6.
Pumps and Pumping Systems
6.1 Centrifugal Pumps
Pump Performance Curve
Hydraulic power, pump shaft power and electrical input power
Hydraulic power Ph = Q (m3/s) x Total head, hd - hs (m) x (kg/m3) x g (m2/s) 1000 Where hd - discharge head, hs suction head, - density of the fluid, g acceleration due to gravity
Pump shaft power Ps = Hydraulic power, Ph pump efficiency, Pump
Electrical input power = Pump shaft power P Motor
6.2 System Characteristics
Static Head
Static Head vs. Flow
Dynamic (Friction) Head
Friction Head vs. Flow
System with high static head
System with low static head
Pump curve
Pump operating point
Typical pump characteristic curves
Selecting a pump
System Curve Head Meters
Flow (m 3/hr)
Selecting a pump
Pump Curve at Const. Speed
82% Operating Point Head Meters System Curve
500 m3/hr
Flow (m3/hr)
Selecting a pump
Pump Curve at Const. Speed
82% Head, m
50
Operating Point System Curve
300
Flow (m3/hr)
500
Selecting a pump
Pump Curve at Const. Speed
70
Pump Efficiency 77% 82% Full open valve
Partially closed valve
Head, m
50
System Curves
300
Flow (m3 /hr)
500
Selecting a pump
Pump Curve at Const. Speed 70 m 50 m 42 m Head Meters System Curves Pump Efficiency 77%
Partially closed valve
B A
Full open valve
82%
C
Operating Points 300 m3 /hr 500 m3 /hr
Static Head
Flow (m /hr)
Efficiency Curves
28.6 kW
14.8 kW
If we select E, then the pump efficiency is 60%
Hydraulic Power =
Q (m3/s) x Total head, hd - hs (m) x (kg/m3) x g (m2/s) 1000
= (68/3600) x 47 x 1000 x 9.81 1000 = 8.7 kW Shaft Power - 8.7 / 0.60 = 14.5 Kw Motor Power - 14.8 / 0.9 = 16.1Kw (considering a motor efficiency of 90%)
If we select A, then the pump efficiency is 50%
Hydraulic Power =
Q (m3/s) x Total head, hd - hs (m) x (kg/m3) x g (m2/s) 1000
(68/3600) x 76 x 1000 x 9.81 1000 = 14 kW Shaft Power - 14 / 0.50 = 28 Kw Motor Power - 28 / 0.9 = 31 Kw (considering a motor efficiency of 90%)
Using oversized pump !
As shown in the drawing, we should be using impeller "E" to do this, but we have an oversized pump so we are using the larger impeller "A" with the pump discharge valve throttled back to 68 cubic meters per hour, giving us an actual head of 76 meters.
Hence, additional power drawn by A over E is 31 16.1 = 14.9 kW. Extra energy used - 8760 hrs/yr x 14.9 = 1,30,524 kw. = Rs. 5,22,096/annum In this example, the extra cost of the electricity is more than the cost of purchasing a new pump.
Flow vs Speed
If the speed of the impeller is increased from N1 to N2 rpm, the flow rate will increase from Q1 to Q2 as per the given formula:
The affinity law for a centrifugal pump with the impeller diameter held constant and the speed changed:
Flow:
Q1 / Q2 = N1 / N2 Example: 100 / Q2 = 1750/3500
Q2 = 200 m3/hr
Head Vs speed
The head developed(H) will be proportional to the square of the quantity discharged, so that
Head:
H1/H2 = (N1 ) / (N2 ) Example: 100 /H2 = 1750 2 / 3500
H2 = 400 m
2 2
Power Vs Speed
The power consumed(W) will be the product of H and Q, and, therefore
Power(kW):
kW1 / kW2 = (N13) / (N23) Example: 5/kW2 = 17503 / 35003
kW2 = 40
Effect of speed variation
The affinity law for a centrifugal pump with the speed held constant and the impeller diameter changed
Flow: Q1 / Q2 = D1 / D2 Example: 100 / Q2 = 8/6 Q2 = 75 m3/hr Head: H1/H2 = (D1) x (D1) / (D2) x (D2) Example: 100 /H2 = 8 x 8 / 6 x 6 H2 = 56.25 m Horsepower(BHP): kW1 / kW2 = (D1) x (D1) x (D1) / (D2) x (D2) x (D2) Example: 5/kW2 = 8 x 8 x 8 / 6 x 6 x 6 kW2 = 2.1 kW
Reducing impeller diameter
Changing the impeller diameter gives a proportional change in peripheral velocity Diameter changes are generally limited to reducing the diameter to about 75% of the maximum, i.e. a head reduction to about 50% Beyond this, efficiency and NPSH are badly affected However speed change can be used over a wider range without seriously reducing efficiency For example reducing the speed by 50% typically results in a reduction of efficiency by 1 or 2 percentage points. It should be noted that if the change in diameter is more than about 5%, the accuracy of the squared and cubic relationships can fall off and for precise calculations, the pump manufacturers performance curves should be referred to
Impeller Diameter Reduction on Centrifugal Pump Performance
Pump suction performance (NPSH)
Net Positive Suction Head Available (NPSHA) NPSH Required (NPSHR) Cavitation NPSHR increases as the flow through the pump increases as flow increases in the suction pipework, friction losses also increase, giving a lower NPSHA at the pump suction, both of which give a greater chance that cavitation will occur
Pump control by varying speed:Pure friction head
Reducing speed in the friction loss system moves the intersection point on the system curve along a line of constant efficiency The affinity laws are obeyed
Pump control by varying speed:Static + friction head
Operating point for the pump moves relative to the lines of constant pump efficiency when the speed is changed The reduction in flow is no longer proportional to speed A small turn down in speed could give a big reduction in flow rate and pump efficiency At the lowest speed illustrated, (1184 rpm), the pump does not generate sufficient head to pump any liquid into the system
Pumps in parallel switched to meet demand
Pumps in parallel with system curve
