Attachment 0031 TE 5.2-07 -- USAG-RIA PM GUIDE - 20230821.pdf

TE 5.2-07 USAG-RIA PREVENTIVE MAINTENANCE GUIDE

HEATING VENTILATION AND AIR CONDITIONING

TE 5.2-07 -- USAG-RIA PREVENTIVE MAINTENANCE (PM) GUIDE

TABLE OF CONTENT

HEATING VENTILATION, AIR CONDITIONING AND REFRIGERANTION

DESCRIPTION PAGE

General Overview 4 Equipment Standard Number 4 Good Maintenance Practices 5

EQUIPMENT/SYSTEM: PAGE

Air Compressor (AC) 7 Air-Cooled Condenser (ACC) 11 Air-Cooled Condensing Unit (ACCU) or (CU) 14 Air Cooled Chillers (CACO, CACR, CACS, and CACC) 18 Air Distribution Systems 22 Air Dryer (AD) 24 Air Handling Unit (AHU) 27 Air Terminal Unit and Control Boxes (ATU, FPVAV, FPVAVR, VAV, and VAVR) 31 Blower Coil Unit (BCU) 36 Close Circuit Dry Glycol Cooler (DC) 39 Control Central Systems (CCS/DDC) 42 Computer Room Air Conditioning Unit (CRAC) 45 Cooling Tower (CT) 49 Electric Unit Heater (EUH) 56 Energy Recovery Unit (ERU) or (ERV) 59 Expansion Tank (ET) 61 Fans – centrifugal (EF, FAN, PRE, PRS, RAF, SF) 63 Fans – propeller or axial (EF, FAN, PRE, PRS, RAF, SF) 66 Fan Coil Unit (CUH, FCU, and UH) 69 Furnace (FUR) 73 Gas Unit Heater (GUH) 76 Heat Exchanger (HE) 78 Heat Pumps (HAAP and HAAS) 80 Hot Water (Hydronic) Boiler (BW, and HWB) 83 Heating Ventilating Unit (HVU) 89 Humidifier (HMDF) 93 Infrared Heater and Radiant Heater (IR, IRH, IRVF, and RH) 95 Indoor Section Duct-Free Splits Devices 100 Low-Speed High Volume Fans (LSHVF) 102 Make-up Air Unit (MAU) 105 Motorized Air Damper (MD) 109 Natural Gas Regulator (NGR) 112 Outdoor Air Heat Exchanging Systems 114

TABLE OF CONTENT

HEATING VENTILATION, AIR CONDITIONING AND REFRIGERANTION

EQUIPMENT/SYSTEM: (continued) PAGE Package Terminal Air Conditioners or Heat Pumps (BCU, CRAC, HAAP, and HAAS) 116 Pumps – centrifugal (BFWP, BP, CTP, CWP, DPP, HCP, and SP) 118 Pumps – condensate (CCP) 120 Remote Monitoring Systems (RMS) 123 Roof Top Unit (RTU) 124 Side Stream Filter (SSF) 128 Steam Boiler (SB) 130 Steam Generator (SG) 137 Steam Distribution Systems 135 Steam Pressure Reducer Valve (SPRV) 131 Unit Ventilator (UV) 139 Valves 140 Variable Frequency Drive (VFD) 143 Variable Refrigerant Flow (VRF) 146 Walk-In Cooler and Walk-In Cooler Compressor (WIC, and WICC) 150 Water-Cooled Chillers (CWCC, CWCS, and CWCR) 152 Water Distribution Systems 165 Water Softener (WS) 167 Window Unit (TWACU or WU or WACI or WACO) 169 Vibration Analysis Program (VAP) 171 Spike Energy Greasing 186 Test and Balance 202

General Overview:

This technical exhibit provides guidance for preventive maintenance to maximize the efficiency of operation and the useful life of equipment, and systems. They are generic in nature and not intended to substitute for manufacturer’s instructions or to apply uniformly across all types and configurations of equipment and systems installed in Rock Island Arsenal Buildings. USAG-RIA expects from the contractor to incorporate these tasks as part of the Preventive Maintenance Plan (PMP). These tasks are not the minimum PMP requirements of the contract. Contractor shall be responsible for acquiring all material required to perform Preventive Maintenance (PM) tasks as part of FFP. Some samples of material are air filters oil, coil cleaning solution, grease, glycol, oil, paint, refrigerant, refrigerant filter, salt (water softener), water filters, and water treatment chemicals. Contractor shall be responsible for acquiring all equipment/tools required to perform Preventive Maintenance (PM) tasks as part of FFP. Some samples of equipment/tools are blower (carpet dryer), brushes, clamp on meter, cutting pliers, drive socket set, emery cloth, extension cords, fin comb, fish tape, flaring tool, gloves, grease gun, hack saw, hammer, label maker, leak detector, lifts, level, measuring tape, milliammeter, nameplate maker, ohmmeter, paint brush, personal protective equipment (PPE), packing kit, pocket thermometer, pressure washer, refrigerant recovery unit, refrigeration gauges, refrigeration manifold, respirator, safety goggles, scrapers, screwdrivers, soldering kit, tubing cutter, vacuum, voltmeter, wire brush, wire strippers, and wrenches.

Prior to start of contract performance, maintenance contractor must submit their own maintenance plan to the KO/COR for review and approval.

Equipment proper naming structure on labels/nameplates:

The mechanical equipment associated with this contract follows a specific naming convention that details its location and sequence. Please refer to Technical exhibit 1.2-02 for full list of USAG-RIA HVAC&R equipment list.

An example of the proper naming structure on labels/nameplates is AHU-060-2-02. This standard naming structure information as follows:

AHU - 060 - 2 - 02

The first section or tier is for equipment type. In this example “AHU” refers to Air Handler Unit. Refer to TE-5.2-06 for full list of equipment types.

The second section or tier is for building number, where the equipment is physically located.

In this example “060” refers to building 60. Refer to TE-1.2-01 for full list of buildings.

The third section or tier is for the floor number, where the equipment is physically located.

In this example “2” refers to the second floor of building 60.

The fourth section or tier is for equipment sequence. In this example “02” refers to the second AHU on the second floor of building 60.

Good Maintenance Practices:

The following are good practices expected from the contractor.

(1) Machinery and equipment shall be cleaned and touch up painted as necessary to restore surface conditions and inhibit corrosion.

(2) Install replacement parts that are new and appropriate to the equipment, its operating conditions, and the required performance levels.

(3) Proper documentation through a system of record keeping is required; GFEBS and share-drive.

(4) The intent of language suck as “check”, “inspect”, “verify”, “ensure”, etc., it’s to determine the status of the equipment and to take appropriate corrective action to eliminate any deficiencies found on during the preventive maintenance task if within contract limits, or, to notify the COR through ArMA as practicable when repair exceeds contract limits or cannot be repaired during the preventive maintenance task.

(5) Maintenance work shall be scheduled to minimize the disruption to building occupants and operations. Proper notification and coordination shall be made when maintenance work necessitates shutting down equipment or otherwise terminating services to the building occupants.

(6) Equipment under warranty shall be maintained in accordance with warranty instructions and conditions. Warranty provisions will be stringently met.

(7) When performing maintenance on equipment that requires working with (CFC’s) refrigerants. Those working on the equipment must maintain the applicable certifications for working on such equipment. All applicable local, state, federal guidelines and regulations must be adhered to with respect to documentations, handling and disposal or refrigerants. Where regulations or guidelines conflict, the most stringent shall apply.

(8) When performing maintenance in existing spaces, provide adequate steps for the protections of government property.

(9) When performing maintenance in spaces that may be occupied or accessible during the performance of the work, provide adequate steps for the protections of the public, and employees.

(10) Trash, debris, and wastes from contract work inside buildings shall be removed daily. Premises shall be left neat and clean after each work shift and after each work task is completed. Area shall be left is such a way that the Government business can proceed without interruption.

(11) Contractor shall maintain at all time a visible copy of a list of Tasks for Preventive Maintenance (PM), and Preventive Maintenance Schedule next to or near to each equipment. Each Preventive Maintenance Schedule indicating technician initials, last PM date, and next PM date.

(12) Contractor shall maintain a sticker showing change oil information on each equipment, showing the technician initials, the last time the oil was change, the next time the oils shall be change.

(13) Contractor shall sign, date and write the next air filter change on each individual filter. An example is an AHU with a bank of air filters that consisting of 12 air filters, then the contractor shall write` 12 technician initials, 12 dates or replacement and 12 expected dates of next air filter change; one for each air filter.

TE 5.2.07 – USAG – RIA PREVENTIVE MAINTENANCE (PM) GUIDE

Maintenance schedule tasks for Air Compressors (AC) serving USAG-RIA.

Frequency

Semi- Annual Annual

Air Filter: Clean air intake filter on compressor X

Replace air intake filter on compressor X

Belt: The Contractor shall annually replace belts in air compressors listed in TE 1.2-02 called “USAG-RIA HVAC&R Equipment List”. During the annual belt replacement, the Contractor shall check for excessive wear on sheaves.

Any sheaves in need of replacement shall be replace as part of the scheduled work (FFP). Motor amperage draws and RPM reading shall be checked and noted to verify proper unit operation. Belts/sheaves/amperage draw shall be re-checked, and adjustments made, as needed, 14-16 calendar days after initial installation.

X

Ensure belt guard is installed prior to putting air compressor back in service. X

Controls: Verify proper operation of lead lag controls ensuring that each compressor gets equal run time. X

Verify pressure controller is turning the compressor on and off at the correct pressures. X

Check cut in and cut out of compressor pressure controller, readjust if necessary for proper air pressure requirements. Do not exceed ASME maximum tank pressure. X

Electrical: Inspect the wiring and connections to the motors for any signs of wear, or deterioration. X

Inspect the wiring and connections of the power wiring for any signs of wear, or deterioration. X

Inspect the wiring and connections of the control wiring for any signs of wear, or deterioration. X

Inspect the disconnect for proper electrical rating, any signs of wear, or deterioration. X

Inspect the wiring and connections to the contactors or starters. X

Tightening any connections as needed.

X

Maintenance schedule tasks for Air Compressors (AC) serving USAG-RIA. (continued) Frequency

Semi- Annual Annual

Electrical:

(continued) Inspect the contact points on the contactors for signs of arcing. X

Clean contact points as needed to remove carbon buildup, dust, or other debris. X

Gauges: Inspect pressure gauges for leaks, or any signs of wear. X

Check accuracy of gauges with calibrated test gauge. X

General: Perform normal tour checks and operations. Perform a visual inspection of the air system, noting any obvious leaks or portions of the air distribution network that may be subject to physical damage. X

Verify unit to be clearly labeled with the proper naming structure. Relocated existing label as required or acquire and install new label with proper naming structure, as required. Label shall be easily readable from finish floor and at a distance not greater than 5ft.

X

Verify unit location is clearly marked on drawing. X

Verify unit make, model, serial, and other pertinent information. X

Change compressor crankcase oil. X

Check air dryer, automatic condensate drains, and air tank for proper operation. Clean condenser coils and cover grills. X

Inspect oil separators for any sign of oil entering the system. X

Check for corrosion and scale on water cooled units. X

Clean heat exchanger surfaces. X

On two stage compressors, check intermediate pressure. X

Frequency

Semi- Annual Annual

General:

(continued) Check operation of compressor unloaders, repair or replace is not loading properly. X

Check compressor suction and discharge valves for proper operation. Replace leaking valves. X

Ensure the pressure vessel inspection certificate is posted at machine. X

Check if air compressor is running excessively or frequently cycling on and off (possible leaks). Log hour meter readings. X

Perform an air leak check of the compressor and air distribution network in the mechanical room, using an appropriate ultrasonic scanning device. Check hoses connections, hose fittings, quick couplers, filters, regulators, and lubricators. Correct or schedule repair as a work item. Tag location and date of leaks. Repair air leaks as soon as possible.

X

Thoroughly inspect unit prior to restarting. X

All tests shall conform to the appropriate NETA test procedure and the values used as standards shall conform to the manufacturer’s, NETA, and ANSI Standards specifications. X

Work order(s) shall be requested in ArMA to address any deficiency(ies) or issue(s) identified during the maintenance. X

Fill out maintenance checklist, passed and failed report with deficiencies and ArMA case #. X

Housekeeping: Clean area around unit. X

Clean unit of any dust or debris. X

Remove rust with emery cloth or wire brush. X

Apply rust transforming paint. X

Frequency

Semi- Annual Annual

Housekeeping:

(continued) Clean the tank with water and a mild soap. X

Paint any corroded surfaces to help prevent them from getting worse. X

Relief Valves: Inspect relief valves for signs of wear or leaks. X

Verify the sizing on the valve is the correct rating for the piece of equipment utilizing it. X

Check operation of pressure relief valve. X

The Contractor shall pressure test and inspect relief valves on air compressors listed in TE 1.2-02 called “USAG- RIA HVAC&R Equipment List”. The Contractor shall test safety relief valves using overpressure to ensure proper relief setting, verify tank pressure, and safety relief unload set points. Safety valves will be set and sealed to unload at 115 percent of normal operating pressure. Valves in need of repair or replacement shall be repaired immediately through a DMO submitted through ArMA.

X

The Contractor shall attach a legible tag to the base of the safety relief valve indicating the date of the last test, the scheduled date of the next test, and the safety relief valve set point. X

NOTES:

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

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

(3) Tank shall be inspected and tested by qualified inspector as required by DoD regulations for pressure vessels.

(4) Hand hole covers shall be removed only when the vessel is at atmospheric pressure.

(5) Contractor shall maintain a sticker showing change oil information on each equipment, showing the technician initials, the last time the oil was change, the next time the oils shall be change.

Maintenance schedule tasks for Air-Cooled Condensers (ACC) serving USAG-RIA Frequency

Semi- Annual Annual

Condenser: Inspect the unit for damage, signs of wear, corrosion, or deterioration. X

Inspect sight glass while unit is running, to check for flashing (bubbles in the refrigerant). X

Look for signs of a possible leak, such as oil on the ground or the coil. X

Inspect refrigerant lines, insulation, and supports for signs of wear, corrosion, or deterioration. X

Coil Cleaning: The condenser will get tuned off locked out and tagged out. X

Prior to cleaning a thorough inspection of the coils will be done to note any existing damage or areas of concern. X

All coils shall be clean with a chemical coil cleaner and garden hose sprayer. X

Condenser coils will be rinsed thoroughly until there is no evidence of chemical left on the coils. X

The pad or area the condenser is located on will be hosed off as well to keep the lint like debris from getting sucked or blown back into the coils. X

Prior to restarting the unit, a thorough inspection of the coils will be done to ensure no damage occurred while the cleaning process took place. X

Lockout tagout will be removed and unit will be turned back on. X

All coils located near tree lines (100fts) shall be clean with a chemical coil cleaner and garden hose sprayer. X

Electrical: Inspect the wiring and connections to the motors for any signs of wear, or deterioration. X

Inspect the wiring and connections of the control wiring for any signs of wear, or deterioration. X

Maintenance schedule tasks for Air-Cooled Condensers (ACC) serving USAG-RIA. (continued) Frequency

Semi- Annual Annual

Electrical:

(continued) Inspect the wiring and connections of the power wiring for any signs of wear, or deterioration. X

Inspect the disconnect for proper electrical rating, any signs of wear, or deterioration. X

Inspect the wiring and connections to the contactors or starters. X

Tightening any connections as needed. X

Inspect the contact points on the contactors for signs of arcing. X

Clean contact points as needed to remove carbon buildup, dust, or other debris. X

Fan Assembly: Check fan blades, and fan housing. Clean with water and a mild soap to ensure proper operation. X

Check bearing for obstructions/debris. Clean and grease, as applicable. X

Check and clean motor with water and a mild soap. Check fan wheel are securely mounted X

Lubricate motors, as applicable X

Lubricate fan shaft bearings, as applicable. X

General: Verify unit to be clearly labeled with the proper naming structure. Relocated existing label as required or, acquire and install new label with proper naming structure. Label shall be easily readable from finish floor and from a distance not greater than 5ft.

X

Verify unit location is clearly marked on drawing. X

Verify unit make, model, serial, and other pertinent information. X

Maintenance schedule tasks for Air-Cooled Condensers (ACC) serving USAG-RIA. (continued) Frequency

Semi- Annual Annual

General:

(continued) Thoroughly inspect unit prior to restarting. X

Check for damaged insulation in exposed pipelines. X

All tests shall conform to the appropriate NETA test procedure and the values used as standards shall conform to the manufacturer’s, NETA, and ANSI Standards specifications. X

Work order(s) shall be requested in ArMA to address any deficiency(ies) or issue(s) identified during the maintenance. X

Fill out maintenance checklist, passed and failed report with deficiencies and ArMA case #. X

Housekeeping: Clean area around unit. X

Paint any corroded surfaces to help prevent them from getting worse. X

Clean unit of any dust or debris. X

Remove rust with emery cloth or wire brush. X

Apply rust transforming paint, as need it. X

NOTES:

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

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

(3) Comply with the latest provision of the Clean Air Act and Environmental Protection Agency (EPA) regulations.

(4) Whenever refrigerant is added or removed from equipment, record the quantities on USAG-RIA Refrigerant Log Tally.

(5) Equipment shall be serviced prior to the cooling season.

Maintenance schedule tasks for Air-Cooled Condensing Unit (ACCU) serving USAG-RIA.

Frequency

Semi- Annual Annual

Compressor:

Check the resistance of the windings with a multimeter. X

Check windings to ground with a multimeter. X

Condenser: Inspect the unit for damage, signs of wear, corrosion, or deterioration. X

Check open drive couplings, bearings, and seals for evidence of wear or alignment problem. Lubricate and repair or replace as needed. X

Look for signs of a possible leak, such as oil on the ground or the coil. X

Coil Cleaning: The condenser will get tuned off locked out and tagged out. X

Prior to cleaning a thorough inspection of the coils will be done to note any existing damage or areas of concern. X

All coils shall be clean with a chemical coil cleaner and garden hose sprayer. X

Condenser coils will be rinsed thoroughly until there is no evidence of chemical left on the coils. X

The pad or area the condenser is located on will be hosed off as well to keep the lint like debris from getting sucked or blown back into the coils. X

Prior to restarting the unit, a thorough inspection of the coils will be done to ensure no damage occurred while the cleaning process took place. X

Lockout tagout will be removed and unit will be turned back on. X

All coils located near tree lines (100fts) shall be clean with the same annual process mentioned above. X

Controls: Check control system and devices for evidence of improper operation. Clean, lubricate, repair, adjust, or replace components as needed to ensure proper operation. X

Maintenance schedule tasks for Air-Cooled Condensing Unit (ACCU) serving USAG-RIA. (continued) Frequency

Semi- Annual Annual

Controls:

(continued)

Check low ambient head pressure control sequence for evidence of improper operation. Repair or replace components or modify software/algorithm to ensure proper operation. X

Check control box for dirt, debris, and/or loose terminations. Clean and tighten as needed. X

Electrical: Inspect the wiring and connections to the motors for pitting or other signs damage, wear, or deterioration. X

Inspect the wiring and connections to the compressors for any signs of wear, or deterioration. X

Inspect the wiring and connections to the crank case heaters for any signs of wear, or deterioration. X

Inspect the wiring and connections of the control wiring for any signs of wear, or deterioration. X

Inspect the wiring and connections of the power wiring for any signs of wear, or deterioration. X

Inspect the disconnect for proper electrical rating, any signs of wear, or deterioration. X

Inspect the wiring and connections to the contactors or starters. X

Tightening any connections as needed. X

Inspect the contact points on the contactors for signs of arcing. X

Clean contact points as needed to remove carbon buildup, dust, or other debris. X

Fan Assembly: Check fan blades, and fan housing. Inspect or blower for bent blades or imbalance; adjust as necessary. Clean blades with water and a mild soap to ensure proper operation. X

Check bearing for obstructions/debris. Clean and grease, as applicable. X

Frequency

Semi- Annual Annual

Fan Assembly:

(continued) Check and clean motor with water and a mild soap. Check fan wheel are securely mounted X

Lubricate motors, as applicable X

Lubricate fan shaft bearings, as applicable. X

Check fan belt tension. Check for belt wear and replace annually. Check sheaves for evidence of improper alignment or evidence or wear and correct as needed. X

General: Verify unit to be clearly labeled with the proper naming structure. Relocated existing label as required or, acquire and install new label with proper naming structure. Label shall be easily readable from finish floor and from a distance not greater than 5ft.

X

Verify unit location is clearly marked on drawing. X

Verify unit make, model, serial, and other pertinent information. X

Thoroughly inspect unit prior to restarting. X

Check for damaged insulation in exposed pipelines. X

Work order(s) shall be requested in ArMA to address any deficiency(ies) or issue(s) identified during the maintenance. X

Fill out maintenance checklist, passed and failed report with deficiencies and ArMA case #. X

Housekeeping: Clean area around unit. X

Paint any corroded surfaces to help prevent them from getting worse X

Clean unit of any dust or debris. X

Frequency

Semi- Annual Annual

Housekeeping:

(continued) Remove rust with emery cloth or wire brush. X

Apply rust transforming paint, as need it. X

Refrigerant: Inspect refrigerant lines, insulation, and supports for signs of wear, corrosion, or deterioration. X

Check refrigerant oil levels for refrigerant systems with oil pressure/level controls. Repair, replace, or adjust as need to ensure proper operation, as applicable. X

Check refrigerant system pressures or temperatures. If outside of recommended levels, find cause, repair, and adjust refrigerant to achieve optimal operating levels. X

Inspect sight glass while unit is running, to check for flashing (bubbles in the refrigerant). X

NOTES:

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

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

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

(4) Whenever refrigerant is added or removed from equipment, record the quantities on USAG-RIA Refrigerant Log Tally.

(5) Equipment shall be serviced prior to the cooling season.

Maintenance schedule tasks for Air-Cooled Chillers serving USAG-RIA.

Air-Cooled Chillers are identified as Air-Cooled Rotary Scroll Chiller (CACO), Air-Cooled Reciprocating Chiller (CACR), Air- Cooled Rotary Screw Chiller (CACS), and Centrifugal Air-Cooled Chiller (CACC).

Frequency

Weekly Monthly Semi- Annual Annual

Compressor: Check compressor oil level and/or pressure on refrigerant systems having oil level and/or pressure measurement means. Repair, replace, or adjust as needed to ensure proper control.

Inspect gearbox for excessive wear. Repair or replace as needed. X

Check motor contactor for pitting or other signs of damage. Repair or replace as needed. X

Condenser: Inspect air-cooled condenser surfaces for damage or evidence of leaks. Repair or clean as needed.

X

Condenser coils will be cleaned using a chemical coil cleaner and garden hose sprayer. X

Condenser coils will be rinsed thoroughly until there is no evidence of chemical left on the coils.

X

The pad or area the condenser is located on will be hosed off as well to keep the lint like debris from getting sucked or blown back into the coils.

X

Controls: Check control system and devices for evidence of improper operation. Clean, lubricate, repair, adjust, or replace components as needed to ensure proper operation.

X

Check variable-frequency drive for proper operation. Correct as needed. X

Check control box for dirt, debris, and/or loose terminations. Clean and tighten as needed. X

Check low ambient head pressure control sequence for evidence of improper operation.

Repair or replace components or modify software/algorithm to ensure proper operation.

X

Fan(s): Check fan belt tension. Check for belt wear and replace if necessary to ensure proper operation. Check sheaves for evidence of improper alignment or evidence or wear and correct as needed.

Check fan blades and fan housing. Clean, repair, or replace as needed to ensure proper operation.

Maintenance schedule tasks for Air-Cooled Chillers serving USAG-RIA. (continued) Air-Cooled Chillers are identified as Air-Cooled Rotary Scroll Chiller (CACO), Air-Cooled Reciprocating Chiller (CACR), Air- Cooled Rotary Screw Chiller (CACS), and Centrifugal Air-Cooled Chiller (CACC).

Frequency

Weekly Monthly Semi- Annual Annual

General: Verify unit to be clearly labeled with the proper naming structure. Relocated existing label as required or acquire and install new label with proper naming structure. Label shall be easily readable from finish floor and from a distance not greater than 5ft.

Verify unit make, model, serial, and other pertinent information. X

Perform chemical testing of system water. Treat as needed to ensure proper water chemistry and freeze protection. X

Check open drive alignment, wear, seating, and operation. Repair or replace as necessary. X

Assess field-serviceable bearings. Lubricate if necessary. X

Check for evidence of buildup or fouling on heat exchange surfaces. Restore as needed to restore proper operation. X

Check for proper fluid flow and for fluid leaks. Clean, adjust, and repair as needed to restore proper flow. X

Clean area around equipment. X

Work order(s) shall be requested in ArMA to address any deficiency(ies) or issue(s) identified during the maintenance. X

Fill out maintenance checklist, passed and failed report with deficiencies and ArMA case #. X

Oil Analysis An analysis of the oil will be performed annually measuring acid, moisture, and wear metals content. A Field Supervisor will make a review of laboratory results and a written report submitted.

X

Pressure Test: Pressurize system to l0# PSIG with hot water and leak test all O-rings & gaskets as required. Pressure test will be performed with an electronic leak detector. X

Air-Cooled Chillers are identified as Air-Cooled Rotary Scroll Chiller (CACO), Air-Cooled Reciprocating Chiller (CACR), Air- Cooled Rotary Screw Chiller (CACS), and Centrifugal Air-Cooled Chiller (CACC).

Frequency

Weekly Monthly Semi- Annual Annual

Pump Logging: During the cooling season established by the contract:

a. Primary and secondary chilled water pump, chiller circulating pumps and cooling tower pumps are to be logged on Tuesdays and Thursdays of each week.

X

b. Tertiary pumps are to be logged once weekly. X

Refrigerant: Check refrigerant system pressure and/or temperatures. If outside of recommended levels, find cause, repair, and adjust refrigerant charge to achieve optimal operating levels.

X

An analysis of the refrigerant will be performed annually measuring acid and moisture content, and to check for system contamination. A Field Supervisor will make a review of laboratory results and a written report submitted.

X

Water Treatment:

During the cooling season established by the contract:

a. Perform a bacteria dip-slide test once per week to confirm the amount of biological growth in the system is within the acceptable tolerances.

b. Verify conductivity sensor calibration once per week.

c. Verify blowdown valve functionality once per week.

d. Collect a water sample and perform a corrosion inhibitor spectrometer test to verify the inhibitor levels are in the proper range.

e. Three (3) samples per week when ambient temperature exceeds 80°F.

f. Two (2) samples per week when the ambient temperature does not exceed 80°F.

g. Assess test results for conductivity and corrosion inhibitor levels.

h. Adjust corrosion inhibitor additions as needed to maintain the optimal levels.

X

During the cooling season established by the contract:

a. Verify proper water treatment levels, during the established cooling season.

b. Collect sample to have tested by third party consultant twice per month.

c. Assess test results for conductivity and corrosion inhibitor levels.

d. Adjust corrosion inhibitor additions as needed to maintain the optimal levels.

e. Verify the makeup water valve is maintaining optimal system pressure.

Air-Cooled Chillers are identified as Air-Cooled Rotary Scroll Chiller (CACO), Air-Cooled Reciprocating Chiller (CACR), Air-Cooled Rotary Screw Chiller (CACS), and Centrifugal Air-Cooled Chiller (CACC).

NOTES:

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

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

(3) Contractor shall perform Vibration Analysis, refer to Vibration Analysis Program (VAP) described in this TE. Review manufacturer’s instructions and guidelines for vibration analysis. Consult chiller manufacturer for pass/fail specifications as it pertains to vibration.

(4) Contractor shall perform an Eddy Current Tube Analysis on each chiller. Eddy Current Tube Analysis shall identify unusual wear and pitting of the tube bundles. This analysis should be performed, during PoP THREE of the contract, on the condenser and evaporator tube bundles.

Contractor shall be responsible for repair insulation as part of the FFP.

(5) Always purge chiller after it has been opened for servicing.

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

(7) Whenever refrigerant is added or removed from equipment, record the quantities on USAG-RIA Refrigerant Log Tally.

(8) Equipment shall be serviced prior to the cooling season.

Maintenance schedule tasks for Air Distribution Systems serving USAG-RIA.

Frequency

Semi- Annual Annual

General: Verify unit to be clearly labeled with the proper naming structure. Relocated existing label as required or acquire and install new label with proper naming structure. Label shall be easily readable from finish floor and from a distance not greater than 5ft.

X

Check control system and devices for evidence of improper operation. Clean, lubricate, repair, adjust or replace components to ensure proper operation. X

Visually inspect grilles, registers and diffusers for dirt accumulation. X

Assess field-serviceable bearings. Lubricate if necessary. X

Check for proper damper operation. Clean, lubricate, repair, replace, or adjust as needed to ensure proper operation. X

Visually inspect areas of moisture accumulation for biological growth. If present, clean or disinfect as needed.

Visually inspect exposed ductwork for insulation and vapor barrier integrity. Correct as needed. X

Visually inspect internally lined ductwork until the first turn or up to 20ft from a potential moisture source, such as a supply plenum, from air handler, outdoor air damper, humidifier, etc. for water damage and/or biological contamination and, if necessary, take corrective action.

X

Work order(s) shall be requested in ArMA to address any deficiency(ies) or issue(s) identified during the maintenance. X

Fill out maintenance checklist, passed and failed report with deficiencies and ArMA case #. X

Housekeeping: Clean area around unit. X

Maintenance schedule tasks for Air Distribution Systems serving USAG-RIA. (continued)

NOTES:

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

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

Maintenance schedule tasks for Air Dryers (AD) serving USAG-RIA.

Frequency

Semi- Annual Annual

Air Dryer: Inspect the unit for damage, signs of wear, corrosion, or deterioration. X

Look for signs of a possible leak, such as oil on the ground or the coil. X

Inspect refrigerant lines, insulation, and supports for signs of wear, corrosion, or deterioration. X

Inspect airline piping, joints, and supports for signs of wear, corrosion, or deterioration. X

Turn off power lockout and tagout unit. X

Electrical:

Inspect the wiring and connections to the motors for any signs of wear, or deterioration. X

Inspect the wiring and connections to the compressors for any signs of wear, or deterioration. X

Inspect the wiring and connections of the control wiring for any signs of wear, or deterioration. X

Inspect the wiring and connections of the power wiring for any signs of wear, or deterioration. X

Inspect the disconnect for proper electrical rating, any signs of wear, or deterioration. X

Inspect the wiring and connections to the contactors or starters. X

Tightening any connections as needed. X

Inspect the contact points on the contactors for signs of arcing. X

Clean contact points as needed to remove carbon buildup, dust, or other debris. X

Maintenance schedule tasks for Air Dryers (AD) serving USAG-RIA. (continued) Frequency

Semi- Annual Annual

Fan Assembly:

Ensure the blades and bearings are unobstructed. X

Clean all fan blades, motor shaft(s), and compressors with water and a mild soap. X

Verify the motors and fan wheel are securely mounted. X

Lubricate motors and fan shaft bearings if applicable. X

Filters:

Drain oil/moisture from and inspect prefilter. X

Replace prefilter elements. X

Replace control air filter elements. X

General:

Verify unit to be clearly labeled with the proper naming structure. Relocated existing label as required or acquire and install new label with proper naming structure. Label shall be easily readable from finish floor and from a distance not greater than 5ft.

Verify unit make, model, serial, and other pertinent information. X

Check outlet dew point. X

Thoroughly inspect unit prior to restarting. X

Fill out maintenance checklist, passed and failed report with deficiencies and ArMA case #. X

Work order(s) shall be requested in ArMA to address any deficiency(ies) or issue(s) identified during the maintenance. X

Maintenance schedule tasks for Air Dryers (AD) serving USAG-RIA. (continued) Frequency

Semi- Annual Annual

Housekeeping:

Clean area around unit. X

Clean unit of any dust or debris. X

Clean Condenser Coil. X

Remove rust with emery cloth or wire brush. X

Apply rust transforming paint. X

Paint any corroded surfaces to help prevent them from getting worse. X

Add plastic buckets to catch drainage water. X

Refrigerant: Check traps. X

Check refrigerant level and moisture content. If low level or moisture is indicated, check for refrigerant leaks using a halogen leak detector or similar device. If leaks are not able to be stopped or corrected, report leak status to COR.

X

NOTES:

(1) Maintenance of Air Dryers shall be performed in conjunction with the maintenance on the associated air compressor.

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

(3) Contractor shall execute annual inspection on drain valves and lubricate the valve, as need it, for all AD units manufactured by Air-Tech and with drain valves.

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

(5) Whenever refrigerant is added or removed from equipment, record the quantities on USAG-RIA Refrigerant Log Tally.

Maintenance schedule tasks for Air Handler Units (AHU) serving USAG-RIA.

Frequency

Semi- Annual Annual Every 2

Years Every 4 Years

Air Filter(s): Replace air filters (MERV 8) to ensure proper operation. X

Check air filter fit and housing seal integrity. Correct as needed X

Clean metal (external) mesh filter and/or insect screen for outside air intake. These filters shall be cleaned by rinsing with mild detergent in warm water. X

Repair, install, or replace deficient on any metal mesh and/or insect screen. X

Coil(s): Check for proper operation of control valves and vents. Correct as required. X

Check P-trap. Prime as needed to ensure proper operation. X

Check for proper fluid flow and for fluid leaks. Clean, adjust, and repair as needed to restore proper flow. X

Check refrigerant/heating system temperatures. Adjust refrigerant charge to achieve optimal operating levels. If coil performance is outside of recommended levels, find cause. Report situation with feasible solutions.

X

Check for evidence of build-up or fouling on heat exchanger surfaces. Restore as needed to ensure proper operation. X

Check drain pan, drain line, coil, and other areas of moisture accumulation for biological growth. Clean or disinfected as needed. X

Check for damaged coil fins. Restore if possible. Report if coil require replacement to return to proper functioning. X

Inspect for evidence of moisture carryover beyond the drain pan from cooling coils and biological growth. Make corrections or repairs to eliminate the condition. X

Check condensate pump. Clean or replace as needed. (where required.) X

Clean coil removing all dirt, by brush or vacuum clean. As allowed, coils shall be cleaned using a chemical coil cleaner and garden hose sprayer. X

Maintenance schedule tasks for Air Handler Units (AHU) serving USAG-RIA. (continued) Frequency

Semi- Annual Annual Every 2

Years Every 4 Years

Controls: Check control system and devices for evidence of improper operation. Clean, lubricate, repair, adjust, or replace as needed to ensure proper operation. X

Check Variable Frequency Drive for proper operation. Correct as needed. X

Check control box for dirt, debris and/or loose terminations. Clean and tighten as needed. X

Damper(s): Check for proper damper(s) operation. Clean, lubricate, repair, or adjust as needed to ensure proper operation. X

Ensure zone dampers span from the heating coil to the cooling coil properly. X

Fan: Check fan belt tension. Check for belt wear and replace if necessary to ensure proper operation. Check sheaves for evidence of improper alignment or evidence of wear and correct as needed.

X

Replace belts X X

Check Fan blades and fan housing. Clean, repair, or replace as needed to ensure proper operation. X

Assess field serviceable bearings. Lubricate if necessary. X

General: Verify unit to be clearly labeled with the proper naming structure. Relocated existing label as required or acquire and install new label with proper naming structure. Label shall be easily readable from finish floor and from a distance not greater than 5ft.

X

Verify unit location is clearly marked on drawing. X

Verify unit make, model, serial, and other pertinent information. X

Check integrity of all panels on equipment. Replace fasteners as needed to ensure proper integrity and fit/finish of equipment. X

Frequency

Semi- Annual Annual Every 2

Years Every 4 Years

General:

(continued)

Check for proper damper operation. Clean, lubricate, repair, replace, or adjust as needed to ensure proper operation. X

Inspect temperature and pressure gauges for functionality, leaks, or any signs of wea X

Visually inspect exposed ductwork (flex & rigid), flex connections and external piping.

Identify signs of wear, deterioration, and/or damage on flex connections, duct work, piping or insulation or integrity of vapor barrier(s). Correct as needed. Report uncap pipe and/or ductwork.

X

Perform an air and water balance on AHU System X

Work order(s) shall be requested in ArMA to address any deficiency(ies) or issue(s) identified during the maintenance. X

Fill out maintenance checklist, pass and fail report with deficiencies and ArMA case #. X

Motor: Check motor contactor for pitting or other signs of damage. Repair or replace as needed. X

Housekeeping: Clean area around unit. X

Remove rust with emery cloth or wire brush. X

Apply rust transforming paint. X

Paint any corroded surfaces to help prevent them from getting worse. X

NOTES:

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

NOTES: (continued)

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

(3) Motor, coil, fan, and filter PMs service shall be performed at the same time as the AHU PM.

(4) Contractor shall perform Vibration Analysis, refer to Vibration Analysis Program (VAP) described in this TE.

(5) The Contractor shall provide air and water balance on HVAC systems in coordination with AHU maintenance. General air handler maintenance, DDC Controller, VAV box, EF, RF, and zone control maintenance shall had been performed prior to beginning air balancing. PM shall only occur on VAV boxes with reheat (steam, hot water or electric). Airflow adjustments shall be noted in the balancing report. The report shall include detailed information on systems balanced, design, actual and adjusted airflows for all VAV units in the quadrant tested.

(6) The Contractor shall provide PM on air handler units and associated VAV, VAVR, FPVAVR, and FPVAV Boxes listed in TE 1.2-02 called “USAG-RIA HVAC&R Equipment List”. The Contractor shall perform general air handler equipment PM on a quadrant basis, once a year, as detailed in the below table.

PoP Quadrant BLDGs Base 0 0-99 One 1 100-199 Two 2 200-299 Three 3 300-399 Four 0 0-99

(7) The Contractor shall replace all belts on PoPs BASE, TWO and FOUR (every two years) in all air handler units listed in TE 1.2-02 called “USAG-RIA

HVAC&R Equipment List”. During the annual belt replacement, the Contractor shall check for excessive wear on sheaves. Any sheaves in need of replacement shall be replace as part of the scheduled work (FFP). Motor amperage draws and RPM reading shall be checked and noted to verify proper unit operation. Belts/sheaves/amperage draw shall be re-checked, and adjustments made, as needed, 14-16 calendar days after initial installation.

(8) The Contractor shall check for spike energy and properly grease the unit until the spike energy level is below 0.5 gSE. If the spike energy level does not drop after greasing, the Contractor shall stop and check additional bearings to see if vibration is being transmitted from other bearing sites.

Maintenance schedule tasks for Air Terminal and Control Boxes serving USAG-RIA.

Air Terminal and Control Boxes are identified as air terminal units (ATU), fan power variable air volume boxes (FPVAV), fan powered variable air volume boxes with reheat coil (FPVAVR), variable air volume boxes (VAV), and variable air volume boxes with reheat coil (VAVR).

Frequency

Semi- Annual Annual

Air Filter:

(Only for equip.

w/ filters)

Replace air filters (MERV 8) to ensure proper operation. X

Check air filter(s) fit and housing seal integrity. Correct as needed. X

Coil(s):

(Only for equip.

w/ coils or heating elements)

Check for proper operation of control valves and vents. Correct as required. X

Check P-trap. Prime as needed to ensure proper operation, as applicable. X

Check for proper fluid flow and for fluid leaks. Clean, adjust, and repair as needed to restore proper flow. X

Check refrigerant/heating system temperatures. Adjust refrigerant charge to achieve optimal operating levels.

If coil performance is outside of recommended levels, find cause. Report situation with feasible solutions. X

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

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

Comb fins as required. X

Remove obstruction to air flow. X

Check coils for leaks. Correct or report any leaks to COR. X

Check for evidence of build-up or fouling on heat exchanger surfaces. Restore as needed to ensure proper operation. X

Check drain pan, drain line, coil, and other areas of moisture accumulation for biological growth. Clean or disinfected as needed. X

Check for damaged or bend coil fins/heating elements. Restore if possible. Report if coil or heating elements require replacement to return to proper functioning. X

Maintenance schedule tasks for Air Terminal and Control Boxes serving USAG-RIA. (continued) Terminal and Control Boxes are identified as air terminal units (ATU), fan power variable air volume boxes (FPVAV), fan powered variable air volume boxes with reheat coil (FPVAVR), variable air volume boxes (VAV), and variable air volume boxes with reheat coil (VAVR).

Frequency

Semi- Annual Annual

Coil(s):

(Only for equip.

w/ coils or heating elements (continued)

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

Inspect for evidence of moisture carryover beyond the drain pan from cooling coils and biological growth. Make corrections or repairs to eliminate the condition. X

Check condensate pump. Clean or replace as needed. (where required.) X

Record air flow and differential air pressure across the coil.

DDC Controls: Check control system and devices for evidence of improper operation. Clean, lubricate, repair, adjust, or replace components as needed to ensure proper operation. X

Check for proper damper operation. Clean, lubricate, repair, replace, or adjust as needed to ensure proper operation. X

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. X

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

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

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

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

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

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

Inspect the wiring and connections of the power wiring for any signs of wear, or deterioration. X

Terminal and Control Boxes are identified as air terminal units (ATU), fan power variable air volume boxes (FPVAV), fan powered variable air volume boxes with reheat coil (FPVAVR), variable air volume boxes (VAV), and variable air volume boxes with reheat coil (VAVR).

Frequency

Semi- Annual Annual

Pneumatic Controls: Check damper linkage for tightness or damage. Lightly oil moving parts using an approved lubricant. X

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

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

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

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

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

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

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

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

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

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. X

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

Check all installed pressure gages for proper range and operability as applicable. Replace if needed. X

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

Terminal and Control Boxes are identified as…