DA Form 7478-R: Chilled Water System Inspection Checklist – Chilled water systems are critical to cooling mission-essential facilities across U.S. Army installations. Whether supporting command centers, data rooms, or C4ISR operations, these systems must deliver reliable performance, energy efficiency, and safety. The DA Form 7478-R — officially titled Chilled Water System Inspection Checklist (LRA) — is the standardized U.S. Army tool used to verify that every component meets design specifications and operational standards.
Released in December 2002 by the U.S. Army Corps of Engineers (COE), this one-page reproducible form remains the current official checklist for chilled water system commissioning, inspection, and testing. It is used in conjunction with TM 5-697, Commissioning of Mechanical Systems for Command, Control, Communications, Computer, Intelligence, Surveillance, and Reconnaissance (C4ISR) Facilities.
If you are a facility manager, public works technician, maintenance contractor, or engineer working on Army bases in the United States, this guide explains exactly what DA Form 7478-R covers, why it matters, how to complete it, and where to download the latest fillable PDF.
What Is DA Form 7478-R?
DA Form 7478-R is a specialized inspection checklist designed exclusively for chilled water systems (CHWS) in Army facilities. It documents pre-functional and functional performance testing of chillers, pumps, hydronic piping, controls, and supporting components.
Key features:
- Date: DEC 2002 (latest version; no superseding form identified as of 2026)
- Proponent: U.S. Army Corps of Engineers (COE)
- Reference: TM 5-697
- Format: Fillable PDF, locally reproducible (LRA)
- Condition Codes: A = Acceptable, R = Needs Repair/Replacement/Adjustment, C = Corrected, NA = Not Applicable
It pairs with its counterpart DA Form 7477-R (Heating Water System Inspection Checklist) for complete hydronic system oversight.
Purpose and Importance for U.S. Army Facilities
The primary goal of DA Form 7478-R is to confirm that the chilled water system is installed correctly, operates safely, and performs to design specifications before it is accepted for regular use. This process — known as commissioning — prevents costly failures, reduces energy waste, and ensures mission readiness in critical facilities.
Using the checklist helps:
- Verify system integrity and safety (grounding, interlocks, pressure ratings)
- Document compliance with Army engineering standards
- Support energy conservation and sustainability goals at DoD installations
- Provide a permanent record for future maintenance and audits
In short, completing this form is a required step in the commissioning process outlined in TM 5-697 and protects the Army’s investment in HVAC infrastructure nationwide.
How to Fill Out DA Form 7478-R? (Step-by-Step)
The form is divided into clear sections for easy completion. Always use black ink or the official fillable PDF.
Section A – Customer Data
- Plant, Location, Job Number
- Equipment description
- Cooling Water Loop Designation
- Date (YYYYMMDD)
- Test Equipment used
- Tested By (name/signature of qualified inspector)
Section B – Equipment Data
- Chiller: Manufacturer, Model No., Serial No., BTU Rating
- Pump: Manufacturer, Model No., Serial No., Rated Flow, HP @ RPM, Rated NPSH, Rated Pressure
Section C – Visual and Mechanical Inspection Inspect and record condition for each checkpoint:
- Exterior of equipment
- Completeness of assembly
- Equipment rotation
- Electrical/mechanical interlocks
- Instruments
- Proper grounding
- Proper insulation
- Tightness of bolted connections
- Proper lubrication
- Refrigerant installed
- Sensors, controllers, actuators
- Relief valves
- Bracing, labeling/tagging, working space, anchorage
- System flushed and cleaned
- Comparison to drawings
- Control system
- Water treatment installed
Section D – Calibration and Set Point Document calibration of sensors, controllers, and set points.
Section E – Hydronic System Tests
- Chiller and pump performance
- Hydrostatic test
- Balance test
- Cooling coil checks
- Expansion tank/air separator
- Control valves
- System test (temperatures, pressures, flows, operating modes, levels)
Notes Section: Record any deficiencies, corrective actions, or additional observations.
Mark every item with the appropriate condition code (A/R/C/NA) and add detailed notes where needed. The inspector and supervisor must sign and date the completed form.
Key Inspection Areas Covered
The checklist ensures comprehensive coverage of:
- Mechanical integrity — Proper assembly, lubrication, and rotation
- Electrical safety — Grounding, interlocks, insulation
- Controls & instrumentation — Sensors, actuators, calibration
- Hydronic performance — Flow rates, pressures, temperatures, balancing
- System readiness — Flushing, cleaning, water treatment, and compliance with drawings
Benefits of Proper Use
- Prevents unexpected downtime in mission-critical facilities
- Improves energy efficiency and lowers operating costs
- Meets DoD and Army commissioning requirements
- Creates auditable records for compliance and warranty claims
- Supports long-term preventive maintenance programs
Where to Download the Official DA Form 7478-R PDF?
Official U.S. Army source (recommended for the most current fillable version): → Download DA Form 7478-R PDF here
Always download directly from the Army Publishing Directorate (armypubs.army.mil) to ensure you have the authorized form.
Related Resources
- TM 5-697 – Commissioning of Mechanical Systems (available via WBDG or Army sources)
- DA Form 7477-R – Heating Water System Inspection Checklist
- UFC and Army engineering standards for HVAC systems
Final Tips for U.S. Army Personnel & Contractors
- Only qualified personnel trained in TM 5-697 should perform the inspection.
- Use calibrated test equipment and document serial numbers.
- Retain completed forms with project records for the life of the system.
- Address any “R” (repair) items and re-inspect before final acceptance.
- Coordinate with the installation Directorate of Public Works (DPW) for local procedures.
Need the form right now?
Click here to download the official DA Form 7478-R Chilled Water System Inspection Checklist (LRA) PDF
By using DA Form 7478-R correctly, you help keep America’s Army facilities cool, efficient, and mission-ready. Bookmark this page for quick reference and share it with your team. Questions about completing the form or chilled water system commissioning? Contact your local Corps of Engineers or DPW office for guidance.