CW & ACW SYSTEM

 Introduction
 Types of cooling systems &
towers
 Our cooling tower
 Water management
 Monitoring &Performance
INTRODUCTION

 CW SYSTEM:
– TAKES THE LATENT HEAT OF
CONDENSATION FROM THE
CONDENSER
ACW SYSTEM:
- SUPPLIES COLD WATER TO ALL THE
AUXILIARY EQUIPMENTS & HEAT
EXCHANGERS.
Cooling Tower – JSWEL – Counter flow Induced Draft- Design

EVAPORATION 243 M3/HR

DRIFT 17.5 M3/HR
BLOW DOWN FOR 3 COC 121.5 M3/HR
COOLING WATER FLOW 17500 M3/HR
CW INLET TEMPERATURE 42 OC
CW OUTLET TEMPERATURE 32 OC
WET BULB TEMPERATURE 27 OC
DRY BULB TEMPERATURE 36 OC
TOTAL HEAD 20M
CW MOTOR POWER 1350 KW
COOLING TOWER FANS PER UNIT 10 NOS
POWER PER FAN 45 KW
NUMBER OF CELLS 10 NOS
CHLORINATION SYSTEM 900 kg CONTAINER * 6 NOS

SHULPHURIC ACID DOSING TO MAINTAIN 7.5 PH OF CW SYSTEM AT VARIABLE

STROKE
 Water diagram - JTPCL

TB
Clarifier
DAM

Refractory &
Cooling Tower Settling
Bottom Ash
Basin

Air Washer

Cooling
DM Pond
Neutralizing pit
Plant

Boiler In-House
Plantation

Soak
Potable Water Septic Tank Pit
 Water Requirement of JSWEL

21
10512
12528
2167 2141 21
Bottom ash Settling
Cooling handling basin
tower
144 2141
Air washer 62

206
13763 887 DM plant & boiler
206
blow down Neutralization
Cooling
pond
80
41
service & ash

20 10
Plant Septic Soak
potable tank pit

Ash handling
All values in cubic metre And Green belt
development
 RANKINE CYCLE (Sub/Under cooling)

SUB-COOLING: Velocity of LP exhaust steam increases and work done decreases & To
compensate this loss additional heat energy is required. (This will happen
during Vacuum high conditions)
LOW VACUUM : TTD increases as a result heat transfer decreases, so heat rejection in
condenser increases.
COMPONENTS OF COOLING TOWER
• CONSTRUCTION MATERIAL:(TIMBER,CONCRETE,FIBRE GLASS)
• FILLS:(HEART OF COOLING TOWER):GENERALLY PVC
• DRIFT ELIMINATORS:
• WATER DISTRIBUTORS/SPRAY NOZZLES:
• HOT WATER CHANNEL:
• MAKE UP VALVE
• COOLING WATER PIPING
• FANS & MOTORS
• DRIVES
• PUMPS
TYPES OF COOLING SYSTEM
COOLING SYSTEM

OPEN SYSTEM CLOSED SYSTEM MIXED SYSTEM

WATER COOLING AIR COOLING

COOLING COOLING INDIRECT

DIRECT
PONDS TOWERS AIR
DRY TYPE
COOLING
CLOSED COOLING SYSTEM
STEAM FROM
TURBINE
0.02 mw (EVAPORATION LOSS)

CONDENSER

CONDENSATE
TO BOILER

MW

0.02MW MAKE UP
WATER

0.98MW
COUNTER FLOW
CROSS FLOW
Counter flow induced draft. cooling tower.
The fans at the top
discharge the hot, moisture
laden air upward and away
from the air entering at the
bottom of the tower, thus
preventing any
recirculation of warm air.
Warm water from the
building enters the
distribution system located
just under the drift
eliminators. The fans and
their drive are mounted on
the top deck.
OPEN COOLING SYSTEM
HEAT FROM THE PROCESS IS REMOVED / COOLED BY WATER DRAWN
FROM OPEN SOURCE LIKE SEA / RIVER / LAKE AND DISCHARGED BACK
INTO THE SOURCE.

CLOSED RECIRCULATING COOLING.

HEAT FROM THE PROCESS REMOVED BY THE WATER DRAWN FROM A
SOURCE LIKE SEA / RIVER ETC IS RECIRCULATED BACK AFTER
COOLING THE SAME IN A COOLING TOWER.

DRY COOLING.
HEAT FROM THE PROCESS S REMOVED BY ATMOSPHERIC AIR EITHER
DIRECTLY OR INDIRECTLY
HEAT UTILISATION
HEAT UTILISATION

HEAT UTILOSED FOR POWER

PRODUCTION
39%
TG & CONDENSER LOSSES
51%

BOILER LOSSES
10%
The rate of heat transfer between hot water and the air
depends
•Internal temperature of hot water
Temperature of atmospheric air
Relative humidity of air
Movement of air
Solar radiation

Higher DBT,
Lower WBT gives better cooling
Higher air movement

Difference between dry bulb & wet bulb temperature

indicates the capacity of air absorbing the water vapor.
 FOR OPTIMUM & BETTER PERFORMANCE OF
THE TOWER,ENSURE THE FOLLOWING:

» TOWER SHOULD OPERATE WITH WATER FLOW

BETWEEN 90 TO 110%
» ENSURE THAT ALL BLADES OF THE FAN ARE PITCHED AT
THE SAME ANGLE (12 to 15 deg.)
» ENSURE CLOCKWISE ROTATION WHILE VIEWING FROM
TOP
» ENSURE THAT ALL THE DOORS ARE CLOSED PROPERLY
DURING THE OPERATION OF COOLING TOWER
» ENSURE THAT SPRAY NOZZLES ARE FITTED PROPERLY
WITH THE HOT WATER DISTRIBUTION PIPES TO AVOID
DAMAGE TO FILL AND FOR ACHIVING DESIGNED
COOLING DUTY
» CHECK / INSPECT ALL TOWER COMPONENTS
PERIODICALLY AS PER MAINTAINANCE CHART.
 REPRESENTATION OF COOLING RANGE & APPROACH

DRY BULB TEMP OF ENTERING AIR

WET BULB TEMP OF ENTERING AIR

COOLING TEMP.OF WATER ENTERING THE TOWER

APPROACH

COOLING
RANGE TEMP.OF WATER LEAVING THE TOWER
 Cooling T ower M aintenance Schedule
Da ily/We e kly
Test water sample for proper
concentration of dissolved solids.
Adjust bleed water flow as
needed.
Measure the water treatment
chemical residual in the
circulating water. Maintain the
residual recommended by your
water treatment specialist.
Check the strainer on the bottom
of the collection basin and clean
it if necessary.
Operate the make-up water float
switch manually to ensure proper
operation.
Pe riodic
Check the distribution
spray nozzles to ensure
even distribution over the
fill.
Check the distribution
basin for corrosion,
leaks, and sediment.
Operate flow control
valves through their
range of travel and re-set
for even water flow
through the fill.
Remove any sludge from
the collection basin and
check for corrosion that
could develop into leaks.
Annua l
Check the casing, basin, and
piping for corrosion and decay.
Without proper maintenance,
cooling towers may suffer from
corrosion and wood decay.
Welded repairs are especially
susceptible to corrosion. The
protective zinc coating on
galvanized steel tower
Leaks in the cooling tower casing
may allow air to bypass the fill.
All cracks, holes, gaps, and door
access panels should be properly
sealed.
Remove dust, scale, and algae
from the fill, basin, and
distribution spray nozzles to
maintain proper water flow.

Inspect all moving parts such as Check the drift

drive shafts, pulleys, and belts.
Check for excessive vibration in
motors, fans, and pumps.
Manually test the vibration limit
switch by jarring it.
Look for oil leaks in gear boxes.
Check for structural deterioration,
loose connectors, water leaks,
and openings in the casing.
eliminators, air intake
louvers, and fill for scale
build-up. Clean as
needed.
Look for damaged or out-
of-place fill elements.
Inspect motor supports,
fan blades, and other
mechanical parts for
excessive wear or
cracks.
Lubricate bearings and
bushings. Check the
level of oil in the gear
box. Add oil as needed.
Adjust belts and
pulleys.
 ANY QUESTIONS PLEASE?
THANK Q
 SCALING
• Scaling is defined as the precipitation and deposition of hard crystalline water insoluble salts
on heat transfer surfaces and return lines.
• Commonly encountered scales in cooling water systems
• CACO3 Calcium carbonate, marble ,lime scales.

• CASO4,2H2O Calcium sulphate, gypsum.

• MgSiO3 Magnesium Silicate.
• CA5 (PO4)3(OH): Calcium phosphate, Hydroxyapatite
• All naturally occurring waters will contain varying amounts of Ca, Mg ( Hardness Salts )
with HCO3-, CO3-, SO4-, SiO2 etc.
• as their concentration increases ,and the cooling water comes in contact with hot metal
surfaces ,these ions combine and precipitate to give rise to scaling.
FACTORS INFLUENCING MICROBIAL GROWTH

PH
MOST CW SYSTEM OPERATE AT NEUTRAL OR SLIGHTLY
ALKALINE PH WHICH IS IDEAL FOR MICROBIOAL GROWTH
TEMPERATURE
RANGE IS 35 TO 45 DEG.C-THIS IS ALSO IDEAL FOR
MICROBIOAL GROWTH
STAGNANT CONDITION
THE CT BASIN,HEAT EXCHANGERS WITH LOW FLOW (SHELL
SIDE COOLING),
SIDE STREAM FILTERS SHELTER LARGE MICROBIOAL
POPULATION
ENSURING CLEAN WATER & KEEPING CONTAINMENTS TO A
BARE MINIMUM CAN GREATLY HELP IN REDUCING
BACTRERIAL PROBLEMS
 FOULING
• Accumulation of deposits in heat transfer equipment
is know as fouling .fouling originates.
• 1.Corrosion
• 2.Scale formation , precipitation, sludge
• 3.Microbial slimes
• 4.Deposition of suspended matter brought in by make
up water and air.
 Control Techniques
•Control techniques to over come all the problems of a
cooling water system can be broadly divided into two
parts
•Part A : controlling CW Quality by good operating
techniques , using commonly available commodity
chemicals and using mechanical means
•Part B : Modifying CW properties By using
chemical Inhibitors
EFFECT OF HIGH EVALUATION
FACTORS
•Variation in Tower Dimension become predominant between
various bids leading to confusion during evaluation . Such
variations are not so evident in designs produced in developed
countries.
•Major Variation in Power Consumption between various bids
may be noted.
•Result in over Optimised cooling tower design to reduce the
Power consumption leading to design in violation of minimum
air velocities & rain densities etc.
•Claiming high efficiencies for the drive system to reduce
Power consumption

Sometimes leads to aberration like power loading value

working out more than the cost of cooling tower
Recirculation allowance may get neglected to reduce the
power Consumption
High evaluation factor & low penalty factor is disadvantages to
the owner
 DRY COOLING SYSTEMS
SL.NO DESCRIPTION DIRECT INDIRECT HELLER

TURBINE BACK
1 LOW HIGH HIGH
PRESSURE
2 CAPITAL COST MEDIUM HIGH HIGH
AUX.POWER
3 HIGH LOW LOW
CONSUMPTION
PLOT AREA
4 LOW HIGH HIGH
REQUIREMENT
Table compares relative costs
for various types of cooling
towers meeting specified
criteria. The table provides
relative capital costs and
operating costs for different
cooling tower designs. Cost
comparisons are based on a
cooling tower designed to
handle 48,000 gal/min; 16°F
(9°C) range; 13°F (7°C)
approach; 72°F ( 40°C) wet
bulb; 30 PSF wind velocity
pressure at a seismic zone
UBC 2 or less. The occupied
ground area for each
comparison has been kept
constant to achieve
comparable values. It is fair to
assume that these
comparisons apply to a range
of cooling towers.
FACTORS INFLUENCING CORROSION RATE

• TYPE OF MATERIAL: FERROUS METALS CORRODE FASTER

• SURFACE DEPOSITS: RATE ACCELERATES UNDER DEPOSITS
• TEMPERATURE: EVERY 10OC RISE IN TEMP DOUBLES CORROSION
RATE
• FLOW RATE: HIGHER MASS TRANSFER OF DISSOLVED O2 TO
CORRODING SITES

• CONDUCTIVITY: GREATER FLOW OF CORROSION CURRENT

• P H: AT LOWER PH, THE PROTECTIVE FILM DISSOLVE

FASTER TO EXPOSE METAL TO WATER
• MICROBIAL GROWTH: BACTERIAL SLIMES CAUSE UNDER DEPOSIT
CORROSION,THEY GENERATE ACIDS & SOME
BACTERIA CAN DIRECTLY ATTACK METALS
» CONSUMPTION OR LOSSES OF WATER IN A COOLING SYSTEM CAN
BE CALCULATED ACCURATELY FROM A FEW MEASURED
PARAMETERS. THE FORMULAE ARE AS BELOW.
» E = R * DT/1000
WHER E - EVPORATION RATE
R- RECIRCULATION RATE
DT - COOLING RANGE IN OC
» W = 0.05% R WHERE, W= WINDAGE RATE
(THIS IS THE INDUSTRY STANDARD WHICH CAN OFTEN BE
IGNORED)
» COC = CONC. OF A SALT IN CIRCULATING WATER.
CONC. OF SAME SALT IN MAKE UP WATER
( ’COC’ : THE NO. OF TIME WATER HAS BEEN REUSED)
» B = E , WHERE, B - BLEED OFF, THE QUANTITY OF WATER DRAINED
FROM C-1 SYSTEM TO MAINTAIN ‘COC’ CONTANT
» M = E +B WHERE, M - MAKE UP WATER NEEDED TO REPLINISH
LOSSES.
 Water diagram - JTPCL

TB
Clarifier
DAM

Refractory &
Cooling Tower Settling
Bottom Ash
Basin

Air Washer

Cooling
DM Pond
Neutralizing pit
Plant

Service &
Boiler In-House
Wash
Plantation

Soak
Potable Water Septic Tank Pit