Industrial processes are extremely productive, but not everything they produce is beneficial. For example, equipment can generate a lot of waste heat as they operate. This not only makes the workplace uncomfortable and potentially hazardous for workers, but it also impacts the health and longevity of the machinery itself. Without proper cooling, excessive heat can cause equipment to wear down prematurely and lead to costly breakdowns. This is why cooling towers are essential additions to most industrial environments.
A cooling tower serves to remove excessive heat from water heated up by industrial processes, releasing it into the air. This helps manage the temperature of machines, ensuring proper performance and extending their lifespan. However, these towers need to be kept in good condition if they’re to be expected to do their jobs. This is why industrial cooling tower maintenance is so critical for manufacturers and other heavy-duty operations. Without proper cooling tower maintenance, power generation, HVAC and manufacturing equipment can lose their efficiency and break down on a more-frequent basis. If your facility doesn’t already follow a cooling tower maintenance checklist, now is the time to streamline your efforts.
How cooling towers work
In general, cooling towers reduce heat through the process of heat exchange and evaporation. Hot water generated by industrial processes is pumped into the tower, where it is sprayed over a series of fill media to increase its surface area. Airflow introduced into the tower helps speed up the evaporation of the water, which removes some of the heat from it. The heated water vapor is allowed to escape through the top of the tower and dissipate into the air. The cooler water that remains is collected at the bottom of the tower and is then recirculated back into the facility to be used again.
Common issues that arise without proper maintenance
As this cycle is repeated numerous times throughout the day, mineral scale and biofilm can begin to develop in the water that passes through cooling towers. This can clog valves and pumps within the cooling tower, leading to corrosion and contamination that impacts the towers’ performance. Some of the most common issues that can develop without proper maintenance include:
- Scale and mineral deposits: As water evaporates, it can leave behind minerals that can accumulate inside the tower. This can reduce the efficiency of the heat transfer process and increase the equipment’s energy consumption.
- Biological growth: If algae or bacterial biofilms are allowed to grow, they can clog the tower’s fill media and introduce the risk of Legionnaire’s disease as well as regulatory compliance issues.
- Corrosion and structural damage: If metal components deteriorate due to neglect, cooling towers may develop leaks or become structurally unstable.
- Excessive drift and water loss: Drift eliminators serve to collect water droplets as they rise during evaporation and return as much as possible back into the tower. If they don’t work as intended, too much water can escape from the tower and impact the efficiency of the process.
Industrial cooling tower maintenance best practices
Fortunately, keeping an industrial cooling tower in good working order can be handled easily with regular maintenance. Performing these preventive maintenance tasks when required can have a significant impact on how well these units perform and how long they can last:
- Inspections: These should include checking the water levels, looking at the fan blades and verifying the temperature differentials. Any signs of leaks or mineral scaling should be noted, as well.
- Cleaning and descaling: Thorough cooling tower cleaning is essential for removing mineral deposits and bacterial biofilm buildup.
- Fan and motor checks: Fans used for circulation and airflow should be properly lubricated and checked to make sure they are balanced.
- Seasonal shutdown: If the cooling towers won’t be in use during the winter or other off-season periods, they should be completely drained and cleaned to prevent issues the next time they are activated.
Cooling tower maintenance checklist
It’s important to establish a regular schedule for these and other preventative maintenance jobs. A proper routine is necessary to make sure tasks are performed when needed and to prevent small issues from developing into larger ones. Here is a recommended schedule of when certain maintenance tasks should be performed for industrial cooling towers:
Daily/weekly tasks:
- Inspect the water clarity, temperature and flow rate
- Check chemical feed levels and adjust dosing as needed
- Confirm fan operation by looking out for unusual noises or vibration
Monthly/bi-monthly tasks:
- Thoroughly clean out fill media and basins with a brush or low-pressure water hose
- Inspect drift eliminators for signs of damage or buildup
- Verify water treatment logs and adjust chemical programs
Quarterly/seasonal tasks:
- Conduct deeper inspections for corrosion or structural wear
- Lubricate motors, bearings and other mechanical components
- Test efficiency by measuring approach temperatures and comparing to the baseline
Annual/off-season tasks:
- Drain and thoroughly descale the entire system if possible
- Check all accessories for wear or leaks, including hoses, valves and pumps
- Review and update standard operating procedures for tower operation
Record-keeping and review:
- Maintain a log or CMMS record to note each completed task
- Analyze data trends and plan for improvements
Cooling tower monitoring and technology
Modern technology makes it possible to keep track of a cooling tower’s performance at all times to help direct maintenance activities. This includes automated sensors that report back data about the equipment’s condition in real time. This means operators can track key performance indicators such as temperature differentials, conductivity, water flow rate, cycle of concentration and energy usage whenever the tower is in operation. Based on this detailed information, technicians can plan for preventive maintenance activities and spot any dips in performance before they get worse.
Your facility’s cooling towers are critical elements of keeping processes running as smoothly as possible, and they should be treated as such. With proper maintenance scheduling, you can ensure this essential equipment continues to perform as well as expected so you can remain productive and profitable. If you want expert support for your cooling towers, the team at ATS is here to help. Get in touch with us today to learn more about our specialized maintenance services or to schedule a cooling tower assessment.
