Performance Evaluation

of High speed Centrifugal pump at Varied Speed Conditions

S. Sivaprakash, RE
Fluid Control Research Institute
Palakkad, Kerala 6780623, www. fcriindia.Com

Introduction
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Objective

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Study the discharge, head, efficiency characteristics at varied speed conditions Study the NPSH characteristics at varied speed conditions

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Introduction

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Engg. Class II Class C

ISO 5198 1987, IS 13538 -1993 (RA 2002) Generally used for acceptance tests ISO 9906 1999 (ISO 3555 1977) IS 10981 1985 Special cases, Pump performance more precisely defined ISO 2548 1973 IS 9137 - 1978 Only when the Engg. Class test is inadequate for the precision required

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Engg. Class I Class B

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Precision Class Class A

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Definitions Associated
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Measuring System Measuring Instrument Steady operating conditions Unsteady operating conditions Discharge/ Flow rate Head/ Pressure NPSH Power Efficiency

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Scope of Testing
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Hydrostatic Test Head Vs Flow

Total

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head at the agreed flowrate or vice versa of the pump or the combined pump-

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Efficiency
Efficiency

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motor unit

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NPSH Required

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Standard Requirements of Test

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An Axially Symmetric Velocity distribution A uniform Static pressure distribution Freedom from swirl induced by installation Inlet straight length

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Test Conditions
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Sufficient

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time Duration Multiple readings Steady Conditions of Operation Unsteady Conditions

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More is always better Only Speed and temperature allowed to be controlled

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Accuracy of Measurement
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Quantity Rate of flow Pump total head Pump power input Electrical power input (for overall efficiency tests) Speed of rotation Overall efficiency (computed from the rate of flow, total head and electrical power) Pump efficiency
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Instruments 1,5 1,0

Overall limit 2,0 1,5

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0,35 -

0,5 2,5

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2,8

Accuracy of Measurement
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Quantity Rate of flow Pump total head Pump power input Electrical power input (for overall efficiency tests) Speed of rotation Overall efficiency (computed from the rate of flow, total head and electrical power) Pump efficiency
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Instruments 1,5 1,0

At FCRI 0,10 0.04 0.20

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0,35 2,5

0,1 0,3

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2,8

0,5

Procedure for Measurement

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Measurement

of flow rate

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Weighing Method Volume Tank Method dP meters method Precision Flow meters

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Procedure for Measurement

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Precision

Flow meters

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Electro magnetic Flow meter TFMs MFMs

Other

methods

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Velocity area Tracer Methods Ultra Sonic Flow meter

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Procedure for Measurement

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Measuring

Section

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Inlet Measuring Section Outlet Measuring Section

Swirl

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free region Head loss between measuring section and pump end

Choice of Measuring Section

Velocity

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should be small Cross-sectional area shall be well defined

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Procedure for Measurement

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Measuring

Section

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Pressure measurement at inlet and outlet flanges of pump is desirable 2D from upstream flange, 5D straight length upstream 2D from downstream flange, 1D straight length downstream atleast.

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Procedure for Measurement

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Measurement

of Head

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Inlet Total Head Outlet Total Head Friction loss at Inlet & Outlet Pump Total head
Liquid

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column manometers Transducers Smart Transmitters

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Procedure for Measurement

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Measurement

of Speed (0.05 0.2)

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Normal Tachometer Non contact type Tachometer Optical Devices Spectrometer

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Measurement

of Torque

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Dynamometer Torque Transducer

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Procedure for Measurement

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Measurement

of Electrical Power

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Motor shall be operated only at conditions where the efficiency is known Direct and Indirect Method Two/three Wattmeter method Power meter Voltage/ Current/ Power factor measurement

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The Test setup

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941mm

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Performance test
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Suction Size Delivery Size Pump Speed Date

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80 80 7000 23.02.05

mm mm rpm

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Sl. suction No. Head bar 1 2 3 4 5 6 7 8 9 10 1.53 1.57 1.51 1.53 1.55 1.58 1.59 1.60 1.62 1.72

suction H Del H Del Head Gauge gauge corrected corrected m WC 16.2063 16.6147 16.0021 16.2063 16.4105 16.7168 16.8189 16.9210 17.1252 18.1462 bar 2.740 4.290 4.722 4.999 5.160 5.454 5.625 5.830 5.920 6.075 m WC 28.5604 44.3859 48.7966 51.6248 53.2686 56.2703 58.0163 60.1093 61.0282 62.6108

Total Head bar 1.2100 2.7200 3.2120 3.4690 3.6100 3.8740 4.0350 4.2300 4.3000 4.3550

Total Head m WC 12.3541 27.7712 32.7945 35.4185 36.8581 39.5535 41.1974 43.1883 43.9030 44.4646

Corrected Pump Total Speed Head to rpm 7000 rpm m WC 6990 6990 6990 6990 6990 6990 6990 6990 6990 6990 12.3895 27.8507 32.8884 35.5199 36.9636 39.6668 41.3153 43.3120 44.0287 44.5919

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Performance test
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Rated Flowrate Design Total Head Design NPSH Rated Speed

: : : :

200 120 10 7000

USGPM feet feet RPM

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Qcorrected Total to Head 7000 rpm corrected usgpm 305.114 258.377 224.515 198.413 178.483 142.196 113.757 80.688 54.982 0.000 ft WC 40.649 91.375 107.904 116.537 121.274 130.143 135.551 142.102 144.454 146.301

m3/hr 69.200 58.600 50.920 45.000 40.480 32.250 25.800 18.300 12.470 0.000

usgpm 304.68 258.01 224.19 198.13 178.23 141.99 113.59 80.57 54.90 0.00

Pump Meas. Motor power motor i/p KW o/p power i/p 83.5% m3/sec KW x kw kw 0.0192 0.0163 0.0142 0.0125 0.0113 0.0090 0.0072 0.0051 0.0035 0.0000 2.3264 4.4284 4.5441 4.3371 4.0601 3.4712 2.8923 2.1507 1.4898 0.0000 7.8200 7.9500 7.6100 7.3110 6.9600 6.3800 5.5500 5.5500 5.5500 5.5500 6.5297 6.6383 6.3544 6.1047 5.8116 5.3273 4.6343 4.6343 4.6343 4.6343

Qrtd

Motor i/p KW corr KW 6.5578 6.6668 6.3817 6.1309 5.8366 5.3502 4.6542 4.6542 4.6542 4.6542

35.47 66.43 71.21 70.74 69.56 64.88 62.15 46.21 32.01 0.00

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Performance test
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Performance test
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Performance test
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The value of Head varies a/c to speed, but he head characteristic is holding. The duty point of the pump is agreeing with the theoretical value. The peak Pump efficiency is holding at varied speed condition of pump. The discharge at which the pump gives peak efficiency is varying according to the pump speed.

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NPSH Tests
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Cavitation

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inside the pump shall not affect the system Cavitation gas should not affect the functioning of instrumentation When Control valve is used, the valve shall be full of water

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Net Positive Suction Head

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Safety

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Margin At constant Flowrate At varied NPSH conditions By adjusting the suction head By adjusting the suction/ Delivery head

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Net Positive Suction Head

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Method

of test

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Can be either with Positive/ Negative suction Positive suction is better At a constant Flow rate Reduce the suction head Repeat till it is possible to keep the flow rate constant

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NPSH Tests
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Suction Size Delivery Size Pump Speed Date

: : : :

80 80 7000 24.02.05

mm mm rpm

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Sl. suction No. Head bar

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suction H Del H Del Head Gauge gauge corrected corrected m WC -2.1717 -2.3759 -2.8354 -3.1927 -3.3969 -3.7543 -4.2137 -4.6732 bar 2.984 2.955 2.845 2.660 2.450 2.125 1.582 1.077 m WC 31.0516 30.7556 29.6325 27.7436 25.5995 22.2813 16.7372 11.5812

Total Head bar 3.2540 3.2450 3.1800 3.0300 2.8400 2.5500 2.0520 1.5920

Total Head m WC 33.2233 33.1315 32.4678 30.9363 28.9964 26.0355 20.9509 16.2543

Corrected Pump Total Speed Head to rpm 7000 rpm m WC 7000 7000 7000 7000 7000 7000 7000 7006 33.2233 33.1315 32.4678 30.9363 28.9964 26.0355 20.9509 16.2265

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1 2 3 4 5 6 7 8

-0.270 -0.290 -0.335 -0.370 -0.390 -0.425 -0.470 -0.515

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NPSH Tests
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Rated Flowrate Design Total Head Design NPSH Rated Speed

: : : :

200 120 10 7000

USGPM feet feet RPM

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Qcorrected Total to Head 7000 rpm corrected usgpm 200.33 200.11 200.11 200.42 200.86 200.51 200.64 199.76 ft WC 109.000 108.699 106.521 101.497 95.132 85.418 68.736 53.236

v m/s 2.5144 2.5117 2.5117 2.5155 2.5211 2.5166 2.5183 2.5073

v /2g m 0.3224 0.3217 0.3217 0.3227 0.3241 0.3229 0.3234 0.3205

Inlet total Head H1 -1.8493 -2.0542 -2.5137 -2.8700 -3.0728 -3.4313 -3.8903 -4.3526

NPSHA NPSHA m 7.939 7.734 7.274 6.918 6.715 6.357 5.898 5.435 ft 26.045 25.373 23.866 22.697 22.031 20.855 19.349 17.833

m3/hr 45.500 45.450 45.450 45.520 45.620 45.540 45.570 45.410

usgpm 200.33 200.11 200.11 200.42 200.86 200.51 200.64 199.93

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NPSH Tests
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NPSH Tests
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Brief Specifications of the Main Water Flow Laboratory

Maximum Flow rate Maximum Size In Mass Flow rate 0.04% (Upto 250 T/h) 0.10% (300 to 1800 T/h) Measurement Uncertainty In Volume Flow rate 0.04% (Upto 250 m3/h) 0.10% (300 to 1800 m3/h) 0.25% (1800 to 5000 m3/h) In Total Volume In Total mass

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5000 m3/h
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900 mm

0.01% 0.05% ( for 0 to 2000 kg) (Upto 20 m3) 0.025% ( 2000 to 20000 kg)

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Major Reference Instruments PSL Mass flow meter Electromagnetic Flow NVL meters Insertion Flow meters EIL Ultra sonic Flow meter Online Densito meter Research Institute Fluid Control

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Pumps

Capacity 5000 m3/h Tech. details Size : 80 mm NB Size : 15 to 500 mm NB Upto 3000 mm NB Upto 1200 mm NB Coriolis Type

Head 30 mWC Accuracy 280 Tons/h upto 5000 m3/h 5 m/s 10 m/s 0-3000 kg/m3 0.10% 0.20% 1.00% 1.00% 0.02%

Facilities at FCRI
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The 100mm Water Flow Laboratory

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250 m3/hr and 100 mm

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The 600mm Water Flow Laboratory

4500 m3/hr and 600 mm

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The Large Water Flow Laboratory

1500 m3/hr and 2000 mm

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Facilities at FCRI
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