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Model Study Midland Cooling Pond. Prepared for CPC for Transmittal to Bechtel Corp
	ML19329F222
Person / Time
Site:	Midland
Issue date:	01/31/1970
From:	Ferron A; ALDEN RESEARCH LABORATORY
To:	;
References
	NUDOCS 8006230748
	Download: ML19329F222 (46)
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NM, MIDLAND COOLING POND

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MODEL STUDY MIDLAND COOLING POND CONSUMERS POWER GOMPANY fo r BECHTEL CORPORATION POWER AND INDUSTRI AL DIVISION Albert G. Ferron l

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Profenor Lawrence C. Neale, Director

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ALDEN RESEARCH LABORATORIES I

WORCESTER POLYTECHNIC INSTITUTE I

HOLDEN, MASSACHUSETTS, 01520 Ja*nuary, 1970

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i TABLE OF CONTENTS Page ABSTRACT 1

INTRODUCTION 2

OBJECTIVES 3

MODEL CONSTRUCTION 4

SCALE 5

APPARATUS 8

TEST PROCEDURE 10 RESULTS 12

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Flow Distribution 12 Temperature Distribution 13 l

CONCLUSIONS 17 FIGURES 1 through 27 18 APPENDIX A i

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1 ABSTRACT Model tests on the 880 acre Midland Cooling Pond were utilized to provide optimum baffle location and temperature distribution throughout the pond.

Basically the tests showed 1) that a single dog-legged baffle is needed to maximize the usage of the pond and 2) that the heat transfer characteristics of the pond can be improved by discharging the condenser cooling water to a " hot pool" and allowing the heated water to flow over a submerged weir whose crest elevation con be varied according to the water elevation in the pond.

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i INTRODUCTION

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The proposed Midland Plant for the Consumers Power Company is located in Midland, Michigan.

The plant site is adjacent to the Tittobowassee River and encompasses an 880 acre surface area cooling pond.

Condenser cooling water from the two units is circulated through the cooling pond 3

i old its temperature is reduced by atmospheric heat transfer prior to entering the cooling water intake. The flow thtcugh Unit No.1 is 207,000 gallons per minute with a 20F temperatece rise and the flow through Unit No. 2 is 351,000 gallons per minute with a 31.5F temperature rise.

The pond is designed to operate with a maximum variation of nine feet between the maximum and the minimum water surface elevations.

This study of the temperature patterns and flow regime in the cooling pond was under-taken for the Bechtel Corporation of San Francisco, California.

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h OBJECTIVES l

The objectives of the study were:

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1. To evoluote baffle arrangements relative to pond utilization and cooling effects.

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2. To maximize cooling by evaluating the method of discharging the condenser i

f cooling water.

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3. To measure horizontal and vertical temperature distributions for calculation of the prototype cooling performance.

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4 MODEL CONSTRUCTION The outdoor site chosen for the model is located in the lower model basin area be-tween on existing model and one of the buildings. At the site, there already exists a source of both cold and heated water.

I Preliminary construction involves grading the site and placing a concrete slab on which to build the model. The north-south and east-west grid lines were then pointed on the slab. (Fig.1)

Wolls were erected around the o ee of the model. In general, the inside face of I

the 4" thick wall corresponds to the top of the inner face of the perimeter dikes. (Fig. 2)

Wooden templates outlining the bottom topography of the cooling pond and templates

,for the sloping sides of the perimeter dikes wete installed and checked for elevation us-ing on engineer's level. (fig. 3 and Appendix A) These templates were backfilled with grovel to within two inches from the top and screen was stapled to the templete,s prior to concreting (Fig. 4). The model was then finished by placing a concrete topping even l

with the top of the templates. (See Frontispiece) l l

During the template construction three model structures, two representing the dis-charges and one representing the two intakes, were fabricated (Fig. 5). These were poor-ly positioned in the model prior to the finish concreting.

I After coating the model, movable baffle sections were built of concrete and placed atop the concrete (Fig. 6). Suitable gasket material was used on the bottom and between the various baffle sections,

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5 SCALIN G l

The model was constructed using a scale of 1 to 200 horizontal and 1 to 25 vertical.

For the minimum pond water level the vertical scale used was 1 to 15.

Theoretically from c heat transfer point of view, with horizontal scale of 1 to 200 the vertical scale should be 1 to 34.2. With such a scale, the depths of most of the cool-ing pond would be too shallow to properly duplicate flow patterns.

It was therefore nec-essary to utilize two different vertical scales in the studies and to make flow compensations

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to properly duplicate heat transfer chorocteristics.

I The flow process is basically a Froude scaling proposition. In this respect, the Froude number in the model must be equal to the Froude number in the prototype.

Horizontal dimension in prototype HR=

Horizontal dimension in model and Vertical dimension in prototype Vg Vertical dimension in model then the various model parameters based on Froude scaling are os follows:

PARAMETER MODEL PROTOTYPE Horizontal Distance L

(H ) (L)

R Vertical Distance y

(V ') (Y)

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Velocity v

Flow Q

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Since heat transfer to the atmosphere is of prime importance the equations for the i

heat input and output to the model cooling pond are predominant in this part of the study.

i The total heat input to the pond from the plant is qi = Q cp AT) where q; = heat transferred to the cooling pond Bru/hr i

O = flow rate in cu. ft/hr l

l p = specific heat in Bru/lb 'F c

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= specific weight in Ibs/ft3 ATj = plant temperature differential *F l

The output from tha cooling pond is qo = K A AT2 where go = heat transferred from the cooling pond Bru/hr K = heat transfer coefficient Bru/hr 'F Ft2 A = Surface area ft2 AT2 = driving temperature difference between water surface i

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Assuming that all the heat is lost to the atmosphere and that there are no other heat sources or sinks q; = qo l

If the ratio of the heat output to heat input in model and prototype are to be equal,

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2 then O rototype = H R Omodel p

This equation is arrived at by the following reasoning:

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1. Since both the rnodel and the prototype utilize water, and cp are the some for the model and prototype.

2. The heat transfa coefficient K is assumed to be the some since the model is located outdoors and meteorological effects are assumed equal.

l The radiation effects may be slightly different in the model due to i

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3. The results of the temperature tests should be such that the ATj and the i

AT2 are the some in the model and prototype when 1. and 2. above are true.

During the testing the discharge flow was reduced as per the lost equation above in urder to maintain the some heat output per cooling pond surface creo. Therefore, the 1

flows corresponding to prototype flows of 207,000 spm and 351,000 gpm would be 129,000 gpm and 219,000 gpm respectively to give the model and the prototype the some heat load per unit surface l

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8 APPAP.ATUS The model was located near a large boiler used for heating water for similar model studies. Water was brought from this boiler through two-inch piping to a constant head tank.' This tank was also supplied with the cooled intoke water. Both the hot and cold water were mixed in two separate compartments and then discharged through calibrated orifice p!otes. These v oters exited at the discharge of both Units No.1 and No. 2 at the correct flow and the correct temperature increase. (Fig. 7 and Fig. 8)

Water from the intokes was brought to the head tank by two centrifugal pumps (Fig.

8) and was metered by separate orifice plates for each unit.

Surface temperatures in seventy-two fixed locations in the model were recorded with three Esterline 24-point temperature recorders. (Fig. 8) The sensing elements, cop-per-constanton thermocouples, were installed in the model using a series of stands or supports (Fig. 9).

For measuring vertical temperature distributions a portable probe using five spaced copper-constanton thermocouples was used. Temperatures in the mixing tanks were mon-itored using thermistors and a thermistor meter.

As a guide to the baffle study, o two-dimensional model, roughly 2 feet x 2 feet x 2 inches was used. A small centrifugal pump was used in this portion of the study to simu-late the water flow through the condensers. This model provided on opportunity to evolu-ote qualitatively a wide variety of arrangements.

During the temperature studies a series of fixed weirs was used in addition to vones to guide the discharge water to the surface ot.o reduced velocity in order to induce strati-I fica tion. (Fig.10) e a

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5e diurnal study was performed by use of a block plastic sheeting that con be deployed over the model at a prescribed time interval to eliminate the direct effects of the sun on the model. (Fig.11)

During oil the tests, on insulated container, opened to the atmosphere only at the surface was used as o reference to obtain dato on the changes in the model due to the ot-mosphere. This " bucket" was placed near the discharge and intake creas during the stud and was kept free from shadows of the instrument protection cover.

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TEST PROCEDURE i

Boffle Arrangement l

To study baffle arrangements the differential temperature across the plant and the l

I flow modeled according to Froude scaling was used. Various baffle arrangements were tested in the model by changing the location and configuration of the movable baffles.

The studies were conducted using dye as a tracer and, also, by timing model drogues and noting their progress through the cooling pond.

To maximize the number of baffle arrangements that could be studied, o small two-dimensional model was built and tests conducted at the some time os those on the large model. The best baffle configurations obtained on the smaller model were then checked on the larger model until the maximum surface crea was active and the maximum reten-tion time in the cooling pond of all discharge water was obtained. The time required for the discharge water to reach the intake corresponded to 30 prototype hours.

Heat Potterns in the first series of tests the model was operated by filling the model to elevation 625 with cold water and storting Units 1 and 2 after fil;ing disturbances had ceased.

Horizontal temperature data was recorded from the stort of the test and vertical tempero-ture profiles of selected points in the model were token of the end of the test. During all the tests the discharge temperature of the condenser circulating water was maintained at the some temperature increment over the intake temperature as prescribed.

From this technique two questions arise. The first question is whether there is heat j

transfer through the bottom of the model and the second question is whether true equilib-j rium has been reached.

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To try to answer the first question the rnodel bottom was insula ed with 1/2-inch i

styrofoam and tests repeated. No significant changes in temperature potterns were ob-l served. Another check was performed by removing from the center of the model o 4-foot x 4-foot section of the styrofoam bottom insulation and checking the vertical tem-l perature distribution top to bottom at various points on and off the styrofoam. Again no significant changes were noted in the vertical distribution of temperature and the bottom t

I temperatures measured on either the concrete or the styrofoam were the some.

To help onswer both of the above questions a different testing opproach was devel-oped.

The model was heated as hot as possible with the existing boiler from 3 a'.m. to.

8 c. m. prior to the daytime test. At 8 a. m. the temperature difference across the plant i

and the plant flows were set and the temperature difference was maintained during the rest of the day.

It was found that the model came to equilibrium near mid-afternoon.

i Surface temperatures were continuously recorded and when equilibrium was reached a sur-l vey was made to obtain the vertical temperature distribution at some dozen areas in the model.

The tests on the final configuration were all performed using this latter technique.

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RESULTS Flow Distribution Six different central baffle configurations were installed and tested in the model beginning with baffle arrangement case "A" (Dwg SK-C-168) and ending with the final baffle configuration. In addition to those tests, numerous other arrangements were studied i

on the two-dimensionc! model.

l The studies with case "A" baffle showed the creo around E1000 and 57500 to be almost stagnant with no visible flow utilizing this oreo. Two other oreos (between W2500 i

and W500 in the crea of 56500 and south of the baffle between W2000 and W500) dis-1 l

plcyed sizable eddies.

in addition, the flow between the baffle and the west dike had a tendency to follow clong the west and the south dikes. With this flow distribution the pond utilization south 6

of the baffle is inefficient. (Fig.12)

Use of additional baffles protruding from the west and south dikes failed to improve the overall flow distribution in the pond. These baffles showed improvements in some areas but these improvements were more than offset by resulting eddies downstream of the ba ffles. From these preliminary studies in both models, it was deduced that a simple bef-fle arrangement could be utilized more efficiently than numerous smaller baffles located around the cooling pond.

The baffle that showed the best flow distribution throughout the pond was a dog-legged baffle running southeasterly from between the intake and discharge to 56780, E1600 and proceeding southwesterly to S7900, W1000. This configuration resulted in a reduced eddy along the north dike area and behind the baffle and a rrore uniform flow distribution south of the baffle (Fig.12).

13 Temperature Distribution in this section it should be noted that the flows of 129,000 spm for Unit No.1 and 219,000 spm for Unit No. 2 represent, based on the considerations described on pages 6 and '7, the model flows utilized during the studies. This was necessitated in order to properly model the heat load per surface crea due to the medel scales used in the tests.

Curves of surface water temperature versus area were plotted for all tests described below. These curves indicate the relative cooling efficiency of various configurations tested. Ideally, the curve for the most efficient use of the pond for cooling purposes would plot as a straight line running from the discharge temperature at zero creo ratio to the intoke temperature at 1.0 orea ratio. The larger the concave deviations from this line the more inefficient the pond becomes. Since the mechanism of cooling pond heat trans-fer relies on the driving force resulting from the difference in surface water temperature and equilibrium temperature a larger amount of heat transferred per surface creo results if the water temperature at the surface con be kept as high as possible. For this reason, the steeper the slope of the creo-temperature curve at the discharge end of the pond the more inefficient is this portion of the pond.

A. Original Discharge (Figs. 13, 14, 15)

Figures 13 and 14 show the horizontal and vertical temperature distribution using a sub-surface jet discharge. (Dwg. SK-C-166). The jet velocity for Units Nos.1 and 2 is appreximately 8 ft/sec.

In the case of the two tests (Nos. 34 and 40), performed on two different days, the results are substantially identical. As seen on Figure 15 the condenser cooling water temperature dropped 16% in the first 2% to 3% of the cooling,

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14 pond arco due to the mixing cetion of the jet.

4 Stratification was of the order of 5F to 6F at the discharge and IF to I.5 F of the intake. The high degree of mixing and the resultant small amount of l

i stratification resulted in inefficient surface heat transfer where, in the cose of

'the cooling pond, the heat must be transferred to the atmosphere.

j The results of these tests showed that some mechanism might be utilized in the pond to reduce the mixing, especially in the creo of the discharge where the temperatures were the highest, in order to maximize the temperature difference between the equilibrium and surface water temperatures. A weir across the en-trance creo of the pond appeared to be the best device to accomplish this.

B. Weir (Figs. 16, 17, 18) i Tests No. 37 and No. 38 (Figs.16,17) were performed with a vertical sto-tionary weir with crest at elevation 615 and a movable weir crest set at elevation 623.5. Test No. 38 has, in addition, a sloping rock upstream face starting from the bottom of the discharge pipe to the top of the stationary part of the weir at elevation 615.

Stratification, in the order of 15F to 20F, was obtained in the upper 10 feet of the exit of the discharge weir. Stratification around the intake was maintained at 1F.

Figure 18 indicates the performance difference in the initial 30% of pond crea, test No. 38, and the jet discharge, test No. 40. The creo between the two curves in the initial 30% of the pond creo represents a substantial increase in heat tionsferred to the atmosphere in this section of the pond, but the change

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in intoke temperatures decreased by only about 1.5%.

C. Weir Variations (Figs. 17, 19, 20, 21)

Figure 19 shows the location of two weirs of different lengths that were tested. The variations in temperature distribution (Figs.17, 20) and the tem-perature versus crea distribution is negligible and therefore the increase in weir length was deemed inadvisable because of the increased costs of the 750-foot Weir.

D. Effects of Cooling Pond Water Elevations (Figs. 17, 22, 23, 24)

The stratification in the top five feet near the discharge weir was essentially the some for cooling pond water elevations of 625, 620 and 616.'

The isotherms south of the baffle extend basically south from the baffle and indicated good temperature distribution. In the cose of the water elevation at 616, the southeast corner of the pond was not fully utilized as indicated by the stagnated waters in this corner which were at a lower water temperature than those of the intake. The intake temperature at this elevation was, however, the lowest compared to the tests at pond elevations of 625 and 620.

To go along with the vertical and horizontal temperature distribution, the area temperature curves were essentially the some os of the higher temperatures, except near the intoke as shown in Figure 24.

E. Diurnal Tests (Figs. 25, 26, 27) 1 The test to simulate diurnal effects was conducted on a bright sunny day.

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The model was covered and uncovered by a plastic shade located some 10 feet l

v above the model. The covering and uncovering simulated 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> of prototype N

16 day and night.

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The only noticeable differences during these tests were reductions of about 2F at the surface near the weir discharge during the period when the model was covered. It is noted that the reference bucket temperature during this portion of the test was reduced also by abcut 2F. However, outside of the pond crea neorest the weir, the remainder of the pond did not show a significantly meo-sured drop in temperature at the surface.

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CONCLUSIONS The conclusions obtained from this study cre:

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1. A significunt reduction of the baffle length in the cooling pond and a better flow distribution were obtained by modifying the configuration and location of the origi-nolly designed baffle.

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2. More efficient heat transfer results in the initial 3096 of the pond crea were ob-toined by placing a 500-foot long submerged weir downstream of the discharge from the 1

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two units. However, the ratio of the intake temperature to the overage pond tempero-6 ture was only 1.5% lower for the weir tests than for tests with the submerged jet. (See f

Figure 18.)

i

3. The weir crest elevations found to give the best initial stratification were 623.5 i

for a pond elevation of 625,618.5 for a pond elevation of 620 and 614.75 for o pond elevation of 616.

4.

The iieot transfer obtained by using the " hot pool" established between the dis-charge structure and the weir could be maximized by proper design of the discharge structures. The momentum of the jet could not be contained within the confines of the

" hot pool" without the addition of directional vones at the exit to the discharge structures.

The un-directed jet, as designed, caused mixing to occur downstream of the weir.

5. The test at different pond elevations showed slight improvement in the heat trans-fer over the initial 60% of the pond area os the pond level decreased. The ratio of the l

intake temperature to the overage pond temperature decreased for decreasing pond elevo-tion.

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0. 9 1.0 ACCUMUL ATED ARE A TOTAL AREA NOTES.

Test Ave. Pond Pond D.ischarge MIDL AND MODEL STUDY Number Temp.

Level Con fig, TEMPERATURE VERSUS POND AREA 11 Uncov.

102.09 625.0 ft 500 ft weir OlURNAL STUDY elev 623.5 i

ALDEN RESEARCH LABORATORIES il co v.

101.95 625.0 ft 500 ft weir

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APPENDIX A Bechtel Drawings Used in Model Construction

1. Station Arrangement SK-C-167 Rev. A.

2. Baffle A Configuration SK-C-168 Rev. A.

3. Perimeter Dikes C-9 Rev. B.

C-116 Rev. B.

C-117 Rev. B.

4.

Topogrcphy C-109 Rev. B.

C-110 Rev. B.

C-111 Rev. B.

C-112 Rev. B.

l S. Discharge Structure SK-C-166 5/7/69

6. Intake Structure SK-7220-C-77 5/19/69 t

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