Cooling Tower Troubleshooting: Common Problems, Causes & Solutions

Maintenance and Adjustments

  1. Sprinkler Head
  2. If any scale of sludge collects in the sprinkler head, it will impede its rotation. Should sprinkler rotation stop or slow down, first check whether the circulation rate is normal. If correct, dismantle the rotary head for cleaning and check.

  3. Sprinkler Pipes
  4. The sprinkler pipes must be kept clean to prevent any blockage in holes. When cleaning the sprinkler pipes, loosen the sprinkler pipes lock nut for small models and unscrew the bolts in sprinkler head for large models.

  5. Casing
  6. No coating is needed for the casing as it is made of FRP. If it becomes soiled, wash it with soap and water.

  7. Water Basin
  8. Scrub the water basin when it becomes dirty. Flush any dirt out through the drain. Regularly clean the strainer which is fitted inside the basin. If splash mat is attached to the water basin, it should also be cleaned as often as water basin.

  9. Fills
  10. No specific attention is necessary for fills with proper water quality control. Remember do not walk or stand directly on the fills. Always place plywood or hardboard over the fills while repairing.

  11. Water Quality Control
  12. Because of poor quality cooled water or air pollution, such cases as corrosion, scale & algae growth which not only impedes the performance of equipments but also damage the equipments.
    (1) Make quality analysis of circulating & make up water.
    (2) Water treatment is strongly recommended. Periodic blow down or automatic blow down can also keep the operation within the acceptable water quality.


Cooling Tower Rotary Sprinkler Head Assembly Diagram – Lock Nut and Washer Type
Cooling Tower Sprinkler Head Assembly Diagram – Bearing and Seal Sectional View

Trouble Shooting

Trouble Cause Remedy
Rise in cooling water temperature 1.Excessive or inadequate cooling water 1.Adjust to the specified flow.
2.Irregular flow of air. 2.Improve ventilation.
3.Re-circulation of air from tower outlet. 3.Improve ventilation.
4.Irregular rotation of sprinkler pipes. 4.Remove dirt and scale.
5.Improper flow of air from fan. 5.Adjust the angle of fan blades.
6.Blocking of the Fills. 6.Clean the blocked area.
Abnormal water flow 1.Blocking of the sprinkler pipe holes. 1.Clean sprinkler pipes.
2.Blocking of strainer mesh. 2.Remove strainer and clean.
3.Water level decrease in the water basin. 3.Adjust float valve or rapid water make up system.
4.Improper selection of water circulating pump. 4.Replace the pump with proper capacity.
Noise and vibration 1.Fan blade tips touching casing. 1.Adjust the fan mounting.
2.Bending of fan shaft. 2.Adjust bend at special shop.
3.Loose bolts. 3.Tighten loose bolts.
4.Motor's bearing damage. 4.Repair or replace motor.
5.Damage in fan and/or motor fan. 5.Replace fan.
Excessive current flow 1.Drop in voltage. 1.Check supply voltage.
2.Irregularities in the angles of the fan blades. 2.Make careful adjustment.
3.Damage in motor. 3.Repair or replace motor at manufacturer.
4.Overload through excessive air flow. 4.Adjust fan blades angles.
Water carry over 1.Irregular rotation of sprinkler pipes. 1.Adjust the angle of the sprinkler pipes and check the sprinkler head.
2.Blocking of the fill. 2.Eliminate blockage at the upper edge of the fill.
3.Improper installation of eliminator. 3.Improve & repair eliminator.
4.Excessive circulating water. 4.Adjust the water flow with valve.
5.Excessive air flow. 5.Adjust fan blades angles.

Inspection And Maintenance Schedule

Fan Motor Elimination PVC Fills Water Basin Sprinkler Systems Structural Mambers FRP Casings Float Value Bleed Rate Flow Control Values Air Inlet Mesh
Inspect for clogging W W W W
Check for unusal noise or vibration D D Y D
Inspect keys and set Screws S S
Lubricate Y
Check water level/quality D
Check flow rate M
Check for leakage S S S
Inspect general condition Y Y Y S Y Y S
Clean R S R R S R R R W
Repaint R R
Completely open and close S

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About Us

Gem Equipments entered the engineering and fabrication industry in 1984. We specialise in design, engineering and fabrication of Cooling Towers, Compressed Air Dryers, Industrial Chillers and Compressed Air Treatment Accessories.

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S.F. No.103, Avinashi Road, Arasur,
Coimbatore - 641 407,
Tamil Nadu , India

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