PERFORMANCE STUDY & ENHANCEMENT OF COOLING TOWER (PH#1) 2*70 MW POWER PLANT Project Work by

ABHISHEK SRIVASTAVA ANKUSH TOMAR DEEP CHATTERJEE NITIN PANDEY

PROJECT GUIDE
M.R.L. SHARMA(SR.MANAGER )

JINDAL STEEL & POWER LIMITED (C.G.)

CONTENT

PROJECT OBJECTIVE

ABOUT COOLING TOWER

STUDY OF DESIGN PARAMETER

DATA COLLECTION & ANALYSIS

COOLING TOWER LOSS STUDY

OVERALL

Project Objective
To meet design efficiency by applying necessary and corrective measures.

COOLING TOWERS

COMPONENTS OF A COOLING TOWER

Cooling tower supplied, erected & commissioned by Paharpur cooling tower in the year 2001

Frame and casing : RCC built counter flow cooling tower Fill : PVC Drift eliminators : Plastics Nozzles : PVC Fans : Glass reinforced polyester

COMPONENTS MAKE
COMPONENTS : MAKERS

GEAR BOX FAN MOTOR FAN

: GEARREDUCER - SERIES 36 & 38 : KIRLOSKAR : MARLEY COOLING TOWER CO.

CT-FAN

CT-MOTOR

FILLS

Induced Draft Counter Flow CT

Hot water enters at the top Air enters at the bottom and exits at the top Uses induced draft fan/s

STUDY OF DESIGN PARAMETERS

MEASURED PARAMETERS
Wet bulb temperature of air Dry bulb temperature of air Cooling tower inlet water temperature Cooling tower outlet water temperature Water flow rate

PERFORMANCE PARAMETERS
1. Range 2. Approach 3. Effectiveness 4. Evaporation 5. Cycles of concentration 6. Blow down

1. RANGE
Difference between cooling water inlet and outlet temperature: Range (C) = CW inlet temp CW outlet temp
Hot Water Temperature (In)

Range

(In) to the Tower (Out) from the Tower

Cold Water Temperature (Out)

Approach

Wet Bulb Temperature (Ambient)

2. APPROACH
Difference between cooling tower outlet cold water temperature and ambient wet bulb temperature: Approach (C) = CW outlet temp Wet bulb temp
Hot Water Temperature (In)

Range

(In) to the Tower (Out) from the Tower

Cold Water Temperature (Out)

Approach

Wet Bulb Temperature (Ambient)

3. EFFECTIVENESS

Effectiveness in % = Range / (Range + Approach) = (CW in temp CW out temp) (CW in temp Wet bulb temp) X 100

4. EVAPORATION
Water quantity (m3/hr) evaporated for cooling. = theoretically, 1.8 m3 for every 10,000,000 kcal heat rejected. (approx. value as the evaporation varies according to the atmospheric condition) = 0.00085 x 1.8 x circulation rate (m3/hr)x (T1-T2) T1-T2 = Temp. difference between inlet and outlet water

5. CYCLES OF CONCENTRATION (C.O.C.)

Ratio of dissolved solids in circulating water to the dissolved solids in make up water

6. BLOW DOWN
Evaporation Loss = (C.O.C. 1)

Data Collection

COOLING TOWER LOSSES STUDY

COOLING TOWER LOSSES STUDY

 COOLING TOWER RANGE = 8.60 COOLING TOWER APPROACH = 5.90 COOLING TOWER EFFICTIVENESS (%) RANGE/ (RANGE+APPROACH)x100 8.6/(8.6+5.90) x100 59.30 RATED COOLING TOWER EFFICTIVENESS (%) RANGE/ (RANGE+APPROACH) x100 10/(10+4) x100 71.42

 EVAPORATION IN M3/Hr 0.00085x1.8x CIRCULATION RATE(m3/h)x(O/L-I/L) 0.00085 x1.8 x12000 x8.60 158 m3/hr DESIGN EVAPORATION IN M3/Hr 0.00085x1.8x CIR. RATE (m3/hr)x(O/L-I/L) 0.00085 x1.8 x 13300 x 10 = 203.49 m3/hr

BLOW DOWN (ACTUAL ON FORMULA BASIS) EVAPORATION LOSS/(C.O.C.-1) 158/(6.66-1) =27.9 M3/Hr DESIGN BLOW DOWN 203.49/(10-1) = 22.95 M3/Hr BLOWDOWN IS SLIGHTLY MORE THAN DESIGN VALUE

MAKE UP WATER REQUIRED EVAPORATION LOSS + BLOW DOWN LOSS 158 + 27.90 =185.9 M3/Hr

OBSERVATIONS: LESS EVAPORATION THAN DESIGN VALUE 1. LACK OF COOLING HENCE AFFECTING THE RANGE. 2. LESS AIR FLOW THAN REQUIRED. 3. BLOCKED SPRAY NOZZLES. 4. SCALING / FOULING ON FILL PACKS.

HIGHER BLOW DOWN THAN DESIGN VALUE

1. WORKING PERSONNEL TAKING WATER

FROM COOLING TOWER SUMP FOR FILTER BACKWASH 2. SOMETIME TO MAINTAIN THE REQUIRED WATER CHEMISTRY & PH MORE BLOWDOWN REQUIRED

OVERALL.
(1) PERIODICAL CHECKING AND CLEANING OF ALL
(2) (3) (4) (5) SPARY NOZZLES. OPTIMISE COOLING TOWER BLADE ANGLE ON SEASONAL AND LOAD BASIS. DEFECTIVE DRIFT ELIMINATOR REPLACEMENT. DAMAGED COATED FILL PACK REPLACEMENT. CONSIDERATION SHOULD BE TAKEN IN ORDER TO MAINTAIN BALANCE BETWEEN AUXILLARY POWER COMSUMPTION & COOLING WATER TEMPERATURE. (6) MAINTAING WATER QUALITY PARAMETERS STRINGENTLY THERE BY MINIMIZING BLOWDOWN

THANKS