1 7-Jun-16 FOR APPROVAL SANCO

0 30-May-16 FOR APPROVAL SANCO

Des Pro.
Rev. Date Description By Check Eng. App.
sup Eng.

OWNER:

EPC CONTRACTOR: DESIGNER:

ORASCOM CONSTRUCTION

Via Ravizza, 13/A - 28066 GALLIATE (Novara) - Italy

TEL. +39 0321 807575 - Fax + 39 0321 806699
e-mail: sanco@sanco-spa.it - web: www.sanco-spa.it
PROJECT:

NEW CAPITAL POWER PLANT PROJECT - EGYPT

TITLE:
FIRE FIGHTING SYSTEM - PUMPING STATION
F.F.S. PUMPING STATION PACKAGE PERFORMANCE TEST
PROCEDURES
Contract No.: Document No.:
ACTION NAME DATE TPD-FPO-NCP-M-002-2016

Issue By: SANCO 7-Jun-16 Doc. Status: 10091-9-V1C-MPGF-00028

Prepared By:
Checked By: Scale: Sheet Of Sheets Rev.
Approved By: Size: A4 1 of 18 1
 Firefighting System According to
NFPA20 std FM

FACTORY ACCEPTANCE TEST

CUSTOMER SANCO S.p.A.

EGYPT - NEW CAPITAL 4800 MW

PLANT COMBINED CYCLE POWER PLANT
PROJECT
ITEM : 00SGA11-001 /
POSITION / LOCATION
00SGA12-001 / 00SGA13-001
NFPA20 std. FM FIREFIGHTING 1600676
SERVICE PURCHASE ORDER N.
WATER SYSTEM Dated 12/02/2016

DOCUMENT N FAT-2001239 - Sheet 1 of 17 INTERNAL JOB 2001239

B 07/06/2016 Re-issued for Approval F. CANIS D.ROSSINO L.NEGRINI

A 30/05/2016 Issued for Approval F. CANIS D.ROSSINO L.NEGRINI

Prepared Verified Approved Client

Rev. Date Issue Description
by by by Approval
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INDEX
1.0 General 3
1.1 Diesel engine pump; Electropumps and jockey
pumps functional test 3
1.2 Control panels functional test 3
1.3 Complete unit 3

2.0 Reference standards and Project Documents 3

3.0 Performance test 4

3.1 Plant configuration 4
3.2 Instrumentation to be used 5
3.3 Functional test 6
3.4 Diesel Engine Pump 6
3.5 Electric Pump 6
3.6 Jockey Pump 7
3.7 Pump rotation speed 9
3.8 Total head 9
3.9 Evaluation of results 9

4.0 NPSH test 9

4.1 Methods for NPSH test 11
4.2 Test management and valuation of the results 11

5.0 Control Panel Functional Test 13

5.1 Diesel Engine Control Panel 13
5.2 Electropump Control Panel 13
5.3 Jockey pump Control Panel 13

6.0 Curves 13
6.1 Diesel Engine pump Curve 13
6.2 Electropump Curve 13
6.3 Jockey pump Curve 13

7.0 Used Format

7.1 Format for Performance Test 13
7.2 Format for Vibration Test 14
7.3 Format for Noise test 15
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1.0 General
The object of this operative instruction is to define the execution modalities of the NFPA 20
standard test and compliance to project specification for diesel engine pump, electric pumps and
jockey pumps.
Tests will be described in the following sections:

1.1 DIESEL ENGINE PUMP, ELECTRIC PUMPS AND JOCKEY PUMPS FUNCTIONAL TEST
It will be performed according to as description at 4.0 Performance Test
(Witness tests with certificates release).

1.2 CONTROL PANELS FUNCTIONAL TEST

It will be performed: Signal and Alarms simulation. (Witness tests with certificates
release).

1.3 COMPLETE UNIT

They will be performed: Visual and dimensional check. (Witness control check with
certificates release).

2.0 Reference standards and Project Documents

The reference standards are:

- NFPA20 std (hydraulic Institute 14.6) for Diesel Engine pump performance test (Q-H).
- NFPA20 std (hydraulic Institute 14.6) for Electric pumps performance test (Q-H-R).
- ISO 9906 Gr.2 for Jockey pumps performance test (Q-H-R).
- NFPA20 std. for control panels functional test.
- Acc. to technical specification 10091-9-3PS-MPGF-00001 Appendix B) for vibration test
(only for Electropump & jockey pump).
- Acc. to technical specification 10091-9-3PS-MPGF-00001 Appendix B) for noise test.
- Hydraulic Institute 14.6 for NPSH test for electric and diesel pump.
- ISO 9906 Gr. 2 for NPSH for jockey pump.

The reference Project Document are:

- Pump Data Sheet

- DS-2001239-3 Fire Water Jockey Pump.
- DS-2001239-2 Fire Water Electric Pump.
- DS-2001239-1 Fire Water Diesel Pump.
- Inspection and Test Plan QCP-2001239.
- Technical specification 10091-9-3PS-MPGF-00001.
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3.0 Performance Test

During tests, we will use the components of the Job, except fuel tank and batteries.

3.1 Plant configuration

The pump must be installed in the Tests Room on a conditions suitable to guarantee a proper
operation during test.
3.1.1 A straight pipe must be connected with the delivery flange pump.
The length of this straight pipe must be at least 4 times its diameter.
After this must be present: a magnetic flow meter, a rectilinear pipe with a diameter twice
bigger than the magnetic flow- meter one, a gate valve and, at the end, a pipe that
carries the liquid in the open tank.
The pipe connected with the suction side of the pump must have diameter equal or
bigger than that of the suction flange and a length of four times this diameter.
The suction side pipe will finish with a gate valve if the loss of total head dont influence
the results of performance tests, otherwise the suction side pipe must be installed
without gate valve and before start-up, the pump will be primed by means a vacuum
pump.
3.1.2 Suction pressure take-off
For horizontal pumps, the suction pressure take-off must be present on a rectilinear pipe
at a distance of 2 times the flange diameter and positioned before this flange.
3.1.3 Delivery pressure take-off
For horizontal pumps, the delivery pressure take-off must be present on a rectilinear pipe
at a distance of 2 times the flange diameter and positioned after this flange.
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3.1.4 Test room photo.

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3.2 Instrumentation to be used

During performance tests, Gruppo Aturia will supply calibration certificates of test room
instruments.

3.2.1 Speed rotation

The pump speed rotation is measured with use of electronic detector (stroboscopic
meter).
Accurancy of measure: +/- 5%.

3.2.2 Capacity
Capacity is measured by magnetic flow meter.
Accurancy of measure: +/- 1%.

3.2.3 Pressure
The delivery pump pressure is measured with pressure electronic transducer or
BOURDON manometers. The suction pump pression is measured with BOURDON
manometers.
Accurancy of measure: +/- 1%.

3.2.4 Electric tests

The electric tests are realized with electronic power meter and current transformer (digital
wattmeter).
Accurancy of measure: +/- 1%.

3.2.5 Vibration tests

The vibration tests are realized with vibrometer.
Accurancy of measure: +/- 7%.

3.2.6 Noise tests

The noise tests are realized with noisemeter.
Accurancy of measure: +/- 5%.

3.2.7 Temperature measurement

The temperature is measured with digital termometer.
Accurancy of measure: +/- 2%.
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3.3 Functional Test

After the pump start, the duty point will be reached by regulating the motorized valve set on the
delivery pump pipe, by means of a push-button located on the test bench.

3.4 Diesel Engine Pump

3.4.1 Check the low and idle speed ( adjust if necessary ) 2970 rpm;
3.4.2 Check vibrations.
3.4.3 Control of Noise level.
3.4.4 Control of NPSH value.

The pump shall be tested as follow points:

3
Shut off: Q= 0 m /h
80% of duty point: Q = 364 m3/h
3
Duty point: Q = 455 m /h
3
120% of duty point: Q = 546 m /h
150% of duty point: Q = 683 m3/h
Tolerances in according to Hydraulic Institute par.14.6.

3.5 Electric Pumps

3.5.1 Check electric motor speed.
3.5.2 Check vibrations.
3.5.3 Control of Noise level.
3.5.4 Verify correct rotation direction (view from motor side).
3.5.5 Control of NPSH value.

The pump shall be tested as follow points:

3
Shut off: Q= 0 m /h
80% of duty point: Q = 364 m3/h
3
Duty point: Q = 455 m /h
120% of duty point: Q = 546 m3/h
150% of duty point: Q = 683 m3/h
Tolerances in according to Hydraulic Institute par.14.6.
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3.6 Jockey Pumps

3.6.1 Check electric motor speed.
3.6.2 Check vibrations.
3.6.3 Control of Noise level.
3.6.4 Verify correct rotation direction (view from motor side).
3.6.5 Control of NPSH value.

The pump shall be tested as follow points:

3
Shut off: Q = 0 m /h.
30% of duty point: Q = 2 m3/h.
80% of duty point: Q = 5,5 m3/h.
Duty point: Q = 7 m3/h.
3
120% of duty point: Q = 8,4 m /h.
Tolerances allowed on duty point : +/-5% for head and +/-8% for capacity.
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3.7 Pump rotation speed

The pump can be tested with a reduced speed motor, but must be guaranteed the following
condition:
- the difference between pump rotation speed and test speed must be given by the following
formula:
Dn = (np-nsp)/nsp %
Dn = +/- 20%

3.8 Total head

P2 P1 V22 - V12
H = Z 2 - Z1 + x10.2 - x 10.2 + (meters)
g g 2g
With:
- H = total head (m)
- p1 = vacuum pressure (bar)
- p2 = manometer pressure (bar)
g = liquid specific weight (liquid density)
3
- (kg/dm )
- Z1 = difference of level from pressure take-off to suction side pipe centre (m)
- Z2 = difference of level from manometer centre to pump centre (m)
- V1 = fluid speed at suction pressure take-off (m/s)
- V2 = fluid speed at delivery side pressure take-off (m/s)
- g = acceleration due to gravity (9.81) (m/s2)
- np = rotation speed (rpm)
- nsp = test speed (rpm)

3.9 Evaluation of Results

The evaluation is linked with values of test result and data from tables.
Tests result:
- H = total head (m)
- Q = capacity (m3/h)
- PA = Absorbed power (only for Electric pumps and
jockey pumps) (Watt)
- I = Absorbed current (only for Electric pump and jockey pumps) (Amp)
- V = Voltage (V)

Data from tables:

- m m= motor efficiency (as declared by motor supplier) (only for Electric pumps and
jockey pumps)
- g = liquid specific weight
Rated hydraulic power (only for Electric pumps and jockey pumps) PR = H x Q x g/ 0,367 (Watt)
Power factor (only for Electric pumps and jockey pumps) Cos f = PA/ V x I x 1,73
Absorbed power pump shaft (only for Electric pumps and jockey pumps) (PR)a = PA x
m m(Watt)
Total efficiency (only for Electric pumps and jockey pumps) m t = PR/PA x 100 (%)
Pump efficiency (only for Electric pumps and jockey pumps) m p = m t/m m x 100
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4.0 NPSH test

4.1 Methods for NPSH test

NPSH test is realised with lamination flow at the suction side using gate valve positioned at
length bigger 4 times than the diameter of flange suction pipe.
The pressure take-off must be positioned to equal distance between the suction flange and gate
valve of lamination, however to not less of 2 diameters from it.

4.2 Test management and valuation of the results

The cavitation test will be realised with the following method:

- a test on NPSH pump curve up to notice cavitation effects, realised with a loss of the 3% of
total head at a fixed capacity.
- Test shall be recorded at five points, including minimum flow, rated flow and maximum flow
(as per technical specification 10091-9-3PS-MPGF-00001, item 3.5.11).

The NPSH required value is given by:

(NPSH)r = (pb/g + p1/g - pv/g + V12/2g) x 10.2

- pb = atmospheric pressure at level of pumped liquid (bar)

- p1 = suction pressure measured on vacuum (bar)
- pv = vapour pressure reported on liquid degree (bar)
- V1 = fluid speed reported to pressure take-off (m/s)
- g = liquid specific weight (liquid density) (kg/dm3)
2
- g = acceleration due to gravity (m/s )
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5.0 Control Panel Functional test

After the pump performance tests will be effected functional tests on control panels with signals
and alarms simulation as follows:

5.1 Diesel engine control panel

- Controller trouble

- Engine run

- HoA in off / hand position

- Engine trouble

- Pump room trouble

- High fuel level
- Low fuel level

- Engine fail to start

- High engine temperature

- Engine low oil pressure

- Engine overspeed
5.2 Electropump control panel
- Motor run
- Power available

- Phase reversal
- Pump room alarm

- Motor trouble

- Motor fail to start

5.2 Jockey pump control panel

- Pump Failure

- Phase reversal
- Overload

- Loss of power
- Motor run.
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6.0 Curves
6.1 Diesel engine pump curve
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6.2 Electropump curve

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6.3 Jockey pump curve

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7.0 Used format

7.1 Format for Performance Test
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7.2 Format for Vibration Test

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7.3 Format for Noise Test