A detailed Water Cooled Compression Chiller DAILY preventive maintenance checklist
Daily Visual Inspection
- Look for puddles or moisture on the ground.
- Inspect joints, fittings, and hoses for wet spots.
- Check for corrosion or mineral deposits around pipes.
- Listen for hissing sounds indicating gas leaks.
- Look for rust or discoloration on the chiller surface.
- Check for dents, scratches, or other physical damage.
- Assess the paint condition; peeling indicates corrosion.
- Ensure no components are loose or missing.
- Check that all fasteners are tightened.
- Inspect hinges for wear or damage.
- Confirm all seals are intact to prevent leaks.
- Ensure doors are not obstructed.
- Remove any debris, tools, or equipment from the area.
- Check that airflow paths are clear.
- Ensure no flammable materials are nearby.
- Inspect for slippery surfaces or hazards.
- Look for torn or missing insulation material.
- Check for moisture accumulation on insulation.
- Assess insulation integrity; replace if damaged.
- Confirm insulation is securely fastened.
- Listen for rattling or grinding sounds.
- Observe if the chiller is shaking excessively.
- Check for loose components causing noise.
- Monitor any changes in operational sound.
- Look for visible dust or dirt accumulation.
- Check for any physical obstruction on coils.
- Inspect coil fins for straightness and cleanliness.
- Assess for any signs of corrosion.
- Inspect for white frost on pipes and coils.
- Check for condensation leading to ice formation.
- Confirm proper airflow is maintained.
- Monitor temperature settings to prevent freezing.
- Inspect guards for cracks or breaks.
- Confirm that all fasteners are secure.
- Check that no guards are missing.
- Ensure guards are properly aligned.
- Look for water pooling around the base of the tower.
- Check for cracks or damage in the structure.
- Inspect for rust on metal components.
- Ensure water levels are stable.
- Check that indicators show normal flow rates.
- Inspect for any blockages in indicator lines.
- Ensure that all connections are secure.
- Monitor for any erratic readings.
- Look for nests or droppings around the chiller.
- Check for any visible insects or pests.
- Inspect entry points for signs of infestation.
- Ensure pest control measures are in place.
- Check that all light fixtures are operational.
- Ensure pathways to the chiller are clear.
- Verify that emergency exits are marked.
- Inspect for adequate lighting during nighttime.
- Look for any illuminated warning indicators.
- Check for error codes displayed on the screen.
- Verify that all controls are functioning.
- Ensure the panel is clean and accessible.
- Check the ambient temperature reading on the panel.
- Ensure temperature is within specified range.
- Monitor for any unusual temperature fluctuations.
- Verify that vents are unobstructed.
Operational Checks
- Inspect the display for any error codes.
- Document and address any alarms immediately.
- Ensure the display is functioning properly.
- Check the temperature and pressure gauges.
- Compare readings with specified ranges.
- Record any deviations for further analysis.
- Stand close to the chiller and listen carefully.
- Identify any abnormal sounds.
- Investigate the source of any unusual noises.
- Observe the compressor for proper cycling.
- Ensure it starts and stops as per schedule.
- Look for any irregularities in operation.
- Use a flow meter to measure water flow.
- Compare measurement with design specifications.
- Adjust flow rate if necessary.
- Inspect the valve for any leaks.
- Ensure it is opening and closing correctly.
- Monitor for any fluctuations in performance.
- Check the evaporator surface for frost or ice.
- Ensure proper airflow around the evaporator.
- Schedule defrosting if necessary.
- Monitor the outlet temperature of the condenser.
- Ensure there is no blockage in airflow.
- Check for proper water flow through the condenser.
- Inspect refrigerant lines for any leaks or damage.
- Check the sight glass for clarity.
- Record refrigerant levels and replenish if low.
- Manually test each control valve.
- Ensure valves open and close as required.
- Monitor system performance for inconsistencies.
- Measure inlet and outlet temperatures.
- Calculate the temperature differential.
- Ensure it aligns with operational parameters.
- Check energy consumption readings.
- Identify any spikes in energy usage.
- Investigate causes of inefficiencies.
- Listen for unusual sounds from pumps and fans.
- Inspect for any vibrations or overheating.
- Ensure all components are functioning smoothly.
- Access and review operational logs.
- Identify any recurring issues or anomalies.
- Take corrective actions based on findings.
Fluid Levels and Quality
- Open the cooling tower access panel.
- Check the water level gauge.
- Ensure water is at the marked optimal level.
- Add water if needed, following safety protocols.
- Close the access panel securely.
- Use a refractometer or test kit.
- Collect a sample of glycol solution.
- Compare results to manufacturer specifications.
- Adjust concentration if outside limits.
- Document findings for records.
- Inspect refrigerant sight glass for clarity.
- Check for discoloration or particles.
- Listen for unusual noises from the compressor.
- Look for any leaks around fittings.
- Document the condition and any actions taken.
- Locate the oil sight glass on the compressor.
- Check if the oil level is within range.
- Add manufacturer-recommended oil if low.
- Ensure no spills occur during topping up.
- Secure the oil fill cap after checking.
- Use a calibrated pH meter or test strips.
- Take a sample of the cooling tower water.
- Record the pH reading and compare to standards.
- Adjust the pH with chemicals if necessary.
- Log the results for future reference.
- Visually inspect pipes and components for scaling.
- Check for rust or corrosion on surfaces.
- If scaling is found, consider acid cleaning.
- Treat corrosion with appropriate inhibitors.
- Document any issues and corrective actions.
- Use a conductivity meter for measurement.
- Take a sample of cooling tower water.
- Record the conductivity reading.
- Compare to acceptable limits specified by manufacturer.
- Adjust water treatment as needed.
- Check for discoloration or foul odors in fluid.
- Use a microscope if necessary for inspection.
- If growth is detected, apply appropriate biocide.
- Flush system if contamination is severe.
- Log treatment actions and results.
- Check the antifreeze concentration with a refractometer.
- Refer to manufacturer guidelines for mixing ratios.
- Ensure solution is clear and free of particulates.
- Adjust the mixture if concentrations are off.
- Document the antifreeze condition and adjustments.
- Visually inspect all connections and hoses.
- Look for wet spots or drips around fittings.
- Use a leak detection dye if necessary.
- Repair any leaks found immediately.
- Document any leaks and repairs made.
- Check the chemical addition log.
- Verify dosage against manufacturer recommendations.
- Assess the effectiveness of the last treatment.
- Make adjustments if dosage was insufficient.
- Record findings and any changes made.
- Inspect each sampling port for cleanliness.
- Flush ports with clean water if needed.
- Ensure caps are secure and intact.
- Replace any damaged components.
- Document the condition of sampling ports.
- Use a maintenance log or software.
- Record all measurements and observations.
- Note any corrective actions taken.
- Ensure documentation is clear and detailed.
- Store records in an accessible location.
Electrical Checks
- Inspect all terminals and connectors.
- Tighten loose connections using appropriate tools.
- Clean any corrosion with a wire brush or contact cleaner.
- Apply anti-corrosion compound if necessary.
- Examine insulation for fraying or cracking.
- Look for signs of overheating, such as discoloration.
- Check for exposed wires or loose connections.
- Replace any damaged components immediately.
- Manually test each circuit breaker by toggling it.
- Check for any tripped breakers and reset if needed.
- Inspect for signs of arcing or damage.
- Replace any non-functioning circuit breakers.
- Test each safety control for functionality.
- Ensure alarms sound and are audible.
- Verify indicator lights operate correctly.
- Document any malfunctions for immediate attention.
- Inspect grounding straps and connections.
- Check for corrosion or loose connections.
- Use a multimeter to test grounding continuity.
- Repair or replace as necessary.
- Look for discoloration or melted parts.
- Check that cooling fans are operational.
- Ensure all components are securely mounted.
- Replace any burnt components found.
- Activate each relay and contactor manually.
- Listen for clicking sounds indicating operation.
- Check for signs of wear or arcing.
- Replace any faulty relays or contactors.
- Use a multimeter to measure voltage.
- Check current draw on critical components.
- Compare readings with manufacturer specifications.
- Document any discrepancies for follow-up.
- Verify settings and parameters on the VFD.
- Listen for unusual noises during operation.
- Check for error codes on the display.
- Test response to speed adjustments.
- Inspect each fuse visually for damage.
- Use a multimeter to test continuity.
- Replace any blown fuses with the correct rating.
- Document any replacements made.
- Check connections and insulation for damage.
- Look for signs of overheating, such as discoloration.
- Ensure ventilation openings are not blocked.
- Replace or repair worn equipment immediately.
- Test each emergency stop button by pressing it.
- Ensure it stops equipment immediately.
- Check that buttons are clearly labeled.
- Check accessibility for quick access.
- Verify timers are set to required schedules.
- Test operation by observing equipment response.
- Check for battery backup if applicable.
- Document any setting changes made.
- Listen for grinding, buzzing, or rattling sounds.
- Observe vibrations during operation.
- Identify the source of any unusual noises.
- Investigate and address any issues found.
Filter and Strainer Inspection
- Turn off the chiller and ensure safety precautions are in place.
- Remove access panels to reach filters.
- Visually check filters for visible dirt, dust, or debris accumulation.
- Note any excessive buildup that may require immediate attention.
- If filters are dirty, gently clean using compressed air or a soft brush.
- If filters are damaged or excessively dirty, replace them with new ones.
- Ensure replacement filters match specified dimensions and type.
- Reinstall filters securely and ensure no gaps are present.
- Locate the strainers in the system and remove them from their housing.
- Inspect for debris or buildup that may restrict flow.
- Use water or a brush to clean strainers thoroughly.
- Reinstall strainers ensuring they are properly positioned.
- Examine the filter housing for cracks or corrosion.
- Check for any loose fittings or signs of leaks.
- Ensure that the housing is structurally sound.
- Document any findings for repair or replacement planning.
- Check that each filter is aligned correctly in its housing.
- Ensure that filters are tightened and secure to prevent air leaks.
- Look for any misalignment that could affect performance.
- Adjust or reinstall as necessary.
- Locate the differential pressure gauge connected to the filter system.
- Record the current pressure readings.
- Compare readings to baseline values for normal operation.
- Take action if readings exceed acceptable limits.
- Use a maintenance log or digital record-keeping system.
- Note the date of inspection, filter condition, and any actions taken.
- Include any observations regarding airflow or performance.
- Ensure records are accessible for future maintenance reviews.
- Remove pre-filters and post-filters for visual inspection.
- Check for dirt accumulation or damage.
- Clean or replace filters as necessary to maintain efficiency.
- Ensure proper reinstallation after inspection.
- Look for rust or corrosion on the strainer surface.
- Check for any signs of deterioration that could affect functionality.
- Document any issues and schedule repairs or replacements.
- Clean strainers to prevent further corrosion.
- Inspect seals and gaskets for wear or damage.
- Replace any damaged or worn seals to prevent leaks.
- Ensure that all seals provide a tight fit.
- Check for proper seating of gaskets during installation.
- Listen for any irregular sounds while inspecting filters and strainers.
- Note any vibrations that seem out of the ordinary.
- Document findings in maintenance logs for future analysis.
- Report significant issues to maintenance personnel.
- Check filter specifications against manufacturer guidelines.
- Ensure that the media type is suitable for the application.
- Replace filters that do not meet system requirements.
- Verify compatibility with the chiller’s operating conditions.
- Inspect the interior of filter and strainer housings for obstructions.
- Use a flashlight if necessary to see inside.
- Clear any blockages to restore proper flow.
- Reassemble and secure all components after checking.
Condensate and Drainage
- Visually examine the drain for clogs.
- Use a flashlight to check for hidden blockages.
- Run water through the drain to confirm flow.
- Remove any visible debris or obstructions.
- Power on the pump and listen for operational sounds.
- Check for vibrations indicating normal function.
- Inspect the control panel for any warning lights.
- Ensure water is being pumped away effectively.
- Look for puddles or damp areas near the unit.
- Check surrounding surfaces for water stains.
- Inspect insulation for moisture damage.
- Ensure drainage pathways are clear.
- Look for cracks, tears, or corrosion.
- Check connections for leaks or loose fittings.
- Ensure the line is securely fastened.
- Replace any damaged sections immediately.
- Inspect all joints and connections for tightness.
- Use a cloth to check for moisture around fittings.
- Ensure no water is dripping from the drain.
- Tighten any loose fittings as necessary.
- Manually lift the float switch to test activation.
- Listen for the pump to engage and disengage.
- Inspect the float for any obstructions.
- Ensure proper alignment and movement of the float.
- Remove visible debris using a soft brush.
- Wipe down the pan with a damp cloth.
- Use a mild cleaning solution if necessary.
- Ensure the drain holes are clear.
- Inspect the pump housing for foreign objects.
- Listen for any grinding or unusual sounds.
- Check for vibrations indicating problems.
- Clear any obstructions found.
- Check the discharge line for proper alignment.
- Ensure no kinks or blockages are present.
- Confirm that water is flowing away from the unit.
- Adjust the line if necessary.
- Visually inspect for green or slimy deposits.
- Use a disinfectant to clean affected areas.
- Wipe down surfaces to remove any growth.
- Consider using algae inhibitors if necessary.
- Note the date and time of the inspection.
- Record any issues found and corrective actions taken.
- Document the pump's operational status.
- Sign off on the maintenance log.
- Inspect each valve visually for signs of wear.
- Check the position of each valve against system requirements.
- Operate each valve to ensure smooth function.
- Lubricate any stiff valves as necessary.
- Approach the system and sniff for foul odors.
- Investigate areas where odors are strongest.
- Identify any sources of stagnant water.
- Take appropriate cleaning or maintenance actions.
Documentation and Reporting
Safety Checks
- Inspect each guard and device visually.
- Check for any signs of damage or wear.
- Ensure all bolts and fasteners are secure.
- Confirm guards are correctly positioned and functional.
- Locate all emergency shut-off switches.
- Test each switch to confirm functionality.
- Clear any obstructions around switches.
- Label switches clearly for easy identification.
- Check inventory of PPE items: gloves, goggles, helmets.
- Inspect each item for signs of wear or damage.
- Ensure items are clean and properly stored.
- Replace any defective or missing equipment.
- Gather personnel for a safety briefing.
- Distribute copies of safety procedures.
- Discuss emergency protocols and responsibilities.
- Encourage questions and clarify any confusion.
- Check that extinguishers are easily reachable.
- Verify pressure gauge is in the green zone.
- Inspect maintenance tags for recent inspections.
- Ensure extinguishers are mounted securely.
- Locate all first aid kits in the facility.
- Open kits and verify all supplies are present.
- Replace any used or expired items.
- Ensure kits are clearly labeled and accessible.
- Inspect all exit signs for visibility and functionality.
- Clear any items blocking exit paths.
- Confirm that lighting is adequate along routes.
- Review maps and postings for exit locations.
- Check that all safety signs are intact and legible.
- Ensure proper placement of signs in high-visibility areas.
- Replace any faded or damaged signs.
- Verify the correct use of labels for hazards.
- Walk the area systematically, looking for hazards.
- Note any spills, debris, or uneven surfaces.
- Address hazards immediately or report them.
- Ensure flooring is in good condition.
- Inspect labeling of all electrical panels.
- Check for proper identification of circuits.
- Ensure panels are free from obstructions.
- Confirm that panels can be easily opened.
- Review training records for all personnel.
- Schedule refresher training if necessary.
- Conduct hands-on demonstrations of emergency equipment.
- Encourage personnel to ask questions.
- Inspect storage areas for proper containment.
- Ensure all chemicals are clearly labeled.
- Verify that Material Safety Data Sheets (MSDS) are available.
- Check for any leaks or signs of deterioration.
- Gather personnel for a LOTO review session.
- Discuss specific LOTO procedures relevant to the chiller.
- Conduct a practice drill to reinforce procedures.
- Ensure all personnel understand their roles.
- Listen for abnormal noises during operation.
- Check for unusual vibrations by touch.
- Look for leaks or unusual odors.
- Report any anomalies to maintenance immediately.
Use in Manifestly