1|Page

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About Author

Mr. L.K. Singh is an NIT graduate having 14 years of

versatile experience in oil & gas (onshore/offshore),
refinery, petrochemical & chemical Technology
research & development, engineering design &
consultancy including commission in India & abroad.
While working in top companies in India & abroad.
He got a great insight for equipment design &
process design engineering special studies work. He
is professionally Charted Chemical Engineer from
IChemE, UK Council, London since 2014.

He has also published few technical papers on his

innovative design work. Now he is running his own
engineering design company. He is a CEO & founder
of his company Petrohorizon Oil & Gas Engineering.
He is providing Engineering Design Consultancy
Services to Oil & Gas & other hydrocarbon field
operating & producing companies. Authors also
provide internship & training to engineers to become
design professionals.
3|Page

Preface

This book is all about the fluid mechanics concept

and centrifugal pump design/sizing calculations. This
book will provide in depth insight to engineers for
understanding fluid mechanics and performing pump
design calculations like the design professional
engineers. Fresher & undergraduate engineers will
get the practical concept to understand fluid flow/
fluid mechanics concept to solve any competitive
exams and academics subject problems. This is a first
edition and first volume of the book & I have tried to
include all the required concept & calculation with
example to make the easily understandable for
reader.

Any valuable suggestion from the reader & design

professional will be valuable for us to make this book
next edition more accurate & valuable.
4|Page

Introduction

This book starts with required unit conversion for

pump design/ sizing calculation. In this book the
content is not divided into chapters. In spite of that,
step by step topic is listed in the Index. It in
mandatory for a reader to read this book step wise
to understand fundamentals and concepts; required
for design calculations. If you read this book,
sequence wise, step by step, you will be able to
perform the pump design calculation like a
professional Process Design Engineer and
understand fluid mechanics in depth.

In this book, I have included manual calculation for

steady state curves [when pump is not running] and
dynamics curves [when pump is running], with the
help of this book you can draw each pump curve
manually using excel.

Book provides clear understanding where process

design engineer usually get confused.
 5|Page

Index

 Unit conversion
 List all 43 topics
(1) Bernoulli’s Equation Application
(2) Centrifugal pump suction & Discharge piping size
calculations
(3) What is pump?
(4) Pump parts explanation
(5) How pump produce pressure?
(6) How to design pump? What are the design
parameters we need to calculate for pump sizing
calculation?
(7) What is NPSHA?
(8) What is NPSHR?
(9) How to calculate pump Impeller diameter?
(10)How to select pump impeller type?
(11)Pump impeller geometry
(12)Pump affinity laws
(13)Pump specific speed
(14)Pump suction & discharge piping or pump loop
schematic & PIDS
(15)Pump suction & discharge piping hydraulic
calculation
(16)Pump control valve pressure drop calculation
 6|Page

(17)Pump NPSHA calculation

(18)Pump discharge head calculation
(19)Pump differential head calculation
(20)Pump shut off pressure calculation
(21)Pump characteristic curves
(22)Pump performance curves
(23)Pump system resistance curve
(24)Pump operating points
(25)Pump power consumption calculation
(26)Pump operating & control philosophy
(27)Pump minimum recirculation
(28)Pump discharge line PZAHH & TZAHH set point
calculation
(29)Pump PSV/TSV/TRV sizing
(30)Pump casing vent & drain connections
(31)Cavitation / Back flow or Reverse flow
(32)Pump startup procedure based on impeller types
(33)Pump capacity & head control keeping fixed
impeller diameter
(34)Pump capacity & head control keeping speed
constant
(35)Pump capacity & head control using recirculation &
orifice
(36)Pump casing fluid temperature rise during
recirculation
 7|Page

(37)Pump capacity control using VFD or Gear Drive

(38)How to read pump vender curves (characteristic
curves)?
(39)How to generate pump performance curves using
vendor pump characteristic curves?
(40)Complete pump design example
(41)Pump series operation & H Vs Q curve generation
(42)Pump parallel operation & H Vs Q curve generation
(43)Pump affinity laws detailed explanation
(44)Useful Standard Data and Charts
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(1) Bernoulli’s Equation Application

First we need to understand

What is Bernoulli equation?

And why we use it and what are its assumptions and

limitations.

It’s an Energy balance equation for incompressible

fluid flowing through pipe or closed channels.

Assumption:

1- Fluid behave ideally

2- Density of fluid is constant
3- Mass is constant
4- Volume is constant

Applications:

It’s used for calculating the pressure gain or loss and

kinetic energy gain or loss due to change in
elevations.

It’s also applicable to calculate the velocity head or

pressure head loss in piping and fittings.
10 | P a g e

We can use this equation to convert pressure head

into velocity head and vice a versa.

Limitations:

It’s applicable for incompressible fluids (liquids),

where density remains constant. It’s not applicable
for compressible fluids (gases or vapors).

Consider a section of pipe in the pump discharge

piping from point 1 to 2.
Energy balance for a section of pipe from (1) → (2)
Energy in = Energy out
E1 = E2
E1 E2 constant
E1 E2 constant
E1 Pressure energy at point (1) + K.E at point (1)
+P.E at point (1)
11 | P a g e

E2 Pressure energy at point (2) + K.E at point (2)

+P.E at point (2)
If the pump discharge pressure “P”
Then pressure energy input by pump in the fluid
streams
For pursing liquid volume “V” is =PV
We know work done=P.ΔV
1
herefore E1 P1 V 2
m V1 2 mg 1

1
E2 P2 V 2
m V2 2 mg 2

E1 E2
1
P1 P2 V 2
m V1 2 V2 2 mg

Dividing by “m” on both side

V 1
P1 P2 V1 2 V2 2 g 1 2
m 2

Bernoulli’s Equation
If the pipe is on horizontal plane & 1 2

Then equation

P 1
2
V2

P V2
=pressure head & 2
=velocity head

For ideally liquid using this equation, we can convert

pressure head into velocity head & vice a versa.
 12 | P a g e

But for real liquid & real process equation becomes

P 1
2
V2

K=energy loss constant or factor of loss for

conversion of energy in pipes & fittings

Continuously equation:
It a mass balance equation for flowing
incompressible fluids in the pipe section from 1 to 2.
Mass Balance
Mass in at point (1) =mass out at point (2)
m1 m2
V1 A1 V2 A2
This is a Continuity Equation.

(2) Centrifugal pump suction & Discharge piping

size calculations
Normal pump suction piping recommended velocity
is =1.0m/sec & discharge piping velocity is =2.5m/sec
First of all we need to calculate the Reynolds number
for suction & Discharge piping for given flow rate &
assumed pipe size for initial calculation.
 13 | P a g e

Assumptions:
1- Suction piping equivalent length is 10 meter
2- Discharge piping equivalent length is 100 meter
3- Required pump flow rate 4 m3/hr
Let first calculate the initial suction and discharge
pipe size require for 4 m3/hr flow rate using simple
formula:
m 1m
VA m sec
D2

m sec 1m sec D2

1
D

1 1 1 1
D
2 1 12 1

1
D 12 1
m

D mm 2 inch
14 | P a g e

We can calculate the pump discharge piping size by

using the above method or we can use engineering
design thumb rule discharge for calculating pump
discharge pipe size, which is half of suction pipe as
per the thumb rule. Therefore discharge pipe size=
1inch

For Suction piping

VD 1 1
e 1
Turbulent

flow

Pressure drop will be calculated using Darcy

f v2
Equation ΔP 2D

Here f=moody friction factor for turbulent flow when

For laminar flow f= when e

e

For calculating friction factor “f” for turbulent flow,

either use moody chart which is e Vs D

Where

D is ID of pipe & ε is pipe material roughness factor

Or use imperial equation.

15 | P a g e

In imperial equation you have to use heat & trial

method for different value of ‘f’ so that equation

LHS (Left Hand Side) =RHS (Right Hand Side)

Once you know the friction factor ‘f’ you can use
Darcy equation to calculate the friction pressure
drop in suction & discharge piping for given flow rate
& the pipe sizes.

f V2
Darcy equation is ΔP 2D

Where L=equivalent length of piping

D=ID of piping

V=fluid velocity in piping

Ρ= density of fluid

f= friction factor

If all units of variable in this equation are MKS units

then calculated value of ΔP (Pressure drop) would be
in Pascal.

1 bar=100 KPa

1 bar= 100,000 Pa
16 | P a g e

Note:
Dynamic or Absolute Viscosity =1 CP

We know by Newton’s Law of Viscosity

Inserting MKS units

(MKS unit)
1Pa.sec=1000cP
1cP= Pa.sec

If the frictional pressure drop calculated value in

suction and discharge piping is more than the
allowable value of pressure drop as per the system
design and NPSHA calculation, then we can increase
the piping sizes. But suction fluid velocity should
not fall below 0.8 m/s.
 17 | P a g e

(3) What is pump?

In simplest language pump is a pressure producing
machine. It take suction fluid at low pressure &
deliver at higher pressure from discharge side by
using any of the mechanical power supplying device
such as electrical motor ,gas engine, turbine. Electric
Motor, gas engine or turbine connected with pump
by shaft coupling as shown in the figure. Power is
supplied to the pump in the form of BHP [Break
Horse Power] and pump utilizes it in the form of
WHP [Water Horse Power].

Electrical Power Supply to Motor in – KW [Kilo Watt]

Electrical Motor Rated in- Hp [Horse Power]
Electrical Motor Supply Power to Pump in – BHp
[Break Horse Power]
Pump Produce- WHP [Water Horse Power]
WHP- It’s a useful work done by pump to produce
pressure.
Pump Efficiency: Ratio of WHP to BHP
 18 | P a g e

(4) Pump parts:

1- Impeller vanes
2- Impeller eye
3- Pump casing
4- Diffuser section
5- Impeller
(5) How Pump Produce Pressure?
Pump impeller rotates; pump suck liquid in the
suction, liquid enters into the pump through the
impeller eye & rotates on the impeller surface.
Impeller increases the fluid momentum & kinetic
energy by centrifugal action while rotating with
angular velocity. Impeller vanes guide the fluid
 19 | P a g e

toward the periphery of impeller. High kinetic energy

fluid leaves the impeller surface & enters into the
low cross sectional area in the pump casing & moves
towards the diffuse section of larger area where the
fluid velocity (kinetic energy) reduces & get
converted into the pressure energy (pressure head).
Conversion of kinetic energy to pressure energy is as
per energy conservation law. In this way pump
produce pressure using the mechanical power
supplied by Electric Motor or any other devices.

(6) How to design Pump? What are the design

parameters we need to calculate?
Initially, we know that how much head [in meter] we
have to develop and flow rate [in m3/hr or liter/hr] is
required to transfer liquid. Here head means the
vertical height from the base of the pump to the
vessel and tank liquid level, where we have to
transfer liquid from the suction vessel.
Required flow rate is calculated on the basis of liquid
volume [in m3 or liter] required to transfer per hour.
For required flow rate & head (discharge pressure)
to design/sizing a centrifugal pump
 20 | P a g e

We need to calculate following parameters:

1- NPSHA[Net Positive Suction Head Available]
2- Differential Head/ Discharge Pressure
3- Required Power Consumption
4- Impeller Diameter
5- Design flow rate/ Shut off Head
6- Design pressure/Design Temperature

(7) What is NPSHA:

NPSHA= Net Positive Suction Head Available.

Simply, it’s a pressure gauge reading at the suction
of pump. More precisely it’s a pressure head (suction
pressure) in meter available at the suction of the
pump when the pump not running. When the pump
start & run at certain speed NPSHA will reduce by
pressure drop in the suction piping due to friction
and required velocity head for fluid movement in the
suction piping and reach to the suction of pump.

It is calculated by Process Design Engineer using

engineering tools & calculations.
 21 | P a g e

(8) What is NPSHR?

NPSHR= Net Positive Suction Head Required Simply,
It’s a pressure head (suction pressure) in meter
required to run the pump without cavitation &
delivering required flow rate and producing required
discharge pressure. NPSHR is provide by vender
based on the pump test run performed in the
vendor laboratory for testing equipment based on
water as fluid.

(9) How to calculate pump Impeller diameter?

Suppose we want to through a cricket ball up a
certain vertical height, for that we need to through a
ball with some initial velocity so that our balls reach
up to the required vertical height. To calculate the
initial velocity, we can use the “equations of
motion”.
Pump impeller diameter is calculated based on the
concept of required initial discharge velocity to
achieve the height equivalent to required discharge
head.
Recall the equation of motion” ”
using this equation we can calculate the required
initial velocity “u”
Final velocity “V” will be zero at height “h”
 22 | P a g e

Therefore initial velocity will be m/sec if

Height[h] in meter and g is 10 m/sec2.
Use this velocity in meter,

where r= Impeller radius in meter

u= peripheral velocity of impeller m/sec calculated

by
= angular velocity of impeller
n= revolution per minutes [rpm].
Therefore, Impeller Diameter = 2* Impeller radius

(10) How to select pump impeller type?

Impeller type is selected based on the flow & head
requirement.
There are three basic types of impellers:

1- Radial: It is selected for high head and low flow

requirement
2- Axial: It is selected for low head & higher flow
requirement
3- Mixed: It is selected for medium head & medium
flow requirement.

Impellers could be open, closed, semi open impeller.

 23 | P a g e

(11) Pump impeller geometry:

Pump impeller geometry includes impeller diameter
and impeller vanes types, forward lean, backward
lean or straight.
Axial impeller & vanes are like table fan.

(12) Pump affinity laws:

Pump affinity laws define the relationship between
the pump diameters, pump speed, and pump flow
rate, developed discharge head, power consumption
& NPHR.
If we know the pump flow rate, head, power
consumption & NPSHR at some speed with fixed
diameter. Then using pump affinity laws, we can
calculate the pump flow rate, head, power
consumption, NPSHR at different speeds.
 24 | P a g e

Similarly, for fixed speed pump, if we know the

pump flow, head, power consumption, NPSHR and
impeller diameter. Then, using pump affinity laws we
can calculate the pump flow rate, head, power
consumption, NPSHR at different impeller diameters.

(13) Pump Specific Speed:

Pump specific speed is not pump speed it’s a
dimensionless number related with pump impeller
geometry & types.

Where,

Ns= Pump Specific Speed

n= Pump rotational speed, rpm

Q=GPM

H=head in feet

We can use this equation to determine which

impeller design can best match the requirements of
a particular application.
25 | P a g e

Example: If we need an impeller that will produce

1000 GPM at 200 feet of head.

If we enter Q&H values in above equation & motor

speed 3600 rpm (based on 50 Hz frequency AC
power supply) we obtain a specific speed of 2140.
Based on this specific speed we can select the
geometry & type of the impeller.

(1500-3000)- Francis Impeller

(4000-8000)-Mixed Impeller

(9000-15000)-Axial Impeller
 26 | P a g e

(14) Pump Suction & Discharge Piping or Pump

Loop Schematic & PID
 27 | P a g e

Pump Suction Side

1- Suction piping
2- Filter strainer in suction piping
3- Pressure and Temperature gauge in suction
4- Expander in suction
5- Pressure Differential Transmitter

Pump Discharge Side

1- Discharge piping
2- Reducer
3- Pressure and Temperature gauge
4- Pressure Safety Valve[PSV/PRV/TSV]
5- Isolation valve
6- Recirculation line connection
7- FCV[Flow Control Valve]
8- NRV[Non Return Valve/Check Valve]
9- PDT[Pressure Differential Transmitter]
 28 | P a g e

Pump

1- Pump Casing
2- Vent connection on pump casing
3- Drain connection at the side bottom of pump
casing
4- Priming connection on Pump casing, if the pump is
not self priming
(15) Pump suction & discharge piping hydraulic
calculation
Hydraulic calculation mean head loss (pressure) and
frictional pressure drop calculation in suction as well
as discharge piping of pump loop.

If the suction equivalent length of the piping is=

& discharge equivalent length of the piping is =

 Then frictional pressure drop in the suction piping

is

&
 Frictional pressure drop in the discharge piping is
 29 | P a g e

Static head gain or loss can be calculated as:

 Head Gain =Liquid moving from higher elevation to

lower elevation with reference to the pump
center line
 Head Loss= Liquid moving from lower elevation to
higher elevation with reference to the pump
center line

Pressure drop across control valve can be calculated

as:
[Use FPS units]

(16) Pump control valve pressure drop calculation:

Pressure drop across the flow control valve in the
pump discharge line could be calculated using

control valve equation

Pressure drop across control valve varies with the

square of flow rate. It means, if the pump flow rate is
 30 | P a g e

increased to double then pressure drop across

control valve will increase, approximately & four
times.
It can be calculated using the relationship

Where
ΔP is in Psi; Cv = control valve flow coefficient;
Q=flow in gpm; sp.gr= fluid specific gravity

(17) Pump NPSHA calculation:

Pump NPSHA is calculated as:

If the suction tank is open to Atmosphere

1- NPSHA= [Atm. Pressure (m)]+ [Suction static head

( ) in meter] – [Suction piping frictional loss
(m)]-[ Fluid vapor pressure at maximum operating
temperature] – [Piping Entry loss]-[Piping Exit loss]

If the suction tank (vessel) is closed

2- NPSHA= [Suction pressure at minimum operating

pressure]+ [Suction static head at minimum
 31 | P a g e

operating liquid level in suction vessel]- [suction

piping frictional losses]- [fluid vapor pressure at
maximum operating temperature]

If the suction vessel is open to atmosphere and

below the pump suction eye level (Negative Suction
lift)

3- NPSHA=[Atmospheric pressure (m)]- [suction lift

(pump suction eye to liquid level height)]- [Suction
piping frictional losses]- [Fluid Vapor pressure@
maximum operating pressure]- [Piping Entry Loss]-
[Piping Exit Loss]

(18) Pump discharge head calculation:

In this case reverse hydraulic calculation is
performed, i.e. form delivery point (A) to pump
discharge nozzle (B)
Pump required static discharge head= required
delivery pressure ‘P0’ + frictional pressure drop in
piping from (A) to (B) Design flow rate + discharge
static head
This is the pressure, which pump has to develop to
perform its duty.
 32 | P a g e

(19) Pump differential head calculation:

It’s a pressure difference across the pump suction
nozzle & discharge nozzle while pump is running.

Pump differential head=ΔH= [Discharge pressure

in (m)] - [Suction pressure in (m)]
This differential head is used to calculate the pump
power requirement.
 33 | P a g e

(20) Pump shut off pressure calculation:

It is the maximum pressure developed by the pump,
if the pump is running & pump discharge valve is
closed.
Pump shut off pressure= [Maximum suction

pressure] + 1.20*[Pump differential head]

(21) Pump characteristic curves:

Pump curve provided by the vendor which includes
head (based on impeller diameter) Vs flow, pump
power, pump efficiency, NPSHR, curves are called
pump characteristic curves.
These curves provide the basic information of the
pump behavior. How pump discharge pressure,
power, efficiency, NPSHR will vary with change of
pump flow rate, impeller diameter.
 34 | P a g e

(22) Pump performance curve:

These curves are produced, when the pump is
running by varying rpm, flow, suction pressure,
discharge line control valve percentage opening for
fixed suction & discharge piping size of pump.
System resistance curve is plotted with vendor pump
characteristic curves for a fixed impeller diameter.
When system resistance is included in characteristic
curves then combined curved are called pump
performance curve. Now performance is obtained
corresponding to system resistance and H-Q curve
intersection point.

Pump system resistance curve:

System resistance curve is produced when the pump
is running i.e. pump is in Dynamic mode. It tells us
the total resistance in pump suction & discharge
piping system i.e. Frictional pressure drop &
required velocity head in the pump suction &
discharge piping. System resistance is plotted on the
same H-Q characteristic curves of pump. It will be
system resistance Vs flow rate curve.
 35 | P a g e

System resistance= [Frictional Pressure (Pf1) drop in

suction] + Piping system [Velocity head (Hv1) req. in
suction piping to achieve mini suction fluid velocity]
+ [Frictional pressure drop (Pf2) in discharge piping
system] + [Velocity head (V2) req. in discharge piping
to provide minimum fluid velocity] + Pressure drop
across control valve

(23) Pump operating points:

When the pump is running at some rpm with fixed
impeller diameter then developed system resistance
curve will intersect flow Vs head curve at some
point. This point is called pump operating point.
Corresponding to this point we can read all the
performance variables of the pump. For fixed size of
 36 | P a g e

suction & discharge piping pump operating point on

H-Q curve will vary left or right by changing pump
speed (rpm), suction pressure, control valve opening,
flow rate and arrangement of suction and discharge
piping.

(24) Pump power consumption calculation:

Pump power consumption is calculated based on the
pump discharge flow rate, pump efficiency, density,
viscosity (dynamic) and differential head of the
pump.

(25) Pump operating & control philosophy

It includes pump startup, shutdown & operating
parameter control system. Operating & control
philosophy of the pump explain about how pump is
 37 | P a g e

started and stopped normally and during emergency

shutdown or operation emergency.
It also explain about the various alarm & trip system,
primary & secondary safe guarding instrument &
mechanical items, their tag number, set points &
sequence of opening & closing of valves. Attachment
with this report should includes (1) P&ID, (2) PFD (3)
PSFD (4) CEM (5) Vendor Curves (6) Pump Datasheet
(Process & Mechanical).

(26) Pump minimum recirculation:

Recirculation means diverting flow back to pump
suction vessel from pump discharge. Recirculation is
required for startup & turn down operations.
Minimum recirculation is the minimum amount or
percentage of pump discharge flow diverted back to
pump suction vessel or suction line; which is
minimum requirement to keep pump running
operation stable with minimum and within limitation
of temperature rise in the pump casing or
recirculation loop. Minimum recirculation flow is 20-
35% of pump discharge flow for stable operation &
to avoid cavitation in the pump casing. Based on the
pump efficiency, power loss by the pump is
converted into heat for conservative case.
 38 | P a g e

(27) Pump discharge line PZAHH & TZAHH set

point calculations:
Based on the pump shutoff pressure PZAHH
(Pressure Trip Alarm High High) is set at 90% of
pump shutoff pressure, whereas PAH (Pressure
Alarm High) is set at 80% of pump shut off pressure.
If the pump shutoff pressure is 100 bar, then PZAHH
set point will be 90 bar & PAH set point would be 80
bar.

Pump discharge piping design pressure, class &

pressure rating at maximum operating pressure will
be based on the pump shutoff pressure. TZAHH
(Temperature Trip Alarm High High) will be set at the
temperature at 90% of the temperature at which the
39 | P a g e

pressure rating of the discharge piping class will be

de-rated to the pump shut off pressure whereas TAH
(Temperature Alarm High) set point will be 10%
lower than the TZAHH set point.

[Pump Discharge Piping PZAHH, TZAHH, PAH and TAH Schematic

Drawing]

Let say pump discharge piping is 150# & Pump shut

off pressure is 15 bar & maximum operating
pressure of pump is 35° C.
At 0°C 150# piping rating as per API 526 & ASME
B16.5 pressure rating is 19 bar.
At 50° C it is de-rated to 17 bar. If the temperature
rise further at 80°C or above 150# pressure rating
may de-rate below 15 bar. This means around 70-
75°C is limit. Therefore we can keep TZAHH set point
at 70°C & TAH at 65 or TAH set at 10% below TZAHH
set point.
 40 | P a g e

(28) Pump PSV/TSV/TRV Sizing:

PSV/TSV is mounted either on the pump casing or on
the pump discharge line before flow control valve,
isolation valve and check valve to avoid catastrophic
failure of pump casing & discharge piping. PSV
(Pressure Safety Valve) is a mechanical item used as
ultimate equipment safeguarding item during
emergency, fire case. TSV/TRV (Thermal Safety or
Relief Valve) is installed on the pump casing or
discharge or suction piping to safeguard against
failure due to liquid thermal expansion in piping. The
size of TRV is normally fixed and taken as ¾”. As per
design engineering practice ¾ inchTRV size is found
suitable for wide range of process fluid in piping.

(29) Pump casing vent & drain connections:

Vent & drain point is provided on the pump casing
top & button (side button). Vent is useful to remove
the vapor generated or air pockets. Drain connection
is use to drain the casing for taking pump into
maintenance.
 41 | P a g e

(30) Cavitation/ Back flow or Reverse flow:

Cavitation is a phenomenon of vapor formation, air
ingress or bubble formation and bursting on the
impeller surface or inside the pump casing or at the
pump suction line.
Cavitation causes damage to pump impeller surface,
head loss, flow loss & pump casing heating.
Cavitation occurs majority in liquid pump when the
NPSHA at the pump suction is negative.
NPSHA= [Suction pressure head -friction loss-Vapor
pressure of liquid].
 42 | P a g e

Refer to the following plot. If available suction

pressure at the pump suction is below vapor
pressure of pumping fluid. In such case liquid start
boiling, flashing, and forming bubble & cause
cavitation. To avoid these problems, we should keep
the suction pressure at the inlet of the pump above
the vapor pressure of the liquid at maximum
operating temperature for more conservative design
calculation.

(31) Pump startup procedure based on impeller

types:
There are three basic types of impeller (1) Radial (2)
axial (3) mixed
1- If the impeller is Axial, then pump could be started
by keeping the discharge valve full open.
 43 | P a g e

2- If the impeller is Radial, then one should start

pump keeping discharge valve full close to let it
develop discharge pressure and flow. Once the
discharge pressure is fully developed, discharge
valve could be open slowly to its full open position.
3- If the impeller is Mixed type, then one should start
the pump keeping discharge valve partially/
cracked open. The moment flow is fully developed;
discharge valve could be open slowly to its full
open position.

(32) Pump capacity & head control keeping fixed

impeller diameter:
When the pump impeller diameter is fixed, pump
capacity & head could be controlled by varying the
motor rpm using VFD (variable frequency drive) or
varying the resistance in the discharge line as
44 | P a g e

represented in the following diagram. The resistance

in the discharge piping could be varies by changing
the percentage opening of control valve. As shown in
the following diagram, if the speed increases pump
discharge pressure increases, flow also increases to
some extent but not too large.

Pump discharge pressure could be change by

increasing/decreasing the resistance in the discharge
piping either by throttling the flow control FCV) in
the pump discharge piping or changing the discharge
piping size. By reducing the piping size,
resistance/pressure drop in the piping increases.
45 | P a g e

1- When the rpm of motor increased or decreased

then operating point either shift vertically upward
on the higher rpm pump curve or straight vertically
downwards on the lower rpm curve.

P= Initial operating point

Pi=operating point on variation of percentage
opening or rpm
46 | P a g e

2- When the control valve percentage opening is

increased, by keeping the fixed rpm, then operating
point (P) shift to right along the H-Q curve. On the
other-hand, if the percentage opening of control
valve decreased, then operating point (P) shift to the
left along the H-Q curve.
3- If both rpm (motor) and control valve percentage
opening is increased then the operating point (P) will
move right side between the horizontal & vertical
direction as shown in the diagram.
 47 | P a g e

(33) Pump capacity & head control keeping speed

constant:
When the pump driver motor speed in kept
constant, then pump capacity & head could be
control by changing the control valve percentage
opening and changing the impeller diameter.
Changing impeller diameter is one time capital
investment, whereas throttling down (reducing
percentage opening) the control valve is continuous
power loss due to pressure drop across control valve.
Initially, we try to accommodate the required pump
flow and head for the installed impeller diameter by
changing the pump motor rpm and control valve
percentage opening. If it is not possible by changing
rpm of pump motor and percentage opening of
 48 | P a g e

control valve. Then only last option we will use to

change the impeller with different diameter.
(34) Pump capacity & head control using
recirculation & orifice:

When pump driver motor rpm is fixed and impeller

diameter is also fixed, only option to control the
pump capacity and pump discharge head is either
recirculation or installation of RO (restriction orifice)
plate in the pump discharge line. But capacity and
head control will be on the cost of power loss.
Because in recirculation and restriction orifice
pressure drop, there will be continuous power loss.
This method should be used as last option for
capacity and head control.
 49 | P a g e

(35) Pump casing fluid temperature rise during

recirculation:
During recirculation of flow, pump is still running at
same rpm but pump is wasting energy in flow
recirculation and pressure drop across flow control
valve since flow control valve percentage opening is
adjusted for flow recirculation.
Therefore if the pump efficiency at the operating
point during recirculation is 60% then remaining 40%
energy will be wasted in terms of pressure drop
across flow control valve and doing work for
recirculation flow and mechanical losses inside the
pump casing which get converted into heat &
increase the temperature of fluid in the pump casing
or in recalculating loop. The flow recirculation
percentage should be kept in such a way that
temperature rise of the fluid (when the pump
started with recirculation) should not rise beyond
the TZAHH installed on the pump discharge piping. If
temperature rises very soon above TZAHH set point
after starting the pump, then before fully opining the
flow control valve in the pump discharge line, pump
will trip (stop) due to TZAHH action. In such case
operator will not be able to start the pump and run it
50 | P a g e

continuously. When such type of case happens then

what to do

In such case either we need to increase the TZAHH

set point or increase the percentage of recirculation
flow or increase the fluid volume in the complete
recirculation loop (by changing the location of
recirculation line connection in pump suction piping
or vessel) to avoid the high temperature rise in the
pump casing/ discharge time/ recirculation loop and
temperature trip (TZAHH) which shutdown cause to
stop the pump. Since TZAHH is routed by hard wire
to PLC system which cannot be override during
pump startup unlike DCS control system.
 51 | P a g e

(36) Pump capacity control using VFD or Gear

Drive:

Pump rpm could be changed by using gear system or

installing VFD (Variable Frequency Drive) for
controlling or changing the main electrical power
frequency. VFD is similar to smooth rotating knob of
ceiling fan regulator, which is used to change the
 52 | P a g e

rpm of fan. VFD could be used to fine tune the

required pump rpm; whereas gear drive could
change the rpm of pump only in certain fixed ratio.
This is the reason VFD is more energy efficient than
Gear Drive. But initial capital investment for VFD is
higher than the Gear Drive (Mechanical). But in long
run VFD saved a lot of power & could be used to fix
rpm at absolute desired or required rpm.

(37) How to read pump vender curves

(characteristic curves)?
To understand & read pump curve, first of all we
should have a general idea of shapes of pump curves
like: H Q, efficiency, NPSHR, power, resistance.
As per affinity laws at constant speed (m) & at
constant impeller diameter (D)

(linear curve)
(square curve)
(cubic curve)
53 | P a g e

H or ΔP or
Therefore H Q
[Head] [Flow] curve will be reverse square curve
shape slop of the H Q curve depends on the
impeller type and geometry.
 54 | P a g e

1- Radial impeller[ H Q] curve is quick falling curve

(High Head low flow range)
2- Axial impeller [H Q] curve is slow falling curve.
(medium head & higher flow range)
3- Mixed impeller [H Q] curve slop is between
Radial & Axial (medium Head & Medium flow range)
 System resistance Flow (Q) curve is square or
parabolic shape
Starting point (P) of system curve depends on the
suction static head available at inlet of the pump
suction. If suction pressure is zero than system curve
will start from origin (0, 0) like curve (B).
If suction pressure is “P” then system curve will start
at point P in diagram curve (A). System curve tells
 55 | P a g e

you the pressure drop (resistance) variation in the

suction & discharge piping loop (including pump
casing) when the pump is running (pump is in
dynamic mode).

Since system curve is produced only when the pump

is running, without resistance in the discharge piping
pump will not develop any head (discharge pressure)

 NPSHR flow[Q] curve

Curve tells us that initial NPSHR is higher when the
flow increases towards the BEP then NPSHR
decrease. NPSHR is minimum at BEP (best efficiency
point) as shown point (P) on NPSHR curve.
 56 | P a g e

As the flow increase & pump operating (intersection

point of system curve & H-Q curve) point moves
right to the BEP, then NPSHR start increasing. Once,
flow increase beyond the sweet zone range (which
20-30% left of BEP & 10-15% right of BEP on the
pump H Q curve) NPSHR increase rapidly.

 Power Flow curve

Power curve is cubic shape continuously rising
curve almost similar to the NPSHR curve. By
increasing flow rate, power consumption
increases.
 57 | P a g e

When, flow increase further beyond the” sweet

operating zone”, power requirement or
consumption increased to large extent. This is called
“pump run out condition” operation of pump at run
out condition is avoided due to excessive power
consumption, low efficiency, high vibration & more
powerless.

 Efficiency flow curve

Efficiency curve is either parabolic shape or half
circle shape as shown in two diagrams. In vender
provided pump characteristics curve either of these
two types of efficiency curve is shown in combined
pump characteristics diagrams.
58 | P a g e

Efficiency is maximum at the BEP & average high

when the pump operating point is in sweet operating
zone. Sweet operating zone means; where the pump
operation is stable and efficiency is high.
 59 | P a g e

(38) How to generate pump performance curves

using vendor pump characteristic curves?
Vender gives us the pump characteristic curves as
shown in diagram (A). Vendor gives H-Q curve for
different impeller diameters. One curve at rated or
selected impeller diameter, second curve at higher
diameter & third curve at lower diameter then
selected impeller diameter keeping pump speed
constant (Design Speed).
Other characteristic curves of the pump like power,
efficiency, NPSHR are fixed shape curve for particular
selected geometry of the impeller. Only H-Q curve
shifted up & down on Y-axis (pump head) axis by
changing the impeller diameter and pump rpm.
Vendor selected pump impeller diameter such that
our required design flow rate & pump discharge
head falls on BEP (Best efficiency point) on the pump
H-Q curve. The cut point shown on the H-Q curve for
the selected impeller diameter tells us the BEP point
for our design flow rate and discharge pressure
required for process. As other pump characteristic
curves shapes are fixed for specific impeller
geometry i.e. radial, mixed, axial etc.
60 | P a g e

Therefore, corresponding to BEP point marked on

the H-Q axis curve as explained above the power
requirement, efficiency, rpm and NPSHR could be
read from the vendor pump characteristic curves.
The length of the sweet zone (“_____”) marked on
the selected impeller dia. H-Q curve on both side of
the BEP point depends on the types of selected
impeller geometry.

For radial types of impeller sweet zone length is

small as compared to mixed & axial types of
impeller. For axial type of impeller the length of
61 | P a g e

sweet zone is maximum among all other types of

impeller geometry.
Length of sweet zone tells us the stable operating
range of pump with average higher pump efficiency.
Now where will be the operating point on H-Q curves
when pump run; depends on the resistance
(pressure drop) in the suction & discharge piping.
Therefore, for new pump installation suctions &
discharge piping size should be selected in such a
way that system resistance curve intersects the
pump H-Q curve preferred in BEP point or left of BEP
point on H-Q curve sweet operating zone.
62 | P a g e

For the entire range of pump operation system

resistance curve preferably intersect H-Q curve
within the sweet zone (A---B) as shown in the
diagram. Pump system resistance curve developed
when pump is in running condition; since pressure
drop (resistance) develops in the suction & discharge
piping due to friction, fitting loss, velocity head
required. If the pump is not running then there is no
friction (which occurs due to fluid flow) and no
velocity head required.
When pump is not running the pump curve will be
like shown in figure (2)
 63 | P a g e

(39) Complete pump design example:

Piping

Fitting

Total suction piping & fitting+ discharge

piping & fitting
Total suction +
64 | P a g e
65 | P a g e

= It represents the energy consumed or lost due

to the velocity of the fluid moving through the
system.
are linked & connected because is used
to calculate .
66 | P a g e

Pump is parallel:
67 | P a g e
68 | P a g e

Pump is series:
69 | P a g e
 70 | P a g e

(40) Pump series operation & H Vs Q curve

generation:
Pumps are connected in series to obtain higher
discharge pressure with same flow rate as delivered
by one pump.
It means it required pump discharge head is
increased for the same flow rate, and then we need
to install another pump in series with first pump of
same flow rate.
Series arrangement means discharge of (1) pump is
suction for second (2) pumps.

To draw series operation curve (B)

flow Pump Pump (1)&(2) in series

(Q) (1) (2) this head
head head
 71 | P a g e

Note down the at least (5) different flow rates and

corresponding head from H-Q curves of both
individual pump. Then draw both pump is series
curve by keeping the same flow rates points and
head by adding the head of both the pumps at
corresponding flow rates as shown in the table. Take
flow at x- axis and combined head at Y-axis.

(41) Pump parallel operation & H Vs Q curve

generation:
Pumps are connected in parallel to obtain higher
flow rate with same discharge head. It means if
required pump discharge flow rate is increased for
the same discharge head. Then we need to install
another pump in parallel with first pump of same
head.
Parallel arrangement means suction of both the
pumps are individual separate but both pump
discharge piping is connected with one discharge line
using T- connection as shown in diagram.
It is mandatory to have same discharge head
according to flow rate or same H-Q curve to connect
then in parallel. If different than we need to install
an orifice plate in the discharge line of higher head
pump to drop the pressure, so that both pump
 72 | P a g e

discharge line pressure is same before mixing or

connected to single discharge piping/ pipeline. If the
pressure is not equal than higher discharge pressure
pump will create back pressure or resistance for the
lower discharge pressure pump flow to enter into
mixture or single final piping

To draw parallel operation pump (B)

Head Pump Pump (2) (1)&(2) parallel

(H) (1) flow flow q combine flow
Q

Take (Q+q) on x-axis & head on Y-axis and draw the

curve of combined parallel operation curve.

(42) Pump Affinity Laws Detailed Explanation:

Pump affinity laws explains the relationship between
flow, head, rpm power, pump impeller diameter and
NPSHR when the pump is under running condition.
73 | P a g e

By using the affinity law relationship you can predict

the flow, head, NPSHR, power requirement of pumps
by varying the pump impeller diameter and pump
driver motor rpm.
As per affinity laws

For two different running conditions

Similarly

For two different running conditions

74 | P a g e

If changes are made to both Impeller diameter and

pump speed (rpm) the equations can be combined
to:

Note:
The affinity laws are valid only under conditions of
constant efficiency.
Head losses in suction and discharge pipes
respectively
Static pressure measured at suction and
discharge branch respectively.
Static pressure above suction & discharge
liquid level, respectively.
Vapor pressure of pumping fluid.

(Bernaulli’s Equation)
 75 | P a g e

1- To get the head at inlet equation shown in above

table, apply Bernoulli equation at two points (1) &
(2) shown in diagram above.
Pe Ve 2 P V 2
e HV
g 2g g 2g

2- To get the heat at outlet, apply Bernoulli equation

between point (3) & (4) shown in above diagram
Pa Va 2 Pd Vd 2
Hd g a 2g g d 2g

Bernoulli’s equation for pump suction & discharge

two points
Pd P Vd 2 V 2
H d s
g 2g

Vd V Fluid velocity in discharge & suction piping

NPSHA Total dynamic head Head at outlet
76 | P a g e
77 | P a g e

or the liquid level e, which is necessary for

the plant to operate properly must be calculated
from the condition P HA
 Equivalent length of straight pipe for valves and fittings (m)

4 4.0 1.4 1.7 5.2 6.4 4.0 33.6 0.8 5.5 11.6 12.8
3 3.4 1.2 1.2 3.7 5.2 3.4 24.1 0.6 5.5 8.2 10.4
2½ 2.8 1.1 1.0 2.8 4.0 2.8 18.9 0.5 5.5 6.7 8.8
2 2.6 1.1 0.8 2.3 3.7 2.6 16.5 0.5 5.5 5.8 8.2
1 1/2 2.3 1.0 0.6 1.7 3.0 2.3 12.8 0.4 5.5 4.6 6.1
1 1/4 2.0 1.0 0.5 1.4 2.7 2.0 11.3 0.3 5.5 4.0 5.5
1 1.6 0.8 0.4 1.0 2.0 1.6 8.8 0.3 5.2 3.4 2.3
¾ 1.3 0.7 0.3 0.7 1.6 1.3 7.3 0.2 4.6 2.7 2.0
(43) Roughness factor:

1/2 1.1 0.7 0.2 0.5 1.3 1.1 6.7 0.2 4.6 2.4 1.5
3/8 0.9 0.6 0.2 0.4 1.1 0.9 6.7 0.1 4.6 2.2 1.4
Pipe size
78 | P a g e

1/4 0.7 0.5 0.1 0.2 0.7 0.7 6.4 0.1 3.9 2.2
Regular Long Regular Line Branch Regular Globe Gate Angle Swing

Screwed
fitting
90° radius 45° flow flow 180° check
Elbows 90° Tees Return Valves Straine
bends r
 10 4.3 2.4 2.7 1.6 9.2 4.3 2.4 94.6 1.0 36.6
Equivalent length of straight pipe for valves and fittings (meter)

8 3.7 2.1 2.3 1.4 7.3 3.7 2.1

79.3 1.0 27.5
6 2.7 1.7 1.7 1.2 5.5 2.7 1.7
58.0 1.0 19.2
5 2.2 1.5 1.4 1.0 4.6 2.2 1.5 45.8 0.9 15.3
4 1.8 1.3 1.1 0.9 3.7 1.8 1.3 36.6 0.9 11.6
3 1.3 1.0 0.8 0.7 2.9 1.3 1.0
28.7 0.9 8.5
2 1/2 1.1 0.9 0.6 0.6 2.3 1.1 0.9 23.5 0.8 6.7
2 0.8 0.5 0.5 2.0 0.9 0.8
0.9 21.4 0.8 6.4
1½ 0.7 0.7 0.4 0.5 1.6 0.7 0.7 18.0 0.0 5.5
1 1/4 0.6 0.6 0.3 0.4 1.3 0.6 0.6
16.5 0.0 5.5
1 0.5 0.5 0.2 0.3 1.0 0.5 0.5
Pipe size

13.7 0.0 5.2

3/4 0.4 0.4 0.2 0.3 0.8 0.4 0.4
12.2 0.0 4.6
79 | P a g e

1/2 03 0.3 0.1 0.2 0.6 0.3 0.3

11.6 0.0 4.6
Long radius Branch Regular Long radius
Regular 90° Regular 45° Line flow Globe Gate Angle
90° flow 180° 180°

Flanged
fitting
Elbows Tees Return bends Valves
 80 | P a g e

(44) Moody chart:

 81 | P a g e

(45) Water Vapor Pressure:

Temperature (°C) Pressure (kPa)

0 0.6113
5 0.8726
10 1.22
15 1.70
20 2.33
25 3.16
30 4.24
35 5.62
40 7.38
45 9.58
50 12.34
55 15.75
60 19.93
65 25.02
70 31.17
75 38.56
80 47.37
85 57.81
90 70.11
95 84.52
100 101.32
 82 | P a g e

(46) Pipe fitting:

 83 | P a g e

(47) K factor:

Surface Absolute Roughness-K

(m) (feet)
Copper, Lead, Brass, 0.001-0.002 3.3-6.7
Aluminum (new)

PVC and Plastic Pipes 0.0015-0.007 0.5-2.33

Epoxy, vinyl ester & 0.005 1.7

isophthalic pipe
Stainless steel 0.015 5
Steel commercial pipe 0.045-0.09 1.5-3

Stretched steel 0.015 5

Weld steel 0.045 1.5
Galvanized steel 0.15 5
Rusted steel 0.15-4 5-133
(corrosion)
New cast iron 0.25-0.8 8-27
Worn cast iron 0.8-1.5 2.7-5
Rusty cast iron 1.5-2.5 5-8.3
84 | P a g e

AUTHOR’S UPCOMING BOOKS

 Heat transfer concept & shell & tube heat exchange

design volume 1.
 Engineering thermodynamics concept &
centrifugal/turbo compressor design volume 1.
 Engineering thermodynamics concept & reciprocating &
axial compressor design volume 2.
 Mass transfer concept & distillation column
design/sizing volume 1.
 Mass transfer concept & all types of separators & vessel
design/ sizing volume 2.
 Onshore/offshore engineering concept & offshore
production facilities & structure volume 1.
 Oil & gas (onshore/offshore) engineering concept &
subsea & onshore export pipeline design using pipe SIM
volume 2.
 Oil & gas (onshore/offshore) engineering concept &
flow assurance & transient study using OLGA volume 3.
 Oil & gas (onshore/offshore) engineering concept &
offshore production facilities design, simulation &
modeling using Aspen HYSYS. Volume 4
 Oil & gas (onshore/offshore) engineering concept &
dynamic simulation using Aspen HYSYS.
 Oil & gas (onshore/offshore) engineering concept &
blow down/ depressurization/ PSV sizing relief system
(flare net) design.