Cawangan Kejuruteraan Mekanikal – Edition 1

SECTION 5.0 SPECIFICATIONS FOR COMPREHENSIVE SERVICE AND

MAINTENANCE OF THE AIR CONDITIONING PLANT AND
ARCILLARY EQUIPMENT

5.1 WATER COOLED CHILLER SYSTEM

1 GENERAL

The work covered by this Specification is for the supply of all materials,
appliances, labour and necessary incidentals for the service and maintenance of
the Air- Conditioning Plant and Ancillary Equipment.

All work to be performed under this Specification shall be in accordance with the
best commercial practice and must be strict accordance with the Specification.

2 WORKMANSHIP AND MATERIALS

The Work described in this Specification shall be performed by workmen skilled

in the service, maintenance and repair of all types of Air-Conditioning Plant and
shall be executed in accordance with the best commercial practice.

All materials to be supplied in connection with work under this Specification shall
be new and unused and shall generally be of the best quality as regards
manufacture and performance.

3 SUPERVISION

The Contractor shall have a Foreman in charge of service, maintenance and

repair work to be carried out under this Specification. This Foreman must be
thoroughly competent in supervising the service, maintenance and repair of all
types of Air-Conditioning Plant and shall be in direct employ of the Contractor and
acceptable to the Superintending Officer.

4 SCOPE OF WORK

All machinery and equipment compromising the complete Air-Conditioning Plant

and Ancillary Equipment shall be serviced and maintained in strict accordance
with the Servicing and Maintenance Schedule as set in Clause 5.5 below.

The Contractor shall advise the Superintending Officer of any defects in any part
or parts of complete Air-Conditioning Plant and Ancillary Equipment observed
during routine inspection and service and shall repair such defects if required to
do so by the Superintending Officer.

The Contractor shall also provide emergency repair service during normal
working hours and also during overtime hours if required to do so by the
Superintending Officer.

COMPREHENSIVE SERVICE & MAINTENANCE SPECIFICATION Section 5 / page 1

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5 SERVICING AND MAINTENACE SCHEDULE

The Contractor shall inspect and service all machinery and equipment
compromising the complete Air-Conditioning Plant and Ancillary Equipment at the
above premises at least once a month, except where otherwise directed by the
Superintending Officer.

As such monthly inspection and service of the complete Air-Conditioning Plant

and Ancillary Equipment, the work detailed below shall be performed by the
Contractor:

No Frequency
Item Every Every 3 Every 6 Every
Month Month Month Year
1 REFRIGERANT COMPRESSOR &
SYSTEM
a Take and record the reading of motor
amperage and voltage, refrigerant
pressures and temperatures,
condenser water entering-leaving
temperatures, chilled water entering-
X
leaving temperatures, chiller load, etc.
Compare with the design technical
specifications. If abnormal, trace faults
and rectify as necessary.

b Check crankcase heater operation. If

abnormal, rectify as necessary. X

c Check the purge unit operation. If

abnormal, rectify as necessary. X

d Check all seals, gaskets and pipelines

for leaks and rectify as necessary. X

e Check all refrigerant and oil levels, and

charge the refrigerant and oil into the
X
refrigerant system as necessary.

f Check the operation of all refrigerant

controls. Clean, adjusts, repair, replace
X
and lubricate as necessary.

g Check the operation of all safety

devices. Clean, adjust, repair, replace
X
and lubricate as necessary.

h Check the suction and discharge

pressures of all refrigerant
compressors. If abnormal trace the X
faults and rectify as necessary.

i Check all bolts and nuts for tightness

and tighten as necessary. X

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 Cawangan Kejuruteraan Mekanikal – Edition 1
No Frequency
Item Every Every 3 Every 6 Every
Month Month Month Year
j Service the chiller including changing
of compressor oil, filter and topping up
X
refrigerant and carry out leak test.

2 WATER PUMPS
a Check all pump mechanical seals for
leaks (for pump gland leakage rate is a
maximum of 10 drops per min if not
specified by the manufacturer). Adjust, X
re-pack and replace pump glands or
mechanical seals as necessary.

b Check all pump bearings for excessive

noise, vibration and wear. Lubricate
with oil or grease or replace if X
necessary.

c Take reading and record the noise and

vibration levels for all pumps and
compare with the design technical
specifications/standards. If abnormal, X
trace the faults and rectify as
necessary.

d Check the alignment and condition of

all rubber couplings between pumps
and drive motors, and rectify as X
necessary.

e Check each pump mountings. Tighten

all bolts and nuts as necessary. X

3 EVAPORATOR/AIR HANDLING UNIT

a Check all filters. Clean and renew as
necessary. X

b Check all water coils, seals and

pipelines for leaks and rectify as
X
necessary.

c Clean cooling coil with high pressure

water jet and biodegradable alkaline
X
cleaning chemicals.

d Purge air from all water coils.

X
e Check all fan and motor bearings for
excessive noise, vibration and wear.
Lubricate with oil or grease or replace if X
necessary.

f Check the tension of all belt drives.

X
Adjust or replace as necessary.

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No Frequency
Item Every Every 3 Every 6 Every
Month Month Month Year
g Check the operation of all automatic
water regulating valves. Clean, adjusts
X
and lubricate as necessary.

h Check the operation of all automatic

multi-blade face and by-pass dampers.
Clean, adjusts and lubricate as X
necessary.

i Check the operation of thermostat to

ensure the set temperature is
X
achieved.

j Clean all condensate pans, trays and X

drains.

4 COOLING TOWER
a Check all fan and motor bearings for
excessive noise, vibration and wear.
Lubricate with oil or grease or replace if X
necessary.

b Check the tension of all belt drives.

Adjust or replace as necessary. X

c Clean all water screens.

X
d Check the operation of all water
nozzles and clean as necessary. X

e Drain, clean and flush out the water

tanks of the cooling tower when found
X
necessary.

f Check the float valve operation and

adjust the water level as necessary. X

g Chemical water treatment for cooling

tower to eliminate/control micro-
biological growth, scale and corrosion.

- Field water test shall be carried out X

and the result to be recorded.

5 ELECTRIC MOTOR
a Check all motor bearings for excessive
noise, vibration and wear. Lubricate
with oil or grease or replace if X
necessary.

b Check carbon brushes and slip rings of

all motors and clean as necessary. X
Replace carbon brushes if necessary.

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 Cawangan Kejuruteraan Mekanikal – Edition 1
No Frequency
Item Every Every 3 Every 6 Every
Month Month Month Year
c Check safety devices fitted to all
motors. Clean, adjust and lubricate as
X
necessary.

6 ELECTRICAL SWITCHBOARD AND

CONTROL PANEL
a Inspect and test the control wiring and
circuitry. Retighten, repair or replace as
X
necessary.

b Check the operation of selector

switches and stop-start button. Repair X
or replace as necessary.
c Check the routine operation of all
electrical starters, electrical control
gears and ancillary electrical
X
apparatus. Repair or replace as
necessary.

d Clean or renew electric contactors as

necessary. X

e Renew electric fuses as necessary.

X
7 PIPING AND FITTINGS
a Inspect all piping for leaks and rectify
as necessary. X

b Inspect the chilled water pipe

insulation. Repair or replace as
X
necessary.

c Inspect the condition of every valve

and fitting. Repair or replace as
X
necessary.

8 DUCTING, GRILLES AND DAMPERS

a Inspect for moisture and condensation.
Trace the faults and rectify as
X
necessary.

b Inspect ductwork for leaks or damages.

Repair or replace as necessary. X

c Inspect the condition of all support,

brackets and hangers. Rectify or repair
X
as necessary.

d Measure and record the air flow.

Adjust and balance the air flow as
X
necessary.

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Others:

a) Check the performance of the complete air-conditioning plant and adjust

the air volume control dampers as necessary.

b) Instruct the operators responsible for the operation of the plant and
equipment on correct method of operating the plant and equipment, and
on the maintenance points to be watched.

c) Report in writing to the Superintendent Officer any defects observed on

any part or parts of the complete Air-Conditioning Plant and Ancillary
Equipment. The report shall state the cause/s of the defect/s observed
and shall include and estimate of the cost of repairs required.

6 CONSUMABLE MATERIAL

The Contractor shall supply the following consumable materials as and when
required:-

a) All oils and grease required for lubrication of compressors, fan bearings,
motor bearings, pivots and other moving parts.

b) All refrigerant required to replace refrigerant losses in the refrigerant

system.

c) All carbon brushes required to replace worn brushes in electric motors.

d) All consumable filter elements.

e) All electric contact points required to replace worn electric contact points
in switch gears, motor starter gears, electric control gears and electric
relays.

f) All electric fuses required to replace blown fuses.

g) All cotton waste, soap detergent and other cleaning materials required for
cleaning purposes.

The costs of these consumable materials shall not be charged for separately by
the Contractor, but shall be included in the fixed monthly rate quoted by the
Contractor for the Service and Maintenance of the Complete Mechanical System
and Ancillary Equipment after the guarantee period.

7 REPAIRS

The Contractor shall repair defects in the complete Mechanical Systems and
Ancillary Equipment on the instructions of the Superintending Officer. The costs
of such repair shall not be included in the fixed monthly rate quoted by the
Contractor for the Service and Maintenance of the complete Mechanical Systems
and Ancillary Equipment but shall be charged for separately by the Contractor.

All repairs on the complete Mechanical Systems and Ancillary Equipment shall be
guaranteed by the Contractor against defects in workmanship and materials for a

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 Cawangan Kejuruteraan Mekanikal – Edition 1
period of one year to take effect from date of completion of repairs.
During the guarantee period the Contractor shall rectify defects in repairs carried
out by him with no additional charge to the Government.

8 SERVICE AND MAINTENANCE RECORD

The Contractor shall provide a service and maintenance record book for the
complete Mechanical Systems and Ancillary Equipment being serviced and
maintained by him. This record book shall be kept in the plant room or control
room of the Mechanical System and Ancillary Equipment being serviced and
maintained, and brief details of all service, maintenance and repairs carried out
on the complete Mechanical System and Ancillary Equipment shall be entered by

the Contractor into this book for checking purposes. The address and telephone

number of the Contractor's service station shall also be entered into this record
book to facilitate emergency service calls.

The Contractor shall also keep an accurate detailed record in duplicate of all
service, maintenance and repair work carried out by him on the complete
Mechanical System and Ancillary Equipment. This record shall be in the form of a
Maintenance/Repair Sheet, and shall be countersigned by the Superintending
Officer each time the Mechanical Systems and Ancillary Equipment is attended to
by the Contractor.

9 RATES FOR SERVICE AND MAINTENACE

The rates for the Service and Maintenance of the complete Mechanical Systems
and Ancillary Equipment shall be as shown in the Schedule of Prices for this
Contract.

These rates shall be quoted for by the Contractor at the time he submits his
tender, and shall hold good for the period of THREE years commencing from the
end of the free maintenance period. The Contractor may be required to enter into
a contract for the above period with the Government on the Standard Form of
Contract for Service and Maintenance of Mechanical Systems and Ancillary
Equipment (a copy of this Standard Form may be inspected at the Office of the
Pengarah Kanan, Cawangan Kejuruteraan Mekanikal, Ibu Pejabat J.K.R.
Malaysia, Kuala Lumpur.

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