General System Overview
- Perform thorough visual inspection of entire chiller system for leaks, corrosion, cracks, or physical damage
- Inspect piping, insulation, and support structures for integrity and proper condition
- Check operating hours log and verify equipment is within expected monthly service intervals
- Review alarm history for recurring issues and document all findings
- Verify all alarm and monitoring systems are functioning correctly
- Check equipment room conditions including temperature, humidity, and ventilation
Compressor & Refrigerant System
- Inspect compressor for wear and tear, listening for abnormal sounds like grinding or rattling
- Check refrigerant pressure levels and verify against manufacturer specifications
- Perform comprehensive leak detection using electronic detectors and bubble tests
- Inspect compressor oil and perform oil analysis for contamination or degradation
- Replace compressor oil if analysis indicates contamination or breakdown
- Test oil heater functionality and verify temperature regulation capabilities
- Check inlet guide vane operation and calibration
- Document refrigerant charge and any additions or recoveries performed
Electrical System
- Confirm chiller receiving correct voltage, amperage, and frequency per specifications
- Inspect all electrical connections, control panels, and circuit breakers for damage or wear
- Check for signs of overheating, corrosion, or loose connections
- Test safety switches and verify proper operation
- Inspect motor insulation resistance and record readings
- Check motor performance, lubrication, and bearing condition
- Verify fans functioning properly with unobstructed air circulation
- Perform thermographic scan of electrical components if available
Water & Cooling System
- Check chilled water flow rate, pressure, and temperature against design parameters
- Verify pumps and valves functioning optimally with no cavitation or excessive noise
- Inspect condenser water flow rate and temperature within normal operating parameters
- Verify water treatment systems working properly to prevent scaling and corrosion
- Test water chemistry including pH, conductivity, and inhibitor levels
- Clean water strainers and check differential pressure across filters
- Inspect expansion tanks and air separators for proper operation
- Check for proper water flow through all circuits and document flow rates
Heat Exchangers
- Perform visual inspection for fouling or scaling on condenser and evaporator surfaces
- Clean coils as required using approved cleaning methods and chemicals
- Inspect airflow through heat exchangers and verify no debris blocking flow
- Clean fans and ensure proper rotation and balance
- Check approach temperatures and log values for trending
- Inspect tube sheets and end bells for corrosion or damage
- Verify proper refrigerant subcooling and superheat values
Safety & Protection Systems
- Test high/low pressure safety switches for proper operation and setpoints
- Verify temperature sensors and emergency shutoffs functioning correctly
- Perform emergency shutdown system test and verify response times
- Check all safety interlocks including flow switches and freeze protection
- Inspect relief valves for proper seating and test dates
- Verify lockout/tagout procedures are current and accessible
- Test refrigerant leak detection system and alarms
- Verify emergency eyewash and safety equipment accessibility
Performance Monitoring
- Assess system efficiency by comparing operational parameters with historical data
- Review monthly energy usage trends and calculate kW/ton efficiency
- Analyze cooling output versus energy consumption for optimization opportunities
- Compare actual performance with manufacturer design specifications
- Document capacity control response to varying load conditions
- Review and update control setpoints for seasonal optimization
- Perform vibration analysis on rotating equipment
Documentation & Reporting
- Record all inspection findings and maintenance actions in equipment log
- Document any issues addressed and parts replaced during inspection
- Ensure compliance with environmental, safety, and operational regulations
- Update preventive maintenance schedule based on equipment condition
- File refrigerant management documentation per EPA requirements
- Prepare monthly performance report with recommendations
- Schedule follow-up actions for any deficiencies identified