Pump Performance and Reliability Testing Protocol

I. Documentation of equipment to be evaluated.

a. Pump and Motor Identification, assign unique ID numbers

b. Determine run time for each piece of equipment

(a. And b. part of preliminary meetings, review of existing documents/drawings, and plant tour)

c. Pump and motor nameplate information

c. For wells, determine water level and amount of draw down

d. Construct a simplified flow diagram of the facility

1. Pumps

2. Discharge Check Valves

3. Pressure tap locations

4. Discharge measuring points

5. Wiring Components

II. Preliminary Measurements

a. No load voltage measurements (equipment de-energized)

b. Three phase-to-phase readings (reference point)

c. Measure inside pipe diameter

III. Install Portable Flow Sensor Meter and Pressure gages

a. Install temporary Ultrasonic Flow Meter if possible or estimate

flow from a fill and/or draw down test using a tank or clearwell or by other means, based on specific site conditions.

b. Install calibrated pressure test gages

c. Record suction and discharge pressure and reference elevation values

d. Determine flow rate and compare with flow rate provided by the permanent plant flow meter

IV. Electric Power Measurements

a. Determine Power (Kw) from meter, if dedicated meter available

(time revolutions, Kh factor, and scaling factor for calculations)

b. In no dedicated meter, compute Kw using two-wattmeter method

V. Voltage and Current Measurements

a. Measure voltage and current on three phases (energized)

using portable electric power meters (< 600 volt equipment)

b. If equipment is greater than 600 volts, estimate power using plant permanently installed motor current indicators and PSAT software or using measurements of power on the secondary side of permanently installed current transformers.

VI. Calculate Overall “Wire to Water” Efficiency and Estimate Individual Component (pump and motor) Efficiencies

Summary of Electrical Parameter Measurements and Calculations:

1. Total power (Kw) from meter or two wattmeter calculations (record)

2. Individual phase currents (portable meter and CT’s)

3. Individual phase-to-phase voltages (portable meter, record)

4. Calculated Apparent Power

5. Power Factor (ratio of total to apparent power) calculate and record

VII. Shaft Power Estimates

a. Motor Nameplate Data, Efficiency Rating in percent

b. Measured electric power (Kw)

VIII. Overall Efficiency Calculation

IX. Rotational Speed Measurements

Important especially if Adjustable Speed Drive (ASD)

(manual setting for consistent speed or use pump affinity laws to compute)

a. Use an adjustable stroboscope to obtain rotational speed. Speed is generally a low priority item and will only be measured if requested.

X. Final Report Product

Assessment of Energy Efficiency of Pumping System

Data on flow rate, pressure, motor current, and power data are evaluated using the Pumping System Assessment Tool (PSAT), a software program developed by the U.S. Department of Energy and endorsed by the Hydraulic Institute. Output from the program will identify areas where the greatest potential energy savings can be found.

Among the results of the PSAT analysis is a comparison of existing annual cost of pump operation with that of an optimal pump and motor operating under the same conditions. If manufacturers performance curves are available, the measured performance will be compared to the like-new performance. Informed decisions can then be made if equipment repairs are needed or if replacement of pumping equipment is being considered.

Estimates of payback periods for system modifications will also be provided to assist the facility in justifying expenditures. Previous experience has shown that substantial amounts of energy savings are available in many pumping systems (20% to 50% and more). A payback period of one to three years is common, more than justifying the cost of an assessment and the capital expenses required to implement changes in the pumping system.

Study results are documented in a comprehensive final report complete with infrared images on CD-ROM. Data collected provide a baseline of information that can be used to benchmark equipment for future evaluations and to document energy savings once changes are implemented.

The following services can be provided for a more comprehensive evaluation and should be included in the initial evaluation of each facility.

Predictive/Preventive Maintenance Services

(Monitor switchgear, motors, and pumps)

I. Document Pumping System Components

a. Digital Pictures of equipment, associate data with photo

b. Document physical Piping Layout

c. Identify Electrical Components of pumping system

II. Infrared Imaging of Pumps and Motors

a. Collect digital and infrared image of electrical panels

b. Collect digital and infrared images of motors

c. Document hot spots or anomalies for further study

III. Vibration Monitoring

a. Monitor vibration in two radial planes on upper and lower bearings

b. measure axial vibration using the 5-Point Approach

c. measure vibration of pump mechanical seals

d. Check bearing models versus database values to determine

bearing fault frequencies

e. Record lubricants and oils used

f. Sample oils for metals and particle count data

g. Conduct Electric Signature Analysis

IV. Conduct Unbalance and Alignment Tests on Critical Equipment