COOLTWR-A Cooling Tower, Maintenance - Annual

                                             50 Tons & Under  Man Hours 6
                                                  50-500 Tons Man Hours 30
                                                500-1000 Tons Man Hours 50
                                               Over 1000 Tons Man Hours 60

Special Instructions:

1.  Schedule performance of this PM activity prior to seasonal start-up.
    Consider the time needed to effect any required repairs.
2.  Review the Procedure for "Controlling Hazardous Energy
3.  Perform cleaning of the tower in accordance with PM COOLTWR-Q before
    performing this PM activity.
4.  Review manufacturer's instructions.
5.  Deenergize, lock out, and tag electrical circuits.
6.  Review the Procedure for "Selection, Care, and Use of
    Respiratory Protection".
7.  Properly dispose of any debris, excess oil, and grease.
8.  Check the building's asbestos management plan to see if the wet deck panels
    have been tested for asbestos.  If they are suspect but have not been tested,
    have them tested.  Manage asbestos in accordance with the plan.

Items to Check & Initial Completion:

Exterior Structural:

1. ___ Inspect louvers for correct position and alignment, missing or defective
       items, and supports.
2. ___ Inspect casings and attaching hardware for leaks or defects. Check the
       integrity and secure attachment of the corner rolls.
3. ___ Inspect for loose or rotten boards on wood casings.  Examine from the
       interior.  Extensive damage may require replacement with fiberglass
4. ___ Inspect condition of access doors and hinges.  Repair as necessary.
5. ___ Inspect the distribution system including flange connectors and gaskets,
       caulking of headers on counterflow towers, deterioration in distribution
       basins, splash guards, and associated piping on crossflow towers.  If
       configured with water troughs check boards for warpage, splitting, and
6. ___ Examine the drain boards for damage and proper drainage.  Check the
       fasteners also.
7. ___ Inspect stairways including handrails, knee rails, stringers, structure
       and fasteners for rot, corrosion, security and acid attack.
8. ___ Shake ladders to verify security, and check all rungs.
9. ___ Check the security, rot, and corrosion on walkway treads.  Check treads,
       walkways, and platforms for loose, broken, or missing parts.  Tighten or
       replace as necessary.
10.___ Ladders must be checked for corrosion, rot, etc.  Verify
       compliance with Occupational Safety and Health regulations regarding
       height requirements.  Check ladder security.
11.___ Check fan decks and supports for decay, missing and broken
       parts, and gaps.  Check the security.
12.___ Fan cylinders must be securely anchored.  Check fastening
       devices.  Note any damaged, missing, or corroded items.  Watch for wood
       rot and corrosion of steel.  Verify proper tip clearance between the fan
       blade and interior of cylinder.  Verify compliance with OSHA requirements
       regarding height.  Check its condition.
13.___ Apply protective coatings as needed on exterior surfaces.  Be
       sure rust and dirt have been removed first.

Interior Structural:

14.___ Inspect the distribution system piping for decay, rust, or
       acid attack.  Check the condition and tightness of connections and branch
       arms.  Observe spray pattern of nozzles if possible and note missing and
       defective nozzles.  Note condition of the redistribution system under the
       hot water system.
15.___ Inspect mechanical equipment supports and fasteners for
       corrosion.  Wood structural members in contact with steel should be
       checked for evidence of weakness.  Check condition of springs or rubber
       vibration absorption pads, including adjusting bolts, ferrous members, and
       rubber pads.
16.___ Check valves and operating condition of fire detection
       system. Check for corrosion of pipes and connectors.  Check wiring of any
       thermocouple installed.
17.___ Check drift eliminators and supports.  Remove any clogging
       debris.  Replace missing blades.
18.___ Inspect tower fill for damage, ice breakage, deterioration,
       and misplaced, missing, or defective splash bars.
19.___ Examine interior structural supports.  Test columns, girts,
       and diagonal wood members for soundness by striking with a hammer.  A high
       pitched, sharp sound indicates good wood, whereas a dull sound indicates
       soft wood.  Probe rotted areas with a screw driver to determine extent of
       rot.  Look for iron rot of metal fasteners in contact with wood.  Check
       condition of steel internals.  Check condition and tightness of bolts.
20.___ Inspect the nuts and bolts in partitions for tightness and
       corrosion.  Look for loose or deteriorated partition boards.  Note if
       partitions are installed so as to prevent wind milling of idle fans.  Make
       sure wind walls parallel to intake louvers are in position.  Boards or
       transite members should be securely fastened.  Check condition of wood or
       steel supports for rot and corrosion.
21.___ Check wooden cold water basins for deterioration, warps,
       splits, open joints, and sound of wood.  Inspect steel basins for
       corrosion and general condition.  Inspect concrete basins for cracks,
       breaking joints, and acid attack.
22.__  Check all sumps for debris, condition of screens,
       antiturbular plates, and freely operating drain valves.


1.___ Check alignment of gear, motor, and fan.
2.___ Inspect fans and air inlet screens and remove any dirt or debris.
    a.___ Check hubs and hub covers for corrosion, and condition of attaching
    b.___ Inspect blade clamping arrangement for tightness and corrosion.
3.  Gear box
    a.___ Clean out any sludge.
    b.___ Change oil.  Be sure gear box is full to avoid condensation.
    c.___ Rotate input shaft manually back and forth to check for backlash.
    d.___ Attempt to move the shaft radially to check for wear on the input
          pinion shaft bearing.
    e.___ Look for excessive play of the fan shaft bearings by applying a force
          up and down on the tip of a fan blade.  Note:  Some output shafts have
          a running clearance built into them.
4.  Power transmission.
    a.___ Check that the drive shaft and coupling guards are installed  and that
          there are no signs of rubbing.  Inspect the keys and set screws on the
          drive shaft, and check the connecting hardware for tightness.  Tighten
          or install as required.
    b.___ Look for corrosion, wear, or missing elements on the drive shaft
    c.___ Examine the exterior of the drive shaft for corrosion, and check the
          interior by tapping and listening for dead spots.
    d.___ Observe flexible connectors of both ends of the shaft.
    e.___ Inspect bearings, belts, and pulleys for excessive noise, wear or
          cracking, alignment, vibration, looseness, surface glazing, tension.
          Replace or repair as required.
5.___ Check water distribution.  Adjust water level and flush out troughs if
      necessary.  Check all piping, connections, and brackets for looseness.
      Tighten loose connections and mounting brackets.  Replace bolts and braces
      as required.
6.___ Check nozzles for clogging and proper distribution.
7.___ Inspect keys and keyways in motor and drive shaft.


1.___ Check electric motor for excessive heat and vibration.  Lubricate all motor
      bearings as applicable.  Remove excess lubricant.
2.___ Inspect fused disconnect switches, wiring, conduit, and electrical controls
      for loose connections, charred or broken insulation, or other defects.
      Tighten, repair, or replace as required.
3.___ Remove dust from air intakes, and check for corrosion.  Check TEFC motors
      for conditions of air passages and fans.
4.___ If there is a drain moisture plug installed, see if it is operational.
5.___ Check amps and volts at operating loads, recommend pitching of fan blades
      to compensate.
6.___ Look for corrosion and security of mounting bolts and attachments.

Tools & Materials:

1.  Standard Tool kit.
    Plus Pipe wrenches to 24"
         Tubing cutters
         Flaring tool
         Small acetylene outfit
         Packing tool kit and packing
         3/4" socket set
         Crescent wrenches to 14"
2.  Protective coating, brushes, solvent, etc.  Consult the Material Safety Data
    Sheets (MSDS) for hazardous ingredients and proper personal protective
    equipment (PPE).
3.  Manufacturer approved lubricants.  Consult the MSDS for hazardous ingredients
    and proper PPE.
5.  Cleaning tools and materials.  Consult the MSDS for hazardous ingredients and
    proper PPE.
6.  Respirator.
7.  Safety goggles
8.  Work gloves
9.  OSHA approved ladders of appropriate size or scaffolding.  Check ladder for
    defects. Do not use defective ladders.
10. Amp probe and volt meter.
11. High pressure washer.

Table of Contents    |    Next