A detailed Cooling Tower MONTHLY preventive maintenance checklists
1. Visual Inspection
2. Water Quality Testing
3. Mechanical Components
4. Fill and Drain System
- Remove fill media access panels.
- Visually inspect for dirt, algae, or debris.
- Use a soft brush or vacuum for cleaning.
- Rinse with clean water to remove residues.
- Replace panels securely after cleaning.
- Locate all drain valves in the system.
- Manually operate each valve to check for movement.
- Inspect for any debris or buildup around the valve.
- Ensure valves fully open and close without resistance.
- Lubricate moving parts if necessary.
- Inspect overflow pipes for visible blockages.
- Flush overflow pipes with clean water.
- Ensure overflow outlet is clear and functioning.
- Check for any leaks around overflow connections.
- Test the system by filling the basin to the overflow level.
- Remove fill media access panels.
- Visually inspect for dirt, algae, or debris.
- Use a soft brush or vacuum for cleaning.
- Rinse with clean water to remove residues.
- Replace panels securely after cleaning.
- Locate all drain valves in the system.
- Manually operate each valve to check for movement.
- Inspect for any debris or buildup around the valve.
- Ensure valves fully open and close without resistance.
- Lubricate moving parts if necessary.
- Inspect overflow pipes for visible blockages.
- Flush overflow pipes with clean water.
- Ensure overflow outlet is clear and functioning.
- Check for any leaks around overflow connections.
- Test the system by filling the basin to the overflow level.
- Inspect distribution nozzles for clogs or damage.
- Check alignment of nozzles to ensure proper coverage.
- Adjust nozzles if necessary for uniform distribution.
- Monitor water flow during operation.
- Clean nozzles if uneven distribution is observed.
- Examine fill media for cracks or breaks.
- Look for signs of biological growth or corrosion.
- Check for warping or sagging of media sections.
- Replace damaged fill media as needed.
- Document any findings for future reference.
- Use a dipstick or gauge to measure water level.
- Compare the level against operational specifications.
- Make adjustments to the water supply if necessary.
- Inspect for any leaks that may affect levels.
- Record the water level for maintenance logs.
- Visual inspection of all visible piping connections.
- Look for signs of rust, corrosion, or water stains.
- Check joints and fittings for tightness.
- Repair or replace any corroded or leaking sections.
- Ensure all insulation is intact and in good condition.
- Manually activate float switch to check response.
- Ensure level sensors provide accurate readings.
- Calibrate sensors if necessary for accuracy.
- Inspect wiring for wear or damage.
- Document any issues or required adjustments.
- Remove any visible debris from the basin.
- Use a vacuum or siphon to clear sediment.
- Inspect basin walls for biological growth.
- Wash down basin surfaces with clean water.
- Schedule regular cleaning to maintain basin hygiene.
- Inspect pump mounts for stability and alignment.
- Check pump seals and gaskets for leaks.
- Test pump operation for smooth performance.
- Ensure electrical connections are secure.
- Lubricate motors and bearings as required.
- Inspect insulation for wear or damage.
- Ensure insulation is intact around all piping.
- Replace any missing or damaged insulation.
- Check for condensation on uninsulated surfaces.
- Document insulation condition and any repairs.
- Record all inspections in a maintenance log.
- Note any repairs or replacements made.
- Include dates and personnel involved in the inspection.
- Use standardized forms for consistency.
- Review logs regularly for trends or recurring issues.
5. Pump and Piping Inspection
- Inspect all joints and connections for moisture.
- Use a moisture meter to identify hidden leaks.
- Tighten loose fittings as needed.
- Replace damaged sections of piping.
- Listen for unusual noises during operation.
- Check pump speed and flow against specifications.
- Use a vibration analyzer to assess performance.
- Lubricate bearings as per manufacturer's instructions.
- Remove strainers or filters from their housing.
- Rinse with water to remove debris and contaminants.
- Inspect for damage; replace if needed.
- Reinstall after ensuring they are clean.
- Manually operate each valve to check for movement.
- Inspect valve seats for wear or damage.
- Lubricate valve stems as required.
- Replace faulty valves to ensure proper operation.
- Inspect all joints and connections for moisture.
- Use a moisture meter to identify hidden leaks.
- Tighten loose fittings as needed.
- Replace damaged sections of piping.
- Listen for unusual noises during operation.
- Check pump speed and flow against specifications.
- Use a vibration analyzer to assess performance.
- Lubricate bearings as per manufacturer's instructions.
- Remove strainers or filters from their housing.
- Rinse with water to remove debris and contaminants.
- Inspect for damage; replace if needed.
- Reinstall after ensuring they are clean.
- Manually operate each valve to check for movement.
- Inspect valve seats for wear or damage.
- Lubricate valve stems as required.
- Replace faulty valves to ensure proper operation.
- Check for leaks around the seal area.
- Examine seals for cracks or deterioration.
- Replace seals that show signs of wear.
- Ensure proper installation of new seals.
- Use a laser alignment tool for accuracy.
- Adjust mounting as needed for proper alignment.
- Check alignment after any maintenance work.
- Document alignment settings for future reference.
- Inspect insulation for tears or wet spots.
- Replace damaged insulation to prevent heat loss.
- Check for mold or mildew growth.
- Ensure insulation is securely fastened.
- Check gauges for accuracy against known values.
- Inspect for any leaks or blockages in lines.
- Record readings and identify trends over time.
- Investigate any abnormal readings immediately.
- Inspect all exposed surfaces for rust or pitting.
- Use a wire brush to remove surface corrosion.
- Apply protective coatings to prevent further corrosion.
- Replace heavily corroded components as necessary.
- Check for loose or damaged supports.
- Tighten or replace supports as needed.
- Inspect for signs of stress or fatigue.
- Document any issues for follow-up.
- Check for cracks or splits in the joints.
- Assess the flexibility and movement of joints.
- Replace joints that show significant wear.
- Ensure proper installation of replacement joints.
- Inspect lubricant levels in reservoirs.
- Add lubricant as per manufacturer's specifications.
- Check for leaks in lubrication system.
- Document lubrication maintenance performed.
- Operate the bypass valves manually.
- Check for leaks during operation.
- Ensure that valves return to closed position.
- Document any issues found during testing.
- Measure actual flow rates using flow meters.
- Compare with design specification values.
- Investigate discrepancies for potential issues.
- Document flow rate findings for future reference.
- Inspect guards for damage or looseness.
- Ensure all access panels are securely fastened.
- Replace any missing or damaged guards.
- Document status of safety equipment.
- Record inspection results in maintenance log.
- Prioritize repairs based on urgency and safety.
- Communicate findings with maintenance team.
- Schedule follow-up inspections as needed.
Use in Manifestly