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Working Guide
to Pumps and
Pumping Stations
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Working Guide
to Pumps and
Pumping Stations
Calculations and Simulations
E. Shashi Menon, P.E.

and
Pramila S. Menon, MBA
AMSTERDAM • BOSTON • HEIDELBERG • LONDON • NEW YORK

OXFORD PARIS • SAN DIEGO • SAN FRANCISCO • SINGAPORE
SYDNEY • TOKYO
Gulf Professional Publishing is an imprint of Elsevier
Gulf Professional Publishing is an imprint of Elsevier

30 Corporate Drive, Suite 400, Burlington, MA 01803, USA
Linacre House, Jordan Hill, Oxford OX2 8DP, UK
© 2010 E. Shashi Menon. Published by Elsevier Inc. All rights reserved.
No part of this publication may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying, recording, or any information storage
and retrieval system, without permission in writing from the publisher. Details on how to
seek permission, further information about the Publisher’s permissions policies and our
arrangements with organizations such as the Copyright Clearance Center and the Copyright
Licensing Agency, can be found at our website: www.elsevier.com/permissions.
This book and the individual contributions contained in it are protected under copyright by
the Publisher (other than as may be noted herein).
Notices
Knowledge and best practice in this field are constantly changing. As new research and
experience broaden our understanding, changes in research methods, professional practices,
or medical treatment may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge
in evaluating and using any information, methods, compounds, or experiments described
herein. In using such information or methods they should be mindful of their own safety and
the safety of others, including parties for whom they have a professional responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or
editors, assume any liability for any injury and/or damage to persons or property as a matter
of products liability, negligence or otherwise, or from any use or operation of any methods,
products, instructions, or ideas contained in the material herein.
Library of Congress Cataloging-in-Publication Data
British Library Cataloguing-in-Publication Data

A catalogue record for this book is available from the British Library.
ISBN: 978-1-85617-828-0
For information on all Gulf Professional Publishing

publications visit our Web site at www.elsevierdirect.com
10 11 12 13 14 10 9 8 7 6 5 4 3 2 1
Printed in United States of America
Dedicated to our parents

Contents
Preface ix
Author Biography xi
1 Introduction 1
2 Pump Performance 23
3 Liquid Properties versus Pump Performance 47
4 Pressure Loss through Piping Systems 69
5 System Head Curves 113
6 Pump Performance at Different Impeller Sizes and Speeds
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7 NPSH and Pump Cavitation 149
8 Pump Applications and Economics 157
9 Pump Simulation Using PUMPCALC Software 195
Appendices
A Summary of Formulas 207
B Units and Conversion Factors 221
C Properties of Water—USCS Units 227
D Properties of Common Liquids 231
E Properties of Circular Pipes—USCS Units 233
F Properties of Circular Pipes—SI Units 251
G Head Loss in Water Pipes—USCS Units 267
H Darcy Friction Factors 275
I Least Squares Method 277
References 281
Index 283
Preface
This book is about the application of pumps and pumping stations used in pipelines
transporting liquids. It is designed to be a working guide for engineers and techni-
cians dealing with centrifugal pumps in the water, petroleum, oil, chemical, and
process industries. The reader will be introduced to the basic theory of pumps and
how pumps are applied to practical situations using examples of simulations, with-
out extensive mathematical analysis. In most cases, the theory is explained and fol-
lowed by solved example problems in both U.S. Customary System (English) and SI
(metric) units. Additional practice problems are provided in each chapter as further
exercise.
The book consists of nine chapters and nine appendices. The first chapter intro-
duces the reader to the various types of pumps used in the industry, the properties of
liquids, performance curves, and the Bernoulli’s equation. The next chapter discusses
the performance of centrifugal pumps in more detail, including variation with impel-
ler speed and diameter. The concept of specific speed is introduced and power calcu-
lations explained. Chapter 3 reviews the effect of liquid specific gravity and viscosity
on pump performance and how the Hydraulic Institute Method can be used to cor-
rect the pump performance for high viscosity liquids. The temperature rise of a liquid
when it is pumped and pump operation with the discharge valve closed are discussed.
Chapter 4 introduces the various methods of calculating pressure loss due to fric-
tion in piping systems. The Darcy equation, friction factor, the Moody diagram,
and the use of the two popular equations for pressure drop (Hazen-Williams and
Colebrook-White) are reviewed, and several examples illustrating the method of
calculation are solved. Minor losses in valves and fittings, and equivalent lengths
of pipes in series and parallel, are explained using example problems. Chapter 5
introduces pipe system head curves and their development, as well as how they are
used with the pump head curves to define the operating point for a specific pump
and pipeline combination. Chapter 6 explains Affinity Laws for centrifugal pumps
and how the pump performance is affected by variation in pump impeller diameter
or speed. The method of determining the impeller size or speed required to achieve
a specific operating point is explained using examples.
Chapter 7 introduces the concept of net positive suction head (NPSH) and its
importance in preventing cavitation in centrifugal pumps. Using examples, the
method of calculating the NPSH available in a piping system versus the NPSH
required for a specific pump is illustrated. Chapter 8 covers several applications and
x Preface
economics of centrifugal pumps and pipeline systems. Pumps in series and paral-
lel configuration as well as several case studies for increasing pipeline throughput
using additional pumps and pipe loops are discussed. Economic analysis, consider-
ing the capital cost, operating and maintenance costs, and rate of return on invest-
ment for the most cost effective option are discussed. Finally, Chapter 9 reviews
pump simulation using the popular commercial software package PUMPCALC
(www.systek.us).
The appendices consist of nine sections and include a list of all formulas pre-
sented in the various chapters, unit and conversion factors, the properties of water and
other common liquids, the properties of circular pipes, a table of head loss in water
pipes, the Darcy friction factor, and the least squares method (LSM) for fitting
pump curve data.
Those who purchase this book may also download additional code from the pub-
lisher’s website for quickly simulating some of the pump calculations described in
this book.
We would like to thank Dan Allyn and Barry Bubar, both professional engineers
with extensive experience in the oil and gas industry, for reviewing the initial outline
of the book and making valuable suggestions for its improvement.
We would also like to take this opportunity to thank Kenneth McCombs, Senior
Acquisitions Editor of Elsevier Publishing, for suggesting the subject matter and
format for the book. We enjoyed working with him as well as with Andre Cuello,
Senior Project Manager, and Daisy Sosa from MPS Content Services.

Lake Havasu City, Arizona
Author Biography

E. Shashi Menon, P.E. is Vice President of SYSTEK Technologies, Inc. in Lake
Havasu City, Arizona, USA.
He has worked in the Oil and Gas and manufacturing industry for over 37 years. He
held positions of design engineer, project engineer, engineering manager and chief
engineer with major oil and gas companies in the USA. He has authored three tech-
nical books and co-authored over a dozen engineering software applications.

Pramila S. Menon, MBA is the President of SYSTEK Technologies, Inc. in Lake
Havasu City, Arizona, USA.
She has worked in the Oil and Gas and Financial industry over the last 31 years.
Her experience includes systems modeling, feasibility studies, cost analysis and
project evaluation.
Chapter extract
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E. Shashi Menon, P.E.

Pramila S. Menon, MBA

AMSTERDAM • BOSTON • HEIDELBERG • LONDON • NEW YORK

Gulf Professional Publishing is an imprint of Elsevier

© 2010 E. Shashi Menon. Published by Elsevier Inc. All rights reserved.

Library of Congress Cataloging-in-Publication Data

British Library Cataloguing-in-Publication Data

For information on all Gulf Professional Publishing

Dedicated to our parents

This page intentionally left blank

This page intentionally left blank

E. Shashi Menon, P.E.

E. Shashi Menon, P.E.

Pramila S. Menon, MBA

This page intentionally left blank

To buy the full file, and for copyright

All requests should by sent in the first instance to

Please ensure you have book-marked our website.

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