Cooling towers are a valuable piece of machinery and are important for many industries. Industrial cooling towers remove the heat absorbed in circulating cooling water systems and produce cool air for buildings that are too large for traditional HVAC systems. You find them in power plants, refineries, processing plants, and even places such as schools and hospitals.
Considering their importance, it’s vital to properly maintain your cooling tower to keep it running efficiently and to prolong its lifespan. If taken care of, your cooling tower can last up to 20 years. Not only that, replacing a cooling tower can cost upwards of $100,000 or more. That’s quite a hit on your bottom line.
Fortunately, if you know what problems to look for, your cooling tower will last for years to come.
Common Cooling Tower problems and how to repair them
1 Internal Corrosion
Corrosion is a common cooling tower problem, especially if the tower’s water isn’t properly treated. Corrosion occurs when contaminants in the water, including gasses like oxygen and carbon dioxide, cause the metal to degrade. Also, the corrosion gets worse as the water’s pH levels become more unstable.
Signs of corrosion include:
- Pitting in the metal
- Rust spots on metal surfaces
- Discoloration of plastic parts
Corrosion is a serious issue that can lead to equipment failure, loss of heat transfer, and costly downtime. However, a professional technician can easily diagnose the extent of the corrosion and repair damaged parts to prevent further damage. This cooling tower repair might include a filter system or even chemical corrosion inhibitors.
2 Clogged Water System
A clogged water system can stop your cooling tower in its tracks. Cooling towers run day after day, and particles slowly build up in the system. This can be any particle that is in the water and gets trapped inside the tower. Whether they are small or large, these particles can clog up filters and the water flow system and result in a cooling tower repair.
It’s important to know the common signs of a clogged water system, so you know when repairs are needed and when to contact a professional cooling tower technician. These are good indicators that you have a clog in your cooling tower’s water system:
- Low water flow rate
- Unexpected water loss
- Cooling capacity has lowered suddenly
- Water temperature rises
If you spot any of these issues, it’s a good time to discuss how to repair the problem with a cooling tower specialist. It might involve flushing the system, cleaning the inner workings of the tower, or replacing filters.
3 Leaks
When properly maintained, your cooling tower will provide a comfortable environment for residential, commercial, and industrial buildings for many years. A leaking cooling tower can compromise that. See a sudden increase in your water bills? It might be due to a leak.
Leaks can be caused by many things, including constant weather exposure, faulty equipment, routine wear and tear, and even clogged lines. The most common sign of a leak will be pooling water near the cooling tower. Here are some other places you’ll want to check if you suspect you have a leak.
- Near joints and seams in your cooling tower
- Pipe systems
- Fan components
Leaks can cause a loss of cooling capability from your cooling towers. Cooling tower repairs can lead to excessive downtime and degradation of your cooling tower equipment. In more severe cases, it can lead to a costly cooling tower replacement.
If you suspect your cooling tower is leaking, the smart thing is to contact a professional. They can help you find the leak, diagnose the problem, and propose a cost-effective solution and they will keep your cooling tower running efficiently for years to come.
4 Improper Water Chemistry
Improper water chemistry is when the water in your cooling tower, including the cooling tower feed water, circulation water, and blowdown, isn’t treated correctly. This is a common cooling tower problem and can lead to many other issues that will result in cooling tower repairs and services being needed.
Indicators that you might have an issue include:
- Scaling
- Corrosion
- Fouling
- Biological Growth
- Discoloration
Not only that, but you might even see a rise in your energy bills. These issues affect energy and water usage and decrease the efficiency of your cooling tower. That impacts your monthly expenses and bottom line.
Luckily many treatment methods can successfully resolve the issues and have your cooling tower operating at peak efficiency again. A professional technician can tell you all of the possible solutions based on your specific cooling tower specifications.
5 Broken Fan Motors
Without a fan in your cooling tower, it doesn’t matter if everything else is in pristine, working condition. A broken fan motor means that water will not be properly cooled, and your cooling tower will not perform its job. Period. If not corrected quickly, you might be looking at a larger cooling tower repair bill.
A cooling tower fan is made of many working parts. There are several things to be on the lookout for if you think you have a broken fan motor, including poor air circulation and unexplained loud noises.
If you think you have a broker fan motor, it’s a good idea to call a cooling tower professional. They can walk you through the necessary repairs. Whether it’s replacing the broken motor or just its bearings, you can rest easy knowing your cooling tower will soon be operating at 100% again.
The Wrap Up
Your cooling tower is an expensive investment, and you have a lot riding on it functioning efficiently. To do that, there are some common cooling tower problems you need to be aware of so you can spot problems and know what to do.
Pinnacle CTS is a cooling tower service and repair company serving the Greater Tri-State area (New Jersey, New York, Pennsylvania, and Connecticut) with factory-trained mechanics and technicians that are readily available for complimentary inspections, walk-throughs, and consultations. We’re also on call 24/7 for emergency service.
Contact us for all your cooling tower repairs, cleaning, and preventative maintenance needs. We’re safety-driven, detail-oriented, and quality focused.
