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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
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.
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.
5
ELECTRIC SYSTEM
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.
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DATA ACQUISITION, EVALUATION AND PRESENTATION
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).
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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.
12
PRESSURE MEASUREMENTS
13
PRESSURE MEASUREMENTS
14
PRESSURE MEASUREMENTS
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.
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VIBRATION METER & MACHINE ANALYSER (samples)
The End
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