A detailed Water Cooled Compression Chiller SEMI ANNUALLY preventive maintenance checklist
1. General Inspection
- Conduct a visual assessment of the chiller's exterior.
- Look for any physical damage or wear.
- Check the cleanliness of the surrounding area.
- Ensure there are no materials obstructing access.
- Examine joints and connections for moisture.
- Inspect for rust or discoloration on metal surfaces.
- Look for any pooling of water under the chiller.
- Document and report any findings for repair.
- Verify that all guards are present and undamaged.
- Check that covers are securely fastened.
- Test the stability of each safety feature.
- Replace any missing or damaged components.
- Inspect labels for fading or wear.
- Ensure warning signs are visible and correctly positioned.
- Replace any illegible or damaged labels.
- Confirm compliance with safety regulations.
- Listen for unusual sounds during chiller operation.
- Monitor vibrations with a handheld device.
- Check mounting points for looseness or wear.
- Report any abnormalities for further investigation.
- Inspect drain lines for blockages.
- Ensure condensate is flowing freely.
- Look for any signs of water pooling.
- Clean any debris found in drainage pathways.
- Use a level to check horizontal alignment.
- Inspect anchor bolts for tightness.
- Adjust or shim if the chiller is uneven.
- Document any adjustments made.
- Check that access panels are closed and latched.
- Remove any debris obstructing panel openings.
- Inspect seals for wear or damage.
- Replace seals if necessary.
- Check insulation for tears or wear.
- Look for signs of moisture on insulation surfaces.
- Ensure insulation is properly secured.
- Replace any damaged sections.
- Inspect the area around the chiller for blockages.
- Ensure vents and intake areas are clear.
- Measure airflow using an anemometer.
- Report and remove any identified obstructions.
- Wipe down the control panel with a damp cloth.
- Check for any signs of moisture ingress.
- Ensure all buttons and indicators are functional.
- Document any issues for follow-up.
- Examine pipes for leaks or corrosion.
- Check fittings and joints for tightness.
- Look for signs of scale or buildup.
- Report any issues for maintenance.
- Look for droppings or nests nearby.
- Inspect for gnaw marks on materials.
- Check around electrical outlets and ducts.
- Report findings to pest control if necessary.
- Assess cleanliness of the area.
- Ensure tools and materials are stored properly.
- Look for any safety hazards present.
- Recommend improvements if needed.
2. Electrical Components
- Use a torque wrench to check tightness.
- Look for frayed wires or corrosion.
- Ensure all connections are secure.
- Examine wires for cracks or abrasions.
- Check insulation for discoloration or damage.
- Replace any compromised wiring.
- Verify functionality by activating controls.
- Check indicator lights for proper operation.
- Inspect for any unusual noises or heat.
- Inspect fuses for signs of damage.
- Test circuit breakers for proper tripping.
- Replace any faulty fuses or breakers.
- Use a torque wrench to check tightness.
- Look for frayed wires or corrosion.
- Ensure all connections are secure.
- Examine wires for cracks or abrasions.
- Check insulation for discoloration or damage.
- Replace any compromised wiring.
- Verify functionality by activating controls.
- Check indicator lights for proper operation.
- Inspect for any unusual noises or heat.
- Inspect fuses for signs of damage.
- Test circuit breakers for proper tripping.
- Replace any faulty fuses or breakers.
3. Refrigerant System
- Use electronic leak detectors or soap solution.
- Check all joints, fittings, and connections.
- Record any detected leaks and repair promptly.
- Ensure safety protocols are followed during the process.
- Remove debris, dirt, or obstructions from coils.
- Look for signs of corrosion or physical damage.
- Clean coils using appropriate coil cleaning solutions.
- Ensure airflow is not obstructed by surrounding equipment.
- Inspect caps and seals for integrity.
- Ensure ports are free from corrosion and dirt.
- Verify that service ports are easily reachable.
- Replace damaged or missing caps immediately.
- Check for proper operation during cooling cycles.
- Adjust settings according to manufacturer specifications.
- Inspect for any signs of leakage around the valve.
- Clean or replace as necessary to ensure efficiency.
- Examine all visible piping connections and joints.
- Look for rust, leaks, or physical damage.
- Check for proper support and alignment.
- Document any findings and schedule repairs if necessary.
- Inspect insulation for tears, moisture, or deterioration.
- Ensure insulation is tightly fitted with no gaps.
- Look for signs of condensation indicating insulation failure.
- Replace damaged insulation to improve efficiency.
- Remove and inspect refrigerant filters and dryers.
- Clean filters or replace if heavily contaminated.
- Check dryer operation and replace if functionality is compromised.
- Document replacement dates for maintenance records.
- Use calibrated gauges to measure pressures at key points.
- Record temperatures at evaporator and condenser outlets.
- Compare readings with manufacturer specifications.
- Note any deviations and investigate further if necessary.
- Calibrate gauges according to manufacturer instructions.
- Cross-check readings with a secondary gauge.
- Replace any faulty or inaccurate gauges.
- Maintain a log of gauge calibration dates.
- Ensure sight glass is free from dirt and buildup.
- Check for bubbles indicating low refrigerant levels.
- Clean with appropriate solvents if necessary.
- Replace the sight glass if damaged.
- Monitor flow indicators for normal operation.
- Inspect evaporator and condenser coils for frost or ice.
- Clear any blockages found in refrigerant lines.
- Test system performance after addressing flow issues.
- Listen for hissing, banging, or other irregular sounds.
- Identify the source of the noise for further inspection.
- Document any concerns for follow-up maintenance.
- Investigate and address any mechanical issues promptly.
- Review refrigerant logs and update as needed.
- Ensure compliance with safety and environmental regulations.
- Cross-check inventory against system specifications.
- Document any changes made to refrigerant types or quantities.
- Examine current recovery procedures for compliance.
- Update procedures to reflect regulatory changes.
- Train staff on updated recovery methods.
- Maintain records of training and procedure updates.
4. Water System
- Examine joints and connections for signs of leakage.
- Check insulation for integrity and damage.
- Look for moisture accumulation around pipes.
- Ensure all insulation is securely in place.
- Remove filters from their housings.
- Inspect for dirt or debris accumulation.
- Clean filters with water or replace if damaged.
- Reinstall filters securely in the system.
- Listen for unusual noises from pumps.
- Measure flow rates with a flow meter.
- Inspect for vibrations or overheating.
- Ensure pumps are operating within specified parameters.
- Check for dust or debris accumulation.
- Look for scale buildup on surfaces.
- Inspect for algae or other biological growth.
- Clean as necessary to maintain efficiency.
- Review treatment logs for consistency.
- Test water samples for chemical levels.
- Adjust treatment as needed based on results.
- Document any changes or findings.
- Remove strainers/screens from the system.
- Inspect for debris buildup or blockage.
- Clean with water or replace if damaged.
- Reinstall ensuring a secure fit.
- Test flow switches for responsiveness.
- Observe water level controls for accurate readings.
- Calibrate if readings are inconsistent.
- Document any issues or repairs needed.
- Check water levels against manufacturer specifications.
- Inspect for rust or corrosion on tank surfaces.
- Look for leaks around fittings and connections.
- Perform necessary maintenance to ensure integrity.
- Test each valve for smooth operation.
- Inspect for leaks around valve bodies.
- Ensure valves are easily accessible.
- Lubricate moving parts as necessary.
- Use calibrated instruments for accuracy.
- Record readings at regular intervals.
- Compare against standard operating ranges.
- Investigate any anomalies promptly.
- Look for surface rust or pitting.
- Check for visible cracks or leaks.
- Assess insulation condition and replace if needed.
- Schedule repairs for any damaged sections.
- Test the make-up water system for flow.
- Inspect connections for leaks.
- Ensure float valves are operating correctly.
- Document any issues or maintenance performed.
- Inspect drain lines for blockages.
- Test drainage flow to ensure efficiency.
- Check for any signs of standing water.
- Clear any obstructions as required.
- Inspect heat exchanger surfaces for fouling.
- Check for leaks or corrosion.
- Evaluate thermal performance against benchmarks.
- Schedule cleaning or maintenance as needed.
5. Mechanical Components
- Use appropriate lubricant for each part.
- Check for dirt and debris around moving parts.
- Ensure proper lubrication levels to prevent wear.
- Rotate fans manually to confirm smooth operation.
- Replace any worn or damaged bearings.
- Listen for unusual sounds during operation.
- Use a vibration analyzer to assess performance.
- Inspect for loose components contributing to noise.
- Check for overheating; ensure proper airflow.
- Document any deviations from normal operation.
- Use a calibrated reference gauge for comparison.
- Adjust gauges to match reference readings.
- Inspect connections for leaks or damage.
- Ensure gauges are easily readable and accessible.
- Record calibration results for maintenance logs.
- Inspect all bolts and fasteners for tightness.
- Check for signs of wear or corrosion.
- Ensure mounts are level and properly aligned.
- Replace any damaged or missing supports.
- Test stability by gently shaking components.
- Use appropriate lubricant for each part.
- Check for dirt and debris around moving parts.
- Ensure proper lubrication levels to prevent wear.
- Rotate fans manually to confirm smooth operation.
- Replace any worn or damaged bearings.
- Listen for unusual sounds during operation.
- Use a vibration analyzer to assess performance.
- Inspect for loose components contributing to noise.
- Check for overheating; ensure proper airflow.
- Document any deviations from normal operation.
- Use a calibrated reference gauge for comparison.
- Adjust gauges to match reference readings.
- Inspect connections for leaks or damage.
- Ensure gauges are easily readable and accessible.
- Record calibration results for maintenance logs.
- Inspect all bolts and fasteners for tightness.
- Check for signs of wear or corrosion.
- Ensure mounts are level and properly aligned.
- Replace any damaged or missing supports.
- Test stability by gently shaking components.
- Remove any debris blocking airflow to coils.
- Use a soft brush or vacuum to clean surfaces.
- Check for bent fins; straighten if necessary.
- Inspect for leaks or corrosion on coils.
- Rinse with water to remove remaining dirt.
- Inspect joints and seams for moisture buildup.
- Check for rust or corrosion on surfaces.
- Use a leak detection solution for testing.
- Ensure proper insulation is intact.
- Document any findings and necessary repairs.
- Observe valve operation under varying loads.
- Listen for unusual sounds indicating malfunction.
- Inspect connections for leaks or damage.
- Test with a manometer to ensure correct pressure.
- Replace any defective components as needed.
- Check for cracks, frays, or bulges in hoses.
- Inspect fittings for tightness and integrity.
- Look for signs of fluid leakage around connections.
- Ensure hoses are properly routed and supported.
- Replace any damaged or worn hoses immediately.
- Inspect insulation for rips, tears, or moisture.
- Check for signs of mold or mildew.
- Ensure insulation is securely attached.
- Replace any damaged sections promptly.
- Monitor temperature differences before and after insulation.
- Test safety devices according to manufacturer guidelines.
- Inspect valves for signs of wear or damage.
- Ensure proper labeling and accessibility of devices.
- Document all tests and any replacements made.
- Confirm reset functionality after testing.
- Check for unusual noises during operation.
- Inspect seals for leaks or wear.
- Monitor pump vibrations and temperature.
- Ensure proper flow rates are being achieved.
- Replace any worn components or bearings.
- Check for proper tension using a tension gauge.
- Inspect belts for signs of wear or cracking.
- Ensure alignment with pulleys is correct.
- Replace any damaged or worn belts.
- Lubricate pulleys if applicable to reduce wear.
- Check drainage lines for clogs or debris.
- Ensure all connections are secure and leak-free.
- Test flow rate by observing drainage speed.
- Clean any accessible drainage screens or filters.
- Document any necessary maintenance actions taken.
- Inspect seals visually for cracks or deformation.
- Check for any signs of fluid leakage around seals.
- Ensure seals are properly installed and seated.
- Replace any worn or damaged seals immediately.
- Document condition and any replacements in logs.
- Use a laser alignment tool for precision.
- Adjust misaligned components as necessary.
- Check for wear patterns on coupling surfaces.
- Ensure all mounts are secure and stable.
- Document alignment adjustments made.
- Inspect for physical damage or dents.
- Check for rust or corrosion on surfaces.
- Ensure all protective coatings are intact.
- Document any findings and necessary repairs.
- Clean surfaces to prevent further deterioration.
6. Performance Testing
- Use calibrated thermometers and pressure gauges.
- Record inlet and outlet temperatures.
- Document suction and discharge pressures.
- Ensure measurements are taken during normal operation conditions.
- Obtain manufacturer’s performance data.
- Identify key performance indicators for comparison.
- Analyze recorded data against specifications.
- Document any discrepancies for further investigation.
- Simulate typical operational loads.
- Monitor chiller response to load changes.
- Record temperature and pressure changes during the load test.
- Evaluate system stability and performance under load.
- Collect data on energy usage over a defined period.
- Calculate the coefficient of performance (COP).
- Identify any spikes or irregularities in energy consumption.
- Compare current metrics to historical data.
- Use flow meters to assess water flow rate.
- Compare flow rate against system specifications.
- Check for obstructions or issues in the piping.
- Document flow rate readings accurately.
- Utilize an ammeter or power meter.
- Record voltage, current, and power factor.
- Analyze power consumption against expected levels.
- Document findings for future reference.
- Verify control system settings and parameters.
- Test responsiveness of control adjustments.
- Check for software updates and bugs.
- Document any anomalies in control behavior.
- Inspect cooling tower operation and water flow.
- Assess the condenser water temperature and flow rates.
- Check for scaling or fouling in both systems.
- Document performance metrics for both systems.
- Use gauges to measure superheat and subcooling.
- Compare readings to manufacturer recommendations.
- Adjust refrigerant charge if necessary.
- Document all measurements thoroughly.
- Listen for abnormal sounds during operation.
- Use vibration analysis tools if available.
- Inspect all mechanical components for wear or damage.
- Document any findings and recommended actions.
- Simulate alarm conditions if applicable.
- Verify that alarms activate as intended.
- Check alarm indicators for clarity and visibility.
- Document any issues with alarm functionality.
- Measure pressure drop across both components.
- Compare readings to acceptable ranges.
- Investigate any significant pressure drops.
- Document findings and recommended maintenance.
- Gather historical performance data for analysis.
- Identify patterns or deviations from normal operation.
- Highlight any recurring issues or inefficiencies.
- Prepare a report summarizing findings.
- Check calibration of all measuring instruments.
- Adjust or replace any faulty sensors.
- Document calibration dates and results.
- Ensure all equipment is ready for testing.
- Use a thermal imaging camera to scan equipment.
- Identify areas with abnormal heat signatures.
- Document hotspots and assess potential causes.
- Plan corrective actions based on findings.
7. Documentation and Reporting
8. Safety Review
- Gather current safety protocols and documentation.
- Schedule a meeting with maintenance and operational staff.
- Discuss each protocol and its relevance to current operations.
- Identify any gaps or areas needing clarification.
- Document any changes required for protocols.
- Review emergency procedures with all staff.
- Provide written copies of emergency procedures.
- Conduct a drill to practice emergency response.
- Encourage questions and feedback on procedures.
- Post emergency procedures in visible locations.
- Collect current SDS for all substances in use.
- Verify that SDS are up-to-date and compliant.
- Ensure easy access to SDS for all personnel.
- Educate staff on how to interpret SDS information.
- File updated SDS in a designated binder or digital format.
- Inspect PPE for wear and tear.
- Ensure sufficient quantities of PPE are available.
- Replace any damaged or expired PPE immediately.
- Train staff on proper use and care of PPE.
- Store PPE in a designated, accessible location.
- Identify all tasks performed during chiller operation.
- Evaluate risks associated with each task.
- Prioritize risks based on likelihood and severity.
- Document findings and recommendations for safety improvements.
- Review assessment regularly and update as needed.
- Test all safety interlocks for proper operation.
- Ensure emergency stop buttons are unobstructed and labeled.
- Document any issues found during testing.
- Repair or replace non-functional safety devices promptly.
- Train staff on the location and use of safety devices.
- Check that fire extinguishers are fully charged and tagged.
- Confirm that extinguishers are located in designated areas.
- Inspect accessibility and visibility of emergency equipment.
- Document any maintenance or replacement needs.
- Schedule regular inspections per fire code requirements.
- Inspect all warning labels for wear and visibility.
- Replace any faded or damaged labels immediately.
- Ensure signage is compliant with safety standards.
- Position labels and signs where they are easily seen.
- Train staff on the meaning of warning signs.
- Gather current LOTO procedures and documentation.
- Review procedures with maintenance personnel.
- Ensure all devices are properly labeled and tagged.
- Conduct a walkthrough to verify compliance.
- Update procedures based on any new equipment or changes.
- Schedule a training session for all relevant staff.
- Prepare materials covering chiller hazards and PPE use.
- Engage staff with demonstrations and practical examples.
- Document attendance and training completion.
- Solicit feedback for future training improvements.
- Inspect ventilation systems for operational effectiveness.
- Ensure airflow is unobstructed and meets specifications.
- Monitor air quality regularly to detect refrigerant leaks.
- Schedule maintenance for ventilation systems as needed.
- Document findings and any necessary corrective actions.
- Inspect first aid kits for completeness and expiration dates.
- Restock supplies as needed and replace expired items.
- Ensure kits are easily accessible and visible to staff.
- Train staff on the location and contents of first aid kits.
- Document inspection and restocking activities.
- Collect all incident reports from the past period.
- Analyze reports for common themes or issues.
- Identify areas where safety practices can be enhanced.
- Share findings with staff and management.
- Implement recommendations and follow up on effectiveness.
- Inspect spill containment equipment for readiness.
- Ensure containment measures are compliant with regulations.
- Train staff on proper spill response procedures.
- Document the location and accessibility of containment measures.
- Schedule regular reviews of spill containment effectiveness.
Use in Manifestly