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 damage
- Record operating hours and compressor starts from control panel
- Review alarm history for recurring issues and document findings
- Verify all monitoring systems are functioning correctly
- Check equipment room ventilation and ambient conditions
Compressor & Refrigerant System
- Inspect screw compressors for wear, abnormal sounds (grinding, rattling)
- Check refrigerant pressure levels against manufacturer specifications
- Perform comprehensive leak detection using electronic leak detector
- Analyze compressor oil for contamination or degradation
- Change/replace compressor oil if needed per analysis results
- Test oil heater functionality and temperature regulation
- Verify oil pressure and differential pressure across filter
- Check slide valve operation and capacity control response
Electrical System
- Confirm correct voltage, amperage, and frequency per specifications
- Inspect all electrical connections for damage, corrosion, or wear
- Test control panels, circuit breakers, and safety switches
- Check motor insulation resistance with megohmmeter
- Verify motor performance and lubrication status
- Ensure fans functioning properly with unobstructed air circulation
- Tighten all electrical connections to proper torque specifications
- Test variable frequency drive (VFD) operation if equipped
Water & Cooling System
- Check chilled water flow rate, pressure, and temperature
- Verify pumps and valves functioning optimally
- Inspect condenser water flow rate and temperature parameters
- Verify water treatment system preventing scaling and corrosion
- Test water quality and adjust chemical treatment as needed
- Clean Y-strainers and check differential pressure
- Inspect expansion tanks and air separation devices
- Verify proper operation of flow switches and sensors
Heat Exchangers
- Inspect condenser and evaporator coils for fouling or scaling
- Clean coils as required using approved cleaning methods
- Inspect airflow through heat exchangers for obstructions
- Clean fans and ensure no debris blocking airflow
- Check approach temperatures and log deviations
- Inspect tube sheets for signs of corrosion or damage
- Verify refrigerant distribution is uniform across circuits
Safety & Protection Systems
- Test high/low pressure safety switches for proper operation
- Verify temperature sensors and emergency shutoffs functional
- Perform emergency shutdown system test and document results
- Check all safety interlocks and protective devices
- Verify proper operation of pressure relief valves
- Test refrigerant leak detection system and alarms
- Ensure all emergency stops are clearly labeled and accessible
- Verify lockout/tagout procedures are current and posted
Performance Monitoring
- Assess system efficiency by comparing operational parameters
- Compare energy consumption and cooling output with historical data
- Review monthly energy usage trends for optimization opportunities
- Calculate and document current kW/ton efficiency
- Verify capacity control matches building load profile
- Check superheat and subcooling values for optimization
- Document any performance degradation for trending analysis
Documentation & Reporting
- Record all inspection findings in maintenance log
- Document all maintenance actions performed
- Log any issues addressed and corrective actions taken
- Verify compliance with environmental regulations
- Ensure compliance with safety and operational regulations
- Update equipment history and trend data
- Generate monthly performance report for management review
- Schedule any required follow-up maintenance activities