Pumps and Pumping Systems

• Categories and Types

• Performance Characteristics
• Key Design Parameters
• Calculation Method
• Specification Data Sheet
• Selection Guidelines
• Control Systems
• Typical Operating Problems
 Pumps and Pumping Systems
Categories and Types

• Positive Displacement
• Reciprocating
• Rotary

• Kinetic or Centrifugal
• Radial
• Axial
Pumps and Pumping Systems
Selection Guidelines
1820m

30.5m

2.3m3/h
227m3/h
Pumps and Pumping Systems
Positive Displacement Pumps
 Pumps and Pumping Systems
Centrifugal Pumps

1.Casing, volute
2. Impeller, vanes, vane
tips, backplate,
frontplate (shroud),
back vanes, pressure 8
equalising passages
3. Back cover parallel
to Plane of the impeller
intake
4. Stuffing Box -
Gland/mechanical seal
housing,
packing/lantern ring
5. Pump shaft
6. Pump casing
7. Bearing housing
8. Bearings
9. Bearing seals
9
Pumps and Pumping Systems
Centrifugal Pumps
Pumps and Pumping Systems
Centrifugal Pumps
Pumps and Pumping Systems
Centrifugal Pumps
Pumps and Pumping Systems
Centrifugal Pumps
 Pumps and Pumping Systems

• Positive displacement Pumps are

Constant Volume Pumps

• Centrifugal Pumps are

Constant Head Pumps
 Pumps and Pumping Systems
Centrifugal Pumps
Effect of Fluid Density on Pressure with Constant Head

Water Brine Gasoline

SG=1.0 SG=1.2 SG=0.75
100m

100m

100m
9.8 bar 11.8 bar 7.4 bar

P = gh: g = 9.81 m/s2

 Pumps and Pumping Systems
Centrifugal Pumps
Pump Head Calculation: Example 1
Calculate the total differential head for the following
pumping system:
8” check valve

1.8 bar
8” gate valve
20m

45m of 8” pipe
3m of 10” pipe

340 m3/h capacity

3m

Hydrocarbon, sg = 1, μ = 0.9cP
 Pumps and Pumping Systems
Centrifugal Pumps
Pump Head Calculation: Example 1
Discharge head:

Static head = 20m

Pressure head = 280/(9.81x1) = 28.5 m

Friction: for 8” line, flow = 340 m3/h:

u = 340/3600/((π/4)*0.2032) = 2.9m/s

Re = 1000 x 2.9 x 0.203/0.0009 = 6.5 x 105

ε/d = 0.0018/7.98 = 0.00023

f = 0.016

ΔP/100m = 0.016 x 100 x 1000 x 2.92/(2 x 0.203) = 33.1 kPa/100m

 Pumps and Pumping Systems
Centrifugal Pumps
Pump Head Calculation: Example 1
Length of 8” pipe = 45m
3 x 8” elbows = 3 x 20.2ft = 60.6ft = 18.5m
1 x gate valve = 4.5 ft = 1.4 m
1 x check valve = 50 ft = 15.2m
Exit loss = 20 ft = 6.1m
Total = = 86.2m

ΔP friction = 86.2/100 x 33.1 = 28.5 kPa

Δh friction = 28.5/(9.81 x 1) = 2.9 m, add 20% safety for pump
Δh friction = 1.2 * 2.9 = 3.5 m

Total Discharge head = 3.5 + 20 + 28.5 = 52 m

 Pumps and Pumping Systems
Centrifugal Pumps
Pump Head Calculation: Example 1
Suction head:

Static head = -3m

Pressure head = 100/(9.81x1) = 10.2 m

Friction: for 10” line, flow = 340 m3/h:

u = 340/3600/((π/4)*0.2552) = 1.85m/s

Re = 1000 x 1.85 x 0.255/0.0009 = 5.2 x 10 5

ε/d = 0.0018/10.02 = 0.00018

f = 0.015

ΔP/100m = 0.015 x 100 x 1000 x 1.852/(2 x 0.255) = 10.1 kPa/100m

 Pumps and Pumping Systems
Centrifugal Pumps
Pump Head Calculation: Example 1
Length of 10” pipe = 3m
1 x 10” elbows = 26ft = 8m
Entrance loss = 15 ft = 4.6m
Total = = 15.6m

ΔP friction = 15.6/100 x 10.1 = 1.6 kPa

Δh friction = 1.6/(9.81 x 1) = 0.16 m, add 20% safety for pump
Δh friction = 1.2 * 0.16 = 0.2 m

Total Suction head = -3 + 10.2 – 0.2 = 7 m

Total differential head = 52 – 7 = 45 m

Pumps and Pumping Systems
Centrifugal Pumps
Pumps and Pumping Systems
Centrifugal Pumps
Pumps and Pumping Systems
Centrifugal Pumps
 Pumps and Pumping Systems
Centrifugal Pumps

 For similar conditions of flow (ie the same

efficiency):
– Capacity is directly proportional to speed
– Head is directly proportional to the square of
speed &
– Power is directly proportional to the cube of
speed
 Pumps and Pumping Systems
Centrifugal Pumps

This translates into the corresponding formulae (for variations in

speed with impeller diameter remaining constant) :

Q2 = Q1 x (N2 ÷ N1)
H2 = H1 x (N2 ÷ N1)2 and
P2 = P1 x (N2 ÷ N1)3

However, the above formulae can also be used to determine the

relationship between impeller Diameter and flow, Head and Power
by substituting speed (N) with Impeller Diameter (D), keeping
Speed constant. Results in this case are approximate as these
formulae are analogous to the Affinity Laws above.

Q2 = Q1 x (D2 ÷ D1)
H2 = H1 x (D2 ÷ D1)2 and
P2 = P1 x (D2 ÷ D1)3
Pumps and Pumping Systems
Centrifugal Pumps

Design Parameters

• Temperature
• Properties
• Capacity
• Head (TDH)
• Cavitation (NPSH)
• Horsepower
• Efficiency
Pumps and Pumping Systems
Centrifugal Pumps

Liquid Properties

• Specific Gravity
• Composition/Quality
• Vapour Pressure
• Viscosity
Pumps and Pumping Systems
Effect of Viscosity on Pump Performance
 Pumps and
Pumping Systems
Viscosity Correction
Pumps and Pumping Systems
Centrifugal Pumps

NPSH
• Cavitation

• NPSH = Net Positive Suction Head

• Available
• Required

• Calculation
 Pumps and Pumping Systems
Centrifugal Pumps

Cavitation
 Formation of vapour bubbles in pump
 Occurs when pressure NPSHA falls below
vapour pressure
 Reduces capacity and efficiency
 Eventually flow ceases
 Causes noise, vibration, erosion and pump
failure if allowed to persist for a prolonged
period of time
 Pumps and Pumping Systems
Centrifugal Pumps
Avoiding Cavitation
 Establish accurate range of flow for pump.
 If running speed higher than pump curve data multiply
NPSHR at curve speed by speed ratio ( eg. NPSHR = 3.2 x
(1800 / 1500) = 3.84 m)
 Avoid suction specific speeds of over 6750 (metric) or
11,000 (usgpm).
 If possible select a pump with rated flow within 10% of
best efficiency point (BEP).
 Select for NPSHA 10% above NPSHR.
 Require witnessed pump tests over flow range for critical
service applications.
 Don’t accept model tests as a basis for larger pumps.
 Centrifugal Pumps
NPSH
Net Positive Suction Head Available (NPSHA)= Static Head + Head
developed

NPSHA = hps + hs – hvps – hfs

 hps Pressure Head

 hs Static suction Head (@ min. supply level)
 hvps Vapour pressure Head (@ max. pumping temperature)
 hfs Friction Head
ps

hvps
hs

hfs
 Centrifugal Pumps
NPSH Example
The cooling water used for cooling of the reactor during the reaction is
pumped from an open tank. Calculate the NPSHA for the pump given the
following conditions:
Temperature of Water = 30c, Density (r) @ 30C = 995.7 kg / m3
Vapour Pr @ 30c = 4.241 kPa (abs), Ha = atmospheric pr = 101.325 kPa
Gravitational acceleration = 9.81 m/s2
 Centrifugal Pumps

NPSH Example 1
Using the formula: NPSHA = Hts – Hvap

Where Hts = total static head

= Atmospheric Pr (Ha) – suction lift (Hs) –
friction losses (Hf)
= Ha x 1000 – 2.6 – (1 + 0.9 + 0.4 + 0.1)
gxr
= 101.325 x 1000 – 2.6 – 2.4
9.81 x 995.7
= 10.38 – 2.6 – 2.4
= 5.38m
Hvap = 4.241 x 1000
9.81 x 995.7
= 0.43m
NPSHA = 5.38 – 0.43
= 4.95m

Add 10% safety factor for value specified to pump supplier:

The NPSH required is thus 4.95/1.1 = 4.5 m
 Centrifugal Pumps
NPSH Example 2
Water temperature - 125 C
Density @ 125 C – 939 kg/m3
Vapour pr @ 125 C = 230 kPa (absolute)
Gauge pr = 130 kPag
Gravitational acceleration = g = 9.81 m/s^2
Suction head (Hs) = 4.0m max, 1.0m min
Pipe friction loss = 1.1m
Valve friction loss = 0.1m
NPSHA = Hts - Hvap
max

Hs’min = 1m
 Centrifugal Pumps
NPSH Example 2

Hts = Ha + Hs - Hf
= (101.325 + 130) x 1000 + 1 – (1.1 + 0.1)
9.81 x 939
= 25.1 + 1 – 1.2
= 24.9 m
Hvap = 230 x 1000
9.81 x 939
= 25.0 m
NPSHA = 24.9 – 25.0
= -0.1 m

(as NPSHA is negative, the pump will start to cavitate when the tank level drops to
minimum level)

To solve this problem? Increase elevation of tank!

 Pumps and Pumping Systems
Centrifugal Pumps

Pump Calculation Method

• Define Liquid Properties: SG, VP, Vis 1
• Establish Flow Rates1: Normal & Design
• Calculate ‘Net” Suction Pressure
• Calculate NPSH ‘Available’
• Calculate ‘Net’ Discharge Pressure at Normal Flow including
Control Valve ΔP 2
• Calculate Differential Pressure & Head
• Select Efficiency: Calculate Power

1. At pumping temperature
2. Allow ⅓ of total friction ΔP at Normal Flow for control valve.
Verify control valve ΔP at Design Flow minimum 70 kPa
 Pumps and Pumping Systems

Centrifugal Reciprocating Rotary

Pressure max, bar abs 350 1000 350
Temperature max, ºC 500 370 400
ΔP max, kPa 200 1400 200
Capacity max, m3/h 3600 450 340
Viscocity max Pa.s 0.2 400 400
Efficiency, % range 50–80 60–90 40-85
Capacity Turndown H M M
Relative Cost L H M

H = High, M = Medium, L = Low

Pumps and Pumping Systems
Typical Operating Problems

• Cavitation / Low NPSH

• Low Suction Pressure
• High Discharge Pressure
• High SpGr/Viscocity
• Capacity Loss
• Driver Overload