A process chiller runs 6,000 to 8,000 hours a year, often outdoors, often in dust and 45 °C heat. Treated well, a Teqtive chiller runs 15–20 years. The difference between that and a five-year life is almost entirely maintenance. Print this checklist and keep it with the log sheet.
Daily — the log sheet
Take the same readings at the same time every day, and look at the trend, not the value.
| Reading | Why it matters | Act when |
|---|---|---|
| Coolant inlet / outlet temperature | Shows actual load and whether the set point is being held | Outlet drifts above set point under normal load |
| Suction pressure & temperature | Low suction = low charge, blocked filter, low flow or iced evaporator | Falls steadily over days |
| Discharge pressure & temperature | High discharge = dirty condenser, non-condensables, overcharge, high ambient | Rises steadily, or discharge temp above ≈ 100 °C |
| Oil pressure & level | Lubrication and oil return | Level falling, or differential below the compressor's minimum |
| Compressor amps | Load and motor health | Above nameplate, or unbalanced between phases |
| Condenser water in/out or ambient air | Heat-rejection health | Condenser ΔT narrowing — tubes scaling |
| Pump pressure / flow | Coolant circulation | Pressure rises (blockage) or falls (pump wear, low level) |
Weekly
- Clean or blow down air-cooled condenser coils; check fan rotation and bearings.
- Check cooling-tower water level, bleed-off and chemical dosing; inspect for algae.
- Check sight glass: clear and bubble-free under steady load. Bubbles mean low charge or a restriction.
- Inspect the coolant tank level and top up with the correct brine or glycol concentration — never plain water into a glycol loop.
- Listen for new noises: liquid slugging, bearing rumble, loose panels.
- Check for oil stains around joints, valves and shaft seals — an oil spot is a refrigerant leak.
Monthly
- Verify refrigerant charge against superheat and subcooling, not just sight glass.
- Clean coolant strainers and Y-strainers; check pump seals.
- Check brine or glycol concentration with a refractometer and inhibitor level per the supplier's data sheet; correct pH on salt brines.
- Tighten electrical terminals; check contactor faces; thermograph the panel if you can.
- Test the flow switch, antifreeze thermostat and high/low pressure cut-outs by simulation.
- Check insulation and vapour barrier on low-temperature lines — any frost or sweating means heat is leaking in.
- Review the log for trends and record run hours and starts per hour (frequent starts shorten compressor life).
Annual service
- Condenser: mechanically brush or chemically clean water-cooled tubes; chemically clean air-cooled coils; eddy-current test tubes on older units.
- Evaporator: inspect and clean the coolant side; check for erosion or corrosion on brine chillers.
- Oil: analyse for acidity, moisture and metals; change oil and filters; replace the filter-drier core.
- Leak test the whole circuit; repair and re-charge as needed.
- Megger-test motors; check vibration on open-drive machines; align couplings and check belts.
- Calibrate pressure and temperature transmitters and the controller sensors.
- Service the expansion valve or check the electronic valve's stroke and feedback.
- Reciprocating compressors: inspect valves, pistons and bearings per run hours; screw compressors: check slide-valve operation and bearing condition.
- Test every safety device and record the trip points.
Warning signs that mean call for service now
- High-pressure trips in cool weather
- Oil level dropping with no visible leak
- Compressor short-cycling
- Ice on the evaporator shell or suction line of a water chiller
- Discharge temperature over ≈ 110 °C
- Acidic or dark oil
- Frequent low-suction trips on a brine chiller
Keeping it efficient, not just running
Every 1 °C rise in condensing temperature costs roughly 2–3 % in power; every 1 °C of unnecessary low set point costs about the same. A clean condenser, a correct charge and an honest set point are worth more than any upgrade. Our efficiency guide shows how to measure your kW/TR, and how an industrial chiller works explains what each reading means.
Teqtive supports every chiller it builds with spares, service visits and annual maintenance contracts from its Ghaziabad works. Contact the service team to schedule an inspection or set up an AMC.
Frequently asked questions
How often should an industrial chiller be serviced?
Log readings daily, check the condenser and strainers weekly, carry out a monthly inspection of refrigerant charge, oil and electricals, and do a full annual service that includes condenser tube cleaning, oil analysis or change, safety-device testing and a leak test. Low-temperature brine chillers and dusty sites need more frequent condenser cleaning.
What is the most common cause of chiller failure?
Dirty condensers. Fouled coils or scaled tubes raise condensing pressure, which raises power consumption, cuts capacity and eventually trips the high-pressure safety. In India, dust on air-cooled coils and scale from hard tower water are the two biggest culprits.
What readings should be logged on a chiller every day?
Chilled-water or brine inlet and outlet temperatures, suction and discharge pressures and temperatures, oil pressure and level, compressor amps, condenser water or ambient air temperature, and the coolant flow or pump pressure. A rising discharge pressure or falling suction pressure over several days is the earliest sign of trouble.
Should I sign an AMC for my chiller?
If you do not have a trained refrigeration technician on site, an annual maintenance contract with the manufacturer or a competent refrigeration contractor is usually cheaper than one emergency breakdown in peak season.
