6. Document tasks performed during visit and report any observations to the appropriate

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1 Chiller Annual Maintenance RFP Attachment B Services Required Tasking: Vibration Analysis 1. All work shall be performed in accordance with safety policies 2. Check with appropriate customer representative for operational deficiencies 3. Record equipment specific information for reference 4. Install pads and labels (if applicable) 5. Install sensors in proper location 6. Start equipment and run at normal operating conditions 7. Record readings and remove sensors 8. Submit readings for report generation and deliver to customer with recommendations 9. Document tasks performed during visit and report any observations to appropriate customer representative Oil Sample and Analysis 1. All work shall be performed in accordance with safety policies 2. Check with appropriate customer representative for operational deficiencies 3. Remove sample in approved container 4. Drop off for analysis 5. Label and complete paperwork indicating present operating conditions 6. Document tasks performed during visit and report any observations to the appropriate customer representative Additional Service Requirements 1. Calibrate refrigerant monitor annually to ensure proper operation (If applicable) 2. If motors need to be adjusted for any reason laser alignment must be used to realign motor Phase I Comprehensive Annual Inspection Centrifugal Chillers Review customer logs with customer for operational problems and trends. Remove refrigerant. Lube System Megger oil pump motor and record readings. Measure and record oil pump voltage and amperage. Inspect the starter for signs of overheating, arcing, burns, etc. Verify operation of oil cooling system.* Clean oil solenoid strainer. Tighten terminal connections on the oil pump motor. Verify operation of the oil heater.

2 Change the compressor oil and filter. ** Motor and Starter (Less than 600 Volts) Clean starter cabinet. Inspect starter and starter components for signs of discoloration, burns, moisture, etc. Inspect wires for discoloration and burns. Test accuracy of motor current (amp meter). Test tightness of terminal connections. Check dash pot oil and add as necessary. Megger motor at the starter terminals; record readings. Measure operating voltage and record. Controls and Safeties Inspect and calibrate all safety and operating controls. Inspect the control panel for cleanliness, control air leaks, etc. (clean if needed) Inspect wiring and connections for signs of overheating, burns. Verify operation of the vane control system: Check for free and smooth operation. Check mechanical linkages for wear and secureness. Test vane close switch. Report accuracy of all gages and thermometers (use masters). Verify working condition of all indicator and alarm lights. Verify operation of automatic and manual capacity control. Verify operation of start, stop, and anti recycle timers. Test the operation of all pump auxiliary contacts (chw, cw, oil, etc.).* Verify operation of oil temperature and pressure controller(s). Test chilled water low temperature cutout and recycle switch calibrate and record. Test condenser high pressure cutout calibrate and record. Test refrigerant low temperature cutout calibrate and record. Test low oil pressure cutout calibrate and record. Test oil filter high pressure cutout calibrate and record. Test bearing transmission high temperature cutout calibrate and record. Test all flow switch cutouts (cw, chw).* Test motor winding high temperature safety circuit and record. Purge Unit Evacuate unit to 200 microns, Filter and transfer refrigerant back into chiller. Add compressor oil per manufactures recommendations. Drain, clean, and inspect purge drum. Clean sight glass and report condition. Clean and inspect purge float assembly. Verify operation of refrigerant pump. Lubricate purge pump. Measure and record pump voltage and amperage. Test purge safety switch* and adjust if required.

3 Change filter dryer in purge line.* Test the secureness of mounting points; tighten all major points. Test and calibrate purge operating controls. Run purge and verify operation Transmission and Bearing Inspection Inspect transmission (through access) for signs of wear, moisture, dirt, etc. Clean sump and oil heater. Replace access cover gasket. Inspect transmission s internal piping. Inspect transmission s internal wiring (hi temp, bearing safety). Inspect motor end bearings.* Diffuser Wall Verify operation of diffuser walls by manual loading and unloading of the compressor. Check calibration of the diffuser wall controller and calibrate, as required. Check calibration of the diffuser wall feedback potentiometer and calibrate, as required. Compressor and Vessels Remove condenser water box cover and brush tubes with Goodway tube brushing machine. Reinstall cover with new gaskets. Pressurize chillers to 10 PSIG and electronically leak test. Inspect for leaks and report results. Check refrigerant charge. Replace filter/dryer in motor cooling line.* Replace venturi filter. Clean demister and oil magnetic plug. Test the secureness of mounting points; tighten all major points. Inspect volute drain filter and replace if necessary. Record refrigerant level. Review machine operation with operator. Log machine at departure. Report machine condition and repair requirements (if any). Run complete interlocking circuit where possible. Re insulate and touch up paint as needed, due to servicing. * Where applicable **Remove oil from lube system after evacuating to 29 inches of mercury vacuum with refrigerant recovery unit and maintaining 140 degree oil temp to remove all refrigerant from used oil. Remove used oil from job site.

4 Phase II Spring Start up and Operational Annual Inspection Centrifugal Chillers Review customer logs with customer for operational problems and trends. System Run and record a complete test log on the equipment. Report unusual noises, vibrations, odors, etc. Verify capacity control reaction. Verify operation of vane linkage. Verify operation of flow switch. Record refrigerant level as seen in sight glass. Test complete interlocking circuit where possible. Report any drop in level of vane shaft oiler.* Run full load test if operating conditions permit. Check for leaks (high side). Check for proper refrigerant charge. Check for air in machine and purge as needed. Adjust running oil temp with water regulating valve. Check chilled water low water temperature cutout set point. Fine tune chiller for optimum efficiency. Starter (Less than 600 Volts) Open starter cabinet; check starter contacts for signs of overheating, arcing, burns, discoloration, etc. Lube System Inspect oil pump starter enclosure for cleanliness, moisture, and signs of oil. Inspect the starter for overheating, arcing, burns, etc. Additional Tasks and/or Special Instructions: Measure and record motor amperage. Verify operation of the oil heater and oil cooler. Record oil level as seen in sight glass. Purge Unit Verify operation of purge compressor. Measure and record compressor amperage. Measure and record compressor and separator oil levels. Check all sight glass levels. Measure and record volume of water drained from unit. Verify operation of purge heaters. Diffuser Wall Verify operation of diffuser wall by manually loading and unloading the compressor. Confirm and record all operating temperatures, pressures, amperage, control panel readings, etc. Upon completion, review machine operation with operator.

5 Report machine condition and repair requirements (if any). NOTE: The preceding inspection tasks will be completed when operating conditions permit. * Where applicable Phase III Mid Season Operational Inspection Centrifugal Chillers Same as Phase II plus Vibration Analysis Phase I/II/III Comprehensive Inspection Split System with Indoor Coil Review operation with customer for problems and trends. Fan(s) and Motor(s) Verify operation of system motor, gages, etc. Inspect flexible connections and ductwork for damage and leaks. Inspect tension on drive and fan belts, and change as needed. Lubricate fan shaft bearings. Lubricate motor bearings. Lubricate dampers. Clean intake screen on motor. Inspect fan wheel for free rotation, cracks and alignment. Inspect for vibrations and unusual noises. Report condition of dampers. Test secureness of guards, doors and panels. Inspect humidifier parts. Inspect roof curb flashing. Inspect all major stop valves and report condition. Inspect all structural elements for corrosion and damage. Report condition of coils clean/dirty. Inspect motor windings for cleanliness. Starter(s) Inspect wiring for secureness and damage. Megger motor at starter and record reading. Inspect switch gear, starter and contactor points. Inspect starter for signs of wear, arcing, overheating, burns, etc. Inspect electrical connections for tightness and absence of moisture. Measure and record operating voltage. Measure and record operating amperage. Compressor(s) Inspect vibration eliminators for secureness and damage. Tighten terminal connections at heater elements. Test secureness of mounting points, and tighten all major points.

6 Controls Inspect control center; clean and tighten connection; inspect components. Test low pressure cutout and record; calibrate if needed. Test high pressure safety and record; calibrate if needed. Operational Test Compressor(s) Run and record a complete test log on machine. Verify refrigerant charge. Verify oil level. Verify superheat adjustment. Inspect for vibrations and unusual noises in bearings, motor, etc. Inspect moisture indicator for evidence of moisture. Test accuracy of all pressure gages. Record compressor oil pressure. Record compressor suction pressure. Record compressor discharge pressure. * Where applicable Phase I Comprehensive Inspection Screw Chiller Review customer logs with customer for operational problems and trends. Inspect vibration eliminators for secureness and damage. Change oil and filter element (as needed)* Annual oil sample. Test secureness of mounting points, and tighten all major points. Open Compressor (Only) Lubricate motor bearings. Clean motor air intake screens. Lubricate coupling.* Inspect motor windings and report condition. Visually inspect coupling. Motor and Starter Megger motor at starter and record reading. Tighten terminal connections at heater elements. Tighten terminal connections at starter. Measure operating voltage and record readings. Inspect starter for signs of wear, arcing, overheating, burns, etc. Measure operating amperage and record readings. Clean enclosure. Controls Inspect control center clean and tighten connections. Inspect wiring and connections for signs of wear

7 Verify operation of oil temperature control. Inspect components. Test oil low temperature switch; calibrate if needed.* Test high pressure safety; calibrate if needed,* Verify operation of start, stop, and all other timers. Operational Test Verify oil level. Verify refrigerant charge. Leak test refrigerant system. Test accuracy of all pressure gauges. Inspect for vibrations and unusual noises in bearings, motors, etc. Verify superheat adjustment Inspect moisture indicator for evidence of moisture. Record compressor suction pressure. Record compressor discharge pressure. Record compressor oil pressure. Run and record a complete test log on machine. Report machine condition and repair requirements (if any). Inspect control center; clean and tighten connections. Inspect wiring and connections for signs of wear, overheating, burns, etc. Test oil high temperature cutout; calibrate if needed.* Verify capacity control reaction. Update chiller control software. *Where applicable Phase II Operational Screw Chiller Review customer logs with customer for operational problems and trends. System Run and record a complete test log on machine. Inspect for vibrations and unusual noises in bearings, motors, etc. Inspect control center; clean and tighten connections. Inspect wiring and connections for signs of wear, overheating, burns, etc. Verify capacity control reaction. Inspect components. Verify operation of start, stop, and all other timers. Verify operation of oil temperature control. Verify oil level. Verify refrigerant charge. Verify superheat adjustment Inspect moisture indicator for evidence of moisture.

8 Additional Tasks and/or Special Instructions: Starter (Less than 600 Volts) Measure operating amperage and record readings. Clean enclosure. Inspect starter for signs of wear, arcing, overheating, burns, etc. Confirm and record all operating temperatures, pressures, amperage, control panel readings, etc. Upon completion, review machine operation with operator. Report machine condition and repair requirements (if any). NOTE: The preceding inspection tasks will be completed when operating conditions permit. *Where applicable Phase III Mid Season Operation Inspection Screw Chillers Same as Phase II plus Vibration and Oil Analysis Phase I Comprehensive Annual Inspection Reciprocating Chillers and/or Standalone Compressors Review customer logs with customer for operational problems and trends. Compressor(s) Inspect vibration eliminators for secureness and damage. Tighten terminal connections at heater elements. Test secureness of mounting points, and tighten all major points. Controls Inspect control center; clean and tighten connection; inspect components. Verify operation of bypass valve. Verify capacity control reaction. Test low pressure cutout and record; calibrate if needed. Test high pressure safety and record; calibrate if needed.* Verify operation of cooling water (valve) regulator.* Test freeze control cutout and record temperature.* Verify operation of oil temperature control. Test oil high temp cutout and record; calibrate if needed.* Starter Inspect wire insulation for signs of overheating, burns, etc. Megger motor at starter and record reading. Measure operating amperage and record readings. Clean enclosure. Tighten terminal connections at starter. Measure operating voltage and record readings.

9 Inspect starter for signs of wear, arcing, overheating, burns, etc. Operational Test Run and record a complete test log on machine. Verify refrigerant charge. Verify oil level. Verify superheat adjustment. Inspect for vibrations and unusual noises in bearings, motors, etc. Inspect moisture indicator for evidence of moisture. Test accuracy of all pressure gauges. Record compressor oil pressure. Record compressor suction pressure. Record compressor discharge pressure. Report machine condition and repair requirements. Check glycol concentration for Liebert dry coolers. Check glycol concentration for Carrier Chiller serving YFS building. Leak test refrigerant system. * Where applicable Phase II and III Operational Inspection Reciprocating Chillers and Standalone Compressors Review customer logs with customer for operational problems and trends. Controls Verify operation of bypass valve. Verify capacity control reaction. Verify operation of oil temperature control.* Verify operation of cooling water (valve) regulator.* Starter Measure operating amperage and record readings. Inspect starter for signs of wear, arcing, overheating, burns, etc. Operational Test Run and record a complete test log on machine. Verify refrigerant charge. Verify oil level. Verify superheat adjustment. Inspect for vibrations and unusual noises in bearings, motors, etc. Inspect moisture indicator for evidence of moisture. Record compressor oil pressure. Record compressor suction pressure. Record compressor discharge pressure. Report condition and repair requirements (if any).

10 NOTE: The preceding inspection tasks will be completed when operating conditions permit. * Where applicable Phase I/II/III Comprehensive Annual Inspection Computer Room Units Review operation with customer for problems and trends. Fan(s) and Motor(s) Verify operation of system motor, gages, etc. Inspect flexible connections and ductwork for damage and leaks. Inspect tension on drive and fan belts, and change as needed. Lubricate fan shaft bearings. Lubricate motor bearings. Lubricate dampers. Clean intake screen on motor. Inspect fan wheel for free rotation, cracks and alignment. Inspect for vibrations and unusual noises. Report condition of dampers. Test secureness of guards, doors and panels. Inspect humidifier parts.* Inspect roof curb flashing.* Inspect all major step valves and report condition. Inspect all structural elements for corrosion and damage. Report condition of coils clean/dirty. Inspect motor windings for cleanliness. Starter Inspect wiring for secureness and damage. Megger motor at starter and record reading. Inspect switch gear, starter and contactor points. Inspect starter for signs of wear, arcing, overheating, burns, etc. Inspect electrical connections for tightness and absence of moisture. Measure and record operating voltage. Measure and record operating amperage. Condenser Fan Motor(s) Inspect for vibrations and unusual noises in bearings, motors, etc. Wipe down motor(s) to remove loose dirt and oil buildup. Inspect fans for vibrations and tightness. Inspect wiring and connections for signs of wear, overheating, burns, etc. Lubricate motor bearings. Compressor(s) Inspect vibration eliminators for secureness and damage.

11 Tighten terminal connections at heater elements.* Test secureness of mounting points, and tighten all major points. Controls Inspect all panel lights. Inspect control center; clean and tighten connections; inspect components. Check all alarm points. Test low pressure cutout and record; calibrate if needed. Test high pressure safety and record; calibrate if needed.* Test temperature sensors. Verify operation of fan speed control.* Verify economy cycle control.* Verify operation of fan cycling controller.* Verify operation of damper cycling controller.* Operational Test Compressor(s) Run and record a complete test log on machine. Verify refrigerant charge. Leak test refrigerant system. Verify oil Ievel.* Verify superheat adjustment Inspect for vibrations and unusual noises in bearings, motor, etc. Inspect moisture indicator for evidence of moisture.* Test accuracy of all pressure gages.* Record compressor oil pressure.* Record compressor suction pressure. Record compressor discharge pressure. Electric Reheat Inspect coil for damage to element. Measure and record reheat amperage. Inspect isolators for damage or cracks. Brush coil. Remove dust and debris. Torque heating terminals. Verify operation of control. Verify staging of heating elements. Steam and Hot Water Reheat Inspect coil for leaks or damage. Brush coil. Remove dust and debris. Check and clean strainers.* Verify operation of steam trap(s).* Verify operation of controls. Humidifier* Verify operation of humidity probes. Check steam orifice and clean, if necessary.*

12 Inspect humidifier pan. Inspect infrared bulbs and clean, if needed.* Report machine condition and repair requirements. *Where applicable

CENTRIFUGAL CHILLER. Lubrication System Pull oil sample for spectroscopic analysis.

CENTRIFUGAL CHILLER. Lubrication System Pull oil sample for spectroscopic analysis. CENTRIFUGAL CHILLER Annual Inspection Refrigerant Circuit Check and record refrigerant level Inspect for leak results Calculate refrigerant lass and report to the customer. Repair minor leaks as required