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Centrifugal Pump Webinar

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Presented by Jeff Sines, ESI Training Lead

©2010 Engineered Software, Inc. All Rights Reserved
Objectives
• In this webinar we will:
– Identify the major parts of a centrifugal pump
– Review the theory of operation of centrifugal pumps
– Understand the importance of the pump curve and the
key information found on the curve
– Describe NPSH and its impact on pump cavitation
– Learn the Pump Affinity Rules
– Learn how to calculate pump power and operating costs
– Review the process for sizing a pump
– Understand how a pump and system interact
– Understand parallel and series pump operation
Pumps Convert Energy
• Output of the driver (motor, turbine, or engine) is
mechanical energy in the form of a rotating shaft
• The pump converts this mechanical energy into
hydraulic energy and adds it to the fluid in the form
of pressure and flow
– Centrifugal pumps use a rotating shaft and impeller
– Positive displacement pumps use rotation or linear motion
to displace fluid
 Major Pump Parts Discharge

Casing
Pump
Shaft
Impeller

Bearings Suction

Pump Seal

Volute

Photo courtesy of Truflo Pumps (www.truflo.com)

 Theory of Operation
• A pump converts mechanical energy into hydraulic
energy
– Fluid enters the pump suction and flows into the eye of the
rotating impeller
– As fluid approaches the eye, fluid pressure drops as it feels
the centrifugal forces and changes direction from axial flow
to radial flow
• The eye of the impeller is the
lowest pressure point in the
pump.
• The low pressure at the eye
helps pull more liquid into
the suction
Theory of Operation
– The fluid proceeds radially outward from the eye and is
accelerated along the impeller vanes by the centrifugal forces
created by the rotating impeller
– The fluid leaves the tips of the vanes at a high velocity
• Fluid enters the volute, a
region of increasing cross
sectional area, where the fluid
slows down and increases
pressure
• Velocity head is converted into
pressure head
• The fluid exits the pump at a
higher pressure
Velocity & Pressure Profile
Pump Casing
• The casing contains the diffusing element that
converts velocity head to pressure head

Single Volute Double Volute Diffuser

Radial Loads
 Operating Point Affects Reliability
Low Flow Low Bearing
High Reduced
Cavitation and Seal Life
Temperature Impeller
Rise Life

Suction
Recirculation
Discharge
Recirculation

Low Bearing
and Seal Life
Cavitation
Impeller Types

Open Impeller Semi-Open Impeller Closed Impeller

Impeller Leakage
Semi-open Impeller Closed Impeller
 4 - 13
Pump Bearings and Seals

skf.com
Pump Performance Curve
• Pump curve defines the relationship between the
flow rate and the total head developed by the
pump
– Needed for selecting a pump to fit the system
– Used for monitoring the “health” of a pump
– Good tool for troubleshooting pump operation
• If the pump is operating as designed, it must
operate at a location on the pump curve based on
the resistance of the system it is pumping into
• The pump curve is the most critical piece of
information needed about the pumping system
Typical Pump Curve
Individual Pump Curve
Curves for Different Types of Centrifugal Pumps
Pump Efficiency
• Efficiency is the ratio of the energy added to the
liquid to the energy applied to the shaft

– Provided by manufacturer, typically on the pump curve

– Best efficiency point occurs where there is the least
amount of vibration of the pump
– Efficiency decreases to the right and left of the BEP
– Seal and bearing maintenance increases the farther the
pump is operated from the BEP
Pump Power Calculations
• Water horse power (whp): power added to the fluid
(pump output power)

• Brake horse power (bhp): power applied to the pump

shaft; also the output power of the motor

• Electrical horse power (ehp): electrical power applied

to the VFD or motor
 Power Added to the Fluid
• Area formed by a rectangle at the operating point on the pump
curve represents the amount of power added to the fluid (whp)
• BHP takes pump efficiency into account
Calculating Pump Operating Cost

where: Q = volumetric flow rate (US gpm)

H = total head (ft)
ρ = fluid density (lb/ft3)
ηp = pump efficiency
ηm = motor efficiency
ηVSD = variable speed drive efficiency
hrs = time period for analysis (hrs)
$/kWh = energy cost per kilowatt-hour
 Example: Pump Power and Operating Cost
• Calculate whp, bhp, ehp, motor power (kW), and operating
cost for a fixed speed pump with a 17.3125 ” diameter
impeller pumping 6,000 gpm of water at 60 °F
Given:
• Time = 8,000 hours
• Power cost =
$0.08 / kWh
• motor = 93%
• ρ = 62.4 lb/ft3

From Pump Curve:

• TH = 250 ft
• pump = 87%
Example: Pump Power and Operating Cost
Cavitation
• The formation and subsequent collapse of vapor
bubbles as the fluid’s pressure drops below, then
rises above, the vapor pressure
– Fluid pressure reaches its lowest
point at the eye of the impeller
– If pressure falls below the vapor
pressure, vapor bubbles will form
– As the fluid moves along the
impeller vanes, pressure increases
above the vapor pressure
– The vapor bubbles collapse,
creating a high velocity jet of
water that implodes on the
surface of the impeller vane or
pump casing
Effects of Cavitation
• Vapor bubbles take up more space than the same mass of liquid,
causing a reduction in the mass flow rate through the pump
• Collapsing vapor bubbles may be barely audible or very loud like
the sound of gravel passing through the pump
• Pump discharge pressure may oscillate
• Increased vibration levels may result in bearing or seal damage
• Long term cavitation will damage the impeller and degrade
pump performance, or cause catastrophic failure of the impeller

http://en.wikipedia.org/wiki/File:Cavitation.jpg

http://commons.wikimedia.org/wiki/File:Kavitation_at_pump_impeller.jpg
Net Positive Suction Head (NPSH)
• NPSH: the amount of fluid energy at the pump suction
• NPSH required: the amount of fluid energy at the eye of
the impeller when cavitation is just beginning to occur
• NPSH available: the amount of fluid energy the system
provides at the pump suction
• NPSHa must be greater than NPSHr to prevent cavitation
• NPSHr is determined by the pump manufacturer
– Pump is run at a constant flow rate in a test system
– Supply tank pressure is lowered until the pump cavitates, as
indicated by a 3% drop in pump total head from the pump curve
– NPSH is calculated
– Test is repeated at various flow rates
Calculating NPSHa
144
𝑁𝑃𝑆𝐻𝑎 = 𝑃𝑡𝑎𝑛𝑘 + 𝑃𝑎𝑡𝑚 − 𝑃𝑣𝑝 × + 𝑍𝑡𝑎𝑛𝑘 + 𝑍𝐿𝑒𝑣𝑒𝑙 − 𝑍𝑝𝑢𝑚𝑝 − ℎ𝐿
𝜌
where:
Ptank = pressure on the liquid surface of the supply tank (psig)
Patm = local atmospheric pressure (psia)
Pvp = vapor pressure of the liquid entering the pump suction (psia)
ρ = fluid density (lb/ft3)
Ztank = bottom elevation of the supply tank (ft)
Zlevel = liquid level measured from the bottom of the tank (ft)
Zpump = elevation of the centerline of the pump suction (ft)
hL = total head loss in the suction pipeline (ft)
A reasonable approximation using pump suction pressure gage:
144
𝑁𝑃𝑆𝐻𝑎 ≅ 𝑃𝑖𝑛 + 𝑃𝑎𝑡𝑚 − 𝑃𝑣𝑝 ×
where: 𝜌
Pin = pressure gage reading at the pump’s suction (psig)
NPSHa Calculation for Flooded Suction
Pvp = 0.256 psia
ρ = 62.4 lb/ft3

144
𝑁𝑃𝑆𝐻𝑎 = 𝑃𝑡𝑎𝑛𝑘 + 𝑃𝑎𝑡𝑚 − 𝑃𝑣𝑝 × + 𝑍𝑡𝑎𝑛𝑘 + 𝑍𝐿𝑒𝑣𝑒𝑙 − 𝑍𝑝𝑢𝑚𝑝 − ℎ𝐿
𝜌
𝑖𝑛2
144 2
𝑓𝑡
𝑁𝑃𝑆𝐻𝑎 = 14.7 − 0.256 𝑝𝑠𝑖𝑎 × + 100 + 5 − 95 𝑓𝑡 − 1.7 𝑓𝑡 = 41.6 𝑓𝑡
𝑙𝑏
62.4 3
𝑓𝑡
 NPSHa Calculation for Suction Lift

Pvp = 0.256 psia

ρ = 62.4 lb/ft3

144
𝑁𝑃𝑆𝐻𝑎 = 𝑃𝑡𝑎𝑛𝑘 + 𝑃𝑎𝑡𝑚 − 𝑃𝑣𝑝 × + 𝑍𝑡𝑎𝑛𝑘 + 𝑍𝐿𝑒𝑣𝑒𝑙 − 𝑍𝑝𝑢𝑚𝑝 − ℎ𝐿
𝜌

𝑖𝑛2
144 2
𝑓𝑡
𝑁𝑃𝑆𝐻𝑎 = 14.7 − 0.256 𝑝𝑠𝑖𝑎 × + 85 + 5 − 95 𝑓𝑡 − 1.7 𝑓𝑡 = 26.6 𝑓𝑡
𝑙𝑏
62.4 3
𝑓𝑡
Solutions for a Cavitating Pump
• Reduce pump flow rate to reduce NPSHr and increase
NPSHa
• Raise the supply tank level or pressure
• Reduce fluid temperature
• Reduce head loss in suction line
– Use low resistance isolation valves (ball, gate, or butterfly valves
vs. globe valve)
– Use larger pipe size to reduce fluid velocity and head loss
– Minimize number of elbows and other fittings
• Install an inducer on the impeller
• Use impeller and casing made of harder material
• Select a different pump with lower NPSHr
• If designing a new system:
– Raise supply tank elevation
– Lower pump suction
Pump Affinity Rules
• Pump performance can be changed by changing
the pump speed or impeller diameter
– Changing pump speed
Capacity Q1 /Q2 =N1 / N2
Head H1 /H2 = (N1/N2)2
Power P1 /P2 = (N1/N2)3

– Changing pump impeller diameter*

Capacity Q1 /Q2 = D1 /D2
Head H1 /H2 = (D1/D2)2
Power P1 /P2 = (D1/D2)3
* Use for small changes
Affinity Rules for Speed Are Very Accurate
Affinity Rules for Impeller Size Not as
Accurate Due to Hydraulic Dissimilarities
• Best to interpolate between the manufacturer’s
catalog curves
Sizing a Centrifugal Pump
• A pump is selected to meet the hydraulic needs of the piping
system based on design flow rates, system configuration, and
end user requirements
– Static head: elevation and pressure differences between
the end user and supply tank
𝑺𝒕𝒂𝒕𝒊𝒄 𝑯𝒆𝒂𝒅 = ∆ 𝑬𝒍𝒆𝒗𝒂𝒕𝒊𝒐𝒏 𝑯𝒆𝒂𝒅 + ∆ 𝑷𝒓𝒆𝒔𝒔𝒖𝒓𝒆 𝑯𝒆𝒂𝒅

𝑬𝒍𝒆𝒗𝒂𝒕𝒊𝒐𝒏 𝒐𝒇 𝑷𝒓𝒐𝒅𝒖𝒄𝒕 𝑬𝒍𝒆𝒗𝒂𝒕𝒊𝒐𝒏 𝒐𝒇 𝑺𝒖𝒑𝒑𝒍𝒚

∆ 𝑬𝒍𝒆𝒗𝒂𝒕𝒊𝒐𝒏 𝑯𝒆𝒂𝒅 = −
𝑻𝒂𝒏𝒌 𝑳𝒊𝒒𝒖𝒊𝒅 𝑺𝒖𝒓𝒇𝒂𝒄𝒆 𝑻𝒂𝒏𝒌 𝑳𝒊𝒒𝒖𝒊𝒅 𝑺𝒖𝒓𝒇𝒂𝒄𝒆

𝑫𝒊𝒔𝒄𝒉𝒂𝒓𝒈𝒆 𝑻𝒂𝒏𝒌 𝑺𝒖𝒑𝒑𝒍𝒚 𝑻𝒂𝒏𝒌 𝟏𝟒𝟒

∆ 𝑷𝒓𝒆𝒔𝒔𝒖𝒓𝒆 𝑯𝒆𝒂𝒅 = −
𝑺𝒖𝒓𝒇𝒂𝒄𝒆 𝑷𝒓𝒆𝒔𝒔𝒖𝒓𝒆 𝑺𝒖𝒓𝒇𝒂𝒄𝒆 𝑷𝒓𝒆𝒔𝒔𝒖𝒓𝒆 𝝆

– Dynamic head: sum of head loss for pipelines, valves,

fittings, and components at the desired flow rate
• Includes the “Control Head”, the desired amount of head available
for control of flow or pressure using a control valve
– Design Margin
Example: Sizing a Centrifugal Pump

• Static Head = Δ Elevation Head + Δ Pressure Head

– Elevation Head = (50 ft + 15 ft) – (0 ft + 25 ft) = 40 ft
– Pressure Head = (10 psi – 0 psi) x 144/ 62.4 = 23.1 ft
– Total Static Head = 40 ft + 23.1 ft = 63.1 ft
• Dynamic Head =  Individual Head Losses
– Dynamic head = (1.2 + 1.5 + 57.8 + 1.3 + 1.5) = 63.3 ft
Example: Sizing a Centrifugal Pump
• Control Head
– Varies depending on controllability required for the process
– Various thumb rules are used:
• 30% of total dynamic head
• 10 to 25 psi pressure drop at maximum flow rate
– Head produced by the pump above that needed by the process will
be dissipated across the control valve as additional control head
• Design Margin
– Based on uncertainty in the amount of dynamic head
– 10 to 30% of dynamic head
• Total Head Needed = 170.5 ft
– Static + dynamic head: 126.4 ft
– Control head: 15 psi = 34.6 ft
– Design margin: 15% (of 63.3 ft of dynamic head) = 9.5 ft
Example: Sizing a Centrifugal Pump
• Range charts (family curves)
– 2,500 gpm and 170 ft TH falls
in envelop of 3 or 4 potential
pumps
• Select a pump and impeller
trim that has an operating
point close to the BEP
Example: Sizing a Centrifugal Pump

• Pump and control valve sizing go hand-in-hand

– With a pump selected and the Total Head determined, the actual control
valve differential pressure can be calculated and the valve can be
appropriately sized
– Additional pump head added because of the design margin will have to
be dissipated across the control valve
Pump and System Interaction: Operating Point
• Pump must operate somewhere on its curve
• Pump operates at the intersection of the Pump Curve
and the System Resistance Curve
 Effect of Throttling on the SRC
• Throttling can be viewed
two ways on the Pump and
System Resistance Curves
– SRC becomes steeper and
pivots as the operating
point moves to the left on
the pump curve

– SRC represents the system

with all control valves fully
open and stays the same,
the amount of head loss
across the throttled valve is
the difference between the
SRC and pump curve at the
pump flow rate
40
 Control Valve Regulates System Flow Rate
• System operating at
2500, 2000, 1500, and
1000 gpm for 2,000
hours/year each
— Total power used:
725,978 kWh
— Energy Costs at
$0.10/kWh: $72,598
 Pump Speed Controls System Flow Rate
• System operating at
2500, 2000, 1500, and
1000 gpm for 2,000
hours/year each
— Total power used:
388,600 kWh
— Total Energy Costs at
$0.10/kWh: $38,860
— Savings: $33,740
(46%)
Parallel Pump Operation
Series Pump Operation
 Questions?
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Centrifugal Pump Webinar

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