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© 2015. Shiv Kumar Shah & Dr. Rajendra Shrestha. This is a research/review paper, distributed under the terms of the Creative
Commons Attribution-Noncommercial 3.0 Unported License http://creativecommons.org/licenses/by-nc/3.0/), permitting all non
commercial use, distribution, and reproduction in any medium, provided the original work is properly cited.
Design Modification of Cooling Water System for
Hydropower Plants [A Case Study of Middle
Marsyangdi Hydropower Plant in Nepal]
Shiv Kumar Shah α & Dr. Rajendra Shrestha σ
2015
CWS. Due to this, the existing system has been experiencing
unex pected unit breakdown as well as frequent maintenance
Year
that ultimately cause a severe impact on the power generation.
This problem could be overcome by introducing a
close loop circuit along with an open loop circuit of cooling 9
water supply which passes through a Tubular Heat Exchanger
directly submerged into Draft Tube water where heat transfer
M
the open loop of CWS. This excessive silt is not only
iddle Marsyangdi Hydropower Plant is located
causing frequent unit breakdown but also damaging
in Lamjung district of Nepal with an installed
various components associated with cooling water
capacity of 70 MW and annual design
Pumps, Heat Exchangers, Automatic Water Strainers,
generation of 398 GWh. It has two turbine units together
Pipings, Backwash Flushing and other accessories.
with other Auxiliary equipment. It was commissioned in
Frequent replacement of these damaged parts is not
2008 with assistance from Government of Germany and
only expensive but also time consuming process when
Government of Nepal at an estimated cost of NRs. 30
the unit cannot generate power. Cleaning of Heat
billion. Discharge from the river is diverted through 5.2
Exchangers, Automatic Water Strainers and Pipings
Km long power tunnel constructed along the right-bank
requires considerable time and the maintenance crews
of Marsyangdiriver up to Sinudibar where the
have to be engaged from time to time in carrying out
Powerhouse is situated. The major components of
such maintenance during monsoon affecting the other
MMHPP consist of combined concrete gravity and rock
scheduled maintenances.
fill dam with gated Spillway, three numbers of There is no doubt that the existing CWS of
underground Desander caverns, Headrace Tunnel, MMHPP is based on the latest and recent design and is
Surge Tank, Valve Chamber, Penstock, Powerhouse, better than the older system which exists at other large
Tailrace Structure, two numbers of Power Transformer power plants such as Kaligandaki HPP, Marsyangdi
bays and a 132 kV outdoor sub-station. The entire HPP etc in Nepal. The older design incorporates only
generated power is being sent to the Integrated Nepal one loop i.e. open loop of Cooling Water Supply which
Power System (INPS) via MMHPP 132 kV transmission either taps water directly from the Penstock (by gravity
line. flow) or draws water from the Draft Tube by means of a
water pump and supplies water to various consumers
and sent back to the Draft Tube after cooling. Since
MMHPP water from both sources is very dirty (full of silt)
especially during monsoon, apart from damaging the
associated components of CWS, it also damages the
Author α: Electromechanical Design Division, Engineering Services components associated with the various consumers at
Directorate, NEA. e-mail: shivshahmm@hotmail.com different locations where such dirty water is being
Author σ: Department of Mechanical Engineering, Pulchowk Campus, supplied.
Institute of Engineering, Tribhuvan University, Nepal. The existing compact Plate Heat Exchanger
e-mail: rsfluid@hotmail.com provides highly effective cooling and is very useful with
clean water, however in context of Nepal, where most of Middle Marsyangdi CWS is designed to be in
the rivers are originated from Himalayas and have function fully automatic. No manual interference is
excessive quartzite sand, it is getting damaged quickly required. Cooling system is divided in two main cooling
with sandy water as in the open loop of MMHPP. circuits and two water entrance supplies. In the first
Hence the existing system is not serving the entrance for open circuit, water is taken from Penstock
desired purposes effectively and necessitates some before turbine inlet valve and directed to one of two
design modification for improved and reliable cooling “Automatic self-cleaning Filter”. From this filter, water
system which could have better performance even with circulates through one of two “Heat Exchangers” and
sandy water. The concept is to design a Heat Exchanger then discharges back to Draft Tube. In the second
in the form of a cooling coil or a Shell and Tube type of entrance for open circuit, water is pumped by two of two
Heat Exchanger (without Shell) and the entire unit shall 50% capacity pumps, from Draft Tube and directed to
be placed directly inside the Draft Tube or Tailrace one of two “Automatic self-cleaning Filter”. From this
chamber at appropriate location where optimum cooling filter, water circulates through one of two “Heat
2015
effect for the close loop circulating water with minimum Exchangers” and then discharges back to Draft Tube.
Year
erosion of the unit can be achieved with the flowing Sediments and dirt are automatically directed to the
water coming out of the runner exit via Draft Tube. Pump sump of the powerhouse from self-cleaning filters.
10 Proper sizing and selection of material of the In the closed circuit, water is circulated by one
cooling coil, its configuration, connection to the existing of two 100% capacity circulation pumps to following five
system, appropriate location for easy installation shall consumers:
Global Journal of Researches in Engineering ( F ) Volume XV Issue VI Version I
be determined during the design phase of the entire unit • Governor Oil Cooler: 1.3 m³/h
is performed in detail installation work. Hence the main • Turbine Guide Bearing: 1.5 m³/h
objective of this paper is to modify the design of existing • Combined Bearing: 14.1 m³/h
Cooling Water Supply System of MMHPP in order to • Generator Guide Bearing: 3.9 m³/h
achieve improved plant reliability with reduced plant
• Generator Air Cooler : 119.2 m³/h
breakdown and maintenance costs.
All cooling water pressure, flow and
II. Research Methodology temperature in both open and close circuits are
controlled by governor and in case of malfunction, stand
Review of existing design of CWS system of by unit is automatically activated to cover and keep
MMHPP was performed. All necessary design turbine in function.
calculations associated with the modified system and For each closed circuit two circulation pumps
proper analysis to ensure its technical and financial with adjustable speed are provided, each one with 100%
feasibility, were carried out. discharge capacity of the flow required under full load of
a) Review of Cooling Water System of Mmhpp) System the generator for the given temperature difference (350C
Description to 280C).The discharge of one pump shall be not less
MMHPP consists of FUNKE horizontally than 40 lit/sec. The required head of the pump depends
arranged Plate Heat Exchangers (PHE) is provided for on the hydraulic resistance of all components within the
exchanging heat between the closed and open circuit. It closed circuit it uses motor capacity of 30 kW.
consists of a package of embossed heat transfer plates. For each open circuit two centrifugal pumps
The plates are assembled in a 180° angle to each other with constant speed are provided, each one with 50%
and provided with gaskets which seal the various flow discharge capacity of the flow required under full load of
gaps from the outside and separate the media from one the generator for the given temperature difference (250C
another. Effective heat transfer, warm and cold media to 280C).The discharge of one pump shall be not less
are normally led through the PHE in one-pass or multi- than 70 lit/sec. The required head of the pump depends
pass counter flow. on the hydraulic resistance of all components within the
open circuit it uses motor capacity of 55 kW. Water flow
velocity for each circuit shall not be higher than 2 m/s.
EXISTING CWS AT MIDDLE MARSYANGDI HYDROPOWER PLANT III. Data analysis and Processing
Unit/Plant tripping outage and maintenance
CIRCULATION M NORMALLY
PUMP OPEN
NON
RETURN
GENERATOR GUIDE
M
M
MOTOR
OPERATED
System collected from MMHPP for the years 2010, 2011
& 2012 had been thoroughly reviewed and analyzed.
BEARING VALVE
NORMALLY
OPEN BACK-UP
COMBINED BEARING
The maintenance frequency and duration of the entire
CWS (Heat Exchanger, Automatic Water Strainer,
MAIN
SUPPLY
TURBINE GUIDE BEARING
levels.
PENSTOCK
DRAFT
TUBE
CLOSE LOOP
2015
OPEN LOOP
7 No. of Unit Trips
Year
6 Maintenance Hours
No. of Trips
Exchanger at MMHPP 4 11
Despite of its innovative and compact design, 3
the service of existing PHE has been severely affected
b) Major Maintenance Works Carried out in the Cws of Fig.3.1 : Monthly tripping and maintenance hrs 2010
Mmhpp
During the years 2010, 2011 & 2012, mainly 25
following major maintenance activities had been carried No. of Unit Trips
20
out in the Cooling Water System of MMHPP: Maintenance Hours
maintenance; 10
• Heat Exchanger & Plates cleaning and
maintenance; 5
• Replacement of ruptured Heat Exchanger Plates 0
with the new ones; 0 1 2 3 4 5 6 7 8 9 10 11 12
-5
• Cleaning and maintenance of Backwash filter Months
with replacement of Diaphragm seal;
• Replacement of complete set Backwash shut-off Fig.3.2 : Monthly tripping and maintenance hrs 2011
valve of AWS and Backwash filter transformer;
• Cleaning and maintenance of Backwash flushing
5
system; No. of Unit Trips
• Cooling Water Inlet/Outlet Orifice plates cleaning 4
and maintenance;
No. of Trips
3
• Replacement of old tubes for AWS with the new
ones; 2
• Removing mud and sand from motor operated 1
valves of AWS;
• Replacement of Shaft Coupling for Cooling Water 0
Pump; -1 0 1 2 3 4 5 6 7 8 9 10 11 12
• Repair, maintenance and replacement of Cooling Months
Water Pump Impeller;
• Cleaning and maintenance of open circuit cooling Fig.3.3 : Monthly tripping and maintenance hrs 2012
water pipes and valves;
25 Monthly Trippings and Maintenance Hours a) Design Considerations And Underlying Theories
2010, 2011, 2012 Case being as forced convection, we should
analytically consider the problem of heat transfer in fully
No. of Trips/Maintenance Hours
20 No. of Unit
Trips developed laminar or turbulent tube flow as the case
Maintenance
may be. The cases of underdeveloped laminar flow, flow
15
Hours systems where the fluid properties vary widely with
temperature, and turbulent-flow systems are
10
considerably more complicated but are of very
important practical interest in the design of heat
5
exchangers and associated heat-transfer equipment.
These more complicated problems may sometimes be
0 solved analytically, but the solutions, when possible, are
very tedious. For the design and engineering purposes,
2015
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
-5 Months empirical correlations are usually of greatest practical
Year
utility.
Fig. 3.4: Monthly tripping and maintenance hrs 2010, b) Flow Inside Tubes
12
2011 and 2012
Q
Global Journal of Researches in Engineering ( F ) Volume XV Issue VI Version I
Calculation were performed for various sizes and best come to be 0.027 and 0.805 respectively from this
suitable is found for following parameters: Hence, if 1” Table. Hence,
diameter and 1.5 m long tubes are selected, 33 pieces ∴Nud = 0.027 × (73,867)0.805× (0.076)0.33
will be required. Increased number of tubes leads to
bulky heat exchanger with bigger flanges. Since the = 0.023 ×8300.5× 0.42724
objective is to design optimum size Heat Exchanger, = 81.56
1.5” mild steel tube is considered to reduce the overall Also, Nud = (ho× Do) / kor, ho = (Nud× k) /
size of the Heat Exchanger in Case II below: Do = (81.56× 54) / 0.04826 = 91,261
Nominal Diameter (Dn) = 1.5” = 0.0381 m
Inside Diameter (Di) = 1.61” = 0.040894 m, ∴ho = 91,261 W/m2 0C
Inner Radius (ri) = 0.020447 m Now, the overall heat transfer coefficient (Uo)
Outside Diameter (Do) = 1.9” = 0.04826 m, can be determined by using the equation 2−15 or 2−16
Outer Radius (ro) = 0.02413 m on Page no. 35 of “Heat Transfer” by J. P. Holman,
2015
d) Flow Inside Tube eighth edition.
Year
Reynolds Number (Re) = (Vi× Di) /ν 𝟏𝟏
𝐔𝐔𝐨𝐨 = 𝐫𝐫
= (2 ×0.040894)/(9.8 × 10−7) = 83,457 𝐀𝐀𝐨𝐨 × 𝐥𝐥𝐥𝐥 ( 𝐨𝐨 ) 13
𝐀𝐀𝐨𝐨 𝟏𝟏 𝐫𝐫𝐢𝐢 𝟏𝟏
Since Re > 4000, the flow inside tube is turbulent. � � + + +
𝐀𝐀𝐢𝐢 𝐡𝐡𝐢𝐢 𝟐𝟐π𝐤𝐤𝐤𝐤 𝐡𝐡𝐨𝐨
Thus, total surface area required to transfer the size but enough to transfer the desired quantity of heat
desired amount of heat with 1” mild steel tube comes to from the hot water coming from the various consumers.
be 5.453 m2. Because of space limitation inside the Based on the existing CWS configuration, location,
Draft Tube, 1.5 m long tube was assumed. Hence, arrangements, space limitations and reviewing the
number of 1.5 m long mild steel tubes; N required can relevant Mechanical as well as Civil As-Built drawings of
be calculated as: MMHPP, the following figures are identified for the
𝐀𝐀𝐬𝐬 = 𝟐𝟐π𝐫𝐫𝐨𝐨 × 𝐤𝐤 × N proposed modification works. The connections are
shown by the Conceptual Drawing in Figure 4.3 below.
𝐀𝐀𝐬𝐬 𝟓𝟓. 𝟎𝟎𝟓𝟓𝟎𝟎 h) Advantages of Locating the Tubular he Beside the
𝐍𝐍 = = = 𝟐𝟐𝟎𝟎. 𝟗𝟗𝟎𝟎 Side Wall of Draft Tube
𝟐𝟐π𝐫𝐫𝐨𝐨 × 𝐤𝐤 𝟐𝟐π × 𝟎𝟎. 𝟎𝟎𝟐𝟐𝟎𝟎𝟏𝟏𝟎𝟎 × 𝟏𝟏. 𝟓𝟓
≅ 𝟐𝟐𝟎𝟎 𝐏𝐏𝐏𝐏𝐬𝐬. Since the existing pipe aligns along the side
wall, shorter pipe length is required by installing the HE
2015
In this case with 1.5” diameter and 1.5 m long Unit in the same alignment hence less loss in pipes and
tube, we have found that only 24 pieces are enough to bends occur. No obstruction to free flow of draft tube
Year
transfer the desired heat from the flowing water through water is achieved. No direct impact (hitting) of water
tubes for the desired inlet and outlet temperatures. Such and silt over the Unit protecting it against any physical
14 a reduced number of tubes leads to comparatively damages.
smaller size and compact Heat Exchanger and hence
Global Journal of Researches in Engineering ( F ) Volume XV Issue VI Version I
cheaper in price. Hence second option i. e. 1.5”φ× 1.5 m PROPOSED CONNECTIONS AND ARRANGEMENTS OF EXISTING
CLOSED LOOP PIPING WITH TUBULAR HEAT EXCHANGER
× 24 pieces mild steel tubes for making the required COLD WATER OUT FLOW
f) Design Summary
RCC SLAB TO BE
FLOW
DRILLED TO
INSERT NEW 200
2015
Therefore, Implementation Costs =NRs. 2.345 million 6. Heat Exchanger Design, World Academy of
Year
b. Total Annual Savings Science, Engineering and Technology 46-2008.
7. Voith Hydro GmbH Germany (Lot M Contractor for
Savings on frequent Unit/Plant Breakdown = NRs. 7.1 Middle Marsyangdi Hydropower Project), 2008, 15
million Operation Maintenance Manual.
Savings on Spare Parts Consumption = NRs. 1.4 million 8. Voith Siemens GmbH Germany (Lot M Contractor
16
Global Journal of Researches in Engineering ( F ) Volume XV Issue VI Version I