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BES-SEG-RHB-PR-COM-001-0
BES-SEG-RHB-PR-COM-001-0
1 APPROVED
3 REJECTED
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1. PURPOSE
The aim of this procedure is to ensure overall quality and safety of the commissioning work for cooling
towers.
The Scope covers for pre-commissioning and commissioning procedure for cooling towers.
3. REFERENCES
4. DEFINITION
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5. GENERAL INFORMATION
5.2 Equipment
Make : Truwater
Selection : EC-S Series
Tower Model : ECS 2213G1-1B
Type : Induced Draft, Counterflow Square
Heat Load : 2,270,455kcal/hr, or 2639kW
No. of Cells : 2 x 10
Water Flow : 818 m3/h per cooling tower
Inlet Temperature : 36.11℃
Outlet Temperature : 30.56℃
Cooling tower is part of the cooling water system for providing cooling water to the plant. Total 10 units
of cooling tower are provided and the capacity per unit is 2,270,455kcal/hr. The cooling water will be
circulated by cooling water pump to chiller and cooling tower. The design temperature for cooling water
supply is 30.56℃ and return is 36.11℃.
Commissioning
Doc No BES-SEG-RHB-PR-COM-001
COOLING TOWER COMMISSIONING PROCEDURE Revision 0
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6. PRE-COMMISSIONING
Pre-commissioning form shall be used to ensure all pre-commissioning items are completed
prior to the commissioning.
Before proceed, remove any dirt, sediment and trash from cold water basin, sump and
screen.
6.1.1 Fan Blade Angle and Tip Clearance Adjust and Check
a. Rotate fan by hand to ensure free rotation.
b. Ensure tip clearance is within the allowable range of 20mm to 40mm.
c. Measure fan pitch angle as per technical data sheet.
d. The maximum admissible tolerance is ±1°. Re-setting if required.
Commissioning
Doc No BES-SEG-RHB-PR-COM-001
COOLING TOWER COMMISSIONING PROCEDURE Revision 0
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b. Check the motor rotation is in correct or wrong direction. If wrong, the power must be
isolated at the main panel and any two wires on the electric motor changed over.
c. Start and stop the cooling tower immediately again.
d. Confirm the motor rotation is correct.
7. COMMISSIONING
Commissioning form shall be used to ensure all commissioning items are completed prior to the overall
commissioning.
Before proceed, remove any dirt, sediment and trash from cold water basin, sump and screen.
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Zone A: Low vibration levels associated with well aligned and balanced equipment on high quality structures.
Zone B: Acceptable vibration levels suitable for unrestricted long term operation.
Zone C: Suggested value for initial Alarm level setting of continuously monitored systems.
Noted: For vibration level over than Zone C, cooling towers shall stop immediately for safety of the cooling
tower and personnel in the vicinity. Correction must be made to the fan drive system before starting the fan
again.
Procedure:
a. The readings of vibration level are preferably to be carried out when cooling tower is in services
with full load.
b. Take readings in three different directions of motors (Axial, Vertical and Horizontal).
c. Compare the results taken to the vibration chart (table above).
d. If the vibration level is exceeding the standard vibration level, solving the cause is necessary.
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8. ATTACHMENT
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ATTACHMENT 1
2 Mainframe structure
- Bolts and nuts Properly tightened TCT-F41 P M W
3 Internal Components
- Fill properly installed Vendor drawing TCT-F41 P M W
5 Mechanical Equipment
- Fan
a) Fan blades installed in proper sequence Vendor spec TCT-F41 P M W
b) Fan blades pitch angle Vendor spec TCT-F42 P M W
c) Fan tip clearance 20 - 40 mm TCT-F42 P M W
- Motor
a) All bolt and nuts Properly tightened TCT-F41 P M W
- Fan support
a) All bolt and nuts Properly tightened TCT-F41 P M W
Legend :
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ATTACHMENT 2
CUSTOMER : DATE :
PROJECT : JOB NO. :
TOWER MODEL : CELL NO.:
3. Internal Components
Infill Neat and properly installed As per installation drawing
Drift Eliminator Neat and properly installed As per installation drawing
Inlet connection All bolts installed and properly Randomly check on the tightened
tightened bolts and nuts.
Spray nozzles All nozzle properly installed As per installation drawing
4.External Components
Casing Properly installed As per installation drawing
Louver Properly installed As per installation drawing
5. Mechanical Equipment
Mechanical Bolts and nuts properly tightened All bolts and nuts for were properly
Support tightened
Fan Blade Properly installed & bolts and nuts All bolts and nuts for were properly
were tightened tightened
Fan Hub Properly installed & bolts and nuts All bolts and nuts for were properly
were tightened tightened
Motor Properly installed & bolts and nuts All bolts and nuts for were properly
were tightened tightened
V-Belts and Properly installed & bolts and nuts All bolts and nuts for were properly
Pulley were tightened. tightened
Maintenance Properly installed with sufficient Grease nipple properly tightened and
Grease Line grease proper connect to grease hose
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ATTACHMENT 3
FAN PITCH ANGLE AND TIP CLEARANCE INSPECTION CHECKLIST - BELT DRIVE
CUSTOMER : DATE :
PROJECT : JOB NO. :
TOWER MODEL : CELL NO.:
FAN
Fan Specifications:
Brand : Model :
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ATTACHMENT 4
CUSTOMER : DATE :
PROJECT : JOB NO. :
TOWER MODEL : CELL NO.:
Belt Drive
Belt Alignment:
A Bad Alignment
B Good Alignment
Diameter of Pulley
SN / cell no. L A* Force w'(kg) Judgement Test Date
Large (D) Small (d)
A*: Deflection of Belt = Allowable clearance: Center distance (meter) X 16 mm (deflection) = Actual belt deflection
Deflection (mm) = x 16 =
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ATTACHMENT 5
CUSTOMER : DATE :
PROJECT : JOB NO. :
TOWER MODEL : CELL NO.:
Fan hub and blades installed accordingly Fan blades free rotation (for gear drive without back stop)
Fan blades installed in proper sequence
Fan blades pitch angle shall properly set at °
Blade No. 1 2 3 4 5 6 7 8
Pitch Angle (°)
Fan tip clearances are properly set within the allowable range (Tolerance: 20mm - 40mm)
Fan bolts are properly tighten / torque
2.1 BELT DRIVE Applicable Non-applicable
Motor greasing No grease leaking found
Bearing housing and motor bolts are properly tighten / torque
Pulley properly tightened and aligned
2.2 GEAR DRIVE Applicable Non-applicable
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ATTACHMENT 6
CUSTOMER : DATE :
PROJECT : JOB NO. :
TOWER MODEL : CELL NO.:
Vibration (mm/s.)
Check Point Horizontal Vertical Axial
Drive End
( DE )
Non-drive End
( NDE )
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ATTACHMENT 7
INSTRUMENT BY TRUWATER