Chilled Water Pumps Testing & Commissioning

Below is a precise testing and commissioning method statement for chilled water pumps on a project site.

The purpose of this method of statement or standard operating procedure is to define the step by step method to implement the correct practices for the pre-commissioning & commissioning of CHW chilled water pumps.

By following the guidelines contained herein the contractor shall ensure that the job execution complies with the project requirements and serves the intended function to satisfactory level of the client/consultant.

Before doing the pump testing make sure that chilled water pump installation work is complete and approval is available in writing from consultant/client.

Testing and commissioning team shall make sure that all installations are done and approved as per contract specifications, approved shop drawings, approved material submittals and manufacturer’s instructions. Additionally equipment operation and maintenance manuals shall be followed for startup and commissioning of the systems.

Below is list of necessary tools / instruments for chilled water pump testing.

• Technician Toolbox
• Pressure Gauges
• Clamp Meter
• Portable Hand tools
• Tachometer

Chilled Water Pump Commissioning Procedures

Visual Checks

Ensure that the pump installation is complete and mechanical completion is approved.

Thoroughly make inspections to make sure that no damage has occurred between the durations of mechanical completion & pre-commissioning.

Repair all damages to the equipment if any including apparent damages to paint finish.

Ensure that the pumps are identified location wise and service wise, approved tags/nameplates are provided.

Note the details of each motor such as make, model number, frame size, KW rating and RPM.

Check that the Chiller water & Condenser pump piping network is complete with proper valves, pressure switches and instruments in place as per final approved shop drawings.

Ensure the pump shafts are rotated by hand freely.

Make sure that electrical power connections and earthing is done properly and approved.

Ensure that the field wiring is pretested for continuity and insulation resistance, test reports are available on the site.

Check and ensure that all the relevant valves are in open position.

Pump discharge valve should be in closed position.

Direction of rotation and RPM shall be checked during commissioning.

Check the pumps are properly bolted.

Ensure that pipe alignment is done and all lengths are in straight lines.

Make sure that installation of pressure gauges is as per approved shop drawings.

Check identification and labeling for all piping’s and equipment’s.

Chilled Water Pump Start Up Procedure

Ensure that all the pre-commissioning checks are carried out successfully.

Ensure the discharge valve is closed.

Open the suction valve & allow water to flow into the pump.

Start the pump and record shutoff head.

Open the discharge valve fully & record the head of the pump.

Check pumps for overheating by feeling it physically by hand (there is no specific criteria for checking the overheating of pump).

Also check for any undue vibration/noise (it is just physical hearing of undue vibration / noise during operation).

Calculate the actual pump performance and plot actual performance curve.

Check current, voltage & rpm of the motor & record the values.

Check & ensure that the pumps shut off at low water level.

The wiring diagram of pump controls & schematic piping shall be displayed near or inside the control panel.

On successful completion of the chilled water testing and commissioning get consultant approval using the approved forms and inspection requests.

Also complete the specialist suppliers commissioning report / documents as per approved ITP.

Health & Safety Requirements

All safety precautions shall be followed as per the established Project Safety Plan.

Only experienced and skilled technicians shall be engaged for carrying out startup and commissioning of chilled water pump.

Safety Guards shall be in place and secured prior to startup of any equipment’s.

Cable test reports shall be verified prior to energization.

Appropriate Warning signs and tapes shall be placed during startup and commissioning as required.

All PPE shall be worn as appropriate according to the nature of the job.

Work area shall be maintained neat and clean.

Attachments

• Schedule of Chilled Water Pumps
• Pre-Commissioning check list for Chilled Water Pumps
• Commissioning check list for Chilled Water Pumps
• Chilled Water Pump Schematic diagram
• Manufacturer Operation Manual