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 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:
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 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 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 μm) Limit in allowable range: 2,6 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 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.
