Appendix-3.

0
Scope of chiller maintenance works
The FM service provider shall engage specialized chiller contractor, to carry out all reactive
preventive and predictive maintenance activities in accordance with the manufacturer
recommendations and guidelines. The major maintenance activities are listed below as guidance,
the service provider is required to provide a detailed job description and necessary list.
PPM Schedule (Annual Preventive Maintenance) : During peak summer & under full-load
operating conditions, chiller equipment checks are to be carried out. Based on the compiled data
& derived findings, Annual Preventive Maintenance is to be planned & scheduled.
The specialized chiller contractor is required to submit PPM Checks Report (draft given
hereunder, but not limited to), complete with Method Statements for each of the intended
Preventive maintenance activities and arrange to keep ready all the consumables & spares,
required for Annual Preventive Maintenance implementation. Chiller equipment shut-down to
facilitate Annual Preventive Maintenance shall be in winter months (November to February).
(Consumables such as refrigerant, oil, filters, driers are part of contractors responsibility)
Annual Maintenance: Annual maintenance is to be carried out once in a year according to the standard
procedure. This service will be performed at the start of the maintenance service term. Thereafter this
shall be conducted, as mentioned in paragraph # 2- PPM schedule.
Preventive maintenance: This service provides for regularly scheduled preventive maintenance
inspections. There will be three preventive maintenance visits per year at approximately equal intervals.
Emergency service includes emergency calls between inspections as required for the purpose of
diagnosis of trouble adjustment, minor repair or resetting of controls
Oil analysis indicates the need to change the oil. It should help avoid system failures and shut downs.
Oil analysis report is to be submitted to the client.
Written reports Reports shall be provided at the end of each inspection with recommendations of
necessary repairs and maintenance procedure
Parts are excluded whereas consumables are included in the contract. Unit prices are to be submitted and
agreed for the parts.
Condenser cleaning condenser cleaning will be carried out along with the scheduled preventive and
annual maintenance. Whereas, monthly cleaning is to be carried out by the FM service provider.
Annual operators training one day training will be provided to customers operator at the job site. They
will gain overall understanding and improve their ability to operate on daily basis. FM service provider is
required to operate the chiller equipment according to the Daily checklist.

FOLLOWING THE BELOW PPM CHECKS & FINDINGS, CONTRACTOR IS TO REPORT DERIVED
FINDINGS & IMPLEMENT CORRECTIVEACTIONS AS PART OF EACH VISIT, :
VISIT 1

DESCRIPTION OF PPM CHECK

CHECK MAIN POWER TO EQUIPMENT

POWER

PERFORM VOLTAGE IMBALANCE CALCULATION (see below)

PERFORM MEGGAR TEST ON ALL COMPRESSOR MOTORS
CHECK CONTACTORS CONTACT POINT AND REPLACE WHERE NECESSARY
CHECK MOTOR AMPERAGE AS AGAINST FLA AND VOLTAGE
CHECK STARTER/ WIRING CONNECTIONS
CHECK STARTER OPERATION

CONTOLS

CHECK CONTROL POWER

CHECK MICROPROCESSOR AND RECORD DATA
CHECK CHILLER SAFETY/ OPERATING CONTROLS
Thermistors and pressure transducers functioning in conjunction with the control system to provide the unit
with the following protections- Loss of refrigerant charge protection, Low water flow detection, Low
chilled water temperature protection, Low and high superheat protection, Low oil protection for each
compressor, Low control voltage to unit protection, Ground current protection for each compressor,
Compressors protections against Pressure Overload & Electrical overload. Diagnostic display for all alarms
and set points
CHECK REFRIGERANT CHARGE by superheat and sub-cooling temperatures

REFRIGERANT CIRCUIT

CHECK EXPANSION VALVE FUNTIONING & STATUS

LOG EVAPORATOR REFRIGERANT TEMP
EVAPORATOR REFRIGERANT APPROACH TEMP
LOG EVAPORATOR PRESSURE
CHECK REFRIGERANT LIQUID GLASS

(IF CLEAR )

CHECK FOR ANY LEAK IN REFRIGERANT SYSTEM AND OIL SIDE

LOG CONDENSER REFRIGERANT TEMP
LOG CONDENSER PRESSURE
LOG CONDENSER SUBCOOLER PRESSURE

CONDENSER

CHECK FOR RESTRICTION ACROSS DRIER CORES & REPLACE WHERE REQUIRED
LOG ENTERING CONDENSER AIR TEMPERATURE (ON-COIL AIR TEMP)
LOG LEAVING CONDENSER AIR TEMPERATURE (OFF-COIL AIR TEMP)
CHECK CONDENSER FANS FOR CLEARANCE AND ALIGNMENT, BLADES STATUS
LUBRICATE FAN MOTOR BEARINGS ( IF BEARINGS ARE OPEN TYPE)

OIL

LOG OIL LEVEL

LOG OIL PRESSURE

CHILLED WATER

PERFORM OIL ANALYSIS

LOG CHW FLOW DELTA P
LOG CHW PUMP DELTA P
LOG CHW TEMP
LOG LEAVING CHW TEMPERATURE
LOG ENTERING CHW TEMPERATURE
PERFORM CHW ANALYSIS AND ADVISE RECOMMENDATIONS

#2

#3

#4

CALIBRATE CHW FLOW SWITCH ( IF NOT ELECTRNIC TYPE )

INSPECT CHW PIPE LINE/ CLEAN STRAINERS
DETECT AND REPORT ANY SIGNS OF CORROSION
GENERAL

CHECK PAINTWORK AND APPLY NEW IF NECESSARY

REVIEW AND EVALUATE LOG READINGS
CHECK GENERAL OPERATION

The above PPM Checks shall specifically & categorically comprise the below details:
1. Submit the details of No of Compressors failed, complete with Mean Time to Repair & Mean
Time between Failures.

2.
3.
4.
5.
6.
7.

Status of Filter/Drier core replacement

Status of oil test & replacement based on findings
Status of Expansion valve functioning
Additional Refrigerant topping up where identified/applicable
Purging where identified/applicable
Based on the previous track history of repeated Compressors failure frequency, perform
Eddy current testing to (once in five years) to detect tube degradation such as pits,
cracks, or wall loss over time & subsequent moisture entry into compressors.
8. Submit Maintenance program Accomplished Vs Planned
9. Prevention of Motor overheat by means of internal temperature sensors
10. Prevention of Motor overload
11. Condenser fan & motor replacements status
12. Thermistors & Transducers functioning & set-points verification (details are to be
submitted)
13. Assign qualified Maintenance personnel (approval is to be obtained from Account
Manager) to identify and initiate PPM works based on the findings from the equipment
history & current status and to carry out Verification & Validation of Maintenance works
is to be carried out.
14. Resource details (Planned Vs Actual site status) are to be submitted
15. Method statements are to be submitted