FA reciprocating pumps, power ralings Purpose ‘The purpose of this section is to define terms used in pump ratings. These ratings are character- istics of pump design and not conditions of the specific application, Stroke One complete uni-directional motion of piston or plunger, Stroke length is expressed in inches. Pump Capacity (@) The capacity of a reciprocating pump is the total volume through-put per unit of time at suction con- ditions. It includes both tiquid and any dissoived or entrained gases at the stated operating conditions. The standard unit of pump capacity is the U.S. gal- lon per minute. Pump Displacement (D) The displacement of a reciprocating pump is the volume swept dy all pistons or plungers per unit time. Deduction for piston rod volume is made on double-acting piston type pumps when calculating displacement. The standard unit of pump displace: ment is the U.S. gallon per minute For single-acting pumps: For double-acting piston pumps with no tail-rod(s) (2A-a) sam p= (2Asa) sam 231 Plunger or piston area, square inch iston rod cross-sectional area, square inch (double-acting pumps) $= Stroke length, inch PM of crankshaft lumber of pistons or plungers Plunger or Piston Speed (v) The plunger or piston speed is the average speed of the plunger or piston. It is expressed in feet per minut yn MS 6 Pressures The standard unit of pressure is the pound force per square inch, 230 Discharge Pressure (py)~The liquid pressure at the centerline of the pump discharge port. Suction Pressure (p.)—The liquid pressure at the centerline of the suction port Differential Pressure (pis)—The difference be- tween the liquid discharge pressure and suction pressure. Net Positive Suction Head Required (NPSHR) The amount of suction pressure, over vapor pres- sure, required by the pump to obtain satisfactory volumetric efficiency and prevent excessive cavita- tion. ‘The pump manufacturer determines (by test) the et positive suction head required by the pump at the specified operating conditions. NPSHR is related to losses in the suction valves of the pump and frictional losses in the pump suc- tion manifold and pumping chambers. Required NPSH does not include system acceleration head, which is a system-reiated factor Slip (S) Slip of a reciprocating pump is the loss of capac ity, expressed as a fraction or percent ot dispiact ment, due to leaks past the valves (including the back-flow through the valves caused by delayed closing) and past double-acting pistons. Slip does not include fivid compressibility or leaks from the liquid end. Power (P) Pump Power input (P))—The mechanical power delivered to a pump input shaft, at the specified operating conditions, Input horsepower may be cal culated as follows: Ox pe P= TF1d Xn Pump Power Output (Po)—The hydraulic power imparted to the liquid by the pump, at the specified operating conditions. Output horsepower may be calculated as follows: axpu Po= 1714 The standard unit for power is the horsepower Efficiencies (») Pump Efficiency (yp) (also called pump mechani cal efficiency) —The ratio of the pump power outpu to the pump power inputsnes msiitartvonioyinsesenier womens onteccapinccho oF HCE we Volumetric Efficiency ())—The ratio of the pump capacity to displacement. wep plunger Load (Single-Acting Pump) ‘The computed axial hydraulic toad, acting p>? cone plunger during the discharge portion of Ihe It is the product of stroke is the plunger load. tw recipracaling pumps, power ” ratings plunger area and the gauge discharge pressure tis fexpressed in pounds force piston Rod Load (Double-Acting Pump) The computed axiah hydraulic toad, acting Yar one piston rod during the forward stroke (toward hhead end) is the piston rod oad ‘tis the product of piston area and discharge Pr sure, less the product of net piston area oe ach serscted) and suction pressure. It is expressed in pounds force.STANDARD FOR RECIPROCATING Test POWER PUMPS GENERAL Scope ig Standard is intended 10 provite procedures, for conducting and ceporting tests cof reciprocating power pumps at the manufacturer's test Facilities Finree generat categories a tests covered: Hydro- Tatie, Performance, and NPSH Performance tests statfrther subdivided into three 10% sume pewer pumps, becouse of the large quantity produced, and consistency Of ‘construction, require Bhty spot testing to assure a7 ‘acceptable quality level. eis the intent of this Standard | offer testing procedures for use by PUP, manufacturer. It is not Pee intent to limit or restrict tests 1 only those de- Mined herein. Variations in test procedures may erst without violating the intent of these Standards. Witnessing of Tests “The purchaser or designated representative may witness any test if previously aBreed 0 ‘between put chaser and manufacturer Instrumentation ‘Test instrumentation should Be sufficient to ad2: quately measure relevant test conditions. aacah pressure gauge connection IN flowing, gtream should be flush with ang normal to the wall Sine liquid passage, anathe wal) ‘should be smooth and parallel with the ‘ow in the vicinity of the gauee gonnection orifice. Connections ssnould be free from airs or ieregularties. Throttling oF pressure gauges urtrowable i care is taken to av01e distortion of the readings. Definition of Specified Conditions specified conditions are the conditions at which ne pump will be operated By the ¥Ser HYDROSTATIC TESTS, Object ‘Fo demonstvate that the Figuid end, when sub: jected to hydrostatic pressurels) ‘with not Yeak or fail structurally. pumps, power peciprocaling ipst standards Test Procedure - Hydrostatic tests) may be performed using water, ont special cases, with {ght Of Kerosene, at or Mant temperature and at BFesSUeS) of 1.5 times gre maximum allowable working pressurets) ear anita} should be Hyarestacaly tested at 1b times maximum atfowable Sut pressure 2 8 arate unit of wile ateched the liquid Binder, tsolation deviees. such O-ring ploess cipe installed in place of the SHIT valves 10 ray rane suction sanO18 ting ngastatc est Treef te liquid oytinger. the PUM suction valves ire used to isolate the suction manifold, leakage are ag the valves wil nat be cause 1 rejection, al- trae kage between a seat and cide! should bbe corrected viydeostatic test pressurel®) fo at least 15 minutes should be maintained Records complete records should be KePE of all relevant safermation. This information shewle include 1, Liquid end identification by model, size, seriat number. 2, Liquid cylinder maximum allowable working pressure(s) and temperature yarostatic. test pressurets) and test dure: tiontsh Te gentification of individual responsible for re cording the test results PERFORMANCE TESTS Scope ‘Theos types of performance (ests 21 described in this Standard, The type of test {0 be performed and the auxiliary equipment t0 DE used (purchaser's twer, gear box, eXc.), should be agreed upon by the ivenaser and manufacturer PHO! Yo testing. The liquid used for testing will normally be water, put may be an alternate Tavis ‘acceptable 10 the purchaser ané manufactorer Mee standard appiies to the test of the pump omily, and the values of power ‘and efficiency «eter saly to the pump. However, Ihe recorded data and Fimat report may include information 6h the complete dre Gneluding over ang ausliany £0 ipment 233KA reciprocating jumps, nOWEr lest standards Object The object of these tests is to demonstrate the pump's ability to perform both mechanically and hydraulically Test Types Type A Speed and pressure are recorded during test. Capacity and power may be calculated by estab: lished applicable methods. (See Ratings section, page 230.) Type B Speed, pressure and capacity are recorded dur- ing test. Data is adjusted to specitied conditions by calculation, if required. Power may be caleu- lated by established applicable methods. (See Ratings section, page 230.) Type C Speed, pressure, capacity, and power are re- corded during test. Data is adjusted to specified conditions by calculation, if required, Catculation procedure should be mutually agreed upon between purchaser and manufacturer. Test Tolerances Recommended maximum percentage deviation of test conditions from specified conditions: —— #20% £5% 2 points of efficiency* Speed Discharge Pressure Volumetric Efficiency _ Mechanical (Pump) Efficiency. NPSHR, H “Tested volumettic efficiency may exceed that speci fied by 5 points if the purchaser's driver will not be over loaded at specified conditions, Volumetric efficiency may be adjusted for differences in compressibility between test quid and specified liquid. (Volumelc efficiency is relatively constant within a 20% speed range.) 1 point of efficiency +0 Once speed has been established, it should vary no more than 3% during the test (or as agreed upon by purchasor and manufacturer.) When the test facility has insufficient power to ‘meet the specified conditions, the tests mey be per formed in either of the following manners: 1, Specilied speed and reduced discharge pres- re 2, Reduced speed and specified discharge sure 234 es: Test Setup’ ‘The pump test may utilize (but is not limited to) the following 1. The factory test stand. 2. Facility or purchaser-furnished driver. (A type C test will require accurate power input measure ment.) 3. Facility or purchaser-furnished speed-reduc- tion unit, if required. (To accuretely establish pump input power, efficiency data may be required.) 4, Facility test packing in the stuffing box, un- less otherwise specified. 5. Asuction pipe or hose from a booster pump or available water supply, properly sized for the pump being tested. 6. Asuction pressure gauge suitable for measur ing the complete range of pressures whether posi- tive or negative. 7. A discharge pressure gauge suitable for mea- suring the complete range of pressures. 8. Throttling devices for the suction and dis- charge gauges, such 2s needle valves or capitlary tubes. 9. Adischarge pipe or hose with a pressure break- down (throttling) device. 10, A suction stabilizer (dampener) 11. Calibrated flow meters, weighing tanks, or volume measuring tanks, When ¢ flow meter is used on the discharge, it is preferable to install it in the high pressure section between the pump and the pressure breakdown valve. If the working pressure of the meter is too law, it may be installed down- stream of the pressure breakdown valve, with a back pressure valve located downstream of the flow meter to insure that it will stay properly filled during operation, 12, Arelief valve, rupture disc or equivalent, set al a pressure no more than 25% higher than the specified pressure located in the discharge line up- stream of the pressure breakdown vaive, Test Procedure Install pump, driver, and other related equipment, Check the following items: 1. Alignment of couplings and components, 2. Direction of rotation. 3. Tightness of electrical connections. Operate pump untoaded, check for the fotlowing, and correct before proceeding: 1. Abnormal noise or vibration.2. Liquid end leaks, except for normal stuffing box packing leakage. : 3. Excessive temperature of stuffing boxes, : 4. Bearing overheating, particularly pinion beating housings, crankshaft bearing housings, and crosshead guides. ) 5. Leaks of incorrect pressures or levels of power end lubricants. 6. Scoring of plungers, bushings, or rods Operate pump at the maximum test conditions with NPSHA in excess of NPSHR, for a time at least equal to following: Pump Rated Horsepower Hours Oto 150 1 oC 151 to 360 2 E 361 and above 4 if capacity is measured on the discharge side un- der high pressure, a correction may be made for water compressibility, correcting the rate to atmospheric pressure. (See Table 4—WATER COMPRESSIBIL- ITY, page 248.) Records Complete records should be kept of all data rele: vant to the tests. The manufacturer's serial number, type and size, : of other means of identification of each pump and driver involved in the test should be recorded. ‘Test data should be adjusted to reflect any signif icant difference between test speed and specified speed. ‘The foliowing data should be recorded with each : change of speed and/or pressure (suction or dis. charge) Type A Type 8 Type € ‘Speed Speed Speed Suetion (Inlet) Suction (intet) Suction (Valet) Pressure Pressure Pressure Discharge (Outie!) Discharge (Outlet) Discharge (Outi) Pressure Pressure Pressure Capacity Capacity Power reciprocating pumps, power fest standards NET POSITIVE SUCTION HEAD TEST Object To determine the NPSH required (NPSHR} by the pump when tested at the manufacturer's test facil- ity on water. It should be noted that an NPSH test is rerely per formed on a power pump. It is normally justified only when a previously untested pump is to be applied to a service where NPSH is critical Test Procedure ‘The NPSH test should be performed at constant discharge pressure (specified discharge pressure, tuniess limited by available power) and speed (within 100% and 105% of specified speed) while measur ing capacity at different values of NPSH available (NPSHA). The NPSHA shouts then be incrementally reduced until capacity loss exceeds 3%, or until Clearly audible cavitation noise is generated Some methods of varying NPSHA are by throttling the flow into the pump with a valve (see Fig. 46), by use of vacuum and/or heat on the suction supply (see Fig, 47), and by varying the fiquid level in a deep supply tank located below the level of the pump (see Fig. 48). The actual point of NPSHR will be established by the existence of one of the following conditions 1. A.3% drop in capacity (see Fig. 49). 2. Clearly audible cavitation noise. Records Complete records should be kept of all data rele- vant to the tests. The manufacturer's serial number, type and size, or other means of identification of each pump in- volved in the test should be recorded. The following data should also be recorded: " 1. Specified NPSHR/NPSHA. 2. Height of suction gauge, above or below centerline of pump suction connection 2. Inside diameter of pipe at location of suc: tion pressure tap. 4. Catculated suction line acceleration head {if significant). {Mt is more conservative to ignore acceleration head in this test.) 5. Observed Data (each run) Water Temperature Discharge Pressure Suction Pressure Capacity (Flow Rate Crankshaft Speed sReter to “Ratings” portion of these standards for complete delioitions of terms,-Peclgracating pumps, DOWEE test standards Pressure Gauge Safety Relief Valve Discharge Stabilizer Gate Valve for i Throttling Suction (Optionad Suction Stabilizer — (Optional) Flow Meter if Located in o \ Dampening a \ \ \ emma er Ve f x Oa EE eT Suction UH _— Booster Pump may be Loaded Back Pressure Installed if additional Valve or Adjustable Choke a eee Fig. 46 SUPPRESSION TYPE NPSH TEST Gas Pressure Heat Exchanger Flow Distributor Vacuum Pump. Heat or Cooling Coil suction ee | Remainder of System Same as Figure 46 eee Priming Connection Discharge Remainder of System Same as Figure 46 Suction 3 | | ' | _Fluid Level ——"Variance _- Baffle Fig. 48 LEVEL CONTROL NPSH TEST Fig. 47 VACUUM AND/OR HEAT CONTROL NPSH TEST (CLOSED LOOP)Peclpracating pumps, power test standards 6. Equation for NPSHA: line acceleration head may be subtracted. (For @ NPSHA=Total suction pressure -Vapor more detailed guide to NPSHA calculations, see pressure Applications section, Figs. 55 and $6.) The results should be plotted on graph paper. The Total suction pressure must include atmospheric abscissa will indicate NPSHA of water and the ordi- pressure, velocity head at gauge connection, and nate will indicate capacity. The NPSHR for the ~~ Porrection for gauge elevation. Calculated suction pump should be marked on the curve (see Fig. 49), Determine point on curve 3% below maximum. Capacity @ NPSHR NPSHA of Water Fig. 49 CAPACITY VS NPSHA 237