Appendix 5 - Packaged Tasks.pdf
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- Attached to
- Chiller Maintenance and Repair Services
- Contract number
- 505CAP-M26-AD251110-00
- Issued by
- Wisconsin
About this file
Summary
This document is Appendix 5 of a State of Wisconsin maintenance contract detailing seasonal maintenance tasks for packaged reciprocating, screw, and scroll chillers located at various state facilities. The contract involves the Wisconsin Department of Administration (DOA) and multiple state agencies including the Executive Residence, State Archive Preservation Facility, State Lab of Hygiene, and various State Office Buildings located in Madison, Waukesha, Milwaukee, Green Bay, Eau Claire, La Crosse, and Wisconsin Rapids. The chiller equipment is manufactured by Carrier, Multistack, Trane, and McQuay, with 16 total chiller units specified across the locations.
The contract requires comprehensive maintenance performed across three seasonal cycles: Mid-season Operational Check (beginning second week of July), Winter Shutdown/Annual Preventative Maintenance (November 1 through April 1), and Comprehensive Spring Start-Up (by week of April 1). Contractor obligations include electronic leak testing with detailed documentation, safety device verification and calibration, oil and refrigerant sampling with spectrochemical analysis at state-designated laboratories, alignment checks with re-lubrication of gear couplings, vibration data collection and analysis, megger testing, starter control inspection and maintenance, and submission of detailed inspection reports to facility managers. All analytical testing must meet specified parameters with documented acceptable limits, and reports identifying non-conforming results must include probable causes and recommended corrective actions. The contract specifies strict deadlines for report submission, including the requirement that all findings and recommendations be delivered to facility managers by the end of the first week in December.
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Appendix 5 - SEASONAL MAINTENANCE TASKS
PACKAGED RECIPROCATING, SCREW AND SCROLL CHILLERS
Mid-season Operational Check:
Work must begin the second week in July (coordinate with Facility Manager).
Record all findings, results, and observations. Discuss with facility manager and communicate any recommendations.
Contractor must:
• Electronically leak-test chiller units, purge pump units, refrigerant receivers, associated refrigerant piping and equipment, and relief vent pipe outlet. Tests must be performed in compliance with manufacturer’s recommendations using an electronic leak detector capable of detecting a leak rate of one (1) ounce per year. Once leaks have been located using the electronic leak detector, they must then be confirmed using a liquid leak detector solution. Size and location of leaks must be recorded on a service report, along with any recommendations to repair significant leaks and the leak locations identified on a graphic representation of the chiller. Contractor must provide a marked-up chiller pictorial indicating location of chiller refrigerant leak(s) in accordance with Section 3.2.5.
Location # Location Street Address City Chiller Make & Model No. Chiller Serial
No.
2 Executive Residence 99 Cambridge Ave. Madison Carrier 09DPM0355C 3113Q48734 2 Executive Residence 99 Cambridge Ave. Madison Carrier 30MPA030 3213Q2123 3 State Archive Preservation Facility 204 South Thornton Avenue Madison Multistack MS030DN AF07-56 3 State Archive Preservation Facility 204 South Thornton Avenue Madison Multistack MS030DN AF07-57 3 State Archive Preservation Facility 204 South Thornton Avenue Madison Multistack MS085XC AF07-59 3 State Archive Preservation Facility 204 South Thornton Avenue Madison Multistack MS085XC AF07-60 3 State Archive Preservation Facility 204 South Thornton Avenue Madison Multistack MS085XC AF07-61 3 State Archive Preservation Facility 204 South Thornton Avenue Madison Multistack MS085XC AF07-62
7 State Lab of Hygiene - SLH 2601 Agriculture Drive Madison Multistack MS70X6H2H1-R410A AA-020-202
State Lab of Hygiene – SLH COLAB 2601 Agriculture Drive Madison Multistack MS070XC2H2H2AA JOB 533-L005
State Lab of Hygiene – SLH COLAB 2601 Agriculture Drive Madison Multistack MS50XC2H2 AB06-025
11 Waukesha 141 N.W. Barstow Street Waukesha Trane RTHC1B2FOHOC U01M07507 12 Crime Lab Milwaukee 1578 South 11th Street Milwaukee McQuay WHR090D-A 5YA017710 12 Crime Lab Milwaukee 1578 South 11th Street Milwaukee Carrier 05HY040DH400 2333-208 12 Crime Lab Milwaukee 1578 South 11th Street Milwaukee Carrier 05HY040DH400 2333-209 13 Green Bay State Office Bldg 200 N. Jefferson Street Green Bay Trane RTWD 110F U09B03198 14 Eau Claire State Office Bldg 718 West Clairemont Ave Eau Claire Trane Model RTHD – UB1F U09A03047 15 LaCrosse State Office Bldg 3550 Mormon Coulee Rd La Crosse Trane RTHB-130ALF U98E00267
Wisconsin Rapids State Office Bldg 1681 2nd Ave South Wisconsin
Rapids Trane RTHB-150 U999L02450
• Check with Facility Manager to verify that chiller safety devices have been operating according to manufacturer’s specifications.
a) Evaporator Low Suction Pressure Cut Out
b) Low Chilled Water Temperature Cut Out
c) Low Chilled Water Temperature Alarm
d) High Condenser Pressure Cut Out
e) Compressor Auxiliary Oil Pump Pressure Switch
f) Compressor Low Oil Pressure Cut Out
g) Low Chilled Water Flow
h) Test any safety devices that are questionable, calibrate if instructed to, and record their operation
• Check control operation, pressure and temperature gauges on chiller.
• Check operation of operating controls and chiller related pressure and temperature gauges.
• Check chiller system operation while online.
• Determine if operating temperatures and pressures are running within manufacturer's recommended ranges.
• Take an oil sample from each chiller compressor and take refrigerant samples from each chiller evaporator while in operation.
o Provide a spectrochemical analysis for each sample taken including a detailed report of analysis results and recommendations.
o Test results including recommendations must be submitted to the Facility
Manager in person, within four (4) weeks of sample collection.
• Reports must include the tests results for each item listed below. Next to each test result list the acceptable limits for each type of oil or refrigerant sample. For all tests that do not meet acceptable limits provide a probable cause or causes of abnormality along with the recommended course of action to be taken to rectify the problem.
o Tests a-f are to be performed for both oil and refrigerant samples. Test g for oil only. Tests h and i refrigerant only.
a) Aluminum PPM
b) Copper PPM
c) Iron PPM
d) Tin PPM
e) Zinc PPM
f) Moisture PPM
g) Acid Number Oil (oil only)
h) Acid Number Oil Residue (refrigerant only)
i) Acid Number Refrigerant (refrigerant only) o All analytical tests are to be performed at the State designated testing laboratory as per Section 3.2.2.
• Follow manufacturer's recommended guidelines for placement of dial indicators. (Note:
No variances from these procedures must be allowed) Completely fill out information on each alignment log sheet.
• Alignment Checks- Chiller availability must determine when alignment checks can be performed. Readings must be taken prior to chiller shut down. The Facility Manager may elect to have a cold alignment check performed during the Winter Shut Down in place of this hot alignment check.
o Re-lubricate chiller gear couplings according to coupling manufacturer's instructions, including using the grease in compliance with the manufacturer’s recommendations.
• Review chiller operation and complete Preventative Maintenance sheets.
• Make recommendations for additional work to be performed during the Winter Shut Down maintenance.
o Include these recommendations on the written annual report.
o Submit completed written annual report to the Facility Manager no later than the end of the first week in December.
• Contractors must collect vibration data on chiller motor, compressor, cold water pumps, condenser pumps and cooling tower fans while operational during the mid-season inspection. Perform spectral and time waveform analysis and make recommendations to DOA staff in writing.
Winter Shut Down/Annual Preventative Maintenance:
Work must start in the first week of November 1 and be completed by April 1.
Record all findings, results, and observations. Discuss with facility manager and communicate any recommendations.
Contractor must:
• Lock out and tag-out all chiller electrical power sources.
• Pressurize the machine to a minimum pressure of 100 psig unless otherwise directed by the manufacturer and electronically leak test all fabricated compressor vessel and piping joints.
• Remove two oil samples from crankcase for field testing and lab analysis.
o Replace any external oil filter element and lubricant if it is acidic based on the analysis.
o Recharge the compressor lube system new oil with the proper grade.
• Check the following safety and operating controls set points, record settings and recalibrate as required:
o Condenser high-pressure cutout.
o Oil low pressure cutout.
o Oil thermostat.
o Refrigerant low temperature cutout.
o Check and verify proper operation of water flow switches.
• Re-leak test the work performed above and repair any leaks noted. Minimum pressure 100 psig unless otherwise directed by the manufacturer. Contractor must provide a marked-up chiller pictorial indicating location of chiller refrigerant leak(s) in accordance with Section 3.2.5.
• Megger test the compressor and record values. (Phase to ground)
• Inspect starter controls for pitting, corrosion, spring tension and freedom of mechanical linkage.
o Clean all contacts.
o Tighten all power and control wire at termination in starter and control console.
• Winter Inspection Report o Provide a detailed end of year inspection report, including oil analysis report and submit a recommendation of any maintenance or repairs that may need to be completed. This report must be delivered before the end of the first full week of December to the Facility Manager in person.
Comprehensive Spring Start-Up:
Contractors must have Chillers fully operational according to the tasks defined below each year by the week of April 1, or within one (1) week of DOA notification to Contractor that chillers shall be put in service.
Record all findings, results, and observations. Discuss with facility manager and communicate any recommendations.
Contractor must:
• Start-up chillers.
• Verify correct operation as per manufacturers guidelines.
• Check overall performance of machines and review operating procedures with facility maintenance personnel.
• Record fluid levels.
• Make recommendations for additional work to be performed during the mid-season inspection.
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