Cooling towers are the central heat rejection units of HVAC systems. They help manage excess heat in residential and office buildings, hospitals, data centers, and industrial facilities and keep the temperature in check. If they are not functioning as expected, you are looking at a long list of repairs.
But, like any other machine, cooling towers have a set lifespan, even with proactive maintenance or repairs. At some point, you will have to decide whether to repair your cooling tower or replace it.
To make the right decision, you must consider factors like your cooling tower’s maintenance history, age, current performance, and any red flags in its operational costs.
Curated by the experts from Pinnacle Cooling Tower Services, this post will explain how to decide when you need a cooling tower replacement and when only repairs will suffice.
Let’s dive in:
1. Check the Age of Your Cooling Tower
Most cooling towers have a lifespan of 15 to 25 years, depending on their build material, usage, and maintenance history. If your system is less than 15 years old, repairs are the most practical solution. But, if its age is over 20 years, meaning it’s nearing the end of its lifecycle, then cooling tower replacement is a smart move.
Signs that age is affecting your cooling tower’s health include:
- Frequent breakdowns, leading to unplanned downtime and costly emergency repairs.
- Structural deterioration, such as rust, leaks, and cracks in metal or fiberglass components.
- Reduced productivity, resulting in higher energy and water consumption.
2. Consider the Cost of Repairs vs. Replacement
If you are already deciding whether you need a cooling tower repair or replacement, the 50% rule might come in handy. The rule is, that if the cost of repairs exceeds 50% of the price of a new cooling tower, it is time for a replacement.
When Repairs Make Sense:
- Small leaks or minor corrosion are easily dealt with by sealants or occasional polyurea coatings.
- Replacing components like fan motors, pumps, or drift eliminators is enough.
- Routine maintenance issues like scaling or biological growth can be fixed with the help of professional cooling tower cleaning services.
When Replacement Is a Better Option:
- Permanent structural damage, such as a deteriorated basin or rusted framework.
- Frequent repairs cost thousands of dollars and are increasing every year
- Diminished cooling capacity that fails to meet the operational demands of your HVAC system.
3. Evaluate Energy and Water Efficiency
Despite regular cooling tower repairs, if your system is still less energy-efficient and consumes a lot more water, upgrading to a new one is the right decision. It can save you 30-50% in energy costs and reduce water usage significantly.
Newer models come with:
- Variable Frequency Drives (VFDs) to optimize fan speed and reduce energy waste.
- High-efficiency drift eliminators to minimize water wastage.
- Corrosion-resistant materials such as HDPE and FRP, reduce cooling tower maintenance costs.
If your current system is sending your energy bills through the roof, replacing it with the latest model will pay for itself in the long run.
4. Estimate Downtime and Operational Impact
Downtime is non-negotiable for facilities that operate 24/7. If your cooling tower repairs take a big chunk out of your budget and still leave you with a system prone to failures, you might want to consider a full replacement.
When Are Cooling Tower Repairs Perfect:
- If repairs are done quickly and will extend the tower’s lifespan by at least 5 years.
- If your system has a backup to handle the workload while repairs are performed.
When Is Cooling Tower Replacement Ideal:
- If your tower faces multiple shutdowns and affects your overall operations.
5. Evaluate Maintenance History and Structural Integrity
It is no secret that preventive maintenance leads to lasting and better performance. If your tower has been serviced before with proper water treatment, repairs may be enough. But, lack of maintenance can lead to permanent damage, making the cooling tower replacement unavoidable.
Signs That Repairs Are Still Possible:
- Your cooling tower is serviced without delays, and only minor issues exist (if any).
- Corrosion is limited to specific components of the tower, not the entire system.
Signs That Replacement Is Needed:
- The cooling tower parts like fill media, basin, and piping have widespread corrosion or scaling.
- You’ve made multiple fan or pump replacements in the past 12 months.
- The framework is deteriorating, posing safety risks that require immediate attention.
6. Compliance with Regulations and Environmental Standards
While your older cooling towers may be in excellent condition, they still need to comply with the latest regulations like ASHRAE 188 and OSHA.
Depending on where and how you operate your cooling tower, you will also need to meet EPA’s regulations for water treatment and Legionella control. Failure to do this can result in hefty fines, severe health risks in your workplace, and legal action.
Repair If:
- Minor upgrades (adding drift eliminators and upgrading filtration) can bring your cooling system to comply with the latest regulations.
Replace If:
- The system is outdated and cannot be upgraded to meet current safety and environmental regulations.
Repair or Replace: Which Is a Better Choice?
Whether you want to invest in extensive repairs or a cooling tower replacement will depend on the current state of your system, its age, operational requirements, and budget.
Choose Repair If:
- The cooling tower is less than 15 years old and in good working condition.
- Repairs are less than 50% of the new cooling tower’s cost.
- Efficiency is still acceptable, and performance meets operational demands.
- The current system complies with all the latest regulations.
Choose Replacement If:
- The cooling tower is more than 20 years old, with a history of frequent and costly repairs.
- Frequent repairs are causing unwanted downtime in your facility.
- Energy bills are rising due to poor efficiency and outdated technology.
- The system fails to meet compliance regulations and operational needs.
Need Help Deciding? Contact Pinnacle CTS!
If you’re still unsure whether to repair or replace your system, Pinnacle CTS can help! Our expert technicians will check your system and offer practical recommendations. Our goal is to ensure your cooling tower functions at its best for years to come.
We specialize in preventive maintenance, cooling tower replacements, and new installations. Our team also provides round-the-clock support for emergency repairs. We serve the Greater Tri-State area. Contact us today to schedule your inspection!
