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1. Casing
Pump Casing Inspection
The pump casing inspection starts with material inspection, non-destructive testing
and ends with hydrostatic testing.

Pump Casing Hydrostatic Test

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The pump casing hydrostatic test is performed after successful completion of the pump
casing inspection. The casing shall be tested by liquid at the 1.5 times of maximum
allowable working pressure. The pump hydrostatic test pressure can be found on the
pump datasheet.

The inspector does not need to calculate the test pressure since this is calculated by
manufacturer pump designer and approved by customer pump SME (Subject Matter
Expert). The inspector should make sure the pump casing hydrostatic test procedure
is being submitted to the customer and being approved.

Pump Casing Hydrostatic Test in API 610

The water temperature for testing shall be higher than casing material transition
temperature from ductile to brittle fracture. The material transition temperature can be
obtained from the metal handbook, or ASME Code Section VIII Div.1 USC-66 curve
A, B, C, D can be used as a guide.

This requirement avoids from catastrophic brittle fracture during hydrostatic testing.

As you might know, the material loses its toughness below the certain temperature (it
is different from material to the material) and a small imperfection in the casing body
can lead to the fracture if the testing liquid temperature is less than the material
transition temperature.
The API 610 also requires that the wetting agent being added to the testing liquid in
the certain condition. The most important ones are when the pump service has the
specific gravity less than 0.7 (the specific gravity can be found in the pump datasheet)
or when the pump design temperature is higher than 500-degree Fahrenheit.

The code requires the test liquid chloride content be less than 50 ppm for casing with
stainless steel material to avoid stress corrosion cracking. Besides, upon completion
of the test all testing water shall be removed and dried instantly.

As per API 610, the casing shall be under hydrostatic pressure for minimum 30
minutes. The hydrostatic test result shall be considered satisfactory if no leak or
seepage observed from pressure containing part.

The mechanical seal shall not be included in the casing hydrostatic testing. If seal
chamber is a removable type, then shall be tested separately.

The pump casing cooling water passages, (if any) bearing jackets and seal chamber,
etc. shall be tested at minimum 150 PSI.

The steam, lubricating oil and cooling water piping system shall be tested at the 1.5
times of the Maximum Operating Pressure or 150 PSI whichever is greater.

The hydrostatic testing shall be performed by calibrated pressure gage, and the
inspector shall verify the calibration and expiration dates. The preferable range of
pressure gage shall be twice of the test pressure but in no case shall be less than 1.5
times and not more than 4 times of the test pressure.

For example, if test pressure is 1000 PSI, the best pressure gage for testing will be
2000 PSI pressure gage. As per above requirements the 1200 PSI and 5000 PSI
pressure gages will not be acceptable.
Depends on pump design, the casing might made from casting or forging, but the
majority of the pump are made from the casting.

Let's explain the casing material inspection with an example. You are reviewing the
pump approved datasheet and finding following information:

Casing Material: ASTM A743 Gr. CA 15 (12% Chromium)

Inspection Class: III

The ASTM A 743 refers to the Standard Specification for

Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion

Resistant, for General Application.

Pump Impeller Dynamic Balancing

The pump impeller dynamic balancing is done based on API 610 requirements. The
standard requires the balancing be performed based on ISO 1940-1 to the Grade
G2.5

Some calculation needed to be performed to determine the acceptance criteria, but

these are done by pump manufacturer design engineer. The inspector shall verify the
approved balancing test procedure and identify following information:

 Is it the single plane or Double plane balancing?

 Arbour Speed (RPM)?
 Acceptance Criteria?
Example for Pump Impeller Dynamic Balancing

You are attending to the pump manufacturer to witness an impeller dynamic

balancing test. You review approved test procedure and find the following
information.

 It is Double Plane Balancing

 The Arbour Speed is 1800 RPM (the impeller mounted in the Arbour)
 Acceptance Criteria is 0.001 oz-in

 The balancing technician mounts the impeller in the arbour and place them on
the balancing machine. The machine starts running and spinning the impeller
at 1800 RPM. (Revelation per Minute)

 You see the following information on the screen:

 Run 1
 Left -183 mg at 217° unbalance 367 mg-in (0.0129 oz-in)

 Right -190 mg at 295° unbalance 286 mg-in (0.0100 oz-in)

 As you see, the amount of unbalance in both left and right planes are more
than acceptance unbalance value (0.001 oz-in)

 So the technician works on the impeller by grinding and removing some

weight from certain area to reach the amount of unbalance to the 0.001 oz-in

 He stops grinding and runs the machine to measure the amount of unbalance.
The result is as following:
 Run 2
 Left -146 mg at 216° unbalance 292 mg-in (0.0103 oz-in)

 Right -134 mg at 297° unbalance 201 mg-in (0.0070 oz-in)

 As you see in the run 2, the amount of unbalance reduced but still is not
meeting the acceptance criteria. These values shall be reduced to the 0.001
oz-in

 The technician continues working on the grinding and balancing the impeller
and run the machine several times and collects the data. See following for
final run.

 Run 10
 Left -7.32 mg at 296° unbalance 14.6 mg-in (0.00051 oz-in)

 Right -10.7 mg at 75° unbalance 16.0 mg-in (0.00056 oz-in)

 So this time the amount of unbalance in both planes are less than 0.001 oz-in
and pump impeller dynamic balancing can be approved.

 Now let see how pump design engineer calculates the acceptance criteria (the
permissible unbalance amount)

 Permissible Unbalance (g-mm) = (1000 x balance grade value x weight of

impeller in (Kg)/ angular velocity (rad/S)

 For example, if you have an impeller with 2 Kg weight and with rotor rpm of
3000 RPM, then permissible unbalance will be as following:

 Permissible Unbalance = (1000 x 2.5 x 2) / 314.2 = 15.91 g-mm ( 0.022 oz-in)

 The 2.5 is the "grade of balance" is taken from ISO 1940-1 and required by
API 610 to be 2.5. The unit for 2.5 is mm/s

 The 314.2 is angular velocity of shaft speed. We divided 3000 RPM to 9.54 to
obtain speed in rad/s

 The inspector does not need to perform this calculation since the calculated
value is provided in the approved procedure.
 Centrifugal Pump Performance Test
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The centrifugal pump performance test is conducted by pump manufacturer after

completion of the assembly to prove the pump has the required specification as
indicated in the pump datasheet and other purchase documents.

The performance test is conducted after completion of casing inspection, casing

hydrostatic test, impeller, and rotor dynamic balancing. The NPSH test, mechanical
running test, and final inspection are done after performance test. The vibration
testing is carried out during performance test and mechanical running test. You may
also want to review a general centrifugal pump inspection and test procedure.

The performance test is conducted after completion of casing inspection, casing

hydrostatic test, impeller, and rotor dynamic balancing. The NPSH test, mechanical
running test, and final inspection are done after performance test. The vibration
testing is carried out during performance test and mechanical running test. You may
also want to review a general centrifugal pump inspection and test procedure.

Let explain the performance test by an example. You are attending to the pump
manufacturer shop to witness a centrifugal pump performance test which is a hold
point on the pump ITP. You review the pump approved datasheet and find following
information:

Rate flow = 238.5 m³/h (1050.08 Gal/Min)

Rated Differential Head = 2690.28 m (8826.37 feet)

Rated Power = 2985 KW (4003 HP)

Rated Efficiency = 68 %

Upon completion of the centrifugal pump performance test, the pump manufacturer
provides you following performance curve. You need to match this curve with
datasheet specification to make sure the pump passed the performance test.

Upon completion of the centrifugal pump performance test, the pump manufacturer
provides you following performance curve. You need to match this curve with
datasheet specification to make sure the pump passed the performance test.

Let's start with head-capacity curve, we draw a verticle line at 238.5 (in the horizontal
axis), and it will cross head-capacity curve, then we draw a horizontal line from the
cross point, and it crosses the vertical axis at 2640. So the measured head at the
238.5 m³/h is 2640 meter.

What was expected value in the datasheet? It was 2690.28 m but the test result was
2640 m.

What is the test result ( the head almost is 50.28 meters less than required value)?
The pump outperforming or underperforming?

The API 610 at table 18 says the head can be +/- 3% of the rated value. The 3 % of
the rated value (2690.28 x 3%) would be 80.7 which is greater than 50.28, the pump
underperforming but the test result is acceptable.
et's assess the power consumption; we repeat the same process but this time with the
power curve. The curve indicates the consumed power at 238.5 m³/h is 2600KW
(power consumption was provided at the left side of the vertical axis). Compare 2600
KW with datasheet value which is 2985 KW.

Obviously, the pump outperforming since consumes less power. However, API 610
acceptance range is 4% it means the pump test result would be satisfactory even if
consumes more than 4 % from what indicated in the datasheet.

We also need to check the efficiency. The minimum efficiency in the approved
datasheet is 68 %. Check the efficiency curve, the efficiency amount at the 238.5 m³/h
is 70%. So the pump is outperforming and gives higher efficiency than what required
in the datasheet.

So the result of the centrifugal pump performance test for the differential head, power
consumption, and efficiency is satisfactory.

The head value also shall be checked in shut off point but since this pump is high
energy pump, the centrifugal pump performance test at the shut-off point (no flow at
discharge valve) is not a requirement based on API 610.

The above example was a simplified example. The pump manufacturers usually
provide a tabulated format to make it easy for review.

The manufacturers also simulate the test result to actual field condition. The pump
might be designed for crude oil, but in the shop will be tested by the water. In such
cases, the attained values will be converted to field condition by engineering
calculation.

Subsequently, you need to check bearing housing and shaft vibration FFT spectrum
(Plot) at each data point from minimum to maximum flow to ensure the vibration values
are within acceptance range.

The Pump NPSH Test (Net Positive Suction Heat Test) report also shall be verified
against approved datasheet values.

The pump mechanical running test is performed after successful completion of

performance and NPSH test.

Now let deepen in the centrifugal pump performance test by the understanding of
flowrate, total head, power, and efficiency.
What is the Flowrate and Head in Centrifugal
Pump Performance Test?
Volume flow rate (Q), also referred to as capacity, is the volume of liquid that travels
through the pump in a given time (measured in gallons per minute or GPM).

It defines the rate at which a pump can push fluid through the system. Flowrate is the
first parameter specified by the process designer, who determines the pump
requirement on the flowrate that the process needs to function.

This 'rated' flowrate is normally expressed in volume terms, and it is represented by the
symbol q, with units of cubic meters/ second or GPM.

The static head of a pump is the maximum height (pressure) it can deliver. The capability of
the pump at a certain RPM can be obtained from its Q-H curve.

The pump manufacturers are interested in providing pump performance curve in a way
that does not depend on to the pumped fluid physical properties.

That is why they are using head instead of pressure. The following formula converts
pressure to the head; H(meter) = 10.2 P/SG or H(feet)= 2.3P/SG

Once the rated flowrate has been determined, the designer subsequently specifies the
total head (H) needed at this flowrate.

This is expressed in meter or feet and represents the usable mechanical work
transmitted to the fluid by the pump. Together q and H define the duty point.

The q/H Curve Test;

The test is carried out at a nominally constant shaft speed, and the head (H) decreases
as flowrate (q) increases, giving a negative slope to the curve. (See above H-Q curve)

Look at the following sketch; this illustrates a simple H-Q curve loop. The test engineer
changes the flowrate through discharge control valve and takes measurement of
different variables and calculates the corresponding head.

The first set of measurements is taken at duty point (100 percent q). The valve is
opened to give a flowrate greater than the duty flow (normally 120 or 130 percent q),
and further readings are taken.

The valve is then closed in a series of steps, progressively decreasing the flow (note
that we are moving from right to left on the Q-H curve). With some pumps, the final
reading can be taken with the valve closed, i.e. the q = 0 or shut-off condition.

Once the test points are obtained, you can now check against the acceptance criteria
requirements

Power Consumption in Centrifugal Pump

Performance Test
The power consumption is measured at different flowrates similarly, and the power-
flowrate curve is plotted. A wattmeter is connected to motor power input, by multiplying
wattmeter amount at motor efficiency the motor output power is calculated at different
flowrates. Through these corresponding readings, the power-flowrate curve is plotted.
The Efficiency-Flowrate Curve at Centrifugal Pump
Performance Test
The efficiency-flowrate (ƞ-Q) curve can be plotted based on measured values from
combination of H-q curve and P-q curve and this formula ƞ=(P out of Pump)/(P input
of Pump)=ρgHQ/(P input of pump) (ρ is density, g is gravitational acceleration, H is
Head and Q is Flowrate)

Pump efficiency (ƞ percent): the efficiency is the ratio of transferred mechanical work
of the fluid to consumed power (P) in watts by the pump.

The efficiency test; the efficiency is checked using the same set of test
measurements as the q/H test. Pump efficiency is plotted against q in above figure.

You may also review third party inspection for centrifugal pump and pump inspection
and test plan articles as supplementary information.

This content provides you with a sample Centrifugal Pump Performance Test
Procedure in the manufacturing shop. The procedure is very brief and general.
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 ρ= 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.
 Δ v2 /2g=(v2 d-v2 s)/2g
 Vd = velocity discharge side
 Vs = velocity suction side
 Δ = 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 (η)

 The pump efficiency is determined for each measuring point immediately

following the measurement by the testing system.
 According to the following formula:
 η=(Q×H×ρ×100)/(367×P)
 Flow rate Q [m³/h]
 Head H [m]
 Density ρ [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 ΔH≤1.5 %

 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% ΔH)

 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/(ρ×g)

Atmospheric pressure (absolute)

Atmospheric height (absolute)

b_0 [m]=P_O/(ρ×g)

Distance reference level/measurement level

Y[m]

Speed at suction side

(V_S2 )/2g[m]

Density of test field water

ρ[kg/(dm3 )]

Acceleration due to gravity

g [m/s²]

The NPSH is calculated according to the following formula:

NPSH=P_O/(ρ×g)-H_S-P_D/(ρ×g)+(V_S2)/2g∓Y

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* =Q×n* /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 2.5 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 μm)

Limit in allowable range: 2,5 mils (65 μm)

Vertical

4,0 mils (100 μm)

5,2 mils (130 μm)

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

he 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.

Pump Net Positive Suction Head Test (NPSH Test)

The centrifugal pump net positive suction head test (NPSH Test) is conducted after
completion of the performance test. We perform the NPSH test to measure the ability
of the pump to avoid cavitation in the inlet section of the pump.
Let's get started with an example. You are witnessing an NPSH test at the
manufacturing shop. The pump approved datasheet indicates the following
information:

NPSHA = 11.09 m (36.38 feet)

Rated Flow = 238.5 m³/h (1050.08 Gal/Min)

The NPSHA stands for "net positive suction head available." Pump purchaser provides
the NPSHA to the pump manufacturer for design purposes.

The measured/ calculated value in the NPSH test is named NPSHR (net positive
suction head required).

So you have to delineate these two terms as below:

NPSHA comes from pump purchaser (customer)

NPSHR provided by pump manufacturer, and it is actual measured value

The NPSH Test result will be satisfactory if the NPSHR is less than NPSHA.

Look at the following curve and determine the result of NPSH test?

Locate NPSH curve, the NPSH @ 238.5 m³/h is 8 m which is less than 11.09. So the
result of the test is OK.
This is the way you determine the pump net positive suction head test result and
now let be a little bit more in-depth on the subject:

Cavitation and Pump Net Positive Suction Head

Test
The following curve illustrates that cavitation is not happening on the curve (a)
because suction pressure is higher than vapor pressure. Contrary, the curve (b)
illustrates a cavitation problem because the suction pressure is less than vapor
pressure. The suction section is the Achilles heel of the centrifugal pump.

The cavitation is the vaporizing of pumped fluid and bursting on pump impellers, and this
process happens at the 0.01 second and is very unstable.

Saturation temperature means boiling point. The saturation temperature is the

temperature for a corresponding saturation pressure at which a liquid boils into its
vapor phase.
The saturation temperature is affected by pressure for instance water boils at 100º C
or 212º F at sea level that can be considered 1 bar or 14.7 psi. Now if you increase
the pressure the water will boil higher than 100º C or 212º F.

Contrary if you reduce the pressure the water will boil less than 100º C or 212º F. This
is what happening in the impeller eye, an area exists with negative pressure (vacuum)
and creates a low-pressure system in the impeller eye. So, water changes to vapor
phase and water bubble forms and cause cavitation.

The cavitation causes the reduction in efficiency and increase of noise and vibration.
The bursting of bubbles can produce a localized pressure up to 〖10〗^5 PSI that is
very detrimental.

NPSHA; NPSH (Net Positive Suction Head) determined by the purchaser for the
pumping system with the liquid at the rated flow and normal pumping temperature.

NPSHR; Net Positive Suction Head Required (NPSHR or NPSH3) NPSH that results
in a 3 % loss of head (first-stage head in a multistage pump) determined by the vendor
by testing with water.

Pump Net Positive Suction Head Test Process

The suction pressure is reduced in a series of steps (by vacuum pump or throttling
valve). For each step, the pump outlet valve is adjusted to keep the flowrate (q) at a
constant value.

The final reading is taken at the point where the pump head has decreased by at least
3 percent. This shows that a detrimental level of cavitation is occurring and defines the
attained NPSHR value. To be acceptable, this reading must be less than NPSHA.
It means we gradually reduce the suction pressure until we achieve 3% reduction on
the head, then we stop the test and record NPSHR.

Then we start the pump net positive suction head test with another flowrate and attain
the NPSHR for the second flowrate. So if you have 5 test points, you have to repeat
the test 5 times. One test per each flowrate. Then you can draw the Q-NPSH curve.

In other words, the NPSHR is vapor pressure in the impeller eye and NPSHA is the
suction pressure, suction pressure always should be higher than vapor pressure to
avoid cavitation.

If the pump operates in the A region, your pump is operating on the safe condition
regarding cavitation. If it operates on the B, you are on the discreet region because
your NPSHA still is higher than NPSHR but if for any reason your NPSHA being
decreased by choking or pettiness on connecting suction pipe, your pump might
experience cavitation.

The pump in the C area completely works on the cavitation region and cavitation will happen
definitely.
Pump Vibration Testing

The pump vibration testing is performed during performance test at different

flowrates and also during the mechanical running test at the rated flow.

Depends on pump design, bearing housing vibration and shaft vibration are measured
and plotted in the FFT (Fast Fourier Transform) spectrum at each data point from
minimum to maximum flow to ensure the vibration values are within acceptance range.

Pump Bearing Housing Vibration Testing

The bearing housing vibration is measured with velocity meter or accelerometer
transducers (sensor). If the accelerometer is used, then the software makes a
calculation and changes that to the velocity.

The velocity vibration acceptance range for the overhung and between-bearing pump
is provided in Table 8 and for vertically suspended pump addressed on table 9 of API
610.

Based on the API 610 requirement the overall vibration for overhung pump shall be
less than 3 mm/s (0.12 in/s) for overall frequency and 2 mm/s (0.08 in/s) for discrete
frequency.

The API 610 requires out of preferred operating region the vibration level shall not be
more than 30% of above-mentioned limits. Please note this only applies to
performance test since the pump is tested in different flowrates.

In the mechanical running test, the pump will run on the rated flow, so this 30% extra
limit is not applied to the mechanical running test.

Let's continue with an example

Following FFT plot refers to the bearing housing vibration of centrifugal pump
performance test in X, Y and Z axis

X Axis Vibration @ Pump Bearing Housing

The overall vibration is 1.1817 mm/s and it is less than 3 mm/s so the overall vibration
test result is OK.

The left side table indicates max amplitude is 0.8686mm/s at 29.167 hertz
(synchronous vibration). The 0.8686 mm/s is less than 2 mm/s so the result of test for
discreet frequency is OK

Note: The synchronous vibration means the amount of vibration amplitude at the shaft
RPM, in this example, the pump shaft speed is 1750 rpm which equals to the 29.167
HZ). We usually experience high spike at shaft 1X, 2X, etc. frequencies regarding the
mass of unbalance on the rotor.

Y Axis Vibration @ Pump Bearing Housing

he overall vibration is 1.6863 mm/s and it is less than 3 mm/s, so the overall vibration
is OK.

The left side table indicates max amplitude is 0.9516 mm/s at 29.167 hertz
(synchronous vibration). The 0.9516 mm/s is less than 2 mm/s so the result of test
for discreet frequency is OK

Z Axis Vibration @ Pump Bearing Housing

The overall vibration is 0.5529 mm/s and it is less than 3 mm/s, so the overall vibration
is OK.

The left side table indicates max amplitude is 0.1586 mm/s at 29.167 hertz
(synchronous vibration). The 0.9516 mm/s is less than 2 mm/s so the result of test for
discreet frequency is OK

So above FFT plot verified for rated flow. The pump manufacturer provides FFT plots
for each flowrate, and all of these plots shall be verified. As per API 610, the pump
shall be subjected to the performance test at least for 5 data points. So you need to
review one set of the above-illustrated plot for each data point.

Shaft Vibration @ Pump Vibration Testing

The shaft vibration is measured by proximity probe and acceptance range based on
API 610 is 50 μm (2.0 mils) for overall frequency and "0.33 times overal vibration" for
discreet frequency.

Let's continue with an example. See following FFT plot for shaft vibration.
The overall vibration was measured as 16.83 μm, and it was less than 50 μm, and so
the result is OK. The vibration at the discreet frequency of 68.75 Hertz was measured
as 2.55 μm which is less than (16.83 x 0.33 = 5.55 ) and the result of test for discreet
frequency also was OK.

This was for one axis; two more plots shall be verified to complete assessment for this
data point.

As mentioned in above, at least 5 data points (5 different flowrates) shall be taken so

totally 5 sets of FFT plots (3 plot for each set) shall be received and verified for the
pump vibration testing at performance testing part.

Pump Vibration Testing @ Mechanical Run Test

After successful completion of the performance test, the pump is subjected to the
mechanical running test for 4 hours (at the rated flow) and pump vibration testing data are
collected in real time basis. The pump manufacturer provides these plots for review after
completion of the test. The plots shall be reviewed and checked against acceptance range.
 Inspection and Test Plan for Centrifugal Pump -
Sample
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Inspection and Test Plan for Centrifugal Pump

You may also review centrifugal pump testing and centrifugal pump inspection
procedure/instruction articles.

The API 610 standard requirements are normally applied for the inspection and
test plan in a manufacturing shop.

The witness of some inspection and testing by third party inspectors is

mandatory and cannot be waived.

Some others must only be monitored and full witnessing is not necessary; for
these items, the inspection man-days etc. depend on the purchaser’s decision.
Some prefer stringent monitoring and even assign a resident inspector in the
manufacturing shop, and others relay to the quality control system of the
manufacturer and assign only a few days for monitoring points.

These are some of the inspection points that need to be witnessed, checked
monitored and reviewed by a third party inspector for a centrifugal pump
construction.

ITP for Centrifugal Pump - Important Points

 Centrifugal Pump casings to be identified against foundry test certificates

and thicknesses checked to conform to approved drawings.

 Witnessing hydrostatic test on pump casing

 Witnessing Centrifugal pump Impeller run out and dynamic balance tests

 Witnessing Centrifugal pump performance test

  Witnessing mechanical running test on pumps including NPSH where
applicable

 Strip inspection of pumps on completion of running tests, where specified in

data sheet. Wearing surfaces to be checked and recorded. All materials to be
checked against test certificates or Vendor`s bill of materials.

 Inspection and final dimensional check of pump (including driver, when fitted)
mounted on baseplate

 Heat run or standard abbreviated tests, as mutually agreed and specified, to be

witnessed on electric motor drives.

 Inspection and final dimensional check to be carried on motor drivers.

 Checking all test certificates

Third Party Inspection for Centrifugal Pump - Procedure

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The Third Party Inspection for Centrifugal Pump article provides a sample procedure
for pump inspection and testing in manufacturing shop and includes horizontal,
vertical and in-line pumps. The article might be reviewed with centrifugal pump
inspection and test plan.

This content guides you through all the necessary stages in the production of the
centrifugal pumps, including the material, fabrication, casing inspection, casing
hydrostatic testing, performance test, mechanical running test, net positive suction
heat test, vibration test to the final inspection, preservation and packing, and dispatch
to site.

You need to take this point into account: this article is written for a typical centrifugal
pump and might not be detailed for special cases.
All centrifugal pump inspection and testing is done against the approved drawings,
purchase order specifications, purchasers or company standards, and within the
practices and rules of the country, state or province and any government decrees,
laws, ordinance or regulation as may apply.

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

 Design code
 Purchase order specification
 Purchaser's standards
 Approved drawings

And the applicable codes and standard are:

 API 610

The applicable codes and standards may be based on other international standards
such as BS 7784, etc. This content is general and can be useful even if the design
code is different from the API Code.

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
Documents
 Centrifugal Pump Impeller Inspection Procedure
 Centrifugal Pump Performance Test Procedure
 Centrifugal Pump Mechanical Running Test Procedure
 Centrifugal Pump Net Positive Suction Head Test Procedure
 Centrifugal Pump Vibration Test (FFT Plot) 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 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.

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

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

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

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

Third Party Inspection for Centrifugal Pump – Mechanical Running Test

When required by the contract or purchase order, where the pump runs for a pre-
determined 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

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.

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 manufacturer’s 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:

 Chloride tesing and solvent cleaning (if required)

 Cleaning method (near-white metal blast cleaning, commercial balst cleaning,
etc.)
 Surface Preparation
 Freedom from weld spatter, blow-holes and other defects, dust
 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.

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 and packing inspection
 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