Republic of the Philippines

North Eastern Mindanao State University

Bislig Campus
Formerly Surigao del Sur State University
Maharlika, Bislig City, Surigao del Sur
bislig.sdssu.offical@gmail.com
(086) 645-6452

Name MIKE E. SUAN Date April 16, 2024

Subject ME LABORATORY 2 Section BSME-3A
AY Period 2ND Semester, Academic Year 2023 – 2024 Plate No. 7

LABORATORY REPORT ACTIVITY NO. 7

TEST OF A SERIES AND PARALLEL PUMP FLOW

OBJECTIVE
At the end of this activity, the student should be able to;
1. To determine the functions of series and parallel pump flow.
2. To determine how a series and parallel pump flow works.
3. To evaluate the series and parallel pump flow by doing a test.

BRIEF BACKGROUND
In fluid systems, pumps play a vital role in driving fluid flow, whether it's water in pipelines or
chemicals in industrial processes. Understanding how pumps can be configured in series or parallel is crucial
for optimizing system performance. In a series configuration, pumps are arranged sequentially along the
pipeline. This setup is akin to a relay race, where each pump passes on the fluid to the next one. While the
flow rate through each pump remains constant, the total head, or pressure, that the pumps can collectively
provide increases. This is because each pump adds its head to the system, creating a cumulative effect.
However, the total flow rate of the system decreases compared to a single pump, as each pump adds to the
pressure but not to the flow rate. Series configurations are often used when higher pressures are required,
such as in high-rise buildings or long-distance pipelines. On the other hand, in a parallel configuration, pumps
are connected side by side, with each pump receiving the same input flow. It's akin to multiple lanes on a
highway, where each pump operates independently but contributes to the overall flow. In parallel, the total
flow rate of the system increases because each pump adds to the flow. However, the total head provided
by the system remains the same as that of a single pump because each pump operates at the same pressure.
Parallel configurations are beneficial when higher flow rates are needed, such as in large-scale industrial
processes or firefighting systems.

ACTIVITY
1. Literature review and theory of pumps.
2. Classifications of common types of pumps.
3. Working principle of the series and parallel pump flow.
4. Testing of series and parallel pump flow.
3. Guided Questions:
I. Define the effectiveness of series and parallel pump flow.
II. Which parameters are measured on the series and parallel pump flow to evaluate the
performance?
III. Problem Solving
Literature review and theory of pumps

A pump is a device that moves fluids (liquids or gases), or sometimes slurries, [1] by mechanical action,
typically converted from electrical energy into hydraulic energy.

Mechanical pumps serve in a wide range of applications such as pumping water from wells, aquarium
filtering, pond filtering and aeration, in the car industry for water-cooling and fuel injection, in the energy
industry for pumping oil and natural gas or for operating cooling towers and other components of heating,
ventilation and air conditioning systems. In the medical industry, pumps are used for biochemical processes
in developing and manufacturing medicine, and as artificial replacements for body parts, in particular the
artificial heart and penile prosthesis.

When a pump contains two or more pump mechanisms with fluid being directed to flow through them in
series, it is called a multi-stage pump. Terms such as two-stage or double-stage may be used to specifically
describe the number of stages. A pump that does not fit this description is simply a single-stage pump in
contrast.

In biology, many different types of chemical and biomechanical pumps have evolved; biomimicry is
sometimes used in developing new types of mechanical pumps. In the past, pumps were used almost
exclusively for transporting water from a lower to higher level, that is, in a mine, water distribution, or in an
irrigation installation. Then it was practical to use the concept of delivery head (delivery height) as a criterion
of the pumps performance ability.

Pump Types
Pumps come in a variety of sizes for a wide range of applications. They can be classified according to their
basic operating principle as dynamic or displacement pumps. Dynamic pumps can be sub-classified as
centrifugal and special effect pumps. Displacement pumps can be sub-classified as rotary or reciprocating
pumps.
In principle, any liquid can be handled by any of the pump designs. Where different pump designs could
be used, the centrifugal pump is generally the most economical followed by rotary and reciprocating pumps.
Although, positive displacement pumps are generally more efficient than centrifugal pumps, the benefit of
higher efficiency tends to be offset by increased maintenance costs.
Since, worldwide, centrifugal pumps account for the majority of electricity used by pumps, the focus of
this chapter is on centrifugal pump.
Centrifugal Pumps
A centrifugal pump is of a very simple design. The two main parts of the pump are the impeller and the
diffuser. Impeller, which is the only moving part, is attached to a shaft and driven by a motor. Impellers are
generally made of bronze, polycarbonate, cast iron, stainless steel as well as other materials. The diffuser (also
called as volute) houses the impeller and captures and directs the water off the impeller.
Water enters the center (eye) of the impeller and exits the impeller with the help of centrifugal force. As
water leaves the eye of the impeller a low-pressure area is created, causing more water to flow into the eye.
Atmospheric pressure and centrifugal force cause this to happen. Velocity is developed as the water flows
through the impeller spinning at high speed. The water velocity is collected by the diffuser and converted to
pressure by specially designed passageways that direct the flow to the discharge of the pump, or to the next
impeller should the pump have a multi-stage configuration.
The pressure (head) that a pump will develop is in Figure 6.1 Centrifugal pump direct relationship to the impeller
diameter, the number of impellers, the size of impeller eye, and shaft speed. Capacity is determined by the
exit width of the impeller. The head and capacity are the main factors, which affect the horsepower size of the
motor to be used. The more the quantity of water to be pumped, the more energy is required.
A centrifugal pump is not positive acting; it will not pump the same volume always. The greater the depth
of the water, the lesser is the flow from the pump. Also, when it pumps against increasing pressure, the less it
will pump. For these reasons it is important to select a centrifugal pump that is designed to do a particular job.
Since the pump is a dynamic device, it is convenient to consider the pressure in terms of head i.e. meters
of liquid column. The pump generates the same head of liquid whatever the density of the liquid being
pumped. The actual contours of the hydraulic passages of the impeller and the casing are extremely important,
in order to attain the highest efficiency possible. The standard convention for centrifugal pump is to draw the
pump performance curves showing Flow on the horizontal axis and Head generated on the vertical axis.
Efficiency, Power & NPSH Required (described later), are conventionally shown on the vertical axis, plotted
against Flow, as illustrated in Figure 6.2.

Figure 6.2Pump Performance Curve

Given the significant amount of electricity attributed to pumping systems, even small improvements in
pumping efficiency could yield very significant savings of electricity. The pump is among the most inefficient
of the components that comprise a pumping system, including the motor, transmission drive, piping and
valves.

Hydraulic power, pump shaft power and electrical input power

Hydraulic power Ph = Q (m3/s) x Total head, hd - hs (m) x ρ (kg/m3) x g (m/s2) / 1000

Where hd – discharge head, hs – suction head, ρ – density of the fluid, g – acceleration due to gravity

Pump shaft power Ps = Hydraulic power, Ph / pump efficiency, ηPump

Electrical input power = Pump shaft power Ps
ηMotor
System Characteristics
In a pumping system, the objective, in most cases, is either to transfer a liquid from a source to a required
destination, e.g. filling a high level reservoir, or to circulate liquid around a system, e.g. as a means of heat
transfer in heat exchanger.
A pressure is needed to make the liquid flow at the required rate and this must overcome head 'losses' in
the system. Losses are of two types: static and friction head.
Static head is simply the difference in height of the supply and destination reservoirs, as in Figure 6.3. In
this illustration, flow velocity in the pipe is assumed to be very small. Another example of a system with only
static head is pumping into a pressurised vessel with short pipe runs. Static head is independent of flow and
graphically would be shown as in Figure 6.4.
 Figure 6.3 Static Head Figure 6.4 Static Head vs. Flow
Friction head (sometimes called dynamic head loss) is the friction loss, on the liquid being moved, in
pipes, valves and equipment in the system. Friction tables are universally available for various pipe fittings
and valves. These tables show friction loss per 100 feet (or metres) of a specific pipe size at various flow rates.
In case of fittings, friction is stated as an equivalent length of pipe of the same size. The friction losses are
proportional to the square of the flow rate. A closed loop circulating system without a surface open to
atmospheric pressure, would exhibit only friction losses and would have a system friction head loss vs. flow
curve as Figure 6.5.

Figure 6.5 Friction Head vs. Flow

Most systems have a combination of static and friction head and the system curves for two cases are shown
in Figures 6.6 and 6.7. The ratio of static to friction head over the operating range influences the benefits
achievable from variable speed drives which shall be discussed later.

Figure 6.6 System with High Static Head Figure 6.7 System with Low Static Head

Static head is a characteristic of the specific installation and reducing this head where this is possible,
generally helps both the cost of the installation and the cost of pumping the liquid. Friction head losses must
be minimised to reduce pumping cost, but after eliminating unnecessary pipe fittings and length, further
reduction in friction head will require larger diameter pipe, which adds to installation cost.

Pump Curves
The performance of a pump can be expressed graphically as head against flow rate. The centrifugal pump has
a curve where the head falls gradually with increasing flow. This is called the pump characteristic curve (Head
- Flow curve) -see Figure 6.8.
 Figure 6.8 Head- Flow Curve
Pump operating point
When a pump is installed in a system the effect can be illustrated graphically by superimposing pump and
system curves. The operating point will always be where the two curves intersect. Figure 6.9.

Figure 6.9 Pump Operating Point

If the actual system curve is different in reality to that calculated, the pump will operate at a flow and head
different to that expected.
For a centrifugal pump, an increasing system resistance will reduce the flow, eventually to zero, but the
maximum head is limited as shown. Even so, this condition is only acceptable for a short period without
causing problems. An error in the system curve calculation is also likely to lead to a centrifugal pump
selection, which is less than optimal for the actual system head losses. Adding safety margins to the calculated
system curve to ensure that a sufficiently large pump is selected will generally result in installing an oversized
pump, which will operate at an excessive flow rate or in a throttled condition, which increases energy usage
and reduces pump life.

Factors Affecting Pump Performance

Matching Pump and System Head-flow Characteristics
Centrifugal pumps are characterized by the relationship between the flow rate (Q) they produce and the
pressure (H) at which the flow is delivered. Pump efficiency varies with flow and pressure, and it is highest
at one particular flow rate.
The Figure 6.10 below shows a typical vendor-supplied head-flow curve for a centrifugal pump. Pump
head-flow curves are typically given for clear water. The choice of pump for a given application depends
largely on how the pump head-flow characteristics match the requirement of the system downstream of the
pump.
 Figure 6.10 Typical Centrifugal Pump Performance Curve

Effect of over sizing the pump

As mentioned earlier, pressure losses to be overcome by the pumps are function of flow – the system
characteristics – are also quantified in the form of head-flow curves. The system curve is basically a plot of
system resistance i.e. head to be overcome by the pump versus various flow rates. The system curves change
with the physical configuration of the system; for example, the system curves depends upon height or
elevation, diameter and length of piping, number and type of fittings and pressure drops across various
equipment - say a heat exchanger.
A pump is selected based on how well the pump curve and system head-flow curves match. The pump
operating point is identified as the point, where the system curve crosses the pump curve when they are
superimposed on each other.
The Figure 6.11 shows the effect on system curve with throttling.

Figure 6.11 Effect on System Curve with Throttling

In the system under consideration, water has to be first lifted to a height – this represents the static head.
Then, we make a system curve, considering the friction and pressure drops in the systemthis is shown as
the green curve.
Suppose, we have estimated our operating conditions as 500 m3/hr flow and 50 m head, we will chose a
pump curve which intersects the system curve (Point A) at the pump's best efficiency point (BEP).
But, in actual operation, we find that 300 m3/hr is sufficient. The reduction in flow rate has to be effected
by a throttle valve. In other words, we are introducing an artificial resistance in the system.
Due to this additional resistance, the frictional part of the system curve increases and thus the new system
curve will shift to the left -this is shown as the red curve.
So the pump has to overcome additional pressure in order to deliver the reduced flow. Now, the new
system curve will intersect the pump curve at point B. The revised parameters are 300 m3/hr at 70 m head.
The red double arrow line shows the additional pressure drop due to throttling.
You may note that the best efficiency point has shifted from 82% to 77% efficiency.
 So what we want is to actually operate at point C which is 300 m3/hr on the original system curve. The
head required at this point is only 42 meters.
What we now need is a new pump which will operate with its best efficiency point at C. But there are
other simpler options rather than replacing the pump. The speed of the pump can be reduced or the existing
impeller can be trimmed (or new lower size impeller). The blue pump curve represents either of these options.

Energy loss in throttling

Consider a case (see Figure 6.12) where we need to pump 68 m3/hr of water at 47 m head. The pump
characteristic curves (A…E) for a range of pumps are given in the Figure 6.12.

Figure 6.12 Pump Characteristic Curves

Efficient Pumping System Operation
To understand a pumping system, one must realize that all of its components are interdependent. When
examining or designing a pump system, the process demands must first be established and most energy
efficiency solution introduced. For example, does the flow rate have to be regulated continuously or in steps?
Can on-off batch pumping be used? What are the flow rates needed and how are they distributed in time?
The first step to achieve energy efficiency in pumping system is to target the end-use. A plant water balance
would establish usage pattern and highlight areas where water consumption can be reduced or optimized.
Good water conservation measures, alone, may eliminate the need for some pumps.
Once flow requirements are optimized, then the pumping system can be analysed for energy conservation
opportunities. Basically this means matching the pump to requirements by adopting proper flow control
strategies. Common symptoms that indicate opportunities for energy efficiency in pumps are given in the
Table 6.1.

TABLE 6.1 SYMPTOMS THAT INDICATE POTENTIAL OPPORTUNITY FOR ENERGY

SAVINGS
Symptom Likely Reason Best Solutions
Throttle valve-controlled Oversized pump Trim impeller, smaller
systems impeller, variable speed
drive, two speed drive,
lower rpm
Bypass line (partially or Oversized pump Trim impeller, smaller
impeller,
completely) open variable speed drive, two
speed drive, lower rpm
Multiple parallel pump Pump use not Install controls
system
with the same number of monitored or
pumps always operating controlled
Constant pump operation in Wrong system On-off controls
a batch environment design
High maintenance cost Pump operated far Match pump capacity with
(seals,
bearings) away from BEP system requirement

Effect of speed variation

As stated above, a centrifugal pump is a dynamic device with the head generated from a rotating impeller.
There is therefore a relationship between impeller peripheral velocity and generated head. Peripheral velocity
is directly related to shaft rotational speed, for a fixed impeller diameter and so varying the rotational speed
has a direct effect on the performance of the pump. All the parameters shown in fig 6.2 will change if the
speed is varied and it is important to have an appreciation of how these parameters vary in order to safely
control a pump at different speeds. The equations relating rotodynamic pump performance parameters of flow,
head and power absorbed, to speed are known as the Affinity Laws:

Where:
Q = Flow rate
H = Head
P = Power absorbed
N = Rotating speed
Efficiency is essentially independent of speed

Flow: Flow is proportional to the speed

 Q1 / Q2 = N1 / N2 Example: 100 / Q2 = 1750/3500 Q2 = 200 m3/hr

Head: Head is proportional to the square of speed

H1/H2 = (N12) / (N22)

Example: 100 /H2 = 17502 / 35002
H2 = 400 m

Power(kW): Power is proportional to the cube of speed

kW1 / kW2 = (N13) / (N23) Example: 5/kW2 = 17503 / 35003 kW2 = 40

As can be seen from the above laws, doubling the speed of the centrifugal pump will increase the power
consumption by 8 times. Conversely a small reduction in speed will result in drastic reduction in power
consumption. This forms the basis for energy conservation in centrifugal pumps with varying flow
requirements. The implication of this can be better understood as shown in an example of a centrifugal pump
in Figure 6.13 below.

Figure 6.13 Example of Speed Variation Effecting Centrifugal Pump Performance

Points of equal efficiency on the curves for the 3 different speeds are joined to make the isoefficiency
lines, showing that efficiency remains constant over small changes of speed providing the pump continues to
operate at the same position related to its best efficiency point (BEP).
The affinity laws give a good approximation of how pump performance curves change with speed but in
order to obtain the actual performance of the pump in a system, the system curve also has to be taken into
account.

Effects of impeller diameter change

Changing the impeller diameter gives a proportional change in peripheral velocity, so it follows that there are
equations, similar to the affinity laws, for the variation of performance with impeller diameter D:

Efficiency varies when the diameter is changed within a particular casing. Note the difference in iso-
efficiency lines in Figure 6.14 compared with Figure 6.13. The relationships shown here apply to the case for
changing only the diameter of an impeller within a fixed casing geometry, which is a common practice for
making small permanent adjustments to the performance of a centrifugal pump. Diameter changes are
generally limited to reducing the diameter to about 75% of the maximum, i.e. a head reduction to about 50%.
Beyond this, efficiency and NPSH are badly affected. However speed change can be used over a wider range
without seriously reducing efficiency. For example reducing the speed by 50% typically results in a reduction
of efficiency by 1 or 2 percentage points. The reason for the small loss of efficiency with the lower speed is
that mechanical losses in seals and bearings, which generally represent <5% of total power, are proportional
to speed, rather than speed cubed. It should be noted that if the change in diameter is more than about 5%, the
accuracy of the squared and cubic relationships can fall off and for precise calculations, the pump
manufacturer's performance curves should be referred to.
 Figure 6.14 Example: Impeller Diameter Reduction on Centrifugal Pump Performance

The illustrated curves are typical of most centrifugal pump types. Certain high flow, low head pumps have
performance curve shapes somewhat different and have a reduced operating region of flows. This requires
additional care in matching the pump to the system, when changing speed and diameter.
Pump suction performance (NPSH)
Liquid entering the impeller eye turns and is split into separate streams by the leading edges of the impeller
vanes, an action which locally drops the pressure below that in the inlet pipe to the pump.
If the incoming liquid is at a pressure with insufficient margin above its vapour pressure, then vapour
cavities or bubbles appear along the impeller vanes just behind the inlet edges. This phenomenon is known as
cavitation and has three undesirable effects:
1) The collapsing cavitation bubbles can erode the vane surface, especially when pumping water-based
liquids.
2) Noise and vibration are increased, with possible shortened seal and bearing life.
3) The cavity areas will initially partially choke the impeller passages and reduce the pump performance.
In extreme cases, total loss of pump developed head occurs.
The value, by which the pressure in the pump suction exceeds the liquid vapour pressure, is expressed as
a head of liquid and referred to as Net Positive Suction Head Available – (NPSHA). This is a characteristic of
the system design. The value of NPSH needed at the pump suction to prevent the pump from cavitating is
known as NPSH Required – (NPSHR). This is a characteristic of the pump design.
The three undesirable effects of cavitation described above begin at different values of NPSHA and
generally there will be cavitation erosion before there is a noticeable loss of pump head. However for a
consistent approach, manufacturers and industry standards, usually define the onset of cavitation as the value
of NPSHR when there is a head drop of 3% compared with the head with cavitation free performance. At this
point cavitation is present and prolonged operation at this point will usually lead to damage. It is usual
therefore to apply a margin bywhich NPSHA should exceed NPSHR.
As would be expected, the NPSHR increases as the flow through the pump increases, see fig 6.2. In
addition, as flow increases in the suction pipework, friction losses also increase, giving a lower NPSHAat the
pump suction, both of which give a greater chance that cavitation will occur. NPSHR also varies
approximately with the square of speed in the same way as pump head and conversion of NPSHR from one
speed to another can be made using the following equations.
Q∝N
NPSHR ∝ N 2
It should be noted however that at very low speeds there is a minimum NPSHR plateau, NPSHR does not
tend to zero at zero speed It is therefore essential to carefully consider NPSH in variable speed pumping.

Flow Control Strategies

Pump control by varying speed
To understand how speed variation changes the duty point, the pump and system curves are over-laid. Two
systems are considered, one with only friction loss and another where static head is high in relation to friction
head. It will be seen that the benefits are different. In Figure 6.15,
 Figure 6.15 Example of the Effect of Pump Speed Change in a System With Only Friction Loss
reducing speed in the friction loss system moves the intersection point on the system curve along a line of
constant efficiency. The operating point of the pump, relative to its best efficiency point, remains constant and
the pump continues to operate in its ideal region. The affinity laws are obeyed which means that there is a
substantial reduction in power absorbed accompanying the reduction in flow and head, making variable speed
the ideal control method for systems with friction loss.
In a system where static head is high, as illustrated in Figure 6.16, the operating point for the pump moves
relative to the lines of constant pump efficiency when the speed is changed. The reduction in flow is no longer
proportional to speed. A small turn down in speed could give a big reduction in flow rate and pump efficiency,
which could result in the pump operating in a region where it could be damaged if it ran for an extended period
of time even at the lower speed. At the lowest speed illustrated, (1184 rpm), the pump does not generate
sufficient head to pump any liquid into the system, i.e. pump efficiency and flow rate are zero and with energy
still being input to the liquid, the pump becomes a water heater and damaging temperatures can quickly be
reached.

Figure 6.16 Example for the Effect of Pump Speed Change with a System with High Static Head.

The drop in pump efficiency during speed reduction in a system with static head, reduces the economic
benefits of variable speed control. There may still be overall benefits but economics should be examined on a
case-by-case basis. Usually it is advantageous to select the pump such that the system curve intersects the full
speed pump curve to the right of best efficiency, in order that the efficiency will first increase as the speed is
reduced and then decrease. This can extend the useful range of variable speed operation in a system with static
head. The pump manufacturer should be consulted on the safe operating range of the pump.
It is relevant to note that flow control by speed regulation is always more efficient than by control valve.
In addition to energy savings there could be other benefits of lower speed. The hydraulic forces on the impeller,
created by the pressure profile inside the pump casing, reduce approximately with the square of speed. These
forces are carried by the pump bearings and so reducing speed increases bearing life. It can be shown that for
a centrifugal pump, bearing life is inversely proportional to the 7th power of speed. In addition, vibration and
noise are reduced and seal life is increased providing the duty point remains within the allowable operating
range.
The corollary to this is that small increases in the speed of a pump significantly increase power absorbed,
shaft stress and bearing loads. It should be remembered that the pump and motor must be sized for the
maximum speed at which the pump set will operate. At higher speed the noise and vibration from both pump
and motor will increase, although for small increases the change will be small. If the liquid contains abrasive
particles, increasing speed will give a corresponding increase in surface wear in the pump and pipework.
The effect on the mechanical seal of the change in seal chamber pressure, should be reviewed with the
pump or seal manufacturer, if the speed increase is large. Conventional mechanical seals operate satisfactorily
at very low speeds and generally there is no requirement for a minimum speed to be specified, however due
to their method of operation, gas seals require a minimum peripheral speed of 5 m/s.
Pumps in parallel switched to meet demand
Another energy efficient method of flow control, particularly for systems where static head is a high proportion
of the total, is to install two or more pumps to operate in parallel. Variation of flow rate is achieved by
switching on and off additional pumps to meet demand. The combined pump curve is obtained by adding the
flow rates at a specific head. The head/flow rate curves for two and three pumps are shown in Figure 6.17.

Figure 6.17 Typical Head-Flow Curves for Pumps in Parallel

The system curve is usually not affected by the number of pumps that are running. For a system with a
combination of static and friction head loss, it can be seen, in Figure 6.18, that the operating point of the
pumps on their performance curves moves to a higher head and hence lower flow rate per pump, as more
pumps are started. It is also apparent that the flow rate with two pumps running is not double that of a single
pump. If the system head were only static, then flow rate would be proportional to the number of pumps
operating.
It is possible to run pumps of different sizes in parallel provided their closed valve heads are similar. By
arranging different combinations of pumps running together, a larger number of different flow rates can be
provided into the system.
Care must be taken when running pumps in parallel to ensure that the operating point of the pump is
controlled within the region deemed as acceptable by the manufacturer. It can be seen from Figure 6.18 that
if 1 or 2 pumps were stopped then the remaining pump(s) would operate well out along the curve where NPSH
is higher and vibration level increased, giving an increased risk of operating problems.

Figure 6.18 Typical Head-Flow Curves for Pumps in Parallel, With System Curve Illustrated.

Stop/start control
In this control method, the flow is controlled by switching pumps on or off. It is necessary to have a storage
capacity in the system e.g. a wet well, an elevated tank or an accumulator type pressure vessel. The storage
can provide a steady flow to the system with an intermittent operating pump. When the pump runs, it does so
at the chosen (presumably optimum) duty point and when it is off, there is no energy consumption. If
intermittent flow, stop/start operation and the storage facility are acceptable, this is an effective approach to
minimise energy consumption.
 The stop/start operation causes additional loads on the power transmission components and increased
heating in the motor. The frequency of the stop/start cycle should be within the motor design criteria and
checked with the pump manufacturer.
It may also be used to benefit from "off peak" energy tariffs by arranging the run times during the low
tariff periods.
To minimise energy consumption with stop start control it is better to pump at as low flow rate as the
process permits. This minimises friction losses in the pipe and an appropriately small pump can be installed.
For example, pumping at half the flow rate for twice as long can reduce energy consumption to a quarter.
Flow control valve
With this control method, the pump runs continuously and a valve in the pump discharge line is opened or
closed to adjust the flow to the required value.

Figure 6.19 Control of Pump Flow by Changing System Resistance Using a Valve.

To understand how the flow rate is controlled, see Figure 6.19. With the valve fully open, the pump
operates at "Flow 1". When the valve is partially closed it introduces an additional friction loss in the system,
which is proportional to flow squared. The new system curve cuts the pump curve at "Flow 2", which is the
new operating point. The head difference between the two curves is the pressure drop across the valve.
It is usual practice with valve control to have the valve 10% shut even at maximum flow. Energy is
therefore wasted overcoming the resistance through the valve at all flow conditions. There is some reduction
in pump power absorbed at the lower flow rate (see Figure 6.19), but the flow multiplied by the head drop
across the valve, is wasted energy. It should also be noted that, while the pump will accommodate changes in
its operating point as far as it is able within its performance range, it can be forced to operate high on the
curve, where its efficiency is low, and its reliability is affected.
Maintenance cost of control valves can be high, particularly on corrosive and solids-containing liquids.
Therefore, the lifetime cost could be unnecessarily high.

By-pass control
With this control approach, the pump runs continuously at the maximum process demand duty, with a
permanent by-pass line attached to the outlet. When a lower flow is required the surplus liquid is bypassed
and returned to the supply source.
An alternative configuration may have a tank supplying a varying process demand, which is kept full by
a fixed duty pump running at the peak flow rate. Most of the time the tank overflows and recycles back to the
pump suction. This is even less energy efficient than a control valve because there is no reduction in power
consumption with reduced process demand.
The small by-pass line sometimes installed to prevent a pump running at zero flow is not a means of flow
control, but required for the safe operation of the pump.
Fixed Flow reduction
Impeller trimming
Impeller trimming refers to the process of machining the diameter of an impeller to reduce the energy
added to the system fluid.
Impeller trimming offers a useful correction to pumps that, through overly conservative design
practices or changes in system loads are oversized for their application.
Trimming an impeller provides a level of correction below buying a smaller impeller from the
pump manufacturer. But in many cases, the next smaller size impeller is too small for the pump load.
Also, smaller impellers may not be available for the pump size in question and impeller trimming is
the only practical alternative short of replacing the entire pump/motor assembly. (see Figures 6.20 &
6.21 for before and after impeller trimming).
Impeller trimming reduces tip speed, which in turn directly lowers the amount of energy imparted
to the system fluid and lowers both the flow and pressure generated by the pump.
The Affinity Laws, which describe centrifugal pump performance, provide a theoretical
relationship between impeller size and pump output (assuming constant pump speed):
Where:
Q = flow
H = head

Figure 6.20 Before Impeller trimming

Figure 6.21 After Impeller Trimming

BHP = brake horsepower of the pump motor
Subscript 1 = original pump,
Subscript 2 = pump after impeller trimming D = Diameter

Trimming an impeller changes its operating efficiency, and the non-linearities of the Affinity
Laws with respect to impeller machining complicate the prediction of pump performance.
Consequently, impeller diameters are rarely reduced below 70 percent of their original size.

Meeting variable flow reduction

Variable Speed Drives (VSDs)
In contrast, pump speed adjustments provide the most efficient means of controlling pump flow.
By reducing pump speed, less energy is imparted to the fluid and less energy needs to be throttled
or bypassed. There are two primary methods of reducing pump speed: multiple-speed pump motors
and variable speed drives (VSDs).
Although both directly control pump output, multiple-speed motors and VSDs serve entirely
separate applications. Multiple-speed motors contain a different set of windings for each motor
speed; consequently, they are more expensive and less efficient than single speed motors. Multiple
speed motors also lack subtle speed changing capabilities within discrete speeds.
VSDs allow pump speed adjustments over a continuous range, avoiding the need to jump from
speed to speed as with multiple-speed pumps. VSDs control pump speeds using several different
types of mechanical and electrical systems. Mechanical VSDs include hydraulic clutches, fluid
couplings, and adjustable belts and
pulleys. Electrical VSDs include eddy
current clutches, woundrotor motor
controllers, and variable frequency drives
(VFDs). VFDs adjust the electrical
frequency of the power supplied to a
motor to change the motor's rotational
speed. VFDs are by far the most popular
type of VSD.
However, pump speed adjustment is
not appropriate for all systems. In
applications with high static head,
slowing a pump risks inducing vibrations
and creating performance problems that
are similar to those found when a pump
operates against its shutoff head. For systems in which the static head repre- Figure
6.22 Effect of VFD sents a large portion of the total head, caution should be used in
deciding whether to use VFDs. Operators should review the performance of VFDs
in similar applications and consult VFD manufacturers to avoid the damage that can
result when a pump operates too slowly against high static head.
For many systems, VFDs offer a means to improve pump operating efficiency despite changes
in operating conditions. The effect of slowing pump speed on pump operation is illustrated by the
three curves in Figure 6.22. When a VFD slows a pump, its head/flow and brake horsepower (BHP)
curves drop down and to the left and its efficiency curve shifts to the left. This efficiency response
provides an essential cost advantage; by keeping the operating efficiency as high as possible across
variations in the system's flow demand, the energy and maintenance costs of the pump can be
significantly reduced.
VFDs may offer operating cost reductions by allowing higher pump operating efficiency, but
the principal savings derive from the reduction in frictional or bypass flow losses. Using a system
perspective to identify areas in which fluid energy is dissipated in non-useful work often reveals
opportunities for operating cost reductions.
For example, in many systems, increasing flow through bypass lines does not noticeably impact
the backpressure on a pump. Consequently, in these applications pump efficiency does not
necessarily decline during periods of low flow demand. By analyzing the entire system, however,
the energy lost in pushing fluid through bypass lines and across throttle valves can be identified.
Another system benefit of VFDs is a soft start capability. During startup, most motors
experience in-rush currents that are 5 – 6 times higher than normal operating currents. This high
current fades when the motor spins up to normal speed. VFDs allow the motor to be started with a
lower startup current (usually only about 1.5 times the normal operating current). This reduces
wear on the motor and its controller.

Energy Conservation Opportunities in Pumping Systems

■
Ensure adequate NPSH at site of installation
■
Ensure availability of basic instruments at pumps like pressure gauges, flow meters.
■
Operate pumps near best efficiency point.
■
Modify pumping system and pumps losses to minimize throttling.
■
Adapt to wide load variation with variable speed drives or sequenced control of multiple units.
■
Stop running multiple pumps - add an auto-start for an on-line spare or add a booster pump in
the problem area.
■
Use booster pumps for small loads requiring higher pressures.
■
Increase fluid temperature differentials to reduce pumping rates in case of heat exchangers.
■
Repair seals and packing to minimize water loss by dripping.
■
Balance the system to minimize flows and reduce pump power requirements.
■
Avoid pumping head with a free-fall return (gravity); Use siphon effect to advantage:
■
Conduct water balance to minimise water consumption
■
Avoid cooling water re-circulation in DG sets, air compressors, refrigeration systems, cooling
towers feed water pumps, condenser pumps and process pumps.
■
In multiple pump operations, carefully combine the operation of pumps to avoid throttling
■
Provide booster pump for few areas of higher head
■
Replace old pumps by energy efficient pumps
■
In the case of over designed pump, provide variable speed drive, or downsize / replace
impeller or replace with correct sized pump for efficient operation.
■
Optimise number of stages in multi-stage pump in case of head margins
■
Reduce system resistance by pressure drop assessment and pipe size optimisation
 QUESTIONS
1. What is NPSH of a pump and effects of inadequate NPSH?
2. State the affinity laws as applicable to centrifugal pumps?
3. Explain what do you understand by static head and friction head?
4. What are the various methods of pump capacity control normally adopted?
5. Briefly explain with a diagram the energy loss due to throttling in a centrifugal pump.

6. Briefly explain with a sketch the concept of pump head flow characteristics and system
resistance.
7. What are the effects of over sizing a pump?
8. If the speed of the pump is doubled, power goes up by a) 2
times b) 6 times c) 8 times d) 4 times
9. How does the pump performance vary with impeller diameter?
10. State the relationship between liquid kW, flow and pressure in a pumping application.

11. Draw a pump curve for parallel operation of pumps (2 nos).

12. Draw a pump curve for series operation of pumps (2 nos).
13. List down few energy conservation opportunities in pumping system.

CLASSIFICATION OF PUMPS

Pumps are divided into 2 major categories: Dynamic and Positive Displacement (aka
Displacement).

Following is some of the pumps under both categories (it is impossible to list all):

DYNAMIC

• Centrifugal pumps
• Vertical centrifugal pumps
• Horizontal centrifugal pumps
•
• Submersible pumps
• Fire hydrant systems

POSITIVE DISPLACEMENT

• Diaphragm pumps
 • Gear pumps
• Peristaltic Pumps
• Lobe pumps
• Piston Pumps

DYNAMIC PUMPS

CENTRIFUGAL PUMPS

Centrifugal pumps are the most used pump type in the world, due to simple working principle
and relatively inexpensive manufacturing cost.

HOW IT WORKS
An increase in the fluid pressure from the pump inlet to its outlet is created when the pump is in
operation. This pressure difference drives the fluid through the system or plant.

SUBMERSIBLE PUMPS

Submersible pumps (also known as storm water pumps, sewage pumps, septic pumps)
can still operate when being fully submerged in water.

FIRE HYDRANT SYSTEMS

Fire hydrant pump system (also known as fire pump, hydrant booster, fire water pump) is
technically not a pump but a system by itself. The hydrant booster pump usually consists of 1
centrifugal pump and other components such as control panel and coupled with either a diesel
or electric driven motor.

POSITIVE DISPLACEMENT PUMPS

DIAPHRAGM PUMPS

There are 2 main types of diaphragm pumps: Air-operated and Mechanical.

As the name suggested, air-operated diaphragm pumps (aka AOD pumps or AODD pumps) are
powered solely by air making them suitable for dangerous and tough environments. They are
also used for chemical transfer, de-watering underground coal mines, food manufacturing or
where the liquid being pumped has a high solids content or high viscosity.

GEAR PUMPS

Gear pumps transfer fluid by gears coming in and out of mesh to create a non-pulsating pumping
action. They are able to pump at high pressures and excel at pumping high viscosity liquids
efficiently.

Internal and external gear pumps are the two basic types of gear pumps. The main differences
between the two types of gear pumps are the placement of the gears and where the fluid is
trapped.

PERISTALTIC PUMPS

Peristaltic pumps creates a steady flow for dosing and blending and is able to pump a variety of
fluids, ranging from toothpaste to all sorts of chemicals. They are widely used in water treatment,
chemical processing and food processing industries.
LOBE PUMPS

Lobe pumps offer superb sanitary qualities, high efficiency, reliability, corrosion resistance, and
good clean-in-place and sterilise-in-place (CIP/SIP) characteristics. Thus they are very popular in
F&B and pharmaceutical industries.

PISTON PUMPS

A piston pump is a type of positive displacement pump where the high-pressure seal reciprocates
with the piston. Piston pumps can be used in multiple applications and can be used to transfer
paint, chocolate, pastry, etc.

Pumps in Parallel & Series

Pumps in Parallel

Pumps are often installed in Parallel in systems which exhibit considerable variations in
flow or when the system has variable flow requirements and when these requirements
can be achieved by switching the parallel pumps on and off. Typically, pumps installed in
parallel are of a similar type and size. The pumps however can be of a different size or
the pumps can be speed-controlled which of course means the pump performance curves
will be different.

Figure 1 provides an illustration of a system with two identical pumps installed in parallel.
The image shows how non-return valves are installed in series and downstream of each
pump. This is to prevent bypass circulation when a pump is not running.

The total system performance curve for parallel pumps can be determined by adding
Q1 and Q2 for every value of head which is the same for both pumps, i.e. H1 = H2. As
the pumps, in this case, are identical, the resultant composite pump curve has the same
maximum head value, Hmax but the maximum flow Qmax is twice as large. So, for each
value of the head, the flow is double that of a single pump in operation.
 Fig 1: Pumps in Parallel.

Pumps are sometimes installed in parallel in pressure booster systems for water supply
and for water supply in large buildings. Operational advantages can be achieved by
connecting two or more pumps in parallel instead of installing just one single large pump.
The total pump output is usually only required for a limited period. If a single pump was
used in this instance, it would operate at a comparatively lower efficiency.

When a number of smaller pumps are installed in parallel, the system can be controlled
to optimise or minimize the number of pumps operating and the pumps which are on will
operate at or close-to the BEP (best efficiency point). To operate at the most optimal
point, one of the pumps installed in parallel must have variable speed control.

The composite pump chart for pumps installed in parallel can be plotted in FluidFlow as
shown in Figure 2.
 Fig 2: FluidFlow Composite Pump Chart - Pumps in Parallel.

Pumps in Series

Many pumping applications require fluids to be transported over long distances and
against high static heads or total heads which are well in excess of the head that can be
developed by a single pump. Examples of such scenarios would be, pumping tailings,
power station ash, underground fill and pumping concentrates. Centrifugal pumps are
occasionally installed in series to increase the operating range and standby capacity of
the plant. Multi-stage pumps can be considered as a series type installation of single-
stage pumps. However, single stages in multi-stage pumps cannot be decoupled.

If one of the pumps in a series type installation is not operational, it causes considerable
resistance to the system. In an effort to overcome this, a bypass with non-return valve
could be installed as shown in Figure 3.

Fig 3: Pumps in Series.

The head associated with a given flow rate for pumps installed in series is can be
determined by adding the single heads vertically as shown in Figure 4.
 Fig 4: Pumps in Series.

The composite pump chart for pumps installed in series can be plotted in FluidFlow.

Fig 5: Composite Pump Chart - Pumps in Series.

Pump installed in parallel are typically identical pumps. There may however, be
applications or scenarios where dissimilar pumps are installed. Figure 6 shows an
example system which has a total of four pumps, three of which are operating.

Fig 6: Composite Pump Chart – Dissimilar Pumps in Parallel.

Pump 10 and 11 are dissimilar pumps (two different sized pumps) installed in the
system. The composite curve for any combination of pumps can be plotted in FluidFlow.
Figure 7 shows the composite curve for pumps 10 and 11.

Fig 7: Composite Pump Chart – Dissimilar Pumps in Parall

• PistonPump
Diaphragm
Gear
Lobe
Vane
Screw PumpPump
Pump
pump – reciprocating
- flexible diaphragm
piston
PUMPS
-Facilitating the movement of fluids
-Ability to transfer, circulate and control fluids
IMPORTANCE:
1. WATER MANAGEMENT
- supplying clean water
-Distributing water from sources
2. MANUFACTURING
-Manufacturing process
-Help move liquids through different stages of production
3. ENERGY GENERATION
-Circulate cooling water, manage steam and fuel
-Control flow of fluids (power generation process)
TYPES OF PUMPS
➢ CENTRIFUGAL PUMPS
-Uses impeller to create centrifugal force
➢ POSITIVE DISPLACEMENT PUMPS
-Traps fluid and push it through the system
➢ SUBMERSIBLE PUMPS
-Submerged in the fluid
-Groundwater extraction and sewage pumping

NOTE: Series and parallel pumps are used to achieve specific flow and pressure requirements
SERIES PUMPS
-two or more pumps are connected in sequential manner
-increases total head pressure
-to overcome high static/dynamic head requirements

PARALLEL PUMPS
-multiple pumps are connected side by side
-used when the system requires higher flow rate

BASICS OF PUMP OPERATION

1. PRESSURE INCREASE
-Mechanical energy increases the fluid kinetic energy and pressure
-in centrifugal pumps, kinetic energy is converted to pressure energy
2. FLOW CONTROL
-Control mechanisms can regulate the flow rate and pressure of the pumped fluid

ROLES OF PUMPS IN FLUID TRANSPORTATION

-Convert mechanical energy into fluid energy
-Allows to overcome the resistance of pipes, valves, etc.

WHY TEST A PARALLEL PUMP FLOW?

1. PARALLEL PUMP SYSTEMS PROVIDE
HIGHER FLOW RATES AND SYSTEM FLEXIBILTY
2. TESTING ENSURES EVEN DISTRIBUTION OF FLOW AMONG PUMPS
3. PROPER TESTING PREVENTS OVERLOADING AND CAVITATION IMPROVING PUMP LONGEVITY
TESTTING EQUIPMENT:

•FLOW METERS
-Measure the flow rate

•PRESSURE GAUGES
-Monitor pressure levels
FLOW CONTROL VALVES
-Adjust flow distribution

•VISUAL AIDS
-Images of equipment

TESTING PARAMETERS

•FLOW RATE
-Volume of fluid passing

•HEAD
-Energy to move fluid against gravity and friction

•EFFICIENCY
-How effectively the pumps convert power input to fluid flow

•PRESSURE
-Force exerted by the fluid

TEST SIZING
1. PROPER PIPE SIZING
-Match pipe size with pump capacity
2. VALVE ADJUSTMENTS
-Set valves to regulate flow distribution
3. SAFETY PRECAUTIONS
-Ensure personnel safety
DATA COLLECTION AND ANALYSIS
1. COLLECT DATA USING FLOW METERS, PRESSURE GAUGES AND OTHER INSTURMENTS
2. ANALYZE THE DATA USING SPECIALIZED SOFTWARE FOR ACCURATE INTERPRETATION

INTERPRETING RESULTS
1. COMPARE MEASURED PARAMETERS WITH EXPECTED VALUES
2. DETERMINE IF FLOW DISTRIBUTION IS EVEN AMONG PUMPS
3. EVALUATE PUMP EFFICIENCY AND SYSTEM PERFORMANCE

BENEFITS OF TESTING
1. IMRPOVED EFFICIENCY
-Even flow distribution leads to better energy utilization
2. REDUCED MAINTAINANCE COSTS
-Prevents issues through regular testing
3. EXTEDED EQUIPMENT LIFESPAN
-Proper testing increases pump longevity
WHY IS IT CALLED A POSITIVE DISPLACEMENT PUMP?
-displaces or moves a fixed, positive volume of fluid with each cycle or rotation
-consistent volume of fluid is moved

ADVANTAGES
1. PRECISE FLOW CONTROL
2. HANDLING VISCOUS FLUID
3. SELF PRIMING
4. CONSTANT FLOW
5. CAN GENERATE HIGH PRESSURE

DISADVANTAGES
1. LIMITED FLOW RATES AT HIGH PRESSURE
2. SENSITIVITY TO VISCOSITY CHANGES
3. SLIPPAGE AT HIGH SPEEDS
4. COMPLEX MAINTAINANCE
5. POTENTIAL FOR SEAL AND PACKING ISSUES
6. HIGHER INITIAL COST
7. PULSATING FLOW
8. LIMITED USE FOR NON NEWTONIAN FLUID
9. ENERGY CONSUMPTION
10. SIZE AND WIEGHT
11. LIMITED SELF PRIMING ABILITY

TYPES OF POSITVE DISPLACEMENT PUMP

1. RECIPROCATING PUMP
-reciprocating motion
•Piston Pump – reciprocating piston (single or double acting)

•Diaphragm Pump - flexible diaphragm

2. ROTARY PUMP
-rotating mechanism to move fluid

•Gear Pump
-two intermeshing gears that trap and move
fluid

•Lobe Pump
-lobes (cogs) that rotate and mesh together

•Vane pump
-use sliding vanes that are pushed in and out

•Screw Pump
-utilize rotating screws or helical rotors
3. PERISTALTIC PUMP
-hose pumps or tube pumps
-these pumps use rollers to compress and release a flexible tube
-peristaltic wave
4. PROGRESSIVE CAVITY PUMP
-helical rotor within a stator to create a series of cavities
-fluid is moved progressively
DANGER IN POSITIVE DISPLACEMENT PUMP
1. High Pressure Operation
2. Fluid Contamination
3. Cavitation and Fluid Hammer
4. Mechanical Failure
5. Overheating
6. Noise and Vibration
7. Incorrect Installation and Operation
8. Electric Shock and Fire
9. Explosive or Flammable Fluid
GUIDELINES:
1. Proper Training
2. Regular Inspection and Maintenance
3. Safety Equipment
4. Pressure Relief Valve
5. Emergency Shutdown Procedures
6. Compatibility
7. Ventilation
8. Grounding and Electrical Safety
References:
1. British Pump Manufacturers' AssociationBEE
2. (EMC) Inputs PCRA Literature
3. Grundfos, The Centrifugal Pump.
4. Grundfos, The Pump Handbook.