In order to maintain a high degree of accuracy and professionalism while presenting a standard and uniform pump test the following standards are set down.
Section 1. a, Water flow measurement equipment:
Water flow may be measured by any of the following methods: Pitot tube, ultrasonic flow meter, orifice, venturi tube or water meter. The equipment used must be in the accuracy class of 2% or better. Weirs and volumetric methods may also be used. It is up to the test technician to determine the most suitable device for measuring the flow under the existing circumstances.
Section 1.b.1, Pump discharge head measurement:
The discharge head will be measured with a test pressure gauge in the accuracy class of 0.5%. For low head pumps a water column and tape measure may be used.
Section 1.b.2, Pump suction head measurement:
The suction head will be measured with a test pressure gauge or test suction gauge in the accuracy class of 0.5%.
Section 1.b.3, Static and pumping water levels in wells and sumps.
Water levels in wells or sumps will be measured with an electric well sounder. The sounder line may be pre-marked at intervals to facilitate the measurement. A calibrated air line and test pressure gauge in the accuracy class of 0.5% may also be used for determining the water level in wells or sumps.
Section 1.c, kW input measurements to pump motors:
Pump motor kW input may be determined by timing the Utility installed billing meter. KW input may be measured with a portable kW meter in the accuracy class of 2%.
Section 1.d, Pump speed measurement:
Pump speed may be measured with an electronic tachometer, strobe light, or pole slip method.
Section 1.e, Voltage measurement, 600 volts systems and below:
The voltage will be measured with a voltmeter in the accuracy class of 1%.
Section 1.f, Current measurement, 600 volt systems and below:
Currant will be measured with a clamp-on amp meter in an accuracy class of 2%.
Section 1.g, Voltage and current measurement, above 600 volts:
Voltage and current readings should only be taken from panel mounted meters on high voltage systems.
Classification of tests*
Pump tests should be classified as follows:
Shop tests are also called laboratory, manufacturer's, or factory acceptance tests. They are conducted in the pump manufacturer’s plant under geometrically similar, ideal, and controlled conditions and are usually assumed to be the most accurate tests.
Field tests are made with the pumping unit installed in its exact environment and operating under existing field or ultimate conditions. reliability of field testing depend on the instrumentation used, installation, and advance planning during the design stages of the installation. By mutual agreement, field tests can be used as acceptance tests.
Index tests Index tests are a form of field testing usually made to serve as a standard of comparison of wear, changing conditions, or overhaul evaluation. Index tests should always be run by the same procedures, instruments, and personnel where possible, and a very accurate record and log of events should be kept to give as complete and comparable a history of the results as possible.
Model tests precede the design of the prototype and are usually quite accurate. They supplement or complement field tests of the prototype for which the model was made. The role of the model test must be clearly established as early in the design as possible, preferably in the specification or invitation to bid. Model tests may be used when very large units are involved, when the performances of several models must be compared, and when an advance indication of prototype design is required.
*Igor J. Karassik: Pump Handbook 13.2 "Pump Testing"
These standards address field tests and index tests only.
Section 2.1 Test reports, measured values
Section 2.1.a, Total lift, booster pumps:
The pump test report shall consist of the following measured information: The discharge head and suction head expressed in pounds per square inch or vacuum and converted to feet expressed to the nearest tenth of a foot. The datum shall be the centerline of the discharge pipe.
Section 2.1.b Total lift, well pumps:
The report shall consist of the following measured information: The standing water level and pumping water level measured to the nearest tenth of a foot and the discharge pressure/vacuum expressed in pounds per square inch and feet, measured to the tenth of a foot. The datum shall be the centerline of the discharge pipe.
Section 2.1.c, Fluid flow, usually expressed in gallons per minute. Other values such as cubic feet per second or million gallons per day may be used as appropriate to the industry.
Section 2.1.d, Power input to the motor measured in kW and converted to horsepower input.
Section 2.1.e, Pump RPM
Section 2.2 Test report, calculated values:
Section 2.2.a The following calculated values should be included in the test report: Drawdown and specific yield in well pump reports; total lift; acre feet pumped in 24 hour day; brake horsepower and/or percent of motor load; kilowatt hours, therms or gallons per acre foot; overall plant efficiency. On well pumps, the centerline of the pump discharge to elevation may also be included.
Section 3.1 There shall be four levels of qualified test technicians.
Section 3.1.a, Technician State Qualification:
A testman shall hold a valid Contractors License classification of C10 (Electrical Contractor) and C61/D21 (Limited Specialty, Machinery and Pumps Contractor).
Section 3.1.b, Apprentice Test Technician:
A testman shall be considered an apprentice while in training and for the first two years and 500 pump tests.
Section 3.1.c, Journeyman Test Technician:
A testman will be considered a journeyman on completion of two years of testing, the completion of 500 pump tests and passing an oral or written test given by Pump Check.
Section 3.1.d, Pumping systems analyst:
A testman will be considered a Pumping Systems Analyst on completion of five years of testing and a demonstration of knowledge of complete hydraulic systems for agriculture, municipal water systems and industrial/commercial applications.