A cooling tower is a specialized heat exchanger where air and water come into direct contact with each other to reduce the water’s temperature. They’re commonly used to cool large buildings and remove heat that is built up from industrial processes. Cooling tower mechanical services use evaporation to remove heat and turn it into cool air.
However, there are plenty of issues in a cooling tower operation that can hamper the functionality.
Cooling water towers are primarily used for heating and air conditioning – as well as ventilation for industrial and office buildings, schools, and even hospitals. It’s important to maintain and monitor your cooling towers to ensure they are always functioning properly. This can help to increase efficiency and safety for your operators and individuals in and around your buildings.
So what are some of the issues that can arise in cooling towers?
Let’s take a look at five of the most common issues that may require cooling tower repairs.
1. Scale Buildup
Scale buildup occurs when mineral deposits accumulate on the interior surfaces of the cooling tower. The minerals create thin layers that attach to the surfaces – which reduces efficiency and can also shorten the lifespan of the tower. This can lead to costly repairs or even a total cooling tower replacement.
Minerals often build up on surfaces in cooling towers and negatively impacts the efficiency of the heat transfer process. Scaling can also form and collect within tubes, resulting in blockages that can cause damage within the cooling tower operation. If not identified and corrected quickly, this could lead to extensive cooling tower rebuilds and repairs.
Scaling is primarily due to water hardness. Hard water with high levels of calcium causes the water to form scales. Once you identify scaling within your cooling tower, it must be removed so your cooling tower can function properly and efficiently again. If you have questions, it’s a good idea to contact a cooling tower professional to assess any water cooling problems.
2. Corrosion
Corrosion occurs when the metal surfaces of your cooling tower are deteriorated due to chemical reactions with water or the air. Corrosion is common in water systems. The chance for corrosion to occur in cooling towers is especially high due to the chemicals present in water treatment and the high concentration of electrolytes in the water due to evaporation.
Corrosion can cause serious problems – and potentially result in large cooling tower repairs. Debris from corrosion causes metal debris to enter the water system, which can lead to contamination, blocked pipes, and cooling inefficiency.
Corroded metal can also create small holes in the cooling tower system, exposing the water system to the outside. This can lead to water leaks or biological contaminants entering the system.
Equipment failure and leakages are the direct results of corrosion, and if left unchecked, you’ll face cooling tower repairs that can lead to costly downtime – not to mention the high cost. In the case of corrosion, you might need a cooling tower repair to fix the damaged areas.
3. Biological Growth
Cooling towers provide a damp, warm environment that is ideal for microorganisms, such as algae and bacteria to thrive in. Algae, rust, scale, and biofilms provide sources needed for bacteria to grow. Biological fouling is a challenge faced in many water applications in industrial plants – and your cooling tower operation is no exception. Growth can lead to increased corrosion, maintenance issues, and lost productivity due to downtime and costly cooling tower repairs.
Biological contaminants can quickly clog system equipment and lead to poor water quality. This cuts down on the efficiency of your tower and creates safety issues for anyone exposed to this water.
Contaminants like algae and bacteria can also lead to internal fouling of the heat exchange media – creating blockages in pipes and nozzles that can negatively affect water flow and the efficiency of your system. Regular cleaning and disinfection can help prevent the growth of cooling tower bacteria. If you’re not sure what’s needed to keep your cooling tower operation running efficiently and safely, contact a professional.
4. Leaks
You should visually inspect your cooling tower regularly. If you see leaks, it’s important to contact an expert to come out for HVAC cooling tower maintenance. Leakage in a cooling tower can result in lost water and reduced efficiency. The longer this goes unresolved, the more money it will cost you in cooling tower repairs.
Cooling towers are crucial pieces of equipment and leaks can lead to equipment failure and even structural damage in the cooling tower. You’re most likely to see leaks in the following locations:
- Joints and Seams
- Pipe Systems
- Fan Components
The loss of cooling capability can be costly and paralyzing for your company if cooling tower repairs require extended periods of downtime. Seemingly minor issues can lead to potentially bigger impacts on your business. Regular inspections and timely repairs are crucial to prevent cooling tower system leaks.
5. Improper Cooling Tower Operation
There are many tasks involved in keeping a cooling tower operation running smoothly. This includes maintaining proper water levels, controlling the water flow rate, and monitoring the air flow. These steps are important to prevent significant cooling tower repairs.
Part of this process also includes regular inspections and HVAC cooling tower maintenance. Proper training is important so operators know how to run your cooling towers. They need to know what to look for in the event of unforeseen issues.
It’s possible for your operators and technicians to visually inspect your cooling towers for issues with the naked eye. Unfortunately, not all problems can be seen from the outside. In these instances, it’s important to contact a cooling tower expert. They’ll come out and inspect your cooling towers and determine if there is an issue that will require professional intervention.
In Conclusion
When it comes to any type of HVAC system, proper maintenance is important to prevent minor issues from becoming major headaches. Knowing what to look for will help you determine when to call a cooling tower professional. Neglecting your system will eventually lead to an expensive cooling tower rebuild and repairs.
Pinnacle CTS is your cooling tower expert with over 20 years of experience in the Greater Tri-State area. We’re available 24 hours a day, 7 days a week to assist you with your cooling tower repairs and service. Whether it’s a cleaning, maintenance, or a full rebuild , you can count on us to get the job done right.
Contact us immediately if you see any of the cooling tower issues listed above. We’ll come out and provide a free inspection and estimate. Pinnacle CTS promises to provide high-quality results along with a safe work environment – no matter what.
