Custom Courses Engineering & Technical Maintenance

Chiller Plant Operations and Maintenance Training

SAQA US AATICD-0253 | NQF 5 | Credits 10 | Duration 5 Days
From $913 per delegate

Description

This course equips learners with the knowledge and skills to operate, monitor, and maintain chiller plant systems in commercial and industrial settings. It covers safe operational practices, routine maintenance procedures, and troubleshooting techniques to ensure optimal performance and energy efficiency.

Learning Outcomes

  • Apply safe work practices and procedures when operating chiller plant systems.
  • Demonstrate the ability to start up, monitor, and shut down chiller plant equipment.
  • Analyze chiller plant performance data to identify operational issues and inefficiencies.
  • Implement routine maintenance tasks including cleaning, inspection, and replacement of components.
  • Evaluate system faults and perform basic troubleshooting to restore normal operation.
  • Document maintenance activities and report on system status according to organizational standards.

Target Audience

This course is designed for plant operators, maintenance technicians, and facilities managers responsible for chiller plant operations and maintenance in commercial, industrial, or institutional buildings.

Prerequisites

None — open enrollment

Course Outline

Day 1: Fundamentals of Chiller Plant Systems

Objectives:
• Explain the basic refrigeration cycle and its components.
• Identify different types of chillers and their applications.
• Describe the role of chillers in HVAC systems.
• Understand key thermodynamic principles and refrigerants.

Topics:
• Introduction to chiller plants and their importance
• Refrigeration cycle: compressor, condenser, expansion valve, evaporator
• Types of chillers: air-cooled, water-cooled, absorption
• Refrigerants and environmental regulations
• Heat transfer principles and psychrometrics
• Chiller components: pumps, cooling towers, heat exchangers
• Safety protocols in chiller operations

Day 2: Chiller Plant Operation and Control

Objectives:
• Operate chiller plant equipment following standard procedures.
• Interpret control system parameters and alarms.
• Adjust setpoints and troubleshoot basic operational issues.
• Perform routine start-up and shutdown sequences.

Topics:
• Operating procedures: start-up, shutdown, normal operation
• Control systems: sensors, controllers, actuators
• Setpoint adjustments and sequencing
• Monitoring: temperatures, pressures, flow rates
• Alarm handling and emergency shutdown
• Energy efficiency strategies: VSD, condenser water reset
• Log keeping and reporting

Day 3: Preventive Maintenance of Chiller Plants

Objectives:
• Develop and execute a preventive maintenance schedule.
• Inspect and maintain key chiller components.
• Identify wear and tear indicators and perform corrective actions.
• Apply lubrication, cleaning, and calibration techniques.

Topics:
• Maintenance planning and scheduling
• Compressor maintenance: oil checks, belt tension
• Condenser and evaporator cleaning
• Cooling tower maintenance: water treatment, fan alignment
• Pump and motor maintenance
• Valve and actuator inspection
• Calibration of sensors and gauges
• Documentation and record keeping

Day 4: Troubleshooting and Diagnostics

Objectives:
• Diagnose common chiller faults using systematic approaches.
• Use diagnostic tools and interpret readings.
• Perform root cause analysis and implement corrective actions.
• Apply safety procedures during troubleshooting.

Topics:
• Common faults: low refrigerant, high head pressure, oil issues
• Diagnostic tools: multimeters, pressure gauges, thermometers
• Electrical troubleshooting: starters, contactors, VSDs
• Refrigerant leak detection and recovery
• Water flow issues: pump cavitation, air locks
• Control system diagnostics
• Repair vs. replace decision-making

Day 5: Advanced Applications and Practical Integration

Objectives:
• Optimize chiller plant performance through advanced strategies.
• Integrate chiller systems with BMS for remote monitoring.
• Apply energy management and sustainability practices.
• Conduct a simulated performance assessment and report.

Topics:
• Energy optimization: load management, thermal storage
• BMS integration and data analytics
• Sustainable refrigerants and green building standards
• Retrofit and upgrade considerations
• Performance metrics: kW/ton, IPLV, EER
• Case studies of chiller plant retrofits
• Final assessment and review

Practicals

16 hours of practicals To be conducted online or on-campus or in-house
Overview

Hands-on practical sessions are integral to this course, allowing learners to apply theoretical knowledge to real chiller plant equipment. These sessions cover safe operation, preventive maintenance, troubleshooting, and performance optimization under instructor supervision.

Practical Activities
  • Chiller Plant Walkthrough and Safety Induction — Learners tour a chiller plant, identify major components, and practice safety protocols including lockout/tagout. (2h)
  • Start-Up and Shutdown Procedures — Learners perform complete start-up and shutdown sequences on an operational chiller, monitoring parameters and recording data. (3h)
  • Preventive Maintenance Tasks — Learners perform routine maintenance tasks including oil level checks, belt tensioning, condenser cleaning, and sensor calibration. (4h)
  • Troubleshooting Common Faults — Learners diagnose and rectify simulated faults such as low refrigerant, high head pressure, and electrical issues using diagnostic tools. (4h)
  • Performance Optimization and BMS Interaction — Learners adjust setpoints, implement energy-saving strategies, and interact with a BMS to monitor and log performance data. (3h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total
Component Out of Weight
Practical Assignments (rubric-scored) 100% 30%
Daily Average (multiple choice) 100% 20%
Final Test (multi-answer multiple choice) 100% 50%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Practicals 30% + Daily Average 20% + Final Test 50%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 40% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

Upcoming Training Sessions
Online training — attend live sessions from anywhere via our virtual classroom.
Start End Delivery Season Price Action
Mon 05 Oct 2026 Fri 09 Oct 2026 Virtual Spring 2026 $913 Register
Mon 07 Dec 2026 Fri 11 Dec 2026 Virtual Summer 2026 $913 Register
Mon 04 Jan 2027 Fri 08 Jan 2027 Virtual Summer 2026 $913 Register
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Mon 07 Jun 2027 Fri 11 Jun 2027 Virtual Winter 2027 $913 Register
Mon 21 Jun 2027 Fri 25 Jun 2027 Virtual Winter 2027 $913 Register
Mon 05 Jul 2027 Fri 09 Jul 2027 Virtual Winter 2027 $913 Register
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Mon 20 Dec 2027 Fri 24 Dec 2027 Virtual Summer 2027 $913 Register
Mon 03 Jan 2028 Fri 07 Jan 2028 Virtual Summer 2027 $913 Register
On-Campus training — face-to-face sessions at our training venues across Africa and beyond.
Showing all 392 sessions across 26 venues
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Mon 05 Oct 2026 Fri 09 Oct 2026 Kigali, Rwanda Spring 2026 $3,343 Register
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Mon 05 Oct 2026 Fri 09 Oct 2026 Lusaka, Zambia Spring 2026 $2,587 Register
Mon 05 Oct 2026 Fri 09 Oct 2026 Windhoek, Namibia Spring 2026 $2,587 Register
Mon 05 Oct 2026 Fri 09 Oct 2026 Nairobi, Kenya Spring 2026 $3,343 Register
In-House training — we bring the trainer to your organisation, tailored to your team.
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Mon 12 Oct 2026 Fri 16 Oct 2026 Your Premises Spring 2026 $1,188 Register
Mon 14 Dec 2026 Fri 18 Dec 2026 Your Premises Summer 2026 $1,188 Register
Mon 11 Jan 2027 Fri 15 Jan 2027 Your Premises Summer 2026 $1,188 Register
Mon 08 Feb 2027 Fri 12 Feb 2027 Your Premises Summer 2026 $1,188 Register
Mon 08 Mar 2027 Fri 12 Mar 2027 Your Premises Autumn 2027 $1,188 Register
Mon 14 Jun 2027 Fri 18 Jun 2027 Your Premises Winter 2027 $1,188 Register
Mon 28 Jun 2027 Fri 02 Jul 2027 Your Premises Winter 2027 $1,188 Register
Mon 12 Jul 2027 Fri 16 Jul 2027 Your Premises Winter 2027 $1,188 Register
Mon 13 Sep 2027 Fri 17 Sep 2027 Your Premises Spring 2027 $1,188 Register
Mon 27 Sep 2027 Fri 01 Oct 2027 Your Premises Spring 2027 $1,188 Register
Mon 11 Oct 2027 Fri 15 Oct 2027 Your Premises Spring 2027 $1,188 Register
Mon 13 Dec 2027 Fri 17 Dec 2027 Your Premises Summer 2027 $1,188 Register
Mon 27 Dec 2027 Fri 31 Dec 2027 Your Premises Summer 2027 $1,188 Register
Mon 10 Jan 2028 Fri 14 Jan 2028 Your Premises Summer 2027 $1,188 Register
Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 40% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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