PHARMA DEVILS

ENGINEERING DEPARTMENT

Title: Operation of Chiller System

SOP No.: Revision No.: 00
Effective Date: Supersedes No. Nil
Review Date: Page No. 1 of 6

1.0 OBJECTIVE:
To lay down a procedure for Operation of Chiller System.

2.0 SCOPE:
This SOP is applicable for Operation of Chiller System.

3.0 RESPONSIBILITY:
Operator/Officer / Executive - Engineering

4.0 ACCOUNTABILITY:
Head – Engineering

5.0 ABBREVIATIONS:
ID No. Identification Number
LT Low Tension
LTD. Limited
PVT. Private
HMI Human Machine Interface
KPA Kilo Pascal
QA Quality Assurance
SOP Standard Operating Procedure
2
Kg/cm Kilogram per centimeter square
NMT Not more than
NLT Not less Than

6.0 PROCEDURE:

6.1 CHECK BEFORE START-UP OF CHILLER PLANT:

6.1.1 Check and ensure that all the measuring device/instrument are in calibrated stage.

6.1.2 Check and ensure that inlet pressure at chiller from condenser pump is NMT 3.0 kg/cm2.
6.1.3 Check and ensure that outlet pressure from condenser pump is NMT 2.5 kg/cm2.

6.1.4 Check and ensure that inlet pressure at chiller from evaporator pump is NMT 6.0 kg/cm2.

6.1.5 Check and ensure that outlet pressure from evaporator pump is NMT 5.0 kg/cm2.

6.1.6 Make sure that all pressure gauges are indicating proper pressure before start.

6.1.7 Make sure that cooling tower sump is filled with water and make up inlet is open.

6.1.8 Check and ensure that all the line valves of circulation of chilled water & cooling tower are in
open condition.
 PHARMA DEVILS
ENGINEERING DEPARTMENT

Title: Operation of Chiller System

SOP No.: Revision No.: 00
Effective Date: Supersedes No. Nil
Review Date: Page No. 2 of 6

6.1.9 Before starting chiller, check and ensure that crankcase heaters have operated.

6.1.10 Check the refrigerant system for any leakage by the use of soap solution.

6.1.11 Ensure that power supply is available at the main electrical panel for the operation of chiller.

6.1.12 Switch on the power supply of local electrical panel to start cooling tower pumps and chilled
water circulation pumps from LT panel.

6.1.13 Switch on the required compressor by moving selector switch towards manual side.

6.1.14 Check on local control panel of chiller that green light emitting device (LED) which indicates
that the chiller is in operation.

6.1.15 The unit shall start automatically.

6.2 OPERATION PROCEDURE:

6.2.1 Check that the chiller system is running normally.

6.2.2 Check that the suction pressure is in between NLT 180 KPA if the same is not achieved than
check the refrigerant level and if found low than charge the refrigerant system.

6.2.3 Check that the discharge pressure is NMT 1000 KPA, if the same is not achieved and found in
higher side than check the inlet cooling tower, water inlet temperature at condenser inlet, it
should be NMT 350C, if the same is not achieved than check the cooling tower fan operation
for proper working and also check the condenser tubes for any scaling by stopping the chiller
and cooling tower circulation pump.

6.2.4 Check the inlet and outlet pressure of cooling tower at condenser, it should be NMT 3 Kg/cm2
for inlet & not more than 2.5 Kg/cm2 for outlet.

6.2.5 Check the inlet and outlet pressure of chilled water circulation, it should be NMT 6.0 Kg/cm2
for inlet & 5.0 kg/cm2 for outlet.

6.2.6 Check and ensure that outlet temperature of chilled water shall be NMT 15°C.

6.2.7 Check for any leakage in refrigerant circuit with the use of soap solution, if in any case
leakage is observed than stop the respective chiller immediately and close the suction and
discharge valve of compression. Rectify the leakage and charge the refrigerant gas and start
the respective chiller system.
 PHARMA DEVILS
ENGINEERING DEPARTMENT

Title: Operation of Chiller System

SOP No.: Revision No.: 00
Effective Date: Supersedes No. Nil
Review Date: Page No. 3 of 6

6.3 CHECKS THE FAULT ALARMS DURING OPERATION:

6.3.1 Check whether any unusual sound is coming from moving parts.

6.3.2 Check for the “High Pressure alarms” for low water flow and high condenser water
temperature.

6.3.3 Check for the inlet and outlet water temperature difference in both Condenser and Evaporator
units.

6.3.4 Check for the “Load Alarm” if compressor stops suddenly. To rectify check the High pressure
& low pressure transducer.

6.3.5 Check for “Low Oil Pressure Alarms”. Check for low condenser water temperature and oil
filter pressure sensor.

6.4 AT THE TIME OF STOPPING CHILLER:

6.4.1 To stop the chiller, press the push button of compressors one by one.

6.4.2 After stoppage of chiller, stop the respective condenser and chiller pump.

6.4.3 Now stop the cooling tower fans and switch off the power supply from electrical panel.

6.5 Record the Operation Details of Chiller System in Annexure-I, Titled “Chiller System
Operation Record”.

6.6 Record the Operation Details of Circulation Pump in Annexure-II, Titled “Circulation Pump
Operation Record”.

7.0 ANNEXURES:

ANNEXURE No. TITLE OF ANNEXURE FORMAT No.

Annexure-I Chiller System Operation Record

Annexure-II Circulation Pump Operation Record

ENCLOSURES: SOP Training Record

 PHARMA DEVILS
ENGINEERING DEPARTMENT

Title: Operation of Chiller System

SOP No.: Revision No.: 00
Effective Date: Supersedes No. Nil
Review Date: Page No. 4 of 6

8.0 DISTRIBUTION:
 Controlled Copy No. 01 Quality Assurance
 Controlled Copy No. 02 Engineering
 Master Copy Quality Assurance

9.0 REFERENCES:
Operation & Maintenance Manual of Chiller.

10.0 REVISION HISTORY:

CHANGE HISTORY LOG

Revision Change Details of Changes Reason for Change Effective Updated

No. Control No. Date By
 PHARMA DEVILS
ENGINEERING DEPARTMENT

Title: Operation of Chiller System

SOP No.: Revision No.: 00
Effective Date: Supersedes No. Nil
Review Date: Page No. 5 of 6

ANNEXURE – I

CHILLER SYSTEM OPERATION RECORD

Block: ____________ Chiller ID No. : ______________________ Frequency: 3 Hours Date: _________

Chilled Water Chilled Water Condenser Water Cond. Water Discharge Compressor Compressor Done By
Suction Remarks
Temperature Pressure Pressure Temp. Pressure C1 C2 Sign & Date
Start Stop Reading Pressure
Inlet Outlet Inlet Outlet Suction Discharge Inlet Outlet NMT :
Time Time Time NLT:
NMT: NMT: NMT: NMT:5 NMT: 3 NMT: 2.5 NLT: NMT: 1050 Amp. Load Amp. Load
180 KPA
18°C 15°C 5 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 26°C 40°C KPA

Reviewed By
Sign & Date
 PHARMA DEVILS
ENGINEERING DEPARTMENT

Title: Operation of Chiller System

SOP No.: Revision No.: 00
Effective Date: Supersedes No. Nil
Review Date: Page No. 6 of 6

ANNEXURE – II

CIRCULATION PUMP OPERATION RECORD

Block: ____________ Frequency: 3 Hours Date: _________

Chilled Water Pump (Amp.) Cooling Tower Fan (Amp.) Done
Cooling Tower Pump (Amp.) By
Primary Pump Secondary Pump C.T-01 C.T-02 C.T.-03 C.T-04 C.T.-05 Remarks
Sign &
S. No. Date
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 1 2 1 2