Daikin WRC – Yearly Chiller Maintenance Procedure
Use this checklist to conduct comprehensive annual maintenance on Daikin WRC vapor absorption chillers to ensure safety, performance, and regulatory compliance.
Comprehensive System Evaluation
- Complete visual inspection of all components, piping, insulation, and structural supports
- Document total annual operating hours and compare with design expectations
- Review complete maintenance history and identify recurring issues
- Assess remaining service life of major components and plan replacements
- Verify all equipment labeling, safety signage, and operating procedures current
- Update equipment documentation and as-built drawings with any modifications
Solution System Overhaul
- Perform complete laboratory analysis of lithium bromide solution
- Filter entire solution charge to remove suspended solids and contaminants
- Adjust solution chemistry including pH, alkalinity, and inhibitor levels
- Replace octyl alcohol to restore proper heat transfer enhancement
- Clean solution sumps and remove any accumulated sediment
- Verify solution charge quantity and adjust to manufacturer specifications
Heat Exchanger Service
- Perform mechanical or chemical cleaning of all tube bundles
- Conduct eddy current testing to assess tube wall thickness
- Replace spray nozzles showing wear or improper spray patterns
- Clean or replace eliminator pads in absorber and evaporator
- Inspect tube sheets for corrosion and repair as necessary
- Document post-cleaning heat transfer performance improvement
Vacuum System Overhaul
- Replace all accessible gaskets, O-rings, and valve packing
- Overhaul vacuum pump with new seals, oil, and filters
- Perform comprehensive leak detection using helium mass spectrometer
- Service purge unit including chamber cleaning and valve replacement
- Calibrate all vacuum gauges and replace if accuracy compromised
- Document system vacuum hold test results after service
Control System Upgrade
- Update control system software to latest version available
- Replace aging sensors and transmitters proactively
- Calibrate all instruments using certified reference standards
- Upgrade obsolete control components before failure
- Implement advanced control strategies for efficiency optimization
- Archive all control system configurations and parameters
Electrical System Maintenance
- Perform comprehensive infrared thermography of all connections
- Meggering test all motors and record insulation resistance values
- Clean and torque all electrical connections to specifications
- Replace motor starter contacts showing wear or pitting
- Test and calibrate all protective relays and circuit breakers
- Update electrical single-line drawings with any modifications
Mechanical Components Service
- Rebuild solution pumps including seal and bearing replacement
- Perform laser alignment of all pump-motor couplings
- Replace motor bearings based on operating hours or vibration
- Service all control valves including actuator calibration
- Replace isolation valves showing leakage or wear
- Document vibration analysis results and trends
Safety Systems Recertification
- Recertify all pressure relief valves per code requirements
- Test and document all safety interlocks under simulated conditions
- Verify crystallization protection system with complete functional test
- Replace batteries in emergency lighting and alarm systems
- Update all safety procedures and emergency response plans
- Conduct comprehensive safety training for all operators
Annual Performance Review
- Compile and analyze annual energy consumption data
- Calculate annual average COP and compare with design values
- Review maintenance costs and identify cost reduction opportunities
- Document all equipment modifications and upgrades performed
- Create comprehensive annual report for management review
- Develop maintenance plan and budget for upcoming year