A detailed Air Cooled Compression Chiller ANNUAL preventive maintenance checklist
1. Visual Inspection
- Look for any visible fluid leaks, corrosion, or rust on the chiller.
- Inspect insulation for tears, wear, or missing sections on refrigerant lines.
- Check for dust, dirt, or debris accumulation on and around the unit.
- Ensure no plants, leaves, or items block airflow around the unit.
- Examine the chiller housing for cracks, dents, or other signs of damage.
- Verify alignment of components; inspect belts and pulleys for wear.
- Check for signs of nests, droppings, or other pest activities nearby.
- Inspect fan blades for chips, cracks, or debris buildup affecting operation.
- Ensure drain pans and condensate lines are clean and unobstructed.
- Check rubber mounts and vibration isolators for any cracks or degradation.
- Inspect access panels and doors for secure closure and physical integrity.
- Look for loose, frayed, or damaged wiring and electrical connections.
- Check the sight glass for clarity and appropriate refrigerant levels.
- Verify that all safety and warning labels are present and readable.
2. Electrical Components
- Use a torque wrench to check tightness.
- Look for corrosion or discoloration.
- Tighten loose connections securely.
- Replace any damaged connectors.
- Inspect for fraying, cracks, or breaks.
- Ensure insulation is intact and not brittle.
- Look for signs of overheating.
- Replace any compromised wiring.
- Start the motors and listen for unusual noises.
- Measure operational voltage and current.
- Check for vibration or excessive heat.
- Confirm proper rotation direction.
- Test each safety switch manually.
- Check for indicator lights or alarms.
- Inspect wiring and connections to switches.
- Replace any faulty safety devices.
- Visual inspection for burn marks or damage.
- Reset tripped breakers and test operation.
- Replace blown fuses with correct rating.
- Ensure breakers are securely mounted.
- Use a multimeter for voltage measurements.
- Clamp meter for current draw readings.
- Compare readings with manufacturer specifications.
- Document any discrepancies for follow-up.
- Turn off power before cleaning.
- Use a vacuum or soft brush to remove dust.
- Wipe down surfaces with a damp cloth.
- Inspect seals and gaskets for integrity.
- Use a calibrated reference sensor for comparison.
- Adjust calibration settings as necessary.
- Record calibration results for documentation.
- Replace any sensors that are out of tolerance.
- Check for physical damage or wear.
- Use a multimeter to test continuity.
- Ensure contacts are clean and making contact.
- Replace any faulty relays or contactors.
- Check each indicator light for proper operation.
- Test alarm functionality by simulating faults.
- Inspect control panel for physical damage.
- Document any issues for repair.
- Inspect grounding wires for damage.
- Tighten any loose connections.
- Check grounding points for corrosion.
- Verify continuity with a multimeter.
- Check for signs of leakage or swelling.
- Clean surfaces with a soft brush.
- Ensure all connections are secure.
- Replace any defective components.
- Compare current wiring with schematics.
- Update documentation to reflect changes.
- File updated documents in a central location.
- Ensure all staff have access to current schematics.
- Use a thermal camera to scan components.
- Look for abnormal temperature readings.
- Document any hot spots for further inspection.
- Schedule repairs as needed.
3. Refrigerant System
- Use a pressure gauge to measure refrigerant levels.
- Inspect all connections and joints for oil residue.
- Listen for hissing sounds indicating a leak.
- Check the area around the compressor for signs of leakage.
- Visually assess coils for dirt or debris accumulation.
- Look for bent or damaged fins that may obstruct airflow.
- Check for corrosion or rust on coil surfaces.
- Ensure there are no blockages around the coil area.
- Turn off power to the unit before cleaning.
- Use a coil cleaner solution to remove grime.
- Rinse with water to remove cleaning residues.
- Ensure coils are completely dry before re-energizing.
- Check for proper valve positioning during operation.
- Look for signs of frost on the valve indicating issues.
- Assess the temperature difference before and after the valve.
- Confirm the valve opens and closes appropriately.
- Use a pressure gauge to measure refrigerant levels.
- Inspect all connections and joints for oil residue.
- Listen for hissing sounds indicating a leak.
- Check the area around the compressor for signs of leakage.
- Visually assess coils for dirt or debris accumulation.
- Look for bent or damaged fins that may obstruct airflow.
- Check for corrosion or rust on coil surfaces.
- Ensure there are no blockages around the coil area.
- Turn off power to the unit before cleaning.
- Use a coil cleaner solution to remove grime.
- Rinse with water to remove cleaning residues.
- Ensure coils are completely dry before re-energizing.
- Check for proper valve positioning during operation.
- Look for signs of frost on the valve indicating issues.
- Assess the temperature difference before and after the valve.
- Confirm the valve opens and closes appropriately.
- Examine coils for dust and debris accumulation.
- Look for ice formation that could indicate airflow issues.
- Check drain pans for proper drainage and cleanliness.
- Ensure fan operation is unobstructed.
- Inspect insulation for tears or wear.
- Ensure all refrigerant lines are properly insulated.
- Look for moisture accumulation indicating insulation failure.
- Replace damaged insulation as necessary.
- Tighten any loose fittings with appropriate tools.
- Inspect O-rings and gaskets for wear.
- Check for leaks using a leak detection solution.
- Replace any damaged fittings or seals.
- Use temperature and pressure gauges to measure values.
- Calculate superheat and subcooling based on readings.
- Compare results against manufacturer specifications.
- Adjust system parameters as needed based on readings.
- Check the calibration of pressure switches.
- Simulate conditions to verify switch activation.
- Inspect wiring and connections for damage.
- Replace faulty switches or sensors as necessary.
- Start the compressor and listen for unusual sounds.
- Check for vibrations that could indicate misalignment.
- Monitor operating temperatures against normal ranges.
- Inspect electrical connections for signs of wear.
- Collect a refrigerant sample for analysis.
- Check for contaminants or moisture in the refrigerant.
- Assess the quality against manufacturer standards.
- Decide if a refrigerant change is needed.
- Remove any debris or dirt from the accumulator.
- Check for signs of wear or corrosion.
- Ensure all connections are secure.
- Replace the accumulator if it shows significant damage.
- Inspect service ports for damage or corrosion.
- Ensure caps are present and in good condition.
- Verify that ports are easily reachable for servicing.
- Clean any dirt or debris around the ports.
- Compare current refrigerant levels to specifications.
- Adjust the charge if levels are outside recommended ranges.
- Document any changes made to refrigerant levels.
- Ensure compliance with environmental regulations.
- Label all refrigerant containers clearly.
- Document the type and amount of refrigerant used.
- Maintain records of refrigerant usage and maintenance.
- Ensure documentation is readily available for inspections.
4. Lubrication
- Inspect the oil sight glass or dipstick.
- Add oil to the appropriate level using the correct type.
- Ensure the area around the oil fill is clean before opening.
- Check for discoloration, particles, or unusual odor.
- Take a sample for laboratory analysis if contamination is suspected.
- Document findings for future reference.
- Refer to the manufacturer's lubrication schedule.
- Use recommended lubricant type and application method.
- Ensure all moving parts receive adequate lubrication.
- Inspect oil filters for clogs or excessive dirt.
- Replace filters as per the manufacturer's guidelines.
- Check for proper sealing upon installation.
- Inspect the oil sight glass or dipstick.
- Add oil to the appropriate level using the correct type.
- Ensure the area around the oil fill is clean before opening.
- Check for discoloration, particles, or unusual odor.
- Take a sample for laboratory analysis if contamination is suspected.
- Document findings for future reference.
- Refer to the manufacturer's lubrication schedule.
- Use recommended lubricant type and application method.
- Ensure all moving parts receive adequate lubrication.
- Inspect oil filters for clogs or excessive dirt.
- Replace filters as per the manufacturer's guidelines.
- Check for proper sealing upon installation.
- Check all lines for signs of oil leakage.
- Inspect fittings for tightness and wear.
- Replace damaged lines or fittings immediately.
- Check alignment of pumps and motors.
- Adjust components as needed to ensure straight paths.
- Use alignment tools if necessary.
- Refer to the equipment manual for specifications.
- Verify lubricant containers are labeled correctly.
- Check expiration dates on lubricant products.
- Remove old lubricant and clean reservoirs thoroughly.
- Inspect for rust or corrosion inside the reservoir.
- Refill with fresh lubricant only after cleaning.
- Use a calibrated thermometer for accurate readings.
- Document temperature readings regularly.
- Investigate any temperature deviations from the norm.
- Inspect hoses for cracks or wear.
- Ensure all connections are secure and leak-free.
- Replace any damaged hoses immediately.
- Check the operation of automatic lubrication pumps.
- Inspect for proper delivery of lubricant to components.
- Document any issues for follow-up.
- Track operating hours to determine oil change intervals.
- Document oil change dates and any observations.
- Set reminders for upcoming oil changes.
- Assess current lubrication practices for effectiveness.
- Gather feedback from maintenance personnel.
- Update procedures based on best practices and technology.
5. Cooling Tower Inspection (if applicable)
6. Control Systems
- Use calibrated testing equipment to assess settings.
- Compare actual readings to manufacturer specifications.
- Adjust settings as necessary to ensure compliance.
- Document any changes made during testing.
- Check sensor readings against known standards.
- Calibration should be performed if discrepancies are found.
- Inspect sensors for physical damage or corrosion.
- Ensure proper placement and mounting of sensors.
- Trigger alarms to confirm they activate correctly.
- Test visual and audible indicators for functionality.
- Review alarm settings for accuracy and appropriateness.
- Document any issues or required adjustments.
- Analyze programming for efficiency and accuracy.
- Make updates based on operational changes or improvements.
- Backup existing programming before making changes.
- Test new programming thoroughly before final implementation.
- Power down equipment before cleaning.
- Use a vacuum or soft brush to remove dust.
- Wipe surfaces with a damp cloth to remove residue.
- Check seals and gaskets for integrity.
- Compare thermostat readings to a calibrated reference.
- Adjust settings to align with manufacturer guidelines.
- Document calibration results and adjustments.
- Perform periodic checks to maintain accuracy.
- Verify connectivity to remote access points.
- Check data transmission for accuracy and timeliness.
- Ensure alert systems function as intended.
- Document any issues for follow-up.
- Test data exchange between systems.
- Check for proper reporting of chiller status.
- Look for any communication errors in logs.
- Ensure protocols and settings are compatible.
- Review manufacturer’s website for updates.
- Download and backup current software version.
- Follow update instructions carefully during installation.
- Test system functionality post-update.
- Collect data from monitoring systems.
- Analyze historical performance for anomalies.
- Document any trends or patterns observed.
- Use data to inform future maintenance decisions.
- Check all wiring insulation for fraying or cracking.
- Tighten loose connections to prevent arcing.
- Replace any damaged wiring immediately.
- Document the condition of wiring and any repairs made.
- Test backup power systems under load conditions.
- Inspect batteries and connections for integrity.
- Replace any failing components as needed.
- Document the results of the backup test.
- Manually operate valves to check responsiveness.
- Inspect actuator movement for any binding or delays.
- Calibrate as necessary to ensure proper operation.
- Document any maintenance performed on valves.
- Verify that safety interlocks function as intended.
- Test emergency shut-off systems for responsiveness.
- Review integration points for any potential issues.
- Document findings and any required corrections.
7. Performance Testing
- Use calibrated pressure gauges.
- Record readings in a log.
- Ensure all readings are stable.
- Compare with manufacturer specifications.
- Place temperature probes at inlet and outlet.
- Record temperatures accurately.
- Calculate the differential.
- Ensure values align with operational benchmarks.
- Use an energy meter to record kWh.
- Compare against historical performance data.
- Identify any discrepancies.
- Document findings for analysis.
- Use a vibration analyzer tool.
- Inspect frequency and amplitude of vibrations.
- Compare data to acceptable limits.
- Look for signs of imbalance or misalignment.
- Use calibrated pressure gauges.
- Record readings in a log.
- Ensure all readings are stable.
- Compare with manufacturer specifications.
- Place temperature probes at inlet and outlet.
- Record temperatures accurately.
- Calculate the differential.
- Ensure values align with operational benchmarks.
- Use an energy meter to record kWh.
- Compare against historical performance data.
- Identify any discrepancies.
- Document findings for analysis.
- Use a vibration analyzer tool.
- Inspect frequency and amplitude of vibrations.
- Compare data to acceptable limits.
- Look for signs of imbalance or misalignment.
- Check for physical damage or leaks.
- Verify proper opening and closing.
- Test operational response to changes.
- Ensure consistent refrigerant flow.
- Use flow measuring devices.
- Compare current rates to specifications.
- Check for blockages or restrictions.
- Document any irregularities.
- Calculate the cooling output.
- Compare with manufacturer ratings.
- Note any deviations.
- Investigate causes of reduced capacity.
- Use thermal imaging cameras.
- Scan key components of the system.
- Identify areas with excessive heat.
- Document findings for further inspection.
- Check fan motor performance.
- Ensure airflow is unobstructed.
- Measure air temperature before and after coils.
- Document airflow measurements.
- Use accurate thermometers or sensors.
- Record ambient conditions.
- Measure discharge temperatures.
- Ensure readings are within expected ranges.
- Listen for unusual sounds.
- Identify source of noises.
- Document any findings.
- Schedule further inspection if necessary.
- Access control system settings.
- Verify calibration against standards.
- Adjust settings as needed.
- Document any changes made.
- Access alarm history and logs.
- Identify recurring issues.
- Investigate root causes.
- Plan corrective actions.
- Test each safety interlock.
- Simulate failure conditions.
- Ensure system shuts down correctly.
- Document results of tests.
- Use electronic leak detectors.
- Inspect all connections and components.
- Document any leaks found.
- Schedule repairs for detected leaks.
8. Documentation and Reporting
9. Safety Checks
- Check for any physical damage or corrosion.
- Test the functionality of pressure relief valves.
- Ensure safety switches operate correctly under load.
- Document findings and replace any faulty devices.
- Verify signage is visible and legible.
- Confirm location of shut-off procedures is accessible.
- Ensure procedures are up to date and accurate.
- Review posting with personnel for awareness.
- Review local and national safety regulations.
- Conduct a checklist comparison with regulatory standards.
- Document compliance status and any discrepancies.
- Plan corrective actions for non-compliance issues.
- Evaluate training records for all personnel.
- Identify any gaps in training or certification.
- Schedule refresher courses as needed.
- Gather feedback from personnel on training effectiveness.
- Press each emergency stop button to check response.
- Ensure all buttons reset properly after activation.
- Document any malfunctioning buttons for repair.
- Communicate any issues to maintenance staff immediately.
- Inspect labels for clarity and visibility.
- Ensure compliance with labeling standards.
- Replace any missing or damaged labels.
- Conduct a review of labeling with maintenance staff.
- Walk the area around exits and equipment.
- Remove any obstacles blocking access.
- Ensure pathways are clear and well-marked.
- Document any access issues and corrective actions taken.
- Check the pressure gauge on each extinguisher.
- Inspect for physical damage or corrosion.
- Ensure extinguishers are mounted properly and marked.
- Confirm that inspection tags are current.
- Inspect guards and covers for damage or wear.
- Check that all fasteners are tight and secure.
- Document any missing or damaged guards.
- Schedule repairs or replacements as necessary.
- Conduct a thorough walkthrough of the area.
- Engage personnel in identifying potential hazards.
- Document all findings in a risk assessment report.
- Plan mitigation strategies for identified risks.
- Review MSDS files for currency and completeness.
- Ensure documents are stored in a designated location.
- Communicate any changes to personnel.
- Document any missing or outdated materials.
- Inspect grounding connections for corrosion or damage.
- Test grounding systems using a multimeter.
- Document testing results and corrective actions.
- Ensure compliance with electrical safety standards.
- Examine hoses for cracks, fraying, or bulging.
- Check connections for tightness and leaks.
- Document any damaged hoses and schedule replacements.
- Ensure hoses are rated for the operating conditions.
- Evaluate current LOTO procedures for completeness.
- Update procedures to reflect any equipment changes.
- Train personnel on updated LOTO practices.
- Document all changes and ensure accessibility.
- Schedule a walkthrough with all relevant personnel.
- Review emergency procedures and safety protocols.
- Encourage questions and feedback during the walkthrough.
- Document attendance and any concerns raised.
- Inspect PPE for wear and functionality.
- Ensure adequate supply of PPE for all personnel.
- Replace any damaged or expired PPE immediately.
- Review PPE usage with personnel for compliance.
Use in Manifestly