ct perf monitoring 31aug10

8/4/2019 CT Perf Monitoring 31Aug10

1/74

CenPEEP

Cooling Tower

Performance Monitoring &Improvement Aspects

Centre for Power Efficiency & EnvironmentalProtection

Centre for Power Efficiency & EnvironmentalCentre for Power Efficiency & EnvironmentalProtectionProtection

Partha NagSr. Manager (CenPEEP)


2/74

CenPEEPNTPC Coal Station

1 kcal//kWh Coal Saving

55,000 Tons

CO2 Reduction

68,750 Tons

Cost Reduction

Rs. 7.66 Crores

67 kcal//kWh

Improvement

1 % Eff.

Improvement

Coal Saving

36,85,000 Tons

CO2 Reduction

46,06,250 Tons

Installed Capacity 24400 MW, GCV 3500 kcal/kg ,

Coal Cost Rs 1400 per Ton, PLF 90%, FC 34%

Cost Reduction

Rs. 436.62 Crores

Prepared on 16thMarch, 2010

All data on annual basis

Same as above, Heat rate 2350 kcal/kWh

Per day Coal

Consumption

7,020 Tons

500 MW Unit Annual Coal

Consumption

25,62,300 Tons

Annual CoalCost Rs. 358.7

Crores

Annual CO2Production

32,02,875 Tons

Same as above, Specific coal consumption 0.65 kg/kWh

5 kcal//kWh

Improvement

500 MW Unit Coal Saving

5,635 Tons

CO2 Reduction

7,044 Tons

Cost Reduction

Rs. 0.785 Crores

Same as above

1 Million Ton CO2 ~ 2,74,000 Cars

You could check this directly using an electric kettle. Put in 1 liter of water

(1 Kilocalorie will heat this by 1 deg celsius) Note the kettle wattage, and

the cold water temperature, then note how many seconds to reach boiling

temp (100 celsius). The number of kilocalories is just the temperature rise

in degrees C, the number of Kwseconds is the wattage times the time to

reach boiling in seconds.


3/74

CenPEEP

Effect of Condenser Vacuum on Heat Rate

10 mmHg Improvement in CondenserVacuum Leads to 20 Kcal/ kw h Improvement

in Heat Rate for a 210 MW Unit


4/74

CenPEEP

Factors affecting Condenser Performance

Tube fouling

Air ingress into the system

High Condenser heat load

CW Inlet temperature

CW Flow

Condenser Performance Monitoring


5/74

CenPEEP

Cooling water system plays a vital role indissipation of waste heat in power station.

More than 60 % of total heat input to theplant is finally dissipated as waste heat. Thewaste heat from the power plant is carried

away by circulating water and ultimately getsdissipated in cooling tower.

Importance of Cooling Tower Performance

Monitoring

Cooling Tower Thermal Performance Testing


6/74

CenPEEP

Cooling Tower Heat Duty

For a 200 MW Unit : Cooling Tower Heat Duty is

equivalent to approx. 275 MW

For a 500 MW Unit : Cooling Tower Heat Duty isequivalent to approx. 700 MW


7/74

CenPEEP

Cold water temperature expected to improve by 2-3 deg

C by improving Tower performance

This will improve Condenser Vacuum by 6 9 mm Hg

Improvement in Heat Rate 12 18 kcal/kwh.

Reduction in fuel consumption of the order of11200 -

16800 tons per year for one 500 MW unit.

Annual savings of Rupees 9 - 13.5 million for one

500 MW unit.

Assumptions : PLF - 80%, GCV - 3750 kcal/kg, Coal cost - Rs. 800 per ton

Importance of Cooling Tower PerformanceMonitoring


8/74

CenPEEP

Test CodeTest Code Cooling Tower Institute (CTI) has issuedCooling Tower Institute (CTI) has issued

guidelines for carrying out the thermalguidelines for carrying out the thermal

performance test of cooling tow ers.performance test of cooling towers.

CTI ATCCTI ATC -- 105105



9/74

CenPEEP

Parameters to be Measured

Wet Bulb Temperature (WBT) at Tower inlet

Cold Water Temperature

Hot Water Temperature

CW Flow to each Tower

Fan Motor Power



10/74

CenPEEP

Acceptable Test Condit ions

CW Flow rate : 90 110% of Design

Cooling Range : 80 120% of Design

Wet-Bulb Temp : Design +/- 8.50 C

Fan Motor Power : 90 110% of Design

Average wind velocity : < 4.5 m/s



11/74

CenPEEP

Salient Terms Used in CT Testing

Approach

Difference between the Cold Water Temperatureat CT outlet and Inlet air Wet Bulb Temperature

Range

Difference between the Hot Water Temperature(inlet to CT) and Cold Water Temperature (outletof CT)

Cooling Tower Performance


12/74

CenPEEP

Salient Terms Used in CT Testing

Tower Capability

The most reliable means to assess the coolingtower thermal performance.

It is defined as the percentage of water thatthe tower can cool to the design cold water

temperature when the inlet wet-bulb, coolingrange, water flow rate and fan motor power areall at their design value.



13/74

CenPEEP

Tower Capability

Tower Capability in Percentage = Adjusted Test Flow RatePredicted Water Flow Rate

Adjusted Test = Measured flow x { Design KW of fans}0.333

Flow Rate { Test KW of Fans }

Predicted Water Flow Rate =Calculated from Manufacturergraphs and actual test conditions

i.e. WBT, Range and Cold watertemperature.



14/74

CenPEEP

Tower Capability = { QT } * { CellD } * { PD }.333

* 100

{ Qpred } { CellT } { PT }

Where :

QT = Measured water flow rate, t/hrQpred = Predicted water flow rate, t/hr

CellD = No. of cells for design water flow rate

CellT = No. of cells in operation during test

PD = Fan motor power design, kW

PT = Fan motor power measured, kW



15/74

CenPEEP

TEST VALUE UNITS

Average Hot Water Temperature T HOT WATER 46.30 C

Average Cold Water Temperature T COLD WATER 36.10 C

Average Inlet Air WBT T WBT 28.50 C

Average Wind Velocity V WIND 2.97 Meter / sec

Actual KW of Fans during Test (Average) PAct

36.59 kW

No. of Cells in Service during Test 18 No.

Design CT Flow (90 %) 26100 T/Hr



Design Cold Water Temperature (C) 32.00 C

Design Range of Cooling Tower (C) 11.00 C

Design Approach of Cooling Tower (C) 4.40 C

No. of Cells Design 18 No.

Design KW of Fans P Des 47.81 kW

CW Duct Inner Dia (ID) 0.60 meter

Pitot Constant 0.9928

DATA DERIVED FROM MANUFACTURERS CURVE

T COLD WATER - 90% 32.25

From CT [90%]

Characteristic curve


From CT [100%]



rom


27790.00 T/HrActual CW Flow

Expected Cold Water Temperature : 90%

Flow


Flow


Flow

TEST DATA

DESIGN DATA

PITOT CONSTANT DATA

CT Performance Test


16/74

CenPEEP

Variation Between CW Flow Vs Expected Cold WaterTemperature

y = 0.00022069x + 26.50333333

32.00

32.20

32.40

32.60

32.80

33.00

33.20

33.40

33.60

33.80

22000 24000 26000 28000 30000 32000 34000

CW Flow Rate [Tons/Hr]

Expected

ColdWater

Temperature[C]

CT Performance Test


17/74

CenPEEPFIELD TEST PARAMETERS UNITS TEST VALUE

Average Hot Water Temperature C 46.30

Average Cold Water Temperature C 36.10Average Inlet Air WBT C 28.50

Average Wind Velocity m/sec 2.97

COMPUTATION OF EXPECTED COLD WATER TEMPERATURE

Average Inlet Air WBT C 28.50

Average CW Cooling Range C 10.20

Expected Cold Water Temperature : 90% Flow C 32.25



Expected Cold Water Temp: Actual Flow C 32.64

CORRECTION IN EXPECTED COLD WATER TEMPERATURE DUE TO WIND

Correction factor due to Wind Velovity C 0.31

Expected Cold Water Temp C 32.95

RESULTS DESIGN EXPECTED ACTUAL

Cold Water Temperature (C) 32.00 32.95 36.10

Cooling Range of Cooling Tower (C) 11.00 13.35 10.20

Approach of Cooling Tower (C) 4.40 4.45 7.60

Cooling Tower Effectiveness (%) 71.43 75.02 57.30

No. of Cells Design 18No. of Cells in Service during Test 18

Measured CW Flow (T/Hr) Q Meas 27790.00

Predicted CW Flow corres.to Test Cold Water Temp. Q Pred. 43484.83

Design KW of Fans P Des 47.81

Actual KW of Fans during Test (Average) PAct

36.59

Adjusted CW Flow (T/Hr) Q Adj 30378.66

Tower Capability % 69.86

TOWER CAPABILITY

CT Performance Test


18/74

CenPEEP

80.0480.0487.1387.13100100CapabilityCapability

64.464.463.2263.22Effectiveness (EXP)Effectiveness (EXP)

55.5955.59

57.457.4

73.6273.62

EffectivenessEffectiveness

(Actual)(Actual)

7.427.426.816.814.34.3ApproachApproach

9.299.299.189.181212RangeRange

43.8443.8445.6545.6547.8147.81Fan PowerFan Power

(Average)(Average)

251525152520252022222222CW FlowCW Flow

24.4224.4224.5224.5227.727.7WBTWBT

41.1341.1340.5140.514444HWTHWT

31.8431.8431.3331.333232CWTCWT

CT Cell (17mmCT Cell (17mm

flute)flute)CT Cell (19mmCT Cell (19mm

flute)flute)DesignDesign

CT Performance Test


19/74

CenPEEP

Design and Test dataDesign and Test data

DescriptionDescription UnitUnit DesignDesign PredictedPredicted ActualActual

FlowFlow m3/ hr 40,000 53,333m3/ hr 40,000 53,333 44,18944,189

Hot waterHot water Deg CDeg C 4444 -- 41.141.1

Cold waterCold water Deg.CDeg.C 3232 30.4930.49 31.631.6

Wet BulbWet Bulb Deg.CDeg.C 27.727.7 -- 24.624.6ApproachApproach Deg.CDeg.C 4.34.3 5.895.89 7.07.0

RangeRange Deg.CDeg.C 1212 10.6110.61 9.59.5

Fan PowerFan Pow er KWKW 47.8147.81 47.8147.81 44.1744.17

Effectiveness %Effectiveness % 73.6273.62 64.3264.32 57.5857.58

CapabilityCapability %% 100100 -- 85.0585.05



20/74

CenPEEP

Performance Analysis

CT degradation to be assessed based onCapability test

Deviation to be derived from actualtemperature and predicted cold watertemperature



21/74

CenPEEP

Fill cloggingFill clogging

Increase in weight of 2Increase in weight of 2--3 times3 times

Deposition in the fills comes fromDeposition in the fills comes from

the turbidity of make up waterthe turbidity of make up water

air borne dust from the atmospheric airair borne dust from the atmospheric airbeing drawn into the cooling towerbeing drawn into the cooling tower

precipitates of dissolved silicaprecipitates of dissolved silica

Causes for Performance Deterioration


22/74

CenPEEP

Damage of fills.Damage of fills.

Chocking of nozzle.Chocking of nozzle.

Falling of nozzle.Falling of nozzle.

Damage of splash bars.Damage of splash bars.

Algae formation on splash barsAlgae formation on splash bars Damaged drift eliminatorsDamaged drift eliminators

Unequal water flow in different cells.Unequal water flow in different cells.

Recirculation of vaporsRecirculation of vapors

Poor air flow due to less blade angle.Poor air flow due to less blade angle.



23/74

CenPEEP

Hot water distribution pipe damageHot water distribution pipe damage

Annular clearance between distribution pipeAnnular clearance between distribution pipe

and hot water channeland hot water channel Growth of trees/plants/bushes near coolingGrowth of trees/plants/bushes near cooling

towertower

Overflow of cold water basin.Overflow of cold water basin. Improper quality of waterImproper quality of water

Control of COCControl of COC

Control of TurbidityControl of Turbidity

Rain/any other water entering in openRain/any other water entering in openchannelchannel



24/74

CenPEEP

Maintaining proper L/G ratioMaintaining proper L/G ratio Equal water distribution between the cellsEqual water distribution between the cells

Visual inspection of pipes, nozzles, fills, etc., forVisual inspection of pipes, nozzles, fills, etc., forproper water distribution.proper water distribution.

Increasing the air flowIncreasing the air flow

By increasing blade angle to obtain max allowableBy increasing blade angle to obtain max allowableloading of fansloading of fans By plugging all air path that do not pass through the fillBy plugging all air path that do not pass through the fill

zonezone

i Sealing shaft hole of fan.i Sealing shaft hole of fan.

ii Sealing door openings of fan chamber.ii Sealing door openings of fan chamber.

iii Sealing the fan hub area.iii Sealing the fan hub area.

iv Maintaining blade tip clearancesiv Maintaining blade tip clearances

v Reducing drift handled by fanv Reducing drift handled by fan

Optimizing Cooling Tower Performance


25/74

CenPEEP

Cleaning of fills with water jetsCleaning of fills with water jets

Cleaning of fills manually by removingCleaning of fills manually by removingfrom towerfrom tower

Cleaning of cold water basin duringCleaning of cold water basin during

overhauls.overhauls.

Regular cleaning/checking of nozzles.Regular cleaning/checking of nozzles.

Continuous Chlorination & Shock dozingContinuous Chlorination & Shock dozingto maintain required FRCto maintain required FRC

Optimizing Cooling Tower Performance


26/74

CenPEEP

CT# 7A CT# 7B CT# 8A CT# 8B CT# 7A CT# 7B CT# 8A CT# 8B

Unit Load 500 510 510 510 510 512 512 509 509

No.of Cells in service [Ns]---

8 8 8 8 8 8 8 8

Hot basin temp. 42.5 45.8 45.7 46 46.4 42.5 42.9 43.2 42.6

Cold basin temp. 32 37.4 35.6 37.3 35.6 32.6 32.4 32.4 32.1

Cooling Range [(4)-(5)] 10.5 8.4 10.1 8.7 10.8 9.9 10.5 10.8 10.5

Dry Bulb Temp.--- 30.5 31.2 31.3 30.8 30.7 31.4 31.1 31.2

Wet Bulb Temp. 27.4 27.8 26.8 27.3 26.6 27.8 27.6 27.1 27

Approach [(5)-(8)] 4.6 9.6 8.8 10 9 4.8 4.8 5.3 5.1

Effectiveness [(6) / (6) +

(9)] 69.5 46.7 53.4 46.5 54.5 67.3 68.6 67.1 67.3

CW Flow (As measured)

[Qa]

30000 29215 29666 29541 28862

Predicted cold Water

Temp [Qp]

32 31.6 31.5 31.3 31.6 31.9 32.1 31.8 31.5

Shortfall in Cold Water

Temp.

0.0 5.8 4.1 6.0 4.0 0.7 0.3 0.6 0.6

Before CT Fill Cleaning (Aug 2005) After CT Fill Cleaning (Jul 2007)Parameters Design

Predicted Cold Water Temp

calculated at 100% flow

Remarks : Fill cleaning started in Jan 2006 and completed in May 2007.

Improvement due to Fill cleaning/replacement


27/74

CenPEEP

Fill used (New)

Paharpur (4 X 4 X 1)-17mm flute Cells 7A1 (Part), 7A3 (Full), 7A4(part)

Kooldag (4 X 1 X 1)-19mm flute Cells 7A6 (Full), 8A6 (Full)Kooldag (4 X 2 X 1)-19mm flute Cells 7A7 (Full), 7A8 (Full)

Cells 7B3 (Full), 7B4 (Full), 7B5 (Full), 7B6 (Full), 7B8 (Full), 7B9 (Full)Cells 8A9 (Full), 8B9 (Full)

In rest of the cells original fill packs were cleaned and reused.

Brief of Fill cleaning / replacement :

Improvement due to Fill cleaning/replacement


28/74

CenPEEP

For better performance of cooling tower L/G ratio

should be uniform all across the tower.

Cooling Tower Thermal Performance Testing to bedone minimum 30 days after installation of new fills.

Increasing Fan stack height helps in reducing Fanpower consumption. Stack height can be increased

upto 18 feet.

Increasing Fan stack height also helps in reducingvapor recirculation

Best Practices on Cooling Tower


29/74

CenPEEP

FRP blades are efficient than Metallic blades and reducespower consumption.

When replacing Metallic blades with FRP blades assessmentof air flow to be carried out.

To reduce recirculation of air inside the stack- Blade tip clearance with stack to be minimum possible.- Arrangement of Seal disc at the middle of Fan hub.Without seal disc arrangement air flow may be reducedby 15%.

Calibration of Pitot tube for CW flow measurement to be doneat every two years as per CTI

WBT and DBT measurement to be carried out within 5 feet of

air intake and at different heights.

Best Practices on Cooling Tower


30/74

CenPEEP

Study of variation in CT Fan power and air flow dueStudy of variation in CT Fan power and air flow due

to change in Liquid/Gas ratioto change in Liquid/Gas ratio

Study of variation in CT performance due to changeStudy of variation in CT performance due to change

in Liquid/Gas ratioin Liquid/Gas ratio

Study on Effect of L/G ratio on CTStudy on Effect of L/G ratio on CT

Thermal PerformanceThermal PerformanceObjective of the Study


31/74

CenPEEP

Liquid/Gas Ratio (L = water; G = air), of a cooling tower isLiquid/Gas Ratio (L = water; G = air), of a cooling tower is

the ratio between the water and air mass flow ratesthe ratio between the water and air mass flow rates Low L/G ratio indicates that cooling tower is under utilized.Low L/G ratio indicates that cooling tower is under utilized.

High L/G ratio indicates availability of less air for actualHigh L/G ratio indicates availability of less air for actualcooling water flowcooling water flow

CT Characteristic (CT Characteristic (KaVKaV/L) is dependent on designed L/G/L) is dependent on designed L/Gratioratio

Heat removed from the water must be equal to the heatHeat removed from the water must be equal to the heatabsorbed by the surrounding airabsorbed by the surrounding air

Effect of L/G ratioEffect of L/G ratio on CT Thermal PerformanceEffect of L/G ratio on CT Thermal Performance

C PEEP


32/74

CenPEEP

3 hole3 hole pitotpitot tube for CW flow measurementstube for CW flow measurements

24 no calibrated thermocouples24 no calibrated thermocouples alongwithalongwith data loggersdata loggersfor cold water temperature measurementfor cold water temperature measurement

One no. calibrated Battery operatedOne no. calibrated Battery operated psychrometerpsychrometer forforWBT measurementsWBT measurements

Two nos. calibrated thermometers for DBTTwo nos. calibrated thermometers for DBT

measurementsmeasurements One no. calibrated thermocouple for WBT & DBTOne no. calibrated thermocouple for WBT & DBT

measurement of exit airmeasurement of exit air

One Power analyzer for power measurements of CT fansOne Power analyzer for power measurements of CT fans

One no. calibrated thermocouple for hot waterOne no. calibrated thermocouple for hot watertemperature measurementtemperature measurement

Two nos. anemometer (with a read out and 6 M cableTwo nos. anemometer (with a read out and 6 M cablelength)length)

Instrument Used

Effect of L/G ratio on CT Thermal PerformanceEffect of L/G ratio on CT Thermal Performance

C PEEP


33/74

CenPEEP

Findings of the Study

42.442.480.480.41.601.601010111144

38.938.977.877.81.661.6699111133

44.344.379.879.81.511.511010131322

40.340.377.177.11.561.5699131311

Fan PowerFan Power

ConsumConsum

ptionption

kWkW

CellCell

CapabiliCapabili

tyty

%%

L/G Ratio (WaterL/G Ratio (Water

flow / Airflow / Air

Flow )Flow )

Fan BladeFan Blade

AngleAngle

CellCell

NoNo

..

Sr.Sr.

NN

o.o.


C PEEP


34/74

CenPEEP

Findings of the Study

Measured L/G ratio was higher than the design L/G ratio ofMeasured L/G ratio was higher than the design L/G ratio of1.441.44

CT fan air flow and power consumption varied proportionatelyCT fan air flow and power consumption varied proportionatelywith change in blade anglewith change in blade angle

The test indicates that by changing the L/G ratio ( increasing tThe test indicates that by changing the L/G ratio ( increasing thehefan blade angle by 1fan blade angle by 1 ) , the effectiveness of cell varied by more) , the effectiveness of cell varied by morethan 1%than 1%

Cooling tower capability varied by more thanCooling tower capability varied by more than 2.5 %2.5 % withwith

change in L/G ratiochange in L/G ratio Higher capability observed with low L/G ratio i.e. high air flowHigher capability observed with low L/G ratio i.e. high air flow

for same CW flowfor same CW flow



35/74

CenPEEP


36/74

CenPEEP

Improvement in HR byImprovement in HR by 2 kcal/2 kcal/kwhkwh is equivalent tois equivalent to

improvement in unit load by aroundimprovement in unit load by around 205205 KwKw (for a(for atypical 200 MW unit)typical 200 MW unit)

Improvement in HR byImprovement in HR by 2 kcal/2 kcal/kwhkwh is equivalent tois equivalent to

annual savings of aroundannual savings of around 1111 lacslacs (for a typical 200(for a typical 200MW unit)MW unit)

Observations of the Study


CenPEEP


37/74

CenPEEP

Fan blade angle vs Air flow

CT Cell 11

109

1504

1447

0

500

10001500

2000

1 2 3

Blade Angle

Air Flow TPH

L/G Ratio vs Capability

CTCell 11

1.60

1.66

77.8

80.4

1.5601.5801.6001.6201.6401.660

1.680

1 2 3

76

77

78

7980

81L/G Ratio

( Water flow /

Air Flow )

Cell Capability

Fan blade angle vs Power

Consumption

CT Cell 13

10

44.3

9

40.3

0

20

40

60

1 2 3

Blade Angle

Power

Consumption

Fan blade angle vs power

consumption,

CT Cell 11

109

42.438.9

0

10

20

30

40

50

1 2 3

Blade

Angle

Pow er

Consumpti

on


CenPEEP


38/74

CenPEEP

CenPEEP


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CenPEEP

Test Setup

WBT Measurement Done on both sides of the tower at air inlet path

using Psychrometers.

The instrument shall be located within 1.5 M of the

air intake.

The number of stations for inlet wet bulb

temperature measurement depends on the size and

layout of the cooling tower. For a typical 500 MWunit having 2 cooling towers, there can be 16

locations per cooling tower (8 on each side) for an

accurate measurement of wet bulb temperature


CenPEEP


40/74

CenPEEP

Location Of Inlet Wet Bulb Temperature for Station with Counter Flow TowerCooling Tower Thermal Performance Testing

L L

L < 2 Meters, X Measurement Station.

CenPEEP


41/74

CenPEEP

Location Of Inlet Wet Bulb Temperature for Station with Cross Flow Tower


L < 2 Meters, X Measurement Station.

LL

CenPEEP


42/74

CenPEEP

Wet Bulb Temp. measurement setup


CenPEEP


43/74

CenPEEP

Test Setup

Cold Water Temperature Measurement

The recooled water temperature can be measured

directly at the point where the circulating water is

discharged from the basin.

The temperature measurement instruments shall be

located where the water will be thoroughly mixed.

It is better to have a grid arrangement in the

channel for cold water measurement.


CenPEEP


44/74

CenPEEP

CenPEEPCooling Tower Thermal Performance Testing


45/74

CenPEEP

Grid setup for Cold Water Temp. measurement


CenPEEP


46/74

Grid setup for Cold Water Temp. measurement of single cell


CenPEEP


47/74

Grid setup for Cold Water Temp. measurement of single cell


CenPEEP


48/74

Grid Measurement for Cold Water Temperature for one Cell

Grid of 48 probes

CenPEEP


49/74

Test Setup

Hot water temperature measurement

At the tower risers or at the discharge of the inlet

risers

Fan Power Measurement

At the individual fan switch gear


CenPEEP


50/74

CW Flow Measurement CW flow Measurement using Pitot Traverse

Pitot traverse is done in two planes i.e. vertical andhorizontal at 90 degrees to each other.

CW flow Q = dp0.5 (504.4883 x C x A) t/hr

Where

Q = CW Flow in t/hr

dp = average dp measured in mmwcl

C = Pitot coefficient

A = Area of duct in m2

CenPEEP


51/74

CW Flow Measurement

CenPEEPCW Flow Measurement


52/74

CW Flow Measurement

CenPEEPCW Flow Measurement


53/74

CenPEEPOn line CW Flow Monitoring using Elbow Tap dp


54/74

Elbow Tap ArrangementElbow Tap Arrangement

Circulating

WaterElbowDP

Out

let

WB

Cond

enser

Measurement of CW flow using Pitot traverse and calibratingElbow Tap dp for on-line monitoring.

Benefits On-line measurement of CW flow available

in control room

Helps in assessing Condenser performance

On-line CW Flow Monitoring using Elbow Tap dp

Pitot Traverse at CW outlet duct

Elbow Tap

CW outlet duct

CenPEEPOn-line CW Flow Monitoring using Elbow Tap dp


55/74

165400525107.5257.5500-dP atcondenser

end (mmWC)

Elbow TapMethod

45326132781959357063960412500CW Flow atCondenser

Outlet (t/hr)

450450450450450450450ACW Flow(t/hr)

498265828269638575131005412950MeasuredFlow at CT

end (t/hr)

using 3-hole

Pitot

Reduced Flow (CW

outlet valve

throttled)

Reduced

Flow (CW

outlet

valve

throttled)

Full Flow(WB

Valves open)

Reduced

Flow (CW

outlet valve

throttled)

Reduced Flow

(CW outlet

valve

throttled)

Full Flow(WB

Valves open)

One CW PP runningTwo CW PPsrunningOne CW PP runningTWO CW PPrunning

CW Pass II (RHS-CT-2 side)CW Pass I (LHS-Road side)Design

Flow

T/Hr

328.56431.59Constant K value

2022.9116.04622.36SQRT of dP

400525257.5500Elbow tap dP ( mmwcl)

6132781970639604CW Flow at Condenser

Outlet (t/hr)

CW Pass II (RHS-CT-2

side)

CW Pass I (LHS-

Road side)

Y= 431.59*X

For LHSFor LHS

Y= 328.56*X

For RHS



56/74

90% Flow; Cold Water vs. Wet Bulb

27.0

28.029.030.031.032.033.034.0

35.036.037.0

23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0

Wet Bulb (C)

COLDWAT

ER

TEMPERATU

REC

C-8.8C B-11.0C A- 13.25C




57/74


28.0

29.030.0

31.0

32.033.034.0

35.036.0

37.0

23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0

Wet Bulb (C)

COLDWATER

TEMPERATUREC

C-8.8C B-11.0C A- 13.25C




58/74

110 % Flow; Cold Water vs. Wet Bulb

28.0

29.030.031.032.0

33.034.0

35.036.037.0

23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0

Wet Bulb (C)

COLDWAT

ER

TEMPERATU

REC

C-8.8C B-11.0C A- 13.25C




59/74


27.028.029.030.031.032.033.034.035.036.037.0

23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0

Wet Bulb (C)

COLDWATER

TEMPERAT

UREC

C-8.8C B-11.0C A- 13.25C


Test WBT 25.7 C



60/74

Cold Water vs. Cooling Range

29.4

29.6

29.8

30.0

30.230.4

30.6

30.8

8.0 9.0 10.0 11.0 12.0 13.0 14.0

COOLING RANGE (C)

COLDWATER

TEMPERATUR

E(C)

90% Flow




61/74

Cold Water vs. Cooling Range

29.0

29.5

30.0

30.5

31.0

31.5

32.0

8.0 9.0 10.0 11.0 12.0 13.0 14.0

COOLING RANGE (C)

COLD

WATERTEMPERATURE

(C)

90% Flow 100% Flow 110% Flow Test Range


Test Cooling Range 10.1 C



62/74

Cold Water vs. Predicted Flow

29.6

29.8

30.0

30.2

30.4

30.6

30.8

80 85 90 95 100 105 110 115

Predicted Flow (%)

COLDWATER

TEMPERATURE

(C)


Test Cold Water Temp 35.9 C



63/74

Cold Water vs. Predicted Flow

25.0

27.0

29.0

31.0

33.0

35.0

37.0

25,000 35,000 45,000 55,000 65,000 75,000 85,000

Predicted Flow (t/hr)

COLDW

ATERTEMPER

ATURE

(C)

Cooling owe he mal e fo mance esting

Test Cold Water Temp 35.9 C

Predicted Flow 77,000 t/hr, Actual Flow - 30,977 t/hr

CenPEEPDEPOSITS IN FILLDEPOSITS IN FILL


64/74

CenPEEPFalling of Nozzles


65/74

Falling of Nozzles


66/74

CenPEEPUnequal Water Distribution


67/74

U equa ate st but o

CenPEEPRecirculation of vapors


68/74

p

CenPEEPRain Water Entering Cold Water BasinRain Water Entering Cold Water Basin


69/74

CenPEEPAIR PASSAGE THROUGH SHAFT OPENINGAIR PASSAGE THROUGH SHAFT OPENING


70/74

CenPEEP


71/74

SEALING OF AIR PASSAGE THROUGH SHAFT OPENINGSEALING OF AIR PASSAGE THROUGH SHAFT OPENING

CenPEEPSEALING FAN HUB AREASEALING FAN HUB AREA


72/74

CenPEEPSEALING FAN HUB AREASEALING FAN HUB AREA


73/74

CenPEEPONLINE FILL CLEANING RIHANDONLINE FILL CLEANING RIHAND


74/74

ct perf monitoring 31aug10

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