Professional Documents
Culture Documents
Kavita Anuje
Kavita Anuje
Maintenance
Maintenance
Regimens
Regimens
Trevor
Trevor
Hegg
Hegg
Operating Strategies & Water Treatment
Operating Strategies & Water Treatment
-
-
Paul Lindahl
Paul Lindahl
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Terminology
Forced Draft Counterflow
Forced Draft Counterflow
Induced Draft Counterflow
Induced Draft Counterflow
Forced Draft Crossflow
Forced Draft Crossflow
Induced Draft Crossflow
Open Cooling Towers
Open Cooling Towers
Closed Circuit
Closed Circuit
Cooling Towers
Cooling Towers
Induced Draft Crossflow
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Open Cooling Tower
Open Cooling Tower
An evaporative piece of equipment that exposes
An evaporative piece of equipment that exposes
water directly to the cooling atmosphere, thereby
water directly to the cooling atmosphere, thereby
transferring the source heat load directly to the air.
transferring the source heat load directly to the air.
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Closed Circuit Cooling Tower
Closed Circuit Cooling Tower
An evaporative piece of equipment that contains two
An evaporative piece of equipment that contains two
separate fluid circuits. The first is an external circuit
separate fluid circuits. The first is an external circuit
where water is exposed to the atmosphere as it
where water is exposed to the atmosphere as it
cascades over the tubes of a coil bundle. The second
cascades over the tubes of a coil bundle. The second
is an internal circuit in which the fluid to be cooled
is an internal circuit in which the fluid to be cooled
circulates inside the tubes of the coil bundle.
circulates inside the tubes of the coil bundle.
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Forced Draft
Forced Draft
Type of mechanical draft tower in which one or
Type of mechanical draft tower in which one or
more fans are located at the air inlet to force air into
more fans are located at the air inlet to force air into
the cooling tower.
the cooling tower.
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Induced Draft
Induced Draft
Type of mechanical draft tower in which one or
Type of mechanical draft tower in which one or
more fans are located in the air outlet to induce air
more fans are located in the air outlet to induce air
through the air inlets.
through the air inlets.
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Counterflow
Counterflow
In a counterflow cooling tower, the air enters at the
In a counterflow cooling tower, the air enters at the
base of the tower, flows upward and interfaces
base of the tower, flows upward and interfaces
counter currently with the falling hot water.
counter currently with the falling hot water.
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Crossflow
Crossflow
In a crossflow cooling tower, the air flows
In a crossflow cooling tower, the air flows
horizontally through the cooling tower and interfaces
horizontally through the cooling tower and interfaces
perpendicularly with the falling hot water.
perpendicularly with the falling hot water.
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Air Flow
Direction
Water Flow
Direction
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Air Flow
Direction
Water Flow
Direction
Fluid Inlet
Fluid Outlet
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Air Flow
Direction
Water Flow
Direction
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Air Flow
Direction
Water Flow
Direction
Fluid Inlet
Fluid Outlet
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Air Flow
Direction
Water Flow
Direction
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Air Flow
Direction
Water Flow
Direction
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Air Flow
Direction
Water Flow
Direction
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Water Distribution Systems
Water Distribution Systems
Gravity distribution system
Gravity distribution system
Spray distribution system
Spray distribution system
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Gravity Distribution System
Gravity Distribution System
Open basins
Open basins
Large orifice, 360 nozzles
Large orifice, 360 nozzles
Easily accessed for maintenance
Easily accessed for maintenance
Basin water level used to balance flow
Basin water level used to balance flow
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Spray Distribution System
Spray Distribution System
Pressurized system
Pressurized system
Large orifice, 180 directional nozzles
Large orifice, 180 directional nozzles
Spray header and branches
Spray header and branches
2 PSI spray pressure at the header inlet
2 PSI spray pressure at the header inlet
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Heat Transfer Surface (Fill or Wet Deck)
Heat Transfer Surface (Fill or Wet Deck)
PVC wet deck surface
PVC wet deck surface
Specialty wet deck materials
Specialty wet deck materials
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
PVC Wet Deck Surface
PVC Wet Deck Surface
Impervious to rot, decay, fungus and biological
Impervious to rot, decay, fungus and biological
attack
attack
130F limitation for counterflow cooling towers
130F limitation for counterflow cooling towers
120F limitation for crossflow cooling towers
120F limitation for crossflow cooling towers
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
High Temperature PVC Wet Deck Surface
High Temperature PVC Wet Deck Surface
Impervious to rot, decay, fungus and biological
Impervious to rot, decay, fungus and biological
attack
attack
150F limitation for counterflow cooling towers
150F limitation for counterflow cooling towers
135F limitation for crossflow cooling towers
135F limitation for crossflow cooling towers
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Specialty Wet Deck Surfaces
Specialty Wet Deck Surfaces
Available for process type applications
Available for process type applications
Galvanized or stainless steel wet deck
Galvanized or stainless steel wet deck
surface
surface
Dirty water fill
Dirty water fill
Splash fill
Splash fill
Contact equipment manufacturer for
Contact equipment manufacturer for
performance information
performance information
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Air Moving Systems
Air Moving Systems
Axial fans
Axial fans
Centrifugal fans
Centrifugal fans
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Axial Fans
Axial Fans
Over 80% of cooling towers on HVAC
Over 80% of cooling towers on HVAC
applications use axial fans
applications use axial fans
High volume/ Low static pressure
High volume/ Low static pressure
High efficiency
High efficiency
Low energy consumption
Low energy consumption
Improved sound ratings
Improved sound ratings
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Centrifugal Fans
Centrifugal Fans
High volume/Static pressures
High volume/Static pressures
Indoor installations
Indoor installations
Inlet or discharge ductwork
Inlet or discharge ductwork
High energy consumption
High energy consumption
Quiet operation
Quiet operation
Tight layout requirements
Tight layout requirements
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
1,500 GPM of Water
1,500 GPM of Water
95F EWT
95F EWT
85F LWT
85F LWT
78F EWB
Counterflow, centrifugal
Counterflow, centrifugal
fan unit requires 60 HP
fan unit requires 60 HP
Crossflow, axial fan unit
Crossflow, axial fan unit
requires 30 HP
requires 30 HP
Axial fan units require less
Axial fan units require less
HP than centrifugal fan
HP than centrifugal fan
units
78F EWB
units
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Drive Systems
Drive Systems
Belt drive
Belt drive
Gear drive
Gear drive
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Proven performance on cooling
Proven performance on cooling
tower application
tower application
Efficient and designed for moist
Efficient and designed for moist
air applications
air applications
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Cooling Tower Equipment Layout
Cooling Tower Equipment Layout
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Prevent warm air or drift from being introduced into fresh
Prevent warm air or drift from being introduced into fresh
air intakes or from being carried over populated areas
air intakes or from being carried over populated areas
Consider the potential for plume
Consider the potential for plume
Note the direction of the prevailing winds
Note the direction of the prevailing winds
Ensure adequate supply of fresh air to the air intake
Ensure adequate supply of fresh air to the air intake
Provide adequate space for piping and proper servicing and
Provide adequate space for piping and proper servicing and
maintenance
maintenance
Top of the unit discharge must be at least level with the
Top of the unit discharge must be at least level with the
adjacent wall
adjacent wall
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Layout Examples
Layout Examples
Adjacent to a wall or building
Adjacent to a wall or building
In an enclosure
In an enclosure
Adjacent to a louvered or slotted wall
Adjacent to a louvered or slotted wall
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Nominal
Nominal
1,500 GPM 95/85/78
1,500 GPM 95/85/78
1F Recirculation
1F Recirculation
1,384 GPM 95/85/79
1,384 GPM 95/85/79
8%
8%
Derate
Derate
2F Recirculation
2F Recirculation
1,258 GPM 95/85/80
1,258 GPM 95/85/80
19%
19%
Derate
Derate
Prevailing Wind
Induced Draft
Cooling Tower
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Nominal
Nominal
1,500 GPM 95/85/78
1,500 GPM 95/85/78
1F Recirculation
1F Recirculation
1,500 GPM
1,500 GPM
95.77/85.77/79
95.77/85.77/79
2F Recirculation
2F Recirculation
1,500 GPM
1,500 GPM
96.56/886.56/80
96.56/886.56/80
Prevailing Wind
Induced Draft
Cooling Tower
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Every 1F Increase in CWT Corresponds to a
Every 1F Increase in CWT Corresponds to a
2% Decrease in Chiller Efficiency
2% Decrease in Chiller Efficiency
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Correct cooling tower
Correct cooling tower
installation when
installation when
located adjacent to a
located adjacent to a
building or wall
building or wall
Induced Draft
Cooling Tower
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
What is the distance
What is the distance
between the wall and
between the wall and
the air inlet to the
the air inlet to the
cooling tower?
cooling tower?
Maximum air velocity
Maximum air velocity
should not exceed 300
should not exceed 300
FPM
FPM
Air entry envelope
Air entry envelope
consists of top and two
consists of top and two
sides
sides
Based on 125,900
Based on 125,900
CFM, an inlet height of
CFM, an inlet height of
10 feet and an air inlet
10 feet and an air inlet
length of 12 feet, the
length of 12 feet, the
distance to the wall is
distance to the wall is
6.5 feet
6.5 feet
Induced Draft
Cooling Tower
D
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
When cooling towers
When cooling towers
are positioned with air
are positioned with air
inlets facing each
inlets facing each
other, the distance
other, the distance
between cooling
between cooling
towers is 2 x D
towers is 2 x D
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
What is the distance between
What is the distance between
the wall and the air inlet to the
the wall and the air inlet to the
cooling tower for a well
cooling tower for a well
enclosure?
enclosure?
Maximum air velocity should not Maximum air velocity should not
exceed 400 FPM exceed 400 FPM
Center the cooling tower within Center the cooling tower within
the enclosure for uniform air flow the enclosure for uniform air flow
to the air inlets to the air inlets
Air entry is from the top only Air entry is from the top only
Based on 125,900 CFM, an air Based on 125,900 CFM, an air
entry area as indicated by the entry area as indicated by the
shaded area, the distance to the shaded area, the distance to the
wall is 8 feet wall is 8 feet
D D
Well Installation with an
Induced Draft Cooling Tower
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
What is the distance between
What is the distance between
the louvered wall and the air
the louvered wall and the air
inlet to the cooling tower for a
inlet to the cooling tower for a
well enclosure?
well enclosure?
Center the cooling tower within Center the cooling tower within
the enclosure for uniform air flow the enclosure for uniform air flow
to the air inlets to the air inlets
Louver must provide at least 50% Louver must provide at least 50%
net free area net free area
Louver air velocity should not Louver air velocity should not
exceed 600 FPM exceed 600 FPM
Maintain at least 3 feet between Maintain at least 3 feet between
the tower air inlets and the the tower air inlets and the
louvered wall louvered wall
D D
Louvered Well Installation with an
Induced Draft Cooling Tower
Cooling Tower Operation and Maintenance
for Improved Energy Efficiency
Maintenance Regimens Trevor Hegg
Maintenance Guidelines for
Open Cooling Towers &
Closed Circuit Cooling Towers
MAINTENANCE
Maintenance and water treatment are
Maintenance and water treatment are
the most important factors affecting
the most important factors affecting
the life and energy efficient operation
the life and energy efficient operation
of evaporative cooling equipment!
of evaporative cooling equipment!
MAINTENANCE? Who needs it?
MAINTENANCE
Maintenance and water treatment are the
Maintenance and water treatment are the
most neglected regimens of cooling
most neglected regimens of cooling
tower operation, and cooling towers are
tower operation, and cooling towers are
generally the most neglected
generally the most neglected
components in the mechanical system.
components in the mechanical system.
Why?
Why?
People
People
Training
Training
Budgets
Budgets
MAINTENANCE
Objectives:
Objectives:
After start
After start
-
-
up and
up and
Monthly thereafter.
Monthly thereafter.
Regular inspection allows quick
Regular inspection allows quick
treatment and control of corrosion
treatment and control of corrosion
and mechanical failures.
and mechanical failures.
MAINTENANCE REGIMEN
Circulating Water System
Clogged distribution nozzles cause:
Clogged distribution nozzles cause:
Reduced or mal
Reduced or mal
-
-
distributed water flow =
distributed water flow =
capacity reduction
capacity reduction
Heat Exchanger surface scaling/fouling =
Heat Exchanger surface scaling/fouling =
capacity reduction
capacity reduction
Overflowing distribution boxes = water &
Overflowing distribution boxes = water &
chemical loss
chemical loss
Excessive drift = water & chemical loss
Excessive drift = water & chemical loss
Fan motor over
Fan motor over
-
-
amping
amping
(forced draft) =
(forced draft) =
reduced motor life
reduced motor life
MAINTENANCE REGIMEN
Circulating Water System
Suction Strainers:
Suction Strainers:
Designed to protect pump
Designed to protect pump
and nozzles.
and nozzles.
Inspect & clean weekly.
Inspect & clean weekly.
Operating environments
Operating environments
laden with airborne fibrous
laden with airborne fibrous
materials (agricultural,
materials (agricultural,
paper, textile processing)
paper, textile processing)
demand more frequent
demand more frequent
strainer cleaning.
strainer cleaning.
MAINTENANCE REGIMEN
Circulating Water System
Poor Strainer maintenance leads to:
Poor Strainer maintenance leads to:
Pump
Pump
cavitation
cavitation
= pump repair costs
= pump repair costs
and objectionable plant noise
and objectionable plant noise
Scale on coil
Scale on coil
walls is a direct
walls is a direct
heat transfer
heat transfer
barrier.
barrier.
Capacity
Capacity
diminishes with
diminishes with
increased
increased
fouling.
fouling.
MAINTENANCE REGIMEN
Heat Transfer Surface
Closed Circuit Cooling Tower Performance vs.
Scale Accumulation on Heat Transfer Coil
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
100.0%
0 0.002 0.004 0.006
Fouling Factor & Approximate Scale Thickness On Coil
T
o
w
e
r
P
e
r
f
o
r
m
a
n
c
e
C
a
p
a
b
i
l
i
t
y
1/32" Scale 1/16"
Scale Clean Tube
3/32" Scale
High Heat Flux Coil
Low Heat Flux Coil
( 0.8 mm ) ( 1.6 mm ) ( 2.4 mm )
Closed Circuit Tower Coil
Closed Circuit Tower Coil
MAINTENANCE REGIMEN
Heat Transfer Surface
Cleaning heavy scale or bio
Cleaning heavy scale or bio
-
-
fouling is difficult.
fouling is difficult.
Often the fill or coil are damaged in the process.
Often the fill or coil are damaged in the process.
Results of a scaled coil
Results of a scaled coil
cleaned with acid.
cleaned with acid.
This coil is ruined.
This coil is ruined.
IT IS ESSENTIAL TO MAINTAIN A
IT IS ESSENTIAL TO MAINTAIN A
PREVENTATIVE
PREVENTATIVE
WATER TREATMENT
WATER TREATMENT
PROGRAM.
PROGRAM.
MAINTENANCE REGIMEN
Drift Eliminators
Separate water droplets from leaving air stream
Separate water droplets from leaving air stream
Subject to corrosion
Subject to corrosion
Damaged eliminator
Damaged eliminator
section, which should
section, which should
be replaced.
be replaced.
MAINTENANCE REGIMEN
Drift Eliminators
Proper placement and good physical condition
Proper placement and good physical condition
Remove bio
Remove bio
-
-
growth and debris. Notify
growth and debris. Notify
treatment service of bio
treatment service of bio
-
-
growth.
growth.
Remove bio
Remove bio
-
-
growth and debris. Notify
growth and debris. Notify
treatment service of bio
treatment service of bio
-
-
growth.
growth.
Schedule regular
Schedule regular
defrost cycles.
defrost cycles.
Biocide
Biocide
to reduce Microbe and
to reduce Microbe and
Biofilm
Biofilm
Growth [corrosion and scaling effect]
Growth [corrosion and scaling effect]
Inhibitors
Inhibitors
to protect Metals from Corrosion
to protect Metals from Corrosion
Inhibitors
Inhibitors
to prevent Scale Precipitation
to prevent Scale Precipitation
Surfactant
Surfactant
= Bio
= Bio
-
-
penetration
penetration
Anti
Anti
-
-
foam
foam
= Reduce visible effect of
= Reduce visible effect of
biocide
biocide
Water Quality
General Guidelines
General Guidelines
:
:
Note: for tower water, not make
Note: for tower water, not make
-
-
up
up
High Temperature
High Temperature
:
:
< 120
< 120
F
F
PH: 6.5
PH: 6.5
9.0
9.0
Iron: < 3
Iron: < 3
ppm
ppm
C = (R x EPD + BD + D)/(BD + D)
C = (R x EPD + BD + D)/(BD + D)
Concentrations and Blowdown
Example:
Example:
Evaporation = 0.08% circulating water
Evaporation = 0.08% circulating water
per degree of range
per degree of range
Drift = 0.02% of circulating water rate
Drift = 0.02% of circulating water rate
Range = 10 Deg F
Range = 10 Deg F
Concentrations = 5
Concentrations = 5
Blowdown = 0.18% of circulating water
Blowdown = 0.18% of circulating water
rate
rate
Concentrations and Blowdown
Range 1.5 2 2.5 3 4 5 6
5 0.78 0.36 0.23 0.21 0.11 0.08 0.06
10 1.58 0.76 0.50 0.41 0.24 0.18 0.14
15 2.38 1.16 0.77 0.61 0.37 0.28 0.22
20 3.18 1.56 1.03 0.81 0.51 0.38 0.30
25 3.98 1.96 1.30 1.01 0.64 0.48 0.38
30 4.78 2.36 1.57 1.21 0.77 0.58 0.46
35 5.58 2.76 1.83 1.41 0.91 0.68 0.54
Based on: 0.02 % drift rate and 0.08 % evaporation rate
Operation for System Efficiency
Condensing Water Temperature
3 GPM/TR (95/85/78)
3 GPM/TR (95/85/78)
2 GPM/TR (105/85/78)
2 GPM/TR (105/85/78)
Lower condensing
Lower condensing
temperatures, fans full,
temperatures, fans full,
gives coldest water at
gives coldest water at
chiller
chiller
Chiller energy savings
Chiller energy savings
almost always outweighs
almost always outweighs
tower fan energy
tower fan energy
consumption
0.035
0.04
0.045
0.05
0.055
0.06
0.065
0.07
0.075
0.08
0.085
80 81 82 83 84 85 86 87
3 GPM/TON 2 GPM/TON
DESIGN COLD WATER TEMP. (F)
H
P
p
e
r
T
O
N
DESIGN COOLING TOWER FAN HP VARIATION
FAN HP PER TON OF LOAD
(BASIS: 75F WET-BULB)
consumption
Capacity Control Methodologies
Multi
Multi
-
-
speed Motors
speed Motors
Free Cooling
Free Cooling
Run Wild
Run Wild
Capacity Control Dampers