Cooling towers

COOLING TOWERS

Introduction

A cooling tower is a device used to reduce the temperature of water. The water is then recycled back into the many processes and industries that use it. Some industries use the water to control the temperature (sensible heat), of a process, like a car radiator. The HVAC industry uses the water to condense the refrigerant (latent heat). In the past most of the processes requiring cooling use piped town water through the equipment, cooling the equipment, and then drained the water to the gutter (100% waste). Because Australia is such a dry continent the water supply authorities introduced the Water Conservation Act, which forced all the industries to install cooling towers to recycle the water.

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Terminology Approach, is the difference between the temperature of the water leaving the tower and the Wet Bulb temperature of the air entering the tower. Generally between 4 6K. The smaller the approach the more efficient is the tower Range, is the difference between the temperature of the water entering and the water leaving the tower. Generally between 8 10K. Drift, is the evaporated water carried out of the tower with the air. The amount of drift must be controlled because the microorganisms can live in the drift and travel to and infect humans. (Legionaries Disease) Drift Eliminators, are to catch and condense the tower water as it is discharged as drift, causing it to fall back into the tower basin as droplets. Bleed Off, is the amount of tower water that is purposely drained away to waste in order to dilute the circulating water with fresh town water. This is needed as only the H2O evaporates leaving behind all the minerals that get into the tower water. The H2O is constantly evaporating to reduce the temperature of the remaining water. Fill, is the component of the tower that causes the circulating water to spread out over a large surface area, which will increase the evaporation rate by offering the water to a greater volume of air. Water Distribution System, is designed to evenly spray the circulating water over the Fill. Make Up Water, is the fresh town water that is constantly being fed into the tower basin via a Ball Valve, to replace the water that is lost to; Drift (Evaporation) Bleed Off Louvers, are there to reduce sunlight on the water inside but allow air to be directed onto the fill. They also retain the splash from the droplets falling from the fill. Plume. Under certain atmospheric conditions the drift leaving the tower with condense as it hits the surrounding air. It looks like fog but because it originates from a process it is referred to as Plume. Dissolved Solids. The particles of dirt and minerals that circulate with the water rather than sink to the bottom as mud. Side Filtration. Some of the circulating water is pumped through a filter to remove the dissolved solids. Inhibitor. Is a chemical added to the circulating water to prevent the dissolved solids in the water causing rust and clogging the systems tubing. Microbial Growth. Or bio-fouling is the Algae, Fungi and Bacteria that find the cooling tower environment ideal for their growth. Biocide. A chorine base chemical added to the circulating water to prevent microbial growth. Ultra violet light. Is another method of killing bacteria where the circulating water is passed through clear tubes that are exposed to ultra violet lights. The water must be kept very clean with filters for this method to work (side filtration). Ozone injection. Another means of killing bacteria. Monitoring. Of the circulating water is needed to ensure the chemical additives are at the required concentration. Legionnaires Disease. Is caused by the bacteria Legionella Pneumophilia Bacillus, which grows in the cooling tower water and infects humans as they breathe in the aerosols from the tower discharge.

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Construction

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Operation

The Basic Principle of Operation. Evaporating some of the circulating water, cools the majority of the water in a cooling tower. How it Works The evaporation process only takes place on the surface of a liquid and needs latent heat of vaporization to happen (2256 kJ/kg). Sensible heat (4.19 kJ/kgK), is drawn from the body of the water to the surface to supply the energy needed for the latent heat. It can be seen that for a little evaporation a lot of sensible heat will be needed therefore the main body of the circulating water is cooled for very little lost of water. Warm to hot water from the cooling process is pumped to the top of the cooling tower and into the sprays where the water is broken up into droplets and distributed over the Fill. The water droplet spreads out as it slides down the Fill creating the surface area necessary for evaporation. The evaporation rate of the water is restricted by the amount of moisture already in the air around it. To maintain evaporation the moistened air must be replaced with dry air, usually by fans blowing air through the tower, (see types of towers). A cooling tower takes the heat transfer law the greater the exposed surface area, the greater will be the rate of heat transfer

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Types of Towers

Two basic types;

Natural Draft Mechanical Draft
Natural Draft Towers, rely on the heat of the water to generate the air movement inside the tower. They are only used for very large capacity where systems they are such as Electricity Generation Plants, called

Hyperbolic Towers.

Cooling towers are not part of the refrigeration system, as no refrigerant flows through them.

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Mechanical Draft, are fitted with fans to improve the airflow through the tower which increases the evaporation rate of the water which increases the capacity of the tower. Mechanical Draft Towers are used just about everywhere including the HVAC industry. Generally a centrifugal fan is used to force the air into a tower, and tube axial (propeller) fans are used to induce the air out the tower. Mechanical towers are classified by the way the air flows through the water. (remember, the water always falls). Induced draft cross flow Induced draft counter flow Forced draft cross flow Forced draft counter flow

Forced draft cross flow Induced draft counter flow

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Evaporative Condensers. An evaporative condenser (EC), is considered to be part of the refrigeration system as it directly condensers the refrigerant. An EC doesnt have fill it uses the refrigerant piping to break up the water drop as they spread around the piping absorbing Latent Heat directly from the refrigerant.

Evaporative Condenser and Chillers Circuit

Capacity control for evaporative condensers is limited to varying the volume of air flowing in to the fan.

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Water Circuits
Open Water Circuit. These systems have the water that is doing the condensing or cooling being passed through the air to reject the heat, e.g. a cooling tower is an Open Water Circuit system. Closed Water Circuits, (like a car radiator) The condensing water in this situation is contained within a closed loop circuit (i.e. the water being circulated between the evaporative cooler and the shell and tube condenser never comes in contact with the outside atmosphere). The water is pumped through a device only the like gives an the up evaporative sensible condenser from although

water in the tubes heat

circulating

water. The cooled circulating water is then fed to the remote water-cooled condensers, (generally the shell and tube type). This arrangement is common in situations where a large number of individual condensing units are used (e.g. supermarkets). Closed water circuits operate with a high Td because the heat energy is passed from the refrigerant to the closed circuit water (in the shell and tube condenser) and then from the closed circuit water to the water in the evaporative cooler, then to the air.

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CAPACITY CONTROL In order to maintain the required condensing or process temperature against the changing ambient WB temperature and varying load, cooling towers need some form of capacity control. The capacity of the tower depends on the wet bulb temperature of the air entering the cooling tower. 1. The simplest form of control is Fan Cycling. It is inexpensive, but the fan should not be cycled too often as it can lead to motor burnout. This system is used on
The lower the WB temperature the greater the capacity

single and multi fan units, and units that do not require critical temperature control.

2. The next step is to have multi speed fan motors with cycling control combinations. This method offers reduced operational costs and broader capacity control. Useful on single fan towers. Both of the methods described above are used on tube axial fan units. Centrifugal fans normally use the following. 3. Modulating dampers are placed in the inlet of the centrifugal fan housing. As the water temperature reduces the dampers are moved towards a closed position. is used. 4. If the ambient remains above freezing a modulating valve can be used to recirculate the water back to the condenser bypassing the cooling tower. This method of capacity control is also used when multiple condensers are connected to the one cooling tower. If they close fully the modulating motor will trip a limit switch isolating the fan motor. This method offers the best regulation if the fan type capacity control

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CALCULATING THE CAPACITY

Three factors need to be known: The mass flow rate of the water flowing through the tower (kg/sec) The specify heat capacity of the water (kJ/kg.K) The change in temperature of the water (RANGE of the Tower). Where: Q = M = c = = THUS: Quantity of energy in kJ/sec ( or kW) Mass Flow Rate kg/sec (or L/s) Specific heat in kJ/kg.K (c of water = 4.19 kJ/kg.K) Change in Temperature (K) Q = M c

EXAMPLE 1 A Cooling Tower has 6.7 litres (6.7kg/sec), of water passing through it per second. The water is entering the tower at 34o C and leaving the tower at 28 o C. Calculate the capacity. 6.7kg/sx4.19kJ/kg Kx6K 6.7x4.19x6 168.438 kJ/s or (kW)

APPROACH The APPROACH is the difference of the WATER LEAVING the tower and the WB TEMPERATURE of the AIR ENTERING the tower. With a WB temp of 22 'C, Approach = Water temp leaving - WB temp of air entering = 28C-22C = 6K

RANGE The RANGE is the difference between the temperature of the WATER ENTERING the tower and the WATER LEAVING the tower. Range = 34C - 28C = 6 K

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Water used over the operational time of the tower

Water will be lost because of the evaporation of water and a percentage of water will be bled off to reduce TDS. Evaporation requires Latent Heat, LH = 2256 kJ/kg this is a constant. Our example system has a capacity to remove 168.438 kJ/s of heat so if we divide the capacity by the latent heat the answer will be the amount of water evaporated to carry away the heat from the system. Water = Q LH 168.438kJ/sec 2256 kJ/kg = 0.075kg/sec.

The amount of water bled off to waste is proportional to the amount of water evaporated, which is proportional to the Range of the tower and the flow rate. Therefore our example system has a towers range of 6K, which equals 0.41% bleed off. Convert % to decimal (0.41 / 100) that equates to 0.0041 Bleed off rate = Flow rate (kg /sec) x % of bleed off (as a decimal). 6.7kg/sec x 0.0041 = 0.0275kg/sec. If our example tower operates for 12 hours (12 x 3600 sees) each day then the volume of water used will be; Operation time (in seconds) x Evaporation Rate + Bleed off rate (kg/sec) Water used =12 hours x 3600 secs x (0.075 kg/sec + 0.0275kg/sec = 4426.7 litres

Cooling Range K % of Bleed Off. 3.5 0.15 4.0 0.22 5.5 0.33 6.0 0.41 8.5 0.55 11.0 0.75 15.0 1.00

OTHER FACTORS (affecting the Tower Capacity) The amount of surface area the water evaporates off and length of exposure time; The velocity of the air passing through the cooling tower (too fast results in excessive 'drift'); The direction of airflow in relation to the water flow.

The lowest temperature to which the water can be cooled is the W.B. temperature of the air entering, in which the water vapour in the leaving air will be saturated, (any heat removed will cause the water to change back to a liquid).

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Review questions.
1. What type of heat is removed by the cooling tower water for the purpose of the HVAC industry? . 2. Why did Australia introduce cooling towers? . 3. What is Bleed Off? .. 4. Why can Dissolved Solids become a problem? .. .. 5. List the two types of Biocides? 6. How do humans catch Legionnaires Disease? 7. How is cooling of the water achieved in a cooling tower? 8. Why is the greater surface area heat transfer law applied to cooling towers? 9. What will restrict the amount of heat transfer within a cooling tower? .. .. 10. List the two basic types of cooling towers? . . 11. Where are hyperbolic towers used?

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12. List the four types of fan draft towers? 13. What two types of fans are used on cooling towers? .. .. 14. Is an evaporative condenser part of the refrigeration system? 15. Do evaporative condensers have fill? .. 16. List the two types of water circuits? 17. What is the difference between them? .... . 18. Why is capacity control necessary on cooling towers? . . 19. List the types of capacity control devices used on cooling towers? . . 20. Explain why a modulating valve is needed on multiple condenser systems? . .. ..

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Legionnaires Disease
Legionnaires Disease is a form of pneumonia that can be fatal. It is caused by the common bacteria Legionella Pneumophila Bacillus. It is possible for anyone to catch the disease, provided the bacteria can get to the deep parts of the lungs where the disease can grow, but certain groups within the community are more prone to the illness that are others. The groups most at risk generally include people with one or more of the following characteristics: Age over 50 years of age; Are male; Have a history of smoking; Have a history of heavy alcohol intake; Have a medical condition or are undergoing a treatment that impairs the bodys natural defence mechanisms. Legionella is found in moist environments such as Lakes, Rivers, Creeks, Mud and other water sources at temperatures ranging from approximately 5oC to 55oC. However no cases of Legionnaires Disease has been proven to have been caused by Legionella present in the natural environment. All of the Legionnaires Disease outbreaks have been attributed to man made environments. The optimum conditions for the multiplication of Legionella Bacteria has been shown to be between 35oC and 37oC with an acid balance between pH 6.5 and pH 6.9. COOLING TOWERS and, EVAPORATIVE CONDENSERS provide this environment. The primary concern with the cooling tower is its ability to spread the Legionella over a vast area due to the Drift (aerosols) carrying the bacteria from the tower. The aerosols are small enough to get into the lungs.

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Operational and Servicing Checks of Cooling Towers

Before working on any cooling towers you must be aware and familiar with the following Legislation The NSW Public Health Act 1991, Part 4, and the Regulation 2000 covers cooling towers and lays out the laws controlling the maintenance and cleaning of cooling towers, in the Public Health Act, a cooling tower is referred to as a Regulated System. Other states may have their own statuary requirements. Standards AS/NZS3666 parts 1,2,3. Part 1 covers installation of Air Handling and Water Systems. Part 2, covers Operation and Maintenance. Part 3, covers control of Legionella through constant monitoring of water quality. In New South Wales the AS/NZS 3666 has been incorporated into the Public Health Act, so anything in AS/NZS 3666 is enforceable by the act. Hand Book 32 (HB32), explains the Australian Standard 3666 and helps to show how some procedures are to be done. The New Zealand standard uses another publication. Code of Practice. By the NSW Health Department. Explains what the Health Department wants done to control microbial growth. On page 29 of the code of Practice it states that only competent persons be employed to carry out work on regulated systems. To be classed as competent, a person needs to have completed some form of recognized training. Therefore it is recommended that any person that is required to work on a cooling tower complete a Health Department approved course,

As part of the licensing agreement with the NSW Department of Fair Trading, the refrigeration trade course must contain an element of microbial control and the Public Health Act part 4, and the Regulations
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Class Exercise. Aim. To be able to use AS/NZS 3666 parts 1, 2, 3, the Public Health Act and Regulations. Purpose. Because of the requirement of the Department of Fair Trading licensing, and because the standards are incorporated into the NSW Public Health Act you must be able to reference information from them. Task. Use the Australian standards, Acts and Regulation to locate the answers for the following questions. Record where you found the answers.

a. What is the purpose of the Public Health Act part 4 or any other state equivalent Act.

b. In order to comply with AS/NZS 3666.2 what manuals must be with the regulated system?

c. What is the required interval between cooling tower cleans?

d. Can a cooling tower that does not have a working disinfection process installed be turned on?

e. From the NSW PH.act Regulation 2000, list the two maintenance precautions?

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f. Use AS/NZS 3666.2 to list the personal protective equipment needed to clean a cooling tower?

g. According to AS/NZS 3666.2 what must be done to an evaporative cooler every three months?

h. How often should a water sample be taken? Refer to AS/NZS 3666.3

i. How long should the results from water sample be kept? ..

j. List the requirements for the location of air intakes according to AS/NZS 3666.1?

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Safety
Personal Safety.
Clothing should conform to Australian Standards AS/NZS 3666, part 2, which incorporates other standards, AS 1715 and AS 1716. AS 1715 specification of respirators and AS 1716, the wearing of the respirators and masks. The gloves and waterproof coveralls are used to protect your skin from the biocides in the circulating water.

Only used to take water sample

Full Face Cartridge Respirator

Wear gloves, waterproof shoes and water resistance coveralls and a half face respirator with P2 grade twin filter

Public safety.
Always restrict public access when cleaning, and ensure that the cleaning spray is contained within the operational area.

The safety and responsibilities can not be stressed enough when microbial infection is involved

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Taking a Water Sample. Safety. If the sample has to be taken from an operational tower, then all the appropriate safety clothing should be worn. Make sure the gloves are long enough so that none of the circulating water will come into contact with the skin. Equipment. A sterile 250ml re-sealable container, containing Sodium Thiosulphate to neutalize the chlorine. Usually supplied by the analysing company. A means of keeping the sample between 2 and 6oC, while transporting it for analysing. A means of recording sample location and time of sample taking.

Procedure. Only open the container once it is in the water to be sampled. Do not open it and leave it sitting, as other contamination can enter giving false readings. Take the sample from circulating water, not some place where the water is still. Place the container in an insulated transport vessel. Do not leave in direct sunlight. Record the sample taken for Authorities records.

Water Analysis. Only use a National Analytical Test Authority (NATA) accredited laboratory to analyze a sample. The laboratory must notify you if they find a sample that has a high legionella count. The results of the test must be recorded and stored safely for seven years.

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Water Sample Collection Practical.

Aim: To be able to collect a water sample from an operating
cooling tower in accordance with AS/NZS 3666 part 3, while meeting the OH&S requirements.

Task.
1. Read AS/NZS 3666 part 3 section 2 ( risk assessment) 2. Read AS/NZS 3666 part 3 section 2 (technique for sample collection). 3. Complete the risk assessment and hand it in to the teacher for approval. 4. Complete the water sample collection while the teacher is present.

Review.
Complete the worksheet on water sample collection from the package or hand out.

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Decontamination If a tower has a high Legionella reading confirmed by the analysing laboratory, then the system will have to be shut down and decontaminated. Recommended procedure; 1. Circulate a dispersant throughout the system. 2. Drain and refill. 3. Dose with Sodium hypochlorite to maintain a free chlorine residual of 25 to 50 mg/l at a pH of 7 to 7.6 for 30 minutes. 4. Drain and refill. 5. Dose with Sodium Hypochlorite to maintain a Chlorine residual of 5 mg/l at a pH of 7 to 7.6 for 12 hours. 6. Drain the system and clean cooling tower wetted surfaces. 7. Dose with Sodium Hypochlorite to maintain a free Chlorine residual of 5mg/l at a pH of 7 to 7.6 for one hour. 8. Drain and refill. 9. Start full water treatment and put system back into service. 10. Wait at least 72 hours before taking another water sample. Draining of the system should be to the sewer or in accordance with Local Authority or other relevant authority. Some authorities require the water to be pumped into a container for disposal.

Safety with Chemicals The chemicals used to clean and disinfect a cooling tower are harmful and extreme care must be observed when using them. There must be Material Safety Data Sheets for all the chemicals where they are stored and used.

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Cleaning Cooling Towers & Evaporative Condensers

The most effective way of avoiding all the problems encountered with a cooling tower is a regular and thorough manual washout every six months. (see AS/NZS 3666 Part 2) The process is particularly important before a tower is commissioned or restarted after a shutdown period of one week or more. Wash out is compulsory under the Public Health Act, which carry heavy fines if it is not done. Before cleaning a tower the operator must check the service and maintenance records to see if there has been any changes made to the system or if anything needs to be done before shut down. Also the tower should be inspected for any possible faults that may affect the cleaning process. During the cleaning process the public must be kept out of the operational area, and the sprays must be confined to the operational area. The tower must be fully dismantled and the interior and components scrubbed with a high pressure water cleaner Local councils have been given the job of monitoring the installation maintenance and cleaning of cooling towers, as set out in the Public Health Act 1991. They are required by the Public Health Act 1991, to set up a register of all the regulated systems (cooling towers),in their area and to routinely go and check that the systems complies with the Act. The council officer has the right under the Act to inspect any Regulated System and view all associated maintenance records, when ever the council thinks it is necessary. The council will also require written notification of any changes that are made to a Regulated System. Any maintenance must be recorded (Public Health Act 1991), giving the details of the work and the record must be signed by the person doing the work and the owner or owner appointed representative.
Local Councils have an obligation to the public to conduct inspections and to police accurate records of maintenance, cleaning and microbial control.

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Practical.

Cleaning a Cooling Tower

Aim: to learn the skills necessary to clean a cooling tower. Task: Clean a cooling tower as required by AS/NZS3666 and the Public Health Act.

Equipment: a. Safety clothing as required by AS/NZS3666. b. Cooling tower. c. Operation manual. d. Cleaning equipment.

Procedure: a. Complete a Risk Assessment for the task. b. Wear all required PPE. c. Follow operation manual and shut down the tower. d. Dismantle tower. e. High pressure clean all internal components as instructed. f. Reassemble tower. g. Fill the tower with water to the required depth. h. Follow the operations manual and start the tower. i. Check operation.

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Maintenance
Expensive breakdowns, Legionella, inefficiencies and increased running costs can mostly be attributed to poor maintenance. Preventative maintenance should provide the owner/user with the following;

Early detection of problems that may lead to a breakdown. Maintain the systems efficiency. Determine that the system is complete and operating correctly. Remove the need to do corrective repairs. Maintain Bacteria to safe levels.

The maintenance management should contain the following; Inspection reports, each individual system, regardless if they are side by side and the same brand, need to have an inspection report developed for it. Maintenance and Operating Manuals, need to be clear and comprehensive, there should be no doubt as what needs to be done. The object of the manuals is to apply AS 3666, to the system and to ensure that the maximum performance and operating life are gained with effective use of labour. All manuals should have the following generic information; 1. Define the system that the manual applies to. 2. List the function and performance of the system. 3. Provide normal operating instructions. 4. Detail shut down and corrective procedures. 5. Provide details of any repairs, modifications or breakdowns. Records and log book, of any work on the system must be kept on-site, and copies should be given to the owner/user. Water treatment information should include a Material Safety Data Sheet for all chemicals stored on-site. There also should be an authorisation to use the chemicals for the type of system on-site. All maintenance and maintenance records are to be completed to the AS 3666 minimum standard. Failure to comply with these Standards can result in Supreme Court action under the Public Health Act 1991. It is imperative that service personnel, owners and users of cooling towers are committed to ongoing preventative maintenance

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Operational Check List.

Cooling Tower Casing.
rattles and vibrations. water and air leaks while in operation. amount of drift discharge. signs of rusting. condition of louvres and screens. paint or coating for damage.

Cooling Tower Internal Components.

fill for alignment, seal, distortion, damage, slime, algae and poor water coverage. sprays or decks for operation and uniformity of distribution over the fill. drift eliminators for location, damage, seal, scale, algae, slime or blockage. Ball float operation.

Fan.
noise, vibration and free running. where fitted, the fan drive for adjustment and alignment. guards and screens for rust and fixing. motor full load amps. condition of impeller, housing scroll, shaft, bearings and supports.

Pump and Pipe work. leaks. corrosion. vibration. Drains are clear. pumps smooth running. pump's gland. motor amps.

Chemical Dosing System, (normally a separator contractor).

Pumps operation. Chemical levels and types, safety data sheets. Bleed off rate.

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Sample of a maintenance report of a Water Cooling System.

Date of Service. Type of service Maintenance................ Water sample.............. Name of Owner or User............................................................................................... Address of Premises.................................................................................................... Location of Tower......................................................................................................... Tower: Site Number....................................................................................................... Type.................................................................................................................. Make and Model............................................................................................... Treatment Type.............................................................................................................. Brand and chemicals used............................................................................................. Water Sample; Total Plate Count.................................................................................... Legionella report required yes. no. Report forwarded to Local Authority yes no Physical Condition of tower.......................................................................................... Cleanliness of Tower.................................................................................................... Nature of any work preformed ..................................................................................... ....................................................................................................................................... ....................................................................................................................................... Date of next maintenance ............................................................................................ Nature of any repairs to be made during the next maintenance ....................................... ....................................................................................................................................... ....................................................................................................................................... Signature of service person .. Signature of Owner/user .............................................................................................. To Be Completed by the Local Authority (if required Report checked by .................................................................................................. Signature ................................................................................................................. Date ......................................................................................................................... Any action to be taken: No Yes, ......................................................................................................................... ..................................................................................................................................

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Shut Down.
This process should be followed if the tower is to be off line for a while. Drain the system to prevent stagnant water, or circulate the chemicals if the water is to be left in the system. Repair any rust or damaged paint. Clean the tower. Co-ordinate a condenser clean for this time period.

Emergency Shut Off. A procedures manual should be written for each individual C.T. and site, but generally; 1. Notify the owner and users of the cooling tower. 2. Shut off condensers and all other equipment supplied by the Cooling Tower. 3. Stop the fan. 4. Stop the pump.

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Review Questions
1. List four groupings of components that need to be checked during a service?

2. List three items that need to be checked on the Dosing system?

3. List the four steps for an emergency shut down?

4. How long must the results from a water sample be kept?

5. What must be done to the sump water from a cooling tower during cleaning?

6. Why are towers cleaned?

7. How often are they cleaned?

8. List the two pre-cautions that must be followed during a tower clean?

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9. Where does Legionnaires disease manifests? (C of P)

10. Why are cooling towers such a concern regarding Legionnaire disease?

11. Beside Legionnaire disease what other things are harmful in cooling towers?

12. What are the optimum conditions for the growth of Legionella?

13. What is the purpose of preventative maintenance?

14. Why are new cooling tower installations washed out before use?

15. What must be added to the circulating water after the clean?

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Assignment.
Aim. To gain an understanding of the pipe work and components of an operational cooling tower. Task. Draw a schematic diagram of the twin cooling towers installation at TAFE NSW Sydney Institute. Procedure. Locate and record all the components attached to the systems pipe work. Draw a sketch of the pipe work and component placement. Convert your sketch to a schematic using the correct symbols or labelling the component on the drawing. Hand in the drawing for marking.

Cooling tower Pipe work

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OH&S HAZARD IDENTIFICATION AND RISK ASSESSMENT OF WORKING PROCEDURES IN TAFE Examples of Potential hazards may include but are not limited to:
Electrical
Contact with live wires or terminals causing Shock Flash to eyes Burns Falls Discharge of capacitor causing Shock Flash to eyes Burns Falls

Mechanical
Caught by operating machinery Struck by moving machinery or objects Caught by movement of mechanical parts Crushed by objects moving or falling Entrapment Excessive vibration

Pressure
Injury from releases of stored energy in Refrigerants Nitrogen Oxy Acetylene. Propane. Ammonia.

Chemical
Fire or Explosion from Build up of flammable gases Ignition of existing flammable products Contaminants/ Toxins causing Suffocation Burns Poisoning from products

Gravity / Noise
Falls from or into vessels Falls from structures Impact injuries from falling objects Engulfment by product Sound levels >85dBA causing hearing damage from Operating machinery Using equipment

Gas Welding
Injury due to - burns -high temperature - naked flames - releases from stored pressure vessels. - fire hazard. - risk of explosions - lack of ventilation. -

Radiation
Extremes of temperature Burns UV from welding flashes UV from exposure to sun X-Ray exposure Eye damage from laser

Biomechanical
Strains and sprains lifting objects Strains and sprains moving objects Slips and trips from Spillage/slippe ry surfaces Uneven/unstab le surfaces Poor lighting Crush injury

Biological
Disease or illness from fungal spores eg. Legionnaires Disease from blood products eg. Hepatitis, brucellosis

Determine the Risk Ranking 1-2 = High (Immediate action required) 3-5 = Medium Risk
1.

6 = Low
Provide PPE Appropriate PPE for the task training in how to use

How severely could it 2. How likely is it to be that bad what is the probability of It happening hurt someone VERY LIKELY LIKELEY UNLIKELEY VERY UNLIKELEY Or Could happen at How Ill could it make Could happen Could happen very Probably never will any time rarely happen someone? occasionally KILL OR PERMANENTLY 1 1 2 3 ABLED LONG TERM ILLNESS OR 1 2 3 4 RIOUS INJURY LOST TIME INJURY 2 3 4 5 FIRST AID

Safe work procedures Correct work procedures Job rotation Relieve stress/boredom Training Know the dangers. How to do work rectly Design Design out or modify Eliminate Remove or substitute Adopt a safer process Can it be done any other way Enclose or isolate Use guards, close off Ventilation Provide adequate ventilation

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OHS Risk Assessment and Control (Educational) By activity) College: Sydney Institute/Ultimo Activity Potential Hazards Section/ Refrigeration Risk Rating Topic: Cooling Towers. Responsibility Implementation Date Revised Risk Rating

Control Measures

Students Name: _______________________ Position: __________________ Signature: _________________

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Answers to review questions. Section1 1. Latent heat. 2. Because of the Water Conservation Act. 3. Controlled draining of the circulating water to reduce TDS. 4. Reduce chemical effectiveness, clog system pipe work. 5. Oxidizing and Non-oxidizing. 6. Breathing in Legionella enriched aerosols. 7. By evaporating some the circulating water. 8. To increase the evaporation rate. 9. High RH% and air flow 10. Natural and Forced draft. 11. Very large industrial process. 12. a. b. c. d. Induced draft counter flow. Induced draft cross flow. Forced draft counter flow. Forced draft cross flow.

13. Propeller and centrifugal. 14. Yes. 15. No. 16. Open and closed. 17. Closed, the circulating water doesnt come into contact with the atmosphere, an open does. 18. To compensate for load charges. 19. Fan speed and water by-pass. 20. Individual condensers regulating valves will reduce the amount of water flowing in them therefore the cooling tower will need to regulate the volume of water flowing from it to them.

Complied by Bruce Davison.

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Cooling Towers

Answers to Law Questions.

a. NSW Public Health Act Part 4 clause 43. b. AS/NZS 3666.2 2.6.1 c. AS/NZS 3666.2 2.5.1 d. AS/NZS 3666.1 4.1.4 also in the Regulation 2000 part 3 clause 9 (2) e. Regulation 2000 part 4 clause 10. f. AS/NZS 3666.2 g. AS/NZS 3666.2 table A1. 2.3.4.

h. Refer to AS/NZS 3666.3 foreword and 3.3.1. i. AS/NZS 3666.3 3.7.

j. AS/NZS 3666.1 2.3.2

Complied by Bruce Davison.

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Section 2. 21. 1. 2. 3. 4. 5. 22. 1. pump 2. chemical levels 3. bleed off rate. 23. 1. 2. 3. 4. Notify the owner. Stop any equipment connected to the cooling tower. Stop the fan. Stop the pump. Cooling tower casing. Internal components. Fan. Pump and pipe work. Dosing system.

24. Seven years. 25. Drained to sewer or contained by trade waste company. 26. It is the LAW. 27. Every six months. 28. Kept the public away and contain the spray from cleaning. 29. In human lungs. 30. They have the ability to spread the disease. 31. Chemicals. 32. 35 to 37oC. 33. Reduce running costs. 34. To remove construction waste. 35. Corrosion inhibitor.

Complied by Bruce Davison.

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