1305M2Q0025_-_Example_Service_Checklists.pdf

NOAA Disaster Response Center: Annual Generator Transfer Switch Maintenance Checklist

NOAA Disaster Response Center

7344 Zeigler Blvd Mobile, AL 36608

Annual Generator Transfer Switch Maintenance Checklist

Unit name: _______________________ Date:_________________

_____ Disconnect power from both the generator source and utility source and ensure these sources are locked out and tagged for safety

_____ Vacuum and clean the switch cabinet to remove all dirt and debris from the enclosure

_____ Thoroughly clean the transfer switch, taking care to prevent liquid form entering external switches or the interior of the cabinet

_____ Inspect the switch for carbon tracking, cracks, corrosion, or any other type of deterioration.

Note any problems

_____ Covers of the contact mechanisms shall be removed and the contacts shall be inspected for abnormal wear or degradation. Note any problems

_____ After the transfer switch is cleaned and reassembled, all the power and control connections shall be checked for deterioration and re-torqued according to manufacturer’s specifications. In particular, check for wear on wiring which goes across doors and any wiring which is connected to a moving part

_____ When maintenance is completed, a full power failure test shall be completed

_____ The power supply to the facility shall be physically opened, so that the generator set and power transfer system must function exactly as in a real power failure situation

_____ Verify that the generator can start and run the connected loads

Notes:

Inspection completed by: ___________________________________________________

NOAA Disaster Response Center: Monthly Generator Transfer Switch Maintenance Checklist

Monthly Generator Transfer Switch Maintenance Checklist

_____ Test can be initiated by either manual operation or automatic time clock

_____ Transfer switch shall signal the generator set to start, monitor the generator as it starts, and transfer load to the generator set

_____ When the test is complete, the transfer switch shall transfer load back to the normal service and shut down the generator set after a cool-down period

_____ Test shall verify that the generator set will start and carry load and verify the ability of the transfer switch to detect a power failure and mechanically connect to the alternate power source

NOAA Disaster Response Center: Quarterly Avtron Load Bank Maintenance Checklist

Quarterly Avtron Load Bank Maintenance Checklist

_____ Remove any restrictions to the airflow through the Load Bank

_____ Check the screens to make sure that no objects have blocked or entered the openings

_____ Verify that the airflow is in the proper direction

_____ Assure that there is no recirculation of the exhaust air through the Load Bank

_____ Verify that all heaters and temperature switches are functional

_____ Remove the access panels and screens, and inspect the load resistors for mechanical breakdown which is demonstrated by excessive sagging of the elements. Note need for replacement of resistor elements.

_____ Inspect for broken ceramic insulators. Note the need for replacement ceramic insulators.

_____ Inspect for loose hardware or connections. Tighten where required.

_____ Inspect all connections for oxidation or corrosion. Clean the connection or note the need to replace hardware where required.

_____ Verify that the airflow switch works properly.

_____ Inspect all magnetic contactors to make sure that the contacts are not severely pitted or corroded. The contacts must move freely and be properly seated. Note any discrepancies.

_____ Clean all dirt and debris out of the Load Bank. This can be accomplished by blowing the inside of the units with clean, dry compressed air (not to exceed 40 psi). Eye protection should be worn when cleaning the Load Bank with compressed air.

_____ Inspect all the wiring for any sign of insulation failure. Note any issues.

_____ Replace all access panels and screens. Tighten all the fastening hardware securely.

_____ Check the indicator lamps on the control panel to ensure they are working properly.

NOAA Disaster Response Center: Quarterly Avtron Load Bank Maintenance Checklist

NOAA Disaster Response Center: Annual Avtron Load Bank Maintenance Checklist

Annual Avtron Load Bank Maintenance Checklist

_____ Lubricate the fan/blower motor per the motor manufacturer’s requirements and specifications on the motor nameplate, if applicable.

NOAA Disaster Response Center: Annual Cutler-Hammer Panelboard Maintenance Checklist

Annual Cutler-Hammer Panelboards Maintenance Checklist

_____ Clean out any accumulation of dust/dirt from the panelboard

_____ Visually inspect electrical joints and terminals in the bus and wiring system. Adjust/tighten as necessary. Note any needed repairs.

_____ Visually inspect all conductors and connections. Clean and adjust as necessary. Parts which show evidence of overheating or looseness shall be cleaned and re-torqued as necessary. Ensure all nuts and bolts are tightened at bus joints to manufacturer’s specifications. Note any needed repairs.

_____ Examine fuse clip contact pressure and contact means. Note needed repairs for any fuse clips that show signs of overheating.

_____ Re-lighten plug fuses.

_____ Check circuit breakers, switches and fusts to ensure they have the proper ampere, voltage and interrupting ratings. Adjust as necessary. Note any needed repairs.

_____ Operate each switch or circuit breaker several times to ensure that all mechanisms are free and in proper working order. Note any needed repairs.

_____ Check the operation of all mechanical components and note any needed repairs.

_____ Exercise switch operating mechanisms and external operators for circuit breakers to determine that they operate freely to their full on and off positions. Adjust as necessary and note any needed repairs.

_____ Check the integrity of all electrical and mechanical interlocks and padlocking mechanisms.

Adjust as necessary and note any needed repairs.

_____ Check devices for missing or broken parts, proper spring tension, free movement, corrosion, dirt, and excessive wear. Adjust as necessary and note any needed repairs.

_____ Clean and dress readily accessible copper electrical contacts, blades, and jaws according to the manufacturer’s instructions when inspection indicates the need.

_____ Look for and note any moisture or signs of previous wetness or dripping inside the cabinet.

NOAA Disaster Response Center: Annual Cutler-Hammer Panelboard Maintenance Checklist

_____ Seal off any conduits which have dripped condensate, and provide means for further condensate to drain away from the panelboard if required.

_____ Seal off any cracks or openings which have allowed moisture to enter the enclosure. Eliminate the sources of dripping on the enclosure and any other source of moisture, if needed.

_____ Thoroughly dry and clean any insulating material which is wet or damp or shows an accumulation of deposited material from previous water intrusion. Note if replacement is needed.

_____ Inspect all component devices for moisture damage. Note findings.

_____ Test the ground fault protection system in accordance with the manufacturer’s instructions and note findings.

_____ Check insulation resistance if any of the following have occurred: sever short circuit, replacement or cleaning of insulating surfaces, panelboard has been exposed to high humidity, condensation or dripping moisture.

NOAA Disaster Response Center: Semi-annual Eaton Dry-type Distribution Transformer Maintenance Checklist

Semi-annual Eaton Dry-Type Distribution Transformer Maintenance Checklist

_____ Clean terminations and vents.

_____ Inspect insulators, terminals, terminal boards for tracking (discharge)/breaks/cracks or burns.

Clean as needed and note any necessary repairs.

_____ Check terminal quality and connections, including taps for tightness. Adjust as needed and note any necessary replacements.

_____ Inspect ground connections and ground contact surfaces. Adjust as needed and note any necessary repairs.

_____ Check for moisture impacts.

_____ Inspect paint finish for scratches, wear and corrosion. Note any needed repairs.

NOAA Disaster Response Center: Monthly Generator Set Maintenance Checklist

Monthly Generator Set Maintenance Checklist

_____ Exercise generator for 30 minutes at 30% load rating.

_____ Check generator for oil, fuel, cooling, and exhaust system leaks and note any issues.

_____ With the generator set operating, inspect the entire exhaust system visually and audibly including the exhaust manifold, muffler, and exhaust pipe. Note any issues.

_____ Check for leaks in the exhaust system at all connections, welds, gaskets, and joints and make sure that exhaust pipes are not heating surrounding areas excessively. Document and report any suspected leaks immediately.

_____ Check engine oil, coolant, and battery electrolyte levels. Replenish fluids as necessary.

_____ With the generator set operating, inspect the fuel supply lines, return lines, filters, and fittings for leaks. Check any flexible sections for cuts, cracks, or abrasions and make sure they are not rubbing against anything that could cause breakage. Note and report all leaks immediately.

_____ Check and document the following while the generators are operating:

Frequency __________________

AC voltage at no load ________________

AC Ammeter with no load ___________________

_____ Check that all panel lamps are illuminating. Note any issues.

_____ Check the terminals on the batteries and ensure all connections are clean and tight. Check and tighten battery vent plugs as necessary.

_____ Use a battery hygrometer to check the specific gravity of the electrolyte in each battery cell.

Note any battery readings that aren’t between 1.215 – 1.260. Check the electrolyte levels and fill as necessary.

_____ Check generator air outlet and remove any debris or obstructions. Note and report any discoloration or signs of excessive heat.

NOAA Disaster Response Center: Monthly Generator Set Maintenance Checklist

_____ Inspect the coolant heaters. Note and report any discrepancies.

_____ Inspect the battery charging system. Note and report any discrepancies.

_____ With the generator set stopped after testing, check for loose belts, fittings, leaking gaskets or hoses or any other signs of mechanical damage. Document and report any problems immediately.

NOAA Disaster Response Center: Semi-annual Generator Set Maintenance Checklist

Semi-annual Generator Set Maintenance Checklist

_____ Inspect drive belts and air cleaners. Document and report any problems that should be addressed.

_____ Inspect radiator hoses for wear and cracks. Document and report any problems that should be addressed.