Appendix 8 - SEASONAL MAINTENANCE TASKS

YORK Y1 ABSORBERS

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

1 Capitol Heat & Power Plant 624 E Main St. Madison York Y1A-ST-8E1-46-B-S UMKM003098 1 Capitol Heat & Power Plant 624 E Main St. Madison York Y1A-ST-8E1-46-B-S UMKM003097

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.

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.

• 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.

• Change oil in purge vacuum pump, install vacuum pump to remove non-condensable and disconnect when completed and check water flow/pressure drop and record data.

• 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:

• Change oil in purge unit accordance to the manufacturer's instructions, including using the oil in compliance with the manufacturer's recommendations.

• Inspect pump contactor and overload

• Replace purge belt according to the manufacturer's instructions, including using a purge belt in compliance with the manufacturer's recommendations.

• Purge and start the purge pump.

o Check and record motor AMP draw

• Purge and start the purge pump and verify deep vacuum.

o record micron level

• Electrical visual inspection

• Inspect for condensation

• Internal inspection and remove dust as needed

• Check and verify electrical connections

• Verify and record output voltages on control panel power supplies

• Control Sequence - Equipment linked to facility automation system, verify sequence for accuracy

• Verify indicator and alarm lights are in proper working condition and replace as needed

• Inspect steam valve for wear

• Inspect steam valve for proper modulation

• Inspect steam system piping and components for leaks

• Leak analysis - Analyze Vacuum / Gauge Data

• Inspect and leak check sight glass

• Check low refrigerant temp cutout switch

• Check condenser water flow switch

• Check chilled water flow switch

• Check high temp cutout switch

• Accuracy check of thermistors, sensors and transducers

• Check condenser and evaporator pressure gauges and record results

• Solution and refrigerant pumps - Inspect contactors and overloads

• Solution and refrigerant pumps - Check electrical connections

• Solution and refrigerant pump motors - Megger OHM and record results

• Review and note any issues for the Manual log inspection details

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:

• Check generator steam pressure

• Verify sequence of operation with microprocessor

• Compare operating log with microprocessor

• Check purge system for leaks

• Review diagnostics log

• Review operating log

• Record operating and performance values

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