Consortiwm Awdurdodau Lleol Cymru Consortium Local Authorities Wales

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1 Consortiwm Awdurdodau Lleol Cymru Consortium Local Authorities Wales SPECIFICATION FOR BOILER SERVICING MAINTENANCE Maintenance Module 11 March 2012 issue This document has been compiled by the Engineering Project Group in association with Marald Engineering Consultants Boiler Servicing Maintenance. : Page 1 of 4

2 INDEX GENERAL ASSET REGISTER MAINTENANCE REPORTS MANUFACTURER S REQUIREMENTS PERMIT TO WORK CERTIFICATION ACCESS MINOR REPAIRS EMERGENCY CALL OUTS Boiler Servicing Maintenance. : Page 2 of 4

3 GENERAL The Contractor shall be deemed to have read the CLAW document entitled General Conditions and Preliminaries Applying to the Whole of the Maintenance Works and shall ensure his full compliance with the aforementioned document The Contractor shall be deemed to have allowed against each item or in his rates for the cost of complying with all the requirements of the Preliminaries All the items contained in the Preliminaries shall apply to the whole of the Works. The headings of the clauses in this Specification shall not effect the interpretation thereof The Contractor may be required to prepare a detailed breakdown of his pricing of the Preliminary items before the Contract is signed ASSET REGISTER The Contractor shall ensure that all the asset registers attached to this specification shall be verified during the first month of the contract period and any discrepancies made known, in writing, to the Contract Administrator At the commencement of the Contract period, a set of services drawings may be issued to the Contractor who shall ensure that, during each maintenance service element, the respective drawing shall be marked up by him to indicate the actual installed services. At the completion of each element the markedup drawings shall be returned to the Contract Administrator MAINTENANCE REPORTS The Contractor shall ensure that, following all inspection visits, condition reports shall be submitted to the Contract Administrator in electronic format, including all specialist reports and test equipment printouts In addition the Contractor shall ensure that a Site Logbook be maintained on site with the Site Manager containing duplicate copies of all the reports information submitted to the Contract Administrator The Site Logbook shall also contain a copy of the Site Risk Assessment, Method Statement and COSHH for the Contractors operatives and all specialist sub-contractors MANUFACTURER S REQUIREMENTS Where manufacturers instructions exceed the requirements of this document they shall be adhered to in their entirety. Boiler Servicing Maintenance. : Page 3 of 4

4 PERMIT TO WORK CERTIFICATION If it is deemed necessary by the Contract Administrator for the need for a permit to be issued before any work is undertaken on the system, the Contractor shall ensure his compliance with the permit to work system as employed by the Contract Administrator PRESUMED PRESENCE OF ASBESTOS In the furtherance of operative safety the Contractor shall presume that there will be a presence of asbestos containing materials forming some constituent part of any boiler plant unless evidenced to the contrary Appropriate work methods shall be employed ACCESS The Contractor shall ensure that he undertakes a risk assessment and provides a method statement for his means of access to allow for inspection and testing All works shall be carried out in strict accordance with the requirements of The Work at Height (Amendment) Regulations The Contractor shall ensure that all personnel employed upon this contract are suitably trained and experienced and competent to work at height MINOR REPAIRS The Contractor shall, during servicing and testing, carry out minor repairs such as tightening joints, replacement of bolts, screws, electrodes, thermocouples, etc. to ensure completeness and safety of equipment EMERGENCY CALL OUTS The Contractor shall be required to provide a 24 hour breakdown service 365 days per annum The Call Out is to be covered as soon as possible and the operative attending site must be on site within 2 hours of receiving the Emergency Call Out notice The Contractor shall submit in his tender the details of additional charges when such calls take place outside normal working hours (defined as 8.00 am 4.40 pm Monday to Friday) Boiler Servicing Maintenance. : Page 4 of 4

5 Boilers LTHW and MTHW Sheet 1 of 4 1 Check operation, in particular, safety controls. Annually Note any visible defects. Ensure system is full of water and the circuits are open. 2 Combustion test. Annually Start up and carry out tests. On larger systems combustion tests should be carried out on a regular basis to monitor performance. The test should include smoke, draught chamber and flue, flue temperature, fuel input and gas analysis including carbon monoxide. 3 Thermostats, pressure sensors, altitude gauges Annually Check for correct operation and settings. and thermometers. 4 Electrical services. Annually Shut down, disconnect or remove fuses. Locate isolation switch, if not in accordance with I.E.E. regulations. Report to building owner 5 Boiler return temperature and associated controls. Annually Check if appropriate 6 Boiler flueways, combustion chamber and Annually Open and remove by brushing and/or vacuum connecting flues. all soot and scale. 7 Refractory linings. Annually Check condition and report. 8 Boiler flueways and chamber. Annually Reseal, check for air leaks, seal as necessary. 9 Flue. Annually Carry out smoke test. 10 Water quality Annually Check system water quality and inhibitor type Where system water quality is controlled, water and concentration. Top up if necessary. treatment and dosing plant should be maintained according to the manufacturer's instructions.

6 Boilers LTHW and MTHW Sheet 2 of 4 11 Boiler Mountings Annually Examine pipe connections, valve spindles and glands and repack as necessary. Test safety valves. Clean and test valves for free travel, repack and adjust as necessary. Examine drain cocks. 12 Instruments and Gauges Annually Clean and check altitude, pressure and temperature gauges for accuracy, calibration and serviceability. Examine all meters. 13 Pumps Annually Clean and examine. Lubricate as necessary. Examine drive for alignment; adjust as necessary. Examine pulleys and keys. Test pipe and valve connection for leaks. Repack glands as necessary. Report on condition. Ensure all guards are in place. Renew V belts. Ensure spare V belt is available on site. Test run duplicate pumps

7 Boilers LTHW and MTHW Sheet 3 of 4 14 Fan (if provided) Annually Check operation and clean blades. Build up of deposits on the blades can reduce their efficiency and lead to poor combustion. 15 Boiler. Annually Reconnect and test fire, carry out combustion A boiler is capable of exploding if safety controls test, refit casing and thoroughly clean down. fail and blocked flues will cause flue gas to leak into surrounding areas, causing damage and risks to life and to health through carbon monoxide poisoning. 16 Distribution Pipework Annually Examine pipework, hangers, supports and thermal insulation. Check that ID banding is correctly installed. Examine weatherproofing on external runs. Examine for corrosion. Test for leaks. 17 Expansion Tanks Annually Examine water level. Test ball valve and stop cock. Examine condition of tank and insulation Examine overflows; ensure they are clear. 18 Vent Pipes and Cold Feed Annually Examine vent pipes; ensure they are clear. Examine cold feed; ensure free flow. Test valves for free travel; repack and adjust as necessary. Test drain cocks. Report "Black Iron" construction, and presence of isolating valves and d.o.c's. Examine insulation including ID banding Report on results. Report on results. Report on condition. Report on results.

8 Boilers LTHW and MTHW Sheet 4 of 4 19 Valves Annually Check isolating valves. Clean thermostatic valves and sensing devices. Test motorised valves. Test timers and controls. Test valves for free travel; repack and adjust as necessary.

9 Atmospheric Gas Burners Sheet 1 of 3 1 Gas, electrical and ventilating systems. 6 monthly Check that all are in accordance with current Codes of Practice. Refer to MM22 for ventilation recommendations 2 General 6 monthly Check casing for damage or breakages. Inspect for loose fittings or connections and any sign of leaks. 3 Combustion test. 6 monthly Carry out flue gas analysis using certified Complete report to Client test equipment Forward the original printout to the Contract Administrator. (Certificates must be made available to the Contract Administrator for acceptance). Affix service sticker to boiler casing. 4 Before proceeding with dismantling of boiler. Annually Check casing for damage or breakages. Remove previous servicing sticker from casing, Inspect for loose fittings or connections and and note on report when last service took place. any sign of leaks. Refer to manufacturer's specification. 5 Isolate boiler for gas and electrical supplies. Annually Isolate electrically, disconnect or remove fuses, turn off and isolate the gas supply. Record any work which needs rectification or replacement. 6 Thermocouple, probe pilot assembly, spark Annually Disconnect and remove from boiler, clean Cleaning should be thorough and carried out as electrode and main burners. pilot and main burner per the manufacturer's instructions. 7 Spark electrode and thermocouple / probe Annually Renew and refit along with main burner.

10 Atmospheric Gas Burners Sheet 2 of 3 8 Wiring to ignitor and/or probe, gas valve and Annually Examine flexible cables for wear, fraying braid boiler thermostats. and brittle insulation. Ensure that wiring terminal connections are sound. 9 Remove burners and pilot assembly and baffles Annually Brush all flueways thoroughly from top to if fitted. bottom, clean all deposits from the burner box, refit baffles and flue cover - checking cover seal. 10 Pilot assembly Annually Remove. Pilot head Remove and clean ports. Pilot injection Unscrew and clean. Clean by blowing through or washing. NOTE: Do not use pin as this will damage the injector. Thermocouple tip Renew thermocouples and probes in each Make sure head lines up with thermocouple and boiler reassemble Pilot. not burner. 11 Lint filter (if fitted) Remove from burners and clean. 12 Burner top. Annually Brush and check flame parts are clear, remove any deposits inside burner. Check for cracking or wear. Filters Burners. Gas valve, thermocouple and pilot tube. Refit. Refit. Reconnect.

11 Atmospheric Gas Burners Sheet 3 of 3 13 Electricity. Annually Switch on. Make sure boiler thermostat is in off position. 14 Flame failure and associated controls. Annually Turn on gas, check and adjust pilot flame to Test flame setting and thermocouple sensitivity envelope thermocouple / probe test flame and check manifold gas pressure against failure device. manufacturer's settings, adjust if required. 15 Gas settings Annually Carry out burner rating test to ensure that Forward the original printout to the Contract the burner and boiler output are matched. Administrator. Check and adjust pressure to main burner. 16 General Annually Examine securing bolts and tighten as necessary. Check door seals and gaskets, repair or renew as necessary. Check all joints for leakage and repair as required. Clean boiler fronts of combustion products and repaint with suitable approved paint. Clean and descale heating surfaces. De-sludge as necessary. 17 Recommendations Annually Provide written report. This report should be signed by the servicing engineer and kept by the Client together with all the relevant manufacturer's literature.

12 Blown Gas Burners Sheet 1 of 1 1 Gas, electrical and ventilating systems. 6 monthly Check that all are in accordance with current Codes of Practice. Refer to MM22 for ventilation recommendations 2 General 6 monthly Examine the burner under normal operating conditions 3 Combustion test. 6 monthly Carry out full test with approved certified test meter Provide written report to Client 4 Burner general Annually Carry out burner rating test to ensure that Forward the original printout to the Contract the burner and boiler output are matched. Administrator. Check pilot and mains gas pressures, adjust governors as necessary. Examine burner head, clean as necessary. 5 Electrical Annually Inspect H.T. leads from transformer to electrodes, check terminals, clean and reconnect as necessary. Clean and test flame failure photocell or probe and viewing glasses. Ensure "Fail Safe" operation. 6 Fan Annually Check fan impellers for condition and true running, clean and adjust as necessary. Clean and lubricate motors to manufacturer's instructions. 7 Controls Annually Check function of control boxes, hydromotors and pressure boosters. Provide written report to Client

13 Light Oil Pressure Jet Burners Sheet 1 of 3 1 Operational status of burner. 3 monthly Check whether plant operating or not. For safety and operational reasons the status of the plant should be checked. 2 Oil, electrical and ventilating systems. 3 monthly Check that all are in accordance with current Codes of Practice. 3 Burner 3 monthy Switch on, carry out safety check of flame failure. Note any visible defects. 4 Combustion test. 3 monthly Carry out and note any visual defects. Pay particular attention to carbon monoxide (CO) as its presence can be dangerous and wastes energy. 5 Isolation from electricity and oil supply. 3 monthly Switch off, remove fuses and turn off oil supply. Before starting any dismantling of equipment it is essential for safety reasons that the plant be isolated from incoming services. 6 Jet arm assembly. 3 monthly Remove, clean combustion head, ignition electrodes and inspect HT leads. 7 Nozzle and filter. 3 monthly Clean filter and inspect nozzle for wear. Erosion or surface defects on the nozzle can effect the profile of the emerging jet of oil and lead to a poor flame shape and bad combustion. 8 Burner 3 monthly Reassemble and set heat to manufacturer's requirements. 9 Motor and fan. 3 monthly Remove, clean and lubricate as required, clean Inspect oil pump flexible drive coupling before fan scroll. reassembling.

14 Light Oil Pressure Jet Burners Sheet 2 of 3 10 Oil pump filter. 3 monthly Remove and clean, inspect pump seals for signs of wear. 11 Wiring to burner etc. 3 monthly Examine flexible cables for wear, fraying braid and brittle insulation. Ensure that wiring terminal connections are sound. 12 Reassembling burner. 3 monthly Inspect flexible oil line coupling, clean photo cell and adjust position. 13 Burner 3 monthly Switch on and check flame shape and appearance if visible. 14 Oil pressure 3 monthly Test and record oil pressure. 15 Flame failure device. 3 monthly Test for satisfactory operation. 16 General 3 monthly Check security of mechanical parts and A maintenance check should be carried out on secure mounting of appliance. this type of burner twice a year but refer to manufacturer's specification.

15 Light Oil Pressure Jet Burners Sheet 3 of 3 17 Recommendations Annually Provide written report which should be signed Premature failure will result if a satisfactory by the service engineer and kept by the service is not carried out. Client together with all the relevant All service and maintenance must be carried manufacturer's literature. out by a registered engineer in accordance with the Public Health and Safety requirements. All service and maintenance works must be carried out by a competent engineer in accordance with BS Codes of Practice for oil firing.

16 Fuel Storage and Transfer Sheet 1 of 2 Storage System 1 Fuel Bunker Weekly Inspect integrity of fuel bunker and check moisture content Conveyor Belt Transfer System 2 Drive Assembly Weekly Check belt alignment Lock out power to motor before doing any Check that idler wheels are not sticking maintenance work Clean idlers Check belt wear and splices Report condition 3 Motors Annually Check:- a) condition of motor brushes and replace if necessary b) clean and test windings c) tightness of terminals d) full load current e) bearing wear f) replace lubricant in motor bearings Conveyor Screw Transfer System 4 Drive Assembly Inspect all drive components for wear Lock out power to motor before doing any maintenance work Report condition 5 Bearings Weekly Where required by manufacturer lubricate in accordance with their instructions

17 Fuel Storage and Transfer Sheet 2 of 2 Conveyor Screw Transfer System cont'd 6 Motors Annually Check:- a) condition of motor brushes and replace if necessary b) clean and test windings c) tightness of terminals d) full load current e) bearing wear f) replace lubricant in motor bearings

18 Boilers - Fire and Safety Circuits Sheet 1 of 2 1 Oil - manual fire valve Annually Check valve and associated couplings for It is essential that the system will provide a positive oil shut off. positive shut off of the oil supply in an emergency. quick release mechanism. Annually Actuate and check that any dead weight or solenoid valves operate correctly. valve and quick release systems. Annually Reset. Check that all interconnecting tension wire, fusible links fire buttons and pulleys are free for operation. 2 Gas - manually operated valves Annually Check to establish positive shut off of gas is achieved. pressure switches on gas boosters. Annually Check for operation and sensitivity. gas detection unit. Annually Test sensitivity. It may be necessary to recalibrate, if so carry out strictly according to the manufacturer's instructions. manual quick release mechanism. Annually Actuate and recheck operation of the dead weight valve or solenoid. valves and quick release mechanism. Annually Reset. Check that all interconnecting tension wire, fusible links fire buttons and pulleys are free for operation.

19 Boilers - Fire and Safety Circuits Sheet 2 of 2 3 Boiler control and high limit thermostats (thermal Annually Ensure these are set correctly. Check Operation should be within the manufacturer's or manual reset). operation of pressure switches. switching differential. Adjust if necessary. 4 Pressure switches Annually Check operation. 5 Foam inlets Annually Ensure foam inlet pipes are free from Inspect diffuser nozzles for damage. blockage. 6 Smoke/heat detection. Annually Check operation. Refer to Code of Practice BS General. 6 monthly Check all fuel supply valves for free Ensure that each fuel supply valve is complete operation. with own wheel or key. 8 Combustion air source into plant room. Annually Check that original provision has been left Inadequate combustion air provisions can create clear of any obstruction dirt. a hazard to both the equipment and the occupants of the plant room.

20 Pipework Sheet 1 of 3 1 Distribution pipework Annually Test for leaks. Examine hangers, expansion joints and supports; adjust as necessary. Examine thermal insulation. Examine for corrosion. Examine weatherproofing on external runs. Examine pipework, hangers, supports and thermal insulation. Check that ID banding is as per item 4 Record and report repairs or renewal required. Record and report results. 2 Valves Annually Check isolating valves. Test valves for free travel; repack and adjust as necessary. Clean thermostatic valves and sensing devices. Test motorised valves. Test timers and controls. Test valves for free travel; repack and adjust as necessary. Record and report results.

21 Pipework Sheet 2 of 3 3 Strainers Annually Isolate the strainer from the system pressure and drain. Where strainers have a screwed cap, remove in an anti-clockwise direction to enable the withdrawal of the strainer element. Where strainers have a bolted cover, Slacken all bolts gradually and remove sequentially taking care to support the weight of the cover as the final bolt is removed Clean the strainer element using a brush and or water jet. Once the strainer element has been cleaned the strainer can be re-assembled. The sealing gasket should be renewed if damage has occurred. Ensure the body and cover joint faces are clean. Replace the strainer element into the strainer body ensuring damage to the gasket does not occur.

22 Pipework Sheet 3 of 3 Item Item 4 Pipework Identification Pipe Contents Basic Colour Colour Code Indication Drinking Water Green Blue Cooling Water Green White Boiler Feed Water Green Crimson/White/Crimson Condensate Water Green Crimson/White/Crimson Central Heating <100 C Green Blue/Crimson/Blue Central Heating >100 C Green Crimson/Blue/Crimson Hot Water Supply Green White/Crimson/White Fire Extinguisher Green Safety Red Compressed Air Light Blue Light Blue Steam Silver Grey Silver Grey Natural Gas Yellow Ochre Yellow Ochre Oil(Furnace Fuel) Brown Brown

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