Functional Testing Guidance Valve Leak-By Test

This functional testing guidance is designed to aid in developing test procedures for a specific project by
describing the steps involved in testing. The guidance should be adapted as necessary to address the control
sequences, configuration, and performance requirements of the particular system being tested. Additionally,
codes may require specific testing procedures that may not be addressed in this document. All tests based on
this guidance should be reviewed carefully to ensure that they are complete and appropriate.
Test Procedure: Valve Leak-By Test
Overview
Valves are tested for leak-by to determine if they are leaking water when they have been commanded
closed. There are several possible test methods, and the most appropriate one depends on whether the
purpose of the test is to detect small leaks (!" of design flow or less# or large leaks after the system and
component configuration is known. $ome test procedures are more time consuming and others can be
inconclusive. This document covers the most common valve configurations for air handlers, air and water
terminal and fan coil units, and e%uipment automatic isolation valves. &ethods that are time-efficient and
generally conclusive are described in more detail. 'ther methods are summarily mentioned. Table
provides a summary guide on the features and applications of the various methods.
This document describes the following test methods(
1. Heating/cooling Coil Valves
Balancing Valve
)ater Temperature *cross +oil
,nfrared Thermometer
*ir Temperature *cross +oil-$pot Test
'ther +oil +ontrol Valve &ethods
*ir Temperature *cross +oil-. /our Test
0ifferential 1ressure *cross +oil
+oil 0rain 0own
2. Automatic Isolation Valves
Visual ,nspection
Balancing Valve
,nstalled 2low &eter
'ther ,solation Valve &ethods
3ltrasonic 2low &eter
0ifferential 1ressure *cross Boiler or +hiller
&i4ed Temperature
1ump 0ifferential 1ressure

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Functional Testing Guidance Valve Leak-By Test
Table 1. Valve ea!"b# Test $et%od A&&lication 'uide
Test $et%od
Can (etect
)mall ea!s
*+1,-.
/uic! To
Per0orm
$ost Common
A&&lication
Coil Control Valves
. Balancing Valve 5es 5es Large and small leaks of air handler cooling
and heating water coils and chiller
evaporator isolation valves.
.. )ater Temperature *cross
+oil
5es 6o Large and small leaks of air handler coils.
7. ,nfrared Thermometer 6o 5es Large leaks or improper function of small
heating and cooling coils of terminal and fan
coil units and radiators.
8. *ir Temperature *cross
+oil-$pot Test
6o 5es Large leaks of air handler coils, terminal and
fan coil units.
%. &t'e( )oil )ont(ol Valve *et'ods
!. *ir Temperature *cross
+oil-79 &inute Test
1ossibly 6o Large and small leaks of air handler coils
and air terminals when discharge is
monitored.
!.. 0ifferential 1ressure
*cross +oil
6ot usually 5es Large leaks of air handler coils and chiller
isolation valves.
!.7 +oil 0rain 0own 5es 6o Large and small leaks of air terminal units.
Automatic Isolation Valves
. Visual ,nspection 5es 5es Large and small leaks of chiller condenser
and cooling tower isolation valves only.
.. Balancing Valve 5es 5es Large and small leaks of chiller and boiler
isolation valves.
7. ,nstalled 2low &eter 5es 5es Large and small leaks of chiller and boiler
isolation valves.
+. &t'e( ,solation Valve *et'ods
8. 3ltrasonic 2low &eter 1ossibly 6o Large and small leaks of chiller and boiler
isolation valves.
8.. 0ifferential 1ressure
*cross Boiler or +hiller
6o 5es Large leaks of chiller and boiler isolation
valves.
8.7 &i4ed Temperature 6o 6o Large leaks of chiller and boiler isolation
valves.
8.8 1ump 0ifferential 1ressure 6o 5es Large leaks of chiller and boiler isolation
valves.

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Functional Testing Guidance Valve Leak-By Test
)#stem (escri&tion
Valves applicable for these test procedures include all types of automatically controlled hydronic valves
that serve heating and cooling coils on air handlers, fan coil and terminal units, and radiators, as well as
automatic isolation valves on chillers, cooling towers and boilers.
Valve Con0igurations and Pre0erred Test $et%ods
Air Handler 1nit Heating and Cooling Coil Valves. 2or air handlers with valve flow rates of 79 gpm or
more, a test that will detect small leaks (:!"# is warranted on most valves. 2or this application, the
Balancing Valve &ethod is preferred. )hen valve flow rates are between ! to 79 gpm, testing a smaller
sample, like 79", is more appropriate. /owever, the Balancing Valve &ethod is still preferred to detect
small leaks. 2or valves with flow rates less than ! gpm, refer to the *ir Terminal and 2an +oil section
below.
Air Terminals2 3an Coil 1nits and 3in"Tube 4adiators. Typically these devices have small copper
piping with small valves and no test ports or other means of measuring the temperature of the water
directly. The air stream may or may not be monitored by the B*$. The energy penalty for an individual
device is small for minor valve leakage because the design flow is so small. /owever, in most pro;ects
there is a large number of terminal devices, which typically ;ustifies testing for leak-by using a sampling
strategy. )hen the air terminal unit discharge air temperature is not monitored, the preference is to look
only for larger leaks using the ,nfrared Thermometer &ethod on a large fraction of the total units. *n
alternative approach for air terminal units is to rigorously check a sample of 9" to !" of units using
the +oil 0rain 0own &ethod to detect both small and large leaks. )hen discharge air temperature for the
air terminal unit is available, using the *ir Temperature *cross +oil-79 minute Test method or the
,nfrared Thermometer &ethod is preferred.
Automatic Isolation Valves. The Balancing Valve Test (often a triple-duty valve# on parallel chillers and
boilers is the preferred method, because it is efficient and provides confident results, unless an insertion
flow meter has been installed.
)am&ling
,t may not be necessary, or economical, to test every single valve for a given pro;ect. The number of
devices tested and their acceptance criteria depends on the how critical valve leak-by is to either system
operation, energy consumption, or thermal comfort. $ampling is a method that seeks to balance reliable
results with a reasonable amount of effort. $uggestions for sampling rates are given in the previous
sections, but typically pro;ect specifications will stipulate either a given sample percent or a minimum
number of systems that must be tested. Then if a given percentage of the samples fail, all remaining
devices must be tested or sampled. 6ote that in order to make sampling effective, selection of the devices
for testing should be done randomly.
Corrections to ea!ing Valves
,f a valve is leaking by, check that the valve stroke time programmed into the B*$ is 9" or !" longer
than the specified stroke time of the valve actuator. 2or pneumatic actuators try increasing the pressure.
The valve close-off pressure should be at least e%ual to the pump<s operating pressure. *$/=*>
recommends !9" of the pump pressure. +heck that the valve closes under the force of the actuator, not
the spring if the valve actuator is e%uipped with a spring. +heck the close-off specifications for the valve
and compare to the water pressure in the piping to make sure the valve has the capacity to completely
close off against the water pressure. 'ther possible causes for inade%uate closure are incorrect wiring,
sticking components and damaged valve components caused by cavitation from oversi?ed valves.

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Test 56ui&ment
>ach test method re%uires a different set of tools, as e4plained in the respective test procedure. ,n
general, typical test e%uipment can include(
0ifferential pressure gage
0igital thermometer
,nfrared thermometer
3ltrasonic flow meter
*ll test e%uipment must provide accurate readings in order to verify system performance. 2or all the
methods described in this document e4cluding the ,nfrared Thermometer &ethod, the absolute accuracy
of the measuring instrument is not critical if the intent of the test is to measure a differential value and the
same instrument is used to make both measurements. The reason is that measurement error will be
subtracted out when calculating a differential value. ,nstruments with accuracies of @.92 for
temperature and @7" of full scale for pressure transducers are sufficiently accurate for this purpose.
/owever, since pressure transducer accuracy is typically rated against full scale, it is recommended that
the pressure transducer selected for use is close to the e4pected pressure. 2or e4ample, a 9-799 psi
transducer should not be used if the e4pected pressure range is between 79 to 89 psi.
0irect flow measurements using the installed flow meter(s# or a portable ultrasonic flow meter are more
susceptible to inaccuracy in the measuring device. ,nstalled flow meters are normally sufficiently
accurate if they have been factory calibrated, installed correctly, and then used on clean water. 3ltrasonic
flow meters have good accuracy potential, but are very sensitive to pipe conditions, user set up and user
application.
The location where the readings are taken is very important. 'ften the most difficult issue with any
temperature-based leak-by test method is identifying an acceptable location for the hand-held temperature
measuring instrument. >ach pro;ect will have a different set of choices for taking temperature
measurements of the water in the piping. Below is a description of these choices listed in order of the
most preferred (easiest and most accurate# to least preferred. $ee 2igure for an illustration of a typical
air handler coil with marked temperature measurement locations. 6ote that the gages in this particular
application can<t be used for temperature measurements because they are not fitted with isolation
petcocks.

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3igure 1. T#&ical Air Handling 1nit Pi&ing
P/T Ports. 1AT (pressure A temperature# ports are designed for a hand-held metal temperature probe to be
inserted directly into the water stream. ,n many cases even a thermocouple wire end can be carefully
pushed through the hole in the rubber seal of the port and into the water. These ports also are used
directly for taking pressure measurements.
T%ermometer 7ells. To use a thermometer well to measure temperature, unscrew the thermometer and
insert the end of the handheld instrument<s thermocouple wire to the end of the well. 3sing heat transfer
grease around the thermocouple is ideal, but not necessary. +lose off the opening of the well to prevent
heat e4change with the ambient air with insulation (if insulation is not available, use crumpled paper or
cloth.# =esponse time to temperature changes in the water are slower than with sensors directly in the
water by to 7 minutes.
Pressure and Tem&erature 'age and Vent 3ittings. 1ressure and temperature gages installed with
isolation valves between the gage and the main pipe can be used to measure water temperature directly.
+lose the isolation valve and remove the gage. ,nsert the handheld instrument thermocouple into the open
pipe end and slowly bleed water out past the thermocouple, letting the water drop into a bucket. * fitting
setup with a 1AT port for the thermocouple and bypass drain hose offers a BcleanerC test.
Pi&e )ur0ace. ,f there are no appropriately located ports, wells or gages take temperature measurements
directly on the outside of the pipe. 2or the )ater Temperature *cross +oil &ethod find a location at least
7 or 8 feet away from the coil so that the pipe wall temperature at the hand-held sensor is not affected
during the test by the change in coil temperature. ,f the pipe is insulated, make a small slice through the
insulation, slide the thermocouple wire under the insulation, and get it directly against the pipe surface.
$lide it back and forth a few times while observing the temperature reading until good contact is made
(i.e. measured temperature is close e4pected temperature#. Tape the wire to the outside of the insulation,
if necessary, to keep thermocouple from moving around during the test. 'nce the test is completed, make
sure to tape over the slice with appropriate vapor-barrier tape to prevent condensation potential. 2or bare
pipe, wipe any dirt and dust off the pipe and place the thermocouple directly on the pipe. $ecure it in

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place with duct tape and cover with A.C foam or C or more of fiberglass insulation, e4tending at least
four inches on all sides of the thermocouple.
Test Procedure Outline
'eneral Procedures
1. Pre&aration
. +reate a test form
.. 0etermine acceptance criteria
.7 1rovide instructionsAprecautions
.8 $pecify test participants and rolesAresponsibilities
2. 4eview all &re0unctional c%ec!lists 0or com&leteness
Heating and Cooling Coil Valve Test
1. 8alancing Valve $et%od
. Test setup
.. Valve closure performance
.7 =eturn system to normal
2. 7ater Tem&erature Across Coil $et%od
.. Test setup
... >stablish baseline
..7 Valve closure performance
..8 =eturn system to normal
9. In0rared T%ermometer $et%od
7. 1lanning
7.. Test setup
7.7 =eadings
7.8 ,nterpretation
7.! =eturn system to normal
:. Air Tem&erature Across Coil )&ot Test $et%od
8. Test setup
8.. >stablish baseline
8.7 Valve closure performance
8.8 =eturn system to normal
,. Ot%er Coil Control Valve $et%ods
!. *ir Temperature *cross +oil D 79 minute test

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!.. 0ifferential 1ressure *cross +oil
!.7 +oil 0rain 0own
Automatic Isolation Valve Test
1. Visual Ins&ection $et%od
. +ondenser Bundle ,solation Test
.. +ooling Tower ,solation Test
.7 =eturn system to normal
2. 8alancing Valve $et%od
.. Test setup
... Valve closure performance
..7 =eturn system to normal
9. Installed 3low $eter $et%od
7. Test setup
7.. Test and evaluation
7.7 =eturn system to normal
:. Ot%er Isolation Valve $et%ods
8. 3ltrasonic 2low &eter
8.. 1ressure 0ifferential *cross +hiller or Boiler
8.7 &i4ed Temperature
8.8 1ump 0ifferential 1ressure
'eneral Procedures
1. Pre&aration
. Create a test 0orm. Testing will be easier, more conclusive and efficient if the test procedure
is thought through and documented before conducting the test. 0eveloping a test form will
assist in data collection and subse%uent evaluation and may allow less e4perienced staff to
e4ecute the tests.
.. (etermine acce&tance criteria. Leak-by tests are normally a simple passAfail based on
whether there is leakage. 0etermining minor leakage on every valve may not be practical or
cost effective. /ence, the tests should focus on those applications that can contribute to
energy waste or lead to control problems. ,n these applications, any leak-by result designates
a failed test.
.7 Provide instructions/&recautions. 'perating the system with no-flow through a coil during
the test for more than 79 minutes may lead to indoor comfort complaints if the space is
occupied. 6egative building pressures and potential condensation in hot and humid climates
can also be a problem, if the associated e4haust fans are not shut down when supply fans are
turned off.

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.8 )&eci0# &artici&ants and roles/res&onsibilities. The testing guidance provided in this
document can assist in verifying proper system performance in both new construction and
e4isting building applications. The following people may need to participate in the testing
process. =efer to the 2unctional Testing Basics section of the 2unctional Test Euide for a
description of the general roles and responsibilities of the participants. These roles and
responsibilities should be customi?ed based on actual pro;ect re%uirements.
New Construction Project Existing Building Project
+ommissioning 1rovider +ommissioning 1rovider
&echanical +ontractor Building 'perating $taff
+ontrol +ontractor +ontrols +ontractor
T*B +ontractor
2. 4eview all &re0unctional c%ec!lists 0or com&leteness
1rior to performing any functional tests, the commissioning pre-start, start-up, and verification
checklists should be completed, as well as applicable manufacturerFs pre-start and start-up
recommendations.
1refunctional checklists items include, but are not limited to, the following(
Technician available to command valves open and closed from the building automation system.
Valves in normal operating control.
*ir handler, pumps and water heating and cooling e%uipment (boiler and chiller# in service.
$ensor(s# is installed per the location specified on the plans.
*ll air handling unit(s# being tested have been functionally tested and are capable of serving
normal operating loads.
*ll terminal unit(s# being tested have been functionally tested and capable of serving normal
operating loads.
*ir and water system have been balanced per design.
+entral hot water and chilled water plants have been functionally tested and are capable of
service normal operating loads.
*ll safeties and interlocks have been tested and are operational.
*ll se%uence of operations are programmed per design.
Heating and Cooling Coil Valve Test Procedures
1. 8alancing Valve $et%od
&any air handlers have balancing valves (circuit setters# on the pipes to their heating or cooling
coils which can be used to detect valve leakage by measuring the pressure difference across the
valve. This method is only valid with .-way control valves. *nother test method must be used if
testing a 7-way control valve.
. Test )etu&. Turn the water pump '6 and ensure it is providing normal flow to the air
handler. +arefully mark the balancing valve<s setting, if not already marked. 2or linear gage
types, mark the gage. 2or screw type ad;ustments, count the turns as you turn the balancing

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valve fully closed. 'pen all balancing valves serving the control valve being tested to 9"
open. The balancing valve must not be open further than about 9" or a small control valve
leak would give too small a pressure drop across the balancing valve to be conclusive.
.. Valve Closure Per0ormance. +ommand the coil control valve closed. &easure the pressure
drop across the balancing valve. * pressure drop more than one psi indicates leak-by. ,f
results are inconclusive, close the manual isolation valves and see if the balancing valve
differential pressure lowers, indicating leak-by in the first test. )hen taking pressure
measurements, be sure to keep the transducer at the same elevation during each measurement
of a given port so that atmospheric pressure doesn<t skew the results.
.7 4eturn s#stem to normal. =elocate the balancing valve precisely to the pre-test setting.
2. 7ater Tem&erature Across Coil $et%od
Because of the effort re%uired by this method, it is most suited to larger valves (G. inches# on air
handling units when balancing valves are not available. This method provides very conclusive
results and is applicable to both .-way and 7-way control valves.
.. Test )etu&. Turn the water pumps and the heating or cooling plant (chiller or boiler# '6, so
there is a source of heat e4change. The pump flow rate may be fi4ed or variable (i.e., leave in
normal control#. The water supply temperature set point typically can be left in normal mode
with any reset se%uence in place, since the reset is slow in relation to the test duration.
... 5stablis% 8aseline. 0etermine central air handler or fan coil unit baseline by commanding
the supply and return fans '22 and commanding the coil valve being tested to 99" open.
2or a terminal bo4, baseline can be established by commanding air handler '22 or
commanding the primary terminal bo4 air damper 99" closed and the coil valve being
tested commanded 99" open. ,f a fan-powered terminal bo4 (either series or parallel# is
being tested, ensure the terminal bo4 fan is commanded '22 in addition to following the
damperAvalve commands outlined for a standard terminal bo4. +ommand the central hot
water or chilled water plants (i.e. boilers, chillers, distribution pumps, etc.# to be operating
and delivering water at design temperature through the system. The intent of turning off fans,
closing dampers, and opening the control valve is to eliminate heat transfer from the water
due to air flow across the coil. *llow the system to operate for appro4imately five minutes to
stabili?e the system.
+heck the following(
.... &easure the supply water temperature near the coil or use the building automation
system reading from near the plant. &easure the return water temperature between
the outlet of the coil and the point the coil leg returns into the main return pipe. The
return water measurement should be made at a point one to two feet (or more# away
from the coil as well as two or more feet away from where the coil return pipe ties in
with the main distribution pipes. The intent is to minimi?e the influence that the coil
or main distribution pipes may have on the temperature readings. The length of time
that the measurements will be valid is significantly reduced, the closer the
measurements are made to either the coil or distribution lines, due to heat transfer in
the pipe and water from the coil.
..... The supply and return water temperatures should be within 2 of each other when
the supply water is measured near the coil and within 72 when the temperature is
measured near the plant (to account for heat loss along the piping length#. =ecord this
water temperature difference (supply H return#.

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..7 Valve Closure Per0ormance. +ontinuing from the last step with the supply and return water
temperatures stabili?ed, command the coil valve closed and command the corresponding
supply fan '6 andAor damper open (terminal bo4#. The intent is to allow air to flow across
the coil and remove heat or BcoolC from the water in the coil. *llow the system to operate at
this condition for at least 7 to ! minutes. 2igure . illustrates the supply and return
temperature profile for a sample valve leak-by test for both heating and cooling coils. 2igure
7 illustrates how the water temperature will change over time at the return measurement
location when there is no leak-by, based on pipe diameter and the differential between the
return water in the pipe and ambient air temperatures.
3igure 2 Coil Valve ea!"b# Test Illustration

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3igure 9 ;o"ea!"b# 4eturn 7ater Tem&erature C%ange in 3irst Hour
+heck the following(
..7. &easure supply and return water temperature at the same location used to establish
baseline temperature difference. ,f there is leak-by at the control valve, the return
water temperature will change rapidly due to the heat transfer of the air stream across
the coil. ,f there is no leak-by at the control valve, the stagnant return water will
slowly creep towards the temperature of the surrounding air. *fter 7 to ! minutes, if
the supply - return water temperature difference has changed by more than .2 then
leak-by is indicated. ,f the readings are taken longer than 9 minutes after the valve
was closed, there may be some detectable change in the return water temperature
(and thus the supply H return difference# even when there is no leak-by, as shown in
2igure . and 2igure 7.
..7.. ,f the test data is inconclusive, try e4ecuting the entire test again but closing the
manual isolation valves along with the control valve. This should provide the
temperature profile for a positively closed coil valve. ,f the test fails, the test must be
performed again once the necessary repairs are made by the appropriate party.
..8 4eturn )#stem to ;ormal. 'nce all tests are complete, return all control parameters back to
original set points and conditions per the design se%uence of operations.
9. In0rared T%ermometer $et%od
This method is a variation of the )ater Temperature *cross +oil &ethod and measures the
temperature of the e4posed coil or piping from a distance. ,t most applicable in identifying gross
valve malfunctions and is not generally suited to detecting small fractions of leak-by (: 9" of
design flow#. ,t is fast and efficient and is recommended for checking large numbers of reheat coils

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in air terminal bo4es or valves serving radiant heating devices. This method is applicable to both .-
way and 7-way control valves.
7. Planning. ,n new construction, inform the construction team that you will need access to all
terminal bo4es or radiators for this test. 2or terminal bo4es, this will mean keeping the
ceiling tiles below the bo4es left out until after the test. &ake sure infrared thermometer used
during the test is suitable. ,t should be at least accurate to @72 and have a large
measurement area-to-distance ratio. *mong various models, the typical measurement area-
to-distance ratios range from I( to .9(, with a larger ratio being more accurate. 2or
e4ample, a .9( ratio means that when taking a measurement ! feet from the device , the
instrument will average the temperature readings over a 9..! foot (7 inch# diameter spot
J4!A.9K. )hereas, an I( ratio instrument will average the same temperature over a L inch
diameter spot measured at a distance of ! feet. * larger measurement area-to-distance ratio
means that a more accurate reading can be made at a further distance.
7.. Test )etu&. 2or air terminal bo4es, command the central air handler supply fans '6 and the
respective primary air valves 99" open. +ommand all the heating coil valves being tested
99" closed. This will typically be by floor or group of floors. )ait at least 79 minutes
more before taking any temperature measurements so that any residual heat in the coil has
fully dissipated and the coil temperature is near supply air stream temperature for air terminal
bo4es and near room temperature for radiant coils or radiators.
&ake sure heating water is being supplied to all ?ones to be tested. +ommand the
distribution water pumps and the heating plant '6. The pump flow rate can be left in normal
mode, but should be variable if all valves will be shut at once. The hot water supply
temperature set point can be left in normal mode with any reset se%uence in place.
7.7 4eadings. Take a temperature reading using an infrared thermometer on the e4posed coil
ends near the supply-side of the coil for air terminal units. 2or radiant coils or fin tubes take
a reading directly on the fins on the supply-side of the device. 'nly take readings near the
supply end of the coil, since hot water from a small leak may be totally cooled off by the time
it gets to the outlet of the coil. ,t is recommended that the distance between the infrared
thermometer and surface being measured be ! feet or less to ensure an accurate measurement.
7.8 Inter&retation. *n e4posed coil end fin tube near the entering supply should read within
92 to .92 of the supply air temperature for an air terminal unit or ambient air temperature
for a radiantAfin tube device if there is no leak-by at the valve and the system passes.
,f hot water was flowing through the coil prior to closing the valve and the temperature
measurement is made on the supply piping close to the coil because the coil end is not
accessible, then the acceptable temperature variation will be larger than the range provided
above. =emember that an insulated pipe with stagnant M9 2 supply water in a M9 2 room
will still be about 89 2 after one hour (refer to 2igure 7#. ,n this case if the temperature
measurement is less than 892, there is most likely no leak-by at the coil and the system
passes. 6ote( )ith the infrared thermometer, $*T at the diffuser could also be checked and
compared to $*T at the *ir handler.
7.! 4eturn s#stem to normal. 'nce all tests are complete, return all control parameters back to
original set points and conditions per the design se%uence of operations.
:. Air Tem&erature Across Coil $et%od < )&ot Test
This method is fast, but can be inconclusive unless there is a large control valve leak. The results
can be inconclusive because in some circumstances. 2or e4ample, a .92 differential coil with a

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valve leakage of 9" will only result in appro4imately .2 temperature change in the air stream.
$uch a small differential may be difficult to detect across the entire air stream via spot (i.e. single
point# measurements. This test is applicable to central air handling units and terminal unit coils
with either .-way or 7-way control valves.
8. Test )etu&. &ake sure hot or chilled water is capable of being provided to all ?ones being
tested. +ommand the distribution water pumps and the central heating and cooling plants
'22.
8.. 5stablis% 8aseline. 2or central air handling units, command the supply fan '6. ,f testing
air terminal bo4es, command the central air handler supply fan '6 and the respective
primary air valves 99" open. +ommand all the coil valves being tested to 99" closed.
This will typically be by unit for central systems and by floor or group of floors for terminal
units. ,n addition, close the manual isolation valves on the supply and return pipes serving
each device to guarantee no water flow through the coil. )ait at least 79 minutes before
taking any temperature measurements so that any residual energy in the coil has fully
dissipated.
+heck the following(
8... &easure the mi4ed and supply air temperature upstream and downstream, of the coil.
,f possible, make the measurements using the same temperature sensor in several
locations within the mi4ed air plenum and supply air plenum to determine an average
temperature for both parameters.
8.... +alculate the differential between the average mi4ed and supply air temperatures.
They should be within .2 of each other. ,f the temperature difference is greater than
.2, then there may be sensor error (if using multiple sensors# or not enough time has
elapsed to remove all residual energy from the coil. )ait an additional 9 minutes
before taking the readings again.
8.7 Valve Closure Per0ormance. +ontinuing from the last step with the coil valve 99" closed
and the mi4edHsupply air temperature differential stabili?ed, open the manual isolation
valves. +ommand the distribution water pumps and the central heating and cooling plants
'6. The pump flow rate can be left in normal mode, but should be variable, if all valves will
be shut at once. The hot and chilled water supply temperature setpoint can be left in normal
mode with any reset se%uence in place. )ait at least ! minutes before taking any
measurements.
+heck the following(
8.7. &easure the mi4ed and supply air temperature upstream and downstream, of the coil.
,f possible, make the measurements using the same temperature sensor in several
locations within the mi4ed air plenum and supply air plenum to determine an average
temperature for both parameters.
8.7.. +alculate the differential between the average mi4ed and supply air temperatures. ,f
the temperature difference is greater than !2, then there is likely leak-by at the valve.
)ith careful measurements, even a 72 differential can mean leak-by. 3nfortunately,
the normal variation of air temperature across the coil and the inaccuracies of sensors
don<t allow firm conclusions with differences less than 72. ,f the results are
inconclusive, consider performing an alternate test.
8.8 4eturn all s#stems to normal. 'pen manual valves, release fan and pump overrides, etc.

Valve_Leak_By_Test_Guidance.doc (last updated: 8/0! "age #. o$ #
Functional Testing Guidance Valve Leak-By Test
,. Ot%er Coil Control Valve $et%ods
There are other viable methods for detecting leak-by on coil cooling and heating valves, but they
are generally more time consuming or less conclusive. They are briefly mentioned here for
reference.
!. Air Tem&erature Across Coil = 9> minute Test. This test is viable when the B*$
accurately monitors air handler supply and mi4ed air temperatures or the terminal unit
discharge air on a terminal unit valve test (or an array of data loggers could be used#. This
method only works if the sensors on both sides of the coil are calibrated to be reading within
9..2 of each other first. The method involves monitoring the air flow for 79 minutes with the
control valve commanded closed and then with the all manual isolation valves closed. This
method is more conclusive than the Air Temperature Across CoilSpot Test method. The test
and evaluation procedures are the same as for the spot test, e4cept that the mi4ed and supply
air temperatures are trended for at least 79 minutes at . minute intervals once the initial
79 minute time delay to remove residual heat from the coil has e4pired.
!.. (i00erential Pressure Across Coil. This method measures the change in differential pressure
across the coil. The method is fast, but can only detect larger leakage rates, since a small leak
through the valve represents a very small pressure drop across the coil. The procedures are to
turn '6 the pump and close all manual coil isolation valves on both supply and return to
ensure no flow through the coil. &easure the pressure across the coil. The difference should
be ?ero. Then, command the automatic isolation valve closed. 'pen the manual isolation
valves. &easure the differential pressure again. ,f the readings with the automatic isolation
valve commanded closed show a consistent differential pressure over psi, then leak-by is
likely.
!.7 Coil (rain (own. This method is absolutely conclusive, but is suited only to small coils or
air terminal bo4es with .-way control valves installed on the supply-side of the coil.
Location of the control valve is critical since water will continue to flow to the coil if the
control valve is not in the supply line. The test is only recommended for smaller coils since
the method re%uires the entire coil to be drained down, and it should only be performed when
potential water spillage will not result in damage to the surrounding area. To e4ecute this
test, command the coil vale to 99" closed. &anually close the isolation valve on supply
side of coil and open the air bleed cap. 'pen the drain-down cock and drain water from coil.
)ater should eventually stop draining. ,f it doesn<t there is a leak past the control valve.
Automatic Isolation Valves
The methods described below apply to valves designed to isolate e%uipment, such as chillers, boilers, and
cooling towers, from the rest of the plant when they are not in use. Eenerally, tests on isolation valves are
performed to find large leaks.
1. Visual Ins&ection $et%od
. Condenser 8undle Isolation Test. +ommand all chillers '22, all condenser bundle
isolation valves closed, all cooling tower isolation valves open, and condenser water pump(s#
'6. )ith all of the condenser bundle isolation valves closed and the condenser water pumps
operating, this in effect creates a Bdead headC condition on the pump and should not be
operated for more than ! minutes at this condition. Visually inspect for any water entering
the cooling towers. ,f water is flowing, then the test fails. The source of the problem must be
fi4ed before the system can be retested.

Valve_Leak_By_Test_Guidance.doc (last updated: 8/0! "age #+ o$ #
Functional Testing Guidance Valve Leak-By Test
.. Cooling Tower Isolation Test. +ontinuing from above with all chillers '22 and condenser
water pump(s# '6, command all condenser bundle isolation valves open and all cooling
tower isolation valves closed. )ith all of the cooling tower isolation valves closed and the
condenser water pumps operating, this in effect creates a Bdead headC condition on the pump
and should not be operated for more than ! minutes at this condition. Visually inspect for any
water entering the cooling towers. ,f water is flowing, then the test fails. The source of the
problem must be fi4ed before the system can be retested.
.7 4eturn )#stem to ;ormal. 'nce all tests are complete, return all control parameters back to
original set points and conditions per the design se%uence of operations.
2. 8alancing Valve $et%od
&ost 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.
>ach 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 %uick to perform and should identify a small leakage rate through the valve(s# being tested.
.. Test )etu&. +arefully mark each balancing valve<s setting before making any ad;ustments.
2or linear gage types, mark the gage. 2or screw type ad;ustments, mark the stem as well as
count the turns as the balancing valve is fully closed. *d;ust each balancing valve serving the
isolation valve being tested to 9" open to ensure a small valve leak can be detected.
+ommand all chillers and boilers '22 to ensure they will not try to operate without any water
flow. +ommand the isolation valve on the unit being tested closed, and close the manual
isolation valve on the units not being tested. +ommand one pump '6.
... Valve Closure Per0ormance. &easure the pressure drop across the balancing valve. ,f there
are no leaks in the system, the differential pressure across the balancing valve should be ?ero.
* pressure drop of more than two psi indicates leak-by. ,f 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. ,f it is, then it confirms the valve is leaking.
)hen taking pressure measurements, be sure to keep the transducer at the same elevation
during each measurement of a given port so that atmospheric pressure doesn<t skew the
results. =epeat this procedure with all other units to be tested.
..7 4eturn s#stem to normal. =elocate the balancing valve precisely to the pre-test setting and
return controlled e%uipment to auto or pre-test conditions.
9. Installed 3low $eter $et%od
&any 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. ,n 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.
7. Test )etu&. +ommand all chillers and boilers '22 to ensure they will not try to operate
without any water flow. +ommand the isolation valve on the unit being tested closed, and
close the manual isolation valve on the units not being tested. ,f the flow meter is in the
primary loop, proceed directly to the Test and >valuation step. ,f the flow meter is in a
secondary decoupled loop, manually valve off the bypass leg and command the secondary
pumps '22.

Valve_Leak_By_Test_Guidance.doc (last updated: 8/0! "age #% o$ #
Functional Testing Guidance Valve Leak-By Test
7.. Test and 5valuation. Turn '6 the primary pump. There is leak-by if the flow meter
consistently reads a flow rate. =epeat this procedure with all other units to be tested.
7.7 4eturn all s#stems to normal. =eturn all manual valves to pre-test positions. =eturn all
automatic devices to auto or pre-test conditions.
:. Ot%er $et%ods 0or 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.
8. 1ltrasonic 3low $eter. The test procedures are similar to the ,nstalled 2low &eter 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. ,n
addition, the accuracy of the ultrasonic meter at reduced flow may make it difficult to identify
small leaks.
8.. Pressure (i00erential Across C%iller or 8oiler. This method measures the change in
differential pressure across the evaporator chiller bundle or boiler heat e4changer. 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 '22N turn
'6 the pump and close manual isolation valves to ensure no flow. &easure the differential
pressure across the device (which should be ?ero#. Then, command the automatic isolation
valve closed, open the manual isolation valves, and measure the differential pressure again.
,f the readings with the automatic isolation valve commanded closed show a consistent
differential pressure over . psi, then leak-by is likely.
8.7 $i?ed Tem&erature. The method works for e%uipment that is piped in parallel and the
output from each unit is mi4ed together before it is delivered to the loads. The intent is to
measure the mi4ed water temperature to determine if there is leakage past a unit that is not
operating. This is best illustrated through the following e4ample( +hiller is '6 and
producing 8.2 water. +hiller . is '22 with its automatic isolation valve closed. )ith no
leakage through the +hiller . isolation valve, the mi4ed water temperature will be 8.2. ,f
there is leakage, the mi4ed water temperature would be higher due to blending of warm
return water with the 8.2 water. The test procedure follows this e4ample H command one
unit '6 and the other(s# '22 with the isolation valves closed. ,f the mi4ed 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 mi4ed water temperature.
8.8 Pum& (i00erential Pressure. This method is similar to the balancing valve method e4cept
the balancing valve is 99" closed rather than 9" open, and the differential pressure is
measured across the pump rather than balancing valve. * change in the differential pressure
across the pump with the automatic isolation valve closed indicates leakage. /owever, many
pumps have a very flat impeller curve, making a small flow rate due to valve leakage difficult
to detect.

Valve_Leak_By_Test_Guidance.doc (last updated: 8/0! "age # o$ #