Paint Specifications

Bearings, coupling and seal data

Material Certificates
Casing Hydrotesting procedure
Impeller dynamic Balancing testing procedure
Rotor balancing testing procedure
Performance testing procedure
Run-out testing procedure
NPSH-Required
Purchase order
Drawings
Applicable codes and standards
Installation drawing of pump in the dry well indicating required NPSH, floor level of
pump

The applicable codes and specifications for a centrifugal pump that is under the
construction process are:

Design code

Purchase order specification

Purchaser's standards

Approved drawings

And the applicable codes and standard are:

API 610

BS 7784
Required Documents for Third Party Inspector Review:

The list of documents normally is agreed upon in the Pre-Inspection meeting, which is
held several weeks before the actual commencement of the inspection work. The
parties that participate in this meeting are the manufacturer, purchaser and third party
inspection agency representatives.
These are the list of documents that are normally agreed upon to be presented to the
inspector:

Centrifugal Pump Purchase Order or Contract

Centrifugal Pump Manufacture Quality Control Plan

Centrifugal Pump Inspection and Test Plan

Centrifugal Pump Data Sheet

Centrifugal Pump Approved Drawings

Centrifugal Pump Material Test Reports

Centrifugal Pump Welding Specification Procedures (WPS) and Procedure Qualification Records(PQR)

Centrifugal Pump Welding Map

Centrifugal Pump Welders Qualifications Reports

Centrifugal Pump NDE Procedures (Radiography,

Ultrasonic, Magnetic

Particle, Dye Penetration, etc.)

Centrifugal Pump NDE Personnel Qualifications Reports

Centrifugal Pump Heat Treatment Procedure

Centrifugal Pump Calibration Certificates for Test Equipment

Centrifugal Pump Hydrostatic Testing Procedure and Water Quality Document

Centrifugal Pump Impeller Inspection Procedure

Centrifugal Pump Performance Test Procedure

Centrifugal Pump Preparation and Painting Procedure

Centrifugal Pump Preservation, Packing and Shipping Procedure

Centrifugal Pump Packing List

Third Party Inspection for Centrifugal Pump - Material Inspection

The first actual inspection work in the centrifugal pump is the raw materials inspection.
The original or authenticated copies of mill certificates of material normally are available
at the manufacturer's premises.
The third party inspector examines these certificates for compliance with specifications,
and where appropriate, drawings.
The review includes checks on:

Certificate No.

Heat or Cast No.

Chemical Composition

Mechanical Properties

Heat Treated Condition

NDE Applied and Results

Surface Finish

Then the inspector witnesses the materials identification on the certificates against the
materials marking. It is also necessary to check these with the centrifugal pump drawing
datasheet, material list and other specifications as appropriate.
Visual inspection for surface finish and probable defects is done and dimensional
compliance with specification need to be controlled, as well.
When the third party inspector carries out the material inspection, then provides the
inspection visit report (IVR), the report contains the following items:

Confirmation of satisfactory document review

Record of the endorsement of certification reviewed/witnessed

Record of all non-conformities

Record of any tests witnessed and the result

Third Party Inspection for Centrifugal Pump - Casing Inspection

When the centrifugal pump raw material inspection is carried out, and the results were
satisfactory or non-conformities were closed by remedial action, then the centrifugal
pump manufacturer will start fabrication.
The third party inspector checks the following points on the centrifugal pump, based on
the inspection and test plan (ITP), which has already been agreed upon between the
purchaser and the centrifugal pump manufacturer.
The inspection scope is determined in the ITP. Some purchasers prefer to have
stringent controls and assign the TPI for more hold or witness points for inspection and
test activities, and some others prefer less hold or witness points and assign the TPI
much more work in the review document.
This depends in the inspection budget, which purchasers assign for inspection. Much
more inspection will have a much larger cost and less risk, and conversely, less
inspection will have less cost but more risks.
For more details, review the Inspection and Test Plan for Centrifugal Pump article.
There is a draft of the ITP in this article, which we believe is the best practice for
centrifugal pump inspection.
The third party inspector checks the following items in the centrifugal pump casing
inspection process:

Visual inspection for damage

Dimensional check to drawing requirements

Witness or review hydrostatic test

Witness or review NDE examination

Application of test marks

Visual examination of welded on connections

Review weld qualification and weld procedure records

If the third party inspector is not in the hold or witness point in the ITP for this inspection
stage, then he/she will review the centrifugal pump manufacturer quality control report in
his/her coming visit or on the final inspection day.
Third Party Inspection for Centrifugal Pump - Impeller Inspection
The third party inspector checks the following items in the centrifugal pump impeller
inspection process:

Witness or review Run Out test

Witness or review Dynamic Balance test

Review NDE examination results

Similarly, If the third party inspector is not in the hold or witness point in the ITP for this
inspection stage, then he/she will review the centrifugal pump manufacturer quality
control report in his/her coming visit or on the final inspection day.
Third Party Inspection for Centrifugal Pump - Performance Test
After complete assembly, the pump is submitted to a performance test. The test is
conducted within the contract and code requirements. The third party inspector
witnesses the following items:

Collection of test data

Preparation of test curves
Rated speed
Check bearings for overheating
Noise test
Vibration test
Similarly, if third party inspector is not in hold or witness point in the ITP for this
inspection stage, then will review centrifugal pump manufacture quality control report in
his/her coming visit or in final inspection day.
For more details, review the Centrifugal Pump Performance Test article.
Third Party Inspection for Centrifugal Pump - NPSH Test

Where required by the contract or purchase order, the third party inspector witnesses
the NPSH test and approves the results.
The inspector checks the following points:

Test method is as required by the contract that is used

Confirmation of results
Similarly, If the third party inspector is not in the hold or witness point in the ITP for this
inspection stage, then he/she will review the centrifugal pump manufacturer quality
control report in his/her coming visit or on the final inspection day.
For more details, review the Centrifugal Pump Performance Test article.
Third Party Inspection for Centrifugal Pump Mechanical Running Test
When required by the contract or purchase order, where the pump runs for a predetermined time depending on its type, the pump and its driver will be as complete as
possible. The third party inspector will check the following items:

Flow requirement
Excessive vibration
Excessive noise
Bearing temperatures
Similarly, If the third party inspector is not in the hold or witness point in the ITP for this
inspection stage, then he/she will review the centrifugal pump manufacturer quality
control report in his/her coming visit or on the final inspection day.
Third Party Inspection for Centrifugal Pump Dismantling Inspection
A pump with three or more stages is inspected by dismantling after the test. Other types
may be inspected when required by the contract or purchase order.
The third party inspector checks, as necessary, to ensure that no damage has occurred
during tests, and that the necessary care is taken during re-assembly, including rust
prevention procedures where necessary.
Similarly, If the third party inspector is not in the hold or witness point in the ITP for this
inspection stage, then he/she will review the centrifugal pump manufacturer quality
control report in his/her coming visit or on the final inspection day.

Third Party Inspection for Centrifugal Pump Clearance Checking

The establishment of running clearances is determined by giving consideration to
variables such as pumping temperature, suction condition, fluid characteristics, thermal
expansion or galling characteristics of the materials, etc.
The final clearances are based in accordance to the manufacturers standard. Where
required, the third party inspector confirms that the standards have been met.
Similarly, If the third party inspector is not in the hold or witness point in the ITP for this
inspection stage, then he/she will review the centrifugal pump manufacturer quality
control report in his/her coming visit or on the final inspection day.
Third Party Inspection for Centrifugal Pump Final Visual and Dimensional Control
After completion of all of the manufacturing and tests, the third party inspector carries
out a final inspection of the pump. Paying particular attention to:

Main dimensions to drawing requirements

Base plate dimensions

Size rating and position of flanged connections

Size and type of threaded connection

Inspection for workmanship, defects and damage

Check on installed condition of parts, assemblies

Third Party Inspection for Centrifugal Pump - Name Plate Control

The third party inspector checks the content in accordance with the approved drawings
and specifications and makes sure it is stamped in accordance with the code
requirements.
Third Party Inspection for Centrifugal Pump - Painting and Coating Inspection
Surface preparation for painting is checked for the following points, according to
specification by third party inspector:

Cleaning method (Blast or scraping and wire brushing)

Preparation grades

Freedom from weld spatter, blow-holes and other defects

Dry film thickness is checked according to specification

It is necessary that the surface condition is free from pin-holes, runs damage and other
discontinuity.

Similarly, If the third party inspector is not in the hold or witness point in the
ITP for this inspection stage, then he/she will review the centrifugal pump
manufacturer quality control report in his/her coming visit or on the final
inspection day.
Third Party Inspection for Centrifugal Pump - Spare Parts, Loose Items
and Accessories
Spare parts, loose items and accessories are checked visually for their
dimensions, materials, workmanship and quantity, according to the purchase
order specification.
Test marks and tags are checked for correct identification.
Third Party Inspection for Centrifugal Pump - Reporting
The third party inspector provides an Inspection Visit Report (IVR) after each
visit, as well as a final report summarizing the activities carried out during the
pump production in accordance with the contract requirements and circulated
within the time limits specified in the contract.
The report is in the format required by the client and clearly indicates final
acceptance or rejection of the centrifugal pump.
Third Party Inspection for Centrifugal Pump - Release Note
When required by the contract or purchase order, a release note is issued by
the third party inspection agency and given to the manufacturer when the
pumps have been accepted.
Third Party Inspection for Centrifugal Pump - Packing, Marking and
Shipping:
The following points are checked by the third party inspector:
All exterior machined surfaces are coated with rust preventative
All internal surfaces that are susceptible to corrosion are coated with
rust preventative

 All flanged openings are fitted with metal protectors in accordance with
the specification
All threaded connections are provided with steel plugs
Exposed shafts and shaft couplings are covered with waterproof
material and sealed
Check manuals and instructions are included to the specification
requirements
Packing style and suitability for overseas shipment
Shipping marks are correct
Pre-assembled systems are marked as required by the specification
Third Party Inspection for Centrifugal Pump - Final Book (Dossier)
The following final documents are reviewed and signed off by the third party
inspector:
Manufacturers data report, Material certification, Dimensional record, NDE
reports, Hydrostatic test reports, Performance test requirements, NPSH
reports, Run-test reports, Strip down reports, Final inspection report, Marking
inspection report, Packing list and Spare parts list
Centrifugal Pump Performance Test Procedure
1. Scope
This description of procedure defines the conditions for the hydraulic testing of
centrifugal pumps according to API Standard 610.
Scope of test, type of test, test class and guarantee values are defined by standardized
test plans agreed between pump manufacturer and pump purchaser.

2. Objective

Objective of the tests is the continuous control of performance data as process control,
keeping the guarantees given according to the supply agreement, testing of relevant
pump functions.
Preparation of test reports and test curves according to the supply agreement as
integral part of the test documentation.
3. Standards and Other Regulations Applicable

API 610
Manufacture Standard
4. Centrifugal Pump Performance Test procedure
4.1 Testing Personnel
For the handling of the test beds, only trained personnel is employed. The setting of test
data is done semi-automatically and requires appropriate test experience and accuracy.
4.2 Place and Time Of Testing
The testing is done on the test bay of the manufacturer. Only pure cold water with a
density of = 1 kg/dm3 is used as the test medium.
Pump block units are normally tested with installed motor. In case of acceptance by the
customer, the readiness for the acceptance inspection is notified in time to the sales
departments.
4.3 Pump Test Beds
Both of following test beds are available and will be utilized as per purchase order
specification

Closed System
Open System, Alternatively With Booster Pump
4.4 Measurement And Testing Methods
The measurement and evaluation of hydraulic characteristic values is made by means
of an electronic data logger.
All relevant data are recorded at the site by means of electronic measuring devices and
presented with online electronic data processing at the test sites. After termination of the
measurements, the data is transferred to the central computer of the test bay

supervision. Unless otherwise specified, the acceptance performance tests are carried
out in acc. with API 610, para. 7.3.3.
4.4.1 Measurements Of Flow Rate Q
The flow rate is measured using magnetic inductive flow measuring devices having the
specified stabilization distances in front and after the measuring unit. The setting of the
capacity is effected by control valves in the discharge pipe.
4.4.2 Measurement of head H (Hd - Hs)
Pressure measurements are made using calibrated measuring transmitters for the
measuring point Hs (measuring range -10 up to +40 m wc), for measuring point Hd
(measuring range -10 up to +180 m, 150 up to 630 m wc). For visual comparison,
calibrated spring manometers are connected in parallel for analogous display.
4.4.3 Measurement of Velocity Head
The velocity head is calculated using the flow rate and the flow cross-section at the
pressure measuring point.

v2 /2g=(v2 d-v2 s)/2g

Vd = velocity discharge side
Vs = velocity suction side
= velocity difference between suction and discharge side
4.4.4 Measurement of power input (P)
The power input of the pump is determined either electrically by means of a calibrated
test motor or by directly measuring the speed of rotation using a torque measuring hub.
The electrical measurement is made according to the two-watt meter method for
determining the motor power input. The motor power output is calculated using the
motor efficiency curve stored in the test system.
For comparison of guaranteed data, the test system converts the pump power input
required for the customer conditions, i.e to the standardized speed and the density of
the acually pumped medium.
4.4.5 Measurement Of Speed (n)
The speed measurment occurs by means of a light barrier or photo sensor. For canned
motor pumps, not accessible from the outside, the speed is determined by means of a
bend coil or by frequency analysis.
4.4.6 Measurement of Pump Effeciency ()

The pump efficiency is determined for each measuring point immediately following
the measurement by the testing system.
According to the following formula:

=(QH100)/(367P)
Flow rate Q [m/h]
Head H [m]
Density [kg/dm3] of pumped medium
Power P [kW]
4.4.7 Measurement of the NPSH value of the pump (NPSH required)
Normally in the closed circuit, the measurement of the NPSH value is made by reducing
the system pressure by means of a vacuum pump. Measurement also is done by
throttling using a throttle valve in the suction line, as the case may be.
Reaching the guaranteed value at the required NPSH value can be proven using the
following 2 measuring methods.
a) Standard
Proof of reaching the required NPSH value by setting the peripheral conditions which
are equal inthe system such as flow rate, head when reducing the suction pressure
depending on the water temperature and the barometric level.
Comparison of head, taken from the characteristic curve measurement above, with the
head measured at actual suction negative pressure where the guaranteed NPSH value
is achieved or is not achieved.
The head decrease may not exceed 3 % of H, but does not have to achieve 3 % (for
single-stage pumps).
According to the specifications in the order, 1 or 3 to 5 measuring points are used. For 2
stage pumps, the max head decrease may not be H1.5 %
So NPSH test for multi stage pump is not possible.
b) Optional as Head Breakdown Curve
Proof of the min. achievable NPSH value at a specific constant flow. By reducing the
suctionhead, starting at NPSH = 40 m, a number of measuring points (8-12) are
recorded until the pumping breaks down. The cut-off point at 3 % head decrease since
the beginning of the measurement results in the cavitation condition of the pump at this

point and is defined in the applicable standards as NPSH required (for 2 stage pumps
1.5% H)
Reference level for calculation of the NPSH
a) Horizontal Pumps
Horizontal level through the shaft axis
b) Vertical Pumps
Plane surface vertical to shaft axis at impeller inlet
Calculation of The NPSH Based on The Measured or Known Parameters:
The calculation of the NPSH value occurs simultaneously with the measurement.
The following parameters are required for this:
Suction head

H_S [m]
Water temperature

t_w [C]
Steam pressure of water(absolute vaporization pressure)

H_t [m]=P_D/(g)
Atmospheric pressure (absolute)
Atmospheric height (absolute)

b_0 [m]=P_O/(g)
Distance reference level/measurement level

Y[m]
Speed at suction side

(V_S2 )/2g[m]
Density of test field water

[kg/(dm3 )]
Acceleration due to gravity

g [m/s]
The NPSH is calculated according to the following formula:

NPSH=P_O/(g)-H_S-P_D/(g)+(V_S2)/2gY
NPSH=b_0-H_S-H_t+(V_S2 )/2g
The conversion of the NPSH value from the measured speed to the nominal speed is made according to
the following formula (only valid for the speed range 3 %):

n* /n>0.97<1.03
NPSH* =NPSH[n* /n]2 [m]
Q* =Qn* /n [m3 /h]
4.4.8 Additional measurements

Upon request, the electrical current I [A] and the voltage U [V] can also be measured.
4.5 Number of measuring points
The number of measuring points for the pump characteristic curve or NPSH
measurements must
be agreed in the supply agreement.
Characteristic curve at 0, Qmin, Qmean, Qnom, Q120%, standard measurement of 5
points (9 max.)
NPSH measurement 0, Qmin, Qmean, Qnom, Q120% 4 points (7 max.)
5 Centrifugal Pump Performance Test - Guarantees
The rated values of the pump are guaranteed in compliance with API 610 provided that
no other customer requirements exist. The measuring of tolerances is done
automatically by the measuring system.
For viscous media, only the specified data for cold water is guaranteed. The results with
viscosity will be shown for information as conversion curves according to Hydraulic
Institute.
6 Centrifugal Pump Performance Test - Vibration measurement
To assess the mechanical and hydraulic operating behavior of the pump tested,
vibrations are recorded at the same time as the hydraulic date (min. 5 points).
Measurement is carried out in three planes - horizontal, vertical and axial - by means of
vibration pick-ups fitted on the bearing bracket. The measureng criterion is the root
mean square velocity of all vibrations determined (vibration velocity RMS in mm/s).

The limit stipulated by API 610 is for horizontal pumps 3 mm/s in the preferred operating
range of the pump. In the allowable operating range, a vibration velocity of up to 3.9
mm/s (max.) is permissible. For vertical pumps the limit 5 mm/s in the preferred range
and 6,5 mm/s in the allowable range is applicable.
Alternatively, it is also possible to measure the max. vibration amplitude (peak-to-peak).
Horizontal
Limit in preferred range: 2,0 mils (50 m)
Limit in allowable range: 2,6 mils (65 m)
Vertical
4,0 mils (100 m)
5,2 mils (130 m)
The frequency spectrum (FFT analysis) can be measured, if requested.
7 Centrifugal Pump Performance Test - Measurement of Bearing Temperature
If required, the measurement of the bearing temperature will be performed for a
specified operating time. The measurement is taken on the bearing bracket on the
outside at the level and position of the pump side or motor side bearing in horizontal
direction.
8 Centrifugal Pump Performance Test report
The test results are stored in the central computer of the test bay supervision and on
other electronic data carriers. Upon request, test reports and test curves are prepared
for the customer.