Common problems the operation of cooling tower systems in industry

The use of cooling towers in the industrial sector is an important factor in reducing heat in the production process to increase efficiency and stability of the machine. However, use without a clear maintenance plan may lead to efficiency problems, including damage that affects the operation of the plant. Good maintenance planning will help reduce such problems and increase the sustainability of the use of Cooling Tower systems in the industry to maintain maximum efficiency. In this article, we will talk about common problems in the cooling tower system, the importance of maintenance planning, and guidelines for maintaining each cooling tower component, along with advice on choosing a repair service and replacing cooling tower parts from experts. For the use of cooling tower systems that do not have a long-term plan to look after cooling tower components, they often face several problems, which can be divided into the following main problems:

Accumulation of scale and dirt

Scale is caused by minerals in the water that build up in the system, reducing water circulation and increasing the pressure in the system. This makes the system work harder and use more energy. In addition, dust and other unwanted debris build up in the water tank, which is another factor that reduces the efficiency of the system

Corrosion and rust in metal components

The metal structure and piping of cooling towers are often susceptible to rust and corrosion. Without proper protection and care, corrosion can lead to leaks and damage that renders the system inoperable

Damage to cooling tower parts

Cooling tower parts such as fans, motors and water pumps are heavy duty components that will be used over a long period of time. The deterioration of these parts not only reduces efficiency but also increases the risk of production disruptions

Growth of microorganisms and bacteria

Unmaintained cooling tower water systems can become breeding grounds for bacteria and microorganisms, which can be harmful to employee health and the environment

Water leakage problem

Water leakage problems in cooling tower systems not only waste resources but also increase energy and maintenance costs

The importance of cooling tower maintenance planning

Proper maintenance planning for cooling tower repair is essential to help the cooling tower system work continuously, efficiently and reduce the risk of possible damage in the future. The benefits of cooling tower maintenance planning include:

Reduce the chance of Break Down Maintenance

Helps reduce the chance of sudden downtime of cooling tower system

Increase system performance

Regular maintenance allows the cooling tower system to operate at its full potential, reducing unnecessary water and energy usage

Reduce long-term repair and spare part replacement costs

Regular system checks allow minor problems to be addressed before they escalate into major damage that requires significant repair costs

Extend the life of the system

Proper planning for cooling tower maintenance reduces wear and tear on cooling tower components and ensures long-term system operation

Reduce the risk of environmental hazards and problems

Unmaintained cooling tower systems can release wastewater or chemicals into the environment, so maintenance can help reduce these impacts and support environmental sustainability

Basic maintenance methods for various cooling tower components

Maintaining the various components of a cooling tower is an important step to maintain efficiency and extend the life of the system in the long run. Each part should be properly inspected and maintained as follows:

Cleaning of water retention tank and Spray-Nozzle (Hot Basin)

The water tank and Spray-Nozzle are parts where water flows all the time. Therefore, there is a chance of scale and dirt accumulation, which may cause blockage in the system and reduce the efficiency of water circulation. Cleaning the water tank should be done at least twice a year, starting with cleaning scale with appropriate chemicals to prevent corrosion in the water tank material. Then wash away dirt with a high-pressure water jet to remove dust and sediment that has accumulated inside. In addition, the Spray-Nozzle should be checked for clogging or wear, and if a problem is found, the Spray-Nozzle should be replaced immediately to ensure the most efficient water distribution

Inspection and replacement of cooling tower parts

Cooling tower parts such as blades, fans and motors are the parts that have to bear heavy loads in the system, so they are prone to deterioration easily. Regular inspection and replacement of parts can help prevent system disruptions. Start by inspecting the blades and fans to ensure that they are not cracked or worn, and check that they are firmly installed. If a problem is found, the parts should be replaced immediately. For motors, if they make unusual noises or do not work smoothly, the electrical system should be inspected and lubricated according to the manufacturer's recommendations. When replacing parts, only quality and standard parts should be used, such as parts from reliable manufacturers

Corrosion protection in metal structures

The metal structure of cooling towers is often exposed to corrosion due to moisture and chemicals in the system. Corrosion prevention is an important step to extend the life of the structure. It should start with the application of suitable anti-rust coatings in areas that are regularly exposed to water and high humidity, and adding chemicals to the water to reduce the chances of corrosion in the metal structure. Then, check for connections and joints that are prone to rust. If any corrosion or cracks are found, they should be repaired or replaced immediately to prevent further deterioration

Maintenance of water pumps and pipes

The water pump and water pipes are the heart of the cooling system. Proper maintenance reduces leakage and blockage. The water pump should be inspected regularly for leaks, pressure and operation. If there is an abnormal noise, it should be fixed or repaired immediately. The water pipes should also be checked for blockages or leaks that may reduce the efficiency of the system and should be cleaned or replaced if problems are found

Water quality monitoring in the system

Water used in cooling tower systems should be filtered through a sand filter system and its quality checked regularly to prevent the accumulation of sediment and growth of bacteria in the system, which can affect the health of employees. It is important to check the pH value of the water to ensure that it is suitable for use in the system, and water conditioning chemicals should be added as recommended by a professional

Complete cooling tower installation, design, spare part replacement and repair services at Innovek

Planning the maintenance of cooling tower components is the key to extending the life of the system and reducing costs in the long run. Proper maintenance of cooling tower components, such as cleaning, replacing parts and preventing corrosion, allows the system to work efficiently. If you are looking for a specialist in installation, design, repair and replacement of cooling tower parts, Innovek is ready to provide a complete Cooling Tower installation service in the industry with a professional team and high-quality parts imported from abroad. In addition, Innovek can also repair old cooling towers or cooling towers that still use the old blades to improve their efficiency, which can save energy by up to 20% - 30%, which is a significant reduction in your business's electricity costs in the long run. We are committed to delivering the best service so that you can operate smoothly with the best equipment. Contact us for consultation and services that meet all your needs today