The approach of summer time is a good time to examine the efficiency and, more importantly, the physical condition of your cooling towers. In spite of everything, it’s simpler to restore a tower when weather circumstances don’t put a strain on its cooling capability.
A cooling tower passes air over tiny droplets or the uncovered surface of a water movie. In both instances, a small quantity of water is vaporized, drawing the latent heat from the remaining liquid water, lowering its temperature. Splash fill repeatedly breaks up droplets of water dropping down the tower; the fill is arranged so the droplets fall from one splash bar to the following, avoiding agglomeration. Film fill spreads the liquid out on extremely wetted plastic, exposing the maximum floor space to the air stream. The quantity of water vaporized depends on the airflow over the droplets or film and the ambient wet bulb temperature. As the wet bulb temperature approaches the smart temperature, the capability of the air to absorb vapor reduces. This, in flip, increases the temperature of water leaving the tower.
You usually can observe the condition of the fill from the face of the tower. Concentrations of circulate can indicate water maldistribution, which may stem from either blockage or lacking distribution units. Sagging or lacking fill could also be seen as properly.
Along the Gulf Coast, ambient weather circumstances could pressure a cooling tower even in the winter; a poorly functioning tower may pose important points in the summer time. A stroll-around adopted by a quick performance take a look at can avoid summer headaches.
Study From Jake
It was a extremely popular August in Texas. Jake had been known as in to assist diagnose a condenser downside. The plant made a part utilized in a downstream facility and a drop in its output was curtailing manufacturing downstream. Jake took a quick look at the condenser operator display. The unit condensed the exhaust steam from the process compressor’s steam turbine drive. The compressor was experiencing diminished circulation, reducing plant manufacturing.
Jake instantly acknowledged that the inlet cooling tower water considerably exceeded design temperature. Ambient situations have been excessive however the temperature was a lot greater than the design strategy temperature. A fast verify on the native weather bureau confirmed his expectation.
As Jake set up temperature loggers, calibrated the evening before, he additionally surveyed the situation of the fill. The plant engineer assigned to help him indicated that upgrading the splash fill to a brand new design was in process. That design, advised in a recent analysis paper, promised to drop the method temperature. The splash fill bars could be installed parallel as a substitute of perpendicular to the circulation. The tower was a cross-flow design, which means the air flowed perpendicular to the down stream of the water droplets. Jake thought the concept made sense.
As they made their survey, Jake noted that he was puzzled by the lack of fill within the front face of the tower. The plant engineer responded that the installer had said the more-efficient design required much less fill. That appeared questionable to Jake; a performance check of the three cells verified the tower was the issue. One unconverted cell was at design performance. Thankfully, out there performance information confirmed the tower had performed to design prior to now.
Jake then contacted the writer of the analysis paper, who indicated the identical quantity of fill was wanted to realize the specified strategy.
The threat of a lawsuit persuaded the installer to complete the installation with the correct amount of fill. Temporary cooling towers were brought in to get the plant through the August/September sizzling spell. Manufacturing was increased and no downstream gross sales were misplaced.
So, examine the performance and situation of your towers proper now. If you’ve upgraded and even replaced the fill, guarantee you bought what’s required. Also, it’s a good suggestion to spend time with the installer’s team to verify they understand the job and to make sure high quality. Contact reputable sources for data in the event you don’t perceive what they are doing or proposing.