Functional Testing Guidance Pump Performance

This functional testing guidance is designed to aid in developing test procedures for a specific project by describing the
steps involved in testing. The guidance should be adapted as necessary to address the control sequences, configuration,
and performance requirements of the particular system being tested. Additionally, codes may require specific testing
procedures that may not be addressed in this document. All tests based on this guidance should be reviewed carefully to
ensure that they are complete and appropriate.
Test Procedure: Pump Performance
Overview
The objectives of testing a systems pump performance are to:
Document system pump performance.
Determine the impeller size currently installed in the pump.
Establish the system curve for the pumping system.
Determine the operating point of the pump; i.e. the point here the pumps impeller curve crosses
the system curve ith the discharge valve throttled and ith the discharge valve fully open.
!ssess the match beteen "full flo#$flo delivered by the pump ith the discharge valve fully
open$and the actual design flo re%uirement.
!ssess the implications of throttled discharge valves and opportunities to open discharge valves and
modify pump performance via trimming the impeller& changing the motor to achieve an incremental
motor'pump speed change or installing a ()D to change the motor'pump speed to a non*incremental
value. The goal of all of these modification techni%ues is to provide design flo ithout the head
imposed by the throttled valve. !s a result& the system ill benefit from reduced pump energy use
and operating costs.
!ssess the flo variations produced in the system as different active elements are repositioned by
their control processes.
Detect and diagnose other control or performance problems.
System Description
The flo delivered by a centrifugal pump depends on pump characteristics +including impeller diameter
and volute design,& pump speed& the distribution system pressure drop& the discharge and control valve
positions& and the effects of other system pumps. -t can be applied to pumping systems that include
individual components& subsystems& or related systems such as single or multiple pumps and their
associated valves +discharge& control& isolation and bypass& balancing& chec.,& motors& heat e/changers&
strainers& impellers& headers& piping& and controls.
When to Conduct Pump Tests
This test can be conducted at any point hen pump performance is in %uestion. -t is typically conducted
in an e/isting building to identify optimization opportunities but it can also be performed in a ne
building to confirm that the pump system is performing in accordance ith design intent.
-f a %uic. building inspection reveals highly throttled discharge valves& this test may be recommended. !
throttled discharge valve introduces head loss into the system in order to restrict flo and achieve design
conditions. This head loss e%uates directly to energy aste& and indicates the pumping system may have
potential for optimization. +0oever& if the valve is oversized& it may not be imposing a significant
pressure drop. This possibility should be investigated before doing the test.,
Pump_Performance_Test_Guidance.doc (last updated: 8/06) Page 1 of 10
Functional Testing Guidance Pump Performance
-f the discharge valve is found to be ide open& the ne/t step is to estimate the amount of head the system
needs compared to the rated nameplate head of the pump. This is achieved by summing all of the head
losses in the system& including piping& valves& elbos& heat e/changers& elevation changes +applicable to
open systems only,& and any other devices in the system that introduce a head loss. -f the pumps rated
head far e/ceeds the head estimated& then the pump may be moving more ater than necessary through
the system& running out its pump curve because of the e/cess head. The tests described belo can be
used to determine if pump optimization opportunities e/ist and can bring the system closer to design flo
re%uirements.
Summary of Documentation
Documentation of the folloing items should be gathered: pump and motor nameplate data& system
diagram& and pump curves.
Test Equipment
Pump suction and discharge pressures ill be measured and recorded under each test condition. Pump
pressure can be measured using e/isting analog gauges if they are calibrated and reliable& or a hand*held
digital pressure gauge if gauges do not e/ist or they are deemed unreliable. 1ote that many engineering
specifications re%uire calibration certification for the gauges used for testing purposes. -f this is a
re%uirement& the results of a test conducted ith gauges that do not meet the re%uirement +due either to
lac. of documentation or out of date documentation, may be deemed invalid and the provider may be
forced to repeat the test at their on e/pense. 2ther useful e%uipment includes a tachometer and amp
probe. 3efer to section 4.5.4 for a detailed discussion about gauge configuration and measurement
locations.
Trending
2ngoing trending of pump poer +or current, ill reveal operational issues such as inappropriate
nighttime operation. 6onitoring pump status +a binary parameter instead of the analog parameter
associated ith poer, ill also provide pump operating data at a potentially loer cost. Trending of
differential pressure in the system loop is useful for ongoing diagnostics in variable flo systems.
Test Precautions
Ensure that hen pumps are ta.en out of service& all isolation valves are set properly& to avoid ater
lea.age.
E/ercise care hen changing operating modes if the e%uipment served by the pump is in operation.
(erify that all components beteen the discharge of the pump and the discharge throttling valve
+including the pump casing, are rated for the pea. pressure on the pump curve ith the largest
impeller installed plus the static pressure on the inlet side of the pump prior to performing a shutoff
test.
!void sudden flo changes to minimize the potential for ater hammer& especially hen throttling a
large valve for a shut*off test.
E/ercise proper caution hen or.ing around live iring and terminals and ta.ing voltage or amp
readings.
E/ercise proper caution hile or.ing around the rotating parts of the pump.
6a.e sure to stop and start the pumps at the motor starter& the ()D& or at a load*rated disconnect
sitch.
Ensure that no jobsite jurisdictional re%uirements are ignored +such as 270!& insurance& and first aid
re%uirements,.
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Functional Testing Guidance Pump Performance
Try to schedule tests hen major e%uipment 8 such as chillers and boilers 8 do not need to be
running to avoid creating uncomfortable conditions and e%uipment damage. -f testing during
occupancy is unavoidable& coordinate ith the people ho could be affected.
Exampe Tests
The folloing tests use the test procedure format proposed here. They are available at
.ftguide.org'ftct'testdir.htm.
0ot 9ater 7ystem Pump Test. -D :: 4;;<
=hilled 9ater 7ystem Pump Test. -D :: 4;4;
=ondenser 9ater 7ystem Pump Test. -D :: 4;44
Sampe Test
The folloing test as not created based on this test guidance but serves as a sample of similar tests. -t is
available at .ftguide.org'ftct'testdir.htm.
Data =ollection Procedures for 0ot 9ater 0eating Pumps: -D :: 4;45
Test Procedure Outine
!" #asic Pump Performance Test Eements
4.4 (erify all pump prefunctional chec.lists are complete
4.5 Prepare for tests
4.> 7pecify test participants and roles'responsibilities
4.? Document as*found status of system
4.@ =hec. for strainer pressure drop
4.A Test pump ith valve in initial position
4.B Test pump ith valve fully closed
4.C Test pump ith valve fully open
4.< 3eturn to normal
$" Tests with %utipe Pumps or %utipe Operating %odes
5.4 Develop a test plan to characterize the performance of all pumps and'or operating modes
5.5 Prepare for and conduct tests
&" 'naysis and Opportunities
>.4 !nalyze data
>.5 Estimate energy use
>.> =onsider additional opportunities
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Functional Testing Guidance Pump Performance
Test Procedure
!" #asic Pump Performance Tests
44 (erify a pump prefunctiona chec)ists are compete. Prior to performing any functional
tests& the commissioning pre*start& start*up& and verification chec.lists should be completed&
as ell as applicable manufacturerDs pre*start and start*up recommendations. Prefunctional
chec.list items include& but are not limited to& the folloing:
4.4.4 -f needed& insert a list of things that should occur during correct operation in this step
of the test. =ontrol system point*to*point chec.out is complete to ensure all pump
input'output points are ired correctly& and all actuators and relays or motor starters
respond to control signals.
4.4.5 Poer is provided to each pump assembly at proper voltage and phase rotation. !s
an alternative to verifying phase rotation& pump rotation should be verified.
4.4.> The system has been proportionally balanced ith all control valves +or for systems
ith a diversity factor& the number of valves re%uired to represent the design
condition, fully open and the number of pumps re%uired to serve the design load
condition in operation.
4.4.? !ll necessary sensors are calibrated.
4.4.@ !ccess to pumps and all components is acceptable for testing& maintenance& and
replacement.
4.4.A Eocations of all pumps& valves& and other system components are clearly and
correctly located on as*built draings.
4.4.B )ill pressure and e/pansion protection is chec.ed +if necessary* refer to the
engineers re%uirements and contractors as*filled pressure and %uantities reported,.
4.5 Prepare for tests" %a)e sure a documentation and resources are ready"
4.5.4 Evaluate instrumentation re%uired for test. -f using digital pressure gauges or other
e%uipment in addition to the e/isting e%uipment& ensure that it is calibrated. -f using
e/isting instrumentation on the pumps& use the same gauge to measure both suction
and discharge pressures& if possible& to reduce measurement errors. This ill
minimize the possibility that any error in a single gauge +i.e. calibration, is nulled
hen the discharge and suction pressures are subtracted to calculate differential
pressure. 0oever& the error associated ith individual gauges can significantly
impact the calculated differential pressure and may lead to improper system analysis.
Pressure measurements must be made on the inlet and outlet flanges of the pump
since this is here the manufacturer measures pressure hen developing the pump
curves. 6easuring pressure at any other location ill introduce error and uncertainty
into the test and may lead to improper system analysis.
4.5.5 7.etch a simple system diagram& shoing all pumps& valves& and other system
components.
4.5.> 2btain pump curves for all pumps in the system. =ertified curves for the e/act pump
provided are preferable to catalog data that applies generally to the pump ma.e and
model.
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Functional Testing Guidance Pump Performance
4.5.? 2btain contact information for the chiller or boiler representative ho can discuss
test results ith regard to chiller or boiler performance. 6ost e%uipment can operate
efficiently and effectively under a range of ater flo rates. 0ence& system
operation may be further optimized if "design# flo rate can be modified ithout
having an adverse impact on the e%uipment being served. 0oever& for ne
construction projects& deviations from the design re%uirements should be coordinated
ith the testing and balancing contractor and approved by the engineer of record.
4.5.@ =oordinate as necessary ith the trades& in particular the T!F and controls
contractors. 7ystem balance must be complete and a controls technician may be
needed to manipulate isolation and control valves as necessary to achieve re%uired
test conditions.
4.> Specify participants and roes*responsi+iities" The testing guidance provided in this
document can assist in verifying proper system performance in both ne construction and
e/isting building applications. The folloing people may need to participate in the testing
process. 3efer to the )unctional Testing Fasics section of the )unctional Test Guide for a
description of the general roles and responsibilities of the participants. These roles and
responsibilities should be customized based on actual project re%uirements.
New Construction Project Existing Building Project
=ommissioning Provider =ommissioning Provider
6echanical =ontractor Fuilding 2perating 7taff
=ontrol =ontractor =ontrols =ontractor
4.? Document as,found status of system" Physically inspect all the components of the system
to document their condition and specifications prior to beginning the tests. This includes:
4.?.4 Document the as*found status of all related pumps& chillers& boilers& condensers&
cooling toers& and valves including positions& temperatures& .9& amps& and other
available indications of the operating state.
4.?.5 Document all pump and motor nameplate data.
4.?.> =hec. the operation of all valves that ill be adjusted during the tests. -f valves
cannot be adjusted ithout damaging them& the test may not be feasible. (alves
should be capable of fully opening and closing. D2=H6E1T T0E P27-T-21 2)
!EE (!E(E7 P3-23 T2 !1I !TTE6PT T2 3EP27-T-21-1G T0E6.
4.@ Chec) for strainer pressure drop" Prior to running performance tests& the condition of the
strainer must be assessed to ensure that e/cessive pressure drops do not invalidate the test
results or cause e%uipment damage.
4.@.4 Ensure that all system control valves are fully open +or are at the ma/imum e/pected
flo position,. -f the system includes ()Ds& ensure that these are at 4;;J speed.
Ensure that all isolation valves are fully open. -f this is not possible& document the
condition as close as possible at the time of test. Falancing valves at the coils should
not be opened& since this alters the proportional balance of the system.
4.@.5 9ith the pump running& record pressure ahead of the strainer and the pump suction
pressure.
4.@.> =alculate strainer pressure drop.
4.@.? -f the strainer pressure drop is e/cessive& suspend the test and inspect and clean the
strainer.
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Functional Testing Guidance Pump Performance
4.A Test pump with discharge vave in as,found position. -nitially document the performance
of the pump ith its current valve position& to record "as found# performance. Document the
discharge valve position so it can be returned to this position after the other tests. 9ith the
pump running& record the folloing:
4.A.4 Pump suction pressure.
4.A.5 Pump discharge pressure.
4.A.> 6otor current +all phases,. 1ote that if the measured current is close to rated full
load current for the motor& step 4.C of the test ith should be conducted ith caution
because the motor can become overloaded hen operated ith discharge valve ide*
open. -f the "as*found# measured current is very close to the rated full*load current
of the motor& motor current should also be measured during the ide*open flo test
to ensure the motor does not operate at an overloaded condition& hich can cause
motor damage.
4.A.? 6otor volts +all phases,. (erify that input voltage is near the nameplate rating to
ensure proper voltage is applied to the motor and to determine if there is an
imbalance beteen legs in a >*phase circuit& hich may impact motor performance.
4.A.@ Document any other secondary indicators deemed desirable. Possibilities include
motor and'or pump speed and the pressure drop across the tube bundle or coil served
by the pump.
4.B Test pump with discharge vave fuy cosed" ! pump shutoff test is used to verify the
pump impeller size. This should be done %uic.ly$in no more than @ minutes$since a no*
flo situation can cause overheating in the pump. !lso& coordinate ith the operating staff
prior to shutting don the pump and disrupting flo to the system. -t may be necessary to
turn on a second parallel pump before shutting don the pump under test to maintain flo in
the system. Turn the pump off and close the discharge valve. Friefly restart the pump& record
the folloing& and then turn the pump off again:
4.B.4 Pump suction pressure.
4.B.5 Pump discharge pressure.
4.C Test pump with vave fuy open" To determine the performance point at full flo& conduct
a test ith the discharge valve ide open. 9ith the pump off& adjust the discharge valve to
the fully open position. Turn the pump on. -f a second pump as started to maintain flo
during the shut*off test& turn it bac. off so you are testing the system ith only one pump
running and record the folloing:
4.C.4 Pump suction pressure.
4.C.5 Pump discharge pressure.
4.C.> 6otor amps +all phases,. -f the motor amperage measured in section 4.@.> is close to
rated full*load amperage& then measure motor amperage during the test and compare
to ma/imum alloable amperage& as determined by:
Max Amps = Rated full-load amps motor service factor
-f measured amperage e/ceeds ma/imum alloable amps& do not operate the motor
for more than 5 minutes to prevent motor damage.
4.< -eturn to norma" !fter conducting the tests& return the system and e%uipment to normal.
4.<.4 3eturn discharge valve to original position.
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Functional Testing Guidance Pump Performance
4.<.5 3emove all test e%uipment.
4.<.> 3eturn the system to the state it as operating in at the start of the test or as re%uested
by the operating staff.
$" Tests with %utipe Pumps or %utipe Operating %odes
5.4 Deveop a test pan to characteri.e the performance of a pumps" 7ystems ith multiple
pumps in parallel or series can have many different operating points. The operation of each
pump ill affect the operation of all other pumps. 7imilarly& the 0(!= system may have
several different operating modes& depending on the flo re%uired through any system loads
at any point in time. -n either case& the pump ill operate at some point along its curve.
These different modes simply change the system that the pump "sees&# putting the pump on a
different system curve. The performance of the system at each potential operating regime
should be documented using the techni%ues outlined previously under Fasic Pump
Performance Tests to identify the point here the system curve+s, intersect the pump
curve+s,. -n essence& the pump is being used as a calibrated flo measuring device to assess
system performance.
5.4.4 -dentify the pumps that are included in the system and dra a simple system diagram.
5.4.5 Define the different combinations of pumps and system loads that represent different
operating modes. Determine the "orst case# scenario ith full flo re%uired at all
system loads to ensure that the system can supply this flo ith any impeller
changes. -f the system includes lead pumps and standby pumps to serve the same
loads& the orst case& ma/imum flo condition ill still need to be determined
because pumps configured in a lead'stand*by configuration ill often see different
system head losses depending on the actual piping layout for each pump.
5.4.> Determine some of the "most common# scenarios ith some loads or pumps
re%uiring only partial flo. Test and optimize the performance for these .ey modes.
5.4.? Determine ho many tests can be done ith the available budget& and select the tests
that ill be conducted.
5.4.@ Develop a testing se%uence that ill run through these tests most efficiently.
5.5 Prepare for and conduct tests as descri+ed in #asic Performance Tests a+ove.
&" 'naysis and Opportunities
>.4 'nay.e data" !fter conducting the tests& the recorded data can be used to assess the pumps
performance. The operation of the system ill alays occur at the point here the pump
curve +hich is concretely defined for a particular pump by the impeller size and the pump
speed, intersects the system curve +hich ill change depending on the operating mode,.
9hen the pump is producing flo greater than necessary& changing either the pump impeller
size or the pump speed can deliver design flo at reduced poer. )igure 4 provides a
graphical e/ample of the analysis procedures discussed belo.
>.4.4 Determine the actual impeller size by plotting no*flo pressure +see section 4.A., on
the set of pump curves provided by the manufacturer. Keep in mind that
measurement errors ill influence the calculated differential pressure across the
pump. -f the pump shut*off test yields a pressure that is reasonably close +ithin
4;J, to the no*flo pressure for the nameplate impeller and discharge valve lea.age&
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Functional Testing Guidance Pump Performance
motor speed and ear ring clearances have been eliminated as reasons for a
mismatch& then it is safe to assume the nameplate diameter is accurate and that
impeller curve can be used. 2therise develop an impeller curve based on the
measured no*flo pressure.
>.4.5 Plot the as*found operating point by folloing the pump curve for the actual impeller
size to the pressure reading from the as*found test +see section 4.@.,. 1ote the flo
rate at this point. -f the balancer did their job& then this flo rate should be close to
the design flo rate. 0oever subse%uent adjustments may have shifted the as*found
operating point from the original setting& so the as*found condition may not match the
original design re%uirement.
>.4.> Plot the ide*open operating point by folloing the pump curve for the actual
impeller size to the pressure reading from the orst*case ide*open test +see section
4.B.,. 1ote the flo rate at this point. This point defines the system curve for the
system ith the discharge valve ide open.
>.4.? Hse the orst*case ide*open point on the pump curve to manually dra in the
system curve on the set of pump curves. Hse the folloing e%uation to determine
appro/imate points for a range of intermediary flo rates on the system curve:
Hintermediary = Hmin + [Hwide-open (Qintermediary Qwide-open!
"
#$
here 0 is head& L is flo& and 0min refers to the minimum pressure re%uirement for
the system. )or e/ample the "lift# for a cooling toer or minimum pressure
differential at the most remote coil ithin the system. 0ence the system curve ill
cross the "head# a/is at the minimum pressure value hen flo is ; gpm.
1ote that pumps in the real orld ill not follo this e%uation e/actly& since it does
not account for issues such as condenser ater lift or elevation differences& or
constant volume regulators. -t is a useful appro/imation& hoever. !ccuracy can be
improved if tests are conducted at several points along the system curve& not just at
the ide*open and no flo points.
1ote that for open systems& for e/ample condenser ater systems& the lift or elevation
difference beteen the highest point in the system and the loest point in the system
that is open to the atmosphere ill not vary ith flo. -n open condenser ater
systems& this ill be the toer lift or the difference beteen the ater level in the
cold basin and the ater level in the hot basin or the discharge of the spray nozzles.
The head at ; gpm ill be this value thus& the system curve ill intersect the head
a/is of the pump curve at this value. =onstant volume regulators and other items that
have a head associated ith then that is independent of flo ill have a similar
effect.
>.4.@ -dentify on the system curve the operating point achievable ith an impeller trim or
speed change: the point on the system curve that corresponds to the design flo rate.
>.4.A Determine the re%uired impeller size to achieve this head and flo rate& by locating
the pump curve closest to the achievable operating point. 3eferring to )igure 4&
design flo crosses the system curve beteen the < inch and 4; inch impeller curves.
Trimming the impeller to appro/imately <.@ inch diameter ould result in the pump
utilizing appro/imately B.@ bra.e horsepoer +bhp, to meet design flo rate
+compared to about 45.@ hp for the ide*open operating condition,. !n alternative
ould be to either trim to or install a ne 4; inch impeller and throttle the discharge
valve slightly to achieve design flo. This ould re%uire appro/imately < bhp to
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Functional Testing Guidance Pump Performance
achieve design flo rate. Trimming an impeller is typically less e/pensive than
installing a ne impeller& but once the impeller is trimmed& the ability to achieve
higher flo rates than design flo is lost.
/ote: -f the design flo rate crosses the system curve belo the smallest impeller for
a particular pump& this limits the size to hich the impeller can be reduced. 0ere& the
least e/pensive solution ould be to trim to the smallest impeller diameter and
throttle bac. the valve until design flo rate is met. 2ther options include reducing
pump speed or some combination of measures to meet re%uired flo rate.
>.5 Estimate energy use" Estimate energy savings by subtracting the motor input poer
re%uired at the as*found condition from the final operating condition& as determined by the
modifications selected for implementation& and multiplying the result by pump operating
hours.
System +ra)e horsepower for both conditions can be estimated from the pump curves or
calculated using the folloing e%uation:
%&p = [flow &ead# ['()* pump efficiency#
here flo is in gallons per minute& head is in feet& and pump efficiency is read off the pump
curve.
%otor input power is cacuated +y:
+, = [%&p *$-.) +,&p# motor efficiency
here motor efficiency can be estimated based on motor rated efficiency and part load
operating point.
0ence energy savings are cacuated +y:
/0 = [+,as-found 1 +,final# pump operatin2 &ours
>.> Consider additiona opportunities" The results of the pump test data analysis may result in
a variety of improvements that can be made to the system& as outlined belo:
>.>.4 -f the as*found flo rate is significantly different from the design flo rate& it calls
for further investigation. Determine the best design flo rate by considering the
design documents and any other changes that may have been made to the system.
>.>.5 -dentify a means of reducing the flo other than throttling the pump or trimming the
impeller. These could include:
-nstalling a ()D to reduce the motor speed +operating at a loer speed creates an
entirely different set of pump curves& and the full range of the ()D can be realized
if the impeller is trimmed and the ()D is alloed to operate near full speed,
7hutting don one parallel pump
3eplacing the motor ith a reduced speed
3eplacing the pump ith a more appropriately sized pump
>.>.> !s stated above& once an impeller is trimmed to a specific size& increases in system
flo ill be minimal or impossible. 6any times a pump is sized for future
e/pansion but current operation is ell belo ma/imum flo of the pump. -t may be
more cost effective in a situation li.e this to retain the e/isting impeller to meet
future flo re%uirements and install a ne& correctly sized impeller to achieve
immediate savings.
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Functional Testing Guidance Pump Performance
>.>.? -f the motor is close to re%uiring replacement& or a spare loer*speed motor +i.e. 45;;
rpm vs. 4C;; rpm, is available& the system may be analyzed ith the loer speed
motor to reduce flo.
>.>.@ ! system ith multiple pumps may call for different staging strategies. -f the system
ill be operating for many hours per year at partial flo& it can be optimized for this
operating point hile still ensuring ade%uate capacity hen full*flo is re%uired.
-deally& pumps should run as close to full load as possible.
Flow, gallons per minute
H
e
a
d
,

f
t
.

w
.
c
.
12 inch
11 inch
10 inch
9 inch
7.5 bhp
5 bhp
10 bhp
Operating oint !chie"able with an
#mpeller $rim or %peed &hange
#mpeller 'ines
(ra)e Horse ower
ump *+cienc,
%,stem &ur"e
-esign Operating
oint
.ide Open Operating
oint
15 bhp
1igure !: &'ample pump cur(es) *it+ s,stem cur(e superimposed. T+e goal of t+ese tests is to
mo(e from t+e design operating point to t+e operating point ac+ie(a-le *it+ an impeller trim or
speed c+ange) *+ic+ re.uires less po*er to pro(ide t+e same flo* rate.
Pump_Performance_Test_Guidance.doc (last updated: 8/06) Page 10 of 10
/o0flo*
1s0found operating
pressure