Appendix C2-preventive Maintenance Checklist 546833
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- Words: 1,635
- Pages: 10
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist INDEX OF PM CHECKLISTS
Check List Equipment No Abbrev
Equipment Type
Cycle
I
CR
Cold room refrigeration system Daily, Monthly, Quarterly and Annually
II
R SB
Roof Switch board
Monthly
III
P
Pump
Daily and Monthly
IV
CR DR
Cold room door
Bi-Monthly
CT
Cooling Tower
Daily, Weekly, Monthly and Quarterly
I
Page 1 of 10
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist
PM SERVICING CHECKS (For Daily, Weekly, Monthly, Quarterly and Annual Cycle) Servicing for Cold room system ___________ on date ________________ (*____ Cycle) NO.
DESCRIPTION
NAME & SIGNATURE
JOB EXPLANATION/REMARKS
I. Cold room Refrigeration System (CR) including but not limited to compressor, FCU, Condenser and Evaporator Daily 1
2
3
Check and ensure no leakage of oil for each compressor. Check and ensure all Freon level for each system (should a shortage appear, the fault must be resolved before charging refrigerant)
Check for ice forming at evaporator (the fault must be clarified, before manual defrost is performed)
Check for head Pressure in the secondary systems. 4
5
6
(The head pressure should be minimum 1 Bar, it need to be filled if needed, the deviation can be leak or air, it must be clarified )
Check and ensure proper functionality of PLC switchboard. (PC and all 11 PLC systems are combined with a mod-bus communication system )
Check cold room temperature monitoring for each room including the automatic log function, the log files are updated with recording files
Monthly 1
2
3
Carry out all daily tasks accordingly. Check and ensure condenser coil fins cleanliness to ensure efficiency of the system. Check and ensure unit cooler fin and evaporator cleanliness. Clean if necessary to ensure
Page 2 of 10
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO.
DESCRIPTION
NAME & SIGNATURE
efficiency of the system.
4
5
6
Check and ensure proper functionality of reverse blowing. For each cooling-unit in fullload.
Low pressure rapport High pressure rapport Amperage compressor.
Check and ensure all refrigerant levels for each compressor and charge if necessary as per manufacturer’s specification (All the system are closed, only in case of mall function the refrigerant can escape, (The leak must be repaired; a pressure check with nitrogen and vacuum check must be done before charging refrigerant.)
Check and ensure proper functionality of control valve
7
8
9
10
For the dx-system the superheat and solenoid valve must be checked For the glycol systems the control valves and the communication thru MP-bus system must be checked with signal boost on the cable work
Check and ensure proper functioning of defrosting function and depend which type of defrost method is used, check functionality of heating elements based on power consumption, Check and ensure proper functioning evaporator and depend which type of evaporator method is used, check functionality on delta T and moisture based on superheat and airflow. Check and ensure proper functions of PLCs batteries, software, memory, backup data and SMS indicator. Rectify or replace accordingly.
For all 12 PLC, backup the separated plc programs and data
Page 3 of 10
JOB EXPLANATION/REMARKS
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO.
DESCRIPTION
NAME & SIGNATURE
files.) For PC software, backup visi+ software and excel converting software. The log files for all HAC needed temperatures must be separated copied to a third computer) (battery can only be changed under power, if not the PLC will be reset to fabricate values without programs. First a backup must be generated before this action)
11
Scan and records chambers room temperature calibration, in according to manual measured room temperatures and the fixed temperature sensors a calibration file needs to be filed in. The used manual temperature sensor must be certificated and updated each year.)
12
Generate a hardcopy report of the temperature trend
13
Clean blower fan, evaporator casing
14
Calibrate temperature sensor accordance to temperature sensor reading chart attached with deviation not more than 0.5ºC (Refer to Table 1)
15
Perform full functional test for all the whole system.
Quarterly 1
Carry out all monthly and daily tasks accordingly.
2
Check for sign of deterioration, condensation and proper functionality for all electrical connections up till the main switchboard.
Page 4 of 10
JOB EXPLANATION/REMARKS
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO. 3
DESCRIPTION Carry out calibration of digital thermometer with correction of not more than ± 0.5ºC
NAME & SIGNATURE
JOB EXPLANATION/REMARKS
Annually 1
2
Carry out all daily, monthly and quarterly tasks accordingly. Perform chemical wash on heat exchanger if needed. (The heat exchanger must be checked on the heat transfer capacity. If this is reduced the cause must be clarified. based on clarification the heat exchanger must be chemical cleaned with the specified and exact dosed according supplier rules)
3
Clean blower fan, evaporator casing.
4
Maintain a hardcopy record for auditing.
II ROOF SWITCHBOARD (R SB) MONTHLY 1 2
3
4
Check fuse Check and ensure proper functionality of s 380,240 and 24. Check and ensure proper functions of PLCs batteries. Replace if necessary. (Battery can only be changed under power, if not the PLC will be reset to fabricate values without programs. First a backup must be generated before this action)
Check and ensure proper functionality of all safety devices. (a rapport must be used to overview all safety devices to clarify all settings and checks)
III. ALL PUMPS (P) including cold and warm double pump (supply and return) Daily 1
Check and ensure proper functionality for pump and valve for the Chiller and freezer, based on pressure
Page 5 of 10
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO.
DESCRIPTION
NAME & SIGNATURE
JOB EXPLANATION/REMARKS
difference and power consumption the pump capacity can be compared with the setting.
Monthly 1
Carry out all daily tasks accordingly
2
Check for sign of leakage and repair if necessary.
3
4 5
Check electric s for sign of loosening. Tighten if necessary. Check and ensure proper functionality of all safety devices. Glycol percentage ( the glycol should be according the -20 and -15°C freezing level)
IV. Cold room Door (CR DR) Including sliding door, roller door and exit door Bi-Monthly
1
Check and ensure proper functionality of all the door components including but not limited to the following: IR Reflector IR emitter Nylon Guide Plate, rollers and brackets Timer and door limit switches on the control box Extension bar and pulling string and switches Control Box Lifting wires Door Hinges Lifting wire tension sensor and bottom wire tension sensor Safety IR sensor and rubber tube Door aluminum bracket and frame
Page 6 of 10
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO. 2
3
4
5
6
7
8
9
10
11
12
DESCRIPTION Check and ensure proper alignment for both sections of the roller tracks. Check and ensure proper functionality all springs, cables, screws, brackets, tension springs, door s leveling, door open/close limits, hinges, rollers and tracks. Reset if necessary. Check and ensure proper functionality of all timers and door operation limits on control box. Reset if necessary. (For overhead and sliding door only) Grease all the springs, wheels, and steel cables and fasten all moving mechanical components of the doors. (For overhead and freezer door only) Check for ice forming and remove if necessary. (For freezer door only) Check and maintain the electric s on the doors, sub-board, battery door heater and cables and rollers. (For freezer door only) Check and ensure proper functionality of all safety devices. Check and ensure proper functionality of all the photo cell sensor alignment (For sliding door only), re-align if necessary.
NAME & SIGNATURE
Fasten all movable mechanical parts. Maintain a hardcopy of the checklist for all the functional tests. All over test ETV freezing doors according manual PLC (12) program and adjust if needed the limit switches on rails and motors.
Page 7 of 10
JOB EXPLANATION/REMARKS
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO.
DESCRIPTION
NAME & SIGNATURE
V. COOLING TOWER (CT) Daily 1
2
Check functionality for float valves and water supply. Check and ensure proper functionality of motors and fans based on amperage rapport.
Weekly
1
Visually check for physical defects, general cleanliness, organic and calcium fouling. Clean if necessary. ( Inform 3rd party contractor who perform the legionnaire test for all the observation (Contractor’s name to be inserted in)
Monthly 1
Carry out all weekly and daily tasks accordingly.
2
Perform ‘standard plate count test’ to comply with latest Code of Practice on Environmental Public Health Regulation (Cooling Towers and water fountain regulations).
3
Check chemical water level. Top up if necessary.
4
5
Check and ensure functionality of all the pumps and fans, based on amperage rapport. Check and ensure proper functionality of all safety devices.
Quarterly 1 2
Carry out all weekly and monthly tasks accordingly. Perform Legionella Bacteria tests comply with latest Environmental Public Health (Cooling Towers and
Page 8 of 10
JOB EXPLANATION/REMARKS
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO.
DESCRIPTION
NAME & SIGNATURE
JOB EXPLANATION/REMARKS
water fountain regulations). 3
Calibrate sensors to the manufacturer specifications and submit calibration reports.
Functional Test ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ REMARKS:
________________________________________________________________ SPARE PARTS: ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ RECOMMENDATIONS: ________________________________________________________________ ________________________________________________________________ ________________________________________________________________
Page 9 of 10
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist
Job Done By: Name
Name
Signature
Signature ---------------
SATS
Legend for Job Explanation: ADJ : Adjustment AWP : Waiting for Parts CLE : Cleaned REP : Repair Good **
RPL TIG
: : : :
Replacement of Part’s Tighten Eq condition, OK Eq condition, No
: “/ “ To carry out servicing, “ -- “ No servicing needed to be carried out.
Page 10 of 10
Apppendix C2 Preventive Maintenance Checklist INDEX OF PM CHECKLISTS
Check List Equipment No Abbrev
Equipment Type
Cycle
I
CR
Cold room refrigeration system Daily, Monthly, Quarterly and Annually
II
R SB
Roof Switch board
Monthly
III
P
Pump
Daily and Monthly
IV
CR DR
Cold room door
Bi-Monthly
CT
Cooling Tower
Daily, Weekly, Monthly and Quarterly
I
Page 1 of 10
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist
PM SERVICING CHECKS (For Daily, Weekly, Monthly, Quarterly and Annual Cycle) Servicing for Cold room system ___________ on date ________________ (*____ Cycle) NO.
DESCRIPTION
NAME & SIGNATURE
JOB EXPLANATION/REMARKS
I. Cold room Refrigeration System (CR) including but not limited to compressor, FCU, Condenser and Evaporator Daily 1
2
3
Check and ensure no leakage of oil for each compressor. Check and ensure all Freon level for each system (should a shortage appear, the fault must be resolved before charging refrigerant)
Check for ice forming at evaporator (the fault must be clarified, before manual defrost is performed)
Check for head Pressure in the secondary systems. 4
5
6
(The head pressure should be minimum 1 Bar, it need to be filled if needed, the deviation can be leak or air, it must be clarified )
Check and ensure proper functionality of PLC switchboard. (PC and all 11 PLC systems are combined with a mod-bus communication system )
Check cold room temperature monitoring for each room including the automatic log function, the log files are updated with recording files
Monthly 1
2
3
Carry out all daily tasks accordingly. Check and ensure condenser coil fins cleanliness to ensure efficiency of the system. Check and ensure unit cooler fin and evaporator cleanliness. Clean if necessary to ensure
Page 2 of 10
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO.
DESCRIPTION
NAME & SIGNATURE
efficiency of the system.
4
5
6
Check and ensure proper functionality of reverse blowing. For each cooling-unit in fullload.
Low pressure rapport High pressure rapport Amperage compressor.
Check and ensure all refrigerant levels for each compressor and charge if necessary as per manufacturer’s specification (All the system are closed, only in case of mall function the refrigerant can escape, (The leak must be repaired; a pressure check with nitrogen and vacuum check must be done before charging refrigerant.)
Check and ensure proper functionality of control valve
7
8
9
10
For the dx-system the superheat and solenoid valve must be checked For the glycol systems the control valves and the communication thru MP-bus system must be checked with signal boost on the cable work
Check and ensure proper functioning of defrosting function and depend which type of defrost method is used, check functionality of heating elements based on power consumption, Check and ensure proper functioning evaporator and depend which type of evaporator method is used, check functionality on delta T and moisture based on superheat and airflow. Check and ensure proper functions of PLCs batteries, software, memory, backup data and SMS indicator. Rectify or replace accordingly.
For all 12 PLC, backup the separated plc programs and data
Page 3 of 10
JOB EXPLANATION/REMARKS
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO.
DESCRIPTION
NAME & SIGNATURE
files.) For PC software, backup visi+ software and excel converting software. The log files for all HAC needed temperatures must be separated copied to a third computer) (battery can only be changed under power, if not the PLC will be reset to fabricate values without programs. First a backup must be generated before this action)
11
Scan and records chambers room temperature calibration, in according to manual measured room temperatures and the fixed temperature sensors a calibration file needs to be filed in. The used manual temperature sensor must be certificated and updated each year.)
12
Generate a hardcopy report of the temperature trend
13
Clean blower fan, evaporator casing
14
Calibrate temperature sensor accordance to temperature sensor reading chart attached with deviation not more than 0.5ºC (Refer to Table 1)
15
Perform full functional test for all the whole system.
Quarterly 1
Carry out all monthly and daily tasks accordingly.
2
Check for sign of deterioration, condensation and proper functionality for all electrical connections up till the main switchboard.
Page 4 of 10
JOB EXPLANATION/REMARKS
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO. 3
DESCRIPTION Carry out calibration of digital thermometer with correction of not more than ± 0.5ºC
NAME & SIGNATURE
JOB EXPLANATION/REMARKS
Annually 1
2
Carry out all daily, monthly and quarterly tasks accordingly. Perform chemical wash on heat exchanger if needed. (The heat exchanger must be checked on the heat transfer capacity. If this is reduced the cause must be clarified. based on clarification the heat exchanger must be chemical cleaned with the specified and exact dosed according supplier rules)
3
Clean blower fan, evaporator casing.
4
Maintain a hardcopy record for auditing.
II ROOF SWITCHBOARD (R SB) MONTHLY 1 2
3
4
Check fuse Check and ensure proper functionality of s 380,240 and 24. Check and ensure proper functions of PLCs batteries. Replace if necessary. (Battery can only be changed under power, if not the PLC will be reset to fabricate values without programs. First a backup must be generated before this action)
Check and ensure proper functionality of all safety devices. (a rapport must be used to overview all safety devices to clarify all settings and checks)
III. ALL PUMPS (P) including cold and warm double pump (supply and return) Daily 1
Check and ensure proper functionality for pump and valve for the Chiller and freezer, based on pressure
Page 5 of 10
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO.
DESCRIPTION
NAME & SIGNATURE
JOB EXPLANATION/REMARKS
difference and power consumption the pump capacity can be compared with the setting.
Monthly 1
Carry out all daily tasks accordingly
2
Check for sign of leakage and repair if necessary.
3
4 5
Check electric s for sign of loosening. Tighten if necessary. Check and ensure proper functionality of all safety devices. Glycol percentage ( the glycol should be according the -20 and -15°C freezing level)
IV. Cold room Door (CR DR) Including sliding door, roller door and exit door Bi-Monthly
1
Check and ensure proper functionality of all the door components including but not limited to the following: IR Reflector IR emitter Nylon Guide Plate, rollers and brackets Timer and door limit switches on the control box Extension bar and pulling string and switches Control Box Lifting wires Door Hinges Lifting wire tension sensor and bottom wire tension sensor Safety IR sensor and rubber tube Door aluminum bracket and frame
Page 6 of 10
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO. 2
3
4
5
6
7
8
9
10
11
12
DESCRIPTION Check and ensure proper alignment for both sections of the roller tracks. Check and ensure proper functionality all springs, cables, screws, brackets, tension springs, door s leveling, door open/close limits, hinges, rollers and tracks. Reset if necessary. Check and ensure proper functionality of all timers and door operation limits on control box. Reset if necessary. (For overhead and sliding door only) Grease all the springs, wheels, and steel cables and fasten all moving mechanical components of the doors. (For overhead and freezer door only) Check for ice forming and remove if necessary. (For freezer door only) Check and maintain the electric s on the doors, sub-board, battery door heater and cables and rollers. (For freezer door only) Check and ensure proper functionality of all safety devices. Check and ensure proper functionality of all the photo cell sensor alignment (For sliding door only), re-align if necessary.
NAME & SIGNATURE
Fasten all movable mechanical parts. Maintain a hardcopy of the checklist for all the functional tests. All over test ETV freezing doors according manual PLC (12) program and adjust if needed the limit switches on rails and motors.
Page 7 of 10
JOB EXPLANATION/REMARKS
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO.
DESCRIPTION
NAME & SIGNATURE
V. COOLING TOWER (CT) Daily 1
2
Check functionality for float valves and water supply. Check and ensure proper functionality of motors and fans based on amperage rapport.
Weekly
1
Visually check for physical defects, general cleanliness, organic and calcium fouling. Clean if necessary. ( Inform 3rd party contractor who perform the legionnaire test for all the observation (Contractor’s name to be inserted in)
Monthly 1
Carry out all weekly and daily tasks accordingly.
2
Perform ‘standard plate count test’ to comply with latest Code of Practice on Environmental Public Health Regulation (Cooling Towers and water fountain regulations).
3
Check chemical water level. Top up if necessary.
4
5
Check and ensure functionality of all the pumps and fans, based on amperage rapport. Check and ensure proper functionality of all safety devices.
Quarterly 1 2
Carry out all weekly and monthly tasks accordingly. Perform Legionella Bacteria tests comply with latest Environmental Public Health (Cooling Towers and
Page 8 of 10
JOB EXPLANATION/REMARKS
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist NO.
DESCRIPTION
NAME & SIGNATURE
JOB EXPLANATION/REMARKS
water fountain regulations). 3
Calibrate sensors to the manufacturer specifications and submit calibration reports.
Functional Test ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ REMARKS:
________________________________________________________________ SPARE PARTS: ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ RECOMMENDATIONS: ________________________________________________________________ ________________________________________________________________ ________________________________________________________________
Page 9 of 10
Tender Ref: CT1210P040
Apppendix C2 Preventive Maintenance Checklist
Job Done By: Name
Name
Signature
Signature ---------------
SATS
Legend for Job Explanation: ADJ : Adjustment AWP : Waiting for Parts CLE : Cleaned REP : Repair Good **
RPL TIG
: : : :
Replacement of Part’s Tighten Eq condition, OK Eq condition, No
: “/ “ To carry out servicing, “ -- “ No servicing needed to be carried out.
Page 10 of 10
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