General System Overview
- Comprehensive visual inspection of all major components and systems for wear, corrosion, or damage
- Review total operating hours and compressor starts for the year against maintenance schedules
- Analyze alarm history for recurring issues and verify corrective actions were effective
- Verify proper support, alignment, and insulation of the chiller unit
- Reset service hour counters and update maintenance tracking systems
- Check structural integrity of chiller mounting and vibration isolation systems
Compressor & Refrigerant System
- Perform detailed compressor inspection including cleaning, lubrication, and worn parts assessment
- Complete oil change and check for contaminants or unusual coloration
- Conduct extensive leak test using advanced leak detection tools
- Perform in-depth refrigerant pressure check and replenish levels if needed
- Test oil heater functionality to prevent refrigerant migration
- Replace compressor seals and gaskets as per manufacturer recommendations
- Verify screw compressor rotor clearances and alignment
- Check slide valve operation and capacity control mechanisms
Electrical System
- Inspect all electrical connections including motors, relays, circuit breakers, and control panels
- Check for loose connections, signs of overheating, or wear and tear
- Perform motor insulation resistance test per manufacturer specifications
- Verify voltage and current consumption against specifications
- Test backup power systems and automatic transfer switches
- Clean and tighten all electrical connections and terminal blocks
- Verify proper operation of Variable Speed Drive (VSD) components
- Check power factor correction equipment if installed
Water & Cooling System
- Review entire chilled water system for proper flow, pressure, and temperature regulation
- Inspect all valves, pumps, and filters, replacing parts showing significant wear
- Inspect condenser water system for obstructions, leaks, or corrosion
- Review water treatment system and replace chemicals as needed
- Inspect water quality to prevent scale and corrosion buildup
- Clean Y-strainers and replace filter elements
- Verify flow switches and differential pressure sensors calibration
- Check expansion tank pressure and bladder integrity
Heat Exchangers
- Perform thorough cleaning of condenser and evaporator to remove dirt, debris, or scale
- Inspect for physical damage and replace components that cannot be cleaned
- Ensure fans, dampers, and air ducts are free of obstructions
- Check fan motor performance and clean air intake filters
- Perform eddy current testing on tubes if applicable
- Verify heat exchanger approach temperatures and log efficiency
- Check tube sheets for erosion or corrosion
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
- Verify refrigerant leak detection system operation
- Check purge unit operation and efficiency
- Test interlocks with building automation system
- Verify proper ventilation in mechanical room
Performance Monitoring
- Conduct full system performance review including energy consumption analysis
- Compare cooling output and efficiency against baseline data
- Review historical data for inefficiency patterns
- Recommend actions to optimize energy use and reduce costs
- Verify control system optimization and setpoint strategies
- Document kW/ton performance at various load conditions
- Update maintenance schedules based on performance trends
Documentation & Reporting
- Record all activities, findings, and corrective actions in annual log
- Include recommendations for improvements or outstanding maintenance
- Ensure compliance with local regulations and industry standards
- Update equipment records with current condition assessment
- Submit environmental compliance reports as required
- Create maintenance budget forecast for upcoming year
- Schedule follow-up actions and next annual inspection