Cooling Towers

Learning Outcome
When you complete this module you will be able to:
Describe the operation and maintenance of cooling towers.

Learning Objectives
Here is what you will be able to do when you complete each objective:
1. List the factors that determine rate of cooling in a cooling tower, and the basic
components of a cooling tower .
2. Describe the construction and operation of a natural draft cooling tower.
3. Describe the construction and operation of a mechanical draft cooling tower.
4. Discuss cold climate operation for cooling towers.
5. Describe the water treatment necessary for cooling water.
6. Apply a cooling tower troubleshooting guide.

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INTRODUCTION
A cooling tower is a device that uses a combination of heat and mass transfer to
lower the temperature of the cooling water. The actual transfer of heat is
accomplished by a sensible heat transfer (heating the air passing through the
tower), and by the removal of latent heat as a result of the evaporation of about
5% of the water. As this small portion of water evaporates, the heat required is
drawn from the remaining water, thus cooling it.
The water to be cooled is distributed in the tower by spray nozzles and splash bars
to expose a very large water surface area to atmospheric air thus aiding
evaporation. Circulation of atmospheric air is accomplished by one of the
following methods: fans, convection currents, natural wind currents, or induction
effects from the water sprays.
The alternative to recycling cooling water through a cooling tower is to use a
once-through system with water from a stream or lake to cool equipment such as
refrigeration condensers and bearings.
Cooling towers are unquestionably the most common type of heat exchanger used
when cooling water is scarce, expensive, and a temperature within 4-6C
(7-10F) of the ambient wet bulb temperature is required.

PRINCIPLE OF OPERATION
The water to be cooled is delivered to the top of the tower by a pump and is
distributed in such a way that it falls through the tower in a finely divided spray.
Air flows through the tower causing part of the water to evaporate. The latent heat
of evaporation, carried away by the water vapour leaving the tower, causes a
reduction in sensible heat content in the remaining water, resulting in a
temperature drop. Some sensible heat is also absorbed by the air flowing through
the water spray. After dropping to the bottom of the tower, the cool water collects
in a basin and is pumped back to the system again.
The rate of heat transfer in any cooling tower system depends on the:
Relative velocity of both air and water during contact.
Area of water surface in contact with the air.
Length of contact time between the air and water.
Difference between the inlet water temperature and the inlet air wet bulb
temperature (relative humidity of the air).
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The basic components of a cooling tower are:

Inlet water distributing box or sprays

Packing or fill
Air moving equipment
Inlet air louvres
Drift eliminators
Cooled water basin

Cooling towers are divided into two classes according to the method of air
circulation. These classes are:
Natural draft
Mechanical draft
NATURAL DRAFT COOLING TOWERS
Natural draft cooling towers are subdivided into:
Atmospheric towers
Chimney towers (which are used mainly in large generating stations)
Atmospheric towers, shown in Figs. 1 and 2, are those in which the air movement
through the tower is dependent on atmospheric conditions. They operate
effectively only in locations where there are relatively constant winds and large
open spaces.

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Figure 1
Atmospheric Spray-Filled Tower

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Figure 2
Packed Atmospheric Tower

The sides of atmospheric towers are louvred and air flows across the tower by
natural currents. As the water falls from a perforated overhead flume or from
spray nozzles, down through the packing or decks, it strikes the faces of the tower
decking and breaks into fine particles. In this process, the fine particles of water
come in close contact with the air currents, enhancing the process of evaporation
and cooling.
To ensure continuous, effective operation of the tower, a monthly inspection
schedule should be implemented. This should include:
Cleaning the louvres, piping, and nozzles to ensure that they are free of
scale, algae, and dirt.
Cleaning the water basin and checking for leaks.
Cleaning the suction screen and checking that the float control valve is
operating properly.
Possible operational problems and their causes are:
High discharge water temperature from the tower. Probable causes of this
problem include high wet bulb air temperature, high concentration of
solids in the water, restriction of air flow through the tower, and poor
water breakup due to worn or dirty nozzles.
A reduction in water flow. This may be due to restrictions created by
algae, scale, or dirt.
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 Tower basin or sump overflowing. This may be caused by a clogged sump

screen, a restriction in the water outlet piping, or a leaking float control
valve.
Excessive water drift may be caused by excessive wind velocity, broken or
missing louvres, or excessive water pressure in the nozzles.

MECHANICAL DRAFT COOLING TOWERS

Mechanical draft towers use one or more fans to move large quantities of air
through the tower. They are divided into two classes:
Forced draft cooling towers
Induced draft cooling towers
The air flow in either class may be crossflow or counterflow with respect to the
falling water. Crossflow indicates that the airflow is horizontal in the filled
portion of the tower while counterflow means the air flow is in the opposite
direction of the falling water.

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The counterflow tower occupies less floor space than a crossflow tower but is
taller for a given capacity. The principle advantages of the crossflow tower are the
low pressure drop in relation to its capacity and lower fan power requirement
leading to lower energy costs.
All mechanical towers must be located so that the discharge air diffuses freely
without recirculating through the tower, and so that air intakes are not restricted.
Cooling towers should be located as near as possible to the refrigeration systems
they serve, but should never be located below them so as to allow the condenser
water to drain out of the system through the tower basin when the system is shut
down.
Forced Draft Cooling Towers
The forced draft tower, shown in Fig. 3, has the fan, basin, and piping located
within the tower structure. In this model, the fan is located at the base. There are
no louvred exterior walls. Instead, the structural steel or wood framing is covered
with paneling made of aluminum, galvanized steel, or asbestos cement boards.

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Figure 3
Forced Draft Tower

During operation, the fan forces air at a low velocity horizontally through the
packing and then vertically against the downward flow of the water that occurs on
either side of the fan. Water entrained in the air is removed by the drift
eliminators located at the top of the tower. Vibration and noise are minimal since
the rotating equipment is built on a solid foundation. The fans handle mostly dry
air, greatly reducing erosion and water condensation problems.

Induced Draft Cooling Towers

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The induced draft tower illustrated in Fig. 4 has one or more fans, located at the
top of the tower, that draw air upwards against the downward flow of water
passing around the wooden decking or packing. Since the airflow is counter to the
water flow, the coolest water at the bottom is in contact with the driest air while
the warmest water at the top is in contact with the moist air, resulting in increased
heat transfer efficiency.
The fans at the top discharge the hot, moisture laden air upward and away from
the air entering at the bottom of the tower, thus preventing any recirculation of
warm air. Warm water from the building enters the distribution system located
just under the drift eliminators. The fans and their drive are mounted on the top
deck.

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Figure 4
Counterflow Induced Draft Cooling Tower

Fig. 5 illustrates the actual components of a counterflow induced draft tower in

greater detail. This type requires large electric motors due to the tortuous path that
the air takes.

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Figure 5
Counterflow Induced Draft Tower

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A schematic drawing of another type of induced draft tower, called the crossflow
is shown in Fig. 6. Crossflow towers provide horizontal air flow as the water falls
through the packing. Single and double air flow designs are constructed to suit the
job location and operating conditions.

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Figure 6
Crossflow Tower Design
The fans, located at the top, draw air through cells or packing that are connected
to a suction chamber partitioned midway beneath each fan. The water falls from
the distribution system in a cascade of small drops over the packing and across the
horizontal flow of air. The total travel path of the air is longer and there is less
resistance to air flow than in the counterflow design.
A newer type of induced draft cooling tower design is illustrated in Fig. 7. The
tower basically consists of a venturi-shaped chamber, a spray manifold, and a
sump. Neither fill nor fan are required in this tower.

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Figure 7
Venturi Tower

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The water to be cooled is injected at the narrow end of the venturi by spray
nozzles, inducing a large airflow into the tower which mixes intimately with the
fine water spray. Heat transfer by evaporation of a small part of the water takes
place while the remaining water drops in temperature. The cooled water falls into
the sump and from there flows to the suction of the cooling water circulating
pump. The air containing the water vapour leaves the tower via the eliminators
and is discharged upward through a cowl.
The advantages of this tower are its quietness of operation due to the absence of
any moving parts and their associated noise and vibration problems, the
elimination of the need for electrical connections, starters, etc., the elimination of
fill, and the reduced maintenance requirements. A cross-sectional view of this
tower is shown in Fig. 8.

Figure 8
Venturi-Type Cooling Tower
(Courtesy of Baltimore Air Coil Co.)

Mechanical Draft Cooling Tower Maintenance

1. Lubricate the fan motor every three months, or as specified by the
manufacturer, using the recommended lubricant.
2. On V-belt driven fans, lubricate the fan shaft monthly and check the
tension on the belt.
3. All tower bolts should be checked monthly.
4. Check the float valve monthly.
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5. Clean and repaint corroding exterior metal surfaces annually. The interior
of the tower should also be inspected at this time.
6. Fan blades should be cleaned annually and painted if necessary.
7. Fans should be cleaned and balanced when high vibration levels are
detected.
8. A water treatment specialist should be consulted if scaling or algae
formation is evident.

COLD CLIMATE CONSIDERATIONS

Cooling towers do not generally need protection from freezing while operating.
An acceptable thin layer of ice may form on the louvres or air intake structure of
the tower. However, if heavy ice forms on the fill jeopardizing the existence and
operation of the heat transfer surface, or if heavy ice forms in a support region
threatening the tower structure, then action must be taken.
Control of both the water flow and the air flow can be useful. A bypass line is
used to direct water flow to the water basin beneath the tower instead of directing
it over the fill. Total bypass is used during startup in cold weather and a partial
bypass may continue during normal operations in especially cold weather. Only
when the water in the water basin reaches 27C (80F) should the bypass be
closed to cause total flow over the fill.
Air flow control through the use of two-speed or variable speed fan motors can
reduce the amount of cold air passing through the tower and hence reduce the heat
loss from the cooling water. Severe ice formation on louvres may require that the
fans be reversed for a period of time. This changes the pattern of falling water,
bringing a deluge of warm water in contact with ice formations for rapid melting.
When the tower is shut down, the water basin must not freeze. Thermostatically
controlled electric heaters or steam coils are sometimes used to prevent the basin
water from freezing. The indoor tank or dry basin method allows water to drain
continuously from the tower basin to an indoor storage tank from where it is
pumped to the refrigeration condensers. A bypass line from the tower supply line
is used to drain the supply line and to regulate the cooling water temperature
during cold weather and low loads, Fig. 9. During a shutdown situation, the
bypass line and the main basin drain allow all water to flow into the indoor tank,
thus removing all water from the freezing environment above the roof level.

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Figure 9
Indoor Storage Tank for Winter Freeze Protection

COOLING WATER TREATMENT

Makeup Water and Bleed-Off
As in evaporative condensers, cooling towers are equipped with a makeup water
supply to compensate for the water lost by evaporation. Both evaporative
condensers and cooling towers are equipped with a bleed line through which a
controlled amount of water is bled off to control the build up of scale-forming
salts in the water left behind by the evaporating water. Without the bleed line, the
chemical concentration would eventually get high enough to cause scale
formation and reduce the efficiency of operation. The amount of bleed-off will
depend on the cooling temperature range, quantity of water circulated, and the
condition of the water supply in the locality.

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Water Treatment
The following problems can occur in cooling towers:

Deposits of airborne solid particles

Scaling
Corrosion
Biological fouling
Wood deterioration

Proper operating procedures and chemical water treatment can control all these
conditions. The following discussion is only a brief overview. A reputable water
treatment specialist should be retained to establish and monitor an effective water
treatment program.
Airborne Particles
Since the tower is open to the air, airborne dust and debris can enter the water and
eventually plug up the system. Strainers or filters will remove most of this
material. They must be cleaned and maintained regularly.
Scaling
Scaling in cooling towers is not as severe as in boilers since the operating
temperatures are much lower. If the bleed-off mentioned earlier is insufficient to
prevent objectionable scale buildup, then a water treatment program is required.
In cooling towers, calcium carbonate scaling is the main scaling problem. It
normally results from the breakdown under heat of dissolved calcium bicarbonate,
a naturally occurring soluble salt.
The reaction is:
Ca(HCO3)2
calcium
bicarbonate

heat

CaCO3
calcium
carbonate

H2O
water

CO2
carbon
dioxide

The degree of scaling depends primarily on the concentration of calcium and

bicarbonate ions in solution and the pH of the cooling water. The rate of calcium
bicarbonate breakdown and calcium carbonate scaling increases with a rise in the
pH and temperature of the cooling tower water.
The traditional method of treating cooling tower water to prevent scaling is to add
sulphuric acid, causing the following reaction:
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Ca(HCO3)2
calcium
bicarbonate

+ H2SO4
sulphuric
acid

CaSO4
calcium
sulphate

2CO2
carbon
dioxide

2H2O
water

Calcium sulphate is more soluble than calcium carbonate. Although calcium

sulphate scale is harder to remove than calcium carbonate scale, the presence of
dissolved calcium sulphate in the cooling water can be tolerated so long as it is
kept in solution through proper pH control and bleed-off. Calcium sulphate
scaling increases with decreasing pH and increasing temperature.
Under a sulphuric acid treatment program, cooling tower water is usually
maintained at a pH of between 6 and 7.5 which necessitates additional treatment
to prevent corrosion of steel components in the cooling system.
Three basic methods of preventing formation of calcium scale in cooling water
systems are:
Calcium hardness is removed from the water through a softening process
prior to use.
Scale-forming salts are kept in solution.
The impurity is precipitated as a removable sludge rather than as a hard
scale.
Softening is accomplished by using an ion exchange softener or by cold-lime
softening which involves the addition of lime (calcium hydroxide-Ca(OH)). Coldlime softening causes the calcium carbonate to precipitate out in a settling tank
before the water enters the cooling system. This method is used mostly in
industrial situations.
Specialty chemicals are added that are able to keep scale-forming salts in solution
at high concentration levels. The most common chemicals used are polymeric
organics (polyaculates) and organic phosphorus compounds. However, some of
these compounds can accelerate corrosion of steel and copper. Some chemicals
can be completely destroyed by chlorine, which is added to control biological
growth. Cooling towers must be balanced with complementary corrosion and
biological controls. Operators should be aware that severe scaling will occur
rapidly if these chemicals be lost from the cooling water. Continuous and uniform
feed is necessary or heavy scale can form within minutes.

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Soft sludge formation is promoted by crystal modification chemicals, which

attach themselves to precipitating solids and prevent the crystals from joining
together in a hard scale. These are low molecular weight polymers such as
polymaleic acids and sulphonated polystyrenes. The sludge is removed by
blowdown from the tower basin or by side-stream filtration. When crystal
modifiers are used, the cooling water should appear turbid indicating that they are
taking effect.
The following table summarizes the applications of common scale control
chemicals.

Agent

Control Action
Solubilization

Lignin/tannin
Starch/alginates
Acids
Polyphosphates
Phosphonates
Phosphate esters
Low molecular
weight polymers

Dispersion

Crystal
Modification

X
X

X
X

X
X
X
X
X

Table 1
Scale Control Agents

Corrosion
Corrosion is the loss of metal resulting from direct chemical reaction or by
electrochemical action. The principle cause of steel corrosion in cooling towers is
dissolved oxygen in the cooling water. Under suitable conditions, the oxygen
combines with the steel to form rust (iron oxide).
The rate of corrosion increases with an increased concentration of dissolved
oxygen in the water. Since cooling tower systems continually aerate the water, the
amount of dissolved oxygen is high.
The rate of corrosion increases as pH decreases. Acidity or even low alkalinity
promotes corrosion by increasing both the dissolution rate of the base metal and
the oxide formation on the metal surfaces. Surprisingly, even a neutral pH of 7.0
or a slightly alkaline pH of 7.5 can be corrosive.
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Lastly, high temperatures will cause corrosion rates to double with every 15-30
degree Celsius rise in temperature up to 70C. Above 70C, further temperature
increases have relatively little effect on corrosion rates in cooling water systems.
The basic methods of corrosion control in cooling water systems, used singly or in
combination, are:
Use corrosion resistant metals and materials.
Apply protective coatings such as paint, metal plating, or epoxy.
Use sacrificial metals and/or induced electric currents to direct corrosion
to sites where it can be tolerated or accepted.
Form protective films with chemical inhibitors which are fed into the
cooling water and transported to the metal surfaces.
The traditional film-forming chemicals used are polyphosphates, chromates, and
zinc, often used in combination with each other to counterbalance severe sideeffects (such as the tendency of polyphosphate to attack copper and aluminum
while it is protecting steel). These chemicals form a thin film on the metal
preventing dissolved oxygen and carbon dioxide in the water from coming in
direct contact with the metal. While effective at corrosion control, these chemicals
cause unacceptable environmental damage when they are released through bleedoff or drainage of the system; therefore combinations that include chromates are
now generally discontinued in any systems from which water can escape into the
environment. Nontoxic alternatives involve zinc, polysilicates, and molybdates.
However, they can be more expensive than the traditional treatments.
Tables 2 and 3 illustrate typical chromate-based and nonchromate-based corrosion
prevention programs.

Treatment Chemicals

Concentrations

Chromate/zinc
Chromate/phosphate/zinc

5-10 ppm CrO4/5-10 ppm Zn

10-30 ppm CrO4/3-5 ppm
PO4/ 3-5 ppm Zn
5-10 ppm CrO4/5-10 ppm SiO2
10-30 ppm CrO4/1-5 ppm MoO4
5-10 ppm CrO4/3-5 ppm phosphonate

Chromate/polysilicate
Chromate/molybdate
Chromate/phosphonate1
1Phosphonate

serves as a scale inhibitor

Table 2
Chromate-Based Corrosion Prevention Programs
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Treatment Chemicals

Concentrations

Polyphosphate
Ortho/polyphosphate
Polyphosphate/zinc
Zinc/phosphonate2
Zinc/tannin2/lignin2
Polysilicate
Molybdate/phosphonate2
Polysilicate/molybdate
Phosphonate/polyacrylate2

10-30 ppm PO4

10-30 ppm total phosphate1
10-20 ppm PO4/1-3 ppm Zn
3-5 ppm Zn/3-5 ppm phosphonate
3-5 ppm Zn/50-100 ppm3
10-15 ppm SiO2
5-20 ppm MoO4/3-5 ppm phosphonate
10-20 ppm SiO2/1-3 ppm MoO4
5-20 ppm/10-20 ppm

1Usually

a 50/50 mixture
serves as deposit inhibitor
3Tannin plus lignin
2Chemical

Table 3
Nonchromate-Based Corrosion Prevention Programs

The speed with which inhibitors form their protective film varies considerably.
Chromate is the most rapid, requiring only a few days. Polyphosphate and zinc
take about 5 days, while polysilicates and molybdates can take 2 weeks. The
inhibitor must form a film everywhere on the metal surfaces. If the initial
concentration of the inhibitor is too weak, there is a good possibility of severe
corrosion occurring at unprotected sites since the entire corrosion potential will be
concentrated there. Rapid and severe pitting can occur.
Table 4 indicates the criteria for choosing a corrosion inhibitor for certain metals.
The limitations indicate the ranges of cooling water conditions for which the
inhibitor is appropriate.

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Inhibitor

Chromate
Polyphosphate
Zinc
Polysilicate
Molybdate
Copper inhibitor

Metal

Limitations

Steel

Copper

Aluminum

Calcium
ppm

Excellent
Excellent
Good
Excellent
Good
Fair

Excellent
Attacks
None
Excellent
Fair
Excellent

Excellent
Attacks
None
Excellent
Fair
Good

0-1200
100-600
0-1200
0-1200
0-1200
0-1200

pH

Total
dissolved
solids, ppm

5.5-10.0
5.5- 7.5
6.5- 7.0
7.5-10.0
7.5-10.0
6.0-10.0

0-20 000
0-20 000
0- 5 000
0- 5 000
0- 5 000
0-20 000

Table 4
Corrosion Inhibitor Criteria

Biological Fouling
Biological fouling of recirculating cooling towers is caused by algae, fungi, and
bacteria growth. The threat is uncontrolled growth of these organisms, which is
enhanced by the warm water, abundant sunlight, and the oxygen-rich environment
found in cooling towers.
These organic growths, called slime, can reduce flow rates in tubes and channels,
can release organic acids and waste products that can corrode metals, and can
attack and destroy the wooden portions of a tower.
Protection against biological fouling is of two types:
Mechanical methods such as trash bars and strainers.
Chemical methods that kill the microorganisms.
Chemical methods operate in several ways. Heavy metals penetrate the cell wall
and destroy protein groups essential to life support. Oxidizing chemicals such as
chlorine irreversibly oxidize protein groups, resulting in a loss of enzyme activity
in the cell and hence death of the cell. Nonoxidizing chemicals such as
chlorinated phenols pass into the cells and cause precipitation of proteins out of
solution inside the cell, causing death.
Table 5 indicates the effectiveness, applicability, and dangers of common
biocides.

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BACTERIA
Slime-forming

Microbiocide
Chlorine

Spore
formers

Nonsporeformers

Irondepositing

Corrosive

Fungi

Algae

+++

+++

+++

Oxidizing, dangerous to handle, corrosive to metals; powder, gas, or liquid;

delignifies tower wood; loses effectiveness at higher pH
Quaternary
ammonium salts

+++

+++

+++

++

++

+++

+++

+++

+++

++

+++

+++

+++

++

++

++

++

++

+++

Foams; cationic
Organo-tin
plus quaternaries
Foams; cationic
Methylene
bisthiocyenate

Not effective at pH above 7.5; nonionic

Isothiazolones

+++

+++

Dangerous to handle; loses effectiveness above pH 7.5; nonionic

Copper salts

+++

+++

+++

++

++

++

++

May cause copper plating

Bromine
organics

+++

Hydrolyzes, must be fed directly from drum

Organo-sulphur

++

+++

Toxic effluent; reduces chromate; anionic

Key to effectiveness rating: +++ Excellent, ++ Very good, + Slight, 0 None

Table 5
Biocide Applicability and Effectiveness

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The effectiveness of biocides is determined by the choice of biocides and their

feeding schedule. Biocides are slug-fed at toxic concentrations to the cooling
system usually twice a week. This method is called shock feeding and it kills
microbiological organisms most effectively by creating a temporary high
concentration of a biocide.
Shock feeding one biocide only will result in organisms becoming immune to that
particular biocide. To prevent this, once a month an alternate biocide is slug-fed
for one week so as to kill off any organisms that are becoming immune to the first
biocide. To prevent dead microbiological growth from fouling cooling systems,
dispersants are added during biocide slug feedings so dead growth will be held in
suspension until it is removed through bleed-off.
Operators should be aware that biocides are poisons and extreme caution should
be employed when working with them. Precautions include rubber gloves,
protective clothing, and eye protection.
Wood Deterioration
Cooling towers may contain a lot of wood which is subject to biological and
chemical attack, resulting in severe wood deterioration. Wood is composed of
cellulose, lignin, and natural extractives. Cellulose exists as long fibres giving
wood its strength. Lignin cements the cellulose fibres together. The extractives
contain the natural compounds that enable wood to resist decay. Unfortunately,
the extractives are water soluble and leach away, leaving wood in cooling towers
vulnerable to decay.

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Chemical attack occurs mainly as delignification. Oxidizing agents such as

chlorine and alkaline solutions are the main agents of delignification. Controlling
delignification is accomplished through use of nonoxidizing biocides or by
keeping the chemical concentration of oxidizing agents sufficiently low.
Biological attack of cooling tower wood occurs as a deterioration of the cellulose
which is a source of carbon for the growth and development of microorganisms.
Methods of control include:
Choosing woods such as redwood that have a natural resistance to
biological attack.
Treatment by wood preservatives such as creosote or chromated copper
arsenate, among others.
Very limited use of nails, screws, or iron hardware which accelerate wood
deterioration in their vicinity.
Water treatment with biocides.
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COOLING TOWER TROUBLESHOOTING GUIDE

TROUBLE

Excessive water
drift

CAUSE

Faulty drift
elimination

REMEDY

1. Check to be sure all louvres,

eliminator sections, or slats and
splash retainers are in place.
2. Top deck assemblies (on early
models) and wood fill splashbars
must be intact and level. There
must be no tendency to channel
water.
Fill packs must be intact and in
place with no sagging or gaps
between packs.
3. Metering orifices of hot water
basins must be in place and clean
of debris.
4. There must be no leaks under hot
water basin sides.

Motor will
not start

Overpumping

Reduce water flow to tower to design

conditions or use larger metering
orifices.

Power not available

at motor terminals

1. Check power at starter. Correct any

bad connections between the
control apparatus and the motor.
2. Check starter contacts and control
circuit. Reset overloads, close
contacts, reset tripped switches or
replace failed control switches.
3. If power is not on all leads at
starter make sure overload and
short circuit devices are in proper
condition.

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TROUBLE

Motor will
not start
(continued)

Unusual motor
noise

CAUSE

REMEDY

Wrong connections

Check motor and control connections

against wiring diagrams.

Low voltage

Check nameplate voltage against

power supply. Check voltage at
motor terminals.

Open circuit in
motor winding

Check stator windings for open

circuits.

Motor or fan drive

stuck

Disconnect motor from load and

check motor and gear reducer for
cause of problem.

Rotor defective

Look for broken bars and rings.

Motor running
single-phase

Stop motor and attempt to start it.

Motor will not start if single-phased.
Check wiring, controls, and motor.

Motor leads
connected
incorrectly

Check motor connections against

wiring diagram on motor.

Ball bearings

Check lubrication. Replace bad

bearings.

Electric unbalance

Check voltage and currents of all

three lines. Correct if required.

Air gap not uniform Check and correct bracket fits

Rotor unbalance
Rebalance.
Cooling fan
hitting guard

Reinstall or replace fan.

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TROUBLE

Motor runs hot

CAUSE

REMEDY

Wrong voltage or
unbalanced voltage

Check voltage and current of all three

lines against nameplate values.

Overload

Check fan blade pitch. See fan

service manual. Check for drag in fan
drive train as from damaged bearings.

Wrong motor
r/min

Check nameplate against poser

supply. Check r/min of motor and
gear ratio.

Bearings
overgreased

Remove grease reliefs. Run motor up

to speed to purge excessive grease.

Rotor rubs stator

bore

If not poor machining, replace worn

bearing.

Wrong lubricant
in bearings

Change to proper lubricant. See

motor manufacturers instructions
and electric motor manual.

One phase open

Stop motor and attempt to start it.

Motor will not start if single-phased.
Check wiring controls and motor.

Poor ventilation

Clean motor and check ventilation

openings. Allow ample ventilation
around motor.

Winding fault

Check with ohmmeter.

Bent motor shaft

Straighten or replace shaft.

Insufficient grease

Remove plugs and regrease bearings.

Deterioration or
foreign material
in grease

Flush bearings and relubricate.

22
PPEQ 6002

TROUBLE

Motor runs hot

(continued)

Motor does not

come up to speed

CAUSE

REMEDY

Bearings damaged

Replace bearings.

Incorrect fan
blade pitch

See fan service manual for blade

pitching instructions.

Voltage too low

at motor terminals
because of line
drop

Check transformer and setting of

taps. Use higher voltage on
transformer terminals or reduce
loads. Increase wire size or reduce
inertia.

Broken motor bars

Look for cracks near the rings. A new

rotor may be required. Have motor
service company check motor.

Wrong rotation
(motor)

Wrong sequence
of phases

Change any two of the three motor

leads.

Gear reducer
noise

Gear reducer
bearings

If new, see if noise disappears after

one week of operation. Drain, flush
and refill gear reducer. See gear
reducer service manual. If still noisy,
replace.

Gears

Correct tooth engagement. Replace

badly worn gears. Replace gears with
imperfect tooth spacing or form.

23
PPEQ 6002

TROUBLE

Unusual fan drive

vibration

CAUSE

REMEDY

Loose bolts and

cap screws

Tighten all bolts and cap screws on

all mechanical equipment and
supports.

Unbalanced drive
shaft or worn
couplings

Make sure motor and gear reducer

shafts are in proper alignment and
match marks properly matched.
Repair or replace worn couplings.
Rebalance drive shaft by adding or
removing weights form balancing cap
screws. See drive shaft service
manual.

Fan

Be sure blades are properly

positioned in correct sockets. Check
match numbers. Make certain all
blades are as far from center of fan as
safety devices permit. All blades
must be pinched the same. See fan
service manual. Clean off deposit
built-up on blades.

Worn gear reducer

bearings

Check fan and pinion shaft endplay.

Replace bearings as necessary.

Motor

Disconnect load and operate motor. If

motor still vibrates, check for bent
shaft or unbalanced rotor. Replace
shaft or rebalance rotor.

Bent gear reducer

shaft

Check fan and pinion shafts with dial

indicator. Replace if necessary.

24
PPEQ 6002

TROUBLE

Fan noise

Scale or foreign
substance in
water

Wood
deterioration

CAUSE

REMEDY

Loose fan hub

cover

Tighten hub cover fasteners.

Blade rubbing
inside of fan
cylinder

Adjust cylinder to provide blade tip

clearance.

Loose bolts in
blade clamps

Check and tighten if necessary.

Lack of or
insufficient
blowdown

Increase bleed off or consult a water

treatment specialist.

Water treatment

Consult competent water treating

specialist.

Improper water
treatment or
micro-biological
attack

See tower manufacturer sales

representative or water treatment
specialist.

25
PPEQ 6002

Notes:

26
PPEQ 6002