How to Clean and Replace Cooling Tower Fill

Cooling tower fill plays a critical role in heat-exchange efficiency. Over time, biological growth, scale, and debris accumulate on the fill, reducing thermal performance and increasing energy consumption. Regular cleaning and timely replacement of the fill ensure stable cooling capacity and extend equipment life.
This article provides a practical guide to inspecting, cleaning, and replacing cooling-tower fill.

1. Safety Precautions

Before any maintenance work, ensure the following safety steps are taken:

• Shut down the cooling tower and isolate electrical power.

• Lockout controls and pumps.

• Wear PPE, including gloves, goggles, non-skid boots, and a respirator (especially for fiberglass or PVC dust).

• Ensure proper fall protection when working inside or above the cooling tower.

• Verify sufficient ventilation to avoid accumulation of chemical fumes.

2. Inspection Before Cleaning

Begin with a detailed inspection to determine whether the fill can be cleaned or must be replaced.

Check for:

• Cracks, fractures, or brittleness in the fill sheets.

• Clogging due to scale, silt, algae, or biological growth.

• Deformation caused by heat or chemical attack.

• Sagging or detachment from structural supports.

If the fill is brittle, warped, or heavily clogged, suggest timely replacement.

3. Cleaning the Cooling Tower Fill

3.1 Remove Debris

• Drain the basin.s

• Manually remove loose debris such as leaves, dirt, and sludge.

• Use a low-pressure water hose to rinse off surface contamination.

3.2 Chemical Cleaning

If scale or biological growth is present, chemical treatment is necessary:

1. Choose appropriate cleaning agents

• Acidic cleaners (mild) for scale and mineral deposits.

• Biocides for algae and microbial slime.

2. Apply chemicals

• Use a sprayer to evenly coat the fill.

• Allow recommended dwell time to dissolve contaminants.

3. Rinse thoroughly

• Use low-pressure water (< 60 psi).

• Avoid high-pressure washing, which can damage the fill sheets.

3.3 Mechanical Cleaning (If Required)

• Soft brushes can be used on stubborn deposits.

• Never use metal brushes or abrasive tools.

3.4 Flush the System

After cleaning:

• Rinse the fill and basin until water runs clear.

• Restart circulation pumps briefly to flush remaining residue.

4. When Fill Should Be Replaced

Fill must be replaced if:

• Sheets are brittle, broken, or melted.

• Channels are fully clogged and cannot be restored by cleaning.

• Fill has lost structural integrity, causing sagging.

• Cooling performance has significantly declined despite routine maintenance.

• There is heavy biological fouling that penetrates deep layers of the fill.

5. How to Replace Cooling Tower Fill

5.1 Remove the Old Fill

• Disassemble the casing or access panels.

• Cut or detach tie-rods and supports holding the fill.

• Carefully lift out old fill blocks to avoid damaging surrounding structures.

• Clean the fill supports, drift eliminators, and basin before installation.

5.2 Prepare the New Fill

• Confirm fill type: splash fill, film fill, cross-flow, or counter-flow design.

• Check dimensions to ensure compatibility.

• Inspect for shipping damage before installation.

5.3 Install New Fill

• Follow the manufacturer's installation layout.

• Position the blocks tightly to prevent air bypass.

• Secure the fill using tie-rods, clips, or the tower's built-in support system.

• Ensure proper alignment with water distribution nozzles.

5.4 Reassemble & Test

• Reinstall all panels and covers.

• Restore water flow and electrical supply.

• Run the cooling tower and check for:

• Proper water distribution

• Airflow uniformity

• Unusual vibration or noise

• Leaks or bypassing water

6. Maintenance Tips for Longer Fill Life

• Maintain proper water treatment to reduce scale and corrosion.

• Clean strainers and basins regularly.

• Perform quarterly inspections of nozzles, drift eliminators, and fans.

• Schedule annual deep cleaning.

• Ensure proper chemical dosing (biocides, scale inhibitors).