General System Overview
- Perform comprehensive inspection of all major components for wear, corrosion, or damage
- Verify proper support, alignment, and insulation of entire chiller system
- Review total operating hours and compressor starts for the year
- Analyze alarm history for recurring issues and corrective action effectiveness
- Reset service hour counters per maintenance schedule
- Update equipment nameplate data and verify model/serial numbers
- Photograph all major components for documentation
Compressor & Refrigerant System
- Perform detailed compressor inspection including cleaning and lubrication
- Replace worn parts, seals, and gaskets as needed
- Conduct extensive leak test using advanced detection tools
- Address all leaks and replenish refrigerant to specifications
- Change compressor oil and replace oil filters
- Perform oil analysis for contaminants and wear metals
- Test oil heater functionality and temperature control
- Inspect and test thrust bearings and alignment
- Verify proper operation of capacity control mechanism
- Replace shaft seals if any leakage detected
Electrical System
- Inspect all electrical connections including motors, relays, and circuit breakers
- Check for loose connections, overheating signs, or wear
- Perform motor insulation resistance test with megohmmeter
- Verify voltage and current consumption against specifications
- Test backup power systems and automatic transfer switches
- Perform infrared thermography scan of all electrical components
- Clean and tighten all electrical connections to proper torque
- Test and calibrate all electrical protection devices
- Replace any worn contactors or relays
Water & Cooling System
- Review entire chilled water system for flow, pressure, and temperature
- Inspect all valves, pumps, and filters for wear
- Replace worn pump seals, gaskets, and filters
- Inspect condenser water system for obstructions and corrosion
- Review and replace water treatment chemicals
- Perform complete water quality analysis
- Clean all water strainers and verify differential pressure
- Test and calibrate all flow meters and sensors
- Inspect expansion tanks and air separation devices
Heat Exchangers
- Perform thorough cleaning of condenser and evaporator coils
- Remove all dirt, debris, and scale buildup
- Inspect for physical damage and replace damaged components
- Ensure fans, dampers, and air ducts free of obstructions
- Check fan motor performance and clean air intake filters
- Perform eddy current testing on tubes if applicable
- Document heat transfer efficiency and approach temperatures
- Replace tube sheets gaskets and seals as needed
Safety & Protection Systems
- Test all safety switches including high/low pressure cutoffs
- Verify temperature switches and emergency shutdown systems
- Test all visual and audible alarms for proper response
- Calibrate all safety sensors and switches
- Test refrigerant leak detection system comprehensively
- Verify proper operation of pressure relief valves
- Update all safety signage and lockout/tagout procedures
- Test ventilation system activation and exhaust fans
Performance Monitoring
- Conduct full system performance review for past year
- Analyze energy consumption, cooling output, and efficiency
- Compare performance against baseline data and benchmarks
- Review historical data for efficiency optimization opportunities
- Recommend actions to reduce operating costs
- Perform full-load and part-load performance tests
- Update performance tracking metrics and KPIs
- Create annual efficiency report with recommendations
Documentation & Compliance
- Record all activities and findings in annual inspection log
- Document all corrective actions taken
- Include recommendations for improvements
- Verify compliance with local regulations and standards
- Ensure compliance with environmental guidelines
- Update equipment history and maintenance records
- Create preventive maintenance schedule for coming year
- Submit warranty compliance documentation if applicable