Check Points for the Pre-Planned Preventive Maintenance of Chiller
The following inspection items will ensure that the unit is operating reliably and efficiently through the cooling season.
a) Inspection of chillers.
b) Checking operation of controls.
c) Checking oil and refrigerant levels.
d) Checking operation of lube system.
e) Checking the oil return system.
f) Checking operation of Compressor motor.
g) Recording operating conditions.
h) Checking log and reviewing chiller and system operation.
i) Reporting repairs and parts that are required.
j) Checking of Compressor compression.
k) Checking of Evaporator fouling.
l) Checking of Condenser fouling.
m) Checking of Oil temperature .
n) Checking of starter.
o) Checking of Oil heater.
p) Checking of Leak.
q) Checking of Microprocessor board.
r) Checking of I/O Board.
s) Checking of Power Module
t) Checking of Current transformer (C. T.)
u) Checking of Optiview Panel Display.
v) Checking of Pressure/ Temperatures.
w) Checking of Pre-rotation vanes
x) Checking of % motor current.
y) Checking of Operating Hours.
z) Checking of Starts.
aa) Checking of Fault status messages.
bb) Checking of Set points.
cc) Checking of High Pressure Safety.
dd) Checking of Low oil Diff. Safety.
ee) Checking of motor current unbalance.
ff) Checking of low water temp.
gg) Checking of flow switch.
hh) Checking of History.
ii) Checking of Anti-recycle timer.
Quarterly checking of flow of water through evaporator and condenser
i) Major Maintenance
Major Annual Service.
Performing Preventive Maintenance Tasks as indicated below:
a) Laboratory Oil analysis
Checking the compressor oil system for the following items:
a) Changing the compressor oil, if required .
b) Changing oil filter and drier. If Required.
c) Checking oil heater.
d) Checking all other oil systems components and strainer where applicable.
Checking motor starter and performing the following tasks:
a) Running diagnostic check.
b) Cleaning contacts or recommending replacement.
c) Meggering the motor.
d) Checking all terminals and tightening connections.
e) Checking overloads.
Review the control panel for the following items:
a) Running diagnostic check of motor control panel.
b) Checking safety shutdowns operation.
c) Checking all terminals and tightening connections.
d) Checking display data accuracy and set points.
Checking condenser for the following items:
a) Checking the water pressure drop.
b) Checking flow switch operation.
c) Checking the refrigerant level
d) Cleaning of Condenser tubes.
Checking the cooler for the following items:
a)Checking the water pressure drop.
b)Checking flow switch operation.
c)Checking the refrigerant level.
d)Cleaning of Evaporator tubes. ( If Required )
Checking the system for the following items:
a) Conducting a leak check and identifying leak sources.
b) Recording the condition of sight glasses.
c) Checking the refrigerant cycle to verify the proper operating balance.
d) Checking condenser water and chilled water heat transfer.
General items included:
a) Repairing insulation removed for inspection and maintenance procedures.
b) Cleaning equipment and surrounding area upon completion of work.
c) Consulting with the operator.
d) Reporting deficiencies and repairs required.
e) Complete service inspection Report Form.
Chiller Consumables
All parts and consumables including Refrigerant etc Required for the Chiller Plants are as Follows
- Sensor
- Transducer
- Micro board
- Power Module
- Display board
- Input / output board
- Solenoid coil
- H P Switch
- Transformer
- Contactor Kit
- Contactor
- Overload
- Timer
- Nitrogen for Pressure testing
- Chemical for cleaning of fins
- Compressor oil
- Oil filters
- Drier core
- Refrigerant
- Valve, Thermal Expansion
- Motor, Variable Orifice
- CM -2 Board
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