BAC (Baltimore Aircoil Company) cooling tower maintenance and repair is essential to keep thermal performance, minimize downtime, and extend equipment life. Below is a practical, field-oriented guide aligned with BAC crossflow and counterflow towers.
1. Preventive Maintenance Schedule (BAC Best Practice)
Daily / Weekly Bac Cooling Tower Maintenance And Repair
* Check cold-water basin level
* Inspect for unusual noise or vibration
* Verify fan motor amps (compare to nameplate)
* Observe water distribution (no dry fill areas)
Monthly Bac Cooling Tower Maintenance And Repair
* Inspect spray nozzles / distribution deck
* Check make-up water valve operation
* Inspect drift eliminators for damage or gaps
* Look for visible corrosion or leaks
Quarterly Bac Cooling Tower Maintenance And Repair
* Clean basin strainers
* Inspect fan blades for cracks or fouling
* Check gearbox oil level & condition
* Verify vibration levels at motor and gearbox
* Inspect fill for scaling or biological growth
Semi-Annual Bac Cooling Tower Maintenance And Repair
* Lubricate:
* Motor bearings
* Fan shaft bearings (if applicable)
* Check fan blade pitch angle
* Inspect couplings and alignment
* Test motor insulation resistance (megger)
Annual (Major Inspection) Bac Cooling Tower Maintenance And Repair
* Drain and clean cold-water basin
* Remove and clean spray nozzles
* Inspect distribution deck panels
* Inspect drift eliminators thoroughly
* Check gearbox oil (change if contaminated)
* Inspect structural members and casing
* Verify tower performance vs design
2. Key BAC Components: Maintenance & Repair
2.1 Water Distribution System
Common issues:
* Clogged nozzles
* Uneven water flow
* Deck sagging (crossflow)
Repair actions:
* Replace damaged nozzles
* Level distribution deck panels
* Maintain correct basin water depth
2.2 Fill Pack
Problems:
* Scaling
* Biofouling
* Brittleness (UV/age)
Solutions:
* Chemical cleaning (with water treatment vendor)
* Partial or full fill replacement
* Upgrade to higher-efficiency BAC-compatible fill
2.3 Drift Eliminators
Failure signs:
* Excessive water carryover
* Cracked or warped blades
Repair:
* Replace entire panel sections
* Ensure tight sealing to prevent air bypass
2.4 Fan, Gearbox & Drive System
Fan
* Check blade balance and pitch
* Clean fouling to prevent vibration
Gearbox
* Use manufacturer-approved oil
* Watch for oil leaks and temperature rise
Motor
* Ensure space heaters operate
* Replace corroded conduit fittings
* Verify VFD parameters if installed
3. Typical BAC Cooling Tower Repairs
| Repair Type | Typical Interval |
| Nozzle replacement | 2–5 years |
| Drift eliminator replacement | 8–15 years |
| Fill replacement | 5–12 years |
| Gearbox overhaul | 8–15 years |
| Fan motor replacement | 10–20 years |
| Basin re-coating | s required |
4. Water Treatment (Critical for BAC Towers)
Proper water chemistry prevents 80% of mechanical failures.
Key control items:
* Scaling index (LSI)
* Biological growth
* Corrosion inhibitors
* Blowdown control
* Side-stream filtration (recommended)
5. Shutdown, Repair & Start-Up Checklist
Before Shutdown
* Record motor amps, vibration, temperatures
* Photograph blade pitch and component positions
During Repair
* Use OEM or BAC-approved equivalent parts
* Replace fasteners with stainless steel
* Maintain original airflow and water distribution geometry
Start-Up
* Verify rotation direction
* Check fan blade pitch
* Monitor amps, vibration, noise for first 24 hours
* Inspect drift and water carryover
6. Bac Cooling Tower Maintenance And Repair Safety Considerations
* Lockout/tagout (LOTO)
* Fall protection
* Confined space precautions
* Chemical handling procedures
* Never enter tower with fan running
7. When to Consider Major Refurbishment
* Cooling capacity loss >10%
* Frequent fan or motor failures
* Excessive water consumption
* Structural corrosion
* Obsolete parts unavailable
8. BAC OEM vs Aftermarket Parts
* OEM BAC parts: guaranteed fit and performance
* Aftermarket: lower cost but must match airflow, drift, and distribution specs exactly
9. Recommended Documentation
* BAC Installation, Operation & Maintenance (IOM) manual
* Motor & gearbox manuals
* Water treatment reports
* Maintenance log
