Pump Testing – Field Procedures and Equipment Standards
1. Upon Arrival
Before beginning any testing, the pump test technician shall review the pumping system, site conditions, and intended test requirements.
Identify the pump or pumps to be tested.
Determine the normal operating conditions of each pump, including:
Source of water.
Destination or discharge point of water.
Normal operating flow and pressure, when available.
Any operational restrictions or limitations.
Determine the required test points, including the number of test points and the desired head and/or capacity at each point.
Verify that the pump can operate continuously for a sufficient period to complete the required testing.
Identify and document any safety hazards, access restrictions, or other site concerns.
Review available pump, motor, electrical, and system information.
Begin completion of the Pump Test Data Sheet and record all applicable equipment and site information.
2. Test Setup
2.1 Flow Measurement
Flow may be measured using a pitot tube, ultrasonic flow meter, or other approved flow-measurement method as appropriate for the installation.
When using a pitot tube:
Determine an appropriate location for installation of the pitot tube.
Isolate and depressurize the piping before drilling or installation.
Drill and tap the appropriate size opening for the pitot tube.
Measure and record the inside diameter of the pipe.
Install the pitot tube.
Connect the manometer and verify proper operation.
When using an ultrasonic flow meter:
Select a suitable section of pipe with adequate straight-run conditions whenever possible.
Verify the pipe material, outside diameter, wall thickness, and other required parameters.
Prepare the pipe surface as necessary.
Install and configure the ultrasonic transducers in accordance with the equipment requirements.
Verify a stable and reliable flow reading before beginning the test.
2.2 Pressure and Head Measurement
Datum: Unless otherwise required by the installation, the centerline of the pump discharge shall be used as the reference datum.
Identify appropriate locations for discharge and suction pressure measurements.
Utilize existing pressure gauge cocks or test connections whenever practical.
When necessary and when site conditions permit, drill and tap the piping for installation of pressure gauge cocks.
If permanent or temporary test connections cannot safely be installed by the test technician, request that the customer install suitable pressure gauge connections.
Verify the elevation of each pressure measurement point relative to the established datum when necessary for total head calculations.
2.3 Electrical Energy Input Measurement
Determine the appropriate location and method for measuring electrical input to the motor.
Electrical input may be determined using:
Utility billing meter, when suitable.
Portable kW/power meter.
Open the appropriate electrical panels following applicable electrical safety procedures.
Identify the required conductors and measurement points.
Verify that the electrical measurement equipment is properly connected and configured before testing.
2.4 Pump Speed Measurement
Determine the appropriate location for measuring pump or motor speed.
When using an electronic photo tachometer, install reflective tape on the rotating component at a safe and accessible location.
When appropriate, pump speed may also be determined using an accelerometer or other suitable instrument.
3. Preparation for Operation
Before starting the pump:
Confirm that all required valves are in the appropriate operating position.
Confirm that electrical panels and test equipment are properly prepared.
Verify that pressure gauges, flow-measurement equipment, electrical instruments, and speed-measurement equipment are ready for operation.
Remove unnecessary equipment and personnel from the immediate test area.
Perform a final site and equipment safety check.
Confirm with the operator or customer representative that the pump may be started and operated through the required test conditions.
4. Test Procedure
4.1 Initial Operation and Adjustments
Start the pump and allow operating conditions to stabilize.
Bleed pressure gauge connections as required.
Install or verify operation of the pressure and/or vacuum gauges.
Adjust system valves as necessary to establish the required test head or flow condition.
Bleed, zero, and position the pitot tube and manometer when used.
When using an ultrasonic flow meter, verify that the signal and flow readings are stable.
Allow the pumping system to stabilize at each operating condition before recording test data.
4.2 Head Measurement
Read and record discharge pressure.
Read and record suction pressure or vacuum, when applicable.
Record any elevation corrections required for calculation of total pumping head.
Verify that pressure readings are stable before recording final values.
4.3 Flow Measurement
Read and record the manometer differential when using a pitot tube, or record the flow rate indicated by the ultrasonic flow meter.
Record the customer's installed flow meter reading at approximately the same time, when available.
Compare the customer meter reading to the test instrument reading and document any significant variance.
4.4 Electrical Energy Measurement
When using a utility billing meter, time the appropriate meter interval and record the necessary information for calculation of electrical input.
When using a portable power meter, measure and record kW input at the appropriate electrical location.
Measure and record operating voltage.
Measure and record operating current.
Record kVA and/or power factor when available or calculate as required.
Note any unusual voltage, current, phase imbalance, power factor, or other electrical operating conditions observed during the test.
4.5 Pump Speed Measurement
Measure pump or motor operating speed using an electronic photo tachometer, accelerometer, or other approved method.
Record operating speed in revolutions per minute (RPM).
Note any unusual speed fluctuation or operating condition.
5. Test Calculations
Using the recorded field measurements, calculate the following as applicable:
Total Pumping Head – Calculate total dynamic head and express the result in feet of water.
Flow Rate – Calculate or verify pumping capacity in gallons per minute (GPM).
Electrical Input – Calculate motor electrical input in kilowatts (kW).
Input Horsepower – Convert measured electrical input to input horsepower as required.
Water Horsepower – Calculate the hydraulic horsepower being delivered by the pumping system.
Wire-to-Water Efficiency – Calculate overall pumping plant efficiency based on measured hydraulic output and electrical input.
kVA – Calculate apparent electrical power when applicable.
Power Factor – Calculate or record power factor when applicable.
Review calculations and field measurements for consistency before finalizing the test results.
6. Additional Test Points
The test procedure shall be repeated for each additional operating point established for the pump.
Adjust the system to the required head and/or flow condition.
Allow the pumping system to stabilize.
Record pressure, flow, electrical input, and pump speed as required.
Repeat the required calculations for each operating point.
Voltage and current measurements may be omitted at subsequent test points when electrical operation has been verified as satisfactory and remains stable.
Obtain enough operating points, when practical, to accurately evaluate pump performance across the desired operating range.
7. Completion of Testing
Upon completion of the test:
Return valves and system controls to their normal operating positions unless otherwise directed by the customer.
Remove temporary test equipment.
Close and secure pressure gauge cocks and test connections.
Verify that any electrical panels opened during testing are properly closed and secured.
Inspect the test area for tools, equipment, leaks, or other conditions requiring attention.
Notify the customer or operator that testing has been completed.
Complete the Pump Test Data Sheet and verify that all required measurements and observations have been recorded.
Review field data for completeness before leaving the site.
8. Testing Standards
Pump performance testing shall be conducted in accordance with applicable Hydraulic Institute test standards and accepted industry practices, to the extent practical based on the physical configuration, accessibility, operating limitations, and existing instrumentation of the pumping plant.
Where site conditions prevent strict adherence to a specific testing method or measurement requirement, the test technician shall use the most appropriate available method and document any significant limitations or deviations that may affect the test results.
9. Pump Test Equipment
The following equipment may be utilized during pump performance and efficiency testing:
Equipment
Typical Accuracy
Hall Pitot Tube and Manometer
±1.5%
FLEXIM Ultrasonic Flow Meter
±1.5%
Fluke kW Meter
±1.5%
Fluke kW / Volt / Amp Meter
±1.5%
Dwyer Digital Pressure Gauge, 0–500 PSI
±0.25%
Dwyer Digital Vacuum Gauge
±0.25%
Electronic Photo Tachometer
±1.0%
Electric Well Sounder – Single-Wire
As Applicable
Electric Well Sounder – Two-Wire
As Applicable
All test equipment shall be maintained in proper operating condition and calibrated or verified at appropriate intervals in accordance with manufacturer recommendations, company procedures, and applicable testing requirements.
10. Field Documentation
The pump test technician shall document all information necessary to provide an accurate and repeatable evaluation of pump performance. Field documentation should include, as applicable:
Pump identification and location.
Pump and motor nameplate information.
Date and time of test.
Technician performing the test.
Test equipment utilized.
Suction and discharge pressure.
Total pumping head.
Flow rate.
Electrical input in kW.
Voltage and amperage.
Pump or motor speed.
Water horsepower.
Input horsepower.
Wire-to-water efficiency.
kVA and power factor, when applicable.
Customer flow meter reading and comparison.
Water level measurements, when applicable.
Number and location of test points.
Unusual operating conditions.
Safety concerns or system deficiencies observed.
Any test limitations, deviations, or conditions that could influence the accuracy or interpretation of the results.
All recorded data shall be reviewed for completeness and reasonable consistency before the pump test report is finalized.