State Of Wisconsin Department Of Administration
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State of Wisconsin Department of Administration
1.0
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 1 of 16
SCOPE: The furnishing of a comprehensive startup, midseason operational inspection and annual preventive maintenance service program services as per manufacturer’s recommended procedures for centrifugal/reciprocating/screw type chillers owned and operated by the State of Wisconsin for the period beginning January 1, 2007 through December 31, 2009. All the chillers are located in Madison, Milwaukee, Green Bay, Eau Claire, La Crosse and Wisconsin Rapids.
2.0
VENDOR: JOHNSON CONTROLS, INC.
2400 Kilgust Rd Madison, WI 53713 Attn: Jim Carrel PHONE: 608-226-5100 FAX: 608-222-9490 FEIN: 39-0380010 E-mail: [email protected] 3.0
CONTRACT TERM: The contract shall cover the State of Wisconsin Department of Administration actual requirements for the three (3) year period and subject to renewal for two (2) one-year extensions if agreeable to both the bidder and State. Contract effective date shall be January 1, 2007.
4.0
INSURANCE RESPONSIBILITY: Insurance will be required from the contractor (see Standard Terms and Conditions of Bid, paragraph #23.0.)
5.0
F.O.B. DESTINATION: Per attached STANDARD TERMS AND CONDITIONS, products & services are to be delivered FOB to our dock(s) at Madison, Milwaukee, Green Bay, Eau Claire, La Crosse and Wisconsin Rapids addresses indicated on the agency purchase order.
6.0
CONTRACT AREAS: The contract is divided into six geographical areas. These areas are as follows: Area 1 Make & Model No. Carrier 19DM78C5CP
Serial No. 85-16-37060
Location Hill Farms State Office Bldg.
Address (in Madison, WI) 4802 Sheboygan Ave.
Carrier 19DM78C5CP
85-16-37061
Hill Farms State Office Bldg.
4802 Sheboygan Ave.
Carrier 19DM5346AE
85-20-37078
DEL - State Revenue Bldg.
4638 University Ave.
Carrier 19DM6582CL
85-17-37079
DEL - State Revenue Bldg.
4638 University Ave.
York YT
SHMM014780
DEL - State Crime Laboratory
4702 University Avenue
York YT
SHMM015650
DEL - State Crime Laboratory
4702 University Avenue
Trane CVHE-450
L99KO3951
New Revenue Bldg
2135 Rimrock road
Trane CVHE-450
L99KO3950
New Revenue Bldg
2135 Rimrock road
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 2 of 16
Area 2 Make & Model No.
Serial No.
Location
Carrier 19XL5151274CL
1194J48340
Wis. State Agriculture Bldg.
2811 Agriculture Drive
Trane CVHE-320
L98A00266
Wis. State Lab of Hygiene
2601 Agriculture Drive
Trane CVHE-320
L98A00267
Wis. State Lab of Hygiene
2601 Agriculture Drive
Carrier 30HS-160-E-620
2596F14746SZ
Employee Trust Funds - ETF
801 West Badger Road
Central Service
202 South Dickinson St
Carrier 30HX
Address (in Madison, WI)
Carrier 19X
5005Q72118
Wisconsin Data Center
5830 Fermite Drive
Carrier 19X
5005Q72119
Wisconsin Data Center
5830 Fermite Drive
Carrier 19X
5005Q72120
Wisconsin Data Center
5830 Fermite Drive
Carrier50ZNW070DZ3600NT
0306U01449
Wisconsin Data Center
5830 Fermite Drive
Area 3 Make & Model No.
Serial No.
Location
Address (in Milwaukee, WI)
McQuay PEHO87-ABBB
58C81025-00
Milwaukee State Office Bldg
819 N. 6 Street
Trane RTHC1BFOHOC
U01Mo7507
Waukesha
141 N.W. Barstow Street
McQuay WHR090D-A
5YA017710
Crime Lab Milwaukee
1578 South 11 Street
Carrier 05HY040DH400
2333-208
Crime Lab Milwaukee
1578 South 11 Street
Carrier 05HY040DH400
2333-209
Crime Lab Milwaukee
1578 South 11 Street
Make & Model No.
Serial No.
Location
Trane 101728
VES103585
Green Bay State Office Bldg
200 N. Jefferson Street
Trane 101728
A2K20D132
Green Bay State Office Bldg
200 N. Jefferson Street
Make & Model No.
Serial No.
Location
Trane CenteravacY-ED3-EQ2
4564
Eau Claire State Office Bldg
718 West Claremont Ave
Trane RTHB-130ALF
U98E00267
La Crosse State Office Bldg
3550 Mormon Coulee Rd
Make & Model No.
Serial No.
Location
Trane RTHB-150
U999L02450
Wisconsin Rapids St Office Bldg 1681 ,2 Ave South
th
th th th
Area 4 Address (Green Bay, WI)
Area 5 Address (EC/LC, WI)
Area 6
7.0
Address (W. Rapids, WI) nd
FIRM PRICES: Pricing must remain firm for the initial contract term. Any proposed price increases after the initial contract term must be submitted to DOA/DSF in writing. All increases in pricing for future contract periods must be fully documented by contractor, shall be based upon industry-wide effects, and must be approved/rejected by DOA/DSF 90 days prior to the renewal of the next contract term.
State of Wisconsin Department of Administration
8.0
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 3 of 16
The total price guarantee: The vendor shall guarantee the total cost stated for each location in each area for the services performed. PRICE: Cost shown below is for each machine’s annual cost. The vendor shall submit monthly invoices only for the work performed to the individual machines. Total Annual cost for shall be each specific individual location with in the bid area. A
B
C
Chiller Start-up
Midseason Inspection
Winter shut -down
Carrier 19DM78C5CP
$402.00
$414.00
$1,255.00
Carrier 19DM78C5CP
$402.00
$414.00
$1,255.00
Carrier 19DM5346AE
$402.00
$414.00
$1,255.00
Carrier 19DM6582CL
$402.00
$414.00
$1,255.00
York VT
$402.00
$414.00
$1,255.00
York VT
$402.00
$414.00
$1,255.00
Trane CVHE-450
$402.00
$414.00
$1,255.00
Trane CVHE-450
$402.00
$414.00
$1,255.00
Sub Total
$3216.00
$3,312.00
$10,040.00
AREA 1 Make & Model No.
Total area 1 (A+B+C)
$16,568.00
AREA 2 Make & Model No. Carrier 19XL5151274CL
$464.00
$476.00
$1,273.00
Trane CVHE-320
$464.00
$476.00
$1,021.00
Trane CVHE-320
$464.00
$476.00
$1,021.00
Carrier 30HS-160-E-620
$282.00
$294.00
$483.00
Carrier 30HX Carrier 19X
$282.00
$294.00
$483.00
$464.00
$476.00
$1,273.00
$464.00
$476.00
$1,273.00
$464.00
$476.00
$1,273.00
$564.00
$567.00
$1,409.00
$3,912.00
$4,011.00
$9,509.00
$476.00
$1,317.00
$415.00
$1,249.00
$264.00
$291.00
$264.00
$291.00
$264.00
$291.00
Carrier 19X Carrier 19X Carrier50ZNW070DZ3600NT Sub Total Total area 2 (A+B+C)
$17,432.00
AREA 3 Make & Model No. McQuay PEHO87-ABBB
$464.00
Trane RTHC1BFOHOC
$404.00
McQuay WHR090D-A
$253.00
Carrier 05HY040DH400
$253.00
Carrier 05HY040DH400
$253.00
Sub Total
$1,627.00 Total area 3 (A+B+C)
$6,749.00
$1,683.00
$3,439.00
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 4 of 16
AREA 4
Make & Model No. Trane 101728
$243.00
$294.00
$311.00
Trane 101728
$223.00
$254.00
$156.00
Sub Total
$466.00
$548.00
$467.00
Total area 4 (A+B+C)
$1,481.00
A
B
C
Chiller Start-up
Midseason Inspection
Winter shut -down
$464.00
$476.00
$1,021.00
Make & Model No. Trane CenteravacY-ED3-EQ2 Trane RTHB-130ALF
$404.00
$415.00
$1,249.00
Sub Total
$868.00
$891.00
$2,270.00
$316.00
$477.00
$1,211.00
$316.00 $2,004.00
$477.00
$1,211.00
Total area 5 (A+B+C)
$4,029.00
AREA 6 Make & Model No. Trane RTHB-150 Sub Total Total area 6 (A+B+C)
Emergency Service must be provided with in two hours Emergency service Cost
$96.00 per hour
(May not exceed 2.5 times Hourly rate) Additional services Hourly rate for service work, normal working hours: Normal working hours: __7:00_AM to __3:30___PM.
$96.00 per hour
Hourly rate for service work, overtime:
$ 144.00 per hour
Hourly rate for service work, weekends & holidays
$ 192.00 per hour
Material cost mark-up above invoice cost:
10%
(Note: Include all costs in this hourly rate DOA will not pay additional charges for travel time, meals, truck charges, tool use charges, environmental fees etc.) Cost of parts and replacement materials used at the unit will be covered by DOA)
9. PURCHASE ORDERS/INVOICES: The using agency shall issue a purchase order to the successful contractor. Contractor is advised not to make any service until such purchase order has been received. Contractor shall submit a copy of the original invoice to DOA/DSF. 10. RETENTION OF RECORDS:
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 5 of 16
The contractor agrees to retain all records and other documents relevant to this contract for (5) five years after final payment or until after the resolution of any audit questions which could be more than five years, whichever is longer. State of Wisconsin auditors and any other persons duly authorized by Department of Administration shall have full access to the said materials.
11. STRIKES, ACCIDENTS, ETC: The contractor shall not be held liable for failure to provide the service due to any strike, accident, fire, governmental action or other causes over which he has no control, provided up to the time such strike or casualty occurred. Contractor shall notify Operations & Management of their inability to provide services and the reason thereof. Otherwise, contractor shall be held in default and responsible under the contract. In the event of the failure or inability of the contractor to deliver this service in accordance with the contract for any cause whatsoever, the state may at its election declare the contract canceled, and award the remainder of the unfilled contract requirements to another contractor. 12. SUBCONTRACTING: The contractor shall not assign this contract or subcontract to another party for performance of the terms and conditions hereof without the written consent of Department of Administration. The Subcontractors’ rate for the job shall not exceed that of the Prime contractor’s rate as in the original bid. Subcontractor’s invoice shall be invoiced directly to the Prime contractor, who in turn shall pass through the costs to the State of Wisconsin without markup. A copy of the subcontractor’s invoice must accompany the Prime contractor’s invoice. 13. SUSPENSION AND TERMINATION: 13.1
If contractor fails to meet the performance standards for any location in one bid area, the State of Wisconsin may terminate this Agreement at any time for convenience, with or without cause, by delivering 30 days written notice to the Contractor.
14. WARRANTY: Per attached STANDARD TERMS AND CONDITIONS, contractor must provide a performance guarantee for the maintenance services being proposed. The contractor must provide recovery cost for all damages resulting from contractors’ services to the equipment.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 6 of 16 GENERAL SPECIFICATIONS
15. MAINTENANCE SERVICES: Chiller maintenance service is only represented in three seasonal periods, however it will require several visits to complete the work outlined in each period. The three seasonal periods are SPRING STATRTUP, MID-SEASON INSPECTION and WINTER SHUTDOWN. Water treatment at chiller sites shall be performed by a qualified water treatment firm and shall be the responsibility of the State. All services must be scheduled in advance with the respective area managers. It is the responsibility of the Contractor to schedule this work prior to the start date of each service period. Unless agreed upon otherwise work should begin in the first week of each period and continue until it is completed. Service work will be performed during normal week day hours excluding Holidays. No one except authorized employees of the Contractor is allowed in the on the premises of State of Wisconsin buildings. The Contractor will repair or replace any worn parts found during the annual service, or when making non routine service calls to maintain the chillers in good working conditions. Replacement parts shall be billed at the Contractor’s cost as bid in the bid form. Labor to perform Regular or After Hours repair service is not included in the preventive maintenance program. Therefore, regular/after hours repairs will be made on a time material basis as submitted in the bid form. Preventative maintenance (PM) sheets are provided with this specification for each period of service required. They are to be filled out by the service technician as work is completed. Contractor must return the completed PM sheets to the Maintenance Supervisor before the end of the allotted time given for each service period in order to receive payment for that period. In the event the work performance of the Contractor is unsatisfactory, the contractor will be notified by the respective building representative and be given 4 hors to correct the work at no cost to the State. Any additional parts replaced shall be billed at contract pricing. Contractor service technicians are required to have a copy of this specification along with the corresponding PM sheets with them any time they are performing contractual work at each location. It is the responsibility of the vendor to remove any used refrigerant from the site. All materials supplied by the vendor shall be billed at invoice cost, plus mark-up and shipping cost. I.
CHILLER START-UP- SERVICE CALLS: (To be performed in March, April, May, and June) Chillers must be fully operational by the first week of April or within one (1) week of DOA notification to contractor that chillers must be put in service. 1.
Electronically leak-test chiller units (three), pump out units (two), refrigerant receivers (two), associated refrigerant piping and equipment, and relief vent pipe outlet. Test to be performed using an electronic leak detector capable of detecting a leak rate of one ounce per year.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 7 of 16
Once leaks have been located using the electronic leak detector they will then be confirmed using a liquid leak detector solution. Size and location of leaks is to be recorded on a service report, along with any recommendations to repair significant leaks. 2.
Trim chiller refrigerant charge for optimum chiller performance. Additional refrigerant will be provided by DOA. Contractor is responsible for charging any additional refrigerant purchased into refrigeration systems.
3.
Start up chillers. Electrical demand period, chiller availability and cooling load will determine when each chiller will be allowed to operate. Record all (3) phases of compressor motor current and voltage and compare with the nameplate data.
4.
Check all safety and operating controls and make sure unit is running properly. Record all pertinent parameters of unit including the following: Refrigerant pressure (cooler and condenser) Refrigerant temperature (cooler and condenser) Water temperature, inlet and outlet (cooler and condenser) a) Pressure drops, waterside (cooler and condenser) b) G.P.M. (cooler and condenser) c) Bearing oil temperature d) Oil sump temperature e) Oil pressure, psig f) Motor volts and amperage (all phases) g) Purge counts and compressor operating hours h) Purge condensing temperature i) Starter transition time (actual) Vibration data collection on motor and compressor
5.
Test and record compressor pre-lube and post-lube cycles. Notify the DOA staff of test results, re-calibrate if instructed to and log their operation on PM sheets.
6.
Check chilled water pump, condenser water pump and cooling tower operation, including tri-axial vibration measurements.
7.
Check overall performance of machines and review operating procedures with building maintenance personnel.
IA.
RECOMMENDATIONS AND REPORTS: 1. Collect an oil sample for analysis from each machine during last operating inspection and forward it to pre-approved testing laboratory at the request of DOA staff. 2. Collect a refrigerant sample for analysis from each machine during last operating inspection and forward it to pre-approved testing laboratory at the request of DOA staff. 3. Collect vibration data during operating inspection, perform spectral and time waveform analysis and make recommendations to DOA staff.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 8 of 16
4. Provide a written annual report of the condition of each chiller and recommendations for any additional maintenance that may be required and submit it to the maintenance supervisor. Report should include a summary of annual maintenance activities, oil and refrigeration analysis results, and vibration analysis results. II.
MID-SEASON INSPECTION: (Work to be started second week in July and completed by the second week of August) 1.
Electronically leak-test chiller units (three), pump out units (two), refrigerant receivers (two), associated refrigerant piping and equipment, and relief vent pipe outlet. Test to be performed using an electronic leak detector capable of detecting a leak rate of one ounce per year. Once leaks have been located using the electronic leak detector they will then be confirmed using a liquid leak detector solution. Size and location of leaks is to be recorded on a service report, along with any recommendations to repair significant leaks.
2.
Check with maintenance supervisor to verify that chiller safety devices have been operating properly - Evaporator Low Suction Pressure Cut Out, Low Chilled Water Temperature Cut Out, Low Chilled Water Temperature Alarm, High Condenser Pressure Cut Out, Compressor Auxiliary Oil Pump Pressure Switch, Compressor Low Oil Pressure Cut Out, Low Chilled Water Flow, test any that are questionable, calibrate if instructed to, and log their operation. Check operation of Operating Controls, Chiller Related Pressure and Temperature Gauges. Check chiller operation while on line. Determine if operating temperatures and pressures are running within manufacturer's recommended ranges. Notify maintenance supervisor of any problems or recommended changes.
3.
Take an oil sample from each chiller compressor, Take refrigerant samples from each chiller evaporator while in operation. Provide a spectrochemical analysis for each sample taken including a detailed report of analysis results and recommendations. Test results including recommendations must be received by DOA within 4 weeks of sample collection.
Reports should include the tests results for each item listed below. Next to each test result list the acceptable limits for each type of oil or refrigerant sample. For all tests that do not meet acceptable limits provide a probable cause or causes of abnormality along with a course of action to be taken to rectify problem.
1. Aluminum PPM Tests 1 through 6 are to be 2. Copper PPM performed for both oil and refrigerant 3. Iron PPM samples. Test 7 for oil only. 4. Tin PPM Tests 8 and 9 refrigerant only. 5. Zinc PPM 6. Moisture PPM 7. Acid Number Oil 8. Acid Number Oil Residue 9. Acid Number Refrigerant All analytical tests are to be performed by Thompson Laboratories Phone 608-784-0688 Address 510 Copeland Avenue, Lacrosse, WI, 54603
State of Wisconsin Department of Administration
4.
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 9 of 16
Check and record hot component shaft alignment for compressor and driver on York units; and for compressor, speed increaser, and driver on Carrier unit. Check and record axial forward and reverse thrust and bearing clearance on all three compressors and Lufkin speed increaser. Compare current readings with factory specifications and readings from previous years. Follow the specific instructions given on the chiller alignment log sheets explaining where to mount dial indicators. (Note: No variances from these procedures will be allowed) Completely fill out information requested on each alignment log sheet. A copy of our plant chiller Hot and Cold Alignment Log sheets has been included with this specification. Chiller availability will determine when alignment checks can be performed. Readings must be taken prior to chiller shut down. Maintenance supervisor may elect to have a cold alignment check performed during the winter maintenance in place of this hot alignment check. Re-lubricate chiller gear couplings using Kop-Flex KHP coupling grease according to coupling manufacturer instructions.
5. Review chiller operation and completed PM sheets with the maintenance supervisor. Make recommendations for additional work to be performed during winter maintenance. Include these recommendations on the PM sheets. Turn over completed PM sheets to the maintenance supervisor on the same day.
III.
WINTER MAINTENANCE: (Work to be started in the first week of December and completed by end of December) MAINTENANCE PROCEDURES CARRIER 19DM / OR HX MACHINES (a) Lock out and tag all chiller electrical power sources. (b) Pressurize the machine to a minimum 12 psig and electronically leak test all fabricated compressor vessel and piping joints. Advise owner of findings. Follow all applicable State and Federal guidelines. (c) Test purge operation and replace inline filter. (d) Drain oil and store in containers provided by owner. Disposal of oil is owner’s responsibility. Oil should be changed in the first year of the contract and then every 3rd run year after or as oil analysis dictates. (e) Install new filter elements and associated o-rings on all machines per manufacturer’s recommendations. All four machines are equipped with Carrier CSP single canister filter units. (f) Inspect condenser tubes. If necessary, tubes will be cleaned by owner. (g) Replace the volute filter, refrigerant filter and purge pump refrigerant strainer/filter. (h) Run control panel test.
(i)
Refill the lube system. Service contractor to supply manufacturer’s recommended oil.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 10 of 16
(i) Check and record the set points, recalibrate as required the following safety and operating controls and record values: 1. 2. 3. 4.
Condenser high-pressure cutout Oil low-pressure cutout Oil heater thermostat Refrigerant low-temperature cutout
(j) Retest the above performed work for leaks and repair as needed. Minimum pressure for this test to be 8 psig (k) If refrigerant is to be removed, transfer it to approved storage containers. Use a transfer device capable of drawing the vessel down to 25MM. Evacuate the machine and perform a standing vacuum test per manufacturer’s specifications. This test is to be witnessed by Owner’s representative. Mercury manometers are not acceptable for this test. Distill the refrigerant before recharging the machine if refrigerant charge is more than 10% oil saturated.
(l)
Using a megger, test the compressor and oil pump motor. Record values. 1. Phase to phase 2. Phase to ground
(m) Inspect starter contacts for pitting and corrosion. Correct spring tension and proper operation of mechanical linkage. Clean starter cabinet and tighten all electrical connections. CARRIER 19XL MACHINE 1. Inspect the Control Center. Perform general cleaning and tightening of connections. Vacuum the cabinet to eliminate dust build-up. 2. Check safety and operating controls. Run control test. (Refer to table 3 for limits and settings.) 3. Change compressor oil filter, use manufacturers recommended procedures. 4. Change compressor oil and have and oil analysis performed. Oil is to be changed the first year and every three years thereafter as a minimum along with an oil analysis. Use manufacturers’ recommended procedures. Use only a pre-approved testing laboratory and provide results to owner. 5. Change the refrigeration filter/dryer. Use manufacturers’ recommended procedures. 6. Change the oil reclaim filters. Use manufacturers’ recommended procedures. 7. Inspect and clean refrigerant float system. Use manufacturers’ recommended procedures. Report any problems to Owner. Remove the float access cover and clean the chamber and valve assembly. This is to be performed in the first and third run years. 8. Inspect the relief valves and piping. Use manufacturers’ recommended procedures. Report any problems to Owner. 9. Inspect and clean the starting equipment. Use manufacturers’ procedures. Report any problems to Owner. 10. Check oil pressure, condenser pressure, and cooler pressure transducers against a pressure gauge. Calibrate as required using manufacturers’ recommended procedures.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 11 of 16
11. Check guide vane linkage. Use manufacturers’ recommended procedures. 12. Inspect condenser tubes. If necessary, tubes are to be cleaned by owner. 13. Electronically leak test all fabricated compressor and piping joints. Advise owner of results. 14. Clean starter cabinet and tighten all electrical connections. 15. Reset service-on-time value on the status 01 screen when service work is completed. 16. Check and calibrate the refrigerant leak detection system as needed. 17. Replace batteries in PIC control panel in the first year. TRANE CVHE-320 MACHINES 1. Megger oil pump motor and record readings. 2. Measure and record oil pump voltage and amperage. 3. Inspect the starter for signs of overheating, arcing, burns, etc. 4. Verify operation of oil cooling system.* 5. Tighten terminal connections on the oil pump motor. 6. Verify operation of the oil heater. 7. Change the compressor oil and filter. 8. Clean starter cabinet. 9. Inspect starter and starter components for signs of discoloration, burns, moisture, etc. 10. Inspect wires for discoloration and burns. 11. Test accuracy of motor current (amp meter). 12. Test tightness of terminal connections. 13. Check dash pot oil and add as necessary. 14. Megger motor at the starter terminals; record readings. 15. Measure operating voltage and record. 16. Inspect the control panel for cleanliness, control air leaks, etc. 17. Inspect wiring and connections for signs of overheating, burns. 18. Verify operation of the vane control system. Check for free and smooth operation. Check mechanical linkages for wear & secureness. 19. Report accuracy of all gauges and thermometers (use masters). 20. Verify working condition of all indicator and alarm lights.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 12 of 16
21. Verify operation of start, stop, and anti-recycle timers. 22. Verify operation of automatic and manual capacity control. 23. Test all flow switch cutouts (cw, chw).* 24. Verify operation of oil temperature and pressure controller(s). 25. Test high condenser pressure safety - calibrate and record. 26. Test low evaporator temperature safety - calibrate and record. 27. Test oil low pressure safety - calibrate and record. 28. Test oil low temperature switch. 29. Test high motor temperature safety - calibrate and record. 30. Verify operation of automatic and manual capacity control. 31. Test the operation of all pump auxiliary contacts (chw, cw, oil, etc.).* 32. Record elapsed run times and start counts. * 33. Drain, clean and inspect purge drum. 34. Clean sight glass and report condition. 35. Clean and inspect purge float assembly. 36. Inspect pulley grooves and belts for alignments, wear, and tension. 37. Lubricate purge motor. 38. Test purge safety switch and adjust if requires.* 39. Verify operation of the purge heater. 40. Change filter dryer in purge line.* 41. Verify operation of the purge timer.* 42. Test the secureness of mounting points; tighten all major points. 43. Megger the purge compressor motor and record condition. 44. Test and calibrate purge operating controls. 45. Clean oil separator.* 46. Set separator float.* 47. Change oil in purge compressor.* 48. Run purge compressor and verify operation. 49. Inspect the belt condition. 50. Lubricate condenser fan motor bearings.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 13 of 16
51. Brush condenser fin surfaces clean, if required.* 52. Verify air flow through the condenser. 53. Test low ambient limit control - calibrate and record. 54. Test bearing temperature control - calibrate and record. 55. Lubricate condenser fan bearings. 56. Inspect condenser fan bearings, shafts, and drive assemblies for wear and alignment. 57. Remove debris from louvers, dampers, and coil faces. 58. Verify operation of condenser fan controls. 59. Verify operation of low oil temperature start inhibitor. 60. Verify distillation valve setting. 61. Inspect area around coupling/gear for oil leaks.* 62. Lubricate coupling.* 63. Test for refrigerant leaks and report results. 64. Check refrigerant charge. 65. Replace filter/dryer in motor cooling line.* 66. Test the secureness of mounting points; tighten all major points. 67. Record refrigerant level. 68. Review machine operation with operator. 69. Log machine at departure. 70. Run complete interlocking circuit where possible. 71. Report machine condition and repair requirements (if any). *where applicable YORK YT MACHINES 1. Megger oil pump motor and record readings. 2. Measure and record oil pump voltage and amperage. 3. Inspect the starter for signs of overheating, arcing, burns, etc. 4. Verify operation of oil cooling system.* 5. Tighten terminal connections on the oil pump motor. 6. Verify operation of the oil heater. 7. Change the compressor oil and filter.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 14 of 16
8. Check operation of the oil return system. 9. Change filter dryer in the oil return line. 10. Clean dirt leg. 11. Clean starter cabinet. 12. Inspect starter and starter components for signs of discoloration, burns, moisture, etc. 13. Inspect wires for discoloration and burns. 14. Test accuracy of motor current (amp meter). 15. Test tightness of terminal connections. 16. Check dash pot oil and add as necessary. 17. Megger motor at the starter terminals; record readings. 18. Measure operating voltage and record. 19. Inspect the control panel for cleanliness, control air leaks, etc. 20. Inspect wiring and connections for signs of overheating, burns. 21. Verify operation of the vane control system. Check for free and smooth operation. Check mechanical linkages for wear & secureness. 22. Report accuracy of all gages and thermometers (use masters). 23. Verify working condition of all indicator and alarm lights. 24. Verify operation of start, stop, and anti-recycle timers. 25. Test all flow switch cutouts (cw, chw).* 26. Verify operation of automatic and manual capacity control. 27. Verify operation of oil temperature and pressure controller(s). 28. Test high condenser pressure cutout - calibrate and record. 29. Test cooler low pressure cutout - calibrate and record. 30. Test oil pressure cutout - calibrate and record. 31. Test high oil temperature cutout - calibrate and record. 32. Test compressor high discharge temperature cutout - calibrate and record. 33. Test low water temperature leaving cooler cutout - calibrate and record. 34. Test the operation of all pump auxiliary contacts (chw, cw, oil, etc.).* 35. Record elapsed run times and start counts. *
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 15 of 16
36. Drain, clean, and inspect purge drum. 37. Clean sight glass and report condition. 38. Clean and inspect purge float assembly. 39. Inspect pulley grooves and belts for alignment, wear, and tension. 40. Lubricate purge motor 41. Test purge safety switch* and adjust if required. 42. Verify operation of the purge heater. 43. Change filter dryer in purge line.* 44. Verify operation of the purge timer.* 45. Test the secureness of mounting points; tighten all major points. 46. Measure and record the purge compressor motor voltage and amperage. 47. Test and calibrate purge operating controls. 48. Clean oil separator.* 49. Set separator float.* 50. Change oil in purge compressor. 51. Run purge compressor and verify operation. 52. Inspect area around coupling/gear for oil leaks.* 53. Lubricate coupling.* 54. Visually inspect coupling for abnormal conditions.* 55. Align shafts. 56. Test for refrigerant leaks and report results. 57. Check refrigerant charge. 58. Replace filter/dryer in motor cooling line.* 59. Test the secureness of mounting points; tighten all major points. 60. Record refrigerant level. 61. Review machine operation with operator. 62. Log machine at departure. 63. Run complete interlocking circuit where possible.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 16 of 16
64. Report machine condition and repair requirements (if any). *where applicable Provide a detailed inspection report and advice of any maintenance that may need to be completed before the next chilling season.
RECIPROCATING CHILLERS 1. Lock out and tag-out all chiller electrical power sources. 2. Pressurize the machine to a minimum pressure of 100 psig unless otherwise directed by the manufacturer and electronically leak test all fabricated compressor vessel and piping joints. Advise owner of findings. 3. Remove two oil samples from crankcase for field testing and lab analysis. Replace any external oil filter element and lubricant if it is acidic based on the analysis. Recharge the compressor lube system new oil with the proper grade. 4. Check the following safety and operating controls set points, record settings and recalibrate as required. a. Condenser high-pressure cutout. b. oil low pressure cutout. c. oil thermostat. d. Refrigerant low temperature cutout. e. Check and verify proper operation of water flow switches. 5. Re-leak test the work performed above and repair any leaks noted. Minimum pressure 100 psig unless otherwise directed by the manufacturer. 6. Meggar test the compressor and record values. (Phase to ground)
1.0
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 1 of 16
SCOPE: The furnishing of a comprehensive startup, midseason operational inspection and annual preventive maintenance service program services as per manufacturer’s recommended procedures for centrifugal/reciprocating/screw type chillers owned and operated by the State of Wisconsin for the period beginning January 1, 2007 through December 31, 2009. All the chillers are located in Madison, Milwaukee, Green Bay, Eau Claire, La Crosse and Wisconsin Rapids.
2.0
VENDOR: JOHNSON CONTROLS, INC.
2400 Kilgust Rd Madison, WI 53713 Attn: Jim Carrel PHONE: 608-226-5100 FAX: 608-222-9490 FEIN: 39-0380010 E-mail: [email protected] 3.0
CONTRACT TERM: The contract shall cover the State of Wisconsin Department of Administration actual requirements for the three (3) year period and subject to renewal for two (2) one-year extensions if agreeable to both the bidder and State. Contract effective date shall be January 1, 2007.
4.0
INSURANCE RESPONSIBILITY: Insurance will be required from the contractor (see Standard Terms and Conditions of Bid, paragraph #23.0.)
5.0
F.O.B. DESTINATION: Per attached STANDARD TERMS AND CONDITIONS, products & services are to be delivered FOB to our dock(s) at Madison, Milwaukee, Green Bay, Eau Claire, La Crosse and Wisconsin Rapids addresses indicated on the agency purchase order.
6.0
CONTRACT AREAS: The contract is divided into six geographical areas. These areas are as follows: Area 1 Make & Model No. Carrier 19DM78C5CP
Serial No. 85-16-37060
Location Hill Farms State Office Bldg.
Address (in Madison, WI) 4802 Sheboygan Ave.
Carrier 19DM78C5CP
85-16-37061
Hill Farms State Office Bldg.
4802 Sheboygan Ave.
Carrier 19DM5346AE
85-20-37078
DEL - State Revenue Bldg.
4638 University Ave.
Carrier 19DM6582CL
85-17-37079
DEL - State Revenue Bldg.
4638 University Ave.
York YT
SHMM014780
DEL - State Crime Laboratory
4702 University Avenue
York YT
SHMM015650
DEL - State Crime Laboratory
4702 University Avenue
Trane CVHE-450
L99KO3951
New Revenue Bldg
2135 Rimrock road
Trane CVHE-450
L99KO3950
New Revenue Bldg
2135 Rimrock road
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 2 of 16
Area 2 Make & Model No.
Serial No.
Location
Carrier 19XL5151274CL
1194J48340
Wis. State Agriculture Bldg.
2811 Agriculture Drive
Trane CVHE-320
L98A00266
Wis. State Lab of Hygiene
2601 Agriculture Drive
Trane CVHE-320
L98A00267
Wis. State Lab of Hygiene
2601 Agriculture Drive
Carrier 30HS-160-E-620
2596F14746SZ
Employee Trust Funds - ETF
801 West Badger Road
Central Service
202 South Dickinson St
Carrier 30HX
Address (in Madison, WI)
Carrier 19X
5005Q72118
Wisconsin Data Center
5830 Fermite Drive
Carrier 19X
5005Q72119
Wisconsin Data Center
5830 Fermite Drive
Carrier 19X
5005Q72120
Wisconsin Data Center
5830 Fermite Drive
Carrier50ZNW070DZ3600NT
0306U01449
Wisconsin Data Center
5830 Fermite Drive
Area 3 Make & Model No.
Serial No.
Location
Address (in Milwaukee, WI)
McQuay PEHO87-ABBB
58C81025-00
Milwaukee State Office Bldg
819 N. 6 Street
Trane RTHC1BFOHOC
U01Mo7507
Waukesha
141 N.W. Barstow Street
McQuay WHR090D-A
5YA017710
Crime Lab Milwaukee
1578 South 11 Street
Carrier 05HY040DH400
2333-208
Crime Lab Milwaukee
1578 South 11 Street
Carrier 05HY040DH400
2333-209
Crime Lab Milwaukee
1578 South 11 Street
Make & Model No.
Serial No.
Location
Trane 101728
VES103585
Green Bay State Office Bldg
200 N. Jefferson Street
Trane 101728
A2K20D132
Green Bay State Office Bldg
200 N. Jefferson Street
Make & Model No.
Serial No.
Location
Trane CenteravacY-ED3-EQ2
4564
Eau Claire State Office Bldg
718 West Claremont Ave
Trane RTHB-130ALF
U98E00267
La Crosse State Office Bldg
3550 Mormon Coulee Rd
Make & Model No.
Serial No.
Location
Trane RTHB-150
U999L02450
Wisconsin Rapids St Office Bldg 1681 ,2 Ave South
th
th th th
Area 4 Address (Green Bay, WI)
Area 5 Address (EC/LC, WI)
Area 6
7.0
Address (W. Rapids, WI) nd
FIRM PRICES: Pricing must remain firm for the initial contract term. Any proposed price increases after the initial contract term must be submitted to DOA/DSF in writing. All increases in pricing for future contract periods must be fully documented by contractor, shall be based upon industry-wide effects, and must be approved/rejected by DOA/DSF 90 days prior to the renewal of the next contract term.
State of Wisconsin Department of Administration
8.0
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 3 of 16
The total price guarantee: The vendor shall guarantee the total cost stated for each location in each area for the services performed. PRICE: Cost shown below is for each machine’s annual cost. The vendor shall submit monthly invoices only for the work performed to the individual machines. Total Annual cost for shall be each specific individual location with in the bid area. A
B
C
Chiller Start-up
Midseason Inspection
Winter shut -down
Carrier 19DM78C5CP
$402.00
$414.00
$1,255.00
Carrier 19DM78C5CP
$402.00
$414.00
$1,255.00
Carrier 19DM5346AE
$402.00
$414.00
$1,255.00
Carrier 19DM6582CL
$402.00
$414.00
$1,255.00
York VT
$402.00
$414.00
$1,255.00
York VT
$402.00
$414.00
$1,255.00
Trane CVHE-450
$402.00
$414.00
$1,255.00
Trane CVHE-450
$402.00
$414.00
$1,255.00
Sub Total
$3216.00
$3,312.00
$10,040.00
AREA 1 Make & Model No.
Total area 1 (A+B+C)
$16,568.00
AREA 2 Make & Model No. Carrier 19XL5151274CL
$464.00
$476.00
$1,273.00
Trane CVHE-320
$464.00
$476.00
$1,021.00
Trane CVHE-320
$464.00
$476.00
$1,021.00
Carrier 30HS-160-E-620
$282.00
$294.00
$483.00
Carrier 30HX Carrier 19X
$282.00
$294.00
$483.00
$464.00
$476.00
$1,273.00
$464.00
$476.00
$1,273.00
$464.00
$476.00
$1,273.00
$564.00
$567.00
$1,409.00
$3,912.00
$4,011.00
$9,509.00
$476.00
$1,317.00
$415.00
$1,249.00
$264.00
$291.00
$264.00
$291.00
$264.00
$291.00
Carrier 19X Carrier 19X Carrier50ZNW070DZ3600NT Sub Total Total area 2 (A+B+C)
$17,432.00
AREA 3 Make & Model No. McQuay PEHO87-ABBB
$464.00
Trane RTHC1BFOHOC
$404.00
McQuay WHR090D-A
$253.00
Carrier 05HY040DH400
$253.00
Carrier 05HY040DH400
$253.00
Sub Total
$1,627.00 Total area 3 (A+B+C)
$6,749.00
$1,683.00
$3,439.00
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 4 of 16
AREA 4
Make & Model No. Trane 101728
$243.00
$294.00
$311.00
Trane 101728
$223.00
$254.00
$156.00
Sub Total
$466.00
$548.00
$467.00
Total area 4 (A+B+C)
$1,481.00
A
B
C
Chiller Start-up
Midseason Inspection
Winter shut -down
$464.00
$476.00
$1,021.00
Make & Model No. Trane CenteravacY-ED3-EQ2 Trane RTHB-130ALF
$404.00
$415.00
$1,249.00
Sub Total
$868.00
$891.00
$2,270.00
$316.00
$477.00
$1,211.00
$316.00 $2,004.00
$477.00
$1,211.00
Total area 5 (A+B+C)
$4,029.00
AREA 6 Make & Model No. Trane RTHB-150 Sub Total Total area 6 (A+B+C)
Emergency Service must be provided with in two hours Emergency service Cost
$96.00 per hour
(May not exceed 2.5 times Hourly rate) Additional services Hourly rate for service work, normal working hours: Normal working hours: __7:00_AM to __3:30___PM.
$96.00 per hour
Hourly rate for service work, overtime:
$ 144.00 per hour
Hourly rate for service work, weekends & holidays
$ 192.00 per hour
Material cost mark-up above invoice cost:
10%
(Note: Include all costs in this hourly rate DOA will not pay additional charges for travel time, meals, truck charges, tool use charges, environmental fees etc.) Cost of parts and replacement materials used at the unit will be covered by DOA)
9. PURCHASE ORDERS/INVOICES: The using agency shall issue a purchase order to the successful contractor. Contractor is advised not to make any service until such purchase order has been received. Contractor shall submit a copy of the original invoice to DOA/DSF. 10. RETENTION OF RECORDS:
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 5 of 16
The contractor agrees to retain all records and other documents relevant to this contract for (5) five years after final payment or until after the resolution of any audit questions which could be more than five years, whichever is longer. State of Wisconsin auditors and any other persons duly authorized by Department of Administration shall have full access to the said materials.
11. STRIKES, ACCIDENTS, ETC: The contractor shall not be held liable for failure to provide the service due to any strike, accident, fire, governmental action or other causes over which he has no control, provided up to the time such strike or casualty occurred. Contractor shall notify Operations & Management of their inability to provide services and the reason thereof. Otherwise, contractor shall be held in default and responsible under the contract. In the event of the failure or inability of the contractor to deliver this service in accordance with the contract for any cause whatsoever, the state may at its election declare the contract canceled, and award the remainder of the unfilled contract requirements to another contractor. 12. SUBCONTRACTING: The contractor shall not assign this contract or subcontract to another party for performance of the terms and conditions hereof without the written consent of Department of Administration. The Subcontractors’ rate for the job shall not exceed that of the Prime contractor’s rate as in the original bid. Subcontractor’s invoice shall be invoiced directly to the Prime contractor, who in turn shall pass through the costs to the State of Wisconsin without markup. A copy of the subcontractor’s invoice must accompany the Prime contractor’s invoice. 13. SUSPENSION AND TERMINATION: 13.1
If contractor fails to meet the performance standards for any location in one bid area, the State of Wisconsin may terminate this Agreement at any time for convenience, with or without cause, by delivering 30 days written notice to the Contractor.
14. WARRANTY: Per attached STANDARD TERMS AND CONDITIONS, contractor must provide a performance guarantee for the maintenance services being proposed. The contractor must provide recovery cost for all damages resulting from contractors’ services to the equipment.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 6 of 16 GENERAL SPECIFICATIONS
15. MAINTENANCE SERVICES: Chiller maintenance service is only represented in three seasonal periods, however it will require several visits to complete the work outlined in each period. The three seasonal periods are SPRING STATRTUP, MID-SEASON INSPECTION and WINTER SHUTDOWN. Water treatment at chiller sites shall be performed by a qualified water treatment firm and shall be the responsibility of the State. All services must be scheduled in advance with the respective area managers. It is the responsibility of the Contractor to schedule this work prior to the start date of each service period. Unless agreed upon otherwise work should begin in the first week of each period and continue until it is completed. Service work will be performed during normal week day hours excluding Holidays. No one except authorized employees of the Contractor is allowed in the on the premises of State of Wisconsin buildings. The Contractor will repair or replace any worn parts found during the annual service, or when making non routine service calls to maintain the chillers in good working conditions. Replacement parts shall be billed at the Contractor’s cost as bid in the bid form. Labor to perform Regular or After Hours repair service is not included in the preventive maintenance program. Therefore, regular/after hours repairs will be made on a time material basis as submitted in the bid form. Preventative maintenance (PM) sheets are provided with this specification for each period of service required. They are to be filled out by the service technician as work is completed. Contractor must return the completed PM sheets to the Maintenance Supervisor before the end of the allotted time given for each service period in order to receive payment for that period. In the event the work performance of the Contractor is unsatisfactory, the contractor will be notified by the respective building representative and be given 4 hors to correct the work at no cost to the State. Any additional parts replaced shall be billed at contract pricing. Contractor service technicians are required to have a copy of this specification along with the corresponding PM sheets with them any time they are performing contractual work at each location. It is the responsibility of the vendor to remove any used refrigerant from the site. All materials supplied by the vendor shall be billed at invoice cost, plus mark-up and shipping cost. I.
CHILLER START-UP- SERVICE CALLS: (To be performed in March, April, May, and June) Chillers must be fully operational by the first week of April or within one (1) week of DOA notification to contractor that chillers must be put in service. 1.
Electronically leak-test chiller units (three), pump out units (two), refrigerant receivers (two), associated refrigerant piping and equipment, and relief vent pipe outlet. Test to be performed using an electronic leak detector capable of detecting a leak rate of one ounce per year.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 7 of 16
Once leaks have been located using the electronic leak detector they will then be confirmed using a liquid leak detector solution. Size and location of leaks is to be recorded on a service report, along with any recommendations to repair significant leaks. 2.
Trim chiller refrigerant charge for optimum chiller performance. Additional refrigerant will be provided by DOA. Contractor is responsible for charging any additional refrigerant purchased into refrigeration systems.
3.
Start up chillers. Electrical demand period, chiller availability and cooling load will determine when each chiller will be allowed to operate. Record all (3) phases of compressor motor current and voltage and compare with the nameplate data.
4.
Check all safety and operating controls and make sure unit is running properly. Record all pertinent parameters of unit including the following: Refrigerant pressure (cooler and condenser) Refrigerant temperature (cooler and condenser) Water temperature, inlet and outlet (cooler and condenser) a) Pressure drops, waterside (cooler and condenser) b) G.P.M. (cooler and condenser) c) Bearing oil temperature d) Oil sump temperature e) Oil pressure, psig f) Motor volts and amperage (all phases) g) Purge counts and compressor operating hours h) Purge condensing temperature i) Starter transition time (actual) Vibration data collection on motor and compressor
5.
Test and record compressor pre-lube and post-lube cycles. Notify the DOA staff of test results, re-calibrate if instructed to and log their operation on PM sheets.
6.
Check chilled water pump, condenser water pump and cooling tower operation, including tri-axial vibration measurements.
7.
Check overall performance of machines and review operating procedures with building maintenance personnel.
IA.
RECOMMENDATIONS AND REPORTS: 1. Collect an oil sample for analysis from each machine during last operating inspection and forward it to pre-approved testing laboratory at the request of DOA staff. 2. Collect a refrigerant sample for analysis from each machine during last operating inspection and forward it to pre-approved testing laboratory at the request of DOA staff. 3. Collect vibration data during operating inspection, perform spectral and time waveform analysis and make recommendations to DOA staff.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 8 of 16
4. Provide a written annual report of the condition of each chiller and recommendations for any additional maintenance that may be required and submit it to the maintenance supervisor. Report should include a summary of annual maintenance activities, oil and refrigeration analysis results, and vibration analysis results. II.
MID-SEASON INSPECTION: (Work to be started second week in July and completed by the second week of August) 1.
Electronically leak-test chiller units (three), pump out units (two), refrigerant receivers (two), associated refrigerant piping and equipment, and relief vent pipe outlet. Test to be performed using an electronic leak detector capable of detecting a leak rate of one ounce per year. Once leaks have been located using the electronic leak detector they will then be confirmed using a liquid leak detector solution. Size and location of leaks is to be recorded on a service report, along with any recommendations to repair significant leaks.
2.
Check with maintenance supervisor to verify that chiller safety devices have been operating properly - Evaporator Low Suction Pressure Cut Out, Low Chilled Water Temperature Cut Out, Low Chilled Water Temperature Alarm, High Condenser Pressure Cut Out, Compressor Auxiliary Oil Pump Pressure Switch, Compressor Low Oil Pressure Cut Out, Low Chilled Water Flow, test any that are questionable, calibrate if instructed to, and log their operation. Check operation of Operating Controls, Chiller Related Pressure and Temperature Gauges. Check chiller operation while on line. Determine if operating temperatures and pressures are running within manufacturer's recommended ranges. Notify maintenance supervisor of any problems or recommended changes.
3.
Take an oil sample from each chiller compressor, Take refrigerant samples from each chiller evaporator while in operation. Provide a spectrochemical analysis for each sample taken including a detailed report of analysis results and recommendations. Test results including recommendations must be received by DOA within 4 weeks of sample collection.
Reports should include the tests results for each item listed below. Next to each test result list the acceptable limits for each type of oil or refrigerant sample. For all tests that do not meet acceptable limits provide a probable cause or causes of abnormality along with a course of action to be taken to rectify problem.
1. Aluminum PPM Tests 1 through 6 are to be 2. Copper PPM performed for both oil and refrigerant 3. Iron PPM samples. Test 7 for oil only. 4. Tin PPM Tests 8 and 9 refrigerant only. 5. Zinc PPM 6. Moisture PPM 7. Acid Number Oil 8. Acid Number Oil Residue 9. Acid Number Refrigerant All analytical tests are to be performed by Thompson Laboratories Phone 608-784-0688 Address 510 Copeland Avenue, Lacrosse, WI, 54603
State of Wisconsin Department of Administration
4.
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 9 of 16
Check and record hot component shaft alignment for compressor and driver on York units; and for compressor, speed increaser, and driver on Carrier unit. Check and record axial forward and reverse thrust and bearing clearance on all three compressors and Lufkin speed increaser. Compare current readings with factory specifications and readings from previous years. Follow the specific instructions given on the chiller alignment log sheets explaining where to mount dial indicators. (Note: No variances from these procedures will be allowed) Completely fill out information requested on each alignment log sheet. A copy of our plant chiller Hot and Cold Alignment Log sheets has been included with this specification. Chiller availability will determine when alignment checks can be performed. Readings must be taken prior to chiller shut down. Maintenance supervisor may elect to have a cold alignment check performed during the winter maintenance in place of this hot alignment check. Re-lubricate chiller gear couplings using Kop-Flex KHP coupling grease according to coupling manufacturer instructions.
5. Review chiller operation and completed PM sheets with the maintenance supervisor. Make recommendations for additional work to be performed during winter maintenance. Include these recommendations on the PM sheets. Turn over completed PM sheets to the maintenance supervisor on the same day.
III.
WINTER MAINTENANCE: (Work to be started in the first week of December and completed by end of December) MAINTENANCE PROCEDURES CARRIER 19DM / OR HX MACHINES (a) Lock out and tag all chiller electrical power sources. (b) Pressurize the machine to a minimum 12 psig and electronically leak test all fabricated compressor vessel and piping joints. Advise owner of findings. Follow all applicable State and Federal guidelines. (c) Test purge operation and replace inline filter. (d) Drain oil and store in containers provided by owner. Disposal of oil is owner’s responsibility. Oil should be changed in the first year of the contract and then every 3rd run year after or as oil analysis dictates. (e) Install new filter elements and associated o-rings on all machines per manufacturer’s recommendations. All four machines are equipped with Carrier CSP single canister filter units. (f) Inspect condenser tubes. If necessary, tubes will be cleaned by owner. (g) Replace the volute filter, refrigerant filter and purge pump refrigerant strainer/filter. (h) Run control panel test.
(i)
Refill the lube system. Service contractor to supply manufacturer’s recommended oil.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 10 of 16
(i) Check and record the set points, recalibrate as required the following safety and operating controls and record values: 1. 2. 3. 4.
Condenser high-pressure cutout Oil low-pressure cutout Oil heater thermostat Refrigerant low-temperature cutout
(j) Retest the above performed work for leaks and repair as needed. Minimum pressure for this test to be 8 psig (k) If refrigerant is to be removed, transfer it to approved storage containers. Use a transfer device capable of drawing the vessel down to 25MM. Evacuate the machine and perform a standing vacuum test per manufacturer’s specifications. This test is to be witnessed by Owner’s representative. Mercury manometers are not acceptable for this test. Distill the refrigerant before recharging the machine if refrigerant charge is more than 10% oil saturated.
(l)
Using a megger, test the compressor and oil pump motor. Record values. 1. Phase to phase 2. Phase to ground
(m) Inspect starter contacts for pitting and corrosion. Correct spring tension and proper operation of mechanical linkage. Clean starter cabinet and tighten all electrical connections. CARRIER 19XL MACHINE 1. Inspect the Control Center. Perform general cleaning and tightening of connections. Vacuum the cabinet to eliminate dust build-up. 2. Check safety and operating controls. Run control test. (Refer to table 3 for limits and settings.) 3. Change compressor oil filter, use manufacturers recommended procedures. 4. Change compressor oil and have and oil analysis performed. Oil is to be changed the first year and every three years thereafter as a minimum along with an oil analysis. Use manufacturers’ recommended procedures. Use only a pre-approved testing laboratory and provide results to owner. 5. Change the refrigeration filter/dryer. Use manufacturers’ recommended procedures. 6. Change the oil reclaim filters. Use manufacturers’ recommended procedures. 7. Inspect and clean refrigerant float system. Use manufacturers’ recommended procedures. Report any problems to Owner. Remove the float access cover and clean the chamber and valve assembly. This is to be performed in the first and third run years. 8. Inspect the relief valves and piping. Use manufacturers’ recommended procedures. Report any problems to Owner. 9. Inspect and clean the starting equipment. Use manufacturers’ procedures. Report any problems to Owner. 10. Check oil pressure, condenser pressure, and cooler pressure transducers against a pressure gauge. Calibrate as required using manufacturers’ recommended procedures.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 11 of 16
11. Check guide vane linkage. Use manufacturers’ recommended procedures. 12. Inspect condenser tubes. If necessary, tubes are to be cleaned by owner. 13. Electronically leak test all fabricated compressor and piping joints. Advise owner of results. 14. Clean starter cabinet and tighten all electrical connections. 15. Reset service-on-time value on the status 01 screen when service work is completed. 16. Check and calibrate the refrigerant leak detection system as needed. 17. Replace batteries in PIC control panel in the first year. TRANE CVHE-320 MACHINES 1. Megger oil pump motor and record readings. 2. Measure and record oil pump voltage and amperage. 3. Inspect the starter for signs of overheating, arcing, burns, etc. 4. Verify operation of oil cooling system.* 5. Tighten terminal connections on the oil pump motor. 6. Verify operation of the oil heater. 7. Change the compressor oil and filter. 8. Clean starter cabinet. 9. Inspect starter and starter components for signs of discoloration, burns, moisture, etc. 10. Inspect wires for discoloration and burns. 11. Test accuracy of motor current (amp meter). 12. Test tightness of terminal connections. 13. Check dash pot oil and add as necessary. 14. Megger motor at the starter terminals; record readings. 15. Measure operating voltage and record. 16. Inspect the control panel for cleanliness, control air leaks, etc. 17. Inspect wiring and connections for signs of overheating, burns. 18. Verify operation of the vane control system. Check for free and smooth operation. Check mechanical linkages for wear & secureness. 19. Report accuracy of all gauges and thermometers (use masters). 20. Verify working condition of all indicator and alarm lights.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 12 of 16
21. Verify operation of start, stop, and anti-recycle timers. 22. Verify operation of automatic and manual capacity control. 23. Test all flow switch cutouts (cw, chw).* 24. Verify operation of oil temperature and pressure controller(s). 25. Test high condenser pressure safety - calibrate and record. 26. Test low evaporator temperature safety - calibrate and record. 27. Test oil low pressure safety - calibrate and record. 28. Test oil low temperature switch. 29. Test high motor temperature safety - calibrate and record. 30. Verify operation of automatic and manual capacity control. 31. Test the operation of all pump auxiliary contacts (chw, cw, oil, etc.).* 32. Record elapsed run times and start counts. * 33. Drain, clean and inspect purge drum. 34. Clean sight glass and report condition. 35. Clean and inspect purge float assembly. 36. Inspect pulley grooves and belts for alignments, wear, and tension. 37. Lubricate purge motor. 38. Test purge safety switch and adjust if requires.* 39. Verify operation of the purge heater. 40. Change filter dryer in purge line.* 41. Verify operation of the purge timer.* 42. Test the secureness of mounting points; tighten all major points. 43. Megger the purge compressor motor and record condition. 44. Test and calibrate purge operating controls. 45. Clean oil separator.* 46. Set separator float.* 47. Change oil in purge compressor.* 48. Run purge compressor and verify operation. 49. Inspect the belt condition. 50. Lubricate condenser fan motor bearings.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 13 of 16
51. Brush condenser fin surfaces clean, if required.* 52. Verify air flow through the condenser. 53. Test low ambient limit control - calibrate and record. 54. Test bearing temperature control - calibrate and record. 55. Lubricate condenser fan bearings. 56. Inspect condenser fan bearings, shafts, and drive assemblies for wear and alignment. 57. Remove debris from louvers, dampers, and coil faces. 58. Verify operation of condenser fan controls. 59. Verify operation of low oil temperature start inhibitor. 60. Verify distillation valve setting. 61. Inspect area around coupling/gear for oil leaks.* 62. Lubricate coupling.* 63. Test for refrigerant leaks and report results. 64. Check refrigerant charge. 65. Replace filter/dryer in motor cooling line.* 66. Test the secureness of mounting points; tighten all major points. 67. Record refrigerant level. 68. Review machine operation with operator. 69. Log machine at departure. 70. Run complete interlocking circuit where possible. 71. Report machine condition and repair requirements (if any). *where applicable YORK YT MACHINES 1. Megger oil pump motor and record readings. 2. Measure and record oil pump voltage and amperage. 3. Inspect the starter for signs of overheating, arcing, burns, etc. 4. Verify operation of oil cooling system.* 5. Tighten terminal connections on the oil pump motor. 6. Verify operation of the oil heater. 7. Change the compressor oil and filter.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 14 of 16
8. Check operation of the oil return system. 9. Change filter dryer in the oil return line. 10. Clean dirt leg. 11. Clean starter cabinet. 12. Inspect starter and starter components for signs of discoloration, burns, moisture, etc. 13. Inspect wires for discoloration and burns. 14. Test accuracy of motor current (amp meter). 15. Test tightness of terminal connections. 16. Check dash pot oil and add as necessary. 17. Megger motor at the starter terminals; record readings. 18. Measure operating voltage and record. 19. Inspect the control panel for cleanliness, control air leaks, etc. 20. Inspect wiring and connections for signs of overheating, burns. 21. Verify operation of the vane control system. Check for free and smooth operation. Check mechanical linkages for wear & secureness. 22. Report accuracy of all gages and thermometers (use masters). 23. Verify working condition of all indicator and alarm lights. 24. Verify operation of start, stop, and anti-recycle timers. 25. Test all flow switch cutouts (cw, chw).* 26. Verify operation of automatic and manual capacity control. 27. Verify operation of oil temperature and pressure controller(s). 28. Test high condenser pressure cutout - calibrate and record. 29. Test cooler low pressure cutout - calibrate and record. 30. Test oil pressure cutout - calibrate and record. 31. Test high oil temperature cutout - calibrate and record. 32. Test compressor high discharge temperature cutout - calibrate and record. 33. Test low water temperature leaving cooler cutout - calibrate and record. 34. Test the operation of all pump auxiliary contacts (chw, cw, oil, etc.).* 35. Record elapsed run times and start counts. *
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 15 of 16
36. Drain, clean, and inspect purge drum. 37. Clean sight glass and report condition. 38. Clean and inspect purge float assembly. 39. Inspect pulley grooves and belts for alignment, wear, and tension. 40. Lubricate purge motor 41. Test purge safety switch* and adjust if required. 42. Verify operation of the purge heater. 43. Change filter dryer in purge line.* 44. Verify operation of the purge timer.* 45. Test the secureness of mounting points; tighten all major points. 46. Measure and record the purge compressor motor voltage and amperage. 47. Test and calibrate purge operating controls. 48. Clean oil separator.* 49. Set separator float.* 50. Change oil in purge compressor. 51. Run purge compressor and verify operation. 52. Inspect area around coupling/gear for oil leaks.* 53. Lubricate coupling.* 54. Visually inspect coupling for abnormal conditions.* 55. Align shafts. 56. Test for refrigerant leaks and report results. 57. Check refrigerant charge. 58. Replace filter/dryer in motor cooling line.* 59. Test the secureness of mounting points; tighten all major points. 60. Record refrigerant level. 61. Review machine operation with operator. 62. Log machine at departure. 63. Run complete interlocking circuit where possible.
State of Wisconsin Department of Administration
CONTRACT NO. 15-93667-700 DATE: January 1, 2007 PAGE: 16 of 16
64. Report machine condition and repair requirements (if any). *where applicable Provide a detailed inspection report and advice of any maintenance that may need to be completed before the next chilling season.
RECIPROCATING CHILLERS 1. Lock out and tag-out all chiller electrical power sources. 2. Pressurize the machine to a minimum pressure of 100 psig unless otherwise directed by the manufacturer and electronically leak test all fabricated compressor vessel and piping joints. Advise owner of findings. 3. Remove two oil samples from crankcase for field testing and lab analysis. Replace any external oil filter element and lubricant if it is acidic based on the analysis. Recharge the compressor lube system new oil with the proper grade. 4. Check the following safety and operating controls set points, record settings and recalibrate as required. a. Condenser high-pressure cutout. b. oil low pressure cutout. c. oil thermostat. d. Refrigerant low temperature cutout. e. Check and verify proper operation of water flow switches. 5. Re-leak test the work performed above and repair any leaks noted. Minimum pressure 100 psig unless otherwise directed by the manufacturer. 6. Meggar test the compressor and record values. (Phase to ground)
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