Chapter (5)

Pump System Curve

Characteristics
of
Centrifugal Pumps
 Characteristics of
Centrifugal Pumps
 Net Positive Suction
Head Required
 The Valves of a
Centrifugal Pump
 Centrifugal Pump
Operation
 Centrifugal Pumps -
Flow & Pressure
 Cavitation
 Air Binding In a
Centrifugal Pump
 Pump System Curve
5.1. Characteristics of Centrifugal Pumps
Centrifugal pumps are specified by four characteristics:
1. Capacity
2. Total Head
 Suction Head
 Discharge Head
3. Power
4. Efficiency
Centrifugal pumps are specified by four characteristics.
1. Capacity
This is defined as the quantity of liquid which is discharged from the
pump in a given time. Capacity is expressed in 'm3/hr', 'gal/min', ..etc. The
capacity of a pump is governed by the 'Head', the 'Speed' and the 'Size' of
the pump.
2. Total Head
The total head of a pump is the difference between the pump suction and
discharge pressures - expressed in terms of meters or feet head.
Suction Head:
This is the vertical distance, in feet or meters, from the centerline of the
pump to the level of liquid in the vessel from which the liquid is being
pumped.
IF THE LIQUID LEVEL IS ABOVE THE PUMP CENTRELINE,
THE SUCTION HEAD IS POSITIVE.
IF IT IS BELOW THE CENTRELINE, THE SUCTION HEAD IS
NEGATIVE.
Discharge Head:
Is the discharge pressure of the pump, expressed in feet or meters of
liquid.
Total Head: = Discharge head -Suction head
(See Figure: 5.1)

Figure: 5.1 – Total Head

In Figure5.1, the pump is taking suction from Tank 'A' and discharging to
Tank 'B'. The Head (or height) of water in 'A' to the centre-line of the
pump is 23 feet. This is called the 'SUCTION HEAD'.
The discharge line inlet to 'B' is 50 feet above the pump centre-line. This
is the 'DISCHARGE HEAD'. The 'TOTAL HEAD' is the difference
between the two figures.
This is 50 -23 = 27 feet.
(Note: If the suction vessel is BELOW the pump centre line, the suction
head will be a NEGATIVE figure).
Using the formula for Static Head Pressure, we can find the suction and
discharge pressures of the pump. (Both tanks are at atmospheric
pressure).
Suction pressure = 23 x 0.433 = 10 Psig.
Discharge pressure = 50 x 0.433 = 21.7 Psig
If a liquid other than water is used, the Specific Gravity of the liquid must
be included in the above formula to obtain the pressures.
E.g.
If we use an oil with S.G. of 0.88, the pressures would be: -
Suction pressure = 23 x 0.433 x 0.88 = 8.8 Psig.
Discharge pressure = 50 x 0.433 x 0.88 = 19.1 Psig
3. Power:
This is the energy used by the pump in a given time. Its unit is
'Horsepower' (HP). 1 HP is equivalent to 0.746 kilowatt. (KW)
4. Efficiency:
This is a percentage measure of the pump's effectiveness in transferring
the power used into energy added to the pumped liquid.
The formula for calculation of efficiency is :
Efficiency = (Output power)/(Input power) X 100%
Pumps in industry, usually operate at 70% to 80% efficiency.
5.2. Net Positive Suction Head Required
The pump manufacturer's specified margin of suction pressure above the
boiling point of the liquid being pumped, is required to prevent
cavitation. This pressure is called the 'Net Positive Suction Head' pressure
(NPSH). In order to ensure that a NPSH pressure is maintained, the
Available NPSH should be higher than that required. The NPSH depends
on the height and density of the liquid and the pressure above it.
5.3. The Valves of a Centrifugal Pump
The suction and discharge piping of a centrifugal pump will generally
have the following valve arrangements:
1. Suction Valve: Allows liquid to enter the pump.
2. Discharge Valve: Allows liquid to flow from the pump to other
parts of the system.
3. Check or Non-Return Valve: In the discharge line -Prevents
back-flow from discharge to suction through the pump.
4. Vent (priming) Valve: This is used to vent off air/gases from the
pump before start-up.
5.Gauge Isolation Valves: Allows the replacement of pressure
gauges on suction and discharge lines, the most important being the
discharge pressure.
6. Gland Seal Valve: (where fitted). Controls the flow of cooling
media to the pump gland cooling fluid.
7. Recycle Valve: This is a flow line valve which is used to recycle
pumped liquid back to the suction side or to the suction vessel, in
order to maintain a flow through the pump when the discharge
valve, (and/or FCV), is closed. (Prevents heat build-up).
8. Drain Valve: Fitted on the bottom of the pump casing and used
to drain the pump prior to maintenance work being done.
( See Figure : 5.2 )

Figure: 5.2
5.4. Centrifugal Pump Operation
I- Pump Start-up Procedure
1. Line up the pump valves.
2. Ensure that the drain valve is closed.
3. Open the suction valve.
4. Open the vent valve to bleed off gases - when liquid comes from
the vent valve - close it again. (This is called 'Priming the pump').
5. Open the gland-seal valve (if fitted).
6. Commission the bearing and oil cooling systems (if fitted).
7. If an oil bottle or 'slinger-ring' reservoir is used for the bearings,
ensure it is full and functioning properly.
8. Check by hand that the pump shaft is freely rotating - (power is
OFF at this point).
9. Energise or, if the rule applies, have the electrician energise, the
power supply.
10. The discharge valve, at this point, should still be closed.
11. Start the pump motor. Check that the pump is rotating in the
correct direction.
12. Check that the discharge pressure is steady - if not check at the
vent and release any further trapped gas.
13. Check for vibration, overheating and/or any undue noise from
the pump, bearings or coupling.
14. Re-check the lube and cooling systems and check for leaks at
the pump glands. (With the 'packed' type gland seal, a slight
leakage is desirable for lubrication and cooling of the gland). Open
the discharge valve
15. Report to control room that the pump is in operation and all is
O.K. (If not O.K. -shut down the pump and have the control room
operator call a maintenance mechanic).
II- Pump Shut-down Procedure
1. Close the discharge valve.
2. Press the stop button.
• Leave the suction open unless the shut-down is for maintenance.
This will prevent pressure build up due to temperature increase on
hot days.
If the shut-down is for maintenance:
3. Close the suction valve and stop other ancillary systems where
fitted.
4. Open the drain and vent valves and ensure that the pump is fully
drained and de-pressured.
5. Report to the control room that the pump is ready for
maintenance.
5.5. Centrifugal Pumps - Flow & Pressure
A. In Parallel:
Where extra flow is required, two or more pumps can be operated in
'parallel'. This means that the pumps all take suction from a common
header and discharge into another common header. The number of pumps
in the parallel line-up, depends on the system flow requirements.
B. In Series:
Where extra pressure is required, pumps may be operated in 'series'.
Here, a pump takes suction from a vessel and discharges into the suction
of another pump which then discharges into the system. The number of
pumps lined up in series depends on the system pressure requirements.
(See Figure: 5.3)
 Figure 5.3
5.6. Cavitation
Cavitation is a problem condition which may develop while a centrifugal
pump is operating. This occurs when a liquid boils inside the pump due to
insufficient suction head pressure. Low suction head causes a pressure
below that of vaporization of the liquid, at the eye of the impeller.
The resultant gas which forms causes the formation and collapse of
'bubbles' within the liquid. This, because gases cannot be pumped
together with the liquid, causes violent fluctuations of pressure within the
pump casing and is seen on the discharge gauge. These sudden changes in
pressure cause vibrations which can result in serious damage to the pump
and, of course, cause pumping inefficiency.
To overcome cavitation:
1. Increase suction pressure if possible.
2. Decrease liquid temperature if possible.
 3. Throttle back on the discharge valve to decrease flow-rate.
4. Vent gases off the pump casing.
5.7. Air Binding In a Centrifugal Pump
Air binding occurs when air is left in a pump casing due to improper
venting, or, air collects when the pump is operating.
The air, as it collects, forms a pocket around the impeller which forces
liquid away from it. The impeller then spins in the air and heat begins to
build up.
Symptoms of air binding:
• Fluctuating pressure for a short time. The pressure may then stop
jumping and fall quickly.
• Overheating of the pump may take place shortly after air binding
occurs.
• An air-bound pump sounds quieter than normal.
To correct air binding:
• Vent the pump during operation.
• In some cases, the pump must be shut down and allowed to cool.
The air must then be vented off.
5.8. System Curves
• For a specified impeller diameter and speed, a centrifugal pump
has a fixed and predictable performance curve.
• The point where the pump operates on its curve is dependent upon
the characteristics of the system in which it is operating, commonly
called the System Head Curve. ..or, the relationship between flow
and hydraulic losses in a system.
• This representation is in a graphic form and, since friction losses
vary as a square of the flow rate, the system curve is parabolic in
shape.
 • By plotting the system head curve and pump curve together, it can
be determined:
1. Where the pump will operate on its curve.
2. What changes will occur if the system head curve or the
pump performance curve changes.

5.8.1. No Static Head - All Friction

• As the levels in the suction and discharge are the same (Fig. 5.4),
there is no static head and, therefore, the system curve starts at zero
flow and zero head and its shape is determined solely from pipeline
losses.
• The point of operation is at the intersection of the system head
curve and the pump curve.
• The flow rate may be reduced by throttling valve.
 (Fig.5.4) - No Static Head All Friction

5.8.2. Positive Static Head

• The parabolic shape of the system curve is again determined by the
friction losses through the system including all bends and valves.
• But in this case there is a positive static head involved.
• This static head does not affect the shape of the system curve or its
"steepness", but it does dictate the head of the system curve at zero
flow rate.
 • The operating point is at the intersection of the system curve and
pump curve.
• Again, the flow rate can be reduced by throttling the discharge
valve. (Fig. 5.5)

(Fig. 5.5) - Positive Suction Head

5.8.3. Negative (Gravity) Head
• In the illustration below (Fig. 5.6), a certain flow rate will occur by
gravity head alone.
• But to obtain higher flows, a pump is required to overcome the
pipe friction losses in excess of "H" - the head of the suction above
the level of the discharge.
 • In other words, the system curve is plotted exactly as for any other
case involving a static head and friction head, except the static
head is now negative.

(Fig. 5.6) - Negative (Gravity) Head

• The system curve begins at a negative value and shows the limited
flow rate obtained by gravity alone.
• More capacity requires extra work.
5.8.4. Mostly Lift- Little Friction Head
• The system head curve in the illustration below starts at the static
head "H" and zero flow. (Fig. 5.7)
 • Since the friction losses are relatively small (possibly due to the
large diameter pipe), the system curve is "flat".
• In this case the pump is required to overcome the comparatively
large static head before it will deliver any flow at all.

(Fig. 5.7) Mostly Lift - Little Friction Head

5.8.5. Calculating System Curve

• Advanced Analysis of Pumping Systems Requires and
Understanding of "System Curve"
• In order to analyze many pumping systems, a thorough
understanding of "System Curve" is required.
• Understanding variable speed systems, parallel pump systems, and
series pump systems all rely on understanding the system curve
• Also, predicting the energy usage of a pump with different
diameter impellers relies on an understanding of system curve.
• Keys to understanding the system curve are:
1. Each piping system has a unique performance curve called
its system curve.
2. The system curve defines the relationship between flow
quantity through the system and the total resistance that the
system offers to flow. Units most often used in the English
system are GPM for flow and "feet" for total resistance
where GPM is short for gallons per minute and "feet" is
short for feet of head.
3. The system curve is completely independent of any pump
curve. One could install any pump in a given piping system,
and the system curve would not change.
4. The system curve is parabolic shaped. It can be
completely defined and plotted if two operating points are
known.
5. When a pump is installed and operated in a system, the
point of operation (expressed in flow and head) will be at a
single point where the pump curve and the system curve
intersect. This is logical, because the system must operate on
its curve, and the pump must operate on its curve, so the
point of operation of an installed pump must be common to
both curves.
6. When we "balance" a pump’s capacity by throttling a
valve, we actually shift the system curve by adding or
subtracting resistance to flow. The balanced point of
 operation is where the pump curve and "new" system curve
intersect.
• To draw a system curve, it is first necessary to calculate the
resistance to flow through the system (the "head") at one operating
point.
• This is normally done at the design flow point.
• For example, if the design flow is 200 GPM, the head is calculated
at 200 GPM.
• The method for doing so is beyond the scope of this paper.
• An understanding of that article is necessary to understand
development of the system curve.
5.8.5.1. System Curve for Closed Systems
• The resistance to flow for a closed system consists only of friction
head (also called pressure drop). Velocity head, static head, and
pressure head do not affect the resistance to flow in a closed
system.
• It is generally accepted that the resistance to flow varies with the
square of the quantity of flow.
• Assume that a flow rate of 100 GPM results in a friction head of 75
ft. in a given system.
 Doubling the flow in the same system to 200 GPM would
result in a friction head of:
(200 GPM/100 GPM)2 X 75 ft. = 300 ft.
 Reducing the flow to 80 GPM in the same system would
result in a friction head of:
(80 GPM/100 GPM)2 X 75 ft. = 48 ft.
  This squared relationship allows us to plot a complete system curve
very quickly once we have calculated the design flow and design
head.
 By completing Table 1, we can quickly determine six points, which
should be a sufficient number to construct a reasonably smooth
curve.
 To use this table, one must first have calculated the design flow
(DF) and the design head (DH).

Table 1, Closed System Curve (Friction Head Only)

Example 1:
• Assume a design flow (DF) of 200 GPM at a design head (DH)
of 30.0 ft. Calculate the system curve points. The points are
calculated as follows:
 Table 2, (Closed System)
Remember that in closed systems, the friction head is the total head as
well, so the values in the right hand column represent the heads for the
system curve.

Typical System Curves for Open and Closed Systems

5.8.5.2. Calculating System Curve Points for Open Systems
• For open systems, the formula for the system head is:
Total System Head = Friction Head +
Static Head +
Pressure Head +
Velocity Head
• Velocity head appears in italics to remind us that velocity head is
generally ignored, as it is insignificant in hydraulic applications.
• Neither static head nor pressure head vary with flow.
• This is logical, because the height of the system (static head)
remains fixed regardless of the flow rate; the pressures in the
"beginning" and "final" vessels are independent of flow rate as
well.
• So each point consists of friction head which varies with flow, and
static and pressure heads, which do not.
• Consider the following example:
 A process system consists of an open tank, a pressurized
tank, and piping between the two.
 A pump delivers water from the open tank to the pressurized
tank.
 The friction head for the piping has been calculated at 30 ft.
at 200 GPM.
 The water level in the pressurized tank is located 5’ above
the level in the open tank.
 The pressurized tank operates at 4 PSIG.
• Calculate the points for the system curve.
• Note that the friction head is exactly the same as in the previous
example, so there is no need to recalculate that.
• The other heads are:
• Static Head = 5’
• Pressure Head = (4 PSIG –0 PSIG) X 2.31 ft./PSIG = 9.2 ft.
• Remember that the static head and pressure head are fixed.
• We can construct the following table (Table 3).

Table 3 (Open System)

 Typical System Curves for Open and Closed Systems
• Note that each curve demonstrates characteristics of its particular
system type.
1. The closed system curve is parabola-shaped and passes
through the origin (0 GPM at 0 ft) and through the design
point (200 GPM at 30 ft.). All closed system curves pass
through the origin in the design point.
2. The open system curve is parabola-shaped and meets the
Y axis at a head equal to the sum of the static head plus the
fixed head. It also passes through the design point. All open
system curves exhibit these traits.
Summary
• The system curve tells us little in and of itself.
• However, when combined with pump curves, it is an essential
element in predicting the point of operation.
• Therefore, it is important to understand how to construct system
curves for both closed and open systems.
5.9. System Head Curve
• To Calculate a System Head Curve several points must be chosen
to calculate friction losses on both the suction and discharge sides
of the pump at various flow rates.
• The static suction head/lift and the static discharge head remain
constant.
Example:
• Calculating TDH for a flooded suction application plot the friction
losses for 50, 90 and 100 GPM as follows:

Suction Side
 Discharge Side
System Head Curve
• Total Dynamic Head(TDH) at 50 GPM
= 70.03’ - 9.67' = 60.36'
• Total Dynamic Head(TDH) at 90 GPM
= 109.5' - 8.93' = 100.6'
• Total Dynamic Head(TDH) at 100 GPM
= 122.4' - 8.70' = 113.7'
5.10. Selecting a pump
A basic pump system
• A pump has two key characteristics. Fluid will be caused to flow at
a particular rate, ie the fluid will be pushed along at a rate.
• Secondly, it will support a head of fluid.
• There are two parts as seen in the diagram:
1. Static head.
2. Losses caused by friction due to the piping.
 System curve showing static head and friction head lost.

• A pump selected for a duty, as the pump curve is superimposed on

the system characteristic curve.
• The curves cross over at the pump’s best efficiency point (BEP) at
the desired flow rate.

The pump curve (left) and pump curve superimposed on the system curve
(right) showing the crossover point.
 • Obtaining a perfect match between the system curve and the best
efficiency point is difficult and not practical.
• In fact, the pump can become unstable.
• In the past the following methods were employed:
 adjusting the pump speed
 adjusting the pump impeller diameter
 changing the impeller design
 adjusting the system resistance
 modifying static head
 providing a system bypass flow route
• A preferred technique is to use a variable speed drive to drive the
pump as this will enable the performance of the pump to be
adjusted instantaneously.
• The VSD motor is a very efficient, low cost method of varying the
motor speed.

Ideal pump performance curves against impeller diameter.

Ideal pump efficiency curves are superimposed.
Real pump performance curves, system curves and efficiency curves