Facilities Management Engineering HVCA Spec

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SFG20

Standard Maintenance Specification for Mechanical Services in Buildings

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INTRODUCTION 1 Standard Maintenance Specification Before the publication of the original specification in 1990, there had been no standard document covering the maintenance of heating, cooling and ventilation plant in buildings. Equipment had become more reliable with the introduction of solid state and microchip technology,and one consequence of this is that there has been a tendency to relax the maintenance of plant with resultant customer dissatisfaction and energy wastage which experience has shown can be as high as 20%. Given this situation, the Heating and Ventilating Contractors’ Association (HVCA) in association with the Chartered Institute of Building Engineers (CIBSE), the Building Research Energy Conservation Support Unit (BRECSU) and, what was then the Energy Efficiency Office at the Department of Energy, developed a Standard Maintenance Specification which was aimed at maintenance contractors and organisationswith the relevant expertise to carry out their own maintenance, by providing a contractual standard against which to evaluate and enforceadequate standards. HVCA members use it as a mandatory standard both for tending and in carrying out the work and those organisations going out for tender also use the standard as an integral part of the tender specification. The revised Standard is produced in alpha sort under 66 service equipment headings, each having the same format and covering major elements in heating, cooling and ventilation. Newly included in this latest version is reference to HVCA’s Guide to Ventilation Hygiene (Ductwork Cleaning).

2 Safety Safe operation of the plant and its immediate environment is a fundamental part of good maintenance practice and should be taken into account at all times. Ventilation and adequate lighting is essential in boiler houses and plant rooms and any deficiencies in these areas must be brought to the client’s attention immediately. The responsibility for ensuring safe access to equipment should be clearly defined. It should be noted that certain specialised functions such as fire prevention and lifts are not covered by the standard and any person working on such equipment should, in the case of fire prevention and alarms, be registered with the Loss Prevention Council or should be the manufacturer’s nominated fire prevention contractor. Similar considerations apply in the case of lifts.

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3 Electrical equipment All electrical equipment should be capable of local isolation in accordance with the regulations of the Institution of Electrical Engineers – Regulations for Electrical Installation (IEE Wiring Regulations Current Edition), BS 7671:2001, and as detailed in guidance note No2, Isolation of switching. All electrical equipment shall be provided with means of isolation, which disconnects the respective item of equipment and any associated control devices and circuits. There are also stringent requirements and guidance in the Electricity at Work Regulations (1989), and of particular importance is Regulation 12 – “Means for cutting off the supply and for isolation”. In this Regulation, isolation means the disconnection and separation of the electrical equipment from every source of electrical energy in such a way that this disconnection and separation is secure. The word ‘secure’ is specifically mentioned in the Electricity at Work Regulations (1989) and requires the means of isolation to be such that it is not likely to fail, become loose, etc. by the action of vibration, mechanical shock or knocks, or be accidentally or inadvertently operated. Padlocking is a widely used means, with clear labelling and warning notices. 4 Maintenance of systems Although the specification is presented in a checklist format describing specific maintenance activities applied to generic types of plant, it is not implied that maintenance responsibilities should be defined in this way. The responsible agent, either as a contractor or as an employee is responsible for maintaining the entire system, not just groups of components. Regarding the maintenance activity in respect of a system care should be taken to ensure that maintenance tasks are carried out by suitably qualified and experienced staff capable of exercising professional standards of judgement and discretion in relation to individual systems. The specification is a statement of typical standards, and further reference to manufacturers should be sought for detailed guidance to supplement the specification. In the absence of a manufacture specification this specification is a minimum standard for safe working and efficiency. 5 Proprietary equipment This Specification represents the best maintenance practice in general terms. For specific items of plant it is essential that the maintenance engineer should be familiar with the equipment manufacturer’s maintenance manual and comply with the instructions contained therein. It is anticipated that this standard will be used not only by maintenance engineers carrying out the maintenance but also by managers as a means of checking that the work has been carried out and conforms to the tender requirements.

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6 Records It is essential that a manual should be kept on site which should record the clearly defined responsibilities of:

(a) Plant attendants (b) Operators (c) Supervisors

Together with a list detailing the equipment and normal settings and the location of operating and maintenance manuals relating to specific plant and control equipment. A record should be kept of all events and changes related to the equipment, the various settings of controls and valve positions. 7 Efficiency and Emissions European Directives and UK law will require Carbon emissions from the combustion process to be controlled in order to achieve low fuel consumption and thus greater overall efficiency. Nitrogen Oxides (NOx) are also produced during combustion. When oxides of nitrogen combine with water in the upper atmosphere, acidic compounds are formed which then lead to the acid rain formation, which can cause damage to plants, aquatic life and buildings. Low NOx boilers are available to counter this effect and to comply with European Directives and UK law, the aim of which is reduce the permitted NO2 emissions from new fossil fuel heat generators to 180mg/Nm3 (normal cubic metres).

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5CONTENTS SFG20 STANDARD MAINTENANCE SPECIFICATION

INTRODUCTION

01 ACTUATORS -01 Introduction-02 Pre-maintenance-03 Thermal-04 Pneumatic-05 Hydraulic-06 Motor driven-07 Power Fail - Motor Return-08 Power Fail - Spring return

02 AIR CONDITIONING -01 Introduction

03 AIR HANDLING UNITS -01 General

04 BELTS -01 General

05 BOILERS/HEAT GENERATORS -01 Introduction-02 Pre-maintenance-03 Atmospheric gas burner - free standing boiler-04 Atmospheric gas burner - condensing boiler-05 Coal fired boilers - bunkers and conveyors-06 Coal fired boilers - coal storage-07 Coal feed - under feed stokers-08 Coal feed - chain grate stokers-09 Ash handling systems-10 Blown gas burner - condensing boiler-11 Blown gas burner - modular boilers-12 Forced draught gas burner - condensing boiler-13 Forced draught oil burner - condensing boiler-14 Boiler MTHW

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05 BOILERS/HEAT GENERATORS continued -15 Boiler controls - multiple boilers-sequence

-16 Boiler controls - single boiler on/off -17 Boiler controls - protection -18 Boiler controls - space temperature -19 Steam boilers - pre-maintenance check -20 Steam boilers - maintenance -21 Electric boilers -22 Electrode boilers -23 Boilers LTHW -24 Boilers - fire & safety circuits -25 Waste & wood burning appliances - safety circuits -26 Waste & wood burning appliances - combustion chamber -27 Waste & wood burning appliances - boiler -28 Atmospheric gas burner/boiler - small wall hung boiler -29 Atmospheric gas burner combination boiler -30 Atmospheric gas burner condensing combination boiler -31 Air to water pump -32 Water to water pump -33 Brine to water pump

06 BURNERS -01 Atmospheric gas burner -02 Blown gas burner -03 Forced draught gas burner -04 Forced draught oil burner heavy fuel oil 220/960 sec -05 Forced draught oil burner -06 Light oil vaporising pot burner -07 Gas/oil burner – dual fuel

07 BUILDING MANAGEMENT SYSTEMS -01 Introduction -02 Glossary of BMS terms -03 Central operator station -04 Communications -05 Outstations -06 Software functions

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08 CATERING EQUIPMENT AND CANOPIES - Seek specialist advice

09 CHILLERS WATER -01 Introduction

-02 Packaged chillers -03 Lithium bromide -04 Gas Fired Absorption

10 COLD ROOMS & FOOD STORAGE -01 Cold rooms -02 Refrigerated Cabinets

11 COMMUNICATION AND P.A. SYSTEMS -01 General

12 COMPRESSORS – REFRIGERATION -01 Reciprocal -02 Screw -03 Centrifugal

13 CONDENSERS -01 Water cooled -02 Air cooled

14 CONTROL PANELS & CONTROLLERS -01 Introduction -02 Electrical services -03 Lamps, meters, alarms etc. -04 Optimiser -05 Heating compensator -06 Single input controller -07 Unit and sensor controllers -08 Controller timers -09 Step controllers -10 Time switches -11 Multi Input Controllers -12 Indicators and displays -13 Alarm Modules -14 Level Controllers -15 Speed Controllers -16 Transducers

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15 COLD WATER STORAGE AND SERVICE - See STORAGE TANKS

16 DUCTING -01 Introduction-02 General-03 Volume control and fire / smoke dampers-04 Acoustics

17 DUCTWORK – CLEANING -01 Hygiene, inspection and monitoring

18 ELECTRICS IN BUILDINGS -01 Introduction

19 EVAPORATORS -01 Shell and Tube / Direct Expansion

20 FANS -01 Introduction-02 Ventilating - general-03 Centrifugal-04 Axial-05 Propeller-06 Mixed flow-07 Bifurcated-08 Fire/smoke extract units

21 FILTERS -01 Introduction-02 Filters

a) Common proceduresb) Disposablec) Reusabled) Roll band/automatice) Absorptionf) Greaseg) Absolute (HEPA)

-03 Electro static

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922 FIRE ALARM SYSTEMS -01 Fire alarm system

-02 Associated equipment

23 FIRE PROTECTION SYSTEMS -01 Introduction-02 Hose reels – pressure boosting-03 Hose reels – static or swinging-04 Rising mains and hydrants-05 Halon fire protection systems-06 Carbon dioxide systems-07 Expansion foam systems-08 Fire extinguishers - Halon-09 Fire extinguishers - Carbon dioxide-10 Fire extinguishers - Foam-11 Fire extinguishers - Powder-12 Fire extinguishers - Water-gas cartridge-13 Fire extinguishers - Water stored pressure

24 FLUES -01 Normal/ Fan assisted/ Fan dilution

25 FOUNTAINS -01 Ornamental

26 GRILLES AND DIFFUSERS -01 Grilles and diffusers-02 Louvres, bird and insect screens

27 HAZARDOUS AREA (ELECTRICS) -01 Introduction-02 Flame proof equipment-03 Lighting-04 Earthing

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28 HEAT EMITTERS -01 Heat emitters - various-02 Gas fired ceramic plaque infra red-03 Gas radiant tube heaters-04 Gas fired natural & fan assisted heaters

29 HEAT EXCHANGERS -01 Heating/cooling coils-02 Electric / air heater-03 Plate recuperator-04 Thermal wheels-05 Run round heat recovery coils-06 Plate heat exchangers-07 Water to water plate heat exchangers

30 HEAT REJECTION SYSTEMS -01 Introduction-02 Cooling towers-03 Dry coolers

31 HOT AND COLD WATER SERVICES -01 Introduction-02 Note on the Water Undertakers Byelaws

32 HOT WATER SUPPLY -01 Introduction-02 Hot Water services - general-03 Calorifier types-04 Calorifiers - pre-maintenance-05 Calorifiers - LTHW or MTHW-06 Calorifiers - steam-07 Calorfiers - hot water supply including load levellers-08 Calorifier and heat exchange - controls-09 Hot Water cylinders-10 Unvented hot water systems-11 Thermal storage cylinder-12 Expansion vessels-13 Direct fired water heaters-14 Instantaneous electric water heaters-15 Packaged electric water heaters

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33 HUMIDIFIERS including disinfection procedures -01 Cold water evaporator-02 Steam injection-03 Electrode boiler-04 Compressed air-05 Ultra sonic-06 Resistance heater-07 Disinfection procedures

34 ICE MAKING MACHINES -01 General

35 INSULATION -01 General

36 LIGHTING -01 Introduction-02 Switches-03 Fittings and luminaires-04 External including signs

37 LIGHTING- EMERGENCY -01 Emergency - self contained-02 Emergency - external powered

38 LIGHTNING PROTECTION -01 Lightning conductor and earth

39 MOTORS -01 Drive elements

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40 PIPEWORK SYSTEMS -01 General-02 Mountings-03 Trace heating-04 Chilled water - condenser water-05 Chilled water - pumps-06 Chilled water - pressurisation units-07 Pneumatic equipment - compressed air-08 Compressed air - compressors-09 Compressed air - dryers and distribution-10 Fuel supply-11 Steam services

41 PNEUMATICS -01 Relays

42 PORTABLE EQUIPMENT -01 PAT testing

43 POWER GENERATION -01-02

IntroductionStand-by generator

-03 Batteries-04 Battery charging-05 Uninteruptable power supplies (UPS)

44 POWER SUPPLIES -01 Introduction-02 Main switch panel at supply intake-03 Maximum demand-04 Armoured cables and conduits-05 Power distribution units-06 Earthing-07 Distribution boards-08 Ring Main and sub-circuits-09 Three phase circuits

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45 PUMPS -01 General-02 Circulating-03 Centrifugal-04 Pressurisation-05 Rotary hand pumps-06 Secondary HW circulating pumps-07 Sewage/drainage pumps - submersible-08 Sewage/drainage pumps - dry well-09 Sewage/drainage pumps - compressed air-10 Sump pumps – extended shaft-11 Domestic water accelerators-12 Water pumping pressure boosting sets

46 REFRIGERANT DISTRIBUTION SYSTEM -01 General

47 ROOM AIR CONDITIONERS -01 Unitary air conditioners

48 SANITARY AND WASTE WATER PLUMBING -01 Introduction-02 Macerators-03 Interceptors – petrol and oil-04 Interceptors – blowdown and sumps-05 Waste water plumbing and drains-06 Air admittance valves-07 Rainwater down pipes and gutters-08 Water saving devices and meters

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49 SECURITY SYSTEMS -01 Intruder alarms

50 SENSORS AND SWITCHING DEVICES -01 Pre-maintenance – electric/electronic and pneumatic-02 Pressure-03 Temperature-04 Relative humidity-05 Absolute humidity-06 Air quality-07 Carbon dioxide-08 Velocity-09 Occupancy-10 Smoke-11 Gas

51 SHOWERS -01 Spray fittings and enclosures-02 Booster pumps

52 SMOKE EXTRACT -01 General-02 Smoke relief – natural ventilators-03 Smoke relief – powered ventilators-04 Smoke curtains

53 SOLAR PANELS -01 Collecting devices

54 SPLIT SYSTEMS INCLUDING HEAT PUMPS -01 Introduction-02 Split/roof top package-cooling and/or full heating

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55 STARTERS -01 General-02 Star delta-03 Two speed - dual wound-04 Two speed - pole change-05 Reversing-06 Auto transformer-07 Quick transition-08 Electrolyte-09 Air break and contactors

56 STORAGE TANKS -01 Introduction-02 Water - cold

(Water – hot - see HWS)-03 Ice-04 Gas LPG-05 Oil

57 SWIMMING POOLS -01 Introduction-02 Swimming pools-03 Filters-04 Pipework

58 SWITCHES -01 On/off-02 Control relays

59 TERMINAL UNITS -01 VAV self powered-02 VAV fan powered-03 VAV pneumatic powered-04 Constant volume mixing box-05 Induction-06 Fan coil-07 VRV

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60 VACUUM SYSTEMS -01 General-02 Cash handling

61 VALVES -01 Valvesa) Gateb) Globec) Lubricated plugd) Butterflye) Floatf) Parallel slideg) Steam safetyh) Steam PRVi) Pressure controlj) Diaphragmk) Boilerj) Radiator TRV

-02 Tap - general-03 Tap - service-04 Tap - mixing-05 Shower

62 VALVES - AUTOMATIC CONTROL -01 Pre-maintenance-02 Rotary - shoe or slipper-03 Butterfly and ball-04 Self acting and thermal-05 Solenoid-06 Pressure control-07 Seat

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63 VEHICLE ACCESS -01 Ramps - underfloor heating-02 Automatic barrier

64 VENTILATION ANCILLARIES -01 Introduction-02 Motor driven exhaust hose reel-03 Spring recoil hose reel-04 Mobile dust separator-05 Mobile cyclone separator-06 Vehicle exhaust rail systems

65 WATER TREATMENT -01 Introduction-02 Ion exchange - commercial-03 Ion exchange - domestic-04 Special water treatment systems-05 Filtration - central plant-06 Filtration - point of use-07 Reverse osmosis-08 Ultra violet-09 Ozonation-10 Chemical dosing

66 WHIRLPOOLS - HYDROTHERAPY -01 Whirlpool / Spa baths-02 Hydrotherapy-03 Steam rooms and humidifiers

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1801-01 ACTUATORS – Introductory Procedures

The following procedures apply to all types of actuator and require that before any maintenance is undertaken all safetyprecautions must be strictly adhered to. Care must be taken to ensure that any maintenance does not unduly interfere with the system'senvironmental conditions.

When working on equipment it should be noted that any auxiliaries fitted may have supplies fed from a separate circuit to that of the actuator.Therefore should the actuator supply be disconnected it should not be taken for granted that the auxiliary supply has also beendisconnected.

To check that the actuator is performing its correct task, it is immaterial as to whether it is mounted on a damper, louvre, valve or any otherpiece of equipment. Its purpose is to control to a position between two limits, by either opening, closing or moving appropriate pieces ofequipment.

Other Actuator Types

The function of an actuator can be split into two main categories: ON/OFF or MODULATING. Falling within these two categories are theseven types listed in this section.

Although the majority of actuator types are covered in the following pages, new developments may mean that the engineer is not fully awareof the operating characteristics of the device under scrutiny. If any doubt arises it would be preferred if the manufacturer were questionedprior to any checks or adjustments being carried out.

An example of the above is the VAV actuator sensor controller. This is a type of actuator that has the controller built into the actuatorhousing. The sensor is connected via a length of cable and will commonly be sensing air velocity or pressure. The controller will have beenset to the required VAV box demand and these settings should not be altered without prior consultation with the client, the VAV boxmanufacturer and the actuator manufacturer. In this example, cross-referencing should be made between the Actuators, Controllers andSensors sections.

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01-02 ACTUATORS - pre-maintenance procedures - all types

Should any discrepancies occur with the following checks the client should be informed as soon as possible to avoid the possibleuneconomical running of his plant.

The frequency of checks should be used as a minimum in the event that the actuator is performing a safety function (i.e. on afire and smoke damper). Lives and property could depend upon this actuator working properly.

1. Cables. Check for signs of heat, damage, chafing or water ingress.

2. Mounting. Check mounting is in accordance with the manufacturer's recommendation.

3. Anchor points. Check security.

4. Mechanical protection. Check for soundness.

5. Earth bonding. Check connection.

6. Actuator torque. Check torque with a torque wrench. This check is of particular importance on spring return type actuatorsbecause the spring will have a maximum life span. Elasticity of the spring and hence the torque will reduce with time, if thetorque is insufficient to complete the action, this could be a hazard to life and property.

7. Working conditions. Check actuator is operating within its design ambient conditions.

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2001-03 THERMAL ACTUATORS

ITEM FREQ. ACTION NOTES1. Electricity supply. 12m Check supply voltage and that

polarities are correct.If supply voltages are not found, check to see ifsupply is via a controller. Refer to manufacturer'sdata sheet.

2. Control signal. 12m Check for presence and thatpolarity is correct.

Refer to manufacturer's data sheet. The previousnote can also apply to the control signal.

3. Auxiliary control functions i.e.on/off switches, frostprotection, position indicators,feedback potentiometers.

12m Check operation. See relevant manufacturer's data sheet andauxiliary section.

4. Manual operation (if fitted). 12m Check to prove actuator willmechanically open/close valveor damper to its working limits.

Ensure that the actuator is returned to the "auto"position after check is completed.

5. Actuator position on powerfailure.

12m Check for correct position forapplication when power fails.

This will entail interrupting the power to theactuator at a convenient point. Do not forget toreconnect the supply when the check iscomplete.

6. Reaction to safety signal i.e.fire/smoke.

6m Check that the actuatorassumes correct position (ifapplicable).

See relevant control/sensor section for thisoperation.

7. Reaction to control signal. 12m Check for correct response tosignal.

See relevant controls section.

8. Running time (if applicable). 12m Check See manufacturer's data sheet.

9. Leakage. 12m Check for signs of leakage ofhydraulic fluid around actuatorseals. Change seals ifnecessary.

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2101-04 PNEUMATIC ACTUATORS

Pneumatic actuators do not have an electrical supply but function by air pressure alone. Therefore should there be any loss in pressure,the performance of the actuator (and thus the whole system) will be impaired making it inefficient.

ITEM FREQ. ACTION NOTES

1. Pressure/leakage/ seizure 12m Check operation betweenactuator and controller.

With a variance in pressure from the controller,the actuator will modulate.

2. Pipe connections. 12m Check condition of glands andseals. Check pipework fordeterioration.

Replace defective glands and seals.

3. Air quality. 12m Check that any filters are clearof water and oil (filter may notbe local to the actuator).

If water and/or oil is present, check withmanufacturer of the system regarding requiredaction.

4. Manual operation (if fitted). 12m Check to ensure actuatorachieves stroke limits.Check for minimum/ maximumsetting.

Ensure manual override is set to correctposition.

5. Linkage assembly, i.e. nutsbolts, spring, valve stem ordamper assembly.

12m Check a)wear, b)security

c)corrosion

Lubricate/replace/tighten as necessary.

6. Lubrication and cleaning. 12m As recommended. See manufacturer's data sheet.Only use manufacturer's recommended cleaningagents and lubricants.

Continued on next page ..

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2201-04 PNEUMATIC ACTUATORS - continued


7. Actuator function. 6m Check calibration - controlleroutput to actuator position.Note: more than one actuatormay be fed from the controlsupply.

Note control pressure operation range is correct(could be sequenced control)

8. Auxiliary control units. e.g.positioners, electricalfeedback units, end switches.

12m Check operation. Refer to manufacturer's data sheets.

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2301-05 HYDRAULIC ACTUATORS

(Should not be confused with pneumatic actuators)ITEM FREQ. ACTION NOTES

1. Electricity supply. 12m Check supply voltage and thatpolarities are correct.

If supply voltages are not found, check to see ifsupply is via a controller. Refer tomanufacturer's data sheet.


Refer to manufacturer's data sheet. Theprevious note can also apply to the controlsignal.

3. Auxiliary control functions i.e.on/off switches, frostprotection, feedbackpotentiometers positionindicators.


4. Manual operation (if fitted). 12m Check to prove actuator willmechanically open/close valveor damper to its working limits.

Ensure that the actuator is returned to the"auto" position after check is completed.



This will entail interrupting the power to theactuator at a convenient point. Do not forget toreconnect the supply when the check iscomplete.


See the relevant controls section.

7. Running time (if applicable). 12m Check. See manufacturer's data sheet.8. Leakage. 12m Check for signs of leakage of

hydraulic fluid around actuatorseals. Change seals ifnecessary.

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2401-06 MOTOR DRIVEN ACTUATORS

ITEM FREQ. ACTION NOTES1. Electricity supply. 12m Check supply voltage and

that polarities are correct.If supply voltages are not found, check to see if supplyis via a controller. Refer to manufacturer's data sheet.

2. Control signal. 12m Check for presence andthat polarity is correct.

Refer to manufacturer's data sheet. The previous notecan also apply to the control signal.

3. Auxiliary control functions i.e.on/off switches, frostprotection, position indicators,feedback potentiometers.

12m Check operation. See relevant manufacturer's data sheet and auxiliarysection.

4. Manual operation (if fitted). 12m Check to prove actuator willmechanically open/closevalve or damper to itsworking limits.

Ensure that the actuator is returned to the "auto"position after check is completed. If the actuator is ofthe direct coupled type, ensure that the clamp assemblyis not worn and the fixings are tight.


12m Check for correct positionfor application when powerfails.

This will entail interrupting the power to the actuator at aconvenient point. Do not forget to reconnect thesupply when the check is complete.

6. Reaction to safety signal i.e.fire/smoke.


The signal could be in any form from a fusible link in thesupply or gear box to an independent signal from acontrol.If the actuator is integrated into the fire alarm circuit,checks may have to be made whilst a fire drill is inoperation. See manufacturer's data sheet on thisactuator and relevant control and/or sensor section.


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2501-06 MOTOR DRIVEN ACTUATORS - continued



See the relevant section.

8. Running time (if applicable) 12m Check. See manufacturer's data sheet.

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2601-07 POWER FAIL - MOTOR RETURN ACTUATORS

Power fail - Motor return actuators are commonly enabled to return to the desired position by means of an electricity supply independentfrom the rest of the building. Care should be taken to monitor the amount of operations left in the batteries and they should bereplaced according to the manufacturer's instructions. The disposal of batteries calls for special arrangements, which should conformto all environmental and Health and Safety requirements.Note:- If the following actuators perform a safety function e.g. fitted to a fire/smoke damper, the frequency of checks should be taken asthe maximum time between checks and reference should be made to the particular manufacturer's recommended frequencies. It shouldbe remembered that people's lives and property could depend on the actuators functioning correctly.

ITEM FREQ. ACTION NOTES1. Electricity supply. 12m Check supply voltage and

that polarities are correct.If supply voltages are not found, check to see ifsupply is via a controller. Refer to manufacturer'sdata sheet.


Refer to manufacturer's data sheet. The previousnote can also apply to the control signal.

3. Auxiliary control functions i.e.on/off switches, frostprotection, feedbackpotentiometers positionindicators.


4. Manual operation (if fitted). 12m Check to prove actuator willmechanically open/closevalve or damper by moving toits working limits.

Ensure that the actuator is returned to the "auto"position after check is completed.



This check must be performed before power isrestored to the system or actuator.

6. Reaction to safety signal, e.g.fire/smoke.



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2701-07 POWER FAIL - MOTOR RETURN ACTUATORS - continued


7. Battery. 6m Check condition. Note use by date and consider life expectancyof battery. See heading note above regardingdisposal.

Auxiliaries

1. Switches. 12m Check to ensure that the switchesare made to make or break at thecorrect position and that theyperform their correct function.

2. Feedback potentiometers. 12m Check to ensure that:a)winding/tracking is not dirty orbroken,b)wiper is making contact and isnot dirty,c)potentiometer performs itscorrect function.

If the winding is broken, do not attempt to repair.Provide a replacement.If the wiper is not making correct contact, gentlybend it until smooth contact is attained.


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2801-07 POWER FAIL - MOTOR RETURN ACTUATORS - continued


3. Linkages,a) visual,

12m Check for:a) corrosionb) deformed or bent componentc) wear on moving parts and

mounting brackets.

Where required, clean and lubricate parts i.e.ball joints and sockets and moving parts.Refer to manufacturer should any item deem tobe in need of replacement.Refer to data sheet on manufacturer'smaintenance instructions.

b) physical check. 12m Ensure that the actuatorachieves the required strokelimits. Adjust if necessary.

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2901-08 POWER FAIL - SPRING RETURN ACTUATOR


1. Electricity supply. 12m Check supply voltage andthat polarities are correct.

If supply voltages are not found, check to see if supply isvia a controller. Refer to manufacturer's data sheet.

2. Control signal. 12m Check for presence andthat polarity is correct.

Refer to manufacturer's data sheet. The previous notecan also apply to the control signal.

3. Auxiliary control functionsi.e. on/off switched, frostprotection, feedbackpotentiometers positionindicators.

12m Check operation. See relevant manufacturer's data sheet and auxiliarysection.

4. Manual operation (if fitted). 12m Check to prove actuator willmechanically open/closevalve or damper to itsworking limits.

The actuator may be fitted with the facility to manuallywind up the spring, if so the spring must be wound upwith the recommended tool. See manufacturer's datasheet. If the tool is capable of being removed, do so atthe end of the test and ensure that the actuator is left inthe original position.Ensure that the actuator is returned to the "auto" position(if fitted) after the check is completed.


12m Check for correct positionfor application when powerfails.

This check must be performed before power is restored tothe system or actuator.

6. Running times of springand motor.

12m Check. Times should be within the tolerances specified in themanufacturer's data.


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3001-08 POWER FAIL - SPRING RETURN ACTUATOR - continued


7. Reaction to safety signal, e.g.fire smoke.


This signal could be in any form, from a fusiblelink in the supply or gearbox to an independentsignal from a control.If the actuator is integrated into the fire alarmcircuit, checks may have to be made whilst a firedrill is in operation.


See manufacturer's data sheet.

Auxiliaries

1. Switches. 12m Check to ensure that theswitches are made to make orbreak at the correct positionand that they perform theircorrect function.

2. Feedback potentiometers. 12m Check to ensure that:a)winding/tracking is not dirtyor broken,b)wiper is making contact andis not dirty,c) potentiometer performs itscorrect function.

If the winding is broken, do not attempt to repair.Provide a replacement.If the wiper is not making correct contact, gentlybend it until smooth contact is attained.


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3101-08 POWER FAIL - SPRING RETURN ACTUATOR - continued


3. Linkages,a) visual

12m Check for:a) corrosionb) deformed or bent

componentc) wear on moving parts and

mounting brackets.

Where required, clean and lubricate parts i.e. balljoints and sockets and moving parts.Refer to manufacturer should any item deem tobe in need of replacement.Refer to data sheet on manufacturer'smaintenance instructions.

b) physical check. 12m Ensure that the actuatorachieves the required strokelimits. Adjust if necessary.

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02-01 AIR CONDITIONING--Introduction

Air conditioning systems range from the single wall/window mounted unit to large installations having compressor drives of several hundredkW. The maintenance requirements of the various systems will differ widely in complexity and skill requirements and this is reflected in thebreakdown of this document. Two environmental problems associated with air conditioning plant, namely the potential depletion of the ozonelayer through the release of chlorofluorocarbons (CFCs) and Legionnellosis from untreated water systems, demonstrates the need for maintaining plant at the highest standard as is outlined in this Standard Maintenance Specification.

Care is also required in the disposal of CFCs. Any practice which releases CFCs into the atmosphere must not be used. Specialist contractors will have refrigeration engineers who have been trained and certified in the handling of CFCs and will have access toand use proper recovery equipment. These contractors should belong to HVCA’s REFCOM Scheme. It is in the building owners’ interest toensure that plant is properly maintained to ensure environmental conditions in the building are acceptable to the staff and that energy is notwasted.

In a subject as complicated as the maintenance of air conditioning plant an approach has been selected which breaks the systems down intotheir component parts such as compressors, condensers, and evaporators or chillers, refrigerant distribution systems with their associatedcontrols. Central and room air conditioning plant are examined in the appropriate detail as Air Handling Units, Humidifiers, Heat RejectionUnitary Air Conditioners. It must be emphasised that although this modular approach has been adopted it is the system as a whole, whichmust be maintained on a regular basis using this Standard Maintenance Specification.

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3303-01 AIR HANDLING UNITS - general


1. Filter. 1m Check manometer reading and renewfilter media as indicated.

Record manometer reading. It should be notedthat checking the filter should be carried outweekly by maintenance staff.

2. Guide vane actuators andmodulating dampers.

1m Check operation.

3. Condensate drains. 1m Check for condensate carry-over andthat drains are clear.

4. Humidifier pumps, spraysand water supply to tank.

1m Check operation.

5. Frost protection, boostthermostat and controls.

6m Check operation. For detailedmaintenance refer relevant section.

This check should be carried out in Septemberand February in Great Britain.

6. Vent air. 1m Air should be vented from heating andcooling coils where fitted.

7. Drive belts. 1m Check tension, alignment, andcondition.

Re-tension or replace as necessary. For detailedmaintenance procedures, see BELT DRIVES.

8. Drive pulleys. 12m Check alignment, security.

9. Drive couplings. 12m Check alignment and for excessiveclearance.

Wear is indicated by excessive clearance andcouplings should be replaced.

10. Damper and guide vanepivots and linkages.

3m Lubricate lightly.


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3403-01 AIR HANDLING UNITS - general - continued


11. Motorised damper. 3m Check to see that louvres areclear and not obstructed,couplings are secure and thatmotor runs without excessivenoise or vibration.

For detailed maintenance see MOTORS.

12. Heating and cooling coils. 12m Check condition and clean.Check air and water pressuredrops across coils.

Even when filters are fitted, dirt can build up causingloss of machine output.

13. Controls and electricalconnections.

12m Check operation and condition. Calibration }Interrogation }Control adjustment }

See relevant section

14. Valves. 12m Fully open and close and thenreset at the original setting.

15. Air handling unit. 12m Thoroughly clean interior andcheck for corrosion. On re-assembly check for airtightness.

Include heating and cooling coils, fan impeller andeliminator plates and other fittings.


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03-01 AIR HANDLING UNITS - general - continued


16. Motors. 12m Check:- a) condition of motor brushes and replace if necessary, b) clean and test windings, c) check tightness of terminals, d) check full load current, e) bearing wear, f) replace lubricant in motor bearings.

This should not exceed data plate value. Measure shaft float and end play.

17. Anti-vibration mountings and ductwork flexible connections.

12m

Check condition.

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3604-01 BELT DRIVES - general


1. Tension. 3m Check and adjust as necessary. The correct tensioning of V-belts preventsexcessive bearing wear. Motor position should beadjusted so that only a slight `bow' appears onthe slack side of the belt when in operation.

Recommended tensions are given in theinstallations instructions.

After a few days running, check tension.

2. Alignment. 3m Check and adjust as required. Poor alignment of the pulleys will causeexcessive wear on the sides of the belt andshorten their lives.

3. Bearings. (`Sealed forlife' bearings should notnormally requireattention).

3m

12m

Check for wear and lubricate atfrequencies recommended by themanufacturer.Where oil filled, drain, strip and cleanbearing assembly, reassemble and fillwith clean oil.

When operating in high temperatureenvironments e.g. above 60oC more frequentmaintenance may be necessary.

4. Guards. 3m Check for secure mounting andpositioning.

Belt replacement. As necessary. New and usedV-belts should not be run together on the sameset.

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05-01 HEAT GENERATORS ( BOILERS and HEATING APPLIANCES ) Introduction In this section on the maintenance of heat generators, the specification is aimed at establishing best maintenance practice, but this is not intended to replace the statutory insurance inspection required by Health and Safety regulations. The term heat generators is a generic one used within the European Community to cover all appliances which burn fuel or convert energy to produce heat. This section covers firstly the general requirements which are common to a group of appliances such as hot water heat generators and then examines the maintenance needs within each group. It must be emphasised that it is still necessary to refer to manufacturer's maintenance schedules for specific makes of appliances. A detailed breakdown of the contents of this section is given in the Index but the format of each subsection is in the form of tables providing details on the item to be maintained, the frequency of maintenance, the action to take, and where appropriate informative notes about the action be taken. It should be noted that the frequency of maintenance relates to average conditions in terms of use and the environment in which the equipment is working. In cases where operating regimes are severe or the environment dirty or corrosive the frequency of maintenance should be increased to meet those conditions. Sections include: Hot water heat generators including condensing heat generators Steam raising heat generators Oil fired heat generators Coal fired heat generators Gas fired heat generators, direct fired, warm air heaters and radiant systems are found in HEAT EMITTERS. Electrode heat generators Electric heat generators Waste/Wood Burning heat generators Controls relating to actual pieces of equipment are covered in the appropriate tables but more sophisticated controls are covered in the relevant sections.

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05-01 HEAT GENERATORS ( BOILERS and HEATING APPLIANCES) - continued Heat generator types The term heat generator covers a wide range of energy conversion appliances which involve a heating source, usually a fossil fuel burner or an electrical resistance element, which applies heat at one side of a metal surface. On the other side is a heating fluid, usually water or air, which absorbs energy from the heat source. This operation is termed heat transfer and anything which hinders that transfer wastes energy. In the case of hot water it can either be circulated at near atmospheric pressure or circulated at higher pressures and temperatures above the normal boiling point. Alternatively the water can be evaporated as steam and the steam circulated as the heating medium. Warm air can be used as a heating medium and if it contains the products of combustion it is said to be direct fired. Alternatively uncontaminated warm air can be provided by passing the burner gases through a heat exchanger. In some cases the combustion gases are passed at high temperature through radiant tubes which provide radiant heat. In most cases, air movement is fan assisted. This section covers all the important aspects of heat generator maintenance including safety controls, combustion and the combustion chamber and heat generator controls. Combustion Correct combustion entails the adequate mixing of the fuel with air to ensure that the fuel is completely burnt without producing excessive smoke or diluting the combustion gases with excess air both of which cause energy wastage. With all fossil fuels, insufficient air produces carbon monoxide, a safety and health hazard, as undetected CO is poisonous and could be fatal; and a visible smoke plume which should lead to prompt corrective action. With gas combustion, no smoke is produced when insufficient air is used and hence the situation can go unnoticed for long periods, leading to significant energy waste unless regular flue gas analyses are carried out and the condition corrected. When smoke is produced it can deposit soot on the heat transfer surfaces and reduce the amount of heat passing through the heat exchanger into the water. This in turn leads to more heat being carried away in the flue gases. This can be detected by monitoring flue gas temperature. Poor combustion can result from: (a) damage to or poor alignment of burner jets or pipework (b) oil not being at the correct atomising temperature (c) insufficient air or draught

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05-01 HEAT GENERATORS ( BOILERS and HEATING APPLIANCES) – continued A poor flame shape can also lead to localised overheating of the heat generator surfaces, deposition of soot and reduced heat transfer. Cleanliness is also required on the water side of the heat exchange surfaces. In steam raising applications, the feedwater should be treated correctly at all times to keep internal surfaces clean, and suitable provision made for the removal of solids that accumulate in the boiler when the feedwater evaporates. 05-02 Pre-maintenance procedures A fundamental element of good practice for the operator or attendant should be to carry out a visual inspection of the heat generator at regular intervals as part of the day-to-day routine. This should including checking for leaks and correct burner flame shape, i.e. it should be uniform in shape, 'sit' on the burner and should not hit the walls or back of the combustion chamber. Prior to carrying out the planned maintenance of the heat generator the following pre-maintenance procedures should be followed: (a) Check equipment status (i.e. on or off) and follow any specific site procedures (including safety) (b) Carry out a general inspection of heat generator casing for signs of damage or breakage (c) Inspect for loose fittings or connections or any signs of leaks, smells or unusual noises (d) Record work which will require repair, adjustment or replacement during the routine service

(e) Record existing services – (combustion/efficiency analysis should be recorded before and after maintenance completion).

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05-03 ATMOSPHERIC GAS BURNER – FREE STANDING BOILER It is essential that there should be adequate ventilation [ratio of one third low to two thirds high level] of the boiler house for safety, plant and combustion air requirements and this should be checked with any new contract. For detailed information reference should be made to CIBSE guides, relevant Institute of Gas Engineers and Managers documents and appropriate British Standards.


1. a) Before proceeding with dismantling of boiler.

12m Check casing for damage or breakages. Inspect for loose fittings or connections and any sign of leaks.

Check for asbestos containing materials prior to dismantling any equipment If suspect cease work and report to supervisor.

b) Test fire.

12m Record settings.

2. Gas electrical & ventilation systems

12m Check that all are in accordance with current legislation and Codes of Practice.

Local electrical isolator should be fitted. Supply to the boiler must be direct i.e. not fed through a time switch.

3. Isolate boiler for gas and electrical supplies.

12m Record any work which needs rectification or replacement.

4. Gas valve. 12m Disconnect thermocouple and pilot tube from burners.

5. Remove burners and pilot assembly and baffles if fitted.

12m Brush all accessible flueways thoroughly from top to bottom, clean all deposits from the burner box, refit baffles and flue cover - checking cover seal. Check for cracking and wear.

Cleaning should be thorough and carried out as per the manufacturers instructions.


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05-03 ATMOSPHERIC GAS BURNER BOILER - continued


6. a) Pilot assembly. 12m Remove.

Pilot head. Remove and clean ports.

Pilot injection. Remove and clean. Clean as described by the manufacturers e.g. by blowing through or washing. Note: Do not use a pin as this will damage the injector.

Thermocouple tip. Replace/clean with fine wire brush, reassemble pilot.

Make sure thermocouple head lines up with the pilot flame.

b) Oxy-pilot assembly 12m Replace.

7. Lint filter (if fitted). 12m Remove from burners and clean.

8. Filters. 12m Refit.

Burners, Gas valve, thermocouple and pilot tube.

Check adjust and refit along with main burner.

9. Boiler and installation. 12m Open gas cock and test for gas soundness, reconnect electrical services. Test controls operation, relight pilot and run up boiler.

Test flame setting and thermocouple sensitivity and check burner gas pressure against manufacturer's settings, adjust if required. If in doubt check gas supply standing pressure at the meter.


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10. a) Safety check – products of combustion

12m Ensure that no products of combustion are entering the area of the building where the boiler is situated. This should be checking the operation of the flue, and examined the combustion ways to ensure tightness

NB - Undetected CO is poisonous, life threatening and also causes energy waste. Flames should be bluish and burning in a stable manner. The burner should be quiet in operation, no excessive noise should occur when the burner ignites or shuts down.

NB in domestic premises, consider the installation of a BS approved CO detector.

b) Safety check - Electrical 12m Check electrical installation for safety and that local isolator is fitted.

If not, provide written report to client.

11. Documentation.

12m Provide written report.

The report should be signed by the servicing engineer and the client/responsible person/clients representative. Premature failure of the plant will result if a satisfactory service is not carried out. Depending on the nature/urgency of the fault and the type of premises this report may be verbal. NB Gas work must be carried out by a competent engineer qualified as required by the Gas Safety (Installation & Use) Regulations.


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12. Unsafe installations

12m Recommendations. Label and take out of service

If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use.

If approval for this action is refused an appropriate label must be attached to the appliance and the HSE informed. A written report should also be signed by the client/responsible person/clients representative.

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05-04 ATMOSPHERIC GAS BURNER - CONDENSING BOILER The essential feature of a condensing boiler is that to increase the efficiency the flue gases are cooled below their dew point with the result that water is produced which has to be removed from the system. It is essential that there should be adequate ventilation [ratio of one third low to two thirds high level] of the boiler house for safety, plant and combustion air requirements and this should be checked with any new contract. For detailed information reference should be made to CIBSE guides, relevant Institute of Gas Engineers and Managers documents and appropriate British Standards.



b) Test fire.

12m Check casing for damage or breakages. Inspect for loose fittings or connections and any sign of leaks.

Record settings.

Check for asbestos containing materials prior to dismantling any equipment If suspect cease work and report to supervisor.

2. Pre-service checks

Condensate flow

12m

12m

Check that there is a steady fall back to the boiler from the flue to allow condensate to run back. With the boiler operating at low return, temperature [less than 50oC], check that condensate flows freely from the drain pipe.

Risk Assessment may be required.

Waste Disposal Licensing Regulations may apply.

3. Gas electrical & ventilation systems.

12m Check that all are in accordance with current legislation and Codes of Practice.



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4505-04 ATMOSPHERIC GAS BURNER - CONDENSING BOILER - continued


4. Condensate level probe(if fitted).

12m Clean and inspect.

5. Secondary heatexchanger (if fitted.

12m Clean with water and a soft brush.

6. Neutralising Unit. 12m Check crystal level and top up ifnecessary.

7. Condensate drain pipeand U-siphon trap.

12m Clean, inspect and flush.

8. Fan. 12m Check operation and clean anydeposits off blades.

9. Isolate boiler for gas andelectrical supplies.

12m Record any work which needsrectification or replacement.

10. Gas valve. 12m Disconnect thermocouple and pilottube from burners.

11. Remove burners and pilotassembly and baffles iffitted.

12m Brush all accessible fluewaysthoroughly from top to bottom, cleanall deposits from the burner box, refitbaffles and flue cover - checking coverseal. Check for cracking and wear.

Cleaning should be thorough and carried out asper the manufacturers instructions.


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Pilot injection. Remove and clean. Clean by blowing through or washing. Note:Do not use pin as this will damage the injector.

Thermocouple tip Replace/clean with fine wire brush, reassemblepilot.

Make sure head lines up with the pilot and notthe burner.

b) Oxy-pilot assembly 12m Replace.

13. Lint filter (if fitted). Remove from burners and clean.

14. Filters. Refit.

Burners, Gas valve,thermocouple andpilot tube.

Check adjust and refit along with main burner.

15. Water treatment. 12m Check treatment regime is correct. Some condensing boilers contain aluminium.

LOW NOX Boilers

16. Kanthal bars/rods. 12m Inspect, clean with compressed air. If there are any signs of bending, replace. Forall condensing boilers, manufacturers specificservice instructions take precedence.

17. Boiler andinstallation.

12m Open gas cock and test for gas soundness,reconnect electrical services. Test controlsoperation, relight pilot and run up boiler.

Test flame setting and thermocouplesensitivity and check manifold gas pressureagainst manufacturer's settings, adjust ifrequired. If in doubt check gas supply standingpressure at the meter.


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18. a) Safety check – productions of combustion

12m Ensure that no products of combustion are entering the area of the building where the boiler is situated.

NB - Undetected CO is poisonous, life threatening and also causes energy waste. Flames should be bluish and burning in a stable manner. The burner should be quiet in operation, no excessive noise should occur when the burner ignitor shuts down.

NB in domestic premises consider the installation of a BS approved CO detector.

b) Safety check - Electrical 12m Check electrical installation for safety and that local isolator is fitted.

If not provide written report to client.

19. Documentation.


The report should be signed by the servicing engineer and the client/responsible person/clients representative. Premature failure of the plant will result if a satisfactory service is not carried out, by a competent engineer qualified as required by the Gas Safety (Installation & Use) Regulations. Depending on the nature/urgency of the fault and the type of premises this report may be verbal.


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12m Recommendations If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use.


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05-05 COAL FIRED BOILERS – Bunkers and Conveyors. The burning of coal is a complex operation involving the storage, handling and combustion of solid material, and the handling and disposal of gaseous and solid waste. The materials are abrasive and the wear and tear on mechanical plant considerable hence regular maintenance is vital to ensure continuous working and a clean environment. The maintenance of each section of the coal burning operation is examined in sequence. WARNING. A risk assessment and method statement should be undertaken before entering any confined space such as a hopper, flue chamber or boiler to ensure that there is adequate ventilation and an absence of any fumes or flue gases. ITEM FREQ. ACTION NOTES

1. Operational status. 1m Check and isolate from electricity supply. Remove fuses.

2. Bunkers. 12m Inspect for wear and corrosion and repair as necessary.

3. Belt conveyors. 12m Inspect, renew worn sections and check and replace joints as necessary.

Lubrication of rollers, idlers and drums should be carried out frequently as part of the client's regular routine.

4. Screw conveyor. 1m Grease outrigger bearing on worm shaft and tube rotation guide.

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05-06 COAL FIRED BOILERS - Coal storage handling and feed mechanisms, automatic ash removal (where fitted) The burning of coal is a complex operation involving the storage, handling and combustion of solid material, and the handling and disposal of gaseous and solid waste. The materials are abrasive and the wear and tear on mechanical plant considerable hence regular maintenance is vital to ensure continuous working and a clean environment. The maintenance of each section of the coal burning operation is examined in sequence. (See also MOTORS )WARNING. A risk assessment and method statement should be undertaken before entering any confined space such as a hopper, flue chamber or boiler to ensure that there is adequate ventilation and an absence of any fumes or flue gases. ITEM FREQ. ACTION NOTES

1. Operational status. 1m Check and isolate from electricity supply. Lock off or remove fuses.

2. Silo. 12m Empty and check for signs of wear or corrosion.

Paint all internal components exposed to coal. If remedial work necessary, report to client.

3. Coal feed lines. 6m Rod through and replace worn components.

Check for erosion and thinning on bends.

4. Screw elevators and feeders.

6m Inspect tooth type drive belt for wear. Replace if necessary. Check for wear.

5. Pneumatic system. (Applies to both coal feed and ash removal, where fitted).

3m

1m

Inspect and replace items listed under notes. Check for air tightness.

(a) air seals on each outlet cyclone, (b) clean blades of fan, (c) ensure timing sequence, (d) check 'bags', (e) check bag shaker and lubricate as appropriate.

Note: It is essential to maintain air tightness on pneumatic systems otherwise the coal feed cannot be maintained, output is reduced and energy wasted.


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05-06 COAL FIRED BOILERS- Coal storage handling and feed mechanisms, automatic ash removal (where fitted) - continued


6. Crusher and gearbox 6m Check oil level and replenish ifnecessary.

12m Replace all oils, check seals andjoints. Clean and lubricate motors.

Examine bearings and teeth of crusher. Check allbolts, nuts and washers for tightness and checkshear pin for soundness.

7. Static electricitydischarge mechanism.

12m Check effectiveness.

8. Fans. 12m Check low level switches, fuses andaction of fan emergency safety switchin OFF position.

Insufficient air can lead to blockage of feed pipeswhilst excessive air can cause degradation of thecoal and produce fines.

9. Coal flow. 12m Check working of vibrator, fan rotation,bunker filters.

10. Coal conveying. 12m Check suction nozzle entrainmentpoint, action of air control valves anddischarge valve.

11. Lubrication. 12m Lubricate fan and motor bearings. Use manufacturer's recommended lubricants. Ina dirty environment more frequent lubrication willbe necessary.


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05-06 COAL FIRED BOILERS- Coal storage handling and feed mechanisms, automatic ash removal (where fitted) - continued


12. Electrical. 12m Check all electrical trips. These should be set for manual reset.

13. Cyclone. 12m Clean separator of any fines whichhave build up on internal surfaces.

Regular monthly checks of air tightness should bemade.

Check condition of baffles. If thinned severely client should be informed ofneed for replacement.

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5305-07 COAL FEED MECHANISMS - Under feed stokers


1. Operational status. 6m Check and isolate from electricitysupply. Remove fuses.

Cables should be checked for insulationbreakdown and the earth continuity checked.

2. Tuyere hole. 6m Check and clean out. Report on condition.

3. Retort. 6m Check end feedscrew and refractorybrickwork.

4. Fly ash. 6m Remove from retort plenum chamber.

5. Belts and chains. 6m Examine and report condition. Checkpickup screw high tension bolt.

Advise client if replacement necessary. Refitsafety guards after service.

6. Smoke elimination tube. 6m Clean air hole and refit.

7. Overfire jet outlet. 6m Clean if fitted.

8. Stauffers. 6m Grease and lubricate.

9. Gearbox or angle stokergear unit.

6m Drain oil and refill with new oil. Check for leaks before and after 'running in' onreturn to operation.

10. Dampers and linkages. 6m Check, free if necessary, andlubricate.

11. Shearpin alignment andbunker screw.

6m Check and adjust shearpin alignmentif necessary.

Free rotary tube if jammed and grease tube joint.

12. Return to operation. 6m Close isolator switch. Run stoker andcheck sequence.

Visually check pressure gauge and boilerthermostat. Report on condition of plant.

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05-08 COAL FEED MECHANISMS - Chain grate stokers WARNING – A RISK ASSESSMENT AND METHOD STATEMENT SHOULD BE UNDERTAKEN BEFORE AN OPERATOR/ENGINEER ENTERS COAL SIL0. ITEM FREQ. ACTION NOTES

1. Operational status. 12m Check and isolate from electricity supply. Lock off or remove fuses.

2. Coal silo. 12m Empty and check internal and external coatings.

If there are signs of deterioration consult the manufacturer.

3. Level probes on coal surge bunkers.

12m Check and clean as necessary.

When plant put back on line prove operation of plant under all plant operating conditions.

4. Drain sump. 12m Ensure excess water can be drained off.

Check coal auger supports. Repair or replace as necessary.

Remove augers and check for wear and distortion.

Repair or replace as necessary.

Reassemble and recoat coal tube. Use bituminised sealant or similar protective coating.

5. Grit arrestors and internal baffles.

12m Check internally for signs of wear and rectify as necessary.

6. Access doors. 12m Check security.

7. Insulation. 12m Check condition and security and make good as required.

8. Stoker. 12m Withdraw and inspect for wear. Check condition of rear skid plate.

Drain oil in gear cases, clean and refill, grease bearings on the force draught fan.


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5505-08 COAL FEED MECHANISMS - Chain grate stokers - continued


9. Stoker grate. 12m Renew rear side steel bars and anylinks showing signs of burning.

Remove a section of chain to inspect inside of airbox and interior seals.

10. Stoker air box. 12m Check bottom plate and chassis fordistortion.

11. Stoker ignition arch. 12m Repair or replace arch and ifnecessary firedoor lining.

Replace any short (worn) link rods.

12. Electrical. 12m Examine and renew switchgearcontacts where necessary. Replaceany worn or damaged regulator parts.

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5605-09 ASH HANDLING SYSTEM


1. Ash line. 6m Check for wear and report if remedialwork required.

2. Ash line valve. 12m Check operation and wear on seals.

3. Ash skip. 12m Check for holes or distortion. Examine rubber tubing to ash skip for wear.

4. Crusher. 1m Grease inner bearing, grease nipplesand jaw crusher outrigger bearingassembly.

Under no circumstances should an excessof grease be applied to the bearingassemblies.

3m Dismantle complete unit and inspectfor tile wear, bearings and seals etc.

5. Spray chamber (if fitted).

Water solenoid valve. 3m Check operation.

Spray jets. 3m Check operation.

Winch unit (if fitted). 3m Grease pulleys, cable guides andwinch unit.

6. Ash conditioner. 6m Clean paddles shaft and end bearinghousing of any build up of ash.

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05-10 FORCED DRAUGHT GAS BURNER CONDENSING BOILER It is essential that there should be adequate ventilation [ratio of one third low to two thirds high level] of the boiler house for safety, plant and combustion air requirements and this should be checked with any new contract. For detailed information reference should be made to the CIBSE guides, relevant Institution of Gas Engineers and Managers documents and appropriate British Standards.


1. Check Operation. 12m Note any visible defects.

2. Safety test. 12m Carry out and note any visual defects, record results.

3. Gas electrical systems. 12m Check that all are in accordance with current Codes of Practice.

4. Pre service checks -

Condensate flow.

12m Check that there is a steady fall back to the boiler from the flue to allow condensate to run back. With the boiler operating at low return, temperature [less than 50oC], check that condensate flows freely from the drain pipe.

Risk Assessment may be required Waste Disposal Regulations may apply.

5. Isolate from electricity and gas supply.

12m Switch off, remove fuses and turn off gas supply at main cock.

Before starting any dismantling of equipment it is essential for safety reasons that the plant be isolated from incoming services.

Continued on next page .

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05-10 FORCED DRAUGHT GAS BURNER CONDENSING BOILER - continued ITEM FREQ. ACTION NOTES

6. Fan/mix chamber, gas train and controller assembly.

12m Remove, thoroughly clean, with a soft brush. Lubricate if necessary.

7. Fan scroll.

12m Clean and check air passages. Ensure air passages are clear to pressure switch.

8. HT & flame probe details. 12m Inspect for soundness.

If probe is bent or shows signs of oxidation it should be replaced.

9. Burner. 12m Reassemble and fire, check air and gas settings, carry out combustion efficiency test.

It is important that reference is made to the boiler and burner manufacturer’s specifications.

10. Air pressure switch. 12m Test under no air conditions.

11. Flame failure. 12m Test and take probe readings.

12. Boiler flue ways and connecting flues.

12m Open and remove by brushing and/or vacuum all soot and scale. Reseal, check for air leaks, and reseal as necessary.


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05-10 FORCED DRAUGHT GAS BURNER CONDENSING BOILER - continued ITEM FREQ. ACTION NOTES 13.a] Boiler tube module. 12m Drain down, remove and

thoroughly clean with wire brush.

b] Boiler tube module. 48m Clean and descale module in accordance with manufacturers instructions.

Always follow recommendations from manufacturer. Note: Waste Disposal Regulations may apply

14. Neutralizing Unit (if fitted). 6m Check crystal level and top up if necessary.

Unit can be separate to boiler.

15. General. 12m Check security of mechanical parts and secure mounting of appliances.

A maintenance check should be carried out on this type of burner twice a year but refer to manufacturer’s specification.

16. Recommendation. 12m Provide written report which should be signed by the service engineer and kept by client.

Premature failure and excessive fuel costs will result if satisfactory service is not carried out. All service and maintenance must be carried out by a Competent and CORGI registered engineer in accordance with Health and Safety requirements and possess accreditation in accordance with the Gas Safety (Installation & Use) Regulations.


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05-10 FORCED DRAUGHT GAS BURNER CONDENSING BOILER – continued


17. Unsafe installations.

12m Recommendations If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use. If approval for this action is refused an appropriate label must be attached to the appliance and the HSE informed .A written report should also be signed by the client/responsible person/clients representative

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05-11 FORCED DRAUGHT GAS BURNER MODULAR BOILER Can comprise several modules, each having separate controls. Each module must be isolated and work carried out consecutively. It is essential that there should be adequate ventilation [ratio of one third low to two thirds high level] of the boiler house for safety, plant and combustion air requirements and this should be checked with any new contract. For detailed information reference should be made to the CIBSE guide, relevant Institution of Gas Engineers and Managers documents and appropriate British Standards.


1. Check Operation. 12m Note any visible defects.

2. Safety test. 12m Carry out and note any visual defects, record results.

3. Gas electrical systems. 12m Check that all are in accordance with current Codes of Practice.

4. Blown burner. 12m Test fire, and record settings.

5. Isolate from electricity and gas supply.

12m Switch off, remove fuses and turn off gas supply at main cock.

Before starting any dismantling of equipment it is essential for safety reasons that the plant be isolated from incoming services.

6. Fan/mix chamber, gas train and controller assembly.

12m Remove, thoroughly clean, with a soft brush. Lubricate if necessary.

7. Fan scroll. 12m Clean and check air passages. Ensure air passages are clear to pressure switch.

8. HT & flame probe details. 12m Inspect for soundness. If probe is bent or shows signs of oxidation it should be replaced.


It is important that reference is made to the boiler and burner manufacturer’s specifications.




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05-11 FORCED DRAUGHT GAS BURNER MODULAR BOILER - continued ITEM FREQ. ACTION NOTES 12. Boiler flue ways and

connecting flues. 12m Open and remove by brushing and/or

vacuum all soot and scale. Reseal, check for air leaks, and reseal as necessary.

13.a] Boiler tube module. 12m Drain down, remove and thoroughly clean with wire brush.

b] Boiler tube module. 48m Clean and descale module in accordance with manufacturer’s instructions.

Always follow recommendations from manufacturer. Note: Waste Disposal Regulations. may apply

14. General. 12m Check security of mechanical parts and secure mounting of appliances.


15. Recommendation. 12m Provide written report which should be signed by the service engineer and kept by client.

Premature failure and excessive fuel costs will result if satisfactory service is not carried out. All service and maintenance must be carried out by a registered engineer in accordance with Health and Safety requirements and possess accreditation in accordance with the Gas Safety Regulations.


12m Recommendations If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use. If approval for this action is refused an appropriate label must be attached to the appliance and the HSE informed. A written report should also be signed by the client/responsible person/clients representative.

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6305-12 FORCED DRAUGHT GAS CONDENSING BOILER

The essential feature of a condensing boiler is that to increase the efficiency the flue gases are cooled below their dew point with theresult that water is produced which has to be removed from the system. It is essential that there should be adequate ventilation [ratio ofone third low to two thirds high level] of the boiler houses for safety, plant and combustion air requirements and this should be checkedwith any new contract. For detailed information reference should be made to the CIBSE guide, relevant Institute of Gas Engineersdocuments and appropriate British Standards.


1. a) Before proceeding withdismantling of boiler.

12m Check casing for damage orbreakages. Inspect for loose fittingsor connections and any sign of leaks.

Check for asbestos prior to dismantling andequipment. If suspect take a sample and ceasework.

b) Test fire. Record settings.

2. Pre-service checks.

Condensate flow

12m

12m

Check that there is a steady fall backto the boiler from the flue to allowcondensate to run back. With theboiler operating at low return,temperature [less than 50oC], checkthat condensate flows freely from thedrain pipe.

Risk Assessment may be required.Waste Disposal Regulations may apply.

3. Gas electrical & ventilationsystems.

12m Check that all are in accordance withcurrent Codes of Practice.

Local electrical isolator should be fitted. Supplyto the boiler must be direct i.e. not fed through atime switch.

4. Burner. 6m Switch on, carry out safety check offlame failure.

Note any visible defects.

5. Safety check. 6m Carry out and note any visibledefects.

Pay particular attention to carbon monoxide(CO) as presence is poisonous and lifethreatening and indicates waste energy.


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6405-12 FORCED DRAUGHT GAS CONDENSING BOILER - continued


6. Isolate from electricity andgas supply.

6m Switch off, remove fuses and turn offgas supply at main cock.

Before starting and dismantling of equipment itis essential for safety reasons that the plant beisolated from incoming services.

7. Fan motor. 6m Remove, thoroughly clean, lubricateif necessary.

9. Fan scroll. 6m Clean and check air passages. Ensure air passages are clear to pressureswitch.

10. Removal of UV cell andhead assembly.

6m Clean, adjust electrode and ifrequired isolation probe.

UV cells should be replaced after a life of10,000 hours.

11. HT & probe details. 6m Inspect for soundness.

12. Burner. 6m Reassemble and fire, check air andgas settings, carry out combustionefficiency test.

Check high/low flame conditions.

It is important that reference is made to theboiler and burner manufacturer’s specifications.


14. Flame failure. 6m Test and take probe or UV cellreadings.

15. Neutralizing Unit (if fitted). 6m Check crystal level and top up ifnecessary.

Unit can be separate to boiler.


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05-12 FORCED DRAUGHT GAS CONDENSING BOILER - continued


16. General. 6m Check security of mechanical parts and secure mounting of appliance.


17. a) Safety check – Gas. 12m Ensure that no products of combustion are entering the area of the building where the boiler is situated.

NB – Undetected CO is life threatening (poisonous) and also causes energy waste. Flames should be bluish and burning in a stable manner. The burner should be quiet in operation, no excessive noises should occur when the burner ignitor shuts down.

b) Safety check – Electric. 12m Check electrical installation for safety and that local isolator is fitted.



12m Recommendations. If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use. If approval for this action is refused an appropriate label must be attached to the appliance and the HSE informed. A written report should also be signed by the client/responsible person/clients representative

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6605-13 FORCED DRAUGHT [PRESSURE JET ] OIL CONDENSING BOILER



12m Check casing for damage orbreakages. Inspect for loose fittingsor connections and any sign of leaks.

b) Test fire. Record settings.

2. Pre-service checks.

3. Condensate flow.

12m

12m

Check that there is a steady fall backto the boiler from the flue to allowcondensate to run back. With theboiler operating at low return,temperature [less than 50oC], checkthat condensate flows freely from thedrain pipe.

Risk Assessment may be required.Waste Disposal Regulations may apply.

4. Oil electrical & ventilationsystems.

6m Check that all are in accordance withcurrent Codes of Practice.

Local electrical isolator should be fitted. Supplyto the boiler must be direct i.e. not fed through atime switch.



6. Safety check. 6m Carry out and note any visibledefects.

Pay particular attention to carbon monoxide(CO) as presence is poisonous and lifethreatening and indicates waste energy.


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6705-13 FORCED DRAUGHT [PRESSURE JET] OIL CONDENSING BOILER - continued


7. Isolate from electricity andoil supply.

6m Switch off, remove fuses and turn offoil supply at main cock.

Before starting and dismantling of equipment itis essential for safety reasons that the plant beisolated from incoming services.

8. Jet arm assembly. 6m Remove, clean combustion head,ignitor electrodes and inspect HTleads.

9. a) Nozzle and filter. 6m Clean filter and inspect nozzle forwear.

Erosion or surface defects on the nozzle caneffect the profile of the emerging jet of oil andlead to a poor flame shape and bad combustion.

b) Nozzle and filter. 12m Renew.

10. Burner. 6m Reassemble and set heat tomanufacturer’s requirements.

11. Motor and fan. 6m Remove, clean and lubricate asrequired, clean fan scroll.

Inspect oil pump flexible drive coupling beforereassembly. (See also MOTORS )

12. Oil pump filter. 6m Remove and clean, inspect pumpseals for signs of wear.

13. Reassembling burner. 6m Inspect flexible oil line coupling,clean and renew oil line filter, cleanphotocell and adjust position.

14. Burner. 6m Switch on and check flame shapeand appearance if visible.

15. Oil pressure. 6m Test, record oil pressure.

16. Safety check. 6m Carry out and check for smoke. On larger systems combustion test shouldbe carried out regularly to monitorperformance and avoid energy waste.


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05-13 FORCED DRAUGHT [PRESSURE JET] OIL CONDENSING BOILER - continued


17. Flame failure device. 6m Test for satisfactory operation

18. Condensate level prove (if fitted).


19. Secondary heat exchanger (if fitted).

6m Clean with water and a soft brush.

20. Neutralising Unit (if fitted)

6m Check crystal level and top up if necessary.

Unit is normally separate to boiler.

21. Condensate drain pipe and U-siphon trap.

6m Clean, inspect and flush.



23. Recommendation 6m Provide written report which should be signed by the service engineer and kept by client.

Premature failure and excessive fuel costs will result if satisfactory service is not carried out. All service and maintenance must be carried out by a registered engineer in accordance with Health and Safety requirements. All service and maintenance works must be carried out by a competent engineer in accordance with BS Codes of Practice for oil firing.

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6905-14 BOILERS MTHW – UP TO 120oC

Applies to boilers manufactured by casting or fabricationITEM FREQ. ACTION NOTES

1. Check operation, inparticular safety controls(prv).

12m Note any visible defects. Ensure system is full of water and thecircuits are open. It is essential for lowwater content boilers that flow rates can bemaintained at or above manufacturersrecommended levels.

2. Efficiency check. 12m Start up system and carry out tests. On larger systems efficiency tests shouldbe carried out on a regular basis to monitorperformance. The test should includesmoke, draught chamber and flue, fluetemperature, fuel input and gas analysisincluding carbon monoxide.

Thermostats, pressure sensors &controls, altitude gauges, vacuumbreaks.

3. Thermostats, vacuum breaks. 12m Check for correct operation and settings.

4. Electrical services. 12m Shut down, disconnect or remove fuses. Locate isolation switch, if not in accordancewith IEE regulations report to buildingowner.

5. Boiler return temperature andassociated controls.

12m Check if appropriate. See relevant section.


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7005-14 BOILERS MTHW – UP TO 120oC - continued

Applies to boilers manufactured by casting or fabricationITEM FREQ. ACTION NOTES

6. Booster Pumps. 12m Check interlocks between controls.

7. Boiler flueways, combustionchamber and connecting flues.

12m Open and remove by brushingand/or vacuum all soot andscale.

8. Refractory linings. 12m Check condition and report.

9. Boiler flueways and chamber. 12m Reseal, check for air leaks, seal asnecessary.

10. Flue. 12m Carry out smoke test. Only if flue problem is suspected.

11. Water quality. 12m Check system water quality andinhibitor type and concentration.Top up if necessary. If waterquality check shows regime isincorrect refer to specialist.

Where system water quality is controlled,water treatment and dosing plant should bemaintained according to the manufacturer'sinstructions.

12. Fan (if provided). 12m Check operation and clean blades. Build up of deposits on the blades can reducetheir efficiency and lead to poor combustion.

13. Boiler. 12m Reconnect and test fire, carry outefficiency test, refit casing andthoroughly clean down.

A boiler is capable of exploding if safetycontrols fail and blocked flues will cause fluegas to leak into surrounding areas, causingdamage and risks to life and to health throughcarbon monoxide poisoning.


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71

05-14 BOILERS MTHW – UP TO 120oC - continued Applies to boilers manufactured by casting or fabrication


14. Gas Trains.

12m

Test for soundness.

15. Boiler house cleanliness.

12m Inspect. Boiler house cleanliness is important. Concrete floors should be sealed to keep dust down.

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7205-15 MULTIPLE BOILERS - sequence controls

All notes referring to sequence controls apply to individual boilers ( not burner modules) in multiple installations.ITEM FREQ. ACTION NOTES

1. Lead/lag control. 12m Check operation. Check the setpoint (and differential).

Check the frequency of operation if hours runare fitted.

2. Sequencing control. 12m Check operation.

3. Controller. 12m Check operation and confirm theset point.

The step controller will have mechanicalswitching using micro- or solid state switching.

4. Step Controller. 12m Check operation.

5. Boiler return butterfly valves. 12m Check operation. Check valve opening proving circuit andensure that valve on leading boiler is open atall times.

6. Boiler diverting valves state. 12m Check operation. Check valve opening proving circuit andensure that valve on leading boiler is open atall times.

7. Boiler shunt pump. 12m Confirm operation. Is there a water proving circuit? Checkoperation if part of sequence controls.See PUMPS maintenance.

8 Non return valves. 12m Check operation.

9. Return/flow sensor.Controller.Step controller.

12m Confirm correct. Calibration }Interrogation }Adjustment }

by CONTROL SPECIALIST

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7305-16 BOILER CONTROLS - Single boiler: on/off

Note: On/Off overall control can be remote from the boiler plant.Certain common maintenance procedures should be carried out for all controls. These are:

1. All common items, e.g. thermostats and the like, that have switching contacts – where they can be seen ensurecontacts make and break easily and that there is no arcing or pitting.

2. Inspect thermostat phial and capillaries for mechanical damage.3. Inspect thermostat pockets for corrosion and leakage.4. Ensure immersion thermostats are secure in their pockets (and that the sensor is in contact with the end of the pocket

and covered with heat conductive compound).5. Inspect motorised valves for leakage and damage to linkage.

For more detailed information regarding the maintenance of motorised valves, checking of gland seals, stroking, etc. refer to relevantsection.


1. Manual switch. 12m Check operation.

2. Time switch. 12m Check operation. Confirm time settings. Time of day. (Keep setting at GMT all yearunless specifically requested by client.)Day of week.Manual override.

3. Boiler control and high limitthermostats – Manual.

- Electronic.

12m Check operation. Confirm set pointsand temperatures.

Check operation. Confirm set pointsand temperatures.

Thermal no longer conforms to currentinsurance requirements.

4. Room thermostat. 12m Check operation. Confirm set point.

5. HWS thermostat. 12m Check operation. Confirm set point.

6. Frost protection thermostat. 12m Check operation. Confirm set point. This may be outside the building on oldersystems.

7. Flow switch. 12m Check operation.


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7405-16 BOILER CONTROLS - Single boiler: on/off - continued


8. Boiler pressure switch. 12m Check operation. Confirm set point.

9. Temperature sensors.Optimum start controllers.

12m Check operation and confirm timesettings.

Check performance.

Time of day.Day of week.Manualoverride.Summer/WinterCalibration }Interrogation }Adjustment }


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7505-17 BOILER PROTECTION CONTROLS


1. Pump overrun timer. 12m Check operation. Confirm timesetting.

2. Pump overrun thermostat. 12m Check operation. Confirm setpoint.

3. Return water thermostat. 12m Check operation. Confirm setpoint.

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7605-18 BOILERS - Space temperature controls


1. Room thermostat. 12m Check operation and confirm setpoint.

Direct switching of boiler or pump on/off.

2. Room thermostat - zone valveoperation.

12m Check operation and confirm setpoint.

Check if auxiliary switch controls boiler orpump on/off.

3. Flow sensor controller. 12m Check operation and confirm setpoint(s).

Variable temperature controller (compensator)of boiler on/off.

4. Space sensor controller. 12m Confirm operation. Calibration }Interrogation}Controladjustment }


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7705-19 STEAM BOILERS – Pre-maintenance check.


1. Status. 12m Check operating status. Before proceeding with maintenance programmecheck with client that boiler can be taken off-line.

2. Condition. 12m Check exterior for signs of damage,leakage from valves, manholes andany loose fittings.

Leakage can lead to corrosion with subsequentcostly refurbishment or replacement ofequipment.

3. Safety circuits. 12m Check operation. Safety system includes low and high level alarms,and pressure relief valves.

4. Combustion Check. 12m Ensure system on load and carry outcombustion tests.

Test should include smoke, draught chamber andflue, flue gas temperature, CO, CO2, and O2.Readings should be checked with boilerinstrumentation and noted.

5. Thermostats, pressuresensors and gauges, andthermometers.

12m Check for correct operation andsettings

6. Shut down. 12m Shut off and isolate steam, water, fuel,and electrical services.

Purge fuel lines and vent boiler to ensure safeconditions.

7. Ventilation. 12m Check that ventilation fans and louvresare functioning properly.

Check that there is adequate ventilation in theboiler house and the conditions comply with therelevant regulations and standards.

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7805-20 STEAM BOILERS – Maintenance schedule.

This is generally carried out at the same time as the Annual Statutory Insurance Inspection.ITEM FREQ. ACTION NOTES

1. Boiler flueways,combustion chamber andconnecting flue.

12m Open, remove by brushing and/orvacuum all soot and scale.

Soot, ash and other fouling deposits impede heattransfer thus wasting energy and putting up costs.

2. Fire tubes. 12m Open boiler end doors and clean firetubes by brushing or rotary scouringequipment.

In multipass boilers it is important to clean allpasses.


4. Boiler flueways, doorsand chamber.

12m Reseal, check for air leaks, seal asnecessary.

5. Flue. 12m Carry out smoke test.

6. Waterside. 12m Remove manholes, clean out scaleand residues. Replace, reseal andensure bolts are tight.

If there are considerable deposits of sludge andscale, this indicates poor water treatment which ifallowed to continue will lead to boiler failure andenergy wastage. Waste Disposal Regulationsmay apply.

7. Boiler. 12m Refill, reconnect and bring on line. Refit casing if necessary and thoroughly cleandown.

8. Instrumentation andflame monitoring.

12m Check for operation and accuracy. Recalibrate and reset if necessary.


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7905-20 STEAM BOILERS – Maintenance schedule. - continued

This is generally carried out at the same time as the Annual Statutory Insurance Inspection.ITEM FREQ. ACTION NOTES

9. Combustion check. 12m Bring up to full load and carry outtests.

On larger systems combustion tests should becarried out on a regular basis to monitorperformance. The test should include smoke,draught chamber and flue, flue temperature,carbon dioxide, oxygen and carbon monoxide.

10. Blow down tank. 12m For maintenance procedures seeSANITARY & WASTE WATERPLUMBING – Interceptors.

HSE document PM60 applies.

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8005-21 ELECTRIC BOILERS

These boilers provide heat to radiator heating systems. Electricity supply can be off-peak/on-peak or a combination of both.ITEM FREQ. ACTION NOTES

1. Isolation from electricitysupplies.

12m Switch off. Remove fuses from bothsupplies.

The boilers have two supplies. The permanentlarge capacity supply and the restricted hourssignal supply.

Report to the client if not capable of isolation.

2. Unit condition. 24m Check physical condition of unit.

3. Heavy current connection inthe control box.

12m Remove control box cover. Check all See also MOTORSheavy current connection fortightness & signs of over heating alsocheck element relay contacts fordamage.

4. Heavy current connection inboiler.

12m Remove top of boiler casing. Checkall heavy current connections fortightness & signs of over heating.

5. Fan cooling air duct. 12m Remove button front casing cleanduct through casing, remove also therear end fan motor which is exposedwhen the casing is removed.

Report if fan motor or pump are noisy. Advisethe customer that the louvres on the outside ofthe casing should be vacuumed at intervals ifthe environment of the boiler is unclean.

6. Water connection. 12m Check for leaks.

7. Water treatment. 12m Ask if the system has been drainedsince last visit & if it was retreatedwith inhibitor.

If system does not contain inhibitor advise it istreated, as this is part of the manufacturersinstructions.

8. Thermal link. 24m Replace.

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8105-22 ELECTRODE BOILERS

Note: In hard water areas maintenance may require to be carried out more frequently.BEWARE - High water conductivity in the boiler circulated water can damage the boiler pressure vessel, only work within the

boiler manufacturers values of conductivity.ITEM FREQ. ACTION NOTES

1. Status. 3m Check and isolate by removing fuselinks.

2. a) Electrical connections. 12m Check all electrical connections in thecubicle and on the boiler electrodes forsoundness and correct any defects.

b) Porcelain insulators. 12m Examine for defects and replace ifnecessary. Clean with non-abrasivematerial.

12m Examine all porcelain mechanicalseals for water leaks.

If there are any leaks or have been leaks,dismantle the assembly and repair by replacingthe sealing gaskets.

3. Water drain unit. 3m Check for free flow of water byoperating the valve. Repair any valvegland leaks.

4. Drain pipe. 12m Check for free flow, actuate main drainif necessary.

5. Feed solenoid (if fitted). 12m Clean solenoid, manifold and strainer. Modern boilers have the load control driven by anelectric motor. See MOTORS.


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8205-22 ELECTRODE BOILERS – continued

ITEM FREQ. ACTION NOTES6. Load control system. 12m Examine mechanism and lubricate. Comply with manufacturers recommendation for

lubrication of the gear box, motor and controlshaft and nut.

Examine for water leaks. If necessary adjust or replace its seal.7. Boiler circulated water. 3m Test for correct conductivity at

20/25oC.This is to be within the boiler makersrecommendation.

Test the hardness. This should be as near commercial ZERO aspossible, if too high, seek the advice of a watertreatment specialist. DO NOT USE TANNIN.

Test the pH index of the water. This should be between 7 & 8 on the pH scale.8. Boiler sequence. 12m Replace all covers and reinstate

electrical supply.Ensure all electrical and mechanical covers are intheir correct places.

Set the controls to 'start' and operateboiler in its normal mode and ensurethe functions are correct.Read the current flow in eachelectrode circuit (phase).

These should balance within +4%. If there is animbalance consult the boiler manufacturer, orisolate the boiler electrically and mechanicallyand examine the boiler interior for defects, i.e.electrode deterioration; control shield damage.

The electrode phase current readingwith the control shield fully exposedmay not be high when the circulatedwater is cold.

This is because the water conductivity is low atlow temperatures and will increase as the waterheats; the current will also increase with thisincrease in water temperature.

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8305-23 BOILERS LTHW UP TO 95oC

Applies to boilers manufactured by casting or fabrication.ITEM FREQ. ACTION NOTES

1. Check operation, inparticular safetycontrols.

12m Note any visible defects. Ensure system is full of water and the circuits are open. Itis essential for low water content boilers that flow rates canbe maintained at or above manufacturers recommendedlevels.

2. Efficiency check. 12m Start up system and carry outtests.

On larger systems efficiency tests should be carried out ona regular basis to monitor performance. The test shouldinclude smoke, draught chamber and flue, fluetemperature, fuel input and gas analysis including carbonmonoxide.

3. Thermostats, pressuresensors, altitude gaugesthermometers.

12m Check for correct operation andsettings.

4. Electrical services. 12m Shut down, disconnect or removefuses.

Locate isolation switch, if not in accordance with IEEregulations report to building owner.

5. Boiler returntemperature andassociated controls.

12m Check if appropriate. See controls.

6. Boiler flueways,combustion chamberand connecting flues.

12m Open and remove by brushingand/or vacuum all soot andscale.

Waste Disposal Regulations may apply.


8. Boiler flueways andchamber.

12m Reseal, check for air leaks, sealas necessary.

9. Flue. 12m Carry out smoke test. Only if flue problem is suspected.


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8405-23 BOILERS LTHW - continued


10. Water quality. 12m Check system water quality andinhibitor type and concentration. Topup if necessary. If water quality checkshows regime is incorrect refer tospecialist.

Where system water quality is controlled, watertreatment and dosing plant should be maintainedaccording to the manufacturer's instructions.

11. Fan (if provided). 12m Check operation and clean blades. Build up of deposits on the blades can reducetheir efficiency and lead to poor combustion.

12. Boiler. 12m Reconnect and test fire, carry outefficiency test, refit casing andthoroughly clean down.

A boiler is capable of exploding if safety controlsfail and blocked flues will cause flue gas to leakinto surrounding areas, causing damage andrisks to life and to health through carbonmonoxide poisoning.

13. Gas Trains. 12m Test for soundness.

14. Boiler house cleanliness. 12m Inspect. Boiler house cleanliness is important. Concretefloors should be sealed to keep dust down.

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05-24 BOILERS - FIRE AND SAFETY CIRCUITS Is the plant safe? It should be noted that fire prevention and fire alarms are not included in the scope of this document. Any persons working on such equipment should be registered with the Loss Prevention Council or should be the Manufacturer's nominated fire prevention contractor. It is essential that the operation of all indicator lights should be checked regularly and that any malfunctions should be corrected as soon as possible. Boiler and Plant Room should not contain loose combustible materials.


1. Oil

fire valve. 12m Check valve and associated couplings for positive oil shut off.

It is essential that the system will provide a positive shut off of the oil supply in an emergency. The valve should comply with current legislation.

quick release mechanism. 12m Actuate and check that any dead weight or solenoid valves operate correctly.

valve and quick release system. 12m Reset.

Check that all interconnecting tension wire, fusible links fire buttons and pulleys are free for operation.

2. Gas -

manually operated valves. 12m Check valve action.

pressure switches on gas boosters.

12m Check for operation and sensitivity.

gas detection unit. 12m Test sensitivity. Determine if a test is possible if not refer to specifier.

Determine if a test is possible, if not refer to specifier. It may be necessary to recalibrate, if so carry out strictly according to the manufacturer's instructions.


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05-24 BOILERS - FIRE AND SAFETY CIRCUITS - continued


manual quick release mechanism

12m Actuate and recheck operation of the dead weight valve or solenoid.

valves and quick release mechanism.

12m

Reset. Check all interconnecting tension wire, fusible links fire buttons and pulleys for free operation.

3. Solid fuel -

fusible links, inter-connecting tension wire and pulleys.

12m Inspect. Check that all are free for operation.

quick release mechanism. 12m Operate to ensure that fuel feed system stops.

Reset as necessary.

4. Boiler control and high limit thermostats (thermal or manual reset).

12m Ensure these are set correctly. Check operation of pressure switches.

Operation should be within the manufacturer's switching differential. Adjust if necessary. This note should be read in conjunction with item 7 -Smoke/heat detection.

5. Pressure switches. 12m Check operation.

6. Foam inlets. 12m Ensure foam inlet pipes are free from blockage.

Inspect diffuser nozzles for damage.

7. Smoke/heat detection. 12m Check operation. Refer to Code of Practice - BS 5839.


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05-24 BOILERS - FIRE AND SAFETY CIRCUITS - continued


8. General.

12m Check all fuel supply valves for free operation.

Ensure that each fuel supply value is complete with own wheel or key.

9. Combustion air source into plant room.

12m Check that original provision has been left clear of any obstruction dirt.

Inadequate combustion air provisions can create a hazard to both the equipment and the occupants of the plant room.

Notify responsible person.

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8805-25 WASTE AND WOOD BURNING APPLIANCES (including boilers) - Fire And Boiler Safety Circuits

Note : Regular cleaning of flues is essential when burning waste and wood because tars and other residues may not be fully burned inthe combustion chamber and condensation of combustion products can lead to blockage and fires in the flues.


1. Solid fue l

fusible links,interconnectingtension wire andpulleys.

3m Inspect.

quick releasemechanism.

Operate to ensure that fuel feedsystem stops.

Reset as necessary.

2. Boiler controls and high limitstats.

3m Ensure these are set correctly. Operation should be within the manufacturer'sswitching differential. Adjust if necessary. Thisnote should be read in conjunction with section 4.Smoke/heat detection.

3. Foam inlets. 3m Ensure foam inlet pipes are freefrom blockage.

Inspect diffuser nozzles for damage.

4. Smoke/heat detection. 3m Check operation. Refer to Code of Practice BS 5839.

5. General. 3m Check all fuel supply valves for freeoperation.

Ensure that each fuel supply valve is completewith its own wheel or key.

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8905-26 WASTE AND WOOD BURNING APPLIANCES (including boilers) - Combustion Chamber


1. Fuel feed.

(a) Mechanical. 3m Inspect, check for broken parts andclean conveyors, feeders, etc.

Waste can be a very variable type of fuel andmay contain stones, metal and other materialswhich can cause damage and breakage of thefeed mechanism.

(b) Pneumatic. 3m Inspect and check for wear. In pneumatic systems wear mainly occurs on thebends and wear plates are usually fitted. Anybadly worn ones should be replaced.

2. Fire grate. 3m Clean of any clinker, report to client ifany repairs required.

Uneven combustion is a feature of waste burningand this can lead to local overheating within thefuel bed. Clinker formation can occur togetherwith distortion or failure of the fire grate bars.

3. Ash removal. 3m Inspect for wear and where operationautomatic reset controls.

4. Automatic ignition. 3m Clean and check operation and reset. Refer to Code of Practice BS 5839.

5. Combustion check. 3m Carry out and adjust primary andsecondary and tertiary (if any) air foroptimum combustion.

Because of the variable nature of the fuelallowance for some excess air is necessary. Withstarved air (two phased combustion) tests shouldbe carried out after each stage and shouldinclude CO.

6. General. 3m Check all fuel supply valves for freeoperation.

Ensure that each fuel supply valve is completewith its own wheel or key.

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05-27 WASTE AND WOOD BURNING APPLIANCES (including boilers) - BOILER (if fitted)


1. Check operation in particular the safety controls.

3m Note any visible defects.

Ensure system is full of water and the circuits are open.

2. Combustion check. 3m Start up system and carry out tests.

Because of the variable nature of the fuel, combustion tests should be carried out on a regular basis to monitor performance. The test should include smoke, draught chamber and flue gases including CO.

3. Thermostats, pressure sensors, altitude gauges and thermostats.

3m Check for correct operation and settings.

4. Electrical services. 3m Shut down, disconnect or remove fuses.

5. Boiler flueways and tubes and connecting flue.

3m Open and remove by brushing and/or vacuum all soot and scale.

When burning waste, the hot surfaces of fire or water tubes (if water tube boiler) can foul up very quickly and mechanical techniques of removing scale should be used. Environmental Regulations may apply.


7. Boiler flue ways and chamber.

3m Reseal, check for air leaks, seal as necessary.

8. Boiler return temperature and associated controls.

3m Check if appropriate. Check manufacturer’s specification.


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9105-27 WASTE AND WOOD BURNING APPLIANCES (including boilers) - BOILER (if fitted) - continued


9. Boiler. 3m Reconnect and test fire, carry outcombustion test, refit casing andthoroughly clean down.

A boiler is capable of exploding if safety controlsfail and blocked flues will cause flue gas to leakinto surrounding areas, causing damage and risksto life and health through carbon monoxidepoisoning.

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05-28 ATMOSPHERIC GAS BURNER BOILER - Small and/or wall hung for domestic and light commercial installations.



12m Check casing for damage or breakages. Inspect for loose fittings or connections and any sign of leaks. Record settings.

Check for asbestos prior to dismantling any equipment If suspect cease work and advise supervisor.

b) Check firing.

12m Observe the main burner. Use a combustion analyzer to measure CO & CO2 content of flue gas.

Check Gas pressure,

Record settings.

Dark mauve flame and excessive lifting off indicate poor combustion.


12m Check that all are in accordance with current Codes of Practice.





5. Remove burners and pilot assembly and baffles if fitted.

12m Brush all accessible flueways thoroughly from top to bottom, clean all deposits from the burner box, refit baffles and flue cover - checking cover seal. Check for cracking and wear.

Cleaning should be thorough and carried out as per the manufacturers instructions.


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05-28 ATMOSPHERIC GAS BURNER BOILER- Small and/or wall hung for domestic and light commercial installations. - continued




Pilot injection. Remove and clean. Clean by blowing through or washing. Note: Do not use pin as this will damage the injector.

Thermocouple tip. Replace/clean with fine wire brush, reassemble pilot.

Make sure head lines up with the pilot and not the burner.

b) Oxy-pilot assembly. 12m Replace.

7. Lint filter (if fitted). 12m Remove from burners and clean.



Check, adjust and refit along with main burner.


Test flame setting and thermocouple sensitivity and check manifold gas pressure against manufacturer's settings, adjust if required. If in doubt check gas supply working pressure at the meter.


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05-28 ATMOSPHERIC GAS BURNER BOILER- Small and/or wall hung for domestic and light commercial installations. - continued


10. a) Safety check – Gas.


NB - Undetected CO is life threatening (poisonous) and also causes energy waste. Flames should be bluish and burning in a stable manner. The burner should be quiet in operation, no excessive noise should occur when the burner ignitor shuts down.

NB in domestic premises consider the installation of a BS approved CO detector.

b) Safety check – Electric. 12m Check electrical installation for safety and that local isolator is fitted.


11. Documentation.


The report should be signed by the servicing engineer and the client/responsible person/clients representative. Premature failure of the plant will result if a satisfactory service is not carried out, by a competent engineer qualified as required by the Gas Safety (Installation and Use )Regulations. Depending on the nature/urgency of the fault and the type of premises this report may be verbal.


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9505-28 ATMOSPHERIC GAS BURNER BOILER – Small and/or wall hung for domestic and light commercial installations. - continued


12. Unsafe installations. 12m Recommendations. If after servicing the appliance is considered unsafethe recommendation to the client is that it must betaken out of use.

If approval for this action is refused an appropriatelabel must be attached to the appliance and a writtenreport must be signed by the client/responsibleperson/clients representative and the gas supplierand a supervisor/manager informed.

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9605-29 COMBINATION ATMOSPHERIC BURNER GAS BOILER

These boilers provide central heating and on demand domestic hot water without the need for a hot water storage cylinder (seeAtmospheric Gas burner/boiler).



12m Check Central Heating system for leaks. Flame should cover all flame parts and belight blue in colour.

b) Test firing. 12m Set appliance to DHW highest flow rate toobserve the main burner. Use a combustionanalyzer to measure CO & CO2 content offlue gas.

Check Gas pressure, Water volume &pressure.

Record settings.

Dark mauve flame and excessive lifting offindicate poor combustion.

If appliance is fitted in a hard water area(above 200 ppm), a suitable water treatmentdevice should be fitted.

2. Gas electrical &ventilation systems.

12m Check that all are in accordance with currentCodes of Practice.

Local electrical isolator should be fitted.Supply to the boiler must be direct i.e. notfed through a time switch.

3. Isolate boiler for gas andelectrical supplies.

12m Record any work which needs rectification orreplacement.

4. Gas valve. 12m Disconnect thermocouple and pilot tube fromburners.

5. Remove burners andpilot assembly andbaffles if fitted.

12m Brush all accessible flueways thoroughlyfrom top to bottom, clean all deposits fromthe burner box, refit baffles and flue cover -checking cover seal. Check for cracking andwear.

Cleaning should be through and carried outas per the manufacturers instructions.


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9705-29 COMBINATION ATMOSPHERIC BURNER GAS BOILER - continued


6. Internal Pipework. 12m Examine connections for waterleaks and rectify as necessary.

7. Heat Exchanger. 12m Brush away deposits using asoft brush.

If in hard water area and water treatment device isnot fitted, the HW Heat Exchanger should bedescaled.

8. Fan. 12m Check for free running,mechanical drainage and cleanwith a soft brush.

9. Lint filter (if fitted). 12m Remove from burners andclean.


Burners, Gas valve,thermocouple and pilot tube.

Check adjust and refit alongwith main burner.

11. Boiler and installation. 12m Open gas cock and test for gassoundness, reconnect electricalservices. Test controlsoperation, relight pilot and runup boiler.

Test flame setting and thermocouple sensitivity andcheck manifold gas pressure against manufacturer'ssettings, adjust if required.If in doubt check gas supply standing pressure at themeter.


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12. a) Safety check – Gas


Flames should be bluish and burning in a stable manner. The burner should be quiet in operation, no excessive noise should occur when the burner ignites or shuts down.

NB - Undetected CO is life threatening (poisonous) and also causes energy waste. In domestic premises consider the installation of a BS approved CO detector.

b) Safety check - Electric 12m Check electrical installation for safety and that local isolator is fitted.


c) Sealed System – Pre Charged 12m Check pressure in system is being maintained and that expansion vessel pressure conforms to the pre charged setting.


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13. Documentation.


The report should be signed by the servicing engineer and the client/responsible person/clients representative. Premature failure of the plant will result if a satisfactory service is not carried out, by a competent engineer qualified as required by the Gas Safety Regulations. Depending on the nature/urgency of the fault and the type of premises this report may be verbal.



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05-30 ATMOSPHERIC GAS BURNER/ CONDENSING COMBINATION BOILER The essential feature of a condensing boiler is that to increase the efficiency the flue gases are cooled below their dew point with the result that water is produced which has to be removed from the system.



12m Check Central Heating system for leaks.

b) Test firing.

12m Set appliance to DHW highest Flame should cover all flame parts and be light flow rate to observe the main blue in colour. burner. Use a combustion analyzer to measure CO & CO2 content of flue gas.

Check Gas pressure, Water volume with the boiler operating at low return temperatures (less than 50oC) check that condensate flows freely from the drain pipe.

Record settings.

Dark mauve flame and excessive lifting off indicate poor combustion.

If appliance is fitted in a hard water area (above 200 ppm), a suitable water treatment device should be fitted.








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101 05-30 ATMOSPHERIC GAS BURNER CONDENSING COMBINATION BOILER - continued


5. Remove burners and pilotassembly and baffles iffitted.

12m Brush all accessible fluewaysthoroughly from top to bottom,clean all deposits from theburner box, refit baffles and fluecover - checking cover seal.Check for cracking and wear.

Cleaning should be through and carried out as perthe manufacturers instructions.

6. a) Internal Pipework. 12m Examine connections for waterleaks and rectify as necessary.

b) Condensate drain. 12m Clean, inspect and flush.

7. Heat Exchanger. 12m Brush away deposits using asoft brush.

If in hard water area and water treatment device isnot fitted, the heat exchanger should be descaled.

8. Fan. 12m Check for free running,mechanical drainage and cleanwith a soft brush.

9. Lint filter (if fitted). 12m Remove from burners andclean.

10. Condensate. 12m Check that condensate flowsfreely at low boiler returntemperatures.


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05-30 ATMOSPHERIC GAS BURNER CONDENSING COMBINATION BOILER - continued




Check, adjust and refit along with main burner. Check that condensate flows freely at low boiler return temperatures.


Test flame setting and thermocouple sensitivity and check manifold gas pressure against manufacturer's settings, adjust if required. If in doubt check gas supply standing pressure at the meter.

13. a) Safety check – Gas


Flames should be bluish and burning in a stable manner. The burner should be quiet in operation, no excessive noise should occur when the burner ignites or shuts down.

NB - Undetected CO is life threatening (poisonous) and also causes energy waste In domestic premises consider the installation of a BS approved CO detector


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05-30 ATMOSPHERIC GAS BURNER CONDENSING COMBINATION BOILER - continued


b) Safety check - Electric 12m Check electrical installation for safety and that local isolator is fitted.


c) Sealed System 12m Check pressure in system is being maintained and that expansion vessel pressure conforms to the pre changed setting.

14. Documentation.


The report should be signed by the servicing engineer and the client/responsible person/clients representative. Premature failure of the plant will result if a satisfactory service is not carried out, by a CORGI Registered and competent engineer qualified as required by the Gas Safety (Installation & Use) Regulations. Depending on the nature/urgency of the fault and the type of premises this report may be verbal.


12m Recommendations. If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use. If approval for this action is refused an appropriate label must be attached to the appliance and the HSE informed. A written report should also be signed by the client/responsible person/clients representative.

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05-31 AIR TO WATER HEAT PUMP For additional information, see manufacturer’s instructions. ITEM FREQ. ACTION NOTES 1. Status. 6m Isolate electrically. Note: Isolation of electrical equipment should be

carried out in accordance with HASAWA requirements.

2. Condensate drain pan. 6m Check pan and drain are clear. Check that drainpipe is properly attached. 3. Water loop connections. 6m Check for leaks. 4. Electrical wiring and

terminals. 6m Check integrity.

5. Return to service. 6m Place on heating cycle, isolate from water loop, check high-pressure safety device stops refrigeration compressor.

Follow by opening water loop connection and resetting high pressure cut out.

6. Controls. 6m Return to standard settings. 7. External cleaning 6m Clean unit externally. Note defects on report to client.

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05-32 WATER TO WATER HEAT PUMP For additional information, see manufacturer’s instructions. ITEM FREQ. ACTION NOTES 1. Status. 6m Isolate electrically. Note: Isolation of electrical equipment should be


2. Water loop connections. 6m Check for leaks. 3. Electrical wiring and





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05-33 BRINE TO WATER HEAT PUMP For additional information, see manufacturer’s instructions. ITEM FREQ. ACTION NOTES 1. Status. 6m Isolate electrically. Note: Isolation of electrical equipment should be


2. Water loop connections. 6m Check for leaks. 3. Brine loop connections. 6m Check for leaks. 4. Electrical wiring and





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06-01 ATMOSPHERIC GAS BURNERS These burners operate by mixing air and gas to provide an efficient combustion flame. This principle is used mainly for domestic and small commercial equipment. Before commencing any work check the installation for asbestos.


1. Operational status. 12m Check and note any defects. Annual maintenance should be sufficient but refer to manufacturer's specification.

2. Gas, electrical and ventilating systems.


3. Burner. 12m Isolate electrically, disconnect or remove fuses, turn off and isolate gas supply.

4.a) Thermocouple, probe pilot assembly, spark electrode and main burners.

12m

Disconnect and remove from boiler, clean pilot and main burner.

Cleaning should be thorough and carried out as per the manufacturer's instructions.

b) Oxy pilot assembly 12m Remove and replace as manufacturers recommendations.

5. Spark electrode and thermocouple/ probe.

12m Check, adjust and refit along with main burner.


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1080806-01 ATMOSPHERIC GAS BURNERS - continued


6. Wiring to ignitor and/orprobprobe, gas valve and boilerther thermomostats.

12m Check.

7. Flame failure andassociated controls.

12m Turn on gas, check and adjustpilot flame to envelopethermocouple/probe test flamefailure device.

8. Electricity. 12m Switch on. Make sure boiler thermostat is in off position.

9. Gas. 12m Check and adjust pressure tomain burner.


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06-01 ATMOSPHERIC GAS BURNERS - continued


10. Safety check 12m Ensure that no products of combustion are entering the area of the building where the boiler is situated.

Flames should be bluish and burning in a stable manner. The burner should be quiet in operation, no excessive noise should occur when the burner ignitor shuts down.

NB - Undetected CO is life threatening (poisonous) and also causes energy waste. In domestic premises consider the installation of a BS approved CO detector.

11. Documentation.


The report should be signed by the servicing engineer and the client/responsible person/clients representative. Premature failure of the plant will result if a satisfactory service is not carried out, by a competent engineer. Depending on the nature/urgency of the fault and the type of premises this report may be verbal.


12m Recommendations. If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use.


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11006-02 BLOWN GAS BURNER

A fan assisted type in which the gas and air is pre-mixed before the fan. This is not a pressure jet type burner. The air/fuel ration iscontrolled by an orifice plate and monitored by a pre-set differential pressure switch.


1. Operating status of burner. 12m Check whether plant operatingor not.

For safety and operational reasons the status of theplant should be checked.

2. Gas, electrical andventilating systems.

12m Check that all are inaccordance with current Codesof Practice.

3. Burner. 12m Switch on, carry out safetycheck of flame failure.


4. Combustion check. 12m Carry out and note any visualdefects.

Arrange for record of test to besent to the client.

Pay particular attention to carbon monoxide (CO)as presence is dangerous and life threatening andindicates waste energy.

5. Isolation from electricity andgas supply.

12m Switch off, remove fuses andturn off gas supply at maincock.

Before starting any dismantling of equipment it isessential for safety reasons that the plant be isolatedfrom incoming services.

6. Fan/mix chamber, gas trainand controller assembly.

12m Remove, thoroughly clean, witha soft brush. Lubricate ifnecessary.

7. Fan scroll. 12m Clean and check air passages. Ensure air passages are clear to pressure switch.

8. HT & probe details. 6m Inspect for soundness. If probe is bent or shows signs of oxidation it shouldbe replaced.


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06-02 BLOWN GAS BURNER - continued



It is important that reference is made to the boiler and burner manufacturer's specifications.




A maintenance check should be carried out on this type of burner twice a year but refer to manufacturer's specification.

13. Recommendation. 12m Provide written report. The report should be signed by the service engineer and the client/client representative/responsible person.

Premature failure and excessive fuel costs will result if satisfactory service is not carried out.

All service and maintenance must be carried out by a registered engineer complying with Health and Safety requirements and possess accreditation in accordance with the Gas Safety Regulations.



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11206-03 FORCED DRAUGHT GAS BURNER

A fan assisted nozzle mix type with fully automatic operation creating an expanding flame.ITEM FREQ. ACTION NOTES



2. Gas, electrical andventilating systems.

6m Check that all are inaccordance with current Codesof Practice.

3. Burner. 6m Switch on, carry out safetycheck of flame failure.


4. Combustion check. 6m Carry out and note any visualdefects.

Arrange for record of test to besent to the client.

Pay particular attention to carbon monoxide (CO)as presence is poisonous and life threatening andindicates waste energy.

5. Isolation from electricity andgas supply.

6m Switch off, remove fuses andturn off gas supply at maincock.

Before starting any dismantling of equipment it isessential for safety reasons that the plant be isolatedfrom incoming services.

6. Fan and motor. 6m Remove, thoroughly clean, MOTORS

lubricate if necessary. 7. Fan scroll. 6m Clean and check air passages. Ensure air passages are clear to pressure switch.

8. Automatic gas valves. 6m Check for gas tightness.

9. Removal of UV cell andhead assembly.

6m Clean, adjust electrode and ifrequired isolate probe.

UV cells should be replaced after a life of 10,000hours.

10. HT & probe details. 6m Inspect for soundness. Consideration should be given to replacing HT leadevery 12 months.


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06-03 FORCED DRAUGHT GAS BURNER - continued



It is important that reference is made to the boiler and burner manufacturer's specifications.


13. Flame failure. 6m Test and take probe or UV cell readings.


A maintenance check should be carried out on this type of burner twice a year but refer to manufacturer's specification.

15. Recommendation. 6m Provide written report. The report should be signed by the service engineer and the client/client representative/responsible person.

Premature failure and excessive fuel costs will result if satisfactory service is not carried out.

All service and maintenance must be carried out by a registered engineer complying with Health and Safety requirements and possess accreditation in accordance with the Gas Safety Regulations.



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11406-04 FUEL OIL BURNERS USING 220/960 Sec OIL

There are four basic fuel systems, which can be subdivided into those used for distillate and those for residual oils. The use ofresidual oils necessitates the inclusion of equipment for pre-heating the fuel oil prior to the burner. This includes preheater coils in thestorage tank, line tracing and final preheater either before or right at the burner nozzle. The oil supply temperature at the burner inletmust be sustained at the burner pump inlet as follows:

Class F (960 sec Redwood No 1 - 20cSt @ 100oC in SI units) 43oC-55oC, at burner nozzle 104oC

Class E (220 sec Redwood No 1 - 8cSt @ 100oC in SI units) 10oC-21oC, at burner nozzle 82oCITEM FREQ. ACTION NOTES

1. Immersion heater/steamcoils and thermostat.

12m Check condition and test actionof thermostat.

Examine condition of wiring and control temperatureof thermostat.

2. Preheater tank. 12m Inspect for soundness. Drainwater from drain valve at baseof tank.

These tanks should be insulated and should bechecked for damage and if outside, attention shouldbe paid to waterproofing and checking for thepresence of corrosion of the tank under the damagedinsulation. Drain water from tank frequently.

3. Trace heating. 12m Check thermostat setting,adjust if necessary.

If electrical, check on current drawn and if differentfrom norm, investigate and report to client. Checkand record the transformer output voltage.

4. Insulation. 12m Examine and replace or repairas necessary.

5. Filters. 12m Clean and change if necessary. Sludge in heavy fuel oil can be a major fault in aburner operation and regular checking of filters andcleaning of tanks may be necessary if oil is only usedintermittently.

To dispose of waste away from site the operator musthave a Waste Disposal License, Risk Assessmentmay be required.


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11506-04 FUEL OIL BURNERS –USING 220/960 Sec OIL


6. Steam traps and drainvalves (steam heatedsystems).

12m Check operation, repair oradjust as necessary.

7. General. 12m Report on condition. Include any recommendations for future action in thereport.

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11606-05 FORCED DRAUGHT [PRESSURE JET] OIL BURNER

A fan assisted nozzle oil air mix fully automatic.ITEM FREQ. ACTION NOTES

1. Operating status ofburner.

3m Check whether plant operating or not.

A combustion test may be necessary.

For safety and operational reasons the status ofthe plant should be checked.

2. Oil, electrical andventilating systems.

3m Check that all are in accordance withCodes of Practice.



4. Safety Check. 3m Carry out and note any visual defects. Leakage of all products of combustion (CO,CO2 , SO2) should be sought. Pay particularattention to carbon monoxide (CO) as itspresence can be dangerous and wastesenergy.

5. Isolation from electricityand oil supply.

3m Switch off, remove fuses and turn off oilsupply.

Before starting any dismantling of equipment it isessential for safety reasons that the plant beisolated from incoming services.

6. Blast tube assembly. 3m Remove, clean combustion head,ignition electrodes and inspect HT leads.

7. Nozzle and filter. 3m Clean filter and inspect nozzle for wear.Renew annually.

Erosion or surface defects on the nozzle canaffect the profile of the emerging jet of oil andlead to a poor flame shape and bad combustion.

8. Burner. 3m Reassemble and set head tomanufacturer's requirements.

9. Motor and fan. 3m Remove, clean and lubricate asrequired, clean fan scroll.

Inspect oil pump flexible drive coupling before re-assembling. (See also MOTORS)


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11706-05 FORCED DRAUGHT [ PRESSURE JET] OIL BURNER - continued

ITEM FREQ. ACTION NOTES10. Oil pump filter. 3m Remove and clean, inspect pump

seals for signs of wear.11. Reassembling burner. 3m Inspect flexible oil line coupling,

clean and renew oil line filter,clean photo cell and adjustposition.

12. Burner. 3m Switch on and check flameshape and appearance if visible.

13. Oil pressure. 3m Test, record oil pressure.14. Combustion tests. 3m Carry out and check. On larger systems combustion tests should be

carried out regularly to monitor performance andavoid energy waste.

15. Flame failure device. 3m Test for satisfactory operation.16. General. 3m Check security of mechanical

parts and secure mounting ofappliance.

A maintenance check should be carried out on thistype of burner twice a year but refer tomanufacturer's specification.

All service and maintenance works must be carriedout by a competent engineer in accordance with BS5410 Codes of Practice for oil firing.

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11806-06 LIGHT OIL VAPORISING POT BURNER

A simple oil burner.ITEM FREQ. ACTION NOTES

1. Operating status of burner. 3m Check whether plant operating ornot.

A combustion test may benecessary.

For safety and operational reasons the status ofthe plant should be checked.

2. Oil, electrical and ventilatingsystems.

3m Check that all are in accordance withCodes of Practice.

3. Burner. 3m Switch on, and note level of floatchamber.


4. Safety Check. 3m Carry out and note any visualdefects.

Leakage of all products of combustion (CO,CO2 , SO2) should be sought. Pay particularattention to carbon monoxide (CO) as itspresence can be poisonous and wastesenergy.

5. Isolation from electricity andoil supply.

3m Switch off, remove fuses and turn offoil supply.

Before starting any dismantling of equipment itis essential for safety reasons that the plant beisolated from incoming services.

6. Burner. 3m Remove, if possible clean andtrim/replace the wick.

7. Float chamber and filter (iffitted).

3m Clean filter and set float chamberlevel in accordance withmanufacturers instructions.

8. Burner. 3m Assemble and switch on in order tocheck the flame shape.


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11906-06 LIGHT OIL VAPORISING POT BURNER - continued


9. Combustion check. 3m Carry out. On larger systems combustion tests should becarried out regularly to monitor performance andavoid energy waste.

10. Recommendation. 3m Provide written report, whichshould be signed by the serviceengineer and kept by the client.

Premature failure will result if satisfactory serviceis not carried out.All service and maintenance must be carried outby a registered engineer in accordance withHASAWA requirements and in accordance with BS Code of Practice for Oil Firing.

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12006-07 GAS/OIL BURNERS - Dual fuel

Burners of this type should be serviced every three months, certain operations require a lesser frequency and this is noted in thefrequency column. These units are specialised and should only be serviced by trained personnel. This does not apply to the filterswhich should be cleaned by the customer at least once per week.




2. Oil, gas, electrical andventilating systems.

3m Check that all are inaccordance with Codes ofPractice.

Check interlock switches - adjust if necessary.

3. Ignitor. 3m Check.

Gas

1. Joints. 12m Carry out leak test of all jointsdownstream of interlockisolator.

2. Main gas valve. 12m Check operation of leak testequipment.

3. Gas throughput. 12m If practical - check. If not practical, check gas manifold.

4. Vent pipework. 12m Check integrity.

Oil

1. Burner. 3m Fire if possible, carry out safetycheck of flame failure device.

Note any visible effects.

2. Linkages. 3m Check and adjust if necessary.


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12106-07 GAS/OIL BURNERS - Dual fuel - continued


3. Oil metering system. 12m Renew seals and gaskets ifnecessary.

4. Main shaft on burner. 12m 'Lift' bearings.

5. Atomisers and spray tip iffitted.

12m Check.

6. Drive belts. 12m Check.

7. Efficiency/Combustionchecks on both fuels.

3m Carry out and note any visualdefects.

Pay particular attention to carbon monoxide (CO) asits presence can be poisonous and wastes energy.

Electrical

1. Wiring. 6m Check panel, junction box andterminals.

2. Fuses. 6m Check rating.

3. Overload relays. 6m Check settings.

General

1. 3m Check security of mechanicalparts and secure mounting ofappliance.


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06-07 OIL/GAS BURNERS - Dual fuel - continued


2. Report & Recommendations.

12m Should be signed by service engineer and kept by the client.

Premature failure may result if satisfactory service is not carried out. All service and maintenance must be carried out by a registered engineer in accordance with current HASAWA requirements.



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12307-01 BUILDING MANAGEMENT SYSTEMS - Introduction

Development

Building Management Systems (BMS) or Building Energy Management Systems (BEMS) have developed from the simple applications of the1970s to complex integrated systems involving outstations and central units whose operation relies on computer interactive managementbacked by detailed and often complex software which provides total management of the environmental conditions in a building. It is an everchanging field and systems currently in operation can include lighting, security, lifts, fire alarms, access and other interfaces.

Monitoring operation

The basic components of a BMS include sensors, actuators, controllers, communication systems and a central unit which can be eitherpassive i.e. monitor and rely upon the outstations to act as local control centres, or active and provide a central control function.

Where Building Management Systems are installed it is essential that the Client should be aware of the need for continuous monitoring ofperformance. Switching off because of a malfunction or lack of data update represents a negation of the investment and can give rise to poorenvironmental conditions and energy wastage.

Energy saving and maintenance

Building Energy Maintenance Systems offer considerable energy and cost savings when compared with more simple equipment butrepresent a considerable investment by the building owner or lessee. If the equipment is not properly commissioned and maintained byspecialist trained personnel who have had training on such equipment and are supported by the manufacturer the benefits of suchinvestment could be lost, energy will be wasted and costs rise.

Building owner or lessee

Building owners or lessees should ensure that their operators have had the appropriate training to ensure that routine but important daily andweekly maintenance tasks are carried out satisfactorily. Such tasks could include monitoring and changing time schedules, set points andenvironmental control settings and simple routine maintenance of the computer hardware. Where changes are made to the software routinesit is essential that back up copies are made to safeguard the changes.

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Software

The owner or lessee should be aware that software is normally covered by copyright and the licence conditions covering its use can be veryrestrictive. The penalties for infringing that copyright can be considerable. The licence may relate to the use of the software or may berestrictive and apply only to a particular application or building. If there is any doubt regarding the above, the manufacturer should becontacted for advice.

Maintenance contractor

For the regular maintenance of the equipment the client should be satisfied that the maintenance contractor employs BMS specialistswho:-

a) have had the necessary training,b) have knowledge of the installed system,c) maintain an up to-date awareness of the manufacturers equipment including computer hardware and software,d) have access to up to-date diagnostic equipment,e) have good technical support,f) are supported by adequate stocks of spares.

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12507-02 GLOSSARY OF BMS TERMS

Term Definition

Alarm Audible or visual indication of a dangerous or undesirable condition.

analogue Pertaining to data or physical quantities that vary continuously.

archiving Long term storage of data in a retrievable form.

building automation systems Synonymous with BMS.

building and energy management An electronic control and/or monitoring system (BEMS) system. The management system(BEMS)The system may have attributes from all facets of building management functionssuch as HVAC, fire, lighting, security and communications.

boost period or preheat period The period immediately before the occupancy period during which the plant is operated at itsrated capacity.

bus or data highway A cable connected to a number of different devices such as sensors, controllers andoutstations that acts as a means of data exchange. There are two main types, serial andparallel. In building services it is most common to use serial types where data flow on just twocores of a cable. A communication link between the various components of BMS along whichthe digital data are transmitted.

central processing unit (CPU) The heart of the computer that co-ordinates and controls the actions of all other units.

central operation station Primary point of access to a BMS and the point from which all user operations are normallyconducted. Synonymous with 'head end' and 'front end'.

compensator A control device whose control function is to reduce heat supply with decreased building load.

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computer programme A set of instructions required by the computer to enable it to perform a task.

control action A term describing the relationship between the input signal and the output signal of a controlelement.

control function A term used to describe the form of control e.g. compensation, optimum start, etc.

control parameters A pre-selected variable used in algorithms, e.g. desired inside temperature, proportional band,etc.

data A representation of facts, concepts, or instructions in a formalised manner suitable forcommunication, interpretation, or processing by humans or a computer.

database A structured collection of data. This is usually arranged in a series of files with access to thedatabase controlled by a computer programme.

digital Pertaining to data or physical quantities that vary in discrete steps.

disk drive A device that reads from and writes to a magnetic disk for the purpose of storing data andcomputer programmes.

duty cycling A control method which sequences the operation of plant in order to bring it regularly into use.

DX Direct expansion (as in chiller).

enthalpy control The processing of optimising the proportions of fresh and recirculated air for a space basedon the enthalpy value estimated from measurements of humidity and temperature.

event initiated programme Computer programmes executed on the occurrence of an input/output operation or an alarm.

feedback control The transmission of a signal from a later to an earlier stage for the purposes of control.

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127firmware Software permanently fixed in the memory which cannot be changed.

hardware Physical equipment as opposed to software.

HPHW High pressure hot water.

hunting Prolonged self sustained oscillation of a controlled device of undesirable amplitude.

HVAC Heating, Ventilating and Air Conditioning.

interface A shared boundary. The hardware or software required to enable one device to communicatewith, sense or control another.

interlock A term which describes the on/off action that links one device to another in a controlsequence.

load cycling A control method whereby management of plant output is achieved by means of variableon/off periods of operation.

local area network (LAN) A communication system with associated software that enables computer based systems tobe linked so that they may communicate with each other without conflict.

local station Synonymous with outstation.

log A chronological record of a series of values or events.

LPHW Low pressure hot water.

maximum demand control A control function which switches off the load in order to keep the total electrical powerdemand below a given maximum, usually to prevent the imposition of penalties imposed bysome tariffs. Synonymous with load shedding.

modulator/demodulator(MODEM) A device that converts digital data to an analogue signal for transmission on telephone

circuits.

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MPHW Medium pressure hot water.

night set-back The reduction of maintained space conditions by a pre-set amount for the overnight period.

node point of connection on a communication system.

optimum start A control system or algorithm which starts plant operation at the latest possible timeconsistent with the attainment of specified conditions within the occupied space by the start ofthe occupant period.

optimum stop A control system or algorithm which stops plant operation at the earliest possible time, suchthat the residual capacity of the system and the space will prevent conditions in the spacedeteriorating beyond pre-set limits by the end of the occupancy period.

outstation A device to which sensors and actuators are connected, capable of monitoring and/orcontrolling building services within its locality. It has also the facility to exchange informationwith the central station.

password A character string that allows a user to have full or limited access to a system or to a set ofdata.

point A physical source of, or destination for, data in the form of analogue or digital signals.

programmable point A control or monitoring point for which the user may programme an associated controlfunction.

proportional band That range of values of deviation corresponding to the full operating range of output signal ofthe controlling unit resulting from proportional action only. The proportional band can beexpressed as a percentage of the range of values of the controlled condition which themeasuring unit of the controller is designed to measure.

proportional action The action of a control element whose output signal is proportional to the deviation from theset point.

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129setpoint The desired value for the controlled condition or variable.

software Computer programmes, procedures, rules and associated documentation.

stand alone controller A description used when, for normal operation, the item of equipment does not depend upon acentral or other processor.

supervisor station Synonymous with central station.

zone An area composed of a building, a portion of a building, or a group of buildings that isseparately controlled separately controlled.

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13007-03 BUILDING MANAGEMENT SYSTEMS - Central Operator Station

Care should be taken with regard to the system status, where necessary arrange co-ordination with building occupiers.ITEM FREQ. ACTION NOTES

PC/Micro Based System

1. Cables andconnectors.

12m Check security, integrity andfor physical damage.

2. Diagnostic routine oncomputer (whereappropriate).

6m Perform diagnostic tasks andcheck computer operation.

This routine will check all aspects of computerhardware and software.

3. Disc drives. 12m Clean according to themanufacturer's instructions.

4. Tape drives. 12m Clean according to themanufacturer's instructions.

5. Tape cassettes (whereappropriate).

12m Clean according to themanufacturer's instructions.

6. Clock battery. 12m Check and replace ifnecessary.

Battery disposal should be in accordance withH&S and Environmental requirements.

7. Cooling fans. 6m Check condition, clean andlubricate if necessary.

8. Filters. 6m Inspect and clean or changeas necessary.

9. Mouse. 12m Check for smooth operationand clean ball as necessary.

Client may ask for more frequent maintenance ofmouse.


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13107-03 BUILDING MANAGEMENT SYSTEMS - Central Operator Station - continued


10. Software archives. 6m

12m

a)Take back up copy of sitespecific data files.b)Verify operating programmesand functionality. Ensure that security is retained and that any

updating of files is incorporated.

11. Visual Display Unit (VDU). 12m Check a)focus, b)contrast, c)brightness,

d)for correct operation.

12. Monitor(s). 12m Check a)focus, b)contrast, c)brightness,

d)for correct operation, e)degauss.

With most VDUs the screen is automaticallydegaussed when equipment is switched on.

13. Keyboard. 12m Check for correct operationand clean.

14. Cleaning. 12m Clean with approved cleanser. Treat with anti-static compound. Depending onuse and location more frequent cleaning may benecessary.

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13207-03 BUILDING MANAGEMENT SYSTEMS - Central Operator Station - continued


Printers

1. Cables and connectors. 12m Check security, integrity, andfor physical damage.

2. Cleaning. 12m Use recommended cleaningagent.

Remove paper or tape debris.

3. Test sequence. 12m Check, adjust andreplace if necessary:-a)paper feed,b)transport system,c)printer ribbon.

4. Consumables (where applicable.) 12m Check stocks.

Visual Display Unit -colourgraphic

1. Cables and connectors. 12m Check security, integrity, andfor physical damage.

2. Cleaning. 12m Use recommended cleaningagent.

3. Colour alignments andadjustments.

12m Check and correct asnecessary.

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13307-04 BUILDING MANAGEMENT SYSTEMS - COMMUNICATIONS

Care should be taken with regard to the system status, where necessary arrange co-ordination with building occupiers.


Data Communications

12m Check integrity of data flow inboth directions.

If more than one path exists all must be verified.

1. Central station units. 12m Check operation visuallyinspect. Check environmentalconditions of all equipment arewithin prescribed limits.

To include modems, line drivers, telemetry cablesand interface units.

2. Central station/remote printer 12m Check operation and visuallyinspect.

3. Central station/out stations. 12m Check integrity of data flow inboth directions.

If more than one data path exists, all must beverified. Caution - There may be interaction withspecialist applications.

4. Connectors. 12m Check security, integrity, andfor damage.

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134 07-05 BUILDING MAINTENANCE SYSTEMS - OUTSTATIONS

Care should be taken with regard to the system status, where necessary, arrange co-ordination with building occupiers.


1. Out station hardware. 12m Check mechanical andenvironmental condition.

Note: environmental conditions e.g. temperature,humidity should be within manufacturer'srecommended limits.

2. Connectors. 12m Check security, integrity andfor damage.

Includes security of incoming cables, preventionof ingress of moisture, door seals etc.

3. Power supplies. 12m Carry out voltage check on allpower supplies.

Check automatic restart, re-booting of softwareprogramme.

4. Stand-by batteries/uninterrupted power supplies(UPS).

12m Check against manufacturer'sspecification.

5. Digital inputs. 12m Check by activating (wherefrom fixed sensing/controldevice)

Note: Care should be taken to isolate localoperation.

6. Digital outputs. 12m Check operation of outputstopping by operating routine(where appropriate). Checkswitching by softwareinterlocks.

Should include starting and stopping operations.Note: Does not apply to connected

devices.

7. Analogue inputs. 12m Read and check calibration ofanalogue inputs.

8. Analogue outputs. 12m Check for accuracy of outputsignal.


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13507-05 BUILDING MAINTENANCE SYSTEMS - OUTSTATIONS - continued


9. Manual override(physical).

12m Check status. Review and report to client.

10. Installed programme. 12m Check integrity, alarms,interlocks, optimisation.

See section on SOFTWARE FUNCTIONS.

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13607-06 BUILDING MANAGEMENT SYSTEMS - SOFTWARE FUNCTIONS

Different manufacturers have adopted different approaches to software development and the tables below show some typical functionsand the action which should be taken.

ITEM FREQ. ACTION NOTES1. Control loops. 12m Check integrity of the

installed programme,Check sequence andoperation of control, outputsand,Check stability of plant.

Frequency should be agreed with client.This action should be related to the critical nature ofthe operation.

2. Optimised start/stop. 12m Verify operation byinterrogatingsoftware/hardware copy.

Building layouts and occupational requirements areseldom of a static nature. Therefore controlstrategies and their suitability need to be reassessedon a regular basis.

3. Time clock 12m Check real time clock foraccuracy throughoutsystem.

4. Time switching. 12m Review current operatingparameters according toclient's needs.

e.g. time settings and schedules.

5. Data logging. 12m Review existing logs. Report to client on the need to review existingarrangements.

6. Alarms - faults, out of limit alarms.

12m Check that plant alarms andsoftware interlocks withsafety implications areoperating correctly. Checkalarm priorities, routings andreactions.

The checking of possible reactions to certain criticalalarms and programmes must be carefully co-ordinated with other trades and building tenants.Where there are safety implications, verify alarmintegrity. Review system of reporting outstandingalarm conditions and report discrepancies.


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137

07-06 BUILDING MANAGEMENT SYSTEMS - SOFTWARE FUNCTIONS - continued


7. Alarm management and report.

12m Review frequencies of generated alarms.

Report as appropriate to client.

8. Power failure and restoration.

12m Check plant start up sequence.

9. Generator loading programme.

12m Check plant start up sequence.

10. Maximum demand/load shedding.

12m Check sequence and operation.

11. Load cycling. 12m Check operation.

12. Software interlocks. 12m Verify operation.

Check Plant rotation point, e.g. interfaces with other building services systems such as :-

fire security

access

13. Manual status review. 12m

Check manual overrides and effect on system, and effect on system operation.

At client access level review parameters, lockouts, changes, all points in manual override and forced analogue values. Review findings with client.

08-00 CATERING EQUIPMENT AND CANOPIES - SEEK SPECIALIST ADVICE

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13809-01 CHILLER / REFIGERATION EQUIPMENT - Introduction

Air conditioning equipment may come in discrete packages where a particular unit operation can be identified with a single piece ofequipment, conversely a number of unit operations can be combined into a single `package'. These packages may be small as in a wallmounted air conditioner or they may be large free standing units of 100 kW or more often placed on the roofs of buildings. Items of plantproducing mechanical cooling include package chillers, absorption type units, refrigerant compressors, evaporators, refrigerationcondensers and refrigeration distribution systems with their associated controls. More detailed maintenance procedures for controls areto be found at relevant sections.

Air conditioning and refrigeration equipment traditionally used ozone depleting refrigerant fluids as the cooling medium. Care should beexercised to check the type of refrigerant currently in use in each system, before service is carried out, as European and UK legislationhas been introduced controlling the use of CFC refrigerants for servicing and phasing out their use totally in servicing by the end of 2000.This action will ensure compliance with statute and avoid environmental damage. Refrigerants R11, R12 and R502 are typical of those inuse, the latter two have acceptable drop in replacements available depending on application.

ALL REFIGERANTS MUST BE RECOVERED FOR RECYCLING OR DESTRUCTION.

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13909-02 PACKAGED CHILLER UNITS

Warning - Chiller units may be operated remotely and it is essential that the equipment be isolated at source before commencing anymaintenance work. These notes should be read in conjunction with the manufacturer's recommended maintenance procedures and inparticular supplementary work may be required in the case of larger units above 50kW. Many packaged water chillers havemicroprocessor controls that can be interrogated using passwords. The password is usually at two levels, level one for interrogation andlevel two for alterations. For service work access to level one is required. These processors can be used for diagnostic purposes andcoupled to pressure transducers can also give pressure readings.


1. Status. 3m Check operating status. Note: With computer room chilling units alwayscheck with computer staff before service ormaintenance. Do not only rely on themicroprocessor readouts, always check againstcalibrated equipment if in any doubt.

2. Refrigeration circuits 3m Check circuit pressures and superheattemperatures. Check alarm and runlights and remote alarm lightsassociated with packs.

Refrigeration circuits should be alternated at leastevery three months by means of the 'lead/leg'selector switch.Where operating information is displayed oncentral console, check that no discrepancies existbetween display and master gauges, if these dooccur report and change transducer(s). For nonelectronic systems check installed gauges againstmaster gauges.

3. Refrigerant 3m Check for refrigerant and all leaks.

4. Expansion valves 3m Adjust if necessary. Only by a competent technician.

5. Chilled water supply 3m Check supply and return watertemperatures.

If closed system check for presence of water.

6. Glycol 3m Check glycol concentration in chilledwater.

If concentration has fallen check pipework forleaks as per item 8.


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14009-02 PACKAGED CHILLER UNITS - continued


7. Chiller water flow rate. 3m Check that this is in accordance withthe manufacturer’s recommendedfigure.

8. Leakage 3m Check all pumps and pipework forleaks and rectify.

Do not overlook remote condensers and pay particular attention to bolted joints, sight glass stands and atmospheric relief valve vent.

9. Refrigerant pipework. 3m Inspect and check for vibration,chaffing security and leakage.

Vibration is usually the result of loose orinadequate fixing of pipe supports and can giverise to leakage of refrigerant.

10. Standby circuits. 3m Check operation.

11. Flood alarm. 3m Check operation. If serving computer facilities, check that alarm isnot connected to computer shut-down system.

12. Digital readouts. 3m Check operation.

13. Controls. 3m Check operation of temperaturecontrol thermostats. Inspect electricalpanel and components for wearespecially the compressorcontactor(s). Check operation ofsafety thermostats and timers.

Calibration }Interrogation }Control adjustment }

by Control Specialist

14. Hours run meter. 3m Check and record.

15. Insulation. 3m Check condition and make good anydefects.

Poor or faulty insulation can lead to ice build up,loss of efficiency and energy wastage.


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141

09-02 CHILLER UNITS - continued ITEM FREQ. ACTION NOTES

16. Electrical. 12m Check for damage to flexible conduits. Tighten all terminal connections. Isolate control panel and inspect for signs of overheating. Check integrity of electrical insulation.

Include pump motors. (See also MOTORS)

17. Safety cut-outs. 12m Check all safety cut-outs including high and low pressure safety cut-outs and the antifreeze thermostat cut-out for operation and correct calibration.

Individual machines vary, cut outs could include i. oil differential switches, ii. oil, high and low temperature, iii. water temperature differential switches on

chillers and evaporators.

18. Pump strainers. 12m Check condition. Check waterside pressure drop across the heat exchanger(s) for fouling.

WORK ON REFRIGERANT SYSTEMS MAY ONLY BE CARRIED OUT BY A TECHNICIAN WHO HOLDS A CERTIFICATE FOR THE SAFE HANDLING OF REFRIGERANT AND WHO WORKS FOR A COMPANY REGISTERED WITH REFCOM.

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14209-03 LITHIUM BROMIDE/WATER ABSORPTION CHILLERS

This is a specialised field and requires highly experienced engineers to maintain this type of equipment.Note - the most important feature of an absorption system is the need to maintain the DESIGN VACUUM CONDITION. Thesemachines require daily recorded checks of machine performance which are compared with the previous readings. Changes must benoted.


1. Specific gravity of solution. 1m Check as per instructions ofmanufacturer.

Record and note changes in specific gravity for givenconditions.

2. Non condensableaccumulation rate.

1m Determine as permanufacturer's instructions.

Note leak rate and compare with manufacturer'smaximum rate. If higher, this indicates that machinehas a leak and action must be taken to trace andrectify.

3. Dilution controls. 2m Check as per instructions ofmanufacturer.

Reset if necessary.

4. Low temperature cut out. 2m Check as per instructions ofmanufacturer.

Reset if necessary.

5. Evaporator water charge. 6m Check as per instructions ofmanufacturer.

Record results and check with last reading.

6. Capacity control valve. 6m Check operation as permanufacturer's instructions.

Record results.

7. Absorber and condenser. 12m Check for scale, action bedetermined by findings.

When chemical cleaning is carried out ensure thatcompetent company and personnel are used.


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14309-03 LITHIUM BROMIDE/WATER ABSORPTION CHILLERS - continued


8. Solution sample. 12m Take as per manufacturer'sinstructions.Add amounts of chemicals asadvised by chemist (i.e. inhibitoroctyl-alcohol etc.)

Record results and compare with last set ofreadings.

Record details of action, compare with last reportand file.

9. i. Absorber loss,ii. Decrystallisation,

(as required)

12m-

Determine as per manufacturer'sinstructions. Experience is vitalin determining the significance ofany loss.

Recorded loss should not be greater than 3° F.Measure and record:-i. refrigerant temperature,ii. temperature and specific gravity of solutioniii. temperature at the outlet of the solution

pump.Note:- Early resolution of any crystallisationproblems is important as damage to pumpsmay occur.

10. Diaphragms of service valves. 24m Replace as per manufacturer'sspecifications.

Inspect diaphragms and record condition.

11. Solution and refrigerantpumps.

1m Inspect according to manufacturer'srecommended frequency.

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14409-04 GAS FIRED ABSORPTION CHILLER UP TO 18 KW COOLING CAPACITY

These units are Direct gas fired and maintenance of the gas burners should be carried out in line with the relevant specification. They areavailable in cooling only or heat pump version. Care should be taken as the refrigeration system contains Ammonia Solutions. Only toolswhich are capable of handling Ammonia should be used. Refer HSE Document PM 8I – 1995 Safe management of NH3 refrigerationsystems.


1. General. 4m Check that unit is level and on goodfoundations

2. Condenser fins. 4m Visually check and clean whenrequired the condenser fins.

3. Absorber. 4m Check absorber visually.

4. Condenser fan. 4m Check that condenser fan height is atdesign setting.

Adjust according to instruction manual.

5. Water pan. 4m Check water level in water pan.

6. Chilled water flow rate. 4m Check and adjust chilled water flowrate (fountain height) see instructionmanual.

Adjust according to instruction manual.

7. Hydraulic pump. 4m Check and top up fluid if necessary

8. Drive Belt. 4m Check or replace if necessary. For further maintenance procedures see BELTDRIVES.

9. Solution pump. 4m Visual check solution pump.

10. Sealed system. 4m Purge pressure check high side andlow side pressure.

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14510-01 COLD ROOMS

It should be noted that the frequency of maintenance relates to equipment which is generally in clean surroundings but where theenvironment is dirty, i.e. dust or fluff, more frequent maintenance may be necessary. (See also MOTORS)


1. Evaporator coils. 6m Clean and check for any damage. Ensure unit thoroughly defrosted and coils arefree of ice before putting back into service.

2. Sensor fittings. 6m Check fixing is secure and wiringproperly clipped.

Ensure wiring is clipped away from tray heaters,fan motors and blades.

3. Fans. 6m Check operation, mountings, guardsand blades. Check bearings, lubricateif necessary.

Where excessive end float or bearing wear isfound, report on need for replacement.

4. Defrost heaters andassociated controls.

6m Check operation and condition.

5. Pipework. 6m Inspect and thoroughly leak test. Corrosion and chafing can occur at duct entriesand joints.

6. Drainage. 6m Check for cleanliness and theoperation of pumps, probes andheaters where fitted.

7. Evaporators. 6m Check for correct operation. Correct operation is indicated by even frostformation on cooler face and/or on distributionlines.

8. Interconnecting pipework(where visible).

6m Check for vibration and test for leaks.Check insulation for damage andreplace/repair as necessary.


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14610-01 COLD ROOMS - continued


9. Alarm system. 6m Check for correct action. Chafing can occur at duct entries and joints.

10. Electrical connections. 6m Isolate panel. Check all connectionsand wiring.

Ensure correct fuses are fitted and spares areavailable.

11. Controls and switchesand indicator lamps.

6m Carry out a visual check for wear andarcing. Check operation of relays,contactors and timers and defrost timeswitch for correct operation. Ensureindicator lamps are working correctly.

12. Plant rooms and housing. 6m Check ventilation not impaired. Leave clean and tidy.

13. Operating temperatures. 6m Check for correctness.

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14710-02 REFRIGERATED DISPLAY CABINETS

Cleaning of cabinets will normally be carried out as part of the regular store maintenance schedule and will to some extent be controlledby the type of merchandise being displayed. This schedule relates to the main maintenance programme.

ITEM FREQ. ACTION NOTES1. Evaporators. 6m

2. Fans 6m Where excessive end float or bearing wear.Report on need for replacement.

3. Defrost heaters andassociated controls.


4. Electrical connections. 6m Check all connections and wiring. Chafing can occur at case entries and joints.

5. Pipework. 6m Inspect and thoroughly leak test. Corrosion and chafing can occur at case entriesand joints.

6. Drainage. 6m Check for cleanliness and clean drainfilter and reinsert.

Additionally this will be carried out as part of thestore's regular cleaning and hygiene schedule.

7. Casework. 6m Check lights, gaskets, door switches,comfort and anti-sweat heaters, wherefitted.

Report wear or damage (especially to cabinetdoor or lid gaskets).

8. Interconnecting pipework(where visible).

6m Check for vibration and test for leaks.Check insulation for damage andreplace/repair as necessary.

9. Case thermometer. 6m Check for correct reading with servicethermometer.

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14811-01 COMMUNICATIONS - PUBLIC ADDRESS SYSTEMS - general


1. Microphones. 3m Inspect and check all connection leads,plugs and sockets,

Operate speech key and check anodecurrents,

Using signal generator measure outputvoltages on preamplifier.

The actual test may vary with the type ofequipment and the manufacturer'sspecific instructions should be followed.

2. Power amplifier. 3m Inspect and test using signal generator.

3. Fire alarm interface. 3m Check functioning of interface.

4. Electrical insulation. 12m Measure insulation resistance ofinstallation cables.

5. Loud speakers. 12m Inspect for damage. Test each speakerand check earthing where appropriate.Check that music and other on-lineactivities are cut out whenannouncements are made.

6. Functional test. 12m Test system.

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14912-01 COMPRESSORS REFRIGERATION - Reciprocal - (includes hermetic, semi-hermetic and open)

These machines come in a wide range of sizes, the larger machines can be complex both in terms of operation and maintenancerequirements. In the case of compressors serving small air conditioning systems which may only run during the summer months, thesemay require less frequent maintenance.For the maintenance of rotary compressors refer to the manfacturer's maintenance instructions.


1. Full load condition (Liaise withclient).

6m Check and record suction anddischarge pressure, oil pressure.

Where gauges are fitted the plant operatorshould record the readings every month.

2. Start and run currents. 6m Check and compare withmanufacturers recommended figures.

3. Operating status. 6m Check whether plant in use. If meterfitted record hours run.

For operational and safety reasons thestatus of the plant should be checked. Toisolate remove fuses and ensure otherservices are switched or valved off.

4. Leaks. 6m Check for oil and refrigerant leaks.Any leak of refrigerant should be dealtwith immediately.

Check for leaks should be part of the routineservicing by plant attendants.

5. Oil in crankcase. 6m Check level and condition. This should be carried out on a monthlybasis by the plant attendant.

6. Crankcase heater. 6m Check operation. The control should be in the 'ON' position atall times.

7. Compressor drive. 6m Check condition and alignment. If undue noise or vibration report to client.Drive belt replacement intervals need to beestablished.


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150 12-01 COMPRESSORS REFRIGERATION - Reciprocal - (includes hermetic, semi-hermetic and open)- continued


8. Compressor and bearingtemperatures.

6m Observe and include crankcase, sealhousing and cylinder surfacetemperature.

9. Safety cut-outs. 6m Test and ensure correct operation. Include high pressure cutouts, low pressurecutouts and oil pressure cutouts.

10. Refrigerant charge. 6m Check quantity and moisture contentat liquid level sight glass.

11. Noise and vibration. 6m Check for any abnormalities. Report to client if excessive.

12. Electric motor. 12m Lubricate according to manufacturer's (See also MOTORS)instructions. Check full load current.

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151 12-02 COMPRESSOR - SCREW


1. Non-return valve. 6m Dismantle and inspect.

2. Unloading gear. 6m Check that it is functioning correctly.

3. Oil de-mist pad (ifaccessible).

6m Inspect at intervals recommended bymanufacturer.

If necessary, take the appropriate correctiveaction.

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152

12-03 COMPRESSORS REFRIGERATION - CENTRIFUGAL - R 11/R 12 REFRIGERANTS OR THEIR SUBSTITUTES R123/134a. Note:- more frequent maintenance checks should be carried out by the plant operators and local maintenance personnel. ITEM FREQ. ACTION NOTES

1. Operation. 3m Check running conditions, oil pressure, purge unit operation, oil level and oil return system. Look for signs of leakage.

Note any unusual noises, check cooling tower operation.

2. Refrigerant charge. 3m

12m Check level and carry out leak test. Take sample for chemical analysis.

3. Holding down bolts. 3m Check compressor and motor holding down bolts and tighten if necessary.

4. Purge unit. 3m Check frequency of discharges. Count should be over a minimum of two cycles.

5. Controls. 3m Check oil pressure differential and chilled water temperature and flow rate.

These should be at the controller set point. Check that condenser water flow rates and temperature levels are within acceptable limits. Examine log to check that there is no evidence of fouled tubes or air on the refrigerant side.

6. Purge unit filter driers (if fitted).

3m Change in accordance with manufacturer's instructions.

7. Compressor oil.

12m

Take sample for analysis.


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153 12-03 COMPRESSORS REFRIGERATION - CENTRIFUGAL - R 11/R 12 REFRIGERANT OR THEIR SUBSTITUTES R123/134a - continued


8. Oil filter. 6m Change both filter and oil drier returnsystem.

9. Purge unit valves, valves andassociated equipment.


10. Float assembly. 12m Remove and flush shell. Clean theorifices.

Orifices are:-a) liquid supply to cooling coil,

b) gas pressure to pressure switch.

11. Oil return filter drier. 12m Change.

12. Foul gas supply filter. 12m Change.

13. Oil return eductor system. 12m Change the filter/drier, check eductortee is undamaged, clean. Clean dirtleg.

14. Main oil filter. 12m Change. Inspect thoroughly for evidence ofmetallic particles. Their presencewould indicate bearing damage.

15. Electrical and safety controls. 12m Check that they are workingsatisfactorily.

Pay particular attention to currentlimiting devices.

16. Condenser and evaporator. 12m Check water pressure drops.

17. Cooling tower. 12m Check settings of cooling tower fancontrols.

See HEAT REJECTION. Check watertreatment and make up supply. Cleanall water strainers.


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154 12-03 COMPRESSORS REFRIGERATION - CENTRIFUGAL - R 11/R 12 REFRIGERANT OR THEIR SUBSTITUTES R123/134a - continued


18. Motors - hermetic. 12m Carry out electrical insulation tests. Ensure that the liquid supply for cooling the motoris adequate. If appropriate remove filter andrenew. (See also MOTORS)

- open. 12m Check air impeller or water cooling coilis clean and efficient. Check motorand compressor alignment.

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15513-01 CONDENSERS - water cooled (See also MOTORS)


1. Compressor full loadoperation.

12m Record inlet and outlet temperature onwater side. Pressure drop acrosscondenser, head pressure and condensingtemperature.

Any marked difference to the design figurescould indicate internal fouling of the condenserand may require additional work.

2. Flow protectiondevices

12m Check.

3. Pump. 12m Check and record pressure drop acrosspump. Check for leakage, bearing noiseand unusual bearing temperature.Lubricate according to manufacturersinstructions. Check motor current.

4. Water strainers 12m Check and clean. On open systems more frequent cleaningwill be necessary. Check that condenser wateris sterile before opening any drains and valves.

Note: System could contain legionellabacterium. Technician should take suitableprecautions.

5. Condenser Tubes. 12m Check condition, if dirty open. If necessaryclean with acid treatment. Inspect foralkaline deposits and/or corrosion.

If tubes are heavily scaled, refer to watertreatment contractor for explanation as to whysystem is not effective. Acid can be used forscale removal by specialist if absolutelynecessary.


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15613-01 CONDENSERS - water cooled - continued


6. Condenser Shell. 12m Check for presence of non-condensable gases, purge or vent ifnecessary.

Presence of non-condensable gases willindicate a possible leak on the vacuum side ofthe refrigerant circuit. Take care not to releaseCFCs.

7. Isolating Valves. 12m Check external condition, leak tightnessof glands and seats, operationalspindles and handwheels.

Repack as necessary.

8. Winter Shutdown. 12m Isolate condensers and drain down. Seek advice from water treatment specialist toprotect from freezing.

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15713-02 CONDENSER - air cooled


1. Operating pressure. 3m Check pressure and pressure switchesusing gauges.

2. Solenoid valves. 3m Ensure that they do not by-pass. Compressor should not cycle on low pressure switch.

3. Head pressure controldevices (fan speedand sequencing)

3m Check operation. These could be three phase.

4. Motor Mountings. 12m Check for security and tightness. (See also MOTORS)

5. Condenser coil. 3m12m

Inspect and clean.Test for refrigerant leak and oil stainingon the end of the coils.

Check for damage to fins, comb out and chemicallyclean if necessary. Blow out with dry, oxygen freenitrogen.

6. Casing. 3m Clean and secure. Remove any rust spots and treat. Check fan guards.Ensure all bolts/screws etc. are in place and tight.

7. Sediment. 3m Remove, if substantial build up hasoccurred, investigate cause.

Substantial build up may indicate significant corrosionand cause should be identified.

8. Alignment and wear ofbelt drives, whereapplicable.

3m Check pulley alignment and belt wear. Drive belt replacement intervals need to beestablished.

9. Head pressure controldamper.

6m Lubricate control damper bearings.

10. Air Filters. 6m Check and replace if necessary.

11. Flexible Connections. 12m Check and repair/replace as necessary. Report faults to client.


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15813-02 CONDENSER - air cooled - continued


12. Electrical connections. 12m Check and tighten as necessary.Check condition of flexible conduits,wiring and insulation.

13. Pipework. 12m Inspect connections, pipes andsupports for damage, loose or missingfittings. Repair as necessary.

Report faults to client.

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15914-01 CONTROL PANELS

Introduction

When working on or testing Control panels it is essential that all local and national statutory regulations should be observed at alltimes. In the United Kingdom the Health and Safety at Work etc. Act 1974 and the Electricity at Work Regulations 1989 are particularlyrelevant. It should be noted that control panels having equipment operating above a nominal 415 Volts are excluded from this specification.This does not imply that safety precautions should not be taken when working on equipment above 415 volts.

Care should be taken to make sure that all remote circuits associated with the switchgear are positively isolated before any work is carriedout. The isolation should be 'secure' that is it should either be at the point of work or precautions should be taken to prevent anyone elseswitching on again when work is in progress. A circuit, whether power or control should never be assumed to be 'dead'. Voltage tests shouldalways be carried out with proven test equipment i.e. a voltage tester should first be checked on a known live source immediately beforeuse and again after use.

Whenever cables are disconnected from switchgear in the course of maintenance or replacement, ensure that the cables are suitablyinsulated and marked for identification for reconnection.

Visually inspect to ensure plant is operating as expected. Check that any meters fitted show a correct reading, and any timers are set at thecorrect times for operation. Check readings against a known source.

Controllers, electrical and pneumatic control equipment

Electronic controllers and pneumatic equipment may be found in control panels and details regarding maintenance schedules can be found inthe appropriate sections of this schedule.

Appropriate safety guides are as follows:-

HSE Guidance Note GS 38/1995, Electrical test equipment for use by electricians.HS(R) 25 - Memorandum of Guidance on the Electricity at Work Regulations 1989.HSG85 Electricity at Work: Safe Working Practices 1993.

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16014-02 CONTROL PANELS - electrical services (excluding electrical controllers and pneumatic relays)

Before commencing any maintenance work on control panels, read introductory notes, very carefully and follow all the safetyprocedures.


1. Panel exterior. 6m Check for any physical or mechanicaldamage. Door locks should be checked.

Any damaged equipment mounted on the frontshould be made safe and replaced as soon aspossible. Locks should be checked for correctsecurity and locking arrangements.

2. Mains isolator (alsocubicle isolator).

6m Inspect for correct mechanical andelectrical operation. Lubricate anymoving parts as required. Check correctoperation of door interlock mechanismand adjust if necessary.Clean out interior.

Physically check for security all mainsconnections. Examine both fixed and movingcontacts for wear or "pitting".Use only manufacturer's recommendedlubricants.Redress or replace contacts according to themanufacturer's instructions.Ensure that any mains "shrouding" is refittedafter the completion of the work.

3. Fuses. Ensure circuitsare dead beforecarrying out actions.

6m Inspect fuse carrier/fuse holder for signsof overheating. Check fuse rating andterminations for tightness. Apply greaseto fuse holder if required.

Replace if necessary and establish cause ofoverheating and rectify.

Value of fuse should be checked against thecircuit application and electrical load.

4. Circuit breakers. 6m Inspect for signs of overheating andreplace if necessary. Inspectconnections and tighten if necessary.Check operation by tripping or "test"facility, if fitted.

Establish cause of overheating andrectify.

Ensure value of breaker corresponds withcircuit application and electrical load.


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16114-02 CONTROL PANELS - electrical services (excluding electrical controllers and pneumatic relays) - continued


5. Residual currentdevices. (RCDs)

12m Test operation using test facility.

12m Carry out electrical test procedures perIEE Regs.

6. Power contactors. 12m Check contact for correct mechanical andelectrical operation.

Strip and clean interior.

Inspect and clean magnetic pole faces.Inspect shaded ring for damage andfixed and moving contacts for wear or"pitting".

Damaged contacts should be redressed orreplaced as necessary.

Use approved contact lubricant if recommendedby the manufacturer. (where fitted)

Inspect coil for overheating or insulationbreakdown.

Spring and contacts should be correctlypositioned and seated.

Clean out arc shutes on re-assembly:avoid damage or loosening of springs orcontacts, ensure correct mechanicaloperation and check all electricalconnections for tightness and security.


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16214-02 CONTROL PANELS - electrical services - continued


7. Starters. 12m Carry out maintenance as forpower contactors.

- direct on line.- star delta- two speed-dual wound- two speed-pole change- reversing- auto transformer

- quick transition, electricheater and electrolytetypes

8. Thermal overloads. 12m Inspect for signs of overheating. Replace if necessary after having establishedthe cause and rectified it.

Check electrical connections fortightness and security.

Inspect trip settings.

Operate the trip/test facilityensuring that the switchgear de-energises in a clean and positiveoperation.

Adjust if necessary to give correct protectionfor the connected load. Record settings.Check for single phasing protection byoperating the starter with one of the powerfuses removed.


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9. Magnetic overloads. 12m Inspect for signs of overheating.

Check electrical connections fortightness and security.

Check oil levels in dashpots andreplenish to correct levels ifneeded.

Completely replace dashpot oil at intervalsrecommended by the manufacturer.

Check "time" mechanism. Select correct dashpot drain hole if necessary.

Operate "test" facility ensureswitchgear de-energises in aclean and positive operation.

Inspect trip settings. Adjust if necessary to give correct protection forconnected load.

Check single phase protection. This is done by operating starter with one of thepower fuses removed.

10. Busbar systems. 12m Isolate supplies, inspect forsigns of overheating, or damageor burnt out cables.Inspect mechanical supportsystems and adjust fixings ifnecessary.

Check all cable crimps for security and fraying.Inspect crimp fasteners for correct torque rating.

11. Incoming power supplies. 12m Measure each line to earth andeach line to neutral.

Record readings and check that measuredvalues are within electricity supplier'sspecification.


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12. Panel wiring. 12m Inspect for signs of overheatingor burn marks.

Replace any suspectconductors.

Check all connections,terminations, earth cables andlinks for security and tightness.

Ensure cable connections aretight and correctly terminated.

Check that panel is correctlybonded to earth.

Test continuity and record readings.

13. Flash test. 36m Carry out within 1.5kV-3.0kVrange to detect potentialdeterioration of the system.

CAUTION - Care should be taken to isolatesensitive equipment.

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16514-03 CONTROL PANELS - lamps, meters, alarms etc.


Indicator lamps

1. Circuit. 6m Check and energise to ensurethat the indicator isoperational. Replace anyblown or discoloured bulbs asrequired.

Replacement bulbs should be of the correct typeand the voltage and power rating must be as perthe manufacturer's specification. A device of ahigher power rating should not be used.

2. Holder assembly. 6m Inspect for signs ofoverheating or electrical burnmarks.

3. Mains/low voltagetransformer (if fitted).

6m Examine for signs ofoverheating or insulationbreakdown.

Low voltage power packs - ac or dctypes.

1. Condition. 12m Inspect for signs ofoverheating.

2. Voltage input and outputtests.

12m Carry out and compare withmanufacturer's tolerance andoperational specifications.

Check polarity of outputs where necessary.

3. Load measurements. 12m Carry out, record and ensurethat the load taken from theunit is within themanufacturer's specification.


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16614-03 CONTROL PANELS - lamps, meters, alarms etc. - continued


4. Associated safety or tripdevices.

6m Check for correct operation.

Metering (Voltmeter)

1. Instrument. 6m Inspect and check for correctmechanical and electricaloperation.

Check actual reading, record and compare with areference voltmeter applied across the samecircuit.

2. Needle (pointer). 6m Check for free and correctmovement.

3. Zero setting. 6m Check and adjust if necessary.

Metering (Ammeter)

1. Instrument. 6m Inspect and check for correctmechanical and electricaloperation.

Check actual reading, record and compare with areference ammeter applied in series in samecircuit.

2. Needle (pointer). 6m Check for free and correctmovement.

3. Zero setting. 6m Check and adjust if necessary.


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Alarm integrator

1. Operation. 12m Inspect and check operation ofeach input channel.

2. Audible and visual alarms. 12m Check operation andindications including alarmcircuits if fitted.

Smoke alarm unit

1. Unit 12m Inspect; check operation byadjusting or operating alarmtest facility (if fitted).

2. Alarm setting. 12m Reduce setting and noteoperation of "smoke condition"

3. Maintenance. Carry out manufacturer's"testing and maintenance"procedures as required atstipulated frequencies.

General

1. Cleaning. 12m The interior of the control panelshould be cleaned.

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Ventilation

1. Grilles. 3m Inspect and check that allgrilles are free of anyobstructions, clean asrequired.

2. Fans (forcedventilation).

3m inspect and check operation offan unit;clean and replace filter unit asrequired.

All power and control circuits should be checkedfor functional operation against the wiringdiagrams relevant to the installation.

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16914-04 OPTIMISERPre-maintenance procedures.

This schedule applies to all types of controllers and requires that all safety precautions and safe working practices be observed.

1. Note all setpoints found.

2. Check mechanically for security of fixings, incoming cables, pneumatic pipework and terminal connections for tightness.

3. Visually check controller for signs of damage. (i.e. ingress of dust or moisture).

4. Check all power, pneumatic air and supply tolerances as per manufacturer's recommendation, and adjust as necessary.

5. Pneumatics. Pay particular attention to the quality of the instrument air. Check for contamination by dirt, water or oil.


1. Outside air temperaturesensor.

12m Check outside sensor forcalibration and display accuracy.

2. Inside air temperaturesensor.

12m Check inside sensor for calibrationand display accuracy.

3. Programme setting. 12m Check programme setting iscorrect.

4. Optimum stop/start operation. 12m Check operation by simulation. Refer to manufacturer's simulation procedures.Any on going problems can be highlighted by theuse of a thermograph.

5. Battery. 12m Check condition. Note life expectancy (use by date) and changeat manufacturer's recommendation. All batteriesshould be disposed of only in accordance withH&S and Environmental regulations.


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17014-04 OPTIMISER - continued


6. Output devices. 12m Check that output devicesrespond to command signals.

7. Energy savings. 12m Agree any changes with systemoperator that may enhanceenergy savings.

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17114-05 HEATING COMPENSATORPre-maintenance procedures.








1. Flow temperature sensor. 12m Check. Refer to sensor checking procedure.

2. Outside air temperaturesensor.

12m Check. Refer to sensor checking procedure.

3. Settings. 12m Check that settings are correct.

4. Output signal. 12m Check output signal and outputdevice operation.

5. Controllers. 12m Check and calibrate for correctrelationship between outsideand flow temperatures.

Refer to manufacturer's recommendedsimulation procedures.

6. System operation. 12m Check system under control forproper operation.

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17214-06 SINGLE INPUT CONTROLLERPre-maintenance procedures.








1. Input signal. 12m Measure value. Check that signal is representative of thecondition being monitored.

2. Settings. 12m Check for correct settings.


4. Controllers. 12m Check and calibrate. Refer to manufacturer's recommendedsimulation procedures.

5. Operation. 12m Check for correct operation.

6. Parameters. 12m Review as necessary.

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17314-07 UNIT CONTROLLERS AND SENSOR CONTROLLERSPre-maintenance procedures.








1. Input signal. 12m Check. Refer to sensor checking procedure.



4. Operation. 12m Check operation and calibrate. Refer to manufacturer's recommendedsimulation procedures.


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17414-08 CONTROLLER TIMERSPre-maintenance procedures.







Note: Timers are often built into the control panel. They can take the form of delay, run on, interval or combinations of all three. The timershould be checked with reference to the control strategy.Before commencing maintenance schedule carry out an operational check.


Electromechanical

1. Time settings. 12m Check time taken to complete operationagainst setting and adjust if required.

2. Operation. 12m Inspect and check operation. Adjust time to the required time setting for theparticular application and put into operation.

Electronic

1. Time settings. 12m Check time taken to complete operationagainst setting and adjust if required.

2. Operation. 12m Inspect and check operation. Adjust time to the required time setting for theparticular application and put into operation.


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17514-08 CONTROLLER TIMERS - continued


3. Battery. 12m Check condition. Note life expectancy (use by date) and changeat manufacturer's recommendation. All batteriesshould be disposed of in accordance withH&S Environmental REGULATIONS.

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17614-09 STEP CONTROLLERSPre-maintenance procedures.








Electromechanical

1. Operation. 12m Inspect and check bothmechanical andelectrical operation.

2. Cam setting/switch assembly. 12m Inspect and check each camsetting/switch assembly.

Adjust if necessary to suit the particularapplication.

3. Angular limit switches. 12m Inspect and check.

4. Drive motor/gear box. 12m Check operation in bothdirections.

Where actuators are involved see relevantsection.

5. Feedback potentiometer (iffitted).

12m Inspect and check.

6. Electrical interlocks. 12m Check any interlocks whichdisable outputs.

Include recycling where appropriate.


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17714-09 STEP CONTROLLERS – continued

ITEM FREQ. ACTION NOTESElectronic

1. Signal range. 12m Inspect and check each stepthroughout its signal range.

2. Step. 12m Check operation of each stepand the differential.

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17814-10 TIME SWITCHESPre-maintenance procedures.








Electromechanical

1. Clocks. 12m Check for satisfactory operationand correct time.

Adjust for British Summer Time/Greenwich MeanTime as necessary.

2. Operation. 12m Inspect and check bothmechanical and electricaloperation.

3. Tappets. 12m Inspect and adjust to requiredon/off operations.

4. Dial. 12m Rotate through one revolutionand check for free operation ofthe levers at the correct time.

Reset to correct day.

5. Monthly dial settings e.g. forsolar time switches.

12m Inspect and check. Replace battery at manufacturer'srecommendations. Batteries should be disposedof in accordance with H&S and Environmental

regulations.Continued on next page ..

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17914-10 TIME SWITCHES - continued


6. Reserve time facility (batteryif fitted).


Electronic

1. Time clocks. 12m Check for satisfactory operationand correct time.

Adjust time for British Summer Time/GreenwichMean Time as necessary.

2. Electrical operation. 12m Inspect and check.

3. Time settings in unit memory. 12m Check settings and adjust ifnecessary.

Settings could be time of day, month or year.

4. Time switch settings. 12m Check for correct installationwithin the memory for particularapplication. Add, delete oradjust if necessary.

5. Battery back up (if fitted). 12m Check condition. Replace battery according to manufacturer'srecommendations. All batteries should bedisposed of in accordance with H&S and Environmental requlations.

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18014-11 MULTI-INPUT CONTROLLERSPre-maintenance procedures.







This includes weather compensation, enthalpy comparison, cascade, low limit, etc.ITEM FREQ. ACTION NOTES

1. Input signals. 12m Check.


3. Output signals. 12m Check output signal and outputdevice operation.

4. Operation. 12m Check and calibrate controllerfor relationship between inputand output signals.

Refer to manufacturer's data sheet andrecommended simulation procedures.

5. System. 12m Check system under control forcorrect operation.


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18114-12 INDICATORS AND DISPLAYS


1. Input signals. 12m Check.

2. Switching differentials. 12m Check.

3. Calibration. 12m Check. Refer to manufacturer's data sheet andrecommended simulation procedures.

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18214-13 ALARM MODULES


1. Input signals 12m Check.

2. Switching differentials. 12m Check.

3. Calibration. 12m Check. Refer to manufacturer's data sheet andrecommended simulation procedures.

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18314-14 LEVEL CONTROLLERSPre-maintenance procedures.








1. Operation. (if test facilityfitted)


2. Media level. 12m Adjust level under control andnote operation of:-a)low level condition,b)high level condition, if fitted,c)calibrate as required.

3. Maintenance. 12m Carry out manufacturer'smaintenance procedures asrequired.

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18414-15 SPEED CONTROLLERSPre-maintenance procedures.








Electromechanical

1. Overheating. 12m Check for signs of overheating.

2. Speed setting. 12m Adjust and note speed variation of thedrive in the particular application.

Auto-transformer

1. Transformer. 12m Inspect for signs of overheating andinsulation breakdown.

2. Speed selector switch. 12m Operate and observe variation in thespeed of the drive in the particularapplication.

3. Air vents. 12m Check that they are clear.

4. Maintenance. 12m Carry out manufacturer's maintenanceprocedures.

Frequency may vary according tomanufacturer's recommendations.


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18514-15 SPEED CONTROLLERS - continued


Variable transformer

1. Transformer. 12m Inspect for signs of overheating andinsulation breakdown.

2. Variable setting. 12m Adjust variable setting of transformer andobserve variation in the speed of the drivein the particular application.

3. Air vents. 12m Check that they are clear.

4. Maintenance. 12m Carry out manufacturer's maintenanceprocedures.

Frequency may vary according tomanufacturer's recommendations.

Eddy current type

1. Controller. 12m Inspect and check for signs of overheatingand insulation breakdown.

2. Input signal. 12m Adjust and observe speed change in thedrive under the particular application.

3. Settings. 12m Check for both minimum and maximumsettings.Adjust as required.

4. Maintenance. 12m Carry out maintenance procedures strictlyin accordance with the manufacturer'sinstructions.


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18614-15 SPEED CONTROLLERS - continued

Electronic inverter type.WARNING:- Due to the very high voltages present within this type of controller it is essential that all safety precautions arestrictly followed. The equipment must only be serviced by competent and qualified personnel. The manufacturer's testing andmaintenance procedures including all safety precautions must be strictly followed.


Inverter type

1. Controller. 12m Inspect and check for any signsof overheating and breakdownof electronic components.

2. Signal. 12m Adjust in either manual orautomatic mode and observespeed change of the drive in thisparticular application.

3. Settings. 12m Check for minimum andmaximum speeds, adjust ifnecessary.

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18714-16 TRANSDUCERS - pneumatic to electronic and electronic to pneumatic


1. Input signal. 12m Check.


3. Operation. 12m Check and calibrate for correctrelationship between input andoutput signal.

Refer to manufacturer's recommendedsimulation procedures.

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188 16-01 DUCTING - Introduction

Ducting and air distribution When installed new ductwork should be clean and therefore not normally require internal cleaning. However during use over a number of years a slow build up of deposits could occur particularly at points where the velocity of the air reduces. Where filters are faulty, poorly installed or maintained more rapid build up of dirt will occur. In normal circumstances internal cleaning of ducts would not be part of this specification but where the situation calls for remedial action, say for example when previous maintenance was faulty or non existent, there has been a system usage change or the plant has been left idle for a considerable period, the client should be informed, with a recommendation that specialist cleaning should be undertaken as detailed in the HVCA Ventilation Hygiene Guide to Good Practice (see DUCTWORK CLEANING). Special cleaning requirements such as are necessary in the pharmaceutical, food and process industries are outside the scope of this specification and should be covered by special arrangements. In kitchen extracts systems where access doors have been specifically provided for duct cleaning purposes, the method and frequency of cleaning should be established and agreed with the client. Sensors in ducts When cleaning or working in ducts it is essential that all sensors or probes should be withdrawn from the duct to prevent any damage. Care should be also taken to prevent any damage to valves, linkages and other control devices which may be located in a duct. Where ducts are internally lined either for acoustic or insulation purposes inspection would normally only be carried out if access doors are provided.

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189

16-02 DUCTWORK SYSTEM - general

Note:- Special requirements are necessary in the food and process industries, clean room applications and kitchensITEM FREQ. ACTION NOTES

1. Access doors. 12m Inspect for any loose panels andsecure.

2. Flexible connections. 12m Check for condition, leaks and securefittings.

Where provisions are made for access.

3. Insulation. 12m Inspect for any damage ordeterioration.

Report to client if remedial work required.

4. Anti-vibration mounts. 12m Inspect for permanent set (in springs). If renewal required, report to client. If replacedensure that the correct type is used.

5. Internal cleanliness. 12m Check internal condition throughsampling points (test points) wherefitted.

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19016-03 DUCTING - VOLUME CONTROL DAMPERS AND FIRE/ SMOKE DAMPERS

CautionAll volume dampers are set up during commissioning and should not normally be subject to further adjustment unless modifications aremade to the ductwork distribution system. If it is essential to move the damper for maintenance purposes extreme care should be takento ensure that the damper is returned to the position as set when commissioned. In the event of a ductwork modification, the systemshould then be re-commissioned.

ITEM FREQ. ACTION NOTES1. Volume control

dampers.6m Check position and ease of

movement and security of lockingdevises.

Ensure that damper opens and closes to desiredpositions.

2. Fire and smokedampers.

6m Check action and proper operation.Inspect all dampers, apply a fewdrops of oil to the mechanism.Replace fusible links if required.

These may be subject to local fire requirements.Maintain a log of all dampers tested, recordfaults and any remedial action taken. This willprovide proof to the fire system inspectors thatregular checks are maintained. If any fire dampersare inaccessible advise client.

3. Linkages on motoriseddampers.

6m Check for wear and lubricate ifappropriate.

Ensure that blades on shaft are secure and arecorrectly aligned.

4. Controls. 6m Check condition and operation. Calibration }Interrogation }Control Adjustment }


5. Electrical. 6m Check for damage to flexibleconduits. Tighten all terminalconnections. Isolate control paneland inspect for signs ofoverheating. Check integrity ofelectrical insulation.

For detailed maintenance information see CONTROLPANELS.

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19116-04 DUCTING - Acoustics


1. Attenuators 12m Inspect internally where access forinspection is provided. Repairsurfaces of sound insulation wherenecessary.

The facings should be inspected to ensure thatany loose fibre does not enter the system.Report on further action needed.

2. Support fixings. 12m Check and ensure that all fixings aresecure.

3. Attenuators (externalsurfaces).

12m Clean, derust and repaint as required. For attenuators on COOLING TOWERS seerelevant section.

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19217-01 DUCTWORK CLEANING – HYGIENE, INSPECTIONS & MONITORING

Note:- H&S Regulations apply and specific Risk Assessments will be required.ITEM FREQ. ACTION NOTES

1. Ductwork. 12m Ascertain age and date of last clean

2. Ductwork Hygiene. 12m Check internal condition by a DepositThickness test or Vacuum Test.

See HVCA Cleanliness of Ventilation Systems –ref. TR/17.

If inspection indicates a full cleaning regime isrequired, inform client.

3. Kitchen Extract Ductwork. 12m Totally Clean. This is minimum cleaning interval, heavy use i.e.12-16 hours per day will necessitate a 3 monthlyclean.

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19318-01 ELECTRICS IN BUILDINGS

Introduction

1 Specification

The specification covers the subjects of power supplies and associated electrical equipment up to 415 V, lighting, security and fire alarms,small scale power generation and communication systems and provides an authoritative maintenance specification for these types ofequipment. Regular preventative maintenance is essential on electrical equipment as breakdowns can affect production, environmentalconditions and energy wastage.

The maintenance frequencies shown in the schedules represent the intervals as recommended by the HVCA and ECA, the actualfrequencies will depend upon the particular application and should be agreed with the client. It may be appropriate that certain elements ofthe maintenance programme should coincide with planned shutdowns.

2. Safety

Fire prevention. Where electric cables pass through cabinets or walls it is standard practice to fit seals to prevent the passage of smoke orflame. When maintaining cables, cabinets or junction boxes it is essential that the integrity of the seals is maintained. Where a seal isreplaced, it should comply with the latest regulations.

Calibration of test equipment. The maintenance contractor should ensure that any test equipment has been checked in accordance with therelevant British Standard.

3. Electrical Equipment

Attention is drawn to the necessity to comply with the requirements of the current Electricity at Work Regulations in all aspects of workassociated with the maintenance of electrical apparatus. Particular attention is drawn to section 14.

All electrical equipment must be capable of local isolation and should be selected and erected in accordance with BS 7671 - Regulationsof the Institution of Electrical Engineers (IEE Regulations).

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1944. Maintenance of Systems

The maintenance activity in respect of a system should be carried out by suitably qualified and experienced staff, capable of exercisingprofessional standards of judgement and discretion in relation to individual systems. The specification is a statement of typical standards,and further reference to manufacturers should be sought for detailed guidance to supplement the specification.

There may be circumstances where maintenance is required on plant where operation is continuous, i.e. industrial processes,ventilation equipment, environmental control, computer installations or special situations. It is essential that in thesecircumstances control circuits etc. should not be isolated or operated until specific instructions are received from the client.

Although polychlorinated biphenyls (PCB’s) (e.g. Pyrachlor and Askeral) are not longer used in modern electrical equipment they may bepresent in older equipment, such as transformers and capacitors. Extreme care should be taken with regard to their disposal and theappropriate statutory regulations should be strictly followed.

5. Maintenance in Hazardous Areas

Certain areas such as those containing flame proof equipment, pharmaceutical laboratories, locations subject to possible contamination byradiation, clean rooms, high risk fume cupboards and inflammable risk situations call for specialist maintenance procedures which should benegotiated individually with the client.

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19519-01 EVAPORATORS


Shell and tube

1. Tank/shell. 12m Check external and internal conditionincluding baffles and covers.

Liquid level for water cooling, brine or glycolsystems should be noted and any leaksinvestigated.

2. Valves and drains. 12m Check external condition, leaktightness of glands and seats. Ensurevalve caps are tight and secure.Check operation.

3. Pipes and connections. 12m Check external condition and leaktightness.

4. Bearers, supports,holding down bolts.

12m Check for security and tighten asnecessary.

5. Insulation. 12m Check for damage.

6. Frost Protection. 12m Check regime including cables andthermostats.

Coil direct expansion (DX)

1. Leaks. 6m Inspect for leaks.

2. Coil. 6m Check condition and clean fins. Use a sterilising solution.

3. Condensate tray anddrain.

6m Check and ensure drain clear. Flushand sterilise if necessary.

4. Condensate pump (ifapplicable)

6m Check operation. Often this equipment may be contaminated, cleanand flush, sterilise if necessary.

5. Electric Heaters. 6m Check condition and operation.

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19620-01 FANS - Introduction

Movement of air, other than by natural circulation, is achieved by means of fans which are mechanically driven, hence before working onany fan the drive should be electrically isolated in accordance with Health and Safety legislation.

Types of fan covered in this section include centrifugal, axial, propeller, mixed flow, bifurcated and fire and smoke extract units. Because oftheir specialist nature and the hazardous circumstances of use, fans associated with fume cupboards, radioactive and nuclear facilities andbiological and clinical areas require specialist attention which is outside the scope of this specification.

Health and Safety

1. Access and Guards

It is dangerous to remove or open access doors, shaft guards, belt guards or remove any section of the fan casing whilst the fan is running. Itshould be noted that any fans which are supplied as bare shaft units must be guarded to BS 5304 before start-up.

2. Erosion and/or Corrosion

Where fans operate in an erosive or corrosive atmosphere, the fan rotating assembly must be inspected at regular intervals (not exceedingsix months) as dictated by plant operating conditions to ensure safe operating conditions.

In addition to checking for component wear, an additional visual check should cover welds. If cracking appears or is suspected, detailed non-destructive testing (NDT) of all impeller welds should be carried out immediately. If cracking is confirmed the wheel should be removed fromservice for repair or replacement.

3. Access

Where fan access cannot be readily obtained, it is the responsibility of the client to provide access facilities which comply in full with therequirements of any Health and Safety at Work legislation.

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19720-02 FANS -VENTILATING - general

The instructions in the table below refer to all air handling fans including exhaust, make up, recirculation and small air handlers.Before working on any moving machinery switch off and ensure that the equipment is isolated electrically in accordance with Health andSafety at Work legislation.


1. Bearings. (`sealed for life'bearings should not beserviced).

6m Inspect and lubricate as necessary. Check bearings for end play and wear.

2. Housing. 6m Clean and inspect for looseness andcorrosion.

3. Drives and belts. 6m Inspect, check condition andalignment of drive and shaft. Adjust orreplace if condition warrants it.

4. Fan wheels. 6m Check and clean. Inspect fortightness.

Check fan rotation.

5. Sheaves and bearingcollar.

6m Check tightness.

6. Mounting bolts. 6m Check and tighten as necessary.

7. Anti-vibration mountings. 6m Check effectiveness.

8. Guide vanes. 6m Check operation and adjust asnecessary.

9. Automatic change overcontrol (where standbyfan installed).

6m Check operation of control switch.

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19820-03 FANS -CENTRIFUGAL


1. Impeller and spinnings. 12m Clean and ensure no build up of dirt. In very dusty environments or wherecontaminants are present more frequent cleaningmay be necessary. If possible avoid scraping butif necessary carry out lightly. With plasticimpellers soapy water is the most effectivecleaner.

2. Motor assembly. 12m Inspect.

3. Motor bearings.(`Sealed for life' bearingsshould not be serviced).

Lubricate with recommended lubricantat intervals noted on fan nameplate.

When carrying out lubrication it is essential thatevery trace of water or dirt is removed fromaround the grease nipple. (See also MOTORS)

4. Fan bearings. 6m Lubricate/grease as necessary. For continuous running more frequent servicingmay be required. Do not overpack with grease.

5. Belt drive (if fitted). 6m Check tension and adjust if necessary.Replace if aligned condition warrantsit.

Ensure motor and drive and pulley are correctlyaligned otherwise excessive wear will occur onthe sides of the belt.

6. `Triggering' device, i.e.humidistat or vane typeflow switch.

6m Check for satisfactory functioning. Vane type flow switch can be activated byrestricting airflow through the motor side inlet ofthe unit.

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199 20-04 FANS- AXIAL - Fixed and/or variable pitch


1. Impeller. 3m Clean and ensure no build up of dirt. In very dusty environments or wherecontaminants are present more frequent cleaningmay be necessary. If possible avoid scraping butif necessary carry out lightly. With plasticimpellers soapy water is the most effectivecleaner.

2. Motor bearings. (`Sealedfor life' bearings shouldnot be serviced).

3m Lubricate with recommended lubricantat intervals noted on fan nameplate.

When carrying out lubrication it is essential thatevery trace of water or dirt is removed fromaround the grease nipple. (See also MOTORS)

3. Belt drive (if fitted). 3m Check tension and adjust if necessary.Replace if condition warrants it.

Ensure motor and drive and pulley are correctlyaligned.

4. Flexible conduitconnections and wiring.

6m Check for soundness and ensureterminal connections are secure.Check integrity of electrical insulation.

5. Belt guards (where fitted). 6m Check these are free from dirt buildup, if necessary, clean.

6. Impeller, variable pitchmechanism.

6m Check that there is no excessivemovement at the wing root.

There should be no loss of grease from wingroots. If there is, impeller must be dismantledand seals replaced after lubricating bearings.


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200 20-04 FANS- AXIAL - Fixed and/or variable pitch - continued


7. Adjustable pitchactuation.

12m Check correct operation. The impeller should operate with smoothmovement over the full pitch angle range with thefan running. If faulty, report to client for furtheraction.

8. Non return flap (wherefitted).

6m Check operation.

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201 20-05 FANS – PROPELLER - Direct driven

ITEM FREQ. ACTION NOTES1. Impeller. 6m Clean and ensure no build up of dirt. In very dusty environments or where

contaminants are present more frequent cleaningmay be necessary.

2. Motor bearings. (`sealedfor life' bearings shouldnot be serviced).

6m Lubricate with recommended lubricant. If lubricators are provided, re-lubrication shouldnot exceed a period of two years. When carryingout re-lubrication it is essential that every trace ofwater and dirt is removed from around the greasenipple. (See also MOTORS)If the operating temperature is over 60oC ashorter re-lubricating period will be necessary,see manufacturer's instructions.

3. Mountings and fittings. 6m Check security of fixing.

4. Flexible conduitconnections and wiring.


5. Non-return flap (wherefitted).

6m Check operation.

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20220-06 FANS-MIXED FLOW - Direct or Belt driven


1. Impeller and spinnings. 6m Clean and inspect. Take care not to disturb impeller balance weights.Cleaning is best carried out with warm soapy waterusing soft brush. Other cleaners may be usedprovided they are not harmful to the paint orgalvanised finish.

2. Motor bearings. (‘sealedfor life' bearings shouldnot be serviced).

6m Lubricate with recommendedlubricant.

If lubricators are provided, re-lubrication should notexceed a period of two years. When carrying out re-lubrication it is essential that every trace of waterand dirt is removed from around the grease nipple.

If the operating temperature is over 60oC a shorterre-lubricating period will be necessary, seemanufacturer's instructions. (See also MOTORS)

3. Drive belts. 6m Check tension and examine forwear. Replace if necessary.

4. Protection guards andautomatic shutters.

6m Clean and check shutter blades forease of action.

In dirty or moist laden environment more frequentinspection and cleaning may be necessary.

5. Flexible conduitconnections and writing.

6m Check for soundness and ensureterminal connections are secure.Check integrity of electricalinsulation.

6. Roof cowl intake/wallentry louvre (whereapplicable).

6m Clean and check mounting.

7. Non return flap. 6m Check operation.

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20320-07 FANS-BIFURCATED

Note:- This type of fan, axial with the motor outside of the airstream, is normally used for fume extracts e.g. kitchens, fire and smokeextraction and for fume removal particularly where corrosive.


1. Unit. 3m Check operation.

2. Fan impeller. 3m Check condition and clean. If handling abrasive or corrosive materials,examine the blades for wear or damage.In kitchen operations e.g. fat and oil frying,regular cleaning will be required.

3. Lubrication. (`Sealed forlife' bearings should notbe serviced).

3m Check and lubricate if necessaryaccording to the manufacturer'sinstructions.

If working in a high temperature environment,more frequent lubrication may be necessary.

4. Standby motor (whereprovided).

3m Check and rotate a few turns by handor electrically.

Units designed for emergency use should be testoperated for no longer than twenty minutes.

(See also MOTORS) 5. Flexible conduitconnections and wiring.


6. Belt drive (if fitted). 6m Check wear, alignment and tension. Replace if cording becomes visible.

7. Automatic shutters(usually fitted on roofunits).

6m Clean and check operation. In moist or dirty environments more frequentservicing may be required.

8. Anti vibration mountings. 12m Check condition.


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20420-07 FANS-BIFURCATED - continued


9. Ductwork including fixingsand insulation (wherefitted).

12m Inspect external condition and report. With kitchen extracts heavy deposits of greasemay be encountered and more frequentinspection will be necessary and client should beinformed of fire risk and a schedule of cleaningdrawn up. See DUCTWORK HYGIENE.

10. Motor. 12m Check full load current and log.

11. Bearings. 12m Check for wear. Remove oil/greaseand clean.

Report if replacement bearings necessary.

12. Micro switches onautomatic shutters.

12m Check operations, reset if necessary.

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20520-08 FANS-EXTRACT - including fire/smoke extracts units, water-cooled and kitchen exhaust.


General

1. Controls. 6m Check correct action. For detailed maintenance refer to relevantsection.

2. Motorised controldampers.

6m Check operation. Refer to design manual for details.

3. Electrical connections. 6m Check all flexible connections andelectrical insulation.

4. Fan and motor. (`Sealedfor life' bearings shouldnot be serviced).

6m Lubricate according to manufacturer's See also MOTORSinstructions.

5. Fan impeller and scroll. 6m Check condition.

6. Motor casing and louvers. 12m Check condition and clean.

7. Anti vibration mountings(where fitted).

6m Check mountings, belts and fixings forsecurity.

8. Non return flap (wherefitted).

6m Check operation.

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20621-01 FILTERS

Introduction

Removal of dust and other non-gaseous matter in airborne streams is carried out by some form of filter or device such as electrostaticprecipitation. Where the air passes through the filter a back pressure is set up which increases as the pores of the filtration medium becomefilled with the particles removed from the air stream, the dirtier the air stream the more quickly the back pressure builds up and the morefrequently the filter has to be cleaned or changed. The maintenance periods given in the tables below refer to average air conditions, in adirty environment more frequent maintenance will be required.

When replacing filters the same grade of filter should be used unless the client specifies differently. Failure to do this or fitting filters of alower specification will lead to poor performance e.g. black markings on ceilings and near grilles. Ineffective filters will mean that FAN COILSwill require more frequent cleaning and accumulation of dust and debris in the ventilation system could give rise to a fire hazard and clogautomatic fire dampers.

Filter replacements should comply with Eurovent 4/5

In normal use air filters do not present a health and safety hazard. However used air filters do contain quantities of dust which, unlessprecautions are taken, may expose maintenance personnel to a `nuisance dust hazard', as defined by the Control of SubstancesHazardous to Health (COSHH) Regulations. A risk assessment must be carried out before the work starts and a method statementproduced. PPE may be needed.

Types of filters covered in this section include roll band, disposable panel, re-usable/disposal, bag, cartridge and electrostatic. Because oftheir specialist nature and the hazardous circumstances of their use certain filters require specialist attention which is outside the scope ofthis specification. These include active carbon, cyclonic and inertia filters, wet and dry dust collectors and filters associated with fumecupboards, radioactive and nuclear facilities and biological and clinical areas.

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207 21-02 FILTERS

Note: - In normal use air filters do not present a health and safety hazard. However used air filters do contain quantities of dust which, unless precautions are taken, may expose maintenance personnel to a `nuisance dust' hazard, as defined by the `Control of Substances Hazardous to Health (COSHH) Regulations'. A risk assessment must be carried out before the work starts and a method statement produced. PPE may be needed. Used filters should be sealed into plastic bags for disposal. Environmental REGULATIONS apply.


a) Filters (common procedures)

12m

1. Air flow. 12m Stop any air flow to filter.

2. Removal. 12m On removal take care that trapped dust remains in the filter medium.

3. Filter housing. 12m Thoroughly clean including surrounding ductwork and floor.

4. Housing. 12m

Inspect for damage and/or corrosion.

5. Replacement. 12m Ensure that edges are adequately sealed to prevent ingress of dirty air.

Spare fillers should not be unpacked until required. Replacement is required when air volume flow drops to 0.5” above initial settings.


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20821-02 FILTERS - continued


b) Filters (disposable)

1. Filter elements. 12m Remove and replace atmanufacturer's recommendedfinal airflow pressure. Ensurethat any spillage or dust isvacuumed away.

Filters may have to be removed more frequentlydepending upon site conditions and operating hours.After removal, used filters should be sealed into plasticbags for disposal.Do not attempt to wash or clean out and reuse.

2. Seals and/or fasteners. Ensure that any damaged sealsor fasteners are replaced.

c) Reusable (cleanable) filters

1. Filter elements. 12m Clean and replace as permanufacturer'srecommendations.

Filters may require more frequent cleaning where theatmosphere is heavily contaminated with dust or fume.When cleaning care should be taken to avoid damage tothe filters either mechanically or by the use ofaggressive solvents. Usually hot soapy water or anapproved cleaning liquid is adequate.

2. Kitchen extract greasefilters.

12m Remove and clean as permanufacturer'srecommendations.

Frequency of cleaning can vary from daily to weeklyintervals. Generally for grease filter panels the use of acommercial dishwasher is possible. Failure tochange/clean filters when loaded with grease mayresult in the carry over of grease into the ducting -thus leading to an increased hazard of a flash overfire to the main ductwork. See DUCTWORKHYGIENE.


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20921-02 FILTERS - continued


d) Absorption type

1. Damage and corrosion. 6m Check and report if found.

2. Filter cartridge. 6m a) check fitting which should betight.b) replace if necessary. Frequency of changing will depend upon the

environment in which the filter is used.

e) Automatic roll band type

1. Damage. 6m Check and report if found. If found to be high this may indicate either bandvelocity is too low or wrong specification.

2. Differential pressure. 6m Measure.

3. Operation. 6m Check for correct operation.

f) Grease filters

1. Condition. 6m Check and clean. The frequency of cleaning will depend upon thedegree of contamination. Failure to change/cleanfilters when loaded with grease may result in thecarry over of grease into the ducting - thusleading to an increased hazard of a flash overfire to the main ductwork. See DUCTWORKHYGIENE.

g) High efficiency - HEPA The maintenance activities for these depend on theindividual installation operating conditions.Reference should be made to the design/operatingmanuals for the building.

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210 21-03 ELECTROSTATIC FILTERS

Note: - In normal use air filters do not present a health and safety hazard. However used air filters do contain quantities of dust which, unless precautions are taken, may expose maintenance personnel to a `nuisance dust' hazard, as defined by the `Control of Substances Hazardous to Health (COSHH) Regulations'. A risk assessment must be carried out before the work starts and a method statement produced. PPE may be needed. Used filters should be sealed into plastic bags for disposal. Environmental REGULATIONS apply


1. Electrical

a) powerpack, 1m Check for correct operation. This should be a daily task for the operator.

b) rectifiers, 1m Check for operation and follow manufacturer's instructions.

Rectifiers fail either through filament burn out or loss of vacuum when the current will flow in both directions leading to shorting.

c) isolation, 1m Isolate electrically in accordance with HASAWA recommendations.

d) ionising wires. 1m Check condition and if broken replace immediately

Broken wires can cause a short circuit.

2. Mechanical

a) cells. 1m Wash according to manufacturer's instructions.

Frequency of cleaning will depend upon the dirt picked up, every four to six weeks is suggested. If the cells are not cleaned regularly dust will eventually build up to a thickness where some is dislodged and blown over.

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21122-01 FIRE ALARM SYSTEM

Note: All tests on equipment and trigger devices should be recorded in the log book. Due to the variety and complexity of fire alarms andassociated systems they are not dealt with in detail in this specification but the table below indicates the minimum requirements. Specialistback up may be required either from the manufacturers or specialist contractors especially in connection with intelligent systems.


1. Operation. 3m Check operation of all soundersand external alarm links.

This action should include auxiliary functionssuch as links with the main gas valve, vent plantand all fault warnings.

2. Condition. 3m Check condition of equipmenti.e. ingress of moisture, damageor other signs of deterioration.

The building occupier should inform themaintenance engineer of any structural oroccupancy changes which might affect the sitingor operation of the detector.

3. Fireman's control for ventplant.

3m Check operation and logoperation of fans and dampers.

4. Wiring and equipment. 12m Visually inspect for damage andintegrity.

5. Detectors including photocells.

12m Check operation in accordancewith the manufacturer'srecommendations.

Inspect heat detectors for damage or othercondition, such as a heavy coat of paint.

6. Emergency manual operatedsystems.

3m Test operation. These devices should be tested frequently byclients' operators.

7. Completion of test. 3m Reset all plant and gas valvesafter test.

8. System test. 36m Test in accordance with therelevant regulations and rectifyany defects.

BS 5839 should be followed.

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212 22-02 FIRE ALARMS - Associated Equipment

TESTING: The client should carry out tests on equipment on a weekly basis in accordance with the local fire regulations. Note: When carrying out maintenance any defects should be reported to the client. ITEM FREQ. ACTION NOTES Break glass boxes 1. Casing and glass front. 12m Check mounting of casing and

replace if cracked. Check operation.

Sounders 1. Decibel level. 12m Check (see notes). The time period for checking sounders should be

agreed with the client. Refer to BS5839: Part1:1988.

Sensors 1. Condition. 12m Check exterior and clean. Check and monitor according to manufacturer's

instructions. WARNING: Ionisation detectors emit radiation, refer to manufacturers data. See SENSORS.

2. Connections. 12m Check condition and make good if necessary.

3. Beam detectors in ducts. 12m Check condition and clean. Frequency will depend upon environmental conditions and should be agreed with the client.

4. Mounting. 12m Check security. Batteries 1. Condition. 12m Check condition and life. Check according to the manufacturer's

recommendations. All batteries should be disposed of in accordance with environmental and H&S requirements, .

Chargers Continued on next page

See POWER GENERATION.

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21322-02 FIRE ALARMS - Associated Equipment - continued

Note: When carrying out maintenance any defects should be reported to the client.ITEM FREQ. ACTION NOTES

Shutters

1. Operation. 12m Check and ensure actionresponds to appropriate signals.

2. Indicator light. 12m Check operation and replaceany faulty lamps.

Drop fire curtains

1. Condition. 12m Check for mechanical damage. See relevant section – SMOKE EXTRACT.

2. Operation. 12m Check operation and controlmechanisms.

Magnetic door latches

1. Condition. 12m Check for mechanical damage. See relevant section – SMOKE EXTRACT.


Smoke relief vents

1. Condition. 12m Check for mechanical damage.


See relevant section – SMOKE EXTRACT.

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21422-02 FIRE ALARMS - Associated Equipment - continued

Note: When carrying out maintenance any defects should be reported to the client.ITEM FREQ. ACTION NOTES

Interlocks

1. Condition. 12m Check for mechanical damage. Interlocks will be with heating, ventilating andcooling equipment and with fire extinguishingand other systems , i.e. SMOKE CURTAINS.


Connection to Alarm Centre

1. Operation. 12m Check function. Inform Alarm Centre before check is made.

Indicator panel

Including remote indicator lamps. 12m Check operation of lamps andreplace any failed lamps.

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215

23-01 FIRE PROTECTION SYSTEMS

Introduction

The need for preventive maintenance on fire prevention systems is essential but in negotiations between contractor and client is vital thataspects of insurance, liability, compliance with regulations etc. are fully agreed by both parties. Both the Loss Prevention Councilrequirements and local fire regulations must be complied with and should any areas of doubt arise it is recommended that these be fullydiscussed with the appropriate representative of the fire prevention bodies.

It is the duty of the contractor to ensure that he has taken out adequate insurance cover to meet all the liabilities and requirements associatedwith the maintenance of fire protection systems and the client should satisfy himself on this account.

Compliance with the relevant fire regulations is necessary for both the client and the contractor and close liaison with the local fire protectionofficer should be maintained at all times.

The Loss Prevention Council (now part of the BRE) has issued a comprehensive schedule of fire prevention measures and these should beadopted by both the client and the contractor.

Sprinkler systems have not been included due to the complexity and variety of design, reference should be made to the Care & Maintenanceof Automatic Sprinkler Systems (TB6 1990.1) published by LPC.

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216

23-02 HOSE REELS PRESSURE BOOSTING SETS

If, due to unforeseen difficulties, an installation is left unavailable for use, the fire brigade should be informed and after reinstatement againinformed.


1. Pump base andconnections.

3m Ensure pump base is level andpipework not strained.

Check that anti-vibration mountings are satisfactory andvibration is not being transferred to the pipework.

2. Strainer elements. 3m Clean.

3. Pump and motoralignment.

3m Check and adjust if necessary. Examine couplings for tightness.

4. Motor and bearings. 3m Oil or grease where external nipplesor lubricators are fitted.

Use recommended grade of lubricant. Motor should beoverhauled annually, see - MOTORS.

5. Drain holes, pipesand tank.

3m Clean and ensure that all blockagesare cleared.

6. Guards and shields. 3m Check for security and safety. Adjust if necessary.

7. Automatic and handoverride controls.

3m Open the highest hose reel nozzleson each rising main to ensure thatset starts automatically. Check handoverride controls. Rectify any faults.

Report any defects to client and fire brigade.This test should be carried out at least once per monthby the operator or caretaker.

8. Pumps and valves. 3m Check to ensure that all pumpsreach their design closed valvepressure and all pump isolatingvalves are left in the open position.

Check against pump manufacturer's specification.


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21723-02 HOSE REELS PRESSURE BOOSTING SETS - continued


9. Hydraulic accumulator (iffitted).

3m Inspect and check gascushion pressure.

Ensure diaphragms are sound.

10. Test run pressurebooster sets,pressurising units, andfilling pump.

3m Carry out adjustments toensure satisfactory operation.

Check operation of all automatic controls and change-over switches, including signal to BMS if fitted.

11. Duty pump failed alarm. 3m Simulate duty pump failure. Reset after test, ensure that alarm is transmitted toauthorised recipient.

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21823-03 HOSE REELS - Static or Swinging

If, due to unforeseen difficulties, an installation is left unavailable for use, the fire brigade should be informed and after reinstatement againinformed.


1. Condition. 12m Completely run out reel,inspect and subject tooperational water pressuretest.

2. Back flow preventiondevices (check valves).

12m Check operation. Ensure that valve is seating properly.

3. Couplings. 12m Check and during wet testingcheck for leakage.

4. Swivel joints (swinginghose reels).

12m Check swinging movement isfree, condition of 'O' rings.

If leakage is evident replace 'O' rings.

5. Nozzles. 12m Check functioning.

6. Associated equipmentand fittings.

12m Ensure glands, tubing andshut-off nozzle are sound andfree from leaks. Check outletof nozzle is unobstructed.

7. Flow test. 12m Test in accordance with therequirements of the LossPrevention Council.

If it is not possible to test every reel, at least the highestreel on each rising main should be tested.

8. Accessibility. 12m Check and report to clientimmediately if there are anyobstructions.

Hose reels and any associated equipment should beaccessible at all times.

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21923-04 RISING FIRE MAINS and HYDRANTS


Dry1. Inlet and landing

boxes.6m Check a) inlets,

b) landing valves,c) drain valves,d) door hinges, ande) locking arrangements.Report any defects.

Special attention should be given to all valves, spindles,glands, and washers to ensure that they are in satisfactorycondition so that all equipment is ready for immediate use.When defective valve assemblies are removed, they shouldbe immediately replaced either with the replacement valve,or plugged or blanked off so that the system remainsoperative.

2. Wet test. 12m Check for leaks.

Wet1. Inlet and landing

boxes.6m Check a) inlets,

b) landing valves,c) drain valves,d) door hinges, ande) locking arrangements.Report any defects.

Special attention should be given to all valves, spindles,glands, and washers to ensure that they are in satisfactorycondition so that all equipment is ready for immediate use.When defective valve assemblies are removed, they shouldbe immediately replaced either with the replacement valve,or plugged or blanked off so that the system remainsoperative.

2. Storage cistern andtanks.

6m Check cleanliness andcondition.

3. Booster pumps. 6m Thoroughly check pumps andassociated mechanical andelectrical equipment.

For more detailed instructions see PUMPS.

Hydrants1. Condition.

12m Check for visible damage, orsigns of corrosion.

Report to client if remedial work necessary.

2. Caps and valves. 12m Check for ease of movement. See notes above in respect of landing boxes.

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22023-05 HALON FIRE PROTECTION SYSTEMS

HALON is a chlorofluorocarbon and as such is being phased out of general use and is being replaced by INERGEN because of’ thedamaging effect HALON has on the upper atmosphere It is essential that leaks should be prevented and residual material not dischargedto the atmosphere. The client/user of the system should check weekly, all pressure gauges, control settings and indicators. Such systemsshall only be maintained and tested by qualified engineers as per the requirements of BS 5306: Part 5.

ITEM FREQ. ACTION NOTES1. System. 6m Check generally for mechanical

damage.2. Cylinders. 6m check labels are securely fixed

and legible,check security of brackets andfixings,check liquid level,

check pressure in cylinder(s).

Level is checked by weighting, if weight lossexceeds 5% cylinder should be replaced orrecharged.If pressure has fallen more than 10% on atemperature corrected basis, cylinder should bereplaced or recharged.

3. Nozzles. 6m Examine for blockages and cleanas necessary.

4. Valve actuators. 6m Where possible, remove cylindervalve and replace action caps.

Carry out procedure in accordance with themanufacturer's recommendations.

5. Master/slave system. 6m Check slave actuation systemincluding pistons in pneumaticvalve actuators.

6. Mechanical integrity. 6m Test for mechanical tightness ofpipework and associatedequipment.

This is to prevent leakage of HALON.

7. Auxiliary electric device/alarm, door closures, etc.

6m Test operation. Operational test to be carried out in accordance withmanufacturer's recommended procedure.

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22123-06 CARBON DIOXIDE TOTAL FLOODING FIRE EXTINGUISHING SYSTEM

The client/user of the system should check weekly, all pressure gauges, control settings and indicators. Such systems shall only bemaintained and tested by qualified engineers as per the requirements of BS 5306: Part 5.


1. System. 6m Check generally formechanical damage.

Report to client any defects or incorrect installation.

2. Cylinders. 6m check labels are securelyfixed and legible,check security of bracketsand fixings,check liquid level,

check pressure in cylinder(s).

Level is checked by weighing, if weight loss exceeds5%, cylinder(s) should be replaced or recharged.If pressure has fallen more than 10% on a temperaturecorrected basis, cylinder(s) should be replaced orrecharged.

3. Nozzles. 6m Examine for blockages andclean as necessary.

4. Valve actuators. 6m Where possible, removecylinder valve and replaceaction caps.

Carry out procedure in accordance with themanufacturer's recommendations.

5. Master/slave system. 6m Check slave actuationsystem including pistons inpneumatic valve actuators.

6. Mechanical integrity. 6m Test for mechanical tightnessof pipework and associatedequipment.

7. Auxiliary electric device/alarm, door closures, etc.

6m Test operation. Operational test to be carried out in accordance withmanufacturer's recommended procedure.

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22223-07 EXPANSION FOAM SYSTEMS

Note: The schedule shall be carried out by a competent person who will provide client with a signed dated report.


1. Alarms. 3m Test all electrical detectionand alarm systems inaccordance with BS 5839.

2. Foam producingequipment.

6m Inspect:for mechanical damage,for corrosion,for blockage of air inlets,clear as necessary,correct manual function of allvalves,strainer and gauzes,proportioning devices.

This may require temporary isolation of the water main.

3. Control valves. 6m Check for corrected manualand automatic operation.

4. Pipework. 6m Examine exposed pipeworkto determine condition.

If visual indication of normally dry pipework indicatesquestionable strength due to corrosion or mechanicaldamage, hydraulically pressure test.

5. Tanks for foamconcentrate and solution.

6m Visually inspect withoutdraining.

Check any concentrate shipping containers for evidenceof deterioration.

6. Concentrate. 12m Check condition. Correct any deterioration according to themanufacturer's recommendations.

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22323-08 FIRE EXTINGUISHERS - HALON

Note: As this type of equipment is pressurised it can be opened for inspection only after discharge. This should be carried out after 10years if the following annual maintenance has been carried out. Because of environmental concerns Halon extinguishers are beingphased out and replaced with Inergen.


1. Pressure indicatingdevice.

12m Check operation and pressure.If pressure loss more than 10%recharge ensuring no vapour loss toatmosphere.

If device inoperative or pressure is belowspecified lower limit refer to manufacturer'sinstructions.If no device fitted use connection, if provided, toverify pressure.

2. Extinguisher body. 12m Examine for corrosion or damage. If replacement indicated report to client.

3. Contents. 12m Weigh and check against records. Report any loss.

4. Nozzle and hose. 12m examine and clean as necessary.check hose for wear or damage andreplace if necessary.

5. Operating mechanism (ifdetachable).

12m Check operating mechanism anddischarge control (where fitted) forfree movement. Clean, rectify orreplace as necessary.

6. Safety clip. 12m Replace after maintenance activityor renew wire seal as appropriate.

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22423-09 FIRE EXTINGUISHERS - CARBON DIOXIDE

Note: For extinguishing kitchen cooking oil fires, Wet Chemical fire extinguishers (Class F) should be in position.


1. Extinguisher body. 12m Examine for corrosion ordamage.

If replacement indicated report to client.

2. Contents. 12m Weigh and check againstrecords. If loss greater than10% recharge.

3. Horn, hose and valveassembly.

12m Examine, clean and replace ifnot in good condition.


12m Check operating mechanismand discharge control (wherefitted) for free movement.Clean, rectify or replace asnecessary.

5. Safety clip. 12m Replace after maintenanceactivity or renew wire seal asappropriate.

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22523-10 FIRE EXTINGUISHERS - FOAM (stored pressure)


1. Pressure indicatingdevice.

12m Check operation andpressure.

If device inoperative or pressure is below specified lowerlimit refer to manufacturer's instructions. If no devicefitted use connection, if provided, to verify pressure.

2. Extinguisher body. 12m Examine for corrosion ordamage.

If replacement indicated report to client.

3. Contents. 12m Weigh and check againstrecords.

Report any loss.

4. Nozzle and hose. 12m Examine and clean asnecessary,Check hose for wear ordamage and replace ifnecessary.




7. Internal inspection. 48m Discharge contents,Examine for corrosion,Refill if condition satisfactory.

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22623-11 FIRE EXTINGUISHERS - POWDER

ITEM FREQ. ACTION NOTES1. Contents. 12m Weigh the extinguisher and if

more than 10% loss ofpowder, recharge.

2. Condition of powder. 12m Open container and examinepowder, if any evidence oflumps, caking or foreignbodies, recharge.

If powder appears satisfactory, agitate by inverting andshaking.

3. Body. 12m Examine internally andexternally for damage.

4. Gas cartridge. 12m Examine for corrosion anddamage. Check weight.

Weight of contents is marked on cartridge, replace ifthere is any loss of weight.Cartridges over 10 years old must be replaced.

5. Vent holes. 12m Examine and clean.6. Nozzle, hose and internal

discharge tube.12m Examine for any blockage,

clean rectify or replace asnecessary.

7. Operating mechanismand discharge control.

12m Check for free movement,clean rectify or replace asnecessary.

8. Washers anddiaphragms.

12m Examine and replace ifnecessary.


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22723-12 FIRE EXTINGUISHERS - WATER – GAS CARTRIDGE

Note: If any soda acid extinguishers are found client should be informed that these must be withdrawn from service.


1. Body. 12m Empty, examine for damage andcorrosion externally and internally.

2. Contents. 12m Check water level after refilling.

3. Gas cartridge. 12m Examine externally for corrosion andweigh and check against that markedon the cartridge.

4. Vent holes. 12m Examine and clean if necessary.

5. Nozzle and strainer and(if fitted) internaldischarge tube andbreather valve.

12m Examine and clean if necessary.

6. Operating mechanismand discharge valve.

12m Check movement, clean, rectify faults orreplace.

7. Sealing washers andhose.

12m Examine and replace if not in goodcondition.

8. Recharge. 12m Fill to correct level. Note any special needs e.g. anti-freeze orcorrosion inhibitor.

9. Safety clip. 12m Replace after maintenance activity orrenew wire seal as appropriate.

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22823-13 FIRE EXTINGUISHERS - WATER STORED PRESSURE


1. Body. 12m Examine externally for corrosionand damage.

2. Contents. 12m Weigh and check againstoriginal weight when put intoservice.

3. Pressure indicator onstored pressureequipment.

12m Check operation, if less thanspecified refer to manufacturer'sinstructions.

Where device not fitted, check by means of connectorprovided.

4. Contents. 12m Weigh and check againstrecords.

Report any loss.

5. Nozzle and hose. 12m Examine and clean asnecessary,Check hose for wear or damageand replace if necessary.




8. Internal inspection. 48m Discharge contents,Examine for corrosion,Refill if condition satisfactory.

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229 24-01 FLUES (all combustible fuels)

These notes should be read in conjunction with relevant sections BOILERS GAS, OIL SOLID FUEL – burning appliances. Ensure that flues conform to relevant guidance and BS/EN and boiler manufacturers recommendation. External dampers/economisers can infringe manufacturers guarantees and also HASAWA. ITEM FREQ. ACTION NOTES 1. Drain plugs at the

base of the flue. 1m Remove, allow any accumulated

condensate to drain away and replace. This should be part of the routine maintenance carried out by in-house staff.

2. Supports. 12m Inspect security of supports and condition of paintwork. Treat any signs of rust or corrosion.

Particular attention should be paid to the condition of the base of the supports.

3. Flue terminals. 12m Where possible, check flue terminals at roof level.

Flue terminals should be undamaged and free from any obstruction.

4. Boiler flue and vertical chimneys.

12m Clean thoroughly with custom made flue brushes and tools.

Use access doors provided and reseal after operation. Remove all soot, fly ash and scale. N.B. when burning wood, coal, heavy oil and volatile waste more frequent cleaning will be necessary, and two monthly checks are advised.

On completion of overhaul check draught pressure.

If the combustion air source is likely to be subject to contamination from chemicals or chemical processes frequent checks should be made for corrosion of the boiler flueway components and the chimney construction.

5. Balanced flue terminals.

12m Check for obstruction, corrosion and if fan assisted check safety circuit.

Obstruction of the flueways can be caused by leaves and any other airborne debris.

6. Induced draught/fan assisted.

12m Check for obstruction and condition of bearings.


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23024-01 FLUES (all fuels) - continued


7. Fan dilution units 12m Check pressure/vane switch action forcorrect operation.

Check pressure/boiler interlock forcorrection operation. If not shut down burner.

8. Dampers. 12m Check action and control switchesinterlocks.

9. Condensing boilers. 12m Check for obstruction and corrosion.If fan assisted check safety circuit.

10. Stabilisers (explosiondoors).

12m Check condition and ensuremovement is free.

11. Structural stability. 12m Check condition and if free standingexamine condition of guy ropes.

After periods of severe weather examine thechimney structure and supports for damage.

12. Smoke test. 12m Check for flue pull and deterioration.

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23125-01 FOUNTAINS - ORNAMENTAL

Notes: Latest ACOP L8, 2001 - Precautions in respect of Legionellosis and legionnaires' disease apply.


1. Spray heads and jets. 12m Clean and check spraypattern.

Frequency will depend upon location and use andshould be agreed with client.

2. Pumps. 12m Check for gland leakage andsatisfactory operation.

More detailed information on the maintenance seerelevant section of PUMPS.

3. Filters. 12m Check condition and clean asnecessary.

Frequency will depend upon location and use andshould be agreed with client.

4. Containment area, e.g.tanking.

12m Check for cracks and signs ofleakage. Report to client ifremedial work is required.

Failure of the waterproof lining or membrane is the mostlikely source of leakage. Frost damage to concrete isanother cause.

5. Water treatment plant.Note: does not applywhen fish present.

12m See – WATER TREATMENT. Presence of fish will required special consideration.

6. Automatic water make-up,a) float operated (ballvalve),

12m See STORAGETANKS –WATER

b) solenoid operated. 12m See - VALVES.

7. Underwater lighting. 12m See - LIGHTING.

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23226-01 GRILLES AND DIFFUSERS


1. Grilles.

a) external 6m Examine, check mountingsand clean.

Leaves can be particular nuisance and one examinationshould be in late Autumn.

b) internal 12m Examine, check fitting andclean.

If removed care should be taken not to disturb valve andother equipment settings behind the grille.

2. Diffusers. 12m Examine, check fitting andclean.

If removed care should be taken not to disturb valve andother equipment settings behind the diffuser.

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23326-02 LOUVRES, BIRD AND INSECT SCREENS


1. Louvres. 6m Clean and remove anydebris, check for damage.

2. Bird screens. 6m Clean and check for anydamage. Replace if holed.

3. Insect screens. 6m Clean and check for anydamage. Replace if holed.

When cleaning care should be taken to avoid damage tothe fine mesh. A low pressure water jet from behindshould clear insect remains.

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23427-01 ELECTRICS IN HAZARDOUS AREAS

Introduction

It is essential that any maintenance work in hazardous areas is only carried out by specialist personnel. Extreme care should be takenwhen carrying out such maintenance and it is very important that equipment such as electric motors, flameproof switchgear and lightingshould be returned to service in a safe condition.

Hazardous areas are classified into three zones.Zone 0 In which an explosive gas-air mixture is continuously present, or for long periods.Zone 1 In which an explosive gas-air mixture is likely to occur i n normal operation.Zone 2 In which an explosive gas-air mixture is not likely to occur in normal operation, and if it occurs will only exist for a

short time.

The above classification does not apply to dusts and an area classification for dusts is being prepared.

BS 5345 Pt 2 is the latest publication dealing with the classification of hazardous areas whilst CP 1003 Part I which covers choice,installation and maintenance of flameproof and intrinsically safe equipment is being slowly withdrawn although it is still in use.

During maintenance in such areas the following points should be noted:-a) all flameproof lighting fittings should be examined for incipient cracks,b) when equipment is returned to service the gap for a particular joint should not exceed that specified by the manufacturers,c) damage to machined flanges must be avoided,d) joints should be wiped clean and non-setting grease or BASEEFA/HSE(M) approved compound as appropriate applied.

Excess grease is not a substitute for containing the flamepath gap.e) Cover bolts are in accordance with the standard requirements of specific minimum strength and should not be replaced by

screws other than those obtained from the manufacturer for that specific purpose.

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23527-02 Hazardous areas - FLAME PROOF EQUIPMENTThe results of inspections, checks and tests should be recorded and compared with previous entries, any significant changes should beinvestigated and specifically reported upon to the client.


1. Condition. 6m Check for mechanical damageor signs of corrosion.

Where bolts or other types of fastenings areused check that numbers are correct and thatthey are secure.

2. Electrical connections. 6m Check integrity.

3. Mechanical faces. 6m Check for damage. Report to client if damage to faces requiresreplacement of equipment.

4. Seals. 6m Check condition and replace asnecessary.


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23627-02 Hazardous areas - FLAME PROOF EQUIPMENT - continued


5. Cable and conduit entries. 6m Check condition of seals.

6. RCDs (if fitted). 3m Test the tripping operation. Responsibility for this check should be agreedwith the client.

12m Test with approved RCD tester Operation should be within 200 milliseconds atrated current output or within 40 milliseconds at5 times rated output.

7. Earth fault loop impedance. 6m Check. This applies to every socket outlet, lightingswitch and luminaire.

8. Labels and notices. 6m Check for presence, clean andcheck security of fixing.

9. Return to service. 6m Ensure that any seals arecorrectly in place and thecorrect number and type ofcover bolts are used.

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23727-03 Hazardous areas - LIGHTING


1. Integrity. 6m Check installation formechanical damage.

2. Fitting and cover. 6m Clean and check condition.Examine for incipient cracks inglass or retaining cement.

Where the glass is cracked or broken no attemptshould be made to re-cement a new glass inplace. A replacement unit should be obtainedfrom the original manufacturer.

3. Lamp. 6m Replace on a planned basis asappropriate.

Maintenance contract should be specific withregard to the responsibility for the provision andreplacement of lamps, and also for the disposalof spent lamps as per statutory regulations.

4. Cable and conduit entries. 6m Check condition of sealing ringsetc.

Note: any cable gland, stopping gland or plug,reducer or adapter must be BASEEFA approvedfor use with the apparatus.

5. Return to service. 6m Ensure that any seals arecorrectly in place and thecorrect number and type ofcover bolts are used.

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23827-04 Hazardous areas - EARTHING


1. Terminations. 6m Check for continuity andbonding. See also POWERSUPPLIES - Earthing.

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23928-01 HEAT EMITTERS

Fan Convectors, Unit Heaters and Perimeter (skirting) Heating.Maintenance of heat emitters can be divided into two main areas, namely the fixtures and fittings directly associated with the supply ofheat and the grilles and heat exchange surfaces through and over which the air passes. The efficiency of the grilles and heat exchangesurfaces can be affected by fluff and fibres, the severity of which depends upon the location and the environment. Thus a dusty carpetedroom with perimeter skirt heating will require much more frequent cleaning of grilles and heating surfaces than a lino covered floor in aclean environment. The frequencies shown in the table below refer to a clean environment but in extreme cases it may be necessary toclean grilles and heat exchangers as often as once a fortnight.

ITEM FREQ. ACTION NOTESFan Convectors1. Casing. 12m Examine condition of casing, access

panels and grilles.Check parts are securely fastened and free from `rattles'.Check condition of access panels. Clean inside of casing.If unit has loose grilles, check seal between unit and grillesto ensure no air leakage or short circuiting occurs.

2. Controls. 6m Check all thermostats and othercontrols operate satisfactorily andare set in accordance withspecification.

If heater battery is fitted with a low temperature cut out(LTC) and hot water is not available, it may be necessaryto insert a temporary link in the electrical control circuit tooperate the unit.

3. Filters. 3m When fitted remove, examine andcheck for damage. Clean orreplace.

Check if filter is cleanable or throwaway type. Thefrequency of cleaning depends upon the dirtiness of theair. Normally cleaning should be every two months butmore frequent cleaning may be necessary.

4. Heat exchanger. 3m Inspect and clean. Purge air fromhot water units.

Clean using an industrial vacuum cleaner. Draw airthrough the heat exchanger in the opposite direction to thenormal air flow. In exceptional cases a high pressure airhose may be required. In a dirty environment morefrequent cleaning will be needed, e.g. quarterly, six weeklyor even monthly.


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24028-01 HEAT EMITTERS - continued


5. Motor/fan assembly. 6m Remove from heater casing ifpractical. Inspect and lubricatefan bearings and resilient mountswhere applicable. Clean fans andmotor. Examine wiring andconnectors.

Check fans are secure, motors operate silently andthat bearings are in good order.

6. Pipework, valves, steamtraps and associatedequipment.

12m Examine for corrosion or leaks.Where applicable clean steamtraps, strainers, non return valvesand scale pockets.

Check operation of steam traps.

7. General. 12m Leave unit in good working order. Report on any further work considered necessary.

Unit Heaters

1. Casing. 12m Examine condition of casing,discharge louvres and inletguards.

Where applicable, check condition of any flexibleducting connections. Check security of mountingbrackets or drop rods. Check that any dischargelouvres are correctly set to give the desired airspread pattern.

2. Controls. 6m Check all thermostats and othercontrols operate satisfactorily andare set in accordance with thespecification.

If heater battery is fitted with a low temperature cutout (LTC) and hot water is not available, it may benecessary to insert a temporary link in theelectrical control circuit to operate the unit. Whereapplicable, check starter overloads are set to suitfull load current.


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ITEM FREQ. ACTION NOTES3. Heat exchanger. 3m Inspect and clean. Purge air from

hot water units.Clean using an industrial vacuum cleaner. Drawair through the heat exchanger in the oppositedirection to the normal air flow. In exceptionalcases a high pressure hose may be required. In adirty environment more frequent cleaning will beneeded, e.g. quarterly, six weekly or even monthly.

4. Filters. 3m When fitted remove, examine andcheck for damage. Clean orreplace.

Check if filter is cleanable or throwaway type. Thefrequency of cleaning depends upon the dirtinessof the air. Normally cleaning should be every twomonths but more frequent cleaning may benecessary.

5. Motor/fan assembly. 6m Lubricate bearings whereapplicable.

Check security of fans and condition of resilientmounts.


12m Examine for corrosion or leaks.Where applicable clean steamtraps, strainers, non-return valvesand scale pockets.




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ITEM FREQ. ACTION NOTESNatural Convectors andPerimeter (Skirting) Heating1. Casing. 12m Examine condition of casing,

access panels and grilles. Whereapplicable, check condition ofdamper seal.

Check parts are securely fastened and free from`rattles'. Check condition of access panels. Cleaninside of casing. If unit has loose grilles, check sealbetween unit and grilles to ensure no air leakage orshort circuiting occurs.

2. Heat exchanger. 3m Inspect and clean. Purge air fromhot water units. Where applicable,examine condition of expansionjoints, guides and anchors.

Clean using an industrial vacuum cleaner. Draw airthrough the heat exchanger in the opposite directionto the normal air flow. In exceptional cases a highpressure hose may be required. In a dirtyenvironment more frequent cleaning will be needed,e.g. quarterly, six weekly or even monthly.


12m Examine for corrosion or leaks.Where applicable clean steamtraps, strainers, non return valvesand scale pockets.

Check operation of steam traps. Check operation ofthermostatic radiator valves (TRVs).

4. Controls. 12m When fitted examine condition ofdamper seals.

When fitted, check damper operates smoothly.



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Radiant Strip

1. Panels and insulation. 12m Examine condition of panels andinsulation.

Clean panels and insulation, check that insulationis fitted and secured.


12m Examine for corrosion or leaks.Where applicable clean steamtraps, strainers, non return valvesand scale pockets. Examinecondition of expansion joints.


3. Suspension. 12m Check condition and security ofdrop rods, hangers and relatedequipment.


Heat Emitters - Safety

ALL ITEMS 12m Cleaning and maintenance. Due to possible difficulties of access cleaning andmaintenance should only be undertaken bycompetent person.When applicable, isolate units(s) from electricalsupply by removing fuses or locking main switch in‘OFF’ position.

Always refer to the manufacturer'sinstructions/recommendations before undertakingany cleaning or maintenance.

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244 28-02 GAS FIRED CERAMIC PLAQUE INFRA RED HEATERS

These heaters are usually placed high up in a building and consequently are not easily accessible. A risk assessment and method statement should be carried out. Access by stepladders is not recommended. Regular maintenance is essential and whilst annual maintenance may be adequate in a clean environment, dusty conditions will require more frequent maintenance. In very dusty environments, e.g. textile factories, it may be more desirable to duct a direct combustion air line to the heater. ITEM FREQ. ACTION NOTES

1. Ceramic plaques. 12m Clean using an 80 p.s.i. air supply. The direction of air flow should be opposite to that of the gas flow.

2. Electrical spark plug. 12m Clean with wire brush, replace if there are any signs of corrosion.

3. Connecting wires. 12m Check for damage. If there are any signs of deterioration, replace.

4. Gas pressure. 12m Check with rated value and adjust if necessary.

The rated value will be found on the identification plate or in the operating instructions.

5. Performance check. 12m

Switch on and when stable plaque should present a uniform cherry red appearance.

If the unit does not perform correctly the plaques should be cleaned. If the specified output is not obtained the unit should be replaced and returned to the manufacturer. Under certain conditions, e.g. broken plaque, the heater may light back, i.e. gas may ignite at the injector resulting in flames being vented from the exhaust of the heater. Apart from the lack of radiant effect light back will cause Carbon Monoxide production and blockage of the plaque with carbon.

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245 28-03 GAS RADIANT TUBE HEATERS


1. Isolation of heater from electrical and gas supply.

12m Switch off, remove fuses and turn off gas supply.

For safety reasons it is essential that the equipment is isolated from electricity and gas before servicing.

2. Burner. 12m Disconnect gas union and remove complete burner unit.

Clean the combustion chamber, inspect for damage and corrosion.

3. Pilot burner jet. 12m Remove, clean and refit. Only the manufacturer’s approved seals or jointing compounds must be used.

4. Main burner jet. 12m Remove, clean, inspect and refit. A competent engineer working for a CORGI registered business and competent as required by the Gas Safety (Installation & Use) Regulations must be used for this work.

5. Air filter. 12m Remove, clean and refit. Cleaning should be carried out using a soft brush or blowing with air. Use new gaskets and renew filter if necessary.

6. Spark plug. 12m Remove, clean and refit. Check ceramic for cracks or breakage. Renew if necessary.

7. Pilot burner orifices. 12m Inspect and clean.

8. Burner grid. 12m Inspect and clean, removing all dust on back of ceramic block.

Check ceramic block and fireclay for signs of cracking. Renew if necessary.

9. Observation windows. 12m Check and clean

10. Vacuum switch. 12m Examine and check switching differentials for correct operation.

11. Acoustic joints. 12m Check for wear. Renew if necessary.

12. Condensate traps. 12m Check for blockages.

13. Vacuum motor pump. 12m If fitted, examine mountings Lubricate pump motor if applicable.


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24628-03 GAS RADIANT TUBE HEATERS - continued


14. Reflectors. 12m Inspect to ensure correct fitting.

15. Gas test. 12m Pressure drop test back to nearestgas cock to ensure soundness.

16. General. 12m Undertake heat test. With heater(s) switched on and system stabilisedcarry out a heat test in accordance with themanufacturer’s recommendations.

Check all burner units for correct ignition sequencepilot and main burner flames for stability andcorrect aeration, adjust if necessary.

The following readings are to be taken and thesystem adjusted to meet the manufacturer’srecommendations:

- vacuum at each end vent

- maximum and minimum pressure

- gas consumption

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247 28-04 GAS FIRED NATURAL AND FAN ASSISTED HEATERS -Conventional and Balanced Flue.


1. Protection guards. 12m Remove internal guard. Check the condition of both internal and external guards.

2. (a) Heating casing. 12m Remove and inspect for damage.

(b) Stub ducts (if fitted). 12m Clean grille.

3. Burner. 12m Disconnect gas union, remove burner assembly complete.

Clean the combustion chamber internally and externally, inspecting closely for signs of corrosion.

4. Ignition. 12m Check operation of ignition assembly.

Clean and adjust electrode as required.

5. Thermocouple. 12m Clean with fine wire brush reassemble pilot and test.

Renew with manufacturer’s approved thermocouple if necessary.

6. Burner Controls. 12m Check operation and condition of all burner controls including combustion fan if fitted.

Check gas pressure to burner and pilot, adjust if required. Lubricate diaphragms to manufacturer’s specification. Check safety interlocks associated with combustion fan. A competent engineer who works for a CORGI registered business and competent as required by the Gas Safety (Installation & Use) Regulations must be used for this work.

7. Flueways. 12m Inspect flue and flueways. Clean as necessary.

8. Gaskets. 12m Renew flue gaskets, ‘O-rings and joints.

9. Heat exchanger. 12m Inspect for corrosion.

10. Room air distribution fan assembly (if fitted).

12m Inspect fan bearings, fan wheel(s) or blades and check speed.

Examine for cleanliness and freedom of operation.

11. General. 12m Check settings and correct operation of thermostats and time clocks.

Make necessary corrections if required.

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24829-01 HEAT EXCHANGERS - COILS

Note:- When cleaning ensure that system fans are off to avoid dirt disturbed during cleaning entering into the system


Water to air

1. Drain pans. 12m Inspect for corrosion and clearobstructions (if any) in condensatedrain piping on cooling side.

Check that condensate traps on cooling coils arefilled with water.

2. Coils:

a) external surface airside,

12m Clean coils and comb out fins. Where necessary clean with appropriate sterilisingsolution, especially when coils operated under moistair conditions or act as a dehumidifier.

b) water side. 12m Flush out coils to removesediment.

On heating coils any scale build up which restrictswater flow should be reported for further action.

3. Coil casing. 12m Inspect for rust and clean andrepaint as required.

4. Coil mounting bolts. 12m Check for tightness and secure ifnecessary.

Corroded bolts should be replaced.

Steam to air

1. Coils;

a) external surface airside,

12m Clean coils and comb out fins. Where necessary clean with appropriate sterilisingsolution.

b) water side. 12m Flush out coils to removesediment.

Report to client on any further action necessary dueto scale or erosion.


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24929-01 HEAT EXCHANGERS - COILS- continued


2. Coil casing. 12m Inspect for rust and clean andrepaint as required.

3. Coil mounting bolts. 12m Check for tightness and secure ifnecessary.

Corroded bolts should be replaced.

4. Operation of steam traps. 1m Check operation, condition of filtersand sight glasses.

Full details of maintenance requirements steamservices, see PIPEWORK SYSTEMS.

12m Clean and overhaul traps, strainersand sight glasses. Check by-passvalves are not leaking.

Indirect gas fired to air

1. Heat exchanger;

a) air side, 12m Clean fins and air-side surfaces. Comb fins if appropriate. Where necessary cleanwith appropriate sterilising solution.

b) flue gas side. 6m Clean surfaces where access isprovided.

Report to client any deterioration of heating surfacewhich requires further attention.

2. Heat exchanger casing. 12m Inspect for rust and clean andrepaint as required.

3. Heat exchangermountings.

12m Check for tightness and secure ifnecessary.

Corroded bolts should be replaced and any leakingjoints between the heat exchanger and discharge ofproducts of combustion must be rectified beforethe heater is put back into service.

4. Gas burners andassociatedequipment.

12m Service. For detailed information on maintenance of gasfired heater see the maunfacturer's instructions.

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25029-02 ELECTRIC/AIR HEATER

Note: When cleaning, ensure that system fans are off to avoid dirt disturbed during cleaning entering the system.


1. Terminal box:

a) external surfaces, 12m Inspect for rust and clean and repaint asrequired.

b) lid retaining screws, 12m Check for tightness and secure ifnecessary.

Missing screws should be replaced.

c) internal connections. 12m Check that terminal screws are tight.Check the integrity of the internal wiring.

Observe correct safety procedures as requiredunder the Electricity at Work Regulations.

2. Elements:

a) within terminal box, 12m Check insulation resistance of eachelement. Check continuity.

Replace if below 1 megohm resistance.

Replace if open circuit.

b) within casing. 12m Clean elements (comb out if finned type). Where necessary clean with appropriatesterilising solution.

3. Casing. 12m Inspect for rust and clean and repaint asrequired.

4. Mounting bolts. 12m Check for tightness and secure asnecessary.

Examine casing mounting flanges for airtightness where appropriate.

5. Thermostats/ controls. 12m Check operation. For detailed maintenance see relevant section.

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25129-03 PLATE RECUPERATOR

The frequency of cleaning will depend upon the working environment.ITEM FREQ. ACTION NOTES

1. External surfaces. 6m Inspect for rust and clean and repaintas required.

2. Internal surfaces. 6m Check and remove any dirt, inspect forrust and repaint as necessary.

Do not use wire brush for dirt removal, blowoff with dry nitrogen or compressed air.

3. Leakage. 6m Check for both internal and externalleaks.

Cross leakage between the two air streams isundesirable as cross contamination couldoccur.

4. Mountings. 6m Check for tightness and secure asnecessary.

5. Fans. 6m Service and lubricate.

6. By-pass control. 6m Check operation. Check summer/winter by pass operation.

7. Heaters. 6m Check operation. Check action of thermostat in air supply side.Setting should be 'air to room' at roomtemperature.

8. Drains (condensation). 6m Check operation, clean and sterilise.

9. Filters. 3m Clean or replace as necessary. Filters are fitted on both inlet and extract tokeep the heat exchangers clean.

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25229-04 THERMAL WHEELS - ROTARY HEAT REGENERATORS


1. Bearings. 6m Lubricate according to themanufacturer's instructions.

'Sealed for life' bearing should not need anymaintenance.

2. Exterior surfaces. 12m Clean and check for rust. If necessaryprepare and repaint rusty areas.

3. Interior surfaces. 12m Clean, examine and treat any rustyareas and repaint.

Note: do not scrape as surfaces may have specialcoatings.

4. Heat exchange mesh. 12m Clean, taking care not to damage themesh.

Low pressure hot water containing detergent isthe best cleaning agent but if the system isdesigned with a hygroscopic surface torecover latent heat refer to manufacturer forcleaning instructions.

5. Seals. 12m Check condition and renew ifnecessary.

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25329-05 RUN ROUND HEAT RECOVERY COILS


1. Pump. 12m Inspect bearings for wear. Check flowrates/speed and leak tightness.Check electrical connections.

Frequency should be in accordance with themanufacturer's instructions.

Observe correct safety procedures as requiredunder the Electricity at Work Regulations.

2. Antifreeze. 12m Check that concentration is correct forthe application.

3. Water. 12m Check for leaks. Remedy if possible, if major problem, refer toclient.

4. Operating pressure. 12m Check. Confirm pressure vessel operating conditions.

5. Coils. 12m Clean with recommended cleaningcompound and flush with water.

6. Air. 12m Check for leaks. Rectify as required providing new seals etc.

7. Condensate traps. 12m Inspect for rust, clean and clear anydebris. Recoat. Check traps are filledwith water on return to service.

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25429-06 PLATE HEAT EXCHANGERS


1. Inspection. 12m Inspect the plate pack for deformed ordamaged edges or for leakage.

Gaskets extruding from the plate pack normallyindicate a damaged plate or failed gasket. Themost common cause of such failure is working atexcess pressure which must be corrected. Amajor overhaul is necessary if the pack isdeformed.

2. Cleaning frame. 12m The exterior finish of the heatexchanger frame (not the plate pack)should be washed down and rubbeddry, then a thin film of cleaner applied.

The correct type of cleaner as recommended bythe manufacturer should be used and this willnormally provide lasting protection provided thetreated services are not subject to hightemperature.

3. Top bar. 12m Clean all surfaces, check tightness offixing screws.

Depending upon the make of heat exchanger,lubricate plate and follower hanger surface eachtime the plate is opened.

4. Bottom bar. 12m Check tightness of fixing screws. Depending upon the type of exchanger, smearsurfaces with a thin film of grease when platepack is open.

5. Liquid connections. 12m Check tightness of flanged or pipeunion fittings on header.

6. Rubber bush linings(where fitted).

12m Check for splits, signs of cracking orother deterioration.

7. Port rings (where fitted). 12m Check for collapsed peaks, splits orhardening.


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25529-06 PLATE HEAT EXCHANGERS - continued


8. Connector grid bossfixing (where fitted).

12m Check security of connector grid bossfixings when plate pack is exposed.

9. Tie bars. 12m Coat all exposed threads withappropriate lubricant.

10. Tightening screws (wherefitted).

12m Grease threads with maker'srecommended grease or paste.

11. Hinge bar thrust pad(where fitted).

12m Clean, apply maker's recommendedgrease.

Inspect for serious wear and replace asnecessary.

12. Spray screens (wherefitted).

12m Always ensure that these are properlyattached when the heat exchanger isoperating.

13. Exchanger operation(where suitable gaugeshave been fitted).

12m Check temperatures on inlet/outlet andpressure drop.

Fluctuating outlet temperatures could indicate aperforated plate, allowing intermixing of primaryand secondary fluids.Low output pressure could possibly be due toscale deposits on the plates, a blockage in theplate pack or inlet pipeline, all of which causeenergy waste. If de-scale or hygienic cleaningis necessary, it should be carried out strictly inaccordance with the heat exchangermanufacturer's recommended procedure.

14. Check safety controls. 12m Safety valve operation.

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25629-07 WATER TO WATER PLATE HEAT EXCHANGERS


1. Inspection. 12m Inspect the plate pack fordeformed or damaged edgesor for leakage.

Gaskets extruding from the plate pack normally indicatea damaged plate or failed gasket. The most commoncause of such failure is working at excess pressurewhich must be corrected. A major overhaul is necessaryif the pack is deformed.

2. Cleaning frame. 12m The exterior finish of the heatexchanger frame (not theplate pack) should bewashed down and rubbeddry, then a thin film of cleanerapplied.

The correct type of cleaner as recommended by themanufacturer should be used and this will normallyprovide lasting protection provided the treated servicesare not subject to high temperature.

3. Top and bottom bars. 12m Clean all surfaces, checktightness of fixing screws.

Depending upon the make of heat exchanger, lubricateplate and follower hanger surface each time the plate isopened with recommended lubricant.

4. Liquid connections. 12m Check tightness of flanged orpipe union fittings on header.

5. Elastomeric bush linings(where fitted).

12m Check for splits, signs ofcracking or otherdeterioration.

6. Port rings (where fitted). 12m Check for collapsed peaks,splits or hardening.


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25729-07 WATER TO WATER PLATE HEAT EXCHANGERS - continued


7. Connector grid bossfixing (where fitted).

12m Check security of connectorgrid boss fixings when platepack is exposed.

8. Tie bars. 12m Coat all exposed threads withappropriate lubricant.

9. Tightening screws(where fitted).

12m Grease threads with maker'srecommended grease orpaste.

10. Hinge bar thrust pad(where fitted).

12m Clean, apply maker'srecommended grease.

Inspection for serious wear and replace as necessary.

11. Exchanger operation(where suitable gaugeshave been fitted).

12m Check temperatures oninlet/outlet and pressuredrop.

Fluctuating outlet temperatures could indicate aperforated plate, allowing intermixing of primary andsecondary fluids.

Low output pressure could possibly be due to scaledeposits on plates, a blockage in the plate pack or inletpipeline, all of which cause energy waste.

If de-scale or hygienic cleaning is necessary, it shouldbe carried out strictly in accordance with the heatexchanger manufacturer's recommended procedure.H&S and Environmental Regulations apply.

12. Safety controls. 3m Check operation.

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25830-01 HEAT REJECTION EQUIPMENT

Introduction

This section covers those items of plant associated with the removal of heat from the equipment producing the cooling. It coversevaporative/wet cooling towers, dry coolers and condensers. Where cooling towers have been, or appear to have been, poorly maintained inthe past there is a danger that Legionella bacteria may be present and it is therefore essential that in those cases, appropriate safetyprocedures as listed in ACOP L8, 2001 should be followed.

Waterside fouling will vary with the hardness of the water, amount of bleed off and the quantity of make up. In hard water areas or whereheavy air pollution occurs it may be necessary to increase the maintenance frequency.

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25930-02 COOLING TOWERS - Precautions against Legionnaires disease (legionella pneumophila)

Action to be taken prior to the visit.I. Notify appropriate local and/or water authority/company, prior to discharging water drained from the cooling tower as the

contaminated water could enter sewers.II. Advise client that cooling tower will be out of action during period of visit.Note:- Towers that have not been regularly maintained should be treated as HAZARDOUS and must not be maintained by personnel whomay be susceptible to LEGIONELLA.

ITEM FREQ. ACTION NOTESInitial Safety Precautions Ensure maintenance personnel read

ACOP L8,2001.

Select personnel who are lesssusceptible to the disease.

Before starting work on cleaning cooling towersit is essential that certain preliminary safetyprecautions are taken. These are listed under'Action'.

Protective clothing and positivepressure respirators.

Personnel should wear positive pressurerespirators when contamination is suspected orthe condition is not known. Note:- respiratorseal may not work with beards.

6m Cooling water analysis. Sample and send to a UKAS accreditedlaboratory for total viable colony count (TVC)Dipslides should be taken weekly. (Immediateaction should be taken if these showunusual results)

Cleansing and disinfectionprocedures

Where cooling towers are situated in rural areasand only in use during the summer months thefrequency of maintenance can be extended totwelve months.

1. Site liaison. 6m Advise client that you are on site. Report to security personnel where appropriate.Continued on next page ..

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26030-02 COOLING TOWERS - continued

ITEM FREQ. ACTION NOTES2. Warning notices. 6m Post at approaches to cooling tower

and enclosure.It is essential that anyone approaching thecooling tower is warned and notices shouldstate:-

Restricted area - do not enter.3. Windows and air inlets 6m Close any in the vicinity of the work.

4. Close down system. 6m Isolate chillers(s) cooling towers andcirculating pumps.

If this involves entering vicinity of cooling towerand if tower is not regularly maintained, donprotective clothing including positive pressurerespirators.

5. Electrical equipment. 6m Ensure that all electrical equipment isisolated except pumps.

Cooling tower fans and any adjacent air intakefans should be isolated in accordance with H&Srequirements.

6. Automatic dosingequipmentcontinuous drains andwater supply.

6m Close water supply, circulate for fifteenminutes, isolate pumps and drain towaste.

7. Bio-dispersant. 6m Add at a recommended concentration. Use of the bio-dispersant breaks down the bio-film which is usually present on most surfaces.

8. Hardness of water. 6m Check pH which should be between 7and 8. If higher contact water treatmentspecialist for advice.

A pH above 8 indicates high alkalinity which willrequire neutralising. If sodium hypochlorite isused at a high pH foaming will result which willprevent correct disinfection.


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261 30-02 COOLING TOWERS - continued


9. Disinfection. 6m

Add sodium hypochlorite to chlorinate, bring up concentration to either 5 ppm or 30 ppm. (see notes)

Any action taken should conform to the requirements of HVCA TM13, HSC ACOP L8, 2001 and other H&S regulations. At 5 ppm the system should be run for at least six hours, at 30 ppm, 2 hours. See item 10.

10. Cooling water pumps. 6m Replace fuses to pumps and switch on and run for 6 or 2 hours (see note 9). After 15 minutes, close down pumps, check chlorination level and if needed add sodium hypochlorite to reinstate chlorine level.

It is probable that once the water starts to circulate the free chlorine level will fall, hence sodium hypochlorite must be added to maintain the chlorination at 5 or 30 ppm during the running cycle.

11. Drain system. 6m Switch off pumps, remove fuses and drain complete system.

When starting to drain, open water supply to assist in neutralising system. Then shut off water supply and allow to drain. It is essential that the whole system is completely drained. Check for drain cocks on pipework serving chiller.

12. Tower packing and drift eliminators, etc.

6m Dismantle so far as is practicable and clean. See comment in 13 below.

If packing shows signs of deterioration - replace. When replacing drift eliminators ensure that these are correctly fitted and secured.


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13. All surfaces. 6m All accessible surfaces to be cleanedwith a wire brush. To remove alldeposits thoroughly chemical cleaningmay be necessary.

Ensure all scale, rust and other mineral andorganic deposits are removed. Any rust areasshould be treated and repainted.

14. All components. 6m Every part of the system must becleaned i.e. feed tank, ball valve,softener etc.

If any part of the system is left uncleanedcontamination of the whole system may result.

15. Disposal of looseneddeposits.

6m Sweep out all loosened deposits andplace in plastic sacks with the topssecurely fastened.

Ensure safe removal of sacks from site.Waste Disposal Regulations may apply.

16. Wash down. 6m Clean with low pressure hose. If possible close valves from tower to chillerduring wash down. If a high pressure hose has tobe used, tent tower to prevent any spray drift.

17. Chlorination. 6m Close drain valves, open water supply,fill system and chlorinate to 5 ppm.Replace pump fuses, switch on pumpsand run system for six hours.

Ensure that chlorination concentration remains at5 ppm throughout 'run' period.

18. Drain system. 6m Repeat actions indicated in note 12.19. Re-fill system. 6m Note:- If chlorine concentration exceeds 2 ppm

prior to activating water treatment regime, drainand refill.

20. Attenuators. 6m Clean, derust and repaint as required.

21. Activation of watertreatment and dosing.

6m Contact water treatment organisation. Water treatment organisation will activate systemand take samples for analytical tests.


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ITEM FREQ. ACTION NOTES22. Protective clothing. 6m Remove and bag before returning

through occupied parts of the building.

23. Complete system. 6m Restart. Check frost protection isoperational.

24. Windows and air inlets. 6m Re-open windows and restartventilation fans.

Remove warning notices.

25. Records. 6m Record all activities carefully in theform of duplicate job sheets.

Give client one copy of the report and retain theother.

26. Completion. 6m Advise client on completion of work. Check out at security.

27. Bacterial checks. 6m Take sample for TVC count. Note:- weekly dip slides will indicate bacterialevels. A high bacterial level does not necessarilymean the Legionella bacteria are present.

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26430-03 DRY COOLERS


1. Status. 6m Isolate from electrical and otherservices.

Isolate electrical supply in accordance with H&Srequirements.

2. Fans. 6m See FANS.

3. Fins. 6m

a) external, 6m Clean by blowing through withcompressed air or steam.

Note:- Any discharged refrigerant (CFCs)must be recovered and NOT released toatmosphere.

Only a Qualified and REFCOM registeredengineer should work on this equipment.

b) internal. 6m Blow through with dry, oxygen free,nitrogen.

4. Coil vent. 6m Check operation.

5. Anti-vibration mountings. 6m Check - visual condition, - effectiveness.

There should be no transfer of vibration or visibledeterioration.

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26531-01 HOT AND COLD WATER SERVICES

Introduction

Hot and Cold Water Services including Drinking WaterThis section covers the maintenance procedures associated with the provision of hot and cold water.

Legionellosis (Legionnaires Disease and Associated Illnesses)

Approved Code of Practice- Legionnaires Disease: The control of legionella bacteria in water systems: Approved Code of Practice L8,2001 sets out certain statutory requirements. In particular each water system, limitations detailed in ACOP,L8,2001 must be identified and assessed for legionellosis risk. Once a risk has been identified and assessed a scheme must be prepared for preventing or controlling it, precautions implemented and managed records kept.

The Standard Maintenance Specifications should be adequate for the majority of well engineered low risk systems conforming to therequirements of ACOP L8,2001. Additional work may be required for less ideal systems and these should be specified as part of the prevention/control scheme.

The client must ensure that one person of adequate status is appointed as being responsible for overseeing the assessment andimplementation of the precautions. Responsibility and lines of communication must be properly defined and personnel must be properlytrained.

The following conditions can all increase the rate of growth of Legionella:a) Water temperatures in the range 20-45º C,b) Presence of sediment, sludge, scale or organic material,c) Certain non approved construction materials,d) Rust,e) Commonly encountered water organisms such as algae, amoeba, slimes and biofilms.

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266Metering

Metering of potable water supplies by the Statutory Water Undertakings is being introduced more widely and is now considered for all newpremises. Metering of potable water supplies may be common practice by the year 2000 and consideration will have to be given to themaintenance of such meters.

Pressure Systems and Transportable Gas Containers Regulations 1989

A written scheme of examination drawn up by a ‘competent person’, must be in place for all plant and equipment which is subject to these regulations.

Most pressure systems carrying a relevant fluid will require written schemes and regular inspection.

The code of practice entitled ‘Safety of Pressure Systems’ gives practical guidance with respect to the Pressure Systems and TransportableContainers Regulations 1989 and defines what systems and which fluids apply.

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267 31-02 Note on the WATER UNDERTAKERS BYELAWS

This Volume on Ancillaries, Plumbing and Sewerage systems covers those services in a building relating to the provision of water and includes hot, cold and drinking water. Such services should conform to the Water Supply (Water Fittings) Regulations (Byelaws in Scotland) and are designed to ensure that the supply of water cannot be contaminated from external sources. The Regulations give statutory powers to all the water companies in England and Wales. The aim of these powers is to prevent waste, misuse, contamination and undue consumption of water supplied by the undertakers. Considerable amounts of energy are used in the purification and pumping of water and the treatment of sewage hence water wastage equates with energy wastage, thus every endeavour should be taken to minimise water wastage apart from the need to conserve a national resource. To ensure some conformity of approach, guidance has been produced by the Water Regulations Advisory Service (WRAS). It has been produced with the aim that it should: a) assist water inspectors, manufacturers, architects, consultants, installers and maintenance personnel and consumers to understand

byelaws based on the Model, b) bring about a uniformity of approach to enforcement, c) be suitable as a training document, d) be based wherever possible on appropriate British Standards.

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268 The guide to the Regulations has been published by the Water Regulations Advisory Scheme (WRAS). The regulations are examined and

explained in detail under a number of basic headings. Penalties for non compliance with the regulations are referred to and most particularly, the need for the installer to inform the local water undertaking of planned work. Water Quality Water portability does not necessarily equate with water quality and except in soft water areas, some form of secondary water treatment may be necessary to remove or inhibit the scale forming elements (i.e. hardness) in the water. Failure to soften or treat the water can lead to excessive scale build up on heaters and heat transfer surfaces with the consequences that efficiency may be reduced leading to energy wastage, or in the worst cases failure of the unit.

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26932-01 Hot Water Supply - Introduction

The provision of hot water entails two important safeguards, namely the avoidance of scalding and the prevention of legionellosis orLegionnaires' disease. It is imperative that the client is aware of these problems and that steps are taken both by his own staff and themaintenance contractor to prevent their occurrence. Specific details relating to the risk of Legionellosis are given in the Health and SafetyACOP L8,2001 and CIBSE publication TM13.

Operating Temperature

ACOP L8,2001 recommends that water services should operate at temperatures that prevent the proliferation of legionella, that is:a) hot water storage (calorifiers), 60°C,b) hot water distribution, at least 50°C attainable at the taps within one minute of running,c) cold water storage temperature, 20°C or below.

Client's staff should check temperatures monthly as required by ACOP L8,2001.

It has been common practice to operate hot water systems in the range 45° to 50°C. At those temperatures there is little risk of scalding, butthere is a risk of legionellosis. The bacteria remains active up to approximately 50°C and is only effectively killed at temperaturesapproaching 60°C.

At water temperatures above 50°C there is a risk of scalding, which increases with temperature and time of contact. In premises used bypersons at risk, e.g. old people, sick persons, and children, fail safe thermostatically controlled mixing valves must be used. The HSEcircular - Controlling Legionella in Nursing and Residential Care Homes INDG 253,1997 suggests that temperatures should be limitedto 43 ± 2°C. This should be checked by client's staff at least monthly.

Where the water temperatures advocated in ACOP L8,2001 cannot be maintained, alternative control measures will need to be considered.These could include weekly disinfection, routine chlorination (at least three monthly), continuous chlorination of water to 2mg/litre, on linepasteurisation, etc.

It is recommended practice that during maintenance the system temperature is raised above 60°C for a period of pasteurisation(disinfection).

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27032-01 Hot Water Supply Introduction - continued

Distribution Pipework

The pipework system must be free of any points where dirt, slime or sediment may accumulate to ensure that there are no deposits, whichcould provide a source of nutriment to sustain the legionella bacteria. Where this is not possible the system should be disinfected on aregular basis. This also applies where pipe replacement or alterations take place and disinfection procedure must be strictly followed.

Hot Water Supply

Pressurised Systems

It should be recognised that danger can arise during the maintenance of pressurised systems if steps are not taken to relieve any residualpressure before opening valves, joints or vessels to atmospheric pressure.

Air Venting

Air is a poor conductor of heat and it should be eliminated from hot water systems using the air vents on the system. These are to be foundat the top of the towel rails and in pressurised systems where automatic air venting valves are provided. It is essential that these are checkedand maintained at the proper frequencies.

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27132-02 HOT WATER SERVICES – generalNote: A log book describing these services should be maintained and details entered about the various maintenance activities and resultsof all the tests.

ITEM FREQ. ACTION NOTES1. Complete system. 12m Check for corrosion, sludge and

slime/algae.Frequency to be agreed with client who should beadvised of any remedial work.

2. Cold water temperature(at outlet of cistern ortank).

1m Monitor to ensure compliance withACOP L8,2001 requirements.

Responsibility for this test should be agreed withclient. Advise client if temperature outsideACOP, L8,2001 requirements for any remedial work to be put in hand.

3. Hot water temperature (atoutlet of calorifier).

1m Monitor to ensure compliance withACOP, L8,2001 requirements.

Responsibility for this test should be agreed withclient. Advise client if temperature outsideACOP, L8,2001 requirements for any remedial work to be put in hand.

4. Drain valves. 12m Open to ensure blow down ofcollected sediment.

This is particularly applicable in vacant buildingswhere services are left running and more frequentopening of drain valves is recommended.

5. Dipslides. weekly Take regular dipslides, record results. *responsibility for taking dipslides should beagreed with client.

6. Water samples: 12m

a) bacterial analysis, 12m Take sample for bacterialexamination, record findings.

If circumstances warrant more frequent sampling,agree frequency with client.

b) legionella. 12m Take sample for UKAS accreditedlaboratory analysis.

If circumstances warrant more frequent sampling,agree frequency with client. Analysis shouldinclude Serogrouping, i.e. identification of variousstrains.

7. Disinfection. 12m If there is a need to disinfect wholesystem, advise client.

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27232-03 CALORIFIER TYPES

In the context of Building Services the term calorifier is used to describe a closed vessel with a cylindrical shell fitted with heat transfersurface. The water in the calorifier is heated indirectly by the tubular primary heater with hot water, steam or electrical immersion heatingelements. A calorifier is used for the supply of a hot water service, for central heating purposes and for industrial applications.The calorifiers are either vertical or horizontal and there are two basic types:

(a) Non-storage, normally used for heating systems(b) Storage, normally used for hot water supply systems where demand usually varies.

This section covers the maintenance of calorifiers including calorifier mountings, and unvented hot water systems but is not intended to coverthe opening up of calorifiers for statutory insurance inspection which requires a separate procedure, which however may be carried out at thesame time as the maintenance.

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27332-04 PRE-MAINTENANCE PROCEDURE

In accordance with good practice the operator should carry out a visual inspection of the calorifier at regular intervals and this should includechecking for leaks.

Prior to carrying out the planned maintenance of the calorifier, the pre-maintenance procedure detailed below should be followed:

(a) Check equipment operating status (i.e. whether in operation or not in use, whether isolated from system) including safety.

(b) Inspect calorifier insulation and/or shell for signs of damage.

(c) Inspect all manholes, mounting, and joints for signs of leaks.

(d) Report any necessary remedial work where repairs, adjustment or replacement will be required during routine maintenance.

(e) Check condition of sacrificial anode and replace if necessary.

CHLORINATION/PASTEURISATION

All secondary systems used to provide a hot waster service must be chlorinated/pasteurised yearly in accordance with ACOP L8,2001 and additionally after a period of shutdown.

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27432-05 CALORIFIERS HEATED BY LTHW OR MTHWWarning – Insulation may contain AsbestosLow temperature hot water systems (LTHW or LPHW) are heating systems operating up to 10 bar (gauge) and 95oC, mediumtemperature hot water systems [MTHW] are heating systems operating in the range 95°-120oC and indirect systems complementaryto them.Prior to carrying out the planned maintenance of the calorifier, the pre-maintenance procedure detailed below should be followed:

(a) Check equipment operating status (i.e. whether in operation or not in use, whether isolated from system) including safety.(b) Inspect calorifier insulation and/or shell for signs of damage.(c) Inspect all manholes, mounting, and joints for signs of leaks.(d) Report any necessary remedial work where repairs, adjustment or replacement will be required during routine maintenance.Check condition of sacrificial anode and replace if necessary.


1. Operation and safetycontrols.

12m Check, note and report anyvisible defects.

Ensure both secondary and primary circuits are full ofwater and circuits are open.

2. Safety valves/PRV. 12m Check operation of safety. N.B. Temperature settings should be in accordance withHSC guidance note ACOP L8,2001 for Hot Water Services. If manually operated for test purposes leakage could occur after test.

3. Thermostats, pressuresensors, altitude gaugesand thermometers.

12m Check for correct operationand settings.

4. Pasteurisation. 12m Cook for one hour above60oC.

N.B. If system has been shut down for any length oftime it must be pasteurised/chlorinated.

5. Chlorination. 12m Chlorinate.

6. Auto controls andprimary side.

12m Shut down primary heatsource.

Check operation of temperature controls and high limitcut-outs.


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27532-05 CALORIFIERS HEATED BY LTHW OR MTHW - continued


7. Drain valve/drain cock onsecondary side.

12m Ensuring secondary valvesare closed draw off a smallquantity of water to removeany sediment.

N.B. If calorifier was in use, the secondary water will behot so care must be taken in carrying out this item of theschedule. If the secondary side of the calorifier is at ahigh temperature, the system must be allowed to coolbefore drain is opened.

8. Heating surface andinternal surfaces of shell

24m Drain down secondary side,remove manholes andinspect for scale formationand corrosion and report.Remove sludge.

The formation of scale reduces heat transfer and causesenergy wastage. Corrosion will cause metal failure andleakage.

If scale is extensive refer to client for further instructions.

9. Bursting discs (wherefitted)

24m Check condition. Report findings.

10. Sacrificial anode 24m Check status.

11. Put back into operation Refit all manholes, refillsecondary side. Hydraulicpressure test. Put primaryside into operation.

Check operation of all temperature controls.

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27632-06 HOT WATER CALORIFIERS HEATED BY STEAM

Note: In the interests of safety and the prevention of scalding, water temperatures and the operation of blending valves should bechecked at least once a month by the caretaker or operator. Insulation which is damaged may be asbestos – appropriate action mustbe taken.Warning: STEAM LEAKS ARE DANGEROUS.

Prior to carrying out the planned maintenance of the calorifier, the pre-maintenance procedure detailed below should be followed:

(a) Check equipment operating status (i.e. whether in operation or not in use, whether isolated from system) including safety.(e) Inspect calorifier insulation and/or shell for signs of damage.(f) Inspect all manholes, mounting, and joints for signs of leaks.(g) Report any necessary remedial work where repairs, adjustment or replacement will be required during routine maintenance.(h) Check condition of sacrificial anode and replace if necessary.

CHLORINATION/PASTEURISATION

All secondary systems used to provide a hot waster service must be chlorinated/pasteurised yearly in accordance with ACOP L8,2001 and additionally after a period of shutdown.


1. Check operation, inparticular safety controls.

12m Note and report any visibledefects.

Ensure secondary is full of water and circuits are open.If safety controls are defective take equipment out ofservice.

2. Safety valves. 12m Check for corrosion andmanually operate.

N.B. If calorifier was in use, the secondary water will behot and can be under pressure, so care must be taken incarrying out this item of the schedule.


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27732-06 HOT WATER CALORIFIERS HEATED BY STEAM - continued


3. Thermostats, pressuresensors, altitude gaugesand thermometers.

12m Check for correct operationand settings.

N.B. Temperature settings for Hot Water Services shouldbe in accordance with HSE ACOP L8,2001.


12m Shut down primary heatsource taking all necessaryprecautions to preventunauthorised use.

Check safe operation of temperature controls and highlimit cut-outs.

5. Drain valve/drain cock onsecondary side.

12m Draw off a small quantity ofwater to remove anysediment.

N.B. If calorifier was in use, the secondary water will behot, and can be under pressure, so care must be takenin carrying out this item of the schedule.

6. Pasteurisation. 12m Cook for one hour above60oC.

7. Chlorinate. 12m Chlorinate.

8. Heating surface andinternal surfaces of shell.

12m Drain down secondary side,remove manhole covers andinspect for scale formationand corrosion.

The formation of scale reduces heat transfer and causesenergy wastage. Client's attention should be drawn tothe presence of excessive scale which indicates the needfor water treatment. Corrosion will cause metal failureand leakage. Remember Waste Disposal Legislation. Ifscale is extensive, refer to client for further instructions.

9. Bursting discs (wherefitted).


10. Gaskets. 12m Check gaskets on steamchest for leakage, replace asnecessary.

Steam leaks are dangerous to personnel and causewastage of energy.


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27832-06 HOT WATER CALORIFIERS HEATED BY STEAM - continued


11. Sacrificial anode. 12m Check status

12. Anti-vacuum valve(where fitted).

24m Check operation and serviceas appropriate.

13. Steam trap/sight glass(on primary connections).

12m Clean and overhaul steamtrap.

Faults can lead to steam and energy wastage.

14. Strainer on primarypipework.

12m Remove strainer, clean andrefit.

Blocked strainers reduce performance.

15. Return to operation. 12m After completion ofmaintenance, refit allmanhole covers, refillsecondary side and putprimary side back intooperation.

Check that all controls are working correctly.

16. Check insulation fordamage.

12m Repair or renew asnecessary.

Damaged lagging reduces efficiency, wastes heat, and ifthe calorifier is in the open air, can become waterloggedand lead to hidden corrosion. Asbestos Regulations mayapply

17. Hydraulic pressure test. 12m If a pressurised system testto Working pressure x 1.5. (see INDG 261)

The Pressure Vessel Regulations may apply.

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27932-07 HOT WATER SUPPLY CALORIFIERS - including LOAD LEVELLERS


1. Operation and safetycontrols.

12m Check, note and report any visibledefects.

Ensure both secondary and primary circuits are full of waterand circuits are open.

2. Safety valves. 12m Check for corrosion and manuallyoperate.

N.B. If calorifier was in use, the secondary water will be hotand can be under pressure, so care must be taken in carryingout this item of the schedule.

3. Thermostats, pressuresensors, altitudegauges andthermometers.

12m Check for correct operation andsettings.

N.B. Temperature settings for Hot Water Services should be inaccordance with HSE ACOP L8,2001.With direct acting valves hot water storage temperaturesshould not exceed those laid down in the above guidancenotes or scalding could occur.


12m Shut down primary heat source. Check operation of temperature controls and high limit cut-outs.

5. Drain valve/drain cockon secondary side.

12m Draw off a small quantity of waterto remove any sediment.

N.B. If calorifier was in use, the secondary water will be hotand can be under pressure, so care must be taken in carryingout this item of the schedule.

6. Heating surface andinternal surfaces ofshell.

24m Drain down secondary side,remove manhole covers andinspect for scale formation andcorrosion and report.

The formation of scale reduces heat transfer and causesenergy wastage. In hard water areas scale can be very difficultto remove if left to build up and more frequent maintenance isrecommended. Corrosion will cause metal failure and leakage.Remember Waste Disposal Regulations.

7. Bursting discs (wherefitted).


8. Put back into operation Refit all manhole covers, refillsecondary side. Put primary sideback into operation.

Check operation of all temperature controls

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28032-08 CALORIFIER AND HEAT EXCHANGE CONTROLS

Certain common maintenance procedures should be carried out for all controls. These are:1. All control items, e.g. thermostats and the like, that have switching contacts ensure contacts make and break easily and

that there is no arcing or pitting.2. Inspect thermostat phial and capillaries for mechanical damage.3. Inspect thermostat pockets for corrosion and leakage.4. Ensure immersion thermostats are secure in their pockets (and that the sensor is in contact with the end of the pocket).5. Inspect motorised valves for leakage and damage to linkage.

For more detailed information regarding the maintenance of motorised valves, checking of gland seals, stroking, etc. refer to relevantsection.


1. Control thermostat. 12m Check operation and confirm setpoint.

Thermostat in-built as part of calorifier orinstalled in/on secondary pipework.

2. High limit thermostat (if fitted). 12m Check operation and confirm setpoint.

Manual or thermal reset?

3. Temperature sensorcontroller. Motorised valve.

12m Check operation and confirm setpoint(s).

4. Power fail return. Motorisedvalve.

12m Check operation. Ensure valve shuts off supply to calorifier anddoes not have let-by.

5. Direct acting control valve. 12m Check operation and confirm setpoint.

6. Direct acting control valve -high limit.

12m Check operation and confirm setpoint.

Ensure valve shuts off supply to calorifier anddoes not have let-by.

7. Temperature sensor.Controller. Motorised valve.Power fail return motor.

12m Check performance. Calibration }Interrogation } by CONTROLS SPECIALIST.Controladjustment }

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28132-09 HOT WATER CYLINDERS


1. Cylinder. 12m Inspect visible seams andbosses for leaks or signs ofcorrosion.

Report adverse findings.

2. Connections. 12m Check connecting pipeunions for leaks.

If found, drain down, clean and remake joint.

3. Insulation. 12m Inspect for deterioration. Refer to client if repairs or renewal required.

4. Immersion heater. 12m Check operation andexamine for scale onelement.

Client's attention should be drawn to the presence ofexcessive scale, which indicates the need for watertreatment.

5. Cold water storagecistern (if combinationcylinder).

12m Inspect seams and bossesfor leaks.

Report adverse findings. See STORAGE – COLDWATER for detailed maintenance schedule of cisterns.

6. Float operated valve andfloat (if combinationcylinder).

12m Check operation and adjustwater level to maximumstorage level.Check float for leakage andsecurity.

Re-washer or replace if necessary.

Replace if necessary.

7. Water temperature. 12m Check water outlettemperature and operation ofauto-temperature controls.

N.B. Temperature setting for Hot Water Services shouldbe in accordance with HSE ACOP L8,2001.

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28232-10 UNVENTED HOT WATER SYSTEMS

Warning - these systems should only be maintained by competent personnel who are competent to maintain them.Note: When the systems are used in buildings subject to the Health and Safety at Work Act 1974 and Northern Ireland 1978Order the schedule of work given below is a requirement.


1. Complete unit. 12m Examine water storagevessel, expansion vessel,pipework and fittings.

Check for any signs of corrosion and water leaks. Resealpipework joints if necessary.

2. Discharge pipework. 12m Examine discharge pipes,ensure that air gap is clearand that there is no blockagein the pipes.

Discharge pipe should be visible and in a safe place. Itshould be of metal and connected to the tundish.

3. Expansion relief valve. 3m Manually operate. Check that the valve seats satisfactorily, water flow ceasedon valve closure and water runs through tundish anddischarge pipes.

4. Temperature relief valve. 3m Manually operate. Check that the valve seats satisfactorily, water flow ceasedon valve closure and water runs through tundish anddischarge pipes.

5. High limit thermostat. 6m Check operation. Should be non self-setting. Thermal cut out should be85°C.

6. Control thermostat. 12m Check temperature setting. N.B. Temperature settings for Hot Water Services shouldbe in accordance with HSE ACOP L8,2001.

7. Diaphragm expansiontank.

12m Check pressure. See – EXPANSION VESSELS.

8. Motorised valve (if fitted). 12m Check operation. Ensure no water flows through valves during shut downpart of the cycle.


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28332-10 UNVENTED HOT WATER SYSTEMS - continued


9. In-line strainer. 12m Inspect and clean asrequired.

10. Back flow preventiondevice.

12m Check operation and ensurethat non-return valve isseating properly.

The operation can be checked by observing anychanges in the upstream level of a vessel preceding thedevice when the incoming supply is isolated.

11. Electrical element. 12m Check for scale on element. Client's attention should be drawn to presence ofexcessive scale which indicates a possible need forwater treatment.

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28432-11 THERMAL STORAGE CYLINDER – (individual dwellings for DHWS)


1. Cylinder. 12m Inspect visible seams andbosses for leaks or signs ofcorrosion.


2. Connections. 12m Check connecting pipeunions for leaks.

If found, drain down, clean and remake joint.

3. Insulation. 12m Inspect for deterioration. Refer to client if repairs or renewal required.

4. Immersion heater. 12m Check operation andexamine for scale onelement.

Client’s attention should be drawn to the presence ofexcessive scale which indicates the need for watertreatment.

5. Feed and expansioncistern (if fitted).

12m Inspect seams and bossesfor leaks.


6. Float operated valve andfloat (if fitted).

12m Check operation and adjustwater level to minimum makeup level.

Check float for leakage.

Re-washer or replace if necessary.

Water level adjustments should only be carried out whenthe heating system and cylinder are cold.

Replace if necessary.

7. Domestic hot waterthermostatic blender.

12m Check operation.

Check water outlettemperature and operation ofauto-temperature controls.

N.B. Temperature settings for Hot Water Servicesshould be in accordance with HSE ACOP L8,2001.

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28532-12 EXPANSION VESSELS


1. Condition. 12m Examine for damage orcorrosion.

If replacement necessary report to client.

2. Diaphragms. 12m Check condition andpressure.

Ensure diaphragms are sound and cushion pressure iscorrect. Top up as necessary, preferably with oxygenfree nitrogen.

DHWS Calorifier

1. Diaphragm expansiontank/s.

3m Check. Ensure air cushion pressure is correct, if necessary topup, preferably with oxygen free nitrogen. Removediaphragm from shell, check and report on condition ofboth. Ensure cushion pressure is correct when re-commissioned.

2. Non-return valve. (Coldwater service (CWS) tocalorifier).

3m Check. Ensure that valve is seating properly.

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28632-13 DIRECT FIRED WATER HEATERSHeater generation may be by electricity, light oil pressure jet burners, forced draught but usually atmospheric gas burners. For specificmaintenance instructions on heat generator see appropriate burner section.WARNING: To avoid the possible risk of scalding, client should carry out monthly checks of the outlet temperature.


Flueways

1. Heat generationequipment.

12m Remove and carry out necessarymaintenance.

See HEAT GENERATORS for maintenance.

2. Fluepipe. 12m Remove at slip collar and clean.

3. Draught diverter (whereapplicable).

12m Remove and clean.

4. Flue baffles. 12m Remove and clean. Note: All debris should be removed with a vacuumcleaner.

5. Flue tubes. 12m Clean with suitable brush.

6. Reassembly. 12m Reassemble in reverse order. Ensure that on reassembly, the flue is sealed in an airtight manner.

7. Smoke test. 12m Carry out a smoke test on flue. See FLUES.

Waterways It is recommended that this operation is carried out atthe same time as flueway maintenance.

1. Isolation. 12m Turn off, isolate and remove heatgenerator. Where applicable,switch off electricity and removefuses. Turn off water supply.

See BURNER section maintenance.


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28732-13 DIRECT FIRED WATER HEATERS - continued


2. Drain down heater. 12m Drain down using drain valveon side of heater.

3. Casing cover. 12m Remove to gain access toinspection plate.

4. Waterways. 12m Remove inspection plate, checkfor scale build up.

If scale build up is excessive, chemical descaling will benecessary.

5. Sacrificial anodes(magnesium).

12m Check for condition, replace ifnecessary.

Do not replace copper and aluminium anodes butreplacement of magnesium anodes may be necessary insteel vessels.

6. Gasket. 12m After inspection of internalsurfaces a new gasket shouldbe fitted to inspection platebefore reassembly.

Note: Ensure that the heater is thoroughly flushed outand that any deposits removed.

7. Reassembly and test. 12m Fill up and test for soundness.Refit heat generator inaccordance with themanufacturer's instructions.Test fire.

Special note :Certain heaters called ENERGY SAVER WATER HEATERS will have an electrically operated damper in the flue to reduce ventilationlosses through the heater. The operation sequence is when the thermostat calls for more heat the damper opens, changing the contactson a microswitch. This then provides power to the heat generation equipment.

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28832-14 INSTANTANEOUS ELECTRIC WATER HEATERS


1. Visual inspection forleaks and damage.

12m Report any remedial workneeded to client and isolate ifunsafe.

2. Water temperature. 12m Check water outlet temperatureand operation of auto-temperature controls.

N.B. Temperature settings should be in accordance withACOP L8,2001 for Hot Water Services.

3. Inbuilt filter (if fitted). 12m Isolate electric supply, turn offwater inlet drain unit, removefilter/strainer and clean filter asnecessary.

4. Operation after filterreplacement.

12m After a filter replacement, checkoperation of heater and set flowas appropriate.

5. Scale. 12m In hard water areas descale.

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28932-15 PACKAGED ELECTRIC WATER HEATERS-cistern type


1. General. N.B. The exact maintenance procedure will dependupon the make and configuration as most packagedunits have different design arrangements.

2. Operating status. 12m Check, if unit out of serviceask client for reasons.

If electrically defective, ensure equipment is leftdisconnected and isolated.

3. External case andpipework connections.

12m Visual inspection for leaksand damage.

4. Water temperaturecontrols.

12m Measure temperature, checkagainst thermostat settings.Adjust thermostat asnecessary.

N.B. Temperature settings should be in accordance withACOP L8,2001 for Hot Water Services

5. High temperatures cut-outs.

12m Check temperature setting. Check operation of temperature controls and high limitcut-outs.

6. Electrical supply. 12m Isolate, remove fuse andcheck rating is correct.

Units must not be left with electrical element if incomingwater supply is isolated.

7. Ball valve operation. 12m Check, if ball valve needs re-washering, isolate watersupply and repair ball valve.Check for leakage andsecurity.

A defective ball valve will cause the cistern to overflow.


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29032-15 PACKAGED ELECTRIC WATER HEATERS Cistern type - continued


8. Presence of scale. 24m Drain down unit, removeinspection covers and inspectfor scale and corrosion. De-scale as appropriate orreplace heating element.

The formation of scale affects heat transfer andincreases energy consumption. It also causesoverheating of the electrical element leading to failure.Corrosion will cause the bare electrical element to beexposed to water and hence will be unsafe.

9. Return to operation. 12m Refit all inspection covers,refill heater and cistern. Turnon water supply to unit andcheck for leaks. Fit fuse andturn on electrical supply.

Check operation of all temperature controls and leave infull operation.

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29133-01 HUMIDIFIER - Cold water evaporator, drum type

Any action taken should conform to HSE environmental health services requirements ACOP L8,2001.Note: In hard water areas more frequent maintenance may be required.


1. Status. 3m Isolate electrically and hydraulically. Note: electrical isolation must meet HASAWAElectricity at Work requirements.

2. Rotor filter pads. 12m Closely inspect. Replace filter padsas necessary.On reassembly use new gasketswhere necessary.

Report condition. If filter pads need replacementit is necessary to first clean the rotor.

3. Water reservoir tank. 3m Flush and clean if necessary.

4. Connections and joints. 3m Check for leakage and make good anydefects.

5. Wiring and flexibleconduits.

3m Check for soundness.

6. Control and indicatorlights.

3m Check for correct functioning.

7. Deposits and sludge. 3m Clean up and remove. Any sludge solids removed should be in sealedbags and any solutions used for cleaning must beflushed away before returning the unit tooperation. Environmental Regulations apply

8. Moving parts. 3m Check that all moving parts can movefreely.

9. Motor gear box. 12m Change oil. See also MOTORS

10. Chain drives. 12m Lubricate.11. Return to service. 12m Check operation. Ensure compliance with HSC ACOP L8,2001.

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29233-02 HUMIDIFIER - Direct steam injection type.

Note:- When in operation, there is intermittent live steam injected from manifold within. DO NOT ATTEMPT TO SERVICE WITHOUTISOLATING STEAM AND ELECTRICITY SUPPLIES.


1. Status. 3m Isolate electrically. Note: electrical isolation should meet HASAWArequirements.

2. Removal of deposits. 3m Clean and flush out. Note: If automatic time controlled flush out valve is fitted,check correct operation by overriding timer. It may benecessary from time to time to adjust between automaticflushing depending upon humidification requirementswhich can vary with the weather conditions.

3. Ball valve. 3m12m

Check operation.Clean and renew washer.

4. Water level. 3m Check level in gauge glasscorresponds with indicator plate.

5. Humidistat. 3m Check operation, clean if necessary. Use a sling hydrometer to check accuracy of operation.

6. Misting sprays. 3m Observe spray pattern, clean ifnecessary.

Clean with compressed air. Do not use wire or pointedobjects as these will enlarge the orifices and lead to apoor misting pattern.

7. Control and indicatorlights.


8. Steam traps. 3m Check operation condition of filtersand sight glasses.

Ensure condensate drain is clear.

12m Clean and overhaul traps, strainersand sight glasses. Check by-passvalves are not leaking.

Faults can lead to steam wastage, excessive condensateand energy waste. Rust scale and solids can blockstrainer and render traps ineffective, regular cleaning istherefore essential


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29333-02 HUMIDIFIER - Direct steam injection type - continued


9. Steam pressure. 3m Check.

10. Strainer (where fitted). 3m Check strainer on steam supply.

11. Water supply. 12m Turn off at ball valve and empty viadrain cock.

12. Steam chamber. 12m Remove out casing lid baffles.Remove any scale either physically orby using suitable chemical descalingagent.

Ensure that any sludge or scale deposits areremoved from the bottom of the steamingchamber. Additional access may be provided onthe side of the vessel to facilitate cleaning. Environmental Regulations will apply

13. Feed water line. 12m Check that it is clear.

14. Re-assembly. 12m Ensure all joint faces are clean and re-assemble using new gaskets.

15. Re-commission. 12m Put back into service and checkwater level in gauge glasscorresponds with indicator plate,ball valve operates correctly,controls and indicator lights functionproperly.

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29433-03 ELECTRODE BOILER HUMIDIFIER

Note: In hard water areas maintenance may require to be carried out more frequently. If output is decreased due to heavy scalingrenewal of the cylinder will be required, refer to client.BEWARE - High water conductivity in the boiler circulated water can damage the boiler cylinder vessel, only work within the boilermanufacturers values of conductivity.Any action taken should conform to the HSE environmental services requirements – ACOP L8,2001


1. Status. 3m Check and isolate both water andelectricity supplies.

Note:- electrical isolation should meetHASAWA and Electricity at Work

requirements.2. Steam cylinder. 3m Check all electrical connections on the

cylinder for soundness and correct anydefects.

3. Cylinder exchange. 3m As per manufacturer's instructions. Cylinder exchange times will vary - hard waterareas 3 months. Soft water areas 12 months.

4. Water drain pump. 3m Check for free flow of water byoperating the pump. Repair any glandleaks. Check manual drain switchactuation.

This may require the removal of the cylinder.

5. Drain pipe. 12m Check for free flow, actuate drain ifnecessary.

6. Feed valve. 12m Clean strainer. Always replace the strainer after cleaning toprevent material lodging in the valve.


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29533-03 ELECTRODE BOILER HUMIDIFIER - continued


7. Unit testing after cylinderexchange.

12m Set the controls to 'start' and operatehumidifier in its normal mode andensure the functions are correct andhumidistat is functioning.

Ensure all electrical and mechanical covers are intheir correct places.

8. Fully automaticmodulating typehumidifier.

12m Check output modulation. As per manufacturer's instructions.

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29633-04 HUMIDIFIERS- Compressed air type

Note - this schedule should be read in conjunction with those on air compressors and pressure Regulations may applyAny action taken should conform to the HSE environmental services requirements – ACOP L8,2001


1. Status. 3m Isolate electrically and hydraulically. Note: electrical isolation should meet HASAWArequirements.

2. Nozzles. 3m Clean dust and debris from outside ofnozzles.

It is advisable to remove the air caps annually toclean thoroughly. Take care not to damage theprotective PTFE coating.

3. "Y" strainer. 3m Inspect and replace strainer screen.

4. Water pressure regulator. 12m Check condition and carry outmaintenance in accordance with themanufacturer's instructions.

Items which may need periodic maintenanceinclude:-2-way air solenoid valve,3-way water solenoid valve,air pressure regulator.

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29733-05 HUMIDIFIERS- Ultra sonic

Any action taken should conform to the HSE environmental services requirements – ACOP L8,2001ITEM FREQ. ACTION NOTES

1. Status. 6m Isolate electrically and hydraulically. Note: electrical isolation must meet HASAWAand Electricity at Work requirements.

2. Water tank. 6m Clean out and refill.

3. Ultra sonic diaphragms. 6m Clean carefully with soft non-scratchcloth.

4. Ultra sonic generator. 12m Check operational efficiency as permanufacturer's instructions. Replaceif necessary.

The life of the ultra sonic generator will depend ontype of manufacture and the water quality.

5. SEDIMENT REMOVAL. 1m Remove as necessary from top ofreservoir.

A risk assessment and method statement should be produced. PPE may be

needed. Environmental Regulations apply.

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29833-06 HUMIDIFIERS- Resistance heater type

In hard water areas more frequent maintenance may be requiredAny action taken should conform to the HSE environmental services requirements – ACOP L8,2001


1. Status. 12m Isolate electrically and hydraulically. Note: electrical isolation must meet HASAWArequirements.

2. Water boiling chamber. 12m Drain.

3. Resistance heaterelement.

12m Inspect and descale as necessary.

4. Scale collecting bag(where fitted).

12m Change as necessary.

5. Float valve, or solenoidvalve on make-up line.


6. Control indicator lights(where part of humidifier).


7. Inbuilt step controller(where fitted).

3m Check for correct operation.

8. Operation. 3m Restore services and put unit back online.

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29933-07 HUMIDIFIER - Disinfection procedures


1. System. 6m Isolate electrically and hydraulically, ifnot already isolated.

Isolation of electrical supply should be inaccordance with HASAWA requirements.

2. Loose debris. 6m Allow humidity water to drain, removesolid debris with 'wet and dry' vacuumcleaner.

3. Humidifier sump. 6m Check condition and repaint asnecessary,Check integrity of in-fill humidifiermedium and replace if worn, damagedor heavily scaled.

4. Disinfection. 6m Refill system with clean fresh water,disinfect system with addition ofsodium hypochlorite solution toachieve free residual chlorine reserveof 15 mg/l, maintain circulation for fourhours.

Ensure drain valve closed during refill.Note:- Free chlorine is rapidly absorbed byorganic matter and partially lost when thechlorinated water cascades through the infillmatter, thus further additions of sodiumhypochlorite may be required to maintain the freechlorine reserve at 15 mg/litre.


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30033-07 HUMIDIFIERS - Disinfection procedures - continued


5. Return to service. 6m Drain and thoroughly flush the sumpand operate the pumps for a further 15minutes. Drain sump, test to ensurethat residual chlorine has dropped tobelow 15 mg/l. Refill sump if unit to beput back into service immediately.

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301 34-01 ICE MAKING MACHINES - general


1. Condition. 12m Empty, check for damageand clean and disinfect.

Report to client if remedial work required.

2. Door seals (if fitted). 12m Check condition, refurbish orreplace as necessary.

Poorly fitting door seals can lead to either ice melting orfusion of ice pieces and energy wastage.

3. Cold water pipework. 12m Clean, disinfect and checkcondition of insulation.

4. Valves. 12m Check action and maintain asappropriate volume.

5. Controls. 12m Check action. For details see relevant section – CONTROLS.

6. Drains. 12m Check for blockage, clear ifnecessary and disinfect.

7. Refrigeration unit. 12m Check operation. For more detailed maintenance procedures, see –CHILLERS.

8. Return to service. 12m Return to ice making andcheck level sensors andother appropriate controlsfunction properly.

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302 35-01 INSULATION

WARNING: Insulation may contain asbestos. Broken Insulation may be dangerous and if in doubt do not start work and inform your supervisor and client.


1. Pipe lagging. 12m Check for dampness and broken condition

Broken & damp insulation washers energy and should be repaired as soon as possible.

2. Boiler lagging.

12m

Check for broken condition and repair if necessary.

3. Pump sound deadening lagging.

12m Check for asbestos. Inform client if asbestos is found.

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30336-01 LIGHTING

Introduction

The design and installation of lighting systems should be in accordance with the CIBSE Code for Interior Lighting and to ensure that thedesign conditions are maintained, regular maintenance is necessary. Failure to carry out that maintenance will lead to reduced lightinglevels, lower efficiency and energy wastage. It must be stressed that lighting is often a significant cause of energy wastage throughilluminations, poor controls and not using modern energy saving lamps.

The maintenance of lighting installations covers four main sectors, these are:-Local wiring and cabling, i.e. at entry and/or exit of fitting or control.Fittings including luminaries.Lamps,Controls.

Normally for wiring and cabling little maintenance is required unless alterations or temporary arrangements have been made. For luminairesand fittings the cleanliness of the environment is an important factor dictating the frequency of cleaning, dirty fittings and tubes cause loss oflight with the consequent effect on the efficiency of the work station and the accuracy of the work being carried out. In a dirty environmentfrequent cleaning may be necessary.

In the case of lamps, bulbs or luminaires the manufacturers quote a rated life. The rated life is the best average of life for a manufacturedbatch.

There is also another factor which may dictate replacement frequency and that is accessibility. Often it is cost effective to replace lamps on aregular basis based on the recommended life of the lamps. Clearly in certain situations such as a shop or hospital or where access is verydifficult a regular replacement schedule may be the most sensible option and this should be agreed with the client.

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30436-02 LIGHTING-SWITCHES-INTERNAL AND EXTERNAL


1. Operation. 12m Check action. This includes pull switches and remote operatedsensor (i.e. infra-red) switches.

2. Earth bonding. 12m Check and correct if defective.

3. Dimming switches. 12m Check operation.

4. Solar operated switches(external and internal).

12m Clean detector surface.Check:switching function,

sensitivity. Note: sensitivity of solar radiation detection cellmay fall with time and should be replaced ifsensitivity has fallen below manufacturer'srecommended limit.

5. Fireman's switch (externaldisplay lighting).

12m Check action.

6. Automatic switching controls(e.g. timers).

12m Check operation and timesettings.

Adjustments for BST should be made by theclient on the appropriate dates. For externallighting regular adjustments should be made tocompensate for changes in daylight hours. Thiswill reduce energy wastage.

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30536-03 LIGHTING FITTINGS including LUMINAIRES – general

ITEM FREQ. ACTION NOTES1. Cleanliness. 12m Clean fittings where

necessary.Frequency of cleaning will depend on environment, in dirty areasmore frequent cleaning may be necessary. Contract should statewhether this is part of the maintenance contract.

2. Lampsa) tungsten filament.

12m Check for failed lamps orsigns of deterioration.Replace as required.

Tungsten filament lamps are inefficient with regard to energy useand could be replaced with more efficient lamp types.

b) fluorescent. 12m Clean and replace any failedor suspect lamps.

Care should be taken in handling as broken glass from brokentubes/lamps can be dangerous.Disposal of tubes/lamps should be in accordance with H&Sand Environmental regulations.

c) discharge. 12m Clean and replace any failedor suspect lamps.

In readily accessible areas failed lamps should be replaced assoon as possible to avoid damage to control gear.Re-lamping - maintenance contract should be specific with regardto the responsibility for the provision and/or replacement of lamps.

3. Security of fitting. 12m Check security fixings andsuspensions.

4. Cable terminations. 12m Check externally for securityand signs of arcing oroverheating.

To be checked by agreed sample.

5. Flexible downleads andconnectors.

12m Check for deterioration renewif necessary.

Tighten or secure as necessary.

6. Diffusers andreflectors.

12m Clean and correctly adjustbefore re-assembly.

7. Lamp control gear. 12m Check operation andcompatibility with lamp.

8. Switches. 12m Check operation. Replace if faulty.

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30636-04 EXTERNAL LIGHTING including ILLUMINATED SIGNS

WARNING : Equipment may operate at voltages above 415 and extra precautions should be taken.ITEM FREQ. ACTION NOTES

1. Condition. 6m Clean and check:For physical damage.Signs of water ingress orcondensation, if present checkseals and report to client.

On plastic surfaces avoid a build up of staticwhich will re-attract dirt. Cleaning materialsshould be compatible with sign fabric.

If evidence of need for re-painting observed,notify client.

2. Electrical wiring. 12m To be checked by agreed sample

3. Earth continuity. 6m Check and remedy if necessary.

4. Lamps or tubes. 12m Check for failed or blackenedtubes or lamps. Replace asnecessary.

Replacement procedures should be agreed withthe client as recommended life can vary withtype of luminaire. Tube or lamp colour shouldconform with original colour specification.Disposal of tubes should be in accordance withH&S and Environmental regulations.

5. Cold cathode tubes. 12m Check for faulty tubes of lowbrightness. Replace or re-process as necessary.

Disposal and re-processing of tubes(particularly mercury tubes) should be inaccordance with statutory regulations. Wherereplacement of a single tube reveals a loss ofbrightness in the remaining tubes, considerationshould be given to block replacement or re-processing. In-fill gas mixture of replacementtubes must be compatible with the circuit design.


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30736-04 EXTERNAL LIGHTING including ILLUMINATED SIGNS - continued

WARNING: Equipment may operate at voltages above 415 and extra precautions should be taken.ITEM FREQ. ACTION NOTES

6. Control gear. 12m Check for correct operation. Replacement equipment must be compatiblewith that removed. Replacement cold cathodetransformers should be re-calibrated to thedesign mA output.

7. Security of fittings. 12m Check condition and security. If corrosion has occurred, inform client of needfor re-painting or replacement.

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308 37-01 EMERGENCY LIGHTING – self contained

Emergency lighting levels in existing installations may have to be upgraded to comply with any legislation. ITEM FREQ. ACTION NOTES 1. Testing. 1m To be carried out monthly in

accordance with BS5266: Part 1:1988. All tests shall be logged as per Appendix C of BS5266.

Client’s operators should be trained to carry out monthly tasks.

6m Test for on hour. If luminaire rated for duration of one hour, test simulating failure (ideally by test key or other suitable means) should be of 15 minutes duration.

12m Test for three hours. The once per year test is for the full duration of the battery and is best carried out when there is least risk to persons is the building i.e. late on Friday, as the battery packs require a twenty-four hour charge to provide the three hours emergency light.

2. Operation. 1m Check operation, if failure is suspected replace lamp.

If fault is not with lamp check that the mains LED is on with the mains supply restored, if not, report to client. Responsibility for monthly check should be agreed with the client.

3. Battery. 12m Check condition and date of expected life. Renew if necessary.

Normal life expectancy is five years. Batteries should be disposed of in accordance with H&S and environmental Regulations.

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309 37-02 EMERGENCY LIGHTING – externally powered

Emergency lighting levels in existing installations may have to be upgraded to comply with any legislation. ITEM FREQ. ACTION NOTES 1. Testing. 1m To be carried out monthly is

accordance with BS5266:Part 1:1988. All tests shall be logged as per Appendix C of BS5266.

Client’s operators should be trained to carry out monthly tasks.

2. Operation. 6m Energise from battery for period of one hour.

If the system is rated for one hour, duration of test simulating failure (ideally by test key or other suitable means) should be fifteen minutes.

12m Test for one hour. The once per year test is for the full duration of the battery and is best carried out when there is least risk to persons in the building i.e. late on Friday.

1m Check operation, if failure is suspected replace lamp.

Responsibility for monthly check should be agreed with client.

3. Battery. 6m Ensure terminals are clean and check electrolyte level. Check condition of battery case(s).

Follow manufacturer’s instructions at all times and advise client if battery replacement is required.

4. Battery charger. 6m Check operation and proper functioning.

If engine driven generator used, check electrical operation and connections. For prime mover refer to specialist maintenance engineer.

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31038-01 LIGHTNING CONDUCTOR AND EARTH

(Does not cover lightning strike prevention.)ITEM FREQ. ACTION NOTES

1. Conductor tape fasteningsand joints.

12m Inspect roof and plantconnections, vertical jointconnectors and earthtermination positions. Ensurethat conductor tapes aresecured firmly to the structureand all joints including those tostructural and service steelworkare mechanically and electricallysound.

Look for evidence of corrosion in thematerial, this is more likely to occur wherethere is contact between two dissimilarmetals or where the atmosphere has thepotential for a high degree of chemicalpollution. If renewal required, report to client.

2. Earth terminations. 12m Test resistance to earth. Advise client if the whole of the lightingprotection system has a resistance to earth over10 ohms. Record details and copy to client.

3. Lightning strike. Record details and copy to client.

After evidence of lightning strike the completeprocedure for inspection and testing should becarried out as soon as possible to ascertain thecondition of the system.

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311 39-01 MOTORS - DRIVE ELEMENTS

Note: Before carrying out any work, check status and isolate in accordance with HASAWA and Electricity at Work requirements. This will normally require the engineer to follow a permit to work system. Dual motor systems should be treated as one.


1. Mountings. 3m Check condition. Motor should run without any excessive vibration.

2. Motor casing. 3m Check ventilating louvres are clear. See also MOTORS

3. Bearings. 3m Lubricate where external nipples or lubricators are fitted.

Check annually bearing wear by measuring shaft float and end play and replace lubricant in motor bearings.

4. Brushes. 12m Check condition and replace if necessary.

5. Windings. 12m Clean and test.

6. Terminals and connections.

12m Check and ensure that they are secure.

7. Rating. 12m Check motor running current. The running current should not exceed the full load value (FLC) shown on the motor data plate.

8. Variable speed drives and other solid state controls.

12m

Refer to manufacturer. Faults and any special maintenance requirements should be referred to the manufacturer as specialised skills are needed to deal with this type of equipment. See CONTROLLERS – Speed controllers.

9. Check, measure and record insulation resistance

10. Check, measure and record earth continuity

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31240-01 PIPEWORK SYSTEMS - General


1. Supports. 12m Check and tighten as necessary. Loose supports can lead to undue strain onpipework.

2. Valves and stopcocks(where normally open)

12m Check operation. Valves should befully closed and then fully opened.Lubricate as necessary.

N.B. Carefully note the number of turns tofully close, so that valve can be reset to itsoriginal position. If operation of valve stiff,repeat operation until clear and then return valveto its original position.

3. Regulating valves. 12m Do not adjust unless alterations oradditions to pipework have beenmade.

If alterations to the pipework have been made itwill be necessary to recommission the system.

4. Double regulating valves. 12m Check operation. Settings should not be altered, but they can beused for regulation.

5. Glands. 12m Rectify any leakages. For severe leakage, immediate emergency actionwill be necessary. For regulating valve seeaction 3 above.

6. Anchor points and guideassemblies.

12m Check for security of fittings.

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31340-02 PIPEWORK SYSTEMS - Mountings


1. Slackness in nuts, screwsand bolts.

3m Check and tighten as necessary. Loose mountings can lead to undue strain onjoints and vibration can result.

2. Fastenings. 3m Check for corrosion. Replace any bolts that show signs of corrosion orwhere corrosion has made the nut a loose fit.

3. Screw heads. 3m Lubricate where exposed. Lubrication prevents corrosion and facilitates theremoval of plant for overhaul and repair.

4. Anti vibration mountings. 3m Inspect for permanent set (in springs).Renew as a matched pair.

Report to client if replacement necessary. Ifreplaced, ensure that the correct type is used.

5. Rubber blocks and mat. 3m Check for shearing and crackingunder load.

Report to client if replacement is necessary.

6. Alignment of plant, ductsor pipe connections.

3m If any mountings are found to besuspect check alignment.

7. Strainers. 12m Clean.

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31440-03 PIPEWORK SYSTEMS-TRACE HEATING


1. Local isolator. 3m Check operation.

2. Connections. 3m Check all connections areclean and tight.

3. Weather proof seals. 3m Check condition and remakeas necessary.

4. Insulation. 12m Check for damage andintegrity.

5. Controls. 12m Check functioning of controls. For more detailed maintenance of thermostats, frostprotection etc., see relevant section.

6. Operation. 12m Check and record the currentdrawn.

If the current drawn differs from the normal valueinvestigate and report to client.

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31540-04 CHILLED WATER-CONDENSER WATER PIPE SYSTEMS

This section relates to the circulation of chilled water and cooling water and covers pumps and the associated pipework. Fouling ofinternal surfaces with scale will reduce efficiency and lead to the waste of energy hence regular water treatment is necessary and theequipment to perform this task should be regularly maintained.

CONDENSATE TRAYS AND PIPELINES


1. System. 6m Isolate electrically and hydraulically. Isolation of electrical supply should be inaccordance with HASAWA requirements.

2. Loose debris. 6m Remove using wet and dry vacuumcleaner.

Ensure that adequate air-break exists betweencondensate trap and drain to prevent siphoning.

3. Condensate Tray 6m Check condition and repaint asnecessary,

Close condensate trap and fill tray tomaximum with clean fresh water.

4. Disinfection. 6m Disinfect tray and trap with addition ofsodium hypochlorite solution toachieve free residual chlorine reserveof 15 mg/litre.

Note:- Free chlorine reserve should bemaintained at a level of 15mg/litre for four hours.

5. Return to service. 6m Drain and thoroughly flush tray andtrap until no water remains incondensate tray. Refill trap with freshwater.

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31640-05 CONDENSER - CHILLED WATER CIRCULATING PUMPS

Warning - Never run pump without water in it and/or with valves closed. If any electrical maintenance is to be carried out system shouldbe capable of electrical isolation in accordance with HASAWA.


1. Motor and pump. Report any abnormal conditions immediately toclient.

i. connections, 1m Check for leaks.

ii. bearings, 1m Check bearings are not runningexcessively hot.

Normally bearing temperatures should bebetween 15° C and 45° C but up to 65° C isacceptable.

iii. noisy running. 1m Report to client. See also MOTORS

2. Isolation valves, strainersand flexibleconnections.

1m Check for leaks.

3. Pump lubrication. 3m Check and lubricate as necessary. Refer to manufacturer's literature and only userecommended lubricants.

4. Pump and motor casings. 3m Inspect and clean.

5. Electrical terminals. 3m Inspect and tighten as required.

6. Motor running current. 3m Check and record.

7. Wiring, insulation andflexible connections.

3m Check condition.


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31740-05 CONDENSER - CHILLED WATER CIRCULATING PUMPS - continued


8. Electrical startermaintenance:-

12m For detailed information.

a) circuit breakercontacts,

12m Inspect and clean all contact surfaces.

b) enclosures, switchesand push buttons,

12m Check and clean.

c) wiring andconnections, andflexible conduits.

12m Check condition, secure and tightenas required.

Look out for broken wire strands, pinched ordamaged insulation.

9. Seals and bearings. 12m Check condition, adjust or replace asnecessary.

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31840-06 PRESSURISATION UNITS - CHILLED WATER

Note:- Checks on pressurisation equipment should only be carried out by trained personnel.


1. Diaphragm expansiontank.

6m Isolate and drain, check cushionpressure.

Ensure diaphragm is in good condition, ifnecessary remove diaphragm for inspection andreport condition. Repair or replace diaphragm.

Check internal surfaces, report oncondition, remove any sharp edges,

Re-assemble, re-charge to correctcushion pressure.

2. Pressurisation unit. 6m Check closed valve pressure andpump capacity,

If necessary, dismantle, clean internal passages,inspect mechanical seal and renew any parts asnecessary.

Remove and clean pressure reducingvalve filter. Check pressure setting,

Dismantle and clean suction non-return valve,

Clean any debris from mains breaktank and if necessary, clean andlubricate ball valve.

Inspect set thoroughly for general condition,report any signs of rusting, damage or otherdefects.

Check and if necessary adjusthydraulic accumulator cushionpressure.


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31940-06 PRESSURISATION UNITS - CHILLED WATER - continued

Note:- Checks on pressurisation equipment should only be carried out by trained personnel.


3. External controls. 6m Check setting of high and lowpressure cut-out switches.

Ensure high and low pressure cut-out switchesinterrupt boiler(s) control circuits.

4. Re-commissioning. 6m Adjust setting of all cushion pressures,pressure switch and pressurereducing valve settings to conformwith above design information.

Leave system for immediate operation if required.

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320

40-07 PNEUMATIC EQUIPMENT – COMPRESSED AIR SYSTEMS - Introduction

For efficient operation of air operated control equipment such as control valves, relays and actuators a supply of clean dry, oil freecompressed air is essential. Pipelines should be adequately sized to minimise pressure loss and checked regularly for leakage as this canresult in mal-operation and energy wastage.

It should be noted that air receivers operating above 0.5 bar gauge pressure are subject to mandatory periodical certification and no workshould be carried out on an uncertified vessel and the client informed of the position.

From the first of July 1994 all parts of the Pressure Systems and Transportable Gas Containers Regulations 1989 will have taken effect.From this date a written scheme of examination will need to be provided for the periodic examination of the whole system. The writtenscheme must be drawn up by a ‘competent person’. Refer also to HSG 39 Compressor Air Safety.

Regular maintenance of the instrument air compressor is essential and particular attention should be paid to the performance of the air drierand oil separator.

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32140-08 AIR COMPRESSORS

It should be noted that to ensure dry, clean, and oil free air there are a number of daily and weekly tasks which the plant operator mustcarry out as part of his duties. These include condensate drainage, pressure drop checks across filters, oil contamination checks andaudible leaks.


1. Capacity Test. 12m Pump up receiver from zeroatmospheric pressure to workingpressure and note time taken.

Any marked difference from the manufacturersspecification may indicate leakage or compressorfaults.

2. General Conditions. 12m Check the following:condition of guards,interstage cooler drains,bearers and holding down bolts,hand operated valves,moisture traps. Check for tightness of glands and seats.

3. Status. 12m Switch off and isolate electricity. Note: Electrical isolation should be carried outaccording to the HASAWA.

Where receivers are subject to Statutory Testsand Examinations for purposes of insurance,major overhauls should coincide with such testsand examinations. Any recommendationsmade by the Insurance Inspector must becompleted before the receiver is returned toservice.

4. Oil. 12m Note level and change usingrecommended lubricating oil.

5. Belt and Drive. 12m Check tension and condition of beltsand drives

Ensure spare belts are available.


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32240-08 AIR COMPRESSORS - continued


6. Condensate removal. 12m Check condensate drainage systemand clean as necessary.

Note: This should be checked daily as part ofthe normal in house maintenance procedures.

The condition of the condensate is an indicationof the condition of the compressor.

7. Pressure relief valve. 12m Operate and check valve for condition,operation, setting and leak tightness.Adjust if necessary.

8. Air filter. 12m Clean. Poor condition can indicate main air intakeproblems.

9. Electrical connections. 12m Check and tighten all connections.Check condition of wiring andinsulation.

For associated equipment, see – MOTORS,PUMPS, FANS.

10. Gauges. 12m Check operation. Defective gauges should be reported with arecommendation that they be replaced.

11. Pipes and connections. 12m Check external condition and leaktightness.

Tighten connections as necessary.

With soldered or brazed joints, these may haveto be remade. To prevent internal scaling usedry, oxygen free nitrogen (OFN) during thejointing process.

12. Controls. 12m Check operation of pressure switchesand auto change over solenoids.

13. Offloaders, mechanicaland electrical.


14. Main air intake air quality. 12m Check air source for possiblecontamination and dangerous gases.

If air quality affected by location of intake, reportto client. Repositioning may be necessary.

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32340-09 AIR COMPRESSORS – Compressed air dryers


Refrigeration type.

1. Pipe connections. 3m Check for leak tightness, remedy asnecessary.

2. Electrical wiring andconduits.

12m Check condition and contacts. Makegood as necessary.

3. Discharge air dewpoint. 12m Measure and record. Compare with manufacturer’s recommendedfigures.

4. Condensate trap bowl. 3m Drain, clean with soapy water andreplace.

5. Evaporator fins. 3m Clean and straighten. Report any severe damage.

Water cooled after coolers.

1. Pipe connections. 12m Check for leaks.

Water absorption type

1. Drying medium. 3m Remove from container, checkcondition and treat as necessary.

Desiccants such as anhydrous calcium chloride,silica gel types or activated alumina, mayrequire different treatment.

2. Cleaning. 3m Where applicable, dismantle andclean with dry oxygen free nitrogen.Examine, test, refit or renew itemslisted under notes.

Items:- Insert casing-felt pads-perforated discs-spring-gauzes-strainers-cotton wool-‘U’ pin-external casing-desiccant as directed.


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32440-09 AIR COMPRESSORS – Compressed air dryers - continued


3. Discharge air quality. 3m Check and record.

a) air dewpoint,

b) air temperature.

Too high a temperature can cause break-up ofdesiccants.

4. Re-activation drying time. 3m Time change-over period. Compare with manufacturer’s recommendation.

Water adsorption type

1. Cartridge. 36m Change complete container.


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32540-09 AIR COMPRESSORS– Compressed air dryers - continued


Compressed air networkdistribution

Note: The Pressure Systems andTransportable Gas Containers Regulationswill apply to the complete system.

1. Filter and pressurereducing station.

3m Check particle filters and change asrequired.

Check oil filter and change asrequired.

Check pressure reducing valvesettings.

Check low pressure safety valve.

Presence of excessive oil indicates a need for athorough examination of the compressor. Clientshould be advised.

2. Moisture drain. 3m Check operation If ‘autotype’, check level valve opens and closesoutlet, if manual, check valve is not blocked.

3. Valves. 12m Check external condition, operation,leak tightness of glands and seats,spindles and handwheels.

4. Safety and reducingvalves.

12m Examine external condition checkoperation, settings and leak tightness.

5. Drains and trap. 12m Check external condition, operationand leak tightness.


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32640-09 AIR COMPRESSORS– Compressed air dryers - continued


6. Filters and strainers. 12m Check external condition, operationand leak tightness.

7. Gauges. 12m Check operation, condition and leaktightness.

Any defective gauges should be reported with arecommendation that they be replaced.

8. Pipes and connections. 12m Check external condition, and leaktightness. Ensure correct ‘sign-writing’(colour coding).

Pay particular attention to supports, hangersand brackets. Uncontrolled vibration can lean topipe breakage.

9. Pipe insulation. 12m Check condition of insulation on drainlegs, etc. and make good if defective.

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32740-10 FUEL SUPPLY FOR LOW PRESSURE GAS (LPG) OR OIL


1. Pipework. 12m Check for leaks. Check sleeves andphysical soundness. Check all endsare suitably plugged/capped.

2. Valves. 12m Check for soundness and leakage. See also VALVES in relevant section.

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32840-11 STEAM SERVICES

ITEM FREQ. ACTION NOTES1. Hangers and

supports.12m Check for breakages or damage. Undetected broken hangers can lead to undue strain

on pipes and possible breakage or sagging which canlead to waterlogging.

2. Valves and flanges. 12m Check for leakage, replacepacking if necessary.

Where insulated, check valve boxes for sign ofdampness - there is usually a small drainage hole atthe bottom of the flange or valve box. Uncheckedleakage wastes energy and causes pipe corrosion.

3. Insulation. 1m Check for damage and loss ofprotection. Renew if necessary.

Damage is often caused by ladders, feet or emergencyrepairs - in open air insulation can become waterloggedand ineffective. N.B. Asbestos Regulations may apply.

12m Remove flange and valve covers,inspect for corrosion.

Hidden corrosion can cause equipment failures whichcan lead to unscheduled plant shutdowns.

4. Valves on drain legsof mains.

12m Check operation. If not working can lead to waterlogging of steam mains,slow start ups and overloading of steam traps and poorheat transfer.

5. Operation of steamtraps.

1m Check operation, condition offilters and sight glasses.

Faults can lead to steam wastage, excessivecondensate, poor heat transfer in associatedequipment and energy wastage.

12m Clean and overhaul traps,strainers and sight glasses.Check by-pass valves are notleaking.

Rust, scale and solids carryover can block strainersand render traps ineffective, regular cleaning istherefore essential.

6. Vents on steam lines. 12m Check operation. Presence of air in steam reduces efficiency of heatexchangers.

7. Steam valves. 12m Renew packing on stems andflanges where necessary.

Wisps of steam escaping soon lead to bigger leakswhich cause scoring of stems and flanges leading toearly replacement.


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32940-11 STEAM SERVICES - continued

ITEM FREQ. ACTION NOTES8. Condensate services. 1m Check for pressure of continuous

discharge of steam. If presentcheck steam trips.

Condensate if uncontaminated is valuable and shouldnot be allowed to run to waste but should be returnedto the boiler if economical to do so.

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33041-01 PNEUMATIC RELAYSElectric to pneumatic, pneumatic to electric and pneumatic to pneumatic.


1. Input signal(s). 6m Check. ]

2. Output signal(s). 6m Check. ] By CONTROLS SPECIALIST

3. Operation. 6m Check for correct relationship betweeninput and output signals.

]

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33142-01 PORTABLE EQUIPMENT PAT TESTINGIt is a requirement of the Electricity at Work Act 1989 (Regulation 4(2)) that portable electrical equipment should be tested regularly (PATtesting) and records kept and equipment identified and marked accordingly. See also ECA document, ref. P119204. Dependant onlocation the frequency may be increased to 24m or more.

ITEM FREQ. ACTION NOTES1. Plug tops. 12m Examine for:

cracks,loose terminals,reverse polarity,tightness of cord grip,correct fuse,earthing and bonding,loose tops,any other defect.

Note: Details should be entered on the portableappliance test register. Where plug tops are accessibleby children, the use of shrouds on the plug top pins ismandatory.Note and report the use of any extension leads ormulti-way adapters. Client should be encouraged tomake monthly checks.

2. Cables. 12m Examine flexible cables for wear,fraying braids and brittleinsulation. Check colour coding.

If replacement necessary, report to client.

3. Detachable mainslead.

12m Check electrical condition andsecurity of attachment.

4. On-off switch. 12m Inspect and check action.

5. Insulating case. 12m Inspect and check for damage. If double insulated, makers mark should be visible, if indoubt carry out flash test. Note: All double insulatedequipment must be tested at least once every fouryears.

6. Accessible fuseholders.

12m Inspect and check rating.

7. Exposed outputconnections.

12m Check condition, for outputsgreater than 50V test short circuitcurrent.

Short circuit currents should be less than 5mA, ifgreater than 5mA, equipment should be labelled‘Unsuitable for use by children’ where GS23 of theElectricity at Work Regulations 1989 applies.

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33243-01 POWER GENERATION

Introduction

Many premises have standby power generation equipment to provide back up in the event of incoming power failures and there has been atendency to 'fit and forget' with the result that the equipment may fail to operate just when it is needed. Regular maintenance and testing istherefore essential and should form part of any maintenance schedule. These units comprise a mechanical prime mover, usually an oil orgas powered internal combustion engine, and an electrical generator with associated equipment and may include mains synchronisation. This specification covers primarily the electricity generation and control equipment and, except for simple tasks, the maintenance of the primemover should be carried out by specialist firms.

A similar position arises with small scale combined heat and power units which are being introduced to many sites, here the equipment canbe divided into three sections, the prime mover, electrical generation and heat recovery. This section covers the electrical generationequipment and the equipment used for utilising the recovered heat is covered within HEAT EMITTERS. Again the prime mover should bemaintained by specialist firms.

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33343-02 POWER GENERATION-STAND-BY GENERATOR

Frequent running and testing of stand-by power generation equipment is essential to ensure immediate availability at time of need. It isrecommended that plant should be run on load for a minimum of four hours on a regular basis.


1. Condition. 6m Visually inspect for oil leaks,loose guards etc.Check:coolant level,

oil level,

These checks should be carried out monthly byclient's operators.

2. Drive belts. 6m Check fan and alternator drivebelts for wear, tension andalignment.

These checks should be carried out monthly byclient's operators.

3. Shut down switches. 6m Check operation of low oil andhigh coolant shutdown switches.

4. Low water switch. 6m Check operation.

5. Coolant. 6m Check coolant level. pH (acidity) and SG (specific gravity) should bechecked regularly by the operator.

6. Injector pump drive belts. 12m Check wear and tightness.

7. Operation and auto-changefacility (where applicable).

12m Check operation and startingsequence.

8. Sump heater. 12m Check operation.

9. Fuel transfer pump. 12m Check operation.

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33443-03 BATTERIES - LEAD ACID - unsealed

Caution: Lead acid batteries give off inflammable gases which can be explosive in confined spaces therefore battery spaces must be wellventilated. Extinguish all naked lights before entering and no smoking.Note: This section is based on the requirements of the Code of Practice BS6133 and all tools used for maintenance must be insulated.Risk assessment and method statement must be carried out. PPE may be needed.


1. Cells. 12m Test and record specific gravityof electrolyte and top up ifnecessary.

Cells should normally be checked on a monthlybasis.

Cell and connector covers should be replacedimmediately work is completed.

2. Connections. 12m Clean, check for tightness andcorrect termination.

3. Fuses. 12m Check that rating is correct.

4. Capacity test. 12m Carry out test in accordancewith manufacturer's instructions.

Record details of test.

5. Ventilation. 12m Check that ventilation of batteryspace is adequate.

Report to client if remedial action is required.

6. Battery stand(s) (ifapplicable).

12m Check condition.

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33543-04 BATTERY CHARGING EQUIPMENT


1. Condition. 12m Check all external and internaldust from the equipment. Checkpaintwork for damage orcorrosion, clean and repaint asnecessary.Check security of doorfastenings and lock.

All ventilation holes and slots should be clear toprevent overheating.

Cause of corrosion should be determined.

2. Insulation. 12m Inspect for damage or signs ofoverheating and make good.

3. Equipment. 12m Check for damage or signs ofoverheating, check all items aresecurely fixed.

4. Contacts. 12m Clean and smear lightly withpetroleum jelly. Clean shrouds(if fitted).

Renew any contacts showing signs ofoverheating.

5. Cable terminations. 12m Check for tightness.

6. Earth connections. 12m Check for tightness.

7. Conduit and glandterminations.

12m Check for tightness.

8. Indicator lamps. 12m Check operation and functions.

9. Ammeter and voltmeter. 12m Check operation.

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33643-05 UNINTERRUPTIBLE POWER SUPPLIES

Because of the vital nature of uniterruptible power supplies the frequency of maintenance should be agreed with the client, a minimumfrequency of at least six months is recommended. It must be emphasised that this is specialist equipment which should be maintainedstrictly in accordance with the manufacturer's instructions.As this equipment is for use in emergencies, check with client that it is safe to proceed with maintenance.

ITEM FREQ. ACTION NOTES1. Cubicle. 6m Check condition and clean,

Check integrity of doors andpanels, including locks,Check for ease of operation ofswitches, isolators and circuitbreakers,Check condition of contactors –see POWER SUPPLIES.

All dirt and foreign bodies should be removed.

Check shrouds are in position, Shrouds should be fitted over terminals ofelectrolytic capacitors if visible with doors open andwhere live conductors are in proximity to operationaldevices.

Check indicator lamps andlenses, replace as necessary.

2. Fuses and MCBs. 6m Check for correct rating of fusesand settings and operation ofMCBs.

3. Relays, contactors andwiring.

6m Check for burn marks andtightness of connections.

Replace as necessary.

4. Earthing. 6m Ensure all sub assemblies withelectrical components mountedon are adequately earthed.

Where star washers are used for earth connectionsmake sure earth connection is good.


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33743-05 UNINTERRUPTIBLE POWER SUPPLIES - continued


5. Rectifier. 6m Switch on and check:Battery trickle charge voltage,Battery charge voltage level.

Check and record calibration of all meters on theequipment.

6. Rectifier alarms. 6m Check and record 'pick-up' and'drop out' voltages of all alarmrelays.

7. Rectifier waveform. 6m Check and record.

8. Inverter. 6m Switch on and check theInverter Control Unit controlvoltage. When operatingcorrectly, check and record theoutput voltage and frequency.

Compare with voltages recorded on testcertificate.Record the results and report any significantdifferences.

Check and record the calibration of all meters.

9. Inverter alarms. 6m Check for correct operation andcheck 'pick-up' and 'drop out'voltages of all AC and DC alarmrelays.

10. Inverter wave forms. 6m Check and record the outputwaveform.

11. Static power switch. 6m Check operation with bothrectifier and inverter switchedon.


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33843-05 UNINTERRUPTIBLE POWER SUPPLIES - continued


12. Output. 6m Check:inverter output voltage andfrequency,bypass voltage and frequency,load transfer,

load voltage and power. Measure and record.

13. Batteries.

a) lead acid, 6m Check condition. See POWER GENERATION BATTERIES.

b) other types. 6m Check condition and report to clientif replacement is required.

Batteries should be disposed of only inaccordance with H&S and Environmental Regulations recommendations.

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33944-01 POWER SUPPLIES

Introduction

The section on Power Supplies covers all those aspects of providing power to the point of use and includes switchgear, cables and outletsoperating at 415 volts and below. Areas needing particular attention are contacts, starters, phase loading, maximum demand control andpower factor correction equipment. The latter two are particularly relevant in terms of energy saving and controlling electricity costs where aclient is on a maximum demand tariff.

Unbalanced loading of phases often occurs where the site electricians make or alter connections to plant and equipment using the nearestavailable power source. Unbalanced currents lead to overheating of conductors, energy wastage and in extreme cases can be the cause offires.

Dirty, pitted or worn contacts can lead to overheating of starters, equipment failure, and cause interference on communications equipment.Lack of attention may result in fusing together of the contacts which could prevent a shut down in an emergency.

Specialist advice and contractors should be sought for supplies above 415 Volts.

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34044-02 MAIN SWITCH PANEL AT SUPPLY INTAKE


1. Panel exterior. 12m Check for physical ormechanical damage. Touch uppaintwork after removing signsof corrosion.

2. Busbars. 12m Check for visible signs ofoverheating, loose connectionsetc.

Check integrity of busbarconnections and tap-offconnections.

Use torque spanner to manufacturer's settings.Check electrical impedance with approved testequipment.

3. Phase balance and loading. 12m Check and report if phases areunbalanced or overloaded.

Unbalanced phases and overloading can lead toover-heating of switchgear and cabling.

4.a) Main ACB. 12m Check switching mechanism, Clean and lubricate as necessary.

Check both mechanical andelectrical interlocks,

Clean and lubricate as necessary. Checktripping and intertripping via test facility orcurrent injection facility.

Check isolation and withdrawalcarriage if applicable,

Clean and lubricate as necessary.

Check condition of isolatablecontacts,


Check operation of shuttermechanism,


Check dashpot oil levels. Top up or renew as necessary.


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34144-02 MAIN SWITCH PANEL AT SUPPLY INTAKE - continued


b) Main fuse switch. 12m Check switching mechanism, Clean and lubricate as necessary.

Check contact blades, Trim or replace if pitting or wear is evident.

Check terminations fortightness,

Check fuse rating against switchrating and/or circuit chart.

Renew if incorrect rating is in use.

c) Main MCCB. 12m Check cable and busbarconnections.

Use torque spanner to panel manufacturer'ssettings. Check electrical impedance withapproved test instrument.

Check circuit breaker switchcontacts (where accessible).

Check auxiliary equipmentconnections and settings.

Check for remote trip, undervoltage etc. asappropriate.

Check overcurrent and earthfault settings against records.

d) Main isolator. 12m Check switching mechanism. Report any variation.

Check contact blades for signsof overheating or burning.


Check cable and busbarconnections.

Trim and lubricate as necessary.


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34244-02 MAIN SWITCH PANEL AT SUPPLY INTAKE - continued


5. Instrumentation For specialised maintenance of instrumentationsee – CONTROL PANELS.

a) ammeters/voltmeters, 12m Check for accuracy andoperation.

b) selector switches, 12m Check for operation.

c) indicator lamps, 12m Replace failed indicator lamps.

d) protective relays 12m Check settings against records. Report any variations.

Check operation by injectiontest.

6. Insulated phase barriers. 12m Ensure that they are in placeand free from contamination.

7. Cabling terminations. 12m Check all neutral, earth andauxiliary connections andterminations.

8. General. 12m Check for presence of moisture,Remove any build up of dirt orother contaminants, Check that appropriate labelsand warning notices are cleanand in place.

Report to client if significant.

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34344-03 MAXIMUM DEMAND and POWER FACTOR CORRECTION

Where electricity is purchased under a tariff incorporating maximum demand (kVA) charges, attention should be paid to the half hourlymaximum demand indicator usually incorporated with the electricity supply meter. Control of maximum demand should be consideredwhere there is evidence of excessive peaks as this will reduce the need to bring on line inefficient peak load plant which leads to energywastage. Apart from bringing on loads at peak times a further contribution to a high maximum demand could be a poor power factorusually caused by inductive loads such as electric motors, fluorescent lamps, inverters etc. To avoid this unnecessary waste power factorcorrection equipment is normally installed.


1. Maximum demand controller(if fitted).

12m Check operation. This action should normally be carried out in thesummer months when maximum demandcharges are not incurred.

2. Power factor correctionequipment (if fitted).

12m Check each capacitor bank isworking.Check installed capacity isadequate for installed load.

This may be a central facility or attached toindividual large machines.A check should be made for additional electricloads which have been installed since theoriginal equipment was introduced or upgradedas the power factor correction equipment maybe no longer adequate to give the requiredpower factor.

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34444-04 ARMOURED CABLES AND CONDUITS


1. Armoured cables. 12m Check for physical damage and signs ofcorrosion.

Overstressing of the conductor canoccur if the radius of curvature at abend in the cable is too great.

2. Conduits. 12m Check:Condition and signs of corrosion.Security of fastenings.Attachment of earth tags.Earth continuity.Sealing where conduit penetrates wall, cablebox or cabinet.

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345 44-05 POWER DISTRIBUTION UNIT (PDU)

Caution: 1. Before commencing any maintenance work on PDUs read the notes in the Introduction. 2.Work should only be carried out by Competent persons . 3. All work should be subject to risk assessment and formal method statements 4. Prior testing care should be taken to isolate voltage sensitive equipment.


1. Panel exterior. 12m Check for physical or mechanical damage. Touch up paintwork after removing signs of corrosion.

2. Mains isolator (Door isolator)

12m Check for correct operation and interlock.

Check main switch blades, for signs of overheating or burning.

Trim and lubricate as necessary, replace if badly worn.

3. Busbars. 12m Check for visible signs of overheating, loose connections etc.

Check integrity of busbar connections and cable tap-off connections.

Use torque spanner to manufacturer's settings. Check electrical impedance with approved test instrument.

4. Insulating barriers. 12m Check that insulating barriers are in place, particularly over incoming terminals.


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34644-05 POWER DISTRIBUTION UNIT (PDU) - continued


5. Power contactors. 12m check contactor for correct mechanicaland electrical operation.strip and clean interior.Inspect and clean magnetic pole faces.Check moving contacts for wear or'pitting',Check coil for overheating or insulationbreakdown,Clean out arc chutes.

Damaged contacts should be redressed orreplaced as necessary. Use approved contactlubricant as recommended by manufacturer.

Use approved contact lubricant if recommendedby the manufacturerOn re-assembly check all electrical connections.

6. Starters, Frequency of maintenance will vary dependingon starting duty/frequency of unit but in nocircumstances should it exceed twelve months.

- direct on line, 12m Carry out maintenance as for powercontactors.

-star delta,-two speed-dualwound,-two speed-polechange,-reversing,-auto transformer-quick transition,electric heater andelectrolytic types,-air break,-inverter starters.

}}}} See relevant sections}}}}


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ITEM FREQ. ACTION NOTES7. Thermal overloads. 12m Inspect for signs of overheating,

Check electrical connections for tightness andsecurity,

Replace if necessary after havingestablished the cause and rectify it.

Inspect trip settings.Operate the trip/test facility ensuring that theswitchgear de-energises in a clean and positiveoperation.

Adjust if necessary to give correctprotection for the connected load.Record settings.Check for single phase protection byoperating the starter.

8. Magnetic overloads. 12m Inspect for signs of overheating,Check electrical connections for tightness andsecurity,Check oil levels in dashpots, if cloudy or sludge hasformed, clean out dashpot with solvent and refill,Check 'time' delay mechanism,Operate 'test' facility to ensure switchgear de-energises in a clean and positive operation,Inspect trip settings.

Use only manufacturer'srecommended fresh oil. Select correctdashpot drain hole if necessary.

Adjust if necessary to give correctprotection for connected load.

9. Panel wiring. 12m Inspect for signs of overheating or burn marks,Replace any suspect conductors,Check all connections, terminations, earth cablesand links for security and tightness,

Ensure cable connections are tight and correctlyterminated,Check that the panel is correctly bonded to earth.


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10. Fuses and/or miniature circuitbreakers (MCB).

12m Check for damage,Check for correct rating,Check tightness of fuse linkconnections,Check free operation of MCBmechanisms,Check for evidence of overheating.

Ensure spare fuses are not 'blown', replacewith correct rating schedule, if necessary.

Renew where necessary.

11. General. 12m Check for presence of moisture.Remove any build up of dust or anyother contamination.

Report to client if significant.

12. Instrumentation. a) ammeters and voltmeters, b) selector switches, c) indicator lamps.

12m

12m12m

Check for accuracy and correctoperation.Check for operation.Test for operation.

Compare with test instrument applied to samecircuit.Replace as necessary

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349 44-06 EARTHING


1. Earth electrodes. 12m Check: Integrity of conductor, Associated connections, Condition of electrode and soil.

Record details and compare with earlier records as any deterioration may be gradual. Resistivity of electrode may be affected by corrosion, damage or soil condition.

12m Test in accordance with method described in BS7430:1991.

See BS 7671 the IEE wiring regulations.

2. Residual current devices (RCD) 3m Test using test button. Responsibility for this check should be agreed with the client.

12m Test with approved RCD tester. Operation should be within 200 milliseconds at rated current output or within 40 milliseconds at 5 times the rated current.

3. Earth fault loop impedance test. 12m Frequency testing varies with location. Origin of the installation, Sub main switchboards /distribution boards, Final circuit distribution boards, Socket outlet circuits,

In certain circumstances there are statutory/local frequencies for testing. Test random selection with a minimum of two per circuit of which one shall be the socket-outlet which is electrically the most remote from the distribution board.

Lighting circuits, Isolated switches/control devices for fixed appliances, Exposed conductive parts of fixed appliances.


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35044-06 EARTHING- continued

ITEM FREQ. ACTION NOTES4. Main equipotential bonds. 12m Check visually and physically.

Any connections showing signsof deterioration by chemical orelectrolytic causes should be re-terminated and the newconnection checked with a'Ducter' test instrument.

Connections onto the main earth bar should bechecked and tightened up, if necessary, with anapproved torque spanner.

5. Earth fault relays 24m Check: Represents maximum interval, actual dictated byenvironmental conditions.

a) electromechanical availability of auxiliary trip supply(if applicable),magnetic gaps for dirt and clean,

Attention should be paid to fuses in tripping suppliesparticularly where no fuse supervision is provided.

contact surfaces,time current characteristic curveat appropriate time and currentsetting,minimum current setting,dust filter, clean or replace asnecessary.

Do not use abrasives or file.

b) electronic relays 24m Routine maintenance notgenerally required.

Regular checks on power available for trippingshould be made.

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35144-07 DISTRIBUTION BOARDS

Note: It is essential to maintain the integrity of cabinets and panels against the ingress of dust and vermin, the latter can cause severedamage to cables and thus create a fire hazard.


1. Distribution board case. 12m Check for physical and mechanical damage,touch up paintwork after removing signs ofcorrosion. Check that door can be securelyclosed.

If moisture present check source and report.

2. Cable insulation. 12m Check condition and inspect for signs ofoverheating.

If possible identify cause of overheating andreport.

3. Fuse carriers and MCBs 12m Check for damage,Check rating(s),Check free operation of MCB mechanisms,

Ensure fuses are not 'blown'.Replace with correct rating as per schedule ifnecessary.

Check for evidence of overheating. Renew where necessary.

4. Circuit charts. 12m Check for accuracy of descriptions. Ensurelabels are securely fixed to exterior of door.

5. Cable terminations. 12m Check all phase, neutral and earthconnections and termination.

6. Conduit and cable glandterminations.

12m Check for tightness.

7. RCDs. 3m Check operation via test button. Responsibility for this check should beagreed with the client.

12m Test with approved RCD tester. Operation should be within 200 millisecondsat rated current output or within 40milliseconds at 5 times the rated current.

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35244-08 RING MAIN and SUB CIRCUITS


1. Polarity and continuity. 12m Check. Carry out checks in accordance with IEEregulations.

2. Sockets. 12m Test action and polarity ofsocket outlets.Damaged socket outlets mustbe replaced.

Ensure shutters are functioning correctly.

3. Earthing. 12m Check arrangements and test. Carry out checks in accordance with IEEregulations.

4. Insulation resistance. 12m Check. Carry out checks in accordance with IEEregulations.

Spur outlets

1. Condition. 12m Check for physical damage.

2. Fuse rating. 12m If fused, check rating.


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35344-09 THREE PHASE CIRCUITS


Power outlets

1. Condition. 12m Examine for physical damage.

2. RCDs 3m Check operation via test button. Responsibility for this check should be agreedwith the client.

12m Test with approved RCD tester. Operation should be within 200 milliseconds atrated current output or within 40 milliseconds at5 times the rated current.

Socket outlets

1. Condition. 12m Check for physical damage.

2. Fuse rating. 12m If fused, check rating forconnected load.

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35445-01 PUMPS - General

Checks on pumps should only be carried out by trained personnel. LPHW pumps should be checked frequently (typically weekly) forexcessive noise or vibration, excessive seal leakage, and that the pressure differential is as required and that the casing is free from air. Itmay be appropriate to change over duty and standby pumps at the same time. Belt drives should be checked and adjusted as necessary(typically once per month), and anti-vibration mountings and flexible pipe couplings checked. Grease lubricated bearings intended forreplenishments should be greased as recommended (typically every six months), taking care not to overfill. All maintenance activitiesshould be logged.

ITEM FREQ. ACTION NOTESGeneral for all pumps.1. Noise, vibration and

overheating.6m Check, rectify if possible and report.

2. Lubrication. 6m Lubricate bearings and motors.3. Drives, pulleys, AV

mounts and drivecouplings.

6m Check and adjust where necessary.

4. Glands. 6m Inspect and adjust if necessary.Repack if required.

5. Suction line strainers. 6m Clean.

6. Pressure switches andlevel controls.

12m Check settings and test functionally.

7. Electrical connections. 12m Check.8. Motor vent slots. 12m Clear. Under certain conditions e.g. a dusty

environment, more frequent cleaning may berequired. See also MOTORS)

9. Drive guards. 12m Check and rectify security.

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35545-02 CIRCULATING PUMPS-general


1. Casings. 3m Inspect and clean as required.

2. Bearings and glands. 3m Inspect for wear, lubricate bearings andmotors, repack glands as required.

Report if defective.

3. Bolts, pulleys, couplingsand belts.

3m Inspect and adjust as required. Replacebelts if worn.

4. Pump pressures. 3m Check and record.

5. Strainers. 3m Inspect and clean as required.

6. Ball valves, float pressureand temperature switches.

3m Check for proper operation andcalibration.

Check and record all temperatures.

7. Motor electrical terminals. 3m Inspect and tighten as required. (See also MOTORS)

8. Full load running current. 3m Check and record.

9. Pulley(s). 3m Check and realign if necessary.

10. Isolation, regulation andnon-return valves.

3m Check operation. Tighten glands orrepack if necessary.

11. Drain and tundish. 3m Check for blockage, clean.

12. Anti-vibration mounts. 3m Check and clean. Generally report any defects to client.

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35645-03 CENTRIFUGAL PUMPS


1. Casing. 3m Inspect for external condition andsigns of leaks.

2. Glands and mechanicalseals.

3m Check external condition and leakrate.

If there are signs of leaks, tighten nuts or repackgland.Caution - do not over tighten.

3. Valves, cocks and drains. 3m Check externally for leaks. Rotate spindles and handwheels to checkfreedom of operation, examine drains for signs ofgland leakage.

4. Strainers and exhausters. 3m Check external condition and freedomof flow.

Check self priming action where fitted.

5. Belt drives. 3m Check for condition and alignment. Correct tensioning where necessary.

6. Couplings, pulleys,guards and holding downbolts.

3m Inspect and rectify any faults.

7. Isolation of pump fromelectrical and mechanicalpower.

3m Remove circuit supply fuses. For safety reasons pump should be isolatedbefore commencing work.

8. Pump. 3m Drain down, and where applicable,strip, test and adjust parts listed in'notes' column. Lubricate and grease.

Parts to be tested and adjusted include : glandsand packing, gland compression springs, lanternrings, seals, throwers, couplings, rubber sleevesand pins, nuts and spring washers.

9. Reassembly. 3m Test functionally.

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35745-04 PRESSURISATION PUMPS


1. Pump base andconnections.

3m Ensure pump base is level andpipework not strained.

Check that anti-vibration mountings aresatisfactory and vibration is not being transferredto the pipework.

2. Strainer elements. 3m Clean.

3. Pump and motoralignment.

3m Check and adjust if necessary. Examine couplings for tightness.

4. Motors and bearings. 3m Oil or grease where external nipplesor lubricators are fitted.

Use recommended grade of lubricant.Motor should be overhauled annually, see –MOTORS.

5. Drain holes, pipes andtank.

3m Clean and ensure that all blockagesare cleared.

6. Guards and shields. 3m Check for security and safety. Adjust if necessary.

7. Control and safetyswitches.

3m Inspect and check. These include low water level cut-out switches,high and low pressure sensing switches,electrodes, connector caps and contacts. Reportany defects to client.

8. Control, pressure reliefand reducing valves, airvents, purgers andconstant flow regulators.

3m Test for correct operation and rectifyany faults.

Report any defects to client.

9. Diaphragm expansiontanks.

3m Inspect. Ensure diaphragms are sound and air cushionpressure is correct.

10. Test run pressure boostersets, pressurising units,and filling pump.

3m Carry out adjustments to ensuresatisfactory operation.

Check operation of all automatic controls andchange-over switches.

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35845-05 ROTARY HAND PUMPS


1. Fixings and hoses. 12m Check security and leak tightness.Remedy any faults.

2. Operation. 12m Check functionality. Examine external condition and remedy anydefects.

3. Inlets and outlets. 12m Check for obstruction and clear ifnecessary.

4. Dismantle. 12m Examine for wear and corrosion. Clean, repair or replace as necessary, thefollowing: clack and ball valves, springs,diaphragms, seals, washers, gaskets, rotor, bodyand front plate.

5. Re-assembly and testing. 12m Check operation

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35945-06 SECONDARY HOT WATER CIRCULATING PUMPS

ITEM FREQ. ACTION NOTES1. Casing. 6m Inspect and clean as required.2. Bearings, glands and

seals.6m Inspect for wear, lubricate bearings

and motors, repack glands asrequired.

Report if defective.

3. Bolts, pulleys, couplingsand belts (where fitted).

6m Inspect and adjust as required.Replace belts if condition warrants it.

Ensure motor and drive and pulley are correctlyaligned. See also MOTORS)

4. Pump pressures. 6m Check and record.5. Strainers. 6m Inspect and clean as required.

6. Isolation, regulation andnon-return valves.

6m Check operation. Tighten glands orrepack if necessary.

7. Drain and tundish (wherefitted).

6m Check for blockage, clean.

8. Anti-vibration mounts. 12m Check and clean. Generally report any defects to client.9. Motor electrical terminals. 12m Inspect and tighten as required .

10. Full load running current. 12m Check and record.

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360 45-07 SEWAGE OR DRAINAGE PUMPS SUBMERSIBLE

Risk assessment and method statements are very important when carrying out maintenance of equipment contaminated by sewage and in terms of disinfection procedures, PPE, equipment and tools.


1. Pump motor/s. 6m Check insulation value of motor windings.

For detailed maintenance schedule, see MOTORS. Advise client if further investigation is required.

2. Pump/s. 6m

12m

Check pumping performance of all pumps. Withdraw pump from pit, check impeller for wear and blockages. Check seal chamber oil.

Visual observation of changing levels satisfactory. Clean and report as necessary. Renew if necessary.

3. Valves. 6m Check satisfactory operation of all isolating and non-return valves.

See relevant section for more detailed information on the maintenance of valves.

4. Controls (operational). 6m Inspect and check. Report any defects to client.

5. Building management system controls.

6m Simulate every function to ensure satisfactory operation.

Reset after test, ensure that alarm and operational information is transmitted to delegated terminal. For more detailed information about the maintenance of BMS see relevant section.

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361 45-08 SEWAGE and DRAINAGE PUMPS: DRYWELL

Risk assessment and method statements are very important when carrying out maintenance of equipment contaminated by sewage in terms of disinfection procedures, PPE, equipment and tools.


1. Drywell. 6m Check for seepage, if necessary pump out.

Report any excessive seepage to client.

2. Drywell high level alarm. 6m Check for correct operation. If defective, report to client as soon as possible.

3. Valves. 6m Check for satisfactory operation of all isolating and non-return valves.

See relevant section for more detailed information on the maintenance of valves.

4. Pump(s). 6m Carry out maintenance. See – PUMPS- GENERAL.

5. Pump motor(s). 6m Check insulation value of motor windings.

For detailed maintenance schedule see - MOTORS. Advise client if further investigation is required.

6. Level or pressure controls.

6m Check settings and test functionally.




Reset after test, ensure that alarm and operational information is transmitted to delegated terminal. For more detailed information about the maintenance of BMS, see relevant section.

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362 45-09 SEWAGE PUMPS: COMPRESSED AIR

Risk assessment and method statements are very important when carrying out maintenance of equipment contaminated by sewage in terms of disinfection procedures, PPE, equipment and tools.


1. Air compressors. 6m Carry out maintenance, if necessary pump out.

For detailed maintenance schedule see – PIPEWORK SYSTEMS.

2. Air receivers. 6m Carry out inspection and maintenance.

Note: The Pressure Systems and Transportable Gas Containers Regulations apply.

3. Valves. 6m Check for satisfactory operation of all isolating and non-return valves.

See VALVES for more detailed information about the maintenance of valves.

4. Ejector/diaphragm pump. 6m

12m

Lubricate all bearings, check pumping performance of all pumps. Withdraw pump from pit, check diaphragm for wear or damage.

Visual observation of changing levels satisfactory. Clean and report condition as necessary.

5. Controls (operational). 6m Check settings and test functionally.




Reset after test, ensure that alarm and operational information is transmitted to delegated terminal.

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36345-10 SUMP PUMPS: EXTENDED SHAFT


1. Motor. 12m Check insulation value ofwindings, clean ventilationslots and lubricate.

For detailed maintenance schedule, see MOTORS.

2. Grease points forextension shaft.

3m Lubricate all bearings. Note and report any excessive bearing noise.

3. Pump/s. 3m

12m

Check pumping performanceof all pumps.Withdraw pump from pit,check impeller for wear andblockages.

Visual observation of changing levels satisfactory.

Clean and report condition as necessary.

4. Valves. 6m Check satisfactory operationof all isolating and non-returnvalves.

5. Controls (operational). 6m Inspect and check. Report any defects to client.

6. Building managementsystem controls.

6m Simulate every function toensure satisfactory operation.

Reset after test, ensure that alarm and operationalinformation is transmitted to delegated terminal. Formore detailed information about maintenance see BMSSection.

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36445-11 DOMESTIC HOT WATER ACCELERATORS

ITEM FREQ. ACTION NOTES1. Casing. 12m Check for damage and clean.2. Motor electrical terminals. 12m Inspect and tighten as required.3. Circulation. 12m Check for water circulation and correct

direction of flow.Ensure rotor/impeller is free to turn. This isparticularly relevant when returning the system toservice.

4. Glands and seals. 12m Check for leaks, tighten glands etc. ifnecessary.

5. Flap valves. 12m Check location and operation. Applies to twin headed pumps only.

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36545-12 WATER PUMPING PRESSURE BOOSTING SETS

ITEM FREQ. ACTION NOTES1. Pump base and

connections.3m Ensure pump base is level and

pipework not strained.Check that anti-vibration mountings aresatisfactory and vibration is not being transferredto pipework.

2. Strainer elements. 3m Clean.3. Pump & motor alignment. 3m Check and adjust if necessary. Examine couplings for tightness.

4. Motors and bearings. 3m Oil or grease where external nipplesor lubricators are fitted.

Use recommended grade of lubricant. Motorshould be overhauled annually, see – MOTORS.

5. Drain holes, pipes andtank.

3m Clean and ensure that all blockagesare cleaned.

6. Guards and shields 3m Check for security and safety. Adjust if necessary.7. Control and safety

switches.3m Inspect and check. These include low water level cut-out switches,

high and low pressure sensing switches,electrodes, connector caps and contacts. Reportany defects to client.

8. Control, pressure relief &reducing valves &constant flow regulators.

3m Test for correct operation and rectifyany faults.


9. Hydraulic accumulator (iffitted).

3m Inspect and check gas cushionpressure and adjust as necessary.

Ensure diaphragms are sound. Use oxygen freenitrogen for topping up pressure as necessary.

10. Test pressure boostersets.

3m Run and carry out adjustments toensure satisfactory operation.

Check operation of all automatic controls andchange-over switches.

11. Building managementsystem controls.

3m Simulate every function to ensuresatisfactory operation.

Reset after test, ensure that alarm andoperational information is transmitted todelegated terminal. See – BMS.

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36646-01 REFRIGERANT DISTRIBUTION SYSTEM - general

ITEM FREQ. ACTION NOTES1. Sight glass(es). 3m Check operation and cleanliness.

Test for refrigerant leaks.Sight glasses, which should be fitted on any system,indicate refrigerant level and the presence ofmoisture. Faults which may be observed are:-a) bubbles in sight glass indicating a shortage ofrefrigerant or a restriction in the liquid line,b) a change in the colour of the moisture monitorfrom green to yellow indicates the presence ofmoisture in the system.

2. Superheat setting ofthermostaticexpansion valve (TEV)

3m Check operation following thesequence outlined in the 'notes'column.To adjust, remove valve cap at baseof valve, turn adjusting stem counterclockwise to lower the superheat orclockwise to increase the superheat.CAUTION: Only make one turn of thestem at a time.

a) measure temperature of the suction line at thepoint where the TEV bulb is clamped.b) read gauge pressure at compressor suctionvalve,c) add estimated pressure drop between bulblocation and suction valve.d) convert the sum of the pressures to theequivalent temperature and subtract this from theactual suction line temperature. This difference isthe superheat.

Note:- It can take thirty minutes for a new balance tobe achieved. Record new setting, it should bebetween 8 and 10 degrees.

3. Oil separators. 12m Inspect:-External condition of shell.Leak tightness of connections.Operation of valves and drains.Operation of float valves.

Many small units are sealed and the sight glass ison the oil separator.


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36746-01 REFRIGERANT DISTRIBUTION SYSTEM - continued


4. Glycol concentration. 3m Check, if low, restore to recommendedconcentration.

A fall in concentration may be the result ofleakage and pipework should be checked.

3m Check operation using followingsequence:-Close pressure switch isolating valvewhere fitted,Examine, clean and service pressureswitch isolating valve where fitted,Where applicable replace lid ofpressure switch,Connect up alarm test set.

Best practice is to use dry oxygen free nitrogenfor pressure testing and blowing out coils.Refrigerant should not be used because ofrelease of CFC's into atmosphere.

Take care not to distort contact arms ormechanism. Change if necessary on small units.

Ensure unit is leak tight.

5. High and low pressureswitches.

12m Check on operation of pressure switchcontacts and re-adjust to correctoperating pressures as necessary,On completion of tests -disconnect airpressure or vacuum equipment andalarm test set.-remake electrical supply and alarmcables-test functionally-return to service.

Apply correct pressure or vacuum reading tocoincide with pressure switch operating limits,note pressure or vacuum reading at whichpressure switch contacts make on both upperand lower limits.

Pressure switch isolation valves to be opened,where fitted.


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36846-01 REFRIGERANT DISTRIBUTION SYSTEM - continued


6. Insulation. 3m Check:-External condition,Soundness of vapour barrierand/or waterproof finishCondition of flange and valveboxes including internallinings and fasteners.

It cannot be stressed too heavily that ingress of watervapour must be minimised otherwise efficiency will bereduced and energy wasted. Pay particular attention toseals round hangers and supports. Look for damage dueto leaks.

Check paintwork and identification bands.

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36947-01 ROOM AIR CONDITIONERS – unitary reverse cycle heat pump terminal units with electric heating and reversing valve

Note: If unit is ceiling mounted cover office equipment immediately below any area of work.ITEM FREQ. ACTION NOTES

1. Status. 6m Isolate electrically. Note: Isolation of electrical equipment should becarried out in accordance with HASAWArequirements.

2. Heating/cooling coil. 6m Remove air entry filter, inspect coil fordirt and clean as required.

Remainder of unit should be cleaned annually.

3. Fan and motor bearings. 12m Lightly oil. Rotate by hand to check wear.4. Condensate drain pan

and pump.6m Check pan and drain are clear. Check that drainpipe is properly attached.

5. Air filter. 6m Wash, dry and refit, renew if required. In a dirty environment more frequent cleaningmay be required.

6. Water loop connections. 6m Check for leaks.7. Refrigeration circuit. 6m Check for leaks. Indicated by oil smears at joints.8. Electrical wiring and

terminals.6m Check integrity.

9. Return to service. 6m Place on cooling cycle, isolate fromwater loop, check high-pressure safetydevice stops refrigeration compressor.

Follow by opening water loop connection,resetting high pressure cut out and after changingto heating cycle check that unit provides heat.

10. Controls. 6m Return to standard settings.11. External cleaning 6m Clean unit externally. Note defects on report to client.

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370

48-01 SANITARY and WASTE WATER PLUMBING - Introduction This section covers all aspects of the disposal of waste water and it is essential that both contractor and client ensure that all actions and practices conform with the Health and Safety at Work Act (H ASAWA) and Environmental regulations. Certain activities may be covered by more than one specialist function and in these areas it is essential that the responsibilities for particular tasks are identified and allocated.

Note HSE Document INDG 197,198. Weil's Disease (Leptospirosis) This reportable disease is carried by rats and can be passed on to humans hence strict precautions should be taken to prevent infection. Attention is drawn to the need to carry out a risk assessment and produce a method statement for operators and maintenance personnel to use. PPE may be necessary.. Dangerous Gases Special care is needed when entering pits and other below ground chambers to ensure that they are properly ventilated and free from harmful gases. Under Food Hygiene Regulations it is essential that operatives and maintenance personnel do not work on clean water systems if they have been in contact with wastewater or sewage. Hospitals and similar facilities may call for specialist services, which should be identified and agreed with the client.

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37148-02 MACERATORS


1. Condition. 12m CheckCondition of body andattrition blades.Bearings.For blockage and clear.Operation.

If there is evidence of severe wear on the attritionblades, advise client of need for replacement. If therehas been abuse or signs of jamming, by for instanceforeign objects, bearing wear or distortion may beevident.

2. Electrical connections. 12m Check for tightness.

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37248-03 INTERCEPTORS - Petrol and Oil

Note: Petrol filling stations are outside the scope of this specification.Great care should be taken when entering brick or concrete drainage pits because of the possible presence of harmful gases. Theyshould be vented to ensure the chamber cannot be pressurised over 0.1 bar g. (1.5 psig). Where entry into confined spaces isnecessary, compliance with HSE Guidance note L101 Safe work in confined spaces 1997 and INDG 258 Work in confined spaces- is required.


Petrol and Oil interceptors.

1. Condition of tankage. 12m Check and report anysignificant deterioration.

Take care not to inhale any fumes.

2. Water. 12m Clean surface and removeany floating solids. Anysurface contamination by oilysubstances to be removed byvacuum separately fromsedimentary solids.

Any liquid or solids removed during the cleaning processmust be disposed of in accordance with H & S

r Environmental regulations.

3. Chamber interconnectors. 12m Check that these are notobstructed.

4. Vent pipes. 12m Check that all vents and ventpipes are clear andunobstructed.

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37348-04 INTERCEPTORS - blowdown and sumps

Note: This subject comes within the scope of the HSE Guidance Notes PM60, L101 and PM5. Great care should be taken when enteringbrick or concrete drainage pits because of the possible presence of harmful gases. They should be vented to ensure the chamber cannot bepressurised over 0.1 bar g. (1.5 psig). Where entry into confined spaces is necessary, compliance with HSE Guidance note L101 SafeWork in confined spaces 1997 and INDG 25 Work in confined spaces - is required.


Blow down pits1. Cleaning. 12m ISOLATE FROM BOILER.

Drain and thoroughly clean out.This work should only be carried out by a competent personand appropriate safety precautions must be observed. Thework may be carried out at the same time as the boilerinspection.

2. Access cover. 12m Check condition and security. Some pits may be fenced and if so the fencing should bechecked and made good if necessary.

3. Vent pipe andsilencer (if fitted).

12m Check condition and ensure there isno blockage.

If replacement or repair necessary, advise client.

4. Anti-siphon hole. 12m Check hole is clear.

Blow down tanks Note: these are pressure vessels and as such come withinthe scope of the Pressure Systems and Transportable GasContainers Regulations. See also HSE document L101.

1. Cleaning. 12m ISOLATE FROM BOILER.Drain and thoroughly clean out.

This work should only be carried out by a competent personand appropriate safety precautions must be observed. Thework is normally carried out at the same time as the boilerinspection.

2. Access cover. 12m Check condition and ensure sealsare clean.

3. Vent pipe andsilencer (if fitted).

12m Check condition and ensure there isno blockage.

If replacement or repair necessary, advise client.

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37448-05 SANITARY, WASTE WATER PLUMBING and DRAINS


Waste water pipework andtraps.1. Condition.

6m Check cleanliness andensure traps etc. run free.

Where remedial work is required advise client.

Kitchen grease traps 1m Inspect and remove anyaccumulated grease andother residues.

It is recommended that client should ensure that his staffare familiar with these traps and clean them at leastonce per month and more frequently if accumulationsare severe.

Sanitary fittings1. Urinals.

6m Inspect and clean, ensuregrids on waste are clear andoutlet(s) run freely.

2. Water closets. 6m Check condition and ensurecorrect flushing and freeoutlet.

3. Cisterns. 6m Check operation and ifnecessary replace washer onintake float valve.

If water is running continuously check diaphragm onsiphon and replace if necessary.

4. Automatic controls andsensors.

6m Check operation. If controls are faulty refer to the manufacturer'smaintenance instructions.

Soil stacks1. Obstructions.

6m Check that there are noobstructions.

External examination should conform to BS8301, para.26, 1-3.

2. Bird guards. 6m Check condition and replaceas necessary.


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375

48-05 SANITARY, WASTE WATER PLUMBING and DRAINS - continued


Drainage 1. Surface water drains.

6m

Check grates and clears of any deposits and water flows freely. Clear any sediment from grate sumps. Check condition of junction and access covers.

Advise client if any replacements are necessary.

2. Waste water drains. Check that drains are free from any obstructions and that any covers are in place and sealed. If cleaning required ensure that H S and Environmental requirements are followed.

If cleaning is required this should be agreed with client.

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37648-06 AIR ADMITTANCE VALVES


1. General. Air admittance valves which are manufactured inaccordance with an Agrément certificate issued byBoard of Agrément do not normally requiremaintenance.

2. Inspection. 12m Visually inspect externally formechanical damage orvandalism.

Report to client if remedial work is required. In the eventof accidental damage or vandalism the cover can beremoved and the damaged components or the completeassembly replaced.

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37748-07 RAINWATER DOWNPIPES AND GUTTERSStagnant water can be a health hazard and appropriate health precautions should be taken.


Gutters1. Condition. 12m Inspect and remove any

deposits. If there are anysigns of corrosion theseshould be treated.

Depending upon location more frequent cleaning maybe necessary i.e. presence of trees or extremes oftemperature.

2. Joints and seals. 12m Inspect, check for evidenceof leakage and rectify anyfaults.

3. Fixings. 12m Check condition and secure ifloose.

4. Trace heating tapes(where fitted).

12m Check operation andposition.

Rain-water pipes1. Condition. 12m

Inspect and remove anydeposits. If there are anysigns of corrosion theseshould be treated.

Depending upon location more frequent cleaning maybe necessary i.e. presence of trees or extremes oftemperature.

2. Joints and seals. 12m Inspect, check for evidenceof leakage and rectify anyfaults.

3. Obstructions. 12m Check for free flow of water,remedy any defects.

4. Fixings. 12m Check condition and secure ifloose.

5. Trace heating tapes(where fitted).

12m Check condition and position.

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48-08 SANITARY AND WASTE WATER PLUMBING-WATER SAVING DEVICES and METERS


1. Timers. 6m Check: Operation, Settings, and adjust as necessary.

Change over GMT/BST saving may have been overlooked.

2. Hydraulic flushing control.

6m Check operation and carry out maintenance procedures in accordance with the manufacturer's instructions.

3. Detection devices. 6m Check operation. For more detailed maintenance instructions, see –SENSORS

4. Strainer. 6m Examine, clean and change if necessary.

5. Electrical connections. 6m Check integrity.

6. Cistern. 6m Check warning pipe is unobstructed.

7. Battery (where fitted). 6m Check remaining life, change as necessary.

Replace battery according to manufacturer's recommendations. All batteries should be disposed of in accordance with H&S and Environmental requirements.

Meters

1. Installation

6m

Check condition.

Supply meter is normally the responsibility of the water undertaking and should be maintained by them.

2. Filter (where fitted) 6m Check condition, clean or replace as necessary.

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379

49-01 SECURITY SYSTEMS - INTRUDER ALARMS For security reasons when the client elects to have the maintenance carried out by the building services contractor, it is suggested that the client should carry out items 1-4 at least once every three months to ensure that the system integrity is maintained. Close circuit television (CCTV equipment), which is usually linked into intruder alarm systems is normally maintained by specialist contractors. ITEM FREQ. ACTION NOTES 1. System integrity. 12m Carry out external examination

of installation. Any evidence of tampering or damage should be recorded and reported to the client.

2. Sensors and contacts. 12m Carry out operational check. If outdoors check beam systems are not impaired by vegetation or other obstacles.

Confirm correct operation and sensitivity, where appropriate check spatial configuration for volumetric devices.

3. Alarm signals. 12m Check response to signal. 4. Sensor covers, terminal

boxes and fixings. 12m Check security,

Check internally for signs of overheating, ingress of dust and moisture.

Clean internal components with soft brush and remove any dirt or fluff. When replacing covers check operation of any tamper switches which may be fitted.

5. Power supplies. 12m Check power supplies and associated batteries,

Batteries should be checked for signs of leakage or corrosion.

Check equipment responds to interrupted mains supply.

6. Detection modules (if applicable).

12m Check and adjust (if necessary) bridge balance.

7. Batteries a) sealed lead acid, b) sealed nickel-cadmium.

36m Replace Batteries should be disposed of in accordance with H&S and Environmental Regulations.

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38050-01 SENSORS and SWITCHING DEVICES - Electric/electronic and pneumatic.

Pre-maintenance procedure.

This procedure applies to all types of sensors and thermostats and requires that all safety precautions and safe working practices beobserved.

1. Check security of mountings.

2. Inspect for physical damage.

3. Check for cleanliness. Obscuration of sensors with dust can reduce sensitivity and effect the signal.

4. Check termination for tightness and corrosion - a) Electric cable, b) Pneumatic pipework.

5. Check cable/pipework locally for fixing and condition.

6. Verify correct location and installation as per manufacturer's instructions and check for any extraneous influences.

7. Note settings prior to commencing maintenance.

8. Check for element deterioration.

9. Pneumatics. Particular attention should be paid to the quality of the instrument air. Check for contamination by dirt, oil orwater.

10. All sensors should be maintained in accordance with the manufacturer's recommendations.

11. Special sensors such as are used for glycol concentration, detection of smoke and gas, and sensors used in water treatmentmay require specialist attention.

When cleaning or working in ducts it is essential that all sensors should be with withdrawn from the duct to prevent damage.Care should also be taken to prevent any damage to linkages or other control devices.

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38150-02 PRESSURE MEASUREMENT SENSORS - static and differential


1. Sampling pipework andconnections.

12m Inspect for leakage andcorrosion.Check for correctconfiguration.

2. Water sampling lines. 12m Purge to remove any air.

3. Operation. 6m Check for correct operation. Check contact condition if a pressure switch.

Refer to manufacturer’s recommended inspectionprocedures.

4. Calibration. 12m Check. Refer to manufacturer’s recommended calibrationprocedures.

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38250-03 TEMPERATURE MEASUREMENT SENSORS


Space temperature sensor

1. Sampling 12m Check for any obstruction.

2. Cleanliness. 12m Check sensor is clean andfree from dirt.

3. Operation. 12m Check for correct operation. Refer to manufacturer's recommended inspectionprocedures.

4. Calibration. 12m Check. Refer to manufacturer's recommended calibrationprocedures.

5. Frost protection. 12m Check operation. Confirm setpoint.

This may be outside the building on older systems.

Outside temperature sensor

1. Sampling. 12m Check for any obstruction.

2. Location influence. 12m Check effect. Examples are solar gain, proximity to warm extractvents, cooling towers, etc.




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38350-03 TEMPERATURE MEASUREMENT SENSORS - continued


Duct mounted sensors

1. Cleanliness. 12m Check sensing element forcleanliness where possible.

Clean as appropriate, refer to manufacturer'sinstructions.

2. Sampling. 12m Check for any obstruction toairflow at sensing element.



Immersion sensor

1. Sensor pocket. 12m Check for leaks.

2. Sensor. 12m Check for good qualitythermal contact.

I.e. Use of heat transfer grease, spring systemsetc. as per manufacturer's recommendations.




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38450-03 TEMPERATURE MEASUREMENT SENSORS - continued


Clamp-on sensor and surfacesensor

1. Surface contact. 12m Check for good surfacecontact.

Use heat transfer grease as per manufacturer'srecommendations.



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38550-04 RELATIVE HUMIDITY SENSORS


Space humidity sensor

1. Sampling 6m Check for any obstruction

2. Cleanliness. 6m Check sensor is clean and freefrom dirt.



Outside humidity sensor


2. Location influence. 12m Check effect. Examples are solar gain, proximity to warmextract vents, cooling towers, etc.




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38650-04 RELATIVE HUMIDITY SENSORS - continued


Duct mounted sensors

1. Cleanliness. 6m Check sensing element forcleanliness where possible.

Clean as appropriate, refer to manufacturer'sinstructions.

2. Sampling. 6m Check for any obstruction toairflow at sensing element.

3. Operation. 12m Check for correct operation. Refer to manufacturer's recommendedinspection procedures.

4. Calibration. 12m Check. Refer to manufacturer's recommendedcalibration procedures.

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38750-05 ABSOLUTE HUMIDITY SENSORS


Space sensor

1. Sampling pipework. 6m Check for any obstruction.

2. Sensor. 6m Check that sensor is clean andfree from dirt.

3. Environment. 6m Check for signs of condensationand a saturated environment.

4. Operation. 12m Check operation. Refer to manufacturer's recommendedinspection procedures.


Duct sensor

1. Sampling pipework. 6m Check for any obstruction.

2. Sensor. 6m Check that sensor is clean andfree from dirt.

3. Environment. 6m Check for signs of condensationand a saturated environment.



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38850-06 AIR QUALITY SENSORS


Space air quality sensor


2. Sensor. 6m Check sensor is clean and freefrom dirt.


Duct air quality sensor

1. Cleanliness. 6m Check sensing element forcleanliness.



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38950-07 CARBON DIOXIDE SENSORS


Space carbon dioxide sensor


2. Sensor. 6m Check sensor is clean and freefrom dirt.



Duct carbon dioxide sensor

1. Cleanliness. 6m Check sensing element forcleanliness.




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39050-08 VELOCITY SENSORS


1. Cleanliness. 6m Check sensing element forcleanliness where applicable.




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39150-09 OCCUPANCY and LIGHT SENSORS


Occupancy

1. Cleanliness. 12m Clean as per manufacturer'sinstructions.

2. Operation. 12m Test for correct operation.

3. Location. 12m Check that sensor is notaffected by extraneous effects.

Light level sensors

1. Cleanliness. 12m Clean as per manufacturer'sinstructions.

In dirty environments more frequent cleaning ofthe sensor may be necessary.

2. Sampling. 12m Check for any interference orobstruction.

e.g. shadows or reflections.

3. Operation. 12m Test for correct operation.

4. Calibration. 12m Test and carry out calibrationprocedure.

Refer to manufacturer's recommendedcalibration procedures.

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39250-10 SMOKE DETECTORS


1. Cleanliness. 12m Check sensing device and whereappropriate sampling system forcleanliness and possibleobstructions.

Refer to the manufacturer's instructions for cleaningprocedures.

2. Operation. 12m Test for correct response andoperation.

Refer to manufacturer's instructions forrecommended testing procedures.

Some type of sensor have a finite life cycle and needto be replaced at intervals specified by themanufacturer.

Certain devices such as ionisation detectors have noserviceable components and should not be exposedas a radioactive risk may occur. Always refer tomanufacturer's instructions and follow allrecommended safety procedures.

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39350-11 GAS DETECTOR SENSORS

Note:- Gas detectors are specialist devices and are often designed to detect a specific gas or family of gases e.g. propane or butane, andit is essential to refer to the manufacturer's instructions before commencing any maintenance work on them.


1. Cleanliness. 12m Check sensing device andwhere appropriate samplingsystem for cleanliness andpossible obstructions.

Refer to the manufacturer's instructions forcleaning procedures.

2. Operation. 12m Test for correct response andoperation.

Refer to manufacturer's instructions forrecommended testing procedures.

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39451-01 SHOWERS

Note: Frequency of maintenance will depend upon use and the quality of the water and should be agreed with the client.ITEM FREQ. ACTION NOTES

Valves See - VALVES.

Spray fittings

1. Outlet sprays. 12m Remove, clean and disinfectspray heads.Check adjustable sprays (iffitted).

Take care not to damage spray outlet holes.

2. Body jets. 12m Remove, clean and disinfectspray heads. Adjust waterflow rates.

Take care not to damage spray outlet holes.

3. Flexible hoses. 12m Check joints and flexiblecovering for damage.

Report to client if replacement recommended.

Shower enclosures and trays

1. Seals. 12m Check for leaks on seals ofdoors and screens.Rectify or replace asappropriate.

Operate shower with door closed and carry out visualinspection.

2. Waste outlet. 12m Clean and unblock wasteoutlet trap as necessary.

If possible fit top access waste trap. More frequentmaintenance may be necessary depending uponfrequency of use.

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39551-02 SHOWERS BOOSTER PUMPS

Note: Frequency of maintenance will depend upon use and the quality of the water and should be agreed with the client.ITEM FREQ. ACTION NOTES

1. Casing. 12m Check for damage and clean.

2. Motor electricalterminals.

12m Inspect and tighten ifrequired.

3. Motor. 12m Clean and check. See MOTORS.

4. Anti-vibration pad(s). 12m Check for wear andmovement out of position.Replace as necessary.

5. Flow switches (wherefitted).

12m Check operation. The two switches fitted to a twin impeller pump forseparate hot and cold water supplies should be checkedseparately.

6. Air pressure switches(where fitted).

12m Check operation. Air switches should be used only where a low statichead is present.

7. Water filters. 12m Remove and clean.

8. Ventilation. 12m Check clearance round pumpfor proper motor ventilation.

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39652-01 SMOKE EXTRACT - general

In many shopping malls, warehouses, staircases and other similar areas openable ventilators are installed to relieve smoke natural ventsand/or to provide natural ventilation. The actual fire prevention equipment does not come within the scope of this document and itsmaintenance should be carried out by specialist contractors.

52-02 SMOKE RELIEF - and/or natural fire ventilators

Frequency of maintenance and testing for smoke relief ventilators should conform to BS7346 part 1 Appendix E and/or the FirePrecautions (Workplace) Regulations and should be in accordance with local authority requirements.


1. Fixing and weathering. 12m Check condition and clean off any dirtwith stiff (not wire) brush from internaland external weathering channels.

In very dirty or aggressive environments, morefrequent attention may be necessary.

2. Louvres/flaps ordampers.

12m Clean bearings and lubricate asnecessary.

3. External hand controlwhere fitted.

12m Check and adjust.

4. Operating mechanism. 12m Check action. Report to client if repairs or replacement required.

5. Smoke vents. 0.25m Check condition and test weekly andrecord as required by BS 7346, andthe Fire Precautions (Workplace)Regulations 1997.

Client to advise if weekly tests are to be includedwithin maintenance contract.

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39752-03 SMOKE RELIEF - Powered fire ventilators


1. Electricity supply. 12m Isolate in accordance with Electricity at work requirements.

Note: Ensure clients is aware thatsystem or part of system is inoperativeduring execution of maintenance.

2. Filters. 12m See FILTERS.

3. Fixings 12m Clean fixing and weathering and clean off all dirtfrom external surfaces of ventilator.

Use brush for dirt removal.

4. Fan impeller of motor. 12m Clean impeller and rotor and check ease ofrotation and correct direction of rotation.

It is important to check for correctclearance between fan shrouds andimpeller. (See also MOTORS)

5. Fan discharge. 12m Check fan inlet and discharge are unobstructed.

6. Non return flaps. 12m Check and adjust for correct operation. Straighten any bent or distorted blades.

7. Water cooling system(where fitted)

12m Checka) spray nozzles are clean and undamaged.b) cleanliness.c) that water system is available at the requiredpressure. Clean strainer where fitted.


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398

52-03 SMOKE RELIEF - Powered Fire Ventaltors - continued


8. Test and run. 0 .25m Test weekly and record Note: Client is to advise whether weekly test is to form part of the maintenance contract.

9. Controls.

12m

Check action.

See CONTROLS for detailed maintenance.

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39952-04 SMOKE CURTAINS


1.Curtains

a) control, 12m Ensure curtain control is isolated from independentcontrol circuits, e.g. smoke detectors.

b) guide rails (where fitted) 12m Check rails are clear of any obstruction.

c) fabric, 12m Check for damage and report.

d) high and low limits, 12m Check and adjust as necessary.

e) zone operation. 12m Operate by zone.

2. Electrical services.

a) battery back up and control, 12m Test operation. Check battery condition andcharge rate.

b) earth and resistance, 12m Test at panel.

c) amperage and voltage, 12m Check and note incoming voltage to controls.

3. Compressor (whereapplicable)

See relevant section.

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40053-01 SOLAR HOT WATER PANELS and similar COLLECTING DEVICES


Plate type collectors1. Glass cover plate. 6m Clean and report condition if

cracked.Frequency will depend on location and localatmospheric condition. Dirt causes loss of collectorefficiency. Cracked glass should be replaced.

2. Seals. 12m Check condition and makegood if necessary.

Poor seals lead to internal condensation and loss ofefficiency. If there are signs of internal algae growth onunderside of glass plate, it should be removed, cleanedand resealed. Care should be taken not to damageabsorber plate as it may have a special coating.

3. Anti-freeze solution (ifused).

12m Check condition and top upto required concentration.

Anti-freeze solution should be replaced every threeyears.

4. Controls. 12m Check operation ofthermostat and pump control.

For more detailed maintenance of controls relevantsection.

5. Pipework andconnections.

12m Check for leaks and signs ofcorrosion and make good asnecessary.

Vacuum tube type1. Tubes. 6m Clean and report condition if

cracked.Frequency will depend on location and localatmospheric condition. Dirt causes loss of collectorefficiency. Cracked tubes should be replaced.

2. Reflectors. 6m Clean and report condition ifcracked.

Frequency will depend on location and localatmospheric condition. Dirt causes loss of collectorefficiency. Care should be taken to avoid damaging thereflector surface.


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40153-01 SOLAR HOT WATER PANELS and similar COLLECTING DEVICES - continued


3. Anti-freeze solution (ifused).

12m Check condition and top upto required concentration.

Anti-freeze solution should be replaced every threeyears.

4. Controls. 12m Check operation ofthermostat and pump control.

For more detailed maintenance of controls see relevantsections.

5. Pipework andconnections.

12m Check for leaks and signs ofcorrosion and make good asnecessary.

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402

54-01 SPLIT SYSTEMS Introduction Unit type air coolers, generally known as unit type air conditioners are stand alone pieces of equipment, the bulk of the equipment being factory assembled, sometimes needing only an electrical supply, and in some instances water/drainage connections, to make them work. Size can vary between 2 and 100kW of cooling. It follows that such units will contain some or all of the elements covered in other sections of this specification and when maintenance is carried out reference should be made to the appropriate section(s). It may be efficient for small units to be serviced at a central workshop. This unit can be divided into two main categories namely:- a) one piece b) split two piece they are variously known as cassettes, wall or window, ducted or portable, multi-splits, console through wall, or free standing. With the split systems pipework is necessary on site to connect the room unit to the condenser unit together with charging up and commissioning. Increased maintenance may be required with these compact units because of the density of the components.

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403

54-02 SPLIT SYSTEMS – air-cooled with direct expansion evaporator (DX), with gas, hot water or electric heaters These are primarily two units with either integral or remote air-cooled condensers working with direct expansion coolers, primarily for room air conditioning applications. The frequency of servicing or cleaning will depend upon the working environment and the amount of usage.


Cooling. 1. Compressor.

6m

Check for undue noise or vibration. Check discharge and suction pressure and check superheat under full load condition.

2. Compressor suction.

6m Check for symptoms of ‘wet’ operation or excessive superheat.

3. Refrigerant. a) charge.

6m

Check level in receiver and/or liquid line sight glass.

Note: Any significant shortfall or frequent topping up may indicate leakage and should be reported to client.

b) leaks 6m

Test accessible parts of system. Pay particular attention to bolted and flare connected joints, sight glass glands and any pressure relief valve vent to atmosphere. Note: any removed refrigerant (CFC) must be recovered and not released to atmosphere. Only a REFCOM registered engineer should work on this equipment.

4. Condenser and evaporator fins.

6m Check for damage and/or dust accumulation. Clean as necessary.

Do not use CFC’s (refrigerant) for cleaning tubes use dry nitrogen or compressed air. Sterilisation may be required.

5. Fans and motors and damper drive motors (if fitted).

6m Check bearings and lubricate as necessary. Inspect and check on fan guard covers and inspection plates.

Where appropriate check drive belts for condition and tension. Adjust or replace as necessary. Ensure that all bolts, screws etc. are in place and tight. (See also MOTORS)

6. Evaporator and drains, dip tray and pump.

6m Check and clean. Check condensate drain is clear and clean.

Sterilisation may be required.


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40454-02 SPLIT SYSTEMS – air-cooled with direct expansion evaporator (DX), with gas, hot water or electric heaters - continued

ITEM FREQ. ACTION NOTES7. Compressor capacity

control and unloadedstart valves (if fitted).

6m Check for correct operation. Checkmotor current against commissioningdata.

Compressor unload on start should reduce andincrease capacity on demand.

8. Refrigerant pipework. 6m Check for vibration and rectify anyloose or inadequate support/fixing.

All pipework joints should be brazed or welded.To prevent internal scaling use dry, oxygen freenitrogen (OFN) during the jointing process.

9. Filters. 6m Check condition and replace asnecessary.

10. Insulation. 6m Check condition. Repair and resealas necessary.

11. General cleanliness. 6m Clean surfaces of compressor andcomponents of condensing unit.

Remove any dirt or rubbish from vicinity of plant.

12. Electrical. 6m Check for damage to flexible conduits.Tighten all terminal connections.Isolate local control panel and inspectfor signs of overheating. Checkintegrity of electrical insulation.

If main fuse carrier connections to compressorsshow any discoloration they must be changed.

Pay particular attention to contactors andterminals including all thermistor controls incompressor terminal box.

13. System operation. 6m Confirm that it is in accordance withdesign parameters.

i.e. Start/stops and capacity regulators should bein accordance with externally applied controlsystems if applicable.

Heating.1. Gas Fired. 6m See relevant BURNER section.2. Hot water supply. 6m See relevant HEAT EMITTER section.

Check for leaks. Check anti-freezeprotection on heating coil.

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405

55-01 DRIVE ELEMENTS – STARTERS - general Note: Before carrying out any work on electrical equipment, isolate in accordance with HASAWA and Electricity at Work Act requirements.


1. Control unit relays, fuses and control lamps, starters overloads and transformers.

12m Check and inspect. Replace lamps as necessary.

Note hours run on plant and check that duty selection has been carried out.

2. Wiring, conduits and flexible conduits.

12m Check condition, replace if necessary. Ensure that all access covers and all screws and hinges are in place and secured.

3. Panel. 12m

Check internally for build up of dirt and vacuum out.

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40655-02 STARTERS - Star Delta


1. Switchgear. 12m Carry out maintenanceprocedures as per powercontactors.

See CONTROL PANELS.

2. Interlocks. 12m Inspect and check bothelectrical and mechanicalinterlocks between 'Star' and'Delta' contactors.

3. Start up sequence. 12m Check for correct sequencefrom start up. Inspect check andadjust setting of timer to matchcharacter of the connected load.

'Star' first then 'Delta' mode.

4. Starter overload settings. 12m Check. If overload is connected into the 'Delta' loop theoverload should be set to 0.58 of the linecurrent.

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40755-03 STARTERS -Two speed - Dual wound



See CONTROL PANELS.

2. Interlocks. 12m Inspect and check bothelectrical and mechanicalinterlocks between 'high' and'low' speed contactors.

3. Timers. 12m Check and set. Timers should be set between 'high to low' and'low to high' operation to match thecharacteristics of the connected loads.

4. Overloads. 12m Check both high and lowoverloads.

Overloads should be set to give the correctprotection to the connected loads.

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40855-04 STARTERS - Two speed - Pole change



See CONTROL PANELS.

2. Interlocks. 12m Inspect and check bothelectrical and mechanicalinterlocks between the 'loop'and 'star' (high) contactors.

3. Timers (if fitted). 12m Check and set. Timers should be set between the 'high to low'and 'low to high' operation to match thecharacteristics of the connected loads.



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40955-05 STARTERS - Reversing



See CONTROL PANELS.

2. Interlocks. 12m Inspect and check bothelectrical and mechanicalinterlocks between the 'forward'and 'reverse' starters.

3. Timers (if fitted). 12m Check and adjust between thetwo modes of operation to suitthe application.

Inspect and check that the drive is operating inthe correct directions.



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41055-06 STARTERS - Auto-transformer



See CONTROL PANELS.

2. Interlocks. 12m Inspect and check bothelectrical and mechanicalinterlocks between the maintransformer load, the load andthe transformer by-passcontactors.

3. Timers (if fitted). 12m Check and adjust the timersetting between the transformerload and by-pass contactors tosuit the connected load.



5. Transformer. 12m Inspect and check for signs ofoverheating.

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41155-07 STARTERS - Quick transition, electric heater



See CONTROL PANELS.

2. Interlocks. 12m Inspect and check bothelectrical and mechanicalinterlocks between the main runand transition contactors.

3. Sequence timers. 12m Check and adjust to suit thecharacteristics of the connectedload.

4. Overloads. 6m Check and set to give correctprotection for the connectedload.

Electric Heater Type

1. Electrical connections. 12m Check.

2. Heater elements. 12m Inspect for signs of overheatingor element breakdown.

Replace as necessary.

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41255-08 STARTERS – electrolyte type


Electrolyte Type

1. Liquid level. 12m Check

2. Specific gravity. 12m Check against manufacturer'svalues.

Follow manufacturer's maintenance instructions.

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41355-09 STARTERS - AIR BREAK, AND CONTACTORS

Before carrying out any work on control panel isolate mains supply at the distribution board.


1. Enclosure. 12m Clean and remove any dirt ordust.

Use cloth free from loose fibres.

2. Insulation. 12m Inspect for signs of tracking,blistering or delamination.Renew where necessary.

3. Condition 12m Inspect for corrosionoverheating or obstruction.

4. Switch contacts. 3m Examine for wear oroverheating or burning. Renewas necessary.

5. Latching contactors. 3m Check operation, adjust orrenew worn parts as necessary.

6. Arc chutes. 3m Clean insulation and renew anydamaged parts.

Ensure arc chutes are precisely repositionedotherwise the moving parts of the contactor maybe impeded and damage caused to the contacts,insulation and the chutes themselves.

7. Auxiliary contacts. 3m Inspect for wear and correctoperation. Renew or adjust asnecessary.

8. Operating magnet.

Continued on next page

12m Check for movement, clean dirtfrom pole faces.

If equipment noisy, check shading coils or ringsfor damage and renew parts as necessary.

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41455-09 STARTERS - AIR BREAK, AND CONTACTORS - continued


9. Push button contacts. 3m Inspect and renew any wornpoints.

10. Resistance units incorporatedin stator/rotor starters.

12m Clean and examine forconnections.

If wear is evident, renew that part of theresistance.

11. Time delay and overloaddevices:

a) thermal, 12m Check correct settings. Renew to manufacturer's instructions.

b) oil dashpot, 12m If oil is cloudy or sludge hasformed, clean out dashpot withsolvent and refill.

c) air dashpot (diaphragm orpiston type),

12m Check that air seals are intact.Renew unit if leaks are evident.

d) magnetic. 12m Check for free movement, if themagnetic spacer is damaged orexcessively worn, renew.

12. Fuses (if fitted). 12m Check for correct rating andtype.

e.g. rewirable fuses have not been installed inthe carriers designed for cartridge fuses.

13. a)prior to return to service. 12m Carry out insulation test andcarry out operational check.

b)after return to service. 12m Check that any meters and pilotlights fitted function correctly.

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415

56-01 COLD WATER STORAGE and SUPPLY Introduction Whilst legionella bacteria are most active in the temperature range 20°C to 45°C, occasions can occur where growth is promoted even in cold water systems. This can arise where the local temperature is raised by: a) heat build up due to solar gain or the proximity to hot water services, or b) the storage capacity is far greater than is necessary. In general terms the storage capacity should not exceed one day's usage. Cleanliness of the system is of primary importance to ensure that the legionella bacteria do not have any nutrients for growth and survival. Such nutrients can come from vegetable, animal and even mineral substances and it is for this reason that storage cisterns should be free from rust, dust, slime, mould, fungi and such items as dead birds, rats, mice, insects etc. and that non metallic materials satisfy the requirements of BS6920. Lists of materials approved by the water industry are published in the Water Fittings and Materials Directory (see Standards List), All new and replacement water fittings should satisfy the Water Supply (Water Fittings) Regulations requirements and be listed in the directory. Cleansing of tanks, cisterns and associated pipework should be followed by full disinfection in accordance with the procedures laid down in HSC ACOP L8.2001. Cisterns must have close fitting lids, which should not be of timber or other porous materials. Lids should have vent pipes of adequate cross section to prevent suction developing on water draw off. All vent pipes and overflows should be fitted with close mesh to prevent the ingress of foreign matter. These should be cleaned annually. The pipework system should be free of any points where pockets of dirt, slime or sediment can build up. Where it is impossible to ensure this the system should be disinfected on a regular basis.

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41656-02 COLD WATER STORAGE TANKS and CISTERNS

Note: Cisterns operate at atmospheric pressure whereas tanks are sealed vessels operating at pressures above atmospheric.ITEM FREQ. ACTION NOTES

1. Float operated ball valve 3m Check operation, waterlevel and shut off.Replace washer ifnecessary. Check float forleakage and security.

2. Level control switches (iffitted).

6m Check for scale deposits,clean as necessary andcheck operation.

For specialist maintenance of level control switches seeLEVEL SWITCHES.

3. Cistern or tank body. 6m Check for leaks and anystructural weaknesses.

Ensure that any brackets, etc. supporting the tank arefirmly fixed.

4. Valves 6m Check valve stems arefree to turn.

Ensure that any insulation or trace heating cable removedduring inspection is replaced or frost damage could ensue.

5. Air vents and overflowscreens.

6m Check for blockage andcondition.

Clean when necessary. Report if replacement needed.

6. Insulation. 6m Check condition, replace ifnecessary.

Look for any damp patches, if necessary removinginsulation to find cause.

7. Manlid and accesscovers.

12m Check condition of seals. If lid has been removed for inspection purposes ensureseals are effective.


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41756-02 COLD WATER STORAGE TANKS and CISTERNS - continued


8. Cistern or tanks. 12m Inspect and reportcleanliness and condition.

Check overflow and warning pipes are unobstructed andthat the ends are conspicuous and well above the floodover level of a gully.If any remedial work needs to be carried out, adviseclient. If painting is required any paint should be non-toxic and WRC Water Byelaws Scheme/WaterRegulations approved.

9. Tanking. 12m Ensure drains are clear,check condition.

Check thoroughly for potential leakage. Report to client.

10. Associated pipework. 12m Check condition and rectifyany faults.

Examine for corrosion, leaks and security of fittings andattachments.

11. Generally. 12m Check that all items ofequipment comply with :Legislation.Bye-laws, andCodes of practice.

Report to client where remedial action is required.

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41856-03 ICE STORAGE SYSTEMS


1. Brine quality. 3m Check Specific Gravity. If checks show continual need for topping upbrine Specific Gravity, examine system for leaks.

2. System pressurisationunit (if used).

6m Check operation.

3. Tank shut off unit (iffitted).

6m Check operation.

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41956-04 STORAGE TANKS - LPG


1. Under pressure valve. 12m Check normal position. Condition of tanks is the responsibility of the gassupplier who will also check safety protection.

2. Over pressure valve. 12m Check normal position.

3. Pressure regulating valves. 12m Check action.

4. Shut valve. 12m Check action.

5. Valves on Multi CylinderInstallation.

12m Check change over.

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42056-05 STORAGE TANKS - OIL


1. Tank. 12m Check condition and note anycorrosion.

Report to client.

2. Filter. 12m Replace if dirty and investigatecause.

3. Balloon Vent. 12m Check condition of wire mesh.

4. Sludge valve. 12m Check for leaks. If opened Waste Disposal Regulations mayapply.

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42157-01 SWIMMING POOLS, SPAS, SAUNAS, etc.

Introduction

There are two major aspects of swimming pool maintenance, water cleanliness and quality, and winterisation.

The maintaining of a high standard of water cleanliness and quality calls for daily monitoring and treatment which must be part of the dailyroutine of the pool attendant and will cover filters, water treatment and general cleanliness. In addition regular maintenance of the equipmentis necessary and except in large installations this would normally be carried out by the maintenance contractor at intervals agreed with theclient.

For outdoor pools which are not used in winter whilst it is not normal practice to empty the pool the specific maintenance procedures shouldinclude provision for ensuring that the plant is secure from frost damage by draining down pumps, pipelines and associated tanks and whereappropriate the pool valves isolated.

This section also covers whirlpool and spa baths, steam rooms e.g. saunas, and hydrotherapy pools. All this equipment uses hot water andin the maintenance procedures account must therefore be taken of the dangers of Legionella, see ACOP L8,2001.

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42257-02 SWIMMING POOLS

The main periods for maintaining outdoor swimming pools are in early autumn when the system is shut down for the winter and theequipment and pool are prepared for the winter and in the late spring when the pool is made ready for the new season. For indoor poolsmaintenance should be programmed for times of minimum use. If fitted constructed with membrane liner care should be taken to avoidperforation with sharp edges of equipment. Maintenance of water quality is a daily operation usually carried out either automatically ormanually by the pool attendant. (See WATER TREATMENT).


1. Shut down. 12m Isolate from electrical supplyby switching off andwithdrawing fuses.

Ensure that water supply is also turned off.

2. Controls. 12m Check settings and action.

3. Pool cover(s). 12m Check for tears andsoundness. Check conditionand security of anchor bolts.

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423

57-03 SWIMMING POOLS - FILTERS Filtration plant. The filtration plant of a pool is designed to remove water from the pool, filter it, disinfect it, and return it to the pool in a sterile condition. The main types of pool filters are: a) Conventional rate pressure sand filtration b) Medium rate pressure sand filtration c) High rate pressure sand filtration d) Pre-coat cartridge (pressure and vacuum) e) Disposable cartridge or glass fibre mat filtration


Conventional, medium and high rate pressure filtration

The terms conventional, medium and fast rate refer to the rate of flow of water through the filter. The maintenance requirements for the three types is similar.

1. Inlet strainer. 12m Check condition and clean. More frequent cleaning by the operator may be necessary if the inlet flow rate falls below the design level. (May be shown by increased suction pressure).

2. Chemical cleaning of filter bed material.

12m Check clean `running' pressure, if high, may indicate fouling of filter medium.

Refer to manufacturer's handbook for instructions and type of chemicals to be used.

3. Rate of flow indicator. 12m Clean and check operation. The accuracy of the flow meter should be within 5%.

Continued on next page

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42457-03 SWIMMING POOLS - FILTERS - continued


Pre-coat filtration1. Inlet strainer. 12m Check condition and clean. More frequent cleaning by the operator may be

necessary if the inlet flow rate falls below the designlevel. (May be shown by increased suction pressure).

2. Filter elements. 12m Clean off any coatingmaterial and check conditionof support elements.

If replacement necessary, report to client.

3. Pipework. 12m Clean off any deposits orsludges.


Cartridge type filters1. Inlet strainer. 12m Check condition and clean. More frequent cleaning by the operator may be

necessary if the inlet flow rate falls below the designlevel. (May be shown by increased suction pressure).

2. Seals. 12m Check condition of seals oncartridge holders. Replace ifnecessary.


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42557-04 SWIMMING POOLS - PIPEWORK, PUMPS, HEATING etc.


1. Circulatory pipework,including solar panels(where fitted).

12m Isolate from pool and draindown. Clean out and dry.

Do not empty the pool in wintertime, frost will damagethe lining if plastic or cause the tile lining to break away.

2. Automatic air vents. 12m Remove, drain and clean.

Heating

3. Heating equipment- Oil

-Gas

6m

12m

Carry out maintenanceprocedures appropriate to thetype of heating plant asdetailed in relevant sections.

Maintenance of heating plant, other than routine, is bestcarried out before the heating season starts.

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42658-01 ON/OFF SWITCHING DEVICES


Thermostats

1. Location. 12m Check that thermostat is notaffected by local heatsources.

For example thermostats may be situated aboveradiators, affected by direct sunlight or in colddraughts. Report to client if change of location isneeded.

2. Condition. 12m Clean and check operationincluding contacts.

3. Setting. 12m Check and report to client ifsignificant variation in setpoint is found.

Wrong settings can cause energy wastage. Ifmanual or auto-reset provided check operation.

4. Calibration. 12m Check against standard.

Humidistats

1. Location. 12m Check that humidistat is notaffected by local heatsources.

For example humidistats may be situated nearmoisture or heat sources.Report to client if change of location needed.

2. Condition. 12m Clean and check operation,including contacts.


If manual or auto-reset provided check operation.

Pressure Switches

1. Condition. 12m Clean and check operation.


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42758-01 ON/OFF SWITCHES - continued




3. Sampling lines. 12m Check for damage orobstruction.


Differential pressure switches


2. Setting 12m Check and report to client ifsignificant variation in setpoint is found.




Vane operated flow switches





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42858-01 ON/OFF SWITCHES - continued




Level switches





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42958-02 CONTROL RELAYS


General

1. Mechanical wear. 12m Inspect for excessive wear.

2. Contacts. 12m Check for wear, redress or replace asrequired.

3. Coil. 12m Inspect for signs of overheating andinsulation breakdown.

4. Electrical operation. 12m Operate relay and check for cleanoperation of each set of operations.

5. Pole faces. 12m Clean if noisy operation of relay.

Plug in type

1. General maintenance. 12m Carry out as per instructions given above.

2. Relay connection pins. 12m Inspect for signs of burning. Replace relay if necessary.

3. Base unit. 12m Inspect for signs of overheating or arcing. Replace base unit if necessary.


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43058-02 CONTROL RELAYS - continued


Mercury switches

1. Mercury bulbs. 12m Inspect and checkmechanical and electricaloperation.

2. Connections to bulbassembly.

12m Inspect for wear, assembly,breakdown of insulation, orfraying of connections.

Latch type.

1. General maintenance. 12m Carry out as per instructionsgiven in CONTROL PANELS.

2. Latched states. 12m Check the mechanical andelectrical operation of bothlatched states.

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43159-01 TERMINAL UNITS VAV - self powered

Introduction

The term Terminal Units covers those items of equipment relating to the ingress of ventilating or conditioned air into the workingenvironment. Operationally their effectiveness may be impaired by the build up of dust and related deposits whilst visually dirt will arisefrom cigarette smoke and dirt in the atmosphere. In a dirty environment it may be necessary to increase the frequency of maintenanceabove that recommended in this specification. Detailed maintenance of the associated controls is covered in the relevant section.


1. Thermostat. 6m Check operation. Air volume will increase/decrease depending uponthermostat position. Ensure space temperature iswithin thermostat range when testing.

Calibration }Interrogation }Control adjustment }

by CONTROLSPECIALIST

2. Unit filter. 12m Check condition and change ifnecessary.

If unit filter is very dirty, check condition of mainfilter.

3. Main filter. 3m Check condition. In a dirty environment it may be necessary toclean/change main filter more frequently.

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43259-02 TERMINAL UNITS VAV - fan powered

Introduction

The term Terminal Units covers those items of equipment relating to the ingress of ventilating or conditioned air into the workingenvironment. Operationally their effectiveness may be impaired by the build up of dust and related deposits whilst visually dirt will arisefrom cigarette smoke and dirt in the atmosphere. In a dirty environment it may be necessary to increase the frequency of maintenanceabove that recommended in this specification. Detailed maintenance of the associated controls is covered in the relevant section.


1. Fan motor. 6m Grease or oil bearings.

2. Dampers. 6m Check operation and lubricatelinkages if necessary.

3. LPH and CW coils. 6m Check operation and clean.

4. Controls. 6m Check operation. Note:-Calibration }Interrogation }Control adjustment }

by CONTROLSPECIALIST

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43359-03 TERMINAL UNITS VAV - pneumatic powered

Introduction

The term Terminal Units covers those items of equipment relating to the ingress of ventilating or conditioned air into the workingenvironment. Operationally their effectiveness may be impaired by the build up of dust and related deposits whilst visually dirt will arisefrom cigarette smoke and dirt in the atmosphere. In a dirty environment it may be necessary to increase the frequency of maintenanceabove that recommended in this specification. For detailed maintenance of associated equipment see CONTROLS.


1. Access to units. 12m Remove access panels or ceiling tiles asappropriate.

Where units are ceiling mounted, cover anymachinery/office equipment situated below theunit. Seek prior permission before switching offany equipment which is to be covered. Takecare not to stain ceiling tiles.

2. Control system (forinformation only)

12m

a) pneumatic Disconnect pneumatic control pipe andcheck unit motors to alternative setting.

orb) electrical

Disconnect electrical control and check unitmotors to alternative setting.

Reconnect.

This is for information only. For details ofmaintenance, see CONTROLS.

3. Air leaks. 12m Check and if found rectify.

4. Insulation. 12m Check condition and make good asnecessary.

5. Actuator. 12m If visible, check for dirt, lightly oilmechanism as required.


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43459-03 TERMINAL UNITS VAV - pneumatic powered - continued


6. Unit thermostat. 12m Operate and check that VAV unitmoves in relation to change in setting.Restore to original setting.

7. Filter. 6m Clean or replace as necessary. Frequency of cleaning will depend upon theenvironment in which the unit operates.

8. Diffusers. 12m Clean, taking care not to stain ceiling.

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43559-04 TERMINAL UNITS - Constant volume including mixing box (high velocity)

Introduction



1. Units. 12m Check operation.

2. Pneumatic thermostats. 12m Check operation by moving set point.Restore to original setting.

For detailed maintenance see relevant section.

3. Control dampers. 12m Check operation. For high velocitymixing box change over dampers.Check seals.

For more information on damper maintenancesee DUCTING GENERAL.

4. Air grilles. 12m Clean, taking care not to dirtysurround.

5. Electrical connections of controls systems.

12m Check soundness of wires andcontacts.

6. Filter. 12m Clean or replace as necessary. In a dirty environment it may be necessary toclean/change the filter more frequently.

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43659-05 TERMINAL UNITS - INDUCTION UNITS

Introduction



1. Secondary air filter. 6m Clean washable filter and retain forre-use.

2. Coil block (where fitted). 6m Inspect for dirt and/or obstructions,cleaning where necessary. Checkalso for water leaks and rectify asnecessary.

3. Primary air nozzles. 6m Check condition, cleaning ifnecessary by brushing.

4. Nozzle air pressure. 6m Check with manometer. Compare with commissioning data and correctany deviations.

5. Damper and/orpneumatic valves.

6m Check correct functioning and rectifyany defects.

6. Chilled water/LPHWcontrol valves.

6m Check functioning. For detailed maintenance see VALVES.

7. Control thermostats. 6m Check operation. Setting should be 19° heating and 24° C cooling.For detailed maintenance see relevant section.


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437

59-05 TERMINAL UNITS - INDUCTION UNITS - continued


8. Isolation valves. 6m Check for leaks and rectify asnecessary.

9. Unit. 6m Clean internally and externally. Refitsecondary air inlet filter. Replaceany casing which was removed.

Ensure filter is correctly seated to prevent air by-passing.

Note any defects on report.

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438

59-06 TERMINAL UNITS - FAN COIL The term Terminal U nits covers those items of equipment relating to the ingress of ventilating or conditioned air into the working environment. O perationally their effectiveness may be impaired by the build up of dust and related deposits whilst visually dirt will arise from cigarette smoke and dirt in the atmosphere. In a dirty environment it may be necessary to increase the frequency of maintenance above that recommended in this specification. For detailed maintenance of associated equipment see CONTROLS.


1. Status. 6m Switch off and isolate. Electrical isolation should be carried out in accordance with HASAWA and Electricity at Work Regulations. Where units are ceiling mounted, cover any office machinery/equipment situated below unit being serviced.

2. Coil block. 3m Vent air from cooler and heating coils (if VAV not fitted).

6m Remove air entry filter, inspect coil block for dirt and clean as necessary.

Depending upon the environment, coil block air entry filter may need more frequent cleaning. Agree frequency with client.

3. Condensate drain connection.

6m Check connection is clear.

4. Permanent filters. 6m Clean and refit, ensuring proper location.

See FILTERS regarding safety instructions.

5. Disposable type filters. 6m Replace ensuring proper location. See FILTERS with regard to safety and disposal procedures.


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43959-06 TERMINAL UNITS - FAN COIL - continued


6. Test unit. 6m Restore power supply and run unit.Check airflow is normal at correctspeed setting.

7. Casing. 6m Clean. Where units are above false ceilings ensure thattiles are not left in a stained condition.

8. Ductwork flexiblecouplings (if fitted).

12m Check condition.

9. Grilles and diffusers. 6m Clean using vacuum or alternativelyremove and clean.

Care should be taken to avoid damage to diffuserceiling lights or ceiling.

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44059-07 TERMINAL UNITS – VRV SYSTEMS

Terminal Units Introduction


VRV Systems are very specialist and should not be treated as a standard split system. They are set up on commissioning and the setpoints should not be disturbed.


Outdoor Unit

1. Unit casings. 3m Check condition.

2. Coils. 3m Clean and remove any debris.

3. PCBs. 3m Check for damage.

4. Electrical Components. 3m Check condition.

5. Sensors. 3m Check for contact and correct location.

6. Running currents and voltage. 3m Check and record.

7. System neutral and earthconnections.

3m Check.


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441

59-07 TERMINAL UNITS – VRV SYSTEMS - continued


Indoor Unit

1. Hand Controllers.

3m

Check function.

Run units on heating and cooling cycles if heat pumps

2. Air Filter and indoor coils. 3m Clean. Air Filters may initially require monthly cleaning dependant on location.

3. Drain Lines. 3m Check for free running

4. Power supply. 3m Check and record.

5. Electrical and Data Cable connections.

3m Check condition.

6. Change over valves and refrigerant control devices.

3m Check action. If a shortage of refrigerant is suspected all should be removed, any leaks rectified and the refrigerant change weighed in after calculation change using the Manufacturers literature. This work should only be carried out by a competent person who works for a firm registered with REFCOM.

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44260-01 VACUUM SYSTEMS - general


Motors. 12m Follow procedure given forMOTORS.

Air systems - cleaning1. Fans. 12m Follow procedure given for

FANS.As used in centralised vacuum cleaning systems.

2. Seals. 12m Examine condition and checkfor leaks.

3. Clips. 12m Check security andoperation.

4. Filters. 12m Check condition and changeas necessary. See FILTERS.

5. Hose connections. 12m Check condition and replaceas necessary.

Liquid systems1. Pumps (liquid systems). 12m Follow procedure given for

PUMPS.As used for swimming and hydrotherapy pools.

2. Seals. 12m Examine condition and checkfor leaks.

3. Filters. 12m Check condition and changeas necessary.

4. Hose connections. 12m Check condition and replaceas necessary.

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44360-02 VACUUM TUBES - cash handling


Central Station1. operation of door and door handle, 6m Check operation and security of lock.

2. switch, 6m Check electrical and mechanical adjustment.

3. sliding air seals, 6m Check efficacy. If renewal indicated, report toclient.

4. door lock solenoid, 6m Check electrical and mechanical adjustment.

5. indicator lights, LEDs, etc., 6m Check function, replace as necessary

6. keyswitch, 6m Check operation.

7. air-valve and seals,8.


8. tube switch (if fitted), 6m Check operation.

9. fixing and tube joints, 6m Check security of fixings and integrity of tubejoints.

10. station. 6m Clean inside and outside.


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44460-02 VACUUM TUBES - cash handling - continued


Cash box - local station

1. door locks. 6m Check operation for easy movement.

2. door fittings. 6m Check condition and security of hinges,door bars and transparent screen.

3. foam pad. 6m Check condition.

4. tube switch. 6m Check operation.

5. fixings. 6m Check security of fixings.6. local station. 6m Check inside and outside.

Blower1. flexible coupling. 12m Check condition. Report to client if replacement required.2. mountings. 12m Check security.

3. overload setting. 12m Check setting and adjust if necessary.

4. contactors. 12m Check operation and condition. For more detailed information on themaintenance of contactors see POWERSUPPLIES – P.D.U.

5. earth continuity. 12m Check For more detailed information on themaintenance of earthing electricalequipment see POWER SUPPLIES –EARTHING.


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44560-02 VACUUM TUBES - cash handling - continued


Controller

1. running time of capsule. 12m Check

2. relay on capsule. 12m Check condition.

General

1. runs. 6m Check flight time of shortest andlongest runs.

2. vacuum. 6m Check vacuum on close circuit. Compare with manufacturer's data and report toclient if significant variation.

3. system filters (if fitted).

4. carrier (capsule(s)).5. carrier velcro and lids. 6m

6m

Check pull.

Check condition.

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44661-01 VALVES


a) Gate valves Preventative maintenance on this type of valve isbest obtained by daily checks on gland or stemleakage and repairing these as they occur.

1. Operational status. 3m Check, rotate handwheel sufficiently toindicate that wedge is not seized inclosed position nor jammed in openposition. If normally open, close valveand reopen.

Action depends upon whether valve is normallyclosed or normally open. If valve is normallyopen, check closure performance in the eventthat corrosive deposits prevent wedge seating.

2. Gland leakage. 3m Check, within first week slightly tightengland nuts. If after a period leakagestill occurs replace gland.

After installation or replacement check for glandleakage daily for one week. Early signs of slightleaks are due to 'bedding in' or drying out and areusually cured by tightening of gland nuts.Continuous leakage can lead to erosion orcorrosion of the valve stem.

3. Overall condition. 12m Inspect for external deterioration dueto leaks at end flanges or aggressiveenvironment.

Leakage from end flanges can be due to pipestrains, ground settlement, poor joints or pipesupports.

b) Globe valves

1. Operational status. 3m Check by rotating handwheelsufficiently to ensure freedom ofmovement.


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44761-01 VALVES - continued


2. Gland leakage. 3m Check within first week, slightly tightengland nuts. If after a period leakage stilloccurs, replace gland.


3. Overall condition. 12m Inspect for external deterioration due toleaks at end flanges or aggressiveenvironment.


c) Lubricated plug valves

1. Operational status. 3m Check by partially rotating plug toensure freedom of movement.

Inject correct compound as recommended by themanufacturer to maintain smooth operation.

2. Stem leakage. 3m If evidence of leakage, inject correctcompound simultaneously rotating plug.

After installation or overhaul check daily for oneweek and then at six monthly intervals.




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ITEM FREQ. ACTION NOTESd) Diaphragm Valves 1. Valve. 12m Isolate and check condition,

Dismantle and clean body,threads, spring and diaphragm.

If diaphragm shows signs of abrasion orchemical attack refer to manufacturer.

2. Diaphragm. 12m Change if condition suspect. The life of a diaphragm will vary according to theworking environment and records relating toeach valve should be kept to plan replacementschedule.

3. Reassembly. 12m Tighten bolts diagonally, do notoverclose the diaphragm.

To ensure correct operation and long life of thediaphragm, avoid overtightening the securingbolts.

e) Pressure Control Valves1. Strainers preceding valves. 6m Clean strainer screens. The level of contamination can provide an

indication of required frequency of valvemaintenance.

2. Control valve. 12m Overhaul using standardmaintenance repair kit.

Observe carefully manufacturer’s instructionsregarding dismantling and installation.

3. Main valve and seat assembly. 12m Examine seat for damage, wearand scale build up.

If they are only slightly worn both the main valvehead and main seat may be lapped on a flatplate using a fine grinding paste. If either isbadly worn or unfit for further use they should bereplaced.


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f) Butterfly valves1. Operational status. 3m Check by partially rotating disc to

ensure freedom of movement.Close valve (if system condition allows) andcheck seat tightness, this tests the condition ofthe elastomeric seal.

2. Stem leakage. 3m Check for freedom from dirt particles.Tighten gland if adjustable type, if notreplace proprietary seals (e.g. 'O'-rings).

After installation or overhaul, check for stemleakage daily for the first week.

3. Overall condition. 12m Check for deterioration externally oraggressive environment.

Wafer pattern unlikely to have flange leakageprovided that flange bolting has been tightenedevenly.

g) Float operated valves1. Operational status. 3m Check for drips from valve indicating

leaking seat.Depress float to flush seat. If leak persists, checkseat for damage or replace washer.

2. Overall condition. 12m Check.

h) Parallel slide valves

1m See Notes. It is recommended that these valves be operatedover their full travel once every four weeks.

1. Operational status. 3m Valve normally closed, rotatehandwheel to ensure freedom ofmovement.

Close valve (if system allows) to check seattightness. If valve normally closed, dropdifferential pressure to 1 bar or less (if systemallows) and partially rotate to check for freedomfrom galling seats.


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ITEM FREQ. ACTION NOTES2. Gland leakage. 0.25m Check, within first week slightly tighten

gland nuts. If after a period leakage stilloccurs, replace gland.


3. Body leakage. 12m Check for body/cover joint leakage andtighten nuts to stop.

As a matter of routine any visible signs of leakageshould be reported to the site supervisor.


Leakage from end flanges can be due to pipestrains, ground settlement, poor joints or poor pipesupports.

i) Steam Safety valves1. Operational status. 3m Check by raising gagging lever to

discharge steam or air. Releasegagging lever to reseat. Check for dirtor damage.

Important: Great care must be exercised to avoidinjury to personnel. Check that discharge is to freespace or if piped, that pipe outlet is not directed topersonnel.NOTE: Check with insurance company forfrequency of mandatory checks.

2. Bursting discs (iffitted).

12m Check condition, report. It is recommended that maintenance on this typeof valve should be carried out at the time of theannual boiler inspection. Persistent leakage at thenormal boiler pressure will be due to deposits. Thevalve should be cleaned and reconditioned assoon as possible.


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j) Steam pressure reducingvalves 18m It is recommended that this type of valve should

be dismantled for a complete overhaul everytwelve to eighteen months, preferably with thevalve removed from the pipeline.

1. Main valve seat and valvehead.

12m Isolate and reduce pressure to zero.Remove screen and clean, cleangasket faces and renew gasket.

The actual maintenance requirements may varywith the type of valve and the manufacturer'sinstructions should be followed carefully.

2. Pilot valve chamberassembly.

12m Isolate and reduce air pressure to zero.Check dimensions of plunger gap andadjust if necessary.

The dimension of the plunger gap is critical andit may be necessary to grind or machine the topof the plunger.

3. Pilot and maindiaphragms.

12m Thoroughly clean upper and lowerdiaphragm chambers, ensure contactfaces are clean and reassemble.

When refitting diaphragms make sure that theyare replaced the same way round as when theywere removed.

k) Boiler valves Note: See also BOILERS for safety valves.

1. Main stop valve. 12m Lap seats, inspect for corrosion, resetvalve at correct set pressure and carryout accumulation test.

2. Main stop valve. 12m Lap seat, repack gland and lubricatespindle, checking for ease of operation.

3. Water level controls. Blowdown and check operation. This should be carried out daily.

0.25m Lower boiler water level and checkoperation.

6m Clean out chambers of any deposits.


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4. Sequencing valve. 12m Clean and lap seats, check for easeof operation.

Note: See BOILERS for safety valves.

5. Water level gauge 6m Refit sight glass, repack cock plugsand check for ease of operation.

Aggressive site conditions may requireincreased frequency of these items. Gaugeglasses should be regularly replaced beforethey break.

l) Radiator Valves – TRVs 12m Check air temperature calibrationagainst surface temperature of heatemitter.

Low temperature surfaces for heat emitters aredesirable in homes for senior citizens/disabled.

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45361-02 TAP AND OUTLET FITTINGS - general

A large range of outlet fittings suitable for high and low pressure supplies are fitted in this country, most requiring little or no regularmaintenance except for the replacement of leaking washers, ceramic disc cartridges or the repacking of spindle glands which should bedone if warranted.

Other fittings which are available with a variety of special outlets, aerators, ball outlet joints, flow straightens, flexible hoses, jet sprays,hand sprays, time delays, dechlorinators, filters and the like should be checked and cleaned in accordance with the manufacturer’sinstructions, using the manufacturer’s recommended spares.

Special care against damaging finishes should be taken with all terminal fittings, especially where gold plating or powder coating has beenused.

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454

61-03 SERVICE VALVES


Stop cocks and stop taps

1. Operational status. 12m Operate head to ensure the stopcock or tap is operating correctly. If normally open, close and then re-open.

Clean exposed stem prior to operation. If cock or tap fails to isolate water supply, re-washer and reset as necessary.

2. Gland leakage 12m Check for weeping gland, slightly tighten gland nut if necessary. If weeping still occurs, replace gland seal.

3. Overall condition 12m Inspect for external deterioration due to leaks.

Sluice valves

1. Operational status. 12m Operate hand wheel or stem to test that wedge is not seized in closed position. If normally open close valve and re-open.

To comply with the Water Regulations, stop valves should be WRC approved and must not be less suitable for the purpose than those which comply with: BS 1010, BS 5433 or BS 5163.

2. Gland leakage 12m Check for weeping gland, slightly tighten gland nut if necessary. If weeping still occurs, replace ‘O’ ring or packing.

3. Overall condition 12m Inspect for external deterioration due to leaks.

Wire brush and paint as necessary.

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45561-04 COMBINATION TAP ASSEMBLIES, MIXING VALVES/TAPS

Note: The frequency and extent of attention required will vary according to the prevailing site and operational conditions, however thefollowing guideline schedule is suggested to cover average duty and site conditions. For higher risk environments e.g. Healthcare, morefrequent checks may be appropriate.


Functional checks If any of the functional checks fails to meet theset parameters, then refer to service checks.

1. Inlet check-valves (if fitted). 6m Check inlet pipework surfacetemperature for indication ofcrossflow.

A more effective test can be considered ifappropriate, utilising drain points positionedbetween isolating and check-valves.

2. Temperature

a) locked,

b) adjustable/pre-set maximum.

6m Operate flow controls and checkblend temperature. Check maximumand minimum blend temperature.

For thermostat and pressure balanced mixers,blend temperature should stabilise quickly andremain with ± 2oC of set value. For manualmixers, refer to commissioning data.

3. Thermal shutdown(Thermostatic valves only).

6m Operate mixer at blend temperature,then isolate cold supply.

Valve must shut down in accordance with themanufacturer’s data.

4. Temperature control. 6m Operate mixer at blend temperature,then open other local cold outlets offcommon supply.

Check shift in blend temperature with referencedata compiled at the commissioning stage.

5. Strainers. 6m Isolate and check visually and cleanas necessary.

6. Flow control(s). 6m Operate fully and check for effectiveclosure.

If time delay is incorporated, check length offlow cycle.

7. Automatic drain valve (iffitted).

6m Check effective operation.


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45661-04 MIXING VALVES/TAPS - continued


8. Spray heads (showers). 3m Check spray pattern and flow rate.Clean as appropriate.

Note ACOP L8,2001 applies.

Service checks

1. Mixing valve:a) temperature control,b) flow control(s),c) inlet check valves,d) automatic drain valve.

12m Carry out visual check of internalserviceable mechanisms. Clean orrenew components as necessary.Lubricate as indicated inmanufacturer’s data.

Refer to manufacturer’s data for recommendedprocedures and cleaning agents/lubricants.For products of (serviceable) cartridgeconstruction, if and commission exchangeunits. Service displaced units in workshop aspart of rolling planned maintenance procedure.

2. Supply pipework. 12m Visually check for damage leak, etc.and rectify. Check that supplypressure and temperature agree withcommissioning data.

3. Recommissioning. 12m On completion conduct functionalchecks.

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45761-05 SHOWER VALVES

Note: Frequency of maintenance will depend upon use and the quality of the water and should be agreed with client.ITEM FREQ. ACTION NOTES

Thermostatic mixing valves

1. Controls. 6m Operate inlet valves and checkindividual flow rates of hot and coldwater supplies.

If valve is stripped down and reassembled allparts should be greased as recommended in themanufacturer’s maintenance instructions.

2. Thermostat. 6m Check mixed water outlet setting. Ensure thermometer bulb is immersed in flowingwater if measurement taken at shower head.

3. Temperature limiter. 6m Check mixed water outlet temperatureat limit safety stop.

Limiter setting 42oC.

4. Strainers (where fitted). 6m Clean.

5. Inlet check valves (wherefitted).

6m Check operation. Non-return valves may have been removed ifoperating with balanced pressure supplies.

6. Fail-safe. 6m Operate thermostatic shower valvewith cold water turn off to establishcorrect ‘fail safe’ operation.

Shower valve fittings

1. Auto drain valve (wherefitted).

6m Operate shower valve and checkautomatic operation of downstreamdrain valve.

2. Push button showertimers.

3m Strip down, clean and reassemble. 3m represents the maximum interval, the actualfrequency will depend upon the water quality andshould be agreed with the client. Regularmaintenance will save water and energy.

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458

62-01 AUTOMATIC CONTROL VALVES Pre-maintenance procedure This procedure applies to all types of automatic control valves and requires that before any maintenance is undertaken all Health and Safety precautions must be adhered to including system isolation. Care must be taken to ensure that any maintenance does not unduly interfere with environmental operating conditions. 1. Inspect, where changes, disconnections or unrecorded settings are found, report and discuss with client. 2. Note any settings made; i.e. min/max travel balancing valve setting etc. 3. Check valve body and fixings for any signs of corrosion or mechanical damage. 4. Check that pipe flange or screw connections are not leaking. 5. Where fitted, check that the actuator yoke and linkages are secure and not bent or damaged. 6. Check correct installation of valve with reference to both type and manufacturer. There are a large number of valve manufacturers who each call for specific maintenance and lubrication procedures for their products and to avoid undue repetition in maintenance the following terms have been used in the schedules. Manufacturer's maintenance instructions. Manufacturer's lubrication instructions.

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459

62-02 ROTARY VALVES - shoe or slipper Pre-maintenance procedure This procedure applies to all types of automatic control valves and requires that before any maintenance is undertaken all Health and Safety precautions must be adhered to including system isolation. Care must be taken to ensure that any maintenance does not unduly interfere with environmental operating conditions. 1. Inspect, where changes, disconnections or unrecorded settings are found, report and discuss with client. 2. Note any settings made; i.e. min/max travel balancing valve setting etc. 3. Check valve body and fixings for any signs of corrosion or mechanical damage. 4. Check that pipe flange or screw connections are not leaking. 5. Where fitted, check that the actuator yoke and linkages are secure and not bent or damaged. 6. Check correct installation of valve with reference to both type and manufacturer. There are a large number of valve manufacturers who each call for specific maintenance and lubrication procedures for their products and to avoid undue repetition in maintenance the following terms have been used in the schedules. Manufacturer's maintenance instructions. Manufacturer's lubrication instructions.

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46062-02 ROTARY VALVES - shoe or slipper - continued


1. Operational status. 12m Operate and check for correctrotary travel.Refer to manufacturer'smaintenanceinstructions.

Check by operation of the actuator, seeACTUATORS - motor driven.

2. Let by. 12m Check that the valve is notletting by excessively.

Normally 'O' ring seals are fitted and cannot beadjusted, replace if leaking and inspect spindlefor wear.

3. Glands/spindle condition. 12m Inspect for gland leakage, referto manufacturer's maintenanceinstructions.

12m For lubrication refer tomanufacturer's lubricatinginstructions.

4. Overall condition. 12m Inspect for externaldeterioration.

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46162-03 BUTTERFLY AND BALL VALVESPre-maintenance procedureThis procedure applies to all types of automatic control valves and requires that before any maintenance is undertaken all safetyprecautions must be adhered to including system isolation. Care must be taken to ensure that any maintenance does not unduly interferewith environmental operating conditions.

1. Inspect, where changes, disconnections or unrecorded settings are found, report and discuss with client.

2. Note any settings made; i.e. min/max travelbalancing valve setting etc.

3. Check valve body and fixings for any signs of corrosion or mechanical damage.

4. Check that pipe flange or screw connections are not leaking.

5. Where fitted, check that the actuator yoke and linkages are secure and not bent or damaged.

6. Check correct installation of valve with reference to both type and manufacturer.

There are a large number of valve manufacturers who each call for specific maintenance and lubrication procedures for their products andto avoid undue repetition in maintenance the following terms have been used in the schedules.

Manufacturer's maintenance ins tructions.

Manufacturer's lubrication instructions.

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46262-03 BUTTERFLY AND BALL VALVES - continued


1. Operational status. 12m Operate and check for correctrotary travel. Refer tomanufacturer's maintenanceinstructions.

Check by operation of the actuator, seeACTUATORS – Motor Driven.

2. Let by. 12m Check that valve is not lettingby excessively.

3. Glands/spindle condition. 12m Inspect for gland leakage, referto manufacturer's maintenanceinstructions.For lubrication refer tomanufacturer's lubricationinstructions.

Normally 'O' ring seals are fitted and cannot beadjusted, replace if leaking and inspect spindle forwear.


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463

62-04 SELF ACTING and THERMAL VALVES Pre-maintenance procedure This procedure applies to all types of automatic control valves and requires that before any maintenance is undertaken all Health and Safety precautions must be adhered to including system isolation. Care must be taken to ensure that any maintenance does not unduly interfere with environmental operating conditions. 1. Inspect, where changes, disconnections or unrecorded settings are found, report and discuss with client. 2. Note any settings made; i.e. min/max travel balancing valve setting etc. 3. Check valve body and fixings for any signs of corrosion or mechanical damage. 4. Check that pipe flange or screw connections are not leaking. 5. Where fitted, check that the actuator yoke and linkages are secure and not bent or damaged. 6. Check correct installation of valve with reference to both type and manufacturer. There are a large number of valve manufacturers who each call for specific maintenance and lubrication procedures for their products and to avoid undue repetition in maintenance the following terms have been used in the schedules. Manufacturer's maintenance instructions. Manufacturer's lubrication instructions.

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46462-04 SELF ACTING and THERMAL VALVES - continued


1. Operational status. 12m Check for correct travel.Check integrity of capillary.Refer to manufacturer's maintenanceinstructions.

Refer to - motor driven actuators. Insome cases manual override is onlyavailable by removal of actuatinghead.

2. Let by. 12m Check that the valve is not letting byexcessively.

3. Glands/spindle condition. 12m Inspect for gland leakage, refer tomanufacturer's maintenance instructions.

Adjust or replace seals as necessary.

Inspect and check for wear and corrosionof the spindle.For lubrication refer to manufacturer'slubricating instructions.

This can cause leakage or damage tothe gland seals, if there are any signsof deterioration the spindle should bereplaced - this will involve the removalof the valve.

4. Overall condition. 12m Inspect for external deterioration.

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465

62-05 SOLENOID VALVES Pre-maintenance procedure This procedure applies to all types of automatic control valves and requires that before any maintenance is undertaken all Health and Safety precautions must be adhered to including system isolation. Care must be taken to ensure that any maintenance does not unduly interfere with environmental operating conditions. 1. Inspect, where changes, disconnections or unrecorded settings are found, report and discuss with client. 2. Note any settings made; i.e. min/max travel balancing valve setting etc. 3. Check valve body and fixings for any signs of corrosion or mechanical damage. 4. Check that pipe flange or screw connections are not leaking. 5. Where fitted, check that the actuator yoke and linkages are secure and not bent or damaged. 6. Check correct installation of valve with reference to both type and manufacturer. There are a large number of valve manufacturers who each call for specific maintenance and lubrication procedures for their products and to avoid undue repetition in maintenance the following terms have been used in the schedules. Manufacturer's maintenance instructions. Manufacturer's lubrication instructions.

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46662-05 SOLENOID VALVES - continued


1. Operation status. 12m Operate and check for correctlinear travel.Check for solenoid noise i.e.buzzing.

Check by operation of the solenoid. Checksupply voltage and that polarities are correct -refer to manufacturer's instructions.Noise can be due to dirty pole faces, remove coiland clean pole faces.

2. Let by. 12m Check that valve is not letting byexcessively.

3. Glands/spindle condition. 12m Inspect for gland leakage, referto manufacturer's maintenanceinstructions.

Adjust or replace seals as necessary.

Inspect and check for wear andcorrosion of the spindle.

This can cause leakage or damage to the glandseals, if there are any signs of deterioration thespindle should be replaced - this will involve theremoval of the valve.

For lubrication refer tomanufacturer's lubricatinginstructions.


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46762-06 PRESSURE CONTROL VALVES


1. Leakage. 12m Check and rectify. Refer tomanufacturer's maintenanceinstructions.

2. Operation. 12m Check.Refer to manufacturer'smaintenance instructions.

3. Setting. 12m Check.

4. Valve 24m Strip and clean.Refer to manufacturer'smaintenance instructions.

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46862-07 SEAT VALVES


1. Operational status. 12m Operate and check for correctlinear movement.

Check by operation of the actuator, MotorDriven Actuators. See ACTUATORS-MotorDriven.

2. Let by. 12m Check that valve is not lettingwhen in closed position.

3. Gland and spindle. 12m CheckFor gland leakageSpindle for wear andcontamination.

For lubrication refer tomanufacturer's instructions.

4. Overall condition. 12m Inspect for external damage ordeterioration.

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46963-01 UNDERFLOOR HEATING including VEHICLE ACCESS RAMPS


1. Electrical continuity. 12m Check for any faults. Note current drawn and check with initial design date.Any significant shortfall may indicate a damaged orbroken conductor.

2. Earthing. 12m Check and ensureconnection(s) are secure.

3. Controls. 12m Check operation. For more detailed maintenance instructions, seerelevant section.

4. Frost actuation. 12m Check sensor, if faulty,replace. Check operation.

For more detailed maintenance instructions, seerelevant section.

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47063-02 AUTOMATIC VEHICLE BARRIER

Inform client before withdrawing or restoring electricity supply to barrier.Isolation electrically should be secure, i.e. it should either be at the point of work or precautions should be taken to prevent anyone elseswitching on again when work is in progress.


1. Barriers. 6m Check vertical and horizontalpositions.

2. Limit switches. 6m Inspect condition and adjust asnecessary.

3. Safety switch. 6m Check operation.

4. Push button for barrierop operation.

6m Check condition.

5. Drive motor and brushes. 6m Check for correct operation.

6. Motor overload. 6m Check for correct operation and (See also MOTORS) adjust as necessary.

7. Electrical terminationsand wiring.

6m Check condition and make good ifnecessary.

8. Mechanical items. Responsibility for the maintenance of these itemsshould be agreed with the client.

9. Induction loop. 6m Check operation.

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471

64-01 VENTILATION ANCILLARIES Introduction 1 Local exhaust ventilation – fume extract In bus and vehicle garages and other areas where the build up of dangerous fumes may occur special air extraction systems are often installed. These may be fixed, flexible or mobile installations often incorporating controls and sensors. It is important to observe that the maintenance, examination and testing of local exhaust ventilation HSG 54, 1998 applies. 2 Life supporting systems This equipment is essential in hazardous areas and it is vital that it should be well maintained. Because of its importance maintenance of such equipment should be carried out by specialist personnel.

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47264-02 MOTOR DRIVEN EXHAUST HOSE REEL

ITEM FREQ. ACTION NOTES1. Hose, both starter hose

and extensions, if fitted,and hose stop.

12m Check for flattening and damage.Check condition of hose stop andlocation on hose.

2. Control box andoperation.

12m Check functions i.e. up, down, on/offfan if ‘RCR’ reel fitted with auto fancontractor.

With pendant control ‘up/down’ only. Remotecontrol reel (RCR) only has ability for:- on hoselowering fan will start and on retraction will switchoff only if reel eithera) combi-unit, orb) fitted with fan contractor.

3. Upper and lowerswitches.

12m Check function and condition of upperand lower limit switch.

Lower limit switch activates when reel haslowered its full length of hose.

4. Infrared transmitter. 12m Check functions and condition. Testbattery and replace if necessary.

Applies to RCR only.

5. Main drive gear. 12m Check overall condition of gear forwear.

Gear will be visible on removal of control cover.

6. Swivel coupling and drivemotor.

12m Check for free drive/rotation of reel. (See also MOTORS)

7. Nozzle. 12m Check damper for damage andoperation of spring. Check operationof grip and general condition ofnozzle.

‘Mole grip’ type clamp only available onrubber/steel construction nozzle.

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47364-03 SPRING RECOIL HOSE REEL

ITEM FREQ. ACTION NOTES1. Hose, both starter hose

and extension, if fitted,and hose stop.

12m Check for flattening and damage.Check condition of hose stop andlocation on hose.

2. Spring and ratchet. 12m Check recoiling action of reel andcorrect tensioning of spring. Checkoperation of ratchet.

3. Swivel coupling anddrum.

12m Check for free movement/rotation ofdrum.

4. Auto on/off switch for fan,if fitted.

12m Check location and mounting of twoswitch trigger blocks on drum side.Check operation of switch for controlfan.

5. Suspension/mountingbolts.

12m Check tension on mounting bolts and‘nip up’ if required.


‘Mole grip’ type clamp only available onrubber/steel constructed nozzles.

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47464-04 MOBILE DUST SEPARATOR FOR SPOT EXTRACTION (See also MOTORS)


1. Suction andinterconnecting hoses.

12m Check condition for damage orflattening.

2. Mounting. 12m Check tension on mounting boltbetween handle, dust collector andmotor and filter housing.

3. Switch cable and motor. 12m Check full length of cable for damageand operation of switch. Check forsmooth running of motor.

4. Pressure reduction hose. 12m Check condition and connections ofsmall bore hose.

5. Gaskets and cyclonemounting rod.

12m Check top of cyclone for debris andcorrect location of mounting rod.

For access, unclip lid assembly from over-bin andunbolt cyclone plate. After replacing lid andcyclone arrangement check seating of gasket.

6. Filter. 12m Check condition and replace asnecessary. On replacement of filtercheck condition of gasket.

Note:- Discarded filter elements should be placedin sealed bags for disposal.

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47564-05 MOBILE ELECTRONICALLY CONTROLLED CYCLONE SEPARATOR


1. Suction andinterconnecting hoses.

12m Check condition for damage orflattening.

2. Mounting. 12m Check tension on mounting bolt totrolley and tighten as necessary.

3. Control box and cable. 12m Check functions of control box, e.g.on/off. Check full length of cable fordamage.

When running check correct direction of rotationof fan.

4. Pre-filter. 12m Visually check condition of main gearwheel on filter and drive gear oncleaning handle. Visually checkcondition of pre-filter and seating ofgasket.

For access, pull back rubber collar at the top ofthe filter housing, remove retaining screws andcarefully remove filter cover.

5. Filter. 12m Check condition of flipstrip filter andreplace if necessary. Ensure correctseating of gasket.

Note:- Discarded filter elements should be placedin sealed bags for disposal. Waste DisposalRegulations may apply

6. Cone valve. 12m Check condition and operation ofvalve.

This valve should rise when the unit is switchedon; and lower as the vacuum decreases when theunit is switched off.

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47664-06 VEHICLE EXHAUST RAIL SYSTEM


1. Hose on suction unit. 12m Check condition of hose for flatteningand damage.

Examine both upper and lower hoses.

2. Safety break coupler. 12m Check overall condition of couplingand location of and condition of springclips between retaining pins.

Access to spring clips is achieved by pulling backcentre rubber collar.


‘Mole grip’ type clamp only available onrubber/steel constructed nozzles.

4. Suction trolley. 12m Check trolley for free rolling without‘play’ movement.

5. Auto disconnect system. 12m Check operation by clamping a smallpiece of steel or alternative betweenjaws of clamp. Slide trolley to‘disconnect’ position and ensurecorrect location.

Not fitted on manual disconnect units.

Clamp jaws should open on ball assemblylocation in disconnection brackets.

6. Rubber seal. 12m Check overall condition. May be lubricated with silicone spray.

7. Suspension/Mountingbolts.

12m Check tension on mounting bolts and‘nip up’ if required.


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47764-06 VEHICLE EXHAUST RAIL SYSTEM - continued


8. Duct connections. 12m Check seal and condition of end capsand fan duct connection pipe.

10. Spring balancer. 12m Check condition of cord and freerotation and recoil of spring balancer.

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47865-01 WATER TREATMENT AND CONDITIONING

Introduction

Water may be used for a variety of purposes within buildings, some of the applications will require the water supplied to the building to betreated in order to render it suitable for the purpose for which it is to be used. The maintenance requirements for water treatment plants willvary and be specific to the equipment used and the nature of the application.

Potable or Drinking WaterPublic water suppliesBuildings in the UK are usually supplied with ‘towns mains’ portable water from a water supply undertaker. (Water Companies in England,Regional Councils in Scotland and the Department of the Environment in Northern Ireland).

The quality of potable water is controlled by legislation and should require no further treatment before consumption provided that the water isfed directly to the point of use. However point of use water treatment devices may be found on these supplies.

Private water suppliesBuildings may have their own water supply such as a borehole or a well, or may receive water from a private supply which services more thanone building. These water supplies may require treatment in order to make them potable.

Main uses of Treated Water

Hot water and steam raisingMost water supplies require some form of treatment in order to avoid the scaling or corrosion of heat exchange surfaces caused by dissolvedsolids or impurities in the water.

Air conditioning and heatingIn air-conditioned buildings treated water is used in the cooling system water. This is essential in order to ensure and maintain effectiveoperation of the equipment. Proper treatment has a bearing on energy costs, the implementation of the HASAWA and legionellosis control.Cooling towers that have not been maintained regularly should be considered as HAZARDOUS and must not be maintained by persons whomay be susceptible to Legionella. (For detailed comment see HEAT REJECTION).

Circulatory heating and cooling systems may be provided with automatic or manual dosing equipment.

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479

65-01 WATER TREATMENT AND CONDITIONING Introduction - continued

HumidificationCertain types of humidification systems also have water treatment equipment which requires regular maintenance to ensure properhumidification performance. (For individual HUMIDIFIERS see relevant section).

Cold water servicesIn certain buildings cold water used for non-portable cold water services may be treated.

Recreational and therapeutic applicationsFacilities such as swimming pools, saunas, whirlpool and spa baths, and hydrotherapy pools all require treatment of the water to maintainmicrobiological and aesthetic conditions suitable for their purpose.

Treatment CategoriesWater treatment falls into the following categories:A Ion exchange

1. Base exchange softening - commercial2. Base exchange softening - domestic3. De-ionisation (de-mineralisation) including de-alkalisation

B Filtration conditioning and pH treatment Central plant

1. Iron removal2. pH correction3. Active carbon filtration4. Turbidity removal (clarification)

Point of use5. Active carbon filtration6. Bacteria removal filters7. Sediment removal filters8. Reverse osmosis (see Section D)9. Ultra violet disinfection (see Section E)

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48065-01 WATER TREATMENT AND CONDITIONING Introduction - continued

C Chemical dosing1. Chlorination2. Bromination3. Oxygen scavenging, corrosion and scale inhibitors4. Phosphate dosing5. Biocide

D Reverse osmosis1. Reverse osmosis purification

E Ultra violetF OzonationG Based on physical principles

1. Magnetic field type2. Electrolytic3. Ultrasonic4. Electromagnetic5. Induction

Not covered by this specification are:Water treatment in process plantSpecialist hospital plant

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48165-02 ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - commercial

Note: Maintenance of water treatment plant is very important to avoid scaling of heat exchange surfaces in plant which can lead todeposits and subsequent blockage of outlet fittings, in addition it can lead to energy wastage and increased costs. The operator shouldrefer to and be familiar with the manufacturer's operator's handbook and follow the manufacturer's recommendations regarding thefrequency at which the various maintenance functions should be carried out. These can vary depending on the type of plant andmanufacturer.


1. Salt saturator (may becombined with brine tank).

6m Check salt level and report asnecessary.

In addition to routine checks, the frequency may bealtered by the client's operator to suit usage.

2. Brine tank (where fittedseparately).

6m Clean as appropriate. Check withbrineometer that brine is fullysaturated.

If brine is not fully saturated, brine system requiresfurther investigation. Client should be advised andmatter referred to manufacturer or equipmentsupplier.

3. Overflow and drain. 6m Clean and clear of debris and dirt.

4. Water leaks. 6m If present, locate source and report. For control valves and vessel, manufacturer's adviceshould be sought.

5. Inlet water hardness. 6m Measure and record in plant log. If the raw water hardness increases or decreases bymore than 5% of the initially specified level, refer tomanufacturer/supplier's instructions.

6. Outlet (soft) waterhardness.

6m Measure from sample of water takenwhen softener is in use and water isflowing.

Treated water may be hard due to over running orfault condition which should be rectified.

7. Electrical control system(where fitted).

6m Check condition of all electricalconnections.

Refer to plant operator's manual.

8. Regeneration sequence. 6m Put plant into regeneration sequenceand check all stages of operation.

If system malfunctioning, refer to manufacturer orsupplier.


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48265-02 ION EXCHANGE PLANT- BASE EXCHANGE SOFTENING - commercial - continued


9. Pressure drop oversoftener (where provisionto measure exists).

6m Check and record in plant log. A gradual build up in back pressure could indicatefouling or breakdown of the ion exchange medium.

10. Booster pumps. 6m Carry out maintenanceprogramme as detailed inPUMPS.

11. Ancillary controls andprobes (where fitted)a) conductivity,b) electro chlorination.

6m Inspect for check operation andreport.

12. Plant. Check overall condition andreport.

13. Valves. 6m Overhaul individual valves.

14. Back flow preventiondevices.

6m Check operation. Where operation is between two tanks, check can becarried out by observing whether there is a change oflevels of the two tanks.

15. Recommissioning. 6m Set up flow rates to suit. Report details to client.

16. Water test. 6m Final water test taken. Back pressure readings will give some indication of thecondition of the resin bed. Take sample and send tolaboratory if part of service schedule agreed with client.

17. Major overhaul. 36m Details should be agreed with client.

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48365-03 ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - domestic (capacity usually below 50 litres)


1. Salt tank. 12m Inspect and clean tank and filterscreens.

2. Overflow and drain. 12m Clean and clear of debris anddirt.

3. Injector screen and flowcontroller.

12m Clean injector screen and flowcontroller.

Where required by equipment manufacturer.

4. Inlet water hardness. 12m Measure and record in plantlog, adjust plant as appropriate.

5. Outlet (soft) waterhardness.

12m Measure from sample of watertaken when softener is in useand water is flowing.

6. Water leaks. 6m If present, locate source andreport.

For control valves and vessel, manufacturer's adviceshould be sought.

7. Electrical control system(where fitted).

6m Check condition of all electricalconnections.

8. Regeneration sequence. 6m Put plant into regenerationsequence and check all stagesof operation.

A gradual reduction in service flow may indicatebreakdown of the medium.


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48465-03 ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - domestic - continued


9. Booster pumps. 6m Carry out maintenanceprogramme as detailed inPUMPS.

10. Ancillary controls andprobes (where fitted)a) conductivity,b) electro chlorination.

6m Inspect for check operation andreport.

11. Back flow preventiondevices.

6m Check operation. Where operation is between two tanks, check can becarried out by observing whether there is a change oflevels of the two tanks.

12. Recommissioning. 12m Set up flow rates to suit. Report details to client.

13. Water test. 6m Take final water test. Back pressure readings will give some indication of thecondition of the resin bed. Take sample and send tolaboratory if part of service schedule agreed with client.

14. Major overhaul. 36m Details should be agreed with client.

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48565-04 SPECIAL WATER TREATMENT SYSTEMS

This type of plant is normally serviced by the manufacturer or his agent.


1. Deionisation (de-mineralisation).

These are specialised items of plant. Refer to themanufacturer or supplier for advice on maintenance.

2. Electrolytic waterc conditioners.

These are generally of 'sealed' type construction, therefore nointernal maintenance is possible. Some products do requirereversal however, this is specific to some models and shouldbe referred to the manufacturer for advice.

3. Ultra-sonic type. These are specialised items of plant. Refer to themanufacturer or supplier for advice on maintenance.

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48665-05 FILTRATION, CONDITIONING and pH CORRECTION - central plant


Iron removal

1. Feed water and treatedwater iron levels.

3m Collection samples of feed andtreated water and visuallycompare differences in clarity.

If the maximum concentration of iron in the treated wateris specified, send sample to laboratory for analysis.

2. Water leaks. 3m If present, trace source andrepair.

Any leaks on control valves or vessels should bereferred to manufacturer or supplier.

3. Control system. 3m Check function of electricalcontrol system.

4. Clean cycle 3m Initiate a clean cycle and checkfor correct function.

Check operations with plant manual. Refer tomanufacturer or supplier if there are any malfunctions.

5. Major overhaul andinspection.

24m Following a clean cycle inspectmedium bed for content andfouling.

Carry out medium replacement if necessary as permanufacturer's instructions. Ensure correct type ofmedium for the application is installed and recommissionafter medium is replenished or replaced.

pH correction

Frequency shall be agreed with the client.

1. Feed water and treatedwater pH levels.

3m Collect samples of feed andtreated water and measure pH.

If the pH in the treated water differs from thespecification, investigate and report to the client.



3. Control system. 3m Check function of controlsystem.


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48765-05 FILTRATION, CONDITIONING and pH CORRECTION - central plant - continued


4. Back wash. 3m Initiate a clean cycle and checkfor correct function.


5. Medium inspection. 3m Following a clean cycle inspectmedium bed for content andfouling.

Carry out medium replacement if necessary as permanufacturer's instructions. Ensure correct type ofmedium for the application is installed and recommissionafter medium is replenished or replaced. Frequencyshould take into account usage and local conditions.

6. Major overhaul. 36m Carry out in accordance withmanufacturer's instructions.

Activated carbon filtration

1. Feed water and treatedwater.

3m Collect samples of feed andtreated water and assesscondition against agreedcriteria.

Criteria of water quality should be agreed with the client.





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5. Medium inspection. 3m Following a clean cycle inspectmedium bed for content andfouling. It is essential not tosaturate carbon filtersystems.

Carry out medium replacement if necessary as permanufacturer's instructions. Ensure correct type ofmedium for the application is installed and recommissionafter medium is replenished or replaced. Frequencyshould take into account usage and local conditions.


Turbidity treatment

1. Feed water and treatedwater.

3m Collect samples of feed andtreated water.

If the turbidity of the treated water is specified sendsamples to laboratory for analysis.





Check operations with plant manual. Refer tomanufacturer of supplier if there are any malfunctions.


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5. Medium inspection. 36m Following a clean cycle inspectmedium bed for content andfouling.

Carry out medium replacement if necessary as permanufacturer's instructions. Ensure correct type ofmedium for the application is installed and recommissionafter medium is replenished or replaced.


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49065-06 FILTRATION and CONDITIONING - POINT OF USE


Active carbon - cartridge filter1. Cartridge. 6m Change cartridge. Maintenance operatives must take suitable precautions

to prevent contamination of potable water supply.

2. 'O' ring seals. 6m Inspect and clean or replace asnecessary.

3. Control isolating valve. 12m Check operation.

4. Sealed type housing. 12m Remove and replace completehousing.

Timescale should be according to the manufacturer'srecommendations. N.B. It is essential not to over runthe recommended timescales.

Bacterial removal filters.

1. Cartridge type. 3m

48m

Remove, clean and disinfectcartridge. Inspect for crackingor damage.Change cartridge.

If flow drops to an unacceptable level earliermaintenance may be necessary. Disinfection may notbe required, refer to manufacturer's instructions.Interval may be less than 48m if frequency of cleaningbecome unacceptably short.

2. Sealed or combined typea) cartridge, 6m Change cartridge. The frequency may vary according to the quality and

usage of the inlet water.

b) control isolating valve. 12m Check operation.


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49165-06 FILTRATION and CONDITIONING - POINT OF USE - continued


Sediment removal filters

1. Cartridge. 6m Change cartridge. Frequency, which will depend upon the quality of theinlet water supply, should be agreed with the client.

2. 'O' ring seals. 6m Inspect and clean or replace asnecessary.

3. Control isolating valve. 12m Check operation.

Magnetic water conditioners

Caution: Before servicing magnetic water conditioners itis advisable to remove watches, cassettes or articleswhich may be damaged by an intense magnetic field.

1. Strainers (where fitted). 3m Clean, inspect and reassemble.

2. Internal surfaces (whereaccessible).

12m Clean. There are many differing designs of magnetic waterconditioners but all will be adversely affected by ironparticles adhering to the faces of the magnets.

3. 'O' rings. 12m Inspect and replace asnecessary.

Refer to manufacturer's instructions.

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49265-07 REVERSE OSMOSIS

This type of plant comes in a wide variety of designs and reference should be made to the maintenance instructions provided by themanufacturer.


1. Inlet and outlet watersamples.

6m Collect samples and submit foranalysis.

If there are any significant differences from the designparameters notify client and refer to equipmentmanufacturer.

2. Water leaks. 6m Check and rectify. Any signs of cross leakage between inlet and outlet ofunit should be referred to the manufacturer.


4. Membrane(s). 6m Check integrity. Need forreplacement should be reportedto the client.

The actual means of checking the integrity of themembrane will carry with the design of the unit andmanufacturer's instructions should be followed.

5. Valves. 6m Check action. Detailed information on the maintenance of VALVES,see relevant section.

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49365-08 ULTRA VIOLET DISINFECTION UNIT

Caution: Ultra violet radiation is dangerous to the eyes, avoid looking directly at the lamp when illuminated.


1. Ultra violet generationunit.

1m Check system operational,clean quartz glass sleeve ifwipers are fitted.

Normally this will be carried out by the client's operativeand frequency of maintenance should be agreed withthe client.

2. Cartridge. 1m Change. See note above as frequency will depend upon waterquality.

3. Ultra violet lamp. 12m Replace and note date in plantlog.

Replacement interval will depend upon type of lamp e.g.medium pressure lamps - six months, low pressurelamps - twelve months.

4. Electrical safety. 12m Check security of connectionsand condition of wiring.

5. Sediment removal pre-filter.

24m Remove, clean and replacequartz glass sleeve or thimble.

If feed water contains iron or organic matter, quartzglass may require more frequent cleaning.

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49465-09 OZONATION PLANT

Note: This schedule applies to larger size plants producing more than 30 grammes of ozone per hour. Smaller sized plant should bechecked weekly by client's staff.


1. Dielectric tubes andelectrode assemblies.

6m Remove ozone generatingmodules, inspect and cleandielectric tubes and electrodeassemblies. All glass tube 'O'rings must be replaced andsteel liners cleaned

After cleaning and reassembly, vacuum test to ensuresoundness of both the intermediate tubeplate and seals.

2. Filter cartridge in mainairline from dryer.

6m Remove and replace. Inspect'O' ring seals, replace ifnecessary.

3. Dew point monitor probe. 6m Check calibration. Refer to manufacturer's instructions.

4. a) solenoid valves (wherefitted),b) proximity switches(where fitted).

6m

6m

Remove and replace valveseals and clean valve seats.Check operation. See SWITCHES.

5. Suction and dischargepiping.

6m Check condition, remove andreplace purge pump membraneand diaphragm.

6. Cooling water flow. 6m Check flow rate and operationof proximity switch.

Each module should be checked.

7. Ozone generator air flow. 6m Check rate and operation ofairflow proximity switch.


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49565-09 OZONATION PLANT - continued


8. High temperatureprotection circuit.

6m Check operation.

9. Internal pipework. 6m Check for leakage or damage.

10. Air dryer control unit. 6m Check the timing and adjust asnecessary.

11. Recommissioning checks.

a) safety control circuits andinterlocks,

6m Restart generator.Check operation.

b) dewpoint of dried air, 6m Check with portable dew pointmonitor.

Warning: H.T. circuit must be isolated when carryingout this check which will test soundness of internalfittings and piping.

c) chiller unit (if fitted), 6m Check operation. For detailed maintenance of refrigeration and chillingunit see CHILLERS.

d) water traps, 6m Check water levels.

e) active carbon unit, 6m Check level of activated carbon,top if necessary.Check operation.

f) filter automatic levelcontrol valves,

6m

g) general. 6m Report to client and manufacturer if further actionrequired.

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49665-10 CHEMICAL DOSING

Regular dosing of treated water may be carried out manually or automatically on a discrete or continuous basis. Certain maintenanceoperations are common for all types of chemical dosing but specific requirements may apply to individual treatments such as:

Chlorination - Bromination - Oxygen scavenging, corrosion and scale inhibitors - Phosphate dosing - BiocidesIn all cases refer to the manufacturer's instructions. Care should be taken in the storage, handling and disposal of all chemicals andnote that COSHH Regulations apply.


Dosing pots - manual operation1. Water sample

3m Take, analyse and assessneed for further treatment.

On high temperature systems sample should be cooledbefore analysis. Special safety procedures apply totaking of samples at high pressure.

2. Low pressure dosing pots.a) valves, 6m Overhaul to ensure correct

operation and check forleaks.

b) dosing pot. 6m Clean and thoroughly flushwith water.

3. Chemicals. 6m Fill dosing pot to correctlevel with appropriatechemical or chemicalsolution for application.

Ensure correct type of chemical treatment is used forapplication. Care is required in the handling ofchemicals which should be carried out in accordancewith COSHH Regulations.

4. Dosing. 6m Manipulate valves to ensurecorrect dosing of the system.

5. Water sample (final). 6m Take and check systemwater conditions.

Sample should only be taken after time has elapsed forfull circulation and mixing through the system.


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49765-10 CHEMICAL DOSING - continued


Dosing pots - automatic operation1. Chemical dosing pumps. 6m Strip down, clean and

reassemble. Checkdosing rate.

Electronically controlled dosing pumps may be affectedby other electrical equipment and should be correctlyisolated.

These pumps are usually made of special steels but maybe subject to corrosion. Seals and packing may requirereplacement.

2. Refillable storage vessels. 12m Empty, clean and checkfor corrosion. Repair orrepaint as necessary.

3. Disposable storage vessels. 12m Check level. Replace as appropriate; frequency to be agreed withclient.

Probes1. Conductivity/bromine probes.

1mIsolate, remove andclean.

2. Other sensing and flow ratecontrol devices.

6m Maintain in accordance with manufacturer's instructions.

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49866-01 WHIRLPOOL/SPA BATHS

Note: Frequency of maintenance will depend upon use and the quality of the water and should be agreed with client.


1. Bath hygiene. 12m Clean pipework, pump andnozzles.

Fill bath with warm water to normal level, add sterilisingsolution or low foaming dishwasher powder and operatefor 10 minutes. Refill with cold water and operate forfive minutes.

2. Suction filter (if fitted). 12m Clean.

3. Nozzle jets. 12m Clean and remove scale, refitand regulate flow rates.

Scale may build up in hard water. Client should beinformed of the possible need for water treatment.

4. Electrical safety. 12m Check operation of earthleakage circuit breaker.

Press test button on earth leakage circuit breaker atleast once every three months.

5. Pump and pipework. 12m Check joints and seals forleaks. Rectify or replace asappropriate.

6. Timer (where fitted). 12m Check operation.

On-line Copy

49966-02 HYDROTHERAPY POOLS

It is essential that detailed records of maintenance activities are kept in respect of any maintenance carried out on hydrotherapy pools anda copy given to the client.


1. Pool cleaning. 12m Drain pool, inspect andthoroughly clean.

Frequency will depend on usage and should be agreedwith client. Report any defects which cannot be easilyremedied.

2. Filters. 12m See section FILTERS. Frequency will depend on usage and should be agreedwith client.

3. Water treatment andquality.

12m See section WATERTREATMENT.

Frequency will depend on usage and should be agreedwith client.

On-line Copy

50066-03 STEAM ROOMS and HUMIDIFIERS


Steam production1. Generator.

12m Check operating thermostattimer and earth leakage circuitbreaker.

For more detailed information on the maintenancerequirements for steam generation see BOILER/HEATGENERATORS.

2. Electric element. 12m Descale electrical element ifnecessary.

Scale may build up in hard water areas. Client shouldbe informed of possible need for water treatment.

3. General. 12m See BOILERS/HEATGENERATORS for morespecific information on themaintenance of steamgenerators.

Date post:	03-Apr-2015
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