Method of Procedure (MOP)

Water Cooled Chiller Annual Preventative Maintenance

Section 01: MOP Schedule Information

MOP Title:	Water Cooled Chiller Annual Preventative Maintenance
MOP Identifier:
Version:
Creation Date:	8/27/2025
Work Description:	Annual Preventative Maintenance
Component Type:	Water Cooled Chiller
Manufacturer:	Carrier
Model Number:	19XRV5P51442LCH64S
Serial Number:	SN-A47B021C
Equipment Number:	CHILLER-1
Location:	Data Hall 1
Duration:	6-8 hours. This timeframe allows for thorough inspection, cleaning, filter changes, lubrication, and testing, which are typical components of an annual chiller PM.
Level of Risk (LOR):	Level 2 (Medium) Single system affected with redundancy available
CET Level Required:	CET-2 required to perform work Standard mechanical maintenance work
Author:
Author CET Level:
Approver:

Section 02: Site Information

Customer:	Glenart Group
Site Name:	GLE-07
Data Center Location:	Data Hall 1
Site Address:	2300 US-34, Oswego, IL 60543
Site Contact:

Section 03: MOP Overview

MOP Title:	Water Cooled Chiller Annual Preventative Maintenance
Work Area:
Building/Floor/Room:
Access Requirements:
Self Delivered / Vendor:	Self-Delivered
Qualifications Required:	Required Certifications: EPA 608 Universal: Required for refrigerant handling OSHA 10/30: General industry safety certification Experience Level: Minimum 5 years of experience with water-cooled chiller maintenance and repair.
Advance notifications required:	Data Center Manager: 24 hours advance - Approve maintenance window and coordinate resources NOC/BMS Operator: 4 hours advance - Prepare monitoring systems and acknowledge alarms IT Operations: 24 hours advance - Plan for any affected systems or redundancy needs Security: Day of work - Arrange access and visitor badges for any contractors
Post notifications required:	Data Center Manager: Completion confirmation with any issues encountered NOC/BMS Operator: System status update and alarm points restored to normal IT Operations: All-clear notification that equipment is back online Maintenance Log: Updated with work performed, readings, and next due date

Section 04: Effect of MOP on Critical Facility

Facility Equipment or System	Yes	No	N/A	Details
Electrical Utility Equipment		✓
Emergency Generator System		✓
Critical Cooling System	✓			Chiller is a primary component of the critical cooling system.
Ventilation System		✓
Mechanical System	✓			The chiller is a core component of the mechanical system.
Uninterruptible Power Supply (UPS)		✓
Critical Power Distribution System		✓
Emergency Power Off (EPO)		✓
Fire Detection Systems		✓
Fire Suppression System		✓
Monitoring System	✓			Chiller performance and status are monitored.
Control System	✓			Chiller operation is controlled by the building management system (BMS).
Security System		✓
General Power and Lighting System		✓
Lockout/Tagout Required?	✓			Annual preventative maintenance requires electrical and mechanical isolation.
Work to be performed "hot"?		✓
Radio interference potential?			✓
Water/Leak Detection System	✓			Water-cooled chiller poses a leak risk.

Section 05: Safety Requirements

REQUIRED PERSONAL PROTECTIVE EQUIPMENT (PPE)

PPE requirements specific to Carrier Water Cooled Chiller maintenance:

PPE Category	Specification	When Required
Eye Protection	Safety glasses with side shields, ANSI Z87.1	REQUIRED - At all times during maintenance work per OSHA 29 CFR 1910.133
Hearing Protection	90dB exposure limit Models: 3M E-A-R Classic (29dB), Howard Leight MAX (33dB)	REQUIRED - When equipment noise exceeds 85 dBA per OSHA 29 CFR 1910.95
Safety Footwear	Steel-toed, slip-resistant, ASTM F2413	REQUIRED - At all times in equipment areas per site safety policy

TOOLS REQUIRED

Specific tools required for Carrier Water Cooled Chiller Annual Preventative Maintenance based on equipment type and task:

Tool Category	Specific Tools	Purpose
Refrigerant Service Tools	• Recovery machine (EPA certified) • Vacuum pump (2-stage, 5 CFM min) • Digital manifold gauge set • Electronic leak detector	Refrigerant service and leak detection for Carrier Water Cooled Chiller
Temperature & Pressure	• Infrared thermometer • Thermocouple probe set • Differential pressure gauge • Psychrometer	Temperature and pressure measurements for Water Cooled Chiller diagnostics
Mechanical Tools	• Socket set (metric and standard) • Pipe wrenches • Tube cutters and flaring tools • Fin comb set	Mechanical service on Carrier Water Cooled Chiller components
Electrical Test Equipment	• Multimeter • Clamp meter • Capacitor tester • Motor rotation tester	Electrical testing of Water Cooled Chiller controls and motors
Safety Equipment	• Lockout/tagout kit • First aid kit • Fire extinguisher (appropriate class) • Emergency eyewash (if chemicals present)	Safety equipment required for all maintenance work
Specialized Carrier Tools		Manufacturer-specific tools required per Carrier 19XRV5P51442LCH64S service manual

SAFETY PROCEDURES

Procedure	Requirements	Initials	Time
Pre-Work Safety Briefing	Conduct safety briefing with all personnel, review hazards specific to Carrier Water Cooled Chiller maintenance, verify PPE
Lockout/Tagout (LOTO)	Follow site LOTO procedure per OSHA 29 CFR 1910.147 for Water Cooled Chiller isolation
Hot Surface Warning	Allow Water Cooled Chiller to cool before service, use thermal protection if required

EMERGENCY CONTACTS

Emergency Type	Contact	Phone Number
Medical Emergency	Emergency Medical Services	911
Fire Emergency	Fire Department	911
Chemical Emergency	Poison Control / CHEMTREC	1-800-222-1222 / 1-800-424-9300
Facility Emergency
Equipment Manufacturer	Carrier Technical Support

LOCAL EMERGENCY SERVICES

Location: 2300 US-34, Oswego, IL 60543

✓ RESEARCHED: The contact information below has been researched for this specific location. Please verify current phone numbers before use as they may change over time.

Service	Contact Name	Phone Number	Address
Local AHJ (Authority Having Jurisdiction)	Village of Oswego Building & Permits Department	630-554-2310	100 Parkers Mill, Oswego, IL 60543
Nearest Hospital	Rush Copley Medical Center	630-978-6200	2000 Ogden Ave, Aurora, IL 60504
Fire Department (Non-Emergency)	Oswego Fire Protection District, Station #1	630-554-2110	3511 Woolley Road, Oswego, IL 60543
Police Department (Non-Emergency)	Oswego Police Department	630-554-3426	3355 Woolley Road Oswego, IL 60543
Local Utility - Electric	ComEd	800-EDISON1 (800-334-7661)	24/7 Emergency Line
Local Utility - Gas	Nicor Gas	888-Nicor4u (888-642-6748)	24/7 Emergency Line

CRITICAL: Work shall NOT proceed until safety briefing is completed and all required PPE is verified available. All personnel must sign the safety briefing attendance sheet.

Section 06: MOP Assumptions

Key Project Assumptions

Category	Assumption
Equipment Condition	Chiller is operating within normal parameters as defined by Carrier's O&M manual, with no known pre-existing mechanical faults (VERIFY WITH MANUFACTURER for specific model).
Spare Parts Availability	Commonly required spare parts (filters, belts, gaskets, oil) are readily available on-site or can be procured within a reasonable timeframe (SITE-SPECIFIC REQUIREMENT based on criticality and lead times).
System Redundancy	System has N+1 redundancy, or a backup chiller is available, allowing maintenance to be performed without critical disruption of cooling services (SITE-SPECIFIC REQUIREMENT).
Environmental Conditions	Ambient environmental conditions (temperature, humidity, air quality) are within the chiller's specified operating range as defined in the Carrier O&M manual.
Personnel Qualifications	Maintenance personnel are certified HVAC technicians with specific training and experience on Carrier water-cooled chillers, including refrigerant handling certification per EPA regulations.
System Documentation	Up-to-date and accurate system documentation, including the Carrier O&M manual, as-built drawings, and maintenance logs, are available and readily accessible to maintenance personnel.
Resources	All required test equipment is calibrated and available on-site
Infrastructure	The facility's electrical and mechanical infrastructure can support equipment isolation without affecting other critical systems
Management	Management approval has been obtained for the maintenance window and potential risks have been communicated to stakeholders

Critical Decision Points for Carrier Water Cooled Chiller (Unit: CHILLER-1, Serial: SN-A47B021C):

If redundant Water Cooled Chiller fails while performing Annual Preventative Maintenance on Carrier Water Cooled Chiller CHILLER-1 - STOP work immediately and return primary unit to service following Carrier restart procedures
If major defect discovered on Carrier Water Cooled Chiller unit CHILLER-1 - Escalate to Chief Engineer for immediate go/no-go decision
If system parameters exceed normal ranges during Annual Preventative Maintenance on unit CHILLER-1 - Implement emergency Water Cooled Chiller recovery procedures
If Annual Preventative Maintenance reveals component failure on Carrier Water Cooled Chiller CHILLER-1 - Notify management for extended maintenance window approval
If building automation system shows critical alarms for Carrier Water Cooled Chiller during Annual Preventative Maintenance - Verify with BMS operator before continuing work on unit CHILLER-1

Section 07: MOP Details

Date Performed:	Time Begun:	Time Completed:
Facilities personnel performing work:
Contractor/Vendor personnel performing work:

Chiller Operational Data Log

Parameter	Compressor 1		Units
Parameter	As Found	As Left	Units
Voltage L1-L2			VAC
Voltage L2-L3			VAC
Voltage L1-L3			VAC
Current L1			Amps
Current L2			Amps
Current L3			Amps
Oil Level			%
Discharge Temp			°F
Suction Temp			°F
Discharge Pressure			PSIG
Suction Pressure			PSIG
Chilled Water Temp In			°F
Chilled Water Temp Out			°F

Chiller Performance Data

Parameter	Units	Acceptable Range
Chilled Water Flow Rate	GPM	Per design specs
Condenser Water Flow Rate	GPM	Per design specs
kW Input	kW	Per nameplate
Cooling Capacity	Tons	Per nameplate

System Fault/Alarm History

Date/Time	Fault/Alarm Code	Description	Action Taken	Initials

Detailed Procedure Steps

Step	Detailed Procedure	Initials	Time
1	Notify Data Center Operations Manager, Site Security, and NOC/BMS Operator that procedure is about to begin
2	Notify relevant personnel of the planned Carrier Water Cooled Chiller (Unit: CHILLER-1, Serial: SN-A47B021C) preventative maintenance.
3	Verify backup chiller system is operational and ready to assume cooling load.
4	Record baseline operating parameters of Carrier Water Cooled Chiller (Unit: CHILLER-1, Serial: SN-A47B021C): entering/leaving water temperatures, pressures, and flow rates. (SITE-SPECIFIC REQUIREMENT)
5	Initiate Lockout/Tagout (LOTO) procedure for Carrier Water Cooled Chiller (Unit: CHILLER-1, Serial: SN-A47B021C) electrical supply and water lines according to OSHA standards and site-specific LOTO procedures.
6	Verify zero energy state for all electrical components of Carrier Water Cooled Chiller (Unit: CHILLER-1, Serial: SN-A47B021C) using appropriate testing equipment (multimeter).
7	Ensure proper Personal Protective Equipment (PPE) is worn: safety glasses, gloves, and any other required PPE based on site-specific safety regulations.
8	Inspect the area around the Carrier Water Cooled Chiller (Unit: CHILLER-1, Serial: SN-A47B021C) for any potential hazards: leaks, obstructions, or unsafe conditions.
9	Close chilled water supply and return valves to isolate the Carrier Water Cooled Chiller (Unit: CHILLER-1, Serial: SN-A47B021C).
10	Drain the water from the chiller barrel. Refer to Carrier manual for specific drain locations and procedures.
11	Inspect chiller barrel for scale, corrosion, and fouling.
12	Clean chiller tubes using appropriate brushes and cleaning solutions. REFER TO Carrier MANUAL for approved cleaning agents.
13	Rinse the chiller barrel thoroughly with clean water to remove any remaining cleaning solution or debris.
14	Inspect all water box gaskets for damage or wear and replace if necessary.
15	Reinstall water boxes, ensuring proper alignment and sealing.
16	Refill the chiller barrel with treated water.
17	Inspect refrigerant lines for leaks, damage, and corrosion.
18	Verify refrigerant type (R-134a or R-410A) for Carrier Water Cooled Chiller (Unit: CHILLER-1, Serial: SN-A47B021C) and refrigerant level.
19	If refrigerant level is low, check for leaks using an electronic leak detector. Repair any leaks before adding refrigerant. FOLLOW EPA GUIDELINES.
20	Record refrigerant pressures (high side and low side). VERIFY ACCEPTABLE RANGES WITH MANUFACTURER (Operating parameters: 120-150 PSIG (high side), 30-50 PSIG (low side)).
21	Inspect compressor for oil leaks, damage, and unusual noise or vibration.
22	Check compressor oil level and add oil if necessary. VERIFY OIL TYPE WITH MANUFACTURER.
23	Analyze compressor oil sample for contamination (moisture, acid, debris). (SITE-SPECIFIC REQUIREMENT)
24	Inspect and clean compressor motor windings.
25	Check compressor motor winding resistance and insulation.
26	Inspect and clean condenser coils. Remove any debris that may restrict airflow.
27	Check condenser fan motor for proper operation and lubrication.
28	Inspect and clean electrical control panel.
29	Tighten all electrical connections in the control panel. Torque values: 40-50 ft-lbs (electrical) - VERIFY WITH MANUFACTURER.
30	Inspect and test all safety controls (high pressure, low pressure, oil pressure, water flow).
31	Verify calibration of all temperature and pressure sensors. (SITE-SPECIFIC REQUIREMENT)
32	Inspect and clean or replace air filters.
33	Check the operation of the chiller's control system.
34	Verify all control settings are correct for optimal performance. (SITE-SPECIFIC REQUIREMENT)
35	Inspect vibration isolators for damage and proper function.
36	Take vibration measurements of the compressor and motors. REFER TO MANUFACTURER SPECIFICATIONS for acceptable vibration levels.
37	Inspect and tighten all mechanical fasteners. Torque values: 25-35 ft-lbs (mechanical) - VERIFY WITH MANUFACTURER.
38	Check the alignment of the motor and compressor.
39	Verify proper grounding of all electrical components.
40	Verify all maintenance tasks are completed and documented.
41	Obtain sign-off from qualified personnel.
42	Remove Lockout/Tagout (LOTO) devices after verification.
43	Restore electrical power to the Carrier Water Cooled Chiller (Unit: CHILLER-1, Serial: SN-A47B021C).
44	Open chilled water supply and return valves.
45	Start the Carrier Water Cooled Chiller (Unit: CHILLER-1, Serial: SN-A47B021C) following the manufacturer's recommended startup procedure. REFER TO Carrier MANUAL.
46	Monitor the chiller's operation closely during startup.
47	Check for any unusual noises or vibrations.
48	Record operating parameters: entering/leaving water temperatures, pressures, and flow rates. (SITE-SPECIFIC REQUIREMENT)
49	Compare the current operating parameters to the baseline readings taken before the maintenance. (SITE-SPECIFIC REQUIREMENT)
50	Make any necessary adjustments to optimize the chiller's performance. (SITE-SPECIFIC REQUIREMENT)
51	Allow the chiller to run for at least one hour to stabilize.
52	Re-inspect for leaks and proper operation.
53	Document all maintenance activities performed, including any repairs or adjustments made.
54	Update the chiller's maintenance log with the date, time, and details of the preventative maintenance.
55	Notify relevant personnel that the Carrier Water Cooled Chiller (Unit: CHILLER-1, Serial: SN-A47B021C) is back in service.
56	Return any temporary equipment to its designated storage location.
57	Clean up the work area and dispose of any waste materials properly.

Critical Step Notes (Steps requiring torque verification or electrical testing):

Section 08: Back-out Procedures

CRITICAL BACK-OUT PROCEDURES

If at any point during the maintenance procedure a critical issue is discovered that could affect data center operations, follow these detailed back-out procedures:

Step	Back-out Procedures	Initials	Time
1	Immediate Actions: Stop all work immediately and secure the area
2	Notify the Facility Technician and Lead Technician immediately
3	Assess the situation and determine if equipment can be safely returned to service
4	If issue cannot be resolved at technician level, escalate to Chief Engineer
5	If Chief Engineer cannot resolve, escalate to Data Center Manager
6	Contact equipment manufacturer service representative if required: Equipment Manufacturer Service Representative
7	Document all findings and actions taken in the incident report
8	If safe to return to service, follow re-energization procedures
9	Monitor equipment for minimum 30 minutes after return to service
10	Complete incident report and schedule follow-up maintenance if required

Section 09: MOP Approval

Review Stage	Reviewer's Name	Reviewer's Title	Date
Tested for clarity:
Technical review:
Chief Engineer approval:
Customer approval:

Approval Requirements:

All stages must be completed in sequence
Technical review must verify all equipment specifications and procedures
Chief Engineer must approve risk assessment and mitigation strategies
Customer approval required before work commencement

MOP Effective Date:

MOP Expiration Date:

Section 10: MOP Comments

MOP Comments

Annual maintenance should be performed per Carrier's recommended procedures (VERIFY WITH MANUFACTURER MANUAL for specific model).
Specialized tools such as refrigerant recovery equipment and tube cleaning brushes may be required (REFER TO MANUFACTURER TOOL LIST).
Inspect condenser tubes for fouling and scaling, a common issue that reduces efficiency. Chemical treatment and regular cleaning are essential (CONSULT MANUFACTURER SERVICE BULLETINS for recommended cleaning procedures).
Maintain a detailed maintenance log, including operating temperatures, pressures, and fluid levels, as required by Carrier and industry best practices (SITE-SPECIFIC REQUIREMENT for record retention).
Consider a spectrometric chemical analysis of the compressor oil annually to identify potential issues such as high water content or particle contamination (SITE-SPECIFIC REQUIREMENT based on operational history).

This MOP is valid for one year from the approval date and must be reviewed/updated if equipment modifications occur.
All test data and readings must be recorded in the equipment log book and uploaded to the CMMS within 48 hours.
Any deviations from this procedure must be documented and approved by the Chief Engineer before proceeding.
Lessons learned from this maintenance should be documented and incorporated into the next revision.

Post-Maintenance Requirements:

Complete and submit maintenance report within 24 hours
Update equipment history in CMMS
Schedule follow-up inspection if any issues were identified
Review and update PM schedule based on equipment condition

Additional Notes:

Section 11: References and Documentation

Comprehensive Reference Library

Equipment-Specific Documentation

Document Title	Type	Access
Carrier Water Cooled Chiller Documentation	Technical Manual	📋 View

Safety Standards and Guidelines

Safety Standard	Authority	Access
OSHA 29 CFR 1910.147 - The Control of Hazardous Energy (Lockout/Tagout)	OSHA	📋 View
OSHA 29 CFR 1910.95 - Occupational Noise Exposure	OSHA	📋 View
OSHA Personal Protective Equipment Standards	OSHA	📋 View
ANSI Z87.1 - Eye and Face Protection	ANSI	📋 View
ASTM Standards	ASTM	📋 View

Additional Resources

Resource	Type	Access
Site-Specific Emergency Response Plan	Internal Document	Internal Document - Request from Site Manager
Equipment History and Maintenance Records	CMMS Database	Internal Document - Request from Site Manager
Safety Data Sheets (SDS) Information	Chemical Safety	📋 View
Environmental Compliance Documentation	Regulatory	Internal Document - Request from Site Manager
Vendor Contact Information and Support Agreements	Service Contract	Internal Document - Request from Site Manager

📚 Reference Usage Guidelines

Pre-Work Review: All applicable documentation must be reviewed before beginning maintenance work
Current Revisions: Verify all documents are current revision levels and not superseded
Access Requirements: Ensure access to online resources and account credentials are available
Local Copies: Maintain current copies of critical documents for offline reference
Update Tracking: Monitor manufacturer bulletins and regulatory updates that may affect procedures

⚠ Important Notice: All external links have been verified as working at the time of MOP creation. However, URLs may change over time. If a link is broken, search for the document by title on the organization's website. Internal documents marked "Request from Site Manager" must be obtained locally and are not available through external links.

📋 Link Verification: All links in this document point to official sources only: • Manufacturer support websites • OSHA.gov regulations • EPA.gov standards • NFPA.org codes • Industry organization websites