WERKNORI / WORKS STANDARD November 2007, 4a 42 43 44 aaa aar 443 aaa 445 446 4a7 AN 1897/ 70-08 -02 Description of Procedure Characteristic Curve Measurement on Centrifugal Pumps ‘ace. to API G10 Contents Scope Objective Standards and other regulations applicable Test procedure ‘Testing personnel Place and time of testing Pump test beds Measurement and testing methods Measurement of flow rate Q Measurement of head H Measurement of velocity head 25 Measurement of power input P Moasurement of speed n Measurement of pump efficiency n Measurement of NPSH value ofthe pump (NPSH required) Additonal measurements Numbor of measuring points Measuring tolerances, Guarantees Vibration measurement onthe bearing brackot Measurement of Bearing Temperature Test port Pump testbed open circu (basic sketch) Pump testbed closed circuit basic sketch) [evoestNansostunosi |satbeoiNenaDsionban [eotcestnaneoamons [ase Dege Nana DstmOse 1 |e von KSB Aktienge: (0412.2007/833 Daun 06 12.2007 Hs20 wiosner 04 122007 sohatt | AN 1897 70.05 £-02 4 oy soe‘This description of procedure defines the conditions forthe hydraulic testing of centrifugal pumps ace. to API 610, Scope of test, type of test, test class and guarantee values are defined by standardized test plans or by the order confirmation as well as via data transfer from the sales departments to the test bed supervision 2 Objective Objective ofthe tests is the continuous control of performance data as process contro, keeping the guarantees given according to the supply agreement, testing of relevant pump functions, Preparation of test reports and test curves according tothe supply agreement as integral part, of the test documentation 3 Standards and other regulations applicable aPl6s0 4 Test procedure 44 Testing personnel For the handling of the test beds, enly trained personnels employed ‘The setting of test data is done semi-automatically and requires appropriate test experience and accuracy. The test manager ofthe Quality Assurance Department is responsible for the execution of the test. 42° Place and time of testing ‘The testing is done on the test bay of the manufacturer. There are 5 testing sites at disposal (test beds) of which 3 are a closed system, 2 are an open system, Only pure, cold water with 2 density of 0 kgldm? is used as test medium ‘As a rule, the tial run is made immediately folowing the pump assembly utlizing the test boy drive (calibrated test bay motors or controllable speed drives with troque measurement hub), ‘Test runs of complete pump units (pump with motor and auailiary systems) are possible only after priar clarification with the test bay. Pump block units are normally tested with installed motor Incase of acceptance by the customer, the readiness for the acceptance inspection is notified in time to the sales departments, KSB Aktiengesellschaft | AN 1897 /70-08 E-0243 4a aad 442 442 444 KSB Aktiengeselischaft | AN 1897/70-05 €.02 Pump test beds See basic sketches pages 8 and 9 Fig1 closed system Fig2 open system, alternatively with booster pump ‘Measurement and testing methods ‘The measurement end 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 atthe 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, Measurements of low 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. Measurement of head H (Hy -H,) Pressure measurements are made using calibrated measuring transmitters for the measuring point Hs (measuring range -10 up to *40 m wc), for measuring point H, (measuring range -10 up to +180 m, 150 up to 630 m we). For visual comparison, calibrated spring manometers ‘are connected in parallel for analogous cisplay. Measurement of velocity head $ ‘The velocity head is calculated using the flow rate and the flow cross-section at the pressure ‘measuring point. pie davis Va = velocty discharge side 29 29 V,. = velocity suction side A. = velocity difference between suction and discharge side Maseurement af power input P ‘The power input ofthe 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 tothe two-watt meter method for determining the motor power input. The mator power cutputis 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, ie. to the standardized speed and the density 9 ofthe actually pumped medium. ‘ng Sain Poo eas44.5 Measurement of speed a The speed measurment occurs by means of a light bari or photo sensor. For canned motor pumps, not accessible from the outside, the speed is determined by means of abend col orby frequency analyss. 44.8 Measurement of pump efficiency n “The pump efficiency is determined for each measuring point immediately flowing the ‘measurement by te testing system. According to the follwing formula: = QxHxox 100 Flow rate Qh q serxP 1 Head Him) Dens» Kglém"] of pumped medium Power P[k) 44.7 Measurement ofthe 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 ofa vacuum pump, Measurement also is done by trotting using a throttle valve in the suction line, 2s the ease may be. Reaching the guaranteed value atthe required NPSH valve 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 in the system such as flow rate, head when reducing the suction pressure depending on the ‘water temperature and the barometric level Comparison of head, taken fom the characteristic curve measurement above, with the head. measured at actual suction negative pressure where the guaranteed NPSH value is achieved or isnot achieved, ‘The head decrease may not exceed 3 % of H, but does not have to achieve 3 % (for single-stage pumps) ‘According tothe specifications inthe order, 1 or 3 fo § measuring points are used. For 2-stage pumps, the max, head decrease may not be AH 1.5%. NPSH tests of mult-stage pumps are thus not possble, nal down Proof ofthe min. achievable NPSH valve at a spectic constant flow. By reducing the suction head, staring al NPSH = 40 m, a number of measuring points (8-12) are recorded unt the Pumping breaks down, The cu-off point at 3 % head decrease since the beginning ofthe ‘measurement results in the cavitation condition ofthe pump at this pont and is defined inthe applicable standards as NPSH requied (for 2-slage purnps 1.5 % AH). Reference level for caleuaton ofthe NPSH 1, Horizontal pumps. Horizontal level through the shaft axis »b, Vertical pumps Pane surface vertical to shaft axis at impeller inlet KSB Aktiengesellschaft | AN 1997/70-05 6-02 mea yGaleulation 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 require for this: ‘suction head Hato Water temperature wear Steam pressure of water oo (ebaclute vaporization pressure) Mins oe ‘Amospheric pressure (abeoits) ep ‘Atmospheric height (absolute axe Distance reference levellmeasurement level Y [mi] ‘Speed at suction side Met im 6 Density of est eld water o tka ‘Acceleration due to gravity mist ‘The NPSH is calculated accordina to the following formula: Nest Po 4,-Po + Ve sy xg oxe * 2a NPSH= by-H,-H,+ —VE 26 ‘The conversion of the NPSII value from the measured speed to the nominal speed is made according tthe following formula (only valid for the speed range = 3 %): 2-097 «103 Nesht = NPsH x[2"]* orsox 2m Additional measurements Upon request, the electrical current | [A] and the voltage U [V] can also be measured. KSB Aktiengesellschaft | AN 1897/70-05 €-02Number of measuring points ‘The number of measuring points for the pump characteristic curve or NPSH measurements must bbe agreed in the supply agreement Characteristic curve at 0, Qnn: Goan: Quen, Gran standard measurement of 5 points (9 max.) NPSH measurement 0, Qn Qhuen: Qnoms Qraon 4 points (7 max.) 46 Meaeuring tolerances Only measuring devices are used whose measuring uncertainty ranges within the permissible limits, The folowing measuring devices are utilized! + Head: Siemens-Teleperm measurement converter DF, class exactness 0.3 % = Flow rate: IDM (magnetic-inductive plotter), Krohne/Fischer & Porter, class exactness 0.5 % - Speed HEM Speed Measurement Equipment, class exactness 0.3% + Power input Measurement of effective power by means of measurement converter and 2-phase current transformer, class exactness 0.5 % Torque measurement using torque measuring hub HBM 32 FNM, class exactness 0.2 % = Water temperature: PT 100 with digital display, class exactness 0.2 % = Calibration intervals: ‘Meaauring hub, PT 100 and spced every 3 years H.Q, annually 5 Guarantees ‘The rated values of the pump are guaranteed in compliance with API 610 provided that no ther 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 wil be shown for information as conversion curves according to Hydraulic Institute, KSB Aktiengeselischaft | AN 1897 /70-05 6-02, Bee Fo ee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 cut in three planes - horizontal, vertical and axial - by means of vibration pick-ups fitted on the bearing bracket. The measureng criterion isthe root mean “square velocity of all vibrations determined (vibration velocity RMS in mmis). ‘Tha limit stiulsted by API 810i for horizontal pumas 3 mmis in the preferred aparating range of the pump. Inthe allowable operating range, a vibration velocity of up to 3.9 mms (max.) Is permissible. For vertical pumps the limit § mm/s in the preferred range and 6,5 mmis| in the allowable range is applicable. Alternatively, itis also possible to measure the max. vibration amplitude (peak-to-peak). horizontal vertical Limit in preferred ranae: 2.0 mils (50 urn) 4.0 mils (100 um) Limit in allowable range 2.6 mils (65 um) 5.2 mils (130 um) ‘The frequency spectrum (FFT analysis) can be measured, if requested 7 Measurement of B ing Temperature Ifrequired, 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 postion of the pump side or motor side bearing im norzontal direction 8 Test report ‘The test results are stored in the central computer ofthe test bay supervision and on other electronic data carriers, Upon request, test reports and test curves are prepared forthe customer. AN 1897 170-08 €-02 KSB Aktiengesellschaft[ww] 2p1s uopons peoy =H PIs SBIEUESIP Peat = FH ‘Aouarya sojoyN = =" a= 0. [wut] apis uorons uu) 4G SZ: 7 ope s8.ey29 — se}oueyp Buds = (Ay ML [wit] }aweip opps Budd = 0 GHOLGEN Gp {wi} jonoy soyeworeg = %q OU yb yd , sven LLL) IGGL UL, YT, YER, a Vb bi \\VG ay 3 n } a let | 5 wn emotions & al 3 z : 2614 KSB Aktiengeselischaft40 {su Ao} uogesa = sans lo a \ voneinauig pasoig — pagisel dung 3 AN 1897 170-08 E-02 KSB Aktiengesellschaft