In 2001 a major worldwide auto producer experienced a tragedy when 4 of its services upkeep staff became ailing with pneumonia-like symptoms that ultimately claimed the lives of two. The cause – Legionnaires Illness caused by the Legionella micro organism present in one of the manufacturers course of cooling towers. The corporate shortly moved to conduct a “trigger analysis” by inspecting its cooling towers worldwide to establish how programs had been being maintained and to determine best maintenance practices. This in the end led to the institution of a world class monitoring and upkeep procedure that ensures such a tragedy won’t ever be repeated at the corporate.
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How a Legionella Tragedy Can Happen
Interestingly, when someone becomes ailing from an unsafe cooling tower it most often is just not the results of an organization’s blatant negligence; relatively, it’s usually the result of an organization not having a transparent understanding of the need for his or her water therapy program to be in alignment with an efficient debris administration and cooling tower maintenance program. While it may seem apparent that if the amount of debris inside of a cooling tower exceeds the established biocide dosage, the demand placed on the dosage will quickly be consumed and could have little impact on the bioactivity. In other phrases, the debris and bioactivity occurring in a cooling tower can overwhelm the chemical dosage. It is well known and necessary to remember that cooling towers are highly environment friendly air scrubbers; anything drifting past a cooling tower is more likely to get caught in its draft and be sucked-in.
When natural debris resembling cottonwood seed, leaves, insects, pollen, grass, birds and their droppings, and so forth. get into the water and decompose, it together with the comparatively warm temperatures of the water create a nutrient wealthy setting for bacterial development including Legionella. Further, it is important to acknowledge that if the quantity of decomposing debris exceeds the chemical dosage’s means to provide management, the cooling tower will silently grow dangerous even whereas chemical dosing continues. The very fact of the matter is that it’s easy for companies to develop a false sense of security that their cooling towers are secure either as a result of they are treating the water themselves or, because they’ve employed a water remedy service to ascertain dosage ranges that should make sure the tower is protected. In both case, if natural debris management isn’t in alignment with water treatment dosage levels and made integral to the maintenance course of, there may be an increased chance of the tower changing into a health and safety hazard. It doesn’t matter how giant or small a company or a cooling tower is; micro organism together with Legionella would not discriminate – it’ll thrive in any poorly managed cooling tower!
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An Apparent Question
“What’s the wanted ratio of water remedy chemicals to that of debris load inside the cooling tower to make sure cooling tower safety?” Although the query is apparent, the reply is not. Natural debris is drawn into cooling towers in different concentrations relying upon location and time of yr. Each kind of debris locations a unique demand upon the biocides and scale inhibitors being dosed into the water; therefore, there is no recognized ratio that may hold constant for every cooling tower. Nonetheless, it’s safe to say that if you don’t deploy diligent maintenance procedures that particularly call for the prevention of natural debris from moving into the cooling tower or its periodic removal, more water therapy chemicals shall be required to keep it protected. Some could say, “load the tower up with chemicals to make sure safety”, nonetheless, federal and state EPA guidelines place restrictions on the quantity and sort of chemicals that can be used, therefore the use of chemical therapy alone will not be the answer. Furthermore, adding chemicals to offset poor maintenance practices is a shortcut that can do little to prevent fouling and clogging of the fill, strainers, blow down valves, chiller and heat exchangers and could finally result in well being and security issues and a reduction in equipment efficiency. Though the answer to the chemical ratio to debris question is not obvious, the reply to how to maintain a secure cooling tower is crystal clear and could be simply stated -“Keep the cooling tower free of debris and deploy a good water therapy program and your cooling tower will function safely and effectively.” This will likely sound like an over simplification, but in actuality if you keep the debris out of the cooling tower, you will break the micro organism supporting food chain. Moreover, whenever you chemically deal with the water you create an atmosphere non-conducive to micro organism habitation. In short, if you eliminate food and shelter for bacteria it will not take-up residence in your cooling tower!
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How to keep a Secure Cooling Tower
In recent years ASHRAE has established glorious recommendations for cooling tower maintenance often called Guideline 12. Along with recommending upkeep actions, it additionally calls for establishing procedures which might be measurable. Although ASHRAE pointers are glorious, firms should ultimately weigh the operational and financial realities of any upkeep process they deploy. Because the old saying goes “There’s more than one method to skin a cat”. If on the one hand upkeep procedures are too frequent, cumbersome or complicated, it commonly results in additional downtime, lost productiveness and better upkeep prices. Furthermore, the natural human tendency is to take shortcuts to rapidly complete an unpleasant job – often times with unsatisfactory results. Conversely, if the intervals between maintenance are too lengthy, it may be more price efficient, however the condition of the cooling tower at each interval may be lower than desirable and doubtlessly place upkeep staff, staff, tenants and the public in danger. So the reply largely lies someplace within the middle where water therapy and managing debris in the tower come collectively.
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As we speak, firms have many choices available to them for managing debris; they embrace a wide range of water based mostly filtration applied sciences and air intake filtration know-how. Water filtration can help manage waterborne and other debris after it will get into the cooling water whereas Air intake filtration know-how is very efficient at stopping airborne debris from entering into the tower by filtering the air because it enters the system. . Furthermore, air intake filtration may be used in glycol based mostly cooling techniques and on different air-cooled condenser programs to maintain airborne debris out of the coils, enabling optimal cooling efficiency.
When figuring out what maintenance and debris management expertise to use, it is important to first decide what the supply of debris is. If the source of debris is waterborne (e.g.; sediment, algae from pond or river, or water with high dissolved solids content), water filtration in combination with a great water treatment program is usually the most effective answer and can protect the chiller and heat exchanger from scaling and fouling. If alternatively, the supply of debris is airborne associated (cottonwood seed, insects, leaves, pine needles, paper, birds & droppings, harvest chaff, building debris, and many others), then water filtration techniques won’t cease the debris from moving into the cooling tower (particularly the fill).
For airborne debris associated issues, the perfect answer is to prevent the debris from stepping into the system by utilizing air intake filtration expertise that filters the air because it enters the system. Air intake filtration together with a very good water therapy program is extremely efficient in stopping the type of debris that clogs strainers, blow down valves, fill, chillers and heat exchangers – In brief, air intake filtration successfully protects the entire system. In extreme circumstances where both waterborne and airborne debris is problematic, both air intake filtration and water filtration in combination with a superb water therapy program could also be required in order to maintain the cooling tower secure and working effectively.
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