Chiller T&C Procedure For Air Conditioning

J KR/CKM/T & C :______________________

CAWANGAN KEJURUTERAAN MEKANIKAL
JABATAN KERJA RAYA
CHILLER TESTING AND COMMISSIONING PROCEDURE


A. TESTING AND COMMISSIONING IN PLANTROOM


1.0 General Procedures For Commissioning

The following procedure is a brief guide how to carry out the Testing & Commissioning of
chiller water system. Further necessary reference will be sought directly from the
appropriate commissioning codes.

After ensuring that all pre-commissioning and setting to work checks have been complete
satisfactorily the following steps for Testing & Commissioning shall be followed.


2.0 Preparation

a) Ensure system has been flushed, refilled and properly vented.
b) Confirm all automatic valves are manually overridden into the full flow condition.
c) Ensure pressurization unit are filled and operational.


3.0 Control System

a) All controllers and actuators shall be tested and adjusted for the modulating range
to ensure correct operation of all control systems.
b) Control sequences shall also be verified.
c) All safety controls shall be tested and if necessary under simulated conditions














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Chiller T&C Procedure For Air Conditioning

4.0 System Start-Up

Ensure that the system to be balanced is in its normal operating condition, i.e.; all normally
open valves are open and normally closed valves are close. (In case where port automatic
control valves are installed they should be set to full flow through the coil and by pass
valve should be isolated).

a) Have an authorized person start up the pump. (Main discharge valve should be
regulated to 50% to limits initial motor start current).
b) Once pump have run up to normal operation speed, check motor running current to
ensure it is within the full load capacity of the motor. Pump developed pressure should
be measured to ensure it does not exceed the system design.
c) Whilst monitoring the motor running current and system pressure open the main valve
to its fully open position or within motor running current and system pressure
tolerances.


4.1 Manual Startup Procedure

1. Selector switch on main switchboard (MSB) is set to manual
2. Selector switch for chiller at MSB is set for which chiller to run
3. Cooling tower is set by pressing the green button on MSB
4. Condenser water pump is started by pressing the green button on MSB
5. Chilled water pump is started by pressing the green button on MSB
6. Chiller is started by pressing compressor power switch on chiller control panel.
(Once the safety conditions of chiller are met e.g flow switch acitivated, oil
sump temperature is warm enough, the chiller will automatically start and
normally takes 15 minutes)






















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Chiller T&C Procedure For Air Conditioning

4.2 Start Up Flow Chart

Start Condenser Water Pump (CWP)
Start Chill Water Pump (CHWP)
Start Chiller
DONE
Start Cooling Tower Operation
Fan Coil U
Started
nit
START















































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Chiller T&C Procedure For Air Conditioning

5.0 Pump Test

a) All pumps shall be tested by taking pressure gauge readings, motor power
consumption and speed and comparing them with factory test result curves.

b) The motor starter heaters setting shall be recorded together with the voltage and
amperage on each phase, and the power factor.

c) All pumps mounting frame vibration isolators and holding bolts shall be checked
and adjusted as necessary to minimize the transmission of noise and vibrations.

5.1 Checking Procedure

1. Unit type, capacity, motor rating, model no, no. of units, and layout is inspected
in accordance to contract specification.
2. Phase rotation angle is inspected via phase rotation meter for correct pump
motor rotation prior to 1
st
start.
3. Coupling, center of pump shaft and motor are inspected using dial gauge.
4. Fan vibration and dynamic balancing are inspected during startup.
5. Abnormal noise and vibration are inspected from pump unit during 1
st
running.
6. With pump running, gradually close main discharge valve fully and record
suction and discharge pressures.
7. Open the discharge balancing valve slowly to the fully open position; record the
discharge pressure, suction pressure and total head.
8. The total the pump flow rate should be within +-10% of the design requirement.
If it is low check pressure drops cross coil, heat exchanges, strainers etc and
cross reference to design figures for anomalies. If the duty is high it will need to
be regulated on the main balancing valve.
9. All bolts and nut for fan, etc are made sure to fully secure.
10. Supply and outlet water pressure are made sure adequate.
11. Lubrication oil level is made sure in normal range.
12. Strainer condition is inspected.
13. Running ampere is made sure in accordance to manufacturer specification and
as on motor name plate.
14. Motor starting method is made sure as per contract specification.















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Chiller T&C Procedure For Air Conditioning
6.0 Piping Systems

a) All pipes, valves, fittings, etc. shall be tested to a hydrostatic pressure of 1 times
the normal working pressure of the system, but in no case less than 100 psig. for a
period of 48 hours. During this period pressure readings as well as the ambient
temperature shall be taken at intervals of 3 hours.

b) During the pressure test, all welding joints, bends, fittings and valves shall be
checked for any leaks or deformations for the entire piping system. Expanded
conditions of all pipings shall be carefully studied and any necessary changes in
hangers, anchors or guide locations shall be made.

c) All equipment not capable of withstanding the test pressure, shall be disconnected
when testing the piping with 100 psig., but shall be reconnected and tested with
actual working pressure and temperature.

d) The flow rates through all of the piping system components shall be verified and
adjusted until the proper temperature differentials are obtained at full load
operation.

e) All control valves shall also be tested for pressure drop and set for the specified
flow rates. When flow rate in the system has been properly set, the spindle and
yoke shall be clearly marked and its control handwheel removed.


6.1 Testing Procedure

1. Pipe material shall be recorded specification against tender specification.
2. Pressure testing is conducted for 24 hours (150 PSI). No pressure drop is allowed
and pressure test is conducted through zoning.
3. Pipe size installation shall be inspected as per approved drawings.
4. Inspect the bracket/hanger spacing (vertical and horizontal) as per contract
document drawing.
5. Welding and connection / fitting shall be inspected. Pipe less than 2 shall be
threaded and screw joint while pipe more than 2 shall be threaded, welded or
flanged joint.
6. Under ground pipe line bedding and trenches shall be inspected against
specification and drawing for load bearing and non load bearing requirements.
7. Corrosion protection (painting / galvanizing / cathodic protection / bitumen
wrapping) applied to pipe and bracket under and above ground shall be inspected.
8. Pipe sleeve through wall / slab shall be inspected based on specifications. Pipe
sleeve shall be anti-vibration and fire retardant.
9. All instrumentation and gauges installed shall be on approved tender and drawing
specification.
10. Valves ang other piping accessories installations shall be inspected as follows:
a. Balancing valve selection chart for valve suitability at rated flow and
pressure
b. Motorized valve regulator rating and required torque
c. Pressure gauge type rating and range for designated installation
d. Suitability and adequacy of air release valve location for effective air lock
removal
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Chiller T&C Procedure For Air Conditioning
7.0 System Balancing

a. Carry out an initial scan of all balancing valve and log result on relevant test
document. Investigate any abnormally low reading form blockage or air lock.
b. With the aid of a single line schematic and the obtained test data identify the index
valve. (Commonly furthest valve from pump).
c. Whilst monitoring the reading on index valve work back towards the pump
adjusting each valve on the respective branch in turn until reading are
proportionally balanced. (Ideally an overall reading of 10% between valves should
be obtainable).
d. Activity (c) should be carried out on all terminal valves until each individual branch
is proportionally balance. At this stage you will generally find some branches higher
than the pump % duty and some lower.
e. Connect a manometer to the index branch and take a reading. Whilst monitoring
this reading, work back towards the pump adjusting each branch valve in turn until
they are all in proportional balance with the index.
f. If are system has more than one riser the next step would be work back from the
index riser carrying out the same exercise as detailed in (d) & (e).
g. Once all terminal, branch and riser valves in balance the by pass valve on the 3
port valve arrangements can be set. These should be regulated to pose an
identical resistance through the by pass pipe as that of the coil. (Bypass valves can
be set at any stage of the balancing procedure as they will not affect the overall
balance).
h. Pressure drops across AHU coils, heat exchangers, condensers, evaporator etc
should be taken where possible and logged as necessary.
i. Valve settings should then be recorded and the valve handles locked in position.

























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Chiller T&C Procedure For Air Conditioning
8.0 COOLING TOWERS

8.1 Checking Procedure

1. Fan is checked for cracks
2. Check for noise of motor
a. check lubrication for gear
b. check and adjust belt tension
3. Check reservoir interior and strainer
4. Check sprayer for clogging by dust
5. Check paint of steel material for corrosion
6. Water treatment to control scale and corrosion due to concentration of impurities in water
as it evaporates
a. By bleeding
i. Overflowing
ii. Bleeding from return line to Cooling Tower
b. By cleaning manually algae and slime on the surface of the material
7. Water flow to cooling tower balancing valve is inspected prior to 1
st
start up.
8. Water quality and is inspected and piping network is flushed prior to 1
st
start up.
9. Phase rotation angle is inspected via phase rotation meter for correct fan motor rotation
prior to 1
st
start.
10. Belting tightness is inspected during 1
st
start.
11. Fan vibration and dynamic balancing is inspected during 1
st
start up.
12. Abnormal noise and vibration from Cooling Tower unit during 1
st
running is inspected.
13. All bolts and nuts for the fan, etc are made sure to fully secure.
14. Fan static pressure during 1
st
run is inspected against contractual specification.
15. Supply and outlet temperature for cooling tower is inspected.
16. Gearbox lubrication oil level is inspected.
17. Cooling tower filter condition is inspected
18. Emergency stop button installation is inspected.
19. Infill condition and cleanliness is inspected
20. Infill water seepage is inspected.
21. Basin cleanliness is inspected.
22. Motor starting method is inspected against contract specification.

















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Chiller T&C Procedure For Air Conditioning
9.0 Switchboard

a) All thermal overloads on starters shall be checked and adjusted for the actual load and the
settings recorded.

b) All circuit breakers overload settings shall be checked and recorded.

c) Each motor shall have its voltage and current draw recorded.


9.1 Switchboard Testing Procedure

1. As built drawing for starter board control scheme for switch gear rating, wire sizing
and professional approval as well as licensed fabricator prior to fabrication of unit is
inspected.
2. Wiring installed is inspected via Mega tester conducted by licensed wiremen
chargeman.
3. Control logic is inspected in accordance to contract specification.
4. Physical wire sizing and type to all power units and motors is inspected in
accordance to IEE regulation.
5. Current leakage protection, earth leakage protection, over loading protection,
switch gears rating, transformers rating, MCCB, MCB, contactors rating is
inspected in accordance to IEE regulation.
6. Incoming power adequacy for starter board power consumption is inspected with
other Discipline.
7. Power factor reading, installed capacitor bank is inspected if necessary.

























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Chiller T&C Procedure For Air Conditioning
B. TESTING AND COMMISSIONING IN BUILDING

1.0 AHU

AHU Room

1. Fan outlet air orientation shall be inspected for optimum fan performance.
2. Drain pipe requirement and orientation including water trap installation shall be
inspected based to contract specification
3. Plinth orientation and dimension including vibration isolation method and
requirement shall be inspected accordance to contract specification.
4. Fresh air intake louvers requirement shall be inspected for size and Volume
Control Damper (VCD) accordance to specification.
5. AHU room insulation material and requirements shall be inspected accordance to
contract specification.
6. AHU roof / ceiling installation shall be inspected for material, strength and rigidity to
avoid the danger of ceiling collapsing due to suction effect.

AHU Unit

1. Model installed is inspected
2. AHU refrigerant circuit is inspected for sign of leakage with leak detector
3. Condenser correct water inlet and pullet piping orientation is inspected as per
manufacturer requirements
4. AHU insulation is inspected as per contract and approved drawing
5. Face velocity of Water Cooled Package (WCP) unit in accordance to contract
requirements. Typically 550 fpm maximum.
6. All bolts and nut for WCP panel, fan, etc are fully secured.
7. Condenser air purging is performed prior to unit 1
st
start up.
8. Water pressure inlet and outlet of condenser is inspected as per manufacturer
recommendation and contract specification.
9. Water flow through condenser balancing valve is inspected prior to 1
st
start up
10. Water quality is inspected and piping network is flush prior to 1
st
start up
11. High Side and Low Side pressure is inspected accordance to manufacturer
specification.
12. Phase rotation angle is inspected via phase rotation meter for correct compression
rotation prior to 1
st
start up.
13. Thermostat installation, setting, devices protection are inspected during 1
st
start up.
14. Off coil temperature is monitored for first 2 days of running.












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Chiller T&C Procedure For Air Conditioning

AHU unit 1
st
test run

1. Abnormal noises and vibration are inspected from the WCP unit during 1
st
run.
2. Fan static pressure is inspected during 1
st
run against contractual specification.
3. Supply air temperature and room temperature, relative humidity and return air
temperature are inspected after system has been running in stable condition.
4. Compressor oil lubrication level is inspected.
5. Condition of filter drier is inspected.
6. Crankcase heater operation is inspected during off cycle.
7. Anti recycles timer in each compressor start is inspected.
8. Timer delay for each motor startup is inspected
9. Superheat condition of the evaporator is inspected in accordance to manufacturer
recommendation.
10. Motor starting method and running ampere is inspected against manufacturer
recommendation and contract specification.



































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Chiller T&C Procedure For Air Conditioning
2.0 Ductwork Testing Procedure

1. Sheet metal, material and thickness is inspected according to contract document and
approved working drawings
2. Insulation thermal conductivity is checked
3. Ducting dimension and insulation is inspected.
4. Ducting joint is inspected
5. Duct brackets and hanger placement is inspected
6. Vapor Barrier type and joints is inspected in accordance to specification and approved
working drawings.
7. Diffuser and air grille material requirements, size, thickness, coating and number installed
are inspected as per contract documents and approved working drawings.
8. Fire damper rating and installation is inspected as per BOMBA standard, contract
documents and approved working drawings.
9. Splitter damper installation is inspected as per contract document and approved working
drawings.
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