A detailed Water Cooled Compression Chiller WEEKLY preventive maintenance checklist

1. Visual Inspection

2. Water System Checks

  • Check inlet pipes for blockages.
  • Ensure all valves are fully open.
  • Inspect the water source for consistent flow.
  • Listen for any unusual sounds in the supply line.
  • Remove strainers from the system.
  • Flush with clean water to remove debris.
  • Inspect for wear or damage.
  • Reinstall securely after cleaning.
  • Use calibrated thermometers for accurate readings.
  • Record temperatures at designated points.
  • Monitor flow rates using flow meters.
  • Compare results against operational specifications.
  • Check pump operation for vibration or noise.
  • Examine seals and connections for leaks.
  • Ensure pump motor is operating smoothly.
  • Look for signs of overheating.
  • Visually inspect all piping and joints.
  • Use a leak detection solution if necessary.
  • Tighten fittings as needed.
  • Replace any damaged components.
  • Use appropriate test kits for accuracy.
  • Record measurements for tracking trends.
  • Adjust chemical treatment if out of range.
  • Consult specifications for acceptable limits.
  • Remove debris from the cooling tower basin.
  • Check fan blades for damage or buildup.
  • Listen for abnormal motor sounds.
  • Ensure proper airflow and fan operation.
  • Inspect chemical feeders for blockages.
  • Test chemical levels regularly with kits.
  • Adjust dosage as needed.
  • Review treatment logs for consistency.
  • Inspect insulation for tears or moisture.
  • Check for thermal efficiency loss.
  • Replace damaged sections immediately.
  • Ensure insulation is securely fastened.
  • Manually operate each valve to check functionality.
  • Verify valve positions against system diagrams.
  • Lubricate moving parts if necessary.
  • Replace faulty valves as needed.
  • Inspect metal surfaces for rust or deterioration.
  • Use a brush to remove scale buildup.
  • Apply anti-corrosion treatments as needed.
  • Record findings for future reference.
  • Check sensor readings against expected values.
  • Calibrate sensors if necessary.
  • Inspect wiring and connections for damage.
  • Replace malfunctioning sensors promptly.
  • Use accurate thermometers for measurement.
  • Log temperatures at discharge and return points.
  • Compare readings with design specifications.
  • Investigate any discrepancies immediately.
  • Check water level against tank markings.
  • Inspect for signs of leaks or corrosion.
  • Ensure air separator is functioning correctly.
  • Adjust water levels as necessary.

3. Refrigerant System Checks

  • Use a gauge to measure refrigerant levels.
  • Inspect joints and connections for signs of oil or frost.
  • Check for unusual sounds indicating leaks.
  • Record any discrepancies for further investigation.
  • Locate the oil sight glass.
  • Ensure oil is at the recommended level.
  • Add oil if low, using the specified type.
  • Check for any leaks around the compressor.
  • Inspect fins for dirt and obstructions.
  • Clean surfaces using a soft brush or vacuum.
  • Ensure water flow is unobstructed.
  • Check for corrosion or physical damage.
  • Check gauge readings against standard values.
  • Calibrate gauges using manufacturer tools if needed.
  • Ensure gauges are securely mounted and visible.
  • Replace any malfunctioning gauges.
  • Listen for grinding, squealing, or rattling sounds.
  • Investigate the source of the noise.
  • Check mounting brackets and supports.
  • Document any concerns for further analysis.
  • Look for kinks, dents, or abrasions.
  • Check insulation for deterioration or missing sections.
  • Ensure lines are securely fastened.
  • Replace or repair any damaged sections.
  • Use thermometers to measure inlet and outlet temperatures.
  • Calculate the temperature differential.
  • Ensure it meets manufacturer specifications.
  • Investigate any significant deviations.
  • Observe the valve during operation.
  • Check for signs of freezing or flooding.
  • Ensure valve adjustments are responsive.
  • Replace if malfunctioning.
  • Measure superheat at the evaporator outlet.
  • Measure subcooling at the condenser outlet.
  • Compare readings to specifications.
  • Adjust system as necessary.
  • Examine valve stems and seals for wear.
  • Check for leakage around valve connections.
  • Operate valves to ensure smooth function.
  • Replace any faulty valves.
  • Check current refrigerant levels against specs.
  • Adjust charge as needed to meet specifications.
  • Document any adjustments made.
  • Monitor system performance post-adjustment.
  • Inspect evaporator surfaces for frost.
  • Check airflow rates and fan functionality.
  • Identify potential blockages in ducts.
  • Address airflow issues immediately.
  • Use a maintenance log template.
  • Record data clearly and accurately.
  • Note date and time of observations.
  • Review trends during future maintenance.

4. Electrical System Inspection

  • Use a torque wrench to check tightness.
  • Look for discoloration or rust on connections.
  • Replace any corroded terminals or connectors.
  • Test each safety device individually.
  • Ensure control devices respond accurately.
  • Replace any faulty devices immediately.
  • Use a soft brush or vacuum to remove dust.
  • Wipe surfaces with a damp cloth.
  • Ensure no tools or loose items are inside.
  • Use a torque wrench to check tightness.
  • Look for discoloration or rust on connections.
  • Replace any corroded terminals or connectors.
  • Test each safety device individually.
  • Ensure control devices respond accurately.
  • Replace any faulty devices immediately.
  • Use a soft brush or vacuum to remove dust.
  • Wipe surfaces with a damp cloth.
  • Ensure no tools or loose items are inside.

5. Performance Monitoring

  • Use calibrated gauges to measure pressures and temperatures.
  • Document readings in a maintenance log.
  • Ensure parameters are recorded at consistent intervals.
  • Include date and time for each entry.
  • Listen for irregular sounds during operation.
  • Use a sound level meter for precise measurement.
  • Compare current sound levels with baseline data.
  • Investigate any deviations immediately.
  • Test all control settings and alarm functionalities.
  • Verify that alarms are audible and visible.
  • Ensure backup systems are operational.
  • Document any discrepancies for follow-up.
  • Access manufacturer specifications for cooling capacity.
  • Compare current performance data against these specifications.
  • Note any significant deviations in a report.
  • Consider adjustments if performance is below specifications.
  • Use a flow meter to measure water flow rate.
  • Document readings in maintenance records.
  • Ensure flow rate meets manufacturer recommendations.
  • Investigate any flow irregularities immediately.
  • Use energy meters to track consumption.
  • Compare current usage with historical data.
  • Identify and document any spikes in consumption.
  • Evaluate potential causes for energy deviations.
  • Check for proper valve operation during cooling cycles.
  • Measure superheat and subcooling levels accurately.
  • Document readings and compare to specifications.
  • Adjust settings if levels are outside acceptable ranges.
  • Use pressure gauges to measure differential pressure.
  • Document readings in the maintenance log.
  • Identify any significant differences indicating potential fouling.
  • Schedule cleaning if necessary.
  • Measure inlet and outlet water temperatures.
  • Calculate the temperature differential.
  • Document readings and check against optimal ranges.
  • Investigate any significant deviations.
  • Analyze logged performance data over time.
  • Identify trends or patterns in performance metrics.
  • Document any concerns and schedule further investigation.
  • Consider preventive measures based on findings.
  • Check calibration status of all gauges and sensors.
  • Perform recalibration if necessary.
  • Document calibration dates and results.
  • Replace faulty gauges or sensors immediately.
  • Document all observed anomalies in detail.
  • Conduct root cause analysis for each anomaly.
  • Prioritize issues based on severity and impact.
  • Implement corrective actions and log resolutions.
  • Record ambient temperature and humidity levels.
  • Assess their potential impact on chiller efficiency.
  • Document any significant changes in environmental conditions.
  • Adjust operational settings if necessary.

6. Cleaning Tasks

  • Turn off the chiller and disconnect power.
  • Use a soft brush or vacuum to remove loose dirt.
  • Spray a coil cleaner on the coils as per instructions.
  • Rinse with water to remove cleaner and debris.
  • Allow coils to dry before re-energizing the system.
  • Inspect the area around the chiller for debris.
  • Use a broom or vacuum to clear leaves, dirt, and trash.
  • Check for any obstructions that may block airflow.
  • Dispose of debris properly to keep the area tidy.
  • Ensure at least three feet of clearance around the chiller.
  • Use a microfiber cloth or soft rag for cleaning.
  • Dampen the cloth with a mild detergent solution.
  • Wipe surfaces gently, avoiding any electrical components.
  • Focus on areas prone to dust buildup, like fans and panels.
  • Allow surfaces to dry before reassembling or powering on.
  • Turn off the chiller and disconnect power.
  • Use a soft brush or vacuum to remove dust and debris.
  • Apply a coil cleaner solution as per manufacturer instructions.
  • Rinse thoroughly with water, ensuring no residue remains.
  • Allow coils to dry before re-energizing the system.
  • Turn off the cooling tower and drain any water.
  • Remove fill media carefully to avoid damage.
  • Rinse with high-pressure water to remove debris and sediment.
  • Inspect for signs of wear or damage, replacing if necessary.
  • Reinstall fill media securely before restarting the system.
  • Shutdown the system and locate the drain pan.
  • Remove any visible debris or standing water.
  • Flush with clean water and use a brush for stubborn buildup.
  • Check the drain line for blockages and clear as needed.
  • Reassemble and ensure proper drainage flow.
  • Turn off water supply to the strainer or filter.
  • Remove the strainer or filter from its housing.
  • Rinse under water to remove dirt and debris.
  • Inspect for damage; replace if necessary.
  • Reinstall securely and restore water supply.
  • Shut down the cooling tower and drain water if needed.
  • Remove nozzles from their fittings carefully.
  • Rinse nozzles with water to clear any blockages.
  • Inspect for wear, replacing any damaged nozzles.
  • Reinstall nozzles securely before restarting the system.
  • Turn off power to the control panel.
  • Use a soft, lint-free cloth to wipe the surfaces.
  • Apply a mild cleaner if necessary, avoiding harsh chemicals.
  • Ensure no moisture enters electrical components.
  • Power the system back on and test functionality.
  • Identify areas with scale buildup on water lines.
  • Use a descaling solution appropriate for the materials.
  • Follow the manufacturer's instructions for application.
  • Flush lines thoroughly with clean water after descaling.
  • Inspect for any remaining buildup and repeat if necessary.
  • Turn off power to the pump before cleaning.
  • Remove any debris, dust, or obstructions around the pump.
  • Wipe down surfaces with a damp cloth.
  • Check for leaks or wear in surrounding areas.
  • Restore power and monitor for proper operation.
  • Turn off the chiller and access the air intake area.
  • Remove the air filters from their housing.
  • Vacuum or rinse filters based on type and manufacturer instructions.
  • Inspect for damage and replace as necessary.
  • Reinstall filters securely before restarting the system.
  • Turn off power and isolate insulated pipes/components.
  • Inspect insulation for signs of wear, moisture, or damage.
  • Clean surfaces using a damp cloth to remove contaminants.
  • Replace any damaged insulation to maintain efficiency.
  • Ensure all insulation is secure and properly fitted.

7. Documentation

8. Safety Checks

  • Inspect all guards and covers for damage.
  • Verify that all fasteners are secure.
  • Ensure guards are correctly positioned.
  • Document any missing or damaged components for repair.
  • Test each emergency shutoff switch.
  • Check for proper labeling and accessibility.
  • Ensure that switches engage and disengage as intended.
  • Report any malfunctioning switches immediately.
  • Access the latest safety data sheets (SDS).
  • Review handling and storage guidelines.
  • Ensure that all personnel are trained on these procedures.
  • Keep SDS accessible in the maintenance area.
  • Check pressure gauges for proper readings.
  • Test manual activation mechanisms.
  • Inspect hoses and nozzles for damage.
  • Ensure extinguishers are accessible and inspected.
  • Review maintenance logs for compliance.
  • Verify labels are clear and legible.
  • Ensure all circuits are correctly identified.
  • Check for any outdated or missing labels.
  • Assess for compliance with local regulations.
  • Document any discrepancies for rectification.
  • Conduct a brief training session.
  • Post evacuation plans in visible locations.
  • Distribute emergency procedure handouts.
  • Verify employee understanding through quizzes.
  • Schedule regular drills to reinforce knowledge.
  • Inspect PPE for wear and tear.
  • Ensure proper sizing and fit for users.
  • Replace any damaged or expired equipment.
  • Store PPE in accessible locations.
  • Provide training on proper usage.
  • Check storage areas for organization.
  • Ensure tools are cleaned after use.
  • Implement a labeling system for easy identification.
  • Conduct regular audits of tool inventory.
  • Train personnel on proper storage practices.
  • Clear any visible debris from drains.
  • Test drainage flow with water.
  • Inspect pipes for leaks or corrosion.
  • Review maintenance records for past issues.
  • Document any necessary repairs.
  • Use leak detection equipment for accuracy.
  • Check all fittings and joints for tightness.
  • Review response protocols for refrigerant leaks.
  • Train staff on emergency response actions.
  • Document findings and repairs needed.
  • Ensure LOTO procedures are current and compliant.
  • Train staff on updated procedures.
  • Conduct audits to verify adherence.
  • Document any changes made to procedures.
  • Post LOTO procedures in accessible locations.
  • Conduct a walk-around inspection.
  • Remove any visible hazards immediately.
  • Report persistent hazards to management.
  • Ensure adequate lighting in the area.
  • Document inspections and actions taken.
  • Check airflow and filter conditions.
  • Inspect ducts for blockages or leaks.
  • Test alarms and sensors for functionality.
  • Review maintenance logs for ventilation checks.
  • Ensure compliance with safety regulations.

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