Hydro is capable of testing horizontal, vertical, submersible, and some reciprocating pumps. We can test pumps up to 5,000 HP and achieve a maximum flow of 42,000 gpm. All testing is completed in accordance with HI 14.6 / 40.6 and/or API 610 (or other relevant standards such as ASME and ISO).

The purpose of a pump performance test is to ensure that the actual performance of a pump achieves the desired operating condition and/or original design condition (i.e. differential head at a given flow capacity).

The test can be applied to a new pump, refurbished pump, or re-engineered pump with the focus being on reliability, assurance of meeting the required operating conditions, and measuring the actual changes in performance if a change was made.

For example, in an energy optimization project, a pump may be designed to achieve a higher efficiency to save on the operating cost of the unit. A performance test can be completed to validate the engineering and design. If a test is not completed, the end user may be going into operation with only the design engineering and reputation of the vendor to count on.

This accreditation recognizes Hydro’s ability to perform pump testing to the 40.6 Pump Efficiency Testing Standards that aim to address the new United States Department of Energy (DOE) testing standards for pumps. Hydro was the first pump test facility to receive this recognition and was awarded the accreditation in September of 2015. Check out this article for more information on the achievement.

The end result of a Certified Performance Test is a certified performance curve showing the differential head versus flow capacity, input power versus flow capacity, and efficiency versus flow capacity curves over the total range of flow capacity for a given pump. This curve is generally presented at the nominal operating speed of the pump; however, this curve can also include additional impeller trim performance curves or additional operating speed curves for the same pump.

In order to provide a proposal for testing services, Hydro will need a general arrangement drawing of the pump(s) to be tested, a proposal curve / expected performance / OEM curve (if available) for reference, and a scope of supply (what tests are required).

Hydro has a vacuum pump connected to the above ground suppression tank used for horizontal pump testing. The vacuum pump can be used to lower the Net Positive Suction Head Available (NPSHA) until the pump reaches cavitation (3% head loss) at a given flow rate. Hydro can also perform NPSH testing on vertical pumps in most cases.

Hydro has a 16-channel vibration analyzer capable of measuring vibration amplitude, frequency, waveform, and phase for 16 channels simultaneously. In addition to condition monitoring of tested machinery, further analysis can help in addressing existing machine issues, resonant frequencies, critical speeds, and machine improvement possibilities.

Yes, we have several Variable Frequency Drives (VFDs) of different horsepower ratings that allow us to control the speed of the motor. This allows for additional performance curves at varying speeds to be tested instead of calculated using the Affinity Laws, critical speed testing, and the simulation of additional off-design conditions.

Yes, Hydro utilizes state-of-the-art vibration analysis techniques to identify critical speeds present below the maximum operating speed of the pump. In the field, a pump can be driven by a Variable Frequency Drive (VFD), which acts to regulate the pump’s speed to reduce power consumption and wear on the pumping system during times of lower pumping demand.

If a critical speed was present below the maximum pump speed, the pump would be subject to damaging resonant vibrations as it passes through or operates within 10% of the critical speed. By identifying the critical speed in a controlled test environment, the customer can avoid operating the pump at or near the critical speed thereby ensuring safe pumping conditions.

Yes. The above ground tank and vertical pit can be connected to cooling tower or refrigeration systems that allow for extended endurance tests.

LabVIEW (short for Laboratory Virtual Instrumentation Engineering Workbench) is a platform and development environment for a visual programming language. LabVIEW is commonly used for data acquisition, instrument control, and industrial automation. LabVIEW will record performance parameters like pressure, flow, power, and so on, and record all the test data used to create the performance curves of the pump.

Hydro has a custom-built pump test program based on the flexible platform provided by LabVIEW. It is a state-of-the-art test program.

Hydro measures uncertainty at every test point recorded. Without this analysis we would be unable to truly quantify the accuracy of the test results. In addition to random measurement fluctuations, known instrument calibration, uncertainty is also included in the final calculation.

Flow is measured using calibrated magnetic flow meters. The specific flow meters for a given test are selected to optimize accuracy and reduce uncertainty in the test results. Depending on the expected flow velocity, the specific magnetic flow meter(s) will be selected automatically through the data acquisition system. The highest flow rate we can measure is 42,000 gpm.

Pressure is measured by using calibrated pressure transducers. The specific transducers used for testing are sized for the expected pressure range of the pump and mounted to the suction and discharge piping per Hydraulic Institute 14.6-2011.

Whenever possible, a calibrated torque meter or strain gage is used to measure input power to the pump. For full train, close-coupled, and/or submersible tests that do not allow space for either a torque meter or strain gage, a calibrated watt meter is used to determine input power. In addition, voltage, current, power factor, and related temperatures are measured when required.

Hydro has many calibrated test motors of various sizes intended to cover various pump designs in the aftermarket. The largest motors are 2-pole and 4-pole 5000 HP motors. Our largest vertical motor is a 4-pole 2000 HP motor.

Horizontal pumps are set up on a 20’x30’ baseplate with movable pump and motor supports. Piping is then installed to the pump and existing manifold connections, which range from 4” to 30.” This allows for a quick and accurate installation. The large size of the baseplate allows for multiple pumps to be installed simultaneously, reducing time between tests and optimizing the piping configuration.

Similarly, vertical and submersible pumps are installed and connected to existing piping configurations in order minimize setup time and ensure an accurate test.

The largest horizontal pump we can test is a 24” discharge and 30” suction. In some specific instances, larger sizes can be accommodated with some planning and hydraulic performance characteristics, but our practical size limit is a 24x30 horizontal pump.

The largest vertical/submersible pump we can test is 35 ft in length, 60” in diameter, and with flow characteristics that can be simulated in our flow loop – considering adjustments using affinity laws as needed.

The discharge inlet is 24” and the suction outlet is 30”. The tank is designed with special plates inside to suppress vortex formation.

The above ground tank is 48 ft. long with a 12 ft. diameter and has the capacity to hold approximately 38,000 gallons of water. The tank can be pressurized up to 100 psi to match a field suction condition. The tank pressure can be depressurized with a vacuum pump.

Our pit is approximately 48 ft. long with varying depths. The deepest section is approximately 35 ft. deep with a 10 ft. diameter section for the lowest 20 ft.