Shahjalal University of Science and Technology, Sylhet

Department of
Chemical Engineering & Polymer Science

Assignment 1

Course Title:
Fluid Mechanics
Course Code:
CEP – 251*

Submitted to:
Md. Delowar Hossain
Lecturer,
Dept. CEP, SUST

Submitted by:
Md Afif Abrar
Reg. No. 2017332043
Session: 2017 – 2018

Date of Submission:
03 – 12 – 2020
Problem:
What is significance of system curve and pump curve in industrial chemical pump selection? What types of
technical difficulties may appear during operation due to deviation between system curve and pump curve?
What would be your recommendations as a Chemical Engineer to troubleshoot the technical difficulties.
Briefly discuss along with graph.
Solution:
We will solve the problem by classifying the cases mentioned above and solve each one at a time. Such as:
1. What is system curve and pump curve? (with graphical representations)
2. Significance of system curve and pump curve in industrial chemical pump selection.
3. Troubleshooting technical difficulties for an industrial pump.

What is system curve and pump curve?

System Curve:
The pump curve describes how a centrifugal pump performs in isolation from plant equipment. How it
operates in practice is determined by the resistance of the system it is installed in: restrictions in the pipework
and downstream frictional losses as well as static inlet or outlet pressures. A graphical representation of these
factors is called the system curve. This shows how the head pressure (at the location to be occupied by the
pump) increases with increasing throughput.

The total pressure caused by a piping system is the sum of the pressure due to inlet and outlet conditions and
the pressure required to overcome friction through the pipes and fittings.
∆𝑃𝑃𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 = (∆𝑃𝑃𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 + ∆𝑃𝑃𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 + ∆𝑃𝑃𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 )𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖−𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 + ∆𝑃𝑃𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓

Pump Curve:
Pumps can generate high volumetric flowrates when pumping against low pressure or low volumetric
flowrates when pumping against high pressures. The possible combinations of total pressure and volumetric
flowrate for a specific pump can be plotted to create a pump curve. The curve defines the range of possible
operating conditions for the pump. If a pump is offered with multiple impellers with different diameters,
manufacturers typically plot a separate pump curve for each size of impeller on the same pump performance
chart. Smaller impellers produce less pressure at lower flowrates. Pump performance charts with multiple
pump curves are shown below.
The power required to push the fluid through the pipe, Wfluid is the product of the volumetric flowrate and
system pressure drop.
𝑊𝑊𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 = 𝑉𝑉 × ∆𝑃𝑃𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡

Graphically, fluid work is represented by the area under the rectangle defined by the operating point on
a pump performance chart. Typically, the efficiency of the pump at converting the power supplied to the
pump into kinetic energy of the fluid is also plotted on the pump performance chart. Pump efficiencies
typically range from about 50% to 80%. Power that is not converted into kinetic energy is lost as heat.
The power required by the pump, which is sometimes called the “shaft work” or “brake horsepower”,
can be calculated from the flow rate, total pressure, and efficiency values from the pump curve, using
the following equation.

𝑊𝑊𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 𝑉𝑉 × ∆𝑃𝑃𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡
𝑊𝑊𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 = =
𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝
Significance of system curve and pump curve in industrial chemical pump selection.
In choosing a pump, we firstly need to ask a few questions. Such as:
Centrifugal or Positive displacement pump?
Is the fluid corrosive?
Does it have entrained solids?
Does it need to be contained?

However, having made those decisions, and if we have identified centrifugal pump technology as being
the most suitable, how do we select a model to give the required performance?

To select the right pump for an application, it is important to understand both system and pump curves. The
system curve describes the increase in head resulting from increasing fluid flow through the pipework and
other equipment in your plant. The pump curve describes the relationship between the rate of fluid flow and
head for the pump itself. When plotted on the same graph, the point at which the system curve and pump
curves intersect is called the operating point – it identifies the capacity you can expect from the pump in this
particular configuration. Ideally, you should choose a pump where the operating point matches the point of
maximum efficiency on the pump curve (BEP). The Affinity Laws allow you to predict how a pump will
perform at different rotational speeds or with an alternative impeller installed.

Overview – The System Approach

It is an established fact that a centrifugal pump will operate at the point of intersection of the impeller
characteristic curve and the system curve. Also known is the fact mathematical expressions that define these
curves can be established. It therefore stands to reason that the simultaneous solution of these two
expressions would result in a numerical demarcation of the pump’s expected operation point. This is the
basis for this course. In order to limit the length of this course, the examples and illustrations employed
utilize ideal, static systems. It cannot be over emphasized that real world systems exhibit variability and that
the range of fluid levels, pressures, temperatures, etc., in any given system must be taken into full
consideration in order to ascertain the most demanding hydraulic scenario. This comprehensive approach
will preclude an over-simplistic analysis that can result in problems. The manual techniques presented in this
course are regularly featured as an automated function in any of a number of commercially available
hydraulic software products. However, it is important to have a complete understanding of the mechanics
that are the basis of this analysis regardless of the format elected, i.e., manual or computerized. A reasonably
accurate piping system design and layout must be complete and available to the Engineer before any attempt
is made to determine the actual operational point of a centrifugal pump, irrespective of the analytical vehicle
employed. While commercially available hydraulic software can perform impressively, the fact remains that
the quality of the input data ultimately determines the merit of the overall analysis. This course is formed of
two major parts. The first part deals with the impeller characteristic curve. This curve is plotted on the pump
manufacturer’s performance curve for a given pump and it shows the relationship between the head and
capacity (flow rate) of a given pump/impeller combination. The second part deals with what is commonly
referred to as the system curve. It depicts a system’s piping circuit resistance to flow at various flow rates.
This curve is not presented on the pump manufacturer’s performance curve because each piping system is
unique and totally independent of the pump’s manufactured performance. In brief, the characteristic curve is
equipment dependent, the system curve is equipment independent. Before mathematical modeling of curves
is undertaken, an explanation of performance curves will be presented and an examination of classical pump
selection methods will be provided.
 Selecting and Sizing a Centrifugal Pump

The actual methods of arriving at the final style and size of a centrifugal pump vary widely. If the entire
system is well defined with one set of constant operating conditions, then sizing a pump is a straightforward,
simple process involving fluid dynamics fundamentals. The design flow rate in many cases are redetermined
by process requirements. Since the required pressure to overcome the various heads and to provide this
design flow rate are readily estimated, too often the pump selection and sizing routine can unfortunately
occur somewhat in this fashion:

Selection and Sizing – Assuming Stead State Conditions

1. An estimate of the maximum flow and head requirement is obtained through an abbreviated analysis of a
process or system whose design is incomplete. To this estimate a margin (maybe as much as 25%) is added
to provide a safety factor.

2. The flow and head values from Step 1, along with other pertinent information, are provided to the pump
manufacturer’s representative for a price quotation. The sales representative adds an additional 5% safety
factor, selects a suitable pump and impeller size based on efficiency, and sizes a motor so that an overload
condition will not occur in case the pump operates “out-on-the-end” of the selected characteristic curve. This
completes the selection process.

3. The Engineer receives a pump performance curve from the sales representative as part of the pump
purchase. It merely reiterates the head and flow values estimated in Steps 1 and 2 by marking their location
on the selected pump’s performance curve with a small right-angle symbol. In some instances, the pump
installed by this selection process is much too large for the actual system conditions. This necessitates the
introduction of artificial resistance in the discharge piping in order to tame the pump’s head or flow, or both.
Unfortunately, much of the installed power is wasted as unnecessary energy to compensate for the excessive
margin that was originally assumed. Moreover, many processes are not steady-state but rather transient.
Many processes operate over a range of conditions and requirements. Embracing an assumption of a
steady-state process in these circumstances is a flawed methodology. Hopefully, the information presented
below will prevent such an outcome.
 Case for Math versus Graphics

In order to fully analyze centrifugal pump process systems, we need equations that describe the impeller
diameter characteristic and a curve known as the system curve. Engineers have long used mathematical
techniques to approximate experimental observations and empirical measurements. This process is known
by various phrases some of which are:

1. Numerical modeling;
2. Least squares analysis;
3. Mathematical “smoothing” of data points and;
4. Curve fitting.

The process may not necessarily result in a curvilinear representation. In the field of statistics, the process is
called regression analysis wherein a population of raw data is reduced to a useful mathematical function. A
multitude of statistical software applications are commercially available to perform this function. It will be
shown momentarily however, that plain old math can be successfully used to “model” a centrifugal pump’s
performance and determine the point of operation. Because the techniques are relatively easy, this numerical
method is far superior to the alternative graphical method which can only produce an estimate of operation
point by approximation from the pump performance curve.

The Impeller Characteristic Curve

The impeller characteristic curve is a plot of a specific impeller’s head versus capacity relationship within a
given pump housing while pumping water. Referring back to Figure 1 on page 2, we see that this particular
pump casing can accept impeller diameters as small as 9 inches and as large as 13 inches. In this case, they
are depicted as a “family” of essentially parallel curves. Pump head and capacity are typically represented
by the letters H and Q, respectively. From this point forward, the impeller characteristic curve will be
referred to as the H-Q curve. Note: All of the curves presented in the example diagrammatic performance
curves here are merely schematic in nature.

H–Q Curve Stability

H-Q curves fall into two defining categories: (1) Stable, and (2) Unstable:
 Figure-1: Stable H-Q Curve Figure-2: Unstable H-Q Curve

Theoretically, with the H-Q curve shown in Figure 3, a pump could have the same head at two or more
capacities. This is highly unlikely in any practical sense. In reality, pump and impeller design combinations
whose tests reveal excessive unstable operation are generally not brought to market. While there has been
mention in the open technical literature about unstable impeller designs, in practical experience impellers
whose characteristic results in less head at shut-off (Q = 0) than at some positive capacity, are rarely ever
encountered. See Figure 3. Mentioned in conjunction with unstable characteristics are impellers that have
been designed for maximum flow per inch of impeller diameter or pumps with a low head coefficient. This
concept was first expounded by German Engineer C. Pfieiderer in 1932. Unstable H-Q curves have also
been referred to as “drooping curves” and pumps that could possibly exhibit this characteristic would be
better suited to non-throttling applications in which the capacity would never be expected to go below a
point corresponding to the “peak” of the H-Q curve.

Types of Stable H-Q Curves

Stable H-Q curves can be (1) Steadily decaying; (2) Steeply sloping and; (3) Relatively flat:

1. Steadily decaying 2. Steeply Sloping 3. Relatively flat

The steadily decaying H-Q curve is the one that is most frequently encountered. It exhibits a falling head-
capacity characteristic in which the head diminishes continuously as the capacity is increased. The best
efficiency point usually occurs somewhere between 15 and 20% below shut-off. This characteristic offers
very stable pump operation. The steeply sloping curve is one where there is a large decrease in head between
that developed at shut-off and that developed far-field. Obviously, this type of H-Q characteristic is best
suited for applications where minimum capacity change is desired with resulting large pressure changes. The
relatively flat H-Q curve refers to a characteristic in which the head changes minimally with changes in the
pump’s capacity.
 Conclusion

1. Using the normal or average flow and head requirement of the process or system obtained from a careful
and considered process study, make a tentative size selection from a pump manufacturer’s graphical
coverage chart (or map) of all available sizes.

2. Superimpose the system curve, preferably mathematically, or alternatively graphically, on the

performance curve of the tentatively selected pump from Step 1.

3. Select the impeller size and speed to match the intersection of the system curve. Generate additional
system curves that represent minimum and maximum flows and/or changes in static fluid levels so that the
performance of the impeller size selected for normal conditions can be evaluated over the entire anticipated
operating range.

4. Check to ensure that ample margin exists between Net Positive Suction Head Available and Net Positive
Suction Head Required at the various operating points.

5. Estimate the pump’s efficiency at the operation point determined in Step 3 and calculate the power
requirements.

6. Repeat the above procedure for larger and smaller pumps in the vicinity of the tentative pump selection to
compare efficiency at the normal operation point.

7. Make the final selection based on a life-cycle cost analysis comparison of each pump considered in Step 6
that efficiently satisfies the process requirements. Step 2 is critical in the pump selection process above.

Summary

1. Pump impeller characteristic (H-Q) curves and piping circuit resistance (system) curves can be
mathematically defined and simultaneously solved to arrive at the true operating point(s) of a centrifugal
pump. This fact is at the heart of a pump system analysis.

2. We are all challenged to use our available resources as efficiently as possible. Forcing an assumed steady-
state system analysis on a transient operating system often results in a simple, incorrect, energy inefficient,
pump selection and size.

3. A systems analysis approach that accounts for all of the requirements and variabilities for a specific
application or process should always dictate the pump selection.

Reference:

Selecting a Centrifugal Pump by System Analysis

© 2003, 2008 Randall W. Whitesides, CPE, PE
Troubleshooting technical difficulties for an industrial pump.
My troubleshooting recommendations as a Chemical Engineer for pump problems are demonstrated below.

No Liquid Being Pumped

Potential Cause How to Fix
Pump is not Ensure the pump and volute are completely full of liquid before operating the pump.
primed If any air is trapped in the pump, it will not operate correctly.
Pump loses prime Check for leaks in the pump, pipeline, and couplings which could cause air to enter
the pump. If you suspect air in the pump, make sure to vent volute/casing to remove
trapped air before resuming pumping.
Suction lift is too Check the pipeline for friction losses and ensure the static lift is not too high. If the
high static lift is too high, you’ll need to lower the pump closer to the source material or
raise the material closer to the pump.
Suction line is Remove obstruction.
clogged
Static discharge Check pipe friction losses, use larger discharge pipes.
head is too high
Rotor speed to low Ensure the motor is receiving the required voltage and correct frequency if using a
variable frequency drive.
Rotor spinning the Check the motor rotation direction as indicated by arrows on the pump casing. Make
wrong direction sure the rotor is spinning in the correct direction when the pump is in operation.
Rotor is clogged Disassemble the pump and volute to clear the rotor jam or clog.
or jammed

Flow Rate is Too Low

Potential Cause How to Fix
Air leaks in the If liquid pumped is water, test flanges for leakage with flame or match. For such
suction hose liquids as gasoline, the suction line can be tested by shutting off or plugging inlet and
putting the line under pressure. A gauge will indicate a leak with a drop of pressure.
Air leaks in the Increase the lubricant pressure to exceed atmospheric pressure, effectively locking air
stuffing box out of the stuffing box.
Cavitation Check NPSHr and NPSHa, you may not have enough positive suction head for what is
required.
Defective rotor Open up the pump and volute casing to inspect the rotor for damages. If the rotor has
been damaged, ensure it is repaired or replaced prior to powering on the pump.
Defective Inspect and replace packing if sufficiently worn.
packing
Rotor spinning Ensure the rotor is spinning in the correct direction by comparing it with the indicator
the wrong on volute. A rotor or impeller spinning in the wrong direction could damage the pump.
direction

Potential Cause
Clogged suction strainer
or inlet
Insufficient hydraulic fluid
Leak in the suction
pipeline or hose
Insufficient suction
pressure
Worn check valves
Low Suction
How to Fix
Clean out the strainer and ensure it is free from obstructions which could clog the suction
inlet.
Ensure the pump motor is filled to proper hydraulic fluid levels. Consult the manual for your
hydraulic equipment for proper fluid levels.
Inspect and repair pipeline or hose for leaks.
Raise the liquid tank level closer to the pump.
Clean or replace broken or worn-out valves to ensure proper operation.
 Pump Motor Won’t Start
Potential Cause How to Fix
Blown fuse or Clean out the strainer and ensure it is free from obstructions which could clog the
breaker suction inlet.
Starter overheating Correct cause of thermal overload and reset the motor.
Low line current Inspect lines and fix the problem.
Motor damaged Check for physical damage to motor, repair, or replace as needed.

Pump Motor Overheating

Potential Cause
Operating motor in excess of
rating
Improper wiring or voltage too low
Hydraulic oil too viscous
High ambient temperatures
How to Fix
Limit discharge pressure to max specified by the motor
manufacturer.
Check power supply vs motor nameplate details for correct specs.
Drain and refill with the correct type of oil.
Increase ventilation or relocate pump to a cooler area.

Reference:

https://www.daepumps.com/resources/common-pump-problems-troubleshooting-guide/