Operator rounds

Operator rounds checklist

A starting route for a plant operator round: pumps, motors, an air compressor, heat exchangers, tanks and housekeeping, with readings against limits and a note for every abnormal finding.

How often
Every shift
Who
Operator
Time
About 30 min
Items
25

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Set it up in Vardian

Before you use it

  • Build each round from the equipment on the route and the ways it fails. Delete what does not apply, add your own equipment and put the checks in walking order.
  • Give every reading a normal range from the manufacturer, the process design or the equipment’s own history, and decide what happens when a reading is outside it.

Pumps

  1. 1

    Scan the pump’s tag

    Checkpoint scan
  2. 2

    No seal leakage

    Pass / fail
  3. 3

    No unusual noise or vibration

    Pass / fail
  4. 4

    Bearing housing temperature

    By touch or infrared thermometer. Set the limits from the manufacturer’s manual and your normal operating range.

    Reading· °C or °F
  5. 5

    Suction pressure

    Set the limits from the manufacturer’s manual and your normal operating range.

    Reading· bar or psi
  6. 6

    Discharge pressure

    Set the limits from the manufacturer’s manual and your normal operating range.

    Reading· bar or psi
  7. 7

    Coupling guard in place

    Pass / fail

Motors

  1. 8

    No unusual noise or smell of hot insulation

    Pass / fail
  2. 9

    Cooling fins and fan cover clear

    Pass / fail
  3. 10

    Motor current

    Where a local meter is fitted.

    Reading· A

Air compressor

  1. 11

    Scan the compressor’s tag

    Checkpoint scan
  2. 12

    Discharge pressure

    Set the limits from the manufacturer’s manual and your normal operating range.

    Reading· bar or psi
  3. 13

    Discharge temperature

    Set the limits from the manufacturer’s manual and your normal operating range.

    Reading· °C or °F
  4. 14

    Oil level in the sight glass

    Pass / fail
  5. 15

    Condensate drains working

    Pass / fail

Heat exchangers

  1. 16

    Inlet temperature

    Set the limits from the manufacturer’s manual and your normal operating range.

    Reading· °C or °F
  2. 17

    Outlet temperature

    Set the limits from the manufacturer’s manual and your normal operating range.

    Reading· °C or °F
  3. 18

    No leaks at heads and flanges

    Pass / fail

Tanks and containment

  1. 19

    Tank level

    Set the limits from the manufacturer’s manual and your normal operating range.

    Reading· %
  2. 20

    No leaks; bund drain valve closed

    Pass / fail

Housekeeping and safety

  1. 21

    Guards in place, drains closed, labels legible

    Pass / fail
  2. 22

    No spills; lighting working

    Pass / fail
  3. 23

    Photo of any abnormal finding

    Photo
  4. 24

    Abnormal findings and who was told

    Note
  5. 25

    Operator

    Signature

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Read more

Field types in this template

  • Checkpoint scan
  • Pass / fail
  • Reading
  • Photo
  • Note
  • Signature

In Vardian, readings are checked against their limits as they are entered, and photos and signatures attach to the check itself.

From the sheet to the round

Build a template as a Vardian form, and each line becomes a checkpoint that knows its limit.

Animation: a paper checklist line, compressor discharge pressure with a blank for the reading in bar, becomes a Vardian checkpoint with a limit of 7.0 to 8.5 bar. Scanning the compressor's NFC tag verifies the checkpoint, a reading of 9.1 bar is flagged out of range, and a work order is created from it.

Related templates

Run this checklist on the round

We'll set it up in Vardian with your checkpoints and limits during a demo.

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