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Maintenance Task Schedule
Comparison of Changes - pre and post November 2012
All changes
November 2012
Whilst reasonable steps have been taken to ensure that the information contained within this report is correct, you should be aware that the information contained within it may be incomplete, inaccurate or may have become out of date. Accordingly,
B&ES Publications make no warranties or representations of any kind as to the content of this report or its accuracy and, to the maximum extent permitted by law, accept no liability whatsoever for the same including, without limit, for direct, indirect or
consequential loss, business interruption, loss of profits, production, contracts, goodwill or anticipated savings. Any person making use of this report does so at his or her own risk [and it is recommended that they seek professional advice from their
own adviser whenever appropriate].
Table Of Contents
Groups Maintenance Task Schedules
Page 1: ACTUATORS
Page 10: AIR CONDITIONING
Page 12: AIR HANDLING UNITS
Page 14: BELTS
Page 16: BOILERS/HEAT GENERATORS
Page 77: BUILDING MANAGEMENT SYSTEMS
Page 85: BURNERS
Page 93: CHILLERS - WATER
Page 100: COLD ROOMS AND FOOD STORAGE
Page 103: COMMUNICATION AND P.A. SYSTEMS
Page 106: COMPRESSORS - REFRIGERATION
Page 114: CONDENSERS
Page 117: CONTROL PANELS & CONTROLLERS
Page 144: DUCTING
Page 149: DUCTWORK CLEANING
Page 151: ELECTRICS IN BUILDINGS
Page 154: EVAPORATORS
Page 157: FANS
Page 174: FILTERS
Page 180: FIRE ALARM SYSTEMS
Page 189: FIRE PROTECTION SYSTEMS
Page 228: FLUES
Page 230: FOUNTAINS
Page 234: GRILLES AND DIFFUSERS
Page 237: HAZARDOUS AREA (ELECTRICS)
Page 243: HEAT EMITTERS
Page 260: HEAT EXCHANGERS
Page 271: HEAT REJECTION SYSTEMS
Page 282: HIGH VOLTAGE WORKS
Page 309: HOT & COLD WATER SERVICES
Page 313: HOT WATER SUPPLY
Page 335: HUMIDIFIERS INCLUDING DISINFECTION PROCEDURES
Page 347: ICE MAKING MACHINES
Page 350: INSULATION
Page 352: LIGHTING
Page 358: LIGHTING- EMERGENCY
Page 366: LIGHTNING PROTECTION
Page 369: MOTORS
Page 371: PIPEWORK SYSTEMS
Page 390: PNEUMATICS
Page 392: PORTABLE EQUIPMENT
Page 397: POWER GENERATORS
Page 406: POWER SUPPLIES
Page 417: PUMPS
Page 437: REFRIGERANT DISTRIBUTION SYSTEM
Page 441: ROOM AIR CONDITIONERS
Page 444: SANITARY AND WASTE WATER PLUMBING
Page 454: SECURITY SYSTEMS
Page 456: SENSORS AND SWITCHING DEVICES
Page 467: SEWAGE TREATMENT WORKS
Page 479: SHOWERS
Page 482: SMOKE EXTRACT
Page 2: 01-01 INTRODUCTORY PROCEDURES
Page 3: 01-02 PRE-MAINTENANCE PROCEDURES
Page 4: 01-03 THERMAL ACTUATORS
Page 5: 01-04 PNEUMATIC ACTUATORS
Page 6: 01-05 HYDRAULIC ACTUATORS
Page 7: 01-06 MOTOR DRIVEN ACTUATORS
Page 8: 01-07 POWER FAIL - MOTOR RETURN ACTUATORS
Page 9: 01-08 POWER FAIL - SPRING RETURN ACTUATOR
Page 11: 02-01 INTRODUCTORY PROCEDURES
Page 13: 03-01 AIR HANDLING UNITS - general
Page 15: 04-01 BELT DRIVES
Page 18: 05-01 INTRODUCTORY PROCEDURES
Page 19: 05-02 PRE-MAINTENANCE PROCEDURES
Page 20: 05-03 ATMOSPHERIC GAS BURNER - FREE STANDING BOILER
Page 22: 05-04 ATMOSPHERIC GAS BURNER - CONDENSING BOILER
Page 24: 05-05 COAL FIRED BOILERS Bunkers and Conveyors.
Page 25: 05-06 COAL FIRED BOILERS - Coal storage handling and feed mechanisms, automatic ash removal (where fitted)
Page 26: 05-07 COAL FEED MECHANISMS - Under feed stokers
Page 27: 05-08 COAL FEED MECHANISMS - Chain grate stokers
Page 28: 05-09 ASH HANDLING SYSTEM
Page 29: 05-10 BLOWN GAS BURNER CONDENSING BOILER
Page 30: 05-11 BLOWN GAS BURNER MODULAR BOILER
Page 31: 05-12 FORCED DRAUGHT GAS CONDENSING BOILER
Page 32: 05-13 FORCED DRAUGHT [PRESSURE JET] OIL CONDENSING BOILER
Page 33: 05-14 BOILERS MTHW UP TO 120 oC
Page 34: 05-15 MULTIPLE BOILERS - sequence controls
Page 35: 05-16 BOILER CONTROLS - Single boiler: on/off
Page 36: 05-19 STEAM BOILERS Pre-maintenance check.
Page 37: 05-20 STEAM BOILERS Maintenance schedule.
Page 40: 05-21 ELECTRIC BOILERS
Page 41: 05-22 ELECTRODE BOILERS
Page 42: 05-23 BOILERS LTHW UP TO 95ºC
Page 43: 05-24 BOILERS - FIRE AND SAFETY CIRCUITS
Page 44: 05-25 WASTE AND WOOD BURNING APPLIANCES (including boilers) - Fire And Boiler Safety Circuits
Page 45: 05-26 WASTE AND WOOD BURNING APPLIANCES (including boilers) - Combustion Chamber
Page 46: 05-27 WASTE AND WOOD BURNING APPLIANCES (including boilers) - BOILER (if fitted)
Page 47: 05-28 Atmospheric Gas Burner Boiler - Small and/or wall hung for domestic/light commercial installation
Page 49: 05-29 COMBINATION ATMOSPHERIC BURNER GAS BOILER
Page 51: 05-30 ATMOSPHERIC GAS BURNER/CONDENSING COMBINATION BOILER
Page 53: 05-31 AIR TO WATER HEAT PUMP
Page 54: 05-32 WATER TO WATER HEAT PUMP
Page 55: 05-33 BRINE TO WATER HEAT PUMP
Page 56: 05-34 PACKAGED STEAM GENERATORS
Page 59: 05-35 PAKAGED STEAM GENERATORS - ELECTRIC
Page 60: 05-36 STEAM BOILER REPORT - PERIODIC EXAMINATION
Page 61: 05-37 BOILER SUPERHEATER
Page 62: 05-38 BIOMASS BOILER
Page 64: 05-39 GAS BOOSTER SETS
Page 65: 05-40 GAS GOVERNOR OR GAS REGULATOR
Page 66: 05-41 GAS INCINERATOR
Page 68: 05-42 WASTE INCINERATOR
Page 72: 05-43 WET SCRUBBER SYSTEM
Contents Page 1 of 7
Page 486: SOLAR PANELS
Page 488: SPLIT SYSTEMS INCLUDING HEAT PUMPS
Page 497: STARTERS
Page 507: STORAGE TANKS
Page 524: SWIMMING POOLS
Page 535: SWITCHES
Page 538: TERMINAL UNITS
Page 553: VACUUM SYSTEMS
Page 556: VALVES
Page 566: VALVES -AUTOMATIC CONTROL
Page 573: VEHICLE ACCESS
Page 576: VENTILATION ANCILLARIES
Page 585: WATER TREATMENT
Page 608: WHIRLPOOLS-HYDROTHERAPY
Page 74: 05-44 FABRIC FILTER SYSTEM
Page 76: 05-45 SANITARY INCINERATOR
Page 79: 06-01 INTRODUCTORY PROCEDURES
Page 80: 06-03 BUILDING MANAGEMENT SYSTEMS - Central Operator Station
Page 82: 06-04 BUILDING MANAGEMENT SYSTEMS - COMMUNICATIONS
Page 83: 06-05 BUILDING MAINTENANCE SYSTEMS - OUTSTATIONS
Page 84: 06-06 BUILDING MANAGEMENT SYSTEMS - SOFTWARE FUNCTIONS
Page 86: 07-01 ATMOSPHERIC GAS BURNERS
Page 87: 07-02 BLOWN GAS BURNER
Page 88: 07-03 FORCED DRAUGHT GAS BURNER
Page 89: 07-04 FUEL OIL DISTRIBUTION & PIPEWORK USING MEDIUM (220/960 Sec) OIL
Page 90: 07-05 FORCED DRAUGHT [PRESSURE JET] OIL BURNER
Page 91: 07-06 LIGHT OIL VAPORISING POT BURNER
Page 92: 07-07 GAS/OIL BURNERS - Dual fuel
Page 94: 09-01 INTRODUCTORY PROCEDURES
Page 95: 09-02 PACKAGED CHILLER UNITS
Page 98: 09-03 LITHIUM BROMIDE/WATER ABSORPTION CHILLERS
Page 99: 09-04 GAS FIRED ABSORPTION CHILLER UP TO 18 KW COOLING CAPACITY
Page 101: 10-01 COLD ROOMS
Page 102: 10-02 REFRIGERATED DISPLAY CABINETS
Page 104: 11-01 COMMUNICATIONS - PUBLIC ADDRESS SYSTEMS
Page 107: 12-01 COMPRESSORS REFRIGERATION - Reciprocal - (includes hermetic, semi-hermetic and open)
Page 109: 12-02 COMPRESSOR - SCREW
Page 110: 12-03 COMPRESSORS REFRIGERATION - CENTRIFUGAL
Page 112: 12-04 COMPRESSOR - SCROLL
Page 115: 13-01 CONDENSERS - water cooled
Page 116: 13-02 CONDENSER - air cooled
Page 118: 14-01 CONTROL PANELS AND CONTROLLERS INTRODUCTORY PROCEDURES
Page 119: 14-02 CONTROL PANELS - electrical services (excluding electrical controllers and pneumatic relays)
Page 120: 14-03 CONTROL PANELS - lamps, meters, alarms etc.
Page 121: 14-04 OPTIMISER
Page 122: 14-05 HEATING COMPENSATOR
Page 123: 14-06 SINGLE INPUT CONTROLLER
Page 124: 14-06 PRE-MAINTENANCE PROCEDURES
Page 125: 14-07 UNIT CONTROLLERS AND SENSOR CONTROLLERS
Page 126: 14-07 PRE-MAINTENANCE PROCEDURES
Page 127: 14-08 CONTROLLER TIMERS
Page 128: 14-08 PRE-MAINTENANCE PROCEDURES
Page 129: 14-09 STEP CONTROLLERS
Page 130: 14-09 PRE-MAINTENANCE PROCEDURES
Page 131: 14-10 TIMESWITCHES
Page 132: 14-10 PRE-MAINTENANCE PROCEDURES
Page 133: 14-11 MULTI-INPUT CONTROLLERS
Page 134: 14-11 PRE-MAINTENANCE PROCEDURES
Page 135: 14-12 INDICATORS AND DISPLAYS
Page 136: 14-13 ALARM MODULES
Page 137: 14-14 LEVEL CONTROLLERS
Page 138: 14-14 PRE-MAINTENANCE PROCEDURES
Page 139: 14-15 SPEED CONTROLLERS
Page 140: 14-15 PRE-MAINTENANCE PROCEDURES
Page 141: 14-16 TRANSDUCERS - pneumatic to electronic and electronic to pneumatic
Page 142: 14-17 DIRECT CURRENT [DC] DRIVES
Page 143: 14-18 EMERGENCY STOP BUTTONS
Page 145: 16-01 DUCTING AND AIR DISTRIBUTION INTRODUCTORY PROCEDURES
Page 146: 16-02 DUCTWORK SYSTEM - GENERAL
Page 147: 16-03 DUCTING - VOLUME CONTROL DAMPERS AND FIRE/ SMOKE DAMPERS
Page 148: 16-04 DUCTING - Attenuators
Page 2 of 7
Page 150: 17-01 DUCTWORK CLEANING HYGIENE, INSPECTIONS & MONITORING
Page 153: 18-01 INTRODUCTORY PROCEDURES
Page 155: 19-01 REFRIGERATION EVAPORATORS
Page 158: 20-01 INTRODUCTORY PROCEDURES
Page 159: 20-02 FANS - VENTILATING - general
Page 161: 20-03 FANS -CENTRIFUGAL
Page 163: 20-04 FANS- AXIAL
Page 165: 20-05 FANS - PROPELLER
Page 167: 20-06 FANS-MIXED FLOW
Page 169: 20-07 FANS-BIFURCATED
Page 171: 20-08 FANS-EXTRACT - including fire/smoke extracts units
Page 172: 22-02 FIRE ALARMS - Associated Equipment
Page 175: 21-01 INTRODUCTORY PROCEDURES
Page 176: 21-02 AIR FILTERS
Page 179: 21-03 ELECTROSTATIC FILTERS
Page 181: 22-01 FIRE ALARM SYSTEM
Page 190: 23-01 INTRODUCTORY PROCEDURES
Page 191: 23-02 HOSE REELS PRESSURE BOOSTING SETS
Page 192: 23-03 HOSE REELS - Static or Swinging
Page 194: 23-04 RISING FIRE MAINS and HYDRANTS
Page 195: 23-05 Gas Extinguishing systems
Page 197: 23-06 CARBON DIOXIDE TOTAL FLOODING FIRE EXTINGUISHING SYSTEM
Page 199: 23-07 EXPANSION FOAM SYSTEMS
Page 202: 23-08 FIRE EXTINGUISHERS - GAS SUPPRESSION (Halon)
Page 203: 23-09 FIRE EXTINGUISHERS - CARBON DIOXIDE
Page 205: 23-10 FIRE EXTINGUISHERS - FOAM (Stored Pressure)
Page 208: 23-11 FIRE EXTINGUISHERS - POWDER (GAS CARTRIDGE)
Page 213: 23-12 FIRE EXTINGUISHERS - WATER - GAS CARTRIDGE
Page 217: 23-13 FIRE EXTINGUISHERS - WATER STORED PRESSURE
Page 220: 23-14 SPRINKLER SYSTEMS
Page 225: 23-15 GAS DETECTION
Page 226: 23-16 KITCHEN HOOD FIRE SUPPRESSION
Page 229: 24-01 FLUES (all combustible fuels)
Page 231: 25-01 FOUNTAINS OUTDOOR - ORNAMENTAL
Page 232: 25-02 FOUNTAINS INDOOR - ORNAMENTAL
Page 235: 26-01 GRILLES AND DIFFUSERS
Page 236: 26-02 LOUVRES, BIRD AND INSECT SCREENS
Page 238: 27-01 INTRODUCTORY PROCEDURES
Page 239: 27-02 Hazardous areas - FLAME PROOF EQUIPMENT
Page 240: 27-03 Hazardous areas - LIGHTING
Page 241: 27-04 Hazardous areas - EARTHING
Page 244: 28-01 HEAT EMITTERS
Page 248: 28-02 GAS FIRED CERAMIC PLAQUE INFRA RED HEATERS
Page 250: 28-03 GAS RADIANT TUBE HEATERS
Page 252: 28-04 GAS FIRED NATURAL AND FAN ASSISTED HEATERS - Conventional and Balanced Flue.
Page 253: 28-05 GAS FIRE
Page 255: 28-06 GAS FIRED UNIT HEATERS
Page 257: 28-07 GAS FIRED RADIANT HEATERS
Page 261: 29-01 HEAT EXCHANGERS - COILS
Page 263: 29-02 ELECTRIC/AIR HEATER
Page 264: 29-03 PLATE RECUPERATOR
Page 265: 29-04 THERMAL WHEELS - ROTARY HEAT REGENERATORS
Page 266: 29-05 RUN AROUND HEAT RECOVERY COILS
Page 267: 29-06 PLATE HEAT EXCHANGERS
Page 268: 29-07 WATER TO WATER PLATE HEAT EXCHANGERS
Page 269: 29-08 HEATING CALORIFIERS - MTHW, HTHW or STEAM
Page 272: 30-01 INTRODUCTORY PROCEDURES
Page 3 of 7
Page 273: 30-02 COOLING TOWERS - Precautions against Legionnaires disease (legionella pneumophila)
Page 278: 30-03 DRY COOLERS
Page 280: 30-04 ADIABATIC COOLERS
Page 283: 70-01 INTRODUCTORY PROCEDURES
Page 284: 70-02 HV PACKAGED SUBSTATIONS
Page 286: 70-03 OIL SWITCHGEAR INCLUDING OIL CIRCUIT BREAKERS AND OIL SWITCHES
Page 290: 70-04 NON-OIL SWITCHGEAR
Page 296: 70-05 VACUUM INDOOR SWITCHGEAR
Page 299: 70-06 FLUID FILLED TRANSFORMER
Page 302: 70-07 CAST RESIN TRANSFORMER
Page 305: 70-08 RING MAIN UNIT
Page 307: 70-09 HV SWITCHPANEL
Page 312: 31-01 INTRODUCTORY PROCEDURES
Page 315: 32-01 INTRODUCTORY PROCEDURES
Page 316: 32-02 HOT WATER SERVICES general
Page 317: 32-03 CALORIFIER TYPES
Page 318: 32-04 PRE-MAINTENANCE PROCEDURES
Page 319: 32-05 CALORIFIERS HEATED BY LTHW
Page 320: 32-06 HOT WATER CALORIFIERS HEATED BY MTHW, HTHW or STEAM
Page 322: 32-07 HOT WATER SUPPLY CALORIFIERS
Page 324: 32-08 CALORIFIER AND HEAT EXCHANGE CONTROLS
Page 325: 32-09 HOT WATER CYLINDERS
Page 327: 32-10 UNVENTED HOT WATER SYSTEMS
Page 328: 32-11 THERMAL STORAGE CYLINDER (individual dwellings for DHWS)
Page 330: 32-12 EXPANSION VESSELS
Page 331: 32-13 DIRECT FIRED WATER HEATERS
Page 332: 32-14 INSTANTANEOUS ELECTRIC WATER HEATERS (non drinks type)
Page 333: 32-15 PACKAGED ELECTRIC WATER HEATERS-cistern type (non drinks)
Page 334: 32-16 VENTED HOT WATER SYSTEMS
Page 336: 33-01 HUMIDIFIER - Cold water evaporator, drum type
Page 337: 33-02 HUMIDIFIER - Direct steam injection type.
Page 340: 33-03 ELECTRODE BOILER HUMIDIFIER
Page 341: 33-04 HUMIDIFIERS- Compressed air type
Page 343: 33-05 HUMIDIFIERS- Ultra sonic
Page 344: 33-06 HUMIDIFIERS- Resistance heater type
Page 345: 33-07 HUMIDIFIER - Disinfection procedures
Page 346: 33-08 SPRAY HUMIDIFIERS
Page 348: 34-01 ICE MAKING MACHINES
Page 351: 35-01 THERMAL INSULATION
Page 353: 36-01 INTRODUCTORY PROCEDURES
Page 354: 36-02 LIGHTING-SWITCHES-INTERNAL AND EXTERNAL
Page 355: 36-03 LIGHTING FITTINGS including LUMINAIRES general
Page 356: 36-04 EXTERNAL LIGHTING including ILLUMINATED SIGNS
Page 359: 37-01 EMERGENCY LIGHTING self contained
Page 361: 37-02 EMERGENCY LIGHTING externally powered
Page 363: 40-04 CHILLED WATER-CONDENSER WATER PIPE SYSTEMS
Page 364: 40-05 CONDENSER - CHILLED WATER CIRCULATING PUMPS
Page 365: 40-06 PRESSURISATION UNITS - CHILLED WATER
Page 367: 38-01 LIGHTNING CONDUCTOR AND EARTH
Page 370: 39-01 MOTORS- DRIVE ELEMENTS
Page 372: 40-01 PIPEWORK SYSTEMS - General
Page 373: 40-03 PIPEWORK SYSTEMS-TRACE HEATING
Page 374: 40-07 PNEUMATIC EQUIPMENT – COMPRESSED AIR SYSTEMS
Page 375: 40-08 AIR COMPRESSORS AND RECEIVERS
Page 379: 40-09 AIR COMPRESSORS Compressed air dryers
Page 380: 40-10 PIPEWORK FOR LOW PRESSURE NATURAL GAS, LIQUEFIED PETROLEUM GAS (LPG) OR OIL
Page 382: 40-11 STEAM SERVICES
Page 4 of 7
Page 384: 40-12 FLASH STEAM VESSEL
Page 386: 40-13 EMERGENCY SOLENOID FUEL VALVES
Page 387: 40-15 PRESSURE REDUCING VALVES
Page 388: 40-16 WATER BUFFER/SURGE TANKS
Page 389: 40-17 WATER MAINS - above ground
Page 391: 41-01 PNEUMATIC RELAYS
Page 393: 42-01 PORTABLE APPLIANCE TESTING (PAT)
Page 398: 43-01 INTRODUCTORY PROCEDURES
Page 399: 43-02 POWER GENERATION--STAND-BY GENERATOR
Page 403: 43-03 BATTERIES - LEAD ACID - unsealed
Page 404: 43-04 BATTERY CHARGING EQUIPMENT
Page 405: 43-05 UNINTERRUPTIBLE POWER SUPPLIES
Page 407: 44-01 INTRODUCTORY PROCEDURES
Page 408: 44-02 MAIN SWITCH PANEL AT SUPPLY INTAKE
Page 410: 44-05 POWER DISTRIBUTION UNIT (PDU)
Page 412: 44-06 EARTHING
Page 413: 44-07 DISTRIBUTION BOARDS
Page 414: 44-08 ELECTRICAL INSTALLATION - GENERALLY
Page 416: 44-10 ISOLATORS/STARTERS/FUSESWITCHES
Page 418: 45-01 PUMPS - General
Page 420: 45-02 CIRCULATING PUMPS-general
Page 421: 45-03 CENTRIFUGAL PUMPS
Page 423: 45-04 PRESSURISATION PUMPS
Page 425: 45-05 ROTARY HAND PUMPS
Page 426: 45-06 SECONDARY HOT WATER CIRCULATING PUMPS
Page 427: 45-07 SEWAGE OR DRAINAGE PUMPS SUBMERSIBLE
Page 429: 45-08 SEWAGE and DRAINAGE PUMPS: DRYWELL
Page 431: 45-09 SEWAGE PUMPS: COMPRESSED AIR
Page 432: 45-10 SUMP PUMPS: EXTENDED SHAFT
Page 434: 45-12 WATER PUMPING PRESSURE BOOSTING SETS
Page 436: 45-13 OGDEN STEAM PUMP
Page 438: 46-01 REFRIGERANT DISTRIBUTION SYSTEM
Page 442: 47-01 ROOM AIR CONDITIONERS
Page 445: 48-01 INTRODUCTORY PROCEDURES
Page 446: 48-02 MACERATORS
Page 447: 48-03 INTERCEPTORS - Petrol and Oil
Page 448: 48-04 INTERCEPTORS - blowdown and sumps
Page 450: 48-05 SANITARY, WASTE WATER PLUMBING and DRAINS
Page 452: 48-06 AIR ADMITTANCE VALVES
Page 453: 48-08 SANITARY AND WASTE WATER PLUMBING - WATER SAVING DEVICES and METERS
Page 455: 49-01 SECURITY SYSTEMS-INTRUDER ALARMS
Page 457: 50-01 PRE-MAINTENANCE PROCEDURES
Page 458: 50-02 PRESSURE MEASUREMENT SENSORS - static and differential
Page 459: 50-03 TEMPERATURE MEASUREMENT SENSORS
Page 460: 50-04 RELATIVE HUMIDITY SENSORS
Page 461: 50-05 ABSOLUTE HUMIDITY SENSORS
Page 462: 50-07 CARBON DIOXIDE SENSORS
Page 463: 50-08 VELOCITY SENSORS
Page 464: 50-09 OCCUPANCY and LIGHT SENSORS
Page 465: 50-10 SMOKE DETECTORS
Page 466: 50-11 GAS DETECTOR SENSORS
Page 468: 71-01 INTRODUCTORY PROCEDURES
Page 469: 71-02 SEWAGE TREATMENT WORKS - package systems
Page 471: 71-03 SEWAGE TREATMENT WORKS - EXTENDED AERATION AND OXIDATION DITCH SYSTEMS
Page 475: 71-04 DRAINAGE FIELDS
Page 476: 71-05 SETTLEMENT TANKS
Page 477: 71-06 SEPERATOR SYSTEMS
Page 5 of 7
Page 480: 51-01 SHOWERS
Page 481: 51-02 SHOWERS BOOSTER PUMPS
Page 483: 52-02 SMOKE RELIEF - Natural smoke and heat exhaust ventilators
Page 484: 52-03 SMOKE RELIEF - Powered smoke and heat exhaust ventilators
Page 485: 52-04 SMOKE CURTAINS
Page 487: 53-01 SOLAR HOT WATER PANELS and similar COLLECTING DEVICES
Page 489: 54-01 INTRODUCTORY PROCEDURES
Page 490: 54-02 DX SPLIT SYSTEMS - with gas, electric or hot water heaters
Page 494: 54-03 SPLIT SYSTEMS/ HEATPUMPS – air-cooled with direct expansion evaporator (DX)
Page 498: 55-01 DRIVE ELEMENTS - STARTERS
Page 499: 55-02 STARTERS - Star Delta
Page 500: 55-03 STARTERS -Two speed - Dual wound
Page 501: 55-04 STARTERS - Two speed - Pole change
Page 502: 55-05 STARTERS - Reversing
Page 503: 55-06 STARTERS - Auto-transformer
Page 504: 55-07 STARTERS - Quick transition, electric heater
Page 505: 55-08 STARTERS electrolyte type
Page 506: 55-09 STARTERS-AIR BREAK AND CONTACTORS
Page 509: 56-01 INTRODUCTORY PROCEDURES
Page 511: 56-02 COLD WATER STORAGE TANKS and CISTERNS
Page 514: 56-03 ICE STORAGE SYSTEMS
Page 516: 56-05 STORAGE TANKS - OIL
Page 519: 56-06 UNDERGROUND OIL STORAGE TANKS
Page 522: 56-07 STORAGE SILO - wood chip / pellets
Page 523: 56-08 STORAGE SILO - COAL
Page 525: 57-01 INTRODUCTORY PROCEDURES
Page 526: 57-02 SWIMMING POOLS
Page 530: 57-03 SWIMMING POOLS - FILTERS
Page 532: 57-04 SWIMMING POOLS - PIPEWORK, PUMPS, HEATING etc.
Page 536: 58-01 ON/OFF SWITCHING DEVICES
Page 537: 58-02 CONTROL RELAYS
Page 539: 59-01 TERMINAL UNITS VAV - self powered
Page 540: 59-01 INTRODUCTORY PROCEDURES
Page 541: 59-02 TERMINAL UNITS VAV - fan powered
Page 542: 59-02 INTRODUCTORY PROCEDURES
Page 543: 59-03 TERMINAL UNITS VAV - pneumatic powered
Page 544: 59-03 INTRODUCTORY PROCEDURES
Page 545: 59-04 TERMINAL UNITS - Constant volume including mixing
Page 546: 59-04 INTRODUCTORY PROCEDURES
Page 547: 59-05 TERMINAL UNITS - INDUCTION UNITS
Page 548: 59-05 INTRODUCTORY PROCEDURES
Page 549: 59-06 TERMINAL UNITS - FAN COIL
Page 550: 59-07 TERMINAL UNITS VRV SYSTEMS
Page 552: 59-07 INTRODUCTORY PROCEDURES
Page 554: 60-01 VACUUM SYSTEMS - general
Page 555: 60-02 VACUUM TUBES - cash handling
Page 557: 61-01 VALVES
Page 560: 61-02 TAP AND OUTLET FITTINGS
Page 561: 61-03 SERVICE VALVES
Page 562: 61-04 COMBINATION TAP ASSEMBLIES, MIXING VALVES/TAPS
Page 565: 61-05 SHOWER VALVES
Page 567: 62-01 PRE - MAINTENANCE PROCEDURES
Page 568: 62-02 ROTARY VALVES - Shoe or Slipper
Page 569: 62-03 BUTTERFLY AND BALL VALVES
Page 570: 62-04 SELF ACTING and THERMAL VALVES
Page 571: 62-05 SOLENOID VALVES
Page 572: 62-07 SEAT VALVES
Page 6 of 7
Page 574: 63-01 UNDERFLOOR HEATING including VEHICLE ACCESS RAMPS
Page 575: 63-02 AUTOMATIC VEHICLE BARRIER
Page 577: 64-01 INTRODUCTORY PROCEDURES
Page 578: 64-02 MOTOR DRIVEN EXHAUST HOSE REEL
Page 579: 64-03 SPRING RECOIL HOSE REEL
Page 580: 64-04 MOBILE DUST SEPARATOR FOR SPOT EXTRACTION
Page 581: 64-05 MOBILE ELECTRONICALLY CONTROLLED CYCLONE SEPARATOR
Page 582: 64-06 VEHICLE EXHAUST RAIL SYSTEM
Page 583: 64-07 WOOD DUST EXTRACTION
Page 588: 65-01 INTRODUCTORY PROCEDURES
Page 589: 65-02 ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - commercial
Page 591: 65-03 ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - domestic (capacity usually below 50 litres)
Page 593: 65-04 SPECIAL WATER TREATMENT SYSTEMS
Page 594: 65-05 FILTRATION, CONDITIONING and pH CORRECTION - central plant
Page 595: 65-06 FILTRATION and CONDITIONING - POINT OF USE
Page 596: 65-07 REVERSE OSMOSIS
Page 597: 65-08 ULTRA VIOLET DISINFECTION UNIT
Page 598: 65-09 OZONATION PLANT
Page 600: 65-10 CHEMICAL DOSING
Page 602: 65-11 ADIABATIC COOLING - Introductory Information and Procedures
Page 603: 65-12 ADIABATIC COOLING SYSTEMS
Page 606: 65-13 CHLORINE DIOXIDE DOSING FOR DOMESTIC LOWLEVEL INJECTION
Page 607: 65-14 CHLORINE DIOXIDE LOW DOSING DOMESTIC WATER SYSTEMS
Page 609: 66-01 WHIRLPOOL/SPA BATHS
Page 611: 66-02 HYDROTHERAPY POOLS
Page 614: 66-03 STEAM ROOMS and HUMIDIFIERS
Page 7 of 7
ACTUATORS
Page 1 of 614
Previous
Version
Updated
Version
Reason For
Change
INTRODUCTORY PROCEDURES01-01 01-01 INTRODUCTORY PROCEDURES
The following procedures apply to all types of actuator and require that before any
maintenance is undertaken all safety precautions must be strictly adhered to. Care must be taken
to ensure that any maintenance does not unduly interfere with the system's environmental 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 been disconnected.
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 other piece of equipment. Its purpose is to control to a position
between two limits, by either opening, closing or moving appropriate pieces of equipment.
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 the seven 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 aware of the operating characteristics of the device under scrutiny.
If any doubt arises it would be preferred if the manufacturer were questioned prior 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 actuator housing. The sensor is connected via a length of cable and will
commonly be sensing air velocity or pressure. The controller will have been set to the required VAV
box demand and these settings should not be altered without prior consultation with the client,
the VAV box manufacturer and the actuator manufacturer. In this example, cross-referencing
should be made between the Actuators, Controllers and Sensors sections.
The following procedures apply to all types of actuator and require that before any maintenance is
undertaken all safety precautions must be strictly adhered to. Care must be taken to ensure that any
maintenance does not unduly interfere with the system`s environmental 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 been disconnected.
To check that the actuator is performing its correct task, it is immaterial as to whether it is mounted on
a damper, louver, valve or any other piece of equipment. Its purpose is to control to a position
between two limits, by either opening, closing or moving appropriate pieces of equipment.
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 the seven 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 aware of the operating characteristics of the device under scrutiny.
If any doubt arises it would be preferred if the manufacturer were questioned prior 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 actuator housing. The sensor is connected via a length of cable and will
commonly be sensing air velocity or pressure. The controller will have been set to the required VAV
box demand and these settings should not be altered without prior consultation with the client, the
VAV box manufacturer and the actuator manufacturer. In this example, cross-referencing should be
made between the Actuators, Controllers and Sensors sections.
Other
Page 2 of 614
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PRE-MAINTENANCE PROCEDURES01-02 01-02 PRE-MAINTENANCE PROCEDURES
Should any discrepancies occur with the following checks the client should be informed as soon as
possible to avoid the possible uneconomical 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 a fire 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.
Actuator torque. Check torque with a torque wrench. This check is of particular importance on spring
return type actuators because the spring will have a maximum life span. Elasticity of the spring and
hence the torque will reduce with time, if the torque 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.
Should any discrepancies occur with the following checks the client should be informed as soon as
possible to avoid the possible uneconomical 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 a fire 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.
Actuator torque. Check torque with a torque wrench. This check is of particular importance on spring
return type actuators because the spring will have a maximum life span. Elasticity of the spring and
hence the torque will reduce with time, if the torque 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.
Other
Page 3 of 614
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THERMAL ACTUATORS01-03 01-03 THERMAL ACTUATORS
Title NotesActionFQTitle FQ Action Notes
1. Electricity
supply.
Check supply voltage and that
polarities are correct.
If supply voltages are not found,
check to see if supply is via a
controller. Refer to manufacturer's
data sheet.
12M 1. Electricity
supply.
Where applicable, Check supply
voltage and that polarities are
correct.
If supply voltages are not found,
check to see if supply is via a
controller. Refer to manufacturer`s
data sheet.
12MTechnical
2. Control signal. Check for presence and that
polarity is correct.
Refer to manufacturer's data sheet.
The previous note can also apply to
the control signal.
12M 2. Control signal. Where applicable, Check for
presence and that polarity is
correct.
Refer to manufacturer`s data sheet.
The previous note can also apply to
the control signal.
12MTechnical
6. Reaction to
safety signal i.e.
fire/smoke.
Check that the actuator assumes
correct position (if applicable).
See relevant control/sensor section
for this operation.
6M 6. Reaction to
safety signal i.e.
fire/smoke.
Check that the actuator assumes
correct position (if applicable).
See relevant control/sensor section
for this operation.
3MOther
9. Leakage. Check for signs of leakage of
hydraulic fluid around actuator
seals. Change seals if necessary.
See manufacturer's data sheet.12M 9. Leakage. Check for signs of leakage of fluid
around actuator seals. Change
seals if necessary.
See manufacturer`s data sheet.12MTechnical
Page 4 of 614
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PNEUMATIC ACTUATORS01-04 01-04 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.
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.
Electro/pneumatic controllers will have an electrical supply to them and therefore all necessary
precautions will need to be taken to isolate supplies.
Technical
Title NotesActionFQTitle FQ Action Notes
3. Air quality. Check that any filters are clear of
water and oil (filter may not be local
to the actuator).
If water and/or oil is present, check
with manufacturer of the system
regarding required action.
12M 3. Air quality. Check that any filters are clear of
water and oil (filter may not be local
to the actuator).
If water and/or oil is present, trace
pipe work back to identify the source
of the water or oil and rectify the
problem
12MTechnical
4. Manual
operation (if fitted).
Check to ensure actuator achieves
stroke limits. Check for minimum/
maximum setting.
Ensure manual override is set to
correct position.
12M 4. Manual
operation (if fitted).
Check to ensure actuator achieves
stroke limits. Check for minimum/
maximum setting.
Ensure manual override is reset to
correct automatic position.
12MTechnical
7. Actuator
function.
Check calibration - controller output
to actuator position. Note: more
than one actuator may be fed from
the control supply.
Note control pressure operation
range is correct (could be
sequenced control)
6M 7. Actuator
function.
Check calibration - controller output
to actuator position. More than one
actuator may be fed from the
control supply.
Note control pressure operation
range is correct (could be
sequenced control)
6MOther
9. Reaction to
safety signal i.e.
fire/smoke.
Check that the actuator assumes
correct position (if applicable).
See relevant control/sensor section
for this operation.
3MAdded
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HYDRAULIC ACTUATORS01-05 01-05 HYDRAULIC ACTUATORS
(Should not be confused with pneumatic actuators) Ensure the correct grade and type of hydraulic oil is used for any topping up purposes.Technical
Title NotesActionFQTitle FQ Action Notes
1. Electricity
supply.
Check supply voltage and that
polarities are correct.
If supply voltages are not found,
check to see if supply is via a
controller. Refer to manufacturer's
data sheet.
12M 1. Electricity
supply.
Where applicable, check supply
voltage and that polarities are
correct.
If supply voltages are not found,
check to see if supply is via a
controller. Refer to manufacturer`s
data sheet.
12MTechnical
2. Control signal. Check for presence and that
polarity is correct.
Refer to manufacturer's data sheet.
The previous note can also apply to
the control signal.
12M 2. Control signal. Where applicable, check for
presence and that polarity is
correct.
Refer to manufacturer`s data sheet.
The previous note can also apply to
the control signal.
12MTechnical
8. Leakage. Check for signs of leakage of
hydraulic fluid around actuator
seals. Change seals if necessary.
See manufacturer's data sheet.12M 8. Leakage. Check for signs of leakage of
hydraulic fluid around actuator
seals. Change seals if necessary.
On completion of the works, bleed
through the system to ensure there
is no air trapped in the pipework
See manufacturer`s data sheet.12MTechnical
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MOTOR DRIVEN ACTUATORS01-06 01-06 MOTOR DRIVEN ACTUATORS
Title NotesActionFQTitle FQ Action Notes
6. Reaction to
safety signal i.e.
fire/smoke.
Check that the actuator assumes
correct position (if applicable).
The signal could be in any form from
a fusible link in the supply or gear
box to an independent signal from a
control. If the actuator is integrated
into the fire alarm circuit, checks
may have to be made whilst a fire
drill is in operation. See
manufacturer's data sheet on this
actuator and relevant control and/or
sensor section.
6M 6. Reaction to
safety signal i.e.
fire/smoke.
Check that the actuator assumes
correct position (if applicable).
The signal could be in any form
from a fusible link in the supply or
gear box to an independent signal
from a control. If the actuator is
integrated into the fire alarm circuit,
checks may have to be made whilst
a fire drill is in operation. See
manufacturer`s data sheet on this
actuator and relevant control and/or
sensor section.
3MOther
Page 7 of 614
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POWER FAIL - MOTOR RETURN ACTUATORS01-07 01-07 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 independent from the rest of the building. Care should be taken to monitor
the amount of operations left in the batteries and they should be replaced according to the
manufacturer's instructions. The disposal of batteries calls for special arrangements, which should
conform to 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 as the maximum time between checks and reference should be
made to the particular manufacturer's recommended frequencies. It should be remembered that
people's lives and property could depend on the actuators functioning correctly.
Power fail - Motor return actuators are commonly enabled to return to the desired position by means
of an electricity supply independent from the rest of the building. Care should be taken to monitor the
amount of operations left in the batteries and they should be replaced according to the manufacturer`s
instructions. The disposal of batteries calls for special arrangements, which should conform to all
environmental and Health and Safety requirements.
If the following actuators perform a safety function e.g. fitted to a fire/smoke damper, the frequency of
checks should be taken as the maximum time between checks and reference should be made to the
particular manufacturer`s recommended frequencies. It should be remembered that people`s lives
and property could depend on the actuators functioning correctly.
Other
Title NotesActionFQTitle FQ Action Notes
6. Reaction to
safety signal, e.g.
fire/smoke.
Check that the actuator assumes
correct position (if applicable).
6M 6. Reaction to
safety signal, e.g.
fire/smoke.
Check that the actuator assumes
correct position (if applicable).
3MLegislative
Page 8 of 614
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POWER FAIL - SPRING RETURN ACTUATOR01-08 01-08 POWER FAIL - SPRING RETURN ACTUATOR
Title NotesActionFQTitle FQ Action Notes
4. Manual
operation (if fitted).
Check to prove actuator will
mechanically open/close valve or
damper to its working limits.
The actuator may be fitted with the
facility to manually wind up the
spring, if so the spring must be
wound up with the recommended
tool. See manufacturer's data sheet.
If the tool is capable of being
removed, do so at the end of the
test and ensure that the actuator is
left in the original position. Ensure
that the actuator is returned to the
'auto' position (if fitted) after the
check is completed.
12M 4. Manual
operation (if fitted).
Check to prove actuator will
mechanically open/close valve or
damper to its working limits.
The actuator may be fitted with the
facility to manually wind up the
spring, if so the spring must be
wound up with the recommended
tool. See manufacturer`s data
sheet. If the tool is capable of being
removed, do so at the end of the
test and ensure that the actuator is
left in the original position. Ensure
that the actuator is returned to the
`auto` position (if fitted) after the
check is completed. Care must be
taken in winding up the mechanism
to ensure then spring is not over
tensioned.
12MTechnical
7. Reaction to
safety signal, e.g.
fire smoke.
Check that the actuator assumes
correct position (if applicable).
This signal could be in any form,
from a fusible link in the supply or
gearbox to an independent signal
from a control. If the actuator is
integrated into the fire alarm circuit,
checks may have to be made whilst
a fire drill is in operation.
6M 7. Reaction to
safety signal, e.g.
fire smoke.
Check that the actuator assumes
correct position (if applicable).
This signal could be in any form,
from a fusible link in the supply or
gearbox to an independent signal
from a control. If the actuator is
integrated into the fire alarm circuit,
checks may have to be made whilst
a fire drill is in operation.
3MOther
Page 9 of 614
AIR CONDITIONING
Page 10 of 614
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INTRODUCTORY PROCEDURES02-01 02-01 INTRODUCTORY PROCEDURES
Air conditioning systems range from the single wall/window mounted unit to large installations having
compressor drives of several hundred kW. The maintenance requirements of the various systems will
differ widely in complexity and skill requirements and this is reflected in the breakdown of this
document. Two environmental problems associated with air conditioning plant , namely the potential
depletion of the ozone layer 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 to and use proper recovery
equipment. These contractors must belong to an Approved Certfied Scheme provider, in accordance
with the "F" Gas and Building Regulations. It is in the building owners’ interest to ensure that plant is
properly maintained to ensure environmental conditions in the building are acceptable to the staff and
that energy is not wasted.
In a subject as complicated as the maintenance of air conditioning plant an approach has been
selected which breaks the systems down into their component parts such as compressors,
condensers, and evaporators or chillers, refrigerant distribution systems with their associated controls.
Central and room air conditioning plant are examined in the appropriate detail as Air Handling Units ,
Humidifiers, Heat Rejection Unitary Air Conditioners. It must be emphasised that although this
modular approach has been adopted it is the system as a whole, which must be maintained on a
regular basis using this Standard Maintenance Specification.
Air conditioning systems range from the single wall/window mounted unit to large installations having
compressor drives of several hundred kW. The maintenance requirements of the various systems will
differ widely in complexity and skill requirements and this is reflected in the breakdown of this
document. Two environmental problems associated with air conditioning plant , namely the potential
depletion of the ozone layer through the release of refrigerants 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 refrigerants. Any practice which releases refrigerants into the
atmosphere must not be used. Specialist contractors will have refrigeration engineers who have been
trained and certified in the handling of refrigerants and will have access to and use proper recovery
equipment. These contractors must belong to an Approved Certified Scheme provider , in accordance
with the "F" Gas and Building Regulations. It is in the building owners’ interest to ensure that plant is
properly maintained to ensure environmental conditions in the building are acceptable to the staff and
that energy is not wasted.
In a subject as complicated as the maintenance of air conditioning plant an approach has been
selected which breaks the systems down into their component parts such as compressors,
condensers, and evaporators or chillers, refrigerant distribution systems with their associated controls.
Central and room air conditioning plant are examined in the appropriate detail as Air Handling Units ,
Humidifiers, Heat Rejection Unitary Air Conditioners. It must be emphasised that although this
modular approach has been adopted it is the system as a whole, which must be maintained on a
regular basis using this Standard Maintenance Specification.
Other
Page 11 of 614
AIR HANDLING UNITS
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AIR HANDLING UNITS - general03-01 03-01 AIR HANDLING UNITS - general
Title NotesActionFQTitle FQ Action Notes
1. Filter. Check manometer reading and
renew filter media as indicated.
Record manometer reading. It
should be noted that checking the
filter should be carried out weekly by
maintenance staff.
1M 1. Filter. Check manometer reading and
renew filter media as indicated.
Check the pressure differential
across the filters. It should be noted
that checking the filter should be
carried out weekly by the client.
1MOther
7. Drive belts. Check tension, alignment, and
condition.
Re-tension or replace as necessary.
For detailed maintenance
procedures, see BELT DRIVES.
1M 8. Drive belts. Check tension, alignment, and
condition.
Re-tension or replace as necessary.
For detailed maintenance
procedures, see Belt drives SFG
04-01
1MOther
8. Drive pulleys. Check alignment, security.12M 9. Drive pulleys. Check alignment, security.12MOther
9. Drive
couplings.
Check alignment and for excessive
clearance.
Wear is indicated by exessive
clearance and couplings should be
replaced.
12M 10. Drive
couplings.
Check alignment and for excessive
clearance.
Wear is indicated by excessive
clearance and couplings should be
replaced.
12MOther
10. Damper and
guide vane pivots
and linkages.
Lubricate lightly.3M 11. Damper and
guide vane pivots
and linkages.
Lubricate lightly.3MOther
11. Motorised
damper.
Check to see that louvres are clear
and not obstructed, couplings are
secure and that motor runs without
excessive noise or vibration.
For detailed maintenance see
MOTORS.
3M 12. Motorised
damper.
Check to see that louvers are clear
and not obstructed, couplings are
secure and that motor runs without
excessive noise or vibration.
For detailed maintenance see
Actuators SFG 01-01 to 01-08
3MOther
12. Heating and
cooling coils.
Check condition and clean. Check
air and water pressure drops
across coils.
Even when filters are fitted, dirt can
build up causing loss of machine
output.
12M 13. Heating and
cooling coils.
Check condition and clean. Check
air and water pressure drops across
coils. Check operation of the
heating and cooling coil in
accordance with task Heat
exchangers SFG 29-01
Even when filters are fitted, dirt can
build up causing loss of machine
output.
12MOther
13. Controls and
electrical
connections.
Check operation and condition. Calibration } Interrogation } Control
adjustment } See relevant section
12M 14. Controls and
electrical
connections.
Check operation and condition. Calibration }
Interrogation } Control
adjustment } See relevant
section
12MOther
14. Valves. Fully open and close and then reset
at the original setting.
12M 15. Valves. Fully open and close and then reset
at the original setting.
12MOther
15. Air handling
unit.
Thoroughly clean interior and check
for corrosion. On re-assembly
check for air tightness.
Include heating and cooling coils,
fan impeller and eliminator plates
and other fittings.
12M 16. Air handling
unit.
Thoroughly clean interior and check
for corrosion. On re-assembly
check for air tightness.
Include heating and cooling coils,
fan impeller and eliminator plates
and other fittings.
12MOther
16. Motors. 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.
12M 17. Motors. Check all motors in accordance
with Motors SFG 39-01
This should not exceed data plate
value. Measure shaft float and end
play.
12MOther
17. Anti-vibration
mountings and
ductwork flexible
connections.
Check condition.12M 18. Anti-vibration
mountings and
ductwork flexible
connections.
Check condition.12MOther
7. Fans Check operation of fan in
accordance with the relevant
section of Fans SFG20-01 to 20-08
6MAdded
Page 13 of 614
BELTS
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BELT DRIVES04-01 04-01 BELT DRIVES
Title NotesActionFQTitle FQ Action Notes
3. Bearings.
(`Sealed for life'
bearings should
not normally
require attention).
Check for wear and lubricate at
frequencies recommended by the
manufacturer. Where oil filled,
drain, strip and clean bearing
assembly, reassemble and fill with
clean oil.
When operating in high temperature
environments e.g. above 60 o C
more frequent maintenance may be
necessary.
3M 3. Bearings.
(`Sealed for life`
bearings should
not normally
require attention).
Check for wear and lubricate at
frequencies recommended by the
manufacturer. Where oil filled,
drain, strip and clean bearing
assembly, reassemble and fill with
clean oil.
3MOther
Page 15 of 614
BOILERS/HEAT GENERATORS
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INTRODUCTORY PROCEDURES05-01 05-01 INTRODUCTORY PROCEDURES
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.
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, 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.
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 SFG28
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.
Heat generator types
The term heat generator covers a wide range of energy conversion appliances wh ich 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, 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 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.
Other
Page 17 of 614
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Reason For
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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
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.
Page 18 of 614
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PRE-MAINTENANCE PROCEDURES05-02 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 services
(e) Record existing services – (combustion/efficiency analysis should be recorded before and after
maintenance completion).
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 services
(e) Record existing services – (combustion/efficiency analysis should be recorded before and after
maintenance completion).
Other
Page 19 of 614
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ATMOSPHERIC GAS BURNER - FREE STANDING BOILER05-03 05-03 ATMOSPHERIC GAS BURNER - FREE STANDING BOILER
It is essential that there must is 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 must be checked with any
new contract. For detailed information reference must be made to CIBSE guides, relevant Institute of
Gas Engineers and Managers documents and appropriate British Standards.
The British Standards link is out of date - use www.bsigroup.com
Boiler room ventilation should comply with BS 5440 -2: 2009 for boilers not exceeding 70kW and BS
6644:2005 for boilers with a capacity between 70kW and 1.8MW
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.
Consider the installation of a CO detector that complies with BS EN 50291-1:2010 and BS EN
50292:2002.
Other
Title NotesActionFQTitle FQ Action Notes
1. a) Before
proceeding with
dismantling of
boiler.
Check casing for damage or
breakages. Inspect for loose fittings
or connections and any sign of
leaks.
Check for asbestos containing
material prior to dismantling any
equipment, if suspected STOP
WORK, close off the area. Have
sample Certified as safe before any
works can re-start, if asbestos, take
actions in accordance with the
Asbestos Regulations.
Refer to www.hse.gov.uk for detail.
12M 1. a) Before
proceeding with
dismantling of
boiler.
Check casing for damage or
breakages. Inspect for loose fittings
or connections and any sign of
leaks.
Check for asbestos containing
material prior to dismantling any
equipment, if suspected STOP
WORK, close off the area. Take
actions in accordance with the
Asbestos Regulations.
Refer to www.hse.gov.uk.
12MOther
Pilot injection. Remove and clean. Clean by blowing through or
washing. Note: Do not use pin as
this will damage the injector.
Pilot injection. Remove and clean. Clean by blowing through or
washing. Do not use pin as this will
damage the injector.
12MOther
Burners, Gas
valve,
thermocouple and
pilot tube.
Check adjust and refit along with
main burner.
9. Burners, Gas
valve,
thermocouple and
pilot tube.
Check adjust and refit along with
main burner.
12MOther
9. Boiler and
installation.
Open gas cock and test for gas
soundness, reconnect electrical
services. Test controls operation,
relight pilot and run up boiler.
Test flame setting, 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 .
12M 10. Boiler and
installation.
Open gas cock and test for gas
soundness, reconnect electrical
services. Test controls operation,
relight pilot and run up boiler.
Test flame setting, 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 .
12MOther
10. a) Safety
check
productions of
combustion
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
ignites or shuts down. NB in
domestic premises, consider the
installation of a BS approved CO
detector.
12M 11. a) Safety
check
Combustion
Ensure that no products of
combustion are entering the area of
the building where the boiler is
situated.
The checks should be carried out in
line with the requirements of the
Gas Safety (installations and Use)
regulations
12MOther
Page 20 of 614
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11.
Documentation.
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)
Regulation.
12M 11.
Documentation.
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. Gas work
must be carried out by a competent
engineer qualified as required by the
Gas Safety (Installation and Use)
Regulations.
12MOther
12. Unsafe
installations
Recommendations If after servicing the appliance it is
considered unsafe, the
recommendation to the client is 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 a written report
must be signed by the
client/responsible person/clients
representative. Both the gas
supplier and a supervisor/manager
must be informed.
12M 12. Unsafe
installations
Recommendations If after servicing the appliance it is
considered unsafe, the
recommendation to the client is 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 a written report
must be signed by the
client/responsible person/clients
representative. Both the gas
supplier and a supervisor/manager
must be informed.
12MOther
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ATMOSPHERIC GAS BURNER - CONDENSING BOILER05-04 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 the CIBSE guides, relevant
Institute of Gas Engineers and Managers documents and appropriate British Standards.
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 condensate is produced which has to be removed from the
flue via drainage pipework.
Boiler room ventilation should comply with BS 5440 -2: 2009 for boilers not exceeding 70kW and BS
6644:2005 for boilers with a capacity between 70kW and 1.8MW.
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. In domestic premises, consider the installation of a CO
detector that complies with BS EN 50291-1:2010 and BS EN 50292:2002.
Other
Title NotesActionFQTitle FQ Action Notes
1. a) Before
proceeding with
dismantling of
boiler. b) Test
fire.
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
suspected STOP WORK, close off
the area. Have sample Certified as
safe before any works can re-start, if
asbestos, take actions in
accordance with the Asbestos
Regulations.
Refer to www.hse.gov.uk for detail.
12M 1. a) Before
proceeding with
dismantling of
boiler. b) Test
fire.
Check casing for damage or
breakages. Inspect for loose fittings
or connections and any sign of
leaks. Record settings.
Check for asbestos containing
material prior to dismantling any
equipment, if suspected STOP
WORK, close off the area. Take
actions in accordance with the
Asbestos Regulations.
Refer to www.hse.gov.uk..
12MOther
2. Pre-service
checks
Condensate flow
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 50 o C],
check that condensate flows freely
from the drain pipe.
Risk Assessment may be required.
Waste Disposal Licensing
Regulations may apply.
12M 2. Pre-service
checks
Condensate flow
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 50 deg C],
check that condensate flows freely
from the drain pipe.
Risk Assessment may be required.
Waste Disposal Licensing
Regulations may apply.
12MOther
7. Condensate
drain pipe and
U-siphon trap.
Clean, inspect and flush.12M 7. Condensate
drain pipe and
U-siphon trap.
Clean, inspect and flush. Ensure trap contains water to act as
a seal
12MTechnical
11.Remove
burners and pilot
assembly and
baffles if fitted.
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 through and
carried out as per the manufacturers
instructions.
12M 11.Remove
burners and pilot
assembly and
baffles if fitted.
Brush all accessible flue ways
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 through and
carried out as per the manufacturers
instructions.
12MLegislative
Pilot injection. Remove and clean. Clean by blowing through or
washing. Note: Do not use pin as
this will damage the injector.
Pilot injection. Remove and clean. Clean by blowing through or
washing. Do not use pin as this will
damage the injector.
Other
Burners, Gas
valve,
thermocouple and
pilot tube.
Check adjust and refit along with
main burner.
15. Burners, Gas
valve,
thermocouple and
pilot tube.
Check adjust and refit along with
main burner.
12MOther
15. . Water
treatment.LOW
NOX Boilers
Check treatment regime is correct. Some condensing boilers contain
aluminium.
12M 16. Water
treatment. LOW
NOX Boilers
Check treatment regime is correct. Some condensing boilers contain
aluminium.
12MOther
Page 22 of 614
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16. Kanthal
bars/rods.
Inspect, clean with compressed air. If there are any signs of bending,
replace. For all condensing boilers,
manufacturers specific service
instructions take precedence.
12M 17. Kanthal
bars/rods.
Inspect, clean with compressed air. If there are any signs of bending,
replace. For all condensing boilers,
manufacturers specific service
instructions take precedence.
12MOther
17. Boiler and
installation.
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 manifold gas
pressure against manufacturer's
settings, adjust if required.If in doubt
check gas supply standing pressure
at the meter .
12M 18. Boiler and
installation.
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 manifold gas
pressure against manufacturer`s
settings, adjust if required. If in
doubt check gas supply standing
pressure at the meter .
12MOther
18. a) Safety
check
productions of
combustion
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.
12M 19. a) Safety
check
productions of
combustion
Ensure that no products of
combustion are entering the area of
the building where the boiler is
situated.
The checks should be carried out in
line with the requirements of the
Gas Safety (installations and Use)
regulations
12MLegislative
19.
Documentation.
Provide written report. The report must 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.
12M 19.
Documentation.
Provide written report. The report must 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.
12MOther
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COAL FIRED BOILERS Bunkers and Conveyors.05-05 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, plus the handling, disposal of gaseous and solid waste. The materials are abrasive with 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 must 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.
The burning of coal is a complex operation involving the storage, handling and combustion of solid
material, plus the handling, disposal of gaseous and solid waste. The materials are abrasive with 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.
<B>WARNING</B>. A risk assessment and method statement must be undertaken in accordance
with the Confined Spaces Regulations, 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.
Other
Title NotesActionFQTitle FQ Action Notes
1. Operational
status.
Check and isolate from electricity
supply, remove fuses if used.
1M 1. Operational
status.
Check and isolate and Lock Off
from electricity supply, remove
fuses if used.
Depending on the Establishment, a
Permit to Work system may be in
operation. The Authorised Person
should be approached for the issue
of the permit.
1MOther
Page 24 of 614
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Reason For
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COAL FIRED BOILERS - Coal storage handling and feed mechanisms,
automatic ash removal (where fitted)
05-06 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, combustion of solid
material, together with the handling, 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 must 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.
The burning of coal is a complex operation involving the storage, handling, combustion of solid
material, together with the handling, 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 SFG 39)
<B>WARNING</B>. A risk assessment and method statement must 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.
Other
Title NotesActionFQTitle FQ Action Notes
1. Operational
status.
Check and isolate from electricity
supply. Remove fuses, if used.
1M 1. Operational
status.
Check and isolate and Lock Off
from electricity supply. Remove
fuses, if used.
Depending on the Establishment, a
Permit to Work system may be in
operation. The Authorised Person
should be approached for the issue
of the permit.
1MOther
5.Pneumatic
system. (Applies
to both coal feed
and ash removal,
where fitted).
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.
3M 5.Pneumatic
system. (Applies
to both coal feed
and ash removal,
where fitted).
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 . It is essential to
maintain air tightness on pneumatic
systems otherwise the coal feed
cannot be maintained, output is
reduced and energy wasted.
3MOther
Page 25 of 614
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COAL FEED MECHANISMS - Under feed stokers05-07 05-07 COAL FEED MECHANISMS - Under feed stokers
The burning of coal is a complex operation involving the storage, handling, combustion of solid
material, together with the handling, 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 SFG 39)
WARNING. A risk assessment and method statement must 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.
Added
Title NotesActionFQTitle FQ Action Notes
1. Operational
status.
Check and isolate from electricity
supply. Remove fuses, if used.
Cables should be checked for
insulation breakdown and the earth
continuity checked.
6M 1. Operational
status.
Check and isolate and Lock Off
from electricity supply. Remove
fuses, if used.
Depending on the Establishment, a
Permit to Work system may be in
operation. The Authorised Person
should be approached for the issue
of the permit.
6MOther
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COAL FEED MECHANISMS - Chain grate stokers05-08 05-08 COAL FEED MECHANISMS - Chain grate stokers
WARNING – A RISK ASSESSMENT AND METHOD STATEMENT MUST BE UNDERTAKEN
BEFORE AN OPERATOR/ENGINEER ENTERS COAL SIL0.
The burning of coal is a complex operation involving the storage, handling, combustion of solid
material, together with the handling, 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 SFG 39)
<B>WARNING</B>. A risk assessment and method statement must 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.
Other
Title NotesActionFQTitle FQ Action Notes
1. Operational
status.
Check and isolate from electricity
supply. Remove fuses, if used.
12M 1. Operational
status.
Check and isolate and Lock off
from electricity supply. Remove
fuses, if used.
Depending on the Establishment, a
Permit to Work system may be in
operation. The Authorised Person
should be approached for the issue
of the permit.
12MOther
4. Drain sump. Ensure excess water can be
drained off.
12M 4. Drain sump. Ensure excess water can be
drained off.
Clean and unblock drain as
necessary
12MTechnical
Check coal auger supports. Repair or replace as necessary. a) Check coal auger supports. Repair or replace as necessary.12MOther
Remove augers and check for wear
and distortion.
b) Remove augers and check for wear
and distortion.
12MOther
Reassemble and recoat coal tube. Use bituminised sealant or similar
protective coating.
c) Reassemble and recoat coal tube. Use bituminised sealant or similar
protective coating.
12MOther
Page 27 of 614
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ASH HANDLING SYSTEM05-09 05-09 ASH HANDLING SYSTEM
The burning of coal is a complex operation involving the storage, handling, combustion of solid
material, together with the handling, 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 SFG 39)
WARNING. A risk assessment and method statement must 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.
Added
Title NotesActionFQTitle FQ Action Notes
2. Ash line valve. Check operation and wear on
seals.
12M 2. Ash line valve. Check and isolate and Lock off
from electricity supply. Remove
fuses, if used. Check operation and
wear on seals.
12MTechnical
Spray jets. Check operation.3M Spray jets. Check operation and adjust nozzles
for correct spray pattern if
necessary
3MTechnical
Page 28 of 614
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BLOWN GAS BURNER CONDENSING BOILER05-10 05-10 BLOWN 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 .
Boiler room ventilation should comply with BS 5440 -2: 2009 for boilers not exceeding 70kW and BS
6644:2005 for boilers with a capacity between 70kW and 1.8MW.
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. In domestic premises, consider the installation of a CO
detector that complies with BS EN 50291-1:2010 and BS EN 50292:2002..
Other
Title NotesActionFQTitle FQ Action Notes
1. Check
Operation.
Note any visible defects.12M 1. Check
Operation.
Note any visible defects. Check for asbestos containing
material prior to dismantling any
equipment, if suspected STOP
WORK, close off the area. Take
actions in accordance with the
Asbestos Regulations.
Refer to www.hse.gov.uk.
12MTechnical
3. Gas electrical
systems.
Check that all are in accordance
with current Codes of Practice.
12M 3. Gas, electrical
and ventilation
systems .
Check that all are in accordance
with current Codes of Practice.
Local electrical isolator should be
fitted. Supply to the boiler must be
direct, i.e. not fed through a time
switch.
12MTechnical
4. Pre service
checks -
Condensate flow.
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 50 ºC],
check that condensate flows freely
from the drain pipe.
Risk Assessment may be required
Waste Disposal Regulations may
apply.
12M 4. Pre service
checks -
Condensate flow.
Where applicable, 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 50 deg C], check that
condensate flows freely from the
drain pipe.
Risk Assessment may be required
Waste Disposal Regulations may
apply.
12MTechnical
5. Isolate from
electricity and gas
supply.
Switch off, remove fuses and turn
off oil supply at main cock.
Before starting any dismantling of
equipment it is essential for safety
reasons that the plant be isolated
from incoming services.
12M 5. Isolate from
electricity and gas
supply.
Switch off, remove fuses and/or
lock off 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.
12MTechnical
. b]Boiler tube
module.
Clean and descale module in
accordance with manufacturers
instructions.
Always follow recommendations
from manufacturer. Note: Waste
Disposal Regulations may apply
48M 13 b]Boiler tube
module.
Clean and descale module in
accordance with manufacturers
instructions.
Always follow recommendations
from manufacturer. Waste Disposal
Regulations may apply
48MOther
17. Unsafe
installations.
Recommendations If after servicing the boiler is
considered unsafe the
recommendation to the client is 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 a written report
must be signed by the
client/responsible person/clients
representative with the gas supplier
and a supervisor/manager informed.
12M 17. Unsafe
installations.
Recommendations If after servicing the appliance it is
considered unsafe, the
recommendation to the client is 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 a written report
must be signed by the
client/responsible person/clients
representative. Both the gas
supplier and a supervisor/manager
must be informed.
12MTechnical
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BLOWN GAS BURNER MODULAR BOILER05-11 05-11 BLOWN 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 .
Can comprise several modules, each having separate controls. Each module must be isolated and
work carried out consecutively.
Boiler room ventilation should comply with BS 5440 -2: 2009 for boilers not exceeding 70kW and BS
6644:2005 for boilers with a capacity between 70kW and 1.8MW.
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. In domestic premises, consider the installation of a CO
detector that complies with BS EN 50291-1:2010 and BS EN 50292:2002.
Other
Title NotesActionFQTitle FQ Action Notes
1. Check
Operation.
Note any visible defects.12M 1. Check
Operation.
Note any visible defects. Check for asbestos containing
material prior to dismantling any
equipment, if suspected STOP
WORK, close off the area. Take
actions in accordance with the
Asbestos Regulations.
Refer to www.hse.gov.uk.
12MTechnical
3. Gas electrical
systems.
Check that all are in accordance
with current Codes of Practice.
12M 3. Gas, electrical
and ventilation
systems .
Check that all are in accordance
with current Codes of Practice.
12MTechnical
5. Isolate from
electricity and gas
supply.
Switch off, remove fuses and turn
off oil supply at main cock.
Before starting any dismantling of
equipment it is essential for safety
reasons that the plant be isolated
from incoming services.
12M 5. Isolate from
electricity and gas
supply.
Switch off, remove fuses and/or
lock off 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.
12MTechnical
12. Boiler flue
ways and
connecting flues.
Open and remove all soot and
scale by brushing and/or vacuum.
Reseal, check for air leaks,make
good as required.
12M 12. Boiler flue
ways and
connecting flues.
Open and remove all soot and
scale by brushing and/or vacuum.
Reseal, check for air leaks, make
good as required.
12MTechnical
b] Boiler tube
module.
Clean and descale module in
accordance with manufacturers
instructions.
Always follow recommendations
from manufacturer. Note: Waste
Disposal Regulations. may apply
48M 13. b] Boiler tube
module.
Clean and descale module in
accordance with manufacturers
instructions.
Always follow recommendations
from manufacturer. Waste Disposal
Regulations. may apply
48MOther
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FORCED DRAUGHT GAS CONDENSING BOILER05-12 05-12 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 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 houses 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
Institute of Gas Engineers documents and appropriate British Standards.
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 condensate is produced which has to be removed from the
flue via drainage pipework.
Boiler room ventilation should comply with BS 5440 -2: 2009 for boilers not exceeding 70kW and BS
6644:2005 for boilers with a capacity between 70kW and 1.8MW.
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. In domestic premises, consider the installation of a CO
detector that complies with BS EN 50291-1:2010 and BS EN 50292:2002.
Technical
Title NotesActionFQTitle FQ Action Notes
b) Test fire. Record settings. Check for asbestos prior to
dismantling and equipment, if
suspected STOP WORK, close off
the area. Have sample Certified as
safe before any works can re-start, if
asbestos, take actions in
accordance with the Asbestos
Regulations
b) Test fire. Record settings. Check for asbestos containing
material prior to dismantling any
equipment, if suspected STOP
WORK, close off the area. Take
actions in accordance with the
Asbestos Regulations.
Refer to www.hse.gov.uk.
12MOther
2. Pre-service
checks.
Condensate flow.
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 50 ºC],
check that condensate flows freely
from the drain pipe.
Risk Assessment may be required.
Waste Disposal Regulations may
apply.
12M 2. Pre-service
checks.
Condensate flow.
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 50 deg C],
check that condensate flows freely
from the drain pipe.
Risk Assessment may be required.
Waste Disposal Regulations may
apply.
12MOther
17. a) Safety
check Gas.
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.
12M 17. a) Safety
check Gas.
Ensure that no products of
combustion are entering the area of
the building where the boiler is
situated.
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.
12MOther
18. Unsafe
installations.
Recommendations. If after servicing the boiler is
considered unsafe the
recommendation to the client is 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 a written report
must be signed by the
client/responsible person/clients
representative and both the gas
supplier and a supervisor/manager
informed.
12M 18. Unsafe
installations.
Recommendations. If after servicing the boiler is
considered unsafe the
recommendation to the client is 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 a written report
must be signed by the
client/responsible person
representative and both the gas
supplier and a supervisor/manager
informed.
12MOther
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FORCED DRAUGHT [PRESSURE JET] OIL CONDENSING BOILER05-13 05-13 FORCED DRAUGHT [PRESSURE JET] OIL 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 condensate is produced which has to be removed from the
flue via drainage pipework.
Boiler room ventilation should comply with BS 5440 -2: 2009 for boilers not exceeding 70kW and BS
6644:2005 for boilers with a capacity between 70kW and 1.8MW.
Undetected CO is poisonous, life threatening and also causes energy waste. The burner should be
quiet in operation, no excessive noise should occur when the burner ignites or shuts down. In
domestic premises, consider the installation of a CO detector that complies with BS EN 50291-1:2010
and BS EN 50292:2002.
Added
Title NotesActionFQTitle FQ Action Notes
1. a) Before
proceeding with
dismantling of
boiler.
Check casing for damage or
breakages. Inspect for loose fittings
or connections and any sign of
leaks.
12M 1. a) Before
proceeding with
dismantling of
boiler.
Check casing for damage or
breakages. Inspect for loose
fittings or connections and any sign
of leaks.
Check for asbestos containing
material prior to dismantling any
equipment, if suspected STOP
WORK, close off the area. Take
actions in accordance with the
Asbestos Regulations.
Refer to www.hse.gov.uk.
12MOther
2. Pre-service
checks.
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 50 ºC],
check that condensate flows freely
from the drain pipe.
Risk Assessment may be required.
Waste Disposal Regulations may
apply.
12M 2. Pre-service
checks.
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 50 deg C],
check that condensate flows freely
from the drain pipe.
Risk Assessment may be required.
Waste Disposal Regulations may
apply.
12MOther
7. Isolate from
electricity and gas
supply.
Switch off, remove fuses and turn
off gas supply at main cock.
Before starting and dismantling of
equipment it is essential for safety
reasons that the plant be isolated
from incoming services.
6M 7. Isolate from
electricity and oil
supply.
Switch off, remove fuses and turn
off oil supply at main valve.
Before starting and dismantling of
equipment it is essential for safety
reasons that the plant be isolated
from incoming services.
6MOther
8. Jet arm
assembly.
Remove, clean combustion head,
ignitor electrodes and inspect HT
leads.
6M 8. Jet arm
assembly.
Remove, clean combustion head,
ignition electrodes and inspect HT
leads.
6MOther
11. Motor and
fan.
Remove, clean and lubricate as
required, clean fan scroll.
Inspect oil pump flexible drive
coupling before reassembly.(See
also MOTORS)
6M 11. Motor and
fan.
Remove, clean and lubricate as
required, clean fan scroll.
Inspect oil pump flexible drive
coupling before reassembly.(See
also Motors SFG 39)
6MOther
23.
Recommendation
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.
6M 23.
Recommendation
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 (www.bsi-global.com) for
oil firing.
6MOther
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BOILERS MTHW UP TO 120 oC (Wrong Symbol - Change)05-14 05-14 BOILERS MTHW UP TO 120 oC
Applies to boilers manufactured by casting or fabrication Applies to boilers manufactured by casting or fabrication.
Boiler room ventilation should comply with BS 5440 -2: 2009 for boilers not exceeding 70kW and BS
6644:2005 for boilers with a capacity between 70kW and 1.8MW.
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.
Other
Title NotesActionFQTitle FQ Action Notes
1. Check
operation, in
particular safety
controls (prv).
Note any visible defects. Ensure system is full of water and
the circuits are open. It is essential
for low water content boilers that
flow rates can be maintained at or
above manufacturers recommended
levels.
12M 1. Check
operation, in
particular safety
controls (prv).
Note any visible defects. Check for asbestos containing
material prior to dismantling any
equipment, if suspected STOP
WORK, close off the area. Take
actions in accordance with the
Asbestos Regulations.
Refer to www.hse.gov.uk.
It is likely that a Permit to Work will
be required from the Authorised
Person before any works can be
undertaken on a pressurised system
Ensure system is full of water and
the circuits are open. It is essential
for low water content boilers that
flow rates can be maintained at or
above manufacturers recommended
levels.
12MTechnical
2. Efficiency
check.
Start up system and carry out tests. On larger systems efficiency tests
should be carried out on a regular
basis to monitor performance. The
test should include smoke, draught
chamber and flue, flue temperature,
fuel input and gas analysis including
carbon monoxide.
12M 2. Efficiency
check.
Start up system and carry out tests.12MTechnical
Thermostats,
pressure sensors
& controls, altitude
gauges, vacuum
breaks.
3. Thermostats,
pressure sensors
& controls, altitude
gauges, vacuum
breaks.
Check for correct operation and
settings.
12MTechnical
3. Thermostats,
vacuum breaks.
Check for correct operation and
settings.
12M Deleted
4. Electrical
services.
Shut down, disconnect or remove
fuses.
Locate isolation switch, if not in
accordance with IEE regulations
report to building owner.
12M 4. Electrical
services.
Shut down, disconnect and lock off
or remove fuses.
Local electrical isolator should be
fitted. Supply to the boiler must be
direct i.e. not fed through a time
switch.
12MTechnical
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MULTIPLE BOILERS - sequence controls05-15 05-15 MULTIPLE BOILERS - sequence controls
All notes referring to sequence controls apply to individual boilers (not burner modules) in multiple
installations.
All notes referring to sequence controls apply to individual boilers (not burner modules) in multiple
installations.
This task should be issued with the relevant boiler maintenance task
Other
Title NotesActionFQTitle FQ Action Notes
7. Boiler shunt
pump.
Confirm operation. Is there a water proving circuit?
Check operation if part of sequence
controls. See PUMPS maintenance.
12M 7. Boiler shunt
pump.
Confirm operation. Is there a water proving circuit?
Check operation if part of sequence
controls. See Pumps SFG 45-02
12MTechnical
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BOILER CONTROLS - Single boiler: on/off05-16 05-16 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 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 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 relevant section.
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 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 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 relevant section.
Other
Title NotesActionFQTitle FQ Action Notes
2. Time switch. Check operation. Confirm time
settings.
Time of day. (Keep setting at GMT
all year unless specifically requested
by client.) Day of week. Manual
override.
12M 2. Time switch. Check operation. Confirm time
settings.
Time of day. (Keep setting at GMT
all year unless specifically
requested by client.) Day of week.
Manual override.
6MOther
4. Room
thermostat.
Check operation. Confirm set point. Ensure correct location and no air
movement restrictions. Advise client
of any faults.
12M 4. Room
thermostat.
Check operation. Confirm set
point. Ensure correct location and no air
movement restrictions. Advise client
of any faults.
12MTechnical
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STEAM BOILERS Pre-maintenance check.05-19 05-19 STEAM BOILERS Pre-maintenance check.
Title NotesActionFQTitle FQ Action Notes
1. Status. Check operating status. Before proceeding with
maintenance programme check with
client that boiler can be taken
off-line.
12M 1. Status. Check operating status. Before proceeding with
maintenance programme check with
client that boiler can be taken
off-line.
These works to be carried out in
accordance with the Pressure
Systems Safety Regulations 2000
and Safe Systems of Work
12MLegislative
6. Shut down. Shut off and isolate steam, water,
fuel and electrical services.
Purge fuel lines and vent boiler to
ensure safe conditions.
12M 6. Shut down. Shut off and isolate steam, water,
fuel and electrical services.
Purge fuel lines and vent boiler to
ensure safe conditions. Steam line
should be isolated with either a two
separate valves or a single valve
and spade.
12MTechnical
7. Ventilation. Check that ventilation fans and
louvres are functioning properly.
Check that there is adequate
ventilation in the boiler house and
the conditions comply with the
relevant regulations and standards.
12M 7. Ventilation. Check that ventilation fans and
louvers are functioning properly.
Check that there is adequate
ventilation in the boiler house and
the conditions comply with the
relevant regulations and standards.
Boiler room ventilation should
comply with BS 5440 -2: 2009 for
boilers not exceeding 70kW and BS
6644:2005 for boilers with a
capacity between 70kW and 1.8MW
12MTechnical
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STEAM BOILERS Maintenance schedule.05-20 05-20 STEAM BOILERS Maintenance schedule.
This is generally carried out at the same time as the Annual Statutory Insurance Inspection . The yearly tasks shown below are generally carried out at the same time as the Annual Statutory
(Insurance) Inspection.
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk.
Other
Title NotesActionFQTitle FQ Action Notes
1. Boiler
flueways,
combustion
chamber and
connecting flue.
Open, remove by brushing and/or
vacuum all soot and scale.
Soot, ash and other fouling deposits
impede heat transfer thus wasting
energy and putting up costs.
12M 15. Boiler
flueways,
combustion
chamber and
connecting flue.
Open, remove by brushing and/or
vacuum all soot and scale.
Soot, ash and other fouling deposits
impede heat transfer thus wasting
energy and putting up costs.
12MLegislative
2. Fire tubes. Open boiler end doors and clean
fire tubes by brushing or rotary
scouring equipment.
In multipass boilers it is important to
clean all passes.
12M 16. Fire tubes. Open boiler end doors and clean
fire tubes by brushing or rotary
scouring equipment.
In multipass boilers it is important to
clean all passes.
12MOther
3. Refractory
linings.
Check condition and report.12M 17. Refractory
linings.
Check condition and report.12MOther
4. Boiler
flueways, doors
and chamber.
Reseal, check for air leaks, seal as
necessary.
12M 18. Boiler
flueways, doors
and chamber.
Reseal, check for air leaks, seal as
necessary.
12MOther
5. Flue. Carry out smoke test.12M 19. Flue. Carry out smoke test.12MOther
6. Waterside. Remove manholes, clean out scale
and residues. Replace, reseal and
ensure bolts are tight.
If there are considerable deposits of
sludge and scale, this indicates poor
water treatment which if allowed to
continue will lead to boiler failure
and energy wastage. Waste
Disposal Regulations may apply.
12M 20. Waterside. Remove manholes, clean out scale
and residues. Replace, reseal and
ensure bolts are tight.
If there are considerable deposits of
sludge and scale, this indicates poor
water treatment which if allowed to
continue will lead to boiler failure
and energy wastage. Waste
Disposal Regulations may apply.
12MOther
7. Boiler. Refill, reconnect and bring on line. Refit casing if necessary and
thoroughly clean down.
12M 21. Boiler. Refill, reconnect and bring on line. Refit casing if necessary and
thoroughly clean down.
12MOther
8.
Instrumentation
and flame
monitoring.
Check for operation and accuracy. Recalibrate and reset if necessary.12M 22.
Instrumentation
and flame
monitoring.
Check for operation and accuracy. Recalibrate and reset if necessary.12MOther
9. Combustion
check.
Bring up to full load and carry out
tests.
On larger systems combustion tests
should be carried out on a regular
basis to monitor performance. The
test should include smoke, draught
chamber and flue, flue temperature,
carbon dioxide, oxygen and carbon
monoxide.
12M 23. Combustion
check.
Bring up to full load and carry out
tests.
On larger systems combustion tests
should be carried out on a regular
basis to monitor performance. The
test should include smoke, draught
chamber and flue, flue temperature,
carbon dioxide, oxygen and carbon
monoxide.
12MOther
10. Blow down
tank.
For maintenance procedures see
SANITARY & WASTE WATER
PLUMBING Interceptors .
HSE document PM60 applies.12M 24. Blow down
tank.
For maintenance procedures see
Sanitary and waste water plumbing
SFG 48-04
HSE document PM60 applies.12MOther
Self-monitoring
controls
Added
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1. Water gauge
test
Record time test carried out, log
results with the operator`s name,
date of test plus any corrective
action taken.
1DAdded
2. Water level left
hand gauge
Manually blow down Record time test carried out.1DAdded
3. Water level right
hand gauge
Manually blow down Record time test carried out.1DAdded
4. Water level
control
Test low water level cut-out and
lock-out
At no time during a test should the
water be lowered to the extent that it
disappears from the gauge glass.
Record time test carried out
1DAdded
5. Feed pump
start/stop or
modulation
Check operation. Record time test carried out.1DAdded
6. Pressure
reading
Record pressure gauge reading Record time test carried out.1DAdded
7. Feed water and
condensate check
Check the feed tank level is
adequate and there are no
contaminants. Check that the
chemical dose metering device is
functioning and there are adequate
chemical stocks in the tanks. Check
that the in-house routine sample
results are within their given
parameters provided by the water
treatment specialist and take
remedial action when necessary.
Check the temperature is above the
required level for the treatment
doses specified for oxygen
scavenging.
Record time test carried out, log
results with the operator`s name,
date of test plus any corrective
action taken.
1DAdded
8. TDS water test Carry out TDS water quality test,
record the result and make
adjustments where necessary.
Record time test carried out.1DAdded
9. pH water test Carry out pH water quality test,
record the result and make
adjustments where necessary.
Record time test carried out.1DAdded
10. Blow down record quantity of water blown
down.
Record time test carried out.1DAdded
11. Flame failure Test flame failure lock-out.
This may not be present on non self
monitoring boilers
Record time test carried out.1WAdded
12. Failure to
ignite
Test failure to ignite lock out. Record time test carried out.1WAdded
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13. Water level 1st Test by lowering water level to 1st
low water level, by evaporation and
controlled blowdown, and check
burner locks out and the alarm is
sounded.
Discharge temperature to drain
should not exceed permissible
limits.
Record time test carried out.
At no time during a test should the
water be lowered to the extent that it
disappears from the gauge glass.
1WAdded
14. Water level
2nd
Test by lowering water level to 2nd
low water level, by evaporation and
controlled blowdown, and check
burner locks out and the alarm is
sounded.
Discharge temperature to drain
should not exceed permissible
limits.
Record time test carried out.
At no time during a test should the
water be lowered to the extent that it
disappears from the gauge glass.
1WAdded
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ELECTRIC BOILERS05-21 05-21 ELECTRIC BOILERS
These boilers provide heat to radiator heating systems. Electricity supply can be off-peak/on-peak or a
combination of both.
These boilers provide heat to LTHW and Domestic Hot Water systems. Electricity supply can be
off-peak/on-peak or a combination of both.
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Isolation from
electricity supplies.
Switch off. Remove fuses from both
supplies.
The boilers have two supplies. The
permanent large capacity supply
and the restricted hours signal
supply. Report to the client if not
capable of isolation.
12M 1. Isolation from
electricity supplies.
Switch and lock off. Remove fuses
from both supplies.
The boilers have two supplies. The
permanent large capacity supply
and the restricted hours signal
supply. Report to the client if not
capable of isolation.
12MTechnical
3. Heavy current
connection in the
control box.
Remove control box cover. Check
all heavy current connection for
tightness and signs of over heating,
also check element relay contacts
for damage.
See also MOTORS12M 3. Heavy current
connection in the
control box.
Remove control box cover. Check
all heavy current connection for
tightness and signs of over heating,
also check element relay contacts
for damage.
12MTechnical
5. Fan cooling air
duct.
Remove button front casing clean
duct through casing, remove also
the rear end fan motor which is
exposed when the casing is
removed.
Report if fan motor or pump are
noisy. Advise the customer that the
louvres on the outside of the casing
should be vacuumed at intervals if
the environment of the boiler is
unclean.
12M 5. Fan cooling air
duct.
Remove button front casing clean
duct through casing, remove the
rear end fan motor which is
exposed when the casing is
removed.
Report if fan motor or pump are
noisy. Advise the customer that the
louvers on the outside of the casing
should be vacuumed at intervals if
the environment of the boiler is
unclean.
12MTechnical
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ELECTRODE BOILERS05-22 05-22 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.
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. See manufacturers
information on recommended values.
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk.
Technical
Title NotesActionFQTitle FQ Action Notes
b) Porcelain
insulators.
Examine for defects and replace if
necessary. Clean with non-abrasive
material.
12M Deleted
5. Feed solenoid
(if fitted).
Clean solenoid, manifold and
strainer.
Modern boilers have the load control
driven by an electric motor. See
MOTORS.
12M 5. Feed solenoid
(if fitted).
Clean solenoid, manifold and
strainer.
Modern boilers have the load control
driven by an electric motor. (See
also Motors SFG 39)
12MOther
7. Boiler
circulated water.
Test for correct conductivity at
20/25 ºC.
This is to be within the boiler makers
recommendation.
3M 7. Boiler
circulated water.
Test for correct conductivity at
20/25 deg C.
This is to be within the boiler makers
recommendation.
3MOther
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BOILERS LTHW UP TO 95ºC05-23 05-23 BOILERS LTHW UP TO 95ºC
Applies to boilers manufactured by casting or fabrication. Applies to boilers manufactured by casting or fabrication.
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk.
Technical
Title NotesActionFQTitle FQ Action Notes
4. Electrical
services.
Shut down, disconnect or remove
fuses.
Locate isolation switch, if not in
accordance with IEE regulations
report to building owner.
12M 4. Electrical
services.
Shut down, disconnect or remove
fuses.
Locate isolation switch, if not in
accordance with IEE regulations
report to building owner.
12MTechnical
9. Flue. Carry out smoke test. Only if flue problem is suspected .12M 9. Flue. Carry out smoke test. Only if flue blockage is suspected .12MTechnical
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BOILERS - FIRE AND SAFETY CIRCUITS05-24 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.
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 (www.bre.co.uk/frs) or should be the Manufacturer`s nominated fire prevention
provider. 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.
Other
Page 43 of 614
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WASTE AND WOOD BURNING APPLIANCES (including boilers) - Fire And
Boiler Safety Circuits
05-25 05-25 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 in the combustion chamber and condensation of combustion
products can lead to blockage and fires in the flues
Regular cleaning of flues is essential when burning waste and wood because tars and other residues
may not be fully burned in the combustion chamber and condensation of combustion products can
lead to blockage and fires in the flues
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk.
Technical
Title NotesActionFQTitle FQ Action Notes
fusible links,
interconnecting
tension wire and
pulleys.
Inspect.3M fusible links,
interconnecting
tension wire and
pulleys.
Inspect. Replace fusible links if damaged3MTechnical
4. Smoke/heat
detection.
Check operation. Refer to Code of Practice BS 5839.3M 4. Smoke/heat
detection.
Check operation. Refer to Code of Practice BS 5839
and Fire alarm system SFG 22-01
3MOther
Page 44 of 614
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WASTE AND WOOD BURNING APPLIANCES (including boilers) -
Combustion Chamber
05-26 05-26 WASTE AND WOOD BURNING APPLIANCES (including boilers) -
Combustion Chamber
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk.
Added
Title NotesActionFQTitle FQ Action Notes
(b) Pneumatic. Inspect and check for wear. In pneumatic systems wear mainly
occurs on the bends and wear
plates are usually fitted. Any badly
worn ones should be replaced.
3M (b) Pneumatic. Inspect and check for wear. In pneumatic systems wear mainly
occurs on the bends and wear
plates are usually fitted. Any badly
worn plates should be replaced.
3MOther
3. Ash removal. Inspect for wear and where
operation automatic reset controls.
3M 3. Ash removal. Inspect for wear and where
operation automatic reset controls.
Always follow recommendations
from manufacturer. Waste Disposal
Regulations may apply
3MLegislative
4. Automatic
ignition.
Clean and check operation and
reset.
Refer to Code of Practice BS 5839.3M 5. Automatic
ignition.
Clean and check operation and
reset.
Refer to Code of Practice BS 5839.3MOther
5. Combustion
check.
Carry out and adjust primary and
secondary and tertiary (if any) air
for optimum combustion.
Because of the variable nature of
the fuel allowance for some excess
air is necessary. With starved air
(two phased combustion) tests
should be carried out after each
stage and should include CO.
3M 6. Combustion
check.
Carry out and adjust primary and
secondary and tertiary (if any) air
for optimum combustion.
Because of the variable nature of
the fuel allowance for some excess
air is necessary. With starved air
(two phased combustion) tests
should be carried out after each
stage and should include CO.
3MOther
6. General. Check all fuel supply valves for free
operation.
Ensure that each fuel supply valve is
complete with its own wheel or key.
3M 7. General. Check all fuel supply valves for free
operation.
Ensure that each fuel supply valve
is complete with its own wheel or
key.
3MOther
4. Refractory
linings.
Check condition and report.3MAdded
Page 45 of 614
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Reason For
Change
WASTE AND WOOD BURNING APPLIANCES (including boilers) - BOILER (if
fitted)
05-27 05-27 WASTE AND WOOD BURNING APPLIANCES (including boilers) - BOILER (if
fitted)
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk.
Added
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Atmospheric Gas Burner Boiler - Small and/or wall hung for domestic/light
commercial installation
05-28 05-28 Atmospheric Gas Burner Boiler - Small and/or wall hung for domestic/light
commercial installationTitle NotesActionFQTitle FQ Action Notes
1. a) Before
proceeding with
dismantling of
boiler.
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
suspected STOP WORK, close off
the area. Have sample Certified as
safe before any works can re-start, if
asbestos, take actions in
accordance with the Asbestos
Regulations.
Refer to www.hse,gov.uk for detail.
12M 1. a) Before
proceeding with
dismantling of
boiler.
Check casing for damage or
breakages. Inspect for loose fittings
or connections and any sign of
leaks. Record settings.
Check for asbestos containing
material prior to dismantling any
equipment, if suspected STOP
WORK, close off the area. Take
actions in accordance with the
Asbestos Regulations.
Refer to www.hse.gov.uk.
12MOther
b) Check firing. Observe the main burner. Use a
combustion analyzer to measure
CO & CO 2 content of flue gas.
Check Gas pressure, Record
settings.
Dark mauve flame and excessive
lifting off indicate poor combustion.
12M b) Check firing. Observe the main burner. Use a
combustion analyser to measure
CO & CO 2 content of flue gas.
Check Gas pressure, Record
settings.
Dark mauve flame and excessive
lifting off indicate poor combustion.
12MOther
2. Gas electrical
and ventilation
systems.
Check that all are in accordance
with current Codes of Practice.
Local electrical isolator must be
fitted. Supply to the boiler must be
direct, i.e. not fed through a time
switch.
12M 2. Gas electrical
and ventilation
systems.
Check that all are in accordance
with current Codes of Practice.
Local electrical isolator must be
fitted. Supply to the boiler must be
direct, i.e. not fed through a time
switch.
12MOther
Pilot injection. Remove and clean. Clean by blowing through or
washing. Note: Do not use pin as
this will damage the injector.
Pilot injection. Remove and clean. Clean by blowing through or
washing. Do not use pin as this will
damage the injector.
Other
Burners, Gas
valve,
thermocouple and
pilot tube.
Check adjust and refit along with
main burner.
9. Burners, Gas
valve,
thermocouple and
pilot tube.
Check adjust and refit along with
main burner.
Other
9. Boiler and
installation.
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 manifold gas
pressure against manufacturer's
settings, adjust if required. If in
doubt check gas supply standing
pressure at the meter .
12M 10. Boiler and
installation.
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 manifold gas
pressure against manufacturer`s
settings, adjust if required. If in
doubt check gas supply standing
pressure at the meter .
12MOther
10. a) Safety
check Gas
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. This can be
achieved in domestic premises
consider the installation of a BS
approved CO detector. 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
12M 11. a) Safety
check Gas
Ensure that no products of
combustion are entering the area of
the building where the boiler is
situated.
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 ignition shuts
down. In domestic premises
consider the installation of a BS
(www.bsi-global.com) approved CO
detector
12MOther
Page 47 of 614
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11.
Documentation.
Provide written report. The report must 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.
12M 12.
Documentation.
Provide written report. The report must 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.
12MOther
12. Unsafe
installations
Recommendations If after servicing the appliance is
considered unsafe the
recommendation to the client is 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 a written report
must be signed by the
client/responsible person/clients
representative and both the gas
supplier and a supervisor/manager
informed.
12M 13. Unsafe
installations
Recommendations If after servicing the appliance is
considered unsafe the
recommendation to the client is 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 a written report
must be signed by the
client/responsible person/clients
representative and both the gas
supplier and a supervisor/manager
informed.
12MOther
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COMBINATION ATMOSPHERIC BURNER GAS BOILER05-29 05-29 COMBINATION ATMOSPHERIC BURNER GAS BOILER
Title NotesActionFQTitle FQ Action Notes
1. a) Before
proceeding with
dismantling of
boiler.
Check Central Heating system for
leaks.
Flame must cover all flame parts
and be light blue in colour.
12M 1. a) Before
proceeding with
dismantling of
boiler.
Check Central Heating system for
leaks.
Flame must cover all flame parts
and be light blue in colour.
12MOther
b) Test firing. Set appliance to DHW highest flow
rate to observe the main burner.
Use a combustion analyzer to
measure CO and CO 2 content of
flue gas. Check Gas pressure,
Water volume and pressure.
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.
12M b) Test firing. Set appliance to DHW highest flow
rate to observe the main burner.
Use a combustion analyser to
measure CO and CO 2 content of
flue gas. Check Gas pressure,
Water volume and pressure.
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.
12MOther
2. Gas electrical
and ventilation
systems.
Check that all are in accordance
with current Codes of Practice.
Local electrical isolator must be
fitted. Supply to the boiler must be
direct, i.e. not fed through a time
switch.
12M 2. Gas electrical
and ventilation
systems.
Check that all are in accordance
with current Codes of Practice.
Local electrical isolator must be
fitted. Supply to the boiler must be
direct, i.e. not fed through a time
switch.
12MOther
Burners, Gas
valve,
thermocouple and
pilot tube.
Check adjust and refit along with
main burner.
11. Burners, Gas
valve,
thermocouple and
pilot tube.
Check adjust and refit along with
main burner.
12MOther
11. Boiler and
installation.
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 manifold gas
pressure against manufacturer's
settings, adjust if required.If in doubt
check gas supply standing pressure
at the meter.
12M 12. Boiler and
installation.
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 manifold gas
pressure against manufacturer`s
settings, adjust if required. If in
doubt check gas supply standing
pressure at the meter.
12MOther
12. a) Safety
check Gas
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. This can be
achieved in domestic premises
consider the installation of a BS
approved CO detector. Flames must
be bluish and burning in a stable
manner. The burner should be quiet
in operation, with no excessive;
noise should occur when the burner
ignitor shuts down.
12M 13. a) Safety
check Gas
Ensure that no products of
combustion are entering the area of
the building where the boiler is
situated.
Undetected CO is life threatening
(poisonous) and also causes energy
waste. This can be achieved in
domestic premises consider the
installation of a BS approved CO
detector. Flames must be bluish and
burning in a stable manner. The
burner should be quiet in operation,
with no excessive; noise should
occur when the burner ignition shuts
down.
12MOther
13.
Documentation.
Provide written report. The report must 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 .
12M 14.
Documentation.
Provide written report. The report must 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 .
12MOther
Page 49 of 614
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14. Unsafe
installations
Recommendations If after servicing the appliance is
considered unsafe the
recommendation to the client is 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 a written report
must be signed by the
client/responsible person/clients
representative and both the gas
supplier and a supervisor/manager
informed.
12M 15. Unsafe
installations
Recommendations If after servicing the appliance is
considered unsafe the
recommendation to the client is 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 a written report
must be signed by the
client/responsible person/clients
representative and both the gas
supplier and a supervisor/manager
informed.
12MOther
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ATMOSPHERIC GAS BURNER/CONDENSING COMBINATION BOILER05-30 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.
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.
Boiler room ventilation should comply with BS 5440 -2: 2009 for boilers not exceeding 70kW and BS
6644:2005 for boilers with a capacity between 70kW and 1.8MW.
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. In domestic premises, consider the installation of a CO
detector that complies with BS EN 50291-1:2010 and BS EN 50292:2002.
Other
Title NotesActionFQTitle FQ Action Notes
1. a) Before
proceeding with
dismantling of
boiler.
Check Central Heating system for
leaks.
Flame must cover all flame parts
and be light blue in colour.
12M 1. a) Before
proceeding with
dismantling of
boiler.
Check Central Heating system for
leaks.
Flame must cover all flame parts
and be light blue in colour.
12MOther
b) Test firing. Set appliance to DHW highest flow
rate to observe the main burner.
Use a combustion analyzer to
measure CO and CO 2 content of
flue gas. Check Gas pressure,
Water volume with the boiler
operating at low return
temperatures (less than 50 ºC)
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.
12M b) Test firing. Set appliance to DHW highest flow
rate to observe the main burner.
Use a combustion analyser to
measure CO and CO 2 content of
flue gas. Check Gas pressure,
Water volume with the boiler
operating at low return
temperatures (less than 50 ºC)
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.
12MOther
2. Gas electrical
and ventilation
systems.
Check that all are in accordance
with current Codes of Practice.
Local electrical isolator must be
fitted. Supply to the boiler must be
direct, i.e. not fed through a time
switch.
12M 2. Gas, electrical
and ventilation
systems.
Check that all are in accordance
with current Codes of Practice.
Local electrical isolator must be
fitted. Supply to the boiler must be
direct, i.e. not fed through a time
switch.
12MOther
Burners, Gas
valve,
thermocouple and
pilot tube.
Check adjust and refit along with
main burner. Check that
condensate flows freely at low
boiler return temperatures.
12. Burners, Gas
valve,
thermocouple and
pilot tube.
Check adjust and refit along with
main burner. Check that
condensate flows freely at low
boiler return temperatures.
0MOther
12. Boiler and
installation.
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 manifold gas
pressure against manufacturer's
settings, adjust if required. If in
doubt check gas supply standing
pressure at the meter.
12M 13. Boiler and
installation.
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 manifold gas
pressure against manufacturer`s
settings, adjust if required. If in
doubt check gas supply standing
pressure at the meter.
12MOther
13. a) Safety
check Gas
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. This can be
achieved in domestic premises
consider the installation of a BS
approved CO detector. 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.
12M 14. a) Safety
check Gas
Ensure that no products of
combustion are entering the area of
the building where the boiler is
situated.
Undetected CO is life threatening
(poisonous) and also causes energy
waste. This can be achieved in
domestic premises consider the
installation of a BS approved CO
detector. 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
ignition shuts down.
12MOther
Page 51 of 614
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Reason For
Change
14.
Documentation.
Provide written report. The report must 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.
12M 15.
Documentation.
Provide written report. The report must 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.
12MOther
15.Unsafe
installations
Recommendations If after servicing the appliance is
considered unsafe the
recommendation to the client is 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 a written report
must be signed by the
client/responsible person/clients
representative and both the gas
supplier and a supervisor/manager
informed.
12M 16.Unsafe
installations
Recommendations If after servicing the appliance is
considered unsafe the
recommendation to the client is 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 a written report
must be signed by the
client/responsible person/clients
representative and both the gas
supplier and a supervisor/manager
informed.
12MOther
Page 52 of 614
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AIR TO WATER HEAT PUMP05-31 05-31 AIR TO WATER HEAT PUMP
Title NotesActionFQTitle FQ Action Notes
1. Status. Isolate electrically. Note: Isolation of electrical
equipment should be carried out in
accordance with HASAWA
requirements. THIS LINK IS
WRONG , SHOULD BE -
www.hse.gov.uk
6M 1. Status. Isolate electrically. Isolation of electrical equipment
should be carried out in accordance
with HASAWA (www.hse.gov.uk)
6MOther
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WATER TO WATER HEAT PUMP05-32 05-32 WATER TO WATER HEAT PUMP
Title NotesActionFQTitle FQ Action Notes
1. Status. Isolate electrically. Note: Isolation of electrical
equipment should be carried out in
accordance with HASAWA
requirements.
6M 1. Status. Isolate electrically. Isolation of electrical equipment
should be carried out in accordance
with HASAWA (www.hse.gov.uk)
requirements.
6MOther
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BRINE TO WATER HEAT PUMP05-33 05-33 BRINE TO WATER HEAT PUMP
Title NotesActionFQTitle FQ Action Notes
1. Status. Isolate electrically. Note: Isolation of electrical
equipment should be carried out in
accordance with HASAWA
requirements.
6M 1. Status. Isolate electrically. Note: Isolation of electrical
equipment should be carried out in
accordance with HASAWA
(www.hse.gov.uk) requirements.
6MOther
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05-34 PACKAGED STEAM GENERATORS
The yearly tasks shown below are generally carried out at the same time as the annual statutory
(insurance)inspection.
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the asbestos regulations.
Refer to www.hse.gov.uk.
Added
Title NotesActionFQTitle FQ Action Notes
Self-monitoring
controls
Added
1. Water gauge
test
Record time test carried out, log
results with the operator`s name,
date of test plus any corrective
action taken.
1DAdded
2. Water level left
hand gauge
Manually blow down. Record time test carried out.1DAdded
3. Water level right
hand gauge
Manually blow down. Record time test carried out.1DAdded
4. Water level
control
Test low water level cut-out and
lock-out.
At no time during a test should the
water be lowered to the extent that it
disappears from the gauge glass.
Record time test carried out.
1DAdded
5. Feed pump
start/stop or
modulation
Check operation. Record time test carried out.1DAdded
6. Pressure
reading
Record pressure gauge reading. Record time test carried out.1DAdded
7. Feed water and
condensate check
Check the feed tank level is
adequate and there are no
contaminants.
Check that the chemical dose
metering device is functioning and
there are adequate chemical stocks
in the tanks.
Check that the in-house routine
sample results are within their given
parameters provided by the water
treatment specialist and take
remedial action when necessary.
Check the temperature is above the
required level for the treatment
doses specified for oxygen
scavenging.
Record time test carried out, log
results with the operator`s name,
date of test plus any corrective
action taken.
1DAdded
8. TDS water test Carry out TDS (total dissolved
solids) water quality test, record the
result and make adjustments where
necessary.
Record time test carried out.1DAdded
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9. pH water test Carry out pH water quality test,
record the result and make
adjustments where necessary.
Record time test carried out.1DAdded
10. Blow down Record quantity of water blown
down.
Record time test carried out.1DAdded
11. Flame failure Test flame failure lock-out.
This may not be present on non self
monitoring boilers
Record time test carried out.1WAdded
12. Failure to
ignite
Test failure to ignite lock out. Record time test carried out.1WAdded
13. Water level 1st Test by lowering water level to 1st
low water level, by evaporation and
controlled blowdown, and check
burner locks out and the alarm is
sounded.
Discharge temperature to drain
should not exceed permissible
limits.
Record time test carried out.
At no time during a test should the
water be lowered to the extent that it
disappears from the gauge glass.
1WAdded
14. Water level
2nd
Test by lowering water level to 2nd
low water level, by evaporation and
controlled blowdown, and check
burner locks out and the alarm is
sounded.
Discharge temperature to drain
should not exceed permissible
limits.
Record time test carried out.
At no time during a test should the
water be lowered to the extent that it
disappears from the gauge glass.
1WAdded
15. Boiler flue
ways, combustion
chamber and
connecting flue.
Open, remove by brushing and/or
vacuum all soot and scale.
Soot, ash and other fouling deposits
impede heat transfer thus wasting
energy and putting up costs.
12MAdded
16. Fire tubes. Open boiler end doors and clean
fire tubes by brushing or rotary
scouring equipment.
In multipass boilers it is important to
clean all passes.
12MAdded
17. Refractory
linings.
Check condition and report.12MAdded
18. Boiler flue
ways, doors and
chamber.
Reseal, check for air leaks, seal as
necessary.
12MAdded
19. Flue. Carry out smoke test.12MAdded
20. Waterside. Remove manholes, clean out scale
and residues. Replace, reseal and
ensure bolts are tight.
If there are considerable deposits of
sludge and scale, this indicates poor
water treatment which if allowed to
continue will lead to boiler failure
and energy wastage. Waste
disposal regulations may apply.
12MAdded
21. Boiler. Refill, reconnect and bring on line. Refit casing if necessary and
thoroughly clean down.
12MAdded
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22.
Instrumentation
and flame
monitoring.
Check for operation and accuracy. Recalibrate and reset if necessary.12MAdded
23. Combustion
check.
Bring up to full load and carry out
tests.
On larger systems combustion tests
should be carried out on a regular
basis to monitor performance. The
test should include smoke, draught
chamber and flue, flue temperature,
carbon dioxide, oxygen and carbon
monoxide.
12MAdded
24. Blow down
tank.
For maintenance procedures see
Sanitary and waste water plumbing
SFG 48-04
HSE document PM60 applies.12MAdded
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05-35 PAKAGED STEAM GENERATORS - ELECTRIC
Title NotesActionFQTitle FQ Action Notes
1. Status. Check and isolate by removing fuse
links.
3MAdded
2.Water drain unit. Check for free flow of water by
operating the valve. Repair any
valve gland leaks.
3MAdded
3. Boiler
circulated water.
Test for correct conductivity. This is to be within the boiler makers
recommendation.
3MAdded
4. a) Electrical
connections.
Check all electrical connections in
the cubicle and on the boiler
electrodes for soundness and
correct any defects.
12MAdded
b) Porcelain
insulators.
Examine for defects and replace if
necessary. Clean with non-abrasive
material.
12MAdded
5. Drain pipe. Check for free flow, actuate main
drain if necessary.
12MAdded
6. Feed solenoid
(if fitted).
Clean solenoid, manifold and
strainer.
Modern boilers have the load control
driven by an electric motor. (See
also Motors SFG 39)
12MAdded
7. Load control
system.
Examine mechanism and lubricate. Comply with manufacturers
recommendation for lubrication of
the gear box, motor and control
shaft and nut.
12MAdded
8. Boiler
sequence.
Replace all covers and reinstate
electrical supply.
Ensure all electrical and mechanical
covers are in their correct places.
12MAdded
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05-36 STEAM BOILER REPORT - PERIODIC EXAMINATION
This task is generally carried out and incorporates the yearly maintenance schedule refer to Boilers -
Heat generators SFG 05-20
A written scheme of examination [WSE] for all steam boilers is a legal requirement under regulation 8
of the Pressure Systems Safety Regulations (PSSR) 2000.
The WSE sets out the nature and frequency of examination and should adequately describe the
system, including all the pipework, vessels, safety devices and any other parts that could give rise to
danger. It will also specify any special measures necessary to prepare the system for the examination.
The scheme must be certified by a competent person and be available on site at all times. The client /
owner of the system is responsible for ensuring that a scheme has been drawn up and that the
competent person who certifies it has sufficient relevant knowledge and experience to carry out this
task.
The periodic examination as identified by the WSE for a steam boiler should include an
out-of-service examination (cold, offline, open for inspection) followed by an in-service examination at
normal operating pressure to check that all protective and control devices are working properly.
The competent person does not need to be the same one who compiled the written scheme of
examination, so the current or a controlled copy of the scheme should always be available on site.
The client / owner of the system is responsible for arranging for the competent person to carry out the
examination in accordance with the written scheme of examination.
Records
The following documentation and records need to be retained:
- The report of the last examination under the written scheme of
examination;
- Any details of repairs or modifications to the system (including changes to the operating
parameters);
- Any previous reports containing information relating to the safe
operation of the system;
- Routine testing records for the previous two years; and
- Technical documentation supplied by the manufacturer and installer of the boiler and associated
equipment.
These documents must be available to the boiler operator, the
competent person and any new user or owner of the pressure equipment.
Added
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05-37 BOILER SUPERHEATER
The yearly tasks shown below are generally carried out at the same time as the Annual Statutory
(Insurance) Inspection.
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk.
Added
Title NotesActionFQTitle FQ Action Notes
1. Internal and
external areas
Carry out an internal and external
examination of the heater.
12MAdded
2. Headers Inspect all weld sections for any
signs of cracking. Check for
deposits that have accumulated in
the header, clean out as required.
Thermal cracking at the headers
due to high stresses set up across
the thick welded section is possible.
12MAdded
3. Safety valve
and stop valve
Check for leakage, corrosion and
manually operate.
12MAdded
4. Drain and vent
valves
Inspect and repair as necessary12MAdded
5. Manhole
openings
Check all contact surfaces for
pitting. Clean any scale/deposits.
12MAdded
6. Screen plates Check condition and clean as
necessary.
12MAdded
7. Tubes Check for signs of thermal fatigue
and scale. In the case of scale
being present this should be
cleaned off. It is important to clean
all passes.
Oxide scaling inside or outside may
cause tube failure and at the worst
case a hydrogen fire which is when
iron burns in steam at above 700°C
in an exothermic reaction.
Sodium and vanadium compounds
present in the deposits proved very
corrosive to superheater tube
causing frequent repeated failure.
12MAdded
8. Walk-in spaces Check the supports of the
horizontal super heater tubes for
signs of thermal damage and
potential failure. Clean all deposits
from the spaces. Check the
condition of the tubes special
attention to be paid to tubes
through which there still exists gas
paths as they operate under
excessive metal temperature.
A build-up of deposits is most
troublesome defect in a super
heater. These may result in high
furnace pressure, loss of super
heater and poor combustion.
12MAdded
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05-38 BIOMASS BOILER
The burning of biofuels is a complex operation involving the storage, handling and combustion of solid
material, plus the handling, disposal of gaseous and solid waste. The materials can be abrasive with
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 biomass boiler
is examined in sequence.
Maintenance levels of all biomass boilers will vary according to the type of system and fuel being burnt
for instance a pellet system strongley differs from a woodchip system in terms of frequency .
Added
Title NotesActionFQTitle FQ Action Notes
1. Weekly check Inspect boiler and fuel feed system.
Listen for noisy fan operation.
Check flue gas temperature and the
colour out of the stack. Record in
log. Check boiler temperature and
record in log. Function test
back-burn devices and negative
pressure indicators. Check
pressure switches. Check
emergency stops for both bunker
and auger operate.
1WAdded
2. Hydraulic
aggregate [if fitted]
Check oil level and top up as
required. Check that the pressure
and operational temperature are as
per the manufacturers guidelines.
Check for any oil leaks from the
seals and hoses.
1MAdded
3. Operational
status.
Check and isolate and Lock Off
from electricity supply. Remove
fuses, if used.
Depending on the Establishment, a
Permit to Work system may be in
operation. The Authorised Person
should be approached for the issue
of the permit.
3MAdded
4. Multicyclone Clean the mulitcyclone using an
industrial vacuum cleaner.
3MAdded
5. Rost Remove ash from the rost3MAdded
6. Combustion
Chamber
Clean retort, fire bricks, combustion
surface and combustion chamber
3MAdded
7. Burning Grate Remove ash from the combustion
space and clean grate. Ensure all
ash from beneath the step grate is
removed.
3MAdded
8. Heat exchanger Clean the tubes in the heat
exchanger with the appropriate
brush
3MAdded
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9. Fans Clean suction blower from ash
using an industrial vacuum cleaner.
Check low level switches, fuses and
action of fan emergency safety
switch in OFF position.
Pay attention to the flue gas sensor
when cleaning the flue gas pipe.
3MAdded
10. Flue and
chimney
Clean3MAdded
11. Auger Lubricate the worm bearings.
Inspect for wear.
Use only lubricants as detailed by
the manufacturers guidelines.
3MAdded
12. Ash conveying
system [if fitted]
Lubricate the all bearings. Use only lubricants as detailed by
the manufacturers guidelines.
3MAdded
13.Pneumatic
system. (Applies
to both feed and
ash removal,
where fitted).
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 . It is essential to
maintain air tightness on pneumatic
systems otherwise the coal feed
cannot be maintained, output is
reduced and energy wasted.
3MAdded
14. Ash container Clean out ash content in the
container, empty it when necessary.
This frequency will depend on the
type of system and the hours
system used.
Added
15. Igniters Clean igniter and igniter tube.6MAdded
16. Compressor [if
fitted]
See SFG 40-08 for full compressor
tasks
6MAdded
17. Motors Clean motors see Motors SFG
39-01
6MAdded
18. Boiler room
ventilation
Check that all are in accordance
with current Codes of Practice.
Boiler room ventilation should
comply with BS 5440 -2: 2009 for
boilers not exceeding 70kW and BS
6644:2005 for boilers with a
capacity between 70kW and 1.8MW
12MAdded
19. Electrical. Check all electrical trips. These should be set for manual
reset.
12MAdded
20. Silo discharge Grease gears24MAdded
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05-39 GAS BOOSTER SETS
Before carrying out any maintenance on the Booster, all Electrics and gas pressure should be turned
off.
Maintenance should be carried out in full accordance with the manufacturers instructions and using
only replacement parts supplied or authorised by the manufacturer.
Added
Title NotesActionFQTitle FQ Action Notes
1) General Check for leaks and general
condition. Check for excessive
noise or vibration and ensure that
the mountings are secure and in
good condition.
3MAdded
2). Air fan inlets Check that the air fan inlets are not
obstructed by
dust or dirt and clean out if
necessary
3MAdded
3). Glands and
seals
Ensure that all glands and seals on
gas boosters are sound and that
there is no smell of gas in the area.
3MAdded
4). Warning
notices
Ensure that warning notices are
correctly displayed.
3MAdded
5) Motors The bearings generally are sealed
for life and usually left in service
until their replacement is required.
12MAdded
6) Drive belts Replace drive belts using
manufacturers replacement belts.
If the drive has more than one belt
ensure all belts are changed at the
same time.
Do not apply belt dressing.
1) Isolate the electricity supply.
2) Remove the belt guard.
3) Remove the existing belt.
4) Clean the pulley running
surfaces.
5) Lift the motor platform and
position a new belt on both pulleys.
The smooth side of the belt should
be in contact with the pulley
surfaces.
6) Ensure the belt will run centrally
on the pulley faces.
7) Replace the belt guard.
12MAdded
7) Booster bearing
assemblies
Replace bearing assemblies
irrespective of perceived bearing
condition.
A rise in noise level or vibration
indicates that the bearings are in
need of replacement. With the belt
guard removed a further check can
be made for radial or axial
movement of the shaft within the
bearing housing.
60MAdded
8) Flexible
connectors
Replace flexible connectors.60MAdded
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05-40 GAS GOVERNOR OR GAS REGULATOR
Title NotesActionFQTitle FQ Action Notes
1) Diaphragms Individual appliance governors
should be examined to ensure that
diaphragms are sound and in good
condition.
12MAdded
2). Valves and
seatings
Valves and seatings should be
cleaned and any rust or dust
deposits removed.
12MAdded
3). Impulse pipes Check that impulse pipes are clear,
sound and secure.
12MAdded
4). Outlet pressure Check that the outlet pressure
should be reasonably constant
between low and high fire rates.
12MAdded
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05-41 GAS INCINERATOR
A risk assessment and method statement must be undertaken in accordance with the confined spaces
regulations, 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
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Have sample Certified as safe before any works can re-start, if asbestos,
take actions in accordance with the asbestos regulations.
Refer to www.hse.gov.uk for detail.
Added
Title NotesActionFQTitle FQ Action Notes
1. Outer case /
panels.
Remove as required If a leak is detected, shutdown the
gas source, reduce pressure to
atmospheric, and tighten or redo the
leaking connection. Retest.
12MAdded
2. Grate / Ash pan Riddle the grate, check for freedom
of movement, clear primary
chamber of ash. Remove and
empty ash draw or pan.
12MAdded
3. Pilot burner Remove and clean pilot burner.12MAdded
4. Primary and
secondary burners
Remove and clean primary and
secondary burners.
Check that injectors are clear,
burner tunnel clear and ports are
free from blockage.
12MAdded
5. Refractory
lining, combustion
chambers and flue
ways.
Examine condition of refractory
lining to primary chamber. Clear
any dust from secondary chamber
and check that the flue ways are
clear.
Report any problems to the client.12MAdded
6. Door
mechanism
Clean and check door mechanism.12MAdded
7. Linkages and
interlocks
Clean linkages and interlocks and
adjust if necessary.
12MAdded
8. Gas control
cocks
Check gas control cocks, ease and
grease if required
12MAdded
9. Gas burners Rebuild and install in reverse as
sequence dictates.
12MAdded
10. Gas system Check gas soundness.12MAdded
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11. Ignition Light the appliance and check any
ignition device.
Check pilot stable and correctly
positioned.
Check burner pressures or gas rate
at the meter if necessary.
12MAdded
12. Flue Check flue for pull and spillage12MAdded
13. Controls Check controls
– flame protection device
– timer set correctly
– any other control devices
12MAdded
14. Sequence
timer
Check that the timer returns to
zero, shutting down the appliance
at the end of the combustion cycle.
Added
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05-42 WASTE INCINERATOR
A risk assessment and method statement must be undertaken in accordance with the confined spaces
regulations, 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
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Have sample Certified as safe before any works can re-start, if asbestos,
take actions in accordance with the asbestos regulations.
Refer to www.hse.gov.uk for detail.
Added
Title NotesActionFQTitle FQ Action Notes
1. Ash removal
conveyor
Inspect and clean as required.1HAdded
2. Water quench
pit
Inspect water level and fill as
required.
1HAdded
3. Opacity monitor Check operation of the opacity
monitor and check exhaust for
visible emissions.
Record time test carried out.1DAdded
4. Oxygen monitor Check operation. Record time test carried out.1DAdded
5. Thermocouples Check operation. Record time test carried out.1DAdded
6. Underfire air
ports
Inspect and clean as required.1DAdded
7. Limit switches Inspect for freedom of operation
and potential obstructing debris.
1DAdded
8. Door seals Inspect for wear, closeness of fit,
and air leakage.
1DAdded
9. Ash pit/internal
dropout sump
Clean after each shift. This applies to units that do not
have a continuous ash conveyor
cleaning system.
1DAdded
10. Heat recovery
boiler tubes
Inspect and clean as required.1WAdded
11. Blower intakes Inspect for accumulations of lint,
debris. Clean as required.
1WAdded
12. Burner flame
rods (gas fired
units)
Inspect and clean as required.1WAdded
13. U.V. Scanner
flame sensors
Inspect and clean as required.1WAdded
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14. Swing latches
and hinges
Lubricate.1WAdded
15. Hopper door
support pins
Lubricate.1WAdded
16. Ram feeder
carriage wheels
Lubricate.1WAdded
17. Heat recovery
induced-draft fans
Inspect and clean fan housing as
required.
Check for corrosion and V-belt
drives and chains for tension and
wear.
1WAdded
18. Hydraulic
systems
Check hydraulic fluid level and add
the proper replacement fluid as
required. Investigate sources of
fluid leakage as required.
2WAdded
19. Ash removal
conveyor bearings
Lubricate.2WAdded
20. fuel trains and
burners
Inspect and clean as required.2WAdded
21. Control panels Inspect and clean as required. Keep panel securely closed and free
of dirt .
2WAdded
22. External
surface of
incinerator and
stack
Inspect external "hot" surfaces. White spots or discolouration may
indicate loss of refractory.
1MAdded
23. Refractory Inspect and repair minor wear
areas.
1MAdded
24. Internal ram
faces
Inspect for wear. Stainless steel faces may wear out
and require replacement in 1 to 5
years depending on service.
1MAdded
25.
Upper/secondary
combustion
chamber
Inspect and vacuum and particulate
matter that has accumulated on the
chamber floor.
1MAdded
26. Combustion air
blowers and heat
recovery induced
draft fans
Lubricate. Some of these bearings are sealed
for life so do not need lubricating.
1MAdded
27. Hydraulic
cylinder clevis and
trunnion
attachments to all
moving
components
Lubricate.1MAdded
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28. Burner pilots Inspect and adjust as required.1MAdded
29. Hot external
surfaces
Inspect for signs of damage.6MAdded
30. Chains Inspect and brush clean as
required. Lubricate.
6MAdded
31. Outer case /
panels.
Remove as required If a leak is detected, shutdown the
gas source, reduce pressure to
atmospheric, and tighten or redo the
leaking connection. Retest.
12MAdded
32. Grate / Ash
pan
riddle the grate, check for freedom
of movement, primary chamber
clear of ash. Remove and empty
ash drawer or pan.
12MAdded
33. Pilot burner Remove and clean pilot burner.12MAdded
34. Primary and
secondary burners
Remove and clean primary and
secondary burners. check that
injectors are clear, burner tunnel
clear and ports free from
blockage.
12MAdded
35. Refractory
lining, combustion
chambers and flue
ways.
Examine condition of refractory
lining to primary chamber. Clear
any dust from secondary chamber
and check that the flue ways are
clear.
Report any problems to the client.12MAdded
36. Door
mechanism
Clean and check door mechanism.12MAdded
37. Linkages and
interlocks
Clean linkages and interlocks and
adjust if necessary.
12MAdded
38. Gas control
cocks
Check gas control cocks, ease and
grease if required
12MAdded
39. Gas burners Replace as sequence dictates.12MAdded
40. Gas system Check gas soundness.12MAdded
41. Ignition Light the appliance and check any
ignition device.
Check pilot stable and correctly
positioned.
Check burner pressures or gas rate
at the meter if necessary.
12MAdded
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42. Flue Check flue for pull and spillage12MAdded
43. Controls check controls
– flame protection device
– timer set correctly
– any other control devices
12MAdded
44. Sequence
timer
Check that the timer returns to
zero, shutting down the appliance
at the end of the combustion cycle.
12MAdded
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05-43 WET SCRUBBER SYSTEM
Legionellosis (Legionnaires Disease and Associated Illnesses)
Approved Code of Practice- Legionnaires disease: The control of legionella bacteria in water systems:
Approved Code of Practice, L8,2000 sets out certain statutory requirements. In particular each water
system 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 L8 has a special legal status, Part 1 being regulatory and Part 2
guidance.
The client must ensure that one person of adequate status is appointed as being responsible for
overseeing the assessment and implementation of the precautions. Responsibility and lines of
communication must be properly defined and personnel must be properly trained.
Added
Title NotesActionFQTitle FQ Action Notes
1. Scrubber liquid
pump
Check for proper operation and
leakage. Investigate sources of fluid
leakage and repair as required.
1DAdded
2. Variable throat
activator
Check for proper operation and
leakage.
1DAdded
3. Scrubber liquid
lines
Check for leakage. Repair as
required.
1DAdded
4. Mist eliminator
pressure lines
Check for leakage. Repair as
required.
1DAdded
5. Reagent feed
system
Check for leakage. Repair as
required.
1DAdded
6. Fan, Fan
bearings and fan
belt
Check for vibration and proper
operation. Check for abnormal
noise.
1DAdded
7. Fan Check oil level, oil colour, oil
temperature and lubricate.
1WAdded
8. Scrubber liquid
pump
Check oil level and lubricate pump
motor bearings.
1WAdded
9. Damper air
purge system
Check for proper operation.1WAdded
10. Ductwork Check for leakage. Repair as
required.
1MAdded
11. Fan and motor
bearings
Inspect for leaks, cracks and loose
fittings.
1MAdded
12. Fan blades
and internal
housing
Inspect for material build-up and
clean as required. Inspect for
abrasion and corrosion and repair
as required.
1MAdded
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13. Drain chain
drive mechanism
Check chain tension, sprocket wear
and alignment and oil level.
1MAdded
14. Pipes and
manifolds
Inspect for plugging/leaking and
clean/repair as required.
1MAdded
15. Dampers Check for leakage.1MAdded
16. Spray bars Inspect for nozzle wear and
plugging and clean as required.
1MAdded
17. Pressure
gauges
Check for accuracy.1MAdded
18. Main body of
scrubber
Inspect for material build-up and
clean as required. Inspect for
abrasion and corrosion and repair
as required.
1MAdded
19. Fan, pump,
motor and drag
chain bearings
and gear reducers
Inspect clearances and wear, pitting
and scoring. Inspect for leaks,
cracks and loose fittings.
6MAdded
20. Flow meters Check for accuracy.6MAdded
21. Damper drive
mechanism
Check for proper operation and
alignment.
6MAdded
22. Damper seals,
bearings, blades
and blowers
Check for wear and leakage.6MAdded
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05-44 FABRIC FILTER SYSTEM
Title NotesActionFQTitle FQ Action Notes
1. Stack Check exhaust for visible dust.1DAdded
2. Manometer Check and record fabric pressure
loss and fan static pressure.
Watch and record trends.1DAdded
3. Compressed air
system
Check for air leakage (low
pressure). Check valves.
1DAdded
4. Collector Observe all indicators on control
panel and listen to system for
properly operating subsystems.
1DAdded
5. Damper valves Check all isolation, bypass and
cleaning damper valves for
synchronisation and proper
operation.
1DAdded
6. Rotating
equipment and
drives
Check for signs of jamming,
leakage, broken parts and wear etc.
1DAdded
7. Dust removal
system
Check to ensure that dust is being
removed from the system.
1DAdded
8. Filter bags Check for tears, holes, abrasion,
proper fastening, bag tension, dust
accumulation on surface or creases
and folds.
1WAdded
9. Cleaning
system
Check cleaning sequence and cycle
times for proper valve and timer
operations.
Check compressed air lines
including oilers and filters. Inspect
shaker mechanisms for correct
operation.
1WAdded
10. Hoppers Check for bridging or plugging.
Inspect screw conveyor for correct
operation and lubrication.
1WAdded
11. Shaker
mechanism
Inspect for loose bolts, tighten as
required.
1MAdded
12. Fan(s) Check for corrosion and material
build-up and check V-belt drives
and chains for tension and wear.
1MAdded
13. Monitor(s) Check accuracy of all indicating
equipment.
1MAdded
14. Inlet plenum Check baffle plate for wear, if
applicable wear is evident, replace.
Check for dust deposits and clean
as required.
3MAdded
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15. Access doors Check all gaskets.3MAdded
16. Shaker
mechanism
Tube type:
(tube hooks suspended from a
tubular assembly) Inspect nylon
bushings in shaker bars and clevis
(hanger) assembly for wear.
Channel shakers:
(tube hooks suspended from
channel bar assembly) Inspect drill
bushings in tile bars and connecting
rods for wear.
3MAdded
17. Motors, fans Lubricate all electrical motors,
speed reducers, exhaust and
reverse-air fans and similar
equipment.
6MAdded
18. Collector Check all bolts and welds. Inspect
entire collector thoroughly, clean as
required.
12MAdded
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05-45 SANITARY INCINERATOR
Always ensure that the main external electricity supply is switched off before attending to servicing of
the unit.
Added
Title NotesActionFQTitle FQ Action Notes
1. Ash draw Empty the ash draw The ash drawer must not be allowed
to overfill. If the incinerator is in
constant use it should be emptied
weekly or more often if
it should appear necessary.
1WAdded
2. Ventilation The incinerator should have a
13mm gap between it and the wall
to which it is fixed for ventilation
purposes. Check that the gap is
clean and unobstructed.
1WAdded
3. Wiring Check the supply wiring fuse is of
the correct rating. Check for
soundness and ensure terminal
connections are secure. Check
integrity of electrical insulation.
Some units are fitted with sheathed
wire elements and it is a feature of
such an element that small amounts
of water can be absorbed from the
atmosphere if the unit is not in
regular use. It is possible that this
will decrease the earth leakage
resistance which can cause the
earth leakage cut-out to trip.
12MAdded
4. Test operation Insert the towel by fully opening the
door flap at the top of the unit. This
operation is all that is required and
automatically starts
the burning cycle. Do not fill above
the lower level of the door opening.
12MAdded
5. Time switch Check that the timer returns to
zero, shutting down the appliance
at the end of the combustion cycle.
The time switch should cut out 20
minutes after the door is closed but
the charge will continue to burn.
12MAdded
6. Flue Check flue for pull. Clean flue and
ensure that the flue cleaning trap
gasket is sealed when put back in
operation. Mark positions and clean
any branch run dampers and return
to set positions. Ensure that the
cone cap is in place on the flue
system. Check and clean any
in-line fan units. Check operation
hours of the building and ensure
that any time switch controlling the
fan is running continuously during
these hours plus a run on time of
one to two hours.
12MAdded
Page 76 of 614
BUILDING MANAGEMENT SYSTEMS
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INTRODUCTORY PROCEDURES06-01 06-01 INTRODUCTORY PROCEDURES
Development
Building Management Systems (BMS) or Building Energy Management Systems (BEMS) have
developed from the simple applications of the 1970s to complex integrated systems involving
outstations and central units whose operation relies on computer interactive management backed by
detailed and often complex software which provides total management of the environmental
conditions in a building. It is an ever changing 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 either passive, 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 of performance. Switching off because of a malfunction or lack of
data update represents a negation of the investment and can give rise to poor environmental
conditions and energy wastage.
Energy saving and maintenance
Building Energy Maintenance Systems offer considerable energy and cost savings when compared
with more simple equipment but represent a considerable investment by the building owner or lessee .
If the equipment is not properly commissioned and maintained by specialist trained personnel
who have had training on such equipment and are supported by the manufacturer, the benefits
of such investment 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 and weekly maintenance tasks are carried out satisfactorily.
Such tasks could include monitoring and changing time schedules, set points, environmental control
settings and simple routine maintenance of the computer hardware. Where changes are made to the
software routines it is essential that back up copies are made to safeguard the changes.
Software
The owner or lessee should be aware that software is normally covered by copyright and the licence
conditions covering its use can be very restrictive. The penalties for infringing that copyright can be
considerable. The licence may relate to the use of the software or may be restrictive and apply only to
a particular application or building If there is any doubt regarding the above, the manufacturer
should be contacted for advice.
Maintenance contractor
For the regular maintenance of the equipment the client should be satisfied that the maintenance
contractor employs BMS specialists who:-
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.
Development
Building Management Systems (BMS) or Building Energy Management Systems (BEMS) have
developed from the simple applications of the 1970s to complex integrated systems involving
outstations and central units whose operation relies on computer interactive management backed by
detailed and often complex software which provides total management of the environmental
conditions in a building. It is an ever changing 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 either passive, 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 of performance. Switching off because of a malfunction or lack of
data update represents a negation of the investment and can give rise to poor environmental
conditions and energy wastage.
Energy saving and maintenance
Building Energy Maintenance Systems offer considerable energy and cost savings when compared
with more simple equipment but represent a considerable investment by the building owner or lessee.
If the equipment is not properly commissioned and maintained by specialist trained personnel who
have had training on such equipment and are supported by the manufacturer, the benefits of such
investment 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 and weekly maintenance tasks are carried out satisfactorily.
Such tasks could include monitoring and changing time schedules, set points, environmental control
settings and simple routine maintenance of the computer hardware. Where changes are made to the
software routines it is essential that back up copies are made to safeguard the changes.
Software
The owner or lessee should be aware that software is normally covered by copyright and the licence
conditions covering its use can be very restrictive. The penalties for infringing that copyright can be
considerable. The licence may relate to the use of the software or may be restrictive and apply only to
a particular application or building If there is any doubt regarding the above, the manufacturer should
be contacted for advice.
Maintenance provider
For the regular maintenance of the equipment the client should be satisfied that the maintenance
provider employs BMS specialists who:-
a) have had the necessary training,
b) have knowledge of the installed system,
Technical
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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.
The tasks and frequencies given in the following schedules represent good practice and are typically
applied for sites with five or seven-day operation with plant and controls less than 10 years old. The
frequencies suggested may be varied to meet on-site conditions
(extremes of dust or heat), age of plant and controls, acceptance of risk of failure.
Sites with critical areas such as computer suites or operating theatres may require increased
frequency of maintenance of selected elements. Sites where risk of failure of services is acceptable
may be more selective about the maintenance frequency of certain elements. However, care should
be taken to ensure that energy savings continue to be achieved.
Page 79 of 614
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BUILDING MANAGEMENT SYSTEMS - Central Operator Station06-03 06-03 BUILDING MANAGEMENT SYSTEMS - Central Operator Station
Title NotesActionFQTitle FQ Action Notes
5. Clock and
Calendar
Check real-time clock and date
settings
6MAdded
4. Tape drives. Clean according to the
manufacturer's instructions.
12M Deleted
5. Tape cassettes
(where
appropriate).
Clean according to the
manufacturer's instructions.
12M Deleted
6. Clock battery. Check and replace if necessary. Battery disposal should be in
accordance with www.hse.gov.uk
and Environmental Requirements.
12M 4. Clock battery. Check and replace if necessary. Battery disposal should be in
accordance with www.hse.gov.uk
and Environmental Requirements.
12MOther
7. Cooling fans. Check condition, clean and
lubricate if necessary.
6M 6. Cooling fans. Check condition, clean and
lubricate if necessary.
Do not lubricate if sealed for life
bearings. Wipe off any excess
lubricant as it will attract dust which
will stick to it.
6MTechnical
8. Filters. Inspect and clean or change as
necessary.
6M 7. Filters. Inspect and clean or change as
necessary.
6MOther
9. Mouse. Check for smooth operation and
clean ball as necessary.
Client may ask for more frequent
maintenance of mouse.
12M 8. Mouse. Check for smooth operation and
clean ball as necessary.
client may ask for more frequent
maintenance of mouse.
12MOther
10. Software
archives.
a)Take back up copy of site specific
data files. b)Verify operating
programmes and functionality.
Ensure that security is retained and
that any updating of files is
incorporated.
6M 9. Software
archives.
a)Take back up copy of site specific
data files. b)Verify operating
programmes and functionality.
Ensure that security is retained and
that any updating of files is
incorporated. It is recommended
that a copy of the back-up data is
stored in a fire proof safe or off-site.
6MOther
11. Visual Display
Unit (VDU).
Check a)focus, b)contrast,
c)brightness, d)for correct
operation.
12M 10. Visual
Display Unit
(VDU).
Check a)focus, b)contrast,
c)brightness, d)for correct
operation.
12MOther
12. Monitor(s). Check a)focus, b)contrast,
c)brightness, d)for correct
operation, e)degauss.
With most VDUs the screen is
automatically degaussed when
equipment is switched on.
12M 11. Monitor(s). Check a)focus, b)contrast,
c)brightness, d)for correct
operation, e)degauss.
With most VDUs the screen is
automatically degaussed when
equipment is switched on.
12MOther
13. Keyboard. Check for correct operation and
clean.
12M 12. Keyboard. Check for correct operation and
clean.
12MOther
14. Cleaning. Clean with approved cleanser. Treat with anti-static compound.
Depending on use and location
more frequent cleaning may be
necessary.
12M 13. Cleaning. Clean with approved cleanser. Treat with anti-static compound.
Depending on use and location
more frequent cleaning may be
necessary.
12MOther
3. Test sequence. Check, adjust and replace if
necessary:- a)paper feed,
b)transport system, c)printer ribbon.
12M 3. Test sequence. Check, adjust and replace if
necessary:- a)paper feed,
b)transport system, c)printer
cartridge
12MTechnical
Visual Display Unit
-colourgraphic
Deleted
1. Cables and
connectors.
Check security, integrity, and for
physical damage.
12M Deleted
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2. Cleaning. Use recommended cleaning agent.12M Deleted
3. Colour
alignments and
adjustments.
Check and correct as necessary.12M Deleted
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BUILDING MANAGEMENT SYSTEMS - COMMUNICATIONS06-04 06-04 BUILDING MANAGEMENT SYSTEMS - COMMUNICATIONS
Title NotesActionFQTitle FQ Action Notes
5.Alarms -
receiving
Confirm that all critical alarms are
received by the central supervisor.
Check spurious alarms and
reported faults (as incurred).
12MAdded
6. Alarms -
generating
Check generation of alarms from all
input and output devices
12MAdded
7. Network Check communications between
central supervisory computer and
outstations and other networked
devices
12MAdded
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BUILDING MAINTENANCE SYSTEMS - OUTSTATIONS06-05 06-05 BUILDING MAINTENANCE SYSTEMS - OUTSTATIONS
Title NotesActionFQTitle FQ Action Notes
5. Stand-by
batteries/
uninterrupted
power supplies
(UPS).
Interrupt electrical supply to each
outstation, reinstate and ensure
system restarts satisfactorily
12MAdded
1. Out station
hardware.
Check mechanical and
environmental condition.
Note: environmental conditions, e.g.
temperature, humidity should be
within manufacturer's recommended
limits.
12M 1. Out station
hardware.
Check mechanical and
environmental condition.
Environmental conditions, e.g.
temperature, humidity should be
within manufacturer`s
recommended limits.
12MOther
4. Stand-by
batteries/
uninterrupted
power supplies
(UPS).
Check against manufacturer's
specification.
12M 4. Stand-by
batteries/
uninterrupted
power supplies
(UPS).
Check against manufacturer`s
specification. Replace as necessary
12MTechnical
5. Digital inputs. Check by activating (where from
fixed sensing/control device)
Note: Care should be taken to
isolate local operation.
12M 6. Digital inputs. Check by activating (where from
fixed sensing/control device)
Care should be taken to isolate local
operation.
12MOther
6. Digital outputs. Check operation of output stopping
by operating routine (where
appropriate). Check switching by
software interlocks.
Should include starting and stopping
operations. Note: Does not apply to
connected devices.
12M 7. Digital outputs. Check operation of output stopping
by operating routine (where
appropriate). Check switching by
software interlocks.
Should include starting and stopping
operations. Does not apply to
connected devices.
12MOther
7. Analogue
inputs.
Read and check calibration of
analogue inputs.
12M 8. Analogue
inputs.
Read and check calibration of
analogue inputs.
12MOther
8. Analogue
outputs.
Check for accuracy of output
signal.
12M 9. Analogue
outputs.
Check for accuracy of output signal.12MOther
9. Manual
override (physical).
Check status. Review and report to client.12M 10. Manual
override (physical).
Check status. Review and report to client.12MOther
10. Installed
programme.
Check integrity, alarms, interlocks,
optimisation.
See section on SOFTWARE
FUNCTIONS.
12M 11. Installed
programme.
Check integrity, alarms, interlocks,
optimisation.
See section on Software functions
SFG 06-06
12MOther
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BUILDING MANAGEMENT SYSTEMS - SOFTWARE FUNCTIONS06-06 06-06 BUILDING MANAGEMENT SYSTEMS - SOFTWARE FUNCTIONS
Title NotesActionFQTitle FQ Action Notes
1. Control loops. Check integrity of the installed
programme, Check sequence,
operation of control, outputs and
check stability of plant.
Frequency should be agreed with
client. This action should be related
to the critical nature of the
operation.
12M 1. Control loops. Check integrity of the installed
programme, Check sequence,
operation of control, outputs and
check stability of plant. Undertake
as necessary fine tuning of control
loops. Adjust settings in conjunction
with the building manager to
achieve the required internal
environmental conditions
Frequency should be agreed with
client. This action should be related
to the critical nature of the
operation.
6MTechnical
3. Time clock Check real time clock for accuracy
throughout system.
12M 3. Time clock Check real time clock and date for
accuracy throughout system.
12MTechnical
4. Time
switching.
Review current operating
parameters according to client's
needs.
e.g. time settings and schedules.12M 4. Time
switching.
Review current operating
parameters according to clients
needs.
e.g. time settings and schedules.12MOther
5. Data logging. Review existing logs. Report to client on the need to
review existing arrangements.
12M 5. Data logging. Review need for existing data logs.
Delete/archive logs as required
Report to client on the need to
review existing arrangements.
12MOther
6. Alarms -
faults, out of limit
alarms.
Check that plant alarms and
software interlocks with safety
implications are operating correctly.
Check alarm priorities, routings and
reactions.
The checking of possible reactions
to certain critical alarms and
programmes must be carefully
co-ordinated with other trades and
building tenants. Where there are
safety implications, verify alarm
integrity. Review system of reporting
outstanding alarm conditions and
report discrepancies.
12M 6. Alarms -
faults, out of limit
alarms.
Check that plant alarms and
software interlocks with safety
implications are operating correctly.
Check alarm priorities, routings and
reactions. Check alarm priorities
are appropriate.
The checking of possible reactions
to certain critical alarms and
programmes must be carefully
co-ordinated with other trades and
building tenants. Where there are
safety implications, verify alarm
integrity. Review system of reporting
outstanding alarm conditions and
report discrepancies.
12MTechnical
7. Alarm
management and
report.
Review frequencies of generated
alarms.
Report as appropriate to client.12M 7. Alarm
management and
report.
Review frequencies of generated
alarms. Review alarm log records
for indication of untoward
conditions
Report as appropriate to client.12MTechnical
14. Outstations Back up all outstation files. Make
two copies. Store one on site and
one off site.
6MAdded
15. O&M`s Advise where control strategy
descriptions in operating and
maintenance manuals are incorrect.
Ensure, where appropriate,
additional documentation meets all
quality assurance procedures
12MAdded
16. Schematics Check schematics indicate correctly12MAdded
17. Log Books Maintain a log book of all changes
made to the system
As Necessary0MAdded
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BURNERS
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ATMOSPHERIC GAS BURNERS07-01 07-01 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, if suspected STOP WORK, close off the area. Have sample Certified as safe
before any works can re-start, if asbestos, take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk for detail.
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 if suspected STOP WORK, close off the area. Take actions in accordance
with the Asbestos Regulations.
Refer to www.hse.gov.uk .
Other
Title NotesActionFQTitle FQ Action Notes
6 Wiring to ignitor
and/or probe, gas
valve and boiler
thermostats.
Check.12M 6 Wiring to ignition
and/or probe, gas
valve and boiler
thermostats.
Check.12MOther
10. Safety check Ensure that no products of
combustion are entering the area of
the building where the boiler is
situated.
The report must 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 10. Safety check Ensure that no products of
combustion are entering the area of
the building where the boiler is
situated.
The report must 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.
12MOther
11.
Documentation.
Provide written report. The report must 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 11.
Documentation.
Provide written report. The report must 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.
12MOther
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BLOWN GAS BURNER07-02 07-02 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 is controlled by an orifice plate and monitored by a pre- set differential
pressure switch.
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 is controlled by an orifice plate and monitored by a pre- set differential
pressure switch.
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk.
Technical
Title NotesActionFQTitle FQ Action Notes
13.
Recommendation.
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 posses
accreditation in accordance with the
Gas Safety Regulations.
12M 13.
Recommendation.
Provide written report. The report
should be signed by the service
engineer and the client/clients
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 posses
accreditation in accordance with the
Gas Safety Regulations.
12MOther
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FORCED DRAUGHT GAS BURNER07-03 07-03 FORCED DRAUGHT GAS BURNER
A fan assisted nozzle mix type with fully automatic operation creating an expanding flame . A fan assisted nozzle mix type with fully automatic operation creating an expanding flame .
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk .
Technical
Title NotesActionFQTitle FQ Action Notes
6. Fan and
motor.
Remove, thoroughly clean,
lubricate if necessary.
MOTORS6M 6. Fan and
motor.
Remove, thoroughly clean, lubricate
if necessary.
See Motors SFG 396MTechnical
15.
Recommendation.
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.
6M 15.
Recommendation.
Provide written report. The report
should be signed by the service
engineer and the client/clients
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.
6MOther
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FUEL OIL BURNERS USING 220/960 Sec OIL07-04 07-04 FUEL OIL DISTRIBUTION & PIPEWORK USING MEDIUM (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 of residual oils necessitates the inclusion of equipment for pre-heating the fuel
oil prior to the burner. This includes preheater coils in the storage tank, line tracing and final preheater
either before or right at the burner nozzle. The oil supply temperature at the burner inlet must 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 82oC
There are four basic fuel systems, which can be subdivided into those used for distillate and those for
residual oils. The use of residual oils necessitates the inclusion of equipment for pre-heating the fuel
oil prior to the burner. This includes preheater coils in the storage tank, line tracing and final
preheater either before or right at the burner nozzle. The oil supply temperature at the burner inlet
must be sustained at the burner pump inlet as follows:
Class F (960 sec Redwood No 1 - 20cSt @ 100 deg C in SI units) 43 deg C-55 deg C, at burner
nozzle 104 deg C
Class E (220 sec Redwood No 1 - 8cSt @ 100 deg C in SI units) 10 deg C-21 deg C, at burner
nozzle 82 deg C
Other
Title NotesActionFQTitle FQ Action Notes
4. Insulation. Examine and replace or repair as
necessary.
12M 4. Insulation. Examine and replace or repair as
necessary.
Check for asbestos containing
material prior to dismantling any
equipment, if suspected STOP
WORK, close off the area. Take
actions in accordance with the
Asbestos Regulations.
Refer to www.hse.gov.uk.
12MLegislative
5. Filters. Clean and change if necessary. Sludge in heavy fuel oil can be a
major fault in a burner operation and
regular checking of filters and
cleaning of tanks may be necessary
if oil is only used intermittently. To
dispose of waste away from site the
operator must have a Waste
Disposal License , Risk Assessment
may be required.
12M 5. Filters. Clean and change if necessary. Sludge in medium fuel oil can be a
major fault in a burner operation and
regular checking of filters and
cleaning of tanks may be necessary
if oil is only used intermittently.
12MTechnical
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FORCED DRAUGHT [PRESSURE JET] OIL BURNER07-05 07-05 FORCED DRAUGHT [PRESSURE JET] OIL BURNER
A fan assisted nozzle oil air mix fully automatic. A fan assisted nozzle oil air mix fully automatic.
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk .
Technical
Title NotesActionFQTitle FQ Action Notes
9. Motor and fan. Remove, clean and lubricate as
required, clean fan scroll.
Inspect oil pump flexible drive
coupling before re-assembling.(See
also MOTORS
3M 9. Motor and fan. Remove, clean and lubricate as
required, clean fan scroll.
Inspect oil pump flexible drive
coupling before re-assembling.(See
also Motors SFG 39-01)
3MTechnical
16. General. Check security of mechanical parts
and secure mounting of appliance.
A maintenance check should be
carried out on this type of burner
twice a year but refer to
manufacturer's specification .
All service and maintenance works
must be carried out by a
competetent engineer in
accorddance with BS 5410 codes of
practice for oil firing.
3M 16. General. Check security of mechanical parts
and secure mounting of appliance.
A maintenance check should be
carried out on this type of burner
twice a year but refer to
manufacturer`s specification .
All service and maintenance works
must be carried out by a competent
engineer in accordance with BS
5410 (http://www.bsi-global.com)
codes of practice for oil firing.
3MOther
private All service and maintenance works
must be carried out by a competent
engineer in accordance with BS
Codes of Practice for oil firing.
Deleted
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LIGHT OIL VAPORISING POT BURNER07-06 07-06 LIGHT OIL VAPORISING POT BURNER
A simple oil burner. A simple oil burner.
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk .
Technical
Title NotesActionFQTitle FQ Action Notes
10.
Recommendation.
Provide written report, which should
be signed by the service engineer
and kept by the client.
Premature failure will result if
satisfactory service is not carried
out. All service and maintenance
must be carried out by a registered
engineer in accordance with
HSAWA requirements and in
accordance with BS Code of
Practice for Oil Firing.
3M 10.
Recommendation.
Provide written report, which should
be signed by the service engineer
and kept by the client.
Premature failure will result if
satisfactory service is not carried
out. All service and maintenance
must be carried out by a registered
engineer in accordance with
HSAWA (http://www.hse.gov.uk)
requirements and in accordance
with BS Code of Practice
(http://www.bsi-global.com) for Oil
Firing.
3MOther
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GAS/OIL BURNERS - Dual fuel07-07 07-07 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 the frequency column. These units are specialised and should only be
serviced by trained personnel. This does not apply to the filters which should be cleaned by the
customer at least once per week.
Burners of this type should be serviced every three months, certain operations require a lesser
frequency and this is noted in the frequency column. These units are specialised and should only be
serviced by trained personnel. This does not apply to the filters which should be cleaned by the
customer at least once per week.
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk for detail.
Technical
Title NotesActionFQTitle FQ Action Notes
3. Ignitor. Check.3M 3. Ignition. Check.3MTechnical
4. Main shaft on
burner.
'Lift' bearings.12M 4. Main shaft on
burner.
Lift` bearings.12MOther
2. Report and
Recommendations
.
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
HSAWA requirements.
12M 2. Report and
Recommendations
.
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
HSAWA (http://www.hse.gov.uk)
requirements.
12MTechnical
Page 92 of 614
CHILLERS - WATER
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INTRODUCTORY PROCEDURES09-01 09-01 INTRODUCTORY PROCEDURES
Air conditioning equipment may come in discrete packages where a particular unit operation can be
identified with a single piece of equipment, conversely a number of unit operations can be combined
into a single `package'. These packages may be small as in a wall mounted air conditioner or they
may be large free standing units of 100 kW or more often placed on the roofs of buildings. Items of
plant producing mechanical cooling include package chillers, absorption type units, refrigerant
compressors, evaporators, refrigeration condensers and refrigeration distribution systems with their
associated controls. More detailed maintenance procedures for controls are to be found at relevant
sections.
Air conditioning and refrigeration equipment traditionally used ozone depleting refrigerant fluids as the
cooling medium. Care should be exercised to check the type of refrigerant currently in use in each
system, before service is carried out. European and UK legislation was introduced controlling the use
of CFC refrigerants for servicing and phased out their use in servicing by 2000. This action ensures
compliance with statute and avoids environmental damage. Refrigerants R134a, R407C and R410a
are typical of those currently in use.
These contractors must belong to a Certified Scheme provider, in accordance with the "F" Gas and
Building Regulations.
ALL REFIGERANTS MUST BE RECOVERED FOR RECYCLING OR DESTRUCTION
Refrigeration equipment may come in discrete packages where a particular unit operation can be
identified with a single piece of equipment, conversely a number of unit operations can be combined
into a single `package`. These packages may be small as a wall mounted versa temp type unit or they
may be large free standing units of 100 kW or more often placed on the roofs or in basements of
buildings. Items of plant in the cooling system include package chillers, absorption type units,
refrigerant compressors, evaporators, refrigeration condensers and refrigeration distribution systems
with their associated controls. More detailed maintenance procedures for controls and refrigeration
distribution systems are to be found in relevant SFG sections.
Commercial air conditioning and refrigeration equipment traditionally used ozone depleting
refrigerants in the refrigeration process. Care should be exercised to check the type of refrigerant
currently in use in each system, before service is carried out. European and UK legislation was
introduced controlling the use of HCFC refrigerants for servicing and phased out their use in servicing
by 2015. This action ensures compliance with statute and avoids environmental damage. Refrigerants
R134a, R407C and R410a are typical of those currently in use.
These providers must belong to a Certified Scheme provider, in accordance with the "F" Gas and
Building Regulations.
ALL REFIGERANTS MUST BE RECOVERED FOR RECYCLING OR DESTRUCTION.
ALWAYS UPDATE RECORDS.
Technical
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PACKAGED CHILLER UNITS09-02 09-02 PACKAGED CHILLER UNITS
Warning Chiller units may be operated remotely and it is essential that the equipment be isolated at
source before commencing any maintenance work. These notes should be read in conjunction with
the manufacturer's recommended maintenance procedures and in particular supplementary work may
be required in the case of larger units above 50kW. Many packaged water chillers have
microprocessor controls that can be interrogated using passwords. The password is usually at two
levels, level one for interrogation and level two for alterations. For service work access to level one is
required. These processors can be used for diagnostic purposes and coupled to pressure transducers
can also give pressure readings.
<B>Warning</B> Chiller units may be operated remotely and it is essential that the equipment be
isolated at source before commencing any maintenance work. These notes should be read in
conjunction with the manufacturer`s recommended maintenance procedures and in particular
supplementary work may be required in the case of larger units above 50kW. Many packaged water
chillers have microprocessor controls that can be interrogated using passwords. The password is
usually at two levels, level one for interrogation and level two for alterations. For service work access
to level one is required. These processors can be used for diagnostic purposes and coupled to
pressure transducers can also give pressure readings.
Where the installed power on the refrigeration system exceeds 25kW, a Written Scheme of
Examination may be required to comply with the Pressure Systems Safety Regulations 2000.
Personnel carrying out leak checking, gas recovery or other refrigerant handling activities such as
plant installation and maintenance must have a suitable refrigerant handling qualification. These
works are covered under EC Regulation 842/2006, Fluorinated Greenhouse Gases Regulations 2009
(FGG Regulations 2009)
ALWAYS UPDATE RECORDS
Legislative
Title NotesActionFQTitle FQ Action Notes
16. Condensers Carry out Routine Maintenance For further guidance see
Condensers SFG 13-01
3MAdded
1. Status. Check operating status. Note: With computer room chilling
units always check with computer
staff before service or maintenance.
Do not only rely on the
microprocessor readouts, always
check against calibrated equipment
if in any doubt.
3M 1. Status. Check operating status. Before undertaking the work, check
with the building manager that the
system does not serve a heat
sensitive area such as a computer
room. If it does, confirm with the
building occupants that they are
aware that work is being carried out.
Do not only rely on the
microprocessor readouts, always
check against calibrated equipment
if in doubt.
3MOther
2. Refrigeration
circuits
Check circuit pressures and
superheat temperatures. Check
alarm and run lights and remote
alarm lights associated with packs.
Refrigeration circuits should be
alternated at least every three
months by means of the 'lead/leg'
selector switch. Where operating
information is displayed on central
console, check that no
discrepancies exist between display
and master gauges, if these hese do
occur report and change
transducer(s). For non electronic
systems check installed gauges
against master gauges.
3M 2. Refrigeration
circuits
Check circuit pressures and
superheat temperatures. Check
alarm and run lights and remote
alarm lights associated with packs.
Refrigeration chillers should be
alternated at least every three
months by means of the `lead/leg`
selector switch. Where operating
information is displayed on central
console, check that no
discrepancies exist between display
and master gauges, if these do
occur report and change
transducer(s). For non electronic
systems check installed gauges
against master gauges.
3MTechnical
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3. Refrigerant Check for refrigerant and all leaks. Refrigeration circuits should be
alternated at least every three
months by means of the 'lead/leg'
selector switch. Where operating
information is displayed on central
console, check that no
discrepancies exist between display
and master gauges, if these hese do
occur report and change
transducer(s). For non electronic
systems check installed gauges
against master gauges.
3M 3. Refrigerant Check for refrigerant and all leaks. Refrigeration circuits should be
alternated at least every three
months by means of the `lead/leg`
selector switch. Where operating
information is displayed on central
console, check that no
discrepancies exist between display
and master gauges, if these do
occur report and change
transducer(s). For non electronic
systems check installed gauges
against master gauges. Systems
using R22 can only use reclaimed
stocks of gas for topping up
purposes only and this shall be
prohibited in the maintenance and
servicing of refrigeration and air
conditioning equipment from
01/01/2015.
Normal systems: <3 kg no leak test
required, 3 kg to 30 kg annual leak
test required, 30 kg to 300 kg half
yearly leak test required and >300
kg quarterly leak test required.
Hermetically sealed systems: <6 kg
no leak test required, 6 kg to 30 kg
annual leak test required, 30 kg to
300 kg half yearly leak test required
and >300 kg quarterly leak test
required.
Where a system has a refrigerant
charge greater than 300kg, an
automatic leak detection system
must be installed on the system to
comply with the F Gas Regulations
Do no overlook remote condensers
and pay particular attention to bolted
joints, sight glass stands and
atmospheric relief valve vent.
3MLegislative
5. Chilled water
supply
Check supply and return water
temperatures.
If closed system check for presence
of water.
3M 5. Chilled water
supply
Check supply and return water
temperatures.
abnormal temperatures can be a
sign of low refrigerant or poor heat
rejection
3MTechnical
7. Chiller water
flow rate.
Check that this is in accordance
with the manufacturer s
recommended figure.
3M 7. Chiller water
flow rate.
Check that this is in accordance
with the manufacturer`s
recommended figure.
3MOther
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8.Leakage Check all pumps and pipework for
leaks and rectify.
Do no overlook remote condensers
and pay particular attention to bolted
joints, sight glass stands and
atmospheric relief valve vent.
3M 8.Leakage Check all equipment and pipework
for oil and water leaks and rectify.
Check for leaks should be part of
the routine servicing. “Checked for
leakage” means that the Joints,
valves including stems, seals,
including seals on replaceable driers
and filters, parts of the system
subject to vibration, connections to
safety or operational devices of the
equipment or system is examined
for leakage using direct or indirect
measuring methods, focusing on
those parts of the equipment or
system most likely to leak. The
frequency of testing depends on
refrigerant charge and system type.
3MTechnical
9. Refrigerant
pipework.
Inspect and check for vibration,
chaffing security and leakage.
Vibration is usually the result of
loose or inadequate fixing of pipe
supports and can give rise to
leakage of refrigerant.
3M 9. Refrigerant
pipework.
Inspect and check for vibration,
chaffing, security and leakage.
Vibration is usually the result of
loose or inadequate fixing of pipe
supports and can give rise to
leakage of refrigerant.
3MOther
10. Standby
circuits.
Check operation. Vibration is usually the result of
loose or inadequate fixing of pipe
supports and can give rise to
leakage of refrigerant.
3M 10. Standby
circuits.
Check operation.3MOther
12. Digital
readouts.
Check operation. If serving computer facilities, check
that alarm is not connected to
computer shut-down system.
3M 12. Digital
readouts.
Check operation.3MOther
15. Insulation. Check condition and make good
any defects.
Poor or faulty insulation can lead to
ice build up, loss of efficiency and
energy wastage.
3M 15. Insulation. Check condition and make good
any defects however small.
Poor or faulty insulation can lead to
loss of efficiency and energy
wastage.
3MTechnical
16. Electrical. 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)
12M 17. Electrical. 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 Motors
SFG 39-01
12MOther
17. Safety
cut-outs.
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.
12M 18. Safety
cut-outs.
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.
12MOther
18. Pump
strainers.
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 or
other Mandatory scheme provider.
12M 19. Pump
strainers.
Check condition. Check waterside pressure drop
across the heat exchanger(s) for
fouling.
12MTechnical
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LITHIUM BROMIDE/WATER ABSORPTION CHILLERS09-03 09-03 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 as required by the
manufacturer, especially the specific gravity. These machines require daily recorded checks of
machine performance which are compared with the previous readings. Changes must be noted.
This is a specialised field and requires suitably competent engineers to maintain this type of
equipment.
The most important feature of an absorption system is the need to maintain as required by the
manufacturer, especially the specific gravity. These machines require daily recorded checks of
machine performance which are compared with the previous readings. Changes must be noted.
Lithium bromide/water units use water as the refrigerant. The water inside the unit will be boiling at
temperatures around 3 deg C, and condensing at temperatures only a little above ambient. To achieve
this, the units are under a high vacuum.
If the vacuum degrades, the unit will cease to function properly. Thus it is advisable to monitor the
vacuum level closely, and restore it using a vacuum pump when necessary. After any service work
that requires the unit to be opened, the vacuum, must always be restored, and the unit resealed.
A Written Scheme of Examination may be required to comply with the Pressure Systems Safety
Regulations 2000.
ALWAYS UPDATE RECORDS
Technical
Title NotesActionFQTitle FQ Action Notes
11. i. Absorber
loss, ii.
Decrystallisation,
(as required)
Determine as per manufacturer's
instructions. Experience is vital in
determining the significance of any
loss.
Recorded loss should not be greater
than 3b0 F. Measure and record:- i.
refrigerant temperature, ii.
temperature and specific gravity of
solution iii. temperature at the outlet
of the solution pump. Note:- Early
resolution of any crystallisation
problems is important as damage to
pumps may occur.
12M 11. i. Absorber
loss, ii.
Decrystallisation,
(as required)
Determine as per manufacturer`s
instructions. Experience is vital in
determining the significance of any
loss.
Recorded loss should not be greater
than 3b0 F. Measure and record:- i.
refrigerant temperature, ii.
temperature and specific gravity of
solution iii. temperature at the outlet
of the solution pump. Early
resolution of any crystallisation
problems is important as damage to
pumps may occur.
12MOther
14. Insulation Check condition and make good
any defects however small.
Poor or faulty insulation can lead to
loss of efficiency, energy wastage
and the formation of condensation.
1MAdded
15. General
Inspection
Visually inspect for corrosion,
erosion and deformities.
1MAdded
16. Pressure relief
device
Any pressure relief device should
be checked if fitted.
1MAdded
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GAS FIRED ABSORPTION CHILLER UP TO 18 KW COOLING CAPACITY09-04 09-04 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 are available in cooling only or heat pump version. Care should be
taken as the refrigeration system contains Ammonia Solutions. Only tools which are capable of
handling Ammonia should be used. Refer HSE Document PM 8I – 1995 Safe management of NH3
refrigeration systems.
These units are Direct gas fired and maintenance of the gas burners should be carried out in line with
the relevant specification. They are available in cooling only or heat pump version. Care should be
taken as the refrigeration system contains Ammonia Solutions. Only tools which are capable of
handling Ammonia should be used.
There are a number of Laws and British Standards that must be observed when working on
ammonia systems.
A Written Scheme of Examination may be required to comply with the Pressure Systems Safety
Regulations 2000.
ALWAYS UPDATE RECORDS
Legislative
Title NotesActionFQTitle FQ Action Notes
11. Ammonia
Charge
Measure and record ammonia
charge
Refer to manufacturers instructions4MAdded
12. Oil Analysis take a sample of oil for analysis If excessive moisture is found,
appropriate action shall be taken to
correct the balance. If the oil is PAG
(or similar) great care should be
taken to ensure
that the sample itself is not
contaminated during handling
4MAdded
13. Compressors,
Condensers and
Evaporators
Undertake maintenance on
Compressors
For further guidance see
Compressors SFG 12, Condensers
SFG 13 and Evaporators SFG 19
6MAdded
1. General. Check that unit is level and on good
foundations
4M 1. General. Check that unit is level and on good
foundations. Visually inspect for
corrosion, erosion and deformities.
4MTechnical
2. Condenser
fins.
Visually check and clean when
required the condenser fins.
4M 2. Condenser
fins.
Visually check and clean when
required the condenser fins.
Comb any damaged areas of fins.4MTechnical
4. Condenser
fan.
Check that condenser fan height is
at design setting.
Adjust according to instruction
manual.
4M 4. Condenser
fan.
Check that condenser fan height is
at design setting.
Adjust according to instruction
manual. See also Fans SFG 20
4MOther
8. Drive Belt. Check or replace if necessary. For further maintenance procedures
see BELT DRIVES.
4M 8. Drive Belt. Check or replace if necessary. For further maintenance procedures
see Belts SFG 04
4MOther
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COLD ROOMS AND FOOD STORAGE
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COLD ROOMS10-01 10-01 COLD ROOMS
It should be noted that the frequency of maintenance relates to equipment which is generally in clean
surroundings but where the environment is dirty, i.e. dust or fluff, more frequent maintenance may be
necessary. (See also MOTORS)
It should be noted that the frequency of maintenance relates to equipment which is generally in clean
surroundings but where the environment is dirty, i.e. dust or fluff, more frequent maintenance may be
necessary.
Refrigeration equipment containing 3kg or more of F gas refrigerant must be checked for leakage by
certified personnel on a regular basis. The frequency of testing depends on refrigerant charge and
system type.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Evaporator
coils.
Clean and check for any damage. Ensure unit thoroughly defrosted
and coils are free of ice before
putting back into service.
6M 1. Evaporator
coils.
Check for correct operation. Clean
and check for any damage.
Correct operation is indicated by
even frost formation on cooler face
and/or on distribution lines. Ensure
unit thoroughly defrosted and coils
are free of ice before putting back
into service.
6MOther
5. Pipework. Inspect and thoroughly leak test. Corrosion and chafing can occur at
duct entries and joints.
6M 5 Room Lighting Check operation and condition.6MTechnical
7. Evaporators. Check for correct operation. Correct operation is indicated by
even frost formation on cooler face
and/or on distribution lines.
6M Deleted
8.
Interconnecting
pipework (where
visible).
Check for vibration and test for
leaks. Check insulation for damage
and replace/repair as necessary.
6M 8.
Interconnecting
pipework (where
visible).
Check for vibration and test for
leaks. Check insulation for damage
and replace/repair as necessary.
Corrosion and chafing can occur at
duct entries and joints.
6MOther
9. Alarm system. Check for correct action. Chafing can occur at duct entries
and joints.
6M 9. Alarm system. Check for correct action.6MOther
11.Controls and
switches and
indicator lamps.
Carry out a visual check for wear
and arcing. Check operation of
relays, contactors and timers and
defrost time switch for correct
operation. Ensure indicator lamps
are working correctly.
6M 11.Controls,
switches and
indicator lamps.
Carry out a visual check for wear
and arcing. Check operation of
relays, contactors and timers and
defrost time switch for correct
operation. Ensure indicator lamps
are working correctly.
6MOther
12. Plant rooms
and housing.
Check ventilation not impaired. Leave clean and tidy.6M Deleted
13. Operating
temperatures.
Check for correctness, against
Certified unit.
6M 13. Operating
temperatures.
Check for correctness, against
calibrated unit.
6MOther
14. Door Lock Check for correct operation and
ensure handle is illuminated.
Ensure any personnel can exit the
cold room safely in an emergency
6MAdded
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REFRIGERATED DISPLAY CABINETS10-02 10-02 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 controlled by the type of merchandise being displayed. This schedule
relates to the main maintenance programme.
Cleaning of cabinets will normally be carried out as part of the regular store maintenance schedule
and will to some extent be controlled by the type of merchandise being displayed. This schedule
relates to the main maintenance programme.
Refrigeration equipment containing 3kg or more of F gas refrigerant must be checked for leakage by
certified personnel on a regular basis. The frequency of testing depends on refrigerant charge and
system type.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Evaporators. 6M 1. Evaporators. Check for correct operation. Clean
and check for any damage.
Correct operation is indicated by
even frost formation on cooler face
and/or on distribution lines. Ensure
unit thoroughly defrosted and coils
are free of ice before putting back
into service.
6MTechnical
2. Fans Where excessive end float or
bearing wear. Report on need for
replacement.
6M 2. Fans Check for correct operation. Clean
and check for any damage.
Where excessive end float or
bearing wear. Report on need for
replacement.
6MTechnical
4. Electrical
connections.
Check all connections and wiring. Chafing can occur at case entries
and joints.
6M 4. Electrical
connections.
Check all connections and wiring.6MOther
5. Pipework. Inspect and thoroughly leak test. Corrosion and chafing can occur at
case entries and joints.
6M 5. Pipework. Check for vibration and test for
leaks. Check insulation for damage
and replace/repair as necessary.
Corrosion and chafing can occur at
case entries and joints.
6MOther
8.
Interconnecting
pipework (where
visible).
Check for vibration and test for
leaks. Check insulation for damage
and replace/repair as necessary.
6M 8.
Interconnecting
pipework (where
visible).
Check for vibration and test for
leaks. Check insulation for damage
and replace/repair as necessary.
Corrosion and chafing can occur at
case entries and joints.
6MTechnical
9. Case
thermometer.
Check for correct reading with
Certified service thermometer.
6M 9. Case
thermometer.
Check for correct reading with
calibrated service thermometer.
6MOther
Page 102 of 614
COMMUNICATION AND P.A. SYSTEMS
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COMMUNICATIONS - PUBLIC ADDRESS SYSTEMS11-01 11-01 COMMUNICATIONS - PUBLIC ADDRESS SYSTEMS
Ensure that, following all inspection visits, conditional reports shall be submitted to the client, including
all specialist reports and test equipment printouts.
In addition, ensure that a Site Logbook is maintained on site containing duplicate copies of all the
reports information submitted to the client.
Added
Title NotesActionFQTitle FQ Action Notes
1.Microphones. Inspect and check all connection
leads, plugs and sockets, Operate
speech key and check anode
currents,
3M 1 General Clean equipment , check leads for
breaks, splits and loose
connections.
Damp wipe leads to remove
stickiness check the lead and make
repairs if necessary.
Check all amplifier connections,
knobs and sliders - tighten any that
are loose and remove excess dust
or foreign objects in those that are
sticking.
Ensure all leads are neatly coiled to
avoid twisting and tangles.
Any evidence of tampering or
damage should be recorded and
reported to the client.
12MTechnical
2.Power amplifier. Inspect and test using signal
generator.
3M 2 Audio equipment Clean the heads on audio cassette
decks, cd and minidisc players.
Leave them to dry for a few minutes
before attempting to use the player
again.
12MTechnical
3.Fire alarm
interface.
Check functioning of interface.3M 3 Speakers Check all distribution field wiring
and containment.
Check to ensure that all leads are
plugged in firmly into the correct
connectors which should also be
tightened if loose.
Ensure that sound quality is good
and free from crackling.
Inspect for damage.
Test each speaker and check
earthing where appropriate.
Check that music and other on-line
activities are cut out when
announcements are made.
12MTechnical
4.Electrical
insulation.
Measure insulation resistance of
installation cables.
12M 4 Microphones Check the base of the microphone
for bent or loose pins.
Repair if necessary.
Operate speech key and check
anode currents.
12MTechnical
5.Loud speakers. Inspect for damage. Test each
speaker and check earthing where
appropriate. Check that music and
other on-line activities are cut out
when announcements are made.
12M 5 Canon Leads Undo the screw at the side of the
canon plug, carefully remove the
centre from the casing to it`s limit
(tugging and pulling may disconnect
the wires) and check that the wires
inside are firmly soldered. Any wire
that has become detached should
be re-soldered into place.
12MTechnical
Page 104 of 614
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6. Functional test. Test system.12M Jack & Phono
Leads
Unscrew the casing and lower
gently, check that the wires are
firmly in place and re-solder if
necessary.
12MTechnical
7 Hearing
assistance
induction loop
Check loop is active and is not
suffering any `Blind Spots`.
If any found report to the client.12MAdded
8 Power supplies Check mains power supplies.
Examine all plugs and fuses for
condition.
Measure resistance of installation
cables.
12MAdded
9 System Test system is fully operational Provide a signed engineer’s report,
one copy to be left in Site Log Book
and a further copy to be submitted
to the client.
12MAdded
10. Fire Alarm
interface
Check functioning of interface.12MAdded
Page 105 of 614
COMPRESSORS - REFRIGERATION
Page 106 of 614
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COMPRESSORS REFRIGERATION - Reciprocal - (includes hermetic,
semi-hermetic and open)
12-01 12-01 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 maintenance requirements. In the case of compressors serving small air conditioning
systems which may only run during the summer months, these may require less frequent
maintenance.
For the maintenance of rotary compressors refer to the manfacturer's maintenance instructions.
These contractors must belong to an Approved Certified Scheme provider, in accordance with the "F"
Gas and Building Regulations.
These machines come in a wide range of sizes, the larger machines can be complex both in terms of
operation and maintenance requirements. In the case of compressors serving small air conditioning
systems which may only run during the summer months, these may require less frequent
maintenance.
For the maintenance of rotary compressors refer to the manufacturer`s maintenance instructions.
Where the installed power on the refrigeration system exceeds 25kW, a Written Scheme of
Examination may be required to comply with the Pressure Systems Safety Regulations 2000
Service providers must be registered to an Approved Certified Scheme provider , in accordance with
the F Gas and Building Regulations.
Technical
Title NotesActionFQTitle FQ Action Notes
4. Leaks. Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
Check for leaks should be part of
the routine servicing by plant
attendants.
6M 4. Leaks. Check for leaks should be part of
the routine servicing by plant
attendants.
Where a system has a refrigerant
charge greater than 300kg, an
automatic leak detection system
must be installed on the system to
comply with the F Gas Regulations
Technical
5. Oil in
crankcase.
Check level and condition. This should be carried out on a
monthly basis by the plant
attendant.
6M 5. Oil in
crankcase.
Check level and condition.6MOther
9. Safety
cut-outs.
Test and ensure correct operation. Include high pressure cutouts, low
pressure cutouts and oil pressure
cutouts.
6M 9. Safety
cut-outs.
Test and ensure correct operation. Include high pressure cut-outs, low
pressure cut-outs and oil pressure
cut-outs.
6MTechnical
12. Electric
motor.
Lubricate according to
manufacturer's instructions. Check
full load current.
(See also MOTORS)12M 12. Electric
motor.
Lubricate according to
manufacturer`s instructions. Check
full load current.
See also Motors SFG39-0112MTechnical
A) Normal
systems:
<3 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
B) 3 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
C) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
D) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
E) Hermetically
sealed systems:
<6 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
F) 6 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
Page 107 of 614
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G) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
H) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
Page 108 of 614
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Change
COMPRESSOR - SCREW12-02 12-02 COMPRESSOR - SCREW
These machines come in a wide range of sizes, the larger machines can be complex both in terms of
operation and maintenance requirements. In the case of compressors serving small air conditioning
systems which may only run during the summer months, these may require less frequent
maintenance.
For the maintenance of rotary compressors refer to the manufacturer`s maintenance instructions.
Where the installed power on the refrigeration system exceeds 25kW, a Written Scheme of
Examination may be required to comply with the Pressure Systems Safety Regulations 2000
Service providers must be registered to an Approved Certified Scheme provider , in accordance with
the F Gas and Building Regulations.
Added
Title NotesActionFQTitle FQ Action Notes
A) Normal
systems:
<3 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
B) 3 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
C) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
D) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
E) Hermetically
sealed systems:
<6 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
F) 6 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
G) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
H) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
4. Leaks. Check for leaks should be part of
the routine servicing by plant
attendants.
Where a system has a refrigerant
charge greater than 300kg, an
automatic leak detection system
must be installed on the system to
comply with the F Gas Regulations
Added
Page 109 of 614
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COMPRESSORS REFRIGERATION - CENTRIFUGAL - R 11/R 12
REFRIGERANT OR THEIR SUBSTITUTES R123/134a
12-03 12-03 COMPRESSORS REFRIGERATION - CENTRIFUGAL
Note:- More frequent maintenance checks should be carried out by the plant operators and local
maintenance personnel.
More frequent maintenance checks should be carried out by the client and local maintenance
personnel.
These machines come in a wide range of sizes, the larger machines can be complex both in terms of
operation and maintenance requirements. In the case of compressors serving small air conditioning
systems which may only run during the summer months, these may require less frequent
maintenance.
For the maintenance of rotary compressors refer to the manufacturer`s maintenance instructions.
Where the installed power on the refrigeration system exceeds 25kW, a Written Scheme of
Examination may be required to comply with the Pressure Systems Safety Regulations 2000
Service providers must be registered to an Approved Certified Scheme provider , in accordance with
the F Gas and Building Regulations.
Technical
Title NotesActionFQTitle FQ Action Notes
19. Leaks. Check for leaks should be part of
the routine servicing by plant
attendants.
Where a system has a refrigerant
charge greater than 300kg, an
automatic leak detection system
must be installed on the system to
comply with the F Gas Regulations
Added
17. Cooling
tower.
Check settings of cooling tower fan
controls.
See HEAT REJECTION. Check
water treatment and make up
supply. Clean all water strainers.
12M 17. Cooling
tower.
Check settings of cooling tower fan
controls.
See Heat rejection SFG30-01
Check water treatment and make up
supply. Clean all water strainers.
12MTechnical
18. Motors -
hermetic. open.
Carry out electrical insulation tests.
Check air impeller or water cooling
coil is clean and efficient. Check
motor and compressor alignment.
Ensure that the liquid supply for
cooling the motor is adequate. If
appropriate remove filter and renew.
(See also MOTORS)
12M 18. Motors -
hermetic. open.
Carry out electrical insulation tests.
Check air impeller or water cooling
coil is clean and efficient. Check
motor and compressor alignment.
Ensure that the liquid supply for
cooling the motor is adequate. If
appropriate remove filter and renew.
(See also Motors 39-01)
12MTechnical
A) Normal
systems:
<3 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
B) 3 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
C) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
D) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
E) Hermetically
sealed systems:
<6 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
F) 6 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
Page 110 of 614
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G) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
H) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
Page 111 of 614
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12-04 COMPRESSOR - SCROLL
These machines come in a wide range of sizes, the larger machines can be complex both in terms of
operation and maintenance requirements. In the case of compressors serving small air conditioning
systems which may only run during the summer months, these may require less frequent
maintenance.
Where the installed power on the refrigeration system exceeds 25kW, a Written Scheme of
Examination may be required to comply with the Pressure Systems Safety Regulations 2000
Service providers must be registered to an Approved Certified Scheme provider , in accordance with
the F Gas and Building Regulations.
Added
Title NotesActionFQTitle FQ Action Notes
1. Compressor Oil Check compressor oil level. While the compressor is running,
the oil level may be below the sight
glass but still visible through the
sight glass. The oil level
should never be above the sight
glass.
Oil Appearance. If the oil is dark and
smells burnt, it was overheated
because of compressor operation at
extremely high condensing
temperatures, a compressor
mechanical failure, or occurrence of
a motor burnout. If the oil is black
and contains metal flakes, a
mechanical failure has occurred.
This symptom is often
accompanied by a high amperage
draw at the compressor motor.
If a motor burnout is suspected, use
an acid test kit to check the
condition of the oil. If a burnout has
occurred, test results will indicate an
acid level exceeding 0.05 mg
KOH/g.
1MAdded
2. Refrigerant
Charge
Check unit refrigerant charge by
measuring sub-cooling or visually
checking the sight glass for the
presence of bubbles.
1MAdded
3. Refrigerant
superheat
Check refrigerant superheat at the
compressor suction line. Superheat
should be in the range of 10°-20°F.
1MAdded
Page 112 of 614
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4. Compressor
phasing
Check compressor phasing. Proper phasing of the electrical
power is critical for proper operation
and reliability of the scroll
compressor. If the compressor
electrical phasing is incorrect, the
motor will draw low current, the
suction and discharge pressures will
change very little, and a rumble or
rattle may be heard.
The scroll compressor does not
have suction or discharge valves.
However, the symptoms for a phase
reversal are similar to those for a
valve failure.
1MAdded
5. Electrical With the unit disconnect switch
open, inspect the panel wiring. All
electrical connections should be
secure. Inspect the compressor
contactors. If the contacts appear
severely burned or pitted, replace
the contactor. Do not clean the
contacts.
12MAdded
6. General Remove any accumulation of dust
and dirt
from the unit.
12MAdded
7. Discahrge and
suction
With unit operating, check
refrigerant
discharge and suction pressures.
12MAdded
8. Leaks. Check for leaks should be part of
the routine servicing by plant
attendants.
Where a system has a refrigerant
charge greater than 300kg, an
automatic leak detection system
must be installed on the system to
comply with the F Gas Regulations
Added
A) Hermetically
sealed systems:
<6 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
B) 6 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
C) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
D) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
Page 113 of 614
CONDENSERS
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CONDENSERS - water cooled13-01 13-01 CONDENSERS - water cooled
Title NotesActionFQTitle FQ Action Notes
4. Water strainers Check and clean. On open systems more frequent
cleaning will be necessary. Check
that condenser water is sterile
before opening any drains and
valves. Note: System could contain
legionella bacterium. Technician
should take suitable precautions.
12M 5. Water
strainers
Check and clean. On open systems more frequent
cleaning will be necessary. Check
that condenser water is sterile
before opening any drains and
valves. System could contain
legionella bacterium. Provider
should take suitable precautions.
12MOther
5. Condenser
Tubes.
Check condition, if dirty open. If
necessary clean with acid
treatment. Inspect for alkaline
deposits and/or corrosion.
If tubes are heavily scaled, refer to
water treatment contractor for
explanation as to why system is not
effective. Acid can be used for scale
removal by specialist if absolutely
necessary.
12M 6. Condenser
Tubes.
Check condition, if dirty open. If
necessary clean with a correctly
sized brush through the tubes. If
brushing does not successfully
clean the condenser consider acid
treatment. Regular use of acid will
reduce the working life of the tubes.
Inspect for alkaline deposits and/or
corrosion.
If tubes are heavily scaled, refer to
water treatment provider for
explanation as to why system is not
effective. Acid can be used for scale
removal by specialist if absolutely
necessary but can reduce the
thickness of the tube walls and
hence reduce life expectancy.
12MTechnical
6. Condenser
Shell.
Check for presence of
non-condensable gases, purge or
vent if necessary, but only if Legally
Qualified via Approved scheme..
Presence of non-condensable
gases will indicate a possible leak
on the vacuum side of the
refrigerant circuit. Take care not to
release CFCs.
12M 7. Condenser
Shell.
Check for presence of
non-condensable gases, purge or
vent if necessary, but only if legally
qualified via approved scheme..
Presence of non-condensable
gases will indicate a possible leak
on the vacuum side of the
refrigerant circuit. Do not release
refrigerant to atmosphere.
12MOther
7. Isolating
Valves.
Check external condition, leak
tightness of glands and seats,
operational spindles and
handwheels.
Repack as necessary.12M Deleted
8. Winter
Shutdown.
Isolate condensers and drain down. Seek advice from water treatment
specialist to protect from freezing.
12M 8. Winter
Shutdown.
Isolate condensers and drain down. Seek advice from water treatment
provider to protect from freezing.
Only shut down condensers where
the refrigeration and air conditioning
system has been shut down for the
winter.
12MTechnical
4. Isolating
Valves.
Check external condition, leak
tightness of glands and seats,
operational spindles and hand
wheels.
Repack as necessary.12MAdded
Page 115 of 614
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CONDENSER - air cooled13-02 13-02 CONDENSER - air cooled
Title NotesActionFQTitle FQ Action Notes
4. Motor
Mountings.
Check for security and tightness. (See also MOTORS)12M 4. Motor
Mountings.
Check for security and tightness. (See also Motors SFG39-01)12MOther
5. Condenser
coil.
Inspect and clean. Test for
refrigerant leak and oil staining on
the end of the coils.
Check for damage to fins, comb out
and chemically clean if necessary.
Blow out with dry, oxygen free
nitrogen; only fully Competent
trained staff can do this work.
3M 5. Condenser
coil.
Inspect and clean. Test for
refrigerant leak and oil staining on
the end of the coils.
Check for damage to fins, comb out.
Blow out with dry, oxygen free
nitrogen. The unit can be
chemically clean if necessary,
however, this should be at the last
resort as the fins may be damaged
further by the acid. Only fully
Competent trained staff can do this
work.
3MOther
7. Sediment. Remove, if substantial build up has
occurred, investigate cause.
Substantial build up may indicate
significant corrosion and cause
should be identified.
3M Deleted
8. Alignment and
wear of belt drives,
where applicable.
Check pulley alignment and belt
wear.
Drive belt replacement intervals
need to be established.
3M 7. Alignment and
wear of belt drives,
where applicable.
Check pulley alignment and belt
wear.
Drive belt replacement intervals
need to be established.
3MOther
9. Head pressure
control damper.
Lubricate control damper bearings.6M 8. Head pressure
control damper.
Lubricate control damper bearings.6MOther
10. Air Filters. Check and replace if necessary.6M Deleted
11. Flexible
Connections.
Check and repair/replace as
necessary.
Report faults to client.12M 9. Flexible
Connections.
Check and repair/replace as
necessary.
Report faults to client.12MOther
12. Electrical
connections.
Check and tighten as necessary.
Check condition of flexible
conduits, wiring and insulation.
12M 10. Electrical
connections.
Check and tighten as necessary.
Check condition of flexible conduits,
wiring and insulation.
12MOther
13. Pipework. Inspect connections, pipes and
supports for damage, loose or
missing fittings. Repair as
necessary.
Report faults to client.12M 11. Pipework. Inspect connections, pipes and
supports for damage, loose or
missing fittings. Repair as
necessary.
Report faults to client.12MOther
Page 116 of 614
CONTROL PANELS & CONTROLLERS
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INTRODUCTORY PROCEDURES14-01 14-01 CONTROL PANELS AND CONTROLLERS INTRODUCTORY
PROCEDURES
When working on or testing Control panels it is essential that all local and national statutory
regulations must be observed at all times. In the United Kingdom the Health and Safety at Work
etc. Act 1974 and the Electricity at Work Regulations 1989 are particularly relevant. 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 are not be taken when working on
equipment above 415 volts
Care must be taken to make sure that all remote circuits associated with the switchgear are positively
isolated before any work is carried out. The isolation must be 'secure' that is it must either be at the
point of work or precautions must be taken to prevent anyone else switching on again when work is in
progress. A circuit, whether power or control must never be assumed to be 'dead' . Voltage tests must
always be carried out with proven test equipment. i.e. a voltage tester must first be checked on a
known live source immediately before use and again after use.
Whenever cables are disconnected from switchgear in the course of maintenance or replacement,
ensure that the cables are suitably insulated 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 the correct times for operation. Check readings against a known
Certified 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 in the appropriate sections of this schedule.
Appropriate safety guides are as follows:-
HSE Guidance Note GS38 1995, Electrical test equipment for use by electricians.
When working on or testing Control panels it is essential that all local and national statutory
regulations must be observed at all times. In the United Kingdom the Health and Safety at Work etc.
Act 1974 (www.hse.gov.uk), the Electricity at Work Regulations 1989 (www.hmso.gov.uk) and BS
7671:2008 Requirements for Electrical Installations - IEE Wiring Regulations 2008 are particularly
relevant. 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 are not be taken
when working on equipment above 415 volts.
Care must be taken to make sure that all remote circuits associated with the switchgear are positively
isolated before any work is carried out. The isolation must be `secure` that is it must either be at the
point of work or precautions must be taken to prevent anyone else switching on again when work is in
progress. A circuit, whether power or control must never be assumed to be `dead`. Voltage tests must
always be carried out with proven test equipment. i.e. a voltage tester must first be checked on a
known live source immediately before use and again after use. Care must also be taken as capacitors
can discharge high voltages when all other circuits have been isolated
Whenever cables are disconnected from switchgear in the course of maintenance or replacement,
ensure that the cables are suitably insulated 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 the correct times for operation. Check readings against a known
Certified 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 in the appropriate sections of this schedule.
Appropriate safety guides are as follows:-
HSE (www.hse.gov.uk) Guidance Note GS38 1995, Electrical test equipment for use by electricians.
Technical
Page 118 of 614
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CONTROL PANELS - electrical services (excluding electrical controllers and
pneumatic relays)
14-02 14-02 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 safety procedures.
This task does not cover electrical controllers and pneumatic relays.
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14-01 introductory notes, very carefully and follow all the safety procedures.
Technical
Title NotesActionFQTitle FQ Action Notes
- direct on line. -
star delta - two
speed-dual wound
- two speed-pole
change - reversing
- auto tra
Various Types See
Notes
direct on line.
star delta
two speed-dual wound
two speed-pole change
reversing
auto transformer
Other
10. Busbar
systems.
Isolate supplies,inspect for signs of
overheating, or damage or burnt
out cables. Inspect mechanical
support systems and adjust fixings
if necessary.
Check all cable crimps for security
and fraying. Inspect crimp fasteners
for correct torque rating.
12M 10. Busbar
systems.
Isolate supplies, inspect for signs of
overheating, or damage or burnt
out cables. Inspect mechanical
support systems and adjust fixings
if necessary.
Check all cable crimps for security
and fraying. Inspect crimp fasteners
for correct torque rating.
12MOther
Page 119 of 614
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Reason For
Change
CONTROL PANELS - lamps, meters, alarms etc.14-03 14-03 CONTROL PANELS - lamps, meters, alarms etc.
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Added
Title NotesActionFQTitle FQ Action Notes
1. Circuit. Check and energise to ensure that
the indicator is operational.
Replace any blown or discoloured
bulbs as required.
Replacement bulbs should be of the
correct type and the voltage, the
power rating must be as per the
manufacturer's specification. A
device of a higher power rating
should not be used.
1M 1. Circuit. Check and energise to ensure that
the indicator is operational. Replace
any blown or discoloured bulbs as
required.
Replacement bulbs should be of the
correct type and the voltage, the
power rating must be as per the
manufacturer`s specification.
1MOther
Page 120 of 614
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OPTIMISER14-04 14-04 OPTIMISER
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.
This schedule applies to all types of controllers and requires that all safety precautions and safe
working practices be observed.
1. Note all set points 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).
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Other
Title NotesActionFQTitle FQ Action Notes
1. Outside air
temperature
sensor.
Check outside sensor for
calibration and display accuracy.
This should be on a northerly wall
away from any direct or reflected
heat gains. Where this is not
possible, the sensor should be
mechanically shaded to give the
best result.
12M 1. Outside air
temperature
sensor.
Check outside sensor for calibration
and display accuracy. This should be on a northerly wall
away from any direct or reflected
heat gains. Where this is not
possible, the sensor should be
mechanically shaded to give the
best result.
12MOther
2. Inside air
temperature
sensor.
Check inside sensor for calibration
and display accuracy.
This should be placed in the coldest
chosen representative location,
ensure that it is free from any heat
gains or air movement restrictions.
12M 2. Inside air
temperature
sensor.
Check inside sensor for calibration
and display accuracy. This should be placed in the coldest
chosen representative location,
ensure that it is free from any heat
gains or air movement restrictions.
The design of the system may
incorporate more than one inside
sensor where an average
temperature is used for the
optimiser
12MTechnical
5. Battery. Check condition. Note the life expectancy (use by
date) and change at manufacturer's
recommendation. All batteries
should be disposed of only in
accordance with H&S and
Environmental regulations.
12M 5. Battery. Check condition and change as
required
Note the life expectancy (use by
date) and change at manufacturer`s
recommendation. All batteries
should be disposed of only in
accordance with H&S and
Environmental regulations.
12MTechnical
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HEATING COMPENSATOR14-05 14-05 HEATING COMPENSATOR
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.
This schedule applies to all types of controllers and requires that all safety precautions and safe
working practices be observed.
1. Note all set points 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 supply tolerances as per manufacturer`s recommendation and adjust as
necessary.
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Other
Title NotesActionFQTitle FQ Action Notes
2. Outside air
temperature
sensor.
Check. This should be on a northerly wall
away from direct or reflected heat
gains. Where not possible, it should
have a mechanical shade.
12M 2. Outside air
temperature
sensor.
Check.
This should be on a northerly wall
away from direct or reflected heat
gains. Where not possible, it should
have a mechanical shade.
12MOther
Page 122 of 614
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Change
SINGLE INPUT CONTROLLER14-06 14-06 SINGLE INPUT CONTROLLER
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Added
Page 123 of 614
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PRE-MAINTENANCE PROCEDURES14-06 14-06 PRE-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.
This schedule applies to all types of controllers and requires that all safety precautions and safe
working practices be observed.
1. Note all set points 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 supply tolerances as per manufacturer`s recommendation and adjust as
necessary.
Before commencing any maintenance work on control panels, read SControl panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Technical
Page 124 of 614
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Change
UNIT CONTROLLERS AND SENSOR CONTROLLERS14-07 14-07 UNIT CONTROLLERS AND SENSOR CONTROLLERS
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Added
Page 125 of 614
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Change
PRE-MAINTENANCE PROCEDURES14-07 14-07 PRE-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.
This schedule applies to all types of controllers and requires that all safety precautions and safe
working practices be observed.
1. Note all set points 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 supply tolerances as per manufacturer`s recommendation, and adjust as
necessary.
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Technical
Page 126 of 614
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Change
CONTROLLER TIMERS14-08 14-08 CONTROLLER TIMERS
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Added
Title NotesActionFQTitle FQ Action Notes
3. Battery. Check condition. Note the life expectancy (use by
date) and change at manufacturer's
recommendation. All batteries
should be disposed of in
accordance with H&S Environmental
REGULATIONS.
12M 3. Battery. Check condition and change as
required
Note the life expectancy (use by
date) and change at manufacturer`s
recommendation. All batteries
should be disposed of only in
accordance with H&S and
Environmental regulations.
12MTechnical
Page 127 of 614
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Reason For
Change
PRE-MAINTENANCE PROCEDURES14-08 14-08 PRE-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.
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 timer should be checked with reference to the control strategy.
This schedule applies to all types of controllers and requires that all safety precautions and safe
working practices be observed.
1. Note all set points 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 supply tolerances as per manufacturer`s recommendation and adjust as
necessary.
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 timer should be checked with reference to the control strategy.
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Technical
Page 128 of 614
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STEP CONTROLLERS14-09 14-09 STEP CONTROLLERS
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Added
Title NotesActionFQTitle FQ Action Notes
4. Drive
motor/gear box.
Check operation in both directions. Where actuators are involved see
relevant section.
12M 4. Drive
motor/gear box.
Check operation in both directions. Where actuators are involved see
relevant section Actuators SFG
01-01.
12MTechnical
Page 129 of 614
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Change
PRE-MAINTENANCE PROCEDURES14-09 14-09 PRE-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.
This schedule applies to all types of controllers and requires that all safety precautions and safe
working practices be observed.
1. Note all set points 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 supply tolerances as per manufacturer`s recommendation and adjust as
necessary.
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Technical
Page 130 of 614
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Change
TIMESWITCHES14-10 14-10 TIMESWITCHES
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Added
Title NotesActionFQTitle FQ Action Notes
1. Clocks. Check for satisfactory operation
and correct time.
Adjust for British Summer
Time/Greenwich Mean Time as
necessary.
12M 1. Clocks. Check for satisfactory operation
and correct time.
Adjust for British Summer
Time/Greenwich Mean Time as
necessary.
6MOther
5. Monthly dial
settings e.g. for
solar time
switches.
Inspect and check. Replace battery at manufacturer's
recommendations.Batteries should
be disposed of in accordance with
H&S Environmental regulations.
12M 5. Monthly dial
settings e.g. for
solar time
switches.
Inspect and check. Replace battery at manufacturer`s
recommendations. Batteries should
be disposed of in accordance with
H&S
(www.hse.gov.uk/hthdir/noframes/co
shh/index.htm) Environmental
regulations.
12MOther
1. Time clocks. Check for satisfactory operation
and correct time.
Adjust time for British Summer
Time/Greenwich Mean Time as
necessary.
12M 1. Time clocks. Check for satisfactory operation
and correct time.
Adjust time for British Summer
Time/Greenwich Mean Time as
necessary.
6MOther
5. Battery back
up (if fitted).
Check condition. Replace battery according to
manufacturer's recommendations.
All batteries should be disposed of
in accordance with H&S
Environmental regulations.
12M 5. Battery back
up (if fitted).
Check condition and change as
required
Note the life expectancy (use by
date) and change at manufacturer`s
recommendation. All batteries
should be disposed of only in
accordance with H&S and
Environmental regulations.
12MTechnical
Page 131 of 614
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Change
PRE-MAINTENANCE PROCEDURES14-10 14-10 PRE-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.
This schedule applies to all types of controllers and requires that all safety precautions and safe
working practices be observed.
1. Note all set points 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 supply tolerances as per manufacturer`s recommendation and adjust as
necessary.
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Other
Page 132 of 614
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Change
MULTI-INPUT CONTROLLERS14-11 14-11 MULTI-INPUT CONTROLLERS
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Added
Page 133 of 614
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Reason For
Change
PRE-MAINTENANCE PROCEDURES14-11 14-11 PRE-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.
This schedule applies to all types of controllers and requires that all safety precautions and safe
working practices be observed.
1. Note all set points 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 supply tolerances as per manufacturer`s recommendation and adjust as
necessary.
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Technical
Page 134 of 614
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INDICATORS AND DISPLAYS14-12 14-12 INDICATORS AND DISPLAYS
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Added
Page 135 of 614
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ALARM MODULES14-13 14-13 ALARM MODULES
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Added
Page 136 of 614
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LEVEL CONTROLLERS14-14 14-14 LEVEL CONTROLLERS
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Added
Page 137 of 614
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Change
PRE-MAINTENANCE PROCEDURES14-14 14-14 PRE-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.
This schedule applies to all types of controllers and requires that all safety precautions and safe
working practices be observed.
1. Note all set points 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 supply tolerances as per manufacturer`s recommendation and adjust as
necessary.
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Technical
Page 138 of 614
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SPEED CONTROLLERS14-15 14-15 SPEED CONTROLLERS
Electronic inverter type.
WARNING:- Due to the very high voltages present within this type of controller it is essential
that all safety precautions are strictly followed. The equipment must only be serviced by
competent and qualified personnel. The manufacturer's testing and maintenance procedures
including all safety precautions must be strictly followed.
Electronic inverter type
<B>WARNING</B>:- Due to the very high voltages present within this type of controller it is essential
that all safety precautions are strictly followed. The equipment must only be serviced by competent
and qualified personnel. The manufacturer`s testing and maintenance procedures including all safety
precautions must be strictly followed.
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Overheating. Check for signs of overheating.12M 1. Overheating. Check for signs of overheating. Report any signs of over heating to
the client with proposed remedial
works
12MOther
Page 139 of 614
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Change
PRE-MAINTENANCE PROCEDURES14-15 14-15 PRE-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.
This schedule applies to all types of controllers and requires that all safety precautions and safe
working practices be observed.
1. Note all set points 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 supply tolerances as per manufacturer`s recommendation and adjust as
necessary.
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Technical
Page 140 of 614
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TRANSDUCERS - pneumatic to electronic and electronic to pneumatic14-16 14-16 TRANSDUCERS - pneumatic to electronic and electronic to pneumatic
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14 introductory notes, very carefully and follow all the safety procedures.
Added
Page 141 of 614
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14-17 DIRECT CURRENT [DC] DRIVES
Title NotesActionFQTitle FQ Action Notes
1. Drive Clean all dust and foreign material
that can cause cooling problems,
cause corrosion and cause
problems with arcing.
12MAdded
2. Motor Check motor resistance and
connections see Motors SFG 39-01
Motors often exhibit changes in
resistance prior to failing.
12MAdded
3. Wiring Check and tighten [if loose] all
wiring connections.
12MAdded
4. Test Test that the power supplies have
not drifted out of tolerance. Check
the output waveforms at the
reference and feedback signals.
12MAdded
5. Signal wiring Verify signal wiring shielding is
properly terminated and the
connections are all tight.
Improper shielding can cause erratic
and intermittent behaviour of drive
equipment, and loose signal wiring
is a primary cause of drive
equipment downtimes.
12MAdded
Page 142 of 614
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14-18 EMERGENCY STOP BUTTONS
Test all emergency stop devices. A wiring error or other problems may not be apparent until the
emergency stop device is tested. Push all buttons. Pull all pull cords, activate all emergency stop
devices. If any fail to create the emergency stop condition, count this as a failed test.
Once control power is back on, any any faults cleared, pressing the START button should result in the
machine / equipment restarting. This is correct and the test has been passed.
Added
Title NotesActionFQTitle FQ Action Notes
1. Emergency
Stop buttons
Check correct operation of
Emergency Stop Buttons in
accordance with requirements of
PUWR Regulations.
If resetting the emergency stop
device results in control power
being re-applied, count this as a
failed test.
If you break or damage the machine
/ equipment while testing the
emergency stop system, count this
as a failed test. Advise Client.
3MAdded
2. Start function
test
Once the emergency stop device
has been activated, control power is
normally lost. Pressing any START
function on the control panel,
except POWER ON or RESET
should have no effect. If any aspect
of the machine / equipment starts,
count this as a failed test.
Advise Client.3MAdded
3. Power on or
reset test
Pressing POWER ON or RESET
before the activated emergency
stop device has been reset (i.e. the
e-stop button has been pulled out
to the `operate` position), should
have no effect. If you can turn the
power back on beofre you reset the
emergency stop device, count this
as a failed test.
Advise Client.3MAdded
4. Machine /
Equipment restart
test
Once the emergency stop device
has been reset, pressing POWER
ON or RESET should result in the
control power being restored. This
is acceptable. The machine /
equipment should not restart. If the
machine restarts normal operation,
count this as a failed test.
Advise Client.3MAdded
Page 143 of 614
DUCTING
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INTRODUCTORY PROCEDURES16-01 16-01 DUCTING AND AIR DISTRIBUTION INTRODUCTORY PROCEDURES
Ducting and air distribution
When installed, new ductwork must be certified clean and therefore not normally require internal
cleaning. However during use over a period, subject to use, a build up of deposits will 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 TR/19)>
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.
Ducting and air distribution
When installed, new ductwork must be certified clean and therefore not normally require internal
cleaning. However during use over a period, subject to use, a build up of deposits will 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 B&ES (the Building
& Engineering Services Association, formerly the HVCA) Ventilation Hygiene Guide to Good Practice
(see TR/19)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.
(Ductwork cleaning SFG 17.01)
Other
Page 145 of 614
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DUCTWORK SYSTEM - GENERAL16-02 16-02 DUCTWORK SYSTEM - GENERAL
Note:- Special requirements are necessary in the food and process industries, clean room
applications and kitchens
Special requirements are necessary in the food and process industries, clean room applications and
kitchens
Other
Title NotesActionFQTitle FQ Action Notes
6. Ductwork
Support
Check all ductwork supports and
handers to ensure they are secure
and not loose
Report to client if remedial work
required.
12MAdded
7. Hit Hazards Inspect duct run where it runs
across or parallel to a personnel
access route. Highlight any low
points with the appropriate hazard
tape or paint
12MAdded
5. Internal
cleanliness.
Check internal condition through
sampling points (test points) where
fitted.
12M 5. Internal
cleanliness.
Check internal condition through
sampling points (test points) where
fitted.
Report to client if remedial work
required.
12MTechnical
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DUCTING - VOLUME CONTROL DAMPERS AND FIRE/ SMOKE DAMPERS16-03 16-03 DUCTING - VOLUME CONTROL DAMPERS AND FIRE/ SMOKE DAMPERS
Caution
All volume dampers are set up during commissioning and should not normally be subject to further
adjustment unless modifications are made to the ductwork distribution system. If it is essential to
move the damper for maintenance purposes extreme care should be taken to ensure that the damper
is returned to the position as set when commissioned. In the event of a ductwork modification, the
system should then be re-commissioned. Refer to HVCA TR/19 Section 3 for access requirements
and section 4 Para 4.19 & 4.20 for specific considerations.
Refer to HVCA publication DW145 for Fire Damper detail.
Typically a log of all dampers should be kept to record the results of the inspection , any
recommendations and any remedial work carried out.
Caution
All volume dampers are set up during commissioning and should not normally be subject to further
adjustment unless modifications are made to the ductwork distribution system. If it is essential to
move the damper for maintenance purposes extreme care should be taken to ensure that the damper
is returned to the position as set when commissioned. In the event of a ductwork modification, the
system should then be re-commissioned. Refer to B&ES (the Building & Engineering Services
Association, formerly the HVCA) TR/19 Section 3 for access requirements and Section 4 para 4.19 &
4.20 for specific considerations.
Refer to B&ES publication DW145 for Fire Damper detail.
Typically a log of all dampers should be kept to record the results of the inspection , any
recommendations and any remedial work carried out.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Volume control
dampers.
1. Visual check on condition.2.
Check position and ease of
movement and security of locking
devises.
The dampers should have the 'as
found' setting marked indelibly to
aid re-setting.Ensure that damper
opens and closes to desired
positions.
6M 1. Volume control
dampers.
1. Visual check on condition.
2. Check position and ease of
movement and security of locking
devises.
The dampers should have the `as
found` setting marked indelibly to
aid re-setting.
Ensure that damper opens and
closes to desired positions.
6MOther
2. Fire and
smoke dampers.
1. Visual check on condition.2.
Check action and proper operation.
Inspect all dampers, apply a few
drops of oil to the mechanism.
Replace fusible links if required.
These may be subject to the
requirements of the local fire
brigade. Maintain a log of all
dampers tested, record faults and
any remedial action taken. This will
provide proof to the local fire
brigade that regular checks are
maintained. If any fire dampers are
inaccessible advise client.
6M 2. Fire and
smoke dampers.
1. Visual check on condition. If
damper is shut confirm that this is a
requirement of normal operation. (it
is possible that the fire damper may
have shut during a fire alarm
activation and has not been reset)
2. Check action and proper
operation. Inspect all dampers,
apply a few drops of oil to the
mechanism. Replace fusible links if
required.
These may be subject to the
requirements of the local fire
brigade. Maintain a log of all
dampers tested, record faults and
any remedial action taken. This will
provide proof to the local fire
brigade that regular checks are
maintained. If any fire dampers are
inaccessible advise client.
The dampers can accumulate dirt
which can affect their operation and
may require access panels added to
one or both sides to allow full
cleaning and surface restoration.
3MTechnical
3. Linkages on
motorised
dampers.
1. Visual check on condition.2.
Check for wear and lubricate if
appropriate.
Please refer to notes on Item 1.
Volume control dampers.Ensure that
blades on shaft are secure and are
correctly aligned.
6M 3. Linkages on
motorised
dampers.
1. Visual check on condition.
2. Check for wear and lubricate if
appropriate.
Ensure that blades on shaft are
secure and are correctly aligned.
6MOther
5. Electrical. Check for damage to flexible
conduits. Tighten all terminal
connections. Isolate control panel
and inspect for signs of
overheating. Check integrity of
electrical insulation.
For detailed maintenance
information see CONTROL
PANELS.
6M 5. Electrical. Check for damage to flexible
conduits. Tighten all terminal
connections. Isolate control panel
and inspect for signs of
overheating. Check integrity of
electrical insulation.
For detailed maintenance
information see Control panels and
controllers SFG14-01.
6MTechnical
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DUCTING - Acoustics16-04 16-04 DUCTING - Attenuators
Title NotesActionFQTitle FQ Action Notes
3. Attenuators
(external
surfaces).
Clean, derust and repaint as
required.
For attenuators on COOLING
TOWERS see relevant section.
12M 3. Attenuators
(external
surfaces).
Clean, descale and repaint as
required.
12MTechnical
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DUCTWORK CLEANING
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DUCTWORK CLEANING HYGIENE, INSPECTIONS & MONITORING17-01 17-01 DUCTWORK CLEANING HYGIENE, INSPECTIONS & MONITORING
Note:- H&S Regulations apply and specific Risk Assessments will be required. A variety of specifically hazardous contaminants may be found in the ventilation systems , especially in
industrial or laboratory Local Exhaust Ventilation systems (LEV) whose performance falls under
COSHH regulations.
Reference Health and Safety at Work Regulations.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Ductwork. Ascertain age and date of last
clean
12M 1. Ductwork. Ascertain age and date of last
inspection.
12MOther
2. Ductwork
Hygiene.
Check internal condition by a
Deposit Thickness test or Vacuum
Test.
See HVCA Cleanliness of
Ventilation Systems ref. TR/19. If
inspection indicates a full cleaning
regime is required, inform client.
12M 2. Ductwork
Hygiene.
Check internal condition by a
Deposit Thickness test or Vacuum
Test.
Frequency to be determined by risk
assessment and testing regime as
per B&ES (the Building &
Engineering Services Association,
formerly the HVCA) Cleanliness of
Ventilation Systems ref. TR/19 and
BS EN 15780:2011 both of which
itemises the testing methods to be
adopted.
If inspection indicates a full cleaning
regime is required, inform client. If
the inspection reveals a build up of
moisture, identify the potential
source of moisture, inform client and
seek additional guidance from a
qualified Environmental Specialist
12MTechnical
3. Kitchen Extract
Ductwork.
Totally Clean. This is minimum cleaning interval,
heavy use, i.e. 12-16 hours per day
will necessitate a 3 monthly clean.
The exact timing will depend on a
range of factors, a new system
needs to be monitored to establish
the suitable minimum period.
12M 3. Kitchen Extract
Ductwork.
Clean in accordance with TR/19
section Section7.28 and 7.34.
This is minimum cleaning interval,
heavy use, i.e. 12-16 hours per day
will necessitate a 3 monthly clean
where light use i.e. 2-6 hours per
day will necessitate a 12 monthly
clean. The exact timing will depend
on a range of factors, a new system
needs to be monitored to establish
the suitable minimum period.
12MTechnical
Page 150 of 614
ELECTRICS IN BUILDINGS
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INTRODUCTORY PROCEDURES18-01 18-01 INTRODUCTORY PROCEDURES
1 Specification
The specification covers the subjects of power supplies and associated electrical equipment up to 400
V, lighting, security and fire alarms, small scale power generation, communication systems and
provides an authoritative maintenance specification for these types of equipment. Regular
preventative maintenance is essential on electrical equipment as breakdowns can affect production ,
environmental conditions and energy wastage.
The maintenance frequencies shown in the schedules represent the intervals as recommended by the
HVCA and ECA, the actual frequencies will depend upon the particular application and should be
agreed with the client. It may be appropriate that certain elements of the 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 or flame. When maintaining cables, cabinets or junction boxes it is
essential that the integrity of the seals is maintained. Where a seal is replaced, 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 the relevant 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 work associated 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 - Regulations of the Institution of Electrical Engineers (IEE
Regulations).
4. Maintenance of Systems
The maintenance activity in respect of a system should be 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.
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 these circumstances 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 be present in older equipment, such as transformers and
capacitors. Extreme care should be taken with regard to their disposal and the appropriate statutory
regulations must be strictly followed.
5. Maintenance in Hazardous Areas
Certain areas such as those containing flame proof equipment, pharmaceutical laboratories, locations
subject to possible contamination by radiation, clean rooms, high risk fume cupboards and
inflammable risk situations call for specialist maintenance procedures which should be negotiated
individually with the client.
1. Specification
The specification covers the subjects of power supplies and associated electrical equipment up to 400
V, lighting, security and fire alarms, small scale power generation, communication systems and
provides an authoritative maintenance specification for these types of equipment. Regular
preventative maintenance is essential on electrical equipment as breakdowns can affect production ,
environmental conditions and energy wastage.
The maintenance frequencies shown in the schedules represent the intervals as recommended by the
HVCA (www.hvca.org.uk/) and ECA (www.eca.co.uk), the actual frequencies will depend upon the
particular application and should be agreed with the client. It may be appropriate that certain elements
of the 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 or flame. When maintaining cables, cabinets or junction boxes it is
essential that the integrity of the seals is maintained. Where a seal is replaced, 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 the relevant British Standard (www.bsi-global.com).
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 work associated 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 - Regulations of the Institution of Electrical Engineers (IEE (www.iee.org.uk)
Regulations).
4. Maintenance of Systems
The maintenance activity in respect of a system should be carried out by suitably qualified and
experienced providers, 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.
While it is not always possible to rigidly follow a set procedure in every situation, guidance is given in
HSG 85 "Electricity at Work safe working practices" the following sequence is recommended as a
guide.
Identification - For most circuits and equipment correct labelling is important, but it should never be
assumed that labelling is correct and that work can be started without having first proved that the
equipment or circuit is dead. In some special cases, e.g. underground cables, cable locating
techniques using specialised instruments may be necessary and it may also be necessary to identify
the cable both before and after switching operations and cable spiking.
Disconnection - Disconnect the equipment from every source of electrical energy before working on,
or near, any part which has been live or is likely to be live.
Secure Isolation - To ensure adequate isolation, the disconnecting device should have an isolating
Technical
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gap sufficient for the voltage levels present or likely to occur . Make sure that any switch disconnector
or other means of disconnection is secure. Switches should preferably be locked in the OFF position
using a ‘safety’ lock, i.e. a lock having a unique key. If a plug has been withdrawn, make sure that it
cannot be reconnected to the electrical supply while work is taking place on the circuits or apparatus.
If a fuse is removed, make sure that it or a similar one cannot be reinserted by taking it away or by
locking the box or enclosure until work is completed.
Post notices - Put a notice or label at the place of disconnection so everyone else knows that work is
being done.
Proving dead - Having isolated the circuit or equipment, check at the point of work that the parts to be
worked on or near really are dead, even if the isolation has been achieved automatically through an
interlocking system. If it is a three phase system or equipment with more than one supply, prove that
all supply conductors are dead. The device used for proving dead should itself be proved immediately
before and after testing.
Earthing - all the conductors are earthed using properly designed earthing devices or earthing leads,
usually applied to all points where the circuit or equipment is isolated from the supply.
Adjacent parts - When the circuit or equipment to be worked on has been made dead or where the
work is non-electrical, it may still be necessary to protect against inadvertent contact with other live
parts nearby.
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 these circumstances 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 be present in older equipment, such as transformers and
capacitors. Extreme care should be taken with regard to their disposal and the appropriate statutory
regulations must be strictly followed.
Asbestos – On older types of switchgear there is a risk that the arcshields may contain asbestos. The
asbestos register should be checked to see if there is any reference to the particular piece of
equipment due to be maintained. ALWAYS check for asbestos containing material prior to dismantling
any equipment. If asbestos, take actions in accordance with the Asbestos Regulations. Refer to
www.hse.gov.uk (www.hse.gov.uk) for detail.
5. Maintenance in Hazardous Areas
Certain areas such as those containing flame proof equipment, pharmaceutical laboratories, locations
subject to possible contamination by radiation, clean rooms, high risk fume cupboards and
inflammable risk situations call for specialist maintenance procedures which should be negotiated
individually with the client.
Page 153 of 614
EVAPORATORS
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EVAPORATORS19-01 19-01 REFRIGERATION EVAPORATORS
Title NotesActionFQTitle FQ Action Notes
1. Compressor
full load operation.
Record inlet and outlet temperature
on water side. Pressure drop
across evaporator, refrigerant
pressures or superheat
temperatures and evaporator
temperature.
Any marked difference to the design
figures could indicate internal fouling
of the condenser and may require
additional work.
12MAdded
2. Flow
protection devices
Check for chilled water flow in the
system and correct operation.
12MAdded
3. Pump. Check and record pressure drop
across pump. Check for leakage,
bearing noise and unusual bearing
temperature. Lubricate according to
manufacturers instructions. Check
motor current.
For further guidance see Pumps
SFG 45-01
12MAdded
4. Automatic
Isolating Valves.
Check external condition, leak
tightness of glands and seats,
operational spindles and solenoid.
Some chillers have the ability to
automatically pump down refrigerant
to the evaporators in the event of a
refrigerant leak or other fault. For
further guidance see the
manufacturers instructions
12MAdded
2. Filter-Dryers Where fitted replace the filter
dryer(s) as required
check in line sight glass for
indication of moisture in system
6MAdded
7. Fans (if
applicable)
Check for correct operation and
clean fan blades as required
For further guidance see Fans SFG
20
6MAdded
1. Tank/shell. Check external and internal
condition including baffles and
covers.
Liquid level for water cooling, brine
or glycol systems should be noted
and any leaks investigated.
12M 5. Tank/shell. Check external and internal
condition including baffles and
covers.
Liquid level for water cooling, brine
or glycol systems should be noted
and any leaks investigated and
repaired
12MOther
2. Valves and
drains.
Check external condition, leak
tightness of glands and seats.
Ensure valve caps are tight and
secure. Check operation.
12M 6. Valves and
drains.
Check external condition, leak
tightness of glands and seats.
Ensure valve caps are tight and
secure. Check operation.
For further guidance see Valves
SFG 61
12MTechnical
3. Pipes and
connections.
Check external condition and leak
tightness.
12M 7. Pipes and
connections.
Check external condition and leak
tightness.
12MOther
4. Bearers,
supports, holding
down bolts.
Check for security and tighten as
necessary.
12M 8. Bearers,
supports, holding
down bolts.
Check for security and tighten as
necessary.
12MOther
5. Insulation. Check for damage.12M 9. Insulation. Check for damage. Repair as required.12MOther
6. Frost
Protection.
Check regime including cables and
thermostats.
12M 10. Frost
Protection.
Check regime including cables and
thermostats. Where fitted check
that the defrost system is operating
satisfactorily
12MTechnical
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1. Leaks. Inspect for leaks.6M 1. Leaks. Inspect for leaks. Fore further guidance on the
refrigerant side of this task see
Compresors - refrigeration SFG 12
6MTechnical
2. Coil. Check condition and clean fins. Use a sterilising solution.6M 3. Coil. Check condition and clean fins. Use a sterilising solution.6MOther
3. Condensate
tray and drain.
Check and ensure drain clear.
Flush and sterilise if necessary.
6M 4. Condensate
tray and drain.
Check and ensure drain clear.
Flush and sterilise if necessary.
6MOther
4. Condensate
pump (if
applicable)
Check operation. Often this equipment may be
contaminated, clean and flush,
sterilise if necessary.
6M 5. Condensate
pump (if
applicable)
Check operation. Often this equipment may be
contaminated, clean and flush,
sterilise if necessary.
6MOther
5. Electric
Heaters.
Check condition and operation.6M 6. Electric
Heaters.
Check condition and operation.6MOther
Page 156 of 614
FANS
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INTRODUCTORY PROCEDURES20-01 20-01 INTRODUCTORY PROCEDURES
Movement of air, other than by natural circulation, is achieved by means of fans which are
mechanically driven, hence before working on any fan the drive must 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 of their specialist nature and the hazardous circumstances of use,
fans associated with fume cupboards, radioactive and nuclear facilities and biological 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. It should 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 exceeding six 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 from service 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 the requirements of any Health and Safety at Work legislation .
Movement of air, other than by natural circulation, is achieved by means of fans which are
mechanically driven, hence before working on any fan the drive must be electrically isolated in
accordance with Health and Safety (www.hse.gov.uk) legislation.
The isolator should be locked in the off position when maintenance takes place .
Types of fan covered in this section include centrifugal, axial, propeller, mixed flow, bifurcated and fire
and smoke extract units. Because of their specialist nature and the hazardous circumstances of use,
fans associated with fume cupboards, radioactive and nuclear facilities and biological and clinical
areas require specialist attention which is outside the scope of this specification.
General
If the system incorporates two fans, one for regular use and the second for back-up use if the primary
unit should fail, it is essential that both units be used and that similar levels of maintenance are
applied to both units.
After cleaning and servicing the fan, a label should be placed on the fan housing with details of the
current service date and any
relevant contact information. The label should also indicate the date at which the next routine
maintenance inspection is due.
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. It should be noted that any fans which are supplied as bare
shaft units must be guarded to BS (www.bsi-global.com) 5304 before start-up.
2. Fan rotation
It is essential to note that even when electrically isolated, some fans can have a tendency to rotate
under the action of the ventilation. It is therefore recommended that impellers are locked with integral
brakes (if fitted) or other means if no brake exists.
3. Erosion and/or Corrosion
Where fans operate in an erosive or corrosive atmosphere, the fan rotating assembly must be
inspected at regular intervals (not exceeding six 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 from service for repair or
replacement
4. Access
Where fan access cannot be readily obtained, it is the responsibility of the client to provide access
facilities which comply in full with the requirements of any Health and Safety at Work legislation .
Technical
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FANS - VENTILATING - general20-02 20-02 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 machinary switch off and ensure
that the equipment is isolated electrically in accordance with Health and Safety at Work Regulations.
Ensure to read health and safety notes shown on SFG 20-01 before undertaking the following tasks.
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 and Safety at Work
(www.hse.gov.uk) Regulations.
The isolator should ideally be locked in the off position when maintenance takes place .
Other
Title NotesActionFQTitle FQ Action Notes
1. Bearings.
(`sealed for life'
bearings should
not be serviced).
Inspect and lubricate as necessary. Check bearings for end play and
wear.
6M 1. Bearings. Sealed for life` bearings should not
be serviced.
Inspect and lubricate as necessary.
Where applicable, all set-screws in
bearings should be checked and
tightened.
Check bearings for end play and
wear. Report any faults to the client.
If lubricators are provided,
re-lubrication should not exceed a
period of two years. When carrying
out re-lubrication it is essential that
every trace of water and dirt is
removed from around the grease
nipple. If the operating temperature
is over 60o C a shorter re-lubricating
period will be necessary. Ensure
that the correct oils and/or greases
and quantities are used. It is
particularly important that lubricants
of the correct working range are
used. Oil attracts dust and as a
consequence any excess should be
wiped clear (e.g. fan blades) see
manufacturer`s instructions.
6MTechnical
2. Housing. Clean and inspect for looseness
and corrosion.
6M 2. Housing. Clean and inspect for looseness
and corrosion.
Re-paint with a suitable corrosion
resistant paint as required.
6MTechnical
3. Drives and
belts.
Inspect, check condition and
alignment of drive and shaft. Adjust
or replace if condition warrants it.
6M 3. Drives, guards
and belts.
Inspect, check condition and
alignment of drive and shaft.
Adjust or replace if condition
warrants it.
Check all guards are secure and in
place.
When a new belt (or a new fan) has
been installed, the belt should be
re-tensioned after two weeks in
order to take up any slackness
resulting from stretching.
Guards should be painted a suitable
colour, so that they stand out.
1MTechnical
7. Anti-vibration
mountings.
Check effectiveness.6M 7. Anti-vibration
mountings.
Check effectiveness. The rubber/neoprene can degrade
with age and use. Report any faults
to the client.
6MTechnical
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10. Motor and fan
blade - cleaning
Clean and inspect all grilles. Clean
all dirt from the outside of any
motor.
Clean fan blades. Check for
excessive imbalance.
If dirt builds up on a motor it can act
as insulation which causes the
motor to operate at elevated
temperatures, resulting in shortened
motor life can be shortened and
motors commonly burn-out of
motors.
An excessive build up of dust or
damage to the fan blade can add
imbalance causing excessive
vibration. This can lead to fatigue
and dangerous failure.
Dirt should be removed by cleaning
with suitable equipment.
Fan blades and louvers can be
cleaned with a brush and detergent.
The fan motor casing must be totally
enclosed to prevent water from
damaging motor windings. If the
motor is not totally enclosed, then it
must be removed and cleaned
separately before the housing is
cleaned. If using a brush or
high-pressure washer care must be
taken not to damage the impeller
blades.
6MAdded
11. Motors -
electrical
Check the electrical and thermal
overload protection for the
motor, and if the motor has a
resettable overload protection.
Check that it is fully operational.
6MAdded
12. Electrics A) Check circuit breakers manually
each month.
Examine wiring and other electrical
system components for signs of
deterioration, loose connections
and damage. Check all connections
are tight.
1MAdded
12. B) Clean any sensors re-calibrate if
found to be inaccurate.
6MAdded
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FANS -CENTRIFUGAL20-03 20-03 FANS -CENTRIFUGAL
Ensure to read health and safety notes shown on SFG 20-01 before undertaking the following tasks.
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 and Safety at Work
(www.hse.gov.uk) Regulations.
The isolator should be locked in the off position when maintenance takes place .
Added
Title NotesActionFQTitle FQ Action Notes
7. Motor and fan
blade - cleaning
Clean and inspect all grilles. Clean
all dirt from the outside of any
motor.
Clean fan blades. Check for
excessive imbalance.
6MAdded
8. Motors -
electrical
Check the electrical and thermal
overload protection for the
motor, and if the motor has a
resettable overload protection.
Check that it is fully operational.
6MAdded
9. Electrics Check circuit breakers manually
each month.
Examine wiring and other electrical
system components for signs of
deterioration, loose connections
and damage. Check all connections
are tight.
1MAdded
9. Electrics Clean any sensors re-calibrate if
found to be inaccurate.
6MAdded
1. Impeller and
spinnings.
Clean and ensure no build up of
dirt.
In very dusty environments or where
contaminants are present more
frequent cleaning may be
necessary. If possible avoid
scraping but if necessary carry out
lightly. With plastic impellers soapy
water is the most effective cleaner.
12M 1. Impeller and
inlet venturi.
Clean and ensure no build up of
dirt.
In very dusty environments or where
contaminants are present more
frequent cleaning may be
necessary. If possible avoid
scraping but if necessary carry out
lightly. With plastic impellers soapy
water is the most effective cleaner.
12MOther
2. Motor
assembly.
Inspect.12M 2. Motor
assembly.
Inspect and check for any loose
connections, fixings or cables
12MTechnical
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3. Motor
bearings. (`Sealed
for life' bearings
should not be
serviced).
Lubricate with recommended
lubricant at intervals noted on fan
nameplate.
When carrying out lubrication it is
essential that every trace of water or
dirt is removed from around the
grease nipple. (See also MOTORS).
3. Bearings. Sealed for life` bearings should not
be serviced.
Inspect and lubricate as necessary.
Where applicable, all set-screws in
bearings should be checked and
tightened.
Check bearings for end play and
wear. Report any faults to the client.
When carrying out lubrication it is
essential that every trace of water or
dirt is removed from around the
grease nipple. (See also Motors
SFG 39-01.
Ensure that the correct oils and/or
greases and quantities are used. It
is particularly important that
lubricants of the correct working
range are used. Oil attracts dust and
as a consequence any excess
should be wiped clear (e.g. fan
blades) see manufacturer`s
instructions.
Technical
5. Belt drive (if
fitted).
Check tension and adjust if
necessary. Replace if aligned
condition warrants it.
Ensure motor and drive and pulley
are correctly aligned otherwise
excessive wear will occur on the
sides of the belt.
6M 5. Belt drive and
guards (if fitted).
Check tension and adjust if
necessary. Replace if condition
warrants it. Check all guards are
secure and in place.
Ensure motor and drive and pulley
are correctly aligned otherwise
excessive wear will occur on the
sides of the belt.
Guards should be painted a suitable
colour, so that they stand out.
6MOther
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FANS- AXIAL20-04 20-04 FANS- AXIAL
Ensure to read health and safety notes shown on SFG 20-01 before undertaking the following tasks.
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 and Safety at Work
(www.hse.gov.uk) Regulations.
The isolator should be locked in the off position when maintenance takes place .
Added
Title NotesActionFQTitle FQ Action Notes
2. Motor
bearings. (`Sealed
for life' bearings
should not be
serviced).
Lubricate with recommended
lubricant at intervals noted on fan
nameplate.
When carrying out lubrication it is
essential that every trace of water or
dirt is removed from around the
grease nipple. (See also MOTORS).
3M 2. Bearings. Sealed for life` bearings should not
be serviced.
Inspect and lubricate as necessary.
Where applicable, all set-screws in
bearings should be checked and
tightened.
Check bearings for end play and
wear. Report any faults to the client.
When carrying out lubrication it is
essential that every trace of water or
dirt is removed from around the
grease nipple. (See also Motors
SFG 39-01.
Ensure that the correct oils and/or
greases and quantities are used. It
is particularly important that
lubricants of the correct working
range are used. Oil attracts dust and
as a consequence any excess
should be wiped clear (e.g. fan
blades) see manufacturer`s
instructions.
3MTechnical
5. Belt guards
(where fitted).
Check these are free from dirt build
up, if necessary, clean.
6M 5. Belt guards
(where fitted).
Check these are free from dirt build
up, if necessary, clean. Check all
guards are secure and in place.
Guards should be painted a suitable
colour, so that they stand out.
6MTechnical
6. Impeller,
variable pitch
mechanism.
Check that there is no excessive
movement at the wing root.
There should be no loss of grease
from wing roots. If there
is, dismantle impeler and seals.
replaced after lubricating bearings.
6M 6. Impeller,
variable pitch
mechanism.
Check that there is no excessive
movement at the wing root.
There should be no loss of grease
from wing roots. If there is,
dismantle impeller and seals.
replaced after lubricating bearings.
6MOther
9. Motor and fan
blade - cleaning
Clean and inspect all grilles. Clean
all dirt from the outside of any
motor.
Clean fan blades. Check for
excessive imbalance.
6MAdded
10. Motors -
electrical
Check the electrical and thermal
overload protection for the
motor, and if the motor has a
resettable overload protection.
Check that it is fully operational.
6MAdded
11. Electrics Check circuit breakers manually
each month.
Examine wiring and other electrical
system components for signs of
deterioration, loose connections
and damage. Check all connections
are tight.
1MAdded
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11. Electrics Clean any sensors re-calibrate if
found to be inaccurate.
6MAdded
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FANS - PROPELLER20-05 20-05 FANS - PROPELLER
Ensure to read health and safety notes shown on SFG 20-01 before undertaking the following tasks.
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 and Safety at Work
(www.hse.gov.uk) Regulations.
The isolator should be locked in the off position when maintenance takes place .
Added
Title NotesActionFQTitle FQ Action Notes
6. Motor and fan
blade - cleaning
Clean and inspect all grilles. Clean
all dirt from the outside of any
motor.
Clean fan blades. Check for
excessive imbalance.
6MAdded
7. Motors -
electrical
Check the electrical and thermal
overload protection for the
motor, and if the motor has a
resettable overload protection.
Check that it is fully operational.
6MAdded
8. Electrics Check circuit breakers manually
each month.
Examine wiring and other electrical
system components for signs of
deterioration, loose connections
and damage. Check all connections
are tight.
1MAdded
8. Electrics Clean any sensors re-calibrate if
found to be inaccurate.
6MAdded
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2. Motor
bearings. (`sealed
for life' bearings
should not be
serviced).
Lubricate with recommended
lubricant.
If lubricators are provided,
re-lubrication should not exceed a
period of two years. When carrying
out re-lubrication it is essential that
every trace of water and dirt is
removed from around the grease
nipple.(See also MOTORS). If the
operating temperature is over 60º C
a shorter re-lubricating period will be
necessary, see manufacturer's
instructions.
6M 2. Bearings. Sealed for life` bearings should not
be serviced.
Inspect and lubricate as necessary.
Where applicable, all set-screws in
bearings should be checked and
tightened.
Check bearings for end play and
wear. Report any faults to the client.
If lubricators are provided,
re-lubrication should not exceed a
period of two years. When carrying
out re-lubrication it is essential that
every trace of water and dirt is
removed from around the grease
nipple.(See also Motors SFG 39-01.
If the operating temperature is over
60o C a shorter re-lubricating period
will be necessary, see
manufacturer`s instructions.
Ensure that the correct oils and/or
greases and quantities are used. It
is particularly important that
lubricants of the correct working
range are used. Oil attracts dust and
as a consequence any excess
should be wiped clear (e.g. fan
blades) see manufacturer`s
instructions.
6MTechnical
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FANS-MIXED FLOW20-06 20-06 FANS-MIXED FLOW
Ensure to read health and safety notes shown on SFG 20-01 before undertaking the following tasks.
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 withHealth and Safety at Work
(www.hse.gov.uk) Regulations.
The isolator should be locked in the off position when maintenance takes place .
Added
Title NotesActionFQTitle FQ Action Notes
1. Impeller and
spinnings.
Clean and inspect. Take care not to disturb impeller
balance weights. Cleaning is best
carried out with warm soapy water
using soft brush. Other cleaners
may be used provided they are not
harmful to the paint or galvanised
finish.
6M 1. Impeller and
inlet venturi.
Clean and inspect. Take care not to disturb impeller
balance weights. Cleaning is best
carried out with warm soapy water
using soft brush. Other cleaners
may be used provided they are not
harmful to the paint or galvanised
finish.
6MOther
2. Motor
bearings. ('sealed
for life' bearings
should not be
serviced).
Lubricate with recommended
lubricant.
If lubricators are provided,
re-lubrication should not exceed a
period of two years. When carrying
out re-lubrication it is essential that
every trace of water and dirt is
removed from around the grease
nipple. If the operating temperature
is over 60º C a shorter re-lubricating
period will be necessary, see
manufacturer's instructions.(See
also MOTORS).
6M 2. Bearings. Sealed for life` bearings should not
be serviced.
Inspect and lubricate as necessary.
Where applicable, all set-screws in
bearings should be checked and
tightened.
Check bearings for end play and
wear. Report any faults to the client.
If lubricators are provided,
re-lubrication should not exceed a
period of two years. When carrying
out re-lubrication it is essential that
every trace of water and dirt is
removed from around the grease
nipple. If the operating temperature
is over 60o C a shorter re-lubricating
period will be necessary, see
manufacturer`s instructions.(See
also Motors SFG 39-01).
Ensure that the correct oils and/or
greases and quantities are used. It
is particularly important that
lubricants of the correct working
range are used. Oil attracts dust and
as a consequence any excess
should be wiped clear (e.g. fan
blades) see manufacturer`s
instructions.
6MTechnical
4. Protection
guards and
automatic shutters.
Clean and check shutter blades for
ease of action.
In dirty or moist laden environment
more frequent inspection and
cleaning may be necessary.
6M 4. Protection
guards and
automatic
shutters.
Clean and check shutter blades for
ease of action.
In dirty or moist laden environment
more frequent inspection and
cleaning may be necessary. Guards
should be painted a suitable colour,
so that they stand out.
6MTechnical
6. Roof cowl
intake/wall entry
louvre (where
applicable).
Clean and check mounting.6M 6. Roof cowl
intake/wall entry
louver (where
applicable).
Clean and check mounting. Where maintenance requires
working at height, ensure all
necessary precautions are taken to
prevent falls from a height. Working
at Height Regulations apply.
6MTechnical
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8. Motor and fan
blade - cleaning
Clean and inspect all grilles. Clean
all dirt from the outside of any
motor.
Clean fan blades. Check for
excessive imbalance.
6MAdded
9. Motors -
electrical
Check the electrical and thermal
overload protection for the
motor, and if the motor has a
resettable overload protection.
Check that it is fully operational.
6MAdded
10. Electrics Check circuit breakers manually
each month.
Examine wiring and other electrical
system components for signs of
deterioration, loose connections
and damage. Check all connections
are tight.
1MAdded
10. Electrics Clean any sensors re-calibrate if
found to be inaccurate.
6MAdded
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FANS-BIFURCATED20-07 20-07 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 smoke extraction and for fume removal particularly where corrosive.
This type of fan, axial with the motor outside of the airstream, is normally used for fume extracts e.g.
kitchens, fire and smoke extraction and for fume removal particularly where corrosive.
Ensure to read health and safety notes shown on SFG 20-01 before undertaking the following tasks.
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 withHealth and Safety at Work
(www.hse.gov.uk) Regulations.
The isolator should be locked in the off position when maintenance takes place .
Other
Title NotesActionFQTitle FQ Action Notes
13. Motor and fan
blade - cleaning
Clean and inspect all grilles. Clean
all dirt from the outside of any
motor.
Clean fan blades. Check for
excessive imbalance.
6MAdded
14. Electrics Check circuit breakers manually
each month.
Examine wiring and other electrical
system components for signs of
deterioration, loose connections
and damage. Check all connections
are tight.
1MAdded
14. Electrics Clean any sensors re-calibrate if
found to be inaccurate.
6MAdded
3. Lubrication.
(`Sealed for life'
bearings should
not be serviced).
Check and lubricate if necessary
according to the manufacturer's
instructions.
If working in a high temperature
environment, more frequent
lubrication may be necessary.
3M 3. Bearings. Sealed for life` bearings should not
be serviced.
Inspect and lubricate as necessary.
Where applicable, all set-screws in
bearings should be checked and
tightened.
Check bearings for end play and
wear. Report any faults to the client.
If lubricators are provided,
re-lubrication should not exceed a
period of two years. When carrying
out re-lubrication it is essential that
every trace of water and dirt is
removed from around the grease
nipple. If the operating temperature
is over 60o C a shorter re-lubricating
period will be necessary, see
manufacturer`s instructions.
Ensure that the correct oils and/or
greases and quantities are used. It
is particularly important that
lubricants of the correct working
range are used. Oil attracts dust and
as a consequence any excess
should be wiped clear (e.g. fan
blades) see manufacturer`s
instructions.
3MTechnical
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4. Standby motor
(where provided).
Check and rotate a few turns by
hand or electrically.
Units designed for emergency use
should be test operated for no
longer than twenty minutes.(See
also MOTORS).
3M 4. Standby motor
(where provided).
Check and rotate a few turns by
hand or electrically.
Units designed for emergency use
should be test operated for no
longer than twenty minutes.(See
also Motors SFG 39-01).
3MOther
6. Belt drive (if
fitted).
Check wear, alignment and tension. Replace if cording becomes visible.6M 6. Belt drive and
guards (if fitted).
Check wear, alignment and tension.
Check all guards are secure and in
place.
Replace if cording becomes visible.
Guards should be painted a suitable
colour, so that they stand out.
6MTechnical
7. Automatic
shutters (usually
fitted on roof
units).
Clean and check operation. In moist or dirty environments more
frequent servicing may be required.
6M 7. Automatic
shutters (usually
fitted on roof
units).
Clean and check operation. In moist or dirty environments more
frequent servicing may be required.
Where maintenance requires
working at height, ensure all
necessary precautions are taken to
prevent falls from a height. Working
at Height Regulations apply
6MTechnical
9. Ductwork
including fixings
and insulation
(where fitted).
Inspect external condition and
report.
With kitchen extracts heavy deposits
of grease may be encountered and
more frequent inspection will be
necessary and client should be
informed of fire risk and a schedule
of cleaning drawn up. See
DUCTWORK HYGIENE.
12M 9. Ductwork
including fixings
and insulation
(where fitted).
Inspect external condition and
report.
With kitchen extracts heavy deposits
of grease may be encountered and
more frequent inspection will be
necessary and client should be
informed of fire risk and a schedule
of cleaning drawn up. See Ductwork
hygiene SFG 17-01.
12MOther
10. Motor. Check full load current and log.12M 10. Motor. Check full load current and log.
Check the electrical and thermal
overload protection for the
motor, and if the motor has a
resettable overload protection.
Check that it is fully operational.
12MOther
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FANS-EXTRACT - including fire/smoke extracts units20-08 20-08 FANS-EXTRACT - including fire/smoke extracts units
Ensure to read health and safety notes shown on SFG 20-01 before undertaking the following tasks.
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 and Safety at Work
(www.hse.gov.uk) Regulations.
The isolator should be locked in the off position when maintenance takes place .
Added
Title NotesActionFQTitle FQ Action Notes
4. Fan and
motor. (`Sealed
for life' bearings
should not be
serviced).
Lubricate according to
manufacturer's instructions.
See also MOTORS.6M 4. Bearings. Sealed for life` bearings should not
be serviced.
Inspect and lubricate as necessary.
Where applicable, all set-screws in
bearings should be checked and
tightened.
Check bearings for end play and
wear. Report any faults to the client.
If lubricators are provided,
re-lubrication should not exceed a
period of two years. When carrying
out re-lubrication it is essential that
every trace of water and dirt is
removed from around the grease
nipple. See also Motors (SFG
39-01).
Ensure that the correct oils and/or
greases and quantities are used. It
is particularly important that
lubricants of the correct working
range are used. Oil attracts dust and
as a consequence any excess
should be wiped clear (e.g. fan
blades) see manufacturer`s
instructions.
6MTechnical
9. Motor and fan
blade - cleaning
Clean and inspect all grilles. Clean
all dirt from the outside of any
motor.
Clean fan blades. Check for
excessive imbalance.
6MAdded
10. Motors -
electrical
Check the electrical and thermal
overload protection for the
motor, and if the motor has a
resettable overload protection.
Check that it is fully operational.
6MAdded
11. Electrics Check circuit breakers manually
each month.
Examine wiring and other electrical
system components for signs of
deterioration, loose connections
and damage. Check all connections
are tight.
1MAdded
11. Electrics Clean any sensors re-calibrate if
found to be inaccurate.
6MAdded
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FIRE ALARMS - Associated Equipment22-02
Page 172 of 614
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FIRE ALARMS - Associated Equipment22-02
Page 173 of 614
FILTERS
Page 174 of 614
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INTRODUCTORY PROCEDURES21-01 21-01 INTRODUCTORY PROCEDURES
Removal of dust and other non-gaseous matter in airborne streams is carried out by some form of
filter or device such as electrostatic precipitation. Where the air passes through the filter a back
pressure is set up which increases as the pores of the filtration medium become filled with the
particles removed from the air stream, the dirtier the air stream the more quickly the back pressure
builds up and the more frequently the filter has to be cleaned or changed. The maintenance periods
given in the tables below refer to average air conditions, in a dirty 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 a lower specification will lead to poor performance e.g. black
markings on ceilings and near grilles. Ineffective filters will mean that FAN COILS will require more
frequent cleaning and accumulation of dust and debris in the ventilation system could give rise to a
fire hazard and clog automatic 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, 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.
Types of filters covered in this section include roll band, disposable panel, re-usable/disposal, bag,
cartridge and electrostatic. Because of their specialist nature and the hazardous circumstances of
their use certain filters require specialist attention which is outside the scope of this specification.
These include active carbon, cyclonic and inertia filters, wet, dry dust collectors and filters associated
with fume cupboards, radioactive, nuclear facilities, biological and clinical areas.
Removal of dust and other non-gaseous matter in airborne streams is carried out by some form of
filter or device such as electrostatic precipitation. Where the air passes through the filter a back
pressure is set up which increases as the pores of the filtration medium become filled with the
particles removed from the air stream, the dirtier the air stream the more quickly the back pressure
builds up and the more frequently the filter has to be cleaned or changed. The maintenance periods
given in the tables below refer to average air conditions, in a dirty 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 a lower specification will lead to poor performance e.g. black
markings on ceilings and near grilles. Ineffective filters will mean that FAN COILS will require more
frequent cleaning and accumulation of dust and debris in the ventilation system could give rise to a
fire hazard and clog automatic fire dampers.
Filter replacements should comply with BS EN 779 Primary Filters G4 and secondary filters F5
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
(www.hse.gov.uk/hthdir/noframes/coshh/index.htm)) Regulations. A risk assessment must be carried
out before the work starts and a method statement produced. Used filters must be regarded as
Controlled Waste and appropriate safeguards taken for their disposal .
Types of filters covered in this section include roll band, disposable panel, re-usable/disposal, bag,
cartridge and electrostatic. Because of their specialist nature and the hazardous circumstances of
their use certain filters require specialist attention which is outside the scope of this specification.
These include active carbon, cyclonic and inertia filters, wet, dry dust collectors and filters associated
with fume cupboards, radioactive, nuclear facilities, biological and clinical areas.Technical
Other
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FILTERS21-02 21-02 AIR 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.
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
(www.hse.gov.uk/hthdir/noframes/coshh/index.htm)) Regulations`. A risk assessment must be carried
out before the work starts and a method statement produced. Used filters should be sealed into
plastic bags for disposal. Controlled Waste Regulations apply.
Visual inspection of air filters is a the basic first action. If they are clearly dirty then they can be
changed and form part of a preventative planned maintenance program. (PPM). A better method for
filter change is based on filter change by noting increased operating pressure across the filter. When
the filter pressure is twice the initial value it is time to change. Where possible Low Energy Air Filters
should be selected so that running costs and energy use are minimised. Regular monitoring and
recording of pressure drop readings and recording of filter changes is to be encouraged.
The frequency of duct cleaning will depend upon the degree of contamination.
BS EN 15780:2011 gives three levels of cleanliness for typical applications;
Low - rooms with only intermittent occupancy e.g.
storage rooms, technical rooms.
Medium - offices, hotels, restaurants, schools,
theatres, residential homes, shopping
areas, exhibition buildings, sport buildings,
general areas in hospitals and general
working areas in industries.
High - Laboratories, treatment areas in hospitals
high quality offices.
Filter recommended inspection intervals according to the above cleanliness quality classes are; Low
and Medium 12 months and high is 6 months.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Air flow. Stop any air flow to filter.12M 1. Air flow. Stop any air flow to filter by turning
off the AHU system fan.
12MOther
3. Filter housing. Thoroughly clean including
surrounding ductwork and floor.
12M 3. Filter housing. Thoroughly vacuum and clean
including surrounding ductwork and
floor.
12MTechnical
5. Replacement. 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.
12M 5. Replacement. Ensure that filter header frames are
adequately sealed when fitted to
the mounting frames to prevent
bypass of dirty unfiltered air. Keep
a record card on each AHU
recording filter change time and
operating pressure drop at regular
intervals. Ensure that the filter is
installed the correct way around to
face the direction of the air flow.
Bag filters should have pockets in
vertical orientation.
Air filters should be selected to
deliver clean Indoor Air Quality
(Minimum F7 as EN13779:2007) in
inhabited environments. To minimise
energy usage filters should have a
low operating pressure drop. Filter
media should have a consistent
particulate efficiency. Spare filters
should remain sealed, packed and
in a dry environment until required.
Replacement is advised when the
initial operating pressure drop of the
filter doubles (assuming constant
volume flow. Eg. Initial pressure
drop 110Pa. Change at 220Pa.
12MTechnical
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1. Filter elements. Remove and replace at
manufacturer's recommended final
airflow pressure. Ensure that any
spillage or dust is vacuumed away.
Filters may have to be removed
more frequently depending upon
site conditions and operating hours.
After removal, used filters should be
sealed into plastic bags for disposal.
Do not attempt to wash or clean
out and reuse.
12M 1. Filter elements. Filters may have to be removed
more frequently depending upon
site conditions and operating hours.
Change filters on pressure drop
where possible. After removal, used
filters should be sealed into plastic
bags for disposal.
Do not attempt to wash or clean out
and reuse.
12MTechnical
1. Filter elements. Clean and replace as per
manufacturer's recommendations.
Filters may require more frequent
cleaning where the atmosphere is
heavily contaminated with dust or
fume.
12M 1. Filter elements. Clean and replace as per
manufacturer`s recommendations.
Filters may require more frequent
cleaning where the atmosphere is
heavily contaminated with dust or
fumes.
12MTechnical
2. Kitchen extract
grease filters.
Remove and clean as per
manufacturer's recommendations.
Frequency of cleaning can vary from
daily to weekly intervals. Generally
for grease filter panels the use of a
commercial dishwasher is possible.
Failure to change/clean filters
when loaded with grease may
result in the carry over of grease
ito the ducting - thus leading to
an increased hazard of a flash
over fire to the main ductwork.
See DUCTWORK HYGIENE.
12M 2. Kitchen extract
grease filters.
Remove and clean as per
manufacturer`s recommendations.
Frequency of cleaning can vary from
daily to weekly intervals. Generally
for grease filter panels the use of a
commercial dishwasher is possible.
Failure to change/clean filters when
loaded with grease may result in the
carry over of grease into the ducting
- thus leading to an increased
hazard of a flash over fire to the
main ductwork. See Ductwork
cleaning SFG 17-01.
12MTechnical
e) Automatic roll
band type
e) Automatic roll
band type
Check roller mechanism is
operational
Consider conversion to bag filtersOther
1. Damage. Check and report if found. If found to be high this may indicate
either band velocity is too low or
wrong specification.
6M 1. Damage. Check and report if found. Try and
attribute damage to a cause.
If found to be high this may indicate
either band velocity is too low or
wrong specification.
6MOther
2. Differential
pressure.
Measure6M 2. Differential
pressure.
Measure using an accurate and
easy to read and maintain
instrument.
Take the opportunity to cross
reference readings and calibrate
pressure measuring device
regularly.
6MOther
3. Operation. Check for correct operation.6M 3. Operation. Check for correct operation. Look
for any splitting lacerations in the
media.
Sudden changes in operational
pressure drop across filters need
investigation.
6MOther
1. Condition. Check and clean. The frequency of cleaning will
depend upon the degree of
contamination. Failure to
change/clean filters when loaded
with grease may result in the
carry over of grease into the
ducting - thus leading to an
increased hazard of a flash over
fire to the main ductwork.See
DUCTWORK HYGIENE.
6M 1. Condition. Check and clean. Differentiate
between disposable grease filters
and those that are made to be
cleaned and reused.
The frequency of cleaning will
depend upon the degree of
contamination. Failure to
change/clean filters when loaded
with grease may result in the carry
over of grease into the ducting -
thus leading to an increased hazard
of a flash over fire to the main
ductwork. See Ductwork cleaning
SFG 17-01.
6MTechnical
g) High efficiency
- HEPA
The maintenance activities for these
depend on the individual installation
operating conditions. Reference
should be made to the
design/operating manuals for the
building.
g) High efficiency
- HEPA
Make sure air from supply system is
adequately filtered before reaching
the HEPA filters ensuring a longer
operating life. Regular validation of
the system may be required
depending on purpose of system.
The maintenance activities for these
depend on the individual installation
operating conditions. Reference
should be made to the
design/operating manuals for the
building.
Other
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ELECTROSTATIC FILTERS21-03 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
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
(www.hse.gov.uk/hthdir/noframes/coshh/index.htm)) Regulations`. A risk assessment must be carried
out before the work starts and a method statement produced.
Used filters should be sealed into plastic bags for disposal. Controlled Waste Regulations apply
Other
Title NotesActionFQTitle FQ Action Notes
c) isolation, Isolate electrically in accordance
with HSAWA recommendations.
1M c) isolation, Isolate electrically in accordance
with HSAWA (www.hse.gov.uk)
recommendations.
1MTechnical
Page 179 of 614
FIRE ALARM SYSTEMS
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FIRE ALARM SYSTEM22-01 22-01 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 and associated systems they are not dealt with in detail in this
specification but the table below indicates the minimum requirements. Specialist back up may be
required either from the manufacturers or specialist contractors especially in connection with
intelligent systems. For further information see BS 5836, BS EN 54-2 and BS EN 54-4.
This section should be read in conjunction with the Daily and Weekly testing tasks .
A record of all tests and checks, and any defects remedied, should be maintained in the fire safety
manual / log book.
Arrangements should be made for all fire safety equipment, installations and systems (including fire
detection systems, automatic suppression systems, door control mechanisms, smoke control
systems, evacuation and fire-fighting lifts, emergency lighting, standby power systems, escalators,
and all passive fire protection provisions) to be inspected and tested on a regular basis by a
competent person. Alterations, additions, repairs or modifications to services and equipment should
be carried out only by competent persons.
Although modern fire alarm systems may incorporate a high degree of monitoring, so that faults are
indicated automatically, it is still necessary for the responsible person nominated by the user to ensure
that fault indications at the panel are identified for appropriate action. It is also vital for a regular test to
be carried out to ensure that there has not been any major failure of the entire system, or a significant
part of the system.
Routine testing of the system also provides an opportunity for occupants of the building to become,
and remain, familiar with the fire alarm signal(s) that the system produces. In systems with staged
alarms that incorporate an “Alert” and an “Evacuate” signal, both signals needs to be operated on the
occasion of each test to ensure that occupants are aware of the existence of both signals and their
different meaning.
The period between successive inspection and servicing visits should be based upon a risk
assessment, taking into account the type of system installed, the environment in which it operates and
other factors that may affect the long term operation of the system. If a risk assessment shows a need
for more frequent inspection and servicing visits, then all interested parties should agree the
appropriate inspection and servicing schedule. If this recommendation is not implemented, it should
be considered that the system is no longer compliant with this part of BS 5839.
All tests on equipment and trigger devices should be recorded in the log book. Due to the variety and
complexity of fire alarms and associated systems they are not dealt with in detail in this specification
but the table below indicates the minimum requirements. Specialist back up may be required either
from the manufacturers or specialist service providers especially in connection with intelligent
systems.
For further information see BS 5839 part 1 for fire detection and fire alarm systems, BS EN 54-2 and
BS EN 54-4.
The period between successive inspection and servicing visits should be based upon a risk
assessment, taking into account the type of system installed, the environment in which it operates and
other factors that may affect the long term operation of the system. If a risk assessment shows a need
for more frequent inspection and servicing visits, then all interested parties should agree the
appropriate inspection and servicing schedule. If this recommendation is not implemented, it should
be considered that the system is no longer compliant with this part of BS 5839
Technical
Title NotesActionFQTitle FQ Action Notes
1.Operation. Check operation of all sounders
and external alarm links.
This action should include auxiliary
functions such as links with the main
gas valve, vent plant and all fault
warnings.
3M 1)Log Book The system log book should be
examined. It should be ensured that
any faults recorded have received
appropriate attention.
6MTechnical
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2.Condition. Check condition of equipment i.e.
ingress of moisture, damage or
other signs of deterioration.
The building occupier should inform
the maintenance engineer of any
structural or occupancy changes
which might affect the siting or
operation of the detector.
3M 2) Visual
Inspection
A visual inspection should be made
to check whether structural or
occupancy changes have affected
the compliance of the system with
the recommendations of this
standard for the siting of manual
call points, automatic fire detectors
and fire alarm devices.
Particular care should be taken to
verify whether:
1) all manual call points remain
unobstructed and conspicuous;
2) any new exits have been created
without the provision of an adjacent
manual call point;
3) any new or relocated partitions
have been erected within 500 mm
horizontally of any automatic fire
detector;
4) any storage encroaches within
300 mm of ceilings;
5) a clear space of 500 mm is
maintained below each automatic
fire detector and that the ability of
the detector to receive the stimulus
that it has been designed to detect
has not been impeded by other
means;
6) any changes to the use or
occupancy of an area makes the
existing types of automatic fire
detector unsuitable for detection of
fire or prone to unwanted alarms;
7) any building alterations or
extensions require additional fire
detection and alarm equipment to
be installed
The building occupier should inform
the maintenance engineer of any
structural or occupancy changes
which might affect the siting or
operation of the detector.
6MTechnical
3.Fireman's
control for vent
plant.
Check operation and log operation
of fans and dampers.
3M 3) False Alarms The records of false alarms should
be checked in accordance with
section 30.2i) of BS5839 part 1.
The rate of false alarms during the
previous 12 months should be
recorded. Action taken in respect of
false alarms recorded should
comply with the recommendations
of 30.2j) of BS5839 part 1
6MTechnical
4.Wiring and
equipment.
Visually inspect for damage and
integrity.
12M 4) Standby battery The standby battery should be
disconnected and full load alarm
should be simulated
6MTechnical
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5.Detectors
including photo
cells.
Check operation in accordance with
the manufacturer's
recommendations.
Inspect heat detectors for damage
or other condition, such as a heavy
coat of paint.
12M 5) Batteries Batteries and their connections
should be examined and
momentarily load tested with the
mains disconnected (other than
those within devices such as
manual call points, detectors and
fire alarm sounders of a
radio-linked system), to ensure that
they are in good serviceable
condition and not likely to fail before
the next service visit.
6MTechnical
6.Emergency
manual operated
systems.
Test operation. These devices should be tested
frequently by clients' operators.
3M 6) Fire Alarm
control and
Indicating
equipment
The fire alarm functions of the
control and indicating equipment
should be checked by the operation
of at least one detector or manual
call point on each circuit.
An entry should be made in the log
book indicating which initiating
devices have been used for these
tests.
6MTechnical
7.Completion of
test.
Reset all plant and gas valves after
test.
3M 7) Fire Alarm
devices
The operation of the fire alarm
devices should be checked.
6MTechnical
8.System test. Test in accordance with the relevant
regulations and rectify any defects.
BS 5839 should be followed.36M 8) Controls and
visual indicators
All controls and visual indicators at
control and indicating equipment
should be checked for correct
operation.
6MTechnical
9) Alarm signals The operation of any facility for
automatic transmission of alarm
signals to an alarm receiving centre
should be checked.
Where more than one form of alarm
signal can be transmitted (e.g. fire
and fault signals), the correct
transmission of each signal should
be confirmed.
6MAdded
10) Ancillary
functions
All ancillary functions of the control
and indicating equipment should be
tested.
6MAdded
11) Fault
indicators
All fault indicators and their circuits
should be checked, where
practicable, by simulation of fault
conditions.
6MAdded
12) Printers All printers should be tested to
ensure that they operate correctly
and that characters are legible.
It should be ensured that all printer
consumables are sufficient in
quantity or condition to ensure that
the printer can be expected to
operate until the time of the next
service visit.
6MAdded
13) Radio
Systems
Radio systems of all types should
be serviced in accordance with the
recommendations of the
manufacturer.
6MAdded
14) Manufacturers
checks and tests
All further checks and tests
recommended by the manufacturer
of the control and indicating
equipment and other components
of the system should be carried out.
6MAdded
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15) Completion On completion of the work, any
outstanding defects should be
reported to the responsible person,
the system log book should be
completed and a servicing
certificate should be issued.
6MAdded
a) The work described may be carried
out over the course of two or more
service visits during each twelve
month period
6MAdded
16) Manual Call
Points
The switch mechanism of every
manual call point should be tested,
either by removal of a frangible
element, insertion of a test key or
operation of the device as it would
be operated in the event of fire.
12MAdded
17) Automatic
detectors
All automatic fire detectors should
be examined, as far as practicable,
to ensure that they have not been
damaged, painted, or otherwise
adversely affected. Thereafter,
every detector should be
functionally tested. The tests used
need prove only that the detectors
are connected to the system, are
operational and are capable of
responding to the phenomena they
are designed to detect.
General :
Connections – check condition and
make good if necessary.
Mounting – Check security
12MAdded
18) Heat detectors Every heat detector should be
functionally tested by means of a
suitable heat source, unless
operation of the detector in this
manner would then necessitate
replacement of part or all of the
sensing element (e.g. as in fusible
link point detectors or
non-integrating line detectors).
Special test arrangements will
be required for fusible link heat
detectors. The heat source should
not have the potential to ignite a
fire; live flame should not be used,
and special equipment might be
necessary in explosive
atmospheres
12MAdded
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19) Point smoke
detectors
Point smoke detectors should be
functionally tested by a method that
confirms that smoke can enter the
detector chamber and produce a
fire alarm signal (e.g. by use of
apparatus that generates simulated
smoke or suitable aerosols around
the detector). It should be ensured
that the material used does not
cause damage to, or affect the
subsequent performance of, the
detector; the manufacturer’s
guidance on
suitable materials should be
followed.
12MAdded
20) Optical beam
smoke detectors
Optical beam smoke detectors
should be functionally tested by
introducing signal attenuation
between the transmitter and
receiver, either by use of an optical
filter, smoke or simulated smoke
12MAdded
21) Aspirating fire
detection systems,
VESDA system
Aspirating fire detection systems
should be functionally tested as
described in 45.4d of BS5839 part
1, with each sampling point, or
group of sampling points, in the
pipework of the system treated as a
point detector.
45.4d "Point smoke detectors
should be functionally tested by a
method that confirms that smoke
can enter the detector chamber and
produce a fire alarm signal (e.g. by
use of apparatus that generates
simulated smoke or suitable
aerosols around the detector). It
should be ensured that the material
used does not
cause damage to, or affect the
subsequent performance of, the
detector; the manufacturer’s
guidance on suitable materials
should be followed.
Not all test products may be
appropriate for the purpose
12MAdded
22) Carbon
Monoxide fire
detectors
Carbon monoxide fire detectors
should be functionally tested by a
method that confirms that carbon
monoxide can enter the detector
chamber and produce a fire alarm
signal (e.g. by use of apparatus that
generates carbon monoxide or a
gas that has a similar effect on the
electro-chemical cell as carbon
monoxide
It should be ensured that any test
gas used does not cause damage
to, or affect the subsequent
performance of, the
detector; the manufacturer’s
guidance on suitable test gases
should be followed.
12MAdded
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23) Flame
detectors
Flame detectors should be
functionally tested by a method that
confirms that the detector will
respond to a suitable frequency of
radiation and produce a fire alarm
signal. The guidance of the
manufacturer on testing of
detectors should be followed.
12MAdded
24) Analogue
values
In fire detection systems that
enable analogue values to be
determined at the control and
indicating equipment, it should be
confirmed that each analogue value
is within the range specified by the
manufacturer.
12MAdded
25) Multi-sensor
detectors
Multi-sensor detectors should be
operated by a method that confirms
that products of combustion in the
vicinity of the detector can reach
the sensors and that a fire signal
can be produced as appropriate
The guidance of the manufacturer
on the manner in which the detector
can be functionally tested effectively
should be followed
12MAdded
26) Visual devices All fire alarm devices should be
checked for correct operation. It
should be confirmed that visual fire
alarm devices are not obstructed
from view and that their lenses are
clean.
12MAdded
27) Filament
Lamps
All unmonitored, permanently
illuminated filament lamp indicators
at control and indicating equipment
should be replaced.
12MAdded
28) Radio signal Radio signal strengths in
radio-linked systems should be
checked for adequacy.
12MAdded
29) Cables A visual inspection should be made
to confirm that all readily accessible
cable fixings are secure and
undamaged.
12MAdded
30) Cause & Effect The cause and effect programme
should be confirmed as being
correct.
12MAdded
31) Standby
Power
The standby power supply capacity
should be checked to establish it
remains suitable for continued
service.
12MAdded
32) Shutters Operation - Check and ensure
action responds to appropriate
signals. Indicator lights - Check
operation and replace any faulty
lamps.
12MAdded
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33) Drop fire
curtains
Condition – Check for mechanical
damage.
Operation - Check operation and
control mechanisms
See relevant section Smoke extract
SFG 52
12MAdded
34) Magnetic door
latches
Condition – Check for mechanical
damage.
Operation - Check operation and
control mechanisms
See relevant section Smoke extract
SFG 52
12MAdded
35) Smoke relief
vents - Fireman`s
control for vent
plant
Check operation and log operation
of fans and dampers.
3MAdded
36) Smoke relief
vents
Condition – Check for mechanical
damage.
Operation - Check operation and
control mechanisms
See relevant section Smoke extract
SFG 52
12MAdded
37) Emergency
manual operated
systems.
Test Operation These devices should be tested
frequently by the clients’ operators
3MAdded
38) Interlocks Condition – Check for mechanical
damage.
Operation - Check operation and
control mechanisms.
Interlocks will be with heating,
ventilating and cooling equipment
and with fire extinguishing and other
systems , i.e. Smoke curtains SFG
52-04
12MAdded
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FIRE ALARMS - Associated Equipment22-02 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 must be reported to the
client.
TESTING: The client should carry out tests on equipment on a weekly basis in accordance with the
local fire regulations. When carrying out maintenance any defects must be reported to the client.
Other
Title NotesActionFQTitle FQ Action Notes
1.Decibel level. Check (see notes). The time period for checking
sounders should be agreed with the
client. Refer to BS 5839.
12M 1.Decibel level. Check (see notes). The time period for checking
sounders should be agreed with the
client. Refer to BS
(www.bsi-global.com) 5839.
12MOther
1.Condition. Check exterior and clean. Check and monitor according to
manufacturer's instructions.
WARNING: Ionisation detectors
emit radiation, refer to manufacturer.
See SENSORS.
12M 1.Condition. Check exterior and clean. Check and monitor according to
manufacturer`s instructions. See
Sensors and switching devices SFG
50.
12MOther
1. Condition. Check condition and life. Check according to the
manufacturer's recommendations.
All batteries should be disposed of
in accordance with statutory
requirements, COSHH .
12M 1. Condition. Check condition and life. Check according to the
manufacturer`s recommendations.
12MOther
Chargers See POWER GENERATION. Chargers See Power generators SFG 43-0412MOther
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FIRE PROTECTION SYSTEMS
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INTRODUCTORY PROCEDURES23-01 23-01 INTRODUCTORY PROCEDURES
The need for preventive maintenance on fire prevention systems is essential but in negotiations
between contractor and client is vital that aspects of insurance, liability, compliance with regulations
etc. are fully agreed by both parties. Both the Loss Prevention Council requirements and local fire
regulations must be complied with and should any areas of doubt arise it is recommended that these
be fully discussed 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 associated with 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 protection officer 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 be adopted 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 & Maintenance of Automatic Sprinkler Systems (TB203: 2004) published
by LPC.
The need for preventive maintenance on fire prevention systems is essential but in negotiations
between service provider and client is vital that aspects of insurance, liability, compliance with
regulations etc. are fully agreed by both parties. Both the Loss Prevention Council requirements and
local fire regulations must be complied with and should any areas of doubt arise it is recommended
that these be fully discussed with the appropriate representative of the fire prevention bodies.
It is the duty of the service provider to ensure that he has taken out adequate insurance cover to meet
all the liabilities and requirements associated with 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 service provider
and close liaison with the local fire protection officer should be maintained at all times
The Loss Prevention Council (now part of the BRE) (www.bre.co.uk/frs) has issued a comprehensive
schedule of fire prevention measures and these should be adopted by both the client and the service
provider.
Other
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HOSE REELS PRESSURE BOOSTING SETS23-02 23-02 HOSE REELS PRESSURE BOOSTING SETS
If, due to unforeseen difficulties, an installation is left unavailable for use, the fire brigade must be
informed and again after reinstatement.
Where, due to unforeseen difficulties, it is necessary to leave an installation not available for use, the
fire and rescue service should be informed immediately in order that alternative arrangements can be
made to cover this deficiency should the need arise. In addition a suitable notice to indicate that the
installation is not available for use should be placed in a prominent position.
Technical
Title NotesActionFQTitle FQ Action Notes
3. Pump and
motor alignment.
Check and adjust if necessary. Examine couplings for tightness.3M 3. Pump and
motor alignment.
Check and adjust if necessary,
ensure pump shafts are free to
rotate
Examine couplings for tightness.3MTechnical
4. Motor and
bearings.
Oil or grease where external
nipples or lubricators are fitted.
Use recommended grade of
lubricant. Motor should be
overhauled annually, see -
MOTORS.
3M 4. Motor and
bearings.
Oil or grease where external
nipples or lubricators are fitted.
Use recommended grade of
lubricant. Motor should be
overhauled annually, see Motors
SFG 39
3MTechnical
10. Test run
pressure booster
sets, pressurising
units, and filling
pump.
Carry out adjustments to ensure
satisfactory operation.
Check operation of all automatic
controls and change-over switches,
including signal to BMS if fitted.
3M 10. Test run
pressure booster
sets, pressurising
units, and filling
pump.
Carry out adjustments to ensure
satisfactory operation.
Check operation of all automatic
controls and change-over switches,
including signal to BMS SFG 06. If
operating any booster set pumps in
the Hand position, there is a danger
that if there is NO FLOW in the pipe
work, damage to the mechanical
seals and/or impellers of the pumps
could occur. The Hand Position
should only be used for testing the
pumps or in an emergency situation.
3MTechnical
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HOSE REELS - Static or Swinging23-03 23-03 HOSE REELS - Static or Swinging
If, due to unforeseen difficulties, an installation is left unavailable for use, the fire brigade should be
informed and again after reinstatement.
Where, due to unforeseen difficulties, it is necessary to leave an installation not available for use, the
fire and rescue service should be informed immediately in order that alternative arrangements can be
made to cover this deficiency should the need arise. In addition a suitable notice to indicate that the
installation is not available for use should be placed in a prominent position.
Maintenance should be carried out in accordance with BS EN 671-3:2009
Leave the hose reel and hose system ready for immediate use; if any extensive maintenance is
necessary the hose reel or hose system shall be labelled "OUT OF ORDER" and the competent
person shall inform the user/owner.
Technical
Title NotesActionFQTitle FQ Action Notes
9) Swinging reels Check that the movement is free
and that the reel swings minimum
required angles shown in BS EN
671 parts 1 & 2. Check condition of
‘O’ rings
If leakage is evident replace `O`
rings.
12MAdded
10a) Stop Valves
– Manual reels
check the manual stop valve is of
correct type and that it operates
easily and correctly
12MAdded
10b) Stop Valves
– Automatic reels
check the correct operation of the
automatic valve and check for the
correct operation of the isolating
service valve
12MAdded
11)Back flow
prevention devices
(check valves).
Check operation. Ensure that valve is seating
properly.
12MAdded
12) Notices Check that the location is clearly
marked and that the operating
instructions are clear.
12MAdded
13) Water flow Check that the flow of water is
steady and sufficient
12MAdded
14)Hose All hoses shall be pressurised to
maximum working pressure in
accordance with BS EN 671 parts 1
& 2
60MAdded
1. Condition. Completely run out reel, inspect
and subject to operational water
pressure test.
12M 1)Hose Completely run out reel, inspect
and subject to operational water
pressure test. Check that it is
unobstructed, that there is no
damage, components are not
corroded and that there are no
leaks.
The full length of hose must be
inspected for signs of cracking,
distortion, wear or damage; if the
hose shows any signs of defect it
must be replaced or proof-tested to
maximum working pressure;
12MLegislative
2. Back flow
prevention devices
(check valves).
Check operation. Ensure that valve is seating
properly.
12M 2)Brackets and
fixings
Check that the brackets for wall
mounting are secure.
12MLegislative
3. Couplings. Check and during wet testing check
for leakage.
12M 3) Cabinet If fitted with a cabinet check that the
doors open freely and that there is
no sign of damage.
12MLegislative
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4. Swivel joints
(swinging hose
reels).
Check swinging movement is free,
condition of 'O' rings.
If leakage is evident replace 'O'
rings.
12M 4) Pipework and
couplings
Check the condition of the water
supply pipework and any couplings
pay particular attention to any
flexible pipework for corrosion,
damage or wear.
12MLegislative
5. Nozzles. Check functioning.12M 5) Nozzle Check they are of the correct type,
functioning and easy to operate
12MLegislative
6. Associated
equipment and
fittings.
Ensure glands, tubing, shut-off
nozzle are sound and free from
leaks. Check outlet of nozzle is
unobstructed.
12M 6) Hose clips or
bindings
Check they are securely fastened12MLegislative
7. Flow test. Test in accordance with the
requirements of the Loss
Prevention Council .
If it is not possible to test every reel,
at least the highest reel on each
rising main should be tested.
12M 7) Hose drums Check hose drum rotates freely in
both directions.
If it is not possible to test every reel,
at least the highest reel on each
rising main should be tested.
12MLegislative
8. Accessibility. Check and report to client
immediately if there are any
obstructions.
Hose reels and any associated
equipment should be accessible at
all times.
12M 8)Pressure gauge Check gauge (if fitted) are working
within their operating range and
working satisfactorily.
Hose reels and any associated
equipment should be accessible at
all times.
12MLegislative
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RISING FIRE MAINS and HYDRANTS23-04 23-04 RISING FIRE MAINS and HYDRANTS
Where, due to unforeseen difficulties, it is necessary to leave an installation not available for use, the
fire and rescue service should be informed immediately in order that alternative arrangements can be
made to cover this deficiency should the need arise. In addition a suitable notice to indicate that the
installation is not available for use should be placed in a prominent position.
Added
Title NotesActionFQTitle FQ Action Notes
2. Wet test. Check for leaks.12M 2. Wet test. a) Check earthing arrangement and
ensure continuity between joints
b) Carry out physical check of the
system
c) Static pressure test – flush riser
by turning on water and allow to
flow out of topmost outlet.
d) Charge system to 10 bar
measured at the inlet for 15
minutes minimum. Check system
during this period for leaks etc.
e) Flow test – after static pressure
test a flow test should be carried
out if considered necessary.
f) Water should be passed through
system under pressure and flow
gauge readings recorded
If it is not possible to sustain an
effective fire-fighting jet from the
topmost outlet, or any undue
pressure loss in the rising main
(after allowing for the height
involved) should be investigated
12MTechnical
3. Booster
pumps.
Thoroughly check pumps and
associated mechanical and
electrical equipment.
For more detailed instructions see
PUMPS.
6M 3. Booster
pumps.
Thoroughly check pumps and
associated mechanical and
electrical equipment.
For more detailed instructions see
Pumps SFG 45.
6MTechnical
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HALON FIRE PROTECTION SYSTEMS23-05 23-05 Gas Extinguishing systems
HALON is a chloroflurocarbon and as such has been phased out of general use and has been
replaced by INERGEN because of the damaging effect HALON has on the upper atmosphere.
Where the installation is still legally permitted (Very Restricted), it is essential that leaks must be
prevented and residual material not discharged to the atmosphere. The client/user of the system
should check weekly, all pressure gauges, control settings and indicators. Such systems must only be
maintained and tested by qualified engineers as per the requirements of BS 5306: Part 5.
HALON is a chlorofluorocarbon and as such has been phased out of general use and has been
replaced by various other inert gases such as INERGEN because of the damaging effect HALON has
on the upper atmosphere.
All extinguishant removed from containers during service or maintenance procedures shall be
collected and recycled, or disposed of in an environmentally sound manner, and in accordance with
existing laws and regulations.
Inert gas mixtures based on those gases normally found in the earth`s atmosphere are exempted
from this requirement.
Weekly the client/user of the system should Visually check the hazard and the integrity of the
enclosure for changes which might reduce the efficiency of the system. Carry out a visual check that
there is no obvious damage to pipework and that all operating controls and components are properly
set and undamaged. Check pressure gauges and weighing devices, if fitted, for correct reading and
take the appropriate action specified in the users` manual.
Monthly the client/user of the system should check that all personnel who may have to operate the
equipment or system are properly trained and authorised to do so and, in particular, that new
employees have been instructed in its use.
Such systems must only be maintained and tested by qualified engineers and in accordance with BS
5306-0:2011 and BS EN 15004 part 1:2008
This task is applicable to the extinguishants listed below;
FK-5-1-12, HCFC Blend A, HCFC-123, HCFC-22, HCFC-124, HFC 125, HFC 227ea, HFC 23, IG-01,
IG-100, IG-55, IG-541
Where, due to unforeseen difficulties, it is necessary to leave an installation not available for use, the
fire and rescue service should be informed immediately in order that alternative arrangements can be
made to cover this deficiency should the need arise. In addition a suitable notice to indicate that the
installation is not available for use should be placed in a prominent position.
Technical
Title NotesActionFQTitle FQ Action Notes
8) Master/slave
system.
Check slave actuation system
including pistons in pneumatic valve
actuators.
6MAdded
9) Auxiliary electric
device/ alarm,
door closures, etc.
Test operation. Operational test to be carried out in
accordance with manufacturers
recommended procedure.
6MAdded
10) Enclosure
Integrity test
Check the enclosure for any
boundary penetrations or other
changes to it that could affect
leakage of gas on operation. If this
can not be visually determined an
integrity test should be carried out.
Test should be carried out in
accordance with Annex E BS EN
15004-1:2008
Where the integrity test reveals
increased leakage that would result
in an inability to retain the
extinguishant for the required
period, remedial action shall be
carried out.
12MAdded
1. System. Check generally for mechanical
damage.
6M 1. Electrical
detection and
alarm systems
Test and service in accordance with
appropriate manufacturers’
standards.
3MLegislative
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2. Cylinders. check labels are securely fixed and
legible, check security of brackets
and fixings, check liquid level,
check pressure in cylinder(s).
Level is checked by weighting, if
weight loss exceeds 5% cylinder
should be replaced or recharged. If
pressure has fallen more than 10%
on a temperature corrected basis,
cylinder should be replaced or
recharged.
6M 2) System Check generally for mechanical
damage.
6MLegislative
3. Nozzles. Examine for blockages and clean
as necessary.
6M 3) Pipework &
Nozzles
Externally examine pipework to
determine its condition. Examine
nozzles for blockages and clean as
necessary
Replace or pressure test and repair
as necessary pipework showing
corrosion or mechanical damage
6MLegislative
4. Valve
actuators.
Where possible, remove cylinder
valve and replace action caps.
Carry out procedure in accordance
with the manufacturer's
recommendations.
6M 4) Control Valves check all control valves for correct
manual function and automatic
valves additionally for correct
automatic function
6MLegislative
5. Master/slave
system.
Check slave actuation system
including pistons in pneumatic
valve actuators.
6M 5) Valve actuators. Where possible, remove cylinder
valve and replace action caps.
Carry out procedure in accordance
with the manufacturer`s
recommendations.
6MLegislative
6. Mechanical
integrity.
Test for mechanical tightness of
pipework and associated
equipment.
This is to prevent leakage of
HALON.(fire suppression agents.)
6M 6) Cylinders Check labels are securely fixed and
legible, check security of brackets
and fixings, check liquid level,
check pressure in cylinder(s).
Externally examine containers for
signs of damage or unauthorized
modification, and for damage to
system hoses. If the visual
examination shows any defect, the
hose(s) shall be replaced.
For liquefied gases check weight or
use a liquid level indicator to verify
correct content of containers. If
weight loss exceeds 5% cylinder
should be replaced or recharged.
Pressure gauges –liquefied gas
should be within 10% and
non-liquefied gases within 5% of
correct pressure; replaced or
recharged any showing a greater
loss.
The date of inspection and the
name of the person performing the
inspection shall be recorded on a
tag attached to the container.
As required by statutory regulations
– remove cylinders and pressure
test when necessary.
6MLegislative
7. Auxiliary
electric device/
alarm, door
closures, etc.
Test operation. Operational test to be carried out in
accordance with manufacturer's
recommended procedure.
6M 7) Cylinder gauges Where container pressure gauges
or weight-monitoring devices are
used for this purpose, they shall be
compared to a separate calibrated
device
Operational test to be carried out in
accordance with manufacturer`s
recommended procedure.
12MLegislative
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CARBON DIOXIDE TOTAL FLOODING FIRE EXTINGUISHING SYSTEM23-06 23-06 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 must only be maintained and tested by qualified engineers as per the
requirements of BS 5306: Part 5.
Such systems must only be maintained and tested by qualified engineers and in accordance with BS
5306-4:2001 and BS EN 15004 part 1:2008
During servicing every care and precaution shall be taken to avoid release of extinguishant.
Where, due to unforeseen difficulties, it is necessary to leave an installation not available for use, the
fire and rescue service should be informed immediately in order that alternative arrangements can be
made to cover this deficiency should the need arise. In addition a suitable notice to indicate that the
installation is not available for use should be placed in a prominent position
Other
Title NotesActionFQTitle FQ Action Notes
1. System. Check generally for mechanical
damage.
Report to client any defects or
incorrect installation.
6M 1. Electrical
detection and
alarm systems
Test and service in accordance with
appropriate manufacturers’
standards.
3MLegislative
2. Cylinders. Check labels are securely fixed and
legible, check security of brackets
and fixings, check liquid level
and check pressure in cylinder(s).
Level is checked by weighing, if
weight loss exceeds 5%, cylinder(s)
should be replaced or recharged. If
pressure has fallen more than 10%
on a temperature corrected basis,
cylinder(s) should be replaced or
recharged.
6M 2) System Check generally for mechanical
damage.
6MLegislative
3. Nozzles. Examine for blockages and clean
as necessary.
6M 3) Pipework &
Nozzles
Externally examine pipework to
determine its condition. Examine
nozzles for blockages and clean as
necessary
Replace or pressure test and repair
as necessary pipework showing
corrosion or mechanical damage
6MLegislative
4. Valve
actuators.
Where possible, remove cylinder
valve and replace action caps.
Carry out procedure in accordance
with the manufacturer's
recommendations.
6M 4) Control Valves Check all control valves for correct
manual function and automatic
valves additionally for correct
automatic function
6MLegislative
5. Master/slave
system.
Check slave actuation system
including pistons in pneumatic
valve actuators.
6M 5) Valve actuators. Where possible, remove cylinder
valve and replace action caps.
Carry out procedure in accordance
with the manufacturer`s
recommendations.
6MLegislative
6. Mechanical
integrity.
Test for mechanical tightness of
pipework and associated
equipment.
6M 6) Cylinders Check labels are securely fixed and
legible, check security of brackets
and fixings, check liquid level,
check pressure in cylinder(s).
Externally examine containers for
signs of damage or unauthorized
modification, and for damage to
system hoses. If the visual
examination shows any defect, the
hose(s) shall be replaced
Carbon Dioxide containers - check
weight or use a liquid level indicator
to verify correct content of
containers. If weight loss exceeds
10% cylinder should be replaced or
recharged.
Check contents of pilot containers.
Liquefied gas type should be within
10% and non-liquefied within 5% of
correct charge. Replace or recharge
any showing a greater loss.
The date of inspection and the
name of the person performing the
inspection shall be recorded on a
tag attached to the container.
As required by statutory regulations
– remove cylinders and pressure
test when necessary
6MLegislative
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7. Auxiliary
electric device/
alarm, door
closures, etc.
Test operation. Operational test to be carried out in
accordance with manufacturer's
recommended procedure.
6M 7) Cylinder gauges Where container pressure gauges
or weight-monitoring devices are
used for this purpose, they shall be
compared to a separate calibrated
device
Operational test to be carried out in
accordance with manufacturer`s
recommended procedure.
12MLegislative
8) Master/slave
system.
Check slave actuation system
including pistons in pneumatic valve
actuators.
6MAdded
9) Auxiliary electric
device/ alarm,
door closures, etc.
Test operation. Operational test to be carried out in
accordance with manufacturers
recommended procedure.
6MAdded
10) Enclosure
Integrity test
Check the enclosure for any
boundary penetrations or other
changes to it that could affect
leakage of gas on operation. If this
can not be visually determined an
integrity test should be carried out.
Test should be carried out in
accordance with Annex A BS
5306-4:2001
Where the integrity test reveals
increased leakage that would result
in an inability to retain the
extinguishant for the required
period, remedial action shall be
carried out.
12MAdded
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EXPANSION FOAM SYSTEMS23-07 23-07 EXPANSION FOAM SYSTEMS
Note: The schedule shall be carried out by a competent person who will provide client with a signed
dated report.
Maintenance shall consist of measures necessary for ensuring that all parts of the foam system
remain in operating condition. The availability and reliability of the foam systems shall be assured.
Inspection and maintenance by an approved competent organisation is recommended. Such systems
must only be maintained and tested by qualified engineers and in accordance with BS EN
13565-2:2009 and BS EN 15004 part 1:2008
Where, due to unforeseen difficulties, it is necessary to leave an installation not available for use, the
fire and rescue service should be informed immediately in order that alternative arrangements can be
made to cover this deficiency should the need arise. In addition a suitable notice to indicate that the
installation is not available for use should be placed in a prominent position.
Technical
Title NotesActionFQTitle FQ Action Notes
6) Pipework Visual check of pipework, foam
outlets, nozzles and pipe supports
for damage or deterioration
If visual indication of normally dry
pipework indicates questionable
strength due to corrosion or
mechanical damage, hydraulically
pressure test.
1MAdded
7) Frost protection Check frost protection for the
permanently charged pipework
system
1MAdded
8) Tanks Test automatic refill devices of
water tanks
1MAdded
9) Alarms Check of alarm signalling to a
permanent manned location in the
case of automatic released
extinguishing systems.
1MAdded
10) Air Inlet Check the air inlet opening of foam
generating devices/nozzles are free
from obstruction
1MAdded
11) Strainers Check and clean strainers6MAdded
12) Foam
concentrate
proportioner
Functionally test the foam
concentrate proportioner using
water without the use of foam
concentrate (where specified by the
manufacturer
6MAdded
13) Valves Test the free movement of all
valves and mechanically operated
components. Check for free
operation of stop valves.
6MAdded
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14) Foam
Concentrate
A check of the foam concentrate
properties shall be carried out by
competent and trained foam
laboratory
personnel. The sampling shall be
carried out according to the
manufacturer’s instructions.
The checks shall include; foam type,
specific gravity, PH, undissolved
solids/sediment, drain time, foam
expansion rate, spreading
coefficient - film formation (on
Cyclohexane) – film forming foams
only, alcohol burnback test (AR
foams only).
The results, and ‘pass’ or ‘fail’
conclusions, shall be given in a
report.
If the foam concentrate report does
not give a ‘pass’ i.e. fit for use, as a
result of its quality check tests, it
shall be
replaced immediately using foam
concentrate of the same type which
is passed fit for use
12MAdded
15) Foam
proportioning
accuracy test
A test of the proportioner and
associated fittings shall be carried
out. The test shall be carried out at
the maximum and minimum system
design flow rates. The accuracy of
foam proportioning shall be in
accordance with the tolerance given
in EN 13565-1. These tests should,
where possible, be carried out with
environmentally compatible foam
substitutes.
12MAdded
16) Discharge test A discharge test should be carried
out on each system to verify;
correct function of the system,
nozzles are free from blockage,
correct functioning of valves,
required discharge coverage is
achieved
12MAdded
17) Premix A check of the premixed foam
solutions properties shall be carried
out by competent and trained foam
laboratory personnel. If the
premixed foam solution report does
not give a ‘pass’ i.e. fit for use, as a
result of its quality check tests, it
shall be replaced immediately using
foam concentrate of the same type
which is passed fit for use
12MAdded
18) Concentrate Check the foam concentrate tanks
and components permanently in
contact with foam concentrate for
signs of external defects, e.g.
leakage, debris on seals.
12MAdded
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19) Vapour seals Inspect integrity of vapour seals on
tank foam pourers and burst discs
in subsurface systems
12MAdded
1. Alarms. Test all electrical detection and
alarm systems in accordance with
BS 5839.
3M 1) A) Pumps [not
foam concentrate
pumps]
Check the correct function of the
pumps and their drives (except
foam concentrate pumps). The test
run shall
last for a period in which the normal
operation conditions of the drive
like power consumption, oil and
cooling water temperature have
been reached. At the end of the
test run power consumption in the
case of electrical drives and
revolutions, oil and cooling water
temperature in the case of diesel
engine drives shall be measured.
Test run diesel engines to reach
operating temperatures (minimum
10 min).
1MLegislative
2. Foam
producing
equipment.
Inspect: for mechanical damage,
for corrosion, for blockage of air
inlets, clear as necessary, correct
manual function of all valves,
strainer and gauzes, proportioning
devices.
This may require temporary isolation
of the water main.
6M 1) B) Foam
concentration
pumps
Function test of automatic and
manual pump start devices of foam
concentrate pumps
1MLegislative
3. Control valves. Check for corrected manual and
automatic operation.
6M 2)Oil Levels Check of oil level of pumps,
compressors and diesel engines
1MLegislative
4. Pipework. Examine exposed pipework to
determine condition.
If visual indication of normally dry
pipework indicates questionable
strength due to corrosion or
mechanical damage, hydraulically
pressure test.
6M 3) Flow Pressure Check of the flow pressure in case
of systems feed directly from public
or factory mains
1MLegislative
5. Tanks for foam
concentrate and
solution.
Visually inspect without draining. Check any concentrate shipping
containers for evidence of
deterioration.
6M 4) Batteries Check of batteries concerning the
maintenance instructions given by
the battery manufacturer as well as
function of the battery charger
1MLegislative
6. Concentrate. Check condition. Correct any deterioration according
to the manufacturer's
recommendations.
12M 5)Diesel tanks Check of minimum fuel supply of
diesel engines
1MLegislative
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FIRE EXTINGUISHERS - GAS SUPPRESSION23-08 23-08 FIRE EXTINGUISHERS - GAS SUPPRESSION (Halon)
Note: As this type of equipment is pressurised it can be opened for inspection only after discharge.
This should be carried out after 10 years if the following annual maintenance has been carried out.
When removing parts from extinguishers, competent persons should ensure that they are clear of any
parts which might be ejected. Under no circumstances should any attempt be made to remove the
valves of high pressure extinguishers or cartridges under field conditions. Extreme caution should be
used when opening any extinguisher.
Such devices must only be maintained and tested by qualified engineers and in accordance with BS
5306-3:2009
Service of this type of extinguisher may only be carried out if the extinguisher meets the criteria of the
“critical uses” in Annex VII of EC Regulation 2037/2000
As this type of equipment is pressurised it can be opened for inspection only after discharge. This
should be carried out after 10 years if the following annual maintenance has been carried out.
Other
Title NotesActionFQTitle FQ Action Notes
7) Extinguisher -
Overhaul
Empty the extinguisher and strip the
components down completely.
Reassemble and recharge the
extinguisher with new headcaps
and valves.
Selected halon alternative agents
have superseded halon usage in
fixed fire suppression system and
portable fire extinguisher
applications.
120MAdded
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FIRE EXTINGUISHERS - CARBON DIOXIDE23-09 23-09 FIRE EXTINGUISHERS - CARBON DIOXIDE
Note: For extinguishing kitchen cooking oil fires, Wet Chemical fire extinguishers (Class F) must be in
position.
When removing parts from extinguishers, competent persons should ensure that they are clear of any
parts which might be ejected. Under no circumstances should any attempt be made to remove the
valves of high pressure extinguishers or cartridges under field conditions. Extreme caution should be
used when opening any extinguisher.
Such devices must only be maintained and tested by qualified engineers and in accordance with BS
5306-3:2009
Technical
Title NotesActionFQTitle FQ Action Notes
6) Safety pin Remove the safety pin and check
that the operating lever is
undamaged and its movement is
unobstructed. Safety precautions
should be taken to avoid
inadvertent operation. Return the
safety pin or, where necessary, a
replacement pin to the extinguisher
12MAdded
7) Seals Ensure that all seals for the
discharge horn, the hose, the
nozzle and the valve body are in
place, as prescribed in the
extinguisher manufacturer’s
instructions.
12MAdded
8) Label Complete the details on the
maintenance label
12MAdded
9) Mounting
bracket/stand
Check any mounting bracket or
stand if accessible and rectify any
problems.
12MAdded
10) Report Write an inspection report advising
the responsible person of the state
of maintenance of the extinguisher
12MAdded
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11)Overhaul
procedure every
10 years
a) Discharge the extinguisher.
Remove the swivel horn/hose
assembly, the valve and the valve
assembly, and remove the diptube
from the valve assembly. Destroy
the valve.
b) Pressure-test the body shell in
accordance with the test pressure
indicated on the body. Do not
overhaul the body if it is unmarked.
Permanently mark the body shell
with the retest date and the
identification of the organization
performing the test. (Attention is
drawn to the Carriage of Dangerous
Goods and Use of Transportable
Pressure Equipment Regulations
2007
c) Reassemble and recharge the
extinguisher with new
headcaps/valves
120MAdded
1. Extinguisher
body.
Examine for corrosion or damage. If replacement indicated report to
client.
12M 1) Safety Clip and
indicating devices
Check the safety clip and indicating
devices to determine whether the
extinguisher might have been
operated
12MLegislative
2. Contents. Weigh and check against records.
If loss greater than 10% recharge.
12M 2) External
examination
Examine the exterior for corrosion,
dents, gouges or damage that
could impair the safe operation of
the extinguisher paying particular
attention to any plastics headcap
for signs of degradation.
12MLegislative
3. Horn, hose
and valve
assembly.
Examine, clean and replace if not in
good condition.
12M 3) Weight check Weigh the extinguisher after
removal of the discharge horn/hose
assembly). Check the mass against
that
recorded when first put into service
or when last recharged and record
this on the maintenance label (In
the event of a loss of content of
more than 10%, discharge and
recharge
.
12MLegislative
4. Operating
mechanism (if
detachable).
Check operating mechanism and
discharge control (where fitted) for
free movement. Clean, rectify or
replace as necessary.
12M 4) Operating
instructions
Check the operating instructions for
correctness and legibility, ensuring
that the text is in English.
12MLegislative
5. Safety clip. Replace after maintenance activity
or renew wire seal as appropriate.
12M 5) Opening Open the extinguisher by
unscrewing the headcap. Remove
the gas cartridge.
12MLegislative
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FIRE EXTINGUISHERS - FOAM (Stored Pressure)23-10 23-10 FIRE EXTINGUISHERS - FOAM (Stored Pressure)
When removing parts from extinguishers, competent persons should ensure that they are clear of any
parts which might be ejected. Under no circumstances should any attempt be made to remove the
valves of high pressure extinguishers or cartridges under field conditions. Extreme caution should be
used when opening any extinguisher.
Such devices must only be maintained and tested by qualified engineers and in accordance with BS
5306-3:2009
Added
Title NotesActionFQTitle FQ Action Notes
1. Pressure
indicating device.
Check operation and pressure. If device inoperative or pressure is
below specified lower limit refer to
manufacturer's instructions. If no
device fitted use connection, if
provided, to verify pressure.
12M 1) Safety Clip and
indicating devices
Check the safety clip and indicating
devices to determine whether the
extinguisher might have been
operated.
12MLegislative
2. Extinguisher
body.
Examine for corrosion or damage. If replacement indicated report to
client.
12M 2) Pressure –
indicating devices
Check the pressure-indicating
device where fitted. If it is not
operating freely or if the indicated
pressure is outside the specified
limits, refer to the extinguisher
manufacturer’s instructions to
ascertain the appropriate action to
be taken. Check that any dust
covers needed on
pressure-indicating or
pressure-relief devices are in place
and are of a size that does not
obscure the reading of the gauge.
Where a pressure-indicating device
is not fitted, verify, by means of the
connection provided for this
purpose, that the internal pressure
is correct. If it is not correct, refer to
the extinguisher manufacturer’s
instructions to ascertain the
appropriate action to be taken.
12MLegislative
3. Contents. Weigh and check against records. Report any loss.12M 3) External
examination
Examine the exterior for corrosion,
dents, gouges or damage that
could impair the safe operation of
the extinguisher paying particular
attention to any plastics headcap
for signs of degradation.
12MLegislative
4. Nozzle and
hose.
Examine and clean as necessary,
Check hose for wear or damage
and replace if necessary.
12M 4) Weight check Weigh the extinguisher after
removal of the discharge horn/hose
assembly). Check the mass against
that
recorded when first put into service
or when last recharged and record
this on the maintenance label (In
the event of a loss of content of
more than 10%, discharge and
recharge
12MLegislative
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5. Operating
mechanism (if
detachable).
Check operating mechanism and
discharge control (where fitted) for
free movement. Clean, rectify or
replace as necessary.
12M 5) Operating
instructions
Check the operating instructions for
correctness and legibility, ensuring
that the text is in English.
12MLegislative
6. Safety clip. Replace after maintenance activity
or renew wire seal as appropriate.
12M 6) Removable
operating
mechanism
Where the extinguisher is designed
to have the operating mechanism
removed without the discharge of
contents or loss of pressure,
remove and check the operating
mechanism and discharge control
(where fitted) for free movement.
Clean and lubricate the operating
mechanism, rectify any problems,
or replace with a new operating
mechanism as necessary.
12MLegislative
7. Internal
inspection.
Discharge contents, Examine for
corrosion, Refill if condition
satisfactory.
48M 7) Safety pin Remove the safety pin and check
that the operating lever is
undamaged and its movement is
unobstructed. Safety precautions
should be taken to avoid
inadvertent operation. Return the
safety pin or, where necessary, a
replacement pin to the extinguisher.
12MLegislative
8) Seals The seals for the discharge horn,
the hose, the nozzle and the valve
body should be replaced with new
seals when these components are
removed from the extinguisher. If
the hose is fitted with a diaphragm,
this should always be replaced with
a new diaphragm.
Check the condition and fitness for
use of the discharge nozzle, horn
and hose, and ensure that the
nozzle, horn and hose, if fitted, are
not obstructed, cracked, worn, or
damaged. Replace with a new
nozzle, horn and/or hose if
necessary.
12MAdded
9) Reassembly Reassemble the extinguisher in
accordance with the instructions of
the extinguisher manufacturer.
Replace with new any safety clip
and indicating device designed to
show whether the extinguisher
might have been operated.
12MAdded
10) Label Complete the details on the
maintenance label
12MAdded
11) Mounting
bracket/stand
Check any mounting bracket or
stand if accessible and rectify any
problems.
12MAdded
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12) Report Write an inspection report advising
the responsible person of the state
of maintenance of the extinguisher
12MAdded
Extended Service
procedures every
5 years
60MAdded
13) Prior to performing the test
discharge, the extinguisher should
be examined externally for any
obvious signs of damage to the
body or operating mechanism. If a
plastics headcap is coated in such
a way as to disguise degradation
(e.g. by painting), replace with a
new headcap before proceeding to
action 2. In the case of stored
pressure extinguishers, additional
safety precautions should be
observed.
60MAdded
14) Perform the test discharge on the
extinguisher.
60MAdded
15) Examine the body internally and in
detail for corrosion, dents, cuts,
gouges or lining damage. Pay
special attention to the welds.
Follow the extinguisher
manufacturer’s instructions where
there are any doubts about the
welds.
60MAdded
16) Examine and check all closures for
thread wear, damage and corrosion
as applicable.
60MAdded
17) Return the extinguisher to
operational condition. If the
extinguisher was fitted with a
plastics headcap, it should be fitted
with a new headcap, if this has not
already been fitted in action 13
(above). Reassemble and recharge
the extinguisher in accordance with
the extinguisher
manufacturer’s instructions
60MAdded
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FIRE EXTINGUISHERS - POWDER23-11 23-11 FIRE EXTINGUISHERS - POWDER (GAS CARTRIDGE)
When removing parts from extinguishers, competent persons should ensure that they are clear of any
parts which might be ejected. Under no circumstances should any attempt be made to remove the
valves of high pressure extinguishers or cartridges under field conditions. Extreme caution should be
used when opening any extinguisher.
Such devices must only be maintained and tested by qualified engineers and in accordance with BS
5306-3:2009
Added
Title NotesActionFQTitle FQ Action Notes
10) Gas cartridge Examine the gas cartridge
externally for corrosion or damage.
If the gas cartridge has suffered
mechanical damage or is corroded,
replace as recommended by the
extinguisher supplier. Weigh the
gas cartridge and check the mass
against that marked on the gas
cartridge. If the gas cartridge has
sustained a loss of content greater
than 10% (15% for cartridges with a
content mass of less than 30 g) of
the original content, withdraw it
from service and replace it with a
gas cartridge as recommended by
the extinguisher manufacturer.
Check the date marked on the
cartridge
12MAdded
11) Seals The seals for the discharge horn,
the hose, the nozzle and the valve
body should be replaced with new
seals when these components are
removed from the extinguisher. If
the hose is fitted with a diaphragm,
this should always be replaced with
a new diaphragm.
Check the condition and fitness for
use of the discharge nozzle, horn
and hose, and ensure that the
nozzle, horn and hose, if fitted, are
not obstructed, cracked, worn, or
damaged. Replace with a new
nozzle, horn and/or hose if
necessary.
12MAdded
12) Body - powder Examine the interior with the aid of
an inspection light. Check for
corrosion and deterioration of lining,
if fitted.
0MAdded
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13) Reassembly Reassemble the extinguisher in
accordance with the instructions of
the extinguisher manufacturer.
Replace with new any safety clip
and indicating device designed to
show whether the extinguisher
might have been operated.
12MAdded
14) Label Complete the details on the
maintenance label
12MAdded
15) Mounting
bracket/stand
Check any mounting bracket or
stand if accessible and rectify any
problems.
12MAdded
16) Report Write an inspection report advising
the responsible person of the state
of maintenance of the extinguisher
12MAdded
Extended Service
procedures every
5 years
60MAdded
17) Prior to performing the test
discharge, the extinguisher should
be examined externally for any
obvious signs of damage to the
body or operating mechanism. If a
plastics headcap is coated in such
a way as to disguise degradation
(e.g. by painting), replace with a
new headcap before proceeding to
action 2. In the case of stored
pressure extinguishers, additional
safety precautions should be
observed.
60MAdded
18) Perform the test discharge on the
extinguisher.
60MAdded
19) Examine the body internally and in
detail for corrosion, dents, cuts,
gouges or lining damage. Pay
special attention to the welds.
Follow the extinguisher
manufacturer’s instructions where
there are any doubts about the
welds.
60MAdded
20) Examine and check all closures for
thread wear, damage and corrosion
as applicable.
60MAdded
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21) Return the extinguisher to
operational condition. If the
extinguisher was fitted with a
plastics headcap, it should be fitted
with a new headcap, if this has not
already been fitted in action 13
(above). Reassemble and recharge
the extinguisher in accordance with
the extinguisher
manufacturer’s instructions.
60MAdded
1. Contents. Weigh the extinguisher and if more
than 10% loss of powder, recharge.
12M 1) Safety Clip and
indicating devices
Check the safety clip and indicating
devices to determine whether the
extinguisher might have been
operated.
12MLegislative
2. Condition of
powder.
Open container and examine
powder, if any evidence of lumps,
caking or foreign bodies, recharge.
If powder appears satisfactory,
agitate by inverting and shaking.
12M 2) External
examination
Examine the exterior for corrosion,
dents, gouges or damage that
could impair the safe operation of
the extinguisher paying particular
attention to any plastics headcap
for signs of degradation.
12MLegislative
3. Body. Examine internally and externally
for damage.
12M 3) Weight check Weigh the extinguisher after
removal of the discharge horn/hose
assembly). Check the mass against
that
recorded when first put into service
or when last recharged and record
this on the maintenance label (In
the event of a loss of content of
more than 10%, discharge and
recharge.
12MLegislative
4. Gas cartridge. Examine for corrosion and damage.
Check weight.
Weight of contents is marked on
cartridge, replace if there is any loss
of weight. Cartridges over 10 years
old must be replaced.
12M 4) Operating
instructions
Check the operating instructions for
correctness and legibility, ensuring
that the text is in English.
12MLegislative
5. Vent holes. Examine and clean.12M 5) Opening Open the extinguisher by
unscrewing the headcap. Remove
the gas cartridge.
12MLegislative
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6. Nozzle, hose
and internal
discharge tube.
Examine for any blockage, clean
rectify or replace as necessary.
12M 6) Powder charges Examine the powder of the
extinguisher. Agitate the powder by
inverting and shaking the
extinguisher, taking care to avoid
spillage. If there is any evidence of
caking, lumps, or foreign bodies, or
if the powder is not free flowing, or
if there is any doubt at all about the
condition of the powder, discard all
the powder and recharge. The use
of sieves or machines to remove
foreign bodies or caked or lumpy
material is not recommended since
this will involve considerable
exposure of the powder to
atmospheric humidity with a risk of
subsequent caking
12MLegislative
7. Operating
mechanism and
discharge control.
Check for free movement, clean
rectify or replace as necessary.
12M 7) Operating
mechanism and
air passages
Clean if necessary and pass air
through the air passages, paying
particular attention to the vent holes
(or other venting device) in the
headcap. Check that the strainer
(where fitted), internal discharge
tube and breather valve (where
fitted) are unobstructed.
Rectify any problems or replace
with a new tube or valve if
necessary. Renew gas-band, where
fitted.
Check the operating mechanism
and discharge control (where fitted)
for free movement. Rectify any
problems or replace with a new
operating mechanism or discharge
control as necessary. Protect
moving parts and threads against
corrosion with a lubricant as
recommended by the extinguisher
manufacturer.
12MLegislative
8. Washers and
diaphragms.
Examine and replace if necessary.12M 8) Removable
operating
mechanism
Where the extinguisher is designed
to have the operating mechanism
removed without the discharge of
contents or loss of pressure,
remove and check the operating
mechanism and discharge control
(where fitted) for free movement.
Clean and lubricate the operating
mechanism, rectify any problems,
or replace with a new operating
mechanism as necessary
12MLegislative
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9. Safety clip. Replace after maintenance activity
or renew wire seal as appropriate.
12M 9) Safety pin Remove the safety pin and check
that the operating lever is
undamaged and its movement is
unobstructed. Safety precautions
should be taken to avoid
inadvertent operation. Return the
safety pin or, where necessary, a
replacement pin to the extinguisher.
12MLegislative
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FIRE EXTINGUISHERS - WATER - GAS CARTRIDGE23-12 23-12 FIRE EXTINGUISHERS - WATER - GAS CARTRIDGE
Note: If any soda acid extinguishers are found, the client must be informed that these must be
withdrawn from service.
When removing parts from extinguishers, competent persons should ensure that they are clear of any
parts which might be ejected. Under no circumstances should any attempt be made to remove the
valves of high pressure extinguishers or cartridges under field conditions. Extreme caution should be
used when opening any extinguisher.
Such devices must only be maintained and tested by qualified engineers and in accordance with BS
5306-3:2009
Legislative
Title NotesActionFQTitle FQ Action Notes
1. Body. Empty, examine for damage and
corrosion externally and internally.
12M 1) Safety Clip and
indicating devices
Check the safety clip and indicating
devices to determine whether the
extinguisher might have been
operated.
12MLegislative
2. Contents. Check water level after refilling.12M 2) External
examination
Examine the exterior for corrosion,
dents, gouges or damage that
could impair the safe operation of
the extinguisher paying particular
attention to any plastics headcap
for signs of degradation.
12MLegislative
3. Gas cartridge. Examine externally for corrosion
and weigh and check against that
marked on the cartridge.
12M 3) Weight check Weigh the extinguisher after
removal of the discharge horn/hose
assembly). Check the mass against
that recorded when first put into
service or when last recharged and
record this on the maintenance
label (In the event of a loss of
content of more than 10%,
discharge and recharge
12MLegislative
4. Vent holes. Examine and clean if necessary.12M 4) Operating
instructions
Check the operating instructions for
correctness and legibility, ensuring
that the text is in English.
12MLegislative
5. Nozzle and
strainer and (if
fitted) internal
discharge tube
and breather
valve.
Examine and clean if necessary.12M 5) Opening Open the extinguisher by
unscrewing the headcap. Remove
the gas cartridge.
12MLegislative
6. Operating
mechanism and
discharge valve.
Check movement, clean, rectify
faults or replace.
12M 6) Water,
water-based, and
foam charges
Pour the original charge into a
clean container and, if it is to be
reused, check it in accordance with
the extinguisher manufacturer’s
instructions. Where the additive is
in a separate container, remove this
container and check it for leakage.
If the container has been
leaking, discard the container and
charge. Rinse out the body.
12MLegislative
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7. Sealing
washers and hose.
Examine and replace if not in good
condition.
12M 7) Operating
mechanism and
air passages
Clean if necessary and pass air
through the air passages, paying
particular attention to the vent holes
(or other venting device) in the
headcap. Check that the strainer
(where fitted), internal discharge
tube and breather valve (where
fitted) are unobstructed.
Rectify any problems or replace
with a new tube or valve if
necessary. Renew gas-band, where
fitted.
Check the operating mechanism
and discharge control (where fitted)
for free movement. Rectify any
problems or replace with a new
operating mechanism or discharge
control as necessary. Protect
moving parts and threads against
corrosion with a lubricant as
recommended by the extinguisher
manufacturer
0MLegislative
8. Recharge. Fill to correct level. Note any special needs, e.g.
anti-freeze or corrosion inhibitor.
12M 8) Removable
operating
mechanism
Where the extinguisher is designed
to have the operating mechanism
removed without the discharge of
contents or loss of pressure,
remove and check the operating
mechanism and discharge control
(where fitted) for free movement.
Clean and lubricate the operating
mechanism, rectify any problems,
or replace with a new operating
mechanism as necessary.
Note any special precautions, e.g.
anti-freeze or corrosion inhibitor.
12MLegislative
9. Safety clip. Replace after maintenance activity
or renew wire seal as appropriate.
12M 9) Safety pin Remove the safety pin and check
that the operating lever is
undamaged and its movement is
unobstructed. Safety precautions
should be taken to avoid
inadvertent operation. Return the
safety pin or, where necessary, a
replacement pin to the extinguisher.
12MLegislative
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10) Gas cartridge Examine the gas cartridge
externally for corrosion or damage.
If the gas cartridge has suffered
mechanical damage or is corroded,
replace as recommended by the
extinguisher supplier. Weigh the
gas cartridge and check the mass
against that marked on the gas
cartridge. If the gas cartridge has
sustained a loss of content greater
than 10% (15% for cartridges with a
content mass of less
than 30 g) of the original content,
withdraw it from service and replace
it with a gas cartridge as
recommended by the extinguisher
manufacturer. Check the date
marked on the cartridge
12MAdded
11) Seals The seals for the discharge horn,
the hose, the nozzle and the valve
body should be replaced with new
seals when these components are
removed from the extinguisher. If
the hose is fitted with a diaphragm,
this should always be replaced with
a new diaphragm.
Check the condition and fitness for
use of the discharge nozzle, horn
and hose, and ensure that the
nozzle, horn and hose, if fitted, are
not obstructed, cracked, worn, or
damaged. Replace with a new
nozzle, horn and/or hose if
necessary.
12MAdded
12) Body: water,
water-based
and foam
Examine the interior with the aid of
an inspection light. Check for
corrosion or lining deterioration.
Check separate containers for
additives and replace if they are
leaking or damaged
12MAdded
13) Water and
water-based
(including foam)
charges
Return the original charge to the
extinguisher, or replace with new
charge according the instructions of
the extinguisher manufacturer
12MAdded
14) Reassembly Reassemble the extinguisher in
accordance with the instructions of
the extinguisher manufacturer.
Replace with new any safety clip
and indicating device designed to
show whether the extinguisher
might have been operated.
12MAdded
15) Label Complete the details on the
maintenance label
12MAdded
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16) Mounting
bracket/stand
Check any mounting bracket or
stand if accessible and rectify any
problems.
12MAdded
17) Report Write an inspection report advising
the responsible person of the state
of maintenance of the extinguisher
12MAdded
Extended Service
procedures every
5 years
60MAdded
17) Prior to performing the test
discharge, the extinguisher should
be examined externally for any
obvious signs of damage to the
body or operating mechanism. If a
plastics headcap is coated in such
a way as to disguise degradation
(e.g. by painting), replace with a
new headcap before proceeding to
action 2. In the case of stored
pressure extinguishers, additional
safety precautions should be
observed.
60MAdded
18) Perform the test discharge on the
extinguisher.
60MAdded
19) Examine the body internally and in
detail for corrosion, dents, cuts,
gouges or lining damage. Pay
special attention to the welds.
Follow the extinguisher
manufacturer’s instructions where
there are any doubts about the
welds.
60MAdded
20) Examine and check all closures for
thread wear, damage and corrosion
as applicable.
60MAdded
21) Return the extinguisher to
operational condition. If the
extinguisher was fitted with a
plastics headcap, it should be fitted
with a new headcap, if this has not
already been fitted in action 13
(above). Reassemble and recharge
the extinguisher in accordance with
the extinguisher manufacturer’s
instructions
60MAdded
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FIRE EXTINGUISHERS - WATER STORED PRESSURE23-13 23-13 FIRE EXTINGUISHERS - WATER STORED PRESSURE
When removing parts from extinguishers, competent persons should ensure that they are clear of any
parts which might be ejected. Under no circumstances should any attempt be made to remove the
valves of high pressure extinguishers or cartridges under field conditions. Extreme caution should be
used when opening any extinguisher.
Such devices must only be maintained and tested by qualified engineers and in accordance with BS
5306-3:2009
Added
Title NotesActionFQTitle FQ Action Notes
9) Reassembly Reassemble the extinguisher in
accordance with the instructions of
the extinguisher manufacturer.
Replace with new any safety clip
and indicating device designed to
show whether the extinguisher
might have been operated.
12MAdded
10) Label Complete the details on the
maintenance label
12MAdded
11) Mounting
bracket/stand
Check any mounting bracket or
stand if accessible and rectify any
problems.
12MAdded
12) Report Write an inspection report advising
the responsible person of the state
of maintenance of the extinguisher
12MAdded
Extended Service
procedures every
5 years
60MAdded
13) Prior to performing the test
discharge, the extinguisher should
be examined externally for any
obvious signs of damage to the
body or operating mechanism. If a
plastics headcap is coated in such
a way as to disguise degradation
(e.g. by painting), replace with a
new headcap before proceeding to
action 2. In the case of stored
pressure extinguishers, additional
safety precautions should be
observed.
60MAdded
14) Perform the test discharge on the
extinguisher.
60MAdded
15) Examine the body internally and in
detail for corrosion, dents, cuts,
gouges or lining damage. Pay
special attention to the welds.
Follow the extinguisher
manufacturer’s instructions where
there are any doubts about the
welds.
60MAdded
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16) Examine and check all closures for
thread wear, damage and corrosion
as applicable.
60MAdded
17) Return the extinguisher to
operational condition. If the
extinguisher was fitted with a
plastics headcap, it should be fitted
with a new headcap, if this has not
already been fitted in action 13
(above). Reassemble and recharge
the extinguisher in accordance with
the extinguisher manufacturer’s
instructions
60MAdded
1. Body. Examine externally for corrosion
and damage.
12M 1) Safety Clip and
indicating devices
Check the safety clip and indicating
devices to determine whether the
extinguisher might have been
operated.
12MLegislative
2. Contents. Weigh and check against original
weight when put into service.
12M 2)
Pressure-indicatin
g devices
Check the pressure-indicating
device where fitted. If it is not
operating freely or if the indicated
pressure is outside the specified
limits, refer to the extinguisher
manufacturer’s instructions to
ascertain the appropriate action to
be taken. Check that any dust
covers needed on
pressure-indicating or
pressure-relief devices are in place
and are of a size that does not
obscure the reading of the gauge.
Where a pressure-indicating device
is not fitted, verify, by means of the
connection provided for this
purpose, that the internal pressure
is correct. If it is not correct, refer to
the extinguisher manufacturer’s
instructions to ascertain the
appropriate action to be taken.
12MLegislative
3. Pressure
indicator on stored
pressure
equipment.
Check operation, if less than
specified refer to manufacturer's
instructions.
Where device not fitted, check by
means of connector provided.
12M 3) External
examination
Examine the exterior for corrosion,
dents, gouges or damage that
could impair the safe operation of
the extinguisher paying particular
attention to any plastics headcap
for signs of degradation.
12MLegislative
4. Contents. Weigh and check against records. Report any loss.12M 4) Weight check Weigh the extinguisher after
removal of the discharge horn/hose
assembly). Check the mass against
that recorded when first put into
service or when last recharged and
record this on the maintenance
label (In the event of a loss of
content of more than 10%,
discharge and recharge
.
12MLegislative
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5. Nozzle and
hose.
Examine and clean as necessary,
Check hose for wear or damage
and replace if necessary.
12M 5) Operating
instructions
Check the operating instructions for
correctness and legibility, ensuring
that the text is in English.
12MLegislative
6. Operating
mechanism (if
detachable).
Check operating mechanism and
discharge control (where fitted) for
free movement. Clean, rectify or
replace as necessary.
12M 6) Removable
operating
mechanism
Where the extinguisher is designed
to have the operating mechanism
removed without the discharge of
contents or loss of pressure,
remove and check the operating
mechanism and discharge control
(where fitted) for free movement.
Clean and lubricate the operating
mechanism, rectify any problems,
or replace with a new operating
mechanism as necessary.
12MLegislative
7. Safety clip. Replace after maintenance activity
or renew wire seal as appropriate.
12M 7) Safety pin Remove the safety pin and check
that the operating lever is
undamaged and its movement is
unobstructed. Safety precautions
should be taken to avoid
inadvertent operation. Return the
safety pin or, where necessary, a
replacement pin to the extinguisher.
12MLegislative
8. Internal
inspection.
Discharge contents, Examine for
corrosion, Refill if condition
satisfactory.
48M 8) Seals The seals for the discharge horn,
the hose, the nozzle and the valve
body should be replaced with new
seals when these components are
removed from the extinguisher. If
the hose is fitted with a diaphragm,
this should always be replaced with
a new diaphragm.
Check the condition and fitness for
use of the discharge nozzle, horn
and hose, and ensure that the
nozzle, horn and hose, if fitted, are
not obstructed, cracked, worn, or
damaged. Replace with a new
nozzle, horn and/or hose if
necessary
.
12MLegislative
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SPRINKLER SYSTEMS23-14 23-14 SPRINKLER SYSTEMS
Introduction
Automatic sprinkler systems must be maintained in accordance with BS EN 12845:2004 and the LPC
publication - TB203: 2004.
An automatic sprinkler system is designed to detect a fire and extinguish it with water in its early
stages or hold the fire in check so that extinguishment can be completed by other means.
The sprinklers operate at predetermined temperatures to discharge water over the affected part of the
area below. The flow of water through the alarm valve initiates a fire alarm. The operating temperature
is generally selected to suit ambient temperature conditions.
Under BS EN 12845:2004 there are planned maintenance tasks for 3 and 10 year frequencies these
are not covered in these instruction sets.
Introduction
Automatic sprinkler systems must be maintained in accordance with BS EN 12845:2004 + A2:2009
incorporating corrigendum August 2009 Fixed firefighting systems- automatic sprinkler systems-
Design, Installation and maintenance and the LPC publication - TB203: 2004.
An automatic sprinkler system is designed to detect a fire and extinguish it with water in its early
stages or hold the fire in check so that extinguishment can be completed by other means.
The sprinklers operate at predetermined temperatures to discharge water over the affected part of the
area below. The flow of water through the alarm valve initiates a fire alarm. The operating temperature
is generally selected to suit ambient temperature conditions.
Under BS EN 12845:2004 there are planned maintenance tasks for 3 and 10 year frequencies these
are not covered in these instruction sets.
Only the user should give permission for a sprinkler installation or zone to be shut down for any
reason other than an emergency.
Before a system is wholly or partly shut down every part of the premises should be checked to ensure
that there is no indication of fire.
Where premises are subdivided into separate occupancies constituting buildings in communication or
at risk, protected by common sprinkler systems or installations, all occupiers should also be advised
that the water is to be turned off.
Particular attention should be given to situations where installation pipework passes through walls or
ceilings where these may feed sprinklers in areas needing special consideration
Technical
Title NotesActionFQTitle FQ Action Notes
SERVICE &
MAINTENANCE
The effect of any changes of
structure, occupancy, storage
configuration, heating, lighting or
equipment etc. of a building on
hazard classification or installation
design shall be identified in order
that the appropriate modifications
may be carried out.
Added
1. System Checks The following must be checked and
recorded: all water and air pressure
gauge readings on installation,
trunk mains and pressure tanks;
The pressure in the pipework in dry,
alternate and pre-action installations
should not fall at a rate of more than
1.0 bar per week. All results must be
recorded in Fire Alarm log book
1W 1. System
Checks
The following must be checked and
recorded (in sprinkler Log Book): all
water and air pressure gauge
readings on installation, trunk
mains and pressure tanks;
The pressure in the pipework in dry,
alternate and pre-action installations
should not fall at a rate of more than
1.0 bar per week. All results must be
recorded in Sprinkler log book
1WLegislative
2. System Checks All water levels in elevated private
reservoirs, rivers, canals, lakes,
water storage tanks (including
pump priming water tanks and
pressure tanks);
All results must be recorded in Fire
Alarm log book
1W 2. System
Checks
All water levels in elevated private
reservoirs, rivers, canals, lakes,
water storage tanks (including
pump priming water tanks and
pressure tanks);
All results must be recorded in
Sprinkler log book
1WLegislative
3. System Checks That all main stop valves are in the
correct position.
All results must be recorded in Fire
Alarm log book
1W 3. System
Checks
That all main stop valves are in the
correct position.
All results must be recorded in
Sprinkler log book
1WLegislative
Page 220 of 614
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4. Water motor
alarm test
Each water motor alarm shall be
sounded for no less than 30 s.
Also Known as Mechanical Bell test.
All results must be recorded in Fire
Alarm log book
1W 4. Water motor
alarm test
Each water motor alarm shall be
sounded for no less than 30
seconds.
Also Known as Mechanical Bell test.
All results must be recorded in
Sprinkler log book
1WLegislative
5. Automatic
pump starting
Electric Motor
Tests automatic pumps and include
the following; a) water pressure on
the starting device shall be
reduced, to simulate the condition
of automatic starting; b) when the
pump starts, the starting pressure
shall be checked and recorded;
All results must be recorded in Fire
Alarm log book
1W 5a. Automatic
pump starting test
-Electric Motor
Test automatic pumps and include
the following; a) water pressure on
the starting device shall be
reduced, to simulate the condition
of automatic starting; b) when the
pump starts, the starting pressure
shall be checked and recorded;
All results must be recorded in
Sprinkler log book
1WLegislative
5. Automatic
pump starting
Diesel
Tests automatic pumps and include
the following; a) fuel and engine
lubricating oil levels in diesel
engines. b) water pressure on the
starting device shall be reduced, to
simulate the condition of automatic
starting; c) when the pump starts,
the starting pressure shall be
checked and recorded; d) the oil
pressure on diesel pumps shall be
checked, as well as the flow of
cooling water through open circuit
cooling systems.
All results must be recorded in Fire
Alarm log book
1W 5b. Automatic
pump starting test
- Diesel
Test automatic pumps and include
the following; a) fuel and engine
lubricating oil levels in diesel
engines. b) water pressure on the
starting device shall be reduced, to
simulate the condition of automatic
starting; c) when the pump starts,
the starting pressure shall be
checked and recorded; d) the oil
pressure on diesel pumps shall be
checked, as well as the flow of
cooling water through open circuit
cooling systems.
All results must be recorded in
Sprinkler log book
1WLegislative
6. Diesel engine
restarting test
Immediately after the pump start
test diesel engines shall be tested
as follows: a) the engine shall be
run for 20 min, or for the time
recommended by the supplier. The
engine shall then be stopped and
immediately restarted using the
manual start test button; b) The
water level in the primary circuit of
closed circuit cooling systems shall
be checked. Oil pressure (where
gauges are fitted), engine
temperatures and coolant flow shall
be monitored throughout the test.
Oil hoses shall be checked and a
general inspection made for
leakage of fuel, coolant or exhaust
fumes.
All results must be recorded in Fire
Alarm log book
1W 6. Diesel engine
restarting test
Immediately after the pump start
test diesel engines shall be tested
as follows: a) the engine shall be
run for 20 min, or for the time
recommended by the supplier. The
engine shall then be stopped and
immediately restarted using the
manual start test button; b) The
water level in the primary circuit of
closed circuit cooling systems shall
be checked. Oil pressure (where
gauges are fitted), engine
temperatures and coolant flow shall
be monitored throughout the test.
Oil hoses shall be checked and a
general inspection made for
leakage of fuel, coolant or exhaust
fumes.
All results must be recorded in
Sprinkler log book
1WLegislative
7. Trace heating
and localized
heating systems
Heating systems to prevent
freezing in the sprinkler system
shall be checked for correct
function.
1W 7. Trace heating
and localised
heating systems
Heating systems to prevent freezing
in the sprinkler system shall be
checked for correct function.
1WOther
Page 221 of 614
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1. System
Batteries
The electrolyte level and density of
all lead acid cells (including diesel
engine starter batteries and those
for control panel power supplies)
shall be checked. If the density is
low the battery charger shall be
checked and, if this is working
normally, the battery or batteries
affected shall be replaced.
For the risks above refer to the
COSHH Regulations -
www.hse.gov.uk
All results must be recorded in Fire
Alarm log book
1M 1. System
Batteries
The electrolyte level and density of
all lead acid cells (including diesel
engine starter batteries and those
for control panel power supplies)
shall be checked. If the density is
low the battery charger shall be
checked and, if this is working
normally, the battery or batteries
affected shall be replaced.
For the risks above refer to the
COSHH Regulations -
www.hse.gov.uk
All results must be recorded in
Sprinkler log book
1MLegislative
2. Sprinklers,
multiple controls
and sprayers
Sprinklers, multiple controls and
sprayers affected by deposits (other
than paint) shall be carefully
cleaned. Painted or distorted
sprinkler heads, multiple controls or
sprayers shall be replaced. Any
petroleum jelly coatings shall be
checked. Where necessary the
existing coatings shall be removed
and the sprinklers, multiple controls
or sprayers shall be coated twice
with petroleum jelly (in the case of
glass bulb sprinklers to the sprinkler
body and yoke only). Particular
attention shall be paid to sprinklers
in spray booths, where more
frequent cleaning and/or protective
measures may be necessary.
All results must be recorded in Fire
Alarm log book
3M 1. Sprinklers,
multiple controls
and sprayers
Sprinklers, multiple controls and
sprayers affected by deposits (other
than paint) shall be carefully
cleaned. Painted or distorted
sprinkler heads, multiple controls or
sprayers shall be replaced. Any
petroleum jelly coatings shall be
checked. Where necessary the
existing coatings shall be removed
and the sprinklers, multiple controls
or sprayers shall be coated twice
with petroleum jelly (in the case of
glass bulb sprinklers to the sprinkler
body and yoke only). Particular
attention shall be paid to sprinklers
in spray booths, where more
frequent cleaning and/or protective
measures may be necessary.
All results must be recorded in
Sprinkler log book
3MLegislative
3. Pipework and
pipe supports
Pipework and hangers shall be
checked for corrosion and painted
as necessary. Bitumen-based paint
on pipework, including the threaded
ends of galvanized pipework and
hangers, shall be renewed as
necessary. Tape wrapping on pipes
shall be repaired as necessary. The
pipework shall be checked for
electrical earthing connections.
Sprinkler pipework shall not be
used for earthing electrical
equipment and any earthing
connections from electrical
equipment shall be removed and
alternative arrangements made.
All results must be recorded in Fire
Alarm log book
3M 2. Pipework and
pipe supports
Pipework and hangers shall be
checked for corrosion and painted
as necessary. Bitumen-based paint
on pipework, including the threaded
ends of galvanized pipework and
hangers, shall be renewed as
necessary. Tape wrapping on pipes
shall be repaired as necessary. The
pipework shall be checked for
electrical earthing connections.
Sprinkler pipework shall not be
used for earthing electrical
equipment and any earthing
connections from electrical
equipment shall be removed and
alternative arrangements made.
All results must be recorded in
Sprinkler log book
Bitumen-based paint may need
renewal at intervals varying from 1
to 5 years according to the severity
of the conditions.
3MOther
Page 222 of 614
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4. Water supplies
and their alarms
Each water supply shall be tested
with each control valve set in the
system. The pump(s), if fitted, in
the supply shall start automatically
and the supply pressure at the
appropriate flow rate shall be no
less than the appropriate value
All results must be recorded in Fire
Alarm log book
3M 3. Water supplies
and their alarms
Each water supply shall be tested
with each control valve set in the
system. The pump(s), if fitted, in the
supply shall start automatically and
the supply pressure at the
appropriate flow rate shall be no
less than the appropriate value in
accordance with clause 10 PUMPS
[BS EN 12845:2004+A2:2009
incorporating corrigendum August
2009] and recognising any changes
required due to any changes of
structure, occupancy, storage
configuration, heating, lighting or
equipment etc. of a building on
hazard classification or installation
design
All results must be recorded in
Sprinkler log book
3MLegislative
5. Electrical
supplies
Any secondary electrical supplies
from diesel generators shall be
checked for satisfactory operation.
All results must be recorded in Fire
Alarm log book
3M 4. Electrical
supplies
Any secondary electrical supplies
from diesel generators shall be
checked for satisfactory operation.
All results must be recorded in
Sprinkler log book
3MLegislative
6. Stop valves All stop valves controlling the flow
of water to sprinklers shall be
operated to ensure that they are in
working order and securely
refastened in the correct mode.
This shall include the stop valves
on all water supplies, at the alarm
valve(s) and all zone or other
subsidiary stop valves.
All results must be recorded in Fire
Alarm log book
3M 5. Stop valves All stop valves controlling the flow
of water to sprinklers shall be
operated to ensure that they are in
working order and securely
refastened in the correct mode.
This shall include the stop valves
on all water supplies, at the alarm
valve(s) and all zone or other
subsidiary stop valves.
All results must be recorded in
Sprinkler log book
3MLegislative
7. Flow switches Flow switches shall be checked for
correct function.
All results must be recorded in Fire
Alarm log book
3M 6. Flow switches Flow switches shall be checked for
correct function.
All results must be recorded in
Sprinkler log book
3MLegislative
8. Replacement The number and condition of
replacement parts held as spare
shall be checked.
All results must be recorded in Fire
Alarm log book
3M 7. Replacement The number and condition of
replacement parts held as spare
shall be checked.
All results must be recorded in
Sprinkler log book
3MLegislative
1. Dry alarm
valves
The moving parts of dry alarm
valves, any accelerators and
exhausters, in dry pipe installations
and subsidiary extensions shall be
exercised in accordance with the
supplier’s instructions.
NOTE Alternate installations need
not be tested in this way since they
are exercised twice a year as a
result of the changeover from wet to
dry operation and back.
6M 1. Dry alarm
valves
The moving parts of dry alarm
valves, any accelerators and
exhausters, in dry pipe installations
and subsidiary extensions shall be
exercised in accordance with the
supplier’s instructions.
Alternate installations need not be
tested in this way since they are
exercised twice a year as a result of
the changeover from wet to dry
operation and back.
All results must be recorded in
Sprinkler log book
6MLegislative
2. Fire brigade
and remote central
station alarm
Where fitted central station
monitoring alarms must be tested.
Activate the alarm with central
station on line to test connection. All
results must be recorded in Fire
Alarm log book
6M 2. Fire brigade
and remote central
station alarm
Where fitted central station
monitoring alarms must be tested.
Activate the alarm with central
station on line to test connection. All
results must be recorded in
Sprinkler log book
6MOther
Page 223 of 614
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3. Automatic
pump flow test
Each water supply pump in the
installation shall be tested at the full
load condition (by means of the test
line connection coupled to the
pump delivery branch downstream
of the pump outlet non-return valve)
and shall give the pressure/flow
values stated on the nameplate.
Appropriate allowances shall be
made for pressure losses in the
supply pipe and valves between the
source and each control valve set.
All results must be recorded in Fire
Alarm log book
12M 1. Automatic
pump flow test
Each water supply pump in the
installation shall be tested at the full
load condition (by means of the test
line connection coupled to the
pump delivery branch downstream
of the pump outlet non-return valve)
and shall give the pressure/flow
values stated on the nameplate.
Appropriate allowances shall be
made for pressure losses in the
supply pipe and valves between the
source and each control valve set.
All results must be recorded in
Sprinkler log book
12Mtechnical
4. Diesel engine
failed-to-start test
The failed-to-start alarm shall be
tested
Immediately after this test the
engine shall be started using the
manual starting system. All
results must be recorded in Fire
Alarm log book
12M 2. Diesel engine
failed-to-start test
The failed-to-start alarm shall be
tested
Immediately after this test the
engine shall be started using the
manual starting system. All results
must be recorded in Sprinkler log
book
12Mtechnical
5. Float valves on
water storage
tanks
Float valves on water storage tanks
shall be checked to ensure they
function correctly.
All results must be recorded in Fire
Alarm log book
12M 3. Float valves on
water storage
tanks
Float valves on water storage tanks
shall be checked to ensure they
function correctly.
All results must be recorded in
Sprinkler log book
12Mtechnical
6. Pump suction
chambers and
strainers
Pump suction strainers and settling
chamber and their screens shall be
inspected at least annually and
cleaned as necessary.
All results must be recorded in Fire
Alarm log book
12M 4. Pump suction
chambers and
strainers
Pump suction strainers and settling
chamber and their screens shall be
inspected at least annually and
cleaned as necessary.
All results must be recorded in
Sprinkler log book
12Mtechnical
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23-15 GAS DETECTION
Prior to carrying out any work ensure regulations and site procedures are followed. Never attempt to
open the detector or junction box when flammable gas is present. Ensure that the associated control
panel is inhibited so as to prevent false alarms.
Added
Title NotesActionFQTitle FQ Action Notes
1. Gas detection Check function and operation of all
automatic sensors, ensure for
correct operation/shut-down of
plant and/or any ancillary control
device. Ensure all devices are
returned to their correct settings.
Site practices will dictate the
frequency with which detectors are
tested.
3MAdded
2. Gas Test Carry out gas test in accordance
with the manufaturers guidelines.
6MAdded
3. Calibration Detector should be recalibrated in
accordance with the manufaturers
guidelines.
12MAdded
4. Dust filter if
fitted
Test to ensure filter has not become
blocked. Frequency depends on
local risk assessment and relating
to the ammount of dust in the
atmpshere where the the detector
is installed.
Frequency depends on local risk
assessment and relating to the
ammount of dust in the atmpshere
where the the detector is installed.
Added
Page 225 of 614
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23-16 KITCHEN HOOD FIRE SUPPRESSION
There are three main types of suppression system;
1) Carbon dioxide
2) Chemical both liquid and dry
3) Water
Chemical fire suppressant ia an alkaline compound and all due care and attention should be taken
when handling such a substance.
In addition to the specialist maintenance tasks there should be an operational task carried out by the
client or kitchen head to visually check the whole system on a regular basis.
All systems differ from type and manufacturer to manufacturer. It is essential that the maintenance is
carried out in full accordance with those manufacturers instruction and by a trained specialist who has
undergone the instructions necessary to perform the maintenance and recharge service on the actual
type of equipment in place.
Added
Title NotesActionFQTitle FQ Action Notes
1). Visual
examination
The extinguishing system is in its
proper location
• Manual actuators are
unobstructed
• Tamper indicators and seals are
intact
• The maintenance tag or certificate
is in place
• There is no obvious physical
damage
• Pressure gauges, if provided, are
in operable range
• The blowoff caps are intact and
undamaged
• The hood, duct and protected
cooking appliances have not been
replaced, modified or replaced.
If any deficiencies are found,
appropriate corrective action shall
be taken immediately and the client
informed. A written record of these
findings should be kept.
Each system shall have a tag or
label sucurely attached, indicating
the month and year the
maintenance is performed and
identifying the person performing
the service. Only the current tag or
label shall remain in place.
1MAdded
2). System check Check to see that the hazard has
not changed.
Check of all actuation components,
including remote manual pull
stations, mechanical or electrical
devices, detectors, actuators and
fire-actuated dampers, agent
containers, pipework, hoses and
the liquid level of all non
pressurised wet chemical
containers to ensure that they are
in operable condition.
6MAdded
3). Fire alarm
interconnect
switches
Carry out a visual inspection of fire
alarm interconnect switches.
6MAdded
Page 226 of 614
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4). System test All chemical systems shall be
tested and includes the operation of
the detection system signals and
releasing devices, including manual
stations and other associated
equipment. A discharge of the wet
chemical normally is not part of the
test.
Where the maintenance of the
system reveals defective parts that
could cause an impairment or failure
of proper operation of the system,
the affected parts shall be replaced
or repaired in accordance with the
manufacturers recommendations.
6MAdded
5). Fusible links
and automatic
sprinkler heads.
Fusible links and automatic
sprinkler heads are required to be
replaced at least annually, but may
have to be replaced more
frequently if a visual inspection
shows that to be necessary. By
exception, bulb-type sprinklers or
spray nozzles do not need to be
replaced if an annual examination
shows no buildup of grease or other
material on the sprinkler or spray
nozzles.
The replaced fusible links / heads
shall be destroyed when removed.
The year of manufacture and the
date of installation of the fixed
temperature-sensing element shall
be marked on the system inspection
tag. The tag shall be signed or
initialed by the specialist service
provider.
12MAdded
6). Fire alarm
interconnect
switches
Fire alarm interconnect switches
are required to be tested annually
by mechanically or electrically
operating the switch to verify receipt
of a signal at the fire alarm control
panel. This testing should be
performed as part of the annual test
conducted of the building fire alarm
system.
12MAdded
7). Major overhaul. Major system overhaul [maximum
time this should be carried out].
36MAdded
8). Hydrostatic
testing
Wet chemical containers, auxiliary
pressure containers and hose
assemblies shall be subject to a
hydrostatic pressure test at
intervals not exceeding 12 years.
144MAdded
Page 227 of 614
FLUES
Page 228 of 614
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FLUES (all combustible fuels)24-01 24-01 FLUES (all combustible fuels)
These notes should be read in conjunction with relevant sections BOILERS GAS, OIL SOLID FUEL –
burning appliances. Only GAS SAFE registered contractors are permitted to work on GAS
flues. Ensure that flues conform to relevant guidance and BS/EN and boiler manufacturers’
recommendation. External dampers/economisers can infringe manufacturer’s guarantees and also
HASAWA.
It is essential to ensure that any discharge point does not endanger others, these must be proved
safe.
These notes should be read in conjunction with relevant sections Boilers - Heat generators SFG 05-01
to 05-33 . Only GAS SAFE registered service providers are permitted to work on flues. Ensure that
flues conform to relevant guidance and BS/EN and boiler manufacturers’ recommendation. External
dampers/economisers can infringe manufacturer’s guarantees and also HASAWA (www.hse.gov.uk).
Soot can be found in flues burning oil and coal. Soot is classified as a Hazard and disposed of on
accordance with the Hazard Waste and COSHH Regulations.
It is essential to ensure that any discharge point does not endanger others, these must be proved
safe.
Technical
Title NotesActionFQTitle FQ Action Notes
3. Flue terminals. Where possible, check flue
terminals at roof level.
It is very important that flue
terminals must be undamaged and
free from any obstruction.
12M 3. Flue terminals. Where possible, check flue
terminals at roof level.
It is very important that flue
terminals must be undamaged and
free from any obstruction.
12MOther
Page 229 of 614
FOUNTAINS
Page 230 of 614
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FOUNTAINS - ORNAMENTAL25-01 25-01 FOUNTAINS OUTDOOR - ORNAMENTAL
Notes: Latest ACOP L8,2001 - Precautions in respect of Legionellosis and legionnaires' disease
apply.
Precautions in respect of Legionellosis and legionnaires` disease apply.
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 L8 has a special legal status,
Part 1 being regulatory and Part 2 guidance.
Technical
Title NotesActionFQTitle FQ Action Notes
2. Pumps. Check for gland leakage and
satisfactory operation.
More detailed information on the
maintenance see relevant section of
PUMPS.
12M 2. Pumps. Check for gland leakage and
satisfactory operation.
More detailed information on the
maintenance see relevant section of
Pumps SFG 45-01
12MOther
5. Water
treatment plant.
Note: does not
apply when fish
present.
See WATER TREATMENT. Presence of fish will required special
consideration.
12M 5. Water
treatment plant.
This does not
apply when fish
present.
See Water treatment SFG 65-01 Presence of fish will required special
consideration.
12MOther
6. Automatic
water make-up, a)
float operated (ball
valve),
See STORAGE TANKS WATER12M 6. Automatic
water make-up, a)
float operated (ball
valve),
Check operation, water level and
shut off. Replace washer if
necessary. Check float for leakage
and security
Also See Storage tanks water SFG
56-01
12MTechnical
b) solenoid
operated.
See - VALVES.12M b) solenoid
operated.
Operate and check for correct
linear travel. Check for solenoid
noise i.e. buzzing.b) Check that
valve is not letting by excessively.
c) Inspect for gland leakage, refer
to manufacturer`s maintenance
instructions.d) Inspect for external
deterioration.
Also See - Valves- automatic SFG
65-05
12MTechnical
7. Underwater
lighting.
See - LIGHTING .12M 7. Underwater
lighting.
Clean and check:For physical
damage. Signs of water ingress or
condensation, check seals and
report to client. Check integrity of
electrical wiring and earth
continuity. Check for failed or
blackened tubes or lamps. Replace
as necessary
Also See - Lighting SFG 36-01
12MTechnical
Page 231 of 614
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25-02 FOUNTAINS INDOOR - ORNAMENTAL
Precautions in respect of Legionellosis and legionnaires` disease apply.
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 L8 has a special legal status,
Part 1 being regulatory and Part 2 guidance.
The frequency of the tasks are to be set in relation to the condition of the fountain and in line with the
description with L8.
Added
Title NotesActionFQTitle FQ Action Notes
1. Spray heads
and jets.
Clean and check spray pattern. Frequency will depend upon
location and use and should be
agreed with client.
3MAdded
2. Pumps. Check for gland leakage and
satisfactory operation.
More detailed information on the
maintenance see relevant section of
Pumps SFG 45-01
12MAdded
3. Filters. Check condition and clean as
necessary.
Frequency will depend upon
location and use and should be
agreed with client.
12MAdded
4. Containment
area, e.g. tanking.
Check for cracks and signs of
leakage. Report to client if
remedial work is required.
Failure of the waterproof lining or
membrane is the most likely source
of leakage. Frost damage to
concrete is another cause.
12MAdded
5. Water
treatment plant.
This does not
apply when fish
present.
See Water treatment SFG 65-01 Presence of fish will required special
consideration.
12MAdded
6. Automatic
water make-up, a)
float operated (ball
valve),
Check operation, water level and
shut off. Replace washer if
necessary. Check float for leakage
and security
Also See Storage tanks water SFG
56-01
12MAdded
b) solenoid
operated.
Operate and check for correct
linear travel. Check for solenoid
noise i.e. buzzing.b) Check that
valve is not letting by excessively.
c) Inspect for gland leakage, refer
to manufacturer`s maintenance
instructions.d) Inspect for external
deterioration.
Also See - Valves- automatic SFG
65-05
12MAdded
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7. Underwater
lighting.
Clean and check:For physical
damage. Signs of water ingress or
condensation, check seals and
report to client. Check integrity of
electrical wiring and earth
continuity. Check for failed or
blackened tubes or lamps. Replace
as necessary
Also See - Lighting SFG 36-01
12MAdded
Page 233 of 614
GRILLES AND DIFFUSERS
Page 234 of 614
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GRILLES AND DIFFUSERS26-01 26-01 GRILLES AND DIFFUSERS
Where possible these should be removed for cleaning. Washing to remove grease and staining may
be required.
Diffuser/grille locations and orientation should be marked or recorded if they are to be taken away for
washing, so that they can be returned to the correct location. Opposed blade dampers should have
the ‘as found’ setting marked to aid resetting.
Certain grille and diffuser arrangements may be installed such that they cannot be practicably
removed for cleaning, e.g. linear diffusers or those trapped by partition walls. Insitu cleaning by air line
and extraction to capture dislodged deposits may be used.
Diffusers may have plenum boxes, possibly containing dampers behind them, which also require
cleaning. Access will be required to permit cleaning or air jetting and extraction methods.
Added
Title NotesActionFQTitle FQ Action Notes
a) external Examine, check mountings and
clean.
Leaves can be particular nuisance
and one examination should be in
late Autumn.
6M a) external Examine, check mountings and
clean. Replace if holed.
Where significant bird contamination
or mould problems are encountered
a preliminary disinfection before
starting work may be required and
appropriate protection provided for
cleaning operatives.
6MOther
b) internal Examine, check fitting and clean. If removed care should be taken not
to disturb valve and other equipment
settings behind the grille.
12M b) internal Examine, check fitting and clean.12MOther
2. Diffusers. Examine, check fitting and clean. If removed care should be taken not
to disturb valve and other equipment
settings behind the diffuser.
12M 2. Diffusers. Examine, check fitting and clean.12MOther
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LOUVRES, BIRD AND INSECT SCREENS26-02 26-02 LOUVRES, BIRD AND INSECT SCREENS
Title NotesActionFQTitle FQ Action Notes
1. Louvres. Clean and remove any debris,
check for damage.
6M 1. Louvers. Clean and remove any debris,
check for damage.
Where significant bird contamination
or mould problems are encountered
a preliminary disinfection before
starting work may be required and
appropriate protection provided for
cleaning operatives.
6MOther
Page 236 of 614
HAZARDOUS AREA (ELECTRICS)
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INTRODUCTORY PROCEDURES27-01 27-01 INTRODUCTORY PROCEDURES
It is essential that any maintenance work in hazardous areas is only carried out by specialist
personnel. Extreme care should be taken when carrying out such maintenance and it is very important
that equipment such as electric motors, flameproof switchgear and lighting should 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 in 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 EN 60079 - 2009 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.
It is essential that any maintenance work in hazardous areas is only carried out by specialist
personnel. Extreme care should be taken when carrying out such maintenance and it is very important
that equipment such as electric motors, flameproof switchgear and lighting should be returned to
service in a safe condition.
This task is intended to be applied where there can be a risk due to the presence of explosive gas or
dust mixtures with air or combustible dust layers under normal atmospheric conditions. It does not
apply to
• underground mining areas,
• areas where a risk can arise due to the presence of hybrid mixtures,
• dusts of explosives that do not require atmospheric oxygen for combustion,
• pyrophoric substances.
Hazardous areas are classified into three zones.
GAS
Zone 0 an explosive gas atmosphere is present continuously or for long periods or frequently.
Zone 1 an explosive gas atmosphere is likely to occur in normal operation occasionally.
Zone 2 an explosive atmosphere is not likely to occur in normal operation but, if it does occur, will
persist for a short period only.
DUST
Zone 20 A place in which an explosive dust atmosphere, in the form of a cloud of dust in air, is
present continuously or for long periods or frequently.
Zone 21 A place in which an explosive dust atmosphere, in the form of a cloud of dust in air, is likely to
occur in normal operation occasionally.
Zone 22 A place in which an explosive dust atmosphere, in the form of a cloud of dust in air, is not
likely to occur in normal operation but, if it does occur, will persist for a short period only.
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.
Before commencing any maintenance work on control panels, read Control panels and controllers
SFG 14-01 introductory notes, very carefully and follow all the safety procedures
Other
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Hazardous areas - FLAME PROOF EQUIPMENT27-02 27-02 Hazardous areas - FLAME PROOF EQUIPMENT
The results of inspections, checks and tests must be recorded and compared with previous entries,
any significant changes must be investigated and specifically reported upon to the client.
Before commencing any maintenance work on Flame proof equipment, read Hazardous area
(electrics) introductory procedures SFG 27-01 very carefully and follow all the safety procedures.
Replacement parts shall be in accordance with the safety documentation. Alterations to equipment
shall not be carried out without appropriate authorisation where they adversely affect the safety of the
equipment as stated in the safety documentation. Repairs and reclamation of equipment shall be
carried out in accordance with IEC 60079-19.
Definition - flameproof enclosure “d” enclosure in which the parts which can ignite an explosive gas
atmosphere are placed and which can withstand the pressure developed during an internal explosion
of an explosive mixture, and which prevents the transmission of the explosion to the explosive gas
atmosphere surrounding the enclosure
Other
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Hazardous areas - LIGHTING27-03 27-03 Hazardous areas - LIGHTING
Before commencing any maintenance work on Flame proof equipment, read Hazardous area
(electrics) introductory procedures SFG 27-01 very carefully and follow all the safety procedures.
Replacement parts shall be in accordance with the safety documentation. Alterations to equipment
shall not be carried out without appropriate authorisation where they adversely affect the safety of the
equipment as stated in the safety documentation. Repairs and reclamation of equipment shall be
carried out in accordance with IEC 60079-19.
Added
Title NotesActionFQTitle FQ Action Notes
1. Integrity. Check installation for mechanical
damage.
6M 1. Integrity. Check installation for mechanical
damage.
The etching, painting or screening of
light transmitting parts or the
incorrect positioning of the
luminaires may lead to excessive
temperatures
6MTechnical
3. Lamp. Replace on a planned basis as
appropriate.
Maintenance contract should be
specific with regard to the
responsibility for the provision and
replacement of lamps and also for
the disposal of spent lamps, as per
statutory regulations.
6M 3. Lamp. Replace on a planned basis as
appropriate.
When replacing lamps the correct
rating and type ONLY should be
used, or excessive temperatures
may result. Maintenance contract
should be specific with regard to the
responsibility for the provision and
replacement of lamps and also for
the disposal of spent lamps, as per
statutory regulations.
6MLegislative
4. Cable and
conduit entries.
Check condition of sealing rings
etc.
Note: any cable gland, stopping
gland or plug, reducer or adapter
must be BASEEFA approved for use
with the apparatus.
6M 4. Cable and
conduit entries.
Check condition of sealing rings
etc. Ensure that any seals are
correctly in place
Any cable gland, stopping gland or
plug, reducer or adapter must be
BASEEFA
(www.hse.gov.uk/eecs/eecshome.ht
m) approved for use with the
apparatus.
6MTechnical
5. Return to
service.
Ensure that any seals are correctly
in place and the correct number
and type of cover bolts are used.
6M 5. Return to
service.
Ensure that any seals are correctly
in place and the correct number
and type of cover bolts are used.
Labels shall be inspected to ensure
that they are legible and to ensure
that the equipment actually fitted is
that
Specified and the source of supply
6MTechnical
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Hazardous areas - EARTHING27-04 27-04 Hazardous areas - EARTHING
Before commencing any maintenance work on Flame proof equipment, read Hazardous area
(electrics) introductory procedures SFG 27-01 very carefully and follow all the safety procedures.
Replacement parts shall be in accordance with the safety documentation. Alterations to equipment
shall not be carried out without appropriate authorisation where they adversely affect the safety of the
equipment as stated in the safety documentation. Repairs and reclamation of equipment shall be
carried out in accordance with IEC 60079-19
Added
Title NotesActionFQTitle FQ Action Notes
1. Terminations. Check for continuity and bonding.
See also POWER SUPPLIES -
Earthing.
Earthing of power systems should
be in accordance with BSEN 60079
.
6M 1) Fault loop
impedance or
earthing
resistance
The integrity of the earthing shall be
checked at the initial inspection by
measurement of resistance. The
measurement may be made using
an intrinsically safe resistance
measuring instrument (within the
procedure specified by the
manufacturer). Subsequent sample
inspections may also be carried out
using an intrinsically safe resistance
measuring instrument
Non-intrinsically safe measuring
equipment may be used if a safe
work procedure (see IEC 60079-14)
has been conducted and if the
locations where potentially
incendive sparking could occur, in
case of dust hazards, can be
guaranteed to be free from an
explosive dust atmosphere and
dangerous dust layers by those
responsible for the area.
6MTechnical
a) Earth connections to maintain the
integrity of the intrinsic safety safe
system (such as transformer screen
earth, barrier relay frame earth)
shall be measured. There is no
requirement to measure the earth
loop impedance of mains powered
equipment associated with
intrinsically safe circuits other than
that required for normal control
room instrumentation to protect
against electric shock. Since, in
some equipment, the intrinsic
safety earthing is internally
connected to the equipment frame,
any impedance measurements
(such as between the earth pin of
the plug and the equipment frame,
or the equipment frame and the
control panel) shall be made using
a tester specifically designed for
use on intrinsically safe circuits
6MAdded
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b) Intrinsically safe circuit earthing
and/or insulation
The insulation testing of intrinsically
safe circuits is necessary to confirm
that they are earthed or insulated
from earth throughout, whichever of
these conditions is required by the
original design. This requirement
may be unnecessary if an earth
fault is self revealing, for example, if
a circuit "fails safe" as result of an
earth fault or the circuit uses an
earth leakage monitoring device.
Insulation testing of intrinsically
safe systems or circuits shall only
be carried out using a test device
specifically approved for connection
to such circuits.
Where, in order to carry out these
tests, the common earth connection
to a group of barriers is
disconnected, the tests can only be
made if either the plant is free from
hazard, or if power is removed
completely from all the circuits
which depend upon that common
earth connection. This test is only
required on a sample basis.
6MAdded
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HEAT EMITTERS
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HEAT EMITTERS28-01 28-01 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 of heat and the grilles, the heat exchange surfaces through and
over which the air passes. The efficiency of the grilles and heat exchange surfaces can be affected by
fluff and fibres, the severity of which depends upon the location and the environment. Thus a dusty
carpeted room with perimeter skirt heating will require much more frequent cleaning of grilles and
heating surfaces than a lino covered floor in a clean environment. The frequencies shown in the table
below refer to a clean environment but in extreme cases it may be necessary to clean grilles and heat
exchangers as often as once a fortnight.
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 of heat and the grilles, the heat exchange surfaces through and
over which the air passes. The efficiency of the grilles and heat exchange surfaces can be affected by
fluff and fibres, the severity of which depends upon the location and the environment. Thus a dusty
carpeted room with perimeter skirt heating will require much more frequent cleaning of grilles and
heating surfaces than a lino covered floor in a clean environment. The frequencies shown in the table
below refer to a clean environment but in extreme cases it may be necessary to clean grilles and heat
exchangers as often as once a fortnight.
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.
Technical
Title NotesActionFQTitle FQ Action Notes
7. TRV`s Check air temperature calibration
against surface temperature of heat
emitter. Advise client if air flow
around sensor is restricted or
affected by any reflected or other
thermal gains. Check operation of
thermostatic radiator valves.
Low temperature surfaces for heat
emitters are desirable in homes for
senior citizens/disabled.
12MAdded
8. General. Leave unit in good working order. Report on any further work
considered necessary.
12MAdded
Fan convectors
[electric]
12MAdded
1. Casing Examine condition of casing,
access panels and grilles. Check
unit is secure, free from dust and
dirt especially at air inlet and
discharge grilles.
12MAdded
2.Controls Check all thermostats and other
controls operate satisfactorily and
are set in accordance with
specification.
12MAdded
3.Fan Inspect air circulation fan set(s),
check fan/motor assembly for
damage and for correct alignment.
Check for wear at any resilient
mounts.
12MAdded
4. Heat exchanger Examine heater battery/element,
clean and comb as required.
12MAdded
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7. Electrical Heater Unit Check function &
operation of local isolation device
(stoplock/isolator). Examine and
report condition of all associated
wiring, ensure security of all
terminal connections and check for
satisfactory condition of any flexible
cables/conduits. Ensure plant has
adequate earth conductor and
bonding is secure. Take and log
motor current and compare with
nameplate details. Check all
temperature control devices for
correct operation and function.
12MAdded
5. TRV’s Check air temperature calibration
against surface temperature of heat
emitter. Advise client if air flow
around sensor is restricted or
effected by any reflected or other
thermal gains. Check operation of
thermostatic radiator valves.
Low temperature surfaces for heat
emitters are desirable in homes for
senior citizens/disabled.
12MAdded
Fan Convectors Fan Convectors
(LTHW or Steam)
Other
1. Casing. 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
grilles to ensure no air leakage or
short circuiting occurs.
12M 1. Casing. Examine condition of casing,
access panels and grilles. Check
unit is secure.
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
grilles to ensure no air leakage or
short circuiting occurs.
12MOther
3. Filters. When fitted remove, examine and
check for damage. Clean or
replace.
Check if filter is cleanable or
throwaway type. The frequency of
cleaning depends upon the dirtiness
of the air. Normally cleaning should
be every two months but more
frequent cleaning may be
necessary.
3M 3. Filters. When fitted remove, examine and
check for damage. Clean or
replace.
Check if filter is cleanable or
disposable type. The frequency of
cleaning depends upon the dirtiness
of the air. Normally cleaning should
be every three months but more
frequent cleaning may be
necessary.
3MOther
4. Heat
exchanger.
Inspect and clean. Purge air from
hot water units.
Clean using an industrial vacuum
cleaner. Draw air through the heat
exchanger in the opposite direction
to the normal air flow. In exceptional
cases a high pressure air hose may
be required. In a dirty environment
more frequent cleaning will be
needed, e.g. quarterly, six weekly or
even monthly. advance \U 0.0 -
WHAT DOES THIS MEAN?
3M 4. Heat
exchanger.
Inspect and clean. Purge air from
hot water units.
Clean using an industrial vacuum
cleaner. Draw air through the heat
exchanger in the opposite direction
to the normal air flow. In exceptional
cases a high pressure air hose may
be required. In a dirty environment
more frequent cleaning will be
needed, e.g. quarterly, six weekly or
even monthly.
3MTechnical
6.Pipework,
valves, steam
traps and
associated
equipment.
Examine for corrosion or leaks.
Where applicable clean steam
traps, strainers, non return valves
and scale pockets.
Check operation of steam traps.
Check operation of thermostatic
radiator valves (TRVs)
12M 6.Pipework,
valves, steam
traps and
associated
equipment.
Examine for corrosion or leaks.
Where applicable clean steam
traps, strainers, non return valves
and scale pockets.
Check operation of steam traps.12MTechnical
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7. General. Leave unit in good working order. Report on any further work
considered necessary.
12M Deleted
1. Casing. Examine condition of casing,
discharge louvres and inlet guards.
Where applicable, check condition
of any flexible ducting connections.
Check security of mounting brackets
or drop rods. Check that any
discharge louvres are correctly set
to give the desired air spread
pattern.
12M 1. Casing. Examine condition of casing,
discharge louvers and inlet guards.
check unit is secure and that all
bolts, nuts, setscrews etc. for
security. Check and clean surfaces
of unit casing, check for corrosion,
repair and treat as found
necessary. Ensure all access doors
for fit and can be made secure.
When shut, ensure for air tight seal.
Where applicable, check condition
of any flexible ducting connections.
Check security of mounting brackets
or drop rods. Check that any
discharge louvers are correctly set
to give the desired air spread
pattern.
12MTechnical
3. Heat
exchanger.
Inspect and clean. Purge air from
hot water units.
Clean using an industrial vacuum
cleaner. Draw air through the heat
exchanger in the opposite direction
to the normal air flow. In exceptional
cases a high pressure hose may be
required. In a dirty environment
more frequent cleaning will be
needed, e.g. quarterly, six weekly or
even monthly.
3M 3. Heat
exchanger.
Inspect and clean. Purge air from
hot water units.
Clean using an industrial vacuum
cleaner. Draw air through the heat
exchanger in the opposite direction
to the normal air flow. In
exceptional cases a high pressure
hose may be required. In a dirty
environment more frequent cleaning
will be needed, e.g. quarterly, six
weekly or even monthly. Vent coil at
local air vent. If automatic air vent
provided, check for correct
operation.
3MTechnical
4. Filters. When fitted remove, examine and
check for damage. Clean or
replace.
Check if filter is cleanable or
throwaway type. The frequency of
cleaning depends upon the dirtiness
of the air. Normally cleaning should
be every two months but more
frequent cleaning may be
necessary.
3M 4. Filters. When fitted remove, examine and
check for damage. Clean or
replace.
Check if filter is cleanable or
disposable type. The frequency of
cleaning depends upon the dirtiness
of the air. Normally cleaning should
be every three months but more
frequent cleaning may be
necessary.
3MTechnical
5. Motor/fan
assembly.
Lubricate bearings where
applicable.
Check security of fans and condition
of resilient mounts.
6M 5. Motor/fan
assembly.
Checking fan/motor bearings for
abnormal wear. Cleaning all
surfaces, particularly fan impeller
and motor casing vents. Lubricate
fan/motor bearings where grease
nipples/lubricators are fitted, taking
care not to over-grease. Lightly
grease fan motor slide rails.
Check security of fans and condition
of resilient mounts.
If applicable:
Check condition, tension and
alignment of drive belts and pulleys.
Renew drive belts as necessary.
Check drive guard is in good repair
and securely fixed, providing correct
cover of all moving parts
6MTechnical
7. General. Leave unit in good working order. Report on any further work
considered necessary.
12M 8. General. Leave unit in good working order.
After maintenance, carry out a
general operational check, and
check for excessive noise, vibration
and temperature.
Report on any further work
considered necessary.
12MTechnical
1. Casing. Examine condition of casing,
access panels and grilles. Where
applicable, check condition of
damper seal.
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
grilles to ensure no air leakage or
short circuiting occurs.
12M 1. Casing. Examine condition of casing,
access panels and grilles. Where
applicable, check condition of
damper seal. Check unit is secure.
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
grilles to ensure no air leakage or
short circuiting occurs.
12MOther
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3. Pipework,
valves, steam
traps and
associated
equipment.
Examine for corrosion or leaks.
Where applicable clean steam
traps, strainers, non return valves
and scale pockets.
Check operation of steam traps.
Check operation of thermostatic
radiator valves (TRV s).
12M 3. Pipework,
valves, steam
traps and
associated
equipment.
Examine for corrosion or leaks.
Where applicable clean steam
traps, strainers, non return valves
and scale pockets.
Check operation of steam traps.12MOther
5. General. Leave unit in good working order. Report on any further work
considered necessary.
12M 6. General. Leave unit in good working order. Report on any further work
considered necessary.
12MOther
ALL ITEMS Cleaning and maintenance. Due to possible difficulties of access
cleaning and maintenance should
only be undertaken by competent
person. advance \U 0.0 - WHAT
DOES THIS MEAN? When
applicable, isolate units(s) from
electrical supply by removing fuses
or locking main switch in OFF
position. Always refer to the
manufacturer's
instructions/recommendations
before undertaking any cleaning or
maintenance.
12M All items Cleaning and maintenance. Due to possible difficulties of access
cleaning and maintenance should
only be undertaken by competent
person. When applicable, isolate
units(s) from electrical supply by
removing fuses or locking main
switch in OFF position. Always refer
to the manufacturer`s
instructions/recommendations
before undertaking any cleaning or
maintenance.
12MOther
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GAS FIRED CERAMIC PLAQUE INFRA RED HEATERS28-02 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
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.
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.
Other
Title NotesActionFQTitle FQ Action Notes
1. Ceramic
plaques.
Clean using an 80 p.s.i. air supply. The direction of air flow should be
opposite to that of the gas flow.
12M 2. Ceramic
plaques.
Clean using an air supply. The direction of air flow should be
opposite to that of the gas flow.
12MOther
2. Electrical spark
plug.
Clean with wire brush, replace if
there are any signs of corrosion.
12M 3. Electrical
spark plug.
Clean with wire brush, replace if
there are any signs of corrosion.
Check spark electrode gap for
satisfactory setting, refer to
manufacturer`s manual.
12MOther
3. Connecting
wires.
Check for damage. If there are any signs of
deterioration, replace.
12M 4. Wiring and
controls.
Check for satisfactory operation of
local electrical isolation switch.
Check function and operation of all
control switches and temperature
controls. Examine and report
condition of all associated wiring,
ensure security of all terminations
and check for satisfactory condition
of any flexible cables/conduits.
Ensure plant has adequate earth
conductor and bonding is secure.
12MOther
4. Gas pressure. Check with rated value and adjust if
necessary.
The rated value will be found on the
identification plate or in the
operating instructions.
12M 5. Gas pressure,
gas pipework and
cocks
Check with rated value and adjust if
necessary. Check gas cocks are
free to turn, lubricate as necessary.
Inspect gas pipework system,
check for leaks, loose brackets and
supports, repair as necessary,
report all findings.
The rated value will be found on the
identification plate or in the
operating instructions.
12MOther
5. Performance
check.
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 blockage of the
plaque with carbon.
12M 6. Performance
check.
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 blockage of the
plaque with carbon.
12MOther
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1. General check unit is secure and that all
bolts, nuts, setscrews etc. for
security. Check and clean surfaces
of unit, check for corrosion, repair
and treat as found necessary.
12MAdded
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GAS RADIANT TUBE HEATERS28-03 28-03 GAS RADIANT TUBE 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.
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.
Added
Title NotesActionFQTitle FQ Action Notes
17. Wiring and
Controls
Check for satisfactory operation of
local electrical isolation switch.
Check function and operation of all
control switches and temperature
controls. Examine and report
condition of all associated wiring,
ensure security of all terminations
and check for satisfactory condition
of any flexible cables/conduits.
Ensure plant has adequate earth
conductor and bonding is secure
12MAdded
1. Isolation of
heater from
electrical and gas
supply.
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.
12M 1. General and
Isolation of heater
from electrical and
gas supply
Switch off, remove fuses and turn
off gas supply.
Inspect emitter tube and brush any
dust from the exterior of the emitter
tube. Inspect the emitter tube
internally, clean with a vacuum
cleaner as found necessary.
Inspect and clean injector using a
soft brush. Inspect and clean as
necessary the burner fresh air duct
(where fitted) and air inlet terminal.
Inspect radiant tubes and fittings
internally. If there is any
appreciable build up of dust or
deposits the tubes should be
cleaned internally. If corrosion is
present replace as necessary.
Inspect for evidence of holes and
cracks to tube couplers and replace
if necessary.
For safety reasons it is essential
that the equipment is isolated from
electricity and gas before servicing.
12MTechnical
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6. Spark plug. Remove, clean and refit. Check ceramic for cracks or
breakage. Renew if necessary.
12M 6. Spark plug
spark plug and
burner electrode
assembly
Remove, clean and refit.
Check spark electrode gap for
satisfactory setting, refer to
manufacturer`s manual. Inspect
burner electrode assembly, check
electrodes for build up of carbon or
cracks. Check the spark distance
and position of electrodes relative
to the burner head. Renew
electrode assembly if not in good
condition.
Check ceramic for cracks or
breakage. Renew if necessary.
12MTechnical
9. Observation
windows.
Check and clean12M 9. Observation
windows.
Clean combustion chamber viewing
window.
12MTechnical
11. Acoustic
joints.
Check for wear. Renew if necessary.12M 11. Acoustic
joints.
Inspect acoustic joints for damage
and replace if necessary.
Renew if necessary.12MTechnical
12. Condensate
traps.
Check for blockages.12M 12. Condensate
traps.
Inspect condensate trap for
blockages, dirt and scale, clean if
necessary.
12MTechnical
13. Vacuum
motor pump.
If fitted, examine mountings Lubricate pump motor if applicable.12M 13. Vacuum
motor pump.
If fitted, examine mountings.
Inspect vacuum fan and flue
ductwork for any contamination.
Lubricate pump motor if applicable.12MTechnical
14. Reflectors. Inspect to ensure correct fitting.12M 14. Reflectors. Inspect to ensure correct fitting and
Clean with soft cloth and detergent
in water.
12MTechnical
15. Gas test. Pressure drop test back to nearest
gas cock to ensure soundness.
12M 15. Gas
pressure, gas
pipework and
cocks
Pressure drop test back to nearest
gas cock to ensure soundness.
Check gas cocks are free to turn,
lubricate as necessary.
Inspect gas pipework system,
check for leaks, loose brackets and
supports, repair as necessary,
report all findings
12MTechnical
16. General. Undertake heat test. With heater(s) switched on and
system stabilised carry out a heat
test in accordance with the
manufacturer s recommendations.
Check all burner units for correct
ignition sequence pilot and main
burner flames for stability and
correct aeration, adjust if necessary.
The following readings are to be
taken and the system adjusted to
meet the manufacturer s
recommendations: - -vacuum at
each end vent - -maximum and
minimum pressure - -gas
consumption
12M 16. General. After cleaning and adjustment,
re-assemble, cleaning the reflector
plate. Check all auxiliary controls/
gas shut-off devices. Undertake
heat test.
With heater(s) switched on and
system stabilised carry out a heat
test in accordance with the
manufacturer s recommendations.
Check all burner units for correct
ignition sequence pilot and main
burner flames for stability and
correct aeration, adjust if necessary.
The following readings are to be
taken and the system adjusted to
meet the manufacturer s
recommendations: - -vacuum at
each end vent - -maximum and
minimum pressure - -gas
consumption
12MTechnical
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GAS FIRED NATURAL AND FAN ASSISTED HEATERS - Conventional and
Balanced Flue.
28-04 28-04 GAS FIRED NATURAL AND FAN ASSISTED HEATERS - Conventional and
Balanced Flue.
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.
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.
Added
Title NotesActionFQTitle FQ Action Notes
5. Thermocouple. Clean with fine wire brush
reassemble pilot and test.
Renew with manufacturer s
approved thermocouple if
necessary.
12M 5. Thermocouple. Clean with fine wire brush
reassemble pilot and test.
Renew with manufacturer’s
approved thermocouple if necessary
12MTechnical
11. General. Check settings and correct
operation of thermostats and time
clocks.
Make necessary corrections if
required.
12M 13. General. Check settings and correct
operation of thermostats and time
clocks.
Make necessary corrections if
required.
12MOther
11 Gas pressure,
gas pipework and
cocks
Check with rated value and adjust if
necessary. Check gas cocks are
free to turn, lubricate as necessary.
Inspect gas pipework system,
check for leaks, loose brackets and
supports, repair as necessary,
report all findings.
The rated value will be found on the
identification plate or in the
operating instructions.
12MAdded
12. Wiring and
Controls
Check for satisfactory operation of
local electrical isolation switch.
Check function and operation of all
control switches and temperature
controls. Examine and report
condition of all associated wiring,
ensure security of all terminations
and check for satisfactory condition
of any flexible cables/conduits.
Ensure plant has adequate earth
conductor and bonding is secure.
12MAdded
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28-05 GAS FIRE
Carbon Monoxide (CO) is poisonous, life threatening and also causes energy waste. Flames should
be bluish and burning in a stable manner. The fire should be quiet in operation, no excessive noise
should occur when the fire ignites or shuts down.
Consider the installation of a CO detector that complies with BS EN 50291-1:2010 and BS EN
50292:2002.
Added
Title NotesActionFQTitle FQ Action Notes
1. Vent and Flu. Check ventilation arrangements are
adequate and not blocked. Check
flue termination and that it is
compliant.
12MAdded
2. General Remove the outer case and the
radiant`s or fuel. Check for soot and
rubble behind the closure plate and
clean out if necessary (excessively
large quantities can block the fuel
spigot and cause spillage). Reseal
the closure plate if required,
ensuring that the relief opening is
clear. Clear dirt and lint from the
base of the fire where the cool air
enters from the room.
12MAdded
3. Burner and
injectors
Clean dust and lint from the burner
and the injectors
12MAdded
4. Heat Exchanger Check the heat exchanger for
corrosion damage and clean the
visible flueway.
12MAdded
5. Gas tap Check shut off. Grease gas tap if it
is stiff to turn.
12MAdded
6. Refit fire Reconnect the fire and check for
gas soundness.
Ensure fire is level and secure.
12MAdded
7. Ignition Test the ignition, clean or renew any
batteries or parts as necessary.
Check any electrical components;
wires should be properly insulated,
connections clean and sound. Test
any spark gap and reset if
necessary.
12MAdded
8. Burner pressure Check gas rate by burner pressure
and adjust governor if required
12MAdded
9. Controls Check the operation of any flame
supervision device, if fitted. Check
that thermostat phial is correctly
located and that thermostat
operates satisfactorily.
12MAdded
10. Radiant`s and
case
Replace radiant`s and case.12MAdded
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11. Flue Check flue pull.12MAdded
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28-06 GAS FIRED UNIT HEATERS
The frequency will change depending on the amount of dust in the atmosphere.
Carbon Monoxide (CO) is poisonous, life threatening and also causes energy waste. Flames should
be bluish and burning in a stable manner. The fire should be quiet in operation, no excessive noise
should occur when the fire ignites or shuts down.
Consider the installation of a CO detector that complies with BS EN 50291-1:2010 and BS EN
50292:2002.
Added
Title NotesActionFQTitle FQ Action Notes
1. Burner
assembly
Remove the burner assembly and
clean thoroughly. Check the
condition of the ignitor and clean to
remove all deposits. Check spark
gap and adjust as required to the
manufacturers guide. Check the
sensor and clean as necessary.
Remove any soot deposits from the
burner with a wire brush. Clean the
ports with a degreaser or acetone.
Wipe the inside of the burner tube
clean (cleaning thoroughly with a
degreaser as recommended will
retard future buildup of dirt). Inspect
burner for any damage or
deterioration. If the burner is
damaged or corroded it will need to
be replaced.
Stubborn deposits on the burners
are often best cleaned using
"acetone" as a solvent.
A vacuum cleaner or compressed
air may assist in this cleaning
operation.
12MAdded
2. Heat Exchanger Examine the heat exchanger tubes
internally and externally for any sign
of deterioration. Remove any dust
and grease deposits. Clean the
inner surfaces of the heat
exchanger with a flue brush and
remove all deposits.
The heat exchanger should remain
clean unless a problem has
developed due to poor combustion.
12MAdded
3. Fan Clean the axial fan blades, fan
guard and fan motor to remove all
external dirt. Check the security of
the fan on the motor. Most fan
motors are lubricated for life and do
not require lubricating but check
manufacturers guidelines.
12MAdded
4. Venter Fan Remove any dirt and/or grease that
may have accumulated on the
venter fan motor and its housing.
Most venter fan motors are
lubricated for life and do not require
lubricating but check manufacturers
guidelines.
12MAdded
5. Control valve Clean the exterior of the gas control
valve and check the condition of the
wire connections. Test pressure as
manufacturers instructions.
12MAdded
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6.
Flue/combustion
air
Check the flue/combustion air
system for soundness.
Reseal/replace any parts that are
not sound.
12MAdded
7. Wiring Check all wiring connections.
Check wiring for any signs of
damage. Replace any suspect
wiring with equivalent specification.
12MAdded
8. Controls Check operation of the thermal fan
control and control relay.
12MAdded
9. recommission
unit
When the service is complete carry
out full commissioning as per
manufacturers commissioning
procedure.
12MAdded
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28-07 GAS FIRED RADIANT HEATERS
The frequency will change depending on the amount of dust in the atmosphere.
Carbon Monoxide (CO) is poisonous, life threatening and also causes energy waste. Flames should
be bluish and burning in a stable manner. The fire should be quiet in operation, no excessive noise
should occur when the fire ignites or shuts down.
Consider the installation of a CO detector that complies with BS EN 50291-1:2010 and BS EN
50292:2002.
Added
Title NotesActionFQTitle FQ Action Notes
1. Vent and Flue. Check ventilation arrangements are
adequate and not blocked. Check
flue termination and that it is
compliant. Inspect and clean as
necessary the burner fresh air duct
(where fitted) and air inlet terminal.
12MAdded
2. Burner, injectors
and pilots
Clean the burner, injectors and the
pilots. Check burner electrodes for
build up of carbon or cracks.
Check the spark distance and
position of electrodes relative to the
burner head. Check condition of
burner head insert and flame
retention grid and replace if
necessary.
Replace filter unit if contaminated
with dirt. Clean combustion
chamber viewing window.
12MAdded
3. Gas tap and
pipework
Check shut off. Grease gas tap if it
is stiff to turn. Inspect gas pipework
system, check for leaks, loose
brackets and supports, repair as
necessary, report all findings.
12MAdded
4. Ignition Test the ignition, clean or renew any
parts as necessary. Check any
electrical components; wires should
be properly insulated, connections
clean and sound. Test any spark
gap and reset if necessary.
12MAdded
5. Burner pressure Check gas rate by burner pressure
and adjust governor if required
12MAdded
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6. Controls and
wiring
Check for satisfactory operation of
local electrical isolation switch.
Check function and operation of all
control switches and temperature
controls. Check the operation of
any flame supervision device, if
fitted. Check that thermostat phial is
correctly located and that
thermostat operates satisfactorily.
Examine and report condition of all
associated wiring, ensure security
of all terminations and check for
satisfactory condition of any flexible
cables/conduits. Ensure plant has
adequate earth conductor and
bonding is secure.
12MAdded
7. Reflectors Clean and polish reflectors.12MAdded
8. Ceramic
plaques
Clean ceramic plaques. Dust from the atmosphere builds up
on the rear face of the ceramic
plaques and can cause local
overheating and light-back. It may
be removed by a fine jet of
compressed air at a pressure of
about 5.5 bar. This should be
directed first into the holes in the
plaque and then into the venturi and
finally into the holes again.
Care must be taken not to damage
the plaque or dislodge the sealing
material holding it to the burner
body. Some manufacturers
recommend washing the plaques
using a detergent. It may be
necessary to replace damaged or
badly linted plaques. This is best
done on a bench. The new plaque
must be sealed by the material
appropriate to the particular model
which may be metal strips,
fireproof cement or insulating
material.
12MAdded
9. Combustion air
fan
Inspect heater`s fan assembly, strip
and clean as found necessary.
Check operation, check wiring and
clean casing and blades if possible.
Lubricate bearings in accordance
with manufacturer`s
recommendations using the correct
type of oil they specify.
12MAdded
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10. Suspension
chains, brackets
etc.
Check they are secure.12MAdded
11. Emitter tube Inspect emitter tube and brush any
dust from the exterior of the emitter
tube. Inspect the emitter tube
internally, clean with a vacuum
cleaner as found necessary.
12MAdded
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HEAT EXCHANGERS
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HEAT EXCHANGERS - COILS29-01 29-01 HEAT EXCHANGERS - COILS
Note:- When cleaning ensure that system fans are off to avoid dirt disturbed during cleaning
entering into the system
When cleaning ensure that system fans are off to avoid dirt disturbed during cleaning entering into the
system
Technical
Title NotesActionFQTitle FQ Action Notes
5. Coil vent. Check operation, condition of filters
and sight glasses.
6MAdded
6. Pipework Inspect connections, pipes and
supports for damage, loose or
missing fittings. Repair as
necessary.
12MAdded
5. Pipework Inspect connections, pipes and
supports for damage, loose or
missing fittings. Repair as
necessary
12MAdded
5. Flues Service. For detailed information on
maintenance of Flues see Flues
SFG 24-01.
12MAdded
a) external surface
air side,
Clean coils and comb out fins. Where necessary clean with
appropriate sterilising solution,
especially when coils operated
under moist air conditions or act as
a dehumidifier.
12M a) external surface
air side,
Clean coils by blowing through with
dry, oxygen free, nitrogen from the
opposite side to the air flow. Comb
out fins. Where Nitrogen is used, a
Risk Assessment must be done
prior and suitable training given.
Where necessary clean with
appropriate sterilising solution,
especially when coils operated
under moist air conditions or act as
a dehumidifier. Particularly dirty
coils should be reported to the client
as the filter changing regime may
need to be amended.
12MTechnical
a) external surface
air side,
Clean coils and comb out fins. Where necessary clean with
appropriate sterilising solution.
12M a) external surface
air side,
Clean coils by blowing through with
dry, oxygen free, nitrogen from the
opposite side to the air flow. Comb
out fins. Where Nitrogen is used, a
Risk Assessment must be done
prior and suitable training given.
Where necessary clean with
appropriate sterilising solution.
Particularly dirty coils should be
reported to the client as the filter
changing regime may need to be
amended.
12MTechnical
b) water side. Flush out coils to remove sediment. Report to client on any further action
necessary due to scale or erosion.
12M Deleted
3. Coil casing. Inspect for rust and clean and
repaint as required.
12M 2. Coil casing. Inspect for rust and clean and
repaint as required.
12MOther
4. Coil mounting
bolts.
Check for tightness and secure if
necessary.
Corroded bolts should be replaced.12M 3. Coil mounting
bolts.
Check for tightness and secure if
necessary.
Corroded bolts should be replaced.12MOther
5. Operation of
steam traps.
Check operation, condition of filters
and sight glasses.
Full details of maintenance
requirements steam services, see
PIPEWORK SYSTEMS.
1M 4. Operation of
steam traps.
Check operation, condition of filters
and sight glasses.
Full details of maintenance
requirements steam services, see
Pipework systems SFG 40-11.
1MOther
5. Operation of
steam traps.
Check operation, condition of filters
and sight glasses.
1M Deleted
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a) air side, Clean fins and air-side surfaces. Comb fins if appropriate. Where
necessary clean with appropriate
sterilising solution.
12M a) air side, Clean coils air-side surfaces by
blowing through with dry, oxygen
free, nitrogen from the opposite
side to the air flow. Where Nitrogen
is used, a Risk Assessment must
be done prior and suitable training
given.
Comb fins if appropriate. Where
necessary clean with appropriate
sterilising solution. Particularly dirty
coils should be reported to the client
as the filter changing regime may
need to be amended.
12MOther
4. Gas burners
and associated
equipment.
Service. For detailed information on
maintenance of gas fired heater see
relevant gas burner.
12M 4. Gas burners
and associated
equipment.
Service. For detailed information on
maintenance of gas fired heater see
relevant gas burner see Burners
SFG 07.
12MOther
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ELECTRIC/AIR HEATER29-02 29-02 ELECTRIC/AIR HEATER
Note: When cleaning, ensure that system fans are off to avoid dirt disturbed during cleaning
entering the system.
When cleaning ensure that system fans are off to avoid dirt disturbed during cleaning entering into the
system
Technical
Title NotesActionFQTitle FQ Action Notes
1. Terminal box: 2. Terminal box:Technical
2. Elements: 3. Elements:Technical
a) within terminal
box,
Check insulation resistance of each
element. Check continuity.
Replace if below 1 megohm
resistance. Replace if open circuit.
12M a) within terminal
box,
Check insulation resistance of each
element. Check continuity.
Replace if below 1 meg ohm
resistance. Replace if open circuit.
12MTechnical
3. Casing. Inspect for rust and clean and
repaint as required.
12M 4. Casing. Inspect for rust and clean and
repaint as required.
12MTechnical
4. Mounting bolts. Check for tightness and secure as
necessary.
Examine casing mounting flanges
for air tightness where appropriate.
12M 5. Mounting
bolts.
Check for tightness and secure as
necessary.
Examine casing mounting flanges
for air tightness where appropriate.
12MTechnical
5. Thermostats/
controls.
Check operation. For detailed maintenance see
relevant section.
12M 6. Thermostats/
controls.
Check operation. For detailed maintenance see
relevant section Sensors and
switching devices SFG 50
12MTechnical
1. air side, Clean coils air-side surfaces by
blowing through with dry, oxygen
free, nitrogen from the opposite
side to the air flow. Where Nitrogen
is used, a Risk Assessment must
be done prior and suitable training
given.
Comb fins if appropriate. Where
necessary clean with appropriate
sterilising solution. Particularly dirty
coils should be reported to the client
as the filter changing regime may
need to be amended.
12MAdded
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PLATE RECUPERATOR29-03 29-03 PLATE RECUPERATOR
Title NotesActionFQTitle FQ Action Notes
2. Internal
surfaces.
Check and remove any dirt, inspect
for rust and repaint as necessary.
Do not use wire brush for dirt
removal, blow off with dry nitrogen
or compressed air.
6M 2. Internal
surfaces.
Check and remove any dirt, inspect
for rust and repaint as necessary.
Do not use wire brush for dirt
removal, blow off with dry nitrogen
or compressed air. Where Nitrogen
is used, a Risk Assessment must be
done prior and suitable training
given.
6MTechnical
5. Fans. Service and lubricate.6M 5. Fans. Service and lubricate. For further guidance see Fans SFG
20
6MTechnical
9. Filters. Clean or replace as necessary. Filters are fitted on both inlet and
extract to keep the heat exchangers
clean.
3M 9. Filters. Clean or replace as necessary. Filters are fitted on both inlet and
extract to keep the heat exchangers
clean.
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. Used filters must be
regarded as Controlled Waste and
appropriate safeguards taken for
their disposal.
3Mlegislative
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THERMAL WHEELS - ROTARY HEAT REGENERATORS29-04 29-04 THERMAL WHEELS - ROTARY HEAT REGENERATORS
Title NotesActionFQTitle FQ Action Notes
1. Bearings. Lubricate according to the
manufacturer's instructions.
'Sealed for life' bearing should not
need any maintenance.
6M 1. Bearings. Lubricate according to the
manufacturer`s instructions.
Sealed for life` bearings should not
need any maintenance.
6MOther
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RUN AROUND HEAT RECOVERY COILS29-05 29-05 RUN AROUND HEAT RECOVERY COILS
Title NotesActionFQTitle FQ Action Notes
1. Pump. Inspect bearings for wear. Check
flow rates/speed and leak
tightness. Check electrical
connections.
Frequency should be in accordance
with the manufacturer's instructions.
Observe correct safety procedures
as required under the Electricity at
Work Regulations.
12M 1. Pump. Inspect bearings for wear. Check
flow rates/speed and leak tightness.
Check electrical connections.
Frequency should be in accordance
with the manufacturer`s instructions.
Observe correct safety procedures
as required under the Electricity at
Work Regulations. For further
guidance see Pumps SFG 45.
12MOther
3. Water. Check for leaks. Remedy if possible, if major
problem, refer to client.
12M 3. Water. Check for leaks. Remedy if possible, if major
problem, refer to client .
12MOther
4. Operating
pressure.
Check. Confirm pressure vessel operating
conditions.
12M 4. Operating
Pressure
Check and record. Confirm pressure vessel operating
conditions. A written scheme of
examination may be required for the
system.
12MTechnical
5. Coils. Clean with recommended cleaning
compound and flush with water.
12M 5. Coils Clean with recommended cleaning
compound and flush with water.
12MOther
6. Air. Check for leaks. Rectify as required providing new
seals etc.
12M 6. Air Check for leaks. Rectify as required providing new
seals etc.
12MOther
7. Condensate
traps.
Inspect for rust, clean and clear any
debris. Recoat. Check traps are
filled with water on return to
service.
12M 7. Condensate
traps
Inspect for rust, clean and clear any
debris. Recoat. Check traps are
filled with water on return to service.
12MOther
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PLATE HEAT EXCHANGERS29-06 29-06 PLATE HEAT EXCHANGERS
Title NotesActionFQTitle FQ Action Notes
14. Check safety
controls.
Safety valve operation.12M 14. Check safety
controls.
Check Safety valve operation.12MTechnical
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WATER TO WATER PLATE HEAT EXCHANGERS29-07 29-07 WATER TO WATER PLATE HEAT EXCHANGERS
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29-08 HEATING CALORIFIERS - MTHW, HTHW or STEAM
Most MTHW, HTHW and Steam Calorifiers will be under the control of an Authorised Person. A permit
to Work must be issued by the Authorised Person before any work can commence on a Calorifier
If insulation looks damaged - STOP WORK- this may be Asbestos - Appropriate action must be taken
prior to further works. If the insulation is known or CERTIFIED not to be Asbestos, continue as follows:
-
See SFG 32-01 for further information on temperatures etc.
Prior to carrying out the planned maintenance of the calorifier, the pre-maintenance procedure
detailed below should be followed:
(a) At the entrance to the Plant room, Stop and Listen for a steam leak (High Pressure steam will be
invisible and only the sound of a leak may be present)
(b) Check equipment operating status (i.e. whether in operation or not in use, whether isolated from
system) including safety.
(c)Inspect calorifier insulation and/or shell for signs of damage.
(d)Inspect all manholes, mounting and joints for signs of leaks.
(e) Report any necessary remedial work where repairs, adjustment or replacement will be required
during routine maintenance.
Added
Title NotesActionFQTitle FQ Action Notes
1. Check
operation, in
particular safety
controls.
Check, note and report any visible
defects.
Ensure secondary is full of water
and circuits are open. If safety
controls are defective take
equipment out of service.
12MAdded
2. Safety valves. Check for corrosion and manually
operate.
If calorifier was in use, the
secondary water will be hot and can
be under pressure, so care must be
taken in carrying out this item of the
schedule.
12MAdded
3. Thermostats,
pressure sensors,
altitude gauges
and thermometers.
Check for correct operation and
settings, set against Certified
masters.
12MAdded
4. Auto controls
and primary side.
Shut down primary heat source
taking all necessary precautions to
prevent unauthorised use.
Check safe operation of
temperature controls and high limit
cut-outs. This may include obtaining
a Permit to Work from an Authorised
Person.
12MAdded
5. Drain
valve/drain cock
on secondary side.
Draw off a small quantity of water to
remove any sediment.
If calorifier was in use, the
secondary water will be hot and can
be under pressure, so care must be
taken in carrying out this item of the
schedule.
12MAdded
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6. Heating
surface and
internal surfaces
of shell.
Drain down secondary side, remove
manhole covers and inspect for
scale formation and corrosion.
The formation of scale reduces heat
transfer and causes energy
wastage. Client`s attention should
be drawn to the presence of
excessive scale which indicates the
need for water treatment. Corrosion
will cause metal failure and leakage.
Remember Waste Disposal
Legislation. If scale is extensive,
refer to client for further instructions.
12MAdded
7. Gaskets. Check gaskets on steam chest for
leakage, replace as necessary.
Steam leaks are dangerous to
personnel and cause wastage of
energy.
12MAdded
8. Sacrificial
anode.
Check status. Replace as necessary.12MAdded
9. Steam
trap/sight glass
(on primary
connections).
Clean and overhaul steam trap. Faults can lead to steam and energy
wastage.
12MAdded
10. Strainer on
primary pipework.
Remove strainer, clean and refit. Blocked strainers reduce
performance.
12MAdded
11. Internal
Inspection
Arrange for an internal inspection to
be carried out by a Competent
Person as required by the Written
Scheme of Examination.
Pressure Systems Safety
Regulations 2000 will apply.
12MAdded
12. Primary
heating coil
Test primary heating coil.12MAdded
13. Return to
operation.
After completion of maintenance,
refit all manhole covers and put
back into operation.
Check that all controls are working
correctly.
12MAdded
14. Check
insulation for
damage.
Repair or renew as necessary. Damaged lagging reduces
efficiency, wastes heat, and if the
calorifier is in the open air, can
become waterlogged and lead to
hidden corrosion. Asbestos
Regulations may apply.
12MAdded
15. Hydraulic
pressure test.
If a pressurised system test to
110% of working pressure.
Pressure Systems Safety
Regulations 2000 will apply.
12MAdded
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HEAT REJECTION SYSTEMS
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INTRODUCTORY PROCEDURES30-01 30-01 INTRODUCTORY PROCEDURES
This section covers those items of plant associated with the removal of heat from the equipment
producing the cooling. It covers evaporative/wet cooling towers, dry coolers and condensers. Where
cooling towers have been, or appear to have been poorly maintained in the past, there is a danger
that Legionella bacteria may be present, it is therefore essential that appropriate safety procedures as
listed in ACOP L8,2001 must 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 where heavy air pollution occurs it may be necessary to increase the
maintenance frequency.
This section covers those items of plant associated with the removal of heat from the equipment
producing the cooling. It covers evaporative/wet cooling towers, dry coolers and condensers. Where
cooling towers have been, or appear to have been poorly maintained in the past, there is a danger
that Legionella bacteria may be present, it is therefore essential that appropriate safety procedures as
listed inACOP L8,2000 (www.hse.gov.uk) must be followed.
The cooling system may consist of a cooling tower, evaporative condenser or other cooling element,
the recirculating pipework, the heat exchanger, pumps and ancillary items such as supply tanks and
pre-treatment equipment. All of these items should be subject to the management and control system.
Cooling systems and towers should be kept in regular use wherever possible. Where a system is used
intermittently or is required at short notice, it should be run once a week and, at the same time, be
dosed with water treatment chemicals and water quality monitored. The whole system should be run
for long enough to thoroughly distribute treated water. If a system is out of use for a week or longer
(up to a month), in addition to the above, the water should be treated with biocide immediately on
reuse.
If it is out of use for longer than a month and there are continued management/monitoring
arrangements in place, the system should be kept full of treated water which should be checked (for
biocide levels and water quality) and circulated once a week (see also paragraph 135). If it is not
possible to ensure regular monitoring and circulation (for example if a building falls out of use) the
system should be drained and sealed, with a desiccant left in the system to reduce the effects of
corrosion. Full recommissioning will be required before the system can be bought back into reuse.
Cooling systems that do not operate continuously, such as cooling towers that cycle on and off
automatically or those on regular standby duty, require particular attention with regard to the biocide
programme to ensure that effective levels of biocide are maintained at all times .
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 where heavy air pollution occurs it may be necessary to increase the
maintenance frequency.
technical
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COOLING TOWERS - Precautions against Legionnaires disease (legionella
pneumophila)
30-02 30-02 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 must be treated as HAZARDOUS and must
not be maintained by personnel who may be susceptible to LEGIONELLA.
Approved Code of Practice- Legionnaires disease: The control of legionella bacteria in water systems:
Approved Code of Practice, L8 sets out certain statutory requirements. In particular each water
system 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 L8 has a special legal status, Part 1 being regulatory and Part 2
guidance.
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.
Towers that have not been regularly maintained must be treated as HAZARDOUS and must not be
maintained by personnel who may be susceptible to LEGIONELLA.
Technical
Title NotesActionFQTitle FQ Action Notes
Initial Safety
Precautions
Ensure Competent fully trained
maintenance personnel read ACOP
L8, 2001. Select personnel who are
less susceptible to the disease.
Protecting clothing and positive
pressure respirators.
Cooling water Analysis
Before starting work on cleaning
cooling towers it is essential that
certain preliminary safety
precautions are taken. These are
listed under 'Action'.
Personnel must wear positive
pressure respirators when
contamination is suspected or the
condition is not known. Note:-
respirator seal may not work with
beards.
Sample and send to a UKAS
accredited laboratory for total viable
colony count (TVC) Dipslides should
be taken weekly.
Initial Safety
Precautions
Ensure Competent fully trained
maintenance personnel read ACOP
L8, 2000 (www.hse.gov.uk).
Before starting work on cleaning
cooling towers it is essential that
certain preliminary safety
precautions are taken. These are
listed under `Action`.
Personnel must wear positive
pressure respirators when
contamination is suspected or the
condition is not known. Note:-
respirator seal may not work with
beards.
Sample and send to a UKAS
(www.ukas.com) accredited
laboratory for total viable colony
count (TVC) Dipslides should be
taken weekly.
Legislative
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Cleansing and
disinfection
procedures
Where cooling towers are situated in
rural areas and only in use during
the summer months the frequency
of maintenance can be extended to
twelve months.
Cleansing and
disinfection
procedures
Disinfection, cleaning and manual
desludging of cooling towers should
be undertaken at least twice a year,
but more frequent cleaning may be
necessary depending on local
environmental conditions such as
dirty atmospheres and the
conclusions reached in the risk
assessment. Cooling systems that
have a short operating period may
only need to be cleaned at the
beginning and end of that period. If
on inspection the system shows
signs of a significant build-up of
deposits or slime, then disinfection
and cleaning should
be carried out.
Technical
2. Warning
notices.
Post at approaches to cooling tower
and enclosure.
It is essential that anyone
approaching the cooling tower is
warned and notices must state:-
Restricted area - do not enter.
6M 2. Warning
notices.
Post at approaches to cooling tower
and enclosure.
It is essential that anyone
approaching the cooling tower is
warned and notices must state:-
Restricted area - do not enter.
6MOther
5. Electrical
equipment.
Ensure that all electrical equipment
is isolated except pumps.
Cooling tower fans and any adjacent
air intake fans must be isolated in
accordance with H&S requirements.
Refer to www.hse.gov.uk for detail.
6M 5. Electrical
equipment.
Ensure that all electrical equipment
is isolated except pumps.
Cooling tower fans and any adjacent
air intake fans must be isolated in
accordance with H&S requirements.
Refer to www.hse.gov.uk for detail.
6MOther
9. Disinfection. Add sodium hypochlorite to
chlorinate, bring up concentration
to either 5 ppm or 30 ppm. (see
notes)
Any action taken must conform to
the requirements of CIBSE TM13 ,
HSE 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.
6M 9. Disinfection. Add sodium hypochlorite to
chlorinate, bring up concentration to
either 5 ppm or 30 ppm. (see
notes).
Any action taken must conform to
the requirements of CIBSE TM13 ,
HSE ACOP l8, 2000 and other H&S
(www.hse.gov.uk/hthdir/noframes/co
shh/index.htm) regulations. At 5
ppm the system should be run for at
least six hours, at 30 ppm, 2 hours.
See item 10.
6MOther
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13. All surfaces. All accessible surfaces to be
cleaned with a wire brush. To
remove all deposits thoroughly
chemical cleaning may be
necessary.
Ensure all scale, rust and other
mineral and organic deposits are
removed. Any rust areas should be
treated and repainted.
6M 13. All surfaces. All accessible surfaces to be
cleaned with a wire brush. To
remove all deposits thoroughly
chemical cleaning may be
necessary.
Accessible areas of the tower and
its pack should be adequately
washed but cleaning methods that
create excessive spray, for example
high-pressure water jetting, should
be avoided. If this is not possible,
the operation should be carried out
when the building is unoccupied or,
in the case of permanently occupied
buildings, windows in the vicinity
should be closed, air inlets blanked
off and
the area that is being water-jetted
should be tented. The area should
be isolated and consideration
should also be given to other
occupied premises in the immediate
areas as well as members of the
public who may in the vicinity during
cleaning.
Ensure all scale, rust and other
mineral and organic deposits are
removed. Any rust areas should be
treated and repainted.
6MTechnical
17. Chlorination. Close drain valves, open water
supply, fill system and chlorinate to
5 ppm. Replace pump fuses, switch
on pumps and run system for six
hours.
Ensure that chlorination
concentration remains at 5 ppm
throughout 'run' period.
6M 17. Chlorination. Close drain valves, open water
supply, fill system and chlorinate to
5 ppm. Replace pump fuses,
switch on pumps and run system
for six hours. The use of a
biodispersant will enhance the
effectiveness of this chlorination. If
the system volume is greater than
5m3, the water should be
dechlorinated, drained, flushed and
refilled with fresh water and dosed
with the appropriate start-up level of
treatment chemicals, including the
biocides.
While the maintenance of a
continuous minimum residual of 5
mg/l of free chlorine for a minimum
period of 5 hours is considered the
best practice, if the downtime to
conduct such a lengthy operation is
not viable, some compromise may
be necessary. Under such
circumstances it may be acceptable
to shorten the pre- and
post-chlorination times and to
increase the free chlorine level, e.g.
50 mg/l for 1 hour or 25 mg/l for 2
hours. This should only be done if
the operators are trained in this
process because, at these levels,
there is a greater risk of damaging
the fabric of the system.
6MTechnical
19. Re-fill
system.
Note:- If chlorine concentration
exceeds 2 ppm prior to activating
water treatment regime, drain and
refill.
6M 19. Re-fill
system.
If chlorine concentration exceeds 2
ppm prior to activating water
treatment regime, drain and refill.
6MOther
20.Attenuators. Clean, derust and repaint as
required.
6M 20. Attenuators. Clean, derust and repaint as
required.
6MOther
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27. Bacterial
checks.
Take sample for TVC count. Note:- weekly dip slides will indicate
bacteria levels. A high bacterial level
does not necessarily mean the
Legionella bacteria are present.
6M 27. Bacterial
checks.
Take sample for TVC count. Weekly dip slides will indicate
bacteria levels. A high bacterial level
does not necessarily mean the
Legionella bacteria are present.
Bacterial checks should be
undertaken weekly.
3MOther
Tower HygieneAdded
Tower
Maintenance
Added
1. Fans and
Motors
Check the condition of the fan
motor through temperature or
vibration analysis and compare to
baseline values. Assure that all
bearings are lubricated per the
manufacture`s recommendation.
Check for excessive wear and
secure fastening. Aligning the
motor coupling allows for efficient
torque transfer.
1MAdded
2. Strainers Physically clean screen(s) of all
debris.
1WAdded
3. Drain and
Overflow
Check that drain and overflow are
clear from blockage.
1WAdded
4. Float Switches Operate switch manually to ensure
proper operation.
1WAdded
5. tower structure Check for excessive vibration in
motors, fans, and pumps. Check for
loose fill, connections, leaks, etc.
1WAdded
6. Water
Treatment
Check that water treatment
automatic dosing equipment is
functional.
For Further Guidance see Water
treatment SFG 65.
1WAdded
7. Test water
samples (Open
System)
Test for proper concentrations of
dissolved solids, and
microbiological quality of the pond
water by undertaking a dip slide
test. Adjust blowdown and
chemicals as necessary. Record
the result. Undertake additional
water quality tests such as pH,
conductivity and tests for hardness
salts as determined by risk
assessment.
See `Table 1 Typical on-site
monitoring checks recommended for
good operating practice` page 36 of
L8 3rd Edition 2000.
1WAdded
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8. Test water
samples (Closed
System)
Test for proper concentrations of
dissolved solids, and
microbiological quality of the pond
water by undertaking a dip slide
test. Adjust blowdown and
chemicals as necessary. Record
the result. Undertake additional
water quality tests such as pH,
conductivity and tests for hardness
salts as determined by risk
assessment.
See `Table 1 Typical on-site
monitoring checks recommended for
good operating practice` page 36 of
L8 3rd Edition 2000.
1MAdded
9. All internal
areas
Check internal surfaces for algae,
scale, rust and limescale
accumulation.
1MAdded
10. Drift
eliminators,
louvers, tubes and
fill
Look for proper positioning and
scale build up. Clean as needed
The frequency of the task can vary
depending on the water quality. The
Risk assessment may give greater
or lesser frequencies for this task.
1MAdded
11. Sparge Pipe Make sure water is flowing through
nozzles to ensure even distribution
over the fill.
1MAdded
12. Bearings Inspect bearings and drive belts for
wear. Adjust, repair, or replace as
necessary.
12MAdded
13. Motors Undertake annual maintenance.
For further Guidance see Motors
SFG 39-01.
12MAdded
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DRY COOLERS30-03 30-03 DRY COOLERS
Title NotesActionFQTitle FQ Action Notes
6. Electrical. Check for satisfactory operation of
local electrical isolation device
stoplock/isolator). Examine and
report condition of all associated
wiring, ensure security of all
terminal connections and check for
satisfactory condition of any flexible
cables/conduits. Ensure plant has
adequate earth conductor and
bonding is secure.
6MAdded
7. Insulation. Check condition. Repair and reseal
as necessary.
6MAdded
8. General
cleanliness.
Clean surfaces and components of
unit particularly fan impeller and
motor casing. Check and clean
surfaces of unit casing, check for
corrosion, repair and treat as found
necessary
Remove any dirt or rubbish from
vicinity of plant.
6MAdded
9. System
operation.
Check function and operation of all
automatic sensors /detectors
(flow/temperature). Check for
correct operation/shut-down of
plant. Ensure all devices are
returned to their correct settings.
Clean air inlet & discharge grilles.
Check all access doors for fit and
can be made secure. When shut,
ensure for air tight seal.
i.e. Start/stops and capacity
regulators should be in accordance
with externally applied control
systems if applicable.
6MAdded
1. Status. Isolate from electrical and other
services.
Isolate electrical supply in
accordance with H&S requirements.
6M 1. Status. Isolate from electrical and other
services.
Isolate electrical supply in
accordance with H&S
(www.hse.gov.uk) requirements.
6MOther
2. Fans. See FANS.6M 2. Fans. Clean fan blades and lubricate if
required.
`Sealed for life` bearings should not
be serviced.
See Fans SFG 20.
Ensure that the correct oils and/or
greases and quantities are used. It
is particularly important that
lubricants of the correct working
range are used. Oil attracts dust and
as a consequence any excess
should be wiped clear (e.g. fan
blades) see manufacturer`s
instructions.
6MTechnical
3. Fins. 6M Deleted
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a) external, Clean by blowing through with
compressed air or steam.
Note:- Any discharged refrigerant
(CFCs) must be recovered and NOT
released to atmosphere. Only a
REFCOM or other mandatory
scheme provider registered
engineer, must work on this
equipment.
6M 3a)Fins - external. Clean by blowing through with dry,
oxygen free, nitrogen.
Do not use refrigerant for cleaning
tubes use dry nitrogen or
compressed air. Sterilisation may be
required. Where Oxygen Free
Nitrogen is used, a Risk
Assessment must be carried out
prior to use and suitable training
given.
Any discharged refrigerant must be
recovered and not released to
atmosphere. Any persons working
on these systems must be
registered to an approved Certified
Scheme provider, in accordance
with the "F" Gas and Building
Regulations
6MTechnical
b) internal. Blow through with dry, oxygen free,
nitrogen.
6M 3b) Fins - internal. Blow through with dry, oxygen free,
nitrogen.
Do not use refrigerant for cleaning
fins use dry nitrogen or compressed
air. Where Oxygen Free Nitrogen is
used, a Risk Assessment must be
carried out prior to use and suitable
training given.
6Mtechnical
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30-04 ADIABATIC COOLERS
Title NotesActionFQTitle FQ Action Notes
1. Ultra violet
generation unit.
Check system operational, clean
quartz glass sleeve if wipers are
fitted.
1MAdded
2. UV System
Cartridge.
Change. Frequency will depend upon water
quality.
1MAdded
3. Electrical
equipment.
Ensure that all electrical equipment
is isolated except pumps.
Cooling fans and any adjacent air
intake fans must be isolated in
accordance with H&S requirements.
Refer to www.hse.gov.uk
(www.hse.gov.uk) for detail.
6MAdded
4. Fans. Clean fan blades and lubricate if
required.
`Sealed for life` bearings should not
be serviced.
See Fans SFG 20.
Ensure that the correct oils and/or
greases and quantities are used. It
is particularly important that
lubricants of the correct working
range are used. Oil attracts dust and
as a consequence any excess
should be wiped clear (e.g. fan
blades) see manufacturer`s
instructions.
6MAdded
5 Fins - external. Clean by initially blowing through
with dry, oxygen free or nitrogen.
All accessible surfaces to be
cleaned with a propriatry comb.
It may be necessary to carry out
additional cleaning or descaling to
remove all scale deposits
thoroughly. Chemical cleaning may
be necessary.
Do not use refrigerant for cleaning
tubes use dry nitrogen or
compressed air. Sterilisation may be
required. Where Oxygen Free
Nitrogen is used, a Risk
Assessment must be carried out
prior to use and suitable training
given.
Any discharged refrigerant must be
recovered and not released to
atmosphere. Engineers working on
these systems must belong to an
approved Certified Scheme
provider, in accordance with the "F"
Gas and Building Regulations
6MAdded
6. Water
Distribution
Check that the water distribution
system is free of dirt and debris. All
nozzles, troughs etc. need to be in
place and clean. In case of
contamination, clean the water
distribution system as per
manufacturer’s instructions.
Replace damaged or missing
nozzles, as well as any nozzles
which cannot be cleaned
6MAdded
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7. General
cleanliness.
Clean surfaces and components of
unit particularly fan impeller and
motor casing. Check and clean
surfaces of unit casing, check for
corrosion, repair and treat as found
necessary
Remove any dirt or rubbish from
vicinity of plant.
6MAdded
8. Coil vent. Check operation.6MAdded
9. Anti-vibration
mountings.
Check - visual condition, -
effectiveness.
There should be no transfer of
vibration or visible deterioration.
6MAdded
10 . Electrical. Check for satisfactory operation of
local electrical isolation device
stoplock/isolator). Examine and
report condition of all associated
wiring, ensure security of all
terminal connections and check for
satisfactory condition of any flexible
cables/conduits. Ensure plant has
adequate earth conductor and
bonding is secure.
6MAdded
11. Insulation. Check condition. Repair and reseal
as necessary.
6MAdded
12. System
operation.
Check function and operation of all
automatic sensors /detectors
(flow/temperature). Check for
correct operation/shut-down of
plant. Ensure all devices are
returned to their correct settings.
Clean air inlet & discharge grilles.
Check all access doors for fit and
can be made secure. When shut,
ensure for air tight seal.
i.e. Start/stops and capacity
regulators should be in accordance
with externally applied control
systems if applicable.
6MAdded
13. Ultra violet
lamp.
Replace and note date in plant log. Replacement interval will depend
upon type of lamp, e.g. medium
pressure lamps - six months, low
pressure lamps - twelve months.
12MAdded
14. Electrical
safety.
Check security of connections and
condition of wiring.
12MAdded
15. Sediment
removal pre-filter.
Remove, clean and replace quartz
glass sleeve or thimble.
If feed water contains iron or organic
matter, quartz glass may require
more frequent cleaning.
24MAdded
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HIGH VOLTAGE WORKS
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70-01 INTRODUCTORY PROCEDURES
Established safety rules should be issued or available to all persons operating or working on electrical
switchgear and control gear. Such persons should be familiar with the method of operation, and with
the safety precautions established for the premises. Instructions for the treatment of persons suffering
from electric shock should be displayed. A notice indicating the action to be taken in the event of fire
should be displayed. In premises subject to the requirements of the Factories Act 1961, a copy of the
relevant statutory regulations is to be displayed and any person working with electrical equipment
should have a copy of these regulations available to him. A diagram of the electrical apparatus and
relevant protection details of the installation should be available. Adequate quantities of safety locks
together with caution notices should be available for immediate use to facilitate safe working and
prevent conductors from being accidently or inadvertently electrically charged when persons are
working thereon. Danger notices to warn of the presence of live conductors should also be available
for immediate use. Essential labels should be legible, prominently displayed, made from durable
material and maintained up-to-date.
Emergency exits should be inspected prior to maintenance work on electrical equipment and should
be kept clear.
Because of the widely varying conditions of operation of individual installations, it is not possible to lay
down precise recommendations for the intervals between maintenance required under all
circumstances. However, the manufacturer should be requested to specify the minimum maintenance
frequency under specified conditions and give guidance on how this may vary under other conditions.
These intervals may vary greatly depending upon the design of the equipment, the duty that it is called
on to perform and the environment in which it is situated.
The frequency of maintenance will depend on a number of factors, the most important being the
conditions under which the equipment operates and the severity of duty. For continuously operating
plant it may be necessary to coordinate routine maintenance with the demands of the production
programme, but where there are regular periods during which the plant is shut down, maintenance
schedules may be arranged to coincide with those periods.
The intervals between maintenance operations may therefore be based on the number of operations
performed or on fixed time intervals, the preferred basis being determined by the electrical,
mechanical and environmental duties imposed. In practice, a
combination of these criteria may be used in the light of service experience with individual
installations. Whilst abnormally frequent operation may necessitate an increase in maintenance
frequency the converse is not necessarily true.
Added
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70-02 HV PACKAGED SUBSTATIONS
Please ensure that the introductory section of this task has been read and fully understood especially
in relation to the frequency of tasks being performed.
All works shall be in accordance with the code of practice for Maintenance of electrical switchgear and
control gear for voltages above 1 kV and up to and including 36 kV BS 6626:2010 and HSE keeping
electrical switchgear safe HSG230
Added
Title NotesActionFQTitle FQ Action Notes
1. Non-intrusive
visual inspection
The general inspection check is
intended to ensure that the
switchgear is not under threat from
the environment in which it is
installed. It is intended that this
inspection can be performed with
the switchboard live although care
must be taken only to work on
accessible sides while the
equipment is live.
Carry out a general operating and
status check. Listen for any audible
discharge and check for any
unusual smells, checks for leakage
of coolants, lubricants, the status of
all instrumentation, and general
tidiness of the switchroom.
Inspect switchroom access and
surrounds (including fence and
external walls if outdoors) check for
signs of trespass and /or
interference.
Check for the presence and
legibility of warning notices.
Check fire fighting equipment.
Check signs of water
ingress/dampness in switchroom.
Check that no devices have tripped
and/or no fault passage indicators
are in the alarm condition.
Carry out thermal imaging of all
equipment and look for any local
high-resistant hot spots that may
show.
Should there be any signs of
malfunctioning, report back to the
client.
A check for any abnormal conditions
should be carried out immediately
on entering the substation and if any
danger is suspected then the
inspection should be aborted.
Typical warning signs are:
1) high temperature in switchroom;
2) presence of smoke;
3) smell of ‘hot’ substances (oil,
compound etc.);
4)audible discharges or arcing;
5)smell of ozone;
6)signs of leaked oil in vicinity of oil
circuit-breaker tank;
7)signs of fresh compound leaks;
8)distortion and evidence of sooting
on enclosures.
A limitation-of-access document
should be raised for any
non-intrusive visual-inspection
maintenance of the HV switchgear
and protection system.
6MAdded
2. Special tools Check that all special tools and
isolating equipment are serviceable
and in their correct locations.
6MAdded
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3. Switchgear
general condition
Carry out an external visual
inspection of the switchgear
checking the general condition of
the exposed busbars and air break
switches (where present), check
general condition of the switchgear
checking for rust, oil leaks, oil level
gauge etc. Check for compound
leaks from cable boxes, busbar
chambers, band joints and end
caps. Check ammeters, voltmeters,
operation indicators, protection
equipment. Check labelling,
padlocks and key exchange
interlocks.
The same external inspection
should be carried out on associated
equipment, such as batteries and
chargers, control panels and other
ancillary equipment.
6MAdded
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70-03 OIL SWITCHGEAR INCLUDING OIL CIRCUIT BREAKERS AND OIL
SWITCHES
Please ensure that the introductory section of this task has been read and fully understood especially
in relation to the frequency of tasks being performed.
All works shall be in accordance with the code of practice for Maintenance of electrical switchgear and
control gear for voltages above 1 kV and up to and including 36 kV BS 6626:2010 and HSE keeping
electrical switchgear safe HSG230
Added
Title NotesActionFQTitle FQ Action Notes
1. General
inspection
The general inspection check is
intended to ensure that the
switchgear is not under threat from
the environment in which it is
installed. It is intended that this
inspection can be performed with
the switchboard live although care
must be taken only to work on
accessible sides while the
equipment is live.
Carry out an external visual
inspection of the switchgear
checking the general condition of
the exposed busbars and air break
switches (where present), check
general condition of the switchgear
checking for rust, oil leaks, oil level
gauge etc. Check for compound
leaks from cable boxes, busbar
chambers, band joints and end
caps. Check ammeters, voltmeters,
operation indicators, protection
equipment. Check labelling,
padlocks and key exchange
interlocks.
A check for any abnormal conditions
should be carried out immediately
on entering the substation and if any
danger is suspected then the
inspection should be aborted.
Typical warning signs are:
1) high temperature in switchroom;
2) presence of smoke;
3) smell of ‘hot’ substances (oil,
compound etc.);
4)audible discharges or arcing;
5)smell of ozone;
6)signs of leaked oil in vicinity of oil
circuit-breaker tank;
7)signs of fresh compound leaks;
8)distortion and evidence of sooting
on enclosures.
A limitation-of-access document
should be raised for any
non-intrusive visual-inspection
maintenance of the HV switchgear
and protection system.
6MAdded
2. Ventilation Check ventilated equipment and
any restriction to the airflow
removed. In the case of mechanical
ventilation, the operation of
any airflow interlock should be
checked and corrected if
necessary.
Filters, where appropriate, should
be cleaned or renewed as
necessary.
12MAdded
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3. Protective
relays
Check protective relay settings.
inspection for condition, damage
and deterioration. For an
electromechanical type relay this
should include checks that: relay
movement runs freely; magnet
gaps and induction disc are clean;
contacts are not burnt or pitted
(refurbish as necessary); induction
disc resetting time
(electromechanical IDMT relays);
flag mechanisms and reset knobs
operate correctly; front cover glass
and seals are satisfactory; current
transformer shorting contacts
operate satisfactorily
Any maintenance on relays should
be carried out in accordance with
the manufacturer’s instructions and
should be incorporated in the
maintenance programme which
should include operational checking
of protective and interlock features.
12MAdded
4. Time limit fuses Inspect time limit fuses. Where
possible, actual timing periods
should be verified against the set
values and application
requirements, particularly if the
timing device has been dismantled
or replaced.
Such items should not be
dismantled for maintenance or
overhaul purposes unless this is
recommended in the manufacturer’s
instructions.
12MAdded
5. Shutters Inspect shutters for correct
operation.
12MAdded
6. Interlocks Inspect interlocks
Mechanical elements. All moving
parts should be clean, adequately
lubricated and be free to move as
intended. Any evidence of wear or
excessive free play should be
investigated and, if necessary,
reference made to the
manufacturer. All fixing devices
should be secure.
Electrical elements. If accessible
inspect control wiring for signs of
damage and check terminations for
tightness.
If in doubt concerning the condition
of the control wiring insulation it is
recommended that an insulation
resistance test be carried out.
12MAdded
7. Tank and tank
linings
On oil switches an inspection of the
tank and tank linings should be
carried out. This is not appropriate
at this frequency for Oil circuit
breakers.
12MAdded
8. Operational
check
Carry out an operational check12MAdded
9. Cleaning Clean as required.60MAdded
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10. Closing and
trip mechanism
Check and lubricate circuit-breaker
isolating mechanism
60MAdded
11. Main and
arcing contacts
Examine main/arcing contacts for
excessive burning/damage
recondition or renew as required,
take account of manufacturer’s
requirements for different contact
construction and materials.
60MAdded
12. Auxiliary
contacts
Examine for wear (according to the
manufacturer’s handbook)
and for overheating, misalignment,
failure to disengage correctly
and other defects, and recondition
or renew as required.
Some auxiliary contacts are not
intended to be maintained. Such
items should not, therefore, be
dismantled for maintenance or
overhaul purposes.
60MAdded
13. Secondary
wiring and fuses
Examine secondary wiring and
fuses. Carry out insulation
resistance test.
60MAdded
14. Insulation test Where practicable, porcelain and
moulded insulation should be
inspected for cracks and other
defects. Bonded and laminated
fibrous insulation and other organic
insulation should be inspected for
signs of tracking, treeing,
delamination and mechanical
damage.
Insulation resistance
measurements between poles and
between poles and earth are the
most suitable for insulation testing
under service conditions.
60MAdded
15. Earth
connections
Ensure that earthing connections
are mechanically and electrically
sound and that all contact screws
are tight and good contact is
maintained. Particular care should
be taken to reinstate fully all bolts
and screws, together with any
locking devices that might have
been disturbed during the
maintenance operation.
60MAdded
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16. Insulation oil Examine oil. If the oil is badly
discoloured or is excessively
contaminated by carbon particles in
suspension it may require
changing.
A representative sample of oil
should be taken and electric
strength, water content and acidity
tests which should be carried out in
accordance with BS EN 60422 with
suitable variation for high viscosity
oil. Oil that does not meet the
recommendations given in BS EN
60422 should be replaced with oil
that does. The oil level should be
maintained at the level specified by
the equipment manufacturer.
60MAdded
17. Heaters 60MAdded
18. Devices for arc
control
Examine for cracking or if eroded.
The free operation of the contactors
should be checked. Contacts
should not foul arc chutes or
barriers. The cleaning of barriers
should be carried out accordingly.
On older units some barriers contain
asbestos.
60MAdded
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70-04 NON-OIL SWITCHGEAR
Please ensure that the introductory section of this task has been read and fully understood especially
in relation to the frequency of tasks being performed.
All works shall be in accordance with the code of practice for Maintenance of electrical switchgear and
controlgear for voltages above 1 kV and up to and including 36 kV BS 6626:2010 and HSE keeping
electrical switchgear safe HSG230
Added
Title NotesActionFQTitle FQ Action Notes
1. General
inspection
The general inspection check is
intended to ensure that the
switchgear is not under threat from
the environment in which it is
installed. It is intended that this
inspection can be performed with
the switchboard live although care
must be taken only to work on
accessible sides while the
equipment is live.
Carry out an external visual
inspection of the switchgear
checking the general condition of
the exposed busbars and air break
switches (where present), check
general condition of the switchgear
checking for rust etc. Check for
compound leaks from cable boxes,
busbar chambers, band joints and
end caps. Check ammeters,
voltmeters, operation indicators,
protection equipment. Check
labelling, padlocks and key
exchange interlocks.
A check for any abnormal conditions
should be carried out immediately
on entering the substation and if any
danger is suspected then the
inspection should be aborted.
Typical warning signs are:
1) high temperature in switchroom;
2) presence of smoke;
3) smell of ‘hot’ substances (oil,
compound etc.);
4)audible discharges or arcing;
5)smell of ozone;
6)signs of leaked oil in vicinity of oil
circuit-breaker tank;
7)signs of fresh compound leaks;
8)distortion and evidence of sooting
on enclosures.
A limitation-of-access document
should be raised for any
non-intrusive visual-inspection
maintenance of the HV switchgear
and protection system.
6MAdded
2. Ventilation Check ventilated equipment and
any restriction to the airflow
removed. In the case of mechanical
ventilation, the operation of
any airflow interlock should be
checked and corrected if
necessary.
Filters, where appropriate, should
be cleaned or renewed as
necessary.
12MAdded
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Sulphur
hexafluoride
switchgear -
inspection
Sulphur hexafluoride switchgear is
designed to be low maintenance.
Maintenance using a time-interval
approach, based on manufacturer’s
recommendations, may be applied
to such switchgear.
Sulphur hexafluoride (SF6 ) is listed
as a fluorinated greenhouse gas in
European Union Regulation EC
842/2006 [9] (on certain fluorinated
greenhouse gases), the
requirements of which are referred
to in the Fluorinated Greenhouse
Gases Regulations 2009. As such,
SF6 is subject to strict requirements
governing its use, which are
intended to prevent and minimize
any release into the atmosphere.
EC Regulation 305/2008 [10], which
is also referred to in the Fluorinated
Greenhouse Gases Regulations
2009, requires individuals who carry
out recovery of SF6 gas from high
voltage switchgear to be
appropriately trained and assessed
and to hold a written qualification
issued by a certification body.
Added
3. General
inspection In
addition to item 1.
above check
pressure gauge.
Check the gas pressure gauge
should be checked, a pungent
smell indicates gas leakage.
12MAdded
4. Mechanisms inspection, adjustment and
lubrication of mechanisms
(including shutters where
appropriate)
60MAdded
5. Contacts Examine of primary isolating
contacts for damage, burning,
corrosion - cleaning and
refurbishing (as necessary)
60MAdded
6. Circuit Breaker
isolating
mechanism
Check and lubricate circuit-breaker
isolating mechanism
60MAdded
7. Indicators and
interlocks
Inspect interlocks
Mechanical elements. All moving
parts should be clean, adequately
lubricated and be free to move as
intended. Any evidence of wear or
excessive free play should be
investigated and, if necessary,
reference made to the
manufacturer. All fixing devices
should be secure.
Electrical elements. If accessible
inspect control wiring for signs of
damage and check terminations for
tightness.
If in doubt concerning the condition
of the control wiring insulation it is
recommended that an insulation
resistance test be carried out.
60MAdded
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8. Cable
termination
chambers
Examine inside of cable termination
chambers and other chambers as
appropriate, removal of surface
contamination from accessible solid
insulation (where applicable)
60MAdded
9. Secondary
injection test
Secondary injection testing on
circuit-breaker protection system
(or, if this is not scheduled, carry
out manual trip-test);
60MAdded
10. Auxiliary
contacts
Examine for wear (according to the
manufacturer’s handbook)
and for overheating, misalignment,
failure to disengage correctly
and other defects, and recondition
or renew as required.
Some auxiliary contacts are not
intended to be maintained. Such
items should not, therefore, be
dismantled for maintenance or
overhaul purposes.
60MAdded
11. Secondary
wiring and fuses
Examine secondary wiring and
fuses. Carry out insulation
resistance test.
60MAdded
Vacuum
Switchgear
Vacuum switchgear is designed to
be low maintenance. Maintenance
using a time-interval approach,
based on manufacturer’s
recommendations, may be applied
to such switchgear.
A vacuum interrupter is a sealed unit
on which no internal maintenance
can be carried out. Contact wear is
not normally a problem, however
circuit breakers often have a method
for indicating contact erosion.
The minimum vacuum life of the
vacuum interrupter can be expected
to be stated by the manufacturer as
this is specified in BS EN 62271-1
and is from the date of seal-off not
the date of start of service; however,
experience indicates that the actual
lifetime is well in excess of the
stated minimum value. During this
period, vacuum integrity can be
confirmed by methods
recommended by the manufacturer.
These normally consist of voltage
withstand tests which can confirm
the loss of vacuum but cannot
predict future life expectancy. If a
voltage withstand test confirms loss
of vacuum it is essential that the unit
is replaced.
Added
12. General
inspection - Carry
out item 1. above
Carry out general inspection.12MAdded
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13. Voltage
Transformer
Examine and check voltage
transformer (as required)
Steps should be taken to ensure
that a voltage transformer is dead
and isolated and discharged to earth
before it is examined. Where
protective fuses are fitted, particular
care should be taken to ensure
that the voltage transformer is
discharged to earth.
60MAdded
14. Vacuum
Integrity test
Check the vacuum integrity by a
high-voltage pressure test
With vacuum switchgear, X-rays
may be generated when the open
contact gap is stressed at
high-voltage. There are no harmful
emissions at normal service voltage
but if a high-voltage pressure test is
carried out with the switchgear in an
open position then X-rays may be
generated. Guidance should be
sought from the manufacturer on
the maximum voltage that can be
applied to ensure that the maximum
level of radiation generated is less
than that permitted for unclassified
workers in the Ionising Radiation
(Sealed Sources) Regulations 1969.
60MAdded
15. Mechanisms inspection, adjustment and
lubrication of mechanisms
(including shutters where
appropriate)
60MAdded
16. Contacts Examine of primary isolating
contacts for damage, burning,
corrosion - cleaning and
refurbishing (as necessary).
Carry out measurement of contact
wear where a measurement
method is available
60MAdded
17. Circuit Breaker
isolating
mechanism
Check and lubricate circuit-breaker
isolating mechanism
60MAdded
18. Indicators and
interlocks
Inspect interlocks
Mechanical elements. All moving
parts should be clean, adequately
lubricated and be free to move as
intended. Any evidence of wear or
excessive free play should be
investigated and, if necessary,
reference made to the
manufacturer. All fixing devices
should be secure.
Electrical elements. If accessible
inspect control wiring for signs of
damage and check terminations for
tightness.
If in doubt concerning the condition
of the control wiring insulation it is
recommended that an insulation
resistance test be carried out.
60MAdded
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19. Cable
termination
chambers
Examine inside of cable termination
chambers and other chambers as
appropriate, removal of surface
contamination from accessible solid
insulation (where applicable)
60MAdded
20. Secondary
injection test
Secondary injection testing on
circuit-breaker protection system
(or, if this is not scheduled, carry
out manual trip-test);
60MAdded
21. Auxiliary
contacts
Examine for wear (according to the
manufacturer’s handbook)
and for overheating, misalignment,
failure to disengage correctly
and other defects, and recondition
or renew as required.
Some auxiliary contacts are not
intended to be maintained. Such
items should not, therefore, be
dismantled for maintenance or
overhaul purposes.
60MAdded
22. Secondary
wiring and fuses
Examine secondary wiring and
fuses.
60MAdded
Air-Break
Switchgear
Maintenance using a time-interval
approach, based on manufacturer’s
recommendations, may be applied
to such switchgear.
Added
23. General
inspection - Carry
out item 1. above
Carry out general inspection.12MAdded
24. Contacts Examine main/arcing contacts for
excessive burning/damage
recondition or renew as required,
take account of manufacturer’s
requirements for different contact
construction and materials.
60MAdded
25. Contact
springs
check/adjust spring contact force
and contact alignment as required
60MAdded
26. Arc chutes Remove, examine and clean the
arc chutes - renew if damaged or
eroded
60MAdded
27. Mechanisms inspection, adjustment and
lubrication of mechanisms
(including shutters where
appropriate)
60MAdded
28. Circuit Breaker
isolating
mechanism
Check and lubricate circuit-breaker
isolating mechanism
60MAdded
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29. Indicators and
interlocks
Inspect interlocks
Mechanical elements. All moving
parts should be clean, adequately
lubricated and be free to move as
intended. Any evidence of wear or
excessive free play should be
investigated and, if necessary,
reference made to the
manufacturer. All fixing devices
should be secure.
Electrical elements. If accessible
inspect control wiring for signs of
damage and check terminations for
tightness.
If in doubt concerning the condition
of the control wiring insulation it is
recommended that an insulation
resistance test be carried out.
60MAdded
30. Cable
termination
chambers
Examine inside of cable termination
chambers and other chambers as
appropriate, removal of surface
contamination from accessible solid
insulation (where applicable)
60MAdded
31. Secondary
injection test
Secondary injection testing on
circuit-breaker protection system
(or, if this is not scheduled, carry
out manual trip-test);
60MAdded
32. Auxiliary
contacts
Examine for wear (according to the
manufacturer’s handbook)
and for overheating, misalignment,
failure to disengage correctly
and other defects, and recondition
or renew as required.
Some auxiliary contacts are not
intended to be maintained. Such
items should not, therefore, be
dismantled for maintenance or
overhaul purposes.
60MAdded
33. Secondary
wiring and fuses
Examine secondary wiring and
fuses.
60MAdded
34. Voltage
Transformer
Examine and check voltage
transformer (as required)
Steps should be taken to ensure
that a voltage transformer is dead
and isolated and discharged to earth
before it is examined. Where
protective fuses are fitted, particular
care should be taken to ensure
that the voltage transformer is
discharged to earth.
60MAdded
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70-05 VACUUM INDOOR SWITCHGEAR
Please ensure that the introductory section of this task has been read and fully understood especially
in relation to the frequency of tasks being performed.
All works shall be in accordance with the code of practice for Maintenance of electrical switchgear and
controlgear for voltages above 1 kV and up to and including 36 kV BS 6626:2010 and HSE keeping
electrical switchgear safe HSG230
If equipment is removed from service, before it is re-used perform the following tests
- Main and Earth circuit resistance
- Power frequency
- Protection system
Added
Title NotesActionFQTitle FQ Action Notes
1. General
inspection
The general inspection check is
intended to ensure that the
switchgear is not under threat from
the environment in which it is
installed. It is intended that this
inspection can be performed with
the switchboard live although care
must be taken only to work on
accessible sides while the
equipment is live.
Carry out an external visual
inspection of the switchgear
checking the general condition of
the exposed busbars and air break
switches (where present), check
general condition of the switchgear
checking for rust etc. Check for
compound leaks from cable boxes,
busbar chambers, band joints and
end caps. Check ammeters,
voltmeters, operation indicators,
protection equipment. Check
labelling, padlocks and key
exchange interlocks.
A check for any abnormal conditions
should be carried out immediately
on entering the substation and if any
danger is suspected then the
inspection should be aborted.
Typical warning signs are:
1) high temperature in switchroom;
2) presence of smoke;
3) smell of ‘hot’ substances (oil,
compound etc.);
4)audible discharges or arcing;
5)smell of ozone;
6)signs of leaked oil in vicinity of oil
circuit-breaker tank;
7)signs of fresh compound leaks;
8)distortion and evidence of sooting
on enclosures.
A limitation-of-access document
should be raised for any
non-intrusive visual-inspection
maintenance of the HV switchgear
and protection system.
6MAdded
2. Ventilation Check ventilated equipment and
any restriction to the airflow
removed. In the case of mechanical
ventilation, the operation of
any airflow interlock should be
checked and corrected if
necessary.
Filters, where appropriate, should
be cleaned or renewed as
necessary.
12MAdded
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3. Housing Check all external fixings, labels
and earth connections are present
and tight. Check inside the MV
cable box, busbar system LV
cabinet and pilot cable box for
heavy deposits of dust, ingress of
water or contamination by animal or
plant life. Clean the units thoroughly
and touch up paint work as
necessary.
120MAdded
4. Protection
system
Check that the protection settings
are correct on the relay.
perform a primary or secondary
current injection test to prove
that the protection circuit is OK and
that the tripping mechanism
is OK. (Primary injection is the
preferred method as it proves
the CT’s as well, but it will need the
cables removing so may be
inconvenient)
120MAdded
5. Voltage
Presence Indicator
System [VPIS]
Before the switchgear is isolated
ensure that all three phases are
indicating correctly.
The manufacturers life expectancy
of a VPIS device is between 10 & 20
years, therefore the VPIS device
should be replaced at each major
maintenance interval.
120MAdded
6. Voltage
transformer
Before de-energising the
switchboard measure the
secondary
voltage of the VTs. Check continuity
of VT fuses. For unscreened VTs
clean down the external surface of
the insulation with Isopropanol and
lint free cloths to remove any
excess dust/debris. check the
external surface for signs of partial
discharges.
120MAdded
7. Cable boxes Perform a visual inspection of the
cable termination, looking in
particular for signs of partial
discharges, black or white surface
contamination or over heating. With
Isopropanol alcohol and a lint free
cloth clean down the surface of the
cable termination to remove any
contamination from the surface.
With a vacuum cleaner remove any
excess dust from inside the box
then wipe down the inside surface
of the box with Isopropanol alcohol.
Ensure all seals and fixings are
present. Ensure cable earth is
securely connected back to the
switchgear’s main earth bar.
Added
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8. Busbar
chamber
perform a visual inspection of the
busbars and busbar boots,
looking in particular for signs of
mechanical damage, partial
discharges or over heating. ensure
that the busbar is assembled
correctly and correctly torqued. with
Isopropanol alcohol and a lint free
cloth clean down the surface of the
busbars and the insulated busbar
boots to remove any contamination
from the surface. with a vacuum
cleaner remove any excess dust
from inside the busbar chamber
then wipe down the inside surface
of the chamber with Isopropanol
alcohol. Ensure all seals and fixings
are present.
120MAdded
9. Vacuum circuit
breakers
Perform a resistance test across
the closed circuit breaker
contacts. Perform either a 20kV
Accepted or 25kV DC pressure test
across the open contacts. Ensure
that the pas pressure is in the
green zone of the pressure gauge.
120MAdded
10. Cable test
points and earth
circuits
Open the cable test points and
ensure that the moving earth bars
and the fixed contacts are fixed
securely, clean, free of corrosion
and that the contact surfaces are
lubricated. Perform a
resistance/continuity test from the
switchgears main earth bar back to
the substations main earth point.
120MAdded
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70-06 FLUID FILLED TRANSFORMER
The frequency of maintenance inspection should be determined
by factors such as transformer size, application and importance of service continuity as experience
dictates. Also, local climatic and atmospheric conditions will influence the inspection schedule.
Inspection and some minor maintenance, such as on paintwork, may be carried out with the
transformer live, however, the policy to be followed in making equipment available for maintenance
should always be that it should be isolated, proved dead where possible and immediately earthed. A
"permit to work" should be provided to ensure safety to personnel and equipment.
The ingress of moisture and dirt into the transformer can cause malfunction and danger. Care should
be taken to prevent such ingress whilst work is in progress, and covers should be replaced as soon as
access to the transformer tank / disconnection chambers / termination boxes is no longer required.
Before final closure of any compartment is effected, a careful inspection should be carried out to make
sure no foreign matter or loose material is present.
Before work is undertaken in any chamber containing high / low voltage conductors, tests using
suitable voltage indicators should be carried out. These should include tests between each phase and
earth to ensure all conductors are dead.
Added
Title NotesActionFQTitle FQ Action Notes
1. Non-intrusive
visual inspection
The general inspection check is
intended to ensure that the
switchgear is not under threat from
the environment in which it is
installed. It is intended that this
inspection can be performed with
the switchboard live although care
must be taken only to work on
accessible sides while the
equipment is live.
Carry out a general operating and
status check. Listen for any audible
discharge and check for any
unusual smells, checks for leakage
of coolants, lubricants, the status of
all instrumentation, and general
tidiness of the switchroom.
Check that no devices have tripped
and/or no fault passage indicators
are in the alarm condition.
Carry out thermal imaging of all
equipment and look for any local
high-resistant hot spots that may
show.
Should there be any signs of
malfunctioning, report back to the
client.
A check for any abnormal conditions
should be carried out immediately
on entering the substation and if any
danger is suspected then the
inspection should be aborted.
Typical warning signs are:
1) high temperature in switchroom;
2) presence of smoke;
3) smell of ‘hot’ substances (oil,
compound etc.);
4)audible discharges or arcing;
5)smell of ozone;
6)signs of leaked oil in vicinity of oil
circuit-breaker tank;
7)signs of fresh compound leaks;
8)distortion and evidence of sooting
on enclosures.
A limitation-of-access document
should be raised for any
non-intrusive visual-inspection
maintenance of the HV switchgear
and protection system.
6MAdded
2. Silica Gel
Dryers
If appropriate inspect silica gel
dryers to ensure that the desiccant
is still active.
If the unit indicates that saturation
has been reached change the
desiccant or cartridge as required.
6MAdded
3. Fluid Inspect fluid level.12MAdded
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4. Paintwork Inspect paintwork condition and
carry out remedial painting as
required.
A zinc based primer should then be
applied followed
by a quick drying top coat of paint.
18MAdded
5. Bolted
connections and
fixings
Torque check all bolted connections
and fixings in accordance with the
manufacturers settings.
Thermal cycling and mechanical
forces due to load, wind or local
vibration and shock can result in
relaxation of gaskets and small oil
leaks. Fixings and fasteners should
therefore be periodically checked.
18MAdded
6. Earth Test earth connection integrity.
Earth loop impedance
measurements may be carried out.
18MAdded
7. Fluid Inspect fluid level and take sample
for analysis.
Test dielectric strength, moisture
content &
gas analysis of insulating fluid.
Care should be taken when
obtaining a sample as the head of
fluid above the sample valve will
force the fluid out rapidly. An
equivalent amount of clean new fluid
should be added to the transformer
through its bolted filler cap / cover
positioned on top of the transformer
cover
Renewal / change of dielectric fluid
as required and indicated by
manufacturers recommendation.
It is not a usual requirement to take
fluid samples from an hermetically
sealed transformer, as they are
sealed from the environment, as
such preventing ingress of
contamination to the dielectric fluid.
Samples should only be taken to
establish the condition of fluid after
overload or fault and normally by the
manufacturer.
18MAdded
8. Insulation test Where practicable, porcelain and
moulded insulation should be
inspected for cracks and other
defects. Bonded and laminated
fibrous insulation and other organic
insulation should be inspected for
signs of tracking, treeing,
delamination and mechanical
damage.
Insulation resistance
measurements between poles and
between poles and earth are the
most suitable for insulation testing
under service conditions. Test
insulation resistance measurement
by Megger
18MAdded
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9. Dehydrating
breather
Where fitted inspect dehydrating
breather.
18MAdded
10. Liquid
temperature
indicator
Where fitted inspect and test liquid
temperature indicator.
18MAdded
11. Winding
temperature
indicator
Where fitted inspect and test
winding temperature indicator.
18MAdded
12. Pressure relief
device
Where fitted inspect pressure relief
device.
No maintenance is necessary.18MAdded
13. Gas & Oil
actuated relay
Where fitted inspect gas & oil
actuated relay.
18MAdded
14. Magnetic liquid
level indicator
Where fitted inspect magnetic liquid
level indicator.
18MAdded
15. Vacuum /
pressure gauge
Where fitted inspect vacuum /
pressure gauge.
No maintenance is necessary.18MAdded
16. Off circuit
tapping switch
Check off circuit tapping switch
operation.
18MAdded
17. Ventilation Carry out ventilation check. Checks
should me made that the ventilation
provided for the transformer is
sufficient (e.g. substation ventilation
grills are clean and clear of
obstructions).
The substation ambient temperature
should be checked to ensure it is
defined by BS EN 60076 and IEC
76.
18MAdded
18. Harmonic load Carry out harmonic load test.18MAdded
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70-07 CAST RESIN TRANSFORMER
Please ensure that the introductory section of this task has been read and fully understood especially
in relation to the frequency of tasks being performed.
All works shall be in accordance with the code of practice for Maintenance of electrical switchgear and
controlgear for voltages above 1 kV and up to and including 36 kV BS 6626:2010 and HSE keeping
electrical switchgear safe HSG230
A check for any abnormal conditions should be carried out immediately on entering the substation and
if any danger is suspected then the inspection should be aborted. Typical warning signs are:
1) high temperature in switchroom;
2) presence of smoke;
3) smell of ‘hot’ substances (oil, compound etc.);
4)audible discharges or arcing;
5)smell of ozone;
6)signs of leaked oil in vicinity of oil circuit-breaker tank;
7)signs of fresh compound leaks;
8)distortion and evidence of sooting on enclosures.
A limitation-of-access document should be raised for any non-intrusive visual-inspection maintenance
of the HV switchgear and protection system.
Added
Title NotesActionFQTitle FQ Action Notes
1. Non-intrusive
visual inspection The general inspection check is
intended to ensure that the
switchgear is not under threat from
the environment in which it is
installed. It is intended that this
inspection can be performed with
the switchboard live although care
must be taken only to work on
accessible sides while the
equipment is live.
Carry out a general operating and
status check. Listen for any audible
discharge and check for any
unusual smells, checks for leakage
of coolants, lubricants, the status of
all instrumentation, and general
tidiness of the switchroom.
Check that no devices have tripped
and/or no fault passage indicators
are in the alarm condition.
Carry out thermal imaging of all
equipment and look for any local
high-resistant hot spots that may
show.
Should there be any signs of
malfunctioning, report back to the
client.
6MAdded
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2. Paintwork Inspect paintwork condition and
carry out remedial painting as
required.
A zinc based primer should then be
applied followed
by a quick drying top coat of paint.
12MAdded
3. Bolted
connections and
fixings
Torque check all bolted connections
and fixings in accordance with the
manufacturers settings.
Thermal cycling and mechanical
forces due to load, wind or local
vibration and shock can result in
relaxation of gaskets and small oil
leaks. Fixings and fasteners should
therefore be periodically checked.
12MAdded
4. Clean Vacuum clean, and blow places
which are less accessible, with dry
compressed air or nitrogen.
Clean lead or cable supports, tap
changers, bushings and other
insulating surfaces using brush or
wiping with lint free cloth.
The frequency of cleaning will
depend on environmental
conditions. In case of fast dust
deposits, increase the yearly
frequency, and if necessary filter the
air cooling flow.
In the case of greasy dust deposits,
use only methylated spirit to clean
the resin surfaces.
12MAdded
5. Insulation
Power Factor Test
Using capacitance bridge
instrument, check insulation power
factor of:
i) Primary/Secondary and Earth.
ii) Secondary/Primary and Earth.
Record capacitance values,
dissipation factor and insulation
power factor. Compare field test
results to manufacturer`s factory
test results and to previous
maintenance test results.
12MAdded
6. Ratio Test Carry out ratio test of windings in all
tap positions to ensure accuracy to
within 0.001 percent. Compare test
data to factory test results.
12MAdded
7. Insulation
Resistance
Use megger to measure resistance
between:
i) Primary and Secondary.
ii) Primary/Secondary and Earth.
Iii) Secondary/Primary and Earth.
Compare test results to factory test
data and to previous maintenance
test results.
12MAdded
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8. Core Earth Test Remove earth strap between
laminated core and ground. Megger
test using 250 volt megger (or as
recommended by manufacturer)
between core and ground to ensure
no other grounds exist between
core and ground. Compare values
to factory test values and to
previous maintenance test results.
Reconnect ground strap.
12MAdded
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70-08 RING MAIN UNIT
Please ensure that the introductory section of this task has been read and fully understood especially
in relation to the frequency of tasks being performed.
All works shall be in accordance with the code of practice for Maintenance of electrical switchgear and
controlgear for voltages above 1 kV and up to and including 36 kV BS 6626:2010 and HSE keeping
electrical switchgear safe HSG230
Sulphur hexafluoride (SF6 ) is listed as a fluorinated greenhouse gas in European Union Regulation
EC 842/2006 [9] (on certain fluorinated greenhouse gases), the requirements of which are referred to
in the Fluorinated Greenhouse Gases Regulations 2009. As such, SF6 is subject to strict
requirements governing its use, which are intended to prevent and minimize any release into the
atmosphere.
EC Regulation 305/2008 [10], which is also referred to in the Fluorinated Greenhouse Gases
Regulations 2009, requires individuals who carry out recovery of SF6 gas from high voltage
switchgear to be appropriately trained and assessed and to hold a written qualification issued by a
certification body.
Added
Title NotesActionFQTitle FQ Action Notes
1. Non-intrusive
visual inspection
The general inspection check is
intended to ensure that the
switchgear is not under threat from
the environment in which it is
installed. It is intended that this
inspection can be performed with
the switchboard live although care
must be taken only to work on
accessible sides while the
equipment is live.
Carry out a general operating and
status check. Listen for any audible
discharge and check for any
unusual smells, checks for leakage
of coolants, lubricants, the status of
all instrumentation, and general
tidiness of the switchroom.
Check that no devices have tripped
and/or no fault passage indicators
are in the alarm condition.
Carry out thermal imaging of all
equipment and look for any local
high-resistant hot spots that may
show.
Should there be any signs of
malfunctioning, report back to the
client.
A check for any abnormal conditions
should be carried out and if any
danger is suspected then the
inspection should be aborted.
Typical warning signs are:
1) high temperature in switchroom;
2) presence of smoke;
3) smell of ‘hot’ substances (oil,
compound etc.);
4)audible discharges or arcing;
5)smell of ozone;
6)signs of leaked oil in vicinity of oil
circuit-breaker tank;
7)signs of fresh compound leaks;
8)distortion and evidence of sooting
on enclosures.
A limitation-of-access document
should be raised for any
non-intrusive visual-inspection
maintenance of the HV switchgear
and protection system.
6MAdded
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2. Housing exterior Check all external fixings, labels
and earth connections are present
and tight. Check inside the main
door (if fitted) and pilot cable box
for heavy deposits of dust, ingress
of water or contamination by animal
or plant life. Check condition of the
main door seal.
Where Sulphur hexafluoride [SF6]
gas - Check that the gas indicator is
reading in the green zone [if fitted].
Clean the units thoroughly and
touch up paint work as necessary.
24MAdded
3. Housing interior Open the main and pilot cable box
door. Where Sulphur hexafluoride
[SF6] gas - Check that the gas
indicator is in the green zone and
the protector cap is fitted over the
gas filler valve. For circuit breaker
panels check the electrical
protection system - refer to
manufacturers commissioning
instructions.
Check the operation of the unit and
all mechanical interlocks. Clean the
unit thoroughly.
In the event of a Sulphur
hexafluoride [SF6] gas leak contact
the manufacturers service team
immediately.
60MAdded
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70-09 HV SWITCHPANEL
Please ensure that the introductory section of this task has been read and fully understood especially
in relation to the frequency of tasks being performed.
All works shall be in accordance with the code of practice for Maintenance of electrical switchgear and
controlgear for voltages above 1 kV and up to and including 36 kV BS 6626:2010 and HSE keeping
electrical switchgear safe HSG230
Added
Title NotesActionFQTitle FQ Action Notes
1. Non-intrusive
visual inspection
The general inspection check is
intended to ensure that the
switchgear is not under threat from
the environment in which it is
installed. It is intended that this
inspection can be performed with
the switchboard live although care
must be taken only to work on
accessible sides while the
equipment is live.
Carry out a general operating and
status check. Listen for any audible
discharge and check for any
unusual smells, checks for leakage
of coolants, lubricants, the status of
all instrumentation, and general
tidiness of the switchroom.
Check that no devices have tripped
and/or no fault passage indicators
are in the alarm condition.
Carry out thermal imaging of all
equipment and look for any local
high-resistant hot spots that may
show.
Should there be any signs of
malfunctioning, report back to the
client.
A check for any abnormal
conditions should be carried out
immediately on entering the
substation and if any danger is
suspected then the inspection
should be aborted. Typical warning
signs are:
1) high temperature in switchroom;
2) presence of smoke;
3) smell of ‘hot’ substances (oil,
compound etc.);
4)audible discharges or arcing;
5)smell of ozone;
6)signs of leaked oil in vicinity of oil
circuit-breaker tank;
7)signs of fresh compound leaks;
8)distortion and evidence of sooting
on enclosures.
A limitation-of-access document
should be raised for any
non-intrusive visual-inspection
maintenance of the HV switchgear
and protection system.
6MAdded
2. Feeder circuit
breakers
General inspection and operation,
cleaning of insulation if necessary.
Inspection, cleaning and
de-greasing of isolating contacts.
12MAdded
3. Incoming
isolators
Clean and de-grease the isolator
locks/hooks rotating points and the
external part of shutter. Check that
the cleaned parts rotate correctly
and lubricate in accordance with
manufacturers recommendations.
Check mechanical operation of the
operating mechanism.
12MAdded
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4. Earthing switch Clean earthing switch and
de-greasing the friction points at
roller level and interlock level.
Lubricate friction points in
accordance with manufacturers
recommendations. Check
mechanical operation and function.
12MAdded
5. Earth bar Check earth bar for security and
damage to insulators.
12MAdded
6. Testing Carry out full testing and inspection
in accordance and Safety in
electrical testing at work INDG 354
and EIS 37
12MAdded
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HOT & COLD WATER SERVICES
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INTRODUCTORY PROCEDURES31-01 31-01 INTRODUCTORY PROCEDURES
Hot and Cold Water Services including Drinking Water
This 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 L8 has a special legal status,
Part 1 being regulatory and Part 2 guidance. If you are prosecuted for breach of health & safety law
and it is proved that you did not follow the relevant provisions of the code, you will need to show that
you have complied with the law in some other way or a court will find you at fault. Health and safety
inspectors seek to secure compliance with the law and may refer to the L8 as illustrating good
practise. It is therefore important to comply with it.
In healthcare premises, HTM 04 part A & B now supersede the old HTM 2027 and HTM2040 has
been revised in line with changes to relevant regulations, standards and other guidance and also
technical developments including the ACOP L8. For this reason in healthcare establishments HTM 04
is to be followed. This will automatically satisfy the requirements of L8.
The Standard Maintenance Specifications should be adequate for the majority of well engineered low
risk systems outside of healthcare premises conforming to the requirements 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 and implementation of the precautions. Responsibility and lines of
communication must be properly defined and personnel must be properly trained.
For guidance the following statement is taken from the ACOP L8
1 This Approved Code of Practice gives practical advice on the requirements of the Health and Safety
at Work etc Act 1974 (HSWA) and the Control of Substances Hazardous to Health Regulations 2002
(COSHH) concerning the risk from exposure to legionella bacteria. In particular it gives guidance on
sections 2, 3, 4 and a (as amended by the Consumer Protection Act 1987) of HSWA and regulations
6, 7, 8, 9 and 12 of COSHH. The Code also gives guidance on compliance with the relevant pans of
the Management of Health and Safety at Work Regulations 1999 (MHSWR).
2 This publication replaces two separate documents: the 1995 Approved Code of Practice and the
technical guidance, HSG7O. This has allowed information to be consolidated, with the aim of making
it easier to read and understand the duties under the law. Since the last revision, the Health and
Safety Executive (HSE) and others have funded research to assess the efficacy of new and
alternative control strategies. This current document incorporates the findings of that research and
explains how such strategies can be used safely and effectively .
3 This Code applies to the risk from legionella bacteria (the causative agent of legionellosis including
Legionnaires’ disease) in circumstances where the Health and Safety at Work Act 1974 applies.
4 To comply with their legal duties, employers and those with responsibilities for the control of
premises must:
(a) identify and assess sources or risk— this includes checking whether conditions are present which
will encourage bacteria to mulitply, e.g is the water temperature between 20—45ºC; there is a means
of creating and disseminating breathable droplets, e.g the aerosol created by a shower or cooling
tower and if there are susceptible people who may he exposed to the contaminated aerosols (see
paragraphs 23-38);
(b) prepare a scheme for preventing or controlling the risk;
(c) implement, manage and monitor precautions - if control measures are to remain effective, then
regular monitoring of the systems and the control measures is essential (see paragraphs 61-05).
Monitoring of general bacterial numbers can indicate whether microbiological control is being achieved
(see paragraphs 124-129 and 183-184). Sampling for legionella is another means of checking that a
system is under control (see paragraphs 130-l31 and 185-189);
(d) keep records of the precautions; and
Hot and Cold Water Services including Drinking Water
This 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, L8,2000 sets out certain statutory requirements. In particular each water
system 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 L8 has a special legal status, Part 1 being regulatory and Part 2
guidance.
In healthcare premises HTM 04 part A & B now supersedes the old HTM 2027 and HTM2040 and has
been revised in line with changes to relevant regulations, standards and other guidance, and also
technical developments including the ACOP L8. For this reason in healthcare establishments HTM 04
is to be followed. This will automatically satisfy the requirements of L8.
The Standard Maintenance Specifications should be adequate for the majority of well engineered low
risk systems outside of healthcare premises conforming to the requirements of ACOP L8,2000.
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 and implementation of the precautions. Responsibility and lines of
communication must be properly defined and personnel must be properly trained.
For guidance the following statements are taken from the ACOP L8
1. This Approved Code of Practice gives practical advice on the requirements of the Health and Safety
at Work etc. Act 1974 (HSWA) and the Control of Substances Hazardous to Health Regulations 1999
(COSHH) concerning the risk from exposure to legionella bacteria. In particular it gives guidance on
sections 2, 3, 4 and (as amended by the Consumer Protection Act 1987) of HSWA and regulations 6,
7, 8, 9 and 12 of COSHH. The Code also gives guidance on compliance with the relevant parts of the
Management of Health and Safety at Work Regulations 1999 (MHSWR).
2. This publication replaces two separate documents: the 1995 Approved Code of Practice and the
technical guidance, HSG7O. This has allowed information to be consolidated, with the aim of making
it easier to read and understand the duties under the law. Since the last revision, the Health and
Safety Executive (HSE) and others have funded research to assess the efficacy of new and
alternative control strategies. This new document incorporates the findings of that research and
explains how such strategies can be used safely and effectively .
3. This Code applies to the risk from legionella bacteria (the causative agent of legionellosis including
Legionnaires’ disease) in circumstances where the Health and Safety at Work etc. Act 1974 applies.
4. To comply with their legal duties, employers and those with responsibilities for the control of
premises should:
(a) identify and assess sources or risk— this includes checking whether conditions are present which
will encourage bacteria to multiply, e.g. is the water temperature between 20—45oC; there is a means
of creating and disseminating breathable droplets, e.g. the aerosol created by a shower or cooling
tower; and if there are susceptible people who may he exposed to the contaminated aerosols (see
Technical
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(e) appoint a person to be managerially responsible.
5 The Code and guidance also set out the responsibilities of suppliers of services such as water
treatment and maintenance as well as the responsibilities of manufacturers, importers, suppliers and
installers.
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.
Metering
Metering of potable water supplies by the Statutory Water Undertakings is being introduced more
widely and is now considered for all new premises. Metering of potable water supplies is becoming
more common practice and the need to the maintenance 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.
paragraphs 23-38);
(b) prepare a scheme for preventing or controlling the risk;
(c) implement, manage and monitor precautions - if control measures are to remain effective, then
regular monitoring of the systems and the control measures is essential (see paragraphs 61-05).
Monitoring of general bacterial numbers can indicate whether microbiological control is being achieved
(see paragraphs 124-129 and 183-184). Sampling for legionella is another means of checking that a
system is under control (see paragraphs 130- 131 and 185- 189);
(d) keep records of the precautions; and
(e) appoint a person to be managerially responsible.
5. The Code and guidance also set out the responsibilities of suppliers of services such as water
treatment and maintenance as well as the responsibilities of manufacturers, importers, suppliers and
installers.
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.
Metering
Metering of potable water supplies by the Statutory Water Undertakings is being introduced more
widely and is now required for all new premise and consideration will have to be given to the
maintenance of such meters.
Risk assessment - a site survey of all the water systems should be carried out and should include an
asset register of all associated plant, pumps, strainers and other relevant items. This should include
an up-to-date drawing/diagram showing the layout of the plant or system, including parts temporarily
out of use. The assessment should be reviewed regularly (at least every two years) and, whenever
there is reason to suspect that it is no longer valid. An indication of when to review the assessment
and what needs to be reviewed should be recorded. This may result from, for example:
(a) changes to the water system or its use;
(b) changes to the use of the building in which the water system is installed;
(c) the availability of new information about risks or control measures;
(d) the results of checks indicating that control measures are no longer effective ;
(e) a case of Legionnaires’ disease/legionellosis is associated with the system.
Calorifier maintenance [where appropriate] come under The Pressure Systems Safety Regulations
2000
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.
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Most pressure systems carrying a relevant fluid will require written schemes and regular inspection.
Page 312 of 614
HOT WATER SUPPLY
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INTRODUCTORY PROCEDURES32-01 32-01 INTRODUCTORY PROCEDURES
The provision of hot water entails two important safeguards, namely the avoidance of scalding and the
prevention of legionellosis or Legionnaires' disease. It is imperative that the client is aware of these
problems and that steps are taken both by the site staff and the maintenance contractor to prevent
their occurrence. Specific details relating to the risk of Legionellosis are given in the Health and Safety
ACOP L8,2001 ,CIBSE publication TM13 2002, HTM 04 Part A & B and the 5 page guidance from the
Water Management Society named “How to keep out of court”
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, health care
under HTM 04 Part B states 55°C
c) cold water storage temperature, 20°C or below.
Client's staff should check temperatures monthly as required by ACOP L8,2001 and HTM 04 Part B
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, but there is a risk of legionellosis. The bacteria remains
active up to approximately 50°C and is only effectively killed at temperatures approaching 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 by persons at risk, e.g. old people, sick persons, and children, fail
safe thermostatically controlled mixing valves must be used. The HSE circular - Controlling Legionella
in Nursing and Residential Care Homes INDG 253, 1997 suggests that temperatures should be
limited to 41 ± 2°C. This should be checked by client's staff at least monthly. NHS DO8 applies
Where the water temperatures advocated in ACOP L8, 2001 cannot be maintained, alternative control
measures will need to be considered. These could include ongoing low level disinfection using
Chlorine Dioxide or Silver Copper Ions. These systems are briefly explained in L8 & HTM 04 part A
Chapter 15 page 41
Distribution Pipework
The pipework system should be free of any points where dirt, slime or sediment may accumulate to
ensure that there are no deposits, which could provide a source of nutriment to sustain the legionella
bacteria. Where this is not possible the system should be continually disinfected as in the previous
paragraph. 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 residual pressure before opening valves, joints or vessels to atmospheric
pressure.
Air Venting
Air is a poor conductor of heat and it should be eliminated from primary hot water systems using the
air vents on the system. These are to be found at the top of the towel rails and in pressurised systems
where automatic air venting valves are provided. It is essential that these are checked and maintained
at the proper frequencies. Under no circumstances should air be allowed to disturb the system in
domestic services as this will disturb natural biofilm and lead to providing a food source for the
Legionella bacteria. Also towel rails are not permitted on domestic hot water systems.
Allocated times on Legionella control are not accurate as times are dependant on access and
numbers of systems to be checked. The assessment should be detailed enough to give reasonable
information to estimate times of maintenance.
The provision of hot water entails two important safeguards, namely the avoidance of scalding and the
prevention of legionellosis or Legionnaires` disease. It is imperative that the client is aware of these
problems and that steps are taken both by the site staff and the maintenance provider to prevent their
occurrence. Specific details relating to the risk of Legionellosis are given in the Health and Safety
ACOP L8,2000 ,CIBSE publication TM13 2002, HTM 04 Part A & B.
Operating Temperature
ACOP L8,2000 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, health care
under HTM 04 Part B states 55°C
c) cold water storage temperature, 20°C or below.
client`s staff should check temperatures monthly as required by ACOP L8,2000 and HTM 04 Part B
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, but there is a risk of legionellosis. The bacteria remains
active up to approximately 50°C and is only effectively killed at temperatures approaching 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 by persons at risk, e.g. old people, sick persons, people with
reduced mental capacity, reduced mobility, anyone with sensory impairment and children, fail safe
thermostatically controlled mixing valves must be used. Department of Health, HTM 04-01 Part A sets
out the safe water temperatures and appropriate delivery devices (TMV`s) over a range of
areas/activities. HS(G)220 Health and safety in care homes - issued 12/01 (file 357) recommends that
where vulnerable people are at risk from scalding during whole body immersion, water temperatures
do not exceed 44°C. This should be checked by client`s staff at least monthly. NHS MES (Model
Engineering Specification) D 08 applies.
Where the water temperatures advocated in ACOP L8, 2000 cannot be maintained, alternative control
measures will need to be considered. These could include ongoing low level disinfection using
Chlorine Dioxide or Silver Copper Ions. These systems are briefly explained in L8 & HTM 04 part A.
Distribution Pipework
The pipework system should be free of any points where dirt, slime or sediment may accumulate to
ensure that there are no deposits, which could provide a source of nutriment to sustain the legionella
bacteria. Where this is not possible the system should be continually disinfected as in the previous
paragraph. This also applies where pipe replacement or alterations take place and disinfection
procedure must be strictly followed. The pipe work should be well insulated to prevent heat loss
between calorifier and outlet.
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 residual pressure before opening valves, joints or vessels to atmospheric
Other
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pressure.
Air Venting
Air is a poor conductor of heat and it should be eliminated from primary hot water systems using the
air vents on the system. These are to be found at the top of the towel rails and in pressurised systems
where automatic air venting valves are provided. It is essential that these are checked and maintained
at the proper frequencies. Under no circumstances should air be allowed to disturb the system in
domestic services as this will disturb natural biofilm and lead to providing a food source for the
Legionella bacteria. Also towel rails are not permitted on domestic hot water systems.
Allocated times on Legionella control are not accurate as times are dependant on access and
numbers of systems to be checked. The assessment should be detailed enough to give reasonable
information to estimate times of maintenance.Technical
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HOT WATER SERVICES general32-02 32-02 HOT WATER SERVICES general
Note: A log book describing these services should be maintained and details entered about the
various maintenance activities and results of all the tests.
A log book describing these services should be maintained and details entered about the various
maintenance activities and results of all the tests.
Other
Title NotesActionFQTitle FQ Action Notes
2. Cold water
temperature (at
outlet of cistern or
tank and farthest
outlet from
cistern).
Monitor to ensure compliance with
ACOP L8, 2001 & HTM 04 Part B
requirements.
Responsibility for this test should be
agreed with client. Advise client if
temperature outside ACOP L8, 2001
requirements for any remedial work
to be put in hand.
1M 2. Cold water
temperature (at
outlet of cistern or
tank and farthest
outlet from
cistern).
Monitor to ensure compliance with
ACOP L8, 2000 (www.hse.gov.uk)
& HTM 04 Part B requirements.
Responsibility for this test should be
agreed with client. Advise client if
temperature outside ACOP L8, 2000
requirements for any remedial work
to be put in hand.
1MOther
3. Hot water
temperature (at
outlet of calorifier).
Monitor to ensure compliance with
ACOP L8, 2001 requirements.
Responsibility for this test should be
agreed with client. Advise client if
temperature outside ACOP L8, 2001
requirements for any remedial work
to be put in hand.
1M 3. Hot water
temperature (at
outlet of calorifier).
Monitor to ensure compliance with
ACOP L8, 2000 requirements.
Responsibility for this test should be
agreed with client. Advise client if
temperature outside ACOP L8, 2000
requirements for any remedial work
to be put in hand.
1MOther
4. Drain valves. Open to ensure blow down of
collected sediment.To be carried
out in a safe manner. Requires
method statement for minimal
aerosolation.
This is particularly applicable in
vacant buildings where services are
left running and more frequent
opening of drain valves is
recommended.
12M 4. Drain valves. Open to ensure blow down of
collected sediment. To be carried
out in a safe manner. Requires
method statement for minimal
aerosolation.
This is particularly applicable in
vacant buildings where services are
left running and more frequent
opening of drain valves is
recommended.
12MOther
5. Disinfection. If there is a need to disinfect whole
system, advise client.
Refer to ACOP L8 part 2 page 48
paragraph 190
5. Disinfection. If there is a need to disinfect whole
system, advise client.
Refer to ACOP L8 part 2.Other
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CALORIFIER TYPES32-03 32-03 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 transfer surface. The water in the calorifier is heated indirectly by the
tubular primary heater with hot water, steam or electrical immersion heating elements. A calorifier is
used for the supply of a hot water service, for central heating purposes and for industrial applications.
ACOP L8 also defines calorifiers in the glossery.
(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 cover the opening up of calorifiers for statutory insurance
inspection which requires a separate procedure, which may be carried out at the same time as the
maintenance.
In the context of Building Services the term calorifier is used to describe a closed vessel with a
cylindrical shell fitted with heat transfer surface. The water in the calorifier is heated indirectly by the
tubular primary heater with hot water, steam or electrical immersion heating elements. A calorifier is
used for the supply of a hot water service, for central heating purposes and for industrial applications.
ACOP L8 also defines calorifiers in the glossary.
(a) Non-storage, normally used for heating systems or where there is low demand for hot water
(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 cover the opening up of calorifiers for statutory insurance
inspection which requires a separate procedure, which may be carried out at the same time as the
maintenance.Technical
Other
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PRE-MAINTENANCE PROCEDURES32-04 32-04 PRE-MAINTENANCE PROCEDURES
In accordance with good practice the operator should carry out a visual inspection of the calorifier at
regular intervals and this should include checking 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.
PASTEURISATION
All secondary systems used to provide a hot water service must be chlorinated/pasteurised yearly in
accordance with ACOP L8,2001 and additionally after a period of shutdown.
In accordance with good practice the operator should carry out a visual inspection of the calorifier at
regular intervals and this should include checking 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. This includes obtaining any necessary Permit to Work`s from the Authorised
Person.
(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.
PASTEURISATION
All secondary systems used to provide a hot water service must be chlorinated/pasteurised yearly in
accordance with ACOP L8,2000 (www.hse.gov.uk) and additionally after a period of shutdown. If a
calorifier or any substantial part of a hot water system is on standby
use or has been taken out of service for longer than 1 week, the water in the calorifier should be
brought up to 60°C for 1 hour before being used; this should be measured with normal circulating
pumps operating and not with the system in a stagnant state.Technical
Other
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CALORIFIERS HEATED BY LTHW OR MTHW32-05 32-05 CALORIFIERS HEATED BY LTHW
Warning – Insulation may contain Asbestos
Low temperature hot water systems (LTHW or LPHW) are heating systems operating up to 10 bar
(gauge) and 95°C, medium temperature hot water systems [MTHW] are heating systems operating in
the range 95°C-120°C and indirect systems complementary to 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) (b) Inspect calorifier insulation and/or shell for signs of damage.
(c) (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.
PASTEURISATION
All secondary systems used to provide a hot water service must be pasteurised after a period of
shutdown or standby over a one week period in accordance with ACOP L8 2001 and HTM 04 Part A &
B. This includes shutdown to inspect calorifiers.
<B>Warning</B> – Insulation may contain Asbestos
Low temperature hot water systems (LTHW or LPHW) are heating systems operating up to 95°C,
Prior to carrying out the planned maintenance of the calorifier, the pre-maintenance procedure
detailed in 32-04 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.
PASTEURISATION (Domestic Hot Water Calorifiers)
All secondary systems used to provide a hot water service must be pasteurised after a period of
shutdown or standby over a one week period in accordance with ACOP L8 2000 and HTM 04 Part A &
B. This includes shutdown to inspect calorifiers.
Legislative
Title NotesActionFQTitle FQ Action Notes
1. Operation and
safety controls.
Check, note and report any visible
defects.
Ensure both secondary and primary
circuits are full of water and circuits
are open.
12M 1. Operation and
safety controls.
Check, note and report any visible
defects. Ensure an
Anti-stratification pump has been
fitted on the secondary side of the
calorifier and it is operational
Ensure both secondary and primary
circuits are full of water and circuits
are open.
12MTechnical
2. Safety
valves/PRV.
Check operation of safety. N.B. Temperature settings should be
in accordance with HSE guidance
note ACOP L8, 2001 for Hot Water
Services. If manually operated for
test purposes leakage could occur
after test.
12M 2. Safety
valves/PRV.
Check operation of safety. If manually operated for test
purposes leakage could occur after
test.
12MTechnical
3. Thermostats,
pressure sensors,
altitude gauges
and thermometers.
Check for correct operation and
settings; set against Certified
masters,
12M 3. Thermostats,
pressure sensors,
altitude gauges
and thermometers.
Check for correct operation and
settings; set against Certified
masters,
N.B. Temperature settings should
be in accordance with HSE
(www.hse.gov.uk) guidance note
ACOP L8, 2000 for Hot Water
Services.
12MTechnical
8. Sacrificial
anode
Check status.24M 8. Sacrificial
anode
Check status. Replace as necessary24MTechnical
9. Put back into
operation
Refit all manholes, refill secondary
side. Hydraulic pressure test. Put
primary side into operation.
Check operation of all temperature
controls. Carry out item 6
9. Put back into
operation
Refit all manholes, refill secondary
side. Hydraulic pressure test. Put
primary side into operation.
Check operation of all temperature
controls. Carry out item 3
12MOther
10.
Pasteurisation.
Hold Temperature one hour above
60°C. prior to reinstatement.
Procedure as laid down in HTM 04
Part B Page 23 paragraph 7.74
12M 10.
Pasteurisation.
Hold Temperature one hour above
60°C. prior to reinstatement.
Procedure as laid down in ACOP
L8: 2000, paragraph 154 and HTM
04 Part B.
12MLegislative
11. Bursting discs Check condition. Report findings.12M Deleted
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HOT WATER CALORIFIERS HEATED BY STEAM32-06 32-06 HOT WATER CALORIFIERS HEATED BY MTHW, HTHW or STEAM
WARNING - If insulation looks damaged - STOP WORK - this may be Asbestos - Appropriate action
must be taken prior to further works. If the insulation is known or CERTIFIED not to be Asbestos,
continue as follows: -
Note: In the interests of safety and the prevention of scalding, water temperatures and the operation
of blending valves should be checked at least once a month by the caretaker or operator.
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) (e) Inspect calorifier insulation and/or shell for signs of damage.
(f) (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.
PASTEURISATION
All secondary systems used to provide a hot water service must be pasteurised after a period of
shutdown or standby over a one week period in accordance with ACOP L8,2001 and HTM 04 Part A &
B. This includes shutdown to inspect calorifiers.
Most MTHW, HTHW and Steam Calorifiers will be under the control of an Authorised Person. A permit
to Work must be issued by the Authorised Person before any work can commence on a Calorifier
<B>WARNING</B> - If insulation looks damaged - STOP WORK- this may be Asbestos - Appropriate
action must be taken prior to further works. If the insulation is known or CERTIFIED not to be
Asbestos, continue as follows: -
In the interests of safety and the prevention of scalding, water temperatures and the operation of
blending valves should be checked at least once a month by the caretaker or operator. See SFG
32-01 for further information on temperatures etc.
<B>Warning</B> WATER AND STEAM LEAKS ARE DANGEROUS
Prior to carrying out the planned maintenance of the calorifier, the pre-maintenance procedure
detailed below should be followed:
(a) At the entrance to the Plant room, Stop and Listen for a steam leak (High Pressure steam will be
invisible and only the sound of a leak may be present)
(b) Check equipment operating status (i.e. whether in operation or not in use, whether isolated from
system) including safety.
(c)Inspect calorifier insulation and/or shell for signs of damage.
(d)Inspect all manholes, mounting and joints for signs of leaks.
(e) Report any necessary remedial work where repairs, adjustment or replacement will be required
during routine maintenance.
PASTEURISATION (Domestic Hot Water Calorifiers)
All secondary systems used to provide a hot water service must be pasteurised after a period of
shutdown or standby over a one week period in accordance with ACOP L8,2000 (www.hse.gov.uk)
and HTM 04 Part A & B. This includes shutdown to inspect calorifiers.
Legislative
Title NotesActionFQTitle FQ Action Notes
15. Check
insulation for
damage.
Repair or renew as necessary. Damaged lagging reduces
efficiency, wastes heat, and if the
calorifier is in the open air, can
become waterlogged and lead to
hidden corrosion. Asbestos
Regulations may apply
12M 16. Check
insulation for
damage.
Repair or renew as necessary. Damaged lagging reduces
efficiency, wastes heat, and if the
calorifier is in the open air, can
become waterlogged and lead to
hidden corrosion. Asbestos
Regulations may apply.
12MOther
16. Hydraulic
pressure test.
If a pressurised system test to
Working pressure x 1.1.
Pressure Regulations 1989 may
apply. (see INDG 261)
12M 17. Hydraulic
pressure test.
If a pressurised system test to
110% of working pressure.
Pressure Systems Safety
Regulations 2000 will apply.
12MLegislative
1. Check
operation, in
particular safety
controls.
Note and report any visible defects. Ensure secondary is full of water
and circuits are open. If safety
controls are defective take
equipment out of service.
12M 1. Check
operation, in
particular safety
controls.
Check, note and report any visible
defects. Ensure an
Anti-stratification pump has been
fitted on the secondary side of the
calorifier and it is operational.
Ensure secondary is full of water
and circuits are open. If safety
controls are defective take
equipment out of service.
12MTechnical
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3. Thermostats,
pressure sensors,
altitude gauges
and thermometers.
Check for correct operation and
settings, set against Certfied
masters.
Temperature settings for Hot Water
Services should be in accordance
with HSE ACOP L8, 2001 and HTM
04 Part B.
12M 3. Thermostats,
pressure sensors,
altitude gauges
and thermometers.
Check for correct operation and
settings, set against Certified
masters.
Temperature settings for Hot Water
Services should be in accordance
with HSE ACOP L8, 2000
(www.hse.gov.uk)
12MTechnical
4. Auto controls
and primary side.
Shut down primary heat source
taking all necessary precautions to
prevent unauthorised use.
Check safe operation of
temperature controls and high limit
cut-outs.
12M 4. Auto controls
and primary side.
Shut down primary heat source
taking all necessary precautions to
prevent unauthorised use.
Check safe operation of
temperature controls and high limit
cut-outs. This may include obtaining
a Permit to Work from an Authorised
Person.
12MTechnical
5. Drain
valve/drain cock
on secondary side.
Draw off a small quantity of water to
remove any sediment.
N.B. If calorifier was in use, the
secondary water will be hot, and can
be under pressure, so care must be
taken in carrying out this item of the
schedule.
12M 5. Drain
valve/drain cock
on secondary side.
Draw off a small quantity of water to
remove any sediment.
N.B. If calorifier was in use, the
secondary water will be hot, and can
be under pressure, so care must be
taken in carrying out this item of the
schedule.
12MTechnical
8. Sacrificial
anode.
Check status12M 8. Sacrificial
anode.
Check status. Replace as necessary.12MTechnical
12. Return to
operation.
After completion of maintenance,
refit all manhole covers, refill
secondary side and put primary
side back into operation.
Check that all controls are working
correctly. Carry out item 6
12M 13. Return to
operation.
After completion of maintenance,
refit all manhole covers, refill
secondary side and put primary
side back into operation.
Check that all controls are working
correctly. Carry out item 6
12MOther
13.
Pasteurisation.
Hold Temperature one hour above
60°C. prior to reinstatement.
Procedure as laid down in HTM 04
Part B Page 23 paragraph 7.74
12M 14.
Pasteurisation.
Hold Temperature one hour above
60°C. prior to reinstatement.
Procedure as laid down in ACOP
L8: 2000, paragraph 154 and HTM
04 Part B.
12MLegislative
14. Bursting discs
(where fitted).
Check condition. Report findings.24M 15 Bursting discs
(where fitted).
Check condition. Report findings.24MOther
12 Internal
Inspection
Arrange for an internal inspection to
be carried out by a Competent
Person as required by the Written
Scheme of Examination.
Pressure Systems Safety
Regulations 2000 will apply.
12MAdded
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HOT WATER SUPPLY CALORIFIERS - including LOAD LEVELLERS32-07 32-07 HOT WATER SUPPLY CALORIFIERS
Prior to carrying out the planned maintenance of the calorifier, the pre-maintenance procedure
detailed in 32-04 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.
Added
Title NotesActionFQTitle FQ Action Notes
7. Sacrificial
anode.
Check status. Replace as necessary.12MAdded
1. Operation and
safety controls.
Check, note and report any visible
defects.
Ensure both secondary and primary
circuits are full of water and circuits
are open.
12M 1. Operation and
safety controls.
Check, note and report any visible
defects. Ensure an
Anti-stratification pump has been
fitted on the secondary side of the
calorifier, where it is required and it
is operational and does not run
continuously
Ensure both secondary and primary
circuits are full of water and circuits
are open.
12MLegislative
2. Safety valves. Check for corrosion and manually
operate.
N.B. If calorifier was in use, the
secondary water will be hot and can
be under pressure, so care must be
taken in carrying out this item of the
schedule.
12M 3. Safety valves. Check for corrosion and manually
operate.
If calorifier was in use, the
secondary water will be hot and can
be under pressure, so care must be
taken in carrying out this item of the
schedule.
12MOther
3. Thermostats,
pressure sensors,
altitude gauges
and thermometers.
Check for correct operation and
settings, set against Certfied
masters.
N.B. Temperature settings for Hot
Water Services should be in
accordance with HSE ACOP
L8,2001. With direct acting valves
hot water storage temperatures
should not exceed those laid down
in the above guidance notes or
scalding could occur.
12M 4. Thermostats,
pressure sensors,
altitude gauges
and thermometers.
Check for correct operation and
settings, set against Certified
masters.
Temperature settings for Hot Water
Services should be in accordance
with HSE ACOP L8,2000
(www.hse.gov.uk). With direct
acting valves hot water storage
temperatures should not exceed
those laid down in the above
guidance notes or scalding could
occur.
12MOther
4. Auto controls
and primary side.
Shut down primary heat source. Check operation of temperature
controls and high limit cut-outs.
12M 5. Auto controls
and primary side.
Shut down primary heat source. Check operation of temperature
controls and high limit cut-outs.
12MOther
5. Drain
valve/drain cock
on secondary side.
Draw off a small quantity of water to
remove any sediment.
N.B. If calorifier was in use, the
secondary water will be hot and can
be under pressure, so care must be
taken in carrying out this item of the
schedule.
12M 6. Drain
valve/drain cock
on secondary side.
Draw off a small quantity of water to
remove any sediment.
If calorifier was in use, the
secondary water will be hot and can
be under pressure, so care must be
taken in carrying out this item of the
schedule.
12MOther
6. Heating
surface and
internal surfaces
of shell.
Drain down secondary side,
remove manhole covers and
inspect for scale formation and
corrosion and report.
The formation of scale reduces heat
transfer and causes energy
wastage. In hard water areas scale
can be very difficult to remove if left
to build up and more frequent
maintenance is recommended.
Corrosion will cause metal failure
and leakage. Remember Waste
Disposal Regulations.
24M 8. Heating
surface and
internal surfaces
of shell.
Drain down secondary side, remove
manhole covers and inspect for
scale formation and corrosion and
report.
The formation of scale reduces heat
transfer and causes energy
wastage. In hard water areas scale
can be very difficult to remove if left
to build up and more frequent
maintenance is recommended.
Corrosion will cause metal failure
and leakage.
24MOther
7. Bursting discs
(where fitted).
Check condition. Report findings.24M 9. Bursting discs
(where fitted).
Check condition. Report findings.24MOther
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8. Put back into
operation
Refit all manhole covers, refill
secondary side. Put primary side
back into operation.
Check operation of all temperature
controls
10. Put back into
operation
Refit all manhole covers, refill
secondary side. Put primary side
back into operation.
Check operation of all temperature
controls.
Other
2 Storage
Temperature
Check and record the calorifier
water storage temperature
It is recommended that the hot
water should be stored at 60oC
(ACOP L8). Where temperatures
are recorded below 60oC, increase
set point to achieve the desired
temperature. If the temperature
cannot be maintained, report to
Client
1WAdded
11. Pasteurisation Hold temperature one hour above
60°C. prior to reinstatement.
Procedure as laid down in ACOP
L8: 2000 and HTM 04 Part B
12MAdded
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CALORIFIER AND HEAT EXCHANGE CONTROLS32-08 32-08 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 relevant section.
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 relevant section.
Other
Title NotesActionFQTitle FQ Action Notes
2. High limit
thermostat (if
fitted).
Check operation and confirm set
point.
Manual or thermal reset?12M 2. High limit
thermostat (if
fitted).
Check operation and confirm set
point.
12MOther
3. Temperature
sensor controller.
Motorised valve.
Check operation and confirm set
point(s).
12M 3. Temperature
sensor controller.
Motorised valve.
Check operation and confirm set
point(s).
For guidance on Motorise valves
see Valves - automatic control SFG
62.
12MTechnical
4. Power fail
return. Motorised
valve.
Check operation. Ensure valve shuts off supply to
calorifier and does not have let-by.
12M 4. Power fail
return. Motorised
valve.
Check operation. Ensure valve shuts off supply to
calorifier and does not have let-by.
See Actuators SFG 01-07 and
01-08.
12MTechnical
5. Direct acting
control valve.
Check operation and confirm set
point.
12M 5. Direct acting
control valve.
Check operation and confirm set
point.
For guidance on Motorise valves
see Valves - automatic control SFG
62.
12MTechnical
6.Direct acting
control valve - high
limit.
Check operation and confirm set
point.
12M 6.Direct acting
control valve - high
limit.
Check operation and confirm set
point.
For guidance on Motorise valves
see Valves - automatic control SFG
62.
12MOther
7. Temperature
sensor.
Controller.
Motorised valve.
Power fail return
motor.
Check performance. Calibration } Interrogation } by
CONTROLS SPECIALIST. Control
adjustment advance
12M 7. Temperature
sensor.
Controller.
Motorised valve.
Power fail return
motor.
Check performance.12MOther
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HOT WATER CYLINDERS32-09 32-09 HOT WATER CYLINDERS
Prior to carrying out the planned maintenance of the cylinder, the pre-maintenance procedure detailed
in 32-04 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.
PASTEURISATION
All secondary systems used to provide a hot water service must be pasteurised after a period of
shutdown or standby over a one week period in accordance with ACOP L8,2000 (www.hse.gov.uk)
and HTM 04 Part A & B. This includes shutdown to inspect calorifiers.
Added
Title NotesActionFQTitle FQ Action Notes
11. Temperature
sensor
Ensure that the temperature sensor
has a good surface to surface
contact with the cylinder.
12MAdded
1. Cylinder. Inspect visible seams and bosses
for leaks or signs of corrosion.
Report adverse findings.12M 2. Cylinder. Inspect visible seams and bosses
for leaks or signs of corrosion.
Report adverse findings.12MOther
2. Connections. Check connecting pipe unions for
leaks.
If found, drain down, clean and
remake joint.
12M 3. Connections. Check connecting pipe unions for
leaks.
If found, drain down, clean and
remake joint.
12MOther
3. Insulation. Inspect for deterioration. Refer to client if repairs or renewal
required.
12M 4. Insulation. Inspect for deterioration. Refer to client if repairs or renewal
required.
12MOther
4. Immersion
heater.
Check operation and examine for
scale on element.
Client's attention should be drawn to
the presence of excessive scale,
which indicates the need for water
treatment.
12M 5. Immersion
heater.
Check operation and examine for
scale on element.
client`s attention should be drawn to
the presence of excessive scale,
which indicates the need for water
treatment.
12MOther
5. Cold water
storage cistern (if
combination
cylinder).
Inspect seams and bosses for
leaks.
Report adverse findings.12M 6. Cold water
storage cistern (if
combination
cylinder).
Inspect seams and bosses for
leaks.
Report adverse findings.12MOther
6. Float operated
valve and float (if
combination
cylinder).
Check operation and adjust water
level to maximum storage level.
Check float for leakage and
security.
Re-washer or replace if necessary.
Replace if necessary.
12M 7. Float operated
valve and float (if
combination
cylinder).
Check operation and adjust water
level to maximum storage level.
Check float for leakage and
security.
Re-washer or replace if necessary.
Replace if necessary.
12MOther
7. Water
temperature.
Check water outlet temperature
and operation of auto-temperature
controls.
N.B. Temperature setting for Hot
Water Services should be in
accordance with HSE ACOP L8,
2001.
12M 9. Water
temperature.
Check water outlet temperature and
operation of auto-temperature
controls.
Temperature setting for Hot Water
Services should be in accordance
with HSE ACOP L8, 2000
(www.hse.gov.uk) and HTM 04-01
Part A.
12MOther
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1 Storage
Temperature
Check and record the calorifier
water storage temperature
It is recommended that the hot
water should be stored at 60oC
(ACOP L8). Where temperatures
are recorded below 60oC, increase
set point to achieve the desired
temperature. If the temperature
cannot be maintained, report to
Client
1WAdded
8. Pasteurisation Hold Temperature one hour above
60°C. prior to reinstatement.
Procedure as laid down in ACOP
L8: 2000 and HTM 04 Part B
12MAdded
8. Integral Cold
Water Storage (if
combination
cylinder)
Inspect cold water storage, clean
as necessary.
See STORAGE - COLD WATER for
detailed maintenance schedule of
cisterns. Where these units are
used infrequently or low usage the
cold water storage is likely to rise
above 20ºC therefore promoting the
liklyhood of Legionella poliferaton.
For this reason integral cisterns
should be kept clean and conform to
the Water Supply (Water Fittings)
Regulations 1999.HTM 04 for health
care recommends that these units
are not used.
6M 10. Integral Cold
Water Storage (if
combination
cylinder)
Inspect cold water storage, clean as
necessary.
See STORAGE TANKS - COLD
WATER STORAGE TANKS AND
CISTERNS (SFG 56-02) for detailed
maintenance schedule of cisterns.
Where these units are used
infrequently or low usage the cold
water storage is likely to rise above
20oC therefore promoting the
likelihood of Legionella proliferation.
For this reason integral cisterns
should be kept clean and conform to
the Water Supply (Water Fittings)
Regulations 1999. HTM 04 for
health care recommends that these
units are not used.
6MOther
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UNVENTED HOT WATER SYSTEMS32-10 32-10 UNVENTED HOT WATER SYSTEMS
Title NotesActionFQTitle FQ Action Notes
2. Discharge
pipework.
Examine discharge pipes, ensure
that air gap is clear and that there
is no blockage in the pipes.
Discharge pipe should be visible
and in a safe place. It should be of
metal and connected to the tundish.
12M 2. Discharge
pipework.
Examine discharge pipes, ensure
that air gap is clear and that there is
no blockage in the pipes.
Discharge pipe should be visible
and in a safe place. It should be of
metal and connected to the tun dish.
12MOther
3. Expansion
relief valve.
Manually operate. Check that the valve seats
satisfactorily, water flow ceased on
valve closure and water runs
through tundish and discharge
pipes.
3M 3. Expansion
relief valve.
Manually operate. Check that the valve seats
satisfactorily, water flow ceased on
valve closure and water runs
through tun dish and discharge
pipes.
3MOther
5. High limit
thermostat.
Check operation. Should be non self-setting. Thermal
cut out should be 85b0C.
6M 5. High limit
thermostat.
Check operation. Should be non self-setting. Thermal
cut out should be 85°C.
6MOther
6. Control
thermostat.
Check temperature setting. N.B. Temperature settings for Hot
Water Services should be in
accordance with HSE ACOP L8,
2001.
12M 6. Control
thermostat.
Check temperature setting. Temperature settings for Hot Water
Services should be in accordance
with HSE ACOP L8, 2000
(www.hse.gov.uk) and HTM 04-01
Part A.
12MTechnical
7. Diaphragm
expansion tank.
Check pressure. See EXPANSION VESSELS .12M 7. Diaphragm
expansion tank.
Check pressure. See Hot water supply - expansion
vessels SFG 32-12.
12MOther
8. Motorised
valve (if fitted).
Check operation. Ensure no water flows through
valves during shut down part of the
cycle.
12M 8. Motorised
valve (if fitted).
Check operation. Ensure no water flows through
valves during shut down part of the
cycle. For further guidance see
Valves - automatic control SFG 62.
12MTechnical
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THERMAL STORAGE CYLINDER (individual dwellings for DHWS)32-11 32-11 THERMAL STORAGE CYLINDER (individual dwellings for DHWS)
PASTEURISATION
All secondary systems used to provide a hot water service must be pasteurised after a period of
shutdown or standby over a one week period in accordance with ACOP L8,2000 (www.hse.gov.uk)
and HTM 04 Part A & B. This includes shutdown to inspect calorifiers.
Added
Title NotesActionFQTitle FQ Action Notes
10. Temperature
sensor
Ensure that the temperature sensor
has a good surface to surface
contact with the cylinder.
12MAdded
1. Cylinder. Inspect visible seams and bosses
for leaks or signs of corrosion.
Report adverse findings.12M 2. Cylinder. All secondary systems used to
provide a hot water service must be
pasteurised after a period of
shutdown or standby over a one
week period in accordance with
ACOP L8,2000 (www.hse.gov.uk)
and HTM 04 Part A & B. This
includes shutdown to inspect
calorifiers.
Report adverse findings.12MOther
2. Connections. Check connecting pipe unions for
leaks.
If found, drain down, clean and
remake joint.
12M 3. Connections. Check connecting pipe unions for
leaks.
If found, drain down, clean and
remake joint.
12MOther
3. Insulation. Inspect for deterioration. Refer to client if repairs or renewal
required.
12M 4. Insulation. Inspect for deterioration. Refer to client if repairs or renewal
required.
12MOther
4. Immersion
heater.
Check operation and examine for
scale on element.
Clients attention should be drawn to
the presence of excessive scale
which indicates the need for water
treatment.
12M 5. Immersion
heater.
Check operation and examine for
scale on element.
clients attention should be drawn to
the presence of excessive scale
which indicates the need for water
treatment.
12MOther
5. Feed and
expansion cistern
(if fitted).
Inspect seams and bosses for
leaks.
Report adverse findings.12M 6. Feed and
expansion cistern
(if fitted).
Inspect seams and bosses for
leaks.
Report adverse findings. Ensure
tanks meet the requirements of
ACOP L8:2000 regarding
cleanliness, lids, screens etc.
12MTechnical
6. Float operated
valve and float (if
fitted).
Check operation and adjust water
level to minimum make up level.
Check float for leakage.
Re-washer or replace if necessary.
Water level adjustments should only
be carried out when the heating
system and cylinder are cold.
Replace if necessary.
12M 7. Float operated
valve and float (if
fitted).
Check operation and adjust water
level to minimum make up level.
Check float for leakage.
Re-washer or replace if necessary.
Water level adjustments should only
be carried out when the heating
system and cylinder are cold.
Replace if necessary.
12MOther
7. Domestic hot
water thermostatic
blender.
Check operation. Check water
outlet temperature and operation of
auto-temperature controls.
N.B. Temperature settings for Hot
Water Services should be in
accordance with HSE ACOP L8,
2001.
12M 9. Domestic hot
water thermostatic
blender.
Check operation. Check water
outlet temperature and operation of
auto-temperature controls.
N.B. Temperature settings for Hot
Water Services should be in
accordance with HSE ACOP L8,
2001 (www.hse.gov.uk) and HTM
04-01 Part A.
12MTechnical
1 Storage
Temperature
Check and record the calorifier
water storage temperature
It is recommended that the hot
water should be stored at 60oC
(ACOP L8). Where temperatures
are recorded below 60oC, increase
set point to achieve the desired
temperature. If the temperature
cannot be maintained, report to
Client
1WAdded
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8. Pasteurisation Hold Temperature one hour above
60°C. prior to reinstatement.
Procedure as laid down in ACOP
L8: 2000, paragraph 154 and HTM
04 Part B.
12MAdded
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EXPANSION VESSELS32-12 32-12 EXPANSION VESSELS
Title NotesActionFQTitle FQ Action Notes
3. Drain Discharge by flushing. In most installations the vessel will
be a source of contamination by
acting as a deadleg.
1W 3. Drain Discharge by flushing. In most installations the vessel will
be a source of contamination by
acting as a dead leg.
1WOther
1. Diaphragm
expansion tank/s.
Check. Ensure air cushion pressure is
correct, if necessary top up,
preferably with oxygen free nitrogen.
Remove diaphragm from shell,
check and report on condition of
both. Ensure cushion pressure is
correct when re-commissioned.
3M 1. Diaphragm
expansion tank/s.
Check. Ensure gas cushion pressure is
correct, if necessary top up,
preferably with oxygen free nitrogen.
Remove diaphragm from shell,
check and report on condition of
both. Ensure cushion pressure is
correct when re-commissioned.
A risk Assesment must be done
prior to its use, suitable training
must also be given prior.
3MTechnical
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DIRECT FIRED WATER HEATERS32-13 32-13 DIRECT FIRED WATER HEATERS
Heater generation may be by electricity, light oil pressure jet burners, forced draught but usually
atmospheric gas burners. For specific maintenance instructions on heat generator see appropriate
Burner Section.
WARNING: To avoid the possible risk of scalding, Thermostatic Mixing Valves (TMV’s) must be
considered in line with a risk assessment where vulnerable persons are likely to use the outlets. All
other outlets not blended should have hot water warning signs. Client should carry out monthly checks
of the outlet temperature where blended.
Heater generation may be by electricity, light oil pressure jet burners, forced draught but usually
atmospheric gas burners. For specific maintenance instructions on heat generator see appropriate
Boilers - heat generators SFG 05.
Special note:
Certain heaters called `Energy saver water heaters` will have an electrically operated damper in the
flue to reduce ventilation losses through the heater. The operation sequence is when the thermostat
calls for more heat the damper opens, changing the contacts on a microswitch. This then provides
power to the heat generation equipment.
<B>WARNING</B>: To avoid the possible risk of scalding, Thermostatic Mixing Valves (TMV’s) must
be considered in line with a risk assessment where vulnerable persons are likely to use the outlets. All
other outlets not blended should have hot water warning signs. client should carry out monthly checks
of the outlet temperature where blended.
Department of Health, HTM 04-01 Part A sets out the safe water temperatures and appropriate
delivery devices (TMV`s) over a range of areas/activities.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Heat
generation
equipment.
Remove and carry out necessary
maintenance.
See HEAT GENERATORS for
maintenance.
12M 1. Heat
generation
equipment.
Remove and carry out necessary
maintenance.
See Boilers - heat generators SFG
05 for maintenance.
12MTechnical
7. Smoke test. Carry out and smoke test on flue. See under FLUES.12M 7. Smoke test. Carry out and smoke test on flue. See under Flues SFG 24-01.12MTechnical
1. Isolation. Turn off, isolate and remove heat
generator. Where applicable,
switch off electricity and remove
fuses. Turn off water supply.
See BURNER section maintenance.12M 1. Isolation. Turn off, isolate and remove heat
generator. Where applicable,
switch off electricity and remove
fuses. Turn off water supply.
12MTechnical
8. Pasteurisation. Hold Temperature one hour above
60°C. prior to reinstatement.
Procedure as laid down in HTM 04
Part B Page 23 paragraph 7.74
12M 8. Pasteurisation. Hold Temperature one hour above
60°C. prior to reinstatement.
Procedure as laid down in ACOP
L8: 2000, paragraph 154 and HTM
04 Part B.
12MTechnical
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INSTANTANEOUS ELECTRIC WATER HEATERS32-14 32-14 INSTANTANEOUS ELECTRIC WATER HEATERS (non drinks type)
Title NotesActionFQTitle FQ Action Notes
2. Water
temperature.
Check water outlet temperature
and operation of auto-temperature
controls.
N.B. Temperature settings should be
in accordance with ACOP L8, 2001
for Hot Water Services, i.e. 60°C.
Beware of scalding, consider TMV’s.
12M 2. Water
temperature.
Check water outlet temperature and
operation of auto-temperature
controls.
N.B. Temperature settings should be
in accordance with ACOP L8, 2000
(www.hse.gov.uk) for Hot Water
Services, i.e. 60°C.
12MOther
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PACKAGED ELECTRIC WATER HEATERS-cistern type32-15 32-15 PACKAGED ELECTRIC WATER HEATERS-cistern type (non drinks)
Title NotesActionFQTitle FQ Action Notes
1. General. N.B. The exact maintenance
procedure will depend upon the
make and configuration as most
packaged units have different
design arrangements.
1. General. The exact maintenance procedure
will depend upon the make and
configuration as most packaged
units have different design
arrangements.
Other
2. Operating
status.
Check, if unit out of service ask
client for reasons.
If electrically defective, ensure
equipment is left disconnected and
isolated. Ensure supply is cut off at
spur to avoid deadlegs.
12M 2. Operating
status.
Check, if unit out of service ask
client for reasons.
If electrically defective, ensure
equipment is left disconnected and
isolated. Ensure water supply is
isolated at spur to avoid deadlegs.
12MTechnical
4. Water
temperature
controls.
Measure temperature, check
against thermostat settings. Adjust
thermostat as necessary.
N.B. Temperature settings should be
in accordance with ACOP L8, 2001
for Hot Water Services i.e. 60°C.
Beware of scalding, consider TMV’s
12M 4. Water
temperature
controls.
Measure temperature, check
against thermostat settings. Adjust
thermostat as necessary.
Temperature settings should be in
accordance with ACOP L8, 2000
(www.hse.gov.uk) for Hot Water
Services i.e. 60°C.
12MOther
8. Integral cold
storage
Inspect cold water storage, clean
as necessary.
Where these units are used
infrequently or low usage the cold
water storage is likely to rise above
20°C therefore promoting the
liklyhood of Legionella poliferaton.
For this reason integral cisterns
should be kept clean and conform to
the Water Supply (Water Fittings)
Regulations 1999.
6M 8. Integral cold
storage
Inspect cold water storage, clean as
necessary.
Where these units are used
infrequently or low usage the cold
water storage is likely to rise above
20°C therefore promoting the
likelihood of Legionella proliferation.
For this reason integral cisterns
should be kept clean and conform to
the Water Supply (Water Fittings)
Regulations 1999.
6MOther
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32-16 VENTED HOT WATER SYSTEMS
It is recommended that the hot water should be stored at 60oC (ACOP L8). Where temperatures are
recorded below 60oC, increase set point to achieve the desired temperature. If the temperature
cannot be maintained, report to Client
Added
Title NotesActionFQTitle FQ Action Notes
1. Temperature
relief valve.
Manually operate.3MAdded
2. High limit
thermostat.
Check operation. Should be non self-setting. Thermal
cut out should be 85°C.
6MAdded
3. Complete unit. Examine water storage vessel,
pipework and fittings.
Check for any signs of corrosion
and water leaks. Reseal pipework
joints if necessary.
12MAdded
4. Discharge
pipework.
Examine discharge pipes, ensure
that air gap is clear and that there is
no blockage in the pipes.
Discharge pipe should be visible
and in a safe place. It should be of
metal and connected to the tun dish.
12MAdded
5. Control
thermostat.
Check temperature setting. Temperature settings for Hot Water
Services should be in accordance
with HSE ACOP L8, 2000
(www.hse.gov.uk) and HTM 04-01
Part A.
12MAdded
6. Motorised
valve (if fitted).
Check operation. Ensure no water flows through
valves during shut down part of the
cycle. For further guidance see
Valves - automatic control SFG 62.
12MAdded
7. In-line strainer. Inspect and clean as required.12MAdded
8. Back flow
prevention device.
Check operation and ensure that
non-return valve is seating properly.
The operation can be checked by
observing any changes in the
upstream level of a vessel
preceding the device when the
incoming supply is isolated.
12MAdded
9. Electrical
element.
Check for scale on element. Client`s attention should be drawn
to presence of excessive scale
which indicates a possible need for
water treatment or water
conditioning.
12MAdded
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HUMIDIFIERS INCLUDING DISINFECTION PROCEDURES
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HUMIDIFIER - Cold water evaporator, drum type33-01 33-01 HUMIDIFIER - Cold water evaporator, drum type
Any action taken must conform to HSE requirements, The control of Legionella bacteria in water
systems – ACOP L8,2001 and HEVAC code of best practice - 1.
Note: In hard water areas more frequent maintenance may be required.
Any action taken must conform to HSE requirements, the control of Legionella bacteria in water
systems – ACOP L8,2000 (www.hse.gov.uk) and HEVAC Association code of best practice 4
commissioning and planned maintenance.
Persons responsible for maintenance should record who the competent persons responsible for
maintenance are, tests and results, routine maintenance, cleaning and disinfection dates, as per the
HSE’s Code of Practice L8.
In hard water areas more frequent maintenance may be required.
All monitoring and maintenance activity should be recorded in a log, particularly that relating to
Legionella monitoring and control.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Status. Isolate electrically and hydraulically. Note: electrical isolation should
meet HSAWA requirements.
3M 1. Status. Isolate electrically and hydraulically. Electrical isolation should meet
HSAWA (www.hse.gov.uk)
requirements.
3MOther
2. Rotor filter
pads.
Closely inspect. Replace filter pads
as necessary. On reassembly use
new gaskets where necessary.
Report condition. If filter pads need
replacement it is necessary to first
clean the rotor.
12M 2. Rotor filter
pads.
Closely inspect. Replace filter pads
as necessary. On reassembly use
new gaskets where necessary.
Report condition. If filter pads need
replacement it is necessary to first
clean the rotor.
3MTechnical
9. Motor gear
box.
Change oil. See also MOTORS12M 9. Motor gear
box.
Change oil. See also Motors SFG 29-0112MOther
11. Return to
service.
Check operation. Ensure compliance with HSC ACOP
L8, 2001.
12M 11. Return to
service.
Check operation. Ensure compliance with HSC
ACOP L8, 2000 (www.hse.gov.uk).
12MOther
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HUMIDIFIER - Direct steam injection type.33-02 33-02 HUMIDIFIER - Direct steam injection type.
Note:- When in operation, there is intermittent live steam injected from manifold within. DO NOT
ATTEMPT TO SERVICE WITHOUT ISOLATING STEAM AND ELECTRICITY SUPPLIES FIRST.
Any action taken must conform to HSE requirements, The control of Legionella bacteria in water
systems – ACOP L8,2000 (www.hse.gov.uk) and HEVAC Association code of best practice 4
commissioning and planned maintenance.
Persons responsible for maintenance should record who the competent persons responsible for
maintenance are, tests and results, routine maintenance, cleaning and disinfection dates, as per the
HSE’s Code of Practice L8.
Note:- When in operation, there is intermittent live steam injected from manifold within. DO NOT
ATTEMPT TO SERVICE WITHOUT ISOLATING STEAM AND ELECTRICITY SUPPLIES FIRST.
If the system has been out of operation for more than 3 months then the system should undertake a
yearly maintenance and then be subject to a re-commission.
All monitoring and maintenance activity should be recorded in a log, particularly that relating to
Legionella monitoring and control.
Technical
Title NotesActionFQTitle FQ Action Notes
2. System Check any flange bolts for tightness
and adjust as required. Check all
gland seals adjust as required.
Visually inspect all pipe work and
joints for leaks.
1MAdded
15. Valves Inspect all valves for wear or scale
deposits. Worn or damaged parts
should be replaced as well as the
gland seal packaging. Check for
complete isolation and free
movement.
Graphite packaging is subject to
wear. It is therefore recommended
to replace such items.
12MAdded
18. Switch off
devices
Check the function of the switch-off
devices, e.g. the max hygrostat.
12MAdded
1. Status. Isolate electrically. Note: electrical isolation should
meet HSAWA requirements.
3M 1. Status. Isolate electrically. Electrical isolation should meet
HSAWA (www.hse.gov.uk)
requirements.
3MOther
2.Removal of
deposits.
Clean and flush out. Note: If automatic time controlled
flush out valve is fitted, check
correct operation by overriding
timer. It may be necessary from time
to time to adjust between automatic
flushing depending upon
humidification requirements which
can vary with the weather
conditions.
3M 3.Removal of
deposits.
Clean and flush out the steam
cylinder.
If automatic time controlled flush out
valve is fitted, check correct
operation by overriding timer. It
may be necessary from time to time
to adjust between automatic flushing
depending upon humidification
requirements which can vary with
the weather conditions.
3MOther
3. Ball valve. Check operation. Clean and renew
washer.
3M 4. Ball valve. Check operation. Clean and renew
washer.
See Valves SFG 613MTechnical
4. Water level. Check level in gauge glass
corresponds with indicator plate.
3M 5. Water level. Check level in gauge glass
corresponds with indicator plate.
3MOther
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5. Humidistat. Check operation, clean if
necessary.
Use a sling hydrometer to check
accuracy of operation.
3M 6. Humidistat. Check operation, clean if
necessary. For Further Guidance
see Sensors and Switching Devices
SFG 50-04 and 50-05
Use a hand held hydrometer to
check accuracy of operation.
3MOther
6. Misting sprays. Observe spray pattern, clean if
necessary.
Clean with compressed air. Do not
use wire or pointed objects as these
will enlarge the orifices and lead to a
poor misting pattern.
3M 7. Misting sprays. Observe spray pattern, clean if
necessary.
Clean with compressed air. Do not
use wire or pointed objects as these
will enlarge the orifices and lead to a
poor misting pattern.
3MOther
7. Control and
indicator lights.
Check for correct functioning.3M 8. Control and
indicator lights.
Check for correct functioning.3MOther
8. Steam traps. Check operation condition of filters
and sight glasses.
Ensure condensate drain is clear.3M 9. Steam traps. Check operation condition of filters
and sight glasses.
Ensure condensate drain is clear.3MOther
8. Steam traps. Check operation condition of filters
and sight glasses.
3M Deleted
9. Steam
pressure.
Check.3M 10. Steam
pressure.
Check.3MOther
10. Strainer
(where fitted).
Check strainer on steam supply.3M 11. Strainer
(where fitted).
Check strainer on steam supply
clean or replace as necessary.
3MTechnical
11.Water supply. Turn off at ball valve and empty via
drain cock.
12M 12.Water supply. Turn off at ball valve and empty via
drain cock. Disconnect the water
supply and remove the fill valve
from the humidifier. Remove the
inlet strainer. Clean the fill valve
and inlet strainer using the same
solution as used to clean the steam
cylinder.
12MTechnical
12. Steam
chamber.
Remove out casing lid baffles.
Remove any scale either physically
or by using suitable chemical
descaling agent.
Ensure that any sludge or scale
deposits are removed from the
bottom of the steaming chamber.
Additional access may be provided
on the side of the vessel to facilitate
cleaning. Waste Disposal
Regulations may apply
12M 13. Steam
chamber.
Remove out casing lid baffles.
Remove any scale either physically
or by using suitable chemical
descaling agent. If the electrodes
are deteriorated, replace the steam
cylinder rather than
cleaning it.
Ensure that any sludge or scale
deposits are removed from the
bottom of the steaming chamber.
Additional access may be provided
on the side of the vessel to facilitate
cleaning. Waste Disposal
Regulations may apply.
12MTechnical
13. Feed water
line.
Check that it is clear.12M 14. Feed water
line.
Check that it is clear.12MOther
14. Re-assembly. Ensure all joint faces are clean and
re-assemble using new gaskets.
12M 16. Re-assembly. Ensure all joint faces are clean and
re-assemble using new gaskets. If
the unit does not restart and go to
normal operation, then the
electrodes may be too badly
deteriorated to be reused and the
cylinder must be replaced.
12MTechnical
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15.
Re-commission.
Put back into service and check
water level in gauge glass
corresponds with indicator plate,
ball valve operates correctly,
controls and indicator lights
function properly.
12M 17.
Re-commission.
Put back into service and check
water level in gauge glass
corresponds with indicator plate,
ball valve operates correctly,
controls and indicator lights function
properly.
12MTechnical
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ELECTRODE BOILER HUMIDIFIER33-03 33-03 ELECTRODE BOILER HUMIDIFIER
Note: In hard water areas maintenance may require to be carried out more frequently. If output is
decreased due to heavy scaling renewal 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 boiler manufacturers values of conductivity.
Any action taken should conform to the HSE requirements, The control of Legionella bacteria in
water systems – ACOP L8,2001 and HEVAC code of best practice - 1
In hard water areas maintenance may require to be carried out more frequently. If output is decreased
due to heavy scaling renewal of the cylinder will be required, refer to client.
Persons responsible for maintenance should record who the competent persons responsible for
maintenance are, tests and results, routine maintenance, cleaning and disinfection dates, as per the
HSE’s Code of Practice L8.
High water conductivity in the boiler circulated water can damage the boiler cylinder vessel, only work
within the boiler manufacturers values of conductivity.
Any action taken should conform to the HSE requirements, The control of Legionella bacteria in water
systems – ACOP L8,2000 (www.hse.gov.uk) and HEVAC Association code of best practice 4
commissioning and planned maintenance.
All monitoring and maintenance activity should be recorded in a log, particularly that relating to
Legionella monitoring and control.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Status. Check and isolate both water and
electricity supplies.
Note:- electrical isolation should
meet HSAWA safety requirements.
3M 1. Status. Check and isolate both water and
electricity supplies.
Electrical isolation should meet
HSAWA (www.hse.gov.uk) safety
requirements.
3MTechnical
2. Steam
cylinder.
Check all electrical connections on
the cylinder for soundness and
correct any defects.
3M 2. Steam
cylinder.
Check all electrical connections on
the cylinder for soundness and
correct any defects. If the
electrodes are deteriorated, replace
the steam cylinder.
3MTechnical
3. Cylinder
exchange.
As per manufacturer's instructions. Cylinder exchange times will vary -
hard water areas 3 months. Soft
water areas 12 months.
3M 3. Cylinder
exchange.
As per manufacturer`s instructions. Cylinder exchange times will vary -
hard water areas 3 months. Soft
water areas 12 months.
The procedure for changing a
cylinder can be found in the
manufacturer’s manual, but also if
the cylinder is to be re-used check
that the electrodes have not rotated
within the cylinder and check that
the seal or “O” ring is still in place.
3MTechnical
6. Feed valve. Clean strainer. Always replace the strainer after
cleaning to prevent material lodging
in the valve.
12M 6. Feed valve. Clean strainer. Disconnect the
water supply and remove the fill
valve from the humidifier. Remove
the inlet strainer. Clean the fill valve
and inlet strainer using the same
solution as used to clean the steam
cylinder
Always replace the strainer after
cleaning to prevent material lodging
in the valve.
12MTechnical
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HUMIDIFIERS- Compressed air type33-04 33-04 HUMIDIFIERS- Compressed air type
Note - this schedule should be read in conjunction with those on air compressors and pressure
Regulations may apply.
Any action taken should conform to the HSE, The control of Legionella bacteria in water systems –
ACOP L8,2001 and HEVAC code of best practice - 1
This schedule should be read in conjunction with those on air compressors and pressure Regulations
may apply.
Any action taken should conform to the HSE, The control of Legionella bacteria in water systems –
ACOP L8,2000 (www.hse.gov.uk) and HEVAC Association code of best practice 4 commissioning and
planned maintenance.
Systems that generate an aerosol must be tested for Legionella every six months. In certain
applications, such as food retailers, it is recommended the same water is also tested for E.Coli and
coliform bacteria.
Where systems do not incorporate some of the design features outlined above, or where ambient
temperatures exceed 20°C, or where the risk of aerosol inhalation or infection is greater, more regular
sampling will be required. These might be using Dipslides for TVC, or more frequent testing for
Legionella.
Persons responsible for maintenance should record who the competent persons responsible for
maintenance are, water sampling frequency, tests and results, routine maintenance, cleaning and
disinfection dates and details, as per the HSC’s Code of Practice L8.
All monitoring and maintenance activity should be recorded in a log, particularly that relating to
Legionella monitoring and control.
Legislative
Title NotesActionFQTitle FQ Action Notes
1. Airline
components
Check (visually)inlet and outlet
compressed air and water supply
pressures, visual inspection of the
compressed air filter to check on air
quality, and visual inspection of the
sprays.
1MAdded
6. Water line
components
Water line components in the
control panel are subject to greater
wear and tear particularly in hard
water areas, and sediment filter
elements prior to the control panel
should be changed.
6MAdded
6. Airline
components
Airline components in the control
panel, such as pressure regulators,
pressure switches and solenoid
valves, will require annual
inspection and cleaning. According
to compressed air quality, air filters
immediately prior to the control
panel will need cleaning or
replacement between six months
and a year.
12MAdded
7. UV lamps (if
fitted)
Change UV lamps Weekly inspection of UV-lamp
operation is recommended,
although many compressed air
systems using this technology
incorporate failsafe systems to shut
down the humidifier in the event of
reduced effectiveness or failure.
12MAdded
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1. Status. Isolate electrically and hydraulically. Note: electrical isolation should
meet HSAWA requirements.
3M 2. Status. inspection of the compressed air
filter to check on air quality, and
visual inspection of the sprays.
Electrical isolation should meet
HSAWA (www.hse.gov.uk)
requirements.
3MOther
2. Nozzles. Clean dust and debris from outside
of nozzles.
It is advisable to remove the air caps
annually to clean thoroughly. Take
care not to damage the protective
PTFE coating.
3M 3. Nozzles. Clean dust and debris from outside
of nozzles.
It is advisable to remove the air
caps annually to clean thoroughly.
Take care not to damage the
protective PTFE coating.
3MOther
3. 'Y' strainer. Inspect and replace strainer
screen.
3M 4. `Y` strainer. Inspect and replace strainer screen.3MOther
4. Water
pressure regulator.
Check condition and carry out
maintenance in accordance with
the manufacturer's instructions.
Items which may need periodic
maintenance include:- 2-way air
solenoid valve, 3-way water
solenoid valve, air pressure
regulator.
12M 5. Water
pressure regulator.
Check condition and carry out
maintenance in accordance with
the manufacturer`s instructions.
Items which may need periodic
maintenance include:- 2-way air
solenoid valve, 3-way water
solenoid valve, air pressure
regulator.
12MOther
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HUMIDIFIERS- Ultra sonic33-05 33-05 HUMIDIFIERS- Ultra sonic
Any action taken must conform to the HSE requiements, The control of Legionella bacteria in water
systems – ACOP L8,2001 and HEVAC code of best practice - 1
Any action taken must conform to the HSE requirements, The control of Legionella bacteria in water
systems – ACOP L8,2008 (www.hse.gov.uk) and HEVAC Association code of best practice 4
commissioning and planned maintenance.
Systems that generate an aerosol must be tested for Legionella every six months. In certain
applications, such as food retailers, it is recommended the same water is also tested for E.Coli and
coliform bacteria.
Where systems do not incorporate some of the design features outlined above, or where ambient
temperatures exceed 20°C, or where the risk of aerosol inhalation or infection is greater, more regular
sampling will be required. These might be using Dipslides for TVC, or more frequent testing for
Legionella.
Persons responsible for maintenance should record who the competent persons responsible for
maintenance are, water sampling frequency, tests and results, routine maintenance, cleaning and
disinfection dates and details, as per the HSC’s Code of Practice L8.
All monitoring and maintenance activity should be recorded in a log, particularly that relating to
Legionella monitoring and control.
Legislative
Title NotesActionFQTitle FQ Action Notes
1. Status. Isolate electrically and hydraulically. Note:- electrical isolation must meet
HSAWA requirements.
6M 1. Status. Isolate electrically and hydraulically. Electrical isolation must meet
HSAWA (www.hse.gov.uk)
requirements.
3MTechnical
2. Water tank. Clean out and refill.6M 2. Water tank. Clean out and refill. Unlike the humidifiers that boil
water, water droplets can contain
any impurities that are in the
reservoir, including minerals from
hard water (which then forms a
difficult to remove white dust on
nearby objects and furniture), and
pathogens growing in a stagnant
water tank.
1MTechnical
3.Ultra sonic
diaphragms.
Clean carefully with soft
non-scratch cloth.
6M 3.Ultra sonic
diaphragms.
Clean carefully with soft
non-scratch cloth.
3MTechnical
5. SEDIMENT
REMOVAL.
Remove as necessary from top of
reservoir.
Operators must wear correctly
graded masks. WASTE DISPOSAL
REGULATIONS APPLY.
1M 5. Sediment
removal.
Remove as necessary from top of
reservoir.
Waste disposal regulations apply.1MOther
6. UVC lamps Change lamps UVC lamps in general have a life of
approximately 8,000 hours, however
due to the nature of their
construction; the
degradation in output accelerates
towards the end of its useful life.
12MAdded
7. Automatic
shutdown and
alarm system
Check that the alarm system (both
audible and visual)works when the
automatic shutdown system
operates. Check that the equipment
shuts down correctly and drains the
water reservoir.
12MAdded
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HUMIDIFIERS- Resistance heater type33-06 33-06 HUMIDIFIERS- Resistance heater type
In hard water areas more frequent maintenance may be required
Any action taken should conform to the HSE requirements, The control of Legionella bacteria in
water systems – ACOP L8,2001 and HEVAC code of best practice - 1
In hard water areas more frequent maintenance may be required
Any action taken should conform to the HSE requirements, The control of Legionella bacteria in water
systems – ACOP L8,2000 (www.hse.gov.uk) and HEVAC Association code of best practice 4
commissioning and planned maintenance.
Persons responsible for maintenance should record who the competent persons responsible for
maintenance are, water sampling frequency, tests and results, routine maintenance, cleaning and
disinfection dates and details, as per the HSC’s Code of Practice L8.
All monitoring and maintenance activity should be recorded in a log, particularly that relating to
Legionella monitoring and control.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Status. Isolate electrically and hydraulically. Note:- electrical isolation must meet
HSAWA requirements.
12M 1. Status. Isolate electrically and hydraulically. Electrical isolation must meet
HSAWA (www.hse.gov.uk)
requirements.
12MOther
2. Water boiling
chamber.
Drain.12M 2. Water boiling
chamber.
Drain. Check all electrical
connections on the cylinder for
soundness and correct any defects
12MTechnical
4. Scale
collecting bag
(where fitted).
Change as necessary.12M 4. Scale
collecting bag
(where fitted).
Change as necessary. Waste disposal regulations apply.12MTechnical
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HUMIDIFIER - Disinfection procedures33-07 33-07 HUMIDIFIER - Disinfection procedures
All actions should conform with HSE requirements, L8 ACOP and HEVAC code of best practice - 1 All actions should conform with HSE requirements, L8 ACOP and HEVAC Association code of best
practice 4 commissioning and planned maintenance.
Before chemical disinfection is carried out it is essential that the system is clean and it is important to
ensure that all parts of the system are disinfected, not just those which are readily accessible.
Building occupants should be warned that the water is heavily chlorinated. If tanks and calorifiers are
heavily contaminated by organic materials, the system should be disinfected before cleaning to
reduce risks to cleaning staff and also after cleaning. It may be necessary to add chemical dispersants
to remove organic fouling from pipework etc. and chemical descaling may also be necessary. Where
possible, cleaning methods should not create an aerosol.
Persons responsible for maintenance should record who the competent persons responsible for
maintenance are, water sampling frequency, tests and results, routine maintenance, cleaning and
disinfection dates and details, as per the HSC’s Code of Practice L8.
All monitoring and maintenance activity should be recorded in a log, particularly that relating to
Legionella monitoring and control.
Technical
Title NotesActionFQTitle FQ Action Notes
1. System. Isolate electrically and hydraulically,
if not already isolated.
Isolation of electrical supply should
be in accordance with HSAWA
requirements.
6M 1. System. Isolate electrically and hydraulically,
if not already isolated.
Isolation of electrical supply should
be in accordance with HSAWA
(www.hse.gov.uk) requirements.
6MOther
2.Loose debris. Allow humidity water to drain,
remove solid debris with 'wet and
dry' vacuum cleaner.
6M 2.Loose debris. Allow humidity water to drain,
remove solid debris with `wet and
dry` vacuum cleaner.
Waste disposal regulations apply.6MTechnical
4. Disinfection. Refill system with clean fresh water,
disinfect system with addition of
sodium hypochlorite solution to
achieve free residual chlorine
reserve of 50 mg/l, maintain
circulation for one hour ensuring
the level does not drop below 30
mg/l after one hour.
Ensure drain valve closed during
refill. Note:- Free chlorine is rapidly
absorbed by organic matter and
partially lost when the chlorinated
water cascades through the infill
matter, thus further additions of
sodium hypochlorite may be
required to maintain the free
chlorine reserve at 50mg/litre.
6M 4. Disinfection. Refill system with clean fresh water,
disinfect system with addition of
sodium hypochlorite solution to
achieve free residual chlorine
reserve of 50 mg/l, maintain
circulation for one hour ensuring
the level does not drop below 30
mg/l after one hour.
Ensure drain valve closed during
refill. Free chlorine is rapidly
absorbed by organic matter and
partially lost when the chlorinated
water cascades through the infill
matter, thus further additions of
sodium hypochlorite may be
required to maintain the free
chlorine reserve at 50mg/litre.
6MOther
5. Return to
service.
Drain and thoroughly flush the
sump and operate the pumps for a
further 15 minutes. Drain sump,
test to ensure that residual chlorine
has dropped to below 0.5 mg/l.
Refill sump if unit to be put back
into service immediately.
Particular attention is required if
water used for disinfection is of a
high pH (over 7.3pH) as this will
reduce the effective chlorine. If
using other chemicals for
disinfection, ensure they are WRAS
approved and suppliers method is
followed. All disinfections must be
supported by a detailed disinfection
certificate. NB Chlorine is corrosive
at high levels and other less
aggressive chemicals that are not
pH dependant should be
considered.
6M 5. Return to
service.
Drain and thoroughly flush the
sump and operate the pumps for a
further 15 minutes. Drain sump, test
to ensure that residual chlorine has
dropped to below 0.5 mg/l. Refill
sump if unit to be put back into
service immediately.
Particular attention is required if
water used for disinfection is of a
high pH (over 7.3pH) as this will
reduce the effective chlorine. If
using other chemicals for
disinfection, ensure they are WRAS
approved and suppliers method is
followed. All disinfections must be
supported by a detailed disinfection
certificate. Chlorine is corrosive at
high levels and other less
aggressive chemicals that are not
pH dependant should be
considered.
6MOther
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33-08 SPRAY HUMIDIFIERS
Systems that generate an aerosol must be tested for Legionella every six months. In certain
applications, such as food retailers, it is recommended the same water is also tested for E.Coli and
coliform bacteria.
Where ambient temperatures exceed 20°C, or where the risk of aerosol inhalation or infection is
greater, more regular sampling will be required. These might be using dipslides for TVC, or more
frequent testing for Legionella.
Persons responsible for maintenance should record who the competent persons responsible for
maintenance are, water sampling frequency, tests and results, routine maintenance, cleaning and
disinfection dates and details, as per the HSC’s Code of Practice L8.
In hard water areas maintenance may require to be carried out more frequently. If output is decreased
due to heavy scaling renewal of the cylinder will be required, refer to client.
Any action taken should conform to the HSE requirements, The control of Legionella bacteria in water
systems – ACOP L8,2000 (www.hse.gov.uk) and HEVAC Association code of best practice for
commissioning and planned maintenance.
All monitoring and maintenance activity should be recorded in a log, particularly that relating to
Legionella monitoring and control.
Frequency will change depending on the level of contamination and should be subject to local risk
assessment.
Added
Title NotesActionFQTitle FQ Action Notes
1. Non-Chemical
water treatment
Confirm the operation of
non-chemical water
treatment (if present).
1WAdded
1. Status Isolate electrically and hydraulically,
if not already isolated.
Isolation of electrical supply should
be in accordance with HSAWA
(www.hse.gov.uk) requirements.
6MAdded
2. Humidifier Clean and disinfect spray
humidifiers/air
washers and make-up tanks
including all
wetted surfaces, descaling as
necessary.
Humidifiers and air washers -
atomising humidifiers and
spray-type air washers may use
water from reservoirs or tanks where
the water temperature exceeds
20°C. Unless they are regularly
cleaned and maintained, they can
become heavily contaminated,
especially in industrial
environments. The risk can be
prevented by using humidifiers
which do not create a spray, i.e.
steam humidifiers. ‘Portable’ or
‘room’ humidifiers of the type that
have a water
supply that is sprayed or atomised
into the room are not
recommended for use in NHS
premises.
6MAdded
Page 346 of 614
ICE MAKING MACHINES
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ICE MAKING MACHINES34-01 34-01 ICE MAKING MACHINES
Cleaning and maintenance of ice machines and storage units is essential in preventing contamination
of ice or equipment. Where possible always follow manufacturer’s instructions for maintenance and
cleaning. A regular cleaning schedule should be established and cleaning and maintenance records
maintained. The client should inspect the interior of the machine twice a week for build up of mould or
other contaminants, and clean accordingly.
The water supply to this equipment should be taken from a potable supply via a double check valve to
prevent backflow. Check that the water supply is taken upstream of a regularly used outlet with the
minimum of intervening pipe-run, that is, less than 3 m. The supply should not be softened.
Additionally, it should be established that the usage is sufficient to avoid deterioration in water quality ,
for example that the inlet water temperature does not exceed 20°C.
The Automatic Vending Association of Britain (AVAB) codes of practice should be followed regarding
hygiene and water quality and hygienic operation of vending machines.
Disconnect ice machines before planned water disruptions.
Added
Title NotesActionFQTitle FQ Action Notes
1. Condition. Empty, check for damage and
clean and disinfect.
Report to client if remedial work
required.
12M 1. Condition. Disconnect the unit from the power
supply. Remove and discard ice
from the bin or storage unit and
allow to warm to room temperature.
Inspect for rodent or insect
infestations behind and under the
unit and treat as required. Clean
the ice storage bin with fresh water
and detergent or as recommended
by the manufacturer. Rinse with
clean fresh water. Allow all surfaces
to dry before returning to service.
Some ice storage units require
appropriate sanitation and should
be done so in accordance with
manufacturers recommendations.
Report to client if remedial work
required.
12MOther
2. Door seals (if
fitted).
Check condition, refurbish or
replace as necessary.
Poorly fitting door seals can lead to
either ice melting or fusion of ice
pieces and energy wastage.
12M 2. Door seals (if
fitted).
Check door gaskets and seals for
evidence of leakage or dripping into
the storage bin. Refurbish or
replace as necessary.
Poorly fitting door seals can lead to
either ice melting or fusion of ice
pieces and energy wastage.
12MTechnical
5. Controls. Check action. For details see relevant section
CONTROLS.
12M 5. Controls. Check action. For details see relevant section
Control panels and controllers SFG
14.
12MTechnical
6. Drains. Check for blockage, clear if
necessary and disinfect.
12M 6. Drains. Check for blockage, clear if
necessary and disinfect.
Ensure there are proper air gaps
where the condensate lines meet
the waste lines.
12MTechnical
7. Refrigeration
unit.
Check operation. For more detailed maintenance
procedures, see CHILLERS.
12M 7. Refrigeration
unit.
Check operation. For more detailed maintenance
procedures, see Chillers SFG 09.
12MTechnical
9. Ice Scoop Ensure the ice scoop and scoop
receptacle are also cleaned with
neutral detergent and water and
dried on a regular basis or as
specified by the manufacturer
Scoop should be kept on a chain
short enough not to reach the floor.
The scoop should be kept on a
clean hard surface or dedicated
receptacle and not in the storage
bin.
12MAdded
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10. System check Check temperature of inlet water
temperature.
Ensure that the warm exhaust is
not impinging directly on taps, pipes
or hoses supplying the cold water.
Record temperature in logbook.
Ice should not be allowed to
stagnate in an ice-making machine’s
storage bin, but should be changed
frequently.
12MAdded
Page 349 of 614
INSULATION
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INSULATION35-01 35-01 THERMAL INSULATION
WARNING: Insulation may contain asbestos. If Asbestos is suspected or you are unsure of the
material - STOP WORK - Broken Insulation is dangerous and if in doubt do not start work and inform
your supervisor and client. Work MUST NOT re-start until a Certifcate for safe working is recieved.
<B>WARNING</B>: Insulation may contain asbestos. If Asbestos is suspected or you are unsure of
the material - STOP WORK. Broken Insulation is dangerous and if in doubt do not start work and
inform your supervisor and client. Work MUST NOT re-start until a Certificate for safe working is
received. Refer to www.hse.gov.uk for detail.
Damaged and missing insulation can allow the surface temperature of equipment and pipework to
exceed Dew Point - thus allowing condensation to occur and in sub-zero process ice build up to occur.
Potentially this could result in slippery surfaces, cosmetic damage and fungal infestation or rotting of
susceptible materials.
When an insulating material, becomes wet, the air enclosures fill with water and, because water is a
better conductor than air, the conductivity of the material increases.
The thickness of Thermal insulation should be in accordance with BS 5422:2009
Other
Title NotesActionFQTitle FQ Action Notes
4. Insulation
Jackets
Re-install any valve, flange or
similar fittings boxes / insulation
jackets that have been removed
and left off. Report any of these
missing.
12MAdded
5. Cladding Check all cladding to make sure it
has not been damaged / dented
[especially near step over points].
repair any damage or report if
unable to repair
12MAdded
1. Pipe lagging. Check for dampness and broken
condition
Broken and damp insulation
washers energy and should be
repaired as soon as possible.
12M 1. Pipe lagging. Check for dampness and broken
condition. Report on condition of all
insulation and coverings, paying
particular attention to integrity of
any vapour seals.
Broken and damp insulation wastes
energy and should be repaired as
soon as possible.
12MTechnical
2. Boiler lagging. Check for broken condition and
repair if necessary.
12M 2. Boiler lagging. Check for broken condition and
repair if necessary. Report on
condition of all insulation and
coverings, paying particular
attention to integrity of any vapour
seals.
12MTechnical
Page 351 of 614
LIGHTING
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INTRODUCTORY PROCEDURES36-01 36-01 INTRODUCTORY PROCEDURES
The design and installation of lighting systems should be in accordance with the CIBSE Code for
Interior Lighting and to ensure that the design conditions are maintained, regular maintenance is
necessary. Failure to carry out that maintenance will lead to reduced lighting levels, lower efficiency
and energy wastage. It must be stressed that lighting is often a significant cause of energy wastage
through illuminations, 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 luminaires and fittings the cleanliness of the environment is an
important factor dictating the frequency of cleaning, dirty fittings and tubes cause loss of light with the
consequent effect on the efficiency of the work station and the accuracy of the work being carried out .
In a dirty environment frequent 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 manufactured batch.
There is also another factor which may dictate replacement frequency and that is accessibility. Often it
is cost effective to replace lamps on a regular basis based on the recommended life of the lamps .
Clearly in certain situations such as a shop or hospital or where access is very difficult a regular
replacement schedule may be the most sensible option and this should be agreed with the client.
The environmental factors of the disposal of items must be considered together with the type of
replacement used.
Luminaires 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.
The design and installation of lighting systems should be in accordance with the CIBSE Code for
Interior Lighting and to ensure that the design conditions are maintained, regular maintenance is
necessary. Failure to carry out that maintenance will lead to reduced lighting levels, lower efficiency
and energy wastage.
Maintenance routines can improve lighting efficiency by using a regular programme of cleaning for
lighting diffusers and by replacing luminaires as they become less efficient with age . There may also
be advantages in replacing older type tubular fluorescent lamps with modern, improved efficiency
units with an equivalent lighting output. In a dirty environment more frequent cleaning will be
necessary.
The maintenance of lighting installations covers four main sectors, these are:-
A) Local wiring and cabling, i.e. at entry and/or exit of fitting or control. B) Fittings including luminaries.
C) Lamps D) Controls
Normally for wiring and cabling little maintenance is required unless alterations or temporary
arrangements have been made. For luminaires and fittings the cleanliness of the environment is an
important factor dictating the frequency of cleaning in a dirty environment frequent cleaning may be
necessary. Dirty reflectors, diffusers, lamps and tubes cause loss of light with the consequent effect
on the ‘task’ for which the luminaire was initially installed and the accuracy of the ‘task’ being carried
out. Most lamps should be changed at the end of their useful life which is usually before they fail.
While continuing to consume the same power as when new, a lamp’s output may decline by 50% or
more before it fails. Aim to replace SON and metal halide lamps as soon as they fail. The lamp igniter
will continue to try to restart the failed lamp. This can use more energy than if the lamp was working
normally and, in addition, puts strain on the ballast, causing it to fail in extreme cases.
Manufacturers quote a rated life for Lamps and Tubes.. The rated life is the best average of life for a
manufactured batch.
A note should be made where lamps with different colour temperatures are used in different parts of a
building to avoid a combination of colours in the same room. It is equally important to ensure that
lamps / tubes are replaced with like for like types of the correct colour rendition.
There is also another factor which may dictate replacement frequency and that is accessibility. Often it
is cost effective to replace lamps on a regular basis based on the recommended life of the lamps .
Clearly in certain situations such as retail store or hospital or where access is very difficult a regular
replacement schedule may be the most sensible option and this should be agreed with the service
provider.
The environmental factors of the disposal of items must be considered together with the type of
replacement used. Fluorescent tubes and other mercury containing discharge lamps together with low
and high pressure sodium lamps waste are now classified as hazardous under the Hazardous Waste
Regulations 2005. These regulations came into force 16th July 2005 in England and Wales replacing
the Special Waste Regulations 1996.
See Hazardous area (electrics) SFG 27 for any lighting works in explosive areas or where intrinsically
safe fittings are installed.
Other
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LIGHTING-SWITCHES-INTERNAL AND EXTERNAL36-02 36-02 LIGHTING-SWITCHES-INTERNAL AND EXTERNAL
Title NotesActionFQTitle FQ Action Notes
4.Solar operated
switches (external
and internal).
Clean detector surface.
Check:switching function,
12M 4.Solar operated
switches (external
and internal).
Clean detector surface. Check:
switching function,
12MOther
6.Automatic
switching controls
(e.g. timers).
Check operation and time settings. Adjustments for BST should be
made by the client on the
appropriate dates. For external
lighting regular adjustments should
be made to compensate for
changes in daylight hours. This will
reduce energy wastage.
12M 6.Automatic
switching controls
(e.g. timers).
Check operation and time settings. Adjustments for BST should be
made by the service provider on the
appropriate dates. For external
lighting regular adjustments should
be made to compensate for
changes in daylight hours.
6MOther
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LIGHTING FITTINGS including LUMINAIRES general36-03 36-03 LIGHTING FITTINGS including LUMINAIRES general
Please see Lighting SFG 36-01 introductory procedures before commencing.
Wear cotton gloves on highly reflective luminaire diffusers and when changing tungsten capsule
lamps.
See Hazardous area (electrics) SFG 27 for any lighting works in explosive areas or where intrinsically
safe fittings are installed.
Added
Title NotesActionFQTitle FQ Action Notes
1.Cleanliness. Clean fittings where necessary. Frequency of cleaning will depend
on environment, in dirty areas more
frequent cleaning may be
necessary. Contract should state
whether this is part of the
maintenance contract.
12M 1.Cleanliness. Check each lamp for build-up of
dust and dirt, clean as required.
Frequency of cleaning will depend
on environment, in dirty areas more
frequent cleaning may be
necessary.
12MTechnical
2.Lamps
a)tungsten
filament,
Check for failed lamps or signs of
deterioration.Replace as required.
Tungsten filament lamps are
inefficient with regard to energy use
and could be replaced with more
efficient lamp types.
12M 2.Lamps
a)tungsten
filament,
Check for failed lamps or signs of
deterioration. Replace as required.
12MOther
b)fluorescent, Clean and replace any failed or
suspect lamps.
Care should be taken in handling as
broken glass from broken
tubes/lamps can be
dangerous.Disposal of tubes/lamps
should be in accordance with H&S
and Environmental regulations.
12M b)fluorescent, Check for failed or flickering lamps
or signs of deterioration. Replace
as required
Care should be taken in handling as
broken glass from broken
tubes/lamps can be dangerous.
Disposal of tubes/lamps should be
in accordance with H&S
(www.hse.gov.uk/hthdir/noframes/co
shh/index.htm) and Environmental
regulations.
12MTechnical
8.Switches. Check operation. Replace if faulty.12M 8.Switches and
control contactors
Check operation of all switches.
Check function and operation of
any lighting control contactors;
ensure that lamp circuits operate at
correct times, both for normal
operation and for extended on/off
periods.
Replace if faulty.12MTechnical
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EXTERNAL LIGHTING including ILLUMINATED SIGNS36-04 36-04 EXTERNAL LIGHTING including ILLUMINATED SIGNS
WARNING : Equipment may operate at voltages above 415 and extra precautions should be
taken.
Please see Lighting SFG 36-01 introductory procedures before commencing.
Wear cotton gloves on highly reflective luminaire diffusers and when changing tungsten capsule
lamps.
See Hazardous area (electrics) SFG 27 for any lighting works in explosive areas or where intrinsically
safe fittings are installed.
<B>WARNING</B> : Equipment may operate at voltages above 415v.
Added
Title NotesActionFQTitle FQ Action Notes
External FittingsAdded
1. General Clean and check: For physical
damage. Signs of water ingress or
condensation, if present check
seals and report toclient.
Check mounting
brackets/supports/columns etc., for
corrosion, damage and security,
report all findings
Frequency of cleaning will depend
on environment, in dirty areas more
frequent cleaning may be
necessary.
6MAdded
2. Lamps Check for failed or flickering lamps
or signs of deterioration. Replace
as required
Care should be taken in handling as
broken glass from broken
tubes/lamps can be dangerous.
Disposal of tubes/lamps should be
in accordance with H&S and
Environmental regulations.
12MAdded
3. Cable
connections
Check externally for security and
signs of arcing or overheating.
Renew or re-fix as necessary.12MAdded
4. Lamp control
gear.
Check operation and compatibility
with lamp.
12MAdded
5. Switches and
control contactors
Check operation of all switches.
Check function and operation of
any lighting control contactors;
ensure that lamp circuits operate at
correct times, both for normal
operation and for extended on/off
periods
Replace if faulty.12MAdded
6. Electrical wiring. Check integrity and report to client if
renewal necessary
12MAdded
7. Earth continuity Check and remedy if necessary.6MAdded
SignageAdded
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1.Condition. Clean and check:For physical
damage. Signs of water ingress or
condensation, if present check
seals and report to client.
On plastic surfaces avoid a build up
of static which will re-attract dirt.
Cleaning materials should be
compatible with sign fabric.If
evidence of need for re-painting
observed, notify client.
6M 1.Condition. Clean and check: For physical
damage. Signs of water ingress or
condensation, if present check
seals and report to client.
On plastic surfaces avoid a build up
of static which will re-attract dirt.
Cleaning materials should be
compatible with sign fabric. If
evidence of need for re-painting
observed, notify client.
6MTechnical
4.Lamps or tubes. Check for failed or blackened tubes
or lamps. Replace as necessary.
Replacement procedures should be
agreed with the client as
recommended life can vary with type
of luminaire. Tube or lamp colour
should conform with original colour
specification. Disposal of tubes
should be in accordance with H&S
and Environmental regulations.
12M 4.Lamps or tubes. Check for failed or blackened tubes
or lamps. Replace as necessary.
Replacement procedures should be
agreed with the client as
recommended life can vary with
type of luminaire. Tube or lamp
colour should conform with original
colour specification. Disposal of
tubes should be in accordance with
H&S
(www.hse.gov.uk/hthdir/noframes/co
shh/index.htm) and Environmental
regulations.
12MTechnical
6.Control gear. Check for correct operation. Replacement equipment should be
compatible with that removed.
Replacement cold cathode
transformers should be re-calibrated
to the design mA output.
12M 6.Control gear. Check for correct operation. Replacement equipment should be
compatible with that removed.
Replacement cold cathode
transformers should be re-calibrated
to the design mA output.
12MTechnical
Page 357 of 614
LIGHTING- EMERGENCY
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EMERGENCY LIGHTING self contained37-01 37-01 EMERGENCY LIGHTING self contained
Emergency lighting levels in existing installations may have to be upgraded to comply with current
legislation.
To be carried out in accordance with BS EN 50172:2004 / BS 5266 Part 8: 2004. All tests shall be
logged as section 6 of that document.
In addition to the tasks shown below;
The emergency lighting record logbook or monitoring system should be checked in order that
recorded faults may be rectified. All emergency and escape lighting systems should be inspected
daily.
In particular, it should be ensured that:
a) every lamp is lit if the system is maintained;
b) the control panel for any central battery system or generator
indicates normal operation; This is a visual inspection of indicators to identify that the system is in a
ready condition and does not require a test of operation.
c) any fault found is logged and the appropriate action(s) taken.
Because of the possibility of a failure of the normal lighting supply occurring shortly after a period of
testing of the emergency lighting system or during the subsequent recharge period, all full duration
tests shall wherever possible be undertaken preceding time of low risk to allow for battery recharge.
Alternatively, suitable temporary arrangements shall be made until the batteries have been recharged.
The following minimum inspections and tests shall be carried out at the intervals recommended below.
The regulating authority may require specific tests.
Technical
Title NotesActionFQTitle FQ Action Notes
1.Testing. To be carried out monthly in
accordance with BS 5266:Part 1:
2005. All tests shall be logged as
per Appendix C of BS 5266.
Client s operators should be trained
to carry out monthly tasks.
1M 1.Test - Monthly If automatic testing devices are
used, the results of the short
duration tests shall be recorded.
Switch on in the emergency mode
each luminaire and each internally
illuminated exit sign from its battery
by simulation of a failure of the
supply to the normal lighting for a
period sufficient to ensure that each
lamp is illuminated.
During this period, all luminaires
and signs shall be checked to
ensure that they are present, clean
and functioning correctly.
At the end of this test period, the
supply to the normal lighting should
be restored and any indicator lamp
or device checked to ensure that it
is showing that the normal supply
has been restored.
The period of simulated failure
should be sufficient for the purpose
of this clause whilst minimising
damage to the
system components e.g. lamps.
Any luminaires or exit signs that do
not function correctly should be
repaired or replaced.
Responsibility for monthly check
should be agreed with the client.
1MTechnical
2.Operation. 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.
1M Deleted
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3.Battery. Check condition and date of
expected life. Renew if necessary.
Normal life expectancy is five years.
Batteries must be disposed of in
accordance with H&S and
Environmental Regulations.
12M 3.Battery. Check condition and date of
expected life. Renew if necessary.
Normal life expectancy is five years.
Batteries must be disposed of in
accordance with H&S and
Environmental Regulations.
12MOther
Test for one hour. If luminaire rated for duration of one
hour, test
6M 2. Test - Annually If automatic testing devices are
used, the results of the full rated
duration test shall be recorded.
For all other systems the monthly
inspection shall be carried out and
the following additional tests made:
each luminaire and internally
illuminated sign shall be tested as
per item 1 above [monthly] but for
its full rated duration
in accordance with the
manufacturer`s information;
The supply of the normal lighting
shall be restored and any indicator
lamp or device checked to ensure
that it is showing that normal supply
has been restored. The charging
arrangements should be checked
for proper functioning;
The date of the test and its results
shall be recorded in the system
logbook
Any luminaires or exit signs that do
not function correctly should be
repaired or replaced.
The once per year test is for the full
duration of the battery.
12MTechnical
Test for three hours. The once per year test is for the full
duration of
12M Deleted
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EMERGENCY LIGHTING externally powered37-02 37-02 EMERGENCY LIGHTING externally powered
Emergency lighting levels in existing installations may have to be upgraded to comply with current
legislation; the COSHH Regulations must also be followed - refer to www.hse.gov.uk for details.
To be carried out in accordance with BS EN 50172:2004 / BS 5266 Part 8: 2004. All tests shall be
logged as section 6 of that document.
In addition to the tasks shown below;
The emergency lighting record logbook or monitoring system should be checked in order that
recorded faults may be rectified. All emergency and escape lighting systems should be inspected
daily.
In particular, it should be ensured that:
a) every lamp is lit if the system is maintained;
b) the control panel for any central battery system or generator
indicates normal operation; This is a visual inspection of indicators to identify that the system is in a
ready condition and does not require a test of operation.
c) any fault found is logged and the appropriate action(s) taken.
Because of the possibility of a failure of the normal lighting supply occurring shortly after a period of
testing of the emergency lighting system or during the subsequent recharge period, all full duration
tests shall wherever possible be undertaken preceding time of low risk to allow for battery recharge.
Alternatively, suitable temporary arrangements shall be made until the batteries have been recharged.
The following minimum inspections and tests shall be carried out at the intervals recommended below.
The regulating authority may require specific tests.
Technical
Title NotesActionFQTitle FQ Action Notes
Energise from battery for period of
one hour.
If the system is rated for one hour,
duration of test simulating failure
should be fifteen minutes.
6M 2) TEST -
Annually
If automatic testing devices are
used, the results of the full rated
duration test shall be recorded.
For all other systems the monthly
inspection shall be carried out and
the following additional tests made:
each luminaire and internally
illuminated sign shall be tested as
per item 1 above [monthly] but for
its full rated duration
in accordance with the
manufacturer`s information;
The supply of the normal lighting
shall be restored and any indicator
lamp or device checked to ensure
that it is showing that normal supply
has been restored. The charging
arrangements should be checked
for proper functioning;
The date of the test and its results
shall be recorded in the system
logbook.
Generator - In addition to the above
for generating sets, refer to the
requirement of ISO 8528-12
Any luminaires or exit signs that do
not function correctly should be
repaired or replaced.
The once per year test is for the full
duration of the battery.
12MTechnical
Page 361 of 614
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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.
12M Deleted
1.Testing. To be carried out monthly is
accordance with BS 5266:Part 1:
2005. All tests shall be logged as
per Appendix C of BS 5266.
Client s operators should be trained
to carry out monthly tasks.
1M 1.Test - Monthly If automatic testing devices are
used, the results of the short
duration tests shall be recorded.
Switch on in the emergency mode
each luminaire and each internally
illuminated exit sign from its battery
by simulation of a failure of the
supply to the normal lighting for a
period sufficient to ensure that each
lamp is illuminated.
During this period, all luminaires
and signs shall be checked to
ensure that they are present, clean
and functioning correctly.
At the end of this test period, the
supply to the normal lighting should
be restored and any indicator lamp
or device checked to ensure that it
is showing that the normal supply
has been restored.
Central battery system - In addition
to the above for central battery
systems, the correct operation of
system monitors shall be checked.
Generator - In addition to the above
for generating sets, refer to the
requirement of ISO 8528-12.
The period of simulated failure
should be sufficient for the purpose
of this clause whilst minimising
damage to the
system components e.g. lamps.
Any luminaires or exit signs that do
not function correctly should be
repaired or replaced.
Responsibility for monthly check
should be agreed with the client
1MTechnical
2.Operation. Energise from battery for period of
one hour.
If the system is rated for one hour,
duration of test simulating failure
should be fifteen minutes.
6M Deleted
3.Battery. 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.
6M 3.Battery. Ensure terminals are clean and
check electrolyte level. Check
condition of battery case(s).
In accordance with the
manufacturer’s requirements the
inspection should include a check
of;
voltage setting on the charger; cell
or monobloc battery voltages;
specific gravity (SG) and electrolyte
level, if appropriate; cleanliness,
leakage; tightness of connectors, if
required; ventilation; vent plugs or
valves; battery temperature.
Follow manufacturer s instructions
at all times and advise client if
battery replacement is required
6MTechnical
Page 362 of 614
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CHILLED WATER-CONDENSER WATER PIPE SYSTEMS40-04
Page 363 of 614
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CONDENSER - CHILLED WATER CIRCULATING PUMPS40-05
Page 364 of 614
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PRESSURISATION UNITS - CHILLED WATER40-06
Page 365 of 614
LIGHTNING PROTECTION
Page 366 of 614
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LIGHTNING CONDUCTOR AND EARTH38-01 38-01 LIGHTNING CONDUCTOR AND EARTH
(Does not cover lightning strike prevention.) All inspection, testing and documentation shall be carried out in strict accordance with BS EN 62305-
1 to 4 inclusive:2006
The inspection comprises checking the technical documentation, visual inspections and test
measurements. The object of the inspection is to verify that
– the Lightning electromagnetic pulse protection measures system (LPMS) complies with the design,
– the Lightning electromagnetic pulse protection measures system (LPMS) is capable of performing
its design function,
– any newly added protection measure is integrated correctly into the Lightning electromagnetic pulse
protection measures system (LPMS) .
Inspections shall be made; Periodically, after any alteration of components relevant to the system
and possibly after a lightning flash to the structure (e.g. where indicated by a lightning flash counter, or
where an eyewitness account of a flash to the structure is provided, or where there is visual evidence
of lightning-related damage to the structure).
The frequency of the periodical inspections shall be determined with consideration to
– the local environment, such as corrosive soils and corrosive atmospheric conditions,
– the type of protection measures employed.
Technical
Title NotesActionFQTitle FQ Action Notes
1.Conductor tape
fastenings and
joints.
Inspect roof and plant connections,
vertical joint connectors and earth
termination positions. Ensure that
conductor tapes are secured firmly
to the structure and all joints
including those to structural and
service steelwork are mechanically
and electrically sound.
Look for evidence of corrosion in the
material, this is more likely to occur
where there is contact between two
dissimilar metals or where the
atmosphere has the potential for a
high degree of chemical pollution. If
renewal required, report to client.
12M 1.Conductor tape
fastenings and
joints.
A visual inspection shall be carried
out to verify that;
A) there are no loose connections
nor any accidental breaks in
conductors and joints, B) no part of
the system has been weakened
due to corrosion, especially at
ground level, C) bonding
conductors and cable shields are
intact, D) there are no additions or
alterations which require further
protection measures, E) there is no
indication of damage to the SPDs
[surge protection device] and their
fuses or disconnectors, F)
appropriate line routings are
maintained, G) safety distances to
the spatial shields are maintained
Look for evidence of corrosion in the
material, this is more likely to occur
where there is contact between two
dissimilar metals or where the
atmosphere has the potential for a
high degree of chemical pollution. If
renewal required, report as
neccessary
13MTechnical
2.Earth
terminations.
Test resistance to earth. Advise client if the whole of the
lighting protection system has a
resistance to earth over 10 ohms.
Record details and copy to client.
12M 3.Earth
terminations.
Test resistance to earth Advise client if the whole of the
lighting protection system has a
resistance to earth over 10 ohms.
Record details and copy as
neccessary.
13MOther
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3. Lightning
strike.
Record details and copy to client.
After evidence of lightning strike the
complete procedure for inspection
and testing should be carried out as
soon as possible to ascertain the
condition of the system.
4. Documentation
and report
The inspector shall prepare a
report, which shall be attached to
the technical documentation and
the previous inspection reports. The
inspection report shall contain
information covering
– the general status of the LPMS,
– any deviation(s) from the
technical documentation,
– the result of any measurements
performed
After inspection, all defects noted
shall be corrected without delay. If
necessary, the technical
documentation shall be updated
13MTechnical
2. Electrical
continuity tests
For those parts of an earthing
system and bonding network which
are not visible for inspection,
measurements of electrical
continuity should be performed
13MAdded
Page 368 of 614
MOTORS
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MOTORS- DRIVE ELEMENTS39-01 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 may require the engineer to follow a permit to work system.
Dual motor systems should be treated as one.
Note: Before carrying out any work, check status and isolate in accordance with HASAWA
(www.hse.gov.uk) and Electricity at Work requirements. This may require the engineer to follow a
permit to work system. Dual motor systems should be treated as one.
Other
Title NotesActionFQTitle FQ Action Notes
2. Motor casing. Check ventilating louvres are clear. See also MOTORS.3M 2. Motor casing. Check ventilating louvers are clear.3MOther
8. Variable speed
drives and other
solid state
controls.
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.
12M 8. Variable speed
drives and other
solid state
controls.
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
SFG 14-15 speed controllers.
12MOther
Page 370 of 614
PIPEWORK SYSTEMS
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PIPEWORK SYSTEMS - General40-01 40-01 PIPEWORK SYSTEMS - General
Title NotesActionFQTitle FQ Action Notes
1. Supports. Check and tighten as necessary. Loose supports can lead to undue
strain on pipework.
12M 2. Supports and
Brackets
Check and tighten as necessary.12MOther
2. Valves and
stopcocks (where
normally open)
Check operation. Valves should be
fully closed and then fully opened.
Lubricate as necessary.
N.B. Carefully note the number of
turns to fully close, so that valve can
be reset to its original position. If
operation of valve stiff, repeat
operation until clear and then return
valve to its original position.
12M 3. Valves and
stopcocks (where
normally open)
Check operation. Valves should be
fully closed and then fully opened.
Lubricate as necessary.
N.B. Carefully note the number of
turns to fully close, so that valve can
be reset to its original position. If
operation of valve stiff, repeat
operation until clear and then return
valve to its original position.
12MTechnical
3. Regulating
valves.
Do not adjust unless alterations or
additions to pipework have been
made.
If alterations to the pipework have
been made it will be necessary to
recommission the system.
12M 4. Regulating
valves.
Do not adjust unless alterations or
additions to pipework have been
made.
If alterations to the pipework have
been made it will be necessary to
recommission the system.
12MOther
4. Double
regulating valves.
Check operation. Settings should not be altered, but
they can be used for regulation.
12M 5. Double
regulating valves.
Check operation. Settings should not be altered, but
they can be used for regulation.
12MOther
5. Glands. Rectify any leakages. For severe leakage, immediate
emergency action will be necessary.
For regulating valve see action 3
above.
12M 6. Glands. Check all valves within pipework
run for gland leakage, where
possible at time of inspection adjust
or repack as required. Ensure
packing is the correct size and
material in accordance with
manufacturers recommendations
For severe leakage, immediate
emergency action will be necessary.
12MTechnical
6. Anchor points
and guide
assemblies.
Check for security of fittings.12M 12. Anchor points
and guide
assemblies.
Check for security of fittings.12MOther
1. General Check all pipework for signs of
leaks, if possible repair and stem
leak
12MAdded
7. Expansion
bellows
Check condition and alignment of
expansion bellows /compensators.
Report any defects.12MAdded
8. Sensors,
gauges, detectors
Ensure all pipeline mounted
detectors/sensors and gauges are
in good repair
12MAdded
9. Hit Hazards Inspect pipework run and where it
runs across or parallel to a
personnel access route. Highlight
any low points where heads could
be hit with the appropriate hazard
tape or paint
12MAdded
10. ID tags Check identification tags are
provided for all pipeline mounted
equipment, valves etc.
12MAdded
11. Insulation Report on condition of all insulation
and coverings, paying particular
attention to integrity of any vapour
seals
See Insulation SFG35-01.12MAdded
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Title NotesActionFQTitle FQ Action Notes
5. Controls. Check functioning of controls. For more detailed maintenance of
thermostats, frost protection etc.,
see relevant section.
12M 5. Controls. Check functioning of controls. For more detailed maintenance see
thermostats, frost protection etc.
12MTechnical
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PNEUMATIC EQUIPMENT – COMPRESSED AIR SYSTEMS40-07 40-07 PNEUMATIC EQUIPMENT – COMPRESSED AIR SYSTEMS
For efficient operation of air operated control equipment such as control valves , relays and actuators a
supply of clean dry, oil free compressed air is essential. Pipelines should be adequately sized to
minimise pressure loss and checked regularly for leakage as this can result 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 work should be carried out on an uncertified vessel and the client
informed of the position.
To comply with the Pressure Systems and Transportable Gas Containers Regulations 1989, a written
scheme of examination is required to be provided for the periodic examination of the whole system.
The written scheme must be drawn up by a ‘competent person’. Refer also to HSG39 Compressor Air
Safety.
Regular maintenance of the instrument air compressor is essential and particular attention should be
paid to the performance of the air drier and oil separator.
There are specific statutory requirements for the examination and maintenance of pressure systems
including air receivers (Users should be familiar with the statutory requirements applying to
compressed air systems and air receivers. These are principally contained in the Pressure Systems
and Transportable Gas Containers Regulations 1989. Additional recommendations are given in the
Approved Code of practice safety of pressure systems.). In addition to the specific requirements,
general requirements are set out in Section 2(2)(a) of the HSW Act and PUWER:
There are many ways in which compressed air can be dangerous, for example:
1. it can enter body orifices such as the mouth, ears and anus, causing severe and often fatal injuries:
2. at high pressure it can penetrate the skin;
3. particles or oil carried in an air jet can damage the eyes;
oil-coke deposits in a system can spontaneously ignite and cause an explosion;
4. vessels containing compressed air, even at comparatively low pressure, can explode violently once
their integrity is lost; and
5. dirty or `wet` air car, lead to corrosion and blocked valves which may make the system unsafe.
It should be noted that air receivers operating above 0.5 bar gauge pressure are subject to mandatory
periodical certification and no work should be carried out on an uncertified vessel and the client
informed of the position
Before any pressurised components are dismantled they should be effectively isolated from all
pressure sources and completely vented to atmosphere. Precautions should also be taken to guard
against the possibility of injury through sudden release of trapped springs.
When components, especially valves, are found to be worn and service kits of seals are used to
rebuild them, care should be taken to check thoroughly the function of the rebuilt valve before placing
it in the equipment. Incorrect seal replacement can completely alter the valve`s function and if
replaced in the equipment could present a serious hazardTechnical
Other
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AIR COMPRESSORS40-08 40-08 AIR COMPRESSORS AND RECEIVERS
WARNING - Where Nitrogen is used, a Risk Assessment must be done prior and suitable training
given. The breathing of Oxygen free Nitrogen can be fatal, ensure any discharge can not endanger
others.
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 must carry out as part of his duties. These include condensate
drainage, pressure drop checks across filters, oil contamination checks and audible leaks.
<B>WARNING</B> – All maintenance work, other than routine checks to filters designed for cleaning
in-service, should be undertaken only when the compressor has been stopped, disconnected and
locked off from the power supply and all internal pressure dissipated. Other precautions may also be
necessary: for example, the compressor may have to be scotched to prevent movement of the
mechanism.
Under no circumstances should flammable liquids by used for cleaning. Appropriate safety
precautions should be taken against any toxic vapours liberated during usage of any cleaning or
degreasing liquids.
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 must carry out as part of his duties. These include condensate
drainage, pressure drop checks across filters, oil contamination checks and audible leaks.
The major hazard associated with compressors is over pressurisation, which may arise from:
(a) a blocked outlet or some other restriction to flow:
(b) failure of automatic controls combined with low air consumption;
(c) compressor malfunction, e.g. over speeding;
(d) an external fire near the pressure system: and
(e) overheating and the build-up of carbonaceous deposits, both of which can lead to fires or
explosions. Although they are rare, fires and explosions can also occur as a result of oil or oil vapour
being ignited in the pressure system.
Where receiver is fitted with automatic condensate drain valve, check for correct operation. Where
manual valves are provided, drain condensate.
Dirty or `wet` air can cause a system to fail e.g. by causing fine particles of debris to agglomerate,
blocking safety related valves
Technical
Title NotesActionFQTitle FQ Action Notes
1. Cooling Water. The cooling water should be
visually checked to make sure that
it is circulating properly by
observing the flow outlet or flow
indicator
1DAdded
2. Oil level. The level of the oil in the crank
chamber should be checked using
a dipstick, level gauge or other
device. Any excessive usage of
lubricating oil should be
investigated
1DAdded
3. Oil pressure Oil pressure should be checked1DAdded
4. Oil feed Check oil feed to the cylinders to
make sure that it is adequate but
not excessive. Oil consumption
should be recorded, as excessive
consumption can often lead to
explosions downstream of the
compressor
1DAdded
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5. Air pressure &
temperature
Check and record the outlet air
pressure and temperature.
1DAdded
6. General Check the compressor performance
by listening for any unusual noises
during running.
1DAdded
7. Defects Defects found should be rectified
and a record kept
1DAdded
8. Air receiver Any accumulation of oil and water
should be drained from the air
receiver, the intercooler, the
aftercooler and main supply pipes.
1DAdded
9. Safety valves Safety valves (where design allows)
should be checked by easing them
by hand.
1WAdded
10. Air filter. Inspect air filter, clean/replace as
found necessary.
The condition of the inlet air filters
should be checked and thoroughly
cleaned or replaced. The interval
between successive replacements
will be determined by local
circumstances but is, to a certain
extent, controlled by the capacity of
the filter and the cleanliness of the
atmosphere in the vicinity.
Where oil wetted viscous filters are
used, spare units should be
provided and excess oil should be
drained from the filter units for at
least four to eight hours before the
units are replaced, except where the
manufacturer advises otherwise
1MAdded
14b Oil Drain and change the lubricating oil
using recommended lubricating oil
12MAdded
20a
Delivery Ports and
pipework
Where oil coke deposits are liable
to occur, check the delivery ports
and pipework. Clean as required
The period between inspections can
be modified in the light of
experience gained from operating a
particular installation
6MAdded
24. VALVES
[various]
Check condition of the valves.
Inspect and clean the
non-return/unloader valve
assembly.
Remove and inspect the crankcase
breather valve
After each 2000 hours of running or
annually (whichever is the sooner)
12MAdded
25. cooler section Clean the intercooler and
aftercooler sections.
After each 2000 hours of running or
annually (whichever is the sooner)
12MAdded
26. Radiator the radiator should be drained and
washed out
After each 2000 hours of running or
annually (whichever is the sooner)
12MAdded
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27. Air Receiver Prepare for and assist with
insurance inspection.
The air receiver should be
thoroughly cleaned and examined
internally.
Frequency will be set by Insurance
inspector
24MAdded
1. Capacity Test. Pump up receiver from zero
atmospheric pressure to working
pressure and note time taken.
Any marked difference from the
manufacturers specification may
indicate leakage or compressor
faults.
12M 11. Capacity
Test.
Pump up receiver from zero
atmospheric pressure to working
pressure and note time taken.
Any marked difference from the
manufacturers specification may
indicate leakage or compressor
faults.
12MOther
2. General
Conditions.
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.
12M 12. General
Conditions.
Check the following: condition of
guards, inter-stage cooler drains,
bearers and holding down bolts,
hand operated valves, moisture
traps. Clean down all external
surfaces.
Inspect air receiver; check all
valves, seals etc., operate correctly
Check for tightness of glands and
seats.
12MTechnical
3. Status. Switch off and isolate electricity. Note: Electrical isolation should be
carried out according to the
HSAWA. Where receivers are
subject to Statutory Tests and
Examinations for purposes of
insurance, major overhauls should
coincide with such tests and
examinations.Any recommendations
made by the Insurance Inspector
must be completed before the
receiver is returned to service.
12M 13. Status. Electrical Check for satisfactory
operation of local electrical isolation
device (stoplock/isolator
Note: Electrical isolation should be
carried out according to the
HSAWA (www.hse.gov.uk). Where
receivers are subject to Statutory
Tests and Examinations for
purposes of insurance, major
overhauls should coincide with such
tests and examinations. Any
recommendations made by the
Insurance Inspector must be
completed before the receiver is
returned to service.
12MOther
4. Oil. Note level and change using
recommended lubricating oil.
12M 14a. Oil. Check the quality of oil in the crank
case and, according to the
manufacturer`s recommendations.
replace if necessary
600 hours or 3M (whichever is the
sooner)
3MTechnical
5. Belt and Drive. Check tension and condition of
belts and drives
Ensure spare belts are available.12M 15. Belts, Guards
and Drive.
Check condition, tension and
alignment of drive belts and pulleys.
Renew drive belts as necessary.
Check drive guard is in good repair
and securely fixed, providing
correct cover of all moving parts.
Change lubricant in motor bearings
Ensure spare belts are available.12MTechnical
6. Condensate
removal.
Check condensate drainage system
and clean as necessary.
Note: This should be checked daily
as part of the normal in house
maintenance procedures. The
condition of the condensate is an
indication of the condition of the
compressor. Waste Disposal
Regulations apply.
12M 16. Condensate
removal.
Check condensate drainage system
and clean as necessary.
This should be checked daily as part
of the normal in house maintenance
procedures. The condition of the
condensate is an indication of the
condition of the compressor.
12MOther
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7. Pressure relief
valve.
Operate and check valve for
condition, operation, setting and
leak tightness. Adjust if necessary.
12M 17. Pressure relief
valve and
protective devices
Test safety valve and where fitted,
LP relief valve.
The condition of protective devices
should be checked and tested to
determine that they operate
correctly.
Fusible pellets or complete plugs
should be replaced
12MTechnical
8. Air filter. Clean. Poor condition can indicate main air
intake problems.
12M Deleted
9. Electrical
connections.
Check and tighten all connections.
Check condition of wiring and
insulation.
For associated equipment, see
MOTORS, PUMPS, FANS.
12M 18. Electrical Examine and report condition of all
associated wiring, ensure security
of all terminal connections and
check for satisfactory condition of
any flexible cables/conduits. Ensure
plant has adequate earth conductor
and bonding is secure. Take and
log motor current and compare with
nameplate details.
for associated equipment see;
Motors SFG 39-01
Pumps SFG 45-01
Fans SFG 20-01
12MTechnical
10. Gauges. Check operation. Defective gauges should be
reported with a recommendation
that they be replaced.
12M 19. Gauges. Check operation. Defective gauges should be
reported with a recommendation
that they be replaced.
12MOther
11. Pipes and
connections.
Check external condition and leak
tightness. Tighten connections as
necessary.
With soldered or brazed joints,
these may have to be remade. To
prevent internal scaling use dry,
oxygen free nitrogen (OFN) during
the jointing process. WARNING -
The breathing of Nitrogen can be
fatal, a Risk Assesment must be
done prior to its use, suitable
training must also be given prior.
12M 20b. Pipes and
connections.
In the case of oil lubricated
compressors, the delivery valves,
ports and all the pipework, vessels
and fittings between the delivery
port and that point in the system
at which the air temperature can be
confidently expected to be below
80`C. should be inspected. Any
carbonaceous deposit should be
effectively removed;
Check external condition and leak
tightness. Tighten connections as
necessary.
With soldered or brazed joints,
these may have to be remade. To
prevent internal scaling use dry,
oxygen free nitrogen (OFN) during
the jointing process.
12MTechnical
12. Controls. Check operation of pressure
switches and auto change over
solenoids.
12M 21. Controls. Check that the regulating system
operates correctly Check operation
of pressure switches and auto
change over solenoids. Check and
log settings of high limit pressure
switch (es)
12MTechnical
13. Offloaders,
mechanical and
electrical.
Check operation.12M 22. Offloaders,
mechanical and
electrical.
Check operation.12MOther
14. Main air
intake air quality.
Check air source for possible
contamination and dangerous
gases.
If air quality affected by location of
intake, report to client. Repositioning
may be necessary.
12M 23. Main air
intake air quality.
Check air source for possible
contamination and dangerous
gases.
If air quality affected by location of
intake, report to client.
Repositioning may be necessary.
12MOther
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AIR COMPRESSORS Compressed air dryers40-09 40-09 AIR COMPRESSORS Compressed air dryers
The chambers of air dryers are pressure vessels and should conform with PD 5500:2009
“Specifications for unfired fusion- welded pressure vessels” or to a standard providing equal integrity.
If means are provided for isolating the dryer (and it is good practice to provide means of isolation for
all equipment), either the chambers should be constructed to withstand the maximum pressure that
can be generated by the compressor or a suitable pressure reducing valve and a safety valve should
be fitted to prevent the safe working pressure of the chambers from being exceeded.
Where there is no means of isolating the dryer from a suitable safety valve, e.g. on the receiver, and
where non-return valves are fitted to the dryer outlet (to protect it from stored energy in the system),
no safety valves are needed.
Maintenance operations should only be conducted when the system has been shut down, isolated
and fully depressurised. All connections must be undone with care, paying particular attention to the
areas that become pressurised. Do not modify or adjust control settings. Check all connections for
leakage and secure seating. Ensure all loose parts are removed or secured to the dryer before
operation.
Added
Title NotesActionFQTitle FQ Action Notes
2. Electrical
wiring and
conduits.
Check condition and contacts.
Make good as necessary.
12M 2. Electrical
wiring and
conduits.
Check condition.12MOther
2. Cleaning. WARNING - The breathing of
Nitrogen can be fatal, a Risk
Assessment must be done and
training given prior to use.
Where applicable, dismantle and
clean with dry oxygen free nitrogen.
Examine, test, refit or renew items
listed under notes.
Items:- Insert casing-felt
pads-perforated
discs-spring-gauzes-strainers-cotton
wool- U pin-external
casing-desiccant as directed.
3M 2. Cleaning. A risk Assessment must be done
and training given prior to use.
Where applicable, dismantle and
clean with dry oxygen free nitrogen.
Examine, test, refit or renew items
listed under notes.
Items:- Insert casing-felt
pads-perforated
discs-spring-gauzes-strainers-cotton
wool- U pin-external
casing-desiccant as directed.
3MOther
c) )Water
absorption type
continued
Deleted
4. Re-activation
drying time.
Time change-over period. Compare with manufacturer s
recommendation.
3M 4. Re-activation
drying time.
Time change-over period. Compare with manufacturer`s
recommendation.
3MOther
c) Compressed air
network
distribution
Note: The Pressure Systems and
Transportable Gas Containers
Regulations will apply to the
complete system.
e) Compressed air
network
distribution
Note: The Pressure Systems and
Transportable Gas Containers
Regulations will apply to the
complete system.
Other
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FUEL SUPPLY FOR LOW PRESSURE GAS (LPG) OR OIL40-10 40-10 PIPEWORK FOR LOW PRESSURE NATURAL GAS, LIQUEFIED
PETROLEUM GAS (LPG) OR OIL
The following tasks are to be carried out to all pipework within the designated areaAdded
Title NotesActionFQTitle FQ Action Notes
1b) Pipework
Oil
Visible oil feed pipes should be
inspected annually. Check for
leaks. Check sleeves and physical
soundness. Check all ends are
suitably plugged/capped.
Ensure the fill point drip-tray is
clean, free of water, debris and oil
before and after any oil delivery.
Some Regional requirements mean
some systems should be pressure
tested every 5 years where there
are joints in the system or every 10
years where there are no joints. In
environmentally sensitive areas an
alternative is to have a ‘pipe within a
pipe’ system incorporating a leak
detection and alarm system
12MAdded
2 b) Valves
Oil
Check for soundness and leakage.
Check all fire valves for cut off in
the event of a fire alarm, fire or
overheating
12MAdded
1. Pipework. Check for leaks. Check sleeves and
physical soundness. Check all ends
are suitably plugged/capped.
12M 1a. Pipework -
LPG
Pipework, flanges and fittings
should be inspected for corrosion
and damage. Particular care should
be paid to pipework where it passes
through supports and
walls. Pipework supports should be
checked to ensure that they are
secure and in satisfactory condition.
Thermal insulation should be
inspected for damage. Suspect
areas should be removed to allow
inspection of the pipe.
Gas detector tests should be
carried out in areas where gas can
accumulate and linger, e.g.
enclosed spaces, ducts and voids
and around the pipework entry to
buildings. Gas detector tests may
also be carried out on joints and
over known routes of underground
pipework.
Leak detection fluid may be used to
check exposed joints for leakage.
Soundness and leakage tests may
be carried out as specified in BS
5482 part 1 or LPGA Code of
Practice 1 part 1 or Code of
Practice 22 as appropriate
LPG pipework may, under certain
conditions, deteriorate and could
eventually leak. Such a leak may
result in a fire or explosion if the
LPG accumulates and an ignition
source is present.
Do not forget hidden pipework
where access is provided.
Gas detection instruments having a
scale that can detect to less than
10% of the lower explosive limit of
the gas in air in the pipework should
be used.
Check lists should be used as an
aid to ensuring that inspection and
tests have been carried out in
accordance with the strategy.
The competent person should
review the outcome of the
inspection and make
recommendations for changes to
the strategy as required.
12MTechnical
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2. Valves Check for soundness and leakage. See also VALVES in relevant
section.
12M 2 a) Valves LPG Check for soundness and leakage.
Emergency control valves should
be checked for accessibility and
operation
See also Valves SFG 6112MTechnical
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STEAM SERVICES40-11 40-11 STEAM SERVICES
WARNING - A Risk Assessment is required, before work starts, if Asbestos is thought to be present
STOP WORK, close off the area. Work can NOT re-start until until a Certified Safe to work Certificate
is recieved. If Asbestos is found, follow the Regulations.
The following tasks are to be carried out to all pipework within the designated area.Technical
Title NotesActionFQTitle FQ Action Notes
1. Hangers and
supports.
Check for breakages or damage. Undetected broken hangers can
lead to undue strain on pipes and
possible breakage or sagging which
can lead to waterlogging.
12M 2. Hangers and
supports.
Check for breakages or damage. Undetected broken hangers can
lead to undue strain on pipes and
possible breakage or sagging which
can lead to waterlogging.
12MOther
2. Valves and
flanges.
Check for leakage, replace packing
if necessary.
Where insulated, check valve boxes
for sign of dampness - there is
usually a small drainage hole at the
bottom of the flange or valve box.
Unchecked leakage wastes energy
and causes pipe corrosion.
12M 3. Valves, steam
valves and
flanges.
Check all valves within pipework
run for gland leakage where
possible at time of inspection adjust
or repack as required. Ensure
packing is the correct size and
material in accordance with
manufacturer’s recommendations.
Take all valves (excluding
regulating valves) through total
travel and return to correct position
Wisps of steam escaping soon lead
to bigger leaks which cause scoring
of stems and flanges leading to
early replacement
12Mtechnical
3. Insulation. Check for damage and loss of
protection. Renew if necessary.
Damage is often caused by ladders,
feet or emergency repairs - in open
air insulation can become
waterlogged and ineffective. N.B.
Asbestos Regulations may apply.
1M 4. Insulation. Check for damage and loss of
protection. Renew if necessary.
Damage is often caused by ladders,
feet or emergency repairs - in open
air insulation can become
waterlogged and ineffective.
Asbestos Regulations may apply.
See Insulation SFG35-01.
1MOther
4. Valves on
drain legs of
mains.
Check operation. If not working can lead to
waterlogging of steam mains, slow
start ups and overloading of steam
traps and poor heat transfer.
12M 5. Valves on
drain legs of
mains.
Check operation. If not working can lead to
waterlogging of steam mains, slow
start ups and overloading of steam
traps and poor heat transfer.
12MOther
5. Operation of
steam traps.
Check operation, condition of filters
and sight glasses.
Faults can lead to steam wastage,
excessive condensate, poor heat
transfer in associated equipment
and energy wastage.
1M 6. Operation of
steam traps.
Inspect steam trap sets, ensure
correct function and operation,
check isolating valves shut off,
clean trap set strainers.
Faults can lead to steam wastage,
excessive condensate, poor heat
transfer in associated equipment
and energy wastage.
1MOther
6. Vents on
steam lines.
Check operation. Presence of air in steam reduces
efficiency of heat exchangers.
12M 7. Vents on
steam lines.
Check operation. Presence of air in steam reduces
efficiency of heat exchangers.
12MOther
7. Steam valves. Renew packing on stems and
flanges where necessary.
Wisps of steam escaping soon lead
to bigger leaks which cause scoring
of stems and flanges leading to
early replacement.
12M Deleted
8. Condensate
services.
Check for pressure of continuous
discharge of steam. If present
check steam trips.
Condensate if uncontaminated is
valuable and should not be allowed
to run to waste but should be
returned to the boiler if economical
to do so. Where this is not possible
or is contaminated, it must be taken
to a foul drain or soakaway.
1M 8. Condensate
services.
Check for pressure of continuous
discharge of steam. If present
check steam trips.
Condensate if uncontaminated is
valuable and should not be allowed
to run to waste but should be
returned to the boiler if economical
to do so. Where this is not possible
or is contaminated, it must be taken
to a foul drain or soakaway.
1MOther
1 General Check all pipework for signs of
leaks, if possible repair and stem
leak
Do not forget hidden pipework
where access is provided.
3MAdded
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10. Pressure
reducing devices
Check PRD valve(s) for correct
function and operation, log
upstream and downstream
pressures.
12MAdded
11. Expansion
bellows
Check condition and alignment of
expansion bellows /compensators.
Report any defects.12MAdded
12. Sensors,
gauges, detectors
Ensure all pipeline mounted
detectors/sensors and gauges are
in good repair
12MAdded
13. Hit Hazards Inspect pipework run and where it
runs across or parallel to a
personnel access route. Highlight
any low points where heads could
be hit with the appropriate hazard
tape or paint
12MAdded
14. ID tags Check identification tags are
provided for all pipeline mounted
equipment, valves etc.
12MAdded
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40-12 FLASH STEAM VESSEL
If insulation looks damaged - stop work- this may be asbestos - appropriate action must be taken prior
to further works. If the insulation is known or certified not to be asbestos, continue as follows: -
Prior to carrying out the planned maintenance on the flash steam vessel, the pre-maintenance
procedure detailed below should be followed:
(a) At the entrance to the Plant room, stop and listen for a steam leak (high pressure steam will be
invisible and only the sound of a leak may be present)
(b) Check equipment operating status (i.e. whether in operation or not in use, whether isolated from
system) including safety.
Before starting maintenance be sure that the equipment is not pressurised or hot.
If any of the socket connections are not being used, they must be closed with an appropriate carbon
steel plug.
Added
Title NotesActionFQTitle FQ Action Notes
1. Vessel and
pipework
connections
Inspect for any leaks. The estimated lifetime under
satisfactory working conditions is 5
years ; after this period it is
recommended a wall thickness
examination is carried out using
appropriate inspection equipment.
Poor quality water or corrosive fluids
will reduce this period.
12MAdded
2. Check
insulation for
damage.
Repair or renew as necessary. Damaged lagging reduces
efficiency, wastes heat, and if the
vessel is in the open air, can
become waterlogged and lead to
hidden corrosion. Asbestos
regulations may apply.
12MAdded
3. Safety valveAdded
i. Safety valve -
Operational status.
Check by raising gagging lever to
discharge steam or air. Release
gagging lever to reseat. Check for
dirt or damage.
Check that discharge is to free
space or if piped, that pipe outlet is
not directed to personnel. Check
with insurance company for
frequency of mandatory checks.
3MAdded
ii. Safety valve -
Inspection
Strip down, overhaul and then
rebuild to comply with the
competent persons requirements
under the pressure regulations and
the written scheme of examination.
The competent person may require
additional testing on completion of
the rebuild.
12MAdded
4. Bursting discs
(if fitted).
Check condition, report. The competent person should be
contacted for the routine
replacement frequency for the
bursting discs.
12MAdded
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5. Isolating
valve(s)
Added
i. Operational
status.
Check by rotating hand wheel
sufficiently to ensure freedom of
movement. When fully open, close
valve 1/2 turn to ensure valve does
not jam.
3MAdded
ii. Gland leakage. Ensure correct packing material is
used for the fluid in the pipeline
After installation or replacement
check for gland leakage daily for
one week. Early signs of slight
leaks are due to `bedding in` or
drying out and are usually cured by
tightening of gland nuts.
Continuous leakage can lead to
erosion or corrosion of the valve
stem.
3MAdded
3. Overall
condition.
Inspect for external deterioration
due to leaks at end flanges or
aggressive environment.
Leakage from end flanges can be
due to pipe strains, poor joints or
pipe supports.
12MAdded
6. Float &
thermostatic
steam trap
Added
i) test Test that steam trap is working Test methods include listening
devices, optical sight glasses,
temperature monitoring, and
ultrasonic techniques.
3MAdded
ii) Cleaning Clean , ensure float is not leaking
and check seat of trap. If damaged
renew seat.
12MAdded
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40-13 EMERGENCY SOLENOID FUEL VALVES
Title NotesActionFQTitle FQ Action Notes
1. Emergency
Solenoid Fuel
Valves
Check operation and function of
emergency shut-off valves. Ensure
100% shut-off. Check valve
operation at each emergency
shut-off device (knock-off,
electro-thermal link, fire detector
etc.).
Ensure valve(s) is reset after
maintenance.
3MAdded
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40-15 PRESSURE REDUCING VALVES
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk.
Added
Title NotesActionFQTitle FQ Action Notes
Steam pressure
reducing valves
The written scheme of examination
may require the valves to be
stripped down, overhauled and then
rebuilt to comply with the Competent
Persons requirements under the
Pressure Regulation. If this is the
case it would make the task red.
Added
1. General
operation
Check unit operates without undue
noise or vibration.
3MAdded
2. Pipework Check all pipework supports are
secure.
3MAdded
3. Strainer and
steam traps
Remove, examine and clean
upstream strainer. Check operation
of all steam traps
3MAdded
4. Main valve
seat and valve
head.
Isolate and reduce pressure to
zero. Remove screen and clean,
clean gasket faces and renew
gasket.
The actual maintenance
requirements may vary with the type
of valve and the manufacturer`s
instructions should be followed
carefully.
12MAdded
5. Pilot valve
chamber
assembly.
Isolate and reduce air pressure to
zero. Check dimensions of plunger
gap and adjust if necessary.
The dimension of the plunger gap is
critical and it may be necessary to
grind or machine the top of the
plunger.
12MAdded
6. Pilot and main
diaphragms.
Thoroughly clean upper and lower
diaphragm chambers, ensure
contact faces are clean and
reassemble.
When refitting diaphragms make
sure that they are replaced the
same way round as when they were
removed.
12MAdded
Page 387 of 614
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40-16 WATER BUFFER/SURGE TANKS
In the context of Building Services the term surge or buffer tank is used to describe a closed vessel
which is used to increase the volume of LTHW or Chilled Water in a system and may be designed in
accordance with the Pressure Equipment Directive 97/23/EC.
This section covers the maintenance of the buffer tanks including mountings but is not intended to
cover the opening up of tanks for statutory insurance inspection (where required) which requires a
separate procedure, which may be carried out at the same time as the maintenance.
In accordance with good practice the operator should carry out a visual inspection of the buffer tank at
regular intervals and this should include checking for leaks.
Prior to carrying out the planned maintenance of the buffer tank, the pre-maintenance procedure be
followed:
(a) Check equipment operating status (i.e. whether in operation or not in use, whether isolated from
system) including safety.
(b) Inspect buffer tank 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.
Added
Title NotesActionFQTitle FQ Action Notes
1. Air Vents Where fitted check the operation of
the automatic air vent. Where
Manual vents are fitted open until
water is seen then close the vent
If buffer tank was in use, the water
may be hot and can be under
pressure, so care must be taken in
carrying out this item of the
schedule.
1MAdded
2. Drain
valve/drain cock
Draw off a small quantity of water to
remove any sediment.
If buffer tank was in use, the water
may be hot and can be under
pressure, so care must be taken in
carrying out this item of the
schedule.
6MAdded
3. Thermostats,
pressure sensors,
altitude gauges
and thermometers.
Check for correct operation and
settings, set against Certified
masters.
12MAdded
4. internal
surfaces of shell
and sacrificial
anode.
Isolate the buffer tank from the
system, drain down , remove
manhole covers and inspect for
scale formation and
corrosion.Where fitted, Check
status
Replace as necessary.
The calorifier will have to be drained
and opened up before the anode
can be inspected, therefore it
cannot be a pre-maintenance check
12MAdded
5. Put back into
operation
Refit all manhole covers, refill and
vent off air as required
12MAdded
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40-17 WATER MAINS - above ground
Title NotesActionFQTitle FQ Action Notes
1. Water Mains Check external water main for signs
of leaks, damage or deterioration of
pipework and supports.
6MAdded
2. Valves Rotate isolation valves through one
complete turn to detect leakage via
valve spindle stuffing box . When
fully open, close valve 1/2 turn to
ensure valve does not jam.
6MAdded
3. Insulation Ensure valves and pipework are
properly protected / insulated.
Report any problems to the client.6MAdded
4. Filter Remove and clean water main inlet
filter.
6MAdded
5. Manhole Covers Ensure manhole covers are in
position and are free from
mechanical damage.
Report any problems to the client.12MAdded
Page 389 of 614
PNEUMATICS
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PNEUMATIC RELAYS41-01 41-01 PNEUMATIC RELAYS
Electric to pneumatic, pneumatic to electric and pneumatic to pneumatic. Electric to pneumatic, pneumatic to electric and pneumatic to pneumatic.
Before any pressurised components are dismantled they should be effectively isolated from all
pressure sources and completely vented to atmosphere. Precautions should also be taken to guard
against the possibility of injury through sudden release of trapped springs.
If relays are found to be worn and service kits of seals are used to rebuild them, care should be taken
to check thoroughly the function of the rebuilt relay before placing it in the equipment. Incorrect seal
replacement can completely alter the function and if replaced in the equipment, could present a
serious hazard
Technical
Title NotesActionFQTitle FQ Action Notes
1. Input signal(s). Check. 6M 1. Input signal(s). Check.6MOther
2. Output
signal(s).
Check. By CONTROLS SPECIALIST6M 2. Output
signal(s).
Check.6MOther
3. Operation. Check for correct relationship
between input and output signals.
6M 3. Operation. Check for correct relationship
between input and output signals.
6MOther
Page 391 of 614
PORTABLE EQUIPMENT
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PORTABLE EQUIPMENT PAT TESTING42-01 42-01 PORTABLE APPLIANCE TESTING (PAT)
It is a requirement of the Electricity at Work Act 1989 (Regulation 4(2)) that portable electrical
equipment must be tested regularly (PAT testing) and records kept and equipment identified and
marked accordingly. See also ECA document, ref. P119204. Dependant on location the frequency
may be increased to 24m or more.
It is a requirement from April 1st 1990 the Electricity at Work Regulations 1989, in particular
Regulation 4(2), that "all systems shall be maintained so as to prevent, so far as is reasonably
practicable, danger" . Portable electrical equipment must be tested regularly (PAT testing) and records
kept and equipment identified and marked accordingly. See also ECA document, A GUIDE ON HOW
TO INSPECT AND TEST PORTABLE APPLIANCES SAFELY AND EFFECTIVELY.
The term `portable appliance` can be considered to be an appliance that is intended to be moved
while in operation or an appliance which can easily be moved from one place to another while
connected to the supply, e.g. vacuum cleaner, drill, hair dryer.
The intervals between both inspection and testing can be determined initially by assessing the risk
(the likelihood of danger arising), and will vary with the type of equipment, usage, and the nature of
the environment in which it is used. Also, the age of the equipment and previous test results need to
be considered. The frequency of inspection can be determined by experience and will generally be
more frequent than testing. More onerous conditions will demand more frequent inspection and testing
while less onerous conditions (and good inspection and test results) can lead to a reduced frequency.
The examples below follows the recommendations given in the IEE`s Code of Practice for In-Service
Inspection of Electrical Equipment and can be used until sufficient experience is built up to establish
what is appropriate to the circumstances.
1) Equipment hire external visual inspection – before and after return, full inspection & electrical
testing – before issue [unless earlier inspection indicates immediate testing is necessary.]
2Construction external visual inspection – before initial use and then 1 month, full inspection &
electrical testing – 3 months [unless earlier inspection indicates immediate testing is necessary.]
3) Industrial external visual inspection – before initial use and then 1 to 3 months, full inspection &
electrical testing – 6 – 12 months [unless earlier inspection indicates immediate testing is necessary.]
4) Commercial / Office external visual inspection – 6 months - 2 years, full inspection & electrical
testing – 6 months – 4 years [unless earlier inspection indicates immediate testing is necessary.]
5) Premises used by the public e.g. Hotels external visual inspection – 6 months - 2 years, full
inspection & electrical testing – 12 months – 4 years [unless earlier inspection indicates immediate
testing is necessary.]
6) Schools external visual inspection – 4 months – 1 year, full inspection & electrical testing – before
issue 12 months – 4 years [unless earlier inspection indicates immediate testing is necessary.]
N.B. For full details of tests to be carried out reference should be made to the IEE`S Code of Practice
technical
Title NotesActionFQTitle FQ Action Notes
1. Plug tops. Examine for: cracks, loose
terminals, reverse polarity,
tightness of cord grip, correct fuse,
earthing and bonding, loose tops,
any other defect.
Note: Details must be entered on
the portable appliance test register.
Where plug tops are accessible by
children, the use of shrouds on the
plug top pins is mandatory. Note
and report the use of any extension
leads or multi-way adapters. Client
should be encouraged to make
monthly checks.
12M 1) Mains Lead a) visual inspection
(b) mains plug for cracks, loose
terminals, reverse polarity,
tightness of cord grip, correct fuse,
earthing and bonding, loose tops,
any other defect
.
Pass condition: two layers of
insulation; BS colours; no damage;
correctly connected; cable clamp
gripped to sheath; correct fuse fitted
Where plug tops are accessible by
children, the use of shrouds on the
plug top pins is mandatory. Note
and report the use of any extension
leads or multi-way adapters. Client
should be encouraged to make
monthly checks.
0MTechnical
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2. Cables. Examine flexible cables for wear,
fraying braids and brittle insulation.
Check colour coding.
If replacement necessary, report to
client.
12M 2a) Detachable
mains lead
(a) visual inspection of equipment
male connector
(b) attempt to open socket without
tool
(c) attempt to pull socket cable from
female connector
(d) polarity of 3-pin units
Pass condition
BS type or equivalent
Unopenable
no movement
as per BS 4491
0MTechnical
3. Detachable
mains lead.
Check electrical condition and
security of attachment.
12M 2b)
grommet/clamp
around mains lead
(a) inspection of grommet
(b) sharp pull on cable
(c) rotation of cable
Pass condition
cable insulation protected
no appreciable movement
no rotation
0MTechnical
4. On-off switch. Inspect and check action.12M 4) Conducting
Case (a) visual inspection
b) resistance of earth connections
between plug and equipment.
(c) high voltage insulation 500V dc
minimum test
Pass condition
correct operation; no damage
earth resistance 0.1 ohms and
resistance of supply cable. Earth
resistance 0.5 ohms for luminaires
including resistance of the supply
cable
Insulation resistance of 0.5 M ohms
for
a Class 1 appliance and 1.0 M ohms
for
a class II appliance
0MTechnical
5. Insulating
case.
Inspect and check for damage. If double insulated, makers mark
should be visible, if in doubt carry
out flash test. Note: All double
insulated equipment must be tested
at least once every four years.
12M 5) Insulating case visual inspection Pass condition
maker`s double insulation mark
visible; case undamaged
If double insulated, makers mark
should be visible, if in doubt carry
out flash test. Note: All double
insulated equipment must be tested
at least once every four years
0MTechnical
6. Accessible
fuse holders.
Inspect and check rating.12M 6) Accessible fuse
holders
visual inspection
Pass condition
no damage removal of carrier does
not permit live [Live at more than
50V in use] part to be touched
0MTechnical
7. Exposed
output
connections.
Check condition, for outputs greater
than 50V test short circuit current.
Short circuit currents should be less
than 5mA, if greater than 5mA,
equipment must be labelled
Unsuitable for use by children where
GS23 of the Electricity at Work
Regulations 1989 applies.
12M 7. Exposed
output
connections.
Check condition, for outputs greater
than 50V test short circuit current.
Short circuit currents should be less
than 5mA, if greater than 5mA,
equipment must be labelled
Unsuitable for use by children where
GS23 of the Electricity at Work
Regulations
0MTechnical
Equipment HireAdded
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a). external visual
inspection
Frequency: before and after return0MAdded
b). full inspection
& electrical testing
Unless earlier inspection indicates
immediate testing is necessary.
Frequency: before issue0MAdded
ConstructionAdded
a). external visual
inspection
Frequency: before initial use and
then 1 month
0MAdded
b). full inspection
& electrical testing
Unless earlier inspection indicates
immediate testing is necessary.
3MAdded
IndustrialAdded
a). external visual
inspection
Frequency: before initial use and
then 1 to 3 months
0MAdded
b). full inspection
& electrical testing
Unless earlier inspection indicates
immediate testing is necessary.
Frequency: 6M-12M0MAdded
CommercialAdded
a). external visual
inspection
Frequency: 6 months - 2 years0MAdded
b). full inspection
& electrical testing
Unless earlier inspection indicates
immediate testing is necessary.
Frequency: 6 months – 4 years0MAdded
Premises used by
public e.g. hotels
Added
a). external visual
inspection
Frequency: 6 months - 2 years0MAdded
b). full inspection
& electrical testing
Unless earlier inspection indicates
immediate testing is necessary.
Frequency: 12 months – 4 years0MAdded
SchoolsAdded
a). external visual
inspection
Frequency: 4 months – 1 year0MAdded
b). full inspection
& electrical testing
Unless earlier inspection indicates
immediate testing is necessary.
Frequency: before issue 12 months
– 4 years
0MAdded
Page 395 of 614
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Testing For full details of tests to be carried
out reference should be made to
the IEE`S Code of Practice
For frequencies see examples
above
Added
3) Mains on/off
switch either 4 or
5, and 6
(a) visual inspection Pass condition
correct operation; no damage
0MAdded
8) Labels After each item of equipment is
tested mark it individually indicating
if it has passed or failed, the date of
the test and the date of the next
re-test
0MAdded
9) Log sheet The details of the tests and results
shall be recorded onto a log sheet,
suitable for recording the
information obtained from the test
and inspection carried out on that
item of equipment.
Check to ensure that the details
entered on the test label, fixed to
the equipment, tally with those
entered on the log sheet.
It is of paramount importance that a
record of maintenance, including
test results, is maintained
throughout the life of each item of
equipment. The provision of these
records will demonstrate that testing
has been carried out to an adequate
standard, and any difference
between subsequent tests can be
noted. Should these tests show a
deterioration in any part of the
equipment, remedial action is
necessary to ensure that danger
does not arise.
0MAdded
Page 396 of 614
POWER GENERATORS
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INTRODUCTORY PROCEDURES43-01 43-01 INTRODUCTORY PROCEDURES
Many premises have standby power generation equipment to provide back up in the event of
incoming power failures and there has been a tendency to 'fit and forget' with the result that the
equipment may fail to operate just when it is needed. Regular maintenance and testing is therefore
essential and should form part of any maintenance schedule. These units comprise a mechanical
prime mover, usually an oil or gas powered internal combustion engine, 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
prime mover should be carried out by specialist contractors.
A similar position arises with small scale combined heat and power units which are being introduced to
many sites, here the equipment can be divided into three sections, the prime mover, electrical
generation and heat recovery. This section covers the electrical generation equipment and the
equipment used for utilising the recovered heat is covered within HEAT EMITTERS. Again the prime
mover should be maintained by specialist firms.
Many premises have standby power generation equipment to provide back up in the event of
incoming power failures and there has been a tendency to `fit and forget` with the result that the
equipment may fail to operate just when it is needed. These units comprise a mechanical prime
mover, usually an oil or gas powered internal combustion engine, 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
prime mover should be carried out by specialist contractors.
A similar position arises with small scale combined heat and power units which are being introduced to
many sites, here the equipment can be divided into three sections, the prime mover, electrical
generation and heat recovery. This section covers the electrical generation equipment and the
equipment used for utilising the recovered heat is covered within Heat emitters SFG28. Again the
prime mover should be maintained by specialist firms.
Generating plant, in particular the engine system requires regular attention to ensure reliability,
optimum performance and long life. All maintenance procedures should be fully in accordance with
the generator set operating and maintenance instructions. A maintenance log book should be
established upon accepting the plant after commissioning. This should include a full record of
hours-run readings and a summary of all servicing and repairs carried out, together with fuel and
lubricating oil consumption totals.
Whatever the mode of operation, the generating plant must operate when called upon to do so.
Failure of the battery starting system will prevent the generator set starting and hence this needs
regular and frequent checking. Periodic maintenance recommendations from the supplier will normally
cover routine checks on a frequent basis (possibly after 100 hours of use or at monthly intervals)
depending upon various operating factors. More detailed maintenance, including replacement of items
such as lubricants, filters, belts and coolant, can be expected every, say, 500 hours. Major
maintenance activities are required typically after 5000 hours. This may involve a complete strip-down
of the engine, and inspection and replacement of worn or defective parts
Other
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POWER GENERATION--STAND-BY GENERATOR43-02 43-02 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 is recommended that plant should be run on load for a
minimum of four hours on a regular basis, or as required by Client..
Frequent running and testing of stand-by power generation equipment is essential to ensure
immediate availability at time of need. It is recommended that plant should be run on load for a
minimum of four hours on a regular basis, or as required by client.
Other
Title NotesActionFQTitle FQ Action Notes
10. Drive Belts Check belts for slackness,
alignment or wear, adjust as
necessary.
6MAdded
11. Battery
Charger
Check condition of battery charger,
inspect for damage. Open and
check on condition of wiring and
transformer insulation. Check on all
electrical connections, clean or
blow out. Test operation of any
ON/OFF or selector switches, test
accuracy of meters. Inspect or
renew if damaged any flying leads,
terminals or clips. Take insulation
and earth impedance test.
6MAdded
12. Anti freeze Add anti-freeze to cooling system or
check specific gravity as applicable
6MAdded
13. Fuel Filter Change the fuel filter element and
clean the filter bowl.
6MAdded
14. Air intake
grilles - alternator
Check that air intake grilles on
alternator are clean and
unobstructed. Remove cover from
non-drive and remove any fluff or
dirt that may have accumulated
around diode plates and exciter
assembly.
6MAdded
15 a) Electrical Check all electrical connections for
security. Examine brush gear in the
dynamo and starter and clean
commutator, renew brushes as
necessary.
Check operation of low oil and high
coolant shutdown switches
6MAdded
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15 b) Electrical Open all composite control panels
and associated switchgear. Clean
out interior of all panels. Inspect all
wiring for condition. Inspect all
terminations for security and
overheating. Visually check that an
efficient earth is being maintained.
Open, inspect and clean any
changeover switches on emergency
supply system. Check overloads
are functional and are set to correct
value. Ensure fuses of correct size
and type are fitted. Examine all
contacts for arcing and pitting,
dress or replace contacts as
applicable. Lightly lubricate all
contact faces with pure petroleum
jelly. Check relays for correct
function, replace any defective
components. Examine
switch-blades in isolators, ensure
they are free to move. Lubricate
pivots lightly with grease, ensuring
no grease comes into contact with
a conducting surface. Check for
smooth operation and that switches
are clearly marked. Before carrying
out the following test disconnect L.
V. circuits, i. e. rotating rectifier
diodes and A. V. R. circuits etc.
Carry out the following test:- a.
Insulation Resistance Test on
alternator and wiring. A figure of 1
megohm or above is acceptable. b.
Earth Loop Impedance Test on
alternator frame. Supply voltage =
Maximum allowed 3 X rating of
Fuse in amps, impedance in ohms
12MAdded
16. Operation and
auto-change
facility (where
applicable).
Check engine starter and solenoid
for good strong operation.
Check operation and starting
sequence.
6MAdded
17. Instruments Check that instruments are
functioning correctly and that glass
is clean.
6MAdded
18. Fuel transfer
pump
Check operation12MAdded
1.Condition. Visually inspect for oil leaks, loose
guards etc. Check: coolant level, oil
level,
These checks should be carried out
monthly by client's operators.
6M 1. General Visually inspect for oil leaks, loose
guards etc. Check: coolant level, oil
level,
These checks should be carried out
monthly by client`s operators.
1MTechnical
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2.Drive belts. Check fan and alternator drive belts
for wear, tension and alignment.
6M 2. Oil Check oil in sump using the dipstick
and top up oil if necessary
Ensure correct grade and type of oil
used in accordance with
manufacturers recommendations
1MTechnical
3.Shut down
switches.
Check operation of low oil and high
coolant shutdown switches.
6M 3. Oil Filter and oil Change oil filter elements and clean
oil filter bowls. Drain the sump and
refill with fresh clean oil. Check
operation of sump heater.
Ensure correct grade and type of oil
used in accordance with
manufacturers recommendations
6MTechnical
4.Low water
switch.
Check operation.6M 4. Coolant Check water level in the radiator,
top up if necessary. Check
operation of low water switch
pH (acidity) and S.G. (specific
gravity) should be checked regularly
by the operator.
1MTechnical
5.Coolant. Check coolant level. pH (acidity) and S.G. (specific
gravity) should be checked regularly
by the operator.
6M 5. Fuel tank Check that fuel tank is full Top up as required1MTechnical
6.Injector pump
drive belts.
Check wear and tightness.12M 6. General Run engine and check that oil
pressure is correct, if not trace and
repair fault. Check the electrical
output on the generator control
panel. Examine for any leaks of
coolant, fuel or lubricating oil, rectify
as necessary
Where practicable, generator should
be started under mains failure
conditions.
Run generator on load for 6 hours
per month. Test run should be at
least 50% load for a minimum of 2 -
4 hours
1MTechnical
7.Operation and
auto-change
facility (where
applicable).
Check operation and starting
sequence.
12M 7. Starter battery Check starter batteries are fully
charged. Top up with distilled water
as necessary. Inspect cells ensure
that vent holes in filter caps are
clear. Check that conducting bars
and cable connections are clean
and tight, any trace of verdigras to
be cleaned off and connections to
be coated with petroleum jelly. Take
random test or specific gravity and
cell voltage.
A battery should be fully discharged
and re-charged every six months.
Charge batteries as necessary (in
accordance with instructions in
operating log). Top up electrolyte
using pure distilled water, ensure
that cells are gassing freely whilst
charging. Charge batteries to 1250
s. g. and 2. 1 volts per cell, or
otherwise as specified. Re-check
specific gravity.
a. Electrolyte should be kept to 12
mm above plates, only pure distilled
water to be used for this purpose. b.
Topping up should be carried out
before charging to ensure good
mixing. c. Ventilation holes in filter
caps must be kept clean. d. A lead
acid battery is fully charged when s.
g. is 1250 and all cells are at 2. 4
volts. The battery cells should not
be allowed to fall below 1150 s. g. or
1. 8 volts. e. When the charging rate
is in doubt, a long slow charge is
better than a short sharp one
1MTechnical
8.Sump heater. Check operation.12M 8. Breather and air
cleaners
Examine and clean if necessary6MTechnical
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9.Fuel transfer
pump.
Check operation.12M 9. Bearings and
moving parts
Lightly grease the water pump
bearings and the clutch and power
take off bearings (if fitted).
Check all moving parts for smooth
operation, lubricate any pivoting
spindles as necessary.
.
6MTechnical
19 Load Bank
Testing
Carry out a load test of the
generator including a 110%
overload and 50% drop test
Load Bank Testing – It should be
reviewed and decided why do this
type of testing and what are its
benefits, versus the risks of not
doing this type of testing.
1) Can the facility`s critical load be
taken off line or placed onto a
generator backup in order to have
this type of testing performed?
2) Where will the load banks be
staged? What type of heat will be
generated and how will the added
heat affect the building? When
doing large system tests there will
be a large amount of heat
generated and that can affect
sprinkler systems if the load banks
are staged inside of the building.
3) Are doors going to have load
bank cables ran through them so
that the doors can not be locked or
used for normal use, this may
require extra security personnel
during testing?
In addition, on some older systems
it can make perfect sense to do a
system test with load banks in order
to re-calibrate the system and the
modules. On some of these older
systems that use calibration
potentiometers, these
potentiometers can drift out of
calibration over the years and by
performing a recalibration it will
insure that the system is operating
at peak performance
24MAdded
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BATTERIES - LEAD ACID - unsealed43-03 43-03 BATTERIES - LEAD ACID - unsealed
Caution: Lead acid batteries give off inflammable gases which can be explosive in confined spaces
therefore battery spaces must be well ventilated. Extinguish all naked lights before entering and no
smoking; PPE will be required. Refer to the COSHH Regulations for details - www.hse.gov.uk
Note This section is based on the requirements of the Code of Practice BS 6133 and all tools used for
maintenance must be insulated.
Caution: Lead acid batteries give off inflammable gases which can be explosive in confined spaces
therefore battery spaces must be well ventilated. Extinguish all naked lights before entering and no
smoking; PPE will be required. Refer to the COSHH Regulations for details - www.hse.gov.uk
Safety requirements for secondary batteries and battery installations BS EN 50272-2:2001 and BS EN
50272-1:2010 Safer Batteries
Legislative
Title NotesActionFQTitle FQ Action Notes
1. Cells. Test and record specific gravity of
electrolyte and top up if necessary.
Cells should normally be checked
on a monthly basis.Cell and
connector covers should be
replaced immediately work is
completed.
12M 1. Cells. Test and record specific gravity of
electrolyte and top up if necessary.
Check cell or monobloc battery
voltages
Cells should normally be checked
on a monthly basis. Cell and
connector covers should be
replaced immediately work is
completed.
1MLegislative
5.Ventilation. Check that ventilation of battery
space is adequate.
Report to client if remedial action is
required.
12M 5.Ventilation. Check that ventilation of battery
space is adequate, working and
clear of blockages etc.
Report to client if remedial action is
required.
12MOther
7. Battery charger Check voltage setting on the
charger
1MAdded
8. Vent plugs or
valves
Check6MAdded
9. Battery Check temperature of battery6MAdded
10. General Check for cleanliness and leakage1MAdded
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BATTERY CHARGING EQUIPMENT43-04 43-04 BATTERY CHARGING EQUIPMENT
Title NotesActionFQTitle FQ Action Notes
1. Condition. Check all external and internal dust
from the equipment. Check
paintwork for damage or corrosion,
clean and repaint as
necessary.Check security of door
fastenings and lock.
All ventilation holes and slots should
be clear to prevent overheating.
Cause of corrosion should be
determined.
12M 1. Condition. Check all external and internal dust
from the equipment. Check
paintwork for damage or corrosion,
clean and repaint as necessary.
Check security of door fastenings
and lock.
All ventilation holes and slots should
be clear to prevent overheating.
Cause of corrosion should be
determined.
12MOther
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UNINTERRUPTIBLE POWER SUPPLIES43-05 43-05 UNINTERRUPTIBLE POWER SUPPLIES
Because of the vital nature of uniterruptible power supplies the frequency of maintenance should be
agreed with the client, a minimum frequency of at least six months is recommended. It is emphasised
that this is specialist equipment which should be maintained strictly 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.
Because of the vital nature of uninterruptible power supplies the frequency of maintenance should be
agreed with the client, a minimum frequency of at least six months is recommended. It is emphasised
that this is specialist equipment which should be maintained strictly in accordance with the
manufacturer`s instruction
As this equipment is for use in emergencies, check with client that it is safe to proceed with
maintenance.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Cubicle. Check condition and clean, check
integrity of doors and panels,
including locks, Check for ease of
operation of switches, isolators and
circuit breakers, Check condition of
contractors see POWER
SUPPLIES.
All dirt and foreign bodies should be
removed.
6M 1. Cubicle. Check condition and clean, check
integrity of doors and panels,
including locks, Check for ease of
operation of switches, isolators and
circuit breakers. Check condition of
contactors see Power supplies
SFG44.
All dirt and foreign bodies should be
removed.
6MTechnical
5. Rectifier. Switch on and check:Battery trickle
charge voltage,Battery charge
voltage level.
Check and record calibration of all
meters on the equipment.
6M 5. Rectifier. Switch on and check: Battery trickle
charge voltage, Battery charge
voltage level.
Check and record calibration of all
meters on the equipment.
6MOther
8. Inverter. Switch on and check the Inverter
Control Unit control voltage. When
operating correctly, check and
record the output voltage and
frequency.
Compare with voltages recorded on
test certificate.Record the results
and report any significant
differences. Check and record the
calibration of all meters.
6M 8. Inverter. Switch on and check the Inverter
Control Unit control voltage. When
operating correctly, check and
record the output voltage and
frequency.
Compare with voltages recorded on
test certificate. Record the results
and report any significant
differences. Check and record the
calibration of all meters.
6MOther
a) lead acid, Check condition. See POWER GENERATION
BATTERIES.
6M a) lead acid, Check condition. See Power generation batteries
SFG 43-03.
6MTechnical
b) other types. Check condition and report to client
if replacement is required.
Batteries should be disposed of only
in accordance with H&S and
Environmental Regulations
recommendations.
6M b) other types. Check condition and report to client
if replacement is required.
Batteries should be disposed of only
in accordance with H&S and
Environmental
(www.hse.gov.uk/hthdir/noframes/co
shh/index.htm) Regulations
recommendations.
6MOther
Page 405 of 614
POWER SUPPLIES
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INTRODUCTORY PROCEDURES44-01 44-01 INTRODUCTORY PROCEDURES
The section on Power Supplies covers all those aspects of providing power to the point of use and
includes switchgear, cables and outlets operating at 415 volts and below. Areas needing particular
attention are contacts, starters, phase loading, maximum demand control and power factor correction
equipment. The latter two are particularly relevant in terms of energy saving and controlling electricity
costs where a client 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 nearest available power source. Unbalanced currents lead to
overheating of conductors, energy wastage and in extreme cases can be the cause of fires.
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.
This section on Power Supplies covers all those aspects of providing power to the point of use and
includes switchgear, cables and outlets operating at 415 volts and below. Areas needing particular
attention are contacts, starters, phase loading, maximum demand control and power factor correction
equipment. The latter two are particularly relevant in terms of energy saving and controlling electricity
costs where a client 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 nearest available power source. Unbalanced currents lead to
overheating of conductors, energy wastage and in extreme cases can be the cause of fires.
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 service providers should be sought for supplies above 415 Volts.
Check arc shields for the presence of asbestos containing material prior to dismantling any
equipment, if suspected STOP WORK. Take actions in accordance with the Asbestos Regulations.
Refer to www.hse.gov.uk.
Other
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MAIN SWITCH PANEL AT SUPPLY INTAKE44-02 44-02 MAIN SWITCH PANEL AT SUPPLY INTAKE
The frequencies for the tasks given below are guideline only and shall be individually assessed per
site. Suitable isolation to be undertaken prior to commencement of work.
Added
Title NotesActionFQTitle FQ Action Notes
1. General Carry out a visual inspection and
operational check. check for;
a) All contacts, fuse bridges, phase
barriers etc. for signs of
arcing/burning where accessible
without interrupting the supply.
b) Time clocks, timing relays etc.,
are at correct time/setting.
c) Where provided, all indicator
lamps are working, replace lamps
as required.
d) Check that all trunking, conduit
cable gland terminations are
secure, adjust accordingly.
e) Check all indicator gauges and
meters, check for cracked
glass/covers, replace as found.
f) Check correctness of labelling.
g) Check enclosures for holes and
damage.
Check arc shields for the presence
of asbestos containing material
prior to dismantling any equipment,
if suspected STOP WORK. Take
actions in accordance with the
Asbestos Regulations.
Refer to www.hse.gov.uk.
3MAdded
4. Panel Doors Check all door and cover gaskets.
Inspect door hinges and locks.
Lightly lubricate as found
necessary. Ensure all doors and
access panels can be securely
closed and locked.
12MAdded
11. Earth Bars Check all connections and bonding
to earth bars. Check earth bars and
insulators for security
12MAdded
13. Main
Connections
Check all connections using
infra-red equipment [thermal
imaging].
Must be on normal load24MAdded
1.Panel exterior. Check for physical or mechanical
damage. Touch up paintwork after
removing signs of corrosion.
12M 3.Panel exterior. Check for physical or mechanical
damage. Touch up paintwork after
removing signs of corrosion.
12MOther
2.Busbars. Check for visible signs of
overheating, loose connections etc.
12M 5.Busbars. Check for visible signs of
overheating, loose connections etc.
Check interior of busbar
compartments clean out dust and
dirt
12MTechnical
2.Busbars. Check for visible signs of
overheating, loose connections etc.
12M Deleted
3.Phase balance
and loading.
Check and report if phases are
unbalanced or overloaded.
Unbalanced phases and
overloading can lead to over-heating
of switchgear and cabling.
12M 6.Phase balance
and loading.
Check and report if phases are
unbalanced or overloaded.
Unbalanced phases and
overloading can lead to over-heating
of switchgear and cabling.
12MOther
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4.i)Main ACB. Check switching mechanism, Clean and lubricate as necessary.12M 7.i)Main ACB. Check switching mechanism, Clean and lubricate as necessary.
Check operation of incomer circuit
breakers, both manually and where
possible by simulating a fault via an
injection device
12MTechnical
4.ii) Main fuse
switch.
Check switching mechanism,12M 7.ii) Main fuse
switch.
Check switching mechanism,
Service, clean and lubricate
As per manufacturers
recommendations
12MTechnical
4.iii) Main MCCB. Check cable and busbar
connections.
Use torque spanner to panel
manufacturer's settings. Check
electrical impedance with approved
test instrument.
12M 7.iii) Main MCCB. Check cable and busbar
connections.
Use torque spanner to panel
manufacturer`s settings. Check
electrical impedance with approved
test instrument. Check operation of
incomer circuit breakers, both
manually and where possible by
simulating a fault via an injection
device
12MTechnical
4.iv) Main isolator. Check switching mechanism. Report any variation.12M 7.iv) Main isolator. Check switching mechanism.
Service, clean and lubricate
As per manufacturers
recommendations. Report any
variation.
12MTechnical
5.Instrumentation For specialised maintenance of
instrumentation see CONTROL
PANELS.
8.Instrumentation For specialised maintenance of
instrumentation see Control panels
SFG 14.
12MOther
6. Insulated
phase barriers.
Ensure that they are in place and
free from contamination.
12M 9. Insulated
phase barriers.
Ensure that they are in place and
free from contamination.
12MOther
7. Cabling
terminations.
Check all neutral, earth and
auxiliary connections and
terminations.
12M 10. Cabling
terminations.
Check all neutral, earth and
auxiliary connections and
terminations.
12MOther
8. General. Check for presence of moisture.
Remove any build up of dirt or
other contaminants. Check that
appropriate labels and warning
notices are clean and in place.
Report to client if significant.12M 12. General. Check for presence of moisture.
Remove any build up of dirt or other
contaminants. Check that
appropriate labels and warning
notices are clean and in place.
Look for obvious signs of
malfunction, such as overheating,
unusual odours, discolouration and
noise
Report to the client if significant.12MTechnical
2. General -
Thermal imaging
Check using thermal imaging and
inspect for signs of hot spots and
overheating.
12MAdded
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POWER DISTRIBUTION UNIT (PDU)44-05 44-05 POWER DISTRIBUTION UNIT (PDU)
Caution: 1. Before commencing any maintenance work on PDUs read the notes in the Introduction
2. Work must only be carried out by Competent persons
3. All work must be subject to risk assessment and formal method statements
4. Prior to testing, ensure to isolate voltage sensitive equipment.
Caution: 1. Before commencing any maintenance work on PDUs read the notes in the Introduction
section SFG 44-01.
2. Work must only be carried out by Competent persons
3. All work must be subject to risk assessment and formal method statements
4. Prior to testing, ensure to isolate voltage sensitive equipment.
The frequencies for the tasks given below are guideline only and shall be individually assessed per
site. Suitable isolation to be undertaken prior to commencement of work.
Other
Title NotesActionFQTitle FQ Action Notes
2. General -
Thermal imaging
Check using thermal imaging and
inspect for signs of hot spots and
overheating.
12MAdded
2.Mains
isolator(Door
isolator)
Check for correct operation and
interlock.
12M 3.Mains
isolator(Door
isolator)
Check for correct operation and
interlock.
12MOther
3.Busbars. Check for visible signs of
overheating, loose connections etc.
12M 4.Busbars. Check for visible signs of
overheating, loose connections etc.
12MOther
4.Insulating
barriers.
Check that insulating barriers are in
place, particularly over incoming
terminals.
12M 5.Insulating
barriers.
Check that insulating barriers are in
place, particularly over incoming
terminals.
12MOther
5.Power
contactors.
Check contactor for correct
mechanical and electrical
operation.strip and clean interior.
Inspect and clean magnetic pole
faces. Check moving contacts for
wear or 'pitting'. Check coil for over-
heating or insulation breakdown.
Clean out arc chutes.
Damaged contacts should be
redressed or replaced as necessary.
Use approved contact lubricant as
recommended by manufacturer.
Use approved contact lubricant if
recommended by the manufacturer.
On re-assembly check all electrical
connections.
12M 6.Power
contactors.
Check contactor for correct
mechanical and electrical
operation. Strip and clean interior.
Inspect and clean magnetic pole
faces. Check moving contacts for
wear or `pitting`. Check coil for
over- heating or insulation
breakdown. Clean out arc chutes.
Damaged contacts should be
redressed or replaced as necessary.
Use approved contact lubricant as
recommended by manufacturer.
Use approved contact lubricant if
recommended by the manufacturer.
On re-assembly check all electrical
connections.
12MOther
6.Starters, Frequency of maintenance will vary
depending on starting
duty/frequency of unit but in no
circumstances should it exceed
twelve months.
7.Starters, Frequency of maintenance will vary
depending on starting
duty/frequency of unit but in no
circumstances should it exceed
twelve months.
Other
-star delta,-two
speed-dual wound,
-two speed-pole
change,
-reversing, -auto
transformer.
See relevant sections. -star delta,-two
speed-dual
wound, -two
speed-pole
change,
-reversing, -auto
transformer.
See relevant sections in Starters
SFG 54.
12MTechnical
7.Thermal
overloads.
Inspect for signs of
overheating,Check electrical
connections for tightness and
security,
Replace if necessary after having
established the cause and rectify it.
12M 8.Thermal
overloads.
Inspect for signs of overheating,
Check electrical connections for
tightness and security,
Replace if necessary after having
established the cause and rectify it.
12MOther
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8.Magnetic
overloads.
Inspect for signs of overheating.
Check electrical connections for
tightness and security. Check oil
levels in dashpots, if cloudy or
sludge has formed, 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's
recommended fresh oil. Select
correct dashpot drain hole if
necessary. Adjust if necessary to
give correct protection for connected
load.
12M 9.Magnetic
overloads.
Inspect for signs of overheating.
Check electrical connections for
tightness and security. Check oil
levels in dashpots, if cloudy or
sludge has formed, 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`s
recommended fresh oil. Select
correct dashpot drain hole if
necessary. Adjust if necessary to
give correct protection for connected
load.
12MOther
9.Panel wiring. Inspect for signs of overheating or
burn marks. Replace any suspect
conductors. Check all connections,
terminations, earth cables and links
for security and tightness. Ensure
cable connections are tight and
correctly terminated. Check that the
panel is correctly bonded to earth.
12M 10.Panel wiring. Inspect for signs of overheating or
burn marks. Replace any suspect
conductors. Check all connections,
terminations, earth cables and links
for security and tightness. Ensure
cable connections are tight and
correctly terminated. Check that the
panel is correctly bonded to earth.
12MOther
10.Fuses and/or
miniature circuit
breakers (MCB).
Check for damage. Check for
correct rating. Check tightness of
fuse link connections. Check free
operation of MCB mechanisms.
Check for evidence of overheating.
Ensure spare fuses are not 'blown',
replace with correct rating schedule,
if necessary. Renew where
necessary.
12M 11.Fuses and/or
miniature circuit
breakers (MCB).
Check for damage. Check for
correct rating. Check tightness of
fuse link connections. Check free
operation of MCB mechanisms.
Check for evidence of overheating.
Ensure spare fuses are not `blown`,
replace with correct rating schedule,
if necessary. Renew where
necessary.
12MOther
11.General. Check for presence of moisture.
Remove any build up of dust or any
other contamination.
Report to client if significant.12M 12.General. Check for presence of moisture.
Remove any build up of dust or any
other contamination.
Report to the client if significant.12MOther
12.Instrumentation
. a)
ammeters and
voltmeters,
b) selector
switches,
Check for accuracy and correct
operation. Check for operation. Test
for operation.
Compare with Certified test
instrument applied to same circuit.
Replace as necessary
12M 13.Instrumentation
. a)
ammeters and
voltmeters,
b) selector
switches,
Check for accuracy and correct
operation. Check for operation. Test
for operation.
Compare with Certified test
instrument applied to same circuit.
Replace as necessary
12MOther
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EARTHING44-06 44-06 EARTHING
Danger can arise when removing a conductor connected to earth unless suitable precautions are
taken
Added
Title NotesActionFQTitle FQ Action Notes
1.Earth electrodes. Check: Integrity of conductor.
Associated connections. Condition
of electrode and soil.
Test in Accordance with method in
BS7430:1991.
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.
See BS7671 the IEE wiring
regulations.
12M 1.Earth electrodes. Check: Integrity of conductor.
Associated connections. Condition
of electrode and soil.
Test in Accordance with method in
BS
(www.bsi-global.com)7430:1998.
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.
See BS7671 the IEE
(www.iee.org.uk) wiring regulations.
12MLegislative
2.Residual current
devices (RCD)(to
BS 4293)
Test using test button. Responsibility for this check should
be agreed with the client.
3M 2.Residual current
devices (RCD)
Test using test button. Responsibility for this check should
be agreed with the client.
3MLegislative
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DISTRIBUTION BOARDS44-07 44-07 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 severe damage to cables and thus create a fire hazard.
Confirm details of any pre agreed disruption to electrical supplies.
It is essential to maintain the integrity of enclosures against the ingress of dust and vermin, the latter
can cause severe damage to cables and thus create a fire hazard.
Technical
Title NotesActionFQTitle FQ Action Notes
2.Cable insulation. Check condition and inspect for
signs of overheating.
If possible identify cause of
overheating and report.
12M 3.Cable insulation. Check condition and inspect for
signs of overheating.
If possible identify cause of
overheating and report.
12MOther
3. Fuse carriers
and MCBs
Check for damage,Check rating(s),
Check free operation of MCB
mechanisms,
Ensure fuses are not
'blown'.Replace with correct rating
as per schedule if necessary.
12M 4. Fuse carriers
and MCBs
Check for damage, Check rating(s),
Check free operation of MCB
mechanisms,
Ensure fuses are not `blown`. Any
fuses that are blown should be
replaced with correct rating as per
schedule
12MTechnical
4. Circuit charts. Check for accuracy of descriptions.
Ensure labels are securely fixed to
exterior of door.
12M 5. Circuit charts. Check for accuracy of descriptions.
Ensure labels are securely fixed to
exterior of door.
12MOther
5. Cable
terminations.
Check all phase, neutral and earth
connections and termination.
12M 6. Cable
terminations.
Check all phase, neutral and earth
connections and termination.
12MOther
6.Conduit and
cable gland
terminations.
Check for tightness.12M 7.Conduit and
cable gland
terminations.
Check for tightness.12MOther
7. RCDs. Check operation via test button. Responsibility for this check should
be agreed with the client.
3M 8. RCDs. Check operation via test button. Responsibility for this check should
be agreed with the client.
3MOther
2. General Locally isolate incoming electrical
supply. Open cover panels / access
doors. Check for signs of
overheating, unusual odours and
noises during operation. Remove
any build up of dirt and dust on
insulating components. Clean
equipment generally.
After all works [listed below]
completed securely refix cover
panels / access doors
12MAdded
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RING MAIN and SUB CIRCUITS44-08 44-08 ELECTRICAL INSTALLATION - GENERALLY
Carry out all work and provide all services required to all areas specified. Routine inspection work
includes inspection of installations generally in accordance with 17th Edition of IEE Regulations. Refer
to requirements of BS7671:2008. Testing should be carried out in the following sequence to the
relevant items: Continuity of protective conductors, main and supplementary bonding. Continuity of
ring final circuits. Insulation resistance. Site applied insulation. Protection by separation of circuit.
Protection by barriers or enclosures provided during erection. Insulation of non conducting floor and
walls. Polarity. Earth electrode resistance. Earth fault loop impedance. Operation or residual current
devices (RCD). Electrical testing should be carried out by a competent qualified electrician fully versed
in the system installed. The incoming supply to distribution switch boards must be isolated by locking
off LV circuit breakers, fuse switches and supplies from other distribution switchboards as detailed on
record drawings, as determined on site by the provider and as instructed by the client before any work
commences.
Installation should be checked with suitable, reliable test equipment. Precautions must be taken to
ensure tripped circuit devices cannot be accidentally closed, by either padlocking in the `OFF` position
or withdrawing the device as applicable. Where incoming supplies have been isolated, certain
auxiliary / control supplies may be `LIVE` due to external sources, e. g. Battery units.
It is essential that results from installation testing are recorded and the records are maintained and
updated annually.
Any electrical systems found to deviate from regulatory recommendation should be identified and
appropriate repair action taken.
Frequency shown is a guideline, actual frequencies will vary according to the type of installation, type
and use of building and the findings of any previous inspection.
Added
Title NotesActionFQTitle FQ Action Notes
1.Polarity and
continuity.
Check. Carry out checks in accordance with
IEE regulations.
12M 1. Small Power
Circuits/Outlets
Small Power Circuits/Outlets
Examine all small power outlets
within designated are, check for
damage and ensure any
disconnection switches operate
correctly, isolating electrical supply.
Check operation of RCD-protected
socket outlets by utilising Test
Button, reset RCD following Test.
12MAdded
2.Sockets. Test action and polarity of socket
outlets. Damaged socket outlets
must be replaced.
Ensure shutters are functioning
correctly.
12M Deleted
3.Earthing. Check arrangements and test. Carry out checks in accordance with
IEE regulations.
12M Deleted
4.Insulation
resistance.
Check.12M Deleted
Spur outlets Deleted
1.Condition. Check for physical damage.12M Deleted
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2.Fuse rating. If fused, check rating.12M Deleted
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44-10 ISOLATORS/STARTERS/FUSESWITCHES
The frequencies for the tasks given below are guideline only and shall be individually assessed per
site. Suitable isolation to be undertaken prior to commencement of work.
Added
Title NotesActionFQTitle FQ Action Notes
1. General Carry out a visual inspection and
operational check. check for;
a) All contacts, fuse bridges, phase
barriers etc. for signs of
arcing/burning where accessible
without interrupting the supply.
b) Check that all trunking, conduit
cable gland terminations are
secure, adjust accordingly.
c) Check correctness of labelling.
d) Check enclosures for holes and
damage.
e) Check enclosures and confirm IP
rating is suitable for location.
f) Check for correctness of labeling.
Check arc shields for the presence
of asbestos containing material
prior to dismantling any equipment,
if suspected STOP WORK. Take
actions in accordance with the
Asbestos Regulations.
Refer to www.hse.gov.uk.
3MAdded
2. General -
Thermal imaging
Check using thermal imaging and
inspect for signs of hot spots and
overheating.
12MAdded
3. Isolating
mechanism
Check switching mechanism.
Service, clean and lubricate
As per manufacturers
recommendations. Report any
variation.
12MAdded
4. Fault handling Check equipment to confirm fault
handling capabilities
12MAdded
5. General -
internal
Check interior of device, clean out
dust and dirt
12MAdded
Page 416 of 614
PUMPS
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PUMPS - General45-01 45-01 PUMPS - General
Title NotesActionFQTitle FQ Action Notes
1. Noise,
vibration and
overheating.
Check, rectify if possible and
report.
6M 1. Noise,
vibration and
overheating.
Check, rectify if possible and report.
Check all holding down bolts,
tighten if required.
Check casing for physical or
mechanical damage. Touch up
paintwork after removing signs of
corrosion
6MTechnical
2. Lubrication. Lubricate bearings and motors.6M 2. Lubrication. Lubricate bearings and motors.
Where suitable lubrication points
are provided – do not lubricate
bearings and motors that are fitted
with ‘sealed for life’ varieties. Seek
advice from manufacturer if in
doubt.
Use only oil / grease that is in
accordance with manufacturers
recommendations
6MTechnical
3. Drives, pulleys,
AV mounts and
drive couplings.
Check and adjust where necessary.6M 3. Drives,
pulleys, belts, AV
mounts and drive
couplings.
On belt driven pumps - Inspect and
adjust as required. Replace belts if
condition warrants it. Ensure motor
and drive and pulley are correctly
aligned
6MTechnical
7. Electrical
connections.
Check.12M 7. Electrical Check motor electrical terminals
and tighten as required.
Check electrical connections.
Check and record full load running
current and compare with
nameplate details .
Check function & operation of local
isolation device (stoplock/isolator).
Examine and report condition of all
associated wiring, ensure security
of all terminal connections and
check for
satisfactory condition of any flexible
cables/conduits.
Ensure plant has adequate earth
conductor and bonding is secure.
12MTechnical
8. Motor vent
slots.
Clear. Under certain conditions e.g. a dusty
environment, more frequent
cleaning may be required. (See also
MOTORS)
12M 8. Motor vent
slots.
Clear. Under certain conditions e.g. a
dusty environment, more frequent
cleaning may be required.See also
Motors SFG 39.
12MOther
9. Drive guards. Check and rectify security.12M 9. Drive guards. Check they are in place and
secure.
12MTechnical
10. Valves
Isolation,
regulation and
non-return valves
Check operation. Tighten glands or
repack if necessary
See Valves SFG61.12MAdded
11. Drain and
tundish (where
fitted)
Check for blockage, clean12MAdded
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12. Pump
Pressures
Check and Record12MAdded
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CIRCULATING PUMPS-general45-02 45-02 CIRCULATING PUMPS-general
Title NotesActionFQTitle FQ Action Notes
13. Drive guards.
(where fitted
Check they are in place and secure3MAdded
1. Casings. Inspect and clean as required.3M 1. Noise,
vibration and
overheating.
Check, rectify if possible and report.
Check all holding down bolts,
tighten if required.
Check casing for physical or
mechanical damage. Touch up
paintwork after removing signs of
corrosion
3MTechnical
2. Bearings and
glands.
Inspect for wear, lubricate bearings
and motors, repack glands as
required.
Report if defective.3M 2. Bearings and
glands.
Inspect for wear, lubricate bearings
and motors, repack glands as
required. Where suitable lubrication
points are provided – do not
lubricate bearings and motors that
are fitted with ‘sealed for life’
varieties. Seek advice from
manufacturer if in doubt
Use only oil / grease that is in
accordance with manufacturers
recommendations
Report if defective.
3MTechnical
7. Motor electrical
terminals.
Inspect and tighten as required. (See also MOTORS.)3M 7. Electrical. Check function & operation of local
isolation device (stoplock/isolator).
Examine and report condition of all
associated wiring, ensure security
of all terminal connections and
check for
satisfactory condition of any flexible
cables/conduits.
Ensure plant has adequate earth
conductor and bonding is secure.
Take and log motor current and
compare with nameplate details .
See also Motors SFG 39.3MTechnical
9. Pulley(s). Check and realign if necessary.3M 9. Pulley(s) if
Fitted.
Check and realign if necessary.3MTechnical
10. Isolation,
regulation and
non-return valves.
Check operation. Tighten glands or
repack if necessary.
3M 10. Valves
Isolation,
regulation and
non-return valves
Check operation. Tighten glands or
repack if necessary.
See Valves SFG61.3MTechnical
12. Anti-vibration
mounts.
Check and clean. Generally report any defects to
client.
3M 12. Anti-vibration
mounts.
Check and clean. Generally report any defects to the
client.
3MOther
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CENTRIFUGAL PUMPS45-03 45-03 CENTRIFUGAL PUMPS
Title NotesActionFQTitle FQ Action Notes
1. Casing. Inspect for external condition and
signs of leaks.
3M 1. Casing general
- Noise, vibration
and overheating
Inspect for external condition and
signs of leaks. Check casing for
physical or mechanical damage.
Touch up paintwork after removing
signs of corrosion.
Check all holding down bolts,
tighten if required.
Check, rectify if possible and report
3MTechnical
2. Glands and
mechanical seals.
Check external condition and leak
rate.
If there are signs of leaks, tighten
nuts or repack gland. Caution - do
not over tighten.
3M 4. Glands and
mechanical seals.
Check external condition and leak
rate.
If there are signs of leaks, tighten
nuts or repack gland. Caution - do
not over tighten.
3MOther
3.Valves, cocks
and drains.
Check externally for leaks. Rotate spindles and handwheels to
check freedom of operation,
examine drains for signs of gland
leakage.
3M 5.Valves, cocks
and drains.
Check externally for leaks. Rotate spindles and handwheels to
check freedom of operation,
examine drains for signs of gland
leakage. See Valves SFG61.
3MOther
4. Strainers and
exhausters.
Check external condition and
freedom of flow.
Check self priming action where
fitted.
3M 6. Strainers and
exhausters.
Check external condition and
freedom of flow.
Check self priming action where
fitted.
3MOther
5. Belt drives. Check for condition and alignment. Correct tensioning where necessary.3M 7. Belt drives. Check for condition and alignment.
Replace belts if condition warrants
it.
Correct tensioning where necessary.3MTechnical
6. Couplings,
pulleys, guards
and holding down
bolts.
Inspect and rectify any faults.3M 8. Couplings,
pulleys, guards
and holding down
bolts.
Inspect and rectify any faults.3MOther
7. Isolation of
pump from
electrical and
mechanical power.
Remove circuit supply fuses. For safety reasons pump should be
isolated before commencing work.
3M 2. Isolation of
pump from
electrical and
mechanical power.
Remove circuit supply fuses. For safety reasons pump should be
isolated before commencing work.
3MOther
8. Pump. Drain down and where applicable,
strip, test and adjust parts listed in
'notes' column. Lubricate and
grease.
Parts to be tested and adjusted
include: glands and packing, gland
compression springs, lantern rings,
seals, throwers, couplings, rubber
sleeves and pins, nuts and spring
washers.
3M 9. Pump. Drain down and where applicable,
strip, test and adjust parts listed in
`notes` column. Lubricate and
grease.
Parts to be tested and adjusted
include: glands and packing, gland
compression springs, lantern rings,
seals, throwers, couplings, rubber
sleeves and pins, nuts and spring
washers.
3MOther
9. Reassembly. Test functionally.3M 10. Reassembly. Test functionally.3MOther
3. Electrical Examine and report condition of all
associated wiring, ensure security
of all terminal connections and
check for
satisfactory condition of any flexible
cables/conduits.
Ensure plant has adequate earth
conductor and bonding is secure.
Take and log motor current and
compare with nameplate details
3MAdded
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11. Drain and
tundish (where
fitted)
Check for blockage, clean3MAdded
12. Pump
Pressures
Check and Record3MAdded
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PRESSURISATION PUMPS45-04 45-04 PRESSURISATION PUMPS
Title NotesActionFQTitle FQ Action Notes
7. Valves
Isolation,
regulation and
non-return valves
Check externally for leaks Rotate spindles and handwheels to
check freedom of operation,
examine drains for signs of gland
leakage.
See Valves SFG61.
3MAdded
8. Electrical Examine and report condition of all
associated wiring, ensure security
of all terminal connections and
check for
satisfactory condition of any flexible
cables/conduits.
Ensure plant has adequate earth
conductor and bonding is secure.
Take and log motor current and
compare with nameplate details
3MAdded
13. Pump
Pressures
Check and record3MAdded
1. Pump base
and connections.
Ensure pump base is level and
pipework not strained.
Check that anti-vibration mountings
are satisfactory and vibration is not
being transferred to the pipework.
3M 1. Casing general
- Noise, vibration
and overheating.
Ensure pump base is level and
pipework not strained. Check
casing for physical or mechanical
damage. Touch up paintwork after
removing signs of corrosion.
Check all holding down bolts,
tighten if required.
Check, rectify if possible and report
Check that anti-vibration mountings
are satisfactory and vibration is not
being transferred to the pipework.
3MTechnical
2. Strainer
elements.
Clean.3M 2. Strainer
elements.
Inspect and clean as required3MTechnical
4. Motors and
bearings.
Oil or grease where external
nipples or lubricators are fitted.
Use recommended grade of
lubricant. Motor should be
overhauled annually, see MOTORS.
3M 4. Motors and
bearings.
Oil or grease where external
nipples or lubricators are fitted.
Use recommended grade of
lubricant. Motor should be
overhauled annually. See also
Motors SFG 39.
3MOther
7. Control and
safety switches.
Inspect and check. These include low water level
cut-out switches, high and low
pressure sensing switches,
electrodes, connector caps and
contacts. Report any defects to
client.
3M 9. Control and
safety switches.
Inspect and check. These include low water level
cut-out switches, high and low
pressure sensing switches,
electrodes, connector caps and
contacts. Report any defects to the
client.
3MOther
8. Control,
pressure relief and
reducing valves,
air vents, purgers
and constant flow
regulators
Test for correct operation and
rectify any faults.
Report any defects to client.3M 10. Control,
pressure relief and
reducing valves,
air vents, purgers
and constant flow
regulators
Test for correct operation and
rectify any faults.
Report any defects to the client.3MOther
9. Diaphragm
expansion tanks.
Inspect. Ensure diaphragms are sound and
air cushion pressure is correct.
3M 11. Diaphragm
expansion tanks.
Inspect. Inspect where possible Ensure diaphragms are sound and
air cushion pressure is correct.
3MTechnical
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10.Test run
pressure booster
sets, pressurising
units, and filling
pump.
Carry out adjustments to ensure
satisfactory operation.
Check operation of all automatic
controls and change-over switches.
3M 12.Test run
pressure booster
sets, pressurising
units, and filling
pump.
Carry out adjustments to ensure
satisfactory operation.
Check operation of all automatic
controls and change-over switches.
3MOther
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ROTARY HAND PUMPS45-05 45-05 ROTARY HAND PUMPS
Title NotesActionFQTitle FQ Action Notes
1. Fixings and
hoses.
Check security and leak tightness.
Remedy any faults.
12M 1. Casing, fixings
and hoses
Check security and leak tightness.
Remedy any faults. Check casing
for physical or mechanical damage.
Touch up paintwork after removing
signs of corrosion.
12MTechnical
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SECONDARY HOT WATER CIRCULATING PUMPS45-06 45-06 SECONDARY HOT WATER CIRCULATING PUMPS
Title NotesActionFQTitle FQ Action Notes
1. Casing. Inspect and clean as required.6M 1. Casing general
- Noise, vibration
and overheating
Inspect and clean as required.
Check casing for physical or
mechanical damage. Touch up
paintwork after removing signs of
corrosion.
Check, rectify if possible and report
6MTechnical
2. Bearings,
glands and seals.
Inspect for wear, lubricate bearings
and motors, repack glands as
required.
Report if defective.6M 2. Bearings,
glands and seals.
Inspect for wear, lubricate bearings
and motors, repack glands as
required. Where suitable lubrication
points are provided – do not
lubricate bearings and motors that
are fitted with ‘sealed for life’
varieties. Seek advice from
manufacturer if in doubt.
Use only oil / grease that is in
accordance with manufacturers
recommendations. Report if
defective.
6MTechnical
3. Bolts, pulleys,
couplings and
belts (where
fitted).
Inspect and adjust as required.
Replace belts if condition warrants
it.
Ensure motor and drive and pulley
are correctly aligned. (See also
MOTORS
6M 3. Bolts, pulleys,
couplings and
belts (where
fitted).
Inspect and adjust as required.
Replace belts if condition warrants
it.
Ensure motor and drive and pulley
are correctly aligned. See also
Motors SFG 39.
6MOther
6. Isolation,
regulation and
non-return valves.
Check operation. Tighten glands or
repack if necessary.
6M 6. Isolation,
regulation and
non-return valves.
Check operation. Tighten glands or
repack if necessary.
See Valves SFG61.6MOther
8. Anti-vibration
mounts.
Check and clean. Generally report any defects to
client.
12M 8. Anti-vibration
mounts.
Check and clean. Generally report any defects to the
client.
12MOther
10. Full load
running current.
Check and record.12M 10. Electrical Examine and report condition of all
associated wiring, ensure security
of all terminal connections and
check for
satisfactory condition of any flexible
cables/conduits.
Ensure plant has adequate earth
conductor and bonding is secure.
Take and log motor current and
compare with nameplate details
12MTechnical
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SEWAGE OR DRAINAGE PUMPS SUBMERSIBLE45-07 45-07 SEWAGE OR DRAINAGE PUMPS SUBMERSIBLE
Title NotesActionFQTitle FQ Action Notes
1. Pump motor/s. Check insulation value of motor
windings.
For detailed maintenance schedule
see MOTORS. Advise client if
further investigation is required.
6M 2. Pump motor/s. Check insulation value of motor
windings.
For detailed maintenance schedule
see also Motors SFG 39. Advise the
client if further investigation is
required
6MTechnical
2. Pump/s. 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.
6M 3. Pump/s. Check pumping performance of all
pumps. Check impeller for wear
and blockages. Check seal
chamber oil. Drain sample of oil
from pump and check for moisture,
replenish/replace as required.
Check pump mountings
Visual observation of changing
levels satisfactory. Clean and report
as necessary. Renew if necessary.
6MTechnical
3. Valves. Check satisfactory operation of all
isolating and non-return valves.
See relevant section for more
detailed information on the
maintenance of valves.
6M 5. Valves. Check satisfactory operation of all
isolating and non-return valves.
See relevant section for more
detailed information on the
maintenance of valves. See SFG61
VALVES
6MOther
4. Controls
(operational).
Inspect and check. Report any defects to client.6M 6. Controls
(operational).
Inspect and check. Check operation
of float/level switch controls
Report any defects to the client.6MTechnical
5. Building
management
system controls.
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.
6M 7. Building
management
system controls.
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 see relevant
section BMS SFG 6.
6MOther
1. Casing general
- Noise, vibration
and overheating
Isolate pump(s) and withdraw form
sump. Visually inspect pump for
physical or mechanical damage.
Check pump intake is clear and
unobstructed. Clean pump casing
as required. Touch up paintwork
after removing signs of corrosion.
Check, rectify if possible and report
6MAdded
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4. Electrical Remove motor terminal covers,
check connections for tightness and
terminal block for damage or
dampness. Open starter and check
condition of wiring and contacts,
clean and blow out. Ensure that
overload devices are operational
and set for correct loading. Carry
out the following tests to all pumps
and record results:-a. Insulation
resistance test on wiring and
motors. b. Earth loop impedance
test on case or frame of units. c.
Load test on motors (start and run
current). Compare results with
manufacturers specification.
Check that power leads at motors
are undamaged and are securely
held.
6MAdded
8. Return pump to
service
Check sump is free of debris, clean
as required.
Replace pump(s) and check
operation before closing sump
6MAdded
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SEWAGE and DRAINAGE PUMPS: DRYWELL45-08 45-08 SEWAGE and DRAINAGE PUMPS: DRYWELL
Title NotesActionFQTitle FQ Action Notes
3. Casing general
- Noise, vibration
and overheating
Isolate pump(s) and withdraw form
sump. Visually inspect pump for
physical or mechanical damage.
Check pump intake is clear and
unobstructed. Clean pump casing
as required. Touch up paintwork
after removing signs of corrosion.
Check, rectify if possible and report
6MAdded
1. Drywell. Check for seepage, if necessary
pump out.
Report any excessive seepage to
client.
6M 1. Drywell. Check for seepage, if necessary
pump out.
Report any excessive seepage to
the client.
6MOther
2. Drywell high
level alarm.
Check for correct operation. If defective, report to client as soon
as possible.
6M 2. Drywell high
level alarm.
Check for correct operation. If defective, report to the client as
soon as possible.
6MOther
3. Valves. Check for satisfactory operation of
all isolating and non-return valves.
See relevant section for more
detailed information on the
maintenance of valves.
6M 4. Valves. Check for satisfactory operation of
all isolating and non-return valves.
See relevant section for more
detailed information on Valves
SFG61.
6MOther
4. Pump(s). Carry out maintenance. See PUMPS- GENERAL.6M 5. Pump(s). Check pumping performance of all
pumps. Check impeller for wear
and blockages. Check seal
chamber oil. Drain sample of oil
from pump and check for moisture,
replenish/replace as required.
See Pumps - general SFG456MTechnical
5. Pump
motor(s).
Check insulation value of motor
windings.
For detailed maintenance schedule
see - MOTORS. Advise client if
further investigation is required.
6M 6. Electrical and
Pump motor(s).
Check pump mountings. Remove
motor terminal covers, check
connections for tightness and
terminal block for damage or
dampness. Open starter and check
condition of wiring and contacts,
clean and blow out. Ensure that
overload devices are operational
and set for correct loading. Carry
out the following tests to all pumps
and record results:-a. Insulation
resistance test
on wiring and motors. b. Earth loop
impedance test on case or frame of
units. c. Load test on motors (start
and run current). Compare results
with manufacturers specification.
Check that power leads at motors
are undamaged and are securely
held.
For detailed maintenance schedule
see Motors SFG 39. Advise the
client if further investigation is
required
6MTechnical
6. Level or
pressure controls.
Check settings and test
functionally.
Report any defects to client.6M 7. Level or
pressure controls.
Check settings and test
functionally.
Report any defects to the client.6MOther
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7. Building
management
system controls.
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.
6M 8. Building
management
system controls.
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 see relevant
section BMS SFG 6.
6MOther
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SEWAGE PUMPS: COMPRESSED AIR45-09 45-09 SEWAGE PUMPS: COMPRESSED AIR
Title NotesActionFQTitle FQ Action Notes
1. Air
compressors.
Carry out maintenance, if
necessary pump out.
For detailed maintenance schedule
see PIPEWORK SYSTEMS.
6M 1. Air
compressors.
Carry out maintenance, if
necessary pump out.
For detailed maintenance schedule
see Pipework systems SFG 40-08
6MTechnical
2. Air receivers. Carry out inspection and
maintenance.
Note: The Pressure Systems and
Transportable Gas Containers
Regulations 1989 apply.
6M 2. Air receivers. Carry out inspection and
maintenance.
The Pressure Systems Safety
Regulations 2000 apply.
6MTechnical
3. Valves. Check for satisfactory operation of
all isolating and non-return valves.
See VALVES for more detailed
information about the maintenance
of valves.
6M 3. Valves. Check for satisfactory operation of
all isolating and non-return valves.
See relevant section for more
detailed information on Valves
SFG61.
6MTechnical
6. Controls
(operational).
Check settings and test
functionally.
Report any defects to client.6M 6. Controls
(operational).
Check settings and test
functionally.
Report any defects to the client.6MOther
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SUMP PUMPS: EXTENDED SHAFT45-10 45-10 SUMP PUMPS: EXTENDED SHAFT
Title NotesActionFQTitle FQ Action Notes
1. Motor. Check insulation value of windings,
clean ventilation slots and lubricate.
For detailed maintenance schedule,
see MOTORS.
12M 2. Electrical and
Pump motor(s)
Remove motor terminal covers,
check connections for tightness and
terminal block for damage or
dampness. Open starter and check
condition of wiring and contacts,
clean and blow out. Ensure that
overload devices are operational
and set for correct loading. Carry
out the following tests to all pumps
and record results:-a. Insulation
resistance test on wiring and
motors. b. Earth loop impedance
test on case or frame of units. c.
Load test on motors (start and run
current). Compare results with
manufacturers specification. Check
that power leads at motors are
undamaged and are securely held.
Check insulation value of windings,
clean ventilation slots and lubricate.
For detailed maintenance schedule
see also Motors SFG 39. Advise the
client if further investigation is
required
12MTechnical
2. Grease points
for extension
shaft.
Lubricate all bearings. Note and report any excessive
bearing noise.
3M 3. Grease points
for extension
shaft.
Check, rectify if possible and report Note and report any excessive
bearing noise.
3MOther
3. Pump/s. Check pumping performance of all
pumps. Withdraw pump from pit,
check impeller for wear and
blockages.
Visual observation of changing
levels satisfactory. Clean and report
condition as necessary.
3M 4. Pump/s. Check pumping performance of all
pumps. Check impeller for wear
and blockages. Check seal
chamber oil. Drain sample of oil
from pump and check for moisture,
replenish/replace as required.
Check pump mountings
Visual observation of changing
levels satisfactory. Clean and report
condition as necessary.
3MTechnical
4. Valves. Check satisfactory operation of all
isolating and non-return valves.
6M 5. Valves. Check satisfactory operation of all
isolating and non-return valves.
See relevant section for more
detailed information on Valves
SFG61.
6MTechnical
5. Controls
(operational).
Inspect and check. Report any defects to client.6M 6. Controls
(operational).
Inspect and check. Check operation
of float/level switch controls
Report any defects to the client.6MTechnical
6. Building
management
system controls.
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
maintenance see BMS Section.
6M 8. Building
management
system controls.
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 see relevant
section BMS SFG 6.
6MOther
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1. Casing general
- Noise, vibration
and overheating
Isolate pump(s) and withdraw form
sump. Visually inspect pump for
physical or mechanical damage.
Check pump intake is clear and
unobstructed. Clean pump casing
as required. Touch up paintwork
after removing signs of corrosion.
Check, rectify if possible and report.
12MAdded
7. Return pump to
service
Check sump is free of debris, clean
as required.
Replace pump(s) and check
operation before closing sump
6MAdded
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WATER PUMPING PRESSURE BOOSTING SETS45-12 45-12 WATER PUMPING PRESSURE BOOSTING SETS
Title NotesActionFQTitle FQ Action Notes
5. Electrical Check condition of local isolator,
open and clean if required. Remove
motor terminal covers, check
connections for tightness and
terminal block for damage or
dampness. Open starter and check
condition of wiring and contacts,
clean and blow out. Ensure that
overload devices are operational
and set for correct loading. Carry
out the following tests to all pumps
and record results:-a. Insulation
resistance test on wiring and
motors. b. Earth loop impedance
test on case or frame of units. c.
Load test on motors (start and run
current). Compare results with
manufacturers specification.
Check that power leads at motors
are undamaged and are securely
held
12MAdded
12. Valves Check operation. Tighten glands or
repack if necessary.
See relevant section for more
detailed information on Valves
SFG61.
3MAdded
1. Pump base
and connections.
Ensure pump base is level and
pipework not strained.
Check that anti-vibration mountings
are satisfactory and vibration is not
being transferred to pipework.
3M 1. Casing general
- Noise, vibration
and overheating.
Ensure pump base is level and
pipework not strained. Check
casing for physical or mechanical
damage. Touch up paintwork after
removing signs of corrosion.
Check all holding down bolts,
tighten if required.
Check, rectify if possible and report
Check that anti-vibration mountings
are satisfactory and vibration is not
being transferred to pipework.
3MTechnical
2. Strainer
elements.
Clean.3M 2. Strainer
elements.
Inspect and clean as required3MTechnical
4. Motors and
bearings.
Oil or grease where external
nipples or lubricators are fitted.
Use recommenced grade of
lubricant. Motor should be
overhauled annually, see MOTOR.
3M 4. Motors and
bearings.
Oil or grease where external
nipples or lubricators are fitted.
Use recommenced grade of
lubricant. Motor should be
overhauled annually. See also
Motors SFG 39.
3MOther
5. Drain holes,
pipes and tank.
Clean and ensure that all
blockages are cleaned.
3M 6. Drain holes,
pipes and tank.
Clean and ensure that all blockages
are cleaned. Check water level in
break tank.
3MTechnical
6. Guards and
shields
Check for security and safety. Adjust if necessary.3M 7. Guards and
shields
Check for security and safety. Adjust if necessary.3MOther
7. Control and
safety switches.
Inspect and check. These include low water level
cut-out switches, high and low
pressure sensing switches,
electrodes, connector caps and
contacts. Report any defects to
client .
3M 8. Control and
safety switches.
Inspect and check. These include low water level
cut-out switches, high and low
pressure sensing switches,
electrodes, connector caps and
contacts. Report any defects to the
client.
3MOther
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8. Control,
pressure relief and
reducing valves &
constant flow
regulators.
Test for correct operation and
rectify any faults.
Report any defects to client .3M 9. Control,
pressure relief and
reducing valves &
constant flow
regulators.
Test for correct operation and
rectify any faults.
Report any defects to the client.3MOther
9. Hydraulic
accumulator (if
fitted).
Inspect and check gas cushion
pressure and adjust as necessary.
Ensure diaphragms are sound. Use
oxygen free nitrogen for topping up
pressure as necessary.
3M 10. Hydraulic
accumulator (if
fitted).
Inspect and check gas cushion
pressure and adjust as necessary.
Ensure diaphragms are sound. Use
oxygen free nitrogen for topping up
pressure as necessary. Ensure any
discharge can not endanger others.
3MOther
10.Test pressure
booster sets.
Run and carry out adjustments to
ensure satisfactory operation.
Check operation of all automatic
controls and change-over switches.
3M 11.Test pressure
booster sets.
Run and carry out adjustments to
ensure satisfactory operation.
Check operation of all automatic
controls and change-over switches.
Ensure any discharge of Oxygen
free Nitrogen can not endanger
others.
3MTechnical
11. Building
management
system controls.
Simulate every function to ensure
satisfactory operation.
Reset after test, ensure that alarm
and operational information is
transmitted to delegated terminal.
See BMS.
3M 13. Building
management
system controls.
Simulate every function to ensure
satisfactory operation.
Reset after test, ensure that alarm
and operational information is
transmitted to delegated terminal.
See Building management systems
SFG 06.
3MOther
Page 435 of 614
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45-13 OGDEN STEAM PUMP
Check for asbestos containing material prior to dismantling any equipment, if suspected STOP
WORK, close off the area. Take actions in accordance with the asbestos regulations.
Refer to www.hse.gov.uk.
Added
Title NotesActionFQTitle FQ Action Notes
1. Operation check Carry out operation check in
accordance with manufacturers
instructions.
12MAdded
2. Vent and drain
lines
Ensure all drain lines and vent
pipes are clear.
12MAdded
3. Pump Strip, clean and overhaul pump,
check inlet, outlet and exhaust
valves and seats. Inspect float and
fulcrum pin assembly, check for
wear/damage, renew as required.
Refer to manufacturer`s hand book
before stripping down unit.
12MAdded
4. Steam traps
and pipework.
Examine interconnecting pipework
and steam trap/strainer assemblies,
check for correct operation,
clean/replace
strainer baskets as required.
12MAdded
Page 436 of 614
REFRIGERANT DISTRIBUTION SYSTEM
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REFRIGERANT DISTRIBUTION SYSTEM46-01 46-01 REFRIGERANT DISTRIBUTION SYSTEM
Personnel carrying out leak checking, gas recovery or other refrigerant handling activities such as
plant installation and maintenance must have a suitable refrigerant handling qualification. These
works are covered under EC Regulation 842/2006, Fluorinated Greenhouse Gases Regulations 2009
(FGG Regulations 2009)
Check for leaks should be part of the routine servicing. “Checked for leakage” means that the Joints,
valves including stems, seals, including seals on replaceable driers and filters, parts of the system
subject to vibration, connections to safety or operational devices of the equipment or system is
examined for leakage using direct or indirect measuring methods, focusing on those parts of the
equipment or system most likely to leak. The frequency of testing depends on refrigerant charge and
system type.
Systems containing: <3 kg no leak test required, 3 kg to 30 kg annual leak test required, 30 kg to 300
kg half yearly leak test required and >300 kg quarterly leak test required.
Hermetically sealed systems: <6 kg no leak test required, 6 kg to 30 kg annual leak test required, 30
kg to 300 kg half yearly leak test required and >300 kg quarterly leak test required.
These applications must also be checked for leakage within one month after a leak has been repaired
to ensure that the repair has been effective.
Plants with more than 300 kg must be fitted with a leakage detection system, which is defined as: “a
calibrated mechanical, electrical or electronic device for detecting leakage of refrigerants which, on
detection, alerts the operator”. The detection system must be checked at least once a year to ensure
proper functioning in line with manufacturers’ recommendations.
For any plant fitted with a leakage detection system (including those below the mandatory 300 kg
threshold), the frequency of leak checking can be halved, although an annual check remains the
minimum frequency.
ALWAYS UPDATE RECORDS
Added
Title NotesActionFQTitle FQ Action Notes
1. Leaks. Check for leaks should be part of
the routine servicing by plant
attendants.
Where a system has a refrigerant
charge greater than 300kg, an
automatic leak detection system
must be installed on the system to
comply with the F Gas Regulations
Added
A) Normal
systems:
<3 kg
Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
0MAdded
B) 3 kg to 30 kg Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
12MAdded
C) 30 kg to 300 kg Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
6MAdded
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D) >300 kg Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
3MAdded
E) Hermetically
sealed systems:
<6 kg
Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
0MAdded
F) 6 kg to 30 kg Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
12MAdded
G) 30 kg to 300 kg Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
6MAdded
H) >300 kg Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
3MAdded
1. Sight
glass(es).
Check operation and cleanliness.
Test for refrigerant leaks.
Sight glasses, which should be fitted
on any system, indicate refrigerant
level and the presence of moisture.
Faults which may be observed are:-
a) bubbles in sight glass indicating a
shortage of refrigerant or a
restriction in the liquid line, b) a
change in the colour of the moisture
monitor from green to yellow
indicates the presence of moisture
in the system.
3M 2. Sight
glass(es).
Check operation and cleanliness.
Test for refrigerant leaks.
Sight glasses, which should be fitted
on any system, indicate refrigerant
level and the presence of moisture.
Faults which may be observed are:-
a) bubbles in sight glass indicating a
shortage of refrigerant or a
restriction in the liquid line, b) a
change in the colour of the moisture
monitor from green to yellow
indicates the presence of moisture
in the system.
3MOther
2. Superheat
setting of
thermostatic
expansion valve
(TEV)
Check operation following the
sequence outlined in the 'notes'
column. To adjust, remove valve
cap at base of valve, turn adjusting
stem counter clockwise to lower the
superheat or clockwise to increase
the superheat. CAUTION: Only
make one turn of the stem at a
time.
a) measure temperature of the
suction line at the point where the
TEV bulb is clamped. b) read gauge
pressure at compressor suction
valve, c) add estimated pressure
drop between bulb location and
suction valve. d) convert the sum of
the pressures to the equivalent
temperature and subtract this from
the actual suction line temperature.
This difference is the superheat.
Note:- It can take thirty minutes for a
new balance to be achieved. Record
new setting, it should be between 8
and 10ºC.
3M 3. Superheat
setting of
thermostatic
expansion valve
(TEV)
Check operation following the
sequence outlined in the `notes`
column. To adjust, remove valve
cap at base of valve, turn adjusting
stem counter clockwise to lower the
superheat or clockwise to increase
the superheat. CAUTION: Only
make one turn of the stem at a
time.
a) measure temperature of the
suction line at the point where the
TEV bulb is clamped. b) read gauge
pressure at compressor suction
valve, c) add estimated pressure
drop between bulb location and
suction valve. d) convert the sum of
the pressures to the equivalent
temperature and subtract this from
the actual suction line temperature.
This difference is the superheat. It
can take thirty minutes for a new
balance to be achieved. Record new
setting, it should be between 8 &
10oC.
3MOther
3. Oil separators. 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 is on the oil separator.
12M 4. Oil separators. 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 is on the oil separator.
12MOther
4. Glycol
concentration.
Check, if low, restore to
recommended concentration.
A fall in concentration may be the
result of leakage and pipework
should be checked.
3M 5. Glycol
concentration.
Check, if low, restore to
recommended concentration.
A fall in concentration may be the
result of leakage and pipework
should be checked.
3MOther
4. Glycol
concentration.
Check, if low, restore to
recommended concentration.
3M 6. Glycol
concentration.
Check, if low, restore to
recommended concentration.
3MOther
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5. High and low
pressure switches.
Check on operation of pressure
switch contacts and re-adjust to
correct operating pressures as
necessary. On completion of tests -
disconnect air pressure or vacuum
equipment and alarm test set -
remake electrical supply and alarm
cables - test functionally - return to
service.
Apply correct pressure or vacuum
reading to coincide with pressure
switch operating limits, note
pressure or vacuum reading at
which pressure switch contacts
make on both upper and lower
limits. Pressure switch isolation
valves to be opened, where fitted.
12M 7. High and low
pressure switches.
Check on operation of pressure
switch contacts and re-adjust to
correct operating pressures as
necessary. On completion of tests -
disconnect air pressure or vacuum
equipment and alarm test set -
remake electrical supply and alarm
cables - test functionally - return to
service.
Apply correct pressure or vacuum
reading to coincide with pressure
switch operating limits, note
pressure or vacuum reading at
which pressure switch contacts
make on both upper and lower
limits. Pressure switch isolation
valves to be opened, where fitted.
12MOther
6. Insulation. Check:- External condition.
Soundness of vapour barrier and/or
waterproof finish. Condition of
flange and valve boxes including
internal linings and fasteners.
It cannot be stressed too heavily
that ingress of water vapour has
to be minimised otherwise efficiency
will be reduced and energy wasted.
Pay particular attention to seals
round hangers and supports. Look
for damage due to leaks. Check
paintwork and identification bands.
3M 8. Insulation. Check external condition.
Soundness of vapour barrier and/or
waterproof finish. Condition of
flange and valve boxes including
internal linings and fasteners.
It cannot be stressed too heavily
that ingress of water vapour has to
be minimised otherwise efficiency
will be reduced and energy wasted.
Pay particular attention to seals
round hangers and supports. Look
for damage due to leaks. Check
paintwork and identification bands.
3MOther
Page 440 of 614
ROOM AIR CONDITIONERS
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ROOM AIR CONDITIONERS unitary rev. cycle heat pump terminal units with
elec. htg. and rev. valve
47-01 47-01 ROOM AIR CONDITIONERS
Note: If unit is ceiling mounted cover office equipment immediately below any area of work . Room air conditioners [unitary reverse cycle heat pump terminal units with electrical heating and
reversing valve]
Personnel carrying out leak checking, gas recovery or other refrigerant handling activities such as
plant installation and maintenance must have a suitable refrigerant handling qualification. These
works are covered under EC Regulation 842/2006, Fluorinated Greenhouse Gases Regulations 2009
(FGG Regulations 2009)
Check for leaks should be part of the routine servicing. “Checked for leakage” means that the Joints,
valves including stems, seals, including seals on replaceable driers and filters, parts of the system
subject to vibration, connections to safety or operational devices of the equipment or system is
examined for leakage using direct or indirect measuring methods, focusing on those parts of the
equipment or system most likely to leak. The frequency of testing depends on refrigerant charge and
system type.
Systems containing: <3 kg no leak test required, 3 kg to 30 kg annual leak test required, 30 kg to 300
kg half yearly leak test required and >300 kg quarterly leak test required.
Hermetically sealed systems: <6 kg no leak test required, 6 kg to 30 kg annual leak test required, 30
kg to 300 kg half yearly leak test required and >300 kg quarterly leak test required.
These applications must also be checked for leakage within one month after a leak has been repaired
to ensure that the repair has been effective.
Plants with more than 300 kg must be fitted with a leakage detection system, which is defined as: “a
calibrated mechanical, electrical or electronic device for detecting leakage of refrigerants which, on
detection, alerts the operator”. The detection system must be checked at least once a year to ensure
proper functioning in line with manufacturers’ recommendations.
For any plant fitted with a leakage detection system (including those below the mandatory 300 kg
threshold), the frequency of leak checking can be halved, although an annual check remains the
minimum frequency.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Status. Isolate electrically. Note: Isolation of electrical
equipment should be carried out in
accordance with HSAWA
requirements.
6M 1. Status. Isolate electrically. Note: Isolation of electrical
equipment should be carried out in
accordance with HSAWA
(www.hse.gov.uk) requirements.
6MOther
2.
Heating/cooling
coil.
Remove air entry filter, inspect coil
for dirt and clean as required.
Remainder of unit should be
cleaned annually.
6M 2.
Heating/cooling
coil.
Remove air entry filter, inspect coil
for dirt and clean as required.
Comb any area of fins that are
damaged
Remainder of unit should be
cleaned annually.
6MTechnical
7. Refrigeration
circuit.
Check for leaks. Indicated by oil smears at joints.6M 7. Refrigeration
circuit.
Check for leaks. For more details
on checking for leaks see above
Indicated by oil smears at joints.6MTechnical
10. Controls. Return to standard settings.6M 10. Controls. Return to standard settings. Check
date and times.
On any hand held controllers check
battery and replace as required. All
batteries should be disposed of only
in accordance with H&S and
Environmental requirements.
6MTechnical
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12. Leaks. Check for leaks should be part of
the routine servicing.
Where a system has a refrigerant
charge greater than 300kg, an
automatic leak detection system
must be installed on the system to
comply with the F Gas Regulations
Added
A) Normal
systems:
<3 kg
Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
0MAdded
B) 3 kg to 30 kg Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
12MAdded
C) 30 kg to 300 kg Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
6MAdded
D) >300 kg Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
3MAdded
E) Hermetically
sealed systems:
<6 kg
Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
0MAdded
F) 6 kg to 30 kg Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
12MAdded
G) 30 kg to 300 kg Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
6MAdded
H) >300 kg Check for refrigerant leaks. Any
leak of refrigerant should be dealt
with immediately.
3MAdded
Page 443 of 614
SANITARY AND WASTE WATER PLUMBING
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INTRODUCTORY PROCEDURES48-01 48-01 INTRODUCTORY PROCEDURES
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
(HASAWA) 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 Documents - INDG197 and 198.
Weil's Disease (Leptospirosis)
This reportable disease is carried by rats and can be passed on to humans hence strict
precautions must 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 waste water or sewage.
Hospitals and similar facilities may call for specialist services, which should be identified and agreed
with the client.
Staff training must be up to date.
This section covers all aspects of the disposal of waste water and it is essential that both service
provider and client ensure that all actions and practices conform with the Health and Safety at Work
Act (HASAWA (www.hse.gov.uk)) 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.
HSE Documents - INDG197 and 198.
Weil`s Disease (Leptospirosis)
This reportable disease is carried by rats and can be passed on to humans hence strict precautions
must 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.
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 waste water or sewage.
Hospitals and similar facilities may call for specialist services, which should be identified and agreed
with the client.
Staff training must be up to date.
Other
Page 445 of 614
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MACERATORS48-02 48-02 MACERATORS
Title NotesActionFQTitle FQ Action Notes
1. Condition. Check: Condition of body and
attrition blades. Bearings. For
blockage and clear. Operation.
If there is evidence of severe wear
on the attrition blades, advise client
of need for replacement. If there has
been abuse or signs of jamming, by
for instance foreign objects, bearing
wear or distortion may be evident.
12M 1. Condition. Check: Condition of body and
attrition blades. Bearings. For
blockage and clear. Operation.
If there is evidence of severe wear
on the attrition blades, advise the
client of need for replacement. If
there has been abuse or signs of
jamming, by for instance foreign
objects, bearing wear or distortion
may be evident.
12MOther
2. Electrical
connections.
Check for tightness.12M 2. Electrical Examine and report condition of all
associated wiring, ensure security
of all terminal connections and
check for satisfactory condition of
any flexible cables /conduits. 2.
Check for adequate earth
conductor and bonding is secure. 3.
Check for satisfactory operation of
local electrical isolation device. 4.
Carry out Earth
Continuity/Insulation Resistance
Tests
12MTechnical
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INTERCEPTORS - Petrol and Oil48-03 48-03 INTERCEPTORS - Petrol and Oil
Note: Petrol filling stations are outside the scope of this specification. Where entry into confined
spaces is necessary, compliance with HSE Guidance note L101 Safe work in confined spaces 1997
and INDG 258 Work in confined spaces - is required. Staff training must be up to date.
Petrol filling stations are outside the scope of this specification.Where entry into confined spaces is
necessary, compliance with (www.hse.gov.uk) Guidance note L101 Safe work in confined spaces
1997 Approved code of practice, regulations and guidance 2nd edition (2009) and INDG 258 Work in
confined spaces - is required. Staff training must be up to date.
Legislative
Title NotesActionFQTitle FQ Action Notes
Petrol interceptors.
1. Condition of
tankage.
Check and report any significant
deterioration.
Take care not to inhale any fumes.12M 1. Condition of
tankage.
Check and report any significant
deterioration.
12MOther
2. Water. Clean surface and remove any
floating solids. Any surface
contamination by oily substances to
be removed by vacuum separately
from sedimentary solids.
Any liquid or solids removed during
the cleaning process must be
disposed of in accordance with H &
S and Environmental and water
byelaw regulations.
12M 2. Water. Clean surface and remove any
floating solids. Any surface
contamination by oily substances to
be removed by vacuum separately
from sedimentary solids.
Any liquid or solids removed during
the cleaning process must be
disposed of in accordance with H &
S
(www.hse.gov.uk/hthdir/noframes/co
shh/index.htm) and Environmental
and water byelaw regulations.
12MOther
Petrol interceptors.Added
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INTERCEPTORS - blowdown and sumps48-04 48-04 INTERCEPTORS - blowdown and sumps
Note: This subject comes within the scope of the HSE Guidance Notes PM60, L101 and PM5. Great
care must be taken when entering brick or concrete drainage pits because of the possible presence of
harmful gases. They must be vented to ensure the chamber cannot be pressurised over 0.1 bar g.
(1.5 psig). Where entry into confined spaces is necessary, compliance with HSE Guidance note L101
Safe Work in confined spaces 1997 and INDG 258 Work in confined spaces - is required. Staff
training must be up to date.
This subject comes within the scope of the HSE Guidance Notes PM60, L101 and PM5. Great care
must be taken when entering brick or concrete drainage pits because of the possible presence of
harmful gases. They must be vented to ensure the chamber cannot be pressurised over 0.1 bar g.
(1.5 psig). Where entry into confined spaces is necessary, compliance with (www.hse.gov.uk)
Guidance note L101 Safe Work in confined spaces 1997 Approved code of practice, regulations and
guidance 2nd edition (2009) and INDG 258 Work in confined spaces - is required. Staff training must
be up to date.
Legislative
Title NotesActionFQTitle FQ Action Notes
Blow down pits 1.
Cleaning.
ISOLATE FROM BOILER. Drain
and thoroughly clean out.
This work must only be carried out
by a competent person and
appropriate safety precautions must
be observed. The work may be
carried out at the same time as the
boiler inspection.
12M Blow down pits
1. Cleaning.
At every thorough examination of
the associated steam boilers, or at
such intervals determined by the
competent person, the blowdown
pit should be positively isolated (i.e.
double shut-off or by blank flange)
from the boiler(s) for examination
purposes. The electrical supply to
the automated intermittent
blowdown should be locked off and
, where fitted, any compressed-air
system should be isolated and
de-pressurised. The pit should then
be drained, thoroughly cleaned out
and examined. If the quality of the
boiler feedwater is poor, the
blowdown pit may require draining
and/or cleaning more often
This work must only be carried out
by a competent person and
appropriate safety precautions must
be observed. The work may be
carried out at the same time as the
boiler inspection.
12MTechnical
3. Vent pipe and
silencer (if fitted).
Check condition and ensure there
is no blockage.
If replacement or repair necessary,
advise client.
12M 3. Vent pipe and
silencer (if fitted).
Check condition and ensure there
is no blockage.
If replacement or repair necessary,
advise the client.
12MOther
Blow down tanks Note: these are pressure vessels
and as such come within the scope
of the Pressure Systems and
Transportable Gas Containers
Regulations 2000 . See also HSE
document L101.
Blow down tanks These are pressure vessels and as
such come within the scope of the
Pressure Systems and
Transportable Gas Containers
Regulations 2000 . See also HSE
document L101.
Other
Page 448 of 614
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1. Cleaning. ISOLATE FROM BOILER. Drain
and thoroughly clean out.
This work must only be carried out
by a competent person and
appropriate safety precautions must
be observed. The work is normally
carried out at the same time as the
boiler inspection.
12M 1. Cleaning. At every thorough examination of
the associated steam boilers, or at
such intervals determined by the
competent person, the blowdown
tank should be positively isolated
(i.e. double shut-off or by blank
flange) from the boiler(s) for
examination purposes. The
electrical supply to the automated
intermittent blowdown should be
locked off and , where fitted, any
compressed-air system should be
isolated and de-pressurised. The
tank should then be drained,
thoroughly cleaned out and
examined. If the quality of the boiler
feedwater is poor, the blowdown
tank may require draining and/or
cleaning more often
This work must only be carried out
by a competent person and
appropriate safety precautions must
be observed. The work is normally
carried out at the same time as the
boiler inspection.
12MTechnical
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SANITARY, WASTE WATER PLUMBING and DRAINS48-05 48-05 SANITARY, WASTE WATER PLUMBING and DRAINS
Title NotesActionFQTitle FQ Action Notes
Waste water
pipework and
traps. 1.
Condition.
Check cleanliness and ensure traps
etc. run free.
Where remedial work is required
advise client.
6M Waste water
pipework and
traps. 1.
Condition.
Check cleanliness and ensure traps
etc. run free.
Where remedial work is required
advise the client.
6MOther
Kitchen grease
traps
Inspect and remove any
accumulated grease and other
residues.
It is recommended that client should
ensure that his staff are familiar with
these traps and clean them at least
once per month and more frequently
if accumulations are severe.
1M Kitchen grease
traps
Inspect and remove any
accumulated grease and other
residues.
It is recommended that the client
should ensure that his staff are
familiar with these traps and clean
them at least once per month and
more frequently if accumulations are
severe.
1MOther
Sanitary fittings 1.
Urinals.
Inspect and clean, ensure grids on
waste are clear and outlet(s) run
freely.
6M Sanitary fittings 1.
Urinals.
Check for leaks and damage.
Check water level in cistern, adjust
float valve as necessary, check for
satisfactory cistern fill time. Check
water action around bowl rim.
Check security of all fixings and
brackets. Check function and
operation of urinal water saver unit,
ensure for correct operation/cycle
and water flow. Where dosing
system provided, check solenoid,
battery unit and operation of dosing
system generally.
6MTechnical
2. Water closets. Check condition and ensure correct
flushing and free outlet.
It is recommended that client should
ensure that his staff are familiar with
these traps and clean them at least
once per month and more frequently
if accumulations are severe.
6M 2. Water closets. Check for leaks and damage.
Check tightness of seat and flap,
flush and check water action
around bowl rim. Check water level
in cistern, adjust float valve as
necessary. Check for satisfactory
cistern fill time. Check security of all
fixings and brackets.
6MTechnical
3. Cisterns. Check operation and if necessary
replace washer on intake float
valve.
If water is running continuously
check diaphragm on siphon and
replace if necessary.
6M 4. Cisterns. Check operation and if necessary
replace washer on intake float
valve.
If water is running continuously
check diaphragm on siphon and
replace if necessary.
6MOther
4. Automatic
controls and
sensors.
Check operation. If controls are faulty refer to the
manufacturer's maintenance
instructions.
6M 5. Automatic
controls and
sensors.
Check operation. If controls are faulty refer to the
manufacturer`s maintenance
instructions.
6MOther
Soil stacks 1.
Obstructions.
Check that there are no
obstructions.
External examination should
conform to BSEN 752 - 4
6M Soil stacks
1. Obstructions.
Check that there are no
obstructions.
External examination should
conform to BS EN 752:2008
6MLegislative
Drainage 1.
Surface water
drains.
Check grates and clear of any
deposits and water flows freely.
Clear any sediments from grate
sumps. Check condition of junction
and access covers.
Advise client if any replacements
are necessary.
6M Drainage
1. Surface water
drains.
Check grates and clear of any
deposits and water flows freely.
Clear any sediments from grate
sumps. Check condition of junction
and access covers. For Rainwater
downpipes and gutters see SFG
48-07
Advise the client if any
replacements are necessary.
6MOther
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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.
2. Waste water
drains.
Carry out general inspection of all
designated drainage systems, this
should include: A). Check all waste
and rainwater discharge pipes. B).
Clean any silt build up from traps.
C). Remove inspection covers,
provide warning signs. Clean
cover(s) and frame(s). D). Observe
drainage flow in inspection
chamber and state of inspection
chamber. E). Replace cover,
cleaning out lifting keyholes, grease
and secure as necessary. F). Flush
out all drainage channels and
gulley’s.
Refer to both Environmental and
COSHH Regulations -
www.hse.gov.uk
If cleaning is required this should be
agreed with the client.
0MTechnical
3. Sinks / Basins Check basins/sinks for leaks and
damage. 2. Check traps and
overflows are free from
obstructions/soap build up etc. 3.
Check operation of taps, ensure
plug and chain are secure
6MAdded
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AIR ADMITTANCE VALVES48-06 48-06 AIR ADMITTANCE VALVES
Title NotesActionFQTitle FQ Action Notes
1. General. Air admittance valves which are
manufactured in accordance with an
Agrement certificate issued by
Board of Agrement do not normally
require maintenance.
1. General. Air admittance valves which are
manufactured in accordance with an
Agreement certificate issued by
Board of Agreement
(www.bbacerts.co.uk) do not
normally require maintenance.
Other
2. Inspection. Visually inspect externally for
mechanical damage or vandalism.
Report to client if remedial work is
required. In the event of accidental
damage or vandalism the cover can
be removed and the damaged
components or the complete
assembly replaced.
12M 2. Inspection. Visually inspect externally for
mechanical damage or vandalism.
Report to the client if remedial work
is required. In the event of
accidental damage or vandalism the
cover can be removed and the
damaged components or the
complete assembly replaced.
12MOther
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SANITARY AND WASTE WATER PLUMBING - WATER SAVING DEVICES
and METERS
48-08 48-08 SANITARY AND WASTE WATER PLUMBING - WATER SAVING DEVICES
and METERSTitle NotesActionFQTitle FQ Action Notes
2. Hydraulic
flushing control.
Check operation and carry out
maintenance procedures in
accordance with the manufacturer's
instructions.
6M 2. Hydraulic
flushing control.
Check function and operation of
water saver unit, ensure correct
operation/cycle and water flow.
Check for correct water action
6MTechnical
3. Detection
devices.
Check operation. For more detailed maintenance
instructions, see SENSORS.
6M 3. Detection
devices.
Check operation. Check security of
all fixings and brackets
For more detailed maintenance
instructions, see Sensors SFG 50.
6MTechnical
6. Cistern. Check warning pipe is
unobstructed.
6M 6. Cistern. Check warning pipe is
unobstructed. Check water level in
cistern, adjust float valve as
necessary, check for satisfactory
cistern fill time
6MTechnical
7. Battery (where
fitted).
Check remaining life, change as
necessary.
Replace battery according to
manufacturer's recommendations.
All batteries should be disposed of
only in accordance with H&S and
Environmental requirements.
6M 8. Battery (where
fitted).
Check remaining life, change as
necessary.
Replace battery according to
manufacturer`s recommendations.
All batteries should be disposed of
only in accordance with H&S and
Environmental requirements.
6MOther
Meters 1.
Installation
Check condition. Supply meter is normally the
responsibility of the water
undertaking and should be
maintained by them.
6M Meters
1. Installation
Check condition. Record readings
in logbook
Supply meter is normally the
responsibility of the water
undertaking and should be
maintained by them.
6MTechnical
7. Dosing system
(where fitted)
Where dosing system provided,
check solenoid, battery unit and
operation of dosing system
generally.
6MAdded
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SECURITY SYSTEMS
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SECURITY SYSTEMS-INTRUDER ALARMS49-01 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.
For security reasons when the client elects to have the maintenance carried out by the building
services, service provider, 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
service providers.
Other
Title NotesActionFQTitle FQ Action Notes
8. Control Panel Check control panel internally,
check all control devices, fuse
bridges, phase barriers etc. for
signs of arcing/burning. Check all
indication lamps are working,
replace any defective lamps. Check
panel door(s) can be securely
locked and that door isolation
device is operative.
Added
1.System integrity. Carry out external examination of
installation.
Any evidence of tampering or
damage should be recorded and
reported to the client.
12M 1.System integrity. Carry out external examination of
installation including any external
items including beacons and bells.
Any evidence of tampering or
damage should be recorded and
reported to the client.
12MTechnical
2.Sensors and
contacts.
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.
12M 2.Sensors and
contacts.
Carry out operational check. Test
each intruder detector for correct
operation and function. Check that
no obstacles have been moved
which could impair a detectors
‘view’.
External devices - check beam
systems are not impaired by
vegetation or other obstacles.
Confirm correct operation and
sensitivity, where appropriate check
spatial configuration for volumetric
devices.
12MTechnical
3.Alarm signals. Check response to signal.12M 3.Alarm signals. Check response to signal at control
panel. Reset alarm points after test.
12MTechnical
4.Sensor covers,
terminal boxes and
fixings.
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.
12M 4.Sensor covers,
terminal boxes
and fixings.
Examine and report condition of all
associated wiring, ensure security
of all terminal connections and
check for satisfactory condition of
any flexible cables/conduits. 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.
12MTechnical
7.Batteries 7.Batteries Check function and state of battery
charger. Check battery terminals
connections. Check that the
inter-cell connections are secure
and clean. Check state of charge.
12MTechnical
a) sealed lead
acid, b) sealed
nickel-cadmium.
Replace Batteries must be disposed of only
in accordance with H&S and
Environmental Regulations.
36M a) sealed lead
acid, b) sealed
nickel-cadmium.
Replace Batteries must be disposed of only
in accordance with H&S and
Environmental (www.hse.gov.uk)
Regulations.
36MOther
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SENSORS AND SWITCHING DEVICES
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PRE-MAINTENANCE PROCEDURES50-01 50-01 PRE-MAINTENANCE PROCEDURES
This procedure applies to all types of sensors, thermostats and requires that all safety precautions
and safe working practices be observed.
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.
Pneumatics. Particular attention should be paid to the quality of the instrument air. Check for
contamination by dirt, oil or water.
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, together
with sensors used in water treatment may 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.
This procedure applies to all types of sensors, thermostats and requires that all safety precautions
and safe working practices be observed.
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 or water.
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, together
with sensors used in water treatment may 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.
Other
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PRESSURE MEASUREMENT SENSORS - static and differential50-02 50-02 PRESSURE MEASUREMENT SENSORS - static and differential
Title NotesActionFQTitle FQ Action Notes
3. Operation. Check for correct operation. Check contact condition if a
pressure switch. Refer to
manufacturer s recommended
inspection procedures.
6M 3. Operation. Check for correct operation. Check contact condition if a
pressure switch. Refer to
manufacturer`s recommended
inspection procedures.
6MOther
4. Calibration. Check against Certified instrument. Refer to manufacturers
recommended calibration
procedures.
12M 4. Calibration. Check against Certified instrument
and reset as required
Refer to manufacturers
recommended calibration
procedures.
12MTechnical
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TEMPERATURE MEASUREMENT SENSORS50-03 50-03 TEMPERATURE MEASUREMENT SENSORS
Title NotesActionFQTitle FQ Action Notes
1. Sampling Check for any obstruction.12M 1. Sampling Check for any obstruction. Also
ensure the sensor is away from any
other form of heat source (radiator,
kettle photocopier) which may affect
temperature readings
Report any abnormal findings to the
client.
12MTechnical
4. Calibration. Check against Certfied instrument.12M 4. Calibration. Check against Certified instrument
and reset as required
12MTechnical
Outside
temperature
sensor
This should be on North Facing
surface or mechanical shaded if
not, but away from heat sources.
Report if not. Outside
temperature
sensor
This should be on North Facing
surface or mechanical shaded if
not, but away from heat sources.
Report if not.
Other
4. Calibration. Check against Certfied instrument.12M 4. Calibration. Check against Certified instrument
and reset as required
12MTechnical
4. Calibration. Check against Certfied instrument.12M 4. Calibration. Check against Certified instrument
and reset as required
12MTechnical
4.Calibration. Check against Certfied instrument.12M 4.Calibration. Check against Certified instrument
and reset as required
12MTechnical
3. Calibration. Check against Certfied instrument. Refer to manufacturer's
recommended calibration
procedures.
12M 3. Calibration. Check against Certified instrument
and reset as required
Refer to manufacturer`s
recommended calibration
procedures.
12MTechnical
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RELATIVE HUMIDITY SENSORS50-04 50-04 RELATIVE HUMIDITY SENSORS
Title NotesActionFQTitle FQ Action Notes
1. Sampling Check for any obstruction6M 1. Sampling Check for any obstruction. Also
ensure the sensor is away from any
other source of humidity (kettle,
washing machine etc.) which may
affect humidity readings
Report any abnormal findings to the
client.
6MTechnical
4. Calibration. Check against Certfied instrument.12M 4. Calibration. Check against Certified instrument
and reset as necessary
12MTechnical
4. Calibration. Check against Certfied instrument.12M 4. Calibration. Check against Certified instrument
and reset as necessary
12MTechnical
4. Calibration. Check against Certfied instrument.12M 4. Calibration. Check against Certified instrument
and reset as necessary
12MTechnical
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ABSOLUTE HUMIDITY SENSORS50-05 50-05 ABSOLUTE HUMIDITY SENSORS
Title NotesActionFQTitle FQ Action Notes
5. Calibration. Check against Certfied instrument.12M 5. Calibration. Check against Certified instrument
and reset as necessary
12MTechnical
5.Calibration. Check against Certfied instrument.12M 5.Calibration. Check against Certified instrument
and reset as necessary
12MTechnical
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CARBON DIOXIDE SENSORS50-07 50-07 CARBON DIOXIDE SENSORS
Title NotesActionFQTitle FQ Action Notes
4. Calibration. Check against Certfied instrument.12M 4. Calibration. Check against Certified instrument
and reset as necessary
12MTechnical
4. Calibration. Check against Certfied instrument.12M 4. Calibration. Check against Certified instrument
and reset as necessary
12MTechnical
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VELOCITY SENSORS50-08 50-08 VELOCITY SENSORS
Title NotesActionFQTitle FQ Action Notes
4. Calibration. Check against Certfied instrument. Refer to manufacturer's
recommended calibration
procedures.
12M 4. Calibration. Check against Certified instrument
and reset as necessary
Refer to manufacturer`s
recommended calibration
procedures.
12MTechnical
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OCCUPANCY and LIGHT SENSORS50-09 50-09 OCCUPANCY and LIGHT SENSORS
Title NotesActionFQTitle FQ Action Notes
3. Location. Check that sensor is not affected
by extraneous effects.
12M 3. Location. Check that sensor is not affected by
extraneous effects (i.e. shadows
from trees etc.)
12MTechnical
4. Calibration. Check against Certfied instrument. Refer to manufacturer's
recommended calibration
procedures.
12M 4. Calibration. Check against Certified instrument
and reset as necessary
Refer to manufacturer`s
recommended calibration
procedures.
12MTechnical
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SMOKE DETECTORS50-10 50-10 SMOKE DETECTORS
Title NotesActionFQTitle FQ Action Notes
1. Cleanliness. Check sensing device and where
appropriate sampling system for
cleanliness and possible
obstructions.
Refer to the manufacturer's
instructions for cleaning procedures.
12M 1. Cleanliness. Check sensing device and where
appropriate sampling system for
cleanliness and possible
obstructions.
Special attention should be paid to
areas that have had any building
works carried out to ensure smoke
heads have not been left `bagged
off` or there covers left in place. In
addition where areas have been
subject to any dusty conditions the
heads should be cleaned.
Refer to the manufacturer`s
instructions for cleaning procedures.
12MTechnical
2. Operation. Test for correct response and
operation.
Refer to manufacturer's instructions
for recommended testing
procedures. Some type of sensor
have a finite life cycle and need to
be replaced at intervals specified by
the manufacturer. Certain devices
such as ionisation detectors have no
serviceable components and should
not be exposed as a radioactive risk
may occur. Always refer to
manufacturer's instructions and
follow all recommended safety
procedures.
12M 2. Operation. Test for correct response and
operation.
Refer to manufacturer`s instructions
for recommended testing
procedures. Some type of sensor
have a finite life cycle and need to
be replaced at intervals specified by
the manufacturer. Certain devices
such as ionisation detectors have no
serviceable components and should
not be exposed as a radioactive risk
may occur. Always refer to
manufacturer`s instructions and
follow all recommended safety
procedures. For further guidance on
testing Smoke Detectors see Fire
alarm systems SFG 22-01 and be
carried out in accordance with BS
5839 part 1:2008
12MTechnical
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GAS DETECTOR SENSORS50-11 50-11 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, it is essential to refer to the manufacturer's instructions before
commencing any maintenance work on them.
Gas detectors are specialist devices and are often designed to detect a specific gas or family of
gases, e.g. propane or butane, it is essential to refer to the manufacturer`s instructions before
commencing any maintenance work on them.
Detailed guidance is provided for the maintenance of Gas Detectors in an explosive Atmosphere by
BS EN 60079-29-2:2007
technical
Title NotesActionFQTitle FQ Action Notes
2. Operation. Test for correct response and
operation.
Refer to manufacturer's instructions
for recommended testing
procedures.
12M 2. Operation. Test for correct response and
operation.
For Further Guidance See Fire
alarm systems SFG 22-01.
12MTechnical
Carbon Monoxide
Sensors
Added
Flammable Gases
and Oxygen
Sensors
It is assumed that the operational
staff will undertaken the routine
visual inspections of the installation.
Before proceeding with any
maintenance task, the operative is
to check the faults log for any
outstanding faults conditions.
Fixed gas detectors should be
included in the plant maintenance
schedule. The performance of most
detectors deteriorates with time, the
rate depending on the type of
sensor and the operating
conditions, for example a dusty,
corrosive or damp environment.
These factors will affect the
frequency of inspection,
maintenance and calibration
Repair or maintenance of fixed
apparatus (whether incorporating
single-point sensors, open path
sensors, a combination of these,
or sampling systems) should be
carried out under a control led
procedure. Defective apparatus
should be removed for repair in
a workshop outside the area being
protected. If a replacement
apparatus cannot be provided
immediately, then transport table
apparatus should be used as a
temporary substitute
Before any work is undertaken on
and sensor in a hazardous area,
ensure the notes in Hazardous
areas (electrics) SFG 27 are read
and fully understood. Ensure all
necessary local Permit to Work
procedures are fully complied with.
Added
Page 466 of 614
SEWAGE TREATMENT WORKS
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71-01 INTRODUCTORY PROCEDURES
Exposure to sewage or its products may result in a number of illnesses. These include:
1) Gastroenteritis, characterised by cramping stomach pains, diarrhoea and vomiting;
2) Weil’s disease, a flu-like illness with persistent and severe headache, transmitted by rat urine.
Damage to liver, kidneys and blood may occur and the condition can be fatal;
3) Hepatitis, characterised by inflammation of the liver, and jaundice;
4) Occupational asthma, resulting in attacks of breathlessness, chest tightness and wheezing, and
produced by the inhalation of living or dead organisms;
5) Infection of skin or eyes; and/or
6) Rarely, allergic alveolitis (inflammation of the lung) with fever, breathlessness, dry cough, and
aching muscles and joints.
If you contract the symptoms described after coming into contact with sewage, report to your doctor
immediately and advise him/her of the circumstances.
The bacteria can enter your body through cuts and scratches and through the lining of the mouth and
throat and eyes.
After having worked in sewage or anything contaminated with sewage, wash your hands and forearms
thoroughly with soap and water. If your clothes or boots are contaminated with sewage, wash
thoroughly after handling them.
Take immediate action to wash thoroughly any cut, scratch or abrasion of the skin immediately. Apply
antiseptic to the wound, cover with cotton wool or gauze, and protect with a waterproof plaster.
Do not handle food, drink or smoking materials without first washing your hands.
Sewage gases are potentially explosives and toxic. Do not enter any of the below ground
compartments of the sewage treatment plant.
Before carrying out any maintenance work, the equipment MUST be electrically isolated at the fuse
box from which the blower power supply is derived.
Do not leave covers open for any longer than necessary. Temporary barriers and warning signs
should be erected around any open covers or manways as appropriate.
Added
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71-02 SEWAGE TREATMENT WORKS - package systems
Title NotesActionFQTitle FQ Action Notes
1) Air Blowers Check the operation of the
blower(s).
1WAdded
2) Diffusers Check the operation of the diffusers
(bubbles rising in the Biological
zone).
1MAdded
3) Recycle Flow Check the recycle flow into the inlet
zone. Look at the liquor being
returned, it should run clear by the
end of its cycle.
1MAdded
4) Stilling Zones Check the inlet and outlet stilling
zones are clear of debris( remove
any obstructions ).
1MAdded
5) Air Blowers Check the blower ventilation is
un-obstructed.
1MAdded
6) Filter Media Check the biomass growth on the
filter media. The biomass should be
a light brown colour, not white or
grey.
The odour in the plant should be
`earthy`. here should not be a
noticeable `rotten eggs` smell.
1MAdded
7) Effluent Check the final effluent. If this is
cloudy or contains many
suspended articles, then the humus
tank is likely to require desludging.
1MAdded
8) Pre-settlement
Tank
Inspect sludge level and remove
sludge when the level is reached as
dictated by the manufacturers
recommendations.
This frequency could be increased
to 6M depending on usage and type
of system.
12MAdded
9) Cabling, wiring
and control panel
Check all connections are tight and
that the cable is in good condition.
Check electrical door isolating
switch for correct operation. Check
cabinet door locks for correct
operation. Clean any dust/debris
away from the inside of the cabinet
with soft brush.
12MAdded
10) Inlet Pump The inlet pump must be serviced
and cleaned.
Make sure that the pump works by
checking that it pumps water into
the treatment chamber.
12MAdded
11) Overflow Alarm Clean and check for correct
operation.
12MAdded
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12) Air Blowers The air blowers must be inspected
and their condition noted. The filters
at the top of the air blowers must be
removed and cleaned. Check that
air bubbles surface evenly
throughout the system. Be aware of
abnormal noises. Replace the
filters if they cannot be cleaned
effectively.
The filters must be open and easy
to blow air through after cleaning.
12MAdded
13) Biofilm The biofilm coating on the bioblock
media must be inspected to ensure
there is a healthy level of biomass
on the media. The aeration system
and diffusers must be inspected
and the dissolved oxygen content
measured and recorded. The
bioblock media should be evenly
aerated. It is normal that the
intensity of the air bubbles differs
from one side of the system to
another.
When the system is performing
properly the bioblock media should
not need to be routinely cleaned. A
healthy level of biofilm on the media
is beneficial to increase the
available surface area and there
should be sufficient aeration coming
from the diffusers to prevent
excessive biofilm building up.
However, if the media does need to
be cleaned the level of aeration can
be increased. In severe problem
situations, the water level can be
reduced and the bioblock cleaned
with a pressure washer or the
bioblock media can be removed
cleaned and replaced.
12MAdded
14) Controls Check that the controller is
operating properly and that alarm is
triggered by loss of power to the air
blowers and pump and by high
water in the pump tank.
12MAdded
15) Water
dispersal
Inspect the system outlet to make
sure that it is flowing freely and
unimpeded from debris or
vegetation. Record any likely future
restrictions to the water outlet or
possible threats.
12MAdded
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71-03 SEWAGE TREATMENT WORKS - EXTENDED AERATION AND OXIDATION
DITCH SYSTEMSTitle NotesActionFQTitle FQ Action Notes
1. General Make general observation to ensure
proper operation of equipment.
1DAdded
2. Clarifier Remove floating sludge on clarifier
if present and clean clarifier weir.
1DAdded
3. Test & Records Check dissolved oxygen readings
for unusual values. Perform simple
cone test to give sludge
settleability; and record hours of
operation of individual processes.
A simple cone test using an Imhoff
cone may be carried out every day,
but these results must be used with
caution and will only show up
sudden changes in sludge
characteristics.
1DAdded
4. Sludge return
rate
Adjust sludge return rate and air
injection rate as necessary.
1WAdded
5. Pumps and
Motors
Alternate duty/standby
motors/pumps.
1WAdded
6. Oxygen probes Clean and calibrate dissolved
oxygen probes.
1WAdded
7. Tests Carry out chemical tests as
appropriate (COD, phosphates
etc.).
Carry out Sludge Volume Index
(S.V.I.) test.
Sludge Volume Index (S.V.I.) - the
importance of the SVI test needs to
be stressed as it gives valuable
information on sludge settleability
and it indicates if sludge needs to
be wasted.
1WAdded
8. Aerators /
blowers
Inspect aerators/blowers and
maintain as necessary.
1MAdded
9. Sludge return
pumps
Inspect and maintain inflow and
sludge return pumps.
1MAdded
10. Electrics Inspect and maintain electrical
equipment.
1MAdded
Rotating Biological
Contactors &
Percolating Filters
In general, RBCs and percolating
filter systems require less operation
and maintenance hours per week
than extended-aeration systems.
Added
11. General Examine blockage by rags etc., if
system has no screening.
Make general inspection of system
operation noting any noises from
mechanical plant.
1DAdded
12. Screens Rake screens, if applicable.1DAdded
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13. Clarifier Remove floating sludge from final
clarifiers surface.
1DAdded
14. Biofilm Examine and record biofilm
appearance (colour and thickness),
grey/black could indicate lack of
oxygen, beige/brown indicates
carbonaceous oxidation- reddish
brown indicates nitrification.
1WAdded
15. Distributor
Openings
Clean distributor openings (in
percolating filter systems).
1WAdded
16. Sludge Return sludge from clarifier to
primary settlement tank.
1WAdded
17. Percolating
Filter
Examine surface of percolating filter
for ponding.
1WAdded
18. Bearings Grease all bearings.1WAdded
19. Tests Carry out chemical tests as
appropriate (BOD, COD,
phosphates etc.).
1WAdded
20. Bearings Inspect shaft and bearings in RBC
system.
Added
21. Motors Check oil levels in motors.Added
22. Sludge return
pumps
Inspect and maintain inflow and
sludge return pumps.
1MAdded
23. Electrics Inspect and maintain electrical
equipment.
1MAdded
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Sequencing Batch
Reactors
These incorporate all phases of the
treatment process in one reactor
and are operated on a cyclical
basis, often incorporating several
cycles in oiie day. The phases are
operated in the following sequence:
filtration; aeration; settlement;
decanting They are high technology
systems and are generally only
used above 100 population
equivalent. Equipment includes,
pumps, aeration plant
(compressor/blower or mechanical
aerators), decanting equipment and
sludge draw off plant. Although they
are high technology systems, they
do not require sludge return and as
such their operation is simpler than
extended-aeration systems.
Added
24. General Make general observation to ensure
proper operation of equipment.
1DAdded
25. Test &
Records
Perform simple cone test to give
sludge settleability; and record
hours of operation of individual
processes.
A simple cone test using an Imhoff
cone may be carried out every day,
but these results must be used with
caution and will only show up
sudden changes in sludge
characteristics.
1DAdded
26. Blowers Check oil level of blowers if
applicable and top up if required.
Added
27. Bearings Grease all bearings1WAdded
28. Pumps and
Motors
Alternate duty/standby
motors/pumps.
1WAdded
29. Tests Carry out chemical tests as
appropriate (COD, phosphates
etc.).
Carry out S.V.I. test
1WAdded
30. Cycle times adjust cycle times to optimise
performance
1MAdded
31. Electrics Inspect and maintain electrical
equipment.
1MAdded
32. Sludge waste sludge as necessary.
(generally when MLSS exceeds
4500-5000, mg/l).
1MAdded
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Constructed
Wetlands
There are two types of constructed
wetlands; horizontal flow and
vertical flow wetlands. The
horizontal flow wetlands can be
subdivided into two categories:
a) free water surface wetlands
(FWS)
b) subsurface flow system wetlands
(SFS).
Added
33. General Examine distribution pipes and
channels for blockages (especially
in secondary wetlands).
1WAdded
34. Testing Carry out chemical tests as
appropriate
1WAdded
35. System Clean out all distribution
openings/notches, lower adjustable
outlet level to flush out pipes; and
desludge primary/septic tank as
necessary (for secondary
wetlands).
1MAdded
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71-04 DRAINAGE FIELDS
BS 6297:2007+A1:2008 gives recommendations and guidance on the design and installation of
drainage fields and infiltration systems for use in wastewater treatment. BS 6297 is applicable to
systems for handling discharges from domestic and commercial sources from single households and
upwards. These sources are typically septic tanks and package treatment plants.
Added
Title NotesActionFQTitle FQ Action Notes
1) Inspection Inspect drainage field to check that
it is not water logged and that
effluent is not backing up into the
upstream system.
Particular care should be taken to
avoid compaction or disturbance of
the area over and around the
drainage field.
1MAdded
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71-05 SETTLEMENT TANKS
Title NotesActionFQTitle FQ Action Notes
1. Weirs, screens,
grit channels and
storm tanks.
Clean all weirs and baffles of any
blockages or potential blockages.
Solids should be removed from
screens, grit channels and storm
tanks.
Frequency of these tasks will be set
following local risk assessment and
depending on any extreme weather
condition.
1MAdded
2. Sludge records Record sludge levels Records should be maintained of
the sludge levels in the tanks to
allow optimisation of desludging
operations and to avoid overflow of
sludges into biological zones where
treatment efficiencies can be
affected.
1MAdded
3. Pumps Maintain all system pumps in
accordance with Pumps SFG 45
sections 07, 08 and 09.
6MAdded
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71-06 SEPERATOR SYSTEMS
Grease, light liquids and oils can cause difficulty in a wastewater treatment system. Among other
problems, grease can, coat biofilms so that they are not able to function properly. Great care should
be taken to ensure that grease and oil do not enter the system, as these contaminants may cover the
biofilm and severely limit the movement of oxygen and substrate into the biofilm.
Added
Title NotesActionFQTitle FQ Action Notes
1. Grease
separators
Grease separators should be
inspected, emptied and cleaned
regularly. Attention is drawn to the
need to comply
with national or local regulations for
the disposal of waste.
For further information please refer
to BS EN 1825-2:2004
The frequency of inspection,
emptying and cleaning should be
determined with regard to the
grease and sludge storage capacity
of the separator and in accordance
with operational experience. Unless
otherwise specified, separators
should be emptied, cleaned and
refilled with clean water at least
once a month and, preferably, every
two weeks.
1MAdded
Light liquid
separators e.g. oil
and petrol
The maintenance shall be carried
out in accordance with the
manufacturers instructions.
The cleaning and maintenance
records shall be kept and made
available to the authorities upon
request and shall contain remarks
on specific events (e.g. repairs,
accidents).
For further information please refer
to BS EN 858 -2:2003
Added
2. Sludge trap Determination of sludge volume.6MAdded
3. Separator Measure the thickness of light
liquids. Check the operation of the
automatic closure device. Check
the coalescing devices for
permeability, if the water levels in
front and behind the coalescing
device show significant difference.
Check the function of the warning
device.
Emptying is recommended when
one half of the sludge volume or 80
% of the storage capacity of the
separator is reached.
6MAdded
4. Sampling Shaft Clean the drain channel. Light liquid and sludge shall be
removed as required. Before putting
in service sludge trap and separator
should be re-filled with fresh water.
6MAdded
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5. General
inspection
Empty separator system and check
for tightness of the system,
structural condition, internal
coatings [if present], condition of
inbuilt parts, state of electrical
devices and installations and
checking of adjustment of
automatic closure device, e.g.
floating bodies.
The frequency of 5 years is a
maximum and depends upon local
risk assessment.
60MAdded
Page 478 of 614
SHOWERS
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SHOWERS51-01 51-01 SHOWERS
Note: Frequency of maintenance will depend upon use and the quality of the water and should be
agreed with the client.
Legionellosis (Legionnaires Disease and Associated Illnesses)
Approved Code of Practice- Legionnaires disease: The control of legionella bacteria in water systems:
Approved Code of Practice, L8,2000 sets out certain statutory requirements. In particular each water
system 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 L8 has a special legal status, Part 1 being regulatory and Part 2
guidance.
The client must ensure that one person of adequate status is appointed as being responsible for
overseeing the assessment and implementation of the precautions. Responsibility and lines of
communication must be properly defined and personnel must be properly trained.
Before carrying out the following procedures, consideration should be given to removing infrequently
used showers. If they are removed, the redundant supply pipework should be cut back, as far as
possible, to a common supply, for example to the recirculating pipework or the pipework supplying a
more frequently used upstream fitting.
Where it is difficult to carry out weekly flushing, the stagnant and potentially contaminated water from
within the shower and associated dead-leg needs to be purged to drain before the appliance is used.
It is important that this procedure is carried out with minimum production of aerosols, e.g. additional
piping may be used to purge contaminated water to drain.
Frequency of maintenance will depend upon use and the quality of the water and should be agreed
with the client.
Technical
Title NotesActionFQTitle FQ Action Notes
3. Internal
Surfaces; tiles and
silicone joints
Check internal surfaces for cracks
in the tiles or grouting. Check all
silicone joints and seals. Rake out
damaged grout or silicone and
repair as necessary.
Generally, the day to day cleaning
of the internal surfaces should be
undertaken by the clients staff.
Cracks or chips in the surfaces can
be a breeding ground for bacteria.
3MAdded
Valves See - VALVES. Valves and
Thermostatic
mixing valves
See Valves SFG 06Technical
1. Outlet sprays. Remove, clean spray heads. Check
adjustable sprays (if fitted).
Take care not to damage spray
outlet holes. More often in hard
water areas
3M 1. Outlet sprays. Dismantle, clean spray heads and
descale spray heads. Check
adjustable sprays (if fitted).
Quarterly or as necessary
Take care not to damage spray
outlet holes. More often in hard
water areas
3MTechnical
2. Body jets. Remove, clean spray heads. Adjust
water flow rates.
More often in hard water areas3M 2. Body jets. Dismantle, clean jet heads and
descale body jets. Adjust water flow
rates. Quarterly or as necessary
More often in hard water areas3MTechnical
3. Flexible hoses. Remove, clean. Check joints and
flexible covering for damage.
Report to client if replacement
recommended. More often in hard
water areas
3M 3. Flexible hoses. Dismantle, clean. And descale
hoses. Check joints and flexible
covering for damage. Quarterly or
as necessary
Report to client if replacement
recommended. More often in hard
water areas
3MTechnical
Page 480 of 614
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SHOWERS BOOSTER PUMPS51-02 51-02 SHOWERS BOOSTER PUMPS
Note: Frequency of maintenance will depend upon use and the quality of the water and should be
agreed with the client.
Legionellosis (Legionnaires Disease and Associated Illnesses)
Approved Code of Practice- Legionnaires disease: The control of legionella bacteria in water systems:
Approved Code of Practice, L8,2000 sets out certain statutory requirements. In particular each water
system 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 L8 has a special legal status, Part 1 being regulatory and Part 2
guidance.
The client must ensure that one person of adequate status is appointed as being responsible for
overseeing the assessment and implementation of the precautions. Responsibility and lines of
communication must be properly defined and personnel must be properly trained.
Before carrying out the following procedures, consideration should be given to removing infrequently
used showers. If they are removed, the redundant supply pipework should be cut back, as far as
possible, to a common supply, for example to the recirculating pipework or the pipework supplying a
more frequently used upstream fitting.
Where it is difficult to carry out weekly flushing, the stagnant and potentially contaminated water from
within the shower and associated dead-leg needs to be purged to drain before the appliance is used.
It is important that this procedure is carried out with minimum production of aerosols, e.g. additional
piping may be used to purge contaminated water to drain.
Frequency of maintenance will depend upon use and the quality of the water and should be agreed
with the client.
Technical
Title NotesActionFQTitle FQ Action Notes
2. Motor electrical
terminals.
Inspect and tighten if required.12M 2. Electrical. Check condition of local isolator,
open and clean if required. Remove
motor terminal covers, check
connections for tightness and
terminal block for damage or
dampness. Carry out the following
tests to all pumps and record
results:-a. Insulation resistance test
on wiring and motors. b. Earth loop
impedance test on case or frame of
units. c. Load test on motors (start
and run current). Compare results
with manufacturer’s specification.
Check that power lead at motor are
undamaged and are securely held.
12MTechnical
3. Motor. Clean and check. See MOTORS.12M 3. Motor. Clean and check. See Motors SFG3912MTechnical
7. Water filters. Remove and clean/replace. Or as manufacturers specification6M 7. Water filters. Remove, clean and descale.
Replace as necessary.
Or as manufacturers specification6MTechnical
Page 481 of 614
SMOKE EXTRACT
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SMOKE RELIEF - and/or natural fire ventilators52-02 52-02 SMOKE RELIEF - Natural smoke and heat exhaust ventilators
Frequency of maintenance and testing for smoke relief ventilators should conform to BS EN
12101-2:2003 Smoke and heat control systems and should be in accordance with local
authority requirements.
Maintenance and testing for smoke relief ventilators should conform to BS (www.bsi-global.com) EN
12101-2:2003 Smoke and heat control systems and should be in accordance with local authority
requirements.
Other
Title NotesActionFQTitle FQ Action Notes
1. Fixing and
weathering.
Check condition and clean off any
dirt with stiff (not wire) brush from
internal and external weathering
channels.
In very dirty or aggressive
environments, more frequent
attention may be necessary.
12M 1. Fixing and
weathering.
Check condition and clean all dirt
from internal and external
weathering channels and surfaces
of the ventilator (take precautions to
prevent inhalation of bird droppings
- COSHH Regulations) with stiff
(not wire) brush.
In very dirty or aggressive
environments, more frequent
attention may be necessary.
12MTechnical
2. Louvres/flaps
or dampers.
Clean bearings and lubricate as
necessary.
12M 2. Louvers/flaps
or dampers.
Clean bearings and lubricate as
necessary.
Only use lubricant as recommended
by manufacturer
12MTechnical
4. Operating
mechanism.
Check action. Report to client if repairs or
replacement required.
12M 4. Operating
mechanism.
Check action for smooth operation
and to ensure they open and close
correctly. Lubricate all linkages in
accordance with manufacturers
recommendations.
Only use lubricant as recommended
by manufacturer. Report to client if
repairs or replacement required.
12MTechnical
5. Smoke vents. Check condition and test weekly
and record as required by BS 7346,
and the Fire Precautions
(Workplace) Regulations
1997. Refer to www.hse.gov.uk for
detail.
Client to advise if weekly tests are to
be included within maintenance
contract.
1W 5. Smoke vents. Check condition and test weekly
and record as required by BS 7346,
Regulatory Reform (Fire Safety)
Order 2005 and the Fire Precaution
(Work force) Regulation 1997.
Refer to www.hse.gov.uk for detail.
Client to advise if weekly tests are to
be included within maintenance
contract.
1WOther
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SMOKE RELIEF - Powered fire ventilators52-03 52-03 SMOKE RELIEF - Powered smoke and heat exhaust ventilators
Frequency of maintenance and testing for smoke relief ventilators should conform to BS EN
12101-3:2002 Smoke and heat control systems and should be in accordance with local authority
requirements.
Added
Title NotesActionFQTitle FQ Action Notes
10. Operating
mechanism.
Check action for smooth operation
and to ensure they open and close
correctly. Lubricate all linkages in
accordance with manufacturers
recommendations
Only use lubricant as recommended
by manufacturer. Report to client if
repairs or replacement required.
12MAdded
11. Louvers/flaps
or dampers.
Clean bearings and lubricate as
necessary.
Only use lubricant as recommended
by manufacturer
12MAdded
12. Compressor
(where applicable)
Carry out tasks as directed in
relevant section.
Check rails are clear of any
obstruction so that the curtain will
drop into place when required.
The client should carry out this task
as part of their fire alarm testing
once every week to ensure that the
system integrity is maintained.
See Pipework systems SFG40-08
Added
1. Electricity
supply.
Isolate in accordance with HSAWA
safety requirements. Refer to
www.hse.gov.uk for detail.
Note: Ensure clients is aware that
system or part of system is
inoperative during execution of
maintenance.
12M 1. Electricity
supply.
Isolate in accordance with HSAWA
safety requirements. Refer to
www.hse.gov.uk for detail.
Ensure client is aware that system
or part of system is inoperative
during execution of maintenance.
12MOther
2. Filters. See FILTERS.12M 2. Filters. See Filters SFG2112MTechnical
3. Fixings Clean fixing and weathering and
clean off all dirt from external
surfaces of ventilator.
Use brush for dirt removal.12M 3. Fixing and
weathering.
Check condition and clean all dirt
from internal and external
weathering channels and surfaces
of the ventilator (take precautions to
prevent inhalation of bird droppings
- COSHH Regulations) with stiff
(not wire) brush.
Use brush for dirt removal.12MOther
4. Fan impeller of
motor.
Clean impeller and rotor and check
ease of rotation and correct
direction of rotation.
It is important to check for correct
clearance between fan shrouds and
impeller.(See also MOTORS)
12M 4. Fan impeller of
motor.
Clean impeller and rotor and check
ease of rotation and correct
direction of rotation.
It is important to check for correct
clearance between fan shrouds and
impeller.(See also Motors SFG39)
12MOther
8. Test and run. Test weekly and record same as
required by BS 7346.
Note: Client is to advise whether
weekly test is to form part of the
maintenance contract.
1W 8. Test and run. Test weekly and record same as
required by BS 7346.
Ensure client is aware that system
or part of system is inoperative
during execution of maintenance.
1WOther
9. Controls. Check action. See CONTROLS for detailed
maintenance.
12M 9. Controls. Check action. See Control panel and controllers
SFG 14 for detailed maintenance.
12MTechnical
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SMOKE CURTAINS52-04 52-04 SMOKE CURTAINS
Frequency of maintenance and testing for smoke relief ventilators should conform to BS EN
12101-1:2005 Smoke and heat control systems and should be in accordance with local authority
requirements.
Added
Title NotesActionFQTitle FQ Action Notes
b) guide rails
(where fitted)
Check rails are clear of any
obstruction.
12M b) guide rails
(where fitted)
Check rails are clear of any
obstruction so that the curtain will
drop into place when required.
The client should carry out this task
as part of their fire alarm testing
once every week to ensure that the
system integrity is maintained.
12MTechnical
3. Compressor
(where applicable)
See relevant section. 3. Compressor
(where applicable)
Carry out tasks as directed in
relevant section.
See Pipework systems SFG40-08Technical
Page 485 of 614
SOLAR PANELS
Page 486 of 614
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SOLAR HOT WATER PANELS and similar COLLECTING DEVICES53-01 53-01 SOLAR HOT WATER PANELS and similar COLLECTING DEVICES
Working at heights should be in strict accordance with the Work at Height Regulations 2005Added
Title NotesActionFQTitle FQ Action Notes
Plate type
collectors 1. Glass
cover plate.
Clean and report condition if
cracked. A safe method of gaining
height may be required; staff are to
be fully trained.
Frequency will depend on location
and local atmospheric condition. Dirt
causes loss of collector efficiency.
Cracked glass should be replaced.
6M Plate type
collectors
1. Glass cover
plate.
Check condition and clean all dirt
from surfaces of the unit (take
precautions to prevent inhalation of
bird droppings - COSHH
Regulations) with stiff (not wire)
brush. report condition if cracked
A safe method of gaining height
may be required; operatives are to
be fully trained.
Frequency will depend on location
and local atmospheric condition.
Dirt causes loss of collector
efficiency. Cracked glass should be
replaced.
6MTechnical
Vacuum tube type
1. Tubes.
Clean and report condition if
cracked.
Frequency will depend on location
and local atmospheric condition. Dirt
causes loss of collector efficiency.
Cracked tubes should be replaced.
6M Vacuum tube type
1. Tubes.
Check condition and clean all dirt
from surfaces of the tubes (take
precautions to prevent inhalation of
bird droppings - COSHH
Regulations) with stiff (not wire)
brush. report condition if cracked.
A safe method of gaining height
may be required; operatives are to
be fully trained.
Frequency will depend on location
and local atmospheric condition.
Dirt causes loss of collector
efficiency. Cracked tubes should be
replaced.
6MTechnical
2. Reflectors. Clean and report condition if
cracked.
Frequency will depend on location
and local atmospheric condition. Dirt
causes loss of collector efficiency.
Care should be taken to avoid
damaging the reflector surface.
6M 2. Reflectors. A safe method of gaining height
may be required; operatives are to
be fully trained.
Frequency will depend on location
and local atmospheric condition.
Dirt causes loss of collector
efficiency. Care should be taken to
avoid damaging the reflector
surface.
6MOther
6. Anti-freeze
solution.
Replace anti-freeze solution.36MAdded
6. Anti-freeze
solution.
Replace anti-freeze solution.36MAdded
Page 487 of 614
SPLIT SYSTEMS INCLUDING HEAT PUMPS
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INTRODUCTORY PROCEDURES54-01 54-01 INTRODUCTORY PROCEDURES
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.
Where there is a requiements to connect or dis-connect refrigerant lines, including snap connections,
the law demands that only a REFOM or other mandatory scheme provider registered engineer is
permitted to do this work.
The only difference between a Heat pump and a Split Air conditioning unit is that a heat pump has a
reversing valve to switch the unit from cooling mode to heating mode. The reversing valve changes
the direction of refrigeration flow, making the outdoor condenser the evaporator and the indoor unit
the condenser. The outdoor unit needs frost protection to switch back over when the condenser
freezes.
Where Oxygen Free Nitrogen is used, a Risk Assessment must be carried out prior to use.
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 one piece free standing units to be serviced at
a central workshop.
Units can be divided into two main categories namely:-
a) one piece
b) split two piece
They are variously known as cassettes, ceiling, ceiling suspended, wall or window mounted, side
blow, ducted, 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.
Where there is a requirement to connect or disconnect refrigerant lines, including snap connections,
must have a suitable refrigerant handling qualification and the F Gas regulations demands that only
an engineer who is in possession of full F-gas certification is permitted to carry these works out.
Check for leaks should be part of the routine servicing. “Checked for leakage” means that the Joints,
valves including stems, seals, including seals on replaceable driers and filters, parts of the system
subject to vibration, connections to safety or operational devices of the equipment or system is
examined for leakage using direct or indirect measuring methods, focusing on those parts of the
equipment or system most likely to leak. The frequency of testing depends on refrigerant charge and
system type.
Systems containing: <3 kg no leak test required, 3 kg to 30 kg annual leak test required, 30 kg to 300
kg half yearly leak test required and >300 kg quarterly leak test required.
Hermetically sealed systems: <6 kg no leak test required, 6 kg to 30 kg annual leak test required, 30
kg to 300 kg half yearly leak test required and >300 kg quarterly leak test required.
These applications must also be checked for leakage within one month after a leak has been repaired
to ensure that the repair has been effective.
Plants with more than 300 kg must be fitted with a leakage detection system, which is defined as: “a
calibrated mechanical, electrical or electronic device for detecting leakage of refrigerants which, on
detection, alerts the operator”. The detection system must be checked at least once a year to ensure
proper functioning in line with manufacturers’ recommendations.
For any plant fitted with a leakage detection system (including those below the mandatory 300 kg
threshold), the frequency of leak checking can be halved, although an annual check remains the
minimum frequency.
The only difference between a heat pump and a split air conditioning unit is that a heat pump has a
reversing valve to switch the unit from cooling mode to heating mode. The reversing valve changes
the direction of refrigeration flow, making the outdoor condenser the evaporator and the indoor unit
the condenser. The outdoor unit needs frost protection to switch back over when the condenser
freezes.
Where Oxygen Free Nitrogen is used, a Risk Assessment must be carried out prior to use and
suitable training given.
Technical
Page 489 of 614
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Reason For
Change
SPLIT SYSTEMS – air-cooled with direct expansion evaporator (DX), with
gas, hot water or elec. htrs
54-02 54-02 DX SPLIT SYSTEMS - with gas, electric or hot water 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.
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.
Service providers working on these systems must be registered to an approved Certified Scheme
provider, in accordance with the "F" Gas and Building Regulations
Check for leaks should be part of the routine servicing. “Checked for leakage” means that the Joints,
valves including stems, seals, including seals on replaceable driers and filters, parts of the system
subject to vibration, connections to safety or operational devices of the equipment or system is
examined for leakage using direct or indirect measuring methods, focusing on those parts of the
equipment or system most likely to leak. The frequency of testing depends on refrigerant charge and
system type.
Systems containing: <3 kg no leak test required, 3 kg to 30 kg annual leak test required, 30 kg to 300
kg half yearly leak test required and >300 kg quarterly leak test required.
Hermetically sealed systems: <6 kg no leak test required, 6 kg to 30 kg annual leak test required, 30
kg to 300 kg half yearly leak test required and >300 kg quarterly leak test required.
These applications must also be checked for leakage within one month after a leak has been repaired
to ensure that the repair has been effective.
Plants with more than 300 kg must be fitted with a leakage detection system, which is defined as: “a
calibrated mechanical, electrical or electronic device for detecting leakage of refrigerants which, on
detection, alerts the operator”. The detection system must be checked at least once a year to ensure
proper functioning in line with manufacturers’ recommendations.
For any plant fitted with a leakage detection system (including those below the mandatory 300 kg
threshold), the frequency of leak checking can be halved, although an annual check remains the
minimum frequency.
Technical
Title NotesActionFQTitle FQ Action Notes
3. Refrigerant. 3. Refrigerant. Service providers must registered
to an approved Certified Scheme
provider, in accordance with the "F"
Gas and Building Regulations.
Technical
a) charge. Check level in receiver and/or liquid
line sight glass.
Note: Any shortfall or frequent
topping up may indicate leakage
and must be reported to client.
6M a) charge. Check level in receiver and/or liquid
line sight glass.
Any shortfall or frequent topping up
may indicate leakage and must be
reported to the client.
6MOther
b) leaks 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, or other
mandatory scheme
provider registered engineer must
work on this equipment.
6M Deleted
Page 490 of 614
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Reason For
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4. Condenser and
evaporator fins.
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. A Risk Assessment is
required prior to using Nitrogen.
6M 4. Condenser and
evaporator fins.
Check for damage and/or dust
accumulation. Clean and comb coil
fins, vacuum unit internally.
Do not use refrigerant for cleaning
tubes use dry nitrogen or
compressed air. Sterilisation may be
required. Where Oxygen Free
Nitrogen is used, a Risk
Assessment must be carried out
prior to use and suitable training
given.
6MTechnical
5. Fans and
motors and
damper drive
motors (if fitted).
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)
6M 6. Fans and
motors and
damper drive
motors (if fitted).
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 SFG39.
6MTechnical
6. Evaporator and
drains, dip tray
and pump.
Check and clean. Check
condensate drain is clear and
clean.
Sterilisation may be required.6M 7. Evaporator
[Indoor],drains,
drip tray and
pump.
Check, flush and clean. Check
condensate drain is clear and
clean. Check operation of
condensate pump (if fitted)
Sterilisation of drip tray and drain
may be required.
6MTechnical
7. Compressor
capacity control
and unloaded start
valves (if fitted).
Check for correct operation. Check
motor current against
commissioning data.
Compressor unload on start should
reduce and increase capacity on
demand.
6M 8. Compressor
capacity control
and unloaded start
valves (if fitted).
Check for correct operation. Check
motor current against
commissioning data or nameplate.
Compressor unload on start should
reduce and increase capacity on
demand.
6MTechnical
8. Refrigerant
pipework.
Check for vibration and rectify any
loose or inadequate support/fixing.
All pipework joints should be brazed
or welded. To prevent internal
scaling use dry, oxygen free
nitrogen (OFN) during the jointing
process. A Risk Assessment must
be done prior to using Nitrogen.
6M 9. Refrigerant
pipework.
Check entire refrigerant pipework
run. Ensure pipes are secure.
All pipework joints should be brazed
or welded. To prevent internal
scaling use dry, oxygen free
nitrogen (OFN) during the jointing
process. A Risk Assessment must
be done prior to using Nitrogen.
6MTechnical
9. Filters. Check condition and replace as
necessary.
6M 10. Filters. Check condition and replace as
necessary.
Frequency to be determined
depending on conditions. It is
however important to clean the filter
prior to it becoming clogged. This
can affect the energy efficiency of
the unit by as much as 10% and can
also allow dirt to become clogged
into the evaporator coil.
6MTechnical
10. Insulation. Check condition. Repair and reseal
as necessary.
6M 11. Insulation. Check condition. Repair and reseal
as necessary.
6MOther
11. General
cleanliness.
Clean surfaces of compressor and
components of condensing unit.
Remove any dirt or rubbish from
vicinity of plant.
6M 12. General
cleanliness.
Clean surfaces of compressor and
components of condensing unit
particularly fan impeller and motor
casing. Check and clean surfaces
of unit casing, check for corrosion,
repair and treat as found necessary
Remove any dirt or rubbish from
vicinity of plant.
6MTechnical
Page 491 of 614
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Reason For
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12. Electrical. Check for damage to flexible
conduits. Tighten all terminal
connections. Isolate local control
panel and inspect for signs of
overheating. Check integrity of
electrical insulation.
If main fuse carrier connections to
compressors show any discoloration
they must be changed.
6M 13. Electrical. Check for satisfactory operation of
local electrical isolation device
stoplock/isolator). Examine and
report condition of all associated
wiring, ensure security of all
terminal connections and check for
satisfactory condition of any flexible
cables/conduits. Ensure plant has
adequate earth conductor and
bonding is secure.
If main fuse carrier connections to
compressors show any discoloration
they must be changed.
6MTechnical
13. System
operation.
Confirm that it is in accordance with
design parameters.
i.e. Start/stops and capacity
regulators should be in accordance
with externally applied control
systems if applicable.
6M 14. System
operation.
Check function and operation of all
automatic sensors /detectors
(flow/temperature). Check for
correct operation/shut-down of
plant. Ensure all devices are
returned to their correct settings.
Clean air inlet & discharge grilles.
Check all access doors for fit and
can be made secure. When shut,
ensure for air tight seal. Check that
unit is maintaining space conditions
i.e. Start/stops and capacity
regulators should be in accordance
with externally applied control
systems if applicable.
6MTechnical
1. Gas Fired. See relevant BURNER section.6M 1. Gas Fired. See relevant Burner SFG 07
section.
6MTechnical
2. Hot water
supply.
See relevant HEAT EMITTER
section. Check for leaks. Check
anti-freeze protection on heating
coil.
6M 2. Hot water
supply.
See relevant Heat emitter SFG 28
section. Check for leaks. Check
anti-freeze protection on heating
coil.
6MTechnical
5. Condenser –
general
Check all nuts, (including holding
down bolts) bolts, setscrews, etc.
for security. Check any drip tray for
blockage/leaks etc. Remove any
debris and clean.
6MAdded
b) leaks Check refrigerant Charge,
recharge/report as found
necessary. Check Joints, valves
including stems, seals, including
seals on replaceable driers and
filters, parts of the system subject
to vibration, connections to safety
or operational devices of the
equipment or system. Examine for
leakage using direct or indirect
measuring methods.
Check for leaks should be part of
the routine servicing by plant
attendants.
Any removed refrigerant (CFC) must
be recovered and not released to
atmosphere.
Where a system has a refrigerant
charge greater than 300kg, an
automatic leak detection system
must be installed on the system to
comply with the F Gas Regulations
6MAdded
A) Normal
systems:
<3 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
B) 3 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
Page 492 of 614
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C) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
D) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
E) Hermetically
sealed systems:
<6 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
F) 6 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
G) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
H) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
Page 493 of 614
Previous
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Reason For
Change
SPLIT SYSTEMS/ HEATPUMPS – air-cooled with direct expansion
evaporator (DX)
54-03 54-03 SPLIT SYSTEMS/ HEATPUMPS – air-cooled with direct expansion
evaporator (DX)
Engineers working on these systems must belong to an approved Certified Scheme provider, in
accordance with the "F" Gas and Building Regulations
Check for leaks should be part of the routine servicing. “Checked for leakage” means that the Joints,
valves including stems, seals, including seals on replaceable driers and filters, parts of the system
subject to vibration, connections to safety or operational devices of the equipment or system is
examined for leakage using direct or indirect measuring methods, focusing on those parts of the
equipment or system most likely to leak. The frequency of testing depends on refrigerant charge and
system type.
Systems containing: <3 kg no leak test required, 3 kg to 30 kg annual leak test required, 30 kg to 300
kg half yearly leak test required and >300 kg quarterly leak test required.
Hermetically sealed systems: <6 kg no leak test required, 6 kg to 30 kg annual leak test required, 30
kg to 300 kg half yearly leak test required and >300 kg quarterly leak test required.
These applications must also be checked for leakage within one month after a leak has been repaired
to ensure that the repair has been effective.
Plants with more than 300 kg must be fitted with a leakage detection system, which is defined as: “a
calibrated mechanical, electrical or electronic device for detecting leakage of refrigerants which, on
detection, alerts the operator”. The detection system must be checked at least once a year to ensure
proper functioning in line with manufacturers’ recommendations.
For any plant fitted with a leakage detection system (including those below the mandatory 300 kg
threshold), the frequency of leak checking can be halved, although an annual check remains the
minimum frequency.
Added
Title NotesActionFQTitle FQ Action Notes
A) Normal
systems:
<3 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
B) 3 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
C) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
D) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
E) Hermetically
sealed systems:
<6 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
F) 6 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
G) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
Page 494 of 614
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Reason For
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H) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
5. Condenser –
general
Check all nuts, (including holding
down bolts) bolts, setscrews, etc.
for security. Check any drip tray for
blockage/leaks etc. Remove any
debris and clean.
6MAdded
3. Refrigerant. 3. Refrigerant. Service providers must registered
to an approved Certified Scheme
provider, in accordance with the "F"
Gas and Building Regulations.
Technical
a) charge. Check level in receiver and/or liquid
line sight glass.
Note: Any shortfall or frequent
topping up may indicate leakage
and must be reported to client.
6M a) charge. Check level in receiver and/or liquid
line sight glass.
Any shortfall or frequent topping up
may indicate leakage and must be
reported to the client.
6MOther
b) leaks 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 or
other mandatory scheme
provider registered engineer must
work on this equipment.
6M b) leaks Check refrigerant Charge,
recharge/report as found
necessary. Check Joints, valves
including stems, seals, including
seals on replaceable driers and
filters, parts of the system subject
to vibration, connections to safety
or operational devices of the
equipment or system. Examine for
leakage using direct or indirect
measuring methods.
Check for leaks should be part of
the routine servicing by plant
attendants.
Any removed refrigerant (CFC) must
be recovered and not released to
atmosphere.
Where a system has a refrigerant
charge greater than 300kg, an
automatic leak detection system
must be installed on the system to
comply with the F Gas Regulations
6MTechnical
4.Condenser and
evaporator fins.
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. A Risk Assessment must
be done prior to use.
6M 4.Condenser and
evaporator fins.
Check for damage and/or dust
accumulation. Clean and comb coil
fins, vacuum unit internally
Do not use refrigerant for cleaning
tubes use dry nitrogen or
compressed air. Sterilisation may be
required. Where Oxygen Free
Nitrogen is used, a Risk
Assessment must be carried out
prior to use and suitable training
given.
6MTechnical
5. Fans and
motors and
damper drive
motors (if fitted).
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.
6M 6. Fans and
motors and
damper drive
motors (if fitted).
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.
6MOther
6. Evaporator
and drains, dip
tray and pump.
Check and clean. Check
condensate drain is clear and
clean.
Sterilisation may be required.6M 7. Evaporator
and drains, drip
tray and pump.
Check, flush and clean. Check
condensate drain is clear and
clean. Check operation of
condensate pump (if fitted).
Sterilisation of drip tray and drain
may be required
6MTechnical
7. Compressor
capacity control
and unloaded start
valves (if fitted).
Check for correct operation. Check
motor current against
commissioning data.
Compressor unload on start should
reduce and increase capacity on
demand.
6M 8. Compressor
capacity control
and unloaded start
valves (if fitted).
Check for correct operation. Check
motor current against
commissioning data or nameplate.
Compressor unload on start should
reduce and increase capacity on
demand.
6MTechnical
Page 495 of 614
Previous
Version
Updated
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Reason For
Change
8. Refrigerant
pipework.
Check for vibration and rectify any
loose or inadequate support/fixing.
All pipework joints should be brazed
or welded. To prevent internal
scaling use dry, oxygen free,
nitrogen (OFN) during the jointing
process. A Risk Assessment must
be done prior to use.
6M 9. Refrigerant
pipework.
Check entire refrigerant pipework
run. Ensure pipes are secure, not
sagging is in good repair.
All pipework joints should be brazed
or welded. To prevent internal
scaling use dry, oxygen free,
nitrogen (OFN) during the jointing
process. A Risk Assessment must
be done prior to use.
6MTechnical
9. Filters. Check condition and replace as
necessary.
6M 10. Filters. Check condition and replace as
necessary.
Frequency to be determined
depending on conditions. It is
however important to clean the filter
prior to it becoming clogged. This
can affect the energy efficiency of
the unit by as much as 10% and can
also allow dirt to become clogged
into the evaporator coil.
6MTechnical
10. Insulation. Check condition. Repair and reseal
as necessary.
6M 11. Insulation. Check condition. Repair and reseal
as necessary.
6MTechnical
11. General
cleanliness.
Clean surfaces of compressor and
components of condensing unit.
Remove any dirt or rubbish from
vicinity of plant.
6M 12. General
cleanliness.
Clean surfaces of compressor and
components of condensing unit
particularly fan impeller and motor
casing. Check and clean surfaces
of unit casing, check for corrosion,
repair and treat as found
necessary.
Remove any dirt or rubbish from
vicinity of plant.
6MTechnical
12. Electrical. Check for damage to flexible
conduits. Tighten all terminal
connections. Isolate local control
panel and inspect for signs of
overheating. Check integrity of
electrical insulation.
If main fuse carrier connections to
compressors show any discoloration
they must be changed. Pay
particular attention to contactors and
terminals including all thermistor
controls in compressor terminal box.
6M 13. Electrical. Check for satisfactory operation of
local electrical isolation device
stoplock/isolator). Examine and
report condition of all associated
wiring, ensure security of all
terminal connections and check for
satisfactory condition of any flexible
cables/conduits. Ensure plant has
adequate earth conductor and
bonding is secure.
If main fuse carrier connections to
compressors show any discoloration
they must be changed. Pay
particular attention to contactors and
terminals including all thermistor
controls in compressor terminal box.
6MTechnical
13. System
operation.
Confirm that it is in accordance with
design parameters.
i.e. Start/stops and capacity
regulators should be in accordance
with externally applied control
systems if applicable.
6M 14. System
operation.
Check function and operation of all
automatic sensors /detectors
(flow/temperature). Check for
correct operation/shut-down of
plant. Ensure all devices are
returned to their correct settings.
Clean air inlet & discharge grilles.
Check all access doors for fit and
can be made secure. When shut,
ensure for air tight seal. Check that
unit is maintaining space
conditions.
i.e. Start/stops and capacity
regulators should be in accordance
with externally applied control
systems if applicable.
6MTechnical
14. Gas Fired. See relevant BURNER section.6M 15. Gas Fired. See relevant Burner SFG 07
section.
6MTechnical
15. Hot water
supply.
See relevant HEAT EMITTER
section. Check for leaks. Check
anti-freeze protection on heating
coil.
6M 16. Hot water
supply.
See relevant Heat emitter SFG 28
section. Check for leaks. Check
anti-freeze protection on heating
coil.
6MTechnical
Page 496 of 614
STARTERS
Page 497 of 614
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Version
Reason For
Change
DRIVE ELEMENTS - STARTERS55-01 55-01 DRIVE ELEMENTS - STARTERS
Note: Before carrying out any work on electrical equipment, check status and isolate in accordance
with HASAWA and Electricity at Work Act requirements.
Before carrying out any work on electrical equipment, check status and isolate in accordance with
HASAWA and the Electricity at Work Regulations 1989 requirements.
Other
Page 498 of 614
Previous
Version
Updated
Version
Reason For
Change
STARTERS - Star Delta55-02 55-02 STARTERS - Star Delta
Before carrying out any work on electrical equipment, check status and isolate in accordance with
HASAWA and the Electricity at Work Regulations 1989 requirements.
Added
Title NotesActionFQTitle FQ Action Notes
1.Switchgear. Carry out maintenance procedures
as per power contactors.
See CONTROL PANELS .12M 1.Switchgear. Carry out maintenance procedures
as per power contactors.
See Control panels and controllers
SFG 14
12MTechnical
3.Start up
sequence.
Check for correct sequence from
start up. Inspect check and adjust
setting of timer to match character
of the connected load.
'Star' first then 'Delta' mode.12M 3.Start up
sequence.
Check for correct sequence from
start up. Inspect check and adjust
setting of timer to match character
of the connected load.
Star` first then `Delta` mode.12MOther
Page 499 of 614
Previous
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Version
Reason For
Change
STARTERS -Two speed - Dual wound55-03 55-03 STARTERS -Two speed - Dual wound
Before carrying out any work on electrical equipment, check status and isolate in accordance with
HASAWA and the Electricity at Work Regulations 1989
Added
Title NotesActionFQTitle FQ Action Notes
1.Switchgear. Carry out maintenance procedures
as per power contactors.
See CONTROL PANELS.12M 1.Switchgear. Carry out maintenance procedures
as per power contactors.
See Control panels and controllers
SFG 14
12MTechnical
4.Overloads. Check both high and low overloads.12M Deleted
Page 500 of 614
Previous
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Version
Reason For
Change
STARTERS - Two speed - Pole change55-04 55-04 STARTERS - Two speed - Pole change
Before carrying out any work on electrical equipment, check status and isolate in accordance with
HASAWA and the Electricity at Work Regulations 1989 requirements.
Added
Title NotesActionFQTitle FQ Action Notes
1.Switchgear. Carry out maintenance procedures
as per power contactors.
See CONTROL PANELS.12M 1.Switchgear. Carry out maintenance procedures
as per power contactors.
See Control panels and controllers
SFG 14
12MTechnical
Page 501 of 614
Previous
Version
Updated
Version
Reason For
Change
STARTERS - Reversing55-05 55-05 STARTERS - Reversing
Before carrying out any work on electrical equipment, check status and isolate in accordance with
HASAWA and the Electricity at Work Regulations 1989
Added
Title NotesActionFQTitle FQ Action Notes
1.Switchgear. Carry out maintenance procedures
as per power contactors.
See CONTROL PANELS.12M 1.Switchgear. Carry out maintenance procedures
as per power contactors.
See Control panels and controllers
SFG 14
12MTechnical
Page 502 of 614
Previous
Version
Updated
Version
Reason For
Change
STARTERS - Auto-transformer55-06 55-06 STARTERS - Auto-transformer
Before carrying out any work on electrical equipment, check status and isolate in accordance with
HASAWA and the Electricity at Work Regulations 1989
Added
Title NotesActionFQTitle FQ Action Notes
1.Switchgear. Carry out maintenance procedures
as per power contactors.
See CONTROL PANELS.12M 1.Switchgear. Carry out maintenance procedures
as per power contactors.
See Control panels and controllers
SFG 14
12MTechnical
Page 503 of 614
Previous
Version
Updated
Version
Reason For
Change
STARTERS - Quick transition, electric heater55-07 55-07 STARTERS - Quick transition, electric heater
Before carrying out any work on electrical equipment, check status and isolate in accordance with
HASAWA and the Electricity at Work Regulations 1989
Added
Title NotesActionFQTitle FQ Action Notes
1.Switchgear. Carry out maintenance procedures
as per power contactors.
See CONTROL PANELS.12M 1.Switchgear. Carry out maintenance procedures
as per power contactors.
See Control panels and controllers
SFG 14
12MTechnical
Electric Heater
Type 1. Electrical
connections.
Check.12M Electric Heater
Type
1. Electrical
connections.
Check.12MTechnical
Page 504 of 614
Previous
Version
Updated
Version
Reason For
Change
STARTERS electrolyte type55-08 55-08 STARTERS electrolyte type
Before carrying out any work on electrical equipment, check status and isolate in accordance with
HASAWA and the Electricity at Work Regulations 1989
Added
Page 505 of 614
Previous
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Updated
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Reason For
Change
STARTERS-AIR BREAK AND CONTACTORS55-09 55-09 STARTERS-AIR BREAK AND CONTACTORS
Before carrying out any work on control panel isolate mains supply at the distribution board. Before carrying out any work on control panel isolate mains supply at the distribution board.
Before carrying out any work on electrical equipment, check status and isolate in accordance with
HASAWA and the Electricity at Work Regulations 1989
Technical
Title NotesActionFQTitle FQ Action Notes
b)oil dashpot, If oil is cloudy or sludge has
formed, clean out dashpot with
solvent and refill.
12M b)oil dashpot, If oil is cloudy or sludge has
formed, clean out dashpot with
solvent and refill.
Refill with oil in accordance with
manufacturers recommendations
12MTechnical
12. Fuses (if
fitted).
Check for correct rating and type. e.g. rewirable fuses have not been
installed in the carriers designed for
cartridge fuses.
12M 12. Fuses (if
fitted).
Check for correct rating and type. e.g. check that re-wirable fuses
have not been installed in the
carriers designed for cartridge
fuses.
12MTechnical
b)after return to
service.
Check that any meters and pilot
lights fitted function correctly.
12M b)after return to
service.
Check that any meters and
indicator lights fitted function
correctly.
12MTechnical
Page 506 of 614
STORAGE TANKS
Page 507 of 614
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Version
Updated
Version
Reason For
Change
INTRODUCTORY PROCEDURES56-01 56-01 INTRODUCTORY PROCEDURES
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
c) seasonal variations. In the summertime it is not unusual to have incoming mains supplies
exceeding 20°C. When this occurs the systems should be reassessed with the likely outcome of
increasing regular flushing to these outlets in a safe manner with minimal aerosolation.
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 must 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 BS 6920. Lists of materials approved by the water industry (WRAS) are
published in the Water Fittings and Materials Directory (see Standards List). All new and replacement
water fittings must satisfy Water Supply (water fittings) Regulations 1999 requirements and be listed in
the WRAS directory. (WRAS Simple Steps to Approval)
Cleansing of tanks, cisterns and associated pipe work must be followed by full disinfection in
accordance with the procedures laid down in BS 6700 Rev 2006 and as per chemical
manufacturers specification.
Cisterns must have close fitting lids, which should not be of timber or other porous materials. Lids
must have vent pipes of adequate cross section to prevent suction developing on water draw off . All
vent pipes and overflows must be fitted with close mesh to prevent the ingress of foreign matter.
These must be checked annually and cleaned if necessary.
The pipe-work system must be free of any points where pockets of dirt, slime or sediment can build
up.
The need for full disinfection of Cisterns and associated down services is outlined in HSE's L8 part 2
Guidance page 48 paragraph 190.
WARNING: Subject to age, there are still many items lagged with Asbestos, if uncertain - STOP
WORK. A Certified Test Result MUST be obtained prior to consideration to proceed.
Approved Code of Practice- Legionnaires disease: The control of legionella bacteria in water systems:
Approved Code of Practice, L8,2000 sets out certain statutory requirements. In particular each water
system 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 L8 has a special legal status, Part 1 being regulatory and Part 2
guidance.
The client must ensure that one person of adequate status is appointed as being responsible for
overseeing the assessment and implementation of the precautions. Responsibility and lines of
communication must be properly defined and personnel must be properly trained.
Guidance note L101 Safe work in confined spaces 1997. Approved code of practice, regulations and
guidance 2nd edition (2009).
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
c) seasonal variations. In the summertime it is not unusual to have incoming mains supplies
exceeding 20°C. When this occurs the systems should be reassessed with the likely outcome of
increasing regular flushing to these outlets in a safe manner with minimal aerosolation.
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 must 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 BS (www.bsi-global.com) 6920. Lists of materials approved by the water
industry (WRAS (www.wras.co.uk)) are published in the Water Fittings and Materials Directory (see
Standards List). All new and replacement water fittings must satisfy Water Supply (water fittings)
Regulations 1999 requirements and be listed in the WRAS directory. (WRAS Simple Steps to
Approval)
Cleansing of tanks, cisterns and associated pipe work must be followed by full disinfection in
accordance with the procedures laid down in BS 6700 Rev 2006 [partially superseded by BS EN
806-4:2010] and as per chemical manufacturers specification.
Cisterns must have close fitting lids, which should not be of timber or other porous materials. Lids
must have vent pipes of adequate cross section to prevent suction developing on water draw off . All
vent pipes and overflows must be fitted with close mesh to prevent the ingress of foreign matter.
These must be checked annually and cleaned if necessary.
The pipe-work system must be free of any points where pockets of dirt, slime or sediment can build
up.
The need for full disinfection of Cisterns and associated down services is outlined in HSE`s L8
Guidance page 53 paragraph 190.
<B>WARNING</B>: Subject to age, there are still many items lagged with Asbestos, if uncertain -
Technical
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STOP WORK. A Certified Test Result MUST be obtained prior to consideration to proceed.
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COLD WATER STORAGE TANKS and CISTERNS56-02 56-02 COLD WATER STORAGE TANKS and CISTERNS
Note: Cisterns operate at atmospheric pressure whereas tanks are sealed vessels operating at
pressures above atmospheric.
Approved Code of Practice- Legionnaires disease: The control of legionella bacteria in water systems:
Approved Code of Practice, L8,2000 sets out certain statutory requirements. In particular each water
system 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 L8 has a special legal status, Part 1 being regulatory and Part 2
guidance.
The client must ensure that one person of adequate status is appointed as being responsible for
overseeing the assessment and implementation of the precautions. Responsibility and lines of
communication must be properly defined and personnel must be properly trained.
Guidance note L101 Safe work in confined spaces 1997. Approved code of practice, regulations and
guidance 2nd edition (2009).
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
c) seasonal variations. In the summertime it is not unusual to have incoming mains supplies
exceeding 20°C. When this occurs the systems should be reassessed with the likely outcome of
increasing regular flushing to these outlets in a safe manner with minimal aerosolation.
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 must 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 BS (http://www.bsi-global.com) 6920. Lists of materials approved by the
water industry (WRAS ) are published in the Water Fittings and Materials Directory (see Standards
List). All new and replacement water fittings must satisfy Water Supply (water fittings) Regulations
1999 requirements and be listed in the WRAS directory. WRAS Simple Steps to Approval
Cleansing of tanks, cisterns and associated pipe work must be followed by full disinfection in
accordance with the procedures laid down in BS 6700 Rev 2006 [partially superseded by BS EN
806-4:2010] and as per chemical manufacturers specification.
Cisterns must have close fitting lids, which should not be of timber or other porous materials. Lids
must have vent pipes of adequate cross section to prevent suction developing on water draw off . All
vent pipes and overflows must be fitted with close mesh to prevent the ingress of foreign matter.
These must be checked annually and cleaned if necessary.
The pipe-work system must be free of any points where pockets of dirt, slime or sediment can build
up.
The need for full disinfection of Cisterns and associated down services is outlined in HSE`s L8
Guidance page 53 paragraph 190.
<B>WARNING</B>: Subject to age, there are still many items lagged with Asbestos, if uncertain -
STOP WORK. A Certified Test Result MUST be obtained prior to consideration to proceed.
Technical
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Title NotesActionFQTitle FQ Action Notes
1. General Check for adequate water level and
where provided, check tank warning
pipe for signs of discharge. Inspect
tank for evidence of leaks and
corrosion.
3MAdded
14. Earthing and
bonding
Where pipework, fittings or
appliances are to be replaced,
continuity of earthing and
equipotential bonding shall be
maintained. Where pipework has
been used for earthing, alternative
earthing arrangements shall be
made in accordance with BS 7430
by a competent person. Where
there is no evidence of main
equipotential bonding, which may
be required, the installer should
inform the responsible person that
any bonding should be checked
and remedied where necessary by
a competent person.
12MAdded
1. Float operated
ball valve
Check operation, water level and
shut off. Replace washer if
necessary. Check float for leakage
and security.
3M 2. Float operated
ball valve
Check operation, water level and
shut off. Replace washer and / or
defective parts if necessary. Check
float for leakage and security.
3MTechnical
2. Level control
switches (if fitted).
Check for scale deposits, clean as
necessary and check operation.
For specialist maintenance of level
control switches see LEVEL
SWITCHES.
6M 3. Level control
switches (if fitted).
Check for scale deposits, clean as
necessary and check function and
operation of level switches, by
simulating water level condition,
ensure correct operation of
associated plant
For specialist maintenance of level
control switches see Level switches
SFG 58.
6MTechnical
3. Cistern or tank
body.
Check for leaks and any structural
weaknesses.
Ensure that any brackets, etc.
supporting the tank are firmly fixed.
6M 4. Cistern or tank
body.
Check for leaks and any structural
weaknesses.
Ensure that any brackets, etc.
supporting the tank are firmly fixed.
6MOther
4. Valves Check valve stems are free to turn. Ensure that any insulation or trace
heating cable removed during
inspection is replaced or frost
damage could ensue.
6M 5. Valves Note settings of tank valves
(excluding DRV`s). Check, rotate
handwheel sufficiently to indicate
that wedge is not seized in closed
position nor jammed in open
position. If normally open, close
valve and reopen. When fully open,
close valve 1/2 turn to ensure valve
does not jam.
Ensure that any insulation or trace
heating cable removed during
inspection is replaced or frost
damage could ensue.
See Valves SFG 61
6MTechnical
5. Air vents and
overflow screens.
Check for blockage and condition. Clean when necessary. Report if
replacement needed.
6M 6. Air vents and
overflow screens.
Check tank air vents are clean and
unobstructed, where filters are
provided remove clean and/or
replace as found necessary.
Clean when necessary. Report if
replacement needed.
6MTechnical
6. Insulation. Check condition, replace if
necessary.
Look for any damp patches, if
necessary removing insulation to
find cause.
6M 7. Insulation. Check condition, replace if
necessary.
Look for any damp patches, if
necessary removing insulation to
find cause.
6MOther
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7. Manlid and
access covers.
Check condition of seals. If lid has been removed for
inspection purposes ensure seals
are effective.
12M 8. Manlid and
access covers.
Check condition of seals.
Check Lids, inspection cover(s) etc.
can be correctly located and made
secure.
If lid has been removed for
inspection purposes ensure seals
are effective.
12MTechnical
8. Cistern or
tanks.
Inspect and report cleanliness and
condition. The use of a matrix to
substantiate reasons for cleaning
and continuity between inspecting
personel would be advantageous.
Check overflow and warning pipes
are unobstructed, sized correctly
and that the ends are conspicuous
and well above the flood over level
of a gully and conform to the water
regulations. If any remedial work
needs to be carried out, advise
client. If painting is required any
paint should be non-toxic and WRC
Water Byelaws Scheme/Water
Supply (water fittings) Regulations
1999 WRAS approved.
12M 9. Cistern or
tanks.
All cold water storage cisterns and
cold feed cisterns must be
examined at least annually, paying
particular attention to the presence
of foreign objects, biological
material and excessive corrosion.
On completion of the examinations,
the cisterns should be cleaned, if
required, and any remedial work
carried out. Before the cisterns and
system are put back into use, they
should be disinfected in accordance
with the procedure detailed in
Chapter 17 of Part A.
Carry out full biological testing of
water and report.
Check atmosphere within tank prior
to entry.
Check overflow and warning pipes
are unobstructed, sized correctly
and that the ends are conspicuous
and well above the flood over level
of a gully and conform to the water
regulations. If any remedial work
needs to be carried out, advise
client. If painting is required any
paint should be non-toxic and WRC
Water Byelaws Scheme/Water
Supply (water fittings) Regulations
1999 WRAS approved.
SEE HTM 04 Part A chapter 17 All
cisterns should be internally cleaned
to remove all visible dirt and debris.
Cisterns and distributing pipework
should be drained, filled with fresh
water
and then drained completely. The
cisterns should then be refilled and
the supply servicing valves closed.
On re-fitting it is normal practice to
add high doses of sodium
hypochlorite to the water in the
cisterns, for example to give a
calculated chlorine concentration of
50 ± 10 mg/L (ppm) in the water,
and leave the water to stand for one
hour. Whatever disinfection method
is used, the concentration should be
adjusted if necessary. The use of a
high dose ensures an adequate
residual concentration to allow
proper disinfection of the
downstream services. Each tap or
fitting should then be opened,
progressively away from the
cisterns, and water discharged until
the disinfectant is detected. Each
tap or fitting should then be closed,
and the cistern and pipes left
charged for a further hour. The
tap(s) furthermost from the cisterns
should be opened, and the level of
disinfectant in the water discharged
from the taps measured. If the
levels set are not achieved, the
disinfection process should be
repeated.
12MTechnical
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9. Temperature
Monitoring.
Check and record in logbook for
water hygiene the incoming feed to
the cistern storage at the ball valve
and remote from the ball valve (that
is farthest away from the incoming
supply within the cistern) once in
the summer and once in the winter.
Ensure temperature at ball valve is
<3°C of the incoming supply to the
building and similarly storage is
<3°C from ballvalve.
6M 10. Temperature
Monitoring.
Check and record in logbook for
water hygiene the incoming feed to
the cistern storage at the ball valve
and remote from the ball valve (that
is farthest away from the incoming
supply within the cistern) once in
the summer and once in the winter.
Ensure temperature at ball valve is
<3°C of the incoming supply to the
building and similarly storage is
<3°C from ball valve. Note
maximum temperatures recorded by
fixed max/min thermometers where
fitted
6MTechnical
10. Tanking. Ensure drains are clear, check
condition.
Check thoroughly for potential
leakage. Report to client.
12M 11. Tanking. Ensure drains are clear, check
condition.
Check thoroughly for potential
leakage. Report to client.
12MOther
11. Associated
pipework.
Check condition and rectify any
faults.
Examine for corrosion, leaks and
security of fittings and attachments.
12M 12. Associated
pipework.
Check condition and rectify any
faults.
Examine for corrosion, leaks and
security of fittings and attachments.
12MOther
12. Generally. Check that all items of equipment
comply with Legislation and
guidance (L8), HTM 04 (NHS),
WRAS the Water Supply (water
fittings) Regulations 1999
Report to client where remedial
action is required.
12M 13. Generally. Check that all items of equipment
comply with Legislation and
guidance (L8), HTM 04 (NHS),
WRAS the Water Supply (water
fittings) Regulations 1999
Report to client where remedial
action is required.
12MOther
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ICE STORAGE SYSTEMS56-03 56-03 ICE STORAGE SYSTEMS
Further guidance available from the National Health Service Document HTM 04 – Part B (Chapter 8
paragraph 8.8 to 8.13)
Further guidance available CIBSE TM 18
Air conditioning systems incorporating ice storage can need less general maintenance than
conventional systems. However, they normally have heat exchangers and some additional
instrumentation (flow meters etc.) and controls requiring maintenance. The tasks below should be
supplemented by those given from the specific manufacturer / supplier of the store and the complexity
of the particular system.
Care should be taken to prevent a control malfunction that would allow a total ‘freeze solid’ condition
to occur at the ice store. Primary to secondary heat exchangers should be thoroughly tested
especially in respect of low-temperature protection of secondary circuits.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Brine quality. Check Specific Gravity. If checks show continual need for
topping up brine Specific Gravity,
examine system for leaks.
3M Secondary coolant
circuit
Technical
2. System
pressurisation unit
(if used).
Check operation.6M 1. Glycol / Brine
concentration
Check percentage of glycol
concentration in circuit.
Correct as necessary. If checks
show continual need for topping up
Specific Gravity, examine system for
leaks.
1MTechnical
3. Tank shut off
unit (if fitted).
Check operation.6M 2. Valves Check operation of all isolating and
control valves
See Valves SFG 61 and 626MTechnical
3. Coolant flow
rates
Check and log flow rates and
pressure drops at appropriate loads
and conditions and check against
commissioning data
6MAdded
4. Circulating
pumps
Check operation of pumps. Take account of density of the
secondary coolant.
See Pumps SFG 45
6MAdded
5. Flow and return
temperatures
Check that the flow and return
temperatures across the ice store
are being achieved in both ice
charge and discharge modes.
6MAdded
6. Set points Check control set points for correct
values and operation.
3MAdded
Ice StoreAdded
1. Water level Check correct level of water in
storage container
6MAdded
2. Inventory device Check ice inventory device is
correctly calibrated and operating to
ensure correct glycol concentration
levels.
6MAdded
1. BMS Check that all temperatures,
pressures, flow rates etc., are being
received.
Check sensors for any not working.6MAdded
2. Insulation and
vapour barrier
Check all insulation is in place. Check to ensure the full record of
operating conditions over a period of
time is being saved.
6MAdded
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3. System
pressurisation unit
(if used).
Check operation. Should any pipework be removed
during and maintenance or repairs
ensure that it is reinstated paying
special attention to the quality of the
vapour sealing. The system will
need to be dried out prior to being
reinsulated to avoid sealing in
moisture which could corrode
pipework.
6MAdded
4. Tank shut off
unit (if fitted).
Check operation.6MAdded
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STORAGE TANKS - OIL56-05 56-05 STORAGE TANKS - OIL
The Control of Pollution (Oil Storage) (England) Regulations 2001 set minimum standards. They do
not change other legislation under which it is an offence to cause water pollution . Variations in local
conditions may mean more stringent standards are needed to prevent pollution.
If there is a spill, immediate action must be taken to stop the oil getting into any drains or
watercourses. Soak up the spilt oil with the contents of the spill kit in accordance with the risk
assessment. Don’t hose the spillage down or use any detergents to try to get rid of it. Notify the
Environment Agency by calling their Emergency Hotline on 0800 80 70 60.
If oil soaks into the ground, the soil soaked in oil should be removed, by a specialist company. Store
any materials that are soaked in oil in containers that won’t let the oil run away until it can be correctly
and legally disposed of.
In addition to the tasks there are daily and weekly operational tasks to be carried out including visual
checks of the oil tanks, pipework and bund. Please also see the section below [bund 3 monthly] which
refers to the removal of rain water. This must be done every time there has been heavy rainfall.
Refer to the Control of Substances Hazardous to Health (COSHH) Regulations. Staff to be Competent
and fully trained in COSHH. Risk Assessment / Method Statement requirements must be carried out
before the work starts and a method statement produced. Refer to www.hse.gov.uk for details.
Added
Title NotesActionFQTitle FQ Action Notes
Bulk Oil Storage
[Heavy and
Medium Oils]
If there is a spill, immediate action
must be taken to stop the oil getting
into any drains or watercourses.
Soak up the spilt oil with the
contents of the spill kit in
accordance with the risk
assessment. Don’t hose the
spillage down or use any
detergents to try to get rid of it.
Notify the Environment Agency by
calling their Emergency Hotline on
0800 80 70 60.
Added
Outflow heater(s) Refer to the Control of Substances
Hazardous to Health (COSHH)
Regulations. Staff to be Competent
and fully trained in COSHH. Risk
Assessment / Method Statement
requirements must be carried out
before the work starts and a
method statement produced. Refer
to www.hse.gov.uk for details.
3MAdded
Oil log Check and log oil level. Log also
any inspections, any repair work on
the tanks and who’s done the
works.
3MAdded
Contents Gauge Dip tank to ensure gauge is
working.
3MAdded
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Valves and
pipework
Check valves are locked or have
there hand wheels removed [
vandalism / theft]. Pipework should
be checked for leaks, corrosion,
missing brackets etc. Check any
trace heating and insulation is in
place and working where
appropriate.
3MAdded
Valves and
pipework
Note settings of valves and take
through total travel, returning to
correct settings. Lock or remove
hand wheel as appropriate.
Pipework should be checked for
leaks, corrosion, missing brackets
etc.
12MAdded
Notices Check that the notice showing the
product type, tank capacity and,
where appropriate, tank number is
clearly visible – clean or replace as
necessary. Check all notices are
clearly visible warning that all
valves must be locked when not in
use.
3MAdded
Bund Bunds should be inspected
regularly for signs of damage, e.g.
missing bricks in walls and water in
the bund. Inspect closely where any
draw off / feed lines pass through
the bund wall to ensure it remains
fully sealed to retain oil.
Check that any trigger guns and
hoses are being kept within the
bund or the secure cabinet, which
should be locked shut when not in
use
Checked visually by the operator at
least weekly or after any heavy
rainfall.
Open bund - check the bund after
heavy rainfall. If there’s no rainwater
in the bund, it might not be sealed
properly and you should have it
inspected and repaired. Where rain
water has collected in the bund, it
will reduce the amount of oil it can
contain. To remove accumulated
rainwater, use a manually operated
pump or by bailing from the sump.
Any accumulated water, oil or debris
should be removed
and disposed of in line with waste
management legislation. In all cases
where wastes are removed, as the
waste producer you are obliged
under Waste management, the Duty
of Care, a code of practice (revised
1996) to describe the waste
accurately and dispose of it
properly.
Guidance on the disposal of
condensate and bund water. Joint
OFTEC/WaterUK/Environment
Agency/ SEPA publication.
3MAdded
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Bund A more detailed annual check by a
trained operator, e.g. in the OFTEC
registered scheme.
12MAdded
Overfill prevention
devices
Check that the device sounds the
alarm / shows the visual warning or
automatically stops the delivery –
whatever applies.
3MAdded
Fill points Check that the lockable fill cap and
chain are in place and work. Clean
the fill point drip tray.
3MAdded
Tank 60M Bulk Oil Storage [Heavy Oil]
Clean tank externally, derust and
paint, as found necessary. Place
No Smoking Signs, drain tank,
open manholes and vent tank.
Refer to Permit to Work and safe
Systems of Work before entering
tank, internally inspect, clean and
repair as found necessary. Report
condition before placing tank back
on-line. After maintenance
inspection, close all manholes and
covers, recharged tank and check
for leaks. Clean down exterior of
outdoor tanks and repaint with
bituminous paint. Inspect condition
of any fixed ladders, handrails and
catwalks. Check all fixings for
security
60MAdded
Daily (small) oil
storage
All tasks and frequencies are the
same as for Bulk Oil Storage
[Heavy and Medium Oils] above
without the task for out flow
heaters.
Added
1. Tank. Check condition and note any
corrosion.
Report to client.12M 1. Tank, bund
and surronding
area
Look for leakage and spillage from
the tank resulting from filling or
failure of tank soundness.
Report to client.3MTechnical
2. Filter. Replace if dirty and investigate
cause.
12M 2. Strainer
basket(s)
3MTechnical
3. Balloon Vent. Check condition of wire mesh.12M 3. Balloon Vent. In addition to the tasks there are
daily and weekly operational tasks
to be carried out including visual
checks of the oil tanks, pipework
and bund. Please also see the
section below [bund 3 monthly]
which refers to the removal of rain
water. This must be done every
time there has been heavy rainfall.
3MOther
4. Sludge valve. Check for leaks. If opened Waste Disposal
Regulations apply.
12M 4. Sludge valve /
cocks.
Check operation and freedom of
movement. Moving parts should be
lightly oiler or greased.
If opened Waste Disposal
Regulations apply.
3MTechnical
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56-06 UNDERGROUND OIL STORAGE TANKS
The Control of Pollution (Oil Storage) (England) Regulations 2001 and Groundwater Protection Code:
Petrol stations and other fuel dispensing facilities involving underground storage tanks set minimum
standards. They do not change other legislation under which it is an offence to cause water pollution .
Variations in local conditions may mean more stringent standards are needed to prevent pollution .
If there is a spill, immediate action must be taken to stop the oil getting into any drains or
watercourses. Soak up the spilt oil with the contents of the spill kit in accordance with the risk
assessment. Don’t hose the spillage down or use any detergents to try to get rid of it. Notify the
Environment Agency by calling their Emergency Hotline on 0800 80 70 60.
If oil soaks into the ground, the soil soaked in oil should be removed, by a specialist company. Store
any materials that are soaked in oil in containers that won’t let the oil run away until it can be correctly
and legally disposed of.
In addition to the tasks there are daily and weekly operational tasks to be carried out including visual
checks of the oil tanks, pipework .
Refer to the Control of Substances Hazardous to Health (COSHH) Regulations. Staff to be Competent
and fully trained in COSHH. Risk Assessment / Method Statement requirements must be carried out
before the work starts and a method statement produced. Refer to www.hse.gov.uk for details.
Added
Title NotesActionFQTitle FQ Action Notes
1. Tank, bund
and surronding
area
Look for leakage and spillage from
the tank resulting from filling or
failure of tank soundness.
Report to client.3MAdded
2. Strainer
basket(s)
Remove and clean.3MAdded
3. Balloon Vent. Ensure that the vent is clear and
free from obstruction.
3MAdded
4. Sludge valve /
cocks.
Check operation and freedom of
movement. Moving parts should be
lightly oiler or greased.
If opened Waste Disposal
Regulations apply.
3MAdded
5. Outflow
heater(s)
Ensure that all electrical
connections remain clean, tight and
dry.
Check for liquid leakage around
bolt-to-tank joint and element
sheaths.
When a drain connection is
provided loosen drain valve and
check for sludge build-up. If this is
excessive, isolate heater and drain
off quantity of sludge.
If opened Waste Disposal
Regulations apply.
3MAdded
6. Oil log Check and log oil level. Log also
any inspections, any repair work on
the tanks and who’s done the
works.
3MAdded
7. Contents Gauge Dip tank to ensure gauge is working
and accurate
3MAdded
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8. Water detection Use a suitable paste on the dip
stick / line and check for water.
Remove water and increase
frequency of checks to ensure there
is no leakage into the tank.
3MAdded
9. Valves and
pipework
Check valves are locked or have
there hand wheels removed [
vandalism / theft]. Pipework should
be checked for leaks, corrosion,
missing brackets etc. Check any
trace heating and insulation is in
place and working where
appropriate.
3MAdded
10. Valves and
pipework
Note settings of valves and take
through total travel, returning to
correct settings. Lock or remove
hand wheel as appropriate.
Pipework should be checked for
leaks, corrosion, missing brackets
etc.
12MAdded
11. Notices Check that the notice showing the
product type, tank capacity and,
where appropriate, tank number is
clearly visible – clean or replace as
necessary. Check all notices are
clearly visible warning that all
valves must be locked when not in
use.
3MAdded
12. Overfill
prevention devices
Check that the device sounds the
alarm / shows the visual warning or
automatically stops the delivery –
whatever applies.
3MAdded
13. Fill points Check that the lockable fill cap and
chain are in place and work. Clean
the fill point drip tray.
3MAdded
14. Leakage
detection
Check that the system is operating
correctly as per manufacturers
guidelines.
In addition to this tasks there are
daily and weekly operational tasks
to be carried out to check leakage
detection.
3MAdded
15. Cathodic
protection devices
Added
i) Sacrificial anode Check condition and record results This must be checked within 6
months of any new installation or
repair to the sacrificial anode
system. The results of the last two
tests must be retained on site.
36MAdded
ii) Impressed
current
Check condition and record results The results of the last three tests
must be retained on site.
2MAdded
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16. Soil condition
checks
Check soil conditions in terms of
moisture content, electrical
conductivity, pH, sulphide
concentration and chloride
concentration.
Usually the corrosion of buried steel
occurs as a result of electrochemical
reactions with constituents of the
enclosing soils. In order to assess
the risk of corrosion failure, it is
necessary to ascertain soil
conditions such as moisture content,
electrical conductivity, pH, sulphide
concentration and chloride
concentration. This data, once
collected, can be analysed using a
standard method to determine the
probability of a leak caused by
corrosion, both at present and in the
future. Assessment of corrosion
probability will help to decide if
urgent action is required, e.g. the
fitting of cathodic protection, tank
lining or the replacement of a tank.
12MAdded
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56-07 STORAGE SILO - wood chip / pellets
There are several hazards in entering and working in a silo. The main hazards include difficult access
and egress, which makes entrapment, escape and rescue more problematic; being engulfed in a free
flowing material if the chips/pellets have blocked and
bridged; the accumulation of vapours, gases or fumes; and the lack of ventilation. Some of these
hazards may be introduced into the silo by the nature of the maintenance work (e.g. welding work
or cleaning work with solvents) or by incoming services.
Added
Title NotesActionFQTitle FQ Action Notes
1. Silos and
storage rooms
Chip silos and storage rooms
should be cleaned out at the end of
each heating season, to avoid
accumulation of dust, bacteria and
fungi.
Chip reception pits should be
equipped with a ladder (set
into the wall) to facilitate entry and
egress.
12MAdded
2. Burn back
control
Check the burn back control device
is in place and that the sensor / wax
seal is operational. Check that the
water supply pressure is correct
[normally in excess of 1 bar].
12MAdded
3. Rubber mat In case of bulk-blown pellet
deliveries - check that the rubber
mat is in place and that there is at
least a 20mm air gap from a wall
opposite the inlet to the store.
12MAdded
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56-08 STORAGE SILO - COAL
The burning of coal is a complex operation involving the storage, handling of solid material, together
with the handling. Coal is abrasive and the wear and tear on mechanical plant considerable, hence
regular maintenance is vital to ensure continuous working and a clean environment.
A risk assessment and method statement must be undertaken before entering any confined space
such as a hopper / silo to ensure that there is adequate ventilation and an absence of any fumes or
flue gases.
Added
Title NotesActionFQTitle FQ Action Notes
1. Status. Empty and check internal and
external coatings.
If there are signs of deterioration
consult the manufacturer.
12MAdded
Page 523 of 614
SWIMMING POOLS
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INTRODUCTORY PROCEDURES57-01 57-01 INTRODUCTORY PROCEDURES
There are two major aspects of swimming pool maintenance, water cleanliness, 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 daily routine of the pool attendant and will cover filters, water
treatment and general cleanliness. In addition regular maintenance of the equipment is necessary and
except in large installations this would normally be carried out by the maintenance contractor at
intervals agreed with the client.
For outdoor pools which are not used in winter whilst it is not normal practice to empty the pool the
specific maintenance procedures should include provision for ensuring that the plant is secure from
frost damage by draining down pumps, pipelines and associated tanks and where appropriate 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 and in the maintenance procedures account must therefore be
taken of the dangers of Legionella, see HSE ACOP L8,2001.
There are two major aspects of swimming pool maintenance, water cleanliness / 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 daily routine of the pool attendant and will cover filters, water
treatment and general cleanliness. In addition regular maintenance of the equipment is necessary and
except in large installations this would normally be carried out by the maintenance service provider at
intervals agreed with the client. Maintenance procedures must take account of the dangers of
Legionella, see HSE ACOP L8,2000 (www.hse.gov.uk).
For outdoor pools which are not used in winter whilst it is not normal practice to empty the pool the
specific maintenance procedures should include provision for ensuring that the plant is secure from
frost damage by draining down pumps, pipelines and associated tanks and where appropriate the
pool valves isolated.
This section does not cover whirlpool and spa baths, steam rooms, e.g. saunas and hydrotherapy
pools these are dealt with in Whirlpools - hydrontherapy SFG 66.
Discharge of Water
In England and Wales discharge to sewers requires the consent of the local water service company ;
discharge to a water course has to be authorized by the regional office of the Environment Agency . In
Scotland the relevant authorities are the local water authority and Environment Protection Agency
respectively; in N. Ireland, the Department of the Environment.
These authorities may have specific requirements about the rate and quality of discharges from
backwashing, dilution, pool emptying etc. Such authorities should be consulted about the operation of
a pool and any proposed changes to it.
Backwash water may need dechlorination if it is to be discharged to a surface water drain
Technical
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SWIMMING POOLS57-02 57-02 SWIMMING POOLS
The main periods for maintaining outdoor swimming pools are in early autumn when the system is
shut down for the winter and the equipment and pool are prepared for the winter and in the late spring
when the pool is made ready for the new season. For indoor pools maintenance should be
programmed for times of minimum use. If fitted constructed with membrane liner care should be taken
to avoid perforation with sharp edges of equipment. Maintenance of water quality is a daily operation
usually carried out either automatically or manually by the pool attendant. (See WATER
TREATMENT).
The main periods for maintaining outdoor swimming pools are in early autumn when the system is
shut down for the winter and the equipment and pool are prepared for the winter and in the late spring
when the pool is made ready for the new season. For indoor pools maintenance should be
programmed for times of minimum use. If constructed with membrane liner ,care should be taken to
avoid perforation with sharp edges of equipment. Maintenance of water quality is a daily operation
usually carried out either automatically or manually by the pool attendant. See Water treatment SFG
65. It is also assumed that cleaning of the pool areas to comply with PAS 39:2003 will be undertaken
by the clients operational staff
Technical
Title NotesActionFQTitle FQ Action Notes
1. Shut down. Isolate from electrical supply by
switching off and withdrawing
fuses.
Ensure that water supply is also
turned off.
12M 3. Shut down. If Required, Isolate from electrical
supply by switching off and
withdrawing fuses.
Ensure that water supply is also
turned off.
6MOther
2. Controls. Check settings and action.12M 4a. Controls. Check settings and action.6MOther
3. Pool cover(s). Check for tears and soundness.
Check condition and security of
anchor bolts.
12M 5. Pool cover(s). Check for tears and soundness.
Check condition and security of
anchor bolts. The underside of pool
covers and moveable floors should
be checked regularly and cleaned
as necessary
6MOther
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Water Quality
Testing
Carry out routine testing of the
water quality. Tests should include:
water clarity
disinfectant level
pH
water temperature
air temperature
The manual monitoring and
measurement of the chemical state
of the pool water should be
performed using colorimetric
comparison kits (comparator or
spectrophotometer) or commercially
available test kits using test tablets.
The accuracy of test kits should be
maintained by:
a) keeping them scrupulously clean
(including rinsing glassware
components with deionized water to
ensure that all traces of test
reagents from previous uses are
removed);
b) using separate cells for pH and
disinfectant testing;
c) not exceeding the shelf life of the
test reagents;
d) following storage instructions;
e) using only the test kit
manufacturer’s specified test
tablets;
f) diluting and testing a second
sample for disinfectant residuals if
the first gives a result at the top or
the bottom of the kit’s range;
g) using a test kit with the applicable
range for the water under test; and
h) being aware of the potential false
readings that can arise from things
like high calcium hardness and
contamination with pool cleaning
chemicals.
Where free chlorine levels are not
monitored and controlled
automatically by the water treatment
plant, manual testing should be
carried out, using commercially
available test kits and the
appropriate tablets.
These tests should be undertaken:
a) before the pool opens;
b) every 2 h during opening hours;
and
c) after it closes.
Even when free chlorine levels are
monitored and controlled by
automatic systems, chlorine levels
should be tested manually at least
three times daily at the start,
midway and at the end of each day.
The tests should monitor both free
1DAdded
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chlorine and combined chlorine
residuals.
Pool water samples for analysis
should be taken at a depth of 200
mm to 400 mm, from a part of the
pool that has been found to be
representative of the general
concentration.
Water Quality
Testing
Carry out routine testing of the
water quality. Tests should include:
alkalinity,
cyanuric acid
See Notes above1WAdded
2. Suction Filters. Clean Filters1DAdded
1. Transfer
Channels
If applicable, the deck-level
transfer channels are be drained a
minimum of once a month. They
should be flushed out with a
disinfecting solution suitable for the
task, for example 10 mg/l
chlorinated water, which can be
returned to the balance tank. The
undersides of transfer channel
grilles should be cleaned.
1MAdded
2. Balance Tanks Balance tanks should be drained at
least twice per year. Debris should
be removed and inner surfaces
brushed and flushed down with a
disinfecting solution, for example 10
mg/l chlorinated water, which can
be returned to the circulation
system via the filters. For safety,
individuals should not enter balance
tanks on their own
6MAdded
4b. Controls Re-calibrate automatic monitoring
equipment. Check all control
indicator lamps and alarms.
1MAdded
6. Suspended
ceilings
In the case of an indoor pool having
a suspended ceiling the wire
hangers holding the ceiling frame to
the slab should be checked by a
structural engineer due to the highly
corrosion nature of the atmosphere
and the possibility of the ceiling
collapsing.
6MAdded
7. Log Book Check log book for any reported
defects and attend as required. Any
works carried out should be clearly
recorded in accordance with the
operating code of practice.
This task is in addition to the daily
check carried out as part of any
operational procedure.
1MAdded
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8. Chlorine gas
detectors
Check chlorine gas detectors in the
plantroom / chemical store.
6MAdded
9. Chemical
dosing
Check and clean the chemical
control system including all dosing
and monitoring equipment. In
addition any specialist items like
ozonators and ultraviolet lamps.
Although the frequency has been
set at 6 Months, the DFE guidance
note Guide 2, Managing Schol
Facilities requires a minimum of 4
visits per year
6MAdded
10. ElectricalAdded
Zones 0 & 1 Ensure notices on all outlets and
control devices are in place.
12MAdded
Supplementary
bonding
Check that all extraneous
conductive parts in zones 0, 1 and
2 are connected by supplementary
bonding conductors to the
protective conductors of exposed
conductive parts in these zones.
12MAdded
Added
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SWIMMING POOLS - FILTERS57-03 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
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. Effective filtration should ensure that water
clarity is good enough to allow unclouded or clear sight of the
bottom of the pool at the deep end.
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
Effective filtration should ensure that water clarity is good enough to allow unclouded or clear sight of
the bottom of the pool at the deep end.
The water turbidity should not exceed 0.5 NTU (nephelometric turbidity units).
Other
Title NotesActionFQTitle FQ Action Notes
1. Backwashing Carry out backwashing of main
filters and discharge the back wash
water to waste. Backwash flow
should be fast enough to fluidise
the sand bed and should have a
speed of at least 30 m/h.
Fluidisation of the bed should be
checked visually if possible, through
a viewing window where provided.
Backwashing should continue at
least as long as recommended by
the manufacturer, but certainly until
the backwash water is clear.
Filters should be backwashed at
least once a week and whenever
the pressure loss across the sand
bed reaches the level specified by
the filter manufacturer.
Filters should be backwashed if the
water circulation has been stopped
(because of a failure or for
maintenance). Backwashing is best
done at the end of the working day.
Air scouring prior to the
backwashing at a speed of
approximately 32 m/h can aid the
backwashing process.
If a filter is being backwashed while
other filters are still in service, flow
to the filter should start and stop
slowly over a 15 second to 20
second period to avoid rapid flow
rate change in the in-service filters.
1WAdded
5. Filter bed Inspect the filter and the top of the
sand bed. Check for signs of
corrosion, problems with the
under-drains and problems with the
filter medium e.g. mud balling,
fissures, uneven bed.
12MAdded
1. Inlet strainer. 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).
12M 2. Inlet strainer. 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).
12MOther
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2. Chemical
cleaning of filter
bed material.
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.
12M 3. Chemical
cleaning of filter
bed material.
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.
12MOther
3. Rate of flow
indicator.
Clean and check operation. The accuracy of the flow meter
should be within 5%.
12M 4. Rate of flow
indicator.
Clean and check operation. The accuracy of the flow meter
should be within 5%.
12MOther
Pre-coat filtration
1. Inlet strainer.
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).
12M Pre-coat filtration
1. Inlet strainer.
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).
12MOther
2. Filter
elements.
Clean off any coating material and
check condition of support
elements.
If replacement necessary, report to
client.
12M 2. Filter
elements.
Clean off any coating material and
check condition of support
elements.
The frequency of this task can be
increased where Coagulants
(sometimes called flocculants) are
not used to enhance the removal of
dissolved, colloidal or suspended
material.
1MTechnical
3. Pipework. Clean off any deposits or sludges.12M 3. Pipework. Clean off any deposits or sludge`s.12MOther
Cartridge type
filters 1. Inlet
strainer.
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).
12M Cartridge type
filters 1. Inlet
strainer.
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).
1MTechnical
2. Seals. Check condition of seals on
cartridge holders. Replace if
necessary.
12M 2. Seals. Check condition of seals on
cartridge holders. Replace if
necessary.
1MTechnical
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SWIMMING POOLS - PIPEWORK, PUMPS, HEATING etc.57-04 57-04 SWIMMING POOLS - PIPEWORK, PUMPS, HEATING etc.
Title NotesActionFQTitle FQ Action Notes
3. Heating
equipment - Oil -
Solar
-Gas
Carry out maintenance procedures
appropriate to the type of heating
plant as detailed in relevant
sections.
Maintenance of heating plant, other
than routine, is best carried out
before the heating season starts.
6M 3. Heating
equipment - Oil -
Solar
-Gas - Heat Pump
Carry out maintenance procedures
appropriate to the type of heating
plant as detailed in relevant
sections. Ensure that the pool
temperature is maintained in
accordance with PAS 39:2003
Table 3. The air temperature should
be no more than 1oC above the
pool temperature. For further
guidance on Maintenance see
Boilers - heat generators SFG 05,
Solar panels SFG 53, and Heat
exchangers SFG 29.
Maintenance of heating plant, other
than routine, is best carried out
before the heating season starts.
Although the frequency has been
set at 6 Months, the DFE guidance
note Guide 2, Managing Schol
Facilities requires a minimum of 4
visits per year.
6MTechnical
Hot water
temperature (at
outlet of post swim
showers).
Monitor to ensure compliance with
ACOP L8, 2000 requirements. Hot
water supplied to the showers
should be piped at no less than 50
°C and mixed to (41 ± 2) °C.
Responsibility for this test should be
agreed with client. Advise client if
temperature outside ACOP L8, 2000
requirements for any remedial work
to be put in hand.
1MAdded
Indoor air
temperatures and
RH
Manually check the pool hall air
temperatures and Relative Humidity
levels
The pool hall air temperatures
should be no more than 1 °C above
that of the water temperature.
Air temperatures over 30 °C should
be avoided.
Relative humidity should be
maintained at a level of (60 ± 10) %
throughout the pool hall area.
1WAdded
3. Pump Check for leaks and corrosion,
tighten gland if required. Check
electrical connections for tightness
and signs of corrosion.
See also Pumps SFG 45.
Although the frequency has been
set at 6 Months, the DFE guidance
note Guide 2, Managing Schol
Facilities requires a minimum of 4
visits per year
12MAdded
4. Ventilation Carry out maintenance procedures
on the ventilation plant serving the
pool and changing areas. For
further Guidance on Maintenance
see Air handling units SFG 03,
Ducting SFG 16 and Fans SFG 20.
The Relative humidity should be
maintained at a level of (60 ± 10) %
throughout the pool hall area. It is
understood that manufacturers of
AHU`s and ductwork specified for
swimming pools will coat internal
surfaces to protect from Chlorine
attack. Therefore standard
maintenance frequencies
recommended in SFG 03, 16 and
20 can be used.
3MAdded
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57-04 SWIMMING POOLS - PIPEWORK, PUMPS, HEATING etc.
Once a pool is winterised then the level of regular maintenance required is very much less than during
the season. There are no hard and fast rules governing the actual date of winterising; however the
lower ambient temperature becomes the more expensive the heating becomes.
The Pool must not be emptied, without professional advice, as hydrostatic pressures can force a
concrete structure out of the ground and ground water can lift and displace liners.
All floating covers should be removed from the pool, cleaned and carefully dried and stored safely
away from vermin. Slatted covers should be cleaned and rolled away for the winter. The fitting of a
proper winter cover will help keep the majority of debris and sunlight out of the pool.
Winterising does not mean that the algae will stop growing, therefore there will be a requirement to
treat the water until the water temperature
drops to about 7°C.
Remove, clean and store all pool-side equipment and summer covers etc. Check all filtration, heating
and cleaning equipment and report on its condition. Remove and store pool cleaner if fitted. De-leaf
and clean the pool.
Check the chemical values and adjust including a shock dose. A number of chemicals which are long
lasting are available for winterisation. However the variance of winter weather and temperature affects
the longevity of these products and occasional testing is recommended
Added
Title NotesActionFQTitle FQ Action Notes
Option 1
Winterisation
Lower the level of the pool water* to
approximately 30 cms below the
skimmers as a frost precaution and
plug
and empty out the skimmer. Store
the pumps in a warm environment.
Isolate all electrics and drain all
equipment such as pumps,
filters, heaters etc. Leave the pool
area and plant room in a tidy state.
1YAdded
Water Testing Check the water condition regularly
and dose if required.
This can be easily done by lifting a
corner of the cover.
Chemicals that dissolve quickly in
the summer will be slower
reacting in the winter, so pre
dissolving them is essential.
1MAdded
Option 2
Winterisation
Set the filter pump time clock
control to allow the pump to run for
one hour per day and set a frost
thermostat to 2oC. Install a bypass
around the heater and drain the
heater, electrically disconnect, or
switch off other
equipment..
1YAdded
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Water Testing Check the water condition regularly
and dose if required.
This can be easily done by lifting a
corner of the cover.
Chemicals that dissolve quickly in
the summer will be slower
reacting in the winter, so pre
dissolving them is essential.
1MAdded
Filters backwash the filter, once every 2
months, or if pool water level
increases
from rainfall.
2MAdded
Re-commissioning Remove the winter cover from the
pool, clean it off, dry and fold it,
then store away. . Store the cover
away from vermin.
• Clean the coping stones and
surround paving to remove any
mould or algae growth.
• Re-fit all the pool side equipment
such as ladders, diving boards etc.
• If necessary re-assemble all the
filtration and heating equipment in
the plant room
• Start the equipment and
thoroughly test it. Heaters should
not be left running unless specific
instructions have been provided.
• Set all time clocks forcorrect
running hours.
• Check all valves for freedom of
operation and ease if necessary.
• De-leaf pool and vacuum or set
the pool cleaner in operation.
• Check and adjust the chemical
values.
• Generally tidy and clean the pool
area and plant room.
Once the pool has been
recommissioned,
run the filter continually for the first
5 days, backwashing daily, to
thoroughly clean the water.
1YAdded
Page 534 of 614
SWITCHES
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ON/OFF SWITCHING DEVICES58-01 58-01 ON/OFF SWITCHING DEVICES
Title NotesActionFQTitle FQ Action Notes
1. Condition Clean and check operation.12MAdded
Vane operated
flow switches
Added
Differential
pressure switches
1. Condition.
Clean and check operation.12M Differential
pressure switches
.
Other
4. Calibration. Check against standard.12M Deleted
Vane operated
flow switches 1.
Condition.
Clean and check operation.12M 1. Condition. Clean and check operation.12MOther
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CONTROL RELAYS58-02 58-02 CONTROL RELAYS
Title NotesActionFQTitle FQ Action Notes
1. General
maintenance.
Carry out as per instructions given
in CONTROL PANELS.
12M 1. General
maintenance.
Carry out as per instructions given
in Control panels SFG 14.
12MOther
Page 537 of 614
TERMINAL UNITS
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TERMINAL UNITS VAV - self powered59-01 59-01 TERMINAL UNITS VAV - self powered
Title NotesActionFQTitle FQ Action Notes
2. Unit filter. Check condition and change if
necessary.
If unit filter is very dirty, check
condition of main filter.
12M 3. Unit filter. Check condition and clean or
change if necessary.
If unit filter is very dirty, check
condition of main filter.
3MTechnical
3. Main filter. Check condition. In a dirty environment it may be
necessary to clean/change main
filter more frequently.
3M Deleted
2. Bellows Where fitted, check condition of
bellows and replace as necessary
6MAdded
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INTRODUCTORY PROCEDURES59-01 59-01 INTRODUCTORY PROCEDURES
The term Terminal Units covers those items of equipment relating to the ingress of ventilating or
conditioned air into the working environment. Operationally 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. Detailed maintenance of the associated controls is
covered in the relevant section.
The term Terminal Units covers those items of equipment relating to the ingress of ventilating or
conditioned air into the working environment. Operationally their effectiveness may be impaired by
the build up of dust and related deposits whilst visually dirt will arise from the atmosphere. In a dirty
environment it may be necessary to increase the frequency of maintenance above that recommended
in this specification. Detailed maintenance of the associated controls is covered in the Controls
SFG14 section.
Technical
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TERMINAL UNITS VAV - fan powered59-02 59-02 TERMINAL UNITS VAV - fan powered
Title NotesActionFQTitle FQ Action Notes
5. Reheaters Check operation and carry out
routine maintenance
For further guidance on maintaining
the reheaters see Heat exchangers
SFG 29-01 and 29-02.
6MAdded
1. Fan motor. Grease or oil bearings.6M 1. Fan motor. Grease or oil bearings. For further guidance on maintaining
fan motors see Motors SFG 39-01.
6MTechnical
2. Dampers. Check operation and lubricate
linkages if necessary.
6M 2. Dampers. Check operation and lubricate
linkages if necessary.
For further guidance on maintaining
damper actuators see Actuators
SFG 01.
6MTechnical
3. LPH and CW
coils.
Check operation and clean.6M 3. LPHW and
CW coils.
Check operation and clean. Comb
any fin damaged areas.
6MTechnical
4. Controls. Check operation. Note:- Calibration,
Interrogation, Control adjustment.
6M 4. Controls. Check operation. Calibration, Interrogation, Control
adjustment. For further guidance on
maintaining controls see Control
panels & controllers SFG 14.
6MTechnical
Page 541 of 614
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INTRODUCTORY PROCEDURES59-02 59-02 INTRODUCTORY PROCEDURES
The term Terminal Units covers those items of equipment relating to the ingress of ventilating or
conditioned air into the working environment. Operationally 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.
The term Terminal Units covers those items of equipment relating to the ingress of ventilating or
conditioned air into the working environment. Operationally their effectiveness may be impaired by
the build up of dust and related deposits whilst visually dirt will arise from the atmosphere. In a dirty
environment it may be necessary to increase the frequency of maintenance above that recommended
in this specification. Detailed maintenance of the associated controls is covered in the Controls
SFG14 section.
Technical
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TERMINAL UNITS VAV - pneumatic powered59-03 59-03 TERMINAL UNITS VAV - pneumatic powered
Title NotesActionFQTitle FQ Action Notes
5. Actuator. If visible, check for dirt, lightly oil
mechanism as required.
12M 5. Actuator. If visible, check for dirt, lightly oil
mechanism as described in
Actuators SFG 01-01 - 01-08
12MOther
7. Filter. Clean or replace as necessary. Frequency of cleaning will depend
upon the environment in which the
unit operates.
6M 7. Filter. Clean or replace as necessary. Frequency of cleaning will depend
upon the environment in which the
unit operates.
3MTechnical
Page 543 of 614
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Change
INTRODUCTORY PROCEDURES59-03 59-03 INTRODUCTORY PROCEDURES
The term Terminal Units covers those items of equipment relating to the ingress of ventilating or
conditioned air into the working environment. Operationally 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.
The term Terminal Units covers those items of equipment relating to the ingress of ventilating or
conditioned air into the working environment. Operationally their effectiveness may be impaired by
the build up of dust and related deposits whilst visually dirt will arise from the atmosphere. In a dirty
environment it may be necessary to increase the frequency of maintenance above that recommended
in this specification. Detailed maintenance of the associated controls is covered in the Controls
SFG14 section.
Technical
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TERMINAL UNITS - Constant volume including mixing59-04 59-04 TERMINAL UNITS - Constant volume including mixing
Title NotesActionFQTitle FQ Action Notes
2. Pneumatic
thermostats.
Check operation by moving set
point. Restore to original setting.
For detailed maintenance see
relevant section.
12M 2. Pneumatic
thermostats.
Check operation by moving set
point. Restore to original setting.
12MTechnical
3. Control
dampers.
Check operation. For high velocity
mixing box change over dampers.
Check seals.
For more information on damper
maintenance see DUCTING
GENERAL .
12M 3. Control
dampers.
Check operation. For high velocity
mixing box change over dampers.
Check seals.
For more information on damper
maintenance see Ducting general
SFG16.
12MOther
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INTRODUCTORY PROCEDURES59-04 59-04 INTRODUCTORY PROCEDURES
The term Terminal Units covers those items of equipment relating to the ingress of ventilating or
conditioned air into the working environment. Operationally 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.
The term Terminal Units covers those items of equipment relating to the ingress of ventilating or
conditioned air into the working environment. Operationally their effectiveness may be impaired by
the build up of dust and related deposits whilst visually dirt will arise from the atmosphere. In a dirty
environment it may be necessary to increase the frequency of maintenance above that recommended
in this specification. Detailed maintenance of the associated controls is covered in the Controls
SFG14 section.
Technical
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TERMINAL UNITS - INDUCTION UNITS59-05 59-05 TERMINAL UNITS - INDUCTION UNITS
Title NotesActionFQTitle FQ Action Notes
5. Damper and/or
pneumatic valves.
Check correct functioning and
rectify any defects.
6M 5. Damper and/or
pneumatic valves.
Check correct functioning and
rectify any defects.
For further guidance see Actuators -
pnuematic actuators SFG 01-04.
6MOther
6. Chilled
water/LPHW
control valves.
Check functioning. For detailed maintenance see
VALVES.
6M 6. Chilled
water/LPHW
control valves.
Check functioning. For detailed maintenance see
Valves SFG 62-01 - 62-07.
6MOther
7. Control
thermostats.
Check operation. Setting should be 19ºC heating and
24ºC cooling. For detailed
maintenance see relevant section.
6M 7. Control
thermostats.
Check operation. Setting should be 19oC heating and
24oC cooling. For detailed
maintenance see relevant section
Switches SFG 58-01.
6MTechnical
8. Isolation
valves.
Check for leaks and rectify as
necessary.
6M 8. Isolation
valves.
Check for leaks and rectify as
necessary.
For detailed maintenance see
Valves SFG 62-01 - 62-07.
6MOther
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INTRODUCTORY PROCEDURES59-05 59-05 INTRODUCTORY PROCEDURES
The term Terminal Units covers those items of equipment relating to the ingress of ventilating or
conditioned air into the working environment. Operationally 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.
The term Terminal Units covers those items of equipment relating to the ingress of ventilating or
conditioned air into the working environment. Operationally their effectiveness may be impaired by
the build up of dust and related deposits whilst visually dirt will arise from the atmosphere. In a dirty
environment it may be necessary to increase the frequency of maintenance above that recommended
in this specification. Detailed maintenance of the associated controls is covered in the Controls
SFG14 section.
Technical
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TERMINAL UNITS - FAN COIL59-06 59-06 TERMINAL UNITS - FAN COIL
Title NotesActionFQTitle FQ Action Notes
9. Strainers Inspect and clean strainers as
necessary.
Report any build up of sludge/filing
to the client.
12MAdded
10. Chilled
water/LPHW
control valves.
Check functioning. For detailed maintenance see
Valves SFG 62-01 to 62-07.
6MAdded
11. Thermostats. Check operation by moving set
point. Restore to original setting.
For detailed maintenance see
Switches SFG 58-01.
12MAdded
1. Status. Switch off and isolate. Electrical isolation should be carried
out in accordance with HSAWA
recommendations. Where units are
ceiling mounted, cover any office
machinery/equipment situated below
unit being serviced.
6M 1. Status. Switch off and isolate. Electrical isolation should be carried
out in accordance with HSE
Guidance document HSG85:2007.
Where units are ceiling mounted,
cover any office
machinery/equipment situated
below unit being serviced.
6MTechnical
2. Coil block. Vent air from cooler and heating
coils (if AAV not fitted).
3M Deleted
3. Condensate
drain connection.
Check connection is clear.6M 2. Condensate
drain connection
and pump
Check connection is clear. Ensure
condensate lift pump is operational
and able to discharge condensate
to the drainage pipework.
The check should also ensure that
the condensate drainage pipework
has the correct fall to allow water to
flow to the drainage stack
6MTechnical
4. Permanent
filters.
Clean and refit, ensuring proper
location.
See FILTERS regarding safety
instructions.
6M 3. Permanent
filters.
Clean and refit, ensuring proper
location.
See Filters SFG 21-02 regarding
safety instructions.
6MTechnical
5. Disposable
type filters.
Replace ensuring proper location. See FILTERS with regard to safety
and disposal procedures.
6M 4. Disposable
type filters.
Replace ensuring proper location. See Filters SFG 21-02 with regard
to safety and disposal procedures.
6MTechnical
6. Test unit. Restore power supply and run unit.
Check airflow is normal at correct
speed setting.
6M 5. Test unit. Restore power supply and run unit.
Check airflow is normal at correct
speed setting.
6MTechnical
7. Casing. Clean. Where units are above false ceilings
ensure that tiles are not left in a
stained condition.
6M 6. Casing. Clean. Where units are above false ceilings
ensure that tiles are not left in a
stained condition.
6MOther
8. Ductwork
flexible couplings
(if fitted).
Check condition.12M 7. Ductwork
flexible couplings
(if fitted).
Check condition. Repair/refix any
ductwork to the spigots as
necessary.
12MOther
9. Grilles and
diffusers.
Clean using vacuum or alternatively
remove and clean.
Care should be taken to avoid
damage to diffuser ceiling lights or
ceiling.
6M 8. Grilles and
diffusers.
Clean using vacuum or alternatively
remove and clean.
Care should be taken to avoid
damage to diffuser ceiling lights or
ceiling.
12MOther
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TERMINAL UNITS VRV SYSTEMS59-07 59-07 TERMINAL UNITS VRV SYSTEMS
Where the installed power on the refrigeration system exceeds 25kW, a Written Scheme of
Examination may be required to comply with the Pressure Systems Safety Regulations 2000
Service providers must be registered to an Approved Certified Scheme provider , in accordance with
the F Gas and Building Regulations.
Added
Title NotesActionFQTitle FQ Action Notes
2. Coils. Clean and remove any debris.3M 2. Coils. Clean and remove any debris.
Comb any damaged areas of fin.
3MTechnical
3. PCBs. Check for damage.3M 5. PCBs. Check for damage.3MOther
4. Electrical
Components.
Check condition.3M 6. Electrical
Components.
Check condition.3MOther
5. Sensors. Check for contact and correct
location.
3M 7. Sensors. Check for contact and correct
location.
3MOther
6. Running
currents and
voltage.
Check and record.3M 8. Running
currents and
voltage.
Check and record.3MOther
7. System neutral
and earth
connections.
Check.3M 9. System neutral
and earth
connections.
Check power supply to unit and
neutral and earth connections.
Record.
3MTechnical
Indoor Unit 8.
Hand Controllers.
Check function. Run units on heating and cooling
cycles if heat pumps
3M Indoor Unit
10. Hand
Controllers.
Check function. Run units on heating and cooling
cycles if heat pumps. Replace
batteries on remote control units as
necessary
3MTechnical
9. Air Filter and
indoor coils.
Clean. Air Filters may initially require
monthly cleaning dependant on
location.
3M 11. Air Filter and
indoor coils.
Clean. Air Filters may initially require
monthly cleaning dependant on
location. For further guidance see
Filters SFG 21-02.
3MOther
10. Drain Lines. Check for free running3M 12. Drain Lines. Check for free running3MOther
11. Power supply. Check and record.3M Deleted
12. Electrical and
Data Cable
connections.
Check condition.3M 13. Electrical and
Data Cable
connections.
Check condition.3MOther
13. Change over
valves and
refrigerant control
devices.
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 must only be carried out by
a contractor registered with
REFCOM , or other mandatory
scheme provider.
3M 14. Change over
valves and
refrigerant control
devices.
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
must only be carried out by a
service provider registered with an
authorised scheme provider.
3MTechnical
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3a. Leaks - Oil Check for oil leaks. Any leak of
refrigerant should be dealt with
immediately.
6MAdded
4. Compressors Carry out Service of the
compressor
For further guidance see
Compressors - refrigeration SFG
12-01.
6MAdded
3 . Leaks -
Refrigerant
Check refrigerant Charge,
recharge/report as found
necessary. Check Joints, valves
including stems, seals, including
seals on replaceable driers and
filters, parts of the system subject
to vibration, connections to safety
or operational devices of the
equipment or system. Examine for
leakage using direct or indirect
measuring methods.
Check for leaks should be part of
the routine servicing by plant
attendants.
Any removed refrigerant must be
recovered and not released to
atmosphere.
Where a system has a refrigerant
charge greater than 300kg, an
automatic leak detection system
must be installed on the system to
comply with the F Gas Regulations
Added
A) Normal
systems:
<3 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
B) 3 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
C) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
D) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
E) Hermetically
sealed systems:
<6 kg
Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
0MAdded
F) 6 kg to 30 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
12MAdded
G) 30 kg to 300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
6MAdded
H) >300 kg Check for oil and refrigerant leaks.
Any leak of refrigerant should be
dealt with immediately.
3MAdded
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INTRODUCTORY PROCEDURES59-07 59-07 INTRODUCTORY PROCEDURES
The term Terminal Units covers those items of equipment relating to the ingress of ventilating or
conditioned air into the working environment. Operationally 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.
VRV Systems are very specialist and should not be treated as a standard split system. They are set
up on commissioning and the set points should not be disturbed.
The term Terminal Units covers those items of equipment relating to the ingress of ventilating or
conditioned air into the working environment. Operationally their effectiveness may be impaired by
the build up of dust and related deposits whilst visually dirt will arise from the atmosphere. In a dirty
environment it may be necessary to increase the frequency of maintenance above that recommended
in this specification. Detailed maintenance of the associated controls is covered in the Controls
SFG14 section.
VRV Systems are very specialist and should not be treated as a standard split system.
They are set up on commissioning and the set points should not be disturbed.
Technical
Page 552 of 614
VACUUM SYSTEMS
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VACUUM SYSTEMS - general60-01 60-01 VACUUM SYSTEMS - general
In addition to routine maintenance, examinations of some pressure vessels are required under the
Pressure Systems Safety Regulations 2000 - see relevant section 40-08.
Maintenance should be carried out by only competent persons.
Added
Title NotesActionFQTitle FQ Action Notes
1. Motors. Follow procedure given for
MOTORS.
12M 1. Motors. Follow procedure given for Motors
SFG 39-01.
12MOther
Air systems -
cleaning 2. Fans.
Follow procedure given for FANS. As used in centralised vacuum
cleaning systems.
12M Air systems -
cleaning
2. Fans.
Follow procedure given for Fans
SFG 20.
As used in centralised vacuum
cleaning systems.
12MOther
5. Filters. Check condition and change as
necessary. See FILTERS.
12M 5. Filters. Check condition and change as
necessary. See Filters SFG 21-02.
12MOther
Liquid systems 7.
Pumps (liquid
systems).
Follow procedure given for PUMPS. As used for swimming and
hydrotherapy pools.
12M Liquid systems
7. Pumps.
Follow procedure given for Pumps
SFG 45.
As used for swimming and
hydrotherapy pools.
12MOther
9. Filters. Check condition and change as
necessary.
12M 9. Filters. Check condition and change as
necessary. See Filters SFG 21.
12MOther
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VACUUM TUBES - cash handling60-02 60-02 VACUUM TUBES - cash handling
In addition to routine maintenance, examinations of some pressure vessels are required under the
Pressure Systems Safety Regulations 2000 - see relevant section 40-08.
Maintenance should be carried out by only competent persons.
Added
Title NotesActionFQTitle FQ Action Notes
d) contactors, Check operation and condition. For more detailed information on the
maintenance of contactors see
POWER SUPPLIES P.D.U.
12M d) contactors, Check operation and condition. For more detailed information on the
maintenance of contactors see
Power supplies (P.D.U) SFG 44-05.
12MOther
e) earth continuity. Check For more detailed information on the
maintenance of earthing electrical
equipment see POWER SUPPLIES
EARTHING.
12M e) earth continuity. Check For more detailed information on the
maintenance of earthing electrical
equipment see Power supplies
earthing SFG 44-06.
12MTechnical
Controller 5. a)
running time of
capsule b) relay
on capsule.
Check Check condition.12M Controller 4. a)
running time of
capsule b) relay
on capsule.
Check condition.12MOther
c) system filters (if
fitted), d) carrier
(capsule(s)), e)
carrier velcro and
lids.
Check pull. Check condition.6M c) system filters (if
fitted), d) carrier
(capsule(s)), e)
carrier Velcro and
lids.
Check pull. Check condition. For more detailed information on the
maintenance of system filters see
Filters SFG 21-02.
6MTechnical
Page 555 of 614
VALVES
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VALVES61-01 61-01 VALVES
When opening valves (especially steam valves etc.) they must be done in such a way as to avoid the
chances of `water hammer` occurring.
Added
Title NotesActionFQTitle FQ Action Notes
2. Inspection Strip down, overhaul and then
rebuild to comply with the
Competent Persons requirements
under the Pressure Regulation and
the written scheme of examination.
The Competent Person may require
additional testing on completion of
the rebuild
12MAdded
1. Operational
status.
Check, rotate handwheel
sufficiently to indicate that wedge is
not seized in closed position nor
jammed in open position. If
normally open, close valve and
reopen.
Action depends upon whether valve
is normally closed or normally open.
If valve is normally open, check
closure performance in the event
that corrosive deposits prevent
wedge seating.
3M 1. Operational
status.
Check, rotate handwheel
sufficiently to indicate that wedge is
not seized in closed position nor
jammed in open position. If
normally open, close valve and
reopen. When fully open, close
valve 1/2 turn to ensure valve does
not jam.
Action depends upon whether valve
is normally closed or normally open.
If valve is normally open, check
closure performance in the event
that corrosive deposits prevent
wedge seating.
3MTechnical
2. Gland leakage. Check, within first week slightly
tighten gland nuts. If after a period
leakage still occurs replace gland.
After installation or replacement
check for gland leakage daily for
one week. Early signs of slight leaks
are due to 'bedding in' or drying out
and are usually cured by tightening
of gland nuts. Continuous leakage
can lead to erosion or corrosion of
the valve stem.
3M 2. Gland leakage. Ensure correct packing material is
used for the fluid in the pipeline
After installation or replacement
check for gland leakage daily for
one week. Early signs of slight
leaks are due to `bedding in` or
drying out and are usually cured by
tightening of gland nuts.
Continuous leakage can lead to
erosion or corrosion of the valve
stem.
3MTechnical
1. Operational
status.
Check by rotating handwheel
sufficiently to ensure freedom of
movement.
3M 1. Operational
status.
Check by rotating handwheel
sufficiently to ensure freedom of
movement. When fully open, close
valve 1/2 turn to ensure valve does
not jam.
3MOther
2. Gland leakage. Check within first week, slightly
tighten gland nuts. If after a period
leakage still occurs, replace gland.
After installation or replacement
check for gland leakage daily for
one week. Early signs of slight leaks
are due to 'bedding in' or drying out
and are usually cured by tightening
of gland nuts. Continuous leakage
can lead to erosion or corrosion of
the valve stem.
3M 2. Gland leakage. Ensure correct packing material is
used for the fluid in the pipeline
After installation or replacement
check for gland leakage daily for
one week. Early signs of slight
leaks are due to `bedding in` or
drying out and are usually cured by
tightening of gland nuts.
Continuous leakage can lead to
erosion or corrosion of the valve
stem.
3MTechnical
2. Stem leakage. If evidence of leakage, inject
correct compound simultaneously
rotating plug.
After installation or overhaul check
daily for one week and then at six
monthly intervals.
3M 2. Stem leakage. If evidence of leakage, inject
correct compound simultaneously
rotating plug.
After installation or overhaul check
daily for one week and then at three
monthly intervals.
3MTechnical
1.Operational
status.
Valve normally closed, rotate
handwheel to ensure freedom of
movement.
Close valve (if system allows) to
check seat tightness. If valve
normally closed, drop differential
pressure to 1 bar or less (if system
allows) and partially rotate to check
for freedom from galling seats.
3M 1.Operational
status.
Valve normally closed, rotate
handwheel to ensure freedom of
movement. When fully open, close
valve 1/2 turn to ensure valve does
not jam.
Close valve (if system allows) to
check seat tightness. If valve
normally closed, drop differential
pressure to 1 bar or less (if system
allows) and partially rotate to check
for freedom from galling seats.
3MOther
Page 557 of 614
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2. Gland leakage. Check, within first week slightly
tighten gland nuts. If after a period
leakage still occurs, replace gland.
After installation or replacement
check for gland leakage daily for
one week. Early signs of slight leaks
are due to 'bedding in' or drying out
and are usually cured by tightening
of gland nuts. Continuous leakage
can lead to erosion or corrosion of
the valve stem.
1W Deleted
3. Body leakage. Check for body/cover joint leakage
and tighten nuts to stop.
As a matter of routine any visible
signs of leakage should be reported
to the site supervisor.
12M 2. Body leakage. Check for body/cover joint leakage
and tighten nuts to stop.
As a matter of routine any visible
signs of leakage should be reported
to the site supervisor.
1MOther
4. Overall
condition.
Inspect for external deterioration
due to leaks at end flanges or
aggressive environment.
Leakage from end flanges can be
due to pipe strains, ground
settlement, poor joints or poor pipe
supports.
12M 3. Overall
condition.
Inspect for external deterioration
due to leaks at end flanges or
aggressive environment.
Leakage from end flanges can be
due to pipe strains, ground
settlement, poor joints or poor pipe
supports.
12MOther
1. Operational
status.
Check by raising gagging lever to
discharge steam or air. Release
gagging lever to reseat. Check for
dirt or damage.
Important: Great care must be
exercised to avoid injury to
personnel. Check that discharge is
to free space or if piped, that pipe
outlet is not directed to personnel.
NOTE: Check with insurance
company for frequency of
mandatory checks.
3M 1. Operational
status.
Check by raising gagging lever to
discharge steam or air. Release
gagging lever to reseat. Check for
dirt or damage.
Important: Great care must be
exercised to avoid injury to
personnel. Check that discharge is
to free space or if piped, that pipe
outlet is not directed to personnel.
Check with insurance company for
frequency of mandatory checks.
3MOther
2. Bursting discs
(if ftted).
Check condition, report.12M 3. Bursting discs
(if fitted).
Check condition, report. The Competent Person should be
contacted for the routine
replacement frequency for the
bursting discs
12MOther
Steam pressure
reducing valves
It is recommended that this type of
valve should be dismantled for a
complete overhaul every twelve to
eighteen months, preferably with the
valve removed from the pipeline.
18M Steam pressure
reducing valves
The written scheme of examination
may require the valves to be
Stripped down, overhauled and then
rebuilt to comply with the Competent
Persons requirements under the
Pressure Regulation
12MLegislative
Boiler valves Note: See also BOILERS for safety
valves.
Boiler valves The written scheme of examination
may require the valves to be
Stripped down, overhauled and then
rebuilt to comply with the Competent
Persons requirements under the
Pressure Regulation
Legislative
1. Main stop
valve.
Lap seats, inspect for corrosion,
reset valve at correct set pressure
and carry out accumulation test.
12M 1. Safety valve. Lap seats, inspect for corrosion,
reset valve at correct set pressure
and carry out accumulation test.
12MOther
3. Water level
controls.
Blowdown and check operation. This should be carried out daily. Deleted
4. Sequencing
valve.
Clean and lap seats, check for
ease of operation.
Note: See also BOILERS for safety
valves.
12M 3. Sequencing
valve.
Clean and lap seats, check for ease
of operation.
See also Boilers SFG 05-01 for
safety valves.
12MTechnical
5. Water level
gauge
Refit sight glass, repack cock plugs
and check for ease of operation.
Aggressive site conditions may
require increased frequency of
these items. Gauge glasses should
be regularly replaced before they
break.
6M 4. Water level
gauge (sight
glasses)
Refit sight glass, repack cock plugs
and check for ease of operation
and isolation.
Aggressive site conditions may
require increased frequency of
these items. Gauge glasses should
be regularly replaced before they
break.
6MTechnical
Page 558 of 614
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Reason For
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Radiator Valves
TRVs
Check air temperature calibration
against surface temperature of heat
emitter. Advise client if air flow
around sensor is resticted or
effected by any reflected or other
thermal gains.
Low temperature surfaces for heat
emitters are desirable in homes for
senior citizens/disabled.
12M Radiator Valves
TRVs
Check air temperature calibration
against surface temperature of heat
emitter. Advise client if air flow
around sensor is restricted or
effected by any reflected or other
thermal gains.
Low temperature surfaces for heat
emitters are desirable in homes for
senior citizens/disabled.
12MOther
Page 559 of 614
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TAP AND OUTLET FITTINGS61-02 61-02 TAP AND OUTLET FITTINGS
A large range of outlet fittings suitable for high and low pressure supplies are fitted in this country ,
most requiring little or no regular maintenance except for the replacement of leaking washers, ceramic
disc cartridges or the repacking of spindle glands which should be done 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’s instructions , 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 been used.
A large range of outlet fittings suitable for high and low pressure supplies are fitted in this country ,
most requiring little or no regular maintenance except for the replacement of leaking washers, ceramic
disc cartridges or the repacking of spindle glands which should be done 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’s instructions , 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 been used.
Other
Title NotesActionFQTitle FQ Action Notes
1. Operational
status.
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.
12M 1. Operational
status.
Operate head to ensure the
stopcock or tap is operating
correctly. If normally open, close,
check that the flow of fluid stops
and then re-open. When fully open,
close valve 1/2 turn to ensure valve
does not jam.
Clean exposed stem prior to
operation. If cock or tap fails to
isolate water supply, re-washer and
reset as necessary.
12MTechnical
1.Operational
status.
Operate handwheel 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 Bye-law,
stop valves must not be less
suitable for the purpose than those
which comply with: BS 1010, BS
5433 or BS 5163 .
12M 1.Operational
status.
Operate handwheel or stem to test
that wedge is not seized in closed
position. If normally open close
valve and re-open. When fully
open, close valve 1/2 turn to ensure
valve does not jam.
To comply with the Water Bye-law,
stop valves must not be less
suitable for the purpose than those
which comply with: BS 1010-2:1973,
BS 5433:1976 or BS 5163 -1 & 2:
2004
12MTechnical
Page 560 of 614
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SERVICE VALVES61-03 61-03 SERVICE VALVES
Title NotesActionFQTitle FQ Action Notes
1. Operational
status.
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.
12M 1. Operational
status.
Operate head to ensure the
stopcock or tap is operating
correctly. If normally open, close
and then re-open. When fully open,
close valve 1/2 turn to ensure valve
does not jam.
Clean exposed stem prior to
operation. If cock or tap fails to
isolate water supply, re-washer and
reset as necessary.
12MOther
1. Operational
status.
Operate handwheel 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 must be
WRC approved and must not be
less suitable for the purpose than
those which comply with: BS 1010,
BS 5433 or BS 5163.
12M 1. Operational
status.
Operate handwheel or stem to test
that wedge is not seized in closed
position. If normally open close
valve and re-open. When fully
open, close valve 1/2 turn to ensure
valve does not jam.
To comply with the Water
Regulations, stop valves must be
WRC approved and must not be
less suitable for the purpose than
those which comply with: BS 1010,
BS 5433 or BS 5163.
12MOther
Page 561 of 614
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COMBINATION TAP ASSEMBLIES, MIXING VALVES/TAPS61-04 61-04 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 the following guideline schedule is suggested to cover average duty
and site conditions. For higher risk environments, e.g. Healthcare, more frequent checks may be
appropriate. See HVCA publications (ref; DCHI/1) for values and ACOP L8, 2001 for Legionella
information.
The frequency and extent of attention required will vary according to the prevailing site and
operational conditions, however the following guideline schedule is suggested to cover average duty
and site conditions. For higher risk environments, e.g. Healthcare, more frequent checks may be
appropriate. See B&ES (the Building & Engineering Services Association, formerly the HVCA)
publications ref; DCHI/1 Domestic Central Heating Installation Specification for values and ACOP L8,
2000 (www.hse.gov.uk) for Legionella information.
Other
Title NotesActionFQTitle FQ Action Notes
2. Temperature For thermostat and pressure
balanced mixers, blend temperature
should stabilise quickly and remain
with SYMBOL 177 \f 'Symbol' \s 12
2 oC of set value. For manual
mixers, refer to commissioning data.
TO BE CHECKED AS TO WHAT IS
MEANT!
2. Temperature For thermostat and pressure
balanced mixers, blend temperature
should stabilise quickly and remain
within 1oC to 2oC of set value. For
manual mixers, refer to
commissioning data.
At water temperatures above 50°C
there is a risk of scalding, which
increases with temperature and time
of contact. In premises used by
persons at risk, e.g. old people, sick
persons, people with reduced
mental capacity, reduced mobility,
anyone with sensory impairment
and children, fail safe
thermostatically controlled mixing
valves must be used. Department of
Health, HTM 04-01 Part A sets out
the safe water temperatures and
appropriate delivery devices
(TMV`s) over a range of
areas/activities. HS(G)220 Health
and safety in care homes - issued
12/01 (file 357) recommends that
where vulnerable people are at risk
from scalding during whole body
immersion, water temperatures do
not exceed 44°C. This should be
checked by clients`s staff at least
monthly. NHS MES (Model
Engineering Specification) D 08
applies.
0MTechnical
b)
adjustable/pre-set
maximum.
b)
adjustable/pre-set
maximum.
Operate flow controls and check
blend temperature. Check
maximum and minimum blend
temperature.
6MTechnical
Page 562 of 614
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4. Temperature
control.
Operate mixer at blend
temperature, then open other local
cold outlets off common supply.
Check shift in blend temperature
with reference data compiled at the
commissioning stage.
6M 4. Temperature
control.
Operate mixer at blend
temperature, then open other local
cold outlets off common supply.
Check shift in blend temperature
with reference data compiled at the
commissioning stage.
At water temperatures above 50°C
there is a risk of scalding, which
increases with temperature and time
of contact. In premises used by
persons at risk, e.g. old people, sick
persons, people with reduced
mental capacity, reduced mobility,
anyone with sensory impairment
and children, fail safe
thermostatically controlled mixing
valves must be used. Department of
Health, HTM 04-01 Part A chapter 9
table 4 on page 31 sets out the safe
water temperatures and appropriate
delivery devices (TMV`s) over a
range of areas/activities. HS(G)220
Health and safety in care homes -
issued 12/01 (file 357) recommends
that where vulnerable people are at
risk from scalding during whole body
immersion, water temperatures do
not exceed 44°C. This should be
checked by client`s staff at least
monthly. NHS MES (Model
Engineering Specification) D 08
applies.
6MTechnical
8. Spray heads
(showers).
Check spray pattern and flow rate.
Clean as appropriate.
Note ACOP L8, 2001 applies.3M 8. Spray heads
(showers).
Check spray pattern and flow rate.
Clean and descale as appropriate.
ACOP L8, 2000 (www.hse.gov.uk)
applies.
3MOther
Page 563 of 614
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a) ) temperature
control, b) )flow
control(s), c) )inlet
check valves, d)
)automatic drain
valve.
a) ) temperature
control, b) )flow
control(s), c) )inlet
check valves, d)
)automatic drain
valve.
Operate mixing valve at blend
temperature, then isolate cold
supply. Operate fully and check for
effective closure. Check effective
operation.
Check shift in blend temperature
with reference data compiled at the
commissioning stage.
At water temperatures above 50°C
there is a risk of scalding, which
increases with temperature and time
of contact. In premises used by
persons at risk, e.g. old people, sick
persons, people with reduced
mental capacity, reduced mobility,
anyone with sensory impairment
and children, fail safe
thermostatically controlled mixing
valves must be used. Department of
Health, HTM 04-01 Part A sets out
the safe water temperatures and
appropriate delivery devices
(TMV`s) over a range of
areas/activities. HS(G)220 Health
and safety in care homes - issued
12/01 (file 357) recommends that
where vulnerable people are at risk
from scalding during whole body
immersion, water temperatures do
not exceed 44°C. This should be
checked by clients staff at least
monthly. NHS MES (Model
Engineering Specification) D 08
applies.
Technical
Page 564 of 614
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SHOWER VALVES61-05 61-05 SHOWER VALVES
Note: Frequency of maintenance will depend upon use and the quality of the water and should be
agreed with client.
Frequency of maintenance will depend upon use and the quality of the water and should be agreed
with client. For higher risk environments, e.g. Healthcare, more frequent checks may be appropriate.
See B&ES (the Building & Engineering Services Association, formerly the HVCA) publications ref;
DCHI/1 Domestic Central Heating Installation Specification for values and ACOP L8, 2000 for
Legionella information.
Technical
Title NotesActionFQTitle FQ Action Notes
2. Thermostat. Check mixed water outlet setting. Ensure digital
thermometer/sensor is immersed in
flowing water, if measurement taken
at shower head. It a requirement
that the sensing device is Certified
as within calibration, a mercury
thermometer must not be used.
6M 2. Thermostat. Check mixed water outlet setting. Ensure digital thermometer/sensor
is immersed in flowing water, if
measurement taken at shower
head. It a requirement that the
sensing device is Certified as within
calibration, a mercury thermometer
must not be used.
6MOther
3. Temperature
limiter.
Check mixed water outlet
temperature at limit safety stop.
Limiter setting 42ºC.6M 3. Temperature
limiter.
Check mixed water outlet
temperature at limit safety stop.
Limiter setting should be set
between 37oC and 46oC depending
on the users.
At water temperatures above 50°C
there is a risk of scalding, which
increases with temperature and time
of contact. In premises used by
persons at risk, e.g. old people, sick
persons, people with reduced
mental capacity, reduced mobility,
anyone with sensory impairment
and children, fail safe
thermostatically controlled mixing
valves must be used. Department of
Health, HTM 04-01 Part A sets out
the safe water temperatures and
appropriate delivery devices
(TMV`s) over a range of
areas/activities. HS(G)220 Health
and safety in care homes - issued
12/01 (file 357) recommends that
where vulnerable people are at risk
from scalding during whole body
immersion, water temperatures do
not exceed 44°C. This should be
checked by clients staff at least
monthly. NHS MES (Model
Engineering Specification) D 08
applies.
6MTechnical
4. Strainers
(where fitted).
Clean. Limiter setting 42ºC.6M 4. Strainers
(where fitted).
Check and clean.6MOther
Page 565 of 614
VALVES -AUTOMATIC CONTROL
Page 566 of 614
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PRE - MAINTENANCE PROCEDURES62-01 62-01 PRE - MAINTENANCE PROCEDURES
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, to avoid undue repetition in maintenance the following terms
have been used in the schedules.
Manufacturer's maintenance instructions.
Manufacturer's lubrication instructions.
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. Keep note of 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.
7. Check that control cables have been installed with the correct polarity
There are a large number of valve manufacturers who each call for specific maintenance and
lubrication procedures for their products, to avoid undue repetition in maintenance the following terms
have been used in the schedules.
Manufacturer`s maintenance instructions.
Manufacturer`s lubrication instructions.Technical
Technical
Page 567 of 614
Previous
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Updated
Version
Reason For
Change
ROTARY VALVES - Shoe or Slipper62-02 62-02 ROTARY VALVES - Shoe or Slipper
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, to avoid undue repetition in maintenance the following terms
have been used in the schedules.
Manufacturer's maintenance instructions.
Manufacturer's lubrication instructions
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. Keep a note of 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.
7. Check that control cables have been installed with the correct polarity
There are a large number of valve manufacturers who each call for specific maintenance and
lubrication procedures for their products, to avoid undue repetition in maintenance the following terms
have been used in the schedules.
Manufacturer`s maintenance instructions.
Manufacturer`s lubrication instructions
Technical
Title NotesActionFQTitle FQ Action Notes
1. Operational
status
Operate and check for correct
rotary travel. Refer to
manufacturer's maintenance
instructions.
Check by operation of the actuator,
see - ACTUATORS - MOTOR
DRIVEN.
12M 1. Operational
status
Operate and check for correct
rotary travel. Refer to
manufacturer`s maintenance
instructions.
Check by operation of the actuator,
see - Acuators - motor driven SFG
1-06.
12MOther
Page 568 of 614
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Reason For
Change
BUTTERFLY AND BALL VALVES62-03 62-03 BUTTERFLY AND BALL VALVES
Pre-maintenance Procedure
This procedure applies to all types of automatic control valves and requires that before any
maintenance is undertaken all 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, to avoid undue repetition in maintenance the following terms
have been used in the schedules.
Manufacturer's maintenance instructions.
Manufacturer's lubrication instructions.
Pre-maintenance Procedure
This procedure applies to all types of automatic control valves and requires that before any
maintenance is undertaken all 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. Keep a note of 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
7. Check that control cables have been installed with the correct polarity
There are a large number of valve manufacturers who each call for specific maintenance and
lubrication procedures for their products, to avoid undue repetition in maintenance the following terms
have been used in the schedules.
Manufacturer`s maintenance instructions.
Manufacturer`s lubrication instructions.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Operational
status
Operate and check for correct
rotary travel. Refer to
manufacturer's maintenance
instructions.
Check by operation of the actuator,
see - ACTUATORS - MOTOR
DRIVEN.
12M 1. Operational
status
Operate and check for correct
rotary travel. Refer to
manufacturer`s maintenance
instructions.
Check by operation of the actuator,
see - Acuators - motor driven SFG
1-06.
12MOther
Page 569 of 614
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SELF ACTING and THERMAL VALVES62-04 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
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, to avoid undue repetition in maintenance the following terms
have been used in the schedules.
Manufacturer's maintenance instructions.
Manufacturer's lubrication instructions.
<B>Pre-maintenance procedure</B>
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. Keep a note of any settings made; i.e. min/max travel
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.
7. Check that control cables have been installed with the correct polarity
There are a large number of valve manufacturers who each call for specific maintenance and
lubrication procedures for their products, to avoid undue repetition in maintenance the following terms
have been used in the schedules.
Manufacturer`s maintenance instructions.
Manufacturer`s lubrication instructions.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Operational
status.
Check for correct travel. Check
integrity of capillary. Refer to
manufacturer's maintenance
instructions.
Refer to - motor driven actuators. In
some cases manual override is only
available by removal of actuating
head.
12M 1. Operational
status.
Check for correct travel. Check
integrity of capillary. Refer to
manufacturer`s maintenance
instructions.
Check by operation of the actuator,
see - Acuators - motor driven SFG
1-06. In some cases manual
override is only available by removal
of actuating head.
12MOther
Page 570 of 614
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Reason For
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SOLENOID VALVES62-05 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, to avoid undue repetition in maintenance the following terms
have been used in the schedules.
Manufacturer's maintenance instructions.
Manufacturer's lubrication instructions.
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. keep a note of 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.
7. Check that control cables have been installed with the correct polarity
There are a large number of valve manufacturers who each call for specific maintenance and
lubrication procedures for their products, to avoid undue repetition in maintenance the following terms
have been used in the schedules.
Manufacturer`s maintenance instructions.
Manufacturer`s lubrication instructions.
Other
Page 571 of 614
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Reason For
Change
SEAT VALVES62-07 62-07 SEAT VALVES
Title NotesActionFQTitle FQ Action Notes
1. Operational
status.
Operate and check for correct
linear movement.
Check by operation of the actuator,
Motor Driven Actuators. See
ACTUATORS-Motor Driven.
12M 1. Operational
status.
Operate and check for correct
linear movement.
Check by operation of the actuator,
see - Acuators - motor driven SFG
1-06.
12MOther
Page 572 of 614
VEHICLE ACCESS
Page 573 of 614
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UNDERFLOOR HEATING including VEHICLE ACCESS RAMPS63-01 63-01 UNDERFLOOR HEATING including VEHICLE ACCESS RAMPS
Title NotesActionFQTitle FQ Action Notes
3. Controls. Check operation. For more detailed maintenance
instructors, see relevant section.
12M 3. Controls. Check operation. For more detailed maintenance
instructors, see relevant section
Control panels and controllers SFG
14.
12MOther
4. Frost
actuation.
Check sensor, if faulty, replace.
Check operation.
For more detailed maintenance
instructions, see relevant section.
12M 4. Frost
actuation.
Check sensor, if faulty, replace.
Check operation.
12MOther
Page 574 of 614
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AUTOMATIC VEHICLE BARRIER63-02 63-02 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 else switching on again when work is in progress. This may require a
Permit To Work.
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 else switching on again when work is in progress. This may require a
Permit To Work.
Other
Title NotesActionFQTitle FQ Action Notes
6. Motor
overload.
Check for correct operation and
adjust as necessary.
(See also MOTORS.)6M 6. Motor
overload.
Check for correct operation and
adjust as necessary.
See also Motors SFG39-01.6MOther
Page 575 of 614
VENTILATION ANCILLARIES
Page 576 of 614
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INTRODUCTORY PROCEDURES64-01 64-01 INTRODUCTORY PROCEDURES
1 Local Exhaust Ventilation (LEV) – fume extract
In bus and vehicle garages and many other work areas where the build up of dangerous fumes may
occur, special air extraction systems are often required/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 258, 2008 applies under the
COSHH Regulations. It is esential to ensure that any discharges do not cause harm to others,
discharge areas are to be checked as safe.
2 Life supporting systems
This equipment is essential in hazardous areas and it is vital that it must be well maintained. Because
of its importance maintenance of such equipment must be carried out by qualified specialist
personnel.
1 Local Exhaust Ventilation (LEV) – fume extract
In bus and vehicle garages and many other work areas where the build up of dangerous fumes may
occur, special air extraction systems are often required/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 local exhaust ventilation highlighted in HSG 258: 2008
(www.hse.gov.uk), applies under the COSHH Regulations. It is essential to ensure that any
discharges do not cause harm to others, discharge areas are to be checked as safe.
2 Life supporting systems
This equipment is essential in hazardous areas and it is vital that it must be well maintained. Because
of its importance maintenance of such equipment must be carried out by qualified specialist
personnel.
Other
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MOTOR DRIVEN EXHAUST HOSE REEL64-02 64-02 MOTOR DRIVEN EXHAUST HOSE REEL
Title NotesActionFQTitle FQ Action Notes
1. Extract Fans Carry out routine maintenance of
the extract fans. For Guidance see
Fans - extract SFG 20-08
Depending on what the fans are
extracting, the maintenance
frequencies may need to be
increased.
6MAdded
9 System Undertaken a Thorough test and
Inspection of the system in
accordance with Section 10 of
ACOP 258:2008. Thorough’ means
careful, methodical, painstaking
and complete. The task should
only be carried out by a competent
person. The term Competence is
defined Chapter 2 and the
Appendix 1 of the ACOP 258:2008
The maximum time between tests of
LEV systems is set down in COSHH
and for most systems this is 14
months (see the exceptions in Table
18 of the ACOP 258:2008). In
practice this is normally taken to
mean annually. If wear and tear on
the LEV system is liable to mean
that the system effectiveness will
degrade between tests then
thorough examinations and tests
should be more frequent.
12MAdded
1. Hose, both
starter hose and
extensions, if fitted
and hose stop.
Check for flattening and damage.
Check condition of hose stop and
location on hose.
12M 2. Hose, both
starter hose and
extensions, if fitted
and hose stop.
Check for flattening and damage.
Check condition of hose stop and
location on hose.
12MOther
2.Control box and
operation.
Check functions, i.e. up, down,
on/off fan if RCR reel fitted with
auto fan contractor.
With pendant control up/down only.
Remote control reel (RCR) only has
ability for:- on hose lowering fan will
start and on retraction will switch off
only if reel either a) combi-unit, or b)
fitted with fan contractor.
12M 3.Control box and
operation.
Check functions, i.e. up, down,
on/off fan if RCR reel fitted with
auto fan contractor.
With pendant control up/down only.
Remote control reel (RCR) only has
ability for:- on hose lowering fan will
start and on retraction will switch off
only if reel either a) combi-unit, or b)
fitted with fan contractor.
12MOther
3. Upper and
lower switches.
Check function and condition of
upper and lower limit switch.
Lower limit switch activates when
reel has lowered its full length of
hose.
12M 4. Upper and
lower switches.
Check function and condition of
upper and lower limit switch.
Lower limit switch activates when
reel has lowered its full length of
hose.
12MOther
4. Infrared
transmitter.
Check functions and condition. Test
battery and replace if necessary.
Applies to RCR only.12M 5. Infrared
transmitter.
Check functions and condition.
Test battery and replace if
necessary.
Applies to RCR only.12MOther
5. Main drive
gear.
Check overall condition of gear for
wear.
Gear will be visible on removal of
control cover.
12M 6. Main drive
gear.
Check overall condition of gear for
wear.
Gear will be visible on removal of
control cover.
12MOther
6.Swivel coupling
and drive motor.
Check for free drive/rotation of reel. (See also MOTORS12M 7 .Swivel coupling
and drive motor.
Check for free drive/rotation of reel.12MOther
7. Nozzle. Check damper for damage and
operation of spring. Check
operation of grip and general
condition of nozzle.
Mole grip type clamp only available
on rubber/steel construction nozzle.
12M 8. Nozzle. Check damper for damage and
operation of spring. Check
operation of grip and general
condition of nozzle.
Mole grip type clamp only available
on rubber/steel construction nozzle.
12MOther
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SPRING RECOIL HOSE REEL64-03 64-03 SPRING RECOIL HOSE REEL
Title NotesActionFQTitle FQ Action Notes
1. Hose, both
starter hose and
extension, if fitted,
and hose stop.
Check for flattening and damage.
Check condition of hose stop and
location on hose.
12M 2. Hose, both
starter hose and
extension, if fitted,
and hose stop.
Check for flattening and damage.
Check condition of hose stop and
location on hose.
12MOther
2.Spring and
ratchet.
Check recoiling action of reel and
correct tensioning of spring. Check
operation of ratchet.
12M 3.Spring and
ratchet.
Check recoiling action of reel and
correct tensioning of spring. Check
operation of ratchet.
12MOther
3.Swivel coupling
and drum.
Check for free movement/rotation
of drum.
12M 4.Swivel coupling
and drum.
Check for free movement/rotation
of drum.
12MOther
4. Auto on/off
switch for fan, if
fitted.
Check location and mounting of two
switch trigger blocks on drum side.
Check operation of switch for
control fan.
12M 5. Auto on/off
switch for fan, if
fitted.
Check location and mounting of two
switch trigger blocks on drum side.
Check operation of switch for
control fan.
12MOther
5.
Suspension/mount
ing bolts.
Check tension on mounting bolts
and nip up if required.
12M 6.Suspension/mou
nting bolts.
Check tension on mounting bolts
and nip up if required.
12MOther
6. Nozzle. Check damper for damage and
operation of spring. Check
operation of grip and general
condition of nozzle.
Mole grip type clamp only available
on rubber/steel constructed nozzles.
12M 7. Nozzle. Check damper for damage and
operation of spring. Check
operation of grip and general
condition of nozzle.
Mole grip type clamp only available
on rubber/steel constructed nozzles.
12MOther
1. Extract Fans Carry out routine maintenance of
the extract fans. For Guidance see
Fans - extract SFG 20-08
Depending on what the fans are
extracting, the maintenance
frequencies may need to be
increased.
6MAdded
9 System Undertaken a thorough test and
Inspection of the system in
accordance with Section 10 of
ACOP 258:2008. The task should
only be carried out by a competent
person. The term Competence is
defined Chapter 2 and the
Appendix 1 of the ACOP 258:2008
The maximum time between tests of
LEV systems is set down in COSHH
and for most systems this is 14
months (see the exceptions in Table
18 of the ACOP 258:2008). In
practice this is normally taken to
mean annually. If wear and tear on
the LEV system is liable to mean
that the system effectiveness will
degrade between tests then
thorough examinations and tests
should be more frequent.
12MAdded
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MOBILE DUST SEPARATOR FOR SPOT EXTRACTION64-04 64-04 MOBILE DUST SEPARATOR FOR SPOT EXTRACTION
Title NotesActionFQTitle FQ Action Notes
1. Extract Fans Carry out routine maintenance of
the extract fans. For Guidance see
Fans - extract SFG 20-08
Depending on what the fans are
extracting, the maintenance
frequencies may need to be
increased.
6MAdded
8. System Undertaken a thorough test and
Inspection of the system in
accordance with Section 10 of
ACOP 258:2008. The task should
only be carried out by a competent
person. The term Competence is
defined Chapter 2 and the
Appendix 1 of the ACOP 258:2008
The maximum time between tests of
LEV systems is set down in COSHH
and for most systems this is 14
months (see the exceptions in Table
18 of the ACOP 258:2008). In
practice this is normally taken to
mean annually. If wear and tear on
the LEV system is liable to mean
that the system effectiveness will
degrade between tests then
thorough examinations and tests
should be more frequent.
12MAdded
9. Mobile Unit Undertake a test of the unit
(Portable Appliance Test) in line
with the requirements of the
Electricity at Work Act 1989
(Regulation 4(2)). For Guidance
see Portable equipment PAT testing
SFG 42-01.
12MAdded
1. Suction and
interconnecting
hoses.
Check condition for damage or
flattening.
12M 2. Suction and
interconnecting
hoses.
Check condition for damage or
flattening.
Frequency could be greater
depending on the process that the
LEV has been installed for. See
table 18 in HSG 258: 2008
12MOther
2. Mounting. Check tension on mounting bolt
between handle, dust collector,
plus motor and filter housing.
12M 3. Mounting. Check tension on mounting bolt
between handle, dust collector, plus
motor and filter housing.
12MOther
3. Switch cable
and motor.
Check full length of cable for
damage and operation of switch.
Check for smooth running of motor.
12M 4. Switch cable
and motor.
Check full length of cable for
damage and operation of switch.
Check for smooth running of motor.
12MOther
4. Pressure
reduction hose.
Check condition and connections of
small bore hose.
12M 5. Pressure
reduction hose.
Check condition and connections of
small bore hose.
12MOther
5. Gaskets and
cyclone mounting
rod.
Check top of cyclone for debris and
correct location of mounting rod.
For access, unclip lid assembly from
over-bin and unbolt cyclone plate.
After replacing lid and cyclone
arrangement check seating of
gasket.
12M 6. Gaskets and
cyclone mounting
rod.
Check top of cyclone for debris and
correct location of mounting rod.
For access, unclip lid assembly from
over-bin and unbolt cyclone plate.
After replacing lid and cyclone
arrangement check seating of
gasket.
12MOther
6. Filter. Check condition and replace as
necessary. On replacement of filter
check condition of gasket.
Test pressure of supplies and
ensure they conform to the
manufacturers recommendations
and record results on
commissioning sheet.
12M 7. Filter. Check condition and replace as
necessary. On replacement of filter
check condition of gasket.
Test pressure of supplies and
ensure they conform to the
manufacturers recommendations
and record results on
commissioning sheet.
12MOther
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MOBILE ELECTRONICALLY CONTROLLED CYCLONE SEPARATOR64-05 64-05 MOBILE ELECTRONICALLY CONTROLLED CYCLONE SEPARATOR
Title NotesActionFQTitle FQ Action Notes
1. Suction and
interconnecting
hoses.
Check condition for damage or
flattening.
12M 2. Suction and
interconnecting
hoses.
Check condition for damage or
flattening.
12MOther
2. Mounting. Check tension on mounting bolt to
trolley and tighten as necessary.
12M 3. Mounting. Check tension on mounting bolt to
trolley and tighten as necessary.
12MOther
3. Control box
and cable.
Check functions of control box, e.g.
on/off. Check full length of cable for
damage.
When running check correct
direction of rotation of fan.
12M 4. Control box
and cable.
Check functions of control box, e.g.
on/off. Check full length of cable
for damage.
When running check correct
direction of rotation of fan.
12MOther
4. Pre-filter. Visually check condition of main
gear wheel on filter and drive gear
on cleaning handle. Visually check
condition of pre-filter and seating of
gasket.
For access, pull back rubber collar
at the top of the filter housing,
remove retaining screws and
carefully remove filter cover.
12M 5. Pre-filter. Visually check condition of main
gear wheel on filter and drive gear
on cleaning handle. Visually check
condition of pre-filter and seating of
gasket.
For access, pull back rubber collar
at the top of the filter housing,
remove retaining screws and
carefully remove filter cover.
12MOther
5. Filter. Check condition of flipstrip filter and
replace if necessary. Ensure
correct seating of gasket.
Note:- Discarded filter elements
should be placed in sealed bags for
disposal. Waste Disposal
Regulations advance \U 0.0 may
apply - WHAT IS MEANT HERE?
12M 6. Filter. Check condition of flipstrip filter and
replace if necessary. Ensure
correct seating of gasket.
Discarded filter elements should be
placed in sealed bags for disposal.
Waste Disposal Regulations may
apply
12MOther
6. Cone valve. Check condition and operation of
valve.
This valve should rise when the unit
is switched on and lower as the
vacuum decreases when the unit is
switched off.
12M 7. Cone valve. Check condition and operation of
valve.
This valve should rise when the unit
is switched on and lower as the
vacuum decreases when the unit is
switched off.
12MOther
1. Extract Fans Carry out routine maintenance of
the extract fans. For Guidance see
Fans - extract SFG 20-08
Depending on what the fans are
extracting, the maintenance
frequencies may need to be
increased.
6MAdded
8. System Undertaken a thorough test and
Inspection of the system in
accordance with Section 10 of
ACOP 258:2008. The task should
only be carried out by a competent
person. The term Competence is
defined Chapter 2 and the
Appendix 1 of the ACOP 258:2008
The maximum time between tests of
LEV systems is set down in COSHH
and for most systems this is 14
months (see the exceptions in Table
18 of the ACOP 258:2008). In
practice this is normally taken to
mean annually. If wear and tear on
the LEV system is liable to mean
that the system effectiveness will
degrade between tests then
thorough examinations and tests
should be more frequent.
12MAdded
9. Mobile Unit Undertake a test of the unit
(Portable Appliance Test) in line
with the requirements of the
Electricity at Work Act 1989
(Regulation 4(2)). For Guidance
see Portable equipment PAT testing
SFG 42-01.
12MAdded
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VEHICLE EXHAUST RAIL SYSTEM64-06 64-06 VEHICLE EXHAUST RAIL SYSTEM
Title NotesActionFQTitle FQ Action Notes
1. Extract Fans Carry out routine maintenance of
the extract fans. For Guidance see
Fans - extract SFG 20-08
Depending on what the fans are
extracting, the maintenance
frequencies may need to be
increased.
6MAdded
11. System Undertaken a thorough test and
Inspection of the system in
accordance with Section 10 of
ACOP 258:2008. The task should
only be carried out by a competent
person. The term Competence is
defined Chapter 2 and the
Appendix 1 of the ACOP 258:2008
The maximum time between tests of
LEV systems is set down in COSHH
and for most systems this is 14
months (see the exceptions in Table
18 of the ACOP 258:2008). In
practice this is normally taken to
mean annually. If wear and tear on
the LEV system is liable to mean
that the system effectiveness will
degrade between tests then
thorough examinations and tests
should be more frequent.
12MAdded
1. Hose on
suction unit.
Check condition of hose for
flattening and damage.
Examine both upper and lower
hoses.
12M 2. Hose on
suction unit.
Check condition of hose for
flattening and damage.
Examine both upper and lower
hoses.
12MOther
2. Safety break
coupler.
Check overall condition of coupling
and location of and condition of
spring clips between retaining pins.
Access to spring clips is achieved by
pulling back centre rubber collar.
12M 3. Safety break
coupler.
Check overall condition of coupling
and location of and condition of
spring clips between retaining pins.
Access to spring clips is achieved by
pulling back centre rubber collar.
12MOther
3. Nozzle. Check damper for damage and
operation of spring. Check
operation of grip and general
condition of nozzle.
Mole grip type clamp only available
on rubber/steel constructed nozzles.
12M 4. Nozzle. Check damper for damage and
operation of spring. Check
operation of grip and general
condition of nozzle.
Mole grip type clamp only available
on rubber/steel constructed nozzles.
12MOther
4. Suction trolley. Check trolley for free rolling without
play movement.
Mole grip type clamp only available
on rubber/steel constructed nozzles.
12M 5. Suction trolley. Check trolley for free rolling without
play movement.
Mole grip type clamp only available
on rubber/steel constructed nozzles.
12MOther
5. Auto
disconnect
system.
Check operation by clamping a
small piece of steel or alternative
between jaws of clamp. Slide trolley
to disconnect position and ensure
correct location.
Not fitted on manual disconnect
units. Clamp jaws should open on
ball assembly location in
disconnection brackets.
12M 6. Auto
disconnect
system.
Check operation by clamping a
small piece of steel or alternative
between jaws of clamp. Slide
trolley to disconnect position and
ensure correct location.
Not fitted on manual disconnect
units. Clamp jaws should open on
ball assembly location in
disconnection brackets.
12MOther
6. Rubber seal. Check overall condition. May be lubricated with silicone
spray.
12M 7. Rubber seal. Check overall condition. May be lubricated with silicone
spray.
12MOther
7.
Suspension/Mount
ing bolts.
Check tension on mounting bolts
and nip up if required.
May be lubricated with silicone
spray.
12M 8.
Suspension/Mount
ing bolts.
Check tension on mounting bolts
and nip up if required.
May be lubricated with silicone
spray.
12MOther
8. Duct
connections.
Check seal and condition of end
caps and fan duct connection pipe.
12M 9. Duct
connections.
Check seal and condition of end
caps and fan duct connection pipe.
12MOther
Page 582 of 614
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64-07 WOOD DUST EXTRACTION
Title NotesActionFQTitle FQ Action Notes
1. Extract Fans Carry out routine maintenance of
the extract fans. For guidance see
Fans - Extract SFG 20-08
Depending on what the fans are
extracting, the maintenance
frequencies may need to be
increased.
6MAdded
2. System -
General
Carry out operation check of unit
and note any unusual noises,
vibrations or odours.lean or replace
filters as required.
Check filter retaining frames are in
good condition.
Clean out any dust or shavings
trapped witin the system.
Wipe down fan impeller.
Check motor airways are clear.
Check ductwork and inlet guards
are in good condition, free from
leaks, and allow unimpeded
removal of dust.
Check all brackets, fixings and bolts
are secure.
Check discharge area is clean and
tidy.
Check bag shaker and bag
securing clips.
Test control functions.
Carry out operation check of unit
and note any unusual noises,
vibrations or odours.lean or replace
filters as required.
6MAdded
3. Suction and
interconnecting
hoses.
Check condition for damage or
flattening.
Frequency could be greater
depending on the process that the
LEV has been installed for. See
table 18 in HSG 258: 2011
12MAdded
4. Mounting. Check tension on mounting bolt
between handle, dust collector, plus
motor and filter housing.
12MAdded
5. Switch cable
and motor.
Check full length of cable for
damage and operation of switch.
Check for smooth running of motor.
Check controls are in good
condition. Check local isolator for
signs of overheating and smooth
operation. Open isolator and clean
if required.
12MAdded
6. Pressure
reduction hose.
Check condition and connections of
small bore hose.
12MAdded
7. Gaskets and
cyclone mounting
rod.
Check top of cyclone for debris and
correct location of mounting rod.
For access, unclip lid assembly from
over-bin and unbolt cyclone plate.
After replacing lid and cyclone
arrangement check seating of
gasket.
12MAdded
Page 583 of 614
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8. Filter. Check condition and replace as
necessary. On replacement of filter
check condition of gasket.
Test pressure of supplies and
ensure they conform to the
manufacturers recommendations
and record results on
commissioning sheet.
12MAdded
9. Lighting Check illumination in booths and
hoods if appropriate.
12MAdded
10. System Undertaken a thorough test and
inspection of the system in
accordance with Section 10 of
ACOP 258:2011. The task should
only be carried out by a competent
person. The term Competence is
defined Chapter 2 and the
Appendix 1 of the ACOP 258:2011
The maximum time between tests of
LEV systems is set down in COSHH
and for most systems this is 14
months (see the exceptions in Table
18 of the ACOP 258:2011). In
practice this is normally taken to
mean annually. If wear and tear on
the LEV system is liable to mean
that the system effectiveness will
degrade between tests then
thorough examinations and tests
should be more frequent.
12MAdded
11. Mobile Unit Undertake a test of the unit
(Portable Appliance Test) in line
with the requirements of the
Electricity at Work Act 1989
(Regulation 4(2)). For Guidance
see portable equipment PAT testing
SFG 42-01.
12MAdded
12. Hoods,
canopies and duct
interiors
Check ductwork condition,
especially flexible ducts clean as
appropriate. Check cleanliness of
hoods, especially canopies and
clean as appropriate. Check the
mechanical integrity, eg corrosion,
damage, seals, dampers, sash
suspensions etc.
Check the make-up air is working
without draughts or blockages.
12MAdded
13. Extract
Explosion
Suppression
System
Carry out annual service in strict
accordance with manufacturers
instructions
In accordance with BS EN
14373:2005 Explosion suppression
systems.
12MAdded
Page 584 of 614
WATER TREATMENT
Page 585 of 614
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INTRODUCTORY PROCEDURES65-01 65-01 INTRODUCTORY PROCEDURES
Water may be used for a variety of purposes within buildings, some of the applications will require the
water supplied to the building to be treated in order to render it suitable for the purpose for which it is
to be used. The maintenance requirements for water treatment plants will vary and be specific to the
equipment used and the nature of the application.
Potable or Drinking Water
Public water supplies
Buildings 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 is fed directly to the point of use. However point of use water
treatment devices may be found on these supplies.
Private water supplies
Buildings may have their own water supply such as a borehole or a well, or may receive water from a
private supply which services more than one building. These water supplies may require treatment in
order to make them potable.
Main uses of Treated Water
Hot water and steam raising
Most water supplies require some form of treatment in order to avoid the scaling or corrosion of heat
exchange surfaces caused by dissolved solids or impurities in the water.
Air conditioning and heating
In air-conditioned buildings treated water is used in the cooling system water. This is essential in order
to ensure and maintain effective operation 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 must be considered as HAZARDOUS and must not be maintained by
persons who may be susceptible to Legionella. (For detailed comment see HEAT REJECTION).
Circulatory heating and cooling systems may be provided with automatic or manual dosing equipment
WATER TREATMENT AND CONDITIONING
Humidification
Certain types of humidification systems also have water treatment equipment which requires regular
maintenance to ensure proper humidification performance. (For individual HUMIDIFIERS see relevant
section).
Cold water services
In certain buildings cold water used for non-portable cold water services may be treated.
Recreational and therapeutic applications
Facilities such as swimming pools, saunas, whirlpool, spa baths and hydrotherapy pools, all require
treatment of the water to maintain microbiological and aesthetic conditions suitable for their purpose.
Treatment Categories
Water treatment falls into the following categories:
A Ion exchange
1. Base exchange softening - commercial
2. Base exchange softening - domestic
3. De-ionisation (de-mineralisation) including de-alkalisation
B Filtration conditioning and pH treatment
Central plant
1. Iron removal
2. pH correction
3. Active carbon filtration
4. Turbidity removal (clarification)
Point of use
5. Active carbon filtration
6. Bacteria removal filters
7. Sediment removal filters
Water may be used for a variety of purposes within buildings, some of the applications will require the
water supplied to the building to be treated in order to render it suitable for the purpose for which it is
to be used. The maintenance requirements for water treatment plants will vary and be specific to the
equipment used and the nature of the application.
Potable or Drinking Water
Public water supplies
Buildings in the UK are usually supplied with ‘towns mains’ potable 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 is fed directly to the point of use. However point of use water
treatment devices may be found on these supplies.
Private water supplies
Buildings may have their own water supply such as a borehole or a well, or may receive water from a
private supply which services more than one building. These water supplies may require treatment in
order to make them potable.
Main uses of Treated Water
Hot water and steam raising
Most water supplies require some form of treatment in order to avoid the scaling or corrosion of heat
exchange surfaces caused by dissolved solids or impurities in the water.
Air conditioning and heating
In air-conditioned buildings treated water is used in the cooling system water. This is essential in order
to ensure and maintain effective operation of the equipment. Proper treatment has a bearing on
energy costs, the implementation of the HASAWA (www.hse.gov.uk) and legionellosis control. Cooling
towers that have not been maintained regularly must be considered as HAZARDOUS and must not be
maintained by persons who may be susceptible to Legionella. (For detailed comment see Heat
rejection SFG 30-02.
Circulatory heating and cooling systems may be provided with automatic or manual dosing equipment
WATER TREATMENT AND CONDITIONING
Humidification
Certain types of humidification systems also have water treatment equipment which requires regular
maintenance to ensure proper humidification performance. (For individual Humidifiers including
disinfection procedures SFG 33-01 to 33-07 see relevant section).
Cold water services
In certain buildings cold water used for non-portable cold water services may be treated.
Technical
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8. Reverse osmosis (see Section D)
9. Ultra violet disinfection (see Section E)
C Chemical dosing
1. Chlorination
2. Bromination
3. Oxygen scavenging, corrosion and scale inhibitors
4. Phosphate dosing
5. Biocide
D Reverse osmosis
1. Reverse osmosis purification
E Ultra violet
F Ozonation
Recreational and therapeutic applications
Facilities such as swimming pools, saunas, whirlpool, spa baths and hydrotherapy pools, all require
treatment of the water to maintain microbiological and aesthetic conditions suitable for their purpose.
Treatment Categories
Water treatment falls into the following categories:
A) Ion exchange
1. Base exchange softening - commercial
2. Base exchange softening - domestic
3. De-ionisation (de-mineralisation) including de-alkalisation
B) Filtration conditioning and pH treatment
Central plant
1. Iron removal
2. pH correction
3. Active carbon filtration
4. Turbidity removal (clarification)
Point of use
5. Active carbon filtration
6. Bacteria removal filters
7. Sediment removal filters
8. Reverse osmosis (see Section D)
9. Ultra violet disinfection (see Section E)
C) Chemical dosing
1. Chlorination
2. Bromination
3. Oxygen scavenging, corrosion and scale inhibitors
4. Phosphate dosing
5. Biocide
6. Salinity (Brine systems)
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D) Reverse osmosis
1. Reverse osmosis purification
E) Ultra violet
F) Ozonation
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ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - commercial65-02 65-02 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 to deposits and subsequent blockage of outlet fittings, in addition it
can lead to energy wastage and increased costs. The operator should refer to and be familiar with the
manufacturer's operator's handbook and follow the manufacturer's recommendations regarding the
frequency at which the various maintenance functions should be carried out. These can vary
depending on the type of plant and manufacturer.
Maintenance of water treatment plant is very important to avoid scaling of heat exchange surfaces in
plant which can lead to deposits and subsequent blockage of outlet fittings, in addition it can lead to
energy wastage and increased costs. The operator should refer to and be familiar with the
manufacturer`s operator`s handbook and follow the manufacturer`s recommendations regarding the
frequency at which the various maintenance functions should be carried out. These can vary
depending on the type of plant and manufacturer.
In addition to the routine checks below the client`s operator will undertake operational tasks including
checking salt levels in the salt saturator/brine tank, check and record, in the log book, inlet water
hardness and outlet (soft) water hardness. The operator will check for leaks and if present, locate
source and report (leaks on control valves and vessel, manufacturer`s advice should be sought).
Other
Title NotesActionFQTitle FQ Action Notes
1. Salt saturator
(may be combined
with brine tank).
Check salt level and report as
necessary.
In addition to routine checks, the
frequency may be altered by the
client's operator to suit usage.
6M Deleted
2. Brine tank
(where fitted
separately).
Clean as appropriate. Check with
brineometer that brine is fully
saturated.
If brine is not fully saturated, brine
system requires further
investigation. Client should be
advised and matter referred to
manufacturer or equipment supplier.
6M 1. Brine tank
(where fitted
separately).
Clean as appropriate. Check with
brineometer that brine is fully
saturated.
If brine is not fully saturated, brine
system requires further
investigation. client should be
advised and matter referred to
manufacturer or equipment supplier.
6MOther
3. Overflow and
drain.
Clean and clear of debris and dirt.6M 2. Overflow and
drain.
Clean and clear of debris and dirt.6MOther
4. Water leaks. If present, locate source and report. For control valves and vessel,
manufacturer's advice should be
sought.
6M Deleted
5. Inlet water
hardness.
Measure and record in plant log. If the raw water hardness increases
or decreases by more than 5% of
the initially specified level, refer to
manufacturer/supplier's instructions.
6M Deleted
6. Outlet (soft)
water hardness.
Measure from sample of water
taken when softener is in use and
water is flowing.
Treated water may be hard due to
over running or fault condition which
should be rectified.
6M Deleted
7. Electrical
control system
(where fitted).
Check condition of all electrical
connections.
Refer to plant operator's manual.6M 3. Electrical
control system
(where fitted).
Check condition of all electrical
connections.
Refer to plant operator`s manual.6MOther
8. Regeneration
sequence.
Put plant into regeneration
sequence and check all stages of
operation.
If system malfunctioning, refer to
manufacturer or supplier.
6M 4. Regeneration
sequence.
Put plant into regeneration
sequence and check all stages of
operation.
If system malfunctioning, refer to
manufacturer or supplier.
6MOther
9. Pressure drop
over softener
(where provision to
measure exists).
Check and record in plant log. A gradual build up in back pressure
could indicate fouling or breakdown
of the ion exchange medium.
6M 5. Pressure drop
over softener
(where provision
to measure
exists).
Check and record in plant log. A gradual build up in back pressure
could indicate fouling or breakdown
of the ion exchange medium.
6MOther
10. Booster
pumps.
Carry out maintenance programme
as detailed in PUMPS.
6M 6. Booster
pumps.
Carry out maintenance programme
as detailed in Pumps SFG 45-12
6MTechnical
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11. Ancillary
controls and
probes (where
fitted) a)
conductivity, b)
electro
chlorination.
Inspect for check operation and
report.
6M 7. Ancillary
controls and
probes (where
fitted) a)
conductivity, b)
electro
chlorination.
Inspect for check operation and
report.
6MOther
12. Plant. Check overall condition and report. 8. Plant. Check overall condition and report.6MOther
13. Valves. Overhaul individual valves.6M 9. Valves. Overhaul individual valves as
detailed in Valves SFG 61-03
6MTechnical
14. Back flow
prevention
devices.
Check operation. Where operation is between two
tanks, check can be carried out by
observing whether there is a change
of levels of the two tanks.
6M 10. Back flow
prevention
devices.
Check operation. Where operation is between two
tanks, check can be carried out by
observing whether there is a change
of levels of the two tanks.
6MOther
15.
Recommissioning.
Set up flow rates to suit. Report details to client.6M 11.
Recommissioning.
Set up flow rates to suit. Report details to client.6MOther
16. Water test. Final water test taken. Back pressure readings will give
some indication of the condition of
the resin bed. Take sample and
send to laboratory if part of service
schedule agreed with client.
6M 12. Water test. Final water test taken. Back pressure readings will give
some indication of the condition of
the resin bed. Take sample and
send to laboratory if part of service
schedule agreed with client.
6MOther
17. Major
overhaul.
Details should be agreed with client.36M 13. Major
overhaul.
Details should be agreed with client.36MOther
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ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - domestic
(capacity usually below 50 litres)
65-03 65-03 ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - domestic
(capacity usually below 50 litres)
Maintenance of water treatment plant is very important to avoid scaling of heat exchange surfaces in
plant which can lead to deposits and subsequent blockage of outlet fittings, in addition it can lead to
energy wastage and increased costs. The operator should refer to and be familiar with the
manufacturer`s operator`s handbook and follow the manufacturer`s recommendations regarding the
frequency at which the various maintenance functions should be carried out. These can vary
depending on the type of plant and manufacturer.
In addition to the routine checks below the client`s operator will undertake operational tasks including
checking salt levels in the salt saturator/brine tank, check and record, in the log book, inlet water
hardness and outlet (soft) water hardness. The operator will check for leaks and if present, locate
source and report (leaks on control valves and vessel, manufacturer`s advice should be sought).
Added
Title NotesActionFQTitle FQ Action Notes
4. Inlet water
hardness.
Measure and record in plant log,
adjust plant as appropriate.
12M Deleted
5. Outlet (soft)
water hardness.
Measure from sample of water
taken when softener is in use and
water is flowing.
12M Deleted
6. Water leaks. If present, locate source and report. For control valves and vessel,
manufacturer's advice should be
sought.
6M Deleted
7. Electrical
control system
(where fitted).
Check condition of all electrical
connections.
6M 4. Electrical
control system
(where fitted).
Check condition of all electrical
connections.
6MOther
8. Regeneration
sequence.
Put plant into regeneration
sequence and check all stages of
operation.
A gradual reduction in service flow
may indicate breakdown of the
medium.
6M 5. Regeneration
sequence.
Put plant into regeneration
sequence and check all stages of
operation.
A gradual reduction in service flow
may indicate breakdown of the
medium.
6MOther
9. Booster
pumps.
Carry out maintenance programme
as detailed in PUMPS.
6M 6. Booster
pumps.
Carry out maintenance programme
as detailed in Pumps SFG 45-12
6MTechnical
10. Ancillary
controls and
probes (where
fitted) a)
conductivity, b)
electro
chlorination.
Inspect for check operation and
report.
6M 7. Ancillary
controls and
probes (where
fitted) a)
conductivity, b)
electro
chlorination.
Inspect for check operation and
report.
6MOther
11. Back flow
prevention
devices.
Check operation. Where operation is between two
tanks, check can be carried out by
observing whether there is a change
of levels of the two tanks.
6M 8. Back flow
prevention
devices.
Check operation. Where operation is between two
tanks, check can be carried out by
observing whether there is a change
of levels of the two tanks.
6MOther
12.
Recommissioning.
Set up flow rates to suit. Report details to client.12M 9.
Recommissioning.
Set up flow rates to suit. Report details to client.12MOther
13. Water test. Take final water test. Back pressure readings will give
some indication of the condition of
the resin bed. Take sample and
send to laboratory if part of service
schedule agreed with client.
6M 10. Water test. Take final water test. Back pressure readings will give
some indication of the condition of
the resin bed. Take sample and
send to laboratory if part of service
schedule agreed with client.
6MOther
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14. Major
overhaul.
Details should be agreed with client.36M 11. Major
overhaul.
Details should be agreed with client.36MOther
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SPECIAL WATER TREATMENT SYSTEMS65-04 65-04 SPECIAL WATER TREATMENT SYSTEMS
This type of plant is normally serviced by the manufacturer or their agent. This type of plant is normally serviced by the manufacturer or their agent.Other
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FILTRATION, CONDITIONING and pH CORRECTION - central plant65-05 65-05 FILTRATION, CONDITIONING and pH CORRECTION - central plant
Title NotesActionFQTitle FQ Action Notes
1. Feed water
and treated water
iron levels.
Collection samples of feed and
treated water and visually compare
differences in clarity.
If the maximum concentration of iron
in the treated water is specified,
send sample to laboratory for
analysis.
3M 1. Feed water
and treated water
iron levels.
Collection samples of feed and
treated water and visually compare
differences in clarity. It may be of
benefit to compare samples against
a white background.
If the maximum concentration of
iron in the treated water is specified,
send sample to laboratory for
analysis.
3MTechnical
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FILTRATION and CONDITIONING - POINT OF USE65-06 65-06 FILTRATION and CONDITIONING - POINT OF USE
Title NotesActionFQTitle FQ Action Notes
3. Control
isolating valve.
Check operation.12M 3. Control
isolating valve.
Check operation as described in
Valves SFG 61-03
12MTechnical
Bacterial removal
filters. 1. Cartridge
type.
Remove, clean and disinfect
cartridge. Inspect for cracking or
damage. Change cartridge.
If flow drops to an unacceptable
level earlier maintenance may be
necessary. Disinfection may not be
required, refer to manufacturer's
instructions. Interval may be less
than 48m if frequency of cleaning
become unacceptably short.
3M Bacterial removal
filters. 1.
Cartridge type.
Remove, clean and disinfect
cartridge. Inspect for cracking or
damage. Change cartridge.
If flow drops to an unacceptable
level earlier maintenance may be
necessary. Disinfection may not be
required, refer to manufacturer`s
instructions.
3MTechnical
b) control isolating
valve.
Check operation.12M b) control isolating
valve.
Check operation as described in
Valves SFG 61-03
12MTechnical
3. Control
isolating valve.
Check operation.12M 3. Control
isolating valve.
Check operation as described in
Valves SFG 61-03
12MTechnical
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REVERSE OSMOSIS65-07 65-07 REVERSE OSMOSIS
Title NotesActionFQTitle FQ Action Notes
5. Valves. Check action. Detailed information on the
maintenance of VALVES, see
relevant section.
6M 5. Valves. Check action. Detailed information on the
maintenance of Valves SFG 61-01.
6MTechnical
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ULTRA VIOLET DISINFECTION UNIT65-08 65-08 ULTRA VIOLET DISINFECTION UNIT
Caution: Ultra violet radiation is dangerous to the eyes, avoid looking directly at the lamp when
illuminated.
Caution: Ultra violet radiation is dangerous to the eyes, avoid looking directly at the lamp when
illuminated.
Other
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OZONATION PLANT65-09 65-09 OZONATION PLANT
Note: This schedule applies to larger size plants producing more than 30 grammes of ozone per hour.
Smaller sized plant should be checked weekly by client's staff
This schedule applies to larger size plants producing more than 30 grammes of ozone per hour.
Smaller sized plant should be checked weekly by client`s staff.
There is a significantly greater risk of hazardous exposure from leaks from larger generators,
producing 2 gms or more Ozone per hour. Adequate health and safety data including emergency
procedures, in the event of human exposure above safe exposure limits should be displayed near the
generating equipment and any plant or equipment supplied by it.
A permit to work system may be in place. In which case, the Authorised person must be contacted and
a Permit issued before any work can commence on the equipment.
Technical
Title NotesActionFQTitle FQ Action Notes
1. Joints and
Unions
All mechanical joints and unions
exposed to ozone should be
opened up and the rubber seals
inspected to check if perishing or
any wear and deformation is
occurring If found, the seals should
be replaced before restarting the
equipment again.
1WAdded
1. Dielectric
tubes and
electrode
assemblies.
Remove ozone generating
modules, inspect and clean
dielectric tubes and electrode
assemblies. All glass tube 'O' rings
must be replaced and steel liners
cleaned
After cleaning and reassembly,
vacuum test to ensure soundness of
both the intermediate tubeplate and
seals.
6M 2. Dielectric
tubes and
electrode
assemblies.
Remove ozone generating
modules, inspect and clean
dielectric tubes and electrode
assemblies. All glass tube `O` rings
must be replaced and steel liners
cleaned
After cleaning and reassembly,
vacuum test to ensure soundness of
both the intermediate tubeplate and
seals.
6MOther
2. Filter cartridge
in main airline from
dryer.
Remove and replace. Inspect 'O'
ring seals, replace if necessary.
6M 3. Filter cartridge
in main airline
from dryer.
Remove and replace. Inspect `O`
ring seals, replace if necessary.
6MOther
3. Dew point
monitor probe.
Check calibration. Refer to manufacturer's instructions.6M 4. Dew point
monitor probe.
Check calibration. Refer to manufacturer`s instructions.6MOther
4. i) solenoid
valves (where
fitted), ii) proximity
switches (where
fitted).
Remove and replace valve seals
and clean valve seats. Check
operation.
See SWITCHES.6M 5. i) solenoid
valves (where
fitted), ii) proximity
switches (where
fitted).
Remove and replace valve seals
and clean valve seats. Check
operation.
See Switches SFG 58.6MOther
5. Suction and
discharge piping.
Check condition, remove and
replace purge pump membrane
and diaphragm.
6M 6. Suction and
discharge piping.
Check condition, remove and
replace purge pump membrane and
diaphragm.
6MOther
6. Cooling water
flow.
Check flow rate and operation of
proximity switch.
Each module should be checked.6M 7. Cooling water
flow.
Check flow rate and operation of
proximity switch.
Each module should be checked.6MOther
7. Ozone
generator air flow.
Check rate and operation of airflow
proximity switch.
6M 8. Ozone
generator air flow.
Check rate and operation of airflow
proximity switch.
6MOther
8. High
temperature
protection circuit.
Check operation.6M 9. High
temperature
protection circuit.
Check operation.6MOther
9. Internal
pipework.
Check for leakage or damage.6M 10. Internal
pipework.
Check for leakage or damage.6MOther
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10. Air dryer
control unit.
Check the timing and adjust as
necessary.
6M 11. Air dryer
control unit.
Check the timing and adjust as
necessary.
6MOther
iii) chiller unit (if
fitted),
Check operation. For detailed maintenance of
refrigeration and chilling unit see
CHILLERS .
6M iii) chiller unit (if
fitted),
Check operation. For detailed maintenance of
refrigeration and chilling unit see
Chillers SFG 09.
6MOther
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CHEMICAL DOSING65-10 65-10 CHEMICAL DOSING
Regular dosing of treated water may be carried out manually or automatically on a discrete or
continuous basis. Certain maintenance operations 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 -
Biocides
In all cases refer to the manufacturer's instructions. Care should be taken in the storage,
handling, disposal of all chemicals; note that COSHH Regulations apply.
Regular dosing of treated water may be carried out manually or automatically on a discrete or
continuous basis. Certain maintenance operations 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 -
Biocides
In all cases refer to the manufacturer`s instructions. Care should be taken in the storage, handling,
disposal of all chemicals; COSHH (www.hse.gov.uk/hthdir/noframes/coshh/index.htm) Regulations
apply.
Other
Title NotesActionFQTitle FQ Action Notes
3. Chemicals. Fill dosing pot to correct level with
appropriate chemical or chemical
solution for application.
Ensure correct type of chemical
treatment is used for application.
Care is required in the handling of
chemicals which should be carried
out in accordance with COSHH
Regulations .
6M 3. Chemicals. If required, fill dosing pot to correct
level with appropriate chemical or
chemical solution for application.
Ensure correct type of chemical
treatment is used for application.
Care is required in the handling of
chemicals which should be carried
out in accordance with COSHH
(www.hse.gov.uk/hthdir/noframes/co
shh/index.htm) Regulations .
6MTechnical
4. Dosing. Manipulate valves to ensure correct
dosing of the system.
6M 4. Dosing. If Required, Manipulate valves to
ensure correct dosing of the
system.
6MTechnical
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ADIABATIC COOLING - Introductory Information and Procedures65-11 65-11 ADIABATIC COOLING - Introductory Information and Procedures
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:
heat build up due to solar gain or the proximity to hot water services, or
the storage capacity is far greater than is necessary. In general terms the storage capacity should not
exceed one day's usage
seasonal variations. in the summertime it is not unusual to have incoming mains supplies exceeding
20 °C. When this occurs systems should be reassessed
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 BS 6920. Lists of materials approved by the water industry (WRAS) are
published in the Water Fittings and Materials Directory (see Standards List), All new and replacement
water fittings must satisfy Water Supply (water fittings) Regulations 1999 requirements and be listed in
the WRAS directory.
Cleansing of tanks, cisterns and associated pipe work should be followed by full disinfection in
accordance with the procedures laid down in BS 6700 and as per chemical manufacturers
specification
The pipework system should be free of any points where pockets of dirt, slime or sediment can build
up and stagnation occurs.
Adiabatic Cooling
The effectiveness of air cooled heat rejection systems depend on the difference between the air dry
bulb temperature and the refrigerant condensing temperature. The greater this difference the better
the heat rejection. Traditionally large heat rejection systems use cooling towers or evaporative coolers
to reduce the size of the heat rejection equipment as well as the overall energy consumption due to
lower condensing temperatures than those which would be obtained using dry air cooled condensers.
Unfortunately, the water based corrosion, maintenance and health risks such as legionella have
driven the industry towards the use of less efficient dry heat rejection systems . However, the need to
reduce carbon emissions and energy waste has resulted in a resurgence in the use of evaporative
systems.
As an alternative to conventional cooling towers and evaporative condensers, adiabatic dry air coolers
can reduce the refrigerant condensing temperature by lowering the dry bulb temperature of the air
entering the cooler. This is done by spraying a fine mist of water, usually from the town mains supply,
into the airstream prior to it entering the cooler. As the water is evaporated the airstream is cooled.
Ideally the temperature of the air would be reduced to that of the entering wet bulb. However, the
cooling process is probably some 70% effective and so the dry bulb temperature of the air entering
the cooler is likely to be reduced by about 70% of the wet bulb depression. For example, if the
ambient air is at a dry bulb of 30°C and the wet bulb at 20 °C i.e. a wet bulb depression of 10K, the
dry bulb temperature of the air entering the coil would be 30 °C-0.7x10 K, or 23 °C. For a given
cooling duty this could result in a saving of some 15% in the power required by the chiller. This degree
of saving is only possible during the mid summer for as the dry bulb temperature reduces so does the
wet bulb depression. Nevertheless, such savings at a time of maximum load are a considerable
advantage. Although there is some runoff from the cooler due to not all the water supplied being
evaporated, it is much less than the blowdown from a cooling tower of the equivalent duty.
The use of tank fed water can produce a risk of proliferation of legionella within the system and so
mains water is preferred with timed discharges prior to use to drain away static water and added
protection to remove bacterial formation including legionella.
Tests indicated between 20 and 30% {Note. These figures seem quite high in the light of the 15%
given above. Where do they come from?} reduction in peak electrical load for air cooled chillers and
condensers. The potential for energy saving and carbon emission reduction for industry as a whole is
significant and this can be achieved by simply using the tap water.
Maintenance
Adiabatic Cooling
The effectiveness of air cooled heat rejection systems depend on the difference between the air dry
bulb temperature and the refrigerant condensing temperature. The greater this difference the better
the heat rejection. Traditionally large heat rejection systems use cooling towers or evaporative coolers
to reduce the size of the heat rejection equipment as well as the overall energy consumption due to
lower condensing temperatures than those which would be obtained using dry air cooled condensers.
Unfortunately, the water based corrosion, maintenance and health risks such as legionella have
driven the industry towards the use of less efficient dry heat rejection systems . However, the need to
reduce carbon emissions and energy waste has resulted in a resurgence in the use of evaporative
systems.
As an alternative to conventional cooling towers and evaporative condensers, adiabatic dry air coolers
can reduce the refrigerant condensing temperature by lowering the dry bulb temperature of the air
entering the cooler. This is done by spraying a fine mist of water, usually from the town mains supply,
into the airstream prior to it entering the cooler. As the water is evaporated the airstream is cooled.
Ideally the temperature of the air would be reduced to that of the entering wet bulb. However, the
cooling process is probably some 70% effective and so the dry bulb temperature of the air entering
the cooler is likely to be reduced by about 70% of the wet bulb depression. For example, if the
ambient air is at a dry bulb of 30°C and the wet bulb at 20 °C i.e. a wet bulb depression of 10K, the
dry bulb temperature of the air entering the coil would be 30 °C-0.7x10 K, or 23 °C. For a given
cooling duty this could result in a saving of some 15% in the power required by the chiller. This degree
of saving is only possible during the mid summer for as the dry bulb temperature reduces so does the
wet bulb depression. Nevertheless, such savings at a time of maximum load are a considerable
advantage. Although there is some runoff from the cooler due to not all the water supplied being
evaporated, it is much less than the blowdown from a cooling tower of the equivalent duty.
The use of tank fed water can produce a risk of proliferation of legionella within the system and so
mains water is preferred with timed discharges prior to use to drain away static water and added
protection to remove bacterial formation including legionella.
The potential for energy saving and carbon emission reduction for industry as a whole is significant
and this can be achieved by simply using the tap water.
Maintenance
Specific details relating to the risk of Legionellosis are given in the Health and Safety ACOP L 8,2000
,CIBSE publication TM13 2002, HTM 04 Part A & B.
The general guidance is normally to ensure mains water is used. The spray nozzles must be kept
clean and in good working order. Periodic water testing is taken and independently analysed for
bacterial content including legionella. A disinfection device is normally used and a filter system may be
incorporated thus requiring periodic maintenance in accordance with the manufacturer`s instructions.
It is also likely that a discharge solenoid valve is used to ensure only fresh water is used which must
be included in the maintenance procedures. Also wet pads may be used and these need to be kept
clean.
If fitted in health care settings, permission for use must be obtained from infection control.
All maintenance must be logged and signed for within the site water logbook.
All staff are to be fully trained.
Other
Page 601 of 614
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The general guidance is normally to ensure mains water is used. The spray nozzles must be kept
clean and in good working order. Periodic water testing is taken and independently analysed for
bacterial content including legionella. A disinfection device is normally used and a filter system may be
incorporated thus requiring periodic maintenance in accordance with the manufacturer's instructions. It
is also likely that a discharge solenoid valve is used to ensure only fresh water is used which must be
included in the maintenance procedures. Also wet pads may be used and these need to be kept
clean.
If fitted in health care settings, permission for use must be obtained from infection control.
All maintenance must be logged and signed for within the site water logbook.
All staff are to be fully trained.
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Change
ADIABATIC COOLING SYSTEMS65-12 65-12 ADIABATIC COOLING SYSTEMS
Note: Manufacturers O & M manual should be followed at all times. Manufacturers O & M manual should be followed at all times.
Specific details relating to the risk of Legionellosis are given in the Health and Safety ACOP L 8,2000
,CIBSE publication TM13 2002, HTM 04 Part A & B.
Other
Title NotesActionFQTitle FQ Action Notes
1. Mains supply to
unit and farthest
outlet
Take dipslides and incubate at
30°C 48 hours. Record readings on
a graph..
Action required if > 1041W 1. Mains supply to
unit and farthest
outlet
Take dipslides and incubate at 30°C
48 hours. Record readings on a
graph..
Action required if > 10^41WOther
3. Mains supply
unit and farthest
outlet
Take samples and submit to UKAS
accredited laboratory for the
presence of legionella
Action required if > 100 CFU per
Litre
3M 3. Mains supply
unit and farthest
outlet
Take samples and submit to UKAS
accredited laboratory for the
presence of legionella. Testing
should be in accordance with ISO
11731:1998
The frequency of 3 Months is the
maximum period between testing.
More frequent sampling should be
carried out when commissioning a
system and establishing a treatment
programme. Sampling should be
carried out, on a monthly basis, until
it can be shown that the system is
under control.
Action required if > 100 CFU per
Litre. Refer to Table 2 in the ACOP
L8
3MTechnical
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CHLORINE DIOXIDE DOSING FOR DOMESTIC LOWLEVEL INJECTION65-13 65-13 CHLORINE DIOXIDE DOSING FOR DOMESTIC LOWLEVEL INJECTION
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:
heat build up due to solar gain or the proximity to hot water services, or
the storage capacity is far greater than is necessary. In general terms the storage capacity should not
exceed one day's usage
seasonal variations. in the summertime it is not unusual to have incoming mains supplies exceeding
20 °C. When this occurs systems should be reassessed with the likely outcome of increasing regular
flushing to these outlets in a safe manner with minimal aerosolation.
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 BS 6920. Lists of materials approved by the water industry (WRAS) are
published in the Water Fittings and Materials Directory (see Standards List), All new and replacement
water fittings should satisfy Water Supply (water fittings) Regulations 1999 requirements and be listed
in the WRAS directory.
Cleansing of tanks, cisterns and associated pipe work should be followed by full disinfection in
accordance with the procedures laid down in BS 6700 and as per chemical manufacturers
specification
The pipework system should be free of any points where pockets of dirt, slime or sediment can build
up and stagnation can occur.
When temperature problems are encountered and remedial works are not practical in order to
engineer out the problems, Chlorine Dioxide Dosing can be used.
Chlorine dioxide is an oxidising biocide that is capable of reacting with a wide range of organic
substances. In the inactivation of microorganisms, the chlorine dioxide molecule acts as a free radical
(oxidising biocide) that readily bonds with the amino acids (the basic building blocks of proteins, which
form the living cells). This results in their destruction.
Chlorine dioxide as a control measure
The use of chlorine dioxide as a control measure will depend on the design of the systems in use and
their operational history.
There are two aspects to be taken into consideration:
in the cold water distribution system, chlorine dioxide will be injected into the system upstream of all
parts of the distribution, storage and boosting equipment - that is, at the curtilage of the premises.
Backflow prevention is required if chlorine dioxide is injected into a pipe connected to the mains
supply.
in the case of hot water distribution systems with calorifiers/water heater operating conventionally (that
is, at 60°C), there will be a tendency for chlorine dioxide to be lost by "gassing off", especially if the
retention time in a vented calorifier/water heater is long. In most cases, however, some level of total
oxidant should be found in the hot water, although at concentrations far less than the 0.5 mg/ L
injected. The calorifier/water heater should act as a barrier to dispersal of any pathogenic material by
the hot water system (even if the cold water supply quality is not under control). Chlorine dioxide and
its breakdown products chlorite and chlorate can be deleterious to neonates and renal dialysis
patients, and should be removed from the water supply to these units.
For all practical purposes in water, ppm = mg/L.
Maintenance of the control regimen
This depends on four separate aspects, as follows:
ensuring that the dosing equipment is operating satisfactorily
ensuring that the limit for total oxidant in the system is not exceeded
ensuring that all the parts of cold and blended water systems are exposed to chlorine dioxide
ensuring that a management system is in place to maintain these procedures
ensuring that the dosing equipment is operating satisfactorily
It is normally the responsibility of the supplier of the dosing equipment, who will seek to achieve the
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.
Seasonal variation. In the summertime it is not unusual to have incoming mains supplies exceeding
20 °C. When this occurs systems should be reassessed with the likely outcome of increasing regular
flushing to these outlets in a safe manner with minimal aerosolation.
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 BS 6920-1:2000. Lists of materials approved by the water industry
(WRAS) are published in the Water Fittings and Materials Directory (see Standards List), All new and
replacement water fittings should satisfy Water Supply (water fittings) Regulations 1999 and the
Scottish Water Bylaws 2004 requirements and be listed in the WRAS
(www.wras.co.uk/simple_steps_to_approval.asp) directory.
Cleansing of tanks, cisterns and associated pipe work should be followed by full disinfection in
accordance with the procedures laid down in BS 6700:2006 +A1: 2009 and as per chemical
manufacturers specification
The pipework system should be free of any points where pockets of dirt, slime or sediment can build
up and stagnation can occur.
When temperature problems are encountered and remedial works are not practical in order to
engineer out the problems, Chlorine Dioxide Dosing can be used.
Chlorine dioxide is an oxidising biocide that is capable of reacting with a wide range of organic
substances. In the inactivation of microorganisms, the chlorine dioxide molecule acts as a free radical
(oxidising biocide) that readily bonds with the amino acids (the basic building blocks of proteins, which
form the living cells). This results in their destruction.
Chlorine dioxide as a control measure
The use of chlorine dioxide as a control measure will depend on the design of the systems in use and
their operational history.
There are two aspects to be taken into consideration:
a). in the cold water distribution system, chlorine dioxide will be injected into the system upstream of
all parts of the distribution, storage and boosting equipment - that is, at the curtilage of the premises.
Backflow prevention is required if chlorine dioxide is injected into a pipe connected to the mains
supply.
b). in the case of hot water distribution systems with calorifiers/water heater operating conventionally
(that is, at 60°C), there will be a tendency for chlorine dioxide to be lost by "gassing off", especially if
the retention time in a vented calorifier/water heater is long. In most cases, however, some level of
total oxidant should be found in the hot water, although at concentrations far less than the 0.5 mg/ L
injected. The calorifier/water heater should act as a barrier to dispersal of any pathogenic material by
the hot water system (even if the cold water supply quality is not under control). Chlorine dioxide and
its breakdown products chlorite and chlorate can be deleterious to neonates and renal dialysis
patients, and should be removed from the water supply to these units.
For all practical purposes in water, ppm = mg/L.
Other
Page 604 of 614
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maximum available chlorine dioxide from the generation process. (Systems are not 100% efficient and
the free available chlorine dioxide may be less than the permitted limit of total oxidant of 0.5 mg/ L but
should not be significantly less at the point of injection.) When chemical treatment is introduced as
part of a programme of remedial action of a colonised system, as the system is brought under control,
it should be possible to measure increasing concentrations of available (active) chlorine dioxide. With
a newly installed dosing system, this may not be possible for several weeks. If chlorine dioxide cannot
be identified, tests for total oxidant should be performed.
It will be the responsible person or similar to take responsibility to check that the equipment is
operating and this should include routine checking of available "active" chlorine dioxide on a daily
basis.
Tests for total oxidant are most easily accomplished by DPD1 tablets. The oxidising effect of chlorine
can be removed by first adding glycine and the remaining total oxidants (including chlorine dioxide,
chlorite and chlorate) can then be measured using the DPD1 tablets, following suppliers' instructions.
DPD is an abbreviation for diethyl-p-phenylene diamine. DPD1 tablets are used for detecting oxidants
in water. ensuring that the limit for total oxidant in the system is not exceeded.
The available chlorine dioxide and total oxidant, therefore, will be the result of the disinfection process,
general state of the system and water usage levels. Performance of the dosing equipment is normally
the responsibility of the supplier/service provider. (Water quality overall is ultimately the responsibility
of the owners of the system.)
A representative number of outlets should be tested for total oxidant to ensure that the limits are not
being exceeded. These should include proximal outlets and some distal outlets. (It is not necessary to
check the hot water service.), this ensures that all parts of cold and blended water systems are
exposed to chlorine dioxide.
In addition to the above, it will be necessary to monitor the following:
the quantity of chemicals in the reservoir;
the rate of addition of chlorine dioxide to the water supply;
on a monthly basis, the concentration of chlorine dioxide should be measured at the sentinel taps and
should be at least 0.1 mg/L and no more than 0.5 mg/L
on an annual basis, the chlorine dioxide should be measured at a representative number of outlets
and should be at least 0.1 mg/L and no more than 0.5 mg/L
N.B. Prior to commissioning new equipment, a thorough disinfection of the services to be continually
dosed with chlorine dioxide is required in order to remove as much biofilm as possible. This should be
carried out in order for the new system to settle down in a reasonable time and to ensure levels are
reached throughout the system without the need for overloading in order to reach acceptable levels at
the farthest point in the system.
Maintenance of the control regimen
This depends on four separate aspects, as follows:
ensuring that the dosing equipment is operating satisfactorily
ensuring that the limit for total oxidant in the system is not exceeded
ensuring that all the parts of cold and blended water systems are exposed to chlorine dioxide
ensuring that a management system is in place to maintain these procedures
ensuring that the dosing equipment is operating satisfactorily
It is normally the responsibility of the supplier of the dosing equipment, who will seek to achieve the
maximum available chlorine dioxide from the generation process. (Systems are not 100% efficient and
the free available chlorine dioxide may be less than the permitted limit of total oxidant of 0.5 mg/ L but
should not be significantly less at the point of injection.) When chemical treatment is introduced as
part of a programme of remedial action of a colonised system, as the system is brought under control,
it should be possible to measure increasing concentrations of available (active) chlorine dioxide. With
a newly installed dosing system, this may not be possible for several weeks. If chlorine dioxide cannot
be identified, tests for total oxidant should be performed.
It will be the responsible person or similar to take responsibility to check that the equipment is
operating and this should include routine checking of available "active" chlorine dioxide on a daily
basis.
Tests for total oxidant are most easily accomplished by DPD1 tablets. The oxidising effect of chlorine
can be removed by first adding glycine and the remaining total oxidants (including chlorine dioxide,
chlorite and chlorate) can then be measured using the DPD1 tablets, following suppliers` instructions.
DPD is an abbreviation for diethyl-p-phenylene diamine. DPD1 tablets are used for detecting oxidants
in water. ensuring that the limit for total oxidant in the system is not exceeded.
The available chlorine dioxide and total oxidant, therefore, will be the result of the disinfection process,
general state of the system and water usage levels. Performance of the dosing equipment is normally
the responsibility of the supplier/client. (Water quality overall is ultimately the responsibility of the
owners of the system.)
A representative number of outlets should be tested for total oxidant to ensure that the limits are not
being exceeded. These should include proximal outlets and some distal outlets. (It is not necessary to
check the hot water service.), this ensures that all parts of cold and blended water systems are
exposed to chlorine dioxide.
In addition to the above, it will be necessary to monitor the following:
the quantity of chemicals in the reservoir;
the rate of addition of chlorine dioxide to the water supply;
on a monthly basis, the concentration of chlorine dioxide should be measured at the sentinel taps and
should be at least 0.1 mg/L and no more than 0.5 mg/L
on an annual basis, the chlorine dioxide should be measured at a representative number of outlets
and should be at least 0.1 mg/L and no more than 0.5 mg/L
Page 605 of 614
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Prior to commissioning new equipment, a thorough disinfection of the services to be continually dosed
with chlorine dioxide is required in order to remove as much biofilm as possible. This should be
carried out in order for the new system to settle down in a reasonable time and to ensure levels are
reached throughout the system without the need for overloading in order to reach acceptable levels at
the farthest point in the system.
Page 606 of 614
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CHLORINE DIOXIDE LOW DOSING DOMESTIC WATER SYSTEMS65-14 65-14 CHLORINE DIOXIDE LOW DOSING DOMESTIC WATER SYSTEMS
Sampling and maintenance of chlorine dioxide low dosing
All other requirements for operations and maintenance should be carried out as in the O & M Manual
and normally carried out by the installer/supplier of the equipment
Sampling and maintenance of chlorine dioxide low dosing. All other requirements for operations and
maintenance should be carried out as in the O & M Manual and normally carried out by the
installer/supplier of the equipment
Other
Title NotesActionFQTitle FQ Action Notes
1. Sampling Take sample from first outlet from
the dosing system and test for
C102 concentration. Top up
chemical storage
Adjust dosing according to results.
Not to dose > 0.5 mg/l in drinking
water. In Cat' two fluid, dosage can
be raised to 1 mg/l, be aware of
possible metal corrosion over time.
1W 1. Sampling Take sample from first outlet from
the dosing system and test for Cl02
concentration. Top up chemical
storage
Adjust dosing according to results.
Do not dose if the test results show
levels greater than 0.5 mg/l in
drinking water. In Cat` two fluid,
dosage can be raised to 1 mg/l, be
aware of possible metal corrosion
over time.
1WOther
2. Sampling Sample sentinel outlets for C102
and log in logbook
Ensure dose level is maintained and
in drinking water does not exceed
0.5 mg/l
1M 2. Sampling Sample sentinel outlets for Cl02
and log in logbook
Ensure dose level is maintained and
in drinking water does not exceed
0.5 mg/l
1MOther
Page 607 of 614
WHIRLPOOLS-HYDROTHERAPY
Page 608 of 614
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WHIRLPOOL/SPA BATHS66-01 66-01 WHIRLPOOL/SPA BATHS
Note: Frequency of maintenance will depend upon use, the quality of the water and must be agreed
with client.
A spa pool is designed for sitting or lying in up to the neck, and not for swimming. It is a self-contained
body of water that is filtered and chemically disinfected. A spa pool is not drained, cleaned or refilled
after each user, but after a number of users or a maximum period of time
Whirlpool baths are typically found in beauty parlours, health suites, hotels and dwellings. Water
within the bath is untreated and the bath is drained following each session.
Spa pools
All actions should be taken in line with manufacturers specifications and all guidance should be
followed as set out in the HPA guidance publication on Management of Spa Pools
(www.hpa.org.uk/Publications/)
Frequency of maintenance will depend upon use, the quality of the water and must be agreed with the
client. There must be a written risk assessment for the equipment, which will detail the necessary
maintenance frequencies. This is updated, usually on an annual basis and therefore musty be check
to ensure the maintenance frequencies have not altered.
In addition to the routine checks below the client`s operator will undertake operational tasks including
cleaning the suction filter (if fitted) on a daily basis.
Other
Title NotesActionFQTitle FQ Action Notes
7. Air Filter Clean Input air filter when fitted.1MAdded
8. Safety Systems Check all automatic systems are
operating correctly e.g. safety
cut-outs, automatic timers etc.
1MAdded
9. Water
Treatment
Disinfectant/pH controller - clean
electrode and check calibration
(see manufacturers instructions).
1MAdded
10. Sand Filter Thoroughly check sand filter or
diatomaceous earth filter
membranes
3MAdded
11. Air Lines Where possible clean and
disinfect airlines
3MAdded
12. Sand Filter Check sand filter efficiency12MAdded
1. Bath hygiene. Clean pipework, pump and nozzles. Fill bath with warm water to normal
level, add sterilising solution or low
foaming dishwasher powder and
operate for 10 minutes. Refill with
cold water and operate for five
minutes.
12M 1. Bath hygiene. The following action must be
carried out everytime the pool is
refilled. Clean pipework, pump and
nozzles.
Fill bath with warm water to normal
level, add cleaning/sterilizing
solution and operate for 10
minutes. Refill with cold water and
operate for five minutes.
Other
2. Suction filter (if
fitted).
Clean.12M 2. Suction filter (if
fitted).
Clean.1MLegislative
3. Nozzle jets. Clean and remove scale, refit and
regulate flow rates.
Scale may build up in hard water.
Client should be informed of the
possible need for water treatment.
12M 3. Accessible
Pipework and
Nozzle jets.
Clean and inspect for bio film.
Remove scale, refit and regulate
flow rates.
Scale may build up in hard water.
The client should be informed of the
possible need for water treatment.
1MLegislative
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4. Electrical
safety.
Check operation of earth leakage
circuit breaker.
Press test button on earth leakage
circuit breaker at least once every
three months.
12M 4. Electrical
safety.
Check operation of earth leakage
circuit breaker.
Press test button on earth leakage
circuit breaker at least once every
three months.
1MLegislative
6. Timer (where
fitted).
Check operation.12M 6. Timer (where
fitted).
Check operation.1MTechnical
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HYDROTHERAPY POOLS66-02 66-02 HYDROTHERAPY POOLS
SPA POOLS
All actions should be taken in line with manufacturers specifications and all guidance should be
followed as set out in the HPA guidance publication on Management of Spa Pools
HYDROTHERAPY POOLS
Hydrotherapy is a long established branch of physiotherapy in which patients develop strength and
suppleness during exercise sessions in a pool. Hydrotherapy pools carry similar infection hazards to
swimming pools. In addition, however, they operate with higher water and air temperatures and serve
a population both more vulnerable to infection and more likely to cause accidental contamination. A
second edition of Hygiene for hydrotherapy pools has been published. The book aims to provide
practical advice on the general management of hydrotherapy pools, patient safety, general hygiene
and pool water quality for all those (physiotherapists, engineers, domestic staff, microbiologists and
managers) involved in their installation, maintenance and management. The primary aim is to enable
the recognised difficulties associated with the use of hydrotherapy pools to be avoided , with resulting
benefit to staff and patients.
It is essential that detailed records of maintenance activities are kept in respect of any maintenance
carried out on hydrotherapy pools and a copy given to the client.
HYDROTHERAPY POOLS
Hydrotherapy is a long established branch of physiotherapy in which patients develop strength and
suppleness during exercise sessions in a pool. Hydrotherapy pools carry similar infection hazards to
swimming pools. In addition, however, they operate with higher water and air temperatures and serve
a population both more vulnerable to infection and more likely to cause accidental contamination. The
Public Health Laboratory Service have published a document called. Hygiene for hydrotherapy pools .
The book aims to provide practical advice on the general management of hydrotherapy pools, patient
safety, general hygiene and pool water quality for all those (physiotherapists, engineers, domestic
staff, microbiologists and managers) involved in their installation, maintenance and management. The
primary aim is to enable the recognised difficulties associated with the use of hydrotherapy pools to be
avoided, with resulting benefit to staff and patients.
It is essential that detailed records of maintenance activities are kept in respect of any maintenance
carried out on hydrotherapy pools and a copy given to the client.
In addition to the routine checks below the client`s operator will undertake operational tasks including
cleaning the suction filter (if fitted) on a daily basis.
Other
Title NotesActionFQTitle FQ Action Notes
1. Pool cleaning. Drain pool, inspect and thoroughly
clean.
Frequency will depend on usage
and should be agreed with client.
Report any defects which cannot be
easily remedied.
12M 1. Pool cleaning. Drain pool, inspect and thoroughly
clean.
Frequency will depend on usage
and should be agreed with the
client. Report any defects which
cannot be easily remedied.
12MOther
2. Filters. See section FILTERS. Frequency will depend on usage
and should be agreed with client.
12M 2. Suction Filters. Clean Filters1MTechnical
3. Water
treatment and
quality.
See section WATER TREATMENT.12M 3. Water
treatment and
quality.
See section Water treatment SFG
65.
12MOther
4. Circulatory
pipework,
including solar
panels (where
fitted).
Isolate from pool and drain down.
Clean out and dry.
12MAdded
5. Automatic air
vents.
Remove, drain and clean.12MAdded
6. Heating
equipment - Oil -
Solar
-Gas
Carry out maintenance procedures
appropriate to the type of heating
plant as detailed in relevant
sections.
Maintenance of heating plant, other
than routine, is best carried out
before the heating season starts.
6MAdded
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a) 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
Added
7. 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.
Added
8. Inlet strainer. 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).
1MAdded
9. Chemical
cleaning of filter
bed material.
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.
6MAdded
10. Rate of flow
indicator.
Clean and check operation. The accuracy of the flow meter
should be within 5%.
3MAdded
11. Pre-coat
filtration 1. Inlet
strainer.
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).
1MAdded
12. Filter
elements.
Clean off any coating material and
check condition of support
elements.
If replacement necessary, report to
the client.
1MAdded
15. Cartridge type
filters 1. Inlet
strainer.
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).
1MAdded
16. Seals. Check condition of seals on
cartridge holders. Replace if
necessary.
1MAdded
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17. Rate of flow
indicator.
Clean and check operation. The accuracy of the flow meter
should be within 5%.
3MAdded
Page 613 of 614
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STEAM ROOMS and HUMIDIFIERS66-03 66-03 STEAM ROOMS and HUMIDIFIERS
Title NotesActionFQTitle FQ Action Notes
4. Ventilation Check operation of all ventilation
fans (supply and extract)
For more detailed information on the
maintenance requirements for
steam generation see Fans -
ventilation SFG 20-03.
6MAdded
5. Internal
Surfaces
Check internal surfaces for cracks
in the tiles or grouting. Repair as
necessary with silicone sealant
Generally, the day to day cleaning
of the internal surfaces should be
undertaken by the operational staff.
Cracks or chips in the surfaces can
be a breeding ground for bacteria.
3MAdded
Steam production
1. Generator.
Check operating thermostat timer
and earth leakage circuit breaker.
For more detailed information on the
maintenance requirements for
steam generation see
BOILER/HEAT GENERATORS.
12M 1. Steam
Generator
Check operation of steam
generator . Check operation of
thermostat timer and earth leakage
breaker.
Descale electrical element if
necessary.
For more detailed information on the
maintenance requirements for
steam generation see Humidifiers
including disinfection procedures
SFG 33-03.
Scale may build up in hard water
areas. The client should be
informed of possible need for water
treatment.
3MTechnical
2. Electric
element.
Descale electrical element if
necessary.
Scale may build up in hard water
areas. Client should be informed of
possible need for water treatment.
12M 2. Lighting Check operation of Lighting and
Emergency Lighting
For more detailed information on the
maintenance requirements for
steam generation see Lighting SFG
36-01 to 36-03 and Lighting
-emergency SFG 37-01.
1MTechnical
3. General. See BOILERS/HEAT
GENERATORS for more specific
information on the maintenance of
steam generators.
12M 3. Drainage Check that the drains in the room
are clear and allow all excess water
to drain away from the room
1MTechnical
Page 614 of 614