Cooling Towers & Chillers: Spring Startup Tips

As spring temperatures rise, it’s time to transition your building’s HVAC system from heating to cooling mode—and that means getting your Cooling Towers & Chillers back online. These systems play a crucial role in maintaining comfort and efficiency in large commercial and industrial spaces. But if not properly prepared for seasonal startup, they can lead to system inefficiencies, increased energy bills, or costly breakdowns.

Here’s a step-by-step guide to help facility managers ensure a safe, efficient, and smooth startup of cooling systems this spring.

1. Inspect the Entire System Before Power-Up

Before restarting any equipment, conduct a comprehensive visual inspection:

• Look for leaks, corrosion, or signs of wear on piping, valves, and coils.
• Check insulation on chilled water lines for damage.
• Ensure the area around the chiller and cooling tower is clean and clear of debris.

A pre-startup inspection can catch small issues before they become major repairs.

2. Clean the Cooling Tower

Cooling towers accumulate scale, algae, and debris during the off-season. A dirty cooling tower can reduce efficiency and promote bacterial growth (including Legionella).

• Remove debris and sludge from the basin.
• Clean fan blades and fill media.
• Check drift eliminators and louvers for damage.
• Inspect and clean the strainers.

Consider scheduling a professional tower cleaning to ensure thorough sanitization.

3. Check Mechanical Components

Your mechanical components—especially pumps, fans, belts, and motors—need a close check:

• Lubricate bearings and motors as required.
• Inspect belts for tension and wear; replace if cracked or frayed.
• Verify pump alignment and coupling integrity.
• Confirm that all electrical connections are tight and undamaged.

4. Flush and Treat Water Systems

Stagnant water in cooling loops can harbor contaminants and mineral buildup. Before circulating water through the system:

• Flush the chilled water loop to remove sediment and old treatment chemicals.
• Test water quality and re-establish proper chemical treatment to prevent scaling, corrosion, and biological growth.

Regular water treatment is essential for system longevity and compliance with health and safety standards.

5. Perform a Controlled Startup

Once mechanical and chemical systems are ready, perform a controlled system startup:

• Power on the system slowly, starting with pumps and progressing to the chiller and cooling tower.
• Monitor operating pressures, temperatures, and flow rates.
• Verify that control systems and sensors are reading accurately.

Let the system run under supervision to ensure all components are responding correctly.

6. Review System Controls and BAS Integration

Spring is also a smart time to fine-tune your Building Automation System (BAS):

• Check setpoints, schedules, and occupancy overrides.
• Test alarms and safety interlocks.
• Evaluate if your system could benefit from energy optimization strategies for summer demand.

Need Professional Support?

If your team doesn’t have in-house HVAC expertise—or you’re managing multiple facilities—partnering with a trusted commercial HVAC service provider can ensure your system is primed for summer.

We offer full cooling towers and chillers inspections, startups, water treatment, and performance testing, so you can enter the cooling season with total peace of mind.

Ready to schedule your spring startup?
Contact us today for a site visit or preventive maintenance plan customized to your facility’s needs.

Level One HVAC Services, Inc.

Toll Free 844-616-4822

Headquarters 248-486-6500

Grand Rapids 616-616-4822

West Branch 989-999-4822