Appendix 7 - York Centrifugal Tasks.pdf

Appendix 7 - SEASONAL MAINTENANCE TASKS

YORK CENTRIFUGAL 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.

• 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.

Location # Location Street Address City Chiller Make & Model No. Chiller Serial No.

1 Capitol Heat & Power Plant 624 E Main St. Madison York YKQTQSK3-DCGS SDVM-269350 5 Hill Farms DEL - L Bldg 4638 University Avenue Madison York YKEC7Q6-EMC SACM-151720 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.

• Check and record hot component shaft alignment for compressor and driver, and for compressor speed increaser.

• Check and record axial forward and reverse thrust and bearing clearance on all York centrifugal chiller compressors and their Lufkin speed increaser.

o Compare current readings with factory specifications and readings from previous years.

• 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 shall start in the first week of November 1 and completed by April 1.

Record all findings, results, and observations. Discuss with facility manager and communicate any recommendations

Contractor must:

*where applicable

• Megger oil pump motor and record readings

• Measure and record oil pump voltage and amperage

• Inspect the starter for signs of overheating, arcing, burns, etc.

• Verify operation of oil cooling system*

• Tighten terminal connections on the oil pump motor

• Verify operation of the oil heater

• Change the compressor oil and filter

• Check operation of the oil return system

• Change filter dryer in the oil return line

• Clean dirt leg

• Clean starter cabinet

• Inspect starter and starter components for signs of discoloration, burns, moisture, etc.

• Test accuracy of motor current (AMP meter)

• Test tightness of terminal connections

• Check dash pot oil and add as necessary

• Megger motor at the starter terminals and record readings

• Measure operating voltage and record

• Inspect the control panel for cleanliness, control air leaks, etc.

• Inspect wiring and connections for signs of overheating, burns

• Verify operation of the vane control system. Check for free and smooth operation. Check mechanical linkages for wear & secureness

• Report accuracy of all gages and thermometers (use masters)

• Verify working condition of all indicator and alarm lights

• Verify operation of start, stop, and anti-recycle timers

• Test all flow switch cutouts (CW, CHW)*

• Verify operation of automatic and manual capacity control

• Verify operation of oil temperature and pressure controller(s)

• Test high condenser pressure cutout - calibrate and record

• Test cooler low-pressure cutout - calibrate and record

• Test oil pressure cutout - calibrate and record

• Test high oil temperature cutout - calibrate and record

• Test compressor high discharge temperature cutout - calibrate and record

• Test low water temperature leaving cooler cutout - calibrate and record

• Test the operation of all pump auxiliary contacts (CHW, CW, oil, etc.)*

• Record elapsed run times and start counts*

• Drain, clean, and inspect purge drum

• Clean sight glass and report condition

• Clean and inspect purge float assembly

• Inspect pulley grooves and belts for alignment, wear, and tension

• Lubricate purge motor

• Test purge safety switch and adjust if required*

• Verify operation of the purge heater

• Change filter dryer in purge line*

• Verify operation of the purge timer*

• Test the secureness of mounting points and tighten all major points

• Measure and record the purge compressor motor voltage and amperage

• Test and calibrate purge operating controls

• Clean oil separator*

• Set separator float*

• Change oil in purge compressor

• Run purge compressor and verify operation

• Inspect area around coupling/gear for oil leaks*

• Lubricate coupling*

• Visually inspect coupling for abnormal conditions*

• Align shafts

• Test for refrigerant leaks and report results.

o Contractor shall provide a marked-up chiller pictorial indicating location of chiller refrigerant leak(s) in accordance with Section 3.2.5.

• Check refrigerant charge.

• Replace filter/dryer in motor cooling line*

• Record refrigerant level

• Review machine operation with operator

• Log machine at departure

• Run complete interlocking circuit where possible

• Report machine condition and repair requirements (if any)

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:

• 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.

• Trim chiller refrigerant charge for optimum chiller performance.

o Additional refrigerant will be provided by DOA unless the Facility Manager instructs

Contractor to provide.

o Contractor shall be responsible for charging for any additional refrigerant purchased into refrigeration systems.

• Start-up chillers.

o Electrical demand period, chiller availability and cooling load shall determine when each chiller shall be allowed to operate.

o Record all three (3) phases of compressor motor current and voltage and compare with the nameplate data.

• Check all safety and operating controls and make sure unit is running according to manufacturer’s specifications. Record all pertinent parameters of unit including the following:

o Refrigerant pressure (cooler and condenser) o Refrigerant temperature (cooler and condenser) o Water temperature, inlet and outlet (cooler and condenser) o Pressure drops, waterside (cooler and condenser) o GPM (cooler and condenser) o Bearing oil temperature o Oil sump temperature o Oil pressure, psig o Motor volts and amperage (all phases) o Purge counts and compressor operating hours o Purge condensing temperature o Starter transition time (actual) o Chiller - Check and record motor cooling temperature o Chiller - Review and record operating conditions o Chiller - Inspect vane actuator while stroking the vanes open and closed o Chiller – Inspect high pressure compressor starter for signs of excessive heat, burns, arcing or other deterioration o Chiller - Inspect refrigerant relief valve for leaks or signs of discharge o Centrifugal Chiller Control Panel - Verify set points, stroke vanes, check alarm and diagnostic points o Control Panel - Electrical visual inspection o Control Panel - Inspect for condensation o Verify output voltages on control panel power supplies o Check for refrigerant leaks. Contractor shall provide a marked-up chiller pictorial indicating location of chiller refrigerant leak(s) in accordance with Section 3.2.5.

Perform minor repairs such as valve packing, flare nuts etc.

o Megger oil pump and compressor motor and record readings o Inspect and test integrity of safeties and fuses, performance and wiring

• Test and record compressor pre-lube and post-lube cycles.

o Re-calibrate if needed and record their operation on PM sheets.

• Check overall performance of machines and review operating procedures with facility maintenance personnel.