Pump Performance

Pump Performance
Pump Performance
Pump Performance
Centrifugal Pump System Hydraulics
Head
Revisiting the spinning disk; the fluid exits
the edge of the disk (or impeller) at a
velocity that relates to the speed of the
plate. The droplets of liquid will travel the
same vertical distance, regardless of the
weight of the liquid.
Pump Performance
Head is the height above

the pump that liquid would
start to spill out of an open
Pipe.
Pump Performance

Head
 A centrifugal pump is considered to be a constant head
device. At a given shaft speed it will develop the same
velocity within the pump, regardless of the weight of the
liquid.
 Heavier liquids require more horsepower than a lighter
liquids, but will rise to the same level in a column or pipe.
However, the pressure at the discharge of the pump
would be higher
Pump Performance
Head vs. Pressure
100 feet
Gasoline Water Sulfuric Acid
SG = 0.7 SG = 1.0 SG = 1.8
30.3 psi 43.4 psi 77.9 psi
Head (ft) x Specific Gravity

PSI =
2.31
Pump Performance
Converting head to pressure
Head (ft) x Specific Gravity

PSI =
2.31 psi/ft
540 feet
540 ft x 0.8
PSI =
2.31 psi/ft
SG = 0.8
PSI = 187
Pump Performance
A Typical Process Plant Pumping System

Pump Performance
NPSH
 In order for a pump to move a liquid, the system must

be able to provide liquid to the suction of the pump
as fast as it is being pumped out
 If the liquid passing through the pump vaporizes,
damage and performance degradation are likely
 Each pump design has a minimum head required to
prevent vaporization for the total range of flow rates
 This head is expressed in feet and is referred to as
NPSH - Net Positive Suction Head
Pump Performance

NPSHA & NPSHR
 NPSHA (calculated) is the net positive suction head

available in the system at a defined flow rate (usually
the rated flow)
 NPSHR (determined by test) is the net positive

suction head required by the pump for a defined flow
rate
 NPSHA must always be greater than NPSHR or

damage to the pump may occur due to cavitation or
vapor lock
Pump Performance

Pressure drops
in a centrifugal
pump
Pump Performance

Cavitation
 An often noisy phenominon that occurs when vapor
bubbles form in low pressure regions of a flowing liquid,
then collapse in a higher pressure region
 Occurs if NSPHA is not sufficiently greater than NPSHR
 Collapsing of the bubbles involves a highly concentrated

release of energy, which can cause severe damage to the
pump impeller
 Vibration, resulting from cavitation, can damage other

pump components, including the mechanical seal.
Pump Performance

Calculation of NPSHA – Pressurized
NPSHA = Abs. press – Pvap – friction loss ± elevation

N2 at 20 psig Convert everything to absolute pressure then to feet
(Psia) (2.31)
Pressure in feet =
Water at 80F Specific gravity
with
Pvap = .5 psia Abs. press = 20 psig = 34.7 psia = 80.2 ft
15 ft
Pvap = 0.5 psia = 1.6 ft
NPSHA = 80.2 – 1.6 – 10 + 15 = 83.6 feet
Pipe friction = 10 ft
Pump Performance

Calculation of NPSHA – boiling liquid
NPSHA = Abs. press – Pvap – friction loss ± elevation >>
The formula holds, but the first two values can be
320 psig
ignored, as they are equal!
Light HC with SG
= 0.52 Abs. press = 320 psig = 334.7 psia
Pvap = 334.7 psia
12 ft
NPSHA = 0 – 6 + 12 = 6 feet
Pipe friction = 6 ft
Pump Performance
Centrifugal Pump Hydraulics

The Affinity Law
Relationships of flow (Q), head (H), and brake horsepower (BHP) for changes in
impeller diameter and speed within reasonably similar efficiencies
Diameter Change Speed Change Diameter & Speed Change

D  N  D N 
Q 2  Q 1  2  Q 2  Q 1  2  Q 2  Q 1  2 X 2 
 D1   N1   D1 N1 
2 2
D  N 
2
D N 
H2  H1  2  H2  H1  2  H2  H1  2 X 2 
 D1   N1   D1 N1 
3 3
D  N 
3
D N 
BHP2  BHP1  2  BHP2  BHP1  2  BHP2  BHP1  2 X 2 
 D1   N1   D1 N1 
Pump Performance
Centrifugal Pump Curves

A Map of Performance
Efficiency
Capacity (GPM)
BEP
Pump Performance

At 100 gpm . . . What is the Head?
100
Efficiency
75
65’
50 16
12
25 8
4
0 50 100 150 200
Capacity (GPM)
Pump Performance

At 150 gpm . . . What is the Efficiency?
100
Efficiency 74%
75
50 16
12
25 8
4
0 50 100 150 200
Capacity (GPM)
Pump Performance

At 50 gpm . . . What is the NPSHR?
100
Efficiency
75
50 16
12
25 8
2’ 4
0 50 100 150 200
Capacity (GPM)
Pump Performance

Brake Horse Power
A scale is normally provided as for the

other plots; it is a straight line plot. It is
Efficiency
based on water @SG of 1.0 and is
based on factory testing. To use the
BHP plot, adjustments will have to be
made for fluids of other densities.
Pump Performance

Composite Curves for a Pump
Pump Performance
Centrifugal Pump Operation

Operating at High Flow
 Risks
 Cavitation (lack of Efficiency
NPSHA)
 Hydraulically induced
shaft deflection
 Accelerated bearing wear
Capacity (GPM)
Pump Performance

Operating at Low Flow
 Risks
 Increasing temperature rise
 Suction recirculation
(vibration) Efficiency
 Hydraulically induced shaft

deflection
 Accelerated bearing wear
 In General Capacity (GPM)

 Never operate below 15% of
BEP
 Be aware of designs requiring
higher minimum flow (some
may be 80% of BEP)
Pump Performance

Temperature Rise vs. Flow
Efficiency
Temperature Rise
0 20 40 60 80 100
Capacity (% BEP)
Pump Performance

Calculation of Temperature Rise
Temperature rise in a centrifugal pump is a function of the total head
(H), efficiency (e), and the specific heat (C) of the fluid. (H) & (e) values
must be taken at a specific capacity.
H ( 1 -1)
Efficiency e
Tr =
780 C
Tr in °F
BHP H in feet
C in Btu/lbm -°F
e in decimal format
Capacity (GPM)
Pump Performance

Parallel Operation
H2
Head H1
OK at high flow
H2 backing out at
low flow
Capacity
Many pumps have a flat portion in the head-capacity curve

at the low end of their capacity. This can lead to one pump
being "backed out“ at lower flow rates, resulting in seal
failure and pump damage.
Pump Performance
Centrifugal Pumps
Single Volute Casing
Pump Performance
Centrifugal Pumps
Double Volute Casing
Volute
Wall
Pump Performance
Radial Forces Acting on the Impeller

Single Volute
R
At BEP At low flow
BEP
Efficiency
Radial
Reaction
Capacity
Pump Performance
Radial Forces Acting on the Impeller

Double Volute
R1
R2
This means less shaft deflection!

Pump Performance
Axial Forces Acting on the Impeller

Basic Design
Low Pressure Zone
High Pressure Zone
Thrust Direction
Box pressure is close to discharge

pressure
Pump Performance

Pump Out Vanes
Pump Out
Low Pressure Zone Vanes
High Pressure Zone
Intermediate Pressure
Thrust Direction
Box pressure is less than ½ of discharge

pressure
Pump Performance

Balance Holes & Back Wear Rings
Balance
Low Pressure Zone Holes
High Pressure Zone
Intermediate Pressure
Thrust Direction
Box pressure is very close to suction

pressure
Pump Performance

Double Suction
Low Pressure Zone
High Pressure Zone
No Thrust Direction
Box pressure is suction

pressure

Pump Performance

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Pump Performance

Centrifugal Pump System Hydraulics

Centrifugal Pump System Hydraulics

Head is the height above

Centrifugal Pump System Hydraulics

Head vs. Pressure

Head (ft) x Specific Gravity

Converting head to pressure

Head (ft) x Specific Gravity

A Typical Process Plant Pumping System

 In order for a pump to move a liquid, the system must

Centrifugal Pump System Hydraulics

 NPSHA (calculated) is the net positive suction head

 NPSHR (determined by test) is the net positive

 NPSHA must always be greater than NPSHR or

Centrifugal Pump System Hydraulics

Centrifugal Pump System Hydraulics

 Occurs if NSPHA is not sufficiently greater than NPSHR

 Collapsing of the bubbles involves a highly concentrated

 Vibration, resulting from cavitation, can damage other

Centrifugal Pump System Hydraulics

NPSHA = Abs. press – Pvap – friction loss ± elevation

Centrifugal Pump System Hydraulics

Centrifugal Pump Hydraulics

Diameter Change Speed Change Diameter & Speed Change

Centrifugal Pump Curves

Centrifugal Pump Curves

0 50 100 150 200

Centrifugal Pump Curves

0 50 100 150 200

Centrifugal Pump Curves

0 50 100 150 200

Centrifugal Pump Curves

A scale is normally provided as for the

Centrifugal Pump Curves

Centrifugal Pump Operation

Centrifugal Pump Operation

 Hydraulically induced shaft

 In General Capacity (GPM)

Centrifugal Pump Operation

Centrifugal Pump Operation

Centrifugal Pump Operation

Many pumps have a flat portion in the head-capacity curve

Radial Forces Acting on the Impeller

At BEP At low flow

Radial Forces Acting on the Impeller

This means less shaft deflection!

Axial Forces Acting on the Impeller

Low Pressure Zone

High Pressure Zone

Box pressure is close to discharge

Axial Forces Acting on the Impeller

High Pressure Zone

Box pressure is less than ½ of discharge

Axial Forces Acting on the Impeller

High Pressure Zone

Box pressure is very close to suction

Axial Forces Acting on the Impeller

Low Pressure Zone

High Pressure Zone