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.
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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.
|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.
|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]
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Air-Cooled Chiller Pre-Functional Checklist [Microsoft Word]049f-Air-Cooled-CHILLER-Checklist