Annual service - induced draft cooling tower (crossflow and counterflow)
Estimated duration: 6 - 10 hours • Frequency: every 12 months
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Fill Media & Structure (additional to quarterly) | ||||
| 1 | Replace fill media sections if degraded (scaling, biological fouling beyond cleaning) | REPLACE | ☐ | |
| 2 | Inspect structural steel and framework for corrosion (measure steel thickness if concern) | INSPECT | ☐ | |
| 3 | Clean and re-coat basin/sump (epoxy or protective coating) | SERVICE | ☐ | |
| 4 | Inspect louvres/intake screens | INSPECT | ☐ | |
| Fan & Motor (additional to quarterly) | ||||
| 5 | Full fan motor service (bearings, insulation resistance test/megger, vibration analysis) | SERVICE | ☐ | |
| 6 | Gearbox oil change (gear-driven fans) | DRAIN/FILL | ☐ | |
| Water Treatment & Distribution (additional to quarterly) | ||||
| 7 | Replace distribution nozzles if worn or uneven | REPLACE | ☐ | |
| 8 | Calibrate water treatment controllers and sensors (conductivity, pH, ORP) | CALIBRATE | ☐ | |
| 9 | Inspect and service make-up water valve assembly | SERVICE | ☐ | |
| Compliance & Legionella (additional to quarterly) | ||||
| 10 | Full Legionella risk assessment per AS/NZS 3666 (cooling water systems) | INSPECT | ☐ | |
| 11 | Compliance report (document all findings, test results, remediation) | RECORD | ☐ | |
| Mechanical (additional to quarterly) | ||||
| 12 | Inspect vibration isolators and mounting bolts | INSPECT | ☐ | |
| 13 | Check basin heater (if fitted, for winter operation) | CHECK | ☐ | |
Fluid / Chemical Specifications (General Guide)
| System | Type / Grade | Notes |
|---|---|---|
| Water treatment chemicals | Biocide, anti-scale, corrosion inhibitor | Per water treatment plan |
| Gearbox oil (gear-driven fans) | EP 220 / 320 | Full change at annual |
| Bearing grease | EP2 | As required |
| Basin coating | Epoxy or polyurethane | If re-coating |
| Calibration solutions | pH, conductivity, ORP standards | For sensor calibration |
Specifications are general guidelines. Always refer to the cooling tower manufacturer's manual and your water treatment provider's recommendations. At the annual service, gearbox oil is fully drained and replaced (gear-driven fans).
Parts / Consumables Required (annual additional items)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Water treatment chemicals | As req. | ☐ | |
| 2 | Gearbox oil EP 220/320 | As req. | ☐ | |
| 3 | Motor bearings (if replacing) | As req. | ☐ | |
| 4 | Fill media sections (if replacing) | As req. | ☐ | |
| 5 | Basin coating (epoxy/polyurethane) | As req. | ☐ | |
| 6 | Replacement nozzles | As req. | ☐ | |
| 7 | Drift eliminator sections | As req. | ☐ | |
| 8 | Calibration solutions (pH, conductivity, ORP) | 1 set | ☐ | |
| 9 | Bearing grease EP2 | As req. | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Facilities Manager