Sykes Yakka 150 User manual

PUMPSET MANUAL
CP150iC
Customer:
Reference:

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 2
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
TABLE OF CONTENTS
1.
INTRODUCTION
2.
CUSTOMER SPECIFICATION
3.
TECHNICAL DATA SHEET
4.
YAKKA SPECIFICATIONS
5.
HOW TO READ A PERFORMANCE CURVE
5.1
Example Sykes’ CP150 Pump Curve
5.2
Generalisations
5.3
Radial Thrust
5.4
Cavitation
6.
RISK ASSESSMENT GUIDE
7.
RISK ASSESSMENT –CP150i
8.
AS2417-2001 GRADE 2 ACCEPTANCE TEST
9.
SITE COMMISIONING PROCEDURE
10.
AUTOMATIC PRIMING NRV FUNCTION
11.
PUMP OPERATING INSTRUCTIONS
11.1
Description of Pump Unit
11.2
Procedure Prior to Pump Start Up
11.3
Failure to Prime Pump
11.3.1
Air Leaks
11.4
Pump Dynamic Test
11.5
Ejector Test
11.5.1
Dri-Vac Ejector Pack Assembly
12.
PUMP MAINTENANCE INSTRUCTIONS
12.1
Maintenance Schedule
12.2
Bolt, Studs and Nuts Torque Setting
12.3
Pump Internal Clearances`
12.4
General Pump Inspection Procedure
12.5
Pump Assembly Instructions

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 3
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
12.5.1
Pump Bearing Engine Adaptor
12.5.2
Centrifugal Pump
12.5.3
Ejector Package
12.5.4
Mechanical Seal
12.5.5
Non Return Valve
12.5.6
Engine / Pump Coupling
12.6
Yakka Basic Assembly Procedure
12.7
Air Compressor
12.7.1
Preface
12.7.2
General Description
12.7.3
Performance Chart
12.7.4
Internal Detail of Compressor
12.7.5
Parts List
12.7.6
Operation
12.7.7
Accessories
12.7.8
Piping
12.7.9
Installation Dimensions
12.7.10
Maintenance
12.7.11
Fitting Instructions –Compressor Assembly
12.7.12
Compressor Belt Replacement
13.
PUMP DIAGNOSTICS
13.1
Trouble Shooting Guide
14.
PUMP UNIT SUB-ASSEMBLY
15.
PARTS LIST
15.1
Recommended CP150iC Pump Spare Parts
15.2
Front Cover and Volute Parts List
15.3
Bearing Bracket and Shaft Parts List
15.4
Ejector Package Parts List
15.5
Compressor Parts List
15.6
Compact Non Return Valve Parts List

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 4
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
15.7
Engine / Pump Coupling Parts List
15.8
Yakka Pumpset Parts List
15.9
Yakka Pump and Engine Parts List
15.10
Yakka Canopy Parts List
15.11
Yakka Trailer Parts List (if applicable)
15.12
Yakka Drain Locations
16.
PUMP UNIT ACCESSORIES
17.
DIESEL ENGINE MANUAL (if applicable)
18.
ELECTRIC MOTOR MANUAL (if applicable)
19.
WARRANTY CLAIM PROCEDURE
20.
MIISCELLANEOUS ENGINEERING
INFORMATION
20.1
Main Factors Affecting Pump Suction Lift
20.2
Pump Suction Pipe Velocity
20.3
Total Dynamic Head Explanation Diagram
20.4
pH Compatibility Chart
20.5
Jet and Nozzle Information

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 5
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
1 INTRODUCTION
Congratulations on the purchase of your new Sykes Pump.
With Sykes’ established quality control systems you can be assured your pump
was manufactured with a high level of control and has undergone extensive
testing on Sykes’ certified test facility.
Sykes are pleased to offer a 12 month warranty on your new pump. As with all
warranties, Sykes’ warranty is subject to regular maintenance as per the pump
manual. To ensure your warranty is maintained, make sure your pump is regularly
serviced. Sykes offer maintenance and repairs on our entire range and are able
to offer regular service agreements of required.
Sykes provide local service through a highly trained network of branches and are
able to meet your service and spare parts requirements around the clock. For
spare parts or service enquiries contact Sykes spare parts direct on 1800 131
950.
Turnaround on parts is rapid with Sykes customer service ready to meet your
needs 24 hours a day with spare parts located at branches Australia wide and
around the globe.
Sykes also offer onsite application assistance and training to ensure your pump is
running at its optimum performance. Our Sykes trained staff will assess your
application and help to set up optimum operating settings which will help to
reduce unnecessary wear and tear on the pump whilst ensuring the pump is
operating at its most efficient duty point.
Should you have any after sales issues please do not hesitate to contact your
local Sykes branch or contact Sykes’ After Sales Service on 02 4954 3333.

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 6
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
2 CUSTOMER SPECIFICATION
General Unit Information
Customer
Sykes Job Number
Sykes Serial Number
Plant Number
Pump Information
Pump Type
Pump Size
150 x 150mm
Impeller Diameter
Ø255mm
Engine Information
Engine Make
Engine Serial Number
Tacho Serial Number
Electric Motor Information
Motor Make
Motor Serial Number
Pod Only Information
Dry Weight
Wet Weight
Fuel Capacity
Trailer Information
VIN Number
Tyre Type
Axle Set Up
Pump Extras
Additional Information

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 7
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
3 TECHNICAL DATA SHEET
CP150iC Contractor
Diesel Drive
Compressor Prime Pump
MATERIALS OF CONSTRUCTION
DESIGN DETAILS
Pump Casing:
SG Iron AS1831 Grade 400/12
Pump Designation:
CP150iC Contractor
Suction Cover:
SG Iron AS1831 Grade 400/12
Pump Description:
Centrifugal Single Stage,
Volute Type, 2 Bladed Fully
Open Impeller.
Tee Piece:
SG Iron AS1831 Grade 400/12
Suction Flange:
150mm Table ‘D’
Bearing Bracket:
SG Iron AS1831 Grade 400/12
Delivery Flange:
150mm Slotted Table ‘D’ or ‘E’
Pump Shaft:
431 Stainless Steel
Nominal Casing Thickness:
16mm
Impeller:
316 Stainless Steel
Nominal Shaft Diameter:
40mm
Wear Plates:
316 Stainless Steel
Impeller Eye Diameter:
161mm
Air Injector:
316 Stainless Steel
Maximum Impeller O.D.:
255mm
Mechanical Seal:
Silicon Carbide / Silicon Carbide
Minimum Impeller O.D.:
255mm
Non Return Valve
150mm Compact Ball Style NRV
Solids Handling Size:
77mm
Compressor Pulley:
SPB 2 Groove –180mm
Operating Speed:
MIN: 1400rpm MAX: 1800rpm
Drive Pulley:
SPB 2 Groove –140mm
Maximum Head:
29m
Belt Section:
Link Belt - SPB
Maximum Capacity:
133l/s
Compressor Details:
Bendix 2W 440 R Twin-in-line
cylinders 75mm x 50mm stroke, air
or engine radiator liquid cooled
15cfm (410L/min) at 1000rpm
Lubrication from engine oil system.
Bearing Sizes:
Drive End:
33111 Tapered Roller
Pump End:
33111 Tapered Roller
Ejector Details:
Jet: 23-0568-2016
Nozzle: 23-0571-2016
Bearing Lubrication:
Grease Lubrication Multi Lube
Lithium Grease EP Additives
NLGI #2 or Equivalent

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 8
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
4 YAKKA SPECIFICATIONS
Pump Type
Yakka 150
Pump Inlet (Suction)
150mm Table ‘E’
Pump Outlet (Discharge)
150mm Table ‘E’
Impeller Diameter
255mm
Maximum Solid
77mm
Pump Minimum Speed
1400rpm B.E.P. 69l/sec @ 11.0m T.D.H.
Pump Maximum Speed
1800rpm B.E.P. 85l/sec @ 18.5m T.D.H.
Fuel Capacity
205 litres
Average Noise Level @ 7m
1400rpm –65dBA
1800rpm –67dBA
Volute
Impeller
Wear Plates
Shaft
SG Iron 400/12
316 S/S
316 S/S
431 S/S
Pod Information
Length
2250mm
Height
1375mm
Width
1100mm
Dry Weight
1410kg
Wet Weight
1588kg
Maximum Pump / Engine Speed = 1800 rpm
Maximum Fuel Level
MAXIMUM FUEL LEVEL
Fuel Expansion Chamber

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 9
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
5 HOW TO READ A PERFORMANCE CURVE
5.1 Example Sykes’ CP150 Pump Curve
The lines sloping downwards from left to right represent the varying quantities of
liquid delivered by the pump with variations in head. The intersection of this line at
2000rpm with the zero flow line shows the shut off head (41m) of pressure
developed by the pump.
Total Dynamic Head (m) = Static Suction lift (m) + Static Discharge Head (m) +
Friction Head (m)
Where:
Static Suction Lift:
Difference in elevation between liquid level of the
suction and the centre line of the pump.
Static Discharge Head:
Difference in elevation between liquid levels of the
centre line of the pump and the discharge.
Friction Head:
Equivalent head necessary to overcome friction on the
interior surfaces of the pipework system including all
valves, bends and fittings.

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 10
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
Duty Point: A pump operating at 95l/s at 29m (Total Dynamic Head).
1) Draw a line upwards from Flow (x-axis) at 95l/s (point A).
2) Draw a line across from Total Head (y-axis) at 29m (point C)
3) Where the vertical line of 95l/s intersects the horizontal line of 29m
(point B) determines the pump rpm speed and power required at
this duty.
4) Pump Speed Curve = 2000rpm.
5) Power Requirement = 45kW to run the whole of the 2000rpm
curve.
6) To obtain NPSHR (Net Positive Suction Head Required), draw a
line across from where the vertical line of the 95l/s intersects the
NPSHR curve (point D).
7) NPSHR = 1.1m (point E).
8) Dynamic Suction Lift Available (DSLA)
DSLA = Atmosphere (m) –Velocity Head (allow 1m) –NPSHR
(m)
= 10.3m –1m –1.1m
=8.2m
To determine the actual dynamic lift of pump, it is recommended to fit a vacuum
gauge on the suction side of the pump to obtain a vacuum reading. The vacuum
gauge, for this example, should read no more than 80.4kPa (8.2m). If the vacuum
gauge reading is greater than 80.4kPa then the pump will experience cavitation.
Notes:
To ensure minimal losses to the total suction lift:
Keep suction pipes as short and straight as possible.
Eliminate all possibility of air pockets being trapped in suction pipework.
When choosing foot valves, strainers, bends etc, select those, which will
provide minimal restriction to the flow.
The diameter of the suction pipe should be equal in diameter to the pump
inlet connection.
It is recommended to fit eccentric reducer in conjunction with pipe
diameters larger than the pump inlet to avoid the possibility of air pockets
in the suction pipework.

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 11
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
5.2 Generalisations
(1) Flow (l/s) decreases, as Total Head (m) increases.
(2) Flow (l/s) increases, Power used increases.
It is not recommended to operate the pump outside the recommended pump
operating range. To operate outside this area will lead to cavitation, vibration and
non-uniform radial forces present in the pump. This drastically reduces the
operating life of the mechanical seal, bearings and efficiency of the pump. In
addition, the pump alignment will also be adversely effected due to excessive
vibration. All this will result in an increase of maintenance cost of the pump.
5.3 Radial Thrust
When a pump is operated at its best efficiency flow rate the velocities and hence
the pressures acting on the impeller are uniform around the volute. This is shown
in Figure –A.
At flow rates other than best efficiency point, the pressure distribution is no longer
uniform. At reduced flow rates, the pressures increase spirally towards the
cutwater resulting in a radial reaction F as shown Figure –B.
This will lead to the following operating problems:
Low efficiency of pump.
Noise vibration, reduced life of pump.
Increased radial loads on bearings due to unbalanced volute
pressures.
Temperature rise due to dissipated energy created by low
efficiency.
A similar situation exists at flow rates beyond best efficiency flow rates, with an
approximate opposite (in direction) reaction.
This also will lead to similar problems associated with the reduced flow rates with
an addition of poor suction performance (high NPSHR).
Figure –C shows typical variation of radial thrust with flow rate.

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 12
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
Figure A –100% Best Efficiency Flow
Figure B –Reduced Flow
Figure C –Radial Thrust

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 13
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
5.4 Cavitation
If the Net Positive Head Available of the pump is less than the Net Positive Head
Required, the pumpend liquid will vaporize in the region of the impeller eye i.e.
where the local pressure is less then the vapour pressure.
In this region, the fluid will consist of a liquid plus vapour cavities. This can, in the
extreme, result in the formation of a vapour lock and the prevention of the fluid
entering the impeller.
This phenomenon is called ‘cavitation’. The cavitation cycle comprises therefore
of two phase changes; one from liquid to vapour during the initiation and the other
from vapour back to liquid during cavity collapse.
Cavitation may be caused by excessive suction lift, insufficient NPSHA or
operation at too high a speed. The resulting effects include:
(1) Pitting of material surfaces due to the continual hammering action of the
collapsing vapour cavities.
(2) Significant reduction of performance due to vapour formation.
(3) The crackling noise (like gravel going through the pump) caused by vapour
cavity collapse.
Severe cavitation usually results in excessive noise, vibration and damage to
pump, whereas mild cavitation may produce nothing more than a small reduction
in pump efficiency and moderate wear of pump components.

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 14
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
6 RISK ASSESSMENT GUIDE
The following RISK CLASSIFICATION table should be used to assess the degree of risk
presented by hazardous situations identified when carrying out the assessment.
Consider:
Electrical
Thermal
Noise
Mechanical
Gravity
Pressure
Chemical
Radiant
Biochemical
The numbers indicate how important it is to do something.
1 = Top priority –do something immediately
25 = Low priority –do something when possible
The table does not provide for control actions to be taken to minimise the risk and it is very
important that these are documented, along with time frame and responsibilities.
PROBABILITY
CONSEQUENCES
A
B
C
D
E
1
1
2
4
7
11
2
3
5
8
12
16
3
6
9
13
17
20
4
10
14
18
21
23
5
15
19
22
24
25
Number & Colour
Risk
1 to 3 - Red
Critical
4 to 10 - Yellow
High
11 to 15 - Blue
Medium
16 to 25 - Green
Low
Probability
A
Almost Certain
B
Likely
C
Occasional
D
Unlikely
E
Rare
Injury
Environmental
5
Could cause injury
No detrimental effect
4
Could cause 1st Aid Injury
Temporary or minor damage e.g. minor oil spill
3
Could cause typical MTC/LTI
Substantial temporary or minor permanent
damage e.g Minor water discharge
2
Could cause serious injury (major LTI)
Substantial and permanent damage which would
result in prosecution, adverse local publicity and
complaints
1
Could kill, permanently disable
Major event creating loss of company creditability
with key audiences, national publicity &
complaints & which could close the operation
permanently.

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 15
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
7 RISK ASSESSMENT –Yakka CP150iC
Activity
Hazard
Initial Risk
Current Control Measures
& Action Required - New Press
Residual Risk
P
C
Risk
P
C
Risk
Lifting of Pumpset by single point
lifting frame
Excessive lateral movement of
unit –crushing
C
1
4
Only qualified personnel to use lifting equipment
Hoisting acceleration should not exceed 0.4m/sec2
Ensure lifting equipment is in good condition
Keep all personnel away from Pumpset when it is
suspended
Do not lift Pumpset by any other method than the
central lifting eye
Do not lift in extreme weather conditions
Stop & think
Correct PPE
E
4
21
Setting up the Pumpset
Slips, trips, strain, sprains and
pinch points
B
3
9
Wear correct PPE
Stop and think
Inspect area to ensure safe working conditions
Set up on level ground
Communicate with personnel located/working in
vicinity of Pumpset
Clean up any spillages causing trip hazards
Do not operate Pumpset in known unsafe conditions
Do not use Pumpset in any classification of
hazardous environment unless it has been
specifically designed to do so
Do not operate within a confined space
C
3
13
Operation of Pumpset
Excessive Noise –hearing
loss
B
2
5
Wear correctly fitting hearing protection at all times
when working or operating around the Pumpset
Stop & think
E
2
16

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 16
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
Activity
Hazard
Initial Risk
Current Control Measures
& Action Required - New Press
Residual Risk
Operation of Pumpset
Boom movement (Suction
Hose Boom) –pinch points &
crushing
C
2
8
Wear correct PPE
Stop & think
Do not operate Pumpset in known unsafe conditions
Do not use Pumpset in any classification of
hazardous environment unless it has been
specifically designed to do so
Do not operate within a confined space
Keep all personnel away from Pumpset when boom
is tilted, raised or lowered
Do not move Pumpset whilst operating the boom
Ensure boom lifting equipment is in good condition
Do not operate Boom in known unsafe conditions
Communicate with personnel located/working in
vicinity of Pumpset
D
2
12
Operation of Pumpset
Running engine & Pump Unit –
moving parts, hot pump parts,
hot exhaust and manifolds on
engine –possible burns, pinch
points, cuts and abrasions
B
2
5
Wear correct PPE
Stop & think
Educate employees of burn hazards on engines
Keep access door on enclosures closed and locked
when not required to be open
Ensure that the engine is operated only from the
control panel or from the operator’s position by one
person only
Keep hands, arms, long hair, loose clothing and
jewellery away from pulleys, belts and other moving
parts
Do not remove any safety guards or panel
D
2
12
Operation of Pumpset
Hydraulic, fuel, grease, oil,
radiator coolant, water
pressure, movement of pump
water hose and battery
electrolyte leaks –
environmental pollution,
poisoning, burns & skin
irritation
C
2
8
Stop & think
Wear correct PPE
Check all hoses for cracks and leaks
Check that all covers and caps are secure on
alternator, cooling fan/radiator, engine & fuel tank
Ensure spillages are contained
MSDS available for all items used in Pumpset
Educate employees of burn hazards
D
3
17

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 17
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
Activity
Hazard
Initial Risk
Current Control Measures
& Action Required - New Press
Residual Risk
Operation of Pumpset
(Diesel Driven)
Possible electrocution –
electric shock and burns
C
3
13
Wear correct PPE
Stop & think
Only Authorised Personnel to work on electrical
equipment
Check all conduits for splits, bare wires or
unsecured conduit fitting prior to operation of
Pumpset
Check all circuit breaker boards are secure and
sealed
Check all guards covering electrical section are
secured correctly
Do not attempt to connect or disconnect load while
standing in water or on wet or soggy ground
Ensure all electrical power is isolated from electrical
equipment being serviced
Keep all electrical equipment clean and dry
Keep terminals clean and tight
Test earth leakage equipment regularly
Ensure correct fire extinguisher is available
D
4
21
Operation of Pumpset
Possible electrocution –
electric shock and burns
B
2
5
Wear correct PPE
Stop & think
Only Authorised Personnel to work on electrical
equipment
Check all conduits for splits, bare wires or
unsecured conduit fitting prior to operation of
Pumpset
Check all circuit breaker boards are secure and
sealed
Check all guards covering electrical section are
secured correctly
Do not attempt to connect or disconnect load while
standing in water or on wet or soggy ground
Ensure all electrical power is isolated from electrical
equipment being serviced
Keep all electrical equipment clean and dry
Keep terminals clean and tight
Test earth leakage equipment regularly
Ensure correct fire extinguisher is available
D
3
17

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 18
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
Activity
Hazard
Initial Risk
Current Control Measures
& Action Required - New Press
Residual Risk
Maintenance –Electrical
Battery charging
Possible explosion –burns
and bodily injuries
B
1
2
Wear correct PPE
Stop & think
Correctly isolate equipment
Do not smoke or allow sparks, flames or other
sources of ignition around batteries
To avoid arcing keep grounded conductive objects,
such as tools, away from exposed live electrical
parts, such as terminals
When disconnecting battery disconnect the negative
battery terminal first
When reconnecting battery connect the negative
battery terminal last
Ensure adequate ventilation
Turn off power or disconnect the power to the
battery charger before making or breaking
connections with the battery
D
3
17
Maintenance - Electrical
Possible electrocution –
electric shock and burns
B
3
9
Wear correct PPE
Stop & think
Correctly isolate equipment
Only Authorised Personnel to work on electrical
equipment
Do not attempt to connect or disconnect load while
standing in water or on wet or soggy ground
Ensure all electrical power is isolated from electrical
equipment being serviced
Keep all electrical equipment clean and dry
Keep terminals clean and tight
Test earth leakage equipment regularly
Ensure correct fire extinguisher is available
D
4
21
Maintenance –refilling fuel tank
Fuel leaks –environmental
pollution, poisoning, burns &
skin irritation
B
3
9
Stop & think
Wear correct PPE
Correctly isolate equipment
Check all hoses and fittings for cracks and leaks
Ensure spillages are contained
MSDS available for fuel used in lighting tower
Educate employees of burn hazards
D
4
21

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 19
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
Activity
Hazard
Initial Risk
Current Control Measures
& Action Required - New Press
Residual Risk
Maintenance - mechanical
Engine, hydraulic pump and
centrifugal pumpend
maintenance –explosion,
burns, pinch points, skin
irritation
C
4
18
Stop & think
Wear correct PPE
Correctly isolate equipment
MSDS available for items used in Pumpset
Ensure spillages are contained
Check all hoses and fittings for cracks and leaks
Correctly de-energise hydraulic system
Ensure guarding is in place and secure after
maintenance is finished
Do not remove the radiator filler cap until the coolant
has cooled. Then loosen the cap slowly to relieve
any excess pressure before removing the cap
completely
Educate employees on hazards of hot coolant and
oil under pressure
Bleed Hydraulic Pressure before carrying out
maintenance.
Allow Hydraulic Oil to cool before maintenance.
Educate employees of burn hazards
Ensure correct fire extinguisher is available
D
4
21

Sykes Yakka 150iC –Installation, Operation & Maintenance Manual
Page 20
AllightSykes Spare Parts & Service 24 hours: 1800 131 950
Website: www.allightsykes.com
8 AS2417-2001 GRADE 2 ACCEPTANCE TEST
Sykes Group tests all their manufactured pumps to meet AS2417-2001 Grade 2
standard. This standard outlines the acceptable performance parameters whilst
testing / collecting pump hydraulic performance data.
Please note that all performance test equipment at Sykes Head Office testing
facility is certified to meet relevant standards.
Pump Test performed to meet AS2417 –2001 (ISO 9906: 1999 (E))
Rotodynamic pumps –Hydraulic performance acceptance tests –Grade 2.
Permissible amplitude of fluctuations as a percentage of mean value of quantity
being measured
Flow Rate ±6%
Pump Total Head ±6%
Speed of Rotation ±2%
Permissible values of overall measurement uncertainties
Flow Rate ±3.5%
Pump Total Head ±5.5%
Speed of Rotation ±2%
Values of tolerance factors
Because of manufacturing uncertainties during completion, geometrical deviations
from the drawings are given at every pump. Tolerances shall be allowed, including
the possible deviations in operating dates between the tested pump and a pump
without any manufacturing uncertainties.
Flow Rate ±8%
Pump Total Head ±5%
Pump Efficiency -5%
NPSH3
NPSH required for a drop of 3% of the total head of the first stage of the pump as a
standard base for use in performance curves.
NPSHR
Minimum NPSH given by the manufacturer for a pump achieving a specified
performance at a specified flow rate, speed and pumped liquid (occurrence of
visible cavitation, increase of noise and vibration due to cavitation, beginning of