P14315: Universal Pump Data Acquisition System
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Test Plan

Table of Contents

Outline of Test Plan

This test plan outlines how the team will verify that the Data Acquisition System meets the customer's requirements.

Test 1: Flowrate monitoring

Objective: Test to ensure proper measurement of flow rate within target range

Target Engineering Requirement: ER1, "Monitor flowrate"

Equipment: Final demo station, universal data acquisition system, flow meter, calibrated flow meter

Procedure:

  1. Verify 0 GPM reading when motor is off
  2. Using data acquisition system, turn on pump and motor
  3. Increase flow to maximum flow rate supported by acquisition system (1.3 GPM). Verify 1.3 GPM reading
  4. Save data log
  5. Plot data log and verify continuous increase from 0 GPM to 1.3 GPM
  6. Compare system-reported flow rates to measurements from calibrated flow meter at 0 GPM, 0.375 GPM, 0.65 GPM, 0.975 GPM and 1.3 GPM. Mark as passing if values agree to within ±0.5% of calibrated readings

Test 2: Pressure monitoring

Objective: Test to ensure proper measurement of pressure within target range

Target Engineering Requirement: ER2, "Monitor pressure"

Equipment: Final demo station, universal data acquisition system, 2 pressure transducers, calibrated pressure transducers

Procedure:

  1. Verify 0 PSI reading when motor is off
  2. Using data acquisition system, turn on pump and motor
  3. Increase pressure to maximum pressure supported by acquisition system (150 PSI). Verify 150 PSI reading
  4. Save data log
  5. Plot data log and verify continuous increase from 0 PSI to 150 PSI
  6. Compare system-reported differential pressures to measurements from calibrated pressure transducers at 0 PSI, 37.5 PSI, 75 PSI, 112.5 PSI and 150 PSI. Mark as passing if values agree to within ±0.5% of calibrated readings

Test 3: Current monitoring

Objective: Test to ensure proper measurement of motor current within target range

Target Engineering Requirement: ER3, "Monitor current entering each motor phase"

Equipment: Final demo station, universal data acquisition system, VFD, calibrated current meter

Procedure:

  1. Verify 0 A reading (all 3 phases) when motor is off
  2. Using data acquisition system, turn on pump and motor
  3. Bring system up to maximum output
  4. Save data log
  5. Plot data log and verify continuous increase in current readings (each phase)
  6. Compare system-reported currents to measurements from calibrated current meter at 5 points between maximum and minimum. Mark as passing if values agree to within ±0.5% of calibrated readings.

Test 4: Voltage monitoring

Objective: Test to ensure proper measurement of motor voltage within target range

Target Engineering Requirement: ER4, "Monitor voltage entering each motor phase"

Equipment: Final demo station, universal data acquisition system, VFD, calibrated voltmeter

Procedure:

  1. Verify 0 V reading (all 3 phases) when motor is off
  2. Using data acquisition system, turn on pump and motor
  3. Bring system up to maximum output
  4. Save data log
  5. Plot data log and verify continuous increase in voltage readings (each phase)
  6. Compare system-reported voltages to measurements from calibrated voltmeter at 5 points between maximum and minimum. Mark as passing if values agree to within ±0.5%

Test 5: Test proactive shutdown

Objective: Test to ensure system gently shuts down in response to undesirable (but still safe) parameters

Target Engineering Requirement: ER5, "Demonstrate proactive shutdown"

Equipment: Universal data acquisition system, power supply

Procedure:

  1. Replace sensor inputs with power supplies
  2. Adjust power supplies to simulate each proactive shutdown condition (See below for list of conditions)
  3. Save data log
  4. Verify proactive shutdown condition was met and was followed by a gentle shutdown of the pump system
  5. Repeat each for following conditions:
    1. <Proactive shutdown condition 1, etc.>

Test 6: Test reactive shutdown

Objective: Test to ensure system shuts down immediately under unsafe conditions or if emergency off button is pressed

Target Engineering Requirement: ER6, "Demonstrate reactive shutdown"

Equipment: Universal data acquisition system, power supply

Procedure:

  1. Replace sensor inputs with power supplies
  2. Adjust power supplies to simulate each proactive shutdown condition (See below for list of conditions)
  3. Save data log
  4. Verify proactive shutdown condition was met and was followed by a gentle shutdown of the pump system
  5. Repeat for each of the following conditions:
    1. Flow rate exceeds 1.3 GPM
    2. Pressure exceeds 150 PSI
    3. Temperature exceeds 200°F
    4. Temperature drops below -40°F

Test 7: Temperature monitoring

Objective: Test to ensure proper measurement of temperature within target range

Target Engineering Requirement: ER7, "Monitor temperature"

Equipment: Final demo station, universal data acquisition system, thermocouple, calibrated temperature sensor/thermometer

Procedure:

  1. Using data acquisition system, turn on pump and motor
  2. Lower fluid temperature to -40°F
  3. Raise fluid temperature to 200°F
  4. Save data log
  5. Plot data log and verify proper operation throughout temperature range
  6. Compare system-reported currents to measurements from calibrated temperature sensor/thermometer at -40°F, 20°F, 80°F, 140°F, and 200°F. Mark as passing if values agree to within ±1%

Test 8: Start-up monitoring

Objective: Test to ensure startup parameters are measured

Target Engineering Requirement: ER8, "Monitor critical start-up parameters"

Equipment: Final demo station, universal data acquisition system, VFD, flow meter, 2 pressure transducers

Procedure:

  1. Begin data acquisition
  2. Using data acquisition system, turn on pump and motor
  3. Save data log
  4. Plot data log and verify the following parameters were monitored during startup
    1. Flowrate
    2. Differential pressure
    3. Current (all 3 phases)
    4. Voltage (all 3 phases)
    5. Motor temperature
    6. Fluid temperature

Test 9: Data display

Objective: Test to ensure system is capable of plotting data

Target Engineering Requirement: ER9, "Display data on graphs"

Equipment: Final demo station, universal data acquisition system, VFD, flow meter, 2 pressure transducers

Procedure:

(Note: This test may be covered during the execution of other tests)

  1. Using data acquisition system, turn on pump and motor
  2. Begin data acquisition
  3. Save data log
  4. Plot data log

Test 10: Data storage

Objective: Test to ensure data is properly stored

Target Engineering Requirement: ER10, "Store data points"

Equipment: Universal data acquisition system, power supply or final demo station (preferable)

Procedure:

  1. Begin data acquisition
  2. Using data acquisition system, turn on pump and motor
  3. Leave running for 1-5 days
  4. Save data log
  5. Verify that data log has no missing time stamps and that data points are recorded at the desired resolution

Test 11: Data analysis capabilities

Objective: Test to ensure system is capable of performing all required data analysis

Target Engineering Requirement: ER11, "Analyze data"

Equipment: Final demo station, universal data acquisition system, VFD, flow meter, 2 pressure transducers

Procedure:

  1. Begin data acquisition
  2. Using data acquisition system, turn on pump and motor
  3. Save data log
  4. Perform the following analyses on data:
    1. Linear regression on:
      1. All measured temperatures
      2. Differential pressure
      3. Flow rate
    2. Plot flow-curve (flow rate vs. pressure)

Test 12: Start-up monitoring

Objective: Test to ensure system meets mobility requirements

Target Engineering Requirement: ER12, "Demonstrate mobility"

Equipment: Universal data acquisition system, VFD, flow meter, 2 pressure transducers, thermocouples

Procedure:

  1. Weigh system
  2. Verify system weight is below 50 lbs.

Test 13: Visual aids

Objective: Test visual aids to ensure that their statuses properly reflect pump status

Target Engineering Requirement: ER13, "Use visual aids to display pump statuses"

Equipment: Final demo station, universal data acquisition system, VFD, flow meter, 2 pressure transducers

Procedure:

  1. Verify pump status is indicated as off
  2. Using data acquisition system, turn on pump and motor
  3. Verify pump status is indicated as on
  4. Using data acquisition system, turn off pump and motor
  5. Verify pump status is indicated as off

Test 14: Monitor motor torque

Objective: Test to ensure torque monitoring

Target Engineering Requirement: ER14, "Monitor motor torque"

Equipment: Final demo station, universal data acquisition system, VFD

Procedure:

  1. Using data acquisition system, turn on pump and motor
  2. Begin data acquisition
  3. Save data log
  4. Plot data log and verify continuous increase in torque

Test 15: Monitor motor power

Objective: Test to ensure motor power monitoring

Target Engineering Requirement: ER15, "Monitor motor power"

Equipment: Final demo station, universal data acquisition system, VFD

Procedure:

  1. Using data acquisition system, turn on pump and motor
  2. Begin data acquisition
  3. Save data log
  4. Plot data log and verify continuous increase in power up to maximum power

Test 16: Monitor motor efficiency

Objective: Test to ensure motor efficiency monitoring

Target Engineering Requirement: ER16, "Monitor motor efficiency"

Equipment: Final demo station, universal data acquisition system, VFD

Procedure:

  1. Using data acquisition system, turn on pump and motor
  2. Begin data acquisition
  3. Save data log
  4. Plot data log and verify power efficiency calculations for measured time interval

Test 17: Monitor motor speed

Objective: Test to ensure motor speed monitoring

Target Engineering Requirement: ER17, "Monitor motor power"

Equipment: Final demo station, universal data acquisition system, VFD, calibrated tachometer

Procedure:

  1. Using data acquisition system, turn on pump and motor
  2. Begin data acquisition
  3. Save data log
  4. Plot data log and verify continuous increase in motor speed up to maximum speed
  5. Compare system-reported currents to measurements from calibrated tachometer at 5 points between maximum and minimum. Mark as passing if values agree to within ±0.5% of calibrated readings

Test 18: Access system remotely

Objective: Test to ensure remote access to system

Target Engineering Requirement: ER19, "Access system remotely"

Equipment: Final demo station, universal data acquisition system, external PC

Procedure:

  1. Enable system remote access
  2. Access the system from the external PC over the network interface
  3. Using data acquisition system, turn on pump and motor
  4. Begin data acquisition
  5. Save data log
  6. Verify data log is accessible from remote PC

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