Cooling towers play a crucial role in the water-cooling systems of power generation plants, as well as in-process and petrochemical plants. They are essential for maintaining efficient operations. To achieve optimal efficiency, it is vital to have precise and dependable information about the outdoor wet bulb temperature. This information is necessary to prevent issues such as increased water and energy consumption and the premature wear of fans and pumps within the cooling towers. The operation of cooling towers also presents several safety and health challenges related to water usage. These challenges necessitate continuous monitoring and control of corrosion rates and microbiological growth. The corresponding chemical and physical water treatments are significant factors that impact overall energy consumption in cooling tower operations.

Course Objectives:

By completing this training course, participants will be able to:

Analyze the role of the cooling tower in the plant’s overall water-cooling system
Understand the operation and efficiency of different types of cooling towers
Explore the elements of safety of chemical and physical water treatment
Learn about the performance monitoring and record-keeping
Identify the important steps in the inspection of cooling towers
Learn about the best practices for preventive maintenance of the cooling tower

Who Should Attend?

Engineers and Technicians in Process Plants
Cooling Tower Operators and Supervisors
Technical Personnel in Charge of Maintenance and Repair
Technicians and Operators dealing with HVAC Installations

Course Outlines:

Overview of Cooling Towers and Applications:

Cooling Towers Types and System Configurations
Main Construction Elements
Essential cooling tower treatments
Why treat the waters?
Explain the cyclic process in cooling towers
Associated Equipment: Air Fans and Circulating Water Pumps
Installation Considerations: Recirculation and Environmental Issues
Cooling Tower Accessories and Options; Filters and Vortex Breakers

Operation and Efficiency:

Cooling Load Profile, Water Temperature Range, Approach and Drift Loss
Define efficiency in cooling towers
Operation of Cooling Towers: Regular and Intermittent Use: Year-Round Plan
Modern controls and techniques in cooling towers
PLC and DCS explanation for cooling towers control systems
Water quality requirements and how to measure
Cooling Tower Start-Up & Shut Down: Efficiency of Operation
Efficiency Considerations: Ways to Improve Overall Performance

Operation and Water Management:

Cooling Water Quality Management: Treatment and Monitoring
Water Treatment System Controls: Chemical Dosing
Bleed-Off Water Quality Control
Secondary efficiency measure
Concentration ratio measurement
Cathodic protection techniques to increase lifetime
Modern coating techniques

Water Treatment and Control:

Corrosion: Causes, Problems and Prevention Methods
Chemical Water Treatment: Inhibitors and Passive Methods: DCC Control
Explain Basic motors types in Cooling towers
Prober connection for all accessories (Electrical, Instrumentation)
Grounding connection
Physical Water Treatment Methods: Filtration Systems and Efficiency

Maintenance, Repairs, and Troubleshooting:

Maintenance & Repair: Routine and Preventive Best Practices
Inspection Check List for Mechanical Equipment: Fans and Pumps
Applying FMEA, DFMEA and PFMEA modern techniques to extend the lifetime
Safe operation as per manufactures
Different tests must be applied for all auxiliary systems
Risk Management of Cooling Tower System
Occupational Health & Safety Considerations

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