Sec_C-5.13_Chiller_Maintenance_and_Repair_Index.pdf

Functional Area 5.13

Chiller Maintenance and Repair

Table of Contents

GROUNDS MAINTENANCE

5.13.1 INTRODUCTION

5.13.2 SCOPE OF SERVICES

5.13.2.1 Cooling Seasons

5.13.3.3.1 Personnel

5.13.4 SCHEDULED TASKS

5.13.4.1 Annual Inspections

5.13.4.1.1 Detailed Schedules of Inspection

5.13.4.1.2 Maintenance And Inspection Schedule

5.13.4.1.3 Maintenance and Inspection Plan

5.13.4.1.4 Maintenance Action Report

5.13.4.2 Start-up and Place into Operation

5.13.4.2.1 Perform Operational Inspections

5.13.4.2.2 Perform Yearly Maintenance

5.13.4.2.3 Maintain the Chillers

5.13.5 Maintain HVAC Equipment

5.13.6 Operate and Maintain Equipment at the Cold Storage Facility

5.13.6.1 Correct All Deficiencies Found

5.13.7 Operate Cillers and Auxiliary Equipment

5.13.8 Cooling Tower Treatment Program……………………………………..……………..4

5.13.9 Maintain Ancillary items……………………...………..…………………………….…..5

5.13.10 Operate and Maintain 150 Ton Cooler Tower……………………………………….5

5.13.11 Spot and Mark Underground Chilled Water and Condenser Water Lines…….….5

5.13.12 UNSCHEDULED TASKS

5.13.12.1 OEM Part replacement

5.13.12.2 Clean-up

5.13.12.3 Hazardous Conditions

5.13.12.4 Defective Parts

5.13.12.5 Equipment

5.13.13 Rental Equipment

5.13.14 Applicable Documents…………………………………………………………….5

List of Technical Exhibits

Exhibit Number Title

5.13-001 Chiller Equipment 5.13-002 Chiller Annual Inspection Checklist 5.13-002a Chiller Data 5.13-002b Refrigerant Use Data 5.13-003 5.13-004 5.13-005 5.13-006 5.13-007 5.13-008

Deleted Deliverables Schedule Operational Inspection Checklist

PRS

Government Furnished Property Chiller Annual Maintenance Checklist

Functional Area 5.13

Chiller Maintenance and Repair

5.13.1 INTRODUCTION:

5.13.1.1 Provide all labor, material, and equipment to inspect, start-up, operate, and maintain the chillers as listed on Technical Exhibit 5.13-001 as well as all the associated auxiliary equipment and machinery required to support the chillers such as towers, motors, controls, tube cleaners, piping, expansion tanks, refrigerant monitors/sensors, exhaust fans, pumps, purge units, air compressors, drains, valves, unit heaters, lights, disconnects, variable speed drives, circuit panels, emergency lights, eye-lavages, switch gear, chart recorders. Functional Area work includes complete services required to repair all water-cooled chillers, cooling towers, pumps, valves, controls, and cold storage equipment (except buildings owned by MEDDAC) on Fort Benning, Georgia.

5.13.2 SCOPE OF SERVICE

5.13.2.1 Cooling Season: Chiller systems for buildings 9200, 9201, 9230, 5500 and the cooling tower for building 96 must be capable of operating on a year round basis. Chiller systems for buildings 4, 6 and 398 may be turned on or off year round as directed by the government. The remaining chillers will be turned on for the cooling season and off in the fall as directed by the

Government. The Office in building 398 will be furnished to the Contractor as a base of operation.

5.13.3 Personnel:

5.13.3.1 Qualifications of Contractor: The contractor shall employ personnel regularly engaged in the operation and servicing of chillers and HVAC equipment of the general type indicated for operation, maintenance and repair service. The contractor shall have adequate stocks of new OEM parts to maintain equipment described herein and insure that all replacement parts are available. The contractor shall employ personnel knowledgeable with daily operation and maintenance of cooling plants and equipment indicated in the functional area.

5.13.3.2 Welding: The quality of the welding procedures and the quality of the welding shall be determined by testing the welder's ability to make sound welds under standard working conditions with the equipment to be used in this functional area, all in compliance with MIL-STD-248, AWS B3.0 and D1.1.

5.13.3.3 Qualifications of Welders: The contractor shall submit to the Contracting Officer certified copies of the qualification of each welder employed for this functional area (see TE 5.13-004). Each welder shall be required to identify his work with a code marking, and a listing of the names of the welders with corresponding code marks shall be furnished to the Directorate of Public Works COTR.

5.13.3.4 Qualification of HVAC Chiller Technicians and Mechanics: HVAC Chiller technicians, mechanics and other persons employed to operate, maintain and repair the chillers and associated equipment shall have proper EPA Certification and not less than 2 years experience operating, repairing, inspecting or otherwise maintaining chillers of the general type and rating specified. Exception, helpers or apprentices will be permitted to work directly under the direct supervision of a responsible mechanic. A detailed resume for each technician and chiller mechanic shall be provided in duplicate to the Contracting Officer, including evidence of at least Level III EPA Section 68 HVAC Certification for mechanics and at least Journeyman PM Tech Certification for technicians. http://www.epatest.com/ (Technical Exhibit 5.13-004).

5.13.4 SCHEDULED TASKS:

The contractor shall perform the tasks below on a recurring or scheduled basis and record the work under approved Standing Operating Orders (SOOs). If a requirement for further work on any area beyond the scheduled requirements below is identified, the Contractor may be required to accomplish such work on an approved Individual Job Order (IJO).

5.13.4.1 Perform an annual inspection on all chillers, towers, and pumps as shown on Technical Exhibit 5.13-001. Inspection shall be performed before 28 Feb with bound inspection or compact disc results provided to the government no later than 15 Mar. The initial annual inspection shall be performed within 30 days with bound inspection results provided to the Government no later than 30 days. Contractor shall make all repairs and correct all deficiencies as identified in annual inspection.

5.13.4.1.1 Detailed Schedule of Inspection: The contractor shall submit to the

Contracting Officer or his authorized representative a detailed and complete schedule of the dates on which all weekly, monthly, and annual services are to be performed within 10 calendar days. The proposed schedule shall list the type of work to be performed, the areas to be worked and the estimated time to complete the work in each area. (See Technical Exhibit 5.13- 004).

a. Provide a schedule within five (5) days of each annual contract period for chiller system outlining the periodic maintenance to be performed during each annual contract period.

http://www.epatest.com/

b. Post this schedule at each equipment location.

c. Provide space blocks for each period and instruct chiller mechanic to initial when work has been completed.

5.13.4.1.2 The maintenance and inspection schedule shall provide a program to accomplish all maintenance and inspection as specified in TE 5.13-002.

5.13.4.1.3 Maintenance and Inspection Plan shall be updated every 60 calendar days thereafter, to indicate actual accomplishment for the year to date. The initial maintenance and inspection plan will be completed and submitted in writing to the Contracting Officer or his authorized representative for review to assure that the plan provides for all specified maintenance requirements in an organized and time phased manner. The Contracting Officer will approve or disapprove the schedule and, if disapproved, the contractor shall submit a corrected schedule within two (2) days after notification of disapproved schedule (see TE 5.13- 004).

5.13.4.1.4 Provide the Contracting Officer or his authorized representative a bound copy or compact disc of each maintenance action taken on each piece of equipment. The report shall include the date and time maintenance was performed, equipment designation, building number, maintenance problem, action taken and replacement part information. In addition, maintain a log of all (planned and unplanned) outages, showing start and stop time of those outages. The log will be made available to the government as requested (usually quarterly) and included in the annual report. Report shall be delivered 2 weeks prior the end of contract year (see TE 5.13-004).

5.13.4.2 Start-up and place into operation all chillers, cooling towers, pumps and HVAC equipment when directed by the Contracting Officer. Contractor will be required to valve off steam/hot water heat in buildings listed in TE 5.13-001. Contractor will be provided five calendar days notice before start-ups are to begin and the contractor shall have all chillers operational within 3 calendar days. Seasonal start-up shall include, as a minimum, all of the items below:

a. Utilize manufacturer’s start-up recommendations.

b. Check chiller auxiliary equipment operation.

c. Check for proper voltages.

d. Check oil level, refrigerant level.

e. Check oil sump heater, gear case heater, and purge pump oil heaters.

f. Check vacuum.

g. Check relays, operating, and safety controls.

h. Start chilled water pump(s).

i. Start condenser water pump(s) and cooling tower.

j. Start water chiller.

k. Check purge unit operation.

l. Log operating conditions after unit stabilizes. Make sure unit maintains set point for 24 hours continuous.

m. Shutdown all chillers, towers, and pumps within 24 hours after receiving direction from the contracting officer, or his authorized representative.

5.13.4.2.1 Perform operational inspections on each chiller, tower, and pumps, throughout the air conditioning season. Operational inspections shall include as a minimum the inspections shown on Technical Exhibit 5.13-002. Operational inspections shall be performed at a frequency not less than that shown on TE 5.13-002. Contractor shall make all repairs and correct all deficiencies as identified in operational inspections. Contractor shall maintain records of inspections performed/repairs made and shall provide to contracting officer when requested.

5.13.4.2.2 Perform yearly maintenance on each chiller, tower, and pump as shown on TE

5.13-008.

5.13.4.2.3 Maintain the chillers to operate continuously throughout the air conditioning season.

Make repairs as identified through operational inspections. Respond to chiller, tower, or pump failures, or shut down within one hour of contractor discovering or government notification, and restart chillers. Respond means, be on the site addressing why the chiller failed or shut down.

Contractor may utilize a contractor provided telemeter system to provide notice of chiller failure.

Notification may occur day or night (24 hours/day). The Contractor shall work continuously and diligently until equipment is operational.

5.13.4.4 The Contractor shall furnish the Contracting officer telephone numbers and names of qualified maintenance personnel who can be contacted to respond to emergency after normal working hours. (TE 5.13-004)

5.13.5 Maintain all HVAC equipment to operate continuously year round. Make repairs as identified through operational inspections. Respond to equipment failures, or shut down within one hour of contractor discovering or government notification, and restart HVAC equipment. Respond means be on the site addressing why the HVAC failed or shut down.

Notification may occur day or night (24 hours/day). The Contractor shall work continuously and diligently until equipment is operational.

5.13.6 Operate and maintain the equipment at the cold storage facility located at building 100 (TE 5.13-003). Equipment shall be checked for proper operation on a daily basis.

a. Check compressors, pressure controls (high and low side), refrigerant leaks, oil leaks, oil level, and crank case heater.

b. Check evaporative condensers, spray water pumps, make-up float and valve assembly, discharge water eliminators, belts, fans, liquid receivers, discharge ducts, and roof penetrations of ductwork.

c. Check contacts, disconnects, starters, heaters, and electrical connections.

d. Check unit and product coolers; defrost cycle, motors, fans, drain pan and lines, heat tape, controls, thermostats, and calibrate controls.

e. Check doors and door frames and heaters in both, latches, and seals for securing and sealing rooms.

f. Check equipment base and supports, vibration isolators, frames of equipment, and fan guards.

g. Check air purifier, ductwork, and diffusers in ventilated storage area. Change air filters (new air filters will be dated and have technician’s initials) annotated on the new air filters.

h. Check filter dryers, oil separators, gauges, strainers, and valves, including thermal expansion and solenoid valves.

i. Check and calibrate temperature charts.

j. Check drive couplings and alignment.

5.13.6.1 Correct all deficiencies found. If the government discovers failing or inoperative equipment, then the government will notify the contractor. The contractor shall respond within 1 hour of notification. Respond means that the contractor shall be on-site performing corrective action on the failed equipment. Contractor shall work continuously and diligently until all equipment is in proper operational condition.

5.13.7 Operate chillers and auxiliary equipment in the most energy efficient manner possible. Requirements include such items as:

a. When multiple chillers provide chilled water to a common distribution header, utilize the most energy efficient chiller(s) available.

b. Keeping strainers clean.

c. Keeping variable frequency drives in optimum operation.

d. Maintaining chilled water at highest temperature possible while still meeting space-conditioning requirements.

e. Keeping belts at proper tension.

f. Optimize condenser and evaporator flow and temperature.

g. Maintaining good water treatment program.

h. Replacing mechanical room light bulbs with compact fluorescent as they burn out.

i. Annually cleaning all tubes for optimum chiller operation.

j. Provide continuous cooling tower water treatment program.

5.13.8 The contractor shall be qualified and regularly engaged in the cooling tower water treatment program and shall submit a list of qualifications to the Government. Storage of chemicals shall be in an environmentally safe manner. Provide a list of chemicals to be used along with estimated quantities to the Government prior to air conditioning start-up. The treatment program must be approved by the Operations and Maintenance Mechanical Engineer.

The chemical information will be provided to our Environmental Division for information only.

5.13.9 Maintain all existing ancillary items within each plant to include, but not limited to:

Exhaust fans, relief valves, refrigerant monitors and sensors, piping, including insulation, water closets, sinks urinals, lighting, packing on valves, valves, strainers, pipe couplings, float valves, controls, sensors/gauges, air compressors, grounds around plant (cut grass with approved 4283), pumps (sump, circulating water, condenser), flooring (keep clean and safe), switchgear, eyelavages, unit heaters, strainers, variable speed drives, signage (hearing protection, confined spaces, etc.), air compressors, air dryers, fire extinguishers (wall mounted hand-held type), automatic tube cleaners emergency lighting, and chart recorders.

5.13.10 Operate and maintain 150-ton cooling tower at building 96 to include, pumps, motors, belts, chemical treatment, etc. The tower is the heat rejection source for water source heat pumps, which the contractor will not operate or maintain.

5.13.11 Spot and mark all underground chilled water and condenser water lines as required by the government and other contractors for repair (or new) work.

5.13.12 UNSCHEDULED TASKS

5.13.12.1 All parts replaced under the provisions of this Functional Area will be OEM components. The contractor shall replace or repair the component part rather than the entire unit in cases where the integrity of the unit will not be compromised or placed in jeopardy. If a part costs more than two thousand five hundred dollars ($2500.00), The contractor shall inform the Contract Officer Technical Representative verbally, and confirmed in writing to the Contracting Officer within one calendar day, of the nomenclature, description, and price of component part exceeding the limit that are required to restore the system to serviceable operation (See TE 5.13-004).

5.13.12.2 Clean-Up: The contractor shall be responsible for the general cleaning of spaces that house the equipment. General cleaning shall include removal of debris, dust, and other matter from any spaces utilized or maintained by the contractor.

5.13.12.3 Hazardous Conditions: The contractor shall secure the equipment and immediately notify the COTR verbally and confirm the notification in writing within one calendar day.

5.13.12.4 Defective Parts: All defective parts replaced by the contractor/subcontractor shall remain the property of the Government. The contractor shall tag all parts with the following information, and deliver the parts to a disposal area designated.

a. Building and equipment number.

b. Description of malfunction.

c. Date of removal.

5.13.12.5 Equipment

5.13.12.6 The Contractor is expected to maintain and operate any new Government furnished chillers and associated equipment per the manufacturer’s instructions and as specified.

5.13.13 Rental Equipment

5.13.13.1 Chiller/cooling towers that require extensive repair during cooling cycles shall be required as directed by the Government to be backed up by a rental chiller.

below.

5.13.14 Applicable Documents: Documents applicable to this Functional Area are listed

Government Publications:

Department of the Army http://www.usace.army.mil/publications/

AR 11-27 Army Energy Conservation Program

AR 200-1 Environmental Quality, Environmental Protection and Enhancement

AR 420-53 Refrigeration

AR 420-54 Air-Conditioning and Refrigeration

AR 420-55 Food Service and Related Equipment

TM 5-670 Refrigeration, Air-Conditioning, Mechanical Ventilation, and Evaporative Cooling

TM 5-671 Preventive Maintenance for Refrigeration, Air- Conditioning, Mechanical Ventilation, and Evaporative Cooling

TM 5-785 Engineering Weather Data

TM 5-810-3 Mechanical Refrigeration and Ventilation in Cold Storage Facilities

Non-Governmental Publications

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

http://www.ndt.net/news/1999/cssinfo.htm#1

MSS SP-25 (1993) Standard Marking System for Valves, Fittings, Flanges and Unions

MSS SP-58 (1993) Pipe Hangers and Supports - Materials, Design and Manufacture http://www.usace.army.mil/publications/ http://www.ndt.net/news/1999/cssinfo.htm#1

MSS SP-67 (1995) Butterfly Valves

MSS SP-69 (1996) Pipe Hangers and Supports - Selection and Application

MSS SP-70 (1990) Cast Iron Gate Valves, Flanged and Threaded Ends

MSS SP-71 (1990) Cast Iron Swing Check Valves, Flanges and Threaded Ends

MSS SP-72 (1992) Ball Valves with Flanged or Butt-welding Ends for General Service

MSS SP-73 (1991) Brazing Joints for Copper and Copper Alloy Pressure Fittings

MSS SP-78 (1987; R 1992) Cast Iron Plug Valves, Flanged and Threaded Ends

MSS SP-80 (1987) Bronze Gate, Globe, Angle and Check Valves

MSS SP-85 (1994) Cast Iron Globe & Angle Valves, Flanged and Threaded Ends

MSS SP-110 (1992) Ball Valves Threaded, Socket Welding, Soldered, Grooved /Flared Ends

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

http://www.nfpa.org/index.asp?cookie%5Ftest=1

NFPA 54 (1992) National Fuel Gas Code

NFPA 70 (1996) National Electrical Code

NFPA 37 (1994) Installation and Use of Stationary Combustion Engines and Gas

Turbines

NFPA 90A (1996) Installation of Air Conditioning and Ventilating Systems

NFPA 214 (1996) Water-Cooling Towers

NFPA 90B Warm Air Heating and Air-Conditioning http://www.nfpa.org/index.asp?cookie%5Ftest=1

NFPA 91 Blower and Exhaust Systems

AMERICAN WELDING SOCIETY (AWS)

http://www.aws.org/

AWS A5.8 (1992) Filler Metals for Brazing and Braze Welding

AWS B2.2 (1991) Brazing Procedure and Performance Qualification

COOLING TOWER INSTITUTE (CTI)

http://www.cti.org/

CTI ACT 105 (1990; Supple) Acceptance Test Code for Water Cooling Towers

CTI Std-103 (1986; Rev July 1994) The Design of Cooling Towers with Redwood

Lumber

CTI Std-111 (1986) Gear Speed Reducers

CTI Std-114 (1986; Rev July 1994) Douglas Fir Lumber Specifications

CTI Std-134 (1985) Plywood for Use in Cooling Towers

CTI Std-137 (1988; Rev July 1994) Fiberglass Pultruded Structural Products for Use in Cooling Towers

CTI WMS-112 (1986) Pressure Preservative Treatment of Lumber for Industrial

Water-Cooling Towers

AIR CONDITIONING AND REFRIGERATION INSTITUTE

http://www.aws.org/ http://www.cti.org/ http://ts.nist.gov/Standards/Global/upload/sp903-entries1.pdf

ARI 700-88, Specifications for Fluorocarbon Refrigerants

ARI 740-91, Performance of Refrigerant Recovery, Recycling and/or Reclaim Equipment

AMERICAN SOCIETY OF HEATING, REFRIGERATION AND AIR CONDITIONING

ASHRAE Guideline 3-1990, Reducing Emissions of Fully Halogenated

Chlorofluorocarbon (CFC) Refrigerants in Refrigeration and Air-

Conditioning Equipment and Application

ASHRAE 15-1994, Safety Code for Mechanical Refrigeration

HVAC Systems - Testing, Adjusting, and Balancing

Installation Standards for Heating, Air Conditioning, and

Solar Systems

AMERICAN NATIONAL STANDARDS INSTITUTE

http://publicaa.ansi.org/default.aspx

ANSI B16 Pipe, Flanges, and Fittings

ANSI B31.1 Power Piping

ANSI B36 Iron and Steel Pipe http://ts.nist.gov/Standards/Global/upload/sp903-entries1.pdf http://publicaa.ansi.org/default.aspx