Cooling towers are a critical component of many industrial and commercial facilities, ensuring efficient heat transfer and system reliability. However, when these systems are taken offline for seasonal or extended downtime, proper layup procedures are essential to protect the equipment. Without a structured approach, your cooling tower may fall victim to corrosion, scaling, and microbiological growth—all of which can reduce efficiency, increase maintenance costs, and shorten the system’s lifespan.
At Apex, we understand that downtime doesn’t mean neglect. By following the 8 key steps for an effective cooling tower layup, you can keep your system protected and ensure a smooth restart when operations resume.
Why Is Proper Cooling Tower Layup Important?
Cooling tower layup involves preparing your system for downtime to prevent damage caused by stagnant water, debris, and other risks. Without proper preparation, you risk:
- Corrosion: Oxygen and stagnant water can lead to rapid metal deterioration, damaging components like fill and basins.
- Scaling and Fouling: Without treatment, residual water can lead to scale buildup and fouling, which are difficult and expensive to clean.
- Microbiological Growth: Stagnant conditions create the perfect environment for bacteria, algae, and biofilm, increasing the risk of Legionella and other health hazards.
Taking the time to perform a structured layup process ensures your cooling tower remains safe, efficient, and ready for operation when needed.
8 Key Steps for an Effective Cooling Tower Layup
1. Perform a Thorough Inspection
Before shutting down your cooling tower, inspect all system components for damage, wear, or leaks. Check areas such as the basin, piping, heat exchangers, and fans for signs of corrosion, debris, or fouling.
2. Clean the Cooling Tower Thoroughly
Remove dirt, debris, and sediment from the tower basin, fill, and other components. Residual debris can contribute to scaling and biofilm formation during downtime. Use a high-pressure washer or mechanical cleaning tools to ensure all surfaces are thoroughly cleaned.
3. Drain All Water from the System
Completely drain the cooling tower and connected systems, such as piping, basins, and heat exchangers. Stagnant water left in the system can lead to corrosion, scale formation, and microbiological growth.
4. Treat Remaining Water with Corrosion Inhibitors
If complete drainage isn’t possible, treat any remaining water with appropriate corrosion inhibitors to protect system components. This step is especially critical in partially drained systems or facilities with humid climates.
5. Protect Metal Surfaces with a Passivation Layer
Metal surfaces, particularly in newly cleaned systems, are vulnerable to corrosion when exposed to oxygen. Apply a passivation treatment to create a protective barrier that reduces the risk of rust and oxidation.
6. Address Microbiological Risks
Stagnant conditions during layup can lead to microbiological growth, including algae, bacteria, and biofilm. Use biocides or microbiological inhibitors to reduce this risk and ensure a clean restart.
7. Cover and Secure the Cooling Tower
Protect the cooling tower from external contaminants like dirt, leaves, and pests by securely covering open areas. This step helps maintain cleanliness and minimizes additional maintenance before restart.
8. Create a Restart Plan
Document all steps taken during the layup process and outline a clear plan for restarting the system. This plan should include:
- System inspection before restart.
- Additional cleaning or flushing requirements.
- Water treatment adjustments for initial operations.
Proper documentation ensures your team can restart the system efficiently and safely, minimizing downtime.
How Apex Supports Effective Cooling Tower Layup
At Apex, we’re committed to helping facilities protect their critical systems during downtime. Our comprehensive water treatment services and expertise ensure your cooling tower remains in top condition through every season. Here’s how we can help:
- Tailored Water Treatment Solutions: From corrosion inhibitors to biocides, we provide the right products to protect your system.
- Preventive Maintenance Programs: Our team helps you develop proactive maintenance and layup plans that minimize risks and costs.
- Restart Support: With our expert guidance, your cooling tower can resume operations efficiently and safely after downtime.
Whether you need assistance with cleaning, chemical selection, or developing a detailed layup plan, Apex is here to support you every step of the way.
Protect Your Cooling Tower Today
Proper cooling tower layup is the key to long-term system health and efficiency. By following these 8 essential steps, you can minimize risks like corrosion and microbiological growth while ensuring a seamless restart.
Ready to get started?
Contact Apex today to discuss how we can help you develop a customized cooling tower layup plan. Together, we’ll ensure your system remains protected and efficient—no matter the season.