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Condenser Water System Flow Test

Condenser Water System

Flow test in different operating modes
Purpose:
The condenser system consists of two different sized pumps in parallel pumping from
and to a common header. This header then serves two different size chillers which
are
supplied from and discharge to a common header. The piping to and from the towers
is
common to all chillers and pumps. The tower piping itself is piped symetrically and
should
be nearly self balancing. A bypass valve is provided on level 20A to allow water to

recirculate inside the building during start-up so the chillers can come on line with
out low condensing pressure and low oil pressure problems. The system diagram
developed
for
the project depicts all of this information schematically.
Because of all of the common piping, there will be significant flow variation in the
system
depending on the pump combination selected. The fact that the two pumps that are
in
parallel are different with different pump curves complicates this a little bit. The
system will spend a significant number of hours running with only one pump.
Originally the system was to be provided flow control valves on each chiller to ensure
that the flow rates were constant regardless of operating conditions. Balance valves
were
inadvertantly installed instead. The purpose of this test is to determin if the flow
variations that occur in the system with out the flow control valves are a problem,
anda advantage,
or
non-issue. They will be a problem if:
1.

The pumps run out their curves far enough that they trip overloads

2.

The pumps run out their curves far enough to cavitate.

3.

The tube velocities in the chiller tubes are driven high enough to make
errosion a concern.

4.

The pump energy used when the pump runs out its curve exceeds the chiller
energy saved via lower condensing pressures.

The test will also provide data on the capabilities of individual pumps serving both
condensers
condensers and
and the
the condenser
condenser of
of the
the chiller
chiller they
they are
are not
not normally
normally associated
associated with.
with.
Instructions:
Initial each step if the item is completed satisfactorily or the test item associated
with
the step met the test requirements and passed. If the item is not satisfactory or
the test
step
fails, record an "F" in the appropriate box instead of your initials. Document
the
reason for failing in the comments section as a numbered note and include the note
number
next to the F on the test form. If the test step has data associated with it,
document
it on the test form in addition to your initials and the date and time.

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Condenser Water System Flow Test

Equipment Required:
1.

Digital pressure gauge or a reasonably accurate gauge on the pump.

2
An Amprobe (desirable but not manditory)
Acceptance Criteria:
See the problems listed in 1-4 above. The test is passed if none of these problems
are
noted and the chiller/pump combination uses no more energy in all of the possible
operating modes, relative to the design condition. It make take some discussion with
the
chiller manufacturer subsequent to the test to determine if tube velocities are
satisfactory and what the chiller kW per ton will be at the different flow rates.
Precations:
1.

Exercise care when changing operating modes if a chiller is running.

2.

Verify that all components between the pump discharge and the discharge
service
valve
are
rated
for the peak pressure on the pump curve with the largest impeller
size
installed prior to performing a shut off test.

3.

Avoid sudden flow changes to minimize the potential for water hammer.

4.

Exercise proper precaution while working around live wiring and terminals to
take
amp readings.

5.

Exercise proper precaution while working around the rotating parts of the
pump.

References:
1.

Pump curves for the pumps to be tested.

2.
The system diagram developed by CH2MHill and PECI
Requirement

Data

Completed

Include units

Initials, Date
and Time

Prerequisites:
1.

Gauges and valves are in place at the pump gauge

taps and on the condenser bundles. It is important
that the gauges be measuring pressure at the
same
location used by the manufacturer to develop their
test data.

2.

The system is balanced to design with both

condensers open to flow and both pumps on.

3.

The system can be operated.

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Condenser Water System Flow Test

Preparation:
1.

Obtain pump curves for the system.

2.

Obtain contact information for a Trane

representative who can discuss the test results
with regard to the chiller performance.

3.

Coordinate as necessary with the trades.

4.

Document the as found status of the system

CWP-1
CWP-2
CH-1 condenser
CH-2 condenser
Bypass valve
CT-1
CT-2
CT-3
CT-4

5.

Document the pump name plate data.

CWP-1

CWP-2

Make
Model
Serial Number
Flow
Head
Impeller Size
Motor Make
Motor Model
Motor HP
Motor Speed
Volts
Amps
Hz
Phase
Efficiency
Serial Number
Service Factor
Other
Other
Procedure:
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Condenser Water System Flow Test

1.

Verify the bypass valve on 20A is closed and that

all tower cells are open to flow.

2.

Document the CH1 balance valve position.

3.

Document the CH2 balance valve position.

4.

With both pumps running and both condensers

open
document the following. Note the engineering
units
associated with the reading; i.e. psi or ft.w.c.
CWP-1 pressure ahead of the strainer
CWP-1 suction pressure
Strainer pressure drop (the difference
between the two reading just taken)

5.

If the pressure drop through the strainer exceeds

3 psi/7 ft.w.c. suspend the test and inspect and
cleanstrainer. After the strainer is clean, proceed
the
with the following.
CWP-1 discharge pressure
CWP-1 amps (all phases)
CWP-1 volts (all phases)
CWP-2 pressure ahead of the strainer
CWP-2 suction pressure
Strainer pressure drop (the difference
between the two reading just taken)

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Condenser Water System Flow Test

6.

If the pressure drop through the strainer exceeds

3 psi/7 ft.w.c. suspend the test and inspect and
clean
the strainer. After the strainer is clean, proceed
with the following.
CWP-2 discharge pressure
CWP-2 amps (all phases)
CWP-2 volts (all phases)
CH-1 condenser entering pressure
CH-1 condenser leaving pressure
CH-2 condenser entering pressure
CH-2 condenser leaving pressure

7.

With both pumps running and both condensers

open,the bypass valve and document the following:
open
CWP-1 suction pressure
CWP-1 discharge pressure
CWP-1 amps (all phases)
CWP-2 suction pressure
CWP-2 discharge pressure
CWP-2 amps (all phases)
CH-1 condenser entering pressure
CH-1 condenser leaving pressure
CH-2 condenser entering pressure
CH-2 condenser leaving pressure
Estimated flow over CT-1 (none, some, a
lot)
Estimated flow over CT-2 (none, some, a
lot)
Estimated flow over CT-3 (none, some, a

8.

lot)
Estimated flow over CT-4 (none, some, a
lot)bypass valve
Close the

9.

Shut down CWP-1. With both condensers open

document the following.
CWP-2 suction pressure
CWP-2 discharge pressure
CWP-2 amps (all phases)
CH-1 condenser entering pressure
CH-1 condenser leaving pressure
CH-2 condenser entering pressure
CH-2 condenser leaving pressure

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Condenser Water System Flow Test

10.

Valve out the CH-1 condenser and document the

following.
CWP-2 suction pressure
CWP-2 discharge pressure
CWP-2 amps (all phases)
CH-2 condenser entering pressure
CH-2 condenser leaving pressure

11.

Open the bypass valve and document the following:

CWP-2 suction pressure
CWP-2 discharge pressure
CWP-2 amps (all phases)
CH-2 condenser entering pressure
CH-2 condenser leaving pressure
Estimated flow over CT-1 (none, some, a
lot)
Estimated flow over CT-2 (none, some, a
lot)
Estimated flow over CT-3 (none, some, a

12.
13.

lot)
Estimated flow over CT-4 (none, some, a
lot)bypass valve
Close the
Valve in the CH-1 condenser and valve out the CH2
condenser. Document the following.
CWP-2 suction pressure
CWP-2 discharge pressure
CWP-2 amps (all phases)
CH-1 condenser entering pressure
CH-1 condenser leaving pressure

14.

Shut down CWP-2 and restart CWP-1. Document

the following:
CWP-1 suction pressure
CWP-1 discharge pressure
CWP-1 amps (all phases)
CH-1 condenser entering pressure
CH-1 condenser leaving pressure

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Condenser Water System Flow Test

15.

Valve in the CH-2 condenser and document the

following.
CWP-1 suction pressure
CWP-1 discharge pressure
CWP-1 amps (all phases)
CH-1 condenser entering pressure
CH-1 condenser leaving pressure
CH-2 condenser entering pressure
CH-2 condenser leaving pressure

16.

Valve out the CH-1 condenser and document the

following.
CWP-1 suction pressure
CWP-1 discharge pressure
CWP-1 amps (all phases)
CH-2 condenser entering pressure
CH-2 condenser leaving pressure

17.

Perform a shut off test to verify the pump

impeller
size
by briefly closing the discharge valve and
and documenting the pump differential pressures.
CWP-1 suction pressure
CWP-1 discharge pressure
CWP-2 suction pressure

CWP-2 discharge pressure

Follow up and Return to Normal:
1.

Remove all test equipment.

2.

Return the system to the state it was operating in

at the start of the test or as requested by the
operating staff.

3.

Plot test results on the pump curves to determine

flow rates in all operating modes. Verify impellers
sizes based on the shut of test and document.
CWP-1 impeller size
CWP-2 impellers size

4.

Contact Trane to obtain their input regarding the

tube velocities through their condenser bundle
at the peak flows observed during the test.
Document the peak allowable velocity.
Document the peak observed velocity.

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Condenser Water System Flow Test

5.

Indicate pass if the velocities are acceptable and

fail if they are excessive in any mode.

6.

Contact Trane to obtain the full load kW for the

chillers at the following conditions:
CH-1 at design condenser flow.
CH-2 at design condenser flow.
CH-1 at the condenser flow that occurs wit
CWP-1 on and with CH-2 off and valved out.
CH-2 at the condenser flow that occurs wit
CWP-2 on and with CH-1 off and valved out.

7.

Add the chiller full load kW to the associated

condenser pump kW for each of the following
conditions. The condenser pump kW can be
established by reading the bhp for each operating
condition from the pump curve and multiplying it
by .745. This ignors the motor efficiency and
power factor but we are comparing differentials so
this will not be a significant issue.
CH-1 at design condenser flow.
CH-1 at the condenser flow that occurs wit
CWP-1 on and with CH-2 off and valved out.
CH-2 at design condenser flow.
CH-2 at the condenser flow that occurs wit
CWP-2 on and with CH-1 off and valved out.

8.

Compare the net kWs for each chiller in each of th

two operating modes. Indicate Pass if the kW at th
higher condenser flow rate is lower than the kW
at the design flow rate. Otherwise indicate fail.
CH-1 pass/fail
CH-2 pass/fail

9.

Document the maximum observed flow rate for

each pump and indicate pass if the pump is not in
the "do not select here" portion of its curve at
this flow rate, otherwise, indicate "fail".
CWP-1 maximum observed flow rate
CWP-1 Pass/Fail
CWP-2 maximum observed flow rate
CWP-2 Pass/Fail

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Condenser Water System Flow Test

10.

Inidicate "Pass" if the pumps did not trip their

overloads when they ran out their curves, otherwise
indicate "Fail".
CWP-1 Pass/Fail
CWP-2 Pass/Fail

11.

Inidicate "Pass" for each chiller if it passed all of

the checks listed above (4 total), otherwise indicat
"Fail".
CH-1 Pass/Fail
CH-2 Pass/Fail

Test Coordinator(s)
Name

Affiliation

Work phone Work e-mail

Test Team Members

Name

Affiliation

Work phone Work e-mail

Test Completion Sign Of

This test has been performed to the best of my ability per the requirements of the
procedure. Deviations or problems encountered have been noted at the end of the test
form.

Test coordinator name (print)

Signature, date and time

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Condenser Water System Flow Test

Comments and Notes

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Condenser Water System Flow Test

Comments and Notes

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