GRUNDFOS

High and Broad Band

WHITE PAPER
Efficiencies in Pumps
by Steve Wilson

W hile the terms “high efficiency” and

“broad band efficiency” are relative and
have no real meaning per se, they are terms
Hydraulic Efficiency
Accounts for friction and shock losses in the flow
paths.
often used within the pump industry. It should
be noted that neither of these terms refer to a Each of the items which detract from the efficien-
benefit. High efficiency is a result of good pump cy also detract from the performance of the pump.
design that may yield the benefits of lower oper- Each pump, at design, has the theoretical curve
ating costs and less energy consumption at any associated with it and its specific speed. The losses
duty point. This paper will discuss both terms at internal to the pump detract from the theoretical.
a basic level. In all cases, unless otherwise noted, This relationship is graphically and simplistically
efficiency will refer to pump efficiency. shown in Figure 1.

EFFICIENCY
Simply stated, pump efficiency (Ep) is the ratio of
output power (water horsepower) (whp) divided
by the input power (brake horsepower) (bhp), Theoretical

expressed as a percentage, and can be show as: BEP

Ep = whp x 100.
bhp
Losses due to Shock,
Recirculation, Turbulence,
Efficiency in pumps, as portrayed on pump curves and Friction

or stated on pump data sheets, is a calculated Actual

value based on test results. The amount of work
being done is measured, as is the power con-
sumption by the pump and efficiency calculated
from those results. Figure 1. Actual vs. Theoretical Performance
Many factors impact pump efficiency, which has
3 major components: As seen in Figure 1, the BEP (Best Efficiency Point
Mechanical Efficiency or Design Point) is that point at which the losses
are minimized in total, and the actual curve is
Energy used in bearings, stuffing box and disc
closest to that which is theoretically possible.
friction losses at the wear rings, etc.
(This will be further discussed later in this paper.)
Volumetric Efficiency As the pump performs through its range, moving
Accounts for recirculation and turbulence and away from the BEP, the amount of these losses
other losses at glands, etc. change. These losses have been categorized (and
HIGH AND BROAD BAND EFFICIENCIES IN PUMPS GRUNDFOS WHITE PAPER | 2

again simplified) as Shock (the use of some of mizing the opportunity for internal recirculation
the energy to accelerate and decelerate the fluid through use of dual (double) volutes. Recircula-
being pumped); Turbulence (the absorption and tion losses are also reduced by assuring that the
use of energy associated with molecules of fluid impeller diameter is as large as possible relative
interacting with other molecules of the fluid); Re- to the cutwater (without adding to vane velocity
circulation (the failure of fluid to be discharged, caused erosion and noise).
but to tend to re-circulate back to the suction Friction losses can be reduced through improved
or stay within the casing); and Friction (the use casting technologies for smoother finishes, by
of energy as the fluid interacts with the compo- finishing (matching) surfaces in lieu of leaving
nents of the pump. At low flow conditions, fric- them in the “as cast” state, and by reducing the
tion losses are minimal, but recirculation losses length of the flow path.
are high; at high flow this is reversed, etc. Thus,
the more these losses are reduced, the higher the In the past decade, great advances have been
made in CAD and CAM, in casting technology. In
efficiency.
pump design in general, it is now possible that
HOW LOSSES CAN BE MINIMIZED the actual curves perform in excess of the “old”
theoretical limits. Nonetheless, the same factors
In order to improve efficiencies, losses must be
must be considered, regardless of pure numbers.
reduced. A brief discussion of some of the meth-
ods employed is given here. This is not meant to HIGH EFFICIENCY
be all inclusive.
It is difficult (or impossible) to state what is
Shock losses can be minimized by assuring a meant by high efficiency in a pump. The variety
gradual acceleration and deceleration of the of pump types and intended duties, the specific
fluids within the pumps. Francis vane impellers speeds, pump size, etc., are so varied, that no
may be employed. Assuring that the case and “cardinal number” can be set that encompasses
impeller are designed together will also assist these circumstances. However, it can be stated
in this reduction. Proper attention to the throat that:
area in the casing and much engineering effort is
put into this area. • In general, the larger the pump, the higher the
attainable efficiency.
Turbulence losses can be reduced by assur-
ing that flow paths are smooth and as laminar • Efficiency should be relative to other, similar,
as possible, that internal areas are kept to a pumps of the same size and type. For example,
minimum size, and that internal designs to not a 4-inch non clog pump intended to pass 3-inch
promote turbulence by directing flow inappro- solids with an efficiency of 80% might be
priately. One method of reducing recirculation considered to have high efficiency if the other
which is generally to be avoided is a sharpening pumps capable of performing the same task
of the cutwater(s) through grinding to a sharp had efficiencies of 70% or less even though
edge. While this will indeed improve efficiencies, end suction or split case pumps delivering the
the improvement may well vanish shortly after same flow rates could be expected to exhibit
the pumps are put into service and the “knife efficiencies of at least 80%.
edge” erodes with fluid passage. • Efficiency is only one aspect of pump
Recirculation losses can be minimized by assur- performance, and reliability should not be
ing tight tolerances between the impeller and sacrificed for efficiency improvements.
case at the suction eye (and use of wear rings to • Typically, when efficiency is discussed, it refers
keep this tolerance as tight as possible) and mini- to efficiency at either BEP or a given operating
HIGH AND BROAD BAND EFFICIENCIES IN PUMPS GRUNDFOS WHITE PAPER | 3

condition. It does anyone little good to look is “0” since no work is being done. This efficiency
at a pump with 90% efficiency at design point is expressed on pump curves either through
and hear, “Look how efficient this pump is’ if “iso-efficiency lines” or with a separate efficiency
the point of selection is not at that point. curve. The ideal pump would be one that had
• While efficiency of the pump is important, efficiencies rise rapidly (relative to flow) from
its impact is best totally evaluated by a study shutoff and then stayed high throughout the
of the system in which it is installed. Moving curve, with the efficiencies staying high through
a pump to its BEP by closing valves and a broad operating range. This can be said to be
“balancing a system” will indeed improve its “Broad Band Efficiency.” Such a pump addresses
efficiency, but the system itself may become the needs of the “real world” and not only allows
even more inefficient or worse, less effective. selection at a high efficiency point, but will allow
efficient operation should conditions either vary
BROAD BAND EFFICIENCY or not be as predicted.

The pump efficiency, as discussed above, will Observe the following two curves (Figures 2A and
vary as the pump moves away from its BEP in any 2B) The first pump (2A) shows a typical pump
direction for any reason. At no flow, the efficiency curve with relatively decent efficiency at design
point and normal efficiency bands.

Note 80+ Efficiency Range from 2400 GPM to 4200 GPM

Note 80+ Efficiency Range from 180’ to 135’
If head drops by 20% efficiency drops by 6.5 points
240

220 60%
70% 75%
%
%

200 13”
78
80

82% 84%
180 85%
84%
12”
160 82%
TOTAL HEAD IN FEET

78 0%
%
8

140 11” 75%

NPSH FEET

70%
120
10”
100

80 40
100HP 150HP
60 125HP 30
75HP
D 60HP
40 NPSH REQUIRE

20 10

0 0
0 1000 2000 3000 4000 5000 6000 7000 8000
Capacity in U.S. Gallons Per Minute

Figure 2A. Standard Efficiency Bands

HIGH AND BROAD BAND EFFICIENCIES IN PUMPS GRUNDFOS WHITE PAPER | 4

Note 80+ Efficiency Range from 2000 GPM to 4800 GPM

Note 80+ Efficiency Range from 180’ to 105’
If head drops by 20% efficiency only drops by 1.5 points
275 60% 70% 80
15” 80% 85%
250 88%
14” 90% 70
225
13” 90% 60

TOTAL HEAD IN METERS

200
88%
85%
175 12”
TOTAL HEAD IN FEET

50
80%
150 11” 70%
125
10”
100 30
9”
250
75 20 HP
0H 20
150 P
50 125 HP
10 HP 24
80 75H 0HP 10
25 60 50 60H P
NPSH (FT)

NPSH (M)
HP 16
40 P
0 20 8 0
0 0

0 1000 2000 3000 4000 5000 6000 7000

Capacity in U.S. Gallons Per Minute

Figure 2B. Broad Efficiency Bands

If the head in the system were to drop by CONCLUSION

20% through part loading or actual “as built”
Understanding what is meant by efficiency, high
differences from design, the head would drop
efficiency, and broad band efficiency is valuable
from the 160’ design head to (160 x .8) = 128,
in any discussion or study on pump evaluations.
and the efficiency of the pump in Figure 2A
It is important to recognize when these terms
would be reduced from 84.5% to around 78%.
might come into play so that complete analysis
Pump (2B) exhibits not only higher efficiencies at
may be accomplished. In addition, it is important
design (90% vs. the 84.5%), but has a broad band
to understand what factors are involved in
efficiency so that if the head were to drop to the
efficiency improvements.
128’ efficiency is maintained at 88%. This pump,
in fact, is more efficient at that reduced head
than the other pump is at design point.
 Being responsible is our foundation
Thinking ahead makes it possible
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