Top Maintenance Problems For Cooling Towers
Proper cooling tower maintenance is the foundation for managing every HVAC system. When systems are designed well and properly maintained they will offer occupants in residential, industrial, and commercial properties comfort all year long. While this is the goal cooling towers are many times not given much attention until something is wrong.
The cooling tower is a critical element of a well-functioning HVAC system but will have problems without proper and regular maintenance. The monolith cooling towers common at power plants are made from concrete require less maintenance than the smaller units common on industrial sites, commercial buildings, or large residential buildings. Cooling towers are neglected many times simply because they are on the roof and difficult to repair or maintain.
Cooling Towers Are A Corrosive Environment
While large power plant cooling towers are typically made from concrete these smaller roof top units are made from galvanized steel. Over time the hot and humid conditions in cooling towers leads to chemical attack and corrosion of the steel. With air, heat, chemicals, and water coursing through the cooling tower as its primary function it isn’t surprising that it is an exceptionally corrosive environment.
Most Common Cooling Tower Problems
Various parts of the cooling tower are made from different materials and are exposed to varied degrees of heat, water, air, and chemicals. So which are the most common cooling tower problems? The key in maintaining equipment instead of paying to replace it is regular inspection. Catching cooling tower maintenance issues while they are small preserve the condition of your cooling tower and reduce costs.
Chemical Attack & Corrosion
Cooling towers are a heat exchange device which functions by passing hot water and air by each other to cool the liquid. This accompanied by the presence of chemicals which reduce dissolved solids adds up to an incredibly corrosive environment. Even with the best made parts from select materials like galvanized steel corrosion is a real problem. Corrosion will lead to diminished performance and worse mean the cooling tower is unsafe. Common areas which experience corrosion are seams and joints along with some parts like the holding pans, diffuser trays, and framework. These repairs if not caught while small can add up to costly leaks and repairs.
Pipeline Corrosion
The pipelines that connect the HVAC system to the cooling tower are also susceptible to issues. Internal and external conditions can cause the development of corrosion that lead to thin and through wall defects in pipes. These issues or leaks impact the efficiency and overall performance of the HVAC system significantly. One common issue is the paint systems designed to protect the cooling tower from corrosion. These paints or coatings when not properly applied or not of the highest quality will not last as long or provide a durable cooling tower coating. More than simply costly repair issues leaks along with heat and water provide the perfect environment to develop a Legionnaries’ disease outbreak.
Mechanical Failure & Damage
When inspections and maintenance are not done regularly or properly mechanical issues can mean excessive strain and wear on your cooling tower system. Loose pulleys and fan hubs will end up scored and mean worn fan shafts. When the mechanical components of your cooling tower are not well lubricated or maintained properly it will mean downtime and costly repairs.
Impingement Erosion
Dust particles and moisture commonly cause damage to the leading edge of the fan blades due to impingement. This process causes erosion and corrosion of the fan blades that diminishes the efficiency of the entire system. In extreme cases corrosion can be so advanced that there is no option but complete replacement.
Cooling Tower Corrosion Solution
Clearly corrosion is a major issue for cooling towers and needs to be addressed. Ignoring the issue allows corrosion to fester and potentially go beyond mere repair and require replacement of parts, or worse the entire cooling tower. Replacing a cooling tower is an overwhelmingly large expensive for any industrial or commercial property. Avoid this budget killer and invest in prevention with inspection, regular maintenance, and quality polymeric coating solutions.
Polymeric cooling tower coatings can be used to seal and protect pipework, restore and protect fan blades, rebuild mechanical components, and help prevent internal corrosion.
Phoenix Valley Cooling Tower Maintenance
If you have a residential, industrial, or commercial cooling tower that needs maintenance in the Phoenix Valley, All Kote Lining Inc. is here to help! We inspect your cooling tower to catch potentially costly repair issues while they are small, offer affordable repairs, and provide long lasting durable corrosion protecting cooling tower coatings. For more information about how our cooling tower maintenance services will help extend the life of your cooling tower and help you save on energy costs running it, call us today!