appendix c2-preventive maintenance checklist

Tender Ref: CT1210P040Apppendix C2

Preventive Maintenance Checklist

INDEX OF PM CHECKLISTS

Check List No

Equipment Abbrev Equipment Type Cycle

I CRCold 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

I CT Cooling Tower Daily, Weekly, Monthly and Quarterly

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Preventive Maintenance ChecklistPM SERVICING CHECKS

(For Daily, Weekly, Monthly, Quarterly and Annual Cycle)

Servicing for Cold room system ___________ on date ________________ (*____ Cycle)

NO. DESCRIPTION NAME & SIGNATURE JOB EXPLANATION/REMARKSI. Cold room Refrigeration System (CR) including but not limited to compressor, FCU, Condenser and Evaporator Daily

1

Check and ensure no leakage of oil for each compressor.

2

Check and ensure all Freon level for each system(should a shortage appear, the fault must be resolved before charging refrigerant)

3

Check for ice forming at evaporator (the fault must be clarified, before manual defrost is performed)

4

Check for head Pressure in the secondary systems.(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 )

5

Check and ensure proper functionality of PLC switchboard.(PC and all 11 PLC systems are combined with a mod-bus communication system )

6

Check cold room temperature monitoring for each room including the automatic log function, the log files are updated with recording files

Monthly

1Carry out all daily tasks accordingly.

2

Check and ensure condenser coil fins cleanliness to ensure efficiency of the system.

3 Check and ensure unit cooler fin and evaporator cleanliness. Clean if necessary to ensure

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Preventive Maintenance ChecklistNO. DESCRIPTION NAME & SIGNATURE JOB EXPLANATION/REMARKS

efficiency of the system.

4Check and ensure proper functionality of reverse blowing.

5

For each cooling-unit in full-load.

Low pressure rapport High pressure rapport Amperage compressor.

6

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.)

7

Check and ensure proper functionality of control valve

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

8

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,

9

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.

10 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 files.)

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For PC software, backup visi+ software and excel converting software. The log files for all HACCP 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.)

12Generate a hardcopy report of the temperature trend

13Clean 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)

15Perform full functional test for all the whole system.

Quarterly

1Carry 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.

3Carry out calibration of digital thermometer with

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correction of not more than ± 0.5ºC

Annually

1Carry out all daily, monthly and quarterly tasks accordingly.

2

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)

3Clean blower fan, evaporator casing.

4Maintain a hardcopy record for auditing.

II ROOF SWITCHBOARD (R SB)

MONTHLY

1 Check fuse

2Check and ensure proper functionality of contacts 380,240 and 24.

3

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)

4

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 difference and power consumption the pump capacity can be

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compared with the setting.

Monthly

1Carry out all daily tasks accordingly

2Check for sign of leakage and repair if necessary.

3Check electric contacts for sign of loosening. Tighten if necessary.

4Check and ensure proper functionality of all safety devices.

5Glycol 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 panel aluminum bracket and frame

2Check and ensure proper alignment for both sections of the roller tracks.

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3

Check and ensure proper functionality all springs, cables, screws, brackets, tension springs, door panels leveling, door open/close limits, hinges, rollers and tracks. Reset if necessary.

4

Check and ensure proper functionality of all timers and door operation limits on control box. Reset if necessary. (For overhead and sliding door only)

5

Grease all the springs, wheels, and steel cables and fasten all moving mechanical components of the doors. (For overhead and freezer door only)

6Check for ice forming and remove if necessary. (For freezer door only)

7

Check and maintain the electric contacts on the doors, sub-board, battery door heater and cables and rollers. (For freezer door only)


9

Check and ensure proper functionality of all the photo cell sensor alignment (For sliding door only), re-align if necessary.

10Fasten all movable mechanical parts.

11

Maintain a hardcopy of the checklist for all the functional tests.

12

All over test ETV freezing doors according manual PLC (12) program and adjust if needed the limit switches on rails and motors.

V. COOLING TOWER (CT)Daily

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1 Check functionality for float valves and water supply.

2

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

1Carry 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).

3Check chemical water level. Top up if necessary.

4

Check and ensure functionality of all the pumps and fans, based on amperage rapport.


Quarterly

1Carry out all weekly and monthly tasks accordingly.

2

Perform Legionella Bacteria tests comply with latest Environmental Public Health (Cooling Towers and water fountain regulations).

3 Calibrate sensors to the

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manufacturer specifications and submit calibration reports.

Functional Test

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REMARKS:

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SPARE PARTS:

________________________________________________________________

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RECOMMENDATIONS:

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Preventive Maintenance ChecklistJob Done By:

Name Name

Signature Signature

--------------- SATS

Legend for Job Explanation:ADJ : Adjustment RPL : Replacement of Part’sAWP : Waiting for Parts TIG : TightenCLE : Cleaned : Eq condition, OKREP : Repair : Eq condition, No Good

** : “/ “ To carry out servicing, “ -- “ No servicing needed to be carried out.

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appendix c2-preventive maintenance checklist

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