How to replace cooling tower fill

Cooling tower fill is one of the core components of a cooling tower, whose main function is to expand the contact area between water and air, thereby improving the efficiency of evaporation and heat dissipation. With long-term operation, the fill may experience aging, blockage, deformation, or scaling, leading to a decrease in cooling efficiency, an increase in energy consumption, and even affecting the safe operation of the equipment. Therefore, regular inspection and timely replacement of cooling tower fill are crucial.

When is it necessary to replace the cooling tower fill?

The following situations usually indicate the need for fill updates:

1. Aging or brittleness of fills

PVC fillers will age, break and pulverize easily under high temperature or long-term operation.

2. Severe scaling or blockage occurs

The surface of the fill is covered with a large amount of scale, algae, and sediment, resulting in:

1)Uneven distribution of water

2)Increased wind resistance

3)The cooling efficiency has significantly decreased

3. The circulating water temperature rises

If the outlet temperature of the cooling tower exceeds the normal value by 2-5 ℃ for a long time, it may be caused by packing failure.

4. The filling material falls off or collapses

Damage to the supporting structure or improper installation of fillers may result in collapse and must be replaced immediately.

Preparation work before replacing the cooling tower fill

Before construction, the following preparations should be made:

1. Stop the machine and cut off the power supply

Ensure that the cooling tower and related equipment are completely shut down to avoid danger.

2. Drain the circulating water in the cooling tower

Ensure that the operating area is dry and easy to disassemble.

3. Prepare tools and equipment

Common tools include:

1)Wrench, screwdriver

2)Cutting tools (such as art knives or electric cutting machines)

3)Plastic zip ties, stainless steel wire

4)Labor protection equipment (safety helmet, protective gloves, anti slip shoes)

4. Check the specifications of the new fill material

Confirm that the fill material, thickness, spacing, model, and direction meet the requirements of the cooling tower manufacturer.

5. Check the support system

Ensure that the grille and support beams are not corroded or deformed; Replace or repair synchronously when necessary.

Precautions for replacing cooling tower fill

1. Choose high-quality fills

Priority should be given to selecting fillers from the original factory or those with the same design parameters to avoid affecting performance.

2. Avoid stepping on the filling material

Construction personnel need to use foot pedals or temporary frames to avoid stepping on new fill materials.

3. High temperature water towers require the use of high-temperature resistant fillers

If the export temperature exceeds 50 ℃, PP filler should be used instead of PVC.

4. Ensure good ventilation environment

The construction area may be damp, so attention should be paid to slip resistance and safety.

5. Regular maintenance to extend lifespan

It is recommended to check the filling status every 6-12 months.