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DOCUMENT TITLE :
FACTORY PERFORMANCE TEST PROCEDURE FOR EQ0390

EQUIPMENT NAME : VERTICAL PUMP

ITEM NO. :ALL ITEMS

P-4561 A/B, P-4562 A/B, P-4563 A/B
P-4564 A/B, P-4565 A/B, P-4566 A/B
P-4567 A/B, P-2501 A/B/C/D

STATUS

DATE: APPROVED
01.May.13
APPROVED WITH COMMENTS

SIGNATURE: COMMENTED

M.Jalili REJECTED

Next Issue Description

SHALL BE FILLED BY CLIENT

A3 12-Apr-2013 ISSUED FOR APPROVAL W.Cherry L.Tino C.Ryan

A2 14-Mar-2013 ISSUED FOR APPROVAL W.Cherry L.Tino C.Ryan
A1 04-Mar-2013 ISSUED FOR APPROVAL W.Cherry L.Tino C.Ryan
A0 06-Feb-2013 ISSUED FOR APPROVAL T.Anne L.Tino C.Ryan
REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

DEEP BLUE PUMP CO.

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MODIFICATION / APPROVAL PAGE

Revision Revision
A0 A1 A2 A3 A0 A1 A2 A3
Page Page

1 x x x 15 x

2 x x x 16 x x

3 x 17 x x

4 x x 18 x

5 x 19 x

6 x 20 x

7 x x x 21

8 x 22

9 x 23

10 x 24

11 x 25

12 x 26

13 x 27

14 x 28
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Content
Chapter Content Page
1 Scope 4
2 Applicable Codes and Standards 4
3 Test Requirements 4
4 Performance Test 5
5 NPSH Test 10
6 Mechanical Running Test (Complete unit test) 12
7 Vibration test 14
8 Sound level test 17
9 Temperature Rise Test 17
10 Apparatus, Instruments and Accessories 17
App.1 Check List Format Per Item 18
App.2 Sketch of Test System 19
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FACTORY PERFORMANCE TEST PROCEDURE

1. Scope

1.1 This test procedure describes the requirements, apparatus and accessories,
methods, acceptance criteria and records of factory performance test containing
performance test (capacity, head, efficiency, and shaft power), NPSH, vibration and
temperature rise, etc. for centrifugal pump.
COMPANY/EMPLOYER : Persian Gulf Star Oil Company.
PROJECT : Bandar Abbas Gas Condensate Refinery (BAGCR) Project.
VENDOR: DEEP BLUE PUMP CO.
GOODS : VERTICAL PUMP.
JOB-SITE : Bandar Abbas ( Iran ).

1.2 This is applicable to overhung, between-bearing and vertical types of pumps

designated per API 610 Standard Tenth Edition, October 2004 Table 1 manufactured by
pump vendor.

1.3 The exact scope of tests shall be in accordance with approved inspection and test
plan (ITP) or agreed upon between purchaser and vendor, not limited to this procedure.

2. Applicable Codes and Standards

API 610 Standard Tenth Edition, October 2004

ISO9906:1999 Rotodynamic Pump – Hydraulic performance acceptance tests

GB3214 Methods for Measurement of Capacity of Pump

3. Test Requirements

3.1 General

3.1.1 The exact scope of tests shall be in accordance with the CONTRACT and the
test points will be according to item 4.1 of this procedure.
The test includes:
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1). Performance Test

2). NPSH test (will only performed for the NPSHa-NPSHr margin less than 0.6 m).
3). Mechanical Running Test (Complete unit test)
4). Vibration Test
5). Noise Level Test
6) Temperature Rise Test
3.1.2 Unless otherwise specified, each pump shall be given a performance test.
Performance tests shall be performed using water (The specific gravity of the water is 1,
and the chloride of the water is less than 50ppm) at a temperature less than 65 degree
C.
3.1.3 Check and Verify calibration of all test apparatus and instruments which shall be in
the valid period.

4. Performance Test

4.1 The performance test shall be performed at five points they are: Point 1)Shut off
point (no vibration data required), Point 2)minimum continuous stable flow, Point
3)midway points between minimum and rated flow; Point 4)rated flow; Point 5)maximum
allowable flow (as a minimum, 120% percent of best efficiency point).

4.2 Test Method

The capacity, head, shaft power, efficiency, running speed, vibration, bearing
temperature shall be measured or calculated at each point specified in Chapter 4,5,6,7,8
and 9 below.

4.3.1 Capacity

4.3.1.1 The test method of capacity is in accordance with standard GB3214.

4.3.1.2 GB3214 is Methods for Measurement of Capacity of Pump standard which
specified requirements for the flow meter and the measuring methods.
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4.3.1.3 The instrument for capacity measurement is electromagnetic flow meter, the
parameter of capacity can be read directly from the flow meter during actual duration of
test.

4.3.2 Head measuring

4.3.2.1 Head of pump should be calculated according to the standard ISO 9906:1999.

4.3.2.2 The formula of head:

P 2 − P1
H＝
+ (Z2 － Z1)+
＋ρg
Among them,
H=Head of pump
P1=Suction pressure
P2=Discharge pressure
(Z2-Z1)= The distance between pump suction centerline and discharge surface.
V2= Velocity of medium flow through pump discharge
V2= Q (capacity)/Ad (surface area of the discharge)
V1= velocity of medium flow through pump suction
V1= Q (capacity)/As( surface area of the suction)

4.3.3 Running speed shall be read from digital meter used. The test speed shall be
within 3 percent of the rated speed shown on the pump data sheet.

4.3.4 Shaft Power

Shaft power Pa should be the following when efficiency ηmot of motor is known (Pgr is
input power of motor).
Pa ＝ Pgr × ηmot

4.3.5 Calculation of efficiency of pump

Pu
η＝ ×100%
Pa
Pu: Hydraulic power.
Pu=Qsp * Hsp * SG *9.8* / 3600
Qsp = Capacity at Rated speed( m3/h),
Hsp = Head at Rated speed( m)
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nsp = Rated speed (rpm)

SG: Specific gravity of test water (1.0)

4.3.6 Correction of test result at the rated speed

Qsp = Capacity at n × (nsp / n)

Hsp = Head at n × (nsp / n)2
Psp = Shaft power at n × (nsp / n)3
NPSH at nsp = NPSH at n × (nsp / n)2
Where: nsp — Rated speed
n — Testing speed
NPSH—NPSH required
4.4 Acceptance Criteria

Pumps shall perform within the tolerances given in Table 14 of API610 10th Edition.

Table 14-Performance tolerances

Condition Rated Point % Shut off %
Rated differential head

0 m to 150 m -2 +10
(0 ft to 500 ft) +5 -10 a
151 m to 300 m -2 +8
(501 ft to 1 000 ft) +3 -8 a
Over 300 m -2 +5
(1 000 ft) +2 -5 a
Rated power +4 b ---
Rated NPSH +0 ---
NOTE Efficiency is not a rating value.

a. If a rising head flow curve is specified (see 5.1.13 cited from API 610), the
negative tolerance specified here shall be allowable only if the test curve still shows
a rising characteristic.
b. Under any combination of above (cumulative tolerance are not acceptable).
Maximum allowable noise level is 87 dB(A) @ 1 m for the pump and 90 dB(A) @ 1 m
for the complete train. Don't allow positive tolerance.
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4.4Test report
4.4.1 PUMP PERFORMANCE TEST REPORT
Contract No.:
Item No: Test Date: Record No:

Pump Model: Test Equipment/Instrument

Manufacture Serial No: Name Specification Calibration Period Precision

Impeller Diameter For first stage: mm

Capacity Meter DN (mm) 1 Year
Impeller Diameter For other stage: mm
Suction
Motor Type: KW 1 Year
Manometer
Discharge
Motor Efficiency: % MPa 1 Year
Manometer

Rated Capacity: m3/h Speed Meter rpm 1 Year

Rated Total Head: m Power Meter Watte Meter 1 Year

Suction Discharge DN DN
Rated Speed: r/min
Calculating Position Position (m) Suction(mm) Discharge(mm)
Test Liquid Constant
℃ -----
temperature liquid:

Testing Actual Value

Total Head Capacity Shaft Power
Differential Test
Discharge Suction (H) (Q) (Pa) Efficiency
Velocity Speed
Head (P2) Head(P1) Test Rated Test Rated Power Test Rated (η)
Head (n)
Speed Speed Speed Speed Meter Speed Speed
mm
MPa
MPa/(m) Hg/ m m m m3/h m3/h r/min ---- KW KW %
/(m)
(m)

The difference between test head and rated

head %. Tested By:
Remarks Result
Corrected shaft power kw due to specific Inspected By:
gravity.
Signed and stamped by TPI/ Purchaser
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4.4.2 PUMP PERFORMANCE TEST REPORT (Vibration, Noise and Oil Temp.)

PUMP PERFORMANCE TEST REPORT

(Vibration, Noise and Oil Temp.)

Contract No. Test Equipment/ Instrument

Calibratio
Item No. Name Specification Precision
n Period

Pump Model Capacity Meter

Test Date Discharge Manometer

Record No. Speed Meter

Manufacture
Infrared Thermometer
Serial No.

Rated Capacity m3/h Noise Meter

Rated Head m Vibration Meter

Testing Actual Value

Discharge
Running Capacity Speed Oil Sump
No. Head Vibration Noise
Temperature
(P2) (Q) (n)

MPa m3/h r/min mm/s dB °C

1
2
3
4

Tested by
Result Remark

Inspected by
Signed and stamped by TPI/ Purchaser
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5. NPSH Test

5.1 NPSH Test will only performed for the NPSHa-NPSHr margin less than 0.6 m

5.2 NPSH test (if any) shall be performed at four points, they are: Point1) minimum
continuous stable flow; Point 2) midway points between minimum and rated flow; Point
3) rated flow; Point 4) maximum allowable flow (as a minimum, 120% percent of best
efficiency point).

5.3 NPSH test will be performed for the pumps NPSH margin less than 0.6m.

5.4 NPSH test for vertical pumps shall be done with installed strainer.

5.5 3 % drop in head (first stage head on multistage pumps) shall be interpreted as
indicating performance impairment. The first stage head of pumps with two or more
stages shall be measured using a separate connection to the first stage discharge if
possible. If this is not feasible, testing of the first stage only should be considered.

5.5 Acceptance Criteria

NPSHR at the rated point shall not exceed the quoted value (see API Table 14).,
Pumps NPSH test shall perform within the tolerances given in Table 14 of API610 10th
Edition, please refer to item 4.4 Table 14-Performance tolerances
Dismantling to correct NPSHR requires a retest (see API 7.3.3.5 and 7.4.3.1).
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5.6 Test report

NPSH TEST REPORT
Contract No. Test Date:

Item No. Record No.

Pump Model Manufacture Serial No.

Differential
Test Condition
Position
Suction m Discharge m
Diameter of NPSHR
mm m Speed r/min
Suction Required
Water Atmosphere
℃ Vapor Pressure m m
Temperature Pressure
Capacity Total Head Speed
3
Rated Working Point m /h m r/min

Working Velocity 3 % drop in

Suction Head Discharge Head NPSH Total Head
capacity head head
No.
3
m /h m mm Hg m MPa m m m m

1
2

10

Test By
Result Remarks
Inspected By

Signed and stamped by TPI/ Purchaser

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6. Mechanical Running Test

6.1 When the performance test had been finished, mechanical run test shall be
performed in the capacity which does not affect the motor; rated capacity as usual.
The test standard will be referred to Clause 7.3.4.7.3 of API 610, 10th edition.

6.2 The duration for the mechanical run test is 4 hours after oil temperature has been
stabilized.

6.3 The test data shall be recorded each 30 minutes for the whole performance test
length, such as running speed, temperature rise, vibrations, sound level, flow rate and
discharge pressure, etc.

6.4 During mechanical running test contract motor, seal, seal system, coupling skid
shall be used to make sure run the pumps with the complete unit.
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6.5 Test report

RUNNING TEST REPORT

Contract No. Test Equipment/Instrument

Manufacture Calibration
Item No. Name Precision
No. Period

Product Type Capacity Meter

Test Date Discharge Manometer

Report No. Speed Meter

Manufacture Serial No. Power Meter

m3/
Running Total Capcity Noise Meter
h

Running Total Head m Vibration meter

Testing Actual Value

Discharge
Running Speed
Time Head Vibration Noise Oil sump temperature
Capacity (Q) (n)
(P2)

min Mpa m3/h r/min mm/s dB ℃

15

30

45

60

Result Tested By Inspected By

Signed and stamped by TPI/ Purchaser

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7.Vibration test
7.1 Method: Using the vibration instrument (VT-63) to test the pump’s vibration from
three directions (horizontal, vertical, and Shaft Direction).
For detail standard information, please refer to Clause 5.9.3.6 of API 610.

7.2 Acceptance Criteria

Pumps vibration test shall perform within the tolerances given in Table7 of API610 10th
Edition,

Fig. 28 of API 610

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Table 7-Vibration limits for vertical-suspended pumps

Location of vibration measurement

Pump thrust bearing
housing or
Pump shaft (adjacent to bearing)
Motor mounting flange
see Figure 28
Criteria
Pump bearing type
Hydrodynamic guide bearing
All
adjacent to accessible region of shaft
Vibration at any flow rate within the pump’s preferred
operating region
Au < (6,2 x 106 / n)0.5 um peak-to-
peak
0.5
[(10 000 / n) mils peak-to-peak]
Vu < 5,0 mm/s RMS
Overall
(0,20 in/s RMS)
Not to exceed:
Au < 100 um peak-to-peak a
(4,0 mils peak-to-peak)
Discrete frequencies Vf < 0.67 Vu Af < 0,75Au
Allowable increase in
vibration at flows
outside the preferred
30% 30%
operating region but
within the allowable
operating region
Vibration velocity and amplitude values calculated from the basic limits shall be rounded
of to two significant figures.

Where:
Vu is the unfiltered velocity, as measured;
V f is the filtered velocity;
Au is the amplitude of unfiltered displacement, as measured;
A f is the amplitude of filtered displacement;
f is the frequency;
n is the rotational speed, expressed in revolutions per minute.
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7.3 Test report

VIBRATION AND NOISE LEVEL TEST REPORT

P.O No. Item No.

Product Type Manufacture Serial No.

3
Capacity m /h Running Speed r/min

Height From Upper Surface of Baseplate to The Center of

Head m mm
Pump

VIBRATION MEARAMENT

The Bearing Position Heading The The Bearing Position Heading The
Position
Motor Impeller Standard
Measurement
Requirement
Result (mm/s)
Shaft Shaft (mm/s)
Capacity Vertical Horizontal Vertical Horizontal
Direction Direction
(mm/s) (mm/s) (mm/s) (mm/s)
(mm/s) (mm/s)

m3/h

m3/h

m3/h

m3/h

m3/h

m3/h

Tested
Date
by

Inspected
Result
By
Signed and stamped by TPI/ Purchaser
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8. Sound level test

8.1 Sound level test shall be performed and accepted as agreed between the purchaser
and the vendor, e.g. the sound level limit specified in approved datasheet in order or
approved ITP.

8.2 Test report

Sound level test report please refers to item 4.4.2. and item 6.5

9. Temperature Rise Test

9.1 The test of temperature of bearing oil sump shall be according to the requirements
paragraph 5.10.2.4 of API610 code, so that, oil sump temperature shall be below 82°C.
The sump oil temperature rise shall not exceed 39°C.

9.2 Test report

Oil sump Temperature rise test report please refers to item 4.4.2 and item 6.5

10. Apparatus, Instruments and Accessories

10.1 Control cabinet.

10.2 Connecting cable between the pump unit and the control cabinet
10.3 Piping for testing
10.4 Pressure gauge
10.5 Flow meter
1 .6 Power meter
10.7 Running speed meter
10.8 Noise meter
10.9 Vibration meter
10.10 Schematic diagram of test racks
10.11 Temperature gauge
10.12 Sketch of test system for vertical pumps please kindly refers to APPENDIX 2.
10.13 For vertical pumps, suction strainer should be installed and considered during the
NPSH test.
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APPENDIX1: CHECK LIST FORMAT PER ITEM

Contact No.: Date:
General
Pump Painting Pipe
Item No. Service Serial No. Nameplate Arrangement
Model Appearance Assembly
Dimension

Description:
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APPENDIX 2 Sketch of Test System

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