Here is one of the ways I’ve learned during my short period of serving pumps to define actual operation point

of a pump in field, check the difference between designed duty point and understand potential problems with
a pump.
For reference a good explanation about issues related with incorrect pump performance is given in the article
“Centrifugal Pump : Key Operational issues and remedies to optimize reliability” by Kirit Domadya
https://www.linkedin.com/posts/kiritdomadiya_centrifugal-pump-key-operational-issues-activity-
7111330740046327808-5x74?utm_source=share&utm_medium=member_desktop
This is simplified check which does not include velocity head and pressure gauges location difference between
suction and discharge line. But for the first step to understand an issue in most of the cases it should be enough
as those factors do not give significant impact on calculations. The purpose is general evaluation of a pump
performance issues. The idea is to find actual an actual operation point of the pump having operation data
from end-user’s site and compare with manufacturer data sheet to see any difference.
This way can be helpful during commissioning or performance issues with running pump.
If there is no possibility to get actual consuming current from DCS it can be measured by ammeter directly.
This measurement must be done by qualified personal on-site with electrical permit.
Use manufacturer datasheet with tested performance which should be available along with specific pump. Do
not use performance curves from catalogue.
Step 1. Get operation data from site:
Name Units Where to find Value (specify the identified
values in the column)
P, pressure Pa From pressure P2-P1
gauges on suction P1
and discharge P2
pipes
Q, flow m3/h Flowmeter on site
I, consumed current A Measure by ammeter

𝜌, density of kg/m3 Usually from

pumping liquid datasheet or check
with site operation
team

Р – difference of suction Р1 and discharge pressure Р2 (Pа) – get values form pressure sensors/manometers
and convert to Pa
Р = Р2 - Р1 (Pа)
Q – flow (m3/h) – get from flowmeter
I – consumed current (А) – use ammeter and measure current «U1-V1» or «V1-W1» or «U1-W1» during
operation of a pump.
Below visualized scheme which can be used for collection all info about performance values of a pump.
The others values can be also useful to understand the issues.
Step 2. Figure out actual operation point
Head and pressure are linked with formula 𝑃 = 𝜌∗𝑔∗𝐻, where:
𝜌 – density of pumping liquid (kg/m3),
H- head (m), g – gravitational acceleration (9,81 m*s⁻²),
P – pressure (Pа).
Р
Figure out actual head with formula 𝐻 = , where:
𝜌∗𝑔

Р – difference of measure pressure Р2 - Р1 (Pa),

𝜌 = density of pumping liquid,
g = 9,81.
Knowing head and flow it is possible to identify actual operation point of your pump. Put it on manufacturer
datasheet with performance test and compare with duty point:
Step 3. Define the real mechanical power on the shaft (kW), based on operating current measurements I (А)
Use formula Р = 1,73∗U∗I∗cosϕ∗ƞ, where:

1,73 — constant √3, used for calculating the power of a three-phase system,
U – supply voltage 220V or 380 V depending on you motor,
I – measured current,
cosϕ and ƞ – power factor and efficiency, the values which can be taken as equal to 0.8 for low-power motors
(less than 5.5 kW) or 0.9 for motors with a power more than 15 kW.
Usually, cosϕ is indicated on motor’s name plate.
For example, if you have 380V motor 75 kW the calculation should be the following
Р = 1,73∗380∗I∗0,9∗0,9
This way is possible to define actual operating power on the shaft (kW) on the curve from pump datasheet:

Ideally it matches or near the operating point of your pump. Check this out by straight vertical line (red one
in example below):

Sharing your experience and comments on provided calculations are

welcome and appreciated!