making sense of pump testing standards - how understanding standards can impact the bottom line.pdf
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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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Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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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Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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.
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
• 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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Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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.
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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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Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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.
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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
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%
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%
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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
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%
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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
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%
Grade 1
Total Head tH (%) ± 3%
Rate of
FlowtQ (%) ± 4.5%
Efficiency t (%) -3%
Grade 2
Total Head tH (%) ± 5%
Rate of
FlowtQ (%) ± 8%
Efficiency t (%) -5%
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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%
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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.
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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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Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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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Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
Typical Pump Proposal Datasheet
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Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
Curve Drawn To HI 14.6-2011 1U Tolerance Standard
17Curve says 87% efficiency…
…if there’s no negative efficiency tolerance.
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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.
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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.
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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.
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
Life Cycle Cost Impact Of Higher Power
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www.realgouldsparts.com/calculators-apps
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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
Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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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Making Sense of Pump Testing Standards: How understanding standards can impact the bottom line
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]