A cooling tower preventive maintenance schedule lists the checks and jobs done on the equipment at fixed intervals, how long each takes, and in what order of frequency, so problems are found before the cooling tower fails. This page gives the schedule used in the PlantOps360 task library for cooling tower (induced draft), which follows common industry practice for general-purpose equipment. It is also searched for as evaporative cooler, CT fan, counterflow tower, crossflow tower.
The maker’s manual and your site safety procedures always come first where they differ. Intervals set by law differ by state.
Cooling tower preventive maintenance schedule and checklist
| How often | Task | Estimated time |
|---|---|---|
| Daily | Check basin water level, make-up and blowdown, fan and gearbox for noise or vibration | 5 min |
| Weekly | Check basin and fill for algae, slime or debris; check drift eliminators | 20 min |
| Monthly | Check conductivity, pH and biocide dosing; test water for bacteria as per the water management plan | 45 min |
| Monthly | Check fan gearbox oil level and drive shaft and belts; grease bearings | 30 min |
| Quarterly | Clean strainers, nozzles and hot water basin; inspect fill and louvres | 90 min |
| Half-yearly | Check water quality program: Legionella sampling as per the plan | 90 min |
| Annual | Clean and disinfect the tower and basin; inspect structure, fill and fan blades; change gearbox oil | 600 min |
Cooling tower maintenance frequency and yearly workload
At the estimated times, one cooling tower needs about 82 hours of preventive maintenance a year. The biggest single job is “Clean and disinfect the tower and basin; inspect structure, fill and fan blades; change gearbox oil” at 600 minutes, done annual. Multiply by the number of units you have to see the workload for your plant.
| Frequency | Tasks | Time per round | Hours per year |
|---|---|---|---|
| Daily | 1 | 5 min | 30.4 h |
| Weekly | 1 | 20 min | 17.3 h |
| Monthly | 2 | 75 min | 15.0 h |
| Quarterly | 1 | 90 min | 6.0 h |
| Half-yearly | 1 | 90 min | 3.0 h |
| Annual | 1 | 600 min | 10.0 h |
What goes wrong on a cooling tower without preventive maintenance
- Fill and drift eliminator fouling
- Fan and gearbox faults
- Scale and biological growth in the water
- Basin and strainer blockage
What to watch between services
- Cold water temperature against design
- Water treatment readings
- Fan vibration
Safety and statutory notes for cooling tower maintenance
Cooling towers need water treatment and a Legionella-style risk control. Follow your site’s water-safety procedure.
Where a cooling tower preventive maintenance schedule is used
A cooling tower is found in almost every industry. The industry guides below show how it fits into the wider schedule of each one:
- Preventive maintenance schedule for pharmaceutical plants
- Preventive maintenance schedule for food, dairy and beverage plants
- Preventive maintenance schedule for automotive plants
- Preventive maintenance schedule for chemical, fertiliser and petrochemical plants
- Preventive maintenance schedule for cement, glass, ceramics and building materials plants
- Preventive maintenance schedule for steel, foundry, forging and metal plants
- Preventive maintenance schedule for textile and garment mills
- Preventive maintenance schedule for thermal and hydro power plants
See all industry preventive maintenance schedules.
Related equipment maintenance schedules
- Chiller preventive maintenance schedule
- Air-cooled chiller preventive maintenance schedule
- Air handling unit preventive maintenance schedule
- Fan coil unit, split AC preventive maintenance schedule
- Variable refrigerant flow system preventive maintenance schedule
- Cold room preventive maintenance schedule
- Ammonia refrigeration plant preventive maintenance schedule
- Desiccant dehumidifier preventive maintenance schedule
Browse the full list of equipment preventive maintenance schedules (317 types).
Run this cooling tower schedule in maintenance software
In preventive maintenance software, each row above becomes a recurring task on the asset with its checklist, time estimate and parts. Tasks can be triggered by calendar date, running hours, meter readings or production cycles, each completed task is recorded with the person and date, and a failed check can open a work order. For the method behind it, read the guide to the preventive maintenance schedule, or use the free generator to get a 12-month plan for your whole equipment list.
Build my preventive maintenance schedule (free Excel)
Frequently asked questions
How often should a cooling tower be serviced?
In our schedule a cooling tower has 7 tasks: 1 daily, 1 weekly, 2 monthly, 1 quarterly, 1 half-yearly, 1 annual. The biggest job is “Clean and disinfect the tower and basin; inspect structure, fill and fan blades; change gearbox oil”, which is done annual. Always follow the maker’s manual where it gives a different interval.
What is included in cooling tower preventive maintenance?
It covers routine checks and jobs such as “Check basin water level, make-up and blowdown, fan and gearbox for noise or vibration”, “Check basin and fill for algae, slime or debris; check drift eliminators”, “Check conductivity, pH and biocide dosing; test water for bacteria as per the water…”, up to the annual overhaul or inspection. The full list with times is in the table above.
How many hours of maintenance does a cooling tower need per year?
About 82 hours per unit per year at the estimated times in our library, including the daily checks done every day. Use it to plan workload, not as a benchmark.
Is there a free cooling tower maintenance checklist?
Yes. The table on this page is a ready checklist. The free preventive maintenance schedule generator turns it into a 12-month Excel schedule for your list of equipment, with monthly workload hours.