This air-cooled chiller checklist can be used and completed throughout the project and its different stages covering:
- installation &
Once the pre-functional checks have been completed, the water-cooled chiller’s full functional testing/commissioning can be conducted.
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.
|1||Supplier's consolidated delivery ticket is available, showing all equipment and ancillaries for inspection and being used to check against.|
|2||A copy of the order that was sent to the supplier is available for reference and is being used to check against|
|3||Equipment is packaged, protected, and crated in separate boxes, for maximum protection|
|4||The unit nameplate and technical details match the purchase order|
|5||Delivery protection is dry|
|6||Unit/s are dry internally|
|7||The external casing of the unit/s are undamaged|
|8||All frames, if ordered are included|
|9||All pipework connections are the correct size|
|10||Pipework connections are undamaged|
|11||All pipework handings are correct|
|12||All pipework is blanked for protection of the coil.|
|13||All 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|
|14||Understand if the unit has been shipped charged with refrigerant or nitrogen.|
|15||Ensure that the lifting eyes are available and at locations as per the manufacturers installation manual and drawings.|
|16||Documentation included drawings [piping, wiring etc., data sheets, manuals etc.|
|17||Replace protection that has been removed|
|18||Lifting and material moving plan available and agreed to unload the air-cooled chiller from the trailer.|
If the equipment is to be placed into storage on site prior to installation there will be an inspection completed checking the following.
The following covers the storage of ancillaries
|1||The area is internal and will not be affected by weather.|
|2||The surface where the ancillaries are to be placed is level.|
|3||The ancillaries will be raised from the floor to allow airflow stopping the risk of water ingress.|
|4||The area is well covered and protected.|
|5||The area is well ventilated and no risk of high humidity.|
|6||The area is clean & dust free.|
|7||The area is secure and protected from movement of other materials and vehicles.|
|8||The temperature and humidity of the space has been checked and confirmed can be maintained in line with the manufacturers requirements of the ancillaries.|
The following covers the storage of the air-cooled chiller.
|1||The surface where the equipment is to be placed is level.|
|2||The area is well ventilated and no risk of high humidity.|
|3||The area is clean & dust free.|
|4||The area is secure and protected from movement of other materials and vehicles.|
|5||The temperature and humidity of the space has been checked and confirmed can be maintained in line with the manufacturer’s requirements.
Check installation manual.
Here is our open copy [MS Word] of the AIR COOLED CHILLER Pre-Functional Checklist, for making life a little easier...
We have also recently formatted this checklist to [MS Excel] and included it as a Bonus for FREE.
So get an MS Word & MS Excel for the same price.
Storage of Air-Cooled Chiller
Prior to the air-cooled chiller being placed into storage, the following should be checked and confirmed.
|1||The chiller will not have materials stacked on it/them.|
|2||All ancillaries will be placed in a safe and secure location, so items do not go missing or get damaged.|
|3||All original packaging is intact and not removed.|
|4||Pipework caps are not removed.|
|5||If the chiller will be stored for an extended period, the pressure of the refrigerant circuits should be checked at least|
|6||Ensure the discharge and liquid line isolation valves are closed.|
Prior to the units being installed the following should be checked.
|1||The base is ready and level in line with the manufacturer’s requirement.|
|2||The base can bare the weight of the equipment under normal operating weight.|
|3||The base is finished in line with the requirements of the specification [painted etc.].|
|4||Once installed, ensure that there is enough space under the unit to allow cleaning of the condenser coil.|
|5||Area being installed is not prone to flooding or ponding of water.|
|6||If being installed where there is a risk of snow accumulation near the unit, it will not impede its operation.|
|7||The 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.
|8||The installation of the unit will not impede the installation of the condensate / chilled water / condensate trap/pipework.|
|9||All 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.
|10||Ensure that all access points/doors are clear and not blocked from brackets or other services.|
|11||Check to ensure that all connection kits containing - gaskets, bolts, cleats, screws are available to allow bolting up and mounting of the equipment.|
|12||Remove all transport feet and bolts.|
|13||Check 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.|
|1||There is enough space allowed around and above the unit once installed to perform maintenance and remove components.
[check the manufacturers maintenance instructions for requirements]
|2||All doors can be fully opened to gain access to the control panels and any electrical components.|
|3||Check that there is enough space for coils to be removed.|
Once the air-cooled chiller has been installed and prior to the functional testing and commissioning phase taking place the following will be checked.
We have created this bundle to consolidate all the Equipment Pre-Commissioning and Maintenance Checklists that are available across the site.
The checklists are provided in Microsoft Word and Excel.
|1||Document the information of the unit from its nameplates and cross-reference with the specified information to ensure correct. Checking:
· 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
|2||Air-cooled chiller is free from physical damage|
|3||There is no trash or materials in the close vicinity of the unit that could be pulled in blocking the coils.|
|4||All components are installed [cooler, condenser, compressor, motor, etc.]|
|5||Motor bearings are double sealed and permanently lubricated.|
|6||Ensure unit is level with the deflection in line with the manufacturer’s requirements.|
|7||Ensure all neoprene isolator pads are installed correctly.|
|8||All spring isolators are installed, if being used.|
|9||Seismic restraints, where required, installed for the pipework.|
|10||All access doors can be opened and closed with no obstructions for general access and maintenance.|
|11||Unit and all components including valves and controls are labeled in line with the project naming convention.|
|12||Operation and startup manual for the air-cooled chiller available.|
|13||Manufacturing/dimensioned drawings available|
|14||Manufacturer’s installation check sheet completed and issued to manufacturer for arrangement of engineer.|
Evaporator & Condenser Coil
|1||Coil is clean in good condition and tubes undamaged.|
|2||Ensure that the pipework is correct size.|
|3||Ensure that the flow and return pipework is piped in the correct configuration, flow connected to flow and return to return.|
|4||The installation of the pipework will not put stress on the equipment connections or create vibrations.|
|5||The materials used between the equipment and the chilled pipework system will not cause Electrolysis.|
|6||Pipework has been weld tested.|
|7||Pipework has been pressure tested.|
|8||Pipework has been cleaned and flushed.|
|9||Equipment has been back flushed.|
|10||System has been bled and air removed.|
|11||Chilled water system has been hydraulically balanced.|
|12||Pipework is insulated and vapor sealed|
|13||Insulation is labelled|
|14||Strainers are installed|
|15||Isolation valves are installed.|
|16||Double regulating valves / commissioning stations are installed|
|17||Pressure gauges are installed, and display scale as per design requirements.|
|18||Temperature gauges are installed, and display scale as per design requirements.|
|19||Digital temperature sensors are installed and connected to BMS / controls system|
|20||Test points are installed as per the drawings.|
|21||Air vents are installed as per the drawings.|
|22||Flexible connections installed between chiller and pipework.|
|23||Drain points installed and correct sizes, that allow draining down of the chiller.|
|24||Pipework connections are aligned with the chiller connections, not putting any stress on the system.|
|25||Differential pressure switch installed across the evaporator supply and return of the chiller.|
|26||All valves/control valves/flow switches are installed and in correct direction|
|27||Heaters installed, where required, to guard against any sub-freezing temperatures.|
|28||Trace heating installed on pipework, where required.|
|29||Piping layout and instruments match the approved construction drawing.|
|30||Chilled water pumps are commissioned and available.|
|31||Chemical treatment system commissioned and available.|
|32||System can flow the correct amount of water for the chiller to be commissioned.|
|33||There is enough load to allow the chiller to run.|
|1||Unit has been pressure tested, evacuated, dehydrated, and charged.|
|2||The refrigerant has been charged and is in line with manufacturers requirements.|
|1||Unit and components are fully earthed in line with the manufacturer’s instructions.|
|2||Earthing has been tested|
|3||Emergency disconnect installed for each component in line with NFPA/local code requirements|
|4||Electrical voltage from site matches the unit required voltages.|
|5||All cabling is installed and connected on the correct containment/raceways and not damaged.|
|6||All cabling has been tested/torque tested.|
|7||Local motor control panel [LMCP] has been installed|
|8||Local motor control panel has been electrically tested|
|9||All electrical cabling is labelled in line with project naming convention.|
|11||Wiring diagrams available|
Variable Speed Drive
|1||If a variable speed drive has been installed.|
|2||Variable Speed Drive [VSD] has been electrically tested|
|3||Variable speed drive has been functionally tested|
|4||Main power supply available.|
|1||Ensure all sensors and instruments are installed as per the control logic/manufacturers wiring drawings|
|2||All sensors are calibrated|
|1||Control wiring completed from instruments and interlocks in accordance with the manufacturers wiring diagram.|
|2||Power 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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