1.2Applicable Standard
1IS B8312 "GEAR Pumps and Screw Pump+: Testing methods"
2. Material Inspection
2.1 Method
Making sure the part is one which is described in the material certificate, the material certificate shall be verified with the material standard.
2.2 Part to be Inspected
The following liquid contacting parts shall be inspected. (1) Casing
(2) Casing Cover (3) Stuffing Box (4) Gear
(5) Pinion
(6) Shaft
2.3 Acceptance Criteria
The contents of the material certificate shall be satisfactory to the material standard of 1IS
. code code but equivalent ASME designation shall be specified in all documents.
3. Liquid Penetrant Examination<B>
3.1 Method
See Attachment-I PROCEDURE OF LIQUID PENETRANT EXAMINATION.
3.2 Part to be examined
The following parts shall be examined. (1) Casing
(2) Casing Cover
(3) Stuffing Box(TG250 only)
(4) Bearing Stand(except TG250)
3.3 Acceptance Criteria
See Attachment-I PROCEDURE OF LIQUID PENETRANT EXAMINATION.
4. Hydrostatic Pressure Test
4.1 Test of Pump Body
(1) Time of Test
After machining, before assembling. (2) Test Procedure
Pressure 1.3 times the specified maximum allowable working pressure or over
Fluid Water (ambient temperature) Holding time 15 minutes, or over
Maximum allowable working pressure: lukg/crrr'
(3) Acceptance Criteria
No extemalleakage and no abnormal deformation and no pressure drop by visual inspection. <C>
5. Performance Test
5.1 Testing Condition
(1) Testing Liquid
Depending on the viscosity of the specification, the suitable liquid such as process oil, machine oil and so on shall be used.
(2) Testing Apparatus
Testing shall be done by volumetric method using the apparatus as shown in Fig. 1. (3) Motor
The test, in principle, shall be conducted by the use of the attached motor as specified.
(4) Electric Source
a) Frequency 50Hz (using inverter)
The rated voltage for the attached motor shall be used as a rule. b) Voltage If the rated voltage is not available for the reason of facilities, a
different voltage within a variation range of 10% of the rated
voltage may be used for operation.
(5) Number of Revolution
a) The number of revolution of the pump, at a specified source condition (frequency and voltage) under the specified load shall be taken as the specified number of revolution as it is.
b) For Constant Number of Revolution:
The specified number of revolution shall be used as a rule. If the specified number of revolution is not available for the reason of facilities, a different number of revolution within a variation range of5% of the specified number of revolution may be used for testing.
c) For Varying Number of Revolution :
Where the test has to be conducted by varying the number of revolution, measurement shall be made by varying the number of revolution as necessary after conducting the test at the maximum number of revolution.
5.2 Measuring Items
Capacity, Discharge Pressure, Suction Pressure, Current, Voltage, Input Power, Number of Revolution and Viscosity and Temperature of testing liquid shall be measured and recorded.
Total pressure flow rate and pump efficiency recorded too. <D>
5.3 Conversion of capacity in the case of different number of revolution
(1
Qs = Qt x Ns
|
(m3/min)
(2)
Ns Ls =Ltx- Nt
(kW) <C>
Qs Capacity for the specified number of revolution ms/min Qt : Capacity for the test number of revolution m3/min Ls : Shaft power for the specified number of revolution kW
Lt : Shaft power for the test number of revolution kW Ns : Specified revolution min-I Nt : Test revolution min-l
5.4 Conversion of capacity in the case of different viscosity
Calculate the capacity for the specified viscosity: Qs (m3/min)
Ks
Qs = Qt x - (m3/min)
Kt
|
Qs |
Capacity for the specified viscosity |
m3/min |
|
Qt
Ks |
Capacity for the test viscosity
Flow coefficient for the specified viscosity |
ms/min |
|
Kt |
Flow coefficient for the test viscosity |
|
5.5 Conversion of shaft power in the case of different viscosity
(1) Calculate the shaft power for the test viscosity: Lt (kW) (2) Calculate the pump efficiency for the test viscosity: TJ pt
98xQI xP
TJ pI = 60 X LI
|
npt |
Pump efficiency for the test viscosity |
|
|
P |
Total pressure |
kg/cnr' |
|
Lt |
Shaft power for the test viscosity |
kW |
(3) Calculate the pump efficiency for the specified viscosity: TJ ps (%)
Ks
TJps =TJpl X K
I
TIps Pump efficiency for the specified viscosity Ks Pump efficiency for the specified viscosity Kt Pump efficiency for the test viscosity
(4) Shaft power for the specified viscosity: Ls (kW)
|
-----='-"'-----
60 x TJ ps
5.6 Acceptance Criteria
At th e speer'fiied totaIl pressure, as fioll ows:
Item Acceptance criteria
Capacity Specified capacity or over
Shaft Power Rated output power or less
6. Continuous Mechanical Running Test
6.1 Method
Continuous running test shall be made on the investigation of the operational conditions by running the pump for at least 1 hr. at the maximum number of revolution under the specified discharge pressure in succession with the performance test.
6.2 Test Item and Acceptance Criteria
After 1 hr. continuous operation of the pump, the following items shall be measured every 15 minutes and verified at the above conditions. <C>
Item Measuring Location Acceptance Criteria
Vibration On the bearing stand 60 f.l m or less in full amplitude
(3 direction)
Bearing On the surface of Max. (ambient temp.+40"C) or
Temperature bearing cover
Max. 75°C, which is lesser
Noise Place at a distance 85dB(A)<C>
of 1 m from pump
Leakage Shaft seal No leakage
Mechanical seal
<C>7. Actuation test of relief valve
7.1 Method
Open or close the discharge valve to make sure the operation of the relief valve is reliable 2 to
3 times.
7.2 Acceptance Criteria
Operating is sure at set pressure.
8. Dismantling Inspection
8.1 Method
After the continuous running test, the pump casing cover shall be disassembled to check that the interior of pump is free from scratch due to the contact of gear and other abnormal damage.
8.2 Acceptance Criteria
<C>Dismantling shall be within the tolerance ofpara.8.1 above.
9. Dimensional Inspection
9.1 Time of Inspection
After the completion of assembling.
9.2 Dimensional Tolerance
(1) Position of suction and discharge nozzle: + 4mm
(2) Anchor bolt holes pitch
(3) Flange dimension
(4) Diameter of foundation bolt holes
9.3 Acceptance Criteria
+ 5mm
as per ANSI
+ 0.5mm
Dimension shall be within the tolerance ofpara.9.2. above to the approved drawing. (Outline drawing)
10. Visual Inspection
10.1 Method
The appearance of complete product shall be visual inspected.
10.2 Acceptance Criteria
(1) No harmful flaw such as bruise.
(2) Rust prevention and painting shall be in accordance with the specification. (3) Name plate shall be fitted up tightly, and the description shall be correct. (4) Revolution direction plate and caution plate shall be fitted up correctly.
11. Final Inspection
Prior to packing and dispatch the equipments, following final inspection shall be performed. (1) Accessory per specification
(2) Nameplate per specification (3) Fitting condition of the parts (4) Overall visual inspection
(5) Painting, coating
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