TESTING & COMMISSIONING (T&C) OF HVAC CHILLER

TESTING & COMMISSIONING (T&C) OF HVAC CHILLER

✅ Pre-Commissioning Checks

✔ Verify chiller model, capacity, refrigerant, and installation as per approved drawings.

✔ Check foundation alignment, vibration isolators, and mounting bolts.

✔ Confirm piping connections (CHW & Condenser Water) — flow direction, supports, flexible joints.

✔ Ensure valves installed correctly: isolation, balancing, flow switch, drain, vent.

✔ All electrical connections terminated — proper cable size, breaker, earthing, and isolator.

✔ Sensor wiring & BMS points connected and tested.

✔ Insulation completed and cladding sealed (especially outdoors).

Flushing & Cleaning

⇒ Conduct chemical flushing of CHW & condenser lines:

Use biocide + scale remover.

Flush till water is clear.

⇒ Post-flush: Passivation to protect pipe interiors.

⇒ Hydrostatic pressure test as per code (usually 1.5x working pressure).

⇒ Vent all air pockets using manual/auto air vents.

Dry Run / No Load Test

⇒ Power up the panel — check phase sequence, voltage levels, and alarms.

⇒ Run chilled water pumps (primary/secondary).

⇒ Confirm flow switch operation (cut-in/cut-out).

⇒ Run chiller without load:

❄ Full Load Commissioning

⇒ Start system with actual cooling load (or dummy load if building not ready).

⇒ Monitor:

⇒ Check expansion valve response and superheat.

⇒ Verify auto-cutoff & restart at setpoints (thermostat, overload, flow).

Functional & Safety Tests

⇒ Simulate flow loss — ensure chiller trips.

⇒ Simulate high/low pressure — verify safety shutdown.

⇒ Trip power — confirm auto-restart sequence.

⇒ Test BMS integration:

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