Attachment_6_Repair_Scenario.docx

TECHNICAL REQUIREMENTS FOR CHILLER CONTROLS

TESTING AND REPAIR

PURPOSE:

The purpose of this technical requirement is to document the requirements for the testing and repair of the chiller controls at DECC XXXXXX. The project shall take all means practical and within budget constraints to identify the root cause for the control issues with the chiller plant.

PROJECT BACKGROUND:

DECC XXXXXX operates a mission critical data center in which successful fulfillment of the DECCs mission relies heavily on a fully redundant mechanical system with a high availability rate. The redundant mechanical systems are unfortunately supported by a direct digital controls system (DDC) that doesn’t have the same level of redundancy as the mechanical systems. Since the Nov 2012 timeframe, the site has been experiencing issues controlling the sites chiller plants. The issue is believed to be related to the sites DDC system and could be a result of a number of issues ranging from operator error to system component, program or logic failures.

The past issues associated with controlling of the chiller plants are lead/lag rotation, system response upon chiller/pump/fluid cooler failure, operation in free cooling. An emergency service call was accomplished under this contract in November and was believed to have resolved the system response under failures, but as of recently (past month or so) the site has begun to experience issues when the system is in free cooling and in modulating the chiller output will operating under mechanical cooling.

The site has expressed concern with operating the system in manual configurations due to the complexity of the manual operations.

GENERAL NOTES:

The Project Title is: Chiller Controls Testing and Repair

All technical questions and/or concerns with this statement of work or project are to be addressed and answered by the DISA Enterprise Services task monitor.

PROJECT AND DOCUMENTATION SENSITIVITY/HANDLING:

All documents provided by DISA and/or created by the BAS contractor shall be handled, marked, and documented in accordance with the DD254 that is associated with contract XXXXXX.

Documents related to this project that are considered “for disposal” by the contract team shall be cross cut shredded before being placed into a disposal container.

PROJECT COMMUNICATION:

All communications related to the project will be titled as follows:

· Emails: The subject line in the e mail will contain the GSA contract number, project title, the e mail subject and followed by UNCLASSIFIED. For example, the transmission of an email for submittal review would read.

Chiller Testing–Submittal-UNCLASSIFIED

· Shipments: All shipments to the facility must be marked with the project name on the outside of the package, container, pallet, box etc.

· Visitor Access Requests: All visitor access requests must clearly identify that the person requesting access to the facility is performing work on the ENTERPRISE BAS CONTRACT, and shall identify XXXXXXXX as the Enterprise Services Facility Engineering point of contact.

All communications on the project must include the contracting office.

PROJECT TASK MONITORS (TMs):

For this project, the primary task monitor will be XXXXXXXX with the alternate task monitor being Tony Niederhauser.

PROJECT COORDINATION:

The project coordination expected for this project is expected to consist of:

· Coordinating access to the site with the site facility/security manager

· Working with DISA’s TIM contractor (maintenance provider) on testing, controls changes and training

· Coordinating testing and control changes with the task monitor and facility manager

PROTECTION OF SITE MISSION:

Conduct all tasks and requirements outlined by this document without increasing temperatures in the sites data center or computers to levels greater than 80 deg F.

At no time shall the work associated with this technical requirement disrupt the sites mission.

SUPPORTING DOCUMENTATION:

DISA is providing the as built control drawings and sequence of operation for use in accomplishing the requirements outlined by this document.

DISA is providing the as built control logic document for use in accomplishing the requirements outlined by this document.

TESTING TIMELINE:

DISA is currently seeking approval to conduct chiller system testing starting Jan 22, 2013 and extending until Jan 25, 2013. This date may not be achievable due to operational concerns within DISA’s enterprise as well as a need to repair pipes damaged during recent free cooling operations. DISA is using the week of Jan 28, 2013 as our alternate testing and/repair window.

Provide as part of the technical and cost proposal confirmation that appropriate/qualified personal are available to support these dates.

SITE VISIT REQUIREMENTS:

Site visits are required to provide troubleshooting and testing of the chiller systems. Following the VAR requirements associated with Contract XXXXXXXX

DELIVERABLES:

1. Conduct a review of the existing DDC and Trane Trace programs, configurations, alarms, points and control loops.

a. Utilize the appropriate senior level DDC and Trance BCU technicians to document the dates of when the chiller, pump, fluid cooler or BCU configurations were changed. This is to include but not limited to control loops and communication settings. The review is to go back the past 4 months. Compare the as found conditions with the as built configurations and provide within 36 hours of notice to proceed:

i. A list of discrepancies between as found conditions and the as built documentation.

ii. A list identifying all alarms, setpoints, data points, inputs, outputs, global variables, and binary variables in a manual or non commissioned state.

iii. A recommendation to continue testing as outlined by this document with the current configurations prior to testing or to modify the configurations prior to testing. The recommendation shall explain the rationale behind the recommendation.

b. Utilize the appropriate senior level DDC, and Trane BCU technicians to download the programs currently installed in all chiller, fluid cooler, pump and BCU controllers. Compare the downloaded programs with the as built programs and provide within 36 hours of notice to proceed:

i. A list of discrepancies between the programs

ii. Copies of the downloaded programs

iii. A recommendation to continue testing as outlined by this document with the currently installed programs or to replace the currently installed programs with the as built programs prior to testing. The recommendation shall explain the rationale behind the recommendation.

c. Based on input from the senior level technicians, the ES521 task monitor will evaluate the recommendations with the site and DISA’s TIM contractor. The ES521 task monitor will provide direction on acceptance or rejection of the recommendations prior to sequence of operations testing. For pricing purposes, assume that all existing programs will be replaced with the as built programs.

2. Conduct a complete testing of all chiller plant sequence of operations as outlined by the as built controls documentation.

a. It is DISAs desire to have the following representation present during all testing activities

i. Facility Engineering Representative

ii. Site Facility Manager

iii. TIM contractor (O&M provider)

b. When a testing sequence is unsuccessful and repairs are made to programming or communication configuration, all sequences (even previously successful) must be repeated after the repair is made.

c. During testing, evaluate the communication speed and reliability using industry standard practices and test equipment for the following areas in the network.

i. Between the Trane BCU and the Delta DDC System

ii. Between all chiller plant Delta DDC system components

3. Troubleshooting and Repair

a. During troubleshooting activities, it is expected that some or all sequence of operations or equipment response may not function as intended. When this occurs, troubleshoot the DDC system to determine the root cause for the system deficiency. Changes to communication configurations, DDC programs, DDC settings, control loops are to be coordinated with the task monitor prior to any changes to correct the system deficiency. All changes in programming, communication configurations, DDC settings, equipment settings shall be part of this requirements based bid. When the troubleshooting indicates that a component has failed, coordinate with the contracting officer and task monitor for direction on how to handle the replacement of the component. Possible component replacement options are modification to this requirement, and deferment of the repair.

b. Provide a phenolic label at each chiller system manual operating station that provides directions to the operator on how to operate the system in manual mode (without any DDC controllers).

c. Testing shall include demonstrating failure of infrastructure components to demonstrate proper system response.

4. Establish usernames and passwords in the Delta DDC system for personnel that attend the training and demonstrate proficiency in all aspects of the training.

The access for each user shall only permit the user the ability to operate and trend the systems, but not the ability to change programs, control loops, communication configurations, scale ranges, or graphics.

5. Provide 24 hours of training to the site and TIM contractor on operation of the chiller plant by use of the Delta DDC system. The training shall at a minimum include:

a. Logging into the Delta DDC system

b. Alarm(event) recognition and acknowledgement

c. Setpoint modifications

d. System lead lag

e. Sequence of operations

f. Free cooling operations – transition to and from

g. Manual operation of the system (trainees shall perform this action)

h. Graphics navigation

The training must include a written and hand on exam to evaluate each trainees retention and understanding of the training material.

6. Provide a detailed service report that outlines all findings, tests (successful and unsuccessful), modifications made, pending actions, and recommendations.

7. Provide the following BAS spare parts.

a. Delta Controls Controller part number DSC-1146E (1each)

b. Delta Controls VFD Speed controller part number DISM-E/1 (2 each)

c. Delta Controls Delta Field Module part number DFM-404 (1 each)

d. IDEC 24V 2P relay (4 each)

e. Two of every fuse installed in the Chiller DDC System

f. Schneider Electric 500VA 120/24V transformer part number 9070T500D23 (1each)

8. Provide an updated O&M that is reflective of any changes made to the system.

QUALIFICATIONS:

All sub contractors shall be licensed and intimately familiar in the installation, troubleshooting, testing and design of data center building automation systems.

PERIOD OF PERFORMANCE:

The period of performance for this technical requirement shall not exceed March 31, 2013.

SECURITY:

Follow the documentation requirements as outlined by the DD 254 associated with GSA contract GS08T10BPR0003 and the contract.

Personnel working on this technical requirement shall not be required to possess an IT II security clearance.

END

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