Your cooling towers work extremely hard. A cooling tower will typically last between 15 and 30 years with proper maintenance and regular inspections. Eventually, the time will come when a complete rebuild is necessary. Although this is a pricey undertaking, it’s a necessary one in some situations.
Your new tower will be more energy efficient, function better, and have the latest upgrades. When you think it may be time for a cooling tower rebuild, there are a few key bits of information you need to know first. Let’s get into it.
1. How Do You Know When a Rebuild is Needed?
After operating for many years, cooling towers will require more than what routine maintenance and replacing parts can provide. The first step in determining if you need a cooling tower rebuild will be to schedule an inspection with an experienced technician. The inspection will determine whether a repair or rebuild is needed.
Some warning signs will indicate to your inspector that your cooling tower is worn out and needs to be replaced, including (but not limited to):
- Leaky pipes and missing nozzles
- Calcium buildup-corrosion of mechanical components
- Uneven distribution of water
- Warped or sagging fill packs
- Condition of drift eliminators
- Damaged support grids/deterioration of guardrails and ladders
Increases in energy consumption deterioration, leaking pipes, and corrosion are sure signs that repairs are not enough, and the cooling tower rebuild process is the best and only solution. A rebuild will improve the structure, the cooling tower performance, and the mechanical integrity for long-term benefits.
2. Determine What Upgrades Will Be Installed
If your cooling tower and systems are outdated, you will probably want to install some upgrades to improve its functions and efficiency. Upgrades will save money overall and can also help preserve the life of your cooling tower for many more years.
Some common upgrades that will produce notable returns on your investment include:
Stainless steel construction
- This will extend the life of your cooling tower. It’s stronger than galvanized steel and less likely to corrode
Change from a belt-driven system to a gearbox
- Belt driven systems require belt inspections and replacement more often than a gearbox system. Gearbox systems also operate silently.
Installation of mechanical access platforms for safer inspections
- These are necessary to ensure safety during inspections.
High efficiency fans
- These fans can ensure that the system is delivering optimum cooling efficiency without pulling excessive moisture out of the air.
Fully welded basins
- This will ensure no leaking water, improving efficiency.
Replace wood components with fiberglass-reinforced plastic
- This is a common upgrade that will extend the life of your new cooling tower and help prevent future rebuilds.
Conductivity controller upgrade
- This will maximize water efficiency and cycles of concentration. Installing a reverse osmosis system will work to maximize water efficiency.
Install thermal upgrades
- These upgrades include the installation of a different distribution system, larger mechanical equipment, or more modern and efficient heat transfer media. These upgrades lower your cold water temperature and improve the efficiency of your cooling tower.
A cooling tower rebuild allows you to take advantage of breakthroughs in technology, design, and efficiency. Any or all of these upgrades will ensure that your cooling tower will function at its highest efficiency and provide service for years to come. You’re making a major investment in replacing your cooling tower and upgrades can not only extend the life of the new tower but also save you money in the long run.
3. Cooling Tower Rebuilding
The process of a cooling tower rebuild does not usually involve a total demolition of your existing cooling tower. Some parts will need to be removed and replaced if they are too damaged or worn.
A successful cooling tower rebuild can generate returns in both cooling capacity and structural integrity, which can extend the life of your cooling tower and produce a huge return on your investment.
There are several advantages to having a more modern cooling tower after a rebuild. They include:
- Longer life expectancy
- More flexible, modular designs
- Cooling Tower Rebuilding
- More economical operation
- Environmentally conscious options that can save you money
Once the cooling tower is replaced, it will need to be pre-tested to compare results before and after the rebuild is completed. This will allow factors like temperature and water flow rates to be checked.
A routine maintenance and inspection schedule must be developed and followed once the cooling tower rebuild is complete. Your new cooling tower’s performance will be enhanced compared to your old system, but it still needs to be checked regularly for issues. Normal wear and tear can damage cooling towers and routine inspections and maintenance will catch these potential issues before they can damage your new tower.
Over to You
Your cooling tower works hard around the clock. A cooling tower rebuild is a major project, with a big price tag. If done correctly, your new unit will last 20-30 years and save you money with its cost-efficient features and upgrades.
Contact us
Pinnacle CTS is a cooling tower service and repair company that proudly serves the Greater Tri-State area (New Jersey, New York, Pennsylvania, Connecticut, and Massachusetts). You can count on us for all your cooling tower needs. This includes:
- Rebuilds
- Service
- Cleaning
We are available 24 hours a day, 7 days a week. Our core foundational values are a safe work environment, quality of work performed, and customer satisfaction. We will always honor our core values.
Contact us here for a free inspection, quote or to book us for other cooling tower service needs.
