AIR-COOLED CHILLER | Pre-Functional Checklist Template + Download

July 3, 2022 |

This air-cooled chiller checklist can be used and completed throughout the project and its different stages covering:

  • delivery,
  • storage,
  • installation &
  • pre-commissioning/pre-functional

Once the pre-functional checks have been completed, the water-cooled chiller’s full functional testing/commissioning can be conducted.

Delivery Inspection

Once the Air-Cooled Chiller arrives at the site, usually delivered by a transport company, and before being unloaded and accepted into storage, the following should be checked with the driver.

Any damage that is noted should be reported to the manufacturer/supplier immediately in writing supported with photographs.

RefInspection/Task
1Supplier's consolidated delivery ticket is available, showing all equipment and ancillaries for inspection and being used to check against.
2A copy of the order that was sent to the supplier is available for reference and is being used to check against
3Equipment is packaged, protected, and crated in separate boxes, for maximum protection
4The unit nameplate and technical details match the purchase order
5Delivery protection is dry
6Unit/s are dry internally
7The external casing of the unit/s are undamaged
8All frames, if ordered are included
9All pipework connections are the correct size
10Pipework connections are undamaged
11All pipework handing’s are correct
12All pipework is blanked for protection of the coil.
13All ancillaries [valves, actuators, sensors, flow meters, flow switches, control panels, variable speed drive, vibration mounts/pads/brackets] are included in delivery as per the order and delivery note
14Understand if the unit has been shipped charged with refrigerant or nitrogen.
15Ensure that the lifting eyes are available and at locations as per the manufacturers installation manual and drawings.
16Documentation included drawings [piping, wiring etc., data sheets, manuals etc.
17Replace protection that has been removed
18Lifting and material moving plan available and agreed to unload the air-cooled chiller from the trailer.

Storage Inspection

Storage Area

If the equipment is to be placed into storage on site prior to installation there will be an inspection completed checking the following.

Ancillaries

The following covers the storage of ancillaries

RefInspection/Task
1The area is internal and will not be affected by weather.
2The surface where the ancillaries are to be placed is level.
3The ancillaries will be raised from the floor to allow airflow stopping the risk of water ingress.
4The area is well covered and protected.
5The area is well ventilated and no risk of high humidity.
6The area is clean & dust free.
7The area is secure and protected from movement of other materials and vehicles.
8The temperature and humidity of the space has been checked and confirmed can be maintained in line with the manufacturer’s requirements of the ancillaries.

Air-Cooled Chiller

The following covers the storage of the air-cooled chiller.

RefInspection/Task
1The surface where the equipment is to be placed is level.
2The area is well ventilated and no risk of high humidity.
3The area is clean & dust free.
4The area is secure and protected from movement of other materials and vehicles.
5The temperature and humidity of the space has been checked and confirmed can be maintained in line with the manufacturer’s requirements.

Check installation manual.
Air Cooled Chiller Pre-Functional Checklist Template [MS Word] + [MS Excel]

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Storage of Air-Cooled Chiller

Prior to the air-cooled chiller being placed into storage, the following should be checked and confirmed.

RefInspection/Task
1The chiller will not have materials stacked on it/them.
2All ancillaries will be placed in a safe and secure location, so items do not go missing or get damaged.
3All original packaging is intact and not removed.
4Pipework caps are not removed.
5If the chiller will be stored for an extended period, the pressure of the refrigerant circuits should be checked at least
6Ensure the discharge and liquid line isolation valves are closed.

Pre-Installation Inspection

Prior to the units being installed the following should be checked.

RefInspection/Task
1The base is ready and level in line with the manufacturer’s requirement.
2The base can bare the weight of the equipment under normal operating weight.
3The base is finished in line with the requirements of the specification [painted etc.].
4Once installed, ensure that there is enough space under the unit to allow cleaning of the condenser coil.
5Area being installed is not prone to flooding or ponding of water.
6If being installed where there is a risk of snow accumulation near the unit, it will not impede its operation.
7The area the air-cooled chiller will be installed into is clean and dust free.

If there is dust/construction work, then the air-cooled chiller should be protected and covered to protect it and the coils.
8The installation of the unit will not impede the installation of the condensate / chilled water / condensate trap/pipework.
9All connections of system pipework can be independently supported and not supported by the air-cooled chiller.

Best practice is to install self-supporting brackets prior to the connection of the chiller from the floor.
10Ensure that all access points/doors are clear and not blocked from brackets or other services.
11Check to ensure that all connection kits containing - gaskets, bolts, cleats, screws are available to allow bolting up and mounting of the equipment.
12Remove all transport feet and bolts.
13Check that all required cabling can be run to the unit and on appropriate containment, not impeding access to the areas needed for maintenance and operation of the unit.

Maintenance Access

RefInspection/Task
1There is enough space allowed around and above the unit once installed to perform maintenance and remove components.

[check the manufacturers maintenance instructions for requirements]
2All doors can be fully opened to gain access to the control panels and any electrical components.
3Check that there is enough space for coils to be removed.

Pre-Functional Inspection

Once the air-cooled chiller has been installed and prior to the functional testing and commissioning phase taking place the following will be checked.

General

RefInspection/Task
1Document the information of the unit from its nameplates and cross-reference with the specified information to ensure correct. Checking:

·    Manufacturer
·    Model
·    Serial number
·    Cooling capacity
·    Refrigerant type
·    Refrigerant pressure/charge
·    Allowable testing pressure
·    Condenser fluid flow rate
·    Chilled water fluid type
·    Chilled water flow rate
·    Refrigerant type
·    Compressor model number
·    Compressor serial number
·    Compressor motor rating
·    Compressor motor voltage/phase/frequency
2Air-cooled chiller is free from physical damage
3There is no trash or materials in the close vicinity of the unit that could be pulled in blocking the coils.
4All components are installed [cooler, condenser, compressor, motor, etc.]
5Motor bearings are double sealed and permanently lubricated.
6Ensure unit is level with the deflection in line with the manufacturer’s requirements.
7Ensure all neoprene isolator pads are installed correctly.
8All spring isolators are installed, if being used.
9Seismic restraints, where required, installed for the pipework.
10All access doors can be opened and closed with no obstructions for general access and maintenance.
11Unit and all components including valves and controls are labeled in line with the project naming convention.
12Operation and startup manual for the air-cooled chiller available.
13Manufacturing/dimensioned drawings available
14Manufacturer’s installation check sheet completed and issued to manufacturer for arrangement of engineer.

Evaporator & Condenser Coil

RefInspection/Task
1Coil is clean in good condition and tubes undamaged.
2Ensure that the pipework is correct size.
3Ensure that the flow and return pipework is piped in the correct configuration, flow connected to flow and return to return.
4The installation of the pipework will not put stress on the equipment connections or create vibrations.
5The materials used between the equipment and the chilled pipework system will not cause Electrolysis.
6Pipework has been weld tested.
7Pipework has been pressure tested.
8Pipework has been cleaned and flushed.
9Equipment has been back flushed.
10System has been bled and air removed.
11Chilled water system has been hydraulically balanced.
12Pipework is insulated and vapor sealed
13Insulation is labelled
14Strainers are installed
15Isolation valves are installed.
16Double regulating valves / commissioning stations are installed
17Pressure gauges are installed, and display scale as per design requirements.
18Temperature gauges are installed, and display scale as per design requirements.
19Digital temperature sensors are installed and connected to BMS / controls system
20Test points are installed as per the drawings.
21Air vents are installed as per the drawings.
22Flexible connections installed between chiller and pipework.
23Drain points installed and correct sizes, that allow draining down of the chiller.
24Pipework connections are aligned with the chiller connections, not putting any stress on the system.
25Differential pressure switch installed across the evaporator supply and return of the chiller.
26All valves/control valves/flow switches are installed and in correct direction
27Heaters installed, where required, to guard against any sub-freezing temperatures.
28Trace heating installed on pipework, where required.
29Piping layout and instruments match the approved construction drawing.
30Chilled water pumps are commissioned and available.
31Chemical treatment system commissioned and available.
32System can flow the correct amount of water for the chiller to be commissioned.
33There is enough load to allow the chiller to run.

Refrigerant

RefInspection/Task
1Unit has been pressure tested, evacuated, dehydrated, and charged.
2The refrigerant has been charged and is in line with manufacturers requirements.

Electrical General

RefInspection/Task
1Unit and components are fully earthed in line with the manufacturer’s instructions.
2Earthing has been tested
3Emergency disconnect installed for each component in line with NFPA/local code requirements
4Electrical voltage from site matches the unit required voltages.
5All cabling is installed and connected on the correct containment/raceways and not damaged.
6All cabling has been tested/torque tested.
7Local motor control panel [LMCP] has been installed
8Local motor control panel has been electrically tested
9All electrical cabling is labelled in line with project naming convention.
10Power available
11Wiring diagrams available

Variable Speed Drive

RefInspection/Task
1If a variable speed drive has been installed.
2Variable Speed Drive [VSD] has been electrically tested
3Variable speed drive has been functionally tested
4Main power supply available.

Field Instrumentation

RefInspection/Task
1Ensure all sensors and instruments are installed as per the control logic/manufacturers wiring drawings
2All sensors are calibrated

Controls

RefInspection/Task
1Control wiring completed from instruments and interlocks in accordance with the manufacturers wiring diagram.
2Power available to control panel.

Water-Cooled Chiller Pre-Functional Testing checklist [pdf]

To help us expand the site and create more resources, we have created the below documentation in [Microsoft Word] + [Microsoft Excel] for download.

Click the ‘Buy Here‘ button to purchase the fully editable copy of the document below, which can be used straight away.

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Air-Cooled Chiller Pre-Functional Checklist [Microsoft Word]

049f-Air-Cooled-CHILLER-Checklist

049f-Air-Cooled-CHILLER-Checklist-Excel

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