ABSORBTION CHILLER daily, weekly, monthly, quarterly, semi annaul preventive maintenance checklists
Daily Preventive Maintenance Checklist
- Locate pressure gauges and temperature sensors.
- Record the values and compare with standard operating ranges.
- Note any deviations for further investigation.
- Ensure readings are stable during operation.
- Look for warning lights or error messages.
- Check indicator lights for normal operation.
- Reset any alarms after noting issues.
- Document any abnormalities for follow-up.
- Check the water level gauge.
- Add water if levels are below the minimum mark.
- Inspect for proper float operation.
- Ensure overflow is functioning correctly.
- Measure supply and return temperatures using thermometers.
- Compare with specified temperature limits.
- Investigate any significant temperature differences.
- Record temperatures for maintenance logs.
- Stand near the chiller during operation.
- Identify any loud or irregular noises.
- Check for excessive vibrations by placing your hand on the unit.
- Document any concerns for technical review.
- Inspect all piping and connection points visually.
- Look for water stains, corrosion, or wet areas.
- Use a rag to wipe areas and check for moisture.
- Report any leaks immediately for repair.
- Locate pressure gauges and temperature sensors.
- Record the values and compare with standard operating ranges.
- Note any deviations for further investigation.
- Ensure readings are stable during operation.
- Look for warning lights or error messages.
- Check indicator lights for normal operation.
- Reset any alarms after noting issues.
- Document any abnormalities for follow-up.
- Check the water level gauge.
- Add water if levels are below the minimum mark.
- Inspect for proper float operation.
- Ensure overflow is functioning correctly.
- Measure supply and return temperatures using thermometers.
- Compare with specified temperature limits.
- Investigate any significant temperature differences.
- Record temperatures for maintenance logs.
- Stand near the chiller during operation.
- Identify any loud or irregular noises.
- Check for excessive vibrations by placing your hand on the unit.
- Document any concerns for technical review.
- Inspect all piping and connection points visually.
- Look for water stains, corrosion, or wet areas.
- Use a rag to wipe areas and check for moisture.
- Report any leaks immediately for repair.
Weekly Preventive Maintenance Checklist
- Turn off power to the chiller.
- Use a soft brush or vacuum to remove dust and debris.
- Clean coils with a coil cleaner solution and rinse with water.
- Inspect for any signs of corrosion or damage.
- Check for leaves, dirt, or other debris in the tower.
- Remove any blockages from the water intake and distribution system.
- Flush the system with clean water to remove accumulated dirt.
- Inspect the fill media for scaling or fouling.
- Listen for unusual noises during operation.
- Check for vibrations or excessive heat near bearings.
- Lubricate bearings according to manufacturer specifications.
- Replace worn bearings as needed.
- Examine insulation for tears, gaps, or moisture accumulation.
- Replace damaged insulation to maintain efficiency.
- Ensure all insulation is properly secured.
- Check for signs of mold or mildew.
- Test water chemistry using appropriate test kits.
- Adjust chemical levels to meet required specifications.
- Record chemical usage and balance adjustments.
- Inspect chemical feed systems for proper operation.
- Look for deviations in performance metrics.
- Identify recurring issues and prioritize for follow-up.
- Document any maintenance actions taken.
- Discuss findings with the maintenance team.
- Turn off power to the chiller.
- Use a soft brush or vacuum to remove dust and debris.
- Clean coils with a coil cleaner solution and rinse with water.
- Inspect for any signs of corrosion or damage.
- Check for leaves, dirt, or other debris in the tower.
- Remove any blockages from the water intake and distribution system.
- Flush the system with clean water to remove accumulated dirt.
- Inspect the fill media for scaling or fouling.
- Listen for unusual noises during operation.
- Check for vibrations or excessive heat near bearings.
- Lubricate bearings according to manufacturer specifications.
- Replace worn bearings as needed.
- Examine insulation for tears, gaps, or moisture accumulation.
- Replace damaged insulation to maintain efficiency.
- Ensure all insulation is properly secured.
- Check for signs of mold or mildew.
- Test water chemistry using appropriate test kits.
- Adjust chemical levels to meet required specifications.
- Record chemical usage and balance adjustments.
- Inspect chemical feed systems for proper operation.
- Look for deviations in performance metrics.
- Identify recurring issues and prioritize for follow-up.
- Document any maintenance actions taken.
- Discuss findings with the maintenance team.
- Turn off water flow and remove strainers and filters.
- Rinse with clean water to remove debris.
- Inspect for damage and replace if necessary.
- Reinstall and ensure secure fittings.
- Test safety devices to ensure proper function.
- Check for alarms and indicators on control panels.
- Inspect control wiring for signs of wear.
- Document any malfunctions and report for repair.
- Turn off power before inspection.
- Check connections for tightness using appropriate tools.
- Look for discoloration or burn marks indicating overheating.
- Tighten or replace connections as needed.
- Use a gauge to measure refrigerant levels.
- Look for signs of leaks around joints and fittings.
- Repair any leaks found and replenish refrigerant.
- Document refrigerant levels and repairs performed.
- Inspect expansion valves for signs of damage.
- Listen for unusual noises indicating blockages.
- Clean any debris from valve openings.
- Document any anomalies for follow-up.
- Examine all visible components for rust or decay.
- Check mounting brackets and supports for stability.
- Look for signs of fluid leaks around connections.
- Document any issues and schedule repairs.
- Simulate alarm conditions to test responses.
- Verify that control settings can be adjusted correctly.
- Ensure alarms are audible and visible.
- Document any failures or required adjustments.
- Compare readings to manufacturer specifications.
- Log any anomalies and investigate causes.
- Check for proper calibration of gauges.
- Report consistent deviations to maintenance team.
- Look for signs of corrosion or physical damage.
- Use a leak detection solution to check for leaks.
- Ensure all fittings and connections are secure.
- Document any findings and schedule repairs if necessary.
- Ensure all completed maintenance tasks are logged.
- Update schedules based on any changes or findings.
- Review upcoming maintenance needs.
- Share updated records with relevant team members.
- Listen for unusual sounds during fan operation.
- Check for vibrations that indicate imbalance.
- Inspect fan blades for damage or debris.
- Lubricate motor bearings if applicable.
Monthly Preventive Maintenance Checklist
- Remove air filters from the chiller.
- Use compressed air or a soft brush to clean filters.
- Inspect for damage; replace if necessary.
- Reinstall filters securely.
- Turn off power to the chiller.
- Visually inspect all electrical connections.
- Look for frayed wires, corrosion, or loose connections.
- Tighten or replace connections as needed.
- Activate the chiller and monitor control panel.
- Test all safety alarms and shutdown functions.
- Ensure indicators and alarms respond appropriately.
- Document any issues found for follow-up.
- Check refrigerant gauges for proper levels.
- Inspect joints and connections for signs of leakage.
- Use a leak detection system if available.
- Record findings and address any leaks immediately.
- Use a calibrated reference device.
- Compare readings from sensors with reference device.
- Adjust sensors according to manufacturer specifications.
- Document calibration results for records.
- Access maintenance logs from the previous month.
- Verify completed tasks against the checklist.
- Update records with any new service or repairs.
- Ensure logs are stored securely.
- Remove air filters from the chiller.
- Use compressed air or a soft brush to clean filters.
- Inspect for damage; replace if necessary.
- Reinstall filters securely.
- Turn off power to the chiller.
- Visually inspect all electrical connections.
- Look for frayed wires, corrosion, or loose connections.
- Tighten or replace connections as needed.
- Activate the chiller and monitor control panel.
- Test all safety alarms and shutdown functions.
- Ensure indicators and alarms respond appropriately.
- Document any issues found for follow-up.
- Check refrigerant gauges for proper levels.
- Inspect joints and connections for signs of leakage.
- Use a leak detection system if available.
- Record findings and address any leaks immediately.
- Use a calibrated reference device.
- Compare readings from sensors with reference device.
- Adjust sensors according to manufacturer specifications.
- Document calibration results for records.
- Access maintenance logs from the previous month.
- Verify completed tasks against the checklist.
- Update records with any new service or repairs.
- Ensure logs are stored securely.
Quarterly Preventive Maintenance Checklist
- Shut down the cooling tower system.
- Drain the water basin completely.
- Remove debris and sediment from the basin.
- Use a suitable cleaning solution to scrub the surfaces.
- Rinse thoroughly with clean water.
- Refill with fresh water and restart the system.
- Shut down the chiller unit safely.
- Remove access panels to the heat exchangers.
- Inspect for scale buildup or corrosion.
- Use appropriate cleaning methods to remove contaminants.
- Reassemble the heat exchangers and check for leaks.
- Visually inspect all valves for leaks and damage.
- Manually operate each valve to ensure proper function.
- Calibrate actuators as needed to confirm accuracy.
- Lubricate moving parts to ensure smooth operation.
- Document any anomalies or maintenance required.
- Check for signs of rust, corrosion, or physical damage.
- Inspect welds and joints for structural stability.
- Look for any signs of fluid leaks.
- Ensure all safety guards and enclosures are intact.
- Document findings and recommend repairs if needed.
- Collect water samples for testing chemical levels.
- Assess pH, alkalinity, and conductivity.
- Check for biocide effectiveness and adjust treatment as required.
- Review treatment records for consistency.
- Make recommendations for improving water quality.
- Compile all inspection and maintenance records.
- Identify any recurring issues or new problems.
- Adjust maintenance frequency based on equipment condition.
- Ensure all team members are informed of updates.
- Distribute revised plan to relevant personnel.
- Shut down the cooling tower system.
- Drain the water basin completely.
- Remove debris and sediment from the basin.
- Use a suitable cleaning solution to scrub the surfaces.
- Rinse thoroughly with clean water.
- Refill with fresh water and restart the system.
- Shut down the chiller unit safely.
- Remove access panels to the heat exchangers.
- Inspect for scale buildup or corrosion.
- Use appropriate cleaning methods to remove contaminants.
- Reassemble the heat exchangers and check for leaks.
- Visually inspect all valves for leaks and damage.
- Manually operate each valve to ensure proper function.
- Calibrate actuators as needed to confirm accuracy.
- Lubricate moving parts to ensure smooth operation.
- Document any anomalies or maintenance required.
- Check for signs of rust, corrosion, or physical damage.
- Inspect welds and joints for structural stability.
- Look for any signs of fluid leaks.
- Ensure all safety guards and enclosures are intact.
- Document findings and recommend repairs if needed.
- Collect water samples for testing chemical levels.
- Assess pH, alkalinity, and conductivity.
- Check for biocide effectiveness and adjust treatment as required.
- Review treatment records for consistency.
- Make recommendations for improving water quality.
- Compile all inspection and maintenance records.
- Identify any recurring issues or new problems.
- Adjust maintenance frequency based on equipment condition.
- Ensure all team members are informed of updates.
- Distribute revised plan to relevant personnel.
Semi-Annual Preventive Maintenance Checklist
- Measure the refrigerant levels using appropriate gauges.
- Compare current readings with manufacturer specifications.
- Identify any discrepancies and address them promptly.
- Document the refrigerant charge data for future reference.
- Check the functionality of pressure relief valves.
- Test emergency shut-off switches for proper operation.
- Examine safety alarms and indicators for responsiveness.
- Replace or repair any malfunctioning safety devices.
- Open the chiller casing and inspect internal components.
- Look for signs of wear, corrosion, or leaks.
- Ensure all components are securely mounted and aligned.
- Document any findings and necessary repairs.
- Inspect the expansion valve for blockages or damage.
- Test the valve operation under varying load conditions.
- Ensure proper refrigerant flow and pressure are maintained.
- Adjust or replace the valve if necessary.
- Identify any seals or gaskets showing signs of wear.
- Remove old seals and clean surfaces before replacement.
- Install new seals ensuring a proper fit.
- Test for leaks after installation.
- Evaluate current maintenance practices and their effectiveness.
- Update schedules based on equipment performance and manufacturer recommendations.
- Communicate changes to relevant personnel.
- Document any revisions for future reference.
- Shut down the chiller and ensure it is safe to work on.
- Remove any debris or obstructions from the condenser and evaporator.
- Use appropriate cleaning agents to remove scale or deposits.
- Rinse the surfaces thoroughly with clean water.
- Inspect for any signs of corrosion or damage.
- Power down the unit completely and lockout/tagout.
- Inspect all electrical connections for wear or corrosion.
- Use a torque wrench to tighten connections to manufacturer's specifications.
- Check for any exposed wires or insulation damage.
- Record findings and repair any issues identified.
- Measure inlet and outlet temperatures of the heat exchangers.
- Calculate temperature differentials; compare with manufacturer standards.
- Inspect for any visible blockages or scaling on the heat exchanger surfaces.
- Clean the heat exchangers if scaling is found.
- Document test results for future reference.
- Perform a visual inspection of all piping and insulation.
- Check for signs of wear, corrosion, or leaks.
- Use a leak detection solution to identify any minor leaks.
- Replace or repair any damaged sections of piping or insulation.
- Ensure all repairs are documented and dated.
- Use appropriate monitoring tools to collect energy consumption data.
- Record performance metrics such as flow rates and temperatures.
- Analyze data against historical records for trends.
- Identify any deviations from normal operational parameters.
- Prepare a report summarizing energy consumption and performance.
- Inspect the circulating pump(s) for any signs of wear or leakage.
- Check the lubrication levels and add lubricant if needed.
- Listen for unusual noises during operation that may indicate issues.
- Ensure all pump connections and fittings are secure.
- Document maintenance actions taken.
- Inspect the cooling tower for any visible damage or debris.
- Check the operation of fans and pumps associated with the cooling tower.
- Clean the tower fill to remove dirt and biological growth.
- Inspect for proper water flow and drainage.
- Document the inspection and cleaning activities.
- Collect water samples from the cooling system.
- Test for pH, conductivity, and other relevant parameters.
- Add appropriate chemical treatments to balance water quality.
- Document the analysis results and any treatments applied.
- Schedule follow-up tests as necessary.
- Visually inspect gauges for any signs of damage or leaks.
- Use calibration equipment to test accuracy against known standards.
- Adjust gauges as necessary to ensure they provide accurate readings.
- Record calibration results and any adjustments made.
- Replace gauges that are found to be faulty.
- Gather all operational logs and previous maintenance records.
- Review entries for completeness and accuracy.
- Update any missing information or corrections as necessary.
- Ensure records are stored in a secure and accessible location.
- Prepare a summary report of maintenance activities.
- Inspect all safety signage for visibility and legibility.
- Replace any damaged or outdated signage.
- Ensure that operational manuals are current and available at the chiller site.
- Review manuals for any updates or changes in procedures.
- Document any changes made to signage or manuals.
- Use a vibration analysis tool to assess the compressor.
- Record vibration levels and compare with baseline data.
- Identify any imbalances or unusual vibration patterns.
- Take corrective actions if necessary and retest.
- Document findings and any actions taken.
- Start the absorption chiller and monitor for unusual sounds.
- Listen for irregular vibrations or operational anomalies.
- Inspect components visually while the system is running.
- Take note of specific conditions when noises occur.
- Report any concerns for further investigation.
- Perform a thorough inspection of the chiller room cleanliness.
- Ensure that ventilation systems are unobstructed and functioning.
- Remove any debris or clutter that could impede airflow.
- Check for any signs of water or fluid accumulation.
- Document the cleanliness status and any improvements needed.
- Test each emergency shut-off switch to ensure it operates.
- Check that alarms activate and are audible from a safe distance.
- Inspect wiring and connections for any signs of damage.
- Document test results and any corrective actions taken.
- Replace any faulty components immediately.
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