COOLING TOWER | Pre-Commissioning Checklist and download

November 16, 2022 |

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.

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

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

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

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

Pre-Installation Inspection

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

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

Maintenance/Access

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

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

Electrical General

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

Variable Speed Drive

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

Controls System/Valves & Interlocks

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

Ambient Air Intake & Fill Pack

RefInspection/Task
1The 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.
2All attenuators are installed as shown on the drawings.
3Fill Pack is installed correctly, with correct fixings, in line with the manufacturer’s instructions.
4Fill pack is clean
5The fill pack can be removed for cleaning and maintenance easily.

Pond/Cold Water Basin

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

Electric Heater

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

Sweeper System

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

Makeup Water Connection

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

Bleed-Off/Blow Down Connection

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

Side Stream Filtration Connection

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

Overflow Pipework

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

Drift Eliminator

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

Fan & Motor

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

Ductwork

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

Access

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

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

Pipework from Tower

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

Balance Pipework / Equalizing Pipework

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

Controls

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

Cooling Tower Pre-Functional Checklist [PDF]

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Cooling Tower Pre-Functional Checklist [Microsoft Word]

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Cooling Tower Pre-Functional Checklist [Microsoft Excel]

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