Pre-commissioning Checks (Chilled Water Piping)

Check for completion and Ensure Hydraulic test carried out for every section. Check expansion cum make up tank installed and connected to Return header (Pump suction header). Check all valves and Lubricate gland packing if required. Ensure all gate valves are fully open. Check Flow control valves operation and keep fully open. Check all strainers and ensure cleaning. Check test points and ensure dead nut provided. Check & review pipe condition (Internal).

Pre-commissioning Checks (Chilled Water Piping)

Check flushing,carried out properly and water condition.. Carry out static flushing. Nos of times may be decided based on pipe condition. Add alkaline base chemical agent if required. Ensure additional 8-10 Mesh Strainer provided at Evaporator inlet. Fill the soft & filtered water and ensure air is vented out. from system. Check air vents at individual equipment,Risers, Headers and Branch headers ends.

Pre-commissioning Checks (Chilled water Pumps )

Mechanical Check for installation completion. Check Anti-Vibration pad or isolators are properly located and placed. Check and ensure proper alignment. Check lubrication of

Pump and motor bearings. Shaft glands.

Check free rotation. Ensure suction and discharge valve are open.

Pre-commissioning Checks (Chilled Water Pumps)

Electrical Check connection completion and ensure tightness. Check local Isolator switch or local push button station. Incase Push button station,Ensure stop push button is lockable type. Check fuse rating and overload setting. Check Motor insulation with and without cable. Energize control circuit and check contactor actuation without load. Check change over timing in case of star/delta starter.

Commissioning Checks (Chilled water Pumps)

Give starting kick preferably from local start PB. Check rotation. And Correct if required. Check NRV is working. Check current drawn. Check sound level. Check vibration level. Follow for other Pumps and keep ready for Running start. Give running start to the Chilled water pumps. Observe the Suction pressure, Discharge pressure and Current drawn

Post Commissioning Checks (Chilled Water Pump )

Run required Pump and let system stabilize. Note full load current ( From Pump data sheet). Check Rated current (From motor name plate). Check Current drawn. Check actual Pump Head (Discharge pressure Suction pressure). Check flow with flow meter.
Repeat for all pumps. Compare actual flow with design flow. Compare actual head with calculated (Selected )Head.

If the flow is more than design flow Set the design flow by providing artificial head.

Pre-commissioning Checks (Condenser Water Piping)

Check for completion and Ensure Hydraulic test carried out. Check all valves and Lubricate gland packing if required. Ensure all gate valves are fully open. Check Flow control valves, are open as per flow requirement (Approx). Check strainers and ensure cleaning. Check test points and ensure dead nut provided. Check & review pipe condition (Internal).

Pre-commissioning Checks (Condenser Water Piping)

Check Make water tank is connected to cooling tower basin. Check Float valves and level switches are installed in make-up tank and Tower basin. Carry out static flushing. Nos of times may be decided based on pipe condition. Add alkaline base chemical agent if required. Ensure additional 8-10 Mesh Strainer provided at Condenser inlet.. Fill the soft & filtered water.

Pre-commissioning Checks
(Condenser Water Pumps)
Mechanical Check for installation completion. Check Anti-Vibration pad or isolators are properly located and placed. Check and ensure proper alignment. Check lubrication of Pump and motor bearings. Shaft glands. Check free rotation. Ensure suction and discharge valve are open.

Pre-commissioning Checks
(Condenser Water Pumps)
Electrical Check connection completion and ensure tightness. Check local Isolator switch or local push button station. Incase Push button station,Ensure stop push button is lockable type. Check fuse rating and overload setting. Check Motor insulation with and without cable. Energize control circuit and check contactor actuation without load. Check change over timing in case of star/delta starter.

Commissioning Checks
(Condenser Water Pumps)

Give starting kick preferably from local start PB. Check rotation. And Correct if required. Check NRV is working. Check current drawn. Observe for abnormal sound. Observe for vibration. Follow for other Pumps and keep ready for Running start. Give running start to the Condenser water pumps. Observe Suction pressure - Discharge pressure - Current drawn

Pre-commissioning Checks
(Cooling Tower)

Natural Draft Cooling Tower.

Installation checks. Pre-commissioning checks.

Induced Draft Cooling Tower

Installation checks. Pre-commissioning checks.

Installation Checks
(Natural Draft)

Check all wooden pieces, should be chemically treated. Check all wooden pieces for cracks. All fasteners are Properly galvanized. The foundation height should be enough to : Bottom (Pump suction) connection. accommodate fittings and strainer below the basin level. Provide flooded suction to pumps. Basin leveling and proper loading on foundation. Check the adhesive applied adequately and properly. Ensure tower is wet till operational.

PRE-COMMISSIONING CHECKS (Natural draft )

All spray nozzles are properly fitted and aligned. Nozzles are cleaned. Louvres are properly set in grooves. Basin is leak proof. Basin is clean. Float valve is working and level is set. Level switch is working and level is set. Approach Ladder is installed and nozzle maintenance frame provided.

INSTALLATION CHECKS (Induced Draft )

Check RCC basin Dimension. Level and slope. Post support and mounting. Check all structural members, fasteners and pipe fittings are properly galvanized. Wooden parts are chemically treated. PVC fillings are not broken or cracked. Motor and gear box Alignment by dial guage. Recheck alignment after tightening motor and gear box mounting bolt.

INSTALLATION CHECKS (Induced Draft )

Check Fan blade angle. Check Free rotation. Check spray nozzle are fitted properly and cleaned. Check Nozzle basin and ensure it is covered. Check gear box oil level. Check gear box for seal leakage. Ensure adequate width Approach ladder and access to motors. Check motor lubrication.. Ensure rain protection for motor.

PRE-COMMISSIONING CHECKS (Induced Draft )

Tower should be commissioned in presence of manufacturer. Electrical 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.

PRE-COMMISSIONING CHECKS (Induced Draft)

Check fuse rating and overload setting. Check Motor insulation with and without cable. Energize control circuit and check contactor actuation without load. Check change over timing in case of star/delta starter. Ensure Fan guard is installed. Re-check and ensure that washers are provided at all nut - bolts. Nut-bolts are fully tight.

COMMISSIONING CHECKS (Induced Draft )

Ensure water is flowing thru tower. Give starting kick preferably from local start PB. Check rotation, And Correct if required. Check current drawn. Observe for abnormal sound. Observe for vibration. Follow for other fans 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.

PRE-COMMISSIONING CHECKS (Chiller Package )

Mechanical Check condenser and chilled water pipes are connected with specified valves and fittings. Chilled water circuit is operational. Water is cleaned. Chilled water pumps. AHUs & FCUs Expansion Cum Make-up tank is filled with water. Strainer is cleaned if provided. Thermometers & Pressure gages. Flow switches and flow sensors.

PRE-COMMISSIONING CHECKS (Chiller Package )

Condenser water circuit is operational. Water is cleaned. Condenser water pump. Cooling tower. Make up tank is filled with water. Thermometer & Pressure gages. Flow switch or Flow sensors. Adequate flow thru condenser. Surrounding space is cleaned.

PRE-COMMISSIONING CHECKS (Chiller Package )

Check the refrigeration system for leakage. Gasket Joints. Bolt heads Sight glasses Welding joints Guage and guage connections. Relief valve

PRE-COMMISSIONING CHECKS (Chiller Package )

Electrical

Field wiring completed strictly as per final drawing of respective chiller. Field wiring ferruled and dressed properly. O/ L relays are09 set Flow switch, Temperature Sensors are connected. Ensure that shielded cables are used for connecting flow switches and Sensors

Incoming and control switch are ON. Oil heaters are ON.

POST COMMISSIONING ACTIVITIES

Chilled water balancing. Air balancing. Recording the operating conditions. Individual equipment performance evaluation. Comparing with design conditions. Reviewing the deviation. Reasons Fixing responsibilities. Corrective action.

CHILLED WATER BALANCING

Run chilled water system with designed Pumps, AHU and FCU connected. Ensure all valves are fully open. Set individual Branch headers (Start from extreme end) flow with the help flow control valve. Set individual AHU/ FCU flow (Start from extreme end) with the help of flow control valve. Follow same for other Branch headers, AHUs & FCUs.