PURPOSE. UTILITIES MAINTENANCE PROCEDURES To specify procedures for maintenance in the Utility Maintenance section of the Plant Operations and Maintenance department which includes the Central Utility Plant, Steam Distribution, Energy Management, HVAC, and Elevator Maintenance. BACKGROUND DIFFERENCES DEFINITIONS PROCEDURE 2. Air Compressor a. Frequency: Weekly b. Drain moisture from air receiver and moisture separator. c. Blow down until the compressor switch cuts in, 4. Check for air leaks while compressor is running, and note any unusual noises. Cooling Tower Frequency: Weekly (During Operation) . Check for clogging or stopping of drains. ¢. Remove trash and debris. 4. Listen for unusual noise or vibration from fans. e. Determine if water treatment is sufficient. Chillers a. Frequency: Daily (During Operation) b. Make necessary performance checks and record in operating logs, according to manufacturer's log sheet. ©. Note signs of leaking around fittings, valves, etc. Pumps a. Frequency: Weekly b. Check for leaking at mechanical seal. c. Check coupling for alignment. 4. Listen for unusual noise e £ Make sure mounting bolts are secure. Check gauges for proper operation, Motors a. Frequency: Weekly b. Check for heat, vibration, and unustal noises. ©. Check electrical connections for tightness, d. Make sure mounting bolts are secure. Sump Pumps a. Frequency: Weekly b. Check operation of pump by activating control plunger, c. Listen for sticking valves. Gas Boiler a. Frequency: Daily (When Operational) b. Check pressure and temperature gauges for proper setting. ©. Check mechanical fitings, valves, ete, for signs of leaking d. Check for automatic operation. EMS Alarms a. The constant monitoring of the EMS system will allow the identification of alarm system will allow the identification of alarm status for equipment that is part of the EMS system.. When these alarms occur, the operator should contact the appropriate Zone Supervisor to censure that an immediate response is made to an alarm or emergency condition as indicated by the readout of the computerized energy management system. 10. Chiller-Packaged Type Including Condenser This guide applies o chilled water producing units that consist ofa packaged chiller and a separate individual air-cooled condenser. a. Special Instructions i, Lfnecessary, schedule shutdown with operating personnel. fi, Review manufacturer's instructions. ili, Open, tag and lock circuit serving motor, when applicable. Frequency: Quarterly Checkpoints i. Check unit for proper operation, excessive noise or vibration. Lubricate shaft bearings and motor bearings. Check belts for condition, proper tension and misalignment; adjust for proper tension and/or alignment if applicable. iv. Inspect piping and valves for leaks; tighten connections as necessary. vy. Clean area around equipment. iller-Packaged Type Including Condenser Frequency: Semi-Annually Check Points for Condenser i, Replace throwaway filters. ii, Pressure wash coil with cleaning solution. iii, Straighten fin tubes with fin comb, if necessary. iv, Check electrical connections for tightness, v. Check mounting for tightness. vi, Check for corrosion. vii. Clean and paint, as needed ii-Check mounting for tightness. ix. Inspect pulleys, belts, couplings, etc.; adjust tension and tighten mountings, as, necessary. x. Change badly worn belts. Multi-belts drives should be replaced with matched sets. xi. Perform required lubrication and remove old or excess lubricant. ©. Checkpoints for Compressors i. Lubricate drive couplings. ii, Lubricate motor bearings (non-hermetic). iii, Check and correct alignment of drive couplings. iv, Inspect cooler condenser tubes for scale. Clean, if required. v. Add refrigerant per manufacturer's instructions, if needed. vi. Check compressor oil level. vii, Run machine, check action of controls, relays, switches, etc, to see that: * Compressor(s) run at proper settings. ‘Suction and discharge pressures are proper. Outlet water temperature is set properly. viii.Check and adjust vibration eliminators. d. Checkpoints for Controls i. Check operation of all relays, pilot valves and pressure regulators. ii, Check resulting action of pressure sensing primary control elements such as diaphragms, bellows, and inverted and similar devices when activated by air, water, or similar pressure ©. Checkpoints for Motors i. Check ventilation ports for soil accumulations, clean as necessary, ii, Clean exterior of motor surfaces of soil accumulation. iii, Lubricate bearings according to manufacturer's recommendations. iv. Remove filler and drain plugs (use zerk fittings, if installed). v. Pree drain hole of any hard grease (use wire, if necessary). a.vi. Add grease. Use good grade lithium base grease unless otherwise specified. vii. Check motor windings for accumulation of soil, Blow out with low-pressure air or vacuum, as needed. vili-Check hold down bolts and grounding straps for tightness. ix. Remove tags, start unit and check for vibration or noise. 12. Condensate Pump a. Special Instructions i. Review manufacturer's instructions. b. Frequency: Semi-Annually cc. Checkpoints i. Operate unit to check for steam binding. ii, Check condensate temperature (should be approximately 30° below steam temperature if traps are not leaking). iti, Examine flanges for steam leaks. iv. Pump receiver down. v, Turn condensate to sewer. vi, Shut down unit vii, Clean receiver. viii. Clean and adjust motor float switch. Check float operation on high and low water levels. Inspect pressure switches. ix. Clean and examine receiver, vent pipe, inlet and discharge openings for excessive corrosion. Report condition. x Check alignment of coupling with straight edge. xi. Lubricate pump and motor. xil, Adjust packing glands and change packing when necessary. xiii, Examine vacuum breaker operation, xxiv, Inspeet ball floats, rods, and other linkage; adjust as necessary. 13, Emergeney Generators, Electric (All Fuel Types) a. Special Instructions i. Check fire extinguishers for location and type. ii, Allow no open flames or smoking in the area. ili, Use only approved safety type fuel cans. iv. Obtain and review manufacturer's instructions and specifications. b. Frequency: Monthly c. Check Points i. Drain condensate from bottom of fuel tank and check fuel for quantity and contamination. ii, Check engine oil level ili. Check coolant level and inspect for leaks. Inspect engine air cleaner, replace if dirty, iv. Test and determine specific gravity of starting batteries. Clean terminals. Set proper charge rate after generator has been operated. v. Examine generator for moisture and /or dirt. vi. Start and operate unit under full load for one howr. Itis important that the unit be operated under load. Ifa portion of the building load cannot be ‘connected, a resistance load should be used. vii. While unit is operating, thoroughly observe operation for indication of defects or possible malfunctions. viii After unit has operated for 50 minutes, log the operation to show at least the ‘following information: engine and generator speed in R.P.M.; operating voltage; operating amperes; engine temperatures; engine oil pressure: hour meter readings. ix. Affer unit has been operated, check lubricant and coolant according to ‘manufacturer's instructions to assure that it will be ready to operate in an emergency, 14, Emergency Generators, Electric (All Fuel Types) ~ Continueda. Frequency: Semi-Annually b. Check Points i. Change fuel filters. it, Inspect and adjust rack on unit injector or fuel distribution pump according to manufacturer's instructions ii, Check governor, adjust for correct speed. iv. Determine fuel level, drain water from tank and inspect for contamination. Prior arrangements should be made for local procurement of fuel in emergencies. v. Change engine oil and filter, and perform other lubrication on engine and generator. vi. Inspect cooling system for leaks, air obstructions, anti-freeze solution. Make needed adjustments vii. Inspect generator winding and clean if needed. viii. Clean commutator and collector rings. Check brush wear and tension in accordance with manufacturer's instructions. ix. Inspect generator heaters. x. Remove old oil and diesel fuel from area around generator area when ‘maintenance is complete. 15, Cooling Tower a. Special Instructions i. Perform work before seasonal start-up. ii, Open and tag electrical circuits. iti, Review manufacturer's instructions. b. Frequency: Semi-Annually c. Check Points 1. Check and clean wet deck, Remove all debris and dispose of properly. it, Inspect and clean protective finish inside and out. Look for signs of spot corrosion. Clean and refinish any damage coating. lll. Pressure wash, if possible, rower structure (depending upon condition and type of elements). iv. Change oil in gearbox. v. Check structure for deterioration. Tighten fasteners as required. vi. Inspect motor, Belts, etc., for proper operation. vii, Check alignment of gear, motor and fan. viii, Lubricate all bearings. Remove old or excess lubricant. ix. Check eliminator for buildup and clean, if needed. x Check water distribution, Adjust and flush out troughs, if necessary. xi. Check fans and air inlet screens and remove any dirt or debris. xii, Check nozzles for clogging and proper distribution xiii Inspect keys and keyways in motor and drive shaft. 16. Cooling tower — Continued ‘This guide may be used 1 provide periodic flushing of cooling towers, and should be used only ifthe towers ‘accumulate excessive debris during the operating season a. Frequency: As Required b. Check Points i, Disconnect motors and tag and lock circuits ii, Drain tower; flush out with hose. iii. Clean distribution nozzles and screens. iv, Clean distribution nozzles and sereens. vy. Remove debris from area and dispose of properly. vi, Return unit to service. vii. Adjust bleed, float, and central valve for desired water level 17. Pump, Centrifugal a. Special Instructions i, Review manufacturer’s instructions, " belt tension and properii, Pump maintenance should be scheduled to coincide with drive motor ‘maintenance, b. Frequency: Semi-Annvally ©. Check Points, i, Check that base bolts are securely fastened. ii, After shutdown, drain pump hosing, check suction and discharge valves for holding, Remove cover, gland and packing, Remove corrosion from impeller shaft and housing cover. On pumps with oil ring lubrication, drain oil, flush, and fill to proper oil level with new oil. Inspect wear rings, seals and impeller. Clean strainers. Replace packing reassemble. ix. Start and stop pump, noting vibration, pressure and action of check valve. x. Adjust packing, xi. Lubricate impeller shaft bearings, do not over lubricate, xii, Check drive shaft coupling, xiii,Check motor and pump alignment Coupling Size [Allowable Alignment 1-2" [0.101 total ind.reading Over 2’ 4 [0.015 total ind.reading Over 4" 7" [0.020 total ind. reading 18. Controls, Central System Heating and Air-Conditioning a, Special Instructions i, Read and understand manufacturer's instructions before making adjustments ot calibrations. Obtain “As Built” control diagrams prepared by control contractor. b. Frequency: Semi-Annually ©. Check Points, i. Check set point of controls (temperature, humidity, or Pressure). ii, Compare control point with an external measuring device, note deviations, and adjust. iii, Check the unit over its range of control. If possible, impose simulated conditions to activate controls and check operation. iv. Check for control point cycling, v. Check closeness of differential gap on two position controllers (on-off-open- closed) vi. Check condition and action of primary elements in the controllers (bimetallic strips, sealed bellows with capillary tubes) for remote sensing, ete, vii. Note the action of the controlling device (thermostats, humidistats, and pressure stats) witch changes the controlled device (motors, valves, dampers etc.) Viii.On electronic controls check the source of the signal and its amplification. ix. Check air systems for leaks, check for correct maintenance of pressure in all control devices. Check units for proper closing and loose connections. x. Check the condition and ability of humidity sensing primary control elements, to read the moisture changes and their reaction on the control mechanism. xi, Check resulting action of pressure sensing primary control elements such as diaphragms, bellows, inverted bells, and similar devices when activated by air, ‘water or similar pressure. Check operation of all relays, pilot valves, and pressure regulators, xii. Replace air filtets in sensors, controllers, and thermostats as required, xiii, Use test kits and manufacturer's instructions whenever possible, Replace rather than rebuild a control installed in the system, Take control to shop for repair.19. Controls, Central System Chiller This guide applies to those controls used to protect and control the operation of eemiral refrigeration units. Included are electric, electrani, pneumatic or « combination of several cqpacty-controlers demand controler, temperature and pressure controls and safeties. a, Special Instructions i, Read and understand the manufacturer's instructions. ii, Obtain “As Built” diagrams of the control and safety systems. fii, Replace defective controls and safeties found while performing preventive maintenance, b. Frequency: Annually Check Points i, Check flow or pressure differential switches for proper operation. ii, Calibrate or replace as necessary iii. Check oil temperature control and safety for proper operation. Calibrate and replace as necessary, iv, Check set point for low temperature control and safety for proper operation. Calibrate or replace as necessary. v. Check capacity controller or demand limiter for proper operation. Calibrate or replace as necessary. vi, Check oil pressure control and safety for proper operation. Replat necessary. vii Check high-pressure cutout for proper setting and operation. Adjust for replacement as necessary. viii.Check and clean all electrical contacts and pneumatic orifices. ix. Check pneumatic tubing for leaks and damage. Repair or replace as necessary. x. Check electrical wiring insulation and connections. Tighten or replace if necessary. xi, Check damper or unloader controller for proper operation, Check position on damper for proper operation. Calibrate or replace as necessary. xii, Check all settings and set points with manufacturer's instructions. if 20. Air Dryer, Refrigerated or Regenerative Desiccate Type This guide applies to refrigerated or regenerative desiccant type air dryers, with a capacity of 10 CFM. or greater. Those units with a capacity af ess than 10C.F.M. willbe maintained in conjunction with he air ‘compressor that they are associated to, a. Special Instructions i, Schedule this maintenance in conjunction with maintenance on the associated air compressor. fi, Review manufacturer's instructions. iii, De-energize, lock and tag electrical circuits. b. Frequency: Quarterly Check Points i, Lubricate valves and replace packing, if necessary. Check dryer operating cycle, |. Inspect and clean heat exchanger. Check outlet dew point. v. Check and lubricate blower. vi. Refrigerated type: * Check traps. + Cheok refrigerated level and moisture content, + Clean and lubricate condenser fan motor. vii, Desiccant type: + Replace filter cartridges, both pre-filter and after-filter. * Check the inlet flow pressure, temperature and purge rate * Check the desiccant and replace, if necessary. + Inspect and clean solenoids, purge valves and strainers.21. Motors (1 HP to Less Than 200 HP) This guide is for squirre-cage, wowxd-rotor and synchronous motors in excess of! horsepower. The maintenance specified by this gude is not intended to require disassembly of the motor. This guide does not normally apply to ‘morors rated less than I horsepower. Maintenance for these motors is normally limited to cleaning and lubrication, which is accomplished withthe maintenance of the driven machine. a Special Instructions i. Lfmecessary, schedule shutdown with operating personnel. fi, Review manufacturer's instructions. iii, Open, tag, and lock circuit serving motor, when applicable. iv. Schedule PM on motor in conjunction with driven machine. Frequency: Semi-Annually Check Points i. Check ventilation ports for soil accumulation, clean if necessary. ii, Clean exterior of motor surfaces of soil accumulation iii, Lubricate bearings according to horsepower ratings: HP Range Frequency 1107.5 HP, Every 4 years ‘Over 7.510 50 HP _| Year ‘Over 5 HP Two Times per Vear = Remove filler and drain plugs (use zerk fittings if installed) Free drain hole of any hard grease (use piece of wire if necessary) = Add grease ~ use good grade lithium base grease unless otherwise noted. iv, Check motor windings for accumulation of soil. Blow out with air if required. v. Check hold down bolts and grounding straps for tightness. vi, Remove tags and return to service. 22. Well Pump a. b. c. Special Instructions i, Read and understand manufacturer's instructions, Frequency: Quarterly Check Points i, Remove turbine pump from deep well. ii, Inspect pump body, bowls, water passages and impeller for corrosion, wear or pitting; repair as necessary. ili, Check packing for leaks; tighten or repack as necessary. iv. Adjust impeller for optimum operation. v, Inspect wear ring clearances, thrust and pump bearings for wear; repair as necessary vi. Lubricate all pump parts as required. vii. Clean suetion strainer or replace if damaged, viii.Inspect operation of discharge valve. ix. Inspect electrical system for frayed wires or loose connections; repair as necessary. x. Check operation of pressure and thermal controls. Paint pump with underwater paint. xii, Run pump and check for noise and vibration. xiii.Reinstall pump in deep well and test operation. xiv. Fill out maintenance checklist and report deficiencies. 23. Pump Rotary Positive Displacement a. b. c. Special Instructions i, Read and understand manufacturer's instructions ii, Coordinate PM on motor in conjunetion with this guide. Frequency: Quarterly Check Pointsi, Clean surface of pump with solvent. ii, Operate pump and check for leaks at pipes and connections and for excessive noise and vibration. iii, Lubricate pump. iv. Check shaft alignment and clearances and pump rotation. v, Inspect packing for leaks and tighten, vi, Tighten loose bolts and nuts; replace loose and missing hardware as needed. vii, Inspect electrical system for loose connections and frayed wires; repair as necessary. vili,Operate pump upon completion of maintenance, read and record pressure ‘gauge readings and check discharge pressure. ix. Clean up area around pump after repairs. 24. Valves, Backflow Preventer ‘This gue applies to approved backflow prevention devices installed in water lines to prevent the backflow of treated water in the city water system. Check valves or double check valves are not approved backflow preventers and are not included for servicing under this guide Backflow preventers will normally be found in systems associated and other systems where heated water could backflow ito the ci a. Special Instructions i. Review the manufacturer’s instructions for testing the valve and proper use of the test equipment involved ii, Study the test procedures to be used. iii, Schedule outage of equipment involved. b. Frequency: Annually ©. Check Points Secure the incoming city water line(s). Test for objects lodged in the seat or dise. Test for worn or loose disc or dise guide assembly. iv. Check for damage to seat Check for corrosion build-up. Following the manufacturer's procedures check and calibrate as required, i, Following the manufacturer's procedures vent both chambers and return the system to normal operation. 25. Heat Exchanger a. Frequency: Semi-Annually b. Check Points i. Inspect element header for signs of leaking or corrosion. Remove corrosion and encrustation. ii, Remove heat exchanger or electric heating element and clean only ifa loss of efficiency is indicated, or signs of leaking around header are evident, iii, Tighten all bolts around header. iv. Renew paint/protective coating/insulation as required. v. Drain tank and flush to remove sediment, scale, etc. vi, Clean sight glasses on tanks. vii. Clean strainer, check condition of traps and valves. viii.Report any needed repairs to Maintenance Supervisor. 26. Condensate Return Pump a, Frequency: Quarterly b. Check Points Check for proper operation of pump. Check for leaks on suction and discharge piping, seals, packing glands, ete.; ‘make minor adjustments as required. ‘Check pump and motor operation for vibration, noise, overheating, etc. iv. Check alignment pump and motor; adjust as necessary. v. Lubricate pump and motor. vi. Clean exterior of pump, motor and surrounding area. vii, Fill out maintenance checklist and report deficiencies sth Boilers, central chillers, cooling towers, rater system.27. Boiler, Hot Water; Oil, Gas or Combination a. Special Instructions i, Read and understand manufacturer's instructions. fi, Review operating logs. b. Frequeney i, Monthly-Checkpoints 4,7,10,11,12,13,14,17,18,and 19. ii, Quarterly-Check points 4,5,6,7,10,11,12,13,14,15,17, andl9. iii, Annually-All check points. ec. Check Points i. Check combustion chamber for air or gas leaks. Inspect and clean oil burner gun and ignition assembly where applicable. Inspect fuel system for leaks and change fuel filter element, where applicable. -- Check fuel lines and connections for damage. v. Check for proper operational response of burner to thermostat controls. vi. Check and lubricate bumer and blower motors. vii. Check main flame failure protection and main flame detection scanner on boiler equipped with spark ignition (oil burner). viii. Check electrical wiring to burner controls and blower. ix. Clean firebox (sweep and vacuum). x. Check operation of mercury control switches (i., steam pressure, hot water temperature limit, atomizing or combustion air proving, etc.). xi. Check operation and condition of safety pressure relief valve. xii. Check operation of boiler low water cut off devices. xiii, Check hot water pressure gauges. xiv. Inspect and clean water column sight glass (or replace). xv. Check condition of flue pipe, damper and exhaust stack, xvi.Check boiler operation through complete cycle, up to 30 minutes. xvii, Check fuel level with gauge pole; add as required. Clean area around boiler ll out maintenance checklist and report deficiencies. 28. Boiler, Steam; Oil, Gas or Combination a. Special Instructions i, Read and understand manufacturer's instructions. fi, Review operating logs b. Frequency i,“ Monthly-Check points 1,3,6,8,10,13,15,17,19, and 20, Quarterly-Check points 1,3,4,5,6,7,8,10,11,12,13,14,15,17,19, and 20. i, Annually- All check points. c. Check Points i, Inspect fuel system for leaks or damage. Change fuel filter element and clean strainers; repair leaks, where applicable. . Check main flame failure protection, positive fuel shutoff and main flame detection scanner on boiler equipped with spark ignition (oil bumer) iv. Check for proper operational response of burner to thermostat controls. vv. Inspect all gas, steam and water lines, valves, connections for leaks or damage; repair as necessary. Check feed water system and feed water makeup contro! and pump. Check and lubricate burner, blowers and motors as required. ‘Check operation and condition of safety pressure relief valve. ‘Check combustion controls, combustion blower and damper modulation controls. x. Check all indicator lamps and water/steam pressure gauges. xi, Check electrical panels and wirings to bumer, blowers and other components. xii, Clean blower air-intake dampers, if required xiii. Check condition of flue pipe, damper and exhaust stack. xiv.Check boiler operation through complete cycle, up to 30 minutes.29, xv. Check water column sight glass and water level system; clean or replace sight, glass if required, xvi.Clean firebox (sweep and vacuum). xvii. Check fuel level with gauge pole for oil burning boilers. xviii, Inspect and clean oil burner gun and ignition assembly where applicable. xix.Clean area around boiler. xx. Fill out maintenance checklis Boiler Fuel Oil Pump a. Frequency: Quarterly b. Check Points i. Check with operating or area personnel for deficiencies. ii, Check for leaks on discharge piping and seals, etc. iii, Check alignment and clearances of shaft and coupler. iv. Tighten or replace loose, missing, or damaged nuts, bolts, and screws. v. Lubricate pump and motor as required. vi. Clean pump, motor and surrounding area. vii. Fill out maintenance checklist and report deficiencies. and report deficiencies, 30. Air Compressor a, Special Instructions i. Review manufacturer's instructions. ii, Coordinate motor PM. b. Frequency: Quarterly c. Check Points Change compressor oil, Clean air intake filter. Check motor operation for excessive vibration, noise and overheating; lubricate motor. iv. Clean cooling fans and air cooler on compressor. v. Check operation of pressure relief valve. vi. Check tension, condition, and alignment of V-Belts; adjust as necessary, vii. Drain moisture from air storage tank; check discharge for indication of interior corrosion. vili.Check for proper operation of pressure cut-in and cut-out switches. ix. Clean oil and water trap. x. Clean compressor and surrounding areas. |. Air-Conditioning Package Unit Chilled Water Coils ‘This gue apples to those packaged ype air-conditioning units that are equipped with chilled water coils a. Special Instructions i, Review manufacturer's instru b, Frequency: Quarterly ©. Check Points i. Thoroughly inspect and clean interior and exterior of machine with vacuum (remove panels), ii, Clean drain pan and note excessive corrosion, Treat rusted areas with rust inhibitor. Check for chilled water leaks on all lines, valves, strainers, ¢ Clean strainer on chilled water inlet. v, Check condition of cooling and reheat coils. vi, Clean coils with evaporator coil cleaner. vii, Drain and clean humidifier pan or pad, whichever applies. Replace pad if required, Remove corrosion, as needed. vili.Clean and lubricate motor and squitrel cage fan(s). Check alignment of motor and fan. Check bearings for excessive wear. ix. Check belt tension and condition. Adjust or replace, as required. x. Replace filters, as needed. xi. Run machine, check action of controls, relays, switches, etc,. * Chilled water valve(s) are operating properly.+ Reheat coils activate humidifier. + Humidistat activates humidifier. = Inlet and outlet water pressures are suitable on cooling coils. + Discharge air temperature is set properly. xii, Check and record chilled water inlet and outlet temperatures, xiii.Check and adjust vibration eliminator mounting, if required. 32. Air-Conditioning Package Unit This guide applies o direct expansion (DX) packaged air conditioning units a. Special Instructions Review manufacturer's instruction. b. Frequency: Quarterly ©. Check Points ‘Thoroughly inspect and clean interior and exterior of machine with vacuum (remove panels). ii, Clean drain pan and note excessive corrosion. iii, Check refrigerant levels and recharge, if needed. iv. Check condition of cooling and reheat coils. v. Clean coils with coil cleaner. vi, Drain and clean humidifier drip pan, if applicable. Remove corrosion, as needed, vii. Lubricate motor and fan bearings, if not sealed. Check alignment of motor and fan. vili,Check belt tension and condition. Adjust or replace, as required. ix. Replace filters, if needed. x. Check compressor oil level xi, Run machine, check action of controls, relays, switches, etc, to see that * Compressor(s) run at proper settings. * Reheat coil activate properly. * Humidistat activates humidifier. * Suction and discharge pressures are correct. * Discharge air temperature is set properly. xii, Check and adjust vibration eliminators. 33. Air Handling Unit a, Special Instructions i, Review manufacturer’s instructions. ii, Schedule shunt-downs with operating personnel, as needed. iii, Open, lock and tag electrical circuits iv. Schedule PM on motor, in conjunction with this guide. b. Frequency: Quarterly ec. Check Points, i. Check controls and unit for proper operation. ii, Check for unusual noise and vibration. Check tension, condition and alignment of belts, adjust as necessary. .. Lubricate shaft and motor bearings. Replace air filters. vi. Inspect exterior piping and valves for leaks; tighten connections as required. vii, Clean area around equipment. 34, Air Handling Unit a. Frequency: Semi-Annually b. Check Points, i. Check fan blades for dust build up and clean if needed. Check fan blades and moving parts for excessive wear. Check fan RPM to design specifications /. Check bearing collar set screws on fan shafts to make sure they are tight. v. Check dampers for dirt accumulations. Check felt, repair or replace as required. vi. Check damper motors and linkage for proper operation, Adjust linkage on vanes if out of alignment.vii, Lubricate mechanical connections of damper sparingly. viii.Clean coils with coil cleaner. ix. Check coils for leaking, tightness of fittings. x. Use fin comb to straighten coil fans. xi, Flush and clean condensate pans and drains. xii, Check belts for wear, adjust tension or alignment and replace belts when necessary. Multi-belt drives should be replaced with matched sets. Check rigid couplings for alignment on direct drives and for tightness of assembly. Check flexible couplings for alignment and wear. xiv. Before heating season; Drain cooling coils; blow down to remove moisture; refill with anti-freeze and water solution; drain, (Use solution in other coils). xv. Check freeze-stat for proper operation. xvi. Vacuum interior of unit. xvii. Lubricate fan shaft bearings while unit is running. Add grease slowly until slight bleeding is noted from the seals. Do not over lubricate. Remove old or excess lubricant, 35. Air-Conditioning Package Unit Chilled water Coils Special Instructions i. Review manufacturer's instructions. b. Frequency: Monthly ©. Check Points i, Check unit for proper operation. Check oil level; add oil as required. . Check oil temperature. iv. Check dehydrator on purge system; remove water if observes vy. Run system control tests. vi, Check refrigerant charge level; add as required, Check compressor for excessive noise and vibration. Clean area around equipment. 36. Air-Conditioning Package Unit Chilled Water Coils a. Frequency: Semi-Annually b. Check Points i, Lubricate drive coupling Lubricate motor bearings (non-hermetic). iii, Lightly lubricate vane control linkage bearing ball joints, and pivot points. DO ‘NOT LUBRICATE the shaft of the vane operator. iv. Drain and replace the oil in the compressor oil reservoir including filters, strainers, and traps. DO NOT CHANGE oil in reciprocating machines unless contaminated, ¥. Drain and replace oil in purge compressor. Drain and replace oil in gearbox. Check and clean oil strainer. vi, Drain and replace oil in gearbox. Check and clean oil strainer. vii. Check and correct all alignment of drive coupling. Viii.Inspect cooler and condenser tubes for scale. Clean if required. Leak test tubes using a halogen leak detector. ix. Inspect purge unit Remove cover from refrigerant float chamber and clean the chamber and float valve. Check operation, = Remove and examine float valve plunger. Replace plunger and seat assembly if wear is evident. x. Clean all water strainers in the system. xi, Use oil-dry nitrogen to test for leaks on centrifugals per manufacturer's instructions 37. Fan, Centrifugal a. Special Instructions i, Review manufacturer's instructions. xii sight glass.fi, Schedule shut-downs with operating personnel, as needed. iii. Open, lock and tag electrical circuits, b. Frequency: Semi-Annually Check Points i. Check fan blades for dust buildup and clean if necessary. ii, Check fan blades and moving parts for excessive wear. Clean as needed. iii, Check fan RWM to design specifications. iv. Check bearing collar set screws on fan shaft to make sure they are tight. v. Vacuum interior of unit if accessible. Clean exterior. vi, Lubricate fan shaft bearings while unit is running. Add grease slowly until slight bleeding is noted from the seals. Do not over lubricate, Remove old or excess lubricant. vii, Check belts for wear, adjust tension or alignment, and replace belts when necessary. Multiple belt drives should be replaced with matched sets. viii. Check structural members, vibration eliminators and flexible connections. ix. Schedule PM on motor at the same time. 38. Vacuum Pump a Special Instructions i, Review manufacturer’s maintenance recommendations. ii, Coordinate motor maintenance if applicable +hedule shutdown with operating personnel iv. Secure and tag electrical power and valves to vacuum lines. v. Use appropriate safety protective equipment. b. Frequency: Quarterly c. Check Points i. Check for leaks on suction and discharge piping, seals, ete ii, Check for pump and motor operation for excessive vibration, noise, and overheating iii, Check alignment and clearances of shaft and coupler. iv. Tighten or replace loose, missing, or damaged nuts, bolts, and screws. vv. Lubricate pump and motor as required. vi. Clean pump, motor, and surrounding area. ll out maintenance checklist and report deficiencies. 39. Fan Coil Unit b. Frequency: Quarterly Check Points, i. Check coil unit while operating. ii, Check coils and piping for leaks, damage, and corrosion; repair as necessary. iii, Replace filter as required 40. Fan Coil Unit a Frequency: Semi-Annually b. Check Points Check unit for noise and vibration, Clean and wash permanent filters. Recoat wire mesh filter with ol. i. Replace disposable filters. iv. Drain and clean condensate pan, v. Lubricate fan shaft bearings (if not sealed). vi, Lubricate motor bearings sparingly, using SAE LOW motor oil (if not sealed). vii, Clean coils by vacuuming, brushing, or with coil cleaner. viii.Use fin comb to straighten coil fins. ix. Clean strainer ahead of unit. x. Check controls, trap. Freeze-stat, and control-stat for proper operation, xi, Clean fan blades and interior surfaces of unit. xii, Damp wipe exterior surfaces.’ xiii Tighten all electrical connections.4 42, 43, Heat Pump a. Special Instructions i. Read and understand manufacturer's instructions. ii, De-energize, lock, and tag electrical circuits b, Frequency: Semi-Annually c. Cheek Points i. Inspect piping for evidence of leaks. ii. Inspect all wiring for deterioration, and tighten electrical contacts. Check for corrosion. iii, Check mounting bolts and tighten if needed. iv. Check crankcase heater. vv. Check fan for vibration or excessive noise. Lubricate fan and motor if required. vi. Check refrigerant levels, recharge if necessary. Check for leaks if loss of refrigerant is detected, vii, Check temperature drop across condensing coil Clear air intake and screens. ix. Brush on pressure wash coil surfaces. Straighten fins with fin comb x. Check that reversing valve is energized in the “heat” mode and de-energized in the “cool” mode. Replace defective valves. xi, Vacuum interior of unit and change filters as needed. Sump Pump a. Frequency: Semi-Annually b. Special Instructions i, Strainer cleaning requires removal of pump unit and should be handled as a repair. ii, Excessive sediment and debris, not removed by flushing the pit, should be handled on a project basis, and not considered under this guide. iii, Review manufacturer's instructions. ©. Check Points i, Flush pit and pump out ii, Check bail, floats, rods and switches. Make sure float operates as designed. Inspect and lube motor, and pump. Repack if needed. iv, Inspect check valves. Sump Pump, Sewage Ejector (This guide applies to sump pump pe elector that operates by means of eletre motor and pump) a. Frequency: Semi-Annually b. Special Instructions i, Schedule outage with SRC and operating personnel. ii, Open and tag electrical circuits. iii. Wear rubber apron, gloves, boots, full-face shield, and respirator when performing the work. iv. Ifa person must enter pit, test for oxygen deficiency and supply proper ventilation equipment as needed, v. No open flames or smoking. vi, Strainer and check valve cleaning requires removal of pump unit and should be handled as a repair. Check Points Remove cover plates, flush pit and pump out, Check bail, floats, rods, and switches. Make sure float operates as designed. Clean pump and lubricate as required. iv. Inspect check valves. v, Inspect interior of pit for cracks. vi, Clean motor with vacuum or low pressure air (Iess than 40 PSIG). vii, Check for corrosion. Clean and treat with rust inhibitor as needed. Vili. Inspect cover plate gasket and replace if necessary.