Cooling Towers: Management, Maintenance, and Troubleshooting

Introduction:

Cooling towers are common components in industries utilizing water cooling methods, including power generation, processing, and petrochemicals. Understanding cooling tower operations is essential for enhancing water and energy efficiency while maximizing the lifespan of critical components such as fans and pumps.

This course focuses on the maintenance of cooling towers, emphasizing their operation, water management, and control. Participants will gain insights into operational improvements, with a focus on optimal corrective and preventive measures.

By combining theoretical content with practical scenarios, the Cooling Tower Maintenance and Troubleshooting course equips participants with the necessary maintenance and troubleshooting skills to ensure the safe and efficient operation of cooling towers.

Objectives:

At the end of the Cooling Tower Maintenance and Troubleshooting course, participants will be able to:

• Assess the contribution that a cooling tower makes to a plant’s water cooling system.
• Catalog the construction and performance characteristics of various cooling tower configurations.
• Examine the safety components of chemical and physical water treatment.
• Get acquainted with concepts of performance monitoring and record-keeping for cooling towers.
• Outline the basic inspection procedures that should be conducted on cooling towers.
• Acquire and apply effective methods for organizing preventive maintenance of cooling towers.

Training Methodology:

• Academic lectures and presentations
• Facilitated group activities/panels
• Case studies
• Classwork
• Demonstrations
• Site tours
• Tests and evaluations

Course Outline:

Unit 1: Comprehension of Cooling Towers and Their Use:

• Classification of cooling towers and their arrangements
• Elementary parts of cooling tower construction
• The necessity of treating cooling tower water
• Importance of water treatment in cooling water systems
• Operation of cooling towers as a cyclical unit process
• Supporting equipment: blowers and heat rejection water pumps
• Sub-base preparation: handling recycling and wind pollution
• Proposed building structures: furniture and vortex breakers

Unit 2: Functionality and Performance of Cooling Towers:

• Cooling load profile: range of temperature, approach, and drift loss
• Concept of efficiency in cooling tower operations
• Continuous vs. periodic operation: long-term operational planning
• Advanced controls and techniques in cooling towers
• PLC and DCS systems: controlling cooling towers at a standard level
• Water quality standards and evaluation approaches
• Cooling tower start-up and shut-down procedures for effective operation
• Strategies for improving performance and reducing losses

Unit 3: Cooling Water Circulation Systems and the Status of Cooling Towers:

• Cooling water quality management: treatment and continuous follow-up
• Control of water treatment systems: optimal chemical dosing
• Bleeding control: maintaining water quality
• Additional measures for increasing key performance indicators of cooling towers
• Measurement of concentration ratio and its significance
• Cathodic protection methods for equipment longevity
• Coating techniques in cooling towers

Unit 4: Water Treatment and Control in Cooling Towers for District Heating Systems:

• Causes and reasons for corrosion: an overview
• Chemical treatment of water: DCC control and inhibitors
• Overview of basic motor types used in cooling towers and their operation
• Powering the electrical distribution board: proper connection of electrical and instrumentation accessories
• Importance and implementation of grounding in cooling towers
• Filters: high-efficiency physical water treatment

Unit 5: Repair and Maintenance of Cooling Towers, Methodology of Works and Diagnostics:

• Routine and preventive maintenance best practices within the maintenance ripple
• Mechanical inspection of equipment: fan reliability and pump inspection checklist
• Application of modern techniques (FMEA, DFMEA, PFMEA) for equipment durability
• Ensuring safe operation in compliance with manufacturer requirements
• Testing of all auxiliary systems within cooling towers
• Risk management related to mechanical, electrical, and control systems of cooling towers
• Health and safety at work: adherence to best practices and procedures