Maintenance Program For Equipments

KHARAFI NATIONAL MONTHLY MAINTENANCE REPORT
Client Ministry of Public Works (MPW) Report No.

Project MPW-O&M of Sewage Pumping & Lifting Station-2 Area Year
Contractor Kharafi National KSC (Closed) Contract No.
Equipment MAIN PUMP 450 750 KW Location
Tag No.
Monthly Work Order No.
Maintenance Period & Status
Activity Description
Jan. Feb. Mar. Apr. May. Jun. Jul. Aug.
Grease all bearings.
Check for any blockages in vent and drain lines.
Check pump & motor alignment.
Check all fasteners and tightness of mounting and integrity of supports.
Check pressure gauge and other ancillary vent/drain connections for leaks and blocks and clear as necessary
Electrical
Visually inspect the motor for physical condition.
Open & check the motor supply terminal box for heat up & tighten.
Visual inspection for cooling fan and coating ducts.
Check the motor for over heating & any abnormal round
1653/ TWI 756 Att.30A Rev.2 24 Nov. 2012 Page 1 of 793

Performed by: Signature
Checked by: Signature
Date:
Legend OK
N/A Not Applicable

SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.


Equipment MAIN PUMP 200 450 kW Location
Tag No.
Electrical
1653/ TWI 756 Att. 30B Rev.2 24 Nov. 2012 Page 5 of 793
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment MAIN PUMP 100 200 kW Location
Tag No.
Electrical
1653/ TWI 756 Att. 30C Rev.2 24 Nov. 2012 Page 9 of 793
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment GREASE PUMP Location
Tag No.
Check for any contamination of grease by moisture
Check for the amount of grease discharge and adjust feed accordingly
Check for any undue wear and tear of seals and gaskets and replace as necessary
Electrical
1653/ TWI 756 Att. 30D Rev.2 24 Nov. 2012 Page 13 of 793
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment GRIT PUMP Location
Tag No.
Check pressure gauge and other ancillary vent/drain connections for leaks and blocks and clear as necessary.
Electrical
1653/ TWI 756 Att. 30E Rev.2 24 Nov. 2012 Page 17 of 793
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment BRACKISH/DEWATERING PUMP Location
Tag No.
Electrical
1653/ TWI 756 Att. 30F Rev.2 24 Nov. 2012 Page 21 of 793
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment COOLING PUMPFOR D/G Location
Tag No.
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30G Rev.2 24 Nov. 2012 Page 25 of 793
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
1653/ TWI 756 Att. 30G Rev.2 24 Nov. 2012 Page 26 of 793
Equipment ANTI-HAMMERING VALVE Location
Tag No.
Check for any external leaks
Check the function of ball and air-relief while the pressure main is filled or drained
Visual inspection of smoothness of operation.
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30H Rev.2 24 Nov. 2012 Page 27 of 793
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
1653/ TWI 756 Att. 30H Rev.2 24 Nov. 2012 Page 28 of 793
Equipment AIR-RELEASE VALVE Location
Tag No.
Check for any external leaks
Check the function of ball and air-relief while the pressure main is filled or drained.
Visual inspection of smoothness of operation.
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30I Rev.2 24 Nov. 2012 Page 29 of 793
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
1653/ TWI 756 Att. 30I Rev.2 24 Nov. 2012 Page 30 of 793
Equipment DEWATERING PUMP Location
Tag No.
Check for any joint leaks
Check the opening and closing of NRV and no air locking in raiser pipe
Electrical
Check the ampere for normal motor operation
Check terminal connections at the panel and retighten
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30J Rev.2 24 Nov. 2012 Page 31 of 793
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
1653/ TWI 756 Att. 30J Rev.2 24 Nov. 2012 Page 32 of 793
Equipment PENSTOCK 800 X 800 - 1000 X 1000 Location
Tag No.
Check penstock stem, clean transparent protection tube.
Operate penstock through by opening/closing
Clean by hosing down
Grease all unpainted machine faces, seal faces, wedge face, door guides, stem and nut
Inspect penstock and seal for damage and repair as required
Check and adjust tightness of fasteners
Check for leakage between frame and wall
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30K Rev.2 24 Nov. 2012 Page 33 of 793
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
1653/ TWI 756 Att. 30K Rev.2 24 Nov. 2012 Page 34 of 793
Equipment PENSTOCK1000 X 1000 - 2000 X 2000 Location
Tag No.
Date:
Legend OK
1653/ TWI 756 Att. 30L Rev.2 24 Nov. 2012 Page 35 of 793
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment SLUICE GATES Location
Tag No.
Operate gates through by opening/closing
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30M Rev.2 24 Nov. 2012 Page 39 of 793
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
1653/ TWI 756 Att. 30M Rev.2 24 Nov. 2012 Page 40 of 793
Contractor Kharafi National KSC (Closed) Contract No. SE/S/135
Equipment AUTOMATIC BAR SCREEN Location
Tag No.
Jan. Feb. Mar. Apr. May. Jun. Jul. Aug. Sep.
Clean chute, inspect chute and gearbox for any sign of oil leakage
Check chain tension, adjust if necessary
Check conveyor belt condition and adjust tension if necessary.
Check gearbox oil levels
Electrical
Check the motor for over heating & any abnormal round.
1653/ TWI 756 Att. 30N Rev.2 24 Nov. 2012 Page 41 of 793
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment CLASSIFIER -HYDRO DEGRITTER Location
Tag No.
Jan. Feb. Mar. Apr. May. Jun. Jul. Aug. Sep. Oct.
Check all fasteners for tightness
Greasing of drive motor bearing
Electrical
Date:
Legend OK
1653/ TWI 756 Att. 30O Rev.2 24 Nov. 2012 Page 45 of 793
N/A Not Applicable
135
Remarks
Nov. Dec.
Equipment AIR COMPRESSOR Location
Tag No.
Check all pipe connections for any leakage
Check all foundation mountings and tighten
Check compressor oil level and top-up if necessary
Release moisture from condensate trap
Electrical
Open & check the motor supply terminal box for heat up & retighten.
Visual inspection for cooling fan and airways.
Check the motor for over heating & any abnormal sound
1653/ TWI 756 Att. 30P Rev.2 24 Nov. 2012 Page 49 of 793
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment HEAVY DUTY MUNCHER Location
Tag No.
Re-grease all bearings
Electrical
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30Q Rev.2 24 Nov. 2012 Page 53 of 793
135
Remarks
Nov. Dec.
1653/ TWI 756 Att. 30Q Rev.2 24 Nov. 2012 Page 54 of 793
Equipment SCREW CONVEYOR Location
Tag No.
Check chute and gearbox seals for any sign of leakage
Inspect screw helix and repair if necessary
Check gearbox oil level
Electrical
1653/ TWI 756 Att. 30R Rev.2 24 Nov. 2012 Page 55 of 793
Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
Equipment VENTILLATOR BLOWER Location
Tag No.
Check equipment for excessive vibration, temperature and noise
Clean Air filter.
Check all connections for air leakage
Check and re-grease bearings.
Check V Belt tension and adjust as necessary
Electrical
1653/ TWI 756 Att. 30S Rev.2 24 Nov. 2012 Page 59 of 793
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment OVER HEAD CRANE-10 TON Location
Tag No.
Check drive gearbox oil level refill if necessary.
Check hosting gear break readjust if necessary.
Grease wire rope, rope guide ring and sliding surface of rope guide ring stop.
Check drive units screw joints, welding seams, buffers of carriage and end stop of runways.
Check power supply including flexible liners
Electrical
1653/ TWI 756 Att. 30T Rev.2 24 Nov. 2012 Page 63 of 793
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment OVER HEAD CRANE-5 TON Location
Tag No.
Electrical
1653/ TWI 756 Att. 30U Rev.2 24 Nov. 2012 Page 67 of 793
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment A/C PACKAGE UNIT Location
Tag No.
Check grill temperature and air flow.
Check the gas pressure using pressure gauge.
Fill the gas if required.
Check the system for leak.
Repair the gas leak if existing.
Clean the filters thoroughly (using prescribed cleaning chemical).
Check all cutouts for proper function.
Check the condition of the blower and blower to motor V belts.
Check the cooling fan condition.
Check the control panel and main isolator, clean both.
Replace blown fuses or damaged/deteriorated fuses.
Check the tightness at all component terminals.
Check the condition of Thermostat.
Check the condition of heater repair if necessary.

1653/ TWI 756 Att. 30V Rev.2 24 Nov. 2012 Page 71 of 793
Check the compressor oil level and top up if necessary.
Check cooling fans, cooling fan motors, blowers, blower motors, pulleys etc., for any damage.
Repair or replace pulley-fixing set.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment A/C SPLIT UNIT Location
Tag No.
Check grills temperature and air flow.
Check gas pressure and fill if necessary.
Check the system for gas leak and repair if required.
Clean the filters.
Repair all system gas leak.
Check the auto operation.
Check and clean all the wiring and tighten all junctions.
Check terminals at compressor.
Repair the blower of indoor unit if required.
Repair the cooling fan and motor of outdoor unit if required.
Clean the whole system thoroughly.
Start and check the A/C for auto operation.
Check the condensate drain line repairs if necessary.
1653/ TWI 756 Att. 30W Rev.2 24 Nov. 2012 Page 75 of 793
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment A/C WINDOW UNIT Location
Tag No.
Clean the filters.
Check the condensate drain line repairs if necessary.
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30X Rev.2 24 Nov. 2012 Page 79 of 793
135
Remarks
Nov. Dec.
1653/ TWI 756 Att. 30X Rev.2 24 Nov. 2012 Page 80 of 793
Equipment DIESEL GENERATOR 1000 - 3000 kVA Location
Tag No.
Remove sludge from fuel filter, clean, fill-up and vent.
Clean sludge from edge type filter for circuit lubrication.
Check lubricating oil system and rectify any leaks
Check oil filters, centrifuges of lubricating system
Electrical
Clean the alternator & control panel board.
Check the battery voltage.
Tightening all the junction.
During the test run check the generated voltage.
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30Y Rev.2 24 Nov. 2012 Page 81 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
1653/ TWI 756 Att. 30Y Rev.2 24 Nov. 2012 Page 82 of 793
Equipment DIESEL GENERATOR 500 - 1000 kVA Location
Tag No.
Electrical
Clean the alternator & control panel board.
Check the battery voltage.
Tightening all the junction.
During the test run check the generated voltage.
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30Z Rev.2 24 Nov. 2012 Page 83 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
1653/ TWI 756 Att. 30Z Rev.2 24 Nov. 2012 Page 84 of 793
Equipment VACUUM PUMP Location
Tag No.
Electrical
Date:
1653/ TWI 756 Att. 30A1 Rev.2 24 Nov. 2012 Page 85 of 793
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
Equipment SPURGE PUMP Location
Tag No.
Electrical
Date:
1653/ TWI 756 Att. 30B1 Rev.2 24 Nov. 2012 Page 89 of 793
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment GRIT SCRAPPER Location
Tag No.
Check all equipment for excessive vibration & noise
Electrical
Check the motor for over heating & any abnormal Sound
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30C1 Rev.2 24 Nov. 2012 Page 93 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment BELT CONVEYOR Location
Tag No.
Inspect belt and repair if necessary
Electrical
Check the motor for over heating & any abnormal Sound
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30D1 Rev.2 24 Nov. 2012 Page 95 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment MONORAIL Location
Tag No.
Electrical
Date:
1653/ TWI 756 Att. 30E1 Rev.2 24 Nov. 2012 Page 97 of 793
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment PUMP ROOM SHUTTER Location
Tag No.
Remove dust and grease from rollers and check movements.
Tighten the electrical connections in starter unit and motor terminal box.
Check the limit switch functions.
Lubricate and apply grease to moving rollers
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30F1 Rev.2 24 Nov. 2012 Page 101 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment MOTORIZED SLIDING GATE Location
Tag No.
Operate gates through by opening/closing
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30G1 Rev.2 24 Nov. 2012 Page 103 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment PINCH VALVE Location
Tag No.
Check valve for any sign of leakage.
Check closing and opening of valve for normal operation.
Check for any internal component wear and tightness of all fasteners.
Seal and repair where necessary
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30H1 Rev.2 24 Nov. 2012 Page 105 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment PRESSURE GUAGES Location
Tag No.
Jan. Feb. Mar. Apr. May. Jun. Jul.
Check the Pressure Guage Readings are normal
No Leaks from vent/stop cocks
Clear the vent line if chocked
Remove the guage and check for any blockages and clear as necessary
Check the Dial Glass for visibility,smoking and clean as necessary
Refill with Glycol/Glycerin as needed
Re-fix, check for any leaks and rectify
Calibrate and decommission
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30I1 Rev.2 24 Nov. 2012 Page 107 of 793
o. SE/S/135
Period & Status

Remarks
Aug. Sep. Oct. Nov. Dec.
Equipment CENTRIFUGAL PUMP DRY WELL (Up to 50KW) Location
Tag No.
Electrical
Date:
1653/ TWI 756 Att. 30J1 Rev.2 24 Nov. 2012 Page 109 of 793
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Tag No.
Electrical
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30K1 Rev.2 24 Nov. 2012 Page 113 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment DEWATERING PUMP Location
Tag No.
Check the opening and closing of NRV and no air locking in riser pipe
Electrical
Check ampere for normal motor operation
Yearly
Check the cable for any cut or abrasion
Check the casing for any cracks or pores
Check the motor winding resistance
Check the motor insulation resistance ( with cable ) with respect to earth.
Date:
1653/ TWI 756 Att. 30L1 Rev.2 24 Nov. 2012 Page 115 of 793
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment MAIN SUBMERSIBLE PUMP Location
Tag No.
Check the opening and closing of NRV and no air locking in riser pipe
Electrical
Check ampere for normal motor operation
Yearly
Check the cable for any cut or abrasion
Check the casing for any cracks or pores
Check the motor winding resistance
Check the motor insulation resistance ( with cable ) with respect to earth.
Date:
1653/ TWI 756 Att. 30M1 Rev.2 24 Nov. 2012 Page 119 of 793
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
Equipment SUCTION VALVE(upto-400mm dia) Location
Tag No.
Electrical
Switch off the Power supply.
Clean the Actuators.
Check the terminations.
Switch On the Power supply.
Check the local operations.
Check the remote operations
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30N1 Rev.2 24 Nov. 2012 Page 123 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment PENSTOCK MANUAL Location
Tag No.
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30O1 Rev.2 24 Nov. 2012 Page 125 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment VENTILATOR BL;OWER Location
Tag No.
Check equipment for excessive vibration , temperature and noise.
Clean Air filter.
Electrical
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30P1 Rev.2 24 Nov. 2012 Page 127 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment SUCTION PIPING (upto 250 mm Dia ) Location
Tag No.
Visual inspection of pipeline and joints & flexible connections.
Check for Pressure Gauge and other tapping for leaks and repair as necessary
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30Q1 Rev.2 24 Nov. 2012 Page 129 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment DISCHARGE PIPING(UPTP 250MM DIA) Location
Tag No.
Visual inspection of pipeline and joints & flexible connections.
Check for Pressure Gauge and other tapping for leaks and repair as necessary
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30R1 Rev.2 24 Nov. 2012 Page 131 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment PRESSURE GUAGES Location
Tag No.
Check the Pressure Gauge Readings are normal
No Leaks from vent/stop cocks
Clear the vent line if chocked
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30S1 Rev.2 24 Nov. 2012 Page 133 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment SCREW CONVEYOR(upto 25 KW) Location
Tag No.
Electrical
Date:
Legend OK
1653/ TWI 756 Att. 30T1 Rev.2 24 Nov. 2012 Page 135 of 793
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment SCREW CONVEYOR (>25 KW ) Location
Tag No.
Electrical
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30U1 Rev.2 24 Nov. 2012 Page 139 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment GEAR BOXES Location
Tag No.

Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30V1 Rev.2 24 Nov. 2012 Page 141 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Tag No.
Electrical
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30A Rev.2 24 Nov. 2012 Page 143 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
1653/ TWI 756 Att. 30A Rev.2 24 Nov. 2012 Page 144 of 793
Equipment PENSTOCK MANUAL Location
Tag No.
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30X1 Rev.2 24 Nov. 2012 Page 145 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment VENTILATION BLOWER Location
Tag No.
Check equipment for excessive vibration , temperature and noise.
Clean Air filter.
Electrical
Date:
Legend OK
1653/ TWI 756 Att. 30Y1 Rev.2 24 Nov. 2012 Page 147 of 793
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment A/C WINDOW UNIT Location
Tag No.
Clean the filters.
Check the condensate drain line repairs if necessary
Date:
Legend OK
N/A Not Applicable
1653/ TWI 756 Att. 30Z1 Rev.2 24 Nov. 2012 Page 151 of 793
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment DIESEL GENERATOR SETS(uptp 75KVA) Location
Tag No.
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment DIESEL GENERATOR(75 to125 KVA ) Location
Tag No.
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment CUBICLE Location
Tag No.
Maintenance Period & Stat
Check the Cubicle and clean the same by using vacuum cleaner.
Tighten the screws for fixing the covers, sheets, barriers, wiring .. etc.
Check the cubicle door for proper closing and locking.

Check the gasket and sealing for all the cubicle doors and shutters and change or clean the air filters where
necessary.
Check the cubicle lighting and space heaters.
Check the cubicle for proper dust and vermin proofing.

Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment BUSBAR Location
Tag No.
Jan. Feb. Mar. Apr. May. Jun. Jul. Aug. Sep. Oct. Nov.
Check the bus bars, tighten the connection and clean the bus bar and the supporting.
Clean the post isolators and the through bushings and check for any hairline cracks
Date:
Legend OK
N/A Not Applicable
Remarks
Dec.
Equipment SWITCH & DRIVE MECHANISM Location
Tag No.
Clean the disconnecting mechanism and clean the tightness of the connections.
Slightly lubricate the contact surfaces with contact grease and check the operation of the proper mating of the
contacts.
Check the closing and opening operation under no-voltage condition.
Check links, joints etc. and lubricate wherever necessary.
Check the interlock system including transfer on load interlocking system.
Check the isolator driving motor (if applicable) for proper and load current.
Check the isolator position indication mechanically and electrically, local, remote and supervisory as applicable.
(N.B : For isolators of single break type, care must be taken during operation, check as isolator tips in dead bus bar
compartment will alive if live bus bar isolator is closed, MPW Engineer shall be noted).
All maintenance works on the circuit breaker should be carried out only after discharging the drive mechanism
to avoid an unintentional closing of the breaker.
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment VACUUM CIRCUIT BREAKER Location
Tag No.
Vacuum circuit breakers require little maintenance. In fact only the part subject to normal wear and aging need
be serviced to ensure fully reliable operation.
Maintenance and inspection intervals should be adjusted to suit the particular operating condition of each
interruption. Under the normal condition the vacuum interrupters need not to be serviced frequently, the
maximum permissible contact wear is 3 mm.
Before starting any work the breaker should be isolated short circuited and earthed.
Disconnect the auxiliary supply and open and close the breaker by hand until both springs have been
discharged. Reference should be made to the safety regulation.
Check the circuit breaker for its general condition and for any abnormality.
Measure the contact resistance of the CB and analyze the values to confirm proper CB contact as
recommended by the manufacturer.
Check vacuum leaking current according to the manufacturer recommendation.

Tag No.
Date:
Tag No.
Replace the CB pole by new one (if necessary).
Lubricate the main points of the breaker using anti corrosive oil obtained through the manufacturer representative or approved
supplier. The main point to be lubricated bearing and sliding surfaces, joints and auxiliary switches and all the appropriate
Before putting the breaker into service clean the circuit breaker with lent free cloth.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Project MPW-O&M of Sewage Pumping & Lifting Station-2 Area Year 2010
Equipment DRIVE MECHANISM OF CIRCUIT BREAKER Location
Tag No.
Clean and lubricate the drive mechanism. Lubricating points should be as per the
manufacturer instruction manual, as over lubrication and lubrication on some
components of the trip mechanism can effect the normal operation of the circuit
breaker.
Check the charging, closing and opening operation of the drive mechanism
mechanically and electrically and indication positions local remote and test.
Check and clean auxiliary contacts of the C.B and check for proper functioning.
Check the drive mechanism charging motors for proper load current.
Check the function of the interlocks and the closing, opening and tripping the circuit
breaker.
Date:
Legend OK
N/A Not Applicable
Remarks
Dec.
Equipment SECONDARY PLUG &CONTROL WIRING OF BREAKERS Location

Tag No.
Clean of the contact of the secondary plugs.
Check the alignment and locking of the secondary plugs to socket.
Check for any defects with the wiring terminal connections
Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
Equipment CB TRUCK & CB COMPARTEMENT Location
Tag No.
Clean and lubricate the wheels of the truck, rails, mechanical interlocks and the rocking mechanism.
Checking for the smooth operation of the racking mechanism mechanically and electrically as
applicable.
Clean and check the circuit breaker for any cracks.
Examine point finish.
Check the racking IN / OUT motor for proper load current (if applicable).
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment CURRENT TRANSFORMER Location
Tag No.
Clean and check the insulation.
Check and tighten the primary and secondary connections.
Check current transformer magnetizing curve.

Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
Equipment VOLTAGE TRANSFORMER Location
Tag No.
Check and clean the insulation and tighten the connections.
Check primary contact, clean as slightly lubricate contacts.
Check secondary connection, plugs, secondary circuit MCB, etc., tighten secondary connection.
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment BUSBAR / CABLE EARTHING SWITCHES DRIVING MECHANISM Location

Tag No.
Clean the earthing switches and check the tightness of the connection.
Slightly lubricate the contact surface with contact grease and check the operation for proper mating of the
contacts.
Check the closing and opening operation under no voltage condition and special attention for the voltage
from the other end.
Check lings, joints etc. and lubricate wherever necessary.
Check the interlock system includes.
Check the earthing switch driving motor (if applicable) for proper load current.
Check the earthing switch position indication (as applicable) mechanically and electrically local and remote.
Earthing trucks (if applicable) to be covered for protection against dust.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment CABLE TERMINATION / COMPARTEMENT Location
Tag No.
Check for any damages to the sealing end and see for any leakage of compound or oil (if leakage is noticed it
should be reported to MPW Engineer)
Clean the bushing and tighten the connections.
Check for the efficient earthing of the cable box and cable sheath.
Checking for any corona discharge.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment POWER TRANSFORMER & AUTO TRANSFORMER GENERAL MAINTENANCE Location

Tag No.
Check for any oil leakage.
Clean the transformer thoroughly by using steam jet after necessary precautions to prevent water seepage to
protective instrument and wiring terminals.
After thorough cleaning if any major repair is required to stop the oil leakage, report the matter to the MPW
Engineer.
Check the point finish and carry out re-painting of transformer if required.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment POWER TRANSFORMER & AUTO TRANSFORMER HV & LV CABLE AND BOXES Location
Tag No.
Clean and check for any oil or compound leakage.
If oil and compound are found mixed, report to MPW Engineer for further action.
Check the compound level gauges for any defects.
Check silica gel breather if provided. Clean breather and replace the silica gel.
Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
Equipment POWER TRANSFORMER & AUTO TRANSFORMER MAIN TANK & CONSERVATOR TANK Location
Tag No.
Take oil samples from the main tank and conservator tank for laboratory testing.
Top up oil if required (only new tested or insulated oil should be used for topping up).
Date:
Legend OK
N/A Not Applicable
SE/S/135
us
Remarks
Oct. Nov. Dec.
POWER TRANSFORMER & AUTO TRANSFORMER DEHYDRATOR BREATHER

Equipment COMPARTEMENT Location
Tag No.
Check and tighten the pipe connection if required.
Change the silica gel of the breather and the oil in the dust trap.
Check the normal functioning of the breathers.
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment POWER TRANSFORMER & AUTO TRANSFORMER OIL & OIL LEVEL GAUGES Location
Tag No.
Replace the gauges if found defective.
Clean the gauges glasses if found hazy.
Oil samples are to be taken from all sampling points and to be tested by the contractor, the test
results shall be referred to the permissible values
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
POWER TRANSFORMER & AUTO TRANSFORMER WINDING TEMPERATURE

Equipment INSTRUMENT Location
Tag No.
Note down the maximum temperature readings and reset the same.
Check the setting of alarm and trip.
Test the operation of the instruments.
Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
Equipment POWER TRANSFORMER & AUTO TRANSFORMER WINDING Location

Tag No.
Measure and record the insulation resistance between H.V and L.V windings and between the H.V
windings and earth and between the L.V winding and earth using 2.5 kv or 5 kv Megger. Ambient
temperature should be recorded along with the measured valves of th
Insulation value of the control cable is to be measured and recorded in maintenance sheet
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment POWER TRANSFORMER & AUTO TRANSFORMER BUCHOLTZ & GAS RELAYS Location
Tag No.
Check the operation of the relays (operation of the float relay is to be checked by air pump or any
other facility).
Test the buchholz relays for alarm and trip mechanism, and tap changer gas relay for tripping
operation.
Check the insulation values of all control cables and values shall be recorded in the maintenance
sheets.
Check the stability of these relays against vibrations.
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment POWER TRANSFORMER & AUTO TRANSFORMER TAP CHANGER Location

Tag No.
Cleaning, checking tighting as necessary the operating mechanism, checking of wiring and
inspecting all contactor, micro switches, MCBs .. etc.
Inspection of motor shaft, level gears, position transmitter combination, coupling pins for proper
operation.
Oiling and greasing and tightening are to be done as required.
Checking of tap changer drive cubicle to ensure proper closing, checking of the operation of
tap changer drive for raising, lowering and over runs and limit lockout .. etc.
Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
Equipment MOTOR STARTER VACUUM CONTACTOR SWITCHGEAR Location

Tag No.
Prepare all proper tools and measuring equipment before starting the maintenance works.
Switch OFF the pump motor of the 3.3 kv vacuum contactor cubicle.
Switch OFF the control supply mcb/fuses in the switchgear cubicle.
Operate the bus bar isolating lever to OFF position for disengaging the cubicle from the 3.3 kv
bus bar.- Release the latch lever of the withdraw able cubicle unit.
Withdraw the 3.3 kv vacuum contactor truck (cubicle).
Inspect visually and thoroughly the cubicle for any abnormal condition.
Clean the cubicle with hand blower and hand brush.
Clean the H.T. bus bar with clean cloth.

1653/ TWI 756 Att. 30W2 Rev.2 24 Nov. 2012 Page 206 of 793

Tag No.
Date:

Tag No.
Clean the bus bar isolating contacts with contact cleaner and then with clean and apply also thin
film of petroleum jelly on the surfaces.
Clean the vacuum switch tube of the vacuum contactor with clean cloth.
Check the setting of the magnetic coil unit and its pole faces.
Check and tighten the magnetic coil terminations.
Check the bus bar isolating lever and its mechanism.
Lubricate the moving parts of the above firmly.
Clean the auxiliary switch contacts with contact cleaner and check the correct setting.
Check, clean and tighten the limit switch and its terminal wire connections.
Check and clean the operating mechanism.


Tag No.
Date:

Tag No.
Tighten the vacuum contactor incoming an outgoing terminal bolts and nuts.
Check the braided copper links and tighten its terminals.
Clean the control supply plug and socket with contact cleaner.
Check and tighten terminal wires of motors protection relays.
Clean and lubricate the rolling wheels of the truck unit.
Clean the inside panel compartment.
Check the bus bar closing shutters and its levers lubricate if necessary.
Check, clean and tighten control contactors and relays and their terminal wiring connection.
Check earth leakage relay and tighten its terminal wiring.


Tag No.
Date:
Check the insulation resistance values of each pole-to-Earth with Megger.
Check the emergency and (ON) button and their terminal wiring.
Check the bulb indicator and its holder termination.
Check the control compartment door lock.
Check the magnetic coil control circuit resistor and its terminal wiring.
When every thing satisfied, connect the testing extension cable unit between the cubicle and the
panel and test the cubicle by ON/OFF operation.
Check the opening and closing of the contracts of the vacuum contactor.

Tag No.
Date:

Tag No.
Disconnect and remove the testing extension unit. And insert the cubicle in the panel position.
Engage the latch lever. Operate the bus bar isolating lever to ON position.
Switch ON the control supply.
Switch ON the 3.3 kv pump motor and check the operation of the vacuum contactor and
investigate the proper values of all measuring parameters.
Date:
Legend OK
N/A Not Applicable

135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.

Tag No.
Switch OFF the pump motor of the 3.3 kv vacuum contactor cubicle.
Switch OFF the control supply mcb/fuses in the switchgear cubicle.
Operate the bus bar isolating lever to OFF position for disengaging the cubicle from the 3.3 kv
bus bar.
Release the latch lever of the withdraw able cubicle unit.
Withdraw the 3.3 kv vacuum contactor truck (cubicle).
Inspect visually and thoroughly the cubicle for any abnormal condition.
Clean the cubicle with hand blower and hand brush.


Tag No.
Date:

Tag No.
Clean the H.T. bus bar with clean cloth.
Clean the bus bar isolating contacts with contact cleaner and then with clean and apply also thin
film of petroleum jelly on the surfaces.
Clean the vacuum switch tube of the vacuum contactor with clean cloth.
Check the setting of the magnetic coil unit and its pole faces.
Check and tighten the magnetic coil terminations.
Check the bus bar isolating lever and its mechanism.
Lubricate the moving parts of the above firmly.
Clean the auxiliary switch contacts with contact cleaner and check the correct setting.
Check, clean and tighten the limit switch and its terminal wire connections.

Tag No.
Date:

Tag No.
Check and clean the operating mechanism.
Tighten the vacuum contactor incoming an outgoing terminal bolts and nuts.
Check the braided copper links and tighten its terminals.
Clean the control supply plug and socket with contact cleaner.
Check and tighten terminal wires of motors protection relays.
Clean and lubricate the rolling wheels of the truck unit.
Clean the inside panel compartment.
Check the bus bar closing shutters and its levers lubricate if necessary.
Check, clean and tighten control contactors and relays and their terminal wiring connection.
Check earth leakage relay and tighten its terminal wiring.

Tag No.
Date:

Tag No.
Check the insulation resistance values of each pole-to-Earth with Megger.
Check the emergency and (ON) button and their terminal wiring.
Check the bulb indicator and its holder termination.
Check the control compartment door lock.
Check the magnetic coil control circuit resistor and its terminal wiring.
When every thing satisfied, connect the testing extension cable unit between the cubicle and the
panel and test the cubicle by ON/OFF operation.
Check the opening and closing of the contracts of the vacuum contactor.
Disconnect and remove the testing extension unit. And insert the cubicle in the panel position.

Tag No.
Date:

Tag No.
Engage the latch lever. Operate the bus bar isolating lever to ON position.
Switch ON the control supply.
Switch ON the 3.3 kv pump motor and check the operation of the vacuum contactor and
investigate the proper values of all measuring parameters.
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
SE/S/135
tus
Remarks
Oct. Nov. Dec.
SE/S/135
tus
Remarks
Oct. Nov. Dec.
SE/S/135
tus
Remarks
Oct. Nov. Dec.
SE/S/135
tus
Remarks
Oct. Nov. Dec.
SE/S/135
tus
Remarks
Oct. Nov. Dec.
SE/S/135
tus
Remarks
Oct. Nov. Dec.
SE/S/135
tus
Remarks
Oct. Nov. Dec.
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment LV AIR CIRCUIT BREAKER Location
Tag No.
Prepare all proper tools and measuring equipment before starting the work.
Switch OFF the load connected to the air circuit breaker, and de-energize it.
Follow the manufacturer instructions to draw out the Master pact ACB.
Clean all part of Master pact ACB thoroughly by hand blower and soft brush.
Inspect all part of the ACB, visually and by hand checking.
Close the ACB to check the wear of the contacts.
Check the condition of the arc-chute, make sure that the arc chute body is not broken and
the separators are not corroded.
Check the protection unit, display and adjustment of each parameters, reprogramme it if
required.
Tag No.
Date:
Check the ammeter function of the protection unit for the parameters Ir, Tr, Im, I, In, th,
and follow the manufacturer procedures for readjusting them if required.
Store the correct parameter programmed and lock the settings by means of the sealing
plate.
Remove the front cover, check the condition of MX mobile core with the C.B closed.
Insert the ACB-unit in the panel firmly and check the following :
Open and close the breaker locally and remotely using the different auxiliaries
successively,
Test the order channels.
Test the operation of the control unit with the mini test-kit.
Check the control unit with the complete test-kit.
Tag No.
Check the geared motor power supply.

Date:
Tag No.
Test the protection of the network for overload, short circuit and earth faults.
Measure the current density flowing in each phase physically.
Remove the racking handle and put it in the storage.
Remove disabling and put the ACB into operation.

Date:
Legend OK
N/A Not Applicable
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Tag No.
Switch OFF the load connected to the air circuit breaker, and de-energize it.
Follow the manufacturer instructions to draw out the Master pact ACB.
Clean all part of Master pact ACB thoroughly by hand blower and soft brush.
Check the condition of the arc-chute, make sure that the arc chute body is not broken and the
separators are not corroded.
Check the protection unit, display and adjustment of each parameters, re -programmed it if
required.
Check the ammeter function of the protection unit for the parameters Ir, Tr, Im, I, In, th, and
follow the manufacturer procedures for readjusting them if required.
Tag No.
Date:
Store the correct parameter programmed and lock the settings by means of the sealing plate.
Remove the front cover, check the condition of MX mobile core with the C.B closed.
Insert the ACB-unit in the panel firmly and check the following
Open and close the breaker locally and remotely using the different auxiliaries successively,
Test the operation of the control unit with the mini test-ket.
Tag No.
Date:
Measure the current density flowing in each phase physically.
Remove disabling and put the ACB into operation

Tag No.
Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
Tag No.
Prepare all proper tools and measuring equipment before

starting the work.
Switch OFF the load connected to the air circuit breaker,
and de-energize it.
Follow the manufacturer instructions to draw out the Master
pact ACB.
Clean all part of Master pact ACB thoroughly by hand
blower and soft brush.
Check the condition of the arc-chute, make sure that the arc
chute body is not broken and the separators are not corroded.
Check the protection unit, display and adjustment of each

parameters, reprogrammed it if required.
Tag No.
Date:
Tag No.
Check the ammeter function of the protection unit for the

parameters Ir, Tr, Im, I, In, th, and follow the manufacturer
procedures for readjusting them if required.
Store the correct parameter programmed and lock the

settings by means of the sealing plate.
Remove the front cover, check the condition of MX mobile
core with the C.B closed.
Insert the ACB-unit in the panel firmly and check the
following :
Open and close the breaker locally and remotely using the
different auxiliaries successively,
Test the operation of the control unit with the mini test-ket.
Date:
Tag No.

Test the protection of the network for overload, short circuit
and earth faults.
Measure the current density flowing in each phase
physically.
Remove disabling and put the ACB into operation

Date:
Legend OK
N/A Not Applicable
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Equipment MCCB FOR LV INCOMING FEEDER Location
Tag No.
Jan. Feb. Mar. Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec.
Prepare all proper tools and measuring equipment before

starting the work.
Switch OFF the load connected to the MCCB.

Follow the manufacturers instructions to draw out the
MCCB.
Clean all parts of MCCB thoroughly by hand blower and

soft brush.
Inspect all parts of the MCCB, visually and by hand
checking.
Close the MCCB to check the wear of the contacts.

Check the condition of the arc-chute, make sure that the arc
chute body is not broken and the separators are not
corroded.
Tag No.
Date:
Tag No.
Check the tripping mechanism by pushing the trip test

button and ensure the breaker contacts are open .
Insert the MCCB unit and put back in operation.

Test the protection of the network overload and also
measure the current flow in each phase my meter.
Date:
Legend OK
N/A Not Applicable
Remarks
Remarks
Remarks
Equipment LV MCC WITHDRAWABLE STARTER UNIT Location
Tag No.
MCCs withdraw able starter unit of the main and Remote distribution
panels
Prepare all proper tools and measuring equipment before starting the
preventive maintenance works.
Switch OFF the load connected to the MCC and also switch OFF the
MCC unit and draw it out of the panel.
Inspect visually the MCC unit for any abnormal condition and carry out the
following works:
Clean switch fuse, fuse holder, fuse lever and terminations.
Clean the bus bar isolating contacts with contact cleaner and clean cloth.
Apply thin layer of petroleum jelly on the contact surfaces.
Remove the control supply plug from the socket (in tele-technique MCC
unit only) and clean the contact with contact cleaner and plug it back.
Tag No.
Date:
Tag No.
Check the contactor and tighten its termination.

Check the thermal overload relay and its current setting, tighten the
terminal wires.
Check fuses and fuse holders.
Check the control relays, timers and their terminations.
Check the earth leakage relays and its termination
Check the control supply mcb and its termination.
Check the selector switch, push-buttons and their terminations.

Check the ammeter, indicator lamps and lamp holder and their wiring
terminations.
Check the counter hour meter and its termination.

Tag No.
Date:
Tag No.
Check all internal wiring for any damage or overheating.
Check the terminal connector wiring and tighten it.
When everything satisfied, insert the MCC in the panel and switch ON.
Operate the MCC unit in all modes by charging the selector switch
position.
Check the operation of the indication light, ammeter and hour meter during
loading.
Put the MCC unit in the operation programmed.

MCCs fixed starter unit of the main distribution Panels Manufacturer
:Himel
Arrange proper tools and measuring equipment before starting the
maintenance works.
Switch OFF the incoming air circuit breaker of the MCC panel.
Tag No.
Date:
Tag No.
Switch OFF the MCCB of the MCC unit and carry out the followings :
Check the MCCB / Motor protection switch and operating lever.
Check and tighten terminal wires of MCCB.
Check the ELCB and its terminations.
Check the indication lamp, holder and termination.
Check the terminal connector and terminations.
Check the flexible cable connection for any damage or burnout.
Clean the interior parts of the MCC by clean cloth.

If everything satisfied switch ON the incoming Air Circuit Breaker and
put ON the MCC - unit.
Tag No.
Date:
Legend OK
N/A Not Applicable
Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Tag No.
MCCs withdrawable starter unit of the main and Remote distribution panels
Prepare all proper tools and measuring equipment before starting the preventive maintenance
works.
Switch OFF the load connected to the MCC and also switch OFF the MCC unit and draw it
out of the panel.
Inspect visually the MCC unit for any abnormal condition and carry out the following works:
Clean the bus bar isolating contacts with contact cleaner and clean cloth. Apply thin layer of
petroleum jelly on the contact surfaces.
Date:
Tag No.
Remove the control supply plug from the socket (in tele- technique MCC unit only) and clean the
contact with contact cleaner and plug it back.
Check the thermal overload relay and its current setting, tighten the terminal wires.

Tag No.
Date:
Tag No.
Check the ammeter, indicator lamps and lamp holder and their wiring terminations.
Operate the MCC unit in all modes by charging the selector switch position.
Check the operation of the indication light, ammeter and hour meter during loading.
Tag No.
Date:
Tag No.
MCCs fixed starter unit of the main distribution Panels Manufacturer: Himel
Arrange proper tools and measuring equipment before starting the maintenance works.

Tag No.
Date:
Tag No.

If everything satisfied switch ON the incoming Air Circuit Breaker and put ON the MCC -
unit.
Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
Tag No.
MCCs withdrawable starter unit of the main and Remote distribution panels
Manufacturer Himel
Main Panel :
Inflow structure panel :
Prepare all proper tools and measuring equipment before starting the preventive
maintenance works.
Switch OFF the load connected to the MCC and also switch OFF the MCC unit and
draw it out of the panel.
Inspect visually the MCC unit for any abnormal condition and carry out the following
works:

Tag No.
Date:
Tag No.
Clean the bus bar isolating contacts with contact cleaner and clean cloth. Apply thin layer
of petroleum jelly on the contact surfaces.
Remove the control supply plug from the socket (in telemechanique MCC unit only) and
clean the contact with contact cleaner and plug it back.

Date:
Tag No.
Tag No.
Date:
Tag No.
MCCs fixed starter unit of the main distribution Panels
Manufacturer

Tag No.
Date:
Tag No.

If everything satisfied switch ON the incoming Air Circuit Breaker and put ON the
MCC - unit.
Date:
Legend OK
Tag No.
N/A Not Applicable
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Equipment EL-231 LV MCC WITHDRAWABLE STARTER UNIT Location
Tag No.
MCCs withdraw able starter unit of the main and Remote distribution panels
Manufacturer : Himel
Main Panel : Telemechanique
Inflow structure panel : Cymesco LTD. Cyprus

Prepare all proper tools and measuring equipment before starting the preventive
maintenance works.
Switch OFF the load connected to the MCC and also switch OFF the MCC unit and
draw it out of the panel.
Inspect visually the MCC unit for any abnormal condition and carry out the following
works:

Tag No.
Date:
Tag No.
Clean the bus bar isolating contacts with contact cleaner and clean cloth. Apply thin layer
of petroleum jelly on the contact surfaces.
Remove the control supply plug from the socket (in telemechanique MCC unit only) and
clean the contact with contact cleaner and plug it back.

Tag No.
Date:
Tag No.
Tag No.
Date:
Tag No.
MCCs fixed starter unit of the main distribution Panels
Manufacturer : Himel

Tag No.
Date:
Tag No.

If everything satisfied switch ON the incoming Air Circuit Breaker and put ON the
MCC - unit.
Tag No.
Date:
Legend OK
N/A Not Applicable
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Equipment FIXED MCCs & LOCAL STARTER PANEL Location
Tag No.
Switch OFF the load connected to the panel.
Switch OFF the load break switch or MCCB (if Equipped).
Open the panel carefully and check visually for any abnormality.
Clean the interior of the panel using hand air blower and soft brush.
Check all wiring and tighten the termination of all parts.
Check the contactors, thermal overload relay, timer relays and their terminations.
Check push-buttons, emergency stop and rotary switches and termination.

Date:
Equipment FIXED MCCs & LOCAL STARTER PANEL Location
Tag No.
Check the cable entry hubs, sealing door gasket and correct if necessary.
Check / replace indicator light and holder (if necessary).
Close the panel door after last visual check and switch ON the unit.
Check the operation of the starter panel on-load.

Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
Equipment LOCAL PUSH BUTTON STATION & AUXILLIARIES Location

Tag No.
For various equipment at the pump rooms, inflow structure etc. Start / Stop push-
button emergency push-button, selector switches, cam and rotary switches etc.
Switch OFF the MCC unit connected to the local stations.
Open the local station carefully and check visually for any abnormal condition or
damages.
Check all wiring termination for loose connection or corrosion effect and adjust it.
Clean all contacts and terminals using contact cleaner and soft brush.
Check the entire conduit holes and clean all hubs,
Check the earthing connection, fitting and earthing cables.


Tag No.
Date:

Tag No.
Check the wirings continuity between the push-button station and the related MCC
unit in control room using multimeter.
Clean the interior of push-button box by hand blower and soft brush.
Check the cover gasket condition, replace it (if necessary).
Close the push-button cover firmly and test the operation of the control circuit only.
If everything satisfied, put the selector switch in remote position and start in load for
Date:

Tag No.
Legend OK
N/A Not Applicable
Remarks
Remarks
Remarks
Remarks
Equipment BUILDING ELECTRICAL EQUIPMENTS Location

Tag No.
Check local D.Bs for power and lighting distribution as follows
Clean internal parts by air blower.
Check all wiring condition and tighten (if necessary).
Check mcbs. Proper operation individually.
Check tripping mechanism of ELCBs individually.
Check the live bus bar tightness and condition.
Check the earth cable / wire termination and tightness.
Insure / measure 3-phase load balance.
Check proper closing of D.B. cover and gasket condition.

Check all lighting fitting, replace any defective parts. (Bulbs,holders, tubes, chook, starter,
switches etc.)

Tag No.
Date:

Tag No.
Check all power outlet fitting condition, replace if necessary any defected parts (13 amp. Plug /
socket, socket box, wiring, conduit .. etc.)
Check the telephone network and units, correct if necessary and mal functioning of the circuits,
socket etc.
Check bells and intercom system, repair any damage or defective unit.
Check all kitchen wares and electrical equipment for any damage or defect (electric heater,
boilers, hot plates, kettles, refrigerators, water coolers, exhaust fans, electric ovens etc.).
Check all washing room electrical equipment for any abnormalities and replace all defective
parts

Tag No.
Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
Equipment CONTROL PANEL CONSOLE DESK / MIMIC PANEL Location

Tag No.
Clean the control panel thoroughly with vacuum cleaner and then with hand brush.
Check all the following equipment and tighten their wiring termination.
Auxiliary contactors.
Contactor relays.
Universal relays.
Timing relays.
Different relays.

Tag No.
Date:

Tag No.
Earth leakage circuit breakers.
Earth fault relays.
Electronics relays.
Miniature circuit breakers.
Programmable controllers.
Selector switches.
Cam-switches.
Push buttons.

Tag No.
Date:

Tag No.
Ammemeters, Voltmeters and frequency meter.
Current transformer / bases.
Illumination light fittings.
Light emitting diodes (LEDs)
Indication lamps / holders.
Counter meters.
Water level indicators.
Pressure monitors.
Flow meters / display units


Tag No.
Date:

Tag No.
Check the proper operation of all above equipment and adjust of the correct.
Replace any damage equipment or blown off fuses or lamp indicator.
Test the operation of the water level control system (Huber / Ultrasonic), replace damages
parts.
Test the operation of the emergency push button of the control panel.
Check the terminal strips wiring and label conditions, replace if required.
Check the earthing of the control panel.
Check the door of the panels and door lock operation.

Tag No.
Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
Equipment BATTERY CHARGER PANEL Location
Tag No.
Before starting the maintenance works, check the meter reading of the output voltage,
charging current and charger output current.
Switch OFF the incoming AC supply.
Check the AC power available indication in OFF condition and AC power failure indication
in ON condition.
Again note the reading of the battery charger meters.
Check visually and thoroughly the battery charger for any abnormal condition.
Clean the battery charger with hand blower.
Check and tighten all wire terminals and connector block termination.
Tag No.
Date:
Tag No.
Clean the heat sinks of the thyristors.
Check and clean the cooling fan and filter (if required).
Check all the wiring arrangement for any burnout or damages.
Check the proper fitting of electronic printed circuit boards.
Check the fuses and fuse holders.
Check and tighten all meters terminations
Check and tighten the indication bulb holder terminations.
Check and tighten all outgoing circuit MCB terminals.

Tag No.
Date:
Tag No.
Replace and faulty or damage parts or overheated wiring.
When everything satisfied, switch ON the incoming AC supply and note the meter
readings.
Check the Battery electrolyte level alarm by removing the sensing probe from the Battery.
Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
Equipment BATTERY UNITS Location
Tag No.
Before starting the maintenance of the batteries, switch OFF the

battery charger incoming AC supply.
Check terminal voltage of each battery.

Clean the battery cells individually with soft brush and rinse with
water if required to remove any soft deposits of the top of the
battery, do not use wire brush or solvents of any kind.
Check that all connectors are tight, the connector and pole screws
should be cleaned and corrosion protected by coating with thin
layer of anti-corrosion oil.
Top up the electrolyte level using only distilled or de-ionized water

(only if required), in order to keep the electrolyte at maximum level
(not more). However let the battery fall below the low mark, this
may damage the battery capacity and there may be
Tag No.
Date:
Tag No.
It will ruin the battery, filling bottle, hydrometers.. etc, used with
lead acid battery must never be used with alkaline batteries.
Check the electrolyte density. The density is not influenced by the

state of charge, but increase slightly when electrolyte level is
lowered due to water loss. The density should not measure
immediately after the water has been added, wait a while for the
When taking electrolyte sample for measuring the density, dip the
syringe sufficiently deep to avoid sucking up the cell oil.
Check the proper voltage setting of the charger. It is of great

importance that the recommended charging voltage be kept
unchanged. High water consumption of the battery usually is
caused by in proper voltage setting of the charger.
Date:
Tag No.
Re-clean the batteries after topping up and rub it with dry clean
cloth. A wet batteries can results in earth faults and / or erratic
operation for the system.
For maximum safety while working on the battery, always keep the
flame arresting vent closed except for the moment of topping up.
When everything satisfied, switch ON the battery charger

incoming AC supply.
Date:
Legend OK
N/A Not Applicable
Remarks
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Equipment LIGHTING & POWER DB Location
Tag No.
Prepare all proper tools and measuring equipment before staring the maintenance
works.
Switch OFF all lighting circuit mcbs in the distribution board.
Switch OFF the incoming supply to the lighting D.B.
Clean the lighting D.B with hand blower and hand brush.
Check the incoming load break switches and its operating handle.
Check the terminal wire and its tightness.
Check the operating of the ELCBs and their terminations.
Check the mcbs and their ON/OFF operation.

Tag No.
Date:
Tag No.
Check the mcbs incoming bus bar termination and tighten it.
Check the mcbs outgoing terminal connections.
Check the Neutral bus bar and tighten all wiring termination.
Check the Earth bar and tighten all wiring connection.
Check and retighten all terminal connector wiring.
Check the out door lighting photocell control unit and its connections.
Check the photocell control contactor and its terminations.
Check the voltmeter and voltage selector switch and their wiring connections.
Tag No.
Date:
Tag No.
Repeat all the above steps for checking the power supply circuit of the power
outlet socket1-ph and 3-ph.
Switch ON the incoming power supply to the D.B.
Switch ON all ELCBs and MCBs.
Test the ELCBs by pressing the trip button.
Reset the ELCB and put the distribution board in operation
Date:
Legend OK
Tag No.
N/A Not Applicable
Remarks
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Equipment EMERGENCY LIGHTING UNIT Location
Tag No.
Prepare all proper tools and measuring equipment before staring the works.
Switch OFF the AC power supply to the emergency lighting unit or remove the AC
plug from the wall outlet (if provided).
Check the emergency unit light are glowing properly.
Open the unit cover and inspect visually inside for any abnormal condition.
Check the battery voltage value and then clean the batteries and terminations.
Tighten all battery terminal wiring.
Check the electrolyte level of the battery and top up with distilled water (if required).
Tag No.
Date:
Tag No.
Check the terminal wire of the battery unit.

Check visually the condition of the battery, charging unit and the printed circuit
board for any abnormal notice.
Check the termination of the control transformer and the control unit.
Check the bulb and holders, replace if necessary.
Check the light doom and clean it.
Tighten the unit cover perfectly.

Date:
Tag No.
Check the AC power supply cable and plug, replace it if necessary.
Check the outlet socket of the emergency lighting unit AC supply.
Insert the plug in the socket and switch ON the emergency light
Check now the emergency light unit bulbs are switched OFF and put the unit in the
normal operation.
Date:
Legend OK
N/A Not Applicable
Remarks
Remarks
Remarks
Remarks
Equipment EMERGENCY LIGHTING UNIT EXPLOSION PROOF Location

Tag No.
Switch OFF the AC power supply to the emergency lighting unit or remove the AC
plug from the wall outlet (if provided).

Tag No.
Date:

Tag No.

Check visually the condition of the battery, charging unit and the printed circuit board
for any abnormal notice.


Tag No.
Date:
Insert the plug in the socket and switch ON the emergency light unit.
Check now the emergency light unit bulbs are switched OFF and put the unit in the
normal operation.
Date:
Legend OK
N/A Not Applicable
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Equipment OVERHEAD CRANE & CONTROL PANEL Location
Tag No.
Maintenance Period & Statu
Before starting the maintenance works, arrange the proper tools and testing equipment.
Follow the safety regulation of the manufacturer instruction manual.
Switch OFF the power supply to the over head crane and put the men at work display board at the main
isolating switch.
Clean the control switch gear panel, check and tighten the terminal of the contactor, thermal over load and timer ..
etc.
Check the tightness of all wire connected to the terminal connectors.
Check the traveling cable clamping guide rollers and tighten its termination.
Lubricate the guide of the traveling cable clamping rollers.

Tag No.
Date:
Tag No.
Check and tighten hoist traveling motor fixing bolts and terminations.
Check the insulation resistance value of the motors.
Clean the motor with dry compressed air hand brush.
Check the limit switches position and their operating levers and tighten all wiring termination.
Check the over head power supply rails and its contact carbon brushes and brush holder (if equipped).
Check the brake setting of the hoist motor.
Check and readjust the stopper of the over head crane traveling strokes.
Check / clean the control push-button station, emergency push-button, selector switch and their termination.
Check the tightness of the push-button stations stay wire, always its length should be less than the flexible cable.
Tag No.
Date:
Tag No.
Check the earthing of the overhead crane.
Switch ON the overhead crane and operate all function one by one and note down the motor load current.
Check the operation of the limit switches by operating the hoisting motor.
Check the operation of the emergency push-button and selector switches.
When everything satisfied put the overhead crane in operation.
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
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Equipment 3.3 KV ELECTRIC MOTORS Location
Tag No.
Before starting the maintenance works arrange proper tools, spare and measuring equipment.
Follow the manufacturer maintenance instruction and safety regulations.
Switch OFF the motor and draw out the 3.3 KV MCC switchgear unit.
Display the Men at work board in the MCC Unit.
Switch OFF the Anti Condensating heater.
Inspect the surrounding area of the motor and inspect any dripping of water or any unusual amount of dust over the
motor.
Check any board, cloths, covers.. etc are left on the body which may affect ventilation.
Tag No.
Date:
Check to make sure, grease or oil is not leaking out of the bearing housing if any leakage is present, correct the
condition continuing to operate.
Clean the external cooling fan and check its fixing aids.
Clean the fan impeller covers and cooling air tube with dry compressed air.
Open the terminal box, check the internal condition thoroughly and clean it perfectly as follows:
Clean the internal box walls.
Inspect, clean the terminal bushings.
Check and tighten the cable lugs at the terminal bushings.
Check the earth cable connection and its termination.
Tag No.
Date:
Check the space heater terminal tightness.
Closed the unused entries or holes in the terminal box.
Check the gasket condition.
Check the cable clamping
Retighten of all fixing bolts and nuts.
Check the alignment of motor with pump and coupling.
Re-grease / lubricate the motor bearing as per manufacturer instruction.
Tag No.
Date:
Tag No.
Check the insulation resistance of the motor winding with Megger 5000 Volts and compare the Megger values with
manufacturer specifications.
Switch ON the anti-conducting heating coils and check the operation.
Switch ON the motor and allow it to run for full load test and note down the values of the starting voltage and
current.
Keep the motor running on full load test and check the following condition :
Motor outer temperature.
Bearing sound and temperature.

Date:
Tag No.
Motor vibrations.
Cooling fan sound and air flow.
Motor coupling condition.
Full load, voltage and current values
When everything satisfied, put the motor in the operation program.
Date:
Legend OK
Tag No.
N/A Not Applicable
o. SE/S/135
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Equipment 415V ELECTRIC MOTORS Location
Tag No.
Before starting the maintenance works arrange proper tools, spare and measuring equipment.
Follow the manufacturer maintenance instruction and safety regulations.
Switch OFF the motor and draw out the 415V MCC switchgear unit
Display the Men at work board in the MCC Unit.
Switch OFF the Anti Condensating heater.
Inspect the surrounding area of the motor and inspect any dripping of water or any unusual amount of dust
over the motor.
Check any board, cloths, covers.. etc are left on the body which may affect ventilation.
Tag No.
Date:
Check to make sure, grease or oil is not leaking out of the bearing housing if any leakage is present, correct the
condition continuing to operate.
Clean the external cooling fan and check its fixing aids.
Clean the fan impeller covers and cooling air tube with dry compressed air.
Open the terminal box, check the internal condition thoroughly and clean it perfectly as follows:
Clean the internal box walls.
Inspect, clean the terminal bushings.
Check and tighten the cable lugs at the terminal bushings.

Tag No.
Date:
Check the space heater terminal tightness.
Check the gasket condition.
Check the cable clamping
Retighten of all fixing bolts and nuts.
Check the alignment of motor with pump and coupling.
Re-grease / lubricate the motor bearing as per manufacturer instruction.
Tag No.
Check the insulation resistance of the motor winding with Megger 5000 Volts and compare the Megger values
with manufacturer specifications.
Date:
Switch ON the anti-conducting heating coils and check the operation.
Switch ON the motor and allow it to run for full load test and note down the values of the starting voltage
and current.
Keep the motor running on full load test and check the following condition :
Motor outer temperature.
Tag No.
Motor vibrations.

Date:
Tag No.
Full load, voltage and current values
When everything satisfied, put the motor in the operation program.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
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SE/S/135
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Equipment VALVE ACTUATOR Location
Tag No.
AUMA-VALVE ACTUATOR
Manufacturer : AUMA
Type : SA12E & SA25E
Switch OFF the actuator and draw out the MCC unit.
Provide Men at work display board in the MCC.
Open the cable entry side cover of the actuator unit and carry on the followings.
Clean the terminal block unit.

Tag No.
Date:
Check the tightness of all terminal wires and connections.
Check the motor input wires.
Close the cover and tight it properly.
Remove the selector switch cover and check the operation of the selector switch and its termination.
Check the contactors, over load relay and their termination (type SA12E).
Check and clean the power and control plug in terminals.
Remove the cover of the limit switch mechanism and clean it.
Lubricate sparingly the gear wheels of the limit switch operating mechanism.
Tag No.
Date:
Check the limit switches, termination and settings.
Check the torque switches, termination and settings.
Check the valve position indicators.
Close and insert all components removed for maintenance to the proper locations.
Switch ON the power supply to the valve actuators.
AUMA-VALVE ACTUATOR
Manufacturer : EMG-DREHMO
Type : DATZD19 :
Tag No.
Date:
Switch OFF the power supply of the valve actuator and draw out the MCC unit.
Provide A Men at work safety label at MCC door.
Open the electrical component side cover and carry on the followings:
Check selector switch and its terminal connectors.
Check the push-buttons and its termination.
Check the limit switches and their terminations.
Tag No.
Date:
Tag No.
Check the settings of limit switches and torque switches.
Check the actuator motor and its wiring terminations.
Switch ON the MCC of the valve actuator and operate the valve for opening and closing mechanism.
Check the opening / closing limit switches operation and the position indicator.
When everything satisfied, put the valve actuator in operation.

Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
SE/S/135
& Status
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SE/S/135
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Equipment DIESEL GENERATOR Location
Tag No.
Check the lubricant oil level and inspect the pre-lubrication pump operation (if equipped).
Check the fuel level.
Check the water level in the radiator tank and make-up water tank.
Drain the water and sediments from the air compressor and air charging system (if it is air starting system).
Check the air pressure in the air tank, test the diesel air compressor (if equipped).
Check the air cleaner indicator and clean the engine.
Check the jacket water heater and its operation.
Check the jacket water heater circulation pump (if equipped).

Tag No.
Date:
Tag No.
Check the 24 Volts D.C batteries and clean units, terminals and apply a thin layer of petroleum jelly.
Check the electrolyte level of the battery and top-up with distilled water if its found low.
Clean the control panel interiors.
Check and tighten the control panel wiring and connection.
Check the space heater condition of the alternator in the internal electrical equipment of the control panel.
Run the D.G set in manual mode without load and inspect the engine operation.
Note down all the meter readings.
Stop the D.G set and put it in Auto. Position.

Tag No.
Date:
Tag No.
Inspect the pre-lubrication oil pump and all lubrication system for any leakage.
Inspect fuel system for any leakage.
Drain the sediments in the diesel tank.
Check the air filter indicator, if necessary clean the air filter.
Check the radiator, tank cooling fan motor (if equipped).
Check the D.G. set incomer breakers and clean it.
Check and clean the power transformer (3.3 k.v / 415 Volts) and its oil level (if equipped).
Check the color of the sficajel in transformer.
Run the D.G set in Auto mode with load.

Tag No.
Date:
Tag No.
Note all the meter readings.
Check the D.G set performance and vibration.
Check the engine speed sensor.

Check the automatic voltage regulator (AVR) operation.
Check the automatic transformer switch (ATS) operation.
Check the overhead radiator unit and its cooling fan motor operation.
Stop the D.G set and put it in Auto. Position.
Date:
Tag No.
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
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Equipment H2S MONITORING SYSTEM Location
Tag No.
GENERAL :
The existing H2S monitoring system of the main pumping station comprise of a continuous automatic H2S gas
controller, monitoring the concentration in PPM 0 different locations at the pumping station.
The system includes, SENSYS industrial I/O digital controller units Model S400 A of Sierra product USA
which is processor for measurement and data acquisitions, accepts direct sensor inputs and generate outputs can
be controlled by computer via RS 232 com
The SENSYS controllers are being mounted and installed at the control room of all main pumping station,
connected to different locations on the site. The controller has 16 channels analog input and they are mostly
used for the existing H2S sensors located
Tag No.
Date:
Tag No.
Gas sensors models 4101-05 of sierra product USA are an electrochemical sensors for H2S gases were mounted
at pump room, inflow structure chambers and OCF equipment which may cover most of critical area of the
pumping stations.
B. PREVENTIVE MAINTENANCE OF THE EXISTING SYSTEM :
The contractor shall also be responsible of the maintenance and repair works required to the H2S monitoring
system and all related equipment, fittings, cable and accessories through the whole duration of the contract and
he should keep in his store the re
The contractor shall carry out the following work periodically :
Clean the sensors assembly and all transducers by contact cleaner.

Tag No.
Date:
Tag No.
Check the metal conduit of the signal cable.
Clean H2S controller and all internal components with hand blower and soft brush.
Clean all electrical contact with contact cleaner.
Tight electrical connection and terminations.
Check memory back up and controller back-up batteries.
Check alarm limits of H2S and chlorine gas sensors.
Check controller programmed.

Date:
Tag No.
Due to the high severe atmosphere and the expires of the life time of the existing sensors, the contactor shall
replace all the sensor cells at all main pumping stations by a spare identical cells, which he shall arrange to be
provided and fitted within 6
The Contactor shall be responsible of conducting a periodical field calibration to the system components using
the standard calibration gas samples, supplied as per the manufacturer recommendations. thee contractor shall
supply to the ministry a complete
Date:
Tag No.
The contactor, after each calibration process for all detectors shall submit to Engineer for approval, the test
report for all sensors performance and efficiency and the adjustment of H2S controller being carried out with a
PC in the field.
The Contractor shall utilize adequate tools instruments and kids for adjustment, setting and calibration of the
sensors, complete with enough gas capsules and sensing elements to ensure continuous operation of the system
during the contract period.
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

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Equipment ULTRASONIC LEVEL CONTROL SYSTEM Location
Tag No.
Clean the Ultra-sonic level controller thoroughly with clean and soft brush.
Clean the Ultra-sonic transmitter.

Check and clean the sensors.
Check the solid connection of the ground cable and tighten it.
Paint the sensor enclosure by Anti-corrosive paint (if required).
Tight the sensor cable connections.
Clean and tight electrical connection of the Ultra sonic controller.
Check the programmed setting and adjust it (if required).
Check and clean the display unit and tight electrical connection.
Check the memory back up battery.

Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment HUBER LEVEL CONTROL SYSTEM Location
Tag No.
Clean the contact maker unit with soft brush.
Tight the electrical connection of the contact maker unit.
Readjust the mercury tube position and return spring.
Check the oil container and the membrane functioning for any abnormal condition or oil leakage.
Clean the quid shaft and spring.
Check the operation of the remote level indicator, clean and adjust (if necessary).
Check all parts of the pneumatic connecting pipe (all the route) for any leakage of air from the ai
rbel, clean and tight tube joints.
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment PRESSURE MONITORING SYSTEM Location
Tag No.
Clean and remove choked from impulse pipe.
Check Tee and coupling connection (replace if necessary)
Check the pressure transducer with fresh water and soft brush.
Calibrate pressure transducer and produce calibration report.
Remove and clean isolation valve, check valve leakage (replace if necessary).
Open pressure gauge diaphragm and clean with fresh water.
Replace pressure gauge diaphragm and clean with fresh water.
Replace pressure gauge diaphragm Teflon gasket if necessary.

Tag No.
Date:
Tag No.
Calibration pressure gauge and produce calibration report.
Maintain pressure gauge damping oil level and quantity.
Reinstall pressure transducer, pressure gauge by using thread sealing Teflon tape.
Tighten and clean electrical connection and terminations of the digital display unit.
Check calibration of the digital display unit (adjust if necessary).
Date:
Legend OK
Tag No.
N/A Not Applicable
SE/S/135
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Oct. Nov. Dec.
Equipment FLOWMETER Location
Tag No.
Clean the flow meter transducer, display unit and chart recorders thoroughly with the help of
hand blower and soft brush.
Clean Doppler flow meter sensors with soft clean cloth.
Replace coupling grease of Doppler flow meter sensor and tighten the sensor clamp.
Clean magnetic flow-meter sensors with soft brush and clean cloth.
Clean the magnetic flow meter sensor connections with a good quality contact cleaner.
Check all function of the chart recorders, adjust roller position and speed, pen condition (replace
if necessary or life time expired) and totalize function.
Clean internal part of the chart records using soft brush.

Tag No.
Date:
Tag No.
Check data storage memory card on the chart recorder, adjust slot cartridge.
Check display reading and characters configuration, compare with standard or portable flow
meter readings and adjust if required.
Check the memory back up battery, replace it if required.
Clean the sensors of open channel flow meters.

Clean all electrical contacts and terminations of all types of flow meters with good quality
contact cleaner.
Tighten all electrical connections.
Tag No.
Date:
Legend OK
N/A Not Applicable
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
135
Remarks
Nov. Dec.
Equipment DIFFERENTIAL LEVEL CONTROL SYSTEM Location
Tag No.
Clean silo meter sensor and its in closer.
Check and clean electrical and printed circuit board contact.
Tighten electrical connection of transmitter.
Check programming of the controller, adjust it if required.
Check cable condition and conduit pipes.

Date:
Legend OK
N/A Not Applicable
Remarks
Dec.
Tag No.
Check the gasket and sealing for all the cubicle doors and shutters and change or clean the air filters where
necessary.

Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment BUSBARS Location
Tag No.
Check the bus bars, tighten the connection and clean the bus bar and the supports.
Clean the post isolators and the bushings and check for any hairline cracks.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment DISCONNECTING SWITCHES (ISOLATORS) & DRIVING MECHANISM Location

Tag No.
Slightly lubricate the contact surface with contact grease and check the operation for proper mating of
the contacts.
Check the closing and opening operation under no voltage condition and special attention for the
voltage from the other end.

Date:

Tag No.
Check the earthing switch position indication (as applicable) mechanically and electrically local and
remote.
Date:
Legend OK

Tag No.
N/A Not Applicable
SE/S/135
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Remarks
Oct. Nov. Dec.
SE/S/135
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Oct. Nov. Dec.
Equipment CIRCUIT BREAKER Location
Tag No.
Follow the manufacturers instructions to draw out the MCCB.
Clean all parts of MCCB thoroughly by hand blower and soft brush.
Inspect all parts of the MCCB, visually and by hand checking.

Check the condition of the arc-chute, make sure that the arc chute body is not broken and the separators
are not corroded.
Date:
Tag No.
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
SE/S/135
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Oct. Nov. Dec.
Tag No.
Check and tighten the secondary connections

Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Tag No.
Check primary contact, clean and slightly lubricate contacts.
Check secondary connection, plugs, secondary circuit MCB, etc tighten secondary connection.
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment BUSBAR/ CABLE/ EARTHING SWITCHES Location
Tag No.
Slightly lubricate the contact surface with contact grease and check the operation for proper mating of
the contacts.
Check the closing and opening operation under no voltage condition and special attention for the
voltage from the other end.
Check the interlock system is functional.
Check the earthing switch position indication (as applicable) mechanically and electrically local and
remote.

Tag No.
Date:
Legend OK
N/A Not Applicable
SE/S/135
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Remarks
Oct. Nov. Dec.
SE/S/135
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Oct. Nov. Dec.
Equipment ELPLS-408 LOCAL PUSH BUTTON Location
Tag No.
Maintenance Perio
Jan. Feb. Mar. Apr. May.
For various equipment at the pump rooms, inflow structure etc. Start / Stop push-button emergency push-button, selector
switches, cam and rotary switches etc.
Open the local station carefully and check visually for any abnormal condition or damages.
Check the wirings continuity between the push-button station and the related MCC unit in control room using multimeter.
Equipment ELPLS-408 LOCAL PUSH BUTTON Location
Tag No.
Maintenance Perio
Jan. Feb. Mar. Apr. May.
If everything satisfied, put the selector switch in remote position and start in load for testing.
Date:
Legend OK
N/A Not Applicable
Report No.
Year 2010
Contract No. SE/S/135
Location
aintenance Period & Status

Remarks
Jun. Jul. Aug. Sep. Oct. Nov. Dec.
Report No.
Year 2010
Location
aintenance Period & Status

Remarks
Jun. Jul. Aug. Sep. Oct. Nov. Dec.
Client Ministry of Public Works (MPW)
Project MPW-O&M of Sewage Pumping & Lifting Station-2 Area
Contractor Kharafi National KSC (Closed)
Equipment BUILDING ELECTRICAL EQUIPMENT & MOTOR ROOM

Tag No.
Jan. Feb.
Check local D.Bs for power and lighting distribution as follows:
Clean internal parts by air blower.
Check all wiring condition and tighten (if necessary).
Check mcbs. Proper operation individually.
Check tripping mechanism of ELCBs individually.
Check the live bus bar tightness and condition.
Check the earth cable / wire termination and tightness.
Insure / measure 3-phase load balance.
Check proper closing of D.B. cover and gasket condition.

Tag No.
Jan. Feb.
Check all lighting fitting, replace any defective parts. (Bulbs, holders, tubes, chook, starter, switches etc.)
Check all power outlet fitting condition, replace if necessary any defected parts (13 amp. Plug / socket, socket box, wiring, conduit .. etc.)
Check the telephone network and units, correct if necessary and mal functioning of the circuits, socket etc.
Check bells and intercom system, repair any damage or defective unit.
Check all kitchen wares and electrical equipment for any damage or defect (electric heater, boilers, hot plates, kettles, refrigerators, water coolers,
exhaust fans, electric ovens etc.).
Check all washing room electrical equipment for any abnormalities and replace all defective parts.
Date:

Tag No.
Jan. Feb.
Legend OK
N/A Not Applicable
Report No.
Year
Location

Remarks
Mar. Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec.
Report No.
Year
Location

Remarks
Equipment ELPLS-410 CONTROL PANEL Location
Tag No.
Equipment ELPLS-410 CONTROL PANEL Location
Tag No.

Date:
Legend OK
N/A Not Applicable
Remarks
Dec.
Remarks
Dec.
Equipment 1 LIGHTING & POWER DISTRIBUTION BOARD

Tag No.
Prepare all proper tools and measuring equipment before staring the maintenance works.

Tag No.
Date:

Tag No.
Repeat all the above steps for checking the power supply circuit of the power outlet socket1-ph and 3-ph.
Reset the ELCB and put the distribution board in operation.
Date:
Legend OK
N/A Not Applicable
ublic Works (MPW)
of Sewage Pumping & Lifting Station-2 Area
nal KSC (Closed)
& POWER DISTRIBUTION BOARD
Jan.
ring equipment before staring the maintenance works.
mcbs in the distribution board.
y to the lighting D.B.
lower and hand brush.
itches and its operating handle.
htness.
and their terminations.
operation.
termination and tighten it.
connections.
ten all wiring termination.
wiring connection.
nnector wiring.
ell control unit and its connections.
tor and its terminations.
lector switch and their wiring connections.
ublic Works (MPW)
nal KSC (Closed)
Jan.
ublic Works (MPW)
nal KSC (Closed)
Jan.
king the power supply circuit of the power outlet socket1-ph and 3-ph.
supply to the D.B.
p button.
ution board in operation.
Applicable
Report No.
Year
Location

Feb. Mar. Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec.
Report No.
Year
Location

Report No.
Year
Location

Remarks
Remarks
Remarks
Equipment EMERGENCY LIGHTING UNIT
Tag No.
Switch OFF the AC power supply to the emergency lighting unit or remove the AC plug from the wall outlet (if provided).
Check visually the condition of the battery, charging unit and the printed circuit board for any abnormal notice.
Tag No.
Insert the plug in the socket and switch ON the emergency light unit.
Check now the emergency light unit bulbs are switched OFF and put the unit in the normal operation.
When everything satisfied put the overhead crane back in operation.
Tag No.
Date:
Legend OK
N/A Not Applicable
Report No.
Year
Location

Report No.
Year
Location

Report No.
Year
Location

Remarks
Remarks
Remarks
Equipment ELECTRIC MOTORS Location
Tag No.
Before starting the maintenance work, prepare all tools and spare parts and measuring
equipment.
Switch OFF the motor and draw out its MCC and provide men at work safety label.
Switch OFF the space heater if required.

Inspect the surrounding area and note any dripping of water, fumes, any unusual amount of
dust over the motor body.
Check to make sure grease or oil is not leaking out of the bearings housing.
If any leak is present, check and correct the condition before continuing to operate.
Clean / check the external cooling fan and its proper fixation.
Clean the cooling fan of the stator body with compressed dry air.
Tag No.
Date:
Tag No.
Clean the bells of the motor and fan cover.

Open the terminal box and check the interior area and the walls, clean and blow off any
residues as follows :
Clean the inner sides by soft brush.
Inspect, clean and tighten the cable terminal lugs, nut and bolts.
Check the space heater terminal and retighten of its bolts (if equipped).
Check any abnormal condition of the terminal block (crack or damage).

Tag No.
Date:
Tag No.
Check the cover gasket condition.
Check the cable entry and cable gland.
Check the alignment of motor with the pump (or any equipment) and coupling.
Check the tightness of all fixing bolts.
Re-grease the bearings as per manufacturer recommendation.
Check the insulation resistance of the motor windings with 500 Volt Megger and compare
the resistance values with the manufacturer specification.
During measuring the insulation resistance note down the temperature of the motor
windings.
Switch ON the motor and allow it to run for a full load test and check the following:
Tag No.
Date:
Tag No.
Check the starting voltage and current.
Motor temperature.
Smooth running and vibration.
Full load voltage and current.
When everything is satisfied, put the motor into the operating programme.
Date:
Tag No.
Legend OK
N/A Not Applicable
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Remarks
Dec.
Equipment ULTRASONIC LEVEL SYSTEM Location
Tag No.
Clean the Ultra-sonic level controller thoroughly with cleaner and soft brush.
Check the solid connection of the ground cable and tighten.

Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment HUBER LEVEL CONTROL SYSTEM Location
Tag No.
Check the oil container and the membrane functioning for any abnormal condition or oil leakage.
Clean the quid shaft and spring.
Check all parts of the pneumatic connecting pipe (all the route) for any leakage of air from the airbel, clean and
tight tube joints.
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Tag No.

Check the gasket and sealing for all the cubicle doors and shutters and change or clean the air filters
where necessary.
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment BUSBARS Location
Tag No.
Check the bus bars, tighten the connection and clean the busbar and the supports.
Clean the post isolators and the bushings and check for any hairline cracks.
Date:
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.

Tag No.
Maintenance Period &
Jan. Feb. Mar. Apr. May. Jun.
Slightly lubricate the contact surface with contact grease and check the operation for proper mating of the contacts.
Check the closing and opening operation under no voltage condition and special attention for the voltage from the other
end.

Tag No.
Date:
Legend OK
N/A Not Applicable
rt No.
ract No. SE/S/135
ion
ance Period & Status

Remarks
Jul. Aug. Sep. Oct. Nov. Dec.
rt No.
ract No. SE/S/135
ion

Remarks
Tag No.
- Prepare all proper tools and measuring equipment before starting the work.
Follow the manufacturers instructions to draw out the MCCB.
Clean all parts of MCCB thoroughly by hand blower and soft brush.
Inspect all parts of the MCCB, visually and by hand checking.
Check the condition of the arc-chute, make sure that the arc chute body is not broken and the separators are
not corroded.
1653/ TWI 756 Att. 30AS4 Rev.2 24 Nov. 2012 Page 610 of 793
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Tag No.
Check and tighten the secondary connections.

Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Tag No.
Check primary contact, clean and slightly lubricate contacts.
Check secondary connection, plugs, secondary circuit MCB, etc tighten secondary connection.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Tag No.
Slightly lubricate the contact surface with contact grease and check the operation for proper mating of the contacts.
Check the closing and opening operation under no voltage condition and special attention for the voltage from the other
end.
Check the interlock system is functional.
Tag No.
Date:
Legend OK
N/A Not Applicable
rt No.
ract No. SE/S/135

ion

Remarks
rt No.
ract No. SE/S/135

ion

Remarks
Equipment LOCAL PUSH BUTTON
Tag No.
Main
Jan. Feb. Mar.
For various equipment at the pump rooms, inflow structure etc. Start / Stop push-button emergency push-button, selector switches, cam and
rotary switches etc.
Open the local station carefully and check visually for any abnormal condition or damages.
Check the wirings continuity between the push-button station and the related MCC unit in control room using multimeter.
Equipment LOCAL PUSH BUTTON
Tag No.
Main
Jan. Feb. Mar.
If everything satisfied, put the selector switch in remote position and start in load for testing.
Date:
Legend OK
N/A Not Applicable
Report No.
Year
Location

Remarks
Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec.
Report No.
Year
Location

Remarks
Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec.
Equipment CONTROL PANEL Location
Tag No.

Date:
Equipment CONTROL PANEL Location
Tag No.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment LIGHTING & POWER DISTRIBUTION BOARD

Tag No.
Jan. Feb.
Prepare all proper tools and measuring equipment before staring the maintenance works.

Tag No.
Jan. Feb.

Tag No.
Jan. Feb.
Date:

Tag No.
Jan. Feb.
Repeat all the above steps for checking the power supply circuit of the power outlet socket1-ph and 3-ph.
Reset the ELCB and put the distribution board in operation.
Date:
Legend OK

Tag No.
Jan. Feb.
N/A Not Applicable
Report No.
Year
Location

Remarks
Report No.
Year
Location

Remarks
Report No.
Year
Location

Remarks
Report No.
Year
Location

Remarks
Tag No.
Before starting the maintenance work, prepare all tools and spare parts and measuring equipment.
Switch OFF the motor and draw out its MCC and provide men at work safety label.
Switch OFF the space heater if required.
Inspect the surrounding area and note any dripping of water, fumes, any unusual amount of dust over the motor
body.
Check to make sure grease or oil is not leaking out of the bearings housing.
If any leak is present, check and correct the condition before continuing to operate.
Clean / check the external cooling fan and its proper fixation.
Clean the cooling fan of the stator body with compressed dry air.
Tag No.
Date:
Tag No.
Clean the bells of the motor and fan cover.
Open the terminal box and check the interior area and the walls, clean and blow off any residues as follows :
Clean the inner sides by soft brush.

Tag No.
Date:
Tag No.
Check the alignment of motor with the pump (or any equipment) and coupling.
Check the tightness of all fixing bolts.
Regrease the bearings as per manufacturer recommendation.
Check the insulation resistance of the motor windings with 500 Volt Megger and compare the resistance values
with the manufacturer specification.
During measuring the insulation resistance note down the temperature of the motor windings.
Tag No.
Date:
Tag No.
Motor temperature.
Smooth running and vibration.
When everything is satisfied, put the motor into the operating programmed.
Tag No.
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
o. SE/S/135
Period & Status

Remarks
o. SE/S/135
Period & Status

Remarks
o. SE/S/135
Period & Status

Remarks
o. SE/S/135
Period & Status

Remarks
o. SE/S/135
Period & Status

Remarks
o. SE/S/135
Period & Status

Remarks
o. SE/S/135
Period & Status

Remarks
Tag No.
Check the lubricant oil level and inspect the pre-lubrication pump operation (if equipped).
Check the fuel level.
Check the water level in the radiator tank and make-up water tank.
Drain the water and sediments from the air compressor and air charging system (if it is air starting
system).
Check the air pressure in the air tank, test the diesel air compressor (if equipped).
Check the air cleaner indicator and clean the engine.
Check the jacket water heater and its operation.
Check the jacket water heater circulation pump (if equipped).

Tag No.
Date:
Tag No.
Check the 24 Volts D.C batteries and clean units, terminals and apply a thin layer of petroleum jelly.
Check the electrolyte level of the battery and top-up with distilled water if its found low.
Isolate the control panel and carry-out the following works :
Clean the control panel interiors.
Check and tighten the control panel wiring and connection.
Check the space heater condition of the alternator in the internal electrical equipment of the control panel.
Run the D.G set in manual mode without load and inspect the engine operation.
Note down all the meter readings.
Stop the D.G set and put it in Aut. Position.

Tag No.
Date:
Tag No.
Inspect the pre-lubrication oil pump and all lubrication system for any leakage.
Inspect fuel system for any leakage.
Drain the sediments in the diesel tank.
Check the air filter indicator, if necessary clean the air filter.
Check the radiator, tank cooling fan motor (if equipped).
Check the D.G. set incomer breakers and clean it.
Check and clean the power transformer (3.3 k.v / 415 Volts) and its oil level (if equipped).
Check the color of the sficajel in transformer.
Run the D.G set in Auto mode with load.
Note all the meter readings.

Tag No.
Date:
Tag No.
Check the D.G set performance and vibration.
Check the engine speed sensor.
Check the automatic voltage regulator (AVR) operation.
Check the automatic transformer switch (ATS) operation.
Check the overhead radiator unit and its cooling fan motor operation.
Stop the D.G set and put it in Aut. Position.

Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Tag No.
Clean the Ultra-sonic level controller thoroughly with cleaner and soft brush.
Check the solid connection of the ground cable and tighten.

Date:
Tag No.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment HUBER LEVEL SYSTEM Location
Tag No.
Check the oil container and the membrane functioning for any abnormal condition or oil leakage.- Clean the
quid shaft and spring.
Check all parts of the pneumatic connecting pipe (all the route) for any leakage of air from the airbel, clean and
tight tube joints.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment AUTOMATIC TRANSFER SWITCH Location
Tag No.
Switch OFF the load break switch or MCCB to the ATS.
Check the contactors, phase failure relays, timer relays and their terminations.
Check selector switches and rotary switches.

Tag No.
Date:
Tag No.
Check manual bypass connections
Check the bus bar connections for tightness.
Close the panel door after last visual check and switch ON the panel.
Check the operation of the ATS on different modes, if satisfactory keep in AUTO / NORMAL position.
Date:
Tag No.
Legend OK
N/A Not Applicable
SE/S/135
tus
Remarks
Oct. Nov. Dec.
SE/S/135
tus
Remarks
Oct. Nov. Dec.
SE/S/135
tus
Remarks
Oct. Nov. Dec.
Equipment VERTICAL PUMPS Location
Tag No.
Maintenance Period & Sta
Check and inspect coupling
Check and inspect bearings, re-grease where necessary
Check pipe and connections for any leaks or cracks
Check for any corrosion of parts
Electrical
Visual inspection for cooling fan and air ways.
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment DOSING PUMP Location
Tag No.
Maintenance Period & St
Check and clean dosing pump NRVs for scaling
Check and correct all diaphragm stop valves
Check dosing head for any wear and crack condition
Electrical
Date:
Legend OK
N/A Not Applicable
rt No.
ract No. SE/S/135

ion

Remarks
Equipment BOOSTER PUMP SET Location
Tag No.
Check & inspect coupling.
Check all pipe connections for any sign of crack or leakage
Check all foundation fittings
Electrical
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment CHLORINE DRUM VALVE Location
Tag No.
Check and clean any deposits in the valve and pipe areas
Repaint any corroding parts
Replace gaskets and clean threaded areas
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment DIAPHRAM STOP VALVE Location
Tag No.
Check and clean any deposits in the valve spring area
Check for damage of diaphragm and replace as necessary
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment MAIN CONTROLLER VALVE Location
Tag No.
Check and clean any deposits in the valve spring areas
Replace seal rings and clean threaded areas
Electrical
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment SAFETY VALVE Location
Tag No.
Check for proper tension of spring and safety closing
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment PRE-CONTROLLER VALVE Location
Tag No.
Check for proper tension of spring and safety closing
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment VENTITATORS FAN V100 Location
Tag No.
Clean and replace the intake air filters and pre-filters as necessary
Clean and inspect wear and tear of V-belts and pulley alignments
Greasing of motor bearings
Clean and remove any leaks from duct connections
Check functioning of pressure indicators
Electrical
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Tag No.
Clean and replace the intake air filters and prefilters as necessary
Clean and inspect wear and tear of V-belts and pulley allignment
Check functioning of pressure indicators
Electrical
Check the motor for over heating & any abnormal sound.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Tag No.
Clean and inspect wear and tear of V-belts and pulley alignment
Electrical
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment ACID FEED PUMP Location
Tag No.
Check the peristaltic hose for any wear and tear
Electrical
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment CAUSTIC SODA FEED PUMP Location
Tag No.
Check the peristaltic hose for any wear and tear
Electrical
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment ELECTRIC HOIST Location
Tag No.
Maintenance Period & S
Check drive units screw joints, welding seams, buffers of carriage and end stop of monorail.
Electrical
1653/ TWI 756 Att. 30R5Rev.2 24 Nov. 2012 Page 727 of 793
Date:
Legend OK
N/A Not Applicable
rt No.
ract No. SE/S/135

ion

Remarks
Equipment VALVES (MOV) Location
Tag No.
Greasing all gears in motorized valves
Check and Inspect for damage to the diaphragm for the chemical valves
Check and clean any deposits in the valve insert areas
Lubricate all moving parts
All fasteners check for tightness
Electrical
Date:
Legend OK
N/A Not Applicable
rt No.
ract No. SE/S/135

ion

Remarks
Equipment PRESSURE INDICATOR GAUGES Location
Tag No.
Electrical
Visually inspect the gauge for physical condition.
Isolate and check functioning of pressure gauges
Check for alarm and cut off settings

Date:
Legend OK
N/A Not Applicable
rt No.
ract No. SE/S/135

ion

Remarks
Equipment EXTRACTION FAN Location
Tag No.
Clean and inspect wear and tear of V-belts and pulley alignment
Electrical
Date:
Legend OK
N/A Not Applicable
rt No.
ract No. SE/S/135

ion

Remarks
Equipment PREFILTER Location
Tag No.
Check and clean pre-filter frame and internals

Date:
Legend OK
N/A Not Applicable
rt No.
ract No. SE/S/135

ion

Remarks
Equipment GAS DETECTOR Location
Tag No.
Clean the controller.
Clean the sensors.
Check the terminations in sensors.
Check the terminations in the controller.
Switch On and put in operation.
Calibrate detector against gases in cylinders.
Replace batteries as necessary
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment VENTILATION FAN Location
Tag No.
Maintenance Period & St
Greasing of bearings
Electrical
Date:
Legend OK
N/A Not Applicable
rt No.
ract No. SE/S/135

ion

Remarks
Equipment PRE-FILTER Location
Tag No.
Check and clean pre-filter frame and internals

Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment RECYCLE PUMPS Location
Tag No.
Check and inspect flexible coupling
Check and inspect bearings, re-grease where necessary
Check pipe and connections for any leaks or cracks
Check for any corrosion of parts
Electrical
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment ELECTRICAL SWITCH BOARD Location
Tag No.
Clean the panel externally.
Clean the modules.
Check the indication bulbs.
Check all wiring & terminations.
Test the module and switch ON.
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment ELECTRICAL CONTROL-BOARD Location
Tag No.
Switch off the Power supply from MSB/MCC.
Clean the control panel.
Check the MCBs.
Check the push buttons.
Check the indication bulb.
Check the control relays.
Check the control wiring.
Check the pressure switch, limit switch,
Proximity switch etc., connections with the control panel.
Check the door and door locks
Put the panel into operation.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment AUXILLARY PANNEL Location
Tag No.
Maintenance Period & Stat
Clean the auxiliary panel.
Check the MCBs.
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment MIMIC PANEL Location
Tag No.
Clean the auxiliary panel.
Check the MCBs.
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Tag No.
Switch OFF the load connected to the circuit breaker, and de-energize.
Clean all parts of CB thoroughly by hand blower and soft brush.
Inspect all parts of the CB, visually and by hand checking.
Close the CB to check the wear of the contacts.

Check the condition of the arc-chute, make sure that the arc chute body is not broken and the separators are not
corroded.
Check the protection unit, display and adjustment of each parameters, reprogramme it if required.
Check the ammeter function of the protection unit for the parameters Ir, Tr, Im, I, In, th, and follow the
manufacturer procedures for readjusting them if required.
Store the correct parameter programmed and lock the settings
Insert the ACB-unit firmly in panel and check the following:
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment MOTOR Location
Tag No.
Switch OFF the motor

Inspect the surrounding area and check for any dripping of water, fumes, any unusual amount of dust over the motor
body.
Clean / check the external cooling fan its proper fixation.
Open the terminal box and check the interior area and the walls, clean and blow of any residues as follows :
Clean the inner sides by soft brush

Check the insulation resistance of the motor windings with 500 Volt Megger and compare the resistance values with
the manufacturer specification.
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment VALVE ACTUATORS Location
Tag No.
Switch off the Power supply.
Clean the Actuators.
Switch On the Power supply.
Check the local operations.
Check the remote operations.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Equipment LIGHTING Location
Tag No.
Check all lighting switches.
Check all light fittings.
Check the socket outlet.
Check all junction boxes.
Check all exhaust fans.
Check the terminations in socket outlet.
Check the terminations in junction boxes.
Check the terminations in the light fittings.
Check the light fitting control gear.
Check the earthing of light fittings
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment PH Measuring Electrode Location
Tag No.
Disconnect and remove the sensor.
Clean the sensor with distilled water.
Clean the membrane head of the electrode.
Check the supports of the sensors.
Connect the sensor with the analyzer.
Calibrate pH sensor against buffer solutions
Wait for the sensor reading to stabilize
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment RH MEASURING ELECTRODE Location
Tag No.
Clean the analyzer unit.
Disconnect and remove the sensor.
Clean the sensor with distilled water.
Clean the membrane head of the electrode.
Check the supports of the sensors.
Connect the sensor with the analyzer.
Calibrate rH sensor against multimeter settings
Wait for the sensor reading to stabilize.
Date:
Legend OK
N/A Not Applicable
rt No.
ract No. SE/S/135

ion

Remarks
Equipment CHLORINE GAS ANALYSER Location
Tag No.
Clean the controller.
Clean the sensors.
Check the terminations in sensors.
Check the terminations in the controller.
Top up with the KI solution prepared in Laboratory.
Calibrate detector against gases in cylinders.
Date:
Legend OK
N/A Not Applicable
rt No.
ract No. SE/S/135

ion

Remarks
Equipment CHLORINE CYLINDER WEIGHING SYSTEM Location
Tag No.
Clean the display unit.
Clean the load cell.
Check the fixing of the load cells.
Calibrate dial readings based on test weights
Date:
Legend OK
N/A Not Applicable
o. SE/S/135
Period & Status

Remarks
Equipment ELECTRICAL SWITCHBOARD Location
Tag No.
Clean the panel externally.
Clean the modules.
Check the indication bulbs.
Check all wiring & terminations.
Test the module and switch ON.
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.
Tag No.
Switch OFF the load connected to the circuit breaker, and de-energize it.
Clean all part of CB thoroughly by hand blower and soft brush.
Inspect all part of the CB, visually and by hand checking.
Close the CB to check the wear of the contacts.

Check the condition of the arc-chute, make sure that the arc chute body is not broken and the separators are
not corroded.
Check the protection unit, display and adjustment of each parameters, reprogramme it if required.
Check the ammeter function of the protection unit for the parameters Ir, Tr, Im, I, In, th, and follow the
manufacturer procedures for readjusting them if required.
Store the correct parameter programmed and lock the settings
Insert the ACB-unit firmly in panel and check the following:
Date:
Legend OK
N/A Not Applicable
SE/S/135
& Status
Remarks
Sep. Oct. Nov. Dec.

Maintenance Program For Equipments

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Maintenance Program For Equipments

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KHARAFI NATIONAL MONTHLY MAINTENANCE REPORT

Client Ministry of Public Works (MPW) Report No.

Grease all bearings.

Check for any blockages in vent and drain lines.

Check pump & motor alignment.

Check all fasteners and tightness of mounting and integrity of supports.

Visually inspect the motor for physical condition.

Visual inspection for cooling fan and coating ducts.

1653/ TWI 756 Att.30A Rev.2 24 Nov. 2012 Page 1 of 793

Checked by: Signature

1653/ TWI 756 Att.30A Rev.2 24 Nov. 2012 Page 2 of 793

1653/ TWI 756 Att.30A Rev.2 24 Nov. 2012 Page 3 of 793

1653/ TWI 756 Att.30A Rev.2 24 Nov. 2012 Page 4 of 793

Grease all bearings.

Check for any blockages in vent and drain lines.

Check pump & motor alignment.

Check all fasteners and tightness of mounting and integrity of supports.

Visually inspect the motor for physical condition.

Visual inspection for cooling fan and coating ducts.

Checked by: Signature

Grease all bearings.

Check for any blockages in vent and drain lines.

Check pump & motor alignment.

Check all fasteners and tightness of mounting and integrity of supports.

Visually inspect the motor for physical condition.

Visual inspection for cooling fan and coating ducts.

Checked by: Signature

Check for any contamination of grease by moisture

Visually inspect the motor for physical condition.

Visual inspection for cooling fan and coating ducts.

Performed by: Signature

Checked by: Signature

Grease all bearings.

Check for any blockages in vent and drain lines.

Check pump & motor alignment.

Check all fasteners and tightness of mounting and integrity of supports.

Visually inspect the motor for physical condition.

Visual inspection for cooling fan and coating ducts.

Checked by: Signature

Grease all bearings.

Check for any blockages in vent and drain lines.

Check pump & motor alignment.

Check all fasteners and tightness of mounting and integrity of supports.

Visually inspect the motor for physical condition.

Visual inspection for cooling fan and coating ducts.

Checked by: Signature

Grease all bearings.

Check for any blockages in vent and drain lines.

Check pump & motor alignment.

Check all fasteners and tightness of mounting and integrity of supports.

Performed by: Signature

Checked by: Signature

Check for any external leaks

Visual inspection of smoothness of operation.

Performed by: Signature

Checked by: Signature

Check for any external leaks

Visual inspection of smoothness of operation.

Performed by: Signature

Checked by: Signature

Check for any joint leaks

Check the ampere for normal motor operation

Check terminal connections at the panel and retighten