Facilities Engineering
Chiller Maintenance Schedule & Repair Cost Calculator
Estimate annual preventive maintenance costs, predict major component repair ranges, generate custom servicing checklists, and calculate the high cost of energy waste from scaling and coil neglect.
System Specifications
Requires a cooling tower, condenser water loop, and chemical monitoring.
10 Tons (Packaged)1000 Tons (Centrifugal)
Single Shift: ~2,000 hrs24/7 Process: 8,760 hrs
Neglected maintenance causes condenser fouling, spiking energy bills and increasing compressor load.
Estimated PM Budget
$2,313
Estimated annual preventive maintenance budget.
Neglected Energy Penalty
$0
Loss of 0% efficiency due to scale/soiling.
Chiller Failure Risk
17%
Equipment risk tier: Medium
Uptime Rating
Good
Maintenance index rating based on input parameters.
Chiller Maintenance Alert: Medium Failure Risk
System is drifting. Catch up on baseline oil testing and sensor calibrations to maintain design COP.
Custom Preventive Maintenance Schedule
Interactive, task-by-task schedule generated for a 150 Ton water-cooled chiller operating in a clean environment.
Daily Tasks
Check inlet/outlet water temperatures & pressures
Verify normal approach temperatures.
Check compressor oil level and operating sounds
Note any foaming or abnormal vibrations.
Review microprocessor control panel alerts
Scan status and log active warning indicators.
Weekly Tasks
Inspect piping circuits for leaks
Inspect pump mechanical seals and check valves.
Check fluid levels in the expansion tank
Ensure auto-makeup water valves operate cleanly.
Monthly Tasks
Inspect and clean evaporator/chiller water strainers
Silt and particulate buildup reduces flow rate.
Inspect motor contactors and wiring connections
Look for signs of pitting or heat deformation.
Test cooling tower water chemistry & TDS level
Critical to prevent biological fouling and scale.
Check biocide and inhibitor dosage pumps
Replenish chemical reservoirs as needed.
Semi-Annually Tasks
Run refrigerant leak detection sweep
Check valves, gaskets, and joints.
Calibrate pressure transducers & temperature sensors
Drifting sensors run the system inefficiently.
Annually Tasks
Extract compressor oil sample for wear analysis
Spectroscopic analysis checks for acid and metal shavings.
Perform electrical megohmmeter (megger) insulation test
Test compressor and pump winding insulation integrity.
Brush condenser tubes and chemical descale
Removes calcium scaling. Enhances COP drastically.
Inspect tower fan drive shaft, belt tension & gear oil
Service tower mechanical components.
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