WILO SE

9F Unit 905, Pearl Bank Centre

146 Valero Street, Salcedo Village,
Makati City Philippines
T : 02- 533 - 4016 (www.wilo.com)

PUMP FUNDAMENTALS

Darwin S. Ibanez
darwin.ibanez@wilo-
philippines.com
0917 865 3046
What will we cover?

• Pumping System
• Capacity (Flow Rate)
• Total Dynamic Head
• Static Head
• Dynamic Head
• Suction head
• Suction lift
• Affinity Laws
• NPSHA
• System Curve
Pumping Systems

A pumping system consists of:

• All of the piping
• Vessel
• Other types of equipment (valves, meters, elbows, etc.),
• Everything that is interconnected to form a path for liquid
to flow
Pumping Systems

The amount of liquid

flowing through a
pumping system is
known as the
capacity or flow rate
Pumping Systems

Head
A pump must overcome
the resistance of a Pump
Resistance
pumping system in order
to cause a liquid to flow
completely through the
system

Resistance to liquid flow is

known as a pumping
system’s Total Dynamic
Head (TDH)
Pumping Systems

Total Dynamic Head (TDH) is the sum of two parts:

Static Head
+
Dynamic Head

Total Dynamic Head

All Head values are measured in Feet or Meters -

Trust me for now, more later !!!
Pumping Systems

Static head represents the

resistance of a pumping
system before the liquid
is set into motion

Dynamic head represents

the resistance of a
pumping system while
the pumped fluid is in
motion
Static Head

The primary component of Static head is the elevation difference

between:
• the surface of the liquid at the point of suction
• the surface of the liquid at the point of discharge
Static head also accounts for the pressure differential between the point
of suction and the point of discharge

Static head does not vary with capacity

Centrifugal Pump Hydraulics
Static Pump Head (Flooded Suction)

Example #1 Non-Operating (Static)

Static
Head
Discharge
Head
HD
Suction
Static Head=HD - HS
Head
HS

Pump
Centerline
Centrifugal Pump Hydraulics
Static Pump Head (Flooded Suction)
Example #1 Non-Operating (Static)

120
FT
160
FT Static Head=
160’-40’= 120’
40
FT

Pump
Centerline
Centrifugal Pump Hydraulics
Static Pump Head (Suction Lift)

Example #2 Non-Operating (Static)

Discharge
Head
Static
HD
Head

Pump
Centerline
Suction
Lift L Static Head=HD + LS
S
Note: suction lift requires
self priming pumps or
suction check valves
Centrifugal Pump Hydraulics
Static Pump Head (Suction Lift)

Example #2 Non-Operating (Static)

160
FT
180
FT

Pump
Centerline
20
FT Static Head=
160’+20’= 180’
Dynamic Head

50 psi 30 psi

Dynamic head losses are those losses that are realized

once fluid begins to flow through the pumping
system
These losses are due to friction; often called Friction
Losses
Dynamic head losses are a function of capacity
Dynamic Head

Dynamic head losses are made up of two parts:

Each component of a
pumping system
contributes to the
dynamic head losses for
the entire system
through Friction Losses

Accelerating the pumped

fluid from zero to it’s
final velocity requires
energy - this is known as
Velocity Head Loss
Friction Head Loss

Friction head losses increase drastically with increased flow

• A typical friction loss table for piping illustrates friction losses as a
function of capacity, pipe diameter & pipe length
• See the reference materials in your classroom handout
Head loss in Feet (PSI) per 100’ of pipe
1" 1.25" 1.50" 2"
GPM
Ft. PSI Ft. PSI Ft. PSI Ft. PSI
10 6.9 3.0 1.8 0.8 0.8 0.4 0.3 0.1
20 25.1 10.8 6.3 2.7 2.9 1.3 0.9 0.4
30 54.6 23.5 13.6 5.6 6.3 2.7 1.8 0.8
40 95.0 40.9 23.5 10.1 10.8 4.6 3.1 1.3
45 30.7 13.2 13.5 5.8 3.9 1.7
70 68.8 29.6 31.3 13.5 8.9 3.8
100 62.2 26.8 17.4 7.5
Friction Head Loss

Every component of a pumping system has associated

friction losses
Equivalent length
PSI Flow meters
TYPE 1” 2” 3” 4”
20 90 1.6 3.1 4.4 5.9
1” 2” 3” Elbow
15 Gate 1.2 2.6 2.8 2.9
valve
10 Globe 45 70 94 120
valve
5 Swing 7.2 17 27 38
GPM check
25 100 175 250
Friction loss tables can be obtained from the component manufacturer
or various other reference sources
Friction losses are a function of capacity and component size
Friction Head Loss
20’

System Flow = 100 GPM Nozzle

9.2’ req’d
Pump 18’
20’ 20’
Static Head
2” Pipe 2’

4’ Suction Lift

In this example the friction loss calculation is:

4’ Equivalent length of fittings:
8’ 3 elbows = 3 x (K*V2/2g) = 3 * 0.36 *1.42 = 1.53’
Pipe length = 4’ + 4’ + 2’ + 20’ + 20’ + 18’ + 20’ = 88’
Total friction losses = 1.5’ + (88’ x 17.4/100) = 17’

> Where the pipe friction loss is 17.4’ per hundred feet
Friction Head Loss

System Flow = 100 GPM 20’

Static Head
Nozzle
9.2’ req’d
15’ Suction Head 18’
Pump 20’
20’ 20’
2” Pipe 2’

In this example the friction loss calculation is:

Equivalent length of fittings:

2 elbows = 2 x (0.36 *1.42)’ = 1.02’
Pipe length = 20’ + 20’ + 18’ + 20’ = 78’
Total friction losses = 1.02 +(78’ x 17.4/100) = 15’
 Velocity Head

Velocity ft/sec Hv = V2/2g = .0155 V2

Velocity head loss
in feet

• Velocity Head Loss is simply a function of the velocity of

the fluid flowing through the pumping system
• This value is usually small, and often neglected - Be
Careful
• The appropriate value is given in many friction loss tables
Total Dynamic Head

What is my
system’s TDH?

The pumping
system’s total
dynamic head is
simply the sum of
the system’s static
head and dynamic
head
Total Dynamic Head

20’

System Flow = 100 GPM Nozzle

9.2’ req’d
Pump 18’
20’ 20’
Static Head
2” Pipe 2’

4’ Suction Lift

In this example the total dynamic head is equal to:

4’ Static head = 24’
8’ Dynamic head
> friction losses = 17’
> nozzle = 9.2’
TDH = 24’ + 17’ + 9.2 = 50.2’
Total Dynamic Head

System Flow = 100 GPM 20’

Static Head
Nozzle
9.2’ req’d
15’ Suction Head 18’
Pump 20’
20’ 20’
2” Pipe 2’

In this example the total dynamic head is equal to:

Static head = 3’
Dynamic head
>friction losses = 15’
>nozzle = 9.2’
TDH = 3’ + 15.5’ + 9.2 = 29.1’
Head vs. Pressure

A given pump will

generate the same
Because... ‘feet of head’
regardless of the liquid
being pumped but...
...the discharge pressure
will vary with the
specific gravity of the
liquid!
Centrifugal pumps
develop head - not
pressure!
Head vs. Pressure
Effect of Specific Gravity on Static Head
Specific Gravity

Water = 8.33 lbs/gal Gasoline = 6.0 lbs/gal

• Specific gravity is the ratio of the weight of a liquid

to the weight of water

• The specific gravity of gasoline is 6.0 / 8.33 = .72

 Head vs. Pressure

Water Gasoline

100 PSI 72 PSI

Two identical pumps operating in identical systems will develop the

same ‘head’ but...
discharge gauges will give different readings if the specific gravity
of the liquids being pumped is different
Specific Gravity

Is very important because:

• It affects the brake horsepower requirements of the pump, and...

• All pressure information is converted to ‘feet of head’ by using the
specific gravity of the liquid being pumped

• PSI = Feet of Head x SG Feet of Head = PSI x 2.31

2.31 SG

• Multiply water Hp x SG to get actual Hp

>Example: 20 Hp pump x (.72 fuel) = 14.4 Hp required
Effect S.G. On Pump Performance
System Curve

A System Curve is a graphical representation of

the resistance behavior (TDH) of a pumping
system over it’s entire capacity range
A system curve shows:
>the static head component ( which is constant
over the entire capacity range)
>the dynamic head component ( which increases
with capacity)
System Curve

HEAD

Dynamic
Head

Static Head

CAPACITY

The System curve is a function of the size of piping, type of

equipment, and physical layout of a pumping system
System Curve

HEAD

Dynamic
Head

Static Head
CAPACITY
• The system designer can change the shape of the System
curve by altering the size of piping, type of equipment, and
physical layout of the pumping system
System Curve

HEAD

Dynamic
Head

Static Head

CAPACITY
• The end user can change the shape of the System curve by opening
or closing system valves, changing equipment or piping layouts, and
varying the liquid levels in the suction or discharge tanks
Mental Note

It is a good system design practice to include suction and

discharge valves in a pumping system.

Isolating the pump for maintenance

considerations
Using the discharge valve as a
throttling valve to control the
pump
A discharge check valve may also be
required in high discharge head
applications
A suction check valve is required for
suction lift without a self primer.
 The Suction Side…

Net Positive Suction Head

Calculation and Application
Suction Side Limitations

The importance of keeping within the

suction side limitations of any pump
cannot be emphasized too greatly

KEEP IN MIND THAT...

...90% of all pump problems are due to poor suction

conditions!
Suction Side Limitations

NPSH Available is the term that describes

whether the pressure on the suction side is
adequate for proper pump operation

Self-priming applications must also consider

the amount of air the pump is required to
evacuate
NPSH Available

Proper system design allows for the highest possible NPSHA

Factors affecting NPSH Available include:

Pressure acting on the surface of the liquid

Relative elevation of the liquid
Friction losses in the suction piping
Velocity of the liquid in the suction piping
Vapor pressure of the liquid

These factors constitute a system’s dynamic

suction condition and must be carefully
considered before a final pump selection can
be made
NPSH - The Rule

NPSHA must be sufficiently greater than NPSHR in

order to prevent:

• Poor pump performance

• Excessive vibration
• Noisy operation
• Premature failure of components
• Cavitation
Cavitation - Definition

Vaporization of a liquid followed by rapid condensation (bubble collapse). Occurs when the
local pressure drops below the vapor pressure.
Cavitation - Impeller

Cavitation can occur at the inlet of the impeller if the suction

pressure falls below the liquid vapor pressure.
Cavitation - Effects

* Large vapor volumes can * Bubbles collapsing create

cause reduction in head intense pressures and
generation, or loss of prime. (10,000 psi) shock waves.

* Intense pressures near metal

surfaces exceed material
strength and fatigue metals.

* Large vapor volumes can * Creates pitted surfaces.

cause surging and unstable flows.
 NPSHR

1) Suction head required

to prevent vaporization at
the impeller inlet.
2) The sum of all head
losses / reductions
between the pump inlet
(A) and point of lowest
pressure in the pump (D).
Cavitation Detection & Cures

> Tell Tale Indicators

• Audible Noise (Pumping Rocks\Cracking)
• Loss of Pressure\Flow
• Pitted Impellers
> Verification
• Problem Eliminated By Throttling
• Pressure\Power Triangulation
> Cures
• Increase NPSHa
• Eliminate Suction Obstructions
• Increase System Head
Pressure Acting On The Surface Of The Liquid

Pressure acting on the surface

of a liquid “pushes” it into the
pump

Atmospheric pressure
Pressurized tank
Vacuum tank

The pressure on the liquid is

the major contributor to
the NPSHA of a system
NPSHA

• Pressure values must be converted to “feet of head” using

the following formula:

Feet of head = PSI x 2.31

specific gravity

• Atmospheric pressure = 14.7 PSI (sea level) = 34 Feet

• Pressurized vessel = Absolute pressure gauge reading
• Vacuum vessel = Vacuum gauge reading
 Relative Elevation Of The Liquid

Static suction head implies that the liquid

level is above the inlet of the pump

Static suction lift implies that the liquid

level is below the inlet of the pump

PUMP

• Static suction head increases NPSHA because

gravity helps pull liquid into the pump
• Static suction lift decreases NPSHA because
the pump must work against gravity
Friction Losses In The Suction Piping

20 mm Hg

10 mm Hg

Friction losses in suction piping decrease NPSHA

Factors affecting friction losses include:

>Size of piping
>length of piping
>Fittings and equipment
Vapor Pressure Of The Liquid

The vapor pressure of the liquid

must be carefully considered to
insure proper pump operation

• Vapor pressure indicates the

dividing line between a liquid and
its gaseous state
• Vapor pressure typically varies with
temperature
• The pressure in the suction line
must never fall below the vapor
pressure of the liquid
Vapor Pressure

A liquid with a vapor pressure of 8 psi @ 100 deg F

requires at least 8 psi of pressure acting on it’s
surface to stay a liquid.

The pressure in a fluid handling system must be

equal to or greater than the vapor pressure of the
liquid at every point throughout that system.

Without sufficient pressure the liquid will flash

into a gas and become un-pumpable.
Just Give Me The Formula
Net Positive Suction Head

Available (System) = PB + HS - HF - PV

Atmospheric (Barometric) Pressure Above

PB ( + ) The Suction Source (FT) - Absolute

Lowest Liquid Height Above The Suction

HS ( + )
Centerline Of The Pump (FT)

HF ( - ) Friction Loss From The Source To The

Suction Centerline Of The Pump (FT)

Vapor Pressure Of the Liquid At The

PV ( - )
Maximum Operating Temperature (FT) -
Absolute
Net Positive Suction Head Available

NPSHA = PB + HS - HF - PV

PB All Values Must Be Converted To

Feet From Absolute Pressures!
Use Charts Attached For Vapor
PV Pressures At The Proper
Temperature
HS Use The Minimum Liquid Height
Above The Pump Suction!

HF
NPSHA

Example A
Flooded Suction - Ambient Temp. - Sea Level

PB = 14.7
PSIA NPSHA = PB + HS - HF - PV

= 34 FT + 15 FT - 5 FT - 1.0 FT
60 O F
HS = VP=? = 43.0 FT
15 FT

HF = 5 ‘
NPSHA

Example B
Flooded Suction - High Temp. - High Altitude (5500 FT)

PB = 12.0 PSIA
NPSHA = PB + HS - HF - PV

200 O F = 27.6 FT + 15 FT - 5 FT - 27.6 FT

VP=?
= 10.0 FT
HS =
15 FT

HF = 5 FT
NPSHA
Example C
Suction Lift - Amb. Temp. - Sea Level

NPSHA = PB + HS - HF - PV

HF = 5 FT = 34 FT + (-15 FT) - 5 FT -
1.0 FT
= 13.4 FT
HS =
15 FT PB = 14.7
PSIA

60 O F
VP=1.0
NPSHA

Example D
Boiler Feed - Sea Level

1.0
NPSHA = PB + HS - HF - PV
PSIA

= 2.3 FT + 6 FT - 1 FT - 2.2 FT
100 F O

VP=? = 5.1 FT
HS =
6 FT

HF = 1 FT
THANK YOU!