Scope of Maintenance works

1. Proper maintenance of cooling towers is essential for sustaining peak operating conditions, maximising energy efficiency, and extending equipment lifespan. Cooling towers are designed to remove heat from water, but even a thin layer of scale, dirt, or biological growth can significantly reduce their effectiveness—industry studies show that just 0.6 mm of scale can increase energy consumption by up to 20%. Regular cleaning, descaling, and servicing prevent such buildup, minimise overheating risks, and reduce wear on system components. By maintaining optimal performance, facilities can lower operational costs, extend equipment reliability, and contribute to a more sustainable, environmentally responsible operation.

   Cooling Tower Servicing Procedure

   Regular servicing of cooling towers is essential to maintain energy efficiency, prevent microbiological risks such as Legionella, and comply with local regulations set by the National Environment Agency (NEA), Building and Construction Authority (BCA), and PUB. Typical servicing involves inspection, cleaning, disinfection, and mechanical maintenance. For year-round operation, servicing is generally required at least twice annually, with additional cleaning if fouling is excessive.

   1. Pre-Service Safety Measures

   Isolate power and water: Switch off electrical supply to the tower and pumps using proper lockout/tagout procedures.

   Close valves: Shut off system and makeup water supplies.

   PPE: Wear coveralls, gloves, waterproof boots, face protection, and respirators.

   Safe work conditions: Ensure ventilation inside the tower and avoid working alone.

   2. Mechanical & Structural Inspection

   Check tower structure for leaks, rust, or corrosion.

   Inspect fill media for scale, algae, or sediment buildup.

   Verify drift eliminators are free of blockages.

   Assess moving parts (fans, motors, belts) for wear and lubricate as needed.

   Test safety devices, including overflow protection and vibration cutout switches.

   3. Cleaning & Disinfection

   Apply pre-clean biocide treatment before draining to loosen biofilm and sediment.

   Drain the basin, then remove sludge, scale, and debris.

   Clean fill media, nozzles, casing, fan blades, and decks with low-pressure water or brushing (high-pressure washing only as per manufacturer’s guidance).

   Rinse thoroughly and flush with clean water.

   Conduct post-clean biocide disinfection to eliminate remaining microorganisms.

   4. Post-Service Restart

   Refill the cold water basin and balance water flow.

   Restore power and restart pumps and fans, checking for noise, vibration, or rotation issues.

   Resume chemical water treatment with corrosion and scale inhibitors.

   Log all service activities and, in line with ASHRAE and NEA guidelines, carry out water sampling to validate cleaning effectiveness.