Heating and Gas Installations - December 2014

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Johnathan Wilkinson
5 years ago
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1 This is an example of good practice maintenance specifications. It is not exhaustive and should only be used to assist with facilities management or specification of a maintenance contract. Emergency Gas Shut off Valves Carry out maintenance as necessary. All maintenance shall be carried out in accordance with the manufacturers requirements and relevant legislation, by an approved Gas Service Engineer registered by Gas Safe. - Observations and recommendations for actions to be taken with regards to any damage, deterioration, defects, dangerous conditions and noncompliance with the requirements of the Regulations which may give rise to danger. - Details of the Inspection and Test Company. Gas Tightness and Appliances Testing and Purging To be carried out in accordance with IGE/UP/1A Carry out let-by test: - Ensure appliances are connected to the installation and isolation valves open and that control taps/pilot burner supplies are off. - Raise pressure slowly to approximately 10 mbar. - Turn off the gas supply by closing the valve. - Compare the let-by results with the relevant criteria. Carry out soundness test: - Subject to satisfactory let-by test, raise pressure to 20 mbar. - Turn off pressure and allow one minute temperature stabilisation. - Observe for a period of two minutes and note any loss of pressure. - Check there is no smell of gas. - Compare the pressure drop results with the relevant criteria. Purge system: - Identify purge volume. - Note start position of meter index. - Open control tap of appliance furthest from meter. Purge the volume and confirm presence of gas. If more than 0.02m³ purge volume continually attempt to ignite the purged mixture. - Check volume passed through the meter. - Repeat at each branch as required.

2 - Relight appliances and establish a stable flame. Appliance Flues Confirm operating pressure. Visually inspect (making specific reference, but not confined to): - Signs of damage. - Appliance construction and fixings. - Burner ignition. - Flame picture. - Gas controls. - Safety devices and valves. - Combustion chamber, heat exchanger and heating body. - Location of the thermocouple, pilot, weep jet and electrodes. - Gas pressure. - General condition. - Any other item recommended by manufacturer. Check for correct operation and adjust as required (making specific reference, but not confined to): - Thermostats and overheating devices. - Regulators. - Ignition devices. - Flame failure devices. - Pilots and burners. - Ventilation gas interlock. - Any other item recommended by manufacturer. Confirm that there is sufficient ventilation. Visually inspect (making specific reference, but not confined to): - Is unobstructed, complete and continuous throughout its length, is undamaged and adequately supported. - Serves only one room. - More than one appliance is not connected unless it has been specially adapted. - The terminal is correctly sited. - The joints are weather tight. - The catchment space is free from debris, of the correct size and that any openings are effectively sealed. - Air vents are clear of obstruction. - General condition. - Any other item recommended by manufacturer. Carry out flow test. Carry out spillage test.

3 BOILER SERVICE ATMOSPHERIC GAS CONDENSING Once a year or as per manufacturer s recommendations Clean to remove any build-up of dust or dirt: - Flue ways. - Burner box. - Pilot Assembly - Pilot head. - Pilot injector. - Lint filter. - Condensate level probe. - Secondary heat exchanger. - Condensate drain. - U siphon pump. - Fan Inspect and replace thermocouple if required. Top up neutralising unit if required. Re energise boiler mechanically and electrically. Check water circuit, fire burner Adjust burners, gas valves, thermocouple, pilot tube, lint filter and other controls. Carry-out a combustion efficiency test and safety check. Ensure no products of combustion are entering the building Carryout an electrical safety check. Carry out fire safety circuits checks and ensure all components function satisfactorily. All maintenance shall be carried out in accordance with the manufacturers requirements. - Observations and recommendations for actions to be taken with regards to any damage, deterioration, defects, dangerous conditions and noncompliance with the requirements of the Regulations which may give rise to danger. BOILER SERVICE OIL FIRED BOILER Once a year or as per manufacturer s recommendations Clean to remove any build-up of dust or dirt: - Combustion chamber and flue ways. - Fan motor lubricate as required. - Fan scroll ensure air passages are clear to pressure switch - Jet arm assembly where fitted:- remove and clean combustion head, igniter electrodes and inspect HT leads

4 - Blast tube assembly where fitted: - remove and clean combustion head, igniter electrodes and inspect HT leads - Nozzle and filter clean filter and inspect nozzle for signs of wear Replace nozzle and filter annually - Clean oil pump filter. Inspect pump seals for signs of wear Reassemble burner inspect oil line coupling, clean and renew oil line filter, clean photo cell and adjust position - Re energise boiler mechanically and electrically. Check water circuit, fire burner and check flame shape and appearance, if visible. - Test and record oil pressure - Carry-out combustion efficiency test and safety check. - Check for smoke and ensure no products of combustion are entering the building - Check high/low flame conditions - Check air pressure switch under no-air conditions - Test flame failure device for satisfactory operation - Clean and inspect condensate level proving device, if fitted - Clean the secondary heat exchanger, if fitted - Check crystal level and top up neutralising unit, if fitted - Clean inspect and flush condensate drain pipe and U siphon trap, if fitted - Carry out fire safety circuits checks and ensure all components function satisfactorily. All maintenance shall be carried out in accordance with the manufacturers requirements. Upon completion of the inspection and testing, provide a report, which shall include: - Observations and recommendations for actions to be taken with regards to any damage, deterioration, defects, dangerous conditions and noncompliance with the requirements of the Regulations which may give rise to danger. BOILER SERVICE ATMOSPHERIC GAS Once a year or as per manufacturer s recommendations Clean to remove any build-up of dust or dirt: - Flue ways. - Burner box. - Pilot Assembly - Pilot head. - Pilot injector. - Lint filter. - Condensate level probe. - Secondary heat exchanger. - Condensate drain.

5 - U siphon pump. - Fan Inspect and replace thermocouple if required. Re energise boiler mechanically and electrically. Check water circuit, fire burner Adjust burners, gas valves, thermocouple, pilot tube, lint filter and other controls. Carry-out combustion efficiency test and safety check. Ensure no products of combustion are entering the building. Carry-out electrical safety check. Carry out fire safety circuits checks and ensure all components function satisfactorily. All maintenance shall be carried out in accordance with the manufacturers requirements. - Observations and recommendations for actions to be taken with regards to any damage, deterioration, defects, dangerous conditions and noncompliance with the requirements of the Regulations which may give rise to danger. BOILER SERVICE FORCED DRAFT GAS BOILER Once a year or as per manufacturer s recommendations Clean to remove any build-up of dust or dirt: - Combustion chamber and flue ways. - Fan motor lubricate as required. - Fan scroll ensure air passages are clear to pressure switch - Remove HT leads, UV cell and head assembly - Clean and adjust electrode and isolation probe. - Inspect HT leads and probe for soundness. Reassemble burner, re energise boiler mechanically and electrically. Check water circuit and fire burner. Check air and gas settings. - Carry-out combustion efficiency test and safety check. - Ensure no products of combustion are entering the building. - Check high/low flame conditions - Check air pressure switch under no-air conditions - Check flame failure device and take probe or UV cell readings Carry-out electrical safety check. Check neutralising unit if fitted. Top up crystal level if required. Carry out fire safety circuits checks and ensure all components function satisfactorily. All maintenance shall be carried out in accordance with the manufacturers requirements.

6 - Observations and recommendations for actions to be taken with regards to any damage, deterioration, defects, dangerous conditions and noncompliance with the requirements of the Regulations which may give rise to danger. CIRCULATING PUMPS Inspect and adjust drive belts and pulleys, where fitted. Replace drive belts as required Check electrical terminals for cleanliness and tightness Lubricate pump and motor bearings, as required Check and clean anti-vibration mounts Check operation of isolation, regulation and non-return valves Check drain and tundish for cleanliness/water flow Clean suction line strainer Record full load current All maintenance shall be carried out in accordance with the manufacturers requirements and relevant legislation. - Observations and recommendations for actions to be taken with regards to any damage, deterioration, defects, dangerous conditions and non-compliance with the requirements of the Regulations which may give rise to danger. PRESSURISATION UNITS Operate pumps and ensure correct alignment, smooth operation, and minimum vibration. Ensure anti-vibration mounts are satisfactory Ensure couplings are secure Lubricate pump and motor bearings where facilities are provided Clean strainer elements Ensure that break tanks, pipe work and drain holes are clean and have no blockages: - Ensure break tank make-up valve operates satisfactorily - Ensure break tank water level is correct

7 Inspect and check controls and safety switches to include: - Low water cut-out - High and low pressure sensing switches - Electrodes - Starters, relays, contacts and associated wiring and fittings - Status indicators - Audible and visual alarms Check electrical terminals for signs of corrosion and tightness Check control cabinets for cleanliness and signs of moisture ingress Check for correct operation of control valves, pressure relief valves, reducing valves, air vents, etc Inspect diaphragm expansion tanks to ensure diaphragms are sound and air cushion pressure is correct. Top up air pressure as required Test run pressurisation unit and adjust controls to ensure installation operates satisfactorily Record pump full load current All maintenance shall be carried out in accordance with the manufacturers requirements and relevant legislation. - Observations and recommendations for actions to be taken with regards to any damage, deterioration, defects, dangerous conditions and non-compliance with the requirements of the Regulations which may give rise to danger. Hot Water CALORIFIER Check operation of safety valve Check operation and settings of: - thermostats - pressure sensors - altitude gauges - thermometers Check operation of auto controls and prove high limit cut-outs operate correctly. Isolate primary heating and secondary HWS circuit, isolate electrical circuits to calorifier pumps and controls, drain calorifier and remove manhole cover/inspection plate: - Remove scale and debris from calorifier de-scale chemically if required - Check condition of sacrificial anodes, where fitted. Replace if necessary - Fit new gasket to calorifier manhole cover/inspection plate Refill calorifier and check for leaks Reinstate primary circuit and electrical controls circuits Pasteurise calorifier for 1 hour above 60C. Put calorifier back into normal operation and check correct function of all temperature controls.

8 All maintenance shall be carried out in accordance with the manufacturer s requirements and relevant legislation. - Observations and recommendations for actions to be taken with regards to any damage, deterioration, defects, dangerous conditions and non-compliance with the requirements of the Regulations which may give rise to danger. Heating Controls Motor Control Centres and Control Panels - Inspect panels for security, undue noise, vibration, signs of overheating, moisture ingress and cleanliness - Ensure main electrical isolator is secure, fully functional and that connections are sound - Inspect indicator lamps for correct operation, security, signs of overheating, tightness of connections - Ensure spare indicator lamps are available - Check time switches for security, correct settings, correct function, signs of overheating and tightness of connections - Replace time switch batteries as required - Inspect circuit breakers, RCDs, fuses and fuse holders for security, correct rating and signs of overheating and tightness of connections - Ensure spare fuses are available. - Inspect starter assemblies and contactors for correct operation, security, signs of overheating, tightness of connections and correct overload setting - Inspect relays for security, signs of overheating, tightness of connections - Inspect switches for correct operation, security, signs of overheating, tightness of connections - Ensure trunking covers and wiring looms are in position and secure - Check termination rails are secure, tightness of terminations and labels/numbering is positioned correctly - Ensure visual and audible alarms function satisfactorily Sensing Devices and Thermostats - Inspect device and wiring for signs of damage, loose and corroding terminations and cleanliness - Use UKAS/NAMAS calibrated instrument to calibrate device and to test against medium it measures - Check output is as expected and is monitored correctly Modulating Valves and Dampers and Associated Actuators - Inspect assembly and wiring for security, signs of damage, loose and corroding terminations, leakage from glands and cleanliness - Check assembly linkage/connection for correct positioning and security - Check full travel (stroke) of unit and adjust as necessary

9 - Check unit for correct operation in response to control signal. - Check fail-safe operation, where appropriate. Leave unit at correct setting Flow Switches/Pressure Switches/Level Controls - Inspect assembly and wiring for security, signs of damage, loose and corroding terminations, signs of leakage and cleanliness - Check device settings, instigate operational checks at high and low levels and ensure units function correctly and induces the required response - Check fail-safe operation, where appropriate. Leave device at correct setting Speed Controllers - Inspect device and wiring for security, signs of damage, loose and corroding terminations, signs of overheating and cleanliness - Operate device across full duty range. Ensure response to control adjustments is as required. - Check fail-safe operation, where appropriate. Leave device at correct setting Optimising/Compensating Controllers - Identify operating criteria for plant - Check that the controller settings are as per required system operating parameters - Simulate various modes of operation, including normal operation, frost control and fire activation and ensure system/plant functions correctly - In conjunction with and with agreement from client, make adjustments in plant control to improve operational performance - All maintenance shall be carried out in accordance with the manufacturers requirements and relevant legislation - Compile a detailed log of findings, recording all control and device settings and calibration data Upon completion of the inspection and testing, provide a report, which shall include: - Observations and recommendations for actions to be taken with regards to any damage, deterioration, defects, dangerous conditions and non-compliance with the requirements of the Regulations which may give rise to danger. - A signed declaration by the operative carrying out the testing, inspection and GAS STORAGE WATER HEATER Clean to remove any build-up of dust or dirt: - Flue ways. - Burner box. - Pilot Assembly - Pilot head.

10 - Pilot injector. - Lint filter. - Fan - Inspect and clean/replace thermocouple, where fitted - Inspect and clean/replace ionisation probe, where fitted. - Clean condense extraction and condense tray, where fitted Drain water storage vessel and remove inspection plate. - Remove scale and debris from storage vessel de-scale chemically if required - Check condition of sacrificial anodes. Replace if necessary - Fit new gasket to storage vessel inspection plate Refill storage vessel Re energise water heater mechanically and electrically. Check water circuit, fire burner Adjust burner, gas valves, thermocouple, pilot tube, lint filter and other controls. Ensure gas flows are as per manufactures guidelines Ensure water storage temperature controls at 60C Carry-out a combustion efficiency test and safety check. Ensure no products of combustion are entering the building Carryout an electrical safety check. Carry out fire safety circuits checks and ensure all components function satisfactorily. All maintenance shall be carried out in accordance with the manufacturers requirements and relevant legislation. - Observations and recommendations for actions to be taken with regards to any damage, deterioration, defects, dangerous conditions and non-compliance with the requirements of the Regulations which may give rise to danger.

CENTRIFUGAL CHILLER. Lubrication System Pull oil sample for spectroscopic analysis.

CENTRIFUGAL CHILLER. Lubrication System Pull oil sample for spectroscopic analysis. CENTRIFUGAL CHILLER Annual Inspection Refrigerant Circuit Check and record refrigerant level Inspect for leak results Calculate refrigerant lass and report to the customer. Repair minor leaks as required