Cooling Towers provide the Perfect Storm for Corrosion and Oxidation and they must be maintained and rejuvenated regularly or they will need to be replaced prematurely.
Protecall’s Cooling Tower Restoration System consists of an array of coating solutions that provide superior corrosion and protection from scaling and microbiological growth, extending the life of your system while increasing efficiency. Our coatings can be applied in a wide range of temperatures to allow for work throughout the winter and non-operational times of service. Our system includes Rust Grip® moisture cured urethane for structural steel & dunnage, DTM’s that continue to cure while under water and high solid epoxies that can be built up to repair typical basin failures.
Case Studies – Cooling Tower Restoration
Cooling Tower Restoration Completes NJ Clean Energy ESIP (Energy Savings Improvement Program)
Aging HVAC Systems including: Controls, Chillers, Boilers, Insulation & Cooling Towers were in need of repair or replacement for years but could not be addressed without the NJ Clean Energy ESIP. Protecall partnered with Nass-Tech Mechanical and Vanderweil Engineering to restore and upgrade (2) 26 year old, 150 ton cooling towers that were deteriorated and failing.
The rust, mineral corrosion and microbiological growth was mechanically removed. The rusted sheet metal and transitions were cut out and replaced. The interior and exterior of the towers were completely resurfaced & the Fill was replaced. Nass-Tech replaced the valves & pumps.
The cooling tower was restored to like new condition and was a true testament to the necessity of the NJ Clean Energy ESIP programs.
Cooling Tower Restored at Food Processing Plant
The existing cooling tower was experiencing significant corrosion and deterioration of the steel dunnage and cabinet, including heavy calcium buildup and oxidation of the basin, leading the owners to consider a full tower replacement.
After proper surface preparation and cleaning, HVAC Armor XT was applied to the exterior cabinet and dunnage, and HVAC Armor CT was applied to the interior of the basin and walls to inhibit the microbiological growth and oxidation that had been occurring.
The cooling tower no longer needs replacement and has been restored to like new condition, preventing further corrosion and providing a cleanable basin for a long lasting solution.
Restored Cooling Tower Saves Energy at a Fraction of the Cost to Replace
Years of unprotected cooling tower operation caused severe dunnage deterioration, cabinet corrosion, calcium and algae build up in the basin and oil fouling in the chiller.
After proper cleaning an preparation HVAC ArmorXT was applied to the exterior cabinet and dunnage, HVAC ArmorCT was applied to the interior of the basin and walls and HVAC ArmorOF was installed in the chiller to treat the oil-fouled refrigerant.
The Chiller System is restored to like new condition and operating 15% more efficiently.