The Value of Systecon Performance Testing
The Value of Systecon Performance Testing
The Systecon Process
It starts with the controls. Each control system is tested in Systecon’s engineering department using a test cabinet. Standard sequences saved as blocks for future reference guarantee proper and consistent operation for every system.
The finished control cabinet with logic is installed on the water management system in the factory and manually tested for wiring accuracy to the pumps, motors, and drives. Manual low-stress tests are also performed on the equipment which virtually eliminates start-up damage.
Full-flow, fully automatic testing is performed using Systecon’s 20,000-gallon tank to verify all horsepower and kW readings, and find WWE transition points. Accurate pressure drop readings are taken to check for misalignment of pumps and piping, and to find any potential construction errors. Interfaces to chillers, towers, building automation systems, and ancillary equipment are also tested as much as possible to minimize field commissioning.
We make sure you retain control over your system throughout the design and assembly process and testing is no different. When the owner and/or engineer is present at testing, they can request or implement design changes right at the factory - completing our truly customized process and giving the owner everything possible for total water management.
You aren’t on your own after the system leaves Systecon either - we provide an experienced technician to supervise installation and start-up for every job. They’ll fine tune the system once the field piping and devices are installed, and perform any final adjustments required by field variances. Systecon also provides your operating staff with training on maintenance issues and setpoint adjustments that should last the life of the system.
Test Instrument Calibration
Testing means nothing if the test instruments aren’t calibrated properly. Systecon follows the Hydraulic Institute’s HI 6.6 Standard requirements for the calibration of test instrumentation. This test procedure is recognized by ASHRAE and should become an ANSI Test Standard.
Flow Meter - Systecon uses full throated type magnetic meters to measure flows from 10 to 30,000 GPM. We retain a consulting firm that specializes in the certification of flow measuring devices to certify our flow meters within 4% throughout the full-flow range. These tests are conducted every 12 months with our test stand piping – not special piping used just for meter calibration.
Watt Transmitter - The test watt transmitter has an accuracy within 1% which is certified traceable to NIST by an independent testing laboratory.
Pressure Gauges - Pressure gauges are dead weight tested to an accuracy of ± 2%. The dead weight tester is calibrated independently to the Hydraulic Institute’s requirements and traceable to NIST yearly.
Tachometer - The test stand tachometers are certified annually to have an accuracy within 1% traceable to NIST.
Multimeter - The test stand multimeter that measures electrical power characteristics is certified to have an accuracy within 1% traceable to NIST.
Factory Testing is Best
Testing in the manufacturing environment is ideal. It guarantees the performance of your system upon installation, eliminating most problems found during start-up and commissioning since any problems are found and addressed before the system is delivered to your job site.
Why Not Test in the Field?
- It’s very difficult to get the maximum system flow or the flow ranges required to achieve an accurate test in the field.
- Field instrumentation isn’t always installed and is almost never certified or NIST traceable, particularly flow meters.
- Arranging a certified test in the field is far more expensive than factory testing.
- You have to make electrical arrangements to measure and record volts, amperes, and power factor - kW meters, watt transmitters, and data recorders are needed.
- The piping must be stabilized to guarantee the accuracy of the flow measurements.
- The flow meter and pressure gauges must be calibrated and NIST traceable.
- A qualified professional must be hired to conduct the tests and certify the results.
- If problems are detected in the field, they can be time-consuming and costly to find and fix since they’ll likely require additional equipment and labor.
Why Don’t Other Manufacturers Factory Test?
- They don’t have the space or material handling equipment to test large systems.
- They don’t have the quality assurance technicians or electronic engineers required for a complete factory performance test.
- They don’t have the testing procedures and documentation to certify a factory performance test.
- They don’t have a registered professional engineer on staff to certify the test results.
- They don’t integrate the control system into the pump package and can only test the pumps individually, not as a system.
Factory performance testing elevates the value and advantage of your Systecon system compared to traditional field-built systems and those of many other modular manufacturers. It saves you time and money from the outset by facilitating a faster, easier start-up and commissioning process and continues to do so throughout the life of your system by ensuring you receive the efficient, high-quality system you expect. Quality is always the best value over time.
Performance testing is vital to ensure the quality and efficiency of any system. That’s why performance testing is a requirement for ALL Systecon systems, regardless of size or application. Our proven factory testing and control procedures, developed from our decades of experience, allow us to guarantee certified performance of our systems. We do everything possible to minimize your risk and make sure you get the high-quality system you expect.
Systecon’s in-house flow test stand can handle up to 30,000 GPM, ensuring every project is tested up to full design flow – something that field built systems can’t always accommodate. Our test instruments are NIST certified and we provide ETL certified third party testing. Our factory test also includes full simulation of the control sequences – pump staging, chiller staging, valve operation, failure modes, and transmitter signals. Every component is validated to confirm that your system meets the predicted performance before it leaves our factory.
Factory testing reveals the true efficiency of your system. Systecon can use Wire-to-Water Efficiency (WWE) during the design process to help determine the proper pump selection and sequencing to optimize the performance of your pump system. The WWE report is then used during testing to verify the sequencing, ensuring the efficiency of the pumps, motor, drive, and control combination. And since the tests are performed in a certified testing facility, the results can be kept for future reference to keep your system calibrated and help you avoid wasted energy usage.