WILKRISS NIGERIA LIMITED
PROVISION OF SERVICES FOR MAIN COOLING TOWERS INSPECTION, CLEANING, REPAIRS AND
MAINTENANCE (029604-Dec2024)
DOCUMENT NO: WNL-QAQC-CTI-0971
DOCUMENT Procedure for Cooling Tower Inspection Maintenance
TITLE: and Cleaning
PROCEDURE FOR COOLING TOWER
INSPECTION, MAINTENANCE AND
CLEANING.
REVISION RECORD
ANYANWU UWASOMBA
0 21/06/2024 EZEBUIKE CHARLES
BONIFACE HUMPHREY
Rev Issue Date Description Prepared Reviewed Approved
WILKRISS NIGERIA LIMITED
PROVISION OF SERVICES FOR MAIN COOLING TOWERS INSPECTION, CLEANING, REPAIRS AND
MAINTENANCE (029604-Dec2024)
DOCUMENT NO: WNL-QAQC-CTI-0971
DOCUMENT Procedure for Cooling Tower Inspection Maintenance
TITLE: and Cleaning
TABLE OF CONTENTS
1. Pre-Inspection Preparation...................................................................................................................2
2. Safety Measures.....................................................................................................................................2
3. Structural and Mechanical Inspection.................................................................................................2
4. Operational Inspection..........................................................................................................................3
5. Electrical and Control Systems Inspection..........................................................................................3
6. Documentation and Reporting.............................................................................................................4
7. Post-Inspection Actions.........................................................................................................................4
8. Maintenance Procedure........................................................................................................................4
9. Cleaning Procedure...............................................................................................................................5
10. Post-Maintenance Actions...................................................................................................................5
Frequency Recommendations...................................................................................................................5
WILKRISS NIGERIA LIMITED
PROVISION OF SERVICES FOR MAIN COOLING TOWERS INSPECTION, CLEANING, REPAIRS AND
MAINTENANCE (029604-Dec2024)
DOCUMENT NO: WNL-QAQC-CTI-0971
DOCUMENT Procedure for Cooling Tower Inspection Maintenance
TITLE: and Cleaning
1. Pre-Inspection Preparation
1. Review Maintenance Records:
o Gather previous inspection reports, maintenance logs, and any records of past
issues.
o Identify recurring problems or components that need special attention.
2. Obtain Necessary Documentation:
o Operation manuals, technical drawings, and specifications for the cooling tower.
o Relevant safety procedures and permits (e.g., confined space entry permits).
3. Assemble Tools and Equipment:
o Inspection tools: flashlight, binoculars, borescope, camera.
o Measuring devices: infrared thermometer, vibration analyzer, pH meter, TDS
meter.
o Personal protective equipment (PPE): hard hat, gloves, safety harness, goggles.
4. Notify Relevant Personnel:
o Inform plant operators and maintenance personnel of the planned inspection.
o Schedule downtime if required.
2. Safety Measures
1. Isolation and Lockout/Tagout (LOTO):
o Shut down the cooling tower and isolate it from power sources.
o Apply LOTO devices to prevent accidental start-up.
2. Ensure Safe Access:
o Inspect ladders, handrails, and platforms for stability and safety compliance.
o Use harnesses for elevated work.
3. Monitor Environmental Hazards:
o Ventilate the area to remove any chemical vapors.
o Check for biological hazards like Legionella bacteria.
WILKRISS NIGERIA LIMITED
PROVISION OF SERVICES FOR MAIN COOLING TOWERS INSPECTION, CLEANING, REPAIRS AND
MAINTENANCE (029604-Dec2024)
DOCUMENT NO: WNL-QAQC-CTI-0971
DOCUMENT Procedure for Cooling Tower Inspection Maintenance
TITLE: and Cleaning
3. Structural and Mechanical Inspection
1. Exterior Structure:
o Check for cracks, corrosion, or damage on the tower shell, louvers, and casing.
o Inspect access doors for proper sealing and functionality.
2. Fan Assembly:
o Inspect fan blades for cracks, chips, or deformation.
o Check the fan hub and bearings for signs of wear or misalignment.
o Verify proper operation of the motor and gearbox.
3. Fill Media:
o Examine fill material for fouling, scaling, or physical damage.
o Assess water distribution over the fill for evenness.
4. Drift Eliminators:
o Inspect for blockages, scaling, or warping.
o Ensure proper alignment to minimize water loss.
5. Basin and Sump:
o Check for debris, corrosion, and algae growth.
o Measure water quality parameters (pH, conductivity, and hardness).
o Inspect basin strainers and screens for clogs or damage.
6. Water Distribution System:
o Inspect nozzles for blockages or uneven water spray.
o Check piping and valves for leaks or corrosion.
7. Structural Supports:
o Examine structural beams and connections for rust, cracks, or misalignment.
4. Operational Inspection
1. Water Flow:
o Measure water flow rate to ensure it matches design specifications.
o Check for leaks or abnormal noises in the piping.
2. Temperature and Performance:
o Record inlet and outlet water temperatures.
WILKRISS NIGERIA LIMITED
PROVISION OF SERVICES FOR MAIN COOLING TOWERS INSPECTION, CLEANING, REPAIRS AND
MAINTENANCE (029604-Dec2024)
DOCUMENT NO: WNL-QAQC-CTI-0971
DOCUMENT Procedure for Cooling Tower Inspection Maintenance
TITLE: and Cleaning
o Compare cooling performance against design expectations.
3. Fan and Motor Operation:
o Observe fans during operation for vibration or unusual noises.
o Measure motor current and voltage for anomalies.
4. Drift and Splash:
o Check for excessive water droplets escaping the tower.
o Inspect drift eliminators for proper functionality.
5. Electrical and Control Systems Inspection
1. Electrical Wiring and Components:
o Inspect all wiring, junction boxes, and connections for corrosion or damage.
o Check overload protection devices.
2. Control System:
o Verify the functionality of temperature sensors, pressure gauges, and control
valves.
o Test the operation of automated shutdown systems and alarms.
6. Documentation and Reporting
1. Record Findings:
o Document all observations, measurements, and identified defects.
o Include photographs of critical areas for reference.
2. Prepare Inspection Report:
o Summarize the condition of the cooling tower, identifying issues and
recommended actions.
o Highlight critical repairs needed for safety or performance.
3. Communicate Results:
o Share the inspection report with maintenance and operational teams.
o Schedule repairs and follow-up inspections as required.
WILKRISS NIGERIA LIMITED
PROVISION OF SERVICES FOR MAIN COOLING TOWERS INSPECTION, CLEANING, REPAIRS AND
MAINTENANCE (029604-Dec2024)
DOCUMENT NO: WNL-QAQC-CTI-0971
DOCUMENT Procedure for Cooling Tower Inspection Maintenance
TITLE: and Cleaning
7. Post-Inspection Actions
1. Perform Necessary Maintenance:
o Address issues identified during the inspection (e.g., cleaning, part replacement).
o Re-test systems to confirm functionality.
2. Recommission the Cooling Tower:
o Remove LOTO devices and gradually bring the tower back online.
o Monitor the tower’s performance post-start-up.
3. Archive Inspection Records:
o Store all records and reports for future reference and compliance.
8. Maintenance Procedure
1. Mechanical Maintenance
o Tighten loose bolts and brackets.
o Replace worn belts, bearings, or damaged fan blades.
o Lubricate bearings and motor as per the manufacturer’s guidelines.
2. Water Treatment System
o Clean or replace filtration systems.
o Add biocides to prevent biological growth (follow recommended dosage).
o Adjust chemical dosing systems to maintain water quality (pH, hardness, and
conductivity).
3. Structural Repairs
o Repair or replace damaged louvers, drift eliminators, or fill media.
o Patch cracks or corroded areas in the basin or casing.
9. Cleaning Procedure
1. Debris Removal
o Remove leaves, dirt, and debris from the basin and fill media using a vacuum or
brush.
2. Descaling and Disinfection
WILKRISS NIGERIA LIMITED
PROVISION OF SERVICES FOR MAIN COOLING TOWERS INSPECTION, CLEANING, REPAIRS AND
MAINTENANCE (029604-Dec2024)
DOCUMENT NO: WNL-QAQC-CTI-0971
DOCUMENT Procedure for Cooling Tower Inspection Maintenance
TITLE: and Cleaning
o Apply descaling chemicals to dissolve mineral deposits on fill media and nozzles.
o Use biocide solutions to disinfect all wetted surfaces. Allow sufficient contact
time.
3. Flushing
o Rinse the cooling tower thoroughly with a water hose to remove chemicals and
residues.
o Refill the basin with clean water and test for proper flow through the distribution
system.
4. Final Cleaning
o Scrub stubborn stains or biological growth using brushes and a cleaning solution.
o Reassemble components and ensure all systems are securely fastened.
10. Post-Maintenance Actions
1. System Start-Up
o Refill the cooling tower with water and ensure proper chemical balance.
o Re-energize the system following safety checks and LOTO removal.
o Monitor the system for leaks, unusual noises, or operational issues.
2. Documentation
o Record inspection, maintenance, and cleaning activities.
o Note any repairs or parts replaced.
o Schedule the next inspection and routine maintenance.
Frequency Recommendations
Weekly: Visual checks and water quality tests.
Monthly: Full inspection of mechanical and structural components.
Quarterly/Semi-Annual: Thorough cleaning and descaling.
Annually: Comprehensive inspection, including electrical systems and major repairs.
WILKRISS NIGERIA LIMITED
PROVISION OF SERVICES FOR MAIN COOLING TOWERS INSPECTION, CLEANING, REPAIRS AND
MAINTENANCE (029604-Dec2024)
DOCUMENT NO: WNL-QAQC-CTI-0971
DOCUMENT Procedure for Cooling Tower Inspection Maintenance
TITLE: and Cleaning
