ENERGY AUDIT OF CONDENSER AND

CONDENSER COOLING WATER

SYSTEM

Presented By
M.V.Pande
Dy.Director
NPTI, Nagpur
 Background
Hot
HotWater
Water
Cooling
Condenser Tower
Air Air

Cooled Make-up
CW Pump
Water Water

Condenser:
The condenser is the most important component of the turbine cycle that
affects 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
Background
Cooling towers:
Different 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:
-Induced draft
-Forced draft
- Natural draft cooling
towers
 Background
Cooling water pumps:
 Circulating water pumps supply cooling water at the
required flow rate and pressure to the power plant
condenser and the plant auxiliary cooling water heat
exchangers. These pumps are required to operate
economically and reliably over the life of the plant.
 For once through systems, vertical wet pit pumps are in
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.
Specifications of Typical Cooling Water Pump
 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
 Data Collection
Specifications of cooling towers:
 Data Collection
Specifications of cooling towers- contd…:
 Specification of water pumps and motors
Specification of water pumps and motors:
 Data Collection
Specification of water pumps and motors- contd…:

Rated kW of the pump

 Data Collection- Other 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 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 source, 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 specifications 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)
Data Collection- Condenser Specifications
 Heat load considered for design
 Design inlet cooling water temperature/ Design TTD
 Cleanliness factor/ Cooling water temperature raise
 Condenser back pressure
 Cooling water flow/ 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
 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 flow meter or online flow meter
• Sling hygrometer or digital hygrometer
• Anemometer
• In addition to the above calibrated online instruments
can be used
• PH meter
 Measurements & Observation
 Energy consumption pattern of pumps and cooling tower
fans
 Motor electrical parameters (kW, kVA, Pf, A, V, Hz, THD) for
pumps and cooling tower fans
 Pump operating parameters to be measured/monitored for
each pump are: - Discharge, - Head (suction & discharge) -
Valve position – Temperature - Load 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, condensers, etc)
 Cooling water flow rate to users - Pump /Motor speed
 Actual pressure at the user end
 User area pressure of operation and requirement
 Measurements & Observation
 Cooling tower parameters to be monitored
 Inlet temperature
 Outlet temperature
 Dry bulb temperature
 Wet bulb temperature or relative humidity
 Water flow to cooling tower
 Air flow rate of cooling tower
 Range, oC
 L/G ratio
 Approach, oC
 Fan speed, rpm
 Fan power consumption (kW/cell)
 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
 Operating Efficiency and Performance
Evaluation of the Pumps
 Water flow 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
efficiency of the pumps)
 Monitor present flow control system and frequency of
control valve variation if any (for application of variable
speed drives)
 Fill up the following data sheet for every pump for
comparison with the design / PG test values
Operating Efficiency and Performance
Evaluation of the Pumps
Operating Efficiency and Performance
Evaluation of the Pumps


 Investigations & Recommendations
 Compare the actual values with the design / performance
test values if any deviation is found, investigate for the
contributing factors and arrive 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 specific energy consumption with similar type
of pumps and latest energy efficient pumps
 Cost analysis with savings potential for taking improvement
measures.
 Flow Distribution
• Measure the flow 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
• Specific water flow rate
CONDENSERS
 Performance of Condensers
• Parameters for condenser performance
 Performance of Condensers
• Parameters for condenser performance- contd…
 Performance of Condensers
• The following needs to be computed:
1. Condenser heat load = Q x T x Cp

Parameter Details Unit

Q Water flow rate Kg/h
T Average CW temperature rise oC
Cp Specific heat kcal/kg oC

2. Calculated condenser vacuum =

Atmospheric pressure – Condenser back-pressure
3. Deviation in condenser vacuum =
Expected condenser vacuum - Measured condenser vacuum
4. Condenser TTD =
Saturation temperature – Cooling water outlet temperature
 Performance of Condensers
5. Condenser Effectiveness =
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 - 860 x (Pgen + Pgen
losses + heat loss due to radiation)
7. Condenser tube velocity (m/s) =
Cooling water flow rate (m3/h) x 106
3600 x tube area (mm2) x ( no. of tubes per pass - no. of
tubes plugged per pass )
 Performance of Condensers
8. Determination of actual LMTD
Tout - Tin
LMTD =
Tsat -Tin
Ln
Tsat - Tout
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
ft = ( Saturation Temperature design – LMTD design
)
Tube velocity during test 0.50
fw = ( Tube velocity design ) fw: correction for
water flow rate
Condenser design duty
fq =
(Condenser duty during test ) fq: correction for
cooling water heat load
Observations During Condenser Energy Audit
• Tubes in operation Vs total installed
• Cleaning system operation
• Filtering system for cooling water
• Regular monitoring system for performance
• Comparison of LMTD, TTD, heat load, condenser vacuum, flow,
temperatures, pressures with design / PG test- arriving the factors
causing deviation
• Modifications carried out in the recent past
• Cooling water flow
• Pressure drop on water side and choking
• Affect 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
• Effectiveness of cleaning the tubes
• Circulating water velocity in tubes
COOLING TOWERS
Performance of Cooling Towers
 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 flow 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 airflow shall be measured using an anemometer
and compared with calculated airflow derived from fan
characteristic curves of CT fans with actual power
measurements.
 Calculate range, approach, L/G (Liquid to gas) ratio and
effectiveness for design and operating conditions for each
tower
 Performance of Cooling Towers
1. C.T. Range = Water inlet temperature – Water outlet temp.
2. C.T. Approach = Water outlet temperature – Wet bulb temp.

Range x 100
3. Effectiveness % =
( range + approach )
4. Fan actual airflow (Nm3) / cell =
1/3
Fan rated airflow (Nm3) / h x ( Fan input kW actual )
1/3
( Fan input rated )

5. Air mass flow / cell = flow x density of air

 Performance of Cooling Towers

CW flow (m3/ h) x CT range in 0C

5. Evaporation losses =
675

Evaporation losses
6. Makeup water consumption =
(COC – 1)

 The above readings may be taken on daily basis for three

days on different 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
 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 effectiveness of condenser and TTD
• Cooling water flow adequacy and flow optimization
• Air ingress
• Increasing the TTD of the condenser
Exploration of Energy Conservation Possibilities
 Water pumping and cooling tower
• Improvement of systems and drives
• Use of energy efficient pumps
• Correcting inaccuracies of the Pump sizing / Trimming of impellers
• Use of high efficiency motors
• Integration of variable speed drives into pumps: The integration of
adjustable speed drives (VFD) into compressors could lead to
energy efficiency improvements, depending on load characteristics
• High Performance Lubricants: The low temperature fluidity and high
temperature stability of high performance lubricants can increase
energy efficiency by reducing frictional losses
• Improvements in condenser performance
• Improvement in cooling tower performance
• Application potential for energy efficient fans for cooling tower fans
• Measuring and tracking system performance
Exploration of Energy Conservation Possibilities
• Measuring water use and energy consumption is essential
in determining whether changes in maintenance practices
or investment in equipment could be cost effective

• In this case it is advised to monitor the water flow 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 flow rates
- Heat duty of condenser and cooling towers
- Measures to up keep the performance
Exploration of Energy Conservation Possibilities
 System Effect Factors
• Equipment cannot perform at its optimum capacity if fans,
pumps, and blowers have poor inlet and outlet conditions

• Correction of system effect factors (SEFs) can have a

significant effect on performance and energy savings

• Elimination of cavitation: Flow, pressure, and efficiency are

reduced in pumps operating under cavitation. Performance
can be restored to manufacturer’s specifications through
modifications. This usually involves inlet alterations and
may involve elevation of a supply tank
Exploration of Energy Conservation Possibilities
• Internal Running Clearances: The internal running
clearances between rotating and non-rotating elements
strongly influence 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 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 operation, modifications in piping system