Cooling Tower Slide

Energy conservation in Energy conservation in Paint House Cooling water Paint House Cooling water Pump & Improvement of Pump & Improvement of cooling tower efficiency.cooling tower efficiency.

By: Amit BhadauriaBy: Amit BhadauriaLPP-PED TeamLPP-PED Team

• Cooling tower details Cooling tower details

A) Required head-15 Meter (Top most point sand mills)A) Required head-15 Meter (Top most point sand mills)

B) Cooling tower returning water temprature-17B) Cooling tower returning water temprature-17 00 c c

C) Cooling tower outlet temprarture-14.8 C) Cooling tower outlet temprarture-14.8 00 C C

D) Wet Bulb temprature-12.5D) Wet Bulb temprature-12.500 C C

E) Running efficiency of cooling tower- 48.88%E) Running efficiency of cooling tower- 48.88%

F) Cooling tower fan blade angle-8F) Cooling tower fan blade angle-800

G) Design capacity of cooling tower – 150 TRG) Design capacity of cooling tower – 150 TR

H) Current Heat removal -1475652 KJ/Hr=116 TRH) Current Heat removal -1475652 KJ/Hr=116 TR

I) Flow rate required at Sand Mill SP16-1500 Ltr /Hr (As per manufacturer) I) Flow rate required at Sand Mill SP16-1500 Ltr /Hr (As per manufacturer)

J) Flow rate required at Sand Mill SP16-3000 Ltr /Hr (As per manufacturer)J) Flow rate required at Sand Mill SP16-3000 Ltr /Hr (As per manufacturer)

K) Flow rate required at SS TSD-5000 Ltr /Hr (As per manufacturer)K) Flow rate required at SS TSD-5000 Ltr /Hr (As per manufacturer)

L) Flow rate required at MS TSD-3500 Ltr /Hr (As per manufacturer)L) Flow rate required at MS TSD-3500 Ltr /Hr (As per manufacturer)

M) Required discharge of pump to met above requirement-62.500 MM) Required discharge of pump to met above requirement-62.500 M33/Hr/Hr

N) Required capacity of cooling tower- 103 TRN) Required capacity of cooling tower- 103 TR

OLD SET UPOLD SET UP

• Cooling water circulation pump & Motor Cooling water circulation pump & Motor DetailsDetails

A) Motor KW-18.5A) Motor KW-18.5

B) Motor RPM-2920B) Motor RPM-2920

C) Pump Model- Kirlosker DB 80/16C) Pump Model- Kirlosker DB 80/16

D) Pump discharge-160.20 MD) Pump discharge-160.20 M33/Hr/Hr

E) Pump Head-35.50 MeterE) Pump Head-35.50 Meter

F) Pressure at Pump Header-3 Kg/cmF) Pressure at Pump Header-3 Kg/cm22

G) Pressure at Section (At sand Mills)- 2 Kg/cmG) Pressure at Section (At sand Mills)- 2 Kg/cm22

H) Pump Impeller Diameter-174 MMH) Pump Impeller Diameter-174 MM

I) Pump impeller weight-3.620 KgI) Pump impeller weight-3.620 Kg

J) Average Power Consumed by motor per hour-J) Average Power Consumed by motor per hour-18.75 Kw 18.75 Kw

(Motor continuously running on over load)(Motor continuously running on over load)

OLD SET UPOLD SET UP

Modification - Resizing of pump impellerModification - Resizing of pump impeller

Scientific FactsScientific Facts

A) PA) Pnn / P / Poo = (D = (Dnn/D/Doo))44

B) QB) Qn n / Q/ Qoo = ( D = ( Dnn/D/Doo))22

C) HC) Hn n / H/ Hoo = ( D = ( Dnn/D/Doo))22

Where P,Q,H,D are power , discharge , head , Where P,Q,H,D are power , discharge , head , diameter ofdiameter of

impeller of pump with subscript ‘n for new’ and ‘o impeller of pump with subscript ‘n for new’ and ‘o for for

old’old’

Pump new specification due to change in impeller size

A) Pump discharge-102.52 MA) Pump discharge-102.52 M33/Hr/Hr (Which is more then required discharge) (Which is more then required discharge)

B) Pump Head- 22.72 Meter B) Pump Head- 22.72 Meter (Which is more then required Head)(Which is more then required Head)

C) Pressure at Pump Header-2.3 Kg/cm2C) Pressure at Pump Header-2.3 Kg/cm2

D) Pressure at Section (At sand Mills)- 1.5 Kg/cm2D) Pressure at Section (At sand Mills)- 1.5 Kg/cm2

E) Pump Impeller Diameter-139 MME) Pump Impeller Diameter-139 MM

F) Pump impeller weight-2.430 KgF) Pump impeller weight-2.430 Kg

G) Heat carrying capacity-9,44,417 KJ/HrG) Heat carrying capacity-9,44,417 KJ/Hr

Benefit :Benefit :Power savingPower saving

Hourly:8.4 KwHourly:8.4 Kw

Yearly-8.4*24 hr*310 days=62496 Kw*Yearly-8.4*24 hr*310 days=62496 Kw*

Cost SavingCost Saving Yearly-62496*5 /- Rs/Unit=3,12,480 /- RS*Yearly-62496*5 /- Rs/Unit=3,12,480 /- RS*

*Not final, move to next slides to get final saving in entire *Not final, move to next slides to get final saving in entire systemsystem

Compression of Old power Compression of Old power consumption pattern to newconsumption pattern to new

Power consumption Comprision

0

50

100

150

200

Time 10:36:00 11:53:00 13:10:00 14:27:00 15:44:00 17:01:00

Time

Kilo

wat

t

NEW

OLD

Correction of heat carrying capacity with new set up• ∆T of cooling tower is proportional to L/G Ratio created by CT Fan But L/G=(h2 – h1) / (T1 – T2)

Where L/G is ratio of water vapor weight to mass of air passed by CT Fan

h1 is enthalpy air water vapor mixture at cold water wet bulb temperature

h2 is enthalpy air water vapor mixture at hot water wet bulb temperature

T1 -Hot water temperature

T2 -Cold water temperature

While h1 = ha + X hw

ha= Cpa x T & hw= Cpw .T + hwe

Where Cpa & Cpw are specific heat capacity of air and water vapor at constant pressure & T is temperature

X is mixing ratio of Air and water vapor.

• After calculation from above equations , requirement to increase L/G ratio by 1.80 time arrived.

• Cooling tower bland angel 180 made which was 80 earlier.

Improved efficiency of Improved efficiency of cooling towercooling tower

A) Cooling tower returning water temprature-A) Cooling tower returning water temprature-1919 00 c c

B) Cooling tower outlet temprarture-15.5 B) Cooling tower outlet temprarture-15.5 00 C C

C) Wet Bulb temprature-13.5C) Wet Bulb temprature-13.500 C C

D) D) Heat removal capacity-1502482 KJ/Hr Heat removal capacity-1502482 KJ/Hr =118 TR=118 TR (1.81%  more then old impeller) (1.81%  more then old impeller)

E) E) Efficiency of cooling tower-64.71%Efficiency of cooling tower-64.71%

• Due to change in blade angle of fan ,power consumption for fan Due to change in blade angle of fan ,power consumption for fan running also increasedrunning also increased

Increased load of fan :- (KWHIncreased load of fan :- (KWHoo-KWH-KWHnn)*24 hr*310 days)*24 hr*310 days

= (3.97-2.8)*24*310=8786.95 KWH= (3.97-2.8)*24*310=8786.95 KWH

Net Power saving in entire system:-Net Power saving in entire system:- = Power saving at pump-Increased power consumption at = Power saving at pump-Increased power consumption at

fanfan

= 62496-8786.95 KWH= 62496-8786.95 KWH

= 53727.14 KWH= 53727.14 KWH

Net Cost saving in entire systemNet Cost saving in entire system =Net saving*5 Rs/Unit=Net saving*5 Rs/Unit

=268635.7 /- Rs/year=268635.7 /- Rs/year

Final Results:-

Cost Saving (yearly)- Rs 2,68,635.7 /-

Increased efficiency of cooling tower- 64.71% compare to old 48.88%

THANKTHANK

YOUYOU