Xylem Water Solutions (India) Pvt. Ltd. - NPTI

Xylem Water Solutions (India) Pvt. Ltd. 

PERFORMANCE TESTING OF VERTICAL TURBINE PUMPS 

FOR 

POWER PLANT APPLICATIONS 

Ron Sassoon 

Cell : + 91 7738083550 

Email : ron.sassoon@xyleminc.com April 2012

Xylem Water Solutions (India) Pvt. Ltd., 

Transformation (November 2011) - 

The name Xylem is derived from classical Greek and is the tissue that transports water in 

plants, highlighting the engineering efficiency of our water-centric business by linking it with 

the best water transportation of all — that which occurs in nature 

Xylem is a premier pure-play water technology company 

A singular focus on innovative solutions serving global water markets 

Headquartered in White Plains, N.Y 

12,000 employees worldwide 

Presence in more than 150 countries 

2011 revenues of $ 3.8 billion 

More than a century of experience in the water industry 

Xylem [XYL] will be a leading global water technology provider, enabling customers to 

transport, treat, test and efficiently use water in public utility, residential and commercial 

building services, industrial and agricultural settings. 

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Present scenario : - 

3


Need for change : - 

1. Critical analysis of existing performance qualification methods. 

2. Acceptance of pumps > 90% Efficiency. 

3. Evaluate performance measurement with direct measurements. 

4


Leap forward for high efficiency system: - 

5


Testing pump for 90 % & above : - 

6


Testing pump for 90 % & above ( Multispeed ) : - 

7


Impact of efficiency on the pump operating cost : - 

Case I 

Case II 

Plant capacity 2 x 660 MW 2 x 660 MW 

Pump application 

Circulating cooling water 

Number of pumps 2 x 50 % ( 4 nos ) 2 x 50 % ( 4 nos ) 

Cooling Water required per unit 90,000 Cu.m / Hr 90,000 Cu.m / Hr 

Pump capacity @ head 45,000 Cu.m / Hr @ 25 MWC 45,000 Cu.m / Hr @ 25 MWC 

Pump efficiency 88 % 90 % 

Duty point pump input power 3481.51 KW per pump 3404.14 KW per pump 

Motor rating @ 15 % Margin 4004 KW per pump 3915 KW per pump 

Total duty point power ( 4 pumps 

) 

Difference in duty point power 

13,926.02 KW 13,616.56 KW 

309.46 KW 

Cost of operating a low efficiency circulating cooling water pumps 

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Pump testing : - 

TRADITIONAL 2 WATT METER TESTING 

WITH JOB MOTOR 

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Shortfalls in normal Performance testing method : - 

1. Full column pipe length. 

2. Calibrated job motor. 

3. Full speed. 

4. Indirect way of shaft power measurement. 

5. Manual recording of reading # No data log. 

6. Lack of verification of motor efficiency at full & part load. 

7. Unavailability of performance at variable speed. 

8. All the above results in shaft power measurement errors & inefficiencies. 

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Suggested Performance testing method : - 

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1. SUPPLY WITH HIGH VOLTAGE VFD FOR 50/ 60 HZ CONSTANT 

2. FREQUENCY IRRESPECTIVE OF VARATION OF GRID FREQUENCY 

VARIATION 

3. STEPLESS OUT PUT VOLTAGE SELECTABLE FORM 3.3 KV TO 11 KV. 

4. TORQUE TRANSDUCER BETWEEN PUMP AND MOTOR FOR ACCURATE 

SHAFT POWER MEASUREMENT. 

5. DATA ACQUISITION SYSTEM TO ELEMENT MANUAL READING. 

6. ACCURATE MEASUREMENT OF PUMP AND MOTOR POWER AND 

EFFICIENCY. 

7. NO CALIBRATED MOTOR IS REQUIRED. 

8. PUMP TESTING WITH FULL COLOUMN LENGTH AND FULL SPEED. 

9. PUMP AND MOTOR POWER MEASUREMENT AT MULTI SPEED OPERATION.


Advantage of power measurement by torque transducer : - 

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Key features of the proposed system : - 

1. Supply with high voltage VFD offering 50/ 60 HZ constant. 

2. Stable frequency irrespective of variation of the grid frequency variation. 

3. Step less output voltage selectable from 3.3 KV to 11 KV. 

4. Torque transducer between pump & motor gives accurate shaft power readings. 

5. Automated data acquisition system eliminates requirement of manual readings. 

6. Accurate measurement of pump & motor power & efficiency. 

7. Calibrated motor not required. 

8. Pump to be tested with full column suspension length & at full speed. 

9. Pump & motor power measurements can be had at multi speed operation. 

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Schematic diagram of the proposed system : - 

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Test facility specifications : - 

1. Wet pit 45 mts x 7.9 mts x 10 mts deep for testing vertical turbine pumps. 

2. Dry pit 25 mts x 8 mts x 7 mts deep for testing horizontal split case pumps & 

metallic volute pumps. 

3. Overhead crane capacity 90 T & 40 T. 

4. Variable frequency drive for testing of pumps at 50 Hz & 60Hz frequency. 

5. Supply capacity up-to 7.3 MW. 

6. Flow measuring capacity of up-to 1,20,000 m^3/hr 

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Test facility instrumentation : - 

1. Details of measuring instruments : 

2. Output of all the instruments integrated thru DAS in control room. 

3. No human intervention during testing process to eliminate any errors. 

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Select reference of high efficiency pumps : - 

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Sr. 

No. 

Client 

Year of 

supply 

1 Yanpet, Saudi Arabia 1998 1 132 x 96 WCBR 

2 

3 

Korea Hydro & Nuclear 

Power - Shin Kori Units 1 & 2 

Southern Power Station, 

Israel 

Qty Model Type Discharge 

Cu.M/Hr 

2003 8 100 x 84 WCA 

1982 4 108 x 78 WCAR 

4 We Energies - Elm Road 2007 4 96 WCAX 

5 Amergen - Clinton 2008 1 114 x 84 WMCC 

Vertical 

Column 

Vertical 

Column 

Vertical 

Column 

Vertical 

Column 

Vertical 

Column 

Head 

M 

Speed 

RPM 

Motor 

HP 

60,046 20 212 5360 

44,324 

15 293 3200 

41,328 15 330 3000 

46,597 5.9 225 1750 

43,089 29.8 320 5500


This is not special for us……. 

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Registered Office & Factory : Plot no. 731, GICD Savli, Manjusar, Savli Road, 

Vadodara – 391 770 

Telephone : +91-2667-265 700 

Fax : +91-2667-265 764 

Corporate office : 

Ground & First Floor, Vishnu Shivam Mall, 

Thakur Village, Kandivali (East), 

Mumbai 400 101 

Telephone : + 91 22 40 370 370 

Web : www.xyleminc.com / www.xylemindia.in 

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THANK YOU 

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Xylem Water Solutions (India) Pvt. Ltd. - NPTI

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