GS-08P-14-JA-D-0019 _Amendment_0002 _Attachment_04 _Exhibit_J.17B_Preventive_Maintenance_Guides.pdf

EXHIBIT J.17B (Amendment 0002)

PREVENTIVE MAINTENANCE GUIDES

1. This Exhibit contains the Preventive Maintenance (PM) Guides to be used to establish the minimum performance requirements, which the Contractor must meet to satisfactorily execute the preventive maintenance program specified in this contract.

2. In the absence of a specific PM requirement or frequency on newly installed or reclassified equipment, which is to receive minimum preventive maintenance, PM shall be performed in accordance with the manufacturer's instructions. In the absence of manufacturer's instructions, maintenance shall be performed in accordance with the best practices of the industry. In all such cases, the Contractor will prepare and submit a written PM Guide as specified in Section C.35. Maintenance Program.

3. Preventive maintenance will be performed at the (minimum) frequencies specified on the PM guides, which are as follows:

WEEKLY Once at every 7 day intervals.

MONTHLY Once at every 30 day intervals.

QUARTERLY Once at every 90 day intervals.

SEMI-ANNUALLY Once at every 180-day interval.

ANNUALLY Once at every 365 day intervals.

EVERY 2/3/4/ETC YEARS Once during the base contract year

And repeated at the prescribed

Intervals thereafter.

JillCLong Typewritten Text

GS-08P-14-JA-D-0019

Amendment 0002 Attachment 04

JillCLong Typewritten Text

General Services Administration Preventive Maintenance Guide Effective Date: March, 1993

A-1 Air Dryer, Refrigerated or Frequency: Semiannual Regenerative Desiccant Type

Application:

This guide card applies to refrigerated or regenerative desiccant type air dryers with a capacity of 10 SCFM or greater. Those units with a capacity of less than 10 SCFM will be maintained in conjunction with the air compressor that they are associated with.

Special Instructions:

1. Schedule this maintenance in conjunction with the maintenance on the associated air compressor.

2. Review manufacturer's instructions.

3. Review the Standard Operating Procedure for "Controlling Hazardous Energy Sources."

4. Deenergize, lock and tag electrical circuits.

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

6. No intentional venting of refrigerants is permitted. During the servicing, maintenance, and repair of refrigeration equipment, the refrigerant must be recovered.

7. Whenever refrigerant is added or removed from equipment, record the quantities on the appropriate forms.

8. Recover, recycle, or reclaim the refrigerant as appropriate.

9. If disposal of the equipment item is required, follow regulations concerning removal of refrigerants and disposal of the item.

10. If materials containing refrigerants are discarded, comply with EPA regulations as applicable.

11. Refrigerant oils to be removed for disposal must be analyzed for hazardous waste and handled accordingly.

12. For refrigerant type units, closely follow all safety procedures described in the Material Safety Data Sheet (MSDS) for the refrigerant and all labels on refrigerant containers.

Checkpoint:

1. Lubricate valves and replace packing, if necessary.

2. Check dryer operating cycle.

3. Inspect and clean heat exchanger.

4. Check outlet dew point.

5. Clean and lubricate blower.

6. Check automatic blow down devices.

7. Inspect and replace or reinstall inlet filters.

8. Refrigerated Type:

a. Check traps.

b. 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 cannot be stopped or corrected, report leak status to supervisor.

c. Clean and lubricate condenser fan motor.

9. Desiccant Type:

a. Replace filter cartridges, both prefilter and after filter.

b. Check the inlet flow pressure, temperature and purge rate.

c. Check the desiccant and replace if necessary.

d. Inspect and clean solenoids, purge valves, and strainers.

A-2 Unitary, Heating and Cooling Unit Frequency: Annual

This guide card applies to self-contained heating and cooling units containing a complete cooling system and heating unit (gas or oil burner). These are normally installed on rooftops, but can be in other locations. They are also referred to as climate changers, roof packs, etc.

1. Schedule shutdowns with operating personnel, as needed.

2. Review manufacturer's instructions.

3. Review the Standard Operating Procedure for "Controlling Hazardous Energy Sources."

4. Deenergize, lock and tag electrical circuits.

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

6. No intentional venting of refrigerants is permitted. During the servicing, maintenance, and repair of refrigeration equipment, the refrigerant must be recovered.

7. Whenever refrigerant is added or removed from equipment, record the quantities on the appropriate forms.

8. Recover, recycle, or reclaim the refrigerant as appropriate.

9. If disposal of the equipment item is required, follow regulations concerning removal of refrigerants and disposal.

10. If materials containing refrigerants are discarded, comply with EPA regulations as applicable.

11. Refrigerant oils to be removed for disposal must be analyzed for hazardous waste and handled accordingly.

12. Closely follow all safety procedures described in the Material Safety Data Sheet (MSDS) for the refrigerant and all labels on refrigerant containers.

Checkpoint:

1. Remove debris from air screen and clean underneath unit.

2. Inspect gaskets. Look for leaks between unit and structure, caulk as necessary.

3. Clean condenser, cooling coil fins, and fans.

4. Remove dirt or dust from all interior parts.

5. Replace filter.

6. Inspect and adjust damper.

7. Lubricate motor and fan bearings.

8. Check fan RPM to design specifications.

9. Check bearing collar set screws on fan shaft to make sure they are tight.

10. Check dampers for dirt accumulations. Check felt. Repair or replace as necessary.

11. Check damper motors and linkage for proper operation.

12. Lubricate mechanical connections of dampers sparingly.

13. Clean coils by brushing, blowing, vacuuming or pressure washing.

14. Check coils for leaking, tightness of fittings:

(a) Check for refrigerant leaks using a halogen detector or similar testing device. If leaks cannot be stopped or corrected, report leak status to supervisor. Consult the Material Safety Data Sheets (MSDS) for disposal requirements. Reclaimed and recycled CFCs are exempt from hazardous waste regulations (Consult 40 CFR Part 261).

(b) Check refrigerant levels and recharge if needed.

15. Use fin comb to straighten coil fins.

16. Flush and clean condensate pans and drains.

17. Check belts for wear, adjust tension or alignment and replace belts when necessary. Multi-belt drives should be replaced with matched sets.

18. Check rigid couplings for alignment on direct drives and for tightness of assembly. Check flexible couplings for alignment and wear.

19. Check electrical connections for tightness.

20. Check mounting for tightness.

21. Check for corrosion.

22. Check mounting bolts and tighten if needed.

23. Check and adjust, or replace if necessary, vibration eliminators.

24. Compressor.

(a) Check compressor oil level.

(b) Run machine, check action of controls, relays, switches, etc., to see that:

(1) compressor(s) runs at proper settings.

(2) reheat coils activate properly.

(3). crankcase heater is operating properly.

(4). suction and discharge pressures are proper.

(5). discharge air temperature is set properly.

25. Heating Unit.

a. Gas and/or oil fired (if equipped).

(1). Check burner for flashback and tight shutoff of fuel.

(2). Check operation of controls. Clean and adjust if necessary.

(3). Clean burner, chamber, thermocouple and control. (Use a high suction vacuum and/or brush.) Check combustion chamber for cracks, holes, or other defects.

(4). Adjust pilot or electric ignition device.

(5). Inspect vent and damper operation.

(6). Operate unit and adjust burner.

(7). Check operation of safety pilot, gas shutoff valve, and other burner safety devices.

(8). Check temperature differential and controls.

(9). Check frame of unit with ohmmeter for proper electric ground.

(10). Replace covers (if any) and clean area.

(b) Electrical (if equipped).

(1). Visually inspect for broken parts, contact arcing or any evidence of overheating. Inspect all wiring for deterioration.

(2). Check nameplate for current rating and controller manufacturer's recommended heater size.

(Heater size shall not be changed without the regional design engineer's approval.)

(3). Check line and load connections and heater mounting screws for tightness.

Effective Date: October, 1981

A-3 Humidification Systems Frequency: Semiannual

Special Instructions.

1. Review manufacturer's instructions.

2. Review the Standard Operating Procedure for "Selection, Care, and Use of Respiratory Protection."

3. Turn off water supply.

4. Secure electrical service before servicing Humidification system, if applicable.

5. Use of work gloves may be necessary due to caustic residual mineral deposits.

Checkpoint.

1. Operate humidistat through its throttling range to verify activation, or deactivation of humidifier.

2. Clean and flush condensate pans, drains, water pans, etc. Remove corrosion, and repaint as needed. If a corrosion preventive chemical is used, ensure that it does not become a part of the indoor air by creating large amounts of volatile organic compounds or irritants. Check the Material Safety Data Sheet (MSDS) to see what hazardous products are present. If hazardous products are present rinse very well before the system is returned to use. Ensure that the paint lead level is 0.06% or less.

3. Check condition of heating element. Clean steam coils.

4. Clean steam/water spray nozzles. Adjust/replace as needed.

5. Chemically clean exterior of coil to remove scale and encrustation's.

6. Inspect steam trap for proper operation.

7. Inspect pneumatic controller for air leaks.

8. Inspect water lines for leaks and corrosion. Tighten all connections and repair leaks.

A-3 Humidification Systems Frequency: Semiannual

Effective Date: January, 1995

A-4 Air Compressor Frequency: Semiannual

1. Review manufacturer's instructions and equipment history record.

2. Coordinate motor PM on an annual basis. See Guide M-3.

3. Tank should be inspected and tested by qualified inspector.

4. De energizes, tag, and lock out circuits. Review the Standard Operating Guide on "Controlling Hazardous Energy Sources".

Checkpoints:

1. 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.

2. Change compressor crankcase oil.

3. Clean or replace air intake filter.

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

5. Inspect belt alignment and condition. Adjust or replace belts as required.

6. Check for corrosion and scale on water-cooled units.

7. Clean heat exchange surfaces.

8. Check accuracy of gauges with calibrated test gauge.

9. On two-stage compressor, check intermediate pressure.

10. Test relief valves, replace if leaking or the relief range is incorrect. Do not readjust safety relief valves in the field.

11. Check operation of compressor unloaders, repair or replace if not loading and unloading properly.

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

13. 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.

14. Check to make sure belt guard is installed prior to putting air compressor back in service.

15. No pressure vessel is to have its hand hole or man hole covers removed unless the vessel is at atmospheric pressure.

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

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

A-5 Air Conditioning Machine; Frequency: _ Split System Comfort - Annual Special - Monthly

This guide card applies to those packaged type air conditioning machines that are equipped with chilled water coils or direct expansion coils on split systems. The other portion of the split system, i.e., a refrigeration-condensing unit (PM Guide C-24), or a packaged type chilled water unit (PM Guide R-4), is to be serviced in conjunction with this PM activity.

2. A/C machine maintenance should be scheduled to coincide with condensing unit or package chiller maintenance as noted above.

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

4. No intentional venting of refrigerants is permitted. During the servicing, maintenance, and repair of refrigeration equipment, the refrigerant must be recovered.

5. Whenever refrigerant is added or removed from equipment, record the quantities on the appropriate forms.

6. Recover, recycle, or reclaim the refrigerant as appropriate.

7. If disposal of the equipment item is required, follow regulations concerning removal of refrigerants and disposal.

8. If materials containing refrigerants are discarded, comply with EPA regulations as applicable.

9. Refrigerant oils to be removed for disposal must be analyzed for hazardous waste and handled accordingly.

10. Closely follow all safety procedures described in the Material Safety Data Sheet (MSDS) for the refrigerant and all labels on refrigerant containers.

1. Thoroughly inspect and clean interior and exterior of machine with vacuum (remove panels).

Special - Monthly

2. Clean drain pan and note excessive corrosion. Treat rusted areas with rust inhibitor. Ensure that the rust inhibitor chemical does not add volatile organic compounds or contaminants to the drain pan. If possible, rinse well after application or choose a less hazardous material. Consult the chemicals Material Safety Data Sheet (MSDS) for this information.

3. Perform checks according to the type of unit.

a. Chilled water units:

1). Check for chilled water leaks on all lines, valves, strainers, coils, etc. If leaks cannot be stopped or corrected, report leak status to supervisor.

2). Clean strainer on chilled water unit.

b. Direct expansion units:

Check for refrigeration leaks on all lines, valves, fittings, coils, etc., using a halogen leak detector or similar testing device. If leaks cannot be stopped or corrected, report leak status to supervisor.

4. Check condition of cooling and reheat coils. Use fin comb if need to straighten fins.

5. Clean coils. Use detergent solution and warm water if coil is heavily soiled.

6. Drain and clean humidifier pan or pad, whichever applies. Replace pad if required. Remove corrosion as needed.

7. Clean and lubricate motor and squirrel cage fan(s). Check alignment of motor and fan.

Check bearings for excessive wear.

8. Check belt tension and condition. Adjust or replace as required.

9. Replace pre-filters if needed.

10. Replace final filter if needed.

11. Run machine, check action of controls, relays, switches, etc., to see that:

a. Chilled water units:

1). Chilled water valve(s) are operating properly.

2). Reheat coils activate properly.

3). Humidistat activates humidifier.

4). Valves regulating water pressure are proper on cooling.

5). discharge air temperature is set properly.

6). Check and record chilled water inlet and outlet temperatures.

b. Direct expansion units:

1). Humidistat activates humidifier.

2). Reheat coils activate properly.

3). Discharge air temperature is set properly.

12. Check and adjust vibration eliminator mountings if equipped. Repair or replace if required.

A-6 Air-Conditioning Machine Frequency: Annual Package Unit (Comfort Cooling)

This PM guide applies to units that may have the evaporator, compressor, fan unit components, and condenser within a single housing or may have the condenser separate from the housing. If the condenser is separate, perform the PM on the condensing unit using PM Guide A-9 at the same time.

2. Deenergize, lockout, and tag the electrical circuits.

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

4. No intentional venting of refrigerants is permitted. During the servicing, maintenance, and repair of refrigeration equipment, the refrigerant must be recovered.

5. Whenever refrigerant is added or removed from equipment, record the quantities on the appropriate forms.

6. Recover, recycle, or reclaim the refrigerant as appropriate.

7. If disposal of the equipment item is required, follow regulations concerning removal of refrigerants and disposal of the appliance.

8. If materials containing refrigerants are discarded, comply with EPA regulations as applicable.

9. Refrigerant oils to be removed for disposal must be analyzed for hazardous waste and handled accordingly.

10. Closely follow all safety procedures described in the Material Safety Data Sheet (MSDS) for the refrigerant and all labels on refrigerant containers.

1. Thoroughly inspect and clean interior and exterior of machine with vacuum cleaner, (remove panels).

2. Clean drain pan and note excessive corrosion, prepare metal and paint as necessary. Consult the Material Safety Data Sheet (MSDS) to ensure that the paint lead level is 0.06% or less.

3. Check for refrigerant leaks using a halogen detector or similar testing device. Repair all leaks before recharging unit. If leaks cannot be stopped or corrected, report leak status to supervisor.

Consult the MSDS for disposal requirements. Reclaimed and recycled CFCs are exempt from hazardous waste regulations (Consult 40 CFR Part 261).

4. Check refrigerant levels for proper charge and recharge as needed.

5. Check condition of cooling and reheat coils. Use fin comb if needed to straighten fins.

6. Clean coils, use coil cleaner detergent solution and high-pressure water.

7. Check belts for wear, adjust tension or alignment, and replace when necessary.

8. Drain and clean humidifier drip pan, if applicable. Remove corrosion; prime, and paint as needed.

9. Lubricate motor and fan bearings, if not sealed. Check alignment of motor and fan.

10. Replace prefilters if needed.

11. Replace final filters if needed.

12. Check compressor oil level, if compressor has an oil sight glass.

13. Run machine, check action of controls, relays, switches, etc., to see that:

a. compressor(s) run at proper settings.

b. reheat coils activate properly.

c. humidistat activates humidifier.

d. suction and discharge pressures are proper.

e. discharge air pressure is set properly.

14. check and tighten any loose unit electrical terminals, disconnect switches, or connectors.

15. Check and adjust vibration eliminators. Replace if required.

16. Remove all trash or debris from work area. Consult the MSDS for proper personal protective equipment (PPE).

A-7 Air-Conditioning Machine, Frequency: Monthly Package Unit (Special Purpose)

This equipment is typically found in computer rooms, CAD rooms, laboratories, etc. It is identical in design and configuration to the A-6 unit for comfort cooling. One difference is that it may use a glycol dry cooler during favorable outside air conditions.

1. Review manufacturer's instructions and the Standard Operating Procedure for "Controlling Hazardous Energy Sources."

2. Deenergize, lock out, and tag electrical circuits.

3. Perform any required dry cooler or air cooled condenser maintenance simultaneously with this PM.

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

5. No intentional venting of refrigerants is permitted. During the servicing, maintenance, and repair of refrigeration equipment, the refrigerant must be recovered.

6. Whenever refrigerant is added or removed from equipment, record the quantities on the appropriate forms.

7. Recover, recycle, or reclaim the refrigerant as appropriate.

8. If disposal of the equipment item is required, follow regulations concerning removal of refrigerants and disposal of the equipment.

9. If materials containing refrigerants are discarded, comply with EPA regulations as applicable.

10. Refrigerant oils to be removed for disposal must be analyzed for hazardous waste and handled accordingly.

11. Closely follow all safety procedures described in the Material Safety Data Sheet (MSDS) for

1. Thoroughly inspect and clean interior and exterior of machine with wet/ dry vacuum, (remove panels).

2. Clean drain pan and note excessive corrosion, prepare and paint necessary. Consult the Material Safety Data Sheet (MSDS) to ensure that the paint lead level is 0.06% or less.

3. Check for refrigerant leaks using a halogen detector or similar testing device. If leaks cannot be stopped or corrected, report leak status to supervisor.

4. Check refrigerant levels and recharge if needed. Consult the MSDS for disposal requirements. Reclaimed and recycled CFCs are exempt from hazardous waste regulations (Consult 40 CFR Part 261).

5. Check condition of cooling and reheat coils. Use fin comb if needed to straighten fins.

6. A dirty coil surface can be cleaned using a coil cleaner solution and warm water.

7. Drain and clean humidifier drip pan, replace pan if applicable. Remove scale and paint if necessary.

8. Lubricate motor and fan bearings, if not sealed. Check alignment of motor and fan. Clean fan or blower.

9. Check belt tension and condition. Adjust or replace as required.

10. Replace pre filters if needed.

11. Replace final filters if needed.

12. Check compressor oil level if compressor has a sight glass.

13. Run machine, check action of controls, relays, switches, etc. to see that:

a. Compressor(s) run at proper settings.

b. Reheat coils activate properly.

c. Humidistat activates humidifier.

d. Suction and discharge pressures are proper.

e. Discharge air temperature is set properly.

14. Check and adjust vibration eliminators. Replace if required.

15. Check and tighten all electrical terminals, connections, and disconnect switches.

16. Remove all trash or debris from work area. Consult the MSDS for proper personal protective equipment (PPE).

A-9 Air-Cooled Condenser Frequency: Annual

This PM guide applies to equipment, which has the condenser, fan(s), and fan motor(s) enclosed within the same housing. The compressor and other components are at a separate location. PM of these other devices should be scheduled simultaneously with the units serviced by the condenser. If the condenser motor(s) is/are rated at 1 HP or higher, schedule PM of motor(s) with this PM.

2. Review the Standard Operating Procedure for "Controlling Hazardous Energy Sources."

3. Review the Standard Operating Procedure for "Selection, Care, and Use of Respiratory Protection".

4. Deenergize, lock out, and tag electrical circuit breaker.

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

6. No intentional venting of refrigerants is permitted. During the servicing, maintenance, and repair of refrigeration equipment, the refrigerant must be recovered.

7. Whenever refrigerant is added or removed from equipment, record the quantities on the appropriate forms.

8. Recover, recycle, or reclaim the refrigerant as appropriate.

9. If disposal of the equipment item is required, follow regulations concerning removal of refrigerants and disposal of the equipment.

10. If materials containing refrigerants are discarded, comply with EPA regulations as applicable.

11. Refrigerant oils to be removed for disposal must be analyzed for hazardous waste and handled accordingly.

12. Closely follow all safety procedures described in the Material Safety Data Sheet (MSDS) for

1. Remove debris from air screen and clean underneath unit.

2. Pressure wash coil with coil cleaning solution.

3. Straighten fin tubes with fin comb.

4. Check electrical connections for tightness.

5. Check mounting for tightness.

6. Check for and remove all corrosion or rust from unit and supporting steel, prime and paint as necessary. Consult the Material Safety Data Sheet (MSDS) to ensure that the paint lead level is 0.06% or less. Consult the MSDS for proper personal protective equipment (PPE).

7. Check fan blades and belts. Clean fan blades as necessary.

8. Check wires at condenser electrical fused safety switches for tightness and burned insulation.

Repair as necessary.

9. Clean up work area.

A-10 Heat Pumps Frequency: Annual

1. Review manufacturer's instructions and the Standard Operating Procedure for "Controlling Hazardous Energy Sources."

2. Deenergize, lockout, and tag electrical circuits.

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

4. No intentional venting of refrigerants is permitted. During the servicing, maintenance, and repair of refrigeration equipment, the refrigerant must be recovered.

5. Whenever refrigerant is added or removed from equipment, record the quantities on the appropriate forms.

6. Recover, recycle, or reclaim the refrigerant as appropriate.

7. If disposal of the equipment item is required, follow regulations concerning removal of refrigerants and disposal of the equipment.

8. If materials containing refrigerants are discarded, comply with EPA regulations as applicable.

9. Refrigerant oils to be removed for disposal must be analyzed for hazardous waste and handled accordingly.

10. Closely follow all safety procedures described in the Material Safety Data Sheet (MSDS) for

1. Inspect piping for evidence of leaks and vibration. If leaks cannot be stopped or corrected, report leak status to supervisor.

2. Inspect all wiring for deterioration, and tighten electrical contacts. Check for corrosion, clean, prime, and paint as necessary.

3. Check mounting bolts and tighten if needed.

4. Check crankcase heater.

5. Check fan for vibration or excessive noise. Lubricate fan and motor if required.

6. Check refrigerant levels, recharge if necessary. Check for leaks if loss of refrigerant is detected, using halide leak detector and soap bubbles. If leaks cannot be stopped or corrected, report leak status to supervisor. Consult the Material Safety Data Sheets (MSDS) for disposal requirements. Reclaimed and recycled CFCs are exempt from hazardous waste regulations (Consult 40 CFR Part 261).

7. Check temperature drop across condensing coil.

8. Clean air intake and screens; change filters as necessary.

9. Brush or pressure wash coil surfaces. Straighten fins with fin comb.

10. Check that reversing valve is energized in the "heat" mode and deenergized in the "cool" mode. Replace defective valves.

11. Check all electrical connections and fused disconnect switches.

12. Check all controls, indoor and outdoor thermostats, timers, and control delays, especially for units with electric supplemental heaters. Repair or replace as necessary.

13. Check oil if compressor is equipped with a sight glass.

14. Clean up work area.

A-11 Air Handler Unit Frequency: Annual

1. Schedule shutdown with operating personnel, as needed.

2. Review manufacturer's instructions.

3. Review the Standard Operating Procedure for "Controlling Hazardous Energy Sources."

4. Deenergize, lock out and tag electrical circuit(s).

5. Schedule PM on motor per guide M-3, in conjunction with this guide.

Include the following additional special instructions in cases where the air handler is equipped with a direct expansion-cooling coil:

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

7. No intentional venting of refrigerants is permitted. During the servicing, maintenance, and repair of refrigeration equipment, the refrigerant must be recovered.

8. Whenever refrigerant is added or removed from equipment, record the quantities on the appropriate forms.

9. Recover, recycle, or reclaim the refrigerant as appropriate.

10. If disposal of the equipment item is required, follow regulations concerning removal of refrigerants and disposal of the equipment.

11. If materials containing refrigerants are discarded, comply with EPA regulations as applicable.

12. Refrigerant oils to be removed for disposal must be analyzed for hazardous waste and handled accordingly.

13. Closely follow all safety procedures described in the Material Safety Data Sheet (MSDS) for

1. Check fan blades for dust buildup and clean if necessary.

2. Check fan blades and moving parts for cracks and excessive wear.

3. Check fan RPM against design specifications.

4. Check bearing collar set screws on fan shaft to make sure they are tight.

5. Check dampers for dirt accumulations, clean as necessary. Check felt, repairs or replace as necessary.

6. Check damper actuators and linkage for proper operation. Adjust linkage on dampers if out of alignment.

7. Lubricate mechanical connections of dampers sparingly.

8. Clean coils by brushing, blowing, vacuuming, or pressure washing.

9. Check coils for leaking, tightness of fittings. On direct expansion units, check for refrigerant leaks on all lines, valves, fittings, coils, etc., using a halogen leak detector or similar testing device. If leaks cannot be stopped or corrected, report leak status to supervisor.

10. Use fin comb to straighten coil fins.

11. Flush and clean condensate pans and drains, remove all rust prepare metal and paint.

Consult the Material Safety Data Sheet (MSDS) to ensure that the paint lead level is 0.06% or less. Hose down coils and drain pans and wash with an appropriate EPA approved solution approved solution. Treat condensate pans with an EPA approved biocide.

12. Check belts for wear and cracks, adjust tension or alignment, and replace belts when necessary. Multi-belt drives shall only be replaced with matched sets.

13. Check rigid couplings for alignment on direct drives, and for tightness of assembly. Check flexible couplings for alignment and wear.

14. Before heating season (chilled water coils only): Drain cooling coils; blows down to remove moisture; refill with antifreeze and water solution; drain.

15. Check freeze stat for proper temperature setting and operation.

16. Vacuum interior of unit.

17. Lubricate fan shaft bearings while unit is running. Add grease slowly until slight bleeding is noted from the seals. Do not over lubricate. Remove old or excess lubricant.

18. Clean up work area.

General Services Administration Preventive Maintenance Guide

A-12 Glycol Dry Cooler Frequency:

Comfort - Annual Special - Semiannual

These units will be associated with packaged air conditioning units and refrigeration units, or would stand alone when utilized in free cooling.

1. Schedule outage with operating personnel.

2. Obtain and review manufacturer's instructions for starter to be tested (including the time current characteristic curve).

3. Review the Standard Operating Procedure for "Controlling Hazardous Energy Sources."

4. Review the Standard Operating Procedure for "Selection, Care, and Use of Respiratory Protection."

5. Deenergize, tag, and lock out circuit.

1. Dry Cooler Checkpoint:

a. Remove debris from air screen and clean underneath unit.

b. Pressure wash coil with coil cleaning solution. Check the Material Safety Data Sheets (MSDS) to ensure that the coil cleaner does not contain hydrofluoric acid or another irritating or hazardous compound.

c. Straighten fin tubes with fin comb.

d. Check electrical connections for tightness.

e. Check mounting for tightness.

f. Check for corrosion. Clean and treat with rust inhibitor and touch up paint as needed.

Consult the MSDS for hazardous ingredients and proper personal protective equipment (PPE).

2. Motors and Fans Checkpoint:

a. Inspect pulleys, belts, couplings, etc.; adjust tension and tighten mountings as required.

Change badly worn belts. Multi-belt drives should be replaced with matched sets.

b. Perform required lubrication and remove old or excess lubricant.

c. Clean motor with vacuum or low-pressure air (less than 40 psi). Check for obstructions in motor cooling and airflow.

3. Expansion Tank Checkpoint:

a. Examine exterior of tank, including fittings, manholes, and hand holes for leaks, signs of corrosion. Repair/paint as necessary.

b. Inspect structural supports and repair or replace damaged insulation or covering.

c. Clean, test, and inspect sight glasses, valves, fittings, drains, and controls.

d. Perform hydrostatic test if required.

e. Check antifreeze level with hydrometer and add glycol base antifreeze as required for protection to minus 40 degrees Fahrenheit.

4. Electrical Controls Checkpoint:

a. Visually inspect for broken parts, contact arcing, or any evidence of overheating.

b. Check motor nameplate for current rating and controller manufacturer's recommended heater size. (Heater size shall not be changed without the Regional Design Engineer's approval.)

c. Check line and load connections and heater mounting screws for tightness.

A-13 Air Conditioning Unit, Frequency:

Ceiling/Wall Mounted Comfort - Annual

This guide card applies to ceiling or wall mounted air conditioning units, i.e., mini-mates. The unit may be for comfort or special purpose cooling and can be either air-cooled or water-cooled.

Humidifiers will be operated on those units serving computer space and will be inventoried and serviced under this guide card.

2. Schedule PM on associated equipment in conjunction with this guide, i.e., air-cooled condensers, glycol dry coolers, cooling tower, etc.

3. Review manufacturer's instructions and the Standard Operating Procedure for "Controlling Hazardous Energy Sources."

4. Deenergize, lockout, and tag electric circuits.

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

6. No intentional venting of refrigerants is permitted. During the servicing, maintenance, and repair of refrigeration equipment, the refrigerant must be recovered.

7. Whenever refrigerant is added or removed from equipment, record the quantities on the appropriate forms.

8. Recover, recycle, or reclaim the refrigerant as appropriate.

9. If disposal of the equipment item is required, follow regulations concerning removal of refrigerants and disposal of the equipment.

10. If materials containing refrigerants are discarded, comply with EPA regulations as applicable.

11. Refrigerant oils to be removed for disposal must be analyzed for hazardous waste and handled accordingly.

12. Closely follow all safety procedures described in the Material Safety Data Sheet (MSDS) for

1. Thoroughly inspect and clean interior and exterior of machine with vacuum (remove panels).

2. Clean drain pan and note excessive corrosion. Correct as necessary.

3. Check for refrigerant leaks using a halogen leak detector, soap bubbles, or similar testing device. If leaks cannot be stopped or corrected, report leak status to supervisor. Consult the Material Safety Data Sheets (MSDS) for disposal requirements. Reclaimed and recycled CFCs are exempt from hazardous waste regulations (Consult 40 CFR Part 261).

4. Check refrigerant levels and recharge if necessary.

5. Check condition of cooling and reheat coils. Use fin comb as needed.

6. Clean coils using detergent solution and warm water if coil is heavily soiled.

7. Drain and clean humidifier pan or pad, whichever applies. Replace pad if required. Remove corrosion, prime, and paint as needed.

8. Lubricate motor and fan bearings, if not sealed. Check alignment of motor and fan. Clean all fans or blowers.

9. Check belt tension and condition. Adjust or replace as required if belt driven.

10. On direct drive units, check set screws on fan shaft to make sure they are tight.

11. Replace filters as needed.

12. Check compressor oil level (not on hermetically sealed units) if compressor is equipped with a sight glass.

13. Run machine. Check action of controls, relays, switches, including fused disconnect type, etc., to see that:

a. Compressor(s) run at proper setting.

b. Reheat coils activate properly (if applicable).

c. Humidistat activates humidifier (if applicable).

d. Suction and discharge pressures are proper.

e. Discharge temperature is set properly.

14. Clean up work area.

B-2 Boiler (Coal, Oil, and Gas) Frequency: Annual

1. Review manufacturer's instructions and ASME Boiler and Pressure Vessel Codes for boilers.

2. Review the Standard Operating Procedure for "Selection, Care and Use of Respiratory Protection."

3. Review the Standard Operating Procedure for "Controlling Hazardous Energy Sources."

4. De energizes, tag, and lock out circuits.

5. Close and tag all hand or motorized valves required to isolate the boiler. Chain and lock all valves that are closed for safety. These valves shall not be unlocked and reopened unless authorized by the originator of the work authorization. Enter this information in the boiler log and sign.

6. Wear appropriate respirator, goggles, and gloves while in contact with hazardous materials.

Contact the Safety and Environmental Management Division/Branch if you have questions.

7. If materials to be worked on are known or suspected to contain asbestos, check the building's asbestos management plans to see if they have been tested for asbestos. If they are suspect but have not been tested, have them tested. Manage asbestos in accordance with the plan.

8. Account for all tools, materials, and equipment before closing boiler.

Checkpoints:

1. Apply hydrostatic test of waterside pressure vessel (1½ times operating pressure, safety valve gagged or clamped shut.)

2. Drain boiler, tag valves and controls. NEVER attempt to remove a manhole or hand hole cover with out first properly venting the water or steam side of a boiler to the atmosphere. Prior to opening or entering a boiler it must be at atmospheric pressure. To protect the boiler from unnecessary stresses the boiler water temperature should be allowed to reach the boiler room temperature before draining the boiler.

3. Brush all tubes clean of scale.

4. Brush plate surfaces clean, use vacuum cleaner.

5. Clean breaching, ducts, fireboxes, or main fire tube, and flue passages.

6. Check and replace worn or damaged insulation. Repair the damage and remove the debris. If the insulation contains asbestos, follow the asbestos management plan for isolation, notification, work practice, and waste disposal.

7. Check refractory and brickwork; if damaged notify supervisor and enter this data in boiler log.

8. When the boiler has cooled to the ambient boiler room temperature, wash out mud legs, and flush boiler.

9. Refill boiler with water and chemicals if boiler is to be put back in service or if wet-lay-ups are to be employed.

10. Determine if there is ample provision for expansion between the sections.

11. Check for excessive rust build-up between sections (cast iron type).

12. Examine all steam and water line to controls to determine that they are clear of scale and arranged to insure proper control operations.

13. Clean stems and shafts, and tighten packing nuts on valves and pumps.

14. Flush fuel oil strainer baskets and oil solenoid valve seats.

15. Dismantle low water fuel cut offs and water feeders to insure freedom from obstructions and proper functioning of the working parts. Always replace old gaskets before reassembling.

16. Inspect connecting lines to boiler for accumulations of mud, scale, etc., and clean as needed.

17. Examine all visible wiring for brittle or worn insulation, and make sure electrical contacts are clean, adequately tightened, and functioning properly.

18. On electrical type detection devices, replace vacuum tubes annually, and replace defective solid-state devices.

19. Replace fusible plugs, if applicable.

B-3 Burner, Gas Frequency: Annual

Special instructions:

1. Review manufacturer instructions.

1. Check boiler room for ventilation in accordance with the American Gas Association (AGA) burner requirements.

2. Check operation of all gas controls and valves including: manual gas shutoff; petal gas regulator; safety shutoff valve (solenoid); automatic gas valve; petal solenoid valve; butterfly gas valve, motor, and linkage to air louver; safety petal solenoid (if used.)

3. Check flue connections for tight joints and minimum resistance to airflow. (combustion chamber, flues, breaching, and chimney are clear before firing.)

4. Draft regulators require slightly negative pressure in the combustion chamber at maximum input.

5. On forced draft burners, gas manifold pressure requirements should correspond with modulating (butterfly) valve in full open position and stable at all other firing rates.

6. Take and record and record flue gas readings to determine boiler efficiency. Use manufacturer's instructions if available. If not, use attached table as a guide for performance criteria. If efficiency is low, check baffling and passes for short-circuiting, and boiler for air infiltration. Adjust dampers and controls to optimize efficiency. Run test at following load points.

a. 100%, 70%, and 40% of rated full load for boilers having metering controls or modulation capacity at these load points.

b. At high and low fire rates on boilers equipped with OFF/LOW FIRE/HIGH FIRE control.

c. At single firing load point on boilers equipped with OFF/ON controls only.

7. Check burner for flashback and tight shutoff of fuel.

8. Check operation of automatic controls and combustion flame safeguards. Clean and adjust, if necessary.

9. Operation and adjustments should conform with manufacturer's instructions.

Performance Criteria for Gas Burners

Natural Gas (1,000 BTU/SCF)

Percent Load 40.0% 70.0% 100.0% Carbon Dioxide (CO2) 8.5% 9.0% 10.0% Carbon Monoxide (CO) 0 0 0 Oxygen (O2) 6.0% 5.0% 4.0% Excess Air (XA) 40.0% 25.0% 20.0% Smoke Scale No. 0 0 0

1. Combustibles should be zero or negligible percent in the flue gas.

2. Output (steam or water flow) where meters are available should correspond to combustion level not less than 100% of rated capacity at rated load.

3. Boiler section outlet flue gas temperature is not more than 30°F (17°C) higher than rated. When expected gas temperature is not known, manufacturer should be contacted for typical conditions for type of boiler being tested.

4. Boiler section outlet flue gas temperature should not be more than 150°F to 180°F (84°C to 100°C) higher than the corresponding saturated steam temperature for water tube boilers and 100°F to 125°F (56°C to 70°C) for fire tube boilers.

5. Excess air within 5 percent of manufacturer's performance level.

6. Feed water temperature, burner atomizing pressure, draft loss, and combustion appearance in accordance with manufacturer's data or be close to industry standards.

C-3 Coils Preheat, Reheat, Etc. Frequency: Annual (Remote Locations)

This guide applies to coils that are not part of an air washer or air-handling unit.

Review the Standard Operating Procedure for "Selection, Care, and Use of Respiratory Protection."

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

2. Remove obstructions to airflow.

3. Check coils. Correct or report any leaks.

4. Test and inspect controls that protects coils against freezing.

5. Check for rust or corrosion around coil frame and coil mounting bracket. Clean, prepare for painting and coat with proper type paint as necessary.

C-3 Coils Preheat, Reheat, Etc. Frequency: Annual (Remote Locations)

C-04A Central Mini Computer Frequency: Monthly HVAC System

Special Instructions:

Only persons approved by the equipment manufacturer to perform such work shall perform all of the following tests, inspections and preventive maintenance functions.

CHECKPOINT:

1. PC WORKSTATION - HARD DISK

Check monitor, clean as required.

Check printer, clean as required.

C-04A Central Mini Computer Frequency: Monthly HVAC System

C-04B Central Mini Computer Frequency: Annual

Special Instructions:

Only persons approved by the equipment manufacturer to perform such work shall perform all of the following tests, inspections and preventive maintenance functions.

CHECKPOINT:

1. ANALOG SENSOR

Verify Analog Sensor reading at sensor and compare to point readout at automation system.

2. DPU

Visually inspect cabinet and observe operating environment. Check terminations and wiring. Check incoming power and check power supply voltages. Clean interior and exterior of enclosure.

3. INSIGHT (V.2) S/W SA BASE

Provide Software up date.

Provide documentation update. Review new feature and documentation with COR

4. LAN CONTROLLER

Check diagnostic LED and communication connections, observe general conditions and operating environment. Check incoming power and transformer voltage to controller board. Perform integrity test and system wide function test through random checking, standard report and diagnostic.

5. MBC 40

visually inspects MBC cabinet and observe operating environment. Inspect diagnostic LED's.

Check for air leaks if applicable.

Inspect MBC layout sheet and labels for accuracy.

Check time and date - reset as required.

Check operation of analog output modules - note those cycling. Print a report of disabled points - review with COR. Clean cabinet enclosure (interior and exterior).

C-04B Central Mini Computer Frequency: Annual HVAC System

6. PC WORK STATION - HARD DISK

Inspect work area, Check cables and power connections. Check monitor - clean if required.

Check printer - clean if required.

7. PERIODIC LOOP TUNING (SCU/RCU)

Check PID values and reset as necessary via powers loop tuning device.

8. PERIODIC LOOP TUNING (UC/TEC)

Check PID values and reset as necessary via powers loop tuning device.

9. RH, ROOM, 4-20 MA

Inspect device and clean as required.

10. SW SA GRAPHICS CREATION

Identify with the COR the graphics that need to be created. Create graphics. Review graphics with COR.

11. SCU, TYPE 3

visually inspects SCU cabinet and observe operating environment. Check diagnostic LED's fuses, and surge transient. Check board setting and check cabling for pinching, tears and breaks, ensure that all wiring terminations are secure. Check for air leaks if applicable. Check incoming AC power and power supply, check power supply voltages and adjust to +5 volts if necessary. Check battery charging circuit and battery ( FRE Version controllers boards only). Check the time and reset if necessary. Clean interior and exterior of cabinet.

Perform integrity test and system wide function test through random point checks, commands, selective disabling and standard reports.

12. TEMP ROOM RTD, PLATINUM

Inspect device and clean as required.

13. TEMP, ROOM THERMISTOR

Inspect device and clean as required.

C-04B Central Mini Computer Frequency: Annual HVAC System

14. UNITARY CONTROLLER, 24 POINTS

Visually inspect unitary controller and observe operating environment. Check diagnostic LED's, fuses, and keypad display. Check board seating and check cabling for pinching, tears and breaks. Ensure that all wiring terminations are secure. Check the time reset if necessary.

Evaluate application function and system integrity through set point commanding, trending and standard reports. Back up database and PPCL program. Clean interior and exterior of cabinet.

15. TRAINING DURING SCHEDULED PM VISITS

Conduct informal training on system strategies and operations with personnel designated by the COR

C-04B Central Mini Computer Frequency: Annual

C-04C Central Mini Computer Frequency: 4-Year

Special Instructions:

All of the following tests, inspections and only persons approved by the equipment manufacturer to perform such work shall perform preventive maintenance functions.

CHECKPOINT:

1. MBS 40

Replace battery

2. SCU, TYPE 3

Replace battery (P/N 533-725) and reload database.

(FRE Version 4 controller boards only).

C-04C Central Mini Computer Frequency: 4-Year

C-5 Automatic Mixing Box Frequency: Annual Pneumatic or Electric

1. Review manufacturer's specifications.

1. Check to see that the operating control thermostat activates the damper per design specifications. If not, recalibrate. Replace if it is defective with the same type action (direct or reverse action)and temperature range.

2. Check damper linkage for tightness or damage. Lightly oil moving parts.

3. Inspect dampers for free movement in mixing box. Replace felt or other type seals as required.

4. Inspect mixing box and hot and cold connecting ducts for air leaks. Correct leaks with duct tape or tighten connections, as required.

5. Inspect damper actuators for tightness to mounting brackets.

6. Tighten electrical connections to servomotors, and test if applicable.

7. If pneumatic actuator does not stroke properly, correct sticking valve stem or binding linkage.

Replace diaphragm or actuator if necessary.

8. Inspect for air leaks around actuator and in airline between controller and actuator.

9. Inspect thermostat for proper location and check main and branch airlines at thermostat for crimps, breaks, etc. Repair if needed.

C-5 Automatic Mixing Box Frequency: Annual Pneumatic or Electric

C-7 Condensate or Vacuum Pump Frequency: Annual

2. This maintenance should only be performed when it will not prevent operation of the steam boiler.

Checkpoint.

1. Operate unit to check for steam binding.

2. Check condensate temperature. It should be approximately 30?F (17?C) below steam temperature if traps are not leaking.

3. Examine flanges for steam leaks, replace gaskets as necessary.

4. Pump receiver down.

5. Turn condensate to sewer.

6. Shut down unit.

7. Clean and examine receiver, vent pipe, inlet and discharge openings for corrosion; remove all external corrosion, and paint with appropriate type paint.

8. Clean and adjust motor float switch and float operation on high low water level. Inspect float rods and pressure switches.

Make any adjustments as necessary.

9. Check alignment of motor and pump coupling with straight edge. Align if necessary.