INDUSTRIAL CHILLER MAINTENANCE CHECKLIST & PREVENTIVE MAINTENANCE

Many industrial processes generate significant quantities of heat which must be dissipated as quickly
as possible to prevent damage to sensitive equipment as well as prevent defects in the quality of
finished products.

Industrial chillers are heat exchange machines which exert a cooling effect that helps to rid a process
or machine of unwanted heat. An industrial chiller can be a significant purchase, so it is vital to
understand how to maintain it to keep it operational for as long as possible.

Depending on the chiller types you are considering, the key features of this list may vary slightly. For
example, the points on a water-cooled chiller maintenance checklist won’t necessarily apply to air-
cooled chillers.

Below is a general checklist for chiller machine maintenance with items that apply air-cooled
chillers and/or water-cooled chillers.

Industrial Chiller Maintenance Checklist

 Inspection of all water inlets and outlets for leaks should be done routinely.

 All components of the compressor unit should be inspected including checks for oil levels,
leaks, vibrations, operating temperatures variations.

 Electrical contacts should be inspected and cleaned.

 Filter dryers should be checked, and dirty, old or faulty filters replaced entirely.

Air-cooled Water Chillers Only

 Cooling coils must be inspected for distortion in fins, and signs of corrosion.

 Condenser fan inspections should be carried out with emphasis on bearings check for signs of
wear, poor lubrication. Belts and couplings should also be checked and adjusted when
necessary.

 Condenser coils should be inspected for leaks, corrosion, and areas of kinking or blockage.

 For air-cooled chillers, return air dampers should be inspected for optimal operation,
calibration coupled with checks for bearings alignment and lubrication.
  Fresh air dampers for an air-cooled chiller system should be inspected in the same way as
return air dampers.

Preventive Maintenance for Industrial Chillers

Here are a few tips for maintaining your industrial chillers below:

Maintain your Daily Logs

As basic as this may seem, having a daily record of operating conditions, the pressure and
temperatures in the chiller unit, as well as the fluid levels and flow rate, could help quickly predict the
likelihood of future damage to the chiller machine. Keeping a chiller log sheet is advantageous as a
pre-emptive chiller maintenance schedule can be structured before the onset of actual damages.

Make chiller preventive maintenance easy with the Cold Shot Guardian™ predictive maintenance app.
This tool helps eliminate unscheduled downtime by providing ―real-time‖ chiller guardian app
screenshot operational information through your WIFI, LAN, or even LTE connections.

Keep the Chiller Tubing Clean

The industrial chiller working principle is reliant on heat transfer to exert a cooling effect. In shell and
tube and brazed plate heat exchangers, an obstruction to the flow of cooling fluid through condenser
tubes will significantly diminish how efficiently a chiller transfers heat.

Over time, corrosion can accumulate inside the chiller tubing and impede the removal of generated
heat. Therefore, it is necessary that regular quarterly or at least yearly cleaning of chiller tubes is
scheduled and carried out.

Reduce the Temperature of the Condenser Water

Reducing the temperature of the water entering the condenser of an industrial chiller, significantly
improves efficiency as it has to work less to exert its overall cooling effect. Although not
recommended as standard practice, reducing the temperature of the water passing through the
chiller’s condenser unit may serve as a measure to temporarily overcome problems with its coil.

Inspect the Condenser Water Loops

Although all units Cold Shot Chillers manufactures are closed-loop chillers, some chiller condensers
have water loops which utilize open cooling sources such as air-cooling towers. As a result of this
environmental exposure, there is a tendency for the water to become contaminated with biological
growths, corrosion, and scale which could affect overall heat transfer and chiller efficiency.

Chilled water loops should be inspected at least yearly and treated to remove contaminants. Regularly
inspect your chiller’s ―Y‖ strainer and use an inline cartridge filter for additional protection.

Light should be visible through the condenser coil for dirt or airborne particle build-up. Check deep
into the coils with a flashlight and, if dirty, clean as needed.

Always disconnect the power before cleaning and protect all electrical components from water and
from water entering electrical conduit lines. Remove the covers of the chiller and use water or
compressed air to blow back through the coil in the opposite direction of airflow. Avoid any damage
to coil fins such as bending fins flat.

Monitor for Refrigerant Leaks

The rate of cooling of a chiller is dependent on the amount of refrigerant circulating through its
compressor. Valve stems sometimes vibrate loose and will result in refrigerant leaks. Refrigerant leaks
from the compressor or the introduction of moisture into the system can also impact the cooling
capacity of the chiller.

Checking for leaks and maintaining a proper level of refrigerant in the chiller’s compressor unit will
ensure optimal performance.

Measure the Glycol Concentration

Protection of system components from freezing is critical, as freezing can occur from the external
ambient or internal system temperatures.

The evaporator (or other heat exchanger) is the most susceptible component to freezing, even during
normal operation. The fluid entering the evaporator must be capable of passing through without
forming ice. Ice formation quickly restricts the flow, causing further freezing and eventual rupture.

The chilled fluid needs to have a freeze point that is well below any temperature that the chiller is
capable of cooling.

Maintain an Optimal Chilled Water Flow Rate

The rate of flow of chilled water must be maintained to ensure satisfactory chiller cooling
performance. Chillers need between 2.5 and 3 gallons per minute (GPM) per ton to provide efficient
heat exchange. You will typically see a 10°F temperature exchange at 2.5 GPM per ton, and an 8°F
temperature exchange at 3 GPM per ton.

Look Out for Non-condensables

Another significant aspect of chiller maintenance is keeping air and moisture out of your chiller
system. As these elements can diminish chiller efficiency and increase energy consumption, it is vitally
important that they are quickly purged from the condenser circulation.

Examine the Compressor Oil

Laboratory analysis of the oil from the compressor unit of a chiller should be done every year and
changed according to recommendations from the analyzing lab. When oil changes are made, it is
necessary for filters to be tested and replaced if faulty. However, oil analysis is limited to only
centrifugal chiller operation and maintenance. Newer magnetic bearing frictionless chillers do not
utilize oil.

Inspect Motors and Starting Mechanism

Routine sensor calibration, microprocessor control inspection, safety checks for electrical connections,
wiring, and switchgear, are all recommended. Additionally, regular drive motor checks are required to
keep chillers fully functional.

Install Variable Speed Drives

Chiller motors consume significant amounts of electricity when in use, which increases operation
costs. Installation of variable frequency drives (VFDs) will offer energy savings as varying the motor
speed matches motor efficiency to load, minimizing energy waste. These VSDs can allow chillers to
operate normally even on emergency power generators.

CHILLER MAINTENANCE CHECKLIST AND INSIDER TIPS

May 6, 2021

Nick Smith

Any piece of equipment will experience general wear and tear over time. Which is part of the reason
why it is important to be well acquainted with your commercial or industrial chiller. Maintenance on
large pieces of equipment is essential to ensure the longevity and efficiency of the equipment. A
happy chiller makes for a happy bill. Reducing equipment malfunctions and downtimes by using our
chiller maintenance checklist can be an effective means of lowering costs in your operations. Below
are a few ways to keep your industrial chiller up to par, while saving your company from disastrous
chiller malfunctions.

CHILLER MAINTENANCE CHECKLIST AND DAILY LOGS

Tracking daily operations is half the battle when it comes to maintenance. Keeping a detailed log is
the most efficient means of understanding how your chiller is doing.

These logs should include necessary information like flow rates, operating temperatures, pressures,
and fluid levels. There are many downloadable log sheets to keep these numbers up to date. Remote
monitoring systems are also very popular in supporting daily logs on machinery. It requires less time
and can update as frequently as necessary since it is often an automated system. Many times, remote
monitoring systems can automate insight reports as well, for real-time diagnostics on your chillers.

Performing chiller maintenance is a must. Below are a few items to add to your general maintenance
checklist to ensure you don’t miss a step.
 Note refrigerant and oil levels

 Inspect fan control system

 Check evaporator water temperature differential

 Measure condenser fan motor volts/amps, where applicable

 Check water flow through evaporator

 Measure condenser and evaporator pressures

 Check operation of controls

 Leak-Measure and verify refrigerant, water, oil, etc.

 Check safety control settings

 Check operating control settings

 Inspect compressor motor operation

 Inspect compressor motor efficiency

 Check compressor motor volts/amps

 Secure all cap tubes from chafing

 Check crankcase heater operation

 Check cap control setting/operation

 Inspect condenser/evaporator controls air and water

 Inspect moisture indicator

 Check low/high and oil pressures

 Inspect fan and assembly rotations, etc.

 Check chill water temperature control

  Inspect belts, sheaves – tension and alignment

 Check fan speed controllers

 Listen and look for unusual noises/vibrations

 Check structural integrity of unit

 Compare tonnage being produced vs electricity being consumed

Note: Chiller maintenance will vary from manufacturer to manufacturer and should be assessed on a
case by case basis.

KEEPING TUBES CLEAN

Tubes are the main path for heat transfer in chillers and can be largely responsible for the
performance of your industrial chiller. Contaminants and impurities can increase thermal resistance.
This would reduce heat transfer efficiency as the resistance would affect the consistencies in
approach temperatures in the chiller. It is important to brush these tubes at least once per year. With
a strong monitoring system, you’ll be able to see problems before they occur. Giving you the
opportunity to clean the tubes before they become too much of a problem.

TREAT CONDENSER WATER

Keeping the condenser water clean is important for both boilers and chillers maintenance for many of
the same reasons. Corrosion and scaling both reduce efficiency. Both of which, build up over time if
the water is not well-treated. Untreated can result in higher condenser pressures, impeded heat
transfers and inconsistencies in water temperature and water flow. Regular chemical treatments can
help keep the water clean and filters should be replaced often.

ANALYZE COMPRESSOR OIL

If you’re working with a new chiller, it is standard practice to do an oil and filter change after the first
year. As well as, analyze the oil to determine the frequency of future oil changes. The dirtier, the
more frequently your system will likely require a change. We also recommend doing a spectrometric
chemical analysis of this oil once a year. This will help acquaint you with your system and its potential
issues. Learning how to address various problems, from high water content to the size of the particles
contaminating the oil, can be invaluable.

There are also many chillers that have completely eliminated oil from the equation, thus lowering
potential chiller maintenance costs.

PURGE THE SYSTEM

This process is only for low pressure machines. It involves purging the system of non-condensable
gases. These gasses can be produced in a chiller on the low pressure side where there is a pump or
filter. Because the evaporators operate in a vacuum, these non-condensable elements are able to
leak in. Ensure the air and moisture are at an all-time low by purging.

INCREASE CONDENSER WATER TEMPERATURE

Raising the temperature of chilled water being supplied to a facilities air handling units will improve its
efficiency.

―…centrifugal chillers with, variable speed drives, can typically see a 10%-13% efficiency gain for
every 5 degrees of condenser water temperature relief.

Constant speed chillers also benefit, but only about 5 percent efficiency gain for every 5 degrees of
chilled water relief.‖ –According to Facilitiesnet.com

CONTROL THE FLOW

As with the temperature of the water, the flow of it also plays a big impact on the efficiency of your
boiler. The chilled water flow rate must be above 3 feet per second and below 12 feet per second. If
the flow falls below 3 feet per second, your flow may become laminae. If the flow rises above 12 feet
per second, vibration and noise lead to the ideal environment of tube erosion.

CUT COSTS WITH VARIABLE FREQUENCY DRIVES (VFD)

Variable Frequency Drives (VFDs) motor speed matches the needed load, offering a more cost and
energy-efficient way to operate. They also offer a softer start and lower in-rush of current.

Chillers are a complex unit. In tandem with professional help, you’ll be able to keep your unit
operating efficiently. Whether you’re in need of a consultation, repair, strategic chiller maintenance,
rentals, or parts, we’re here to help. Reach out to the professionals at Rasmussen Mechanical
Services to see what we can do for you.

CHILLER SAFETY CONTROLS

In a good article written by NTT Training, they discuss chiller safety controls and what workers need
to know about them. They go on to say:

Usually, a chiller consists of a compressor, an evaporator, and condensers. Each chiller requires
different setting that corresponds to the load for maximum efficiency. Every chiller has safety controls
that are designed to protect the cooling system from harm. This protects against low refrigerant
temperature, low oil pressure, or high condensing pressure.

Some of these controls include capacity controls and refrigerant flow controls. Capacity controls
maintain the temperature of the chilled water and refrigerant flow controls are set in correspondence
with the compressor used. In the event that these controls fail, the system can be set to shut down.
This avoids more serious machine damage that could affect the health of those around.
CHILLER MAINTENANCE CHECKLIST HELP

From reciprocating, rotary screw, centrifugal and frictionless centrifugal to absorption chillers there
are many different maintenance requirements. As always, follow your manufacturers
recommendations and work with a professional to ensure you don’t miss a step.

We offer consultations, repairs, strategic maintenance, rentals and parts. Let us know what you need,
and we hope this chiller maintenance checklist helps!
Essential chiller maintenance checklist

March 12, 2020/in Articles /

Every chiller or chiller plant should be, for the most part, relatively self-reliant. Yet like all heavy
machinery, regular preventive maintenance can improve performance, prevent breakdowns, and
extend the service life of the equipment. Chillers should be inspected leastwise two times a year if
they are only used during the cooling seasons and four times a year in case of continuous operation.

We recommend the following procedures to keep your chiller system at peak performance and avoid
unexpected shutdowns and costly downtimes. The below checklist has been compiled to help chiller
plant operators conduct detailed and reliable maintenance on air-cooled and water-cooled chillers.

Maintenance Checklist

Logging

Record operating conditions such as temperatures, flow rates, pressures, fluid levels of your system:

 Condensation pressure/temperature

 Evaporation pressure/temperature

 Water flow rate and inlet/outlet water temperatures

 Suction temperature, for all compressors in the system

 Discharge temperature, for all compressors

 Oil temperature and pressure, acidity and humidity

 Superheat and subcooling values

Record power supply parameters:

 Line voltage on each phase

 Absorbed current

Record environmental parameters:

  Ambient temperature

Keep accurate maintenance logs that help to narrow down any issues. Many chillers automatically
save logs with ongoing measurements in their onboard control system.

Inspection Checklist

 Visual inspection. Assure all equipment is operating and that safety systems are in place

 Checking for leakages. Ensure the water and refrigeration pipeworks have no leakages, and
there are no observed spills of refrigerant, oil, or water

 Detect the sources of abnormal vibrations and unusual sounds, if any

Prior to performing the next maintenance tasks, a serviced chiller must be disconnected from the
electrical power supply.

 Check fixings and fastenings, tighten when necessary

 Check the chiller components for corrosion. Pay special attention to pipework and
electrical connections
 Cooling coils must be inspected for fins distortion, and traces of corrosion
 Inspection of the condenser fans should be carried out with emphasis on bearings
check for signs of wear
 Check insulation for damages
 Assess chiller components fouling:
 For condenser coils and fan assemblies (for air-cooled chillers)
 For evaporator – especially important for systems like water-cooled chillers
with heat rejection by open-circuit cooling towers where water may be
contaminated
 Look up for non-condensables: it is vitally important to purge air and
moisture from the refrigeration circuit. Non-condensables may significantly
affect chiller performance and efficiency
 For electrical components and cabling
 Check all motor voltages & amps, electrical starters, contactors, relays, and inspect
unit grounding
 Check electrical connections and terminals for contact and tightness
 Check electrical wiring
 Check low-voltage circuits, transformer voltage, sensors accurate readings
 Check compressors. Check compressor alignments to specification
 Check operation of safety devices
 Check oil levels and oil filters
 Check suction filter
 Inspect valves and valve actuators’ mechanisms
 Check pressure vessels, if any
 Check strainers
 Check if the replacement of consumables is required:
 Process water and glycol. Water quality is critical as failure to manage it will cause
water pipework to corrode, which will inevitably lead to chiller failure. Check the
water treatment quality of the chilled-water circuit. Check glycol condition and
concentration to avoid system freezing under low-ambient conditions
  Refrigerant. Check the refrigerant level and condition using sight-glasses and
compare superheat and subcooling temperature readings to the manufacturer’s
requirements to detect if the current refrigerant charge is correct. Add refrigerant
when necessary
 Lubricant oil. Conduct analysis on oil and check if oil shall be replaced due to
contamination or added if its level is too low

Maintenance Works

As inspection works are completed, an action plan will depend on the outcome of performed checks.
Compare ongoing operating parameters with the initial system setup. Read manufacturer instruction
on servicing and maintenance procedures and execute tasks in strict accordance with it. For all works
that cannot be performed on-site or should be undertaken by competent and trained personnel, it is
necessary to hire qualified technicians or apply for appropriate maintenance contracts offered by the
equipment manufacturer. Kaltra offers tiered maintenance contracts differentiated by the scope of
works and maintenance frequency, including all-inclusive contracts with spare parts and consumables
included in the cost. After finishing the maintenance list, the chiller is ready to be put back into
service.

Using this maintenance checklist, you can maintain optimum performance out of your chiller, prevent
unplanned shutdowns, and ensure longer operating life of the cooling system.

Chiller Maintenance

Immediately resolve potential chiller failures and achieve maximum efficiency through trouble-free
temperature monitoring and real-time data every day

What is 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 vary per type of chiller—
reciprocating, centrifugal, screw, and scroll—preventive chiller maintenance should also be carried
out. Maintaining the good working condition of air-cooled chillers and water-cooled chillers is crucial
to prevent substandard output and avoid increased costs.

Chiller Maintenance Checklist for Commercial Chillers

A chiller maintenance checklist is used to assess if commercial chillers are maintaining the setpoint to
achieve maximum efficiency. This checklist includes the following steps:

 Inspect oil pressure and temperature gauges

 Check chiller is running smoothly

 Examine pump for leaks

 Check fire extinguisher

 Check electrical panels are closed

 Clean mechanical room

Chiller Maintenance Checklist

This chiller maintenance checklist will help you ensure you catch all of the important areas of
your chiller system. In this post we’ve provided an air cooled chiller maintenance checklist as it
is the most common design.

Click To Jump To A Heading:

Maintenance Checklist – Maintenance Tips – Schedule Maintenance

Chillers are a critical element in HVAC systems. Chillers take the heat out of the air and also are
implemented in industrial settings to cool down equipment. This checklist is designed to help chiller
owners and maintenance personnel conduct detailed and reliable maintenance on air-cooled chillers.

Download & View our Chiller Maintenance Checklist PDF

Air Cooled Chiller Maintenance Checklist

Follow this list as you inspect and maintain your chiller. Each item is important and diligent chiller
maintenance will save money and make the system last longer.

1. Inspect water inlet and outlet for leaks

2. Clean out and inspect the sump for corrosion

3. Cooling coils need to be inspected and surfaces cleaned. Check for leaks, corrosion, or bent
fins

4. The zone control actuators should be inspected, cleaned, and all adjustments made

5. The compressor needs various areas checked, these include: refrigerant charge, vibration,
crankcase heater, oil levels and changes, operating temperatures, and if there are any leaks
of refrigerant or oil.

6. Condenser fans should be cleaned, bearings need to be checked for wear and lubricated, and
belts and couplings need to be checked and tightness checked or adjusted as necessary.

7. The condenser coil should be check for corrosion and leaks and all finds or combs need to be
checked for bent sections.

8. The electrical disconnect should be inspected for proper operation and the contacts should be
inspected and cleaned.

9. The exhaust air damper needs to be inspected for proper operation, have the bearings
lubricated, and calibrate or adjust it for optimal operation.

10. Return air dampers also should be checked for proper operation, calibration, and bearings be
lubricated.

11. The fresh air damper should also be inspected, calibrated, and bearings lubricated.

12. The filter dryer also should be inspected and any old, dirty, or damaged filters be replaced.

Chiller Maintenance Tips

The simple fact is that the chiller makes up for a significant portion of your electricity usage, even at
peak performance. If you’ve got maintenance issues it can easily use an extra 10%, which hurts the
bottom line. While technology has improved to remotely monitor chillers and technology has
produced more durable and efficient parts, maintenance is still key.
Maintain A Log Daily

Knowledge is power and saving power is a big deal when it comes to chillers. Recording operating
conditions such as flow rates, pressures, fluid levels, and temperatures helps build a useful record of
your system. While it was standard to do bi-monthly checks today’s continuous monitoring
technology allows you to keep accurate daily logs that will help you narrow down maintenance issues
before there’s a bigger problem.

Condition Your Water

Corrosion and scaling are always a challenge in air cooled chiller systems. Treating the water in your
system helps cut down on corrosion, scaling, and the growth of biological contaminants such as
Legionella. All of these issues can let to a decrease in heat transfer caused by fouling and diminished
heat transfer due to build up inside of pipes. It’s important to continually monitor your chilled water
loops remotely and visually inspect them annually.

Clean Heat Transfer Tubes

A big part of the efficient operation of chillers relies on clean heat transfer tubes. If your system has
mud, minerals, algae, or scaling it will coat the inside of the tubes and insulate them. While
insulation is great at keeping heat out of a home in the summer the heat transfer in chillers is the
cornerstone of how the system functions. Neglecting your chiller tube cleaning will end up inflating
your operating costs and likely result in additional maintenance and more frequent downtime.

Maintain Refrigerant Charge

Your chiller’s ability to cool relies on having the right amount of refrigerant. To ensure your systems
optimal efficient performance make sure you’ve got the right level of refrigerant. If there is air,
moisture, or leaks in your system it will impact it’s performance. With insufficient refrigerant it will
take more electricity for your system to perform the same cooling effect.

Provide Cooler Water

Providing cooler water for the condense improves the chiller’s performance. It will not have to work
as hard to condense the water and will run more efficiently. In some cases this technique can
compensate for problems with coils. While this does fix the problem it is a temporary solution as the
chiller must work harder for the same effect.

Purge Non-Condensables

Chillers function on the principle of condensing refrigerant to cool. If moisture or air leaks into the
system it introduces non-condensable elements into the system that rob it of efficiency. The
percentage can be as high as 7% below the rated performance of the chiller system you have. When
considering how much energy a chiller uses to begin with and extra 7% adds up quickly.

Maintain Appropriate Flow Rate

The rate at which your chilled water flows through the chiller does impact the chiller’s
performance. If it is too slow it lowers efficiency. Too fast and it will cause erosion, vibration, and
noise. It is best to keep the flow rate of your chiller somewhere between three and twelve feet per
second. The exact speed will depend on your chiller’s design and the load needed by your location.

Upgrade To Variable Speed Drives

In most cases the chiller motor is the largest draw on electricity in the entire building. Single speed
drives are on or off and cannot adjust for the difference in load the system is running under. In
contrast a variable speed drive saves energy as it can adjust the speed to match the load. This saves
a significant amount of energy in your chiller system. In addition variable speed allows the system to
ramp up more smoothly in the case it is turned on in an emergency situation.

Check Oil In Compressor

If your compressor uses oil make sure you send a sample of it for inspection at a laboratory once per
year. Due to the hermetically sealed nature of a close refrigerant system the compressor oil should
only be changed if the lab deems it necessary. If there’s excessive moisture it can point to there
being a problem with purging the system effectively. If the oil is changed ensure the filters are
tested and replaced when there are pressure drops. In the case your system uses magnetic bearings
and is frictionless your system will not have compressor oil.

Inspect Motors & Starters

You can save energy and downtime if you inspect your motors and starters. To do so inspect the
sensor calibration and safety on the microprocessor controls. Also take the time to inspect the wiring
and connections in your chiller system at common wear points and hot spots. Pay attention to signs
of refrigerant leaks and test motors for insulation faults.

When To Inspect Chillers

Chillers should be inspected and maintained at least 2 times a year in areas where they are only used
during the cooling seasons, or 4 times a year in areas that cool in all 4 seasons. Quarterly inspection
helps your chillers, HVAC system, and cooling towers last longer and run more efficiently.

Maintained Chillers Operate More Efficiently

Using this checklist you can get better performance out of your chiller and cooling system. The better
maintained your chiller is the less energy it uses, and that saves you money on utilities. As the chiller
and HVAC system is one of the largest draws of electricity in many commercial, industrial, and
medical facilities it is important to inspect, maintain, and repair chillers. Regular inspection and chiller
maintenance will help save money and make the system last longer.

Chiller Maintenance in Arizona

If you have a property such as a commercial building, medical facility, or industrial site that uses
chillers for processes or HVAC All Kote Lining, Inc can help you take care of the chiller
maintenance you need to keep your energy use down and make your equipment last longer. We
inspect, maintain, repair, and line chillers with the most durable coatings available. Give us a call
today to find out what we can do for your company at 480-966-4446.