Running an HVAC system for a commercial building or an industrial setup means relying heavily on cooling towers. If you plan to install a new cooling tower or upgrade an existing one, you must do it correctly.
Poorly installed cooling towers often cause trouble, including uneven water distribution, lackluster performance, and a substantial waste of money. On the other hand, a perfectly installed tower keeps your HVAC system running without hiccups. Besides meeting your performance requirements, it runs your whole operation as cost-effectively as possible.
As cooling tower installation experts, we know how challenging this job can be. You’ll have to plan every detail to get your new tower up and running quickly and efficiently. In this post, we’ll explain how you can do just that.
Factors to Consider Before Installing a Cooling Tower
1. Get the Basics in Place
The first step in installing a cooling tower is deciding where it will go. Think about the size of your facility, how much cooling power it needs, and whether you have enough space to fit the unit. Typically, you can install a new cooling tower on the roof or the ground.
2. Think of the Weather
Cooling towers are outdoor structures, which means you will have to consider how the local climate can affect their efficiency. When it’s humid, the air can’t absorb as much moisture, making evaporation less effective. And when temperatures drop too low, there’s a risk of parts freezing up. So, when installing a cooling tower, be sure it’s equipped to handle the weather in your area.
3. Keep the Operating Costs Low
Water and electricity are expensive. To cut down on these two, install a cooling tower with variable frequency drives (VFDs), high-efficiency motors, and smart heat exchange materials. Modern cooling towers typically come with these features and help keep your running costs under check.
4. Stay on Top of Regulations
Like all construction sites, you will need to follow local construction rules and regulations when installing your cooling tower. In New York State, for instance, all construction sites must comply with noise and air pollution regulations.
Once your tower is up and running, you’ll have to stay on top of local water treatment regulations and follow guidelines like ASHRAE 188 to avoid fines, shutdowns, and safety risks.
4 Steps Involved in a Typical Cooling Tower Installation
1. Start with a Concrete Plan
A successful cooling tower installation starts with concrete planning. It includes:
- Planning Your Budget and Timeline: This means factoring in equipment, labor, and permits, and setting aside funds for unexpected expenses. A solid plan helps you stay on track and finish installing your cooling tower on time.
- Choosing the Right Cooling Tower: Choosing the right type of cooling tower depends on space, budget, local regulations, and efficiency. Remember, each tower comes with its own set of advantages and drawbacks.
While crossflow towers are easier to maintain, counterflow designs take up less space and save you on power bills. On the other hand, open circuit towers are more budget-friendly but tend to accumulate contaminants over time.
Likewise, closed circuit systems keep the water clean and reuse it efficiently, which makes them a great choice for HVAC systems and industrial applications. However, unlike forced draft models which are quieter, these systems can be noisy. In other words, installing a forced draft tower, though not as efficient, might be the right choice for a commercial or residential building where noise regulations are strict.
Pro Tip: Work with a cooling tower service company to select a system that meets ASHRAE standards, local regulations, and your energy efficiency goals.
2. Get the Site Ready
The next step is getting the site ready for cooling tower installation, which involves:
- Sound Structure: If you are installing a cooling tower on a building, make sure it can handle the tower’s weight, water load, and vibrations. Keep everything within the structure’s limits to keep your tower safe and stable.
- Proper Drainage: Plan for proper drainage. Without it, you can run into wastewater problems, like flooding, slow drains, and foul smell. Besides disrupting your everyday operations, wastewater can lead to serious health risks.
- Clear Airflow: Installing your cooling tower too close to walls or other obstructions traps heat, making it work harder than required. This will shoot up your bills and result in frequent breakdowns. Give your tower enough room to breathe to avoid these issues.
Pro Tip: If you are installing a cooling tower on a building, consult professionals to ensure the building can support it.
3. Choose Materials That Last in Tough Conditions
Cooling towers take a beating from environmental elements, so the materials you choose will decide how frequently and how much you’ll spend on repairs. Some popular cooling tower materials include:
- Stainless Steel: Stainless steel is built to last, but if you’re dealing with a lot of moisture or chemicals, you’ll have to apply a protective polyurea coating to prevent rust.
- Fiberglass-Reinforced Plastic (FRP): It’s lightweight, won’t corrode, and holds up well in coastal areas or places with heavy chemical exposure.
- High-Density Polyethylene (HDPE): Another solid option. It resists corrosion and doesn’t need a lot of extra chemicals to keep water clean.
Pro Tip: The material you choose affects the upfront cost and long-term cooling tower maintenance. However, investing in high-quality materials pays for itself in the long run as face breakdowns less frequently.
4. Focus On Safety
Keep your crew and those around your construction site safe when installing a cooling tower. This means:
- Using OSHA-Approved Protection: The fall protection gear and equipment must meet OSHA standards, giving workers the security they need to focus on the job.
- Keeping Electrical Work Safe with LOTO: LOTO stands for Lockout/Tagout. When working with electrical equipment, your crew must follow Lockout/Tagout (LOTO) best practices. It involves shutting off and locking power sources so no one accidentally turns them back on.
- Installation in Tight Spaces: Limited airflow and movement make safety a priority in small spaces. However, proper gear, a clear plan, and emergency protocols can keep your workers safe when installing your tower.
Pro Tip: Conduct a pre-installation safety meeting with all contractors and workers to avoid workplace accidents.
Things You Shouldn’t Ignore
Choose Professional Cooling Tower Installation
Choosing professional cooling tower installation means less stress and more efficiency. Experts handle every detail, ensuring your system meets all safety regulations, so you don’t have to worry about compliance.
A properly installed cooling tower runs more efficiently, using less energy while maximizing productivity. Plus, with quality installation, you’ll deal with fewer breakdowns and maintenance issues. So, let the pros take care of it from the get-go.
Cooling Tower Maintenance: What to Do After Installation?
Installing a cooling tower is only the first half of the equation. The second half involves keeping it in top shape. Here’s what to focus on:
- Keep It Clean: Routine cleaning prevents scale and biofilm buildup, helping the system run smoothly.
- Check The Essentials: Regularly inspect fans, pumps, and fill media to catch issues early.
- Manage Water Quality: Proper water treatment prevents corrosion and microbial growth, protecting the system and water quality.
Final Thoughts
Installing a cooling tower takes careful planning, the right materials, and a setup that meets your HVAC requirements. Skipping any of these steps or cutting corners can lead to expensive mistakes. Plus, since a cooling tower, whether a new one or an upgrade, is a substantial investment, it’s worth bringing in professionals who know what they’re doing.
If you want to install or repair a cooling tower in the Tri-State area, Pinnacle Cooling Tower Service is here to help. We can help you with new installation, upgrades, cleaning, and preventive maintenance, including 24/7 emergency support.
Call us at 732-570-9392 or Contact us today to get your project started.
