Testing the durability of a pump

Screw pumps, also known as screw pumps, are among the most widely used pumps in the oil and gas, petrochemical, food, pharmaceutical, and refining industries. Thanks to their special design, these pumps can handle liquids of varying viscosities , including those containing solids, corrosive substances, and sensitive materials .

Despite the use of advanced technologies and high-quality raw materials, preliminary tests or production controls are often insufficient. To ensure stable operation, a long service life, and resistance to harsh operating conditions, every pump must undergo endurance testing . These tests are a crucial part of quality control and guarantee the product’s performance under real-world conditions.

What is a stress test?

A continuous running test is a long-term performance test in which a single pump is operated under defined operating conditions for a defined period of time under constant or intermittent load.

The aim of this test is to simulate real operating conditions and to verify the performance of various pump components under wear, fatigue, corrosion, pressure, temperature and other operating conditions.

The goal is to test the durability of a pump.

Age verification:
- Expected operating time of the pump under normal conditions (without significant malfunctions).
Assessment of the durability of critical components:
- Rotor, stator, shaft, bearings and mechanical seals.
Design or material defects were found:
- Potential problems were identified that were not detected in short-term tests.
Ensuring stable operation under industrial conditions:
- Strengthen customer confidence in product quality.
Comparison with technical standards and specifications:
- Ensure that the test results comply with international standards such as API, ISO and DIN.

Leading railway pump

Parameters that were examined during the durability tests

When testing the durability of a single pump, several key factors must be monitored and recorded:

Traffic flow: Does it remain constant or does it decrease over time?
Operating pressure: The pressure drop or pressure fluctuation in a system.
Energy consumption: The change in energy demand during operation.
Component temperatures: especially rotor, stator and bearing temperatures.
Component wear: Measurement of rotor and stator wear.
Leaks: Check the condition of the mechanical seal.
Vibrations and noises: These indicate mechanical problems or imbalances.

Method for durability testing of a single pump

1. Preparing the pump

Mount the pump on a standard test bench.
Choose the appropriate test fluid (water, oil or chemical solution) for your application.
Determine the initial conditions, including inlet pressure, fluid temperature, and rotational speed.

2. Conduct long-term tests.

Operate the water pump under the specified operating conditions.
It can be operated continuously or intermittently over a certain period of time (hundreds or even thousands of hours) .
High-precision sensors are used for the continuous monitoring of various parameters.

3. Data collection and analysis

The data were collected during the experiment.
Analysis of trends in flow, pressure, energy, and temperature.
Recognizing the first signs of a problem.

4. Checking the components after the test

Turn on the water pump and carefully check each component.
Measurement of the wear level of the rotor and stator.
Check for cracks, corrosion, or changes in the elastomer properties.

Types of durability tests

Resistance test:
- The water pump continues to run continuously for a long period of time.
Cyclic fatigue test:
- Real operating conditions are simulated by alternately switching the pump on and off.
Overload test:
- The pump was operated beyond its rated power to test its maximum load capacity.

Problems in testing the durability of a single pump

Time required: Sometimes tests can take several months.
High costs: Requires modern testing equipment and specialist personnel.
Energy and fluid consumption: Long-term experiments consume significant amounts of energy and fluid.
Simulation of real-world conditions: Sometimes industrial conditions (such as the presence of solid particles or high abrasiveness) cannot be fully replicated in a laboratory environment.

Advantages of durability testing

Increased customer confidence: Positive test results confirm the actual quality of the product.
Reducing the number of failures in operation: Durability tests help to identify weaknesses in products before they are launched on the market .
Design improvements and material selection: The test results are used to improve the next generation of individual pumps.
Reduction of costs for warranty and customer service.
Meets international standards.

An example of a checklist for testing the durability of a single pump.

Check the initial installation and operating conditions.
Pressure, flow rate , power , and temperature were recorded during the test.
Vibration and noise monitoring.
Note the moment when the first signs of a malfunction appear.
After testing, check and measure the wear of the rotor and stator.
The results of the analysis were compared with the design specifications.

The role of durability testing in various industries

Oil and gas: Ensuring stable operation during the transport of aggressive and heavy liquids.
Food and pharmaceutical industries: Ensuring shelf life and hygiene when in contact with sensitive materials.
Chemical industry: Testing the pump’s resistance to aggressive chemicals and high temperatures.
Water supply and wastewater disposal: Assessment of the stability of sludge and liquids containing solids during transport.

In conclusion

Endurance tests are a crucial aspect of quality control for individual pumps, as they confirm the performance of the devices under real operating conditions . During these tests, the pump is subjected to stress for extended periods, with parameters such as flow rate, pressure, power, temperature, vibration, and wear being monitored.

The results of these tests help manufacturers identify design and material defects, thus enabling them to produce high-quality products . Furthermore, consumers can purchase products with greater confidence after reviewing durability test reports.

In short, durability tests are more than just a technical test; they are an investment in customer confidence, reduced maintenance costs, and a longer pump lifespan.