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COOLING TOWER
Venue :POWER MANAGEMENT INSTITUTE
28 -30-JULY 2008
by
T.P.Chandrawanshi
DGM(OS-BoP)
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- • Cooling tower is the most important equipment for closed
cycle water recirculation system.• The efficiency of cooling tower has direct effect on,
station.
• 1oC rise in cold water temperature in a 200MW unit
Rs 50-60 lakhs of loss per annum in terms of direct fuelcost.
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-
•
monitoring and its proper operation andmaintenance is ver im ortant for theefficient and economic running of the
plant.• At present about 96 cooling towers are in
operation in NTPC and if only 1 deg. Cent.
mprovemen n co wa er can savecrores of rupees.
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TYPES of TOWERS in NTPC
• NATURAL DRAUGHT
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Scheme Of O en Recirculatin T e
C.W.System
CONDENSER
BLOW
DOWN
.
HstaticCOOLING
TOWER
C.W.SUMP
-
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cooling tower.exe
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IDCT Counter Flow
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NATURAL DRAFT COOLING TOWERS (4 X 210 MW)
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- Total 102 cooling towers installed as given below in
Induced Draught Cooling Towers
• Cross flow type 24
• Counter flow splash bar fill type 24
• Counter flow film fill type 44
Natural Draught Cooling Towers
.(Splash type 8 and Film type 4)
•
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COOLING PRINCIPLE
•HOT WATER IS COOLED IN A COOLINGTOWER IN CONTACT WITH COLD AIR
DUE TO:EVAPORATION ABOUT 75%
BY MASS TRANSFER
•SENSIBLE HEAT TRANSFER ABOUT 25%
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COOLING PRINCIPLE
MASS TRANSFER IS DUE TOFLOW OF WATER VAPOUR FROM
THE HOT WATER TO THE COLD AIR DEPENDING ON WET BULB
AIR.
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COOLING PRINCIPLE
INCREASES AS THE WET BULBTEMPERATURE INCREASES.
• THE FILL WITHIN THE COOLING TOWER IS
THE CRITICAL THERMAL COMPONENT. INWET COOLING TOWERS IT IS THE MEDIUMOVER WHICH THE HOT WATER IS
.PRIMARY FUNCTION IS TO PROVIDE AN
TRANSFER .
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FILL IS REQUIRED IN A COOLING TOWER
TO CREATE LARGE SURFACE AREA WHICHPROVIDES NECESSARY TIME OF
CONTACT BETWEEN AIR AND WATER
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TYPES OF FILLS
SPLASH TYPE CONSISTING OF SPLASHBARS USED FOR CROSSFLOW AND
COUNTERFLOW.
• FILM TYPE CONSISTING OF THIN
SHEETS USED MOSTLY FOR
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SPLASH FILLS
IN SPLASH FILL, THE HOT WATER STRIKES OVER THE BARS AND BREAKSUP INTO MANY SMALLER DROPS.
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TYPES OF SPLASH FILLS USED IN NTPC
PROJECTS
• RCC BARS
• PVC PERFORATED V-SHAPED BAR
• PP GRID
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TYPES OF SPLASH FILLS
RCC BARS
SPLASH FILL
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TYPES OF SPLASH FILLS
PVC PERFORATED V-SHAPED BAR
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FILM FILLS
FILM FILL CONSISTS OF FLAT OR FORMED
WHICH WATER AND AIR COME IN CONTACT
STRETCHES DROPLETS OF WATER INTO A
THIN FILMS AS THE WATER PROCEEDS VERTICALLY DOWNWARD THROUGH THECELLS, THEREBY MAXIMIZING THE
SURFACE AREA AND PERMITTING THE AVAILABLE CROSSFLOW OR COUNTERFLOW AIR TO COOL THE ENTIRE MORE RAPIDLY
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FILM FILLS
FILM FILL CREATES A VERY LARGE
WATER DISPERSES ITSELF AS A THIN
TRAVELING THROUGH THE TOWER,
COOLING. FILM FILL IS MORE COMPACTTHAN SPLASH FILL AND CAN THEREBY BE MORE COST EFFECTIVE.
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CW PUMPING HEAD REQUIREMENTSFOR DIFF. TOWERS
•ND-SPLASH : 14 M
• ND-FILM : 10 M
• ID- SPLASH : 13 M
• ID-FILL : 9 M
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• EFFECT OF FILL HEIGHT IN CT DESIGN
IF HEIGHT IS RESTRICTED TO APARTICULAR VALUE AIR FLOW IS TO BEINCREASED WHICH REQUIRES HIGHER
POWER CONSUMPTION. OTHERWISEPLAN AREA TO MAINTAIN FILL VOLUMEIS TO BE INCREASED WHICH CALLS FOR
.
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•
NEW FILM FILLS HELP REDUCE OR ELIMINATE THE PROBLEM. GENERALLY,
AND THE CORRUGATIONS TEND TO BE.
VELOCITY APPEARS TO BE SIGNIFICANT IN
THE FILL SURFACE.
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C f CT P P f
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Cause of CT Poor Performance
6. Chocking of nozzle by OLTC balls.
. .
8. Hot water distribution pipe.
9. Fill clogging
. e .
11.Lot of trees/plants/bushes growth near
12.Poor quality of water (make-up)
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Optimizing CT Performance
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Optimizing CT Performance.
• Cleaning of civil structure annually and removal of algae from DE,Fills.
• Fan door and an other air in ress oint to be sealed.
• Regular condition monitoring of CT fans.
• Continuous chlorine dosing to be done.• Sludge disposal pump to be run once in a day minimum for 15
m nu es.
• Monthly checking of effectiveness of tower for comparisonpurpose and once checking of perf. during mansion as per OGN.
•about 1.5 meter height and both side about 2 meter wide brickpaving to be done to avoid any plant growth
• At CT outlet screen to be provided to remove any debris, plastic.
• To protect OLTC balls and any other material going to nozzles;nozzle protector to be provided which is a hollow steel pipeinserted into H.W.D. pipe with wire mesh.
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• Fill clo in and su ort structure failure
• Sagging of PVC Drift Eliminators in counter flowtype: It has no support in between.
• ACB hot water distribution pipe failure.
• Growth of trees/bushes/plants near CT after c ean ng aga n an aga n.
• Civil structure reinforced steel exposed
o a mosp ere.• Algae growth in CT structure.
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Best Practices in NTPC
• Quarterly film fill pack weight is taken to know the clogging status
during PM (Rihand, Sipat)
• All around CW-OAC, brick paving is done for about 4 meter and
nylon net is placed over to avoid growth of plants near POAC andfalling of suspended particle in OAC.
• At CT outlet screen is provided to remove any debris, plastic pieces
falling into the cold water basin.(Kh, TTPS)
• Civil structure is cleaned by bleaching powder during PM to keep itfree from algae (Rihand)
• To arrest the OLTC balls from going to nozzles, nozzle protector
sleeve with mesh is provided in hot water distribution pipes (RSTPP)
• CW duct cleaning and painting done in all 6 units of ST-I (VSTPP)
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Algae Growth in the Intake Channel
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Algae Growth in the Intake Channel
at Jhanor Gandhar
Al ae rowth
View of Chocked & clean PVC fills
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e o C oc ed & c ea C s
Chocked PVC Fills
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Deposited dust
articles
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Deposited
dust articles
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Clogging Of Fill Packs-TSTPS-II
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gg g
Clogged Fills
PVC fill pack sagging-TSTPS-II
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PVC fill pack sagging-TSTPS-IIxcess ve we ginitiating bending
of SS Supports
Sagging of SS supports of PVC fills
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Sagging of SS supports of PVC fills
at TSTPS-II
PVC Fills resting on RCC beams after
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PVC Fills resting on RCC beams after
sagging at TSTPS-II
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Hub Seal Disctte tg-
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PVC Fills resting on RCC beams
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& temporary supports given
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Hub Seal Disctte tg-
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To be sealed
properly
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