The Beginning of knowledge is the discovery

of something we do not understand

-Frank Herbert

PRESENTED BY
DINESH GUPTA
PRIYABRATA SATAPATHY

Cooling Towers
Introduction
Types of cooling towers
Assessment of cooling towers

Introduction
Main Features of Cooling Towers

Introduction
Components of a cooling tower
Frame and casing: support exterior
enclosures
Fill: facilitate heat transfer by
maximizing water / air contact
Splash fill
Film fill

Cold water basin: receives water at

bottom of tower
5

Introduction
Components of a cooling tower
Drift eliminators: capture droplets in
air stream
Air inlet: entry point of air
Louvers: equalize air flow into the fill
and retain water within tower
Nozzles: spray water to wet the fill
Fans: suck air flow in the tower

Cooling Towers
Introduction
Types of cooling towers
Assessment of cooling towers

Types of Cooling Towers

Natural Draft Cooling Towers
Hot air moves through tower
Fresh cool air is drawn into the
tower from bottom
No fan required
Concrete tower <200 m
Used for large heat duties
8

 Air drawn across

Types of Cooling Towers

falling water
Fill located
outside tower

Natural Draft Cooling

Cross flow

Air drawn up

through falling
water
Fill located
inside tower
Towers

Counter flow
9

Types of Cooling Towers

Mechanical Draft Cooling Towers
Large fans to force air through

circulated water
Water falls over fill surfaces:

maximum heat transfer

Cooling rates depend on many

parameters
Large range of capacities
Can be grouped, e.g. 8-cell tower

10

Types of Cooling Towers

Mechanical Draft Cooling Towers
Three types
Forced draft
Induced draft cross flow
Induced draft counter flow

11

Types of Cooling Towers

Forced Draft Cooling Towers

Air blown through tower

by centrifugal fan at air
inlet

Advantages: suited for

high air resistance

Disadvantages:
recirculation due to high
air-entry and low air-exit
velocities
12

Types of Cooling Towers

Induced Draft Cooling Towers

Two types
Cross flow
Counter flow

Advantage: less recirculation than forced

draft towers

Disadvantage: fans and motor drive

mechanism require weather-proofing
13

Types of Cooling Towers

Induced Draft Counter Flow CT

Hot water enters at the top

Air enters at bottom and exits at top

Uses forced and induced draft fans

14

Types of Cooling Towers

Induced Draft Cross Flow CT

Water enters top and passes over fill

Air enters on one side or opposite sides

Induced draft fan draws air across fill

15

COOLING TOWER OF
apml
Manufacturer
PAHARPUR
Model no
Height of CT
Height of inlet pipe
Air flow rate (outside)

85454-6.0-22B
12.04m
8.23m
1100000cfm
20 nos CT fan are running & 2 nos are
standby for normal operation.

16

SPECIFICATION (COOLING
TOWER
fan)

Manufacturer
Model
Type
No of fans per cell
Total cells per unit
No of blade per fan
Dia of fan assembly
Hub dia
Blade tip clearance

PCTIL
HP-6-8
Axial flow
1

22
8
10m
1.52 m
50mm(+1 - 0 .25)
17

Continued.

Fan blade of adjustable pitch

Degree of adjustment
Blade angle design
Fan blade and shank
Hub cover
Colour of fan blade
Blade type
Wet bulb temp
Fan speed
M.I of fan

YES
5 20 deg
14.75 0 at 58.6kw
GRP
GRP
Gray
Aerofoil
27.1 0C
98rpm
2542 kgm 2
18

19

20

SPECIFICATION (GEAR
BOX)
Model no
10-4001-2
Serial no
Gear reducer ratio

J-1-775
14.54/1
Oil
Turbine type mineral oil
Oil is changed every 6 month or after 3000 hours of
operation.

21

22

23

24

25

Design parameters of
apml
Drift loss (max)
0.05%
Space of each drift blade 49mm
Fill material
PVC film fill pack-MC-

67
length of fill pack
Drift blade height
Fill pack coating

1.829m
146mm
TiO 2

Coupling type

Flexible bush

type
26

27

28

SPECIFICATION (MOTOR)
Manufacturer
Type
Voltage
Frequency
Rated Power
Current
Speed
Efficiency
Power factor
Winding connection

MARATHON
3 phase squirrel cage
induction motor
415 volt
50 Hz
75 kw,100hp
128 amp
1480 rpm
93.6%
0.87
(delta)
29

30

SPECIFICATION (RISER
VALVE)
Manufacturer
AUDCO INDIA
LTD
Model
Gear ratio
Rated torque
Size
Max pressure
Max. temp

G400 MS
70:1
4000Nm
800 mm
0.6kg/cm2
950C

31

32

PRESTART CHECK LIST

No permit to work pending
Riser valve should be opened 100%
Ensured equal distribution of water.
Lube oil level should be normal and ensured no

oil leakage.
CT blower should be electrically normal.

STARTING PROCEDURE
Start CT blower ,check vibration, current, rotation and

abnormal sound of motor.

33

shutdown
CT fan stopped
Electrically isolate the system
Riser valve is closed

34

Cooling Towers
Introduction
Types of cooling towers
Assessment of cooling towers

35

Assessment of Cooling Towers

Measured Parameters

Wet bulb temperature of air

Dry bulb temperature of air

Cooling tower inlet water temperature

Cooling tower outlet water temperature

Exhaust air temperature

Electrical readings of pump and fan

motors

Water flow rate

Air flow rate

Assessment of Cooling Towers

Performance Parameters
1. Range
2. Approach
3. Effectiveness
4. Cooling capacity
5. Evaporation loss
6. Cycles of concentration
7. Blow down losses
8. Liquid / Gas ratio
37

Assessment of Cooling Towers

1. Range
Hot Water Temperature (In)

High range = good

performance

(In) to the Tower

(Out) from the Tower

Cold Water Temperature (Out)

Approach

Range (C) = CW inlet

temp CW outlet temp

Range

Difference between
cooling water inlet and
outlet temperature:

Wet Bulb Temperature (Ambient)

38

Assessment of Cooling Towers

2. Approach

Approach (C) =
CW outlet temp Wet
bulb temp
Low approach = good
performance

Range

Hot Water Temperature (In)

(In) to the Tower

(Out) from the Tower

Cold Water Temperature (Out)

Approach

Difference between
cooling tower outlet cold
water temperature and
ambient wet bulb
temperature:

Wet Bulb Temperature (Ambient)

39

Assessment of Cooling Towers

3. Effectiveness
Hot Water Temperature (In)

= Range / (Range +
Approach)

Range

Effectiveness in %

= 100 x (CW temp CW

out temp) / (CW in
temp Wet bulb temp)

Cold Water Temperature (Out)

Approach

High effectiveness =
good performance

(In) to the Tower

(Out) from the Tower

Wet Bulb Temperature (Ambient)

40

Assessment of Cooling Towers

4. Cooling Capacity

= mass flow rate of water

X specific heat X
temperature difference
High cooling capacity =
good performance

(In) to the Tower

(Out) from the Tower

Cold Water Temperature (Out)

Approach

Heat rejected in kCal/hr

or tons of refrigeration
(TR)

Range

Hot Water Temperature (In)

Wet Bulb Temperature (Ambient)

41

Assessment of Cooling Towers

5. Evaporation Loss
Hot Water Temperature (In)

= theoretically, 1.8 m3 for

every 10,000,000 kCal heat
rejected

Range

Water quantity (m3/hr)

evaporated for cooling duty

(In) to the Tower

(Out) from the Tower

= 0.00085 x 1.8 x circulation

rate (m3/hr) x (T1-T2)

Approach

Cold Water Temperature (Out)

Wet Bulb Temperature (Ambient)

T1-T2 = Temp. difference

between inlet and outlet water
42

Assessment of Cooling Towers

6. Cycles of concentration (C.O.C.)
Ratio of dissolved solids in circulating water to
the dissolved solids in make up water

Depend on cycles of concentration and

the evaporation losses
Blow Down =
Evaporation Loss / (C.O.C. 1)
43

Assessment of Cooling Towers

7. Liquid Gas (L/G) Ratio
Ratio between water and air mass flow rates
Heat removed from the water must be equal to
the heat absorbed by the surrounding air
L(T1 T2) = G(h2 h1)
L/G = (h2 h1) / (T1 T2)
T1 = hot water temp (oC)
T2 = cold water temp (oC)
Enthalpy of air water vapor mixture at inlet wet bulb temp (h1)
and outlet wet bulb temp (h2)

44

Parameters calculations
of
apml
Water
I/L temp = 41 c
o

Water O/L temp =32.1oc

Range = 41-32.1 = 8.9oc
Wet bulb temp = 27.1oc
Approach = 32.1-27.1 = 5oc
Effectiveness = 8.9/(8.9+5) = 64%
Cooling capacity = 79650*8.9*1 = 708.885kcal/hr
Evaporation loss = 0.00085*1.8*79650*8.9

=1084.594m3/h
Cycles of concentration = 6
Blow down = 1084.594/(6-1) = 216.9188m3/hr
Net heat transferred = 790497kj/s
Drift loss = 0.0005*79650 = 39.825m3/hr

45

Cooling water treatment

system

Provided to make the circulating water

conductive for effective heat exchange in
condenser and ACW system.

Mainly following treatment methods are used.

46

Scale cum Corrosion

Inhibitor
Dosing
System

done at the CW Common Forebay.

to prevent scaling caused by circulating water
in the Condenser and the CW piping.
Two (2) Nos. MSRL tanks with motorized
Agitator & all accessories.
Tank capacity 1.2 m3 *2.
Two (2) x 100% dosing pumps.

47

Bio dispersant Dosing

System
Done at CW Common Forebay.
Done for prevention control of organic

fouling.
Two (2) Nos. MSRL tank with motorized
Agitator & all accessories.
Tank capacity 1.2m3 *2.
Two (2) x 100% dosing pumps

48

49

50

Sulphuric Acid Dosing

System
Dosed in the CW pump common Forebay .
To convert scale forming calcium and

magnesium bi-carbonates into corresponding

sulphate compounds having higher solubility.
Two (2) Nos. Sulphuric acid storage tanks with
accessories.
Tank capacity 30m3 *2.
Two (2) x 100% Sulphuric Acid Unloading
pumps
Two (2) x 100% Sulphuric Acid Dosing pumps
51

52

53

Biocide

Dosing

Biocide shall be fed into the circulating water

forebay for protection against microbiological

growth in the circulating water system.
Biocide shall be dumped into the CW
forebay as per stipulated interval of time.
One (1) No MSRL tank with motorized Agitator
& all accessories.
Tank capacity 3.2m3.

54

Side Stream
Filtration
System
Provided near the CW
forebay,
Sized for 1% of total CW flow of all Cooling

Towers and designed for CW Pumps shutoff

pressure.
From the CW return header, cooling water is
fed to the filters. The filtered water is fed back
to CW forebay.
The Backwash for the side stream filters shall
be from CW pump discharge header in a
counter flow manner .
55

56

57

Continued
Nine (9) nos Pressure sand Filter units with

interconnecting piping, necessary

instrumentation for complete automation.
Two (2) x 100% backwash waste transfer
Pumps of required capacity and Head.
One (1) x 100% backwash collection sump.

58

Cw pump house
The function of CW Pump is to circulate

cooling water in condenser and condense

turbine exhaust Steam.
Pump discharge valve is hydraulic operated.
Pump discharge water is used to cool motor
windings.
For initial start-up, service water will be used.
59

60

61

PUMP SPECIFICATION & OTHER DETAILS

Manufacture
Pump type
Motor Rating
Speed
Make
Motor Weight
Pump Discharge
Total Head
Pump Efficiency
Pump Input

KIRLOSKAR BROTHERS LIMITED

: BHM135, Single stage, Self water
lubricating pump
:3600 KW
: 330 RPM (NOM)
: WEG
: 35300 KG
: 39825 M^3/HR
: 26 M
: 92 %
: 3049.73 KW

62

SPECIFICATION(MOTOR)

Type

Three phase induction motor

Power
3600 kw
Speed
330 rpm
Frequency
50Hz
Duty
S1
Voltage
11kv
Current
245.5 amp
Insulation class
F
Efficiency
96(-2%)

63

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65

66

67

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69

70

71

72

Pre CHECK LIST

No PTW pending of CT, MCWP, CWS &

condenser.
Min. 10 nos. riser v/v in open condition for one
pump.
All air relief v/v in service.
MCWP discharge header in fill up condition.
Sump level normal.

73

START PERMISSIVE

Discharge BFV 100% close.

Discharge BFV hydraulic system is available and

ready for remote operation.

Motor Winding temperature not High.
Motor DE & NDE Bearing temperature not High.
Pump Thrust Bearing Metal Temperature not
High.

74

Continued..
Pump Thrust Bearing Oil Temperature not

High.
Sump water level of MCW pumps should not
be lower than normal water level.
MCW Pump & Booster Pump in cooling water
system switchgear is available and ready for
remote operation.
Cooling water skid (CWS) are available and
ready for operation.
75

Continued

Physically check and confirm that all the

Manual Valves on the CWS are in open

condition.
Condenser Inlet / outlet path is open.
Manual confirmation that inlet/outlet valve of
duty booster CWS pump & duty strainer is
open.
Vibration High earlier alarm if any is to be
reset.
Motor leak detector signal healthy.
76

START SEQUENCE
First selected MCW Pump is given start

command.
MCW Pump ON feedback is monitored
BFV open command is given.
BFV opening initiated (Full close limit switch
feedback withdrawn) is monitored.
Flow switch contacts in cooling circuit are
bypassed for set time of 60 seconds.

77

Contd..
Rated Flow of CWS achieved is monitored

after above 60 seconds set time.

Timer is initiated for monitoring full opening of
Main Discharge BFV and BFV to open fully
within 60 seconds.
If all the above requirements are achieved as
designed, Pump set successful start is
established.

78

Contd
If in the CWS the required pressure & flow of

cooling water in the discharge booster pump

is not established within set time , alarm is
generated.
Additionally the system should take care that
minimum 60 seconds time gap is there after
start command is given for the first MCW
Pump.

79

STOP SEQUENCE

Give MCW Pump stop command.

The BFV will be given close command.
BFV closing initiated (Full open limit switch

feedback withdrawn) is monitored.

BFV to close up to 80% on arrival of this
feedback, main MCW Pump switch gear to be
given stop command.
MCW Pump off feedback is monitored.
BFV full closing time is initiated.

80

Contd.
BFV to close within above set time.
BFV should close fully (100%) within 20

seconds of receiving MCW Pump OFF

feedback.
If BFV fails to close fully (from 80% close to
100% close) within set time then give alarm
BFV closing trouble.

81

TRIP CONDITIONS:
Motor Stator Winding Temperature is High

High (1400C).
Motor DE & NDE Bearing Temperature High
High (1050C).
Pump Thrust Bearing Temperature High
High.(850C)

82

Contd.
Pump Thrust Bearing Vibrations High High.
Motor DE & NDE Bearing Vibrations High

High(10mm\s)
On arrival of this signal both/all the MCW
Pumps of a unit will trip, CWS discharge
pressure sustainedLow Low.
On arrival of this signal both/all the MCW
Pumps of a unit will trip, CWS Differential
Pressure sustained across strainer is High.
83

Contd..
Cooling water sustained flow Low at any of the 4
flow inlets.
On arrival of this signal both/all the MCW Pumps
of a unit will trip, Sump Water Level of MCW
Pumps is at Low Low Level(7.55).
BFV do not open fully (100%) within approx. 60
seconds. No trip but sequence stops.
MCW pump discharge pressure High High for
more then 300 seconds.

84

Forebay level

85

TRIP SEQUENCE
This sequence is executed when any one or

more of the Trip condition arrives.

The MCW Pump Motor will immediately stop and
the BFV will be open more than 20% (Most of
the times 100% open) and alarm is generated.
The BFV should be given emergency close
command so that it closes from 100% open to
20% open within10 seconds and the balance
20% within 20 seconds.

86

Daily Check list

Oil level of Gear box & pump thrust bearing.
Vibration of CT fan. Motor, pumps.
Temps of brg. & wdg.
Any abnormal sound.
Any cable & switch gear heating.
DP of booster p/p filter.
House keeping of concerned area.

87

Surge Protection Valve for

CW System
COMBINATION AIR VALVE
LOCATION

One each near the elbow downstream of

pump discharge valve.

On top of inlet water box of LP Shell.
On top of outlet water box of LP Shell.
On top of outlet water box of HP Shell.

88

Vacuum breaker valve

LOCATION

Near the elbow downstream of vacuum pump

cooler 1A.
Near the elbow downstream of vacuum pump
cooler 1B.
Near the elbow upstream of vacuum pump
cooler 1B.

89

DO
S
&
DONT
S
OF
cwph
Do:
Ensure safety.
Follow SOPs
Maintain house keeping.
Maintain proper lighting.

90

Dont
Dont open CT fan enclosure.
Dont start pump if sump level low.
Dont start CT fan if oil level low.
Dont waste electricity.
Optimum utilization of water & chemicals.
Dont touch any rotating parts.
Dont panic during emergencies etc .

91

Quiz.pptx

92