p m v subbarao professor · dense fluid is pressed left by a cooler denser fluid. • forced...
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Fundamentals of Air Cooled Steam Condensers
After Coal, Water to hit India’s Power Sector – Is there
enough water to fuel India’s power expansion?
Avoid Usage of More Water and Conserve Water …..
P M V Subbarao
Professor
Mechanical Engineering Department
I I T Delhi
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Introductory Remarks
• The production of electricity requires a reliable, abundant,
and predictable source of freshwater.
• A resource that is limited throughout the world.
• The process of power generation from fossil fuels such as
coal, oil, and natural gas is water intensive.
• In a country where hardly any city gets 24-hour supply of
drinking water …
• The per capita water availability is shrinking at an
incredible pace ..
• Water levels of India’s dams are falling to record lows ..
• Agriculture draws approximately 90% of domestic water ..
• It is inevitable that India will be water stressed not in the
medium term but in the immediate short term.
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The Scarcity of Water
• With the present population of over 1,200 million, the per
capita water availability is around 1.170 m3/person/year.
• This translates to 1170 litres/person/per year or less than 3
litres per day per person.
• The urban area consumption is in upwards of 100-150
litres per day.
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The Water Requirement
• The water requirement for coal based plant with cooling tower
used to be about 7 m3/h per MW without ash water recirculation
and 5 m3/h per MW with ash water recirculation.
• In recent past, plants have been designed with water
consumption requirement in the range 3.5 - 4 m3/h per MW.
• This is important for a country like India, which has about 16%
of the world’s population as compared to only 4 per cent of its
water resources.
• An installed capacity of 130,370 MW of thermal power plants if
assumed running even at 75% PLF would consume over 30 bcm
of water.
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Water Withdrawal in Cooling Towers
Coal Power Plants
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Water Withdrawal in Cooling Towers
Water consumption Vs Power Generation Technology
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Alternative Cooling Systems
• Direct Dry Cooling Systems.
• Indirect Dry Cooling Systems.
• Hybrid Cooling Systems.
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Direct Dry Cooling Systems.
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Indirect Dry Cooling Systems.
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Hybrid Cooling System
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Air Cooled Steam Condensers
• Air Cooled Condensers Types
• Natural Convection: Occurs when a heater with a reduction of
dense fluid is pressed left by a cooler denser fluid.
• Forced Convection: Occurs when an outer force pushes a fluid,
such the same as water of air, to create it move about and transfer
heat.
• Geometrical Designs
• The nearly all accepted style of Air Cooled Condenser is the
modularized ('A' frame structured design), used on industries and
power plants of all sizes.
• The 'A' frame structured designs are mostly used in the power
plants.
• Coil Design : Advanced Smart Circuitry Coil Technology.
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Natural Convection ACSC
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Forced Convection ACSC
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Mixed Convection ACSC
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A Frame Mechanical Draught ACSC
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Coil Type Mechanical Draught ACSC
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World Market Evolution for large Power Plants with
ACSCs
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Development of Design Conditions
• The minimum amount of information required to establish
the simplest design point for an ACSC is:
• Steam flow, W (tons/hr)
• Turbine exhaust team quality, x (kg dry steam/kg turbine
exhaust flow)
• Turbine backpressure, pb (mm Hga)
• Ambient temperature, Tamb (deg C)
• Site elevation, (m---above sea level)
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Site Characteristics
• In addition to these basic quantities, the ACC design (and
cost) may be affected by a number of plant and site
characteristics which are listed below.
• Site characteristics
• Meteorology
• Annual temperature duration curves
• Prevailing wind speeds and directions
• Extreme conditions (hottest day; freezing conditions)
• Topography and obstructions
• Nearby hills, valleys, etc.
• Nearby structures, coal piles, etc.
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• Nearby heat sources---aux. coolers, plant vents, etc.
• Other
• Noise limitations
• At ACSC
• At some specified distance---neighbors, sanctuaries, etc.
• Maximum height restrictions
• “Footprint” constraints (length, width)
• Location restrictions---distance from turbine exhaust
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Basic Design Determination
• Specification of the quantities and characteristics above are
sufficient to obtain a “budget” estimate from ACC
vendors.
• Consider a case study to illustrate the considerations in
selecting an appropriate design point.
• An ACC for installation at a 500 MW (nominal), gas-fired
combined-cycle plant located in an arid, desert region
selected the following design values:
• Steam flow, W (tons/hr): 497.2
• Quality, x (kg/kg) 0.95
• Backpressure, pb (cm Hga) 10.16
• Ambient temperature, Tamb (C) 27
• Site elevation Sea level (pamb = 75.9968 cm Hga)
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Number of Cells : Air-Cooled Steam Condenser
• The number of cells (also referred to as modules) is
clearly an important part of the supplier data.
• Obviously, the number of cells dictates the amount of
mechanical equipment (i.e. fans, motors, gear boxes).
• Further, many current large-scale designs use components,
whose dimensions are optimized for shipping and erection.
• For instance, use of 10 meter diameter fans and individual
tube bundle sections of approximately 11m and with 2.5m
bundle and 5 bundles per cell per side for a plan area of 11
m by 12.4 m per cell per side.
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• As a result, the number of cells often dictates a number of
features of the air-cooled condenser, including the
mechanical equipment as well as the amount of heat
transfer surface.
• The total number of cells or modules is the sum of the
Primary and Secondary Modules.
• The Primary Modules are responsible for the majority of
the heat transfer and condensing, while the Secondary
Cells are responsible for residual heat transfer and
condensables collection and evacuation
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• Number of Primary Modules – The number of Primary
Modules is typically about 80 percent of the total number of
modules.
• Length of Primary Modules - The length of the primary
modules is typically on the order of 10-13 m for a Single Row
Condenser type system.
• Number Of Secondary Modules – The number of Secondary
Modules is typically about 20 percent of the total number of
modules and there is typically one module per row (or street).
• Length of the Secondary Modules – these modules are
typically shorter than the primaries by about 1 – 1.5 m.
• Primary Module Dimensions – (Width) – must be greater
than the fan diameter and typically run on the order of 15-25
percent larger than the fan diameter.
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• Fan Characteristics – Fan diameters for ACC’s used on
most recent power plant applications are typically 10-12m.
• The number of blades per fan will minimally be 5 but may
be as many as 8-10 depending upon the fan supplier and
the performance requirements.
• Motor Characteristics – Fan motor power must be equal
to that required by the fan shaft power divided by the
motor and gear box efficiencies.
• Often a margin of 5-10 percent if provided, in addition to
service factor margins.
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Thermo-hydraulic Specifications of ACSC
• Overall Heat Transfer coefficient, U, (based on air-side
surface area)
• Total Air-Side Surface Area, A
• Total Mass Flow Rate of Air at Each Design Condition,
mair
• Fan Static Pressure (pstatic) or the total system pressure
drop.
• Log Mean Temperature Difference (LMTD)
• Steam Duct Pressure Drop
• Heat Exchanger Bundle Pressure Drop (Steam Side)
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Important Global Parameters
• Thermal Duty – It is important to verify that the thermal
duty solicited (i.e. the amount of heat to be rejected) is matched
or exceeded by the supplier’s offering.
• Heat transfer Area – This is calculated knowing the total heat
transfer area of the tubes in the ACC’s.
• For a Single Row Condenser (SRC), the ratio of the airside
surface area and the total “face” area is approximately 124.
• Outlet Air Temperature – The outlet air temperature is
obviously less than the steam temperature and can be calculated
from the following equation.
• Face Velocity of the Air - The face velocity of the air, can be
calculated from the mass of air flow rate, the air density, and the
total face area of the ACC.
• Typical values will run from about 1m/s) to as much as 3 m/s)
with the average being about midway between those limits.
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• Fan Static Pressure - Fan Static Pressures will vary
depending upon whether the fan is a low-noise or more
standard design.
• Fan Static Pressure, which in essence is the force required
to overcome the system resistance (with the required
design air flow rate), will run on the order of ~100 Pa +/-
20%) for a standard fan and system design.
• Fan Shaft Power or Brake Horsepower - Depending
upon the fan static efficiency, one can calculate whether
the fan system will deliver the appropriate amount of air.
• Power Requirements - Total fan power can be calculated
using the aforementioned information and assuming
nominal gear box efficiencies of ~97% and motor
efficiencies ~92-94%.
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Operating characteristics of an air-cooled steam
condenser - I
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Operating characteristics of an air-cooled steam
condenser - II
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Operating characteristics of an air-cooled steam
condenser -III
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Performance Impacts
• Wind Effects :Prevailing ambient winds can be high (>10-
20 mph) at some sites, leading to:
• Flow separation at the fan inlet and poor fan performance,
• Recirculation of the hot exit air into the air inlet of the
ACC, and
• mal-distribution of the air in the plenum and across the
heat exchange surfaces.
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Local Interferences
• The location of the ACSC is necessarily closer to heat
sources such as service water cooling systems, turbine
exhaust piping, etc. than evaporative cooling towers
typically are from the Plant.
• The entrained air from adjacent sources is very likely to be
warmer than design or ambient conditions and therefore
the performance of the ACSC is negatively impacted.
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ACSC Unit with 30 A frames
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Streamline plot: Global flow field
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Volumetric effectiveness of fans
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Air inlet temperature of the fans in row 6, and the
wind in the x-direction
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Volumetric effectiveness of ACSC
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Thermal effectiveness of ACSC
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Ambient temperature and wind effect on saturation
temperature of the turbine exhaust steam.
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Ambient temperature and wind effect on turbine
back pressure
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Distribution of dimensionless heat rejection rate under
different wind speeds (a) 0 m/s (b) 6 m/s (c) 15 m/s.
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Schematic of the deflecting plates
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Dimensionless total heat rejection versus wind speed
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Identifying the Steam-Condenser Problem
• A successful air-cooled steam condenser must continuously and
completely gather and discharge all of the noncondensables in the
system.
• These are the gases that result from atmospheric air leaks into the
vacuum portions of the steam-cycle equipment, and from the
chemicals used for boiler feed water treatment.
• The noncondensables are left behind inside the tubes and headers
when the steam condenses.
• They accumulate if not removed from the system at the release
rate.
• Such trapping of noncondensables is responsible for the steam
condenser problem.
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Steam-condensing system ties in with turbine and
with air-removal package
![Page 53: P M V Subbarao Professor · dense fluid is pressed left by a cooler denser fluid. • Forced Convection: Occurs when an outer force pushes a fluid, such the same as water of air,](https://reader033.vdocuments.site/reader033/viewer/2022041723/5e4fbe9b68f4742ab41a5603/html5/thumbnails/53.jpg)
Trapping of noncondensables causes the steam-
condenser problem
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Backflow Problems