Department of Chemical and Biochemical

Engineering. Pilot Plant

Chemical and biochemical unit operations

Exercise 1B

PUMP SYSTEMS

Original version: LGK/10.12.2013

Last revision: Stelar/14.01.2022
 Exercise 1B

Exercise 1B: Pump systems

Background

Pumping of liquids are perhaps the most frequent and important parts of process plants; they are
used practically everywhere in industry, utility and public and private houses. The understanding of
pump characteristics and the system behaviour is therefore essential to any process engineer. When
pump conditions change – for instance reduction in rotational speed – or when opening of control
valves change the system properties, a new balance is established. The understanding of the fluid
mechanic behaviour also includes such factors as media properties, pump NPSH and cavitation risk,
valve characteristics etc.

Purpose

In the exercise pump behaviour in terms of pressure, flow, power and rotational speed are
investigated and related to system and control valve characteristics. Theoretical conditions for pump
cavitation as well as pump performance related to fluid properties are determined.

Equipment

The experimental setup is shown in the photo in figure 1 and in the P&I-diagram figure 2. Water
supplied from a temperature controlled (only heating) insulated vessel is used for the experiments.
The centrifugal pump operation can be controlled using a frequency converter, a typical way of
adapting the pump performance to the system demand. The frequency converter is operated using a
remote control. How to use the remote control is explained in appendix 2.
The pump circulates the water in a loop, where the other components are an automatic control valve
of globe valve type, gate valves, a bypass around the control valve, manometers, a magnetic flow
sensor and a rotameter with manual reading.
The pressure drop across the control valve is measured by a pressure transmitter.

The magnetic flow sensor FI1 is connected to a controller FC1 located in the centre of the control
board. For controller operation see appendix 2. On the control board is also an ampere-meter (AI1)
to record to current for the pump motor.
A rotameter measures the flow as a mean to check the flow meter (FI1). Full scale value
corresponds to 2720 liters/h.

All piping’s are 1” galvanized carbon steel with inner diameter: 25 mm.

In the vessel T1 is a 3 kW heating element with a safety temperature sensor and a thermometer
(TI1) for monitoring. The temperature controller TC1 (PR signal controller 2286) is located in the
left side of the control board. For the controller operation see appendix 2.
For the moment heating opportunities are not considered in the exercise.

Page 2 of 15
 Exercise 1B

FI
AI
2
1
FC
1 Rotameter
SY
FI
1

V1 V2 V3
PI P1 PI
TC TI 2 3
1 1
V4
V7
ΔPT
T1
T1 1
V5
~ HE1

V6

Figure 2- P&I diagram of the pump system setup

Page 3 of 15
 Exercise 1B

Procedure.

Safety and Precautions.

Before starting any practical work, safety issues related to operating the equipment, and the relevant
safety data sheets for the involved chemicals, must be studied carefully. Before the work can start in
the Pilot Plant, the students must be approved by the teacher regarding the hazards and the
emergency response for running the equipment and for the chemicals in use.
Use safety glasses or goggles all time during the exercise, and gloves when stated in chemical risk
assessment

Getting ready.
Spend some time to inspect the equipment and identify the components. Use the PI diagram as
assistant.
1. Check that the vessel T1 on the ground floor is filled with cold water, otherwise refill.
2. Check V1 is open and V2 and V4 closed.
3. Open the compressed air supply to the control valve actuator and adjust the pressure to about
4 bar.
4. Turn the power on (Switch on side of control panel).
5. Open fully the control valve V3 using the flow controller FC1 in manual operation, (Full open
“out” = 0%, full close = 100% use the arrow up/down.)
6. Make sure the temperature controller TC1 is set to 20 oC. We don’t use this controller, since
only heating is possible. Instead read and note temperature at start-up and at end of
experiments.
7. Read ΔPT1 offset value (should be “0”) at zero flow.
8. Start the pump using the pump/frequency-converter remote control (for operation see
appendix 2) and adjust the speed to 100%. Open V2 fully and remove any air from the pump.
If the pump suction pipe is not full of water the pump may have function problems. In this
case add water to the suction pipe through V7.

Operation.
The following procedures in paragraph 1, 2 and 3 are performed in order to be able to record the
pump and the system characteristic. By varying pump speed, identical system conditions (for
instance 20 % control valve opening) for the two pump curves will provide a number of system
curves.
Pump curves are determined for constant pump conditions and varied system conditions, while the
system curves are determined for fixed system conditions and varying pump speed.
9. Check pump speed is 100% and V4 is closed.
Run a program of operating conditions by varying the control valve opening to (“out” = ) 0%,
5%, 10%, 15%, 20 %, 25%, 30 %, 35%, 40 %, 45%, 50 %, 55%, 60%.. etc. until the flow as a
consequence of this throttling is below 5 liters/min. For each condition read the pump speed
(n) on the remote control, read the flow (Q, liter/min) on FC1 (“PV”), the ampere meter AI1,
the differential pressure ΔPT1 across V3, the temperature TI1, pressure PI2 and PI3 and flow

Page 4 of 15
 Exercise 1B

FI2.
Repeat all measurements at same operating conditions, going backwards in valve openings.
10. Open V4 and repeat the reading of the instruments with the control valve fully opened. This
will identify the bypass operational condition for adjusting the pump performance.
11. Change the pump speed on the remote control to 80%, and repeat point 1 and 2 above.

End of experiment and cleaning

1. Stop the pump and switch off the power and compressed air.
2. Measure up piping lengths, heights, and number of bends and tees for the whole setup to use
for report calculations.

In case you have realized any problems with the equipment, please make a note in the logbook.

Reporting

Use ref. 1 or 2 or any other textbook on unit operations as source for theory and calculations not
shown in this manual.

Pump characteristics
1. Prepare the diagrams H-Q, Ne -Q and η-Q for 100% and 80% pump speed and compare
with the pump information in appendix 1. On the H-Q diagram also plot the various system
curves (for the different valve openings).
Include data from all double determinations and comment on the found results.
2. What does the intersections of the pump H-Q curves and the system H-Q curve mean? What
is the name of the intersection point? Under which conditions can (H,Q) = (0,0) be
considered as a point on the system curve?
3. Make a NPSHsy (net pressure suction head) calculation for the system in the case of
maximum flow at operation conditions and compare with the NPSHpu curve from figure 5.
4. Explain briefly what is cavitation and in relation to NPSH how to prevent cavitation. Is the
condition to avoid cavitation met in this system?
5. With the data from 100% and 80% pump speed check and comment on the validity of the
laws of affinity for centrifugal pumps (Use literature for Q-n, H-n and N-n relationships).
6. Instead of pumping water at 25°C we will pump a solution of 50 v/v% of ethylene
glycol/water at approx. 5°C, using the same pump. How will a possible pump curve (H-Q)
and the efficiency curve (η-Q) looks like for this situation? Place the curves in diagrams
with similar curves from the experiment. Comment on the curves.

Page 5 of 15
 Exercise 1B

Valve characteristics
7. Based on the measurements at 100% pump speed with closed V4 make a control valve
characteristic (flow versus degree of opening) and identify the linear part. Why is the valve
characteristic important using the valve as control valve?
8. Calculate the Kv-value for the two pump speed situations and for opening and closing the
control valve. Also include the Kv value with the bypass valve open.

System characteristics
9. The exercise plant can be considered as a closed loop pump system, in which the static
pressure changes from point to point. Make for the 80% case and V3 fully open a diagram
(Pstatic vs distance/position) that illustrates the static pressure development through the
system from the buffer tank T1 and back, considering fittings, piping and physical heights.
Add a P&I diagram to mark the positions selected.
10. Use measurements where the bypass valve V4 is closed/open as a mean to discuss plant
components connected in parallel to each other (parallel resistances).

References

1. Kiørboe, L, et al., Kemiske Enhedsoperationer, Polyteknisk Forlag 2019

2. McCabe, W.L. et al., Unit Operations of Chemical Engineering, McGraw-Hill, any ed. 2005
3. Pump Handbook, issued by Grundfos Industry 2004. (Excellent reference – Can be
downloaded for free)
4. Mackay, R., Practical Pumping Handbook. Elsevier 2004. Knovel Electronic book, DTV.
5. Lars Kiørboe, Compendium in Experimental Process Technology, any version after 2018
6. Perry’s Chemical Engineers Handbook. McGraw-Hill. Any edition.
7. Andersen, E.B.: Pumpe Ståbi (in Danish), Teknisk Forlag, any edition

Page 6 of 15
 Exercise 1B

Appendices.

Appendix 1- Theory

Pump hydraulics and performance.

For centrifugal pumps the flow capacity in the pump curves is the volumetric flow, which is largely
independent of the density of the fluid. The head H of a pump is an expression of how high the
pump can lift a liquid and is therefore measured in meter. The pump head can be calculated from:
𝑃𝑃2 − 𝑃𝑃1 𝑣𝑣22 − 𝑣𝑣12
𝐻𝐻 = (ℎ )
+ 2 − ℎ1 + (1)
𝜌𝜌𝜌𝜌 2𝑔𝑔

where index 1 refers to the pump inlet, index 2 to pump outlet, P is the static pressure [Pa], ρ is the
liquid density [kg/m3]), g is the gravity [m/s2], h is the vertical physical height [m] above a
reference level and v is the liquid velocity [m/s]. If the pump inlet and outlet pipe sizes are equal
there will be no difference in liquid velocity.
The liquid velocity contributes to the total pressure of a fluid according to relation ½ρv2, which is
called the dynamic pressure. For most systems in the chemical industry the dynamic pressure is
small compared to the static pressure.

Pump curves
The pump curve (head/flow) for 100% pump speed given by the supplier Grundfos for the multi-
stage centrifugal pump type CRE 5-2 is shown in figure 3.

Figure 3 - Pump curve for actual pump (supplier information)

Page 7 of 15
 Exercise 1B

If pump performance curves are not available, the characteristics of a particular pump can be
predicted from a similar pump and the theoretical equations from the ideal pump. This is
useful when an existing pumps impeller diameter or speed will be modified to give a different
head or capacity instead of investing in a new pump. The relationship between impellor size
and speed to capacity, head and power are called the affinity laws. The three affinity laws for
centrifugal pumps can be found in the literature, e.g. ref 1 or 6.

Pump power and efficiency.

The power transferred to the pumped liquid is:
Nt = QHgρ (2)

where Nt is in watt, Q is volume flow [ m3/s] and H is the head [mWG] (meter Water Gauge),
The pump efficiency (in percentage) is:
𝑁𝑁𝑡𝑡 (3)
η= ∙ 100
𝑁𝑁𝑒𝑒
where Ne is the power consumption of the pump motor; the efficiency covers losses in the pump,
bearings etc. Ne for a single phase AC (alternative current) motor is equal to:
Ne= U . I ⋅cos(ϕ) (4)

where U the voltage is 230 V, the current I [A] is read from AI1 and cos(φ) ~ 1.
The power consumption can also be read from the remote control, but is rather un-accurate.
Figure 4 shows the supplier information on pump efficiency at full speed.

Figure 4 - Pump efficiency at full speed (supplier information)

Net Pressure Suction Head (NPSH).

The NPSH value of a pump is the minimum absolute pressure that has to be present at the pumps
suction side to avoid cavitation. Cavitation occurs if the pressure inside the pump is lower than the
vapour pressure of the liquid. Vapour bubbles form but collapse (implode) again when the pressure
raise at the outlet of the pump which releases shock waves. Cavitation can be noisy and violent, and

Page 8 of 15
 Exercise 1B

can damage the impeller of the pump why cavitation must be avoided under normal operation. The
risk of cavitation can be estimated from a calculation of the system-NPSH (available NPSH).
The available system NPSHsy (net pressure suction head) is defined as:

NPSHsy = Ha – Hh – Hf – Hd (all calculated in mWG) (5)

where Ha is the absolute pressure on the liquid surface in the vessel on the suction side, Hh is the
difference in height between this liquid surface and the centre of the pump inlet. (Hh < 0 if the pump
inlet is lower than the liquid surface), Hf is the friction loss from liquid surface to pump inlet and Hd
is the vapour pressure of the liquid at the actual temperature.
NPSHsy must be compared with the NPSH required (NPSHpu) for the pump (in most cases informed
by the manufacturer of the pump, figure 5 shows the NPSHpu), and in order to operate without
problems (cavitation etc.):

NPSHsy > NPSHpu for all pumping conditions.

Figure 5 - Pump NPSH for actual pump

Corrections for viscosity/density

Pump curves are usually made for water at room temperature. Using a liquid with different viscosity
and/or different density will change the head, flow, efficiency and power consumption. When
handling viscous liquids there is a marked increase in power consumption, a reduction in total head
(H) and some reduction in capacity (Q). In order to make corrections, when using a liquid with
another viscosity or density, some correction factors CH, CQ and Cη can be used (ref.4):

Hl = CH Hw (6)
Ql = CQ Qw (7)
ηl = Cη ηw (8)

Page 9 of 15
 Exercise 1B

where H, Q and η have the same meaning as above, index “w” denotes water and index “l” denotes
the new liquid.
The factors CH, CQ and Cη can be determined from figure 6, where the kinematic viscosity ν is
measured in cSt (centistokes, ν = μ/ρ) and/or SSU (Seconds Saybolt Universal). The kinematic
viscosity of water at 20oC is 1 cSt.
The figure and the relations can be used to identify the performance of an existing pump while
using another liquid or to define the requirements of a new pump for a new liquid.

Finding the correction factors: Select on the x-axis the required volume flow of the liquid Q
(typically at highest pump efficiency). Move vertically to the intersection with the sloped curve for
the required or to Q associated head H. From here, move horizontally to the intersection with the
viscosity line of the new liquid (ηl), and finally move vertically to intersections with the curves for
the correction factors. Use equation (6), (7) and (8) to find the equivalent pumping parameters.
Finally the power consumption can be found from equation (2) and (3) using the new liquid data.

Page 10 of 15
 Exercise 1B

Figure 6 –Correction factors for pump characteristic’s with liquid different than water

Page 11 of 15
 Exercise 1B

Control valve characteristics.

The flow-pressure relationship in valves are:
(9)
∆𝑝𝑝
𝑄𝑄 = 𝐾𝐾𝑣𝑣 �
𝛾𝛾

where Q is the flow [m3/h], Δp the pressure drop [bar], γ the relative density of the liquid (density of
liquid divided by the density of water at the same temperature) and Kv is the valve constant. Kv is
normally defined as the quantity of liquid flowing through the fully open valve when the pressure
drop is 1 bar. Kv depends on the degree of opening of the valve, s %. s = 100 % when the valve is
fully open.
To use a valve for flow control, it is important that there is a proportional and reliable relationship
between % of valve opening and flow. A linear relationship is preferable.

Pressure losses in piping’s and components

For a stationary liquid flow from point “1” to point “2” with no energy input a mechanical energy
balance leads to equation (10) and (11):

𝑝𝑝1 + ½𝜌𝜌𝑉𝑉12 + 𝜌𝜌𝜌𝜌ℎ1 = 𝑝𝑝2 + ½𝜌𝜌𝑉𝑉22 + 𝜌𝜌𝜌𝜌ℎ2 + ∆𝑝𝑝𝑓𝑓 (10)

(𝑝𝑝2 − 𝑝𝑝1 ) + ½𝜌𝜌(𝑉𝑉22 − 𝑉𝑉12 ) + 𝜌𝜌𝜌𝜌(ℎ2 − ℎ1 ) + ∆𝑝𝑝𝑓𝑓 = 0 (11)

Where Δpf is the pressure loss due to friction [Pa], (p2-p1) is the measured static pressure drop
between position “1” and “2” [Pa], V is the average linear liquid velocity [m/s], g the gravity [m/s2],
ρ the density [kg/m3], h is the vertical height [m] above a ground level.
For zero friction equation (11) equals the well-known Bernoulli equation.

The total friction loss from stationary turbulent flow of a liquid in a pipe system can be calculated
from Fannings equation:
𝐿𝐿 𝑉𝑉 2 (12)
𝛥𝛥𝑝𝑝𝑓𝑓 = 𝜌𝜌 �4𝑓𝑓 + � 𝐾𝐾�
𝐷𝐷 2

The first term in the bracket express the friction in straight horizontal pipes of diameter D [m] and
length L[m] where f is Fannings friction factor. V is the average linear liquid velocity [m/s]. At
contractions and expansions of the piping, V refers to the smallest pipe diameter.

The term ΣK denotes the sum of loss coefficients for the fittings and valves in the system. Friction
in fittings and valves are usually described in two ways: As equivalent pipe length or as velocity
heads (loss coefficients). The sizes vary considerably from source to source, but some data are
presented in table 1 below or in reference 1 or 6.
Please recognize that for horizontal flow with no change of pipe dimension the measured static
pressure difference numerically equals the friction loss according to equation (11).

Page 12 of 15
 Exercise 1B

Table 1 - Loss coefficients

Component Loss coefficient, K

Globe valve, wide open 10.0
Gate valve, wide open 0.2
Gate valve, half open 5.6
Pipe Tee (used as elbow) 1.3
Pipe bend (elbow), 90 o 0.9
Pipe U-bend, small radius 1.7
Pipe U-bend, large radius 1.2

Pressure losses due to friction in pipes are dependent on surface smoothness of the pipes (ε) and the
turbulence of the liquid. Turbulence is described by the well-known Reynolds number (Re):

𝜌𝜌𝜌𝜌𝜌𝜌 (13)
𝑅𝑅𝑅𝑅 =
𝜇𝜇

Where µ is the viscosity of the liquid [Pa⋅s].

The relationship between frictions factor f, roughness ε (0.15 mm for galvanized steel), pipe
diameter D and Reynold number for Newtonian liquid is shown in figure 7.

Figure 7 - friction factor for Newtonian liquids based on Re and the relative roughness ε/D

Page 13 of 15
 Exercise 1B

Appendix 2- Operation of controllers

Pump/frequency-converter remote control operation.

Use the remote control to run the pump and to collect informations on performance.
To activate the remote control press “OK” twice and a “START” display appears.
Direct the remote control towards and close to the pump and press “OK”; a red lamp on the pump
will flash to indicate communication. On the display is now a picture of a pump curve. Using the
left-right and up-down arrows you can navigate around in the menu according to figure 8.

On the pump curve display press “+” to set the pump curve. Start with “100%”, which is the
maximum output. Confirm by pressing “OK”, and “OK” is always used to facilitate communication
(update information) to/from the pump.
The pump is stopped on the pump curve display by pressing “-“ to “STOP” position and “OK”.

Figure 8 – Pump remote control navigation

Flow controller operation.

The magnetic flow sensor (FI1) is connected to a controller FC1 located in the centre of the control
board. The controller can run in manual or automatic mode. To shift between manual and auto press
the button “2nd” and then the button “man/auto”.
When the controller display shows “out” during manual operation the control valve position can be
opened or closed using the “up” and “down” buttons. The valve is controlled in reverse mode, i.e.
0% refers to full open valve and 100% to complete closed valve.
When the display is shifted to PV (using the black button), the value in the display shows the actual
liquid flow in liters/min. The display “SP” means “set point” and is only of interest when running in
automatic mode.

Temperature controller operation.

The temperature controller TC1 (PR signal controller 2286) is located in the left side of the control
board. In normal conditions the display shows the actual temperature. There are three buttons on the
controller:
1. The upper one is pressed to change the set point. When pressed it is also used to reduce the
set point: The display is changing between a temperature and the word “Set”.
2. The centre button is used to increase the set point.

Page 14 of 15
 Exercise 1B

3. The lower button is used to confirm the changes.

3. Legend

Legend Description SI Unit

d Diameter m
f Friction factor -
g Gravity acceleration m/s2
h Height m
p Pressure Kg/m*s2
v Velocity m/s
H Head m or mWG 1)
I Current Ampere
K Loss coefficient -
Kv Valve constant m3/h @ pressure
NPSH Net pressure suction head m
Nt Power J/s, Kg*m2/s3, watt
Q Flow m3/h
U Voltage volt
ρ Density Kg/m3
η Efficiency %
μ Dynamic viscosity Kg/m*s, Pa*s
ν Kinematic viscosity m2/s or cSt
γ Relative density -

1) Meter water gauge

Page 15 of 15