Cooling towers are critical components in various industrial systems, but their constant exposure to harsh elements can lead to numerous issues affecting their performance and lifespan. At Torraval Cooling, we want to share valuable information about the most common challenges these units face and how to prevent them.
Structure and enclosure: the foundation of the system
The structure of a cooling tower must remain intact to ensure proper operation. However, it is common to encounter:
- Cracks in enclosure panels: lead to air/water leaks outside and water carryover between cells, forming vortices that significantly reduce thermal transfer efficiency.
- Corrosion in metal components: affects support beams, equipment bases, and safety elements such as railings and ladders. This can cause parts to fall inside the cell, generate vibrations, or even lead to tower collapse, compromising safety during inspections.
- Support failures: when fastening elements fail, fill blocks or spacers may fall into the basin, causing uneven distribution of recirculating flow.
- Leaks between panel joints: cause water loss and promote algae and biofilm growth, degrading the tower’s appearance and performance.
Mechanical equipment: the heart of the system
The mechanical components are essential for the tower’s efficient operation. Common issues include:
- Fan alterations: changes in blade angle, wear, or breakage directly affect airflow and heat transfer.
- Transmission misalignment: generates vibrations that loosen mechanical components and may cause blade-diffuser contact.
- Lubrication problems: poor gearbox maintenance increases motor energy consumption, potentially causing motor burn-out or gearbox seizure.
- Chemical corrosion: treatment products may degrade components and cause oil leaks into the cooling circuit.
Distribution system: effective water distribution
The distribution system must operate precisely to ensure thermal efficiency:
- Deterioration in channels: corrosion and perforations in primary and secondary channels hinder uniform water distribution.
- Contamination: solids in the circuit, oil, or scale can clog the system.
- Misalignment and breaks: separation of secondary channels from the main header or cracks result in poor water distribution.
- Nozzle/plate issues: clogging or detachment causes overpressure, loss of thermal transfer, and carryover of particles into the fill.
Drift eliminator: emission control
The drift eliminator reduces water emissions to the environment:
- Material degradation: Thermal stress or UV radiation can crystallize the material, affecting its function.
- Component detachment: Falling blocks or blades increase droplet carryover, creating rain around the tower and risk of contamination.
- Contamination: Lime deposits and external dirt increase pressure loss and reduce cooling efficiency.
Fill: thermal efficiency
The fill media is the core of thermal exchange and may be affected by:
- Material degradation: Over time and under thermal stress, material crystallizes and loses effectiveness.
- Breakage: Overpressure or falling foreign elements can fragment the blocks.
- Blockages: Dirt accumulation creates preferential paths, reducing heat exchange surface.
- Scale deposits: Decrease flow section, increase flow resistance and motor power consumption.
Early identification of these problems and proper preventive maintenance are key to maintaining optimal cooling tower performance. At Torraval Cooling, we have the experts and solutions needed to ensure maximum efficiency and equipment durability.