Industrial and commercial establishment checklist

Commercial facilities usually consume a significant amount of electricity on a regular basis.

Some of these places need their own power supply plants and dedicated electrical equipment maintenance
teams.
Nevertheless, even the most organized commercial establishment can benefit from a checklist that includes
some crucial and sometimes overlooked maintenance pointers.

These are:

 Check all power meters for regular function before shutting them down for maintenance.
 Confirm that indicators, sensors, and warning lights are functioning correctly.
 Torque test and inspect bolted electrical connections to specified levels whenever needed.
 Visually inspect primary control points for signs of deterioration and overheating.
 Disassemble battery tripping packs and check for signs of general battery integrity and any signs of
corrosion or heat damage.
 Perform thermal imaging surveys using precise thermography equipment.
 Check for signs of persistent overheating and single out specific areas for repair or part replacement.
 Inspect motor control circuits and check for appropriate overcurrent protection.
 Confirm that all motor disconnects are close to the motors and are easily accessible for maintenance.
 Check if multi-unit conductors are properly supplying to all connected units and if they are rated for
their connections.
 Verify that ground-fault and feeder short-circuit protection is sized according to the specific
application.
 Confirm if the transformers rated at over 1,000 volts have adequate overcurrent protection (install
protection if necessary)
 Inspect transformers for any failsafe elements or means of disconnecting immediately.
 Conduct a detailed survey of all machinery and moving systems (elevators, dumbwaiters, and platform
lifts), check for proper wiring, and ensure correct voltage supply.
Furthermore, make sure all room circuits are rated for the number of machines and other electric equipment they
are connected to.

While such programs involve a huge variety of maintenance tasks, there are some basic procedures that every
program includes.
These are:

 Regular inspections of all living areas including bedrooms, kitchens, lounges, hallways, and bathrooms.
 Close examination of inlets, circuit breakers, panelboards, and electrical distribution systems.
 Detailed surveys of residential feeders and various service equipment.
 Inspections and repair of commercial transformers, capacitors, and wiring manifolds.
 Checking indoor and outdoor lighting, relays, and control panels.
 Monitoring of running electrical systems in Class I, II, and III hazardous locations.
  Initial and finished surveys of special occupancy units.
Additionally, this includes checking for all major and minor signs of electrical malfunction such as short
circuits, loose connections, visible burning and arcing, and small (serial) explosions.
All electrical equipment -- motors, transformers, circuit breakers, controls and should be a thorough
inspection and evaluation.
• Determining physical condition, the survey should determine if the equipment is operating within its
rating.
• In the course of the survey, it is imperative that the condition of electrical protective devices be
checked. Such devices include fuses, circuit breakers, protective relays, and motor overload relays.
• These devices are the safety valves of an electrical system. They should be in proper operating
condition to ensure safety of personnel, protection of equipment, and reduction of economic loss.

Class I
Areas in which flammable gases or vapors may be present in the air insufficient quantities to be explosive.
Group A: Atmospheres containing acetylene.
Group B: Atmospheres such as butadiene, ethylene oxide, propylene oxide, acrolein, or hydrogen ( or gases or
vapors equivalent in hazard to hydrogen such as manufactured gas).
Group C: Atmospheres such as cyclopropane, ethyl ether, or gases or vapor of equivalent hazard.
Group D: Atmospheres such as acetone, alcohol, ammonia, benzene, benzol, butane, gasoline, hexane, lacquer
solvent vapors, naphtha, natural gas, propane, or gas or vapor of equivalent hazard.

Class II
Areas made hazardous by the presence of combustible dust.
Group E: Atmospheres containing combustible metals: aluminum, magnesium, titanium, zinc, bronze,
chromium, tin, cadmium.
Group F: Coal, charcoal, carbon black
Group G: Atmospheres containing combustible alfalfa, cocoa, coffee, corn, cornstarch, malt, rice, sugar, wheat,
cellulose acetate.

Class III
Areas made hazardous by the presence of easily ignitable fibres or flyings, but which are not likely to be in
suspension in the air in quantities that are sufficient to ignite.
Division 1 & 2: Cotton lint, flax, rayon.

Electrical Installation Testing Procedures

in Electrical Testing, Safety

Electrical Testing Procedures

Electrical products are an essential part of modern living. Without these innovative (and sometimes lifesaving)
products life would be very different. However, electricity is also unpredictable and without regular and
rigorous testing can be incredibly dangerous. Check out our Testing Procedures below

That’s why there’s so much legislation in place when it comes to working with electricity. So, to ensure that
your electrical installations are safe you need to work with certified experts. Not only will this keep you within
the boundaries of the law, but it will also provide a much-needed layer of safety. Naturally, you will want to
understand the test procedures that these experts will use, so let’s take a closer look at them.

How Do You Test Electrical Installations?

Electrical circuits are complex and technical networks which require specialist training to understand and test.
Two main tests are required to ensure that electrical products are safe:

 New Installation Testing:

All new electrical installations need to go through an initial testing procedure to be verified as safe to use. This
test, which can only be performed by a qualified and competent electrician, evaluates the electrical installation.
Factors such as the earthing arrangements, types of conductors, supply parameters and safety devices are all
evaluated and documented.

 Periodic Inspection Testing:

Existing electrical installations must, by law, be periodically inspected by an electrician to ensure
that they are safe. These periodic inspections include both a visual and electrical inspection. The
results of these tests should highlight any faults or hazards which either require attention or fail to
comply with existing BS7671 standards.

The most common electrical testing procedures:

 Protective Conductor Continuity:
It’s crucial that every protective conductor in a circuit meets current electrical standards. They also
need to be correctly connected in order to remain safe. An electrician will carry out this test on all
accessible and exposed conductors using an insulation tester.

 Circuit Breaker Functionality:

All circuit breakers, RCDs and isolators need to be thoroughly tested to confirm that they can
disconnect an electrical supply if necessary. An electrician will need to confirm the effectiveness
of these devices and verify that they are correctly maintained and labelled.

 Ring Circuit Testing:

Every ring circuit must be tested in order to confirm the continuity of each conductor in the circuit.
This procedure is completed using a continuity tester to determine whether the ring circuit is
complete. This test, however, is not considered crucial if previous test records are available. If
changes have been made to the circuit, though, it becomes essential that this test is completed.

 Polarity Testing:
Verifying the polarity of all circuits is an important procedure when it comes to testing electrical
installations. The polarity must be measured at the point of installation, all accessible socket
outlets, distribution boards and before any connection to the power supply. The best way to
complete this test is by working with either a continuity tester or multi tester.

They may include:

o Check all power meters for functionality before shutting down
o Visually inspect primary controls for deterioration and overheating
o Conduct a general survey of electrical connections in all habituated areas of residential facilities
o Clean thoroughly, vacuum and visually inspect exterior and interior low voltage switchboards,
circuit breakers, inlets, panel boards, electric distribution systems for wear and tear
o Check locking devices on electrical units for signs of damage or wear
o Examine boxes for warning lights and other indicators
 o Confirm that indicators, lamps, sensors, and warning lights are functioning correctly
o Check that all labels are correct and in place
o Inspect and repair capacitors, transformers, and wiring manifolds
o Examine all outdoor and indoor lighting and relays for signs of wear and/or dimming
o Continuously monitor electrical systems residing in hazardous locations
o Check for malfunctions like loose connections, short circuits, signs of burning and small
explosions
o Look over cable assemblies in combination with other wiring methods and installations
o Ensure grounding conductors are working properly with installed equipment
o Inspect lighting outlets and make sure they are correctly wired on specified circuits
o Inspect countertop, wall floor and ceiling receptacle proximity and spacing in relation to cold, heat
and water
o Survey branch circuit types for all applicable receptacle outlets
o Identify and mend any frayed wires
o Investigate irregular wiring arrangements
o Inspect grounding electrode conductor connections including buried connections for heat damage
and suitable placement
o Examine and repair surge protection units
o Inspect timers, power supply units, fuse carriers, relays and control wiring for humidity or
temperature damage, as well as regular wear
o Detect signs of electrical disturbance as an indicator of shorts and sparking
o Ensure proper voltage in all rooms and areas of electrical usage
o Torque test and inspect bolted electrical connections to specified levels
o Disassemble battery tripping packs and check for signs of battery integrity, as well as corrosion or
damage
o Perform thermal imaging surveys where necessary
o Check for signs of persistent overheating and determine specific areas for repair or replacement
o Inspect all control circuits and check for overcurrent protection
o Confirm that all motor disconnects are close to the motors and are easily accessible
o Check if multi-unit conductors are properly supplying all units and if they are correctly rated
o Verify that ground-fault and feeder short-circuit protection is sized according to the specific
application
o Confirm transformers have adequate overcurrent protection and/or install protection if necessary
o Inspect transformers for failsafes or means of disconnecting immediately
o Conduct a detailed survey of all machinery and moving systems including proper wiring, and
correct voltage supply
o Make sure all room circuits are rated for the number of machines and other electric equipment they
are connected to
o Ensure proper insulation along panel boards and outlets
o Ensure the number of receptacles are in compliance for special occupancy facilities including
hospitals and patient-care areas
o Check to see if power sources and feeder capacities are adequate and review the load calculations
for essential systems
o Inspect supply routes to critical life-support systems and perform detailed checks on dedicated
backup generators
o Inspect, repair, and/or replace supply lines for alternate power sources
o Identify load imbalances and isolate the source of extra consumption
o Relocate excess power consumers and balance supply as needed
o Check all air circuit breakers (ACBs) for continued integrity of all mechanical and electrical
components
o Visual inspection of all busbar and accessories
o Check meter voltage connections, current transformer connections and modbus connections
o Check all components of molded case circuit breakers
o Examine all power distribution units (PDUs) for functioning, control circuit fuse rating, etc.
o Ensure the “all clear” after work is completed, but before fitting covers
o Conduct a final visual inspection of panels, boxes and other major system components after
maintenance work is completed

Here are 4 reasons why your commercial building needs preventive maintenance:
1. 77% of equipment breakdowns can be reduced by implementing a preventative maintenance program.
2. The Institute of Electrical and Electronics Engineers report that the failure of electrical components is
three times higher for systems without preventative maintenance programs.
3. An effective electrical preventative maintenance program will help to avoid the extra expense that
disruptions and lost profit that can cause.
4. On average a small electrical failure could cause a minimum of six hours of interruption
With preventive maintenance, there is no ‘one size fits all’ approach; programs must be custom designed to fit
the characteristics of the facility and vulnerability of the business. You therefore should take the following
considerations into account:
 Type of business
 Redundancy in production
 Sensitivity to disruptions (customers)
 Business interruption costs
 Potential loss of good will
 Spoilage of product (consequential)
 Age of equipment
 Changes in system loads over the years (design and expansion)
 Type of loads (increasing digital loads)
 Sensitivity to power quality
 Geographical consideration (weather)
 Environmental conditions in which your facility operates (moisture, dirt, dust)

Preventative Maintenance Checklist for Electrical Distribution Systems:

Intrusive LV Switchboards
❒ Check function of all power meters before shutdown.
❒ Check function of lamps and indicators.
❒ Inspect locking devices for signs damage or worn.
❒ Clean thoroughly, vacuum and full visual inspection of exterior and interior of all LV switchboards.
❒ Inspect control wiring, relays, power supply units, timers, etc. where applicable.
❒ Check electronic surge protection is intact where installed.
❒ Verify control circuit fuse rating and continuity.
❒ Check and torque test bolted electrical connections as necessary to specified levels.
❒ ACB maintenance withdrawable or fixed, check contacts, arc chutes secondary injection, etc.
❒ Visual inspection for signs of overheating or deterioration.
❒ Final visual inspection to insure all clear after work completed.
❒ Inspection of all panels for paint work damage and signs of corrosion.
❒ Check battery tripping packs, battery integrity, signs of defects, etc.

Non-Intrusive LV Switchboards
Note: These maintenance procedures require no shutdowns.
❒ Check function of all power meters before shutdown.
❒ Check function of lamps and indicators.
❒ Inspect locking devices for signs damage or worn.
❒ Clean thoroughly, vacuum and full visual inspection of exterior only.
❒ Visual inspections of control wiring, relays, power supply units, timers and fuse carriers.
❒ Check electronic surge protection is intact where installed.
❒ Visual inspection for signs of overheating or deterioration.
❒ Inspection of all panels for paint work damage and signs of corrosion.
❒ Check battery tripping, battery integrity, signs of defects.

ACB Chassis
❒ Rack out ACB.
❒ Clean/ vacuum internal chassis.
❒ Check operation of safety shutters closing.
❒ Check shutter locking devices are intact.
❒ Check operation and position of contacts.
❒ Operate padlocking system.
❒ Grease clusters as necessary.

ACB’s
❒ Check general condition of the device.
❒ Clean with diluents Henkel 273471, vacuum ACB.
❒ Check filters clean/vacuum arc-chutes.
❒ Visual check for contact wear.
❒ Check auxiliary wiring insulation.
❒ Check ACB locking devices.
❒ Open/close manually.
❒ Charge the device manually.
❒ Secondary injection with FFT Kit, produce trip curve report.
❒ Check earth fault protection/earth leakage protection.
❒ Grease disconnect contacts as necessary.
❒ MCCB trip test with report.

Busbar & Accessories

❒ Visual inspection all Power bar runs
❒ Check supports
❒ Check alignment, straight runs, joint packs and directional change pieces
❒ Check panel flanges, earth continuity etc.
❒ Thermal image survey of complete runs

Meters
❒ Voltage connections
❒ CT connections
❒ Modbus connections

MCCB checks
❒ Motor operator
❒ Under voltage release
❒ Power supply unit
❒ Control relays
❒ Fuse and fuse holders

PDU
❒ Clean thoroughly exterior and interior PDU switchboards
❒ Check function of all power meters
❒ Verify control circuit fuse rating and continuity
❒ Check function of lamps and indicators
❒ Check and torque test bolted electrical connections as necessary to specified levels
❒ Check all cable connections for tightness and torque terminals
❒ Visual inspection for signs of overheating or deterioration
❒ Inspection of all panels for paint work damage and signs of corrosion
❒ Inspection to insure all clear after work completed before fitting covers
❒ All labeled secure in place

Thermal Imaging Surveys

Thermal imaging is becoming more common within preventive maintenance programs to help detect excess heat
in electrical components. It can be carried out while the system is under a full load with no impact to operations
Thermal imaging technology can detect loose connections, corroded elements, short circuits, overloaded circuits
and busway-joint analysis. This non-invasive technique also allows to gather data from a remote location, away
from potentially dangerous situations.