2018 GSA PM Guide Pt 3.pdf

General Services Administration Preventive Maintenance Guide Effective Date: December 31, 2018

This maintenance standard applies to most terminal units (mixing boxes) which are found in most types of air handling systems. The terminal unit may be VAV, CAV, dual duct, with or without heating/re-heating or cooling, and be pressure dependant or pressure independent. These mixing boxes will be controlled by either pneumatics or Direct Digital Controls (DDC). The re-heat coil maintenance shall be combined with this standard.

Special Instructions:

1. In addition to the procedure(s) outlined in this standard, the equipment manufacturer's recommended maintenance procedure(s) and/or instruction(s) shall be strictly adhered to.

2. Review manufacturer's specifications.

3. Read and understand manufacturer's instructions of each device before making adjustments to the device or to the system. Understand what effects making adjustments will have on the overall Building Automation System and the operation of the building PRIOR to making any control changes.

4. For pneumatic systems, verify proper main line pressure per manufacturer's specifications.

5. De-energize or discharge all hydraulic, electrical, mechanical, or thermal energy prior to beginning work. Follow lock out/tag out procedures at all times.

Check Points:

1. DDC:

2. Check to see that the operating control sensor activates the damper per design specifications. If not, recalibrate or replace the operating control sensor with the same temperature range sensor.

3. Check damper linkage for tightness or damage. Lightly oil moving parts using an approved lubricant.

4. Inspect damper(s) for free movement in mixing box. Replace felt or other type seals as required.

5. Inspect mixing box and connecting ductwork for air leaks. Correct leaks with approved duct tape or tighten connections, as required.

6. Tighten electrical connections to all servo-motor actuators, and test as applicable.

7. Check the heating or cooling valve (if present) for leakage around the stem or between the seat and disk. Repair or replace as needed.

8. Check velocity sensor tubing for cracks, tightness, or holes if applicable.

9. Re-heat (if applicable)

10. Check electrical connections and insulators on re-heat coils.

11. Vacuum or blow out the fins, coils, etc.

12. Comb fins as required.

13. Remove obstructions to air flow.

14. Check coils for leaks. Correct or report any leaks.

15. Test and inspect controls that protect coils against freezing.

16. Check for rust or corrosion around coil frame and coil mounting bracket.

17. Clean, prepare for painting and coat with proper type paint as necessary.

18. Record differential air pressure across the coil.

19. Pneumatic:

20. Check damper linkage for tightness or damage. Lightly oil moving parts using an approved lubricant for pneumatic systems.

21. Inspect damper(s) for free movement in mixing box. Replace felt or other type seals as required.

22. Inspect mixing box and connecting ductwork for air leaks. Correct leaks with approved duct tape or tighten connections, as required.

23. Inspect damper actuator(s) for tightness to mounting brackets.

24. Inspect damper actuator diaphragm for leaks by performing a pressure test of the diaphragm.

25. Check the damper actuator spring range. Replace spring, adjust pilot positioner, or add pilot positioner as needed.

26. If pneumatic actuator does not stroke properly, correct sticking valve stem or binding linkage. Replace or repair the diaphragm or actuator if necessary.

27. Check the heating or cooling valve for leakage around the stem or between the seat and disk. Repair or replace as needed.

28. Inspect the valve actuator for leaks by performing a pressure test of the diaphragm. Repair or replace as needed.

29. Check the spring range of the valve actuator. Replace spring, adjust pilot positioner or add pilot positioner as needed.

30. Inspect for air leaks around actuator and in the air line between controller and pneumatic actuator.

31. Inspect operating control thermostat and/or pressure sensor for proper location and check main and branch air lines at thermostat for crimps, breaks, etc. Repair or replace if needed.

32. Check all inline filters for oil and/or moisture. Replace as needed.

33. Check all installed pressure gages for proper range and operability as applicable.

Replace if needed.

34. Perform a spring range check for all remaining end devices.

35. Calibrate the operating control thermostat. Replace if it is defective with the same type action (direct or reverse action) and temperature range.

36. Check to see that the operating control thermostat activates the damper per design specifications. If not, recalibrate the operating control thermostat.

37. Re-heat (if applicable)

38. Check electrical connections and insulators on re-heat coils.

39. Vacuum or blow out the fins, coils, etc.

40. Comb fins as required.

41. Remove obstructions to air flow.

42. Check coils for leaks. Correct or report any leaks.

43. Check for rust or corrosion around coil frame and coil mounting bracket.

44. Clean, prepare for painting and coat with proper type paint as necessary.

45. Record differential air pressure across the coil.

Recommended Tools, Materials, and Equipment:

1. 50 ft (15 m) non conductive tape.

2. Control drawings

3. Lubricants. Consult the Material Safety Data Sheet (MSDS) for hazardous ingredients and proper Personal Protective Equipment (PPE).

4. Safety goggles

5. Calibration tools

6. Tool Group B

7. Cleaning materials and equipment. Consult the Material Safety Data Sheets (MSDS) for hazardous ingredients and proper personal protective equipment

(PPE).

HVAC-TMU-

02-03M

Terminal Units, Pneumatic or Electric, Predictive Maintenance Quarterly

Application:

This maintenance standard applies to most terminal units (mixing boxes) which are found in most types of air handling systems. The terminal unit may be VAV, CAV, dual duct, with or without heating or cooling, and be pressure dependant or pressure independent. These terminal units will be controlled by Direct Digital Controls (DDC) ONLY. This standard includes some predictive maintenance tasks and can be used as an alternative to the purely preventive maintenance standard for DDC controlled units only. The use of a fault detection diagnostic tool, such as VAV Box Performance Assessment Control Charts (VPACC, form NIST) which uses a small number of control charts to assess the performance of VAV boxes is the primary means for this predictive maintenance task. This standard assumes that the diagnostic tools is installed and functioning properly and that staff has been trained on its use. O&M contractors may propose changes to this standard. Such changes are subject to GSA approval. Proposed changes to standards must be submitted showing markups of changes for GSA approval.This standard may be used in lieu of standard HVAC-TMU-01-01Y. However, this standard is performed quarterly.

Special Instructions:

1. In addition to the procedure(s) outlined in this standard, the equipment manufacturer's recommended maintenance procedure(s) and/or instruction(s) shall be strictly adhered to.

2. Review manufacturer's specifications.

3. Read and understand manufacturer's instructions of each device before making adjustments to the device or to the system. Understand what effects making adjustments will have on the overall Building Automation System and the operation of the building PRIOR to making any control changes.

4. For pneumatic systems, verify proper main line pressure per manufacturer's specifications.

5. De-energize or discharge all hydraulic, electrical, mechanical, or thermal energy prior to beginning work. Follow lock out/tag out procedures at all times.

Check Points:

1. DDC:

2. Check to see that the operating control sensor activates the damper per design specifications. If not, recalibrate or replace the operating control sensor with the same temperature range sensor.

3. Check damper linkage for tightness or damage. Lightly oil moving parts using an approved lubricant.

4. Inspect damper(s) for free movement in mixing box. Replace felt or other type seals as required.

5. Inspect mixing box and connecting ductwork for air leaks. Correct leaks with approved duct tape or tighten connections, as required.

6. Tighten electrical connections to all servo-motor actuators, and test as applicable.

7. Check the heating or cooling valve (if present) for leakage around the stem or between the seat and disk. Repair or replace as needed.

8. Check velocity sensor tubing for cracks, tightness, or holes if applicable.

9. Predictive Maintenance Checkpoints

10. Ensure that diagnostic tool has been installed properly.

11. Review all alarms associated with the diagnostic tool and any corrective actions that have been taken as a result. All alarming functions that were originally set up in the diagnostic tool should be responded to at the time of the alarm.

12. Review all trend data generated by the diagnostic tool where alarms are present.

13. Based on the results, repair or correct the terminal unit mechanical or control related deficiency as required by qualified staff.

14. Ensure that the diagnostic tool remains in operation and that operators are trained on its use.

Recommended Tools, Materials, and Equipment:

1. Tool Group B

2. Lubricants. Consult the Material Safety Data Sheet (MSDS) for hazardous ingredients and proper Personal Protective Equipment (PPE).

3. Cleaning materials and equipment. Consult the Material Safety Data Sheets (MSDS) for hazardous ingredients and proper personal protective equipment

(PPE).

4. Safety goggles

5. 50 ft (15 m) non conductive tape.

6. Calibration tools

7. Control drawings

HVAC-TWR-01-

01Y

Cooling Tower, Maintenance Annually

Application:

Cooling towers are used in an open loop cooling water system. The most common use of a cooling tower is to cool the condenser water of a chiller. A cooling tower is composed of a fan, spray nozzles, heat transfer media and a water basin (sump). Within the cooling tower the water is sprayed over a heat transfer media called fill, as the first stage of cooling. The second stage of cooling occurs when the cooling tower fan is turned on.

This fan is either a constant speed fan, a two speed fan or a variable speed fan.

Special Instructions:

1. In addition to the procedure(s) outlined in this standard, the equipment manufacturer's recommended maintenance procedure(s) and/or instruction(s) shall be strictly adhered to.

2. Review manufacturer's instructions.

3. Follow lock out/tag out procedures at all times. De-energize or discharge all hydraulic, electrical, mechanical, or thermal energy prior to beginning work.

4. Schedule performance of this PM activity prior to seasonal start-up. Consider the time needed to effect any required repairs.

5. Perform cleaning of the tower in accordance with PM standard

6. Wear air purifying respirator fitted with HEPA cartridges, or 3M N95 disposable mask, after being enrolled in a respiratory protection program and receiving training on respirator use.

7. 3M mask shall only be worn if it is sufficiently appropriate for the potential airborne hazards. Consult regional GSA safety staff for additional assistance.

8. Properly dispose of any debris, excess oil, and grease.

9. If materials to be worked on, such as the wet deck panels (tower fill media), are known or suspected to contain asbestos, check the building's asbestos management plan to see if they have been tested for asbestos. If they are suspect but have not been tested, have them tested. Manage asbestos in accordance with the plan.

10. Children of this Piece of Equipment:

11. Fan Motors

12. Variable Frequency Drives

Check Points:

1. Exterior Structural:

a. Inspect louvers for correct position and alignment, missing or defective items, and supports.

b. Inspect casings and attaching hardware for leaks or defects. Check the integrity and secure attachment of the corner rolls.

c. Inspect for loose or rotten boards on wood casings. Examine from the interior.

Extensive damage may require replacement with fiberglass sheathing.

d. Inspect condition of access doors and hinges. Repair as necessary.

e. Inspect the distribution system including flange connectors and gaskets, caulking of headers on counterflow towers, deterioration in distribution basins, splash guards, and associated piping on crossflow towers. If configured with water troughs check boards for warpage, splitting, and gaps.

f. Examine the drain boards for damage and proper drainage. Check the fasteners also.

g. Inspect stairways including handrails, knee rails, stringers, structure and fasteners for rot, corrosion, security and acid attack.

h. Shake ladders to verify security, and check all rungs.

i. Check the security, rot, and corrosion on walkway treads. Check treads, walkways, and platforms for loose, broken, or missing parts. Tighten or replace as necessary.

j. Ladders must be checked for corrosion, rot, etc. Verify compliance with Occupational Safety and Health regulations regarding height requirements.

Check ladder security.

k. Check fan decks and supports for decay, missing and broken parts, and gaps.

Check the security.

l. Fan cylinders must be securely anchored. Check fastening devices. Note any damaged, missing, or corroded items. Watch for wood rot and corrosion of steel.

Verify proper tip clearance between the fan blade and interior of cylinder. Verify compliance with OSHA requirements regarding height. Check its condition.

m. Apply protective coatings as needed on exterior surfaces. Be sure rust and dirt have been removed first.

2. Interior Structural:

a. Inspect the distribution system piping for decay, rust, or acid attack. Check the condition and tightness of connections and branch arms. Observe spray pattern of nozzles if possible and note missing and defective nozzles. Note condition of the redistribution system under the hot water system.

b. Inspect mechanical equipment supports and fasteners for corrosion. Wood structural members in contact with steel should be checked for evidence of weakness. Check condition of springs or rubber vibration absorption pads, including adjusting bolts, ferrous members, and rubber pads.

c. Check valves and operating condition of fire detection system. Check for corrosion of pipes and connectors. Check wiring of any thermocouple installed.

d. Check drift eliminators and supports. Remove any clogging debris. Replace missing blades.

e. Inspect tower fill for damage, ice breakage, deterioration, and misplaced, missing, or defective splash bars.

f. Examine interior structural supports. Test columns, girts, and diagonal wood members for soundness by striking with a rubber mallet. A high pitched, sharp sound indicates good wood, whereas a dull sound indicates soft wood. Probe rotted areas with a scew driver to determine extent of rot. Look for iron rot of metal fasteners in contact with wood. Check condition of steel internals. Check condition and tightness of bolts.

g. Inspect the nuts and bolts in partitions for tightness and corrosion. Look for loose or deteriorated partition boards. Note if partitions are installed so as to prevent wind milling of idle fans. Make sure wind walls parallel to intake louvers are in position. Boards or transite members should be securely fastened. Check condition of wood or steel supports for rot and corrosion.

h. Check wooden cold water basins for deterioration, warps, splits, open joints, and sound of wood. Inspect steel basins for corrosion and general condition.

Inspect concrete basins for cracks, breaking joints, and acid attack.

i. Check all sumps for debris, condition of screens, antiturbular plates, and freely operating drain valves.

3. Mechanical:

a. Check alignment of gear, motor, and fan.

b. Inspect fans and air inlet screens and remove any dirt or debris.

4. Check hubs and hub covers for corrosion, and condition of attaching hardware.

5. Inspect blade clamping arrangement for tightness and corrosion.

c. Gear box

6. Clean out any sludge.

7. Change oil. Be sure gear box is full to avoid condensation.

8. Rotate input shaft manually back and forth to check for backlash.

9. Attempt to move the shaft radially to check for wear on the input pinion shaft bearing.

10. Look for excessive play of the fan shaft bearings by applying a force up and down on the tip of a fan blade. Note: Some output shafts have a running clearance built into them.

d. Power transmission.

11. Check that the drive shaft and coupling guards are installed and that there are no signs of rubbing. Inspect the keys and set screws on the drive shaft, and check the connecting hardware for tightness. Tighten or install as required.

12. Look for corrosion, wear, or missing elements on the drive shaft couplings.

13. Examine the exterior of the drive shaft for corrosion, and check the interior by tapping and listening for dead spots.

14. Observe flexible connectors of both ends of the shaft.

15. Inspect bearings, belts, and pulleys for excessive noise, wear or cracking, alignment, vibration, looseness, surface glazing, tension. Replace or repair as required.

e. Check water distribution. Adjust water level and flush out troughs if necessary.

Check all piping, connections, and brackets for looseness. Tighten loose connections and mounting brackets. Replace bolts and braces as required.

f. Check nozzles for clogging and proper distribution.

g. Inspect keys and keyways in motor and drive shaft.

16. Electrical:

a. Check electric motor for excessive heat and vibration. Lubricate all motor bearings as applicable. Remove excess lubricant.

b. Inspect fused disconnect switches, wiring, conduit, and electrical controls for loose connections, charred or broken insulation, or other defects. Tighten, repair, or replace as required.

c. Remove dust from air intakes, and check for corrosion. Check TEFC motors for conditions of air passages and fans.

d. If there is a drain moisture plug installed, see if it is operational.

e. Check amps and volts at operating loads, recommend pitching of fan blades to compensate.

f. Look for corrosion and security of mounting bolts and attachments.

17. Winterizing: (if applicable) If Cooling Tower is seasonal.

a. Check that all electrical energy switches condenser pumps, fans, sump heaters have been de-energized and tagged out.

b. Check that tower is drained, water make-up has been secured at an interior building location tagged off and exterior line is drained and left open to prevent freezing.

c. Check that tower drains are locked in the open position and tagged.

d. If there are piping heaters, check to make sure they are energized and working.

e. Check that tower supply and return lines have been drained down to a point inside the building where water in them will not freeze and that the water has been pre treated to prevent corrosion and bacteria growth.

f. Check that any water treatment pumps that serve the cooling tower system have been secured.

g. Drain and secure cooling tower filtering systems that are exposed to freezing conditions.

Recommended Tools, Materials, and Equipment:

1. Cleaning tools and materials. Consult the Material Safety Data Sheets (MSDS) for hazardous ingredients and proper personal protective equipment (PPE).

2. Tool Group C

3. Safety goggles

4. Respirator appropriate for the hazard. All respirator users shall have been traine d and enrolled in respiratory protection program.

5. Protective coating, brushes, solvent, etc. Consult the Material Safety Data Sheets (MSDS) for hazardous ingredients and proper personal protective equipment

(PPE).

6. High pressure washer

7. Manufacturer approved lubricants. Consult the MSDS for hazardous ingredients and proper PPE.

8. Ladders of appropriate size constructed in accordance with OSHA/ANSI standards or scaffolding. Check ladders for defects. Do not use defective ladders.

9. Work gloves

10. Amp probe and volt meter.

HVAC-TWR-01-03M Cooling Tower, Cleaning Quarterly

Application:

This applies to all cooling towers and evaporative condensers. Those located on the mezzanine or lower levels and near fresh air intakes are particularly important. Since cooling tower and evaporative condensers can become contaminated with microorganisms which are harmful.

Special Instructions:

1. In addition to the procedure(s) outlined in this standard, the equipment manufacturer's recommended maintenance procedure(s) and/or instruction(s) shall be strictly adhered to.

2. Perform work before seasonal start-up (unless system has remained clean and free of bio-deposits), before seasonal shutdown, and quarterly during the cooling season.

3. If unit is not used year round drain and clean at least twice per year.

4. Review manufacturer's instructions.

5. Follow lock out/tag out procedures at all times. De-energize or discharge all hydraulic, electrical, mechanical, or thermal energy prior to beginning work times.

6. Wear air purifying respirator fitted with HEPA cartridge, or 3M N95 disposable mask, after being enrolled in a respiratory protection program and receiving training on respirator use.

7. 3M mask shall only be worn if it is sufficiently appropriate for the potential airborne hazards. Consult regional GSA safety staff for additional assistance.

8. Ensure that there are safe and sturdy ladders and platforms to perform the lifting and cleaning required.

9. If biological growth is excessive, have the water tested for legionella bacteria and if positive, clean and disinfect using the Wisconsin protocol. Then have a qualified water treatment specialist review your treatment program.

10. Refer to Table A for information on chlorine use.

11. If materials to be worked on, such as the wet deck panels (fill), are known or suspected to contain asbestos, check the building's asbestos management plan to see if they have been tested for asbestos. If they are suspect but have not been tested, have them tested. Manage asbestos in accordance with the plan.

Check Points:

1. Close building air intake vents within the vicinity of the cooling tower until the cleaning procedure is complete.

2. Shut down, drain, and flush the cooling tower with water (check with state to determine if there are any restrictions on discharging the water). Isolate the cooling tower from the rest of the condenser water system where applicable.

3. Clean the wet deck, remove all debris, and dispose of properly. If the wet deck panels contains asbestos, it is considered hazardous waste. Refer to Appendix G for the Universal Waste Guide.

4. Inspect the tower, the tower basin and holding tank for sediment and sludge, and any biological growth.

5. Using low pressure water hose or brushes, clean the tower, floor, sump, fill, spray pans and nozzles and removable components such as access hatches, ball float, and other fittings until all surfaces are clean and free of loose material. Porous surfaces such as wooden and ceramic tile towers will require additional cleaning and brushing. Clean cracks and crevices where buildup is not reached by water treatment.

6. Use caution when cleaning and handling sludge or water with biological growth, to make sure droplets or spray is not inhaled. Clean off skin with soap and water after the cleaning.

7. Clean all system strainers and strainer housings.

8. Remove drift eliminators and clean thoroughly using a hose, steam, or chemical cleanser.

9. Check fan and air inlet screens and remove any dirt or debris.

10. Reassemble components, and fill tower and cooling system with water.

11. Monitor the water pH and maintain pH within a range of 7.5 to 9.5. The pH can be monitored with litmus paper or a pH meter.

12. Add chemicals need to maintain water chemistry properties recommended by a water treatment consultant.

13. Perform the following if a more thorough disinfectant cleaning is needed;

14. Add a silicate-based low or non-foaming detergent as a dispersant at a dosage of 10-25 pounds per thousand gallons of water in the system.

a. If the total volume of water in the system is not known, it can be estimated to be ten (10) times the recirculating rate (gallons per minute) or 30 gallons per ton of refrigeration capacity.

b. The dispersant is best added by first dissolving it in water and adding the solution to a turbulent zone in the water system, such as the cooling tower basin near the pump suction.

c. Contact a professional water treatment specialist for a dispersant which may be safely used without interfering with the operation of the system.

15. Add chlorine disinfectant to achieve 25 parts per million (ppm) of free residual chlorine.

a. Maintain 10 ppm of free residual chlorine in water returning to the cooling tower for 24 hours.

b. A swimming pool test kit may be used to monitor the chlorine. Follow the manufacturer's instructions. Test papers such as those used to monitor restaurant sanitizing tanks may also be used.

c. Monitor every 15 minutes for two hours to maintain the 10 ppm level. Add chlorine as needed to maintain this level.

d. Two hours after the slug dose or after three measurements are stable at 10 ppm of free residual chlorine, monitor at two hour intervals to maintain the 10 ppm of free residual chlorine.

e. Some kits cannot measure 10 ppm. In this case dilute the test sample with distilled water to bring it within the test set range.

16. After 24 hours, drain the system (check with state to determine if there are any restrictions on discharging the water).

17. Adjust bleed, float, central valve for desired water level.

18. Open any building air vents that were closed prior to the cleaning of the cooling tower.

19. Implement an effective routine treatment program for microbial control.

20. Document all maintenance and cleaning procedures by date and time. Record the brand name and the volume or weight of chemicals used.

Recommended Tools, Materials, and Equipment:

1. Cleaning tools and materials. Consult the Material Safety Data Sheets (MSDS) for hazardous ingredients and proper personal protective equipment (PPE).

2. Rubber boots if wet.

3. Appropriate chemicals and detergents (see standard card for details). Consult the Material Safety Data Sheets (MSDS) for hazardous ingredients and proper personal protective equipment (PPE).

4. Waterproof clothing (while working inside a wet tower).

5. Gloves (refer to MSDS on chemicals used for the type of gloves required).

6. Litmus paper or pH meter.

7. High pressure washer

8. Respirator with acid/gas/mist/HEPA filters. For other chemicals, refer to the Material Safety Data Sheet (MSDS) for recommended respirator).

9. Test kits as required

10. Tool Group C

11. Safety goggles

TABLE OF VALUES

Chlorine Compounds Percent Available Chlorine

Weight per 1000 gallons

Hypochlorites

Calcium, Ca(OCl)2 (HTH) 70 0.3 lb.

Sodium, NaOCl

Industrial grade 12-15 1.5 lb.

Domestic grade (bleach) 3-5 5.25 lb.

Empty Empty

Potassium or sodium Empty Empty

Chlorinated Isocyanurates 55-65 0.4 - 0.33 lb.

66-90 0.33 - 0.25 lb.

* Only those compounds commonly available in most communities are listed.

Other appropriate compounds may be suggested by a water treatment specialist.

** These weights are approximate and are calculated to attain a free chlorine level of 25 ppm in a theoretical cooling tower system with no bio-deposits. If bio-deposits are present, additional chlorine will be required. Calculate the volume of the entire cooling tower system, including the cooling tower water and the recirculating water; it should be several times more than the holding capacity of the tower.

*** Select only fast-release compounds, which are available in pellets, granular or extra granular forms in the 55-65% available chlorine category. Compounds with higher percentages of available chlorines (66-90%) release more slowly; use only the granular or extra granular forms.

HVAC-UHT-01-

01Y

Unit Heater, Steam or Hot Water Annually

Application:

Unit heaters are usually used to heat otherwise unconditioned spaces. These units can be horizontal or vertical and are usually heating only.

Special Instructions:

1. In addition to the procedure(s) outlined in this standard, the equipment manufacturer's recommended maintenance procedure(s) and/or instruction(s) shall be strictly adhered to.

2. Review manufacturer's instructions.

3. Schedule shutdown with operating personnel.

4. Follow lock out/tag out procedures at all times. De-energize or discharge all hydraulic, electrical, mechanical, or thermal energy prior to beginning work.

Check Points:

1. Check valve for full stroke operation in both directions.

2. Check valve for signs of abnormal wear and leaks. Replace packing if needed.

3. Clean the coil with vacuum cleaner.

4. Comb the fins as needed.

5. Clean all fans and motors.

6. Check operation of controls and safeties.

7. Lubricate as required.

8. Check all motors, belts, pulleys, shafts, etc. for alignment.

9. Treat all rusted areas with rust inhibitor and touch up paint.

Recommended Tools, Materials, and Equipment:

1. Small vacuum cleaner or cleaning brush.

2. Tool Group A

3. Rust inhibitor, paint, brushes. Consult the Material Safety Data Sheet (MSDS) for hazardous ingredients and proper personal protective equipment (PPE). Consult the MSDS to ensure that the paint lead level is 0.06% or less.

4. Cleaning and patching materials. Consult the MSDS for hazardous ingredients and proper personal protective equipment (PPE).

HVAC-UHT-02-01Y Unit Heater, Gas or Oil Annually

Application:

Unit heaters are usually used to heat otherwise unconditioned spaces. These units can be horizontal or vertical and are usually heating only.

Special Instructions:

1. In addition to the procedure(s) outlined in this standard, the equipment manufacturer's recommended maintenance procedure(s) and/or instruction(s) shall be strictly adhered to.

2. Review manufacturer's instructions.

3. Review the Standard Operating Procedure for "Selection, Care, and Use of Respiratory Protection."

4. Schedule shutdown with operating personnel.

5. Follow lock out/tag out procedures at all times. De-energize or discharge all hydraulic, electrical, mechanical, or thermal energy prior to beginning work.

6. Coordinate other related preventive maintenance items, such as, burners, fuel tank, humidifier, or other equipment.

Check Points:

1. Remove access panels if applicable.

2. Check the fire box liner or refractory for cracks and leaks.

3. Check oil pump for leaks. Repair or replace as needed (oil units only)

4. Change the oil filter and oil spry nozzles (oil units only).

5. Check all gas lines for leaks. Repair as needed.

6. Check smoke stack for obstructions, leaks, etc.

7. Clean bottom of smoke stack (breaching).

8. Clean all fans and motors.

9. Check operation of controls and safeties.

10. Lubricate as required.

11. Replace access panels if removed.

12. Check all motors, belts, pulleys, shafts, etc. for alignment.

13. Treat all rusted areas with rust inhibitor and touch up paint.

Recommended Tools, Materials, and Equipment:

1. Rust inhibitor, paint, brushes. Consult the Material Safety Data Sheet (MSDS) for hazardous ingredients and proper personal protective equipment (PPE). Consult the MSDS to ensure that the paint lead level is 0.06% or less.

2. Small stiff brush.

3. Respirator, goggles and gloves.

4. Tool Group A

5. Small vacuum cleaner or cleaning brush.

6. Cleaning and patching materials. Consult the MSDS for hazardous ingredients and proper personal protective equipment (PPE).

HVAC-VLV-01-

01Y

Valve, Pneumatic or DDC Operated Annually

Application:

This standard applies to all valves which are controlled through the BAS system and operated with an electric motor, pneumatic actuator or electric device such as a solenoid.

Special Instructions:

1. In addition to the procedure(s) outlined in this standard, the equipment manufacturer's recommended maintenance procedure(s) and/or instruction(s) shall be strictly adhered to.

2. Review manufacturer's instructions for all system components.

3. Follow lock out/tag out procedures at all times. De-energize or discharge all hydraulic, electrical, mechanical, or thermal energy prior to beginning work.

4. If materials to be worked on are known or suspected to contain asbestos, check the building's asbestos management plan to see if they have been tested for asbestos. If they are suspect but have not been tested, have them tested. Manage asbestos in accordance with the plan.

Parent of this Piece of Equipment

5. Air handlers, chillers, cooling towers

Check Points:

1. Clean unit and make visual examination of all parts.

2. Operate from limit to limit. Observe operation, look for binding, sluggishness, action of limits, etc.

3. Determine if valve seats and holds properly.

4. Check condition of packing.

5. Apply graphite to moving parts of valve.

6. For electronic motors complete steps 6 to For pneumatic actuators perform steps 1to 1

7. DDC:

8. Check to see that the operating control sensor activates the valve per design specifications. If not, recalibrate or replace the operating control sensor with the same temperature range sensor.

9. Inspect actuator for free movement.

10. Tighten electrical connections to all servo-motor actuators, and test as applicable.

11. Check all voltages or resistance at the actuator. Refer to manufacturer's specifications for values.

12. Skip to step 1

13. Pneumatic:

14. Inspect actuator diaphragm for leaks by performing a pressure test of the diaphragm.

15. Check the actuator spring range. Replace spring, adjust pilot positioner, or add pilot positioner as needed.

16. If pneumatic actuator does not stroke properly, correct sticking valve stem or binding linkage. Replace or repair the diaphragm or actuator if necessary.

17. Inspect for air leaks around actuator and in the air line between controller and pneumatic actuator.

18. Inspect operating control thermostat and/or pressure sensor for proper location and check main and branch air lines at thermostat for crimps, breaks, etc. Repair or replace if needed.

19. Check all inline filters for oil and/or moisture. Replace as needed.

20. Check all installed pressure gages for proper range and operability as applicable.

Replace if needed.

21. Check to see that the operating control thermostat activates the actuator per design specifications. If not, recalibrate the operating control thermostat.

22. Clean up work site.

1. Lubricants. Consult the Material Safety Data Sheet (MSDS) for hazardous ingredients and proper Personal Protective Equipment (PPE).

2. Cleaning equipment and materials. Consult the Material Safety Data Sheet (MSDS) for hazardous ingredients and proper Personal Protective Equipment

(PPE).

3. Tool Group C

HVAC-WTM-01-01M Water Treatment Standard Monthly

Application:

This is applicable to both condenser water and chilled water systems. Included are open recirculating systems, closed systems, air washers, and sprayed coil unit and evaporative condensers. Once through systems are not applicable. Note: This maintenance standard does not eliminate daily testing where it is an established policy.

Special Instructions:

1. Chemicals must comply with the Environmental Protection Agency (EPA) regulations and handled in accordance with occupational safety requirements.

Employ personal protection against corrosive or hazardous treatment chemicals as appropriate.

2. Be familiar with the Material Safety Data Sheets of any chemicals used in the water treatment program.

3. Water treatment specialists must be properly trained.

4. Water treatment must be based on proven standard engineering practices.

Treatment methods that claim mysterious magnetic or catalytic forces shall not be used.

5. Follow treatment as directed by manufacturer or water treatment company.

6. Maintenance includes chemicals, chemical feeding, maintaining proper water conditions, controlling bleed off, protecting idle equipment, and recordkeeping.

7. Select water treatment methods which protect the life of equipment, maximize heat transfer, and minimize scale, corrosion, solid matter buildup, algae, fungi, biological growth, and water usage. Alternate biocides. Changes to higher dosage levels may be required to control growth.

8. Ensure chemicals are properly stored, test equipment clean, and that chemicals have not passed expiration date.

9. Special attention must be paid to wooden towers and solar heating systems which can be more difficult to properly maintain.

10. Physical inspections of towers and piping systems are to be made to determine water treatment effectiveness.

11. Maintain records and test results.

Recommended Tools, Materials, and Equipment:

1. Standard Tools - Basic

2. Rubber gloves, face shield and apron.

HVAC-WTM-03-06M Chemical Feeder Semi-annually

Application:

This is applicable to both condenser water and chilled water systems. Included are open recirculating systems, closed systems, air washers, and sprayed coil unit and evaporative condensers. Once through systems are not applicable. Note: This maintenance standard does not eliminate daily testing where it is an established policy.

Special Instructions:

1. Chemicals must comply with the Environmental Protection Agency (EPA) regulations and handled in accordance with occupational safety requirements.

Employ personal protection against corrosive or hazardous treatment chemicals as appropriate.

2. Be familiar with the Material Safety Data Sheets of any chemicals used in the water treatment program.

3. Water treatment specialists must be properly trained.

4. Water treatment must be based on proven standard engineering practices.

Treatment methods that claim mysterious magnetic or catalytic forces shall not be used.

5. Follow treatment as directed by manufacturer or water treatment company.

6. Maintenance includes chemicals, chemical feeding, maintaining proper water conditions, controlling bleed off, protecting idle equipment, and recordkeeping.

7. Select water treatment methods which protect the life of equipment, maximize heat transfer, and minimize scale, corrosion, solid matter buildup, algae, fungi, biological growth, and water usage. Alternate biocides. Changes to higher dosage levels may be required to control growth.

8. Ensure chemicals are properly stored, test equipment clean, and that chemicals have not passed expiration date.

9. Special attention must be paid to wooden towers and solar heating systems which can be more difficult to properly maintain.

10. Physical inspections of towers and piping systems are to be made to determine water treatment effectiveness.

11. Maintain records and test results.

Recommended Tools, Materials, and Equipment:

1. Standard Tools - Basic

2. Rubber gloves, face shield and apron.

HVAC-WTM-04-

01Y

Water Treatment, Chemical Free Annually

Application:

This standard is intended for maintaining chemical free water treatment systems such as eH20 and Flozone. Each manufacturer has specific requirements; manufacturer recommendations shall be followed. This standard summarizes the typical tasks found in manuals for chemical free water treatment systems.

Special Instructions:

1. Manufacturer specific guidelines shall be followed. This standard only summarizes typical annual tasks and shall not be considered inclusive of all necessary activities.

Parent of this Piece of Equipment

2. Cooling Tower

Check Points:

1. Per manufacturer recommendations, check hours of operation of the devices (i.e.

purifier, oxygen concentrator). If run hours exceed 8,000 hours, devices shall either be re-built or replaced. Consult manufacturer recommendations.

Recommended Tools, Materials, and Equipment:

1. Consult manufacturer recommendations

HVAC-WTM-04-

03M

Water Treatment, Chemical Free Quarterly

Application:

This standard is intended for maintaining chemical free water treatment systems such as eH20 and Flozone. Each manufacturer has specific requirements; manufacturer recommendations shall be followed. This standard summarizes the typical tasks found in manuals for chemical free water treatment systems.

Special Instructions:

1. Manufacturer specific guidelines shall be followed. This standard only summarizes typical quarterly tasks and shall not be considered inclusive of all necessary activities.

Parent of this Piece of Equipment

2. Cooling Tower

Check Points:

1. Per manufacturer recommendations, all sensors and probes shall be cleaned monthly. Follow manufacturer specific procedures for cleaning each probe.

Typical probes include pH probes and conductivity probes; typical sensors include Oxygen percentage.

2. Per manufacturer recommendations, all filters shall be inspected, cleaned and replaced if necessary (if filter feels wet to the touch). Follow manufacturer specific procedures for inspecting, cleaning and replacing filters. Note: it may be necessary to perform a manual backwash, consult manufacturer specifications and recommendations.

3. Per manufacturer recommendations, desiccant indicators shall be inspected.

Follow manufacturer specific procedures for verifying moisture content: the manufacturer shall be notified if high moisture content is present.

4. Per manufacturer recommendations, a visual inspection of the equipment shall be performed, with specific focus on loose fittings or other notable damage.

5. Per manufacturer recommendations, sensors and probes shall be calibrated.

Follow manufacturer specific procedures for calibrating sensors.

6. Per manufacturer recommendations, coupons shall be changed out (this is manufacturer specific). Follow manufacturer specific procedures for replacing coupons.

1. Consult manufacturer recommendations

KITCHEN

KTCH-DSH-01-03M Dishwashing Machine Quarterly

Application:

This maintenance standard applies to electric and steam operated cafeteria kitchen dishwashing equipment.

Special Instructions:

1. Preventive maintenance services should be performed by a qualified manufacturer's service representative.

2. Notify cafeteria operator and get permission prior to performing all maintenance.

3. If any safety deficiencies are found which could cause injury or damage, notify the cafeteria operator immediately and secure the equipment from further operations.

4. Review manufacturer's instructions.

5. Review the Standard Operating Procedure for "Controlling Hazardous Energy Sources".

6. De-energize, lock out, and tag electrical circuits and fuel service.

7. Follow all instructions of Material Safety Data Sheets for lubricants and cleaners.

Check Points:

1. Check with operator or manager for any deficiencies, verify cleaning program.

2. Check motor and bearings for excessive noise, vibration, and overheating. Clean motor ventilator openings

3. Check electric insulators, connection and wiring, including inside access panels and junction boxes, and final connections. Tighten loose connections.

4. Test electrical controls, signal lights, timer, and OFF/ON switches. Test timer and switches.

5. Examine all pump suction and discharge connections for leakage, adjust packing nuts as required.

6. Check temperature regulator and adjust or calibrate as required.

7. Check thermostatic control solenoid valve for a minimum of 1000 prewash, 1400 for wash, and 1400 or 1800F for final rinse. (Low temp machines at 1400F.)

8. Check operation of wash and rinse spray mechanism for spray coverage and drainage.

9. Inspect soap and spray solution feeder lines; clean as necessary.

10. Inspect water/steam lines and fittings for leaks; tighten fittings as necessary.

11. Check packing glands on wash, rinse, and drain valves; add or replace packing as required. Tighten nuts, bolts, and screws.

12. Check lubricant in gear case; add manufacturer's recommended oil if required.

13. Inspect splash curtain for tears, clearance, and water tightness; adjust if required.

14. Check proper operation of solenoid valve and float in fill tank; adjust as required.

Check and repair insulation as needed.

15. Check proper operation of micro-switch.

16. Check doors for operations of chains and counterweights, warping, alignment and water tightness. Replace door gaskets if needed

17. Clean lime off thermostatic probe and heating elements. Drain booster heater to remove scale from the bottom.

Recommended Tools, Materials, and Equipment:

1. Tool Group A

KTCH-FRY-01-03M Fryer Quarterly

Application:

This maintenance standard applies to electric or gas fired cafeteria kitchen fryer equipment, including deep fat, counter-top, drop-in, and free standing varieties.

Special Instructions:

1. Notify cafeteria operator and get permission prior to performing all maintenance.

2. In addition to the procedure(s) outlined in this standard, the equipment manufacturer's recommended maintenance procedure(s) and/or instruction(s) shall be strictly adhered.

3. If any safety deficiencies are found which could cause injury or damage, including tank leaks, notify the cafeteria operator immediately and secure the equipment from further operations.

4. Review manufacturer's instructions.

5. Review the Standard Operating Procedure for "Controlling Hazardous Energy Sources".

6. De-energize, lock out, and tag electrical circuits and fuel service.

Check Points:

1. Check pilot and flame on gas operated unit; adjust as necessary.

2. Check all gas connections for tightness and for leaks.

3. Check all electrical connections and wiring for tightness and signs of overheating.

4. Check thermostat; calibrate, if necessary.

5. Check basket raising mechanism.

6. Check basket/rack for bends, breaks, or defects; straighten bends or repair as necessary.

7. Check operation of unit.

8. Check flue for proper draft or obstructions.

9. If electric model, check heating elements by amperage draw and check against nameplate.

10. Check nuts, bolts, and screws for tightness; tighten or replace as necessary.

11. Verify that drop-in units must have flange to counter seal.

12. Clean interior walls and elements to obtain maximum heat transfer.

13. Inspect grease compartment.

14. Lubricate gas valves.

Recommended Tools, Materials, and Equipment:

1. Tool Group A

KTCH-GRL-01-03M Grill Quarterly

Application:

This maintenance standard applies to electric operated or gas fired cafeteria kitchen grill equipment, including flat-top, open grill, drop-in, or free standing varieties.

Special Instructions:

1. Notify cafeteria operator and get permission prior to performing all maintenance.

2. If any safety deficiencies are found which could cause injury or damage, notify the cafeteria operator immediately and secure the equipment from further operations.

3. In addition to the procedure(s) outlined in this standard, the equipment manufacturer's recommended maintenance procedure(s) and/or instruction(s) shall be strictly adhered.

4. Review manufacturer's instructions.

5. Review the Standard Operating Procedure for "Controlling Hazardous Energy Sources".

6. De-energize, lock out, and tag electrical circuits and fuel service.

Check Points:

1. Check with operator to verify cleaning program

2. Check with operating or area personnel for any deficiencies.

3. Check nuts, bolts, and screws for tightness; tighten or replace as required.

4. Inspect grease trough, drip tray, splash guard, and surface condition.

5. Examine gas utility supply line, valve packing, tighten fittings as required.

6. Examine/clean burners and elements.

7. On gas operated units, check pilot and gas burners for uniform flame; adjust as required.

8. On electrically operated units, check switches, connections, and wiring for loose or overheated conditions.

9. Check calibration of thermostats; calibrate if required

10. Check flue for proper draft or obstructions.

11. Lubricate gas valves.

12. Check elements to obtain maximum heat transfer take amperage measurement and check against nameplate.

13. Examine burner guards, grates, covers or cook top surfaces for cracks or damage.

14. Check all controls, mechanisms for proper operation; adjust as required.

15. Check electric power line condition, switch, disconnect, etc.; or check condition of gas supply, valves, regulators, and inspect pilot, check for Gas leaks.

16. Examine control knobs and indicating lights; adjust/replace as required.

Recommended Tools, Materials, and Equipment:

1. Tool Group A

KTCH-ICE-02-03M Ice Maker Quarterly

This maintenance standard applies to cafeteria kitchen ice makers, including storage and dispenser types.

Special Instructions:

1. Preventive maintenance services should be performed by a qualified manufacturer's service representative.

2. In addition to the procedure(s) outlined in this standard, the equipment manufacturer's recommended maintenance procedure(s) and/or instruction(s) shall be strictly adhered.

3. Review manufacturer's instructions.

4. Notify cafeteria operator and get permission prior to performing all maintenance.

5. If any safety deficiencies are found which could cause injury or damage, notify the cafeteria operator immediately and secure the equipment from further operations.

6. Review the Standard Operating Procedure for "Controlling Hazardous Energy Sources".

7. De-energize, lock out, and tag electrical circuits.

8. Comply with the latest provisions of the Clean Air Act and Environmental Protection Agency (EPA) regulations as they apply to protection of stratospheric ozone.

9. No intentional venting of refrigerants is permitted. During the servicing, maintenance, and repair of refrigeration equipment, the refrigerant must be recovered.

10. Whenever refrigerant is added or removed from equipment, record the quantities on the appropriate forms.

11. Recover, recycle, or reclaim the refrigerant as appropriate.

12. If appliance is disposed, follow regulations concerning removal of refrigerants and disposal of the appliance.

13. If materials containing refrigerants are discarded, comply with EPA regulations as applicable.

14. Refrigerant oils to be treated as hazardous waste. Refer to Appendix G for the Universal Waste Guide.

15. Closely follow all safety procedures described in the Material Safety Data Sheet (MSDS) for the refrigerant and to all labels on refrigerant containers.

16. Only approved cleaning chemicals shall be used.

1. Check with operating or area personnel for any deficiencies; verify cleaning program.

2. Visually check for refrigerant, oil and water leaks.

3. Inspect ice condition/size.

4. Check and tighten any loose screw-type electrical connections.

5. Check all controls; adjust if necessary.

6. Examine water connection; open and close water valve; test ice dispensing valve and (door) metering adjustment.

7. Check and clear ice…