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FRP Storage Tank Linings VS Replacing Steel Tank Bottoms?

 

Are you searching for “FRP Storage Tank Linings VS Replacing Steel Tank Bottoms?” If so you are probably trying to decide if it is better to get a linking, or replace the bottom of your steel tank.  There are a lot of chemicals that can be really corrosive to any above ground metal storage tanks, which can result in a leak. The normal corrosion rate for many carbon-steel storage tanks in certain temperatures is more than 1 mil per year, with a leak happening in less than 5 years. These leaks will often result in costs for environmental penalties and tank repair.

Tank corrosion can also increase whenever there is a layer of water that is containing soluble chlorides and salts that settle at the bottom. These compounds are considered highly corrosive to begin with, but they can also generate strong electrolytes that will cause corrosion from within. There can also be an issue with external tank corrosion too. The bottoms of above ground storage tanks are quite susceptible to various types of corrosion, especially if the tanks are subjected to stray electrical currents in soil or are close to salt water.

If the above ground tank bottom is corroding, it will need to be coated with a thick film FRP or fiberglass reinforced plastic that has about a 65 mil dry film thickness or be replaced. Since replacing the tank bottom can be time consuming and expensive, FRP linings have really become a popular solution for tank bottom repair.

FRP Lining For A Water Tank

FRP linings are great options for water tanks and other chemical storage needs.  They are more corrosion and heat resistant than other options for tank lining.  The polymer used to make FRP linings is what gives this tank lining product superior heat and corrosion performance.  In addition fiberglass fibers add to it’s strength and durability.  This combination of durability makes FRP linings a favorite for water tanks, especially in areas with extreme conditions such as snow, ice, and use of salt.  With lifespans of up to about 20 years companies and communities can choose FRP linings with confidence that they will last and protect water tanks.

Steel Tank FRP Linings

Steel tanks are common storage and flow containers which need to be protected from corrosion.  FRP epoxy lining systems are perfect for pitted steel storage tanks.  The interior of the tank on all surfaces can be coated with an FRP lining. It is used on steel tank floors, walls, and ceilings to provide a complete solution for corrosion. These linings also provide structural support while extending the life of the tanks from chemical attacks, high heat, and abrasion.   These coatings are applied to be a thick lining which is high performance and provides many years of reliable use.

Learn about: How FRP linings are applied to steel tanks

FRP Lining Installation

This recent trend has a lot of places shifting away from just replacing the tank bottom and moving towards the FRP lining system. Installing the lining system means that you have to apply primer, putty, a catalyzed resin that has a glass mat and then a seal coat. The tank has to be dry and the surface must be fully prepared. The whole process is a lot quicker and less costly than replacing the tank bottom.

The FRP lining is considered to be a secondary bottom that is bonded tightly to the storage tank. Whenever it is properly applied, it will prevent any leakage because of internal corrosion for about 20 years. If the supporting steel bottom becomes perforated, the lining will help to minimize the issue of exterior corrosion by giving it strength to bridge the small perforation. Even if there is severe corrosion on the outside, it may be possible to apply a double layer for a thickness of around 120 mil. A lining that is less than 20 mil when dry will not be able to protect against leakage. It is recommended at that for new tanks that have no underside corrosion or pitting.

FRP Development

Introduced in the 1950s, FPR laminates were made from orthophthalic polyesters that would bridge gaps caused by corrosion and were thought to protect from internal corrosion. Although in the 1960s, it was found that isophthalic polyester resin was better to withstand corrosion. Vinyl ester resin was founded in mid-1960s and performed great, but it was so expensive that it was only used when high performance was needed. Now, FRP linings are made of epoxy novolacin vinyl ester.

Just like with any repair, FPR linings will have its disadvantages and advantages.

Advantages

  • For most installations, FRP linings will have a 35+ year service history.
  • FRP linings are less expensive than replacing a steel tank bottom.
  • FRP linings are quickly installed, minimize down time, and work better than replacing the bottom of the tank.
  • FRP linings that have vinyl ester resin can resist various corrosive things at high temperatures.
  • FRP linings can bridge a hole up to 8 inches in diameter and a double laminate can withstand 82psi while single laminates can handle 37psi.

Disadvantages

  • Cyclic loading could affect the ability of FRP Linings to bridge a clear, large opening, the extent of effect hasn’t been known yet.
  • Whenever a pigmented gel coat is used, you cannot see the bottom to find the extent of the corrosion. Although, new technology and high power magnets can now scan laminates to find information about the corrosion.
  • The applicator must be aware of the installation procedures and the importance of contaminant free substrates before applying.

Standing Up to Pressure

There haven’t been a lot of articles about FRP laminates that talk about the pros and cons of being used instead of replacing a steel tank bottom. There was a case that describe a 211ft diameter tank that had FPR laminate installed in 1985. During 1995 a leak started in the sump area which was caused by bottom side corrosion. 2 holes had been created, each about a foot wide. Although, it was determined that the FPR lining didn’t fail. It was the lining that was actually containing the contents of the tank and it did until hydraulic pressure caused it to bust.

Now you may be asking just how much pressure can the lining stand? A physical pressure test was done in a water filled chamber that would let steam be pumped into a pipe loop until it hit 140 degrees. 8 plates of 12* ¥ 11/2* ¥ 4* steel were made with a set of holes cut in the middle of the plates to represent corrosion. The holes ranged in diameter and were filled with melted wax and isophthalic polyester laminate on top. Just a single laminate was used on 1 set of the plates while double laminates on the other. A deflection gauge was installed on the bottom to measure the deflection amount.

Although there were some failures on one of the plates at 28psi for single laminate and 66psi on double laminate, this was caused by mistakes in the steel fabrication.  None of the edges had been radius, the laminates were shoved into the holes, which caused it to fail.

A new test was done and 4 new plates were made that had edges. 2 were done with single laminates and the other were with double laminates. The single laminates did better in the second test with 37psi before the laminate went through the hole. While the double laminate held until 82psi.

According to the tests, it is assumed that bottom side corrosion won’t happen with sharp edges and that it will be gradual, so it is assumed that FRP linings will contain the contents of the storage tank where the internal pressure doesn’t exceed 37psi for single and 82psi for double. Since 22psi happens to be a typical internal pressure, it would seem that FRP linings will offer a margin of safety for internal hydraulic pressure.

Conclusion

An important alternative to having to replace a steel tank bottom is the Thick film FRP lining system which will mitigate external and internal corrosion. Based on the applications over the years, it would a proven history of being successful. While using FRP lining systems have their disadvantages and advantages, one main advantage is the test results that have measured the performance under hydraulic pressure.

Phoenix Tank Lining Company

If you are looking for the highest quality tank linings for your FRP and steel tanks in the Phoenix metro area All Kote Lining, Inc. can handle all of your needs. We take care of linings and tank restorations for companies both big and small and no job is too large or little. We are punctual, professional, and provide the highest quality tank linings available. If you have tanks that have some damage, need regular maintenance, or need an overhaul call All Kote Lining today for service by calling 480-966-4446.

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Types Of Chiller Systems

Types Of Chiller Systems

If you are searching for Types Of Chillers, this post should help! Industrial chillers are an integral part of keeping large commercial buildings comfortable during the warmer months. They typically work in conjunction with a cooling tower which helps reduce the overall temperature of the cooling system. There are two main categories of chillers, these are air and water chillers.

Contents on this page:[one-half-first]

  1. Types of Chillers
  2. Air Chillers
  3. Water Chillers
  4. Evaporative Condensed Chillers
  5. Chiller Subcategories
  6. Reciprocating Chillers
  7. Rotary Screw Chillers
  8. Centrifugal Compression Chillers
  9. Absorption Chillers
  10. Where Are Chillers Used?

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[one-half]Types-Of-Chillers Industrial[/one-half]

Types Of Chillers

There are 3 types of chillers that cool things using air, water, and evaporation.  Each type may have subcategories based on how each of them accomplish this goal.  Technology varies and depending on the age of the building you own or manage the type of chiller you have may fit into one of the following categories.

[one-half-first]

  • Air Chillers
  • Water Chillers
  • Evaporative Condensed Chillers
  • Reciprocating Chillers
  • Rotary Screw Chillers

[/one-half-first]
[one-half]

  • Centrifugal Chillers
  • Frictionless Centrifugal Chillers
  • Screw Driven Chillers
  • Absorption Chillers

[/one-half]

Air Chillers

Air chillers can be split in various configurations or used as a single piece unit. Air chillers vary in size from small capacity to 100+ ton models that are used to cool commercial buildings. The difference between air cooled and water cooled chillers is that air chillers use ambient air as the condensing source and a fan that moves the air over the coil. Water chillers on the other hand use water as the condensing source and a pump that circulates water through the condenser out to the cooling tower that releases it into the atmosphere.

Water Chillers

Water chillers are mechanical devices/refrigeration systems that are used to dehumidify air and cool fluids in industrial and commercial facilities. They have many applications from process use to space cooling. The difference between water and air chillers is that the water is sent to a cooling tower to cool the water in a water chiller.

Evaporative Condensed Chillers

An evaporative condensed chiller is an alternative to water and air condensed chillers. Most evaporative condensed chillers range from 15-200 tons but one should select a system that is best suited for their individual facility. Maximizing heat rejection in evaporative chillers is done by recalculating the water constantly to provide on-going wetting of the condenser tubes while mechanical fans pull the air over them, which evaporates the water and rejects the heat to the atmosphere.

Sub-Categories Of Chillers

These chillers are sub-categories of the main 3 types of chillers: reciprocating, rotary screw, and absorption chillers.  Each have their own design and pro vs. cons.  Choosing the right chiller for your facility is an important decision.  It will decide how well you are equipped to take care of your industrial process or use the chiller as part of your HVAC system in a commercial building.

Reciprocating Chiller

Gas is compressed inside these types of chillers with pistons, not unlike a car engine. There are multiple pistons that continue to compress the gas to heat it. The difference is that the hot gas is used inside the system, not simply exhausted out of a tailpipe. The demand is matched by the adjustable intake and exhaust valves that can be opened to allow the piston to simply idle. Idling the piston when demand for chilled water helps manage capacity. This system is very flexible and can cope with the specific demands from load on the system. It is also possible to manage the capacity to match the demand with a hot gas bypass, but it is not considered to be as efficient. Some systems use both capacity control systems which unload pistons but also utilize the hot-gas bypass to match demand.

Rotary Screw Chillers

The screw compressor is also known and a helical compressor. Inside the stationary housing it contains to mating helically grooved rotors. Direct volume reduction is achieved when the helical rotors rotate. The capacity of a rotary screw compressor varies between 20 and 450 tons and is controlled by a sliding inlet valve or variable speed drive.

Centrifugal Compression Chillers

One of the main features of the centrifugal compression chiller is that they offer a high cooling capacity in a compact design. They operate via an impeller, much like a water pump. The impeller compresses the refrigerant. These chillers can be outfitted with both variable speed drives and inlet vanes which are used to regulate the control of the chilled water capacity. These are high capacity and can handle 150 tons and up.

Frictionless Centrifugal Chillers

Much like the regular centrifugal design these operate via the same principles but do so with magnetic bearings. The use of magnetic bearings eliminates the need for lubricant and features variable speed DC motors. These motors are typically direct drive and attached directly to the chillers. The capacity of these chillers range anywhere from 60 to 300 tons.

Absorption Chillers

Instead of utilizing a mechanical compressor the absorption chillers use a heat source to be the driving force behind the refrigeration cycle. These chillers typically use two liquids, one to cool and one to absorb. The absorbent liquid is usually ammonia or lithium bromide, and the coolant is usually water.

The two liquids are separated and recombined during the absorption cycle. Due to the low pressure conditions in the chiller water can change phase easily. Water and the absorption liquid also perform well in chillers because of their natural properties of affinity.

The refrigeration cycle starts with the heating of the combined liquids. This boils the water out of the absorption liquid at a high pressure.  The next step is sending the refrigerant water vapor past a condenser coil where the heat is rejected and the water vapor is phased into a high pressure liquid. Then the high pressure liquid is passed along to the lower pressure evaporator where adiabatic flash evaporation returns the water to a gas. This absorbs the heat from the water that needs to be chilled. The last step is the concentrated absorption liquid is sent back to be recombined with the lower pressure water vapors coming from the evaporator.

Where Are Chillers Used?

In the industrial world there are millions of machines which generate incredible heat.  For these machines not to overheat and melt themselves they must be cooled.  This is what a chiller is designed to do. Chillers are used for processes that operate at 60°F or lower.  For processes which operate at 85° or higher cooling towers are a better fit. Listed below you’ll find some of the common areas in which chillers are used:

HVAC Systems

Cooling systems are more than just a matter of comfort in Arizona, they are matter of health and safety.  For commercial locations cooling expenses typically make up about 30% to 50% of the energy costs.  With the cost of electricity always on the rise and the phasing out of HCFCs and CFCs there is an incredibly high demand for replacing large commercial air conditioning and refrigeration systems with chilling systems.

Plastic Fabrication

Chillers used in plastic fabrication typically take on one or both of two roles, cooling the plastic products and cooling the machinery used to make them.  The products which are blown, stamped, or extruded.  The chiller units are also used to keep the barrel of the extruder, and hydraulics of the molding machine cool.  This not only saves on energy but it also helps extend the life of the plastic fabrication equipment.

Medical Facilities

Medical facilities, especially those which do MRIs, laboratory testing, scanning, and blood cooling all rely on chillers to get the job done.  The scanning equipment such as MRI machines produce a lot of heat that must be dissipated quickly and safely to preserve the condition of the equipment.

Printing Houses

Chiller play a critical role in high volume printing houses.  There is a lot of heat generated by friction through the printing rollers and as ink is dried in ovens.  To keep the rollers in good condition and freshly printed paper in good condition chillers are used.  They remove the heat from the process and keeps the parts and paper in good condition despite the high heat conditions.

Beverage Industry

A common step of many types of beverage production is cooking, mixing, and pasteurizing.  Whether its soda, beer, milk, or other drinks the beverage industry relies on chillers to remove heat produced by these processes.

Laser Applications

Lasers are fast becoming a more common element of production, and one that produces a lot of heat.  To keep the lasers and products they cut cool chillers are integrated into these systems.

Rubber Fabrication

The rubber industry relies on chillers to cool the multizone water temperature control units.  This keeps the rubber mill, rubber extruder barrel, bambury mixers and calendars cool and working properly.

Where Are Chillers Installed?

Chillers are usually located in mechanical rooms where other industrial equipment is installed. In other cases the chiller may be outdoors or between the cooling tower and process that requires chiller.   This usually depends on the application, the size, and type of chiller and the compressor.  No matter where they are they will need regular chiller maintenance to operate efficiently.  All Kote Lining, Inc. offers full service cooling tower and chiller maintenance to locations all over the Phoenix Valley.

Phoenix Valley Chiller Repair & Maintenance

All Kote Lining Inc. does far more than just apply protective coatings to your chiller tubes, chillers, and cooling towers. We service and repair chillers in the Phoenix area. We can help you get the most out of your commercial HVAC system by helping maintain the cooling tower and the chiller systems to ensure they are performing their best, and using as little energy as necessary. Give us a call today if you need repairs or service on your chiller system.

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How To Clean A Cooling Tower

To clean a cooling tower you’ll need to power down the fans, wear protective gear, identify dirty and clogged areas, and kill disease causing bacteria from your cooling tower.

Cooling towers draw an enormous amount of energy, and dirty ones pull even more.

Cleaning your cooling tower will restore efficiency and help reduce energy consumption.

In this post we will show you how to clean your cooling tower and reduce your electric bill.

Step by Step Cooling Tower Cleaning

With wind kicking up dirt, sand, leaves, and other debris it’s no surprise that cooling towers get absolutely filthy.  Suddenly there’s a thick layer of sludge and slime at the bottom of the tower in the basin.  Cooling tower water that’s dirty can clog fill media and foul tubes in your chiller.

1.      Turn off the cooling tower fans!

It’s critical to your safety and those that are helping clean the cooling tower to power down the fans.  They move at incredible speeds and can severely harm or kill a person.

2.      Inspect Cooling Tower For Problem Areas

Take the time to inspect your cooling tower and find areas that needs attention. Check your fill media for fouling and for sludge in the hot water basin.

3.      Protect Yourself With Safety Gear

Cooling towers heat and moisture encourage the growth of some dangerous bacterias such as Legionella. You’ll need to wear respiratory protection and eye protection.  This prevents you from becoming sick while cleaning the cooling tower.

4.      Spray Cooling Tower For Mold

Before cleaning it’s a good step to treat the cooling tower surfaces and water with a mold killing product.  It helps control the workspace to ensure workers are safer and their health is protected.

5.      Vacuum Out Sludge From Basin

To remove the sludge from the basin specialized vacuums are used.  These tower vacuums clean the hot water basin floor without the need to shut down the system or drain the basin.  During this process you’ll need to connect to a power source and either connect to a drainage outlet or use a filter system to return the water to the cooling tower.

6.      Fill Tower Water Level

It’s nearly impossible to clean the cooling tower basin without losing some of the makeup water.  Once you’ve removed all of the sludge you should check to make sure the water levels are filled to operating parameters.

7.      Clean Cooling Tower Fill Media

Fill media is the heart of the cooling tower and where the primary heat exchange takes place.  The fill directs the air being pulled through by the fans to come in contact with the hot water needing to be cooled.  If sections are fouled or clogged the distribution will be off.  This will cause diminished performance and cause your system to consume more electricity. Clean the fill with detergents or replace it when possible.

8.      Set Up Bi Annual Cooling Tower Cleaning

Cooling towers need to be completely cleaned at least 2 times per year.  Most operators choose to do this before starting them for the year and at shutdown.  If your location requires your cooling tower to be online for more of the year ensure you’re scheduling some downtime to maintain your towers.

Control Legionella With Cooling Tower Cleaning

One of the biggest risks of neglecting your cooling tower is the airborne disease legionella. While dirty cooling towers use much more electricity a Legionnaires disease outbreak is simply bad business. It can lead to negative public opinion and even fines from your city or state.

It’s impossible to smell, see, or completely get rid of the legionella bacteria.  While cooling towers are absolutely indispensable elements of commercial and industrial processes the potentially deadly bacteria must be controlled.  The way to control this disease is to keep your cooling tower clean.  While biocide will kill legionella it can’t kill all of it if the cooling tower is excessively dirty.

Keep your cooling tower clean so your biocide in the water can keep a legionella bacteria outbreak from happening.

Schedule Cooling Tower Cleaning

All Kote Lining, Inc. specializes in cooling tower and chiller cleaning in the Phoenix Valley.  If you’ve got  a cooling tower our team offers fast, affordable, and through cooling tower cleaning service.  We can come clean a single time or you can sign up for bi-annual service.  For more information about our cooling tower cleaning services or to schedule please give us a call.

Call 480-966-4446 or Contact Us

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Chiller Maintenance Checklist

This chiller maintenance checklist will help you ensure you catch all of the important areas of your chiller system.  In this post we’ve provided an air cooled chiller maintenance checklist as it is the most common design.

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Maintenance Checklist – Maintenance Tips – Schedule Maintenance

Chillers are a critical element in HVAC systems.  Chillers take the heat out of the air and also are implemented in industrial settings to cool down equipment. This checklist is designed to help chiller owners and maintenance personnel conduct detailed and reliable maintenance on air-cooled chillers.

Download & View our Chiller Maintenance Checklist PDF

Air Cooled Chiller Maintenance Checklist

Follow this list as you inspect and maintain your chiller.  Each item is important and diligent chiller maintenance will save money and make the system last longer.

  1. Inspect water inlet and outlet for leaks
  2. Clean out and inspect the sump for corrosion
  3. Cooling coils need to be inspected and surfaces cleaned. Check for leaks, corrosion, or bent fins
  4. The zone control actuators should be inspected, cleaned, and all adjustments made
  5. The compressor needs various areas checked, these include: refrigerant charge, vibration, crankcase heater, oil levels and changes, operating temperatures, and if there are any leaks of refrigerant or oil.
  6. Condenser fans should be cleaned, bearings need to be checked for wear and lubricated, and belts and couplings need to be checked and tightness checked or adjusted as necessary.
  7. The condenser coil should be check for corrosion and leaks and all finds or combs need to be checked for bent sections.
  8. The electrical disconnect should be inspected for proper operation and the contacts should be inspected and cleaned.
  9. The exhaust air damper needs to be inspected for proper operation, have the bearings lubricated, and calibrate or adjust it for optimal operation.
  10. Return air dampers also should be checked for proper operation, calibration, and bearings be lubricated.
  11. The fresh air damper should also be inspected, calibrated, and bearings lubricated.
  12. The filter dryer also should be inspected and any old, dirty, or damaged filters be replaced.

Chiller Maintenance Tips

The simple fact is that the chiller makes up for a significant portion of your electricity usage, even at peak performance.  If you’ve got maintenance issues it can easily use an extra 10%, which hurts the bottom line.  While technology has improved to remotely monitor chillers and technology has produced more durable and efficient parts, maintenance is still key.

Maintain A Log Daily

Knowledge is power and saving power is a big deal when it comes to chillers.  Recording operating conditions such as flow rates, pressures, fluid levels, and temperatures helps build a useful record of your system.  While it was standard to do bi-monthly checks today’s continuous monitoring technology allows you to keep accurate daily logs that will help you narrow down maintenance issues before there’s a bigger problem.

Condition Your Water

Corrosion and scaling are always a challenge in air cooled chiller systems.  Treating the water in your system helps cut down on corrosion, scaling, and the growth of biological contaminants such as Legionella.  All of these issues can let to a decrease in heat transfer caused by fouling and diminished heat transfer due to build up inside of pipes.  It’s important to continually monitor your chilled water loops remotely and visually inspect them annually.

Clean Heat Transfer Tubes

A big part of the efficient operation of chillers relies on clean heat transfer tubes.  If your system has mud, minerals, algae, or scaling it will coat the inside of the tubes and insulate them.  While insulation is great at keeping heat out of a home in the summer the heat transfer in chillers is the cornerstone of how the system functions.  Neglecting your chiller tube cleaning will end up inflating your operating costs and likely result in additional maintenance and more frequent downtime.

Maintain Refrigerant Charge

Your chiller’s ability to cool relies on having the right amount of refrigerant. To ensure your systems optimal efficient performance make sure you’ve got the right level of refrigerant.  If there is air, moisture, or leaks in your system it will impact it’s performance.  With insufficient refrigerant it will take more electricity for your system to perform the same cooling effect.

Provide Cooler Water

Providing cooler water for the condense improves the chiller’s performance.  It will not have to work as hard to condense the water and will run more efficiently.  In some cases this technique can compensate for problems with coils.  While this does fix the problem it is a temporary solution as the chiller must work harder for the same effect.

Purge Non-Condensables

Chillers function on the principle of condensing refrigerant to cool.  If moisture or air leaks into the system it introduces non-condensable elements into the system that rob it of efficiency.  The percentage can be as high as 7% below the rated performance of the chiller system you have.  When considering how much energy a chiller uses to begin with and extra 7% adds up quickly.

Maintain Appropriate Flow Rate

The rate at which your chilled water flows through the chiller does impact the chiller’s performance.  If it is too slow it lowers efficiency. Too fast and it will cause erosion, vibration, and noise.  It is best to keep the flow rate of your chiller somewhere between three and twelve feet per second. The exact speed will depend on your chiller’s design and the load needed by your location.

Upgrade To Variable Speed Drives

In most cases the chiller motor is the largest draw on electricity in the entire building.  Single speed drives are on or off and cannot adjust for the difference in load the system is running under.  In contrast a variable speed drive saves energy as it can adjust the speed to match the load.  This saves a significant amount of energy in your chiller system. In addition variable speed allows the system to ramp up more smoothly in the case it is turned on in an emergency situation.

Check Oil In Compressor

If your compressor uses oil make sure you send a sample of it for inspection at a laboratory once per year.  Due to the hermetically sealed nature of a close refrigerant system the compressor oil should only be changed if the lab deems it necessary.  If there’s excessive moisture it can point to there being a problem with purging the system effectively.  If the oil is changed ensure the filters are tested and replaced when there are pressure drops. In the case your system uses magnetic bearings and is frictionless your system will not have compressor oil.

Inspect Motors & Starters

You can save energy and downtime if you inspect your motors and starters.  To do so inspect the sensor calibration and safety on the microprocessor controls.  Also take the time to inspect the wiring and connections in your chiller system at common wear points and hot spots. Pay attention to signs of refrigerant leaks and test motors for insulation faults.

When To Inspect Chillers

Chillers should be inspected and maintained at least 2 times a year in areas where they are only used during the cooling seasons, or 4 times a year in areas that cool in all 4 seasons. Quarterly inspection helps your chillers, HVAC system, and cooling towers last longer and run more efficiently.

Maintained Chillers Operate More Efficiently

Using this checklist you can get better performance out of your chiller and cooling system. The better maintained your chiller is the less energy it uses, and that saves you money on utilities.  As the chiller and HVAC system is one of the largest draws of electricity in many commercial, industrial, and medical facilities it is important to inspect, maintain, and repair chillers.  Regular inspection and chiller maintenance will help save money and make the system last longer.

Chiller Maintenance in Arizona

If you have a property such as a commercial building, medical facility, or industrial site that uses chillers for processes or HVAC All Kote Lining, Inc can help you take care of the chiller maintenance you need to keep your energy use down and make your equipment last longer.  We inspect, maintain, repair, and line chillers with the most durable coatings available. Give us a call today to find out what we can do for your company at 480-966-4446.

Chillers
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Cooling Tower Components | Cooling Tower Parts & Functions

Cooling tower components include: Instrumentation and Electrical Systems, Cooling Tower Nozzles, Cooling Tower Valves, Mechanical Equipment Support, Drive Shafts, Gear Boxes, Cooling Tower Louvers, Fan Deck, Fan Cylinder, Water Distribution Piping, Cooling Tower Fans, Drift Eliminators, Cooling Tower Fill, Cooling Tower Structure, and Cold Water Basin.

Below we go over the individual cooling tower parts and functions.

List Of Cooling Tower Components:

Cooling Tower Parts & Functions

Cooling Tower Instrumentation:

Instrumentation systems found in most cooling towers include Blow Down Rate, Flow Meters For Cooling Tower Makeup Water, Thermocouples for Cold & Hot Water Measurement Of Temperature, Water Level Switches For Cold & Hot Water Basins, Low & High Oil Level Switches, and Vibration Switches.

Cooling Tower Fan Motor:

Cooling Tower Fan Motor

Refinery & Petrochemical cooling tower applications require explosion proof fan motors due to the potentially leaky heat exchangers. Fan motors should be provided with over load relay and Earth fault relay protection systems.

Cooling Tower Nozzles:

Cooling Tower Nozzles

Most cooling tower nozzles are made out of plastic. These plastics include glassfilled nylon, polypropylene, ABS, and PVC plastics. Nozzles allow for uniform distribution of the hot water that’s inside a cooling tower cell.

Distribution Valves:

Distribution Valves are a part of the cooling tower that regulates the flow of hot water to evenly distribute in cells. The valve body in a distribution valve is manufactured to stand up to corrosive environments.

Drive shafts:

Cooling Tower Driveshaft

Drive shafts transmit power the from the motor’s output shaft to the gear reduction unit’s input shaft.

Gear Box:

Gear boxes reduce the amount of speed depending on your cooling tower fan’s requirements. The torque tube permanently alights the gear reducer, driveshaft, and motor.

Cooling Tower Louvers:

Asbestos sheets are what cooling tower louvers are made out of. Louvers serve 2 purposes:  1. Retain the circulating water within a cooling tower. 2. Distribute air flow equally into the fill media.

Fan Cylinder & Fan Deck:

Cooling-Tower-Fans

The fan deck is simply a supporting platform for the fan cylinders and also creates an access way to the water distributions system and fan.

Water Distribution Piping:

Water distribution piping requires burial underground or needs to be supported in ground to avoid thrust loading of the cooling tower due to water pressure in the pipe and self weight.

Cooling Tower Fans:

Cooling Tower Fans - Cooling Tower Components

Cooling tower fans are one the major parts/components of cooling towers. Most cooling tower fans are made out of hot-dipped galvanized steel, Glass Fiber, (FRP) Fiber Reinforced Plastic, and Aluminum. FRP is one of the best options because it is light weight and reduces the energy requirements (energy consumption) of the cooling tower fan. Pinch blade angles of cooling tower fan blades are varied depending on the season. For example, the pinch angle is increases during the summer season when the density is low to increase the capacity of the fan.

Cooling Tower Structure:

Cooling Tower Structure

The most common cooling tower structure is made up of Wood (Chemically Treated). Although, some newer cooling towers are being manufactured using FRP and Reinforced Cement Concrete (RCC) depending on the application the cooling tower is need for.

Cold Water Basin:

Cold water basins serve two functions and are normally manufactured using RCC. The first function of a cold water basin is to act as storage and collect cold water from the tower. The second function of a cold water basin is the provide the main structure and foundation for the cooling tower itself. Cold water basins usually lye below ground level or on top of the soil. Cooling tower height is found my measuring the distance between the fan assembly to the top of the water basin.

 

Drift Eliminators:

Cooling-Tower-Drift-Eliminators

Eliminators reduce the amount of water that escapes into the discharge air in the cooling tower.  They project air in multiple directions and prevent unnecessary loss of water. These drift eliminators are manufactured using PVC. More passes through the drift eliminator will decrease the amount of drift loss while also increasing the pressure drop which increases the fan power consumption. For larger industrial applications, some use heavy duty drift eliminators.

Cooling Tower Fill Media:

Cooling tower fill media puts as much air in contact with as much water surface area as possible. The film fills make the water form in thing flowing sheets so that the most amount of water surface area interacts with the flow of air. Fill media is manufactured using either wood, polypropylene, or PVC. There are three different types of fill media including: Vertical fill (Splash Fill), Vertical offset fill (Splash Fill), and cross corrugated fill (Film Fill).

Thank you for reading our “Cooling Tower Components” list. Stay tuned for more from the experts at All Kote Lining Inc.

Cooling Towers
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FRP Linings for Storage Tanks Repairs

If you are responsible for an organization that uses storage tanks, corrosion is one of your concerns.  This post takes a look at how FRP linings for storage tank repairs save companies and municipalities significant money over replacing storage tank bottoms. Above ground storage tanks are notoriously corrosive which leads to leaks.  In fact the rate of corrosion at ambient temperatures in carbon steel is more than 1 mil every year.  That means that your new storage tank could leak in as little as 5 years.  Not only do leaks lead to costly repairs but can also lead to penalties for harming the environment.

Corrosion is accelerated when later rich in chlorides and soul be salts lay at the bottom of these storage tanks.  In addition to being highly corrosive on their own these elements can result in a strong electrolyte that causes corrosion to accelerate even more.  The exterior of storage tanks are also under attack from corrosion.  This is especially true for places which have stray electrical currents in the ground or are close to salt water or snow removal including salt.

As above ground tanks corrode they must either be repaired using FRP linings, the bottom repaired, or the entire tank replaced.  FRP linings or coatings are a much more cost-effective option for corroding storage tanks.  Generally, when they are used in highly corrosive environments the thickness should be no less than 60 mils.

Installing FRP Linings

For municipalities and industrial locations using above ground storage tanks the trend has been stepping away from replacing the storage tank bottoms and instead installing FRP linings.  The process of installing an FRP lining is cheaper and faster than completely replacing the tank bottom.  To install an FRP tank lining the tank must be empty, dry, primed, puttied, and include a catalyzed resin with a glass mat.  Lastly the system is finished with a sealcoat.

Thick FRP Lining Lifespan

When the correct FRP lining is selected and installed correctly it will act as a secondary bottom for the storage tank.  It is tightly bonded and will prevent leaks caused by internal corrosion for up to 20 years.  In the case that the storage tank has perforations the lining can assist in bridging these small areas and help prevent leaking.  Exterior corrosion is a concern but can be avoided by even thicker coatings of FRP  coatings.  When the thickness is increased to 120 mils an FRP lining on the inside can prevent even advanced corrosion on the exterior of the storage tank.

FRP Lining Pros & Cons

Every system is going to have pros and cons.  FRP linings are widely used as they are durable and cost effective but you should know all of the characteristics before deciding on any course of action.

FRP Lining Pros

  • FRP linings offer great budget savings compared to replacing the bottom of the tank.
  • FRP linings have great lifespan and can last longer than 30 years.
  • FRP lining installation is faster so you won’t experience as much downtime.
  • FRP linings are strong and can bridge 8” holes and over 80 psi with double laminates.

FRP Lining Cons

  • Preparation is key and installers must be highly trained to complete the installation correctly.
  • If pigmentation is used ascertaining the condition of the storage tank bottom is problematic.
  • Potential weakness for cyclic loading which needs further research.

Hydraulic Pressure & FRP Linings

FRP linings are designed to protect and reinforce storage tanks.  They are not however designed specifically to withstand high pressure which is common in hydraulic pressure systems. In one installation FRP lining was installed and after 10 years the tank sprung a leak.  It was found that the leak was caused by bottom side corrosion.  While this is the area that the FRP lining was installed to protect it was found that the FRP was not at fault.  In fact the two holes were both about a foot in width and the only thing that had held the tank together was the FRP lining.

What Is The Pressure Limit for FRP Linings?

Studies have shown that with average temperatures common in tanks that the FRP linings will over 37 psi of strength at a single laminate thickness.  However when you double the laminate thickness the coating will withstand up to 82 psi.  As the average internal tank pressure is about 20 psi it can safely be said that FRP linins are up to the job even if hydraulic pressure is present.

Phoenix Valley FRP Lining Installation

If you are searching for a company that does FRP linings in storage tanks, All Kote Lining Inc. has all your needs covered.  We proudly install FRP linings in any size tank for both public works, industrial facilities, and other locations that have storage tank needs.  To find out how we can save you money on repairs for your storage tanks with FRP linings, please call

Storage Tanks
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Cooling Tower Replacement Cost

If you’re searching for “cooling tower replacement cost” you’re facing a costly proposition.  The majority of cooling tower manufacturers say the average life span of a commercial cooling tower is about 15 to 20 years.

After 20 years the cooling towers need to be replaced or rebuilt.  That means commercial spaces built before the year 2000 have cooling towers that need to be replaced or rebuilt.  Commercial property owners can save thousands of dollars having cooling tower refurbishment instead of breaking the bank replacing them.  Read more about the cost of replacing cooling towers below.

Cooling Tower Replacement Cost

The cost of cooling tower replacement is about $50,000 per 200-ton cooling tower.  Large commercial spaces will use more than one of these 200-ton cooling towers so the cost of replacing the cooling tower system can easily reach $200,000 for the units, labor, and crane to lift them into place.

Replacement Cost Per Ton

Cooling towers are rated on how much air they can process in tons.  The replacement cost per ton depends on the brand of cooling tower, size, and any options for water treatment and epoxy coatings.  The larger the cooling tower the more they cost to buy, transport, and have craned onto a roof.  Property owners who already own cooling tower equipment can save an incredible amount of money by refurbishing cooling towers instead of replacing.

Cooling Tower Refurbishment Cost

All Kote Lining Inc. can restore your aging cooling towers and make them like new for a faction of the cost!  Depending on the size of the cooling tower system we can save commercial property owners literally tens of thousands of dollars over cooling tower replacement costs.

For the same type of 4-unit 200-ton cooling tower system refurbishment will cost around $80,000.  That is a $120,000-dollar saving!  And many times, the cost of cooling tower refurbishment isn’t classified as repairs instead of capital equipment.  This can mean some property owners will be able to get funding for the refurbishment.

Phoenix Valley Cooling Tower Refurbishment

If you own a commercial property and your cooling towers have reached the end of their lifespan All Kote Lining Inc. can save you thousands of dollars.  Our team offers complete cooling tower refurbishment that will save your company tens of thousands of dollars over buying and installing new cooling towers.  Cooling tower refurbishment adds about another 15 years of life to your equipment and helps you get your money’s worth out of your original investment in your cooling tower or property.

Cooling Towers
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