ANSI/HI 1.6-2000 American National Standard for - Centrifugal Pump Tests ‘Sponsor Hydraulic Institute www. pumps.org Approved October 27, 1999 American National Standards Institute, Inc. Recycled paperAmerican National Standard Published By Approval of an American National Standard requires verification by ANSI that the requirements for due process, consensus and other criteria for approval have been met by the standards developer. Consensus is established when, in the judgement of the ANSI Board of Standards Review, substantial agreement has been reached by directly and materially affected interests. Substantial agreement means much more than a simple majority, but not nec- essarily unanimity. Consensus’ requires that all views and objections be considered, and that a concerted effort be made toward their resolution. The use of American National Standards is completely voluntary; their existence does ‘not in any respect preclude anyone, whether he has approved the standards or not, from manufacturing, marketing, purchasing, or using products, processes, or proce: dures not conforming to the standards. ‘The American National Standards Institute does not develop standards and will in no circumstances give an interpretation of any American National Standard. Moreover, no person shall have the right or authority to issue an interpretation of an American National Standard in the name of the American National Standards Institute. Requests for interpretations should be addressed to the secretariat or sponsor whose name ‘appears on the ttle page of this standard . CAUTION NOTICE: This American National Standard may be revised or withdrawn at any time. The procedures of the American National Standards Institute require that action be taken periodically to reaffirm, revise, or withdraw this standard. Purchasers of American National Standards may receive current information on all standards by call- ing or writing the American National Standards Institute Hydraulic Institute 9 Sylvan Way, Parsippany, NJ 07054-3802 www.pumps.org Copyright 2000 © Hydraulic institute All rights reserved. ‘No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher. Printed in the United States of America ISBN 1-880952-30-0Contents Page Foreword v 16 Test 1 1.6.1 Scope 1 1.6.2 Typesoftests 1 1.6.3 Terminology 1 1.64 Hydrostatic test 7 1.6.5 Performance test. aad Tons 9 1.6.6 Net positive suction head required test (optional)............... 19 1.6.7 Mechanical test (optional) a 23 1.6.8 Priming time test - ants 24 1.6.9 Measurement of rate of flow - wee 25 1.6.10 Head — measurement coves 29 1.6.11 Power measurement. . 30 1.6.12 Speed measurement. . . 3 1.6.13 Temperature measurement and instruments cones 82 1.6.14 Model tests ree sees 32 ‘Appendix A References. 35 ‘Appendix B Index 36 Figures 4.113 — Horizontal unit - (Single or double suction) (Double suction not shown) . : . 4 4.114 — Vertical single suction pump 4 1.115 — Vertical double suction pump 4 1.116 — Test with suction lift... . ceveeeeeeee 1.117 — Open or closed tank cee . 13 4.118 — Pump performance (all data is corrected to rated speed) 16 1.119 — Suppression type NPSH test with constant level sump 19 1.120 — Level control NPSH test with deep sump supply... . 20 1.121 — Vacuum and/or heat control NPSH test with closed loop 20 1.122 — NPSH test with rate of flow held constant... oe eeeeee eee 21 1.123 — NPSH test with suction head held constant. 24 1.124 — NPSH test with flow rate held constant cee eeeeeeeeee ees 2 1.125 — Suction line for static lft test 1.126 — Pressure tap opening1.127 — Welded-on pressure tap opening .... 1.128 — Single tap connection ...... . 1.128 — Loop manifold connecting pressure taps. 1.130 — Gauge connections . . Tables 1.18 — Symbols. 1.19 — Subscripts . : 1.20 — Recommended instrument calibration interval 1.21 — Straight pipe required folowing any fing before venturi meter in diameters of pipe 1.22— Straight pipe required folowing any yng before nozzle or orifice plate meter in diameters of pipe 1.23 — Straight pipe required folowing downstream pressure tap of anozzle or orifice plate meter before any fitting in diameters of pipe . 12 27 28 28Foreword (Not part of Standard) Purpose and aims of the Hydraulic Institute ‘The purpose and aims of the Institute are to promote the continued growth and well-being of pump manufacturers and further the interests of the public in such matters as are involved in manufacturing, engineering, distribution, safety, trans- Portation and other problems of the industry, and to this end, among other things: a) To develop and publish standards for pumps; b) To collect and disseminate information of value to its members and to the public; ©) To appear for its members before governmental departments and agencies and other bodies in regard to matters affecting the industry: 4) Toincrease the amount and to improve the quality of pump service to the public; e) To support educational and research activities; f) To promote the business interests of its members but not to engage in bus- ness of the kind ordinarily carried on for profit or to perform particular services for its members or individual persons as distinguished from activities to improve the business conditions and lawful interests of all ofits members. Purpose of Standards 1) Hydraulic Institute Standards are adopted in the public interest and are designed to help eliminate misunderstaridings between the manufacturer, the purchaser and/or the user and to assist the purchaser in selecting and obtaining the proper product for a particular need. 2). Use of Hydraulic Institute Standards is completely voluntary. Existence of Hydraulic Institute Standards does not in any respect preclude a member from manufacturing or selling products not conforming to the Standards. Definition of a Standard of the Hydraulic Institute Quoting from Article XV, Standards, of the By-Laws of the Institute, Section B: “An Institute Standard defines the product, material, process or procedure with reference to one or more of the following: nomenclature, composition, construc- tion, dimensions, tolerances, safety, operating characteristics, performance, qual- ity, rating, testing and service for which designed.” Comments from users ‘Comments from users of this Standard will be appreciated, to help the Hydraulic Institute prepare even more useful future editions. Questions arising from the con- tent of this Standard may be directed to the Hydraulic Institute. It will direct all such questions to the appropriate technical committee for provision of a suitable answer. Ita dispute arises regarding contents of an institute publication or an answer pro- vided by the Institute to a question such as indicated above. the point in question shall be referred to the Executive Committee of the Hydraulic Institute, which then shall act as a Board of Appeals.Revisions The Standards of the Hydraulic institute are subject to constant review, and revi- sions are undertaken whenever it is found necessary because of new develop- ments and progress in the art. If no revisions are made for five years, the standards are reaffirmed using the ANSI canvass procedure. Scope This Standard is for centrifugal, sealless centrifugal and regenerative turbine pumps of all industrial types except vertical multistage diffuser type. It includes detailed procedures on the setup and conduct of hydrostatic and performance tests of such pumps. Several methodologies to test centrifugal and vertical pump equipment are avail- able to pump manufacturers, users and other interested parties. The United States has two sets of pump test standards which represent two approaches to Conducting and evaluating pump performance. One, promulgated by the American Society of Mechanical Engineers (ASME) and designated PTC 8.2, Centrifugal Pumps, provides for two levels of tests in which the test procedures are less restrictive. The ASME Code relies on the parties to the test to agree beforehand on the Scope and Conduct of the test and does not specify how the test results shall be used to compare with guarantee. The ASME is especially suited to highly detailed pump testing, whereas HI Standards detail test scope, conduct and acceptance criteria, and are thus suited to commercial test practices. ASME Codes do not permit the use of acceptability tolerances in reporting results, while the HI Standards do. It is recommended that the specifier of the test standard become familiar with both the ASME Code and the Hi Standards before selecting the one best suited for the equipment to be tested, since there are a number of other differences between the two which may affect the accuracy or cost of the tests Both the ASME and HI Standards can be used for testing in either field or factory installations. The detailed requirements of the ASME Test Code are intended to reduce the effect of various installation arrangements on performance results and are applied more to field testing. The HI Standard specifies test piping and more controllable conditions which is more suitable to factory testing. The Hl Standards do not address field testing. Surveys have shown that both ASME and HI Stan- dards have been applied successfully to applications from small chemical pumps (1 hp) to large utility pumps (over 5000 hp). Units of Measurement Metric units of measurement are used: and corresponding US units appear in brackets. Charts, graphs and sample calculations are also shown in both metric and US units. Since values given in metric units are not exact equivalents to values given in US Units, itis important that the selected units of measure to be applied be stated in reference to this standard. fno such statement is provided, metric units shall govern. wiConsensus for this standard was achieved by use of the Canvass Method ‘The following organizations, recognized as having an interest in the standardiza- tion of centrifugal pumps were contacted prior to the approval of this revision of the standard. inclusion in this list does not necessarily imply that the organization ‘concurred with the submittal of the proposed standard to ANSI AR. Wilfley & Sons ANSIMAG Inc. Bechtel Corp. Black & Veatch Brown & Caldwell ‘Camp Dresser & McKee, Inc. Carver Pump Company Cheng Fluid Systems, Inc. Crane Company, Chempump Div. Cuma S.A Dean Pump Div, Metpro Corp. DeWante & Stowell Dow Chemical EnviroTech Pumpsystems Essco Pump Division Exeter Energy Ltd. Partnership Fairbanks Morse Pump Corp. Fluid Sealing Association Franklin Electric GKO Engineering Grundfos Pumps Corp. tlinois Dept. of Transportation IMC - Agrico Chemical Corp. Ingersoll-Dresser Pump Company ITT Fluid Handling (B & G) ITT Fluid Technology ITT Industrial Pump Group Iwaki Walchem Corp. J.P. Messina Pump & Hydr. Cons. John Crane, Inc. Krebs Consulting Service KSB. Inc. M.W. Kellogg Company Malcolm Pine, Inc. Marine Machinery Association Marley Pump Company Marshall Engineered Products ‘Company Montana State University MW, Moving Water Industries ‘Oxy Chem, Pacer Pumps Paco Pumps, Inc. Pinellas Cty, Gen. Serv. Dept. The Process Group, LLC Raytheon Engineers & Constructors Reddy-Buffaloes Pump, Inc. Robert Bein, Wm. Frost & Assoc. Scott Process Equipment Corp. Settler Supply Company ‘Skidmore ‘South Florida Water Mgmt. Dist. Sta-Rite Industries, Inc. Sterling Fluid Systems (USA), Inc. Stone & Webster Engineering Corp. Sulzer Bingham Pumps, Inc. ‘Summers Engineering, Inc. Systecon, Inc. Val-Matic Valve & Mig. Corp, ‘Yeomans Chicago Corp. Zoeller Engineered ProductsThis page intentionally blank.4.6 Test 1.6.1. Scope This standard is limited to the testing of centrifugal pumps with clear water. The tests conducted under these standards shall be made and reported by quali- fied personnel. This standard only applies to tests of the pump unless stated otherwise. ‘The type of test(s) performed, and the auxiliary equip- ment to be used, should be agreed upon by the pur- chaser and manufacturer prior tothe test It is not the intent of this standard to limit or restrict tests to only those described herein. Variations in test procedures may exist without violating the intent of this standard. Exceptions may be taken if agreed upon by the parties involved without sacriticing the validity of the applicable parts of this standard. 1.6.1.1 Objective This standard is intended to provide uniform proce- dures for hydrostatic, hydraulic, and mechanical per- formance testing of centrifugal pumps and recording of the test results. This standard is intended to define test procedures which may be invoked by contractual agreement between a purchaser and manufacturer. It is not intended to define a manufacturer's standard practice. 1.6.2 Types of tests This standard describes the following tests: a) Performance test to demonstrate hydraulic and mechanical integrity; Optional tests as follows when specified b) Hydrostatic test of pressure-containing components; ©) Net positive suction head required test (NPSHR. test); d) Mechanical test; ) Priming time test. For airborne sound testing see HI 9.1-9.5-2000, Pumps ~ General Guidelines. HI Centrifugal Pump Tests — 2000 1.6.2.1 Test conditions Unless otherwise specified, the rate of flow, head, eff- ciency, NPSHR and priming time are based on shop tests using water corrected to 20°C (68°F). Ifthe facil ity cannot test at rated speed because of limitations in power, electrical frequency or available speed chang- ers, the pump may be tested at between 80% and 120% of rated speed. It is permissible on pumps greater than 225 kw (300 hp) to test at speeds between 60% and 140% of rated speed. 1.6.3 Terminology ‘The following terms are used to designate test param- eters or are used in connection with pump testings: 1.6.3.1. Symbols See Table 1.18 1.6.32 Subscripts See Table 1.19. 1.6.3.3 Specified condition point Specified condition point is synonymous with rated condition point. 1.6.3.4 Rated conditi n point Rated condition point applies to the rate of flow, head, speed, NPSH and power of the pump as specified by the purchase order. 4.6.3.5 Normal condition point Normal condition point applies to the rate of flow, head, speed, NPSH and power at which the pump will normally operate. It may be the same as the rated con- dition point 1.6.3.6 Best efficiency point (BEP) ‘The rate of flow and head at which the pump efficiency (np) is a maximum, 1.6.3.7 Shut off (SO) The condition of zero flow where no liquid is flow- ing through the pump, but the pump is primed and operating,HI Centrifugal Pump Tests — 2000 ‘SUN V}OU = SUN SP x JOYDEY UOISIONLOD — sv0e'0 u 19) L euou ‘uou er0e'0 995) puosaspee ose" wa ye9}-punod 81g x (20-4) 4. weyuarye sees6ap 1 - ss9juoisueuip z0'9 “ | ]~ ‘Adjustable Spring Loaded / Back Pressure Valve or ‘Adjustable Choke Valve Note: Postion of these ‘vices may be reversed insome sat ups. Figure 1.117 — Open or closed tank Throttling devices may be used for the suction and discharge instruments, such as needle valves or capillary tubes to dampen out the pres- sure pulsations; ‘A means for measuring input power to the pump shall be provided and be suitable for measuring the complete range of power ‘A means for measuring pump speed shall be provided; ‘Test setups intended for NPSH testing shall be provided with a means for lowering the suction Pressure to the pump, such as a suction throttle valve (with optional screen or straightening vanes), variable level sump in an open system, or a closed tank with a mechanism to create a vao- uum or pressure: ‘A means for measuring the temperature of the test liquid shall be provided: The actual dimensions of the suction and dis- charge pipes where pressure readings are to be taken shall be determined so that proper velocity head calculations can be made; m) Flow measuring device(s). 1.6.56 Performance test data requirements The following data shall be obtained prior to the test run and written for the record to be retained for two years (see sample data sheet on page 14): a) Record of pump type, size and serial number; b) To verify the liquid properties, the temperature of the liquid shall be taken before and after testing, ‘Temperature readings should be taken more often when testing for NPSHR or high-power pumps. ©) Ambient conditions, such as temperature and barometric pressure: 4) Records of critical installation dimensions, such as. tank internal dimensions, pipe internal dimensions and lengths, and liquid levels (submergence) rela- tive to datum; ) Record of driver data, such as type, serial number, horsepower, speed range, amperage, voltage and efficiency; 4) Record of auxiliary equipment, such as vibration monitors, temperature sensors, low- or high- Pressure monitors, leakage detectors, alarms, et. 13HI Centrifugal Pump Tests — 2000 ‘Summary of necessary data on pumps to be tested The 1 following information should be furnished on pumps to be tested’ General 1. Owner's name 2. Plant location 3. Elevation above sea level 4. Type of service Pump: Manufactured by. ‘Manutacturer’s designation ‘Manufacturer's serial number ‘Arrangement: horiz vertical Inlet: ‘single double . Number of stages Size suction; nominal actual Size discharge: nomins actual @ Nogaens Intermediate transmission: 4."Manufactured by 9, Net positive suction head required (NPSHR) 10, Total discharge head (he) _ 11. Total head (H). 42. Output power (Py, 13. Efficiency (np) 44 Input power (P,) 15. Speed Test information Test information should be listed substantially as follows: General: 1. Where tested 2. Date 3, Tested by 4. Test witnessed by Rate of flow: 1. Method of measurement. 2. Meter—make and serial number 2. Type 3. Serial number 3. Calibration data 4. Speed ratio 5. Efficiency Head: 1. Suction gauge—make and serial number Driver: 4. Manufactured by 2. Calibration data 2. Serial number — 3: Tye: motor. twine other 3. Discharge gauge—make and serial number 4. Rated horsepower 5. Rated speed 4. Calibration data 6. Characteristics (voltage, frequency, ete.) . Calibration data Driver efficiency Specifying rated conditions ‘The following information is necessary in specifying rated conditions: 14 1. Liquid pumped (water, oi, etc.) Power: 1, Method of measurement, 2, Make and serial number of instrument 3. Calibration data Spood: 2. Specifie weight 1. Method of measurement 3. Viscosity at pumping temperature —_ 4, Temperature 2. Make and serial number of instrument 5. Vapor pressure e 6. Rate of fiow 3. Calibration data 7. Total suction lft (hs) 8. Total suction head (nh)9). Instrument calibration records and correction fac- tors in accordance with instrumentation calibration section; h) Identity and authority level of test personnel in charge of tests; i) The actual dimension of the areas where pressure readings are to be taken shall be determined so that proper velocity head corrections can be made. 1.6.5.7 Performance test records Complete written or computer records shall be kept of all information relevant to a test and kept on fle, avail able to the purchaser by the test facility, for two years. The manufacturer's serial number, type and size, or ‘other means of identification of each pump and driver (if calibrated and used to obtain the pump’s efficiency) involved in the test shall be recorded to avoid mistakes in identity. While these records apply to the complete unit, includ- ing the driver, the standard itself applies only to tests, of the pump, 1.6.5.8 Calculations 16. Calculation of total suction head (h,) he = Ng. thy+Z, 1.6.5.8.2 Calculation of total discharge head (hg) hg = hg, + hy, + Zq 1.6.5.8.3 Calculation of total head (H) H= hg-h, For definition of terms and algebraic summation of the parts, see Section 1.6.3.12 1.6.5.8.4 Calculation of input power The input power (P,), when measured by transmission dynamometer, is calculated from the following formula: nt (Metric units): Py = a5 a HI Centrifugal Pump Tests — 2000 = 2nLWn ont (US units): Py = Fron ~ B55 Where: L_ = _ Length of lever arm in m (ft); W = Net force in N (1b) n= Pump speed in rpm; 1 = Torque in N-m (pound-feet) ‘The electrical horsepower input to an electric motor is given by: (Metric) Pro, = KW. kW. (US Units) Por ~ grag Where: AW = Electrical input power in kilowatts. The input power to a pump driven by an electric motor is: Not Pmot™ 05 1.6.5.8.5 Calculation of output power The liquid horsepower (P,,) is computed by the follow- ing formula: a) Metric units: QH(s) Pw = “366 b) US units: pounds of total head liquid pumped in feet of per min. liquid 33,000 When the specific weight of the liquid is 62.3 pounds per cubic foot, which is the value for water at a stan- dard temperature of 68°F, then 15HI'Centrifugal Pump Tests — 2000 OH 3960 P, Ifthe pump is handling a liquid with different specific weight, or water at a temperature resulting in a specific ‘weight per cubic foot other than 62.3 pounds, the above formula must be corrected s0 that: ans) Pu = 3960 lf pump output is measured in pounds per square inch, the formula for output power, regardless of the specific weight of the liquid, becomes: Qap Pa 70 1.6.5.8.6 Calculation of efficiency ‘The pump efficiency expressed in percent is calcu- lated by: Pw 100 "= eB, The overall efficiency of a motor-driven unit expressed in percent is calculated by: (Fm "mot : Tot Noa ™ "p* 9g Noa 1.6.5.8.7 Plotting performance test results The total head, efficiency and power input are usually plotted as ordinates on the same sheet with rate of flow as the abscissa, as shown on Figure 1.118, 1.6.5.8.8 Performance test at other than rated speed 1.6.5.8.8.1 Test of a full-sized pump at reduced speed In tests at reduced speed, the relative power loss in bearing and stuffing-box friction may be increased, an effect which may be appreciable in small pumps. The hydraulic friction losses may be relatively increased when the Reynolds number for the water passages is reduced, an effect which may be appreciable in small Pumps of low specific speed. Therefore, these factors must be considered in determining an acceptable test speed. 16 In order to maintain hydraulic similarity with the field ‘operation; the following relationships are used for determining the head, rate of flow, power and NPSHR at the rated point. These relationships which follow definite rules are known as the affinity jaws. The power relationship is based on the criteria that the efft- ciency stays constant with change in speed. Q, my _ (HOS _ (P,)0993 _ /NPSHR,\05 Qn () ~ @) nPSHR,) Where’ Q, = rate of flow on test; Q) = rate of flow on installation; ny = speed on test in rpm; ng = speed on installation in rpm; Hy = headon test; Hy = head on installation; P, = power on test; 2 = power on installation; NPSHR, = NPSH on test; NPSHR» = NPSH on installation ur Eficlney Input Power NPSHA Rate of fow Figure 1.118 — Pump performance (all data is corrected to rated speed)Sealless pumps incur significant eddy current losses which are affected by speed. Impeller input power var- jes approximately with the cube of rpm as they do in conventionally sealed pumps. Eddy current losses are proportional to rpm squared. Therefore the following ower correction for speed is made: P2 = (Py EC Xngin,)® + ECy(nging P, = Power on test in kW (bhp); P2 = Power on installation in kW (bhp); EC, = Eddy current losses on test in kW (bhp). Eddy current losses, EC;, are normally measured by manufacturers during development studies. Values from these tests may be used in lieu of measurements during the contractural performance test. 1.6.5.8.8.2 Performance test of full-sized pumps at increased speed Under unusual circumstances, it may be desirable to carry out tests at higher speeds than specified for the installation. This may be due to the limitations of avail able prime movers or correct electrical frequency. In this case, if such tests do not exceed safe operating limits of the pump, all of the above considerations con- tinue to apply. 1.6.5.8.8.3 Performance test correction to rated speed For purposes of plotting, the rate of flow, head and power shall be corrected from the test values at test speed to the rated speed of the pump. The corrections, are made as follows: Rate offiow: a, ~ [72a 2 ~ [72] vost: Hy = [22F a M4. rowtponee P,~ [Pe mM. Example (Metric): A pump for 90.8 m®/h, 68.5 meters, total head and 8 m NPSHA running at 3550 rpm is to be tested at 2950 rpm. What head, rate of flow and NPSHA should be used in the factory test? HI Centrifugal Pump Tests — 2000 Applying the relationships given above, the head per stage to be used in the factory test is: ‘The rate of flow to be used in the factory testis: 2, = 0," = s09[2250) = 755mm 1 = Ole [so] since: — M2Q2)°% _ 3550(90.8)25 _ 1420 8, DIS ~ Gg 5075 Hy 68.5075 then, P01) _ 2950(75.5)95 _ 1420 sa ~ DTS ~~ 473078 ‘The NPSH to be used in the factory test is: : 2 west, = nesi[™] = 62050 - 55m 2 Example (US Units): A pump for 400 gpm, 225 feet total head and 26.1 ft NPSHA running at 3550 rpm is to be tested at 2950 rpm. What head, rate of flow and NPSHA should be used in the factory test? Applying the relationships given above, the head per stage to be used in the factory test is: 2 2 Hy = nlZ) = 225[ 2050)" = 155% ‘The rate of flow to be used in the factory test is: Q, a,f7) = a00f! since: 3550(400)05 Sagurs— ~ 1220 7Hi Centrifugal Pump Tests — 2000 then, = PQS _ 2950(332)°5 _ 99 st APS 1950-75 ‘The NPSH to be used in the factory test is: 2950" NesH, = NPSH,|"*]° = 26.1129)? - 198 i> mesial] = 209[55c6) ~ This will keep the specific speeds the same in the fac- tory test as in the feld instalation 1.6.5.8.9 Performance test correction for temperature variations Variations in the temperature of the liquid pumped cause changes in the specific weight and viscosity, with resultant changes in the performance of the pump. Any reduction in specific weight, as caused by an increase in temperature, results in a directly propor- tional reduction in output and input power; therefore, the efficiency is not changed. Reduced viscosity of water at increased temperature will have an influence on efficiency. For pumps in the lower range of specific speed typically below 1750 (1800), such as high pressure, multi-stage boiler feed pumps and large, single-stage hot water circulating pumps, reduced viscosity wil: — increase the internal leakage losses; — reduce disc friction losses; — reduce hydraulic skin friction or flow losses. ‘The net effect of a reduction in viscosity due to higher, temperature will depend on specific speed and on the design details of the pump. Where substantiating data are available, performance data from a cold water test may be adjusted to hot water operating conditions on the basis of the following formula: a no 2) Where: Efficiency at test temperature, decimal value; m= 18 Tor = Efficiency at’operating temperature, deci- ‘mal value; Vor = Kinematic: viscosity at operating tempera- ture, mm?/s; ve = Kinematic viscosity at test temperature, mms; x = Exponent to be established by manufac- turer's data (probably in the range of 0.01 t0.0.1). Example: (Metric) Typical efficiency adjustment for increased temperature. A test on water at 37.8°C. resulted in an efficiency of 80%. What will be the probable efficiency at 17°C? Ror = 1-c1-na( 2, nog = 4-(4- 00 (225), 1~(0.2)(.868), Not Mor = -826 = 82.6% Example: (US units) Typical efficiency adjustment for increased temperature. A test on water at 10°F resulted in an efficiency of 80%. What will be the probable efficiency at 350°F? Not = tno (2Y, (00000185)? Nor = 1 (1 80)( ener Mop = 1~(0.2)(.868), Nor = 826 = 82.6% 1.6.5.8.10 Performance test correction for specific weight variations. Ifthe test is run with a liquid of different specific weight from that of the field installation, there will be a revision in required input power which will be determined as follows, x@ (Pa = Poy xG There is no change in efficiency.Sealless centrifugal pumps incur significant eddy cur- rent losses which are not affected by specific weight variations. Power correction for installation specific weight different from test specific weight is made as follows: (PEO) + EC, Where: P, = Power for a specific weight on test in kW. (bhp); P2 = Power for a specific weight on installation in KW (bhp); EC, = Eddy current losses on-test in kW (bhp), 1.6.5.8.11 Performance test correction for viscosity variations Viscosity has a very definite effect on the operating conditions of the pump with respect to head, rate of flow, efficiency and input power. Pumps for viscous service, which are tested with water, will require cor- rections to approximate the performance with the vis- cous liquid. (See ANSV/HI 1.3-2000, Centrifugal Pump Operation.) ‘Thermometer Dampening Valve — Throtting Suction Fiow Meter it Located i Constant Lovel Vanes Booster Pump may be installed if additonal suction pressure Straightening is required \ ————— Return to sump Discharge HI Centrifugal Pump Tests — 2000 1.6.5.9 Performance test correction for solids in ‘suspension - Solids in suspension affect the operating performance of the pump in varying degrees, depending on the per- centage and nature of the solids. No definite correc- tions can be recommended, 1.6.5.10 Report of performance test All parties to the test shall be furnished a copy of the performance curve at constant speed. 1.6.6 Net positive suction head required test (optional) 1.6.6.1 NPSHR test objective To determine the NPSH required (NPSHR) by the pump. 4 2. NPSHR test arrangements ‘Three typical arrangements are shown for determining the NPSHR characteristics of pumps. In the first arrangement, Figure 1.119, the pump is supplied from a constant level supply through a throttle valve which is followed by a section of pipe containing straightening vanes or a minimum of seven diameters, Pressure Gauge —— Dampening Device | Flow Meter Located in Discharge Discharge Control Vai, or => ‘Adjustable Spring Loaded Back Pressure Valve or Adjustable Choke Valve Heat exchanger, eared —/ =] =f Note: Sf Position of these ‘devices may be reversed insome satupe, Figure 1.119 — Suppression type NPSH test with constant level sump 19HI Centrifugal Pump Tests — 2000 of straight pipe to straighten flow. This arrangement dissipates the turbulence produced by the throttle valve and makes possible an accurate reading of suc- tion pressure at the pump inlet, This simple arrangement usually is satisfactory for NPSHR greater than 3 meters (10 feet), although the- turbulence at the throttle valve tends to accelerate the release of dissolved air or gas from the liquid which, takes place as the pressure on the liquid is reduced. A test made with this arrangement usually indicates higher NPSHR than that which can be expected with, deaerated liquid In the second arrangement, Figure 1.120, the pump is supplied from a sump in which the liquid level can be varied to establish the desired NPSH. This arrange- ment provides an actual suction lift and hence more nearly duplicates operating conditions of pumps on. water service. Care should be taken to prevent vortex- ing as liquid level is varied. The priming connection, should be installed above the eye of the impeller either in the suction pipe or on the pump. In the third arrangement, Figure 1.121, the pump is supplied from a closed tank in which the level is hed constant and the NPSHA is adjusted by varying the air or gas pressure over the liquid, by varying the temper- ature of the liquid, or by varying both This third arrangement tends to strip the liquid of dis- solved air or gas. It gives a more accurate measure- ment of the pump performance uninfluenced by the — Priming connection t ° Suction _ F 4, Remaindar of system | same as Figure 1.117 Discharge | or 3.119 Go (7 Witer ove! variance optional bat: spacing between 2) sition and discharge pipes io TF, te equalto or greater than 6 times the sum ofthe nominal UD pipe diametars. Wen spacing ZL) iat be reduced, a bale 28 Shown required Figure 1.120 — Level control NPSH test with deep ‘sump supply 20 release of air or gas. This arrangement more nearly duplicates service conditions where a pump takes its, supply from a closed vessel at or near its vapor pres- sure. It is also acceptable to test with a closed loop without the closed tank on the suction side In each of these arrangements, water shall be used as, the test liquid. Aeration shall be minimized by taking the following precautions: — submerged return lines; — reservoir sized for long retention time to allow air to escape; — inlet ine property located to prevent vortexing; — reservoir baffles to isolate inlet from return line; — tight pipe joints and stuffing boxes to guard against air leakage into the system. 1.6.6.3 NPSHR test procedure ‘The cavitation characteristics of a pump can be deter- mined by one of the following procedures: Using one of the test arrangements shown, the pump, is run at constant rate of flow and speed with the suc- tion condition varied to produce cavitation. Plots of head shall be made for various NPSH values. Gas Pressure Heat Exchanger _ Flow Distributor Heating or Cooling Coil Figure 1.121 — Vacuum and/or heat control NPSH test with closed loopAs NPSHA is reduced, a point is reached where the curves break away from a straightline trend, indicat- ing a condition under which the performance of the ump may be impaired. The degree of impairment will depend upon the specific speed, size and service of the pump. Figure 1.122 shows results typical of a test for NPSH at flow rates both greater and less than nor- mal. The 3% drop in head is the standard to determine NPSHR. Another technique for determining the NPSH charac- teristics is to hold the speed and suction head (h.) constant and to vary the rate of flow. For any given suction head, the pump head may be plotted against rate of flow. A series of such tests will result in a family of curves, as shown in Figure 1.123. Where the curve for any suction head (h,) breaks away from the enve- lope by 3%, NPSHR is established. When it is impractical to conduct a test to the above criteria on large pumps due to size, rate of flow or faci ity NPSHA, a model test may be used to determine NPSHR values 4 3% 1 0, 100% cap, T —__* Le NPSHA, Total head Figure 1.122 — NPSH test with rate of flow held constant _7~ NPSHR values ‘3% reduction in total head Total head Rate of flow Figure 1.123 — NPSH test with suction head held constant HI Centrifugal Pump Tests — 2000 NPSHR characteristics. The relationship between model results and predicted full-size characteristics is desoribed in Section 1.6.13, Accurate determination of the cavitation point requires. careful control of all factors which influence the opera- tion of the pump. A minimum of five test points brack- ‘eting the point of change shall be taken, and the data plotted to determine when the performance breaks: away from that with excess NPSHA. Any change in Performance, either a deficiency at a given rate of flow, or change in sound or vibration, may be an indication of cavitation. But because of the difficulty in determin- ing just when the change starts, a drop in head of 3%, Which is the standard value in determining NPSHR, is accepted as evidence that cavitation is present. The 3% head drop is based on the first stage head for multi-stage pumps. The NPSHA value required to properly establish the non-cavitating performance of a pump should be determined from prior full-scale or model tests of the specific pump in question. If no such prior test results are available, a recommended NPSHA value of twice the predicted NPSHR, for rated flow rates greater than 85% of the best efficiency point, or an NPSHA value of at least two and a half times the NPSHR, for rated flow rates below 85% of the best efficiency point, is recom mended for maximum assurance. It should be noted that the average pump will give full performance at NPSHA values only 1.3 times the NPSHR value at flow rates above 85% of the best efficiency point and 1.7 times the NPSHR value at flow rates below 85% of the best efficiency point. Accordingly, the test per- formed at constant rate of flow, as shown in Figure 1.124, should begin with the non-cavitating pertor- mance NPSHA value established above, or greater. When testing with water, an accurate temperature measurement usually is sufficient to establish the vapor pressure, but the degree of aeration of the water, may have a considerable influence on performance. Consistent results are more readily obtained when the water is deaerated. ‘Cases may arise in which the limitations of the factory test facilities may preclude the securing of sufficient NPSHA to produce the installation NPSHA. In such cases, the NPSHR can be obtained by an increase in the pump speed with a corresponding increase in Pumping head and flow rate instead of by a reduction in NPSH available: a) Correction to specified speed for net positive suc- tion head (PSH): 2HI Centrifugal Pump Tests — 2000 b) Head 22 nest, = (%2F NPs, Where: NPSH; = Net positive suction head at test speed; PSH, = Net positive suction head at specified speed; ny = Test speed in rpm; ing = Specified speed in rpm; Q, = Test rate of flow; = Rate of flow at specified speed; NPSH — Experimental deviation from the square law. The affinity relationships define the manner in which head, rate of flow, input power, and NPSHR vary in a centrifugal or axial flow pump with respect to speed changes. If a pump operates at Or near its cavitation limit, other factors also have an effect, and the limiting NPSHR value may vary other than as the square of the speed. Some of these factors are: thermodynamic effect on the vapor pressure of the liquid, change in surface tension, and test differences due to the relative air Content ofthe liquid. Fa Atrates of fow 85% yp ores oF BER 7 | won |. zsxwon || J Airates of tow reater than | 85% of BEP, NPSH test at constant rato of ow Recommended NPSHA range for NPSHR test when no previous data on pumps. {ul performance is available. Figure 1.124 — NPSH test with flow rate held constant If the manufacturer can demonstrate that, with a given pump under particular conditions, an expo- nent different than the square of the speed exists, such exponent may be recognized and used accordingly. 1.6.6.4 NPSHR test suction conditions ‘The total suction head is to be determined as specified in Section 1.6.3.12.4 ‘The NPSHA on the test stand shall exceed the NPSHR of the pump with sufficient margin throughout the operating range to ensure that it wll have no effect ‘on the pump performance. See Section 1.6.3.12.10 for a description of NPSHA. For pumps in free-surface systems, the approach must be free of obstructions. The flow towards the pumps must be uniform and free of eddies and vorti- ces. Intake structures should be designed as described in the ANSI/HI 9.8-1998, Pump Intake Design. 1.6.6.5 NPSHR test records Complete written or computer records of all data rele- vant to the NPSHR tests shall be kept by the test facil- ity and available to the purchaser for a minimum of two years (see sample data sheet on page 14) This information should include: a) Specified NPSHR and NPSHA; b) Height of suction gauge, above or below the datum line; ©) Inside diameter of pipe at location of suction pres- sure tap; d) Observed data (each run); water temperature; suction pressure; shaft speed; discharge pressure: rate of flow. e) Type of test setup;f) Type of flow meter and calibration; 9) Type, number and calibration of pressure gauges; h) Note any abnormal observation (noise, vibration, etc.) i) Identification of materials at liquid end of pump; i) Type and serial number of pump and driver; k) Date of test; |) Identity of personnel in charge. 1.6.6.6 Report of NPSHR test All parties to the test shall be furnished a copy of the NPSHR curve or curves as described in Section 16.6.3. 1.6.7. Mechanical test (optional) 16.7.1, Mechanical test objective ‘To demonstrate the satisfactory mechanical operation of a pump, at the rated conditions, including: vibration levels; lack of leakage from shaft seals, gaskets, and lubricated areas; and free running operation of rotating parts. When specified, bearing temperature stabiliza- tion will be recorded ‘These tests do not apply to submersible pumps as described in ANSW/HI 1.1~1.2-2000 Figures 1.7 and 18. References to shaft seal do not apply to sealless pumps. 1.6.7.2 Mechanical test setup ‘The test setup shall conform to the requirements of Section 1.6.5.5 where applicable, and the test liquid shall be clear water. In addition, instrumentation shall be added to measure the following: a) Vibration at the pump bearing housing, in two directions perpendicular to the shaft plus the axial direction, b) Temperature of both bearings or bearing housings. ¢) Leakage from mechanical seals, gaskets, and bearing lubricant. Visual observation is sufficient for all leakage. HI Centrifugal Pump Tests — 2000 ) Oil temperature, when oil sump is used. 1.6.7.3. Mechanical test operating conditions. ‘The mechanical test shall be conducted under the fol- lowing operating conditions: a) Shaft speed - as required to meet rated conditions, as specified in the customer's order. Facility 60 or ‘50 hertz speeds may be used when customers hertz are not available, or as agreed to by customer. b)_ Rate of flow - the rated rate of flow for which the pump is sold, or as adjusted to a speed other than contract by Section 1.6.5.8.8. ©) Suction pressure - as available from the test facility. 4) Liquid temperature - at ambient condition. ) Ambient air temperature. 1.6.7.4 Mechanical test instrumentation 1.6.7.4.1 Vibration Vibration instruments can be either hand held or rigidly attached to the pump. The sensor(s) shall be velocity type designed to read the nominal RMS velocity with- out filtering to specific vibration frequencies. Readings ‘can be taken manually or with recording instruments 1.6.7.4.2 Temperature Temperature instruments can be any recognized tem- perature sensor such as pyrometers, thermometers, thermocouples and the like. They shall be capable of measuring the metal temperature on the outside of the housing of both bearings, and may be hand held or rig- idly attached to the bearing housing. The top center ‘over the bearing is usually the location of the highest temperature. Where temperature sensors are built into the pump, they shall be used instead of sensors on the bearing housing. If buit-in, they must be at a location where temperature is of interest. 4.6.7.5 Mechanical test procedure The pump rate of flow and suction pressure shall be set per Section 1.6.7.3. The pump shall be operated for a minimum of 10 minutes, and the following obser- vations made and data recorded: a) Leakage from shaft seals, gaskets, mechanical seal piping, and bearing housing{s) 23HI Centrifugal Pump Tests — 2000 b) Vibration level at both inboard and outboard bear- ings, in two directions perpendicular to the shaft plus the axial direction. Only the nominal RMS velocity values need be recorded. Refer to the lat- est HI Standard for acceptable values, ©) Bearing temperatures at both inboard and out- board bearings shall be recorded. When specified, the pump shall be operated until the bearing tem- perature stabilizes. See ANSI/HI 1.4-2000, Cen- trfugal Pumps, Section 1.45.23, for the temperature stabilization procedure, d) Rubbing of rotating parts shall be checked for by listening for unusual or excessive noise, and observing the coast down of the pump when power is cut off. Torque readings or other changes in similar instrument readings can also indicate rubbing, e) Liquid temperature and ambient air tempera- ture shall be taken manually or with recording instruments 1.6.7.6 Mechanical test acceptance levels ‘The mechanical performance is considered accept- able when each of the following is achieved: ) Vibration levels on both bearings in any direction do not exceed the allowable limits specified in or {as specified on the order document. b) Temperature of both bearings’ housing surface does not exceed the pump manufacturer's stan- dard for the product as established prior to test. c) Mechanical seals may have an initial small leak- ‘age, but shall have no visible leakage when run- ning at test operating conditions for a minimum of 10 minutes. When shut down, there shall be no visible leakage from seals for five minutes with the test suction pressure applied. The purpose of this testis to ensure that the entire seal (cartridge) has been properly installed. Soft packing shall have no more than 12 drops per minute leakage for a 25-mm (‘-inch) shaft up to ‘3500 rpm. For larger shafts or higher test speeds and pressures, allowable leakage shall be increased proportionately with shaft diameter speed and pres- ‘sure of as agreed to by the purchaser. There shall be no visible leakage through pres- sure containment parts, gaskets, seal recirculation 24 piping, bearing housing, etc. Minor leakage at ump suction and discharge flanges shall not be cause for rejection since these joints are discon- nected and reconnected in the field, d) Rubbing of rotating parts shall not be apparent from excessive noise during operation nor abrupt ‘stopping of the pump when power is cut off. 1.6.7.7 Mechanical test records ‘The following data shall be recorded in either written ‘or computer form and kept on file, available to the pur- chaser by the test facility, for two years. a) The manufacturer's serial number, pump type and size, or other means of identification of the pump. b) Vibration levels on both bearings in two directions perpendicular to the shaft plus the axial direction. ©) Temperature at both bearings. ) Ambient air temperature €) Leakage from the pump as observed at the following: — Pump pressure containment components = Pump gaskets = Mechanical seal piping = Mechanical seal(s) or packing = Bearing housing(s) f)Free-running rotating parts 9) Date of test fh) Name of test technician 4.6.8 Priming time test Priming tests should only be conducted on pumps designed for this application. 1.6.8.1 Pri pumps ing time testing of self-priming In addition to the standard performance tests, as out- lined in preceding paragraphs, it may be desirable to test self-priming pumps to determine the priming time. For this test, the suction line shall be substantially thesame as that shown in Figure 1.125. Static lift between the eye of the impeller and the liquid level shall not be less than 3 meters (10 feet). No check or foot valve shall be installed in the suction piping, In making this test, proceed as follows: — Start the unit: The priming time then shall be the total elapsed time between starting the unit and the time required to obtain a steady discharge gauge reading, or full flow through the discharge nozzle. During this phase of the test, the dis- charge pipe must be vented if the priming system is the recirculating type. This will prevent a back pressure from being developed as the result of the accumulation of gas. If the unit is equipped with a priming pump of the separate type, it wil be nec- essary for the discharge pipe to be sealed with a column of water that will prevent air being drawn from the discharge side of the unit. 1.6.8.2 Pi 1g time conversion factor If a suction pipe is used which is different in size than the pump suction size, it is necessary to compute the performance for the normal size of pipe. Use the following equation’ True priming time = ui juction size\? Measured priming timex a el ‘actual pipe size i suc cate D- DAMETEROF IPE Figure 1.125 — Suction line for static lift test HI Centrifugal Pump Tests — 2000 1.6.8.3 Determination of maximum developed vacuum by means of dry vacuum test ‘The test procedure is: With the unit in operation and delivering full flow, close gate valve in the suction line. The reading on the vacuum gauge will then be the maximum developed vacuum. The gate valve shall be located on the pump flange so maximum vacuum capability can be credited to the pump. 1.6.9 Measurement of rate of flow 1.6.9.1 Introduction ‘Any flow measuring system may be used for measur- ing pump rate of flow. However, it must be installed so that the entire flow passing through the pump also asses through the instrument section so that the instrument can measure rate of flow with an accuracy of + 1.5% at BEP. Rate of flow instruments are classified into two func- tional groups. One group primarily measures batch quantity; the other primarily measures rate of flow. 1.6.9.2 Rate of flow measurement by weight Measurement of rate of flow by weight depends upon the accuracy of the scales used and the accuracy of the measurement of time. A certification of scales shall, become part of the test record, or in the absence of certification, the scales shall be calibrated with stan- dard weights before or after the test. Time interval for the collection period shall be measured to an accuracy of one-quarter of 1%, 1.6.9.3 Rate of flow measurement by volume Measurement of rate of flow by volume is done by measuring the change in volume of a tank or reservoir during a measured period of time. The tank or reser- voir can be located on the inlet or discharge side of the pump, and all flow into or out of the tank or reservoir must pass through the pump. In establishing reservoir volume by linear measure- ments, considerations shall be given to the geometric, regularity (flatness, parallelism, roundness, etc.) of the reservoir surfaces, dimensional changes due to 25HI Centrifugal Pump Tests — 2000 thermal expansion or contraction, or deflection result- ing from hydrostatic pressure of the liquid Liquid levels shall be measured by means such as hook gauges, floats and vertical or inclined gauge glasses. In some locations and under some circumstances, evaporation and loss of liquid by spray may be signifi- cant and may be greater than the effects of thermal expansion or contraction. Allowance for such loss must be made, or the loss prevented. 1.6.9.4 Rate of flow measurement by head type rate meters Measurement of rate of flow by head meters is done by introducing @ reduced area in the flow stream which results in a reduction in gauge head as the velocity is increased. The gauge head differential is measured and used to determine the rate of flow. The meters dis- cussed in Sections 1.6.9.4.1, 1.6.9.4.2 and 1.6.9.4.3 use this principle. Meters falling within this classification and acceptable for rate’ of flow determination under this standard, when used as prescribed herein, are venturis, nozzles and ofifice plates. For any such meter, compliance with this standard requires that a certified curve showing the calibration of the meter shall be obtained from the calibrating agency. This certification must state the method used in calibration and whether the meter itself was cali- brated, or whether calibration was obtained from an exact duplicate. ‘When a flow meter is used on the discharge, itis pref- erable to install it in the high pressure section between the pump and the pressure breakdown valve. If the working pressure of the meter is lower than the pump discharge pressure at shut off, it may be installed downstream of the pressure breakdown valve, with a back pressure valve located downstream of the flow meter to ensure that the pressure will stay above vapor pressure during operation and be free of cavita- tion in the high-velocity section of the meter. ‘These precautions are stipulated to ensure uniform flow velocity within + 20% at the meter inlet and stable flow at the downstream pressure taps. If there is a question as to whether or not uniform flow has been obtained, it shall be checked by a velocity head traverse of the pipe immediately preceding the meter to ensure symmetrical velocity distribution within the pipe. The pipe for one diameter preceding the upstream pressure taps shall be free from tubercles or other sur- face imperfections which would establish a local dis turbance inline with these openings. The pressure tap ‘opening shall be flush with the interior of the pipe or meter element as appropriate and shall be free of burrs (see Figures 1.126 and 1.127). 1.6.9.4.1 Rate of flow measurement by venturi meter ‘To ensure accurate results in the measurement of flow rates with venturi meters, certain minimum lengths of straight pipe are required upstream of the meter. Table 1.21 shows these minimum lengths, expressed ‘in terms of pipe diameters, Brass plug D=3t06mm (1/8 to 1/4 in.) F_| ‘Nipple connects here Approx.2 rad, jure 1.126 — Pressure tap opening Nipple connects here Pipe coupling D=s06mm t=} { (178 to 1/4 in) F ‘Weld D Approx. rad. Figure 1.127 — Welded-on pressure tap openingHI Centrifugal Pump Tests — 2000 Table 1.21 — Straight pipe required following any fitting before venturi meter in diameters of pipe Meter ratio B (throat to inlet diameter) (One standard short radius elbow ‘Two elbows in same plane ‘Two elbows in planes at 90 degrees and with straightening vanes Standard C.1. flanged reducer Standard C.I. flanged increaser Globe valve — with straightening vanes Gate valve — 0.2 open Gate valve — 0.5 open Gate valve — full open 04 05 os | o7 08 2 3 4 6 3 4 6 8 3 4 5 7 5 75 10 13, 2 3 45 6 4 6 9 12 4 6 9 2 3 4 6 8 05 1 2 3 1.6.9.4.2 Rate of flow measurement by nozzles To ensure accurate results in the measurement of rate of flow with nozzle type meters, a length of straight pipe is required preceding and following the nozzle Tables 1.22 and 1.23 show the length of straight pipe required, NOTE: A centrifugal pump discharging directly into a venturi meter should have at least 10 diameters of straight pipe between it and the meter. 1.6.9.4.3 Rate of flow measurement by thin ‘square-edged orifice plate ‘Whenever possible, the orifice plate should be cali- brated in place in the piping system by weight or vol ume. When this is not possible, a certified curve showing the calibration of the orifice plate shall be obtained. This certification shall conform to require- ments given in Section 1.6.9.4 and shall, in addition, indicate the exact location and size of pressure taps, ‘which are then to be duplicated in the test installation ‘To ensure accurate results in the measurement of rate of flow with orifice type meters, a length of straight pipe is required preceding and following the orifice plate. Tables 1.22 and 1.23 show the length of straight pipe required, expressed in terms of equivalent pipe diameters. 1.6.9.5 Rate of flow measurement by weirs This is done in open channel flow by allowing the liquid to cascade over a dam through a sharp crested con- traction in the dam, which results in an increase in velocity at the contraction. The drop in liquid level at, the contraction is measured and used to determine rate of flow. The rectangular sharp-crested weir with smooth verti- cal crest wall, complete crest contraction, free over-fall and end contraction suppressed is acceptable for rate of flow determination under this standard. It may be Used for either factory or field testing, For a detailed discussion of weirs, their construction, installation and operation, the user is referred to Fluid Meters, Their Theory and Application, a report of the ASME Research Committee on Fluid Meters. 1.6.9.6 Rate of flow measurement by pitot tubes. A pitot tube is a double tube, one within the other. Rate of flow is measured by inserting the tube so that it Points into the flow stream. The inner tube measures aHI'Centrifugal Pump Tests — 2000 Table 1.22 — Straight pipe required following any fitting before nozzle or orifice plate meter in diameters of pipe Meter ratio (throat to inlet diameter) 02 | 03 | 04 | os | o6 | o7 | o8 Tee or wye within ine flow 6 | 6 |6s| 7 | es | 105| 14 One elbow, branch flow thru tee or wye, or flow from 6 | 6 |65) 7 | 9 | 13 | 205 drum or separator Globe valve — wide open 9 | 9 | 95 | 105) 13 | 15 | 21 | Gate valve — wide open 6) 6|6 6 | 75| 95 | 135 Two or more short radius elbows or bends inthesame | 7.5 | 75 | 85 | 105/135 | 18 | 25 plane | Two or more long radius elbows or bends in the same 6 | 6 )65| 8) | 16 23 plane ‘Two short radius elbows or bends in diferent planes 145 | 16 | 175 | 205 | 245 | 30 | 40 Two long radius elbows or bends in different planes 7 | 8 | 10 | 12] 16 | 2 | 93 NOTE: A centrifugal pump pumping directly into a nozzle or orifice should have at least 10 diameters of straight pipe between it ‘and the meter. Table 1.23 — Straight pipe required following downstream pressure tap of a nozzle or orifice plate meter before any fitting in diameters of pipe Meter ratio 6 (throat to inlet diameter) 02 | 03 | o4 | os | os | o7 | 08 | Gate valve —wide open 7 Jo}ololo|o}jol|o Wwe }o}o]oj]of}o}o 4 Tee o}o}o]o]o|as| 4 Expansion joint o}ol]o]o}|o|35| 4 45 degree elbow o|o}o)o0/35|35) 4 Long radius elbow or bend | 2 |as}2s]| 3 |as]as| 4 | Regulators, control valves, and partly throtled gate | valves 6/e6/e6le6}]e6|c6]e 28the velocity head and gauge head of the liquid, and the other tube with holes in the outer wall measures. gauge head only. The head differential is measured and used to determine velocity head which in tum determines flow rate. Where it is impossible to employ one of the methods described above, the pitot tube is often used. When the flow conditions are steady during the time required to make a traverse that has variations less than + 0.5%, the flow may be determined with a fair degree of accuracy. ‘The procedure set forth in the ANSVASME PTC 18- 1992 Hydraulic Turbines is recommended. 1.6.9.7 Other methods of flow rate measurement When the methods of flow rate measurement described above are not applicable, there are other methods not included in this standard which may be utiized, provided the accuracy of the instrument as described in Section 1.6.5.4.2 can be demonstrated. 1.6.10 Head — measurement The units of head and the definition of total head and its component parts are covered in Section 1.6.3.12. 1.6.10.1 Pressure tap location 1.6.10.1.1. Pressure tap location for level “A” tests ‘The taps shall be located in the piping a minimum of two (2) diameters of straight pipe before the suction flange and after the discharge flange. Figure 1.128 shows a single tap connection. To provide uniform velocity before the suction pressure tap, a straight pipe unvarying cross section of at least five pipe diameters Vent To gauge Drain Figure 1.128 — Single tap connection HI Centrifugal Pump Tests — 2000 in length as a minimum’shall precede the gauge tap, unless otherwise agreed to by the pump manufacturer and the purchaser. If the pipe friction loss between the pump suction or discharge flange and the point of instrument connec- tion exceeds 0.1% of the pump head, adjustment shall be made to the total head. The friction factor used for the friction loss calculation shall be based on the appro- priate roughness factors for the actual pipe section. 1.6.10.1.2 Pressure tap location for level “B” tests (On pumps with tangential discharge, the taps may be located at the suction and discharge flange of the pump, provided V/2g is less than 8% of total head ‘The following precautions shall be taken in forming ‘openings for pressure-measuring instruments and for making connection: ‘The opening in the pipe shall be flush with and normal to the wall of the water passage, ‘The wall of the water passage shall be smooth and of unvarying cross section. For a distance of at least 300 mm (12 inches) preceding the opening, all tubercles and roughness shall be removed with a file or emery cloth, if necessary. ‘The opening shall be of a diameter from 3 to 6 mm (‘/g to '/4 inch) and a length equal to twice the diameter. ‘The edges of the opening shall be provided with a suit- able radius tangential to the wall of the water passage and shall be free of burrs or irregularities. Figures 1.126 and 1.127 show suggested arrangements of taps or orifices in conformity with the above, Where more than one tap of orifice is required at a given measuring section, separate connections, prop- erly valved, shall be made and separate instruments shall be provided, When multiple openings (see Figure 1.129) are agreed upon as an alternative, they shall not be con- ected to @ head-measuring instrument unless there will be no more than 1% pressure variance between Pressures at each opening. If pressure variance exceeds 1%, they shall be measured separately and averaged. ‘All connections or leads from the opening tap shall be free of liquid leakage. These leads shall be as short 29HI Centrifugal Pump Tests — 2000 ‘and direct as possible. For the dry-tube type of leads, suitable drain pots shall be provided and a loop shall be formed of sufficient heights to keep the pumped liq- Lid from entering the leads. For the wet-tube type of leads, vent cocks for flushing shall be provided at any high point or loop crest to ensure that there are no leaks. Suitable dampening devices may be used in the leads. 1.6.0.2 Head measurement by means of pressure gauges The definitions in Section 1.6.3.12 apply to Figure 1.130 where temperature effects are negligible. ‘The quantities (Z4) and (Z,) are negative if the corre- sponding values are below the datum elevation. Figure 1.129 — Loop manifold connecting pressure taps, When the head(s) at the gauge connection(s) is below ‘atmospheric pressure and the lead line is completely filled with air, Z is then measured from datum to the corresponding gauge connection instead of the gauge centerline. The air-filled line should be drained before a reading is made in order to avoid the affect of liquid in the line, Manometers, pressure transducers and other pres- ‘sure devices can be used in place of pressure gauges. However, the basic expression for total head and the placement of the instruments is the same. 1.6.11 Power measurement Pump input power may be determined by transmission dynamometers, torsion dynamometers, strain gauge type torque measuring devices or other sufficiently accurate measuring devices which result in measure- ment accuracy of + 1.5% at the specified condition, Readings of power shall be taken at the same time that rate of flow is measured. When pump input power is determined by transmis- sion dynamometers, the unload dynamometer shall be statically checked prior to the test by measuring the load reading deflection for a given torque and by tak- ing the tare reading on the dynamometer scale at rated speed with the pump disconnected. After the test, the dynamometer's tare value shall be rechecked to ensure that no change has taken place. In the event of a change of 1.0% of the power at BEP, the test shall be rerun. An accurate measurement of speed within 0.3% is essential : Z4 connettion ‘Os || cm v Pump Figure 1.130 — Gauge connections 30The use of calibrated dynamometers or motors is an acceptable method for measurement of pump input power. Calibration of the dynamometer shall be conducted with the torsion-indicating means in place. The indica- tor shall be observed with a series of increasing load- ings and then with a series of decreasing loadings. During the taking of readings with increasing loadings, the loading is at no time to be decreased; similarly, during the decreasing loadings, the loading shall at no time be increased. The calculation of output shall be based on the average of the increasing and decreas- ing loadings as determined by the calibration. Ifthe dif- ference in readings between increasing and decreasing loadings exceeds 1%, the torsion dynamometer shall be deemed unsatisfactory. Dynamometers shall not be employed for testing Pumps with a maximum torque below one-quarter of the rated dynamometer torque. When strain gauge type torque measuring devices are used to measure pump input power, they shall be call brated annually, wth their accompanying instrumenta- tion. After the test, the readout instrumentation balance shall be rechecked to ensure that no appre- ‘iable change has taken place. In the event of a ‘change of 1.0% of the power at BEP, the test shall be rerun. Calibrated laboratory type electric meters and trans- formers shall be used to measure power input to all motors, Calibrated electric motors are satisfactory to deter- mine the input power to the pump shaft. The electrical input to the motor is observed and the observations are multiplied by the motor efficiency to determine input power to the pump shaft. Noncalibrated pur- chased, furnished or facility motors may be used when ‘agreed upon by the purchaser. ‘The use of transmission dynamometers and motors that have been calibrated by acceptable methods pre- viously covered shall be considered as giving the actual input power to the pump, 1.6.12 Speed measurement Test speeds for centrifugal pumps may be in the range of a few hundred to thousands of revolutions per minute. Since the pump test data will be taken under steady state conditions, the maximum permissible short-term speed fluctuation shall be no more than HI Centrifugal Pump Tests — 2000 0.3%, The instruments shall also be capable of mea- suring speed with an accuracy of # 0.3%. The speed measuring methods described, therefore, are those which, at moderate speeds, will give a measure of the average speed over an interval of from less than one second up to two minutes, depending on the type of instrumentation ‘The revolution counter and timer method, as its name implies, involves the counting of the number of revolu- tions over an interval of time. A major source of error is inexact synchronization of counter and timer. In cases where this is automatic (e.g.. digital tachometers), accuracy is achieved over a time interval of a few sec- fonds. In the case where a handheld counter and stop- watch are used, the timing interval should be about ‘wo minutes. During this time the speed must be con- stant, and slippage of the counter on the shaft must be avoided. The stopwatch shall be periodically checked against a standard timer. ‘Tachometers provide a direct reading of speed aver- aged over a fixed time interval. Some types automati- cally repeat the reading process; handheld units must be reset manually. The above comments regarding uniform speed and slippage pertain here also. A tachometer shall be checked periodically against a counter and stopwatch. Frequency responsive devices have the advantage of not requiring direct contact with the motor or pump shaft, and hence impose no additional load on the motor. The vibrating reed type is useful only when the shaft is completely inaccessible. Electronic units may be converted to read rpm directly using a shaft- ‘mounted gear and a non-contacting magnetic pickup. Since normally the line frequency (which determines the timing interval) is 60 Hz + 0.1%, the method is accurate to the nearest rpm, as read on a digital read- ‘out. The timing interval may be set as short as 0.1 sec- ond, thus making any speed fluctuations readily discernible Most stroboscopes are limited in accuracy due to uncertainty in the precision of the strobe frequency. ‘The only approach suitable for pump test purposes is to use the strobe to determine motor slip under load relative to synchronous speed, using a stopwatch to time the slippage while driving the strobe at line fre- quency (which is known to the accuracy given above and can be determined with even greater precision for the time and location of the test). 34HI Centrifugal Pump Tests — 2000 1.6.13 Temperature measurement and instruments ‘Temperature shall be measured as close to the pump inlet as possible. The temperature measuring device shall have no effect on the measurements of pressure and flow rate. All temperature sensing instruments shall be properly Supported and installed directly into the liquid stream, When this is not feasible, wells filed with suitable intermediate conducting materials may be used. ‘Temperature may be measured by etched stem, liquid- in-glass thermometers, thermocouples or resistance thermometers. Thermocouples and resistance ther- mometers, when employed, require potentiometric instruments. 1.6.14 Model tests 1.6.4.1 Model test procedure In many installations involving large pumps, mode! tests are often necessary. Even when it might be feasi- ble to test the large unit in the factory, a model may often be tested with greater accuracy and thorough- ness. By adopting a standard size of model for various Pumps, comparable performances can be obtained. The model impeller should be not less than 300 mm, (12 inches) outside diameter. The exact model-to-pro- totype ratio shall be selected by the builder. Compari- ‘sons between model tests are valid only when all dimensions of the mode! hydraulic passages to proto- type are in accordance with model-to-prototype ratio. Testing models in advance of final design and installa- tion of a large pump not only provides advance assur- ance of performance but makes design alterations possible in time for incorporation in the prototype pump. Not all installations lend themselves to a practical model investigation. The pumping of water carrying considerable quantities of sand or other foreign mate- Fial is not readily reproduced in model operation. This, standard, therefore, is limited to the pumping of clear water, free from abnormal quantities of air or solids, both in field installation and factory tests. The effects of wear and deterioration, the effects of free-surface disturbances in open channel sumps, interference between neighboring units, and peculiar problems caused by abnormal settings are covered by model ‘sump tests, ‘The model hydraulic passages should have complete geometric similarity with the prototype, not only in the pump proper, but also in the intake and discharge con- duits as specified above for tests on full-size pumps. If cavitation tests are not available, the NPSHA should be such as to give the same suction specific speed as the prototype. As previously explained, ifthe prototype NPSHR is known to be safely below the NPSHA, then a higher NPSHA can be used for the model tests, although it is preferable to maintain the same value. There is danger of air separation destroying similarity relationships if the absolute pressure is reduced too low. Consequently, condensate pumps should not be modeled. If corresponding diameters of model and prototype are 1D, and Dz respectively, then the model speed n; and model rate of flow Q,, under the test head H,, must agree with the relationships: a er ng Dy ILAp, Q a (esl DaMH. The efficiency of the model will not, in general, be exactly equal to that of the prototype. In testing a model of reduced size, the above conditions being observed, complete hydraulic similarity may not be attained because of certain influences. For example, complete geometric similarity will not be obtained unless the relative roughness of the impelier and pump casing surfaces are the same. With the same surface texture in both model and prototype, the model efficiency will be lower than that of the larger unit. Fur- ther, itis generally not practical to model running clear- ances or bearing sizes. When such is the case, the model efficiency will be reduced. When a high degree of understanding exists between manufacturer and user relative to the comparison limi- tations encountered going from model to prototype, thought may be given to the practicality of increasing the prototype efficiency on the basis of model test results. However, this should be done only by mutual agreement before the job is let, on the basis of all the available test data of a similar nature. Numerous comparisons of prototype and model efft- ciencies, with consistent surface finish of models andprototypes, are necessary for a given factory to estab- lish a basis for calculating model performance to field performance. This calculation can be applied conve- niently according to the formula in use for turbines; namely tn ey tng LDy. ‘The exponent (x) is to be determined from actual data as described above. ‘The values for the exponent (x) have been found to vary between zero and 0.26, depending on relative surface roughness of model and prototype and other factors. Example (Metric): A single-stage pump designed to deliver 20,000 mm against a'head of 120 meters at 450 rpm and have an impeller diameter of 2 meters. This pump is too large for a factory test and, in place of such test on the actual pump, a model is to be tested at a reduced head of 100 meters. The model impeller is to be 0.5 meters in diameter. Determine speed and rate of flow for the above model test. Fepy tbe ebove iaonsties oy _ pBayphines 7” Loli) « ovo mde) (450[22][409]"°) - 164 rom Oy pDyyepHy 05 3, ~ Loa! a) or ov eles) Hi Centrifugal Pump Tests — 2000 os 8 = 1141 mm ‘The model pump should therefore be run at a speed of 1643 rpm delivering 1141 mh against a head of 100m, ‘To check these results, it will be noted that the specific, speed of the prototype is: = Q)08 ls = “Ha75 450(20,000)28 120078 = 1755 and the specific speed of the model will be: = 1643(1141)08 Is = —“aqg075 = 1755 ‘Therefore, the specific speeds are the same as required, Example (US Units): A single-stage pump designed to deliver 90,000 gpm against a head of 400 feet at 450 rpm and have an impeller diameter of 6.8 feet. This Pump is too large for a factory test and, in place of such test on the actual pump, a model is to be tested at a reduced head of 320 feet. The model impeller is to be 18 inches in diameter. Determine speed and rate of flow for the above model test. Apply the above relationships: a Bley or Dyes mo lle = 4501887320795 — ng = a50[S2][S22 7° = 1625 pm Q, eee Q Dz) Lp. or 33HI Centrifugal Pump Tests — 2000 a, = of Fes = or) [i Q, = 90,000 sey = 3920 gpm 400. ‘The model pump should therefore be run at a speed of, 1825 rpm delivering 3920 gpm against a head of 320, feet. ‘To check these results, it will be noted that the specific speed of the prototype i _. 0(Q)°5 _ 450(90,000)95 Ns pore “400075 1510 and the specific speed of the model will be: 1825(3920)5 N 3200.75 = 1510 ‘Therefore, the specific speeds are the same as required, 1.6.14.2 Model test at increased head Under special and unusual circumstances, it may be desirable to cary out factory tests at higher heads than the prototype head. This, for example, may be due to the limitations of available test motors or electri- cal frequency. In this case, all of the above consider- ations continue to apply. ‘The choice of using a model is based on balancing the cost benefits of a smaller model versus the manufac- turing and test accuracies. It should be pointed out, however, that with a reduced- size model, coupled with an increase in head, the increase in speed corresponding to the head increase tends to minimize the change in Reynolds number, that is, the product of flow velocity and linear dimen- sions of the model tends to approach equality with the same product in the prototype. This effect tends to restore dynamic similarity in model and prototype and to approach equality of efficiencies and other perfor- mance factors. With increased head, however, the preservation of the same suction specific speed value in the model as in the prototype must still be observed, and this value will assume increased importance, requiring an increase in submergence or reduction in suction lift in the factory test. The last mentioned requirement may result in another reason for the use of an increased head in the factory test. Cases may arise in which the limitations of the factory test setup may preclude obtaining sufficient suction lift to reproduce the prototype suction specific speed. In such cases, the required value can be obtained by an increase in the pumping head instead of by a reduction in suction head or increase in suction lift