A detailed ABSORBTION CHILLER WEEKLY preventive maintenance checklist
1. Safety Precautions
- Wear gloves and goggles as per standard protocols.
- Inspect gear for any damage or wear before use.
- Ensure gear is appropriate for specific tasks.
- Switch off the chiller using the main control panel.
- Apply lockout/tagout devices to prevent accidental reactivation.
- Verify with a voltage tester that the unit is de-energized.
- Gather all personnel and discuss emergency procedures.
- Review evacuation routes and emergency contact numbers.
- Ensure everyone understands their roles in emergencies.
- Wear gloves, goggles, hard hats, and other required safety gear.
- Inspect gear for damages before use.
- Ensure all personal protective equipment is suitable for the task.
- Switch off the power supply to the chiller.
- Use lockout/tagout devices to secure the power source.
- Verify that the chiller cannot be accidentally powered on.
- Review the safety manual specific to the absorption chiller.
- Discuss emergency procedures with the team.
- Ensure everyone knows the location of emergency exits.
- Clear the work area of tools, materials, and debris.
- Identify and remove any slip, trip, or fall hazards.
- Ensure adequate space for safe movement around the chiller.
- Inspect tools for defects or wear before starting work.
- Use only tools that are suitable for the job.
- Ensure all equipment is properly maintained.
- Look for any oil, refrigerant, or chemical leaks.
- Clean up any spills immediately and safely.
- Report any leaks to the supervisor.
- Open windows or doors to allow fresh air circulation.
- Use fans if necessary to enhance ventilation.
- Check for gas fumes or odors before starting work.
- Check first aid kit for supplies and equipment.
- Ensure all team members know where the kit is located.
- Review first aid procedures with the team.
- Check that fire extinguishers are in place and accessible.
- Verify that extinguishers are charged and inspected.
- Review the use of fire extinguishers with the team.
- Confirm all personnel have received safety training.
- Review each person's responsibilities during maintenance.
- Ensure communication devices are functional.
- Establish a clear communication method for emergencies.
- Designate a point person for communication during maintenance.
- Ensure everyone understands the communication plan.
- Identify potential hazards related to maintenance tasks.
- Assess risks based on the specific maintenance activities.
- Document findings and address any significant risks.
- Label hazardous materials clearly and correctly.
- Store materials in designated, secure locations.
- Follow all handling and disposal guidelines.
- Wear gloves and goggles as per standard protocols.
- Inspect gear for any damage or wear before use.
- Ensure gear is appropriate for specific tasks.
- Switch off the chiller using the main control panel.
- Apply lockout/tagout devices to prevent accidental reactivation.
- Verify with a voltage tester that the unit is de-energized.
- Gather all personnel and discuss emergency procedures.
- Review evacuation routes and emergency contact numbers.
- Ensure everyone understands their roles in emergencies.
2. Visual Inspection
- Look for wet spots or stains on surfaces.
- Inspect joints, fittings, and connections closely.
- Use a flashlight to enhance visibility in dark areas.
- Listen for hissing sounds that may indicate gas leaks.
- Check for tears, holes, or missing sections.
- Ensure insulation is securely fastened to surfaces.
- Look for signs of moisture buildup or mold.
- Assess insulation thickness for effectiveness.
- Inspect metal surfaces for discoloration or flaking.
- Pay attention to joints and seams for deterioration.
- Use a wire brush to check underneath rust spots.
- Consider the need for protective coatings if corrosion is found.
- Manually operate each valve to ensure smooth movement.
- Look for leaks or corrosion around valve bodies.
- Check for proper alignment and secure fittings.
- Verify that valve handles are intact and functional.
- Look for dark stains or pooling liquids.
- Inspect seals and gaskets for integrity.
- Use absorbent materials to check for hidden leaks.
- Identify the source of any fluids if found.
- Observe the chiller during operation for unusual movement.
- Check mounting and leveling of the chiller unit.
- Listen for unusual noises that indicate mechanical issues.
- Ensure all fasteners are tight and secure.
- Inspect supports for signs of corrosion or wear.
- Ensure brackets are securely mounted and aligned.
- Check for loose or missing fasteners.
- Verify that piping is not sagging or misaligned.
- Check for any visible damage to the cooling tower structure.
- Inspect fans and motors for proper operation.
- Look for algae growth or debris in the water basin.
- Ensure water levels are appropriate and circulation is effective.
- Inspect heat exchanger surfaces for buildup or discoloration.
- Look for signs of reduced efficiency or performance.
- Consider cleaning procedures if scaling is present.
- Verify that flow rates are within specifications.
- Check for tight seals and proper alignment of panels.
- Inspect hinges and latches for functionality.
- Look for cracks or damage in covers.
- Ensure no foreign objects obstruct access.
- Remove any debris, leaves, or obstructions.
- Check that drainage systems are clear and functional.
- Ensure there are no pooling areas that could cause issues.
- Maintain an organized area to facilitate maintenance access.
- Look for nests, droppings, or signs of pest activity.
- Inspect for debris that could attract pests.
- Consider traps or deterrents if necessary.
- Maintain a clean perimeter to reduce pest risk.
- Inspect all labels for fading or damage.
- Replace any missing or illegible signage.
- Ensure safety instructions are easily accessible.
- Verify compliance with safety regulations.
3. Fluid Levels
- Locate the sight glass or level gauge.
- Ensure chilled water and hot water levels are within recommended ranges.
- Record the readings for monitoring.
- Add water if levels are below the minimum threshold.
- Use a refractometer or hydrometer for measurement.
- Compare the reading to the manufacturer's specifications.
- Adjust concentration by adding absorbent as needed.
- Document the concentration level for future reference.
- Identify the coolant reservoir.
- Check the coolant level against the markings.
- Add coolant if levels are low, ensuring compatibility.
- Seal the reservoir securely after topping off.
- Locate the sight glass or level gauge.
- Ensure chilled water and hot water levels are within recommended ranges.
- Record the readings for monitoring.
- Add water if levels are below the minimum threshold.
- Use a refractometer or hydrometer for measurement.
- Compare the reading to the manufacturer's specifications.
- Adjust concentration by adding absorbent as needed.
- Document the concentration level for future reference.
- Identify the coolant reservoir.
- Check the coolant level against the markings.
- Add coolant if levels are low, ensuring compatibility.
- Seal the reservoir securely after topping off.
4. Performance Checks
- Use calibrated thermometers.
- Position sensors at designated inlet and outlet points.
- Allow sufficient time for temperature stabilization.
- Record readings in a maintenance log.
- Compare with manufacturer specifications.
- Inspect pressure gauges for accuracy and functionality.
- Ensure gauges are clean and free from obstructions.
- Record pressure values in the maintenance log.
- Verify against standard operating pressures.
- Look for any unusual fluctuations.
- Inspect the control panel for indicator lights.
- Check for any active alarms or error codes.
- Document any issues found in the maintenance log.
- Reset alarms if applicable, following protocol.
- Test the functionality of control buttons and interfaces.
- Use calibrated thermometers.
- Position sensors at designated inlet and outlet points.
- Allow sufficient time for temperature stabilization.
- Record readings in a maintenance log.
- Compare with manufacturer specifications.
- Inspect pressure gauges for accuracy and functionality.
- Ensure gauges are clean and free from obstructions.
- Record pressure values in the maintenance log.
- Verify against standard operating pressures.
- Look for any unusual fluctuations.
- Inspect the control panel for indicator lights.
- Check for any active alarms or error codes.
- Document any issues found in the maintenance log.
- Reset alarms if applicable, following protocol.
- Test the functionality of control buttons and interfaces.
- Use flow meters at designated points.
- Ensure flow meters are calibrated and functional.
- Record flow rates in the maintenance log.
- Compare with design specifications.
- Adjust valves as necessary to optimize flow.
- Calibrate the refractometer before use.
- Collect samples of the absorption solution.
- Measure concentration and record findings.
- Compare results with manufacturer guidelines.
- Adjust solution concentration if necessary.
- Measure temperatures at inlet and outlet points.
- Calculate the temperature differential.
- Record the differential in the maintenance log.
- Compare with expected performance metrics.
- Investigate any significant deviations.
- Obtain necessary data: cooling output and energy input.
- Calculate COP using the formula: COP = Cooling Output / Energy Input.
- Document the COP in the maintenance log.
- Compare with baseline performance standards.
- Identify any performance issues based on COP.
- Check operational status of pumps and fans.
- Listen for unusual noises or vibrations.
- Inspect for leaks or wear on components.
- Record performance data in the maintenance log.
- Assess against manufacturer specifications.
- Visually examine heat exchanger surfaces.
- Check for signs of corrosion or buildup.
- Use cleaning tools if necessary.
- Record findings in the maintenance log.
- Plan for chemical cleaning if scaling is present.
- Operate the chiller and listen attentively.
- Identify any abnormal noises (grinding, squeaking).
- Document any concerns in the maintenance log.
- Investigate potential sources of noise.
- Schedule repairs if needed.
- Use a vibration meter to assess levels.
- Check for excessive vibrations on components.
- Record vibration data in the maintenance log.
- Investigate any areas with abnormal vibration patterns.
- Adjust or repair misaligned components as needed.
- Collect utility bills and usage data.
- Analyze trends in energy consumption.
- Document any unusual spikes or reductions.
- Compare with historical performance data.
- Identify areas for potential energy savings.
5. Component Inspection
- Check for dirt or mineral buildup inside the evaporator.
- Use a soft brush or cloth for light cleaning.
- If fouling is severe, consider chemical cleaning.
- Inspect for physical damage or leaks.
- Look for any obstructions on the condenser coils.
- Clear away any dirt, leaves, or debris.
- Check air intake areas for blockages.
- Inspect for any signs of corrosion or leaks.
- Listen for unusual noises indicating malfunction.
- Inspect seals and connections for any fluid leaks.
- Ensure the pump is running at the correct RPM.
- Check the pump’s vibrations; they should be minimal.
- Look for rust or discoloration on the absorber surface.
- Inspect welds and joints for integrity.
- Check for any physical damage or leaks.
- Ensure that insulation is intact and unbroken.
- Inspect for any visible leaks or moisture.
- Look for signs of scaling or fouling on surfaces.
- Use a pressure test if necessary to find hidden leaks.
- Ensure connections are tight and secure.
- Manually open and close each valve to check operation.
- Inspect for any signs of leaks around valve bodies.
- Ensure handles are secure and not worn.
- Check for proper alignment and seating.
- Look for visible signs of rust or corrosion.
- Check joints and fittings for leaks.
- Inspect pipe insulation for damage.
- Ensure there are no kinks or obstructions.
- Look for tears, moisture, or signs of wear.
- Replace damaged insulation to maintain efficiency.
- Check for gaps that could lead to energy loss.
- Ensure insulation is securely fastened.
- Manually operate valves to check for smooth action.
- Monitor for any delays in response.
- Inspect for leaks at valve connections.
- Ensure actuators are functioning correctly.
- Check the pressure gauges against manufacturer specifications.
- Look for signs of refrigerant leaks.
- Ensure that the system is properly charged.
- Document any discrepancies for further analysis.
- Listen for any unusual noises during operation.
- Ensure the valve opens and closes smoothly.
- Inspect for leaks around the valve body.
- Check temperature differences across the valve.
- Listen for any irregular sounds or vibrations.
- Check for proper alignment of motor and drive.
- Inspect bearings and lubrication levels.
- Ensure all mounting hardware is secure.
- Inspect all wiring and connections for signs of wear.
- Look for corrosion on terminals and connectors.
- Ensure connections are tight and secure.
- Check for any frayed or damaged wires.
- Test safety valves to ensure they open at the correct pressure.
- Inspect for any signs of leaks or corrosion.
- Ensure access to safety devices is unobstructed.
- Document any issues for immediate attention.
6. Electrical System
- Look for frayed wires, loose terminals, and corrosion.
- Ensure connections are tight and free from rust.
- Use a flashlight for better visibility during inspection.
- Inspect fuses for signs of blown elements.
- Test circuit breakers to confirm they trip correctly.
- Replace any defective fuses or reset tripped breakers.
- Activate each relay and switch to check function.
- Listen for clicks or observe indicator lights.
- Replace any non-responsive components immediately.
- Look for frayed wires, loose terminals, and corrosion.
- Ensure connections are tight and free from rust.
- Use a flashlight for better visibility during inspection.
- Inspect fuses for signs of blown elements.
- Test circuit breakers to confirm they trip correctly.
- Replace any defective fuses or reset tripped breakers.
- Activate each relay and switch to check function.
- Listen for clicks or observe indicator lights.
- Replace any non-responsive components immediately.
- Check grounding connections for tightness and integrity.
- Use a multimeter to test grounding continuity.
- Ensure grounding complies with safety standards.
- Use a multimeter to check voltage at specified points.
- Compare readings against manufacturer’s specifications.
- Document any voltage irregularities found.
- Look for cracks, cuts, or frayed areas on insulation.
- Check for exposure of bare wires.
- Replace damaged wiring to prevent electrical failures.
- Check that all panel doors are closed tightly.
- Inspect latches and locks for proper function.
- Ensure panels are free from obstructions.
- Activate each emergency shut-off switch.
- Confirm that systems respond as intended.
- Replace any non-functioning switches immediately.
- Inspect components for discoloration or deformation.
- Feel for excessive heat during inspection.
- Replace any overheated components to prevent failures.
- Use a soft brush or vacuum to remove dust.
- Avoid using water or cleaning agents on electrical parts.
- Ensure enclosures are free from foreign objects.
- Check labels for clarity and completeness.
- Replace any faded or missing labels.
- Ensure identification matches the actual components.
- Compare installed components with the schematic diagram.
- Note any discrepancies or missing components.
- Update schematic documentation as necessary.
- Record all observations in the maintenance log.
- Note any repairs performed and parts replaced.
- Ensure documentation is clear and accessible.
7. Cleaning
- Turn off the chiller and ensure it's safe to clean.
- Use a soft brush or vacuum to remove loose dirt.
- Apply a coil cleaner to the coils as per manufacturer instructions.
- Rinse thoroughly with water to remove cleaner residue.
- Inspect the area surrounding the chiller for debris.
- Clear away any leaves, dirt, or other obstructions.
- Ensure proper airflow around the unit for efficiency.
- Dispose of debris in accordance with safety regulations.
- Use a damp cloth with mild detergent to wipe surfaces.
- Pay attention to areas with visible dirt or buildup.
- Dry surfaces with a clean, dry cloth to prevent moisture accumulation.
- Check for any signs of rust or corrosion during cleaning.
- Turn off the chiller and ensure it's safe to clean.
- Use a soft brush or vacuum to remove loose dirt.
- Apply a coil cleaner to the coils as per manufacturer instructions.
- Rinse thoroughly with water to remove cleaner residue.
- Inspect the area surrounding the chiller for debris.
- Clear away any leaves, dirt, or other obstructions.
- Ensure proper airflow around the unit for efficiency.
- Dispose of debris in accordance with safety regulations.
- Use a damp cloth with mild detergent to wipe surfaces.
- Pay attention to areas with visible dirt or buildup.
- Dry surfaces with a clean, dry cloth to prevent moisture accumulation.
- Check for any signs of rust or corrosion during cleaning.
- Turn off the chiller and allow it to cool down.
- Remove any access panels to reach the evaporator coils.
- Use a soft brush or vacuum to clean the coils.
- Ensure no debris blocks airflow to the coils.
- Locate the air filters and remove them carefully.
- Inspect filters for dirt and damage; replace if necessary.
- Clean reusable filters with water or a vacuum.
- Reinstall filters securely before restarting the chiller.
- Turn off the chiller and isolate the water circuits.
- Use a suitable flushing agent as per manufacturer guidelines.
- Run the flushing agent through the circuits for the recommended duration.
- Drain and refill with clean water or solution.
- Remove any stored items or clutter from the vicinity.
- Inspect for signs of pests and take appropriate measures.
- Maintain clear access for maintenance personnel.
- Ensure proper drainage to avoid standing water.
- Access the drain pan by removing necessary panels.
- Check for clogs and remove any debris.
- Clean the pan with a mild detergent and rinse thoroughly.
- Ensure drainage pathways are clear and functioning.
- Turn off power to the chiller for safety.
- Carefully use a vacuum with a soft brush attachment.
- Blow compressed air to remove stubborn dust from crevices.
- Avoid direct contact with sensitive electrical parts.
- Inspect insulation for damage or wear and replace if necessary.
- Clean insulation surfaces with a damp cloth if dirty.
- Ensure insulation is securely in place and without gaps.
- Check for condensation issues that may require attention.
8. Documentation
9. Final Checks
- Inspect each access panel for proper alignment.
- Check for any signs of wear or damage.
- Close panels firmly and ensure latch mechanisms engage.
- Document any panels that require attention.
- Inspect all safety guards for proper installation.
- Ensure no guards are missing or damaged.
- Check that guards are securely fastened.
- Document any issues with safety guards.
- Check all system indicators for normal status.
- Ensure no alarms are triggered.
- Power up the chiller and monitor startup sequence.
- Listen for unusual noises during startup.
- Examine all joints and seals for moisture.
- Use a flashlight to inspect hard-to-see areas.
- Report any leaks found during inspection.
- Consider using leak detection solution if necessary.
- Conduct a physical inventory of all tools.
- Check under and around the chiller for forgotten items.
- Return tools to their designated storage locations.
- Ensure no hazardous materials are left behind.
- Inspect labels for wear or fading.
- Replace any illegible labels immediately.
- Ensure safety notices are positioned correctly.
- Document any labels that need replacement.
- Check for entries regarding unresolved maintenance tasks.
- Prioritize outstanding issues based on severity.
- Assign tasks to relevant personnel for follow-up.
- Document any new issues discovered during maintenance.
- Inspect water supply lines for pressure and flow.
- Check drainage for clogs or backups.
- Test system operation to ensure proper functioning.
- Report any anomalies to maintenance supervisor.
- Activate emergency shut-off system and observe response.
- Check for alarms or notifications triggered by shutdown.
- Ensure system resets correctly after testing.
- Document testing results and any required actions.
- Compare settings against standard operating procedures.
- Adjust settings based on current operational needs.
- Document any changes made to control panel configurations.
- Ensure all indicators show normal operation post-adjustment.
- Inspect the entire maintenance area for debris.
- Ensure that all safety equipment is in place.
- Verify that exit routes are clear and accessible.
- Report any safety hazards found during the walkthrough.
- Review all maintenance records for completeness.
- File documentation in the designated maintenance folder.
- Confirm that all signatures are obtained where necessary.
- Notify supervisor of completed documentation.
- Prepare a brief report of any issues found.
- Schedule a meeting or send an email to relevant staff.
- Ensure that all critical issues are communicated verbally.
- Follow up to confirm that concerns are addressed.
Use in Manifestly