EMSD O&M Best Practices

1. Introduction

2. Design Considerations

Thermal Storage Tanks

2.5

Circulation Pumps for Heat Transfer Fluid

Application of Technology

3. Operation and Maintenance

3.1

Factors Affecting System Performance

3.2

Operation Procedures

3.3

Emergency Preparedness

3.4

Preventive Maintenance

3.5

Corrective Maintenance

3.6

Spare Parts Management

3.7

Safety and Environmental Management

3.8

Structure and Qualifications of O&M Teams

4. Record/Documentation

4.1

Asset Information

4.2

Maintenance Record Management

4.3

Information Management

4.4

Stakeholders Management

5. Appendix A:Sample Checklist for Inspection and Testing of Solar Water Heating Systems

Appendix A:Sample Checklist for Inspection and Testing of Solar Water Heating Systems

Appendix A: Sample Checklist for Inspection and Testing of Solar Water Heating Systems

Installation Address: ________________________________________

(a) Solar Collectors		Tested by/Date (N/A if not applicable)
(i)	Clean the collectors (when they are cool) to remove dust, debris and other contaminants on the collector surface.
(ii)	Check the collectors for cracked, broken or deformed glass, shading, deterioration of absorber paint/coating, tubes and insulation.
(iii)	Check the surface temperature of the absorbers for abnormal temperature.
(iv)	Check for excessive condensation or outgassing under glazing.
(v)	Check the frames for corrosion.
(vi)	Check the earthing conductor conditions of collectors with sensors.
(vii)	Test the flow rate for compliance with manufacturer’s recommendations and the temperature of each collector group in the array.
(viii)	Check the absorbers and pipes for any leakage.
(ix)	Remove scaling inside pipework.

(b) Supporting Frames		Tested by/Date (N/A if not applicable)
(i)	Check the physical connections and fixing components to make sure the solar collectors and pipework are securely fixed.
(ii)	Check all hardware for signs of corrosion; remove rust; re-paint and replace if necessary.

(c) Solar Collector Arrays		Tested by/Date (N/A if not applicable)
(i)	Check for abnormal position and movement of solar collectors.
(ii)	Check hot water flow rate of collector arrays.

(d) Heat Transfer Fluid		Tested by/Date (N/A if not applicable)
(i)	Check heat transfer fluid conditions, concentration and degradation for indirect type; refill heat transfer fluid if necessary.
(ii)	Check the water quality for direct type.
(iii)	Check that provisions are made for draining and filling the system (air vents, drains, pipes are correctly graded in-between).

(e) Pipework		Tested by/Date (N/A if not applicable)
(i)	Check pipework for signs of cracks, defects and leaks, damage, blockage, or degradation of thermal insulation.
(ii)	Inspect for signs of defects, sagging, cracks; replace if necessary.
(iii)	Check the air locks or blockages of the pipework.
(iv)	Check signs of deformation not holding slopes to drain.
(v)	Check for abnormal operation temperature; stop circulation in the collection loop and release the excessive pressure inside pipework if any.
(vi)	Remove scaling from pipework.

(f) Valves		Tested by/Date (N/A if not applicable)
(i)	Check valves for any damage, leakage, getting stuck or signs of corrosion; check valve settings and valve position.
(ii)	Test operation according to the O&M manual and manufacturer's recommendations.

(g) Strainers		Tested by/Date (N/A if not applicable)
(i)	General cleaning and check for signs of corrosion and getting stuck.

(h) Heat Exchangers		Tested by/Date (N/A if not applicable)
(i)	Check heat exchangers for signs of leakage or corrosion and the associated supports.
(ii)	Test flow rate for compliance with manufacturer’s recommendations.
(iii)	Remove scaling from heat exchangers.

(i) Thermal Storage Tanks		Tested by/Date (N/A if not applicable)
(i)	Check storage tanks for cracks, leaks, rust or signs of corrosion.
(ii)	Check the insulation for damage or degradation.
(iii)	Check the system pressure and temperature; depressurise the excessive system pressure if any.
(iv)	Discharge water inside.
(v)	Remove scaling from thermal storage tanks.
(vi)	Check that provisions have been made to prevent reverse heating of the solar thermal storage by the domestic hot-water back-up heater.
(vii)	Check the thermostat and control of the backup heating element if backup heating is provided.

(j) Expansion Tanks		Tested by/Date (N/A if not applicable)
(i)	Check the expansion tanks with diaphragms in by briefly depressing the Schrader valve for leaks of fluid.

(k) Pumps		Tested by/Date (N/A if not applicable)
(i)	General cleaning and re-paint.
(ii)	Check that the electrical connections are securely fastened and the earth bonding conductors are properly connected.
(iii)	Check the piping connections for leakages.
(iv)	Lubricate the moving parts.
(v)	Check that the pumps are operating correctly, without abnormal movement or water leakage.
(vi)	Check the pressure and flow to ensure the operation condition of the pump is in order.

(l) Make-up Water Tanks		Tested by/Date (N/A if not applicable)
(i)	Drain and flush out the tank to remove sediment.
(ii)	Check the water tank for cracks, leaks, rust or signs of corrosion.

(m) Controls, Sensors and Meters		Tested by/Date (N/A if not applicable)
(i)	Check operational indicators of temperature and pressure to ensure proper operation of the pump and controls.
(ii)	Check the sensor wiring for avoidance of losing connection.
(iii)	Check the accuracy of the sensors and controls; re-calibrate if necessary.
(iv)	Check that controls, water level sensors, temperature sensors are operating sensibly.
(v)	Open pump control panel box and check that no fuses/ MCBs have blown and that all electrical connections are tight.
(vi)	Check pump control panel for water incursion and corrosion damage.
(vii)	Conduct functional tests of the pump panel control.
(viii)	Conduct functional tests of isolation switches and protection devices for the pump panel control.
(ix)	Check ventilation condition and dust cleaning from heat rejection fins.
(x)	Check and make sure the valve is not stuck or closed.

(n) Safety and Warning Notices and Labels		Tested by/Date (N/A if not applicable)
(i)	Check for warning signs and labels and replace if necessary.
(ii)	Check the tags or labels which indicate the positions or flow direction at each valve and pipe.

(o) Instruments		Tested by/Date (N/A if not applicable)
(i)	Check the monitoring instruments (e.g., temperature sensors) to make sure they are operational.
(ii)	Calibrate instruments by an accredited laboratory. Replace instruments, temperature sensors, and meters as necessary.

(p) System Monitoring and Data Logging Systems		Tested by/Date (N/A if not applicable)
(i)	Monitor the operating status, flow rate, temperature, alarms and alert parameters.
(ii)	Check the Building Management System for solar water heating system; check the hardware for signal interface and upgrade software as necessary.
(iii)	Maintain a log of cumulative electrical energy consumption (kWh to date), operating temperature and flow rate against date.
(iv)	Check the monthly mean in-plan solar irradiation, monthly mean solar energy absorbed by the system and monthly electrical energy consumption of the circulation pump.

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