General System Overview
- Thorough inspection of entire chiller system for leaks, corrosion, physical damage
- Verify operating hours and compressor starts within expected monthly limits
- Review complete alarm history for recurring issues or patterns
- Inspect piping insulation integrity and support structures
- Check equipment room ventilation and ambient conditions
- Verify all safety signage and equipment labels are legible
Compressor & Oil System
- Perform comprehensive compressor performance analysis
- Oil sample collected and sent for laboratory analysis
- Replace oil filter if pressure drop exceeds specifications
- Test oil heater functionality and temperature regulation
- Check oil separator efficiency and clean if necessary
- Verify slide valve operation through full capacity range
- Record vibration readings at multiple load conditions
Refrigerant System
- Comprehensive leak detection using electronic methods
- Verify refrigerant charge and adjust if necessary
- Test and calibrate vapor injection system components
- Replace filter driers if moisture indicators show contamination
- Check superheat and subcooling at various load conditions
- Inspect and test electronic expansion valve operation
- Document refrigerant pressures and temperatures
Electrical System
- Verify voltage, amperage, and frequency per specifications
- Infrared scan of all electrical connections for hot spots
- Test motor insulation resistance and record readings
- Inspect and clean VSD cooling fans and heat sinks
- Check starter contacts for pitting or wear
- Verify proper operation of all control circuits
- Test ground fault protection systems
Water & Cooling System
- Analyze water quality for pH, conductivity, and treatment levels
- Clean water strainers and document pressure drop
- Verify flow rates and adjust balancing valves if needed
- Inspect pump seals and bearings for wear
- Test water flow switches and clean sensing elements
- Check cooling tower operation and water distribution
Heat Exchangers
- Measure and record approach temperatures for trending
- Inspect tube sheets for signs of erosion or corrosion
- Perform eddy current testing if fouling suspected
- Clean heat exchanger tubes if approach exceeds limits
- Verify refrigerant distribution in evaporator
- Check gaskets and mechanical seals for leaks
Controls & Sensors
- Calibrate all temperature sensors against known standards
- Calibrate pressure transducers and verify accuracy
- Update control software/firmware to latest version
- Test all control sequences and staging operations
- Verify BMS communication and data accuracy
- Backup control parameters and settings
Safety & Protection Systems
- Test all safety interlocks and document response times
- Verify pressure relief valve settings and test dates
- Test emergency shutdown from all activation points
- Inspect rupture disks for damage or corrosion
- Verify refrigerant monitor calibration and alarms
- Test oil pressure and temperature safety controls
Performance Analysis
- Calculate and record monthly average kW/ton efficiency
- Compare performance against manufacturer baselines
- Analyze energy consumption trends and patterns
- Review capacity utilization and load profiles
- Identify optimization opportunities and document
- Verify vapor injection system efficiency gains
Documentation & Compliance
- Complete detailed maintenance log with all findings
- Update equipment history and maintenance records
- File refrigerant usage reports per EPA requirements
- Document all safety test results and corrective actions
- Update preventive maintenance schedule based on findings
- Generate monthly performance report for management