Top 5 Significant Cooling Tower Parts and Components

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Top 5 Significant Cooling Tower Parts and
Components

• Submitted By Tower Tech Cooling Systems Pvt.
  Ltd

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• Cooling towers play a significant role in every
  industrial process. Just like any other
  industrial equipment, cooling towers are also
  made up of different parts that work together to
  ensure the system functions effectively and
  efficiently. These parts need to be fixed or
  replaced a few times during the entire lifetime
  of the cooling tower. Here are some of them
• Cooling towers play a significant role in every
  industrial process. When industrial machinery and
  equipment are running at the same time, the
  amount of heat inside the industrial factory
  increases significantly. This increased heat will
  not only pose health and security risks to the
  factory workers and operators, but it will also
  increase the likelihood of industrial machinery
  and equipment to get damaged. Needless to say,
  when the industrial equipment gets damaged, the
  production rate will also decline. Not to mention
  the cost of cooling tower services and of
  repairing or replacing broken parts.

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• Just like any other industrial equipment, cooling
  towers are also made up of different parts. These
  parts work together in order for the cooling
  tower to function effectively and efficiently.
  Aside from the fan motor, water pumps, water
  supply basin, and the draft towers that we have
  already previously discussed, cooling towers also
  include other important parts. These significant
  parts usually need to be fixed or replaced a few
  times during the entire lifetime of the cooling
  tower. These parts include

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Drift reducers

• The drift reducer or eliminator is one among the
  essential parts of the cooling tower. It is
  designed to capture and eliminate large water
  droplets in the air that are caught in the
  cooling tower air steam and to minimize loss of
  process water. The eliminator abruptly forces the
  mist and water droplets in another direction,
  redirecting them to another part of the system
  and preventing them from escaping the cooling
  tower. The moisture is then separated from the
  air and recycled for operational processes.

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Driveshafts

• The cooling tower driveshaft is the link that
  connects the input shaft of the gearbox and the
  electric motor. Its main purpose is to transmit
  power from the motors output shaft to the gear
  eliminators input shaft.
• The driveshaft operates within the harmful
  environment inside the tower. With this, you need
  to pick a driveshaft that is highly corrosion
  resistant. It should also be well balanced or at
  least can be re-balanced whenever needed as it
  has to turn at full motor speed.

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Cooling tower nozzles

• The crossflow cooling towers usually come with
  nozzles. These cooling tower elements function by
  harnessing the power of gravity for water
  distribution. The main task of the nozzles is to
  get the warm water that needs to be cooled down
  and deliver it to the fill.
• The water is usually pushed up to the dispersal
  reservoirs which are located on top of the fill
  media. The gravity will then help the water fall
  down through the fill media via the nozzles which
  are found at the bottom of the reservoirs.

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Splash style fill

• The splash style fill breaks up the moisture. It
  is consists of a few layers of horizontal bars or
  slats. Traditionally, splash style fill media are
  made from wood but there are some modern designs
  that are made from PVC. Nowadays, more and more
  industries are trusting PVC-made splash style
  fill as it is more efficient and it allows better
  and faster heat transfer than the one made from
  wood. This type of fill is more ideal for
  industrial processes that generate dirty or poor
  quality water.

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How does splash-style fill work?

• The splash style fill works by spreading and
  breaking the warm water as it hits the bars
  surface. Small droplets are then formed, which
  increases the contact between the water and air.
  This makes evaporation and cooling accelerate
  faster.
• You can use the splash style fill if you are
  dealing with poor quality water as it does not
  have any channel or parts where debris and dirt
  may be trapped or accumulated. The accumulated
  debris and dirt can reduce the mediums
  efficiency.

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Film-style fill

• The film-style fill material or media is
  basically made from thin sheets of PVC material
  which are positioned close to each other. This
  fill is characterized by its corrugated pattern,
  flat, or textured surface where the water travels
  across.
• Unlike splash style fill, film-style fill
  material cannot be used for dirty or poor quality
  water as it is made with parts where debris and
  dirt can be accumulated or trapped. Again, when
  debris and dirt from the water build up in the
  fill, the overall performance and efficiency of
  the cooling tower will be reduced. Needless to
  say, this fill material is more suitable for
  cooling clean and quality water. However, if the
  film-style fill material is the only available
  option you have and you need to cool dirty or
  poor quality water, you may choose to use the one
  with wider flutes. Regular cooling tower water
  treatment can also be of great help.

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How does film-style fill work?

• The film-style fill material creates a large
  surface area and distributes the water across a
  flat layer. As the hot recirculated water hits
  the fill, it will spread out and form a thin
  film, allowing more contact with the air. This
  enables the heat to evaporate faster, making the
  water cools down at an accelerated rate.
• The primary function of the fill media, though,
  is to prolong the residence time of cooling
  water, to distribute water evenly, and to
  increase heat transfer area and heat dissipation.
  It helps optimize the cooling process of the
  cooling towers by making the surface area between
  the air and the water flow larger.

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• Over time, the fill media will get brittle or
  clogged. Some may lose their film during
  upgrades. When this happens, you need to have the
  fill media replaced. When choosing a fill media,
  you need to consider a few important factors.
  These are the vulnerability to contamination,
  total suspended solids or TSS levels, water
  composition, and intended use.

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Gearboxes

• The gearbox is the collection of gears attached
  to the cooling tower motor through the
  driveshaft. This important component transforms
  electrical energy into mechanical energy. It also
  serves as a speed reducer that helps slow down
  the rotational speed from the cooling towers
  incoming motor to the outgoing fan. The reduction
  of speed from the gearboxes acts as a torque
  multiplier. It also helps optimize the
  performance of the fan.
• If the cooling tower you use does not have a
  gearbox, its motors should be gigantic enough to
  directly handle the fans torque requirement.
  Unfortunately, gigantic and high capacity motors
  are quite heavy and expensive, making it an
  impractical option for many industrial plants.
  With the gearbox acting as a torque multiplier,
  you can be able to make the overall mechanical
  system of the cooling tower more cost-effective
  and at the same time keep the motor smaller.

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• Power industries, companies that run chemical
  processes, and other businesses that operate
  high-capacity production plants, need to use
  cooling towers that are designed with large
  amounts of heat rejection capacity. In order to
  support the cooling towers variable strengths
  and fan speeds, the cooling tower suppliers made
  this element available in different styles and
  reduction rates.
• The gearbox within the motor should be checked
  regularly to prevent corrosion. When rust starts
  to build up, the mechanical efficiency of both
  the motor and the gearbox will greatly decline.
  Rust build-up, if left unaddressed, can even lead
  to equipment failure. You can either buy a new
  gearbox or hire a professional to renew or
  restore the gearbox.

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• Apart from the five important elements of cooling
  towers mentioned above (gearboxes, fill media,
  nozzles, drift reducers, and driveshafts) and the
  other parts we already discussed before (fan
  motor, water pumps, water supply basin, and the
  draft towers), there are other parts that help
  cooling tower function well. This includes the
  reservoir heaters, electric float valves, and air
  intake louvers.

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• Tower Tech Cooling Systems Pvt. Ltd

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