How to Clean a Cooling Tower

Importance of Cleaning a Cooling Tower

In industrial and commercial building HVAC systems, cooling towers supplied by MachCooling play a critical role in heat rejection. Over time, sludge, scale, algae, biofilm, and microorganisms accumulate inside the cooling tower. These contaminants reduce cooling efficiency, increase energy consumption, cause corrosion and blockage, and may even harbor harmful bacteria such as Legionella.

Regular, thorough cleaning and disinfection are essential to maintaining safe, efficient, and reliable cooling tower operation. Most industry recommendations advise cleaning at least twice per year.

This article provides a complete cooling tower cleaning guide, compatible with MachCooling tower designs.

Preparations Before Cleaning

1. Inspect the Tower

• Before cleaning, conduct a full inspection of the tower body, fill media, basin, spray nozzles, pipes, fan, pump, and structural fasteners.

• Check whether the fill is clogged, whether spray nozzles are blocked, whether the basin contains sludge, and whether any components are damaged.

• Take photos for before-and-after comparison and maintenance documentation.

2. Worker Safety Protection

• Shut down and lock out the pumps and fan motors to prevent accidental start-up.

• Because cooling towers can harbor bacteria and mold, workers must wear PPE: masks, gloves, eye protection, and waterproof clothing.

3. Drain the System

• Close the make-up water supply and isolate the tower from the HVAC system.

• Drain all circulating water from the basin and piping.

• Allow sludge and debris to flush out completely before beginning cleaning.

 Cleaning Procedure

Below is a standard cleaning workflow suitable for most induced-draft and crossflow cooling towers, including MachCooling models.

Step 1: Remove Debris and Sludge

• Use brushes and/or a power washer to remove mud, algae, leaves, and accumulated debris from the basin and lower sections.

• For heavy sludge, a cooling-tower vacuum system can be used.

 Step 2: Clean the Fill Media

• Fill media is crucial for heat exchange. Clogged fill greatly reduces cooling efficiency.

• Wash the fill using a high-pressure washer, ensuring all surfaces and corners are flushed.

• For severe scaling, approved chemical cleaners may be used.

• Replace fill if it shows deformation, brittleness, or broken sections.

Step 3: Clean the Spray System and Drift Eliminators

• Remove mineral deposits and debris from spray headers, nozzles, distribution pipes, and over-spray components.

• Clean drift eliminators to restore proper airflow and reduce water loss.

 Step 4: Chemical Cleaning & Disinfection

• When mechanical washing is insufficient, chemical descaling using approved tower-safe agents is needed to remove mineral scale, oil, and hardened residue.

• Apply appropriate biocides to disinfect the entire system and eliminate bacteria and algae.

• Follow chemical manufacturer guidelines on concentration and circulation time.

Step 5: Rinse, Drain, and Neutralize

• After chemical treatment, rinse the entire tower thoroughly with clean water.

• Neutralize chemical residues (especially chlorine-based disinfectants) before draining, meeting environmental discharge regulations.

Step 6: Refill, Restart, and Document

• Refill with treated/softened water per MachCooling specifications.

• Restart pumps and fans, check for leaks, abnormal noise, uniform water distribution, and smooth airflow.

• Record all cleaning data: date, chemicals used, problems found, and corrective actions.

Example — Cooling Tower Cleaning Workflow Table

 MachCooling Tower — Special Cleaning Recommendations

When cleaning a cooling tower supplied by MachCooling (https://www.machcooling.com/), observe the following:

1. Follow MachCooling manuals — Materials differ (FRP, galvanized steel, stainless steel, PVC), so chemical compatibility must be checked.

2. Routine cleaning + water treatment — At least every six months, or more frequently in dusty or high-mineral areas.

3. Strict safety protocols — Cooling towers contain bioaerosols; PPE must be worn at all times.

4. Environmental compliance — Neutralize chemical wastewater before disposal according to local regulations.

5. Water quality monitoring — Record pH, microbial counts, hardness, and keep cleaning logs for long-term system reliability.

Conclusion

Cooling tower cleaning is not a one-time task but a continuous maintenance process involving mechanical cleaning, chemical descaling, disinfection, rinsing, refilling, and documentation. Regular cleaning keeps the system energy-efficient, prolongs equipment life, prevents bacterial growth, and maintains safe operation.

Users of MachCooling cooling towers are recommended to clean their units at least twice per year, especially before peak summer operation or winter shutdown.