Water_Cooled_Chillers_Checklist_&_Condition_Assesment.docx

Page 2 of 2 Water Cooled Chillers

INSTRUCTIONS FOR COMPLETING – CHECKLIST AND CONDITION ASSESSMENT The Contractor shall complete for each asset and its associated components covered under this contract. This form must be completed annually and submitted as part of the Annual Preventive Maintenance documentation package. Check off next to each completed task.

Location

Description

Lubricate and adjust equipment as required by manufacturer’s recommendations.

Inspect and perform Megger testing of electric wiring from the line side starter to its respective motor including VFDs.

Inspection of refrigerant piping between two or more pieces of equipment (excluding chilled water piping) and the insulation of the piping.

Inspect all pressure and temperature controls, thermometers, gauges, linkages, control devices and thermostats located at equipment and calibrate as required.

Inspect the starters; ensure proper torque and contact.

Verify the working condition of all indicator/alarm lights and LED/LCD displays.

Check all safety switches and alarms for proper operation. Calibrate or adjust as required.

This shall include, but not limited to:

Low oil pressure switch

Oil pump timers

Flow switches

Pump interlocks

System monitor timers

System freeze stats

Vane closing switches

Check operation of all operating controls and calibrate as required:

Temperature control stats

Motor load limit controls

Vane operation controls

Timers

Variable frequency drive units (if applicable)

Check compressor operation:

Performance evaluation

Check and record voltage imbalance

Check and record amperage balance

Check terminal lug torque to specifications

Check lubricating system, oil levels, and temperatures

Check vane operation under various loaded conditions

Check operation of expansion valve, superheat settings

Check and evaluate performance of purge compressor unit (if applicable)

Check operation of chiller unit:

Leak check compressor fittings and terminals

Leak check purge compressor (if applicable)

Leak check oil pump and fittings

Leak check relief valves and rupture disk

Leak check all service valves

Locate leaks if refrigerant charge is low

Check operation of main starter:

Examine contacts on all electrical connections

Verify overload and trip settings

Test all electrical connections per manufacturer’s torque specifications

Check terminal lug torque to specifications

Check operation of chiller:

Measure and record condenser and evaporator approach

Notes

Verify operation of the lead lag sequence and change if applicable

Oil Analysis: This will include a full spectrum analysis to be collected under EPA guidelines. The spectrochemical analysis will test for wear and corrosion elements in the oil sample. This will include, but not limited to: iron, chromium, aluminum, lead, silicon, tin, and zinc. The Karl Fisher method shall determine the water content of the oil

Vibration Analysis: Shall be conducted on an annual basis and a baseline trend established, charted, and compared with the manufacturer’s specifications.

Perform Megger Insulation Test on compressor motor per manufacturer’s specifications and schedule.

Notes

Complete leak check of chiller and minor leak repairs. Calculate and report refrigerant loss.

Notes

Checks all seals and replace as needed.

Change all filters per chiller maintenance recommendation.

Inspect all wiring and connections for tightness and signs of overheating and discoloration.

Inspect starter panel and main contacts for pitting/burring. Torque all connections and clean starter with approved cleaner.

Inspect internal piping, internal wiring, motor bearings, transmission gears and nuts and check for signs of moisture.

Measure and record bearing clearings.

Check all linkages for wear and for free and smooth operation.

Start Value

Finish Value

Measure and record motor voltage and amperage and calculate the voltage and current imbalance.

Compare amperage with rated amperage.

Notes

Date:

Contractor Signature:

County Representative Signature:

Condition Rating Scale

Notes

Description of Condition Rating Scale