Condenser & Heater Performance

CENPEEP
CONDENSER
CENPEEP
CONDENSER
• The condenser is the most important component
that effects the Turbine cycle Heat Rate.
• For condensing of the steam, condenser remove

heat of vaporization from steam and reject it.
• About 60 % of heat of combustion is rejected to

the circulating water through condenser
CENPEEP
STEAM
INLET NON-CONDENSABLE
OUTLET
AIR/VAPOR NON-COND.
OUTLET REMOVAL
SYSTEM
CONDENSATE
LEVEL
WATER OUTLET
WATER INLET
CIRCULATING
CIRCULATING
CONDENSATE
LEVEL
TYPICAL CONDENSER
CENPEEP
CONDENSER
•Turbine output
changes with P1
CENPEEP
Effect Of varying Condenser Back
Pressure
•10 To 15 mm Hg Improvement In
Condenser Vacuum Leads To 20 To 30 kcal/kWh
(1%) Improvement In Heat Rate For A 210 MW
Unit
•An Estimated Coal Saving Worth Of Rs 1 To 2

Crore Per Year For A Rail Fed Station
CENPEEP
Pressure
•Lowering Back pressure always result in

increased Output ? No.
•As Back pressure Increases Certain Losses
increase.
Increased CW Pumping Power

Increased Leaving loss
Reduced condensate Temperature
Increase wetness
CENPEEP
Pressure
So Optimization of Back pressure is required for

Optimum gain.
CENPEEP
Pressure
Graph Heat consumption Vs Vacuum

Heat Consumption
Cond. Vacuum
CENPEEP
CONDENSER DESIGN
CENPEEP
CONDENSER DESIGN AND
FUNCTIONS
Objectives Of Good Condenser Design
• To Condense The Exhaust Steam
• An Economical Heat Sink
• Minimum Under cooling Of The Condensate
• Minimum Pressure Drop On Steam Side
• Effective Removal Of Non Condensable From The
Steam
• Effective Prevention Of Cooling Water Leakage
CENPEEP
FUNCTIONS
Further Considerations
• Economy In Overall Size i.e. Optimum
Surface Area
• Economy In Cooling Water Pumping
Power
• Ease Of Maintenance And Construction
CENPEEP
FUNCTIONS
Condenser Design Parameters

• Sized For VWO Flow, 3 % Make Up And
Design CW Temp.
• Fouling Factor
- 0.9 For SS Tubes
- 0.85 For Cu-Ni
• Design As Per HEI Standard
CENPEEP
FUNCTIONS
• Temp. Rise Across Condenser
• Tube Dia
• Tube Velocity
• Condenser Pressure Drop
• Tube OD < 19.05 mm Not Adopted Due To
Flow Induced Vibration Problems
• Tube Thickness
- 22 BWG For SS , Titanium
- 18 BWG For Cu – Ni
CENPEEP
CONDENSER DESIGN AND FUNCTIONS
• Shell Side Design Temp – 1200 C

• Condenser Shell Design For Full Vacuum
And Internal Pressure Of 1.08 Kg/cm2
• Water Box Design Pressure - CW Pump Shut
Off Pressure And Vacuum
• Water Box Design Temp. - 60 Deg C
CENPEEP
FUNCTIONS
• O2 (MAX) – 15 ppb
• Condensate Temp Not Less Than Saturation

Temp At All Loads
• Provision Of 10% Margin On The Number Of

Tubes Without Affecting Thermal, Mechanical
Performance
CENPEEP
FUNCTIONS
• When Half The Condenser Is Isolated ,

Efficient Distribution Of Steam To Be
Ensured
• Corrosion Allowance
– Water Box, Tube Plate -Min 3.2 MM

- Shell , Hot Well And -Min 1.6 MM
CENPEEP
Condenser Tubes:
Tube Material Commonly Used

• Admirality Brass
• Cupro Nickel
• Stainless Steel
• Titanium
CENPEEP
FUNCTIONS
Admirality Brass
Advantage
-Good Heat Transfer Properties
-Prevent Bio fouling
Disadvantage
-Failures Mainly Due To Erosion/ Corrosion ,
Stress Corrosion Cracking & Pitting.
CENPEEP
FUNCTIONS
Cupro – Nickel
Advantages
- More Resistant To Stress Corrosion Cracking
-Resistance To Bio fouling
Disadvantages
-Poor Resistance To Sulphur Compounds
CENPEEP
Stainless – Steel
Advantages
-Excellent Corrosion And Erosion Resistance In
Fresh Water
-Immunity To Ammonia And Sulfide Water
-No Stress Corrosion Cracking
-High Resistance To Condensate Corrosion
-Excellent Physical Properties
Disadvantages
-Susceptible To Waterside Chloride Attack
-Bio fouling
CENPEEP
Titanium
Advantages
• Highly Resistant To Erosion/ Corrosion, Stress
Corrosion Cracking And Pitting
Disadvantage
• Most Expensive
CENPEEP
COMPARISON OF COST FOR TEMP. RISE

OF 50C & 100C FOR TYPICAL 250 MW UNIT
TEMPERATURE RISE 50C 100C
CONDENSER FLOWM3/HR 57000 29000
DUCT DIA (MM) 3450 2540
MOTOR HP 4500 2550
CONDENSER BACK PR. 57.6 82.6
CONDENSER COST , CRORE 22 13.5
DUCT COST 16.6 11
PUMP + MOTOR COST 11.7 8
CAPITAL COST 17.9 _
HEAT RATE PENALTY BASE 8
PUMPING POWER PENALTY 38.6 22
DIFF. OPER COST 7.4 BASE
DIFF. TOTAL EVALUATED COST 25.4 BASE
CENPEEP
200 MW UNITS
FLOW TEMP RISE
(M3/HR) (0C)
• SINGRAULI 27000 8.78

• KORBA 28570 8.3
• RAMAGUNDAM 27790 7.8
• VINDHYACHAL 27500 8.4
• FARAKKA 28570 7.7
• NCTPP 22800 10.79
CENPEEP
500 MW UNITS
FLOW TEMP RISE
(M3/HR) (0C)
• SINGRAULI 55000 10.3
• KORBA 58300 10.0
• FARAKKA 57000 10.2
• RAMAGUNDAM 55000 10.6
• RIHAND 59000 9.83
CENPEEP
CONDENSER PERFORMANCE
OPTIMISAION
CENPEEP
OBJECTIVES OF PERFORMANCE
OPTIMISATION
• Condenser A Virtually Neglected Component

As Compared To Rotating Equipment
• Operation Activities Limited To Establishing

And Maintaining Vacuum & Starting /
Stopping CW Pump
• Negligence Is Based On Mistaken Priorities

CENPEEP
OBJECTIVES OF PERFORMANCE
OPTIMISATION
• Condenser And Associated System Problems

Cause Significant Loss Of Heat Rate And
Efficiency
• Most Of The Losses Are Recoverable With

Improvement In Operation, Maintenance,
Material And Design
CENPEEP
Condenser Performance Monitoring

Factors affecting Condenser Performance
• Tube fouling
• Air ingress into the system
• High Condenser heat load
• CW Inlet temperature
• CW Flow
CENPEEP
Condenser Performance
Tube Fouling
• Decision for condenser cleaning
 Cleaning of tubes at Part load / during

opportunity shut down / annual overhaul
 Fixing limit for deterioration in vacuum10-15

mm of Hg.
CENPEEP
Condenser Tube Cleaning Techniques
• HP Jet
• Sponge Rubber Balls (On Line)
• Back Washing (Use Of Four Way Valve)
• Water Powered Cleaners
• Chemical Cleaning (in Worst Case)

CENPEEP CenPEEP
Approach For Condenser Performance

Improvement
30 mm HG
(~ 75 kcal/kWh)
(no cleaning
between OH)
15 mm HG
(~ 38 kcal/kWh) 15 mm HG
Effective Condenser tube cleaning (~ 38 kcal/kWh)
during opportunity S/D – 12 mm HG (cleaning
improvement 12 mm HG between OH)
3 mm HG
1.4.2004 1.10.2004 1.4.2005
Say O/H Middle O/H
Description With Cleaning Without cleaning
1st half average loss 7.5 mm HG 7.5 mm HG
2nd half average loss 9 mm HG 22.5 mm HG
Average loss for the year 8.25 mm HG 15 mm HG
Net Improvement 6.75 mm HG (~17
kcal/kWh)
CENPEEP
Condenser Performance
• Condenser Vacuum detoriation from O/H to O/H due to dirty
tube is around 10 mm/20 Kcal/kWh, if no opportunity
cleaning is carried out..
• If ‘No’ Cleaning carried out between O/H, revenue loss will be

around Rs 197 Lac/unit/year (500 mw unit)
• Recovery of losses by cleaning at part load / during

opportunity S/D, Vacuum can improve by around 8 mmHg /
16 kcal/kWh
• Improvement in HR during the financial year is expected to

be about 9 kcal/kWh resulting in saving of around Rs 54
Lac/unit/year
CENPEEP
Condenser air-in-leak
• Air-in Leakage Adversely Affects Condenser

Vacuum, Heat Rate, Corrosion Rate Of
System
• Air Blanketing On The Tubes Severely Affects

The Heat Transfer.
• 1 mm Layer Of Air Equals 16 Meter Thick Of

Copper.
CENPEEP
Condenser air-in-leak test
Major Areas Of Air Ingress.
• LP Turbine Glands.
• LP Turbine Diaphragms.
• LP Turbine Parting Plane.
• CEP Glands (Standby Pump)
• Hot well
• TDBFP (As Applicable)
• Valve Glands, Flange Joints Etc
CENPEEP
On Line Methodology To Assess Increase

In Air-in-leak.
• Increase In Sub-cooling Of Air-steam

Mixture.
• Air Steam Flow At Ejector / Vacuum
Pump.
• Dissolved Oxygen In Condensate.
CENPEEP
Technique To Check Air-in-leak Locations
 Offline flood test during O/H
 Steam pressurization during O/H
 Online Helium leak detection

CENPEEP
High Heat Load
• High heat load due to

 Poor Turbine performance
 Passing of high energy drains
 Installation of thermocouples on down stream
 Progressive replacement of High energy drain
valves
 Attending valves during opportunity shut down.
 Checking of valve of valve passing before O/H
 Joint checking by Operation & TMD after unit
startup
 Poor condenser upkeep
 Low inlet steam parameters
CENPEEP
CW Temp / Flow
• CW inlet temperature
 Higher CW inlet temperature due to poor CT
Performance
 High lake Water Temperature
• Low CW flow
 Poor pump performance
 Low intake level
 Tube chocking
CENPEEP APPROACH FOR ANALYSIS
Condenser Back Yes CW Temp Higher Yes CT Not Cooling
Pressure High Than Design Water
No
CW Temp Rise
Yes CW Flow Low or
Higher
High Heat Load
Than Design
No
No TTD Higher Yes Low Flow +

Instrument Error CW DP High
Than Design High DP
Yes
High TTD & Normal Out No Micro Fouling

Temp Dirty Tube & Air Ingress
High Temp Rise

Low Pressure & Yes
TTD Close to Design CW Discharge Press Low
Normal TTD
Check Pump
No
No
Condenser TTD High Check Instrument
Yes
High Heat Load

Suspected
CENPEEP
Calculation of Expected
Condenser Back Pressure
CENPEEP
• Expected BP derived from design BP after

applying corrections for Load and CW inlet temp.
and CW flow
• Expected BP calculated from expected LMTD

CENPEEP
Computation of Log Mean Temp. Difference

(LMTD)
Tout - Tin
LMTD = ----------------- deg.C
Tsat - Tin
Ln ---------------
Tsat - Tout
Where:
LMTD = deg.C
Tsat = deg.C (saturation temp.corresponding to
back pressure)
CENPEEP
LMTD Expected = LMTD test x ft x fw x fq deg.C
Where:
* Correction for C.W. inlet temperature (ft)
| Saturation Temp Test - LMTD test |¼

ft = | ------------------------------------------------ |
| Saturation Temp Design - LMTD design |
* Correction for C.W. flow (fw)
| Tube velocity test | 1/2

fw = | ----------------------- |
| Tube velocity design |
*Correction for condenser heat load (fq)
Cond. duty design

fq = ------------------------
Cond. duty test
CENPEEP
Water Velocity in Condenser Tube
C.W Flow Rate x 106 Tube Velocity

= ---------------------------------------------------------
3600 x Tube Area x (No. Tubes – Tube plugged)
Where:
Tube Velocity = m/sec
C.W Flow Rate = m3/hr
Tube Area = mm2 (Area of flow passage)
CENPEEP
Determination of Condenser Duty:
Cond Duty = CW Flow x Cp (Tout - Tin) x D
Where:
C.W Flow = m3/hr

Cond Duty = Kcal/hr
Cp = 1 Kcal/Kg deg. C (Specific
heat of water)
D = 1000 Kg/ m3 (Density of water)
Tout = deg.C (Average CW Outlet temp)
Tin = deg.C (Average CW Inlet temp)
CENPEEP
[Tin – Tout x eZ]
Sat. Temp. Expected: = --------------------------- oC
[1 - eZ]
Where:
Tin = Design C.W. inlet temp.

Tour = Design C.W. outlet temp.
Tout – Tin
Z = --------------------
Expected LMTD
Expected Back Pressure

= Derived from Steam Table Corresponding to expected
Saturation Temperature
CENPEEP
Break up of Condenser Back

Pressure Deviation
CENPEEP
S.N Parameter Unit Test

Measured Parameters
Load MW P 210
1 Condenser Pressure mm Hg Pc 120.8
2 CW In Temp Deg.C Ti 34.16
3 CW Out Temp Deg.C To 45.09
4 Condensate Temperature Deg.C Tcon 55
5 Air suction Temp Deg.C Ta 48.9/50.04
Calculated Parameters
6 Saturation Temp Deg.C Tsat 55.56
7 Expected Back Pressure * mm Hg Pxp 85
* Expected BP to be derived from design BP after applying corrections for Load

and CW inlet temperature during test
CENPEEP
S.N Parameter Unit Test
8 Design CW Temp Rise Deg.C dT 10

9 Design TTD Deg.C TTD 2.5
10 Back Pressure due to CW Inlet mm Hg Ti+dT+TTD 79

Temperature
11 Back Pressure due to CW Flow mm Hg To+TTD 81
12 Variation due to CW Inlet mm Hg 7-10 -6

Temperature
13 Variation due to CW Flow mm Hg 11-10 2
14 Variation due to air/Dirty Tubes mm Hg 1-11 39.8

15 Total variation mm Hg 1-10 41.8
CENPEEP
Condenser Air-in-leak Detection
Techniques
Helium Leak Detector
• Sensitivity Is Very High

- 0.00001 To 0.000001 SCFM
• Being Gas, Approachable To All Locations.
• On Line Detection .
• Approx. Level Of Air-in-leak Can Be Assessed.
• Less Time Consuming
CENPEEP
Condenser air-in-leak Detection
Why Use Helium As A Tracer Gas
• Non Toxic Gas

• Does Not React Chemically With Other
Element
• Due To Small Molecules Easily Passes Through
Smallest Leaks
• ITS CONCENTRATION IN AIR IS ONLY 5 PPM
• Therefore Little Back Ground Interference In
Detecting Leak
CENPEEP
HEATER
CENPEEP
Feed Water Heaters

In a regenerative Cycle , Steam is extracted
from steam Turbine at various stages and
used to heat the feed water.
This results in a higher cycle Efficiency by
increasing the temperature of the feed
water and by reducing the amount of
energy lost in the condenser.
CENPEEP
Design Considerations
No of Feed water heaters used in any

specific cycle depends mainly on
• The size of the turbine
• The inlet and exhaust steam condition,
• Plant cycle & Economic consideration.
CENPEEP
Types of Feed water Heaters

Open type : Extraction steam directly mixes
with the feed water to be Heated.e.g.
Deaerator
Closed Type : Heaters maintains a
separation of Extraction steam and feed
water to be heated.Called as Feed Water
Heaters.
CENPEEP
Feed water Heaters

LP Heaters : These Heaters are either of
closed type or open type and Extraction
steam at low pressure or sub atmospheric.
HP heaters : These Heaters are closed type

and Extraction steam at high pressure
CENPEEP
CENPEEP
HP Heaters have direct impact on machine reliability

and plant Heat Rate / Efficiency.
Heat Rate Loss in a 210 mw Unit in case

HP Heaters not in service
is about 68 kcal / kwh
CENPEEP
HP Heater Performance Monitoring
Factors affecting HP Heater Performance
• Tube fouling
• Failure to vent non condensable gases
• Changes in heater level
• Partition plate passing
• Heater bypass valve passing

CENPEEP
H P Heater Performance Monitoring
• Parameters to be monitored
- FW inlet/exit pressure & temperature
- Extraction Steam pressure & temperature
- Drip temperature
- Feed Water flow

CENPEEP
CENPEEP
Performance of H.P. Heaters can be analyzed by

monitoring / trending:
• The terminal temperature difference (TTD)
• The drain Cooler approach temperature (DCA)
• The pressure drop on the feed water side
• The temperature rise across the heater

CENPEEP
Terminal Temperature Difference (TTD) &
Drain Cooler Approach (DCA)
• Terminal Temperature Difference (TTD) i.e. the

difference between the Saturation temp. of steam
corresponding to shell pressure(ts) and feed water
outlet temp. (to) :
TTD = ts – to
• Drain Cooler Approach (DCA) i.e. the difference

between heater drain outlet temp.(tdo) and the
feed water inlet temp (ti) :
DCA = tdo – ti
CENPEEP
H P Heater Performance Improvement
• Minimize TTD deviation
• Determination of optimum operating level
• Deviation in final FW temperature
 Passing of water box partition plate
 Passing of bypass valves
• Monitoring of FW outlet temperature after top

heater and after by pass valve
CENPEEP
Operating Conditions for Performance Testing:
• Unit operation at rated load
• Stabilized operating conditions
• Levels set as per test requirement
• Drain cascading system – Normal
• Heater vent Valves Open / Close as per operating

instructions
CENPEEP
Operation of Unit With Heater out Of

Service
1. Increased Steam flow through remaining
section of the turbine.
2. For Given Throttle flow Turbine output
increases.
3. Turbine cycle Heat Input Increases
because of low Feed Water temperature.
4. Turbine & Plant Heat rate are Poorer.
CENPEEP
COOLING TOWER
CENPEEP
Cooling Tower Thermal Performance
Testing
Importance of Cooling Tower Performance
Monitoring
Cooling water system plays a vital role in
dissipation of waste heat in power station.
More than 60 % of total heat input 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 the station.
• 1oC rise in cold water temperature in a
200MW unit corresponds to 5mm vacuum
loss which corresponds to Rs 45 lakhs of loss
per annum in terms of direct fuel cost.
CENPEEP
Causes for Performance Deterioration.

Common causes are
1. Recirculation of vapors.
2. Poor air flow due to less blade angle, algae,
deposition on blade.
3. Higher blade tip clearance.
4. Fan door sealing not proper, other opening
in suction of the fan.
5. Damaged DE causes more makeup
6. Chocking of nozzle.
7. Falling of nozzle.
CENPEEP
Causes for Performance Deterioration.

8. Hot water distribution pipe
leaking/breaking/end cover falling.
9. Fill clogging
10. Damage of fills.
11. Lot of trees/plants/bushes growth near
cooling tower Overflow of cold water basin.
12. Unequal water flow in different cells.
13. Improper quality of water.
14. Rain/any other water entering in OAC.
CENPEEP
Optimizing Cooling Tower
Performance.
• Cleaning of cold water basin during

overhauls.
• Quarterly cleaning of nozzles.
• Visual inspection of pipes, nozzles, fills, etc.,
for proper water distribution.
• Checking of fan pitch angle, fan blade tip
clearance, fan seal disc cover (at hub).
• Annual cleaning of fills with water jets. And
cleaning it manually by removing from tower
when chocking is more.
CENPEEP
Optimizing Cooling Tower
Performance.
• Cleaning of civil structure annually and
removal of algae from DE, Fills.
• Fan door and any other air ingress point 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 minutes.
• Monthly checking of effectiveness of tower
for comparison purpose and once checking
of perf. during mansion as per OGN.
CENPEEP
Cooling 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 Performance
Salient Terms Used in CT Testing
Approach
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
Tower Capability
 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.
CENPEEP
Tower Capability
Tower Capability in Percentage = Adjusted Test Flow Rate

Predicted Water Flow Rate
Adjusted Test = Measured flow x { Design KW of fans}0.333

Flow Rate { Test KW of Fans }
Predicted Water Flow Rate =Calculated from Manufacturer

graphs and actual test conditions
i.e. WBT, Range and Cold water
temperature.
CENPEEP
Acceptable Test Conditions
• CW Flow rate : 90 – 110% of Design
• Cooling Range : 80 – 120% of Design
• Wet-Bulb Temp : Design +/- 8.50 C
• Fan Motor Power : 90 – 110% of Design
• Average wind velocity : < 4.5 m/s

CENPEEP
Test Setup
• WBT Measurement
 Done on both sides of the tower at air inlet path
using Psychrometers.
 The instrument shall be located within 1.5 M of
the air intake.
 The number of stations for inlet wet bulb
temperature measurement depends on the size
and layout of the cooling tower. For a typical 500
MW unit having 2 cooling towers, there can be 16
locations per cooling tower (8 on each side) for an
accurate measurement of wet bulb temperature
CENPEEP
Cooling Tower Performance Testing
Location Of Inlet Wet Bulb Temperature for Station with
Counter Flow Tower
L L
“L” < 2 Meters, “X” Measurement Station.

CENPEEP
Cooling Tower Performance Testing
Location Of Inlet Wet Bulb Temperature for Station with
Cross Flow Tower
L L
“L” < 2 Meters, “X” Measurement Station.

CENPEEP
Wet Bulb Temp. measurement setup
CENPEEP
Test Setup
• Cold Water Temperature Measurement
 The recooled water temperature can be

measured directly at the point where the
circulating water is discharged from the
basin.
 The temperature measurement
instruments shall be located where the
water will be thoroughly mixed.
 It is better to have a grid arrangement in
the channel for cold water measurement.
CENPEEP
Grid setup for Cold Water Temp. measurement
CENPEEP
Test Setup
• Hot water temperature measurement
At the tower risers or at the discharge of

the inlet risers
• Fan Power Measurement
 At the individual fan switch gear

CENPEEP
Test Setup
• CW flow Measurement using Pitot Traverse
 Pitot traverse is done in two planes i.e. vertical

and horizontal at 90 degrees to each other.
CW flow Q = dp0.5 (504.4883 x C x A) t/hr
Where
Q = CW Flow in t/hr
dp = average dp measured in mmwcl
C = Pitot coefficient
A = Area of duct in m2
CENPEEP
Reading No Dia Location dp dp0.5
x mmwcl
1 0.013
2 0.039
3 0.067
4 0.097
5 0.129
6 0.165
7 0.204
8 0.25
9 0.306
10 0.388
11 0.612
12 0.694
13 0.75
14 0.796
15 0.835
16 0.871
17 0.903
18 0.933
19 0.961
20 0.987
Average
CENPEEP
CW flow measurement using Pitot traverse
CENPEEP
90% Flow; Cold Water vs. Wet Bulb
37.0
TEMPERATURE C
36.0
COLD WATER
35.0
34.0
33.0
32.0
31.0
30.0
29.0
28.0
27.0
23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0
Wet Bulb (C)
C-8.8C B-11.0C A- 13.25C

CENPEEP
37.0
TEMPERATURE C
36.0
COLD WATER
35.0
34.0
33.0
32.0
31.0
30.0
29.0
28.0
23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0
Wet Bulb (C)
C-8.8C B-11.0C A- 13.25C

CENPEEP
110 % Flow; Cold Water vs. Wet Bulb
37.0
TEMPERATURE C
36.0
COLD WATER
35.0
34.0
33.0
32.0
31.0
30.0
29.0
28.0
23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0
Wet Bulb (C)
C-8.8C B-11.0C A- 13.25C

CENPEEP
CASE STUDY
Design and Test data
Description Unit Design CT 5A CT 6B
Flow m3/hr 30,000 30,977 25,573
Hot water Deg C 43 46 45.3
Cold water Deg.C 32 35.9 33.6
Wet Bulb Deg.C 28 25.7 25.1
Approach Deg.C 4 10.2 8.5
Range Deg.C 11 10.1 11.7
Fan Power KW 65 47.2 56.8
Capability % 100 45 47
CENPEEP
TEMPERATURE C
COLD WATER
37.0
36.0
35.0
34.0
33.0
32.0
31.0
30.0
29.0
28.0
27.0
23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0
Wet Bulb (C)
C-8.8C B-11.0C A- 13.25C
Test WBT – 25.7 C

CENPEEP
Cold Water vs. Cooling Range
30.8
TEMPERATURE (C)
30.6
COLD WATER
30.4
30.2
30.0
29.8
29.6
29.4
8.0 9.0 10.0 11.0 12.0 13.0 14.0
COOLING RANGE (C)
90% Flow
CENPEEP
32.0
COLD WATER TEMPERATURE
31.5
31.0
(C)
30.5
30.0
29.5
29.0
8.0 9.0 10.0 11.0 12.0 13.0 14.0
COOLING RANGE (C)
90% Flow 100% Flow 110% Flow Test Range
Test Cooling Range – 10.1 C

CENPEEP
Cold Water vs. Predicted Flow
30.8
TEMPERATURE (C)
30.6
COLD WATER
30.4
30.2
30.0
29.8
29.6
80 85 90 95 100 105 110 115
Predicted Flow (%)
Test Cold Water Temp – 35.9 C

CENPEEP
37.0
35.0
33.0
(C)
31.0
29.0
27.0
25.0
25,000 35,000 45,000 55,000 65,000 75,000 85,000
Predicted Flow (t/hr)
Test Cold Water Temp – 35.9 C

Predicted Flow – 77,000 t/hr, Actual Flow - 30,977 t/hr
CENPEEP
Tower Capability = { QT } * { CellD } * { PD }.333 * 100
{ Qpred } { CellT } { PT }
Where :
QT = Measured water flow rate, t/hr

Qpred = Predicted water flow rate, t/hr
CellD = No. of cells for design water flow rate
CellT = No. of cells in operation during test
PD = Fan motor power design, kW
PT = Fan motor power measured, kW
Tower Capability – 45 %
CENPEEP
CENPEEP
Thank You
CENPEEP
Cooling 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
Approach
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

Tower Capability
 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.
CENPEEP
Tower Capability
Tower Capability in Percentage = Adjusted Test Flow Rate

Predicted Water Flow Rate
Adjusted Test = Measured flow x { Design KW of fans}0.333

Flow Rate { Test KW of Fans }
Predicted Water Flow Rate = Calculated from Manufacturer

graphs and actual test
conditions
i.e. WBT, Range and Cold water
temperature.
CENPEEP
Acceptable Test Conditions
• CW Flow rate : 90 – 110% of Design
• Cooling Range : 80 – 120% of Design
• Wet-bulb Temp : Design +/- 8.50 C
• Fan Motor Power : 90 – 110% of Design

CENPEEP
 Test Code
 Cooling Tower Institute (CTI) has issued

guidelines for carrying out the thermal
performance test of cooling towers.
 CTI ATC - 105

CENPEEP
37.0
TEMPERATURE C
36.0
COLD WATER
35.0
34.0
33.0
32.0
31.0
30.0
29.0
28.0
27.0
23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0
Wet Bulb (C)
C-8.8C B-11.0C A- 13.25C

CENPEEP
37.0
TEMPERATURE C
36.0
COLD WATER
35.0
34.0
33.0
32.0
31.0
30.0
29.0
28.0
23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0
Wet Bulb (C)
C-8.8C B-11.0C A- 13.25C

CENPEEP
110 % Flow; Cold Water vs. Wet Bulb
37.0
TEMPERATURE C
36.0
COLD WATER
35.0
34.0
33.0
32.0
31.0
30.0
29.0
28.0
23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0
Wet Bulb (C)
C-8.8C B-11.0C A- 13.25C

CENPEEP

TEMPERATURE C
COLD WATER
37.0
36.0
35.0
34.0
33.0
32.0
31.0
30.0
29.0
28.0
27.0
23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0
Wet Bulb (C)
C-8.8C B-11.0C A- 13.25C

CENPEEP
30.8
TEMPERATURE (C)
30.6
COLD WATER
30.4
30.2
30.0
29.8
29.6
29.4
8.0 9.0 10.0 11.0 12.0 13.0 14.0
COOLING RANGE (C)
90% Flow
CENPEEP
32.0
31.5
31.0
(C)
30.5
30.0
29.5
29.0
8.0 9.0 10.0 11.0 12.0 13.0 14.0
COOLING RANGE (C)
90% Flow 100% Flow 110% Flow Test Range

CENPEEP
30.8
TEMPERATURE (C)
30.6
COLD WATER
30.4
30.2
30.0
29.8
29.6
80 85 90 95 100 105 110 115
Predicted Flow (%)
CENPEEP
37.0
35.0
33.0
(C)
31.0
29.0
27.0
25.0
25,000 35,000 45,000 55,000 65,000 75,000 85,000
Predicted Flow (t/hr)
CENPEEP
Steps for determining Predicted water Flow Rate

1. Manufacturer has provided design graphs of cold water
temp vs wet bulb temp for 90%, 100% & 110% flows and
different cooling ranges
2. Based on the actual test WBT, cold water temp is
determined for different ranges and flows from the
manufacturer curves
3. Graph plotted with cold water temp vs cooling range for
90%, 100% & 110% flows
4. From the above graph(at step 3), based on actual test
cooling range, cold water temp determined for 90%,
100%, 110% flows
5. Graph plotted with cold water temp vs predicted flow
6. From the above graph(at step 5), based on actual test
cold water temp, predicted flow determined.
CENPEEP
Thank You

Condenser &amp; Heater Performance

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Condenser &amp; Heater Performance

Hochgeladen von

Copyright:

Verfügbare Formate

CENPEEP

• For condensing of the steam, condenser remove

• About 60 % of heat of combustion is rejected to

•An Estimated Coal Saving Worth Of Rs 1 To 2

•Lowering Back pressure always result in

Increased CW Pumping Power

So Optimization of Back pressure is required for

Graph Heat consumption Vs Vacuum

Condenser Design Parameters

CONDENSER DESIGN AND FUNCTIONS

Condenser Design Parameters

• Shell Side Design Temp – 1200 C

• Condensate Temp Not Less Than Saturation

• Provision Of 10% Margin On The Number Of

• When Half The Condenser Is Isolated ,

– Water Box, Tube Plate -Min 3.2 MM

CONDENSER DESIGN AND FUNCTIONS

Tube Material Commonly Used

COMPARISON OF COST FOR TEMP. RISE

CONDENSER DESIGN AND FUNCTIONS

• SINGRAULI 27000 8.78

CONDENSER DESIGN AND FUNCTIONS

• Condenser A Virtually Neglected Component

• Operation Activities Limited To Establishing

• Negligence Is Based On Mistaken Priorities

• Condenser And Associated System Problems

• Most Of The Losses Are Recoverable With

Condenser Performance Monitoring

• Air ingress into the system

• High Condenser heat load

• Decision for condenser cleaning

 Cleaning of tubes at Part load / during

 Fixing limit for deterioration in vacuum10-15

Condenser Tube Cleaning Techniques

• Sponge Rubber Balls (On Line)

• Back Washing (Use Of Four Way Valve)

• Water Powered Cleaners

• Chemical Cleaning (in Worst Case)

Approach For Condenser Performance

• If ‘No’ Cleaning carried out between O/H, revenue loss will be

• Recovery of losses by cleaning at part load / during

• Improvement in HR during the financial year is expected to

• Air-in Leakage Adversely Affects Condenser

• Air Blanketing On The Tubes Severely Affects

• 1 mm Layer Of Air Equals 16 Meter Thick Of

Condenser air-in-leak test

Major Areas Of Air Ingress.

Condenser air-in-leak test

On Line Methodology To Assess Increase

• Increase In Sub-cooling Of Air-steam

Condenser air-in-leak test

Technique To Check Air-in-leak Locations

 Offline flood test during O/H

 Steam pressurization during O/H

 Online Helium leak detection

• High heat load due to

No TTD Higher Yes Low Flow +

High TTD & Normal Out No Micro Fouling

High Temp Rise

High Heat Load

• Expected BP derived from design BP after

• Expected BP calculated from expected LMTD

Computation of Log Mean Temp. Difference

LMTD Expected = LMTD test x ft x fw x fq deg.C

Condenser & Heater Performance

Condenser & Heater Performance