Cooling Tower Myth Busting: What Every Facility Manager Needs to Know

Keeping your facility running smoothly is no easy feat, especially when it comes to cooling towers. These critical systems are often misunderstood, and even well-meaning facility managers may fall prey to outdated or inaccurate advice. In this post, we’re busting some of the most common myths that can lead to inefficiencies, increased costs, and unexpected downtime. Let’s separate fact from fiction.

Myth #1: “Any fill fits any tower.”

Reality: Fill media isn’t one-size-fits-all. Using the wrong type or density of fill can severely reduce thermal performance, increase drift loss, or even damage the tower.

Expert Insight: Leading cooling tower specialists customize fill media based on tower type, water chemistry, and performance requirements to ensure peak thermal efficiency.

Myth #2:  “Cooling towers only need annual maintenance.” 

Reality: Waiting a full year between service visits allows scale, biological growth, and mechanical wear to progress unchecked. 

Expert Insight: Industry professionals recommend at least semi-annual cleaning and inspections. Partnering with a team that offers structured preventive maintenance can prevent larger issues and maintain optimal performance. 

Myth #3:  “Bigger fans always mean better cooling.” 

Reality: Oversized fans can disrupt airflow, create imbalance, and increase energy use without delivering better results.

Expert Insight: Experienced engineers evaluate system load, fan performance curves, and tower design to ensure the right fit and avoid unnecessary energy consumption.

Myth #4:  “All mechanical components wear out at the same rate.” 

Reality: Components like motors, gearboxes, and drive shafts experience wear differently based on usage, alignment, and upkeep.

Expert Insight: Experienced engineers evaluate system load, fan performance curves, and tower design to ensure the right fit and avoid unnecessary energy consumption. 

Myth #5:  “All water treatment systems are the same.” 

Reality: A one-size-fits-all approach to water treatment often leads to scale, corrosion, or microbial issues that hurt system performance. 

Expert Insight: Effective service providers work closely with water treatment experts to tailor a program suited to each cooling tower’s design and environmental conditions. 

Myth #6:  “If it’s running, it doesn’t need servicing.” 

Reality: Just because a cooling tower is operating doesn't mean it's running efficiently. Hidden inefficiencies can result in higher energy use or early equipment failure. 

Expert Insight: Routine performance checks and servicing are key to identifying hidden issues before they lead to costly repairs or system failure. 

Myth #7:  “Replacement is always more cost-effective than repair.” 

Reality: Many cooling towers can be restored through focused repairs such as replacing fill media, upgrading drift eliminators, or improving basin design. These upgrades can extend system life at a significantly lower cost than a full replacement. 

Expert Insight: A qualified specialist will evaluate the condition of your system and your performance goals to determine whether strategic repairs or complete replacement is the most cost-effective option. 

Conclusion: Do Not Let Myths Manage Your Cooling Towers

Facility managers juggle many competing priorities, and cooling tower performance is often one of the most overlooked. Making decisions based on myths rather than accurate information can lead to higher operating costs, more frequent breakdowns, and unnecessary system replacements.

To avoid these issues, consider working with a company that specializes in cooling tower systems. Industry experts can help you assess performance, plan maintenance, and identify upgrades that improve efficiency and reliability. Informed decisions today can prevent expensive problems tomorrow.