Volume 8 – Mechanical and Electrical Services - Malaysia Geoportal

Chapter 1 PUMPING INSTALLATION
Commissioning
Upon satisfactory operational test run of system and each piece of the equipment, the whole system
will be ready for commissioning whereby the whole system will subject to performance test to
determine compliance with the contract and specification requirements. Conduct the performance
tests in accordance with the approved test format. Test results and records should be witnessed and
certified by the relevant parties concerned.
1.16 PUMP TESTING
Pump supplied is tested to ensure it meets the required performance specifications. Depending on
the size of the pump, all large pumping units are subjected to factory test to verify its hydraulic and
mechanical integrity, while it is suffice to have sampling test for smaller pumping units. Where
necessary, witnessed pump testes can be carried out prior to the delivery. In the purchase of pump
contract, such factory acceptance tests could be specified for pumps above 500 l/sec and/or where
its application is of critical service. Where provision is allowed for in the contract, such pre-delivery
inspection at the Manufacturer’s works should be encouraged for technology exposure to the
technical staff witnessing the test.
Pump tests at the factory generally follow the standard methodology as published by the established
institutions such as BS, JIS and ANS. However, to witness a pump test at factory the engineer
concerned shall be familiar with the procedure in witnessing the pump test. Typical of the guidelines
is as shown in the Appendix 1.2 attached. Table below shows the tolerance values for pump
acceptance test based on ISO 2548 & ISO 3555, and the latest testing standard ISO 9906
Table 1.5 Permissible Tolerance
Permissible Tolerances
Standard
Pump capacity Pump head Pump Efficiency
ISO 2548 Class C ± 7% of Q rated ± 4% of H rated - 5% of rated
efficiency
ISO 3555 Class B ± 4% of Q rated ± 2% of H rated - 2.8% of rated
efficiency
ISO 9906 Grade 2
(Pumps above 10kW)
± 9% of Q rated ± 7% of H rated - 7% of rated
efficiency
Comprehensive field operational tests are important as the whole entire pumping installation
including the pumps, motors, controls, instruments, valves and electrical components etc will be
subjected to operational tests for operational integrity and function. Any deficiency and
malfunctioning of the system can easily be identified for rectification. Flow measurement may be
taken for reference. Such tests are normally carried out during the commissioning stage. If the
performance of the pumps installed at site becomes critical, final pump acceptance tests may be
required. It is based on the field pump performance with reward/penalty clauses written into the
contract for failure of the pump to perform within specified limits.
1.17 PUMPING STATION MODEL TEST
Hydraulic models are essential to the design of hydraulic structures that are used to convey or
control the flow of water. Model testing is recommended for pumping stations in which the
geometry differs from the recommended standards as in the case of limitations due to space
constraint. Good engineering practices call for model tests for all major pumping stations for pumps
above 1000 l/sec and if multiple pump combinations are used. Sometimes model tests are
conducted for existing pump stations to which different set of new pumps are being installed.
March 2009 1-27