A detailed Cooling Tower DAILY preventive maintenance checklists
1. Visual Inspection
- Look for leaks or water accumulation near the cooling tower.
- Check for corrosion or structural damage on the tower.
- Confirm water level in the basin is within normal range.
- Listen for unusual noises indicating mechanical issues.
- Examine the exterior for wear or deterioration signs.
- Inspect drift eliminators for blockages or damage.
- Verify all access panels and doors are closed and sealed.
- Check for debris, leaves, or obstructions around the tower.
- Inspect water distribution system for wear or leaks.
- Observe fan blades for damage or dirt accumulation.
- Look for algae or biological growth on surfaces.
- Check insulation material on pipes for wear or damage.
- Ensure safety guards and protective covers are secure.
- Inspect surrounding area for proper drainage and pooling.
2. Water Quality Check
- Use a calibrated pH meter or test kit.
- Collect water sample from the cooling tower.
- Compare pH reading to optimal range.
- Add acid or alkaline as needed to adjust pH.
- Re-test water to confirm adjustments.
- Visually examine water surface and sides.
- Look for green or brown discoloration.
- Use a net or scoop to check for floating debris.
- Document any findings for treatment planning.
- Consider applying biocide if growth is detected.
- Inspect the basin for visible debris.
- Use a net or vacuum to remove large particles.
- Flush the basin with water to dislodge sediment.
- Collect sediment samples for analysis if needed.
- Dispose of debris in accordance with waste regulations.
- Review chemical dosing logs for accuracy.
- Use test kits to measure chemical concentrations.
- Compare results with manufacturer recommendations.
- Adjust dosing rates if levels are outside of range.
- Document chemical levels and any adjustments made.
- Use a calibrated pH meter or test kit.
- Collect water sample from the cooling tower.
- Compare pH reading to optimal range.
- Add acid or alkaline as needed to adjust pH.
- Re-test water to confirm adjustments.
- Visually examine water surface and sides.
- Look for green or brown discoloration.
- Use a net or scoop to check for floating debris.
- Document any findings for treatment planning.
- Consider applying biocide if growth is detected.
- Inspect the basin for visible debris.
- Use a net or vacuum to remove large particles.
- Flush the basin with water to dislodge sediment.
- Collect sediment samples for analysis if needed.
- Dispose of debris in accordance with waste regulations.
- Review chemical dosing logs for accuracy.
- Use test kits to measure chemical concentrations.
- Compare results with manufacturer recommendations.
- Adjust dosing rates if levels are outside of range.
- Document chemical levels and any adjustments made.
3. Fan and Motor Inspection
- Examine blades for cracks, bends, or chips.
- Remove any dirt, leaves, or other debris.
- Check for proper blade alignment and spacing.
- Ensure blades are securely attached to the hub.
- Start the motor and observe its running condition.
- Listen for any grinding, rattling, or humming noises.
- Check for excessive heat or vibrations.
- Ensure the motor is operating at the correct speed.
- Identify lubrication points on the motor.
- Use the recommended type of lubricant.
- Apply lubricant sparingly to avoid excess buildup.
- Check for any signs of leakage around bearings.
- Inspect belts for cracks, fraying, or wear.
- Check belt tension using a tension gauge.
- Adjust tension as necessary to manufacturer's specifications.
- Ensure belts are properly aligned with pulleys.
- Check for rust, pitting, or structural damage.
- Look for loose or missing bolts and fasteners.
- Ensure seals are intact to prevent water ingress.
- Clean any corrosion with appropriate cleaning agents.
- Use alignment tools to verify parallel alignment.
- Adjust motor position as needed for correct alignment.
- Inspect mounting hardware for tightness and integrity.
- Recheck alignment after any adjustments.
- Use a clamp meter to measure current draw.
- Compare readings to manufacturer specifications.
- Identify any significant deviations from normal.
- Investigate causes of abnormal amperage readings.
- Examine wiring for fraying or insulation damage.
- Check terminals for tightness and clean connections.
- Look for corrosion on connectors and terminals.
- Replace any faulty or worn electrical components.
- Refer to operational specifications for speed settings.
- Adjust speed control settings as needed.
- Monitor fan speed with a tachometer.
- Document any changes made to fan speed.
- Use a soft brush or vacuum to remove debris.
- Wipe down surfaces with a damp cloth.
- Avoid using excess water that could cause damage.
- Ensure air intake areas are clear for optimal airflow.
- Use a vibration meter to measure levels.
- Compare readings to acceptable thresholds.
- Look for patterns indicating imbalance or misalignment.
- Address any unusual vibration patterns immediately.
- Check all mounting points for security.
- Inspect for any cracks or damages to the guard.
- Remove any objects obstructing airflow.
- Ensure guard complies with safety standards.
- Test thermal overloads for proper functioning.
- Inspect vibration sensors for responsiveness.
- Ensure alarms and cutoffs activate as designed.
- Document the status of safety features.
- Record all inspection results in a maintenance log.
- Note any corrective actions taken.
- Highlight recurring issues for follow-up.
- Ensure documentation is clear and accessible.
4. Fill and Distribution System Check
- Remove fill media access panel.
- Visually inspect for dirt, debris, or biological growth.
- Use a soft brush or vacuum to clean surfaces.
- Check for any physical damage or deterioration.
- Replace or repair any damaged fill media.
- Examine the distribution pipes for leaks or drips.
- Inspect joints and connections for signs of wear.
- Ensure all components are securely fastened.
- Check for any unusual vibrations or noises during operation.
- Report any issues to maintenance for repair.
- Visually inspect each spray nozzle for blockages.
- Remove nozzles and clean with water if necessary.
- Check spray patterns to ensure even distribution.
- Replace any nozzles that are damaged or non-functional.
- Test nozzles under normal operating conditions.
- Remove fill media access panel.
- Visually inspect for dirt, debris, or biological growth.
- Use a soft brush or vacuum to clean surfaces.
- Check for any physical damage or deterioration.
- Replace or repair any damaged fill media.
- Examine the distribution pipes for leaks or drips.
- Inspect joints and connections for signs of wear.
- Ensure all components are securely fastened.
- Check for any unusual vibrations or noises during operation.
- Report any issues to maintenance for repair.
- Visually inspect each spray nozzle for blockages.
- Remove nozzles and clean with water if necessary.
- Check spray patterns to ensure even distribution.
- Replace any nozzles that are damaged or non-functional.
- Test nozzles under normal operating conditions.
- Use a flow meter to measure water flow rate.
- Compare readings to manufacturer specifications.
- Adjust valves or pumps if flow is outside range.
- Document flow rate readings.
- Report any discrepancies immediately.
- Inspect visible sections of pipes for rust or corrosion.
- Look for cracks or leaks in the pipe surfaces.
- Check insulation for signs of damage.
- Report any significant findings for further evaluation.
- Consider replacing severely damaged sections.
- Shut down the cooling tower system before cleaning.
- Remove debris using appropriate tools, such as brushes or vacuums.
- Flush out the distribution system with water.
- Inspect and clean the fill media thoroughly.
- Ensure all cleaned areas are free of residues.
- Inspect the alignment of pipes and nozzles.
- Make adjustments to ensure proper positioning.
- Secure all components to maintain alignment.
- Test water distribution after adjustments.
- Document any alignment issues found.
- Check drip trays for standing water or debris.
- Clear any blockages that may impede drainage.
- Ensure drain lines are free-flowing.
- Look for signs of corrosion or damage in trays.
- Report any significant issues for repair.
- Visually inspect all components for algae or biofouling.
- Use biocides or other treatments to eliminate growths.
- Scrub surfaces as necessary to remove any buildup.
- Monitor for reoccurrence and adjust treatments accordingly.
- Document findings and actions taken.
- Use calibrated thermometers to measure water temperatures.
- Record temperatures at both entry and exit points.
- Compare temperatures to expected operational ranges.
- Investigate significant temperature differences.
- Document all temperature readings.
- Use a pressure gauge to measure inlet and outlet pressures.
- Compare readings with manufacturer's specifications.
- Adjust system settings if pressures are out of range.
- Document pressure readings for records.
- Report any persistent pressure issues.
- Use a maintenance log or checklist for documentation.
- Record date, time, and details of each inspection.
- Note any repairs or maintenance actions taken.
- File documentation in an accessible location.
- Ensure all team members are informed of findings.
5. Basin and Sump Maintenance
- Use a suitable cleaning tool to remove large debris.
- Vacuum the basin and sump to eliminate finer sediment.
- Dispose of removed materials per environmental regulations.
- Rinse with clean water to ensure no residues remain.
- Remove strainers or filters from their housing.
- Rinse with water to dislodge dirt and debris.
- Check for tears or significant wear; replace if necessary.
- Reinstall cleaned components securely.
- Visually inspect the drain for visible obstructions.
- Test the drain by pouring water to see if it flows freely.
- Use a plumbing snake or similar tool for stubborn blockages.
- Confirm that the drain is securely attached and leak-free.
- Use a dipstick or level gauge to measure water height.
- Compare the measurement against operational specifications.
- Add or remove water as needed to maintain proper levels.
- Document the water level reading.
- Look for rust, pitting, or cracking on basin surfaces.
- Use a wire brush for light corrosion removal.
- Apply appropriate sealants or coatings to protect exposed areas.
- Schedule further repairs for extensive damage.
- Check the water supply valve for proper operation.
- Listen for any unusual sounds indicating issues.
- Inspect piping for leaks or blockages.
- Confirm that the make-up system maintains the water level.
- Manually activate the pump to test functionality.
- Observe for smooth operation and proper shut-off.
- Check electrical connections and power supply.
- Document any anomalies or required repairs.
- Listen for grinding, rattling, or excessive vibration.
- Check for loose components or misalignment.
- Inspect mounting brackets for tightness.
- Schedule maintenance if unusual sounds persist.
- Visually inspect surfaces for green or slimy growth.
- Use appropriate biocide treatments to control growth.
- Consider physical cleaning methods for heavy infestations.
- Document treatment actions taken.
- Inspect liners for tears, blisters, or peeling.
- Use a flashlight to check hard-to-see areas.
- Mark any areas needing repair for follow-up.
- Schedule maintenance for significant wear.
- Use a calibrated thermometer for accurate readings.
- Record the temperature in a maintenance log.
- Compare the temperature against standard operational limits.
- Adjust system parameters if necessary.
- Visually check weirs for blockage or debris.
- Test overflow function by simulating high water conditions.
- Clear any found obstructions promptly.
- Ensure water flows freely over the weir.
- Use a standardized maintenance log format.
- Include details such as date, time, and actions taken.
- Note any observations or follow-up actions required.
- Ensure log is stored in an accessible location.
6. Electrical System Inspection
- Visually inspect all connections and terminals.
- Look for discoloration, melting, or corrosion.
- Test connections with a multimeter for continuity.
- Tighten any loose connections to prevent arcing.
- Open control panels and visually check for damage.
- Verify that all indicator lights are operational.
- Test all buttons and switches for responsiveness.
- Ensure that display screens show accurate readings.
- Locate the emergency shutoff switch.
- Activate the switch and confirm that all systems shut down.
- Reset the system and ensure normal operation resumes.
- Document any issues found during testing.
- Visually inspect all connections and terminals.
- Look for discoloration, melting, or corrosion.
- Test connections with a multimeter for continuity.
- Tighten any loose connections to prevent arcing.
- Open control panels and visually check for damage.
- Verify that all indicator lights are operational.
- Test all buttons and switches for responsiveness.
- Ensure that display screens show accurate readings.
- Locate the emergency shutoff switch.
- Activate the switch and confirm that all systems shut down.
- Reset the system and ensure normal operation resumes.
- Document any issues found during testing.
- Check the status of all circuit breakers.
- Test fuses with a multimeter for continuity.
- Replace any burnt or tripped fuses or breakers.
- Label any replaced components for future reference.
- Examine wires for cuts, abrasions, or deterioration.
- Use a continuity tester to check for shorts.
- Replace any damaged wires immediately.
- Securely fasten any new wiring to prevent movement.
- Inspect grounding connections for corrosion or looseness.
- Use a ground resistance tester to measure resistance.
- Ensure readings meet safety standards.
- Repair or replace any faulty grounding components.
- Inspect mounts and brackets for tightness.
- Verify that motors are aligned according to specifications.
- Look for signs of wear on mounting surfaces.
- Adjust or realign components as necessary.
- Activate each relay and contactor to check operation.
- Listen for clicks and observe movement.
- Replace any units that do not operate correctly.
- Document all tested components for maintenance records.
- Check for noise or heat indicating bearing issues.
- Clean bearings and apply appropriate lubricant.
- Ensure lubrication is within manufacturer recommendations.
- Monitor for changes in motor performance.
- Gather all current schematics and documentation.
- Compare with actual installations and systems.
- Update any discrepancies or changes made.
- File updated documents in accessible locations.
- Test each safety interlock mechanism.
- Ensure they prevent operation under unsafe conditions.
- Inspect components for physical damage.
- Replace any interlocks that do not function as required.
- Check all light fixtures for proper operation.
- Replace any burnt-out bulbs immediately.
- Ensure adequate lighting levels are maintained.
- Clean fixtures to improve light output.
- Inspect electrical enclosures for moisture or corrosion.
- Look for cracks or gaps around seals and joints.
- Apply sealant or replace gaskets as needed.
- Document any issues for follow-up.
- Use a thermal camera to scan electrical components.
- Identify and document any hotspots observed.
- Investigate causes of elevated temperatures.
- Plan corrective actions for identified issues.
- Use a vacuum or cloth to clean panel surfaces.
- Check for moisture accumulation inside panels.
- Ensure all ventilation openings are unobstructed.
- Schedule regular cleaning as part of maintenance.
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