Procedure Number

PF – 07JR Rev - 0
Page: 1 of 11 Date: 1-Mar-10

TEST PROCEDURE
CUSTOMER ACCEPTANCE TEST
CAVITATION TEST

REVISION HISTORY:

Revision 0 Initial Submittal 29-Jul-05

1.0 SCOPE

1.1 This procedure is intended to define the test procedure for performing flow visualization
testing using a single centrifugal pump stage.

1.2 Purpose of the flow visualization testing is to determine the suitability of an impeller
design for operation under cavitating conditions.

1.3 Acceptance test conditions can be suitably scaled for lower rpm, by appropriately scaling
the actual plant operating conditions (Ref. 2.3).

1.4 Acceptance criteria for impeller design is defined as exhibiting a cavitation bubble length
on the suction surface of the test impeller less than some critical length as determined
using the Prediction of Life Under Cavitating Conditions equation (Ref. 2.4).
 Procedure Number

PF – 07JR Rev - 0
Page: 2 of 11 Date: 1-Mar-10

2.0 REFERENCE DOCUMENTS

2.1 Flowserve, Jebel Ali Aux Boiler Feed Water Pumps Manufacturer Data Sheet

2.2 Hydraulic Institute, ANSI/HI 1.6-2000, Centrifugal Pump Tests

2.3 Guidelines for Prevention of Cavitation in Centrifugal Feed Pumps, EPRI GS-6398

2.4 Pump Handbook, 3rd Edition, McGraw-Hill, 2001

2.5 Soth, Brkich, & Stahl, Suction-Head Correction for Centrifugal Pumps, Division of
Refining, Vol. 39 [III], 1959

Procedure Owner: Written By:

Approvals

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 Procedure Number

PF – 07JR Rev - 0
Page: 3 of 11 Date: 1-Mar-10

3.0 TEST CONDITIONS

3.1 Comparison of reference conditions for plant and flow visualization test, Table 1. The
data for flow visualization is scaled to the test rpm of 1,500, from the full speed, main
pump performance. Scaling laws used are in accordance with Reference 2.3 (Section
1.6.5.8.8.3).

3.2 The testing will be conducted in a closed test loop with de-aerated water.
 Procedure Number

PF – 07JR Rev - 0
Page: 4 of 11 Date: 1-Mar-10

4.0 TEST CONFIGURATION

4.1 Test Loop (Figure 1)

ATM.
PRESSURE
CV
1
VACUUM
PUMP
PLANT COMPRESSOR,
AIR; 6,0 BAR

COMPENSA Ø14”
TION TANK.
27 M3
CV DRAG
2
TTI VALVE, Line filter PI PI
2 ANSI: 2500 , 1 2
DIÁM: 8”

VTI
1
PT
Ø 14”

CV
3 Strobo light
DEAIREAT and camera
OR PUMP
150 M3/H PT
@2,5 BAR Test Pump 2
Ø 2 1/2”

Ø14”
Ø 4”

Ø 8”

VA VA VA
2 1 3

5”
Closed

Open
Closed

Closed

FT FI
1 1

# ABBREVIATORS DESCRIPTION
1 CV/1 3 way valve
2 CV/2 Main discharge valve
3 CV/3 Secondary discharge valve
7 PI/1 Suction Pressure indicator
8 PI/2 Discharge pressure indicator
4 PTI/1 Suction pressure transducer
5 PTI/2 Discharge pressure transducer
9 VA/1 3way valve actuator
10 VA/2 Main discharge valve actuator
11 VA/3 Secondary discharge valve actuator
12 VT1/1 Velocity transducer and indicator
13 TTI/1 Temperature transducer and indicator
14 FT/1 Flow transducer
15 FI/1 Flow indicator
 Procedure Number

PF – 07JR Rev - 0
Page: 5 of 11 Date: 1-Mar-10

Photograph of typical test pump in this test loop shown in Figure 2.

Figure 2. Typical Test Pump and Data Acquisition Equipment. The inlet pipe
hydrophone, casing accelerometer and suction bay pressure transducer are visible in
this photo. The digital video camera and strobe light are also shown. The computers
and monitors are required to support the range of test parameters being collected.
The strobe light is synchronized to the shaft rotation allowing for direct or video
observation of cavity length.
 Procedure Number

PF – 07JR Rev - 0
Page: 6 of 11 Date: 1-Mar-10

4.2 Test Instrumentation – Table 2 lists key instrumentation used for performing test
described in this Procedure.

Instrument Manufacturer Model # Serial Number

Flow Venturi FLOWSERVE 8IN 38
Differential Transducer SIEMENS 001 D-11081
Suction Transducer TRAFAG 8891233315 249967-002
Discharge Transducer TRAFAG 8891233315 82520.0.00.02-001
Temperature AQUILANT 34970A -
RPM MKS SX540 20204427
Strobe Light CHECKLINE PK2 -
Table 2

4.3 Test Pump with Flow Visualization Features (Figure 3)

4.3.1 Test pump uses exact model of suction bay

4.3.2 Test pump simulates rotating shaft blockage

4.3.3 Test pump uses production impeller

4.3.4 Test pump uses production design vaned diffuser

4.3.5 Test pump collects flow from diffuser via volute collector

4.3.6 Test pump uses full 360° window for visual access to eye of impeller
 Procedure Number

PF – 07JR Rev - 0
Page: 7 of 11 Date: 1-Mar-10

Figure 3

4.4 Performance Calculations

4.4.1 Prior to testing, a Test Configuration summary sheet will be prepared, basis Ref.
2.2, (Section 1.6.5.6) showing information regarding pump, driver, rated
conditions (full-speed and test-speed), test methods, instrumentation and
calibration information. A sample of this summary sheet is provided in
Appendix A of this procedure.

4.4.2 Calculation of the NPSH level for all test conditions will be done in accordance
with Ref. 2.2. The basic equation follows (NPSH is the total suction head of
liquid absolute, determined at the suction nozzle and referred to the pump
centerline, less the absolute vapor pressure of the liquid in head of the liquid
pumped):

NPSH = hatm + hs − hvp

where: hatm = local atmospheric pressure expressed in meters (feet)
hs = total suction head – sum of suction gauge and velocity head
hvp = head based on vapor pressure of fluid being pumped
 Procedure Number

PF – 07JR Rev - 0
Page: 8 of 11 Date: 1-Mar-10

4.4.3 Scaling of test data between the reduced speed model and the full speed
condition will be made by calculation, using Ref. 2.2 (section 1.6.5.8.8.1)
as reference:
0.5 0.5
Q1 n1  H 1   NPSH 1 
= =  =  
Q2 n 2  H 2   NPSH 2 

where: Q = volumetric flow rate

n = shaft rpm
H = Pump total head
NPSH = Net Positive Suction Head
Subscripts represent two different speed conditions
 Procedure Number

PF – 07JR Rev - 0
Page: 9 of 11 Date: 1-Mar-10

4.4.4 Impeller life shall be determined from the following calculation using Ref 2.4
(section 2.1:

.75t
Life =
MDPR
n
L 
( )
C  cav  τ A − φe2 U e6 ρ L3 A
3

MDPR = 
10  mm
8 Fmat (TS )
2 hr

8.28 E − 06 Suction
Where: C = 
 396 E − 06 Pr essure
2.83 Suction
n=
2.60 Pr essure
NPSH
τ = U2 m
, (Ue in /s)
e
2g

V
φe = U m,1
2
e
2g
(Vm,1 is average axial inlet velocity)
ρ L = 1000SG
1.00 Cold
A=
.705 350° F
1.0 Martensitic
Fmat = 
1.7 Austenitic
 8 .6 E 8 13CR
TS = 
5.52 E 8 18CR,8 Ni
 Procedure Number

PF – 07JR Rev - 0
Page: 10 of 11 Date: 1-Mar-10

5.0 OPERATIONAL PROCEDURE

5.1 Impeller Preparation – Prior to flow visualization testing, the test impeller will be marked
with a grid pattern oriented span-wise on the suction surface of each blade. The first
span-wise line will be a band with a width equal to the critical length with its upstream
edge touching the line formed by the leading edge radius and the suction blade surface.
Additional lines will be placed at 10mm intervals from the leading edge for further
reference points. The first band will serve as a visual reference for identifying the critical
bubble length. An example of this style of grid lines (although the pattern shown is much
coarser than required here) is found in Figure 4.

5.2 Instrumentation Calibration – Pressure transducers will be calibrated prior to test

according to Ref. 2.2 (1.6.5.4.3, Suitable Interval between calibrations of performance
test instruments).

5.3 Test Loop Preparation – Prior to testing, the test loop will be filled with ordinary tap
water. The pump shall be operated and all air vented from the system piping and test
pump. For a minimum of two hours the test pump and circulating water pumps shall be
operated with the vacuum pump providing the minimum possible pressure at the
Compensation Tank surface. Simultaneously the test loop circulating water pump shall
pass water through a filter and back to the compensation tank. This operation will assure
optical clarity for flow visualization and the removal of dissolved air.

5.4 Test Conditions – Following the Test Loop Preparation, the system shall be pressurized
to approximately 30 m. The test pump shall be operated at the test speed and flow rate
shown in Table 1. The NPSHA will be lowered until achieving value on table 1, then the
 Procedure Number

PF – 07JR Rev - 0
Page: 11 of 11 Date: 1-Mar-10

Impeller Life will be calculated according equation in section 4.4.5. The readings of all
the pressure, flow and temperature sensors will be recorded at this condition and also
pictures will be acquired. A similar test condition is shown in Figure 4 for a different test
impeller. In this figure, the lines painted on the blade surface are at approximately 12mm
intervals.

6.0 DELIVERABLES

6.1 Test Configuration Summary Sheet (see section 4.4.1 of this Procedure)

6.2 Data sheet containing NPSH inception point raw data and reduced data to show flow,
NPSHA and rpm at both test speed and full-speed condition

6.3 Picture file (.jpg format) of the impeller eye at the NPSH condition.