Centrifugal Pump Testing Standards - Presentation by ITT

Making Sense of PumpTesting Standards: How understanding standards can impact the bottom line

October 22, 2013

Simon Bradshaw Stan KnechtDirector, API Product Director, Product MarketingDevelopment & Technology ITT Goulds Pumps

ITT Goulds Pumps

Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line

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

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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.

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Why Do We Need Tolerances?

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• 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.


• 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

Hydraulic Institute, API And ISO Pump Performance Standards

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Previous Testing Standards

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• 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 considere d obsolete.


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

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HI 14.6-2011 & ISO 9906-2012(E)

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Test

Parameter

Guarantee

Requirement

Grade Grade 1 Grade 2 Grade 3

∆tQ10% 16% 18%

∆tH6% 10% 14%

Acceptance Grade

Symbol 1B 1E 1U 2B 2U 3B

Rate of

FlowMandatory tQ (%) ± 5% ± 5% 0% to +10% ± 8% 0% to +16% ± 9%

Total

HeadMandatory tH (%) ± 3% ± 3% 0% to +6% ± 5% 0% to +10% ± 7%

Powera

Optional

(either/or)

tP (%) +4% +4% +10% +8% +16% +9%

Efficiencya t (%) -3% -0% -0% -5% -5% -7%

• 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 specif ied duty points are subject

to acceptance grade 3B.


HI 1.6-2000 level A to HI 14.6-2011 1U

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• The old level A is converted to Grade 1U.

• The acceptance bands currently don’tchange with rated head or flow.

• You can now specify either a power or efficiency tolerance – not both.

Test

Parameter

Guarantee

Requirement


∆tQ10% 16% 18%

∆tH6% 10% 14%

Acceptance Grade


Rate of


Total


Powera

Optional

(either/or)

tP (%) +4% +4% +10% +8% +16% +9%

Efficiencya t (%) -3% -0% - 0% -5% -5% -7%

Pump

rated Head

ft

(m)

< 200

(<60)

< 200

(<60)

200 to 500

(60 to 150)

>500

(>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% 0% to +3%

Rate of

FlowtQ (%) 0% to +10%

Efficiency t (%) -0%


HI 1.6-2000 level B to HI 14.6-2011

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• There is no close equivalent of Level B in the new standard.

• You need to pick the grade that best meets your needs.

Pump

rated Head

ft

(m)

< 200

(<60)

< 200

(<60)

200 to 500

(60 to 150)

>500

(>150)

Pump

rated Flow

gpm

(m3/h)

0 to 2999

(0 to 680)

>=3000

(>=681)All

Total Head tH (%) -3% to +5% 0% to +3%

Rate of

FlowtQ (%) -5% to +5%

Efficiency t (%) - 100/[(120/ηp)-0.2]%

??

Test

Parameter

Guarantee

Requirement


∆tQ10% 16% 18%

∆tH6% 10% 14%

Acceptance Grade


Rate of


Total


Powera

Optional

(either/or)

tP (%) +4% +4% +10% +8% +16% +9%

Efficiencya t (%) -3% -0% - 0% -5% -5% -7%


ISO 9906-1999 to HI 14.6-2011/ISO 9906-2012

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• The old Grade 1 is now Grade 1B, with a rounding of the head tolerance.

• The old Grade 2 is now Grade 2B.

• You can now specify either a power or efficiency tolerance – not both.

Test

Parameter

Guarantee

Requirement


∆tQ10% 16% 18%

∆tH6% 10% 14%

Acceptance Grade


Rate of


Total


Powera

Optional

(either/or)

tP (%) +4% +4% +10% +8% +16% +9%

Efficiencya t (%) -3% -0% - 0% -5% -5% -7%

Grade 1

Total Head tH (%) ± 3%

Rate of

FlowtQ (%) ± 4.5%


Grade 2

Total Head tH (%) ± 5%

Rate of

FlowtQ (%) ± 8%



API 610 8th-10th / 11th edition

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• API 610 8th through 10th edition had distinct tolerances.

• 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.

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%-8% to +8% -5% to +5%

Power tP (%) +4%

API 610 11th Edition

Pump rated

Head

ft

(m)

<=250

(<=75)

>250 to 1000

(>75 to 300)

> 1000

(> 300)

Total Head tH (%) -3% to +3%

Shutoff Head tHS (%)-10% to

+10%-8% to +8% -5% to +5%

Power tP (%) +4%


HI 14.6-2011 Recommended Default Acceptance Grade Based On Purchaser's Intended Service

Default acceptance grade based on purchaser's intended service

Application

Rated shaft power of pump

>10 to 100kW

(13 to 134 hp)

>100kW

(134 hp)

Municipal water

and wastewater 2B 1B

Building trades and

HVAC 2B 1B

Electric power

industry 1B 1B

Oil and gas industry

API pumps 1B 1B

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.

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• 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.


CategoryANSI Process

PumpLarge

Process

ISO 5199 Process Pump

Vertical Turbine/

Can

Multi-stage

Double Suction Pump

Slurry Pumps

APIAxial Flow

Model

3196, 3796, CV3196 LF3196

3996, 3298

3180/85, 3175

IC, ICP ICM

VITVIC

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 (ISO 9906)

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)

ITT Default Performance Standards

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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.

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Typical Pump Proposal Datasheet

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Curve Drawn To HI 14.6-2011 1U Tolerance Standard

17Curve says 87% efficiency…

…if there’s no negative efficiency tolerance.


Curve Drawn To HI 14.6-2011 1U Tolerance Standard

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• 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.


Curve Drawn To ISO Grade 2B Tolerance Standard

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Curve could say 90.5% efficiency……if there’s a negative efficiency tolerance allowed by standard used.


Curve Drawn To ISO Grade 2B Tolerance Standard

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• 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.


Life Cycle Cost Impact Of Higher Power

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www.realgouldsparts.com/calculators-apps


Other Pump Tests That May Be Specified

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Type of Test HI 14.6-2011ISO 9906-

2012(E)

API 610 11th

EditionHI 9.6.4-2009

ISO 9908, 5199,

9905

ISO 3740,

3744, 3746

Hydrostatic

TestP, A P, A

NPSH Test P, A P, A P, A

Vibration Test P, A P, A P, A

Sound Level

(Noise) TestP P

Mechanical

Run TestP, A P, A

String Test P

P = Test procedure is definedA = Acceptance level is defined


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.

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A recording of this presentation will be available on www.gouldspumps.com after

Friday, October 25th.

Questions?

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For more information, contact:

ITT Goulds [email protected]

Education

Centrifugal Pump Testing Standards - Presentation by ITT