With pump performance under growing scrutiny, comprehensive testing has become essential—not only to verify design integrity but also to ensure efficiency, reliability, and compliance across a wide range of operating conditions.
Hydraulic design, 3D modelling, intellectual property (IP), and manufacturing expertise are all vital components in the development of efficient, high-performing pumps. With increasing emphasis on energy efficiency and the ongoing demand for reliability, manufacturers must continually assess and refine design and production methods.
Theoretical design lays the groundwork for pump development. However, casting and machining processes significantly affect how well a design performs in practice. Variations in these processes can lead to discrepancies in final pump performance, making real-world testing an essential step in the manufacturing cycle.
Pump testing verifies whether the intended design translates into operational success. It allows for identifying and implementing improvements, helping to optimise efficiency, durability, and performance.
Testing is equally critical for reconditioned pumps that have been re-rated or modified to meet new hydraulic conditions.
Melbourne-based manufacturers United Pumps and Sterling Pumps operate two dedicated test facilities that support this process. One is a 1 megawatt (MW) facility in Pakenham, focused on deep-well submersible and vertical turbine pumps, featuring a 15-metre-deep test pit. The other is a 2.5MW facility in Sunshine dedicated to horizontal pumps. This site includes two independent sealed test loops and a 400,000-litre underground tank. Together, these facilities accommodate flow rates of up to 3000 cubic metres per hour (m³/h) and heads of up to 1800 metres.
These testing environments enable comprehensive performance validation, including flow, head, power, efficiency, vibration, sound, and net positive suction head required (NPSHr). The ability to assess performance across the full operating range – including mechanical run and endurance testing – assures that each pump will operate reliably under real-world conditions.
United Pumps provides end-to-end pump engineering and manufacturing services, covering the full lifecycle from concept and design through to fabrication and testing. The company produces API?-compliant, high-quality centrifugal pumps for industrial and municipal applications.
Engineering teams conduct detailed analysis using finite element analysis (FEA) and torsional analysis to ensure mechanical integrity and low-noise, low-vibration operation. Design principles such as double volute casings, balanced impellers, and double suction impellers are used to minimise stress on shafts and thrust bearings, improving long-term reliability.
Many clients require legacy pumps – including those from other manufacturers – to be overhauled and re-rated for new duty parameters. This work is supported by full-scale factory testing to ensure both pump and motor meet the updated performance and operational requirements.
Additional capabilities at the test facilities include in-house mechanical seal systems, which allow for the evaluation of pumps fitted with pressurised dual seals, and in-house variable speed drives for testing across a broad range of speeds.
Testing is conducted in accordance with the following recognised industry standards:
- API 610
- AS ISO 9906
- ANSI/HI 14.6
Through robust design validation and rigorous testing, manufacturers can ensure that each pump delivers the efficiency, reliability, and performance demanded by modern applications.
For more information, visit sterlingpumps.com.au
