SIBA

A Field Dev
velopment Project

Clien
nt:
Kuwwait Energgy Iraq Lim
mited (KE
EIL),
P.O.B
Box. 5614, SSalmiya, Ku
uwait

PMC
C:
Toucchstone.
P.O.B
Box. 72129,, Sharjah, U
UAE

EPC Contractor:
ROJET
PETR
P.O. B
Box. 2048,H
Horreya‐Heeliopolice
Cairoo, EGY

THE DOCUMENT IS RETAINED FOR INFORMATION.

Engiineering C
Consultan
nt Vendo
or / Supp
HOWEVER lier Name
THIS DOCUMENT e;‐ BE REVIEWED BY PETROJET.
SHALL
Mottt‐MacDon nald Hamo
on Coolingg Tower C
Company

Project Title:
SIB
BA FIEL
LD DEV
VELOPMENT PROJE
ECT
Conttract No:
KEIL//SIBA/2015/C‐051
1‐REV‐CP
PF EPC

Docu
ument Tittle:
Pre
e‐Com
mmissio
oning a
and Co
ommisssionin
ng Pro
ocedurre

A 31/01/16 For Ap
pproval PN AS AC
Prepared Approved Approveed
Rev. Date Rev. Desscription Checked By
y Rep.
PMC R Clien
nt Rep.
By By PTJ

PO No.. :DXB13//735/TRK
K/2016
Docu
ument No
o: C‐051‐V
VP‐040‐CLTW‐PRO
O‐0007
SDRL C
Code: P03
3
Form
mat Pages

A
A4 Page 1 of 11
 SIBA FIE
ELD DEV
VELOPME
ENT PROJJECT
KEIL
L/SIBA/2015/C-051-REV–CPF EPC
C

Document Num
mber Doccument Title Page Page 2 of 11
Rev. A
C-051-V
VP-040-CLTW
W-PRO-0007 Pre-Comm
missioning an
nd Commissioning Proccedure Date 31/01/16

A
Amendm
ment Summary

Revision
n No D
Date Descrip
ption

A 31//01/16 For App

proval

Discclaimer: ‐ “This document is issued for the party wh hich commissioned it and ffor specific purposes conn
nected with th
he
capttioned project only. It shou
uld not be rellied upon by any other party or used fo
or any other ppurpose.

Page 2 o
of 11 
 SIBA FIE
ELD DEV
VELOPME
ENT PROJJECT
KEIL
L/SIBA/2015/C-051-REV–CPF EPC
C

Document Num
mber Doccument Title Page Page 3 of 11
Rev. A
C-051-V
VP-040-CLTW
W-PRO-0007 Pre-Comm
missioning an
nd Commissioning Proccedure Date 31/01/16

TA
ABLE OF
O CONTENT
TS

e-Commisssioning and Com

Pre mmissioning Proce
edure ................................................... 4

Page 3 o
of 11 
 SIBA FIELD PROJECT

SUBMITTAL NO: C-051-VP-040-COMP-PRO-0007

PRE-COMMISSIONING AND COMMISSIONING PROCEDURE

ISSUED FOR
0 01/10/2015 AI KS AS
APPROVAL
Rev No. DESCRIPTION DATE PREPARED BY CHECKED BY APPROVED BY

Doc no. C-051-VP-040-CLTW-PRO-0007 RevA Page 4 of 11

 CONTENTS:

1.0 Scope of work

2.0 Purpose of method of statement

3.0 List of Tools / Equipments

4.0 List of Manpower

5.0 Responsibilities

6.0 Pre commissioning activities

7.0 Electrical scope

8.0 Commissioning and Start up of CT Towers

9.0 Reference

Doc no. C-051-VP-040-CLTW-PRO-0007 RevA Page 5 of 11

 1.0 Scope of Work:

This method statement defines the procedures and instructions for cooling
tower pre-commissioning activities.

2.0 Purpose of method of statement:

The purpose of this method of statement is to cover all the activities in pre-
commissioning the CT towers. The pre-commissioning must be carried out
strictly accordance with the approved manuals, installation manual & Hamon
Supervisor instructions.

3.0 List of Tools / Equipments:

 Measuring tape 5m 02 Nos.

 Digital protractor 01 Nos.

 Adjustable spanner 02 Nos.

 Torque wrench (Range 100-1000N/M) 02 Nos.

 Spanners 17, 19, 25, 30, 36, 41,46mm 06 Nos.

 Cutting snips 01 Nos.

 Hydraulic jack small 01 nos

4.0 List of Manpower:

 Mechanical Engineer

 Hamon Engineer

 Safety Officer

 Site Supervisor

 Fitters, Mill-wrights

 Helpers

Doc no. C-051-VP-040-CLTW-PRO-0007 RevA Page 6 of 11

  Electrical & instrumentation team. (Engineer, supervisor, labours etc.)

5.0 Responsibilities.

Mechanical engineer:

 To ensure the availability of all the required tools and equipments.

 To study all the approved manuals related to pre-commissioning and refer

manufacturer recommendation.

 To assign good mill-Wright supervisor and ensures that he is aware of all the
tools and equipment required for pre-commissioning and commissioning the
cooling towers.

 To Coordinate with Hamon Engineer for the commissioning as per the

manufacturer recommendations.

 To coordinate with the QA/QC and the safety officer.

 To ensure that the work progress is as planned and in accordance to the

schedule.

Hamon Engineer/Supervisor:

 To provide technical assistance to EPC contractor team for cooling tower

commissioning activities.

 To train the team for special jobs or methods arising in the cooling tower pre-
commissioning.

Safety officer:

 To ensure the safe working conditions prior and during the pre commissioning
activities.

 To ensure that the team is wearing the proper and the necessary PPE.

 To ensure the proper barricading and safety signs surrounding the working
area is maintained.

Doc no. C-051-VP-040-CLTW-PRO-0007 RevA Page 7 of 11

  To ensure the safety procedures are followed during the execution of the
work.

Site supervisor:

 To create a work force that is supported with the qualified fitters, mill-wrights,
and helpers with proper tools.

 To distribute the job on all of the team members.

 To coordinate with the Mechanical engineer, Hamon supervisor, QA/QC and

the safety officer.

 To ensure that the work is done with proper work permits and safely.

6.0 Pre commissioning activities:

Prior to start the cooling tower commissioning the following activities should be
completed.

 Check FRP basin

 Dimension.
 Level and slope (slope if applicable).
 Post support and mounting.
 Basin is leak proof.
 Basin is clean.
 Float valve is working properly.
 Level switch is working and level is set.

 Check all structural members, fasteners, pipe fittings and mechanical

equipment supports for proper tightness.

 PVC fittings are not Broken or cracked

 Check spray nozzles are fitted properly and cleaned.

 Check fill packs laying orientation and gaps.

 Air inlet louvers are properly set in grooves.

Doc no. C-051-VP-040-CLTW-PRO-0007 RevA Page 8 of 11

  Check mechanical equipment supports and the 0-0 level for torque
tube.

 Geared motor alignment.

 Recheck alignment after tightening geared motor mounting bolt, with

relevant torque values.

 Check fan blade angle (as per hamon pitch angle data table).

 Check the tip clearances between the blades and the fan stack.( as per
hamon tip clearance design range)

 Check fan stack anchoring points and tightness.

 Check free rotation

 Check gear box oil level

 Check gear box for seal leakage.

 Ensure adequate width approach ladder and access to gear box and
fan.

 Check motor lubrication ( if applicable)

 Tower should be commissioned in presence of manufacturer.

7.0 Electrical scope:

 Check connection completion and ensure tightness.

 Check local Isolator switch or local push button station is connected.

 In case of push button station, Ensure stop push button is lockable

type.

 Check vibration switch installed and connected in control circuit.

 Check fuse ratings and overload ratings.

 Check Motor insulation with and without cable.

Doc no. C-051-VP-040-CLTW-PRO-0007 RevA Page 9 of 11

  Energize control circuit and check contractor actuation without load.

 Check change over timing incase of star/delta starter.

 Recheck and ensure that

 Structure tightness for entire cooling tower.

 Water tightness of cladding

 Make sure Proper torque value is attained (for structure fasteners,

mechanical equipment supports, motor, gearbox, shaft, fan etc…)

 Pith angle of fan blades.

 Oil level in gear box

 Vibration switches connection to control circuit.

 Alignment for geared motor.

 Tip clearance between fan blade and fan stack.

 Make sure tower is clean.

NOTE:

 FRP Material has to be handled with care. When tightening bolt it

is essential that the components not to be cracked: tighten the
nut up to the touch point, and then apply half a turn. Twisting by
more than half a turn will crack the component.

 Make sure all these points are covered before first startup of CT
towers.

8.0 Commissioning and start up of CT towers:

 Ensure water is flowing through tower.

 Give starting kick preferably from local start PB

Doc no. C-051-VP-040-CLTW-PRO-0007 RevA Page 10 of 11

  Starting frequency should be 5 to 10% and then gradually raises it to 100%.
Note the readings in Hamon VFD data Table.

 Check rotation, And correct if required ( In case of one way drive

gearbox rotational test to be conducted before proceeding the
alignment)

 Check current drawn.

 Observe for abnormal sound

 Observe for vibration.

 Note the VFD data in the Hamon VFD data table.

 Follow for other cells and keep ready for running start.

 Give running start to the fans

 Re- observe the above

 Do not sign installation report until and unless you are fully satisfied.

9.0 Reference:

Refer the following Hamon manual and installation guides.

Manual Geared Motor - SIEMENS

Manual Fan - COFIMCO

Fill the data’s on the Inspection Check List, Pitch angle data table, tip clearance data
table, Alignment data table and VFD data Table.

Doc no. C-051-VP-040-CLTW-PRO-0007 RevA Page 11 of 11