CES Commissioning Guidelines

VERIFICATION
a nd
FUNCTIONAL PERFORM ANCE TEST PLAN
for
PACKAGED AIR -COOLED CHILLER
includ ing
PRE -STARTUP INSPECTION CHECKLIST,
VERIFICATION TEST CH ECKLIST,
a nd
FUNCTIONAL PERFORM ANCE T EST
CHECKLIST

Revision No. 0: 5/95

Test Plans 6-234

CES Commissioning Guidelines

6.10.1

High-Efficiency Packaged Air-Cooled

Chiller

Commissioning Process Summary

The Commissioning Process for the high-efficiency packaged air-cooled chiller EEM
includes pre-startup inspections of the installed equipment, systems, and subsystems,
and the execution of the verification and functional performance testing of the chiller,
pumps, and chiller control system. The fundamental operational and performance
parameters to be verified through the testing include 1) drop in chilled water
temperature across the evaporator (T, F), 2) chilled water flow rate (gpm), 3)
electrical power consumption of the chiller and chilled water pump (kW), 4) chiller
efficiency (kW/ton) under full-load and part-load operation, and 5) function of the
system controls sequences.
These performance parameters will vary depending on the systems operating
conditions. Although manufacturers performance data can typically be obtained for
most chillers, the actual in situ performance of a chiller may vary considerably. This
performance, to be determined accurately, should be evaluated within the context of
the entire chiller system. Therefore, actual field monitoring of a chiller system in
accordance with an established monitoring protocol is often required.
A protocol for monitoring chiller-system performance has been provided in Section
3.6.2 of these Guidelines for use during the functional performance testing. The scope
of the protocol is limited to electric chiller systems, and their associated pumps and
heat-rejection equipment. The chiller-system monitoring protocol applicable to
commissioning consists of three distinct stages Stage one: development of a chillersystem monitoring plan for submittal to and approval by PG&E; Stage two:
implementation of procedures for actual field installation, placement and calibration of
chiller-system operation during he monitoring period; and Stage three: collection,
analysis and reporting of data and results. During a limited monitoring period, which
will generally last two to eight weeks but can last longer, the chiller system should
experience a wide range of operating conditions.
The commissioning fieldwork for this dynamic EEM is conducted in accordance with
the project-specific verification and functional performance test plan. This test plan
must include a clear description of the design specifications and information which
pertains to chiller controls sequence, manufacturer cut sheets and equipment
performance specifications, installation instructions and O&M manuals in addition to
the pre-startup inspection checklist, verification test checklist and the functional
performance test checklist. This information will form the basis of the commissioning
acceptance criteria and is necessary to evaluating the results of the inspections and
tests. The final commissioning test plan must incorporate all the details required to
describe the particular application and the operation of the high-efficiency packaged
air-cooled chiller system being commissioned.
In addition, a successful commissioning process will require coordination with all
commissioning team members. The responsibilities of the team members are identified
by the shaded boxes in the columns under each members title in the attached Team
Revision No. 0: 5/95

Test Plans 6-235

CES Commissioning Guidelines

Members Responsibilities chart as a means of facilitating this coordination. The
attached EEM-specific Commissioning Process Flow Chart provides an overview of the
commissioning process for this energy-efficiency measure.
The pre-startup inspection of subsystems verifies, through visual examination, simple
measurements and reference to contractors reports, that the components are installed in
accordance with manufacturers specifications, meet design criteria and are ready for
system start-up. The pre-startup checklist addresses verification of the physical
installation, electrical system, system controls, test and balance for pumps, collection of
equipment nameplate data and documentation. In addition, related pre-startup
inspection checklists, non-compliance and corrections of components that do not meet
the acceptance criteria and inspection checklists are addressed. The checklists provided
are intended to serve as a guideline in the preparation of the project-specific pre-startup
inspection checklists. The project-specific pre-startup inspection checklists must be
finalized and approved by the CES Project Manager prior to performing any
inspections.
Following the completion of the pre-startup inspection, the verification checks and
tests can commence. They should follow the order presented in the verification test
checklist provided in this section, although the project-specific character of the testing
must be considered. The checklist provided is not intended to replace the contractors
normal and accepted procedures for installing and pre-testing equipment or relieve the
contractor of the standard check-out and start-up responsibilities. The verification test
checklists should be refined, as required, with the information gathered during the prestartup inspections. This testing is intended to verify that all components, equipment,
systems, and interfaces between systems operate in accordance with contract
documents. The chiller, which includes the chiller soft start and restart sequences,
chilled water pumping system and chiller system controls are all tested as part of this
test procedure.
Following the completion of the verification tests, the functional performance testing
can commence. This testing should follow the order presented in the functional
performance test checklist provided in this section, although the project-specific
character of the testing must be considered. The functional performance test checklist
should be refined, as required, with the information gathered during the pre-startup
inspections and verification tests. The functional performance testing is intended to
measure the energy-efficient performance of the packaged air-cooled chiller as defined
in the final design-intent document.
Prior to the verification and functional performance testing, the Prime Contractor may
need to coordinate with the building operator to modify the system control setpoints to
facilitate the operation of connected equipment for the duration of the testing. Once
stable system operation has been established, the Prime Contractor can proceed to gather
the required data. Any equipment found not to comply with the acceptance criteria must
be repaired or corrected and then retested until satisfactory results are obtained.
Following the on-site testing, the test results must be prepared, documentation compiled
and the verification and functional performance test certified in accordance with these
Guidelines. The testing procedures and results of all tests must be clearly documented in
the final commissioning report.
Revision No. 0: 5/95

Test Plans 6-236

CES Commissioning Guidelines

Owner's O&M Staff

Controls Subcontractor

Balancing Subcontractor

Electrical Subcontractor

Mechanical Subcontractor

Prime Contractor

Commissioning Team Members

Quality Assurance Engineer

Action Item

Team Members Responsibilities

CES Project Manager

Pre-Start up Inspections,
Verification Checks and Tests
and Functional Performance Testing
for Packaged Air-Cooled Chiller System EEM

Verification Activities
Prepare Inspection Checklists
Approve Inspection Checklists
Coordinate with Team Members
Pre-Start up Inspection
Conduct Pre-Start up Inspections
On-site for Inspection
Louvers, Controllers, Sensors, Connected Equipment & Wiring
Luminaires, Sensors, Controls, Connected Equipment & Wiring

Electrical Panels, Motors, Power Packs, etc.

Power Available to Components
System Controls
Equipment Nameplate Data
Documentation & Submittals
Obtain Vendor Cut sheets and Performance Specs
Obtain Manufacturer's Installation Instructions
Obtain Manufacturer's O&M Manuals
Prepare Related Checklists
Non-Compliance & Corrections
Determine Non-compliance components
Corrections and Repairs
Pre-Start up Inspection Follow-up
Record Inspection Results
Certify Pre-Startup Checklists
Approve Pre-Startup Checklists
Verification Testing
Prepare Verification Test Checklists
Initiate Start-up of System Components
Verify Test and Balance Report
Certify Readiness for Conducting Verification Testing
Authorization to Proceed with Verification Testing
Conduct Verification Testing
Functional Performance Testing
Prepare Functional Performance Checklists
Authorization to Proceed with FPT
Conduct Functional Performance Testing
On-Site for Verification & Functional Performance Testing
Documentation and Non-Compliance
Record Results of Testing
Determine Non-Compliance Components
Corrections and Repairs
Verify Results of Testing
Approve Results
Prepare Final Commissioning Report
Prepare System Manual

Revision No. 0: 5/95

Test Plans 6-237

PACKAGED AIR-COOLED CHILLER EEM

COMMISSIONING PROCESS FLOW CHART

BEGIN
COMMISSIONING
FIELD WORK

COORDINATION WITH
COMMISSIONING
TEAM MEMBERS BY
PRIME CONTRACTOR

VERIFY TOOLS
REQUIRED
VERIFY DESIGN
INFORMATION

CERTIFICATION OF
PRE-START UP CHECKLISTS
BY PRIME CONTRACTOR AND
QUALITY ASSURANCE ENGINEER

PREPARE EQUIPMENT
SPECIFIC VERIFICATION
INSPECTION CHECKLISTS

BEGIN
FUNCTIONAL
PERFORMANCE
TESTING

PRE-INSPECTION
ACTIVITIES

CALCULATE CHILLER
EFFICIENCY AND COMPARE
PERFORMANCE TO
RATED EFFICIENCY

BEGIN
SYSTEM
START-UP
NO

COORDINATION WITH
COMMISSIONING
TEAM MEMBERS

APPROVAL OF
PRE-START UP
CHECKLISTS
BY PG&E
REVIEW MATERIAL
DOCUMENTATION

CHECK & REPORT

UNUSUAL VIBRATION
ESTABLISH STABLE
PART-LOAD
OPERATION AND
COLLECT DATA

COMPLETE START-UP

ESTABLISH STABLE
FULL-LOAD
OPERATION AND
COLLECT DATA

YES
PHYSICAL INSPECTIONS OF
INSTALLATIONS
CONDUCT VERIFICATION
INSPECTIONS OF MATERIALS
AND COMPONENTS IN
COMPLIANCE WITH
CONSTRUCTION DOCUMENTS

TEST, ADJUST & BALANCE

NON-COMPLIANCE
AND CORRECTIONS

CORRECTION
AND
REPAIRS

DOCUMENTATION
EQUIPMENT
NAMEPLATE DATA

PREPARE VERIFICATION
AND FUNCTIONAL
PERFORMANCE
TEST PLANS

TEST & BALANCE

FOR PUMPS
CONTROLS

ACTIVATE SYSTEM
CONTROLS FOR CHILLER
START SEQUENCE

NONCOMPLIANCE
REPORT

REVISE

FUNCTIONAL PERFORMANCE
TESTING

PROVIDE SIMULATED
COOLING LOAD
IN BUILDING

ELECTRICAL
PHYSICAL
INSTALLATION

NO

PRE-START UP INSPECTION
AND VERIFICATION OF
EQUIPMENT AND SUBSYSTEMS

DOCUMENTATION
OF PERFORMANCE

RECEIVE
AUTHORIZATION
FROM PG&E
TO PROCEED

VERIFICATION OF
INSTALLATIONS IN
ACCORDANCE WITH CONTRACT
REQUIREMENTS BY
QUALITY ASSURANCE ENGINEER

BEGIN
VERIFICATION
TESTING

REPAIRS

SUBSYSTEMS
START-UP

FAIL

NON-COMPLIANCE
REPORT

EVALUATION
& DIRECTED
MODIFICATIONS

PASS
CERTIFICATION OF VERIFICATION
AND FUNCTIONAL PERFORMANCE
TEST BY PRIME CONTRACTOR AND
QUALITY ASSURANCE ENGINEER

COORDINATION WITH
COMMISSIONING
TEAM MEMBERS

FAIL

CORRECTION
AND
REPAIRS
CONDUCT VERIFICATION OF
OPERATION OF DYNAMIC SYSTEMS
IN ACCORDANCE WITH
CONTRACT REQUIREMENTS

PASS

COORDINATE
TEST & BALANCE
SUBCONTRACTOR
ACTIVITIES

VERIFY
COMPLIANCE WITH
DESIGN INTENT AND
MANUFACTURERS
SPECIFICATIONS

FAIL

YES

PG&E
APPROVAL OF
PERFORMANCE

PASS

COMPLETE AS-BUILT
DRAWINGS, SYSTEM
MANUAL, AND CORRECTED
O & M MANUALS

DOCUMENTATION OF OPERATION
MODIFICATIONS
NON-COMPLIANCE

INTEGRATE
FACILITY
AUTOMATION
SYSTEM

COMPLETE
PRE-START UP
INSPECTION FOR
FULL SYSTEM
START-UP

PREPARE FINAL
COMMISSIONING REPORT

FAIL

VERIFICATION OF
OPERATION OF DYNAMIC
SYSTEMS IN ACCORDANCE
WITH CONTRACT
REQUIREMENTS
NON-COMPLIANCE
ISSUES

NO

FINAL
ACCEPTANCE
OF FIELD
VERIFICATION
INSPECTIONS AND
DYNAMIC TESTING
BY PG&E

YES

END

PASS

Revision No. 0: 5/95

Test Plans 6-238

VERIFICATION AND FUNCTIONAL PERFORMANCE

TEST PLAN
FOR HIGH-EFFICIENCY PACKAGED
AIR-COOLED CHILLER
PROJECT SPECIFIC INFORMATION
Project Name:
Building Occupancy Type:
Prime Contractor:

Project Number:
Gross Floor Area:

Required Operating Permits Obtained Prior to Commissioning:

Yes

No

INSTALLATION ACCEPTANCE CRITERIA

EEM Description:
Required Specification:
Construction Installation Drawing (Sheet #, Detail #):
Manufacturer's Installation Requirement:
Special Installation Considerations:
(per Contract Documents)
PERFORMANCE ACCEPTANCE CRITERIA
Statement of Design Intent for EEM:
(Definition of Performance Acceptance Criteria)
System Description:
Design Parameters (applicable to acceptance of performance):
Global priorities established by design intent, which affect performance acceptance criteria
(Refer to Guideline Section 2.2.2.3):
Describe the expected results of each test procedure:
Description of Design Day Conditions:

Recommended Weather Conditions for Testing:

Revision No. 0: 5/95

Test Plans 6-239

VERIFICATION AND FUNCTIONAL PERFORMANCE

TEST PLAN
FOR HIGH-EFFICIENCY PACKAGED
AIR-COOLED CHILLER
Building Cooling System Description:
Cooling coils capacity (tons):
Total design air flow (cfm):
Additional information:

Description of System Controls and Sequence of Operation:

Controls Operating Setpoints:

Is Energy Management System (EMS) used?

Yes

Are control valves connected to EMS?

If yes, identify valves:

Yes

No
No

EQUIPMENT DESCRIPTION
Chiller:
Manufacturer:
Model Number:
Type:
Options Code:
Rated Full-Load Capacity (tons):
Rated Full-Load Efficiency (kW/ton):
Motor Voltage/Phase/Hz:
Motor Horsepower:
Number of Chillers:
Symbol/Designation from Drawings:
Location:
Additional Information:

Revision No. 0: 5/95

Test Plans 6-240

VERIFICATION AND FUNCTIONAL PERFORMANCE

TEST PLAN
FOR HIGH-EFFICIENCY PACKAGED
AIR-COOLED CHILLER
Chilled Water Pump:
Manufacturer:
Model Number:
Design Parameters:
Motor Voltage/Phase/Hz:
Motor Horsepower:
Number of Pumps:
Symbol/Designation from Drawings:
Pump Arrangement:
Parallel
Additional Information:

gpm @

Series

TDH

Other

Schedule Requirements:

Start-up testing
Pre-startup inspections
Verification testing
Functional performance testing
Seasonal testing for design day conditions

Required Tools and Instruments:

Multimeter for electrical measurements

Ammeter
Power measurement transducer (PMT)
Power factor meter
Calibrated thermometer
Pressure gauge for water
Miscellaneous hand tools

Description of Calibration Procedures:

For all instruments that require calibration, provide the following information:

Instrument description/identification
Manufacturers calibration requirements
Copy of most recent calibration certificates
Date of most recent calibration
Description of calibration procedure

Revision No. 0: 5/95

Test Plans 6-241

VERIFICATION AND FUNCTIONAL PERFORMANCE

TEST PLAN
FOR HIGH-EFFICIENCY PACKAGED
AIR-COOLED CHILLER
Field-Initiated Modifications to Approved Testing:

Describe the conditions that invalidate the approved testing procedure.

Identify the specific steps or tests in the approved procedures that are invalidated.
Describe the modified steps to the procedures.
Explain how these new steps address the unanticipated on-site conditions without altering
the intent or the outcome of the testing.
For responsible subcontractors, obtain the written agreement of the Prime Contractor.
Obtain the written agreement of the Quality Assurance Engineer.
Proceed with the modified testing procedure.

Revision No. 0: 5/95

Test Plans 6-242

PRE-COMMISSIONING INSPECTION CHECKLIST

PACKAGED AIR-COOLED CHILLER

CHECKLIST ITEM

YES

NO

1.0 Physical Installation of Chiller, Chilled Water Pump and Piping

1.1 Chiller installed in accordance with manufacturers specifications
1.2 Chiller refrigerant charge correct. Number of pounds:
1.3 Refrigerant purging and charging connections installed
and functional
1.4 Chiller oil sump accessories and connections installed
and functional
1.5 Chilled water pump grouted in place
1.6 Manufacturers recommended clearances provided for
service access and air circulation around equipment
1.7 Pump vibration isolation devices functional
1.8 Pump alignment verified
1.9 Piping installed in accordance with design drawings
1.10 Piping flushed clean and leak tested
1.11 Pumps not leaking
1.12 Lubrication complete
1.13 Piping properly labeled
1.14 Valves properly labeled
1.15 Temperature gauges installed
1.16 Pressure gauges installed across chilled water circulation pump
1.17 Air circulation fan(s) for air-cooled condenser installed
and functional
1.18 Airways and screens for air-cooled condenser installed and cleaned
1.19 Condenser heat exchanger installed correctly in relation to airflow
1.20 External surfaces of condenser heat exchanger clean
1.21 Comments and Observations

2.0 Electrical
2.1 Disconnect panels installed and labeled
2.2 Fuse ratings correct for connected equipment
2.3 Switch gear installed and functional
2.4 Power available to chiller starter
2.5 Power available to chiller control panel
2.6 Power available to chilled water disconnect
2.7 Chiller motor rotation correct

Revision No. 0: 5/95

Test Plans 6-243

PRE-COMMISSIONING INSPECTION CHECKLIST

PACKAGED AIR-COOLED CHILLER

2.8
2.9
2.10
2.11
2.12
2.13

CHECKLIST ITEM
Chilled water pump motor rotation correct
Motor protection devices installed and functional
Control system contactors functional
Control system interlocks functional
Shielded wiring used on electronic controls
Comments and observations:

YES

NO

3.0 Controls
3.1 Factory start-up and check-out complete
3.2 Chiller safety/protection devices tested
3.3 Chilled water flow switch installed
3.4 Chilled water flow switch tested
3.5 Chilled water pump interlock installed
3.6 Chilled water pump interlock tested
3.7 Control circuit logic for motors starting verified
3.8 Outside air sensor calibrated
3.9 Comments and observations:

4.0 Test and Balance

4.1 Water balance complete with design maximum flow verified
4.2 Test and balance report submitted
4.3 Chemical water treatment complete
4.4 Comments and observations

5.0
5.1

Equipment Nameplate Data

Chiller
Manufacturer:
Model Number:
Serial Number:
Motor Voltage/Phase/Hz:
Motor Horsepower:
Location:
Additional Information:

Revision No. 0: 5/95

Test Plans 6-244

PRE-COMMISSIONING INSPECTION CHECKLIST

PACKAGED AIR-COOLED CHILLER

5.2

Water Temperature Controller:

Manufacturer:
Model Number:
Serial Number:
Electrical Data:
Other:

5.3

Chilled Water Pumps:

Manufacturer:
Model Number:
Serial Number:
Motor Voltage/Phase/Hz:
Motor Horsepower:
Number of Pumps:
Location:
Pump Arrangement:
Additional Information:

6.0 Documentation
6.1 Vendor cut sheets, chiller part-load curves and pump curves
6.2 Manufacturers product design data
6.3 Operation and maintenance manuals
6.4

7.0

YES

NO

Comments and Observations:

Non-Compliance and Corrections

The following items did not comply with manufacturers or contract specifications and require
correction.

7.1
7.2
7.3
7.4
7.5

Revision No. 0: 5/95

Test Plans 6-245

PRE-COMMISSIONING INSPECTION CHECKLIST

PACKAGED AIR-COOLED CHILLER

8.0

Certification
We the undersigned participated in this pre-startup inspection, acknowledge that the pre-startup
process for the packaged air-cooled chiller EEM has been completed and that all corrections have
been made.
Date:

8.1

Name:
Company name:
Role in inspection:
Signature:

8.2

Name:
Company name:
Role in inspection:
Signature:

8.3

Name:
Company name:
Role in inspection:
Signature:

8.4

Name:
Company name:
Role in inspection:
Signature:

Revision No. 0: 5/95

Test Plans 6-246

VERIFICATION TEST CHECKLIST

PACKAGED AIR-COOLED CHILLER
Verification Tests: The Prime Contractor shall demonstrate operation of the chilled water
system in accordance with manufacturers and contract specifications. The building operators
assistance will be required to change setpoints for the duration of the testing and restore them to
their original settings after the tests have been completed. The tests will be conducted while the
occupant and equipment loads are minimal.
The following checklist shall serve as a general guideline for verification testing, although the
project-specific character of the tests required must be considered. This checklist should be
refined by the Prime Contractor to address project-specific details and the information gathered
during the pre-startup inspections.

Revision No. 0: 5/95

Test Plans 6-247

VERIFICATION TEST CHECKLIST

PACKAGED AIR-COOLED CHILLER

1.0 Provide simulated cooling load in building:

1.1 Modify control system setpoints, as required, to facilitate chillers response to simulated building
load.
1.2 Switch system to warm-up mode in order to open all supply ducts, where VAV boxes may be
present, and set fan powered box coils to full heat.
1.3 Start the building air handling units in order to provide a cooling load for the chiller(s).
1.4 Operate boilers or use outside air to provide cooling load in building depending upon the outside
air temperature.
2.0 Activate system controls for chiller start sequence as follows:
2.1 Start chilled water pump and establish chilled water flow. Modulate the chilled water control
valve to prevent a slug of hot water from entering the chiller. Verify operation of chillers
chilled water flow switch.
Result:
2.2 Determine that chilled water temperature is above setpoint.
Record water temperature:
2.3 Verify that control system energizes chiller start sequence.
Result:
2.4

Verify that chiller senses chilled water temperature above setpoint and control system activates
chiller start.
Result:

2.5

Verify functioning of soft start sequence.

Result:

2.6

Shut off air handling equipment to remove load on chilled water system. Monitor chilled water
temperature to determine when temperature drops below setpoint. Verify that chiller shut-down
sequence is initiated and accomplished after load is removed.
Result:

2.7

Restart air handling equipment one minute after chiller shut-down. Monitor chilled water
temperature to determine when temperature rises above setpoint. Verify operation of chiller
restart sequence.
Result:

3.0 Establish stable, full-load operation of the chiller, then measure and record the following data:
3.1 Chilled water flow (gpm):
Record chiller inlet/outlet pressure readings and compare to chiller design conditions, Test and
Balance Report and chiller manufacturers performance data.
DESIGN
T&B
F.P.T.
ACTUAL
Chiller Inlet Pressure (psig)
Chiller Outlet Pressure (psig)
3.2 Record chilled water supply and return temperature readings and compare to readout on chiller
control panel.
DISPLAYED
ACTUAL
Chilled Water Supply Temp (F)
Chilled Water Return Temp (F)

Revision No. 0: 5/95

Test Plans 6-248

VERIFICATION TEST CHECKLIST

PACKAGED AIR-COOLED CHILLER

3.3

Record for chiller: amperage each phase, voltage phase to phase, voltage phase to ground, and
power factor.
PHASE 1
PHASE 2
PHASE 3
Amperage
Voltage
Voltage
Voltage to Ground
Power Factor
KW (use PMT)

3.4

Record for chilled water pump: amperage each phase, voltage phase to phase, voltage phase to
ground, and power factor.
PHASE 1
PHASE 2
PHASE 3
Amperage
Voltage
Voltage
Voltage to Ground
Power Factor
KW (use PMT)

3.5

Record the following information:

Ambient outside air DB temperature (F):
Entering chilled water temperature (F):
Leaving chilled water temperature (F):

4.0

Establish stable, part-load operation at each of the following percentages of full-load operation
(50%, 60%, 70%, 75%, 80%, 85%, 90%, and 95%), then measure and record the same data as
requested in Section 3.0 above for all expected entering-condition air temperatures.

5.0

Check and report unusual vibration, noise, etc.

6.0

Use the following equation to calculate kW with the electrical data collected in Section 3 above:
VA = 3 VI

where V =
I =

voltage phase to phase

amperage per phase

PF = Sin
KW = VA PF

where =

phase angle between V & I

Revision No. 0: 5/95

Test Plans 6-249

VERIFICATION TEST CHECKLIST

PACKAGED AIR-COOLED CHILLER

7.0

Calculate chiller efficiency (kW/ton) at full-load operation and the part-load operation levels tested
above and plot the results, as follows:

7.1

Sort data into separate sets according to supply chilled water temperature ranges (for example,
one set of data in the range of 50 to 52F, a second set for 53 to 55F, etc.). Select the smallest
range that includes an adequate number of data points and proceed with plot preparation.

7.2

Plot chiller kW versus chiller tons for each sorted data set. Where outside air temperatures
differed by more than 5F (for example, 60 to 64F, 75 to 79F, etc.) during the test, identify
the plotted points common to each range.

7.3

Curve fit each group (designated by outside temperature range) of plotted points.

8.0

Record Results

8.1

Prime Contractor shall record and submit results of the verification testing to CES Project
Manager.

8.2

If specified equipment is not installed or operational, Prime Contractor shall report remedial
action required and reschedule verification tests.

9.0

Non-Compliance and Corrections

The following items did not comply with manufacturers or contract specifications and require
correction:

9.1
9.2
9.3
9.4

Revision No. 0: 5/95

Test Plans 6-250

FUNCTIONAL PERFORMANCE TEST CHECKLIST

PACKAGED AIR-COOLED CHILLER
Functional Performance Tests: The Prime Contractor shall demonstrate performance of
chilled water system in accordance with the final design-intent document and
manufacturers and contract specifications. The building operators assistance will be
required to change setpoints for the duration of the testing and restore them to their
original settings after the tests have been competed. The tests will be conducted while
the occupant and equipment loads are minimal.
The following checklist shall serve as a general guideline for the functional performance testing, although the project-specific character of the tests required must be
considered. This checklist should be refined by the Prime Contractor to address
project-specific details and information gathered during the pre-startup inspections and
verification testing.

Revision No. 0: 5/95

Test Plans 6-251

FUNCTIONAL PERFORMANCE TEST CHECKLIST

PACKAGED AIR-COOLED CHILLER

1.0 Provide simulated cooling load in building:

1.1 Modify control system setpoints, as required, to facilitate chillers response to simulated building
load.
1.2 Switch system to warm-up mode in order to open all supply ducts, where VAV boxes may be
present, and set fan powered box coils to full heat.
1.3 Start the building air handling units in order to provide a cooling load for the chiller(s).
1.4 Operate boilers or use outside air to provide cooling load in building depending upon the outside
air temperature and the design conditions to be simulated.
2.0

Establish stable operation of the chiller in accordance with the final design-intent document, then
measure and record the following data:

2.1

Chilled water flow (gpm):

Record chiller inlet/outlet pressure readings and compare to chiller design conditions, Test and
Balance Report and chiller manufacturers performance data.
DESIGN
T&B
F.P.T.
ACTUAL
Chiller Inlet Pressure (psig)
Chiller Outlet Pressure (psig)

2.2

Record chilled water supply and return temperature readings and compare to readout on chiller
control panel.
DISPLAYED
ACTUAL
Chilled Water Supply Temp (F)
Chilled Water Return Temp (F)

2.3

Record for chiller: amperage each phase, voltage phase to phase, voltage phase to ground, and
power factor.
PHASE 1
PHASE 2
PHASE 3
Amperage
Voltage
Voltage
Voltage to Ground
Power Factor
KW (use PMT)

2.4

Record for chilled water pump: amperage each phase, voltage phase to phase, voltage phase to
ground, and power factor.
PHASE 1
PHASE 2
PHASE 3
Amperage
Voltage
Voltage
Voltage to Ground
Power Factor
KW (use PMT)

2.5

Record the following information:

Ambient outside air DB temperature (F):
Entering chilled water temperature (F):
Leaving chilled water temperature (F):

Revision No. 0: 5/95

Test Plans 6-252

FUNCTIONAL PERFORMANCE TEST CHECKLIST

PACKAGED AIR-COOLED CHILLER

3.0

4.0

Use the following equation to calculate kW with the electrical data collected in Section 2 above:
VA = 3 VI

where V =
I =

voltage phase to phase

amperage per phase

PF = Sin
KW = VA PF

where =

phase angle between V & I

Calculate chiller efficiency (kW/ton) at the specified load-levels tested above and plot the results,
as follows:

4.1

Sort data into separate sets according to supply chilled water temperature ranges (for example,
one set of data in the range of 50 to 52F, a second set for 53 to 55F, etc.). Select the smallest
range that includes an adequate number of data points and proceed with plot preparation.

4.2

Plot chiller kW versus chiller tons for each sorted data set. Where outside air temperatures
differed by more than 5F (for example, 60 to 64F, 75 to 79F, etc.) during the test, identify
the plotted points common to each range.

4.3

Curve fit each group (designated by outside temperature range) of plotted points.

5.0

Compare chiller calculated performance and plotted curves to manufacturers rated efficiency,
performance specifications and part-load curves:

6.0

Record Results

6.1

Prime Contractor shall record and submit results of the functional performance testing to CES
Project Manager.

6.2

If specified equipment performance is not verified, Prime Contractor shall report remedial action
required and reschedule functional performance tests.

7.0

Non-Compliance and Corrections

The following items did not comply with the final design-intent document or manufacturers or
contract specifications and require correction:

7.1
7.2
7.3
7.4
8.0 Documentation required in complete Final Commissioning Report
9.1 Certified pre-startup checklists
8.2 Certified verification and functional performance test checklists
8.3 Test and Balance Report
8.4 Vendor cut sheets and pump curves
8.5 Manufacturers product design data
8.6 Operation and maintenance manuals
8.7 Manufacturers installation specifications
8.8 Final as-built drawings
Revision No. 0: 5/95

Test Plans 6-253

FUNCTIONAL PERFORMANCE TEST CHECKLIST

PACKAGED AIR-COOLED CHILLER

9.0

Certification
We the undersigned witnessed the verification and functional performance tests and certify that the
testing procedures for the packaged air-cooled chiller EEM identified above have been completed,
that the equipment tested has met the established operational and performance requirements and
that all corrections required due to non-compliance with the contract documents, manufacturers
specifications and final design-intent document have been made.
Date:

9.1

Name:
Company name:
Role in inspection:
Signature:

9.2

Name:
Company name:
Role in inspection:
Signature:

9.3

Name:
Company name:
Role in inspection:
Signature:

9.4

Name:
Company name:
Role in inspection:
Signature:

Revision No. 0: 5/95

Test Plans 6-254