Home > Manufacturing > A detailed Air Cooled Compression Chiller SEMI ANNUALLY preventive maintenance checklist

A detailed Air Cooled Compression Chiller SEMI ANNUALLY preventive maintenance checklist

1. Visual Inspection

Check for signs of leaks around the compressor and piping.

Inspect the chiller for any signs of corrosion or physical damage.

Ensure that all access panels and enclosures are secure.

Sure! Here are some additional steps that could be included in the "1. Visual Inspection" section of the Air Cooled Compression Chiller SEMI ANNUALLY preventive maintenance checklist

Inspect the area around the chiller for any obstructions or debris that could affect airflow

Check for any signs of oil or refrigerant stains on the ground beneath the chiller

Ensure that the fan blades are free of obstructions and are in good condition

Observe the condition of insulation on refrigerant lines; look for signs of wear or damage

Verify that all labels and identification tags on the unit are legible and intact

Check for signs of excessive vibration or unusual noises during operation

Inspect the condition of the water supply and drain lines, if applicable

Ensure that the unit is level and properly supported

Look for evidence of pest infestations around the unit

Examine the condition of any safety guards and screens for integrity and security

These additional steps will help ensure a thorough visual inspection of the chiller

2. Electrical System Check

Inspect all electrical connections for tightness and signs of wear.

Use a torque wrench to check tightness.
Look for corrosion or discoloration.
Ensure no wires are frayed or damaged.
Check for any loose connections.
Document findings for future reference.

Verify that all control wiring is intact and in good condition.

Inspect insulation for cuts or abrasions.
Check for proper routing and securing of wires.
Examine connectors for signs of wear.
Test continuity using a multimeter.
Report any damaged wires for replacement.

Test the operation of safety and control devices.

Activate devices to ensure they respond correctly.
Check indicator lights for functionality.
Test reset functions where applicable.
Document operational status and any anomalies.
Ensure compliance with safety standards.

Here are some additional steps that could be included in the "Electrical System Check" section of the Air Cooled Compression Chiller SEMI ANNUALLY preventive maintenance checklist

Check the condition of fuses and circuit breakers for any signs of damage or tripping

Inspect for physical damage or discoloration.
Confirm that fuses are the correct rating.
Check that circuit breakers reset properly.
Test overload protection functionality.
Replace any defective components immediately.

Measure voltage and current levels at key points to ensure they are within specified ranges

Use a multimeter for voltage measurements.
Check current levels with a clamp meter.
Compare readings to manufacturer's specifications.
Document all measurements for analysis.
Investigate any discrepancies found.

Inspect and clean electrical panels and enclosures to prevent dust and moisture accumulation

Remove dust using a vacuum or dry cloth.
Check gaskets for proper sealing.
Inspect for any signs of moisture ingress.
Ensure all components are securely mounted.
Document the condition before and after cleaning.

Verify the proper functioning of relays and contactors, ensuring they engage and disengage as expected

Manually operate relays to check response.
Listen for audible clicks during operation.
Inspect contacts for wear or pitting.
Test with a multimeter for continuity.
Replace any malfunctioning components.

Ensure that all grounding connections are secure and effective

Inspect ground connections for corrosion.
Verify continuity from equipment to ground.
Check that grounding conductors are appropriately sized.
Test ground resistance with a meter.
Document the status of all grounding points.

Check for any signs of overheating or thermal damage on electrical components and connections

Look for discoloration or melting on wires.
Touch components to identify excessive heat.
Use an infrared camera for detailed inspection.
Replace any damaged components promptly.
Log any findings and corrective actions taken.

Inspect the condition of insulation on wires and cables for any signs of degradation or wear

Check for cracking, fraying, or discoloration.
Ensure insulation is intact and secure.
Test insulation resistance with a megohmmeter.
Replace any damaged insulation immediately.
Document findings for maintenance records.

Test the operation of variable frequency drives (VFDs) for proper functionality and settings

Check display settings for accuracy.
Verify input and output parameters.
Test response to load changes.
Ensure proper cooling of the VFD unit.
Document operational status and settings.

Confirm that all emergency shutoff switches are operational and accessible

Test each switch to confirm operation.
Ensure switches are clearly labeled.
Check for any obstructions around switches.
Document the accessibility and functionality.
Report any issues found during testing.

Review the operation of any alarms or indicators related to the electrical system for proper functionality

Test each alarm for audible and visual signals.
Check for proper response to fault conditions.
Ensure alarms are correctly configured.
Document alarm status and any irregularities.
Replace or repair non-functional alarms.

Ensure that all electrical components are adequately rated for the system’s operational parameters

Verify component ratings against system specifications.
Check for compatibility with voltage and current levels.
Document any mismatched components.
Replace inadequately rated components promptly.
Review specifications regularly for updates.

Document any discrepancies or issues found during the electrical system check for follow-up

Record all findings in a maintenance log.
Include descriptions and locations of issues.
Assign follow-up actions and responsibilities.
Ensure documentation is accessible for future reviews.
Review log during the next maintenance cycle.

3. Refrigerant System Inspection

Check refrigerant levels and inspect for proper charge.

Use a reliable gauge to measure refrigerant levels.
Compare readings with manufacturer specifications.
Identify if any adjustments are necessary.
Record the refrigerant charge for maintenance logs.

Look for any signs of refrigerant leaks at connections and joints.

Inspect all joints and connections visually.
Use a leak detection solution to identify leaks.
Check for oil spots, which can indicate refrigerant leaks.
Document any leaks found for repair scheduling.

Ensure that the expansion valve is functioning properly.

Check for proper temperature differentials across the valve.
Listen for unusual noises indicating malfunction.
Inspect the valve for physical damage or wear.
Confirm that the valve opens and closes as intended.

Here are some additional steps that could be included in the "3. Refrigerant System Inspection" section of your Air Cooled Compression Chiller preventive maintenance checklist

Inspect the refrigerant lines for any signs of wear, damage, or insulation deterioration

Examine lines for cracks, bends, or corrosion.
Check insulation for moisture or degradation.
Ensure all lines are securely fastened.
Replace any damaged lines or insulation as needed.

Verify the operation of the sight glass (if equipped) to ensure proper refrigerant flow and visibility of refrigerant state

Check for bubbles in the sight glass indicating low charge.
Ensure the sight glass is clean and unobstructed.
Confirm visibility of refrigerant state under normal operating conditions.
Document the condition of the sight glass.

Check for any unusual noises from the compressor that may indicate refrigerant issues

Listen for knocking, grinding, or hissing sounds.
Identify the source of any abnormal noises.
Check compressor mounting and alignment.
Report any unusual noises for further investigation.

Measure and record the superheat and subcooling values to confirm optimal refrigerant performance

Use appropriate tools to measure superheat and subcooling.
Compare values with manufacturer specifications.
Document readings and any deviations.
Adjust system settings if necessary.

Inspect the receiver (if applicable) for proper operation and signs of contamination or water accumulation

Check receiver for proper pressure levels.
Look for any signs of rust, oil, or debris.
Ensure drain valves are functioning properly.
Document findings for maintenance records.

Ensure that all service valves are functioning correctly and are fully accessible

Test all service valves for proper operation.
Check for leaks around valve stems and connections.
Ensure valves are not obstructed for easy access.
Lubricate valves if needed for smooth operation.

Confirm that the refrigerant system is free from any obstructions or restrictions in the flow path

Inspect evaporator and condenser coils for debris.
Ensure airflow is unobstructed around the unit.
Check filters for cleanliness and replace if necessary.
Document any obstructions found during inspection.

Review the system’s refrigerant type and ensure compatibility with system components

Check the refrigerant label on the unit.
Verify compatibility with all system parts.
Consult manufacturer guidelines for correct refrigerant use.
Document refrigerant type for maintenance records.

Document any findings related to refrigerant charge or leaks for future reference and compliance

Record all measurements and observations.
Note any repairs or adjustments made.
Keep a log of refrigerant usage and leaks.
Ensure documentation is accessible for future audits.

4. Condenser Maintenance

Clean the condenser coils to remove any dirt or debris.

Turn off power to the chiller.
Use a soft brush or vacuum to remove loose dirt.
Rinse coils with water from a hose, avoiding damage.
Inspect for any bent fins and straighten if necessary.

Inspect the fan operation and check for any unusual noises.

Power on the chiller and observe fan operation.
Listen for any grinding or rattling sounds.
Check for smooth rotation and proper speed.
Turn off power and inspect for loose components if issues arise.

Verify that the fan blades are free from obstructions.

Power off the unit before inspection.
Examine blades for debris or foreign objects.
Remove any obstructions carefully.
Ensure blades are intact and not damaged.

Certainly! Here are some additional steps that could be included in the **4. Condenser Maintenance** section of your preventive maintenance checklist

Check for signs of corrosion or damage on the condenser unit

Inspect the condenser exterior for rust or deterioration.
Look for bubbling paint or leaks.
Document any corrosion and consider repair options.
Ensure all surfaces are clean for accurate inspection.

Ensure that the condenser is level and properly mounted to avoid vibration issues

Check the mounting brackets for tightness.
Use a level to assess the unit's position.
Adjust supports if necessary to ensure level placement.
Inspect for signs of excessive vibration during operation.

Inspect and clean the condenser drain pan to prevent water buildup and potential overflow

Locate the drain pan and inspect for debris.
Remove any accumulated dirt or algae.
Ensure that the drain is clear and functional.
Check for any signs of leaks around the pan.

Verify that the condenser airflow is unobstructed by checking surrounding areas for any obstacles

Inspect the area around the condenser for blockages.
Remove any plants, debris, or materials obstructing airflow.
Ensure at least 3 feet of clear space around the unit.
Monitor airflow during operation for any issues.

Measure and record the condenser discharge temperature to ensure it is within manufacturer specifications

Use a thermometer to measure discharge temperature.
Compare the reading with manufacturer specifications.
Document the temperature for maintenance records.
Investigate any deviations from expected performance.

Inspect electrical connections and look for signs of wear or overheating

Power off the unit and check wiring for damage.
Look for burned or frayed wires and replace if needed.
Ensure all connections are tight and corrosion-free.
Use a multimeter to test electrical integrity.

Test the operation of the condenser unit under load conditions to ensure it is functioning efficiently

Start the chiller and monitor the unit under normal load.
Check pressure and temperature readings during operation.
Listen for unusual sounds indicating operational issues.
Document performance metrics for future reference.

Check refrigerant levels and ensure there are no leaks in the condenser circuit

Use appropriate gauges to assess refrigerant levels.
Inspect the condenser for visible signs of leaks.
Record levels and any necessary adjustments.
Address leaks promptly to maintain efficiency.

Lubricate fan motor bearings if applicable, following manufacturer recommendations

Consult the user manual for lubrication points.
Use the recommended lubricant sparingly.
Apply lubricant to bearings according to the schedule.
Wipe off excess to prevent dirt accumulation.

Inspect the condenser for any signs of refrigerant oil on the exterior, indicating a potential leak

Check for oil spots or residue around the condenser.
Document any findings for further investigation.
Perform necessary repairs if oil is detected.
Ensure surrounding area is clean for accurate inspection.

These additional steps can help ensure thorough maintenance of the condenser, promoting optimal performance and longevity of the chiller system

5. Evaporator Maintenance

Inspect evaporator coils for cleanliness and proper operation.

Remove debris and dust from coils using a soft brush or vacuum.
Check for any signs of corrosion or damage.
Ensure airflow is unobstructed around the coils.
Verify that the coils are free from leaks.

Check for signs of ice buildup and ensure proper drainage.

Inspect evaporator surfaces for ice accumulation.
Ensure drain lines are clear and free of obstructions.
Test the drainage system for proper water flow.
Check the temperature settings to prevent future ice buildup.

Test the operation of the evaporator fan.

Activate the fan and listen for any abnormal sounds.
Check the fan speed to ensure it meets specifications.
Inspect the fan blades for damage or dirt accumulation.
Confirm the fan is securely mounted and operates smoothly.

Here are some additional steps you could include in the "5. Evaporator Maintenance" section of your preventive maintenance checklist for an air-cooled compression chiller

Verify the integrity of the evaporator insulation and repair any damaged areas

Inspect insulation for tears, gaps, or moisture.
Replace or repair damaged insulation using appropriate materials.
Ensure insulation is properly fitted and secured.
Check for condensation that may indicate poor insulation.

Inspect and clean the evaporator drain pan to prevent clogs and water accumulation

Remove any debris or dirt from the drain pan.
Flush the drain pan with a mixture of water and mild cleaner.
Ensure the drain pan is level for effective drainage.
Inspect drainage connections for leaks.

Check the refrigerant flow to the evaporator and ensure that it is within manufacturer specifications

Measure refrigerant pressure using a gauge.
Compare readings with manufacturer specifications.
Check for signs of refrigerant leaks around connections.
Ensure proper refrigerant levels are maintained.

Examine the evaporator for leaks and address any identified issues immediately

Use a leak detection solution on all joints and connections.
Listen for hissing sounds that may indicate leaks.
Repair any leaks found using appropriate sealants or components.
Document and report any major leaks for further action.

Test the temperature differential across the evaporator to ensure efficient heat exchange

Measure inlet and outlet temperatures using thermometers.
Calculate the temperature differential.
Ensure the differential aligns with manufacturer guidelines.
Investigate any significant deviations from expected values.

Inspect and lubricate the evaporator fan motor as needed

Check the fan motor for signs of wear or damage.
Apply lubricant to the motor bearings if required.
Inspect electrical connections for security and corrosion.
Test the motor operation after lubrication.

Ensure that all electrical connections to the evaporator are secure and free of corrosion

Inspect all electrical connections visually.
Tighten any loose connections as needed.
Clean any corroded terminals with a wire brush.
Ensure proper insulation on all electrical wiring.

Check for any unusual noises or vibrations from the evaporator components during operation

Listen for abnormal sounds while the system operates.
Check for vibrations that could indicate misalignment.
Inspect mounting brackets for secure fastening.
Document any unusual findings for further assessment.

Review the evaporator's operating conditions and compare them with manufacturer's guidelines to ensure optimal performance

Gather performance data during operation.
Compare data with manufacturer specifications.
Identify any discrepancies and investigate causes.
Adjust settings or components as necessary for improvement.

6. Mechanical Components Check

Inspect all mounting brackets and vibration isolators for wear.

Look for cracks, rust, or other signs of deterioration.
Ensure all isolators are securely mounted and not compressed.
Check for any movement or looseness in the brackets.

Check the compressor oil levels and quality.

Remove the oil dipstick and wipe clean before reinserting.
Inspect the oil for clarity and check for contaminants.
Top off oil if levels are low, using manufacturer-recommended type.

Test the operation of all moving parts for smooth operation.

Manually rotate parts where applicable to check for resistance.
Listen for unusual sounds and monitor for vibrations.
Lubricate moving parts as necessary to ensure smooth operation.

Certainly! Here are some additional steps that could be included in the "Mechanical Components Check" section of a semi-annual preventive maintenance checklist for an air-cooled compression chiller

6. Mechanical Components Check

Inspect all mounting brackets and vibration isolators for wear

Look for cracks, rust, or other signs of deterioration.
Ensure all isolators are securely mounted and not compressed.
Check for any movement or looseness in the brackets.

Check the compressor oil levels and quality

Remove the oil dipstick and wipe clean before reinserting.
Inspect the oil for clarity and check for contaminants.
Top off oil if levels are low, using manufacturer-recommended type.

Test the operation of all moving parts for smooth operation

Manually rotate parts where applicable to check for resistance.
Listen for unusual sounds and monitor for vibrations.
Lubricate moving parts as necessary to ensure smooth operation.

Inspect and tighten all bolts and fasteners on mechanical components

Use the appropriate tools to check the tightness of each bolt.
Look for any missing or damaged fasteners that need replacement.
Document any adjustments made to ensure accountability.

Check for any signs of leaks in the compressor, including seals and gaskets

Inspect all visible seals and gaskets for discoloration or cracking.
Use a leak detection solution to spot any escaping refrigerant.
Tighten or replace any leaky components as necessary.

Inspect the condition of the drive belts for wear and proper tension

Check belts for cracks, fraying, or glazing.
Ensure belts are tensioned according to manufacturer's specifications.
Replace any belts that show significant wear or damage.

Verify the alignment of the motor and compressor shafts

Use a dial indicator to measure any misalignment.
Adjust mounting positions or shims to correct alignment.
Retest to ensure proper alignment is achieved.

Check the condition of bearings and lubricate as necessary

Inspect bearings for signs of wear, such as noise or heat.
Use appropriate lubricant and apply according to specifications.
Replace bearings if excessive wear or damage is observed.

Examine the fan blades for damage, corrosion, or obstructions

Check for any visible dents, cracks, or bent blades.
Ensure blades are free of debris that could impede airflow.
Clean blades if necessary to maintain efficiency.

Assess the condition of the condenser fan motor and its electrical connections

Inspect motor for signs of overheating or wear.
Check electrical connections for corrosion or loose wires.
Test motor operation to ensure it runs smoothly.

Inspect the water and refrigerant lines for proper insulation and signs of wear

Look for any exposed areas or damaged insulation.
Check for corrosion or leaks along the lines.
Replace any worn insulation to prevent energy loss.

Ensure all access panels and covers are secure and free of debris

Verify that panels are tightly closed and fastened.
Remove any accumulated dust or debris from surfaces.
Check for any signs of damage to panels or seals.

Check for any unusual noises or vibrations during operation

Listen closely during operation for any irregular sounds.
Monitor vibrations with a handheld device if available.
Document any findings for further investigation.

Inspect and clean any filters associated with the mechanical components

Remove filters and visually inspect for dirt and debris.
Clean or replace filters according to the manufacturer's guidelines.
Reinstall filters securely before testing operation.

Confirm that all safety switches and devices are operational and properly mounted

Test each safety switch to ensure it activates correctly.
Check mounting brackets and connections for security.
Replace any faulty safety devices to maintain system integrity.

These steps will help ensure the mechanical integrity and operational efficiency of the air-cooled compression chiller

7. System Controls Testing

Test the chiller control panel for proper functionality.

Power on the control panel.
Check for any error messages or alerts.
Verify display readings against expected values.
Test all buttons and switches for responsiveness.
Ensure communication lights indicate normal operation.

Verify that all sensors are calibrated and providing accurate readings.

Check each sensor's calibration date.
Use a reference standard for comparison.
Adjust calibration settings if readings are off.
Record calibration data for documentation.
Ensure sensors are securely mounted and undamaged.

Review alarm history and ensure that all alarms are functioning.

Access the alarm history log.
Check for any unresolved alarms.
Test alarm sound and visual indicators.
Reset any alarms after verification.
Document alarm responses and outcomes.

Certainly! Here are some additional steps that could be included in the "7. System Controls Testing" section of your Air Cooled Compression Chiller SEMI ANNUALLY preventive maintenance checklist

Check the operation of the temperature and pressure set points to ensure they are within specified limits

Access control settings for temperature and pressure.
Verify set points against manufacturer specifications.
Adjust set points if necessary.
Monitor readings to confirm stability.
Document any changes made during testing.

Test the communication between the chiller control panel and any building management systems (BMS) to ensure proper integration

Establish a connection with the BMS.
Send test commands from the control panel.
Verify that BMS receives and responds correctly.
Check for any communication errors.
Document the integration status.

Inspect and test the operation of safety interlocks and emergency shut-off systems

Identify all safety interlocks and shut-off systems.
Manually trigger interlocks to ensure activation.
Test each emergency shut-off for responsiveness.
Verify proper labeling and accessibility.
Document inspection results.

Validate the operation of variable frequency drives (VFDs) if applicable, ensuring they respond correctly to control signals

Access VFD settings and parameters.
Send control signals to the VFD.
Monitor VFD response to changes.
Check for any abnormal noises or vibrations.
Document VFD operational status.

Perform a functional test of all control logic to ensure that the chiller operates as intended under various load conditions

Simulate different load conditions.
Observe control logic responses during testing.
Verify operation of all control sequences.
Check for any unexpected behavior.
Document test findings and adjustments.

Check the operation of the chiller's start/stop sequence to confirm reliability and adherence to operational protocols

Initiate start and stop sequences.
Monitor each step for proper execution.
Check for any delays or malfunctions.
Ensure adherence to operational protocols.
Document sequence performance.

Test the operation of the remote monitoring and control features, if available, ensuring they are accessible and functional

Access remote monitoring interface.
Test all remote control functions.
Verify data transmission accuracy.
Check user accessibility and permissions.
Document remote access performance.

Review the control software for any available updates or patches and implement them as needed

Check the version of the current software.
Visit the manufacturer's website for updates.
Download and install any available patches.
Test software functionality post-update.
Document version changes and updates applied.

Document any discrepancies found during testing and recommend corrective actions if necessary

Record all test results and findings.
Identify discrepancies and potential issues.
Provide recommendations for corrective actions.
Ensure documentation is clear and detailed.
Review findings with relevant personnel.

8. System Performance Evaluation

Measure the operating pressures and temperatures.

Use calibrated gauges to measure suction and discharge pressures.
Record temperatures at key points, including evaporator and condenser.
Ensure measurements are taken under normal operating conditions.
Compare readings against manufacturer specifications.

Compare current performance metrics with baseline data.

Gather historical performance data for comparison.
Identify key performance indicators (KPIs) for evaluation.
Analyze trends in efficiency and performance metrics.
Document any discrepancies from baseline performance.

Document any deviations and address with appropriate adjustments.

Record any performance deviations from expected values.
Identify potential causes of deviations for further investigation.
Implement necessary adjustments to restore optimal performance.
Log all changes made for future reference.

Here are some additional steps that could be included in the "System Performance Evaluation" section of the preventive maintenance checklist for an air-cooled compression chiller

Analyze the energy consumption data to evaluate efficiency

Collect energy consumption data for the chiller.
Calculate the coefficient of performance (COP).
Identify any unusual spikes in energy usage.
Compare energy metrics with industry benchmarks.

Check the flow rates of the refrigerant and water systems to ensure they are within specified ranges

Measure refrigerant flow rates using appropriate flow meters.
Check water flow rates at inlet and outlet points.
Compare flow rates against manufacturer specifications.
Adjust flow rates if they fall outside acceptable ranges.

Monitor the chiller's cycling frequency and duration to assess load matching

Record the number of cycles over a defined period.
Measure the duration of each cycle.
Evaluate if cycling aligns with load requirements.
Make adjustments if short cycling is observed.

Evaluate the performance of the expansion valve and ensure it is operating correctly

Inspect the expansion valve for signs of wear or damage.
Check for proper superheat settings.
Ensure the valve opens and closes smoothly.
Replace the valve if performance is inadequate.

Inspect the refrigerant superheat and subcooling levels to confirm optimal operation

Measure superheat at the evaporator outlet.
Check subcooling at the condenser outlet.
Verify levels against manufacturer recommendations.
Adjust refrigerant charge if necessary.

Review the operation of the compressor, including noise levels and vibration assessments

Listen for unusual noises during operation.
Use vibration analysis tools to assess compressor health.
Check for any signs of overheating.
Document any concerns for follow-up.

Assess the quality of the chilled water supply and return temperatures

Measure supply and return temperatures with calibrated thermometers.
Calculate the temperature differential.
Ensure temperatures meet design specifications.
Investigate any significant temperature variances.

Verify the accuracy of temperature and pressure gauges against calibrated standards

Use calibrated reference gauges for comparison.
Check each gauge's accuracy at multiple points.
Replace gauges that are out of calibration.
Document any discrepancies found.

Conduct a trending analysis of system performance over time to identify patterns or issues

Collect historical performance data over a defined period.
Analyze data for trends and anomalies.
Identify recurring issues that need addressing.
Prepare a summary report of findings.

Review and document any changes in system load conditions that may affect performance

Note any changes in building occupancy or equipment loads.
Document seasonal variations that impact chiller performance.
Assess how changes may affect efficiency.
Update maintenance records with relevant information.

9. Documentation and Reporting

Record all findings and maintenance activities performed.

Update any maintenance logs and service records.

Schedule any necessary follow-up actions or repairs.

10. Safety Checks

Ensure that all safety devices are operational.

Test each safety device individually.
Check alarms, shut-off valves, and pressure switches.
Ensure devices respond correctly to simulated faults.
Document any non-functional devices for immediate repair.

Review emergency shutdown procedures with staff.

Schedule a meeting to discuss procedures.
Demonstrate the shutdown process physically.
Provide printed materials for reference.
Encourage questions to clarify understanding.

Confirm that all safety signage is visible and legible.

Inspect all safety signs for wear or damage.
Ensure signs are placed at required locations.
Clean any obscured signs to enhance visibility.
Replace any signs that are not legible.

This checklist should be used as a guideline for semi-annual preventive maintenance on air-cooled compression chillers, ensuring optimal performance and longevity of the system.

Certainly! Here are some additional steps that could be included in the "Safety Checks" section of the preventive maintenance checklist for an air-cooled compression chiller

10. Safety Checks

Ensure that all safety devices are operational

Test each safety device individually.
Check alarms, shut-off valves, and pressure switches.
Ensure devices respond correctly to simulated faults.
Document any non-functional devices for immediate repair.

Review emergency shutdown procedures with staff

Schedule a meeting to discuss procedures.
Demonstrate the shutdown process physically.
Provide printed materials for reference.
Encourage questions to clarify understanding.

Confirm that all safety signage is visible and legible

Inspect all safety signs for wear or damage.
Ensure signs are placed at required locations.
Clean any obscured signs to enhance visibility.
Replace any signs that are not legible.

Inspect all safety interlocks and ensure they function correctly

Test each interlock for proper operation.
Check for any signs of wear or damage.
Ensure interlocks are correctly aligned and installed.
Document any malfunctioning interlocks for repair.

Check for proper grounding of all electrical components

Inspect grounding connections for corrosion or looseness.
Measure resistance to ensure effective grounding.
Verify compliance with electrical safety codes.
Document the condition of grounding systems.

Verify that all access panels and doors close securely and are not obstructed

Inspect each access panel for proper alignment.
Ensure hinges and locks function as intended.
Remove any obstructions that prevent closure.
Document panels needing repair or replacement.

Ensure that fire extinguishers are accessible, charged, and inspected

Check pressure gauges to confirm they are within range.
Ensure extinguishers are mounted in designated spots.
Inspect for signs of damage or corrosion.
Document the inspection date and any maintenance performed.

Assess the condition of personal protective equipment (PPE) and ensure it is available for maintenance personnel

Inspect PPE for wear and tear.
Ensure all required PPE is available on-site.
Replace any damaged or expired equipment.
Train staff on proper usage and storage.

Confirm that the area around the chiller is clear of debris and hazards

Conduct a thorough walk-around inspection.
Remove any items that could obstruct access.
Clear spills or hazards immediately.
Document any persistent hazards for follow-up.

Review and update safety data sheets (SDS) for refrigerants and other chemicals used in maintenance

Gather all relevant SDS documents.
Verify the accuracy and currency of each sheet.
Distribute updated SDS to all maintenance personnel.
Store SDS in an accessible location.

Conduct a risk assessment of the work area before performing maintenance tasks

Identify potential hazards present in the area.
Evaluate risks associated with each hazard.
Implement control measures to mitigate risks.
Document the assessment results for future reference.

Ensure that all tools and equipment used during maintenance are in good condition and accounted for

Inspect tools for damage or wear.
Ensure proper calibration of measuring instruments.
Account for all tools before and after tasks.
Replace or repair any defective tools.

Check that emergency lighting is functional in the maintenance area

Test all emergency lights for operation.
Replace any burnt-out bulbs immediately.
Document the condition and functionality of lighting.
Ensure lights are unobstructed and accessible.

Verify that communication devices (e.g., radios, phones) are operational and accessible

Test all communication devices for functionality.
Ensure batteries are charged and replaced as needed.
Keep devices in designated areas for easy access.
Document any issues for prompt repair.

Review lockout/tagout (LOTO) procedures to ensure compliance during maintenance activities

Ensure all staff are trained on LOTO procedures.
Conduct a walkthrough to verify compliance.
Update LOTO procedures if necessary.
Document compliance checks and any issues found.

These additional steps help to enhance the overall safety of the maintenance process and ensure that personnel are prepared for emergencies

Download CSV Download JSON Download Markdown

Use in Manifestly

AI Checklist Generator

A detailed Air Cooled Compression Chiller SEMI ANNUALLY preventive maintenance checklist

1. Visual Inspection

2. Electrical System Check

3. Refrigerant System Inspection

4. Condenser Maintenance

5. Evaporator Maintenance

6. Mechanical Components Check

7. System Controls Testing

8. System Performance Evaluation

9. Documentation and Reporting

10. Safety Checks

Related Checklists

Inventory Management

Shipping and Receiving Checklist

Employee Termination

Regulatory Compliance

Production Planning

Equipment Maintenance Checklist

Employee Onboarding

Performance Evaluation Checklist

Quality Assurance

Environmental Compliance

Workplace Safety Checklist

Employee Training Checklist