What is Chiller Maintenance?
Chiller maintenance consists of scheduled inspections of commercial or industrial chillers aimed at extending equipment life and maintaining optimum efficiency. Poorly maintained chillers result in substandard performance and increased costs.
What is a Chiller Maintenance Checklist?
A chiller maintenance checklist is an assessment tool used by maintenance technicians to evaluate a commercial chiller’s working condition during scheduled inspections. It is also used by operators and maintenance personnel for daily temperature readings. A chiller maintenance checklist is an essential tool for coming up with preventive measures to avoid costly breakdowns.
This article features: 1) elusive chiller failures you should resolve before they worsen; 2) smart technology for trouble-free temperature readings daily; and 3) free chiller maintenance checklists you can download, customize, and use.
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3 Often-missed Signs of Chiller 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:
1. 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.
2. 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-condensables, or trapped air and moisture, also increases condenser pressure and compressor power, resulting in more power consumption.
3. Limited Refrigeration/Cooling Load
If a chiller consistently fails to reach full refrigeration load, oil may have migrated into the refrigerant which causes improper refrigerant levels. Changes in oil characteristics may mean significant compressor wear. When liquid refrigerant enters the compressor and evaporates, it leads to decreased cooling capacity, overloaded motor condition, and possible compressor impeller damage.
Daily chiller maintenance tasks which involves manually keeping maintenance logs can be burdensome and time-consuming. Never miss another maintenance check using iAuditor, the world’s most powerful inspection platform. Now equipped with new temperature sensors, chiller operators and maintenance technicians can efficiently perform the following:
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Mobile-ready Chiller Maintenance Checklists
A chiller maintenance checklist is used to assess if commercial chillers are maintaining the setpoint to achieve maximum efficiency. Use this checklist to easily inspect pressure and temperature gauges, detect potential chiller failures, and prevent short cycling. This checklist has been designed to make it easier for chiller maintenance technicians to efficiently:
- Inspect the chiller area and its general condition and intended function
- Take/attach photos of damages, repairs, and more
- Assign corrective actions with a due date and priority level
- Complete the chiller maintenance check with a digital signature
- Store the chiller maintenance log in the cloud
A chiller system repair and maintenance checklist is used by manufacturing facility chiller operators and maintenance personnel to daily inspect different types of industrial chillers such as centrifugal, screw, reciprocating, and absorption. Easily check an unlimited number of industrial chillers and take photos of detected defects or done repairs with this intuitive checklist. If critical repairs cannot be done on the spot, you can use this checklist to create an action and assign it to key personnel with a priority level and due date.
A chiller plant maintenance checklist is used by maintenance supervisors to schedule weekly or monthly inspections, implement appropriate preventive measures, and protect the cooling plant from breakdowns. Use this chiller plant preventive maintenance schedule checklist to easily log temperature readings, observe excessive noise or vibration, inspect the refrigerant level and more. Schedule maintenance checks in advance and receive notifications when completed.
A chiller commissioning checklist is used to thoroughly record observations before and after the start-up of chiller systems. Accurately capture suction, discharge, oil, and brine temperatures using iAuditor temperature sensors. Automate temperature monitoring of chiller systems, easily manage risks through proactive alerts to the right people when something goes wrong, and stay in control of your day-to-day operations.