Understand the six major hidden dangers and common problem faults of cooling towers in one article

A cooling tower is a device that uses water as a circulating coolant to absorb heat from a system and release it into the atmosphere to lower the water temperature. A cooling tower is composed of the tower body, water distribution system, water distribution device, ventilation system and water collection pool. The tower body is often built in a circular, rectangular or polygonal shape. There are two types of cooling towers: wet and dry. Cooling towers can be classified into counter-flow type and cross-flow type according to the direction of air and water flow. According to the ventilation method, cooling towers can be classified into natural ventilation cooling towers and mechanical ventilation cooling towers. Its function is to transfer the heat in water to the air and diffuse it into the atmosphere, thereby achieving the effect of reducing the heat in water. It is mainly used for regulating air room temperature, manufacturing and processing, etc. The working principle is to utilize the flow and contact between water and air. During the flow and contact process, steam is generated, and the heat is carried away by the evaporation of steam, thereby achieving the effect of cooling and heat dissipation.

Possible reasons for poor cooling effect of the cooling tower

1.Excessive or insufficient circulating water volume: 

The water flow exceeds the design range, affecting the heat exchange efficiency. 

2. Clogging or scaling of packing: 

The accumulation of scale, algae and impurities leads to a reduction in the heat dissipation area. 

3. Insufficient fan speed or belt slippage:

 Insufficient air volume affects evaporation and heat dissipation.

 4. Excessively high intake air temperature: 

High ambient temperature or blocked air inlet can affect the cooling effect.

Solution: 

1. Adjust the water pump flow to the rated range. 

2. Regularly clean the cooling tower packing and use descaling agents or bactericides to prevent clogging. 

3. Check the tightness of the fan motor and belt, and replace them if necessary. 

4. Clean the air intake to ensure smooth ventilation and add shading measures if necessary.

Possible reasons for excessive noise from the cooling tower: 

1. Deformation or loosening of the fan blades: 

This leads to unbalanced operation and generates vibration noise. 

2. Bearing wear or poor lubrication:

 Obvious mechanical friction sounds. 

3. Uneven water spraying: 

Water droplets hitting the tower body or the water collection tray produce noise. 

4. Structural loosening or resonance: 

The fixing bolts of the tower body are loose, causing abnormal noises during operation.

Solution: 

1. Check if the fan blades are deformed and re-tighten or replace them. 

2. Regularly add grease and replace damaged bearings. 

3. Adjust the water distributor to ensure uniform spraying and reduce water splashing. 

4. Inspect the structure of the tower body, reinforce loose components, and eliminate resonance sources.

The possible reasons for severe water drift in the cooling tower (large water mist loss) are as follows

1. Excessively high wind speed: 

The fan rotates too fast, causing a large amount of water droplets to be carried out. 

2. Damaged or aged water collector: 

Unable to effectively intercept water droplets. 

3. Excessive circulating water volume: 

The spray pressure is too high, and the splashing of water droplets intensifies.

Solution: 

1. Adjust the fan speed to a reasonable range. 

2. Replace the damaged water collector to ensure its integrity and correct installation Angle. 

3. Control the flow rate of the water pump to avoid excessive water pressure.

Possible causes for overheating or frequent tripping of the cooling tower motor

1. Unstable voltage: 

Excessively high or low voltage leads to motor overload. 

2. Bearing jamming or poor lubrication: 

Increase the load on the motor. 

3. Poor heat dissipation: 

Damaged motor fan or excessively high ambient temperature. 

4. Loose wiring or short circuit:

 Causes abnormal current.

Solution: 

1. Check the power supply voltage to ensure it is within the rated range (±10%). 

2. Lubricate or replace the bearings to reduce frictional resistance. 

3. Clean the motor's heat dissipation holes to ensure good ventilation. 

4. Inspect the electrical circuits, tighten the terminal blocks, and eliminate the risk of short circuits.

Possible causes of water leakage at the bottom of the cooling tower

1. Cracking or corrosion perforation of the tower body welds:

Long-term use leads to metal aging. 

2. Damage to the connecting flange or gasket: 

Water leaks from the interface. 

3. Damaged water collection tray: 

Leakage caused by freezing and cracking or external impact.

Solution: 

1. Weld and repair the cracks. Replace the tower body components when there is severe corrosion. 

2. Replace the flange gasket and tighten the bolts. 

3. Repair the water collection tray or replace it with a new one. In winter, make sure to empty it to prevent freezing.

Possible reasons for the growth of algae or microorganisms in cooling towers: 

1. Poor water quality: 

Long-term untreated, leading to the growth of bacteria and algae. 

2. Direct sunlight:

 Promotes the growth of algae. 

3. Failure to add fungicides regularly: 

Uncontrolled reproduction of microorganisms.

Solution: 

1. Regularly clean the tower body and use bactericides and algaecides (such as sodium hypochlorite). 

2. Install sunshade nets or use dark-colored tower bodies to reduce light exposure. 

3. Install an automatic dosing device to keep the water clean.