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Pre-Commissioning Checks

1. Documentation and Manuals
   • Verify that all documentation, including operation manuals, maintenance guides, and commissioning procedures, are available.
2. Physical Inspection
   • Inspect the chiller for any physical damage.
   • Check for proper installation of the unit, ensuring it is level and securely anchored.
3. Piping and Connections
   • Verify that all piping connections (inlet, outlet, and refrigerant lines) are correctly installed and free of leaks.
   • Ensure that all electrical connections are properly made and secured.
   • Check that all insulation on refrigerant lines and chilled water pipes is intact.
4. Electrical Checks
   • Verify the correct power supply voltage and phase.
   • Ensure all electrical connections are tight and that wiring is correct according to the wiring diagram.
   • Check the proper operation of all safety and control devices (e.g., circuit breakers, overload relays).
5. Refrigerant Levels
   • Check the refrigerant charge and ensure it is within the manufacturer’s recommended levels.

Initial Start-Up Checks

1. System Flush and Fill
   • Flush the chilled water system to remove debris and contaminants.
   • Fill the system with the appropriate mixture of water and glycol (if used).
2. Pre-Start Inspections
   • Verify that all valves (chilled water, condenser water, refrigerant) are in the correct positions for start-up.
   • Ensure that the cooling tower (if applicable) and associated pumps are operational.
3. Power On and Initial Test
   • Energize the control circuit and verify that the chiller control panel powers up correctly.
   • Check that the control panel displays and indicators are functioning.
4. Lubrication
   • Verify that all lubrication systems (e.g., oil pumps, oil heaters) are operational.
   • Check oil levels and pressures, ensuring they are within the recommended ranges.

Operational Checks

1. Compressor Operation
   • Start the compressor and monitor for any unusual noises or vibrations.
   • Check suction and discharge pressures and compare them to expected values.
2. Temperature and Pressure Monitoring
   • Verify the temperature and pressure readings at various points in the system (evaporator, condenser, etc.).
   • Ensure that the temperature differential across the evaporator and condenser is within the manufacturer’s specifications.
3. Flow Rates
   • Check chilled water and condenser water flow rates and ensure they meet design specifications.
   • Verify that the flow switches and sensors are operating correctly.
4. Control System Verification
   • Test the operation of the control system, including setpoints, alarms, and safety cutouts.
   • Verify the operation of any remote monitoring systems or Building Management System (BMS) interfaces.
5. Performance Testing
   • Perform a load test to ensure the chiller can handle the expected cooling load.
   • Monitor system performance over a period to ensure stability and reliability.

Post-Commissioning Checks

1. Safety Checks
   • Verify the operation of all safety devices, including high and low-pressure cutouts, oil pressure safety switches, and temperature sensors.
   • Test emergency shutdown procedures.
2. System Balancing
   • Adjust and balance the system to ensure even distribution of cooling load.
   • Check for and correct any hot spots or uneven cooling.
3. Final Inspection and Documentation
   • Perform a final inspection of the chiller and associated systems.
   • Document all test results, settings, and any adjustments made during commissioning.
4. Training and Handover
   • Provide training to the operations and maintenance personnel on the proper operation and maintenance of the chiller.
   • Handover all commissioning documentation, including test reports, manuals, and as-built drawings.

Chiller commissioning checks Checklist Template

Pre-Commissioning Checks

• Documentation and manuals are available
• Physical inspection for damage
• Proper installation verification
• Correct piping and connection checks
• Electrical checks
• Refrigerant levels checked

Initial Start-Up Checks

• System flush and fill
• Pre-start inspections
• Control panel power-up verification
• Lubrication systems operational

Operational Checks

• Compressor operation check
• Temperature and pressure monitoring
• Flow rates verification
• Control system testing
• Performance testing

Post-Commissioning Checks

• Safety checks
• System balancing
• Final inspection and documentation
• Training and handover

Implementing Chiller commissioning checks and Using the eAuditor Audits & Inspection

1. Create Checklists
   • Use the eAuditor Audits & Inspection’s form builder to create the Chiller commissioning checks checklists based on the templates above.
   • Organize the Chiller commissioning checks checklists into modules for easy navigation.
2. Assign Tasks
   • Assign specific tasks to team members.
   • Set deadlines and reminders for each task.
3. Collect Data
   • Team members can input data directly into the app during the commissioning process.
   • Use photo uploads for visual confirmation of completed tasks.
   • Collect signatures for accountability.
4. Review and Approve
   • Supervisors can review the completed checklists.
   • Approve or request further action based on the data collected.
5. Generate Reports
   • Generate comprehensive reports from the collected data.
   • Export reports in PDF or Excel format for record-keeping and handover.
6. Continuous Monitoring
   • Use the eAuditor Audits & Inspection for ongoing monitoring and maintenance checks post-commissioning.
   • Update checklists and procedures as needed based on feedback and operational data.

Example of eAuditor Audits & Inspection Setup

Using eAuditor

1. Create Template
   • Open eAuditor and create a new Chiller commissioning checks template.
   • Add sections for Pre-Commissioning, Initial Start-Up, Operational, and Post-Commissioning Checks.
2. Add Items
   • For each section, add items with interactive elements like checkboxes, text fields, and photo uploads.
3. Assign and Schedule
   • Assign the template to relevant team members.
   • Schedule inspections and set reminders.
4. Data Collection
   • Team members complete the checklist in the eAuditor Audits & Inspection, uploading photos and notes as needed.
   • Sign off on completed tasks.
5. Review and Export
   • Review the completed checklists in the eAuditor Audits & Inspection.
   • Export the results to PDF or other formats for documentation.

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