REVIEW 2014 – 0010A

SUPPLEMENTAL NOTES IN PUMPING OF WATER WILO SE

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

PUMP FUNDAMENTALS

Darwin S. Ibanez
darwin.ibanez@wilo-
philippines.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 pumping Pump
Resistance
system in order to cause a
liquid to flow completely
through the system

Resistance to liquid flow is known

as a pumping system’s 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 L
S
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= 160’+20’=
FT
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 it’s 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’ req’d
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’ req’d
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
system’s TDH?

• The pumping system’s

total dynamic head is
simply the sum of the
system’s static head
and dynamic head
 Total Dynamic Head

20’

System Flow = 100 GPM Nozzle

9.2’ req’d
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’ req’d
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 ‘feet of head’
Because...
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 it’s
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 discharge check valve may also be
required in high discharge head
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 system’s 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 it’s 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 The Suction

PB ( + ) Source (FT) - Absolute

Lowest Liquid Height Above The Suction Centerline Of The

HS ( + )
Pump (FT)

HF ( - ) Friction Loss From The Source To The Suction Centerline Of

The Pump (FT)

Vapor Pressure Of the Liquid At The Maximum Operating

PV ( - )
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 Pressures At
PV The Proper Temperature
Use The Minimum Liquid Height Above The
HS Pump Suction!

HF
NPSHA

Example A
Flooded Suction - Ambient Temp. - Sea Level

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

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

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

= 13.4 FT

HS =
15 FT PB = 14.7 PSIA

60 O F
VP=1.0
NPSHA

Example D
Boiler Feed - Sea Level

1.0 PSIA
NPSHA = PB + HS - HF - PV

= 2.3 FT + 6 FT - 1 FT - 2.2 FT
100 O F
VP=? = 5.1 FT
HS =
6 FT

HF = 1 FT
THANK YOU!