The document discusses cooling tower performance assessment conducted by CenPEEP. It provides definitions of key performance parameters like approach, range, and tower capability. Tower capability indicates what percentage of water the tower can cool to the design cold water temperature under design conditions. The document outlines factors that affect performance like fill clogging, nozzle damage, and methods to optimize performance including increasing air flow and regular cleaning. Plots of test data show relationships between cold water temperature and wet bulb/cooling range.
The document discusses cooling tower performance assessment conducted by CenPEEP. It provides definitions of key performance parameters like approach, range, and tower capability. Tower capability indicates what percentage of water the tower can cool to the design cold water temperature under design conditions. The document outlines factors that affect performance like fill clogging, nozzle damage, and methods to optimize performance including increasing air flow and regular cleaning. Plots of test data show relationships between cold water temperature and wet bulb/cooling range.
The document discusses cooling tower performance assessment conducted by CenPEEP. It provides definitions of key performance parameters like approach, range, and tower capability. Tower capability indicates what percentage of water the tower can cool to the design cold water temperature under design conditions. The document outlines factors that affect performance like fill clogging, nozzle damage, and methods to optimize performance including increasing air flow and regular cleaning. Plots of test data show relationships between cold water temperature and wet bulb/cooling range.
The document discusses cooling tower performance assessment conducted by CenPEEP. It provides definitions of key performance parameters like approach, range, and tower capability. Tower capability indicates what percentage of water the tower can cool to the design cold water temperature under design conditions. The document outlines factors that affect performance like fill clogging, nozzle damage, and methods to optimize performance including increasing air flow and regular cleaning. Plots of test data show relationships between cold water temperature and wet bulb/cooling range.
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CenPEEP
Centre for Power Efficiency & Environmental Protection
Cooling g Tower Performance Assessment
M.K.S. M K S Kutty DGM (CenPEEP)
CenPEEP Cooling Tower Thermal Performance Testing Importance po a ce o of Cooling oo g Tower o Performance o Monitoring
Cooling water system plays a vital role in dissipation of waste heat in power station. More than 60 % of total heat input p to the plant is finally dissipated as waste heat. The waste heat from the power plant is carried away by circulating water and ultimately gets dissipated in cooling tower.
CenPEEP Importance of Cooling Tower Performance
Monitoring
The efficiency of cooling tower has direct effect on condenser vacuum and in turn, the heat rate of f the h station. i 1oC rise i in i cold ld water t t temperature t corresponds d to 2.5mm vacuum loss or 5 kcal/kWh in HR which c co corresponds espo ds to app approx. o Rs. s 68 lakhs a so of loss per annum in terms of direct fuel cost for a 500 MW unit.
CenPEEP Cooling g Tower Thermal Performance Testing
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
CenPEEP Cooling Tower Thermal Performance Testing Acceptable Test Conditions CW Flow rate Cooling Range Wet-Bulb Temp Fan Motor Power : 90 110% of Design : 80 120% of Design : Design +/- 8.50 C : 90 110% of Design
Average wind velocity : < 4.5 m/s
Cooling Tower Performance Salient Terms Used in CT Testing A Approach h
CenPEEP
Difference between the Cold Water Temperature at CT outlet and Inlet air Wet Bulb Temperature Range Difference between the Hot Water Temperature (inlet to CT) and Cold Water Temperature (outlet of CT)
CenPEEP Cooling g Tower Performance Salient Terms Used in CT Testing T Tower Capability C bilit The most reliable means to assess the cooling tower thermal performance. It is defined as the percentage of water that the tower can cool to the design cold water temperature when the inlet wet-bulb, cooling range, water flow rate and fan motor power are all at their design value. value
CenPEEP Cooling g Tower Performance Tower Capability
Tower Capability in Percentage Adjusted Test Flow Rate = Adjusted Test Flow Rate Predicted Water Flow Rate
= Measured flow x { Design KW of fans}0.333 { Test KW of Fans }
Predicted Water Flow Rate =Calculated from Manufacturer graphs g p and actual test conditions i.e. WBT, Range and Cold water temperature.
Where : QT = Measured water flow rate, t/hr Predicted water flow rate, t/hr No. of cells for design water flow rate No. of cells in operation during test Fan motor p power design, g kW Fan motor power measured, kW
Qpred = CellD = CellT = PD PT = =
CenPEEP Cooling g Tower Performance Performance Analysis CT degradation to be assessed based on Capability test Deviation to be derived from actual temperature and predicted cold water temperature
CenPEEP Causes for Performance Deterioration Fill clogging Increase in weight of 2-3 times Deposition in the fills comes from the turbidity of make up water air borne dust from the atmospheric air being drawn into the cooling tower precipitates of dissolved silica
CenPEEP Causes for Performance Deterioration
Damage of fills. Ch ki of Chocking f nozzle. l Falling of nozzle. Damage of splash bars. Algae g formation on splash bars Damaged drift eliminators Unequal water flow in different cells. Recirculation of vapors. Poor air flow due to less blade angle angle.
CenPEEP Causes for Performance Deterioration Hot water distribution pipe damage Annular clearance between distribution pipe and hot water channel Growth of trees/plants/bushes near cooling tower Overflow of cold water basin. Improper quality of water Control of COC Control of Turbidity
Rain/any other water entering in open channel
CenPEEP Optimizing Cooling Tower Performance Maintaining proper L/G ratio
Equal water distribution between the cells Visual inspection of pipes, nozzles, fills, etc., for proper water distribution.
Increasing the air flow
By increasing blade angle to obtain max allowable loading of fans By plugging all air path that do not pass through the fill zone i ii iii iv v Sealing shaft hole of fan fan. Sealing door openings of fan chamber. Sealing the fan hub area. Maintaining blade tip clearances Reducing drift handled by fan
CenPEEP Optimizing Cooling Tower Performance
Cleaning of fills with water jets Cleaning of fills manually by removing from tower Cleaning of cold water basin during overhauls. Regular cleaning/checking of nozzles. Continuous Chlorination & Shock dozing to maintain required FRC
CenPEEP
CenPEEP g Tower Thermal Performance f Testing g Cooling
Location Of Inlet Wet Bulb Temperature for Station with Counter Flow Tower
L < 2 Meters, ,
X Measurement Station.
CenPEEP g Tower Thermal Performance f Testing g Cooling
Location Of Inlet Wet Bulb Temperature for Station with Cross Flow Tower
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