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Cooling Tower Maintenance Cost Calculator
Cooling towers require water treatment + mechanical maintenance; Legionella compliance critical.
Annual cost
$16,800
Water treatment
$9,600
Amortized media
$1,500
How the math works
Total = water treatment × 12 + mechanical + Legionella + amortized media.
$800 × 12 + $4,500 + $1,200 + $12,000/8 = $9,600 + $4,500 + $1,200 + $1,500 = $16,800.
How to Use
- Enter cooling tower tons.
- Enter water treatment monthly.
- Enter mechanical annual.
- Enter Legionella testing cost.
- Enter fill/media replacement cycle.
- Read annual cost.
Frequently Asked Questions
Cooling tower basics?
Cooling tower rejects chiller heat via water evaporation. Key systems: fans, spray nozzles, fill/media (water distribution), basin, water treatment, sump pumps. Sizing: 2.5-3 gallons water evaporated per hour per ton of cooling. 500-ton tower: 1,200-1,500 gph evaporation. Water treatment critical: biocides, corrosion inhibitors, scale control, pH buffering.
Legionella compliance?
ASHRAE 188: required water management plan for cooling towers in most jurisdictions. Routine testing: monthly biocide + quarterly Legionella test. $100-500/test. Legionella positive event: immediate hyperchlorination + state notification. Legal liability: major outbreak associated with fatalities ($millions). Facility-level water management team recommended. Documentation required for audit.
Mechanical maintenance?
Fan belt adjustment/replacement: monthly/quarterly. Fan balance + vibration analysis: annually. Drift eliminator cleaning: 2-4× per year. Fill/media cleaning: annual. Fill replacement: every 5-10 years ($3-15k). Basin cleaning: annual or bi-annual. Sump pump inspection: monthly during cooling season. Total maintenance: $1,500-8,000/year per tower depending on size.
Winterization?
Shutdown protocol (late October-November): drain system, flush lines, protect exposed components, antifreeze if loop drain incomplete, cover/mothball. Startup protocol (March-April): refill, water treatment reset, inspection, leak test, fan startup, alarm testing. Damage risk: frozen lines can burst ($5-50k damage). Proper winterization: $2-5k consultant cost, saves much more in preventing damage.
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