FS DOCUMENT No. FPD-PTP-MAS PERFORMANCE TEST PROCEDURE : FLOWTECH ENGINEERS : CETHAR VESSELS LTD

Transcription

1 FS No. SHEET 1 OF 7 TITLE PROCEDURE CUSTOMER END USER : FLOWTECH ENGINEERS : CETHAR VESSELS LTD CUSTOMER PO No. EQUIPMENT TAG No. SERVICE PUMP MODEL FS REF. No. : FS/FT/CVL/012/10-11 : WPP13001 A/B,WPP13002 A/B,WPP53002 A/B,WPP63001 A/B,WPP13005 A/B/C,WPP13003 A/B/C,WPP13004 A/B,WPP13006 A/B,WPP13007 A/B,WPP13002,WPP63002,WPP63006 : DM FEED PUMP,DM REGENERATION PUMP,CAUSTIC UNLOADING PUMP,PUMP,NEUTRALIZED WATER TRANAFER PUMP,CT MAKE UP TRANSFER PUMP,DM WATER TRANSFER PUMP, BOILER INITIAL FILLING PUMP,SERVICE WATER TRANSFER PUMP,PORTABLE WATER TRANSFER PUMP, EFFULUENT TRANSFER PUMP,DUST SUPPRESSION TRANSFER PUMP. : 65-40CPX160,80-50CPX160,50-32CPX200,80-50CPX250,32-20CPX200,65-40CPX160 : MAS QTY. : 2,2,2,2,3,3,2,2,2,1,1 REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

2 SHEET 2 of 7 1. OBJECTIVE: This procedure establishes the minimum requirements for performance testing of CPX pumps in accordance to EN ISO 9906:1999 Grade 2, will form the guideline for performance test operators and Test Engineer to comply with. The tests are done to determine the conformance of the pumps performance with the designed and approved specifications as applicable. 2. SCOPE: This procedure establishes performance test and NPSH test procedure and practices to be complied with during testing of CPX pumps. 3. REFERENCES: i. EN ISO 9906:1999 ii. ISO 5199 / BS 6836 iii. Hydraulic Institute Standard 4. SAFETY PRECAUTIONS: Personnel performing and witnessing the tests shall take special precautions in handling the equipment and it s maintenance in observance of safe practices. 5. TEST BED DETAILS: i. The test bed is designed with closed loop system. ii. The test bed is equipped with latest equipment like flow meter for capacity measurements and pneumatic control valves for precise flow control. iii. The test bed consists of overhead reservoir with suction line connected to pump with flexible spools. iv. From the pump discharge the line is connected back to the overhead tank and flow meter is installed in the discharge line. The brief details of instruments /equipments are as follows: Panel Rating : 0.75 kw to 298 kw HI-REL Make. Flow meter : KHRONE MARSHALL Make : RANGE 0 m 3 /hr 1944 m 3 /hr Reservoir : CAPACITY 40 m 3 Pneumatic Valves : KHRONE MARSHALL make m 3 /hr.

3 SHEET 3 of 7 Pressure Transmitters : Suction side: (-1.5) bar g. Discharge side: 0-24 bar g.. Temperature Transmitters : C. Noise Meter : Digital Type-Hand Held Noise meter Tachometer : Digital Non contact type Vibration Measurement : KOSHA DYNAMICS Make Model MV410 (B). v. The Test bed is designed for the following Capabilities. A] Flow : m 3 /hr. B] Head. :-Up to 240 m. C] Power :-Up to 298 kw. D] Speed. :-3600 RPM. E] NPSHr :-Upto Min 0.5 m. Notes : Valid Calibration Certificates shall be available for review by customer representative and / or 3rd Party. 6. PROCEDURE: i. Each pump will be tested using water as medium at temperatures less than 65 O C. ii. The stuffing box shall be assembled with gland packings wherever seals are not in scope of supply for testing. Shop motor with shop couplings shall be used. For mechanical seals where flushing connections are required connect the water line piping appropriately. Single seal testing with water does not require any flushing and quenching arrangement. iii. For mechanical seals no leakage will be allowed. For gland pack pumps a suitable rate of leakage will be allowed. iv. Pumps manufactured with oil lubrication system shall be topped with oil. Those with grease lubrication system shall be grease filled. v. All the joints and connections will be checked for leak tightness and any leakage will be corrected. vi. All protective and control devices used during the test will be checked for proper operation. vii. Pump performance data shall be taken for parameters viz., Head, Flowrate, Power, vibration, speed, noise and bearing oil temperature at a minimum of six points as stated below: Shut off valve (No vibration Data required). Minimum stable flow

4 SHEET 4 of 7 Between minimum flow and rated flow or best efficiency point, whichever is lower. Rated flow. Maximum allowable flow (as a minimum of 120% of BEP) viii. All running and mechanical tests will be completed before inspection. ix. Test results will be converted to the anticipated results at the rated speed. x. The input readings are converted for rated speed, operating viscosity and specific gravity. xi. The curve shall be plotted using the output readings. xii. The output readings are compared with the specified values for verifying the conformance of pump performance. xiii. The Flowserve standard format for input, output, graphical representation and sample calculation are used to record the performance test data. xiv. The acceptability tolerances shall be as per EN ISO 9906:1999, Values of tolerance Factors listed in Table 10, Grade -2. xv. The pumps will be operated for a minimum of 1 hour. xvi. If it is necessary to dismantle the pump after performance for the sole purpose of reduce impeller diameter to meet the tolerances, retest requirement shall be the subject of a mutual agreement. In such cases where the difference between measured values and specified values is small it is possible to apply the proportionality rules which allow the evaluation of the new characteristics with the possibility to avoid a new series of tests. This shall be done in accordance with Annex B of EN ISO 9906:1999. xvii. Vibration values shall be recorded for all points except shut off. Vibration values shall be taken on pump locations at three positions on the bearing housing in axial, vertical and horizontal directions. These values shall be measured radially at the bearing housings at a single operating point at rated speed (± 5%) and rated flow (± 5%) when operating without cavitation. The vibration measured during the performance test shall not exceed the values shown in Table* below. Maximum r.m.s values of the vibration velocity Speed of Rotation, for the shaft centerline height h1. n h1 < 225 mm h1 > 225 mm min -1 mm/s mm/s n< < n < * Table is referred from BS xviii. The bearing oil temperature shall be measured before start and after test.

5 SHEET 5 of 7 xix. The temperature rise shall not exceed value specified by customer specifications above ambient temperature during the shop test. xx. The noise level shall be tested by holding the noise measuring device at a distance of 1m from the pump. It shall not exceed 85 db (A). This shall be applicable for all measured points and for NPSH test also. 7. NPSH TEST PROCEDURE: i. The NPSHr test shall be performed if at the rated point NPSHa NPSHr 1m. ii. Set the rated / duty flow rate by throttling discharge valve or increasing vacuum as per above specified applicable method. iii. Record the suction pressure, discharge pressure, flow rate, speed, water temperature, noise level and atmospheric pressure using a barometer. Reduce the suction pressure for the next point. Record all the parameters as above. Repeat for different suction pressures until 3% head drop is observed. Feed the values in the Flowserve standard formats and the output values and graphical representation shall be recorded. 8. STRIP TEST: i. The pump casing shall be dismantled from the assembly. Parts having close clearance such as impeller profile and casing profile shall be checked for any abnormal rubbing and wear. 9. RECORDS: i. The performance and NPSH (if applicable) test record is maintained in format No. FPD/CBE/QA/F/11 Rev. No: 00. ii. The report is endorsed by authorized QA signatory and customer / TPIA review is done as applicable.

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