Lessons Learned in Field Mounted Cooling Tower Installation
In every field erected cooling tower installation project, Torraval applies the lessons learned over the years to improve each stage and ensure lasting results. We know that each installation poses new challenges and opportunities for growth. In this article, we share the key steps in our field-mounted cooling tower installation process and some of the best practices we have developed.
Step 1 – Cooling tower design
The initial design is always a challenge. Not only do we analyse the cooling needs and flow rates required, but we also face space and time constraints. Every project is different, and forces us to adapt our designs to balance performance, space and time. At this stage, communication with the client and flexibility in design are crucial to meet the specific needs of each installation.
Step 2 – Material selection
The choice of materials is one of the most carefully considered decisions as itdirectly influences the life of the tower and its performance. Factors such as water temperature and water quality guide our decisions on materials for the fill and structure. We know that working with 65°C water demands different materials than those that can withstand temperatures up to 85°C, such as PP rather than PVC. Concrete structures, for example, offer long-term durability, while steel facilitates faster construction. In each case, we balance these options according to project priorities.
Step 3 – Coordination with suppliers
Coordination with suppliers is one of the most challenging areas. At Torraval, we have learned the importance of a detailed follow-up of each supply to ensure the quality of the materials and avoid delays. However, we know that not everything always goes according to plan, so we maintain constant communication with our suppliers and periodically review the progress of each component. This coordination can delay the project or allow it to move forward despite any obstacles that may arise.
Step 4 – On-site coordination
During the construction phase, accurate planning is essential to reduce the risk of errors and delays. This includes reviewing 3D designs and conducting quality inspections before each component is brought to site. While in some cases we must duplicate teams to meet deadlines, we know that efficiency depends on the proper use of resources. Each site has its own particularities, and we adjust our approach according to the client’s needs and site conditions.
Step 5 – Risk management and quality control
In critical installations, the margin for error is minimal, and quality control becomes a top priority. Risk management has taught us to anticipate problems and be prepared to deal with any setbacks. This phase is essential in projects where the client has very tight downtimes, and requires close attention to every detail.
Step 6 – Innovation and continuous improvement
We are always on the lookout for technologies that improve the efficiency of our installations. For example, permanent magnet motors eliminate the need for transmissions and gearboxes, optimising costs and reducing the risk of failure. We apply the lessons learned from each project to refine our installation processes and maximise efficiency, knowing that there is always room for improvement.
Step 7 – Commissioning
Before completion, we conduct extensive testing to ensure that the tower is ready for operation. Commissioning is a critical phase, where we fine-tune the system to ensure optimum performance from day one. However, we take nothing for granted; we know that every system has its particularities and we work closely with the customer to resolve any final adjustments.
For us, every field erected cooling tower installation is more than a project, it is a commitment. Our step-by-step approach is based on rigorous planning, precise material selection and thorough quality control. Our process ensures a cooling system that not only meets, but exceeds expectations for performance and durability.