Appendix A - Original Davis Chiller Plant DDC Contractor Design Drawings.pdf

OPTIMA CONTROLS, LTD.

Optimized Building Automation Systems And Commissioning Services 40 Meander Lane Levittown New York 11756

Phone: 516-520-5818 Fax: 516-706-6707 www.optimacontrols.com

System Notes &

Manual Procedures

START-UP/SHUTDOWN PROCEDURES

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GENERAL

1. Since DPW drains the chilled water from all rooftop units located in the remote Barracks for the winter you will need to circulate water once the system is filled to get the air out of the system prior to running chiller. Perform the following procedure to bleed the system of air:

a. Disable the system.

b. In each Barracks open every chilled water valve at the rooftop units to 100%.

c. In the Chiller Plant open every Chiller chilled water valve (FCV-0101 – 0107) to 100%.

d. Open TCV-0101 to 100% – Davis Secondary System

e. Close TCV-0102 – Loop Bypass Valve

f. Manually enable CHWP-1-5 and initially set the speed to 50%. Increase or decrease the speed until the

Scott Differential Pressure transmitter (PDT-0109) reads 15.0 psi.

g. Run in this configuration for a minimum of 2 hours.

h. The operator must constantly monitor the system for alarms and verify that PDT-0109 does not exceed 20.0 psi.

i. After 2 hours release all overrides and enable the system

SYSTEM DISABLE

1. From the “System Modes” graphic select the “Set Enable” button and perform the following:

a. Answer “Yes” to “Are you sure you wish to invoke “Set”

b. Select “Disable” and press Enter.

2. The system will automatically shutdown incorporating manufacturer shutdown time delays.

SYSTEM ENABLE

1. SYSTEM ENABLE:

a. Select “Set Enable” and answer “Yes” to “Are you sure you wish to invoke “Set””

b. Select “Enable” and press Enter. The system will start based on the Lead/Lag configurations for all system equipment.

SYSTEM MODES

1. GENERAL:

a. When disabled the system defaults to the last operating mode (Mechanical Cooling or Free Cooling).

b. The Operator can manually select either Mechanical Cooling or Free Cooling through the “Set Mode” button by performing the following:

i. Set “Set Mode” and answer “Yes” to “Are you sure you wish to invoke “Set Plant State”

ii. Select either “Mechanical Cooling” or “Free Cooling” and press Enter.

c. If the conditions change while the system is Disabled it will notify the operator on the System Mode graphic and the operator can approve the new control mode or leave it in the last operating mode.

2. SWITCH FROM MECHANICAL COOLING TO FREE COOLING:

a. When the system is operating in Mechanical Cooling and the Free Cooling enable parameters are achieved the BMS will send the following message to the Operator: “Notice of Free Cooling – Available”.

b. The Operator will need to manually index the system into Free Cooling mode by performing the following on the System Modes screen:

i. The “Notify Free Cooling Available” will state “Yes” and be highlighted in Green.

ii. Select “Approve Free Cooling” and answer “Yes” to “Are you sure you wish to invoke “Allow Free Cooling”

iii. Select “Yes” and press Enter.

iv. Plant Mode will now display “Free Cooling” and the system will change the equipment configuration to run in Free Cooling.

START-UP/SHUTDOWN PROCEDURES

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3. SWITCH FROM FREE COOLING TO MECHANICAL COOLING:

a. When the system is operating in Free Cooling and the Mechanical Cooling enable parameters are achieved the BMS will send the following message to the Operator: “Notice of Mechanical Cooling – Available”.

b. The Operator will need to manually index the system into Mechanical Cooling mode by performing the following on the System Modes screen:

i. The “Notify Mech Cooling Available” will state “Yes” and be highlighted in Green.

ii. Select “Approve Mech Cooling” and answer “Yes” to “Are you sure you wish to invoke “Allow Mechanical Cooling”

iii. Select “Yes” and press Enter.

iv. Plant Mode will now display “Mechanical Cooling” and the system will change the equipment configuration to run in Mechanical Cooling

4. DAVIS SECONDARY PUMP OVERRIDE – TEMP CHILLER ONLY

a. When the system is Disabled and a temporary chiller is installed you will need to enable this point to run the secondary pumps for Davis Barracks.

i. Select the current command and change to “Enabled”, select the “Override Value” and then set the duration for the override.

EQUIPMENT CONTROL & OVERRIDES

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GENERAL

When enabled the lead equipment, as selected automatically by runtime or manually by the Operator, will be put into service and will start. After the lead equipment is online the BAS will automatically energize and de-energize Chillers, Pumps and Cooling Towers as required to maintain the chilled water set-point.

CHILLER SELECTION & OVERRIDES

Operator selectable buttons:

1. General:

a. Chiller-1, 2, 3, 4, 5 & 6 buttons link to the individual Chiller graphic

b. The system consists of 6 Chillers and 1 Heat Exchanger, which only operates in Free-Cooling mode.

i. Group 1: Chiller-1 & 2 / Daikin - Electric 325 TON (existing from original Chiller Plant)

ii. Group 2: Chiller-3 & 4 / Johnson Controls – Steam 850 TON

iii. Group-3: Chiller-5 & 6 / Daikin – Electric 850 TON

c. All of the Chillers will operate in any scenario but they are best utilized to be set as the Lead Group within the following parameters:

i. OAT is between 42ºF - 50 ºF: Chiller-1 &2

ii. OAT is above 50ºF and low electrical Demand: Chiller-5 & 6

iii. OAT is above 50ºF and high electrical Demand: Chiller-3 & 4

2. “Set Cmd” – Sets the Chiller Service Command. Chiller’s are always in service unless they are manually indexed to “Maintenance Shutdown” or in an “Alarm Shutdown”.

a. To set the Chiller to “Maintenance Shutdown” perform the following procedure:

i. Select “Set CMD” and answer “Yes” to “Are you sure you wish to invoke “Set Service Flag”?

ii. Select “Out of Service”

iii. Press “OK” to take the Chiller out of service.

iv. Current State will indicate “Maintenance Shutdown” and the Operator Status will indicate “Out of

Service”

b. To set the Chiller back to normal operation perform the following procedure:

i. Select “Set CMD” and answer “Yes” to “Are you sure you wish to invoke “Set Service Flag”?

ii. Select “In Service”

iii. Press “OK” to return the Chiller to service.

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3. Alarm Reset” – Resets the individual Chiller Alarms that have been cleared after physical evaluation. When a Chiller is in an alarm condition the Current State will indicate “Alarm Shutdown” in RED and the Operator Status will indicate “Out of Service”. If all of the associated alarms have not been cleared the “Reset” will not work.

4. “Rotation Schedule” – Time schedule for automatic Lead/Lag operation based on Runtime:

a. Chiller’s rotate based on a monthly time schedule initially set for the 1st Monday of the month at 9:00AM.

From here you can change or add schedules for the Chiller rotation

b. Within a Chiller Group The Lead/Lag schedule is based on runtime.

c. The “Next Rotation” date/time indicates when the next scheduled Lead/Lag event will occur.

5. “Delay Rotation” – This is only active during the 4 hour (not adjustable) time window from when the rotation notification is received and it will stop the next rotation and delay it until the next scheduled date.

6. “Initiate Now” - This is only active during the 4 hour (not adjustable) time window from when the rotation notification is received and it will immediately rotate the Chillers.

7. “Set Lead/Lag” – Lead/Lag Control: The Lead/Lag sequence can be manually set by the Operator by perform the following procedure. For this Group it sets the Chiller Group Lead / Lag1 / Lag2 rotation.

a. Select “Set Lead/Lag Group” answer “Yes” to “Are you sure you wish to invoke “Set Groups”?

b. Select the Lead / Lag1 / Lag2 rotation based on the current facility and OA conditions.

c. Press “OK” to change the rotation

8. All adjustable timers and set-points will highlight BLUE when you move the mouse over them. When any of these are overridden they will indicate PURPLE and will remain that way until released by the operator.

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PRIMARY CHILLED WATER PUMP SELECTION & OVERRIDES

a. CHWP-1, 2, 3, 4 & 5 buttons link to the CHW Pump VFD graphic.

2. “Set Cmd” – Sets the CHWP Service Command. CHWP’s are always in service unless they are manually indexed to “Maintenance Shutdown” or in an “Alarm Shutdown”.

a. To set the CHWP to “Maintenance Shutdown” perform the following procedure:

i. Select “Set CMD” and answer “Yes” to “Are you sure you wish to invoke “Set Service Flag”?

ii. Select “Out of Service”

iii. Press “OK” to take the CHWP out of service.

iv. Current State will indicate “Maintenance Shutdown” and the Operator Status will indicate “Out of

Service”

b. To set the CHWP back to normal operation perform the following procedure:

i. Select “Set CMD” and answer “Yes” to “Are you sure you wish to invoke “Set Service Flag”?

ii. Select “In Service”

iii. Press “OK” to return the CHWP to service.

3. “Reset” – Resets the individual CHWP Alarms that have been cleared after physical evaluation. When a CHWP is in an alarm condition the Current State will indicate “Alarm Shutdown” in RED and the Operator Status will indicate “Out of Service”. If all of the associated alarms have not been cleared the “Reset” will not work.

4. “Rotation Schedule” – Time schedule for automatic Lead/Lag operation based on Runtime:

a. CHWP’s rotate based on a monthly time schedule initially set for the 1st Wednesday of the month at

10:00AM. From here you can change or add schedules for the Pump rotation

b. The Lead/Lag schedule is based on runtime.

c. The “Next Rotation” date/time indicates when the next scheduled Lead/Lag event will occur.

5. “Delay Rotation” – This is only active during the 4 hour (not adjustable) time window from when the rotation notification is received and it will stop the next rotation and delay it until the next scheduled date.

6. “Initiate Now” - This is only active during the 4 hour (not adjustable) time window from when the rotation notification is received and it will immediately rotate the CHWP’s.

7. “Set Lead/Lag” – Lead/Lag Control: The Lead/Lag sequence can be manually set by the Operator by perform the following procedure:

a. Select “Set Lead/Lag” answer “Yes” to “Are you sure you wish to invoke “Set Lead/Lag”?

b. Select the Lead / Lag1 / Lag2 / Lag3 / Lag4 rotation.

c. Press “OK” to change the rotation

8. All adjustable timers and set-points will highlight BLUE when you move the mouse over them. When any of these are overridden they will indicate PURPLE and will remain that way until released by the operator.

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DAVIS SECONDARY CHILLED WATER PUMP SELECTION & OVERRIDES

a. SCHWP-1 & 2 buttons link to the CHW Pump VFD graphic.

2. “Set Cmd” – Sets the SCHWP Service Command. SCHWP’s are always in service unless they are manually indexed to “Maintenance Shutdown” or in an “Alarm Shutdown”.

a. To set the SCHWP to “Maintenance Shutdown” perform the following procedure:

i. Select “Set CMD” and answer “Yes” to “Are you sure you wish to invoke “Set Service Flag”?

ii. Select “Out of Service”

iii. Press “OK” to take the SCHWP out of service.

iv. Current State will indicate “Maintenance Shutdown” and the Operator Status will indicate “Out of

Service”

b. To set the SCHWP back to normal operation perform the following procedure:

i. Select “Set CMD” and answer “Yes” to “Are you sure you wish to invoke “Set Service Flag”?

ii. Select “In Service”

iii. Press “OK” to return the SCHWP to service.

3. “Reset” – Resets the individual SCHWP Alarms that have been cleared after physical evaluation. When a

SCHWP is in an alarm condition the Current State will indicate “Alarm Shutdown” in RED and the Operator Status will indicate “Out of Service”. If all of the associated alarms have not been cleared the “Reset” will not work.

4. “Rotation Schedule” – Time schedule for automatic Lead/Lag operation based on Runtime:

a. SCHWP’s rotate based on a monthly time schedule initially set for a weekly rotation on Tuesday at

10:00AM. From here you can change or add schedules for the Pump rotation

b. SCHWP’s do not rotate based on runtime, only based on the Rotation Schedule.

c. The “Next Rotation” date/time indicates when the next scheduled Lead/Lag event will occur.

5. “Delay Rotation” – This is only active during the 4 hour (not adjustable) time window from when the rotation notification is received and it will stop the next rotation and delay it until the next scheduled date.

6. “Initiate Now” - This is only active during the 4 hour (not adjustable) time window from when the rotation notification is received and it will immediately rotate the SCHWP’s.

7. “Rotate Lead/Lag” – Lead/Lag Control: The Lead/Lag sequence can be manually set by the Operator by perform the following procedure:

a. Select “Rotate Lead/Lag” answer “Yes” to “Are you sure you wish to invoke “Rotate”?

b. This immediately changes the Lead/Lag od the SCHWP’s..

8. All adjustable timers and set-points will highlight BLUE when you move the mouse over them. When any of these are overridden they will indicate PURPLE and will remain that way until released by the operator.

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COOLING TOWER SELECTION & OVERRIDES

a. The system consists of 6 Cooling Towers (CT), CT-1 (existing from original Chiller Plant)

b. Tower-1, 2, 3, 4, 5 & 6 buttons link to the individual CT graphic

2. “Set Cmd” – Sets the CT Service Command. CT’s are always in service unless they are manually indexed to “Maintenance Shutdown” or in an “Alarm Shutdown”.

a. To set the CT to “Maintenance Shutdown” perform the following procedure:

i. Select “Set CMD” and answer “Yes” to “Are you sure you wish to invoke “Set Service Flag”?

ii. Select “Out of Service”

iii. Press “OK” to take the CT out of service.

iv. Current State will indicate “Maintenance Shutdown” and the Operator Status will indicate “Out of

Service”

b. To set the CT back to normal operation perform the following procedure:

i. Select “Set CMD” and answer “Yes” to “Are you sure you wish to invoke “Set Service Flag”?

ii. Select “In Service”

iii. Press “OK” to return the CT to service.

3. “Reset” – Resets the individual CT Alarms that have been cleared after physical evaluation. When a CT is in an alarm condition the Current State will indicate “Alarm Shutdown” in RED and the Operator Status will indicate “Out of Service”. If all of the associated alarms have not been cleared the “Reset” will not work.

4. “Set Drain” – Allows the Operator to manually drain a CT.

a. To manually drain the CT perform the following procedure:

i. Select “Set Drain” and answer “Yes” to “Are you sure you wish to invoke “Set Tower Drain State”?

ii. Select “Drain”

iii. Press “OK” to drain the CT. The Current State will state “Draining”.

b. To set the CT back to normal operation perform the following procedure:

i. Select “Set Drain” and answer “Yes” to “Are you sure you wish to invoke “Set Tower Drain State”?

ii. Select “Normal”

iii. Press “OK” to drain the CT.

5. “Set DeIce” – Allows the Operator to manually DeIce a CT.

a. Notes:

i. CT-1 does not have the ability to operate in Reverse so the DeIce mode is not available.

ii. DeIce mode operates for a total of 3 minutes and cannot be stopped other than indexing the CT to “Out of Service”

b. To manually DeIce the CT perform the following procedure:

i. Select “Set DeIce” and answer “Yes” to “Are you sure you wish to invoke “DeIce”?

ii. Select “DeIce”. The Current State will state “DeIce”.

iii. Press “OK” to DeIce the CT.

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6. “Rotation Schedule” – Time schedule for automatic Lead/Lag operation based on Runtime:

a. CT’s rotate based on a monthly time schedule initially set for the 1st Tuesday of the month at 9:00AM.

From here you can change or add schedules for the CT rotation

b. The Lead/Lag schedule is based on runtime.

c. The “Next Rotation” date/time indicates when the next scheduled Lead/Lag event will occur.

7. “Delay Rotation” – This is only active during the 4 hour (not adjustable) time window from when the rotation notification is received and it will stop the next rotation and delay it until the next scheduled date.

8. “Initiate Now” - This is only active during the 4 hour (not adjustable) time window from when the rotation notification is received and it will immediately rotate the CT’s.

9. “Set Lead/Lag” – Lead/Lag Control: The Lead/Lag sequence can be manually set by the Operator by perform the following procedure:

a. Select “Set Lead/Lag” answer “Yes” to “Are you sure you wish to invoke “Set Lead/Lag”?

b. Select the Lead / Lag1 / Lag2 / Lag3 / Lag4 / Lag4 rotation.

c. Press “OK” to change the rotation

10. All adjustable timers and set-points will highlight BLUE when you move the mouse over them. When any of these are overridden they will indicate PURPLE and will remain that way until released by the operator.

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CONDENSER WATER PUMP SELECTION & OVERRIDES

a. CWP-1, 2, 3, 4 & 5 buttons link to the CHW Pump VFD graphic.

2. “Set Cmd” – Sets the CWP Service Command. CWP’s are always in service unless they are manually indexed to “Maintenance Shutdown” or in an “Alarm Shutdown”.

a. To set the CWP to “Maintenance Shutdown” perform the following procedure:

i. Select “Set CMD” and answer “Yes” to “Are you sure you wish to invoke “Set Service Flag”?

ii. Select “Out of Service”

iii. Press “OK” to take the CWP out of service.

iv. Current State will indicate “Maintenance Shutdown” and the Operator Status will indicate “Out of

Service”

b. To set the CWP back to normal operation perform the following procedure:

i. Select “Set CMD” and answer “Yes” to “Are you sure you wish to invoke “Set Service Flag”?

ii. Select “In Service”

iii. Press “OK” to return the CWP to service.

3. “Reset” – Resets the individual CWP Alarms that have been cleared after physical evaluation. When a CWP is in an alarm condition the Current State will indicate “Alarm Shutdown” in RED and the Operator Status will indicate “Out of Service”. If all of the associated alarms have not been cleared the “Reset” will not work.

4. “Rotation Schedule” – Time schedule for automatic Lead/Lag operation based on Runtime:

a. CWP’s rotate based on a monthly time schedule initially set for the 1st Monday of the month at 10:00AM.

From here you can change or add schedules for the Pump rotation

b. The Lead/Lag schedule is based on runtime.

c. The “Next Rotation” date/time indicates when the next scheduled Lead/Lag event will occur.

5. “Delay Rotation” – This is only active during the 4 hour (not adjustable) time window from when the rotation notification is received and it will stop the next rotation and delay it until the next scheduled date.

6. “Initiate Now” - This is only active during the 4 hour (not adjustable) time window from when the rotation notification is received and it will immediately rotate the CWP’s.

7. “Set Lead/Lag” – Lead/Lag Control: The Lead/Lag sequence can be manually set by the Operator by perform the following procedure:

a. Select “Set Lead/Lag” answer “Yes” to “Are you sure you wish to invoke “Set Lead/Lag”?

b. Select the Lead / Lag1 / Lag2 / Lag3 / Lag4 rotation.

c. Press “OK” to change the rotation

8. All adjustable timers and set-points will highlight BLUE when you move the mouse over them. When any of these are overridden they will indicate PURPLE and will remain that way until released by the operator.

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GENERAL

The Chillers, Cooling Towers & Heat Exchanger have individual graphics that have their associated Overrides. All of the Chilled Water Pumps share an override screen and also the Condenser Water Pumps share an override screen.

INDIVIDUAL CHILLER OVERRIDES

1. Chiller-1 & 2:

a. Chiller S/S:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the duration for the override.

b. Chilled Water Valve FCV-010#:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the duration for the override.

c. Condenser Water Valve FCV-020#:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the

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2. Chiller-3 & 4:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the duration for the override.

b. Chilled Water Valve FCV-010#:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the duration for the override.

c. Condenser Water Valve FCV-020#:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the duration for the override.

d. Blowdown Valve XCV-010#:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the

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3. Chiller-5 & 6:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the duration for the override.

b. Chilled Water Valve FCV-010#:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the duration for the override.

c. Condenser Water Valve FCV-020#:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the

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HEAT EXCHANGER OVERRIDES

4. HX-1:

a. Chilled Water Valve FCV-010#:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the duration for the override.

b. Condenser Water Valve FCV-020#:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the

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COOLING TOWER OVERRIDES

1. Cooling Tower-1, 2, 3, 4, 5 & 6:

a. Cooling Tower S/S:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override” select the “Override Value” and then set the duration for the override.

b. Chilled Water Speed:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the duration for the override

c. Return Water Valve FCV-0208 - 0213:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the duration for the override.

d. Supply Water Valve FCV-0214 - 0219:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the duration for the override.

e. Equalizer Water Valve FCV-0220 - 0225:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the

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f. Drain Valve FCV-0226 - 0231:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the duration for the override.

g. Basin Heater:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override” select the “Override Value” and then set the duration for the override

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CHWP & SCHWP OVERRIDES

a. Pump S/S:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override” select the “Override Value” and then set the duration for the override.

b. Pump Speed:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the

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CWP OVERRIDES

a. Pump S/S:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override” select the “Override Value” and then set the duration for the override.

b. Pump Speed:

i. Select “Auto” and change to “Override”, select the “Override Value” and then set the duration for the override.

ii. Select the current command and change to “Override”, select the “Override Value” and then set the

40 Meander Lane Levittown New York 11756

The following design set-points were changed from the approved Sequence of Operations during the testing period with USACE:

1. Chiller Control Values

a. “Floating Chiller Valve Position” for CH-1 & 2 was changed from 80% to 70%.

b. “Min Flow Stage Up Setpoint Delay” timer from 60 minutes to 15 minutes.

c. “CHW Temp Stage Up Setpoint Delay” timer from 10 minutes to 60 minutes.

d. “Min Time Required Before Stage Down” timer from 30 minutes to 60 minutes.

e. “CHW Temp Stage Up Setpoint” from 1.0ºF to 1.5ºF.

2. CHWP-1 – 5

a. “Initial Pump Min On Before Stage Up Delay” timer from 60 minutes to 5 minutes.

b. “Pump Min On Before Stage Up Delay” timer from 30 minutes to 5 minutes.

c. “Lag Pump Stage Down Delay” timer from 10 minutes to 15 minutes.

d. “Lag Stage Down Speed” from 30% to 55%.

3. SCHWP-1 & 2

a. “Lag Stage Down Speed” timer from 30% to 60%.

b. “Davis SCHW Return SP” from 58ºF to 42ºF.

4. Condenser Water Control

a. “Tower Fan VFD Stage Up Delay” timer from 5 minutes to 0.5 minutes.

b. “Tower Fan VFD Stage Down Delay” timer from 5 minutes to 0.5 minutes.

c. “Basin Bypass Vlv Control SP Offset” temperature from 2ºF to 8ºF.

Valve &Control P I D Values

Project:

Date:

Item Valve Description P I D Ramp Time (minutes)

Location

1 TCV-0101 Davis Barracks Secondary Loop - CHWRT Cnntrol 0.750 1.000 0.000 5:00 Config/PlantLogic/Pumps/TCV_101Control/TCV_101ReturnPID 2 TCV-0101 Davis Barracks Secondary Loop - CHWST Control 3.000 2.000 0.000 5:00 Config/PlantLogic/Pumps/TCV_101Control/TCV_101SupplyPID 3 TCV-0102 Main Chilled Water Plant Loop 0.100 0.500 0.000 5:00 Config/PlantLogic/MinFlowControl/LowFlowBypassCntl 4 FCV-0101 Chiller-1 Chilled Water Control 0.500 0.200 0.000 3:00 Config/PlantLogic/Chillers/Group1/ValveControl1/EvapControl 5 FCV-0201 Chiller-1 Condenser Water Control 0.050 0.100 0.000 3:00 Config/PlantLogic/Chillers/Group1/ValveControl1/CondControl 6 FCV-0102 Chiller-2 Chilled Water Control 0.500 0.200 0.000 3:00 Config/PlantLogic/Chillers/Group1/ValveControl2/EvapControl 7 FCV-0202 Chiller-2 Condenser Water Control 0.070 0.200 0.000 3:00 Config/PlantLogic/Chillers/Group1/ValveControl2/CondControl 8 FCV-0103 Chiller-3 Chilled Water Control 1.000 0.500 0.000 3:00 Config/PlantLogic/Chillers/Group2/ValveControl3/EvapControl 9 FCV-0203 Chiller-3 Condenser Water Control 0.050 0.100 0.000 3:00 Config/PlantLogic/Chillers/Group2/ValveControl3/CondControl 10 FCV-0104 Chiller-4 Chilled Water Control 1.000 0.500 0.000 3:00 Config/PlantLogic/Chillers/Group2/ValveControl4/EvapControl 11 FCV-0204 Chiller-4 Condenser Water Control 0.030 0.100 0.000 3:00 Config/PlantLogic/Chillers/Group2/ValveControl4/CondControl 12 FCV-0105 Chiller-5 Chilled Water Control 1.000 0.500 0.000 3:00 Config/PlantLogic/Chillers/Group3/ValveControl5/EvapControl 13 FCV-0205 Chiller-5 Condenser Water Control 0.030 0.100 0.000 3:00 Config/PlantLogic/Chillers/Group3/ValveControl5/CondControl 14 FCV-0106 Chiller-6 Chilled Water Control 1.000 0.500 0.000 3:00 Config/PlantLogic/Chillers/Group3/ValveControl6/EvapControl 15 FCV-0206 Chiller-6 Condenser Water Control 0.050 0.100 0.000 3:00 Config/PlantLogic/Chillers/Group3/ValveControl6/CondControl 16 FCV-0107 HX-1 Chilled Water Control 0.200 0.150 0.000 5:00 Config/PlantLogic/HX/HXEvapValveControl 17 FCV-0207 HX-1 Condenser Water Control 0.150 0.400 0.000 5:00 Config/PlantLogic/HX/HXCondValveControl 18 TCV-0202 Cooling Tower Bypass 0.070 0.200 0.000 2:30 Config/PlantLogic/BasinBypassValve/LoopPoint1 19 FCV-0208 Cooling Tower-1 CWR 0.100 0.100 0.000 3:00 Config/PlantLogic/Towers/Tower1/Valves/ReturnVlvPID 20 FCV-0209 Cooling Tower-2 CWR 0.100 0.100 0.000 3:00 Config/PlantLogic/Towers/Tower2/Valves/ReturnVlvPID 21 FCV-0210 Cooling Tower-3 CWR 0.100 0.100 0.000 3:00 Config/PlantLogic/Towers/Tower3/Valves/ReturnVlvPID 22 FCV-0211 Cooling Tower-4 CWR 0.100 0.100 0.000 3:00 Config/PlantLogic/Towers/Tower4/Valves/ReturnVlvPID 23 FCV-0212 Cooling Tower-5 CWR 0.100 0.100 0.000 3:00 Config/PlantLogic/Towers/Tower5/Valves/ReturnVlvPID 24 FCV-0213 Cooling Tower-6 CWR 0.100 0.100 0.000 3:00 Config/PlantLogic/Towers/Tower6/Valves/ReturnVlvPID 25 CHWP-1 - 5 Chilled Water Pumps Differential Pressure Control 0.500 1.000 0.000 5:00 Config/PlantLogic/Pumps/CHWPumps/CHModPumpSpeed 26 SCHWP-1 & 2 Chilled Water Pumps Differential Pressure Control 1.000 1.250 0.000 5:00 Config/PlantLogic/Pumps/SecondaryPumps/SecondaryPumpPID 27 CWP-1 - 5 Condenser Water Pumps Differential Pressure Control 0.300 2.000 0.000 5:00 Config/PlantLogic/Pumps/CondPumps/CHModPumpSpeed 28 CT VFD Cooling Tower VFD Speed 4.000 2.000 0.000 10:00 Config/PlantLogic/CoolingTowers/Towers/FanSpeedPID

April 11, 2024

Davis Barracks Chiller Plant United States Military Academy West Point, NY 10996

Optimized Building Automation Systems And Commissioning Services 40 Meander Lane • Levittown • New York • 11756 Phone: 516-520-5818 • www.optimacontrols.com

40 Meander Lane Levittown New York 11756

Sequence of Operations

SEQUENCE OF OPERATIONS

Sequence: Chilled Water System – As-Built

Davis Barracks Chilled Water Plant Page 1 of 11 U.S. Military Academy, West Point, NY October 01, 2024

WATER COOLED CHILLED SYSTEM CONTROL

Typical of: Chillers: CH-1, CH-2, CH-3, CH-4, CH-5 & CH-6 Typical of Cooling Towers: CT-1, CT-2, CT-3, CT-4, CT-5 & CT-6 Typical of Pumps: CHWP-1, 2, 3, 4 & 5; CWP-1, 2, 3, 4 & 5; SCHWP-1 & 2 Typical of Heat Exchanger: HX-1

I. GENERAL:

A. The chiller plant control system will monitor and control the chilled water system including the chillers, pumps, cooling towers, and variable speed drives (VFD). The built-in chiller control panels and factory installed instrumentation will be determined to provide sequences utilizing LON interface with Building Automation System

(BAS).

B. All BAS control panels, and associated devices, will be connected to the Davis chiller plant UPS system. The BAS will monitor the main switchgear status and when the building loses power the BAS will cycle off all of the connected equipment and return them to their failsafe positions. Upon restoration of normal building power the BAS will have to be manually restarted as indicated below in the “Enable” sequence.

C. The operator will be able to manually put any component “Out Of Service” for any reason. When a component is out of service or in an alarm condition it will bypassed by the sequence of operations and not started until it is manually put back into service by the operator.

D. Chiller-1, 2, 5 & 6 (Daikin Electric Chiller) Condenser Water Valve Control: The condenser water flow control valve at each operating chiller shall modulate as required to maintain the rated flow through its respective chiller (Chiller-1 & 2 @ 910 GPM & Chiller-5 & 6 @ 2550 GPM).

1. In head pressure mode the Daikin factory 0-10vdc condenser water valve output will directly control the condenser water flow control valve based on the Chillers internal flow requirement.

2. When the Daikin signal is greater than 9.5vdc the Chiller will be indexed out of Head Pressure mode.

3. When in Head Pressure mode the lower of the 2 valve signals (Daikin or BMS) will control the signal to the

CW Valve to prevent a total loss of flow to the chiller unless the Chiller is calling for no flow.

4. The BMS will have a manual operator override control of the condenser water flow through these Chillers.

E. Chiller-3 & 4 (JCI Steam Chiller) Condenser Water Valve Control: The condenser water control valve will modulate to maintain flow set-point of 2550 GPM when the chiller is in service and the BMS will have a manual operator override control of the condenser water flow through these Chillers.

II. ENABLE:

A. The system will be enabled through a manual input in the BAS by the Plant Operator. When enabled the lead equipment, as selected automatically by runtime or manually by the Operator, will be put into service and will start the equipment. After the lead Chiller is online the BAS will automatically energize and de-energize Chillers, Pumps and Cooling Towers as well as the Free-Cooling system as described in this document.

III. INTEGRATION:

A. The Chiller control panel will be fully integrated into the BAS through a LonWorks interface.

B. All VFD’s will be fully integrated into the BAS through a LonWorks interface.

IV. EQUIPMENT DESIGN LOADS

System

CHWS

CWS System CHWS CWS Min Max

Chiller-1 332 557 910 Cooling Tower-1 1930 Chiller-2 332 557 910 Cooling Tower-2 2000 Chiller-3 612 1270 2550 Cooling Tower-3 2000 Chiller-4 612 1270 2550 Cooling Tower-4 2000 Chiller-5 755 1270 2550 Cooling Tower-5 2000 Chiller-6 755 1270 2550 Cooling Tower-6 2000

CHWP-1 - 5 1275

CWP-1 - 6 1930

HX-1 / CHWS 1050 1050

Davis Barracks Chilled Water Plant Page 2 of 11 U.S. Military Academy, West Point, NY October 01, 2024

V. LEAD/LAG DESCRIPTION:

A. CHILLERS:

1. The Chillers will be setup in 3 groups of operation:

a. Group 1 – Chiller 1 & 2 (Electric) / 325 TON

b. Group 2 – Chiller 3 & 4 (Steam) / 850 TON

c. Group 3 – Chiller 5 & 6 (Electric) / 850 TON

2. The operator will manually select which Group will be the LEAD / LAG1 / LAG2 sequence based on the facility load requirements.

3. Lead/Lag rotation will occur at the same time and day of the week as set by the operator through the graphical interface on a monthly schedule.

4. The BAS will notify the operator 4 hours before it will rotate the Lead/Lag equipment. The operator will have the option to delay the Lead/Lag switching by selecting the “Delay Rotation” button and entering into the BAS the number of hours to delay the switching or may manually initiate the switching by selecting the “Initiate Now” button.

B. COOLING TOWERS:

1. The initial LEAD Cooling Tower will be selected by the lowest runtime value.

2. When Lead/Lag switching is initiated the BAS will start the highest tier lag equipment and re-designate that unit as the lead and re-designate the prior lead equipment as the lowest tier lag equipment. Lower tier lag equipment (LAG1 / LAG2 / LAG3 / LAG4 / LAG5) will be indexed up one level.

3. The operator will have the ability to manually select which Cooling Tower will be the LEAD / LAG1 / LAG2 / LAG3 / LAG4 / LAG5 sequence.

4. Lead/Lag rotation will occur at the same time and day of the week as set by the operator through the graphical interface on a monthly schedule.

5. The BAS will notify the operator 4 hours before it will rotate the Lead/Lag equipment. The operator will have the option to delay the Lead/Lag switching by selecting the “Delay Rotation” button and entering into the BAS the number of hours to delay the switching or may manually initiate the switching by selecting the “Initiate Now” button.

C. PRIMARY CHILLED AND CONDENSER WATER PUMPS:

1. The initial LEAD Pump will be selected by the lowest runtime value.

2. The BAS will automatically rotate the Lead/Lag positions of the pumps monthly (adjustable) to equalize the run time and will occur at the same time and day of the week as set by the operator through the graphical interface on a monthly schedule.

3. When Lead/Lag switching is initiated the BAS will start the highest tier lag equipment and re-designate that unit as the lead and re-designate the prior lead equipment as the lowest tier lag equipment. Lower tier lag equipment (LAG1 / LAG2 / LAG3 / LAG4) will be indexed up one level.

4. The operator will have the ability to manually select which Pump will be the LEAD / LAG1 / LAG2 / LAG3 / LAG4 sequence.

5. The BAS will notify the operator 4 hours before it will rotate the Lead/Lag equipment. The operator will have the option to delay the Lead/Lag switching by entering into the BAS the number of hours to delay the switching or may manually initiate the switching by selecting the “Delay Rotation” button and selecting the “Initiate Now” button.

D. DAVIS SECONDARY CHILLED WATER PUMPS:

1. The initial LEAD Pump will be selected by the lowest runtime value.

2. The BAS will automatically rotate the Lead/Lag positions of the pumps weekly (adjustable) to equalize the run time and will occur at the same time and day of the week as set by the operator through the graphical interface on a weekly schedule.

3. When Lead/Lag switching is initiated the BAS will start the lag pump.

4. The operator will have the ability to manually select which Pump will be the Lead/Lag sequence.

5. The BAS will notify the operator 4 hours before it will rotate the Lead/Lag equipment. The operator will have the option to delay the Lead/Lag switching by entering into the BAS the number of hours to delay the switching or may manually initiate the switching by selecting the “Delay Rotation” button and selecting the “Initiate Now” button.

Davis Barracks Chilled Water Plant Page 3 of 11 U.S. Military Academy, West Point, NY October 01, 2024

VI. MECHANICAL COOLING CYCLE:

A. Once a Chiller is indexed to run each Chiller will automatically be started and stopped through the BAS based on the demand for chilled water.

B. Pumps and isolation/flow control valves will be controlled through the BAS. Any pump is capable of serving any chiller. Safety interlocks and control of internal chiller operation will be by the control panel provided by the chiller manufacturer.

C. Chiller run schedule: Subject to the manufacturers requirements a chiller will not be restarted for 30 minutes (adjustable) and after starting will run for at least 15 minutes (adjustable) before stopping. Chillers will be limited to two (2) starts per hour and a maximum of five (5) starts in any 24-hour period. The supply water temperature set-point for each Chiller will be initially set for 42ºF.

D. Lead/Lag Chiller combinations will be adjustable and as selected by the operators. Contractor will coordinate Lead/Lag Chiller sequencing during the system programming and Commissioning to include all new and existing Chillers.

VII. CHILLER CONTROL:

A. GENERAL: The number of Chillers running at any time will be determined by either flow or temperature as indicated in the Chiller Staging sequence.

B. SAFETIES & ALARMS:

1. If a Chiller fails to start due to a Chiller fault it will be locked out, its isolation valves closed, the next scheduled lag Chiller will start and a “Davis Barracks - Chiller CH-# Failure Alarm” will be sent to the base-wide BAS. The BAS lockout the Chiller until a manual reset in the BAS is selected to reinstate the Chiller into service.

2. If a Chiller isolation/flow valve is commanded to be open and after a 3 minute time delay (adjustable) the valve is closed a “Davis Barracks - Chiller CH-# FCV-#### Failure Alarm” will be sent to the base-wide BAS.

The BAS lockout the Chiller until a manual reset in the BAS is selected to reinstate the Chiller into service.

3. If a Chiller isolation/flow valve is commanded to be closed and after a 3 minute time delay (adjustable) the valve is open a “Davis Barracks - Chiller CH-# FCV-#### Failure Alarm” will be sent to the base-wide BAS.

The BAS lockout the Chiller until a manual reset in the BAS is selected to reinstate the Chiller into service.

4. If the LON communication is lost to the Chiller a “Davis Barracks - Chiller CH-# LON Network Failure Alarm” will be sent to the base-wide BAS. The BAS lockout the Chiller until a manual reset in the BAS is selected to reinstate the Chiller into service.

C. CHILLER STAGING:

1. Normally a minimum of one (1) Chiller will be running at all times when there is a need for chilled water & the Free-Cooling cycle is unable to maintain the discharge temperature set-point. Start sequence may be disabled by the operator through the BAS.

2. After the lead Chiller has been running for 15 minutes (adjustable) the next lag Chiller sequence will be initiated based on either on of the following criteria:

a. The temperature at chilled water supply temperature sensor TT-0114 is more than 1.0ºF (adjustable) above the chilled water set-point for more than 60 consecutive minutes (adjustable).

b. The chilled water flow is 90% of the online Chiller flow rate.

3. The operator shall select a “floating” chiller. The control valve for the “floating” chiller shall be set according to the following table:

Chiller CHW Valve

Position

Chillers 1 & 2 70% (Adjustable) Chillers 3 & 4 70% (Adjustable) Chillers 5 & 6 85% (Adjustable)

Davis Barracks Chilled Water Plant Page 4 of 11 U.S. Military Academy, West Point, NY October 01, 2024

4. The remaining chiller control valves shall modulate in unison as described above with the setpoint and process variables as follows:

The set point for each chiller’s control valve shall be according to the formula below:

Total Connected Chilled Water Flow (FT-0108 + FT-0109 + FT-0110) / (Total Rated Flow of all On-line Chillers) The process variable:

(Flow at Each Chiller FT-0101 to FT-0106) / (Individual Chiller Rated Flow)

With multiple chillers in operation the evaporator CHW control valves (FVC-0101 to FCV-0106) will modulate based on their respective flow transmitter (FT-0101 to FT-0106) to maintain equal flow through all operating chillers on a percentage basis as compared to their rated flow such that all active chillers are operating at the same percent load.

5. The next lag Chiller start sequence will be initiated based on the same criteria as the first lead chiller with a 15-minute (adjustable) time delay between starts. This criteria will also apply to energizing the additional lag Chillers.

6. With multiple Chillers running for 60 minutes (adjustable), and the chilled water flow as measured by the Total Connected Chilled Water Flow (FT-0108 [Scott Barracks] + FT-0109 [Lee/Sherman Barracks] + FT- 0110 [Davis Barracks]), is less than 85% of the sum of the rated flows of all online Chillers less the highest active lag Chiller, the following will occur:

a. Formula (for clarification): Total Connected Chilled Water Flow (FT-0108 + FT-0109 + FT-0110) < 0.85

* (sum of rated flow for all online chillers – rated flow of high lag chiller)

b. The BAS will stop the programmed highest lag Chiller and after an adjustable time delay, as indicated on the Chilled Water Control graphic for each Chiller, close the chilled and condenser water flow control valves.

c. When the Condenser water flow control valve position feedback signal indicates that the valve has begun to close, the BAS will shut off the associated Condenser water pump and close the associated Cooling Tower isolation valve.

7. The same sequence applies to shutting down each of the operational lag Chillers in sequence. Shutdown of the lead Chiller will only be permitted if authorized by the operator. The BAS will notify the operator of lack of load status.

8. With only one (1) chiller operating the Chillers CHW flow control valve (FCV-0101 – FCV-0106) will fully open and remain 100% open.

VIII. CONDENSER WATER AND COOLING TOWER OPERATION:

A. GENERAL:

1. The BAS will permit the operator to pre-program the number of Cells required to support a range of cooling loads or the operating equipment. Initially the system will be configured to energize Cooling Towers based on the number of Chiller as follows:

a. Chillers 1 & 2: One (1) Cooling Tower will operate when either or both Chillers are running.

b. Chillers 3 – 6:

i. First Chiller operating will require two (2) Cooling Towers

ii. Subsequent Chillers operating will require one (1) Cooling Tower.

B. SAFETIES & ALARMS:

1. If a Cooling Tower isolation/flow valve is commanded to be open and after a 3 minute time delay (adjustable) the valve is closed a “Davis Barracks – Cooling Tower CT-# FCV-#### Failure Alarm” will be sent to the base-wide BAS. The BAS lockout the Cooling Tower until a manual reset in the BAS is selected to reinstate the Cooling Tower into service.

2. If a Cooling Tower isolation/flow valve is commanded to be closed and after a 3 minute time delay (adjustable) the valve is open a “Davis Barracks – Cooling Tower CT-# FCV-#### Failure Alarm” will be sent to the base-wide BAS. The BAS lockout the Cooling Tower until a manual reset in the BAS is selected to reinstate the Cooling Tower into service.

3. If the LON communication is lost to the Cooling Tower VFD a “Davis Barracks – Cooling Tower CT-# LON Network Failure Alarm” will be sent to the base-wide BAS. The BAS lockout the Cooling Tower until a manual reset in the BAS is selected to reinstate the Cooling Tower into service.

Davis Barracks Chilled Water Plant Page 5 of 11 U.S. Military Academy, West Point, NY October 01, 2024

4. If a Cooling Tower fails to start due to a VFD fault it will be locked out and a “Davis Barracks - Cooling Tower CT -# VFD Fault Alarm” will be sent to the base-wide BAS. The BAS lockout the Cooling Tower until a manual reset in the BAS is selected to reinstate the Cooling Tower into service.

5. If a Cooling Tower vibration sensor goes into alarm it will be locked out and a “Davis Barracks - Cooling Tower CT -# Vibration Alarm” will be sent to the base-wide BAS. The BAS lockout the Cooling Tower until a manual reset in the BAS is selected to reinstate the Cooling Tower into service.

6. If the main condenser water temperature (TT-0222) Cooling Tower rises 3ºF above the active set-point and after a 15 minute time delay (adjustable) a “Davis Barracks – Main Condenser Water High Temperature Alarm” will be sent to the base-wide BAS.

C. COOLING TOWER VALVE CONTROL:

1. When a Cooling Tower is not in service all of its associated control valves will be closed.

2. Whenever any of the Cooling Towers are active the associated Basin equalization isolation valve (FCV-0220

– FCV-0225) will open prior to the opening of the Cooling Towers supply and return valves.

3. Once the Basin equalization valve is open, as sensed by its position indicator, the Cooling Towers Supply and

Return isolation and control valves will open.

4. Condenser water pumps will not start until the lead Cooling Towers supply, return and equalization valves are open as sensed by their respective end switches.

5. When only one (1) Cooling Tower is in service the return control valve will modulate fully open. When more than one (1) Cooling Tower is in service the return control valves will modulate to maintain the equal water flow through all active Cooling Towers.

D. TOWER-TO-BASIN BYPASS VALVE

1. The Tower-To-Basin Bypass Valve (TCV-0202) control will be based on feedback from the CWS temperature sensor (TT-0222) located in the condenser main local to the Cooling Towers and downstream of all CWS branch lines from the Cooling Towers.

2. Upon initial start-up of the system the following will occur:

i. The Tower-To-Basin Bypass Valve (TCV-0202) will be 100% open.

ii. As the condenser water temperature rises the Tower-To-Basin Bypass Valve (TCV-0202) will modulate closed until the flow over the Cooling Towers is 50% of the rated in-service Cooling Tower flow. The bypass valve position at this point will be considered the “maximum” valve position, I.E. the Maximum Modulating position of the valve before it goes full open.

iii. As the condenser water temperature continues to increase the bypass valve will be released to modulate and close…