Technical Article

CAVITATION – A DANGEROUS ENEMY TO PUMPS

 
By
 
Robert J. Hart, P.E.
Robert J. Hart Enterprises, LLC
 
The term “Net Positive Suction Head – Required” applies to all pumps. It is a term
that has been – and continues to be – misunderstood by many of those selecting
pumps and designing the piping systems in which they are installed. As a result,
a number of pumps operate in varying degrees of cavitation, an underlying cause
of the high maintenance costs often associated with them. Cavitation, at its
worst, sounds like loose gravel passing through the pump. Damage to seals,
bearings and impellers will usually be experienced well before the noise
of cavitation can be detected by the human ear.
 
The values of NPSH-Required, published in most manufacturers’ Generalized
Performance Curves, are values that place the pump in controlled, but
heavy cavitation. The NPSH-Required is defined as the NPSH applied to the pump
at a given flow rate which causes sufficient cavitation to reduce the Total
Dynamic Head (TDH) by 3%. This is an established pump industry standard
procedure used to indirectly measure, at a reasonable cost, the suction side
pressure loss inside a pump before mechanical action increases the liquid
pressure. The measurement is taken while pumping water with a minimum of inlet
stream turbulence (i.e. no close connected, double elbows), no entrained gas,
and frequently, with water that has most dissolved gas removed. These factors
will increase the NPSH-Required values obtained during the test. While this may
appear to be an idealistic system, and is not realistic for actual operating
conditions, it is the only method that can provide reproducible test results. The
user must apply a margin between the liquid in let total pressure and its vapor
pressure greater than this pressure loss to prevent vapor formation at the
impeller inlet.
 
Even though Figure 1 illustrates the typical vendors’ published non-
cavitating Total Dynamic Head curves (head vs. Flow) and the NPSH-Required
curve (NPSH-Required vs. Flow) on the same graph, it must be understood the
NPSH-R values applied to the pump will reduced the Total Dynamic Head
developed by the pump by 3% at any flow rate. While the hydraulic loss due to
reduced TDH is typically not significant, the resulting shock on the equipment
can reduce the mechanical life of the seal, bearings, and impellers.
 
  
Figure 1 Published generalized performance curve compared to TDH with NPSH-
A/NPSH-R = 1.0
 
NPSH-Available
 
Manufacturers expect the user to supply an NPSH-Available which exceeds the
NPSH-Required value that is published. The margin between the NPSH-Required
becomes a commercial decision and should be properly evaluated by the person
selecting the pump and developing the piping system. Systems which are
pumping liquids at their equilibrium condition, i.e. ready to flash with an increase
in temperature or a decrease in pressure, require special consideration when
pump is being selected and the system is being designed. The NPSH-Available in
such systems normally can be significantly increas3d only by:
 
      increasing the supply tank elevation above the pump;
      lowering the pump relative to the supply vessel;
      providing a booster pump;
      cooling the liquid to reduce the vapor pressure characteristic.
 
PUMP APPLICATION CONSIDERATIONS
 
As a guideline, the NPSH-Available should exceed the NPSH-Required by a
minimum of 5 feet, or be equal to 1.35 times the NPSH-Required, whichever is the
greater value. As an example, for an NPSH-Required of 20 feet, the NPSH-
Available should be a minimum of 27 feet. This is considered the minimum
acceptable margin, and even then, some degree of mechanical and erosion
damage can be experienced. Increasing the margin will improve the reliability and
acceptable operating range of the pump. In order to totally eliminate cavitation,
which affects the Total Dynamic Head, the Net Positive Suction Head-Available
must be from two to five tomes the NPSH-Required, depending on the operating
flow rate relative to the Best Efficiency Point flow rate of the pump design, as
Figure 2 illustrates.
 

 
Figure 2 Mechanical damage requires little elapse time (hours to weeks). Erosion
damage requires longer elapse time (days to months)
 
Pumps that operate with NPSH-A/NPSH-R ratio above 1.35, but below the 2X to 5X
parameter, can have what is considered “acceptable” (but not optimal) seal and
bearing life; however, they may be vulnerable to erosion damage to the impeller,
which will require more frequent impeller replacement than would otherwise be
experienced had the cavitation been totally eliminated.
 
Anyone developing pumping systems designed with these minimum
recommended margins should consider testing the equipment to be delivered to
confirm that it meets the published data. The following information should be
considered when ordering the pumps to decide if tests should be conducted:
 
      Most manufacturers do not hydraulically test pumps unless required to do
sop by the purchaser
      The first test5 of a specific pump may result in higher NPSH-Required and
Total Dynamic Head values than indicated by the published data due to
casting variations of the casing and impeller and the manufacturer’s
documentation to test procedures. To correct this condition, the manufacturer
may have to grind the controlling surfaces of the impeller and case to reduce
the NPSH-Required and reduce the impeller diameter to reduce the TDH values
within acceptable tolerances. After such modifications are made, the pump is
retested to confirm the result of the rework.
 The testing procedures followed by most manufacturers (per hydraulic
      
Institute Standards) typically yield the minimum information, which is not
considered adequate for most critical services, especially as it relates to
NPSH-Required testing. Recommended test procedures, the critique of
proposed test procedures and/or witnessing of critical equipment tests can be
supplied on requests.
 
In today’s business environments, plant investment must reap the maximum
return. It is advisable that those making decisions regarding new pumping
systems or troubleshooting existing systems take heed of this information.
Assistance on thee topics can be supplied on request.
 
Note: Bob Hart has spent 27 years as a Principal Consult in the Rotating
Machinery Group with the Engineering Department of theDuPont Company,
Wilmington, DE
 
 
Low NPSH requirements help to keep thick sludges

and large solids moving as available suction head

decreases. It also reduces installation costs.