STANDARD OPERATING PROCEDURE - CHILLER PPM

 OBJECTIVE:

To establish a procedure for Chiller PPM activity

 

POLICY:

The Chiller PPM activity shall be carried out to extend chiller unit life and prevent downtime.

 

RESPONSIBILITY:

 

Shift Engineer

 

PROCEDURE:

 

Before starting PPM activity below list of precautions required to take.

· The machine is switched off. Apply LOTO to the breaker.

· The machine has cooled down.

 

· Mechanical & Refrigerant Circuit

1. Check for any abnormal vibration/sound.

2. Check for oil tracing

3. Check the color of refrigerant (clear / turbid)

4. Check drier/filter core condition

5. Check solenoid valves operation

6. Check thermowell for heat sink compound

7. Check for refrigerant leakages

8. Check suction side insulation for any air gap or damage

9. Check any glycol leakage in coolant pump

10. Check door gasket for proper sealing

· Lubrication Circuit

11. Check & record oil level, 1/4.1/2.3/4 or full.

12. Check the color of oil (Bluish, Yellowish, Dark Brown and bIack)

13. Check and record oil heater operation & current if applicable

 

· condenser

14. Check condenser coils for dirt/debris and clean if necessary

15. Check for air obstruction/fins damage/oil traces

16. Check pressure relief valve for any rust formation (if applicable)

17. Check fan sound and vibration

18. Check fan for unbalance

19. Check fan guards for looseness or rust formation

20. Check fan blades for looseness

21. Check for splashed grease symptoms

22. Check rain cap for in position or damage

· Cooler

23. Check heater operation (if applicable)

24. Check pressure relief valve for any rust formation (if applicable)

25. Check Cooler insulation for any air gap / looseness

26. Check condition for vibration isolators (if applicable)

· Electrical and Controls

27. Check and record the control voltage on power supply board

28. Check and record Actual Current and FLA % if applicable

29. Check for tightness of all electrical connections, fuse links and earthing

30. Check for any carbon / dust deposition inside the panel / Electronic cards

31. Check and record voltage between control line and ground

· starter - Variable Speed Drive

32. Check for looseness of terminal connections, fuse links and earthing

33. Check and record the coolant level/color if applicable

34. Check for any carbon / dust deposition inside the cabin

35. Check internal cabinet fan operation if applicable

36. Check VSD cooling fan and coolant pump operation if applicable

37. Check and ensure that VSD fans switched off while chiller is switched Off if applicable

38. Check voltage suppression's fuse condition

39. Check and record Incoming Voltage in RY/YB/BR

40. Check and record the current drawn in R/Y/B

· Parameters

41. Check and record Operating Parameters in Log Sheet and attach the same

42. Check and record PH/ TDS valve of chilled water

43. Evaporator water flow in US gpm, m3/hr (if applicable)

44. Check for alarm History

45. Check operating Parameters at full / Part load and attach the printout reading

46. Check and record Brine Specific Gravity if applicable

 

 

· Safety Checks

47. Evaporator/ Water flow switch operation

48. Check and confirm programmed set points as per recommendation.

 

· At any job motto should be safety first.

· In case of any major problem, inform the Facility Manager immediately.

 

 

 

 

 

REVISION GUIDE:

Any change in the systems will need a change in the SOP.