MANAGEMENT OF PLANNED MAINTENANCE

AUTOMATIC CONTROL & BMS SYSTEMS TASK INSTRUCTIONS TASK

MANAGEMENT OF PLANNED MAINTENANCE AUTOMATIC CONTROL AND BMS SYSTEMS

TASKS 43.1, 43.2, 43.3

HEALTH AND SAFETY 1.1 Comply with any specific warning notices or site restrictions as identified within the site safety plan held by the responsible person, and with any other specific/temporary hazards identified during site induction/at time of visit. 1.2 Relevant PPE shall be used as indicated by the relevant risk assessment 1.3 Caution should be exercised where surface temperatures are above 50C to avoid injury through accidental contact. 1.4 A specific risk assessment, to satisfy The Management of Health & Safety at Work Regulations and any other statutory regulations,ect... must be made prior to carrying out any task detailed below. Risk assessments are to be carried out by the operatives employer 1.5 Where required under safe working procedures, a permit to work shall be obtained from the responsible person before any work is commenced. For other, limited tasks suitable care shall be taken to ensure proper electrical isolation of plant before removing covers etc. or before working on normally moving parts 2. GENERAL REQUIREMENTS 2.1 This task is to be undertaken only by suitably and properly trained staff having knowledge of the installed system, an up to-date awareness of the manufacturers equipment including computer hardware and software, have access to up to-date diagnostic equipment, have good technical support, and are supported by adequate stocks of spares. 2.2 To ensure that the systems being controlled are operating within stated parameters. 2.3 Liase with the building managers where access to building internal areas is required before starting and when finishing work. 2.4 All measuring equipment shall have a current certificate of calibration: Certificate No shall be written on PPM work sheet 2.5 It is the Responsible Persons responsibility to produce an inventory of all actuators, sensors, and control devices in each building for issue with the checklist. 2.6 Checklist 1 is for use with Task 043.1 2.7 Checklist 2 is for use with Task 043.2 2.8 Checklist 3 is for use with Task 043.3 2.9 The attached Checklist is to be included on the Work Docket issued to the craftsman. A copy of the Task Instructions is to be available to the craftsman for information 2.10 Record all inspection findings. All items requiring repair shall be listed on the PPM work docket, any repairs carried out under the Contract Lump Sum shall be indicated as such, any other items in this category requiring shut downs or spares shall be carried out

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following agreed procedures. Any deviation from accepted operation or any defects considered to present a safety hazard shall be reported to the responsible person, who will advise the client as required. 2.11 The attached task instructions highlight the basic elements that should be carried out as a minimum requirement. The sub-contractor may adopt these instructions or submit there their own method statements for approval. The task instructions provided are generic in form and will require modifying to suit specific equipment/systems being maintained. It should be noted that the full requirements of the relevant reference documents must be complied with; the list provided here is not exhaustive. Lead reference documents: Heating and Ventilation Contractors Association Standard Maintenance Specification Volume 3 Control Energy and BMS Systems: 1998 BS EN 12098-1:1997 Controls for heating systems. Outside temperature control equipment for hot water heating systems. BS EN 12098-2:2001 Controls for heating systems. Optimum Stop-Start control equipment for hot water heating systems. 01/710844DC prEN 12098-3. Controls for heating system. Part 3 outside temperature compensated control equipment for electrical heating systems. BS 5384:1977 Guide to the selection and use of control systems for heating, ventilation and Air Conditioning installations. 99/712285 DC-prEN 13646. Building control systems equipment characteristics. 99/712286 DC-prEN ISO 16484. Building control systems. Part 1 Overview and definitions. 99/712287 DC-prEN ISO 16484. Building control systems. HVAC control system functionality. MEEG Vol. 5 Section12 HSE Guidance Note GS 38-Electrical test equipment for use by electricians 1995 HS(R) 25 - Memorandum of Guidance on the Electricity at Work Regulations 1989. HSG 85 Electricity at Work. Safe working Practices 1993

Task Numbers AD-PPM-043 is to be shown on all work dockets as appropriate

*Mandatory Frequencies to individually assess per site, approved through Authorizing Engineers Table below guideline only.

Task No 43.1

Task

Lead Ref.

Status Mandatory

Frequency 6 MONTHLY (6M) or as reqd

Remarks

Check operation of all safety HVC alarms, interlocks, indicators A and devices. Back-up all Vol. 3 software & archive. Inspect all panels internally and

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externally. 43.2 Check HVC operation/function/accuracy of A all sensors, actuators, alarms, Vol. 3 time programmes Inspect, clean, service, adjust HVC & overhaul all components of A the system Vol. 3 Mandatory ANNUALL Y (1Y)

43.3

Mandatory

ANNUALL Y (1Y)

TASK 043.1 (6M) CHECK OPERATION OF SAFETY ALARMS, INTERLOCKS INDICATORS AND DEVICES. BACKUP ALL SOFTWARE AND ARCHIVE. INSPECT ALL PANELS INTERNALLY & EXTERNALLY

PROCEDURES CENTRAL OPERATOR STATION 1. Cables and connectors. Check security, integrity and for physical damage. 2. Perform routine diagnostic tasks on computer (where appropriate) and check operation. This routine will check all aspects of computer hardware and software.

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3. Check operation and clean, Disc drives, Tape drives, Tape cassettes, Keyboards, VDUs, Monitors, Printers etc. (where appropriate), according to the manufacturer's instructions. 4. Clock battery. Check and replace if necessary 5. Cooling fans. Check condition, clean and lubricate if necessary 6. Filters Inspect and clean or change as necessary. 7. Mouse. Check for smooth operation and clean ball as necessary. 8. Software archives. Take back up copy of site-specific data files. Verify operating programmes and functionality. Ensure that security is retained and that any updating of files is incorporated. COMMUNICATIONS 1. Data Communications Check integrity of data flow in both directions. If more than one path exists all must be verified. 2. Central station units Check operation and visually inspect. Check environmental conditions of all equipment are within prescribed limits, including modems, line drivers, telemetry cables and interface units 3. Central station/out stations Check integrity of data flow in both directions. If more than one data path exists, all must be verified. Caution - There may be interaction with specialist applications. 4. Out station hardware. Check mechanical and environmental condition. Note environmental conditions e.g. temperature; humidity should be within manufacturer's recommended limits. 5. Power supplies. Carry out voltage check on all power supplies. Check automatic restart, re-booting of software programmed. 6. Stand-by batteries/ uninterrupted power supplies (UPS). Check against manufacturer's specification 7. Digital inputs. Check by activating (from fixed sensing/control device) Note Care should be taken to isolate local operation. 8. Digital outputs. Check operation of output stopping by operating routine (where appropriate). Check switching by software interlocks should include starting and stopping operations. Note does not apply to connected devices. 9. Analogue inputs. Read and check calibration of analogue inputs. 10. Analogue outputs. Check for accuracy of output signal. 11. Manual override (physical). Check status. Review and report to client. 12. Installed program me. Check integrity, of alarms, interlocks, and optimization. SOFTWARE FUNCTIONS 1. Control loops: - Check integrity of the installed program me, Check sequence and operation of control outputs. Check stability of plant, frequency should be agreed with client. This action should be related to the critical nature of the operation.

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Optimized start/stop. Verify operation by interrogating software/hardware copy. Building layouts and occupational requirements are seldom of a static nature. Therefore control strategies and their suitability need to be reassessed on a regular basis. 3. Time clock. Check real time clock for accuracy throughout system. 4. Time switching. Review current operating parameters according to client's needs. 5. Data logging. Review existing logs Report to client on the need to review existing arrangements. 6. Alarms (a) faults, (b) out of limit alarms. Check alarms and software interlocks with safety implications are operating correctly. Check alarm priorities, routings and reactions. The checking of possible reactions to certain critical alarms and programmers must be carefully co-ordinate with other trades and building tenants. Where there are safety implications, verify alarm integrity. Review system of reporting outstanding alarm conditions and report discrepancies. 7. Alarm management. Review frequencies of generated alarms. Report as appropriate to client. 8. Power failure and restoration. Check plant start up sequence. 9. Generators loading program me. Check plant start up sequence. 10. Maximum demand/load shedding Check sequence and operation. 11.Load cycling. Check operation.
2.

12. Software interlocks. Verify operation. 13. Plant rotation point, e.g. interfaces with other building services systems such as :-(a) fire, (b) security, and (c) access. 14. Manual status review Check manual overrides and effect on system, and effect on system operation. At client access level review parameters, lockouts, changes, all points in manual override and forced analogue values. Review findings with client. OPERATION OF SAFETY ALARMS Simulate alarm conditions in all controlled systems and prove system fails to program safe condition. BACKUP ALL SOFTWARE AND ARCHIVE The backup copying of data/history to disk is to be carried out. Following backup remove all unnecessary files and information from hard disc and de-fragment. Leave system in fully operational condition. TASK 43.2 (1Y) CHECK OPERTION/FUNCTION/ACCURACY OF ALL SENSORS, ACTATORS, ALARMS, and TIME PROGRAMMES PROCEDURES SENSORS (e.g. Pressure, Temperature, Relative and Absolute Humidity, Air Quality, CO2, Velocity, Smoke and Gas, Occupancy and Light Sensitivity) Check all field devices. Field devices include sensors and actuators linked directly to the BMS. Sensors and actuators should be recalibrated and maintained at recommended intervals stated in the maintenance instructions supplied by the manufacturer. This procedure applies

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to all types of sensors and thermostats and requires that all safety precautions and safe working practices be observed. 1. Check security of mountings. Inspect for physical damage. 2. Check for cleanliness. Obscuration of sensors with dust can reduce sensitivity and effect the signal 3. Check termination for tightness and corrosion on Electric cable, and Pneumatic pipe work. Check the cable/pipe work locally for fixing and condition. 4. Calibrate sensors. Note settings prior to commencing maintenance. 5. Status points which operate very infrequently (e.g. frost status, high/low level limits etc) are to be activated. 6. The actual value at the sensor should be measured and the value obtained compared to that displayed at the outstation, central facility etc and corrected accordingly at the central monitor. 7. Compare the measured value to the control point set value. 8. Check the stability of the plant visually and with the aid of a trend log, alter settings to achieve stability. 9. Thermally test for let-by on all valves. 10. Change the position of the valve from maximum to minimum, using override facilities within the software, and visually check the operation of the valve, note the sequence of operation and stroke of all the actuators. 11. Inspect all valves for leaks and damage. Clean, service, adjust, and overhaul, as necessary all components of the system. 12. Sampling pipe work and connections. Inspect for leakage and corrosion. Check for correct configuration. 13. Check effect for location influence on sensors. Examples are solar gain, proximity to warm extract vents, cooling towers, etc. 14. Test the plant fail-safe position/condition in the event of a power failure with a simulated mains failure condition. 15. Verify correct location and installation as per manufacturer's instructions and check for any extraneous influences. 16. Pneumatics. Particular attention should be paid to the quality of the instrument air. Check for contamination by dirt, oil or water. 17. All sensors should be maintained in accordance with the manufacturer's recommendations. 18. 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 withdrawn from the duct to prevent damage. Care should also be taken to prevent any damage to linkages or other control devices

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TASK 43.3(1Y) INSPECT, CLEAN, SERVICE, ADJUST & OVERHALL ALL COMPONENTS OF THE SYSTEM PROCEEDURES 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.

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AUTOMATIC CONTROL VALVES (e.g. Rotary, Butterfly and Ball, Self-Acting, Solenoid, Check, Pressure Control and Safety, Seat Valves)
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 it is to be taken as read that the Manufacturer's maintenance and lubrication instructions for each type shall be used.

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 (see page 33). 1. Check correct installation of valve with reference to both type and manufacturer. 2. Operate and check for correct travel. 3. Check that valve is not letting by excessively. Strip and clean as required 4. Inspect for gland leakage ACTUATORS (e.g. Electrical, Hydraulic, Pneumatic) 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. 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. Disposal of batteries calls for special arrangements, which should conform to COSHH requirements. To check that the actuator is performing its correct task, it is immaterial as to whether it is mounted on a damper, louver, valve or any other piece of equipment. Its purpose is to control to a position between two limits, by opening, closing or moving appropriate pieces of equipment.
In the event that the actuator is performing a safety function (i.e. on a fire and smoke damper) it shall be operated in simulated emergency conditions to prove it actual operation. Lives and property could depend upon this actuator working properly.

1. Cables. Check for signs of heat, damage, and chafing or water ingress. 2. Mounting. Check mounting is in accordance with the manufacturer's recommendation. 3. Anchor points. Check security.

MANAGEMENT OF PLANNED MAINTENANCE

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 only have a maximum life span. Elasticity of the spring and hence the torque will reduce with time, if the torque is insufficient to complete the action, this could be a hazard to life and property. 7. Working conditions. Check actuator is operating within its design ambient conditions. 8. Check supply voltage and those polarities are correct. 9. Check for presence of control signal and that polarity is correct. 10. Check operation of Auxiliary control functions i.e. on/off switches, frost protection, position indicators, and feedback potentiometers. 11. Check to prove actuator will mechanically open/close valve or damper to its working limits. 12. Actuator position on power failure. Check for correct position for application when power fails. 13. Check for signs of leakage of hydraulic fluid or compressed air around actuator seals. 14. Check condition of glands and seals. Check pipe work for deterioration. On hydraulic fluid or compressed air systems 15. Linkage assembly, i.e. nuts bolts, spring, valve stem or damper assembly. Check for wear, security, and corrosion 16. Check calibration - controller output to actuator position. Note: more than one actuator may be fed from the control supply. 17. Check to ensure that the switches are made to make or break at the correct position and that they perform their correct function. CONTROLLERS (e.g. Optimizer, Compensator, Single Input, Unit/Sensor Controllers, Control Timers, Step Controllers, Time Switches, Multi Input, Indicators, Alarm Modules, Level Controllers, Speed Controllers, Transducers)
This schedule applies to all types of controllers and requires that all safety precautions and safe working practices be observed.

SPEED CONTROLLERS Electronic inverter type. WARNING: - Due to the very high voltages present within this type of controller it is essential that all safety precautions be 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. 1. Note all set points found. 2. Check mechanically for security of fixings, incoming cables, pneumatic pipe work and terminal connections for tightness.

MANAGEMENT OF PLANNED MAINTENANCE

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. 6. Outside/Inside air temperature sensor Check for calibration and display accuracy. 7. Check program me setting is correct. 8. Check Battery condition 9. Check that output devices respond to command signals. 10.Check Flow temperature sensor. 11.Check Controllers and calibrate for correct relationship between outside and flow temperatures. 12.Check system under control for proper operation. 13.Check time taken to complete operation against setting and adjust if required. 14.Inspect and check each cam setting/switch assembly. 15.Drive motor/gear box. Check operation in both directions 16.Check Time switch settings for correct installation within the memory for particular application. Add, delete or adjust if necessary. 17. Replace battery according to manufacturer's recommendations. All batteries should be disposed of only in accordance with COSHH requirements. 18.Inspect Transformers for signs of overheating and insulation breakdown. CONTROL PANELS (e.g. Electrical Services, Starters, Control Relays, Switches, Lamps, Meters, and Alarms) When working on or testing Control panels it is essential that all local and national statutory regulations should be observed at all times. 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.

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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. 1. Check Panel exterior for any physical or mechanical damage. Door locks should be checked. 2. Inspect Mains isolator (also cubicle isolator) for correct mechanical and electrical operation. Lubricate any moving parts as required. Check correct operation of door interlock mechanism and adjust if necessary. Clean out interior. 3. Inspect fuse carrier/fuse holder for signs of overheating. Check fuses rating and terminations for tightness. Apply grease to fuse holder if required 4. Inspect Circuit breakers for signs of overheating and replace if necessary. Inspect connections and tighten if necessary. Check operation by tripping or "test" facility, if fitted. 5. Test Residual current devices. (RCDs) operation using test facility. 6. Carry out electrical test procedures per IEE Regs. 7. Check Power contactors for correct mechanical and electrical operation (a) Strip and clean interior (b) Inspect and clean magnetic pole faces (c) Inspect shaded ring for damage and fixed and moving contacts for wear or pitting". (d) Inspect coil for overheating or insulation breakdown. (e) Clean out arc shutes. On re-assembly avoid damage or loosening of springs or contacts, ensure correct mechanical operation and check all electrical connections for tightness and security. 8. Carry out maintenance on all types of Starters as per manufactures instructions. 9. Inspect Thermal overloads for signs of overheating. 10. Inspect Magnetic overloads for signs of overheating 11. Check oil levels in dashpots and replenish to correct levels if needed. 12. Inspect Panel wiring for signs of overheating or burn marks. 13. Check that panel is correctly bonded to earth 14. Carry out Flash test within 1.5kV-3.0kV range to detect potential deterioration of the system. CAUTION - Care should be taken to isolate sensitive equipment. 15. Check and energize Circuit to ensure that the indicator is operational. Replace any blown or discolored bulbs as required. 16. Inspect and check that all grilles are free of any obstructions, clean as required. 17. Inspect and check operation of fan unit

MANAGEMENT OF PLANNED MAINTENANCE

Establishment____________________ Location_________________________ System-Heating, Cooling System TypeFrequency- (6M) Complete cells with S/NS as required Record any defects here: Date-Week Comm. Task 043.1 Check
CENTRAL OPERATOR STATION

Task Group 8 Automatic Control and BMS Systems Checklist No1 Tasks-043.1

Week No

Initials

operation of all safety alarms, interlocks, indicators and devices. Back-up all software & archive. Inspect all panels internally and externally.
Check cables and connectors for security Check and replace Clock battery if necessary Check environment al conditions are within limits, for modems, line drivers, telemetry cables and interface units Check and clean, all drives, Keyboards, VDUs, and Printers Check Central station/out stations integrity of data flow in both directions Check and clean Cooling fans, Carry out voltage check on all power supplies. Check automatic restart Inspect Filters and clean or change as necessary Check Stand-by batteries/ uninterrup ted power supplies (UPS). Check Mouse clean ball as necessary Check Digital inputs. Activating (from fixed sensing/con trol device) Back up Software archives. Copy sitespecific data files Check Digital outputs operation Verify operating programme s

Check integrity of data flow in both directions

Analogue inputs. Read and check calibration of analogue inputs.

COMMUNICATIONS

Read and check calibration of analogue inputs.

Analogue outputs. Check for accuracy of output signal.

Installed programme. Check integrity, of alarms, interlocks, and optimisation.

SOFTWARE FUNCTIONS

Check integrity of the installed programme,

Optimised start/stop. Verify operation

Check real time clock for accuracy

Data logging. Review existing logs

Check alarms and software interlocks with safety implication s

Alarm manageme nt. Review frequencies of generated alarms

Power failure and restorati on. Check plant start up sequence.

Software interlocks. Verify operation

Generator loading programme. Check plant start up sequence.

OPERATION OF SAFETY ALARMS

Simulate alarm conditions in all controlled systems fails to programmed safe condition

Maximum demand/load shedding Check sequence and operation. BACKUP ALL SOFTWARE AND ARCHIVE

Check interfaces with other systems as fire, security, and access. Remove all unnecessary files and information from hard disc and de-fragment

Check manual overrides and effect on system Leave system in fully operational condition.

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Establishment_____________________ Location_________________________ System-Building Management Systems Control Equipment Frequency- (Y) Indicate S/NS as required Record any defects here: -

Task Group 8 Building Management Systems Checklist No2 Tasks-043.2

Date-Week Comm. Week No. Check operation/function/accuracy of all sensors, actuators, alarms, time programmes
Date Room Description Equipment type Condition of equipment Equipment operates correctly Equipment left working in automatic Initial

Establishment_____________________

Task Group 8

MANAGEMENT OF PLANNED MAINTENANCE

Location_________________________ System-Building Management Systems Tasks-043.3 Control Equipment Insert S/NS or reading Frequency- (Y) Record any defects here: - Date-Week Comm. Week No. Inspect, clean, service, adjust & overhaul all components of the system
Automatic Control Valves Valve No Valve No Valve No Valve No Valve No Actuators Check actuator torque Actuator condition and fixing Supply voltage and polarities correct Control signal present and correct Check auxiliary control functions Controller output to actuator position calibration Note settings max/min travel etc. Valve condition and fixing Linkages condition Correctly installed Valve let by Gland leakage Initials

Building Management Systems Checklist No3

Actuator No

CONTROLLER State type of controller e.g. optimiser, level control Control Panels

Note all set points

Controller condition and fixing

Check calibration of associated sensors

Program setting and times correct Check condition of and test electrical equipment

Note settings

Panel condition and fixing

Condition of electrical services

Check power supplies and battery back up Carry out maintenan ce of starters

Calibrate for correct relationship between sensors Carry out flash test 1.5kV-3kV

Panel No Panel No