Pumping Station Id stn-1 stn-2 stn-3 RS/UNIT 6

VT pump
% 90.14 90.32 90.26
effi
motor
efficiency % 94.9 94.9 94.6
@3/4 load
discharge m3/hour 3840 3785 3785
head m 69 92 83
motor kw 1000 1300 1200
no. of pumps installed 6 6 6
supply voltage kV 11 11 11
kWh/ML/day 4884 6500 5886
Rs./ML/day 29307 38998 35318

Calculation for One Pump at Pumping Station - 1

CASE - 1 CASE - 2 CASE - 3
1.0 Engineering data
1.1 Pump data
1.1.1 Type of pump : Centrifugal, turbine : Centrifugal, turbine : Centrifugal, turbine
1.1.2 Pump mounting : Vertical : Vertical : Vertical
1.1.3 Pump service : Water supply : Water supply : Water supply
1.1.5 Pump head H : 69 m H : 92 m H : 83 m
1.1.6 Pump flow or discharge Q : 3840 m3/hr Q : 3785 m3/hr Q : 3785 m3/hr
: 3840 KL/hr : 3785 KL/hr : 3785 KL/hr
: 1.067 m3/s : 1.051 m3/s : 1.051 m3/s
: 1066.67 ltr/s : 1051.39 ltr/s : 1051.39 ltr/s
: 3.84 ML/hr : 3.785 ML/hr : 3.785 ML/hr
: 92.16 MLD : 90.84 MLD : 90.84 MLD
1.1.7 Efficiency of pump hp : 90.14 % hp : 90.32 % hp : 90.26 %
1.2 Driving motor data
1.2.1 Motor rating (Output power) Pm : 1000 kW Pm : 1300 kW Pm : 1200 kW
1.2.2 Supply voltage V : 11 kV V : 11 kV V : 11 kV
1.2.3 Power factor
i. PF @ 100% load cosq : 0.86 cosq : 0.86 cosq : 0.86
ii. PF @ 75% load cosq : 0.85 cosq : 0.85 cosq : 0.85
1.2.4 Motor efficiency
i. Efficiency @ 100% load hm : 95.1 % hm : 95.1 % hm : 95.1 %
ii. Efficiency @ 75% load hm : 94.9 % hm : 94.9 % hm : 94.6 %
1.3 Misc. technical data
1.3.1 Density of water r = 1000 kg/m3 r = 1000 kg/m3 r = 1000 kg/m3
1.3.2 Acceleration due to gravity g : 9.81 m/s2 g : 9.81 m/s2 g : 9.81 m/s2
1.3.3 Pump operating hours per day hrs : 22 hr/day hrs : 22 hr/day hrs : 22 hr/day

2.0 Power input required for pumping

rgQH rgQH rgQH
2.1 Hydraulic power required for pumping PH = kW PH = kW PH = kW
1000 1000 1000
1000 x 9.81 x 1.067 x 69 1000 x 9.81 x 1.067 x 69 1000 x 9.81 x 1.067 x 69
= = =
1000 1000 1000
PH = 722.02 kW PH = 948.90 kW PH = 856.07 kW

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 PH PH PH
2.2 Power input to pump P = kW P = kW P = kW
hp hp hp
722.02 948.90 856.07
= kW = kW = kW
90.14 90.32 90.26
P = 800.99 kW P = 1050.60 kW P = 948.45 kW

3.0 Power input to driving motor

P P P
3.1 Power input to driving motor PM = kW PM = kW PM = kW
hM x hC hM x hC hM x hC
where
Motor efficiency considered hM : 94.9 % (load>80%) hM : 94.9 % (load>80%) hM : 94.6 % (load>80%)
Coupling efficiency (assumed) hC : 99 % hC : 99 % hC : 99 %
800.99 1050.60 948.45
PM = PM = PM =
94.9X99 94.9X99 94.6X99
Motor input power PM = 852.57 kW PM = 1118.24 kW PM = 1012.72 kW

3.2 Power input to driving pump motor for PM1 PM1 PM1
01 ML/hr flow PM1 = kW PM1 = kW PM1 = kW
Q in ML Q in ML Q in ML
852.57 1118.24 1012.72
PM1 = kW PM1 = kW PM1 = kW
3.84 3.785 3.785
PM1 = 222.02 kW/ML PM1 = 295.44 kW/ML PM1 = 267.56 kW/ML

4.0 Power input/ML/day

4.1 Power input/ML/day PM2 = PM1 x hrs of operation PM2 = PM1 x hrs of operation PM2 = PM1 x hrs of operation
= 226.12 x 22 = 226.12 x 22 = 226.12 x 22
PM2 = 4884 kWh/ML/day PM2 = 6500 kWh/ML/day PM2 = 5886 kWh/ML/day
29307 kWh/ML/day (for all pump) 38998 kWh/ML/day (for all pump) 35318 kWh/ML/day (for all pump)
5.0 Cost of power/ML/day
5.1 Estimated cost of power/ML/day EC1 = PM2 x Per unit cost EC1 = PM2 x Per unit cost EC1 = PM2 x Per unit cost
where
Per unit cost of power Rs. : 6.00 per kWh Rs. : 6.00 per kWh Rs. : 6.00 per kWh
EC1 = 29307 Rs./ML/day EC1 = 38998 Rs./ML/day EC1 = 35318 Rs./ML/day
175842 Rs./ML/day (for all pumps) 233988 Rs./ML/day (for all pumps) 211908 Rs./ML/day (for all pumps)

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5.3 for two similar pumps P1/P2 = (Q1/H1)/(Q2/H2) = n13D15/n23D25 = (n1/n2)3(D1/D2)3

6 Specific speed

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6.1 Specific speed : speed of rotation of geometrically similar pump of
such size ensuring delivery, Q of 75 ltr/sec at head, H
of 1 mtr
flow Q2 : 75 ltr/sec
: 0.075 m3/s
head H2 : 1 mtr
6.2 from equation 3.4 H1 / H 2 = (n1/n2)2 (D1/D2)2
H/ 1 = (n/ns)2 (D/Ds)2
6.3 from equation 2.6 Q1 / Q2 = (n1/n2) (D1/D2)3
Q / 0.075 = (n/ns) (D/Ds)3
6.4 Ds eliminated by raising equation 5.2 to 3/2 power H /1
3/2
= (n/ns)3 (D/Ds)3
6.5 divide equation 5.4 by 5.3 Q / 0.075 H 3/2
= (ns / n)3
3.65 n Ö Q
6.6 Specific speed, speed with dimensionsns =
H3/4
rpm Ögal/min rpmÖm3/s
ns = or 51.64
(foot)3/4 (m)3/4
nÖQ
6.7 nominal specific speed nq =
H3/4
6.8 dimensionless specific speed
nÖQ
substitute (gH) in place of H nq =
(gH)3/4

7 Pump shape number

7.1 Pump shape number Ns : dimensionless number - pump and its performance
independent of impeller size and liquid properties
1000 n Ö Q
Ns =
(gH)3/4

7 Pump shape number

Kns n√Q
7.2 also Pump shape number Ns =
(gH)3/4
pump speed n : rps rps
ft3/s
ft
32.2 ft/s2
value Kns : 0.095 1.232

8 Laws of affinity or similitudes

( )
2
8.1 with diameter D of impeller constant Q1/Q2 = n1/n2 Q1 n1 H1 n
= = 1
H1 / H 2 = (n1/n2)2 Q2 n2 H2 n2
P1 / P2 = (n1/n2)3
8.2 with speed n of impeller constant Q1/Q2 = D1/D2
H1 / H 2 = (D1/D2)2
P1 / P2 = (D1/D2)3

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 9 Understanding of head
9.1 components of head
9.1.1 suction head hss : +ve, mtr [source of supplu above pump center line]
9.1.2 suction lift hss : -ve, mtr [source of supplu below pump center line]
9.1.3 static discharge head hsd : mtr [pump discharge into open vessel, vertical
distance between pump centre line and point of free
discharge or surface of liquid
9.1.4 total static head hts : mtr [vertical distance between free level of source of
supply and point of free discharge or surface of liquid

9.1.5 velocity head hv = V2 / 2g mtr [kinetic energy per unit weight of

liquid handled]
9.1.6 friction head hfs : mtr [head to overcome resistance to flow in pipe and
hfd : fittings]
9.1.7 total suction head hs = hss + (V2/2g) - hfs
total suction head reading for pump : pressure gauge reading mounted on suction flange
converted to metre, corrected to pump centre line
plus velocity head at point of pr. measurement
hs = ± hgs + Zs + (Vs2/2g)
9.1.8 total discharge (dynamic) head hd = hsd + (Vd2/2g) + hfd
total discharge head reading for pump : pressure gauge reading mounted on discharge flange
converted to metre, corrected to pump centre line
plus velocity head at point of pr. measurement

hd = hgd + Zd + (Vd2/2g)
9.1.9 total head H, or total dynamic head TDH H = hd - hs mtr [with suction head]
H = hd + hs mtr [with suction lift]

9.1.10 Manometric head Hmano = Hmd - Hms mtr [difference in reading of pr. gauges
installed on suction and discharge flange
of pump]

10 Power required by pump

10.1 basic equation for pump power P = ggQH watts
power for different units of g as follows
QHg
10.2 power input ot pump - brake horse powe PS = bhp metric
K1 hp
10.2.1 value of factor K1 for different units Q H g K1
ltr/s mtr gm/cm3 75
m3/hr mtr gm/cm3 270
m3/s mtr kg/m3 75
QHg
10.3 power input ot pump - electric unit P = kW
K2 hp
10.3.1 value of factor K2 for different units Q H g K2

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 ltr/s mtr gm/cm3 102
m3/hr mtr gm/cm 3
367
kg/hr mtr gm/cm 3
200000
10.4 water horse power or liquid power QHg
PS = bhp metric
K1
QHg
P = kW
K2
GPM x total dynamic headin ft x g
P(hp) =
3960

11 Efficiency of pump
power output Pw x 100
11.1 Efficiecy of pump hp = % at pump coupling
powerinput Ps
11.2 overall efficiency h0 = hp x hm x hpulley/gear/belt %
liquid power x 100 %
h0 =
power input to prime mover
Q Hm g x 100
h0 = %
powerinput to shaft

12 Flow from pump through throttle plate (orifice plate)

12.1 cross sectional area of pipeline F1 : mm2
12.2 cross sectional area of throttle opening F2 : mm2
12.3 bore t : mm
12.4 flow coefficient with throttle plate, m1 : dimensionless unit, from curves
based on ratio F2/F1
12.5 basic principle, for smooth flow through Area : F2 > 0.1 F1
throttle plate
12.6 bore t ≈ 0.1 D1

flow through throttle plate Q = m1F2√ 2g (H1 - H2) m3/s

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 Page 1of2

Fundamentals of Pump Selection - Specimen # 5

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 1 Engineering data
1.1 liquid data
1.1.1 type of liquid : viscous liquid
1.1.2 specific weight g : 1.2 kg/dm3
: 1200 kg/m3
1.1.3 specific gravity r :
1.1.4 absolute viscosity h : 150 centi-poise
standard conversion 1 m2/s = 1.05 x 10-6 CP
kinematic viscosity v = 150 / 1.05x10-6
= CP / g
: 150 / 1.2
v : 125.0 x 10-6 m2/s
: 125.0 Cst
: 17.0 0
E
1.2 rated data for pump
1.2.1 maximum pump efficiency hp : % from curves
1.2.2 other parameters at max. efficiency point from curves
i. pump discharge Q : 35 m3/hr
: 0.0097 m3/s
ii. impeller diameter D1 : 130 mm
ii. pump head, geodesic head Hgeod : 25 mtr
1.2.3 pump speed n : 1450 rpm
1.4 pipeline data
1.4.1 material of construction : steel drawn pipe
1.4.2 length of pipeline L : 100 mtr
1.4.3 internal diameter of pipeline d : 40 mm
: 0.04 mtr
: 4 cm
1.4.4 cross section area A : pd/42

: 3.142 x 0.0652 / 4
: 0.0013 mtr2
1.4.5 absolute roughness of pipe surface K : 0.05 from tables
1.5 pipe fittings data and equivalent length
1.5.1 900 bends
i. nos. of bends Nb : 8 nos.
ii. equivalent length for one bend Lb : 0.65 mtr, from standard tables
iii. equivalent length of bends Leqb = Nb x Lb
= 8 x 0.65
Leqb = 5.200 mtr
1.5.2 gate type valves
i. nos. of valves Nv : 4 nos.
ii. equivalent length for one valve Lv : 22.5 mtr, from standard tables
iii. head loss in valves Leqv = Nb x Lv
= 4 x 22.5
Leqv = 90.000 mtr
1.5.3 T-joint
i. nos. of T-joints Nt : 1 nos.
ii. equivalent length for one Tee Ltee : 1.8 mtr, from standard tables
iii. head loss in valves Leqt = Nt x Ltee
= 1 x 1.8
Leqt = 1.800 mtr
Vinscous liquid

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 Q : 5.0 m3/hr
H : 2.5 mLc

Page 2of2

Fundamentals of Pump Selection - Specimen # 4

1.6 throttle plate data on discharge at half flow

1.6.1 cross sectional area of pipeline F1 : 12.57 cm2
1.6.2 cross sectional area of throttle opening F2 : to be calculated cm2
1.6.3 bore t : mm
1.6.4 flow coefficient with throttle plate, m1 : dimensionless unit, from curves
based on ratio F2/F1
1.6.5 throttle opening diameter dt : to be calculated cm or mm

1.7 standard engineering data

1.7.1 acceleration due to gravity g : 9.81 mtr/sec2

2 Calculations total equi. length and head loss in pipeline

2.1 Total equi. length of pipeline incl. fittings Lt = L + Leqb + Leqv + Leqt
= 100 + 5.2 + 90.0 + 1.8
Lt = 197.0 mtr
2.2 velocity of fluid in pipeline V = Q/A
= 0.00972 / 0.00126
V = 7.737 mtr/sec
2.3 calculation for friction factor f
dVr
i. Reynolds Number Re =
m
v = m/r
Re = dV/v
= 0.065 x 2.93 / 38.1 x 10-6
= 8122.5
ratio of pipe dia to roughness d/K = 40.00 / 0.050
= 800
K/d = 0.00125
from standard curves, friction factor f = 0.038
2.4 loss of head for fluids in pipelines
1.10.1 head loss in pipeline hf = f (L/d) (v2g / 2g) mmWc or kg/cm2
= [0.038x(197/0.065)x(2.932*1050/2x9.81)]
hf = 685146 mmWc
converting into mtrLc = hf / g
= 685146 / 1.2
hf = 571.0 mLc (mtr liquid column)

3 Calculation for total head

3.1 total head htotal = hf + hgeod
= 571.0 + 25
htotal = 596.0 mtr

4 Calculation for actual impeller diameter

4.1 calculation for factor with Engler values and data from new Q-H curve

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 for 5.50E viscoous fluid, data from
4.1.1 Q = 8.4 m3/hr
curves
H = 5.5 mtr
factor = QÖH
= 8.4 x Ö 5.5
= 19.70

Page 3of2

Fundamentals of Pump Selection - Specimen # 4

4.1.2 using above value, factors from curve max.

factors Engler values
for kinematic viscosity 5.5 E
0 value
Q, m3/hr 8.4 Qf 0.83 QE 90.0x1.0 6.97
H, mtr 5.5 Hf 0.86 HE 79x0.97 4.73
hp, % 44 hf 0.42 hE 55x0.86 18.48

2.4 new Q - H and power curves drawn with Engler data

head at 35 m3/hr flow from new curves 95
H1 : mtr against required 40 mtr

impeller diameter required D1 : 260 mm

total actual head required as calculated 596.0
H2 : mtr

suggestion to trim impeller diameter D2 : to be calculated

2.6.1 impeller diameter, applying law of affinity H1 / H2 = (D1/D2)2
diameter of impeller after trimming D2 = D1 Ö H2/H1
= 260 x Ö 75.4 / 95
= 651.2 mm
say D2 = 232.0 mm

5 Power required with trimmed impeller for viscous liquid

5.1 power required with original impeller for PE1 : 29.00 kW, from curves
water at new flow and head
5.2 power required with trimmed impeller PE1 / PE2 = (D1/D2)3
for lifting water PE2 = PE1 (D2/D1)3
= 29 x (232/260)3
PE2 = 20.60 kW
5.3 power required for viscous fluid PE2 = 20.60 x g
= 20.60 x 1.2
PE2 = 24.72 kW

6 Throttle requirement at pump working at half load

6.1 pump flow at half load Q1 : 17.50 m3/hr
0.0049 m3/s
6.2 flow through throttle plate Q1 = m1F2√ 2g (H1 - H2) m3/s
Q1
mF2 =
Ö 2g (H1 - H2)
0.0049
=
Ö 2x9.81 (95 - 75.4)
= Err:502 m2

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 = Err:502 cm2
assumed m = 0.64
then F2 = Err:502 / 0.64
= Err:502 cm2
6.3 pipeline cross sectional area, (Ain m 2) F1 = 12.57 cm2
ratio F2/F1 = Err:502 / 12.57

Page 4of2

Fundamentals of Pump Selection - Specimen # 4

6.4 throttle plate opening diameter

flow coefficient with throttle plate m = 0.60 from curves
hence F2 = Err:502 / 0.60
= Err:502 cm2
now F2/F1 = Err:502 / 12.57
= Err:502 OK as per F2>0.1F1
6.5 throttle plate opening diameter pd /4
t
2
= F2
dt = Ö 4.13 x 4 / 3.142
= Err:502 cm
= Err:502 mm
throttle plate opening diameter dt = 23.00 mm

7 Calculation for points Zt for new Q-H curve 10.00

7.1 new Q - H curve to be plotted using throttle plate
7.2 flow rate in m3/s for flow 10 m3/hr Q10 = 0.00278 m3/s
flow rate in m3/s for flow 30 m3/hr Q30 = 0.00833 m3/s
7.3 point for for flow 10 m3/hr Zt1 = Q102 / (2g m2 F22)
= 0.002782 / 2 x 9.81 x 0.62 x 4.132
= Q102 / Err:502

Q E HE
2.3 power required for Engler values PE =
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2.3 power required for Engler values PE =
367 hE
90.0 x 76.63
=
367 x (47.3/100)
= 0.49 kW

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 impeller outlet : 2
casing outlet, discharge : d
1.1.2 theorem applied for fluid flow between
two consecutive points
i. flow from point 0 to point 1, through (V12/2g)+(p1/w)+Z1= (V02/2g)+(p0/w)+Z0 - hf(0-1)
stationary pipeline
velocity of flow at suction inlet V0 : mtr/sec
velocity of flow at impeller inlet V1 : mtr/sec
fluid pressure at suction inlet p0 : kg/cm2
fluid pressure at impeller inlet p1 : kg/cm2
elevation above horizontal datum level Z : mtr
friction losses between two sections hf : mtr
total head or energy H : mtr
weight per unit volume/density of fluid w : kg/m3
acceleration due to gravity g : 9.81 mtr/sec2

2 Specific speed
nÖQ
2.1 nominal specific speed nq =
H3/4
1450 Ö 0.0167
=
203/4
= #REF!
say = 20

3 pump selection
3.1 centrifugal, radial type pump to be selected based on shape number

ii. flow from point 1 to point 2, through

moveable impeller
[(W22/2g)-(U22/2g)]+(p2/w)+Z2 = [(W12/2g)-(U12/2g)]+(p1/w)+Z1- hf(1-2)
relative velocity of water at impeller inlet W1 : mtr/sec
relative velocity of water at impeller outle W2 : mtr/sec
tangential velocity of water at impeller inl U1 :

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 tangential velocity of water at impeller ou U2 :

iii. flow from point 2 to point d, through (Vd2/2g)+(pd/w)+Zd = (V22/2g)+(p2/w)+Z2 - hf(2-d)

stationary casing
relative velocity of water at impeller inlet W1 : mtr/sec
relative velocity of water at impeller outle W2 : mtr/sec

iv. adding equations at i., ii., iii. and rearranging

[(V22-V12/2g)+(W12-W22/2g)+ [(Vd2/2g)+(pd/w)+Zd]+[(V02/2g)+(p0/w)+Z0]+
=
(U22-U12/2g)] (hf(0-1)+hf(1-2)+hf(2-d))
gross manometric head of pump total pump losses due to fluid friction inside

v. rewriting equation iv,

(V22-V12/2g)+(W12-W22/2g)+(U22-U12/2g) = Hmano + DHmano
fundamental equation of centrifugal pump

Hmano
manometric efficiency hmano =
Hmano + DHmano

Pumps

2 Dimensional analysis of centrifugal pumps

2.1 relation between dimensions of two D1/D2 = b1/b2 or D2/D1 = b2/b1
geometrically similar pumps = constant
2.2 relation between kinemetical two similar V1/V2 = (Q1/pD1b1) x(pD2b2/Q2) = Q1/Q2
pumps
U1/U2 = (pD1n1/60) (60/pD
x 2n2) = n1/n2
2.3 for similar operating conditions V1/V2 = U1/U2 = constant
Q1/Q2 = n1/n2
2.4 for kinemetic similarity for given pump Q/n = constant

2.5 again V1/V2 = (Q1/pD1b1) x(pD2b2/Q2) = (Q1/Q2)(D2/D1)2

U1/U2 = (pD1n1/60) (60/pD
x 2n2) = D1n1/D2n2

2.6 substituting values of equation 2.5 in 2.3 (Q1/Q2)(D2/D1)2 = D1n1/D2n2

or Q1/n1D 1
3
= Q2/n2D23
general formulae of kinemetic similarity Q/nD3

3 Taking into consideration head

3.1 forces at corresponding point of impeller : bearing same ratio
3.2 force proportional to square of velocity F µ V2 or U2
F = Area x Pressure
= AxP
3.3 pressure depends on head P µ H

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 F/V2 = constant
H/V2 or H/U2 = constant
3.4 tangential velocity depends on impeller d U µ D
H1 / n12D12 = H2 / n22D22

4 Power required for pumping

4.1 power required for pumping P = ggQH watts
ggQH
P = kw
1000 h
4.2 for clear water g = 1000 kg/m3
g = 9.81 mtr/sec2
9.81 Q H
for clear water pumps P = kw
h
4.3 for two similar pumps P1/P2 = (Q1/H1)/(Q2/H2) = n13D15/n23D25 = (n1/n2)3(D1/D2)3

5 Specific speed
5.1 Specific speed : speed of rotation of geometrically similar pump of
such size ensuring delivery, Q of 75 ltr/sec at head, H
of 1 mtr
flow Q2 : 75 ltr/sec
: 0.075 m3/s
head H2 : 1 mtr
5.2 from equation 3.4 H1 / H 2 = (n1/n2)2 (D1/D2)2
H/ 1 = (n/ns)2 (D/Ds)2

Pumps

5 Specific speed
5.3 from equation 2.6 Q1 / Q2 = (n1/n2) (D1/D2)3
Q / 0.075 = (n/ns) (D/Ds)3
5.4 Ds eliminated by raising equation 5.2 to 3/2 power H3/2 / 1 = (n/ns)3 (D/Ds)3
5.5 divide equation 5.4 by 5.3 Q / 0.075 H3/2 = (ns / n)3
3.65 n Ö Q
5.6 Specific speed, speed with dimensionsns =
H3/4
rpm Ögal/min rpmÖm3/s
ns = or 51.64
(foot)3/4 (m)3/4
nÖQ
5.7 nominal specific speed nq =
H3/4
5.8 dimensionless specific speed
nÖQ
substitute (gH) in place of H nq =
(gH)3/4

6 Pump shape number

6.1 Pump shape number Ns : dimensionless number - pump and its performance
independent of impeller size and liquid properties
1000 n Ö Q
Ns =
(gH)3/4

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 Kns n Ö Q
6.2 also Pump shape number Ns =
(gH)3/4
pump speed n : rps rps
pump discharge Q : m3/s ft3/s
pump head H : mtr ft
acceleration due to gravity g : 9.81 m/s2 32.2 ft/s2
value Kns : 0.095 1.232

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