REVIEW 2014 0010A

SUPPLEMENTAL NOTES IN WILO SE

9F Unit 905, Pearl Bank Centre
PUMPING OF WATER 146 Valero Street, Salcedo Village,
Makati City Philippines
T : 02- 533 - 4016 (www.wilo.com)

PUMP FUNDAMENTALS

Darwin S. Ibanez
darwin.ibanez@wilo-philippi
nes.com

0917 865 3046

What will we cover?

Pumping System
Capacity (Flow Rate)
Total Dynamic Head
Static Head
Dynamic Head
Suction head
Suction lift
Affinity Laws
NPSHA
System Curve
Pumping Systems

A pumping system consists of:

All of the piping

Vessel
Other types of equipment (valves, meters, elbows, etc.),
Everything that is interconnected to form a path for liquid
to flow
Pumping Systems

The amount of liquid

flowing through a
pumping system is
known as the
capacity or flow rate
 Pumping Systems

Head
A pump must overcome
the resistance of a Pump
Resistance
pumping system in order
to cause a liquid to flow
completely through the
system

Resistance to liquid flow is

known as a pumping
systems Total Dynamic
Head (TDH)
 Pumping Systems

Total Dynamic Head (TDH) is the sum of two parts:

Static Head

Dynamic Head

Total Dynamic Head

All Head values are measured in Feet or Meters - Trust

me for now, more later !!!
 Pumping Systems

Static head represents the

resistance of a pumping
system before the liquid
is set into motion

Dynamic head represents

the resistance of a
pumping system while
the pumped fluid is in
motion
 Static Head

The primary component of Static head is the elevation difference

between:
the surface of the liquid at the point of suction
the surface of the liquid at the point of discharge
Static head also accounts for the pressure differential between the point
of suction and the point of discharge

Static head does not vary with capacity

 Centrifugal Pump Hydraulics
Static Pump Head (Flooded Suction)

Example #1 Non-Operating (Static)

Static
Head
Discharge
Head
HD
Suction Static Head=HD - HS
Head
HS

Pump
Centerline
 Centrifugal Pump Hydraulics
Static Pump Head (Flooded Suction)
Example #1 Non-Operating (Static)

120
FT
160
FT Static Head=
160-40= 120
40
FT

Pump
Centerline
 Centrifugal Pump Hydraulics
Static Pump Head (Suction Lift)

Example #2 Non-Operating (Static)

Discharge
Head
Static HD
Head

Pump
Centerline
Suction Static Head=HD + LS
Lift LS
Note: suction lift requires
self priming pumps or
suction check valves
 Centrifugal Pump Hydraulics
Static Pump Head (Suction Lift)

Example #2 Non-Operating (Static)

160
FT
180
FT

Pump
Centerline
20 Static Head=
FT 160+20= 180
 Dynamic Head

50 psi 30 psi

Dynamic head losses are those losses that are realized

once fluid begins to flow through the pumping
system
These losses are due to friction; often called Friction
Losses
Dynamic head losses are a function of capacity
 Dynamic Head

Dynamic head losses are made up of two parts:

Each component of a
pumping system
contributes to the
dynamic head losses for
the entire system
through Friction Losses

Accelerating the pumped

fluid from zero to its final
velocity requires energy -
this is known as Velocity
Head Loss
 Friction Head Loss

Friction head losses increase drastically with increased flow

A typical friction loss table for piping illustrates friction losses as a
function of capacity, pipe diameter & pipe length
See the reference materials in your classroom handout

Head loss in Feet (PSI) per 100 of pipe

1" 1.25" 1.50" 2"
GPM
Ft. PSI Ft. PSI Ft. PSI Ft. PSI
10 6.9 3.0 1.8 0.8 0.8 0.4 0.3 0.1
20 25.1 10.8 6.3 2.7 2.9 1.3 0.9 0.4
30 54.6 23.5 13.6 5.6 6.3 2.7 1.8 0.8
40 95.0 40.9 23.5 10.1 10.8 4.6 3.1 1.3
45 30.7 13.2 13.5 5.8 3.9 1.7
70 68.8 29.6 31.3 13.5 8.9 3.8
100 62.2 26.8 17.4 7.5
 Friction Head Loss
Every component of a pumping system has associated friction losses

Equivalent length
PSI Flow meters
TYPE 1 2 3 4
20 90 1.6 3.1 4.4 5.9
1 2 3 Elbow
15 Gate 1.2 2.6 2.8 2.9
valve
10 Globe 45 70 94 120
valve
5 Swing 7.2 17 27 38
GPM check

25 100 175 250

Friction loss tables can be obtained from the component

manufacturer or various other reference sources
Friction losses are a function of capacity and component size
Friction Head Loss
20

System Flow = 100 GPM Nozzle

9.2 reqd
Pump 18
20 20
Static Head
2 Pipe 2

4 Suction Lift

In this example the friction loss calculation is:

4 Equivalent length of fittings:
8 3 elbows = 3 x (K*V2/2g) = 3 * 0.36 *1.42 = 1.53
Pipe length = 4 + 4 + 2 + 20 + 20 + 18 + 20 = 88
Total friction losses = 1.5 + (88 x 17.4/100) = 17
> Where the pipe friction loss is 17.4 per hundred feet
Friction Head Loss

System Flow = 100 GPM 20

Static Head
Nozzle
9.2 reqd
15 Suction Head 18
Pump 20
20 20
2 Pipe 2

In this example the friction loss calculation is:

Equivalent length of fittings:

2 elbows = 2 x (0.36 *1.42) = 1.02
Pipe length = 20 + 20 + 18 + 20 = 78
Total friction losses = 1.02 +(78 x 17.4/100) =
15
 Velocity Head

Velocity ft/sec Hv = V2/2g = .0155 V2

Velocity head loss
in feet

Velocity Head Loss is simply a function of the velocity of

the fluid flowing through the pumping system
This value is usually small, and often neglected - Be Careful
The appropriate value is given in many friction loss tables
 Total Dynamic Head

What is my
systems TDH?

The pumping
systems total
dynamic head is
simply the sum of
the systems static
head and dynamic
head
 Total Dynamic Head

20

System Flow = 100 GPM Nozzle

9.2 reqd
Pump 18
20 20
Static Head
2 Pipe 2

4 Suction Lift

In this example the total dynamic head is equal to:

4 Static head = 24
8 Dynamic head
friction losses = 17
nozzle = 9.2
TDH = 24 + 17 + 9.2 = 50.2
 Total Dynamic Head

System Flow = 100 GPM 20

Static Head
Nozzle
9.2 reqd
15 Suction Head 18
Pump 20
20 20
2 Pipe 2

In this example the total dynamic head is equal to:

Static head = 3
Dynamic head
friction losses = 15
nozzle = 9.2
TDH = 3 + 15.5 + 9.2 = 29.1
Head vs. Pressure

A given pump will

generate the same
Because...
feet of head
regardless of the liquid
being pumped but...
...the discharge
pressure will vary with
the specific gravity of
the liquid!
Centrifugal pumps
develop head - not
pressure!
Head vs. Pressure
Effect of Specific Gravity on Static Head
 Specific Gravity

Water = 8.33 lbs/gal Gasoline = 6.0 lbs/gal

Specific gravity is the ratio of the weight of a liquid to the weight

of water

The specific gravity of gasoline is 6.0 / 8.33 = .72

 Head vs. Pressure

Water Gasoline

100 PSI 72 PSI

Two identical pumps operating in identical systems will develop the

same head but...
discharge gauges will give different readings if the specific gravity
of the liquids being pumped is different
 Specific Gravity
Is very important because:

It affects the brake horsepower requirements of the

pump, and...
All pressure information is converted to feet of head
by using the specific gravity of the liquid being
pumped

PSI = Feet of Head x SG Feet of Head = PSI

x 2.31
2.31
SG
Multiply water Hp x SG to get actual Hp
Example: 20 Hp pump x (.72 fuel) = 14.4 Hp required
Effect S.G. On Pump Performance
 System Curve

A System Curve is a graphical representation

of the resistance behavior (TDH) of a pumping
system over its entire capacity range
A system curve shows:
the static head component ( which is
constant over the entire capacity range)
the dynamic head component ( which
increases with capacity)
System Curve

HEAD

Dynamic
Head

Static Head

CAPACITY
The System curve is a function of the size of piping, type of equipment, and physical layout of a pumping system
System Curve

HEAD

Dynamic
Head

Static Head
CAPACITY
The system designer can change the shape of the System
curve by altering the size of piping, type of equipment, and
physical layout of the pumping system
System Curve

HEAD

Dynamic
Head

Static Head

CAPACITY
The end user can change the shape of the System curve by opening or closing system valves,
changing equipment or piping layouts, and varying the liquid levels in the suction or discharge tanks
 Mental Note

It is a good system design practice to include suction and discharge valves in

a pumping system.

Isolating the pump for

maintenance considerations
Using the discharge valve as a
throttling valve to control the
pump
a y o ut
A discharge check valve may also mL
ys t e
p r i nt s
be required in high discharge head S e
Blu
applications
A suction check valve is required
for suction lift without a self
primer.
The Suction Side

Net Positive Suction Head

Calculation and Application
Suction Side Limitations

The importance of keeping within the

suction side limitations of any pump
cannot be emphasized too greatly

KEEP IN MIND THAT...

...90% of all pump problems

are due to poor suction
conditions!
 Suction Side Limitations

NPSH Available is the term that describes

whether the pressure on the suction side is
adequate for proper pump operation

Self-priming applications must also consider the

amount of air the pump is required to evacuate
 NPSH Available

Proper system design allows for the highest possible NPSHA

Factors affecting NPSH Available include:

Pressure acting on the surface of the liquid

Relative elevation of the liquid
Friction losses in the suction piping
Velocity of the liquid in the suction piping
Vapor pressure of the liquid

These factors constitute a systems dynamic

suction condition and must be carefully considered
before a final pump selection can be made
 NPSH - The Rule

NPSHA must be sufficiently greater than NPSHR in order to prevent:

Poor pump performance

Excessive vibration
Noisy operation
Premature failure of components
Cavitation
 Cavitation - Definition

Vaporization of a liquid followed by rapid condensation (bubble collapse). Occurs when the
local pressure drops below the vapor pressure.
 Cavitation - Impeller

Cavitation can occur at the inlet of the impeller if the suction

pressure falls below the liquid vapor pressure.
 Cavitation - Effects

* Large vapor volumes can * Bubbles collapsing create

cause reduction in head intense pressures and
generation, or loss of prime. (10,000 psi) shock waves.

* Intense pressures near metal

surfaces exceed material
strength and fatigue metals.

* Large vapor volumes can * Creates pitted surfaces.

cause surging and unstable flows.
 NPSHR

1) Suction head required

to prevent vaporization at
the impeller inlet.
2) The sum of all head
losses / reductions
between the pump inlet
(A) and point of lowest
pressure in the pump (D).
 Cavitation Detection & Cures

> Tell Tale Indicators

Audible Noise (Pumping Rocks\Cracking)
Loss of Pressure\Flow
Pitted Impellers

> Verification
Problem Eliminated By Throttling
Pressure\Power Triangulation

> Cures
Increase NPSHa
Eliminate Suction Obstructions
Increase System Head
Pressure Acting On The Surface Of The Liquid

Pressure acting on the surface of a liquid

pushes it into the pump

Atmospheric pressure
Pressurized tank
Vacuum tank

The pressure on the liquid

is the major contributor to
the NPSHA of a system
 NPSHA

Pressure values must be converted to feet of head using

the following formula:

Feet of head = PSI x 2.31

specific gravity

Atmospheric pressure = 14.7 PSI (sea level) = 34 Feet

Pressurized vessel = Absolute pressure gauge reading
Vacuum vessel = Vacuum gauge reading
 Relative Elevation Of The Liquid

Static suction head implies that the liquid

level is above the inlet of the pump

Static suction lift implies that the liquid

level is below the inlet of the pump

PUMP

Static suction head increases NPSHA because

gravity helps pull liquid into the pump
Static suction lift decreases NPSHA because
the pump must work against gravity
Friction Losses In The Suction Piping
20 mm Hg

10 mm Hg

Friction losses in suction piping decrease NPSHA

Factors affecting friction losses include:

Size of piping
length of piping
Fittings and equipment
Vapor Pressure Of The Liquid

The vapor pressure of the liquid must be

carefully considered to insure proper pump
operation

Vapor pressure indicates the

dividing line between a liquid and
its gaseous state
Vapor pressure typically varies with
temperature
The pressure in the suction line
must never fall below the vapor
pressure of the liquid
 Vapor Pressure

A liquid with a vapor pressure of 8 psi @ 100 deg

F requires at least 8 psi of pressure acting on its
surface to stay a liquid.

The pressure in a fluid handling system must be

equal to or greater than the vapor pressure of the
liquid at every point throughout that system.

Without sufficient pressure the liquid will flash into

a gas and become un-pumpable.
Just Give Me The Formula
Net Positive Suction Head

Available (System) = PB + HS - HF - PV

Atmospheric (Barometric) Pressure Above

PB ( + ) The Suction Source (FT) - Absolute

Lowest Liquid Height Above The Suction

HS ( + )
Centerline Of The Pump (FT)

HF ( - ) Friction Loss From The Source To The

Suction Centerline Of The Pump (FT)

Vapor Pressure Of the Liquid At The

PV ( - )
Maximum Operating Temperature (FT) -
Absolute
Net Positive Suction Head Available

NPSHA = PB + HS - HF - PV

PB
All Values Must Be Converted To
Feet From Absolute Pressures!
Use Charts Attached For Vapor
PV Pressures At The Proper
Temperature
HS Use The Minimum Liquid Height
Above The Pump Suction!

HF
NPSHA

Example A
Flooded Suction - Ambient Temp. - Sea Level

PB = 14.7
NPSHA = PB + HS - HF - PV
PSIA

= 34 FT + 15 FT - 5 FT - 1.0 FT
60 O F
VP=? = 43.0 FT
HS =
15 FT

HF = 5
NPSHA

Example B
Flooded Suction - High Temp. - High Altitude (5500 FT)

PB = 12.0 PSIA
NPSHA = PB + HS - HF - PV

200 O F = 27.6 FT + 15 FT - 5 FT - 27.6 FT

VP=? = 10.0 FT
HS =
15 FT

HF = 5 FT
NPSHA

Example C
Suction Lift - Amb. Temp. - Sea Level

NPSHA = PB + HS - HF - PV

= 34 FT + (-15 FT) - 5 FT - 1.0

HF = 5 FT FT
= 13.4 FT
HS = PB = 14.7
15 FT
PSIA

60 O F
VP=1.0
NPSHA

Example D
Boiler Feed - Sea Level

1.0
NPSHA = PB + HS - HF - PV
PSIA

= 2.3 FT + 6 FT - 1 FT - 2.2 FT
100 FO

VP=? = 5.1 FT
HS =
6 FT

HF = 1 FT
THANK YOU!