5. Useful Forms/ Check List – Samples
5.1 Recommended Minimum Monitoring Frequency for Different Water Quality Parameters for Cooling Tower System
| Parameters | Minimum Monitoring Frequency for Cooling Water |
|---|---|
| Conductivity | Monthly |
| Total dissolved solids | Monthly |
| Suspended solids | Monthly |
| Calcium hardness | Monthly |
| pH | Monthly |
| Total alkalinity | Quarterly |
| Oxidising biocide | Monthly |
| Inhibitor level | Monthly |
| Temperature | Monthly |
| Chloride as mg/L Cl | Quarterly |
| Sulphate as mg/L SO4 | Quarterly |
| Total iron as mg/L Fe | Quarterly |
| Residual Cl/ Oxidation Reduction Potential (ORP) | Monthly |
| 5-day Biochemical oxygen demand (BOD5) | Monthly |
| Chemical Oxygen Demand (COD) | Monthly |
| Heterotrophic colony count | Monthly |
| Legionella | Quarterly* |
*Remarks: Cooling tower systems installed at medical and health care premises should be monitored ex-ceptionally closely. Water sampling for cooling tower systems installed in these locations should be carried out at least once a month for both legionella test and HCC. Moreover, if legionella or HCC is found to be greater than the specified requirement under routine sampling, more fre-quent water sampling is required to form part of the system operation programme.
| Parameters | Minimum Monitoring Frequency for Bleed-off Water |
|---|---|
| Colour | Quarterly |
| Turbidity | Quarterly |
| Threshold Odour No. | Quarterly |
| Ammoniacal Nitrogen | Quarterly |
| Suspended Solids | Quarterly |
| Dissolved Oxygen | Quarterly |
| 5-day Biochemical Oxygen Demand | Quarterly |
| Synthetic Detergents | Quarterly |
| E. Coli/ 100mL | Quarterly |
Note: The above checklists are for reference only. The owners of the cooling towner systems should develop their own water quality monitoring schedules to suit their systems.
5. Useful Forms/ Check List – Samples
5.2 Recommended Routine Inspection Checklist for Cooling Tower System
| Procedures | Inspection Frequency | |
|---|---|---|
| 1. | Check condenser water pumps | Weekly |
| 2. | Check cooling water quality | Monthly |
| 3. | Check internal surfaces of cooling towers/evaporative condenser for scale, rust, sludge and biofilm accumulation | Monthly |
| 4. | Check cooling water for clarity, odour, surface debris and temperature. | Weekly |
| 5. | Check strainers | Weekly |
| 6. | Check drains | Weekly |
| 7. | Check float valves | Weekly |
| 8. | Check water treatment dosing equipment and conductivity sensors | Weekly |
| 9. | Check water treatment chemicals for adequacy and safety | Weekly |
| 10. | Check condition/cleanliness of fill pack/tubes | Monthly |
| 11. | Check condition/cleanliness of drift eliminators | Monthly |
| 12. | Check condition/cleanliness of distribution troughs/spray headers and nozzles | Monthly |
| 13. | Check fans, drives and gearbox | Weekly |
| 14. | Check water level of basin | Weekly |
| 15. | Check bleed-off valve | Weekly |
| 16. | Check for system leakage and overflow from cooling towers | Monthly |
| 17. | Check air inlets and fan screens | Weekly |
Note: The above checklists are for reference only. The owners of the cooling tower systems should develop their own inspection checklists to suit their systems.
5. Useful Forms/ Check List – Samples
5.3 Recommended Routine and Preventive Maintenance Checklist for Cooling Tower System
| Checklists | Maintenance Frequency | |
|---|---|---|
| 1. | Tighten all fasteners | Every 6 months |
| 2. | Clean strainers | Monthly |
| 3. | Clean water basin and all internal surfaces of cooling towers | Every 6 months |
| 4. | Adjust and lubricate pumps and pump motors | Quarterly |
| 5. | Adjust and lubricate fans and fan motors | Quarterly |
| 6. | Remove drift eliminators and fills for cleaning | Every 6 months |
| 7. | Adjust and lubricate valves | Quarterly |
| 8. | Clean water distribution pipework, including nozzles | Quarterly |
| 9. | Remove end cap in each header tor cleaning | Every 6 months |
Note: The above checklists are for reference only. The owners of the cooling tower systems should develop their own routine and preventive maintenance checklists for their systems.
5. Useful Forms/ Check List – Samples
5.4 Recommended List of Personal Protective Equipment
| Job | Potential Hazzard | Respirator and Clothing |
|---|---|---|
| Testing and commissioning | Aerosol | Half face piece, capable of filtering smaller than 5μm particulates, ordinary work clothing |
| Inspection | Aerosol | Half face piece, capable of filtering smaller than 5μm particulates, ordinary work clothing |
| Water Sampling | Aerosol | Half face piece, capable of filtering smaller than 5μm particulates, ordinary work clothing |
| High pressure spraying | Aerosol | Respirator as above, waterproof overalls, gloves, boots, goggles or face shield |
| Chemical treatment with sodium hypochlorite solution in ventilated space | Spray mist and very low concentration chlorine | Half face piece, acid gas and particulate respirator, goggles or face shield, overalls, gloves, and boots |
| As above, in confined space | Unknown chlorine concentration, high mist, possible lack of oxygen | To comply with the requirement under the Factories and Industrial undertakings (Confined Spaces) Regulation |
5. Useful Forms/ Check List – Samples
5.5 Sample Operation and Maintenance Records for Cooling Power System
A. System Description
| Record | Details |
|---|---|
| Building Name & Building Address | |
| Cooling tower type | |
| Number of cooling towers in system | |
| Heat rejection capacities of the cooling towers | |
| Building owner's name/contact details* | |
| Owner of cooling towers’ name and contact details* | |
| O&M contractor of cooling towers’ name and details* | |
| Water treatment services provider’s name and contact details* | |
| Water sampling/laboratory contractor's name and contact details* |
* To include company name, contact person’s business and after office hours telephone numbers
B. Weekly Monthly Records for the month ( ) of year ( )
| Procedures | Date of Action | |||||
|---|---|---|---|---|---|---|
| Week1 | Week2 | Week3 | Week4 | Monthly | ||
| 1. | Check cleanliness, organic fouling and physical debris | |||||
| 2. | Inspect for slime and algal growth | |||||
| 3. | Inspect for deterioration of materials, damage to components, blockages and corrosion | |||||
| 4. | Inspect for correct operation of fans, motors and pumps | |||||
| 5. | Inspect water leaks from seams | |||||
| 6. | Inspect misshaped exterior or collapsed internal supports | |||||
| 7. | Inspect supporting framework | |||||
| 8. | Inspect fill and drift eliminator | |||||
| 9. | Check condition and operation of ball value | |||||
| 10. | Check fan thermostat (if equipped) | |||||
| 11. | Check sprays and distribution deck | |||||
| 12. | Check bleed-off rate | |||||
C. Quarterly/6-monthly/Yearly Records for the year ( )
| Procedures | Date of Action | |||||
|---|---|---|---|---|---|---|
| Quarter1 | Quarter2 | Quarter3 | Quarter4 | |||
| 1. | Lubricate fan and pump bearings/ gearbox | |||||
| 2. | Drain basin and clean distribution deck, fill and drift eliminator | |||||
| 3. | Check security of all bolts and fittings | |||||
| 4. | Clean fan blades | |||||
| 5. | Clean all components as required | |||||
D. Monthly Water Sample Bacterial Test Records for the year ( )
| Bacteria Test | Testing Laboratory | Data of Test | Test Results (cfu/mL) | Action | |
|---|---|---|---|---|---|
| Heterotrophic colony count | Month 1 | ||||
| Month 2 | |||||
| Month 3 | |||||
| Month 4 | |||||
| Month 5 | |||||
| Month 6 | |||||
| Month 7 | |||||
| Month 8 | |||||
| Month 9 | |||||
| Month 10 | |||||
| Month 11 | |||||
| Month 12 | |||||
| Total legionella count | Month 1 | ||||
| Month 2 | |||||
| Month 3 | |||||
| Month 4 | |||||
| Month 5 | |||||
| Month 6 | |||||
| Month 7 | |||||
| Month 8 | |||||
| Month 9 | |||||
| Month 10 | |||||
| Month 11 | |||||
| Month 12 |
Note: The above formats are for reference only. The owners of the cooling towner systems should develop their own formats for their systems.
5. Useful Forms/ Check List – Samples
5.6 Sample Independent Audit Report for Cooling Tower System
| Cooling Towner EMSD Registration No. | PS- ______________No._________to____________ |
| Auditing Period | __________ (month/ year) to ________ (month/ year) |
A. System Description
| Record | Details |
|---|---|
| Building Name & Building Address | |
| Cooling tower type | |
| Number of cooling towers in system | |
| Heat rejection capacities of the cooling towers | |
| Building owner's name/contact details | |
| Owner of cooling towers’ name and contact details | |
| Designer of cooling towers’ name and contact details | |
| O&M contractor of cooling towers’ name and contact details | |
| Water treatment services provider’s name and contact details |
*To include company name, contact person’s business and after office hours telephone numbers
B. Documents Checking
| Documents | Record available | Recommendation | |
|---|---|---|---|
| Yes | No | ||
| Operation & maintenance manual | |||
| Testing & commissioning records | |||
| System schematic and layout drawings | |||
| Routine inspection records | |||
| Routine maintenance records | |||
| Routine cleaning and disinfection records | |||
| Monthly heterotrophic colony count (HCC) results | |||
| Monthly/Quarterly* total legionella count results | |||
| Routine water quality monitoring records (if available) | |||
*Delete as appropriate
C. Visual Inspection
| Items | Acceptable | Recommendation | |
|---|---|---|---|
| Yes | No | ||
| General cleanliness of cooling tower system | |||
| Integrity of components including ladders, rails and platforms | |||
| Operation condition of cooling towers and pumps | |||
| Operation condition of water treatment equipment | |||
| Cleanliness of plant area | |||
| Drift loss control | |||
D. Risk Identification
| Assessment of Cooling Tower System | Recommendation/ remedial action required | |
|---|---|---|
| System alteration | Any system addition, alteration and improvement work carried out in the previous year? ☐ Yes ☐ No | |
| If yes, has operation and maintenance programme been reviewed? ☐ Yes ☐ No | ||
| External environment | Is there any newly occupied building regarded as high risk designation located in vicinity to the system? ☐ Yes ☐ No | |
| If yes, has operation and maintenance programme been reviewed? ☐ Yes ☐ No | ||
| Is there any construction site found nearby? ☐ Yes ☐ No | ||
| If yes, has operation and maintenance programme been reviewed? ☐ Yes ☐ No | ||
| Is the separation between the cooling towers and the nearest opening(s) maintained to meet the separation requirements as stipulated in Section 4.1 of Code of Practice Part 1? ☐ Yes ☐ No (please specify in details) | ||
| System performance | Has fouling of cooling towers system occurred in the previous year? ☐ Yes ☐ No | |
| If yes, has appropriate rectify work been carried out? ☐ Yes ☐ No | ||
| Water treatment programme performance | Has HCC results exceeded 100 000 cfu/mL during the previous year? ☐ Yes ☐ No | |
| If yes, has appropriate rectified work, including cleaning and disinfection and water treatment programme review been carried out? ☐ Yes ☐ No | ||
| Has total legionella count results exceeded 10 cfu/mL during the previous year? ☐ Yes ☐ No | ||
| If yes, has appropriate rectified work, including cleaning and disinfection and water treatment programme review been carried out? ☐ Yes ☐ No | ||
| Compliance of Code of Practice for Fresh Water Cooling Towers | Is the system complied with the Code of Practice? ☐ Yes ☐ No | |
| Potential risk identified during walkthrough inspection |
E. Progress of remedial works
| Assessment of Cooling Tower System | Recommendation/ remedial action required | |
|---|---|---|
| Remedial works | Are all the remedial works as recommended in the previous year being carried out? ☐ Yes ☐ No ☐ N/A |
F. Other recommendation ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
G. Personal declaration
Part I: To be completed by Auditor*
*I, _____________________________ (Full name of Auditor), Registered Professional Engineer (*Building Services / Mechanical Discipline), RPE Registration No: ____________________, have carried out annual independent audit for the above cooling tower system in according to section 4.3 of the Code of Practice for Fresh Water Cooling Towers, Part 2. And I am not involved in any O&M activities of this cooling tower systems.
OR
*I, _______________________________________ (Full name of Auditor), holder of_________________________________________ (Qualification of Auditor), issued by ____________________________________ (Institute issue the Qualification), have carried out annual independent audit for the above cooling tower system in according to Section 4.3 of the Code of Practice for Fresh Water Cooling Towers, Part 2. And I am not involved in any O&M activities of this cooling tower systems. (* delete as appropriate)
Signed by the Auditor: ______________________
Full name of Auditor: ______________________
Registration no.: ______________________
Date: ______________________
#Remarks: The Auditor should have relevant operation and maintenance experience on cooling tower systems and possess either one of the following qualifications. a) Registered Professional Engineer in Building Services or Mechanical discipline,
or
b) Higher Certificate or above in building services engineering or mechanical engineering or air-conditioning system, plus at least five years of operation and maintenance experience on cooling tower systems
Part II: To be completed by the owner of cooling tower system
I am the owner of this cooling tower system. I acknowledge that I have read this annual audit report and understand the latest conditions of this cooling tower system.
Signed by the Owner of cooling tower(s): ______________________
Full name of Owner of cooling tower(s): ______________________
Date: ______________________
