The life expectancy of a cooling tower will depend on variables such as its material, maintenance, climate, water quality, and usage. Considering that cooling towers can cost tens or hundreds of thousands of dollars to replace, it is essential to consider their lifespan and explore ways to extend it. Another alternative to replacing a cooling tower is refurbishing it, which can greatly extend the useful life of your cooling tower. The lifespan of a cooling tower is 15 to 20 years according to manufacturers, but there are many factors to consider.
Cooling towers out in the world today should last 15-20 years based on manufacturer guidelines for most builds. Yet, many will beat this, especially if they are well-maintained cooling towers or those in forgiving environments. Some cooling towers are around from the 70s, 80s, and 90s, although they likely are not operating efficiently at that point if they have not been refurbished.
Refurbishing vs replacing a cooling tower will depend on how many parts of the cooling tower are still in good shape and have been replaced, and the labor costs involved in installing a new cooling tower vs refurbishing the cooling tower. It is important to keep in mind the actual total cost of an installed, functioning cooling tower. When it comes to refurbishing a warranty is strongly recommended as labor costs can vary wildly with large equipment, so you will want to make sure you are covered in case something was installed wrong or not refurbished properly. With a new cooling tower, you have standardization in how it was manufactured, because “refurbished towers” are a custom build there is a higher chance of something potentially being off.
It is most common for this to be done with a type of steel cooling tower. Refurbishing a cooling tower may involve patching and grinding surfaces to a like-new condition. This will make the metal properties transfer heat effectively like it did when it was new and will remediate scale, corrosion, holes, and other uneven, obstructed surfaces on the surface. Additionally, replacing the media fill, recoating/resealing, and repairing broken parts are common aspects of refurbishing a cooling tower.
As soon as a cooling tower is installed, it is important to start maintaining the system to make it last as long as possible. This should start with passivating if it is a galvanized cooling tower. Then, all cooling towers should have water treatment equipment set up to feed chemicals at regular intervals. A qualified technician will be able to install controllers, pumps, and remote monitoring/operating equipment.
Once your equipment is set up, it is important to treat the water chemistry in the cooling tower for the following issues: scale, corrosion, and bacteria. As soon as water touches the surface of a cooling tower, the water will gradually cause all of these issues over time if left untreated. A water treatment technician can utilize scale and corrosion inhibitors, as well as biocides to control these issues. In addition to feeding chemicals, they should regularly test the water for pH, mineral hardness, alkalinity, dissolved solids, chlorine, etc. Consistently testing the water allows a technician to tweak the water chemistry if certain levels are off. This allows the technician to preemptively avoid issues like scale when the number of dissolved solids starts to go up and add more scale inhibitors to the water.
A big part of a water treatment technician’s job is not just preventing issues; it is also helping the cooling tower operate efficiently. Controlling pH, adjusting the cycles of concentration (number of times the cooling tower is flushed, and other methods allow for the cooling tower to operate as efficiently as possible, saving on energy costs and water consumption. The cost of cooling tower maintenance expenses is much less than replacing a tower or remediating significant issues.
Another way to extend the longevity of your cooling tower and increase its efficiency is to clean it. The scale buildup, sludge, algae, and biofilm not only reduce the heat transfer capability of a cooling tower but can degrade it over time. There are issues such as microbiologically induced corrosion that can shorten the lifespan of a cooling tower. Essentially, keep your cooling tower treated and clean if you want to improve its lifespan. The basin of a cooling tower can accumulate sludge, vacuuming this is necessary when cleaning the tower. Additionally, fouling can occur in the fill media of a cooling tower with cleaning chemicals. Cleaning these and other areas of the cooling tower periodically will improve the lifespan of your cooling tower.
Chardon Labs has been in business for over 60 years. We are dedicated to helping you maintain your cooling tower. Our chemical water treatment team will extend the life of your cooling tower, protecting your investment. To book a free on-site survey or hear more about our services reach out via a quick contact form.
