Automated Pump Test System
PC based highly precise automated test system to control and perform functional tests on a centrifugal pump. Centrifugal pumps are among the important equipment in any process plant. This system helps to analyze the performance and characteristics of the pumps at the assembly level and the end of line. Also allows to monitor and log the system parameters and calculating some other parameters like head, efficiency, etc.
The test system splits the software testing into units to provide precise results. The various tests conducted are as follows
- Mechanical Run test
- NPSH – Net Positive Suction Head Test
- Performance/Flow Rate test
- Pressure test
All the test Parameters are captured and verified by API or ISO standards which are automatically saved in database. Recorded test data can be retrieved in a graphical user interface in the form of graphs. It provides users with different filtering options. Also, exports report in PDF and Excel file formats.
| Software Functions | Hardware used and Interfaced |
|---|---|
| Test database manager | Ethernet CompactRIO Chassis with FPGA |
| Pump test data acquisition | Multiple NI cSeries measurement modules |
| Pump test sequencer | Various PLCs |
| Valve Controlling | Various motor controllers |
| Pump test pass/fail calculations | |
| Report Generator | |
| Test Data Exporter |
Measurement Parameter
The behaviour of a pump is assessed by looking for the following parameters
| Parameter | Sensor |
|---|---|
| Power consumption | Electrical: Current & Voltage; Mechanical: Schneider Power Meters |
| Pressure | Suction and Discharge |
| Component temperature | Thermocouple, RTD, Thermistor, IR sensor, and others |
| Position and speed | Shaft encoder, Quadrature or Normal, N/rev Pulse Prox or Optical Slot Pickup |
| Fluid properties (e.g., head and flow), both inlet and outlet | Flow Meter, Temperature, Pressure |
| Flow | Magnetic Flow Meters |
| Efficiency | - |
| Vibration | Accelerometers |
| Sound | Microphone |
Benefits
- Single software tests up to 5 Test beds
- Single operator can do all the tests
- No chances of typing error, calculation error
- Automatic report generation
- Less operating/testing time
- Report view software for managers
Features
- Live values and graph display (Flow Vs Head, Flow Vs Power, Flow Vs Efficiency and NPSHA graph with 1-3% Drop)
- Live cH correction factor calculation
- Ideal trim diameter curve projection for rated values
- Multiple model testing with one system
- Auto generation of daily based report, calibration report, test bed utilization report, statistical report
- Multiple HMI Display supports
- Achieving and maintaining specific operating conditions
- Vibration spectrum and Octave band noise report
