Here’s a clear, practical guide on cooling tower nozzle replacement — what to check, how to choose the right replacement, and the steps to change them safely.
✅ Cooling Tower Nozzle Replacement Guide
1. When Should Nozzles Be Replaced?
Replace spray/distribution nozzles if you notice:
* Uneven water distribution on fill
* Reduced thermal performance
* Clogged or partially blocked orifices
* Cracked ABS/PP/nylon material
* Missing splash cones or diffusers
* Excessive scale buildup that can’t be cleaned
✅ 2. Types of Cooling Tower Nozzles
Before replacing, confirm the type used in your tower:
A. Splash / Spiral Nozzles
* ABS or PP material
* Common in Marley, BAC, Evapco towers
* Install by threading, snapping, or hanging
B. Target / Orifice Nozzles
* Used in pressurized systems
* Brass, ABS, or PP
* Designed for consistent droplet distribution
C. Full-cone or Hollow-cone Spray Nozzles
* Used in pressurized towers
* Available in multiple orifice sizes for precise flow control
✅ 3. How to Select the Correct Replacement Nozzle
Match the following specifications:
✔ Mounting Type
* **Threaded (½”, ¾”, 1”)**
* **Snap-in**
* **PVC pipe end–mounted**
* **Bayonet-type / clip-on**
✔ Flow Rate & Pressure
* Usually 2–10 psi in gravity systems
* 10–25 psi in pressurized systems
* Nozzle DPM (drops per minute) and GPM rating must match OEM
✔ Spray Pattern
* Full-cone is most common
* Angle typically 90°–120°
✔ Material
* ABS (most common)
* PP (chemical resistant)
* Nylon (high temp)
* Brass / stainless steel (industrial, high-pressure)
If you tell me your tower brand (Marley, BAC, Evapco, Liang Chi, etc.), I can identify the exact nozzle type.
✅ 4. Step-by-Step Replacement Procedure
Step 1 – Shut Down & Lockout
* Turn off fan and pump
* Isolate water supply
Step 2 – Access Hot Water Basin or Header
* Remove basin covers
* Drain or lower water to safe level
Step 3 – Remove Old Nozzles
* Unthread by hand or with pliers
* Snap-in types: twist and pull
* Clip-on types: release retaining clips
Step 4 – Inspect Distribution Pipes / Basin
* Check for cracks, blockage
* Clean debris, algae, scale
Step 5 – Install New Nozzles
* Ensure proper orientation
* Do not overtighten plastic nozzles
* For snap-in types, confirm a tight seat
Step 6 – Check Orifice Size
* Verify consistency across the basin
* Replace all nozzles in a cell (best practice)
Step 7 – Restart the Pump
* Observe water distribution
* Look for:
* Dead spots on fill
* Overspray/underspray
* Leaks or misalignment
✅ 5. Recommended OEM & Aftermarket Nozzle Sources
If you need a list of manufacturers, here are common options:
* Marley / SPX – Spiral Target Nozzles
* BAC – Steel and plastic nozzles
* Evapco – ABS orifice nozzles
* Longhua / Liang Chi – Hanging ABS nozzles
* Delta – Polyethylene nozzles
