H&MProject_TylerLenzen_Spring2014H&MProject_TylerLenzen_Spring2014
H&MProject_TylerLenzen_Spring2014Tyler Lenzen
 
Basics on Cooling Tower & Water.pdf sana parveen
Basics on Cooling Tower & Water.pdf sana parveenBasics on Cooling Tower & Water.pdf sana parveen
Basics on Cooling Tower & Water.pdf sana parveenSana Khan
 
4.4.heat exchanger
4.4.heat exchanger4.4.heat exchanger
4.4.heat exchangercmyan
 
EXH2200 Cooling Tower Design Guidelines.pdf
EXH2200 Cooling Tower Design Guidelines.pdfEXH2200 Cooling Tower Design Guidelines.pdf
EXH2200 Cooling Tower Design Guidelines.pdfZeeshanAlam90
 
Energy audit of Condenser and CW System
Energy audit of Condenser and CW SystemEnergy audit of Condenser and CW System
Energy audit of Condenser and CW SystemManohar Tatwawadi
 
Ashrae chillers inseries
Ashrae chillers inseriesAshrae chillers inseries
Ashrae chillers inseriesKoo Kong
 
2003 ASME Power Conference Performance Evaluation of Feedwater Heaters for Nu...
2003 ASME Power Conference Performance Evaluation of Feedwater Heaters for Nu...2003 ASME Power Conference Performance Evaluation of Feedwater Heaters for Nu...
2003 ASME Power Conference Performance Evaluation of Feedwater Heaters for Nu...Komandur Sunder Raj, P.E.
 
Case Study: Energy Audit For Cooling Tower
Case Study: Energy Audit For Cooling Tower Case Study: Energy Audit For Cooling Tower
Case Study: Energy Audit For Cooling Tower Hina Gupta
 

Similaire à Ea of cw, ct & cond. system (20)

Case study Energy Audit for Chiller Plant
Case study Energy Audit for Chiller PlantCase study Energy Audit for Chiller Plant
Case study Energy Audit for Chiller Plant
 
Condenser pg test
Condenser pg testCondenser pg test
Condenser pg test
 
ENERGY AUDIT METHODOLOGY FOR TURBINE CYCLE IN A POWER PLANT
ENERGY AUDIT METHODOLOGY FOR TURBINE CYCLE IN A POWER PLANTENERGY AUDIT METHODOLOGY FOR TURBINE CYCLE IN A POWER PLANT
ENERGY AUDIT METHODOLOGY FOR TURBINE CYCLE IN A POWER PLANT
 
Heat rate- pulse rate of power plant
Heat rate-  pulse rate of power plantHeat rate-  pulse rate of power plant
Heat rate- pulse rate of power plant
 
IRJET- CFD Analysis of Double Pipe Heat Exchanger with Different Inner Se...
IRJET-  	  CFD Analysis of Double Pipe Heat Exchanger with Different Inner Se...IRJET-  	  CFD Analysis of Double Pipe Heat Exchanger with Different Inner Se...
IRJET- CFD Analysis of Double Pipe Heat Exchanger with Different Inner Se...
 
Chapter8
Chapter8Chapter8
Chapter8
 
Condenser performance test
Condenser performance testCondenser performance test
Condenser performance test
 
H&MProject_TylerLenzen_Spring2014
H&MProject_TylerLenzen_Spring2014H&MProject_TylerLenzen_Spring2014
H&MProject_TylerLenzen_Spring2014
 
Basics on Cooling Tower & Water.pdf sana parveen
Basics on Cooling Tower & Water.pdf sana parveenBasics on Cooling Tower & Water.pdf sana parveen
Basics on Cooling Tower & Water.pdf sana parveen
 
Project ppt
Project pptProject ppt
Project ppt
 
Similateur
SimilateurSimilateur
Similateur
 
4.4.heat exchanger
4.4.heat exchanger4.4.heat exchanger
4.4.heat exchanger
 
project
projectproject
project
 
EXH2200 Cooling Tower Design Guidelines.pdf
EXH2200 Cooling Tower Design Guidelines.pdfEXH2200 Cooling Tower Design Guidelines.pdf
EXH2200 Cooling Tower Design Guidelines.pdf
 
Gross turbine cycle_heat_rate_ch-8.2
Gross turbine cycle_heat_rate_ch-8.2Gross turbine cycle_heat_rate_ch-8.2
Gross turbine cycle_heat_rate_ch-8.2
 
Energy audit of Condenser and CW System
Energy audit of Condenser and CW SystemEnergy audit of Condenser and CW System
Energy audit of Condenser and CW System
 
Ashrae chillers inseries
Ashrae chillers inseriesAshrae chillers inseries
Ashrae chillers inseries
 
CT PERFORMANCE.pdf
CT PERFORMANCE.pdfCT PERFORMANCE.pdf
CT PERFORMANCE.pdf
 
2003 ASME Power Conference Performance Evaluation of Feedwater Heaters for Nu...
2003 ASME Power Conference Performance Evaluation of Feedwater Heaters for Nu...2003 ASME Power Conference Performance Evaluation of Feedwater Heaters for Nu...
2003 ASME Power Conference Performance Evaluation of Feedwater Heaters for Nu...
 
Case Study: Energy Audit For Cooling Tower
Case Study: Energy Audit For Cooling Tower Case Study: Energy Audit For Cooling Tower
Case Study: Energy Audit For Cooling Tower
 

Plus de D.Pawan Kumar

Indian energy efficiency scene..a macro perspective.
Indian energy efficiency scene..a macro perspective.Indian energy efficiency scene..a macro perspective.
Indian energy efficiency scene..a macro perspective.D.Pawan Kumar
 
Roadmap for distribution loss reduction.. a step by step approach
Roadmap  for distribution loss reduction.. a step by step approachRoadmap  for distribution loss reduction.. a step by step approach
Roadmap for distribution loss reduction.. a step by step approachD.Pawan Kumar
 
Water conservation opportunities.
Water conservation opportunities.Water conservation opportunities.
Water conservation opportunities.D.Pawan Kumar
 
Turnkey implementation of distribution projects
Turnkey implementation of distribution projectsTurnkey implementation of distribution projects
Turnkey implementation of distribution projectsD.Pawan Kumar
 
Cogeneration: regional experiences
Cogeneration: regional experiencesCogeneration: regional experiences
Cogeneration: regional experiencesD.Pawan Kumar
 
Energy efficient technology procurement
Energy efficient technology  procurementEnergy efficient technology  procurement
Energy efficient technology procurementD.Pawan Kumar
 
Boiler ea case study 16 jan 2012 varanasi
Boiler ea case study  16 jan 2012 varanasiBoiler ea case study  16 jan 2012 varanasi
Boiler ea case study 16 jan 2012 varanasiD.Pawan Kumar
 
Training manual on energy efficiency for SMEs
Training manual on energy efficiency for SMEsTraining manual on energy efficiency for SMEs
Training manual on energy efficiency for SMEsD.Pawan Kumar
 
Electricity demand side management and end use efficiency
Electricity demand side management and end use efficiencyElectricity demand side management and end use efficiency
Electricity demand side management and end use efficiencyD.Pawan Kumar
 
As run energy efficiency of cooling towers
As run energy efficiency of cooling towersAs run energy efficiency of cooling towers
As run energy efficiency of cooling towersD.Pawan Kumar
 
Focus areas in economic operation of DG sets
Focus areas in economic operation of DG setsFocus areas in economic operation of DG sets
Focus areas in economic operation of DG setsD.Pawan Kumar
 
Hrsg & turbine as run energy efficiency assessment
Hrsg  & turbine as run energy efficiency assessmentHrsg  & turbine as run energy efficiency assessment
Hrsg & turbine as run energy efficiency assessmentD.Pawan Kumar
 
How to conduct energy audit
How to conduct energy auditHow to conduct energy audit
How to conduct energy auditD.Pawan Kumar
 
Desirable as run information system for energy efficiency of utility clas...
Desirable as run information system  for energy efficiency  of  utility  clas...Desirable as run information system  for energy efficiency  of  utility  clas...
Desirable as run information system for energy efficiency of utility clas...D.Pawan Kumar
 
As run boiler performance assessment for energy efficiency
As run boiler performance assessment for energy efficiencyAs run boiler performance assessment for energy efficiency
As run boiler performance assessment for energy efficiencyD.Pawan Kumar
 
Energy efficiency in pumps and fans ppt
Energy efficiency in pumps and fans pptEnergy efficiency in pumps and fans ppt
Energy efficiency in pumps and fans pptD.Pawan Kumar
 
Energy efficiency in buildings
Energy efficiency in buildingsEnergy efficiency in buildings
Energy efficiency in buildingsD.Pawan Kumar
 
Compressed air and refrigeration system
Compressed air and refrigeration systemCompressed air and refrigeration system
Compressed air and refrigeration systemD.Pawan Kumar
 

Plus de D.Pawan Kumar (19)

Indian energy efficiency scene..a macro perspective.
Indian energy efficiency scene..a macro perspective.Indian energy efficiency scene..a macro perspective.
Indian energy efficiency scene..a macro perspective.
 
Roadmap for distribution loss reduction.. a step by step approach
Roadmap  for distribution loss reduction.. a step by step approachRoadmap  for distribution loss reduction.. a step by step approach
Roadmap for distribution loss reduction.. a step by step approach
 
Water conservation opportunities.
Water conservation opportunities.Water conservation opportunities.
Water conservation opportunities.
 
Turnkey implementation of distribution projects
Turnkey implementation of distribution projectsTurnkey implementation of distribution projects
Turnkey implementation of distribution projects
 
Cogeneration: regional experiences
Cogeneration: regional experiencesCogeneration: regional experiences
Cogeneration: regional experiences
 
Energy efficient technology procurement
Energy efficient technology  procurementEnergy efficient technology  procurement
Energy efficient technology procurement
 
Boiler ea case study 16 jan 2012 varanasi
Boiler ea case study  16 jan 2012 varanasiBoiler ea case study  16 jan 2012 varanasi
Boiler ea case study 16 jan 2012 varanasi
 
Ee opportunities
Ee opportunities Ee opportunities
Ee opportunities
 
Training manual on energy efficiency for SMEs
Training manual on energy efficiency for SMEsTraining manual on energy efficiency for SMEs
Training manual on energy efficiency for SMEs
 
Electricity demand side management and end use efficiency
Electricity demand side management and end use efficiencyElectricity demand side management and end use efficiency
Electricity demand side management and end use efficiency
 
As run energy efficiency of cooling towers
As run energy efficiency of cooling towersAs run energy efficiency of cooling towers
As run energy efficiency of cooling towers
 
Focus areas in economic operation of DG sets
Focus areas in economic operation of DG setsFocus areas in economic operation of DG sets
Focus areas in economic operation of DG sets
 
Hrsg & turbine as run energy efficiency assessment
Hrsg  & turbine as run energy efficiency assessmentHrsg  & turbine as run energy efficiency assessment
Hrsg & turbine as run energy efficiency assessment
 
How to conduct energy audit
How to conduct energy auditHow to conduct energy audit
How to conduct energy audit
 
Desirable as run information system for energy efficiency of utility clas...
Desirable as run information system  for energy efficiency  of  utility  clas...Desirable as run information system  for energy efficiency  of  utility  clas...
Desirable as run information system for energy efficiency of utility clas...
 
As run boiler performance assessment for energy efficiency
As run boiler performance assessment for energy efficiencyAs run boiler performance assessment for energy efficiency
As run boiler performance assessment for energy efficiency
 
Energy efficiency in pumps and fans ppt
Energy efficiency in pumps and fans pptEnergy efficiency in pumps and fans ppt
Energy efficiency in pumps and fans ppt
 
Energy efficiency in buildings
Energy efficiency in buildingsEnergy efficiency in buildings
Energy efficiency in buildings
 
Compressed air and refrigeration system
Compressed air and refrigeration systemCompressed air and refrigeration system
Compressed air and refrigeration system
 

Ea of cw, ct & cond. system

  • 1. A PRACTICAL APPROACH to ENERGY AUDIT IN CW, CT & CONDENSER SYSTEM in THERMAL POWER STATIONS D.Pawan Kumar And R.Virendra
  • 2. 1.0 BACKGROUND Cooling Water Circuit and System performance, holds the key in maintaining optimum vacuum in a thermal or a GT combined cycle plant. In current times, there is an increasing demand on power plant professionals, to address concurrently, complex tasks like ; Cooling water Consumption optimization, Achieving vacuum conditions and Optimizing power consumption in CW pumps and CT fans, despite plant side variations, like frequency, cooling water quality, availability, load variations, O & M demands, etc. While it is a challenge, experiences show that with the level of infrastructure and information available at most sites, it should be possible to conduct a reasonably detailed and functional energy audit, deploying in- house resources, to bring out improvement options.
  • 3. 2.0 AUDIT FOCUS CW / CT system and condenser vacuum being focal points for energy audit study, the various improvement issues addressed in the CW audit include ; 2.1 Condenser Related  Cleanliness of tube surfaces  Tube leakages  High inlet water temperature  CW flow adequacy
  • 4. 2.2 CW Pump Related  Efficiency of CW pumps  Fore bay level inadequacy  Mains frequency related  CW flow tapping for other purposes  Parallel operations and effects 2.3 Cooling Tower Related  Approach, range of cooling towers  L/G ratio of cooling towers  Tuning scope in cooling towers, with seasonal variations with regard to water load, CT fan blade angle, etc.  Maintenance of fills  Quality of Cooling Water and COC improvement  CT fan blade material such as FRP/GRP, etc.
  • 5. 2.4 Overall Optimization related such as ;  Optimize CW pump operations with respect to thermal load  Optimizing L/G ratios during various seasons  Optimize CW pump efficiency through need based maintenance, retrofit, replacement options.  Optimize condenser operations through O & M
  • 6. 3.0 Based on experiences at various plants The following steps are envisaged as illustrative help tools for the CW / CT audit teams in conduct of energy audit in thermal power plants and GT based combined cycle plants.
  • 7. 3.1 Scope of Audit The scope of audit pertains to Energy Audit of Cooling Water System including Cooling Towers & Condenser is made into systems as given below :  CW System : Audit for water consumption  Cooling Tower : Audit for CT effectiveness  Condenser : Audit for condenser heat load, CW flow & Vacuum The energy audit on above system will be carried out to determine main features such as : 1. Consumption of circulating water flow 2. Performance of CW pumps w.r.t. CW flow 3. CT effectiveness and L/G ratio 4. Performance of condenser w.r.t. heat load and vacuum and CW pressure drop across condenser. 5. Comparison of measured performance with reference to designed / rated values. 6. Recommendations based on the performance of the above system.
  • 8. 3.2 Methodology for Energy Audit 1. Discussion with operation, Electrical Maintenance, Mechanical Maintenance, C&I and Chemistry 2. Selection of equipments and instruments for power measurement for CW pumps & CT fans 3. Data collection based on power measurement, DBT / WBT measurement for cooling performance, UCB data collection for heat load calculation 4. Analysis of data 5. Calculation of performance to determine key indicators for assessing the performance of various systems. Contd..
  • 9. 3.3 Preparations for Audit  Selection of appropriate time for conducting audit.  Selection of units for audit.  Selection of equipments & instruments for measurement.  Calibration of instruments for pressure & temperature measurement in DAS.  Assistance from O & M personnel.  Design / rated parameters from technical operating manuals, equipments name plates, etc.
  • 10. 3.4 DESIGN DATA COLLECTION 3.4.1 DESIGN DATA – CONDENSER S. DESCRIPTION DATA NO 1. Tube Material 2. Tube Outside dia (mm) 3. Tube Thickness (mm) 4. Total Number of Tubes 5. Tube Length (Meters) 6. No. of Plugged Tubes 7. No. of Passes 8. Design Surface Area (SQM) 3.4.2 DESIGN DATA – STEAM SIDE 9. Back Pressure (kg / sq. cm) 10. Condenser Duty
  • 11. 3.4.3 DESIGN DATA – WATER SIDE S. DESCRIPTION DATA NO 11. Cooling Water Flow 12. CW Inlet Temperature 13. CW Outlet Temperature 14. Design Water Velocity 15. CW Pressure Drop 16. CW Source 17. Design Cleanliness Factor 3.4.4 DESIGN DATA – GENERATOR S. DESCRIPTION DATA NO 18. Design Heat Rate kCal / kWh at ….. MW 19. Gross Power Generated MW
  • 12. 3.4.5 WATER CHEMISTRY - DESIGN VALUES S. DESCRIPTION DATA NO 1. PH at 250C 2. Conductivity 3. T.D.S 4. Total hardness 5. Calcium Hardness 6. Magnesium Hardness 7. P-Alkalinity 8. M-alkalinity 9. Chloride 10. Sulphate 11. Cycle of Concentration 12. L.S.I
  • 13. 3.5 Equipments & Measurements The following instruments are typically used for measuring various parameters in the context of energy audit of CW, CT & Condenser performance. Intake air DBT & WBT at each cell (ground level) Psychrometer CW inlet temperature common) (risers or CT top) Hg in glass thermometer CW outlet temperature (common) (fills bottom) Hg in glass thermometer CW sump / basin temperature (overall) - Do - UCB Data : MW load, frequency, condenser, inlet / DAS outlet temperature, condenser vacuum, extraction steam flow from heaters, etc. CW pump elect. Data : Motor amps, volts, power Measurement by power factor, kilo watt analyser CT pump house fore-bay level Physically measured CW pump readings for TDH CT fans : Amps Tong tester CT transformer – Amp., Volts, PF, kW Power analyser Lab analysis data of CW (inlet), OAC and makeup Lab water analysis water
  • 14. 3.6 AUDIT DATA COLLECTION The following parameters are typically chosen for spot observations. 1. UCB Parameters : MW load, frequency, main steam flow, extraction steam flow for various heaters, LPT exhaust steam flow, steam temperatures & pressures, condenser vacuum etc., for calculation of condenser heat load & CW flow. 2. ELECTRICAL Parameters : Measurement of voltage, power factor & kW for CW pumps, CT transformer & CT fans. 3. MECHANICAL Parameters CW PUMPS : Measuring data for TDH of CW pumps and Fore bay level. 4. CHEMICAL / THERMAL Parameters : Measurement of DBT / WBT of air at cooling tower, CT basin water temperature, CW quality I.e., TDS & COC for CT performance & CW system water consumption.
  • 15. SAMPLE DATA SHEET – 1 S. Parameters Unit Design Unit Data No Value . 1. Unit Load MW 210.0 211.0 2. Frequency Hz 50.0 51.2 3. M.S. Temperature 0 C 535.0 530.0 4. M.S. Flow T/Hr. 651.3 730.0 5. HRH Pr. Kg/Sq. Cm 24.8 24.5 6. HRH Temperature 0 C 535.0 535.0 7. CRH Pr. Kg/sq. Cm 28.8 30.3 8. CRH Temperature 0 C 328.0 324.0 9. Feed Water Flow T/Hr. 651.3 689.0 10 F.W. Temperature at Inlet of HPH 5 0 C 167.0 164.0 HPH 6 0 C 182.0 185.0 HPH 7 0 C 225.0 220.0 11. F.W. temperature at outlet of HPH 5 0 C 182.0 185.0 HPH 6 0 C 225.0 220.0 HPH 7 0 C 248.0 257.1 Contd..
  • 16. SAMPLE DATA SHEET – 1 Contd.. S. Parameters Unit Design Unit Data No Value . 12. Drip Temperature from HPH 5 0 C 177.0 171.8 HPH 6 0 C 192.0 202.6 HPH 7 0 C 235.0 236.1 13. Ex. Steam temperature at inlet to HPH 5 0 C 440.0 455.9 HPH 6 0 C 328.0 323.7 HPH 7 0 C 378.0 415.5 14. Ex. Steam pressure at inlet to HPH 5 Kg / sq. cm 12.7 12.3 HPH 6 Kg / sq. cm 28.8 28.9 HPH 7 Kg / sq. cm 42.2 40.7 15. Condensate temperature at inlet of LPH 1 0 C 44.0 58.0 LPH 2 0 C 66.0 59.0 KPH 3 0 C 105.0 97.0 LPH 4 0 C 127.0 119.0 Contd..
  • 17. SAMPLE DATA SHEET – 1 Contd… S.N Parameters Unit Design Value Unit Data o 16. Condensate temperature at outlet of LPH 1 0 C 63.0 59.0 LPH 2 0 C 105.0 97.0 KPH 3 0 C 127.0 119.0 LPH 4 0 C 159.0 156.0 17. Drip temperature from LPH 1 0 C 66.0 59.0 LPH 2 0 C 102.0 105.0 KPH 3 0 C 115.0 117.0 LPH 4 0 C 150.0 158.0 18. Ex. Steam Temperature at inlet to LPH 1 0 C 95.0 97.0 LPH 2 0 C 177.0 169.0 KPH 3 0 C 252.0 261.0 LPH 4 0 C 352.0 388.0 19. Ex. Steam pressure at inlet to LPH 1 0 C 0.3 0.2 LPH 2 0 C 1.5 1.8 KPH 3 0 C 3.0 3.3 0
  • 18. SAMPLE DATA SHEET – 1 Contd… S.N Parameters Unit Design Value Unit Data o 20. CW inlet temperature 0 C 30.0 32.5 Pass – A 0 C 30.0 32.6 Pass – B 0 C 30.0 32.4 21. CW outlet temperature 0 C 38.4 44.2 Pass – A 0 C 38.4 44.2 Pass – B 0 C 38.4 44.1 22. LPT exhaust temperature 0 C 43.2 50.4 Pass – A 0 C 43.2 50.8 Pass – B 0 C 43.2 50.0 23. CEP suction temperature 0 C 43.0 48.9 24. Condenser vacuum (as per DAS) Kg/Sq Cm. 0.911 0.871 25. Con. Vac (Kinetometer) Cm Hg. 66.95 64.60 Con. Vac (Kinetometer) Kg/Sq. Cm 0.911 0.879 Con. Vac (as per LPT exhaust) Kg/Sq. Cm 0.911 0.872 26. Air / Steam mixture temp. (Ejec-A) 0 C 46.0 Air / Steam mixture temp. (Ejec-B) 0 C 42.0 27. Ejector steam pressure Kg/Sq. Cm 19.19 28. CW pressure at condenser inlet Kg/Sq. Cm N/A 29. CW pressure at condenser outlet Kg/Sq. Cm N/A CW pressure drop across cond. Tubes Kg/Sq. Cm 0.370 --
  • 19. SAMPLE DATA SHEET – 2 CT FAN DUTY Item Ref. Units Design Fan- Fan Fan- Fan- Fan- Fan- Fan- Fan Fan Sum A - B C D E F G -H -I Voltage V 415 418 418 418 418 418 418 418 418 418 (measured) Current A 113 90 88 98 0 85 88 90 85 90 714 (measured) Motor 0.897 0.897 0.897 0.897 0.897 0.897 0.897 0.897 0.897 power factor Motor 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 efficiency (Ref.) Fan input kW 67 52.60 51.43 57.27 49.67 51.43 52.60 49.67 52.60 52.16 power CT fan air Kg / 2654 2448 2430 2519 2402 2430 2448 2402 2448 19528 flow × 1000 hr
  • 20. SAMPLE DATA SHEET – 3 CHEMICAL DATA FOR CIRCULATING WATER Month TDS Na COC pH Turbidity ppm ppm NTU March 150 9.8 1.5 8.3 22 April 174 11.5 1.64 8.31 8.5 May 161 11.5 1.55 8.48 13.0 S.N Quality of Water Effect of Quality o 1. Low COC = 1.6 to 1.8 Less corrosive effect 2. High COC > 2.0 Scale deposition increases 3. Acidic pH Very corrosive 4. pH > 8.5 [A ]. Copper pick increases Material of Condenser tube = Cu 95 % Ni 5 % [B ] Chlorine effect reduces 5. COC V. Low = < 1.3 No scale deposition (because less TDS in CW system); but metal pick increases fast 6. Turbidity MU water turbidity = 20 NTU (make-up water) 7. TDS Values Raw MU Water TDS = 100 / 110 PPM
  • 21. FORMULAE USED FOR CALCULATIONS - A 1. Condenser heat load calculation : The following data is required for heat load calculation : a) LPT exhaust flow b) Enthalpy of exhaust steam c) Enthalpy of condensate a) LPT exhaust flow = [Main steam flow – Extraction steam flow – Aux. Steam flow – D/A steam flow – ESV leak-off – Seals leakage] Contd..
  • 22. FORMULAE USED FOR CALCULATIONS - A Extraction steam flow is calculated by heat balance i.e., Extraction Steam Flow = Feed Water flow (FW I/L temp. - FW O/L temp. Enthalpy of exhaust steam −Drip temperatur e     Condenser heat load = [ LPT exh. Steam enthalpy – Condensate enthalpy] × Exhaust Steam flow rate CW flow can be calculated by heat balance CW Flow = Condenser heat load (k Cal / Hr.) CW temperatur e rise (0 C)
  • 23. FORMULAE USED FOR CALCULATIONS - B 2. CW flow calculation as per power measurement : Power input to motor = 3 V I × PF kW 1000 Power input to pump = Motor efficiency × Power input to motor LKW = Pump efficiency × Motor efficiency × Power input to motor CW pump discharge flow = LkW × 3600 M3 / Hr. TDH× 9.81 Actual CW flow thro’ condenser = less than 100 % of CW discharge flow as  Part of CW flow is often used for cooling purposes in turbine side boiler side, ash slurry, etc.
  • 24. FORMULAE USED FOR CALCULATION - C 3. CT fan air flow calculation : Power input to motor = 3 V I × PF kW 1000 Power input to fans = Motor efficiency × Power input to motor kW 3   Fan input power   Fan air flow actual =   × Fan rated CMH Rated fan input power    Air flow per fan G/L Ratio = Air flow per cell (by wt.) CW flow per cell (by wt.) Evaporation losses = CT Flow × CT Range M3/Hr. 675 Makeup water = Evaporation loss M3/Hr. (COC- 1) Contd..
  • 25. FORMULAE USED FOR CALCULATION - D 4. COC is defined as the ratio of total dissolved solids in basin water to TDS in makeup water. Water Consn. = (Evaporation Losses + Makeup water) M3/Hr. CT Range = CW temp. at CT inlet – CW temp. at bottom fills CT approach = CW temp. at CT outlet – WBT at ground level  Range  % CT effectiven ess =     × 100  Range + Approach    CWT Inlet - CWT Outlet  =   × 100 %   CWT Inlet - WBT  
  • 26. SAMPLE CALCULATION SHEET FOR CONDENSER HEAT LOAD CALCULATION Steam parameters at salient points : S. Parameters Unit Design Unit Data No Value . 1. Enthalpy of LPT exhaust steam kCal/kg 585.7 619.3 2. Enthalpy of condenser at CEP kCal/kg 43.2 48.9 suction 3. Enthalpy of ex. Steam at HPH 5 I/L kCal/kg 799.2 807.4 4. Enthalpy of ex. Steam at HPH 6 I/L kCal/kg 733.0 730.2 5. Enthalpy of ex. Steam at HPH 7 I/L kCal/kg 754.6 776.4 6. Enthalpy of ex. Steam at LPH 1 I/L kCal/kg 615.9 640.1 7. Enthalpy of ex. Steam at LPH 2 I/L kCal/kg 675.4 670.3 8. Enthalpy of ex. Steam at LPH 3 I/L kCal/kg 709.7 713.4 9. Enthalpy of ex. Steam at LPH 4 I/L kCal/kg 756.9 774.7 Contd.
  • 27. SAMPLE CALCULATION SHEET FOR CONDENSER HEAT LOAD CALCULATION Steam parameters at salient points : S. Parameters Unit Design Value Unit Data No. 1. Extraction steam flow at HPH 5 T/hr. 16.4 22.8 2. Extraction steam flow at HPH 6 T/hr. 53.1 45.7 3. Extraction steam flow at HPH 7 T/hr. 28.6 47.3 4. Extraction steam flow at LPH 1 T/hr. 16.6 0.8 5. Extraction steam flow at LPH 2 T/hr. 31.2 31.7 6. Extraction steam flow at LPH 3 T/hr. 18.1 17.4 7. Extraction steam flow at LPH 4 T/hr. 25.3 28.3 8. Auxiliary steam flow T/hr. 17.0 17.0 9. HPT seal leakage T/hr. 12.0 12.0 10. HPT ESV leak off T/hr. 2.0 2.0 11. Ext. to deaerator T/hr. 4.0 4.0 12. LPT exhaust flow (calculated) T/hr. 436.7 501.1 13. Av. CW temperature rise 0 C 8.4 11.7 14. Condenser heat load kCal/kg 542.5 570.4 15. Condenser heat load × 1000 kCal/kg 236910 285831 16. CW flow (CMH) CW Flow = (Heat load / T/hr. 28203.5 24534.8 CW Temperature difference)
  • 28. SAMPLE CW PUMP DUTY ASSESSMENT Total diff. Head calculation : S. Item Reference Unit Design Unit No. Value Data 1. Fore bay level MSL 279.4 2. Fore bay to floor mWC 4.25 3. Bowl loss (Reference) mWC 0.20 4. Height of pressure gauge mWC 1.33 5. Discharge pressure mWC 21.8 – 22.00 22.6 6. Velocity head @ 1.89 m/s mWC 0.18 7. Total differential head mWC 27.96
  • 29. SAMPLE FLOW BALANCE OF CW PUMP BY MOTOR a) LOADING Power measurement by power analyser (Accuracy – Class-I (0.1 %) b) CW flow calculation based on power measurement S. Item Reference Unit Design Unit Data No. Value Pump-A Pump-B 1. Voltage (measured) V 6600 6681 6502 2. Current (measured) A 205 173.98 175.43 3. Power factor (measured) - 0.85 0.6418 0.675 4. Power input to motor kW 2000 1292 1334 5. Power input to pump kW 1221 1260 (@ 94.5% motor efficiency) 6. Average pump input power kW 1241 7. LKW (@ 87 % pump efficiency) 2 × 1130 2159 8. Total CW discharge flow CMH 32350 28332 9. Cooling water for Aux. (15 %) CMH 4850 4250 10. CW flow through condenser CMH 27500 24082 11. CW taken for HP/LP pumps CMH 410 570 12. CW going back to CT CMH 30000 27479 13. CW fans in service CMH 8 8 14. CW flow per cell CMH 3750 3435
  • 30. SAMPLE CT FAN DUTY ASSESSMENT Power Measurement by Power Analyser Accuracy Class-I (0.1 %) S. Item Reference Unit Design Unit Data No. Value 1. Voltage (measured) V 6600 6509 2. Current (measured) A 45.86 3. Motor power factor -- 0.8969 4. Motor efficiency (Ref.) -- 0.9 5. CT Xmer input power kW 603 417.33 6. Ct fan motor input power kW 67 52.16 7. CT fan flow per tower × 1000 Kg/hr 21229 19530 8. Air flow per cell × 1000 Kg/hr 2654 2441
  • 31. SAMPLE CT PERFORMANCE ASSESSMENT S. Design Unit No. Item Reference Unit Value Data 1. Water inlet temperature to CT 0 C 43 45 2. Water outlet temperature from 0 C 33 31.5 CT 3. Wet Bulb temperature @ CT 0 C 28.4 24.5 bottom 4. Dry bulb temperature ambient 0 C -- 32
  • 32. SAMPLE CT SYSTEM KEY INDICATORS S. Item Reference Unit Design Unit Data No. Value 1. CT range 0 C 10 13.5 2. CT approach 0 C 4.6 7 3. CT effectiveness 0.685 0.659 4. Water / Air ratio (L/G Ratio) 1.41 1.41 5. Air / Water Ratio (G/L Ratio) 0.71 0.71 6. Evaporation losses CMH 444 550 7. TDS PPM 174 174 8. C.O.C. 2.50 1.64 9. Makeup water CMH 296 859 10. Water consumption CMH 741 1408 11. % water consumption % 2.29 4.97
  • 33. SAMPLE OVERALL SYSTEM KEY INDICATORS S. Item Reference Unit Design Unit Data No. Value 1. Unit load MW 210 211 2. Frequency Hz 50.0 51.2 3. M.S. flow T/hr 651.3 730 4. F.W. flow T/hr 651.3 689 5. Total C.W. flow T/hr 32350 24535 6. C.W. flow thru condenser T/hr 27500 24535 7. Average CW temperature rise 0 C 8.4 11.7 8. Condenser heat load kCal/hr 236910 285831 × 1000 9. Terminal temperature difference 0 C 4.8 6.2 10. LMTD 0 C 8.30 11.04 11. Condenser vacuum Kg/sq.cm 0.911 0.871 12. CW pump pressure drop Meter 3.70 Not (across condenser) Measurabl e
  • 34. ILLUSTRATIVE COMPARISON : CONDENSER VACUUM AND CW FLOW CHARACTERISTICS Exhaust Design Value Actual Steam Actual CW Actual Condenser Hood Steam Flow to Flow to Condense Vacuum Tempera- Condenser Condenser r Heat ture Load Case T / Hr. T / Hr. kCal/hr T / Hr. 0 C 1. Reference 436.7 28203 236910 0.91 43.2 × 1000 2. Reference 440 27500 0.91 44 3. Reference 480 27500 0.91 45 4. Reference 480 25000 0.9 46 5. Reference 500 25000 0.9 46.1
  • 35. ILLUSTRATIVE COMPARISON : CW PUMP PERFORMANCE S. Item Reference Unit Design Unit No. Value Data 1. Average CW pump motor input kW 1335 1313 2. Average CW pump LKW kW 1130 1079.5 3. CW discharge flow CMH 32350 28332 (16175 CMH each Pump) 4. CW flow thro’ condenser CMH 27500 24082 5. CW flow per cell CMH 3750 3445 6. CT fans on line Nos. 8 8
  • 36. ILLUSTRATIVE COMPARISON : CT FAN PERFORMANCE S. Item Reference Unit Design Unit No. Value Data 1. Fan input power kW kW 67 52.17 2. CT fan air flow per tower Kg/hr × 21229 19530 1000 3. CT fan air flow per cell Kg/hr × 2654 2441 1000 4. CW flow per cell Kg/hr × 3750 3445 1000 5. Water/Air ratio (L/G ratio) 1.41 1.41 Dry air density Kg/M 3 1.0555 CT fans in operation No 8 (for design performance)
  • 37. ILLUSTRATIVE COMPARISON : COOLING TOWER PERFORMANCE DESIGN DATA HP KW CW FLOW 30,000 CMH FAN BHP 76.4 57.0 Hot Water Temp. 109.4 43 C MOTOR HP 90 67.1 F Cold Water Temp. 91.4 F 33 F Fan air flow 21229 kg/hr × 1000 Wet Bulb Temp. 83.1 F 28.4 C CT fans in 8 Nos. 22 F 12.2 C operation CT air flow / 2654 kg/hr × 1000 18 F 10 C cell 14 F 7.8 C Contd..
  • 38. ILLUSTRATIVE COMPARISON : COOLING TOWER PERFORMANCE DESIGN DATA Units Unit Item Reference Data CT Range 0 C 13.5 Wet bulb temperature 0 C 24.5 (measured) 76.1 F Cold water temperature 0 C 31.5 (measured) Cold water temperature 0 C 32.5 (design)
  • 39. ILLUSTRATIVE COMPARISON : COOLING TOWER PERFORMANCE CW FLOW (M 3 / Hr) S. Item Reference Design Unit No. Value Data A. By process parameters 28203 24535 B. By CW pump motor 27500 24082 loading C. By LMTD calculation 28728 24000
  • 40. SAMPLE SCAN OF CW PUMPS – ENERGY AUDIT OBSERVATIONS Eqpt. kW Drawn Flow Pressure (kg/cm2) Pumps (mmWc) for Fans Liquid kW Combined S.C.E Unit Ref. of Air kW Efficiency (%) (kWh/Ton) Motor Kw TPH Suction* Discharge Differential Loadin Gen. Freq. g% (MW) (Hz) Design Actual Design Actual Desi Actu Design Actual Desi Actual Design Actual Design Actual Design Actual gn al gn CWP – 1377 1021 15000 13295 0 0 2.5 1.90 2.5 1.90 1021 688.3 74.18 67.43 0.092 0.0768 74.24 189.6 47.91 1 CWP – 1377 1014 15000 13274 0 0 2.5 1.90 2.5 1.90 1021 687.2 74.18 67.76 0.092 0.0764 73.78 186.2 47.85 2 CWP – 1377 1018 15000 13422 0 0 2.5 1.90 2.5 1.90 1021 694.9 74.18 68.23 0.092 0.0759 74.07 191.6 48.36 3 CWP – 1377 1078 15000 13310 0 0 2.5 1.75 2.5 1.75 1021 634.7 74.18 58.89 0.092 0.0810 78.39 193.9 48.20 4 CWP – 1377 983 15000 13159 0 0 2.5 1.85 2.5 1.85 1021 663.4 74.18 67.50 0.092 0.0747 71.47 194.5 47.81 5 CWP – 1377 1104 15000 13197 0 0 2.5 1.80 2.5 1.80 1021 647.3 74.18 68.64 0.092 0.0838 80.28 194.1 47.90 6 CWP – 1377 1143 15000 13183 0 0 2.5 1.95 2.5 1.95 1021 700.5 74.18 61.31 0.092 0.0867 83.09 194.7 47.84 7
  • 41. CONCLUSIONS The audit conclusions are site specific and situation specific. The menu of recommendations substantiated adequately are most likely to include ;  Timely descaling of condensers  Ensuring adequacy of CW flow through condensers  Improving operational energy efficiency of CW pumps by maintenance or retrofit or replacement options  Tuning of CT operations for achieving best CT range, L/G ratio, approach for given loading, ambient conditions.  Water quality improvements and design COC improvements.  Debottlenecking of any O & M constraints  Fill replacement/replenishment in cooling towers  Improvements in instrumentation and MIS for enabling continuous efforts by O & M and O & E teams.