A detailed Absorption Chiller WEEKLY preventive maintenance Inspection checklist
1. General Inspection
2. Fluid Levels
3. Fluid System
- Inspect all visible sections of piping.
- Look for rust, pitting, or discoloration.
- Check for any physical damage such as dents.
- Report any findings for further evaluation.
- Check for any visible tears or gaps in insulation.
- Ensure insulation is dry and not moldy.
- Look for signs of water damage or thermal loss.
- Replace any damaged insulation as needed.
- Listen for unusual noises from pumps.
- Ensure valves open and close fully without obstructions.
- Check for vibrations indicating misalignment.
- Inspect for leaks around seals and joints.
- Use calibrated thermometers to check temperatures.
- Monitor temperatures at entry and exit points.
- Ensure readings are within operational specifications.
- Document any temperature anomalies.
- Use flow meters to measure fluid flow.
- Compare readings to manufacturer specifications.
- Look for fluctuations or irregular flow patterns.
- Adjust flow rates if necessary.
- Examine all joint areas for moisture accumulation.
- Use a cloth to wipe and identify the source of leaks.
- Repair any leaks promptly to prevent fluid loss.
- Monitor for future leaks during subsequent inspections.
- Collect fluid samples for laboratory analysis.
- Check pH levels, viscosity, and concentration.
- Compare results to required fluid specifications.
- Replace or treat fluid if quality is inadequate.
- Observe the response of expansion devices during operation.
- Check for sticking or slow responses.
- Ensure that settings are appropriate for operating conditions.
- Calibrate or replace devices as needed.
- Inspect strainers and filters for debris accumulation.
- Clean or replace strainers/filters showing significant buildup.
- Check flow rates before and after cleaning.
- Document maintenance performed.
- Inspect all connection points for tightness.
- Use appropriate tools to tighten any loose connections.
- Check seals for wear or damage.
- Replace seals if necessary to prevent leaks.
- Examine tank interiors for rust or debris.
- Check for any chemical reactions affecting the tank.
- Test fluid samples for contamination.
- Schedule cleaning or repairs if contamination is found.
- Test gauges for responsiveness and accuracy.
- Calibrate gauges that are not functioning correctly.
- Replace gauges that are damaged or not repairable.
- Document calibration results.
- Keep detailed notes of all findings.
- Prioritize issues based on urgency.
- Ensure documentation is clear and accessible.
- Report findings to appropriate maintenance personnel.
4. Electrical Components
5. Heat Exchangers
- Check for any visible damage or leaks.
- Ensure tubes are free from blockages.
- Look for signs of wear or corrosion.
- Verify proper alignment of tubes.
- Inspect surfaces for buildup or discoloration.
- Use a suitable cleaning method if fouling is present.
- Document the condition for future reference.
- Ensure proper flushing if necessary.
- Use flow meters to assess flow rates.
- Compare readings against manufacturer specifications.
- Inspect valves for proper operation.
- Adjust flow as needed to meet standards.
- Check for any visible damage or leaks.
- Ensure tubes are free from blockages.
- Look for signs of wear or corrosion.
- Verify proper alignment of tubes.
- Inspect surfaces for buildup or discoloration.
- Use a suitable cleaning method if fouling is present.
- Document the condition for future reference.
- Ensure proper flushing if necessary.
- Use flow meters to assess flow rates.
- Compare readings against manufacturer specifications.
- Inspect valves for proper operation.
- Adjust flow as needed to meet standards.
- Check for cracks, tears, or gaps in gaskets.
- Use a leak detection solution if needed.
- Replace worn or damaged gaskets promptly.
- Ensure proper sealing after replacement.
- Inspect for rust or pitting on surfaces.
- Use a wire brush to clean minor corrosion.
- Apply protective coatings as needed.
- Document any severe corrosion for further action.
- Use temperature sensors at inlet and outlet.
- Calculate the temperature difference.
- Ensure the differential is within acceptable range.
- Investigate any abnormal readings.
- Check insulation for tears or moisture.
- Replace damaged insulation to maintain efficiency.
- Ensure insulation is properly secured.
- Document any areas needing attention.
- Inspect brackets for tightness and stability.
- Look for signs of wear or fatigue.
- Tighten any loose connections.
- Ensure supports are free from rust.
- Listen for any abnormal sounds during operation.
- Check for vibrations using handheld tools.
- Investigate sources of noise or vibration.
- Document findings for further analysis.
- Remove any dust or debris near exchangers.
- Ensure there are no blocks to airflow.
- Check for proper placement of airflow guards.
- Maintain a clear area around the units.
- Examine past maintenance logs for patterns.
- Identify any frequent repairs or replacements.
- Discuss recurring issues with the maintenance team.
- Plan for preventative measures based on findings.
6. Absorber and Generator
- Examine surfaces for rust, pitting, or flaking.
- Look for discoloration or material loss.
- Inspect welds and joints for integrity.
- Check for any moisture accumulation.
- Listen for unusual sounds indicating malfunction.
- Inspect for fluid leaks around seals and joints.
- Verify that the generator reaches operational temperature.
- Check gauges for normal pressure and performance levels.
- Listen for abnormal noises from the pump.
- Check for vibrations that indicate wear.
- Inspect pump housing for leaks.
- Ensure proper flow rate is maintained.
- Examine surfaces for rust, pitting, or flaking.
- Look for discoloration or material loss.
- Inspect welds and joints for integrity.
- Check for any moisture accumulation.
- Listen for unusual sounds indicating malfunction.
- Inspect for fluid leaks around seals and joints.
- Verify that the generator reaches operational temperature.
- Check gauges for normal pressure and performance levels.
- Listen for abnormal noises from the pump.
- Check for vibrations that indicate wear.
- Inspect pump housing for leaks.
- Ensure proper flow rate is maintained.
- Use appropriate testing kit to measure concentration.
- Compare results with manufacturer specifications.
- Document findings in maintenance log.
- Adjust concentration if necessary.
- Check for tears, wear, or moisture damage.
- Ensure insulation is securely attached.
- Look for signs of heat loss or cold spots.
- Replace damaged insulation as needed.
- Check bolts and screws for proper torque.
- Inspect gaskets for wear or damage.
- Look for signs of leakage at joints.
- Replace any worn or damaged fittings.
- Measure inlet and outlet temperatures accurately.
- Calculate the temperature differential.
- Compare results to acceptable limits.
- Investigate any discrepancies immediately.
- Use appropriate cleaning solutions for surfaces.
- Remove dust, dirt, and any obstructions.
- Ensure that no cleaning residues remain.
- Inspect for any damage during cleaning.
- Review operational data and compare with benchmarks.
- Identify any performance drops or anomalies.
- Document findings for further analysis.
- Adjust operations if efficiency metrics are not met.
- Check for flow rates and temperature changes.
- Inspect for any visible blockage signs.
- Clean heat exchanger surfaces if necessary.
- Document operational efficiency.
- Check for visible rust or corrosion.
- Listen for hissing sounds indicating leaks.
- Inspect joints and fittings for tightness.
- Replace any damaged piping as needed.
- Measure flow rates using calibrated equipment.
- Compare measured flow rates with specifications.
- Adjust flow controls if necessary.
- Document measurements for records.
- Listen closely for grinding or rattling sounds.
- Record any irregular sounds for analysis.
- Investigate sources of noise immediately.
- Schedule repairs if issues are detected.
- Check for recurring issues noted in logs.
- Identify trends or patterns in maintenance needs.
- Plan follow-up actions based on history.
- Document any new findings in the log.
7. Safety Devices
8. Controls and Automation
- Initiate the control system start-up sequence.
- Monitor system response to commands.
- Verify operation of all control functions.
- Document any discrepancies in performance.
- Access the control system display.
- Record any error codes present.
- Refer to the manual for troubleshooting.
- Address warnings as necessary.
- Inspect each sensor for dust or debris.
- Clean sensors using appropriate methods.
- Test sensor readings against known values.
- Replace any faulty sensors.
- Use calibrated instruments for verification.
- Adjust sensors to match reference standards.
- Document calibration results.
- Schedule recalibration if needed.
- Examine all wiring visually.
- Look for fraying, corrosion, or loose connections.
- Repair or replace damaged components.
- Ensure all connections are secure.
- Check communication logs for errors.
- Test data transmission between systems.
- Verify that BMS displays current chiller status.
- Address any communication issues promptly.
- Manually operate valves to check movement.
- Inspect seals for leaks or wear.
- Ensure actuators respond to control signals.
- Lubricate moving parts as required.
- Access the performance log database.
- Identify and analyze any unusual patterns.
- Investigate causes of anomalies.
- Report findings to maintenance management.
- Check version numbers of installed software.
- Review release notes for available updates.
- Download and install updates as necessary.
- Backup current configurations before updates.
- Locate manual override controls on the system.
- Activate manual overrides and observe responses.
- Ensure all systems return to normal function.
- Document any issues encountered.
- Open control panel and enclosures carefully.
- Use a vacuum or soft brush to remove dust.
- Wipe surfaces with a damp cloth.
- Ensure ventilation openings are clear.
- Review current operational parameters.
- Adjust settings for efficiency as needed.
- Consult operational guidelines for benchmarks.
- Document any changes made.
- Review alarm settings against specifications.
- Simulate alarm conditions to test functionality.
- Verify alarm signals are audible and visible.
- Make adjustments if thresholds are incorrect.
Use in Manifestly