Filtration Methods Can Cut back Maintenance and Downtime.
To strike an interesting analogy, your cooling tower and heat exchanger is what the lungs and heart are to the human body; when both aren’t working properly, it results other elements of the body and your well being suffers. Equally, when your cooling tower and heat exchanger is not clean, the heat alternate course of would not work efficiently and the health of your production and process cooling system suffers.
Course of cooling programs that rely on cooling towers to dissipate heat from process cooling water accomplish this by drawing large volumes of air into the cooling tower because the water travels by the fill materials on its approach again to the basin. By way of the natural evaporative course of, heat is dissipated from the water before it reaches the water basin from which it’s re-circulated by means of the chiller then by the heat exchanger and again again (type of like if you sweat whereas working and letting the air evaporate the perspiration to cool you down). It will be significant to understand that cooling towers are gigantic air scrubbers that capture all airborne debris that occur to be floating close by, and in case your system does not have effective filtration, the debris can clog the fill and get circulated and trapped within the heat exchanger where it may construct-up, limit water move and trigger your process equipment to malfunction attributable to overheating.
An instance of that is illustrated by a major automotive assembly facility that had faced periodic downtime due to their robotic welding methods not holding tolerances and inflicting quality problems. After the robotic technicians spent several days making an attempt to initially solve the issue, one of the maintenance staff opened the heat exchanger and discovered that it was impacted with cottonwood seed, insects and other debris – move had been diminished and the robotic gear was operating sizzling. Now you is perhaps asking your self, whey did not they have some sort of filtration equipment? The answer is straightforward; on the time the power was constructed, the ambient conditions in that space didn’t require a filtration system. Nonetheless, because the years went by and the world turned extra developed and cottonwood tree populations grew, the necessity ultimately surfaced.
The attention-grabbing thing to notice about this situation is that though cleansing the heat exchanger received the robotic welding system again on-line and working at peak efficiency, it did not solve the issue. In reality, cleansing heat exchangers is like taking a chilly capsule to relieve the symptoms of a cold. Unless you deal with the basis cause of the problem, the cooling system will undergo time and again. The basis cause on this case and in most heat exchanger fouling situations is the cooling tower – cease the debris from getting into the cooling tower and it will protect the entire course of cooling system together with fill, cooling water, chiller and heat exchanger. With the proper filtration technology, your process cooling system will keep clean and operating efficiently all season long.
Deciding on The appropriate Filtration System
It is necessary to appreciate that optimizing the ecology and operational effectivity of your evaporative cooling system is best accomplished by combining a chemical remedy regimen with some type of filtration. The reason being that chemical remedy specifically targets suspended solids and particulates of forty microns and below, while filtration programs are designed to cease larger debris, especially the kind that causes system clogging and fouling.
For cooling tower filtration, there are two normal technologies: Water Based mostly Techniques for which there are a few totally different variations and Air Intake Filtration Systems. With water-primarily based techniques, the choices embody primary water strainers that take away debris by merely passing water by way of a mesh strainer; sand filtration systems that take away debris by passing the water by means of sand and centrifugal separators that spin the water and remove the debris by centrifugal action. In contrast, Air Intake Filter Systems take away the debris by filtering the air as it’s being drawn into the cooling tower, conserving the debris out of the system in the first place. When contemplating your filtration options, the next questions ought to be asked.
– What’s the fee related to downtime on account of heat exchanger or cooling tower fouling or clogging? (Realizing this can help you justify your filtration system price)
– What sort of debris is most problematic (can you see it or is it microscopic)?
– Specifically what part of the system does the filter protect?
– Which system offers the greatest filtration floor area (this will immediately impact frequency of cleaning – the smaller the filter the extra incessantly it needs cleansing)
– Can the system be put in with out shutting down the cooling tower? (If the cooling tower must be shut down for installation, it’s essential to factor lost productiveness into the cost of your filtration system if it isn’t being put in during shutdown durations.)
– What is the price related to each the filter and installation?
– How straightforward is the system to install and maintain?
Answering the above questions will help you to totally perceive your choices and to make your best option to your operation.
In the case of the automotive producer, the answer they chosen was the Air Intake Filter system. The reason was that they needed a system that will protect their complete course of cooling system together with fill material, cooling water, chiller and heat exchanger. When they evaluated water-based mostly techniques, they discovered that the choices supplied various levels of protection for the chiller and heat exchanger but did not protect the cooling tower where the foundation of their problem was. If they’d selected a water-based system, their cooling tower would have nonetheless drawn airborne debris into both the fill and water where the water filter would have captured the debris earlier than it circulated throughout the system. From a upkeep standpoint, that would have solved the heat exchanger downside but it could have executed little to cut back maintenance on the cooling tower. Additional, once they in contrast the cost of water primarily based filtration versus air intake filtration applied sciences, Air Intake Filtration was found to be the extra price efficient approach for his or her operation.
If you aren’t currently utilizing a filtration system as a part of your course of cooling system, then any filtration know-how will provide you with extra safety than you’ve now, however, selecting a solution best suited to your operation requires that you know what kind of debris is the issue and the place it’s moving into the system. As a rule of thumb, ” do not choose a small debris solution to unravel a big debris downside”. Conversely, “do not choose a large debris answer to solve a small debris drawback”. There’s clearly a spot for both water based mostly filtration and air intake filtration – make certain you are selecting the correct filtration for your particular want.
If you’re looking to protect only your chiller and heat exchanger from airborne debris, then one of the water-primarily based filtration applied sciences in combination with a good water remedy program can enable you to manage the debris that gets into the cooling water. If then again, you are in search of full course of cooling system safety, then you need to have a look at Air Intake Filtration – It is going to stop the debris from stepping into your system in the primary place.