A detailed Absorption Chiller WEEKLY preventive maintenance Inspection checklist
1. Safety Precautions
2. General Inspection
3. Fluid Levels
- Locate the solution level gauge on the absorber.
- Ensure the level is within the manufacturer's specified range.
- Add ammonia/water solution if levels are low.
- Document any adjustments made.
- Access the refrigerant sight glass.
- Check for proper refrigerant level, looking for bubbles.
- If levels are low, consult service manual for recharge procedures.
- Record findings in maintenance log.
- Check the cooling water reservoir for adequate levels.
- Verify the flow rate through the system is consistent.
- Inspect the cooling water piping for blockages or leaks.
- Make adjustments as necessary.
- Locate the solution level gauge on the absorber.
- Ensure the level is within the manufacturer's specified range.
- Add ammonia/water solution if levels are low.
- Document any adjustments made.
- Access the refrigerant sight glass.
- Check for proper refrigerant level, looking for bubbles.
- If levels are low, consult service manual for recharge procedures.
- Record findings in maintenance log.
- Check the cooling water reservoir for adequate levels.
- Verify the flow rate through the system is consistent.
- Inspect the cooling water piping for blockages or leaks.
- Make adjustments as necessary.
- Check the chilled water tank level indicator.
- Ensure it meets the minimum requirement specified by the system.
- Add chilled water if levels are below the threshold.
- Document the findings.
- Locate the hot water level gauge on the generator.
- Verify that the level is within the recommended range.
- Add hot water if levels are insufficient.
- Record any changes made.
- Identify the heat exchange fluid reservoir.
- Check the fluid level against the operational range.
- Top up fluid if necessary, following safety guidelines.
- Note the fluid condition and levels in maintenance records.
- Locate the expansion tank and its level indicator.
- Check that the fluid level is within the designated range.
- Refill if needed, ensuring proper fluid type is used.
- Log the level status.
- Examine the condensate drain for any blockages.
- Ensure that water is draining freely and not pooling.
- Clear any obstructions found in the drain line.
- Record the status of the drain system.
- Use a testing kit to assess chemical levels.
- Compare results against manufacturer specifications.
- Adjust chemical treatments if levels are outside the range.
- Document the results and any corrective actions taken.
- Inspect all visible piping and tanks for moisture or stains.
- Look for corrosion or damage around joints and connections.
- Repair any leaks found immediately.
- Record any issues and actions taken.
4. Temperature and Pressure Readings
- Use calibrated thermometers for accurate measurements.
- Take readings at designated points: evaporator inlet/outlet, condenser inlet/outlet.
- Note ambient temperature for context.
- Document readings in maintenance log for future reference.
- Inspect pressure gauges for visibility and accessibility.
- Record readings from all relevant gauges: high and low pressure.
- Ensure gauges are within calibration dates.
- Log pressure readings in maintenance records.
- Refer to the manufacturer’s specifications for acceptable ranges.
- Compare current readings against specification limits.
- Highlight any discrepancies in maintenance logs.
- Notify maintenance supervisor if readings are outside specifications.
- Check calibration certificates for each gauge.
- Perform calibration checks using standard reference tools.
- Adjust gauges if necessary, following manufacturer guidelines.
- Document calibration status in maintenance records.
- Access historical maintenance logs for reference.
- Analyze data for significant changes over time.
- Flag any unusual trends for further investigation.
- Summarize findings in weekly maintenance reports.
- Examine thermocouples for corrosion or physical damage.
- Check pressure sensors for leaks or abnormal wear.
- Replace any damaged components as necessary.
- Document inspection results in maintenance logs.
- Inspect insulation for wear, tears, or gaps.
- Ensure insulation is securely attached to lines.
- Replace damaged insulation to maintain accuracy.
- Log insulation condition in maintenance records.
- Test pressure relief valves for proper operation.
- Look for signs of leaks or corrosion.
- Replace any malfunctioning valves as needed.
- Record valve condition in maintenance logs.
- Use a hygrometer and thermometer to measure conditions.
- Note ambient conditions in proximity to the chiller.
- Include readings in maintenance logs for context.
- Monitor changes that could impact chiller efficiency.
- Measure inlet and outlet temperatures at each component.
- Calculate temperature differential for both evaporator and condenser.
- Record results to assess system performance.
- Report significant deviations from expected differentials.
- Look for oil spots or residue around fittings and joints.
- Use electronic leak detectors if available.
- Document any signs of leaks in maintenance logs.
- Notify maintenance team for immediate action if leaks are found.
- Ensure chiller is operating under normal load conditions.
- Take all readings at the same time during operation.
- Document operational status during measurements.
- Compare readings against consistent benchmarks.
- Record all deviations in the maintenance log.
- Include details such as time, date, and specific readings.
- Notify relevant personnel for follow-up analysis.
- Maintain thorough documentation for future reference.
5. Component Inspection
6. Electrical Systems
7. Water Treatment
- Collect water samples from various points in the system.
- Test for chemical concentrations using appropriate kits.
- Ensure chemical levels meet manufacturer specifications.
- Adjust chemical dosing as required based on test results.
- Check all equipment for visible wear or damage.
- Ensure equipment is functioning within normal parameters.
- Listen for unusual noises indicating potential issues.
- Record operational status in the maintenance log.
- Examine pipes and components for mineral deposits.
- Look for any slime or discoloration indicating biofilm.
- Use a brush or chemical cleanser to remove buildup.
- Document findings and actions taken in maintenance records.
- Collect water samples from various points in the system.
- Test for chemical concentrations using appropriate kits.
- Ensure chemical levels meet manufacturer specifications.
- Adjust chemical dosing as required based on test results.
- Check all equipment for visible wear or damage.
- Ensure equipment is functioning within normal parameters.
- Listen for unusual noises indicating potential issues.
- Record operational status in the maintenance log.
- Examine pipes and components for mineral deposits.
- Look for any slime or discoloration indicating biofilm.
- Use a brush or chemical cleanser to remove buildup.
- Document findings and actions taken in maintenance records.
- Use a calibrated pH meter for accurate readings.
- Compare results with recommended pH range for chiller.
- Add necessary chemicals to adjust pH levels.
- Log pH adjustments and results for future reference.
- Utilize a conductivity meter for testing.
- Record conductivity readings and compare with standards.
- Evaluate TDS levels and determine if action is required.
- Adjust chemical treatment if TDS exceeds acceptable limits.
- Remove strainers and filters for inspection.
- Clean components using water and appropriate cleaning agents.
- Check for clogs and replace filters as needed.
- Reinstall cleaned or replaced components securely.
- Check pump operation and verify dosing rates.
- Inspect connections for leaks or blockages.
- Test alarms and safety features for functionality.
- Document pump performance and any adjustments made.
- Measure flow rates at various points in the system.
- Ensure flow rates meet design specifications.
- Inspect pumps and valves for proper operation.
- Make adjustments to optimize flow as necessary.
- Check tanks for signs of corrosion or leaks.
- Ensure all seals and gaskets are intact.
- Clean tank exteriors and remove any debris.
- Document tank conditions and any repairs needed.
- Check logs for completeness and accuracy.
- Update any changes in chemical usage or water quality.
- Ensure compliance with regulatory and manufacturer standards.
- File logs appropriately for reference and audits.
- Review inventory levels of chemicals and equipment.
- Contact suppliers for replenishment orders as needed.
- Schedule servicing with qualified technicians.
- Document scheduled services and expected delivery dates.
- Establish a routine for regular monitoring.
- Record any anomalies in performance or water quality.
- Communicate findings to relevant personnel.
- Adjust treatment processes based on documented changes.
8. Lubrication
- Locate oil sight glass on compressors and pumps.
- Ensure oil level is within recommended range.
- Top up with manufacturer-approved oil if low.
- Record oil levels for future reference.
- Identify all moving components requiring lubrication.
- Use appropriate lubricant according to manufacturer specifications.
- Apply lubricant evenly without over-greasing.
- Wipe off excess lubricant to prevent debris accumulation.
- Examine all joints, seals, and connections for signs of leakage.
- Look for oil stains or residue on surrounding surfaces.
- Tighten loose fittings or replace faulty components as needed.
- Document any leaks found for further action.
- Locate oil sight glass on compressors and pumps.
- Ensure oil level is within recommended range.
- Top up with manufacturer-approved oil if low.
- Record oil levels for future reference.
- Identify all moving components requiring lubrication.
- Use appropriate lubricant according to manufacturer specifications.
- Apply lubricant evenly without over-greasing.
- Wipe off excess lubricant to prevent debris accumulation.
- Examine all joints, seals, and connections for signs of leakage.
- Look for oil stains or residue on surrounding surfaces.
- Tighten loose fittings or replace faulty components as needed.
- Document any leaks found for further action.
- Refer to the equipment manual for lubricant specifications.
- Verify viscosity and chemical compatibility with components.
- Label each lubricant container clearly to avoid mix-ups.
- Consult with a lubrication specialist if unsure.
- Use a clean cloth or brush to remove dirt from grease fittings.
- Ensure no debris enters the fitting during lubrication.
- Inspect fittings for damage or blockage.
- Replace fittings if they cannot be cleaned effectively.
- Check lines for cracks, leaks, or abrasions.
- Ensure fittings are secure and free from corrosion.
- Replace any damaged lines or fittings immediately.
- Document findings for maintenance records.
- Identify seals that show signs of wear or damage.
- Remove old seals carefully to avoid further damage.
- Install new seals that match specifications.
- Test for leaks after replacement.
- Review the maintenance log for lubrication frequency.
- Adjust schedules based on operating conditions and usage.
- Ensure all components are lubricated according to the plan.
- Communicate any changes in schedule with the team.
- Perform visual inspections for discoloration or debris.
- Use viscosity testing tools to measure lubricant condition.
- Replace lubricant if it shows signs of contamination.
- Record lubricant condition in the maintenance log.
- Record date, time, and details of lubrication performed.
- Note any issues encountered during the process.
- Include quantities of lubricant used for tracking.
- Review log entries regularly for trends and improvements.
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