Performance Evaluation of High speed Centrifugal pump at Varied Speed Conditions

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1 Performance Evaluation of High speed Centrifugal pump at Varied Speed Conditions S. Sivaprakash, RE Palakkad, Kerala , www. fcriindia.com

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

3 Introduction Engg. Class II Class C Engg. Class I Class B ISO , IS (RA 2002) Generally used for acceptance tests ISO (ISO ) IS Special cases, Pump performance more precisely defined Precision Class Class A ISO IS Only when the Engg. Class test is inadequate for the precision required

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

5 Scope of Testing Total head at the agreed flowrate or vice versa Efficiency Efficiency of the pump or the combined pump- motor unit Hydrostatic Test Head Vs Flow NPSH Required

6 Standard Requirements of Test An Axially Symmetric Velocity distribution A uniform Static pressure distribution Freedom from swirl induced by installation Inlet straight length

7 Test Conditions Sufficient time Duration Multiple readings Steady Conditions of Operation Unsteady Conditions More is always better Only Speed and temperature allowed to be controlled

8 Accuracy of Measurement Quantity Instruments Overall limit Rate of flow ± 1,5 ± 2,0 Pump total head Pump power input Electrical power input (for overall efficiency tests) ± 1,0 ± 1,5 Speed of rotation ± 0,35 ± 0,5 Overall efficiency (computed from the rate of flow, total head and electrical power) - ± 2,5 Pump efficiency - ± 2,8

9 Accuracy of Measurement Quantity Instruments At FCRI Rate of flow ± 1,5 ± 0,10 Pump total head Pump power input Electrical power input (for overall efficiency tests) ± 1,0 ± 0.04 Speed of rotation ± 0,35 ± 0,1 Overall efficiency (computed from the rate of flow, total head and electrical power) ± 2,5 ± 0,3 Pump efficiency ± 2,8 ± 0,5 ± 0.20

10 Procedure for Measurement Measurement of flow rate Weighing Method Volume Tank Method dp meters method Precision Flow meters

11 Procedure for Measurement Precision Electro magnetic Flow meter TFM s MFM s Other Flow meters methods Velocity area Tracer Methods Ultra Sonic Flow meter

12 Procedure for Measurement Measuring Section Inlet Measuring Section Outlet Measuring Section Swirl free region Head loss between measuring section and pump end Choice of Measuring Section Velocity should be small Cross-sectional area shall be well defined

13 Procedure for Measurement Measuring Section 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.

14 Procedure for Measurement Measurement Inlet Total Head Outlet Total Head Friction loss at Inlet & Outlet Pump Total head Liquid of Head column manometers Transducers Smart Transmitters

15 Procedure for Measurement Measurement Normal Tachometer Non contact type Tachometer Optical Devices Spectrometer Measurement of Speed (± ) of Torque Dynamometer Torque Transducer

16 Procedure for Measurement Measurement of Electrical Power 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

17 The Test setup 941mm

18 Performance test Suction Size Delivery Size Pump Speed Date Sl. suction No. Head bar : : : : suction H Del H Del Head Gauge gauge corrected corrected m WC bar m WC mm mm rpm Total Head Total Head bar m WC Corrected Pump Total Speed Head to rpm 7000 rpm m WC

19 Performance test Rated Flowrate Design Total Head Design NPSH Rated Speed Q Q m3/hr usgpm : : : : Qcorrected Total to Head 7000 rpm corrected usgpm USGPM feet feet RPM Qrtd ft WC Pump Meas. Motor power motor i/p KW o/p power i/p 83.5% m3/sec KW x kw kw Motor i/p KW corr KW η

20 Performance test

21 Performance test

22 Performance test 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.

23 NPSH Tests Cavitation 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

24 Net Positive Suction Head Safety Margin At constant Flowrate At varied NPSH conditions By adjusting the suction head By adjusting the suction/ Delivery head

25 Net Positive Suction Head Method of test 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

26 NPSH Tests Suction Size Delivery Size Pump Speed Date Sl. suction No. Head bar : : : : suction H Del H Del Head Gauge gauge corrected corrected m WC bar m WC mm mm rpm Total Head Total Head bar m WC Corrected Pump Total Speed Head to rpm 7000 rpm m WC

27 NPSH Tests Rated Flowrate Design Total Head Design NPSH Rated Speed Q Q : : : : Qcorrected Total to Head 7000 rpm corrected m3/hr usgpm usgpm ft WC USGPM feet feet RPM v v /2g Inlet total Head m/s m H NPSHA NPSHA m ft

28 NPSH Tests

29 NPSH Tests

30 Brief Specifications of the Main Water Flow Laboratory Maximum Maximum Flow rate Size 5000 m3/h 900 mm Measurement Uncertainty In Mass Flow rate In Volume Flow rate ±0.04% (Upto 250 T/h) ±0.10% (300 to 1800 T/h) ±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 ±0.01% ±0.05% ( for 0 to 2000 kg) (Upto 20 m3) ±0.025% ( 2000 to kg) Pumps Capacity 5000 m3/h Major Reference Instruments Mass flow meter Head 30 mwc Tech. details Accuracy Size : 80 mm NB 280 Tons/h 0.10% Electromagnetic Flow meters Insertion Flow meters Size : 15 to 500 mm NB upto 5000 m3/h 0.20% Upto 3000 mm NB 5 m/s 1.00% Ultra sonic Flow meter Upto 1200 mm NB 10 m/s 1.00% Coriolis Type kg/m3 0.02% Online Densito meter

31 Facilities at FCRI The 100mm Water Flow Laboratory 250 m3/hr and 100 mm φ The 600mm Water Flow Laboratory 4500 m3/hr and 600 mm φ The Large Water Flow Laboratory 1500 m3/hr and 2000 mm φ

32 Facilities at FCRI

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