Automatic Isolation Valves Test Procedures

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The methods described below apply to valves designed to isolate equipment, such
as chillers, boilers, and cooling towers, from the rest of the plant when they are
not in use. Generally, tests on isolation valves are performed to find large leaks.

This article covers the Automatic Isolation Valves Test Procedures.  Refer to Valve
Leak-By Test Procedures for full testing guidance.

1. Visual Inspection Method

1.1  Condenser Bundle Isolation Test - Command all chillers OFF, all condenser
bundle isolation valves closed, all cooling tower isolation valves open, and
condenser water pump(s) ON.  With all of the condenser bundle isolation valves
closed and the condenser water pumps operating, this in effect creates a “dead
head” condition on the pump and should not be operated for more than 5
minutes at this condition.   Visually inspect for any water entering the cooling
towers If water is flowing then the test fails The source of the problem must be
towers.  If water is flowing, then the test fails.  The source of the problem must be
fixed before the system can be retested.

1.2  Cooling Tower Isolation Test - Continuing from above with all chillers OFF
and condenser water pump(s) ON, command all condenser bundle isolation
valves open and all cooling tower isolation valves closed.  With all of the cooling
tower isolation valves closed and the condenser water pumps operating, this in

effect creates a “dead head” condition on the pump and should not be operated
for more than 5 minutes at this condition.   Visually inspect for any water
entering the cooling towers.  If water is flowing, then the test fails.  The source of
the problem must be fixed before the system can be retested.

1.3  Return System to Normal - Once all tests are complete, return all control
parameters back to original set points and conditions per the design sequence of
operations.

2. Balancing Valve Method

Most chillers and boilers designed to operate in parallel with other units will have
automatic isolation valves to prevent water from flowing through the unit when
not in operation.   The distribution pumps serving these units may be configured
as constant or variable primary flow.  Each pump will be fitted with either a
triple-duty valve or a dedicated balancing valve at the discharge of the pump,
which can be used to help identify valve leakage.  The following procedures are
quick to perform and should identify a small leakage rate through the valve(s)
being tested.

2.1  Test Setup - Carefully mark each balancing valve’s setting before making any
adjustments.  For linear gauge types, mark the gauge.  For screw type
adjustments, mark the stem as well as count the turns as the balancing valve is
fully closed.  Adjust each balancing valve serving the isolation valve being tested
to 10% open to ensure a small valve leak can be detected.  Command all chillers
and boilers OFF to ensure they will not try to operate without any water flow.
 Command the isolation valve on the unit being tested closed, and close the
manual isolation valve on the units not being tested.  Command one pump ON.

2.2  Valve Closure Performance - Measure the pressure drop across the
balancing valve. If there are no leaks in the system, the differential pressure
across the balancing valve should be zero.  A pressure drop of more than two psi
indicates leak-by.  If results are inconclusive, close the manual isolation valves on
the tested unit and see if the differential pressure across the balancing valve is
lower that the first reading.  If it is, then it confirms the valve is leaking.  When
taking pressure measurements, be sure to keep the transducer at the same
elevation during each measurement of a given port so that atmospheric pressure
elevation during each measurement of a given port so that atmospheric pressure
doesn’t skew the results.  Repeat this procedure with all other units to be tested.

2.3  Return system to normal - Relocate the balancing valve precisely to the pre-
test setting and return controlled equipment to auto or pre-test conditions.

3. Installed Flow Meter Method

Many larger boiler and chiller systems contain permanently installed flow meters
on their primary or secondary loops, and occasionally on the primary leg to each
chiller or boiler.  In such cases, using the installed flow meter offers an easy way
to detect isolation valve leakage if the device can measure accurately at very low
flow rates.  The procedures for using installed flow meters are described below.

3.1  Test Setup - Command all chillers and boilers OFF to ensure they will not try
to operate without any water flow.  Command the isolation valve on the unit
being tested closed, and close the manual isolation valve on the units not being
tested.  If the flow meter is in the primary loop, proceed directly to the Test and
Evaluation step.  If the flow meter is in a secondary decoupled loop, manually
valve off the bypass leg and command the secondary pumps OFF.

3.2  Test and Evaluation - Turn ON the primary pump.  There is leak-by if the
flow meter consistently reads a flow rate.  Repeat this procedure with all other
units to be tested.

3.3  Return all systems to normal - Return all manual valves to pre-test positions.
Return all automatic devices to auto or pre-test conditions.

4. Other Methods for Isolation Valves

There are other viable methods for detecting leak-by on chiller and boiler
isolation valves, but they are generally more time consuming or less conclusive.
 They are briefly mentioned here for reference.

4.1  Ultrasonic Flow Meter - The test procedures are similar to the Installed Flow
Meter method described above.  This test may be more time consuming due to the
potential necessity to remove and replace at least two feet of pipe insulation in
order to measure water flow.   In addition, the accuracy of the ultrasonic meter at
reduced flow may make it difficult to identify small leaks.

4.2  Pressure Differential Across Chiller or Boiler - This method measures the
change in differential pressure across the evaporator chiller bundle or boiler heat
exchanger.  The method is fast, but can only detect larger leakage rates, since a
small leak represents a very small pressure drop across the unit.  The procedures
are to turn the chiller or boiler OFF; turn ON the pump and close manual isolation
valves to ensure no flow.  Measure the differential pressure across the device
(which should be zero).  Then, command the automatic isolation valve closed,
open the manual isolation valves, and measure the differential pressure again.  If
the readings with the automatic isolation valve commanded closed show a
consistent differential pressure over 2 psi, then leak-by is likely.

4.3  Mixed Temperature - The method works for equipment that is piped in
parallel and the output from each unit is mixed together before it is delivered to
the loads.  The intent is to measure the mixed water temperature to determine if
there is leakage past a unit that is not operating.  This is best illustrated through
the following example:   Chiller 1 is ON and producing 42°F water.  Chiller 2 is
OFF with its automatic isolation valve closed.  With no leakage through the Chiller
2 isolation valve, the mixed water temperature will be 42°F.  If there is leakage,
the mixed water temperature would be higher due to blending of warm return
water with the 42°F water.  The test procedure follows this example – command
one unit ON and the other(s) OFF with the isolation valves closed.  If the mixed
temperature is higher than discharge water temperature from the unit that is
operating, there is leakage.  The procedures would be repeated until all units
have been tested.   This method may be inconclusive due to the difficulty in
measuring the mixed water temperature.

4.4  Pump Differential Pressure - This method is similar to the balancing valve
method except the balancing valve is 100% closed rather than 10% open, and the
differential pressure is measured across the pump rather than balancing valve.  A
change in the differential pressure across the pump with the automatic isolation
valve closed indicates leakage.  However, many pumps have a very flat impeller
curve, making a small flow rate due to valve leakage difficult to detect.