Centrifugal Pump Performance Test

9/1/2020 Centrifugal Pump Performance Test
Inspection 4
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article useful? Performance Test
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Like and G+1 The centrifugal pump performance test is
buttons! conducted by pump manufacturer after Search this
completion of the assembly to prove the Site! More than 300
pump has the required specification as
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indicated in the pump datasheet and other
purchase documents.
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The performance test is conducted after

completion of casing inspection, casing
GENERAL
hydrostatic test, impeller, and rotor dynamic
THIRD PARTY
balancing. The NPSH test, mechanical
Third Party INSPECTION
running test, and final inspection are done
Inspection
after performance test. The vibration SERVICES
Vendor testing is carried out during performance test
Inspection and mechanical running test. You may also
want to review a general centrifugal pump CONTACT US
Factory
Acceptance Test inspection and test procedure.
Inspection and Let explain the performance test by an

Test Plan example. You are attending to the pump
Commodity manufacturer shop to witness a centrifugal
Inspection pump performance test which is a hold point
on the pump ITP. You review the pump
Industrial
approved datasheet and find following
Inspection
information:
Quality Control
https://www.inspection-for-industry.com/centrifugal-pump-performance-test.html 1/19
Plant Inspection
Coating
Inspection
Pre-Shipment
Inspection
FIX
EQUIPMENT
Rate flow = 238.5 m³/h (1050.08 Gal/Min)
Pressure Vessel
Heat Exchanger Rated Differential Head = 2690.28 m

(8826.37 feet)
Piping System
Industrial Valve Rated Power = 2985 KW (4003 HP)
Steam Boiler
Rated Efficiency = 68 %
Storage Tank
Process Heater Upon completion of the centrifugal pump

performance test, the pump manufacturer
provides you following performance curve.
ROTARY You need to match this curve with datasheet
specification to make sure the pump passed
EQUIPMENT
the performance test.
Centrifugal
Pump
Centrifugal
Compressor
Reciprocating
Compressor
Gas Turbine
Steam Turbine Let's start with head-capacity curve, we draw

a verticle line at 238.5 (in the horizontal
Fan & Blower
axis), and it will cross head-capacity curve,
then we draw a horizontal line from the cross
point, and it crosses the vertical axis at 2640.
E&I So the measured head at the 238.5 m³/h is

2640 meter.
EQUIPMENT
What was expected value in the datasheet?
Electric
It was 2690.28 m but the test result was
Generator
2640 m.
Electric Motor
What is the test result ( the head almost is
Power
50.28 meters less than required value)? The
Transformer
pump outperforming or underperforming?
Control Panel
The API 610 at table 18 says the head can
Switchgear
be +/- 3% of the rated value. The 3 % of the
Power Cable rated value (2690.28 x 3%) would be 80.7
which is greater than 50.28, the pump
underperforming but the test result is
I4I acceptable.
ACADEMY
Let's assess the power consumption; we
I4I Academy repeat the same process but this time with
Courses the power curve. The curve indicates the
consumed power at 238.5 m³/h is 2600KW
API Sourse
(power consumption was provided at the left
Inspector Fixed
side of the vertical axis). Compare 2600 KW
Equipment
with datasheet value which is 2985 KW.
API 510 Training
- Prep Course Obviously, the pump outperforming since
consumes less power. However, API 610
API 510 Exam
acceptance range is 4% it means the pump
Questions
Package test result would be satisfactory even if
consumes more than 4 % from what
API 570 Training indicated in the datasheet.
- Prep Course
API 570 Exam We also need to check the efficiency. The

Questions minimum efficiency in the approved
Package datasheet is 68 %. Check the efficiency
curve, the efficiency amount at the 238.5
CWI m³/h is 70%. So the pump is outperforming
Endorsement and gives higher efficiency than what
Course required in the datasheet.
ASME Training So the result of the centrifugal pump

Course performance test for the differential head,
power consumption, and efficiency is
ASME IX
satisfactory.
Training Course
I4I Academy The head value also shall be checked in shut

Contact off point but since this pump is high energy
pump, the centrifugal pump performance test
at the shut-off point (no flow at discharge
SERVICES valve) is not a requirement based on API
610.
Services
The above example was a simplified
example. The pump manufacturers usually
GET IN provide a tabulated format to make it easy
TOUCH for review.
About Us The manufacturers also simulate the test

result to actual field condition. The pump
Contact Us
might be designed for crude oil, but in the
Blog shop will be tested by the water. In such
cases, the attained values will be converted
Privacy Policy
to field condition by engineering calculation.
Subsequently, you need to check bearing

We will be updating housing and shaft vibration FFT spectrum
and growing this (Plot) at each data point from minimum to
site with more and
maximum flow to ensure the vibration values
more of industrial
are within acceptance range.
inspection related
articles.
The Pump NPSH Test (Net Positive Suction
Please subscribe to Heat Test) report also shall be verified
my monthly against approved datasheet values.
newsletter so you
don't miss a thing. The pump mechanical running test is
performed after successful completion of
performance and NPSH test.
Email
Now let deepen in the centrifugal pump

performance test by the understanding of
flowrate, total head, power, and efficiency.

Enter Your First
Name (optional)
What is the Flowrate and

I am at least 16
Head in Centrifugal
years of age. Pump Performance
I have read
Test?
and accept the
privacy policy. Volume flow rate (Q), also referred to as
capacity, is the volume of liquid that travels
I understand through the pump in a given time (measured
that you will use
in gallons per minute or GPM).
my information to
send me a
newsletter. It defines the rate at which a pump can push
fluid through the system. Flowrate is the first
Subscribe parameter specified by the process designer,
who determines the pump requirement on
the flowrate that the process needs to
function.
This 'rated' flowrate is normally expressed in

volume terms, and it is represented by the
symbol q, with units of cubic meters/ second
or GPM.
The static head of a pump is the maximum

height (pressure) it can deliver. The
capability of the pump at a certain RPM can

be obtained from its Q-H curve.
The pump manufacturers are interested in

providing pump performance curve in a way
that does not depend on to the pumped fluid
physical properties.
That is why they are using head instead of

pressure. The following formula converts
pressure to the head; H(meter) = 10.2 P/SG
or H(feet)= 2.3P/SG
Once the rated flowrate has been

determined, the designer subsequently
specifies the total head (H) needed at this
flowrate.
This is expressed in meter or feet and

represents the usable mechanical work
transmitted to the fluid by the pump.
Together q and H define the duty point.
The q/H Curve Test;
The test is carried out at a nominally

constant shaft speed, and the head (H)
decreases as flowrate (q) increases, giving a
negative slope to the curve. (See above H-Q
curve)
Look at the following sketch; this illustrates a

simple H-Q curve loop. The test engineer
changes the flowrate through discharge
control valve and takes measurement of
different variables and calculates the
corresponding head.
The first set of measurements is taken at

duty point (100 percent q). The valve is
opened to give a flowrate greater than the

duty flow (normally 120 or 130 percent q),
and further readings are taken.
The valve is then closed in a series of steps,

progressively decreasing the flow (note that
we are moving from right to left on the Q-H
curve). With some pumps, the final reading
can be taken with the valve closed, i.e. the q
= 0 or shut-off condition.
Once the test points are obtained, you can

now check against the acceptance criteria
requirements
Power Consumption in
Centrifugal Pump
Performance Test
The power consumption is measured at
different flowrates similarly, and the power-
flowrate curve is plotted. A wattmeter is
connected to motor power input, by
multiplying wattmeter amount at motor
efficiency the motor output power is
calculated at different flowrates. Through
these corresponding readings, the power-

flowrate curve is plotted.
The Efficiency-Flowrate
Curve at Centrifugal
Pump Performance Test
The efficiency-flowrate (ƞ-Q) curve can be
plotted based on measured values from
combination of H-q curve and P-q curve and
this formula ƞ=(P out of Pump)/(P input of
Pump)=ρgHQ/(P input of pump) (ρ is
density, g is gravitational acceleration, H is
Head and Q is Flowrate)
Pump efficiency (ƞ percent): the efficiency is

the ratio of transferred mechanical work of
the fluid to consumed power (P) in watts by
the pump.
The efficiency test; the efficiency is checked

using the same set of test measurements as
the q/H test. Pump efficiency is plotted
against q in above figure.
You may also review third party inspection

for centrifugal pump and pump inspection
and test plan articles as supplementary
information.
This content provides you with a sample

Centrifugal Pump Performance Test
Procedure in the manufacturing shop. The
procedure is very brief and general.
Centrifugal Pump Performance Test

Procedure
1.Scope
This description of procedure defines the

conditions for the hydraulic testing of
centrifugal pumps according to API Standard
610.
Scope of test, type of test, test class and

guarantee values are defined by
standardized test plans agreed between
pump manufacturer and pump purchaser.
2. Objective
Objective of the tests is the continuous

control of performance data as process
control, keeping the guarantees given
according to the supply agreement, testing of
relevant pump functions.
Preparation of test reports and test curves

according to the supply agreement as
integral part of the test documentation.
3. Standards and Other Regulations

Applicable
API 610
Manufacture Standard
4. Centrifugal Pump Performance Test

procedure
4.1 Testing Personnel
For the handling of the test beds, only

trained personnel is employed. The setting of
test data is done semi-automatically and
requires appropriate test experience and
accuracy.
4.2 Place and Time Of Testing
The testing is done on the test bay of the

manufacturer. Only pure cold water with a
density of ρ= 1 kg/dm3 is used as the test
medium.
Pump block units are normally tested with

installed motor. In case of acceptance by the
customer, the readiness for the acceptance
inspection is notified in time to the sales
departments.
4.3 Pump Test Beds
Both of following test beds are available and

will be utilized as per purchase order
specification
Closed System
Open System, Alternatively With
Booster Pump
4.4 Measurement And Testing Methods
The measurement and evaluation of

hydraulic characteristic values is made by
means of an electronic data logger.
All relevant data are recorded at the site by

means of electronic measuring devices and
presented with online electronic data
processing at the test sites. After termination
of the measurements, the data is transferred
to the central computer of the test bay
supervision. Unless otherwise specified, the
acceptance performance tests are carried
out in acc. with API 610, para. 7.3.3.
4.4.1 Measurements Of Flow Rate Q
The flow rate is measured using magnetic

inductive flow measuring devices having the
specified stabilization distances in front and
after the measuring unit. The setting of the
capacity is effected by control valves in the
discharge pipe.
4.4.2 Measurement of head H (Hd - Hs)
Pressure measurements are made using

calibrated measuring transmitters for the
measuring point Hs (measuring range -10 up
to +40 m wc), for measuring point Hd
(measuring range -10 up to +180 m, 150 up
to 630 m wc). For visual comparison,
calibrated spring manometers are connected
in parallel for analogous display.
4.4.3 Measurement of Velocity Head
The velocity head is calculated using the

flow rate and the flow cross-section at the
pressure measuring point.
Δ v2 /2g=(v2 d-v2 s)/2g
Vd = velocity discharge side
Vs = velocity suction side
Δ = velocity difference between suction and

discharge side
4.4.4 Measurement of power input (P)
The power input of the pump is determined

either electrically by means of a calibrated
test motor or by directly measuring the
speed of rotation using a torque measuring
hub.
The electrical measurement is made

according to the two-watt meter method for
determining the motor power input. The
motor power output is calculated using the
motor efficiency curve stored in the test
system.
For comparison of guaranteed data, the test

system converts the pump power input
required for the customer conditions, i.e to
the standardized speed and the density of
the acually pumped medium.
4.4.5 Measurement Of Speed (n)
The speed measurment occurs by means of

a light barrier or photo sensor. For canned
motor pumps, not accessible from the
outside, the speed is determined by means
of a bend coil or by frequency analysis.
4.4.6 Measurement of Pump Effeciency

(η)
The pump efficiency is determined for each

measuring point immediately following the
measurement by the testing system.
According to the following formula:
η=(Q×H×ρ×100)/(367×P)
Flow rate Q [m³/h]
Head H [m]
Density ρ [kg/dm3] of pumped medium
Power P [kW]
4.4.7 Measurement of the NPSH value of

the pump (NPSH required)
Normally in the closed circuit, the

measurement of the NPSH value is made by
reducing the system pressure by means of a
vacuum pump. Measurement also is done by
throttling using a throttle valve in the suction
line, as the case may be.
Reaching the guaranteed value at the

required NPSH value can be proven using
the following 2 measuring methods.
a) Standard
Proof of reaching the required NPSH value

by setting the peripheral conditions which
are equal inthe system such as flow rate,
head when reducing the suction pressure
depending on the water temperature and the
barometric level.
Comparison of head, taken from the

characteristic curve measurement above,
with the head measured at actual suction
negative pressure where the guaranteed
NPSH value is achieved or is not achieved.
The head decrease may not exceed 3 % of

H, but does not have to achieve 3 % (for
single-stage pumps).
According to the specifications in the order, 1

or 3 to 5 measuring points are used. For 2
stage pumps, the max head decrease may
not be ΔH≤1.5 %
So NPSH test for multi stage pump is not

possible.
b) Optional as Head Breakdown Curve
Proof of the min. achievable NPSH value at

a specific constant flow. By reducing the
suctionhead, starting at NPSH = 40 m, a
number of measuring points (8-12) are
recorded until the pumping breaks down.
The cut-off point at 3 % head decrease since
the beginning of the measurement results in
the cavitation condition of the pump at this
point and is defined in the applicable
standards as NPSH required (for 2 stage
pumps 1.5% ΔH)
Reference level for calculation of the

NPSH
a) Horizontal Pumps
Horizontal level through the shaft axis
b) Vertical Pumps
Plane surface vertical to shaft axis at

impeller inlet
Calculation of The NPSH Based on The

Measured or Known Parameters:
The calculation of the NPSH value occurs

simultaneously with the measurement.
The following parameters are required for

this:
Suction head
H_S [m]
Water temperature
t_w [°C]
Steam pressure of water(absolute

vaporization pressure)
H_t [m]=P_D/(ρ×g)
Atmospheric pressure (absolute)
Atmospheric height (absolute)
b_0 [m]=P_O/(ρ×g)
Distance reference level/measurement level
Y[m]
Speed at suction side
(V_S2 )/2g[m]
Density of test field water
ρ[kg/(dm3 )]
Acceleration due to gravity
g [m/s²]
The NPSH is calculated according to the

following formula:
NPSH=P_O/(ρ×g)-H_S-P_D/(ρ×g)+
(V_S2)/2g∓Y
NPSH=b_0-H_S-H_t+(V_S2 )/2g
The conversion of the NPSH value from the

measured speed to the nominal speed is
made according to the following formula
(only valid for the speed range ± 3 %):
n* /n>0.97<1.03
〖NPSH〗* =NPSH×〖[n* /n]〗2 [m]
Q* =Q×n* /n [m3 /h]
4.4.8 Additional Measurements
Upon request, the electrical current I [A] and

the voltage U [V] can also be measured.
4.5 Number of measuring points
The number of measuring points for the

pump characteristic curve or NPSH
measurements must
be agreed in the supply agreement.
Characteristic curve at 0, Qmin, Qmean,

Qnom, Q120%, standard measurement of 5
points (9 max.)
NPSH measurement 0, Qmin, Qmean,

Qnom, Q120% 4 points (7 max.)
5 Centrifugal Pump Performance Test -

Guarantees
The rated values of the pump are

guaranteed in compliance with API 610
provided that no other customer
requirements exist. The measuring of
tolerances is done automatically by the
measuring system.
For viscous media, only the specified data

for cold water is guaranteed. The results with
viscosity will be shown for information as
conversion curves according to Hydraulic
Institute.

Vibration measurement
To assess the mechanical and hydraulic

operating behavior of the pump tested,
vibrations are recorded at the same time as
the hydraulic date (min. 5 points).
Measurement is carried out in three planes -

horizontal, vertical and axial - by means of
vibration pick-ups fitted on the bearing
bracket. The measureng criterion is the root
mean square velocity of all vibrations
determined (vibration velocity RMS in mm/s).
The limit stipulated by API 610 is for

horizontal pumps 3 mm/s in the preferred
operating range of the pump. In the
allowable operating range, a vibration
velocity of up to 3.9 mm/s (max.) is
permissible. For vertical pumps the limit 5
mm/s in the preferred range and 6,5 mm/s in

the allowable range is applicable.
Alternatively, it is also possible to measure

the max. vibration amplitude (peak-to-peak).
Horizontal
Limit in preferred range: 2,0 mils (50 μm)
Limit in allowable range: 2,6 mils (65 μm)
Vertical
4,0 mils (100 μm)
5,2 mils (130 μm)
The frequency spectrum (FFT analysis) can

be measured, if requested.

Measurement of Bearing Temperature
If required, the measurement of the bearing

temperature will be performed for a specified
operating time. The measurement is taken
on the bearing bracket on the outside at the
level and position of the pump side or motor
side bearing in horizontal direction.
8 Centrifugal Pump Performance Test

report
The test results are stored in the central

computer of the test bay supervision and on
other electronic data carriers. Upon request,
test reports and test curves are prepared for
the customer.
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9/1/2020 Centrifugal Pump Performance Test

Home General Fix Equipment Rotary Equipment

E & I Equipment I4I Academy Services Get in Touch

Did you find this Centrifugal Pump Follow on

The performance test is conducted after

Inspection and Let explain the performance test by an

Heat Exchanger Rated Differential Head = 2690.28 m

Industrial Valve Rated Power = 2985 KW (4003 HP)

Process Heater Upon completion of the centrifugal pump

Steam Turbine Let's start with head-capacity curve, we draw

E&I So the measured head at the 238.5 m³/h is

API 570 Exam We also need to check the efficiency. The

ASME Training So the result of the centrifugal pump

I4I Academy The head value also shall be checked in shut

About Us The manufacturers also simulate the test

Subsequently, you need to check bearing

Now let deepen in the centrifugal pump

flowrate, total head, power, and efficiency.

What is the Flowrate and

This 'rated' flowrate is normally expressed in

The static head of a pump is the maximum

capability of the pump at a certain RPM can

The pump manufacturers are interested in

That is why they are using head instead of

Once the rated flowrate has been

This is expressed in meter or feet and

The q/H Curve Test;

The test is carried out at a nominally

Look at the following sketch; this illustrates a

The first set of measurements is taken at

opened to give a flowrate greater than the

The valve is then closed in a series of steps,

Once the test points are obtained, you can

these corresponding readings, the power-

Pump efficiency (ƞ percent): the efficiency is

The efficiency test; the efficiency is checked

You may also review third party inspection

This content provides you with a sample

Centrifugal Pump Performance Test

This description of procedure defines the

Scope of test, type of test, test class and

Objective of the tests is the continuous

Preparation of test reports and test curves

integral part of the test documentation.

3. Standards and Other Regulations

4. Centrifugal Pump Performance Test

4.1 Testing Personnel

For the handling of the test beds, only

4.2 Place and Time Of Testing

The testing is done on the test bay of the

Pump block units are normally tested with

4.3 Pump Test Beds

Both of following test beds are available and

4.4 Measurement And Testing Methods

The measurement and evaluation of

All relevant data are recorded at the site by

4.4.1 Measurements Of Flow Rate Q

The flow rate is measured using magnetic

4.4.2 Measurement of head H (Hd - Hs)

Pressure measurements are made using

4.4.3 Measurement of Velocity Head

The velocity head is calculated using the

pressure measuring point.

Δ v2 /2g=(v2 d-v2 s)/2g