CENTRIFUGAL PUMP ENVELOPE 160 7.45 76.

11036
172 7.03 71.81957
Problem Statement 180 6.7 68.44824
200 5.73 58.53857
A Centrifugal pump is used to transfer water (at 200C
220 4.49 45.87054
and viscosity of 1cP) from a horizontal vessel to a
storage tank as shown in Fig. 2. 232 3.61 36.88032

Solution
The above pump curve is supplied by the vendor.
Performing a curve fitting (using excel) with the above
data yields the curve,

y = -0.0000007404x3 + 0.0001156315x2 -
0.0124113949x + 9.5097576475
Figure 2. Pump System Schematic
where y = Head (bar)
The centrifugal pump has the following Head (H) vs.
Flow (Q) characteristics as shown in Table 1 and x = Flow rate (m3/h)
operates with a flow control valve at its discharge line.
The flow rate required to be maintained is 189.2 m3/h
1. Given Parameters
with the receiving tank pressure at 1.02 bara and 1.1. Pump Suction Conditions
suction vessel pressure at 1.04 bara.
Liquid Temperature [T] = 200C
The pump system has piping components/fittings like Liquid Density [𝜌] = 997.8 kg/m3
block valves, check valves, flow elements, Y- strainers,
bends, elbows, concentric reducers, etc. which add a Dynamic Viscosity [μ] = 1Cp = 0.001 kg/m.s
dynamic pressure loss to the pump flow. These minor Vapour Pressure [PV] = 0.023 bara
pressure/head losses can be estimated by using the
relationship, Critical Pressure [PC] = 217.7 bara

𝐾𝑉 2 Pump Operating Flow [Q] = 189.2 m3/hr

hL = 2𝑔
(1)
= 0.05256 m3/s
Where, K is the Loss Coefficient and can be
Pump NPSHR = 0.69 bar
estimated from sources such as Crane’s Handbook. In
Discharge Head [PH] = -0.0000007404(189.2)3 +
this tutorial, the total minor head loss is assumed to 0.0001156315(189.2)2 - 0.0124113949(189.2) +
be 0.5 bar. Additionally, as the liquid exits the 9.5097576475 = 6.29 bar
discharge piping, the exit losses is taken to be 5 m
(~0.04 bar) based on Eq. 1.1. Pump System Piping Details
Developed a pump envelope for various flow rates Suction Pipe Size [NPSS] = 8 inches
and discharge control valve CV.
Suction Pipe Size [NDS] = 8.625 inches (Read from
The pump curves of the centrifugal pump are; ASME B36.1 pipe table)

Table 1 Suction Pipe Schedule = 40

Pump Curve Suction Pipe [WT] = 8.18 mm (Read from ASME B36.1
3
Flow(m /h) Head(bar) Head(m) pipe table)

Suction Pipe IDN [DS] = 0.2027 m = 7.98 in

0 9.51 97.15564
93 8.76 89.49352 Suction Pipe CS Area [AS] = 0.03227 m2
100 8.68 88.67623
Suction Pipe Roughness [ε] = 0.0000452
120 8.41 85.91787
140 8.01 81.83141 Suction ε/D = 0.0002

1
Suction Pipe Length = 5 m Flow Behaviour = Turbulent

Discharge Pipe Size [NPSD] = 6 inches Friction Factor Equation = Swamee-Jain

Discharge Pipe Size [NDD] =6.625 inches (Read from 0.25 0.25
Friction Factor = ε/D 5.74 = 0.0002 5.74
log[ + 0.9 ]2 log[ + ]2
ASME B36.1 pipe table) 3.7 𝑅𝑒 3.7 3296740.9

Discharge Pipe Schedule = 40 = 0.0163

𝑓×𝑙×𝜌×𝑉 2 0.0163×5×997.8×1.632
Discharge Pipe [WT] = 7.11mm (Read from ASME Pressure Drop [ΔPS] = =
2𝐷𝑆 2×0.2027
B36.1 pipe table)
= 0.0053 bar
Discharge Pipe ID [DD] = 0.1541m = 6.07 in
2.2. Discharge Side Frictional Losses
Discharge Pipe CS Area [AD] = 0.01864 m2
Q 0.05256
Discharge Pipe Roughness [ε] = 0.0000452m Discharge Velocity (VD) = A = 0.01864 = 2.82m/s
D

Discharge ε/D = 0.00029 DD ×VD ×𝜌 0.1541×2.82×997.8

Reynolds Number [ReD] = 𝜇
= 0.001
Discharge Pipe Length = 500m
= 433605
1.2. Pump Suction Conditions Flow Behaviour = Turbulent
Suction Vessel Pressure [PSV] = 1.04bar Friction Factor Equation = Swamee-Jain
Suction Vessel Elevation = 2m 0.25 0.25
Friction Factor = ε/D 5.74 2 = 0.00029 5.74
log[ + ] log[ + ]2
Suction Vessel Low Low LL =0.25m 3.7 𝑅𝑒0.9 3.7 4336050.9

Discharge Vessel Pressure [PDV] = 1.02 bar = 0.0165

𝑓×𝑙×𝜌×𝑉 2 0.0165×5×997.8×2.822
Discharge Vessel Elevation = 1m Pressure Drop [ΔPD] = =
2𝐷𝐷 2×0.1541

Discharge Vessel High High LL= 4m = 2.12 bar

1.3. Control Valve Details 3. Total Dynamic Loss Calculation
Control Valve Cv@100% FL Total Static Head [ΔPTSH] =
Opening
4” Size 0.82 [(ℎ𝐻𝐻𝐿𝐿 + ℎ𝑒𝑙𝑒𝑣 ) 𝑇𝑎𝑛𝑘 − (ℎ𝐿𝐿𝐿𝐿 + ℎ𝑒𝑙𝑒𝑣 )𝑉𝑒𝑠𝑠𝑒𝑙 ] × 𝜌 × 𝑔
236 105
6” Size 0.84 [(4+1)−(0.25+2)]×997.8×9.81
433 = 105
= 0.27 bar

NPSHA = ΔPTSH + PSV - PV - ΔPS

1.4. Minor Losses NPSHA = 0.27 + 1.04 - 0.023 - 0.0053 = 1.28 bar
ΔPMinor Losses = 0.5 bar Pump Suction Pressure[PS] =
ΔPExit Losses = 0.04 bar (ℎ𝐿𝐿𝐿𝐿 +ℎ𝑒𝑙𝑒𝑣 )𝑉𝑒𝑠𝑠𝑒𝑙 ×𝜌×𝑔
PSV + 105
- ΔPS
2. Pump System Pressure Losses (0.25+2)×997.8×9.81
= 1.04 + 105
-0.0053 = 1.25 bar
Calculation
Pump Discharge Pressure[PD] = PH + PS = 6.29 + 1.25
2.1. Suction Side Frictional Losses
= 7.54 bar
Q 0.05256
Suction Velocity (VS) = = = 1.63m/s
AS 0.03227 Control Valve Pressure Drop [ΔPCV] =
DS ×VS ×𝜌 0.2027×1.63×997.8
Reynolds Number [ReS] = 𝜇
= 0.001 PD - ΔPD - ΔPTSH - PDV - ΔPMinor Losses - ΔPExit Losses

= 329674 = 7.54 – 2.12 - 0.27 – 1.02 – 0.5 – 0.04 = 3.59 bar

2
Total Dynamic Losses[TDH] = ΔPS + ΔPD + ΔPTSH + Reinserting the calculated Cv value of 124.25, the
ΔPMinor Losses - ΔPExit Losses + ΔPCV value of Fp, FLP and new Cv is re-computed iteratively,

= 0.0053 + 2.12 + 0.27 + 0.5 + 0.04 +3.59 = 6.53 bar Iterations FP CV

1 0.921579 124.2485
2 0.976281 117.2866
4. Control Valve CV Required 3 0.978783 116.9868
For 4”, Cv@100% opening = 236; FL = 0.82 4 0.978888 116.9743
5 0.978893 116.9738
Calculating for Piping Geometry (Fp) & Liquid Pressure 6 0.978893 116.9737
Recovery Factor (FLP) 7 0.978893 116.9737
∑ 𝐾 𝐶𝑉 2 −1/2 8 0.978893 116.9737
FP = [1 + ( ) ]
𝑁2 𝑑 2 9 0.978893 116.9737
∑𝐤 = 𝐤𝟏 + 𝐤𝟐 + 𝐤𝐁𝟏 - 𝐤𝐁𝟐 10 0.978893 116.9737
2 2
𝑑2 42
K1 = 0.5 × [1 − 𝐷2 ] = 0.5 × [1 − 7.982 ] = 0.28
1 Therefore, for a flow of 189.2 m3/h, the Cv required is
𝑑2
2
42
2 116.97 gpm/√psi. For the 4” valve selected, the % Cv
K2 = 1 × [1 − 𝐷2 ] = 1 × [1 − 6.072 ] = 0.32 becomes %CV =
116.97
= 49.56%
2 236
𝑑 4 4 4
KB1 = 1 − (𝐷 ) = 1 − (7.98) = 0.94 5. Pump Operating Envelope
1

𝑑 4 4 4 To generate the pump operating envelope, the above

KB2 = 1 − ( ) = 1 − ( ) = 0.81 set of calculations is performed for various % Cv
𝐷2 6.07
between 20% to 80% to estimate the total dynamic
∑𝐤 = 0.28 + 0.32 + 0.94 - 0.81 = 0.73
head at various flows. Considering the maximum flow
0.73 236
FP = [1 + 890 ( 42 )2 ]−1/2 = 0.921 given on the pump curve, 232 m3/h, the various flows
can be taken as 0%, 10%, 20%, 30%…100% of the
−1⁄ maximum flow. With that, the following flow can be
1 𝐾1 +𝐾𝐵1 𝐶𝑉 2 2
FLP = [𝐹 2 + 𝑁2
(𝑑 2 ) ] generated.
𝐿

−1⁄ %Flow Flow Rate(m3/h) = % of 232

1 0.28+0.94 236 2 2
FLP = [0.822 + ( 2) ] = 0.75 0 0
890 4

The inlet pressure in psig for choke flow equation is 10 23.2

calculated by considering pressure drop between 20 46.4
Pump Discharge and Control Valve Inlet as, 30 69.6
𝑃1 = (7.54 × 14.7) - 14.7 = 96.1 𝑝𝑠𝑖𝑔 40 92.8
50 116
𝑃2 = 96.1 − (3.59 × 14.7) = 43.4 𝑝𝑠𝑖𝑔
60 139.2
∆𝑃SIZING = 96.1 − 43.4 = 53 𝑝𝑠𝑖 70 162.4
𝑃𝑉 0.023 80 185.6
FF = 0.96 − 0.28√ = 0.96 − 0.28√ = 0.957
𝑃𝐶 217.7 90 208.8
𝐹 2 100 232
∆𝑃CHOKED = [ 𝐹𝐿𝑃 ] [𝑃1 − 𝐹𝐹 𝑃𝑉 ]
𝑃

0.75 2
= [0.921] [96.1 − 0.957 ∗ 0.023] = 63.419 For each of the generated flow rates, total dynamic
head losses will be estimated for the several %CVs of
Since ∆𝑃sizing ≤ ∆𝑃Choked, then ∆𝑃sizing = 53 psi 20, 30, 40, …, 80. This can be achieved by solving
𝑄 189.2 backwards from percentage CV determination.
CV = = 53
= 124.25
∆𝑃 1∗0.921√
𝑁1 𝐹𝑃 √ 𝜌𝑆𝐼𝑍𝐼𝑁𝐺
1⁄ 0.9978
𝜌0

3
 𝑓×𝑙×𝜌×𝑉 2 0.022×5×997.8×2.822
Example: For flow rate = 23.2 m3/h = Pressure Drop [ΔPD] = 2𝐷𝐷
= 2×0.1541
0.00644 m3/h;
= 0.042 bar
I. 20% CV Total Dynamic Loss Calculation
20×236 Total Static Head [ΔPTSH] =
CV = 100
= 47.2
𝑄×4.4028675 2 𝜌 [(ℎ𝐻𝐻𝐿𝐿 + ℎ𝑒𝑙𝑒𝑣 ) 𝑇𝑎𝑛𝑘 − (ℎ𝐿𝐿𝐿𝐿 + ℎ𝑒𝑙𝑒𝑣 )𝑉𝑒𝑠𝑠𝑒𝑙 ] × 𝜌 × 𝑔
∆𝑃CV = [ 𝐶 𝑁 𝐹 ] [ 1⁄𝜌0 ]
𝑉 1 𝑃 105
23.2×4.4028675 2
=[ ] [0.9978] = 0.374 Bar [(4+1)−(0.25+2)]×997.8×9.81
47.2∗1∗0.921 = 105
= 0.27 bar
Discharge Head [PH] = -0.0000007404(23.2)3 +
NPSHA = ΔPTSH + PSV - PV - ΔPS
0.0001156315(23.2)2 - 0.0124113949(23.2)+
9.5097576475 = 9.27 bar NPSHA = 0.27 + 1.04 - 0.023 - 0.00011 = 1.286 bar
2
(
𝑄
) ×𝜌×9.81 0.00644 2 Pump Suction Pressure[PS] =
𝐴𝐷 ( ) ×997.8×9.81
ΔPExit Losses = = 0.01864
2×105 2×105 (ℎ𝐿𝐿𝐿𝐿 +ℎ𝑒𝑙𝑒𝑣 )𝑉𝑒𝑠𝑠𝑒𝑙 ×𝜌×𝑔
PSV + 105
- ΔPS
= 0.00584 Bar
(0.25+2)×997.8×9.81
Suction Side Frictional Losses = 1.04 + 105
-0.00011 = 1.26 bar

Q 0.00644 Pump Discharge Pressure[PD] = PH + PS = 9.27 + 1.26

Suction Velocity (VS) = A = 0.03227 = 0.199m/s
S

DS ×VS ×𝜌 0.2027×0.199×997.8
= 10.53 bar
Reynolds Number [Re] = 𝜇
= 0.001
Total Dynamic Losses[TDH] = ΔPS + ΔPD + ΔPTSH +
= 40366 ΔPMinor Losses - ΔPExit Losses + ΔPCV

Flow Behaviour = Turbulent = 0.00011 + 0.042 + 0.27 + 0.5 + 0.00584 + 0.374 =

1.19 bar
Friction Factor Equation = Swamee-Jain
0.25 0.25
Friction Factor = ε/D 5.74 = 0.0002 5.74
log[ + 0.9 ]2 log[ + ]2
3.7 𝑅𝑒 3.7 403660.9
II. Repeat for 30% CV, 40% CV, …,
= 0.0226 80%CV
𝑓×𝑙×𝜌×𝑉 2 0.0226×5×997.8×1.632
Pressure Drop [ΔPS] = = Do same for all generated flow rates and note the
2𝐷𝑆 2×0.2027
Total Dynamic Losses [TDH]
= 0.00011 bar

Discharge Side Frictional Losses The below Total Dynamic Losses table is gotten after
Discharge Velocity (VD) =
Q
=
0.00644
= 0.35m/s repeating for the various flow rates and valve CV
AD 0.01864
The centrifugal pump envelope is then generated by
DD ×VD ×𝜌 0.1541×0.35×997.8
Reynolds Number [Re] = = plotting the Total Dynamic losses against the various
𝜇 0.001
flow rates for different valve CVs
= 53115

Flow Behaviour = Turbulent

Friction Factor Equation = Swamee-Jain

0.25 0.25
Friction Factor = ε/D 5.74 2 = 0.00029 5.74
log[ + ] log[ + ]2
3.7 𝑅𝑒0.9 3.7 531150.9

= 0.022

4
 TDH(Bar)
%Flow Flow 20%Cv 30%Cv 40%Cv 50%Cv 60%Cv 70%Cv 80%Cv Pump Curve
Rate
(m3/h)
0 0 0.8 0.8 0.8 0.8 0.8 0.8 0.8 9.50975764
10 23.2 1.19128092 0.98333 0.910552 0.876865 0.85856612 0.84753221 0.84037078 9.27480528
20 46.4 2.4392571 1.60747 1.316344 1.181595 1.10839794 1.06426231 1.03561658 9.10885492
30 69.6 4.5085710 2.63705 1.982018 1.678831 1.51413791 1.41483273 1.35037985 8.95643357
40 92.8 7.3979128 4.07076 2.906263 2.367265 2.07447621 1.89793367 1.78335077 8.76206823
50 116 11.106653 5.90798 4.088451 3.246267 2.78878413 2.51293641 2.33390063 8.47028590
60 139.2 15.63443 8.14835 5.528220 4.315475 3.65669998 3.25947926 3.00166773 8.02561360
70 162.4 20.981017 10.791 7.225340 5.574659 4.67799258 4.13733105 3.78642092 7.37257832
80 185.6 27.14625 13.8376 9.179651 7.023659 5.85250335 5.14633318 4.68800158 6.45570707
90 208.8 34.130015 17.2863 11.39103 8.662362 7.18011768 6.28637106 5.70629513 5.21952686
100 232 41.932228 21.1375 13.85941 10.49068 8.66074949 7.55735860 6.84121548 3.6085647

CENTRIFUGAL PUMP ENVELOPE

20%Cv 30%Cv 40%Cv 50%Cv
60%Cv 70%Cv 80%Cv Pump Curve
10
9
8
7
6
TDH(Bar)

5
4
3
2
1
0
0 50 100 150 200 250
flow rate (m3/h)