Cooling Water

And Cooling
Tower
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 Contents
Water mass balance


Cooling water system



Cooling towers


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 Water Mass Balance
Water mass balance: is indentifying the requirement of
water, estimation and optimization of water requirement for
a given power plant .
Which includes re-using (recycling) of water, waste water

treatment and design the system to minimize the water

wastage.
Water balance to be done keeping water availability for

particular power plant as a boundary condition.

As per the Central Water Commission’s (CWC) the

sanctioned water for the SUMPP is 15000M3/hr

 Water mass balance
 The typical water requirement for a Coal based thermal
power plant is
­ Raw Water
­ Clarified water ( pre treatment )
­ De Mineralized water
­ Cooling water
­ Service water
­ Fire Water
­ Portable water
­ Raw water for ash handling purpose
­ Raw water for coal handing purpose

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 Water Mass Balance
The RW water requirement for SUMMP- a Coal based
thermal power plant is
1.Clarified water(10332M3/hr)
 Cooling water for Condenser system & auxiliary
systems -make up water(9639M3/hr)
 Cooling water for HVAC system(300M3/hr)
 Service water
 Fire water
 Portable water (82M3/hr)

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 Water Mass Balance
2. DM water ( 224M3/hr)
 Make up to Heat Cycle ( Includes Soot blowing,

Leakages,etc)
 • Input to Hydrogen Generation plant

 • Make up to Auxiliary Steam system

 • Make up for Closed cycle Equipment cooling

system.
 • Condensate Polishing unit (CPU)

3. for Ash handling system(4891M3/hr)

4. Water for coal handling system(188M3/hr)

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 Water Mass Balance
 Total Supply(RW )water required is
­ Clarified water =10332M3/hr
­ Dm water = 242M3/hr
­ Water for ash handling =4891M3/hr
­ Water for coal handling=188M3/hr
­ Service water = 250M3/hr
Total requirement is 16143M3/hr
By recycling water through water treatment method
supplied water reduced to = 16143-5981 = 10162M3/hr
The Total RW requirement is =10162+397( evaporation and
disposal wastage)=10559M3/hr

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 Cooling Water system
 The main purpose of cooling water system is to take away
heat rejected by Condenser.
 The secondary function of cooling water is take way heat
rejected by auxiliary units and cooling equipment.
 After taking heat from condenser and Auxiliary units, the
water will be cooling in the cooling towers and re-cuirculate
back by CW pumps
 The heat to be exchanged in condenser is 789367KJ/s.
 The exchange surface area in condenser is 34000 M2
 52.Final SOP for CW sump filling and CT basin filling.docx
 38.SOP-Cooling_Water_Pump.doc

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CW Pump

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Basic parameter for Design of the CW pump
 Design flow : 40000 cum/h
 Total Head : 26 MWC
 Operating Speed : 333 RPM
 Water quality : Clarified water
 Pump House : Condenser cooling water pumps will be located in the

condenser cooling water pump house.

There will be two (2) nos. of condenser cooling water

pump houses, each serving 3 x 660 MW units

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 Mechanical and Electrical scope
 Twelve (12) numbers of Vertical, wet pit, turbine type (VT), Circulating
water pumps, associated motor drives each of capacity 40,000 m3/hr and
26 MWC head, complete with all accessories such as base plate of each
pump set, sole plate, foundation bolts and nuts, anchor, sleeves, stuffing
boxes (if applicable), thrust pads etc as required.

 11KV, 3600KW, Rated current 252.3 A motor with accessories, terminal

box, base plate, coupler, coupling guard, shims, foundation bolts, dowel
pins etc.
 Local Push Button Station (start, stop, Ammeter suitable for 4-20 mA
input).
 Secondary Earthling

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 Cooling water system
 The cooling water required to exchange heat from condenser
is
 71300M3/h with velocity of 2.2M/s
 Supply water temperature is 32deg C
 Return water temperature is 42 deg C.
 Cooling water required for Auxiliary units is 3800M3/h
 The water will be circulated by 2 nos CW pumps of capcity
40000M3/h through 3500mm Dia CS pipe.
 At Pump discharge and condenser hook up the line
branched out to 2500mm dia.

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Cooling Water system

clarifier

Plate heat exchanger

Vacuum pump cooler
Compressor cooler
Bottom ash crusher
Ash handling ins. Air compressor
Ash handling transport air
compressor
Ash pump fluid coupling cooler

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 Cooling Water System

Evaporation

Heat
Condenser
Load
Cooling
Auxiliary
Makeup Tower cooling
water
system
Blowdown Recirculating
Cooling water
Pump
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 Auxiliary cooling water system.
 Auxiliary cooling water is required for following Auxiliary units
­ Plate Heat Exchangers
­ Vacuum pump coolers
­ Air Compressor cooler
­ Bottom ash crusher
­ Ash slurry pump fluid coupling cooler
­ Ash handling transport air compressor cooler
­ Ash handling instrument air compressor cooler
­ HFO & LDO return oil cooler

Cooling water 3800M3/h for above units will be circulated by branch

out line of1100mm Dia pipe from main CW supply line going to
condenser and return line of ACW line is connected to CW return line.

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 Cooling Towers
 A cooling tower is an equipment used to reduce the
temperature of a water stream by extracting heat from water
and emitting it to the atmosphere.
 The basic principle of the cooling tower operation is that of
evaporative condensation and exchange of sensible heat.
The air and water mixture releases latent heat of vaporization
which has a cooling effect on water by turning a certain
amount of liquid into its gaseous state thereby releasing the
 latent heat of vaporization.
 Approximately 25% of the sensible heat transfer occurs in the
tower while the balance of the 75% cooling is due to the
evaporative effect of latent heat of vaporization.

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 Losses In Cooling Tower
 Windage or Drift — Water droplets that are carried out of the cooling tower
with the exhaust air. Drift droplets have the same concentration of impurities
as the water entering the tower. The drift rate is typically reduced by employing
baffle-like devices, called drift eliminators, through which the air must travel
after leaving the fill and spray zones of the tower. Drift can also be reduced by
using warmer entering cooling tower temperatures.
 Blow-out — Water droplets blown out of the cooling tower by wind, generally
at the air inlet openings. Water may also be lost, in the absence of wind,
through splashing. Devices such as wind screens, louvers, splash deflectors
and water diverters are used to limit these losses.
 Plume — The stream of saturated exhaust air leaving the cooling tower. The
plume is visible when water vapor it contains condenses in contact with cooler
ambient air, like the saturated air in one's breath fogs on a cold day. Under
certain conditions, a cooling tower plume may present fogging or icing hazards
to its surroundings. Note that the water evaporated in the cooling process is
"pure" water, in contrast to the very small percentage of drift droplets or water
blown out of the air inlets.
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
 TERMINOLOGY
 Draw-off or Blow-down — The portion of the circulating water flow that is
removed (usually discharged to a drain) in order to maintain the amount of
Total Dissolved Solids (TDS) and other impurities at an acceptably low level.
Higher TDS concentration in solution may result from greater cooling tower
efficiency. However the higher the TDS concentration, the greater the risk of
scale, biological growth and corrosion. The amount of blow-down is primarily
designated by measuring the conductivity of the circulating water. Biological
growth, scaling and corrosion can be prevented by chemicals (respectively,
biocide, sulfuric acid, corrosion inhibitor). On the other hand, the only practical
way to decrease the conductivity is by increasing the amount of blow-down
discharge and subsequently increasing the amount of clean make-up water.
 Make-up — The water that must be added to the circulating water system in
order to compensate for water losses such as evaporation, drift loss, blow-
out, blow-down, etc.

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 TERMINOLOGY
 Approach — The approach is the difference in temperature between the
cooled-water temperature and the entering-air wet bulb temperature (twb).
Since the cooling towers are based on the principles of evaporative cooling,
the maximum cooling tower efficiency depends on the wet bulb temperature
of the air. The wet-bulb temperature is a type of temperature measurement
that reflects the physical properties of a system with a mixture of a gas and a
vapor, usually air and water vapor
 Range — The range is the temperature difference between the warm water
inlet and cooled water exit.
 Fill — Inside the tower, fills are added to increase contact surface as well as
contact time between air and water, to provide better heat transfer. The
efficiency of the tower depends on the selection and amount of fill. There are
two types of fills that may be used:

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 Parameter for Design

Design flow : 38500 cum/h

 Range of Cooling Tower : 10 degree Centigrade ( From 42 degree C to
32 degree C)
 Design ambient wet bulb temperature : 27.4 degree centigrade
 Recirculation allowance : 0.8 degree minimum
 Design average ambient relative humidity : 50 %

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 Mechanical and Electrical scope

 TWO (2) number of cooling tower for each unit .SIXTEEN (16) numbers of fans in
one cooling tower axial/ propeler type, reduction spiral bevel type gearbox 12
number of adjusting fan blades.+/- 5 deg from normal setting

 415KV, 75KW, Rated current 125 A Sq. Cage Induction motor with accessories,

 Type of cooling tower design :

 Counter Flow design
 Induced draft design.
 The cooling tower super structure is of RCC construction .

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Cooling Tower

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 Cooling towers
 Range: CT Range (°C) =
[CW inlet temp (°C) – CW outlet temp (°C)]
 Approach :CT Approach (°C) =
[CW outlet temp (°C) – Wet bulb temp (°C)]
 CT Efficiency (%) =
(CW in temp – CW out temp) /
X 100
(CW in temp – WB temp)
 Cooling capacity. This is the heat rejected
in kCal/hr given as product of mass
flow rate of water, specific heat and temp-
erature difference.
Wet bulb Temp : it is the lowest temperature to
which water can be cooled
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 Cooling tower
Evaporation loss. This is the water quantity evaporated for cooling duty.

 Liquid/Gas (L/G) ratio. The L/G ratio of a cooling tower is the ratio
between the water and the air mass flow rates. Cooling towers have certain
design values, but seasonal variations require adjustment and tuning of water
and air flow rates to get the best cooling tower effectiveness. Adjustments can
be made by blade angle adjustments. Thermodynamic rules also dictate that
the heat removed from the water must be equal to the heat absorbed by the
surrounding air.

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 Types of cooling towers
 Natural draught cooling tower use principle of hot air tend to move upwards
and due shape and height of cooling tower there is a pressure difference and
air moves upwards.
 Mechanical draft cooling towers use power driven fan motors to force or draw
air through the circulating water. These can be categorized as forced draft (air
pushing) or induced draft (draw-thru) arrangement by virtue of the location of
the fan.
 Forced draft
 In forced draft cooling towers, air is "pushed" through the tower from an inlet
to an exhaust.
 Induced draft
 An induced draft mechanical draft tower is a draw-through arrangement,
where a fan located at the discharge end pulls air through the tower. The fan
induces hot moist air out the discharge.

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Types of cooling towers

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Types of cooling towers

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 cooling towers
Cross flow cooling towers Counter flow cooling towers
Water flow through gravity no spray Hot water distribution to be pressure
nozzles required spray through nozzles
Low pump pressure required. In turn low High pump pressure is required
cost.
Reduce drift loss Due to counter flow high horse power
fans are required(air travelled against
water spray)
Easy maintenance More efficient use of air due to finer
droplets from pressure spray

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Components of cooling tower

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Components of cooling tower
Components of cooling tower

Drift Eliminator ID Fan Assembly

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 Cooling water treatment
 In cooling towers, evaporated water is pure and
dissolved minerals in remaining water will increase. Due
to this water become alkaline and PH value will increase.
If PH value > 8.3 Scale is formed.
 Scale stubbornly stick to the surfaces condenser and
obstruct the heat transfer.
 To overcome above problem acid dosing will be done to
convert( adjust the PH value) scale forming material to
more soluble form.
 Sulfuric acid or Hydrochoric acid is used for our plant.

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 Chlorination of cooling water
 The conditions inside a circulating cooling system are very often conducive to
build up of micro-organisms, which in turn can lead to problems of heat
exchanger fouling and a deterioration in tower performance.
 The three main groups of organisms which may prove troublesome in re-
circulating cooling water systems are (1) algae (2) bacteria and (3) fungi.
 For example, chlorine, sodium hypochlorite, chlorophenols, amines, organo
sulphurs, organo tine etc., are widely used.
 In cooling water systems, the effective application of chlorine minimizes the
presence of micro-organisms that can cause biological fouling, contribute to
corrosion, and reduce heat transfer.

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 Cooling Towers
 Cycles of concentration (C.O.C). This is the ratio of dissolved solids
in circulating water to the dissolved solids in make up water.

SUMPP cooling towers are designed COC of 5.

 Process of concentration is not interrupted or limited, the solubility of a range

of dissolved sparingly soluble compounds will be exceeded, and precipitation
will result in sludge formation and probably lead to scale formation. We limit
the concentration process by “blowing down”,“bleeding off”, or removing a
portion of the concentrated cooling water.
 Blow down losses depend upon cycles of concentration and the
evaporation losses and is given by formula:
 Blow down = Evaporation loss / (C.O.C. – 1)

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THANK
YOU
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