How to face common problems of cooling towers

How to face common problems of cooling towers

For the cooling towers to remain effective, you should keep in mind certain things. It should be checked regularly and repair and maintenance must be done by experts. This not only increases the life of the system, but also reduces costs and avoids serious problems in the system. This is the most ideal way to reduce significant repair costs.

Common problems of cooling towers:


Corrosion is very common in cooling tower systems. Many companies tend to ignore the situation. They accept corrosion as an inevitable process, especially in older cooling towers. The cooling towers are installed outside and the corrosion in the cooling tower is the result of environmental factors. Such a process includes microbiological growth, deposition, aerated cooling water, etc.

Over time, corrosion gets worse and requires more than just repair. In many cases, parts of the cooling tower must be replaced due to corrosion. If that does not work, the only solution is to modify the entire cooling system. This also affects other parts of the cooling system. This means that more money must be spent on repairs and malfunctions.


Calcium phosphate, calcium carbonate, magnesium silicate and silica are the compounds present in water that are insoluble in heated water. These insoluble compounds cause hard deposits in the heat exchange surface of the system. This development is called scaling.

Tartar will damage the piping and the internal surface of the cooling system. It can also reduce the efficiency of cooling towers and increase energy consumption.


When unwanted materials accumulate in the cooling towers, it is called fouling. Contamination in cooling systems is not only the result of the accumulation of dust, dirt and derbies, but also other materials such as cracks, microbiological growth, migration corrosion products, sand, etc.

Failure to address the problem in a timely manner can lead to serious problems, such as a significant reduction in cooling tower efficiency, degradation of system performance, and increased operating and energy costs. .

Biological contamination

Biological contamination or microbiological contamination occurs by mistake. When microbes, such as algae, fungi and bacteria enter the system through the air or through the flow of water into the system Nutrient content in water increases with water use, process leakage and water evaporation. When incorporated in hot water, it creates an ideal environment for reproduction and growth of microorganisms.

Such bacterial growth is not only harmful to the environment but also affects the efficiency of the cooling system. It promotes corrosion in the cooling system. One of the reasons for the scaling in the cooling system is the growth of the bio films. This leads to increased energy consumption and harms human health.

Cooling tower solutions

The problems of each cooling tower are different. The water source of the site, the age of the cooling tower and even the air used to cool the water vary depending on the location. This means that maintenance of cooling towers and water treatment is a sophisticated and tailor-made enterprise. There is no single solution for the maintenance of cooling towers. Choosing a cooling tower maintenance company that provides control over the four performance issues reduces operating costs.

Avoid corrosion

There are three ways to control corrosion: epoxy coatings, adding orthophosphate for water treatment or raising the pH of water to around 9.0. Balancing these approaches can help extend the life of your cooling tower and components. If the pH is too high, the water in the cooling tower cannot be treated as effectively with chlorine treatments that help control biological contaminants. Although orthophosphate also helps prevent corrosion, it can be used as a fertilizer for some types of microbiological species. High quality cooling tube liners and coatings for the cooling tower help protect the metal from carbon steel corrosion.

Remove scaling

Tartar is a thin layer of minerals or chemicals that insulates the tube and prevents efficient heat transfer to create increasing back pressure and also limits the unit's output. Calcium in make-up water is the main problem that can cause deposits and needs to be monitored and treated as needed. Pipe coatings made from polymers are one way to prevent flaking. These coatings provide a surface that promotes heating to maintain performance, but they do not leave room for calcium to stick. In case of large deposits, there are cleaning procedures in which deposits are removed. This is the perfect time to use cooling tube liners to prevent future deposits.

Fouling treatment

Pollution in the cooling towers results in a reduction in the capacity of the cooling tower, resulting in increased energy consumption. Fouling does this when deposits or biological agents prevent the system from evenly distributing water in pipes, nozzles, fillers or other areas where water requires unrestricted movement. Chlorine can be used to treat dirt, filling can be changed and nozzles or other material replaced by new parts to restore performance of the cooling tower.

Treat biological contamination

The first and last step, after discovering that a cooling tower is contaminated by biological growth, involves taking a water sample. It is also the last solution. Here we examine the order in which you should treat a cooling tower system with biological contamination. Contamination is dangerous to the health of people living in the building and near the site, as contaminants can cause respiratory infections. To treat it, the system is shaken with chlorine at different concentrations for 48 hours, then rinsed thoroughly and filled with new water.

To prevent future contamination, all leaks must be removed from the cooling water system. At the end of the cleaning process, a sample is taken and sent for analysis. If the test is positive for L. pneumohphila, water chlorination and sampling should be repeated. As a result, companies should only hire experienced companies in the field of cooling tower maintenance to avoid unnecessary downtime.

Therefore, you must first look for the cooling towers manufacturer. After installing quality water cooling towers, you must be prepared for the above problems. Corrosion, deposits and contamination can be prevented and controlled. Investment in service and maintenance is necessary. It secures the cooling system and avoids unnecessary problems in cooling towers.



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