Industrial
Air-cooling vs water-cooling: a guide to choosing cooling systems for industrial applications
During summer every year, something very unexpected occurs in the UK; we glimpse a fleeting moment of sunshine. During this, there is often a debate about what the best way is to cool down from the seemingly unbearable heat, with some people choosing the humble fan and others opting for a dip in the pool. A similar debate often occurs when businesses look for ways to keep their machinery cool. Here, Steve Hughes, managing director of power quality specialist REO UK, explores how businesses can choose between air-cooling and water-cooling systems for industrial applications
There are two main ways of regulating device temperature, air-cooling and water- cooling. Air-cooling is the most commonly used and, as the name suggests, uses fan technology to circulate air around the device. Water-cooling, on the other hand, uses liquid coolants to transfer heat out of equipment and is often met with apprehension by plant managers. However, both have their place within industrial environments if used correctly.
Air-cooling considerations While the humble fan is what many people initially think of when asked about cooling, it is not without its limitations. For example, the inclusion of a fan often means that the enclosure of a device needs to be bulkier to accommodate it, which can cause problems with integrating devices into certain industrial setups.
Steve Hughes M
ost of us can appreciate that industrial equipment gets hot during use, damaging
components and hindering functionality. This is particularly true of electrical equipment where, in addition to the typical operational temperature, there is also the heat generated by electrical currents on the network. Being acutely aware of this, it is commonplace for plant managers and original equipment manufacturers (OEMs) to install cooling systems into equipment. However, cooling electrical infrastructure and industrial equipment isn’t as simple and straightforward as just turning on a fan. In fact, even something seemingly unrelated like the location of the device is vital in ensuring that the system is cooled effectively and safely. Considering these factors, engineers can choose the right cooling system for their equipment.
38 September 2017
This is especially true with electrical power controllers, as many are integrated into transformer cabinets. In instances such as this, the bulkier design of products featuring fans may cause problems and engineers may require the sleeker design of a water-cooled power controller. Yet air-cooling does offer benefits to businesses. The reason that these systems have proven so popular is because they are relatively inexpensive and typically require less maintenance beyond the replacement of filters. So long as engineers are vigilant, fan-based systems will not encounter too many operational difficulties. Fans are also independent in use, able to
provide effective heat transfer in more remote applications. Liquid cooling requires a series of tubes for the coolant to flow through, taking away the heated fluid to another part of the plant for use in another process. This may sound efficient but some applications are unable to facilitate such a system, making the uncomplicated design of fans desirable.
In addition to this, there is an element of Components in Electronics
peace-of-mind with air-cooling. One of the biggest concerns plant managers have with alternative systems such as liquid coolants is their safety and stability. Many electrical engineers have reservations about using water-based systems in close proximity to electrical equipment.
Liquid coolants and water-cooling Initial safety concerns aside, water- cooling boasts a range of benefits for industrial applications that go beyond those offered by traditional air-based systems. In fact, these systems are able to deliver on the areas where fans often fall short. Water-based systems operate on a very simple principle of heat exchange: pipes containing a liquid coolant circulate around an enclosure and out of the device to keep components cool. The excess heat generated during use is thermally conducted by the water in the pipes. This heated water is then transferred out of the device and into other industrial processes, such as plant heating. The development of cooling technology
in recent years means that it now poses no risk of causing an electrical fire. This is due to the self-contained housing that these systems include as standard, which ensures that no water can reach critical components in the unlikely event of a coolant leakage.
Despite this added safety measure, the
system remains compact so that it can be easily fitted into equipment without increasing the product footprint. This solves the problem faced by air-cooling and means that water cooling can now be used in environments where space is limited. The biggest selling point for water- cooling is its increased energy efficiency. Not only are fans are limited by their reliance on ambient temperatures to cool down overheating components — after all, air conducts less heat than water — in order to provide sufficient cooling, multiple fans might be necessary. This increases the energy consumption of the cooling system. Conversely, water has a high heat conductivity so systems only require a single pump to effectively cool infrastructure. This coolant can also be stored in the pipes at a temperature below a plant’s ambient level for an even faster cooling.
Engineers looking to specify liquid cooling need to consider the fact that, although it will have a higher return on investment, the initial setup of liquid cooled systems is more complex and more costly than air-cooled systems.
How do you choose? The first step to selecting the right cooling
system is by identifying where the device will be used and what the typical operating challenges will be. For example, businesses in the electroplating sector will find that a lot of the copper sulphate particulates produced during plant production can get into the enclosure vents of air-based systems and corrode core components and wiring. In these situations liquid-cooled alternatives might be preferential. Likewise, high voltage electrical infrastructure generates more heat than a standard electronic device. To this end, electrical OEMs such as REO UK can work with electrical engineers to determine the best solution for particular electrical requirements.
The REOTRON MDW 700 power
controller, for example, is designed for use with industrial transformers and is available in both air and water-cooled versions. For transformers expected to operate at more than 50A, it is advisable that businesses opt for either additional fans for the air-cooled model or opt for the water-cooled REOTRON MDW 700 WK model to eliminate the risk of overheating. The final step to choosing the right cooling system is to determine how regularly it will realistically be maintained. Fan filters need replacing frequently to avoid a build-up of contaminants that can lead to overheating, so using these systems in difficult-to-reach or less frequently maintained applications is not recommended.
Just as choosing between standing in
front of a fan and standing in the ocean on a warm day can be a difficult decision, so too is selecting the right cooling system for industrial applications. By considering the factors that affect equipment performance further down the line, engineers can ensure they make the right choice every time.
www.reo.co.uk www.cieonline.co.uk
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