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Performance Curves For Centrifugal Pumps PDF
Performance Curves For Centrifugal Pumps PDF
Page 1 of 17
Net Theoretical head Relationship
From the velocity triangle shown in Fig. 1, the
net theoretical head is the head developed
based on a finite number of vanes in the
impeller. The aerodynamic relationship
between the net theoretical head (HNet
Theoretical) developed by the fluid for a given
impeller speed and its respective velocity
components at the impeller inner diameter
(ID) represented by subscript ‘1’ and outer
diameter (OD) represented by subscript ‘2’ is
written as,
HTheoretical
1
U 2V 2 U1V1 (1)
g
H Net Theoretical
1
g
U 2V' 2 U1V'1 (2)
Figure 1. Vane Geometry and Power Consumption
Volumetric Flow, Q D2b2Vr 2 2 (3)
In the current undertaking, a backward vane
positioned impeller is chosen considering From the above relationships, a contraction
lower power consumption at higher flow factor (2) is applied to estimate the flow that
rates for a single stage radial flow pump. takes into account the decrease in inlet area
of the impeller due to vane thickness. The
Principle of Performance Curves impeller outlet diameter passage width (b2)
Based on the impeller geometry, is considered to estimate the flow rate (Q)
performance curves are derived from an into the impeller. The chief parameter based
aerodynamic analysis of the pump impeller. on which other impeller parameters such as
The basic equation that governs fluid vane angle, passage width, number of vanes,
behaviour at the pump’s impeller is the etc. are calculated is the impeller inner
Euler’s Turbomachine equation relating diameter (ID), D1 and outer diameter (OD),
pump head and fluid velocity. To apply D2 for a given impeller speed (N).
Euler’s Equation, the fluid’s velocity
components are expressed as shown in Fig. 2. Pump Specific Speed (Ns)
Pump specific speed is a measure to
determine what kind of pumps can be
selected for a given service. Based on the
pump specific speed value, the choice of
pumps can vary from radial, Francis Vane,
mixed flow or axial flow. The pump specific
speed [3] is calculated in metric terms with
the below described equation,
m3
N Q rpm.
Specific Speed, s
N min (4)
H m 4
4
3 3
Volumetric efficiency is used to estimate the The slippage factor () is computed by
total flow rate entering into the impeller eye relating to the number of vanes (Z) and inlet
which in turn is used to calculate the impeller and outlet diameter vane angle, 1 and 2 as,
eye diameter. Therefore (Qs’) is computed as,
Sin 2 R
1 , For, 1 lim it (10)
Total Flow rate, Qs'
Q
(6) 1 Z 0.7
R2
v
1
3
Qs’ represents the flow that is required to R1 lim it
enter the impeller to meet the discharge flow Sin 2 R2
And, 1 1
conditions indicated by ‘Q’ since a portion of 1Z 0.7 1 lim it
the incoming fluid is expected to accumulate
in the pump. Hence all impeller design and
performance curves calculations are made R1
For, lim it (11)
with Qs’ to meet conditions of Q. R2
8.16 Sin 2
Speed and Angular Velocity Relationship
And, lim it e Z
(12)
The impeller diameters are calculated by
relating the impeller dimensions to the The number of vanes (Z) required is
impeller speed (N). The impeller speed is calculated as,
converted to velocity terms, i.e., angular
velocity (). The relationship between
D D1 2
Z 6.5 2 Sin 1 (13)
impeller speed and angular velocity is, D2 D1 2
Page 3 of 17
Impeller Dimensions Relationship The contraction factor () for the inner and
The main parameters required to be outer diameters can be estimated by using
estimated are, End of Main Shaft Diameter the thickness of the impeller passage (t) at
(Ds), Hub Diameter (DH), Hub Length (LH), the inlet and outlet diameters as,
impeller inlet passage width (b1), impeller
Zt
outlet passage width (b2) impeller eye Contraction factor, 1 (28)
DSin
diameter (D0), impeller inner diameter (D1),
and impeller outlet diameter (D2). The The values of Ku, Km1, Km2 and D2/D1 can be
impeller outer diameter (D2) can be computed from Stepanoff Chart [3],
calculated using Stepanoff Chart [2]. To
calculate the above mentioned parameters,
the following equations can be used.
PHP 321000
1
3
Shaft Dia, Dsh (15)
N rpm S s psi
Hub Diameter, DH 1.5 to 2.0 Dsh (16)
60 U 2
Impeller Outer Diameter, D2 (23)
N
D2 Figure 4. Stepanoff Chart for Ku, Km1, Km2, D2/D1
Impeller Outer Diameter, D1 D2 (24)
D1 From the equations presented, design
procedures can be commenced by assuming
D1 N
Impeller ID Tip Speed, U1 (25) ‘2’ and iteratively calculating until the actual
60
head calculated matches with the required
Qs' pump head. Followed by calculating the net
Inlet Passage Width, b1 (26)
D1Vr1 1 theoretical head, the actual head is calculated
Qs' by subtracting the pump losses for a range of
Outlet Passage Width, b2 (27) flow rates.
D2Vr 2 2
Page 4 of 17
Pump Losses The slip velocity is normalized by the
In a realistic scenario, centrifugal pumps impeller tangential velocity as [6],
experience different forms of mechanical
Vs
losses. The different types of losses expected s 1 (33)
U
during pump operation are (i) Circulation
losses, (ii) Inlet Incidence losses, (iii) Surface Therefore the slip velocities at the inlet
Friction losses, (iv) Volute Friction losses and diameter (ID) and outlet diameter (OD) are,
(v) Diffusion losses. In addition, parasitic Vs1 1 s1 U1 V'1 V 1 (34)
losses are also considered such as (vi) Disc
Friction losses and (vii) Recirculation losses. Vs 2 1 s 2 U 2 V 2 V' 2 (35)
When these losses are subtracted from the
With the assumption that the slip factor is
theoretical head, the actual head developed
nearly equal at both the impeller ID and OD,
by the pump is arrived at. The below figure
the whirl velocities are written as,
shows the difference between the net
theoretical head and actual pump head. V'1 U1 2 s1 Vr1Cot1 (36)
Page 5 of 17
such as stationary vanes, diffuser and the rest Disc Friction Losses
of the impeller surfaces, the surface frictional Disc friction losses are the result of a viscous
head loss is calculated as, friction between the outside portion of the
impeller Disc and the surface of the pump
b2 D2 D1 W1 W2 2
hsf (40) casing. Hence in the case of open impellers,
2 Sin 2 H r 4 g
the Disc friction is lower than the case where
D closed impellers are used. The Disc friction
b2 2 Sin 2 losses can be calculated as [6],
Z
Where, H R (41)
D D D1
5
b2 2 Sin 2 Pdf CM 2
3
(49)
Z 2
V Rearranging with =Qs’/v,
Where, W1 r1 (42)
Sin1 D D1
5
CM 3 2
Vr 2
hdf
Pdf
2
J / kg (50)
Where, W2 (43)
Sin 2 m Qs'
D D1
5
Diffusion Losses CM 2
3
2 kJ 1
Diffusion Losses are characterized by a loss hdf (51)
of head when the inlet impeller relative
Qs' kg 1000
D D1
5
velocity exceeds the outer impeller’s relative
CM 2
3
velocity by a certain factor due to which a 2 102.04
hdf m (52)
portion of the velocity head difference is lost. Qs' 1000
The diffusion head loss is calculated as [6],
D D1
5
W 2 W 2 0.10204 CM 2 3
hDL 0.25 1 2 2 (44) hdf 2
m (53)
W2 2g Qs'
Where,
If, W1 W2 1.4
0.25 0.1
ks s
Volute Friction Losses CM Re0.2 (54)
0.5 D2 0.5 D2
The pump volute receives the fluid pumped
Where, b4 is the volute width
by the impeller. Due to its curved shape and
changing area, pressure head is lost as the U 2 D2 2
Re (55)
fluid moves towards the discharge flange.
Modifying Ref [1] with respect to volute The value of Disc friction loss coefficient (Cm)
throat area, the volute friction loss is, depends on the Disc surface roughness (ks)
2 and also the axial gap width (s).
D2 Qs'
2
2
V
D3 A3 Recirculation Losses
hvf 0.8 (45)
2g Recirculation losses are caused due to eddies
formed in the pump impeller. The
Assuming that, D3 1.3 D2 (46) recirculation losses also depend on the size of
Taking Volute Width, b3 2 b2 (47) the impeller in addition to the flow rates into
the pump that decide the flow pattern. Hence
Volute Throat Area, A3 D3 b3 (48) with larger diameter impellers the
Page 6 of 17
recirculation losses increase. Pumps with As per Ref [8], a wearing ring clearance of
high specific speeds also tend to exhibit a 0.01 inch for rings up to 6 inch diameter or
higher chance of recirculation. The head loss less is a good practice. For rings greater than
due to recirculation is estimated as [5], 6 inches and up to 12 inch, the clearance is
3 D12 Q
2.5 increased by 0.001 inch for every inch of ring
hRL 0.005 1 (56)
Q Q0 diameter. For over 12 inch, increase by
0.0005 inches per inch of ring diameter over
Where, Q0 = Design Flow rate 12 inches. Therefore the clearance width
The value of 0.005 for the loss coefficient is taking into consideration the above criteria,
described as the default value as per Ref [5]. D D1
bcl 0.01in 0.001 2 6in (60)
Using the default value of 0.005, it is 2
observed by the Author to be very high and
yields recirculation losses with negative Actual Pump Head
numbers. The recirculation loss coefficient The Actual Pump Head is calculated by
depends on the piping configuration subtracting all the different head losses
upstream of the pump in addition to the calculated from the theoretical pump head.
geometrical details of the inlet. The current Therefore the actual head (HAct) is,
paper does not account for the upstream H Act H NT hcirc hin hsf hdL hvf hdf hRL
piping and the Author iteratively estimates (61)
that the recirculation losses coefficient is to
be taken in the order of 1 10-3 to 1 10-2 in A Case Study
order to compensate for the piping losses and To understand and validate the described
arrive at non-negative recirculation loss methodology, procedures are applied to
coefficients. estimate the performance curves for a certain
model of an industrial water pump with a
Pump Leakage Losses chosen set of process data. The pump model
Pump leakage losses cause a loss of head and used for validation is a Grundfos Model No.
subsequently efficiency due to leakages NB 200-400/392, 4 Pole, 50 Hz, End Suction
through the Disc and wearing ring. These single stage centrifugal pump, Ref [10]. The
volumetric losses can be modelled as loss of table below gives a summary of the input
flow through an orifice. From Ref [8] and Ref data used to predict the performance curves.
[9], the leakage loss can be worked out as,
Table 1. Input Process and Mechanical Data
QL CL AL 2 g H L (57) Service Industrial Water
From Ref [5], leakage Area is estimated as, Flow Rate [Q] 364 m3/h
Ref [9] provides an approximated value of 0.6 Discharge Pressure [P2] 10.0 bara
and this has been incorporated into the Required Head [H] 52.4 m
present undertaking.
Page 7 of 17
OEM Pump Efficiency [p] 73.1 % manufacturer’s data, the percentage
deviation for predicted pump head is largely
Motor Rated Capacity 110 kW
within 5% for most data points. The pump
OEM Impeller ID [D2] 392 mm hydraulic efficiency calculated however
shows a deviation of most points in the range
Results of 10% with respect to manufacturer’s data.
With the data presented in Table 1, The pump curve upon approaching shut-off
calculations were performed and repeated as head droops towards y-axis indicating a fall
shown in Table 3 for various range of pump in head as the pump approaches zero flow.
flow rates to arrive at the pump performance This is a characteristic of end suction
curves as shown in below (H vs. Q, vs. Q). centrifugal pumps where the volute friction
losses begin to increase at lower flow rates
contributing to a decrease in pump head as
shut-off conditions approach. The key
impeller geometry parameters calculated is
shown in Table 2 as follows,
Table 2. Calculated Impeller Parameters
Hub Diameter 84 mm
Figure 6. Calculated Pump Performance Curve
Hub Length 126 mm
In deriving the performance curves, the
Diameter of Impeller Eye 195 mm
min/max operable region is assigned for a
range of 80% to 110% of the best efficiency Impeller Outer Diameter 392 mm
point (BEP) while the preferred region of Impeller Inner Diameter 177 mm
operation is 70% to 120% of BEP to
Vane Angle at Inlet 27.60
minimize failure due to seal and bearing
failure. A plot is made between Vane Angle at Outlet 190
manufacturer’s data and predicted pump Number of Impeller Vanes 7
performance curves to assess the deviation
Blade Thickness 3.175 mm
as shown below.
Inlet Impeller Passage Width 57 mm
Affinity Laws
Pump flow can be treated as incompressible
flow since liquids are largely incompressible.
Fan laws can be used to derive performance
curves for various speeds based on the
following relationships.
Figure 7. Deviation between Predicted and OEM Values Q N (62)
From the deviation calculated between the H N2 (63)
predicted pump performance data and
Page 8 of 17
Constants ‘k1’ and ‘k2’ can be estimated for 4. It is not always possible to operate the
the base speed of 1493 rpm by re-writing as, pump at the BEP for the conditions
Q required and hence a flow variation of
Q k1 N k1 (64)
N 1493rpm 10% of BEP is allowed.
H
2 5. Minimum stable continuous flow (MSCF)
H k2 N k2 2
2
(65) is the minimum flow below which the
N 1493 rpm
pump is not allowed to operate. Although
The calculated values of ‘k1’and ‘k2, can be
API 610 recommends that the rated region
used to estimate the H vs. Q performance
is located between 80% and 110% of BEP
curves for speeds of 60%, 70%, 80% and
the preferred region of flow is between
90%, as shown below.
70% and 120% of BEP.
6. Clause 6.1.12 of API 610 11th edition
states “Setting limits for preferred
operating region and the location of rated
flow is not intended to lead to the
development of additional sizes of small
pumps or preclude the use of high-specific-
speed pumps. Small pumps that are known
to operate satisfactorily at flows outside of
Figure 8. Pump Performance Curves – Various Speeds the specified limits and high specific speed
pumps that may have a narrower preferred
Technical Notes
operating region than specified should be
1. For a given set of hydraulic conditions, a
offered…” Therefore the Allowable
centrifugal pump is designed to operate
Operating Region is set by the
for one set of flow and head. Deviation
manufacturer as the allowable region to
from this operating point is allowed only
operate with stability whilst conforming to
to some degree.
predefined API 610 vibration limits.
2. Pump selection closer to the BEP will yield
7. The Net Positive Suction Head Available
a more efficient pump with the least
(NPSHA) should always be higher than the
amount of vibration and radial forces
(NPSHR) required.
acting on the shaft. Pump system
resistance curve should be calculated 8. Pumps that are expected to operate less
accurately because the pump operates frequent can be chosen such that they
where the performance curve intersects operate at lower speeds at the cost of
the system curve. efficiency. Since the pump is selected to
operate intermittently, a slightly lower
3. In the case of single volute pumps,
efficiency pump is acceptable compared to
operating away from the BEP will cause
a higher speed pump. This will ensure a
the shaft to deflect with bearings and seals
longer operating life cycle.
rubbing against the casing components.
The fluid flow angle into the impeller will
also not align to match impeller speeds
and vane angles causing suction
recirculation, fluid to stall and cavitation.
Page 9 of 17
Calculations for Pump Performance Curves
A Set of calculations is presented to demonstrate the methodology for pump data presented.
Table 3. Pump Performance Curves Calculations
Output Data
Shaft Dimensions
52.4 kJ
0.1011m s 973.6 kg
3
Shaft Power
m H
3
m 102.04 kg
[L] L 69.1kW
0 0.731
3
Pump Specific N Q 1493 6.067 rpm. m min
Speed [Ns] NS 189
H
3
4 52.434 m
3
4
Main Shaft
PHP 321000
1 1
3
125 321000 3
End Diameter Dsh 1.89inch (~ 48mm)
[dsh] N rpm S s psi 1493 4000
1 1
Volumetric v 0.967 or 96.7%
1.124 1.124
Efficiency [v] 1 2
1 2
Ns 3 189 3
Hub Dimensions
Impeller Dimensions
Page 10 of 17
Angular 2 N rpm 2 1493
156 m s
Velocity [] 60 60
Impeller
Outer Taken as D2 = 0.392m (392 mm) from Table 1)
Diameter [D2]
Impeller OD
D2 156 0.392
Tip Speed U2 30.6 m s
[U2]
2 2
Impeller
D
Inner D1 D2 2 0.392 0.452 0.177m or177mm
Diameter [D1] D1
Impeller ID
ND1 1493 0.177
Tip Speed U1 13.9 m s
[U1]
60 60
Inlet Flow
Radial Vr1 K m1 2gH 0.149 2 9.81 52.4 4.8 m s
Velocity [Vr1]
Outlet Flow
Radial Vr 2 K m2 2 gH 0.113 2 9.81 52.4 3.6 m s
Velocity [Vr2]
Vane Dimensions
Vane Angle at
Assume 2=27.60 (Note: To be solved iteratively till HActual=HRequired)
Outlet [2]
Vr1
Tan 1
Vane Angle at 4.8
1 Tan1 19
0
Inlet [ 1] U1 13.9
D D1 2
Z 6.5 2 Sin 1
Number of D2 D1 2
Impeller
Vanes [Z] 0.392 0.177 27.6 19
Z 6.5 Sin 6.84 Z 7
0.392 0.177 2
8.16 Sin 2 8.16Sin27.6
lim it 2 e Z
e 7
0.583
8.16 Sin1 8.16Sin19
Check lim it1 e Z
e 7
0.685
R1
lim it R1 0.177
0.452 lim it1 lim it 2 ,
R2 R2 0.392
Sin 2
Therefore, 1
1 Z 0.7
Page 11 of 17
Slippage Sin 2 Sin27.6
s2 1 1 0.991
Factor [s2] 1 Z 0.7
19 7 0.7
Blade
Taking, 0.125 inches (0.0032m)
Thickness [t]
Thickness of
Inlet Impeller Taking, 0.3175 inches (0.0081m)
Passage [t1]
Thickness of
Outlet
Taking, 0.3175 inches (0.0081m)
Impeller
Passage [t2]
Outlet Zt 2 7 0.0081
Contraction 2 1 1 0.901
Factor [2] D2 Sin 2 0.392 Sin27.6
Inlet Impeller
Qs'
0.057 m 57mm
0.1045
Passage b1
Width [b1]
D1Vr1 1 0.177 4.8 0.688
Outlet
Qs'
0.026m 26mm
Impeller 0.1045
b2
Passage D2Vr 2 2 0.392 3.6 0.901
Width [b1]
D D1
bcl 0.01in 0.001 2 6in
Clearance 2
Width (bcl) 0.392 0.177 1000
bcl 0.01 0.001 6 0.0152in ~ 0.4 mm
2 25.4
Leakage Head
3 U 2 U12 3 30.6 2 13.9 2
HL 2
28.5 m
Loss [HL] 4 2 g 4 2 9.81
Leakage Head
QL 0.6 0.000223 2 9.81 28.5 0.00317m3 s
Loss [QL]
Outlet Qs'
Adding Leakage Loss, Qs’=Qs’ + QL, V 1 U1
Tangential Z t b1
Tan1 D1b1
Velocity [V1]
Sin1
Page 12 of 17
0.1045 0.00317
V 1 13.9 2.7 m s
7 0.0032 0.057
Tan19 0.177 0.057
Sin 190
Qs'
V 2 U1
Z t b2
Tan 2 D2b2
Outlet
Sin 2
Tangential
0.1045 0.00317
Velocity [V2] V 2 30.6 24 m s
7 0.0032 0.026
Tan27.6 0.392 0.026
Sin 27.60
Actual Whirl
V'1 U1 2 s1 Vr1Cot1 13.9 2 0.991
4.8
Velocity at 0.09 m s
Tan19
Inlet [V1']
Actual Whirl
V' 2 U 2 s 2 Vr 2Cot 2 30.6 0.991
3.6
Velocity at 23.5 m s
Tan27.6
Inlet [V2']
Slip Velocity
Vs1 1 s1 U1 V'1 V 1 0.09 2.7 2.6 m s
at Inlet [Vs1]
Slip Velocity
Vs 2 1 s 2 U 2 V 2 V' 2 24 23.3 0.7 m s
at Inlet [Vs2]
Net
Theoretical
H Net Theoretical
1
U 2V' 2 U1V'1
30.6 23.5 13.9 0.09 73.1m
Head g 9.81
[HNetTheoretical]
Theoretical
Power Qs' H 0.1045 0.00317 973.6 73.1
PNet Theoretical 75.1kW
Absorbed 102.04 102.04
[PTheoretical]
Theoretical
U 22 U12 30.6 2 13.9 2
Shut-off Head H Shutoff 75.6 m
[Hshut-off] g 9.81
Pump Losses
Circulation Losses
Circulation
H Circ
U 2Vs 2 U1Vs1 30.6 0.7 13.9 2.6 1.5m
Head Loss g 9.81
Page 13 of 17
Surface Friction Losses
Volute Throat
Assuming, D3 1.3 D2 1.3 0.392 0.51m
Diameter [D3]
Volute Width
b3 2 b2 2 0.026 0.052m
[b3]
Volute Throat
A3 D3 b3 0.5096 0.052 0.084m2
Area [A3]
2
D2 Qs'
2
V 2
D3 A3
Volute hvf 0.8
2g
Friction Loss
2
0.392 0.1034 0.00317
2
Head
24
0.51 0.084
hvf 0.8 13.8 m
2 9.81
Disc Friction Losses
Disc Friction
Taking Disc Surface Roughness [ks] = 5 microns (5 x 10-6)
Loss Head
Page 14 of 17
0.25
5 106
0.1
0.0127
CM 0.2
6416773 2.35 10
3
0.10204 CM 2 3
hdf 2
Disc Friction Qs'
Loss Head
0.392 0.177
5
3
0.10204 2.35 10 156 3
hdf 2 0.1m
0.1045 0.00317
Recirculation Losses
2.5
Recirculation 3 D12 Q
hRL 0.005 1 , Here the value of 0.005 is replaced with 0.00075
Loss Head Q Q0
Taking Max Flow Rate, Q0= 110% of Rated Flow = 1.1 x 1.1 =0.11 m3/s
2.5
3 D12 Qs'
hRL 0.00075 1
Qs' Q0
1563 0.1772 0.1045 0.00317
2.5
hRL 0.00075 1 0m
973.6 0.1045 0.00317 0.11
Diffusion Losses
Diffusion Loss
W 2 W 2
hDL 0.25 1 2 2 , If, W1 W2 1.4
Head W2 2g
V 4.8 V 3.6
W1 r 1 15m / s ; W2 r 2 8m / s
Sin1 Sin19 Sin 2 Sin27.6
W1 15
1.875 1.4
W2 8
W 2 W 2 15 2 82
hDL 0.25 2
1 2
0.25 2 1.24 m
W2 2g 8 2 9.81
Actual Head
H Actual H Net Theoretical hcirc hin hsf hvf hdf hRL hDL
[HActual]
Page 15 of 17
Nomenclature LH Hydraulic Power [kW]
HIn Incidence Head Loss [m] Veye Velocity of Impeller Eye [m/s]
Hsf Surface Friction Head Loss [m] Vr1 Radial Velocity of Flow at Inlet [m/s]
Hvf Volute Friction Head Loss [m] Vr2 Radial Velocity of Flow at Outlet [m/s]
Hdf Disc Friction head Loss [m] V1 Tangential Velocity of Flow at Inlet [m/s]
HdL Diffusion Head Loss [m] V2 Tangential Velocity of Flow - Outlet [m/s]
HL Leakage Head Loss [m] V1’ Actual Whirl Velocity Flow at Inlet [m/s]
HRL Recirculation Head Loss [m] V2’ Actual Whirl Velocity Flow at Outlet [m/s]
HActual Actual head Loss [m] Vs1 Slip Velocity at Inlet [m/s]
HR Hydraulic Radius [m] Vs2 Slip velocity at Outlet [m/s]
ks Disc Surface Roughness [m] W1 Relative Velocity at Inlet [m/s]
Ku Stepanoff Coefficient W2 Relative Velocity at Outlet [m/s]
km1 Stepanoff Coefficient Z Number of Impeller Vanes [-]
km2 Stepanoff Coefficient 1 Vane Angle at Inlet [degrees]
L Shaft Power [kW] 2 Vane Angle at Outlet [degrees]
LAH Available Hydraulic Power [kW] limit1 Limiting Radius Ratio at Inlet [-]
Page 16 of 17
limit2 Limiting Radius Ratio at Outlet [-] 7. API 610, 11th Edition
1 Contraction Factor at Inlet [-] 8. Centrifugal Pumps and Blowers, Church
2 Contraction Factor at Outlet [-] A.H., John Wiley & Sons, 1950
Page 17 of 17