Attachment 5 501 Heating Cooling 10Oct19 rev5 14Jul2020.pdf

Attachment 5

Heating and Cooling Services

10 October 2019

REVISION-5 14 July 2020

CLS 501 Heating & Cooling i

Table of Contents

1.0 GENERAL INFORMATION

1.1 Overview

1.2 Air Pollution Regulations

1.3 Facility Temperature Levels

2.0 DESCRIPTION OF SERVICES

2.1 Scope

2.2 Heating and Boiler Plant Staffing

2.3 Operation of Heating Plants

2.4 Central Boiler Plants

3.0 PURCHASE OF FUELS

3.1 Fuel Oil

3.2 Natural Gas Distribution System

4.0 AC AND REFRIGERATION PLANTS AND SYSTEMS

4.1 Scope

4.2 Daily Inspection of Chillers

1.0 General Information.

1.1 Overview. Heating and Cooling Services provide steam (for heating and cooling), dehumidification, hot water, cooling, domestic hot water, and facility processes using Government-owned central heating and cooling plants, and distribution systems.

Operating Government-owned central heating and cooling plants; and distribution systems includes all contract costs associated with full operation staff, oversight of contracted plant (other than a Utilities Privatization Contractor), operation, periodic regulatory inspections and certifications, purchase of fuels (coal, natural gas, fuel oil, etc.), storage of fuels; maintenance, inspection, and certification of fuel storage facilities;

periodic operators training and certification, supervision and administration tasks, and purchase of chemicals and supplies.

1.2 Air Pollution Regulations. The Contractor shall operate all heating plants in compliance with all Federal, State, and local air pollution regulations. Compliance requirements are identified in Attachment 6 “Environmental Compliance”. The Contractor shall address all non-compliance issues immediately to the Contracting Officer’s Representative (COR) or Alternate Contracting Officer’s Representative

(ACOR).

1.3 Facility Temperature Levels. Facility temperature levels are to be maintained at 68 degrees Fahrenheit during heating season and 78 degrees Fahrenheit during cooling season. Warehouses normally are not air conditioned or heated and, therefore, have no set requirements for heating and cooling unless special storage requirements are warranted. For warehouses with special storage requirements, temperature levels shall be maintained at 55 degrees Fahrenheit during the heating season. Thermostats are adjusted to maintain these levels. If thermostats indicate proper settings yet temperatures are not within 2 degrees Fahrenheit of above target levels, the Contractor shall notify the building custodian. If the HVAC equipment is inadequate to maintain the design levels, the deficiency shall be noted in the quarterly energy conservation report (see Attachment 1 “CLS 400 Engineering Services” paragraph 1.3.1).

2.0 Description of Services.

2.1 Scope. The Contractor shall economically and efficiently operate all central boiler plants, heating plants, steam distribution, condensate return system and systems (steam meters, automatic tank monitoring system, boilers, and furnaces) used in the production of domestic heat (including the provision of unscheduled services) as directed by the COR/ACOR. The Contractor shall operate the heating and cooling systems to maximize the benefits derived from purchased commodities (e.g., steam, gas, and electricity) while minimizing overall energy consumption. Major components and all other heating plants and equipment (including domestic hot water heaters) are listed in Technical Exhibit (TE) #15.

The Contractor shall provide management, supervision, personnel, labor, materials, transportation, tools, maintenance equipment, and personnel protective equipment for the operation, and calibration, of the central boiler plants, heating plants, steam distribution, condensate return system and hot air furnaces (boiler/heating plants) at RSA. These services shall be performed in accordance with (IAW) the standards listed in AR 420-1.

Summary of Expectations. Heating and Cooling Services are provided throughout the installation and are critical to meet mission requirements. Heating Services are not required in US Army Garrison-Redstone (USAG-R) Family Housing which has been privatized. The Contractor shall provide Heating services at all times, to meet mission requirements.

Unless otherwise directed in writing by the KO/COR, the Contractor shall maintain all idle boilers in a ready-to-use condition. When any boiler cannot be placed in operation within eight (8) consecutive hours, the Contractor shall notify the KO/COR.

This notice should include probable cause. This notice should include probable cause.

Proper lay-up procedures shall be used IAW Technical Manual (TM) 5-650, Repairs and Utilities: Central Boiler Plants, when deactivating boilers.

2.2 Heating and Boiler Plant Staffing. The Contractor shall provide boiler operators who are properly certified in conformance with all applicable Federal, State, and local laws and regulations.

2.3 Operation of Heating Plants. The Contractor shall operate the steam/hot water heating plants listed in TE #43. Operation of these plants includes start-up and shutdown of heating equipment; operator maintenance and inspection (maintenance required to operate heating plants on a daily basis; e.g., during operational visits ensure the plant is operating properly). Operation also includes keeping required logs, correction of improper operating conditions, and making minor adjustments to the plant and equipment. The Contractor shall operate and maintain records of operation for all boilers and heating plants per Title V Major Source Operating Permit.

Operating logs maintained on these plants shall be submitted to the COR/ACOR by the 10th of each month for the preceding month. The Contractor shall submit the Cumulative Steaming Hours Report for each boiler to the COR/ACOR on Monday of each week for the preceding week. The operator shall employ lead/lag procedures in the buildings when required, based on temperatures and conditions.

Unattended Heating Plants. The Contractor shall operate all unattended heating plants. Operation of these plants shall include seasonal start up and shut down of heating equipment.

2.4 Central Boiler Plants. The central boiler plants located in Buildings listed in TE#42 via steam and condensate lines. The approximate age of the boiler plants varies but all have been kept in very good condition and the condition of associated piping is satisfactory. The major components of each of the boiler plants are listed in TE #15.

The Contractor’s roving patrol shall visit the plant once each eight (8) hours during the heating season: 1 November to 1 May times may be changed by the COR due to weather conditions. Operational visits shall include observation of a complete cycle of the operation of the plant. Visits by roving operators shall be recorded on the Daily

Operating Log to include time of inspection, as directed by the COR/ACOR. The Contractor shall submit all logs to the COR/ACOR upon request.

Turning On Boilers in Fall. The Contractor shall turn on boilers and heating systems in the fall when directed by the KO/COR. See TE #43 for a list of all boilers.

All heat shall be completely turned on within two (2) weeks after notification by KO/COR of turn-on date. Heat shall be turned on in the following order:

a. Administrative, training, research and development

b. Utilities and general storage

c. All remaining facilities

Turning Off Boilers in Spring. The Contractor shall turn off boilers and heating systems in the spring, when directed by the KO/COR. Heat shall be turned off in the following order:

a. Administrative, training, research and development

b. Utilities and general storage

c. All remaining facilities

Summer Overhaul. The Contractor shall schedule summer overhauls for boiler plants that cannot be overhauled during the heating season because of operational requirements. The Contractor shall perform shutdowns over weekends and holidays when required by the COR/ACOR. The Contractor shall submit a written schedule of summer boiler shutdowns to the Contracting Officer (KO) for approval at least 30 calendar days prior to the beginning of the proposed shutdown period. The approved shutdown schedule shall have minimal disruptions.

Standby Boilers. All boilers not in use shall be maintained in a fully operational condition, except when deactivated. In the event that any boiler cannot be placed on-line within two (2) hours, a notification that includes the probable cause shall be submitted to the COR/ACOR. Proper lay-up procedures shall be used IAW Technical Manual (TM) 5-650, Repairs and Utilities: Central Boiler Plants, when deactivating boilers.

Monthly Inspections. The Contractor shall perform monthly visual inspections of the central steam and hot water distribution and condensation systems. The inspection shall include, but not be limited to, general condition and cleanliness of all exterior and working parts, and evidences of large or small leaks from steam or hot water equipment, emissions, pipes, valves, and covers. The Contractor shall submit a report outlining the results of the inspection to the COR/ACOR within three (3) working days.

However, any defects identified by the Contractor shall be submitted in writing to the COR/ACOR on the same work day.

Boiler/Heat Plant Shutdowns. The Contractor shall inform the COR/ACOR within thirty (30) minutes of shutting down any boiler or heating plant for unplanned repairs The Contractor shall provide written notice thirty (30) days in advance of planned repairs that require the shutdown of any boiler or heat plant, unless shutdown is otherwise requested by the COR/ACOR.

Boiler Water Treatment Chemicals. The Contractor shall supply the chemicals necessary to maintain all boiler water chemistry IAW TM 5-650. The Contractor shall be responsible for keeping chemical treatments in closed water loop systems (Heating and Cooling) to prevent corrosion and other operational factors depending on the system, so that operation is efficient and life cycle maximized. The Contractor shall be responsible for keeping chemical treatments in open loop systems (ex. Cooling towers) to prevent corrosion and bacterial growth so that the system operates efficiently and the life cycle is maximized.

2.4.7.1 The Contractor shall perform the tests listed and treat water daily to meet the Bureau of Mines Standards listed under Boiler Water Ranges per Table 2.4.7.1-1.

Table 2.4.7.1-1 Boiler Water Tests and Ranges

TESTS BOILER WATER RANGES

Tannin Color Light to Medium

Hydroxide (OH) (Causticity) 20 to 200 parts per million

Sulfate (SO4) 30 to 46 parts per million

Phosphate (PO4) 30 to 60 parts per million

Phosphate, minimum required for scaling control

30 parts per million

Dissolved Solids by Conductivity 1,000 to 4,000 parts per million

Boiler Water Test Samples. In addition to the required boiler and distribution system water testing and treatment, the Contractor shall submit monthly, a series of boiler plant water tests as identified in Table 2.4.7.1-1. Analysis, results, and comments will be sent to the COR. The water samples submitted each month shall include a boiler water sample, a condensate sample, and the Contractor plant test results for these samples. Test results and water samples from one (1) boiler/condensate system are required from each of the high-pressure boiler plants operated for the Government.

2.4.8.1 Additional tests may be required if the Contractor's test results and the lab's test results vary by ten (10) percent. Additional tests shall be at the Contractor’s expense.

The Contractor shall provide copies of Lab Water Analysis Reports to the COR/ACOR within five (5) days after receipt. Water sample bottles and shipping containers are available from the Government designated lab. The Contractor shall furnish required boiler plant water test kits and test material.

2.4.8.2 The Government will have the boilers inspected and tested semiannually by an inspector certified by the National Board of Boiler and Pressure Vessel Inspectors.

During these inspections, the Contractor shall provide all field support required by the inspector. The Government will provide the Contractor a copy of the Boiler Inspection Report. The Contractor shall take corrective action on all deficiencies and provide documentation of such actions to the COR. IAW DI-MISC-80508B, CDRL/Deliverable #52, the Contractor shall file a copy of the inspection report and corrective action taken.

Prepare Boilers and Coordinate Boiler Inspections. The Contractor shall schedule and prepare high-pressure boilers for the boiler inspections required by AR 420-49, Section VII. Preparation of boilers for inspection shall be IAW TM 5-650, Chapter 3, paragraph 65. The Contractor shall provide to the COR/ACOR in writing, a proposed schedule of high-pressure boiler inspections. The Contractor shall post a copy of the most recent Boiler Inspection Report in the plant where each inspected boiler is located.

Boiler Plant Calibration. Prior to semi-annual boiler inspections, the Contractor shall calibrate all pressure and temperature gauges. A self-adhesive seal shall be attached on each gauge certifying that it has been calibrated. The date of the calibration and the initials of the person performing the calibration shall be noted on the sticker.

The gauges shall be calibrated over the full operational range and accuracy tested for compliance with the manufacturer's published data. The gauges shall be calibrated against standard dead weight tester or a calibrated master gauge. In addition to the normal annual calibration, the Contractor shall at all times recalibrate any gauge that is suspected of being in error. All tests shall be IAW the applicable provisions of the American Society of Mechanical Engineers (ASME).

Emergencies. Operational emergencies which reduce the steam rate by ten (10) percent or boiler pressure by twenty (20) percent, for a period exceeding thirty (30) minutes, shall be reported by the Contractor within thirty (30) minutes of occurrence to the COR/ACOR. Such emergencies include, but are not limited to, ruptured tubes, loss of boilers, and loss of power. The Contractor shall report operational emergencies together with identification of the probable cause and the estimated time required before full pressure and steam rate can be restored.

3.0 Purchase of Fuels.

3.1 Fuel Oil. The Contractor shall estimate fuel requirements for operating the fuel-fired boiler/heating plants. The request shall be provided to the COR. The COR will obtain fuel directly from Defense Logistics Agency (DLA) for this requirement.

3.2 Natural Gas Distribution System. Natural gas is purchase from the City of Huntsville Utilities (HSVUTL) with nine (9) metering points that are located on the North side of RSA (Goss Road) from a portion of HSVUTL distribution system that is inside of RSA boundaries and that RSA distribution system does not exist. RSA distribution system is serviced by four (4) transport meters (Skinner & Goss, Patton road (2), and Buxton road) that transport gas bought on the open market thru DLA (Contract SF1449 SPE604-19-D-7507 – for April 2019 to April 2020) this contract is for one year only and is re-competed every year.

4.0 AC and Refrigeration Plants and Systems.

4.1 Scope. The AC plants and systems include central systems for multi-building cooling. TE #15 lists the AC plant inventory.

The Contractor shall provide management, supervision, personnel, labor, materials, transportation, tools, equipment, and personnel protective equipment for the operation, calibration, and repair of central cooling plants at RSA. These services shall be performed IAW the standards listed in AR 420-1.

Summary of Expectations. Cooling Services are provided throughout the installation and are critical to meet mission requirements. The Contractor shall provide cooling services at all times, to meet mission requirements.

Operate Cooling Plants and Distribution Systems services includes chilled water for central cooling plants.

The Contractor shall economically and efficiently operate central cooling plants.

The Contractor shall operate the cooling systems to maximize the benefits derived from purchased commodities (e.g., steam, gas, and electricity) while minimizing overall energy consumption.

Cooling/Heating Chemical Treatment. The Contractor shall be responsible for keeping chemical treatments in closed water loop systems (Heating and Cooling) to prevent corrosion and other operational factors depending on the system, so that operation is efficient and life cycle maximized. The Contractor shall be responsible for keeping chemical treatments in open loop systems (ex. Cooling towers) to prevent corrosion and bacterial growth so that the system operates efficiently and the life cycle is maximized.

4.2 Daily Inspection of Chillers. The Contractor shall perform daily inspections of all chiller units in Buildings 3316, 5306, 5221, and 5400.

Daily Log. The Contractor shall observe the complete cycle of the mechanical operation of the chiller plant and cooling tower, and report any problems to the COR/ACOR immediately. The Contractor shall provide and maintain a daily log that includes, but is not limited to, the data listed below and based on system configuration.

a. Chiller MCD number,

b. Purifier purge monitor and start-up number,

c. Chiller supply and return water temperature,

d. Compressor suction and discharge pressure and MCD number,

e. Refrigerant temperature in the evaporator,

f. Branch line control pressure,

g. Evaporator pressure,

h. Measure and record pressure drop through the condenser,

i. Oil pressure,

j. Condenser in and out water temperature,

k. Oil temperature in bearings,

l. Oil temperature in sump,

m. Oil pump motor amperage,

n. Outdoor temperature and relative humidity,

o. Any abnormalities occurring in the operation of the unit.