Cooling Tower Fault Handling: The "Cool Guardian" Protecting Industrial Circulation

Beside the roaring units of thermal power plants, amid the scorching heat waves of petrochemical facilities, and deep within the continuous heat flow from the dense servers in data centers, cooling towers act as silent and crucial guardians, constantly cooling the pulsation of industry. However, when this "coolness guardian" malfunctions itself - the water temperature surges abnormally, strange noises occur suddenly, and water mist spreads out of control - the stable operation of the entire system instantly sounds the alarm. Mastering the precise identification and efficient handling of cooling tower faults is a core skill for ensuring production continuity and economic benefits.

I. Core Mission and Common Fault Map of Cooling Towers

As the core heat dissipation hub of industrial circulating water systems, cooling towers reduce the circulating water temperature carrying the waste heat of equipment to a reusable level through direct or indirect contact between water and air, using evaporative heat dissipation (approximately 540kcal of heat is carried away by the evaporation of 1kg of water) and sensible heat exchange. Its efficient operation affects the energy consumption and stability of the entire system.

Common fault phenomenon warnings

Abnormal water temperature: The outlet water temperature is significantly higher than the design value or the historical normal level.

Water imbalance: Abnormal increase in water replenishment (leakage?) Severe water drift?" Or the water level inside the tower is unstable.

Noise and vibration: The fan emits abnormal whistling, periodic impact sounds, and the overall vibration intensifies.

Visual abnormality: Severe scaling, blockage and damage on the surface of the packing material; There is a large amount of uncontrolled water mist (floating water) around the tower body.

Performance decline: Under the same heat load and meteorological conditions, the cooling capacity is significantly insufficient.

II. In-depth Analysis: Common Fault Root Causes and Precise Handling Strategies

1.Abnormally high water temperature - decline in cooling capacity

Dig deeper into the reasons

Air duct blockage: Large-scale scaling of the packing, algae growth, debris blockage, or severe dust accumulation on the air inlet louvers/filters, hindering air circulation.

Fan weakness: The belt is loose, slipping, worn and broken. Motor failure (bearing damage, unstable voltage); The Angle of the fan blade is deviated, deformed or the surface is covered with too thick dirt.

Uneven water distribution: Nozzle blockage, detachment or damage; The water distribution pipe burst, causing the water flow to be unable to evenly cover the surface of the packing, forming a "dry zone" and sharply reducing the effective heat exchange area.

Excessive circulating water volume: exceeding the designed processing capacity of the cooling tower, and the water flow stays in the packing for too short a time.

Environmental factors: Extreme high temperature and humidity weather, air approaching saturation, and the efficiency of evaporation and heat dissipation drops sharply.

Precise processing

Unblock the air passage: Thoroughly clean the packing with a high-pressure water gun and remove algae and debris. Clean the air inlet louvers/filters. Severely scaled packing materials need to be chemically cleaned or replaced.

Restore the fan's performance: Check and adjust the belt tension or replace the belt. Inspect and repair the motor (lubricate the bearings, check the wiring and voltage); Calibrate, clean or replace the fan blades. (Safety first: Make sure to cut off the power supply and lock it before operation!)"

Optimize water distribution: Check, unclog or replace each failed nozzle one by one; Repair the damaged water distribution pipe.

Adjust the water volume: Under the premise of meeting the process requirements, check and appropriately close the outlet valve of the water pump, or verify whether the actual flow exceeds the standard based on the design parameters.

Dealing with extreme weather: Within the allowable range of system design, it is advisable to consider appropriately increasing the circulating water volume (it is necessary to assess the capacity of the water pump and whether it will cause other problems), or to activate the backup cooling equipment.

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2. Excessive water drift - a double loss of water resources and the environment

Dig deeper into the reasons

Fan wind speed out of control: The fan speed is too high (commonly seen in improper frequency setting of the frequency conversion tower or motor failure).

Water collector failure: The water collector (water separator) is deformed, damaged, fallen off or severely clogged, losing its function of capturing water droplets.

Excessive water spray: The nozzle pressure is too high (either due to excessive system pressure or incorrect nozzle selection), causing water droplets to be directly sprayed upwards and splashed out.

Packing damage: Large pieces of packing fragments are carried out by the airflow.

Excessively high water level: Exceeding the designed water level line increases the risk of water droplets being carried by air currents.

Precise processing

Regulate the fan: Check and adjust the frequency converter Settings to a reasonable speed range. Repair motors that are operating abnormally at high speeds.

Repair/Replace the water collector: Carefully inspect the condition of the water collector, correct deformed parts, thoroughly clean the clogged areas, and replace the water collector modules that cannot be repaired.

Optimize the water distribution pressure: Check the system pressure and adjust the operating parameters of the water pump or the valve opening if necessary. Replace with low-pressure and high-efficiency nozzles.

Cleaning and replacement of packing: Remove the fallen packing fragments and replace the packing with large areas of damaged packing.

Calibrating the water level: Inspect and adjust the float valve or liquid level controller to ensure that the water level is within the designed range.

3. Abnormal Noise and Vibration - The "Painful Groans" of Machinery

Dig deeper into the reasons

Fan imbalance: blade deformation, corrosion damage, uneven distribution of surface scale, or failure to calibrate the balance during installation.

Bearing failure: Wear of the fan bearing or motor bearing, lack of oil lubrication, or damage.

Loose connections: The fastening bolts of the fan blades, the bolts of the motor base, and the connecting parts of the transmission shaft are loose.

Structural resonance: Resonance of the tower structure is triggered at a specific rotational speed.

Foreign object intrusion: Debris or packing fragments are drawn into the tower (such as the fan area).

Precise processing

Fan balance correction: After the machine is shut down and the blades are cleaned, professional dynamic balance calibration is carried out.

Bearing maintenance: Shut down the machine to check the condition of the bearings, and promptly replenish qualified grease or replace damaged bearings.

Comprehensive tightening: Systematically inspect and tighten all bolts and connectors that may be loose.

Avoid resonance points: For variable-frequency fans, try to fine-tune the operating frequency to avoid the resonance speed zone.

Thorough clearance: Remove all foreign objects from the fan area and its surroundings.

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4. Filler Scaling and Blockage - "blood clots" in the heat dissipation channels

Dig deeper into the reasons

Excessively high water hardness: The content of calcium and magnesium ions in water is high, which is prone to form carbonate/sulfate scale.

Water treatment failure: dosing system malfunction (insufficient chemicals, pump shutdown), improper selection of chemicals or failure to drain regularly.

The growth of algae and bacteria: Suitable sunlight, temperature and nutrients (dust, nutrients) lead to the massive reproduction of microorganisms.

Suspended solids deposition: Silt, corrosion products, biofilm, etc. brought in by the circulating water system.

Precision handling and prevention

Physical cleaning: Strong flushing with a high-pressure water gun (note water pressure to avoid damaging the packing). In severe cases, manual disassembly and scrubbing are required.

Chemical cleaning: For different types of dirt (scale, biofilm), select safe and effective specialized cleaning agents for circulation cleaning or immersion cleaning, and strictly follow safety regulations and discharge requirements.

Strengthen water management

Pre-treatment for water replenishment: Measures such as softening and filtration are adopted based on water quality.

Scientific dosing: Regularly add scale and corrosion inhibitors, bactericides and algaecides, and ensure the reliable operation of the dosing system.

Control the concentration ratio: Prevent excessive concentration of dissolved solids by regular Blowdown. Installing a conductivity meter to automatically control sewage discharge is an efficient approach.

Regular inspection and maintenance: Establish a regular inspection, cleaning and drainage plan for the cooling tower and water system.

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5. Abnormal water volume (leakage and sudden increase in water replenishment

Dig deeper into the reasons

Pipeline leakage: Leakage at the connection points of the internal distribution pipes, spray pipes, and water collection trays of the tower body, or in the external circulating water pipelines.

Leakage of the water collection tray: cracking of the welds on the tray body, perforation due to material aging.

Valve failure: The drain valve and the make-up water valve are not closed tightly.

Uncontrolled water drift: As mentioned earlier, severe water drift leads to significant water loss.

Precise processing

Comprehensive leak inspection: Carefully inspect the internal pipes, interfaces, and water collection trays of the tower body (especially welds and corners), as well as the external pipelines and valves. Conducting static pressure tests during shutdown can help identify hidden leakage points.

Repair leakage: Depending on the condition of the leakage point, methods such as welding, replacing pipe sections/valves, and using special repair agents (such as epoxy resin) are adopted to seal it.

Water drift control: Refer to the aforementioned water drift treatment measures.

6. Electrical and control system faults

Common problems: Motor overload tripping (phase loss, bearing jamming, excessive load), inverter failure, sensor (temperature, liquid level, vibration) malfunction, control logic error, loose wiring, etc.

Precise processing

The detection and diagnosis are carried out by qualified electricians using professional tools (such as multimeters, galvanometers, etc.).

Reset the protection device (after checking for errors), replace damaged components (motors, frequency converter modules, sensors, etc.), tighten the terminal blocks, and correct the control program parameters.

III. Building a Defense Line: Preventive Maintenance is the most efficient "fault handling"

Rather than passively dealing with faults, it is better to proactively build a defense line. The preventive maintenance plan of the system can significantly reduce the probability of sudden failures of cooling towers.

Regular inspection (daily/weekly/monthly) : Observe water level, water drift, abnormal noise and vibration; Check the tension of the belt; Visually inspect the condition of the packing and the water collector.

Planned cleaning (quarterly/semi-annual/annual) : Regularly clean the packing material, water collection tray and air inlet based on water quality and environmental conditions.

Strict water quality management: Continuously monitor water quality parameters (pH, conductivity, hardness, etc.) to ensure the reliable operation of the dosing system and scientific sewage discharge.

Key component condition monitoring and maintenance: Regularly inspect the fan blades (balance, corrosion), bearings (lubrication, temperature rise, noise), motors (insulation, current), and transmission components (belt wear, coupling alignment).

Seasonal maintenance: Take anti-freezing measures in winter (drain or add antifreeze, turn on the heater); During the season with strong wind and sand, strengthen the cleaning of the air inlet filter screen.

Complete record: Detailed records of operation parameters, maintenance contents, and fault handling processes provide a basis for trend analysis and optimization.

Summary: Every efficient operation of the cooling tower is supplying the indispensable "cool blood" to the huge industrial body. The jumping numbers on the water temperature gauge, the rotation trajectory of the fan blades, and the sound of water flowing through the packing are all the keys to the system's health. An experienced engineer once shared: "The first thing I do every morning is to listen to the sound of the tower and observe the posture of the water." Subtle changes are often the earliest signs of a malfunction.

Mastering the art of handling cooling tower faults lies not only in the proficient use of tools and methods, but also in cultivating a keen perception of the equipment's condition and a proactive maintenance awareness. Only in this way can we truly become the guardians of the "cool guardians" of industry, allowing cooling towers to continuously play a stable and efficient symphony in the industrial symphony.