Winter Operation Tips for Cooling Towers: Preventing Freezing and Ice Build-Up

Operating a cooling tower in freezing conditions requires careful attention, but with the right approach, freezing water and ice damage can be avoided. At VHF, we want to help you maximize performance and protect your equipment, even in sub-zero temperatures.

During winter, cooling towers work by bringing cold air into contact with the circulating water. The more cold air that flows through the tower, the colder the water becomes. Fortunately, for properly designed systems, the water temperature rarely drops to freezing. Most ice formation occurs only when small droplets or streams escape the main water flow and are fully exposed to the cold air.

To ensure safe and efficient operation during cold weather, follow these guidelines:

• Operate at Maximum Heat Load: Cooling towers continuously remove heat from circulating water. Without a heat load, water temperatures may drop to near freezing. Keeping the system under load helps maintain safe water temperatures.

• Maintain Proper Water Flow: Ensure the water flows over the fill as designed. Reduced flow can create semi-dry areas that freeze quickly.

• Control Fan Operation: Install thermostats to shut fans off when water temperatures get too low. For towers with VFDs or two-speed motors, operate at lower speeds to slightly raise water exit temperatures.

• Cycle Fans Regularly: Running fans intermittently prevents ice from building up on louvers.

• Use Fan Reversal When Needed: Briefly reversing fan direction can help melt minor ice formation by directing warm water into the tower.

• Inspect Frequently: Sub-freezing operation requires routine visual inspections and maintenance. Never overlook this step.

• Exercise Caution When Removing Ice: If ice builds up, carefully remove it to prevent damage to the tower or risk of injury.

By following these strategies, you can keep your cooling towers running efficiently and safely, even in the harshest winter conditions. At VHF, we’re here to help you select, size, and maintain your equipment for reliable year-round performance.