COOLING TOWER | Pre-Commissioning Checklist and download

This cooling tower commissioning checklist can be used and completed throughout the project and its different stages:

• delivery,
• storage,
• installation &
• pre-commissioning

Once the pre-functional checks have been completed, the cooling tower’s full functional testing/commissioning can be conducted.

Delivery Inspection

Once the Cooling Tower arrives at the site, usually delivered by a transport company, the following should be checked with the driver before being accepted into storage or placed into position.

Any noted damage should be reported to the manufacturer/supplier within 1 day in writing, supported with photographs.

Ref	Inspection/Task
1	Supplier's consolidated delivery ticket is available, showing all equipment and ancillaries for inspection and being used to check against.
2	A copy of the order that was sent to the supplier is available for reference and is being used to check against
3	Equipment is packaged and crated in separate boxes for maximum protection.
4	The cooling tower nameplate and details match the purchase order.
5	Delivery protection is dry.
6	The cooling tower is dry internally.
7	The external casing of the cooling tower is undamaged.
8	Access door opens/closes and undamaged.
9	Basin Guard Filter [if purchased as an option] included and undamaged
10	Basin Sweeper System [if purchased as an option] included and undamaged.
11	Basin Heater System [if purchased as an option] included and undamaged.
12	Air Inlet Screens [if purchased as an option] included and undamaged.
13	Portable Crane [if purchased as an option] included and undamaged.
14	Ladder Safety Cage [if purchased as an option] included and undamaged for access to the roof/fan deck of the tower.
15	Guard Rail System [if purchased as an option] included and undamaged for access around the roof/fan deck of the tower.
16	Access door platform [if purchased as an option] included and undamaged for access to the tower door if installed on a high steelwork frame.
17	Maintenance platform [if purchased as an option] included and undamaged for access around the tower and any motors/parts mounted on the tower's external frame.
18	Internal Plenum Walkway [if purchased as an option] included and undamaged. This is for access inside the tower.
19	Attenuation [if purchased as an option] included and undamaged.
20	All pipework connections are the correct size.
21	Pipework connections are undamaged.
22	All pipework handings and positions are correct.
23	All nozzles are installed on the pipework and undamaged.
24	All ducting connections are the correct size.
25	All ancillaries [valves, actuators, fill pack, filters, etc.] are included in delivery as per the order and delivery note
26	Spin the fan to ensure not damaged and out of line
27	Check all fill pack for damage externally and internally.
28	Replace and protection that has been removed

Storage Inspection

Storage Area

If the equipment is to be placed into storage on-site before installation, there will be an inspection completed checking the following.

Ref	Inspection/Task
1	The area is internal and will not be affected by the weather. [if the unit is not rated for external use]
2	The surface where the equipment is to be placed is flat.
3	The equipment will be raised from the floor to allow airflow and stop the risk of water ingress.
4	The area is well covered and protected. [if the unit is not rated for external use]
5	The area is well ventilated and has no risk of high humidity.
6	The area is clean & dust-free.

Storage of Cooling Tower

Before the cooling tower being placed into storage, the following should be checked.

Ref	Inspection/Task
1	The cooling tower will not have materials stacked on it.
2	All ancillaries will be placed in a safe and secure location, so items do not go missing or get damaged.
3	All original packaging is intact and not removed.
4	Pipework caps are not removed.
5	Cooling tower and all components placed on a flat surface.
6	Barriers placed around the cooling tower to protect against any damage

Pre-Installation Inspection

Before the cooling tower being installed, the following should be checked.

Ref	Inspection/Task
1	The steelwork/plinth/base is ready, flat, and level & can bear the installation weight.
2	The area being installed is not prone to flooding or ponding of water.
3	The area the cooling tower will be installed into is clean and dust-free. If there is dust/construction work, then the cooling tower should be protected.
4	Ensure the cooling tower can be fixed to the steelwork/plinth/base. Check for mounting requirements with the manufacturer.
5	If there is a buildup of snow within the location of the cooling tower, it will not affect its operation or maintenance requirements.
6	The installation of the cooling tower will not impede the installation of the pipework, cables, etc.
7	All connections, pipework/ductwork, etc., can be independently supported and not supported by the cooling tower. The best practice is to install self-supporting brackets before the connection of the cooling tower.
8	Ensure that all access doors are clear and not blocked from brackets or other services.
9	Check to ensure that all connection kits containing - gaskets, bolts, cleats, screws are available to allow bolting up of the cooling tower.
10	Remove all transport feet and bolts.
11	Check that all required cabling can be run through the cooling tower and on appropriate containment.
12	Ensure there is enough space under the cooling tower to allow connecting of pipework etc.

Maintenance/Access

Ref	Inspection/Task
1	Once installed, enough space is allowed around and above the cooling tower to perform maintenance and remove components. [check the manufacturers' maintenance instructions for requirements]
2	All doors can be fully opened to gain access to the cooling tower internal area.
3	Check that there is enough space for the fill pack and fans to be removed and replaced.
4	If the cooling tower is mounted on a steel/high platform, confirm that there is a safe manner to gain access, remove the parts and components.

Pre-Commissioning Inspection

Once the equipment has been installed and before the functional testing and commissioning phase, the following will be checked.

General

Ref	Inspection/Task
1	Document the cooling tower information from its nameplates and cross-reference with the specified information to ensure correct.
2	Ensure the cooling tower is level.
3	Ensure all gaskets are installed and sealed.
4	Ensure that all cleats and fixings are installed as per the manufacturer’s instructions.
5	All-access doors can be open and closed with no gaps or leakage.
6	Check that all transport bolts and feet are removed.
7	Fan housing ducting, if being used, is installed and fixed.
8	All vibration mounts installed.
9	Seismic restraints, where required, installed.
10	No leaks from the tower base and all joints were sealed.
11	The cooling tower and all components, including valves and controls, are labeled according to the project naming convention.
12	Operation and startup manual for the cooling tower available.

Electrical General

Ref	Inspection/Task
1	The cooling tower and components are fully earthed in line with the manufacturer’s instructions.
2	Earthing has been tested.
3	Emergency disconnect installed for each component in line with NFPA/local code requirements.
4	Electrical voltage from the site matches the cooling tower motor required voltages.
5	All cabling is installed and connected on the correct containment/raceways and not damaged.
6	All cabling has been tested/torque tested.
7	A local motor control panel [LMCP] has been installed
8	The local motor control panel has been electrically tested.
9	All electrical cabling is labeled in line with the project naming convention.
10	Cooling tower ready for energization

Variable Speed Drive

Ref	Inspection/Task
1	A variable speed drive has been installed.
2	Variable Speed Drive [VSD] has been electrically tested
3	Variable speed drive has been functionally tested.

Controls System/Valves & Interlocks

Ref	Inspection/Task
1	Motorized valves installed as per the drawings and open/close freely.
2	All controls and panels have been installed to operate the valves, fans, and interlocks.
3	Freezing safety interlocks installed as per the design.
4	Pressure differential measuring devices are installed across all strainers.

Ambient Air Intake & Fill Pack

Ref	Inspection/Task
1	The position of ambient air intake is in line with the design and manufacturer requirements and will not be affected by space restrictions or any recirculation of surrounding exhaust ducts.
2	All attenuators are installed as shown on the drawings.
3	Fill Pack is installed correctly, with correct fixings, in line with the manufacturer’s instructions.
4	Fill pack is clean
5	The fill pack can be removed for cleaning and maintenance easily.

Pond/Cold Water Basin

Ref	Inspection/Task
1	Access door opens/closes and undamaged
2	Basin is the correct size.
3	Basin is clean and free of debris.
4	The water level is correct, and the float valve is aligned with the design/manufacturer’s instructions.
5	Access platform installed, clean and undamaged.
6	The Basin guard is fitted, clean, and undamaged.
7	Vortex preventer is installed, clean and undamaged.

Electric Heater

Ref	Inspection/Task
1	Electric heater installed for freeze protection, clean and undamaged.
3	Heater elements are not obstructed by debris.
4	All electrical testing was completed, including torque tests of connections.
5	All safety components are connected and operational, including all thermostats to cut power to the heater if needed.
6	All controls cabling is connected and installed in line with the manufacturers/design drawings.
7	Power is available to the electric heater/control panel for operation.

Sweeper System

Ref	Inspection/Task
1	Cooling Tower sweeper system installed in line with manufacturers requirements, clean and undamaged.
2	Sweeper system pipework and nozzles clean and undamaged

Makeup Water Connection

Ref	Inspection/Task
1	Makeup water connected and correct size with float/level valve correctly set.
2	Float valve undamaged.

Bleed-Off/Blow Down Connection

Ref	Inspection/Task
1	Bleed-Off/Blowdown water connected, correct size, clean and undamaged.

Side Stream Filtration Connection

Ref	Inspection/Task
1	Sidestream filter connected, correct size, clean and undamaged.

Overflow Pipework

Ref	Inspection/Task
1	Overflow pipework connected, correct size, clean and undamaged.

Drift Eliminator

Ref	Inspection/Task
1	Drift eliminators installed as per manufacturers requirements, correct size, fixed, clean, and undamaged.

Fan & Motor

Ref	Inspection/Task
1	Electrical connections and cables are complete, fully tested, and torqued according to project/manufacturer requirements.
2	Motor protection installed and operating [Overload]
3	Motor protections calibrated
4	Voltage from electrical systems is correct for the cooling tower requirements [within +/-10%]
5	The fan housing is clean and dust-free
6	Fan, blades, and motors are clean and dust-free.
7	Ensure the fan wheel is centered on the intake section
8	Check the tightness of fixings [torque]
9	Impeller is balanced
10	Fan/motor rotates in the correct direction with no obstructions [by hand]
11	Fan/motor rotates in the correct direction with no obstructions [electrically bump unit on]

Ductwork

Ref	Inspection/Task
1	Fan housing cowl/ducting installed with relevant mesh and is unobstructed.
2	The meshfree area meets the design requirements.

Access

Ref	Inspection/Task
1	Portable Crane installed in line with the manufacturer’s instructions and undamaged.
2	Ladder Safety Cage installed and undamaged for access to the roof/fan deck of the tower.
3	Guard Rail System installed and undamaged for access around the roof/fan deck of the tower.
4	Access door platform installed and undamaged for access to the tower door if installed on a high steelwork frame.
5	Maintenance platform installed and undamaged for access around the tower and any motors/parts mounted on the tower's external frame.
6	Internal Plenum Walkway installed and undamaged. This is for access inside the tower.

Pipework to Nozzles

Ref	Inspection/Task
1	Ensure that the pipework and connections are the correct size and in line with the drawing.
2	Ensure the installation of the pipework will not put stress on the cooling tower connections or create vibrations.
3	The materials used between the cooling towers and the condenser water system will not cause Electrolysis.
4	Pipework that is to connect to the cooling tower has been weld tested.
5	Pipework that is connected to the cooling tower has been pressure tested.
6	Pipework that is connected to the cooling tower has been cleaned and flushed.
7	Pipework is insulated and vapor sealed where required.
8	Insulation is labeled
9	All pressure gauges installed and display scale as per design requirements.
10	All valves/control valves are installed and in the correct direction.
11	All commissioning devices are installed in line with the manufacturer’s instructions, including expected diameters from turbulence.
12	All Strainers are installed and inspected to ensure the mesh is clean.
13	All expansion/rubber bellows are installed.

Pipework from Tower

Ref	Inspection/Task
1	Ensure that the pipework and connections are the correct size and in line with the drawing.
2	Ensure the installation of the pipework will not put stress on the cooling tower connections or create vibrations.
3	The materials used between the cooling towers and the condenser water system will not cause Electrolysis.
4	Pipework that is to connect to the cooling tower has been weld tested.
5	Pipework that is connected to the cooling tower has been pressure tested.
6	Pipework that is connected to the cooling tower has been cleaned and flushed.
7	Pipework is insulated and vapor sealed where required.
8	Insulation is labeled
9	All pressure gauges installed and display scale as per design requirements.
10	All valves/control valves are installed and in the correct direction.
11	All commissioning devices are installed in line with the manufacturer’s instructions, including expected diameters from turbulence.
12	All Strainers are installed and inspected to ensure the mesh is clean.
13	All expansion/rubber bellows are installed.

Balance Pipework / Equalizing Pipework

Ref	Inspection/Task
1	Ensure that the pipework and connections are the correct size and in line with the drawing.
2	Ensure the installation of the pipework will not put stress on the cooling tower connections or create vibrations.
3	The materials used between the cooling towers and the pipework system will not cause Electrolysis.
4	Pipework that is to connect to the cooling tower has been weld tested.
5	Pipework that is connected to the cooling tower has been pressure tested.
6	Pipework that is connected to the cooling tower has been cleaned and flushed.
7	All expansion/rubber bellows are installed.

Controls

Ref	Inspection/Task
1	Ensure all sensors and instruments are installed as per the control logic/manufacturers wiring drawings
2	All sensors are calibrated.

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Cooling Tower Pre-Functional Checklist [PDF]

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Cooling Tower Pre-Functional Checklist [Microsoft Word]

Cooling Tower Pre-Functional Checklist [Microsoft Excel]

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