COOLING TOWER MAINTENANCE, CLEANING, & RESTORATION

Cooling towers have a naturally humid environment. This constant humidity paired with contaminants in the water and dust in the air cause clogging in the fill media, and spray nozzles. The humidity also causes corrosion to the metal parts such as the water level controls of the cooling tower. When the metallic parts are corroded and rusting they are not as strong as they were originally and can lead to the structural failure of the cooling tower.

The clogging of media or nozzles dramatically reduces the thermal efficiency of the cooling tower. This means the system has to run harder and longer to get the job done. It uses more energy to achieve the same goal. Any plastic components also tend to wear out. Heat causes plastic parts to become brittle and tend need to be replaced.

For cooling towers to achieve the performance they were designed with clean is done and coatings are applied. The interior of the cooling tower and all of its parts are thoroughly cleaned. Sandblasting is used to remove corrosion from the metal parts and to remove any old coatings.

After the sandblasting is done a coating is applied to protect all of the metal and concrete parts. Flexible stripping is added to seams to make the system water tight. Restoration removes the clogging and reconditions the interior of the tower and makes it new again.

Fill media spends the most time in contact with cooling tower water. For this reason it is also prone to getting clogs and having reduced efficiency. Restoration generally includes the replacement of the fill material. The thermal capacity of the cooling tower is reliant on how the fill media performs. If it is old or clogged there are less open channels for the air to cool the water going through the cooling tower.

Some older cooling towers use wood as fill material. During cooling tower restoration replacing wood media with trickle pads or splash fill media is a opportunity for cooling towers to achieve much greater energy efficiency and maintenance.

GRP is a composite material that is corrosive resistant, durable, and very strong. Replacing elements of cooling towers with GRP parts is a cost effective way to maximize efficiency. GRP is also a very customizable material. This means that it can be made into just about any specifications needed for a particular cooling tower. This durability and ease of customizing parts makes GRP a preferred material for the replacement of cooling tower elements

With energy costs always on the rise proper cooling tower maintenance is more important than ever.  Well maintained cooling towers use less energy and last longer.  When it uses less electricity and lasts more years it will help keep your company more profitable. Cooling towers that are neglected suffer from corrosion, scaling, fouling, and simply cannot do their job properly.  They draw more and more energy to satisfy the needs of the property they serve.  This translates into higher operating costs and overhead.  In fact for every 2 degrees your cooling tower temperature rises you’ll use 6% more electricity.

If you’d like to save up to 15 percent on your commercial or industrial electricity costs these simple maintenance tips can help you save money.  Regular maintenance also will help you save on water and extend the life of your cooling equipment.

What you need to know – A step by step guide to help you

• Listen for any unusual noises to set a baseline which will help you notice any possible problems. Also check the condition of the unit as a whole.
• If it requires some hands on work make sure that you follow the lock-out protocol and disconnect the motor switches to make sure you’re working safely.
• Clean debris from strainers to keep the system clear from excess materials and inspect it thoroughly.
• Take a look at the water distribution system and keep an eye out for dry areas over the fill coil area. This will help avoid scale buildup and help add years to the system’s lifespan.  If the surface is not fully wetted, inspect the nozzles for cracks and clogs.
• Flush debris and dirt from the cold water basin out the tower drain or use a sump strainer to maintain water filtration and prevent dirt from collecting.
• To conserve water and reduce air entrainment check the makeup water supply for the predetermined water level that is considered appropriate.
• To prevent an accumulation of solids from recirculating water match the bleed rate according to your local evaporation rate regulations and local water quality.
• Address any tension issues on the belt to ensure the best belt-drive system performance.
• Following the manufacturer’s recommendations make sure to routinely check oil level, shaft alignment, oil quality if you’ve got a gear driven system.
• Lubricate fan shaft bearings on a quarterly interval at the very least to ensure proper operation. Consider talking to the professionals about installing automatic bearing greasers that will save you on monthly maintenance.

The frequency of your maintenance can vary depending on the condition of the water and environment in which you operate your machinery.  Solid maintenance habits will help avoid failure and increase the lifespan of your cooling tower.