Grootvlei Power Station’s thermal efficiency had been on a steady declining trend since it was re-commissioned in 2008, which had tremendous financial implications to the company at the time of writing. The main contributory factor to the thermal efficiency losses was identified to be the condenser backpressure losses that the station was experiencing. This loss was responsible for approximately 17% of the total efficiency losses. Therefore an investigation was conducted to determine the potential impact of the condenser backpressure loss on the thermal efficiency and the financial implications thereof. The deliverables were to determine the cause of the condenser backpressure loss and propose possible resolutions, to quantify the financial effect and to produce a cost benefit analysis in order to justify certain corrective actions. Grootvlei Power Station is one of the older power stations in South Africa and it was used as the first testing facility for dry-cooling in South Africa. It consists of six 200MW units, two of which are dry-cooled units. In 1990 it was mothballed and due to rising power demands in South Africa, it was re-commissioned in 2008. Thermal efficiency has been playing a great role due to the power constraints and therefore it was deemed necessary to conduct this study. The approach that was used was one of experimental and quantitative research and analyses, incorporating deductive reasoning in order to test various hypotheses of factors that could have been contributing to the backpressure losses. In order to do so, a logic diagram was designed which could be used to aid in the identification of possible causes of the condenser backpressure losses. The logic diagram was able to identify whether the problem had to do with the cooling tower or the condenser. It was able to identify which area on the condenser was defective i.e. whether the pumps were not performing, or whether the air ejectors were not performing. It was also able to indicate whether the inefficiency was due to air ingress or fouling. Alongside the logic diagram, a condenser efficiency analysis was used in order to strengthen and improve on the investigation. This analysis was able to identify whether the condenser was experiencing fouling conditions, air ingress, passing valves or low cooling water flow. After the investigation commenced, it was decided to focus on the two largest contributing units since the largest contributor was a dry-cooled unit and the second largest contributor was a wet-cooled unit, thus some comparison between the units was incorporated. The condenser efficiency analysis on Unit 3 (wet-cooled unit) indicated a low cooling water flow, fouling as well as air ingress. The logic diagram indicated poor cooling tower performance, high air ingress as well as fouling. Further tests and analyses as well as visual inspections confirmed these phenomena and condenser fouling was identified to be the largest contributor to the backpressure loss on this unit. The condenser efficiency analysis on Unit 6 indicated that air was entering the condenser. The logic diagram indicated that a segment of the backpressure loss was due to poor cooling tower performance. Inspection of the cooling tower indicated damage and leaks. A cooling tower performance test was conducted and the result of the test indicated that the tower was in need of cleaning. Further analyses according to the logic diagram indicated that the condenser was experiencing air ingress which concurred with the condenser efficiency analysis. A helium test, condensate extraction pump pressure test as well as a flood test was conducted on this unit and various air in-leakage points were identified. The financial implications of the backpressure losses were investigated and found to be costing millions each month. The condenser backpressure loss was contributing more than 2% to the thermal efficiency loss. The cost benefit analysis indicated that the cost of cleaning the condenser on Unit 3 would be made up within six months and a return on investment of 16,6% was calculated. The cost benefit analysis motivates for extended outage times for the purpose of cleaning the condensers from a financial perspective. Therefore, it was recommended to clean the condenser on Unit 3 and fix all known defects on the unit as well as on Unit 6. The cooling towers were recommended to be refurbished. Further investigation was recommended to determine the feasibility of installing an online cleaning system on the wet-cooled units’ condensers such as a Taprogge system. Alternative investigation methods were suggested such as smoke stick analyses for air ingress determination. It was also recommended to review the maintenance strategies that were being used since many of the defects were found to be maintenance related. If the identified problem areas are attended to, the condenser backpressure loss will decrease and the condensers transfer heat more efficiently which will lead to financial gains for Grootvlei Power Station as well as efficiency gains, plant reliability and availability gains. / MIng (Development and Management Engineering), North-West University, Potchefstroom Campus, 2015

Grootvlei Power Station’s thermal efficiency had been on a steady declining trend since it was re-commissioned in 2008, which had tremendous financial implications to the company at the time of writing. The main contributory factor to the thermal efficiency losses was identified to be the condenser backpressure losses that the station was experiencing. This loss was responsible for approximately 17% of the total efficiency losses. Therefore an investigation was conducted to determine the potential impact of the condenser backpressure loss on the thermal efficiency and the financial implications thereof. The deliverables were to determine the cause of the condenser backpressure loss and propose possible resolutions, to quantify the financial effect and to produce a cost benefit analysis in order to justify certain corrective actions. Grootvlei Power Station is one of the older power stations in South Africa and it was used as the first testing facility for dry-cooling in South Africa. It consists of six 200MW units, two of which are dry-cooled units. In 1990 it was mothballed and due to rising power demands in South Africa, it was re-commissioned in 2008. Thermal efficiency has been playing a great role due to the power constraints and therefore it was deemed necessary to conduct this study. The approach that was used was one of experimental and quantitative research and analyses, incorporating deductive reasoning in order to test various hypotheses of factors that could have been contributing to the backpressure losses. In order to do so, a logic diagram was designed which could be used to aid in the identification of possible causes of the condenser backpressure losses. The logic diagram was able to identify whether the problem had to do with the cooling tower or the condenser. It was able to identify which area on the condenser was defective i.e. whether the pumps were not performing, or whether the air ejectors were not performing. It was also able to indicate whether the inefficiency was due to air ingress or fouling. Alongside the logic diagram, a condenser efficiency analysis was used in order to strengthen and improve on the investigation. This analysis was able to identify whether the condenser was experiencing fouling conditions, air ingress, passing valves or low cooling water flow. After the investigation commenced, it was decided to focus on the two largest contributing units since the largest contributor was a dry-cooled unit and the second largest contributor was a wet-cooled unit, thus some comparison between the units was incorporated. The condenser efficiency analysis on Unit 3 (wet-cooled unit) indicated a low cooling water flow, fouling as well as air ingress. The logic diagram indicated poor cooling tower performance, high air ingress as well as fouling. Further tests and analyses as well as visual inspections confirmed these phenomena and condenser fouling was identified to be the largest contributor to the backpressure loss on this unit. The condenser efficiency analysis on Unit 6 indicated that air was entering the condenser. The logic diagram indicated that a segment of the backpressure loss was due to poor cooling tower performance. Inspection of the cooling tower indicated damage and leaks. A cooling tower performance test was conducted and the result of the test indicated that the tower was in need of cleaning. Further analyses according to the logic diagram indicated that the condenser was experiencing air ingress which concurred with the condenser efficiency analysis. A helium test, condensate extraction pump pressure test as well as a flood test was conducted on this unit and various air in-leakage points were identified. The financial implications of the backpressure losses were investigated and found to be costing millions each month. The condenser backpressure loss was contributing more than 2% to the thermal efficiency loss. The cost benefit analysis indicated that the cost of cleaning the condenser on Unit 3 would be made up within six months and a return on investment of 16,6% was calculated. The cost benefit analysis motivates for extended outage times for the purpose of cleaning the condensers from a financial perspective. Therefore, it was recommended to clean the condenser on Unit 3 and fix all known defects on the unit as well as on Unit 6. The cooling towers were recommended to be refurbished. Further investigation was recommended to determine the feasibility of installing an online cleaning system on the wet-cooled units’ condensers such as a Taprogge system. Alternative investigation methods were suggested such as smoke stick analyses for air ingress determination. It was also recommended to review the maintenance strategies that were being used since many of the defects were found to be maintenance related. If the identified problem areas are attended to, the condenser backpressure loss will decrease and the condensers transfer heat more efficiently which will lead to financial gains for Grootvlei Power Station as well as efficiency gains, plant reliability and availability gains. / MIng (Development and Management Engineering), North-West University, Potchefstroom Campus, 2015

Cooling towers form an important part of chilled water systems and perform the function of rejecting the heat to the atmosphere. These systems are often not operated optimally, and cooling towers being an integral part of the system present a significant area to study and determine possible energy saving measures. Operation of cooling towers in economizer mode in winter and variable frequency drives (VFDs) on cooling tower fans are measures that can provide considerable energy savings. The chilled water system analysis tool (CWSAT) software is developed as a primary screening tool for energy evaluation for chilled water systems and quantifies the energy usage of the various components and typical measures that can be applied to these systems to conserve energy, all while requiring minimum number of inputs to analyze component-wise energy consumption and incurred overall cost. A careful investigation of the current model in CWSAT indicates that the prediction capability of the model at lower wet bulb temperatures and at low fan power is not very accurate. A new model for accurate tower performance prediction is imperative, since economizer operation occurs at low temperatures and most cooling towers come equipped with VFDs. In this thesis, a new model to predict cooling tower performance is created to give a more accurate prediction of energy savings for a tower. Further the economic feasibility of having additional cooling tower capacity to allow for economizer cooling, in light of reduced tower capacity at lower temperatures is investigated.

Com base em um modelo fenomenológico e a partir de dados experimentais obtidos numa planta piloto, foi obtida uma correlação entre o desempenho de uma torre de resfriamento em função das principais variáveis de processo: fluxos mássicos do gás e da água pela torre, e temperatura de entrada da água. Os resultados apresentaram boa consistência, comparados com os da literatura. A metodologia desenvolvida pode, com relativa facilidade, ser aplicada para torres de resfriamento industriais, pois se baseia em medidas de variáveis, factíveis em termos práticos. Efetuou-se também um estudo paralelo com base em modelagem e simulações matemáticas do comportamento de uma torre de resfriamento de água em condições severas, com temperatura da água de alimentação superior a 50°C. Constatou-se que o coeficiente de transporte de massa na torre de resfriamento aparentemente não é afetado. / Cooling towers are widely used in many industrial and utility plants and its thermal performance is of vital importance. In the present work, using a phenomenological model and by experiments carried on over a pilot installation, the mass transfer coefficient dependence of air and water flow rates and inlet cooling water temperature is determined. The approach proposed may be useful in addition for characterization of industrial cooling towers since it depends on temperature and flow rate measurement usually available in typical plants. A parallel study concerning high mass transfer rate theory is accomplished. Through mathematical modeling and simulations based on this study no influence is detected on the mass transfer coefficient in the cooling tower, operating under harsh conditions with inlet water temperature up to 90°C.

Com base em um modelo fenomenológico e a partir de dados experimentais obtidos numa planta piloto, foi obtida uma correlação entre o desempenho de uma torre de resfriamento em função das principais variáveis de processo: fluxos mássicos do gás e da água pela torre, e temperatura de entrada da água. Os resultados apresentaram boa consistência, comparados com os da literatura. A metodologia desenvolvida pode, com relativa facilidade, ser aplicada para torres de resfriamento industriais, pois se baseia em medidas de variáveis, factíveis em termos práticos. Efetuou-se também um estudo paralelo com base em modelagem e simulações matemáticas do comportamento de uma torre de resfriamento de água em condições severas, com temperatura da água de alimentação superior a 50°C. Constatou-se que o coeficiente de transporte de massa na torre de resfriamento aparentemente não é afetado. / Cooling towers are widely used in many industrial and utility plants and its thermal performance is of vital importance. In the present work, using a phenomenological model and by experiments carried on over a pilot installation, the mass transfer coefficient dependence of air and water flow rates and inlet cooling water temperature is determined. The approach proposed may be useful in addition for characterization of industrial cooling towers since it depends on temperature and flow rate measurement usually available in typical plants. A parallel study concerning high mass transfer rate theory is accomplished. Through mathematical modeling and simulations based on this study no influence is detected on the mass transfer coefficient in the cooling tower, operating under harsh conditions with inlet water temperature up to 90°C.