ITT FCDN

LARGE SUBMERSIBLE PUMP

TEST FACILITY
INDEX

Description Page N

Introduction 3

System Description
General 4
Discharge stands 5
Piping system 6
Electrical system 7
Control room 8
Data acquisition, evaluation and presentation 9
Data acquisition system (figure n3) 10
Data acquisition system (figure n4) 11
Data acquisition system (figure n5) 12
Flow metering 13
Pressure measurement 14
Pressure measurement (ITT Barton data sheet, page1) 15
Pressure measurement (ITT Barton data sheet, page2) 16
Electrical measurements 17
Brel & Kjaer vibration meter 18
IRD Mechanalysis machine analyser model n838 19

2
 INTRODUCTION

ITT FCDN's large submersible pump test facility is specially designed to

accommodate Flygt's Submersible Centrifugal Pumps in the range from 75kW
(100hp) to 500kW (670hp) at flows from 70 l/s. to 1900 l/s (30,115 usgpm).
The facility's primary objective is to conduct certified performance tests, i.e. to
show proof that a designated pump complies with the appropriate customer
performances specifications. The facility is also used for various quality
control testing, such as vibration testing, hydrostatic testing, external cooling
flow requirements, performance assessments, sampling of production pumps,
etc. The test facility is built to fulfill the ISO 3555 and the Hydraulic Institute
Test Standard Requirements.

SYSTEM DESCRIPTION

General:

The test facility consists of a concrete tank holding approximately 57,750 litres
(15,250 US gallons) of water, pump discharge connections, stainless-steel
manifolds and piping, throttling and isolation valves, flowmeter, pressure
transducer and electrical power and instrumentation systems, required to
conduct performance tests on ITT Flygt Submersible Pumps (see figure n1).

Figure n1:

3
 DISCHARGE STANDS

The primary capability designed into the test facility is the hydraulic
performance testing of self-coupling Flygt Submersible Wastewater Pumps.
Flygt pumps automatically connect to the discharge line when lowered into
place onto specially constructed discharge stands (see figure n2). Hydraulic
performance tests can also be run on pumps intended for non-submersible
dry-pit applications, by adding the ITT Flygt standard inlet elbow to the pump
and lowering the water level of the tank to clear the pump motor. This
simulates a unit pumping from a pipework system with the motor running in
air.

Located at a distance of two-outlet diameter after the pump outlet, the

discharge stands also incorporate the pressure sampling taps and lines
required to measure the pressure developed by the pump. The pressure taps
are made precisely as shown in the detail of the loop manifold connecting
pressure taps in figure n2.

Figure n2:

4
 PIPEWORK

All pipework (ref. figure n1) including manifolds, elbows and reducers
(except for the valves) are made of type 304 stainless-steel *. The pipework
system is built around two manifolds, the first one handles the 8", 12", 14"
and 20" discharge stands and the second one handles the 24" discharge
stand. Each discharge stand is connected to the manifold by a pneumatic
isolating valve, which is operated either fully open (for tests) or closed
(isolated).

Both manifolds are connected to a 24" return line, which also includes a 24"
electric operated throttling butterfly valve to control the water flow and a 24"
magnetic flowmeter used for flow metering (see additional details further).
To maintain high accuracy, the length of straight pipe before and after the
flowmeter is 15x and 5x pipe diameter.

To minimise the flow turbulence, the return line includes two Vortex breakers.
The return line is also terminated by pipework of larger diameters (24" to 30"
and 30" to 36"), to reduce the velocity of the water flow returning in the tank.
These measures, in addition to the diffuser screen located at the exit of the
returning line in the tank, create minimal turbulence or other interference
with the water in vicinity of the inlet of the pump being tested, and increase
the accuracy of the flow metering.

* The pipework is built of SCH-10 stainless-steel piping, which has a pressure

rating of 191 psi at 30C (106F).

5
 ELECTRIC SYSTEM

The electrical distribution consists of a 700A two-step auto-transformer

starter, 3-phase, 60Hz, rated 700Hp at 600V, made by Asea Brown Boveri
and a 400A variable frequency drive (VFD), 3-phase, with adjustable voltage
output from 208V to 600V, made by Siemens.

Selection of line or VFD power source is made via an 800A automatic transfer
switch.

The starter is equipped with variable overload, phase protection, ground fault
relay, motor leakage and temperature monitoring, and panel meters for
reference.

6
 CONTROL ROOM

The control room, located on the vicinity of the electrical system (see figure
n1 and pictures below), contains the control console, used to select the
required discharge stand size and pressure tapping line, and to control the
throttling valve.

It also includes the instrumentation used to acquire the various hydraulic and
electric test parameters. 4 - 20mA signals from the several measuring
instruments are fed to a data acquisition and curve plotting system. Details of
the metering and recording systems are given in the following sections.

7
 DATA ACQUISITION, EVALUATION AND PRESENTATION

Data acquisition, evaluation and presentation of the measuring results are

made by a transducer, scanner, computer and plotter system.

As shown in the diagram of figure n3 (page 10), the various transducers feed
4mA to 20mA data signals to a Prema 5000 multimeter scanner with IEEE
interface, which has an overall accuracy of 0.005%. The scanner transforms
the readings from analog to digital, allowing zero distortion of the signals
processed to the personal computer.

The data is processed by using the ITT Flygt proprietary CAPT-PC standard
software (ccomputer-a aided pump testing) (figure n4, page 11). The software
generates hydraulic performance points from the readings of the flowmeter
and the pressure transducers electric performance points from the various
electrical transducers, and the pumps overall efficiency are calculated with the
hydraulic and electric points. As the testing is performed each processed
head, flow and input-power are displayed on the computer monitor in a
graphical form (see picture). Upon completion of the test, the computer
generates a combined graphical and tabular test report on the plotter (figure
n5, page 12).

8
 DATA ACQUISITION SYSTEM
Figure n3, Monitoring instrument connection diagram:

9
 DATA ACQUISITION SYSTEM
Figure n4, Computer-aided pump testing (CAPT):

10
 DATA ACQUISITION SYSTEM
Figure n5, CAPT Performance Test Report:

11
 FLOW METERING

Flow measurements are made using a 24" Fisher & Porter Copa-X magnetic
flowmeter with dual range programmed for 0 - 700 l/s (0 - 11080 gpm) and
0 - 2000 l/s (0 - 31660gpm), covering the flow range of the ITT Flygt large
pump line up to model 3602. The design configuration of the tank and the
placement of the flowmeter in the return lines fulfill the necessary "full pipe"
condition of the magnetic flowmeter, which is under the actual water level in
the tank.

The Fisher & Porter Copa-X magnetic flowmeter and its signal converter were
calibrated by the manufacturer to an overall accuracy of +/- 0.5%. Fisher &
Porter flowmeters are hydraulically calibrated in accordance with MIL-STD
45662 and are traceable to the National Institute of Standards and
Technology.

In addition to the manufacturer's calibration, periodic comparisons of test

data run and the same pump in ITT Flygt Test Facilities in Sweden and Canada
are performed.

Figure n6: Copa-X Magnetic Flowmeter

12
 PRESSURE MEASUREMENTS

Pressure measurements are made using an ITT Barton differential pressure

transducer model FHCCG38W1-AEBYY, which has ranges of 0 - 43/0 - 430psi,
allowing measurement of heads up to 105 meters (345 feet).

Loop manifolds connected to pressure taps, located at appropriate distance

from the pump outlet and the discharge stands (see figure n2), transmit the
pressure to the transmitter.

The pressure transducer outputs 4 - 20mA DC signals, proportional to the

pressure, which is then read by the Prema scanner. Overall pressure-system
accuracy is verified with an Ametek CAL-PAL pressure calibrator model n200,
and is maintained to within +/- 0.25% of full scale. The certified accuracy of
the pressure calibrator is +/- 0.05% of full scale, and is also traceable to the
National Institute of Standards and Technology and conforms to MIL-STD
45662a.

13
 PRESSURE MEASUREMENTS

Pressure transducer specification sheet (page 1):

14
 PRESSURE MEASUREMENTS

Pressure transducer specification sheet (page 2):

15
 ELECTRICAL MEASUREMENTS

Power, voltage and amperage inputs to the pumps under test are measured
using Ohio Semitronics transducers models P-144E / VT-8-010E and CT-8-
014E for amperage.

The range of these transducers is 0 - 500kW / 0 - 600V / 0 - 500A, the

accuracy is +/- 1% of rated output power, +/- 0.25% FS for voltage, +/-
0.5% FS for amperage, and 50 - 400Hz for the frequency range. Each of the
transducers has an output of 4 - 20mA.

Current readings are made via 3 x Ohio Semitronics 500:5 current

transformers model n12317, which have an output accuracy of 0.3%.

Overall accuracy of the electrical measurements is verified by a Yokogawa

digital power meter, model n 2533-13, which has a certified accuracy of
0.1% of range, +/- 0.1% of reading, and is traceable to National Institute of
Standards and Technology.

16
VIBRATION METER & MACHINE ANALYSER (samples)

The End

17