ENERGY AUDIT OF CONDENSER AND CONDENSER COOLING WATER SYSTEM

1
ENERGY AUDIT OF CONDENSER AND CONDENSER COOLING
WATER SYSTEM

• Presented By
• M.V.Pande
• Dy.Director
• NPTI, Nagpur

2
Background
Hot Water
CW Pump

• Condenser
• The condenser is the most important component of
  the turbine cycle that affects the turbine heat
  rate. The function of the condenser is to
  condense exhaust steam from the steam turbine by
  rejecting the heat of evaporation to the cooling
  water passing through the condenser. Generally,
  twin shell- double pass- surface type condensers
  are employed for higher capacity units

3
Background

• Cooling towers Different types of cooling towers
  are used in the power plants depending upon the
  location, size, infrastructure and water
  resources etc.
• Close cycle wet cooling systems
• -Induced draft
• Forced draft
• - Natural draft cooling towers

4
Background

• Cooling water pumps
• Circulating water pumps supply cooling water at
  the required flow rate and pressure to the power
  plant condenser and the plant auxiliary cooling
  water heat exchangers. These pumps are required
  to operate economically and reliably over the
  life of the plant.
• For once through systems, vertical wet pit pumps
  are in common usage.
• For re-circulating cooling systems, vertical wet
  pit and horizontal dry pit are used about
  equally, with occasional use of vertical dry pit
  pumps.

5
Specifications of Typical Cooling Water Pump
6
Steps Involved in Energy Audit

• The major energy consuming equipments in the CW
  systems are
• Cooling towers and fans
• Cooling water pumps
• Make up water pumps
• Condensers
• The steps involved in conducting energy audit of
  cooling water and cooling tower are
• Data collection
• Observations and Analysis
• Exploration for energy conservation measures
• Report preparation

7
Data Collection

• Specifications of cooling towers

8
Data Collection

• Specifications of cooling towers- contd

9
Specification of water pumps and motors

• Specification of water pumps and motors

10
Data Collection

• Specification of water pumps and motors- contd

Rated kW of the pump
11
Data Collection- Other Information

• Performance characteristics of all pumps and
  motors
• Compile design, P. G. Test, previous best and
  last energy audit value with respect to cooling
  tower and cooling water system along with the
  condensers
• If the pumps are operated in parallel then it is
  advised to collect the performance curve for the
  parallel operation
• Schematic diagram of Water pumping network (which
  depict the source, pumps in operation stand by,
  line sizes and users)
• Water and pressure equipments at the users as per
  the design requirements
• Brief description of the system with the key
  specifications in which pumps are used (for
  example, if pumps are used for supplying water to
  condenser, then add a brief write up about the
  cooling water system)

12
Data Collection- Condenser Specifications

• Heat load considered for design
• Design inlet cooling water temperature/ Design
  TTD
• Cleanliness factor/ Cooling water temperature
  raise
• Condenser back pressure
• Cooling water flow/ Cooling water side pressure
  drop
• No of cooling water pass/ Total heat transfer
  area
• No. of tubes - Condensing zone - Air cooling
  zone
• Tube dimensions - Tube OD x thickness - Length
  of tube
• Tube material - Condensing zone - Air cooling
  zone
• Water box design pressure

13
Instruments Required

• Power Analyzer Used for measuring electrical
  parameters of motors such as kW, kVA, pf, V, A
  and Hz
• Temperature Indicator Probe
• Pressure Gauge To measure operating pressure and
  pressure drop in the system
• Stroboscope To measure the speed of the driven
  equipment and motor
• Ultra sonic flow meter or online flow meter
• Sling hygrometer or digital hygrometer
• Anemometer
• In addition to the above calibrated online
  instruments can be used
• PH meter

14
Measurements Observation

• Energy consumption pattern of pumps and cooling
  tower fans
• Motor electrical parameters (kW, kVA, Pf, A, V,
  Hz, THD) for pumps and cooling tower fans
• Pump operating parameters to be
  measured/monitored for each pump are -
  Discharge, - Head (suction discharge) - Valve
  position Temperature - Load variation, Power
  parameters of pumps - Pumps operating hours and
  operating schedule
• Pressure drop in the system (between discharge
  and user point)
• Pressure drop and temperatures across the users
  (heat exchangers, condensers, etc)
• Cooling water flow rate to users - Pump /Motor
  speed
• Actual pressure at the user end
• User area pressure of operation and requirement

15
Measurements Observation

• Cooling tower parameters to be monitored
• Inlet temperature
• Outlet temperature
• Dry bulb temperature
• Wet bulb temperature or relative humidity
• Water flow to cooling tower
• Air flow rate of cooling tower
• Range, oC
• L/G ratio
• Approach, oC
• Fan speed, rpm
• Fan power consumption (kW/cell)

16
Observations and Analysis

• System familiarization and operational details
• Energy consumption Pattern

• The energy consumption of cooling water
  kWh/day and associated system
• Total auxiliary power consumption kWh/Day

17
Operating Efficiency and Performance Evaluation
of the Pumps

• Water flow rate and pressure of pumps / headers
• Velocity in the main headers and pumps and major
  lines (to verify adequacy of line sizes)
• Power consumption of pumps (for estimating the
  operating efficiency of the pumps)
• Monitor present flow control system and frequency
  of control valve variation if any (for
  application of variable speed drives)
• Fill up the following data sheet for every pump
  for comparison with the design / PG test values

18
Operating Efficiency and Performance Evaluation
of the Pumps
19
Operating Efficiency and Performance Evaluation
of the Pumps
20
Investigations Recommendations

• Compare the actual values with the design /
  performance test values if any deviation is
  found, investigate for the contributing factors
  and arrive at appropriate suggestions
• The investigations for abnormality are to be
  carried out for problems. Enlist scope of
  improvement with extensive physical checks /
  observations.
• Based on the actual operating parameters, enlist
  recommendations for action to be taken for
  improvement, if applicable such as
• Replacement of pumps/ Impeller replacement/
  trimming
• Variable speed drive application, etc
• Compare the specific energy consumption with
  similar type of pumps and latest energy efficient
  pumps
• Cost analysis with savings potential for taking
  improvement measures.

21
Flow Distribution

• Measure the flow at the individual pump discharge
  side, main header, at
• the users (for the major and large users) along
  with the pressure and
• velocity. Depict these values in schematic
  diagram
• Ensure Line adequacy by measuring the velocity in
  the major pipe lines
• Pressure drop in the distribution network
• Specific water flow rate

22
CONDENSERS
23
Performance of Condensers

• Parameters for condenser performance

24
Performance of Condensers

• Parameters for condenser performance- contd

25
Performance of Condensers

• The following needs to be computed
• 1. Condenser heat load Q x T x Cp

Parameter Details Unit
Q Water flow rate Kg/h
T Average CW temperature rise oC
Cp Specific heat kcal/kg oC
2. Calculated condenser vacuum
Atmospheric pressure Condenser back-pressure
3. Deviation in condenser vacuum
Expected condenser vacuum - Measured condenser
vacuum 4. Condenser TTD Saturation
temperature Cooling water outlet temperature
26
Performance of Condensers

• 5. Condenser Effectiveness
• Rise in cooling water
  temperature
• Saturation temperature - Cooling water inlet
  temperature
• 6. Condenser heat duty in kcal/h
• Heat added by main steam heat added by
  reheater heat added by SH attemperation heat
  added by RH attemperation heat added by BFP -
  860 x (Pgen Pgen losses heat loss due to
  radiation)
• 7. Condenser tube velocity (m/s)
• Cooling water flow rate (m3/h) x
  106
• 3600 x tube area (mm2) x ( no. of tubes per
  pass - no. of tubes plugged per pass )

27
Performance of Condensers

• 8. Determination of actual LMTD

9. LMTD expected LMTD test x ft x fw x fq
ft Correction for cooling water inlet temperature
0.25
(
Saturation Temperature during test LMTD during
test Saturation Temperature design LMTD
design
)
ft
fw correction for water flow rate
fq correction for cooling water heat load
28
Observations During Condenser Energy Audit

• Tubes in operation Vs total installed
• Cleaning system operation
• Filtering system for cooling water
• Regular monitoring system for performance
• Comparison of LMTD, TTD, heat load, condenser
  vacuum, flow, temperatures, pressures with design
  / PG test- arriving the factors causing deviation
• Modifications carried out in the recent past
• Cooling water flow
• Pressure drop on water side and choking
• Affect of present performance of cooling tower
• Accurate metering of vacuum
• Absolute back pressure deviation from expected
  value
• Sub cooling of air steam mixture and condensate
• Circulation water temperature raise
• Effectiveness of cleaning the tubes
• Circulating water velocity in tubes

29
COOLING TOWERS
30
Performance of Cooling Towers
31
Performance of Cooling Towers

• While conducting the cooling tower, visual
  observations need to be made with respect to
• Adequate water level in the trough
• Cross flow air from other cooling towers (which
  are under
• maintenance)
• Nozzle condition and operation
• Fill condition
• Change of blade angles during change of seasons
• The CT airflow shall be measured using an
  anemometer and compared with calculated airflow
  derived from fan characteristic curves of CT fans
  with actual power measurements.
• Calculate range, approach, L/G (Liquid to gas)
  ratio and effectiveness for design and operating
  conditions for each tower

32
Performance of Cooling Towers

• 1. C.T. Range Water inlet temperature Water
  outlet temp.
• 2. C.T. Approach Water outlet temperature Wet
  bulb temp.
• 3.

4.
5. Air mass flow / cell flow x density of air
33
Performance of Cooling Towers

• The above readings may be taken on daily basis
  for three days on different atmospheric
  conditions say during mid summer, winter
  monsoon period. Once in the mid day and once in
  the mid night time and a record duly maintained.
• Collect unit load (MW), frequency, and condenser
  vacuum condition while taking the cooling tower
  measurement

34
Performance of Cooling Towers

• Power consumption of CT fans

• Exploration of Energy Conservation Possibilities
• Condenser
• Possibility of Improvement in condenser vacuum
• Turbine heat rate Reduction possibilities
• Improving the effectiveness of condenser and
  TTD
• Cooling water flow adequacy and flow
  optimization
• Air ingress
• Increasing the TTD of the condenser
• Fouling of tubes

35
Exploration of Energy Conservation Possibilities

• Water pumping and cooling tower
• Improvement of systems and drives
• Use of energy efficient pumps
• Correcting inaccuracies of the Pump sizing /
  Trimming of impellers
• Use of high efficiency motors
• Integration of variable speed drives into pumps
  The integration of adjustable speed drives (VFD)
  into compressors could lead to energy efficiency
  improvements, depending on load characteristics
• High Performance Lubricants The low temperature
  fluidity and high temperature stability of high
  performance lubricants can increase energy
  efficiency by reducing frictional losses
• Improvements in condenser performance
• Improvement in cooling tower performance
• Application potential for energy efficient fans
  for cooling tower fans
• Measuring and tracking system performance

36
Exploration of Energy Conservation Possibilities

• Measuring water use and energy consumption is
  essential in determining whether changes in
  maintenance practices or investment in equipment
  could be cost effective
• In this case it is advised to monitor the water
  flow rate and condenser parameters, cooling tower
  parameters periodically i.e. at least once in a
  three months and energy consumption on daily
  basis. This will help in identifying the -
• - Deviations in water flow rates
• - Heat duty of condenser and cooling towers
• - Measures to up keep the performance

37
Exploration of Energy Conservation Possibilities

• System Effect Factors
• Equipment cannot perform at its optimum capacity
  if fans, pumps, and blowers have poor inlet and
  outlet conditions
• Correction of system effect factors (SEFs) can
  have a significant effect on performance and
  energy savings
• Elimination of cavitation Flow, pressure, and
  efficiency are reduced in pumps operating under
  cavitation. Performance can be restored to
  manufacturers specifications through
  modifications. This usually involves inlet
  alterations and may involve elevation of a supply
  tank

38
Exploration of Energy Conservation Possibilities

• Internal Running Clearances The internal running
  clearances between rotating and non-rotating
  elements strongly influence the turbo machine's
  ability to meet rated performance. Proper set-up
  reduces the amount of leakage (re-circulation)
  from the discharge to the suction side of the
  impeller
• Reducing work load of pumping Reducing of
  obstructions in the suction / delivery pipes
  thereby reduction in frictional losses. This
  includes removal of unnecessary valves of the
  system due to changes. Even system and layout
  changes may help in this including increased pipe
  diameter. Replacement of components deteriorated
  due to wear and tear during operation,
  modifications in piping system

39
THANK YOU