Circulating Water System

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 Cooling Water requirement

• Bulk requirement of water is used in thermal

plants for the purpose of cooling the steam in
condensers. The requirement of water for this
purpose is of the order of 1.5-to2.0 cusecs/MW of
installation.
• Where sufficient water is available once through
system is used.
• Where water supply is not consistent, closed loop
cooling system with cooling tower is used.
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 Circulating water scheme
• A circulating water pump house
• Intake channel
• Trash rack
• A chlorination plant
• Traveling water screen
• Connecting pipe line to condensed
• Outlet channel
• A cooling tower
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 Circulating water scheme
• We shall discuss the open loop system first.

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 Function of each component
• A circulating water pump house
– It houses the main CW pumps. Vertical
submergible pump with operating pressure
around 1 Kg/ cm2.
– The pump house resides on the fore bay.
– The fore bay is flooded through intake system.

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 Intake
 It is RCC open trench from where Raw water is taken through
canal/reservoir.
 The intake level is normally 10-15 ft. above from flood level of the
water source and 12 m in depth.

Trash Rack
•Trash rack to avoid entering wood, tree branches, animal, plastic,
floating object.
• provides uniform flow/suction to the CW pump
Traveling Water Screen
•leaves
It catches small pieces of coal, sand, gravel, wood, plastic, herbs,
which can go into the impeller and may choke/damage the
pump.
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 Once through system
 Chemical dosing done for disabling micro
organism development inside the tube.
• Condenser is fitted with 4 way valve to enable
reverse flow through condenser when required.
• initial
An air purging line fitted with condenser for
charging
• Hot water coming out from condenser is allowed
to pass through long outlet channel to get cool
down before meeting the main stream of water.
• Performance of condenser mainly depends on
Inlet temp. to the condenser, Condenser tube
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 Types of CWCT systems
Open Loop system:
Water is abundant…
Reduction in the APC..

Steam from Turbine

Cold Water
Condenser
Pump
Hot water

River Flow

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CW scheme…

Reservoir/ River Canal Intake

Trash rack
Cooling tower

TWS
CT pumps

Hot Pond CW pumps

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Condenser
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Hot Pond:

•Hot Water from the condenser discharged to hot pond

and provide source for the CT pump.

CT Pump

•It takes suction from the Hot pond and discharged

the water to the riser tubes of Cooling towers

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 Cooling Tower - Introduction

• A cooling tower is an air and water management

device, which consists of fan stacks, fans, drift
eliminators, fill and water/air distribution
systems.
• It uses principle of evaporation of water in
unsaturated air.

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 Cooling Tower - Introduction
• Cooling tower is the most important
equipment for closed cycle water recirculation
system.
• The efficiency of cooling tower has direct
effect on condenser vacuum and in turn, the
heat rate of the station.
• 1oC rise in cold water temperature in a
200MW unit corresponds to 5mm vacuum loss
leading to 7.5 Kcal/kwh loss in heat rate and
in 500MW, 5.74 Kcal/kwh loss in heat rate..
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 Types of cooling Tower
• Wet type
• Dry type
• Wet type cooling towers are two type
• 1.natural draft
• 2.mechanical draft
• Mechanical draft may be devided in to two
type
• 1.forced draft
• 2.induced draft
• Both of these can be counter flow type or
cross flow type.
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 Cooling Tower – in NTPC Ltd.

There are 75 cooling towers in operation in

NTPC.
Induced Draught Cooling Towers

• Cross flow type 24

• Counter flow splash bar fill type 21
• Counter flow film fill type 20

Natural Draught Cooling Towers

• Natural draught type.

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 NATURAL DRAFT C.T.
• It produces air flow through utilisation of stack
or chimney effect.pressure diff. causing air
flow is given by p=(douter-dinner)H.g
• The fill is located in the lower portion of shell
with upper 85 to 90% of shell empty which is
used to create chimney effect.
• They are more suitable in the area of high
relative humidity ratio and low temp.
• They may be of cross flow or counter flow.

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 MECHANICAL DRAFT C.T.
• Forced draft
• Advantage:-fan is subjected to less severe
condition
• Disadvantage:-recirculation more (why?)
• Induced draft
• Advantage:-min recirculation (why?)
• Disadvantage:-fan is subjected to warm humid
condition.

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 MECHANICAL DRAFT C.T.
• Counter flow :-fill is arranged over entire tower
plan.fill is typically film type.
• Advantage:-more thermal efficiecy,smallest
tower,lower capital cost, lower pumping head
• Disad:-increased pressure drop requires more
horse power of fan.
• Cross flow:-fill is arranged at the outer perimeter.
• Advantage:-large air inlet area hence pressure
drop is less.
• Disad:-high pumping head due to more height of
fill.
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 Types of Cooling Towers

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A BIRD’s EYE VIEW OF NDCTs OF DADRI-Coal (4 X 210 MW)
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 ARRANGEMENT OF C.T.
• 1.rectangular type:-each cell indentical,more
long area required, low capital cost,for plant
upto 250mw.
• 2.round type:-less recirculation,more capital
cost,for plant more than 250mw.

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 Cooling Tower Thermal Design
Parameters are used to develop the tower design :

• Water flow rate

• Cooling range
• Design Heat load
• Design Wet-bulb temperature.
• Recirculation and interference
• DBT and relative humidity
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 DESIGN HEAT LOAD
• Condenser and c.t. are designed on the basis
of MCR load point.

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 Design Wet-bulb Temperature
• The impact the design wet-bulb temperature has on the size
and power requirements of a cooling tower is critical to
optimizing the cooling tower economics.
• In the majority of applications, the design duty of an
evaporative cooling tower is based upon an
acceptable/required cold water return temperature
• If investment and operational costs were not a concern, the
ideal design wet-bulb temperature would be equal to, or higher
than, the highest local wet-bulb temperature recorded.
• In this way, the returned water temperature would never be
higher than the acceptable/required cold water temperature.
• Design W.B.T.=DESIGN AMBIENT D.B.T.+RECIRCULATION
ALLOWANCE.

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 Component Design : Fills
• The component most likely to provide
improvement in tower performance is the fill
packing.
• The earliest and most common designs
utilized splash type fills
• Film type counter flow designs using relatively
low cost PVC materials.
• The new film type designs provide energy
savings both in fan power and pump head
through the high surface areas per cubic feet
of fill.
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TYPES OF FILLS

• Splash type consisting of splash

Bars used for crossflow and
Counterflow.

• Film type consisting of thin film of

Sheets used mostly for counterflow

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 SPLASH FILLS
In splash fill, the hot water strikes the bar and
breaksup into many smaller drops.

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 FILM FILLS
Film fill consists of flat or formed sheets to provide a
surface upon which water and air come in contact
for heat exchange.

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 Drift Eliminators
• A cooling tower drift eliminator is a low pressure, momentum
filter.
• Components are arranged to force the air leaving the fill
section to make a series of directional changes.
• Water droplets, which cannot negotiate these turns, impinge
on the surface of the eliminator, from which they are
collected and drained back into the wet side of the tower.
• The designer's goal is to provide the maximum drift
elimination at reasonable cost and minimum pressure loss.
• The design o drift eliminators has undergone tremendous
improvement in the last decade.
• New eliminator configurations accomplish this improvement
while actually reducing eliminator pressure losses

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 Drift Eliminators
• Cellular eliminators are typically constructed of
PVC sheets vacuum formed into very precise,
compound shapes, with an integral honeycomb
strength. The compound shape allows significant
improvements in drift eliminations and the use of
cellular structure appreciably reduces the
pressure losses through the eliminator when
compared to either the wood lath or wave form
eliminators.
• The net free are of well-designed, modern cellular
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 Air-Water Distribution System Design
1) Water Distribution:

• Assured performance is a function of nozzle design, nozzle installation pattern,

nozzle distance, and the structural cleanliness of the spray chamber.

• To provide the primary function of precise water distribution, the nozzle must be
designed with other considerations in mind:

• The location of counter flow nozzles and the potential for poor quality circulating
water demands that the nozzle system be designed to minimize fouling.

• The nozzle must be capable of providing uniform distribution over a wide range
of flows, without significant loss in nozzle performance.

• The nozzle must be capable of efficient operation while consuming a minimum of

expensive pump energy.

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 Air-Water Distribution System Design
2) Air Distribution: Three variables control the distribution of air to the
fill in a counter flow configuration.

• The first is the air inlet geometry.

• Pressure Ratio : The pressure ratio reflects the ratio of resistance to

available entering air energy. The higher the ratio, the better entering
air will be spread out before entering the fill. The lower the pressure
ratio, the less uniform, and less stable the distribution of air flow
becomes. The degradation of air flow uniformity is readily apparent,
particularly at the inlet.
(Pressure Ratio = Static Pressure / Velocity Pressure at Air Inlet)

• The third is the fan coverage over the eliminators

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 Fan Design
• Each fan has only one design point which is
established by a specific air flow, total
pressure, air density, and fan speed.
• The factors that must be known when
replacing a fan on an existing installation are:

1. Fan diameter.
2. Installed motor horsepower.
3. Gear reduction ratio of gear reducer.
4. Shaft size or gear reducer model.
5. Some estimate of elevation above sea level of
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 Cooling Tower Performance

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 Cooling Tower Performance
 Cooling Tower Effectiveness = Range/(Range+Approach)

 Cooling Tower Capacity = mass flow rateXspecific Heat x

Temperature Difference

 Evaporation Loss in cub mtr/Hr = 0.00085x1.8xcirculation

ratexTemperature Diff.

 Cycle of Concentration = Dissolve solid in circulating

water/Dissolve solid in make up water

 Blow Down = Evaporation Loss/(C.O.C.-1)

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 THANK YOU

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