Performance Testing of Vertical Turbine Pumps For Power Plant Applications

Xylem Water Solutions (India) Pvt. Ltd.
PERFORMANCE TESTING OF VERTICAL TURBINE PUMPS

FOR
POWER PLANT APPLICATIONS
Ron Sassoon
Cell : + 91 7738083550
Email : ron.sassoon@xyleminc.com April 2012
Xylem Water Solutions (India) Pvt. Ltd.,
Transformation (November 2011) -
The name Xylem is derived from classical Greek and is the tissue that transports water in
plants, highlighting the engineering efficiency of our water-centric business by linking it with
the best water transportation of all that which occurs in nature
Xylem is a premier pure-play water technology company
A singular focus on innovative solutions serving global water markets
Headquartered in White Plains, N.Y
12,000 employees worldwide
Presence in more than 150 countries
2011 revenues of $ 3.8 billion
More than a century of experience in the water industry
Xylem [XYL] will be a leading global water technology provider, enabling customers to
transport, treat, test and efficiently use water in public utility, residential and commercial
building services, industrial and agricultural settings.
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Present scenario : -
3
Need for change : -
1. Critical analysis of existing performance qualification methods.
2. Acceptance of pumps > 90% Efficiency.
3. Evaluate performance measurement with direct measurements.
4
Leap forward for high efficiency system: -
5
Testing pump for 90 % & above : -
6
Testing pump for 90 % & above ( Multispeed ) : -
7
Impact of efficiency on the pump operating cost : -
Case I Case II
Plant capacity 2 x 660 MW 2 x 660 MW
Pump application Circulating cooling water
Number of pumps 2 x 50 % ( 4 nos ) 2 x 50 % ( 4 nos )
Cooling Water required per unit 90,000 Cu.m / Hr 90,000 Cu.m / Hr
Pump capacity @ head 45,000 Cu.m / Hr @ 25 MWC 45,000 Cu.m / Hr @ 25 MWC
Pump efficiency 88 % 90 %
Duty point pump input power 3481.51 KW per pump 3404.14 KW per pump
Motor rating @ 15 % Margin 4004 KW per pump 3915 KW per pump
Total duty point power ( 4 pumps
)
13,926.02 KW 13,616.56 KW
Difference in duty point power 309.46 KW
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Cost of operating a low efficiency circulating cooling water pumps ???
Pump testing : -
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TRADITIONAL 2 WATT METER TESTING
WITH JOB MOTOR
Shortfalls in normal Performance testing method : -
1. Full column pipe length.
2. Calibrated job motor.
3. Full speed.
4. Indirect way of shaft power measurement.
5. Manual recording of reading # No data log.
6. Lack of verification of motor efficiency at full & part load.
7. Unavailability of performance at variable speed.
8. All the above results in shaft power measurement errors & inefficiencies.
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Suggested Performance testing method : -
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1. SUPPLY WITH HIGH VOLTAGE VFD FOR 50/ 60 HZ CONSTANT
2. FREQUENCY IRRESPECTIVE OF VARATION OF GRID FREQUENCY
VARIATION
3. STEPLESS OUT PUT VOLTAGE SELECTABLE FORM 3.3 KV TO 11 KV.
4. TORQUE TRANSDUCER BETWEEN PUMP AND MOTOR FOR ACCURATE
SHAFT POWER MEASUREMENT.
5. DATA ACQUISITION SYSTEM TO ELEMENT MANUAL READING.
6. ACCURATE MEASUREMENT OF PUMP AND MOTOR POWER AND
EFFICIENCY.
7. NO CALIBRATED MOTOR IS REQUIRED.
8. PUMP TESTING WITH FULL COLOUMN LENGTH AND FULL SPEED.
9. PUMP AND MOTOR POWER MEASUREMENT AT MULTI SPEED OPERATION.
Advantage of power measurement by torque transducer : -
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Key features of the proposed system : -
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1. Supply with high voltage VFD offering 50/ 60 HZ constant.
2. Stable frequency irrespective of variation of the grid frequency variation.
3. Step less output voltage selectable from 3.3 KV to 11 KV.
4. Torque transducer between pump & motor gives accurate shaft power readings.
5. Automated data acquisition system eliminates requirement of manual readings.
6. Accurate measurement of pump & motor power & efficiency.
7. Calibrated motor not required.
8. Pump to be tested with full column suspension length & at full speed.
9. Pump & motor power measurements can be had at multi speed operation.
Schematic diagram of the proposed system : -
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Test facility specifications : -
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1. Wet pit 45 mts x 7.9 mts x 10 mts deep for testing vertical turbine pumps.
2. Dry pit 25 mts x 8 mts x 7 mts deep for testing horizontal split case pumps &
metallic volute pumps.
3. Overhead crane capacity 90 T & 40 T.
4. Variable frequency drive for testing of pumps at 50 Hz & 60Hz frequency.
5. Supply capacity up-to 7.3 MW.
6. Flow measuring capacity of up-to 1,20,000 m^3/hr
Test facility instrumentation : -
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1. Details of measuring instruments :
2. Output of all the instruments integrated thru DAS in control room.
3. No human intervention during testing process to eliminate any errors.
Select reference of high efficiency pumps : -
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Sr.
No.
Client Year of
supply
Qty Model Type Discharge
Cu.M/Hr
Head
M
Speed
RPM
Motor
HP
1 Yanpet, Saudi Arabia 1998 1 132 x 96 WCBR
Vertical
Column
60,046 20 212 5360
2
Korea Hydro & Nuclear
Power - Shin Kori Units 1 & 2
2003 8 100 x 84 WCA
Vertical
Column
44,324
15 293 3200
3
Southern Power Station,
Israel
1982 4 108 x 78 WCAR
Vertical
Column
41,328 15 330 3000
4 We Energies - Elm Road 2007 4 96 WCAX
Vertical
Column
46,597 5.9 225 1750
5 Amergen - Clinton 2008 1 114 x 84 WMCC
Vertical
Column
43,089 29.8 320 5500
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This is not special for us.
Registered Office & Factory : Plot no. 731, GICD Savli, Manjusar, Savli Road,
Vadodara 391 770
Telephone : +91-2667-265 700
Fax : +91-2667-265 764
Corporate office : Ground & First Floor, Vishnu Shivam Mall,
Thakur Village, Kandivali (East),
Mumbai 400 101
Telephone : + 91 22 40 370 370
Web : www.xyleminc.com / www.xylemindia.in
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THANK YOU
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Performance Testing of Vertical Turbine Pumps For Power Plant Applications

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PERFORMANCE TESTING OF VERTICAL TURBINE PUMPS

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