Professional Documents
Culture Documents
Cooling Towers Introduction
Cooling Towers Introduction
b. In order to comply with AS/NZS 3666.2 what manuals must be with the
regulated system?
c. What is the required interval between cooling tower cleans?
d. Can a cooling tower that does not have a working disinfection process
installed be turned on?
e. From the NSW PH.act Regulation 2000, list the two maintenance
precautions?
Cooling towers
Produced by Bruce Davison.
17
f. Use AS/NZS 3666.2 to list the personal protective equipment needed to
clean a cooling tower?
g. According to AS/NZS 3666.2 what must be done to an evaporative cooler
every three months?
h. How often should a water sample be taken? Refer to AS/NZS 3666.3
i. How long should the results from water sample be kept?
..
j. List the requirements for the location of air intakes according to AS/NZS
3666.1?
Cooling towers
Produced by Bruce Davison.
18
Safety
Personal Safety.
Clothing should conform to Australian Standards AS/NZS 3666, part 2, which
incorporates other standards, AS 1715 and AS 1716.
AS 1715 specification of respirators and AS 1716, the wearing of the respirators
and masks.
The gloves and waterproof coveralls are used to protect your skin from the biocides in
the circulating water.
Wear gloves, waterproof shoes and water resistance coveralls and a half face
respirator with P2 grade twin filter
Public safety.
Always restrict public access when cleaning, and ensure that the cleaning spray is
contained within the operational area.
Full Face
Cartridge
Respirator
The safety and responsibilities can not be stressed
enough when microbial infection is involved
Only used to take
water sample
Cooling Towers
Complied by Bruce Davison.
19
Taking a Water Sample.
Safety.
If the sample has to be taken from an operational tower, then all the
appropriate safety clothing should be worn. Make sure the gloves are long
enough so that none of the circulating water will come into contact with the
skin.
Equipment.
A sterile 250ml re-sealable container, containing Sodium Thiosulphate to
neutalize the chlorine. Usually supplied by the analysing company.
A means of keeping the sample between 2 and 6
o
C, while transporting it
for analysing.
A means of recording sample location and time of sample taking.
Procedure.
Only open the container once it is in the water to be sampled.
Do not open it and leave it sitting, as other contamination can enter giving
false readings.
Take the sample from circulating water, not some place where the water is
still.
Place the container in an insulated transport vessel.
Do not leave in direct sunlight.
Record the sample taken for Authorities records.
Water Analysis.
Only use a National Analytical Test Authority (NATA) accredited laboratory to
analyze a sample. The laboratory must notify you if they find a sample that
has a high legionella count.
The results of the test must be recorded and stored safely for seven years.
Cooling Towers
Complied by Bruce Davison.
20
Water Sample Collection Practical.
Aim: To be able to collect a water sample from an operating
cooling tower in accordance with AS/NZS 3666 part 3, while
meeting the OH&S requirements.
Task.
1. Read AS/NZS 3666 part 3 section 2 ( risk assessment)
2. Read AS/NZS 3666 part 3 section 2 (technique for sample
collection).
3. Complete the risk assessment and hand it in to the teacher
for approval.
4. Complete the water sample collection while the teacher is
present.
Review.
Complete the worksheet on water sample collection from the
package or hand out.
Cooling Towers
Complied by Bruce Davison.
21
Decontamination
If a tower has a high Legionella reading confirmed by the analysing
laboratory, then the system will have to be shut down and decontaminated.
Recommended procedure;
1. Circulate a dispersant throughout the system.
2. Drain and refill.
3. Dose with Sodium hypochlorite to maintain a free chlorine residual of 25 to
50 mg/l at a pH of 7 to 7.6 for 30 minutes.
4. Drain and refill.
5. Dose with Sodium Hypochlorite to maintain a Chlorine residual of 5 mg/l at
a pH of 7 to 7.6 for 12 hours.
6. Drain the system and clean cooling tower wetted surfaces.
7. Dose with Sodium Hypochlorite to maintain a free Chlorine residual of
5mg/l at a pH of 7 to 7.6 for one hour.
8. Drain and refill.
9. Start full water treatment and put system back into service.
10. Wait at least 72 hours before taking another water sample.
Draining of the system should be to the sewer or in accordance with Local
Authority or other relevant authority. Some authorities require the water to be
pumped into a container for disposal.
Safety with Chemicals
The chemicals used to clean and disinfect a cooling tower are harmful and
extreme care must be observed when using them. There must be Material
Safety Data Sheets for all the chemicals where they are stored and used.
Cooling Towers
Complied by Bruce Davison.
22
Cleaning Cooling Towers & Evaporative Condensers
The most effective way of avoiding all the problems encountered with a
cooling tower is a regular and thorough manual washout every six months.
(see AS/NZS 3666 Part 2) The process is particularly important before a
tower is commissioned or restarted after a shutdown period of one week or
more. Wash out is compulsory under the Public Health Act, which carry heavy
fines if it is not done.
Before cleaning a tower the operator must check the service and
maintenance records to see if there has been any changes made to the
system or if anything needs to be done before shut down.
Also the tower should be inspected for any possible faults that may affect the
cleaning process.
During the cleaning process the public must be kept out of the operational
area, and the sprays must be confined to the operational area.
The tower must be fully dismantled and the interior and components scrubbed
with a high pressure water cleaner
Local councils have been given the job of monitoring the installation
maintenance and cleaning of cooling towers, as set out in the Public Health
Act 1991.
They are required by the Public Health Act 1991, to set up a register of all the
regulated systems (cooling towers),in their area and to routinely go and
check that the systems complies with the Act.
The council officer has the right under the Act to inspect any Regulated
System and view all associated maintenance records, when ever the council
thinks it is necessary.
The council will also require written notification of any changes that are made
to a Regulated System.
Any maintenance must be recorded (Public Health Act
1991), giving the details of the work and the record must
be signed by the person doing the work and the owner
or owner appointed representative.
Local Councils have an
obligation to the public
to conduct inspections
and to police accurate
records of maintenance,
cleaning and microbial
control.
Cooling Towers
Complied by Bruce Davison.
23
Practical.
Cleaning a Cooling Tower
Aim: to learn the skills necessary to clean a cooling tower.
Task: Clean a cooling tower as required by AS/NZS3666 and the Public
Health Act.
Equipment:
a. Safety clothing as required by AS/NZS3666.
b. Cooling tower.
c. Operation manual.
d. Cleaning equipment.
Procedure:
a. Complete a Risk Assessment for the task.
b. Wear all required PPE.
c. Follow operation manual and shut down the tower.
d. Dismantle tower.
e. High pressure clean all internal components as instructed.
f. Reassemble tower.
g. Fill the tower with water to the required depth.
h. Follow the operations manual and start the tower.
i. Check operation.
Cooling Towers
Complied by Bruce Davison.
24
Maintenance
Expensive breakdowns, Legionella, inefficiencies and increased running costs
can mostly be attributed to poor maintenance.
Preventative maintenance should provide the owner/user with the following;
Early detection of problems that may lead to a breakdown.
Maintain the systems efficiency.
Determine that the system is complete and operating correctly.
Remove the need to do corrective repairs.
Maintain Bacteria to safe levels.
The maintenance management should contain the following;
Inspection reports, each individual system, regardless if they are side by
side and the same brand, need to have an inspection report developed for it.
Maintenance and Operating Manuals, need to be clear and comprehensive,
there should be no doubt as what needs to be done.
The object of the manuals is to apply AS 3666, to the system and to ensure
that the maximum performance and operating life are gained with effective
use of labour.
All manuals should have the following generic information;
1. Define the system that the manual applies to.
2. List the function and performance of the system.
3. Provide normal operating instructions.
4. Detail shut down and corrective procedures.
5. Provide details of any repairs, modifications or breakdowns.
Records and log book, of any work on the system must be kept on-site, and
copies should be given to the owner/user.
Water treatment information should include a Material Safety Data Sheet for
all chemicals stored on-site. There also should be an authorisation to use the
chemicals for the type of system on-site.
All maintenance and maintenance records are to be completed to the AS
3666 minimum standard. Failure to comply with these Standards can result in
Supreme Court action under the Public Health Act 1991.
It is imperative that service personnel, owners and users of cooling towers are
committed to ongoing preventative maintenance
Cooling Towers
Complied by Bruce Davison.
25
Operational Check List.
Cooling Tower Casing.
rattles and vibrations.
water and air leaks while in operation.
amount of drift discharge.
signs of rusting.
condition of louvres and screens.
paint or coating for damage.
Cooling Tower Internal Components.
fill for alignment, seal, distortion, damage, slime, algae and
poor water coverage.
sprays or decks for operation and uniformity of distribution
over the fill.
drift eliminators for location, damage, seal, scale, algae, slime
or blockage.
Ball float operation.
Fan.
noise, vibration and free running.
where fitted,
the fan drive for adjustment and alignment.
guards and screens for rust and fixing.
motor full load amps.
condition of impeller, housing scroll, shaft, bearings and
supports.
Pump and Pipe work.
leaks.
corrosion.
vibration.
Drains are clear.
pumps smooth running.
pump's gland.
motor amps.
Chemical Dosing System, (normally a separator contractor).
Pumps operation.
Chemical levels and types, safety data sheets.
Bleed off rate.
Cooling Towers
Complied by Bruce Davison.
26
Sample of a maintenance report of a Water Cooling System.
Date of Service.
Type of service Maintenance................
Water sample..............
Name of Owner or User...............................................................................................
Address of Premises....................................................................................................
Location of Tower.........................................................................................................
Tower: Site Number.......................................................................................................
Type..................................................................................................................
Make and Model...............................................................................................
Treatment Type..............................................................................................................
Brand and chemicals used.............................................................................................
Water Sample;
Total Plate Count....................................................................................
Legionella report required yes. no.
Report forwarded to Local Authority yes no
Physical Condition of tower..........................................................................................
Cleanliness of Tower....................................................................................................
Nature of any work preformed .....................................................................................
.......................................................................................................................................
.......................................................................................................................................
Date of next maintenance ............................................................................................
Nature of any repairs to be made during the next maintenance
.......................................
.......................................................................................................................................
.......................................................................................................................................
Signature of service person ..
Signature of Owner/user ..............................................................................................
To Be Completed by the Local Authority (if required
Report checked by ..................................................................................................
Signature .................................................................................................................
Date .........................................................................................................................
Any action to be taken: No
Yes, .........................................................................................................................
..................................................................................................................................
Cooling Towers
Complied by Bruce Davison.
27
Shut Down.
This process should be followed if the tower is to be off line for a while.
Drain the system to prevent stagnant water, or circulate the
chemicals if the water is to be left in the system.
Repair any rust or damaged paint.
Clean the tower.
Co-ordinate a condenser clean for this time period.
Emergency Shut Off.
A procedures manual should be written for each individual C.T. and site, but
generally;
1. Notify the owner and users of the cooling tower.
2. Shut off condensers and all other equipment supplied by the
Cooling Tower.
3. Stop the fan.
4. Stop the pump.
Cooling Towers
Complied by Bruce Davison.
28
Review Questions
1. List four groupings of components that need to be checked during a
service?
2. List three items that need to be checked on the Dosing system?
3. List the four steps for an emergency shut down?
4. How long must the results from a water sample be kept?
5. What must be done to the sump water from a cooling tower during
cleaning?
6. Why are towers cleaned?
7. How often are they cleaned?
8. List the two pre-cautions that must be followed during a tower clean?
Cooling Towers
Complied by Bruce Davison.
29
9. Where does Legionnaires disease manifests? (C of P)
10. Why are cooling towers such a concern regarding Legionnaire
disease?
11. Beside Legionnaire disease what other things are harmful in cooling
towers?
12. What are the optimum conditions for the growth of Legionella?
13. What is the purpose of preventative maintenance?
14. Why are new cooling tower installations washed out before use?
15. What must be added to the circulating water after the clean?
Cooling Towers
Complied by Bruce Davison.
30
Assignment.
Aim.
To gain an understanding of the pipe work and components of an
operational cooling tower.
Task.
Draw a schematic diagram of the twin cooling towers installation at
TAFE NSW Sydney Institute.
Procedure.
Locate and record all the components attached to the systems pipe
work.
Draw a sketch of the pipe work and component placement.
Convert your sketch to a schematic using the correct symbols or
labelling the component on the drawing.
Hand in the drawing for marking.
Cooling tower Pipe work
Cooling Towers
Complied by Bruce Davison.
31
OH&S HAZARD IDENTIFICATION AND RISK ASSESSMENT OF WORKING PROCEDURES IN TAFE
Examples of Potential hazards may include but are not limited to:
Electrical Mechanical Pressure Chemical Gravity / Noise Gas Welding Radiation Biomechanical Biological
Contact with
live wires or
terminals causing
- Shock
- Flash to eyes
- Burns
- Falls
Discharge of
capacitor causing
- Shock
- Flash to eyes
- Burns
- Falls
Caught by
operating
machinery
Struck by
moving machinery
or objects
Caught by
movement of
mechanical parts
Crushed by
objects moving or
falling
Entrapment
Excessive
vibration
Injury from releases
of stored energy in
- Refrigerants
- Nitrogen
- Oxy
Acetylene.
- Propane.
- Ammonia.
Fire or
Explosion from
- Build up of
flammable gases
- Ignition of
existing flammable
products
Contaminants/
Toxins causing
- Suffocation
- Burns
- Poisoning from
products
Falls from or
into vessels
Falls from
structures
Impact injuries
from falling
objects
Engulfment by
product
Sound levels
>85dBA causing
hearing damage
from
- Operating
machinery
Using
equipment
Injury due to
- burns
-high temperature
- naked flames
- releases from
stored pressure
vessels.
- fire hazard.
- risk of explosions
- lack of ventilation.
-
Extremes of
temperature
Burns
UV from
welding flashes
UV from
exposure to sun
X-Ray
exposure
Eye damage
from laser
Strains and
sprains lifting
objects
Strains and
sprains moving
objects
Slips and trips
from
- Spillage/slippe
ry surfaces
- Uneven/unstab
le surfaces
- Poor lighting
Crush injury
Disease or
illness from fungal
spores eg.
Legionnaires
Disease from
blood products eg.
Hepatitis,
brucellosis
Determine the Risk Ranking
1-2 = High (Immediate action required) 3-5 = Medium Risk 6 = Low
2. How likely is it to be that bad what is the probability of It happening 1. How severely could it
hurt someone
Or
How Ill could it make
someone?
VERY LIKELY
Could happen at
any time
LIKELEY
Could happen
occasionally
UNLIKELEY
Could happen very
rarely
VERY UNLIKELEY
Probably never will
happen
KILL OR PERMANENTLY
ABLED
1 1 2 3
LONG TERM ILLNESS OR
RIOUS INJURY
1 2 3 4
LOST TIME INJURY
2 3 4 5
FIRST AID
3 4 5 6
Design Design out or modify
Eliminate Remove or substitute
Adopt a safer process Can it be done any other way
Enclose or isolate Use guards, close off
Ventilation Provide adequate ventilation
Provide PPE Appropriate PPE for the task
training in how to use
Safe work procedures Correct work procedures
Job rotation Relieve stress/boredom
Training Know the dangers. How to do work
rectly
Cooling Towers
Complied by Bruce Davison.
32
OHS Risk Assessment and Control (Educational) By activity)
College: Sydney Institute/Ultimo Section/ Refrigeration Topic: Cooling Towers.
Activity Potential Hazards
Risk
Rating
Control Measures Responsibility
Implementation
Date
Revised
Risk
Rating
Students Name: _______________________ Position: __________________ Signature: _________________
Cooling Towers
Complied by Bruce Davison.
33
Answers to review questions.
Section1
1. Latent heat.
2. Because of the Water Conservation Act.
3. Controlled draining of the circulating water to reduce TDS.
4. Reduce chemical effectiveness, clog system pipe work.
5. Oxidizing and Non-oxidizing.
6. Breathing in Legionella enriched aerosols.
7. By evaporating some the circulating water.
8. To increase the evaporation rate.
9. High RH% and air flow
10. Natural and Forced draft.
11. Very large industrial process.
12.
a. Induced draft counter flow.
b. Induced draft cross flow.
c. Forced draft counter flow.
d. Forced draft cross flow.
13. Propeller and centrifugal.
14. Yes.
15. No.
16. Open and closed.
17. Closed, the circulating water doesnt come into contact with the
atmosphere, an open does.
18. To compensate for load charges.
19. Fan speed and water by-pass.
20. Individual condensers regulating valves will reduce the amount of water
flowing in them therefore the cooling tower will need to regulate the volume of
water flowing from it to them.
Cooling Towers
Complied by Bruce Davison.
34
Answers to Law Questions.
a. NSW Public Health Act Part 4 clause 43.
b. AS/NZS 3666.2 2.6.1
c. AS/NZS 3666.2 2.5.1
d. AS/NZS 3666.1 4.1.4 also in the Regulation 2000 part 3 clause 9 (2)
e. Regulation 2000 part 4 clause 10.
f. AS/NZS 3666.2 table A1.
g. AS/NZS 3666.2 2.3.4.
h. Refer to AS/NZS 3666.3 foreword and 3.3.1.
i. AS/NZS 3666.3 3.7.
j. AS/NZS 3666.1 2.3.2
Cooling Towers
Complied by Bruce Davison.
35
Section 2.
21.
1. Cooling tower casing.
2. Internal components.
3. Fan.
4. Pump and pipe work.
5. Dosing system.
22.
1. pump
2. chemical levels
3. bleed off rate.
23.
1. Notify the owner.
2. Stop any equipment connected to the cooling tower.
3. Stop the fan.
4. Stop the pump.
24. Seven years.
25. Drained to sewer or contained by trade waste company.
26. It is the LAW.
27. Every six months.
28. Kept the public away and contain the spray from cleaning.
29. In human lungs.
30. They have the ability to spread the disease.
31. Chemicals.
32. 35 to 37
o
C.
33. Reduce running costs.
34. To remove construction waste.
35. Corrosion inhibitor.