CHAPTER-3

G U I D E T O ACCEPTANCE TESTS FOR C E N T R I F U G A L PUMPS

3.1 INTRODUCTION

This chapter has been designed as a short guide based on ISO code for Class C and Class B
acceptance tests, mainly for those who are engaged in pump performance testing.
Testing o f the equipment to be purchased is o f great importance from the buyer's point of
view as both capital and operational costs o f the equipment are very high and a high degree
o f reliability is expected in the water industry.
The main equipment involved in a pumping station include the pump, prime mover (motor
generally), valves and piping. For Radial (centrifugal), Mixed flow and Axial flow pumps
there are three acceptance test standards namely class A, B and C in the ISO code which
basically differ by the amount o f the overall tolerances o f the performance data and by the
permissible measurement tolerances.

Class A is the most precise and Class C is the least precisely defined. The use o f Class A &
B is restricted to special cases where a very high degree o f precision is required. For water
industry, Class C (ISO 2548) standard would suffice.

3.2 ISO CLASS ' C & 'B' ACCEPTANCE TESTS (ISO 2548:1973 AND

ISO 3555:1977)
The contents o f the two codes can be summarized as follows:

Definition o f terms and symbols.

* Total head developed by pump, capacity, power, NPSH and how to measure them.

* Methods of determining flow & NPSH.

* Test installations in order to ensure accuracy and correct results. ^ V ^ l ^

* How to ensure correct instrument readings.

Required degree of accuracy of test instruments.

Permitted tolerances of performance.

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3.3. GUARANTEES AND PURPOSE OF THE TESTS

Generally it is agreed in the contract which values are guaranteed by the manufacturer and
under what conditions.
One or more o f the following are usually guaranteed.
* Rate of flow at the agreed total head and speed of rotation within permissible
tolerances.

* Efficiency of the pump or the overall efficiency of the pumping set at the guaranteed
duty point within permissible tolerances.

* NPSH . R

The purpose o f these tests are to ascertain whether the performance o f the pump is in
accordance with the manufacturer's guarantee.

3.4. ACCURACY OF MEASUREMENTS

The following systematic error levels are allowed in the measuring devices:

Measured Permissible Systematic Error (%)

Quantity

Class C Class B

Rate o f flow ±2.5 ± 1.5

Total head ±2.5 ± 1.0

Power absorbed by pump ±2.5 ± 1.0

Power input ±2.0 ± 1.0

Motor efficiency ±2.0 ~

Speed o f rotation ± 1.4 ±0.35

Table 3.1 - Systematic Error Levels

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 I f the measuring devices are used in accordance with these rules and the methods o f
measuring are applied as indicated in the ISO-Code for acceptance tests the following
maximum permissible measurement tolerances are allowed.

Measured Maximum permissible limit (%)

quantity

Class C Class B

Rate o f flow ±3.5 ±2.0

Total head ±3.5 ± 1.5

Power absorbed by pump ±3.5 ± 1.5

Power input ±3.5 ± 1.5

Speed o f rotation ±2.0 ±0.5

Pump efficiency ±5.0 ±2.8

Overall efficiency o f the ±4.5 ±2.8

pumping set

Table 3.2 - Measurement Tolerances

35 CONVERSION OF TEST RESULTS

All measured values which were determined at a speed o f rotation 'n' which deviates from
the nominal speed o f rotation n specified in the contract have to be converted into data
N

based on the nominal speed o f rotation n . The speed o f rotation may deviate as follows:
N

* When measuring head and rate o f flow + 2 0 % to - 5 0 %

* When measuring efficiency + 2 0 % to - 2 0 %

* When measuring NPSH + 2 0 % to - 2 0 %

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Conversion o f measured values shall be as follows.

Q 2 = QiGWn)
2
H2 = Hi(nN/n) [Subscript 1 = measured value
2 = converted value]
2
NPSH = NPSH!(n /n)
2 N

3
P 2 =Pi(n /n)
N

Tl2 =ti 1

36 CAVITATION TESTING

The cavitation test is done to ensure that the pump will be free from cavitation erosion during
its service life under normal conditions.
The two distinct possible types available on cavitation test are:
i). A check to show that the pump is free o f cavitation at the specified duty
point and N P S H A .

ii). By Reducing NPSHA until measurable effects are noted.

Type (i) is simple and in this case if another test at a N P S H higher than the specified gives
A

the same flow rate at the same total head, then the characteristics can be assumed to be free o f
the effects o f cavitations.
Type (ii) involves throttling the suction side and observing the drop in head at constant flow.
Cavitation is regarded as being fully developed when the head generated by the pump at a
given flow rate is reduced by approximately 3%.

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3.7. VERIFICATION OF GUARANTEES (Q, H & i\)

To check whether the guarantee has been fulfilled a straight line is drawn through the origin
and the guaranteed duty point Q H . The distance AQ and AH are measured and the
N N

efficiency t][ at which this line cut the QH curve is obtained as shown in the Fig 3 . 1 .

H k

(H X /AH)
G H
2
+ (QqXq/AQ) 2
> 1

The overall tolerances ± X and ± Xq depends on the test class. I f no special arrangements
H

have been agreed upon the following values will apply.

Class C Class B

X H = 0.04 X H = 0.02

Xq = 0.07 Xq = 0.04

Table 3.3

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 The efficiency shall be derived from the measured QH curve where it is intersected by the
straight line passing through the specified duty point and the origin o f the QH axes.

The efficiency at the point o f intersection shall be as given in the table below:

Test Class

C B

Pump efficiency T h > 0 . 9 5 r,N TI,> 0.972 ri N

Overall efficiency TI,> 0.955 TIN t i , > 0.975 r, N

Table 3.4

38 GUARANTEES FOR MASS - PRODUCED PUMPS

The characteristic curves published by a manufacturer for mass produced pumps after Class
' C tests, the results should not vary from the values o f the published curve by more than
± 6% for total head
± 8 % for rate o f flow
± 8% for power input

39 OTHER INSPECTIONS & TESTS

The other important inspections and tests the main pump is subjected to are;

* Hydrostatic test :- 1.5 times shut-off head over 3 minutes.

* Bearing Temperature :- 75° C (Max)

* Vibration :- See chapter 1.10 for levels

* Materials o f construction :- As specified.

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Along with the pump performance tests its driver (generally motor) is also tested for its

performance.

Valves and piping are tested for the material o f construction, hydrostatic test pressure,
dimensions etc. Electrical switch gear and other auxiliary equipment are also tested for
their proper operation quality etc. against the specifications. Details o f which are not
dealt with in this manual.

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