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NTG Concrete Cool
Shenzhen Newin Machinery
Low Operation Cost, Excellent
Performance, Easy Maintenan
Saving
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ENERGY AUDIT OF CONDENSER
CONDENSER COOLING WATER SYSTEM
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CONDENSER
COOLING
WATER
SYSTEM"—
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1
ENERGY AUDIT OF CONDENSER AND CONDENSER COOLING
WATER SYSTEM
Presented By
M.V.Pande
Dy.Director
NPTI, Nagpur
2
Background Condenser Cooled Water Cooling Tower Air Make-
up Water
Hot Water
Hot Water
CW Pump
Condenser:
The condenser is the most important component of the turbine cycle that
a ects 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: Di erent 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:
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energy audit of cooling towers
-Induced draft
Forced draft
- Natural draft cooling towers
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powerpoint presentation
water cooled condenser auditing pp
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Background Cooling
water
pumps:
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Circulating
pumps
supply
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cooling
water
at
the
required
work ow process
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ow rate and pressure to the
power plant condenser and the
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energy saving in condensers
plant auxiliary cooling water
heat exchangers. These pumps
are
required
to
operate
economically and reliably 134
over
the life of the plant.
For once through systems,
vertical wet pit pumps are in
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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
Speci cations 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
Speci cations of cooling towers:
8
Data Collection
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Speci cations of cooling towers- contd…:
9
10
Speci cation of water pumps and motors
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Data Collection Speci cation of water pumps and motors-
contd…:
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Data CollectionOther 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
134
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
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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 speci cations 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 Speci cations
Heat load considered for design
Design inlet cooling water temperature/ Design TTD
Cleanliness factor/ Cooling water temperature raise
Condenser back pressure
Cooling water ow/ 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 ow meter or online ow meter
Sling hygrometer or digital hygrometer
Anemometer
/
In addition to the above calibrated online instruments can be used
PH meter
14
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
Measurements & Observation
Energy consumption pattern of pumps and cooling tower fans
Motor electrical parameters
A, V,
THD) for pumps
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Pump operating parameters
to be measured/monitored
for each
pump
system. Share
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you!
are: - Discharge, - Head (suction & discharge) - Valve position –
Temperature - Load Buttons:
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,
134
condensers, etc)
Cooling water ow rate to users - Pump /Motor speed
Actual pressure at the user end
User area pressure of operation and requirement
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15
Measurements & Observation
Cooling tower parameters to be monitored
Inlet temperature
Outlet temperature
Dry bulb temperature
Wet bulb temperature or relative humidity
Water ow to cooling tower
Air ow 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 E
ciency and Performance Evaluation of the
Pumps
Water ow 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 e ciency of
the pumps)
Monitor present ow control system and frequency of control valve
variation if any (for application of variable speed drives)
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Fill up the following data sheet for every pump for comparison with the
design / PG test values
18
Pumps
19
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Operating E ciency and Performance Evaluation of the
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Operating E
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ciency and Performance Evaluation of the
Pumps
134
20
Investigations & Recommendations
Compare the actual values with the design / performance test values if
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any deviation is found, investigate for the contributing factors and
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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 speci c energy consumption with similar type of pumps
and latest energy e cient pumps
Cost analysis with savings potential for taking improvement measures.
21
Flow Distribution
Measure the ow 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
Speci c water ow rate
22
CONDENSERS
23
Performance of Condensers
Parameters for condenser performance
24
Performance of Condensers
Parameters for condenser performance- contd…
/
25
Performance of Condensers
26
Performance of Condensers

The following needs toDownload
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1. Condenser heat load = Q x T x Cp
Parameter
Details
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Water ow rate
Kg/h
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T
Average CW temperature rise
oC Cp
134
Speci c heat
kcal/kg oC
2. Calculated condenser vacuum =
Atmospheric pressure – Condenser back-pressure
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3. Deviation in condenser vacuum =
Expected condenser vacuum - Measured condenser vacuum
4. Condenser TTD =
Saturation temperature – Cooling water outlet temperature
5. Condenser E ectiveness =
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 x
(Pgen + Pgen losses + heat loss due to radiation)
7. Condenser tube velocity (m/s) =
Cooling water ow 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
Tsat - Tout
Ln
LMTD =
Tout - Tin
Tsat -Tin
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 =
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Tube velocity during test
Tube velocity design
()
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fw: correction for water
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fq =
Condenser design duty
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Condenser duty during test
()
fq: correction for cooling water heat load
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28
Observations During Condenser Energy Audit
Tubes in operation Vs total installed
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Cleaning system operation
Filtering system for cooling water
Regular monitoring system for performance
Comparison of LMTD, TTD, heat load, condenser vacuum, ow,
temperatures, pressures with design / PG test- arriving the factors
causing deviation
Modi cations carried out in the recent past
Cooling water ow
Pressure drop on water side and choking
A ect 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
E ectiveness 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 ow 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 air ow shall be measured using an anemometer and compared
with calculated air ow derived from fan characteristic curves of CT fans
with actual power measurements.
Calculate range, approach, L/G (Liquid to gas) ratio and e ectiveness for
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design and operating conditions for each tower
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Performance of Cooling Towers
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1. C.T. Range = Water inlet temperature – Water outlet temp.
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2. C.T. Approach = Water outlet temperature – Wet bulb temp.
3.
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E ectiveness % =
Range x 100
( range + approach )
134
4.
Fan actual air ow (Nm3) / cell =
Fan rated air ow (Nm3) / h x ( Fan input kW actual )
( Fan input rated )
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1/3
5. Air mass ow / cell = ow x density of air
32
33
Performance of Cooling Towers
5. Evaporation losses =
CW ow (m3/ h) x CT range in 0C
675
6. Makeup water consumption =
Evaporation losses
(COC – 1)
The above readings may be taken on daily basis for three days on
di erent 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 e ectiveness of condenser and TTD
Cooling water ow adequacy and ow optimization
Air ingress
Increasing the TTD of the condenser
Fouling of tubes
/
35
Exploration of Energy Conservation Possibilities
36
Exploration of Energy Conservation Possibilities
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Water pumping and cooling
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Improvement of systems and drives
Use of energy e cient pumps
Correcting inaccuracies of the Pump sizing / Trimming of impellers
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Use of high e ciency motors
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Integration of variable speed drives into pumps: The integration of
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adjustable speed drives (VFD) into compressors could lead to energy
e ciency improvements,
depending on load characteristics
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High Performance Lubricants: The low temperature uidity and high
temperature stability of high performance lubricants can increase energy
e ciency by reducing frictional losses
134
Improvements in condenser performance
Improvement in cooling tower performance
Application potential for energy e cient fans for cooling tower fans
Measuring and tracking system performance
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Measuring water use and energy consumption is essential in determining
whether changes in maintenance practices or investment in equipment
could be cost e ective
In this case it is advised to monitor the water ow 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 ow rates
- Heat duty of condenser and cooling towers
- Measures to up keep the performance
37
Exploration of Energy Conservation Possibilities
System E ect Factors
Equipment cannot perform at its optimum capacity if fans, pumps, and
blowers have poor inlet and outlet conditions
Correction of system e ect factors (SEFs) can have a signi cant e ect on
performance and energy savings
Elimination of cavitation: Flow, pressure, and e ciency are reduced in
pumps operating under cavitation. Performance can be restored to
manufacturer’s speci cations through modi cations. 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 in uence 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
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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
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COOLING WATER SYSTEM"
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