Did you know you can make your cooling tower more efficient this summer? All you need is the right guidance. This article will walk you through the steps needed to keep your industrial cooling system in working order all year round.
Cooling towers are typically found in industrial settings, as they are utilized for cooling water used in manufacturing processes. The process is called &#;cooling&#; because the water removes heat from the air.
So, what is a cooling tower? A cooling tower is a heat exchanger used to cool water that has been used to turn energy into electricity. When the water is heated by the plant&#;s machinery, it transfers its heat to the air and becomes cooler. If all goes as planned, we end up with cold water that can be reused in the plant or sent back into the environment.
That being said, there are many ways in which you can improve the efficiency of cooling tower systems. For example, you can use a smaller or larger fan for better distribution of air, or you can upgrade your pump for more efficient pumping.
Find out how cooling towers and chillers work together.
The performance of a cooling tower is largely dependent on the amount of heat the tower can remove from the water, which is determined by a few different things. The factors below all play a role in how much heat can be removed from the water.
Summer is the perfect time for a break. It is also the perfect time for a cooling tower maintenance check. After all, most industrial chiller failures are caused by a lack of proper maintenance. Here are some tips to help you maintain your industrial cooling tower systems during this summer season.
It is important to inspect your cooling tower fans regularly so that you can identify any problems before they become bigger problems and lead to downtime or even replacement costs. You should also make sure that you are following all manufacturer recommendations when it comes time for regular inspections, such as changing out filters on a regular basis.
It is important to check the water level in the water cooling tower on a regular basis. If there is too much water, it will overflow and leak out. This can be very costly because you have to replace the water that has leaked and fix the physical damage caused by the leak.
Insulating pipes is often overlooked as a maintenance task for cooling towers. Insulation keeps the pipe warm in winter and cool in summer, which helps to reduce energy consumption when running the industrial cooling tower pump. It also helps prevent any accidental freezing or bursting pipes due to low temperatures.
Cooling tower cleaning is a must. It is important to keep the surface of the tower clean to maintain efficiency and avoid corrosion. The best way to do this is with a pressure washer. It is also recommended that you periodically inspect the inside of the tower for any debris, dirt, or dust that may have accumulated there as well.
If you hear unusual noises coming from your HVAC cooling tower, it is a sign that something might be wrong. If there are no leaks or damage, then the most likely culprit is low water levels. This can happen for various reasons including evaporation, improper drainage, or low water pressure. Noisy cooling tower systems could be a sign of trouble and should not be ignored! Contact a professional immediately if you need cooling tower repairs.
Summer chiller maintenance is a necessary part of any facility that has a cooling system on the premises. It is important to keep in mind that this type of maintenance is not just for the cooling system. Summer chiller maintenance also includes checking and cleaning the condenser coils, inspecting the compressor and other cooling tower parts, and replacing air filters.
Based in Houston, Texas, Cold Shot Chillers is an industrial chiller company that specializes in the design, installation, and maintenance of commercial cooling systems. We have a wide range of solutions that are built to meet the needs of customers from various industries. A few of our best-selling products include:
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Cooling towers are some of the most cost-effective cooling systems today. They remove unwanted heat from water by bringing cool air and warm water into contact, transferring or rejecting the heat via evaporation.
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Wet and dry cooling towers differ in how they remove heat. Most cooling towers are wet, while air-cooled heat exchangers are dry. However, both designs use an axial fan to move air inside the tower, feature a covering to contain the fan and funnel the air into the fan and have plenums (specific spaces) to direct the air, allowing the heat to be transferred by direct or indirect contact.
Cooling towers are categorized as either crossflow or counterflow towers. In crossflow towers, the water and the air move almost perpendicular to each other, while in counterflow towers, the water and air move in opposite directions. In addition, cooling towers can be classified as induced-draft or forced-draft towers. In induced-draft towers, the fan, commonly at the top of the tower, pulls the air through the tower&#;s fills. Conversely, in forced-draft towers, the air is pushed toward the fill media from the tower&#;s base.
Cooling tower mechanical upgrades can significantly improve efficiency while increasing reliability and performance. Investing in fan and drive system upgrades can lead to major energy savings, reduce maintenance costs and extend the cooling tower&#;s life span. In this discussion, we will focus on three mechanical improvements:
System efficiency is one of the best ways to reduce energy costs and increase airflow for the cooling system to run at its best. Fan design should not be based on a &#;one size fits all&#; concept but rather a carefully designed airfoil custom-built for the cooling tower&#;s specific duty conditions. A low-drag airfoil shape designed with features such as high-blade twist, wide-chord width and superior finish will result in high efficiency levels.
The most efficient blade designs feature a seamless, hollow construction to ensure durability. They are made from lightweight, corrosion-resistant materials such as fiberglass-reinforced plastics from polyester or epoxy resin, depending on the application. The lightweight designs ensure a low moment of inertia, reducing wear and stress on the cooling tower&#;s motor, bearings and drive system.
Ultimately, a properly designed cooling tower fan with the design features outlined above will provide more air flow with less power consumption than the typical metallic fan blades supplied by many cooling tower manufacturers. It is common to realize power savings of 10%-40% with custom-designed blades.
Cooling towers come in all shapes and sizes and can utilize several forms of power transmission, including gear, belt and direct drives. Our focus will be on large-capacity cooling towers that require lower fan speeds and higher torque.
The most common method used in these larger towers is a mechanical gearbox, with a high-speed input from an electric motor that sits outside the turret and is connected via a drive shaft to the gearbox input shaft. The gearbox&#;s output shaft, which sits vertically, is directly coupled to the fan blade. These gearbox systems are supplied in various frame sizes in primarily single- and double-reduction configurations. Horsepower (hp) and reduction ratios vary depending on the drive size. Typical horsepower capacities range from 7.5 to 150 hp, with ratios varying from 5:1 to 70:1.
Cooling tower gearboxes are needed to drive the cooling tower fan blade, which develops airflow through the tower&#;introducing an exchange of heat. The fan drive application is often exposed to extreme environmental conditions with large temperature swings, moisture, chlorine and chemical exposures&#;depending on the tower&#;s design.
In the fan drive application, the gearbox&#;s output shaft is connected to the fan blade, typically in a vertical position. This creates a heavy thrust load on the shaft and increases the exposure of the output shaft seal to moisture and contamination. Heat loads on these gearboxes can be large, often requiring cooling fins in the gearbox housing to dissipate heat faster.
Key features improving drive efficiency
Robust gearbox design with:
As is the case in most mechanical drive systems, there are plenty of opportunities to extend drive life and reduce downtime by paying attention to the simple things. One challenge with cooling tower fan drives is that the drive is not easily accessible, resulting in an &#;out of sight, out of mind&#; mentality. A preventive maintenance plan is the best way to mitigate unscheduled downtime and cooling tower failure.
Here are some proactive steps that can prevent unnecessary downtime costs:
Vibration analysis: Consider installing permanent vibration sensors that provide real-time, remote vibration data. Monitoring for trends can identify issues before failure occurs.
Regular lubrication and oil analysis during scheduled outages: Check for leaking seals, ensure proper lubrication levels and periodically analyze fluid
for contaminants and wearing of internal materials.
Proper choice of lubrication: Consider synthetic lube oil over petroleum-based lube oil for longer changeout intervals and higher heat loads. Work with your gearbox supplier for the optimum lubrication choice.
Proper repair: Partner with an experienced repair provider to ensure that quality bearings, seals, materials and craftsmanship are used.
Other factors can affect overall cooling tower efficiency, such as feed water quality, water circulation and chemical usage. However, focusing on fan design and the drive system will provide the largest increase in efficiency and the quickest return on improvement investment.
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