Top 5 Cooling Tower Problems & How to Fix Them
Cooling towers are essential to maintaining efficient HVAC and industrial operations across Arkansas, whether you’re running a manufacturing facility, hospital, data center, or commercial building. But these systems face unique challenges due to the region’s humidity, seasonal temperature swings, and mineral-rich water sources.
When issues go unchecked, cooling tower performance drops, energy costs rise sharply, and equipment lifespan shortens. In more severe cases, untreated problems can lead to compliance risks or unplanned shutdowns.
In the following guide, we outline the five main cooling tower problems, how to detect them early, and the best solutions to address them before they incur high costs.
1. Scaling and Mineral Buildup
Arkansas water commonly contains elevated levels of calcium, magnesium, and silica. As tower water evaporates, these minerals concentrate and harden onto heat-exchange surfaces.
Even a thin layer of scale can reduce heat transfer efficiency by 20–30%, causing your system to work harder and run longer, which increases operating costs. Some signs of scaling you should watch for include:
Reduced cooling capacity
Higher energy use
Hard, white or brown deposits on fill or tubes
Decreased water flow
Increased approach temperature
How to Fix It
Implement proper water softening and chemical treatment. Use anti-scalants designed for high-hardness water profiles typical in Arkansas.
Increase blowdown rate during peak summer months. This helps maintain ideal cycles of concentration.
Schedule periodic descaling. Mechanical or chemical cleaning removes mineral deposits that have already formed.
Add side-stream filtration. Reduces suspended solids that contribute to scaling and fouling.
2. Corrosion and Metal Deterioration
Cooling tower water chemistry can be naturally corrosive if not properly balanced. That’s why it's important to monitor factors that can speed up corrosion, such as high chloride levels, low pH, poor passivation, and galvanic corrosion from dissimilar metals.
Corrosion can quickly compromise structural components and heat-exchange surfaces, leading to costly repairs or the need to replace the entire equipment. Arkansas facilities with older galvanized towers are especially at risk.
Check for these signs of corrosion in your cooling tower:
Rust-colored water
Pitting on metal surfaces
Leaks or thinning materials
Flaking or delamination
How to Fix It
Maintain proper pH and alkalinity. A balanced program prevents corrosive conditions.
Apply corrosion inhibitors. Choose formulations suited to your cooling tower materials.
Install sacrificial anodes when applicable.
Inspect metal components at least twice per year.
Consider upgrading to corrosion-resistant materials if your current tower is nearing the end of its lifespan.
Photo by HSSR
3. Biological Growth (Algae, Slime, and Bacteria)
Arkansas’s warm, humid climate creates ideal conditions for rapid biological growth, especially from late spring through early fall.
Biofilm can reduce heat transfer efficiency by up to 50%, cause fouling and clogging, and increase the risk of harmful bacteria, including Legionella, if water treatment is not properly managed.
Look for these signs of biological growth in your cooling tower:
Green, brown, or slimy surfaces
Clogged strainers or nozzles
Strong odors
Reduced water distribution
Visible algae on the tower basin
How to Fix It
Implement a consistent biocide program. Alternate oxidizing and non-oxidizing biocides for maximum effectiveness.
Maintain proper residuals and monitor weekly.
Ensure the tower is receiving adequate sunlight protection. UV exposure encourages algae formation.
Clean strainers, fill, and basins regularly.
Follow CDC guidelines for maintaining cooling towers to prevent Legionella risks.
4. Mechanical Component Failures
Mechanical failure not only causes downtime but also poses safety risks and can lead to significantly increased repair costs if left unaddressed. Facilities in Arkansas that operate heavily during summer tend to experience faster wear, often due to poor lubrication, imbalanced loads, worn bearings, motor fatigue, and misaligned belts.
How can you identify mechanical issues in a cooling tower? Watch for these signs:
Excessive vibration
Loud or unusual noises
Overheated fan motors
Belt slippage
Irregular fan speed
How to Fix It
Follow a preventive maintenance schedule with monthly, quarterly, or annual tasks.
Lubricate bearings and inspect belts routinely.
Test vibration levels to catch early imbalance.
Replace worn components proactively.
Ensure proper alignment after every repair.
💡 HSSR Tip: Consider installing vibration sensors for real-time monitoring.
5. Poor Water Distribution and Airflow Restrictions
Airflow restrictions and poor water distribution reduce tower capacity, increase energy costs, and put additional load on chillers, which eventually shortens the system’s lifespan. This typically results from blocked nozzles, dirty drift eliminators, fouled fill, uneven water distribution, and fan performance issues.
To prevent this scenario, watch for these signs:
Hot spots in the fill
Uneven water spread
High approach temperature
Reduced cooling capacity
How to Fix It
Clean or replace clogged nozzles.
Wash or replace drift eliminators and fill when fouling exceeds safe limits.
Check for basin blockages.
Inspect fan blades for debris or imbalance.
💡 HSSR Tip: If your tower is older, upgrading to high-efficiency fill and newer nozzles can significantly improve performance with a modest investment.
Photo by HSSR
Bonus: Arkansas-Specific Factors to Consider
Cooling tower problems can escalate faster in Arkansas due to:
High Summer Humidity: Increases biofilm formation and reduces evaporation efficiency.
Hard Water: This requires tailored anti-scaling programs to prevent significant complications.
Seasonal Pollen: Spring pollen can clog filters, strainers, and airflow components.
Wide Seasonal Temperature Swings: Encourage corrosion when water chemistry isn’t adjusted accordingly.
A localized water treatment and maintenance strategy is essential for long-term performance.
How to Prevent Most Cooling Tower Issues?
The good news is that you can solve most cooling tower problems without significantly impacting your budget. It all comes down to knowing when your cooling tower needs maintenance and taking action.
For that matter, here are some tips that will help you feel more confident when managing a cooling tower in Arkansas:
1. Partner with a Cooling Tower Specialist
A trained hydronic systems team can:
Optimize the cycle of concentration.
Implement a custom water treatment program.
Perform mechanical inspections.
Clean and restore system components.
🧰 Looking for a reliable partner to work with? At HSSR, we know how to keep your cooling tower running at peak performance. Contact us to schedule a visit.
2. Maintain a Routine Inspection Schedule
Cooling tower maintenance is crucial for detecting and addressing minor problems early, helping avoid expensive repairs. Most companies plan monthly, quarterly, or yearly inspections. Pick the frequency that feels right for you, depending on your specific situation.
3. Implement Advanced Monitoring
Consider monitoring real-time data for your cooling tower’s conductivity, biological activity, pH, corrosion rates, and vibration. This reduces guesswork and safeguards your investment.
Conclusion
Cooling towers are critical to keeping industrial and commercial facilities in Arkansas running efficiently, but they require proactive care. By understanding the most common problems and addressing them early, you can extend your equipment's lifespan, reduce costly downtime, and maintain compliance with safety guidelines.
If your cooling tower shows reduced performance, unusual noises, or water-quality issues, the next best step is a site evaluation by a hydronic systems specialist.
