Maintenance and Inspection System Checklist

Customer Name: Date:

Site Name:

System Model:

Hypochlorite Generator Rack/Skid Yes No N/A

Check for any leaks. ☐ ☐ ☐
Check cartridge filter at the rack and advise if replacement is needed. ☐ ☐ ☐
Check Gem Sensors for free movement. ☐ ☐ ☐
Verify flow rate on flow meters’ match HMI reading. ☐ ☐ ☐
Check all 3 flow meters for proper operation and no broken rods. ☐ ☐ ☐
Check cell straps are not too tight. ☐ ☐ ☐
Verify drain paddle switch does not stick. ☐ ☐ ☐
Verify operation of the pressure gauge. ☐ ☐ ☐
Verify free movement of discharge ball valves. ☐ ☐ ☐

Electrolytic Cell and Electrode Yes No N/A

Observe status of the electrode; is there bridging or is the electrode clean. ☐ ☐ ☒
If the electrode is dirty, acid washes the system, check customer’s maintenance log to see when ☐ ☐ ☐
last acid wash or cleaning was done.
Are there loose pieces of hardware in the bottom of the electrode? ☐ ☐ ☐
Verify there are no warped plates. ☐ ☐ ☐
Remove cable clamps from buss bar and verify buss bar is coated with paste and tight. ☐ ☐ ☐
Re-attach cable clamps to buss bar and tighten to 50 ft. lbs. And coated with the paste. ☐ ☐ ☐
Verify clam shell clamps are tightened to 50 ft. lbs. And coated with the paste. ☐ ☐ ☐
Verify level switch is not full of water and float operates correctly. ☐ ☐ ☐
Verify there are no leaks from temperature switch orifice or level switch orifice. ☐ ☐ ☐
Verify all wires are attached properly and not shorted together. ☐ ☐ ☐
Measure voltage of each cell to be sure that they are fairly equal to each other. ☐ ☐ ☐

Rectifier Yes No N/A

Verify lugs have paste and are tightened to 50 ft lbs. ☐ ☐ ☐
Check overall system for corrosion and any water drip marks. ☐ ☐ ☐
Verify the E-Stop switch operates with your meter. ☐ ☐ ☐
Verify rectifier is clean on the inside. ☐ ☐ ☐
Observe for loose wires or broken wires. ☐ ☐ ☐
While the system is running verify voltage between positive and negative bus is what is reading ☐ ☐ ☐
at voltage meter on the rectifier and at the cells and all match what is being shown on HMI.
While the system is running, verify current on cables is what is reading at amperage meter on the ☐ ☐ ☐
rectifier and at the cells and all match what is being shown on HMI.
Verify cables to SCR fuses are tight to 40 ft. lbs. ☐ ☐ ☐

Control Panel Yes No N/A

Inspect all wires for burn marks and loose connections. ☐ ☐ ☐
If there is a UPS present, check battery voltage both under load and stand alone. ☐ ☐ ☐
Verify UPS operation by turning off the main power. ☐ ☐ ☐
Verify voltage at 24VDC power supply is correct. ☐ ☐ ☐
Look for any arc marks around the bases of the control relays. ☐ ☐ ☐
Look for any arcing on the covers of the control relays. ☐ ☐ ☐
Verify all fuses are properly seated and there are no arc marks. ☐ ☐ ☐
Verify no wires are jumped out or bypassed, each one should be in its own terminal. ☐ ☐ ☐
 Maintenance and Inspection System Checklist
With a hand held vacuum cleaner clean the control panel. ☐ ☐ ☐
Verify there are no metal shavings anywhere in the panel. ☐ ☐ ☐
Determine the age of PLC battery and suggest a change if more than 2 years old. ☐ ☐ ☐
Verify HMI screen saver is working to prevent burn in. ☐ ☐ ☐
If fans are present clean filters, if filters are not present, note on report and have customer get ☐ ☐ ☐
new ones

Water Softener and Concentration Yes No N/A

Measure water hardness before water softener. ☐ ☐ ☐
Measure water hardness after the water softener. ☐ ☐ ☐
Check cartridge filter at softener and advise if replacement is needed. ☐ ☐ ☐
Check customer’s maintenance log to see when last hardness test was done. ☐ ☐ ☐
While the system is running, obtain a sample of hypo and check the temperature. ☐ ☐ ☐
Check customer’s maintenance log to see when last hypo temperature was recorded. ☐ ☐ ☐
While the system is running, obtain a sample of hypo and check concentration. ☐ ☐ ☐
Check customer’s maintenance log to see when last hypo concentration was recorded ☐ ☐ ☐
.

Notes, recommendations, or comments:

Technician:
Maintenance and Inspection System Checklist
 At the workshop
Mean

Preventive
Corrective
System Number of Tools and Associated

Routine

On-site
Detailed description of the Detailed description of allocated Qualifications
Frequency operators equipment consumables and
Component maintenance reason for maintenance
required
time per required
required spare parts
operator

Prevent fouling of VR inlet Every cylinder Basic mechanical Hand tools and
1 X x Change inlet gas filter. 1 5 minutes Filter floss.
valve and venting. change. skills. PPE.
Replacement inlet
Annually or
Change out inlet valve VR will vent gas when inlet Basic mechanical Hand tools and capsule assembly
Vacuum 2 X X when VR is 1 15 minutes
capsule. valve is dirty. skills. PPE. or inlet valve PM
Regulator venting.
Kit.
Chlorinator service Hand tools and
3 X X Rebuild VR body. Preventive maintenance. Annually. 1 2 hours VR body PM Kit.
training. fixture kit.
4
5
Exercise vacuum switchover
1 X X Preventative maintenance. Weekly. 1 10 minutes System Operator. None. None.
module.
Chlorinator service Hand tools and Switchover
2 X X Rebuild switchover module. Preventative maintenance. Annually. 1 1 hour
Switchover training. PPE. module PM Kit.
Module 3
4
5
Hand tools,
Can not read float position Annually or as Basic mechanical cotton swabs,
1 X X Clean flowmeter glass. 1 30 minutes Meter gaskets.
or float stuck in tube. needed. skills. small bottle
brush, PPE.
Basic mechanical Hand tools and Flowmeter PM
Flowmeter 2 X X Rebuild meter panel. Preventative maintenance. Annually. 1 30 minutes
skills. PPE. Kit.
3
4
5
Chlorinator service Hand tools and Auto valve PM
1 X X Rebuild auto valve wet end. Preventative maintenance. Annually. 1 1 hour
training. PPE. Kit.
Hand tools,
Chlorinator and
Recalibrate valve after multimeter,
2 X X Assure proper operation. Annually. 1 2 hours instrument service None.
rebuild. signal
Control Valve training.
generator.
3
4
5

As indicated on
Replace cathodic protection Maintain operation of the Chlorinator service Hand tools and Replacement
1 X X the vaporizer 1 2 hours
anodes. cathodic protection circuit. training. PPE. anodes.
controller.
 Hoist, steam
Steam clean vaporizer cleaner, hand
Vaporizer chamber clean- Annually or on Chlorinator service
2 X X chamber of impurities to 1 2 days tools, PPE, Vaporizer PM Kit.
out. low superheat. training.
Vaporizer restore proper heat transfer. nitrogen or dry
air
Rebuild pressure reducing Chlorinator service Hand tools and Pressure reducing
3 X X Preventative maintenance. Annually. 1 2 hours
valve. training. PPE. valve PM Kit.
Replace filter elements in Annually or as Basic mechanical Hand tools and
4 X X Preventative maintenance. 1 2 hours Gas filter PM Kit.
gas filter. needed. skills. PPE.
5
Replace check valve seat, o- When water backs up into Annually or as Chlorinator service Hand tools and
1 X X 1 30 minutes Ejector PM Kit.
ring, diaphragm. the gas feeder. needed. training. PPE.
Chlorinator service Hand tools and
2 X X Rebuild ejector-check valve. Preventative maintenance. Annually. 1 1 hour Ejector PM Kit.
training. PPE.
Ejector
3
4
5

Hand tools,
Can not read float position Annually or as Basic mechanical cotton swabs,
1 X X Clean flowmeter glass. 1 30 minutes Meter gaskets.
or float stuck in tube. needed. skills. small bottle
brush, PPE.
Basic mechanical Hand tools and Flowmeter PM
2 X X Rebuild meter panel. Preventative maintenance. Annually. 1 30 minutes
skills. PPE. Kit.
Gas Feed Wall Chlorinator service Hand tools and Auto valve PM
3 X X Rebuild auto valve wet end. Preventative maintenance. Annually. 1 1 hour
Panels training. PPE. Kit.
Hand tools,
Chlorinator and
Recalibrate valve after multimeter,
4 X X Assure proper operation. Annually. 1 2 hours instrument service None.
rebuild. signal
training.
generator.
Differential
Rebuild differential pressure Chlorinator service Hand tools and
5 X X Preventative maintenance. Annually. 1 2 hours pressure
regulator. training. PPE.
regulator PM Kit.
Replace kinked or damaged Cylinder valve Lead gaskets, flex
1 X X Prevent a chlorine gas leak. As needed. 1 1 hour System Operator.
flexible connectors. wrench. connectors.
As
recommended Cylinder valve Lead gaskets, flex
2 X X Replace flexible connectors. Preventative maintenance. 1 1 hour System Operator.
by wrench. connectors.
Manifolds and manufacturer.
Flexible Check drip leg heaters for
Prevent chlorine liquid from Basic mechanical Hand tools and Replacement
3 X X proper operation, replace as Daily. 1 5 minutes
Connectors entering the gas feeder. skills. PPE. heater.
necessary.
Check gas filter in wall and
Prevent fouling of VR inlet Quarterly or as Basic mechanical Hand tools and Replacement filter
4 X X ton manifold, replace as 1 1 hour
valve and venting. needed. skills. PPE. and lead gasket.
needed.
5
Hand tools,
Can not read float position Annually or as Basic mechanical cotton swabs,
1 X X Clean flowmeter glass. 1 30 minutes Meter gaskets.
or float stuck in tube. needed. skills. small bottle
brush, PPE.
 Basic mechanical Hand tools and Flowmeter PM
2 x X Rebuild meter panel. Preventative maintenance. Annually. 1 30 minutes
skills. PPE. Kit.
Chlorinator service Hand tools and Auto valve PM
Gas Feed 3 X X Rebuild auto valve wet end. Preventative maintenance. Annually. 1 1 hour
training. PPE. Kit.
Cabinets Hand tools,
Chlorinator and
Recalibrate valve after multimeter,
4 X X Assure proper operation. Annually. 1 2 hours instrument service None.
rebuild. signal
training.
generator.
Differential
Rebuild differential pressure Chlorinator service Hand tools and
5 X X Preventative maintenance. Annually. 1 2 hours pressure
regulator. training. PPE.
regulator PM Kit.
Chlorinator and
Amperometric type, rebuild Hand tools and
1 X X Preventative maintenance. Annually. 1 2 hours instrument service Analyzer PM Kit.
cell. PPE.
training.
Chlorinator and
Probe type, replace Hand tools and Replacement
2 X X Preventative maintenance. Quarterly. 1 30 minutes instrument service
electrolyte in probe. PPE. electrolyte.
training.
Chlorine Chlorinator and
Probe type, replace Hand tools and Replacement
Residual 3 X X Preventative maintenance. Annually. 1 30 minutes instrument service
membrane cap. PPE. membrane.
training.
Analyser Chlorinator and
DPD type, replace black Hand tools and DPD analyzer PM
4 X X Preventative maintenance. Quarterly. 1 1 hour instrument service
pump tubes. PPE. Kit.
training.
Chlorinator and
Hand tools and DPD analyzer PM
5 X X DPD type, replace all tubing. Preventative maintenance. Annually. 1 1 hour instrument service
PPE. Kit.
training.
Chlorinator and Titator or DPD
6 X X All types, calibration check. Assure proper operation. Weekly. 1 1 hour instrument service residual test None.
training. kit.
Chlorine
Basic mechanical
1 X X Test sensor. Assure proper operation. Monthly. 1 30 minutes Sensor test kit. bleach/powder
skills.
and weak acid.
Chlorinator and
Chlorine Gas Hand tools and
2 X X Calibrate sensor. Preventative maintenance. Annually. 1 1 hour instrument service None.
Detector training.
PPE.
Chlorinator and
Hand tools and Replacement
3 X X Replace sensor element. Preventative maintenance. 2 years. 1 1 hour instrument service
PPE. sensor element.
training.
4
5
Wet or dry type, operate Hand tools and
1 X X Assure proper operation. Monthly. 1 15 minutes System Operator. None.
scrubber for 15 minutes. PPE.
Neutralization Wet type, test caustic Lab and
2 X X Preventative maintenance. Monthly. 1 30 minutes Chemist. None.
System concentration. titrator.
Wet or dry type, pump and Basic mechanical Hand tools and
3 X X Preventative maintenance. Annually. 1 2 hours As required.
blower maintenance. skills. PPE.