Optimizing Tower Performance

ucing energy costs fm your oling tower may be as simple as regular maintenance. This Technology Update will explain how proper maintenance will
create optimum heat transfer conditions and help your equipment operate more efJl6ently.

k!

Is not unusual for the water in an improperly maintained cooling t ' tower to be 5 to 10"F warmer than the water in a properly maintained cooling tower. Your chiller could consume up to 3.5percent more
energy for each degree hotter the return (cold) water of the cooling tower becomes. If, for example, your cooling system uses $50,000 of electricity per year, it would cost you an additional $1,750 per year for every 1 "F rise in cooling water temperature. This means that if your cooling water temperature operates 5 to 10 ?F warmer you could expect to pay an additional $8,750 to $17,500 a year for electricity. Let's look at another example. If you operate a 100 kW chiller 4,000 hours per year and pay $0.05 per kWh, it will cost you an additional $700.00 per year for every degree cooling water temperature rises. I f your cooling water temperature operates 5 to IO "F warmer you can expect to pay an additional $3,500 to $7,000 a year.

Efficient Operation
1. Hot water from chiller 2. Flow control valve 3. Distribution nonels 4. Drift eliminators 5. Make-u water infeed 6. Float vave 7. Collection basin 8. Strainer 9. Cooled water to chiller 10. Fan 11. Gear box 12. Drive shaft 13. Fan drive 14. Bleed water

Cooling towers found in industry, schools, office buildings, hospitals, and other commercial buildings are usually "open loop" systems. In one application, water is circulated around condensing tubes of a chiller where it picks up heat. The warm water is then broken into small drops by spraying it over the "fill" in the cooling tower (see Figure 1).Ar is i blown through the fill where it picks up heat from the water. Direct heat transferred to the air accounts for only about 25 percent of the heat removed from the water. The remaining 75 percent of the heat is removed as the water is evaporated. The cooled water is then collected in the tower basin where it is recirculated through the system. Water is constantly being added to the system because so much water is removed by evaporation. When water evaporates from the cooling

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PROBLEM
Scale deposits form on the surface of the fill, pipes, and nozzles.
I .

CAUSE
Evaporation and water treatment are problems.

EFFECT
The amount o heat f transferred from the water to the air is reduced. Operation efficiency is reduced and q u i ment life is shortens. Cooling tower water is hotter and its flow through the fill is reduced. Water temperaturein the cooling tower is hotter than necessary.

SOLUTION
Measure the water treatment chemical residual in the circulation water and maintain the residual recommended by your water treatment specialist. Maintain proper water treatment chemical residual. Clean the strainer on the bottom of the basin regularly. Remove sediment from the basin and clean strainer regularly.

Spray nozzles are clogged.

Algae and sediment are mitted to collect in the

Kn i .

Water and air flow through the fill is uneven.

Spray nozzles are clogged.

tower it leaves scale deposits on the surface of the fill from minerals that were dissolved in the water. These deposits are composed mostly of calaum, iron, and silica. Allowing the scale to build up on the fill surface of closed circuit cooling towers reduces the amount of heat transferred from the water to the air. Excessive scale build-up on an open cooling tower may indicate inadequate water treatment.

Algae and sediment, permitted to collect in the basin, will interfere with water circulation and drastically reduce cooling tower performance. Clogged spray nozzles will cause uneven water distribution and affect air flow. More air will flow through the dry section of the fill because of reduced resistance and rob air from the wet parts. Table 1is a list of common problems, causes, effects, and solutions to cooling tower performance.

Maintenance
A properly maintained cooling tower will keep your equipment operating more efficiently and save you money. Scheduleyour maintenance regularly and keep a record of al maintenance perl formed (Table 2).

DAILY
H Collect and test a water sample

PERIODIC
Check the distribution spray nozzles to ensure even distribution over the fill. Check the distribution basin for corrosion, leaks, and sediment. Operate flow control valves through their range of travel and reset for even water flow through the fill. Remove any sludge from the collectionbasin and check for corrosion that could develop into leaks.
H Check the drift eliminators, air

ANNUAL
H Check the casing, basin, and

using the kit provided by your water treatment consultant. ,Measurethe cycles of concentration of the water flowin6 through the tower. Maintain the proper concentration of dissolved solids by adjusting the bleed water flow.

I Measure the water treatment

chemical residual in the circulation water. Maintain the residual recommended by your water treatment specialist.
I Check the strainer on the bottom

i ing for corrosion and decay. u h o u t proper maintenance cooling towers may suffer from corrosion and wood decay Welded repairs are especially susceptible to corrosion. Prime and paint any welded repairs with a corrosion-resistant coating. The rotective Zinc coating on g vanized steel towers is burned off during the welding process.

H Leaks in the cooling tower casing

of the basin and clean it if necessary.

H Operate the make u p water float

may allow air to bypass the fill. All cracks, holes, ga s, and door access panels shoul be properly sealed.

switch manually to ensure proper operation.

intake louvers, and fill for scale build-up. Clean louvers and drift eliminators with high-pressure wash. The fill may require acid cleaning.
H Look for dama

Remove dust, scale, and algae from the fill, basin, and distribution spray nozzles to maintain proper water flow.

H Inspect all moving parts, such as

drive shafts, pulleys, and belts.

H Check for excessive vibration in

ed or out-of-place fil elements.

motors and pumps.

I Look for ol leaks in gear boxes. i
HTest the vibration limit switch by

Ins ct motor supports, fan bla es, and other mechanical parts for excessive ware or cracks.

g.

HCheck the level of oil in the gear

pur$sely jarrin8 it. the SWI ch for corrosion tha could prevent it from o r t i n g properly. N v r lsconnect the ee vibration limit switch. If it cuts o f f often, look for the source of vibration.
loose connectors,water leaks, and

h$d

box. Add oil as needed.

H Lubricate bearings and bushings. HAdjust belts and pulleys.

HMake sure there is pro

I Check for structural deterioration,

clearance between the an blades and the shroud. Move the shroud or fan as required.

! F

openings in the casing.

HDuring periods of cold weather,

check wnterization equipment. Make sure any ice accumulation is within acceptable levels.

HCheck the amount of vertical lay in the gear box output shaft &ypulling u on the tip of the fan blades. 1p the drive shaft urn back and forward to determine the amount of free rotation on the drive shaft. If movement in either shaft seem excessive, call a qualified cooling tower service contractor.

i
V Electric Ideas Clearinghouse i a s comprehensive n i@ source fm commercial and industrial energy users. It is operated by the Washington State E w g y Office and is part o f the Electric Ideas technology transfer program sponsored by participating utilities and the Bonneuille Power Administration.
V Neither the United States nor the

Bibliography
Air-conditioning and Refrigeration Institute. xefvigeration and Air-Conditioning. Prentice-Hall. pp. 133-137.1987.

Burns,R. Cooling Towers, The Neglected Energy Resource. Republished i Retrofit Opportunities For Energy Management and n Cogeneration. pp. 47-53. The Association of Energy Engineers.Compiled and edited by F.W. Payne. Prentice-Hall. 1989.
Graves, P. Understanding Air Conditioning Systems For Better Energy Efficiency Prepared for the Illinois Dept. of Energy, ILENR/BE87/01.1987.

Bonneville Power Administration, the state of Washington, the Washington State Energy O@e, nor any of their contractors, subcontractors, or their employees make any mrranty, expressed or implied, or assume any legal responsibility for the accuracy, completeness, or usefulness of any information,apparatus, prcduct, or process disclosed within the publication.
V Technology Update CH-12 V Toll-freeHotline:

Iris Communications,Inc. Keeping up with cooling towers,from Building Operator, Number 4. Tualatin, Oregon. November 1990.
McQuiston, F.C. and J.D.Parker. Heating, Ventilating,and Air Conditioning Analysis and Design. JohnWiley & Sons, Inc. pp. 537-547.1988. Trane Corporation. Air Conditioning Training Manual. 1965.

1-800-872-3568 Fax: 1-800-872-3882 Electronic Bulletin Board: 1-800-762-3319

DOVBP-39833-34
June 1992

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