Centrifugal Pump Testing Standards - Presentation by ITT

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This presentation will give you all the details you need to know about Centrifugal Pumps Testing Standards.

It talks about API 610 , HI1.6, ISO 9906. What standards to follow while specifying pump testing and tolerances.

Published in: Education, Business, Technology

Centrifugal Pump Testing Standards - Presentation by ITT

  1. 1. Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line Simon Bradshaw Director, API Product Development & Technology ITT Goulds Pumps October 22, 2013 Stan Knecht Director, Product Marketing ITT Goulds Pumps
  2. 2. Agenda • Overview of new testing standards used in the market today • Testing tolerances: Why they’re needed and how they work • Understanding how tolerances impact the product received and plant operating performance • Which performance standards to specify, and how 2 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  3. 3. Overview:ANSI/HI 14.6-2011 • The ANSI/HI Standard 14.6-2011 is intended to be used for centrifugal pump acceptance testing at recognized pump test facilities (i.e., a manufacturer’s facility or test laboratory). • HI 14.6-2011 is available for download at www.pumps.org. 3 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  4. 4. Why Do We Need Tolerances? • There is no such thing as a perfect cast or machined part. Everything is subject to some variation. • The combination of variations in the pump impeller, pump casing and overall assembly yield a scatter in performance. • The test loop components and instrumentation introduce further variability and scatter. • The scatter can be reduced by better manufacturing techniques (i.e., investment cast impellers instead of sand cast ones). • Better manufacturing and test techniques typically cost more. 4 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  5. 5. Hydraulic Institute, API And ISO Pump Performance Standards • HI 14.6-2011 “American National Standard for Rotodynamic Pumps for Hydraulic Performance Acceptance Tests”* (supersedes HI 1.6 and 2.6) • API 610 11th edition • ISO 9906-2012 “Rotodynamic pumps – Hydraulic performance acceptance tests”* • The direction is toward one worldwide standard for pump acceptance testing. *In practice HI 14.6-2011 ~ ISO 9906-2012 with common acceptance criteria 5 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  6. 6. Previous Testing Standards • HI Standard 1.6-2000 (for centrifugal pumps) had two acceptance levels: Level A: (default level) At a rated head or rated flow (not both), it allowed for a positive tolerance for head, flow and efficiency, but no negative tolerance. Level B: At a rated head or rated flow (not both), it allowed for a positive and negative tolerance for head, flow and efficiency. • HI Standard 2.6 (for vertical pumps) had an acceptance standard the same sas Level A. • ISO 9906-1999 had two acceptance levels: Grade 1 and Grade 2 Both had bilateral tolerances for rated head or rated flow and allowed a negative tolerance on efficiency. • All the above standards are withdrawn and considered obsolete. 6 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  7. 7. Other Pump Testing Standards You May Encounter • ASME PTC 8.2: Mainly used on testing of larger pumps for power station application • DIN 1944: Obsolete and replaced by ISO 9906 • ISO 2548: Withdrawn and replaced by ISO 9906 • ISO 3555: Withdrawn and replaced by ISO 9906 7 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  8. 8. HI 14.6-2011 & ISO 9906-2012(E) Grade Test Guarantee Parameter Requirement Grade 1 Grade 2 Grade 3 ∆tQ 10% 16% 18% ∆tH 6% 10% 14% Acceptance Grade Symbol 1B 1E 1U 2B 2U 3B Rate of Flow Mandatory tQ (%) ± 5% ± 5% 0% to +10% ± 8% 0% to +16% ± 9% Total Head Mandatory tH (%) ± 3% ± 3% 0% to +6% ± 5% 0% to +10% ± 7% tP (%) +4% +4% +10% +8% +16% +9% t (%) -3% -0% -0% -5% -5% -7% Powera Efficiencya Optional (either/or) • The power and efficiency tolerances are not the result of an exact calculation using the maximum values of a related column. They are instead reflecting real life experience. For grade 1E and 1U, no negative tolerance on efficiency is allowed. • Note: All tolerances are percentages of values guaranteed. • Unless agreed upon with the buyer, any other specified duty points are subject to acceptance grade 3B. 8 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  9. 9. HI 1.6-2000 level A to HI 14.6-2011 1U Pump rated Head ft (m) < 200 (<60) < 200 (<60) 200 to 500 (60 to 150) Pump rated Flow gpm (m3/h) 0 to 2999 (0 to 680) >=3000 (>=681) All All Total Head tH (%) 0% to +8% 0% to +5% 0% to +5% Rate of Flow tQ (%) 0% to +10% Efficiency t (%) • The old level A is converted to Grade 1U. >500 (>150) -0% • The acceptance bands currently don’t change with rated head or flow. 0% to +3% • You can now specify either a power or efficiency tolerance – not both. Grade Test Guarantee Parameter Requirement Grade 1 Grade 2 Grade 3 ∆tQ 10% 16% 18% ∆tH 6% 10% 14% Acceptance Grade Symbol 1B 1E 1U 2B 2U 3B Rate of Flow Mandatory tQ (%) ± 5% ± 5% 0% to +10% ± 8% 0% to +16% ± 9% Total Head Mandatory tH (%) ± 3% ± 3% 0% to +6% ± 5% 0% to +10% ± 7% tP (%) +4% +4% +10% +8% +16% +9% t (%) -3% -0% - 0% -5% -5% -7% Powera Efficiencya Optional (either/or) 9 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  10. 10. HI 1.6-2000 level B to HI 14.6-2011 ft (m) < 200 (<60) < 200 (<60) Pump rated Flow gpm (m3/h) 0 to 2999 (0 to 680) >=3000 (>=681) Total Head tH (%) Rate of Flow tQ (%) t (%) • There is no close equivalent of Level B in the new standard. • You need to pick the grade that best meets your needs. -5% to +5% Efficiency >500 (>150) 0% to +3% Pump rated Head 200 to 500 (60 to 150) - 100/[(120/ηp)-0.2]% All -3% to +5% ?? Grade Test Guarantee Parameter Requirement Grade 1 Grade 2 Grade 3 ∆tQ 10% 16% 18% ∆tH 6% 10% 14% Acceptance Grade Symbol 1B 1E 1U 2B 2U 3B Rate of Flow Mandatory tQ (%) ± 5% ± 5% 0% to +10% ± 8% 0% to +16% ± 9% Total Head Mandatory tH (%) ± 3% ± 3% 0% to +6% ± 5% 0% to +10% ± 7% tP (%) +4% +4% +10% +8% +16% +9% t (%) -3% -0% - 0% -5% -5% -7% Powera Efficiencya Optional (either/or) 10 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  11. 11. ISO 9906-1999 to HI 14.6-2011/ISO 9906-2012 Grade 1 • The old Grade 1 is now Grade 1B, with a rounding of the head tolerance. Grade 2 Total Head tH (%) ± 3% Total Head tH (%) ± 5% Rate of Flow tQ (%) ± 4.5% Rate of Flow tQ (%) ± 8% Efficiency t (%) -3% Efficiency t (%) -5% • The old Grade 2 is now Grade 2B. • You can now specify either a power or efficiency tolerance – not both. Grade Test Guarantee Parameter Requirement Grade 1 Grade 2 Grade 3 ∆tQ 10% 16% 18% ∆tH 6% 10% 14% Acceptance Grade Symbol 1B 1E 1U 2B 2U 3B Rate of Flow Mandatory tQ (%) ± 5% ± 5% 0% to +10% ± 8% 0% to +16% ± 9% Total Head Mandatory tH (%) ± 3% ± 3% 0% to +6% ± 5% 0% to +10% ± 7% tP (%) +4% +4% +10% +8% +16% +9% t (%) -3% -0% - 0% -5% -5% -7% Powera Efficiencya Optional (either/or) 11 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  12. 12. API 610 8th-10th / 11th edition API 610 8th, 9th, 10th Edition Pump rated Head ft (m) < 500 (<150) 501 to 1000 (151 to 300) > 1000 (> 300) Total Head tH (%) -2% to +5% -2% to +3% -2% to +2% Shutoff Head tHS (%) -10% to +10% Power tP (%) • API 610 8th through 10th edition had distinct tolerances. -8% to +8% -5% to +5% +4% API 610 11th Edition Pump rated Head ft (m) Total Head tH (%) Shutoff Head tHS (%) Power tP (%) <=250 (<=75) >250 to 1000 (>75 to 300) > 1000 (> 300) -3% to +3% -10% to +10% -8% to +8% +4% -5% to +5% • API 610 11th edition is functionally equivalent to HI 14.6-2011and ISO 9906-2012 Grade 1B, with an added test point for shutoff head. • API 610 does not have a rated flow tolerance, making it unsuitable for testing high specific speed pumps. • API 610 does not have any guarantee of efficiency (only power), making it unsuitable for efficiency-critical applications. 12 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  13. 13. HI 14.6-2011 Recommended Default Acceptance Grade Based On Purchaser's Intended Service Default acceptance grade based on purchaser's intended service Rated shaft power of pump Application >100kW >10 to 100kW (134 hp) (13 to 134 hp) Municipal water and wastewater 2B 1B Building trades and HVAC 2B 1B Electric power industry 1B 1B API pumps 1B 1B Oil and gas industry Pipeline 1B 1B Water injection Not applicable 1B Chemical industry 2B 2B Cooling tower 2B 2B Pulp and paper 2B 2B Slurry 3B 3B General industry 3B 2B Dewatering, drainage and irrigation 3B 2B Pumps not listed above 3B 2B Note: This table applies where a guarantee point has been agreed upon, but no tolerance standard has been specified. • Both HI 14.6 and ISO 9906 set a default test tolerance when it is not defined by the purchaser. • The default tolerance may not be sufficient for your process. • It is important that you actively review what tolerance you require. 13 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  14. 14. ITT Default Performance Standards Category ANSI Process Pump Large Process ISO 5199 Process Pump Vertical Turbine/ Can Multistage Double Suction Pump Slurry Pumps API Axial Flow Model 3196, 3796, CV3196 LF3196 3996, 3298 3180/85, 3175 IC, ICP ICM VIT VIC 3355, 3393 3410, 3409, 3420, 3498 XHD,5500, SRL, JC, VJC 3700,3910 3620, 3600, 7200 AF ITT Default Std 1U (1B future) (HI 14.6) 1B (HI 14.6) 2B API 610 11th Ed/ 1B/2B 1B (HI 14.6) 1B (HI 14.6) 2B (HI 14.6) API 610 11th Ed. 2B (HI 14.6) (ISO 9906) 14 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  15. 15. Make Sure You Understand What Is Being Quoted To You By Your Supplier • If you have not specified any performance criteria, what is the supplier standard ? • This should be identified either in the supplier proposal or on the performance curve submitted with the bid. • This is a critical question to ask, whether you are purchasing a performance test or not. • Note: It is common practice in the pump industry that all pumps are not performance tested as standard. Many pump manufacturers can rely on historical test data to assure pump performance quality. • However, all industrial pumps are pressure tested as standard to ensure safety and structural integrity. 15 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  16. 16. Typical Pump Proposal Datasheet 16 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  17. 17. Curve Drawn To HI 14.6-2011 1U Tolerance Standard Curve says 87% efficiency… …if there’s no negative efficiency tolerance. Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line 17
  18. 18. Curve Drawn To HI 14.6-2011 1U Tolerance Standard • The HQ curve must pass through at least one of the red lines representing the flow and head tolerance. • The power curve must pass through the vertical red line representing the power tolerance. OR • The efficiency curve must pass through the vertical red line representing the efficiency tolerance. 18 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  19. 19. Curve Drawn To ISO Grade 2B Tolerance Standard Curve could say 90.5% efficiency… …if there’s a negative efficiency tolerance allowed by standard used. Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line 19
  20. 20. Curve Drawn To ISO Grade 2B Tolerance Standard • The HQ curve must pass through at least one of the red lines representing the flow and head tolerance. • The power curve must pass through the vertical red line representing the power tolerance. OR • The efficiency curve must pass through the vertical red line representing the efficiency tolerance. 20 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  21. 21. Life Cycle Cost Impact Of Higher Power www.realgouldsparts.com/calculators-apps 21 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  22. 22. Other Pump Tests That May Be Specified Type of Test HI 14.6-2011 Hydrostatic Test P, A NPSH Test P, A ISO 99062012(E) HI 9.6.4-2009 ISO 9908, 5199, 9905 P, A ISO 3740, 3744, 3746 P, A P, A P, A P, A P, A Vibration Test Sound Level (Noise) Test Mechanical Run Test API 610 11th Edition P P, A P P, A P String Test P = Test procedure is defined A = Acceptance level is defined 22 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  23. 23. Key Takeaways • New pump performance standards from both HI and ISO have been aligned to make it easier to specify reliable and predictable pump performance on a global basis. • It’s important to understand what performance will be provided if no pump performance is specified–default standards can apply. • Most performance standards allow for bi-lateral tolerance, which can impact life cycle costs, as well as system performance. 23 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
  24. 24. Questions? For more information, contact: ITT Goulds Pumps IP.communications@itt.com A recording of this presentation will be available on www.gouldspumps.com after Friday, October 25th. 24 Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line

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