Pipework

The Challenge of Cooling Tower Pipework

Cooling towers and their associated pipework operate in extreme environments.

They are constantly exposed to:

• Chemical Attack: Highly corrosive chemicals like chlorine, biocides, and inhibitors used for water treatment can rapidly corrode steel and damage paints.
• Temperature Fluctuations: Water temperatures ranging from 25°C to 60°C, combined with chemical exposure, accelerate corrosion due to splash-out and drift.
• Vibration: Constant vibration from rotating fans and water distribution pumps stresses bolts and pipework joints, leading to leaks and failures.
• Refrigeration Leaks: Leaks from refrigeration systems can also cause significant corrosion to pipework, vessels, and tanks.

Without adequate protection, pipework is prone to failure, leading to costly repairs and operational downtime.

Case Study: Protecting Cooling Tower Pipework with RepelCoat

The Challenge: A Harsh Environment for Critical Pipework

Cooling towers and refrigeration systems are vital for many businesses, but they create an incredibly harsh environment for their associated pipework. Imagine pipes constantly exposed to:

• Aggressive Chemicals: Water in cooling towers is treated with chemicals like chlorine, biocides, and inhibitors. While essential for controlling bacteria, these substances are highly corrosive to steel and can quickly degrade standard paints and coatings. Chemical splash-out and spray from the fans relentlessly cover surrounding pipework.
• Extreme Temperatures & pH: Cooling tower water temperatures can swing from 25°C up to a scorching 60°C. Combined with chemically treated water, which can have an acidic or alkaline pH, this creates a perfect storm for accelerated corrosion. Hot water and chemicals lead to splash-out and ‘drift’ (fine water droplets carried by airflow) settling on pipes, supports, vessels, tanks, and even steel roofing, causing widespread damage.
• Constant Vibration & Stress: The continuous operation of rotating fans and water distribution pumps creates significant vibration. This relentless movement stresses bolts and pipework joints, making them vulnerable to leaks and eventual failure.
• Refrigeration Leaks: Even minor leaks from refrigeration systems add another layer of corrosive attack on adjacent pipework, vessels, and tanks.

Without specialised protection, this critical pipework is on a fast track to failure, leading to costly leaks, operational disruptions, and expensive replacements.

Key Outcomes & Benefits of RepelCoat PV-300 / 400:

• Corrosion Elimination: Effectively stops the progression of existing corrosion and prevents new corrosive attacks, significantly extending the operational life of pipework.
• Superior Chemical Resistance: Forms a resilient barrier that withstands harsh chemicals, extreme high or low pH levels, and constant chemical splash-out.
• Enhanced Durability: Provides a tough, flexible coating that endures constant vibration and excessive joint flexing without cracking or delaminating.
• Leak Prevention: Seals existing minor leaks and creates an impervious surface, preventing future water and chemical leaks.
• UV Protection: Crucially protects PVC pipework from UV degradation, which can lead to embrittlement and failure.
• Cost-Effectiveness: Proactively coating pipework at the first sign of corrosion is a highly economical strategy, representing a fraction of the cost and disruption associated with full pipework replacement.
• Safety & Compliance: Enables clear colour identification of different pipework lines, improving workplace safety and reducing the risk of HAZCHEM accidents.