Standard Maintenance Specification for Mechanical Services in Buildings

Home , Fuse (explosives)

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Standard Maintenance Specification for Mechanical Services in Buildings

On-line Copy SFG20 Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

2 INTRODUCTION

1 Standard Maintenance Specification

Before the publication of the original specification in 1990, there had been no standard document covering the maintenance of heating, cooling and ventilation plant in buildings. Equipment had become more reliable with the introduction of solid state and microchip technology, and one consequence of this is that there has been a tendency to relax the maintenance of plant with resultant customer dissatisfaction and energy wastage which experience has shown can be as high as 20%.

Given this situation, the Heating and Ventilating Contractors’ Association (HVCA) in association with the Chartered Institute of Building Engineers (CIBSE), the Building Research Energy Conservation Support Unit (BRECSU) and, what was then the Energy Efficiency Office at the Department of Energy, developed a Standard Maintenance Specification which was aimed at maintenance contractors and organisations with the relevant expertise to carry out their own maintenance, by providing a contractual standard against which to evaluate and enforce adequate standards. HVCA members use it as a mandatory standard both for tending and in carrying out the work and those organisations going out for tender also use the standard as an integral part of the tender specification.

The revised Standard is produced in alpha sort under 66 service equipment headings, each having the same format and covering major elements in heating, cooling and ventilation. Newly included in this latest version is reference to HVCA’s Guide to Ventilation Hygiene (Ductwork Cleaning).

2 Safety

Safe operation of the plant and its immediate environment is a fundamental part of good maintenance practice and should be taken into account at all times. Ventilation and adequateOn-line lighting is essential in boiler housesCopy and plant rooms and any deficiencies in these areas must be brought to the client’s attention immediately. The responsibility for ensuring safe access to equipment should be clearly defined.

It should be noted that certain specialised functions such as fire prevention and lifts are not covered by the standard and any person working on such equipment should, in the case of fire prevention and alarms, be registered with the Loss Prevention Council or should be the manufacturer’s nominated fire prevention contractor. Similar considerations apply in the case of lifts.

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

3 3 Electrical equipment

All electrical equipment should be capable of local isolation in accordance with the regulations of the Institution of Electrical Engineers – Regulations for Electrical Installation (IEE Wiring Regulations Current Edition), BS 7671:2001, and as detailed in guidance note No2, Isolation of switching.

All electrical equipment shall be provided with means of isolation, which disconnects the respective item of equipment and any associated control devices and circuits.

There are also stringent requirements and guidance in the Electricity at Work Regulations (1989), and of particular importance is Regulation 12 – “Means for cutting off the supply and for isolation”. In this Regulation, isolation means the disconnection and separation of the electrical equipment from every source of electrical energy in such a way that this disconnection and separation is secure. The word ‘secure’ is specifically mentioned in the Electricity at Work Regulations (1989) and requires the means of isolation to be such that it is not likely to fail, become loose, etc. by the action of vibration, mechanical shock or knocks, or be accidentally or inadvertently operated. Padlocking is a widely used means, with clear labelling and warning notices.

4 Maintenance of systems

Although the specification is presented in a checklist format describing specific maintenance activities applied to generic types of plant, it is not implied that maintenance responsibilities should be defined in this way. The responsible agent, either as a contractor or as an employee is responsible for maintaining the entire system, not just groups of components. Regarding the maintenance activity in respect of a system care should be taken to ensure that maintenance tasks are carried out by suitably qualified and experienced staff capable of exercising professional standards of judgement and discretion in relation to individual systems. The specification is a statement of typical standards, and further reference to manufacturers should be sought for detailed guidance to supplement the specification. In the absence of a manufacture specification this specification is a minimum standard for safe working and efficiency. On-line Copy 5 Proprietary equipment

This Specification represents the best maintenance practice in general terms. For specific items of plant it is essential that the maintenance engineer should be familiar with the equipment manufacturer’s maintenance manual and comply with the instructions contained therein. It is anticipated that this standard will be used not only by maintenance engineers carrying out the maintenance but also by managers as a means of checking that the work has been carried out and conforms to the tender requirements.

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

4 6 Records

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

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

Together with a list detailing the equipment and normal settings and the location of operating and maintenance manuals relating to specific plant and control equipment. A record should be kept of all events and changes related to the equipment, the various settings of controls and valve positions.

7 Efficiency and Emissions

European Directives and UK law will require Carbon emissions from the combustion process to be controlled in order to achieve low fuel consumption and thus greater overall efficiency.

Nitrogen Oxides (NOx) are also produced during combustion. When oxides of nitrogen combine with water in the upper atmosphere, acidic compounds are formed which then lead to the acid rain formation, which can cause damage to plants, aquatic life and buildings. Low NOx boilers are available to counter this effect and to comply with European Directives and UK law, the aim of which is reduce the permitted NO2 emissions from new fossil fuel heat generators to 180mg/Nm3 (normal cubic metres). On-line Copy

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

5 CONTENTS SFG20 STANDARD MAINTENANCE SPECIFICATION

INTRODUCTION

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

02 AIR CONDITIONING -01 Introduction

03 AIR HANDLING UNITS -01 General

04 BELTS -01 General

05 BOILERS/HEAT GENERATORS -01 Introduction -02 Pre-maintenance -03 Atmospheric gas burner - free standing boiler -04 Atmospheric gas burner - condensing boiler -05 Coal fired boilers - bunkers and conveyors -06 Coal fired boilers - coal storage On-line-07 Coal feed - underCopy feed stokers -08 Coal feed - chain grate stokers -09 Ash handling systems -10 Blown gas burner - condensing boiler -11 Blown gas burner - modular boilers -12 Forced draught gas burner - condensing boiler -13 Forced draught oil burner - condensing boiler -14 Boiler MTHW Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

05 BOILERS/HEAT GENERATORS continued -15 Boiler controls - multiple boilers-sequence -16 Boiler controls - single boiler on/off -17 Boiler controls - protection -18 Boiler controls - space temperature -19 Steam boilers - pre-maintenance check -20 Steam boilers - maintenance -21 Electric boilers -22 Electrode boilers -23 Boilers LTHW -24 Boilers - fire & safety circuits -25 Waste & wood burning appliances - safety circuits -26 Waste & wood burning appliances - combustion chamber -27 Waste & wood burning appliances - boiler -28 Atmospheric gas burner/boiler - small wall hung boiler -29 Atmospheric gas burner combination boiler -30 Atmospheric gas burner condensing combination boiler -31 Air to water pump -32 Water to water pump -33 Brine to water pump

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

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

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

08 CATERING EQUIPMENT AND CANOPIES - Seek specialist advice

09 CHILLERS WATER -01 Introduction -02 Packaged chillers -03 Lithium bromide -04 Gas Fired Absorption

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

11 COMMUNICATION AND P.A. SYSTEMS -01 General

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

13 CONDENSERS -01 Water cooled -02 Air cooled

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

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

15 COLD WATER STORAGE AND SERVICE - See STORAGE TANKS

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

17 DUCTWORK – CLEANING -01 Hygiene, inspection and monitoring

18 ELECTRICS IN BUILDINGS -01 Introduction

19 EVAPORATORS -01 Shell and Tube / Direct Expansion

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

21 FILTERS -01 Introduction -02 Filters On-linea) Common Copy procedures b) Disposable c) Reusable d) Roll band/automatic e) Absorption f) Grease g) Absolute (HEPA) -03 Electro static Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

9 22 FIRE ALARM SYSTEMS -01 Fire alarm system -02 Associated equipment

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

24 FLUES -01 Normal/ Fan assisted/ Fan dilution

25 FOUNTAINS -01 Ornamental

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

27 HAZARDOUS AREA (ELECTRICS) -01 Introduction -02 Flame proof equipment On-line-03 Lighting Copy -04 Earthing Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

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

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

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

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

32 HOT WATER SUPPLY -01 Introduction -02 Hot Water services - general -03 Calorifier types -04 Calorifiers - pre-maintenance -05 Calorifiers - LTHW or MTHW On-line-06 Calorifiers -Copy steam -07 Calorfiers - hot water supply including load levellers -08 Calorifier and heat exchange - controls -09 Hot Water cylinders -10 Unvented hot water systems -11 Thermal storage cylinder -12 Expansion vessels -13 Direct fired water heaters -14 Instantaneous electric water heaters -15 Packaged electric water heaters Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

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

34 ICE MAKING MACHINES -01 General

35 INSULATION -01 General

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

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

38 LIGHTNING PROTECTION -01 Lightning conductor and earth On-line39 MOTORS -01 Drive elements Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

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

41 PNEUMATICS -01 Relays

42 PORTABLE EQUIPMENT -01 PAT testing

43 POWER GENERATION -01 Introduction -02 Stand-by generator -03 Batteries -04 Battery charging -05 Uninteruptable power supplies (UPS)

44 POWER SUPPLIES -01 Introduction -02 Main switch panel at supply intake -03 Maximum demand On-line-04 Armoured cablesCopy and conduits -05 Power distribution units -06 Earthing -07 Distribution boards -08 Ring Main and sub-circuits -09 Three phase circuits Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

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

46 REFRIGERANT DISTRIBUTION SYSTEM -01 General

47 ROOM AIR CONDITIONERS -01 Unitary air conditioners

48 SANITARY AND WASTE WATER PLUMBING -01 Introduction -02 Macerators -03 Interceptors – petrol and oil -04 Interceptors – blowdown and sumps -05 Waste water plumbing and drains -06 Air admittance valves -07 Rainwater down pipes and gutters On-line-08 Water saving Copy devices and meters Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

49 SECURITY SYSTEMS -01 Intruder alarms

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

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

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

53 SOLAR PANELS -01 Collecting devices

54 SPLIT SYSTEMS INCLUDING HEAT PUMPS -01 Introduction On-line-02 Split/roof topCopy package-cooling and/or full heating Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

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

56 STORAGE TANKS -01 Introduction -02 Water - cold (Water – hot - see HWS) -03 Ice -04 Gas LPG -05 Oil

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

58 SWITCHES -01 On/off On-line-02 Control relays Copy 59 TERMINAL UNITS -01 VAV self powered -02 VAV fan powered -03 VAV pneumatic powered -04 Constant volume mixing box -05 Induction -06 Fan coil -07 VRV Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

60 VACUUM SYSTEMS -01 General -02 Cash handling

61 VALVES -01 Valves a) Gate b) Globe c) Lubricated plug d) Butterfly e) Float f) Parallel slide g) Steam safety h) Steam PRV i) Pressure control j) Diaphragm k) Boiler j) Radiator TRV -02 Tap - general -03 Tap - service -04 Tap - mixing -05 Shower

62 VALVES - AUTOMATIC CONTROL -01 Pre-maintenance -02 Rotary - shoe or slipper -03 Butterfly and ball -04 Self acting and thermal On-line-05 Solenoid Copy -06 Pressure control -07 Seat Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

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

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

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

66 WHIRLPOOLS - HYDROTHERAPY -01 Whirlpool / Spa baths -02 Hydrotherapy On-line-03 Steam rooms Copy and humidifiers 18 01-01 ACTUATORS – 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 manufacturerOn-line. In this example, cross-referencing Copy should be made between the Actuators, Controllers and Sensors sections. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 19

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

Should any discrepancies occur with the following checks the client should be informed as soon as possible to avoid the 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.

6. 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 actuatorOn-line is operating within its design ambient Copy conditions. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 20 01-03 THERMAL ACTUATORS ITEM FREQ. ACTION NOTES 1. Electricity supply. 12m Check supply voltage and that If supply voltages are not found, check to see if polarities are correct. supply is via a controller. Refer to manufacturer's data sheet. 2. Control signal. 12m Check for presence and that Refer to manufacturer's data sheet. The previous polarity is correct. note can also apply to the control signal. 3. Auxiliary control functions i.e. 12m Check operation. See relevant manufacturer's data sheet and on/off switches, frost auxiliary section. protection, position indicators, feedback potentiometers.

4. Manual operation (if fitted). 12m Check to prove actuator will Ensure that the actuator is returned to the "auto" mechanically open/close valve position after check is completed. or damper to its working limits. 5. Actuator position on power 12m Check for correct position for This will entail interrupting the power to the failure. application when power fails. actuator at a convenient point. Do not forget to reconnect the supply when the check is complete. 6. Reaction to safety signal i.e. 6m Check that the actuator See relevant control/sensor section for this fire/smoke. assumes correct position (if operation. applicable). 7. Reaction to control signal. 12m Check for correct response to See relevant controls section. On-linesignal. Copy 8. Running time (if applicable). 12m Check See manufacturer's data sheet.

9. Leakage. 12m Check for signs of leakage of hydraulic fluid around actuator seals. Change seals if necessary. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 21 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. ITEM FREQ. ACTION NOTES 1. Pressure/leakage/ seizure 12m Check operation between With a variance in pressure from the controller, actuator and controller. the actuator will modulate.

2. Pipe connections. 12m Check condition of glands and Replace defective glands and seals. seals. Check pipework for deterioration.

3. Air quality. 12m Check that any filters are clear If water and/or oil is present, check with of water and oil (filter may not manufacturer of the system regarding required be local to the actuator). action.

4. Manual operation (if fitted). 12m Check to ensure actuator Ensure manual override is set to correct achieves stroke limits. position. Check for minimum/ maximum setting.

5. Linkage assembly, i.e. nuts 12m Check a)wear, Lubricate/replace/tighten as necessary.

bolts, spring, valve stem or b)security

On-line Copy damper assembly. c)corrosion

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

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 22 01-04 PNEUMATIC ACTUATORS - continued

ITEM FREQ. ACTION NOTES 7. Actuator function. 6m Check calibration - controller Note control pressure operation range is correct output to actuator position. (could be sequenced control) Note: more than one actuator may be fed from the control supply. 8. Auxiliary control units. e.g. 12m Check operation. Refer to manufacturer's data sheets. positioners, electrical feedback units, end switches.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 23 01-05 HYDRAULIC ACTUATORS

(Should not be confused with pneumatic actuators) ITEM FREQ. ACTION NOTES 1. Electricity supply. 12m Check supply voltage and that If supply voltages are not found, check to see if polarities are correct. supply is via a controller. Refer to manufacturer's data sheet. 2. Control signal. 12m Check for presence and that Refer to manufacturer's data sheet. The polarity is correct. previous note can also apply to the control signal. 3. Auxiliary control functions i.e. 12m Check operation. See relevant manufacturer's data sheet and on/off switches, frost auxiliary section. protection, feedback potentiometers position indicators.

4. Manual operation (if fitted). 12m Check to prove actuator will Ensure that the actuator is returned to the mechanically open/close valve "auto" position after check is completed. or damper to its working limits.

5. Actuator position on power 12m Check for correct position for This will entail interrupting the power to the failure. application when power fails. actuator at a convenient point. Do not forget to reconnect the supply when the check is complete. 6. Reaction to control signal. On-line12m Check for correct response Copy to See the relevant controls section. signal. 7. Running time (if applicable). 12m Check. See manufacturer's data sheet. 8. Leakage. 12m Check for signs of leakage of hydraulic fluid around actuator seals. Change seals if necessary. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 24 01-06 MOTOR DRIVEN ACTUATORS

ITEM FREQ. ACTION NOTES 1. Electricity supply. 12m Check supply voltage and If supply voltages are not found, check to see if supply that polarities are correct. is via a controller. Refer to manufacturer's data sheet. 2. Control signal. 12m Check for presence and Refer to manufacturer's data sheet. The previous note that polarity is correct. can also apply to the control signal.

3. Auxiliary control functions i.e. 12m Check operation. See relevant manufacturer's data sheet and auxiliary on/off switches, frost section. protection, position indicators, feedback potentiometers.

4. Manual operation (if fitted). 12m Check to prove actuator will Ensure that the actuator is returned to the "auto" mechanically open/close position after check is completed. If the actuator is of valve or damper to its the direct coupled type, ensure that the clamp assembly working limits. is not worn and the fixings are tight.

5. Actuator position on power 12m Check for correct position This will entail interrupting the power to the actuator at a failure. for application when power convenient point. Do not forget to reconnect the fails. supply when the check is complete.

6. Reaction to safety signal i.e. 6m Check that the actuator The signal could be in any form from a fusible link in the fire/smoke. On-lineassumes correct position (ifCopysupply or gear box to an independent signal from a applicable). 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. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 25 01-06 MOTOR DRIVEN ACTUATORS - continued

ITEM FREQ. ACTION NOTES 7. Reaction to control signal. 12m Check for correct response to See the relevant section. signal. 8. Running time (if applicable) 12m Check. See manufacturer's data sheet.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 26 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. ITEM FREQ. ACTION NOTES 1. Electricity supply. 12m Check supply voltage and If supply voltages are not found, check to see if that polarities are correct. supply is via a controller. Refer to manufacturer's data sheet. 2. Control signal. 12m Check for presence and that Refer to manufacturer's data sheet. The previous polarity is correct. note can also apply to the control signal.

3. Auxiliary control functions i.e. 12m Check operation. See relevant manufacturer's data sheet and on/off switches, frost auxiliary section. protection, feedback potentiometers position indicators. 4. Manual operation (if fitted). 12m Check to prove actuator will Ensure that the actuator is returned to the "auto" mechanically open/close position after check is completed. valve or damper by moving to On-lineits working limits. Copy 5. Actuator position on power 12m Check for correct position for This check must be performed before power is failure. application when power fails. restored to the system or actuator.

6. Reaction to safety signal, e.g. 6m Check that the actuator fire/smoke. assumes correct position (if applicable). Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 27 01-07 POWER FAIL - MOTOR RETURN ACTUATORS - continued

ITEM FREQ. ACTION NOTES 7. Battery. 6m Check condition. Note use by date and consider life expectancy of battery. See heading note above regarding disposal. Auxiliaries

1. Switches. 12m Check to ensure that the switches are made to make or break at the correct position and that they perform their correct function.

2. Feedback potentiometers. 12m Check to ensure that: If the winding is broken, do not attempt to repair. a)winding/tracking is not dirty or Provide a replacement. broken, If the wiper is not making correct contact, gently b)wiper is making contact and is bend it until smooth contact is attained. not dirty, c)potentiometer performs its correct function. Continued on next page .. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 28 01-07 POWER FAIL - MOTOR RETURN ACTUATORS - continued

ITEM FREQ. ACTION NOTES 3. Linkages, 12m Check for: Where required, clean and lubricate parts i.e. a) visual, a) corrosion ball joints and sockets and moving parts. b) deformed or bent component Refer to manufacturer should any item deem to c) wear on moving parts and be in need of replacement. mounting brackets. Refer to data sheet on manufacturer's maintenance instructions. b) physical check. 12m Ensure that the actuator achieves the required stroke limits. Adjust if necessary.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 29 01-08 POWER FAIL - SPRING RETURN ACTUATOR

ITEM FREQ. ACTION NOTES 1. Electricity supply. 12m Check supply voltage and If supply voltages are not found, check to see if supply is that polarities are correct. via a controller. Refer to manufacturer's data sheet. 2. Control signal. 12m Check for presence and Refer to manufacturer's data sheet. The previous note that polarity is correct. can also apply to the control signal. 3. Auxiliary control functions 12m Check operation. See relevant manufacturer's data sheet and auxiliary i.e. on/off switched, frost section. protection, feedback potentiometers position indicators.

4. Manual operation (if fitted). 12m Check to prove actuator will The actuator may be fitted with the facility to manually mechanically open/close wind up the spring, if so the spring must be wound up valve or damper to its with the recommended tool. See manufacturer's data working limits. 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. 5. Actuator position on power 12m Check for correct position This check must be performed before power is restored to failure. On-linefor application when power Copythe system or actuator. fails. 6. Running times of spring 12m Check. Times should be within the tolerances specified in the and motor. manufacturer's data.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 30 01-08 POWER FAIL - SPRING RETURN ACTUATOR - continued

ITEM FREQ. ACTION NOTES 7. Reaction to safety signal, e.g. 6m Check that the actuator This signal could be in any form, from a fusible fire smoke. assumes correct position (if link in the supply or gearbox to an independent applicable). 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. 8. Reaction to control signal. 12m Check for correct response to See manufacturer's data sheet. signal. Auxiliaries

1. Switches. 12m Check to ensure that the switches are made to make or break at the correct position and that they perform their correct function. 2. Feedback potentiometers. 12m Check to ensure that: If the winding is broken, do not attempt to repair. a)winding/tracking is not dirty Provide a replacement. or broken, If the wiper is not making correct contact, gently b)wiper is making contact and bend it until smooth contact is attained. is not dirty, c) potentiometer performs its On-linecorrect function. Copy

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 31 01-08 POWER FAIL - SPRING RETURN ACTUATOR - continued

ITEM FREQ. ACTION NOTES 3. Linkages, 12m Check for: Where required, clean and lubricate parts i.e. ball a) visual a) corrosion joints and sockets and moving parts. b) deformed or bent Refer to manufacturer should any item deem to component be in need of replacement. c) wear on moving parts and Refer to data sheet on manufacturer's mounting brackets. maintenance instructions. b) physical check. 12m Ensure that the actuator achieves the required stroke limits. Adjust if necessary.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 32

02-01 AIR CONDITIONING--Introduction

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 should belong to HVCA’s REFCOM Scheme. 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. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 33 03-01 AIR HANDLING UNITS - general

ITEM FREQ. ACTION NOTES 1. Filter. 1m Check manometer reading and renew Record manometer reading. It should be noted filter media as indicated. that checking the filter should be carried out weekly by maintenance staff. 2. Guide vane actuators and 1m Check operation. modulating dampers.

3. Condensate drains. 1m Check for condensate carry-over and that drains are clear. 4. Humidifier pumps, sprays 1m Check operation. and water supply to tank. 5. Frost protection, boost 6m Check operation. For detailed This check should be carried out in September thermostat and controls. maintenance refer relevant section. and February in Great Britain. 6. Vent air. 1m Air should be vented from heating and cooling coils where fitted. 7. Drive belts. 1m Check tension, alignment, and Re-tension or replace as necessary. For detailed condition. maintenance procedures, see BELT DRIVES. 8. Drive pulleys. On-line12m Check alignment, security. Copy 9. Drive couplings. 12m Check alignment and for excessive Wear is indicated by excessive clearance and clearance. couplings should be replaced. 10. Damper and guide vane 3m Lubricate lightly. pivots and linkages. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 34 03-01 AIR HANDLING UNITS - general - continued

ITEM FREQ. ACTION NOTES 11. Motorised damper. 3m Check to see that louvres are For detailed maintenance see MOTORS. clear and not obstructed, couplings are secure and that motor runs without excessive noise or vibration.

12. Heating and cooling coils. 12m Check condition and clean. Even when filters are fitted, dirt can build up causing Check air and water pressure loss of machine output. drops across coils. 13. Controls and electrical 12m Check operation and condition. Calibration } connections. Interrogation } See relevant section Control adjustment } 14. Valves. 12m Fully open and close and then reset at the original setting. 15. Air handling unit. 12m Thoroughly clean interior and Include heating and cooling coils, fan impeller and check for corrosion. On re- eliminator plates and other fittings. assembly check for air On-linetightness. Copy Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

35 03-01 AIR HANDLING UNITS - general - continued

ITEM FREQ. ACTION NOTES 16. Motors. 12m Check:- a) condition of motor brushes and replace if necessary, b) clean and test windings, c) check tightness of terminals, d) check full load current, e) bearing wear, f) replace lubricant in motor bearings. This should not exceed data plate value. Measure shaft float and end play.

17. Anti-vibration mountings 12m Check condition. and ductwork flexible connections.

On-line Copy

36 04-01 BELT DRIVES - general

ITEM FREQ. ACTION NOTES 1. Tension. 3m Check and adjust as necessary. The correct tensioning of V-belts prevents excessive bearing wear. Motor position should be adjusted so that only a slight `bow' appears on the slack side of the belt when in operation. Recommended tensions are given in the installations instructions. After a few days running, check tension. 2. Alignment. 3m Check and adjust as required. Poor alignment of the pulleys will cause excessive wear on the sides of the belt and shorten their lives. 3. Bearings. (`Sealed for 3m Check for wear and lubricate at When operating in high temperature life' bearings should not frequencies recommended by the environments e.g. above 60oC more frequent normally require manufacturer. maintenance may be necessary. attention). 12m Where oil filled, drain, strip and clean bearing assembly, reassemble and fill with clean oil.

4. Guards. 3m Check for secure mounting and Belt replacement. As necessary. New and used positioning. V-belts should not be run together on the same On-line Copyset. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

37 05-01 HEAT GENERATORS ( BOILERS and HEATING APPLIANCES )

Introduction

In this section on the maintenance of heat generators, the specification is aimed at establishing best maintenance practice, but this is not intended to replace the statutory insurance inspection required by Health and Safety regulations. The term heat generators is a generic one used within the European Community to cover all appliances which burn fuel or convert energy to produce heat.

This section covers firstly the general requirements which are common to a group of appliances such as hot water heat generators and then examines the maintenance needs within each group. It must be emphasised that it is still necessary to refer to manufacturer's maintenance schedules for specific makes of appliances.

A detailed breakdown of the contents of this section is given in the Index but the format of each subsection is in the form of tables providing details on the item to be maintained, the frequency of maintenance, the action to take, and where appropriate informative notes about the action be taken. It should be noted that the frequency of maintenance relates to average conditions in terms of use and the environment in which the equipment is working. In cases where operating regimes are severe or the environment dirty or corrosive the frequency of maintenance should be increased to meet those conditions.

Sections include:

Hot water heat generators including condensing heat generators Steam raising heat generators Oil fired heat generators Coal fired heat generators Gas fired heat generators, direct fired, warm air heaters and radiant systems are found in HEAT EMITTERS. Electrode heat generators Electric heat generators On-line Copy Waste/Wood Burning heat generators

Controls relating to actual pieces of equipment are covered in the appropriate tables but more sophisticated controls are covered in the relevant sections.

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38 05-01 HEAT GENERATORS ( BOILERS and HEATING APPLIANCES) - continued

Heat generator types

The term heat generator covers a wide range of energy conversion appliances which involve a heating source, usually a fossil fuel burner or an electrical resistance element, which applies heat at one side of a metal surface. On the other side is a heating fluid, usually water or air, which absorbs energy from the heat source. This operation is termed heat transfer and anything which hinders that transfer wastes energy.

In the case of hot water it can either be circulated at near atmospheric pressure or circulated at higher pressures and temperatures above the normal boiling point. Alternatively the water can be evaporated as steam and the steam circulated as the heating medium.

Warm air can be used as a heating medium and if it contains the products of combustion it is said to be direct fired. Alternatively uncontaminated warm air can be provided by passing the burner gases through a heat exchanger. In some cases the combustion gases are passed at high temperature through radiant tubes which provide radiant heat. In most cases, air movement is fan assisted.

This section covers all the important aspects of heat generator maintenance including safety controls, combustion and the combustion chamber and heat generator controls.

Combustion

Correct combustion entails the adequate mixing of the fuel with air to ensure that the fuel is completely burnt without producing excessive smoke or diluting the combustion gases with excess air both of which cause energy wastage. With all fossil fuels, insufficient air produces carbon monoxide, a safety and health hazard, as undetected CO is poisonous and could be fatal; and a visible smoke plume which should lead to prompt corrective action. With gas combustion, no smoke is produced when insufficient air is used and hence the situation can go unnoticed for long periods, leading to significant energy waste unless regular flue gas analyses are carried out and the condition corrected.

When smoke is produced it can depositOn-line soot on the heat transfer surfaces Copy and reduce the amount of heat passing through the heat exchanger into the water. This in turn leads to more heat being carried away in the flue gases. This can be detected by monitoring flue gas temperature.

Poor combustion can result from:

(a) damage to or poor alignment of burner jets or pipework (b) oil not being at the correct atomising temperature (c) insufficient air or draught

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39 05-01 HEAT GENERATORS ( BOILERS and HEATING APPLIANCES) – continued

A poor flame shape can also lead to localised overheating of the heat generator surfaces, deposition of soot and reduced heat transfer. Cleanliness is also required on the water side of the heat exchange surfaces. In steam raising applications, the feedwater should be treated correctly at all times to keep internal surfaces clean, and suitable provision made for the removal of solids that accumulate in the boiler when the feedwater evaporates.

05-02 Pre-maintenance procedures

A fundamental element of good practice for the operator or attendant should be to carry out a visual inspection of the heat generator at regular intervals as part of the day-to-day routine. This should including checking for leaks and correct burner flame shape, i.e. it should be uniform in shape, 'sit' on the burner and should not hit the walls or back of the combustion chamber.

Prior to carrying out the planned maintenance of the heat generator the following pre-maintenance procedures should be followed:

(a) Check equipment status (i.e. on or off) and follow any specific site procedures (including safety)

(b) Carry out a general inspection of heat generator casing for signs of damage or breakage

(d) Record work which will require repair, adjustment or replacement during the routine service

(e) Record existing servicesOn-line – (combustion/efficiency analysis should Copy be recorded before and after maintenance completion).

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

40 05-03 ATMOSPHERIC GAS BURNER – FREE STANDING BOILER It is essential that there should be adequate ventilation [ratio of one third low to two thirds high level] of the boiler house for safety, plant and combustion air requirements and this should be checked with any new contract. For detailed information reference should be made to CIBSE guides, relevant Institute of Gas Engineers and Managers documents and appropriate British Standards. ITEM FREQ. ACTION NOTES 1. a) Before proceeding with 12m Check casing for damage or Check for asbestos containing materials prior dismantling of boiler. breakages. Inspect for loose fittings or to dismantling any equipment If suspect cease connections and any sign of leaks. work and report to supervisor.

b) Test fire. 12m Record settings.

2. Gas electrical & 12m Check that all are in accordance with Local electrical isolator should be fitted. Supply ventilation systems current legislation and Codes of to the boiler must be direct i.e. not fed through a Practice. time switch.

3. Isolate boiler for gas and 12m Record any work which needs electrical supplies. rectification or replacement.

4. Gas valve. 12m Disconnect thermocouple and pilot tube from burners. On-line Copy 5. Remove burners and pilot 12m Brush all accessible flueways Cleaning should be thorough and carried out as assembly and baffles if thoroughly from top to bottom, clean per the manufacturers instructions. fitted. all deposits from the burner box, refit baffles and flue cover - checking cover seal. Check for cracking and wear.

Continued on next page ..

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41 05-03 ATMOSPHERIC GAS BURNER BOILER - continued

ITEM FREQ. ACTION NOTES 6. a) Pilot assembly. 12m Remove. Pilot head. Remove and clean ports. Pilot injection. Remove and clean. Clean as described by the manufacturers e.g. by blowing through or washing. Note: Do not use a pin as this will damage the injector. Thermocouple tip. Replace/clean with fine wire brush, Make sure thermocouple head lines up with reassemble pilot. the pilot flame. b) Oxy-pilot assembly 12m Replace. 7. Lint filter (if fitted). 12m Remove from burners and clean.

8. Filters. 12m Refit. Burners, Gas valve, Check adjust and refit along with main thermocouple and pilot burner. tube. 9. Boiler and installation. 12m Open gas cock and test for gas Test flame setting and thermocouple sensitivity soundness, reconnect electrical and check burner gas pressure against services. Test controls operation, manufacturer's settings, adjust if required. On-linerelight pilot and run up boiler. CopyIf in doubt check gas supply standing pressure at the meter.

Continued on next page ..

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42 05-03 ATMOSPHERIC GAS BURNER BOILER - continued

ITEM FREQ. ACTION NOTES 10. a) Safety check – products 12m Ensure that no products of combustion NB - Undetected CO is poisonous, life of combustion are entering the area of the building threatening and also causes energy waste. where the boiler is situated. This Flames should be bluish and burning in a stable

should be checking the operation of manner. the flue, and examined the combustion The burner should be quiet in operation, no ways to ensure tightness excessive noise should occur when the burner ignites or shuts down.

NB in domestic premises, consider the installation of

a BS approved CO detector.

b) Safety check - Electrical 12m Check electrical installation for safety If not, provide written report to client. and that local isolator is fitted. 11. Documentation. 12m Provide written report. The report should be signed by the servicing engineer and the client/responsible person/clients representative. Premature failure of the plant will result if a satisfactory service is not carried out. Depending on the nature/urgency of the fault and the type of On-line Copypremises this report may be verbal. NB Gas work must be carried out by a competent engineer qualified as required by the Gas Safety (Installation & Use) Regulations.

Continued on next page ..

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43 05-03 ATMOSPHERIC GAS BURNER BOILER - continued

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

On-line Copy

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

44 05-04 ATMOSPHERIC GAS BURNER - CONDENSING BOILER

The essential feature of a condensing boiler is that to increase the efficiency the flue gases are cooled below their dew point with the result that water is produced which has to be removed from the system. It is essential that there should be adequate ventilation [ratio of one third low to two thirds high level] of the boiler house for safety, plant and combustion air requirements and this should be checked with any new contract. For detailed information reference should be made to CIBSE guides, relevant Institute of Gas Engineers and Managers documents and appropriate British Standards. ITEM FREQ. ACTION NOTES 1. a) Before proceeding with 12m Check casing for damage or Check for asbestos containing materials prior to dismantling of boiler. breakages. Inspect for loose fittings or dismantling any equipment If suspect cease work connections and any sign of leaks. and report to supervisor. b) Test fire. Record settings. 2. Pre-service checks 12m Check that there is a steady fall back Risk Assessment may be required. to the boiler from the flue to allow Waste Disposal Licensing Regulations may condensate to run back. With the apply. boiler operating at low return, temperature [less than 50oC], check Condensate flow 12m that condensate flows freely from the drain pipe. 3. Gas electrical & 12m Check that all are in accordance with Local electrical isolator should be fitted. Supply ventilation systems. current legislation and Codes of to the boiler must be direct i.e. not fed through a Practice. time switch. Continued on next page .. On-line Copy

45 05-04 ATMOSPHERIC GAS BURNER - CONDENSING BOILER - continued

ITEM FREQ. ACTION NOTES 4. Condensate level probe 12m Clean and inspect. (if fitted). 5. Secondary heat 12m Clean with water and a soft brush. exchanger (if fitted. 6. Neutralising Unit. 12m Check crystal level and top up if necessary. 7. Condensate drain pipe 12m Clean, inspect and flush. and U-siphon trap. 8. Fan. 12m Check operation and clean any deposits off blades. 9. Isolate boiler for gas and 12m Record any work which needs electrical supplies. rectification or replacement. 10. Gas valve. 12m Disconnect thermocouple and pilot tube from burners. 11. Remove burners and pilot 12m Brush all accessible flueways Cleaning should be thorough and carried out as assembly and baffles if thoroughly from top to bottom, clean per the manufacturers instructions. fitted. all deposits from the burner box, refit baffles and flue cover - checking cover On-lineseal. Check for cracking and wear.Copy Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 46 05-04 ATMOSPHERIC GAS BURNER - CONDENSING BOILER - continued

ITEM FREQ. ACTION NOTES 12. a) Pilot assembly. 12m Remove. Pilot head. Remove and clean ports. Pilot injection. Remove and clean. Clean by blowing through or washing. Note: Do not use pin as this will damage the injector. Thermocouple tip Replace/clean with fine wire brush, reassemble Make sure head lines up with the pilot and not pilot. the burner. b) Oxy-pilot assembly 12m Replace. 13. Lint filter (if fitted). Remove from burners and clean.

14. Filters. Refit. Burners, Gas valve, Check adjust and refit along with main burner. thermocouple and pilot tube. 15. Water treatment. 12m Check treatment regime is correct. Some condensing boilers contain aluminium. LOW NOX Boilers 16. Kanthal bars/rods. 12m Inspect, clean with compressed air. If there are any signs of bending, replace. For On-line Copyall condensing boilers, manufacturers specific service instructions take precedence. 17. Boiler and 12m Open gas cock and test for gas soundness, Test flame setting and thermocouple installation. reconnect electrical services. Test controls sensitivity and check manifold gas pressure operation, relight pilot and run up boiler. against manufacturer's settings, adjust if required. If in doubt check gas supply standing pressure at the meter. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

47 05-04 ATMOSPHERIC GAS BURNER - CONDENSING BOILER - continued

ITEM FREQ. ACTION NOTES 18. a) Safety check – 12m Ensure that no products of combustion NB - Undetected CO is poisonous, life productions of are entering the area of the building threatening and also causes energy waste. combustion where the boiler is situated. Flames should be bluish and burning in a stable manner.

The burner should be quiet in operation, no excessive noise should occur when the burner ignitor shuts down.

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

b) Safety check - Electrical 12m Check electrical installation for safety If not provide written report to client. and that local isolator is fitted.

19. Documentation. 12m Provide written report. The report should be signed by the servicing engineer and the client/responsible person/clients representative. Premature failure of the plant will result if a On-line Copysatisfactory service is not carried out, by a competent engineer qualified as required by the Gas Safety (Installation & Use) Regulations. Depending on the nature/urgency of the fault and the type of premises this report may be verbal.

Continued on next page ..

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05-04 ATMOSPHERIC GAS BURNER - CONDENSING BOILER - continued

ITEM FREQ. ACTION NOTES 20. Unsafe installations 12m Recommendations If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use. If approval for this action is refused an appropriate label must be attached to the appliance and the HSE informed. A written report should also be signed by the client/responsible person/clients representative.

On-line Copy

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

49 05-05 COAL FIRED BOILERS – Bunkers and Conveyors.

WARNING. A risk assessment and method statement should be undertaken before entering any confined space such as a hopper, flue chamber or boiler to ensure that there is adequate ventilation and an absence of any fumes or flue gases.

ITEM FREQ. ACTION NOTES 1. Operational status. 1m Check and isolate from electricity supply. Remove fuses.

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

3. Belt conveyors. 12m Inspect, renew worn sections and Lubrication of rollers, idlers and drums should be check and replace joints as carried out frequently as part of the client's necessary. regular routine.

4. Screw conveyor. On-line 1m Grease outrigger bearing on Copyworm shaft and tube rotation guide.

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

50 05-06 COAL FIRED BOILERS - Coal storage handling and feed mechanisms, automatic ash removal (where fitted)

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

ITEM FREQ. ACTION NOTES 1. Operational status. 1m Check and isolate from electricity supply. Lock off or remove fuses. 2. Silo. 12m Empty and check for signs of wear or Paint all internal components exposed to corrosion. coal. If remedial work necessary, report to client.

3. Coal feed lines. 6m Rod through and replace worn components. Check for erosion and thinning on bends.

4. Screw elevators and 6m Inspect tooth type drive belt for wear. Replace feeders. if necessary. Check for wear. 5. Pneumatic system. 3m Inspect and replace items listed under notes. (a) air seals on each outlet cyclone, (b) (Applies to both coal On-lineCheck for air tightness. Copyclean blades of fan, (c) ensure timing feed and ash removal, 1m sequence, (d) check 'bags', (e) check where fitted). 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. Continued on next page ..

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

ITEM FREQ. ACTION NOTES 6. Crusher and gearbox 6m Check oil level and replenish if necessary.

12m Replace all oils, check seals and Examine bearings and teeth of crusher. Check all joints. Clean and lubricate motors. bolts, nuts and washers for tightness and check shear pin for soundness. 7. Static electricity 12m Check effectiveness. discharge mechanism.

8. Fans. 12m Check low level switches, fuses and Insufficient air can lead to blockage of feed pipes action of fan emergency safety switch whilst excessive air can cause degradation of the in OFF position. coal and produce fines.

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

10. Coal conveying. On-line12m Check suction nozzle entrainment Copy point, action of air control valves and discharge valve.

11. Lubrication. 12m Lubricate fan and motor bearings. Use manufacturer's recommended lubricants. In a dirty environment more frequent lubrication will be necessary. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 52

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

ITEM FREQ. ACTION NOTES 12. Electrical. 12m Check all electrical trips. These should be set for manual reset.

13. Cyclone. 12m Clean separator of any fines which Regular monthly checks of air tightness should be have build up on internal surfaces. made.

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

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 53 05-07 COAL FEED MECHANISMS - Under feed stokers

ITEM FREQ. ACTION NOTES 1. Operational status. 6m Check and isolate from electricity Cables should be checked for insulation supply. Remove fuses. breakdown and the earth continuity checked. 2. Tuyere hole. 6m Check and clean out. Report on condition. 3. Retort. 6m Check end feedscrew and refractory brickwork. 4. Fly ash. 6m Remove from retort plenum chamber. 5. Belts and chains. 6m Examine and report condition. Check Advise client if replacement necessary. Refit pickup screw high tension bolt. safety guards after service.

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

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

8. Stauffers. 6m Grease and lubricate. 9. Gearbox or angle stoker 6m Drain oil and refill with new oil. Check for leaks before and after 'running in' on gear unit. return to operation. 10. Dampers and linkages. 6m Check, free if necessary, and On-linelubricate. Copy 11. Shearpin alignment and 6m Check and adjust shearpin alignment Free rotary tube if jammed and grease tube joint. bunker screw. if necessary. 12. Return to operation. 6m Close isolator switch. Run stoker and Visually check pressure gauge and boiler check sequence. thermostat. Report on condition of plant. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

54 05-08 COAL FEED MECHANISMS - Chain grate stokers

WARNING – A RISK ASSESSMENT AND METHOD STATEMENT SHOULD BE UNDERTAKEN BEFORE AN OPERATOR/ENGINEER ENTERS COAL SIL0. ITEM FREQ. ACTION NOTES 1. Operational status. 12m Check and isolate from electricity supply. Lock off or remove fuses. 2. Coal silo. 12m Empty and check internal and If there are signs of deterioration consult the external coatings. manufacturer. 3. Level probes on coal 12m Check and clean as necessary. When plant put back on line prove operation of surge bunkers. plant under all plant operating conditions. 4. Drain sump. 12m Ensure excess water can be drained off. Check coal auger supports. Repair or replace as necessary. Remove augers and check for wear Repair or replace as necessary. and distortion. Reassemble and recoat coal tube. Use bituminised sealant or similar protective coating. 5. Grit arrestors and internal 12m Check internally for signs of wear and baffles. rectify as necessary. 6. Access doors. On-line 12m Check security. Copy 7. Insulation. 12m Check condition and security and make good as required. 8. Stoker. 12m Withdraw and inspect for wear. Drain oil in gear cases, clean and refill, grease Check condition of rear skid plate. bearings on the force draught fan. Continued on next page ..

55 05-08 COAL FEED MECHANISMS - Chain grate stokers - continued

ITEM FREQ. ACTION NOTES 9. Stoker grate. 12m Renew rear side steel bars and any Remove a section of chain to inspect inside of air links showing signs of burning. box and interior seals.

10. Stoker air box. 12m Check bottom plate and chassis for distortion. 11. Stoker ignition arch. 12m Repair or replace arch and if Replace any short (worn) link rods. necessary firedoor lining. 12. Electrical. 12m Examine and renew switchgear contacts where necessary. Replace any worn or damaged regulator parts.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 56 05-09 ASH HANDLING SYSTEM

ITEM FREQ. ACTION NOTES 1. Ash line. 6m Check for wear and report if remedial work required. 2. Ash line valve. 12m Check operation and wear on seals. 3. Ash skip. 12m Check for holes or distortion. Examine rubber tubing to ash skip for wear. 4. Crusher. 1m Grease inner bearing, grease nipples Under no circumstances should an excess and jaw crusher outrigger bearing of grease be applied to the bearing assembly. assemblies. 3m Dismantle complete unit and inspect for tile wear, bearings and seals etc. 5. Spray chamber (if fitted). Water solenoid valve. 3m Check operation. Spray jets. 3m Check operation. Winch unit (if fitted). 3m Grease pulleys, cable guides and winch unit. 6. Ash conditioner. 6m Clean paddles shaft and end bearing On-linehousing of any build up of ash.Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

57 05-10 FORCED DRAUGHT GAS BURNER CONDENSING BOILER

ITEM FREQ. ACTION NOTES 1. Check Operation. 12m Note any visible defects.

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

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

4. Pre service checks - 12m Check that there is a steady fall back Risk Assessment may be required Waste to the boiler from the flue to allow Disposal Regulations may apply. Condensate flow. condensate to run back. With the boiler operating at low return, temperature [less than 50oC], check that condensate flows freely from the On-linedrain pipe. Copy

5. Isolate from electricity and 12m Switch off, remove fuses and turn off Before starting any dismantling of equipment it gas supply. gas supply at main cock. is essential for safety reasons that the plant be isolated from incoming services.

Continued on next page .

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05-10 FORCED DRAUGHT GAS BURNER CONDENSING BOILER - continued

ITEM FREQ. ACTION NOTES 6. Fan/mix chamber, gas train 12m Remove, thoroughly clean, with a and controller assembly. soft brush. Lubricate if necessary. 7. Fan scroll. 12m Clean and check air passages. Ensure air passages are clear to pressure switch.

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

9. Burner. 12m Reassemble and fire, check air It is important that reference is made to the boiler and and gas settings, carry out burner manufacturer’s specifications. combustion efficiency test.

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

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

12. Boiler flue ways and On-line12m Open and remove by brushingCopy connecting flues. and/or vacuum all soot and scale. Reseal, check for air leaks, and reseal as necessary.

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59 05-10 FORCED DRAUGHT GAS BURNER CONDENSING BOILER - continued

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

b] Boiler tube module. 48m Clean and descale module in Always follow recommendations from manufacturer. accordance with manufacturers Note: Waste Disposal Regulations may apply instructions.

14. Neutralizing Unit (if fitted). 6m Check crystal level and top up if Unit can be separate to boiler. necessary.

15. General. 12m Check security of mechanical A maintenance check should be carried out on this parts and secure mounting of type of burner twice a year but refer to manufacturer’s appliances. specification.

16. Recommendation. 12m Provide written report which Premature failure and excessive fuel costs will result should be signed by the service if satisfactory service is not carried out. engineer and kept by client. All service and maintenance must be carried out by a Competent and CORGI registered engineer in accordance with Health and Safety requirements and On-line Copypossess accreditation in accordance with the Gas Safety (Installation & Use) Regulations.

Continued on next page ..

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60 05-10 FORCED DRAUGHT GAS BURNER CONDENSING BOILER – continued

ITEM FREQ. ACTION NOTES 17. Unsafe installations. 12m Recommendations If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use. If approval for this action is refused an appropriate label must be attached to the appliance and the HSE informed .A written report should also be signed by the client/responsible person/clients representative

On-line Copy

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

61 05-11 FORCED DRAUGHT GAS BURNER MODULAR BOILER Can comprise several modules, each having separate controls. Each module must be isolated and work carried out consecutively.

It is essential that there should be adequate ventilation [ratio of one third low to two thirds high level] of the boiler house for safety, plant and combustion air requirements and this should be checked with any new contract. For detailed information reference should be made to the CIBSE guide, relevant Institution of Gas Engineers and Managers documents and appropriate British Standards. ITEM FREQ. ACTION NOTES 1. Check Operation. 12m Note any visible defects. 2. Safety test. 12m Carry out and note any visual defects, record results. 3. Gas electrical systems. 12m Check that all are in accordance with current Codes of Practice. 4. Blown burner. 12m Test fire, and record settings. 5. Isolate from electricity and 12m Switch off, remove fuses and turn Before starting any dismantling of equipment it is gas supply. off gas supply at main cock. essential for safety reasons that the plant be isolated from incoming services. 6. Fan/mix chamber, gas train 12m Remove, thoroughly clean, with a and controller assembly. soft brush. Lubricate if necessary.

7. Fan scroll. 12m Clean and check air passages. Ensure air passages are clear to pressure switch. 8. HT & flame probe details. 12m Inspect for soundness. If probe is bent or shows signs of oxidation it should be On-line Copyreplaced. 9. Burner. 12m Reassemble and fire, check air It is important that reference is made to the boiler and and gas settings, carry out burner manufacturer’s specifications. combustion efficiency test. 10. Air pressure switch. 12m Test under no air conditions. 11. Flame failure. 12m Test and take probe readings. Continued on next page ..

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

62 05-11 FORCED DRAUGHT GAS BURNER MODULAR BOILER - continued

ITEM FREQ. ACTION NOTES 12. Boiler flue ways and 12m Open and remove by brushing and/or connecting flues. vacuum all soot and scale. Reseal, check for air leaks, and reseal as necessary. 13.a] Boiler tube module. 12m Drain down, remove and thoroughly clean with wire brush. b] Boiler tube module. 48m Clean and descale module in Always follow recommendations from manufacturer. accordance with manufacturer’s Note: Waste Disposal Regulations. instructions. may apply 14. General. 12m Check security of mechanical parts A maintenance check should be carried out on this and secure mounting of appliances. type of burner twice a year but refer to manufacturer’s specification. 15. Recommendation. 12m Provide written report which should Premature failure and excessive fuel costs will result be signed by the service engineer if satisfactory service is not carried out. and kept by client. All service and maintenance must be carried out by a registered engineer in accordance with Health and Safety requirements and possess accreditation in accordance with the Gas Safety Regulations. 16. Unsafe installations. 12m Recommendations If after servicing the appliance is considered unsafe the client should be advised that it must be taken out On-line Copyof use. If approval for this action is refused an appropriate label must be attached to the appliance and the HSE informed. A written report should also be signed by the client/responsible person/clients representative.

63 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. ITEM FREQ. ACTION NOTES 1. a) Before proceeding with 12m Check casing for damage or Check for asbestos prior to dismantling and dismantling of boiler. breakages. Inspect for loose fittings equipment. If suspect take a sample and cease or connections and any sign of leaks. work. b) Test fire. Record settings. 2. Pre-service checks. 12m Check that there is a steady fall back Risk Assessment may be required. to the boiler from the flue to allow Waste Disposal Regulations may apply. condensate to run back. With the Condensate flow 12m boiler operating at low return, temperature [less than 50oC], check that condensate flows freely from the drain pipe. 3. Gas electrical & ventilation 12m Check that all are in accordance with Local electrical isolator should be fitted. Supply systems. current Codes of Practice. to the boiler must be direct i.e. not fed through a time switch. 4. Burner. On-line6m Switch on, carry out safety checkCopy of Note any visible defects. flame failure.

5. Safety check. 6m Carry out and note any visible Pay particular attention to carbon monoxide defects. (CO) as presence is poisonous and life threatening and indicates waste energy.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 64 05-12 FORCED DRAUGHT GAS CONDENSING BOILER - continued

ITEM FREQ. ACTION NOTES 6. Isolate from electricity and 6m Switch off, remove fuses and turn off Before starting and dismantling of equipment it gas supply. gas supply at main cock. is essential for safety reasons that the plant be isolated from incoming services. 7. Fan motor. 6m Remove, thoroughly clean, lubricate if necessary. 9. Fan scroll. 6m Clean and check air passages. Ensure air passages are clear to pressure switch. 10. Removal of UV cell and 6m Clean, adjust electrode and if UV cells should be replaced after a life of head assembly. required isolation probe. 10,000 hours. 11. HT & probe details. 6m Inspect for soundness. 12. Burner. 6m Reassemble and fire, check air and It is important that reference is made to the gas settings, carry out combustion boiler and burner manufacturer’s specifications. efficiency test. Check high/low flame conditions.

13. Air pressure switch. 6m Test under no air conditions.

14. Flame failure. On-line6m Test and take probe or UVCopy cell readings.

15. Neutralizing Unit (if fitted). 6m Check crystal level and top up if Unit can be separate to boiler. necessary. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

65 05-12 FORCED DRAUGHT GAS CONDENSING BOILER - continued

ITEM FREQ. ACTION NOTES 16. General. 6m Check security of mechanical parts A maintenance check should be carried out on and secure mounting of appliance. this type of burner twice a year but refer to manufacturer’s specification. 17. a) Safety check – Gas. 12m Ensure that no products of NB – Undetected CO is life threatening combustion are entering the area of (poisonous) and also causes energy waste. the building where the boiler is Flames should be bluish and burning in a stable situated. manner. The burner should be quiet in operation, no excessive noises should occur when the burner ignitor shuts down.

b) Safety check – Electric. 12m Check electrical installation for safety If not provide written report to client. and that local isolator is fitted. 18. Unsafe installations. 12m Recommendations. If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use. If approval for this action is refused an appropriate label must be attached to the appliance and the HSE informed. A written report should also be signed by the On-line Copyclient/responsible person/clients representative

66 05-13 FORCED DRAUGHT [PRESSURE JET ] OIL CONDENSING BOILER

ITEM FREQ. ACTION NOTES 1. a) Before proceeding with 12m Check casing for damage or dismantling of boiler. breakages. Inspect for loose fittings or connections and any sign of leaks.

b) Test fire. Record settings.

2. Pre-service checks. 12m Check that there is a steady fall back Risk Assessment may be required. to the boiler from the flue to allow Waste Disposal Regulations may apply. condensate to run back. With the 3. Condensate flow. 12m boiler operating at low return, temperature [less than 50oC], check that condensate flows freely from the drain pipe.

4. Oil electrical & ventilation 6m Check that all are in accordance with Local electrical isolator should be fitted. Supply systems. current Codes of Practice. to the boiler must be direct i.e. not fed through a time switch.

5. Burner. On-line6m Switch on, carry out safety checkCopy of Note any visible defects. flame failure.

6. Safety check. 6m Carry out and note any visible Pay particular attention to carbon monoxide defects. (CO) as presence is poisonous and life threatening and indicates waste energy.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 67 05-13 FORCED DRAUGHT [PRESSURE JET] OIL CONDENSING BOILER - continued

ITEM FREQ. ACTION NOTES 7. Isolate from electricity and 6m Switch off, remove fuses and turn off Before starting and dismantling of equipment it oil supply. oil supply at main cock. is essential for safety reasons that the plant be isolated from incoming services. 8. Jet arm assembly. 6m Remove, clean combustion head, ignitor electrodes and inspect HT leads. 9. a) Nozzle and filter. 6m Clean filter and inspect nozzle for Erosion or surface defects on the nozzle can wear. effect the profile of the emerging jet of oil and lead to a poor flame shape and bad combustion. b) Nozzle and filter. 12m Renew. 10. Burner. 6m Reassemble and set heat to manufacturer’s requirements. 11. Motor and fan. 6m Remove, clean and lubricate as Inspect oil pump flexible drive coupling before required, clean fan scroll. reassembly. (See also MOTORS ) 12. Oil pump filter. 6m Remove and clean, inspect pump seals for signs of wear. 13. Reassembling burner. 6m Inspect flexible oil line coupling, clean and renew oil line filter, clean On-linephotocell and adjust position. Copy 14. Burner. 6m Switch on and check flame shape and appearance if visible. 15. Oil pressure. 6m Test, record oil pressure. 16. Safety check. 6m Carry out and check for smoke. On larger systems combustion test should be carried out regularly to monitor performance and avoid energy waste. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

68 05-13 FORCED DRAUGHT [PRESSURE JET] OIL CONDENSING BOILER - continued

ITEM FREQ. ACTION NOTES 17. Flame failure device. 6m Test for satisfactory operation 18. Condensate level 6m Clean and inspect. prove (if fitted). 19. Secondary heat 6m Clean with water and a soft brush. exchanger (if fitted). 20. Neutralising Unit (if 6m Check crystal level and top up if Unit is normally separate to boiler. fitted) necessary. 21. Condensate drain pipe 6m Clean, inspect and flush. and U-siphon trap. 22. General. 6m Check security of mechanical parts A maintenance check should be carried out on this and secure mounting of appliance. type of burner twice a year but refer to manufacturer’s specification. 23. Recommendation 6m Provide written report which should be Premature failure and excessive fuel costs will result signed by the service engineer and if satisfactory service is not carried out. kept by client. 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 On-line Copyout by a competent engineer in accordance with BS Codes of Practice for oil firing.

69 05-14 BOILERS MTHW – UP TO 120oC

Applies to boilers manufactured by casting or fabrication ITEM FREQ. ACTION NOTES 1. Check operation, in 12m Note any visible defects. Ensure system is full of water and the particular safety controls circuits are open. It is essential for low (prv). water content boilers that flow rates can be maintained at or above manufacturers recommended levels. 2. Efficiency check. 12m 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. Thermostats, pressure sensors & controls, altitude gauges, vacuum breaks. 3. Thermostats, vacuum breaks. 12m Check for correct operation and settings.

4. Electrical services. 12m Shut down, disconnect or remove fuses. Locate isolation switch, if not in accordance with IEE regulations report to building On-line Copyowner. 5. Boiler return temperature and 12m Check if appropriate. See relevant section. associated controls.

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Applies to boilers manufactured by casting or fabrication ITEM FREQ. ACTION NOTES 6. Booster Pumps. 12m Check interlocks between controls.

7. Boiler flueways, combustion 12m Open and remove by brushing chamber and connecting flues. and/or vacuum all soot and scale.

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

9. Boiler flueways and chamber. 12m Reseal, check for air leaks, seal as necessary. 10. Flue. 12m Carry out smoke test. Only if flue problem is suspected. 11. Water quality. 12m Check system water quality and Where system water quality is controlled, inhibitor type and concentration. water treatment and dosing plant should be Top up if necessary. If water maintained according to the manufacturer's quality check shows regime is instructions. incorrect refer to specialist. 12. Fan (if provided). 12m Check operation and clean blades. Build up of deposits on the blades can reduce On-line Copytheir efficiency and lead to poor combustion. 13. Boiler. 12m Reconnect and test fire, carry out A boiler is capable of exploding if safety efficiency test, refit casing and controls fail and blocked flues will cause flue thoroughly clean down. gas to leak into surrounding areas, causing damage and risks to life and to health through carbon monoxide poisoning.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

71 05-14 BOILERS MTHW – UP TO 120oC - continued

Applies to boilers manufactured by casting or fabrication ITEM FREQ. ACTION NOTES 14. Gas Trains. 12m Test for soundness.

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

On-line Copy

72 05-15 MULTIPLE BOILERS - sequence controls

All notes referring to sequence controls apply to individual boilers ( not burner modules) in multiple installations. ITEM FREQ. ACTION NOTES 1. Lead/lag control. 12m Check operation. Check the set Check the frequency of operation if hours run point (and differential). are fitted. 2. Sequencing control. 12m Check operation. 3. Controller. 12m Check operation and confirm the The step controller will have mechanical set point. switching using micro- or solid state switching. 4. Step Controller. 12m Check operation.

5. Boiler return butterfly valves. 12m Check operation. Check valve opening proving circuit and ensure that valve on leading boiler is open at all times.

6. Boiler diverting valves state. 12m Check operation. Check valve opening proving circuit and ensure that valve on leading boiler is open at all times.

7. Boiler shunt pump. 12m Confirm operation. Is there a water proving circuit? Check On-line Copyoperation if part of sequence controls. See PUMPS maintenance. 8 Non return valves. 12m Check operation. 9. Return/flow sensor. 12m Confirm correct. Calibration } Controller. Interrogation } by CONTROL SPECIALIST Step controller. Adjustment } Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 73 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. ITEM FREQ. ACTION NOTES 1. Manual switch. 12m Check operation. 2. Time switch. 12m Check operation. Confirm time settings. Time of day. (Keep setting at GMT all year unless specifically requested by client.) Day of week. Manual override. 3. Boiler control and high limit 12m Check operation. Confirm set points Thermal no longer conforms to current thermostats – Manual. and temperatures. insurance requirements. - Electronic. Check operation. Confirm set points On-lineand temperatures. Copy 4. Room thermostat. 12m Check operation. Confirm set point. 5. HWS thermostat. 12m Check operation. Confirm set point. 6. Frost protection thermostat. 12m Check operation. Confirm set point. This may be outside the building on older systems. 7. Flow switch. 12m Check operation.

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ITEM FREQ. ACTION NOTES 8. Boiler pressure switch. 12m Check operation. Confirm set point. 9. Temperature sensors. 12m Check operation and confirm time Time of day. Optimum start controllers. settings. Day of week. Manual override. Check performance. Summer/Winter Calibration } by CONTROL SPECIALIST Interrogation } Adjustment }

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 75 05-17 BOILER PROTECTION CONTROLS

ITEM FREQ. ACTION NOTES 1. Pump overrun timer. 12m Check operation. Confirm time setting. 2. Pump overrun thermostat. 12m Check operation. Confirm set point. 3. Return water thermostat. 12m Check operation. Confirm set point.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 76 05-18 BOILERS - Space temperature controls

ITEM FREQ. ACTION NOTES 1. Room thermostat. 12m Check operation and confirm set Direct switching of boiler or pump on/off. point.

2. Room thermostat - zone valve 12m Check operation and confirm set Check if auxiliary switch controls boiler or operation. point. pump on/off. 3. Flow sensor controller. 12m Check operation and confirm set Variable temperature controller (compensator) point(s). of boiler on/off. 4. Space sensor controller. 12m Confirm operation. Calibration } Interrogation} by CONTROL SPECIALIST Control adjustment }

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 77 05-19 STEAM BOILERS – Pre-maintenance check.

ITEM FREQ. ACTION NOTES 1. Status. 12m Check operating status. Before proceeding with maintenance programme check with client that boiler can be taken off-line. 2. Condition. 12m Check exterior for signs of damage, Leakage can lead to corrosion with subsequent leakage from valves, manholes and costly refurbishment or replacement of any loose fittings. equipment. 3. Safety circuits. 12m Check operation. Safety system includes low and high level alarms, and pressure relief valves. 4. Combustion Check. 12m Ensure system on load and carry out Test should include smoke, draught chamber and combustion tests. flue, flue gas temperature, CO, CO2, and O2. Readings should be checked with boiler instrumentation and noted. 5. Thermostats, pressure 12m Check for correct operation and sensors and gauges, and settings thermometers. 6. Shut down. 12m Shut off and isolate steam, water, fuel, Purge fuel lines and vent boiler to ensure safe and electrical services. conditions. 7. Ventilation. 12m Check that ventilation fans and louvres Check that there is adequate ventilation in the are functioning properly. boiler house and the conditions comply with the On-line Copyrelevant regulations and standards. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 78 05-20 STEAM BOILERS – Maintenance schedule.

This is generally carried out at the same time as the Annual Statutory Insurance Inspection. ITEM FREQ. ACTION NOTES 1. Boiler flueways, 12m Open, remove by brushing and/or Soot, ash and other fouling deposits impede heat combustion chamber and vacuum all soot and scale. transfer thus wasting energy and putting up costs. connecting flue. 2. Fire tubes. 12m Open boiler end doors and clean fire In multipass boilers it is important to clean all tubes by brushing or rotary scouring passes. equipment. 3. Refractory linings. 12m Check condition and report.

4. Boiler flueways, doors 12m Reseal, check for air leaks, seal as and chamber. necessary. 5. Flue. 12m Carry out smoke test. 6. Waterside. 12m Remove manholes, clean out scale If there are considerable deposits of sludge and and residues. Replace, reseal and scale, this indicates poor water treatment which if ensure bolts are tight. allowed to continue will lead to boiler failure and energy wastage. Waste Disposal Regulations may apply. 7. Boiler. 12m Refill, reconnect and bring on line. Refit casing if necessary and thoroughly clean On-line Copydown. 8. Instrumentation and 12m Check for operation and accuracy. Recalibrate and reset if necessary. flame monitoring. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 79 05-20 STEAM BOILERS – Maintenance schedule. - continued

This is generally carried out at the same time as the Annual Statutory Insurance Inspection. ITEM FREQ. ACTION NOTES 9. Combustion check. 12m Bring up to full load and carry out On larger systems combustion tests should be tests. 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. 10. Blow down tank. 12m For maintenance procedures see HSE document PM60 applies. SANITARY & WASTE WATER PLUMBING – Interceptors.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 80 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. ITEM FREQ. ACTION NOTES 1. Isolation from electricity 12m Switch off. Remove fuses from both The boilers have two supplies. The permanent supplies. supplies. large capacity supply and the restricted hours signal supply. Report to the client if not capable of isolation. 2. Unit condition. 24m Check physical condition of unit.

3. Heavy current connection in 12m Remove control box cover. Check all See also MOTORS the control box. heavy current connection for tightness & signs of over heating also check element relay contacts for damage. 4. Heavy current connection in 12m Remove top of boiler casing. Check boiler. all heavy current connections for tightness & signs of over heating. 5. Fan cooling air duct. 12m Remove button front casing clean Report if fan motor or pump are noisy. Advise duct through casing, remove also the the customer that the louvres on the outside of rear end fan motor which is exposed the casing should be vacuumed at intervals if when the casing is removed. the environment of the boiler is unclean.

6. Water connection. On-line12m Check for leaks. Copy 7. Water treatment. 12m Ask if the system has been drained If system does not contain inhibitor advise it is since last visit & if it was retreated treated, as this is part of the manufacturers with inhibitor. instructions. 8. Thermal link. 24m Replace. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 81 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. ITEM FREQ. ACTION NOTES 1. Status. 3m Check and isolate by removing fuse links. 2. a) Electrical connections. 12m Check all electrical connections in the cubicle and on the boiler electrodes for soundness and correct any defects. b) Porcelain insulators. 12m Examine for defects and replace if necessary. Clean with non-abrasive material. 12m Examine all porcelain mechanical If there are any leaks or have been leaks, seals for water leaks. dismantle the assembly and repair by replacing the sealing gaskets. 3. Water drain unit. 3m Check for free flow of water by operating the valve. Repair any valve gland leaks. 4. Drain pipe. 12m Check for free flow, actuate main drain On-lineif necessary. Copy 5. Feed solenoid (if fitted). 12m Clean solenoid, manifold and strainer. Modern boilers have the load control driven by an electric motor. See MOTORS.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 82 05-22 ELECTRODE BOILERS – continued

ITEM FREQ. ACTION NOTES 6. Load control system. 12m Examine mechanism and lubricate. Comply with manufacturers recommendation for lubrication of the gear box, motor and control shaft and nut. Examine for water leaks. If necessary adjust or replace its seal. 7. Boiler circulated water. 3m Test for correct conductivity at This is to be within the boiler makers 20/25oC. recommendation. Test the hardness. This should be as near commercial ZERO as possible, if too high, seek the advice of a water treatment specialist. DO NOT USE TANNIN. Test the pH index of the water. This should be between 7 & 8 on the pH scale. 8. Boiler sequence. 12m Replace all covers and reinstate Ensure all electrical and mechanical covers are in electrical supply. their correct places. Set the controls to 'start' and operate boiler in its normal mode and ensure the functions are correct. Read the current flow in each These should balance within +4%. If there is an electrode circuit (phase). imbalance consult the boiler manufacturer, or isolate the boiler electrically and mechanically and examine the boiler interior for defects, i.e. electrode deterioration; control shield damage. On-lineThe electrode phase current readingCopyThis is because the water conductivity is low at with the control shield fully exposed low temperatures and will increase as the water may not be high when the circulated heats; the current will also increase with this water is cold. increase in water temperature. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 83 05-23 BOILERS LTHW UP TO 95oC

Applies to boilers manufactured by casting or fabrication. ITEM FREQ. ACTION NOTES 1. Check operation, in 12m Note any visible defects. Ensure system is full of water and the circuits are open. It particular safety is essential for low water content boilers that flow rates can controls. be maintained at or above manufacturers recommended levels. 2. Efficiency check. 12m Start up system and carry out On larger systems efficiency tests should be carried out on tests. 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. 3. Thermostats, pressure 12m Check for correct operation and sensors, altitude gauges settings. thermometers. 4. Electrical services. 12m Shut down, disconnect or remove Locate isolation switch, if not in accordance with IEE fuses. regulations report to building owner. 5. Boiler return 12m Check if appropriate. See controls. temperature and associated controls. 6. Boiler flueways, 12m Open and remove by brushing Waste Disposal Regulations may apply. combustion chamber On-lineand/or vacuum all soot and Copy and connecting flues. scale. 7. Refractory linings. 12m Check condition and report. 8. Boiler flueways and 12m Reseal, check for air leaks, seal chamber. as necessary. 9. Flue. 12m Carry out smoke test. Only if flue problem is suspected. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 84 05-23 BOILERS LTHW - continued

ITEM FREQ. ACTION NOTES 10. Water quality. 12m Check system water quality and Where system water quality is controlled, water inhibitor type and concentration. Top treatment and dosing plant should be maintained up if necessary. If water quality check according to the manufacturer's instructions. shows regime is incorrect refer to specialist. 11. Fan (if provided). 12m Check operation and clean blades. Build up of deposits on the blades can reduce their efficiency and lead to poor combustion.

12. Boiler. 12m Reconnect and test fire, carry out A boiler is capable of exploding if safety controls efficiency test, refit casing and fail and blocked flues will cause flue gas to leak thoroughly clean down. into surrounding areas, causing damage and risks to life and to health through carbon monoxide poisoning.

13. Gas Trains. 12m Test for soundness.

14. Boiler house cleanliness. 12m Inspect. Boiler house cleanliness is important. Concrete On-line Copyfloors should be sealed to keep dust down. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

85 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. ITEM FREQ. ACTION NOTES 1. Oil fire valve. 12m Check valve and associated It is essential that the system will provide a positive couplings for positive oil shut off. shut off of the oil supply in an emergency. The valve should comply with current legislation. quick release mechanism. 12m Actuate and check that any dead weight or solenoid valves operate correctly. valve and quick release system. 12m Reset. Check that all interconnecting tension wire, fusible links fire buttons and pulleys are free for operation. 2. Gas - manually operated valves. 12m Check valve action. pressure switches on gas 12m Check for operation and boosters. sensitivity. gas detection unit. 12m Test sensitivity. Determine if a Determine if a test is possible, if not refer to specifier. It On-linetest is possible if not refer toCopy may be necessary to recalibrate, if so carry out specifier. strictly according to the manufacturer's instructions. Continued on next page ..

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86 05-24 BOILERS - FIRE AND SAFETY CIRCUITS - continued

ITEM FREQ. ACTION NOTES manual quick release 12m Actuate and recheck operation of mechanism the dead weight valve or solenoid. valves and quick release 12m Reset. Check all interconnecting tension wire, fusible links fire mechanism. buttons and pulleys for free operation.

3. Solid fuel - fusible links, inter-connecting 12m Inspect. Check that all are free for operation. tension wire and pulleys. quick release mechanism. 12m Operate to ensure that fuel feed Reset as necessary. system stops. 4. Boiler control and high 12m Ensure these are set correctly. Operation should be within the manufacturer's limit thermostats (thermal Check operation of pressure switching differential. Adjust if necessary. This note or manual reset). switches. should be read in conjunction with item 7 - Smoke/heat detection. 5. Pressure switches. 12m Check operation. 6. Foam inlets. 12m Ensure foam inlet pipes are free Inspect diffuser nozzles for damage. On-linefrom blockage. Copy 7. Smoke/heat detection. 12m Check operation. Refer to Code of Practice - BS 5839. Continued on next page ..

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87 05-24 BOILERS - FIRE AND SAFETY CIRCUITS - continued

ITEM FREQ. ACTION NOTES 8. General. 12m Check all fuel supply valves for Ensure that each fuel supply value is complete with free operation. own wheel or key. 9. Combustion air source 12m Check that original provision has Inadequate combustion air provisions can create a into plant room. been left clear of any obstruction hazard to both the equipment and the occupants of the dirt. plant room. Notify responsible person.

On-line Copy

88 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.

ITEM FREQ. ACTION NOTES 1. Solid fuel fusible links, 3m Inspect. interconnecting tension wire and pulleys. quick release Operate to ensure that fuel feed Reset as necessary. mechanism. system stops. 2. Boiler controls and high limit 3m Ensure these are set correctly. Operation should be within the manufacturer's stats. switching differential. Adjust if necessary. This note should be read in conjunction with section 4. Smoke/heat detection. 3. Foam inlets. 3m Ensure foam inlet pipes are free Inspect diffuser nozzles for damage. from blockage. 4. Smoke/heat detection. 3m Check operation. Refer to Code of Practice BS 5839. 5. General. 3m Check all fuel supply valves for free Ensure that each fuel supply valve is complete On-lineoperation. Copywith its own wheel or key. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 89 05-26 WASTE AND WOOD BURNING APPLIANCES (including boilers) - Combustion Chamber

ITEM FREQ. ACTION NOTES 1. Fuel feed. (a) Mechanical. 3m Inspect, check for broken parts and Waste can be a very variable type of fuel and clean conveyors, feeders, etc. may contain stones, metal and other materials which can cause damage and breakage of the feed mechanism. (b) Pneumatic. 3m 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. 2. Fire grate. 3m Clean of any clinker, report to client if Uneven combustion is a feature of waste burning any repairs required. and this can lead to local overheating within the fuel bed. Clinker formation can occur together with distortion or failure of the fire grate bars.

3. Ash removal. 3m Inspect for wear and where operation automatic reset controls. 4. Automatic ignition. 3m Clean and check operation and reset. Refer to Code of Practice BS 5839.

5. Combustion check. 3m Carry out and adjust primary and Because of the variable nature of the fuel On-linesecondary and tertiary (if any) Copyair for allowance for some excess air is necessary. With optimum combustion. starved air (two phased combustion) tests should be carried out after each stage and should include CO. 6. General. 3m Check all fuel supply valves for free Ensure that each fuel supply valve is complete operation. with its own wheel or key. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

90 05-27 WASTE AND WOOD BURNING APPLIANCES (including boilers) - BOILER (if fitted)

ITEM FREQ. ACTION NOTES 1. Check operation in 3m Note any visible defects. Ensure system is full of water and the circuits are particular the safety open. controls. 2. Combustion check. 3m Start up system and carry out Because of the variable nature of the fuel, combustion tests. tests should be carried out on a regular basis to monitor performance. The test should include smoke, draught chamber and flue gases including CO. 3. Thermostats, pressure 3m Check for correct operation and sensors, altitude gauges settings. and thermostats.

4. Electrical services. 3m Shut down, disconnect or remove fuses. 5. Boiler flueways and 3m Open and remove by brushing When burning waste, the hot surfaces of fire or water tubes and connecting and/or vacuum all soot and tubes (if water tube boiler) can foul up very quickly flue. scale. and mechanical techniques of removing scale should be used. Environmental Regulations may apply. 6. Refractory linings. 3m Check condition and report. On-line Copy 7. Boiler flue ways and 3m Reseal, check for air leaks, seal chamber. as necessary. 8. Boiler return temperature 3m Check if appropriate. Check manufacturer’s specification. and associated controls. Continued on next page ..

91 05-27 WASTE AND WOOD BURNING APPLIANCES (including boilers) - BOILER (if fitted) - continued

ITEM FREQ. ACTION NOTES 9. Boiler. 3m Reconnect and test fire, carry out A boiler is capable of exploding if safety controls combustion test, refit casing and fail and blocked flues will cause flue gas to leak thoroughly clean down. into surrounding areas, causing damage and risks to life and health through carbon monoxide poisoning.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

92 05-28 ATMOSPHERIC GAS BURNER BOILER - Small and/or wall hung for domestic and light commercial installations.

ITEM FREQ. ACTION NOTES 1. a) Before proceeding with 12m Check casing for damage or Check for asbestos prior to dismantling any dismantling of boiler. breakages. Inspect for loose fittings or equipment If suspect cease work and advise connections and any sign of leaks. supervisor.

Record settings. b) Check firing. 12m Observe the main burner. Use a Dark mauve flame and excessive lifting off combustion analyzer to measure CO & indicate poor combustion.

CO content of flue gas. 2 Check Gas pressure,

Record settings. 2. Gas electrical & 12m Check that all are in accordance with Local electrical isolator should be fitted. Supply ventilation systems. current Codes of Practice. to the boiler must be direct i.e. not fed through a time switch. 3. Isolate boiler for gas and 12m Record any work which needs electrical supplies. rectification or replacement. 4. Gas valve. 12m Disconnect thermocouple and pilot tube from burners. 5. Remove burners and pilot 12m Brush all accessible flueways Cleaning should be thorough and carried out as assembly and baffles if thoroughly from top to bottom, clean per the manufacturers instructions. fitted. On-lineall deposits from the burner box,Copy refit baffles and flue cover - checking cover seal. Check for cracking and wear. Continued on next page ..

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93 05-28 ATMOSPHERIC GAS BURNER BOILER- Small and/or wall hung for domestic and light commercial installations. - continued

ITEM FREQ. ACTION NOTES 6. a) Pilot assembly. 12m Remove. Pilot head. Remove and clean ports. Pilot injection. Remove and clean. Clean by blowing through or washing. Note: Do not use pin as this will damage the injector. Thermocouple tip. Replace/clean with fine wire brush, Make sure head lines up with the pilot and not the reassemble pilot. burner. b) Oxy-pilot assembly. 12m Replace. 7. Lint filter (if fitted). 12m Remove from burners and clean.

8. Filters. 12m Refit. Burners, Gas valve, Check, adjust and refit along with main thermocouple and pilot burner. tube. 9. Boiler and installation. 12m Open gas cock and test for gas Test flame setting and thermocouple sensitivity soundness, reconnect electrical and check manifold gas pressure against services. Test controls operation, manufacturer's settings, adjust if required. relight pilot and run up boiler. If in doubt check gas supply working pressure at On-line Copy. the meter

Continued on next page ..

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94 05-28 ATMOSPHERIC GAS BURNER BOILER- Small and/or wall hung for domestic and light commercial installations. - continued

ITEM FREQ. ACTION NOTES 10. a) Safety check – Gas. 12m Ensure that no products of combustion NB - Undetected CO is life threatening are entering the area of the building (poisonous) and also causes energy waste.

where the boiler is situated. Flames should be bluish and burning in a stable manner.

The burner should be quiet in operation, no

excessive noise should occur when the burner ignitor shuts down.

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

b) Safety check – Electric. 12m Check electrical installation for safety If not provide written report to client. and that local isolator is fitted.

11. Documentation. 12m Provide written report. The report should be signed by the servicing engineer and the client/responsible person/clients representative. Premature failure of the plant will result if a On-line Copysatisfactory service is not carried out, by a competent engineer qualified as required by the Gas Safety (Installation and Use )Regulations. Depending on the nature/urgency of the fault and the type of premises this report may be verbal.

Continued on next page ..

95 05-28 ATMOSPHERIC GAS BURNER BOILER – Small and/or wall hung for domestic and light commercial installations. - continued

ITEM FREQ. ACTION NOTES 12. Unsafe installations. 12m 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 the gas supplier and a supervisor/manager informed.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 96 05-29 COMBINATION ATMOSPHERIC BURNER GAS BOILER

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

ITEM FREQ. ACTION NOTES 1. a) Before proceeding with 12m Check Central Heating system for leaks. Flame should cover all flame parts and be dismantling of boiler. light blue in colour.

b) Test firing. 12m Set appliance to DHW highest flow rate to Dark mauve flame and excessive lifting off observe the main burner. Use a combustion indicate poor combustion. analyzer to measure CO & CO content of 2 If appliance is fitted in a hard water area flue gas. (above 200 ppm), a suitable water treatment Check Gas pressure, Water volume & device should be fitted. pressure. Record settings. 2. Gas electrical & 12m Check that all are in accordance with current Local electrical isolator should be fitted. ventilation systems. Codes of Practice. Supply to the boiler must be direct i.e. not fed through a time switch. 3. Isolate boiler for gas and 12m Record any work which needs rectification or electrical supplies. replacement. 4. Gas valve. 12mOn-lineDisconnect thermocouple and pilotCopy tube from burners. 5. Remove burners and 12m Brush all accessible flueways thoroughly Cleaning should be through and carried out pilot assembly and from top to bottom, clean all deposits from as per the manufacturers instructions. baffles if fitted. the burner box, refit baffles and flue cover - checking cover seal. Check for cracking and wear. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 97 05-29 COMBINATION ATMOSPHERIC BURNER GAS BOILER - continued

ITEM FREQ. ACTION NOTES 6. Internal Pipework. 12m Examine connections for water leaks and rectify as necessary.

7. Heat Exchanger. 12m Brush away deposits using a If in hard water area and water treatment device is soft brush. not fitted, the HW Heat Exchanger should be descaled. 8. Fan. 12m Check for free running, mechanical drainage and clean with a soft brush.

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

10. Filters. 12m Refit.

Burners, Gas valve, Check adjust and refit along thermocouple and pilot tube. On-linewith main burner. Copy 11. Boiler and installation. 12m Open gas cock and test for gas Test flame setting and thermocouple sensitivity and soundness, reconnect electrical check manifold gas pressure against manufacturer's services. Test controls settings, adjust if required. operation, relight pilot and run If in doubt check gas supply standing pressure at the up boiler. meter.

98 05-29 COMBINATION ATMOSPHERIC BURNER GAS BOILER - continued

ITEM FREQ. ACTION NOTES 12. a) Safety check – Gas 12m Ensure that no products of Flames should be bluish and burning in a combustion are entering the area stable manner.

of the building where the boiler is The burner should be quiet in operation, no situated. excessive noise should occur when the burner ignites or shuts down.

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

b) Safety check - Electric 12m Check electrical installation for If not provide written report to client. safety and that local isolator is fitted.

c) Sealed System – Pre Charged 12m Check pressure in system is being maintained and that

expansion vessel pressure conforms to the pre charged setting. On-line Copy

Continued on next page ..

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99 05-29 COMBINATION ATMOSPHERIC BURNER GAS BOILER - continued

ITEM FREQ. ACTION NOTES 13. Documentation. 12m Provide written report. The report should be signed by the servicing engineer and the client/responsible person/clients representative. Premature failure of the plant will result if a satisfactory service is not carried out, 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. 14. Unsafe installations 12m Recommendations If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use. If approval for this action is refused an appropriate label must be attached to the appliance and the HSE informed. A written report should also be signed by the client/responsible person/clients representative.

On-line Copy

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

100 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.

ITEM FREQ. ACTION NOTES 1. a) Before proceeding with 12m Check Central Heating system dismantling of boiler. for leaks.

b) Test firing. 12m Set appliance to DHW highest Flame should cover all flame parts and be light flow rate to observe the main blue in colour.

burner. Use a combustion Dark mauve flame and excessive lifting off indicate analyzer to measure CO & CO 2 poor combustion. content of flue gas. If appliance is fitted in a hard water area (above 200 Check Gas pressure, Water ppm), a suitable water treatment device should be volume with the boiler operating fitted. at low return temperatures (less o than 50 C) check that condensate flows freely from the drain pipe. Record settings. 2. Gas electrical & ventilation 12m Check that all are in Local electrical isolator should be fitted. Supply to the systems. accordance with current Codes boiler must be direct i.e. not fed through a time On-lineof Practice. Copyswitch. 3. Isolate boiler for gas and 12m Record any work which needs electrical supplies. rectification or replacement. 4. Gas valve. 12m Disconnect thermocouple and pilot tube from burners. Continued on next page ..

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

ITEM FREQ. ACTION NOTES 5. Remove burners and pilot 12m Brush all accessible flueways Cleaning should be through and carried out as per assembly and baffles if thoroughly from top to bottom, the manufacturers instructions. fitted. clean all deposits from the burner box, refit baffles and flue cover - checking cover seal. Check for cracking and wear. 6. a) Internal Pipework. 12m Examine connections for water leaks and rectify as necessary. b) Condensate drain. 12m Clean, inspect and flush. 7. Heat Exchanger. 12m Brush away deposits using a If in hard water area and water treatment device is soft brush. not fitted, the heat exchanger should be descaled. 8. Fan. 12m Check for free running, mechanical drainage and clean with a soft brush. 9. Lint filter (if fitted). 12m Remove from burners and clean.

10. Condensate. 12m Check that condensate flows On-linefreely at low boiler return Copy temperatures. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

102 05-30 ATMOSPHERIC GAS BURNER CONDENSING COMBINATION BOILER - continued

ITEM FREQ. ACTION NOTES 11. Filters. 12m Refit. Burners, Gas valve, Check, adjust and refit along thermocouple and pilot tube. with main burner. Check that condensate flows freely at low boiler return temperatures.

12. Boiler and installation. 12m Open gas cock and test for gas Test flame setting and thermocouple sensitivity and soundness, reconnect electrical check manifold gas pressure against manufacturer's services. Test controls settings, adjust if required. operation, relight pilot and run If in doubt check gas supply standing pressure at the up boiler. meter.

13. a) Safety check – Gas 12m Ensure that no products of combustion are entering the Flames should be bluish and burning in a stable

area of the building where the manner. boiler is situated. The burner should be quiet in operation, no excessive noise should occur when the burner ignites or shuts

down.

On-line CopyNB - Undetected CO is life threatening (poisonous) and also causes energy waste In domestic premises consider the installation of a BS approved CO detector Continued on next page ..

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

103 05-30 ATMOSPHERIC GAS BURNER CONDENSING COMBINATION BOILER - continued ITEM FREQ. ACTION NOTES b) Safety check - Electric 12m Check electrical installation for If not provide written report to client. safety and that local isolator is fitted. c) Sealed System 12m Check pressure in system is being maintained and that expansion vessel pressure conforms to the pre changed setting. 14. Documentation. 12m Provide written report. The report should be signed by the servicing engineer and the client/responsible person/clients representative. Premature failure of the plant will result if a satisfactory service is not carried out, by a CORGI Registered and competent engineer qualified as required by the Gas Safety (Installation & Use) Regulations. Depending on the nature/urgency of the fault and the type of premises this report may be verbal.

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

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

104 05-31 AIR TO WATER HEAT PUMP

For additional information, see manufacturer’s instructions.

ITEM FREQ. ACTION NOTES 1. Status. 6m Isolate electrically. Note: Isolation of electrical equipment should be carried out in accordance with HASAWA requirements.

2. Condensate drain pan. 6m Check pan and drain are clear. Check that drainpipe is properly attached.

3. Water loop connections. 6m Check for leaks.

4. Electrical wiring and 6m Check integrity. terminals. 5. Return to service. 6m Place on heating cycle, isolate from Follow by opening water loop connection and water loop, check high-pressure safety resetting high pressure cut out. device stops refrigeration compressor. 6. Controls. 6m Return to standard settings. 7. External cleaning 6m Clean unit externally. Note defects on report to client.

On-line Copy

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

105 05-32 WATER TO WATER HEAT PUMP

For additional information, see manufacturer’s instructions.

3. Electrical wiring and 6m Check integrity. terminals. 4. Return to service. 6m Place on heating cycle, isolate from Follow by opening water loop connection and water loop, check high-pressure safety resetting high pressure cut out. device stops refrigeration compressor. 5. Controls. 6m Return to standard settings. 6. External cleaning 6m Clean unit externally. Note defects on report to client.

On-line Copy

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

106 05-33 BRINE TO WATER HEAT PUMP

For additional information, see manufacturer’s instructions.

ITEM FREQ. ACTION NOTES 1. Status. 6m Isolate electrically. Note: Isolation of electrical equipment should be carried out in accordance with HASAWA requirements. 2. Water loop connections. 6m Check for leaks. 3. Brine loop connections. 6m Check for leaks. 4. Electrical wiring and 6m Check integrity. terminals. 5. Return to service. 6m Place on heating cycle, isolate from Follow by opening water loop connection and water loop, check high-pressure safety resetting high pressure cut out. device stops refrigeration compressor. 6. Controls. 6m Return to standard settings. 7. External cleaning 6m Clean unit externally. Note defects on report to client.

On-line Copy

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

107 06-01 ATMOSPHERIC GAS BURNERS

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

ITEM FREQ. ACTION NOTES 1. Operational status. 12m Check and note any defects. Annual maintenance should be sufficient but refer to manufacturer's specification. 2. Gas, electrical and 12m Check that all are in accordance ventilating systems. with current Codes of Practice.

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

4.a) Thermocouple, probe pilot 12m Disconnect and remove from Cleaning should be thorough and carried out as per assembly, spark electrode boiler, clean pilot and main the manufacturer's instructions.

and main burners. burner.

b) Oxy pilot assembly 12m Remove and replace as manufacturers recommendations. On-line Copy 5. Spark electrode and 12m Check, adjust and refit along with thermocouple/ probe. main burner.

Continued on next page ..

1008 06-018 ATMOSPHERIC GAS BURNERS - continued

ITEM FREQ. ACTION NOTES 6. Wiring to ignitor and/or 12m Check. probprobe, gas valve and boiler ther thermomostats.

7. Flame failure and 12m Turn on gas, check and adjust associated controls. pilot flame to envelope thermocouple/probe test flame failure device.

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

9. Gas. 12m Check and adjust pressure to main burner. Continued on next page .. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

109 06-01 ATMOSPHERIC GAS BURNERS - continued

ITEM FREQ. ACTION NOTES 10. Safety check 12m Ensure that no products of Flames should be bluish and burning in a stable combustion are entering the manner. area of the building where the The burner should be quiet in operation, no excessive boiler is situated. noise should occur when the burner ignitor shuts down.

NB - Undetected CO is life threatening (poisonous) and also causes energy waste. In domestic premises consider the installation of a BS approved CO detector. 11. Documentation. 12m Provide written report. The report should be signed by the servicing engineer and the client/responsible person/clients representative. Premature failure of the plant will result if a satisfactory service is not carried out, by a competent engineer. Depending on the nature/urgency of the fault and the type of premises this report may be verbal. 12. Unsafe installations. 12m Recommendations. If after servicing the appliance is considered unsafe the client should be advised that it must be taken out On-line Copyof use. If approval for this action is refused an appropriate label must be attached to the appliance and the HSE informed. A written report should also be signed by the client/responsible person/clients representative.

110 06-02 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. ITEM FREQ. ACTION NOTES 1. Operating status of burner. 12m Check whether plant operating For safety and operational reasons the status of the or not. plant should be checked. 2. Gas, electrical and 12m Check that all are in ventilating systems. accordance with current Codes of Practice. 3. Burner. 12m Switch on, carry out safety Note any visible defects. check of flame failure.

4. Combustion check. 12m Carry out and note any visual Pay particular attention to carbon monoxide (CO) defects. as presence is dangerous and life threatening and indicates waste energy. Arrange for record of test to be sent to the client. 5. Isolation from electricity and 12m Switch off, remove fuses and Before starting any dismantling of equipment it is gas supply. turn off gas supply at main essential for safety reasons that the plant be isolated cock. from incoming services. 6. Fan/mix chamber, gas train 12m Remove, thoroughly clean, with and controller assembly. a soft brush. Lubricate if On-linenecessary. Copy 7. Fan scroll. 12m Clean and check air passages. Ensure air passages are clear to pressure switch. 8. HT & probe details. 6m Inspect for soundness. If probe is bent or shows signs of oxidation it should be replaced. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

111 06-02 BLOWN GAS BURNER - continued

ITEM FREQ. ACTION NOTES 9. Burner. 12m Reassemble and fire, check air It is important that reference is made to the boiler and and gas settings, carry out burner manufacturer's specifications. combustion efficiency test.

10. Air pressure switch. 12m Test under no air conditions. 11. Flame failure. 12m Test and take probe readings. 12. General. 12m Check security of mechanical A maintenance check should be carried out on this parts and secure mounting of type of burner twice a year but refer to manufacturer's appliance. specification. 13. Recommendation. 12m Provide written report. The Premature failure and excessive fuel costs will result report should be signed by the if satisfactory service is not carried out. service engineer and the All service and maintenance must be carried out by a client/client registered engineer complying with Health and Safety representative/responsible requirements and possess accreditation in person. accordance with the Gas Safety Regulations. 14. Unsafe installations. 12m Recommendations If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use. If approval for this action is refused an appropriate On-line Copylabel must be attached to the appliance and the HSE informed. A written report should also be signed by the client/responsible person/clients representative.

112 06-03 FORCED DRAUGHT GAS BURNER

A fan assisted nozzle mix type with fully automatic operation creating an expanding flame. ITEM FREQ. ACTION NOTES 1. Operating status of burner. 6m Check whether plant operating For safety and operational reasons the status of the or not. plant should be checked. 2. Gas, electrical and 6m Check that all are in ventilating systems. accordance with current Codes of Practice. 3. Burner. 6m Switch on, carry out safety Note any visible defects. check of flame failure.

4. Combustion check. 6m Carry out and note any visual Pay particular attention to carbon monoxide (CO) defects. as presence is poisonous and life threatening and indicates waste energy. Arrange for record of test to be sent to the client. 5. Isolation from electricity and 6m Switch off, remove fuses and Before starting any dismantling of equipment it is gas supply. turn off gas supply at main essential for safety reasons that the plant be isolated cock. from incoming services.

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

lubricate if necessary. 7. Fan scroll. On-line6m Clean and check air passages. CopyEnsure air passages are clear to pressure switch. 8. Automatic gas valves. 6m Check for gas tightness. 9. Removal of UV cell and 6m Clean, adjust electrode and if UV cells should be replaced after a life of 10,000 head assembly. required isolate probe. hours. 10. HT & probe details. 6m Inspect for soundness. Consideration should be given to replacing HT lead every 12 months. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

113 06-03 FORCED DRAUGHT GAS BURNER - continued

ITEM FREQ. ACTION NOTES 11. Burner. 6m Reassemble and fire, check air It is important that reference is made to the boiler and and gas settings, carry out burner manufacturer's specifications. combustion efficiency test. 12. Air pressure switch. 6m Test under no air conditions. 13. Flame failure. 6m Test and take probe or UV cell readings. 14. General. 6m Check security of mechanical A maintenance check should be carried out on this parts and secure mounting of type of burner twice a year but refer to manufacturer's appliance. specification. 15. Recommendation. 6m Provide written report. The Premature failure and excessive fuel costs will result report should be signed by the if satisfactory service is not carried out. service engineer and the All service and maintenance must be carried out by a client/client registered engineer complying with Health and Safety representative/responsible requirements and possess accreditation in person. accordance with the Gas Safety Regulations. 16. Unsafe installations. 6m Recommendations If after servicing the appliance is considered unsafe the client should be advised that it must be taken out of use. If approval for this action is refused an appropriate On-line Copylabel must be attached to the appliance and the HSE informed. A written report should also be signed by the client/responsible person/clients representative.

114 06-04 FUEL OIL BURNERS USING 220/960 Sec OIL

There are four basic fuel systems, which can be subdivided into those used for distillate and those for residual oils. The use 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 ITEM FREQ. ACTION NOTES 1. Immersion heater/steam 12m Check condition and test action Examine condition of wiring and control temperature coils and thermostat. of thermostat. of thermostat. 2. Preheater tank. 12m Inspect for soundness. Drain These tanks should be insulated and should be water from drain valve at base checked for damage and if outside, attention should of tank. be paid to waterproofing and checking for the presence of corrosion of the tank under the damaged insulation. Drain water from tank frequently. 3. Trace heating. 12m Check thermostat setting, If electrical, check on current drawn and if different adjust if necessary. from norm, investigate and report to client. Check and record the transformer output voltage. 4. Insulation. 12m Examine and replace or repair as necessary. 5. Filters. 12m Clean and change if necessary. Sludge in heavy fuel oil can be a major fault in a On-line Copyburner 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. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 115 06-04 FUEL OIL BURNERS –USING 220/960 Sec OIL

ITEM FREQ. ACTION NOTES 6. Steam traps and drain 12m Check operation, repair or valves (steam heated adjust as necessary. systems). 7. General. 12m Report on condition. Include any recommendations for future action in the report.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 116 06-05 FORCED DRAUGHT [PRESSURE JET] OIL BURNER

A fan assisted nozzle oil air mix fully automatic. ITEM FREQ. ACTION NOTES 1. Operating status of 3m Check whether plant operating or not. For safety and operational reasons the status of burner. the plant should be checked. A combustion test may be necessary. 2. Oil, electrical and 3m Check that all are in accordance with ventilating systems. Codes of Practice. 3. Burner. 3m Switch on, carry out safety check of Note any visible defects. flame failure. 4. Safety Check. 3m Carry out and note any visual defects. Leakage of all products of combustion (CO, CO2 , SO2) should be sought. Pay particular attention to carbon monoxide (CO) as its presence can be dangerous and wastes energy. 5. Isolation from electricity 3m Switch off, remove fuses and turn off oil Before starting any dismantling of equipment it is and oil supply. supply. essential for safety reasons that the plant be isolated from incoming services. 6. Blast tube assembly. 3m Remove, clean combustion head, ignition electrodes and inspect HT leads. 7. Nozzle and filter. 3mOn-lineClean filter and inspect nozzle forCopy wear. Erosion or surface defects on the nozzle can Renew annually. affect the profile of the emerging jet of oil and lead to a poor flame shape and bad combustion. 8. Burner. 3m Reassemble and set head to manufacturer's requirements. 9. Motor and fan. 3m Remove, clean and lubricate as Inspect oil pump flexible drive coupling before re-

required, clean fan scroll. assembling. (See also MOTORS) Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 117 06-05 FORCED DRAUGHT [ PRESSURE JET] OIL BURNER - continued

ITEM FREQ. ACTION NOTES 10. Oil pump filter. 3m Remove and clean, inspect pump seals for signs of wear. 11. Reassembling burner. 3m Inspect flexible oil line coupling, clean and renew oil line filter, clean photo cell and adjust position. 12. Burner. 3m Switch on and check flame shape and appearance if visible. 13. Oil pressure. 3m Test, record oil pressure. 14. Combustion tests. 3m Carry out and check. On larger systems combustion tests should be carried out regularly to monitor performance and avoid energy waste. 15. Flame failure device. 3m Test for satisfactory operation. 16. General. 3m Check security of mechanical A maintenance check should be carried out on this parts and secure mounting of type of burner twice a year but refer to appliance. manufacturer's specification. All service and maintenance works must be carried out by a competent engineer in accordance with BS On-line Copy5410 Codes of Practice for oil firing. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 118 06-06 LIGHT OIL VAPORISING POT BURNER

A simple oil burner. ITEM FREQ. ACTION NOTES 1. Operating status of burner. 3m Check whether plant operating or For safety and operational reasons the status of not. the plant should be checked. A combustion test may be necessary. 2. Oil, electrical and ventilating 3m Check that all are in accordance with systems. Codes of Practice. 3. Burner. 3m Switch on, and note level of float Note any visible defects. chamber. 4. Safety Check. 3m Carry out and note any visual Leakage of all products of combustion (CO, defects. CO2 , SO2) should be sought. Pay particular attention to carbon monoxide (CO) as its presence can be poisonous and wastes energy. 5. Isolation from electricity and 3m Switch off, remove fuses and turn off Before starting any dismantling of equipment it oil supply. oil supply. is essential for safety reasons that the plant be isolated from incoming services. 6. Burner. 3m Remove, if possible clean and On-linetrim/replace the wick. Copy 7. Float chamber and filter (if 3m Clean filter and set float chamber fitted). level in accordance with manufacturers instructions. 8. Burner. 3m Assemble and switch on in order to check the flame shape. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 119 06-06 LIGHT OIL VAPORISING POT BURNER - continued

ITEM FREQ. ACTION NOTES 9. Combustion check. 3m Carry out. On larger systems combustion tests should be carried out regularly to monitor performance and avoid energy waste. 10. Recommendation. 3m Provide written report, which Premature failure will result if satisfactory service should be signed by the service is not carried out. engineer and kept by the client. All service and maintenance must be carried out by a registered engineer in accordance with HASAWA requirements and in accordance with BS Code of Practice for Oil Firing.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 120 06-07 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. ITEM FREQ. ACTION NOTES 1. Operating status of burner. 3m Check whether plant operating For safety and operational reasons the status of the or not. plant should be checked. 2. Oil, gas, electrical and 3m Check that all are in Check interlock switches - adjust if necessary. ventilating systems. accordance with Codes of Practice. 3. Ignitor. 3m Check. Gas 1. Joints. 12m Carry out leak test of all joints downstream of interlock isolator. 2. Main gas valve. 12m Check operation of leak test equipment. 3. Gas throughput. 12m If practical - check. If not practical, check gas manifold. 4. Vent pipework. 12m Check integrity. Oil On-line Copy 1. Burner. 3m Fire if possible, carry out safety Note any visible effects. check of flame failure device.

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

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 121 06-07 GAS/OIL BURNERS - Dual fuel - continued

ITEM FREQ. ACTION NOTES 3. Oil metering system. 12m Renew seals and gaskets if necessary. 4. Main shaft on burner. 12m 'Lift' bearings.

5. Atomisers and spray tip if 12m Check. fitted. 6. Drive belts. 12m Check. 7. Efficiency/Combustion 3m Carry out and note any visual Pay particular attention to carbon monoxide (CO) as checks on both fuels. defects. its presence can be poisonous and wastes energy. Electrical 1. Wiring. 6m Check panel, junction box and terminals. 2. Fuses. 6m Check rating. 3. Overload relays. 6m Check settings. General 1. 3m Check security of mechanical On-lineparts and secure mounting Copyof appliance. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

122

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

ITEM FREQ. ACTION NOTES 2. Report & Recommendations. 12m Should be signed by service Premature failure may result if satisfactory service is engineer and kept by the not carried out. client. All service and maintenance must be carried out by a registered engineer in accordance with current HASAWA requirements.

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

On-line Copy

123 07-01 BUILDING MANAGEMENT SYSTEMS - Introduction

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 On-line Copy 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 and 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. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 124

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. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 125 07-02 GLOSSARY OF BMS TERMS

Term Definition

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

analogue Pertaining to data or physical quantities that vary continuously.

archiving Long term storage of data in a retrievable form.

building automation systems Synonymous with BMS.

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

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

bus or data highway A cable connected to a number of different devices such as sensors, controllers and outstations that acts as a means of data exchange. There are two main types, serial and parallel. In building services it is most common to use serial types where data flow on just two cores of a cable. A communication link between the various components of BMS along which the digital data are transmitted. central processing unit (CPU) On-lineThe heart of the computer that Copyco-ordinates and controls the actions of all other units. central operation station Primary point of access to a BMS and the point from which all user operations are normally conducted. Synonymous with 'head end' and 'front end'.

compensator A control device whose control function is to reduce heat supply with decreased building load. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 126

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

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

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

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

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

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

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

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

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

DX On-lineDirect expansion (as in chiller). Copy

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

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

feedback control The transmission of a signal from a later to an earlier stage for the purposes of control. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 127 firmware Software permanently fixed in the memory which cannot be changed.

hardware Physical equipment as opposed to software.

HPHW High pressure hot water.

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

HVAC Heating, Ventilating and Air Conditioning.

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

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

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

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

local station Synonymous with outstation.

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

LPHW On-lineLow pressure hot water. Copy

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

modulator/demodulator (MODEM) A device that converts digital data to an analogue signal for transmission on telephone circuits. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 128

MPHW Medium pressure hot water.

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

node point of connection on a communication system.

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

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

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

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

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

programmable point A control or monitoring point for which the user may programme an associated control On-linefunction. Copy proportional band That range of values of deviation corresponding to the full operating range of output signal of the controlling unit resulting from proportional action only. The proportional band can be expressed as a percentage of the range of values of the controlled condition which the measuring unit of the controller is designed to measure.

proportional action The action of a control element whose output signal is proportional to the deviation from the set point. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 129 setpoint The desired value for the controlled condition or variable.

software Computer programmes, procedures, rules and associated documentation.

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

supervisor station Synonymous with central station.

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

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 130 07-03 BUILDING MANAGEMENT SYSTEMS - Central Operator Station

Care should be taken with regard to the system status, where necessary arrange co-ordination with building occupiers. ITEM FREQ. ACTION NOTES PC/Micro Based System 1. Cables and 12m Check security, integrity and connectors. for physical damage. 2. Diagnostic routine on 6m Perform diagnostic tasks and This routine will check all aspects of computer computer (where check computer operation. hardware and software. appropriate).

3. Disc drives. 12m Clean according to the manufacturer's instructions. 4. Tape drives. 12m Clean according to the manufacturer's instructions. 5. Tape cassettes (where 12m Clean according to the appropriate). manufacturer's instructions. 6. Clock battery. 12m Check and replace if Battery disposal should be in accordance with necessary. H&S and Environmental requirements. 7. Cooling fans. 6m Check condition, clean and On-linelubricate if necessary. Copy 8. Filters. 6m Inspect and clean or change as necessary. 9. Mouse. 12m Check for smooth operation Client may ask for more frequent maintenance of and clean ball as necessary. mouse.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 131 07-03 BUILDING MANAGEMENT SYSTEMS - Central Operator Station - continued

ITEM FREQ. ACTION NOTES 10. Software archives. 6m a)Take back up copy of site specific data files. b)Verify operating programmes 12m and functionality. Ensure that security is retained and that any updating of files is incorporated. 11. Visual Display Unit (VDU). 12m Check a)focus, b)contrast, c)brightness, d)for correct operation.

12. Monitor(s). 12m Check a)focus, With most VDUs the screen is automatically b)contrast, degaussed when equipment is switched on. c)brightness, d)for correct operation, e)degauss. 13. Keyboard. 12m Check for correct operation and clean. 14. Cleaning. 12m Clean with approved cleanser. Treat with anti-static compound. Depending on use and location more frequent cleaning may be On-line Copynecessary. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 132 07-03 BUILDING MANAGEMENT SYSTEMS - Central Operator Station - continued

ITEM FREQ. ACTION NOTES Printers 1. Cables and connectors. 12m Check security, integrity, and for physical damage. 2. Cleaning. 12m Use recommended cleaning Remove paper or tape debris. agent. 3. Test sequence. 12m Check, adjust and replace if necessary:- a)paper feed, b)transport system, c)printer ribbon. 4. Consumables (where applicable.) 12m Check stocks. Visual Display Unit -colourgraphic 1. Cables and connectors. 12m Check security, integrity, and for physical damage. 2. Cleaning. 12m Use recommended cleaning agent. 3. Colour alignments and 12m Check and correct as adjustments. On-linenecessary. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 133 07-04 BUILDING MANAGEMENT SYSTEMS - COMMUNICATIONS

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

ITEM FREQ. ACTION NOTES Data Communications 12m Check integrity of data flow in If more than one path exists all must be verified. both directions.

1. Central station units. 12m Check operation visually To include modems, line drivers, telemetry cables inspect. Check environmental and interface units. conditions of all equipment are within prescribed limits.

2. Central station/remote printer 12m Check operation and visually inspect.

3. Central station/out stations. 12m Check integrity of data flow in If more than one data path exists, all must be both directions. verified. Caution - There may be interaction with specialist applications. 4. Connectors. 12m Check security, integrity, and On-linefor damage. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 134 07-05 BUILDING MAINTENANCE SYSTEMS - OUTSTATIONS

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

ITEM FREQ. ACTION NOTES 1. Out station hardware. 12m Check mechanical and Note: environmental conditions e.g. temperature, environmental condition. humidity should be within manufacturer's recommended limits. 2. Connectors. 12m Check security, integrity and Includes security of incoming cables, prevention for damage. of ingress of moisture, door seals etc. 3. Power supplies. 12m Carry out voltage check on all Check automatic restart, re-booting of software power supplies. programme. 4. Stand-by batteries/ 12m Check against manufacturer's uninterrupted power supplies specification. (UPS). 5. Digital inputs. 12m Check by activating (where Note: Care should be taken to isolate local from fixed sensing/control operation. device) 6. Digital outputs. 12m Check operation of output Should include starting and stopping operations. stopping by operating routine Note: Does not apply to connected (where appropriate). Check devices. switching by software On-lineinterlocks. Copy

7. Analogue inputs. 12m Read and check calibration of analogue inputs. 8. Analogue outputs. 12m Check for accuracy of output signal. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 135 07-05 BUILDING MAINTENANCE SYSTEMS - OUTSTATIONS - continued

ITEM FREQ. ACTION NOTES 9. Manual override 12m Check status. Review and report to client. (physical). 10. Installed programme. 12m Check integrity, alarms, See section on SOFTWARE FUNCTIONS. interlocks, optimisation.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 136 07-06 BUILDING MANAGEMENT SYSTEMS - SOFTWARE FUNCTIONS

Different manufacturers have adopted different approaches to software development and the tables below show some typical functions and the action which should be taken. ITEM FREQ. ACTION NOTES 1. Control loops. 12m Check integrity of the Frequency should be agreed with client. installed programme, This action should be related to the critical nature of Check sequence and the operation. operation of control, outputs and, Check stability of plant.

2. Optimised start/stop. 12m Verify operation by Building layouts and occupational requirements are interrogating seldom of a static nature. Therefore control software/hardware copy. strategies and their suitability need to be reassessed on a regular basis. 3. Time clock 12m Check real time clock for accuracy throughout system. 4. Time switching. 12m Review current operating e.g. time settings and schedules. parameters according to client's needs. 5. Data logging. 12m Review existing logs. Report to client on the need to review existing arrangements. 6. Alarms - On-line 12m Check that plant alarms andCopyThe checking of possible reactions to certain critical faults, software interlocks with alarms and programmes must be carefully co- out of limit alarms. safety implications are ordinated with other trades and building tenants. operating correctly. Check Where there are safety implications, verify alarm alarm priorities, routings and integrity. Review system of reporting outstanding reactions. alarm conditions and report discrepancies. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

137 07-06 BUILDING MANAGEMENT SYSTEMS - SOFTWARE FUNCTIONS - continued

ITEM FREQ. ACTION NOTES 7. Alarm management 12m Review frequencies of Report as appropriate to client. and report. generated alarms. 8. Power failure and 12m Check plant start up sequence. restoration. 9. Generator loading 12m Check plant start up sequence. programme. 10. Maximum demand/load 12m Check sequence and operation. shedding. 11. Load cycling. 12m Check operation. 12. Software interlocks. 12m Verify operation. Check Plant rotation point, e.g. interfaces with other building services systems such as :- fire security access 13. Manual status review. 12m Check manual overrides and At client access level review parameters, effect on system, and effect on lockouts, changes, all points in manual override On-line system operation. Copyand forced analogue values. Review findings with client.

08-00 CATERING EQUIPMENT AND CANOPIES - SEEK SPECIALIST ADVICE

138 09-01 CHILLER / REFIGERATION EQUIPMENT - Introduction

Air conditioning equipment may come in discrete packages where a particular unit operation can be identified with a single piece 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, as European and UK legislation has been introduced controlling the use of CFC refrigerants for servicing and phasing out their use totally in servicing by the end of 2000. This action will ensure compliance with statute and avoid environmental damage. Refrigerants R11, R12 and R502 are typical of those in use, the latter two have acceptable drop in replacements available depending on application.

ALL REFIGERANTS MUST BE RECOVERED FOR RECYCLING OR DESTRUCTION.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 139 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. ITEM FREQ. ACTION NOTES 1. Status. 3m 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. 2. Refrigeration circuits 3m Check circuit pressures and superheat Refrigeration circuits should be alternated at least temperatures. Check alarm and run every three months by means of the 'lead/leg' lights and remote alarm lights selector switch. associated with packs. 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. 3. Refrigerant On-line3m Check for refrigerant and all leaks. Copy 4. Expansion valves 3m Adjust if necessary. Only by a competent technician. 5. Chilled water supply 3m Check supply and return water If closed system check for presence of water. temperatures. 6. Glycol 3m Check glycol concentration in chilled If concentration has fallen check pipework for water. leaks as per item 8. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 140 09-02 PACKAGED CHILLER UNITS - continued

ITEM FREQ. ACTION NOTES 7. Chiller water flow rate. 3m Check that this is in accordance with the manufacturer’s recommended figure. 8. Leakage 3m Check all pumps and pipework for Do not overlook remote condensers and leaks and rectify. pay particular attention to bolted joints, sight glass stands and atmospheric relief valve vent.

9. Refrigerant pipework. 3m Inspect and check for vibration, Vibration is usually the result of loose or chaffing security and leakage. inadequate fixing of pipe supports and can give rise to leakage of refrigerant. 10. Standby circuits. 3m Check operation. 11. Flood alarm. 3m Check operation. If serving computer facilities, check that alarm is not connected to computer shut-down system.

12. Digital readouts. 3m Check operation. 13. Controls. 3m Check operation of temperature Calibration } by control thermostats. Inspect electrical Interrogation } Control Specialist panel and components for wear Control adjustment } On-lineespecially the compressor Copy contactor(s). Check operation of safety thermostats and timers. 14. Hours run meter. 3m Check and record. 15. Insulation. 3m Check condition and make good any Poor or faulty insulation can lead to ice build up, defects. loss of efficiency and energy wastage. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

141 09-02 CHILLER UNITS - continued

ITEM FREQ. ACTION NOTES 16. Electrical. 12m Check for damage to flexible conduits. Include pump motors. (See also MOTORS) Tighten all terminal connections. Isolate control panel and inspect for signs of overheating. Check integrity of electrical insulation.

17. Safety cut-outs. 12m Check all safety cut-outs including Individual machines vary, cut outs could include high and low pressure safety cut-outs i. oil differential switches, and the antifreeze thermostat cut-out ii. oil, high and low temperature, for operation and correct calibration. iii. water temperature differential switches on chillers and evaporators.

18. Pump strainers. 12m Check condition. Check waterside pressure drop across the heat exchanger(s) for fouling.

WORK ON REFRIGERANT SYSTEMS MAY ONLY BE CARRIED OUT BY A TECHNICIAN WHO HOLDS A CERTIFICATE FOR THE SAFE On-line CopyHANDLING OF REFRIGERANT AND WHO WORKS FOR A COMPANY REGISTERED WITH REFCOM.

142 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 the DESIGN VACUUM CONDITION. These machines require daily recorded checks of machine performance which are compared with the previous readings. Changes must be noted. ITEM FREQ. ACTION NOTES 1. Specific gravity of solution. 1m Check as per instructions of Record and note changes in specific gravity for given manufacturer. conditions. 2. Non condensable 1m Determine as per Note leak rate and compare with manufacturer's accumulation rate. manufacturer's instructions. maximum rate. If higher, this indicates that machine has a leak and action must be taken to trace and rectify. 3. Dilution controls. 2m Check as per instructions of Reset if necessary. manufacturer. 4. Low temperature cut out. 2m Check as per instructions of Reset if necessary. manufacturer. 5. Evaporator water charge. 6m Check as per instructions of Record results and check with last reading. manufacturer. 6. Capacity control valve. 6m Check operation as per Record results. manufacturer's instructions. 7. Absorber and condenser. On-line12m Check for scale, action beCopyWhen chemical cleaning is carried out ensure that determined by findings. competent company and personnel are used. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 143 09-03 LITHIUM BROMIDE/WATER ABSORPTION CHILLERS - continued

ITEM FREQ. ACTION NOTES 8. Solution sample. 12m Take as per manufacturer's Record results and compare with last set of instructions. readings. Add amounts of chemicals as advised by chemist (i.e. inhibitor Record details of action, compare with last report octyl-alcohol etc.) and file. 9. i. Absorber loss, 12m Determine as per manufacturer's Recorded loss should not be greater than 3° F. ii. Decrystallisation, - instructions. Experience is vital Measure and record:- (as required) in determining the significance of i. refrigerant temperature, any loss. 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. 10. Diaphragms of service valves. 24m Replace as per manufacturer's Inspect diaphragms and record condition. specifications. 11. Solution and refrigerant 1m Inspect according to manufacturer's pumps. On-line Copyrecommended frequency. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 144 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.

ITEM FREQ. ACTION NOTES 1. General. 4m Check that unit is level and on good foundations 2. Condenser fins. 4m Visually check and clean when required the condenser fins. 3. Absorber. 4m Check absorber visually. 4. Condenser fan. 4m Check that condenser fan height is at Adjust according to instruction manual. design setting. 5. Water pan. 4m Check water level in water pan.

6. Chilled water flow rate. 4m Check and adjust chilled water flow Adjust according to instruction manual. rate (fountain height) see instruction manual. 7. Hydraulic pump. 4m Check and top up fluid if necessary 8. Drive Belt. On-line4m Check or replace if necessary. CopyFor further maintenance procedures see BELT DRIVES. 9. Solution pump. 4m Visual check solution pump. 10. Sealed system. 4m Purge pressure check high side and low side pressure. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 145 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) ITEM FREQ. ACTION NOTES 1. Evaporator coils. 6m Clean and check for any damage. Ensure unit thoroughly defrosted and coils are free of ice before putting back into service. 2. Sensor fittings. 6m Check fixing is secure and wiring Ensure wiring is clipped away from tray heaters, properly clipped. fan motors and blades. 3. Fans. 6m Check operation, mountings, guards Where excessive end float or bearing wear is and blades. Check bearings, lubricate found, report on need for replacement. if necessary. 4. Defrost heaters and 6m Check operation and condition. associated controls. 5. Pipework. 6m Inspect and thoroughly leak test. Corrosion and chafing can occur at duct entries and joints. 6. Drainage. 6m Check for cleanliness and the operation of pumps, probes and heaters where fitted. 7. Evaporators. 6m Check for correct operation. Correct operation is indicated by even frost formation on cooler face and/or on distribution On-line Copylines. 8. Interconnecting pipework 6m Check for vibration and test for leaks. (where visible). Check insulation for damage and replace/repair as necessary. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 146 10-01 COLD ROOMS - continued

ITEM FREQ. ACTION NOTES 9. Alarm system. 6m Check for correct action. Chafing can occur at duct entries and joints.

10. Electrical connections. 6m Isolate panel. Check all connections Ensure correct fuses are fitted and spares are and wiring. available.

11. Controls and switches 6m Carry out a visual check for wear and and indicator lamps. arcing. Check operation of relays, contactors and timers and defrost time switch for correct operation. Ensure indicator lamps are working correctly.

12. Plant rooms and housing. 6m Check ventilation not impaired. Leave clean and tidy.

13. Operating temperatures. 6m Check for correctness. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 147 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. ITEM FREQ. ACTION NOTES 1. Evaporators. 6m 2. Fans 6m Where excessive end float or bearing wear. Report on need for replacement. 3. Defrost heaters and 6m Check operation and condition. associated controls. 4. Electrical connections. 6m Check all connections and wiring. Chafing can occur at case entries and joints. 5. Pipework. 6m Inspect and thoroughly leak test. Corrosion and chafing can occur at case entries and joints. 6. Drainage. 6m Check for cleanliness and clean drain Additionally this will be carried out as part of the filter and reinsert. store's regular cleaning and hygiene schedule. 7. Casework. 6m Check lights, gaskets, door switches, Report wear or damage (especially to cabinet comfort and anti-sweat heaters, where door or lid gaskets). fitted. 8. Interconnecting pipework 6m Check for vibration and test for leaks. (where visible). Check insulation for damage and On-linereplace/repair as necessary. Copy 9. Case thermometer. 6m Check for correct reading with service thermometer. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 148 11-01 COMMUNICATIONS - PUBLIC ADDRESS SYSTEMS - general

ITEM FREQ. ACTION NOTES 1. Microphones. 3m Inspect and check all connection leads, plugs and sockets,

Operate speech key and check anode currents, Using signal generator measure output The actual test may vary with the type of voltages on preamplifier. equipment and the manufacturer's specific instructions should be followed. 2. Power amplifier. 3m Inspect and test using signal generator. 3. Fire alarm interface. 3m Check functioning of interface. 4. Electrical insulation. 12m Measure insulation resistance of installation cables. 5. Loud speakers. 12m 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. 6. Functional test. On-line12m Test system. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 149 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. ITEM FREQ. ACTION NOTES 1. Full load condition (Liaise with 6m Check and record suction and Where gauges are fitted the plant operator client). discharge pressure, oil pressure. should record the readings every month. 2. Start and run currents. 6m Check and compare with manufacturers recommended figures.

3. Operating status. 6m Check whether plant in use. If meter For operational and safety reasons the fitted record hours run. status of the plant should be checked. To isolate remove fuses and ensure other services are switched or valved off.

4. Leaks. 6m Check for oil and refrigerant leaks. Check for leaks should be part of the routine Any leak of refrigerant should be dealt servicing by plant attendants. with immediately. 5. Oil in crankcase. 6m Check level and condition. This should be carried out on a monthly On-line Copybasis by the plant attendant. 6. Crankcase heater. 6m Check operation. The control should be in the 'ON' position at all times. 7. Compressor drive. 6m Check condition and alignment. If undue noise or vibration report to client. Drive belt replacement intervals need to be established. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 150 12-01 COMPRESSORS REFRIGERATION - Reciprocal - (includes hermetic, semi-hermetic and open)- continued

ITEM FREQ. ACTION NOTES 8. Compressor and bearing 6m Observe and include crankcase, seal temperatures. housing and cylinder surface temperature.

9. Safety cut-outs. 6m Test and ensure correct operation. Include high pressure cutouts, low pressure cutouts and oil pressure cutouts. 10. Refrigerant charge. 6m Check quantity and moisture content at liquid level sight glass.

11. Noise and vibration. 6m Check for any abnormalities. Report to client if excessive.

12. Electric motor. 12m Lubricate according to manufacturer's (See also MOTORS) instructions. Check full load current. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 151 12-02 COMPRESSOR - SCREW

ITEM FREQ. ACTION NOTES 1. Non-return valve. 6m Dismantle and inspect.

2. Unloading gear. 6m Check that it is functioning correctly.

3. Oil de-mist pad (if 6m Inspect at intervals recommended by If necessary, take the appropriate corrective accessible). manufacturer. action.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

152 12-03 COMPRESSORS REFRIGERATION - CENTRIFUGAL - R 11/R 12 REFRIGERANTS OR THEIR SUBSTITUTES R123/134a.

Note:- more frequent maintenance checks should be carried out by the plant operators and local maintenance personnel. ITEM FREQ. ACTION NOTES 1. Operation. 3m Check running conditions, oil Note any unusual noises, check cooling tower pressure, purge unit operation, oil operation. level and oil return system. Look for signs of leakage. 2. Refrigerant charge. 3m

12m Check level and carry out leak test. Take sample for chemical analysis. 3. Holding down bolts. 3m Check compressor and motor holding down bolts and tighten if necessary. 4. Purge unit. 3m Check frequency of discharges. Count should be over a minimum of two cycles. 5. Controls. 3m Check oil pressure differential and These should be at the controller set point. chilled water temperature and flow rate. Check that condenser water flow rates and temperature levels are within acceptable limits. Examine log to check that there is no evidence of On-line Copyfouled tubes or air on the refrigerant side. 6. Purge unit filter driers (if 3m Change in accordance with fitted). manufacturer's instructions. 7. Compressor oil. 12m Take sample for analysis.

Continued on next page ..

153 12-03 COMPRESSORS REFRIGERATION - CENTRIFUGAL - R 11/R 12 REFRIGERANT OR THEIR SUBSTITUTES R123/134a - continued

ITEM FREQ. ACTION NOTES 8. Oil filter. 6m Change both filter and oil drier return system. 9. Purge unit valves, valves and 12m Clean and inspect. associated equipment. 10. Float assembly. 12m Remove and flush shell. Clean the Orifices are:- orifices. a) liquid supply to cooling coil,

b) gas pressure to pressure switch. 11. Oil return filter drier. 12m Change. 12. Foul gas supply filter. 12m Change. 13. Oil return eductor system. 12m Change the filter/drier, check eductor tee is undamaged, clean. Clean dirt leg. 14. Main oil filter. 12m Change. Inspect thoroughly for evidence of metallic particles. Their presence would indicate bearing damage. 15. Electrical and safety controls. 12m Check that they are working Pay particular attention to current On-linesatisfactorily. Copylimiting devices. 16. Condenser and evaporator. 12m Check water pressure drops. 17. Cooling tower. 12m Check settings of cooling tower fan See HEAT REJECTION. Check water controls. treatment and make up supply. Clean all water strainers.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 154 12-03 COMPRESSORS REFRIGERATION - CENTRIFUGAL - R 11/R 12 REFRIGERANT OR THEIR SUBSTITUTES R123/134a - continued

ITEM FREQ. ACTION NOTES 18. Motors - hermetic. 12m Carry out electrical insulation tests. Ensure that the liquid supply for cooling the motor is adequate. If appropriate remove filter and renew. (See also MOTORS) - open. 12m Check air impeller or water cooling coil is clean and efficient. Check motor and compressor alignment.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 155 13-01 CONDENSERS - water cooled (See also MOTORS)

ITEM FREQ. ACTION NOTES 1. Compressor full load 12m Record inlet and outlet temperature on Any marked difference to the design figures operation. water side. Pressure drop across could indicate internal fouling of the condenser condenser, head pressure and condensing and may require additional work. temperature.

2. Flow protection 12m Check. devices 3. Pump. 12m Check and record pressure drop across pump. Check for leakage, bearing noise and unusual bearing temperature. Lubricate according to manufacturers instructions. Check motor current.

4. Water strainers 12m 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 On-line Copyprecautions.

5. Condenser Tubes. 12m Check condition, if dirty open. If necessary If tubes are heavily scaled, refer to water clean with acid treatment. Inspect for treatment contractor for explanation as to why alkaline deposits and/or corrosion. system is not effective. Acid can be used for scale removal by specialist if absolutely necessary. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 156 13-01 CONDENSERS - water cooled - continued

ITEM FREQ. ACTION NOTES 6. Condenser Shell. 12m Check for presence of non- Presence of non-condensable gases will condensable gases, purge or vent if indicate a possible leak on the vacuum side of necessary. the refrigerant circuit. Take care not to release CFCs.

7. Isolating Valves. 12m Check external condition, leak tightness Repack as necessary. of glands and seats, operational spindles and handwheels.

8. Winter Shutdown. 12m Isolate condensers and drain down. Seek advice from water treatment specialist to protect from freezing.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 157 13-02 CONDENSER - air cooled

ITEM FREQ. ACTION NOTES 1. Operating pressure. 3m Check pressure and pressure switches using gauges. 2. Solenoid valves. 3m Ensure that they do not by-pass. Compressor should not cycle on low pressure switch. 3. Head pressure control 3m Check operation. These could be three phase. devices (fan speed and sequencing) 4. Motor Mountings. 12m Check for security and tightness. (See also MOTORS) 5. Condenser coil. 3m Inspect and clean. Check for damage to fins, comb out and chemically 12m Test for refrigerant leak and oil staining clean if necessary. Blow out with dry, oxygen free on the end of the coils. nitrogen. 6. Casing. 3m Clean and secure. Remove any rust spots and treat. Check fan guards. Ensure all bolts/screws etc. are in place and tight. 7. Sediment. 3m Remove, if substantial build up has Substantial build up may indicate significant corrosion occurred, investigate cause. and cause should be identified. 8. Alignment and wear of 3m Check pulley alignment and belt wear. Drive belt replacement intervals need to be belt drives, where established. applicable. 9. Head pressure control 6mOn-lineLubricate control damper bearings. Copy damper. 10. Air Filters. 6m Check and replace if necessary.

11. Flexible Connections. 12m Check and repair/replace as necessary. Report faults to client.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 158 13-02 CONDENSER - air cooled - continued

ITEM FREQ. ACTION NOTES 12. Electrical connections. 12m Check and tighten as necessary. Check condition of flexible conduits, wiring and insulation. 13. Pipework. 12m Inspect connections, pipes and Report faults to client. supports for damage, loose or missing fittings. Repair as necessary.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 159 14-01 CONTROL PANELS

Introduction

When working on or testing Control panels it is essential that all local and national statutory regulations should be observed at 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 should not be taken when working on equipment above 415 volts.

Care should be taken to make sure that all remote circuits associated with the switchgear are positively isolated before any work is carried out. The isolation should be 'secure' that is 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. A circuit, whether power or control should never be assumed to be 'dead'. Voltage tests should always be carried out with proven test equipment i.e. a voltage tester should 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 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:-On-line Copy

HSE Guidance Note GS 38/1995, Electrical test equipment for use by electricians. HS(R) 25 - Memorandum of Guidance on the Electricity at Work Regulations 1989. HSG85 Electricity at Work: Safe Working Practices 1993. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 160 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. ITEM FREQ. ACTION NOTES 1. Panel exterior. 6m Check for any physical or mechanical Any damaged equipment mounted on the front damage. Door locks should be checked. should be made safe and replaced as soon as possible. Locks should be checked for correct security and locking arrangements. 2. Mains isolator (also 6m Inspect for correct mechanical and Physically check for security all mains cubicle isolator). electrical operation. Lubricate any connections. Examine both fixed and moving moving parts as required. Check correct contacts for wear or "pitting". operation of door interlock mechanism Use only manufacturer's recommended and adjust if necessary. lubricants. Clean out interior. Redress or replace contacts according to the manufacturer's instructions. Ensure that any mains "shrouding" is refitted after the completion of the work.

3. Fuses. Ensure circuits 6m Inspect fuse carrier/fuse holder for signs Replace if necessary and establish cause of are dead before of overheating. Check fuse rating and overheating and rectify. carrying out actions. terminations for tightness. Apply grease to fuse holder if required. Value of fuse should be checked against the On-line Copycircuit application and electrical load. 4. Circuit breakers. 6m Inspect for signs of overheating and Establish cause of overheating and replace if necessary. Inspect rectify. connections and tighten if necessary. Check operation by tripping or "test" Ensure value of breaker corresponds with facility, if fitted. circuit application and electrical load. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 161 14-02 CONTROL PANELS - electrical services (excluding electrical controllers and pneumatic relays) - continued

ITEM FREQ. ACTION NOTES 5. Residual current 12m Test operation using test facility. devices. (RCDs) 12m Carry out electrical test procedures per IEE Regs.

6. Power contactors. 12m Check contact for correct mechanical and electrical operation. Strip and clean interior. Inspect and clean magnetic pole faces. Inspect shaded ring for damage and Damaged contacts should be redressed or fixed and moving contacts for wear or replaced as necessary. "pitting". Use approved contact lubricant if recommended by the manufacturer. (where fitted) Inspect coil for overheating or insulation Spring and contacts should be correctly breakdown. positioned and seated.

On-lineClean out arc shutes on re-assembly: Copy avoid damage or loosening of springs or contacts, ensure correct mechanical operation and check all electrical connections for tightness and security. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 162 14-02 CONTROL PANELS - electrical services - continued

ITEM FREQ. ACTION NOTES 7. Starters. 12m Carry out maintenance as for power contactors. - direct on line. - star delta - two speed-dual wound - two speed-pole change - reversing - auto transformer - quick transition, electric heater and electrolyte types 8. Thermal overloads. 12m Inspect for signs of overheating. Replace if necessary after having established the cause and rectified it. Check electrical connections for tightness and security. Inspect trip settings. Adjust if necessary to give correct protection for the connected load. Record settings. Operate the trip/test facility Check for single phasing protection by ensuring that the switchgear de- operating the starter with one of the power On-lineenergises in a clean and Copy positive fuses removed. operation.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 163 14-02 CONTROL PANELS - electrical services - continued

ITEM FREQ. ACTION NOTES 9. Magnetic overloads. 12m Inspect for signs of overheating. Check electrical connections for tightness and security. Check oil levels in dashpots and Completely replace dashpot oil at intervals replenish to correct levels if recommended by the manufacturer. needed. Check "time" mechanism. Select correct dashpot drain hole if necessary. Operate "test" facility ensure switchgear de-energises in a clean and positive operation. Inspect trip settings. Adjust if necessary to give correct protection for connected load. Check single phase protection. This is done by operating starter with one of the power fuses removed. 10. Busbar systems. 12m Isolate supplies, inspect for Check all cable crimps for security and fraying. signs of overheating, or damage Inspect crimp fasteners for correct torque rating. or burnt out cables. Inspect mechanical support On-linesystems and adjust fixingsCopy if necessary. 11. Incoming power supplies. 12m Measure each line to earth and Record readings and check that measured each line to neutral. values are within electricity supplier's specification. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 164 14-02 CONTROL PANELS - electrical services - continued

ITEM FREQ. ACTION NOTES 12. Panel wiring. 12m 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 panel is correctly Test continuity and record readings. bonded to earth. 13. Flash test. 36m Carry out within 1.5kV-3.0kV CAUTION - Care should be taken to isolate range to detect potential sensitive equipment. deterioration of the system. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 165 14-03 CONTROL PANELS - lamps, meters, alarms etc.

ITEM FREQ. ACTION NOTES Indicator lamps 1. Circuit. 6m Check and energise to ensure Replacement bulbs should be of the correct type that the indicator is and the voltage and power rating must be as per operational. Replace any the manufacturer's specification. A device of a blown or discoloured bulbs as higher power rating should not be used. required. 2. Holder assembly. 6m Inspect for signs of overheating or electrical burn marks. 3. Mains/low voltage 6m Examine for signs of transformer (if fitted). overheating or insulation breakdown. Low voltage power packs - ac or dc types. 1. Condition. 12m Inspect for signs of overheating. 2. Voltage input and output 12m Carry out and compare with Check polarity of outputs where necessary. tests. manufacturer's tolerance and On-lineoperational specifications. Copy

3. Load measurements. 12m Carry out, record and ensure that the load taken from the unit is within the manufacturer's specification. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 166 14-03 CONTROL PANELS - lamps, meters, alarms etc. - continued

ITEM FREQ. ACTION NOTES 4. Associated safety or trip 6m Check for correct operation. devices. Metering (Voltmeter) 1. Instrument. 6m Inspect and check for correct Check actual reading, record and compare with a mechanical and electrical reference voltmeter applied across the same operation. circuit. 2. Needle (pointer). 6m Check for free and correct movement. 3. Zero setting. 6m Check and adjust if necessary. Metering (Ammeter) 1. Instrument. 6m Inspect and check for correct Check actual reading, record and compare with a mechanical and electrical reference ammeter applied in series in same operation. circuit. 2. Needle (pointer). 6m Check for free and correct movement. 3. Zero setting. 6m Check and adjust if necessary. Continued on next page .. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 167 14-03 CONTROL PANELS - lamps, meters, alarms etc. - continued

ITEM FREQ. ACTION NOTES Alarm integrator 1. Operation. 12m Inspect and check operation of each input channel. 2. Audible and visual alarms. 12m Check operation and indications including alarm circuits if fitted. Smoke alarm unit 1. Unit 12m Inspect; check operation by adjusting or operating alarm test facility (if fitted). 2. Alarm setting. 12m Reduce setting and note operation of "smoke condition" 3. Maintenance. Carry out manufacturer's "testing and maintenance" procedures as required at stipulated frequencies. General 1. Cleaning. On-line12m The interior of the control Copy panel should be cleaned. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 168 14-03 CONTROL PANELS - lamps, meters, alarms etc. - continued

ITEM FREQ. ACTION NOTES Ventilation 1. Grilles. 3m Inspect and check that all grilles are free of any obstructions, clean as required. 2. Fans (forced 3m inspect and check operation of ventilation). fan unit; clean and replace filter unit as required. All power and control circuits should be checked for functional operation against the wiring diagrams relevant to the installation.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 169 14-04 OPTIMISER 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.

ITEM FREQ. ACTION NOTES 1. Outside air temperature 12m Check outside sensor for sensor. calibration and display accuracy. 2. Inside air temperature 12m Check inside sensor for calibration sensor. and display accuracy. 3. Programme setting. 12m Check programme setting is correct. 4. Optimum stop/start operation. 12m Check operation by simulation. Refer to manufacturer's simulation procedures. On-line CopyAny on going problems can be highlighted by the use of a thermograph. 5. Battery. 12m Check condition. Note 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. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 170 14-04 OPTIMISER - continued

ITEM FREQ. ACTION NOTES 6. Output devices. 12m Check that output devices respond to command signals. 7. Energy savings. 12m Agree any changes with system operator that may enhance energy savings.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 171 14-05 HEATING COMPENSATOR 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.

ITEM FREQ. ACTION NOTES 1. Flow temperature sensor. 12m Check. Refer to sensor checking procedure.

2. Outside air temperature 12m Check. Refer to sensor checking procedure. sensor. 3. Settings. 12m Check that settings are correct. 4. Output signal. 12m Check output signal and output On-linedevice operation. Copy 5. Controllers. 12m Check and calibrate for correct Refer to manufacturer's recommended relationship between outside simulation procedures. and flow temperatures. 6. System operation. 12m Check system under control for proper operation. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 172 14-06 SINGLE INPUT CONTROLLER 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.

ITEM FREQ. ACTION NOTES 1. Input signal. 12m Measure value. Check that signal is representative of the condition being monitored. 2. Settings. 12m Check for correct settings. 3. Output signal. 12m Check output signal and output device operation. 4. Controllers. 12m Check and calibrate. Refer to manufacturer's recommended On-line Copysimulation procedures. 5. Operation. 12m Check for correct operation. 6. Parameters. 12m Review as necessary. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 173 14-07 UNIT CONTROLLERS AND SENSOR CONTROLLERS 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.

ITEM FREQ. ACTION NOTES 1. Input signal. 12m Check. Refer to sensor checking procedure. 2. Settings. 12m Check for correct settings. 3. Output signal. 12m Check output signal and output device operation. 4. Operation. 12m Check operation and calibrate. Refer to manufacturer's recommended simulation procedures. 5. Parameters. On-line 12m Review as necessary. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 174 14-08 CONTROLLER TIMERS 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. Before commencing maintenance schedule carry out an operational check. ITEM FREQ. ACTION NOTES Electromechanical 1. Time settings. 12m Check time taken to complete operation against setting and adjust if required. 2. Operation. 12m Inspect and check operation. Adjust time to the required time setting for the On-line Copyparticular application and put into operation. Electronic 1. Time settings. 12m Check time taken to complete operation against setting and adjust if required. 2. Operation. 12m Inspect and check operation. Adjust time to the required time setting for the particular application and put into operation. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 175 14-08 CONTROLLER TIMERS - continued

ITEM FREQ. ACTION NOTES 3. Battery. 12m Check condition. Note life expectancy (use by date) and change at manufacturer's recommendation. All batteries should be disposed of in accordance with H&S Environmental REGULATIONS.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 176 14-09 STEP CONTROLLERS 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.

ITEM FREQ. ACTION NOTES Electromechanical 1. Operation. 12m Inspect and check both mechanical and electrical operation. 2. Cam setting/switch assembly. 12m Inspect and check each cam Adjust if necessary to suit the particular setting/switch assembly. application. 3. Angular limit switches. 12m Inspect and check. On-line CopyWhere actuators are involved see relevant 4. Drive motor/gear box. 12m Check operation in both directions. section. 5. Feedback potentiometer (if 12m Inspect and check. fitted). 6. Electrical interlocks. 12m Check any interlocks which Include recycling where appropriate. disable outputs. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 177 14-09 STEP CONTROLLERS – continued

ITEM FREQ. ACTION NOTES Electronic

1. Signal range. 12m Inspect and check each step throughout its signal range. 2. Step. 12m Check operation of each step and the differential.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 178 14-10 TIME SWITCHES 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. ITEM FREQ. ACTION NOTES Electromechanical 1. Clocks. 12m Check for satisfactory operation Adjust for British Summer Time/Greenwich Mean and correct time. Time as necessary. 2. Operation. 12m Inspect and check both mechanical and electrical operation. 3. Tappets. 12m Inspect and adjust to required On-lineon/off operations. Copy 4. Dial. 12m Rotate through one revolution Reset to correct day. and check for free operation of the levers at the correct time. 5. Monthly dial settings e.g. for 12m Inspect and check. Replace battery at manufacturer's solar time switches. recommendations. Batteries should be disposed of in accordance with H&S and Environmental regulations. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 179 14-10 TIME SWITCHES - continued

ITEM FREQ. ACTION NOTES 6. Reserve time facility (battery 12m Inspect and check. if fitted). Electronic 1. Time clocks. 12m Check for satisfactory operation Adjust time for British Summer Time/Greenwich and correct time. Mean Time as necessary.

2. Electrical operation. 12m Inspect and check.

3. Time settings in unit memory. 12m Check settings and adjust if Settings could be time of day, month or year. necessary. 4. Time switch settings. 12m Check for correct installation within the memory for particular application. Add, delete or adjust if necessary. 5. Battery back up (if fitted). 12m Check condition. Replace battery according to manufacturer's recommendations. All batteries should be disposed of in accordance with H&S On-line Copyand Environmental requlations. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 180 14-11 MULTI-INPUT CONTROLLERS 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 includes weather compensation, enthalpy comparison, cascade, low limit, etc. ITEM FREQ. ACTION NOTES 1. Input signals. 12m Check. 2. Settings. 12m Check for correct settings. 3. Output signals. 12m Check output signal and output device operation. 4. Operation. 12m Check and calibrate controller Refer to manufacturer's data sheet and for relationship between input recommended simulation procedures. On-lineand output signals. Copy 5. System. 12m Check system under control for correct operation.

6. Parameters. 12m Review as necessary. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 181 14-12 INDICATORS AND DISPLAYS

ITEM FREQ. ACTION NOTES 1. Input signals. 12m Check. 2. Switching differentials. 12m Check.

3. Calibration. 12m Check. Refer to manufacturer's data sheet and recommended simulation procedures.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 182 14-13 ALARM MODULES

ITEM FREQ. ACTION NOTES 1. Input signals 12m Check. 2. Switching differentials. 12m Check.

3. Calibration. 12m Check. Refer to manufacturer's data sheet and recommended simulation procedures.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 183 14-14 LEVEL CONTROLLERS 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.

ITEM FREQ. ACTION NOTES 1. Operation. (if test facility 12m Inspect and check. fitted) 2. Media level. 12m Adjust level under control and note operation of:- a)low level condition, b)high level condition, if fitted, c)calibrate as required. 3. Maintenance. On-line12m Carry out manufacturer's Copy maintenance procedures as required. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 184 14-15 SPEED CONTROLLERS 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. ITEM FREQ. ACTION NOTES Electromechanical 1. Overheating. 12m Check for signs of overheating. 2. Speed setting. 12m Adjust and note speed variation of the drive in the particular application. Auto-transformer 1. Transformer. 12m Inspect for signs of overheating and insulation breakdown. 2. Speed selector switch. On-line12m Operate and observe variationCopy in the speed of the drive in the particular application. 3. Air vents. 12m Check that they are clear. 4. Maintenance. 12m Carry out manufacturer's maintenance Frequency may vary according to procedures. manufacturer's recommendations. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 185 14-15 SPEED CONTROLLERS - continued

ITEM FREQ. ACTION NOTES Variable transformer 1. Transformer. 12m Inspect for signs of overheating and insulation breakdown.

2. Variable setting. 12m Adjust variable setting of transformer and observe variation in the speed of the drive in the particular application. 3. Air vents. 12m Check that they are clear. 4. Maintenance. 12m Carry out manufacturer's maintenance Frequency may vary according to procedures. manufacturer's recommendations. Eddy current type 1. Controller. 12m Inspect and check for signs of overheating and insulation breakdown. 2. Input signal. 12m Adjust and observe speed change in the drive under the particular application. 3. Settings. 12m Check for both minimum and maximum settings. On-lineAdjust as required. Copy 4. Maintenance. 12m Carry out maintenance procedures strictly in accordance with the manufacturer's instructions. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 186 14-15 SPEED CONTROLLERS - continued

Electronic inverter type. WARNING:- Due to the very high voltages present within this type of controller it is essential that all safety precautions 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. ITEM FREQ. ACTION NOTES Inverter type 1. Controller. 12m Inspect and check for any signs of overheating and breakdown of electronic components. 2. Signal. 12m Adjust in either manual or automatic mode and observe speed change of the drive in this particular application. 3. Settings. 12m Check for minimum and maximum speeds, adjust if necessary. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 187 14-16 TRANSDUCERS - pneumatic to electronic and electronic to pneumatic

ITEM FREQ. ACTION NOTES 1. Input signal. 12m Check. 2. Output signal. 12m Check output signal and output device operation. 3. Operation. 12m Check and calibrate for correct Refer to manufacturer's recommended relationship between input and simulation procedures. output signal.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

188

16-01 DUCTING - Introduction

Ducting and air distribution

When installed new ductwork should be clean and therefore not normally require internal cleaning. However during use over a number of years a slow build up of deposits could occur particularly at points where the velocity of the air reduces. Where filters are faulty, poorly installed or maintained more rapid build up of dirt will occur. In normal circumstances internal cleaning of ducts would not be part of this specification but where the situation calls for remedial action, say for example when previous maintenance was faulty or non existent, there has been a system usage change or the plant has been left idle for a considerable period, the client should be informed, with a recommendation that specialist cleaning should be undertaken as detailed in the HVCA Ventilation Hygiene Guide to Good Practice (see DUCTWORK CLEANING).

Special cleaning requirements such as are necessary in the pharmaceutical, food and process industries are outside the scope of this specification and should be covered by special arrangements.

In kitchen extracts systems where access doors have been specifically provided for duct cleaning purposes, the method and frequency of cleaning should be established and agreed with the client.

Sensors in ducts

When cleaning or working in ducts it is essential that all sensors or probes should be withdrawn from the duct to prevent any damage.

Care should be also taken to prevent any damage to valves, linkages and other control devices which may be located in a duct.

Where ducts are internally lined either for acoustic or insulation purposes inspection would normally only be carried out if access doors are provided. On-line Copy 189

16-02 DUCTWORK SYSTEM - general

Note:- Special requirements are necessary in the food and process industries, clean room applications and kitchens ITEM FREQ. ACTION NOTES 1. Access doors. 12m Inspect for any loose panels and secure. 2. Flexible connections. 12m Check for condition, leaks and secure Where provisions are made for access. fittings. 3. Insulation. 12m Inspect for any damage or Report to client if remedial work required. deterioration. 4. Anti-vibration mounts. 12m Inspect for permanent set (in springs). If renewal required, report to client. If replaced ensure that the correct type is used. 5. Internal cleanliness. 12m Check internal condition through sampling points (test points) where fitted. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 190 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. ITEM FREQ. ACTION NOTES 1. Volume control 6m Check position and ease of Ensure that damper opens and closes to desired dampers. movement and security of locking positions. devises. 2. Fire and smoke 6m Check action and proper operation. These may be subject to local fire requirements. dampers. Inspect all dampers, apply a few Maintain a log of all dampers tested, record drops of oil to the mechanism. faults and any remedial action taken. This will Replace fusible links if required. provide proof to the fire system inspectors that regular checks are maintained. If any fire dampers are inaccessible advise client. 3. Linkages on motorised 6m Check for wear and lubricate if Ensure that blades on shaft are secure and are dampers. appropriate. correctly aligned. 4. Controls. 6m Check condition and operation. Calibration } Interrogation } by CONTROL SPECIALIST Control Adjustment } 5. Electrical. 6m Check for damage to flexible For detailed maintenance information see CONTROL conduits. Tighten all terminal PANELS. On-lineconnections. Isolate control panel Copy and inspect for signs of overheating. Check integrity of electrical insulation. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 191 16-04 DUCTING - Acoustics

ITEM FREQ. ACTION NOTES 1. Attenuators 12m Inspect internally where access for The facings should be inspected to ensure that inspection is provided. Repair any loose fibre does not enter the system. surfaces of sound insulation where Report on further action needed. necessary.

2. Support fixings. 12m Check and ensure that all fixings are secure. 3. Attenuators (external 12m Clean, derust and repaint as required. For attenuators on COOLING TOWERS see surfaces). relevant section.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 192 17-01 DUCTWORK CLEANING – HYGIENE, INSPECTIONS & MONITORING

Note:- H&S Regulations apply and specific Risk Assessments will be required. ITEM FREQ. ACTION NOTES 1. Ductwork. 12m Ascertain age and date of last clean 2. Ductwork Hygiene. 12m Check internal condition by a Deposit See HVCA Cleanliness of Ventilation Systems – Thickness test or Vacuum Test. ref. TR/17.

If inspection indicates a full cleaning regime is required, inform client. 3. Kitchen Extract Ductwork. 12m Totally Clean. This is minimum cleaning interval, heavy use i.e. 12-16 hours per day will necessitate a 3 monthly clean.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 193 18-01 ELECTRICS IN BUILDINGS

Introduction

1 Specification

The specification covers the subjects of power supplies and associated electrical equipment up to 415 V, lighting, security and fire alarms, small scale power generation and communication systems and provides an authoritative maintenance specification for these types 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 toOn-line comply with the requirements of the currentCopy 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). Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 194 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 should be strictly followed.

5. Maintenance in Hazardous Areas

Certain areas such as those containing flame proof equipment, pharmaceutical laboratories, locations subject to possible contamination 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. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 195 19-01 EVAPORATORS

ITEM FREQ. ACTION NOTES Shell and tube 1. Tank/shell. 12m Check external and internal condition Liquid level for water cooling, brine or glycol including baffles and covers. systems should be noted and any leaks investigated. 2. Valves and drains. 12m Check external condition, leak tightness of glands and seats. Ensure valve caps are tight and secure. Check operation. 3. Pipes and connections. 12m Check external condition and leak tightness. 4. Bearers, supports, 12m Check for security and tighten as holding down bolts. necessary. 5. Insulation. 12m Check for damage. 6. Frost Protection. 12m Check regime including cables and thermostats. Coil direct expansion (DX) 1. Leaks. 6m Inspect for leaks. 2. Coil. On-line6m Check condition and clean fins. CopyUse a sterilising solution.

3. Condensate tray and 6m Check and ensure drain clear. Flush drain. and sterilise if necessary. 4. Condensate pump (if 6m Check operation. Often this equipment may be contaminated, clean applicable) and flush, sterilise if necessary. 5. Electric Heaters. 6m Check condition and operation. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 196 20-01 FANS - Introduction

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 should be electrically isolated in accordance with Health and Safety legislation.

Types of fan covered in this section include centrifugal, axial, propeller, mixed flow, bifurcated and fire and smoke extract units. Because 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. On-line Copy

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. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 197 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 machinery switch off and ensure that the equipment is isolated electrically in accordance with Health and Safety at Work legislation. ITEM FREQ. ACTION NOTES 1. Bearings. (`sealed for life' 6m Inspect and lubricate as necessary. Check bearings for end play and wear. bearings should not be serviced). 2. Housing. 6m Clean and inspect for looseness and corrosion. 3. Drives and belts. 6m Inspect, check condition and alignment of drive and shaft. Adjust or replace if condition warrants it. 4. Fan wheels. 6m Check and clean. Inspect for Check fan rotation. tightness. 5. Sheaves and bearing 6m Check tightness. collar. 6. Mounting bolts. 6m Check and tighten as necessary. 7. Anti-vibration mountings. 6m Check effectiveness.

8. Guide vanes. On-line6m Check operation and adjust Copy as necessary. 9. Automatic change over 6m Check operation of control switch. control (where standby fan installed). Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 198 20-03 FANS -CENTRIFUGAL

ITEM FREQ. ACTION NOTES 1. Impeller and spinnings. 12m 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. 2. Motor assembly. 12m Inspect. 3. Motor bearings. Lubricate with recommended lubricant When carrying out lubrication it is essential that (`Sealed for life' bearings at intervals noted on fan nameplate. every trace of water or dirt is removed from should not be serviced). around the grease nipple. (See also MOTORS) 4. Fan bearings. 6m Lubricate/grease as necessary. For continuous running more frequent servicing may be required. Do not overpack with grease. 5. Belt drive (if fitted). 6m Check tension and adjust if necessary. Ensure motor and drive and pulley are correctly Replace if aligned condition warrants aligned otherwise excessive wear will occur on it. the sides of the belt. 6. `Triggering' device, i.e. 6m Check for satisfactory functioning. Vane type flow switch can be activated by humidistat or vane type restricting airflow through the motor side inlet of flow switch. On-line Copythe unit. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 199 20-04 FANS- AXIAL - Fixed and/or variable pitch

ITEM FREQ. ACTION NOTES 1. Impeller. 3m 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. 2. Motor bearings. (`Sealed 3m Lubricate with recommended lubricant When carrying out lubrication it is essential that for life' bearings should at intervals noted on fan nameplate. every trace of water or dirt is removed from not be serviced). around the grease nipple. (See also MOTORS) 3. Belt drive (if fitted). 3m Check tension and adjust if necessary. Ensure motor and drive and pulley are correctly Replace if condition warrants it. aligned. 4. Flexible conduit 6m Check for soundness and ensure connections and wiring. terminal connections are secure. Check integrity of electrical insulation. 5. Belt guards (where fitted). 6m Check these are free from dirt build up, if necessary, clean. 6. Impeller, variable pitch 6m Check that there is no excessive There should be no loss of grease from wing mechanism. movement at the wing root. roots. If there is, impeller must be dismantled On-line Copyand seals replaced after lubricating bearings. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 200 20-04 FANS- AXIAL - Fixed and/or variable pitch - continued

ITEM FREQ. ACTION NOTES 7. Adjustable pitch 12m Check correct operation. The impeller should operate with smooth actuation. movement over the full pitch angle range with the fan running. If faulty, report to client for further action. 8. Non return flap (where 6m Check operation. fitted).

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 201 20-05 FANS – PROPELLER - Direct driven

ITEM FREQ. ACTION NOTES 1. Impeller. 6m Clean and ensure no build up of dirt. In very dusty environments or where contaminants are present more frequent cleaning may be necessary. 2. Motor bearings. (`sealed 6m Lubricate with recommended lubricant. If lubricators are provided, re-lubrication should for life' bearings should not exceed a period of two years. When carrying not be serviced). 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 60oC a shorter re-lubricating period will be necessary, see manufacturer's instructions. 3. Mountings and fittings. 6m Check security of fixing.

4. Flexible conduit 6m Check for soundness and ensure connections and wiring. terminal connections are secure. Check integrity of electrical insulation.

5. Non-return flap (where 6m Check operation. fitted). On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 202 20-06 FANS-MIXED FLOW - Direct or Belt driven

ITEM FREQ. ACTION NOTES 1. Impeller and spinnings. 6m 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. 2. Motor bearings. (‘sealed 6m Lubricate with recommended If lubricators are provided, re-lubrication should not for life' bearings should lubricant. exceed a period of two years. When carrying out re- not be serviced). lubrication it is essential that every trace of water and dirt is removed from around the grease nipple. If the operating temperature is over 60oC a shorter re-lubricating period will be necessary, see manufacturer's instructions. (See also MOTORS) 3. Drive belts. 6m Check tension and examine for wear. Replace if necessary. 4. Protection guards and 6m Clean and check shutter blades for In dirty or moist laden environment more frequent automatic shutters. ease of action. inspection and cleaning may be necessary. 5. Flexible conduit 6m Check for soundness and ensure connections and writing. terminal connections are secure. Check integrity of electrical On-lineinsulation. Copy 6. Roof cowl intake/wall 6m Clean and check mounting. entry louvre (where applicable). 7. Non return flap. 6m Check operation. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 203 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. ITEM FREQ. ACTION NOTES 1. Unit. 3m Check operation. 2. Fan impeller. 3m Check condition and clean. If handling abrasive or corrosive materials, examine the blades for wear or damage. In kitchen operations e.g. fat and oil frying, regular cleaning will be required. 3. Lubrication. (`Sealed for 3m Check and lubricate if necessary If working in a high temperature environment, life' bearings should not according to the manufacturer's more frequent lubrication may be necessary. be serviced). instructions.

4. Standby motor (where 3m Check and rotate a few turns by hand Units designed for emergency use should be test provided). or electrically. operated for no longer than twenty minutes. (See also MOTORS) 5. Flexible conduit 3m Check for soundness and ensure connections and wiring. terminal connections are secure. Check integrity of electrical insulation. 6. Belt drive (if fitted). On-line6m Check wear, alignment and tension. CopyReplace if cording becomes visible. 7. Automatic shutters 6m Clean and check operation. In moist or dirty environments more frequent (usually fitted on roof servicing may be required. units). 8. Anti vibration mountings. 12m Check condition.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 204 20-07 FANS-BIFURCATED - continued

ITEM FREQ. ACTION NOTES 9. Ductwork including fixings 12m Inspect external condition and report. With kitchen extracts heavy deposits of grease and insulation (where may be encountered and more frequent fitted). inspection will be necessary and client should be informed of fire risk and a schedule of cleaning drawn up. See DUCTWORK HYGIENE. 10. Motor. 12m Check full load current and log. 11. Bearings. 12m Check for wear. Remove oil/grease Report if replacement bearings necessary. and clean. 12. Micro switches on 12m Check operations, reset if necessary. automatic shutters.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 205 20-08 FANS-EXTRACT - including fire/smoke extracts units, water-cooled and kitchen exhaust.

ITEM FREQ. ACTION NOTES General 1. Controls. 6m Check correct action. For detailed maintenance refer to relevant section. 2. Motorised control 6m Check operation. Refer to design manual for details. dampers. 3. Electrical connections. 6m Check all flexible connections and electrical insulation. 4. Fan and motor. (`Sealed 6m Lubricate according to manufacturer's See also MOTORS for life' bearings should instructions. not be serviced). 5. Fan impeller and scroll. 6m Check condition.

6. Motor casing and louvers. 12m Check condition and clean.

7. Anti vibration mountings 6m Check mountings, belts and fixings for (where fitted). security. 8. Non return flap (where On-line6m Check operation. Copy fitted). Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 206 21-01 FILTERS

Introduction

Removal of dust and other non-gaseous matter in airborne streams is carried out by some form of filter or device such as 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 and dry dust collectors and filters associated with fume cupboards, radioactive and nuclear facilitiesOn-line and biological and clinical areas. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

207 21-02 FILTERS

1. Air flow. 12m Stop any air flow to filter.

2. Removal. 12m On removal take care that trapped dust remains in the filter medium.

3. Filter housing. 12m Thoroughly clean including surrounding ductwork and floor.

4. Housing. 12m Inspect for damage and/or corrosion. On-line Copy 5. Replacement. 12m Ensure that edges are adequately Spare fillers should not be unpacked until sealed to prevent ingress of dirty required. Replacement is required when air air. volume flow drops to 0.5” above initial settings.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

208 21-02 FILTERS - continued

ITEM FREQ. ACTION NOTES b) Filters (disposable) 1. Filter elements. 12m Remove and replace at Filters may have to be removed more frequently manufacturer's recommended depending upon site conditions and operating hours. final airflow pressure. Ensure After removal, used filters should be sealed into plastic that any spillage or dust is bags for disposal. vacuumed away. Do not attempt to wash or clean out and reuse. 2. Seals and/or fasteners. Ensure that any damaged seals or fasteners are replaced.

c) Reusable (cleanable) filters

1. Filter elements. 12m Clean and replace as per Filters may require more frequent cleaning where the manufacturer's atmosphere is heavily contaminated with dust or fume. recommendations. When cleaning care should be taken to avoid damage to the filters either mechanically or by the use of aggressive solvents. Usually hot soapy water or an approved cleaning liquid is adequate. 2. Kitchen extract grease 12m Remove and clean as per Frequency of cleaning can vary from daily to weekly filters. manufacturer's intervals. Generally for grease filter panels the use of a recommendations. commercial dishwasher is possible. Failure to On-line Copychange/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. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

209 21-02 FILTERS - continued

ITEM FREQ. ACTION NOTES d) Absorption type 1. Damage and corrosion. 6m Check and report if found.

2. Filter cartridge. 6m a) check fitting which should be tight. b) replace if necessary. Frequency of changing will depend upon the environment in which the filter is used. e) Automatic roll band type 1. Damage. 6m Check and report if found. If found to be high this may indicate either band velocity is too low or wrong specification. 2. Differential pressure. 6m Measure. 3. Operation. 6m Check for correct operation. f) Grease filters 1. Condition. 6m Check and clean. The frequency of cleaning will depend upon 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 On-line Copyfire to the main ductwork. See DUCTWORK HYGIENE. 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. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

210 21-03 ELECTROSTATIC FILTERS

Note: - In normal use air filters do not present a health and safety hazard. However used air filters do contain quantities of dust which, unless precautions are taken, may expose maintenance personnel to a `nuisance dust' hazard, as defined by the `Control of Substances Hazardous to Health (COSHH) Regulations'. A risk assessment must be carried out before the work starts and a method statement produced. PPE may be needed. Used filters should be sealed into plastic bags for disposal. Environmental REGULATIONS apply ITEM FREQ. ACTION NOTES 1. Electrical a) powerpack, 1m Check for correct operation. This should be a daily task for the operator. b) rectifiers, 1m Check for operation and follow Rectifiers fail either through filament burn out or loss of manufacturer's instructions. vacuum when the current will flow in both directions leading to shorting. c) isolation, 1m Isolate electrically in accordance with HASAWA recommendations. d) ionising wires. 1m Check condition and if Broken wires can cause a short circuit. broken replace immediately 2. Mechanical a) cells. 1m Wash according to manufacturer's Frequency of cleaning will depend upon the dirt picked up, instructions. every four to six weeks is suggested. If the cells are not cleaned regularly dust will eventually build up to a thickness On-line whereCopy some is dislodged and blown over.

211 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. ITEM FREQ. ACTION NOTES 1. Operation. 3m Check operation of all sounders This action should include auxiliary functions and external alarm links. such as links with the main gas valve, vent plant and all fault warnings. 2. Condition. 3m Check condition of equipment The building occupier should inform the i.e. ingress of moisture, damage maintenance engineer of any structural or or other signs of deterioration. occupancy changes which might affect the siting or operation of the detector.

3. Fireman's control for vent 3m Check operation and log plant. operation of fans and dampers. 4. Wiring and equipment. 12m Visually inspect for damage and integrity. 5. Detectors including photo 12m Check operation in accordance Inspect heat detectors for damage or other cells. with the manufacturer's condition, such as a heavy coat of paint. recommendations. 6. Emergency manual operated 3m Test operation. These devices should be tested frequently by systems. On-line Copyclients' operators. 7. Completion of test. 3m Reset all plant and gas valves after test. 8. System test. 36m Test in accordance with the BS 5839 should be followed. relevant regulations and rectify any defects. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

212 22-02 FIRE ALARMS - Associated Equipment

TESTING: The client should carry out tests on equipment on a weekly basis in accordance with the local fire regulations. Note: When carrying out maintenance any defects should be reported to the client. ITEM FREQ. ACTION NOTES Break glass boxes 1. Casing and glass front. 12m Check mounting of casing and replace if cracked. Check operation. Sounders 1. Decibel level. 12m Check (see notes). The time period for checking sounders should be agreed with the client. Refer to BS5839: Part1:1988. Sensors 1. Condition. 12m Check exterior and clean. Check and monitor according to manufacturer's instructions. WARNING: Ionisation detectors emit radiation, refer to manufacturers data. See SENSORS. 2. Connections. 12m Check condition and make good if necessary. 3. Beam detectors in ducts. 12m Check condition and clean. Frequency will depend upon environmental conditions and should be agreed with the client. 4. Mounting. On-line 12m Check security. Copy Batteries 1. Condition. 12m Check condition and life. Check according to the manufacturer's recommendations. All batteries should be disposed of in accordance with environmental and H&S requirements, . Chargers See POWER GENERATION. Continued on next page 213 22-02 FIRE ALARMS - Associated Equipment - continued

Note: When carrying out maintenance any defects should be reported to the client. ITEM FREQ. ACTION NOTES Shutters 1. Operation. 12m Check and ensure action responds to appropriate signals. 2. Indicator light. 12m Check operation and replace any faulty lamps. Drop fire curtains 1. Condition. 12m Check for mechanical damage. See relevant section – SMOKE EXTRACT. 2. Operation. 12m Check operation and control mechanisms. Magnetic door latches 1. Condition. 12m Check for mechanical damage. See relevant section – SMOKE EXTRACT. 2. Operation. 12m Check operation and control mechanisms. Smoke relief vents 1. Condition. 12m Check for mechanical damage. 2. Operation. On-line12m Check operation and Copycontrol See relevant section – SMOKE EXTRACT. mechanisms. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 214 22-02 FIRE ALARMS - Associated Equipment - continued

Note: When carrying out maintenance any defects should be reported to the client. ITEM FREQ. ACTION NOTES Interlocks 1. Condition. 12m Check for mechanical damage. Interlocks will be with heating, ventilating and cooling equipment and with fire extinguishing and other systems , i.e. SMOKE CURTAINS. 2. Operation. 12m Check operation and control mechanisms. Connection to Alarm Centre 1. Operation. 12m Check function. Inform Alarm Centre before check is made. Indicator panel Including remote indicator lamps. 12m Check operation of lamps and replace any failed lamps. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

215 23-01 FIRE PROTECTION SYSTEMS

Introduction

The need for preventive maintenance on fire prevention systems is essential but in negotiations between contractor and client is vital 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 (TB6 1990.1) published by LPC. On-line Copy 216

23-02 HOSE REELS PRESSURE BOOSTING SETS

If, due to unforeseen difficulties, an installation is left unavailable for use, the fire brigade should be informed and after reinstatement again informed. ITEM FREQ. ACTION NOTES 1. Pump base and 3m Ensure pump base is level and Check that anti-vibration mountings are satisfactory and connections. pipework not strained. vibration is not being transferred to the pipework. 2. Strainer elements. 3m Clean. 3. Pump and motor 3m Check and adjust if necessary. Examine couplings for tightness. alignment. 4. Motor and bearings. 3m Oil or grease where external nipples Use recommended grade of lubricant. Motor should be or lubricators are fitted. overhauled annually, see - MOTORS. 5. Drain holes, pipes 3m Clean and ensure that all blockages and tank. are cleared. 6. Guards and shields. 3m Check for security and safety. Adjust if necessary. 7. Automatic and hand 3m Open the highest hose reel nozzles Report any defects to client and fire brigade. override controls. on each rising main to ensure that This test should be carried out at least once per month set starts automatically. Check hand by the operator or caretaker. override controls. Rectify any faults. 8. Pumps and valves. 3mOn-lineCheck to ensure that all pumps CopyCheck against pump manufacturer's specification. reach their design closed valve pressure and all pump isolating valves are left in the open position. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 217 23-02 HOSE REELS PRESSURE BOOSTING SETS - continued

ITEM FREQ. ACTION NOTES 9. Hydraulic accumulator (if 3m Inspect and check gas Ensure diaphragms are sound. fitted). cushion pressure. 10. Test run pressure 3m Carry out adjustments to Check operation of all automatic controls and change- booster sets, ensure satisfactory operation. over switches, including signal to BMS if fitted. pressurising units, and filling pump. 11. Duty pump failed alarm. 3m Simulate duty pump failure. Reset after test, ensure that alarm is transmitted to authorised recipient.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 218 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 after reinstatement again informed. ITEM FREQ. ACTION NOTES 1. Condition. 12m Completely run out reel, inspect and subject to operational water pressure test. 2. Back flow prevention 12m Check operation. Ensure that valve is seating properly. devices (check valves). 3. Couplings. 12m Check and during wet testing check for leakage. 4. Swivel joints (swinging 12m Check swinging movement is hose reels). free, condition of 'O' rings. If leakage is evident replace 'O' rings. 5. Nozzles. 12m Check functioning. 6. Associated equipment 12m Ensure glands, tubing and and fittings. shut-off nozzle are sound and free from leaks. Check outlet of nozzle is unobstructed. 7. Flow test. On-line12m Test in accordance with the CopyIf it is not possible to test every reel, at least the highest requirements of the Loss reel on each rising main should be tested. Prevention Council. 8. Accessibility. 12m Check and report to client Hose reels and any associated equipment should be immediately if there are any accessible at all times. obstructions. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 219 23-04 RISING FIRE MAINS and HYDRANTS

ITEM FREQ. ACTION NOTES Dry 1. Inlet and landing 6m Check a) inlets, Special attention should be given to all valves, spindles, boxes. b) landing valves, glands, and washers to ensure that they are in satisfactory c) drain valves, condition so that all equipment is ready for immediate use. d) door hinges, and When defective valve assemblies are removed, they should e) locking arrangements. be immediately replaced either with the replacement valve, Report any defects. or plugged or blanked off so that the system remains operative. 2. Wet test. 12m Check for leaks. Wet 1. Inlet and landing 6m Check a) inlets, Special attention should be given to all valves, spindles, boxes. b) landing valves, glands, and washers to ensure that they are in satisfactory c) drain valves, condition so that all equipment is ready for immediate use. d) door hinges, and When defective valve assemblies are removed, they should e) locking arrangements. be immediately replaced either with the replacement valve, Report any defects. or plugged or blanked off so that the system remains operative. 2. Storage cistern and 6m Check cleanliness and tanks. condition. 3. Booster pumps. 6mOn-lineThoroughly check pumps and ForCopy more detailed instructions see PUMPS. associated mechanical and electrical equipment. Hydrants 12m Check for visible damage, or Report to client if remedial work necessary. 1. Condition. signs of corrosion. 2. Caps and valves. 12m Check for ease of movement. See notes above in respect of landing boxes. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 220 23-05 HALON FIRE PROTECTION SYSTEMS

HALON is a chlorofluorocarbon and as such is being phased out of general use and is being replaced by INERGEN because of’ the damaging effect HALON has on the upper atmosphere It is essential that leaks should 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 shall only be maintained and tested by qualified engineers as per the requirements of BS 5306: Part 5. ITEM FREQ. ACTION NOTES 1. System. 6m Check generally for mechanical damage. 2. Cylinders. 6m check labels are securely fixed and legible, check security of brackets and fixings, check liquid level, Level is checked by weighting, if weight loss exceeds 5% cylinder should be replaced or recharged. check pressure in cylinder(s). If pressure has fallen more than 10% on a temperature corrected basis, cylinder should be replaced or recharged. 3. Nozzles. 6m Examine for blockages and clean as necessary. 4. Valve actuators. 6m Where possible, remove cylinder Carry out procedure in accordance with the valve and replace action caps. manufacturer's recommendations. 5. Master/slave system. On-line6m Check slave actuation systemCopy including pistons in pneumatic valve actuators. 6. Mechanical integrity. 6m Test for mechanical tightness of This is to prevent leakage of HALON. pipework and associated equipment. 7. Auxiliary electric device/ 6m Test operation. Operational test to be carried out in accordance with alarm, door closures, etc. manufacturer's recommended procedure. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 221 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 shall only be maintained and tested by qualified engineers as per the requirements of BS 5306: Part 5. ITEM FREQ. ACTION NOTES 1. System. 6m Check generally for Report to client any defects or incorrect installation. mechanical damage. 2. Cylinders. 6m check labels are securely fixed and legible, check security of brackets and fixings, check liquid level, Level is checked by weighing, if weight loss exceeds 5%, cylinder(s) should be replaced or recharged. check pressure in cylinder(s). If pressure has fallen more than 10% on a temperature corrected basis, cylinder(s) should be replaced or recharged. 3. Nozzles. 6m Examine for blockages and clean as necessary. 4. Valve actuators. 6m Where possible, remove Carry out procedure in accordance with the cylinder valve and replace manufacturer's recommendations. action caps. 5. Master/slave system. 6m Check slave actuation On-linesystem including pistons inCopy pneumatic valve actuators. 6. Mechanical integrity. 6m Test for mechanical tightness of pipework and associated equipment. 7. Auxiliary electric device/ 6m Test operation. Operational test to be carried out in accordance with alarm, door closures, etc. manufacturer's recommended procedure. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 222 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. ITEM FREQ. ACTION NOTES 1. Alarms. 3m Test all electrical detection and alarm systems in accordance with BS 5839. 2. Foam producing 6m Inspect: equipment. for mechanical damage, for corrosion, for blockage of air inlets, clear as necessary, correct manual function of all valves, strainer and gauzes, This may require temporary isolation of the water main. proportioning devices. 3. Control valves. 6m Check for corrected manual and automatic operation. 4. Pipework. 6m Examine exposed pipework If visual indication of normally dry pipework indicates to determine condition. questionable strength due to corrosion or mechanical damage, hydraulically pressure test. 5. Tanks for foam 6m Visually inspect without Check any concentrate shipping containers for evidence concentrate and solution. On-linedraining. Copyof deterioration. 6. Concentrate. 12m Check condition. Correct any deterioration according to the manufacturer's recommendations. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 223 23-08 FIRE EXTINGUISHERS - HALON

Note: As this type of equipment is pressurised it can be opened for inspection only after discharge. This should be carried out after 10 years if the following annual maintenance has been carried out. Because of environmental concerns Halon extinguishers are being phased out and replaced with Inergen. ITEM FREQ. ACTION NOTES 1. Pressure indicating 12m Check operation and pressure. If device inoperative or pressure is below device. If pressure loss more than 10% specified lower limit refer to manufacturer's recharge ensuring no vapour loss to instructions. atmosphere. If no device fitted use connection, if provided, to verify pressure. 2. Extinguisher body. 12m Examine for corrosion or damage. If replacement indicated report to client. 3. Contents. 12m Weigh and check against records. Report any loss. 4. Nozzle and hose. 12m examine and clean as necessary. check hose for wear or damage and replace if necessary. 5. Operating mechanism (if 12m Check operating mechanism and detachable). discharge control (where fitted) for free movement. Clean, rectify or On-linereplace as necessary. Copy 6. Safety clip. 12m Replace after maintenance activity or renew wire seal as appropriate. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 224 23-09 FIRE EXTINGUISHERS - CARBON DIOXIDE

Note: For extinguishing kitchen cooking oil fires, Wet Chemical fire extinguishers (Class F) should be in position. ITEM FREQ. ACTION NOTES 1. Extinguisher body. 12m Examine for corrosion or If replacement indicated report to client. damage.

2. Contents. 12m Weigh and check against records. If loss greater than 10% recharge.

3. Horn, hose and valve 12m Examine, clean and replace if assembly. not in good condition.

4. Operating mechanism (if 12m Check operating mechanism detachable). and discharge control (where fitted) for free movement. Clean, rectify or replace as On-linenecessary. Copy 5. Safety clip. 12m Replace after maintenance activity or renew wire seal as appropriate. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 225 23-10 FIRE EXTINGUISHERS - FOAM (stored pressure)

ITEM FREQ. ACTION NOTES 1. Pressure indicating 12m Check operation and If device inoperative or pressure is below specified lower device. pressure. limit refer to manufacturer's instructions. If no device fitted use connection, if provided, to verify pressure. 2. Extinguisher body. 12m Examine for corrosion or If replacement indicated report to client. damage. 3. Contents. 12m Weigh and check against Report any loss. records. 4. Nozzle and hose. 12m Examine and clean as necessary, Check hose for wear or damage and replace if necessary. 5. Operating mechanism (if 12m Check operating mechanism detachable). and discharge control (where fitted) for free movement. Clean, rectify or replace as necessary. 6. Safety clip. 12m Replace after maintenance On-lineactivity or renew wire seal asCopy appropriate. 7. Internal inspection. 48m Discharge contents, Examine for corrosion, Refill if condition satisfactory. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 226 23-11 FIRE EXTINGUISHERS - POWDER

ITEM FREQ. ACTION NOTES 1. Contents. 12m Weigh the extinguisher and if more than 10% loss of powder, recharge. 2. Condition of powder. 12m Open container and examine If powder appears satisfactory, agitate by inverting and powder, if any evidence of shaking. lumps, caking or foreign bodies, recharge. 3. Body. 12m Examine internally and externally for damage. 4. Gas cartridge. 12m Examine for corrosion and Weight of contents is marked on cartridge, replace if damage. Check weight. there is any loss of weight. Cartridges over 10 years old must be replaced.

5. Vent holes. 12m Examine and clean. 6. Nozzle, hose and internal 12m Examine for any blockage, discharge tube. clean rectify or replace as necessary. 7. Operating mechanism 12m Check for free movement, and discharge control. clean rectify or replace as On-linenecessary. Copy 8. Washers and 12m Examine and replace if diaphragms. necessary. 9. Safety clip. 12m Replace after maintenance activity or renew wire seal as appropriate. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 227 23-12 FIRE EXTINGUISHERS - WATER – GAS CARTRIDGE

Note: If any soda acid extinguishers are found client should be informed that these must be withdrawn from service. ITEM FREQ. ACTION NOTES 1. Body. 12m Empty, examine for damage and corrosion externally and internally. 2. Contents. 12m Check water level after refilling. 3. Gas cartridge. 12m Examine externally for corrosion and weigh and check against that marked on the cartridge. 4. Vent holes. 12m Examine and clean if necessary. 5. Nozzle and strainer and 12m Examine and clean if necessary. (if fitted) internal discharge tube and breather valve. 6. Operating mechanism 12m Check movement, clean, rectify faults or and discharge valve. replace. 7. Sealing washers and 12m Examine and replace if not in good hose. condition. 8. Recharge. 12m Fill to correct level. Note any special needs e.g. anti-freeze or On-line Copycorrosion inhibitor. 9. Safety clip. 12m Replace after maintenance activity or renew wire seal as appropriate. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 228 23-13 FIRE EXTINGUISHERS - WATER STORED PRESSURE

ITEM FREQ. ACTION NOTES 1. Body. 12m Examine externally for corrosion and damage. 2. Contents. 12m Weigh and check against original weight when put into service. 3. Pressure indicator on 12m Check operation, if less than Where device not fitted, check by means of connector stored pressure specified refer to manufacturer's provided. equipment. instructions. 4. Contents. 12m Weigh and check against Report any loss. records. 5. Nozzle and hose. 12m Examine and clean as necessary, Check hose for wear or damage and replace if necessary. 6. Operating mechanism (if 12m Check operating mechanism detachable). and discharge control (where fitted) for free movement. Clean, rectify or replace as On-linenecessary. Copy 7. Safety clip. 12m Replace after maintenance activity or renew wire seal as appropriate. 8. Internal inspection. 48m Discharge contents, Examine for corrosion, Refill if condition satisfactory. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

229 24-01 FLUES (all combustible fuels)

These notes should be read in conjunction with relevant sections BOILERS GAS, OIL SOLID FUEL – burning appliances. Ensure that flues conform to relevant guidance and BS/EN and boiler manufacturers recommendation. External dampers/economisers can infringe manufacturers guarantees and also HASAWA. ITEM FREQ. ACTION NOTES 1. Drain plugs at the 1m Remove, allow any accumulated This should be part of the routine maintenance base of the flue. condensate to drain away and replace. carried out by in-house staff. 2. Supports. 12m Inspect security of supports and condition of Particular attention should be paid to the paintwork. Treat any signs of rust or condition of the base of the supports. corrosion. 3. Flue terminals. 12m Where possible, check flue terminals at roof Flue terminals should be undamaged and free level. from any obstruction. 4. Boiler flue and 12m Clean thoroughly with custom made flue Use access doors provided and reseal after vertical chimneys. brushes and tools. operation. Remove all soot, fly ash and scale. N.B. when burning wood, coal, heavy oil and volatile waste more frequent cleaning will be necessary, and two monthly checks are advised. On completion of overhaul check draught pressure. If the combustion air source is likely to be subject to contamination from chemicals or chemical processes frequent checks should be made for corrosion of the boiler flueway On-line Copycomponents and the chimney construction.

5. Balanced flue 12m Check for obstruction, corrosion and if fan Obstruction of the flueways can be caused by terminals. assisted check safety circuit. leaves and any other airborne debris.

6. Induced draught/fan 12m Check for obstruction and condition of assisted. bearings. Continued on next page .. 230 24-01 FLUES (all fuels) - continued

ITEM FREQ. ACTION NOTES 7. Fan dilution units 12m Check pressure/vane switch action for correct operation. Check pressure/boiler interlock for If not shut down burner. correction operation. 8. Dampers. 12m Check action and control switches interlocks. 9. Condensing boilers. 12m Check for obstruction and corrosion. If fan assisted check safety circuit. 10. Stabilisers (explosion 12m Check condition and ensure doors). movement is free. 11. Structural stability. 12m Check condition and if free standing After periods of severe weather examine the examine condition of guy ropes. chimney structure and supports for damage.

12. Smoke test. 12m Check for flue pull and deterioration. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 231 25-01 FOUNTAINS - ORNAMENTAL

Notes: Latest ACOP L8, 2001 - Precautions in respect of Legionellosis and legionnaires' disease apply. ITEM FREQ. ACTION NOTES 1. Spray heads and jets. 12m Clean and check spray Frequency will depend upon location and use and pattern. should be agreed with client. 2. Pumps. 12m Check for gland leakage and More detailed information on the maintenance see satisfactory operation. relevant section of PUMPS. 3. Filters. 12m Check condition and clean as Frequency will depend upon location and use and necessary. should be agreed with client. 4. Containment area, e.g. 12m Check for cracks and signs of Failure of the waterproof lining or membrane is the most tanking. leakage. Report to client if likely source of leakage. Frost damage to concrete is remedial work is required. another cause. 5. Water treatment plant. 12m See – WATER TREATMENT. Presence of fish will required special consideration. Note: does not apply when fish present. 6. Automatic water make- up, a) float operated (ball 12m See STORAGETANKS – valve), WATER b) solenoid operated. On-line12m See - VALVES. Copy 7. Underwater lighting. 12m See - LIGHTING. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 232 26-01 GRILLES AND DIFFUSERS

ITEM FREQ. ACTION NOTES 1. Grilles. a) external 6m Examine, check mountings Leaves can be particular nuisance and one examination and clean. should be in late Autumn. b) internal 12m Examine, check fitting and If removed care should be taken not to disturb valve and clean. other equipment settings behind the grille. 2. Diffusers. 12m Examine, check fitting and If removed care should be taken not to disturb valve and clean. other equipment settings behind the diffuser.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 233 26-02 LOUVRES, BIRD AND INSECT SCREENS

ITEM FREQ. ACTION NOTES 1. Louvres. 6m Clean and remove any debris, check for damage. 2. Bird screens. 6m Clean and check for any damage. Replace if holed. 3. Insect screens. 6m Clean and check for any When cleaning care should be taken to avoid damage to damage. Replace if holed. the fine mesh. A low pressure water jet from behind should clear insect remains.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 234 27-01 ELECTRICS IN HAZARDOUS AREAS

Introduction

It is essential that any maintenance work in hazardous areas is only carried out by specialist personnel. Extreme care should be 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 5345 Pt 2 is the latest publication dealing with the classification of hazardous areas whilst CP 1003 Part I which covers choice, installation and maintenance of flameproof and intrinsically safe equipment is being slowly withdrawn although it is still in use.

During maintenance in such areas the following points should be noted:- a) all flameproof lighting fittings should be examined for incipient cracks, b) when equipment is returned to service the gap for a particular joint should not exceed that specified by the manufacturers, c) damage to machined flanges must be avoided, d) joints should be wiped clean and non-setting grease or BASEEFA/HSE(M) approved compound as appropriate applied. Excess grease is not a substitute for containing the flamepath gap. e) Cover bolts are in accordance with the standard requirements of specific minimum strength and should not be replaced by screws other than thoseOn-line obtained from the manufacturer for Copythat specific purpose. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 235 27-02 Hazardous areas - FLAME PROOF EQUIPMENT The results of inspections, checks and tests should be recorded and compared with previous entries, any significant changes should be investigated and specifically reported upon to the client. ITEM FREQ. ACTION NOTES 1. Condition. 6m Check for mechanical damage Where bolts or other types of fastenings are or signs of corrosion. used check that numbers are correct and that they are secure. 2. Electrical connections. 6m Check integrity. 3. Mechanical faces. 6m Check for damage. Report to client if damage to faces requires replacement of equipment. 4. Seals. 6m Check condition and replace as necessary. Continued on next page ..

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 236 27-02 Hazardous areas - FLAME PROOF EQUIPMENT - continued

ITEM FREQ. ACTION NOTES 5. Cable and conduit entries. 6m Check condition of seals.

6. RCDs (if fitted). 3m Test the tripping operation. Responsibility for this check should be agreed with the client. 12m Test with approved RCD tester Operation should be within 200 milliseconds at rated current output or within 40 milliseconds at 5 times rated output. 7. Earth fault loop impedance. 6m Check. This applies to every socket outlet, lighting switch and luminaire. 8. Labels and notices. 6m Check for presence, clean and check security of fixing. 9. Return to service. 6m Ensure that any seals are correctly in place and the correct number and type of cover bolts are used. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 237 27-03 Hazardous areas - LIGHTING

ITEM FREQ. ACTION NOTES 1. Integrity. 6m Check installation for mechanical damage. 2. Fitting and cover. 6m Clean and check condition. Where the glass is cracked or broken no attempt Examine for incipient cracks in should be made to re-cement a new glass in glass or retaining cement. place. A replacement unit should be obtained from the original manufacturer. 3. Lamp. 6m Replace on a planned basis as Maintenance contract should be specific with appropriate. regard to the responsibility for the provision and replacement of lamps, and also for the disposal of spent lamps as per statutory regulations. 4. Cable and conduit entries. 6m Check condition of sealing rings Note: any cable gland, stopping gland or plug, etc. reducer or adapter must be BASEEFA approved for use with the apparatus. 5. Return to service. 6m Ensure that any seals are correctly in place and the correct number and type of On-linecover bolts are used. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 238 27-04 Hazardous areas - EARTHING

ITEM FREQ. ACTION NOTES 1. Terminations. 6m Check for continuity and bonding. See also POWER SUPPLIES - Earthing.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 239 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 and 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. ITEM FREQ. ACTION NOTES Fan Convectors 1. Casing. 12m Examine condition of casing, access Check parts are securely fastened and free from `rattles'. panels and grilles. 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. 2. Controls. 6m Check all thermostats and other If heater battery is fitted with a low temperature cut out controls operate satisfactorily and (LTC) and hot water is not available, it may be necessary are set in accordance with to insert a temporary link in the electrical control circuit to specification. operate the unit. 3. Filters. 3m When fitted remove, examine and Check if filter is cleanable or throwaway type. The check for damage. Clean or frequency of cleaning depends upon the dirtiness of the replace. air. Normally cleaning should be every two months but more frequent cleaning may be necessary. 4. Heat exchanger. 3m Inspect and clean. Purge air from Clean using an industrial vacuum cleaner. Draw air hot water units. through the heat exchanger in the opposite direction to the On-line normalCopy 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. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 240 28-01 HEAT EMITTERS - continued

ITEM FREQ. ACTION NOTES 5. Motor/fan assembly. 6m Remove from heater casing if Check fans are secure, motors operate silently and practical. Inspect and lubricate that bearings are in good order. fan bearings and resilient mounts where applicable. Clean fans and motor. Examine wiring and connectors.

6. Pipework, valves, steam 12m Examine for corrosion or leaks. Check operation of steam traps. traps and associated Where applicable clean steam equipment. traps, strainers, non return valves and scale pockets.

7. General. 12m Leave unit in good working order. Report on any further work considered necessary. Unit Heaters 1. Casing. 12m Examine condition of casing, Where applicable, check condition of any flexible discharge louvres and inlet ducting connections. Check security of mounting guards. brackets or drop rods. Check that any discharge louvres are correctly set to give the desired air spread pattern. 2. Controls. On-line6m Check all thermostats and Copyother If heater battery is fitted with a low temperature cut controls operate satisfactorily and out (LTC) and hot water is not available, it may be are set in accordance with the necessary to insert a temporary link in the specification. electrical control circuit to operate the unit. Where applicable, check starter overloads are set to suit full load current. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 241 28-01 HEAT EMITTERS - continued

ITEM FREQ. ACTION NOTES 3. Heat exchanger. 3m Inspect and clean. Purge air from Clean using an industrial vacuum cleaner. Draw hot water units. 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.

4. Filters. 3m When fitted remove, examine and Check if filter is cleanable or throwaway type. The check for damage. Clean or frequency of cleaning depends upon the dirtiness replace. of the air. Normally cleaning should be every two months but more frequent cleaning may be necessary.

5. Motor/fan assembly. 6m Lubricate bearings where Check security of fans and condition of resilient applicable. mounts.

7. General. On-line12m Leave unit in good working order.CopyReport on any further work considered necessary.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 242 28-01 HEAT EMITTERS - continued

ITEM FREQ. ACTION NOTES Natural Convectors and Perimeter (Skirting) Heating 1. Casing. 12m Examine condition of casing, Check parts are securely fastened and free from access panels and grilles. Where `rattles'. Check condition of access panels. Clean applicable, check condition of inside of casing. If unit has loose grilles, check seal damper seal. between unit and grilles to ensure no air leakage or short circuiting occurs.

2. Heat exchanger. 3m Inspect and clean. Purge air from Clean using an industrial vacuum cleaner. Draw air hot water units. Where applicable, through the heat exchanger in the opposite direction examine condition of expansion to the normal air flow. In exceptional cases a high joints, guides and anchors. pressure hose may be required. In a dirty environment more frequent cleaning will be needed, e.g. quarterly, six weekly or even monthly.

3. Pipework, valves, steam 12m Examine for corrosion or leaks. Check operation of steam traps. Check operation of traps and associated Where applicable clean steam thermostatic radiator valves (TRVs). equipment. traps, strainers, non return valves and scale pockets.

4. Controls. 12mOn-lineWhen fitted examine condition Copyof When fitted, check damper operates smoothly. damper seals.

5. General. 12m Leave unit in good working order. Report on any further work considered necessary.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 243 28-01 HEAT EMITTERS - continued

ITEM FREQ. ACTION NOTES Radiant Strip 1. Panels and insulation. 12m Examine condition of panels and Clean panels and insulation, check that insulation insulation. is fitted and secured. 2. Pipework, valves, steam 12m Examine for corrosion or leaks. Check operation of steam traps. traps and associated Where applicable clean steam equipment. traps, strainers, non return valves and scale pockets. Examine condition of expansion joints. 3. Suspension. 12m Check condition and security of drop rods, hangers and related equipment. 4. General. 12m Leave unit in good working order. Report on any further work considered necessary. Heat Emitters - Safety ALL ITEMS 12m 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 On-line Copy‘OFF’ position. Always refer to the manufacturer's instructions/recommendations before undertaking any cleaning or maintenance. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

244 28-02 GAS FIRED CERAMIC PLAQUE INFRA RED HEATERS

These heaters are usually placed high up in a building and consequently are not easily accessible. A risk assessment and method statement should be carried out. Access by stepladders is not recommended. Regular maintenance is essential and whilst annual maintenance may be adequate in a clean environment, dusty conditions will require more frequent maintenance. In very dusty environments, e.g. textile factories, it may be more desirable to duct a direct combustion air line to the heater.

ITEM FREQ. ACTION NOTES 1. Ceramic plaques. 12m Clean using an 80 p.s.i. air supply. The direction of air flow should be opposite to that of the gas flow. 2. Electrical spark plug. 12m Clean with wire brush, replace if there are any signs of corrosion. 3. Connecting wires. 12m Check for damage. If there are any signs of deterioration, replace. 4. Gas pressure. 12m Check with rated value and adjust if The rated value will be found on the identification necessary. plate or in the operating instructions. 5. Performance check. 12m Switch on and when stable plaque If the unit does not perform correctly the plaques should present a uniform cherry red should be cleaned. If the specified output is not appearance. 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 On-line Copyexhaust of the heater. Apart from the lack of radiant effect light back will cause Carbon Monoxide production and blockage of the plaque with carbon.

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

245 28-03 GAS RADIANT TUBE HEATERS

ITEM FREQ. ACTION NOTES 1. Isolation of heater 12m Switch off, remove fuses and turn For safety reasons it is essential that the equipment is from electrical and off gas supply. isolated from electricity and gas before servicing. gas supply. 2. Burner. 12m Disconnect gas union and remove Clean the combustion chamber, inspect for damage and complete burner unit. corrosion. 3. Pilot burner jet. 12m Remove, clean and refit. Only the manufacturer’s approved seals or jointing compounds must be used. 4. Main burner jet. 12m Remove, clean, inspect and refit. A competent engineer working for a CORGI registered business and competent as required by the Gas Safety (Installation & Use) Regulations must be used for this work. 5. Air filter. 12m Remove, clean and refit. Cleaning should be carried out using a soft brush or blowing with air. Use new gaskets and renew filter if necessary. 6. Spark plug. 12m Remove, clean and refit. Check ceramic for cracks or breakage. Renew if necessary. 7. Pilot burner orifices. 12m Inspect and clean. 8. Burner grid. 12m Inspect and clean, removing all Check ceramic block and fireclay for signs of cracking. dust on back of ceramic block. Renew if necessary. 9. Observation windows. 12m Check and clean 10. Vacuum switch. 12mOn-line Examine and check switching Copy differentials for correct operation. 11. Acoustic joints. 12m Check for wear. Renew if necessary. 12. Condensate traps. 12m Check for blockages. 13. Vacuum motor pump. 12m If fitted, examine mountings Lubricate pump motor if applicable. Continued on next page .. 246 28-03 GAS RADIANT TUBE HEATERS - continued

ITEM FREQ. ACTION NOTES 14. Reflectors. 12m Inspect to ensure correct fitting. 15. Gas test. 12m Pressure drop test back to nearest gas cock to ensure soundness. 16. General. 12m 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 On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

247 28-04 GAS FIRED NATURAL AND FAN ASSISTED HEATERS -Conventional and Balanced Flue.

ITEM FREQ. ACTION NOTES 1. Protection guards. 12m Remove internal guard. Check the condition of both internal and external guards. 2. (a) Heating casing. 12m Remove and inspect for damage. (b) Stub ducts (if fitted). 12m Clean grille. 3. Burner. 12m Disconnect gas union, remove Clean the combustion chamber internally and externally, burner assembly complete. inspecting closely for signs of corrosion. 4. Ignition. 12m Check operation of ignition Clean and adjust electrode as required. assembly. 5. Thermocouple. 12m Clean with fine wire brush Renew with manufacturer’s approved thermocouple if reassemble pilot and test. necessary. 6. Burner Controls. 12m Check operation and condition of Check gas pressure to burner and pilot, adjust if required. all burner controls including Lubricate diaphragms to manufacturer’s specification. combustion fan if fitted. Check safety interlocks associated with combustion fan. A competent engineer who works for a CORGI registered business and competent as required by the Gas Safety (Installation & Use) Regulations must be used for this work. 7. Flueways. 12m Inspect flue and flueways. Clean as necessary. 8. Gaskets. On-line 12m Renew flue gaskets, ‘O-rings Copy and joints. 9. Heat exchanger. 12m Inspect for corrosion. 10. Room air distribution fan 12m Inspect fan bearings, fan wheel(s) Examine for cleanliness and freedom of operation. assembly (if fitted). or blades and check speed. 11. General. 12m Check settings and correct Make necessary corrections if required. operation of thermostats and time clocks. 248 29-01 HEAT EXCHANGERS - COILS

Note:- When cleaning ensure that system fans are off to avoid dirt disturbed during cleaning entering into the system ITEM FREQ. ACTION NOTES Water to air 1. Drain pans. 12m Inspect for corrosion and clear Check that condensate traps on cooling coils are obstructions (if any) in condensate filled with water. drain piping on cooling side.

2. Coils: a) external surface air 12m Clean coils and comb out fins. Where necessary clean with appropriate sterilising side, solution, especially when coils operated under moist air conditions or act as a dehumidifier. b) water side. 12m Flush out coils to remove On heating coils any scale build up which restricts sediment. water flow should be reported for further action. 3. Coil casing. 12m Inspect for rust and clean and repaint as required. 4. Coil mounting bolts. 12m Check for tightness and secure if Corroded bolts should be replaced. necessary. Steam to air 1. Coils; On-line Copy a) external surface air 12m Clean coils and comb out fins. Where necessary clean with appropriate sterilising side, solution. b) water side. 12m Flush out coils to remove Report to client on any further action necessary due sediment. to scale or erosion.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 249 29-01 HEAT EXCHANGERS - COILS- continued

ITEM FREQ. ACTION NOTES 2. Coil casing. 12m Inspect for rust and clean and repaint as required. 3. Coil mounting bolts. 12m Check for tightness and secure if Corroded bolts should be replaced. necessary. 4. Operation of steam traps. 1m Check operation, condition of filters Full details of maintenance requirements steam and sight glasses. services, see PIPEWORK SYSTEMS. 12m Clean and overhaul traps, strainers and sight glasses. Check by-pass valves are not leaking. Indirect gas fired to air 1. Heat exchanger; a) air side, 12m Clean fins and air-side surfaces. Comb fins if appropriate. Where necessary clean with appropriate sterilising solution. b) flue gas side. 6m Clean surfaces where access is Report to client any deterioration of heating surface provided. which requires further attention. 2. Heat exchanger casing. 12m Inspect for rust and clean and repaint as required. 3. Heat exchanger On-line12m Check for tightness and secure Copy if Corroded bolts should be replaced and any leaking mountings. necessary. joints between the heat exchanger and discharge of products of combustion must be rectified before the heater is put back into service. 4. Gas burners and 12m Service. For detailed information on maintenance of gas associated fired heater see the maunfacturer's instructions. equipment. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 250 29-02 ELECTRIC/AIR HEATER

Note: When cleaning, ensure that system fans are off to avoid dirt disturbed during cleaning entering the system. ITEM FREQ. ACTION NOTES 1. Terminal box: a) external surfaces, 12m Inspect for rust and clean and repaint as required. b) lid retaining screws, 12m Check for tightness and secure if Missing screws should be replaced. necessary. c) internal connections. 12m Check that terminal screws are tight. Observe correct safety procedures as required Check the integrity of the internal wiring. under the Electricity at Work Regulations. 2. Elements: a) within terminal box, 12m Check insulation resistance of each Replace if below 1 megohm resistance. element. Check continuity. Replace if open circuit. b) within casing. 12m Clean elements (comb out if finned type). Where necessary clean with appropriate sterilising solution. 3. Casing. 12m Inspect for rust and clean and repaint as required. 4. Mounting bolts. 12m Check for tightness and secure as Examine casing mounting flanges for air On-linenecessary. Copytightness where appropriate. 5. Thermostats/ controls. 12m Check operation. For detailed maintenance see relevant section. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 251 29-03 PLATE RECUPERATOR

The frequency of cleaning will depend upon the working environment. ITEM FREQ. ACTION NOTES 1. External surfaces. 6m Inspect for rust and clean and repaint as required. 2. Internal surfaces. 6m Check and remove any dirt, inspect for Do not use wire brush for dirt removal, blow rust and repaint as necessary. off with dry nitrogen or compressed air. 3. Leakage. 6m Check for both internal and external Cross leakage between the two air streams is leaks. undesirable as cross contamination could occur. 4. Mountings. 6m Check for tightness and secure as necessary. 5. Fans. 6m Service and lubricate. 6. By-pass control. 6m Check operation. Check summer/winter by pass operation. 7. Heaters. 6m Check operation. Check action of thermostat in air supply side. Setting should be 'air to room' at room temperature. 8. Drains (condensation). 6m Check operation, clean and sterilise. 9. Filters. 3m Clean or replace as necessary. Filters are fitted on both inlet and extract to On-line Copykeep the heat exchangers clean. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 252 29-04 THERMAL WHEELS - ROTARY HEAT REGENERATORS

ITEM FREQ. ACTION NOTES 1. Bearings. 6m Lubricate according to the 'Sealed for life' bearing should not need any manufacturer's instructions. maintenance. 2. Exterior surfaces. 12m Clean and check for rust. If necessary prepare and repaint rusty areas. 3. Interior surfaces. 12m Clean, examine and treat any rusty Note: do not scrape as surfaces may have special areas and repaint. coatings. 4. Heat exchange mesh. 12m Clean, taking care not to damage the Low pressure hot water containing detergent is mesh. the best cleaning agent but if the system is designed with a hygroscopic surface to recover latent heat refer to manufacturer for cleaning instructions. 5. Seals. 12m Check condition and renew if necessary. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 253 29-05 RUN ROUND HEAT RECOVERY COILS

ITEM FREQ. ACTION NOTES 1. Pump. 12m Inspect bearings for wear. Check flow Frequency should be in accordance with the rates/speed and leak tightness. manufacturer's instructions. Check electrical connections. Observe correct safety procedures as required under the Electricity at Work Regulations. 2. Antifreeze. 12m Check that concentration is correct for the application. 3. Water. 12m Check for leaks. Remedy if possible, if major problem, refer to client. 4. Operating pressure. 12m Check. Confirm pressure vessel operating conditions. 5. Coils. 12m Clean with recommended cleaning compound and flush with water. 6. Air. 12m Check for leaks. Rectify as required providing new seals etc. 7. Condensate traps. 12m Inspect for rust, clean and clear any debris. Recoat. Check traps are filled On-linewith water on return to service. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 254 29-06 PLATE HEAT EXCHANGERS

ITEM FREQ. ACTION NOTES 1. Inspection. 12m Inspect the plate pack for deformed or Gaskets extruding from the plate pack normally damaged edges or for leakage. indicate a damaged plate or failed gasket. The most common cause of such failure is working at excess pressure which must be corrected. A major overhaul is necessary if the pack is deformed. 2. Cleaning frame. 12m The exterior finish of the heat The correct type of cleaner as recommended by exchanger frame (not the plate pack) the manufacturer should be used and this will should be washed down and rubbed normally provide lasting protection provided the dry, then a thin film of cleaner applied. treated services are not subject to high temperature. 3. Top bar. 12m Clean all surfaces, check tightness of Depending upon the make of heat exchanger, fixing screws. lubricate plate and follower hanger surface each time the plate is opened. 4. Bottom bar. 12m Check tightness of fixing screws. Depending upon the type of exchanger, smear surfaces with a thin film of grease when plate pack is open. 5. Liquid connections. 12m Check tightness of flanged or pipe union fittings on header. 6. Rubber bush linings On-line12m Check for splits, signs of cracking Copy or (where fitted). other deterioration. 7. Port rings (where fitted). 12m Check for collapsed peaks, splits or hardening. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 255 29-06 PLATE HEAT EXCHANGERS - continued

ITEM FREQ. ACTION NOTES 8. Connector grid boss 12m Check security of connector grid boss fixing (where fitted). fixings when plate pack is exposed. 9. Tie bars. 12m Coat all exposed threads with appropriate lubricant. 10. Tightening screws (where 12m Grease threads with maker's fitted). recommended grease or paste. 11. Hinge bar thrust pad 12m Clean, apply maker's recommended Inspect for serious wear and replace as (where fitted). grease. necessary. 12. Spray screens (where 12m Always ensure that these are properly fitted). attached when the heat exchanger is operating. 13. Exchanger operation 12m Check temperatures on inlet/outlet and Fluctuating outlet temperatures could indicate a (where suitable gauges pressure drop. perforated plate, allowing intermixing of primary have been fitted). and secondary fluids. Low output pressure could possibly be due to scale deposits on the plates, a blockage in the plate pack or inlet pipeline, all of which cause energy waste. If de-scale or hygienic cleaning is necessary, it should be carried out strictly in On-line Copyaccordance with the heat exchanger manufacturer's recommended procedure. 14. Check safety controls. 12m Safety valve operation. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 256 29-07 WATER TO WATER PLATE HEAT EXCHANGERS

ITEM FREQ. ACTION NOTES 1. Inspection. 12m Inspect the plate pack for Gaskets extruding from the plate pack normally indicate deformed or damaged edges a damaged plate or failed gasket. The most common or for leakage. cause of such failure is working at excess pressure which must be corrected. A major overhaul is necessary if the pack is deformed. 2. Cleaning frame. 12m The exterior finish of the heat The correct type of cleaner as recommended by the exchanger frame (not the manufacturer should be used and this will normally plate pack) should be provide lasting protection provided the treated services washed down and rubbed are not subject to high temperature. dry, then a thin film of cleaner applied. 3. Top and bottom bars. 12m Clean all surfaces, check Depending upon the make of heat exchanger, lubricate tightness of fixing screws. plate and follower hanger surface each time the plate is opened with recommended lubricant. 4. Liquid connections. 12m Check tightness of flanged or pipe union fittings on header. 5. Elastomeric bush linings 12m Check for splits, signs of (where fitted). cracking or other On-linedeterioration. Copy 6. Port rings (where fitted). 12m Check for collapsed peaks, splits or hardening. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 257 29-07 WATER TO WATER PLATE HEAT EXCHANGERS - continued

ITEM FREQ. ACTION NOTES 7. Connector grid boss 12m Check security of connector fixing (where fitted). grid boss fixings when plate pack is exposed. 8. Tie bars. 12m Coat all exposed threads with appropriate lubricant. 9. Tightening screws 12m Grease threads with maker's (where fitted). recommended grease or paste. 10. Hinge bar thrust pad 12m Clean, apply maker's Inspection for serious wear and replace as necessary. (where fitted). recommended grease. 11. Exchanger operation 12m Check temperatures on Fluctuating outlet temperatures could indicate a (where suitable gauges inlet/outlet and pressure perforated plate, allowing intermixing of primary and have been fitted). drop. secondary fluids.

Low output pressure could possibly be due to scale deposits on plates, a blockage in the plate pack or inlet pipeline, all of which cause energy waste.

If de-scale or hygienic cleaning is necessary, it should On-line Copybe carried out strictly in accordance with the heat exchanger manufacturer's recommended procedure. H&S and Environmental Regulations apply. 12. Safety controls. 3m Check operation. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 258 30-01 HEAT REJECTION EQUIPMENT

Introduction

This section covers those items of plant associated with the removal of heat from the equipment producing the cooling. It 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 and it is therefore essential that in those cases, appropriate safety procedures as listed in ACOP L8, 2001 should be followed.

Waterside fouling will vary with the hardness of the water, amount of bleed off and the quantity of make up. In hard water areas or where heavy air pollution occurs it may be necessary to increase the maintenance frequency.

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Action to be taken prior to the visit. I. Notify appropriate local and/or water authority/company, prior to discharging water drained from the cooling tower as the contaminated water could enter sewers. II. Advise client that cooling tower will be out of action during period of visit. Note:- Towers that have not been regularly maintained should be treated as HAZARDOUS and must not be maintained by personnel who may be susceptible to LEGIONELLA. ITEM FREQ. ACTION NOTES Initial Safety Precautions Ensure maintenance personnel read Before starting work on cleaning cooling towers ACOP L8,2001. it is essential that certain preliminary safety precautions are taken. These are listed under Select personnel who are less 'Action'. susceptible to the disease. Protective clothing and positive Personnel should wear positive pressure pressure respirators. respirators when contamination is suspected or the condition is not known. Note:- respirator seal may not work with beards. 6m Cooling water analysis. Sample and send to a UKAS accredited laboratory for total viable colony count (TVC) Dipslides should be taken weekly. (Immediate action should be taken if these show unusual results) Cleansing and disinfection Where cooling towers are situated in rural areas procedures On-line Copyand only in use during the summer months the frequency of maintenance can be extended to twelve months. 1. Site liaison. 6m Advise client that you are on site. Report to security personnel where appropriate. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 260 30-02 COOLING TOWERS - continued

ITEM FREQ. ACTION NOTES 2. Warning notices. 6m Post at approaches to cooling tower It is essential that anyone approaching the and enclosure. cooling tower is warned and notices should state:-

Restricted area - do not enter. 3. Windows and air inlets 6m Close any in the vicinity of the work. 4. Close down system. 6m Isolate chillers(s) cooling towers and If this involves entering vicinity of cooling tower circulating pumps. and if tower is not regularly maintained, don protective clothing including positive pressure respirators. 5. Electrical equipment. 6m Ensure that all electrical equipment is Cooling tower fans and any adjacent air intake isolated except pumps. fans should be isolated in accordance with H&S requirements. 6. Automatic dosing 6m Close water supply, circulate for fifteen equipment minutes, isolate pumps and drain to continuous drains and waste. water supply. 7. Bio-dispersant. 6m Add at a recommended concentration. Use of the bio-dispersant breaks down the bio- film which is usually present on most surfaces. 8. Hardness of water. On-line6m Check pH which should be betweenCopy 7 A pH above 8 indicates high alkalinity which will and 8. If higher contact water treatment require neutralising. If sodium hypochlorite is specialist for advice. used at a high pH foaming will result which will prevent correct disinfection. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

261 30-02 COOLING TOWERS - continued

ITEM FREQ. ACTION NOTES 9. Disinfection. 6m Add sodium hypochlorite to chlorinate, Any action taken should conform to the bring up concentration to either 5 ppm requirements of HVCA TM13, HSC ACOP L8, or 30 ppm. (see notes) 2001 and other H&S regulations. At 5 ppm the system should be run for at least six hours, at 30 ppm, 2 hours. See item 10.

10. Cooling water pumps. 6m Replace fuses to pumps and switch on It is probable that once the water starts to and run for 6 or 2 hours (see note 9). circulate the free chlorine level will fall, hence After 15 minutes, close down pumps, sodium hypochlorite must be added to maintain check chlorination level and if needed the chlorination at 5 or 30 ppm during the running add sodium hypochlorite to reinstate cycle. chlorine level.

11. Drain system. 6m Switch off pumps, remove fuses and When starting to drain, open water supply to drain complete system. assist in neutralising system. Then shut off water supply and allow to drain. It is essential that the whole system is completely drained. Check for drain cocks on pipework serving chiller. 12. Tower packing and drift 6m Dismantle so far as is practicable and If packing shows signs of deterioration - replace. eliminators, etc. clean. See comment in 13 below. When replacing drift eliminators ensure that these On-line Copyare correctly fitted and secured. Continued on next page .. 262 30-02 COOLING TOWERS - continued

ITEM FREQ. ACTION NOTES 13. All surfaces. 6m All accessible surfaces to be cleaned Ensure all scale, rust and other mineral and with a wire brush. To remove all organic deposits are removed. Any rust areas deposits thoroughly chemical cleaning should be treated and repainted. may be necessary. 14. All components. 6m Every part of the system must be If any part of the system is left uncleaned cleaned i.e. feed tank, ball valve, contamination of the whole system may result. softener etc. 15. Disposal of loosened 6m Sweep out all loosened deposits and Ensure safe removal of sacks from site. deposits. place in plastic sacks with the tops Waste Disposal Regulations may apply. securely fastened.

16. Wash down. 6m Clean with low pressure hose. If possible close valves from tower to chiller during wash down. If a high pressure hose has to be used, tent tower to prevent any spray drift. 17. Chlorination. 6m Close drain valves, open water supply, Ensure that chlorination concentration remains at fill system and chlorinate to 5 ppm. 5 ppm throughout 'run' period. Replace pump fuses, switch on pumps and run system for six hours.

18. Drain system. 6m Repeat actions indicated in note 12. 19. Re-fill system. On-line6m CopyNote:- If chlorine concentration exceeds 2 ppm prior to activating water treatment regime, drain and refill. 20. Attenuators. 6m Clean, derust and repaint as required.

21. Activation of water 6m Contact water treatment organisation. Water treatment organisation will activate system treatment and dosing. and take samples for analytical tests. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 263 30-02 COOLING TOWERS - continued

ITEM FREQ. ACTION NOTES 22. Protective clothing. 6m Remove and bag before returning through occupied parts of the building. 23. Complete system. 6m Restart. Check frost protection is operational. 24. Windows and air inlets. 6m Re-open windows and restart Remove warning notices. ventilation fans. 25. Records. 6m Record all activities carefully in the Give client one copy of the report and retain the form of duplicate job sheets. other.

26. Completion. 6m Advise client on completion of work. Check out at security.

27. Bacterial checks. 6m Take sample for TVC count. Note:- weekly dip slides will indicate bacteria levels. A high bacterial level does not necessarily mean the Legionella bacteria are present. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 264 30-03 DRY COOLERS

ITEM FREQ. ACTION NOTES 1. Status. 6m Isolate from electrical and other Isolate electrical supply in accordance with H&S services. requirements. 2. Fans. 6m See FANS. 3. Fins. 6m a) external, 6m Clean by blowing through with Note:- Any discharged refrigerant (CFCs) compressed air or steam. must be recovered and NOT released to atmosphere. Only a Qualified and REFCOM registered engineer should work on this equipment. b) internal. 6m Blow through with dry, oxygen free, nitrogen. 4. Coil vent. 6m Check operation. 5. Anti-vibration mountings. 6m Check - visual condition, There should be no transfer of vibration or visible - effectiveness. deterioration. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 265 31-01 HOT AND COLD WATER SERVICES

Introduction

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 Standard Maintenance Specifications should be adequate for the majority of well engineered low risk systems 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.

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 constructionOn-line materials, Copy d) Rust, e) Commonly encountered water organisms such as algae, amoeba, slimes and biofilms. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 266 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 may be common practice by the year 2000 and consideration will have to be given 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.

The code of practice entitled ‘Safety of Pressure Systems’ gives practical guidance with respect to the Pressure Systems and Transportable Containers Regulations 1989 and defines what systems and which fluids apply.

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267 31-02 Note on the WATER UNDERTAKERS BYELAWS

This Volume on Ancillaries, Plumbing and Sewerage systems covers those services in a building relating to the provision of water and includes hot, cold and drinking water. Such services should conform to the Water Supply (Water Fittings) Regulations (Byelaws in Scotland) and are designed to ensure that the supply of water cannot be contaminated from external sources.

The Regulations give statutory powers to all the water companies in England and Wales. The aim of these powers is to prevent waste, misuse, contamination and undue consumption of water supplied by the undertakers. Considerable amounts of energy are used in the purification and pumping of water and the treatment of sewage hence water wastage equates with energy wastage, thus every endeavour should be taken to minimise water wastage apart from the need to conserve a national resource.

To ensure some conformity of approach, guidance has been produced by the Water Regulations Advisory Service (WRAS). It has been produced with the aim that it should: a) assist water inspectors, manufacturers, architects, consultants, installers and maintenance personnel and consumers to understand byelaws based on the Model, b) bring about a uniformity of approach to enforcement, c) be suitable as a training document, d) be based wherever possible on appropriate British Standards.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

268 The guide to the Regulations has been published by the Water Regulations Advisory Scheme (WRAS). The regulations are examined and explained in detail under a number of basic headings.

Penalties for non compliance with the regulations are referred to and most particularly, the need for the installer to inform the local water undertaking of planned work.

Water Quality

Water portability does not necessarily equate with water quality and except in soft water areas, some form of secondary water treatment may be necessary to remove or inhibit the scale forming elements (i.e. hardness) in the water. Failure to soften or treat the water can lead to excessive scale build up on heaters and heat transfer surfaces with the consequences that efficiency may be reduced leading to energy wastage, or in the worst cases failure of the unit.

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269 32-01 Hot Water Supply - Introduction

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 his own 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 and CIBSE publication TM13.

Operating Temperature

ACOP L8,2001 recommends that water services should operate at temperatures that prevent the proliferation of legionella, that is: a) hot water storage (calorifiers), 60°C, b) hot water distribution, at least 50°C attainable at the taps within one minute of running, c) cold water storage temperature, 20°C or below. Client's staff should check temperatures monthly as required by ACOP L8,2001.

It has been common practice to operate hot water systems in the range 45° to 50°C. At those temperatures there is little risk of scalding, 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 43 ± 2°C. This should be checked by client's staff at least monthly.

Where the water temperatures advocated in ACOP L8,2001 cannot be maintained, alternative control measures will need to be considered. These could include weekly disinfection,On-line routine chlorination (at least three monthly), Copy continuous chlorination of water to 2mg/litre, on line pasteurisation, etc.

It is recommended practice that during maintenance the system temperature is raised above 60°C for a period of pasteurisation (disinfection). 270 32-01 Hot Water Supply Introduction - continued

Distribution Pipework

The pipework system must be free of any points where dirt, slime or sediment may accumulate to ensure that there are no deposits, which could provide a source of nutriment to sustain the legionella bacteria. Where this is not possible the system should be disinfected on a regular basis. This also applies where pipe replacement or alterations take place and disinfection procedure must be strictly followed.

Hot Water Supply

Pressurised Systems

It should be recognised that danger can arise during the maintenance of pressurised systems if steps are not taken to relieve any 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 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. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 271 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. ITEM FREQ. ACTION NOTES 1. Complete system. 12m Check for corrosion, sludge and Frequency to be agreed with client who should be slime/algae. advised of any remedial work. 2. Cold water temperature 1m Monitor to ensure compliance with Responsibility for this test should be agreed with (at outlet of cistern or ACOP L8,2001 requirements. client. Advise client if temperature outside tank). ACOP, L8,2001 requirements for any remedial work to be put in hand. 3. Hot water temperature (at 1m Monitor to ensure compliance with Responsibility for this test should be agreed with outlet of calorifier). ACOP, L8,2001 requirements. client. Advise client if temperature outside ACOP, L8,2001 requirements for any remedial work to be put in hand. 4. Drain valves. 12m Open to ensure blow down of This is particularly applicable in vacant buildings collected sediment. where services are left running and more frequent opening of drain valves is recommended. 5. Dipslides. weekly Take regular dipslides, record results. *responsibility for taking dipslides should be agreed with client. 6. Water samples: 12m

a) bacterial analysis, 12m Take sample for bacterial If circumstances warrant more frequent sampling, examination, record findings. agree frequency with client. b) legionella. On-line12m Take sample for UKAS accredited CopyIf circumstances warrant more frequent sampling, laboratory analysis. agree frequency with client. Analysis should include Serogrouping, i.e. identification of various strains. 7. Disinfection. 12m If there is a need to disinfect whole system, advise client. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 272 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. The calorifiers are either vertical or horizontal and there are two basic types:

(a) Non-storage, normally used for heating systems (b) Storage, normally used for hot water supply systems where demand usually varies.

This section covers the maintenance of calorifiers including calorifier mountings, and unvented hot water systems but is not intended to cover the opening up of calorifiers for statutory insurance inspection which requires a separate procedure, which however may be carried out at the same time as the maintenance.

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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.

(d) Report any necessary remedial work where repairs, adjustment or replacement will be required during routine maintenance.

(e) Check condition of sacrificial anode and replace if necessary.

CHLORINATION/PASTEURISATION

All secondary systems used to provide a hot waster service must be chlorinated/pasteurised yearly in accordance with ACOP L8,2001 and additionally after a period of shutdown. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 274 32-05 CALORIFIERS HEATED BY LTHW OR MTHW Warning – Insulation may contain Asbestos Low temperature hot water systems (LTHW or LPHW) are heating systems operating up to 10 bar (gauge) and 95oC, medium temperature hot water systems [MTHW] are heating systems operating in the range 95°-120oC 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) Inspect calorifier insulation and/or shell for signs of damage. (c) Inspect all manholes, mounting, and joints for signs of leaks. (d) Report any necessary remedial work where repairs, adjustment or replacement will be required during routine maintenance. Check condition of sacrificial anode and replace if necessary. ITEM FREQ. ACTION NOTES 1. Operation and safety 12m Check, note and report any Ensure both secondary and primary circuits are full of controls. visible defects. water and circuits are open. 2. Safety valves/PRV. 12m Check operation of safety. N.B. Temperature settings should be in accordance with HSC guidance note ACOP L8,2001 for Hot Water Services. If manually operated for test purposes leakage could occur after test. 3. Thermostats, pressure 12m Check for correct operation sensors, altitude gauges and settings. and thermometers. 4. Pasteurisation. 12m Cook for one hour above N.B. If system has been shut down for any length of On-lineo Copy 60 C. time it must be pasteurised/chlorinated. 5. Chlorination. 12m Chlorinate. 6. Auto controls and 12m Shut down primary heat Check operation of temperature controls and high limit primary side. source. cut-outs. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 275 32-05 CALORIFIERS HEATED BY LTHW OR MTHW - continued

ITEM FREQ. ACTION NOTES 7. Drain valve/drain cock on 12m Ensuring secondary valves N.B. If calorifier was in use, the secondary water will be secondary side. are closed draw off a small hot so care must be taken in carrying out this item of the quantity of water to remove schedule. If the secondary side of the calorifier is at a any sediment. high temperature, the system must be allowed to cool before drain is opened. 8. Heating surface and 24m Drain down secondary side, The formation of scale reduces heat transfer and causes internal surfaces of shell remove manholes and energy wastage. Corrosion will cause metal failure and inspect for scale formation leakage. and corrosion and report. Remove sludge. If scale is extensive refer to client for further instructions.

9. Bursting discs (where 24m Check condition. Report findings. fitted) 10. Sacrificial anode 24m Check status. 11. Put back into operation Refit all manholes, refill Check operation of all temperature controls. secondary side. Hydraulic pressure test. Put primary On-lineside into operation. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 276 32-06 HOT WATER CALORIFIERS HEATED BY STEAM

Note: In the interests of safety and the prevention of scalding, water temperatures and the operation of blending valves should be checked at least once a month by the caretaker or operator. Insulation which is damaged may be asbestos – appropriate action must be taken. Warning: STEAM LEAKS ARE DANGEROUS.

Prior to carrying out the planned maintenance of the calorifier, the pre-maintenance procedure detailed below should be followed:

(a) Check equipment operating status (i.e. whether in operation or not in use, whether isolated from system) including safety. (e) Inspect calorifier insulation and/or shell for signs of damage. (f) Inspect all manholes, mounting, and joints for signs of leaks. (g) Report any necessary remedial work where repairs, adjustment or replacement will be required during routine maintenance. (h) Check condition of sacrificial anode and replace if necessary.

CHLORINATION/PASTEURISATION

All secondary systems used to provide a hot waster service must be chlorinated/pasteurised yearly in accordance with ACOP L8,2001 and additionally after a period of shutdown.

ITEM FREQ. ACTION NOTES 1. Check operation, in 12m Note and report any visible Ensure secondary is full of water and circuits are open. particular safety controls. defects. If safety controls are defective take equipment out of service. 2. Safety valves. On-line12m Check for corrosion and CopyN.B. If calorifier was in use, the secondary water will be manually operate. hot and can be under pressure, so care must be taken in carrying out this item of the schedule. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 277 32-06 HOT WATER CALORIFIERS HEATED BY STEAM - continued

ITEM FREQ. ACTION NOTES 3. Thermostats, pressure 12m Check for correct operation N.B. Temperature settings for Hot Water Services should sensors, altitude gauges and settings. be in accordance with HSE ACOP L8,2001. and thermometers. 4. Auto controls and 12m Shut down primary heat Check safe operation of temperature controls and high primary side. source taking all necessary limit cut-outs. precautions to prevent unauthorised use. 5. Drain valve/drain cock on 12m Draw off a small quantity of N.B. If calorifier was in use, the secondary water will be secondary side. water to remove any hot, and can be under pressure, so care must be taken sediment. in carrying out this item of the schedule. 6. Pasteurisation. 12m Cook for one hour above 60oC. 7. Chlorinate. 12m Chlorinate. 8. Heating surface and 12m Drain down secondary side, The formation of scale reduces heat transfer and causes internal surfaces of shell. remove manhole covers and energy wastage. Client's attention should be drawn to inspect for scale formation the presence of excessive scale which indicates the need and corrosion. for water treatment. Corrosion will cause metal failure and leakage. Remember Waste Disposal Legislation. If On-line Copyscale is extensive, refer to client for further instructions. 9. Bursting discs (where 24m Check condition. Report findings. fitted). 10. Gaskets. 12m Check gaskets on steam Steam leaks are dangerous to personnel and cause chest for leakage, replace as wastage of energy. necessary. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 278 32-06 HOT WATER CALORIFIERS HEATED BY STEAM - continued

ITEM FREQ. ACTION NOTES 11. Sacrificial anode. 12m Check status 12. Anti-vacuum valve 24m Check operation and service (where fitted). as appropriate. 13. Steam trap/sight glass 12m Clean and overhaul steam Faults can lead to steam and energy wastage. (on primary connections). trap. 14. Strainer on primary 12m Remove strainer, clean and Blocked strainers reduce performance. pipework. refit. 15. Return to operation. 12m After completion of Check that all controls are working correctly. maintenance, refit all manhole covers, refill secondary side and put primary side back into operation. 16. Check insulation for 12m Repair or renew as Damaged lagging reduces efficiency, wastes heat, and if damage. necessary. the calorifier is in the open air, can become waterlogged and lead to hidden corrosion. Asbestos Regulations may apply 17. Hydraulic pressure test. On-line12m If a pressurised system test CopyThe Pressure Vessel Regulations may apply. to Working pressure x 1.5. (see INDG 261) Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 279 32-07 HOT WATER SUPPLY CALORIFIERS - including LOAD LEVELLERS

ITEM FREQ. ACTION NOTES 1. Operation and safety 12m Check, note and report any visible Ensure both secondary and primary circuits are full of water controls. defects. and circuits are open. 2. Safety valves. 12m Check for corrosion and manually N.B. If calorifier was in use, the secondary water will be hot operate. and can be under pressure, so care must be taken in carrying out this item of the schedule. 3. Thermostats, pressure 12m Check for correct operation and N.B. Temperature settings for Hot Water Services should be in sensors, altitude settings. accordance with HSE ACOP L8,2001. gauges and With direct acting valves hot water storage temperatures thermometers. should not exceed those laid down in the above guidance notes or scalding could occur. 4. Auto controls and 12m Shut down primary heat source. Check operation of temperature controls and high limit cut- primary side. outs. 5. Drain valve/drain cock 12m Draw off a small quantity of water N.B. If calorifier was in use, the secondary water will be hot on secondary side. to remove any sediment. and can be under pressure, so care must be taken in carrying out this item of the schedule. 6. Heating surface and 24m Drain down secondary side, The formation of scale reduces heat transfer and causes internal surfaces of remove manhole covers and energy wastage. In hard water areas scale can be very difficult shell. inspect for scale formation and to remove if left to build up and more frequent maintenance is On-linecorrosion and report. Copyrecommended. Corrosion will cause metal failure and leakage. Remember Waste Disposal Regulations. 7. Bursting discs (where 24m Check condition. Report findings. fitted). 8. Put back into operation Refit all manhole covers, refill Check operation of all temperature controls secondary side. Put primary side back into operation. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 280 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.

ITEM FREQ. ACTION NOTES 1. Control thermostat. 12m Check operation and confirm set Thermostat in-built as part of calorifier or point. installed in/on secondary pipework.

2. High limit thermostat (if fitted). 12m Check operation and confirm set Manual or thermal reset? point. 3. Temperature sensor 12m Check operation and confirm set controller. Motorised valve. point(s). 4. Power fail return. Motorised 12m Check operation. Ensure valve shuts off supply to calorifier and valve. does not have let-by. 5. Direct acting control valve. On-line12m Check operation and confirm Copy set point. 6. Direct acting control valve - 12m Check operation and confirm set Ensure valve shuts off supply to calorifier and high limit. point. does not have let-by. 7. Temperature sensor. 12m Check performance. Calibration } Controller. Motorised valve. Interrogation } by CONTROLS SPECIALIST. Power fail return motor. Control adjustment } Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 281 32-09 HOT WATER CYLINDERS

ITEM FREQ. ACTION NOTES 1. Cylinder. 12m Inspect visible seams and Report adverse findings. bosses for leaks or signs of corrosion. 2. Connections. 12m Check connecting pipe If found, drain down, clean and remake joint. unions for leaks. 3. Insulation. 12m Inspect for deterioration. Refer to client if repairs or renewal required. 4. Immersion heater. 12m Check operation and Client's attention should be drawn to the presence of examine for scale on excessive scale, which indicates the need for water element. treatment. 5. Cold water storage 12m Inspect seams and bosses Report adverse findings. See STORAGE – COLD cistern (if combination for leaks. WATER for detailed maintenance schedule of cisterns. cylinder). 6. Float operated valve and 12m Check operation and adjust Re-washer or replace if necessary. float (if combination water level to maximum cylinder). storage level. Check float for leakage and Replace if necessary. security. 7. Water temperature. 12m Check water outlet N.B. Temperature setting for Hot Water Services should On-linetemperature and operation ofCopybe in accordance with HSE ACOP L8,2001. auto-temperature controls. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 282 32-10 UNVENTED HOT WATER SYSTEMS

Warning - these systems should only be maintained by competent personnel who are competent to maintain them. Note: When the systems are used in buildings subject to the Health and Safety at Work Act 1974 and Northern Ireland 1978 Order the schedule of work given below is a requirement. ITEM FREQ. ACTION NOTES 1. Complete unit. 12m Examine water storage Check for any signs of corrosion and water leaks. Reseal vessel, expansion vessel, pipework joints if necessary. pipework and fittings. 2. Discharge pipework. 12m Examine discharge pipes, Discharge pipe should be visible and in a safe place. It ensure that air gap is clear should be of metal and connected to the tundish. and that there is no blockage in the pipes. 3. Expansion relief valve. 3m Manually operate. Check that the valve seats satisfactorily, water flow ceased on valve closure and water runs through tundish and discharge pipes. 4. Temperature relief valve. 3m Manually operate. Check that the valve seats satisfactorily, water flow ceased on valve closure and water runs through tundish and discharge pipes. 5. High limit thermostat. 6m Check operation. Should be non self-setting. Thermal cut out should be 85°C. 6. Control thermostat. On-line12m Check temperature setting. CopyN.B. Temperature settings for Hot Water Services should be in accordance with HSE ACOP L8,2001. 7. Diaphragm expansion 12m Check pressure. See – EXPANSION VESSELS. tank. 8. Motorised valve (if fitted). 12m Check operation. Ensure no water flows through valves during shut down part of the cycle. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 283 32-10 UNVENTED HOT WATER SYSTEMS - continued

ITEM FREQ. ACTION NOTES 9. In-line strainer. 12m Inspect and clean as required. 10. Back flow prevention 12m Check operation and ensure The operation can be checked by observing any device. that non-return valve is changes in the upstream level of a vessel preceding the seating properly. device when the incoming supply is isolated. 11. Electrical element. 12m Check for scale on element. Client's attention should be drawn to presence of excessive scale which indicates a possible need for water treatment.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 284 32-11 THERMAL STORAGE CYLINDER – (individual dwellings for DHWS)

ITEM FREQ. ACTION NOTES 1. Cylinder. 12m Inspect visible seams and Report adverse findings. bosses for leaks or signs of corrosion. 2. Connections. 12m Check connecting pipe If found, drain down, clean and remake joint. unions for leaks. 3. Insulation. 12m Inspect for deterioration. Refer to client if repairs or renewal required. 4. Immersion heater. 12m Check operation and Client’s attention should be drawn to the presence of examine for scale on excessive scale which indicates the need for water element. treatment. 5. Feed and expansion 12m Inspect seams and bosses Report adverse findings. cistern (if fitted). for leaks. 6. Float operated valve and 12m Check operation and adjust Re-washer or replace if necessary. float (if fitted). water level to minimum make up level. Water level adjustments should only be carried out when the heating system and cylinder are cold. Check float for leakage. Replace if necessary. 7. Domestic hot water 12m Check operation. N.B. Temperature settings for Hot Water Services thermostatic blender. should be in accordance with HSE ACOP L8,2001. On-lineCheck water outlet Copy temperature and operation of auto-temperature controls. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 285 32-12 EXPANSION VESSELS

ITEM FREQ. ACTION NOTES 1. Condition. 12m Examine for damage or If replacement necessary report to client. corrosion. 2. Diaphragms. 12m Check condition and Ensure diaphragms are sound and cushion pressure is pressure. correct. Top up as necessary, preferably with oxygen free nitrogen. DHWS Calorifier 1. Diaphragm expansion 3m Check. Ensure air cushion pressure is correct, if necessary top tank/s. 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. 2. Non-return valve. (Cold 3m Check. Ensure that valve is seating properly. water service (CWS) to calorifier). On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 286 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, client should carry out monthly checks of the outlet temperature. ITEM FREQ. ACTION NOTES Flueways 1. Heat generation 12m Remove and carry out necessary See HEAT GENERATORS for maintenance. equipment. maintenance. 2. Fluepipe. 12m Remove at slip collar and clean. 3. Draught diverter (where 12m Remove and clean. applicable). 4. Flue baffles. 12m Remove and clean. Note: All debris should be removed with a vacuum cleaner. 5. Flue tubes. 12m Clean with suitable brush. 6. Reassembly. 12m Reassemble in reverse order. Ensure that on reassembly, the flue is sealed in an air tight manner. 7. Smoke test. 12m Carry out a smoke test on flue. See FLUES. Waterways It is recommended that this operation is carried out at On-line Copythe same time as flueway maintenance. 1. Isolation. 12m Turn off, isolate and remove heat See BURNER section maintenance. generator. Where applicable, switch off electricity and remove fuses. Turn off water supply. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 287 32-13 DIRECT FIRED WATER HEATERS - continued

ITEM FREQ. ACTION NOTES 2. Drain down heater. 12m Drain down using drain valve on side of heater. 3. Casing cover. 12m Remove to gain access to inspection plate. 4. Waterways. 12m Remove inspection plate, check If scale build up is excessive, chemical descaling will be for scale build up. necessary. 5. Sacrificial anodes 12m Check for condition, replace if Do not replace copper and aluminium anodes but (magnesium). necessary. replacement of magnesium anodes may be necessary in steel vessels. 6. Gasket. 12m After inspection of internal Note: Ensure that the heater is thoroughly flushed out surfaces a new gasket should and that any deposits removed. be fitted to inspection plate before reassembly. 7. Reassembly and test. 12m Fill up and test for soundness. Refit heat generator in accordance with the manufacturer's instructions. Test fire. Special note: On-line Copy 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. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 288 32-14 INSTANTANEOUS ELECTRIC WATER HEATERS

ITEM FREQ. ACTION NOTES 1. Visual inspection for 12m Report any remedial work leaks and damage. needed to client and isolate if unsafe. 2. Water temperature. 12m Check water outlet temperature N.B. Temperature settings should be in accordance with and operation of auto- ACOP L8,2001 for Hot Water Services. temperature controls. 3. Inbuilt filter (if fitted). 12m Isolate electric supply, turn off water inlet drain unit, remove filter/strainer and clean filter as necessary. 4. Operation after filter 12m After a filter replacement, check replacement. operation of heater and set flow as appropriate. 5. Scale. 12m In hard water areas descale. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 289 32-15 PACKAGED ELECTRIC WATER HEATERS-cistern type

ITEM FREQ. 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. 2. Operating status. 12m Check, if unit out of service If electrically defective, ensure equipment is left ask client for reasons. disconnected and isolated. 3. External case and 12m Visual inspection for leaks pipework connections. and damage. 4. Water temperature 12m Measure temperature, check N.B. Temperature settings should be in accordance with controls. against thermostat settings. ACOP L8,2001 for Hot Water Services Adjust thermostat as necessary. 5. High temperatures cut- 12m Check temperature setting. Check operation of temperature controls and high limit outs. cut-outs. 6. Electrical supply. 12m Isolate, remove fuse and Units must not be left with electrical element if incoming check rating is correct. water supply is isolated. 7. Ball valve operation. 12m Check, if ball valve needs re- A defective ball valve will cause the cistern to overflow. washering, isolate water supply and repair ball valve. On-lineCheck for leakage and Copy security.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 290 32-15 PACKAGED ELECTRIC WATER HEATERS Cistern type - continued

ITEM FREQ. ACTION NOTES 8. Presence of scale. 24m Drain down unit, remove The formation of scale affects heat transfer and inspection covers and inspect increases energy consumption. It also causes for scale and corrosion. De- overheating of the electrical element leading to failure. scale as appropriate or Corrosion will cause the bare electrical element to be replace heating element. exposed to water and hence will be unsafe.

9. Return to operation. 12m Refit all inspection covers, Check operation of all temperature controls and leave in refill heater and cistern. Turn full operation. on water supply to unit and check for leaks. Fit fuse and turn on electrical supply.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 291 33-01 HUMIDIFIER - Cold water evaporator, drum type

Any action taken should conform to HSE environmental health services requirements ACOP L8,2001. Note: In hard water areas more frequent maintenance may be required. ITEM FREQ. ACTION NOTES 1. Status. 3m Isolate electrically and hydraulically. Note: electrical isolation must meet HASAWA Electricity at Work requirements. 2. Rotor filter pads. 12m Closely inspect. Replace filter pads Report condition. If filter pads need replacement as necessary. it is necessary to first clean the rotor. On reassembly use new gaskets where necessary. 3. Water reservoir tank. 3m Flush and clean if necessary. 4. Connections and joints. 3m Check for leakage and make good any defects. 5. Wiring and flexible 3m Check for soundness. conduits. 6. Control and indicator 3m Check for correct functioning. lights. 7. Deposits and sludge. 3m Clean up and remove. Any sludge solids removed should be in sealed bags and any solutions used for cleaning must be flushed away before returning the unit to On-line Copyoperation. Environmental Regulations apply 8. Moving parts. 3m Check that all moving parts can move freely. 9. Motor gear box. 12m Change oil. See also MOTORS 10. Chain drives. 12m Lubricate. 11. Return to service. 12m Check operation. Ensure compliance with HSC ACOP L8,2001. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 292 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. ITEM FREQ. ACTION NOTES 1. Status. 3m Isolate electrically. Note: electrical isolation should meet HASAWA requirements. 2. Removal of deposits. 3m Clean and flush out. Note: If automatic time controlled flush out valve is fitted, check correct operation by overriding timer. It may be necessary from time to time to adjust between automatic flushing depending upon humidification requirements which can vary with the weather conditions. 3. Ball valve. 3m Check operation. 12m Clean and renew washer. 4. Water level. 3m Check level in gauge glass corresponds with indicator plate. 5. Humidistat. 3m Check operation, clean if necessary. Use a sling hydrometer to check accuracy of operation. 6. Misting sprays. 3m Observe spray pattern, clean if Clean with compressed air. Do not use wire or pointed necessary. objects as these will enlarge the orifices and lead to a poor misting pattern. 7. Control and indicator 3m Check for correct functioning. lights. On-line Copy 8. Steam traps. 3m Check operation condition of filters Ensure condensate drain is clear. and sight glasses. 12m Clean and overhaul traps, strainers Faults can lead to steam wastage, excessive condensate and sight glasses. Check by-pass and energy waste. Rust scale and solids can block valves are not leaking. strainer and render traps ineffective, regular cleaning is therefore essential Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 293 33-02 HUMIDIFIER - Direct steam injection type - continued

ITEM FREQ. ACTION NOTES 9. Steam pressure. 3m Check. 10. Strainer (where fitted). 3m Check strainer on steam supply. 11. Water supply. 12m Turn off at ball valve and empty via drain cock. 12. Steam chamber. 12m Remove out casing lid baffles. Ensure that any sludge or scale deposits are Remove any scale either physically or removed from the bottom of the steaming by using suitable chemical descaling chamber. Additional access may be provided on agent. the side of the vessel to facilitate cleaning. Environmental Regulations will apply 13. Feed water line. 12m Check that it is clear. 14. Re-assembly. 12m Ensure all joint faces are clean and reassemble using new gaskets. 15. Re-commission. 12m Put back into service and check water level in gauge glass corresponds with indicator plate, ball valve operates correctly, controls and indicator lights function On-lineproperly. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 294 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 environmental services requirements – ACOP L8,2001 ITEM FREQ. ACTION NOTES 1. Status. 3m Check and isolate both water and Note:- electrical isolation should meet electricity supplies. HASAWA and Electricity at Work requirements. 2. Steam cylinder. 3m Check all electrical connections on the cylinder for soundness and correct any defects. 3. Cylinder exchange. 3m As per manufacturer's instructions. Cylinder exchange times will vary - hard water areas 3 months. Soft water areas 12 months. 4. Water drain pump. 3m Check for free flow of water by This may require the removal of the cylinder. operating the pump. Repair any gland leaks. Check manual drain switch actuation. 5. Drain pipe. 12m Check for free flow, actuate drain if necessary. 6. Feed valve. 12m Clean strainer. Always replace the strainer after cleaning to On-line Copyprevent material lodging in the valve.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 295 33-03 ELECTRODE BOILER HUMIDIFIER - continued

ITEM FREQ. ACTION NOTES 7. Unit testing after cylinder 12m Set the controls to 'start' and operate Ensure all electrical and mechanical covers are in exchange. humidifier in its normal mode and their correct places. ensure the functions are correct and humidistat is functioning.

8. Fully automatic 12m Check output modulation. As per manufacturer's instructions. modulating type humidifier.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 296 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 environmental services requirements – ACOP L8,2001 ITEM FREQ. ACTION NOTES 1. Status. 3m Isolate electrically and hydraulically. Note: electrical isolation should meet HASAWA requirements. 2. Nozzles. 3m Clean dust and debris from outside of It is advisable to remove the air caps annually to nozzles. clean thoroughly. Take care not to damage the protective PTFE coating. 3. "Y" strainer. 3m Inspect and replace strainer screen. 4. Water pressure regulator. 12m Check condition and carry out Items which may need periodic maintenance maintenance in accordance with the include:- manufacturer's instructions. 2-way air solenoid valve, 3-way water solenoid valve, air pressure regulator. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 297 33-05 HUMIDIFIERS- Ultra sonic

Any action taken should conform to the HSE environmental services requirements – ACOP L8,2001 ITEM FREQ. ACTION NOTES 1. Status. 6m Isolate electrically and hydraulically. Note: electrical isolation must meet HASAWA and Electricity at Work requirements. 2. Water tank. 6m Clean out and refill.

3. Ultra sonic diaphragms. 6m Clean carefully with soft non-scratch cloth.

4. Ultra sonic generator. 12m Check operational efficiency as per The life of the ultra sonic generator will depend on manufacturer's instructions. Replace type of manufacture and the water quality. if necessary.

5. SEDIMENT REMOVAL. 1m Remove as necessary from top of A risk assessment and method statement reservoir. should be produced. PPE may be needed. Environmental Regulations apply. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 298 33-06 HUMIDIFIERS- Resistance heater type

In hard water areas more frequent maintenance may be required Any action taken should conform to the HSE environmental services requirements – ACOP L8,2001 ITEM FREQ. ACTION NOTES 1. Status. 12m Isolate electrically and hydraulically. Note: electrical isolation must meet HASAWA requirements. 2. Water boiling chamber. 12m Drain. 3. Resistance heater 12m Inspect and descale as necessary. element. 4. Scale collecting bag 12m Change as necessary. (where fitted). 5. Float valve, or solenoid 12m Check operation. valve on make-up line. 6. Control indicator lights 6m Check for correct functioning. (where part of humidifier). 7. Inbuilt step controller 3m Check for correct operation. (where fitted). 8. Operation. 3m Restore services and put unit back on On-lineline. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 299 33-07 HUMIDIFIER - Disinfection procedures

ITEM FREQ. ACTION NOTES 1. System. 6m Isolate electrically and hydraulically, if Isolation of electrical supply should be in not already isolated. accordance with HASAWA requirements.

2. Loose debris. 6m Allow humidity water to drain, remove solid debris with 'wet and dry' vacuum cleaner.

3. Humidifier sump. 6m Check condition and repaint as necessary, Check integrity of in-fill humidifier medium and replace if worn, damaged or heavily scaled.

4. Disinfection. 6m Refill system with clean fresh water, Ensure drain valve closed during refill. disinfect system with addition of Note:- Free chlorine is rapidly absorbed by sodium hypochlorite solution to organic matter and partially lost when the achieve free residual chlorine reserve chlorinated water cascades through the infill of 15 mg/l, maintain circulation for four matter, thus further additions of sodium hours. hypochlorite may be required to maintain the free On-line Copychlorine reserve at 15 mg/litre. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 300 33-07 HUMIDIFIERS - Disinfection procedures - continued

ITEM FREQ. ACTION NOTES 5. Return to service. 6m 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 15 mg/l. Refill sump if unit to be put back into service immediately.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 301 34-01 ICE MAKING MACHINES - general

ITEM FREQ. ACTION NOTES 1. Condition. 12m Empty, check for damage Report to client if remedial work required. and clean and disinfect. 2. Door seals (if fitted). 12m Check condition, refurbish or Poorly fitting door seals can lead to either ice melting or replace as necessary. fusion of ice pieces and energy wastage. 3. Cold water pipework. 12m Clean, disinfect and check condition of insulation. 4. Valves. 12m Check action and maintain as appropriate volume. 5. Controls. 12m Check action. For details see relevant section – CONTROLS. 6. Drains. 12m Check for blockage, clear if necessary and disinfect. 7. Refrigeration unit. 12m Check operation. For more detailed maintenance procedures, see – CHILLERS. 8. Return to service. 12m Return to ice making and check level sensors and other appropriate controls On-linefunction properly. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

302 35-01 INSULATION

WARNING: Insulation may contain asbestos. Broken Insulation may be dangerous and if in doubt do not start work and inform your supervisor and client.

ITEM FREQ. ACTION NOTES 1. Pipe lagging. 12m Check for dampness and broken Broken & damp insulation washers energy and condition should be repaired as soon as possible. 2. Boiler lagging. 12m Check for broken condition and repair if necessary.

3. Pump sound deadening 12m Check for asbestos. Inform client if asbestos is found. lagging.

On-line Copy 303 36-01 LIGHTING

Introduction

The design and installation of lighting systems should be in accordance with the CIBSE Code for Interior Lighting and to ensure that 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 scheduleOn-line may be the most sensible option and thisCopy should be agreed with the client. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 304 36-02 LIGHTING-SWITCHES-INTERNAL AND EXTERNAL

ITEM FREQ. ACTION NOTES 1. Operation. 12m Check action. This includes pull switches and remote operated sensor (i.e. infra-red) switches. 2. Earth bonding. 12m Check and correct if defective. 3. Dimming switches. 12m Check operation. 4. Solar operated switches 12m Clean detector surface. (external and internal). Check: switching function, sensitivity. Note: sensitivity of solar radiation detection cell may fall with time and should be replaced if sensitivity has fallen below manufacturer's recommended limit. 5. Fireman's switch (external 12m Check action. display lighting).

6. Automatic switching controls 12m Check operation and time Adjustments for BST should be made by the (e.g. timers). settings. client on the appropriate dates. For external lighting regular adjustments should be made to compensate for changes in daylight hours. This On-line Copywill reduce energy wastage. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 305 36-03 LIGHTING FITTINGS including LUMINAIRES – general

ITEM FREQ. ACTION NOTES 1. Cleanliness. 12m Clean fittings where Frequency of cleaning will depend on environment, in dirty areas necessary. more frequent cleaning may be necessary. Contract should state whether this is part of the maintenance contract. 2. Lamps 12m Check for failed lamps or Tungsten filament lamps are inefficient with regard to energy use a) tungsten filament. signs of deterioration. and could be replaced with more efficient lamp types. Replace as required. b) fluorescent. 12m Clean and replace any failed Care should be taken in handling as broken glass from broken or suspect lamps. tubes/lamps can be dangerous. Disposal of tubes/lamps should be in accordance with H&S and Environmental regulations.

c) discharge. 12m Clean and replace any failed In readily accessible areas failed lamps should be replaced as or suspect lamps. soon as possible to avoid damage to control gear. Re-lamping - maintenance contract should be specific with regard to the responsibility for the provision and/or replacement of lamps. 3. Security of fitting. 12m Check security fixings and suspensions. 4. Cable terminations. 12m Check externally for security To be checked by agreed sample. and signs of arcing or overheating. 5. Flexible down 12m On-lineCheck for deterioration renew Tighten Copy or secure as necessary. leads and if necessary. connectors. 6. Diffusers and 12m Clean and correctly adjust reflectors. before re-assembly. 7. Lamp control gear. 12m Check operation and compatibility with lamp. 8. Switches. 12m Check operation. Replace if faulty. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 306 36-04 EXTERNAL LIGHTING including ILLUMINATED SIGNS

WARNING : Equipment may operate at voltages above 415 and extra precautions should be taken. ITEM FREQ. ACTION NOTES 1. Condition. 6m Clean and check: On plastic surfaces avoid a build up of static For physical damage. which will re-attract dirt. Cleaning materials Signs of water ingress or should be compatible with sign fabric. condensation, if present check seals and report to client. If evidence of need for re-painting observed, notify client. 2. Electrical wiring. 12m To be checked by agreed sample

3. Earth continuity. 6m Check and remedy if necessary. 4. Lamps or tubes. 12m Check for failed or blackened Replacement procedures should be agreed with tubes or lamps. Replace as the client as recommended life can vary with necessary. 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. 5. Cold cathode tubes. 12m Check for faulty tubes of low Disposal and re-processing of tubes brightness. Replace or re- (particularly mercury tubes) should be in process as necessary. accordance with statutory regulations. Where On-line Copyreplacement of a single tube reveals a loss of brightness in the remaining tubes, consideration should be given to block replacement or re- processing. In-fill gas mixture of replacement tubes must be compatible with the circuit design.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 307 36-04 EXTERNAL LIGHTING including ILLUMINATED SIGNS - continued

WARNING: Equipment may operate at voltages above 415 and extra precautions should be taken. ITEM FREQ. ACTION NOTES 6. Control gear. 12m Check for correct operation. Replacement equipment must be compatible with that removed. Replacement cold cathode transformers should be re-calibrated to the design mA output.

7. Security of fittings. 12m Check condition and security. If corrosion has occurred, inform client of need for re-painting or replacement.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

308 37-01 EMERGENCY LIGHTING – self contained

Emergency lighting levels in existing installations may have to be upgraded to comply with any legislation. ITEM FREQ. ACTION NOTES 1. Testing. 1m To be carried out monthly in Client’s operators should be trained to carry out accordance with BS5266: Part monthly tasks. 1:1988. All tests shall be logged as per Appendix C of BS5266.

6m Test for on hour. If luminaire rated for duration of one hour, test simulating failure (ideally by test key or other suitable means) should be of 15 minutes duration.

12m Test for three hours. The once per year test is for the full duration of the battery and is best carried out when there is least risk to persons is the building i.e. late on Friday, as the battery packs require a twenty-four hour charge to provide the three hours emergency light.

2. Operation. 1m Check operation, if failure is If fault is not with lamp check that the mains LED suspected replace lamp. is on with the mains supply restored, if not, report to client. Responsibility for monthly check should On-line Copybe agreed with the client.

3. Battery. 12m Check condition and date of Normal life expectancy is five years. Batteries expected life. Renew if necessary. should be disposed of in accordance with H&S and environmental Regulations.

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

309 37-02 EMERGENCY LIGHTING – externally powered

Emergency lighting levels in existing installations may have to be upgraded to comply with any legislation. ITEM FREQ. ACTION NOTES 1. Testing. 1m To be carried out monthly is Client’s operators should be trained to carry out accordance with BS5266:Part monthly tasks. 1:1988. All tests shall be logged as per Appendix C of BS5266. 2. Operation. 6m Energise from battery for period of If the system is rated for one hour, duration of test one hour. simulating failure (ideally by test key or other suitable means) should be fifteen minutes. 12m Test for one hour. The once per year test is for the full duration of the battery and is best carried out when there is least risk to persons in the building i.e. late on Friday.

1m Check operation, if failure is Responsibility for monthly check should be suspected replace lamp. agreed with client.

3. Battery. 6m Ensure terminals are clean and Follow manufacturer’s instructions at all times and check electrolyte level. Check advise client if battery replacement is required. condition of battery case(s). 4. Battery charger. 6m Check operation and proper If engine driven generator used, check electrical functioning. operation and connections. For prime mover refer On-line Copyto specialist maintenance engineer.

310 38-01 LIGHTNING CONDUCTOR AND EARTH

(Does not cover lightning strike prevention.) ITEM FREQ. ACTION NOTES 1. Conductor tape fastenings 12m Inspect roof and plant Look for evidence of corrosion in the and joints. connections, vertical joint material, this is more likely to occur where connectors and earth there is contact between two dissimilar termination positions. Ensure metals or where the atmosphere has the that conductor tapes are potential for a high degree of chemical secured firmly to the structure pollution. If renewal required, report to client. and all joints including those to structural and service steelwork are mechanically and electrically sound. 2. Earth terminations. 12m 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. 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 On-line Copycondition of the system. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

311 39-01 MOTORS - DRIVE ELEMENTS

Note: Before carrying out any work, check status and isolate in accordance with HASAWA and Electricity at Work requirements. This will normally require the engineer to follow a permit to work system. Dual motor systems should be treated as one. ITEM FREQ. ACTION NOTES 1. Mountings. 3m Check condition. Motor should run without any excessive vibration. 2. Motor casing. 3m Check ventilating louvres are clear. See also MOTORS 3. Bearings. 3m Lubricate where external nipples or Check annually bearing wear by measuring shaft lubricators are fitted. float and end play and replace lubricant in motor bearings. 4. Brushes. 12m Check condition and replace if necessary. 5. Windings. 12m Clean and test. 6. Terminals and 12m Check and ensure that they are connections. secure. 7. Rating. 12m Check motor running current. The running current should not exceed the full load value (FLC) shown on the motor data plate. 8. Variable speed drives 12m Refer to manufacturer. Faults and any special maintenance requirements and other solid state should be referred to the manufacturer as controls. specialised skills are needed to deal with this type of equipment. See CONTROLLERS – Speed On-line Copycontrollers. 9. Check, measure and record insulation resistance 10. Check, measure and record earth continuity

312 40-01 PIPEWORK SYSTEMS - General

ITEM FREQ. ACTION NOTES 1. Supports. 12m Check and tighten as necessary. Loose supports can lead to undue strain on pipework. 2. Valves and stopcocks 12m Check operation. Valves should be N.B. Carefully note the number of turns to (where normally open) fully closed and then fully opened. fully close, so that valve can be reset to its Lubricate as necessary. original position. If operation of valve stiff, repeat operation until clear and then return valve to its original position. 3. Regulating valves. 12m Do not adjust unless alterations or If alterations to the pipework have been made it additions to pipework have been will be necessary to recommission the system. made. 4. Double regulating valves. 12m Check operation. Settings should not be altered, but they can be used for regulation. 5. Glands. 12m Rectify any leakages. For severe leakage, immediate emergency action will be necessary. For regulating valve see action 3 above. 6. Anchor points and guide 12m Check for security of fittings. assemblies. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 313 40-02 PIPEWORK SYSTEMS - Mountings

ITEM FREQ. ACTION NOTES 1. Slackness in nuts, screws 3m Check and tighten as necessary. Loose mountings can lead to undue strain on and bolts. joints and vibration can result. 2. Fastenings. 3m Check for corrosion. Replace any bolts that show signs of corrosion or where corrosion has made the nut a loose fit. 3. Screw heads. 3m Lubricate where exposed. Lubrication prevents corrosion and facilitates the removal of plant for overhaul and repair. 4. Anti vibration mountings. 3m Inspect for permanent set (in springs). Report to client if replacement necessary. If Renew as a matched pair. replaced, ensure that the correct type is used. 5. Rubber blocks and mat. 3m Check for shearing and cracking Report to client if replacement is necessary. under load. 6. Alignment of plant, ducts 3m If any mountings are found to be or pipe connections. suspect check alignment. 7. Strainers. 12m Clean. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 314 40-03 PIPEWORK SYSTEMS-TRACE HEATING

ITEM FREQ. ACTION NOTES 1. Local isolator. 3m Check operation. 2. Connections. 3m Check all connections are clean and tight. 3. Weather proof seals. 3m Check condition and remake as necessary. 4. Insulation. 12m Check for damage and integrity. 5. Controls. 12m Check functioning of controls. For more detailed maintenance of thermostats, frost protection etc., see relevant section. 6. Operation. 12m Check and record the current If the current drawn differs from the normal value drawn. investigate and report to client. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 315 40-04 CHILLED WATER-CONDENSER WATER PIPE SYSTEMS

This section relates to the circulation of chilled water and cooling water and covers pumps and the associated pipework. Fouling of internal surfaces with scale will reduce efficiency and lead to the waste of energy hence regular water treatment is necessary and the equipment to perform this task should be regularly maintained.

CONDENSATE TRAYS AND PIPELINES

ITEM FREQ. ACTION NOTES 1. System. 6m Isolate electrically and hydraulically. Isolation of electrical supply should be in accordance with HASAWA requirements. 2. Loose debris. 6m Remove using wet and dry vacuum Ensure that adequate air-break exists between cleaner. condensate trap and drain to prevent siphoning. 3. Condensate Tray 6m Check condition and repaint as necessary, Close condensate trap and fill tray to maximum with clean fresh water. 4. Disinfection. 6m Disinfect tray and trap with addition of Note:- Free chlorine reserve should be sodium hypochlorite solution to maintained at a level of 15mg/litre for four hours. achieve free residual chlorine reserve of 15 mg/litre.

5. Return to service. On-line6m Drain and thoroughly flush trayCopy and trap until no water remains in condensate tray. Refill trap with fresh water. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 316 40-05 CONDENSER - CHILLED WATER CIRCULATING PUMPS

Warning - Never run pump without water in it and/or with valves closed. If any electrical maintenance is to be carried out system should be capable of electrical isolation in accordance with HASAWA. ITEM FREQ. ACTION NOTES 1. Motor and pump. Report any abnormal conditions immediately to client. i. connections, 1m Check for leaks. ii. bearings, 1m Check bearings are not running Normally bearing temperatures should be excessively hot. between 15° C and 45° C but up to 65° C is acceptable. iii. noisy running. 1m Report to client. See also MOTORS 2. Isolation valves, strainers 1m Check for leaks. and flexible connections. 3. Pump lubrication. 3m Check and lubricate as necessary. Refer to manufacturer's literature and only use recommended lubricants. 4. Pump and motor casings. 3m Inspect and clean.

5. Electrical terminals. 3m Inspect and tighten as required. 6. Motor running current. On-line3m Check and record. Copy 7. Wiring, insulation and 3m Check condition. flexible connections.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 317 40-05 CONDENSER - CHILLED WATER CIRCULATING PUMPS - continued

ITEM FREQ. ACTION NOTES 8. Electrical starter 12m For detailed information. maintenance:- a) circuit breaker 12m Inspect and clean all contact surfaces. contacts, b) enclosures, switches 12m Check and clean. and push buttons,

c) wiring and 12m Check condition, secure and tighten Look out for broken wire strands, pinched or connections, and as required. damaged insulation. flexible conduits. 9. Seals and bearings. 12m Check condition, adjust or replace as necessary. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 318 40-06 PRESSURISATION UNITS - CHILLED WATER

Note:- Checks on pressurisation equipment should only be carried out by trained personnel.

ITEM FREQ. ACTION NOTES 1. Diaphragm expansion 6m Isolate and drain, check cushion Ensure diaphragm is in good condition, if tank. pressure. necessary remove diaphragm for inspection and report condition. Repair or replace diaphragm. Check internal surfaces, report on condition, remove any sharp edges, Re-assemble, re-charge to correct cushion pressure. 2. Pressurisation unit. 6m Check closed valve pressure and If necessary, dismantle, clean internal passages, pump capacity, inspect mechanical seal and renew any parts as necessary. Remove and clean pressure reducing valve filter. Check pressure setting, Dismantle and clean suction non- return valve, Clean any debris from mains break Inspect set thoroughly for general condition, tank and if necessary, clean and report any signs of rusting, damage or other On-linelubricate ball valve. Copydefects. Check and if necessary adjust hydraulic accumulator cushion pressure. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 319 40-06 PRESSURISATION UNITS - CHILLED WATER - continued

Note:- Checks on pressurisation equipment should only be carried out by trained personnel.

ITEM FREQ. ACTION NOTES 3. External controls. 6m Check setting of high and low Ensure high and low pressure cut-out switches pressure cut-out switches. interrupt boiler(s) control circuits. 4. Re-commissioning. 6m Adjust setting of all cushion pressures, Leave system for immediate operation if required. pressure switch and pressure reducing valve settings to conform with above design information.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 320

40-07 PNEUMATIC EQUIPMENT – COMPRESSED AIR SYSTEMS - Introduction

For efficient operation of air operated control equipment such as control valves, relays and actuators a supply of clean dry, oil 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.

From the first of July 1994 all parts of the Pressure Systems and Transportable Gas Containers Regulations 1989 will have taken effect. From this date a written scheme of examination will need to be provided for the periodic examination of the whole system. The written scheme must be drawn up by a ‘competent person’. Refer also to HSG 39 Compressor Air Safety.

Regular maintenance of the instrument air compressor is essential and particular attention should be paid to the performance of the air drier and oil separator.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 321 40-08 AIR COMPRESSORS

It should be noted that to ensure dry, clean, and oil free air there are a number of daily and weekly tasks which the plant operator must carry out as part of his duties. These include condensate drainage, pressure drop checks across filters, oil contamination checks and audible leaks. ITEM FREQ. ACTION NOTES 1. Capacity Test. 12m Pump up receiver from zero Any marked difference from the manufacturers atmospheric pressure to working specification may indicate leakage or compressor pressure and note time taken. faults. 2. General Conditions. 12m Check the following: condition of guards, interstage cooler drains, bearers and holding down bolts, hand operated valves, moisture traps. Check for tightness of glands and seats. 3. Status. 12m Switch off and isolate electricity. Note: Electrical isolation should be carried out according to the HASAWA. 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 On-line Copycompleted before the receiver is returned to service. 4. Oil. 12m Note level and change using recommended lubricating oil. 5. Belt and Drive. 12m Check tension and condition of belts Ensure spare belts are available. and drives Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 322 40-08 AIR COMPRESSORS - continued

ITEM FREQ. ACTION NOTES 6. Condensate removal. 12m Check condensate drainage system Note: This should be checked daily as part of and clean as necessary. the normal in house maintenance procedures. The condition of the condensate is an indication of the condition of the compressor.

7. Pressure relief valve. 12m Operate and check valve for condition, operation, setting and leak tightness. Adjust if necessary. 8. Air filter. 12m Clean. Poor condition can indicate main air intake problems. 9. Electrical connections. 12m Check and tighten all connections. For associated equipment, see – MOTORS, Check condition of wiring and PUMPS, FANS. insulation. 10. Gauges. 12m Check operation. Defective gauges should be reported with a recommendation that they be replaced. 11. Pipes and connections. 12m Check external condition and leak With soldered or brazed joints, these may have tightness. to be remade. To prevent internal scaling use dry, oxygen free nitrogen (OFN) during the Tighten connections as necessary. On-line Copyjointing process. 12. Controls. 12m Check operation of pressure switches and auto change over solenoids. 13. Offloaders, mechanical 12m Check operation. and electrical. 14. Main air intake air quality. 12m Check air source for possible If air quality affected by location of intake, report contamination and dangerous gases. to client. Repositioning may be necessary. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 323 40-09 AIR COMPRESSORS – Compressed air dryers

ITEM FREQ. ACTION NOTES Refrigeration type. 1. Pipe connections. 3m Check for leak tightness, remedy as necessary. 2. Electrical wiring and 12m Check condition and contacts. Make conduits. good as necessary. 3. Discharge air dewpoint. 12m Measure and record. Compare with manufacturer’s recommended figures. 4. Condensate trap bowl. 3m Drain, clean with soapy water and replace.

5. Evaporator fins. 3m Clean and straighten. Report any severe damage. Water cooled after coolers. 1. Pipe connections. 12m Check for leaks. Water absorption type 1. Drying medium. 3m Remove from container, check Desiccants such as anhydrous calcium chloride, condition and treat as necessary. silica gel types or activated alumina, may On-line Copyrequire different treatment. 2. Cleaning. 3m Where applicable, dismantle and Items:- Insert casing-felt pads-perforated discs- clean with dry oxygen free nitrogen. spring-gauzes-strainers-cotton wool-‘U’ pin- Examine, test, refit or renew items external casing-desiccant as directed. listed under notes. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 324 40-09 AIR COMPRESSORS – Compressed air dryers - continued

ITEM FREQ. ACTION NOTES 3. Discharge air quality. 3m Check and record. a) air dewpoint, Too high a temperature can cause break-up of desiccants. b) air temperature. 4. Re-activation drying time. 3m Time change-over period. Compare with manufacturer’s recommendation. Water adsorption type 1. Cartridge. 36m Change complete container.

Continued on next page ..

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 325 40-09 AIR COMPRESSORS– Compressed air dryers - continued

ITEM FREQ. ACTION NOTES Compressed air network Note: The Pressure Systems and distribution Transportable Gas Containers Regulations will apply to the complete system. 1. Filter and pressure 3m Check particle filters and change as reducing station. required. Check oil filter and change as Presence of excessive oil indicates a need for a required. thorough examination of the compressor. Client Check pressure reducing valve should be advised. settings. Check low pressure safety valve. 2. Moisture drain. 3m Check operation If ‘autotype’, check level valve opens and closes outlet, if manual, check valve is not blocked. 3. Valves. 12m Check external condition, operation, leak tightness of glands and seats, spindles and handwheels. 4. Safety and reducing 12m Examine external condition check valves. operation, settings and leak tightness. 5. Drains and trap. On-line12m Check external condition, operationCopy and leak tightness. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 326 40-09 AIR COMPRESSORS– Compressed air dryers - continued

ITEM FREQ. ACTION NOTES 6. Filters and strainers. 12m Check external condition, operation and leak tightness. 7. Gauges. 12m Check operation, condition and leak Any defective gauges should be reported with a tightness. recommendation that they be replaced. 8. Pipes and connections. 12m Check external condition, and leak Pay particular attention to supports, hangers tightness. Ensure correct ‘sign-writing’ and brackets. Uncontrolled vibration can lean to (colour coding). pipe breakage. 9. Pipe insulation. 12m Check condition of insulation on drain legs, etc. and make good if defective.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 327 40-10 FUEL SUPPLY FOR LOW PRESSURE GAS (LPG) OR OIL

ITEM FREQ. ACTION NOTES 1. Pipework. 12m Check for leaks. Check sleeves and physical soundness. Check all ends are suitably plugged/capped. 2. Valves. 12m Check for soundness and leakage. See also VALVES in relevant section.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 328 40-11 STEAM SERVICES

ITEM FREQ. ACTION NOTES 1. Hangers and 12m Check for breakages or damage. Undetected broken hangers can lead to undue strain supports. on pipes and possible breakage or sagging which can lead to waterlogging. 2. Valves and flanges. 12m Check for leakage, replace Where insulated, check valve boxes for sign of packing if necessary. 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. 3. Insulation. 1m Check for damage and loss of Damage is often caused by ladders, feet or emergency protection. Renew if necessary. repairs - in open air insulation can become waterlogged and ineffective. N.B. Asbestos Regulations may apply. 12m Remove flange and valve covers, Hidden corrosion can cause equipment failures which inspect for corrosion. can lead to unscheduled plant shutdowns. 4. Valves on drain legs 12m Check operation. If not working can lead to waterlogging of steam mains, of mains. slow start ups and overloading of steam traps and poor heat transfer. 5. Operation of steam 1m Check operation, condition of Faults can lead to steam wastage, excessive traps. filters and sight glasses. condensate, poor heat transfer in associated equipment and energy wastage. 12m Clean and overhaul traps, Rust, scale and solids carryover can block strainers strainers and sight glasses. and render traps ineffective, regular cleaning is Check by-pass valves are not therefore essential. On-lineleaking. Copy 6. Vents on steam lines. 12m Check operation. Presence of air in steam reduces efficiency of heat exchangers.

7. Steam valves. 12m Renew packing on stems and Wisps of steam escaping soon lead to bigger leaks flanges where necessary. which cause scoring of stems and flanges leading to early replacement. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 329 40-11 STEAM SERVICES - continued

ITEM FREQ. ACTION NOTES 8. Condensate services. 1m Check for pressure of continuous Condensate if uncontaminated is valuable and should discharge of steam. If present not be allowed to run to waste but should be returned check steam trips. to the boiler if economical to do so.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 330 41-01 PNEUMATIC RELAYS Electric to pneumatic, pneumatic to electric and pneumatic to pneumatic. ITEM FREQ. ACTION NOTES 1. Input signal(s). 6m Check. ] 2. Output signal(s). 6m Check. ] By CONTROLS SPECIALIST 3. Operation. 6m Check for correct relationship between ] input and output signals.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 331 42-01 PORTABLE EQUIPMENT PAT TESTING It is a requirement of the Electricity at Work Act 1989 (Regulation 4(2)) that portable electrical equipment should 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. ITEM FREQ. ACTION NOTES 1. Plug tops. 12m Examine for: Note: Details should be entered on the portable cracks, appliance test register. Where plug tops are accessible loose terminals, by children, the use of shrouds on the plug top pins is reverse polarity, mandatory. tightness of cord grip, Note and report the use of any extension leads or correct fuse, multi-way adapters. Client should be encouraged to earthing and bonding, make monthly checks. loose tops, any other defect. 2. Cables. 12m Examine flexible cables for wear, If replacement necessary, report to client. fraying braids and brittle insulation. Check colour coding. 3. Detachable mains 12m Check electrical condition and lead. security of attachment. 4. On-off switch. 12m Inspect and check action.

5. Insulating case. 12m Inspect and check for damage. If double insulated, makers mark should be visible, if in doubt carry out flash test. Note: All double insulated equipment must be tested at least once every four On-line Copyyears. 6. Accessible fuse 12m Inspect and check rating. holders. 7. Exposed output 12m Check condition, for outputs Short circuit currents should be less than 5mA, if connections. greater than 50V test short circuit greater than 5mA, equipment should be labelled current. ‘Unsuitable for use by children’ where GS23 of the Electricity at Work Regulations 1989 applies. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 332 43-01 POWER GENERATION

Introduction

Many premises have standby power generation equipment to provide back up in the event of incoming power failures and there has been 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, and an electrical generator with associated equipment and may include mains synchronisation. This specification covers primarily the electricity generation and control equipment and, except for simple tasks, the maintenance of the prime mover should be carried out by specialist firms.

A similar position arises with small scale combined heat and power units which are being introduced to many sites, here the equipment 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.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 333 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. ITEM FREQ. ACTION NOTES 1. Condition. 6m Visually inspect for oil leaks, These checks should be carried out monthly by loose guards etc. client's operators. Check: coolant level,

oil level,

2. Drive belts. 6m Check fan and alternator drive These checks should be carried out monthly by belts for wear, tension and client's operators. alignment.

3. Shut down switches. 6m Check operation of low oil and high coolant shutdown switches. 4. Low water switch. 6m Check operation. 5. Coolant. 6m Check coolant level. pH (acidity) and SG (specific gravity) should be checked regularly by the operator. 6. Injector pump drive belts. On-line12m Check wear and tightness. Copy 7. Operation and auto-change 12m Check operation and starting facility (where applicable). sequence. 8. Sump heater. 12m Check operation.

9. Fuel transfer pump. 12m Check operation. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 334 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. Note: This section is based on the requirements of the Code of Practice BS6133 and all tools used for maintenance must be insulated. Risk assessment and method statement must be carried out. PPE may be needed. ITEM FREQ. ACTION NOTES 1. Cells. 12m Test and record specific gravity Cells should normally be checked on a monthly of electrolyte and top up if basis. necessary. Cell and connector covers should be replaced immediately work is completed. 2. Connections. 12m Clean, check for tightness and correct termination. 3. Fuses. 12m Check that rating is correct. 4. Capacity test. 12m Carry out test in accordance Record details of test. with manufacturer's instructions.

5. Ventilation. 12m Check that ventilation of battery Report to client if remedial action is required. space is adequate. 6. Battery stand(s) (if 12m Check condition. applicable). On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 335 43-04 BATTERY CHARGING EQUIPMENT

ITEM FREQ. ACTION NOTES 1. Condition. 12m Check all external and internal All ventilation holes and slots should be clear to dust from the equipment. Check prevent overheating. paintwork for damage or corrosion, clean and repaint as Cause of corrosion should be determined. necessary. Check security of door fastenings and lock. 2. Insulation. 12m Inspect for damage or signs of overheating and make good. 3. Equipment. 12m Check for damage or signs of overheating, check all items are securely fixed. 4. Contacts. 12m Clean and smear lightly with Renew any contacts showing signs of petroleum jelly. Clean shrouds overheating. (if fitted). 5. Cable terminations. 12m Check for tightness. 6. Earth connections. 12m Check for tightness. 7. Conduit and gland 12m Check for tightness. terminations. On-line Copy 8. Indicator lamps. 12m Check operation and functions. 9. Ammeter and voltmeter. 12m Check operation. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 336 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 must be 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. ITEM FREQ. ACTION NOTES 1. Cubicle. 6m Check condition and clean, All dirt and foreign bodies should be removed. 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. Check shrouds are in position, Shrouds should be fitted over terminals of electrolytic capacitors if visible with doors open and where live conductors are in proximity to operational devices. Check indicator lamps and lenses, replace as necessary. 2. Fuses and MCBs. 6m Check for correct rating of fuses and settings and operation of MCBs. 3. Relays, contactors and On-line6m Check for burn marks andCopyReplace as necessary. wiring. tightness of connections.

4. Earthing. 6m Ensure all sub assemblies with Where star washers are used for earth connections electrical components mounted make sure earth connection is good. on are adequately earthed. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 337 43-05 UNINTERRUPTIBLE POWER SUPPLIES - continued

ITEM FREQ. ACTION NOTES 5. Rectifier. 6m Switch on and check: Check and record calibration of all meters on the Battery trickle charge voltage, equipment. Battery charge voltage level.

6. Rectifier alarms. 6m Check and record 'pick-up' and 'drop out' voltages of all alarm relays. 7. Rectifier waveform. 6m Check and record. 8. Inverter. 6m Switch on and check the Compare with voltages recorded on test Inverter Control Unit control certificate. voltage. When operating Record the results and report any significant correctly, check and record the differences. output voltage and frequency. Check and record the calibration of all meters. 9. Inverter alarms. 6m Check for correct operation and check 'pick-up' and 'drop out' voltages of all AC and DC alarm relays. 10. Inverter wave forms. On-line6m Check and record the Copyoutput waveform. 11. Static power switch. 6m Check operation with both rectifier and inverter switched on. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 338 43-05 UNINTERRUPTIBLE POWER SUPPLIES - continued

ITEM FREQ. ACTION NOTES 12. Output. 6m Check: inverter output voltage and frequency, bypass voltage and frequency, load transfer, load voltage and power. Measure and record.

13. Batteries. a) lead acid, 6m Check condition. See POWER GENERATION BATTERIES. b) other types. 6m Check condition and report to client Batteries should be disposed of only in if replacement is required. accordance with H&S and Environmental Regulations recommendations. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 339 44-01 POWER SUPPLIES

Introduction

The section on Power Supplies covers all those aspects of providing power to the point of use and includes switchgear, cables and 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.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 340 44-02 MAIN SWITCH PANEL AT SUPPLY INTAKE

ITEM FREQ. ACTION NOTES 1. Panel exterior. 12m Check for physical or mechanical damage. Touch up paintwork after removing signs of corrosion. 2. Busbars. 12m Check for visible signs of overheating, loose connections etc. Check integrity of busbar Use torque spanner to manufacturer's settings. connections and tap-off Check electrical impedance with approved test connections. equipment. 3. Phase balance and loading. 12m Check and report if phases are Unbalanced phases and overloading can lead to unbalanced or overloaded. over-heating of switchgear and cabling. 4.a) Main ACB. 12m Check switching mechanism, Clean and lubricate as necessary.

Check both mechanical and Clean and lubricate as necessary. Check electrical interlocks, tripping and intertripping via test facility or current injection facility. Check isolation and withdrawal Clean and lubricate as necessary. On-linecarriage if applicable, Copy Check condition of isolatable Clean and lubricate as necessary. contacts, Check operation of shutter Clean and lubricate as necessary. mechanism, Check dashpot oil levels. Top up or renew as necessary. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 341 44-02 MAIN SWITCH PANEL AT SUPPLY INTAKE - continued

ITEM FREQ. ACTION NOTES b) Main fuse switch. 12m Check switching mechanism, Clean and lubricate as necessary.

Check contact blades, Trim or replace if pitting or wear is evident. Check terminations for tightness, Check fuse rating against switch Renew if incorrect rating is in use. rating and/or circuit chart. c) Main MCCB. 12m Check cable and busbar Use torque spanner to panel manufacturer's connections. settings. Check electrical impedance with approved test instrument. Check circuit breaker switch contacts (where accessible). Check auxiliary equipment Check for remote trip, undervoltage etc. as connections and settings. appropriate. Check overcurrent and earth fault settings against records. d) Main isolator. 12m Check switching mechanism. Report any variation. On-lineCheck contact blades forCopy signs Clean and lubricate as necessary. of overheating or burning. Check cable and busbar Trim and lubricate as necessary. connections. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 342 44-02 MAIN SWITCH PANEL AT SUPPLY INTAKE - continued

ITEM FREQ. ACTION NOTES 5. Instrumentation For specialised maintenance of instrumentation see – CONTROL PANELS. a) ammeters/voltmeters, 12m Check for accuracy and operation. b) selector switches, 12m Check for operation. c) indicator lamps, 12m Replace failed indicator lamps. d) protective relays 12m Check settings against records. Report any variations. Check operation by injection test. 6. Insulated phase barriers. 12m Ensure that they are in place and free from contamination. 7. Cabling terminations. 12m Check all neutral, earth and auxiliary connections and terminations. 8. General. 12m Check for presence of moisture, Report to client if significant. Remove any build up of dirt or other contaminants, On-line Check that appropriate Copy labels and warning notices are clean and in place. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 343 44-03 MAXIMUM DEMAND and POWER FACTOR CORRECTION

Where electricity is purchased under a tariff incorporating maximum demand (kVA) charges, attention should be paid to the half hourly maximum demand indicator usually incorporated with the electricity supply meter. Control of maximum demand should be considered where there is evidence of excessive peaks as this will reduce the need to bring on line inefficient peak load plant which leads to energy wastage. Apart from bringing on loads at peak times a further contribution to a high maximum demand could be a poor power factor usually caused by inductive loads such as electric motors, fluorescent lamps, inverters etc. To avoid this unnecessary waste power factor correction equipment is normally installed.

ITEM FREQ. ACTION NOTES 1. Maximum demand controller 12m Check operation. This action should normally be carried out in the (if fitted). summer months when maximum demand charges are not incurred. 2. Power factor correction 12m Check each capacitor bank is This may be a central facility or attached to equipment (if fitted). working. individual large machines. Check installed capacity is A check should be made for additional electric adequate for installed load. loads which have been installed since the original equipment was introduced or upgraded as the power factor correction equipment may be no longer adequate to give the required power factor. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 344 44-04 ARMOURED CABLES AND CONDUITS

ITEM FREQ. ACTION NOTES 1. Armoured cables. 12m Check for physical damage and signs of Overstressing of the conductor can corrosion. occur if the radius of curvature at a bend in the cable is too great. 2. Conduits. 12m Check: Condition and signs of corrosion. Security of fastenings. Attachment of earth tags. Earth continuity. Sealing where conduit penetrates wall, cable box or cabinet.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

345 44-05 POWER DISTRIBUTION UNIT (PDU)

Caution: 1. Before commencing any maintenance work on PDUs read the notes in the Introduction. 2.Work should only be carried out by Competent persons . 3. All work should be subject to risk assessment and formal method statements 4. Prior testing care should be taken to isolate voltage sensitive equipment. ITEM FREQ. ACTION NOTES 1. Panel exterior. 12m Check for physical or mechanical damage. Touch up paintwork after removing signs of corrosion. 2. Mains isolator 12m Check for correct operation and interlock. (Door isolator) Check main switch blades, for signs of overheating or Trim and lubricate as necessary, burning. replace if badly worn.

3. Busbars. 12m Check for visible signs of overheating, loose connections etc. Check integrity of busbar connections and cable tap-off Use torque spanner to manufacturer's connections. settings. Check electrical impedance with approved test instrument.

4. Insulating barriers. 12m Check that insulating barriers are in place, particularly over incoming terminals. Continued on next page .. On-line Copy

346 44-05 POWER DISTRIBUTION UNIT (PDU) - continued

ITEM FREQ. ACTION NOTES 5. Power contactors. 12m check contactor for correct mechanical Damaged contacts should be redressed or and electrical operation. replaced as necessary. Use approved contact strip and clean interior. lubricant as recommended by manufacturer. Inspect and clean magnetic pole faces. Check moving contacts for wear or 'pitting', Check coil for overheating or insulation Use approved contact lubricant if recommended breakdown, by the manufacturer Clean out arc chutes. On re-assembly check all electrical connections. 6. Starters, Frequency of maintenance will vary depending on starting duty/frequency of unit but in no circumstances should it exceed twelve months. - direct on line, 12m Carry out maintenance as for power contactors. -star delta, -two speed-dual } wound, } -two speed-pole } change, } See relevant sections -reversing, } -auto transformer On-line Copy} -quick transition, } electric heater and } electrolytic types, -air break, -inverter starters. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 347 44-05 POWER DISTRIBUTION UNIT (PDU) - continued

ITEM FREQ. ACTION NOTES 7. Thermal overloads. 12m Inspect for signs of overheating, Replace if necessary after having Check electrical connections for tightness and established the cause and rectify it. security, Inspect trip settings. Adjust if necessary to give correct Operate the trip/test facility ensuring that the protection for the connected load. switchgear de-energises in a clean and positive Record settings. operation. Check for single phase protection by operating the starter.

8. Magnetic overloads. 12m 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, Use only manufacturer's Operate 'test' facility to ensure switchgear de- recommended fresh oil. Select correct energises in a clean and positive operation, dashpot drain hole if necessary. Inspect trip settings. Adjust if necessary to give correct protection for connected load. 9. Panel wiring. 12mOn-lineInspect for signs of overheating or burnCopy 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. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 348 44-05 POWER DISTRIBUTION UNIT (PDU) - continued

ITEM FREQ. ACTION NOTES 10. Fuses and/or miniature circuit 12m Check for damage, Ensure spare fuses are not 'blown', replace breakers (MCB). Check for correct rating, with correct rating schedule, if necessary. Check tightness of fuse link connections, Check free operation of MCB mechanisms, Check for evidence of overheating. Renew where necessary.

11. General. 12m Check for presence of moisture. Report to client if significant. Remove any build up of dust or any other contamination.

12. Instrumentation. 12m Check for accuracy and correct Compare with test instrument applied to same a) ammeters and voltmeters, operation. circuit. b) selector switches, 12m Check for operation. Replace as necessary c) indicator lamps. 12m Test for operation. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

349 44-06 EARTHING

ITEM FREQ. ACTION NOTES 1. Earth electrodes. 12m Check: Record details and compare with earlier Integrity of conductor, records as any deterioration may be Associated connections, gradual. Condition of electrode and soil. Resistivity of electrode may be affected by corrosion, damage or soil condition. 12m Test in accordance with method See BS 7671 the IEE wiring regulations. described in BS7430:1991. 2. Residual current devices (RCD) 3m Test using test button. Responsibility for this check should be agreed with the client. 12m Test with approved RCD tester. Operation should be within 200 milliseconds at rated current output or within 40 milliseconds at 5 times the rated current. 3. Earth fault loop impedance test. 12m Frequency testing varies with In certain circumstances there are location. statutory/local frequencies for testing. Origin of the installation, Sub main switchboards Test random selection with a minimum of /distribution boards, two per circuit of which one shall be the Final circuit distribution boards, socket-outlet which is electrically the most Socket outlet circuits, remote from the distribution board. Lighting circuits, On-lineIsolated switches/control Copy devices for fixed appliances, Exposed conductive parts of fixed appliances. Continued on next page .. 350 44-06 EARTHING- continued

ITEM FREQ. ACTION NOTES 4. Main equipotential bonds. 12m Check visually and physically. Connections onto the main earth bar should be Any connections showing signs checked and tightened up, if necessary, with an of deterioration by chemical or approved torque spanner. electrolytic causes should be re- terminated and the new connection checked with a 'Ducter' test instrument. 5. Earth fault relays 24m Check: Represents maximum interval, actual dictated by environmental conditions. a) electromechanical availability of auxiliary trip supply Attention should be paid to fuses in tripping supplies (if applicable), particularly where no fuse supervision is provided. magnetic gaps for dirt and clean, contact surfaces, Do not use abrasives or file. time current characteristic curve at appropriate time and current setting, minimum current setting, dust filter, clean or replace as necessary. b) electronic relays 24m Routine maintenance not Regular checks on power available for tripping On-linegenerally required. Copyshould be made. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 351 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. ITEM FREQ. ACTION NOTES 1. Distribution board case. 12m Check for physical and mechanical damage, If moisture present check source and report. touch up paintwork after removing signs of corrosion. Check that door can be securely closed.

2. Cable insulation. 12m Check condition and inspect for signs of If possible identify cause of overheating and overheating. report. 3. Fuse carriers and MCBs 12m Check for damage, Ensure fuses are not 'blown'. Check rating(s), Replace with correct rating as per schedule if Check free operation of MCB mechanisms, necessary. Check for evidence of overheating. Renew where necessary. 4. Circuit charts. 12m Check for accuracy of descriptions. Ensure labels are securely fixed to exterior of door.

5. Cable terminations. 12m Check all phase, neutral and earth On-lineconnections and termination. Copy 6. Conduit and cable gland 12m Check for tightness. terminations. 7. RCDs. 3m Check operation via test button. Responsibility for this check should be agreed with the client. 12m Test with approved RCD tester. Operation should be within 200 milliseconds at rated current output or within 40 milliseconds at 5 times the rated current. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 352 44-08 RING MAIN and SUB CIRCUITS

ITEM FREQ. ACTION NOTES 1. Polarity and continuity. 12m Check. Carry out checks in accordance with IEE regulations. 2. Sockets. 12m Test action and polarity of Ensure shutters are functioning correctly. socket outlets. Damaged socket outlets must be replaced. 3. Earthing. 12m Check arrangements and test. Carry out checks in accordance with IEE regulations. 4. Insulation resistance. 12m Check. Carry out checks in accordance with IEE regulations. Spur outlets 1. Condition. 12m Check for physical damage. 2. Fuse rating. 12m If fused, check rating. Continued on next page .. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 353 44-09 THREE PHASE CIRCUITS

ITEM FREQ. ACTION NOTES Power outlets 1. Condition. 12m Examine for physical damage. 2. RCDs 3m Check operation via test button. Responsibility for this check should be agreed with the client. 12m Test with approved RCD tester. Operation should be within 200 milliseconds at rated current output or within 40 milliseconds at 5 times the rated current. Socket outlets 1. Condition. 12m Check for physical damage. 2. Fuse rating. 12m If fused, check rating for connected load. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 354 45-01 PUMPS - General

Checks on pumps should only be carried out by trained personnel. LPHW pumps should be checked frequently (typically weekly) for excessive noise or vibration, excessive seal leakage, and that the pressure differential is as required and that the casing is free from air. It may be appropriate to change over duty and standby pumps at the same time. Belt drives should be checked and adjusted as necessary (typically once per month), and anti-vibration mountings and flexible pipe couplings checked. Grease lubricated bearings intended for replenishments should be greased as recommended (typically every six months), taking care not to overfill. All maintenance activities should be logged. ITEM FREQ. ACTION NOTES General for all pumps. 1. Noise, vibration and 6m Check, rectify if possible and report. overheating. 2. Lubrication. 6m Lubricate bearings and motors. 3. Drives, pulleys, AV 6m Check and adjust where necessary. mounts and drive couplings. 4. Glands. 6m Inspect and adjust if necessary. Repack if required. 5. Suction line strainers. 6m Clean.

6. Pressure switches and 12m Check settings and test functionally. level controls. 7. Electrical connections. 12m Check. 8. Motor vent slots. On-line12m Clear. CopyUnder certain conditions e.g. a dusty environment, more frequent cleaning may be required. See also MOTORS) 9. Drive guards. 12m Check and rectify security. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 355 45-02 CIRCULATING PUMPS-general

ITEM FREQ. ACTION NOTES 1. Casings. 3m Inspect and clean as required. 2. Bearings and glands. 3m Inspect for wear, lubricate bearings and Report if defective. motors, repack glands as required.

3. Bolts, pulleys, couplings 3m Inspect and adjust as required. Replace and belts. belts if worn. 4. Pump pressures. 3m Check and record. 5. Strainers. 3m Inspect and clean as required. 6. Ball valves, float pressure 3m Check for proper operation and Check and record all temperatures. and temperature switches. calibration. 7. Motor electrical terminals. 3m Inspect and tighten as required. (See also MOTORS) 8. Full load running current. 3m Check and record. 9. Pulley(s). 3m Check and realign if necessary. 10. Isolation, regulation and 3m Check operation. Tighten glands or non-return valves. repack if necessary. 11. Drain and tundish. 3m Check for blockage, clean. 12. Anti-vibration mounts. On-line3m Check and clean. CopyGenerally report any defects to client. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 356 45-03 CENTRIFUGAL PUMPS

ITEM FREQ. ACTION NOTES 1. Casing. 3m Inspect for external condition and signs of leaks. 2. Glands and mechanical 3m Check external condition and leak If there are signs of leaks, tighten nuts or repack seals. rate. gland. Caution - do not over tighten. 3. Valves, cocks and drains. 3m Check externally for leaks. Rotate spindles and handwheels to check freedom of operation, examine drains for signs of gland leakage. 4. Strainers and exhausters. 3m Check external condition and freedom Check self priming action where fitted. of flow. 5. Belt drives. 3m Check for condition and alignment. Correct tensioning where necessary.

6. Couplings, pulleys, 3m Inspect and rectify any faults. guards and holding down bolts. 7. Isolation of pump from 3m Remove circuit supply fuses. For safety reasons pump should be isolated electrical and mechanical before commencing work. power. 8. Pump. On-line3m Drain down, and where applicable, CopyParts to be tested and adjusted include : glands strip, test and adjust parts listed in and packing, gland compression springs, lantern 'notes' column. Lubricate and grease. rings, seals, throwers, couplings, rubber sleeves and pins, nuts and spring washers. 9. Reassembly. 3m Test functionally. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 357 45-04 PRESSURISATION PUMPS

ITEM FREQ. ACTION NOTES 1. Pump base and 3m Ensure pump base is level and Check that anti-vibration mountings are connections. pipework not strained. satisfactory and vibration is not being transferred to the pipework. 2. Strainer elements. 3m Clean. 3. Pump and motor 3m Check and adjust if necessary. Examine couplings for tightness. alignment. 4. Motors and bearings. 3m Oil or grease where external nipples Use recommended grade of lubricant. or lubricators are fitted. Motor should be overhauled annually, see – MOTORS. 5. Drain holes, pipes and 3m Clean and ensure that all blockages tank. are cleared. 6. Guards and shields. 3m Check for security and safety. Adjust if necessary. 7. Control and safety 3m Inspect and check. These include low water level cut-out switches, switches. high and low pressure sensing switches, electrodes, connector caps and contacts. Report any defects to client. 8. Control, pressure relief 3m Test for correct operation and rectify Report any defects to client. and reducing valves, air any faults. vents, purgers and On-line Copy constant flow regulators. 9. Diaphragm expansion 3m Inspect. Ensure diaphragms are sound and air cushion tanks. pressure is correct. 10. Test run pressure booster 3m Carry out adjustments to ensure Check operation of all automatic controls and sets, pressurising units, satisfactory operation. change-over switches. and filling pump. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 358 45-05 ROTARY HAND PUMPS

ITEM FREQ. ACTION NOTES 1. Fixings and hoses. 12m Check security and leak tightness. Remedy any faults. 2. Operation. 12m Check functionality. Examine external condition and remedy any defects. 3. Inlets and outlets. 12m Check for obstruction and clear if necessary. 4. Dismantle. 12m Examine for wear and corrosion. Clean, repair or replace as necessary, the following: clack and ball valves, springs, diaphragms, seals, washers, gaskets, rotor, body and front plate. 5. Re-assembly and testing. 12m Check operation

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 359 45-06 SECONDARY HOT WATER CIRCULATING PUMPS

ITEM FREQ. ACTION NOTES 1. Casing. 6m Inspect and clean as required. 2. Bearings, glands and 6m Inspect for wear, lubricate bearings Report if defective. seals. and motors, repack glands as required. 3. Bolts, pulleys, couplings 6m Inspect and adjust as required. Ensure motor and drive and pulley are correctly and belts (where fitted). Replace belts if condition warrants it. aligned. See also MOTORS)

4. Pump pressures. 6m Check and record. 5. Strainers. 6m Inspect and clean as required.

6. Isolation, regulation and 6m Check operation. Tighten glands or non-return valves. repack if necessary. 7. Drain and tundish (where 6m Check for blockage, clean. fitted). 8. Anti-vibration mounts. 12m Check and clean. Generally report any defects to client.

9. Motor electrical terminals. 12m Inspect and tighten as required. 10. Full load running current. On-line12m Check and record. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

360 45-07 SEWAGE OR DRAINAGE PUMPS SUBMERSIBLE

Risk assessment and method statements are very important when carrying out maintenance of equipment contaminated by sewage and in terms of disinfection procedures, PPE, equipment and tools. ITEM FREQ. ACTION NOTES 1. Pump motor/s. 6m Check insulation value of For detailed maintenance schedule, see MOTORS. motor windings. Advise client if further investigation is required. 2. Pump/s. 6m Check pumping performance Visual observation of changing levels satisfactory. of all pumps. Withdraw pump from pit, Clean and report as necessary. 12m check impeller for wear and blockages. Check seal chamber oil. Renew if necessary. 3. Valves. 6m Check satisfactory operation See relevant section for more detailed information on of all isolating and non-return the maintenance of valves. valves. 4. Controls (operational). 6m Inspect and check. Report any defects to client. 5. Building management 6m Simulate every function to Reset after test, ensure that alarm and operational system controls. ensure satisfactory operation. information is transmitted to delegated terminal. For more detailed information about the maintenance of On-line CopyBMS see relevant section. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

361 45-08 SEWAGE and DRAINAGE PUMPS: DRYWELL

Risk assessment and method statements are very important when carrying out maintenance of equipment contaminated by sewage in terms of disinfection procedures, PPE, equipment and tools. ITEM FREQ. ACTION NOTES 1. Drywell. 6m Check for seepage, if Report any excessive seepage to client. necessary pump out. 2. Drywell high level alarm. 6m Check for correct operation. If defective, report to client as soon as possible. 3. Valves. 6m Check for satisfactory See relevant section for more detailed information on operation of all isolating and the maintenance of valves. non-return valves. 4. Pump(s). 6m Carry out maintenance. See – PUMPS- GENERAL. 5. Pump motor(s). 6m Check insulation value of For detailed maintenance schedule see - MOTORS. motor windings. Advise client if further investigation is required. 6. Level or pressure 6m Check settings and test Report any defects to client. controls. functionally. 7. Building management 6m Simulate every function to Reset after test, ensure that alarm and operational system controls. ensure satisfactory operation. information is transmitted to delegated terminal. For more detailed information about the maintenance of On-line CopyBMS, see relevant section. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

362 45-09 SEWAGE PUMPS: COMPRESSED AIR

Risk assessment and method statements are very important when carrying out maintenance of equipment contaminated by sewage in terms of disinfection procedures, PPE, equipment and tools. ITEM FREQ. ACTION NOTES 1. Air compressors. 6m Carry out maintenance, if For detailed maintenance schedule see – PIPEWORK necessary pump out. SYSTEMS. 2. Air receivers. 6m Carry out inspection and Note: The Pressure Systems and Transportable Gas maintenance. Containers Regulations apply. 3. Valves. 6m Check for satisfactory See VALVES for more detailed information about the operation of all isolating and maintenance of valves. non-return valves. 4. Ejector/diaphragm pump. 6m Lubricate all bearings, check Visual observation of changing levels satisfactory. pumping performance of all pumps. Withdraw pump from pit, Clean and report condition as necessary. 12m check diaphragm for wear or damage. 5. Controls (operational). 6m Check settings and test Report any defects to client. functionally. 6. Building management 6m Simulate every function to Reset after test, ensure that alarm and operational system controls. On-lineensure satisfactory operation. Copyinformation is transmitted to delegated terminal. 363 45-10 SUMP PUMPS: EXTENDED SHAFT

ITEM FREQ. ACTION NOTES 1. Motor. 12m Check insulation value of For detailed maintenance schedule, see MOTORS. windings, clean ventilation slots and lubricate. 2. Grease points for 3m Lubricate all bearings. Note and report any excessive bearing noise. extension shaft. 3. Pump/s. 3m Check pumping performance Visual observation of changing levels satisfactory. of all pumps. Withdraw pump from pit, Clean and report condition as necessary. 12m check impeller for wear and blockages. 4. Valves. 6m Check satisfactory operation of all isolating and non-return valves. 5. Controls (operational). 6m Inspect and check. Report any defects to client. 6. Building management 6m Simulate every function to Reset after test, ensure that alarm and operational system controls. ensure satisfactory operation. information is transmitted to delegated terminal. For more detailed information about maintenance see BMS On-line CopySection. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 364 45-11 DOMESTIC HOT WATER ACCELERATORS

ITEM FREQ. ACTION NOTES 1. Casing. 12m Check for damage and clean. 2. Motor electrical terminals. 12m Inspect and tighten as required. 3. Circulation. 12m Check for water circulation and correct Ensure rotor/impeller is free to turn. This is direction of flow. particularly relevant when returning the system to service. 4. Glands and seals. 12m Check for leaks, tighten glands etc. if necessary. 5. Flap valves. 12m Check location and operation. Applies to twin headed pumps only.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 365 45-12 WATER PUMPING PRESSURE BOOSTING SETS

4. Motors and bearings. 3m Oil or grease where external nipples Use recommended grade of lubricant. Motor or lubricators are fitted. should be overhauled annually, see – MOTORS. 5. Drain holes, pipes and 3m Clean and ensure that all blockages tank. are cleaned.

6. Guards and shields 3m Check for security and safety. Adjust if necessary. 7. Control and safety 3m Inspect and check. These include low water level cut-out switches, switches. high and low pressure sensing switches, electrodes, connector caps and contacts. Report any defects to client. 8. Control, pressure relief & 3m Test for correct operation and rectify Report any defects to client. reducing valves & any faults. constant flow regulators. 9. Hydraulic accumulator (if 3m Inspect and check gas cushion Ensure diaphragms are sound. Use oxygen free fitted). On-linepressure and adjust as necessary. Copynitrogen for topping up pressure as necessary. 10. Test pressure booster 3m Run and carry out adjustments to Check operation of all automatic controls and sets. ensure satisfactory operation. change-over switches. 11. Building management 3m Simulate every function to ensure Reset after test, ensure that alarm and system controls. satisfactory operation. operational information is transmitted to delegated terminal. See – BMS. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 366 46-01 REFRIGERANT DISTRIBUTION SYSTEM - general

ITEM FREQ. ACTION NOTES 1. Sight glass(es). 3m Check operation and cleanliness. Sight glasses, which should be fitted on any system, Test for refrigerant leaks. 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. 2. Superheat setting of 3m Check operation following the a) measure temperature of the suction line at the thermostatic sequence outlined in the 'notes' point where the TEV bulb is clamped. expansion valve (TEV) column. b) read gauge pressure at compressor suction To adjust, remove valve cap at base valve, of valve, turn adjusting stem counter c) add estimated pressure drop between bulb clockwise to lower the superheat or location and suction valve. clockwise to increase the superheat. d) convert the sum of the pressures to the CAUTION: Only make one turn of the equivalent temperature and subtract this from the stem at a time. 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 10 degrees. 3. Oil separators. 12mOn-lineInspect:- CopyMany small units are sealed and the sight glass is External condition of shell. on the oil separator. Leak tightness of connections. Operation of valves and drains. Operation of float valves. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 367 46-01 REFRIGERANT DISTRIBUTION SYSTEM - continued

ITEM FREQ. ACTION NOTES 4. Glycol concentration. 3m Check, if low, restore to recommended A fall in concentration may be the result of concentration. leakage and pipework should be checked. 3m Check operation using following Best practice is to use dry oxygen free nitrogen sequence:- for pressure testing and blowing out coils. Close pressure switch isolating valve Refrigerant should not be used because of where fitted, release of CFC's into atmosphere. Examine, clean and service pressure switch isolating valve where fitted, Take care not to distort contact arms or Where applicable replace lid of mechanism. Change if necessary on small units. pressure switch, Connect up alarm test set. Ensure unit is leak tight.

5. High and low pressure 12m Check on operation of pressure switch Apply correct pressure or vacuum reading to switches. contacts and re-adjust to correct coincide with pressure switch operating limits, operating pressures as necessary, note pressure or vacuum reading at which On completion of tests -disconnect air pressure switch contacts make on both upper pressure or vacuum equipment and and lower limits. alarm test set. -remake electrical supply and alarm cables -test functionally On-line-return to service. Copy

Pressure switch isolation valves to be opened, where fitted. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 368 46-01 REFRIGERANT DISTRIBUTION SYSTEM - continued

ITEM FREQ. ACTION NOTES 6. Insulation. 3m Check:- External condition, Soundness of vapour barrier and/or waterproof finish It cannot be stressed too heavily that ingress of water Condition of flange and valve vapour must be minimised otherwise efficiency will be boxes including internal reduced and energy wasted. Pay particular attention to linings and fasteners. seals round hangers and supports. Look for damage due to leaks.

Check paintwork and identification bands.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 369 47-01 ROOM AIR CONDITIONERS – unitary reverse cycle heat pump terminal units with electric heating and reversing valve

Note: If unit is ceiling mounted cover office equipment immediately below any area of work. ITEM FREQ. ACTION NOTES 1. Status. 6m Isolate electrically. Note: Isolation of electrical equipment should be carried out in accordance with HASAWA requirements. 2. Heating/cooling coil. 6m Remove air entry filter, inspect coil for Remainder of unit should be cleaned annually. dirt and clean as required. 3. Fan and motor bearings. 12m Lightly oil. Rotate by hand to check wear. 4. Condensate drain pan 6m Check pan and drain are clear. Check that drainpipe is properly attached. and pump. 5. Air filter. 6m Wash, dry and refit, renew if required. In a dirty environment more frequent cleaning may be required.

6. Water loop connections. 6m Check for leaks. 7. Refrigeration circuit. 6m Check for leaks. Indicated by oil smears at joints. 8. Electrical wiring and 6m Check integrity. terminals. 9. Return to service. 6m Place on cooling cycle, isolate from Follow by opening water loop connection, water loop, check high-pressure safety resetting high pressure cut out and after changing device stops refrigeration compressor. to heating cycle check that unit provides heat. 10. Controls. 6m Return to standard settings. 11. External cleaning On-lineClean unit externally. CopyNote defects on report to client. 6m Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

370 48-01 SANITARY and WASTE WATER PLUMBING - Introduction

This section covers all aspects of the disposal of waste water and it is essential that both contractor and client ensure that all actions and practices conform with the Health and Safety at Work Act (H ASAWA) and Environmental regulations. Certain activities may be covered by more than one specialist function and in these areas it is essential that the responsibilities for particular tasks are identified and allocated.

Note HSE Document INDG 197,198.

Weil's Disease (Leptospirosis)

This reportable disease is carried by rats and can be passed on to humans hence strict precautions should be taken to prevent infection. Attention is drawn to the need to carry out a risk assessment and produce a method statement for operators and maintenance personnel to use. PPE may be necessary..

Dangerous Gases

Special care is needed when entering pits and other below ground chambers to ensure that they are properly ventilated and free from harmful gases.

Under Food Hygiene Regulations it is essential that operatives and maintenance personnel do not work on clean water systems if they have been in contact with wastewater or sewage.

Hospitals and similar facilities may call for specialist services, which should be identified and agreed with the client. On-line Copy 371 48-02 MACERATORS

ITEM FREQ. ACTION NOTES 1. Condition. 12m Check If there is evidence of severe wear on the attrition Condition of body and blades, advise client of need for replacement. If there attrition blades. has been abuse or signs of jamming, by for instance Bearings. foreign objects, bearing wear or distortion may be For blockage and clear. evident. Operation. 2. Electrical connections. 12m Check for tightness.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 372 48-03 INTERCEPTORS - Petrol and Oil

Note: Petrol filling stations are outside the scope of this specification. Great care should be taken when entering brick or concrete drainage pits because of the possible presence of harmful gases. They should 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. ITEM FREQ. ACTION NOTES Petrol and Oil interceptors.

1. Condition of tankage. 12m Check and report any Take care not to inhale any fumes. significant deterioration. 2. Water. 12m Clean surface and remove Any liquid or solids removed during the cleaning process any floating solids. Any must be disposed of in accordance with H & S surface contamination by roily Environmental regulations. substances to be removed by vacuum separately from sedimentary solids. 3. Chamber interconnectors. 12m Check that these are not obstructed. 4. Vent pipes. 12m Check that all vents and vent pipes are clear and On-lineunobstructed. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 373 48-04 INTERCEPTORS - blowdown and sumps

Note: This subject comes within the scope of the HSE Guidance Notes PM60, L101 and PM5. Great care should be taken when entering brick or concrete drainage pits because of the possible presence of harmful gases. They should 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 25 Work in confined spaces - is required. ITEM FREQ. ACTION NOTES Blow down pits 1. Cleaning. 12m ISOLATE FROM BOILER. This work should only be carried out by a competent person Drain and thoroughly clean out. and appropriate safety precautions must be observed. The work may be carried out at the same time as the boiler inspection. 2. Access cover. 12m Check condition and security. Some pits may be fenced and if so the fencing should be checked and made good if necessary. 3. Vent pipe and 12m Check condition and ensure there is If replacement or repair necessary, advise client. silencer (if fitted). no blockage. 4. Anti-siphon hole. 12m Check hole is clear. Blow down tanks Note: these are pressure vessels and as such come within the scope of the Pressure Systems and Transportable Gas Containers Regulations. See also HSE document L101.

1. Cleaning. 12m On-lineISOLATE FROM BOILER. ThisCopy work should only be carried out by a competent person Drain and thoroughly clean out. and appropriate safety precautions must be observed. The work is normally carried out at the same time as the boiler inspection. 2. Access cover. 12m Check condition and ensure seals are clean. 3. Vent pipe and 12m Check condition and ensure there is If replacement or repair necessary, advise client. silencer (if fitted). no blockage. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 374 48-05 SANITARY, WASTE WATER PLUMBING and DRAINS

ITEM FREQ. ACTION NOTES Waste water pipework and traps. 6m Check cleanliness and Where remedial work is required advise client. 1. Condition. ensure traps etc. run free. Kitchen grease traps 1m Inspect and remove any It is recommended that client should ensure that his staff accumulated grease and are familiar with these traps and clean them at least other residues. once per month and more frequently if accumulations are severe. Sanitary fittings 6m Inspect and clean, ensure 1. Urinals. grids on waste are clear and outlet(s) run freely. 2. Water closets. 6m Check condition and ensure correct flushing and free outlet. 3. Cisterns. 6m Check operation and if If water is running continuously check diaphragm on necessary replace washer on siphon and replace if necessary. intake float valve. 4. Automatic controls and 6m Check operation. If controls are faulty refer to the manufacturer's sensors. maintenance instructions. Soil stacks On-line6m Check that there are no CopyExternal examination should conform to BS8301, para. 1. Obstructions. obstructions. 26, 1-3. 2. Bird guards. 6m Check condition and replace as necessary. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

375 48-05 SANITARY, WASTE WATER PLUMBING and DRAINS - continued

ITEM FREQ. ACTION NOTES Drainage 1. Surface water drains. 6m Check grates and clears of any deposits and water flows freely. Clear any sediment from grate sumps. Check condition of junction Advise client if any replacements are necessary. and access covers. 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 If cleaning is required this should be agreed with client. that H S and Environmental requirements are followed. On-line Copy 376 48-06 AIR ADMITTANCE VALVES

ITEM FREQ. ACTION NOTES 1. General. Air admittance valves which are manufactured in accordance with an Agrément certificate issued by Board of Agrément do not normally require maintenance. 2. Inspection. 12m Visually inspect externally for Report to client if remedial work is required. In the event mechanical damage or of accidental damage or vandalism the cover can be vandalism. removed and the damaged components or the complete assembly replaced.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 377 48-07 RAINWATER DOWNPIPES AND GUTTERS Stagnant water can be a health hazard and appropriate health precautions should be taken. ITEM FREQ. ACTION NOTES Gutters 1. Condition. 12m Inspect and remove any Depending upon location more frequent cleaning may deposits. If there are any be necessary i.e. presence of trees or extremes of signs of corrosion these temperature. should be treated. 2. Joints and seals. 12m Inspect, check for evidence of leakage and rectify any faults. 3. Fixings. 12m Check condition and secure if loose. 4. Trace heating tapes 12m Check operation and (where fitted). position. Rain-water pipes Inspect and remove any Depending upon location more frequent cleaning may 1. Condition. 12m deposits. If there are any be necessary i.e. presence of trees or extremes of signs of corrosion these temperature. should be treated. 2. Joints and seals. 12m Inspect, check for evidence of leakage and rectify any On-linefaults. Copy 3. Obstructions. 12m Check for free flow of water, remedy any defects. 4. Fixings. 12m Check condition and secure if loose. 5. Trace heating tapes 12m Check condition and position. (where fitted). Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

378 48-08 SANITARY AND WASTE WATER PLUMBING-WATER SAVING DEVICES and METERS

ITEM FREQ. ACTION NOTES 1. Timers. 6m Check: Change over GMT/BST saving may have been Operation, overlooked. Settings, and adjust as necessary. 2. Hydraulic flushing 6m Check operation and carry control. out maintenance procedures in accordance with the manufacturer's instructions. 3. Detection devices. 6m Check operation. For more detailed maintenance instructions, see – SENSORS 4. Strainer. 6m Examine, clean and change if necessary. 5. Electrical connections. 6m Check integrity. 6. Cistern. 6m Check warning pipe is unobstructed. 7. Battery (where fitted). 6m Check remaining life, change Replace battery according to manufacturer's as necessary. recommendations. All batteries should be disposed of in accordance with H&S and Environmental On-line Copyrequirements. Meters 1. Installation 6m Check condition. Supply meter is normally the responsibility of the water undertaking and should be maintained by them. 2. Filter (where fitted) 6m Check condition, clean or replace as necessary.

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

379 49-01 SECURITY SYSTEMS - INTRUDER ALARMS

For security reasons when the client elects to have the maintenance carried out by the building services contractor, it is suggested that the client should carry out items 1-4 at least once every three months to ensure that the system integrity is maintained. Close circuit television (CCTV equipment), which is usually linked into intruder alarm systems is normally maintained by specialist contractors. ITEM FREQ. ACTION NOTES 1. System integrity. 12m Carry out external examination Any evidence of tampering or damage should be of installation. recorded and reported to the client. 2. Sensors and contacts. 12m Carry out operational check. If Confirm correct operation and sensitivity, where outdoors check beam systems appropriate check spatial configuration for are not impaired by vegetation volumetric devices. or other obstacles.

3. Alarm signals. 12m Check response to signal. 4. Sensor covers, terminal 12m Check security, boxes and fixings. Check internally for signs of Clean internal components with soft brush and overheating, ingress of dust and remove any dirt or fluff. moisture. When replacing covers check operation of any tamper switches which may be fitted. 5. Power supplies. 12m Check power supplies and Batteries should be checked for signs of leakage associated batteries, or corrosion.

Check equipment responds to On-lineinterrupted mains supply. Copy 6. Detection modules (if 12m Check and adjust (if necessary) applicable). bridge balance. 7. Batteries a) sealed lead acid, 36m Replace Batteries should be disposed of in b) sealed nickel-cadmium. accordance with H&S and Environmental Regulations.

380 50-01 SENSORS and SWITCHING DEVICES - Electric/electronic and pneumatic.

Pre-maintenance procedure.

This procedure applies to all types of sensors and thermostats and requires that all safety precautions and safe working practices 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. On-line Copy 10. All sensors should be maintained in accordance with the manufacturer's recommendations.

11. Special sensors such as are used for glycol concentration, detection of smoke and gas, and sensors used in water 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. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 381 50-02 PRESSURE MEASUREMENT SENSORS - static and differential

ITEM FREQ. ACTION NOTES 1. Sampling pipework and 12m Inspect for leakage and connections. corrosion. Check for correct configuration. 2. Water sampling lines. 12m Purge to remove any air. 3. Operation. 6m Check for correct operation. Check contact condition if a pressure switch.

Refer to manufacturer’s recommended inspection procedures. 4. Calibration. 12m Check. Refer to manufacturer’s recommended calibration procedures.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 382 50-03 TEMPERATURE MEASUREMENT SENSORS

ITEM FREQ. ACTION NOTES Space temperature sensor 1. Sampling 12m Check for any obstruction. 2. Cleanliness. 12m Check sensor is clean and free from dirt. 3. Operation. 12m Check for correct operation. Refer to manufacturer's recommended inspection procedures. 4. Calibration. 12m Check. Refer to manufacturer's recommended calibration procedures. 5. Frost protection. 12m Check operation. Confirm set This may be outside the building on older systems. point. Outside temperature sensor 1. Sampling. 12m Check for any obstruction. 2. Location influence. 12m Check effect. Examples are solar gain, proximity to warm extract vents, cooling towers, etc. 3. Operation. 12m Check for correct operation. Refer to manufacturer's recommended inspection procedures. 4. Calibration. On-line12m Check. CopyRefer to manufacturer's recommended calibration procedures. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 383 50-03 TEMPERATURE MEASUREMENT SENSORS - continued

ITEM FREQ. ACTION NOTES Duct mounted sensors 1. Cleanliness. 12m Check sensing element for Clean as appropriate, refer to manufacturer's cleanliness where possible. instructions. 2. Sampling. 12m Check for any obstruction to airflow at sensing element. 3. Operation. 12m Check for correct operation. Refer to manufacturer's recommended inspection procedures. 4. Calibration. 12m Check. Refer to manufacturer's recommended calibration procedures. Immersion sensor 1. Sensor pocket. 12m Check for leaks. 2. Sensor. 12m Check for good quality I.e. Use of heat transfer grease, spring systems thermal contact. etc. as per manufacturer's recommendations. 3. Operation. 12m Check for correct operation. Refer to manufacturer's recommended inspection procedures. 4. Calibration. 12m Check. Refer to manufacturer's recommended calibration On-line Copyprocedures. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 384 50-03 TEMPERATURE MEASUREMENT SENSORS - continued

ITEM FREQ. ACTION NOTES Clamp-on sensor and surface sensor 1. Surface contact. 12m Check for good surface Use heat transfer grease as per manufacturer's contact. recommendations. 2. Operation. 12m Check for correct operation. Refer to manufacturer's recommended inspection procedures. 3. Calibration. 12m Check. Refer to manufacturer's recommended calibration procedures.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 385 50-04 RELATIVE HUMIDITY SENSORS

ITEM FREQ. ACTION NOTES Space humidity sensor 1. Sampling 6m Check for any obstruction 2. Cleanliness. 6m Check sensor is clean and free from dirt. 3. Operation. 12m Check for correct operation. Refer to manufacturer's recommended inspection procedures. 4. Calibration. 12m Check. Refer to manufacturer's recommended calibration procedures. Outside humidity sensor 1. Sampling. 6m Check for any obstruction. 2. Location influence. 12m Check effect. Examples are solar gain, proximity to warm extract vents, cooling towers, etc. 3. Operation. 12m Check for correct operation. Refer to manufacturer's recommended inspection procedures. 4. Calibration. 12m Check. Refer to manufacturer's recommended calibration On-line Copyprocedures. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 386 50-04 RELATIVE HUMIDITY SENSORS - continued

ITEM FREQ. ACTION NOTES Duct mounted sensors 1. Cleanliness. 6m Check sensing element for Clean as appropriate, refer to manufacturer's cleanliness where possible. instructions.

2. Sampling. 6m Check for any obstruction to airflow at sensing element. 3. Operation. 12m Check for correct operation. Refer to manufacturer's recommended inspection procedures. 4. Calibration. 12m Check. Refer to manufacturer's recommended calibration procedures.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 387 50-05 ABSOLUTE HUMIDITY SENSORS

ITEM FREQ. ACTION NOTES Space sensor 1. Sampling pipework. 6m Check for any obstruction. 2. Sensor. 6m Check that sensor is clean and free from dirt. 3. Environment. 6m Check for signs of condensation and a saturated environment. 4. Operation. 12m Check operation. Refer to manufacturer's recommended inspection procedures. 5. Calibration. 12m Check. Refer to manufacturer's recommended calibration procedures. Duct sensor 1. Sampling pipework. 6m Check for any obstruction. 2. Sensor. 6m Check that sensor is clean and free from dirt. 3. Environment. 6m Check for signs of condensation On-lineand a saturated environment. Copy 4. Operation. 12m Check operation. Refer to manufacturer's recommended inspection procedures. 5. Calibration. 12m Check. Refer to manufacturer's recommended calibration procedures. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 388 50-06 AIR QUALITY SENSORS

ITEM FREQ. ACTION NOTES Space air quality sensor 1. Sampling. 6m Check for any obstruction. 2. Sensor. 6m Check sensor is clean and free from dirt. 3. Operation. 12m Check operation. Refer to manufacturer's recommended inspection procedures. Duct air quality sensor 1. Cleanliness. 6m Check sensing element for cleanliness. 2. Sampling. 6m Check for any obstruction. 3. Operation. 12m Check operation. Refer to manufacturer's recommended inspection procedures. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 389 50-07 CARBON DIOXIDE SENSORS

ITEM FREQ. ACTION NOTES Space carbon dioxide sensor 1. Sampling. 6m Check for any obstruction. 2. Sensor. 6m Check sensor is clean and free from dirt. 3. Operation. 12m Check operation. Refer to manufacturer's recommended inspection procedures. 4. Calibration. 12m Check. Refer to manufacturer's recommended calibration procedures. Duct carbon dioxide sensor 1. Cleanliness. 6m Check sensing element for cleanliness. 2. Sampling. 6m Check for any obstruction. 3. Operation. 12m Check operation. Refer to manufacturer's recommended inspection procedures. 4. Calibration. 12m Check. Refer to manufacturer's recommended On-line Copycalibration procedures. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 390 50-08 VELOCITY SENSORS

ITEM FREQ. ACTION NOTES 1. Cleanliness. 6m Check sensing element for cleanliness where applicable. 2. Sampling. 6m Check for any obstruction. 3. Operation. 12m Check operation. Refer to manufacturer's recommended inspection procedures. 4. Calibration. 12m Check. Refer to manufacturer's recommended calibration procedures.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 391 50-09 OCCUPANCY and LIGHT SENSORS

ITEM FREQ. ACTION NOTES Occupancy 1. Cleanliness. 12m Clean as per manufacturer's instructions. 2. Operation. 12m Test for correct operation. 3. Location. 12m Check that sensor is not affected by extraneous effects. Light level sensors 1. Cleanliness. 12m Clean as per manufacturer's In dirty environments more frequent cleaning of instructions. the sensor may be necessary. 2. Sampling. 12m Check for any interference or e.g. shadows or reflections. obstruction.

3. Operation. 12m Test for correct operation. 4. Calibration. 12m Test and carry out calibration Refer to manufacturer's recommended On-lineprocedure. Copycalibration procedures. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 392 50-10 SMOKE DETECTORS

ITEM FREQ. ACTION NOTES 1. Cleanliness. 12m Check sensing device and where Refer to the manufacturer's instructions for cleaning appropriate sampling system for procedures. cleanliness and possible obstructions. 2. Operation. 12m Test for correct response and Refer to manufacturer's instructions for operation. 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. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 393 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, and it is essential to refer to the manufacturer's instructions before commencing any maintenance work on them. ITEM FREQ. ACTION NOTES 1. Cleanliness. 12m Check sensing device and Refer to the manufacturer's instructions for where appropriate sampling cleaning procedures. system for cleanliness and possible obstructions. 2. Operation. 12m Test for correct response and Refer to manufacturer's instructions for operation. recommended testing procedures.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 394 51-01 SHOWERS

Note: Frequency of maintenance will depend upon use and the quality of the water and should be agreed with the client. ITEM FREQ. ACTION NOTES Valves See - VALVES. Spray fittings 1. Outlet sprays. 12m Remove, clean and disinfect Take care not to damage spray outlet holes. spray heads. Check adjustable sprays (if fitted). 2. Body jets. 12m Remove, clean and disinfect Take care not to damage spray outlet holes. spray heads. Adjust water flow rates. 3. Flexible hoses. 12m Check joints and flexible Report to client if replacement recommended. covering for damage. Shower enclosures and trays 1. Seals. 12m Check for leaks on seals of Operate shower with door closed and carry out visual doors and screens. inspection. Rectify or replace as appropriate. 2. Waste outlet. On-line12m Clean and unblock waste CopyIf possible fit top access waste trap. More frequent outlet trap as necessary. maintenance may be necessary depending upon frequency of use. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 395 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. ITEM FREQ. ACTION NOTES 1. Casing. 12m Check for damage and clean. 2. Motor electrical 12m Inspect and tighten if terminals. required. 3. Motor. 12m Clean and check. See MOTORS. 4. Anti-vibration pad(s). 12m Check for wear and movement out of position. Replace as necessary. 5. Flow switches (where 12m Check operation. The two switches fitted to a twin impeller pump for fitted). separate hot and cold water supplies should be checked separately.

6. Air pressure switches 12m Check operation. Air switches should be used only where a low static (where fitted). head is present. 7. Water filters. 12m Remove and clean. 8. Ventilation. 12m Check clearance round pump On-linefor proper motor ventilation. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 396 52-01 SMOKE EXTRACT - general

In many shopping malls, warehouses, staircases and other similar areas openable ventilators are installed to relieve smoke natural vents and/or to provide natural ventilation. The actual fire prevention equipment does not come within the scope of this document and its maintenance should be carried out by specialist contractors.

52-02 SMOKE RELIEF - and/or natural fire ventilators

Frequency of maintenance and testing for smoke relief ventilators should conform to BS7346 part 1 Appendix E and/or the Fire Precautions (Workplace) Regulations and should be in accordance with local authority requirements. ITEM FREQ. ACTION NOTES 1. Fixing and weathering. 12m Check condition and clean off any dirt In very dirty or aggressive environments, more with stiff (not wire) brush from internal frequent attention may be necessary. and external weathering channels. 2. Louvres/flaps or 12m Clean bearings and lubricate as dampers. necessary. 3. External hand control 12m Check and adjust. where fitted. 4. Operating mechanism. 12m Check action. Report to client if repairs or replacement required.

5. Smoke vents. 0.25m Check condition and test weekly and Client to advise if weekly tests are to be included record as required by BS 7346, and within maintenance contract. On-linethe Fire Precautions (Workplace) Copy Regulations 1997. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 397 52-03 SMOKE RELIEF - Powered fire ventilators

ITEM FREQ. ACTION NOTES 1. Electricity supply. 12m Isolate in accordance with Electricity Note: Ensure clients is aware that at work requirements. system or part of system is inoperative during execution of maintenance. 2. Filters. 12m See FILTERS. 3. Fixings 12m Clean fixing and weathering and clean off all dirt Use brush for dirt removal. from external surfaces of ventilator.

4. Fan impeller of motor. 12m Clean impeller and rotor and check ease of It is important to check for correct rotation and correct direction of rotation. clearance between fan shrouds and impeller. (See also MOTORS) 5. Fan discharge. 12m Check fan inlet and discharge are unobstructed.

6. Non return flaps. 12m Check and adjust for correct operation. Straighten any bent or distorted blades.

7. Water cooling system 12m Check (where fitted) a) spray nozzles are clean and undamaged. b) cleanliness. On-linec) that water system is available Copy at the required pressure. Clean strainer where fitted.

398 52-03 SMOKE RELIEF - Powered Fire Ventaltors - continued

ITEM FREQ. ACTION NOTES 8. Test and run. 0 .25m Test weekly and record Note: Client is to advise whether weekly test is to form part of the maintenance contract. 9. Controls. 12m Check action. See CONTROLS for detailed maintenance.

On-line Copy 399 52-04 SMOKE CURTAINS

ITEM FREQ. ACTION NOTES 1.Curtains a) control, 12m Ensure curtain control is isolated from independent control circuits, e.g. smoke detectors. b) guide rails (where fitted) 12m Check rails are clear of any obstruction. c) fabric, 12m Check for damage and report.

d) high and low limits, 12m Check and adjust as necessary. e) zone operation. 12m Operate by zone.

2. Electrical services. a) battery back up and control, 12m Test operation. Check battery condition and charge rate. b) earth and resistance, 12m Test at panel.

c) amperage and voltage, 12m Check and note incoming voltage to controls. 3. Compressor (where See relevant section. applicable) On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 400 53-01 SOLAR HOT WATER PANELS and similar COLLECTING DEVICES

ITEM FREQ. ACTION NOTES Plate type collectors 1. Glass cover plate. 6m Clean and report condition if Frequency will depend on location and local cracked. atmospheric condition. Dirt causes loss of collector efficiency. Cracked glass should be replaced. 2. Seals. 12m Check condition and make Poor seals lead to internal condensation and loss of good if necessary. efficiency. If there are signs of internal algae growth on underside of glass plate, it should be removed, cleaned and resealed. Care should be taken not to damage absorber plate as it may have a special coating. 3. Anti-freeze solution (if 12m Check condition and top up Anti-freeze solution should be replaced every three used). to required concentration. years. 4. Controls. 12m Check operation of For more detailed maintenance of controls relevant thermostat and pump control. section. 5. Pipework and 12m Check for leaks and signs of connections. corrosion and make good as necessary. Vacuum tube type 1. Tubes. 6m Clean and report condition if Frequency will depend on location and local On-linecracked. Copyatmospheric condition. Dirt causes loss of collector efficiency. Cracked tubes should be replaced. 2. Reflectors. 6m Clean and report condition if Frequency will depend on location and local cracked. atmospheric condition. Dirt causes loss of collector efficiency. Care should be taken to avoid damaging the reflector surface. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 401 53-01 SOLAR HOT WATER PANELS and similar COLLECTING DEVICES - continued

ITEM FREQ. ACTION NOTES 3. Anti-freeze solution (if 12m Check condition and top up Anti-freeze solution should be replaced every three used). to required concentration. years. 4. Controls. 12m Check operation of For more detailed maintenance of controls see relevant thermostat and pump control. sections. 5. Pipework and 12m Check for leaks and signs of connections. corrosion and make good as necessary.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

402 54-01 SPLIT SYSTEMS

Introduction

Unit type air coolers, generally known as unit type air conditioners are stand alone pieces of equipment, the bulk of the equipment being factory assembled, sometimes needing only an electrical supply, and in some instances water/drainage connections, to make them work. Size can vary between 2 and 100kW of cooling. It follows that such units will contain some or all of the elements covered in other sections of this specification and when maintenance is carried out reference should be made to the appropriate section(s). It may be efficient for small units to be serviced at a central workshop.

This unit can be divided into two main categories namely:-

a) one piece

b) split two piece

they are variously known as cassettes, wall or window, ducted or portable, multi-splits, console through wall, or free standing.

With the split systems pipework is necessary on site to connect the room unit to the condenser unit together with charging up and commissioning. Increased maintenance may be required with these compact units because of the density of the components. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

403 54-02 SPLIT SYSTEMS – air-cooled with direct expansion evaporator (DX), with gas, hot water or electric heaters

These are primarily two units with either integral or remote air-cooled condensers working with direct expansion coolers, primarily for room air conditioning applications. The frequency of servicing or cleaning will depend upon the working environment and the amount of usage. ITEM FREQ. ACTION NOTES Cooling. 1. Compressor. 6m Check for undue noise or vibration. Check discharge and suction pressure and check superheat under full load condition. 2. Compressor 6m Check for symptoms of ‘wet’ suction. operation or excessive superheat. 3. Refrigerant. a) charge. 6m Check level in receiver and/or liquid Note: Any significant shortfall or frequent topping up may line sight glass. indicate leakage and should be reported to client. b) leaks 6m Test accessible parts of system. Pay particular attention to bolted and flare connected joints, sight glass glands and any pressure relief valve vent to atmosphere. Note: any removed refrigerant (CFC) must be recovered and not released to atmosphere. Only a REFCOM registered engineer should work on this equipment. 4. Condenser and 6m Check for damage and/or dust Do not use CFC’s (refrigerant) for cleaning tubes use dry evaporator fins. On-lineaccumulation. Clean as necessary. nitrogenCopy or compressed air. Sterilisation may be required. 5. Fans and motors 6m Check bearings and lubricate as Where appropriate check drive belts for condition and tension. and damper drive necessary. Inspect and check on Adjust or replace as necessary. Ensure that all bolts, screws motors (if fitted). fan guard covers and inspection etc. are in place and tight. (See also MOTORS) plates. 6. Evaporator and 6m Check and clean. Check Sterilisation may be required. drains, dip tray and condensate drain is clear and pump. clean. Continued on next page .. 404 54-02 SPLIT SYSTEMS – air-cooled with direct expansion evaporator (DX), with gas, hot water or electric heaters - continued

ITEM FREQ. ACTION NOTES 7. Compressor capacity 6m Check for correct operation. Check Compressor unload on start should reduce and control and unloaded motor current against commissioning increase capacity on demand. start valves (if fitted). data. 8. Refrigerant pipework. 6m Check for vibration and rectify any All pipework joints should be brazed or welded. loose or inadequate support/fixing. To prevent internal scaling use dry, oxygen free nitrogen (OFN) during the jointing process. 9. Filters. 6m Check condition and replace as necessary. 10. Insulation. 6m Check condition. Repair and reseal as necessary. 11. General cleanliness. 6m Clean surfaces of compressor and Remove any dirt or rubbish from vicinity of plant. components of condensing unit. 12. Electrical. 6m Check for damage to flexible conduits. If main fuse carrier connections to compressors Tighten all terminal connections. show any discoloration they must be changed. Isolate local control panel and inspect for signs of overheating. Check Pay particular attention to contactors and integrity of electrical insulation. terminals including all thermistor controls in compressor terminal box. 13. System operation. 6m Confirm that it is in accordance with i.e. Start/stops and capacity regulators should be design parameters. in accordance with externally applied control On-line Copysystems if applicable. Heating. 1. Gas Fired. 6m See relevant BURNER section. 2. Hot water supply. 6m See relevant HEAT EMITTER section. Check for leaks. Check anti-freeze protection on heating coil. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

405 55-01 DRIVE ELEMENTS – STARTERS - general

Note: Before carrying out any work on electrical equipment, isolate in accordance with HASAWA and Electricity at Work Act requirements.

ITEM FREQ. ACTION NOTES 1. Control unit relays, fuses 12m Check and inspect. Replace lamps as Note hours run on plant and check that duty and control lamps, necessary. selection has been carried out. starters overloads and transformers. 2. Wiring, conduits and 12m Check condition, replace if necessary. Ensure that all access covers and all screws and flexible conduits. hinges are in place and secured. 3. Panel. 12m Check internally for build up of dirt and vacuum out.

On-line Copy 406 55-02 STARTERS - Star Delta

ITEM FREQ. ACTION NOTES 1. Switchgear. 12m Carry out maintenance See CONTROL PANELS. procedures as per power contactors. 2. Interlocks. 12m Inspect and check both electrical and mechanical interlocks between 'Star' and 'Delta' contactors. 3. Start up sequence. 12m Check for correct sequence 'Star' first then 'Delta' mode. from start up. Inspect check and adjust setting of timer to match character of the connected load.

4. Starter overload settings. 12m Check. If overload is connected into the 'Delta' loop the overload should be set to 0.58 of the line current. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 407 55-03 STARTERS -Two speed - Dual wound

ITEM FREQ. ACTION NOTES 1. Switchgear. 12m Carry out maintenance See CONTROL PANELS. procedures as per power contactors. 2. Interlocks. 12m Inspect and check both electrical and mechanical interlocks between 'high' and 'low' speed contactors. 3. Timers. 12m Check and set. Timers should be set between 'high to low' and 'low to high' operation to match the characteristics of the connected loads. 4. Overloads. 12m Check both high and low Overloads should be set to give the correct overloads. protection to the connected loads.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 408 55-04 STARTERS - Two speed - Pole change

ITEM FREQ. ACTION NOTES 1. Switchgear. 12m Carry out maintenance See CONTROL PANELS. procedures as per power contactors. 2. Interlocks. 12m Inspect and check both electrical and mechanical interlocks between the 'loop' and 'star' (high) contactors. 3. Timers (if fitted). 12m Check and set. Timers should be set between the 'high to low' and 'low to high' operation to match the characteristics of the connected loads. 4. Overloads. 12m Check both high and low Overloads should be set to give the correct overloads. protection to the connected loads.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 409 55-05 STARTERS - Reversing

ITEM FREQ. ACTION NOTES 1. Switchgear. 12m Carry out maintenance See CONTROL PANELS. procedures as per power contactors. 2. Interlocks. 12m Inspect and check both electrical and mechanical interlocks between the 'forward' and 'reverse' starters. 3. Timers (if fitted). 12m Check and adjust between the Inspect and check that the drive is operating in two modes of operation to suit the correct directions. the application. 4. Overloads. 12m Check both high and low Overloads should be set to give the correct overloads. protection to the connected loads.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 410 55-06 STARTERS - Auto-transformer

ITEM FREQ. ACTION NOTES 1. Switchgear. 12m Carry out maintenance See CONTROL PANELS. procedures as per power contactors. 2. Interlocks. 12m Inspect and check both electrical and mechanical interlocks between the main transformer load, the load and the transformer by-pass contactors. 3. Timers (if fitted). 12m Check and adjust the timer setting between the transformer load and by-pass contactors to suit the connected load. 4. Overloads. 12m Check both high and low Overloads should be set to give the correct overloads. protection to the connected loads. 5. Transformer. 12m Inspect and check for signs of On-lineoverheating. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 411 55-07 STARTERS - Quick transition, electric heater

ITEM FREQ. ACTION NOTES 1. Switchgear. 12m Carry out maintenance See CONTROL PANELS. procedures as per power contactors. 2. Interlocks. 12m Inspect and check both electrical and mechanical interlocks between the main run and transition contactors. 3. Sequence timers. 12m Check and adjust to suit the characteristics of the connected load. 4. Overloads. 6m Check and set to give correct protection for the connected load. Electric Heater Type 1. Electrical connections. 12m Check. 2. Heater elements. 12m Inspect for signs of overheating Replace as necessary. On-lineor element breakdown. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 412 55-08 STARTERS – electrolyte type

ITEM FREQ. ACTION NOTES Electrolyte Type 1. Liquid level. 12m Check 2. Specific gravity. 12m Check against manufacturer's Follow manufacturer's maintenance instructions. values.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

413 55-09 STARTERS - AIR BREAK, AND CONTACTORS

Before carrying out any work on control panel isolate mains supply at the distribution board.

ITEM FREQ. ACTION NOTES 1. Enclosure. 12m Clean and remove any dirt or Use cloth free from loose fibres. dust. 2. Insulation. 12m Inspect for signs of tracking, blistering or delamination. Renew where necessary. 3. Condition 12m Inspect for corrosion overheating or obstruction. 4. Switch contacts. 3m Examine for wear or overheating or burning. Renew as necessary. 5. Latching contactors. 3m Check operation, adjust or renew worn parts as necessary. 6. Arc chutes. 3m Clean insulation and renew any Ensure arc chutes are precisely repositioned damaged parts. otherwise the moving parts of the contactor may be impeded and damage caused to the contacts, insulation and the chutes themselves. 7. Auxiliary contacts. 3m Inspect for wear and correct On-lineoperation. Renew or adjust Copy as necessary. 8. Operating magnet. 12m Check for movement, clean dirt If equipment noisy, check shading coils or rings from pole faces. for damage and renew parts as necessary.

Continued on next page Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

414 55-09 STARTERS - AIR BREAK, AND CONTACTORS - continued

ITEM FREQ. ACTION NOTES 9. Push button contacts. 3m Inspect and renew any worn points. 10. Resistance units incorporated 12m Clean and examine for If wear is evident, renew that part of the in stator/rotor starters. connections. resistance.

11. Time delay and overload devices: a) thermal, 12m Check correct settings. Renew to manufacturer's instructions. b) oil dashpot, 12m If oil is cloudy or sludge has formed, clean out dashpot with solvent and refill. c) air dashpot (diaphragm or 12m Check that air seals are intact. piston type), Renew unit if leaks are evident. d) magnetic. 12m Check for free movement, if the magnetic spacer is damaged or excessively worn, renew. 12. Fuses (if fitted). 12m Check for correct rating and e.g. rewirable fuses have not been installed in type. the carriers designed for cartridge fuses. 13. a)prior to return to service.On-line 12m Carry out insulation test Copy and carry out operational check. b)after return to service. 12m Check that any meters and pilot lights fitted function correctly. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

415 56-01 COLD WATER STORAGE and SUPPLY

Introduction

Whilst legionella bacteria are most active in the temperature range 20°C to 45°C, occasions can occur where growth is promoted even in cold water systems. This can arise where the local temperature is raised by:

a) heat build up due to solar gain or the proximity to hot water services, or b) the storage capacity is far greater than is necessary. In general terms the storage capacity should not exceed one day's usage.

Cleanliness of the system is of primary importance to ensure that the legionella bacteria do not have any nutrients for growth and survival. Such nutrients can come from vegetable, animal and even mineral substances and it is for this reason that storage cisterns should be free from rust, dust, slime, mould, fungi and such items as dead birds, rats, mice, insects etc. and that non metallic materials satisfy the requirements of BS6920. Lists of materials approved by the water industry are published in the Water Fittings and Materials Directory (see Standards List), All new and replacement water fittings should satisfy the Water Supply (Water Fittings) Regulations requirements and be listed in the directory.

Cleansing of tanks, cisterns and associated pipework should be followed by full disinfection in accordance with the procedures laid down in HSC ACOP L8.2001.

Cisterns must have close fitting lids, which should not be of timber or other porous materials. Lids should have vent pipes of adequate cross section to prevent suction developing on water draw off. All vent pipes and overflows should be fitted with close mesh to prevent the ingress of foreign matter. These should be cleaned annually.

The pipework system should be free ofOn-line any points where pockets of dirt, slime Copyor sediment can build up. Where it is impossible to ensure this the system should be disinfected on a regular basis. 416 56-02 COLD WATER STORAGE TANKS and CISTERNS

Note: Cisterns operate at atmospheric pressure whereas tanks are sealed vessels operating at pressures above atmospheric. ITEM FREQ. ACTION NOTES 1. Float operated ball valve 3m Check operation, water level and shut off. Replace washer if necessary. Check float for leakage and security. 2. Level control switches (if 6m Check for scale deposits, For specialist maintenance of level control switches see fitted). clean as necessary and LEVEL SWITCHES. check operation. 3. Cistern or tank body. 6m Check for leaks and any Ensure that any brackets, etc. supporting the tank are structural weaknesses. firmly fixed.

4. Valves 6m Check valve stems are Ensure that any insulation or trace heating cable removed free to turn. during inspection is replaced or frost damage could ensue.

5. Air vents and overflow 6m Check for blockage and Clean when necessary. Report if replacement needed. screens. condition. 6. Insulation. 6m Check condition, replace if Look for any damp patches, if necessary removing On-linenecessary. insulationCopy to find cause.

7. Manlid and access 12m Check condition of seals. If lid has been removed for inspection purposes ensure covers. seals are effective. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 417 56-02 COLD WATER STORAGE TANKS and CISTERNS - continued

ITEM FREQ. ACTION NOTES 8. Cistern or tanks. 12m Inspect and report Check overflow and warning pipes are unobstructed and cleanliness and condition. that the ends are conspicuous and well above the flood over level of a gully. 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 Regulations approved. 9. Tanking. 12m Ensure drains are clear, Check thoroughly for potential leakage. Report to client. check condition. 10. Associated pipework. 12m Check condition and rectify Examine for corrosion, leaks and security of fittings and any faults. attachments. 11. Generally. 12m Check that all items of Report to client where remedial action is required. equipment comply with : Legislation. Bye-laws, and Codes of practice. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 418 56-03 ICE STORAGE SYSTEMS

ITEM FREQ. ACTION NOTES 1. Brine quality. 3m Check Specific Gravity. If checks show continual need for topping up brine Specific Gravity, examine system for leaks. 2. System pressurisation 6m Check operation. unit (if used). 3. Tank shut off unit (if 6m Check operation. fitted).

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 419 56-04 STORAGE TANKS - LPG

ITEM FREQ. ACTION NOTES 1. Under pressure valve. 12m Check normal position. Condition of tanks is the responsibility of the gas supplier who will also check safety protection. 2. Over pressure valve. 12m Check normal position. 3. Pressure regulating valves. 12m Check action. 4. Shut valve. 12m Check action. 5. Valves on Multi Cylinder 12m Check change over. Installation.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 420 56-05 STORAGE TANKS - OIL

ITEM FREQ. ACTION NOTES 1. Tank. 12m Check condition and note any Report to client. corrosion. 2. Filter. 12m Replace if dirty and investigate cause. 3. Balloon Vent. 12m Check condition of wire mesh. 4. Sludge valve. 12m Check for leaks. If opened Waste Disposal Regulations may apply.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 421 57-01 SWIMMING POOLS, SPAS, SAUNAS, etc.

Introduction

There are two major aspects of swimming pool maintenance, water cleanliness and quality, and winterisation.

The maintaining of a high standard of water cleanliness and quality calls for daily monitoring and treatment which must be part of the 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 ACOP L8,2001.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 422 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).

ITEM FREQ. ACTION NOTES 1. Shut down. 12m Isolate from electrical supply Ensure that water supply is also turned off. by switching off and withdrawing fuses.

2. Controls. 12m Check settings and action.

3. Pool cover(s). 12m Check for tears and soundness. Check condition and security of anchor bolts. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

423 57-03 SWIMMING POOLS - FILTERS

Filtration plant. The filtration plant of a pool is designed to remove water from the pool, filter it, disinfect it, and return it to the pool in a sterile condition. The main types of pool filters are: a) Conventional rate pressure sand filtration b) Medium rate pressure sand filtration c) High rate pressure sand filtration d) Pre-coat cartridge (pressure and vacuum) e) Disposable cartridge or glass fibre mat filtration

ITEM FREQ. ACTION NOTES Conventional, medium and high The terms conventional, medium and fast rate refer to rate pressure filtration the rate of flow of water through the filter. The maintenance requirements for the three types is similar. 1. Inlet strainer. 12m Check condition and clean. More frequent cleaning by the operator may be necessary if the inlet flow rate falls below the design level. (May be shown by increased suction pressure). 2. Chemical cleaning of 12m Check clean `running' Refer to manufacturer's handbook for instructions and filter bed material. pressure, if high, may type of chemicals to be used. indicate fouling of filter medium. 3. Rate of flow indicator. 12m Clean and check operation. The accuracy of the flow meter should be within 5%. Continued on next page On-line Copy 424 57-03 SWIMMING POOLS - FILTERS - continued

ITEM FREQ. ACTION NOTES Pre-coat filtration 1. Inlet strainer. 12m Check condition and clean. More frequent cleaning by the operator may be necessary if the inlet flow rate falls below the design level. (May be shown by increased suction pressure). 2. Filter elements. 12m Clean off any coating If replacement necessary, report to client. material and check condition of support elements. 3. Pipework. 12m Clean off any deposits or sludges. 4. Rate of flow indicator. 12m Clean and check operation. The accuracy of the flow meter should be within 5%. Cartridge type filters 1. Inlet strainer. 12m Check condition and clean. More frequent cleaning by the operator may be necessary if the inlet flow rate falls below the design level. (May be shown by increased suction pressure). 2. Seals. 12m Check condition of seals on cartridge holders. Replace if necessary. 3. Rate of flow indicator. On-line12m Clean and check operation. CopyThe accuracy of the flow meter should be within 5%. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 425 57-04 SWIMMING POOLS - PIPEWORK, PUMPS, HEATING etc.

ITEM FREQ. ACTION NOTES 1. Circulatory pipework, 12m Isolate from pool and drain Do not empty the pool in wintertime, frost will damage including solar panels down. Clean out and dry. the lining if plastic or cause the tile lining to break away. (where fitted). 2. Automatic air vents. 12m Remove, drain and clean. Heating 3. Heating equipment- Oil 6m Carry out maintenance Maintenance of heating plant, other than routine, is best procedures appropriate to the carried out before the heating season starts. -Gas 12m type of heating plant as detailed in relevant sections.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 426 58-01 ON/OFF SWITCHING DEVICES

ITEM FREQ. ACTION NOTES Thermostats 1. Location. 12m Check that thermostat is not For example thermostats may be situated above affected by local heat radiators, affected by direct sunlight or in cold sources. draughts. Report to client if change of location is needed. 2. Condition. 12m Clean and check operation including contacts. 3. Setting. 12m Check and report to client if Wrong settings can cause energy wastage. If significant variation in set manual or auto-reset provided check operation. point is found. 4. Calibration. 12m Check against standard. Humidistats 1. Location. 12m Check that humidistat is not For example humidistats may be situated near affected by local heat moisture or heat sources. sources. Report to client if change of location needed. 2. Condition. 12m Clean and check operation, including contacts. 3. Setting. On-line12m Check and report to clientCopy if If manual or auto-reset provided check operation. significant variation in set point is found. Pressure Switches 1. Condition. 12m Clean and check operation.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 427 58-01 ON/OFF SWITCHES - continued

ITEM FREQ. ACTION NOTES 2. Setting. 12m Check and report to client if If manual or auto-reset provided check operation. significant variation in set point is found. 3. Sampling lines. 12m Check for damage or obstruction. 4. Calibration. 12m Check against standard. Differential pressure switches 1. Condition. 12m Clean and check operation.

2. Setting 12m Check and report to client if If manual or auto-reset provided check operation. significant variation in set point is found. 3. Sampling lines. 12m Check for damage or obstruction. 4. Calibration. 12m Check against standard. Vane operated flow switches 1. Condition. On-line12m Clean and check operation. Copy 2. Setting. 12m Check and report to client if If manual or auto-reset provided check operation. significant variation in set point is found. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 428 58-01 ON/OFF SWITCHES - continued

ITEM FREQ. ACTION NOTES 3. Sampling lines. 12m Check for damage or obstruction. 4. Calibration. 12m Check against standard. Level switches 1. Condition. 12m Clean and check operation. 2. Setting. 12m Check and report to client if If manual or auto-reset provided check operation. significant variation in set point is found. 3. Calibration. 12m Check against standard.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 429 58-02 CONTROL RELAYS

ITEM FREQ. ACTION NOTES General 1. Mechanical wear. 12m Inspect for excessive wear. 2. Contacts. 12m Check for wear, redress or replace as required. 3. Coil. 12m Inspect for signs of overheating and insulation breakdown. 4. Electrical operation. 12m Operate relay and check for clean operation of each set of operations. 5. Pole faces. 12m Clean if noisy operation of relay. Plug in type 1. General maintenance. 12m Carry out as per instructions given above. 2. Relay connection pins. 12m Inspect for signs of burning. Replace relay if necessary.

3. Base unit. 12m Inspect for signs of overheating or arcing. Replace base unit if necessary.

Continued on next page .. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 430 58-02 CONTROL RELAYS - continued

ITEM FREQ. ACTION NOTES Mercury switches 1. Mercury bulbs. 12m Inspect and check mechanical and electrical operation. 2. Connections to bulb 12m Inspect for wear, assembly, assembly. breakdown of insulation, or fraying of connections. Latch type. 1. General maintenance. 12m Carry out as per instructions given in CONTROL PANELS. 2. Latched states. 12m Check the mechanical and electrical operation of both latched states. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 431 59-01 TERMINAL UNITS VAV - self powered

Introduction

The term Terminal Units covers those items of equipment relating to the ingress of ventilating or conditioned air into the 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.

ITEM FREQ. ACTION NOTES 1. Thermostat. 6m Check operation. Air volume will increase/decrease depending upon thermostat position. Ensure space temperature is within thermostat range when testing. Calibration } Interrogation } by CONTROL Control adjustment } SPECIALIST

2. Unit filter. 12m Check condition and change if If unit filter is very dirty, check condition of main necessary. filter. 3. Main filter. 3m Check condition. In a dirty environment it may be necessary to On-line Copyclean/change main filter more frequently. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 432 59-02 TERMINAL UNITS VAV - fan powered

Introduction

ITEM FREQ. ACTION NOTES 1. Fan motor. 6m Grease or oil bearings. 2. Dampers. 6m Check operation and lubricate linkages if necessary. 3. LPH and CW coils. 6m Check operation and clean. 4. Controls. 6m Check operation. Note:- Calibration } by CONTROL Interrogation } SPECIALIST Control adjustment } On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 433 59-03 TERMINAL UNITS VAV - pneumatic powered

Introduction

The term Terminal Units covers those items of equipment relating to the ingress of ventilating or conditioned air into the 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.

ITEM FREQ. ACTION NOTES 1. Access to units. 12m Remove access panels or ceiling tiles as Where units are ceiling mounted, cover any appropriate. machinery/office equipment situated below the unit. Seek prior permission before switching off any equipment which is to be covered. Take care not to stain ceiling tiles. 2. Control system (for 12m information only) a) pneumatic Disconnect pneumatic control pipe and check unit motors to alternative setting. or Disconnect electrical control and check unit This is for information only. For details of b) electrical motors to alternative setting. maintenance, see CONTROLS. Reconnect. 3. Air leaks. 12mOn-lineCheck and if found rectify. Copy 4. Insulation. 12m Check condition and make good as necessary. 5. Actuator. 12m If visible, check for dirt, lightly oil mechanism as required.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 434 59-03 TERMINAL UNITS VAV - pneumatic powered - continued

ITEM FREQ. ACTION NOTES 6. Unit thermostat. 12m Operate and check that VAV unit moves in relation to change in setting. Restore to original setting. 7. Filter. 6m Clean or replace as necessary. Frequency of cleaning will depend upon the environment in which the unit operates. 8. Diffusers. 12m Clean, taking care not to stain ceiling.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 435 59-04 TERMINAL UNITS - Constant volume including mixing box (high velocity)

Introduction

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.

ITEM FREQ. ACTION NOTES 1. Units. 12m Check operation. 2. Pneumatic thermostats. 12m Check operation by moving set point. For detailed maintenance see relevant section. Restore to original setting. 3. Control dampers. 12m Check operation. For high velocity For more information on damper maintenance mixing box change over dampers. see DUCTING GENERAL. Check seals. 4. Air grilles. 12m Clean, taking care not to dirty surround. 5. Electrical connections of 12m Check soundness of wires and controls systems. contacts. 6. Filter. 12m Clean or replace as necessary. In a dirty environment it may be necessary to On-line Copyclean/change the filter more frequently. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 436 59-05 TERMINAL UNITS - INDUCTION UNITS

Introduction

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.

ITEM FREQ. ACTION NOTES 1. Secondary air filter. 6m Clean washable filter and retain for re-use. 2. Coil block (where fitted). 6m Inspect for dirt and/or obstructions, cleaning where necessary. Check also for water leaks and rectify as necessary. 3. Primary air nozzles. 6m Check condition, cleaning if necessary by brushing. 4. Nozzle air pressure. 6m Check with manometer. Compare with commissioning data and correct any deviations. 5. Damper and/or 6m Check correct functioning and rectify pneumatic valves. any defects. 6. Chilled water/LPHW On-line6m Check functioning. CopyFor detailed maintenance see VALVES. control valves. 7. Control thermostats. 6m Check operation. Setting should be 19° heating and 24° C cooling. For detailed maintenance see relevant section. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 437 59-05 TERMINAL UNITS - INDUCTION UNITS - continued

ITEM FREQ. ACTION NOTES 8. Isolation valves. 6m Check for leaks and rectify as necessary. 9. Unit. 6m Clean internally and externally. Refit Ensure filter is correctly seated to prevent air by- secondary air inlet filter. Replace passing. any casing which was removed. Note any defects on report.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

438 59-06 TERMINAL UNITS - FAN COIL

The term Terminal U nits covers those items of equipment relating to the ingress of ventilating or conditioned air into the working environment. O perationally their effectiveness may be impaired by the build up of dust and related deposits whilst visually dirt will arise from cigarette smoke and dirt in the atmosphere. In a dirty environment it may be necessary to increase the frequency of maintenance above that recommended in this specification. For detailed maintenance of associated equipment see CONTROLS.

ITEM FREQ. ACTION NOTES 1. Status. 6m Switch off and isolate. Electrical isolation should be carried out in accordance with HASAWA and Electricity at Work Regulations. Where units are ceiling mounted, cover any office machinery/equipment situated below unit being serviced. 2. Coil block. 3m Vent air from cooler and heating coils (if VAV not fitted). 6m Remove air entry filter, inspect coil Depending upon the environment, coil block air block for dirt and clean as necessary. entry filter may need more frequent cleaning. Agree frequency with client. 3. Condensate drain 6m Check connection is clear. connection. 4. Permanent filters. 6m Clean and refit, ensuring proper See FILTERS regarding safety instructions. location. 5. Disposable type filters. On-line 6m Replace ensuring proper location. Copy See FILTERS with regard to safety and disposal procedures. Continued on next page .. 439 59-06 TERMINAL UNITS - FAN COIL - continued

ITEM FREQ. ACTION NOTES 6. Test unit. 6m Restore power supply and run unit. Check airflow is normal at correct speed setting. 7. Casing. 6m Clean. Where units are above false ceilings ensure that tiles are not left in a stained condition. 8. Ductwork flexible 12m Check condition. couplings (if fitted).

9. Grilles and diffusers. 6m Clean using vacuum or alternatively Care should be taken to avoid damage to diffuser remove and clean. ceiling lights or ceiling.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 440 59-07 TERMINAL UNITS – VRV SYSTEMS

Terminal Units Introduction

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.

ITEM FREQ. ACTION NOTES Outdoor Unit 1. Unit casings. 3m Check condition. 2. Coils. 3m Clean and remove any debris. 3. PCBs. 3m Check for damage. 4. Electrical Components. 3m Check condition. 5. Sensors. 3m Check for contact and correct location. 6. Running currents and voltage. 3m Check and record. 7. System neutral and earth 3m Check. connections. On-line Copy Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

441 59-07 TERMINAL UNITS – VRV SYSTEMS - continued

ITEM FREQ. ACTION NOTES Indoor Unit 1. Hand Controllers. 3m Check function. Run units on heating and cooling cycles if heat pumps 2. Air Filter and indoor coils. 3m Clean. Air Filters may initially require monthly cleaning dependant on location. 3. Drain Lines. 3m Check for free running 4. Power supply. 3m Check and record. 5. Electrical and Data Cable 3m Check condition. connections. 6. Change over valves and 3m Check action. If a shortage of refrigerant is suspected all should refrigerant control be removed, any leaks rectified and the refrigerant devices. change weighed in after calculation change using the Manufacturers literature. This work should only be carried out by a competent person who works for a firm registered with REFCOM. On-line Copy 442 60-01 VACUUM SYSTEMS - general

ITEM FREQ. ACTION NOTES Motors. 12m Follow procedure given for MOTORS. Air systems - cleaning 1. Fans. 12m Follow procedure given for As used in centralised vacuum cleaning systems. FANS. 2. Seals. 12m Examine condition and check for leaks. 3. Clips. 12m Check security and operation. 4. Filters. 12m Check condition and change as necessary. See FILTERS. 5. Hose connections. 12m Check condition and replace as necessary. Liquid systems 1. Pumps (liquid systems). 12m Follow procedure given for As used for swimming and hydrotherapy pools. PUMPS. 2. Seals. On-line12m Examine condition and check Copy for leaks. 3. Filters. 12m Check condition and change as necessary. 4. Hose connections. 12m Check condition and replace as necessary. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 443 60-02 VACUUM TUBES - cash handling

ITEM FREQ. ACTION NOTES Central Station 1. operation of door and door handle, 6m Check operation and security of lock.

2. switch, 6m Check electrical and mechanical adjustment.

3. sliding air seals, 6m Check efficacy. If renewal indicated, report to client. 4. door lock solenoid, 6m Check electrical and mechanical adjustment.

5. indicator lights, LEDs, etc., 6m Check function, replace as necessary 6. keyswitch, 6m Check operation. 7. air-valve and seals, 6m Check operation and condition. 8. 8. tube switch (if fitted), 6m Check operation.

9. fixing and tube joints, 6m Check security of fixings and integrity of tube joints. 10. station. On-line6m Clean inside and outside.Copy Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 444 60-02 VACUUM TUBES - cash handling - continued

ITEM FREQ. ACTION NOTES Cash box - local station 1. door locks. 6m Check operation for easy movement. 2. door fittings. 6m Check condition and security of hinges, door bars and transparent screen. 3. foam pad. 6m Check condition. 4. tube switch. 6m Check operation. 5. fixings. 6m Check security of fixings. 6. local station. 6m Check inside and outside.

Blower 1. flexible coupling. 12m Check condition. Report to client if replacement required. 2. mountings. 12m Check security.

3. overload setting. 12m Check setting and adjust if necessary. 4. contactors. 12m Check operation and condition. For more detailed information on the maintenance of contactors see POWER On-line CopySUPPLIES – P.D.U. 5. earth continuity. 12m Check For more detailed information on the maintenance of earthing electrical equipment see POWER SUPPLIES – EARTHING. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 445 60-02 VACUUM TUBES - cash handling - continued

ITEM FREQ. ACTION NOTES Controller 1. running time of capsule. 12m Check

2. relay on capsule. 12m Check condition. General 1. runs. 6m Check flight time of shortest and longest runs. 2. vacuum. 6m Check vacuum on close circuit. Compare with manufacturer's data and report to client if significant variation. 3. system filters (if fitted). 4. carrier (capsule(s)). 5. carrier velcro and lids. 6m Check pull. On-line6m Check condition. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

446 61-01 VALVES

ITEM FREQ. ACTION NOTES a) Gate valves Preventative maintenance on this type of valve is best obtained by daily checks on gland or stem leakage and repairing these as they occur. 1. Operational status. 3m Check, rotate handwheel sufficiently to Action depends upon whether valve is normally indicate that wedge is not seized in closed or normally open. If valve is normally closed position nor jammed in open open, check closure performance in the event position. If normally open, close valve that corrosive deposits prevent wedge seating. and reopen. 2. Gland leakage. 3m Check, within first week slightly tighten After installation or replacement check for gland gland nuts. If after a period leakage leakage daily for one week. Early signs of slight still occurs replace gland. 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. 3. Overall condition. 12m Inspect for external deterioration due Leakage from end flanges can be due to pipe to leaks at end flanges or aggressive strains, ground settlement, poor joints or pipe environment. supports. b) Globe valves 1. Operational status. 3m Check by rotating handwheel On-linesufficiently to ensure freedom Copyof movement. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

447 61-01 VALVES - continued

ITEM FREQ. ACTION NOTES 2. Gland leakage. 3m Check within first week, slightly tighten After installation or replacement check for gland gland nuts. If after a period leakage still leakage daily for one week. Early signs of slight occurs, replace gland. 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.

3. Overall condition. 12m Inspect for external deterioration due to Leakage from end flanges can be due to pipe leaks at end flanges or aggressive strains, ground settlement, poor joints or pipe environment. supports.

c) Lubricated plug valves 1. Operational status. 3m Check by partially rotating plug to Inject correct compound as recommended by the ensure freedom of movement. manufacturer to maintain smooth operation.

2. Stem leakage. 3m If evidence of leakage, inject correct After installation or overhaul check daily for one compound simultaneously rotating plug. week and then at six monthly intervals.

3. Overall condition. 12mOn-line Inspect for external deterioration due toCopyLeakage from end flanges can be due to pipe leaks at end flanges or aggressive strains, ground settlement, poor joints or pipe environment. supports.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

448 61-01 VALVES - continued

ITEM FREQ. ACTION NOTES d) Diaphragm Valves 1. Valve. 12m Isolate and check condition, If diaphragm shows signs of abrasion or Dismantle and clean body, chemical attack refer to manufacturer. threads, spring and diaphragm. 2. Diaphragm. 12m Change if condition suspect. The life of a diaphragm will vary according to the working environment and records relating to each valve should be kept to plan replacement schedule. 3. Reassembly. 12m Tighten bolts diagonally, do not To ensure correct operation and long life of the overclose the diaphragm. diaphragm, avoid overtightening the securing bolts.

e) Pressure Control Valves 1. Strainers preceding valves. 6m Clean strainer screens. The level of contamination can provide an indication of required frequency of valve maintenance. 2. Control valve. 12m Overhaul using standard Observe carefully manufacturer’s instructions maintenance repair kit. regarding dismantling and installation. 3. Main valve and seat assembly. 12m Examine seat for damage, wear If they are only slightly worn both the main valve and scale build up. head and main seat may be lapped on a flat plate using a fine grinding paste. If either is On-line Copybadly worn or unfit for further use they should be replaced. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

449 61-01 VALVES - continued

ITEM FREQ. ACTION NOTES f) Butterfly valves 1. Operational status. 3m Check by partially rotating disc to Close valve (if system condition allows) and ensure freedom of movement. check seat tightness, this tests the condition of the elastomeric seal. 2. Stem leakage. 3m Check for freedom from dirt particles. After installation or overhaul, check for stem Tighten gland if adjustable type, if not leakage daily for the first week. replace proprietary seals (e.g. 'O'- rings).

3. Overall condition. 12m Check for deterioration externally or Wafer pattern unlikely to have flange leakage aggressive environment. provided that flange bolting has been tightened evenly. g) Float operated valves 1. Operational status. 3m Check for drips from valve indicating Depress float to flush seat. If leak persists, check leaking seat. seat for damage or replace washer. 2. Overall condition. 12m Check. h) Parallel slide valves 1m See Notes. It is recommended that these valves be operated On-line Copyover their full travel once every four weeks. 1. Operational status. 3m Valve normally closed, rotate Close valve (if system allows) to check seat handwheel to ensure freedom of tightness. If valve normally closed, drop movement. differential pressure to 1 bar or less (if system allows) and partially rotate to check for freedom from galling seats. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

450 61-01 VALVES - continued

ITEM FREQ. ACTION NOTES 2. Gland leakage. 0.25m Check, within first week slightly tighten After installation or replacement check for gland gland nuts. If after a period leakage still leakage daily for one week. Early signs of slight occurs, replace gland. 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. 3. Body leakage. 12m Check for body/cover joint leakage and As a matter of routine any visible signs of leakage tighten nuts to stop. should be reported to the site supervisor. 4. Overall condition. 12m Inspect for external deterioration due to Leakage from end flanges can be due to pipe leaks at end flanges or aggressive strains, ground settlement, poor joints or poor pipe environment. supports. i) Steam Safety valves 1. Operational status. 3m Check by raising gagging lever to Important: Great care must be exercised to avoid discharge steam or air. Release injury to personnel. Check that discharge is to free gagging lever to reseat. Check for dirt space or if piped, that pipe outlet is not directed to or damage. personnel. NOTE: Check with insurance company for frequency of mandatory checks. 2. Bursting discs (if 12m Check condition, report. It is recommended that maintenance on this type fitted). of valve should be carried out at the time of the annual boiler inspection. Persistent leakage at the On-line Copynormal boiler pressure will be due to deposits. The valve should be cleaned and reconditioned as soon as possible. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

451 61-01 VALVES - continued

ITEM FREQ. ACTION NOTES j) Steam pressure reducing valves 18m 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. 1. Main valve seat and valve 12m Isolate and reduce pressure to zero. The actual maintenance requirements may vary head. Remove screen and clean, clean with the type of valve and the manufacturer's gasket faces and renew gasket. instructions should be followed carefully. 2. Pilot valve chamber 12m Isolate and reduce air pressure to zero. The dimension of the plunger gap is critical and assembly. Check dimensions of plunger gap and it may be necessary to grind or machine the top adjust if necessary. of the plunger. 3. Pilot and main 12m Thoroughly clean upper and lower When refitting diaphragms make sure that they diaphragms. diaphragm chambers, ensure contact are replaced the same way round as when they faces are clean and reassemble. were removed. k) Boiler valves Note: See also BOILERS for safety valves. 1. Main stop valve. 12m Lap seats, inspect for corrosion, reset valve at correct set pressure and carry out accumulation test. 2. Main stop valve. 12mOn-line Lap seat, repack gland and lubricate Copy spindle, checking for ease of operation. 3. Water level controls. Blowdown and check operation. This should be carried out daily. 0.25m Lower boiler water level and check operation. 6m Clean out chambers of any deposits. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

452 61-01 VALVES - continued

ITEM FREQ. ACTION NOTES 4. Sequencing valve. 12m Clean and lap seats, check for ease Note: See BOILERS for safety valves. of operation. 5. Water level gauge 6m Refit sight glass, repack cock plugs Aggressive site conditions may require and check for ease of operation. increased frequency of these items. Gauge glasses should be regularly replaced before they break.

l) Radiator Valves – TRVs 12m Check air temperature calibration Low temperature surfaces for heat emitters are against surface temperature of heat desirable in homes for senior citizens/disabled. emitter.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

453 61-02 TAP AND OUTLET FITTINGS - general

A large range of outlet fittings suitable for high and low pressure supplies are fitted in this country, most requiring little or no 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.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

454 61-03 SERVICE VALVES

ITEM FREQ. ACTION NOTES Stop cocks and stop taps 1. Operational status. 12m Operate head to ensure the stopcock Clean exposed stem prior to operation. If cock or tap is operating correctly. If or tap fails to isolate water supply, re-washer normally open, close and then re- and reset as necessary. open. 2. Gland leakage 12m Check for weeping gland, slightly tighten gland nut if necessary. If weeping still occurs, replace gland seal. 3. Overall condition 12m Inspect for external deterioration due to leaks. Sluice valves 1. Operational status. 12m Operate hand wheel or stem to test To comply with the Water Regulations, stop that wedge is not seized in closed valves should be WRC approved and must not position. If normally open close be less suitable for the purpose than those valve and re-open. which comply with: BS 1010, BS 5433 or BS 5163. 2. Gland leakage 12m Check for weeping gland, slightly tighten gland nut if necessary. If On-lineweeping still occurs, replace Copy ‘O’ ring or packing.

3. Overall condition 12m Inspect for external deterioration due Wire brush and paint as necessary. to leaks.

455 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. ITEM FREQ. ACTION NOTES Functional checks If any of the functional checks fails to meet the set parameters, then refer to service checks. 1. Inlet check-valves (if fitted). 6m Check inlet pipework surface A more effective test can be considered if temperature for indication of appropriate, utilising drain points positioned crossflow. between isolating and check-valves.

2. Temperature For thermostat and pressure balanced mixers, blend temperature should stabilise quickly and a) locked, 6m Operate flow controls and check remain with ± 2oC of set value. For manual blend temperature. Check maximum b) adjustable/pre-set maximum. and minimum blend temperature. mixers, refer to commissioning data. 3. Thermal shutdown 6m Operate mixer at blend temperature, Valve must shut down in accordance with the (Thermostatic valves only). then isolate cold supply. manufacturer’s data. 4. Temperature control. 6m Operate mixer at blend temperature, Check shift in blend temperature with reference then open other local cold outlets off data compiled at the commissioning stage. common supply. 5. Strainers. On-line6m Isolate and check visually andCopy clean as necessary. 6. Flow control(s). 6m Operate fully and check for effective If time delay is incorporated, check length of closure. flow cycle. 7. Automatic drain valve (if 6m Check effective operation. fitted). Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 456 61-04 MIXING VALVES/TAPS - continued

ITEM FREQ. ACTION NOTES 8. Spray heads (showers). 3m Check spray pattern and flow rate. Note ACOP L8,2001 applies. Clean as appropriate. Service checks 1. Mixing valve: 12m Carry out visual check of internal Refer to manufacturer’s data for recommended a) temperature control, serviceable mechanisms. Clean or procedures and cleaning agents/lubricants. b) flow control(s), renew components as necessary. For products of (serviceable) cartridge c) inlet check valves, Lubricate as indicated in construction, if and commission exchange d) automatic drain valve. manufacturer’s data. units. Service displaced units in workshop as part of rolling planned maintenance procedure. 2. Supply pipework. 12m Visually check for damage leak, etc. and rectify. Check that supply pressure and temperature agree with commissioning data. 3. Recommissioning. 12m On completion conduct functional checks. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 457 61-05 SHOWER VALVES

Note: Frequency of maintenance will depend upon use and the quality of the water and should be agreed with client. ITEM FREQ. ACTION NOTES Thermostatic mixing valves 1. Controls. 6m Operate inlet valves and check If valve is stripped down and reassembled all individual flow rates of hot and cold parts should be greased as recommended in the water supplies. manufacturer’s maintenance instructions. 2. Thermostat. 6m Check mixed water outlet setting. Ensure thermometer bulb is immersed in flowing water if measurement taken at shower head.

3. Temperature limiter. 6m Check mixed water outlet temperature Limiter setting 42oC. at limit safety stop. 4. Strainers (where fitted). 6m Clean. 5. Inlet check valves (where 6m Check operation. Non-return valves may have been removed if fitted). operating with balanced pressure supplies. 6. Fail-safe. 6m Operate thermostatic shower valve with cold water turn off to establish correct ‘fail safe’ operation. Shower valve fittings 1. Auto drain valve (where On-line6m Operate shower valve and Copycheck fitted). automatic operation of downstream drain valve. 2. Push button shower 3m Strip down, clean and reassemble. 3m represents the maximum interval, the actual timers. frequency will depend upon the water quality and should be agreed with the client. Regular maintenance will save water and energy. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

458 62-01 AUTOMATIC CONTROL VALVES

Pre-maintenance procedure

This procedure applies to all types of automatic control valves and requires that before any maintenance is undertaken all Health and Safety precautions must be adhered to including system isolation. Care must be taken to ensure that any maintenance does not unduly interfere with environmental operating conditions.

1. Inspect, where changes, disconnections or unrecorded settings are found, report and discuss with client.

2. Note any settings made; i.e. min/max travel balancing valve setting etc.

3. Check valve body and fixings for any signs of corrosion or mechanical damage.

4. Check that pipe flange or screw connections are not leaking.

5. Where fitted, check that the actuator yoke and linkages are secure and not bent or damaged.

6. Check correct installation of valve with reference to both type and manufacturer.

There are a large number of valve manufacturers who each call for specific maintenance and lubrication procedures for their products and to avoid undue repetition in maintenance the following terms have been used in the schedules.

Manufacturer's maintenance instructions. On-line Copy Manufacturer's lubrication instructions.

Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

459 62-02 ROTARY VALVES - shoe or slipper

Pre-maintenance procedure

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.

Manufacturer's maintenance instructions.

Manufacturer's lubrication instructions.On-line Copy 460 62-02 ROTARY VALVES - shoe or slipper - continued

ITEM FREQ. ACTION NOTES 1. Operational status. 12m Operate and check for correct Check by operation of the actuator, see rotary travel. ACTUATORS - motor driven. Refer to manufacturer's maintenance instructions.

2. Let by. 12m Check that the valve is not Normally 'O' ring seals are fitted and cannot be letting by excessively. adjusted, replace if leaking and inspect spindle for wear. 3. Glands/spindle condition. 12m Inspect for gland leakage, refer to manufacturer's maintenance instructions. 12m For lubrication refer to manufacturer's lubricating instructions. 4. Overall condition. 12m Inspect for external On-linedeterioration. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 461 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.

Manufacturer's maintenance instructions. Manufacturer's lubrication instructions.On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 462 62-03 BUTTERFLY AND BALL VALVES - continued

ITEM FREQ. ACTION NOTES 1. Operational status. 12m Operate and check for correct Check by operation of the actuator, see rotary travel. Refer to ACTUATORS – Motor Driven. manufacturer's maintenance instructions.

2. Let by. 12m Check that valve is not letting by excessively. 3. Glands/spindle condition. 12m Inspect for gland leakage, refer Normally 'O' ring seals are fitted and cannot be to manufacturer's maintenance adjusted, replace if leaking and inspect spindle for instructions. wear. For lubrication refer to manufacturer's lubrication instructions.

4. Overall condition. 12m Inspect for external deterioration. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

463 62-04 SELF ACTING and THERMAL VALVES

Pre-maintenance procedure This procedure applies to all types of automatic control valves and requires that before any maintenance is undertaken all Health and Safety precautions must be adhered to including system isolation. Care must be taken to ensure that any maintenance does not unduly interfere with environmental operating conditions.

1. Inspect, where changes, disconnections or unrecorded settings are found, report and discuss with client.

2. Note any settings made; i.e. min/max travel balancing valve setting etc.

3. Check valve body and fixings for any signs of corrosion or mechanical damage.

4. Check that pipe flange or screw connections are not leaking.

5. Where fitted, check that the actuator yoke and linkages are secure and not bent or damaged.

6. Check correct installation of valve with reference to both type and manufacturer.

Manufacturer's maintenance instructions.

Manufacturer's lubrication instructions.On-line Copy 464 62-04 SELF ACTING and THERMAL VALVES - continued

ITEM FREQ. ACTION NOTES 1. Operational status. 12m Check for correct travel. Refer to - motor driven actuators. In Check integrity of capillary. some cases manual override is only Refer to manufacturer's maintenance available by removal of actuating instructions. head. 2. Let by. 12m Check that the valve is not letting by excessively. 3. Glands/spindle condition. 12m Inspect for gland leakage, refer to Adjust or replace seals as necessary. manufacturer's maintenance instructions. Inspect and check for wear and corrosion This can cause leakage or damage to of the spindle. the gland seals, if there are any signs For lubrication refer to manufacturer's of deterioration the spindle should be lubricating instructions. replaced - this will involve the removal of the valve. 4. Overall condition. 12m Inspect for external deterioration. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

465 62-05 SOLENOID VALVES

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.

Manufacturer's maintenance instructions.

Manufacturer's lubrication instructions.On-line Copy 466 62-05 SOLENOID VALVES - continued

ITEM FREQ. ACTION NOTES 1. Operation status. 12m Operate and check for correct Check by operation of the solenoid. Check linear travel. supply voltage and that polarities are correct - Check for solenoid noise i.e. refer to manufacturer's instructions. buzzing. Noise can be due to dirty pole faces, remove coil and clean pole faces. 2. Let by. 12m Check that valve is not letting by excessively. 3. Glands/spindle condition. 12m Inspect for gland leakage, refer Adjust or replace seals as necessary. to manufacturer's maintenance instructions. Inspect and check for wear and This can cause leakage or damage to the gland corrosion of the spindle. seals, if there are any signs of deterioration the spindle should be replaced - this will involve the removal of the valve. For lubrication refer to manufacturer's lubricating instructions. 4. Overall condition. 12m Inspect for external On-linedeterioration. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 467 62-06 PRESSURE CONTROL VALVES

ITEM FREQ. ACTION NOTES 1. Leakage. 12m Check and rectify. Refer to manufacturer's maintenance instructions. 2. Operation. 12m Check. Refer to manufacturer's maintenance instructions. 3. Setting. 12m Check. 4. Valve 24m Strip and clean. Refer to manufacturer's maintenance instructions.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 468 62-07 SEAT VALVES

ITEM FREQ. ACTION NOTES 1. Operational status. 12m Operate and check for correct Check by operation of the actuator, Motor linear movement. Driven Actuators. See ACTUATORS-Motor Driven. 2. Let by. 12m Check that valve is not letting when in closed position.

3. Gland and spindle. 12m Check For gland leakage Spindle for wear and contamination.

For lubrication refer to manufacturer's instructions. 4. Overall condition. 12m Inspect for external damage or deterioration. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 469 63-01 UNDERFLOOR HEATING including VEHICLE ACCESS RAMPS

ITEM FREQ. ACTION NOTES 1. Electrical continuity. 12m Check for any faults. Note current drawn and check with initial design date. Any significant shortfall may indicate a damaged or broken conductor. 2. Earthing. 12m Check and ensure connection(s) are secure. 3. Controls. 12m Check operation. For more detailed maintenance instructions, see relevant section. 4. Frost actuation. 12m Check sensor, if faulty, For more detailed maintenance instructions, see replace. Check operation. relevant section.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 470 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. ITEM FREQ. ACTION NOTES 1. Barriers. 6m Check vertical and horizontal positions. 2. Limit switches. 6m Inspect condition and adjust as necessary. 3. Safety switch. 6m Check operation. 4. Push button for barrier 6m Check condition. op operation.

5. Drive motor and brushes. 6m Check for correct operation.

6. Motor overload. 6m Check for correct operation and (See also MOTORS) adjust as necessary. 7. Electrical terminations 6m Check condition and make good if and wiring. On-linenecessary. Copy

8. Mechanical items. Responsibility for the maintenance of these items should be agreed with the client. 9. Induction loop. 6m Check operation. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

471 64-01 VENTILATION ANCILLARIES

Introduction

1 Local exhaust ventilation – fume extract

In bus and vehicle garages and other areas where the build up of dangerous fumes may occur special air extraction systems are often installed. These may be fixed, flexible or mobile installations often incorporating controls and sensors. It is important to observe that the maintenance, examination and testing of local exhaust ventilation HSG 54, 1998 applies.

2 Life supporting systems

This equipment is essential in hazardous areas and it is vital that it should be well maintained. Because of its importance maintenance of such equipment should be carried out by specialist personnel.

On-line Copy 472 64-02 MOTOR DRIVEN EXHAUST HOSE REEL

ITEM FREQ. ACTION NOTES 1. Hose, both starter hose 12m Check for flattening and damage. and extensions, if fitted, Check condition of hose stop and and hose stop. location on hose. 2. Control box and 12m Check functions i.e. up, down, on/off With pendant control ‘up/down’ only. Remote operation. fan if ‘RCR’ reel fitted with auto fan control reel (RCR) only has ability for:- on hose contractor. lowering fan will start and on retraction will switch off only if reel either a) combi-unit, or b) fitted with fan contractor. 3. Upper and lower 12m Check function and condition of upper Lower limit switch activates when reel has switches. and lower limit switch. lowered its full length of hose. 4. Infrared transmitter. 12m Check functions and condition. Test Applies to RCR only. battery and replace if necessary. 5. Main drive gear. 12m Check overall condition of gear for Gear will be visible on removal of control cover. wear. 6. Swivel coupling and drive 12m Check for free drive/rotation of reel. (See also MOTORS) motor.

7. Nozzle. 12m Check damper for damage and ‘Mole grip’ type clamp only available on operation of spring. Check operation rubber/steel construction nozzle. On-lineof grip and general condition Copy of nozzle. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 473 64-03 SPRING RECOIL HOSE REEL

ITEM FREQ. ACTION NOTES 1. Hose, both starter hose 12m Check for flattening and damage. and extension, if fitted, Check condition of hose stop and and hose stop. location on hose. 2. Spring and ratchet. 12m Check recoiling action of reel and correct tensioning of spring. Check operation of ratchet. 3. Swivel coupling and 12m Check for free movement/rotation of drum. drum. 4. Auto on/off switch for fan, 12m Check location and mounting of two if fitted. switch trigger blocks on drum side. Check operation of switch for control fan. 5. Suspension/mounting 12m Check tension on mounting bolts and bolts. ‘nip up’ if required.

6. Nozzle. 12m Check damper for damage and ‘Mole grip’ type clamp only available on operation of spring. Check operation rubber/steel constructed nozzles. of grip and general condition of On-linenozzle. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 474 64-04 MOBILE DUST SEPARATOR FOR SPOT EXTRACTION (See also MOTORS)

ITEM FREQ. ACTION NOTES 1. Suction and 12m Check condition for damage or interconnecting hoses. flattening. 2. Mounting. 12m Check tension on mounting bolt between handle, dust collector and motor and filter housing. 3. Switch cable and motor. 12m Check full length of cable for damage and operation of switch. Check for smooth running of motor. 4. Pressure reduction hose. 12m Check condition and connections of small bore hose. 5. Gaskets and cyclone 12m Check top of cyclone for debris and For access, unclip lid assembly from over-bin and mounting rod. correct location of mounting rod. unbolt cyclone plate. After replacing lid and cyclone arrangement check seating of gasket. 6. Filter. 12m Check condition and replace as Note:- Discarded filter elements should be placed necessary. On replacement of filter in sealed bags for disposal. check condition of gasket. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 475 64-05 MOBILE ELECTRONICALLY CONTROLLED CYCLONE SEPARATOR

ITEM FREQ. ACTION NOTES 1. Suction and 12m Check condition for damage or interconnecting hoses. flattening.

2. Mounting. 12m Check tension on mounting bolt to trolley and tighten as necessary. 3. Control box and cable. 12m Check functions of control box, e.g. When running check correct direction of rotation on/off. Check full length of cable for of fan. damage. 4. Pre-filter. 12m Visually check condition of main gear For access, pull back rubber collar at the top of wheel on filter and drive gear on the filter housing, remove retaining screws and cleaning handle. Visually check carefully remove filter cover. condition of pre-filter and seating of gasket. 5. Filter. 12m Check condition of flipstrip filter and Note:- Discarded filter elements should be placed replace if necessary. Ensure correct in sealed bags for disposal. Waste Disposal seating of gasket. Regulations may apply

6. Cone valve. 12m Check condition and operation of This valve should rise when the unit is switched On-linevalve. Copyon; and lower as the vacuum decreases when the unit is switched off. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 476 64-06 VEHICLE EXHAUST RAIL SYSTEM

ITEM FREQ. ACTION NOTES 1. Hose on suction unit. 12m Check condition of hose for flattening Examine both upper and lower hoses. and damage.

2. Safety break coupler. 12m Check overall condition of coupling Access to spring clips is achieved by pulling back and location of and condition of spring centre rubber collar. clips between retaining pins. 3. Nozzle. 12m Check damper for damage and ‘Mole grip’ type clamp only available on operation of spring. Check operation rubber/steel constructed nozzles. of grip and general condition of nozzle. 4. Suction trolley. 12m Check trolley for free rolling without ‘play’ movement. 5. Auto disconnect system. 12m Check operation by clamping a small Not fitted on manual disconnect units. piece of steel or alternative between jaws of clamp. Slide trolley to Clamp jaws should open on ball assembly ‘disconnect’ position and ensure location in disconnection brackets. correct location. 6. Rubber seal. On-line12m Check overall condition. CopyMay be lubricated with silicone spray. 7. Suspension/Mounting 12m Check tension on mounting bolts and bolts. ‘nip up’ if required. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 477 64-06 VEHICLE EXHAUST RAIL SYSTEM - continued

ITEM FREQ. ACTION NOTES 8. Duct connections. 12m Check seal and condition of end caps and fan duct connection pipe.

10. Spring balancer. 12m Check condition of cord and free rotation and recoil of spring balancer.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 478 65-01 WATER TREATMENT AND CONDITIONING

Introduction

Water may be used for a variety of purposes within buildings, some of the applications will require the water supplied to the building to 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. On-line Copy 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 should 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. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 479

65-01 WATER TREATMENT AND CONDITIONING Introduction - continued 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 and 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)On-line Copy 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) Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications

480 65-01 WATER TREATMENT AND CONDITIONING Introduction - continued

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 G Based on physical principles 1. Magnetic field type 2. Electrolytic 3. Ultrasonic 4. Electromagnetic 5. Induction

Not covered by this specification are: Water treatment in process plant Specialist hospital plant On-line Copy 481 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. ITEM FREQ. ACTION NOTES 1. Salt saturator (may be 6m Check salt level and report as In addition to routine checks, the frequency may be combined with brine tank). necessary. altered by the client's operator to suit usage. 2. Brine tank (where fitted 6m Clean as appropriate. Check with If brine is not fully saturated, brine system requires separately). brineometer that brine is fully further investigation. Client should be advised and saturated. matter referred to manufacturer or equipment supplier. 3. Overflow and drain. 6m Clean and clear of debris and dirt. 4. Water leaks. 6m If present, locate source and report. For control valves and vessel, manufacturer's advice should be sought. 5. Inlet water hardness. 6m 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. 6. Outlet (soft) water 6m Measure from sample of water taken Treated water may be hard due to over running or hardness. On-linewhen softener is in use and waterCopy is fault condition which should be rectified. flowing. 7. Electrical control system 6m Check condition of all electrical Refer to plant operator's manual. (where fitted). connections. 8. Regeneration sequence. 6m Put plant into regeneration sequence If system malfunctioning, refer to manufacturer or and check all stages of operation. supplier. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 482 65-02 ION EXCHANGE PLANT- BASE EXCHANGE SOFTENING - commercial - continued

ITEM FREQ. ACTION NOTES 9. Pressure drop over 6m Check and record in plant log. A gradual build up in back pressure could indicate softener (where provision fouling or breakdown of the ion exchange medium. to measure exists). 10. Booster pumps. 6m Carry out maintenance programme as detailed in PUMPS. 11. Ancillary controls and 6m Inspect for check operation and probes (where fitted) report. a) conductivity, b) electro chlorination. 12. Plant. Check overall condition and report. 13. Valves. 6m Overhaul individual valves. 14. Back flow prevention 6m Check operation. Where operation is between two tanks, check can be devices. carried out by observing whether there is a change of levels of the two tanks. 15. Recommissioning. 6m Set up flow rates to suit. Report details to client. 16. Water test. On-line6m Final water test taken. CopyBack 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. 17. Major overhaul. 36m Details should be agreed with client. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 483 65-03 ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - domestic (capacity usually below 50 litres)

ITEM FREQ. ACTION NOTES 1. Salt tank. 12m Inspect and clean tank and filter screens. 2. Overflow and drain. 12m Clean and clear of debris and dirt. 3. Injector screen and flow 12m Clean injector screen and flow Where required by equipment manufacturer. controller. controller. 4. Inlet water hardness. 12m Measure and record in plant log, adjust plant as appropriate. 5. Outlet (soft) water 12m Measure from sample of water hardness. taken when softener is in use and water is flowing. 6. Water leaks. 6m If present, locate source and For control valves and vessel, manufacturer's advice report. should be sought. 7. Electrical control system 6m Check condition of all electrical (where fitted). connections. 8. Regeneration sequence. 6m Put plant into regeneration A gradual reduction in service flow may indicate sequence and check all stages breakdown of the medium. On-lineof operation. Copy Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 484 65-03 ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - domestic - continued

ITEM FREQ. ACTION NOTES 9. Booster pumps. 6m Carry out maintenance programme as detailed in PUMPS. 10. Ancillary controls and 6m Inspect for check operation and probes (where fitted) report. a) conductivity, b) electro chlorination. 11. Back flow prevention 6m Check operation. Where operation is between two tanks, check can be devices. carried out by observing whether there is a change of levels of the two tanks. 12. Recommissioning. 12m Set up flow rates to suit. Report details to client. 13. Water test. 6m Take final water test. Back pressure readings will give some indication of the condition of the resin bed. Take sample and send to laboratory if part of service schedule agreed with client. 14. Major overhaul. 36m Details should be agreed with client. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 485 65-04 SPECIAL WATER TREATMENT SYSTEMS

This type of plant is normally serviced by the manufacturer or his agent.

ITEM FREQ. ACTION NOTES 1. Deionisation These are specialised items of plant. Refer to the (de-mineralisation). manufacturer or supplier for advice on maintenance. 2. Electrolytic water These are generally of 'sealed' type construction, therefore no c conditioners. internal maintenance is possible. Some products do require reversal however, this is specific to some models and should be referred to the manufacturer for advice. 3. Ultra-sonic type. These are specialised items of plant. Refer to the manufacturer or supplier for advice on maintenance.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 486 65-05 FILTRATION, CONDITIONING and pH CORRECTION - central plant

ITEM FREQ. ACTION NOTES Iron removal 1. Feed water and treated 3m Collection samples of feed and If the maximum concentration of iron in the treated water water iron levels. treated water and visually is specified, send sample to laboratory for analysis. compare differences in clarity. 2. Water leaks. 3m If present, trace source and Any leaks on control valves or vessels should be repair. referred to manufacturer or supplier. 3. Control system. 3m Check function of electrical control system. 4. Clean cycle 3m Initiate a clean cycle and check Check operations with plant manual. Refer to for correct function. manufacturer or supplier if there are any malfunctions. 5. Major overhaul and 24m Following a clean cycle inspect Carry out medium replacement if necessary as per inspection. medium bed for content and manufacturer's instructions. Ensure correct type of fouling. medium for the application is installed and recommission after medium is replenished or replaced. pH correction Frequency shall be agreed with the client. 1. Feed water and treated On-line3m Collect samples of feed and CopyIf the pH in the treated water differs from the water pH levels. treated water and measure pH. specification, investigate and report to the client. 2. Water leaks. 3m If present, trace source and Any leaks on control valves or vessels should be repair. referred to manufacturer or supplier. 3. Control system. 3m Check function of control system. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 487 65-05 FILTRATION, CONDITIONING and pH CORRECTION - central plant - continued

ITEM FREQ. ACTION NOTES 4. Back wash. 3m Initiate a clean cycle and check Check operations with plant manual. Refer to for correct function. manufacturer or supplier if there are any malfunctions.

5. Medium inspection. 3m Following a clean cycle inspect Carry out medium replacement if necessary as per medium bed for content and manufacturer's instructions. Ensure correct type of fouling. medium for the application is installed and recommission after medium is replenished or replaced. Frequency should take into account usage and local conditions.

6. Major overhaul. 36m Carry out in accordance with manufacturer's instructions. Activated carbon filtration 1. Feed water and treated 3m Collect samples of feed and Criteria of water quality should be agreed with the client. water. treated water and assess condition against agreed criteria. 2. Water leaks. 3m If present, trace source and Any leaks on control valves or vessels should be On-linerepair. Copyreferred to manufacturer or supplier. 3. Control system. 3m Check function of control system.

Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 488 65-05 FILTRATION, CONDITIONING and pH CORRECTION - central plant - continued

ITEM FREQ. ACTION NOTES 4. Back wash. 3m Initiate a clean cycle and check Check operations with plant manual. Refer to for correct function. manufacturer or supplier if there are any malfunctions.

5. Medium inspection. 3m Following a clean cycle inspect Carry out medium replacement if necessary as per medium bed for content and manufacturer's instructions. Ensure correct type of fouling. It is essential not to medium for the application is installed and recommission saturate carbon filter after medium is replenished or replaced. Frequency systems. should take into account usage and local conditions.

6. Major overhaul. 36m Carry out in accordance with manufacturer's instructions. Turbidity treatment 1. Feed water and treated 3m Collect samples of feed and If the turbidity of the treated water is specified send water. treated water. samples to laboratory for analysis.

2. Water leaks. 3m If present, trace source and Any leaks on control valves or vessels should be On-linerepair. Copyreferred to manufacturer or supplier.

3. Control system. 3m Check function of control system. 4. Back wash. 3m Initiate a clean cycle and check Check operations with plant manual. Refer to for correct function. manufacturer of supplier if there are any malfunctions. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 489 65-05 FILTRATION, CONDITIONING and pH CORRECTION - central plant - continued

ITEM FREQ. ACTION NOTES 5. Medium inspection. 36m Following a clean cycle inspect Carry out medium replacement if necessary as per medium bed for content and manufacturer's instructions. Ensure correct type of fouling. medium for the application is installed and recommission after medium is replenished or replaced.

6. Major overhaul. 36m Carry out in accordance with manufacturer's instructions.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 490 65-06 FILTRATION and CONDITIONING - POINT OF USE

ITEM FREQ. ACTION NOTES Active carbon - cartridge filter 1. Cartridge. 6m Change cartridge. Maintenance operatives must take suitable precautions to prevent contamination of potable water supply. 2. 'O' ring seals. 6m Inspect and clean or replace as necessary.

3. Control isolating valve. 12m Check operation. 4. Sealed type housing. 12m Remove and replace complete Timescale should be according to the manufacturer's housing. recommendations. N.B. It is essential not to over run the recommended timescales. Bacterial removal filters. 1. Cartridge type. 3m Remove, clean and disinfect If flow drops to an unacceptable level earlier cartridge. Inspect for cracking maintenance may be necessary. Disinfection may not or damage. be required, refer to manufacturer's instructions. 48m Change cartridge. Interval may be less than 48m if frequency of cleaning become unacceptably short. 2. Sealed or combined type a) cartridge, On-line6m Change cartridge. CopyThe frequency may vary according to the quality and usage of the inlet water. b) control isolating valve. 12m Check operation. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 491 65-06 FILTRATION and CONDITIONING - POINT OF USE - continued

ITEM FREQ. ACTION NOTES Sediment removal filters 1. Cartridge. 6m Change cartridge. Frequency, which will depend upon the quality of the inlet water supply, should be agreed with the client.

2. 'O' ring seals. 6m Inspect and clean or replace as necessary. 3. Control isolating valve. 12m Check operation. Magnetic water conditioners Caution: Before servicing magnetic water conditioners it is advisable to remove watches, cassettes or articles which may be damaged by an intense magnetic field. 1. Strainers (where fitted). 3m Clean, inspect and reassemble. 2. Internal surfaces (where 12m Clean. There are many differing designs of magnetic water accessible). conditioners but all will be adversely affected by iron particles adhering to the faces of the magnets. 3. 'O' rings. 12m Inspect and replace as Refer to manufacturer's instructions. On-linenecessary. Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 492 65-07 REVERSE OSMOSIS

This type of plant comes in a wide variety of designs and reference should be made to the maintenance instructions provided by the manufacturer.

ITEM FREQ. ACTION NOTES 1. Inlet and outlet water 6m Collect samples and submit for If there are any significant differences from the design samples. analysis. parameters notify client and refer to equipment manufacturer.

2. Water leaks. 6m Check and rectify. Any signs of cross leakage between inlet and outlet of unit should be referred to the manufacturer.

3. Control system. 6m Check function of control system. 4. Membrane(s). 6m Check integrity. Need for The actual means of checking the integrity of the replacement should be reported membrane will carry with the design of the unit and to the client. manufacturer's instructions should be followed.

5. Valves. 6m Check action. Detailed information on the maintenance of VALVES, On-line Copysee relevant section. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 493 65-08 ULTRA VIOLET DISINFECTION UNIT

Caution: Ultra violet radiation is dangerous to the eyes, avoid looking directly at the lamp when illuminated.

ITEM FREQ. ACTION NOTES 1. Ultra violet generation 1m Check system operational, Normally this will be carried out by the client's operative unit. clean quartz glass sleeve if and frequency of maintenance should be agreed with wipers are fitted. the client. 2. Cartridge. 1m Change. See note above as frequency will depend upon water quality. 3. Ultra violet lamp. 12m Replace and note date in plant Replacement interval will depend upon type of lamp e.g. log. medium pressure lamps - six months, low pressure lamps - twelve months. 4. Electrical safety. 12m Check security of connections and condition of wiring. 5. Sediment removal pre- 24m Remove, clean and replace If feed water contains iron or organic matter, quartz filter. quartz glass sleeve or thimble. glass may require more frequent cleaning. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 494 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.

ITEM FREQ. ACTION NOTES 1. Dielectric tubes and 6m Remove ozone generating After cleaning and reassembly, vacuum test to ensure electrode assemblies. modules, inspect and clean soundness of both the intermediate tubeplate and seals. dielectric tubes and electrode assemblies. All glass tube 'O' rings must be replaced and steel liners cleaned 2. Filter cartridge in main 6m Remove and replace. Inspect airline from dryer. 'O' ring seals, replace if necessary. 3. Dew point monitor probe. 6m Check calibration. Refer to manufacturer's instructions. 4. a) solenoid valves (where 6m Remove and replace valve fitted), seals and clean valve seats. b) proximity switches 6m Check operation. See SWITCHES. (where fitted). 5. Suction and discharge 6m Check condition, remove and piping. replace purge pump membrane On-lineand diaphragm. Copy 6. Cooling water flow. 6m Check flow rate and operation Each module should be checked. of proximity switch. 7. Ozone generator air flow. 6m Check rate and operation of airflow proximity switch. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 495 65-09 OZONATION PLANT - continued

ITEM FREQ. ACTION NOTES 8. High temperature 6m Check operation. protection circuit. 9. Internal pipework. 6m Check for leakage or damage. 10. Air dryer control unit. 6m Check the timing and adjust as necessary. 11. Recommissioning checks. a) safety control circuits and 6m Restart generator. interlocks, Check operation. b) dewpoint of dried air, 6m Check with portable dew point Warning: H.T. circuit must be isolated when carrying monitor. out this check which will test soundness of internal fittings and piping. c) chiller unit (if fitted), 6m Check operation. For detailed maintenance of refrigeration and chilling unit see CHILLERS. d) water traps, 6m Check water levels. e) active carbon unit, 6m Check level of activated carbon, top if necessary. On-lineCheck operation. Copy f) filter automatic level 6m control valves, g) general. 6m Report to client and manufacturer if further action required. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 496 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 and disposal of all chemicals and note that COSHH Regulations apply. ITEM FREQ. ACTION NOTES Dosing pots - manual operation 1. Water sample 3m Take, analyse and assess On high temperature systems sample should be cooled need for further treatment. before analysis. Special safety procedures apply to taking of samples at high pressure. 2. Low pressure dosing pots. a) valves, 6m Overhaul to ensure correct operation and check for leaks. b) dosing pot. 6m Clean and thoroughly flush with water. 3. Chemicals. 6m Fill dosing pot to correct Ensure correct type of chemical treatment is used for level with appropriate application. Care is required in the handling of chemical or chemical chemicals which should be carried out in accordance On-linesolution for application. Copywith COSHH Regulations. 4. Dosing. 6m Manipulate valves to ensure correct dosing of the system. 5. Water sample (final). 6m Take and check system Sample should only be taken after time has elapsed for water conditions. full circulation and mixing through the system. Continued on next page .. Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 497 65-10 CHEMICAL DOSING - continued

ITEM FREQ. ACTION NOTES Dosing pots - automatic operation Electronically controlled dosing pumps may be affected 1. Chemical dosing pumps. 6m Strip down, clean and by other electrical equipment and should be correctly reassemble. Check isolated. dosing rate. These pumps are usually made of special steels but may be subject to corrosion. Seals and packing may require replacement.

2. Refillable storage vessels. 12m Empty, clean and check for corrosion. Repair or repaint as necessary. 3. Disposable storage vessels. 12m Check level. Replace as appropriate; frequency to be agreed with client. Probes 1. Conductivity/bromine probes. Isolate, remove and 1m clean. 2. Other sensing and flow rate 6m Maintain in accordance with manufacturer's instructions. control devices. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 498 66-01 WHIRLPOOL/SPA BATHS

Note: Frequency of maintenance will depend upon use and the quality of the water and should be agreed with client.

ITEM FREQ. ACTION NOTES 1. Bath hygiene. 12m Clean pipework, pump and Fill bath with warm water to normal level, add sterilising nozzles. solution or low foaming dishwasher powder and operate for 10 minutes. Refill with cold water and operate for five minutes. 2. Suction filter (if fitted). 12m Clean. 3. Nozzle jets. 12m Clean and remove scale, refit Scale may build up in hard water. Client should be and regulate flow rates. informed of the possible need for water treatment. 4. Electrical safety. 12m Check operation of earth Press test button on earth leakage circuit breaker at leakage circuit breaker. least once every three months. 5. Pump and pipework. 12m Check joints and seals for leaks. Rectify or replace as appropriate. 6. Timer (where fitted). 12m Check operation. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 499 66-02 HYDROTHERAPY POOLS

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.

ITEM FREQ. ACTION NOTES 1. Pool cleaning. 12m Drain pool, inspect and Frequency will depend on usage and should be agreed thoroughly clean. with client. Report any defects which cannot be easily remedied. 2. Filters. 12m See section FILTERS. Frequency will depend on usage and should be agreed with client. 3. Water treatment and 12m See section WATER Frequency will depend on usage and should be agreed quality. TREATMENT. with client.

On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications 500 66-03 STEAM ROOMS and HUMIDIFIERS

ITEM FREQ. ACTION NOTES Steam production 1. Generator. 12m Check operating thermostat For more detailed information on the maintenance timer and earth leakage circuit requirements for steam generation see BOILER/HEAT breaker. GENERATORS.

2. Electric element. 12m Descale electrical element if Scale may build up in hard water areas. Client should necessary. be informed of possible need for water treatment.

3. General. 12m See BOILERS/HEAT GENERATORS for more specific information on the maintenance of steam generators. On-line Copy Licensed copy: cpw, Couch Perry & Wilkes, 13/11/2008, Uncontrolled Copy, ®HVCA Publications