Institute for Reference Materials and Measurements

Retieseweg 111 B-2440 Geel

Document for internal use only; this document can only be passed to third parties with the
agreement of the Director of IRMM

Work I ns t ruc t i on

Title:
Title : WI Number WI-0363
Maintenance of Cooling Towers Revision : 3

Unit/
Unit/Sector : Approved & Released Work
D1-SM-Site Management
Instruction
Group:
Group :
SM-HVAC

Review Period - 365 Days

Document Type :
SM Key Process

1. Aim

This WI describes how to perform the preventative - mechanical and electrical- maintenance
on cooling towers at IRMM in order to:

- reduce breakdown;
- ensure efficient heat transfer, by avoiding and removing scaling and dirt;
- prevent accumulation and spread of dirt and bacteria, in particular Legionella;
- protect them from frost damage in winter.

2. Scope

The list of cooling towers falling under this WI is given in the SM unit record library .
Chemical cleaning or desinfection is outside the scope of this WI.

3. Definitions

- A cooling tower is a heat removal device built to transfer waste heat from a fluid into the
atmosphere.
- Open Circuit cooling towers operate on the principle of evaporation. The working fluid
and the evaporated fluid (usually H2O) are one and the same.
- Dry Cooling Towers operate by heat transfer through a surface that separates the working
fluid from ambient air, such as in a tube to air heat exchanger, utilizing convective heat
transfer. They do not use evaporation.
- Closed Circuit Cooling Towers are cooling towers that pass the working fluid through a
tube bundle, upon which clean water is sprayed and a fan-induced draft applied. The resulting
heat transfer performance is much closer to that of a wet cooling tower, with the advantage
provided by a dry cooler of protecting the working fluid from environmental exposure and
contamination.
- Hybrid Cooling Towers are closed circuit cooling towers in which a part of the tube
bundle is exclusively cooled by convective heat transfer, as in dry cooling towers.

4. Description
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Depending on their function, cooling towers can either function only in summer period or in
summer and winter.
Maintenance tasks and checks are recorded using F-0328

4.1 Weekly maintenance for all towers running

The weekly maintenance checks are recorded using F-0338 .Results are compiled in SM
unit record library .

4.1.1 Visual checks

Verify that:
- no water is excessively running over
- there are no leaks
- that blowdown works correctly (opens periodically but closes afterwards) for the towers
with automatic blowdown.

4.2.2 Auditive checks

Search for abnormal noise indicating:

- Slipping of V-Belt There should be no "chirp" or "squeal" when the fan motor is started
or slapping when running
- Bearing problem
- Heavy vibrations

4.2. Quarterly maintenance for all towers running

The quarterly maintenance of cooling towers must take place each year in January, April
(together with the summer-duty maintenance), July-August, and October (together with
the winter-duty maintenance). When performing maintenance in winter time care
must be taken when the temperature is close to or below 0°C as ice in the vicinity of
the towers could create dangerous situations.
Before performing maintenance ensure that the towers (fans, pumps) are switched
off and safely isolated and foreseen of a lock out tag and padlock.

Check and Clean the sump and strainers

Switch off fan and pump motors and shut off the make-up supply
Empty the cooling tower
Clean the sump and rinse with clean tap water to remove all dirt and sediments
After this rinsing empty the sump remove the strainers and clean them with tap water,
Replace the strainers and fill the bassin with tap water

Check of the Ventilator shaft:

Remove the protection layer with an appropriate cleaning product (degreaser)
Remove surface corrosion (emery cloth plus wire brush)
Re-coat the shaft with soft seal (rust proof paint)

Check of the Ventilator motor

Remove all dirt from the motor to ensure proper cooling
Verify:
the electrical connections
the motor protection devices
the consumed power
the motor bearings for noise/overheating (with a thermal camera)
WI-0363; Rev: 3 - Maintenance of Cooling Towers Page 2 of 6
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motor holding bolts
presence of corrosion

Lubricate the Fan shaft bearings and where possible motor bearings with a suitable
lubricant fittings with a hand grease gun. Lubricants suggested by the manufacturer are
listed here below.

When lubricating, purge the old grease by adding grease until a bead of new grease
appears at the seal of the motor. Clean afterwards.

Check the tension of the V-belts and adjust if necessary. The deflection of the V-belt
should be 10 mm / m free belt length whith the following deflection force

Belt Diameter (mm) motor sheave Deflection force (kg)

profile
XPA 80-125 1.5-2.5
135-200 2.0-3.0
>200 2.5-3.5
SPA 100-125 1.5-2.0
132-212 2.0-2.5
>212 2.0-3.0

4.3 Winter duty maintenance

In addition to the quarterly maintenance described in 4.2, additional tasks must be planned
in a way that the towers are adequately protected against damage. As this maintenance
might imply the acquisition of spare parts (heating elements, etc.) an inventory of
spare parts to be purchased must be known first week of September. Unless weather
conditions or delivery of spare parts impose another planning the maintenance itself must
be performed in October

4.3.1 Cooling towers working all year

- Verify the proper functioning of the heating elements, the (thermal and electrical)
insulation and tracing cables (heating should start when the temperature is below 5°C);
- Verify the proper functioning of the protection devices (low level cut-out switches)

4.3.1.1 Additional tasks for closed cooling towers and hybrid towers

- Verify that the concentration of glycol in the circuit is 30% and that the pH is not below 7
- As soon as the maximum outside temperature is below 10 °C
- Stop the circulation pumps (including the pumps of the HydroVRTX legionella
control system);
- Isolate and drain the outside part of the make-up supply circuit;
- Drain the sump
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- Drain the legionella control circuit, Including the pumps by removing the tap
on the lowest part of the pump

4.3.2 Cooling towers running only in the summer

- Stop and lock/tag the towers, pumps and chillers;

- Drain the water from the circuit at least until inside the building.
- Drain the supplywater pipe at least until inside the building.

4.4 Summer duty maintenance

In addition to the quarterly maintenance described in in 4.2, additional tasks must be

planned in a way that the towers will work efficiently and safely during the summer period.
As this maintenance might imply the acquisition of spare parts (nozzles, eliminators,
package,...) an inventory of spare parts to buy must be known first week of March.
Unless weather conditions impose another planning the maintenance itself must be
performed before May.

Following actions must take place:

- Thorough cleaning of the cooling towers.:
. Switch off fan and pump motors and shut off make-up supply
. Stop if applicable the HydroVRTX legionella control system;
. Remove screens, eliminators access panels and doors and drain the system. Do not
remove sump strainer
. Clean debris from exterior and fan(s) wit soft brush, if necessary use water and soap;
. Clean interior with (soap) water and soft brush, if necessary use high pressure water jet;
. Remove debris from water distribution system and clean any nozzles if clogged. If
necessary nozzle and grommet may be removed for cleaning;
. Replace nozzles (with their grommet) that are damaged or have too much limestone
. Remove debris from heat transfer section (coil/fill). Do not use steam or high pressure
water to clean the cooling tower wet deck surface;
. Flush with clean water and drain to remove accumulated dirt;
. Remove, clean and replace the sump strainer(s);
. Remove debris from screens and eliminators with water jet (no high pressure);
. Replace fill and eliminators if they are damaged or contain too much limestone
. Remove debris from access doors and panels with soft brush and (soap) water and
re-install;
. Check for presence of corrosion. Small corrosion spots (< 1 dm²) can be repaired by a
BALTIBOND protection use kit (BAC part number RK 1057)
. Check for residual biofilm and scaling. Report large residual dirt and scaling > 0,1mm
thickness so that chemical cleaning or disinfection can be ordered
. Close drain and open make-up supply.
- Grease the bearings as in 4.2
- Verify that the heating elements will not start unnecessarily
- Verify the V-belts, re-tension or replace them if needed (as explained in Para 4.2). New
belts must be re-tensioned 24 hours after installion and running
- Verify the proper functioning of the float valve and adjust if necessary. The float must be
adjusted so that with the pumps running and the fans stopped the water level in the sump
(measured from the bottom) is:
. 340 mm for towers type VXT 10 until 135;
. 140 mm for towers type VFL
. 430 mm for towers type VXI 70
- Remove tags and locks, reconnect the fan(s) and pumps and start the cooling tower.

- Inform SHES that the legionella sampling should be made within two weeks.
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4.5 Start-up of circuits that have been (partially) emptied

When a cooling tower is being refilled via the make-up supply, after maintenance or
winter duty, it is likely that other parts of the circuit are empty; therefore on start-up of the
circulation pumps the level in the sump will decrease rapidly. The make-up supply flow is
too small to compensate so the pump(s) could run dry. This is particularly the case for
open cooling towers. Therefore start the circulation pump briefly, stop it before the sump is
empty and wait until the sump is filled again by the make-up supply valve. This process
must be repeated until all piping is filled (sump does not run dry when pump is running).

5. Responsibilities

The SM Unit Head

Approves the different versions of these specifications
Approves the planning
Monitors the regular update of the list of Cooling Towers .
Is informed of the progress by the summary report
The HVAC Section Leader
Ensures the periodical review and update of these specifications;
Assigns a member of his section for the monitoring of the executing sub-contractor(s)
Prepares the planning for periodical maintenance and informs the assigned HVAC staff member
Validates the update of the list of Cooling Towers .
Validates the summary report

The Assigned HVAC Section member

Assists in the update of the specifications;
Assists in the planning
Monitors the execution according to the specifications
Keeps the list of Cooling Towers up-to-date
Makes the bi-annual summary report related to the performed maintenance
Informs SHES when cooling towers have been started-up after summer duty maintenance

The Sub contractor(s)

Execute the maintenance according to the specifications and in line with the planning
Report on the progress and on problems, if any

The sector Head of SHES

Ensures the periodical monitoring for legionella and other biological contamination in line with
the regulations

6. Safety and protection of the environment

According to M-0002 – Radiation Protection Manual and M-0005 - Manual for the
SAFETY & HEALTH and protection of the ENVIRONMENT at the IRMM site, care must
be taken that no equipment can start accidentally when performing maintenance (use of locks,
tags,...)
When working at height, including on roofs at 2 meter or less from the edge and in the
absence of collective protection equipment, personal protective equipment must be used.
When working in the vicinity of a working cooling tower a mask type FFP3 must be worn.

Please take into account that printing this document uses natural resources and
contributes to environmental pollution.

7. Documentation

Records of cooling tower maintenance are archived for at least 5 years and fall under the
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responsibility of the assigned HVAC section member .

8. Annex: None

Associated Documents and References:

M-0002 -- Radiation Protection Manual
M-0005 -- Manual for the SAFETY & HEALTH and protection of the ENVIRONMENT at the IRMM site

F-0328 -- Cooling Tower Checklist

F-0338 -- Cooling Towers - Weekly check form

Document Revision History:

Revision: 3 Date Created: 23/02/2011 Last Approval Date: 10/07/2012
Date of Last Revision: 10/07/2012
Document Author (Editor):
Editor ): Manager : (Process
( Process Owner or Project Leader )
David Lewis

Reason for Change:

Revision : Sec/
Sec /Para Changed Change Made : Date
1 N/A Initial Issue of Document 23/06/2011
2 See next column Unit name(s)/number(s) updated following JRC/IRMM 2012 09/02/2012
re-organisation
Associated documents links updated
A. Fessler + J.Sollami added in distribution list
3 Author/Manager+Appro Changed to DL + DL removed from approvers 27/06/2012
ver

Electronic Notification List: Michael Moynihan, Jose Luis Rodriguez Doherty,

Roger Ruts, Wim Veraghtert, Jacky Sollami,
Andreas Fessler

Approvals:
First Approver's Signature
Name:
Name : Luc Peeters 10/07/2012 - Approved by: Luc Peeters
Title:: SM Quality Manager
Title

Second Approver's Signature

Name:
Name : Marc Wellens 10/07/2012 - Approved by: Marc Wellens
Title:
Title : Unit Head

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