TECHNICAL REPORT ON THE REHABILIATION EFFORTS FOR THE TWO (2) UNITS OF TRANE RECIPROCATING CHILLER (MODEL # ECGAV

21PRA HDEA4 M2N11 12001 0000S) 19 June 2011 I. Background: The Trane reciprocating chillers were installed way back in 1992 (as per nameplate installed in the unit) to serve as a back-up unit for the hydronic system for the cooling load in B3 Command Center in case of sudden power failure. Each chiller consists of two (2) 60TR reciprocating compressors (Trane Model # CRHR600X2HBO) which serve as one lead and one lag units each. Synopsis: This technical report will cover the actions done prior the actual repairs on the unit to see if the chillers are still in good working condition. It has been observed that the chillers were non-operational for the past 8 years, in which the previous maintenance contractors has tried and failed to repair the chillers and the hydronic system as well.

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Analysis / Observations: We have conducted a thorough inspection and test run on the units to see what extent of repairs should be done. Here is the list of observations we have obtained for each section for the chillers and its hydronic system: A. Compressors: 1. All compressors have evident oil leakage marks on its junction terminal lugs in which the o-rings protecting the terminal lugs had been damaged. This may have been caused by high oil temperature in the crankcase during operation. 2. The motor windings on all compressors are in good condition, without any damage on its wirings. 3. The thrust bearing at the lag compressor in Trane Chiller #1 is damaged and needs to be replaced. 4. All compressors (except the lag compressor in Chiller # 1 as stated in item #3) are in good condition, except for the oil leakage observation stated in item #1. 5. All compressors are required to have all its gaskets (overhauling gasket kit) changed due to wear and deterioration during long non-operation of the units. 6. All compressors should have its oil changed (approximately 12 liters for each compressor) 7. The core filters for each compressor should be changed as well. 8. The pressure gauges (HP, LP, oil) on each compressor are defective and needs to be replaced. 9. All compressors should be subjected to leak test (Nitrogen) and vacuum test. This should be done after the compressors have been repaired as such. 10. All compressors should be charged with new R-22 refrigerant (approximately 24kg each compressor) after the necessary leak test and vacuum tests are performed. B. Condensers: 1. All the condenser fans (four fans each chiller) are in good working condition. 2. We have cleaned the condenser coils with water during the rehabilitation works. 3. The entire system (evaporator coils, condenser coils and the compressor) should be subjected for leak test and vacuum test prior charging of new refrigerant. C. Evaporators: 1. The evaporator shell insulation pads and insulation tubing for all chillers should be replaced. 2. The entire system (evaporator coils, condenser coils and the compressor) should be subjected for leak test and vacuum test prior charging of new refrigerant. D. Controls / Instrumentation 1. The PLC controllers for both chillers are in good working condition. It only needs to be reprogrammed upon normal operation conditions to establish the setpoints.

2. The field wiring diagram in the control panel is missing and need to request from Trane for a copy of the wiring diagram for future reference. 3. There is a need to revise the wiring on the crankcase heater connection due to the heaters were energized during operation, when it should be de-energized. This particular problem may have caused the high temperature on the crankcase oil which caused the o-rings in the terminal lug to fail and oil leakage thus followed. 4. The contactors for all compressors should be replaced due to severe wearing on the contact points during operation. This will cause high amperage and damage on the motor windings. 5. The on-delay timer blocks on the relays are defective and needs to be replaced. 6. The phase monitoring relay (which protects the compressor motor during power failure and single-phase connection) is defective and needs to be changed as well. 7. The flow switches connected to the chilled water supply is defective and needs to be replaced. 8. The solenoid valves connected to the low-side system is defective and needs to be replaced. 9. The thermostatic expansion valves (TXV) are in good condition and needs only to be recalibrated during test run operation.

E. Chilled Water Pumps

1. The chilled water pumps installed are two (2) units of 18.5KW KSB Centrifugal pump. 2. The pump is in good working condition with no problems or pump shaft stock-up 3. As per observation, the pumps installed are quite small considering the capacity of the two chillers (at 120TR each chillers) and the proximity of the AHUs to be supplied, and the length of the hydronic piping (approximately 200m of pipe length for each supply and return from the chillers up to B3 Air Handling Units) 4. We will observe the performance of the chilled water pumps after the repairs on the chillers are finished. F. Chilled Water Piping System 1. The isolation valve in Chiller #1 is defective and needs to be replaced. 2. The chilled water thermometers are defective and needs to be replaced. 3. The chilled water pressure gauges are defective and needs to be replaced. 4. There are no evident leakage on the entire piping system 5. The make-up water system is directly connected to the domestic water connection. 6. There is no three-way control valve connection on the hydronic system. This particular design setup is only made as an auxiliary chiller to the main York centrifugal chillers and not as a back-up unit for the B3 Air Handling Units. Once the chillers are in normal condition, we should be able to have an option to install a three-way valve connected on the system. IV. Bill of Materials / Spare Parts Here are the needed materials/spare parts for the rehabilitation of the chillers A. Compressors # Description 01 Overhauling Gasket Set (Trane part # KIT02069) 02 Thrust Bearing (Trane part # BRG00290) 03 Crankcase Heater (Trane part # HTR01566) 04 Compressor o-ring (Trane part # RNG00891) 05 Compressor o-ring (Trane part # RNG00413) 06 External Terminal Plate Insulation (Trane part # INS00200) 07 Junction Box Cover Gasket (Trane part # GKT00989) 08 Junction Box Cover Gasket (Trane part # KIT06659) 09 Trane Compressor Oil 10L (Trane part # OIL0025E) 10 Core Filters (this item is purchased already) Qty 4 4 2 30 30 30 4 4 5 4 Unit Sets pcs set Pcs Pcs Pcs Pcs Pcs Drum Pcs

B. Controls # Description 01 Magnetic Contactor 60HP (ABB) 380V / 60Hz / 3-phase Auxiliary contacts: 2-NO and 2-NC Coil Voltage: 220V 02 Thermal Overload Relay 60HP (ABB) 03 HP Pressure Gauge (Trane part # GAG0047E) 04 LP Pressure Gauge (Trane part # GAG0046E) 05 Oil Pressure Gauge (Trane part # GAG0053E) 06 Flow Switch (Trane part # CNT0282E) 07 Solenoid Valves (220V coil voltage) (this item is purchased already) 08 Phase Monitoring Relay (this item is purchased already) 09 On-delay Timer Block (this item is purchased already) C. Other spare parts # Description 01 Refrigerant R-22 (DuPont) 13.6kg 02 Rubber Insulation Tubing 4 03 Rubber Insulation Mat 1 x 4 x 8 04 Insulation Canvas Tape 05 Copper male adapter 1 06 Terminal lugs 07 Gate Valve 3 Make: Crane or Stockham Flanged-type ANSI standard 08 Thermometer (Mercurial-type) -10C to 100C range 09 Pressure Gauge 100mm dia (0psi to 250psi range) V. Work Plan for rehabilitation works for the units

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1. Purchase/preparation of the materials and spare parts needed 2. Overhauling of the compressors (includes replacement of the overhauling gaskets and cleaning of the junction boxes, replacement of the thrust bearing for the lag unit in Chiller 1) 3. Installation of the field control units (solenoid valves, pressure and temperature gauges, flow control switches) 4. Perform Nitrogen leak test on all compressors, evaporators and condenser coils. 5. Perform Vacuum test on all compressors 6. Repair and re-wiring (if necessary) of both control panels 7. Perform pre-sequence testing on the controls to check the sequencing of the controls for condenser fans and compressors 8. Charging of new compressor oil and refrigerant to the system for both chillers 9. Replacement of the isolation valves on the chilled water line 10. Replacement with fresh chilled water onto the system 11. Checking the performance of the chilled water pump 12. Cleaning of evaporator and condenser coils 13. Installation of new insulation on the evaporator shells 14. Final check on the controls and compressor prior test run. 15. Perform test run on the chillers and evaluate its performance 16. Commissioning of the chillers to reintroduce to the main system and for separate cooling load for B3 Air Handling Units