FUNCTIONAL TEST CHECKLIST
CHILLER (CHLR) - ______Thru _____
Specification Section 15____
Project:______Project No:______
Includes equipment/systems:
____ CHWP _____ thru _____
____ Chiller Loop (chilled water system)
____ Cooling Tower Cells ____ thru ____
____ Condenser Water System (with CWP - ____ thru ____)
____ Primary/Secondary Decoupler for Chiller Loop and Transport Loop (primary system)
Associated Equipment:
____ AHU - _____ thru ______
____ PCHWP ______thru ______
____ B-T Station ______
[______]
Related Tests: ______
1.Participants
Name
/ Firm / ParticipationParty filling out this form & witnessing ______Date of test ______
Approvals. This filled-out checklist has been reviewed. Its completion is approved. Exceptions are noted below or attached.
______
General Contractor [Construction Manager]Date
______
Commissioning Authority/AgentDateOwner’s RepresentativeDate
- Prerequisite Checklist
a)The prefunctional checklist and start-up report for the chiller(s) are complete and approved:
Yes / No
b)The prefunctional checklist for the associated chilled water pump is complete and approved:
Yes / No
c)The prefunctional checklist(s) for the associated cooling tower and condenser water system are complete and approved: Yes / No
d)The prefunctional checklist for the associated chilled water system, including pumps, and AHU(s) are complete and approved: Yes / No
e)The prefunctional checklist for the associated Bridge-Tender station is complete and approved: N/A / Yes / No
f)Testing, Adjusting and Balancing (TAB) completed and approved for the hydronic and air systems connected: Yes / No
g)TAB report provided:Yes / No
h)The functional checklist(s) for the associated cooling tower are complete and approved:
Yes / No
i)All A/E punchlist items for this and related equipment are corrected:Yes / No
j)Sequence of operation is attached:Yes / No
k)Design setpoint information included on forms:Yes / No
l)Controls:
i)DDC loops operational, temperature/pressure setpoints met without hunting:Yes / No
ii)Master transmission diagram is updated on device graph:Yes / No
iii)Graphic programming is complete and operational:Yes / No
iv)System communicates with mainframe:Yes / No
v)Local reading of setpoints agree with remote readings:Yes / No
- Set Points/Status
a)Bridge-Tender/AHU Zones setpoints are recorded on Table 1:Yes / No
b)Chilled water setpoints per chiller are recorded on Table 2:Yes / No
c)Equipment/component status are recorded on Table 3:Yes / No
d)Equipment status (on/off) are per Tables 4, 4A, 5, 5A 6, and 6A:Yes / No
e)Chiller, cooling tower and pump log sheets are completed:Yes / No
- Test Procedure
Perform the Test Procedure below based on the attached Test Sequence Tables (4, 4A, 5, 5A, 6 and 6A). For conditions where load may not be sufficient, artificially increase load by increasing demand (through decrease in Bridge Tender supply water setpoints and/or AHU supply air setpoints or other means). Attach false loading method used.
a)Test Phase 1 (Milestone 1):
i)PreTest:
1)Chiller (ECH) -1 and chilled water pump (CHWP) -1 in Run Mode, as reported by Chiller Control Panel (CCP) – 1 and differential pressure switch (DP- __).
2)ECH-2 and CHWP-2 in Run Mode, as reported by CCP-2 and differential pressure switch (DP- __).
3)ECH-3 and CHWP-3 in Run Mode, as reported by CCP-3 and differential pressure switch (DP- __).
4)ECH-4 in Standby Mode. Evaporator flow control valve/nose valve (V-__) shall have __ (15) psi supplied to the positioner, causing the valve to close. CHWP-4 shall be off. CCP-4 senses that CHWP-4 is off through DP-__ and flow meter (FM-__).
5)ECH-5 in Standby Mode. Evaporator flow control valve/nose valve (V-__) shall have __ (15) psi supplied to the positioner, causing the valve to close. CHWP-5 shall be off. CCP-5 senses that CHWP-5 is off through DP-__ and FM-__.
6)Condenser water pumps (CWP) 1, 2 and 3 are in run mode, existing CWP-4 is in stand-by mode and off, as reported to the chiller plant control panel via DP- __ thru ___. Cooling tower fans (CTF) 1, 2 and 3 are in run mode, as reported through the VFDs to the chiller plant control panel.
7)CCPE Primary chilled water pump (PCHWP) – 1, PCHWP – 2 and PCHWP – 3 are in run mode, as reported through the chiller plant control panel via DP- __ thru __. CCPE PCHWP – 4 in stand-by mode and off, as reported through the chiller plant control panel via DP - __ thru __.
8)CCPW chillers, chiller pumps, cooling towers and condenser water pumps are on-line with four in run mode and one in stand-by mode.
9)CCPW PCHWP- 2 and PCHWP-3 are in run mode. PCHWP-1 and PCHWP-0 are in stand-by mode.
10)Temporary chillers are on-line, with four 400 ton chillers in run mode and two in stand-by mode.
ii)Test Number 1 (transfer of load from temporary chillers):PASS / FAIL
1)ECH-1 and CHWP-1 in Run Mode, as reported by CCP-1 and differential pressure switch (DP- __).
2)ECH-2 and CHWP-2 in Run Mode, as reported by CCP-2 and differential pressure switch (DP- __).
3)ECH-3 and CHWP-3 in Run Mode, as reported by CCP-3 and differential pressure switch (DP- __).
4)ECH-4 Run Mode (started through the existing chiller plant control panel – ExCPCP):
(a)In automatic mode, ExCPCP shall start CHWP-4. Pump operation shall be verified (via DP-__) prior to sending run signal to CCP-4 panel.
(b)Energize and open control valve V-__, by supplying __ (3) psi to the positioner.
(c)When the flow rate through the evaporator rises above the minimum as sensed by DP-__ and flow meter, FM-__, and confirmed through the evaporator safety logic, send start signal to the manufacturer chiller panel, enabling chiller internal start sequence.
(d)Control the flow through the evaporator at _____ GPM, as sensed by DP-__ and flow meter, FM-__, by modulating control valve V-__. Evaporator flow rate may be reset through CCP-4 panel but shall be maintained between low flow limit of _____ GPM (-25%) and high flow limit ____ GPM (+ 25%).
5)ECH-5 and CHWP-5 in standby mode and off, as reported through CCP-5 and DP-__.
6)CWP-1, 2 and 3 in run mode. CTF-1, 2 and 3 in run mode. Send start signal to CWP-4, through ExCPCP. CTF-1, 2 and 3 shall ramp up. Verify pump and fan operation via VFDs and ExCPCP via DP - __ thru __. If CWP-4 does not start or fan(s) do not ramp, verify alarm signal to panel.
7)CCPE PCHWP-1, 2 and 3 are in run mode, as reported through the ExCPCP via DP- __ thru __. Send start signal to CCPE PCHWP – 4. Verify pump operation, as reported through the ExCPCP via DP - __ thru __.
8)CCPW chillers, chiller pumps, cooling towers and condenser water pumps are on-line with four in run mode and one in stand-by mode.
9)CCPW PCHWP- 2 and PCHWP-3 are in run mode. PCHWP-1 and PCHWP-0 are in stand-by mode.
10)Temporary chillers are all placed in stand-by mode (6 – 400 ton chillers).
iii)Test Number 2 (simulating chiller malfunction after transfer from temporary chillers): PASS / FAIL
1)ECH-1 and CHWP-1 in Run Mode, as reported by CCP-1 and DP-__.
2)ECH-2 and CHWP-2 in Run Mode, as reported by CCP-2 and DP-__.
3)ECH-3 Stop Mode (stopped through the ExCPCPC):
(a)Send stop signal to CCP-3 to stop ECH-3 and to CHWP-3
(b)When temperature drop across evaporator (measured by PCHWR T-__ or ECH-3 T-__ and ECH-3 T-__ differential) falls to 2 degrees F, close control valve V-__.
4)ECH-4 and CHWP-4 in Run Mode, as reported by CCP-4 and DP-__.
5)ECH-5 in Run Mode (started through the ExCPCP):
(a)In automatic mode, ExCPCP shall start CHWP-5. Pump operation shall be verified (via DP-__) prior to sending run signal to CCP-5 panel.
(b)Energize and open control valve V-__, by supplying __ (3) psi to the positioner.
(c)When the flow rate through the evaporator rises above the minimum as sensed by DP-__ and flow meter, FM-__, and confirmed through the evaporator safety logic, send start signal to the manufacturer chiller panel, enabling chiller internal start sequence.
(d)Control the flow through the evaporator at _____ GPM, as sensed by DP-__ and flow meter, FM-__, by modulating control valve V-__. Evaporator flow rate may be reset through CCP-5 panel but shall be maintained between low flow limit of _____ GPM (-25%) and high flow limit ____ GPM (+ 25%).
6)CWP-1, 2, 3 and 4 in run mode. CTF-1, 2 and 3 in run mode. Verify pump and fan operation via DP- __ thru __ and VFDs. If fan(s) do not ramp, verify alarm signal from panel.
7)CCPE PCHWP-1, 2, 3 and 4 are in run mode. Send stop signal to CCPE PCHWP-1. Verify pump operation, as reported through the ExCPCP, via DP- __ thru __.
8)CCPW chillers, chiller pumps, cooling towers and condenser water pumps are on-line with four in run mode and one in stand-by mode.
9)CCPW PCHWP- 2 and PCHWP-3 are in run mode. PCHWP-1 and PCHWP-0 are in stand-by mode.
10)Temporary chillers are off line.
b)Test Phase 2 (transfer of load from existing CCPE to new 4000 ton chillers):
i)Pre Test:
1)ECH-1 and CHWP-1 in Run Mode, as reported by CCP-1 and DP-__.
2)ECH-2 and CHWP-2 in Run Mode, as reported by CCP-2 and DP-__.
3)ECH-3 and CHWP-3 in Run Mode, as reported by CCP-3 and DP-__.
4)ECH-4 and CHWP-4 in Run Mode, as reported by CCP-4 and DP-__.
5)ECH-5 and CHWP-5 in stand by mode, as reported by CCP-5 and DP-__.
6)ECH-6 and CHWP-6 in stand by mode, as reported by CCP-6 and new Chiller Plant DCP (CPDCP).
7)ECH-7 and CHWP-7 in stand by Mode, as reported by CCP-7 and CPDCP.
8)ECH-8 and CHWP-8 in stand by mode, as reported by CCP-8 and CPDCP.
9)CWP-1, 2, 3 and 4 in run mode, CTF-1, 2 and 3 in run mode as reported by DP-__ thru DP-__ and VFDs. CWP-5 thru 10 and CTF – 5 thru 8 are in stand-by mode, as reported through the new CWP and new CT DCPs/VFDs.
10)Glycol chillers (GCH-1 and GCH-2), ice storage system and pumps are off, as reported by GCCP-1, GCCP- 2 and CPDCP.
11)CCPE PCHWP-1 thru 4 are in run mode, as reported through DP - __ thru __. CCPE PCHWP – 7 thru 13 are in stand-by mode, as reported through the new PCHWP DCP/VFDs.
12)CCPW chillers, chiller pumps, cooling towers and condenser water pumps are on-line with four in run mode and one in stand-by mode.
13) CCPW PCHWP- 2 and PCHWP-3 are in run mode. PCHWP-1 and PCHWP-0 are in stand-by mode.
14)Primary Booster CHWP-1 and 2 are in stand-by mode, as reported by PBDCP.
ii)Test Number 1 (initial load transfer to new chillers): PASS / FAIL
1)ECH-1 and CHWP-1 are in run mode, as reported by CCP-1 and DP-__.
2)ECH-2 and CHWP-2 are in run mode, as reported by CCP-2 and DP-__.
3)ECH-3 Stop Mode (stopped through the ExCPCP):
(a)Send stop signal to CCP-3 to stop ECH-3 and to CHWP-3
(b)When temperature drop across evaporator (measured by PCHWR T-__ or ECH-3 T-__ and ECH-3 T-__ differential) falls to 2 degrees F, close control valve V-__.
4)ECH-4 Stop Mode (stopped through the ExCPCP):
(a)Send stop signal to CCP-4 to stop ECH-4 and CHWP-4
(b)When temperature drop across evaporator (measured by PCHWR T-__ or ECH-4 T-__ and ECH-4 T-__ differential) falls to 2 degrees F, close control valve V-__.
5)ECH-5 and CHWP-5 in stand-by mode and off, as reported by CCP-5 and DP-__.
6)ECH-6 Run Mode (started through the new CPDCP):
(a)In automatic mode, DCPCP shall start CHWP-6. Pump operation shall be verified (via DP-__) prior to sending run signal to CCP-6 panel.
(b)Energize and open control valve V-__, by supplying __ (3) psi to the positioner.
(c)When the flow rate through the evaporator rises above the minimum as sensed by DP-__ and flow meter, FM-__, and confirmed through the evaporator safety logic, send start signal to the manufacturer chiller panel, enabling chiller internal start sequence.
(d)Control the flow through the evaporator at _____ GPM, as sensed by DP-__ and flow meter, FM-__, by modulating control valve V-__. Evaporator flow rate may be reset through CCP-6 panel but shall be maintained between low flow limit of _____ GPM (-25%) and high flow limit ____ GPM (+ 25%).
7)ECH-7 and CHWP-7 in stand-by mode and off, as reported through CCP-7 and DP-__.
8)ECH-8 and CHWP-8 in stand-by mode and off, as reported through CCP-8 and DP-__.
9)CWP-1 thru 4 in run mode. CTF-1, CTF-2 and CTF-3 in run mode. Send start signal to CT-5 and stop signal to stop signal to CT-3. Send start signal to CWP-5 and 6, and stop signal to CWP-3 and 4. Verify pump and fan operation via DCPs/VFDs. If pump(s) or fan(s) do not start/ramp, verify alarm signal from DCPs. CWP – 3, 4, 7 thru 10 and CTF – 3, 6 thru 8 are in standby mode and off, as reported through the CWP and CT DCPs/VFDs.
10)Glycol chillers (GCH-1 and GCH-2), ice storage system and pumps are off, as reported by GCCP-1, GCCP- 2 and DCP.
11)CCPE PCHWP-1, 2, 3 and 4 are in run mode, as reported through the PCHWP DCP/VFD. Send start signal to CCPE PCHWP-7 and 8, and stop signal to CCPE PCHWP-4. Verify pumps start/ramp up thru PCHWP DCP. CCPE PCHWP – 4, 9 thru 13 are off and in stand-by mode, as reported through the PCHWP DCP/VFDs.
12)CCPW chillers, chiller pumps, cooling towers and condenser water pumps are on-line with four in run mode and one in stand-by mode.
13) CCPW PCHWP- 2 and PCHWP-3 are in run mode. PCHWP-1 and PCHWP-0 are in stand-by mode.
14)Primary Booster CHWP-1 and 2 are in stand-by mode, as reported by PBDCP.
iii)Test Number 2 (incremental transfer to new 4000 ton chillers): PASS / FAIL
1)ECH-1 and CHWP-1 are in run mode, as reported by CCP-1 and DP-__.
2)ECH-2 Stop Mode (stopped through the ExCPCP):
(a)Send stop signal to CCP-2 to stop ECH-2 and to CHWP-2.
(b)When temperature drop across evaporator (measured by PCHWR T-__ or ECH-2 T-__ and ECH-2 T-__ differential) falls to 2 degrees F, close control valve V-__.
3)ECH-3 and CHWP-3 are in stand-by mode and off, as reported by CCP-3 and DP-__.
4)ECH-4 and CHWP-4 are in stand-by mode and off, as reported by CCP-4 and DP-__.
5)ECH-5 and CHWP-5 are in stand-by mode and off, as reported by CCP-5 and DP-__.
6)ECH-6 and CHWP-6 are in run mode, as reported by CCP-6 and DP-__.
7)ECH-7 in Run Mode (started through the new CPDCP):
(a)In automatic mode, DCPCP shall start CHWP-7. Pump operation shall be verified (via DP-__) prior to sending run signal to CCP-7 panel.
(b)Energize and open control valve V-__, by supplying __ (3) psi to the positioner.
(c)When the flow rate through the evaporator rises above the minimum as sensed by DP-__ and flow meter, FM-__, and confirmed through the evaporator safety logic, send start signal to the manufacturer chiller panel, enabling chiller internal start sequence.
(d)Control the flow through the evaporator at _____ GPM, as sensed by DP-__ and flow meter, FM-__, by modulating control valve V-__. Evaporator flow rate may be reset through CCP-7 panel but shall be maintained between low flow limit of _____ GPM (-25%) and high flow limit ____ GPM (+ 25%).
8)ECH-8 and CHWP-8 in standby mode and off, as reported through CCP-8 and DP-__.
9)CWP-1, 2,5 and 6 in run mode. CTF-1, CTF-2 and CTF-5 in run mode. Send start signal to CWP-7 and 8, and stop signal to CWP-2 and 5. Send start signal to CTF- 6 and stop signal to CTF-2. Verify pump and fan operation via DCPs/VFDs. If pump(s) or fan(s) do not ramp, verify alarm signal from DCPs. CWP – 2, 3, 4, 5, 9 and 10, and CTF – 2, 3, 6 thru 8 are in standby mode and off, as reported through the CWP and CT DCPs/VFDs.
10)Glycol chillers (GCH-1 and GCH-2), ice storage system and pumps are off, as reported by GCCP-1, GCCP- 2 and DCP.
11)CCPE PCHWP-1, 2, 3, 7 and 8 are in run mode, as reported through the PCHWP DCP/VFD. Send start signal to CCPE PCHWP-9 and 10, and stop signal to CCPE PCHWP-2 and 7. Verify pump(s) start/ramp up thru PCHWP DCP. CCPE PCHWP – 3, 4, 7, 11 and 13 are off and in stand-by mode, as reported through the PCHWP DCP/VFDs.
12)CCPW chillers, chiller pumps, cooling towers and condenser water pumps are on-line with four in run mode and one in stand-by mode.
13)CCPW PCHWP- 2 and 3 are in run mode. PCHWP-1 and PCHWP-0 are in stand-by mode.
14)Primary Booster CHWP-1 and 2 are in stand-by mode, as reported by PBDCP.
iv)Test Number 3 (complete transfer of CCPE load to new 4000 ton chillers): PASS / FAIL
1)ECH-1 Stop Mode (stopped through the ExCPCP):
(a)Send stop signal to CCP-1 to stop ECH-1 and to CHWP-1.
(b)When temperature drop across evaporator (measured by PCHWR T-__ or ECH-1 T-__ and ECH-1 T-__ differential) falls to 2 degrees F, close control valve V-__.
2)ECH-2 and CHWP-2 are in stand-by mode and off, as reported by CCP-2 and DP-__.
3)ECH-3 and CHWP-3 are in stand-by mode and off, as reported by CCP-3 and DP-__.
4)ECH-4 and CHWP-4 are in stand-by mode and off, as reported by CCP-4 and DP-__.
5)ECH-5 and CHWP-5 are in stand-by mode and off, as reported by CCP-5 and DP-__.
6)ECH-6 and CHWP-6 are in run mode, as reported by CCP-6 and DP-__.
7)ECH-7 and CHWP-7 are in run mode, as reported by CCP-7 and DP-__.
8)ECH-8 Run Mode (started through the CPDCP):
(a)In automatic mode, CPDCP shall start CHWP-8. Pump operation shall be verified (via DP-__) prior to sending run signal to CCP-8 panel.
(b)Energize and open control valve V-__, by supplying __ (3) psi to the positioner.