A detailed ABSORBTION CHILLER SEMI ANNUALLY preventive maintenance checklist
General Information
Visual Inspection
- Inspect all joints and connections.
- Look for moisture or wet spots.
- Check for oil stains, indicating refrigerant leaks.
- Use a leak detection solution if necessary.
- Look for tears, cracks, or missing sections.
- Check for signs of moisture or mold.
- Ensure insulation is secure and properly fitted.
- Replace any damaged insulation promptly.
- Inspect all surfaces for discoloration.
- Check for flaking or peeling paint.
- Look for any exposed metal surfaces.
- Treat any corrosion immediately to prevent further damage.
- Remove any items such as tools or materials.
- Ensure no vegetation is close to the unit.
- Check for any trash or debris buildup.
- Maintain a clear space of at least 3 feet.
- Look for puddles or wet areas.
- Identify potential sources of leaks or drainage issues.
- Ensure proper drainage away from the unit.
- Address any water issues to prevent damage.
- Check for any visible damage or misalignment.
- Ensure all screws or fasteners are intact.
- Verify that panels close securely.
- Replace any missing or damaged panels.
- Inspect for droppings or nesting materials.
- Check for entry points or burrows nearby.
- Use traps or deterrents if necessary.
- Maintain cleanliness to avoid attracting pests.
- Check for any faded or damaged labels.
- Ensure all safety warnings are visible.
- Replace any missing signage.
- Confirm compliance with safety regulations.
- Check for visible clogs or buildup.
- Inspect connections for leaks or corrosion.
- Ensure proper slope and flow of the lines.
- Clear any blockages found during inspection.
- Look for rust, leaks, or discoloration.
- Inspect joints and connections closely.
- Check for proper insulation on pipes.
- Address any signs of wear immediately.
- Ensure brackets are firmly attached.
- Look for cracks or bent components.
- Check for rust or deterioration.
- Tighten or replace any loose or damaged parts.
- Remove any dust or dirt buildup.
- Clean spills or stains promptly.
- Ensure the area is organized.
- Schedule regular cleaning to maintain standards.
- Inspect openings for any blockages.
- Remove debris or dust buildup.
- Ensure airflow is unrestricted.
- Check for proper function of ventilation systems.
Cooling System Check
- Visual inspection for dirt or debris.
- Remove any visible obstructions.
- Use a soft brush or cloth for cleaning.
- Check for bent fins or damage.
- Ensure airflow is not restricted.
- Inspect for mineral deposits or buildup.
- Use a suitable cleaner if scaling is present.
- Check for proper water flow through evaporator.
- Monitor for signs of corrosion.
- Document any required maintenance actions.
- Check the cooling tower for unusual noise.
- Inspect for leaks around joints and connections.
- Ensure water is circulating properly.
- Monitor the overall condition of the structure.
- Test the tower’s ability to dissipate heat.
- Examine pipes for visible rust or wear.
- Check joints and fittings for leaks.
- Look for signs of water pooling.
- Ensure insulation is intact and not damaged.
- Document any repairs needed.
- Manually operate each valve to check function.
- Inspect for signs of leaks or wear.
- Ensure valves are fully open or closed as needed.
- Lubricate moving parts if necessary.
- Replace any faulty valves.
- Listen for unusual noises from fans.
- Measure fan speed with a tachometer.
- Check for proper alignment and mounting.
- Inspect electrical connections for wear.
- Clean fan blades if necessary.
- Visually inspect fill media for debris.
- Remove and clean fill media if dirty.
- Replace damaged or degraded fill media.
- Ensure proper installation of new media.
- Document changes made.
- Check for organic growth or sediment.
- Remove debris and clean surfaces.
- Use appropriate biocides for algae.
- Inspect for signs of deterioration.
- Maintain water levels to prevent stagnation.
- Check float valve for proper operation.
- Inspect for leaks around the valve.
- Ensure water levels are within specifications.
- Clean any obstructions in the float mechanism.
- Replace the float valve if faulty.
- Check distribution nozzles for blockages.
- Ensure even distribution of water.
- Inspect pipes for leaks or corrosion.
- Adjust nozzles for optimal coverage.
- Document any maintenance performed.
- Use calibrated reference instruments for testing.
- Adjust sensors to ensure accuracy.
- Check sensor wiring and connections.
- Document calibration results.
- Replace any faulty sensors.
- Use accurate thermometers to measure temperature.
- Record inlet and outlet temperatures.
- Calculate differential and compare to specs.
- Investigate any significant deviations.
- Document findings for analysis.
- Test water for chemical concentration.
- Adjust chemicals as necessary.
- Review treatment logs for compliance.
- Inspect for signs of scaling or corrosion.
- Document chemical levels and adjustments.
- Remove strainers or filters from system.
- Clean thoroughly with appropriate methods.
- Check for wear or damage.
- Reinstall ensuring proper sealing.
- Document cleaning and any repairs.
- Measure flow rates at various points.
- Compare against system specifications.
- Adjust valves or pumps as necessary.
- Document flow rate adjustments.
- Monitor system performance post-adjustment.
- Use calibrated meters for testing.
- Record pH and conductivity readings.
- Compare results with required specifications.
- Adjust chemical treatments if needed.
- Document findings for future reference.
- Inspect insulation for visible damage.
- Check for moisture or mold growth.
- Repair or replace damaged insulation.
- Ensure insulation is properly sealed.
- Document all repairs made.
Refrigerant System
- Use a calibrated gauge to measure refrigerant levels.
- Compare readings to manufacturer specifications.
- Adjust refrigerant charge if necessary.
- Document the measurements for future reference.
- Visually examine all lines for signs of wear and corrosion.
- Use a leak detection solution to check for leaks.
- Repair or replace damaged lines as needed.
- Tighten any loose fittings to prevent leaks.
- Connect pressure gauges to both high and low sides.
- Record the pressure readings.
- Compare with specified limits in the service manual.
- Adjust system parameters if pressures are out of range.
- Inspect all flow paths and components.
- Clear any obstructions or debris.
- Ensure valves are open and functioning correctly.
- Confirm that flow is steady and consistent.
- Examine the expansion device for leaks or blockages.
- Check for smooth operation during system cycling.
- Replace any worn or damaged components.
- Monitor for unusual noises or vibrations.
- Test each solenoid valve for proper electrical operation.
- Ensure valves open and close as intended.
- Inspect for signs of wear or corrosion.
- Replace any malfunctioning solenoid valves.
- Use thermometers to measure temperatures at evaporator and condenser.
- Calculate superheat and subcooling values.
- Compare results to manufacturer specifications.
- Adjust settings if values are outside acceptable ranges.
- Examine the sight glass for clarity.
- Look for bubbles indicating low refrigerant levels.
- Check for obstructions around the sight glass.
- Replace the sight glass if damaged or unclear.
- Locate and remove filters or strainers from the system.
- Clean or replace filters as necessary.
- Inspect for debris and blockages.
- Reinstall filters securely before system operation.
- Use thermocouples or thermometers at key locations.
- Record temperature readings at each point.
- Compare with ideal temperature profiles.
- Investigate discrepancies to identify potential issues.
- Test safety and pressure relief valves for proper operation.
- Check for leaks around valve seals.
- Replace any faulty or leaking valves.
- Document valve condition and maintenance performed.
- Record any refrigerant losses during maintenance.
- Follow proper protocols for refrigerant recovery.
- Ensure compliance with local environmental regulations.
- Maintain accurate records for regulatory purposes.
- Check the system label for refrigerant type.
- Ensure only specified refrigerants are used.
- Verify that no mixing of refrigerants has occurred.
- Document the refrigerant type in maintenance records.
Electrical Components
- Look for frayed wires or loose terminals.
- Check for discoloration or oxidation on connectors.
- Ensure all connections are tight and secure.
- Use a multimeter to test continuity.
- Inspect fuses for any signs of blowouts or damage.
- Test circuit breakers by toggling them on and off.
- Replace any non-functional fuses or breakers.
- Document any findings for maintenance records.
- Power on the control panel and check display functionality.
- Verify that all indicator lights are illuminated as expected.
- Test button responses to ensure they are working.
- Document any anomalies or malfunctions.
- Check for any visible damage or burnt areas on wires.
- Look for signs of melting or charring.
- Ensure insulation is intact and not frayed.
- Replace any damaged wiring immediately.
- Inspect grounding rods and connections for corrosion.
- Ensure all grounding wires are securely connected.
- Test the grounding system with a multimeter.
- Document the condition of all grounding points.
- Use a multimeter to measure voltage at terminals.
- Record current draw at various points in the circuit.
- Compare measurements to manufacturer specifications.
- Address any deviations from normal ranges.
- Activate the emergency shut-off switch to test functionality.
- Ensure the system shuts down as expected.
- Reset the switch and confirm it returns to normal.
- Document the test results.
- Access the control system software interface.
- Check for any available updates from the manufacturer.
- Review error logs for any recorded issues.
- Implement necessary updates and document changes.
- Check relay contacts for pitting or burning.
- Test relay operation manually to ensure responsiveness.
- Inspect contactor coils for signs of overheating.
- Replace any faulty relays or contactors.
- Inspect seals and gaskets for integrity.
- Check for any signs of moisture ingress.
- Ensure enclosures are tightly closed and secured.
- Replace any damaged seals immediately.
- Test each indicator light for proper illumination.
- Activate alarms to ensure they sound as expected.
- Document any non-functional lights or alarms.
- Replace faulty components as necessary.
- Create a log of noted loose connections.
- Record any abnormal voltage or current readings.
- Prioritize follow-up actions based on severity.
- Ensure documentation is clear and accessible.
- Use a soft brush or vacuum to remove dust.
- Avoid using moisture or liquids near electrical parts.
- Inspect for any build-up that may cause overheating.
- Perform cleaning regularly as part of maintenance.
Mechanical Components
- Use the recommended lubricant type.
- Apply lubricant to bearings, gears, and any other moving parts.
- Ensure excess lubricant is wiped away to prevent accumulation.
- Follow the manufacturer's schedule for intervals and amounts.
- Check belts for cracks, fraying, or glazing.
- Ensure belts are properly aligned and tensioned.
- Inspect pulleys for wear and alignment.
- Replace any worn components as necessary.
- Listen for unusual noises or vibrations.
- Measure motor temperature during operation.
- Check alignment with other components using a straightedge.
- Adjust or realign as needed to prevent wear.
- Examine for signs of corrosion or build-up.
- Use appropriate cleaning agents to remove fouling.
- Ensure all passages are clear and unobstructed.
- Check for thermal performance after cleaning.
- Use a vibration meter to assess levels.
- Look for loose components or misalignment.
- Tighten any loose bolts or connections.
- Replace or repair components showing excessive vibration.
- Check all mounting hardware for tightness.
- Ensure brackets are not corroded or damaged.
- Replace any damaged supports or hardware.
- Confirm structural integrity of the mounting points.
- Look for any signs of wear, damage, or moisture.
- Replace any damaged insulation to prevent energy loss.
- Ensure insulation is securely fastened.
- Check for proper thickness and coverage.
- Inspect all guards for damage or missing parts.
- Ensure screws or fasteners are intact and secure.
- Check that guards do not obstruct ventilation.
- Replace any guards that are not secure.
- Check for leaks around the valve.
- Test operation during system run to assess performance.
- Clean any debris or obstructions from the valve.
- Replace the valve if malfunctioning.
- Inspect all joints, seals, and fittings.
- Use a leak detection solution to identify leaks.
- Tighten or replace components showing signs of leakage.
- Document any findings for future reference.
- Manually operate dampers and valves to check movement.
- Listen for unusual noises during operation.
- Ensure they open and close fully without obstruction.
- Repair or replace any faulty dampers or valves.
- Inspect the surfaces for signs of corrosion.
- Check for any obstructions in airflow.
- Clean fins and tubes for optimal heat exchange.
- Document any signs of wear for future action.
- Analyze maintenance logs for frequency of repairs.
- Identify patterns that may indicate underlying problems.
- Schedule further inspections for components showing anomalies.
- Document findings for future reference.
Water Quality
- Use a calibrated pH meter to measure pH levels.
- Measure conductivity using a conductivity meter.
- Record measurements for comparison with manufacturer specifications.
- Adjust chemical treatments based on results as needed.
- Turn off the system and isolate strainers and filters.
- Remove strainers and filters carefully.
- Rinse with clean water to remove debris.
- Reinstall after ensuring they are clean and dry.
- Review chemical treatment guidelines from the manufacturer.
- Check existing chemical levels in the system.
- Add treatment chemicals as per the guidelines.
- Document the amounts added for future reference.
- Use a water hardness test kit to determine hardness.
- Follow the kit instructions for accurate results.
- Record the hardness level for trend analysis.
- Adjust treatment methods based on findings if necessary.
- Visually inspect tanks and piping for any growth.
- Use a microscope if necessary for small growth.
- If found, treat with appropriate biocide.
- Document findings and actions taken for records.
- Shut down the cooling tower and drain water.
- Remove fill media and inspect for debris.
- Clean fill media with a soft brush and water.
- Reinstall fill and ensure proper alignment.
- Use testing kits for biocide and inhibitor levels.
- Compare results with manufacturer specifications.
- Adjust dosing systems as required.
- Document levels and any adjustments made.
- Collect a water sample from the system.
- Use a turbidity meter to measure turbidity levels.
- Perform a dissolved solids test using appropriate methods.
- Record results for compliance checks.
- Review calibration procedures for each sensor.
- Use calibration solutions as recommended.
- Adjust settings based on manufacturer specifications.
- Document calibration dates and results.
- Visual inspection of piping and fittings for scale.
- Use descaling agents to remove buildup where necessary.
- Flush system with clean water post-cleaning.
- Document the inspection and cleaning results.
- Check current feed rate settings against recommendations.
- Adjust feed rates based on water quality tests.
- Document feed rates and any changes made.
- Monitor system response to adjustments.
- Inspect the expansion tank for leaks or corrosion.
- Check pressure levels and ensure they are within range.
- Clean any debris from the tank inlet and outlet.
- Document the condition and any maintenance performed.
- Use flow meters to measure water flow rates.
- Compare results against system specifications.
- Adjust valves or pump settings as necessary.
- Record flow rate measurements for future monitoring.
Operational Tests
- Turn on the chiller and observe initial operation.
- Check for any error messages on the control panel.
- Allow the system to run for a few minutes.
- Verify that all components are functioning smoothly.
- Use calibrated gauges to measure temperatures at inlet and outlet.
- Record pressure readings at various points in the system.
- Ensure readings are within manufacturer specifications.
- Document all measurements for future reference.
- Listen carefully for any grinding, squeaking, or banging sounds.
- Identify the source of any abnormal noises immediately.
- Check for loose components or misalignments.
- Document any findings and take corrective actions.
- Test the chiller at low, medium, and high load settings.
- Observe temperature and pressure variations during each test.
- Ensure that performance remains stable across all conditions.
- Document results and compare with historical data.
- Simulate alarm conditions to test functionality.
- Ensure alarms activate promptly and clearly.
- Check reset functions for all safety controls.
- Document the results of each test.
- Use flow meters to measure flow rates in both loops.
- Compare readings against manufacturer specifications.
- Inspect for blockages or restrictions in the piping.
- Document any discrepancies and make adjustments as needed.
- Adjust the load settings and monitor system response.
- Record the time taken for the system to stabilize.
- Evaluate performance consistency during load changes.
- Note any delays or issues for future reference.
- Measure input power and output cooling capacity.
- Calculate COP using the formula: COP = Cooling Output / Power Input.
- Compare calculated COP with industry standards.
- Document findings and assess efficiency improvements.
- Check pump operation and listen for unusual noises.
- Inspect pump seals and connections for leaks.
- Verify flow rates and pressure outputs match specifications.
- Document the condition and any maintenance required.
- Monitor the chiller's start-stop cycles during operation.
- Ensure the timing aligns with manufacturer settings.
- Check for smooth transitions without delays.
- Document any irregular cycling patterns.
- Use infrared thermometers to check outlet temperatures.
- Compare temperatures against specified operational parameters.
- Inspect for any signs of thermal insulation failure.
- Document all temperature readings.
- Inspect refrigerant lines for signs of wear or damage.
- Use leak detection methods to identify potential leaks.
- Monitor system pressure to ensure proper refrigerant levels.
- Document any leaks and schedule repairs.
- Check VFD settings and ensure they match operational requirements.
- Test the response of VFDs under varying load conditions.
- Inspect control wiring for any signs of wear.
- Document any findings and adjustments made.
- Review control panel settings against operational specifications.
- Make adjustments to temperatures, pressures, and flow rates as needed.
- Test system performance after adjustments.
- Document all changes made for future reference.
- Create a detailed report of all tests conducted.
- Include measurements, observations, and actions taken.
- Ensure reports are stored in an accessible location.
- Review documentation regularly for continuous improvement.
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