Chiller Maintenance Checklist

Importance of Chiller Maintenance

Chiller maintenance is the process of regularly inspecting commercial or industrial chillers to extend equipment life and maintain optimum efficiency. While chiller maintenance varies per type of chiller: reciprocating, centrifugal, screw, and scroll, preventive chiller maintenance should also be carried out. Maintaining the good working conditions of air-cooled chillers and water-cooled chillers is crucial to prevent substandard output and avoid increased costs.

Chiller Maintenance: 3 Often-missed Signs of Inefficiency

Even professional technicians and operators make the mistake of neglecting regular chiller inspections. It is essential that technicians diligently perform maintenance tasks so minor issues can be identified and resolved before they worsen. Here are the top 3 often-missed signs of chiller inefficiency:

High Approach Temperature

If the temperature difference between the supply water and return water is higher than intended, contaminants may have accumulated in the evaporator and condenser tubes.
Consider improving your current water treatment system or chemically treat chiller tubes when cleaning them. Since heat-transfer efficiency directly correlates with chiller efficiency, it is crucial to keep all tubes free from sludge, scale, and algae.

Gradual Pressure Increase

If condenser pressure steadily rises within the month, water flow rates may be incorrect which reduces the efficiency of the chiller. Calibrate the control system by periodically removing accumulated debris on internal parts with a high-velocity, low-pressure blower. Non-condensable, or trapped air and moisture, also increase condenser pressure and compressor power, resulting in more power consumption.

Limited Refrigeration/Cooling Load

If a chiller consistently fails to reach full refrigeration load, the oil may have migrated into the refrigerant which causes improper refrigerant levels. Changes in oil characteristics may mean significant compressor wear. When the liquid refrigerant enters the compressor and evaporates, it leads to decreased cooling capacity, overloaded motor condition, and possible compressor impeller damage.

What to Include in a Chiller Maintenance Checklist

A chiller maintenance checklist helps facility managers and maintenance technicians easily inspect pressure and temperature gauges and proactively identify potential chiller issues. To make sure that yours is comprehensive, check the following items to include in a chiller maintenance checklist:

• General inspection/housekeeping – Check the cleanliness of the mechanical room, status of electrical panels, piping inspection for leaks, and proper assembly of equipment.
• Temperature readings – Inspect chiller setpoint, return water temperature, supply water temperature, and condenser water temperature.
• Working conditions – Make sure of proper condition of pressure and temperature gauges, ability to maintain setpoint, smooth operation (no short cycling), pump noise levels and leak inspection, and piping insulation condition.
• Water quality – Check any signs of corrosion or scaling
• Oil pressure – Ensure that oil pressure and temperature are at appropriate levels, also check for oil leaks
• Electrical system – Verify that electrical panels are properly closed

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