WATER COOLED CHILLER | Pre-Commissioning Checklist

July 3, 2022 |

This water-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.

This checklist should be used and completed throughout the project, and its different stages, delivery, storage, installation & pre-commissioning, before the functional testing occurs.

Delivery Inspection

Once the Water-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 the 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.
15Documentation included drawings [piping, wiring, etc., datasheets, manuals, etc.
16Replace protection that has been removed
17Lifting and material moving plan available and agreed to unload the water-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.

RefInspection/Task
1The area is internal and will not be affected by the weather. [if the unit is not rated for external use]
2The surface where the equipment is to be placed is level.
3The equipment will be raised from the floor to allow airflow and stop the risk of water ingress.
4The area is well covered and protected.
5The area is well ventilated and has no risk of high humidity.
6The area is clean & dust-free.
7The area is secure and protected from the 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. Check installation manual.
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Storage of Water-Cooled Chiller

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

RefInspection/Task
1Water-cooled chillers will not have materials stacked on 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.
5Water-cooled chiller and all components placed on a level surface.

Pre-Installation Inspection

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

RefInspection/Task
1The plinth/base is ready, flat, and level & can bare the weight of the installation.
2Ensure the slab/floor/plinth is finished in line with the requirements of the specification [painted etc.].
3Isolator pad mounts are installed and in the correct position
4The room/area is dry and watertight.
5The area being installed is not prone to flooding or ponding of water.
6The room/area the water-cooled chiller will be installed into is clean and dust-free. If there is dust/construction work, then the water-cooled chiller should be protected.
7The installation of the unit will not impede the installation of the condensate / chilled water/condensate trap/pipework.
8All connections, pipework, etc., can be independently supported and not supported by the water-cooled chiller. The best practice is to install self-supporting brackets prior to the connection of the chiller from the floor.
9Ensure that all access points/doors are clear and not blocked from brackets or other services.
10Check to ensure that all connection kits containing - gaskets, bolts, cleats, screws are available to allow bolting up and mounting of the equipment.
11Remove all transport feet and bolts.
12Check that all required cabling can be run to the unit and on appropriate containment, not impeding access to the areas needed to gain access for maintenance and operation of the unit.
13The temperature and humidity of the space has been checked and confirmed can be maintained in line with the manufacturer’s requirements. Check installation manual.

Maintenance/Access

RefInspection/Task
1There is enough space allowed around and above the unit once installed to perform maintenance and remove components. [check the manufacturer's maintenance instructions for requirements]
2All doors can be fully opened to gain access to the chiller and electrical components.
3Check that there is enough space for coils the coils to be removed.

Pre-Commissioning Inspection

Once the water-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.
2Checking:
3a. ManufacturerModel
4b. Serial number
5c. Cooling capacity
6d. Condenser fluid type
7e. Condenser fluid flow rate
8f. Chilled water fluid type
9g. Chilled water flow rate
10h. Refrigerant type
11i. Compressor motor rating
12j. Compressor motor voltage/phase/frequency
13The water-cooled chiller is free from physical damage
14All components are installed [cooler, condenser, compressor, motor, etc.]
15Motor bearings are double sealed and permanently lubricated.
16Ensure the unit is level with the deflection in line with the manufacturer’s requirements.
17Ensure all isolator pads are installed correctly.
18All spring isolators are installed if being used.
19Seismic restraints, where required, installed.
20Ensure each end cap of the chiller has been checked and verified as being tight by using a torque wrench for checking each bolt.
21All-access doors can be opened and closed with no obstructions for general access and maintenance.
22Unit and all components including valves and controls are labeled in line with the project naming convention.
23Operation and startup manual for the water-cooled chiller available.
24Manufacturing/dimensioned drawings available
25The manufacturer’s installation check sheet was completed and issued to the manufacturer for the arrangement of the engineer.

Evaporator Coil [Chilled Water Side]

RefInspection/Task
1The coil is clean in good condition and the tubes are undamaged.
2Ensure that the pipework is connected as per the design and the correct size.
3Ensure that the flow and return pipework are piped correctly.
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 backflushed.
10The system has been bled and air removed.
11The chilled water system has been hydraulically balanced.
12Pipework is insulated and vapor sealed
13Insulation is labeled
14Strainer installed
15Isolation valves installed.
16Double regulating valves / commissioning stations installed
17Pressure gauges installed, and display scale as per design requirements.
18Temperature gauges installed, and display scale as per design requirements.
19Digital temperature sensors installed and connected to BMS / controls system
20Test points installed.
21Air vents installed.
22Flexible connections installed between chiller and pipework.
23Drain points installed and correct sizes.
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 the correct direction
27The piping layout and instruments match the approved construction drawing.
28Chilled water pumps are commissioned and available.
29The system can flow the correct amount of water for the chiller to be commissioned.
30There is enough load to allow the chiller to run.

Condenser Coil [Condenser Side]

RefInspection/Task
1The coil is clean in good condition and the tubes are undamaged.
2Ensure that the pipework is connected and the correct size.
3Ensure that the flow and return pipework are piped correctly.
4The installation of the pipework will not put stress on the equipment connections or create vibrations.
5The materials used between the equipment and the condenser 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 backflushed.
10The system has been bled and air removed.
11The condenser water system has been hydraulically balanced.
12Pipework is insulated and vapor sealed.
13Insulation is labeled.
14Strainer installed.
15Isolation valves installed.
16Double regulating valves / commissioning stations installed
17Pressure gauges installed, and display scale as per design requirements.
18Temperature gauges installed, and display scale as per design requirements.
19Digital temperature sensors installed and connected to BMS / controls system
20Test points installed.
21Air vents installed.
22Flexible connections installed between chiller and pipework.
23Drain points installed and correct sizes.
24Pipework connections are aligned with the chiller connections, not putting any stress on the system.
25Differential pressure switch installed across the condenser supply and return of the chiller.
26All valves/control valves/flow switches are installed and in the correct direction
27The piping layout and instruments match the approved construction drawing.
28Condenser pumps are commissioned and available
29Cooling towers are commissioned and available, or able to operate.
30Makeup water/fill system available and operating for the condenser system.
31The system can flow the correct amount of water for the chiller to be commissioned.

Refrigerant

RefInspection/Task
1The unit has been pressure tested, evacuated, dehydrated, and charged.
2The refrigerant has been charged and is in line with the manufacturer's requirements.

Refrigerant Relief Piping

For water-cooled chillers, refrigerant relief piping is connected to the condenser and evaporator and runs to the atmosphere. This is required by code as a safety measure in case there is an over-pressurization of refrigerant gas and needs to be vented, it is run to the atmosphere due to the potential health and safety risk.

RefInspection/Task
1Pipework is sized correctly in line with the design, code, ANSI/ASHRAE-15, and manufacturer's requirements.
2Ensure that the pipework is connected and aligned correctly, with no evidence of horizontal misalignment, vertical offset, or compression.
3Pipework connected to the relief valves on the condenser and evaporator
4A dirt/condensation trap has been installed at the bottom of the vertical leg.
5Flexible connections have been installed in the pipework, prior to the connection on the chiller.
6The installation of the pipework will not put stress on the equipment connections or create vibrations.
7Pipework exits the room to the atmosphere and discharges safely

Condensate drains

RefInspection/Task
1The condensate is installed to the correct fall.
2Ensure is protected from any frost with insulation and/or heating cable.
3There is a trap installed and is installed in line with manufacturer's requirements. [Check manufacturer’s instructions for calculation/requirements]
4If there are multiple coils installed on a unit, ensure the condensate pipework configuration is installed in line with the manufacturer’s requirements.
5Check that the size of the condensate is correct.
6Ensure the trap is filled to the correct level.
7Ensure the drain pan is clean and free of debris

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 the 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.
7A local motor control panel [LMCP] has been installed
8The local motor control panel has been electrically tested
9All electrical cabling is labeled in line with the project naming convention.
10Power available
11Wiring diagrams available

Variable Speed Drive

RefInspection/Task
1A 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

Controller

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

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

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Water Cooled Chiller Pre-Functional Checklist [Microsoft Word]

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Water Cooled Chiller Pre-Functional Checklist [Microsoft Excel]

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