Single-stage pumps, also called screw pumps , are among the most commonly used pumps in the oil and gas, petrochemical, food, pharmaceutical, and wastewater industries. They play a special role in industrial processes where they can transport highly viscous or corrosive liquids as well as solid particles .
To ensure the quality of the pumps and their proper operation, a final performance test is required . This test is the last stage of quality control and is performed before the pump is delivered to the customer. Its purpose is to ensure that the pump performance meets standards, specifications, and customer requirements.
What is the ultimate performance test?
The final performance test of an individual pump is a controlled and standardized process. Key pump parameters include:
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tail
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Head/Pressure
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Energy consumption
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Efficiency
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Leaks and vibrations
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Noise level
This test, after inspection and measurement, directly shows whether the manufactured pump is operational under real industrial conditions.
Whirlling International product catalog
The importance of testing the maximum performance of individual pumps
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Product quality guarantee
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Make sure the pump is operating fully according to its design and specifications.
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Reduced risk of failures at the installation site
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By identifying potential problems before delivery, you can reduce repair costs and production line downtime.
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Gain customer trust
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Providing a final performance test report ensures transparency and strengthens trust in the manufacturer.
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Compliance with international standards
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Many industries only accept devices that have passed internationally recognized tests.
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Extend the life of your pump
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Performance tests under laboratory conditions ensure that the pump components are not subjected to abnormal stresses.
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Standard for testing single pumps
Final performance tests must be conducted according to international standards and technical regulations. Some of the reference standards are:
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ISO 9906 : Standard for testing pump performance.
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API 676 : Standard for positive displacement pumps, including simplex pumps.
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DIN and BS : European standards for the assessment of industrial pumps.
Conducting a final performance test of a single pump
1. Preparation and initial examination
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Check the appearance of the pump (pump body, rotor, stator, shaft, mechanical seal).
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Make sure the components are installed correctly.
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Check lubrication and grease of moving parts.
2. Preparation for the test
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Connect the pump to a power source or mechanical drive .
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Fill the pump with test fluid (usually clean water or simulated process fluid).
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Remove trapped air from the system to prevent cavitation.
3. Measurement of hydraulic properties
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Outlet flow: Measured at several operating points with a flow meter.
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Pressure or head: Check the pressure at the pump inlet and outlet.
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Performance curve: Draw the flow and pressure curve and compare it to the design curve.
4. Check energy consumption and efficiency
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Measure the motor current and motor voltage.
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Calculate the actual power consumption and compare it with the rated power.
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Calculate the pump efficiency (hydraulic efficiency).
5. Mechanical tests
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Vibration test: Measurement of shaft and bearing vibration.
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Noise test: Check the noise level of the pump under different operating conditions.
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Leak test: Check seals and edges for fluid leaks.
6. Tests under special conditions (if necessary)
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Pumping highly viscous liquids.
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Temperature tests are carried out to check durability under certain conditions.
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Durability tests for long-term use.
7. Preparation of the final report
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All data is recorded, including flow, pressure, efficiency, energy consumption, noise and vibration.
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Compare the results with design codes and standards.
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A certificate will be issued upon passing or failing the exam .
Equipment required for the test
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Testing of liquid feed tanks
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Precise flow meters for flow measurement
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Manometer or pressure sensor
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Electricity meters and electrical measuring devices
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Vibration and sound sensors
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Data logger
Benefits of properly conducting final performance tests
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Ensure uninterrupted operation
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Reducing warranty and customer service costs
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Ability to detect design or manufacturing defects
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Increase customer trust and the manufacturer’s reputation
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Compliance with international treaties and requirements
Problems and limitations
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Complex and expensive laboratory equipment is required.
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Please take the time and extra effort to complete the test accurately.
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Differences between laboratory results and actual conditions (depending on the type of fluid and the working environment).
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Testing each individual device is expensive.
Application of extreme performance tests in various industries
Oil and gas industry
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Ensure stable pump operation when transporting crude oil, petroleum products or aggressive liquids.
Food and pharmaceutical industries
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Make sure the pump can handle sensitive liquids such as syrup, milk, or liquid medications.
Water supply and wastewater disposal
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Test the efficiency of pumps when transporting sludge, wastewater or water containing solids.
Chemical and petrochemical industry
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Check the pump’s resistance to aggressive or highly viscous chemicals.
Finally
The final performance testing of monopumps is a critical step in the manufacturing and quality control process. This test ensures that the pump operates at the expected pressure, flow, and efficiency under real industrial conditions .
By properly conducting these tests according to current standards such as ISO 9906 and API 676, manufacturers can demonstrate the quality of their products to their customers and avoid potential failures and additional costs.
In short, the final performance test is not only a technical requirement, but also a cross-industry tool for building trust and ensuring quality.