Product Overview

Summary: This Cooling System Service Safe Operating Procedure provides a clear, step-by-step method for safely inspecting, maintaining and servicing industrial and commercial cooling systems. It helps Australian businesses control WHS risks such as burns, chemical exposure, Legionella growth and electrical hazards, while improving plant reliability and energy efficiency.

Cooling systems – including chillers, cooling towers, condensers and associated pipework – are critical to building services and industrial processes, but they present a complex mix of WHS, environmental and operational risks if not serviced correctly. This Cooling System Service SOP sets out a structured, repeatable method for planning, isolating, servicing and recommissioning cooling systems in accordance with Australian WHS requirements. It addresses the practical realities of working in plant rooms, rooftops and confined plant spaces, where technicians may be exposed to hot and cold surfaces, chemicals, moving parts and elevated work areas.

The procedure helps businesses demonstrate due diligence by embedding hazard identification, lock-out/tag-out, safe chemical handling, Legionella risk control and environmental protection into everyday maintenance tasks. It reduces reliance on “tribal knowledge” by turning good practice into a documented standard that can be used for training, contractor management and audit evidence. By implementing this SOP, organisations can reduce unplanned downtime, extend asset life, improve energy performance and show regulators, clients and insurers that cooling system servicing is being managed in a safe, consistent and compliant manner across all sites.

Key Benefits

• Ensure cooling system servicing is carried out safely and consistently across all sites and technicians.
• Reduce the risk of worker injury from hot or cold surfaces, rotating equipment, electrical components and chemical exposure.
• Support compliance with Australian WHS laws and Legionella management requirements for cooling water systems.
• Standardise documentation, inspection records and sign-off to strengthen audit trails and contractor oversight.
• Optimise cooling system performance, helping to minimise breakdowns, product loss and costly reactive call-outs.

Who is this for?

• Maintenance Technicians
• HVAC Technicians
• Plant and Facility Managers
• WHS Managers and Advisors
• Engineering Supervisors
• Property and Asset Managers
• Operations Managers
• Building Services Contractors

Hazards Addressed

• Exposure to hazardous chemicals such as corrosion inhibitors, biocides and descalers
• Burns from hot water, steam lines, hot pipes and surfaces
• Cold burns and contact injuries from chilled lines and refrigerated components
• Electrical shock or arc flash during work on associated electrical equipment
• Contact with rotating equipment such as fans, pumps and belts
• Legionella and other biological hazards from contaminated cooling water systems
• Slips, trips and falls in wet plant rooms, on rooftops or around cooling towers
• Falls from height when accessing rooftop units or elevated platforms
• Manual handling injuries from lifting covers, pumps, motors and chemical containers
• Exposure to refrigerant leaks, including asphyxiation risk in poorly ventilated areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and System Types (chillers, cooling towers, condensers, package units)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Pre-Service Planning and Risk Assessment (JSA/SWMS)
• 6.0 Required Tools, Equipment and Personal Protective Equipment (PPE)
• 7.0 Isolation, Lock-Out/Tag-Out and Verification of Zero Energy
• 8.0 Chemical Handling, Storage and Spill Response Procedures
• 9.0 Cooling System Inspection Checklist (mechanical, electrical and control components)
• 10.0 Cooling Tower and Water System Service (cleaning, dosing, Legionella control)
• 11.0 Chiller and Refrigeration Component Service (filters, coils, valves, refrigerant checks)
• 12.0 Electrical and Control System Checks (sensors, interlocks, safety devices)
• 13.0 Reassembly, Recommissioning and Functional Testing
• 14.0 Environmental Controls (wastewater discharge, chemical disposal, noise and emissions)
• 15.0 Documentation, Service Reports and Record Keeping
• 16.0 Emergency Procedures (chemical exposure, spills, leaks, electrical incidents)
• 17.0 Training, Induction and Competency Verification
• 18.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and harmonised state and territory WHS legislation
• Safe Work Australia – Model Code of Practice: Managing the Work Environment and Facilities
• Safe Work Australia – Model Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• AS/NZS 3666.1: Air-handling and water systems of buildings – Microbial control – Design, installation and commissioning
• AS/NZS 3666.2: Air-handling and water systems of buildings – Microbial control – Operation and maintenance
• AS/NZS 5149 (series): Refrigerating systems and heat pumps – Safety and environmental requirements
• AS/NZS 3000: Electrical installations (Wiring Rules)
• AS 1657: Fixed platforms, walkways, stairways and ladders – Design, construction and installation
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 4801 / ISO 45001: Occupational health and safety management systems