When and How to Replace Cooling Tower Fills?

Cooling tower fills performs crucial performance in cooling tower system. They need regular maintenance and proper use to guarantee the high efficiency. But when the maintenance don't work so well, the cooling tower fill will use much more energy to do its job. To save money, guarantee the stable running of cooling tower, the worn-out cooling tower fills need to be replaced.

When Cooling Tower Fill Should Be Replaced?

• Increased Energy Consumption
  When the fills can't work, the water flowing through the cooling tower won't getting cooled. This means it will take more electricity to do the same job. While the electricity quantity your cooling tower uses suspend the normal, you need to check the cooling tower fills and see if it need to be replaced.
• Calcium Buildup
  Makeup water contains a lot of dissolved solids including Calcium. Calcium from hard water will build up in the fill causing blockage. When the fills clogged, the air and water cannot pass through smoothly and the cooling tower will not work as normal. If normal cleaning and maintenance cannot remove the Calcium, the cooling tower fills need to be replace in time.
• Uneven Distribution of Water
  Cooling tower can maximize the cold air and hot water contact area to cooling the water. When the water isn't being distributed properly because of the damaged or logged cooling tower fills, the performance will be dramatically impacted. So, you need to replace the cooling tower fills timely.
• Sagging & Warped Fill Packs
  If the cooling tower fills you installed is poor quality or the lifetime is too long, they may be warped from heat or sag with age. At that time, the cooling tower fills cannot work well as original. You need to replace the fill packs immediately.

How to Replace the Cooling Tower Fills?

1. Before the construction, other equipment need to be protected through necessary isolation and listing. Then lay the waterproof construction cloth on the floor.
2. Remove the old support grid.
3. Remove the old fills.
4. Install the support grid from the bottom upwards.
5. Install the fills from the bottom upwards, inside and outside following the support grid.

Note: The motor power should be turn off before beginning the replacement work. And more details of installation steps, just refer to the cooling tower fills installation of the new cooling towers and complete the replacement of fills.