Mataria Faculty of Engineering

Mechanical Power Department

PUMPS
Selection & Operation

By

Dr. Eng. Ahmed Abo-Habsa

Chapter II

Dynamic Pumps
Selection & Operation
1. Pump Data

1.1 Pump Flow Rate Q.

1.2 Pump Head H.

1.3 Speed of Rotation N.

1.4 Efficiency and Input Power P.

1.1 Pump Flow Rate

Q in [m3/s]; [m3/h]; [GPM]; [L/min].

Q shall be estimated from the system demand. The system

may be:
Municipal water system
(100-500 Liter/Person/day)
Irrigation system
(25-50 m3/feddan/day)
Fire fighting system
Liquid conveying system
Any other system comprising liquids
Example-1
It is required to build a new pumping station to
irrigate an area of 42,500 feddans. The area is
cultivated with different crops. The plants water
requirements along the year are given in Fig(1).
Determine the number of pumps and the capacity
of each pump for 24 hours daily operation.

Fig(1)
Solution
Plants peak water requirement= 30 m3/feddan/day
Operation time =24 hours/day
Maximum required flow rate= 42500*30/24/3600 =
The required flow rate
14.7 m year
along the
3
/s is drawn in
fig(2)
3+1 pumps shall be
selected
Each of a capacity of 5.0
m3/s
3 pumps in operation
1 pump stand by
The red line illustrates the
operation sequence of
pumps along the year.

Fig(2)
One pump during Dec, Jan, Feb.
Two pumps during Mar, Apr, Oct, Nov.
Three pumps during May, Jun, Jul, Aug, Sep.
1.2 Pump Head Hpp [m]

The pump head Hp is the energy added by the pump to the fluid
per unit weight of the flowing fluid. Hp [Nm/N] = [m]. The pump
head is determined from the system requirement.

Applying the Bernoullis Equation:

p1 v12 p2 v22 2
Z1 Hp Z2 hL
g 2g g 2g 1

Hence

p v 2 2
Hp Z hL
g 2g 1
Two open Reservoirs System 2

p2 p1
Hp Z 2 Z1 Reservoir B

g Discharge pipe

v v
2 2 2 Gate

hL
Valve

2 1
2g
Pump
1
Check
Valve

2 Suction pipe

H p Z hL
1

1
Strainer

2 Reservoir A

h
1
L h L ,Strainer h L ,suction h L ,Check h L ,Gate h L ,3Bends h L,Dis. h L ,exit
pipe Valve Valve pipe
Open Reservoir Nozzle

& Nozzle System

Vj

Gate
Valve Hose
Gate
Valve

Reservoir Pump

p2 p1 v 2 2
Hp Z 2 Z1 hL 2
g 2g 1
2
vj 2
H p Z hL
2g 1
2

h
1
L hL , Entrance hL , suction hL , 2Gate hL , Hose hL , Noz hL , Exit
pipe Valve
1.3 Speed of Rotation [RPM]

Depends on the driver type

Induction
Electric
Motor DC

Diesel
Internal Combustion
Engine Gasoline

Reference speeds of rotation for the Induction Motors

1.4 Efficiency and Input Power P

Power absorbed by the

pump shaft: 1

Q Hp
Over 2000 m3/h
0.9 2000 m3/h

P 0.8
600 m3/h

0.7
200 m3/h

Pump Overall Efficiency h

100 m3/h

50 m3/h

Where: 0.6
fluid specific gravity for 25 m3/h

water =9810 N/m3 0.5

Q Pump Capacity m3/s

0.4
Hp Developed Head by 0.1 1 10

the pump Shape Number WS

H overall pump efficiency
P in [W]=[Nm/s]= [J/s]
Pump efficiency versus Shape Number
kW=1000 W
(Specific speed NS =S x 2733)
kW=1.36 HP
2. System Curve
Hsys

12
Applying Bernoulli's Equation
to any steady flow system 10

p
H sys Z System Head [m]
6
v2/2g+ hL
g 4

v 2 2
hL
2 p/

2g 1
0
0 50 100 150 200 250 300

Flow rate Q [m3/h]

2.1 Head losses in circular pipes
2.1.1 Darcy Weisbach Equation:

fL v 2 8 fL
h Q 2
L D 2 g 2 g D5
Where

hL the head loss along the pipe [m]

L the pipe length [m]
V the mean velocity in the pipe [m/s]
Q the flow rate in the pipe [m3/s]
D the pipe diameter [m]
f the pipe friction factor, depends on the Reynolds
number and the relative roughness of the pipe
The Moody diagram for pipe friction factor f
:The friction factor formula developed by Swamee and Jane is

2
1
0.9

e
f 1.325 ln o.27 5.74
D Re
Where

e the pipe absolute e [mm] Pipe Material

roughness [m] 0.9-9.0 Riveted steel
D the pipe inside
3-3.00. Concrete
diameter [m]
Re the Reynolds Number 0.25 Cast iron
=vD/ 0.15 Galvanized &
welded steel
0.12 Asphalted CI
0.046 Commercial steel
0.0015 Drawn Tubing
 2.1.2 The Hazen Williams equation

for hL calculations in the irrigation Main lines, Sub-

mains & Laterals (PVC pipes & PE Tubing) it is
preferable to use the Hazen William Equation as
follows:

1.852
Q L
hL 10.675 4.87
C D
where
C Constant according to the pipe roughness
For very smooth pipe C=150
For smooth pipe C=140
Rough pipe C=130-100

Q [m3/s]; L [m]; D [m]

 2.2.1 Steel Pipes
Sch.20 Sch.30 Sch.40
ND OD
Inch [mm] ID W[kg/m ID W[kg/ ID W[kg/m
t [mm] t [mm] t [mm]
[mm] ] [mm] m] [mm] ]
1 33.4 3.38 26.64 2.50

1.25 42.2 3.56 35.08 3.38

1.5 48.3 3.68 40.94 4.05

2 60.3 3.91 52.48 5.43

2.5 73.0 5.16 62.68 8.62

3 88.9 5.49 77.92 11.26

3.5 101.6 5.74 90.12 13.56

4 114.3 6.02 102.26 16.05

5 141.3 6.55 128.20 21.76

6 168.3 7.11 154.08 28.23

8 219.1 6.35 206.40 33.25 7.04 205.02 36.76 8.18 202.74 42.49

10 273.0 6.35 260.30 41.73 7.80 257.40 50.96 9.27 254.46 60.24

12 323.9 6.35 311.20 49.68 8.38 307.14 65.14 10.31 303.28 79.71

14 355.6 7.92 339.76 67.96 9.52 336.56 81.21 11.13 333.34 94.31
 16 bar 10 bar 6 bar

2.2.2 PVC D t ID t ID t ID
mm mm mm mm mm mm
Pipes 20 1.5 17.0
25 1.9 21.2 1.5 22.0
32 2.4 27.2 1.8 28.4
40 3.0 34.0 1.9 36.2 1.8 36.4
50 3.7 42.6 2.4 45.2 1.8 46.4
63 4.7 53.6 3.0 57.0 1.9 59.2
75 5.6 63.8 3.6 67.8 2.2 70.6
90 6.7 76.6 4.3 81.4 2.7 84.6
110 8.2 93.6 5.3 99.4 3.2 103.6
125 9.3 106.4 6.0 113.0 3.7 117.6
160 11.9 136.2 7.7 144.6 4.7 150.6
200 14.9 170.2 9.6 180.8 5.9 188.2
225 16.7 191.6 10.8 203.4 6.6 211.8
250 18.6 212.8 11.9 226.2 7.3 235.4
280 20.8 238.4 13.4 253.2 8.2 263.6
315 23.8 267.4 15.0 285.0 9.2 296.6
355 26.3 302.4 16.9 321.2 10.4 334.2
400 29.7 340.6 19.1 361.8 11.7 376.6
450 21.5 407.0 13.2 423.6
500 23.9 452.2 14.6 470.8
560 26.7 506.6 16.4 527.2
630 30.0 570.0 18.4 593.2
710 20.7 668.6
800 23.3 753.4
900 26.3 847.4
1000 29.2 941.6
2.3 Head Loss
in pipe Fittings
(minor losses)

hL= k (v2/2g)
Head Loss in
valves & pipe
couplings

hL= k (v2/2g)
 BEP

3. Pump
Characteristic
Curves

H-Q Curve
NPSHR-Q Curve

P-Q Curve
Three examples of characteristic curves for pumps of differing specific
speeds. a: radial impeller, s 0.5; b: mixed flow impeller, s 2.0;
c: axial flow impeller, s 4.5
4. Pump selection
PG-2=2.4 bar

Example
It is required to pump 200
m3/h water from reservoir A
to reservoir B. Select a
suitable pump to do this job. Reservoir B

Solution
25 m Discharge Pipe
Applying Bernoullis Eq. Gate
Valve
Inside diam. = 150 mm
Total Length = 100 m
between points 1 & 2 PG-1

p1 v12 p2 v22 2 Pump

Z1 H p Z 2 hL
g 2g g 2g 1 Check
Valve

Z= 25 m 1
Suction Pipe
Inside diam. = 200 mm
p/2.4x10000/9810= 24.5 m Total Length = 10 m

v1=v2=0
hL= hL,Dischage + hL,Suction
Strainer with foot valve
Reservoir A
For water
=9810 N/m3 (specific weight)
= 0.000001 m2/s (kinematic viscosity)
Q=200 m3/h= 200/3600=0.0556 m3/s

Discharge pipe Suction pipe

ND=150 seamless steel
Inside diameter d=159.3 mm
V =4Q/d2= 2.79 m/s
Re = Vd/= 444040
= 0.046 mm
f = 0.0164
fL/d = 15.56
KD =Gate+Check+ 2 El+Exit
= 0.1+2+2*0.3+1= 3.7
hLD= (fL/d +KD) * v2/2g
= 7.6 m
ND=200 welded steel
Inside diameter d=210.1 mm
V =4Q/d2= 1.6 m/s
Re = Vd/= 336676
= 0.15 mm
f = 0.0193
fL/d = 0.92
KD =Strainer + foot valve + El
= 0.8+0.7+0.25= 1.75
hLD= (fL/d +KD) * v2/2g
= 0.35 m

Total required pump Head Hp= 25+24.5+7.6+.35 =57.5 m

Q = 200 m3/h
Characteristic Curves of a pump manufacturer
 5. Operation Point
The pump operates at the Hp Hsys Eff.
intersection point

Overall Efficiency
50.0 2.00
between the pump H-Q
45.0 1.80
curve & the system
BEP
curve. It is a stable 40.0 1.60

operation point. Head H [m]

35.0 Operation 1.40
Point
30.0 1.20

Good selection 25.0 1.00

The operation point is
20.0 0.80
near from the best
efficiency point PEP. 15.0 0.60

10.0 0.40

Bad selection 5.0 0.20

The operation point is far 0.0 0.00
from the BEP 0 50 100 150 200 250 300 350 400

Flow rate Q [m3/h]

Case 1 Hp Hsys-2 Hsys-1 Hsys-3

50.0
The System head losses were
over estimated before 45.0

purchasing the pump. The 40.0 BEP

pump will operate at low eff.
35.0
Head H [m]
Case 2
30.0
The System head losses were
exactly estimated before 25.0

purchasing the pump. The 20.0

pump will operate at BEP.
15.0
Case 3
10.0
The System head losses were
under estimated before 5.0

purchasing the pump. The 0.0

0 50 100 150 200 250 300 350 400
pump will operate at low eff.
Flow rate Q [m3/h]

Other problems resulting from not operating at BEP

Excessive wear due to incidence of separation & vortices.
Motor overloading (radial flow impellers)
The required flow rate is not fulfilled
6. Regulation
6.1 Regulation by throttling
Gate
Valve Hp Hsys-2 Hsys-1 Hsys-3

50.0
Pump Shutoff head
45.0

Check 40.0 BEP

Valve
35.0
Head H [m]
30.0

25.0

Gradually closing the gate 20.0

valve; at the pump 15.0

discharge; will move the 10.0
system curve from Hsys-1 to
5.0
Hsys-2 then to Hsys-3 until
0.0
the pump operates at the 0 50 100 150 200 250 300 350 400

shutoff head by fully closed Flow rate Q [m3/h]

discharge valve.
6.2 Regulation by Varying the Speed
The H-Q curve of the pump is
Hp Hsys n2/n1=.8 n2/n1=.9
at constant speed n1.
50.0
Changing the speed to n2 will
result a new H-Q curve. The 45.0

two curves are related to each 40.0 BEP

other according the similarity
laws: 35.0
Head H [m]
30.0

Q1 n1

25.0

Q2 n2
20.0

15.0

2 10.0 n1
H1 n1 n2
5.0
n2
H 2 n2 0.0
0 50 100 150 200 250 300 350 400

Flow rate Q [m3/h]

1 2
 Example
When the pump runs at 1450 RPM in the system shown on the chart; it
delivers 250 m3/h water and develops 28 m head. What is the speed at
which the pump should run to deliver 200 m3/h?
Solution Hp (n1) Hsys
Similarity Curve Hp (n2)
Known: Q2=200 m3/h
50.0
H2= 23 from sys curve at 200 m3/h
n1 = 1450 RPM 45.0
BEP
Unknown: Q1, H1, n2
40.0
Applying the similarity laws:
Head H [m] 35.0
2
Q H H2
1
1
2
or H1 Q1
2 30.0
Q2 H2 Q22 25.0
n1=1450 RPM
System
H1 .000575 Q12 sim. curve 20.0

15.0
The inter section point between the HQ-
curve at n1 and the similarity curve will 10.0 n2
give Q1 and H1 5.0
Q1= 230 m3/h ; H1=30.4 m
0.0
Hence: 0 50 100 150 200 250 300 350 400 450

n2 200 n2 23 Flow rate Q [m3/h]

0.8696 ; or 0.8698
n1 230 n1 30.4
n2=0.87 x 1450 = 1261 RPM
 Gate
Valve

7. Cavitation Ps
Pump

Elev.

ps vs2 pv Datum Check

NPSH
S Valve

2g -Zs
1

applying Brenoulli ' s eq : Negative

Suction Head
p1 ps vs2 s
Zs 0 0 hL
2g 1 1

Hence
p1 pv s Positive
NPSH A Z s hL Suction Head

1 +Zs

NPSH R is given by the manufacturer Gate

Gate
Valve
Valve

For no Cavitation : Ps
Pump

Datum
NPSH A NPSH R Elev.
S
Check
Valve
8. Parallel and series Operation

Parallel Connection Series Connection

Qtwo Pumps= Qone Pump

Qtwo Pumps=2 x Qone Pump

Htwo pumps= 2 x Hone pump

Htwo pumps= Hone pump

At the same At the same

8. 1 Two Identical Pumps

H-1 2 Parallel 2 Series Hsys-1 Hsys-2

70.0

Two pumps
series
60.0

Rising sys
curve
50.0
Head H [m]

40.0

Flat sys curve

30.0

20.0

Two pumps
10.0 one parallel
pump

0.0
0 100 200 300 400 500 600 700 800

Flow rate Q [m3/h]

Solved Problem
Fig.(1) shows the installation details of a deep Water
Resevoir
well pump. The characteristic curves of the
pump at a motor speed of 1460 rpm are shown
in fig.(2) Imp 7.688. When the gate valve is full
open and the pump runs at 1460 rpm, the pump
delivers 100 m3/h of water into the reservoir. The
40 m
water surfaces in both the reservoir and the well
are subjected to the atmospheric pressure.
Neglect the head loss in the discharge column Discharge
Steel pipe
and suction pipe.
Electric
a- Find the reading of the pressure gage P1. Gate P1
Valve
Motor

Estimate the brake-horsepower required by the Discharge

pump at this operation point. Head

b- It is required to decrease the pump rate of Discharge

10 m
flow to 80 m3/h. This can be obtained by partially Column, steel

closing the gate valve (pump throttling).

Water level
Estimate the brake-horsepower required by the in the well

pump at the new operation point and find the Pump

new reading of the pressure gage P1. 8m
Bowls

c- If it is possible to regulate the pump by Suction flange

level for NPSH
changing the speed while the gate valve is full calculation

open. Find the pump rpm, that will ensure a flow Suction
Pipe
rate of 80 m3/h. Estimate the brake horsepower
required by the pump at the new speed and find Fig.(1) Pump Installation
the reading of the pressure gage P1.
Fig.(2) Pump
Characteristic
curves

The pump first operation point Hsys=Z+KQ2 = Hp=75 m

Discharge valve : Full Open z=10+40=50 m
N= 1450 RPM k =25/(100)2 = 0.0025
Q= 100 m3/h A- the pressure gage reading
H= 75 m at 1st operation point
= 0.75 Applying Bernoullis eq. between
The system curve with full the water surface in the well and
opened valve meets the pump the pressure gage location
curve at this point. 0+0+0+Hp=pG/+10+v2/2g+hL
Neglecting hL, suction & D. column & v2/2g Hp Hsys Similarity n2

pG=(75-10) x 9810/ 100000= 6.4 bar 120

The pump shaft power 100

P=9810x100x75/(0.75x1000x3600)
=27.3 kW=37.0 HP Head H [m] 80

B- Gradually closing the discharge 60

valve until
40
Q=80 m3/h
H= 90 m 20
= 0.8
P=9810x80x90/(0.8x1000x3600) 0
40 50 60 70 80 90 100 110 120
= 24.5 kW=33.3 HP
pG=(90-10)x 9810/10000= 7.8 bar Flow rate Q [m3/h]

C- Changing the speed Hence

Q2=80 m3/h n2/n1=Q2/Q1=80/90=.89
H2=50+.0025 x 802=66 m
n2/n1=(H2/H1)=0.89
n2=?
n1=1450 RPM
n2= 1290 RPM
Q1=?; H1=?
Similarity curve H1=(H2/Q22) x Q12 1=2=0.78
H1=0.0103125 Q12 P=9.81x80x66/(.78x3600)
Q1=90 m3/h = 18.4 kW=25 HP
H1=82 m pG=0.0981x(66-10)=5.5 bar