Preseason Checklist: Getting Your Facility Ready Before First Landing
There's a version of spring startup that goes well: you work through the system methodically in March and early April, fix the two or three things that need fixing, and by the time the first truck rolls in you're ready. There's another version that doesn't — and it involves discovering a seized chiller compressor at 9 PM on your first big landing day.
The difference is almost always preparation. The time to find problems is before 50,000 lbs of lobster shows up at the dock. Here's a structured startup checklist with explanation for each item. Work through it in order, and plan to be done at least two weeks before your anticipated first landing.
Flush and Clean the System
Drain tanks, sumps, and flush all piping
Any standing water left over winter is a contamination risk. Drain completely, inspect for cracks and sediment, then run fresh water through the full pipe circuit. Check all low points where debris can settle. Clean plate heat exchangers now — fouled plates reduce thermal efficiency significantly. A heat exchanger at 60% efficiency is costing you in both energy and temperature control.
Chiller Commissioning
Verify refrigerant charge and inspect the compressor
Refrigerant loss over winter is one of the most common reasons chillers underperform at startup. Even a small leak can drop cooling capacity by 20–30%. Check suction and discharge pressures against manufacturer specs. Inspect compressor oil level and condition, and check condenser fins — bent fins restrict airflow and hurt efficiency.
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Allow the crankcase heater to warm the compressor before starting
To prevent costly chiller repairs, make sure to send power to the condensing unit 24 hours before allowing it to run. This will evaporate and liquid refrigerant in the compressor, preventing damage. This can often be done with a toggle switch on the unit, or by turning up the thermostat to a temperature much higher than the system's water.
Biofilter Seeding — Start 4 to 6 Weeks Early
Assess media condition and re-establish the biofilm
This is the most time-sensitive item on this list. Nitrifying bacteria — which convert toxic ammonia to harmless nitrate — are slow-growing. A biofilter that's been dormant over winter may have lost the majority of its active biomass. Reestablishing a stable biofilm takes 4 to 8 weeks. Put full load on an unestablished biofilter and you'll get an ammonia spike that can persist for days. Seed using ammonia dosing (ammonium chloride at 1–2 mg/L TAN) or by running a small number of animals through the filter. Keep it aerated and running continuously — do not let it go anoxic during the seeding period.
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Verify aeration to the biofilter
Nitrification requires dissolved oxygen. Confirm all diffusers are functioning. DO in the biofilter zone should stay above 4 mg/L — below 3 mg/L, nitrification efficiency drops sharply. On MBBR systems, verify that media is moving freely; stationary media indicates a diffuser problem.
Pump, Plumbing, and Flow Verification
Inspect airlines for damage
As the tanks are filling, turn on your blowers and walk the tanks. Look for any broken airlines, or damaged sock. Any issues will usually present themselves as large air bubbles directly over the damaged area.
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Inspect pump seals, gaskets, and o-rings
Check pumps for signs of leaking seals. This will often be a physical drip, but a large build-up of salt under the pump housing can also be a sign. Listen to the pump and blower motors closely for bearing noise as this is usually the first sign of a failing motor.
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Verify and balance flow rates
Once the system is fully running, confirm that all flow meters are properly reading. The flowrate will be set based on various factors including current ammonia levels, amount of product in the tank, etc. The system should be balanced to maximize heat exchanger efficiency. A balanced system should have little to no water water overflowing the tank direct to the drains. Tanks with heat recovery sumps should have the water level maintained near the middle of the tank.
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Water Quality Baseline
Test water chemistry before loading any animals
Before any products go in, run full water chemistry: TAN, nitrite, nitrate, pH, alkalinity, salinity, and dissolved oxygen. Document the numbers — they're your baseline for comparing against once you start loading. If ammonia is elevated before animals arrive, you have a problem to solve before startup, not after. If you're using municipal water, dechlorinate before adding to the biofilter; chlorine kills nitrifying bacteria.
Pre-Season Test Run
Run at 20–30% load for one week before first landing
If possible, bring in 5,000–10,000 lbs of animals and run them through the full system for a week before your main season starts. This validates that everything works together under real conditions, confirms the biofilter is properly established, and surfaces integration problems that aren't visible during idle commissioning. It also gives your staff a chance to work out the off-season rust before the real pressure begins.
Build Your Facility-Specific List
This checklist covers the baseline. Every facility has its own quirks — the pump that always gives trouble in May, the section of pipe that needs watching after a cold winter. Add those items to your own checklist alongside these. The goal is simple: no surprises during season.
If your facility needs a systematic preseason review or you're commissioning new equipment, Aqua Production Systems can help. We work with live seafood holding operations throughout Atlantic Canada and beyond. Visit aquaproduction.ca or give us a call.