TEST WRITE UP

DOC No : 9518-133-PVM-W-039 rev :04 BARH stage- I CW system

PUMP DETAILS
PUMP TYPE BHM60, 1 STG, EXT. WATER LUB PUMP
O/A NO. Z19G6P8010 QTY :03 Digitally signed by Rajesh
Handa
DN: cn=Rajesh Handa, c=IN,
CLIENT NTPC BARH STAGE -I o=NTPC LTD, ou=EOC,
email=rhanda@ntpceoc.co.in
Reason: CAT-I
PROJECT BARH-I STPP (3x660 MW) Date: 2009.06.24 13:25:16
+05'30'

SERVICE RAW WATER PUMPS

MEASURING INSTRUMENTS
HEAD BOURDON TYPE PRESSURE GAUGE
DISCHARGE RECTANGULAR WEIR /FLOW METER 4
POWER WATTMETER
SPEED DIGITAL TACHOMETER

JOB MOTOR DETAILS

MOTOR MAKE / FRAME SIZE CGL /VTVC 1080
MOTOR RATING / MOTOR RPM 350 KW / 740 RPM

JOB VFD DETAILS

Make Rockwell Automation
Model 20DD650N0NNNBNANE
VFD System Supplier Sai Technologies, Vadodara, Gujarat, India
Rating 650 Amp
Sr. No. 03087287 , 03087288 & 03087289

DUTY POINT
TOTAL HEAD 17.5 M ±5.0% (AS PER HIS) 1
3
DISCHARGE 5510 M /Hr ±1.0% (AS PER HIS)
PUMP EFFICIENCY 88 % (Without -ve Tol.)
PUMP INPUT 298.4 kW
SPEED 740 RPM (NOM)
MIN.SUBMERGENCE REQUIRED 1800 MM
SPECIFIC GRAVITY 1.0
GURANTEED POWER CONSUMPTION AT 316.38 Kw (Motor efficiency 94.3 %) 2
MOTOR TERMINALS

TEST LAB DATA

INTERNAL HEAD LOSS 0.26 M 1
THRUST & TRANS. BRG. LOSS 0.785 Kw.
MINIMUM SUBMERGENCE 1800 MM
SUSPENSION LENGTH 3450 MM (from discharge tee mounting)

• THE PERFORMANCE TESTING WILL BE CARRIED OUT ACCORDING TO HIS.

• THE PERFORMANCE TESTING WILL BE CARRIED OUT WITH REDUCED SUSPENSION
LENGTH IN HYDRAULIC RESEARCH CENTER AT MINIMUM SUBMERGANCE.
• NOISE, VIBRATION READINGS AND BEARING TEMPERATURE SHALL BE TAKEN FOR
RECORD PURPOSE; HOWEVER THESE VALUES SHALL BE GUARANTEED AT THE SITE.

REFERENCES –
TEST LAYOUT: T 21 010 (encl.) TEST PROCEDURE: CT 10000446(encl.)

CHECKED BY: APPROVED BY :

SHITAL CHAUGULE A.U DESAI
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PROCEDURE FOR TESTING OF VERTICAL TURBINE PUMP

1. INTRODUCTION –
This procedure is applicable to acceptance testing of the pump with JOB Motor &
VFD at Hydraulic Research Center of Kirloskar Brothers Limited, Kirloskarwadi.
The procedure described is to be employed for testing the pump individually
without reference to the final installation conditions.

2. PURPOSE OF THE TEST –

2.1 The performance test will be conducted for verifying guaranteed

parameters of Head, Discharge and Efficiency of all the pumps using VFD system
and establish the performance curve
2.2 Range of the performance test-
2.2.1 Readings of Head, Power, Discharge will be taken at seven points.
* One point as near as possible to rated capacity and head (duty
head.)
* Three points above rated head in the operating range (85 %, 70%, and
35 %) Of rated discharge.
* Two point below rated head (110 % and 125 % of rated discharge.)
* One point at shut off.
2.2.2 Job Motor will be employed to test the pump.(Refer Test Write Up )
2.2.3 The liquid used in testing will be water at ambient temperature.(50 Deg.
Max.)
2.3 Noise and Vibration readings for record purpose.
2.4 Checking guaranteed power consumption at motor terminals.
2.5 To check the bearing temperatures (To verify no abnormal rise in the temp
of bearing)
3. TESTING APPARATUS – 1
Calibration certificates for all measuring instruments like Wattmeter, Pressure
Gauge, flow meter / Weir, Sound level meter, Ammeters, Voltmeters and
tachometer will be furnished before start of test and along with the Test Report.

3.1 Speed of test –

The actual speed of rotation will be as obtained at the prevailing voltage,
frequency and load. Actual speed shall be measured at each reading.
3.2 The test condition will be obtained by throttling a valve in the
Delivery pipe / varying the speed of the motor through VFD.

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 4. TESTING ARRANGEMENT –
The pumps will be tested with length as per enclosed Testing arrangement
Drawing and suitable to our test laboratory. Only bowl unit will be replaced for
successive pumps. The losses for test set up length are indicated in Test Write
Up.

5. PROCEDURE FOR MEASUREMENT OF DISCHARGE, HEAD, POWER INPUT

AND SPEED OF ROTATION –

5.1 Discharge Measurement –

The discharge will be measured either by sharp crested rectangular weir or
V notch or flow meter.

5.2 Head Measurement –

Delivery head will be measured by suitable Bourdon type pressure gauge.
The gauge will be calibrated on dead weight gauge before actual testing of
the pump.

5.3 Measurement of Power Input –

The power input will be determined from measurement of the electrical
power input to the motor of tested efficiency coupled to the pump. The
electrical power input to the motor will be measured by Two Wattmeter
Method. Motor output will be computed by using graph of motor efficiency
given by the motor manufacturer for the type tested Job motor.

5.4 Speed Measurement -

The speed will be measured by a tachometer.

5.5 The readings shall be recorded in stabilized condition simultaneously and

only after verifying that the readings taken are logical. Noise, vibration will
be recorded during test at rated discharge and head. Temperature will be
recorded at the end of test. This will give maximum reading.
6. INSTRUMENTS EMPLOYED AND ACCURACY OF MEASUREMENT –

Quantity Instrument Overall Accuracy (within)

Discharge Rectangular Weir / +/- 1.5 %
Flow meter
Head Bourdon type Pressure +/-0.5 % of full scale
Gauge deflection
Power Wattmeter’s, voltmeters, 0.5 % of full scale
ammeters(CT,PT) 4 deflection
Speed Tachometer +/- 1 rpm

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 7) ANALYSIS OF TESTS –
Test data obtained at the speed of rotation in deviation from the specified speed
of rotation will be translated to the specified speed of rotation by using the
following formulae –

Discharge Qsp = Q (Nsp / N)

Total Head Hsp = H (Nsp / N )2
Pump Input Power Psp = P (Nsp / N )3
Pump Efficiency % Effsp = %Eff

where,
suffix ‘sp’ implies specified.

Q – Discharge in lps
H - Total Head In m
P - Pump Input in Kw
N - Speed in rpm
Pump Efficiency will remain unchanged.

7. TOTAL HEAD CALCULATIONS –

Total Head (H) = Delivery gauge reading (Hd)

+ Gauge position correction (α)
+ Velocity head correction {(V)2/2g}

8.1 Pump Efficiency Calculations –

8.1.1 Motor Input in Kw = Summation of wattmeter reading

x Wattmeter Constant

8.1.2 Motor Output in Kw = Motor Input x Motor Efficiency

8.1.3 Pump Input in KW = Motor Output

8.1.4 Pump Output in Kw

Total Head (H) in m x Discharge (Q) in lps

=
102

Pump Output
8.1.5 Pump Efficiency, % = x 100 %
Pump Input
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8. ACCEPTANCE CRITERIA. :

1. Actual capacity and head measured for the pump shall be not less than the
guaranteed parameters.
2. The power consumption at motor terminals at duty point.(316.38 Kw)
3. Strip down test shall be carried-out after performance testing of pump. For
strip down test please refer approved QAP 4

9. Testing of Pump with VFD:

1. One of the Pumps will be tested in factory with all VFD (Variable
Frequency Drive)
2. The Pump Motor will be tested in frequency band by varying the head to
have constant flow as specified in the Table.
3. Only H-Q readings will be taken for frequencies other than 50 Hz

Sr.No Frequency(Hz) Power(kw) Bowl Head Flow(m3/hr) RPM

1 43.9(Approx) - 11.76 5500 650
2 50 316.38 17.76 5510 743(FLS)
3 38.9(Approx) - 6.06 5706 575