Heating System Load Testing

What Is Heating System Load Testing?

Heating system load testing is a process that applies thermal cooling to a heat generation system to validate the operational capacity. It is particularly useful for renewable decarbonised district heating systems requiring certification.

How Does Heating System Load Testing Work?

Heating system load testing works by applying a false load to heat generating system so that its output can be proved against any design calculations, typically, decarbonisation projects that use heat pump and electrical heating use such methods.

Load testing involves the removal of energy from load (heating systems) which generally use water as a method of distributing the heat. The heat removed is measured so that efficiencies can be recorded and that the output is as specified.

So essentially, the process removes heat from the load and dumps it elsewhere, generally into the atmosphere ie. exchanging it from one place to another.

On the right we can see a load testing system that included two 500kw plate heat exchangers and a 1000kw chiller that were installed to test a decarbonisation project.

A 1000kw chiller installed with plate heat exchangers for load testing of a district heating system.

What are the Typical Processes used for Heat Load Testing?

The two main processes used for heating system load testing are;

  1. Direct water to air systems which circulate the heating system water through finned tubed radiators, and using fans force air across the surface to remove heat from the water and dispel to atmosphere. These systems are very effective in lower temperature ambient conditions where there is a large difference between the air and fluid temperatures.
  2. Active refrigeration systems such as water chillers use a vapour compression system to move energy from the water and then to atmosphere. However, they are not suited to working with the higher temperatures of heating systems which means they are generally used with plate heat exchangers for separation .

Advantages/ disadvantages of using direct air to water systems for heat load testing;

  • Advantages; High efficiency in certain conditions/ simple to use and operate.
  • Disadvantages; Changing capacity to remove heat which is dependant on ambient conditions.

Advantages/ disadvantages of using active refrigeration systems for heat load testing;

Advantages; Provides a consistent capacity for heat removal in typical ambient conditions.

Disadvantages; Less efficient/ more complicated to set-up with more component parts and involved control strategy.

A 400kw chiller installed to test air to water heat pumps at a London university.

What Component Equipment is Generally used for Heating System Load Testing?

Various components are assembled for heating system load testing. As above these depend on the application and conditions that the testing is taking place on; the main differences are with the exchange system and cooling medium ie water to water, or water to air.

Component parts typically required for a water to water/ air heat exchange system;

  • Water chiller or a dry air cooler

Water chillers are generally used in lower temperature systems such as air source heat pumps which run at around 45 degrees, or used along with plate heat exchangers at higher temperatures.

Dry air coolers are more suited to higher temperature systems because of the greater differential temperature between the heating process and ambient cooling air. This makes them very efficient.

  • Water pumps

Water pumps are used to circulate water around the component parts. Inverters are used to control the process, adjusting the flow rate to maintain constant temperature.

  • Plate heat exchangers

Plate heat exchangers are used where there is a need to isolate the two sides of a process ie. between the customers primary heat generation and the secondary heat removal side.

This could be because of potential high pressure or heat situations that require limiting to the secondary side, or the ability to apply better control to the heat removal process.

  • pipe-work for connection

For testing purposes flexible pipe-work is generally used as it is quick to install and remove. Different types of pipe are specified depending on the temperature and pressure present.

Rubber EPMD pipe-work has a safe working pressure of 5 Bar and temperature of 70degrees.

Single braided stainless steel pipe-work has a safe working pressure of 15 Bar.

  • Heat meters.

Heat meters are installed in line to measure the quantity of heat that is removed from the heat generation system by the load testing. This gives an accurate figure for the heat generated and when put alongside the input power efficiencies can be calculated.

Contact Us Now For Help With Your Project

Always contactable, by phone or email, we are happy to give the best advice regarding our temporary load testing services.

With depots in the North and South carrying extensive stock of heating system load testing equipment, we have the coverage to respond quickly to any project. This coupled with an experienced team ensures fast, successful outcomes.

Please contact us now for the best advice.

Temporary dry air coolers are a very efficient and simple way to carry out load testing.

FAQ'S

Yes, flexible contracts are available for the rental of all types of temporary load testing equipment that is required for the safe testing of heating equipment.

Rental terms can be agreed for periods of 2 weeks or more. Generally the longer you keep the equipment the cheaper the hire rates are.

Really any type of project where it is useful to either test for full capacity output and/or measure efficiency.

Projects can include;

  • Testing operation of air source to water heat pumps.
  • Testing of electric water heating systems
  • Testing overall efficiencies and outputs of decarbonisation projects.
  • Applying a load to new or existing heating systems to stress test and prove reliable operation under heavy load conditions.
  • Testing of water to water ground source heat pump systems.

If you have a need, it’s best to get in touch immediately with as much information as possible to help the supplier specify suitable equipment and give an indicative price before progressing to a site survey and full quotation.

Useful information that is ensures accurate proposals includes;

  • The type of heating system
  • The design capacity and water flow temperatures.
  • The design pressure of the system.
  • When you would like to carry out the testing ie likely time of year.
  • The location of the site.
  • Any outside space that has been identified for the location of the heat dissipation equipment.
  • Identification of access points to the clients system for pipe-work connection- if available.

A dry air cooler system.

Generally consisting of  a dry air cooler (DAC), a pump and hosing, it has fewer component parts than a active refrigeration system (chiller) and as such, is far simpler to install.

The only caveat to consider in regards of efficiency is the ambient air and heating flow temperatures; generally the larger overall difference between these determines the cooling capacity and efficiency of the dry air cooler.

Yes, temporary heat load testing equipment is supplied as a full turnkey service including the equipment, installation and on-going servicing for the duration of the contract.

Projects typically follow these steps;

  • First contact and initial information gathering.
  • Budget costs for the proposed equipment are provided for consideration
  • A site survey is carried out and costs are formalised for the equipment hire, installation, delivery etc.
  • If agreed the client is to issue an order to reserve the equipment and and installation time frame for the heating system load testing project.
  • The contractor will install the equipment.
  • commissioning and testing to be carried out and the project handed over to the client for their operations.
  • Following completion the equipment will be cleared from site.

Case Studies

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