Summer Internship

Project Report

Topic:
Reduction of Aux. power consumption by
introducing cooling tower in the Aux. cooling system at
Southern Generating station.
Sampad Ghosh
NIT Durgapur

2012

Contents
Objective of the project.

Study the existing cooling system both CCW &

ACW.

Design specification of the current systems.

Operational data of the current system

(measurement).
Existing pains.

Options for CESC to select.

Selection of most efficient option.
Technical and Financial analysis.

Conclusion and comments.

ACKNOWLEDGEMENT
This present project would not have been possible without the help; I
have received from various quarters of Southern Generating Station
of CESC.I extend a special thanks to my project guides Mr. Sudipta
Laha, Mr. S.N.Lahiri, Mr. Suprakash Ghosh for their guidance
throughout the entire period of the project .I also convey special
thanks to all staff members of Southern Generating Station who gave
their precious duty hours to provide an insight into the working of
the power plant. Finally I would like to thank CESC for providing me
this opportunity to work on real life industrial project like this.

OBJECTIVE OF THIS PROJECT:

A power plant produces electrical energy and also consumes a
substantial amount of energy in the form of auxiliary consumption
required for various plant equipments and services. It is one of the
prime objectives of the organization to minimize the plants auxiliary
power consumption.
If we look at the present scenario of auxiliary power consumption of
Southern Generating Station its more than 9% of its generating
capacity which is little higher in compare to the other thermal power
generating station.
This project was solely carried out to reduce the auxiliary power
consumption by converting the Heat exchanger based auxiliary
cooling system to a cooling tower based system by the following
steps:

Feasibility study of conversion of the existing heat exchanger

based closed loop CCW auxiliary cooling system to cooling
tower based auxiliary cooling system.

Also exploring feasibility of inclusion of the present open

circuit ACW cooling system into the cooling tower based
auxiliary cooling system

Primary feasibility on technical aspect followed by commercial

viability of the project

Existing Auxiliary Cooling system of Southern

Generating Station:
The auxiliary cooling system of southern generating station consist of
two cooling circuits; one is auxiliary cooling water circuit (ACW) and
the other one is clarified cooling water circuit (CCW)

1.AUXILIARY COOLING WATER CIRCUIT (ACW)

Type: This is an open type cooling circuit.
Coolant: Raw water from Ganges
Inlet: Raw water from Ganges (from Discharge of CW Pumps)
Outlet: Return to Ganges through CW Outlet discharge channel.
Heat load on the circuit:
Direct Heat load:
TG Oil Coolers (Major) - 2(One for each Unit).
BFP Oil Coolers 6 (One for each BFP).
Coal Mill Lub Oil Cooler 10 (One for each
mill).
Indirect Heat Load:
From CCW(through Heat Exchangers).

2. CLARIFIED COOLOING WATER CIRCUIT(CCW)

Type: This is a close type cooling circuit.
Coolant: Treated water (from Non DM chain of DM Plant)
Heat loads:
Gen. Air Coolers (Major) - 2 (One for each
Unit).
Compressors Coolers.
Bearings of Unit Auxiliaries.

Loss Make up: From Clarified MU tank at 21 meter level

(Gravity make up)

EXISTING ACW AND CCW CIRCUIT LAYOUT:

ID,FD,PA FAN#1
GEN. AIR
COOLER 1

MILL COOLERS
A

C
W
P

A
C
W
R

35 C

T
O
G
A
N
G
E
S

ACWP

COMPRESSOR

CEPS#1

A/C COMP

T G L O C#1

H/EX
A

CCW
TANK#2

BFPS#1

BFP#1

F
R
O
M

CCW
TANK#1

A
C
W
S

CCWP

C
C
W
S

H/EX
B

C
C
W
R

39 C

H/EX
C

38.5 C

D
ID,FD,PA FAN#2

T G L O C#2
MILL COOLERS

BFP#2

CEPS#2
BFPS#2
GEN. AIR
COOLER 2

42 C

QUALITY OF THE COOLANT:

Parameters

ACW (Open Circuit)

CCW (Closed Circuit)

Design

Design

Actual

Actual

Max

Avg.

Max

Avg.

Max

Avg.

Max

Avg.

7.93

8.2

8.06

---

8.5

8.2

TSS (ppm)

400

348

318

161

---

100

100

45

Total Hardness (ppm of

Na)

132

74

122

88

---

144

95

62

Hardness (ppm of Ca)

62

40

67

52.3

---

95

68

40

Hardness (ppm ofMg)

70

34

55

35.7

---

49

27

22

Cationic Load (Ca, Mg,

Na, K)

218

132

178

140

---

238

140

84

Salinity (ppm of NaCl)

30

20

26

22.4

---

64

22

19

Silica (ppm of Si)

18

5.98

8.88

6.36

---

5.72

6.2

5.9

Chloride (ppm of CaCO3)

37

---

22.2

19.1

---

54.7

18.8

16.2

Iron (ppm of Fe)

0.5

<0.5

0.5

<0.5

---

<0.5

0.5

<0.5

pH

SPECIFICATIONS OF EQUIPMENT IN ACW & CCW

SYSTEM:
PUMP SIDE
ACW
Type

Spec.

Centri
-fugal

Net head
(MWC)

35

Flow
(Cu
m/Hr)
485

MOTOR SIDE
Input
power
(KW)

Rated
Power
(KW)

Rated
Volts
(V)

Rated
Amps
(A)

Speed
(RPM)

52.5

75

415

132

1480

PUMP SIDE
CCW
Type

Spec.

Centri
-fugal

Net head

Flow

(MWC)

(Cu m
/Hr)

50

585

MOTOR SIDE
Input
power
(KW)

Rated
Power
(KW)

Rated
Volts
(V)

Rated
Amps
(A)

Speed
(RPM)

95.5

125

415

216

1485

SPECIFICATIONS OF OTHER EQUIPMENTES IN

ACW & CCW SYSTEM:
PRESSURE
DROP

INLET
TEMP.

OUTLET
TEMP

FLOW
RATE/COOLER

(Kg/Cm2)

(Kg/Cm2)

(C)

(C)

(Cu m/Hr)

TG LUB
COOLER
(ACW)

6 (Max)

0.4

31

33

85

BFP OIL
COOLER
(ACW)

0.2

31

35

16.8

12

4.5 (Max)

0.4

36

40

288

H/EX CCW
Side

0.5

40

37

535

H/EX-ACW
Side

0.6

35

39

600

UTILITY

GENERATOR
AIR COOLER

INLET
PRESSURE

Nos.
Present

(CCW)

OPERATIONAL DATA (MEASURED):

Date of reading : 23-05-2012
PUMP

ACW Pump A

Voltage

Current

432.0

75.0

432.0

66.0

0.8

Calculated Power (KW)

45.72

0.8

39.50

Not Measured

ACW Pump D
ACW Pump E

(Design)

Not Measured

ACW Pump B
ACW Pump C

Power Factor

432.0

72.0

0.8

43.10

Not measured

ACW Pump F
CCW Pump A

440.0

173.0

0.8

105.50

CCW Pump B

440.0

166.7

0.8

101.63

CCW Pump C

440.0

155.3

0.8

94.68

CCW Pump D

440.0

183.0

0.8

111.57

OPERATIONAL DATA (MEASURED) :

UTILITY

INLET
PRESSURE

OUTLET

INLET
TEMP.

OUTLET
TEMP.

Approx. FLOW
RATE/COOLER

(C)

(C)

(Cu m/Hr)

(Kg/Cm2)

PRESSURE
(Kg/Cm2)

PA FAN (CCW)

3.60

3.20

39

43

6.00

FD FAN (CCW)

3.60

3.20

39

42

7.00

ID FAN (CCW)

3.55

3.15

39

43

4.50

COMPRESSOR
(CCW)

5.20

3.70

39

43

7.50

BFP SEAL
COOLER(CCW)

Cannot be
measured

3.20

39

42

12

CEP
BEARING(CCW)

Cannot be
measured

Cannot be
measured

38

42

1.5

SAMPLE
COOLER(CCW)

2.60

Cannot be
measured

39

45

2.05

AIR HEATER
BEARING(CCW)

2.60

Cannot be
measured

39

42

2.00

H/EX (CCW)

6.00

5.70

43

39

Cannot be
measured

UTILITY

INLET
PRESSURE

OUTLET

INLET
TEMP.

OUTLET
TEMP.

Approx. FLOW
RATE/COOLER

(C)

(C)

(Cu m/Hr)

(Kg/Cm2)

PRESSURE
(Kg/Cm2)

GEN. AIR
COOLER (CCW)

5.50

5.00

39

42

Cannot be
measured

BFP LUB
COOLER(ACW)

Cannot be
measured

Cannot be
measured

35

37

24.00

COAL MILL
(ACW)

2.70

2.30

35

40

4.00

TG LUB
COOLER(ACW)

2.80

2.00

35

37

Cannot be
measured

H/EX (ACW)

3.70

3.40

35

38

Cannot be
measured

NOTES:
The flow has been measured physically and against atmospheric
pressure.
Temperatures have been measured by thermo gun.
Period of reading: 3rd week of May 2012.

ACW CIRCUIT FLOW BALANCING:

Approx. Flow Rate
/cooler

Utility

(Cu m/Hr)

Total no. of
Total flow rate
cooler
(Cu m/Hr)
present in the
(Approx)
circuit.

85 (Design)

170

Coal mill lub. oil cooler

10

40

BFP lub. oil cooler

24

144

367 (Derived)

1101

See Note 1

See Note 2

TG lub. oil cooler

Heat exchanger

Total ACW flow (3 x rated ACW flow @ 485 Cu. M / Hr)

1455

Note 1: ACW Flow through HE = Total rated flow of 3 ACW Pumps

minus all the other flow
Note 2:
In Summer 3 Heat exchangers are in Service
In Winter 2 Heat exchangers are in Service & the ACW &
CCW of the 3rd Heat exchanger is kept shut

CCW CIRCUIT FLOW CALCULATION:

Utility

Approx. Flow Rate

/cooler
(Cu m/Hr)

Total no. of
Total flow rate
cooler present in
(Cu m/Hr)
two unit

288 (Design)

576

Compressor

7.50

11

82.5

ID fan Bearing
Cooler

4.50

18

FD fan Bearing
Cooler

7.00

28

PA fan Bearing
Cooler

6.00

10

60

Sample cooler

2.05

4.1

Air Heater

2.00

BFP Seal Cooler

12.00

72

CEP Bearing

1.50

Oil centrifuge

0.50

Generator Air
cooler

Total CCW flow

855.6

EXISTING REQUIREMENT
In peak summer condition number of pumps required for proper
cooling of the different auxiliaries are

EXISTING
SYSTEM

ACW PUMPS RUNNING:

CCW PUMPS RUNNING:

INLET BUS
PRESSURE
(Kg/Cm2)

INLET
TEMP.

OUTLET
TEMP

TOTAL FLOW
(Cu. M/ Hr)

POWER
(KW)

(C)

(C)

See Note 1

See Note 2

ACW
System

3.7

35

38.5

1455

128.30

CCW
System

5.5

39

42

855.6

217.07

Note 1: Total flow has been derived on the basis of design values &
measured values wherever design values are not available.
Note 2: Summated measured MAX power value as measured for 3 ACW
Pumps & 2 CCW Pumps for any combination.

EXISTING PAIN.
High Auxiliary Consumption of SGS.
% Aux. consumption.
9.4
9.2
9
8.8
8.6
8.4
% Aux.
consumption.

20072008

20082009

20092010

20102011

20112012

8.84

8.94

9.07

9.35

9.27

Now, if we have a look at the average aux. power consumption of

the Indian thermal power plant, it was 8.33% for the FY 2009-2010.
In comparison with that national scenario, aux. power consumption
is really higher at southern generating station.

Source: CEA -Performance Review of Thermal Power Stations 2009-2010

 Regular Maintenance of Heat Exchangers caused due to:

Cleaning of the depositions over the plates.
Leakage from the plates.
Short circuiting in the backwashing line.
Malfunctioning of valves due to regular operation leading to
unit outage.
Regular manual involvement for strainer cleanings & heat
exchanger backwashing.
Continuous discharge of high temperature ACW Return to
Outfall.

Options available for introduction of cooling

tower

OPTION :A
SEPARATE COOLING TOWER FOR AUXILIARY COOLING WATER
SYSTEM
&
SEPARATE COOLING TOWER FOR CLARIFIED COOLING WATER
SYSTEM

39 C

ID,FD,PA FAN#1

39 C

U 1 BFP COOLERS

ACWP
A
CT#1

35 C
Blow Down

B
C

ELIMINATION
OF
HEAT
EXCHANGERS

A/C COMP

A
C
C
W
S

REDUCTION
OF
ACW FLOW

CCWP
B

D
U 2 TG LOC

Blow Down

ID,FD,PA FAN#2

U 2 MILL COOLERS

U 2 BFP COOLERS

C
C
CT#2 W
R
35 C

High Temp return

to Ganges
eliminated

COMPRESSOR

CEPS#1

U 1 TG LOC

A
C
W
S

CCW
TANK#2

BFPS#1

U 1 MILL COOLERS

EXPECTED
ACW FLOW
1 Pump

CCW
TANK#1

A
C
W
R

GEN. AIR
COOLER 1

EXPECTED ACW
FLOW = 1/2
CCW FLOW

CIRCUIT LAYOUT OF OPTION -A

CEPS#2
BFPS#2
GEN. AIR
COOLER 2

Flow calculation for the two cooling towers.

New ACW circuit

Approx. Flow Rate
/cooler
(Cu m/Hr)

Total no. of
cooler
present in
the circuit.

Total flow
rate
(Cu m/Hr)
(Approx)

85 (Design)

170

Coal mill lub. oil cooler

10

40

BFP lub. oil cooler

24

144

Utility
TG lub. oil cooler

Total ACW flow through CT#1

354

No. of ACW pumps required= 1

The new ACW circuit is a close circuit while the existing one is a
open type circuit.
The coolant in the new ACW circuit should be as in the existing
circuit ; i.e. raw water.

CCW circuit
Approx. Flow Rate
/cooler

Utility

(Cu m/Hr)

Total no. of
cooler present
in two unit

Total flow rate

(Cu m/Hr)

288 (Design)

576

Compressor & Air Drier

7.50

11

82.5

ID fan Bearing Cooler

4.50

18

FD fan Bearing Cooler

7.00

28

PA fan Bearing Cooler

6.00

10

60

Sample cooler

2.05

4.1

Air Heater

2.00

BFP Seal Cooler

12.00

72

CEP Bearing

1.50

Oil centrifuge

0.50

Generator Air cooler

Total CCW flow through CT#2

No of CCW pumps required =2

855.6

Advantages available from option -A

1. ACW & CCW Flow through Heat Exchangers eliminated.
2. Reduction of ACW Load by an amount about 75%.
3. Resistance across Heat Exchangers (Both ACW & CCW)
eliminated.
4. High temperature ACW Return to Ganges fully eliminated.
5. Extent of valve failures in ACW & CCW system leading to unit
outages reduced.

Issues after introduction of Cooling Tower in CCW Circuits:

1. Separate cooling towers for ACW & CCW Circuit.
2. Separate Blow down & make up water arrangement for two
systems.
3. Two different types of coolant in cooling tower systems with
two different systems of chemical treatment.
4. Possibility of siltation in ACW CT basin requiring additional blow
-down load handling.
5. Manual Strainer cleaning in the ACW circuit eliminated.

OPTION-B

PARTIAL TRANSFER OF ACW CIRCUIT LOAD TO CCW CIRCUIT

&
COOLING TOWER SYSTEM FOR CCW CIRCUIT

39 C

ID,FD,PA FAN#1
CCW
TANK#1

GEN. AIR
COOLER 1

A
C
W
R
35 C

U 1 TG LOC

A/C COMP

U 1 BFP COOLERS

ACWP

To
Outfall

A
C
W
S

ELIMINATION
OF
HEAT
EXCHANGERS
REDUCTION
OF
ACW FLOW

C
C
W
S
EXPECTED
CCW
FLOW - 2
Pumps

U 2 MILL COOLERS

Limited High
Temp return
to Ganges

COMPRESSOR

CEPS#1

U 1 MILL COOLERS

FROM
CWP

39 C

BFPS#1

U 2 BFP COOLERS

U 2 TG LOC

CCWP
B

Blow Down

ID,FD,PA FAN#2
CEPS#2
BFPS#2
GEN. AIR COOLER 2

CIRCUIT LAYOUT FOR OPTION- B

C
C
CT#2 W
R
35 C

A
C
W
R

EXPECTED
ACW FLOW
1 Pump

CCW
TANK#2

Flow calculation for the cooling tower(CCW).

New CCW circuit
Utility

Flow rate
(Cu m/Hr)

Previous CCW system

855.6

Coal mill lub. oil cooler

40

BFP lub. Oil cooler

144

Total CCW flow (with 6 kg/cm2 at Discharge)

1039.6

No. of CCW pumps required= 2

Flow calculation for the new ACW circuit.

New ACW circuit
Utility

Flow rate
(Cu m/Hr)

TG lub oil cooler

170

Total CCW flow (with 3.7kg/cm2 at Discharge)

170

No of ACW pumps required=1

Advantages available from option -B

1. ACW & CCW Flow through Heat Exchangers eliminated.
2. Reduction of ACW Load.
3. Resistance across Heat Exchangers (Both ACW & CCW)
eliminated
4. High temperature ACW Return to Ganges partially eliminated
5. Extent of CCW valve failures leading to unit outage eliminated.

Issues after introduction of Cooling Tower in CCW

Circuits:
1. Only one cooling tower for CCW Circuit.
2. Possibility of better CCW supply (CT Outlet) temperature.
3. Additional Blow down system for CCW Only.
4. Chemical treatment for CCW circuit only.
5. Manual strainer cleaning in ACW system remains.

OPTION-C
COMPLETE TRANSFER OF ACW LOAD TO CCW
&
CONVERSION OF THE ENTIRE CCW CIRCUIT TO
COOLING TOWER

39 C

ID,FD,PA FAN#1
GEN. AIR
COOLER 1

A
C
W
R
35 C

U 1 TG LOC

ACWP

To
Outfall

High Temp
return to
Ganges
ELIMINATED

A/C COMP

U 1 BFP COOLERS

FROM
CWP

39 C

COMPRESSOR

CEPS#1

U 1 MILL COOLERS

CCW
TANK#2

BFPS#1

A
C
W
S

ELIMINATION
OF
HEAT
EXCHANGERS

CCWP

C
C
W
S

B
CT#2
C

EXPECTED
CCW
FLOW - 2
Pumps

35 C

A
C
W
R

NO ACW
SYSTEM
REQUIRED

CCW
TANK#1

U 2 MILL COOLERS

Blow Down

ID,FD,PA FAN#2

U 2 BFP COOLERS

CEPS#2

U 1 TG LOC

BFPS#2
GEN. AIR COOLER 2

CIRCUIT LAYOUT FOR OPTION- C

C
C
W
R

Calculation of Flow through the cooling tower.

Utility

Generator Air cooler

Approx. Flow Rate

/cooler (Cu m/Hr)

Total no. of
cooler present in
two unit

Total flow
rate
(Cu m/Hr)

288 (Design)

576

Compressor

7.50

11

82.5

ID fan Bearing Cooler

4.50

18

FD fan Bearing Cooler

7.00

28

PA fan Bearing Cooler

6.00

10

60

Sample cooler

2.05

4.1

Air Heater

2.00

BFP Seal Cooler

12.00

72

CEP Bearing &

1.50

Oil centrifuge

0.50

85 (Design)

170

Coal mill lub. oil cooler

10

40

BFP lub. oil cooler

24

144

TG lub. oil cooler

Total CCW flow (with 6 kg/cm2 at Discharge)

1209.6

 Hydraulic power required for this amount of flow at a

pressure 6 kg/cm2= 197KW
Proposed flow for New CT Pumps (assuming 2 in service):
2 x 700 =1400 Cu m/Hr
Proposed CT Cooling to run with 2 CT Pumps + 2 stand by.
Advantages available from option-C
1. ACW & CCW Flow through Heat Exchangers eliminated.
2. Reduction of ACW Load.
3. Resistance across Heat Exchangers (Both ACW & CCW)
eliminated.
4. High temperature ACW Return to Ganges fully eliminated.
5. Extent of ACW + CCW valve failures leading to unit outage
reduced.

Issues after introduction of Cooling Tower in CCW Circuits:

1. Only cooling tower for CCW Circuit.
2. Possibility of better CCW Supply (CT Outlet) temperature.
3. Additional Blow down system for CCW Only.
4. Chemical treatment for CCW circuit only.
5. Manual strainer cleaning in ACW system eliminated.

Issues for introduction of cooling tower out of

these three options:
1. Option C In terms of power saving, this option ( C ) appears to
be the most suitable, subject to the following validation
a. Coolant of existing ACW loads can be replaced by CCW
water.
b. Pressure requirement of the ACW loads can be derived
from the CT based CCW systems by use of designed
orifice ensuring required flow condition.
c. At least 5 Deg reduction is achievable in Cooling towers in
peak summer at Kolkata.
2. Option C provides the most economic usage of power as
required for the entire cooling circuit.
3. Option C offers lesser number of redundancy as compared to
that in the existing ACW & CCW systems, thereby cost of
maintenance is reduced in future.

Technical analysis:
Energy savings.
Requirement for existing system

345.37 KW

2.887 MU/Yr#1

281.76 KW

2.417 MU/Yr

Requirement for new system(Option-C) (Approx.)

231.76 KW#2

CT pumps.

CT fans.
2x25=50 KW#3
Total requirement for new system(Option C)

Total energy savings(Approx.)

0.47MU/Yr

#1: It has been seen that in the last FY we had to use

#2:

2 ACW pumps & 2 CCW pumps during winter(77 days)

2 ACW pumps & 1 CCW pumps during survey which is
done during winter(15 days)
3 ACW & 2 CCW rest of the year (273days)
Combined motor &Pump efficiency has been taken 85%.

#3: This is a tentative value. This value has been assumed after
comparing the flow capacity with existing Cooling towers fan rating of
other generating stations.

Financial analysis:
Investment required:Cooling tower and auxiliaries.
New CT pumps.
Total
Approx .annual savings by implementation of new system
(Option-C): Rs/-28.2 lakhs
Simple payback period:

CONCLUSION:
The design specification of the CT fan and overall cost of this project is
under consideration of the cooling tower manufacturer and MMDSouthern Generating Station.
Condition for economic viability of the project
Project will be viable if the power saving achieved through this
project is paid back within 24 months.
# Use of the existing CCW pumps in the CT based cooling system
can add on to the enhancement of the payback period of the project.

If the project comes out to be economically viable, then required

strategies for CESC after introduction of cooling tower:
1. Incorporation of the CT Cooling control in DCS.
2. Outsourced maintenance for Cooling Tower (MMD + E&I).
3. Outsourced chemical control system including dosing & blow
down.
4. Testing of water quality at DM LAB.
5. Operation of Cooling Tower system including pumps under MPO
(Operators).