C-ME-HM-008R0-Calculation Sheet For Cooling Water System R0

ZUNGERU HYDROELECTRIC PROJECT
Document Name: Calculation Sheet for Cooling water system
Doc No.: C‐ME‐HM‐008 R0
Rev. No.: R0
Document preparation, review, approval and acceptance:
Position Name Date Signature
Designed: He Pengpeng 30th Jan. 2018
Checked:
Examined:
Verified:
Approved:
Document Revision Table:
Date Rev. No. Description of modifications / revisions
30th Jan. 2018 R0 1st submission
Document no: C‐ME‐HM‐008R0 Revision status: 00 Date Printed: Jan. 2018


FEDERAL REPUBLIC OF NIGERIA, KADUNA RIVER
LEVEL 2
Calculation Sheet for

Cooling water system
Jan. 2018

TABLE OF CONTENTS
1 GENERAL ................................................................................................................................ 1
2 COOLING WATER CONSUMPTION .......................................................................................... 1
2.1 COOLING WATER CONSUMPTION DATA ARE AS FOLLOWS: ........................................................................ 1
3 MODE OF WATER SUPPLY ...................................................................................................... 2
4 CALCULATIONS OF DIAMETER OF PIPES ................................................................................. 3
4.1 FLOW VELOCITY IN PIPES ............................................................................................................................. 3
4.2 CALCULATIONS OF DIAMETER OF PIPES FOR TURBINE –GENERATOR ： .................................................... 3
5 CALCULATION OF HEAD LOSS OF COOLING WATER SYSTEM： ............................................... 4
5.1 FORMULA FOR THE CALCULATION OF HEAD LOSS....................................................................................... 4
5.1.1 Formula for the frictional head loss of pipes ........................................................................................... 4
5.1.2 Formula for local head loss he of pipe auxiliaries and valves ................................................................... 5
5.2 THE HEAD LOSS OF COOLING SUPPLY WATER SYSTEM ................................................................................ 6
5.2.1 The head loss of cooling supply water system for the Turbine‐generator .............................................. 6
6 EQUIPMENT SELECTION ....................................................................................................... 13
6.1 SELECTION OF THE AUTOMATIC BACHWASH STRAINER ............................................................................ 13

i
1 GENERAL
Cooling water system is used for the cooling water supply of the generator air coolers, the
generator upper guide bearing coolers, the generator Lower & Thrust bearing coolers, the
Turbine guide bearing coolers, the Main shaft working sealing, the Runner labyrinths, the Main
transformer and the HVAC equipments.
2 COOLING WATER CONSUMPTION

2.1 COOLING WATER CONSUMPTION FOR ONE UNIT ARE AS FOLLOWS:
No. Specifications Note

1. Cooling water for one generator air coolers Supplied by GE
Cooling water pressure of air cooler 0.2~0.6 MPa
Cooling water consumption for one air cooler 45 m3/h
Head loss of air cooler ≤2 m
Total cooling water consumption for one generator
540 m3/h
air coolers
2 Cooling water for one generator upper guide bearing coolers Supplied by GE
Cooling water pressure of coolers 0.2~0.6 MPa
Head loss of coolers ≤2 m
10 m3/h
upper guide bearing coolers
3 Cooling water for one generator Lower & Thrust bearing coolers Supplied by GE
25 m3/h
Lower & Thrust bearing coolers
4 Cooling water for one Turbine guide bearing coolers Supplied by GE
Total cooling water consumption for one Turbine
30.6 m3/h
guide bearing coolers
Cooling water for one Turbine Main shaft working
5 Supplied by GE
sealing
Cooling water pressure 0.2~0.6 MPa
Page 1 of 13

Cooling water consumption for one Turbine Main
10.2 m3/h
shaft working sealing
6 Cooling water for one Turbine Runner labyrinths
Cooling water pressure ≥ 0.5 MPa Supplied by GE
Cooling water consumption for one Turbine Runner
18 m3/h
labyrinths
7 Cooling water for one Main transformer Estimated
Total cooling water consumption for one Main
~105 m3/h
transformer coolers Qt
Cooling water for whole powerhouse HVAC
8 Estimated
equipments
Total cooling water consumption for for whole
~592 m3/h
powerhouse HVAC equipments coolers Qh
No.1+ No.2+
Total cooling water consumptionfor one Turbine‐ 3
9 633.8 m /h No.3+ No.4+
Generator Qu
No.5+ No.6
Total cooling water consumption for one Main
10 253 m3/h No.7+ No.8
transformer and HVAC equipments Qt+ Qh/4
Total cooling water consumption one
11 Generator,one Turbine, one Main transformer and 886.8 m3/h No.9+ No.10
all HVAC equipments Qu + Qt+ Qh/4
3 MODE OF WATER SUPPLY

The toal water consumption for one Turbine‐generator unit ,one transformer and the HVAC
equipments is about 886.8m3/h , the pressure range requirement of cooling water is
0.2~0.6MPa , and the water head of the hydropower project is 72m to 96.501m.
According to the water consumption , the pressure requirement and the water head of the
project, pressure reducing mode will be used for cooling water supply system except Turbine
Runner labyrinths .Flow by gravity mode will be used for the turbine Runner labyrinths cooling
water supply according to the pressure requirement (≥ 0.5MPa).
The temperature of cooling water will be considered as 30°C, the assumption of temperature
difference between cold and hot water will not exceed 5 °K.
Page 2 of 13
References are made to “Schematic diagram of cooling water System (D‐ME‐HM‐01 R0) and
Schematic diagram of Main transformer and HAVC equipments wate supply system (D‐ME‐HM‐
02 R0)”.
4 CALCULATIONS OF DIAMETER OF PIPES

4.1 FLOW VELOCITY IN PIPES
The flow velocity in cooling water pipes shall in general around 2.0～3.0 m/s to avoid sand
sedimentation and over abrasion.
Reference is made to “Schematic diagram of cooling water System (D‐ME‐HM‐01 R0).
The pipe diameter is calculated by the formula as below:
4Q
D  1000
3600  V
where,
D is inside diameter of the water supply pipe (mm)
Q is the cooling water consumption of equipments (m3/h)；
V is the water flow velocity in the piping system, the flow velocity after reducing valves shall be
adopted to 2.0～3.0 m/s.
CaLculations result of diameter of pipes：
Nominal Diameter
Description Flow (m3/h) Flow Velocity (m/s) (outside diameter × pipe wall
thickness) (mm)
Dm 886.8 2.79 DN350(ø355.6×10)
Du 633.8 2.43 DN300(ø323.9×10)
Dg1 540 2.96 DN250 (ø273.1×9.5)
Dg11 45 2.62 DN80 (ø88.9×5.5)
Dg2 10 1.29 DN50 (ø60.3×4)
Dg3 25 2.09 DN65 (ø76.1×5.5)
Page 3 of 13
Nominal Diameter
Description Flow (m3/h) Flow Velocity (m/s) (outside diameter × pipe wall
thickness) (mm)
Dt1 30.6 2.55 DN65 (ø76.1×5.5)
Dt2 10.2 1.32 DN50 (ø60.3×4)
Dt3 18 2.33 DN50 (ø60.3×4)
Notes：
Dm is diameter of the main water supply pipe (before reducing valves) of Turbine‐generator,
Main transformer and HVAC equipments (mm).
Du is diameter of the main water supply pipe of Turbine‐generator (mm).
Dg1 is diameter of the branch water supply pipe for all air coolers of one generator (mm).
Dg11 is diameter of the branch water supply pipe for one air cooler of one generator (mm).
Dg2 is diameter of the branch water supply pipe for one generator upper guide bearing coolers
(mm).
Dg3 is diameter of the branch water supply pipe for one generator Lower & Thrust bearing
coolers (mm).
Dt1 is diameter of the branch water supply pipe for one Turbine guide bearing coolers (mm).
Dt2 is diameter of the branch water supply pipe for one Turbine Main shaft working sealing
(mm).
Dt3 is diameter of the branch water supply pipe for one Turbine Runner labyrinths (mm).
5 CALCULATION OF HEAD LOSS OF COOLING WATER SYSTEM：
5.1 FORMULA FOR THE CALCULATION OF HEAD LOSS

The head loss of pipe system Hc consists of frictional head loss of pipes hf and local head loss he
of pipe auxiliaries and valves.
5.1.1 Formula for the frictional head loss of pipes
Page 4 of 13
The frictional head loss of pipes will be estimated by Hazen Williams formula
L Q
h f  1.13  10 9 4.871
( )1.852 ;
D C
Where:
L is the length of DN250 branch pipe, L1=15m;
D is inside diameter of pipe;
Q is the water flow in the pipe；
C is Hazen‐Williams factor,for steel pipes,C=120;
5.1.2 Formula for local head loss he of pipe auxiliaries and valves
The local head loss he of pipe auxiliaries and valves will be calculated by their equivalent length.
Equivalent length of pipe auxiliaries and valves are as follows:
Nominal Diameter
Name
DN32 DN40 DN50 DN65 DN80 DN100
45°eblow 0.3 0.6 0.6 0.9 0.9 1.2
90°eblow 0.9 1.2 1.5 1.8 2.1 3.1
Tee 1.8 2.4 3.1 3.7 4.6 6.1
Gate valve / / 0.3 0.3 0.3 0.6
Non‐return valve 1.5 2.1 2.7 3.4 4.3 4.9
Nominal Diameter
Name
DN150 DN200 DN250 DN300 DN350 DN400
45°eblow 2.1 2.7 3.3 4 4.8 5.6
90°eblow 4.3 5.5 6.8 8.2 9.7 11.3
Tee 9.2 10.7 15.3 18.3 21.3 24.3
Gate valve 0.9 1.2 1.5 1.8 2.1 2.4
Non‐return valve 9.8 13.7 16.8 19.8 22.7 25.5
Page 5 of 13
5.2 THE HEAD LOSS OF COOLING WATER SUPPLY SYSTEM
5.2.1 The head loss of cooling water supply system for the Turbine‐generator
The head loss of cooling supply water system for the Turbine‐generator are shown in Table 1:
According to the results in Table 1, the inlet water pressure of the each coolers and main shaft
working sealing is 22.10m~30.90m which is satisfied with the pressure requirement of Cooling
water consumers, and the inlet water pressure of the Runner labyrinth is 86.25m which is aslo
satisfied with the pressure requirement.
Page 6 of 13
Table1 The head loss of cooling supply water system for the Turbine‐generator
Equivalent Frictional Local head Head loss from

Inside length of head loss of lossof pipe
Length pipe inlet to Elevation Pressure
Tube Diameter Flow Velocity pipe pipes auxiliaries and
Description of pipe pipe outlet of device of here
section of pipe (m3/h) (m/s) auxiliaries
(m) hf valves he Hc=hf +he (m) (m)
(mm) and valves
(m) (m) (m)
(m)
pipe inlet 335.6 886.8 2.79 130.00 93.00
4 set of 90° elbow
335.6 886.8 2.79 38.8 0.89
DN350
1 set of 45° elbow
335.6 886.8 2.79 4.8 0.11
DN350
2 set of tee DN350 335.6 886.8 2.79 42.6 0.97
0‐1
4 set of gate valve
335.6 886.8 2.79 10.5 0.24
DN350
1 set of strainer
335.6 886.8 2.79 2
DN350
pipeline 335.6 886.8 2.79 40 0.91
pipe outlet 335.6 886.8 2.79 5.12 124.30 93.58
pipe inlet 303.9 633.8 2.43 124.30 45.00*

6 set of 90° elbow
303.9 633.8 2.43 49.2 0.98
DN300
1‐2
1 set of tee DN300 303.9 633.8 2.43 18.3 0.36
1 set of gate valve
303.9 633.8 2.43 1.8 0.04
DN300
Page 7 of 13

(mm) and valves
(m) (m) (m)
(m)
1 set of non‐return
303.9 633.8 2.43 19.8 0.39
valve DN300
pipeline 303.9 633.8 2.43 30 0.60
pipe outlet 303.9 633.8 2.43 2.37 130.30 36.63
pipe inlet 254.1 540 2.96 130.30 36.63

3 set of 90° elbow
254.1 540 2.96 20.4 0.72
DN350
1 set of tee
254.1 540 2.96 22.95 0.81
2‐3 DN300/DN250
1 set of gate valve
254.1 540 2.96 1.5 0.05
DN300
pipeline 254.1 400 2.96 53 1.87
pipe outlet 254.1 540 2.96 3.46 136.50 26.98
pipe inlet 77.9 45 2.62 136.50 26.98

1set of 45° elbow
77.9 45 2.62 0.9 0.10
DN80
3‐4 1 set of tee
77.9 45 2.62 9.2 1.03
DN250/DN80
1 set of gate valve
77.9 45 2.62 0.3 0.03
DN80
Page 8 of 13

(mm) and valves
(m) (m) (m)
(m)
pipeline 77.9 45 2.62 3 0.34
pipe outlet 77.9 45 2.62 1.51 139.50 22.47
pipe inlet 52.3 10 1.29 130.30 36.63

4set of 90° elbow
52.3 10 1.29 1.5 0.07
DN40
1 set of tee
52.3 10 1.29 6.2 0.30
1‐5 DN300/DN40
1 set of gate valve
52.3 10 1.29 0.3 0.01
DN40
pipeline 52.3 10 1.29 30 1.45
pipe outlet 52.3 10 1.29 1.83 143.00 22.10
pipe inlet 65.1 25 2.09 130.30 36.63

4set of 90° elbow
65.1 25 2.09 1.8 0.16
DN65
1 set of tee
1‐6 65.1 25 2.09 7.4 0.67
DN300/DN65
1 set of gate valve
65.1 25 2.09 0.3 0.03
DN65
pipeline 65.1 25 2.09 25 2.27
Page 9 of 13

(mm) and valves
(m) (m) (m)
(m)
pipe outlet 65.1 25 2.09 3.13 136.50 27.30
pipe inlet 65.1 30.6 2.55 130.30 36.63

6set of 90° elbow
65.1 30.6 2.55 1.8 0.24
DN65
1 set of tee
65.1 30.6 2.55 7.4 0.98
1‐7 DN300/DN65
1 set of gate valve
65.1 30.6 2.55 0.3 0.04
DN65
pipeline 65.1 30.6 2.55 30 3.96
pipe outlet 65.1 30.6 2.55 5.21 132.00 29.73
pipe inlet 52.3 10.2 1.32 130.30 36.63

8set of 90° elbow
52.3 10.2 1.32 1.5 0.08
DN50
1 set of tee
52.3 10.2 1.32 6.2 0.31
DN300/DN50
1‐8
5 set of gate valve
52.3 10.2 1.32 0.3 0.02
DN50
52.3 10.2 1.32 2.7 0.14
valve DN50
1 set filter 52.3 10.2 1.32 2.00
Page 10 of 13

(mm) and valves
(m) (m) (m)
(m)
pipeline 52.3 10.2 1.32 30 1.50
pipe outlet 52.3 10.2 1.32 4.04 132.00 30.90
pipe inlet 52.3 18 2.33 130.30 92.58

6 set of 90° elbow
52.3 18 2.33 1.5 0.22
DN50
1 set of tee
52.3 18 2.33 6.2 0.89
DN350/DN50
1‐9 2 set of gate valve
52.3 18 2.33 0.3 0.04
DN50
52.3 18 2.33 2.7 0.39
valve DN50
pipeline 52.3 18 2.33 30 4.30
pipe outlet 52.3 18 2.33 5.83 130.80 86.25
Note:
93.00 * is the pipe inlet water pressure which caused by upper reservoir water level (223m to 230m), the pipe inlet water pressure is equal to (223‐130=93)m.
45.00 * is the set pressure value of the reducing valve outlet.
Page 11 of 13
0‐1:(form intake to reduing valves)
1‐2:(form reduing valves to the end of DN300 the main water supply pipe of Turbine‐generator)
2‐3:(form the DN300/DN250 tee to the end of the DN250 branch water supply pipe of all the air coolers (the furthest DN250/DN80 tee ))
3‐4:(form the DN250/DN80 tee to the inlet of air cooler )
2‐5:(form the DN300/DN50 tee to the inlet of the upper guide bearing cooler)
2‐6:(form the DN300/DN65 tee to the inlet of the lower guide and thrust bearing cooler)
2‐7:(form the DN300/DN65 tee to the inlet of the turbine guide bearing cooler)
2‐8:(form the DN300/DN50 tee to the inlet of the turbine main shaft sealing)
2‐9:(form the DN300/DN50 tee to the inlet of the runner labyrinths )
Page 12 of 13
6 EQUIPMENT SELECTION
6.1 SELECTION OF THE AUTOMATIC BACHWASH STRAINER
One stage filtering system will be used for water filtering of the cooling water system except
the main shaft working sealing .According to GE's data, when the mesh size diameter of strainer
is 3mm, the turbine and generator bearing coolers and the generator air coolers will not be
clogged, so the the mesh size diameter of strainer will be 3mm.
Two stage filtering system will be used for water filtering of the main shaft working sealing. The
mesh size of the first stage strainer will be 3mm.The mesh size of the second stage high‐
precision strainer will be provided by the turbine manufacturer GE, and the mesh size will be
determined by GE in accordance with the water quality requirements of the main shaft sealing.
According to the cooling water consumpiton and the calculation of diameter of pipes, the
parameters of the automatic bachwash strainer are as follows :
Number: 8
Rated pressure: 1.6MPa
Rated flow: ≥886.8m3/h
Inlet/outlet pipe diameter: DN350
Mesh size: 3mm
Power supply: AC380V/50Hz
Head loss: ≤ 2m
Automatic bachwash time: 0~72h (adjustable)
Note:the parameters of high‐precision strainer for main shaft sealing will be supplied by GE
later
Page 13 of 13

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ZUNGERU HYDROELECTRIC PROJECT

Document Name: Calculation Sheet for Cooling water system

Doc No.: C‐ME‐HM‐008 R0

Document preparation, review, approval and acceptance:

Position Name Date Signature

Designed: He Pengpeng 30th Jan. 2018

Document Revision Table:

Date Rev. No. Description of modifications / revisions

30th Jan. 2018 R0 1st submission

Document no: C‐ME‐HM‐008R0 Revision status: 00 Date Printed: Jan. 2018

Document no: C‐ME‐HM‐008R0 Revision status: 00 Date Printed: Jan. 2018

FEDERAL REPUBLIC OF NIGERIA, KADUNA RIVER

ZUNGERU HYDROELECTRIC PROJECT

Calculation Sheet for

Document no: C‐ME‐HM‐008R0 Revision status: 00 Date Printed: Jan. 2018

2 COOLING WATER CONSUMPTION .......................................................................................... 1

2.1 COOLING WATER CONSUMPTION DATA ARE AS FOLLOWS: ........................................................................ 1

3 MODE OF WATER SUPPLY ...................................................................................................... 2

4 CALCULATIONS OF DIAMETER OF PIPES ................................................................................. 3

4.1 FLOW VELOCITY IN PIPES ............................................................................................................................. 3

4.2 CALCULATIONS OF DIAMETER OF PIPES FOR TURBINE –GENERATOR ： .................................................... 3

5 CALCULATION OF HEAD LOSS OF COOLING WATER SYSTEM： ............................................... 4

5.1 FORMULA FOR THE CALCULATION OF HEAD LOSS....................................................................................... 4

5.1.1 Formula for the frictional head loss of pipes ........................................................................................... 4

5.2 THE HEAD LOSS OF COOLING SUPPLY WATER SYSTEM ................................................................................ 6

6 EQUIPMENT SELECTION ....................................................................................................... 13

6.1 SELECTION OF THE AUTOMATIC BACHWASH STRAINER ............................................................................ 13

Document no: C‐ME‐HM‐008R0 Revision status: 00 Date Printed: Jan. 2018

2 COOLING WATER CONSUMPTION

No. Specifications Note

Document no: C‐ME‐HM‐008R0 Revision status: 00 Date Printed: Jan. 2018

Head loss of coolers ≤2 m

3 MODE OF WATER SUPPLY

4 CALCULATIONS OF DIAMETER OF PIPES

Reference is made to “Schematic diagram of cooling water System (D‐ME‐HM‐01 R0).

The pipe diameter is calculated by the formula as below:

D is inside diameter of the water supply pipe (mm)

Q is the cooling water consumption of equipments (m3/h)；

CaLculations result of diameter of pipes：

Document no: C‐ME‐HM‐008R0 Revision status: 00 Date Printed: Jan. 2018

Du is diameter of the main water supply pipe of Turbine‐generator (mm).

5 CALCULATION OF HEAD LOSS OF COOLING WATER SYSTEM：

5.1 FORMULA FOR THE CALCULATION OF HEAD LOSS

5.1.1 Formula for the frictional head loss of pipes

Document no: C‐ME‐HM‐008R0 Revision status: 00 Date Printed: Jan. 2018

L is the length of DN250 branch pipe, L1=15m;

D is inside diameter of pipe;

Q is the water flow in the pipe；

C is Hazen‐Williams factor,for steel pipes,C=120;

Equivalent length of pipe auxiliaries and valves are as follows:

Document no: C‐ME‐HM‐008R0 Revision status: 00 Date Printed: Jan. 2018

5.2 THE HEAD LOSS OF COOLING WATER SUPPLY SYSTEM

Document no: C‐ME‐HM‐008R0 Revision status: 00 Date Printed: Jan. 2018

Equivalent Frictional Local head Head loss from

pipe outlet 335.6 886.8 2.79 5.12 124.30 93.58

pipe inlet 303.9 633.8 2.43 124.30 45.00*

Document no: C‐ME‐HM‐008R0 Revision status: 00 Date Printed: Jan. 2018

Equivalent Frictional Local head Head loss from

pipe outlet 303.9 633.8 2.43 2.37 130.30 36.63

pipe inlet 254.1 540 2.96 130.30 36.63

pipe outlet 254.1 540 2.96 3.46 136.50 26.98

pipe inlet 77.9 45 2.62 136.50 26.98