Master Build Template v1 - EA North East - AK - duplicate

Title Page

Master Build Template
Environment Agency PUWER Inspection Pack
Generated on 27/11/2023
Conducted on
Contractor
Prepared by
Your reference:
Location
Risk Assessment in place and signed
Method Statement in place and signed
Confined Space working
Any Changes in task
Correct Isolation in place
Working at Height
Work area free from trip hazards
Traffic / pedestrian segregation
Excavation / Services - plans available
Overhead Electrical Hazards
People working overhead / nearby
Scaffold suitable - inspected
Correct Tools
Permits in place
All equipment PAT tested
High Pressure Systems
Noise
Correct PPE
Chemical or Biological Hazard
Risk of Drowning or entrapment
Weather conditions
Have you completed a dynamic risk assessment?

Site Details

Site and Work Order

"SITE NAME"
Work Order: Missing

Asset PPM Report

Complete PPM schedules for all assets as per reference. Add photos where required.

Building Services External Lighting- S_BEX&00_12E_01A

PPM Schedule Ref: Annual Building Electrical Services
Task -
Check operation of access lighting and associated sensors.
Check lighting is labelled up sufficiently and labelling is correct.
Check there is safe access to the columns and no trees / branches affecting the lighting columns
Foundation Base Checks -
Check base for damage / condition
Column foundation bolts for tightness and corrosion.
Column foundation bolts ‘denso’ tape for signs of wear
Column hinge undertake detailed check for signs of wear and corrosion.
Verify Distribution board labelling
Circuit labelling (DB and final circuits).
EICR labelling is present and in date (report if not).
Light electrical supply check
Covers and seals are complete.
Presence and condition of labels and warning signs.
Vermin damage
Water ingress
Wiring for damage and any signs of overheating.
Inspect trunking, cable tray and conduit for damage and completeness.
Check earth bonding to ensure it is mechanically sound, correct, complete and undamaged.
If non LED lighting units are installed, identify unit and note in report.
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done

Building Electrical Services - S_BE&00_12E_01A

PPM Schedule Ref: Annual Building Electrical Services
Inspect meter area
Check that it is accessible
Free from stored equipment
Correct warning signs are fitted
Inspect cables, meters and other associated equipment is free from damage and that there are no exposed live parts. Inform Asset Owner and/or Electricity supply company immediately and take action to prevent assess.
Obtain Ze & PFC at the Supply where applicable & Record
Inspect distribution boards for
Signs of damage
Spare ways have correctly fitted covers
Check that correctly rated fuses and MCB's are fitted and are complete
Test any RCDs, RCCBs and RCBOs using the test button
Check lightning / surge arrestors
Check operation of main switch (Isolator)
Inspect trunking and conduit for damage and completeness
Inspect all switches, sockets, connection units, blanking plates, junction boxes, for damage and completeness.
Visually inspect all permanently fixed equipment for damage and security of fixing.
Check operation of all lights. Ensure that correctly rated bulbs and fitting are being used.
Check operation of emergency lighting and fire exit signs.
Check operation of lighting on PIR or dawn to dusk lighting systems.
Check operation of all sockets. (All voltage ranges both ac and dc)
Inspect room heaters for signs of overheating, completeness and operation of associated thermostats/humidistats.
Inspect water heaters for damage, signs of overheating, completeness and operation of associated thermostats and electrical safety devices.
Inspect transformers and check for damage and operation.
Inspect all supplementary earth bonding both internal and external to the building and correct labels are fitted.
Inspect all equipment which is fed from and external to the building for damage and completeness.
Inspect generator connection sockets for damage and completeness.
Test the resistance to earth of each local earth electrode (with down conductor and earth electrode disconnected).
Test the resistance to earth of the complete earth termination system.
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Incomer & Distribution - S_CI&00_12E_01A

PPM Schedule Ref: S_CI&00_12E_01A - Incomer distribution annual maintenance
Isolate the incomer section before opening doors. Check that the incomer section is not combined with a generator or UPS. If so isolate the generator/UPS
Visually inspect and record
general condition of the incomer section
cables are undamaged and correctly identified
there are no exposed sections of conductors
all covers and insulators are undamaged and complete.
general condition of the equipment i.e. isolators indicators etc
primary and secondary bonding in mechanically correct
panel heaters and fans
ventilation louvers and filters
covers and seals are complete with all fasteners
water ingress
condition of labels and warning signs
vermin damage
Internal distribution boards - Inspect
check operation of disconnectors
test operate all RCDs, RCCBs and RCBOs Report all faulty units and replace as necessary
record time and trip current on adjustable units
check that all MCBs and MCCBs are undamaged and can be operated
check all fuses are the correct type, rating and are undamaged.
surge protectors are undamaged and active.
plug-in components have no signs of visible damage i.e. timers, relays etc
Isolator switches - Inspect
if fuses are inside switch enclosure check that they are the correct type, rating and are undamaged.
Check that all the electricity supplier's equipment is undamaged and firmly fixed. Report any problems.
TT systems only. Check that the TN-C-S (PME) earth conductor has not been reconnected back to the site earth.
Check operation of all protective systems i.e. phase failure relays, power failure relays, earth fault protection etc
Check operation of all timers and record settings. (if fitted)
Check indication lamps and replace as necessary (if fitted)
Check indicators, voltmeters, ammeters and power meters are operating. (if fitted)
Check operation of mechanical interlocks (if fitted)
Lubricate door hinges and locks as necessary
Clean enclosures internally and ensure free from debris
Clean panel front including indicators
Ensure that generators and UPS have been returned to their normal operating condition.

Observations

Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Common Controls - S_CC&00_06E_01A

PPM Schedule Ref : S_CC&00_06E_01A - Common controls 6M maintenance
- general condition of common control section
- general condition of the equipment i.e. contactors, relays, overloads, transformers etc
- primary and secondary earth bonding is mechanically sound and correct
- panel heaters and fans
- ventilation louvres and filters
- presence and condition of labels and warning signs
- operation of all switches, push buttons, safety interlocks, HMI's and indicators. Replace indicators as necessary
- function of all emergency stop devices.
- 20% of all electrical connections. (on larger panels thermal imagery should be used)
- mechanical operation of MCB's, RCBO's etc
- fuses for correct rating
- plug in components i.e. relays, timers etc. are seated correctly and have no visual signs of damage
- mechanical operation of interlocked isolator / other type of isolators
Measure primary and secondary earth bonding resistance reading with calibrated device, report and rectify if greater than 0.1 ohm
Measure control voltage and report if not within +/- 6%
UPS - check system is on line and not indicating a fault condition
Trip amplifier - check calibration and trip setting by injecting current source or carry out at the same time as primary controller.
Level indicators - check calibration and trip setting by injecting current source or carry out at the same time as primary controller.
Operate controls in all modes of operation, check for correct operation. Check indicators, voltmeters, ammeters and instrumentation.
Check operation of all protective systems i.e. low / high level alarms etc
Telemetry - Check in conjunction with EM to ensure correct operation and signal status at outstation terminals
Lubricate door hinges and locks as necessary.
Clean panels internally and ensure free from debris
Clean panel front including indicators

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Star delta starter annual maintenance - S_CW&00_12E_01A -

PPM Schedule Ref: S_CW&00_12E_01A - Star delta starter annual maintenance

Work Schedule

Isolate the starter section and earth the system and allow capacitors (if fitted) to discharge
Visually inspect and record
general condition of the starter section
general condition of the equipment i.e. contactors, capacitors indicators etc
primary and secondary bonding in mechanically correct
panel heaters and fans
ventilation louvers
covers and seals are complete
condition of labels and warning signs
water ingress
Check the below -
operation of all switches, pushbuttons, safety interlocks and indicators
function of emergency devices
20% of all electrical connections (check all if 5% are found faulty and use thermal imagery on larger panels)
fuses are correct rating and undamaged
plug in components have no signs of visible damage i.e. timers, relays etc
mechanical operation of interlocked isolator / other type of isolator

Inspections -

Inspect both sets of contactors for general condition, overheating, and mechanical interlocks are functioning correctly.
Check settings of overload protection devices and record settings.
Measure primary and secondary earth bonding resistance with calibrated instrument, record and rectify if greater than 0.10.
Measure control voltage and report if not within +/- 6%.
Trip amplifier (if fitted) - check calibration and trip setting by injecting with calibrated current source or carry out the same time as primary controller.
Operate controls in all modes of operation, check for correct operation.
Check operation of all protective systems i.e. voltage measuring relays and record settings.
Check operation of all timers and record settings.
Check indication lamps and replace as necessary.
Check indicators and meters are operating.
Lubricate door hinges and locks as necessary.
Clean panels internally and ensure free from debris.
Clean panel front including indicators.
Record hours run

Observations

Observation Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

DOL starter annual maintenance - S_CD&00_12E_01A

PPM Schedule Ref: S_CD&00_12E_01A - DOL starter annual maintenance

Work Schedule

Isolate the starter section and earth the system and allow capacitors (if fitted) to discharge
Visually inspect and record
general condition of the starter section
general condition of the equipment i.e. contactors, capacitors indicators etc
primary and secondary bonding in mechanically correct
panel heaters and fans
ventilation louvers
covers and seals are complete
condition of labels and warning signs
water ingress
Check the below -
operation of all switches, pushbuttons, safety interlocks and indicators
function of emergency devices
20% of all electrical connections (check all if 5% are found faulty and use thermal imagery on larger panels)
fuses are correct rating and undamaged
plug in components have no signs of visible damage i.e. timers, relays etc
mechanical operation of interlocked isolator / other type of isolator

Inspections -

Inspect contactor for general condition, overheating, and mechanical interlocks are functioning correctly.
Check settings of overload protection devices and record settings.
Measure primary and secondary earth bonding resistance with calibrated instrument, record and rectify if greater than 0.10.
Measure control voltage and report if not within +/- 6%.
Trip amplifier (if fitted) - check calibration and trip setting by injecting with calibrated current source or carry out the same time as primary controller.
Operate controls in all modes of operation, check for correct operation.
Check operation of all protective systems i.e. voltage measuring relays and record settings.
Check operation of all timers and record settings.
Record hours run
Check indication lamps and replace as necessary.
Check indicators and meters are operating.
Lubricate door hinges and locks as necessary.
Clean panels internally and ensure free from debris.
Clean panel front including indicators.

Observations

Observation Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Variable Speed Starter annual maintenance - S_CV&00_12E_01A

PPM Schedule Ref: S_CV&00_12E_01A - Variable Speed Starter annual maintenance

Work Schedule

Isolate the starter section and earth the system and allow capacitors (if fitted) to discharge
Visually inspect and record
general condition of the starter section
general condition of the equipment i.e. contactors, capacitors indicators etc
primary and secondary bonding in mechanically correct
panel heaters and fans
ventilation louvers
covers and seals are complete
condition of labels and warning signs
water ingress
Check the below -
operation of all switches, pushbuttons, safety interlocks and indicators
function of emergency devices
20% of all electrical connections (check all if 5% are found faulty and use thermal imagery on larger panels)
fuses are correct rating and undamaged
plug in components have no signs of visible damage i.e. timers, relays etc
mechanical operation of interlocked isolator / other type of isolator

Inspections -

Variable Speed Starter Unit -
general condition
overheating
terminations
heat-sink for cleanliness and clean as necessary
fan (if fitted) operation and cleanliness of filtration. Clean/ replace filter media as necessary.
External cooling fan (if fitted) - Inspect
General Condition
functionality
cleanliness of filtration. Clean/ replace filter media as necessary.
Choke / Line Reactor / Transformer - Inspect
general condition
overheating
breakdown of insulation
terminations
EMC filters - Inspect
general condition
outer casing / shield
overheating
terminations
earth bonding
HMI’s and external key pads (if fitted) - Inspect
general condition
functionality
Connections to soft start drive
indication
Tasks -
Measure primary and secondary earth bonding resistance with calibrated instrument, record and rectify if greater than 0.1Ω.
Operate controls in all modes of operation, check for correct operation check operation of voltmeters, ammeters etc
Check operation of all protective systems i.e. earth fault relays, voltage sensing relays etc and record settings
Record Hours Run
Check indication lamps and replace as necessary
Check indicators and meters are operating

Observations

Observation Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Soft Start annual maintenance - S_CS&00_12E_01A

PPM Schedule Ref: S_CS&00_12E_01A - Soft Start annual maintenance

Work Schedule

Isolate the starter section and earth the system and allow capacitors (if fitted) to discharge
Visually inspect and record
general condition of the starter section
general condition of the equipment i.e. contactors, capacitors indicators etc
primary and secondary bonding in mechanically correct
panel heaters and fans
ventilation louvers
covers and seals are complete
condition of labels and warning signs
water ingress
Check the below -
operation of all switches, pushbuttons, safety interlocks and indicators
function of emergency devices
20% of all electrical connections (check all if 5% are found faulty and use thermal imagery on larger panels)
fuses are correct rating and undamaged
plug in components have no signs of visible damage i.e. timers, relays etc
mechanical operation of interlocked isolator / other type of isolator

Inspections -

Soft Start Unit -
general condition
overheating
terminations
heat-sink for cleanliness and clean as necessary
fan (if fitted) operation and cleanliness of filtration. Clean/ replace filter media as necessary.
External cooling fan (if fitted) - Inspect
General Condition
functionality
cleanliness of filtration. Clean/ replace filter media as necessary.
Choke / Line Reactor / Transformer - Inspect
general condition
overheating
breakdown of insulation
terminations
EMC filters - Inspect
general condition
outer casing / shield
overheating
terminations
earth bonding
HMI’s and external key pads (if fitted) - Inspect
general condition
functionality
Connections to soft start drive
indication
Tasks -
Measure primary and secondary earth bonding resistance with calibrated instrument, record and rectify if greater than 0.1Ω.
Operate controls in all modes of operation, check for correct operation check operation of voltmeters, ammeters etc
Check operation of all protective systems i.e. earth fault relays, voltage sensing relays etc and record settings
Record Hours Run
Check indication lamps and replace as necessary
Check indicators and meters are operating

Observations

Observation Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Resistance Starters annual maintenance - S_CR&00_12E_01A

PPM Schedule Ref: S_CR&00_12E_01A - Resistance Starters annual maintenance

Work Schedule

Isolate the starter section and allow capacitors (if fitted) to discharge
Visually inspect and record:
- general condition of the starter section
- general condition of the equipment i.e. contactors, capacitors indicators etc
- primary and secondary bonding is mechanically sound and correct
- panel heaters and fans
- ventilation louvers
- covers and seals are complete
- presence and condition of labels and warning signs
- water ingress
Check:
- operation of all switches, pushbuttons, safety interlocks, voltmeters, ammeters and indicators
- function of emergency devices
- 20% of all electrical connections. (check all if 5% are found faulty and use thermal imagery on larger panels)
- fuses are correct rating and undamaged
- plug in components have no signs of visible damage i.e. timers, relays etc
- mechanical operation of interlocked isolator / other type of isolator
Dry resistance starter - Inspect resistor banks checking for
damage /breakdown of insulation
overheating
cleanliness
ALL Contactors - Inspect for
general condition
overheating
Check settings of overload protection devices and record settings
Measure primary and secondary earth bonding resistance with calibrated instrument, record and rectify if greater than 0.1Ω.
Measure control voltage and report if not within +/- 6%
Operate controls in all modes of operation, check for correct operation
Check operation of all protective systems i.e. earth fault protection, voltage sensing relays and record settings
Check operation of all timers and record settings.
Check indicators and meters are operating.
Record Hours Run
Lubricate door hinges and locks as necessary
Clean panels internally and ensure free from debris
Clean panel front including indicators

Observations

Observation Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Submersible Pump Maintenance - S_PE&00_12E_01A

PPM Schedule Ref: S_PEL00_12E_01A - Electric submersible pump annual maintenance

Checks

1. Identify and isolate the pump
- water in motor casing
- water in seal
- water in terminal box
- motor temperature thermistors
Check Motor Winding Resistance (continuity)
L1 - L2 (ohms)
L1 - L3 (ohms)
L2 - L3 (ohms)
Check Motor Insulation Resistance (IR)
L1 - E (Mohms)
L2 - E (Mohms)
L3 - E (Mohms)
hours run
Open sump (dewater sump if possible) and without entering the space visually inspect:
- lifting chains or ropes
- guide rails
- discharge pipework
- power and instrumentation cables
- junction boxes
Visually inspect supporting steelwork, access ladders, steps, platforms and edge protection for

Pump Inspection

What is the motor running current?
Is there excessive vibration or noise in the casing and associated pipe work?
Have the control and protection equipment been visually inspected and functionally tested?
Are the low-level protection settings correct?
Are the overload settings correct? Record Readings
Are the restart timers working properly?
Are the discharge inhibit timers working properly?
Is the discharge pipe system visually inspected?
Are the siphon breakers and NRVs in good condition?
Is the weed screen visually inspected?
Is the weed screen mechanically secure?
Are the bars on the weed screen evenly spaced and straight?

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Vertical spindle pump annual maintenance - S_PV&00_12E_01A -

PPM Schedule Ref: S_PV&00_12E_01A - Vertical spindle pump annual maintenance

Work Schedule

If permitted operationally run the pump and check for noise and excessive vibration from the pump and pipework, check the operation of siphon breakers, NRV's, etc. Look for excessive leaking from gland packing, adjust or replace as necessary when the pump is isolated.
Check holding down bolts are tight and undamaged.
Visually inspect pump casing, structure interface, fixings, and fastenings, check for corrosion, cracks, looseness, and leaks. Check intake pipework, discharge pipework, and fixings for leaks, cracks, damage, and corrosion.
For each spindle section, inspect all couplings for looseness, wear, damage to coupling and elements/bushes. Check alignment.
Tighten / repack / lubricate gland packing as necessary.
Check that any air release holes are clear
Oil lubricated bearings only
take oil samples for analysis
change oil as necessary.
ensure that oil is fed to moving parts as required
Grease lubricated bearings only
inspect lubricator /system checking for correct operation
check correct quantity of grease is being delivered at all bearings
all pipes are complete, undamaged and unblocked.
check grease levels and replenish as necessary.
remove excess grease from pump
check that individual mechanical lubricators (if fitted) are functioning correctly
Inspect top bearing assembly checking for adequate lubrication and shaft nuts are tight /locked
Refit guards and covers and confirm completeness and security
Turn pump isolator back on if permitted operationally test run pump, check for excessive vibration and noise and operation of siphon breakers, NRV's and associated pumping system components
Measure motor running current using calibrated test equipment and compare with panel meter and record hours run
Visually inspect and where possible functionally test control and protection equipment control
Hours Run
start level
stop level
low level protection
overload settings
inhibit timers
Visually inspect main and supplementary bonding to the pump system
Visually inspect weed screen is mechanically secure.
bars are evenly spaced and straight
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Pump horizontal centrifugal annual maintenance - S PC&00_12M_01

PPM Schedule Ref: S PC&00_12M_01- Pump Horizontal Centrifugal pump annual maintenance

Work Schedule

bars are evenly spaced and straight
Run pump and check the motor, pump, casing and the associated pipe work for leaks, excessive noise and vibration
Isolate the pump
Inspect structure: checking for corrosion and security of holding down bolts
Take oil samples for analysis. Report to Regional MEICA Engineer (if applicable)
Ensure grease is being fed to moving parts as required. Remove excess grease & oil spills from pump
Drain voids between bearing and pump housings
Check shaft seals and/or gland packing, adjust as necessary
Control Panel (if fitted and is not identified as part of Automation General Maintenance Schedule)
visually inspect and record the condition of the panel for general condition of enclosure, signs of water ingress, internal equipment, earth bonding
check operation of MCB's and RCD's.
check for correct fuse rating
check operation of all switches, pushbuttons, safety interlocks, and indicators.
check function of all emergency stop devices.
check operation of interlocked isolator / other type of isolator.
check operation and settings of motor overloads.
check all motors for continuity of resistance
check all motors for continuity of resistance between phase and earth..
check cables for vermin damage
visually inspect motor casings for damage
check operation of motor heaters (if fitted)
clean motor cooling fan and vents
lubricate motor bearings as required
check bearings and seals for looseness.
visually inspect and where possible functionally test control and protection equipment
inspect couplings and confirm alignment is correct and bolts are tight. Adjust as necessary
check all guards are in position and complete
turn pump isolator back on
if possible, run pump and measure motor running current using test equipment and compare with the panel ammeter
visually inspect pipe system, valves, penstocks, siphon breakers, NRVs and associated pumping components
visually inspect main and supplementary bonding to the pump system

Test Results & Recordings

Motor Tests

Windings - L1 – L2 (Ω)
Windings - L1 – L3 (Ω)
Windings - L2 – L (Ω)
IR L1 to Earth (MΩ)
IR L2 to Earth (MΩ)
IR L3 to Earth (MΩ)
Panel Ammeter (Amps)
Hours Run
Voltage (Volts)
Resistance (Ω)
Overload Setting (Amps)
Timer Settings (Min/Sec)
Thermistor (Ω)
Thermocouple (Ω)
RTD (Ω)
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Positive displacement pump annual maintenance

PPM Schedule Ref: S_PP&00_12M_01A - Positive displacement pump annual maintenance

Motor

IR Phase to Phase L1 – L2 MΩ
IR Phase to Phase L1 – L3 MΩ
IR Phase to Phase L2 – L3 MΩ
IR Phase to Earth L1 MΩ
IR Phase to Earth L2 MΩ
IR Phase to Earth L3 MΩ
Motor Heater Resistance Ω
Overload Setting (Amps)
Motor Running Current (Amps)
Panel Ammeter Reading (Amps)

Pump

Pressure Readings (Bar)

Controls

Restart Timer Settings (Sec/Min)
Inhibit Timer Setting (Sec/Min)
Start Setting (m)
Stop Setting (m)

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Motor LV AC annual maintenance S_M&&00_12E_01A

PPM Schedule Ref: S_M&&00_12E_01A - Motor LV AC annual maintenance

Work Schedule

If possible, run motor to check for excessive noise or vibration, hot spots in casing. On slip ring motor observe brushes and slip rings for arcing while running
Isolate the motor and allow any capacitors or other equipment to discharge prior to commencing removal of covers.
Clean any accumulation of dust or fibres on the frame or around the cooling fan inlet.
Visually inspect the motor for cracking, signs of significant damage, corrosion of the lifting lugs/eyebolts and loose fasteners and fixings
Visually inspect all cables to the motor checking for cracking, rips, twisting, degradation and vermin damage. Ensure glanding is correct and tight
Inspect and remove covers for motor terminal box and any other terminal box in the cable run
Check internal cables and terminations for signs
Check and record :
cracking or fretting of insulation
insulation breakdown
flashover
tightness
Slip ring motors remove brushgear covers and check:
brushes for wear and tensioning vacuum out carbon dust, renew as necessary
terminations
slip rings for arcing/heat damage, patina
brushgear holder fixings for tightness
brushgear posts insulation for damage, tracking etc.
If motor heaters are fitted check for operation.
Check thermistors (if fitted) check resistance and record
Check thermocouples (if fitted) check resistance and record
Check RTDs (if fitted) check resistance and record

Test Results & Recordings

Motor Tests

Windings - L1 – L2 (Ω)
Windings - L1 – L3 (Ω)
Windings - L2 – L (Ω)
IR L1 to Earth (MΩ)
IR L2 to Earth (MΩ)
IR L3 to Earth (MΩ)
Panel Ammeter (Amps)
Voltage (Volts)
Resistance (Ω)
Hours Run
Overload Setting (Amps)
Timer Settings (Min/Sec)
Thermistor (Ω)
Thermocouple (Ω)
RTD (Ω)

Operating Readings

Refit terminal covers and ensure that all seals and glands are complete and correctly fitted.
Visually inspect main and supplementary bonding.
Rotate rotor and listen to bearings. Inspect for excessive grease on shaft at bearing seals, remove any excessive old grease and re grease as necessary. If rotor is mounted on plumber blocks open and inspect bearings, clean and re-grease as necessary .
Inspect automatic greasers (if fitted) adjust and replenish as necessary.
Remove drain plug (if fitted) and ensure any water is thoroughly drained off. Ensure all drain holes are clear.
Vacuum out any internal dust / debris. If necessary clean cooling fan
Check all holding down bolts and coupling fitting for tightness and that they are complete.
Turn the motor isolator back on. (only if driven equipment is available to run)
If possible run motor to confirm correct operation
Measure running current using test equipment and compare with the panel ammeter. (if fitted) and voltages.
Visually inspect and where possible functionally test control and protection equipment (if not part of the MCC / control maintenance)

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Automation Relay Control Annual Maintenance - S_TR&00_12E_01A

PPM Schedule Ref : S_TR&00_12E_01A - Automation Relay Control Annual Maintenance
If you find any item is not in an acceptable condition, please provide full details on report sheet. The range of operating tests is limited to the permitted operation of the equipment, any restrictions are to be noted.
Isolate power to the relay compartment and allow any capacitors or other equipment to discharge prior to commencing removal of covers.
Panel inspection check for: general condition of the relay compartment.
general condition of panel heaters and fans (if fitted).
general condition of ventilation louvers and filters (if fitted).
covers and seals are complete.
presence and condition of labels and warning signs.
vermin damage.
water ingress.
wiring for damage and any signs of overheating.
all terminals are adequately shrouded to IP2X and all shrouding is secure.
operation of all switches, pushbuttons, safety interlocks, HMI's (where fitted) and indicators, replace indicators as necessary.
function of emergency devices.
Integrity of all main current carrying terminations and 20% of all other electrical connections. (Check all if any are found faulty).
fuses and MCB's check for damage and check against drawings they are correct size, type, rating.
plug in components i.e. relays, timers etc. are seated correctly and have no visual signs of damage.
mechanical operation of interlocked isolator / other type of isolator.
panel cubicle lock(s) are installed; section(s) are locked. Tool or key stored in a central secured cabinet.
Inspect wiring for -
damage.
signs of overheating.
Main and supplementary earth bonding -
visually inspect all main and supplementary earth bonding to ensure it is mechanically sound, correct, complete and undamaged.
measure main and supplementary earth bonding connections resistance with calibrated instrument, record and rectify if greater than 0.050.
Lubricate door hinges and locks as necessary.
Clean panel compartment(s) internally and ensure free from debris.
Clean or replace ventilation filters (if fitted).
Clean panel front including indicators.
Check mechanical operation of MCB's / switches supplying the control system and its associated equipment.
Check and record timer settings. (if fitted).
Level probe control relays (if fitted) check for correct operation and record sensitivity setting(s).
Inspect surge and Lightening Protection Units (LPU's) (if fitted) for signs of damage and ensure they are correctly connected and earthed.
Fit all earthing connections that may have been removed as part of the maintenance inspection.
Refit all covers, guards and follow manufacturers recommended procedure for preparing for operation.
Restoration of power -
Ensure closing and tripping circuits are reinstated. Re-establish power in accordance with SSoW. Check and confirm that the system is live and safe to operate.
If operationally permitted, start the plant to confirm correct operation.
Live tests - with power supply reinstated measure and record -
running current
supply voltage
UPS voltage (if fitted).
control voltage (report if not within +10% and - 6%).
UPS (if fitted). Check system is on line and unit indicates fault-free.
Check operation of compartment anti-condensation heater and control thermostat (if fitted), check temperature is set as per drawing.
Upon completion of maintenance works ensure: the equipment / site is left in a fully operational state. The site is left clean and tidy. all waste arising from maintenance activities is cleared from site. the site is secured on departure.

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Level ultrasonic - S_ILU00_06E_01A

S_ILU00_06E_01A - Level ultrasonic 6M maintenance
Take careful note of all original settings and switch positions. Where applicable, locate and place all automatic control functions to hand / local
Visually inspect for damage and security of installation the head and associated cabling.
Where fitted check stilling tube and signal path. Clean stilling tube and ensure signal path is clear. (Entry into any stilling chamber that is designated as a confined space requires a separate and specific risk assessment and safe system of work)
Locate the ultrasonic unit and, having checked the details against the database, place unit into program mode. Refer to the manufacturer instruction manual where necessary. Report any parameters that are not as per the site data sheet.
Where fitted, check the voltage across the memory protection battery. If found to be below 3.00V DC, then replace the battery.
Verify level reading in metres ODN, either by reading gauge board or from dipping at a known datum point.
Make note of the dipped level and check telemetry reading to ensure that the telemetry reading matches the real value from the field. If there is a discrepancy, alter the relevant parameter to make telemetry reading equal to the dipped / gauge board value. Check the alteration has had the desired effect. Record the new value of the parameter on the site data sheet
If no further adjustment is required, return unit to run mode and ensure that reading is correct and stable.
Check that any secondary current loops and isolation amplifiers fed by instrument are reading correctly
Make note of level and check telemetry reading is correct.
Place all automatic equipment back in operational mode as found on arrival

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Level probe - S_ILP00_06I_01A

S_ILP00_06I_01A - Level probe float switch 6M maintenance
Level Probes
Where applicable, locate and place all automatic control functions to hand / local.
Clear probes and stilling well of weed, spiders web and any other debris
Where necessary flush out stilling well to ensure free flow of water. (entry into any stilling chamber that is designated as a confined space requires a separate and specific risk assessment and safe system of work)
Remove probe covers and check that wiring is securely connected and that the termination fittings are complete, free of corrosion and undamaged.
Refit probes and verify start, stop settings by reading gauge board or from dipping at a known datum point and measuring probe distance above or below water level.
Refit covers and wiring as necessary
Check the operation of the conductivity level controller and check that the sensitivity adjustment (if fitted) is suitable for the application
Place all automatic equipment into operational mode as found on arrival.
Float switch
Where applicable, locate and place all automatic control functions to hand/local.
Clear switch of weed and other debris attached to it. If necessary; mark position of and lift up to gain access.
Check operation of switch by tilting or raising and lowering.
Where necessary flush out stilling well to ensure free flow of water. (Entry into any stilling chamber that is designated as a confined space requires a separate and specific risk assessment and safe system of work)
Reposition switch and check for security.
Place all automatic equipment into operational mode as found on arrival.

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Level hydrostatic - S_ILH00_06E_01A

S_ILH00_06E_01A - Level hydrostatic 6M maintenance
1. Take careful note of all original settings and switch positions. Where applicable, locate and place all automatic control functions to hand / local.
2. Locate transducer, withdraw from stilling well/disconnect from pipe, wipe and verify sensor details against records, report if not as recorded.
3. Use proprietary cleaning kit to remove any build up on the transducer body or the sensor element. Check physical condition of transducer and cable. Report any item not in an acceptable condition.
4. Where necessary flush out stilling well (ensure sensor is removed) or flush impulse line (entry into any stilling chamber that is designated as a confined space requires a separate and specific risk assessment and safe system of work)
5. Where instrument is loop powered measure voltage and report if out of tolerance
6. Connect the pressure transducer to the calibrated pressure source and carry out a five-point calibration check, referring to manufacturers literature as required. Carry this out for primary and all secondary loops. Adjust as required. Report any problems.
7. Disconnect transducer from test equipment and return it to correct position in stillage well/pipe
Verify water level readings in metres ODN, either by reading gauge board or from dipping at a known datum point.
Confirm instrument reading is correct, check telemetry reading and adjust/confirm transducer position is correct.
Place all automatic equipment into operational mode as found on arrival.

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Siren /Motor 3 phase LV annual maintenance - S_QSE00_12E_01

PPM Schedule Ref : S_QSE00_12E_01 - Siren /Motor 3 phase LV annual maintenance
WORK SCHEDULE
1. If possible (Authorisation must be granted via FIDO or FIM), run siren / motor to check for excessive noise or vibration, hotspots in casing.
2. Isolate the motor and allow any capacitors or other equipment to discharge prior to commencing removal of covers.
3. Clean any accumulation of dust or fibres on the frame or around the cooling fan inlet.
4. Visually inspect the motor for cracking signs of significant damage, corrosion of the lifting lugs/eyebolts and loose fasteners and fixings.
5. Visually inspect all cables to the motor checking for cracking, rips, twisting, degradation and vermin damage. Ensure glanding is correct and tight.
6. Inspect and remove covers for motor terminal box and any other terminal box in the cable run.
7. Check internal cables and terminations for signs:
- Cracking or fretting of insulation.
- Insulation breakdown.
- Flashover.
- Tightness.
8. Check and record:
- Motor continuity.
L1 - L2 (ohms)
L1 - L3 (ohms)
L2 - L3 (ohms)
- Motor Insulation Resistance -
L1 - E (M -ohms)
L2 - E (M -ohms)
L3 - E (M -ohms)
9. If motor heaters are fitted check for operation.
10. Check thermistors (if fitted) check resistance and record
11. Check thermocouples (if fitted) check resistance and record
12. Check RTDs (if fitted) check resistance and record
13. Refit terminal covers and ensure that all seals and glands are complete and correctly fitted.
14. Visually inspect main and supplementary bonding.
15. Rotate rotor / siren and listen to bearings. Inspect for excessive grease on shaft at bearing seals, remove any excessive old grease and regrease as necessary. If rotor is mounted on plumber blocks open and inspect bearings, clean and regrease as necessary . On Siren check for corrosion around edges and sounding area.
16. Confirm correct alignment. Adjust as necessary and record values.
17. Check all holding down bolts and coupling fitting for tightness and that they are complete.
18. Turn the motor isolator back on. (only if driven equipment is available to run)
19. If possible run motor to confirm correct operation
20. Measure running current using test equipment and compare with the panel ammeter. (if fitted) and voltages.
21. Visually inspect and where possible functionally test control and protection equipment (if not part of the MCC / control maintenance)
 overload settings
 restart timers
 thermistors sensors (if fitted)
 thermocouple sensors (if fitted)
 RTD sensors (if fitted)
 voltmeter readings

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Navigation lighting annual maintenance - S_QNL00_12E_01

PPM Schedule Ref: S_QNL00_12E_01 - Navigation lighting annual maintenance

Work Schedule

Operate the light and confirm the correct operation.
Isolate the lighting circuit prior to commencing removal of covers.
Clean any accumulation of dust, insects or debris from the frame internal fitting and lighting cover.
Visually inspect the light fitting, the reflector (or shield if fitted) and cover for cracking, signs of significant damage and loose fasteners or fixings. Check seals on external covers are sound, replace as necessary
Remove lamp(s) from holder(s) and check lamp and contacts for arcing, wear and looseness, if automated lamp changing fitted check the changing mechanism and motor for wear, jamming and signs of overheating. Refit lamps replacing any defunct lamps. Refit all external covers
Visually inspect all cables to the light checking for cracking, rips, twisting, degradation and vermin damage. Secure any loose cabling in an appropriate manner. Ensure glanding is correct and tight
Inspect and remove covers for lighting control terminal box and any other terminal box in the cable run
Check internal cables and terminations for signs
cracking or fretting of insulation
insulation breakdown
flashover
tightness
Refit terminal covers and ensure that all seals and glands are complete and correctly fitted. In a marine environment protect exposed fixings with Denso tape or grease or equivalent
Visually inspect main and supplementary bonding.
Turn the lighting isolator back on.
Confirm lighting operating correctly. Where an automated lamp changer is fitted rotate the lamps in manual control to ensure all lamps are operational. Return controls to auto after test
Visually inspect and where possible functionally test control and protection equipment (if not part of the
MCC / control maintenance)
overload settings
voltmeter readings

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Actuation electro-mechanical annual maintenance S_AE&00_12E_01A

PPM Schedule Ref: S_AE&00_12E_01A - Actuation electro-mechanical annual maintenance

Work Schedule

WORK SCHEDULE
If you find any item is not in an acceptable condition please provide full details on report sheet. The range of operating tests is limited to the permitted operation of the equipment, any restrictions are to be noted
1. With the power supply on carry out an external examination including:
- general environment and overall condition
- fixings and access seals - check cover screws and replace if required
- rising stem cover and water ingress to stem tube
- cable entries and glanding
- indicator glass and lamps
- evidence of lubrication to spindle shaft
- evidence of oil/ grease leaks
2. Operation of actuator (obtain permission to move) check:
- hand wheel operation and condition
- local and remote control buttons
- auto operation ( by forcing auto control inputs)
- check operation of automatic declutching or other manual operation protective devices
- accuracy of position indicator devices and gauges
With the power supply off and the actuator electrically isolated, carry out an internal examination including :
Terminal Section - Pay particular attention to water ingress.
Control/ contactors - Check rating of internal fuses
For programmable/electronic actuators, some checks are undertaken with the power on.
Limit Switches -
Check the condition of potentiometer, indicators, and locking nuts of limit switches.
check and record the torque trip setting in open and closed positions.
Live tests - With the power supply reinstated, measure and record
the supply voltage
control voltage.
Recalibrate positional feedback if necessary and check values with Hydrometry and Telemetry.
Running Tests - Check measured values against the site data sheet for the actuator.
Monitor noise.

Running Tests

Open Time
Close Time

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Weedscreen cleaner annual maintenance - S_W&&00_12M_01

PPM Schedule Ref: S_W&&00_12M_01A - Weedscreen cleaner annual maintenance
Operate weedscreen cleaner check for excessive noise, vibration, ease of travel and operation of brakes. Ensure that weed screen is cleaned of debris before isolating the weedscreen cleaner for Maintenance
Inspect the weedscreen checking the bars for straightness, twisting, security, cracks and completeness.
Inspect the conditions of any access, supports, ladders, stairs, fixing brackets, anchor points, fasteners and handrails associated with the weedscreen cleaner.
Weedscreen cleaner (dependent upon type) :
security of holding down bolts.
drive chain for wear, distortion, tension, stretch, attachment and lubrication.
drive wire ropes. fraying, distortion, tension, stretch, attachment and lubrication
wheel wear, corrosion, security of attachment, distortion and completeness and lubrication
track / channel for wear, corrosion, security of holding clips, distortion and completeness, for U channels check internally for birds nests and other debris that will interfere with the range of travel
rack and pinion drives for wear, corrosion, security of holding clips, distortion and completeness
travel stops are complete, secure and in the correct position.
travelling carriage frame and covers and component parts for damage, cracks, corrosion, protective coating and security.
operate all limit switches and check all striker plates etc for security
check grab for alignment and security of tangs
lubricate all bearings and greasing points as required.
check alignment of gearboxes to driven equipment, adjust as necessary.
Hydraulics
inspect cylinders checking for leakage, security of fixing and damage.
inspect hydraulic pressure relief valves for signs of tampering and report any concerns.
inspect and replace filters (as recommended by manufacturer or if pressure differential indicates)
inspect pipe, fittings, unions and flexible hoses for leakage, repair or replace as necessary.
check the oil level, top up as necessary
check that all drains and dump connections are secured with locks and/or plugs.
take a sample of oil for analysis, send report to Regional MEICA Engineer.
Electrical :
visually inspect and record the condition of the panel for general condition of enclosure, signs of water ingress and vermin damage, internal equipment, earth bonding.
check operation of MCB's and RCD's.
check for correct fuse rating
check operation of all switches, pushbuttons, safety interlocks, and indicators.
check function of all emergency stop devices.
check operation of interlocked isolator / other type of isolator.
check operation of motor overloads.
inspect catenaries' and cables (if fitted) checking for smooth operation, cable damage and attachment.
check cables for vermin damage
visually inspect motor casings for damage
check operation of motor heaters (if fitted)
clean motor cooling fan and vents
lubricate motor bearings as required
check operation of all brakes, adjust as necessary
confirm that motor alignment is correct, adjust as necessary
open up and inspect operating pendants, check terminations for security, check pushbutton operators and switch blocks for security
Check alignment of gearboxes, motors and brakes, adjust as necessary.
Inspect all guards and ensure they are correctly fitted and secure.
Check that all safety labels are complete, legible and in place.
Travel Motor Test Results
Motor Windings L1 – L2 Ω
Motor Windings L1 – L3 Ω
Motor Windings L2 – L3 Ω
IR Phase to Earth L1 MΩ
IR Phase to Earth L2 MΩ
IR Phase to Earth L3 MΩ
Overload Setting (Amps)
Motor Running Current (Amps)
Hoist Motor Test Results
Motor Windings L1 – L2 Ω
Motor Windings L1 – L3 Ω
Motor Windings L2 – L3 Ω
IR Phase to Earth L1 MΩ
IR Phase to Earth L2 MΩ
IR Phase to Earth L3 MΩ
Overload Setting (Amps)
Motor Running Current (Amps)
HPU Test Results
Motor Windings L1 – L2 Ω
Motor Windings L1 – L3 Ω
Motor Windings L2 – L3 Ω
IR Phase to Earth L1 MΩ
IR Phase to Earth L2 MΩ
IR Phase to Earth L3 MΩ
Overload Setting (Amps)
Motor Running Current (Amps)
Pressure Readings (Bar)
Differential Pressure Reading (Bar)
New Filter Fitted?
Oil Sample Taken?
Automated weedscreen cleaners -
inspect terminals and any plugs/sockets plug in components i.e. relays, timers etc. are seated correctly and have no visual signs of damage other equipment i.e. heaters, PSU's check mechanical operation of MCB's/ switches supplying the PLC and its associated equipment.
visually inspect and check operation of any HMI panel clean HMI display check fuses for correct rating
Power the weedscreen back on, for manually operated systems, if permitted operate the system through its full range of operation. Where pendants have more than one operating position, check operation from each pendant station For automated systems initiate a full cleaning cycle and observe that the cycle executes correctly and that trash removed from screen is correctly placed in skip or drying rack. Where automated systems can be operated manually with a pendant repeat as for a manually operated system

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Lifting appliances overhead crane annual electrical & mechanical maintenance - S_LC&00_12EM_01A

PPM Schedule Ref: S_LC&00_12EM_01A - Lifting appliances overhead crane annual electrical &mechanical maintenance
If you find any item is not in an acceptable condition, please provide full details on report sheet. The range of operating tests is limited to the permitted operation of the equipment, any restrictions are to be noted.
Equipment details, check and record make, type, model, serial number, year of manufacture. (where applicable)
Visually inspect the condition of access walkways, platforms and other structural items associated with access or operation of the overhead hoist.
Visually check and record the general external condition of the mechanical equipment, electrical equipment and control panel(s) of the overhead hoist.
Identify the overhead hoist control panel and isolate power to the motor(s) and allow any capacitors or other equipment to discharge prior to commencing removal of covers.
General condition of the panel
general condition of the equipment, i.e. contactors, capacitors and indicators etc.
terminals and any plugs/sockets
plug in components i.e. relays, timers etc. are seated correctly and have no visual signs of damage.
panel heaters and fans.
ventilation louvers and filters.
covers and seals are complete.
presence and condition of labels and warning signs.
vermin damage.
water ingress.
all terminals are adequately shrouded to IP2X and all shrouding is secure.
inspect wiring for damage and signs of overheating
operation of all switches, pushbuttons, safety interlocks, HMI’s (where fitted) and indicators, replace indicators as necessary.
function of all emergency stop devices.
all main current carrying terminations and 20% of all other electrical connections. (Check all if any are found faulty).
check mechanical operation of MCB’s / switches supplying the control system and its associated equipment.
fuses and MCB’s check for damage and check against drawings they are correct size, type, rating.
mechanical operation of interlocked isolator / other type of isolator.
Contactors - Ensure the below is checked
Over heating
working freely
functioning correctly
contacts not showing signs of pitting
evidence of excessive wear
all components securley fixed
Check settings of overload protection devices and record
visually inspect all main and supplementary earth bonding to ensure it is mechanically sound, correct, complete and undamaged.
Lifting Equipment Electrical
long travel drive & bogie for signs of damage, wear and corrosion.
control pendant, control stations and / or remote-control unit and check for damage, broken controls, integrity of support wire.
long travel catenary / power collector system for signs of damage, wear and corrosion.
operate emergency stop and ensure that hoist cannot operate when activated
Support Structure -Visually inspect the condition of the following for signs of damage, wear and corrosion If cracks are observed then prevent the hoist from being used and report immediately to the Supra-Area MEICA Team-Leader.
any gantry beams, supports and fishplates.
interface of gantry beams with structure.
long travel runway beam, any jointing plates and fasteners
long travel end stops.
long travel carriage and wheels.
tighten any loose fasteners and replace missing fasteners.
Markings - If any of the above are missing then report immediately to the Supra-Area MEICA Team-Leader
check the jib hoist is marked with a SWL and a LOLER ID number
check any attached lifting accessories are stamped with a SWL and a LOLER ID number.
Lubrication - Oil changes / level(s) top ups _ record volume and type used on record sheet.
Operating Hoist - Operate hoist using all operating controls / positions and check for: If defective, report immediately to the Supra-Area MEICA Team-Leader.
correct operation, direction of travel and that all motors stop at their limits of travel.
check hoist and lower functions, fast/slow/inching if fitted
motors stop immediately and brakes operate correctly.
operate long travel drive and check for crabbing in both directions.
operate cross travel drive and check for crabbing in both directions.
check movements of catenary cables, lubricate hangers as necessary.
noise and excessive vibration.
operate emergency stop and ensure that hoist cannot operate when activated.
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Diesel engine annual maintenance - S_E&&00_12M_01A

PPM Schedule Ref: S_E&&00_12M_01A - Diesel engine annual maintenance

Work Schedule

Visually check and record general condition of the engine.
Exhaust System:
inspect the condition of exhaust, support bracket(s), pipes / joints and fasteners.
inspect the condition of exhaust guarding and thermal insulation. Ensure both are firmly fixed and correctly positioned.
inspect the condition of the silencer (if fitted) and drain any liquid present.
ensure all fittings / fasteners are secure.
remove spark arrestors. (if fitted)
tap to loosen any internal deposits and shake to check internal baffles and to remove deposits.
refit
with diesel running under load, check for sparks. Renew as necessary. (refer to item 13)
check for leaks when diesel engine is running. (refer to item 13)
inspect condition of exhaust flap (if fitted)
3. Cooling system (if fitted):
check water level and antifreeze / inhibitor concentration and replenish if required. Replace coolant at the manufacturers recommended intervals.
check all hoses and hose connections
visually check condition of water pump, seals, bearings and any weep holes are clear.
check operation of water heater (if fitted).
inspect the condition of the radiator and ensure it is not blocked. Check all other pipe work is clear and ensure the pressure cap (valve) functions correctly.
inspect the condition of fan blades and safety guarding. Look for looseness and cracks on the blades - clean if required. Ensure guarding is firmly fixed and correctly positioned.
inspect all fixing brackets, mountings and clips. Repair minor leaks.
Lubrication System :
check oil level and replenish if required. Replace engine oil at the manufacturers recommended intervals.
check oil heater (if fitted).
inspect and replace filters (replace at the manufacturers recommended intervals or when pressure differential indicates the need).
visually check condition of external oil pump, seals, oil lubricators and pipe work (if fitted).
visually inspect condition of breather system. Ensure breather pipe and gauze element are clean and not blocked.
repair minor leaks.
Fuel System :
check fuel tank level and condition of fuel, take sample of existing fuel for analysis - results of sample to be sent to the Regional MEICA Engineer. (Only completed on Major Annual Service)
inspect condition of fuel tank, fixing brackets, mountings, valves and filler cap.
inspect fuel tank atmospheric vent. Ensure it is clean and not blocked.
inspect the fuel filter(s). Clean or replace (at the manufacturers recommended intervals).
visually check the fuel injection pump and mountings. Clean fuel pump filter or replace (at the manufacturers recommended intervals) pump filter.
inspect all fuel lines and repair minor leaks.
inspect condition of any bund areas. Look for cracks or other damage where a spillage of fuel could escape.
check function of bund monitoring/alarm system if fitted
inspect emergency fuel cut-off system (if fitted). Check cables, counterbalance, pulleys and fusible links.
Air System :
inspect air filter and clean or replace (at the manufacturers recommended intervals).
visually check the condition of air manifold and joints.
at the manufacturers recommended intervals inspect the turbocharger compressor (if fitted) in accordance with manufactures instructions.
check air flap valve (if fitted) Do not test with engine running as it may cause oil carry over into the exhaust system and damage the diesel engine.
Engine
inspect the main engine mountings, anti-vibration mountings, enclosure cover and any additional heat shield covers for signs of wear or corrosion.
inspect engine linkages, lubricate if required
inspect engine breather (if fitted). Replace if required by manufacturers recommendations.
clean and inspect the turbocharger impeller and compressor casings (if fitted).
inspect all pulleys wheels, auxiliary drive belt(s) and adjust tension if necessary (replace belt(s) at the manufacturers recommended intervals).
check operation of the starter motor(s) electric, hydraulic or pneumatic.
inspect governor.
check all connectors are undamaged and securely fixed
covers are undamaged, secure and complete
Mechanical :
check all springs, linkages for correct movement. Lubricate as necessary
covers are undamaged, secure and complete
screw adjusters are secure and locked in position
Inspect mechanical over speed trip mechanism (if fitted)
Batteries :
check that the battery charger is working.
check that the charger volt and ammeters (if fitted) are registering the correct readings.
inspect batteries for signs of overheating and bulges and vents are clear.
check terminal connections for tightness and corrosion
check cables for fraying and corrosion.
check electrolyte level, top up as necessary
Clutch :
inspect clutch assembly.
lubricate bearings and linkages as necessary
clean out clutch housing and clear vent and drain holes
operate and adjust clutch as necessary checking for a smooth operation.
Acoustic Enclosure (if fitted)
inspect enclosure doors for looseness and fit, adjust as necessary
inspect door stays and gas springs and check that doors remain open, repair/replace as necessary
check ventilation vents are not blocked
if fitted check condition of all ventilation louvers and ensure free from obstructions, check operation of automatic louvers and grease if necessary.
check acoustic material and protective covering for tears and punctures, repair/replace to prevent accumulation of liquids or oil film within the material.
11. Instrumentation
check all instrumentation is undamaged and functional, check against test instrument and replace as necessary. Record readings whilst diesel engine is running. (refer to item 13)
inspect all switches and check for correct operation.
General
visually inspect the condition of any permanent lifting brackets, check for corrosion and comment on any deficiencies.
check operation of all emergency stop button positions
check operation of pre-heater (if fitted)
visually check condition of all electrical cable, glands and conduit
inspect condition of all spill trays and check all are secure, drain off any fluid.
check condition of all warning and safety signs associated with the equipment.
ensure engine room / enclosure is clean and tidy.
report any concerns about any piece of equipment.
(Item 13) Start Engine & Test Run
check that all parts of the engine are functioning correctly and free from leaks.
ensure engine operates to manufacturers recommendations, adjust any settings accordingly
report any concerns i.e. excess vibration, noise or visual appearance of exhaust emissions.
Where possible run for at least 30 minutes and on load

Items Fitted

Lubrication Oil Filter
Air Filter
Engine Breather
Drive Belts

Readings

Battery Voltage (Volts)
Battery Charger Voltage (Volts)
Battery Charger Amperage (Amps)
Hours Run (Hours)
Engine Speed (rpm)
Engine Oil Pressure (Bar psi)
Engine Oil Temperature (ºC)
Engine Cooling Water Temperature (ºC)

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Site safety and operational inspection - S_X&&_6G_02

PPM Schedule Ref: S_X&&_6G_02 - Site safety and operational inspection

Work Schedule

WORK SCHEDULE
1. Liaise with site operator and check and report on any operational problems over the previous 6 months.
2. Visually inspect MEICA equipment for signs of damage.
check external enclosures and equipment housings
isolate electrical enclosures and visually check internal cabling and equipment within enclosures for vermin, heat and water damage
3. Check operation of equipment locks and lubricate if required.
4. Check equipment fluid levels and top up if required. Contain and report leaks
5. Check any fuel or lubricating oil storage or other bunded systems. Check overfill alarms and level indication
6. Check internal and external lighting (replace if so instructed by MEICA team). Check that emergency lighting test records are completed as required.
Check control panel indication lights (press to test or lamp test)
Check machinery guards and equipment barriers for integrity and operation of interlocks
Check operation of equipment - test start and stop plant to prove initial operation and functional controls. Operate valves, siphon breakers, and other manual control devices.
Check operation of critical safety devices such as emergency stops, interlocks and functional isolators.
Check ventilation systems and heating systems
Inspect signage and labelling, report if missing or damaged
Check the condition of any weed screens, booms or safety screens
Check the visible inspection status of equipment subject to the following regulations:
EAWR (PEE)
LOLER
PSSR
Check instrumentation level and position readings against the actual values.

Observations

Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Gearbox - S_R&&00_12M_01A - Gearbox annual maintenance

PPM Schedule Ref: Gearbox - all types annual maintenance

Work Schedule -

Operate equipment to check for vibration and noise
Inspect input and output shafts and access seals for leakage and if possible adjust to correct or otherwise report the defect
Operate any manual or alternative drive input system checking any interlocks or remote indicators that should operate when alternative drives combinations are used. check that any clutches or gear changes are working effectively
If oil temperature gauges are fitted check that they are intact and indicate a sensible ambient temperature. Where oil level sight glasses are fitted check for opacity - replace as necessary
Forced lubrication systems:
check spray heads are clear and oil is discharging as required.
inspect and replace filters (replace at the manufacturers recommended intervals or when pressure differential indicates the need)
check the operation of any pressure gauges through the normal operation of the equipment.
Remove gauges for further "dead weight" testing if they appear faulty.
take a sample of the oil for analysis. Report to be sent to the Regional MEICA Engineer
check and if required top up the oil level.
inspect any sealing devices that prevent dirt and moisture ingress
Non-sealed grease lubricated systems
clean away any excess grease
prove the greasing points are clear and if required apply grease
if required replace canister auto greasing units
if required top up auto greasing units
Splash lubricated systems
check the oil level and top up if required
inspect the oil reservoir for signs of moisture ingress
Inspect any guards and ensure they are correctly fitted and secure
Inspect input and output couplings for wear and unacceptable backlash

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Penstock 6M maintenance - S_GP&00_06M_01A

PPM Schedule Ref: S_GP&00_06M_01A - Penstock 6M maintenance

Visual Checks

Visually inspect to ensure door to spindle attachment is secure and undamaged before attempting to operate.
Grease and operate the penstock. Note any backlash, juddering, jumping or noisy operation of moving parts.
Check for leakage between frame & structure.
Check for leakage between door & frame.
Isolate electrics if required according to written procedures.
NON- RISING STEM- Badly worn threads may not support the weight of the door and could fail causing the door to fall without warning
Lubricate or grease all moving parts as required including the thrust collar using the grease points supplied.
Inspect hand wheel / winding handle is fit for purpose (also keyways and splines etc if handle is not permanent)
Check power pack/gearbox/extension drive spindles etc are secure and are fit for purpose
Check electric actuators and /or gearboxes for excessive noise while operating and test all limits and torque settings.
RISING STEM-As for Check 6 above.
Check lead screw attachment to gate
Check for damage to door guides & to seals on door & frame
Report on any visible corrosion, wear & tear on protective coatings, cracks, chips, broken castings
On completion of maintenance checks test the operation of penstock using actuator (electric or hydraulic) or manually

Observations

Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
undefined

Vertical mitre gate annual maintenance - S_GM&00_12M_01

PPM Schedule Ref: S_GM&00_12M_01 - Vertical mitre gate annual maintenance

Work Schedule

Visually inspect the condition of access walkways, platforms and other structural items associated with access or operation of the gate.
Visually inspect the gate as far as practicable without removing any operating equipment.
Check each gate for impact damage, corrosion and/or wood decay. Report on the condition of the gate, paint system and / or cathodic protection.
Check top hinges for looseness, wear, and corrosion and that attachments are complete and secure. Report any abnormalities.
Check pintle /bottom bearing if exposed at low water.
For counterbalanced gates check that the weight attachment wire ropes/chains are secure and that there are no signs of overstretching or overloading. Inspect wire ropes or chains for defects and report.
Check pulley arrangements are complete and fully operable, grease as necessary.
For linear actuation such as hydraulic rams, screwed rods or racks, the pivot arrangements are critical to ensure that no bending moments are applied. Check pivot arrangements and ensure that any arrangements are clear and working.
Check lubrication points are unblocked and any automatic lubricating arrangements are functioning, top up lubricant if necessary.
Inspect all guarding and ensure it is firmly fixed and correctly positioned. If access points are provided for maintenance inside the guarding, ensure they are accessible, and if they incorporate disabling. interlocks test that these work.
Operate the gate and check that each gate mitres correctly in the central position and that there is not an excessive vertical gap. Report any abnormalities.
Comment on the apparent condition of the gate seals either by visual inspection or assessment of leakage.
Inspect and if possible use any equipment designed for latching or locking the gate into a fixed position. In some cases latching pins are actuated and these should be inspected for operation and adjusted as required. Any obvious deterioration in the arrangement that could reduce the effectiveness of the latch to hold the weight must be reported.
For gates fitted with accessible buoyancy chambers dip the chamber to check for water leaks.

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Gate annual maintenance - S_G&&00_12M_01A

PPM Schedule Ref: S_G&&00_12M_01-Gate annual maintenance

Work Schedule

Visually inspect the condition of access walkways, platforms and other structural items associated with access or operation of the gate.
Check operation of limit switches
Visually inspect winding gear drums, support bearings, gearboxes, plumber blocks couplings etc and ensure any oil and grease lubrication points are unblocked and any automatic lubricating arrangements are functioning and charged with lubricant. Inspect and adjust brakes
Visually inspect the gate lifting equipment as far as you are able to do so without fully removing any chains, racks or lifting ropes. Lubricate as required and comment on any deficiency in routine operator lubrication.
for wire ropes check for evidence of surface corrosion, broken strands and the lay of the rope onto any winding gear. Any separation of the wire rope strands should be reported. Pay particular attention to shackles and other points of connection.
for transmission type chains check as far as you are able for general lubrication on all links that are required to be flexible. Report any link that has seized.
for racks and screws the wear on the drive nut or drive pinion is important. If possible inspect the wear or assess it by estimating the backlash. Report any concerns
for linear actuation such as hydraulic rams, screwed rods or racks the pivot arrangements are critical to ensure no bending moments are applied. Check and inspect pivot arrangements and ensure that any lubrication arrangements are clear and working.
Inspect the guarding and ensure it is firmly fixed and correctly positioned.
if access points are provided for maintenance inside the guarding, ensure they are accessible and if they incorporate disabling interlocks test that these work.
Obtain permission of site responsible officer or FIDO then operate the gate. Inspect and report on the condition of the paint system and / or cathodic protection
Comment on the apparent condition of the gate seals either by visual inspection or assessment of leakage, for tilting gates pay particular attention to the lower pivot seal
Check and adjust any sealing glands, for some types or torque tube gate the shaft seal is critical to the integrity of the dry well - check the seal and assess the rate of leakage if any.
Inspect and if possible, use any equipment designed for latching or locking the gate into a fixed position. In some cases latching pins are actuated and these should be inspected for operation and adjusted as required. Any obvious deterioration in the arrangement that could reduce the effectiveness of the latch to hold the weight must be reported.
Inspect any mechanical torque limiting devices, slipping clutches may be present and the adjustment of them is critical to there operating limits. Ensure that any adjustment locking arrangements are secure and report any evidence that torque settings have been tampered with.

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Tidal large flap valves / Gate - S_GF&00_12M_01A

PPM Schedule Ref: S_GF&00_12M_01A - Tidal large flap valves annual maintenance

Work Schedule

WORK SCHEDULE
1. Carry out the following tasks and checks: note any exceptions or any items that cannot be completed due to site conditions
2. Where fitted, visually check the condition of the winch, its wire rope or chain, for mechanical winches check that the locking pawl system works prior to raising the flap. Raise the flap & flush through to clear silt & debris (if required.)
NEVER WINCH THE FLAP OPEN AGAINST A POSITIVE HEAD. THE ON & OFF SEATING HEADS MUST BE BALANCED.
3. Hose down the flap to remove silt and debris and allow clear access for inspection. (assess the potential pollution arising from the disturbance of silt and debris and seek advice if there is a notable pollution risk)
4. Inspect the flap lifting equipment
check the flap cast/fabricated-lifting eye or screwed eyebolt is fit for the purpose of lifting the flap.
check lifting chains, wire ropes & fittings are fit for purpose.
if a blind threaded eyebolt is fitted, this is to be removed and checked and comments made on the report. It is advisable that the screwed hole in the flap be drilled through, a suitable backing plate provided and an eye bolt pin passed through & secured using compatible nut and washer. (This modification will require a new job number and you must seek the approval of the Regional MEICA Engineer before proceeding.)
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5. Check for damage to seals on flap & frame
6. Check for worn or damaged parts on the operating linkage & for freedom of movement
7. Check all grease lines if fitted for corrosion, kinks, flats, splits & missing pipe clips
8. Lubricate or grease all moving parts as required, checking that grease is reaching all the mechanisms
9. Check for missing or damaged grout between frame & structure. Make good any faults.
10. Check the tightness of all fasteners.
11. Close flap & check for leaks by using the POSITIVE IN head (this may require a return visit when water levels are suitable)

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Mechanical Isolation Valve - S_PXI00_12M_01

PPM Schedule Ref: S_PXI00_12M_01 - Mechanical Isolation valve annual

Work Schedules

Check outer casing for damage, blistering of surface or corrosion.
Check flanges and bolted connections for leakage, damage or corrosion.
Check valve stem for leakage, replace any stem packing as necessary. Check valve hand-wheel (or lever) for completeness and security to stem.
Check security of any locking mechanism fitted
Grease valve if required.
Note valve position and if operational conditions permit, move valve through complete range of movement and return to original position. Note any leakage past stem or valve in fully closed position
If valve had been secured in a particular position then return to position and secure
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Mechanical siphon breaker annual - S_PXS00_12M_01A

PPM Schedule Ref: S_PXS00_12M_01A - Mechanical siphon breaker annual

Work Schedule

Inspect structure, checking for corrosion and security of attachment bolts.
Ensure valve positioning is correct.
Check bend and flange assembly is free of debris.
Operate paddle flap manually and ensure free moving, apply grease if necessary. Check any counterbalance weight is complete, secure and unhindered in its movement
Check mesh over vents is complete, secure and free from debris
Check that any external guarding is complete and secure
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Mechanical Non-Return Valve annual - S_PXN00_12M_01A

PPM Schedule Ref: S_PXN00_12M_01A - Mechanical Non-Return Valve annual

Work Schedule -

If you find any item is not in an acceptable condition please provide full details on report sheet. The range of operating tests is limited to the permitted operation of the equipment, any restrictions are to be noted. Pump must be isolated electrically before commencing checks
Check outer casing for damage, blistering of surface or corrosion.
Check flanges and bolted connections for leakage, damage or corrosion.
Check valve shaft for leakage, damage or corrosion. Check bonnet seals for leakage.
Check valve lever and/or weight for completeness and security to shaft. Check security of any lever.
cage or protection
Grease valve if required.
Note valve position and if operational conditions permit, start and stop pumps to test the operation of the valve. Check valve seating position and note any leakage past valve in fully closed position
Replace all levers, cages, fittings and secure.
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Pedestrian or Vehicular Gate annual maintenance - S_GW&00_12M_01A

PPM Schedule Ref: S_GW&00_12M_01A- Pedestrian or Vehicular Gate annual maintenance

Work Schedule

Sweep clear of all debris on gate sill, plates, rails and hinges
Inspect sill, plates, rails etc checking for completeness, condition of protective coating (paint), corrosion, wear, distortion, cracking, and security. Report defects.
Inspect gate(s) checking for security, completeness, condition of protective coating (paint), corrosion distortion and cracking and security. Report defects.
Inspect attachments to the flood wall (including guide roller if fitted) checking for completeness, condition of protective coating, corrosion, distortion, cracking and security. Report defects.
Sliding gates
inspect rails and wheels checking for completeness, bearing wear, damage, blockages, alignment and security. Lubricate wheels as necessary
inspect gate buffer blocks (if fitted) checking for completeness, distortion and security.
inspect gate location tapers and/or rubbing strips checking for completeness, distortion and security.
inspect integral winches (where fitted) for completeness, wear, corrosion, security and distortion.
inspect gate pulling points, shackles and ropes checking for completeness, wear, corrosion, security and distortion
check securing mechanisms
6. Hinged gates
inspect hinges checking for smooth operation, wear, damage and alignment. Lubricate as necessary
inspect hinge alignment mechanism (if fitted) checking for completeness, condition of protective coating (paint), distortion, cracking and security.
if gate is fitted with hinge lifting mechanisms to assist closure check for completeness, wear,
damage and functionality.
check securing and dogging mechanisms, lubricate as necessary
Inspect seals, seal covers and operating mechanisms (if fitted) checking for completeness, wear, damage and alignment. Lubricate as necessary and report defects.
Close gate in accordance with operating procedures and check for smooth operation, support / guide
Wheel functions correctly and seals fit. Check hazard warning markings, signs and hazard reflectors where fitted Report defects.
Check integrity of collision bollards and other defences , report defects
If necessary adjust hinge alignment mechanism (if fitted) to align gate to ensure correct operation.
If necessary adjust seals.
Inspect gate locking mechanism checking for completeness, wear and damage. Report defects.
Grease all greasing points and exposed threads.
Open gate in line with operating procedures and lock in position.

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Gate stoplogs and lasherboards annual maintenance - S GL&00 12M 01A

PPM Schedule Ref: S GL&00 12M 01A - Gate stoplogs and lasherboards annual maintenance

Work Schedule

Stop logs:- metal
1. Inspect stop log checking for damage, distortion corrosion and completeness. Report and rectify as necessary
2. Inspect guides checking for security, smooth rotation, corrosion. Lubricate bearings (if fitted). Report and rectify as necessary
3. Inspect all rubber seals, (if fitted) checking for rips, tears, distortion and for firm attachment. Rectify as necessary
4. Inspect all wooden bearers (if fitted) checking for distortion, rot, completeness, correct positioning and for firm attachment. Rectify as necessary
5. Inspect lifting points checking for excessive wear. Distortion and damage to welds.
6. Inspect guide cones (if fitted). Checking for completeness, damaged and attachment to stop log.
7. Check protective coating. Repair minor damage as necessary. Report severe damage.
8. Check storage rack (if used) for damage, corrosion security and completeness. Rectify as necessary
Stop logs:- wooden
1. Inspect stop log checking for damage, rot, distortion, warping
2. Inspect guides (if fitted), checking for security, smooth rotation, corrosion. Lubricate bearings (if fitted). Report and rectify as necessary
3. Inspect lifting points checking for secure attachment, corrosion and completeness
4. Inspect all rubber seals, (if fitted) checking for rips, tears, distortion and for firm attachment. Rectify as necessary
5. Check general dimensions to ensure no unauthorized modifications have been made
6. Apply wood preservation material as necessary. Allow to fully penetrate and dry before using stop log in water course
7. Check storage rack (if used) for damage, corrosion, security, and completeness. Rectify as necessary
Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Navigation booms,Wire Ropes & Chains annual maintenance - S_QNB00_12M_01

PPM Schedule Ref: S_QNB00_12M_01 - Navigation booms,Wire Ropes & Chains annual maintenance -

Work Schedule -

Access boom by agreed method
Clear boom of any build up of debris and marine life
Inspect anchor posts; checking for
- Corrosion
- Excessive wear
- Completeness and security of attachment bolts.
Check wire ropes (if fitted) for
- Corrosion
- Broken strands
- Integrity of end fittings
Check chains (if fitted) for
- Corrosion
- Excessive wear
- Areas of weakness and necking
Check floats for
Impact damage
Attachment points are complete and secure
Tears and holes
Sharp edges
Buoyancy
Inspect grab ropes for
Security
Completeness
Wear and material breakdown
Leakage

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Drive Chains and Sprockets - S_RDC00_12M_01

PPM Schedule Ref: S_RDC00_12M_01A - Drive Chains and Sprockets Annual Maintenance

Work Schedule

1. Inspect structure, checking for corrosion and security of attachment bolts.
2. Check chains for damage, elongation of links, and any signs of stretching.
3. Check chain guides.
4. Lubricate chains.
5. Check sprockets for damage, missing teeth, and corrosion.
6. Check sprockets fixing to driveshaft, keyway, and securing bolts for signs of damage and wear.
7. Lubricate sprockets.
8. Check chain securing links, lugs, and points for damage, elongation, and any signs of stretching.
9. If grease nipples are located remote to equipment. Check grease nipples, associated piping and couplings for damage, fractures and leakage. Check for delivery of lubricant at equipment
10. Check that all associated guards are in place and undamaged.
11. Test operate the gate.
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done

Ropes and Pulleys S_LF&00_12M_02A

PPM Schedule Ref: Ropes & pullies Annual maintenance

Visual Checks

Support Structure
Covers and Guards
Lifting equipment
Wire ropes and pullies
Lifting Chains
Gears
Sprockets
Markings
Lubricate
Tightness of Fasteners

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Lifting Ropes and Drums

PPM Schedule Ref: Wire Rope Annual Maintenance

Visual Checks

Visual Inspection
Operation of limit switches
Winding gear
Lifting equipment
Wire ropes and pullies
Lifting Chains
Racks and screws
Guarding
Gears
Sprockets
Markings
Lubricate
Latching and locking
Tightness of Fasteners

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Winches Mechanical - S_LF&00_12M-01A

PPM Schedule Ref: Winches Annual maintenance

Visual Checks

Visually check and record general condition of the winch.
Winch frame inspect the following for signs of damage, wear and corrosion:
- fixing brackets
- anchor points
- fasteners
- tighten any loose fasteners found
- replace any missing fasteners
Covers and guards visually inspect for:
- indications of impact damage
- areas of rubbing on moving parts
- completeness
- security
- if interlocks are fitted check these work
Gears:
- remove all hardened grease from the gears
- inspect gears checking for cracks broken teeth, looseness and misalignment
- lubricate gears
inspect bearings / bushes for wear, cracks, corrosion.
inspect brackets for cracks, corrosion and damage.
ensure any oil and grease lubrication points are unblocked.
lubricate bearings /bushes
Winch drum visually inspect -
lubricate where necessary
inspect bearings / bushes for wear, cracks, corrosion.
inspect brackets for cracks, corrosion and damage.
ensure any oil and grease lubrication points are unblocked.
lubricate bearings /bushes
Operating handle(s) -
inspect handle, checking for cracks, excessive wear, and completeness.
inspect shaft drive - ensure full engagement of handle to all drives shafts (if more than one option)
operate the winch to evenly distribute the new grease on the gears.
Pawl mechanism (if fitted) -
inspect pawl for completeness, damage, broken teeth, corrosion and freedom of movement.
inspect ratchet for completeness, damage, broken teeth, corrosion and freedom of movement.
check operation of pawl and ratchet, ensure full engagement when under load.
Brake (if fitted) -
brush clean any rust from the brake.
adjust brake band to suit.
turn winch to check for adequate friction.
Attachment -
inspect rope/chain attachment for damage, looseness and corrosion.
inspect shackles for completeness, distortion and corrosion.
Wire ropes (if fitted) visually -
inspect rope, checking for surface corrosion, fraying, broken strands, separation of strands and distortion.
check that rope is correctly attached to the drum.
check that the lay of the rope is evenly located on the drum
lubricate chain as necessary.
Chains (if fitted) visually -
inspect chain, checking for fraying wear, elongation, necking distortion and security of fixings.
check that the chain is correctly attached to the drum.
check that chain is evenly located on the drum.
lubricate chain as necessary.
Fairlead (if fitted) -
inspect for completeness and damage.
ensure guide wheel moves and rotates freely.
lubricate as necessary.
Check the wire lifting rope is stamped with a SWL and LOLER ID number. Report immediately to the Regional MEICA Engineer if either is missing.
Manually operate winch system to ensure free and easy movement.
Inspect and record condition of any access walkways, supports, fixing brackets, fastenings and handrails associated with the winch system. Tighten any loose fasteners.
Check the condition of all warning and safety signs associated with the equipment.

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Lifting appliances davit annual maintenance - S_LD&00_12M_01

PPM Schedule Ref: Lifting appliances davit annual maintenance - S_LD&00_12M_01

Work Schedule

1. Visually check and record general condition of the davit.
2. Support structure. Inspect the following for signs of damage, wear and corrosion
- anchor points
- fasteners
- tighten loose fasteners
3. Davit sockets the site may have more than one socket for each davit
- inspect and clean debris from all davit sockets
- where davit sockets have covers ensure they are intact and free to move lubricate as necessary
- clear davit socket drain holes
- proof load test davit sockets
- check the davit socket is stamped with a SWL and a LOLER ID number
4. Davit assemblies - disassemble all davit sections and visually inspect for
indications of impact damage
- cracks defective welds.
- areas of excessive rubbing on moving parts.
- completeness
- corrosion
 check that all removable parts and safety fittings are fitted, undamaged and complete.
Reassemble
 lubricate sections and fittings as necessary
 ensure correct fit into all sockets
 manually move davit through the full arc of travel to ensure free and easy movement
5. Lifting equipment (manual operation)
inspect the condition of the following for damage, wear, distortion and corrosion
 davit
 overhead trolley (including wheels and gears)
 inspect hoist operating chain for wear, elongation, necking and distortion.
 operate and check for smooth operation and correct alignment of chain to gear drive wheel.
If defective, report immediately to the Regional MEICA Engineer
6. Lifting accessories
 inspect for condition and completeness
 check for damage and corrosion.
If defective report immediately to the Regional MEICA Engineer.
7. Markings
check the davit arm is marked with a SWL and a LOLER ID number
 check any attached lifting accessories are stamped with a SWL and a LOLER ID number.
If any of the above is missing then report immediately to the Regional MEICA Engineer
8. Walkways
 inspect the conditions of any access, supports, fixing brackets, anchor points, fasteners and handrails associated with the davit arm/jib.
9. Report on the condition of the paint /protection system for the structure
10. Check the condition of all warning and safety signs associated with the equipment

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Hydraulic Systems - S_Y&&00_12M_01

PPM Schedule Ref: Hydraulic Actuator - all types annual maintenance

Visual Checks

Inspect any guards and ensure they are correctly fitted and secure
Where systems contain accumulators – check that PSSR inspection labels are in date.
Check the operation of manually operable system valves
Check the operation of automatic and control valves
Inspect hydraulic pressure relief valves
Operate equipment to check for vibration and noise
Inspect extending ram gaiters
Operate manual/alternative drives
Replace filters
Operation of pressure gauges
Oil sample / Oil level
Grease points clear
Replace/top up grease units
Oil Level
Moisture ingress
Drain any water from the oil reservoir

Observations

Observations Report
Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Basic Steel Structure Maintenance - S_BS&00_12M_01A

PPM Schedule Ref: S_BS&00_12M_01A - Basic Steel Structure Maintenance

Work Schedule

WORK SCHEDULE
1. Access of steel structure by agreed method
2. Clear structure of any build up of debris.
3. Inspect metal fixing components; checking for
Corrosion,
Excessive wear,
Completeness and security of attachment bolts.
If required, coat metal objects with a suitable protective barrier.
4. Inspect anchor posts; checking for
Corrosion
Excessive wear.
Completeness and security of attachment bolts.
For all of the structures; check for
- Corrosion
- Excessive wear
- Completeness and security of attachment bolts
For Piled structures; check
- Pile Brackets should be checked for the connections to the structure. Any walkway hinge brackets should be checked & greased with a suitable product.
- Check any bolts holding any cleats to make sure they are tight. If there are any power/water connections make sure that the cables & pipes are still secured in the saddles under the gangway and make sure that there are no loose connections to taps & power points
For Strut structures; check
- Check that the Strut & Walkway hinge connections are greased with a suitable product and that there are no loose bolts or pins. Also ensure that cables are tight by adjusting them at the turnbuckles. Turnbuckles should be coated with a suitable lubricant.
Handrailing
Undertake a visual inspection on the handrailing; checking that the railing is secure, undamaged and no parts are missing. Tighten any loose rails and replace any missing rails you notice.
- Check the anchor points for security, check mounting bolts. Tighten any loose mounting bolts noted.
Steel Walkways
Undertake a visual inspection of the walkway to ensure that no plates are missing / damaged. Replace any damaged / missing plates. Check the overall security of the walkway identifying any loose plates. If plates are loose then check the tie downs are tight and not missing. If necessary tighten and / or replace tie downs.
- Check the security of any kickboards present and undertake remedial action if necessary.
- If the walkways are bolted to a subface, check bolts/ nuts for corrosion and tightness. Replace any missing / corroded bolts and tighten bolts / nuts if necessary.
- Undertake visual inspection on all vertical uprights used to support the walkways, check any securing bolts for tightness and completeness. Tighten loose bolts and replace any missing bolts.
- Check for missing or damaged grout and packing between the frame and structure. Make good any faults.
Vertical Ladders
Undertake a visual inspection of the ladder to ensure it is complete, no rungs are broken and that it is securely attached to the subface. Also check for any corrosion that may be visible on the ladder.
- Check the security of the mounting brackets and check the tightness of all mounting bolts / nuts. If necessary tighten.
Steel Stairs
Visually inspect the stairs looking for damage and security. Repair any damage you notice and tighten all joints you notice.
Check any attached handrailing for security and undertake remedial action if railing is not secure.
Visually inspect the weedscreen to ensure it is mechanically secure, complete and the bars are evenly spaced and straight.
Check cables (if fitted) for
corrosion,
wear,
broken strands,
deformation,
heat influence,
elongation,
necking,
distortion,
and integrity of end fittings.
Check chains (if fitted)
for corrosion,
excessive wear,
areas of weakness, and necking.

Observations

Cause
- MAINTENANCE
- NOT FOUND
- BEARING
- BLOCKAGE
- CABLE DAMAGE
- COMPONENT
- CONTROL
- CORROSION
- DEBRIS
- IMPELLOR
- LEAK
- LOW FLUID
- LUBRICATION
- MISUSE
- OVERTEMP
- RELAY FAILED
- UTILITY
- VANDALISM
- WATER
- WORN
Effect
- PLANNED TASK
- DAMAGE
- FAILED START
- HYDRAULIC
- INSTRUMENT
- POWER
- SEIZED
- TRIPPED
- UNKNOWN
- VIBRATION
Likelihood of Failure
Add Time to Repair
Status
- Completed
- Further
- New Work
- Skipped
- Closed
- Hold
Outcome of PPM inspection
Asset Condition and Comments
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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Operational Functional Testing

Test and prove winches, penstocks, flaps and pumps on completion of maintenance.
Site left proved and working
Auto operation available - system healthy
Site has recently been under water

Building and Grounds

Heating functioning, building dry
Compound secure, cabinets locked
All safety notices clearly displayed
Building and assets clean & tidy
Filters cleaned and no vermin

New assets identified

Any new assets identified?
Enter asset information
Description
Asset Condition
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
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PPM Asset Type

Sign and send

Overall Site Condition
- 0 - Not inspected
- 1 - Site Unsafe
- 2 - Further Work Required
- 3 - Not-Standard
- 4 - Ok, Add. Work done
- 5 - Ok, No Add. Work done
Site Photos
Asbestos
I have inspected the above assets to the conditions specified in the referenced PPM schedules, and this report accurately reflects the condition of the site.

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Site Details

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Asset PPM Report

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Observations

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Observations

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Observations

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Work Schedule

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Work Schedule

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Work Schedule

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Site safety and operational inspection - S_X&&_6G_02

Work Schedule