PREFUNCTIONAL TEST CHECKLIST

Condenser Water System Pre-Operational Flushing and Treatment Procedure

PIPE - ______

Specification Section ______

Project: ______Project No: ______

1.  Preparation

a.  All special treatment equipment listed in the specifications is installed: N/A / Yes / No

b.  Potable water source to fill, dump and flush all piping/associated equipment is connected per drawings/specifications: Yes / No

c.  System has been filled with potable water and re-circulated through all piping (cooling tower fan is off): Yes / No

d.  System has been dumped and flushed, at the lowest point, until all loose matter has been removed and water is clear for a minimum of 24 hours: Yes / No

e.  Interior of pipe has been inspected and/or video taped: Yes / No

f.  System has been re-filled with potable water, with air bled from highest points and/or potential air pocket zones: Yes / No

2.  Pre-operational Chemicals/Cleaner

a.  Project Manager and MDAD water treatment company notified for testing of system (minimum 7 day notice is required): Yes / No

b.  System has been placed in normal tower recirculation/operation (tower fans are off): Yes / No

c.  System pH has been adjusted to 6.5 – 7.0 (near neutral): Yes / No

d.  Stainless Steel Systems

i.  Chlorides test results are under 1,000 ppm: Yes / No

ii.  Water temperature does not to exceed 90 F – 120 F: Yes / No

e.  Galvanized Systems

i.  Betzdearborn (or applicable water treatment company) guidelines have been implemented to prevent white rust: Yes / No

ii.  100 ppm of Betzdearborn (or applicable water treatment company) Flogard MS6201 preoperational cleaner (iron & suspended solid dispersant), or PY505 Polymer at 50 ppm, has been added: Yes / No

iii.  5 ppm of Betzdearborn (or applicable water treatment company) AF724 (antifoam) has been added: Yes / No

iv.  40 ppm of Betzdearborn (or applicable water treatment company) Depositrol SF5101 (oil and slime dispersant) has been added: Yes / No

v.  50 ppm of Betzdearborn (or applicable water treatment company) AZ604 (copper corrosion inhibitor) has been added: Yes / No

vi.  System has been re-circulated for 12 hours maximum (or 16 – 24 hrs recirculation, if PY505 Polymer is used): Yes / No

f.  Non-Galvanized Systems

i.  600 ppm of Betzdearborn (or applicable water treatment company) Flogard MS6201 preoperational cleaner (iron & suspended solid dispersant), has been added: Yes / No

ii.  5 ppm of Betzdearborn (or applicable water treatment company) AF724 (antifoam) has been added: Yes / No

iii.  40 ppm of Betzdearborn (or applicable water treatment company) Depositrol SF5101 (oil and slime dispersant) has been added: Yes / No

iv.  50 ppm of Betzdearborn (or applicable water treatment company) AZ604 (copper corrosion inhibitor) has been added: Yes / No

v.  System has been re-circulated for 12 – 48 hours: Yes / No

3.  Recirculation and Pre-operational Treatment

a.  System has been tested for total iron and pH per Table 1, with results recorded: Yes / No

b.  Treatment has been adjusted to meet Table 1 limits: N/A / Yes / No

Table 1
CONTROL LIMITS FOR MS6201 PRE-OPERATIONAL CLEANER

LOWER LIMITS

/ UPPER LIMITS
FIELD TESTS / DATE / DATE / DATE / VALUE / ACTION / VALUE / ACTION
TOTAL IRON / 0.0 / -- / 10,000 PPM / Dump & re-apply chemicals
PH / 6.5 / -- / 7.0 / Add more H2SO4 of HCl until pH = 6.7
Zinc (if Galvainized) / 0 ppm / -- / 1 ppm / Dump, flush and use PY505

4.  Pre-operational Testing

a.  After pre-operational treatment parameters have been met (Table 1), system has been dumped and flushed (at its lowest point) until the water is clear (minimum of 24 hours): Yes / No

b.  Field test parameters have been met and recorded in Table 2: Yes / No

Table 2
TARGET FIELD VALUES OF FINAL PREOPERATIONAL FLUSH

CW LOWER LIMITS

/ CW UPPER LIMITS
FIELD TESTS / MAKEUP /

CW

Effluent / CW Pass (Y/N) / FORMULA / RESULT / FORMULA / RESULT
CONDUCTIVITY / Makeup x 90% / umhos / Makeup x 110% / Umhos
TOTAL IRON / 0 PPM / Makeup x 150% / PPM
PH / Makeup x 97.5% / units / Makeup x 102.5% / Units
TURBIDITY / -- / 0 FTU / Makeup x 110% / FTU
COLOR / CLEAR / CLEAR

c.  Lab test parameters have been met and recorded in Table 3: Yes / No

Table 3
TARGET LAB VALUES OF FINAL PREOPERATIONAL FLUSH
CW LOWER LIMITS / CW UPPER LIMITS

LAB TESTS

/ MAKEUP / CW
Effluent / CW Pass (Y/N) / TARGET / TOLERANCE LIMITS / TARGET / TOLERANCE LIMITS
Freon extractables (O&G) / <1.0 PPM / 0 PPM / 1.0 PPM / 2.0 PPM
Total Iron / <0.1 PPM / 0 PPM / Makeup x 150% / 5.0 PPM
Conductivity / Makeup x 95% / 100 umhos / Makeup x 105% / 330 umhos
PH / Makeup x 95% / 7.0 units / Makeup x 105% / 9.5 units
Total Alkalinity / Makeup x 90% / 30 PPM / Makeup x 110% / 100 PPM
Calcium Hardness / Makeup x 90% / 30 PPM / Makeup x 110% / 120 PPM
Magnesium Hardness / Makeup x 90% / 5 PPM / Makeup x 110% / 30 PPM
Silica / Makeup x 90% / 0 PPM / Makeup x 110% / 20 PPM
Ryznar Saturation Index / 6.0 RSI
Langelier Saturation Index / (At 6-9 cycles) / +1.0 LSI / (At 6-9 cycles) / +3.0 LSI

d.  System is ready for application of initial long term water treatment chemicals: Yes / No

Comments:

PREFUNCTIONAL TEST CHECKLIST

CONDENSER WATER SYSTEM PRE-OPERATIONAL FLUSHING AND TREATMENT PROCEDURE

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