What is the Purpose of Minimum Flow? http://ekwestrel.

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EKWESTREL ENGINEERING LLC



17 FEB 2012

What is the Purpose of Minimum Flow?

Over the years use of the term “minimum �ow” has evolved.  
Decades ago industrial centrifugal pump manufacturers quoted a
single, relatively low value for minimum �ow intended to prevent
users from running their pumps to destruction.  The term
“minimum �ow” generally meant the lowest continuous �ow the
pump was permitted to operate, without reference to duration,
vibration level or other criteria.  Today we have minimum �ow
values for continuous operation, for intermittent operation and
for permissible temperature rise.

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Pump phenomena and minimum �ows

The accompanying chart Pump phenomena and minimum �ows

shows the relationships among the various off-design pump
phenomena and minimum �ow conditions.  The head versus rate
of �ow curve with indicated phenomena is a variation of S.
Gopalakrishnan’s from his well-cited paper titled, “A New Method
for Computing Minimum Flow,” Proceedings of the Fifth
International Pump Users Symposium; Texas A&M University, May
1988, pp. 41-47.  As an aside, I recall Gopal (everyone knew him by
that name) had made a local technical presentation using the now
well-known chart, before it was published.  Evidently the chart
was copied from a handout of the overhead slides and was quickly
pirated by another, and then others.  Copies or variants of this
chart are now found widely in papers and presentations on pumps.

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The quoted minimum �ow for continuous operation is usually

called “Minimum Continuous Stable Flow” or its more common
abbreviation “MCSF.”  It is the �ow below which the pump should
not be operated continuously.  The usual purpose of MCSF is to
achieve satisfactory bearing and seal life; however MCSF may be
based on other considerations.  Any of the following factors may
be considered in establishing the MCSF:

• manufacturer’s experience
• rule of thumb
• calculated onset of suction recirculation or discharge
recirculation
• radial thrust
• temperature rise
• cavitation erosion intensity
• maximum permissible pressure rise (for system purposes)
• maximum permissible power rise (high speci�c speed and
axial �ow pumps)
• a combination of the above factors or others not listed

For hydrocarbon process industry API 610 speci�cation pumps,

the value of MCSF is normally coincident with the lower �ow limit
of the “Acceptable Operating Range” (refer to chart titled
“Vibration limits for Allowable Operating Range and Preferred
Operating Range”) where a speci�ed vibration limit is not to be
exceeded.

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Vibration limits for Allowable Operating Range and Preferred Operating Range

MCSF is a value that can range from roughly 10% to 80% of Best
Ef�ciency Point �ow depending on pump size and type, operating
speed, impeller suction geometry, liquid density, and other
factors.  A size 2” (50mm) discharge single-stage process pump
may have an MCSF as low as 10% of BEP �ow.  MCSF is often in
the range of 30% to 60% of BEP �ow for process pumps with
discharge sizes 3” (75 mm) and larger.  Large mixed �ow vertical
pumps and very high head-per-stage centrifugal pumps may have
an MCSF greater than 60% of BEP �ow.  Axial �ow pumps have a
power curve that rises toward shutoff and minimum �ow may be
limited by the power rating of its driver.

On certain high energy pumps the minimum �ow is governed by

cavitation erosion damage.  Minimum continuous �ow for 40,000-
hour impeller erosion life is where the system NPSH Available

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curve intersects the pump’s NPSH Required curve, at lower-than-

BEP �ow.

Intermittent minimum �ow, when speci�ed, is usually given as a

percentage of MCSF.  On some applications the governing value
may be based on temperature rise.  On large high energy pumps
the value of intermittent minimum �ow could be, for example,
“70% of MCSF and not to exceed 100 hours per year.”

For some applications a thermal minimum �ow or “Minimum

Continuous Thermal Flow” is speci�ed based on permissible liquid
temperature rise.  MCTF is usually, but not necessarily, lower than
MCSF.  While a pump thermal minimum �ow is not always
speci�ed, the end user can readily calculate its value based on
input mechanical power heating up the liquid.  The limiting
temperature rise is based on a safe margin to prevent �ashing of
the pumped liquid to vapor, potentially causing pump seizure.

Thermal minimum �ow is not normally a concern at pump start-up

as long as the closed discharge valve is set to begin opening right
away.  If the margin of system NPSHA above pump NPSHR is
minimal, then the temperature rise conditions at pump start-up
should be checked carefully.

A few pump applications, such as a vertical turbine jockey pump

for maintaining pressure in a large �re sprinkler system, can

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potentially operate continuously at shutoff while pump suction

recirculation mixes with the water in the sump in which it
operates.  The sump acts as a heat sink and a minimal water
temperature rise is not a problem.  This example is a rare
exception to an almost invariable stricture on operating the pump
continuously at shutoff.

The purpose of minimum �ow is generally to prevent undue wear

and tear or damage to the pump.  In the real environment of a
process or utility plant, a pump is operated at just about any
condition demanded by the situation at hand.  Thus there are
different pump minimum �ows for different purposes.

For an independent evaluation of a pump minimum �ow issue,

contact an experienced consulting engineer who can help with
your speci�c application.  Please take a look at our services to see
our areas of expertise.

Filed Under: Pumps

Tagged With: continuous operation, engineering consulting, engineering
consulting services, intermittent minimum �ow, intermittent operation,
MCSF, MCTF, minimum continuous �ow, minimum continuous stable
�ow, minimum continuous thermal �ow, minimum �ow, pump, pump
engineering consulting, shutoff, temperature rise, thermal minimum
�ow

About Randal Ferman

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What is the Purpose of Minimum Flow? http://ekwestrel.com/what-is-the-purpose-of-minimum-flow/

Randal Ferman has more than 45 years’ experience in the

pump industry. He is a registered Professional Engineer in
California and in Texas. During his 32 years with Flowserve, a global pump
manufacturer, his responsibilities covered a broad range of engineering
assignments. He is presently Principal, Ekwestrel Engineering LLC, Austin,
Texas, providing services on new and existing pumping equipment and
systems. His clients span a range of industries including oil & gas, electric
power generation, water, wastewater, solids handling, pump
manufacturing, engineering and construction, energy ef�ciency, pipeline
transportation, and pump service and repair.

Comments

Granger Smith says

February 17, 2012 at 7:20 pm

Well said Randy.

Reply

ricky says
February 21, 2012 at 8:09 pm

So, When we decide using minimum �ow valve or using motor

inverter? thks

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