14 u k mondal.pdf

35
SPOTLIGHT ON COOLING TOWER 4 x 250 MW O.P.JINDAL SUPER THERMAL POWER STATION, JPL- TAMNAR Presented By: Mr. U. K. Mondal Mr. Pradeep Kumar

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Page 1: 14 U K Mondal.pdf

SPOTLIGHT ON COOLING TOWER

4 x 250 MW O.P.JINDAL SUPER THERMAL POWER STATION, JPL-

TAMNAR

Presented By:Mr. U. K. MondalMr. Pradeep Kumar

Page 2: 14 U K Mondal.pdf

Flow of PresentationCompany Profile

Salient Feature of the (4X250 MW) OP Jindal STPP

Requirements of Cooling Tower

JPL experience with the performance of cooling tower

Challenges faced in the Commissioning/Operation of cooling tower

Expectation from the Vendors

Conclusion

Page 3: 14 U K Mondal.pdf

Company Profile

Page 4: 14 U K Mondal.pdf

• First Mega Power Project of 1000 MW in thePrivate Sector.

Salient Feature of (4X250 MW) OP Jindal STPP

• JPL’s 4 units of 250 MW Capacity each hasbeen installed at Tamnar-37 KM fromRaigarh -Chhattisgarh.

• BTG is supplied by BHEL.

• All 4 Units Commissioned from September-2007 to July 2008.

Page 5: 14 U K Mondal.pdf

Continued…

• Established 258 KM long 400 KV Double

circuit transmission line for Power Evacuation.

• Construction of 18 Mtr high Dam over the

river Kurket to meet water requirement.

• Reservoir Capacity is approximately

35MCuM

Page 6: 14 U K Mondal.pdf

• Self sustaining Coal source from the Captive

coal Mines located at Dongamauha 8 KM

from the plant.

• Total Coal Reserve of the mine is 247

Continued…

• Coal Transportation by Cross Country Pipe

Conveyor 6.9 KM Long .

• Second longest Pipe Conveyor in the world

Page 7: 14 U K Mondal.pdf

Unit Heat Rate : 2248 Kcal/KWh @100% MCR (for 0% make up)

Boiler Efficiency : 86.79%

Turbine cycle : 1951 Kcal/hr.

heat rate

Coal Consumption : 157 MT/Hr/Unit

CV of coal : 3600 Kcal/Kg

A P Consumption : 9%

(as per CERC’s guideline)

DM water make-up : 3 %

Major Design Parameter

Page 8: 14 U K Mondal.pdf

Plant Load Factor & Availability in %

Financial Year

Perc

enta

ge

Plant Performance Indices

75

80

85

90

95

100

Fy 08-09 FY 09-10 FY 10-11 FY 11-12

PLFAvailability

Page 9: 14 U K Mondal.pdf

NEED OF COOLING TOWER : In Powerplant, cooling tower cools down the hotwater of Turbine Condenser by theprocess of evaporative cooling andsensible heat transfer. This cold water isrecycled into the system again forcondensation of exhaust steam inCondenser.

Condenser act as heat load and coolingtower plays an important role inmaintaining vacuum in condenser.

Requirement of Cooling Tower

Page 10: 14 U K Mondal.pdf

S.No Details Description

1 No. of Cell per Cooling Tower 14

2 Vendor Paharpur

3 Tower Model 86042-5.0-14

4 Tower Type Induced Draught Counter flow

5 Circulating water flow(CMH)per tower 40000(in 13 operating cell)

6 CW inlet temp( deg C) 42

7 CW outlet temp( deg C) 33

8 Ambient Wet bulb temp.(deg C) 28.5

9 Cooling Range(deg C) 9

10 Approach to Ambient WBT(deg C) 4.5

SPECIFICATION OF COOLING TOWER

Page 11: 14 U K Mondal.pdf

Performance measured by using term “Effectiveness” in percentage is the ratio of range to the ideal range i.e., difference between cooling water inlet temperature and ambient wet bulb temperature, or in other words it is

= Range / (Range + Approach).

“Range” is the difference between the cooling tower water inlet and outlet temperature.

“Approach” is the difference between the cooling tower outlet cold water temperature and ambient Wet bulb temperature

Performance of Cooling Tower in JPL

Page 12: 14 U K Mondal.pdf

Effectiveness of our cooling towers are tabulated below:

The effectiveness of Cooling tower is tested once in a year byO&E Team & National Productivity Council, Delhi.

The effectiveness of cooling tower is calculated bymeasurement of CT fan current, Qty of water flow throughriser pipe, Temperature of CT outlet and CT inlet Water.

Continued…

S No Unit Design Effectiveness

Observed Effectiveness

ObservationDate

1 1 66.67 % 64.7 % 16 Aug 11

2 2 66.67% 58.12 % 22 Aug 11

3 3 66.67% 66.67 % 24 Aug 11

4 4 66.67% 51.41 % 17 Sep 11

Page 13: 14 U K Mondal.pdf

WBT

DBT/ Relative Humidity

Heat Load

Range/Approach

Heat Transfer in the cell

Recirculation

Factors affecting the performance

Page 14: 14 U K Mondal.pdf

Cleaning of fill (film fill) by using air to prevent the clogging of fill otherwise itwould reduce the effective heat transfer area.

Cleaning of Fan blades as the dust/algae deposition on fan blades wouldincrease its weight and power consumption of motor. Cleaning would alsoclean the path on blade for large volume of air to flow and increase theefficiency of fan blades.

Replacing/Repairing damaged diffuser rings , Nozzles, Branch Arms to makethe distribution of water uniform over the fills.

Cleaning of fan cylinder and Drift Eliminators for efficient working of system

Action taken to increase the performance during shutdown

Page 15: 14 U K Mondal.pdf

Rectification of grouting work with quick settling compound GP2between Distribution pipe sleeve with hot water duct. Otherwisedistribution pipe could loose and fall down causing heavy flow ofwater to fall on the fill at a greater pressure and damage thefills, consequently reducing the performance of cooling tower.

Servicing of gearbox of riser pipe valve and its actuator to avoid theproblem of jamming of valve.

Continued…

Page 16: 14 U K Mondal.pdf

Large elevation diff. between Motor base and Gear box base

Disengagement of Distribution Pipes while running and Missing of

sleeves in some places

CT Water outlet sluice gate isolation problem at common duct

Fitting of faulty Nozzles, Diffuser Rings and Branch Arms or Missing

items in some places

Problems in Draining of CT basin Water during AOH

Challenges Faced During Commissioning & AOH

Page 17: 14 U K Mondal.pdf

Reason for elevation difference b/w Motor Base and Gearbox Base

Faulty civil work in foundation at either motor base or Gearbox base.

Use of in-appropriate number and thickness of shim

The elevation difference will result into: Abnormal vibration of Motor, Gearbox

Abnormal sound of Motor, Gearbox

Bearing failure of Motor, Gearbox

Elevation diff b/w motor base and gearbox base

Page 18: 14 U K Mondal.pdf

Solution

Water level checking of base. One end of level gauge should bemeasured at Gear Box coupling end and other end should bemeasured at Motor coupling end.

Adjusting the level by use of shims either on Motor base or Gear boxbase depending upon the level slope.

Continued…

Page 19: 14 U K Mondal.pdf

Reasons for Disengagement of distribution pipe

Improper Grouting

Missing Sleeves in distribution pipe

Use of low quality cements for Grouting

Disengagement of Distribution Pipe while Running will result into

Damage of fills pack

Non-Uniform distribution of water over the fills

Reducing effectiveness as the effective heat transfer area decreases.

Disengagement of distribution pipe while running

Page 20: 14 U K Mondal.pdf

Solution

Check for Missing Sleeves, repair/fitting of sleeve if any.

Proper Grouting of Distribution Pipe and checking of grouting after some hours by pouring water into it.

Grouting with GP2 cement or any other good quality quick settling cement.

Continued…

Page 21: 14 U K Mondal.pdf

Reasons for Fitting of faulty parts

Shortage of Materials at the time of Erection/Commissioning

Pressure of Achieving the target within scheduled date

Fitting of faulty parts or Missing of Parts will result into

Improper Distribution of Water over the fills Reducing Efficiency Channelization Missing of Grommets or fitting of faulty Grommets

could result failure of Fan Blades

Fitting of Faulty parts

Page 22: 14 U K Mondal.pdf

Solution

Proper checking of Faulty or Missing Parts Repair/Replacing the faulty or Missing Parts as early as possible

Continued…

Page 23: 14 U K Mondal.pdf

Reason for improper draining of CT Basin Uneven slope in CT basin

Improper slope will result into Water clogging at the basin of some cells of cooling

tower Downtime increases Using More Manpower/Machine/Money

Solution Forming small pits at some cells to collect the

sludge and water Dewatering water from small pits by using pumps

Draining of CT basin during shutdown

Page 24: 14 U K Mondal.pdf

Abnormal Sound / Vibration in Motor or Gearbox housing

Non-Uniform distribution of water

Challenges faced during operation

Page 25: 14 U K Mondal.pdf

Reasons for abnormal sound/vibration

Misalignment Elevation Difference Unbalancing of Drive Shaft Gearbox/Motor Bearing Failure Cooling Fan hitting Guard Bending of Motor Shaft/Gear Box Shaft

Abnormal Sound/ Vibration will result into

Failure of Motor Bearing/Gear Box Bearing Overloading of Motor Failure of Gears teeth

Abnormal sound / vibration in motor or gearbox

Page 26: 14 U K Mondal.pdf

Solution

Correction of Alignment b/w Gearbox to Drive shaft coupling, Drive Shaft to Motor Coupling if any

Checking elevation b/w Motor Base and Gearbox Base and doing correction by shims if any

Checking for any Unbalancing of rotors(Drive Shaft) and making correction by adding counterweights if required.

Checking of gromets and replacing if necessary

Continued…

Page 27: 14 U K Mondal.pdf

Reasons for Non-Uniform Distribution of water Absence of Diffuser ring or fitting of damaged

diffuser ring Absence of Nozzles or fitting of damaged Nozzles Absence of End cap or end cap broken while

running Disengagement of Distribution Pipe Problem in operation of Riser valve Gearbox

Non-Uniform Distribution of Water will result into Effective heat transfer area decreases Damaging of fills pack Reducing performance of cooling tower

Non-uniform distribution of water

Page 28: 14 U K Mondal.pdf

Solution

Replacing damaged Nozzles/Diffuser ring.

Inspecting the cooling tower at regular interval to find heavy flow of water falling through fills and checking inside the tower after isolating it.

Greasing of riser valve gearbox periodically to prevent from jamming of gearbox

Continued…

Page 29: 14 U K Mondal.pdf

Corrosion resistance coating in RCC hyperbolic structure

Replacement of GRP fan blades with Energy Efficient FRP Hollow Fan blade

Saving in Auxiliary power consumption and Reducing Maintenance by use of Direct Drive System.

After sale service must be satisfactory.

Expectation from Vendors

Page 30: 14 U K Mondal.pdf

Corrosion resistance coating inside hyperbolic RCC structure of cooling tower is done usually by Epoxy Paint. Sometimes it is done after sand blasting to remove the debris/dust etc.

Advantages

Increase the life of CT components

Increase the Performance of Cooling tower

Also good for safety point as it prevent of the growth of algae

Corrosion resistance coating

Page 31: 14 U K Mondal.pdf

Existing GRP fan blades can be replaced with the Energy Efficient FRP Hollow Fan blades

Advantages

Increase the efficiency of fan blades

FRP blades are lighter than GRP blades result in Saving of saving in aux power consumption

Replacement of fan blades

Page 32: 14 U K Mondal.pdf

Cooling tower direct drive is direct mounting of fan blades with fan hub cover on the vertical motor as different to the conventional cooling tower drive

Advantages

Low Maintenance due to elimination of Drive shaft and Gearbox

Low Maintenance cost

Power saving as speed of Motor is variable

Using Direct cooling tower drive

Page 33: 14 U K Mondal.pdf

After sale service by vendors to customers may include giving seminars/conference on the advancement of technologies in concerned areas, brain storming, maintenance or repairing of items.

After sale-service

Page 34: 14 U K Mondal.pdf

Cooling tower plays a vital role in power plant. To achieve the high effectiveness of cooling tower we can look for advancement in technologies( as discussed ) and maintaining and improving operation practices.

CONCLUSION

Page 35: 14 U K Mondal.pdf