Test procedures

for products manufactured by ITT Flygt, Sweden

Test procedures

The general procedures for testing products manufac-

tured by ITT Flygt at the main factory in Emmaboda,
Sweden, are part of our Quality Assurance System
based on the ISO 9001 Standard.

The system was first approved by Det Norske Veritas

in 1992. It is re-audited on an annual basis.

In order to fulfil the Quality Policy, a large number of

tests are performed on products during the manufac-
turing process:

Dimensional checks, chemical analyses, tightness

checks, etc, are carried out on piece parts to ensure
they correspond with drawings and other specifica-
tions.
Parts for standard products are checked randomly.
All parts for Ex-approved products are checked, if
specified in the approval documentation.

Finished products must pass a minimum of three tests:

- tightness test
- dielectric test
- performance test*.

*Performance tests are carried out on a random basis on some of

the smaller pumps.
Tightness test
& dielectric test
Products are tested for tightness dur-
ing assembly.
The most common method used is the
NOLEK vacuum tightness test, which
involves simultaneously evacuating air
from a product and a reference unit.
Leaks are indicated after a specific time
by a pressure difference between the
product and the reference unit.

The dielectric test, which is carried out

during assembly, is done in accordance
with the IEC 60034-1 standard rotat-
ing electrical machines, part 1: rating
and performance.
The standard requires that a voltage
equivalent to 2 x rated voltage +
1000V is applied between the motor
windings and the casing.
Performance test
& test plant
Pumps
Pumps are performance tested in
accordance with ISO 9906 or corre-
sponding test standards.

Pumps are run in clean water under

normal operating conditions in our
onsite pump performance test plants.

The pumps head, rate of flow, current

and power consumption are measured
and checked at rated voltage and
frequency. Pumps can be tested at all
common voltages and frequencies.
Results are measured, evaluated and
logged using the latest software in
most of the test plants. The results
are stored by ITT Flygt for a minimum
of 20 years.
Typical design of test plant for performance testing
Database server PC Instrumentation Mixers
Mixers are dry run tested to check
Pressure Current mechanical integrity, current and power
Flow Voltage consumption at rated voltage and fre-
Power Frequency
quency, under no load conditions.
Performance curves,
test curves, statistics Evaluation and Units are also randomly tested under
presentation
normal operating conditions in ITT
Centrifugal pump test Flygts specially designed mixer test
Control valve
plant. Thrust, current and power con-
Flow meter
Pressure
tappings
sumption are checked at rated voltage
and frequency.

Monitoring sensors
Monitoring sensors built into the prod-
Propeller pump test ucts are connected to an ITT Flygt
Flow meter
standard monitoring system and
checked during the performance test.

Pressure tappings Control valve

Documentation
& calibration

TEST REPORT TEST REPORT

PRODUCT PRODUCT
Serial No. Performance curve No. Motor module/type Voltage (V) Serial No. Performance curve No. Motor module/type Voltage (V)
3201.180 0180127 53- 630-00-6830 193 415 3602.865 0181083 53-840 54-66-8AA 400
Base module Impeller No. Gear type Gear ratio Imp.diam/Blade angle Water temp C Base module Impeller No. Gear type Gear ratio Imp.diam/Blade angle Water temp C
002 384 31 00 18 000 561 05 31 525 29

TEST RESULTS TEST RESULTS

Pump total head Volume rate of flow Motor input power Voltage Current Overall efficiency Pump total head Volume rate of flow Motor input power Voltage Current Overall efficiency
H (m) Q (l /s) P (kW) U (V) I (A) (%) H (m) Q (l /s) P (kW) U (V) I (A) (%)
22.12 14.4 18.30 416 33.9 18.60 1055.6 243.21 402 436.1 79.18
18.06 51.5 18.71 415 34.2 16.22 1242.7 246.91 402 441.4 80.07
14.54 95.4 20.06 415 36.0 14.58 1350.1 245.63 402 439.7 78.63
10.41 144.3 22.22 415 38.9 12.81 1466.8 241.85 402 433.8 76.19
5.82 189.8 22.86 415 39.7 8.43 1753.3 219.26 403 398.6 66.15

Accepted after Test facility Test date Time Chief tester 2050 Accepted after Test facility Test date Time Chief tester 1402
ISO9906/A Lindas Q2 01-12-14 11:07 ISO9906/2 Lindas Q2 01-12-13 15:48
Sweden Sweden

PLOTTED TEST RESULTS Measured point : = Q/H Duty point : = Q/H Calculated point : = Q/ETA overall PLOTTED TEST RESULTS Measured point : = Q/H Duty point : = Q/H Calculated point : = Q/ETA overall
= Q/P = Q/P 1 = Q/P = Q/P 1
= Q/ETA overall = Q/ETA overall

TOTAL HEAD INPUT POWER TOTAL HEAD INPUT POWER

(m) (kW) (m) (kW)

26 18
24 24
16 400
22
20 20 14
18 ETA (%)
12 300
16 16
14 10 100
12 12
8 200 80
10
8 8 6 60

C 6 4 100 40
4 4
2 20
2
0 0 0 0 0
0 40 80 120 160 200 (l/s) 1000 1200 1400 1600 1800 (l/s)
FLOW FLOW

Test report with five measured points plotted toghter with a standard Test report with a measured curve based on five measured points
performance curve. together with a duty point with its ISO tolerances.

Results from performance tests are recorded in test Calibration

reports. The information in the reports corresponds All measuring and test equipment is periodically cali-
with the requirements in ISO, DIN and HI test stand- brated and values are traceable to international meas-
ards. uring standards.

The equipment for testing pump and mixer perform-

ance corresponds to the most common pump test
standards ISO 2548, ISO 3555, ISO 9906, HI and DIN
1944 Class II and III.
ITT Flygt is the worlds leading provider of submersible
pumping and mixing solutions.
ITT Flygts submersible pumps and mixers are used
in wastewater plants, process industries, mines, con-
struction sites and numerous other applications.
Our experience is used by engineers, planners and
consultants to ensure reliable and cost-effective utili-
sation of our systems. ITT Flygt has service and sales
facilities in more than 130 countries.

Test procedures. 02.02. Eng. 2M.04.03. 892433 Trosa Tryckeri AB 46267

www.flygt.com